Intergas 47-291-05 Installation, Service And User Instructions Manual Download

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Intergas Heating Ltd

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

Summary of Contents for 47-291-05

Page 1: ...1 06 ECO RF 36 G C 47 291 07 Installation service and user instructions Please read these installation instructions carefully before installing and using the appliance Keep these installation instruct...

Page 2: ...th the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the scheme Visit www centralheating co uk for more information CONTENT 1 Pref...

Page 3: ...12 4 Combustion 45 13 Electrical diagram 46 13 1 Electrical diagram Combi Compact ECO RF 46 13 2 TC resistances 47 14 Short spares list 48 15 Warranty Conditions 49 16 CE Declaration 49 17 Gas Boiler...

Page 4: ...urrently in force Read these instructions carefully before installing or using the appliance It is the installers responsibility that the installation conforms to the current legislation and Standard...

Page 5: ...llation instructions with the appliance or with the gas meter 1 8 Service and technical support For information about specific adjustments installation maintenance and repair work please contact Inter...

Page 6: ...ceeding 70kW Part 2 Air Supply BS 5546 2000 Installation of gas hot water supplies for domestic purposes BS 5549 1990 Forced circulation hot water systems BS 6700 1997 Design Installation testing and...

Page 7: ...7 1 23 7 7 6 27 0 Rated power kW 6 1 18 2 7 7 23 1 8 2 26 6 Max CH water pressure bar 2 5 2 5 2 5 Max CH water temperature C 90 90 90 Other data Gas consumption G20 m3 h 0 58 2 29 0 74 2 91 0 79 3 39...

Page 8: ...w in flue sets C Boiler controller N Connection block terminal strip X4 D Sensor S1 O Condensate drain pan E Sensor S2 P Hot water sensor S3 F Fan Q Condensate trap G Flow sensor R Heat exchanger H CH...

Page 9: ...oller An electronic control unit consisting of a boiler controller and separate ignition module which is placed on the gas valve provides direct burner ignition and flame supervision along with contin...

Page 10: ...e output is automaticaly adjusted to the heating demand by reducing or increasing the fan speed and the pump speed When the end of the central heating demand is reached the thermostat reaches temperat...

Page 11: ...ault mode See 10 11 5 CH operation An on off thermostat an OpenTherm thermostat an external sensor or a combination of the latter can be connected to the boiler controller When a request for heat is r...

Page 12: ...iod 4 6 Test programs The boiler controller has a facility for placing the appliance in test mode Activation of a test program will result in the appliance starting operation at a fixed fan speed with...

Page 13: ...connections on the boiler It is important to thoroughly flush the water circuits after isolating the boiler in order to remove any fluxes and debris from them This should be done particularly where b...

Page 14: ...p 847000 Bend 45 084661 Bend 90 084660 Deflector kit 081295 Weather slate steep roof 087910 Weather slate flat roof 087372 Extension L 100 incl wall bracket 082975 Horizontal telescopic offset wall te...

Page 15: ...terminal incl boiler adapter 60 100 082973 Plume management kit 081294 Elbow 90 for plume management kit 081284 Elbow 60 for plume management kit 081285 Extension L 100 incl wall bracket for plume ma...

Page 16: ...ons backwards 03010091 Appliance wall mounting jig bracket A Supply CH 22 B Return CH 22 C Gas D Cold tap water 15 E DHW 15 F Condensate drain 25 flexible G Drain PRV 15 H 840 Combi Compact ECO RF 36...

Page 17: ...y be realized by opening a cupboard door Flammable fluids and materials must be stored at least 1 metre away from the boiler The wall on which the boiler is mounted must be sufficiently strong to supp...

Page 18: ...s through the openings sleeves in the jig Note The appliance is wider than the jig Install the CH heating system and the DHW system to the valves CAUTION Make sure that the boiler connections of the s...

Page 19: ...at the same time that the pipes slide into the compression fittings 10 Tighten the compression fittings on the mounting bracket Do not turn tightened valves on pipes as this weakens joints within the...

Page 20: ...on effect during DHW operation mode 8 1 2 Thermostatic radiator valves If all radiators are equipped with thermostatic or radiator valves an auto bypass must be fitted in order to guarantee minimum wa...

Page 21: ...ections below the appliance must be removed 8 2 2 Flow resistance graph for appliance DHW circuit A Combi Compact ECO RF 24 B Combi Compact ECO RF 30 C Combi Compact ECO RF 36 X Bar Y Litres per minut...

Page 22: ...crews to remove the front cover 3 Pull the boiler controller unit forwards the boiler controller will tip downwards to provide access 4 Consult sections 8 3 1 and chapter 13 for making the connections...

Page 23: ...at has te be connected to the contacts 11 and 12 of connector X4 see chapter 13 electrical diagram CAUTION Connecting the Open Therm room thermostat to other contacts than 11 12 may damage the room th...

Page 24: ...er the menu of the wireless room thermostat in the boiler controller 2 Press the service button once In the display above the button a t is shown 3 Bring the room thermostat in test mode please refer...

Page 25: ...iagram B Gully C Condensate discharge from boiler D Servicable waste trap E 5 20 mm meter F 100 mm G 110 mm H 450 mm If an externally run condensate drainage pipe is used the following measures should...

Page 26: ...acing a terminal 600 mm I From a terminal discharging towards another terminal 1200 mm J From an opening in a car port e g door window into a dwelling 1200 mm K Vertically from a terminal on the same...

Page 27: ...g flue length reductions apply 45 bend 1 metre and for a 90 bend this is 1 5 metres CAUTION Only an Intergas approved flue is to be used with this product Failure to comply with this requirement will...

Page 28: ...the flue Hatches must be a minimum of 300mm x 300mm and positioned with the edge of the inspection hatch to 1 5m of any joint and at changes of direction Bends should be viewable from both directions...

Page 29: ...o far as a result of the air bleeding 7 Check all couplings for leakage 8 Fill the condensate trap with water 9 1 2 Hot water supply 1 Open the main tap to pressurise the hot water section 2 Vent the...

Page 30: ...e mirror proceed to put the boiler into operation as follows 1 Set up the boiler to operate at maximum rate as described in 10 7 2 With the boiler operating in the maximum rate condition check that th...

Page 31: ...Heat the installation and the appliance to approximately 80 C 5 Check the temperature difference between the supply and return for the appliance and the radiators This must be approximately 20 C For...

Page 32: ...ted using the installer code 10 1 Directly via the operating panel The following functions can be operated directly 10 1 1 Appliance on off The appliance is started using the key When the appliance is...

Page 33: ...eter to be set on the service display 4 Using the and keys set the parameter to the desired value visible on the main display 5 Once all desired changes have been entered press the key until a P appea...

Page 34: ...Start rpm CH 70 60 50 Adjustment range 50 to 99 of the set maximum rpm F Start rpm DHW 70 60 50 Adjustment range 50 to 99 of the set maximum rpm h Max fan rpm 48 50 50 Adjustment range nominal value 2...

Page 35: ...as soon as the set supply temperature is reached modulate on T flow 10 5 Adjusting pump setting 1 Adjust the pump setting dependent on the maximum power set and the water resistance of the installati...

Page 36: ...mperature in accordance with the heating line set The maximum supply temperature Tmax is set via the main display If desired the heating line can be changed in the parameter list See 10 3 Heating line...

Page 37: ...ate a CH demand Test program H HIGH SETTING 5 Select High setting by simultaneously pressing the and buttons twice H appears in service display DO NOT TEST with h in service display Press and again if...

Page 38: ...ue at max power value at max power Min CO2 value 8 4 9 4 10 Check the CO2 percentage If the values are within the prescribed range the CO2 setting of the boiler is correct If the value is not within t...

Page 39: ...ement and setting reposition the protection cap A on the gas valve and close the sampling point on the flue adapter 4 Adjust the appliance to the maximum power by simultaneously pressing the keys and...

Page 40: ...gas valve for gas tightness 10 Switch on the mains power 11 Check the gas connections after the gas valve for gas tightness during operation 12 Now check the setting of the CO2 percentage at high sett...

Page 41: ...re too low or falling Gas valve or ignition unit not powered 5 Poor flame signal Condensate drain blocked Check adjustment of gas valve Cheack for earth fault 6 Flame detection fault Replace ignition...

Page 42: ...air adjustment No Weak spark Check the ignition gap Replace the ignition electrode Replace the ignition unit on the gas valve 10 12 3 Burner resonating Possible causes Solution Gas supply pressure to...

Page 43: ...culation at least 2 or 3 radiators must be open No The boiler power has not been correctly set for the installation Adjust the power See setting maximum CH power No No heat transfer as a result of lim...

Page 44: ...e the pipe downwards 3 turning it anti clockwise 7 Lift the condensate drain pan on the left hand side from the connection to the condensate trap 4 and turn it to the right with the condensate trap co...

Page 45: ...n the front cover and the flue pipe components for leakage 13 Check the gas air adjustment 14 Fit the casing tighten the two screws left and right of the display and close the display cover 15 Check t...

Page 46: ...oller M Main voltage S2 Return sensor V Fan Connector X4 24V 6 7 On off room thermostat 0 1A 24Vdc and or frost thermostat remove connection 6 7 8 9 External sensor 12k ohm 25 C 11 12 OpenTherm thermo...

Page 47: ...es NTC 12kOhm T C R ohm T C R ohm T C R ohm 15 76020 25 12000 65 2752 10 58880 30 9805 70 2337 5 45950 35 8055 75 1994 0 36130 40 6653 80 1707 5 28600 45 5522 85 1467 10 22800 50 4609 90 1266 15 18300...

Page 48: ...mens Smart 801527 Ignition module Siemens TQG43 801537 Condensate trap 844187 Flow sensor DHW 844797 Condensate collector 847037 Pressure sensor CH 864087 Seal gas valve inlet 875757 O ring gas restri...

Page 49: ...installer authorised for that purpose by or on behalf of the gas company The instructions for installation and use which we issue for the boilers concerned should be complied with in full 5 The manufa...

Page 50: ...Intergas Heating Ltd 50 16 GAS BOILER SYSTEM COMMISSIONING CHECKLIST...

Page 51: ...Intergas Heating Ltd 51 17 SERVICE RECORD...

Page 52: ...wa ISO 9001 certified production faccility Intergas Heating Ltd 884587 01 Intergas Heating Limited Telephone 01527 888000 Building 94 Fax 01384 279480 Bay 1 Vantage Point info intergasheating co uk Th...

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