Intergas Heating Ltd
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12.3
Assembly
CAUTION
When fitting the various seals check for damage, hardening, tears or
hairline tears and/or discoloration. Where necessary fit a new seal.
Also check whether seals are still correctly positioned.
Check
Warranty will be void by not correctly replacing removed parts!
1.
Check if there is a small layer of ceramic grease on the contact surface between the shoulder
bolt and the front plate.
2.
Ensure that the seal around the front cover is installed correctly. Place the front cover on the
heat exchanger and secure it using the socket head screws plus serrated lock washers.
Tighten the shoulder bolts equally hand-tight (10 – 12 Nm), working crosswise. See the picture
for the correct sequence.
N.B. The picture is showing a front plate with 11 shoulder bolts (Kombi Kompakt HRE 28/24,
HRE 36/30 or HRE 36/40). The front plate for the HRE 24/18 has 9 shoulder bolts.
3.
Fit the gas connection below the gas valve.
4.
Fit the connector to the fan and the ignition unit to the gas valve.
5.
Fit the condensate drain by sliding on to the exchanger outlet stump (1) with the condensate
trap connection still in front of the base tray. Then turn it to the left (2) and push it downwards
into the condensate trap connection (3). Make sure in doing this that the back of the
condensate drain pan comes to rest on the lug at the back of the base tray (A).
6.
Fill the condensate trap with water and fit it to the connection below the condensate drain pan.
7.
Slide the flue pipe, turning it anti-clockwise, with the top around the flue adapter, into the top
cover. Insert the bottom into the condensate drain pan and tighten the coupling nut clockwise.
8.
Open the gas tap and check the gas connections below the gas valve and on the mounting
bracket for leakage.
9.
Check the CH and the water pipes for leakage.
10.
Switch on the mains power.
11.
Switch the appliance on with the
key.
12.
Check the front cover, the fan connection on 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 the heating and the hot water supply.
12.4
Combustion
During routine servicing, and after any maintenance or change of part of the combustion circuit the
following must be checked:
•
The integrity of the flue system and the flue seals, as described in § 8.5 and the British Standards
codes of practices, specifically BS 5440.
•
The integrity of the boiler combustion circuit and the relevant seals, as described in § 12.3.
•
The operational (working) gas inlet pressure at maximum rate, as described in
§ 10.7.2.
•
The combustion performance, as described in § 10.7 and § 10.8.
BS 6798: 2009 Specification for installation and maintenance of gas-fired boilers of rated input not
exceeding 70 kW net advises that:
•
The person carrying out a combustion measurement should have been assessed as competent in
the use of a flue gas analyser and the interpretation of the results;
•
The flue gas analyser used should be one meeting the requirements of BS7927 or BS-EN50379-3
and be calibrated in accordance with the analyser manufacturers’ requirements, and
•
Competence can be demonstrated by satisfactory completion of the CPA1 ACS assesment, which
covers the use of electronic portable combustion gas analysers in accordance with BS7967, Parts
1 to 4.
Connect the flue gas analyser to the flue gas sampling point (X) and check combustion as described in
§ 10.7. If the CO
2
percentage reading of the combustion gases at low setting falls into the bandwith
stated in § 10.8 the combustion setting is correct and no further adjustment is needed. If the
combustion reading falls outside the prescribed tolerance band and the integrity of the complete flue
system and combustion circuit seals have been verified as well as the inlet gas pressure proceed to
adjust the gas/air ratio as descibed in § 10.8. When the CO
2
percentage at high setting is not within the
prescribed tolerance band please contact Intergas Heating.
03010078
03010083
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