Professional Documents
Culture Documents
HRE 24/18
HRE 28/24
HRE 36/30
Installation
instructions
Read these installation instructions carefully before installing and using the
appliance.
Keep these installation instructions with the appliance.
Always act in accordance with the instructions indicated.
Intergas Verwarming BV
INDICE
1
1.1
1.2
1.3
1.4
1.5
1.6
SAFETY REGULATIONS
4
General......................................................................................................................................................................................... 4
Central heating installation............................................................................................................................................................ 4
Gas installation............................................................................................................................................................................. 4
Electrical installation..................................................................................................................................................................... 4
Drinking water installation............................................................................................................................................................. 4
Flue pipe and air supply................................................................................................................................................................ 4
2.1
2.2
2.3
2.4
2.5
2.6
Description of appliance
5
General......................................................................................................................................................................................... 5
Operation...................................................................................................................................................................................... 5
Operating modes.......................................................................................................................................................................... 5
PC Interface.................................................................................................................................................................................. 7
Test programs.............................................................................................................................................................................. 7
Accessories.................................................................................................................................................................................. 9
3.1
3.2
3.3
Installation
10
Overall dimensions..................................................................................................................................................................... 10
Installation location..................................................................................................................................................................... 12
Assembly.................................................................................................................................................................................... 13
4.1
4.2
4.3
4.4
4.5
4.6
4.7
Connection
15
Connecting CH installation.......................................................................................................................................................... 15
Connecting DHW installation...................................................................................................................................................... 17
Electrical connection................................................................................................................................................................... 18
Gas connection........................................................................................................................................................................... 19
Flue pipe and air supply.............................................................................................................................................................. 20
Pipe lengths................................................................................................................................................................................ 21
Balanced flue assemblies........................................................................................................................................................... 22
5.1
5.2
5.3
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
7.1
7.2
FAults
40
Fault codes................................................................................................................................................................................. 40
Other faults................................................................................................................................................................................. 40
Maintenance
9
9.1
9.2
43
Technical specifications
45
Electrical diamgram.................................................................................................................................................................... 46
NTC resistances......................................................................................................................................................................... 46
10
Warranty provisions
47
11
CE- Verklaring
47
Intergas Verwarming BV
This manual
This manual will enable you to assemble, install and maintain the appliance safely.
Follow the instructions meticulously.
In case of doubt contact the manufacturer.
Keep these installation instructions with the appliance.
Intergas Verwarming BV
Reffered to as
HE
Appliance
CH installation
DHW installation
Pictograms
The following pictograms are used in this manual:
CAUTION
Procedures which if they are not performed with the
necessary caution can result in damage to the product, the
surrounding area or the environment, or in physical injury.
Product identification
You will find the appliance data on the data plate on the underside of the appliance.
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.
N.
O.
P.
Appliance type
Hot water power rating (kW)
Power rating, upper and lower value (kW)
Rated power (kW)
Gas category
Gas connection pressure (mbar)
Gas type set
Pin
Appliance category
Maximum CH pressure (bar)
Maximum CH water temperature (C)
Maximum DHW pressure (bar)
Electrical connection
NOx number
Serial number
Year of manufacture
Intergas Verwarming BV
SAFETY REGULATIONS
1.1
General
The system as awhole must satisfy the applicable safety and other regulations, as
indicated in:
1.2
The entire installation must comply with the applicable safety and other regulations, as
indicated in:
1.3
Gas installation
The entire installation must comply with the applicable safety and other regulations, as
indicated in:
NEN 1078 (2004): Supply for gas with an operating pressure up to and including 500
mbar performance requirements- new estate
1.4
Electrical installation
The entire installation must comply with the applicable safety and other regulations, as
indicated in:
1.5
1.6
The flue pipe and air supply installation must comply with:
NEN 1078 (2004): Supply for gas with an operating pressure up to and including 500
mbar performance requirements- new estate
NEN 2757: Air supply and smoke outlet of incineration furnaces in buildings
determination methodes.
Intergas Verwarming BV
DESCRIPTION OF APPLIANCE
2.1
General
Intergas Verwarming BV
The Intergas Kombi Kompakt HRE wall mounted, gas fired boiler is a closed appliance.
The appliance is intended to deliver heat to the water in a CH system and the DHW
installation.
The air supply and combustion gas flue can be connected to the appliance by means of
two separate pipes. A concentric connection can be supplied if requested. The
appliance has been inspected in combination with the Intergas combi duct, but it can
also be connected to combi ducts that comply with the universal requirements for combi
ducts and which carry a Gaskeur(Dutch gas certification).
Depending on preference, the appliance may be connected to a mounting bracket, a
frame with top connection and various connection sets. These are supplied separately.
The Intergas Kombi Kompakt HRE 24/18 wall mounted gas fired boiler carries the CE
EP 20 rating and the Gaskeur (Dutch gas certification) labels HR, SV, NZ and CW
Class 3.
This means that the appliance is suitable for supplying at least 6 litres of water per
minute at 60C (this corresponds with 10 litres per minute at 40C) or filling a bath with
100 litres of water of average 40C within 12 minutes.
At the on and eco settings the appliance complies with the Gaskeur (Dutch
gas certification) CW requirements.
It is possible to use the appliance solely for hot water or solely for heating. The unused
system does not have to be connected. (See section 7.3)
The appliance is supplied as standard for natural gas (G25). On request an appliance
can be supplied for propane (G31).
2.2
Operation
The Intergas Kombi Kompakt HRE wall mounted, gas fired boiler is a modulating high
efficiency boiler. This means that the power is adjusted in line with the desired heat
requirement.
The aluminium heat exchanger comprises two separate copper circuits.
As a result of the separately constructed circuits for CH and DHW the heating and hot
water supply can operate independently of each other. The hot water supply takes
priority over the heating. The two systems cannot operate simultaneously.
The appliance is equipped with an electronic burner manager which, each time heat is
requested from the heating or the hot water supply, start the fan, opens the gas valve,
ignites the burner and continuously monitors and controls the flame, depending on the
requested output.
2.3
Operating modes
A code on the service display of the operating panel indicates the appliances operating
mode.
- Off
The appliance is out of operation but is supplied with electrical power. No response
occurs to calls for DHW or CH. The appliance frost protection is active. This means that
the pump operates and the exchanger is heated up if the temperature of the water
present in it falls too far.
If the frost protection is actuated, code 7 is displayed (heating exchanger).
In this operating mode the pressure in the CH installation (in Bar) can also be read on
the temperature display.
Waiting mode
The LED at the
button is lit and possibly one of the LEDs for the DHW comfort
function. The appliance is ready to respond to a request for CH of DHW.
0 Running on of CH
After the end of CH operation the pump continues to run. The running on time is factory set at
he value in accordance with section 7.3 , page:70. This setting can be changed.
Intergas Verwarming BV
In addition, the pump runs automatically for 10 seconds once every 24 hours in order to prevent
seizing. This automatic switching on of the pump occurs at het time of the last call for heat. To
change the time, the room thermostat setting should be increased briefly at the desired time.
Intergas Verwarming BV
The connected sensors are checked regularly by the burner manager. During the check
the manager does not perform any other tasks.
Intergas Verwarming BV
3 Ventilation
When the appliance is started the fan is first brought to starting speed. When the
starting speed has been reached the burner is lit. Code 3 is also visible when postventilation is taking place after the burner has stopped.
4 Ignition
When the fan has reached the starting speed, the burner is ignited by means of
electrical sparks. During ignition the code 4 is visible. If the burner does not ignite, a
new ignition attempt occurs after approximately 15 seconds. If after 4 ignition attempts
the burner is not yet burning, the burner manager goes into fault mode. (See section
8.2.1).
5 CH operation
An of/off thermostat, an OpenTherm thermostat, an external sensor or a combination of
the latter can be connected to the burner manager. (See section 10.1)
When a request for heat is received from a thermostat, the fan is started (code 3 ),
followed by ignition (code 4 ) and CH operating mode (code 5 ).
During CH operation the fan speed and hence the appliance power are controlled by
the burner manager so that the CH water temperature reaches the desired CH supply
temperature.
If an on/off thermostat is connected, this is the CH supply temperature set on the
display. In the case of an OpenTherm thermostat the desired CH supply temperature is
determined by the thermostat. In the case of an external sensor the desired CH suppply
temperature is determined by the heating line programmed in the burner manager. For
the latter two, however, the maximum is the temperature set on the display.
The CH operation the requested CH supply temperature is indicated on the operating
panel.
The CH supply temperature can be set between 30C and 90C. (See section 7.1).
The actual CH supply temperature can be read by pressing the service button during
CH operation.
When the DHW comfort function is switched on (See code 7 ) any OpenTherm
request for heat of less than 40C is ingored.
The resistance R may be removed if the room thermostat does not need anticipation
current. (See section 10.1)
6 DHW operation
The hot water supply takes priority over the heating. If the flow switch detects a need for
more than 2 l/min of DHW, any demand for CH will be interrupted. After the fan has
reached speed (code 3 ) and ignition has taken place (code 4 ) the manager goes to
DHW mode (code 6 ).
During DHW operation the fan speed, and hence the power of the appliance, are
controlled by the burner manager so that the DHW water temperature reaches the DHW
temperature setting.
The water temperature can be set between 40C and 65C (See section 7.1) and is
displayed on the operating panel during DHW operation.
The actual DHW temperature can be read by pressing the service button during DHW
operation.
On: ( LED on) The appliances DHW comfort function is switched on continuously.
The appliance always delivers hot water immediately.
Eco: ( LED on) The appliances DHW comfort function is self learning. The
appliance will adapt to the patttern of use of the hot water tap. As a result, the
temperature of the heat exchanger will not be maintained during the night or in the
case of lengthy absence.
Off: (Both LEDs off) The temperature of the heat exchanger is not maintained, as a
result of which the delivery of hot tapwater takes a little time. If there is no need for
fast delivery of hot tapwater, the DHW comfort function can be switched off.
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In the case of the on an eco settings the apppliance meets the Gaskeur(Dutch gas
certification) central heating requirements.
2.4
PC Interface
The burner manager is equipped with an interface for a PC, which can be connected by
means of a special cable and associated software. This facility allows the behaviour of
the burner manager , the appliance and the heating installation to be monitored over a
longer period.
2.5
Test programs
The burner manager 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, without the control functions being actuated.
The safety functions do remain active.
The test program is ended by pressing the and
simultaneously.
Test programs
Program description
Burner on at minimum CH power
Burner on with maximum CH power
setting (See section 7.3, parameter 3)
Burner on with maximum DHW power
(See section 7.3, parameter 4)
Switch off test program
2.5.1
Button
combinations
and
Display reading
L
and
(1x)
and
(2x)
"H"
and
Actuele
bedrijfssituatie
Frost protection
Note
If the appliance is out of operation ( - on the service display) the appliance frost
protection is active. However, a request for heat from an (external) frost thermostat will
not be responded to.
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Principal components
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
CH pump
Gas block
Burner manager plus operating panel
Supply sensor S1
Return sensor S2
Fan
Flow switch
CH pressure sensor
Mains lead 230 V AC with grounded plug
Manual air bleed
Sight glass
Intergas Verwarming BV
L.
M.
N.
O.
P.
Q.
R.
S.
T.
U.
Air supply
Flue pipe adapter
Connection block / terminal strip X4
Condensate drain pan
Hot water sensor S3
Siphon
Heat exchanger
Operating panel and read-out
Ionisation / Ignition pin
Position of data plate
12
2.6
Accessories
Description
Mounting bracket HRE 24/18
Frame
Sealing cap
Concentrische aansluiting 60x100
Sealing cap
PC Interface cable
Connection set for solar boiler post-heating
Intergas Verwarming BV
Article numbers
092.297
092.557
092.547
092.257
092.517
092.677
203.207
092.637
090.557
090.547
090.407
090.317
13
INSTALLATION
3.1
Overall dimensions
Supply CH
Return CH
Gas
Cold tap water
DHW
Condensate drain
517
590
Air supply
Flue pipe
Flue pipe / air
supply
22
22
(F)
15
15
25 (flexible)
80 (sealing ring)
80 (sealing ring)
60/100, or 80/125
(concentric)
Intergas Verwarming BV
Supply CH
Return CH
Gas
Cold tap water
DHW
Condensate drain
Air supply
Flue pipe
Flue pipe / air
supply
22 (compression)
22 (compression)
15 (compression)
15 (compression)
15
25 (flexibel)
80 (sealing ring)
80 (sealing ring)
60/100, or 80/125
(concentric)
14
Supply CH
Return CH
Gas
Cold tap water
DHW
Condensate drain
834
Air supply
Flue pipe
Flue pipe / air
supply
22
22
(F)
15
15
25 (flexible)
80 (sealing ring)
80 (sealing ring)
60/100, of 80/125
(concentric)
Intergas Verwarming BV
A=
B=
C=
D=
Supply CH
Return CH
Gas
Cold tap water
E=
DHW
F=
Y=
Z1 =
Z2 =
Condensate drain
Air supply
Flue pipe
Flue pipe / air
supply
22
22
15
15 (top pipe end, bottom
compression)
15 (top pipe, bottom
compression)
32 or 40 (spigot end)
80 (sealing ring)
80 (sealing ring)
60/100, or 80/125
(concentric)
15
3.2
Installation location
The appliance should be fitted to a wall that has sufficient bearing strength.
In case of light wall structures the possibility exitsts that resonance noise may occur.
There must be an earthed wall socket within 1 m of the appliance.
If the appliance is installed as an open appliance, the installation location should be equipped
with the necessary openings for the combustion air supply. (See section 4.5.2, page:36.)
To prevent freezing of the condensate drain pipe, the appliance must be installed in a frost free
room.
3.2.1
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3.2.2
For various work on the appliance the cover plate and front panel should be removed from the
appliance. Proceed as follows:
Unscrew the two screws (1) behind the appliance display window.
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3.3
Assembly
Depending on the connection situation, to mount the appliance use is made of a suspension
strip and mounting bracket or a top connection frame and mounting bracket.
On the mounting bracket the installation can be connected before the appliance is installed.
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3.3.1
Secure the suspension strip and the mounting bracket horizontally to the wall with the fastening
materials, in accordance with the drilling template. (See section 3.1)
3.3.2
Using the fastening materials supplied, secure the frame verticlly to the wall
Slide the connection pipes into the frame (only in the case of the complete top connection
set).
Secure the mounting bracket in the frame by inserting it with the flanged side upwards
through the openings in the frame and securing it with the two screws and nuts supplied with
the frame.
Note:
The appliance is wider than the frame.
3.3.3
Fit the filling/drain tap (A) with T-piece 22-1/2"-22 compression (B) to the return connection.
Fit the overflow valve (C) (3 bar) with the T-piece 22x1/2"-22 compression (D) to the supply
connection.
Fit the inlet assembly (E) (15-15 compression 8 bar) to the cold water connection (only in the
case of complete (top) connection set).
Fit the gas tap (F) (with coupling) to the gas connection (only in the case of complete (top)
connection set).
Assemble the drains for the pressure relief valve (G), the inlet assembly (H) and the siphon
(I). Fit the assembly into the mounting bracket (only in the case of complete (top) connection
set).
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3.3.4
1.
2.
20
Intergas Verwarming BV
1.
Operating instructions
Warranty card
3. Check the appliance for possible damage: report damage immediately to the supplier.
4. Check whether the compression rings are sitting squarely in the mounting bracket couplings.
5. Fit the appliance, sliding it downwards over the suspension strip. Ensure at the same time that the pipes slide into the compression fittings.
6. Tighten the compression fittings on the mounting bracket. The nipples must not be allowed to turn!
7. Fit the flexible tube to the siphon outlet.
8. Fill the siphon with water and slide it as far as possible upwards on to the condensate drain connector (C) below the appliance.
9. Connect the flexible tube (A) from the siphon (where applicable together with the overflow pipe from the inlet assembly and the pressure
relief valve) to the drain via an open connection (B).
10. Fit the air supply and the combustion gas flue. (See section 4.5)
3.3.5
Hang the flanged upper edge of the cover plate on the washers under the base of the appliance
and slide the cover plate as far as possible towards the rear.
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CONNECTION
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4.1
1.
Connecting CH installation
Flush the CH system thoroughly to clean.
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2.
3.
4.
Fit the supply pipe (B) and the return pipe (A) to the mounting bracket.
All pipes must be fitted unstressed in order to prevent the pipes from ticking.
Existing connections must not be twisted, in order to avoid leakages.
A filling/draining tap (A) in the return pipe immediately below the appliance.
A 3 bar pressure relief valve (B) in the supply pipe at a maximum distance of 500
mm from the appliance.
There must be no valve or constriction between the appliance and the overflow valve.
A check valve, if pipes run upwards at a short distance from the appliance. This
avoids the occurrence of thermosiphon effect during DHW operation mode.
4.1.1
If all radiators are equipped with thermostatic or regular radiator valves, a bypass must
be fitted in order to guarantee minimum water circulation. The bypass must be at a
distance of at least 6 m from the appliance in order to prevent overheating of the
appliance.
4.1.2
Floor heating
For effective operation of the DHW supply there must not be any undesired circulation
through the appliance as a result of a second pump in the CH circuit.
Connect the floor heating system in a hydraulically neutral manner to the appliance, or
equip the CH circuit with an electric shut-off valve or check valve to prevent flow
through the appliance when there is no CH request for heat.
Connection diagram for floor heating
A. Boiler
B. Pump
C. Floor heating valve
D. Check valve (spring operated)
E. Electrical valve 230 V AC
F. Radiators
G. Room thermostat
H. Maximum thermostat
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4.1.3
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26
The appliance can also be used in combination with an indirectly fired air heater (e.g.
Brink Elan) and a heat recovery unit (e.g. Brink Renovent HR). The appliance is suitable
for the heating of fresh ventilation air by just a few degrees. This guarantees a Minimum
Intake air Temperature.
This MIT regulation can be switched on and off with an external switch.
To save energy the pump setting must be adjusted as low as possible.
MIT regulation connection diagram
A. Intergas Kombi Kompakt
B. Pressure relief valve
C. Expansion vessel
D. Combined fan coil and heat recovery unit
E. Fan
F. Adjustable flow limiter (Taco 23.1202)
H. Electrical Shut-off valve
Operating principle
When the MIT regulation is switched on the appliance pump and DHW comfort function
are also switched on. A small heat flow (maximum 500 W) is admitted to the fancoil via
the adjustable flow limiter. This heats up the outside air by a few degrees. The shut-off
valve is opened when there is a demand for CH heat.
Installation instructions
1.
2.
3.
4.
5.
6.
Note
The MIT regulation only operaters when DHW comforton the appliance display is set
to on. Consult the thermostat manual when using an OpenTherm room thermostat.
Intergas Verwarming BV
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4.2
1.
2.
3.
Notes
At the settings on and eco the appliance meets the Gaskeur (Dutch gas
certification) CW requirements.
For the Kombi Kompakt HRE 24/18 the specific pipe length in the case of a pipe
diameter of 12/10 mm is 23.50 metres. In the case of a pipe diameter of 15/13 mm
this is 13.90 metres for the Kombi Kompakt HRE 24/18.
If the appliance is only used for the provision of hot water, the heating function can
be switched off with the service code on the operating panel. The CH installation
does not then have to be connected or filled.
If the appliance is taken out of operation during the winter and disconnected from the
mains supply, the sanitary water must be drained in order to prevent freezing. For
this purpose the DHW connections below the appliance must be removed.
Flow Resistance graph for appliance DHW circuit
A. Kombi Kompakt HRE 24/18
X. kPa (Bar)
Y. Litres per minute
4.2.1
The appliance carries the NZ label: suitable for solar water heater post-heating.
A special connection kit is applicable for this purpose.
Connection diagram for solar heater post -heating
A. Boiler
B. Storage tank Solar water heater
C. Cold water inlet
D. Inlet assembly
E. Flow switch
F. T max 85C
G. Hot water outlet T>60C
H. Thermostatic mixing valve 40 - 90C (set to aproxx. 60C)
K. Mixed water outlet
Note
When combined with a solar power system a thermostatic mixing valve must always be fitted
after the appliance and set to approx. 60C.
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Intergas Verwarming BV
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4.3
Electrical connection
CAUTION
An earthed wall socket must be located no more than 1 metre
from the appliance.
The wall socket must be easily accessible.
For installation in damp rooms a fixed connection is
obligatory.
When workin on the ectrical circuit always remove the plug
from the wall socket
If the mains lead has to be replaced, this should be carried out
by the manufacturer
Intergas Verwarming BV
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1.
2.
3.
4.
5.
Slide the cover plate (A) (if present) to the front to remove.
Unscrew screw (A) to gain access to the burner manager (B).
Pull the burner manager unit forwards; the burner manager will tip downwards to provide access.
Consult sections 4.3.1 and 10.1 for the making the connections.
After making the desired connections plug the appliance into an earthed wall socket.
4.3.1
Electrical connections
Temperature control
Room thermostat
Modulating thermostat with
comfort function in use
Connector X4
6-7
11 - 12
8-9
4-5
Power supply 24 V DC
67-9
Intergas Verwarming BV
6-7
Notes
6 7 open
Remove connection
between 4 5
Remove connection
Parallel to room
thermostat
6= 24 V DC
7= room thermostat
9= 0 V DC
31
4.3.2
4.3.3
4.3.4
The appliance is equipped with a connection for an outside temperature sensor. The
outside temperature sensor can be used in combination with an on/off room thermostat
or an OpenTherm* thermostat.
Connect the outside temperature sensor. (See section 4.3.1.)
For the heating line setting, see weather-dependent regulation. (See section 7.6, page: 73)
* In case of OpenTherm the thermostat determines the heating line. The appliance onl
passes on the outside termperature.
4.3.5
Modulating thermostat
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4.4
1.
Gas connection
Fit a gas tap (A) between the gas supply and the appliance.
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2.
3.
4.
5.
Fit the connection from the gas tap preferably directly into the connection at the mounting braket.
Install a gas filter mesh in the connection for the appliance if the gas may be contaminated.
Connect the appliance to the gas supply.
Check the gas carrying parts for leakage at a maximum pressure of 500 mmH 2O
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4.5
The pipes for combustion gases and air supply must have a diameter of 80 mm.
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4.5.1
Pipe
Air supply
Diameter
80 mm
Combustion
gas flue
Insulation
80 mm
4.5.2
Material
As per the local fire service and/or power
company regulations.
Spiralotube, single-walled aluminium,
galvanised sheet steel, stainless steel or plastic.
Possibly insulated with 10 mm vapour-tight
insulation material or plastic.
As per table 8 of NEN 1078 (1987).
10 mm vapour-tight insulation material in case
of possibility of condensation on the outside as
a result of a low wall temperature and a high
room temperature with high relative humidity.
1.
Fit the pipe for the combustion gas flue into the flue outlet. The integral sealing ring ensures an airtight connection.
4.5.3
Two-pipe connection
1. Fit the pipes for the air supply and combustion gas flue into the appliance inlet and outlet. The integral sealing rings ensure an airtight
connection.
Concentric connection
With the concentric adapter set the standard two-pipe connection can be changed to a
concentric connection (80/125 or 60/100).
1. Seal the open air supply connection in the appliance with the sealing cap supplied with the kit..
2. Remove the flue pipe adapter from the top of the appliance by turning it anti-clockwise.
3. Remove the o-ring from the adapter flange and fit it around the flange of the concentric adapter.
4. Place the concentric adapter in the top of the appliance and turn it clockwise so that the measurement nipple points straight forwards.
5. Fit the concentric pipe for the air supply and combustion gas flue into the adapter. The integral sealing rings ensure an airtight connection.
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4.6
Pipe lengths
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As the resistance of the flue pipe and air supply pipe increases the appliance power will
decline. The maximum permitted reduction in power is 5 %.
The resistance of the air supply pipe and combustion gas flue depends on the length,
the diameter and all components of the pipe system. The total permitted pipe length of
the air supply and the combustion gas flue is indicated for each appliance category.
The indication of pipe length in metres is based on 80 mm.
4.6.1
Equivalent lengths
Bend 90
Bend 45
Elbow 90
Elbow 45
R/D=1
R/D=1
R/D=0,5
R/D=0,5
2m
1m
4m
2m
In the case of larger or smaller pipe diameters the permissible pipe length is greater or
smaller respectively.
In the case of smaller diameters the following applies:
70: 0,59x the permissible pipe length for 80
60: 0,32x the permissible pipe length for 80
50: 0,15x the permissible pipe length for 80
Contact the manufacturer for check calculations for the resistance of the air supply and
combustion gas flue pipe and the wall temperature at the end of the combustion gas
flue pipe.
4.6.2
Sample calculation
Pipe
Flue pipe
Air supply
Pipe lengths
L1 + L2 + L3 + 2x2 m
L4 + L5 + L6 + 2x2m
Note
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4.7
Assembly general:
The assembly described below applies to all flue systems:
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1. Slide the combustion gas flue pipe into the appliance flue outlet.
2. Slide the combustion gas flue pipes into each other.
Working from the appliance each pipe must be pushed into the previous pipe
3. Fit a non-vertical combustion gas flue pipe with a fall towards the appliance of minimal 5mm per metre
4. Fit flanged seams oriented upwards in a horizontal section.
5. Seal non-gastight connections with heat-and moisture-resistant aluminium tape.
Assemble all air supply pipes as indicates below:
1. Slide the air supply pipe into the appliance inlet.
2. Seal non-airtight connections with moisture-resistant tape.
3. Fit insulation if necessary.
Materials to be used:
Appliance Materials
category
C13
Duct
Other parts
C33
Duct
Duct in the case of Prefab
Other parts
All materials
For the combined air supply /
combustion flue system
Inlet grille
Other parts and flue cowl
All materials and duct
Inlet grille
Main channel
Other parts
C43
C53
C63
C83
4.7.1
Supplier
Intergas
Gastec QA or Intergas
Intergas
Gastec QA, Intergas or
third parties
Gastec QA or Intergas
Third parties
Intergas
Gastec QA or Intergas
Gastec QA
Intergas
Third parties
Gastec QA or Intergas
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Intergas Verwarming BV
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3.
4.
5.
6.
7.
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4.7.2
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CAUTION
Pipes for connecting the air supply and the combustion gas
flue between the appliance and the combi duct must have a
diameter of 80 mm.
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4.
Fit the combi duct and combi extension pipe with a fall towards the appliance.
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4.7.3
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CAUTION
If the Intergas vertical combi duct cannot be used, the air
supply and combustion gas flue must be constructed
separately.
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1.
Fit a standard double-walled flue pipe ( 80 mm) with Giveg approved flue cowl on a sloped roof flashing at the desired position.
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2. Fit a standard ventilation pipe ( 80 mm) with cross cowl and roof flashing for the air supply.
3. Fit a standard double-walled flue pipe ( 80 mm) with Giveg approved cowl at the desired position .
In the case of a flat roof or a structural chimney, for the purposes of the air supply fit a standard ventilation duct ( 80 mm) with cross cowl in an
accompanying flashing plate.
CAUTION
Two terminals must be at least 200 mm apart.
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4.7.4
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The prefab chimney should be equipped with flue pipe and air supply openings of at
least 150 cm2 per connected appliance and must satisfy the minimum dimensions
indicated. The supplier must guarantee the effective operation of the prefabricated
chimney with regard to wind attack, ice formation, rain penetration etc.
As a result of the various designs and dimensions the prefabricated chimneys have to
be adapted to the local situation.
CAUTION
The connection of the air supply and the combustion gas flue
between the appliance and the prefabricated chimney must be
constructed in 80 mm pipe.
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4.7.5
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CAUTION
The air supply in the external wall must be fitted with an
Intergas inlet grill (A).
The prefab chimney should be equipped with flue pipe and air supply openings of at
least 150 cm2 per connected appliance and must satisfy the minimum dimensions
indicated. The supplier must guarantee the effective operation of the prefabricated
chimney with regard to wind attack, ice formation, rain penetration etc.
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4.7.6
Air supply from an external wall and a roof terminal with common
flue system
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Flue diameter
110
130
150
180
200
220
230
240
260
270
280
Common flue
The terminal for the common flue may be constructed at any point in the sloping roof
surface, provided that the terminal in the roof surface has the same orientation as the
ari supply in the external wall. In the case of a flat roof the terminal for the common flue
must be constructed in the free termination area.
Fit a condensate drain.
CAUTION
The common flue system must be equipped with a draught
creating flue cowl (B).
If the common flue system is situated in the outside air, the
flue pipe must be double-walled or insulated.
Note
The common flue system has been tested in combination with the appliance.
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4.7.7
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The common air supply and the common flue may be of a concentric or separate
design.
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5.1
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5.1.1
CH system
WARNING
5.1.2
1.
2.
3.
4.
5.1.3
1.
2.
3.
Gas supply
Vent the gas supply with the pre-pressure measurement nipple (D) on the gas block.
Check the connections for leaks.
Check the pre-pressure and the burner pressure. (See section 7.8.)
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5.2
1
2
3
4
5
6
7
8
Read-out
On / off
CH operation or setting maximum CH temperature
DHW operation or setting DHW termperature
Desired temperature of cH or DHW in C / Ch water pressure in bar / Fault code
DHW comfort function eco or setting number of memory days
DHW comfort function on (continuous) or set heat maintenance temperature
Operating code
Flashes to indicate fault
A
B
C
D
E
F
G
Operation
On / Off button
DHW / CH button, for setting desired temperature
- button
+ button
DHW comfort function off / eco / on
Service button / current temperature read out during DHW operation
Reset button
Once the preceding actions have been carried out, the apliance may be started up.
1. Press the
button , to start the appliance.
The heat exchanger is heated up and the service
display will show 3. , 4 and 7 (depending on the status of the DHW disabling switch
and/or Open Therm regulation)
2. Adjust the pump setting depending on the maximum power set and the resistance in the CH installation. For the water head of the pump
and the pressure loss of the appliance see section 7.5.
3. Set the room thermostat higher than the room temperature. The appliance will now switch to CH operation: 5 will show on the
display.
4. Heat the installation an dthe appliance to apporximately 80C.
5. Check the temperature difference between the supply and return for the appliance and the radiators. This must be approximately 20C. For
this purpose set the maximum power on the service panel. See seting maximum power. If necessary adjust the pump setting and/or the radiator
valves. The minimum flow is:
155 l/h at a power setting of 5.4 kW
510 l/h at a power setting of 17,8 kW
6. Switch the appliance off..
7. Bleed the appliance and the installation after cooling. (if necessary top up.)
8. Check correct operation of the heating and hot water supply.
9. Instruct the user on filling, bleeding and the operation of the heating and hot water supply.
Notes
The appliance is equipped with an electronic burner manager, which ingites the
burner and continuously monitors the flame during each request for heat from the
heating or from the hot water supply.
The circulation pump starts running in response to every request for heat from the
heating. The pump continues running for 1 minute after heating. This post purge
period can be changed if desired.(See section 7.3.)
The pump runs automatically for 10 seconds every 24 hours in order to prevent
seizing. This will occur at the the time of the last request for heat. To change this time
the room thermostat should be turned up briefly at het desired time.
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5.3
Shutting down
CAUTION
5.3.1
Frost protection
To avoid freezing of the condensate drain pipe the appliance must be installed in a
frost-free area.
To avoid freezing of the appliance it is equipped with frost protection. If the
temperature of the geat exchanger becomes too low, the burner switches on until the
temperature of the heat exchanger is sufficient. If there is a possibility of the
installation (or part of it) freezing, an (external) frost thermostat must be installed at
the coldest point of the return pipe. This must be connected in accordance with the
wiring diagram. (See section 10.1.)
Note
If an (external) frost thermostat has been fittted to the installation and connected to the
appliance, this will not be active when the appliance is switched off at the operating panel ( on service
display).
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The functioning of the appliance is determined primarily by the (parameter) settings in the
burner manager. Part of this can be set directly via the operating panel; another part can only be
adjusted using the installer code.
7.1
Appliance on/off
The appliance is started using the key.
When the appliance is in operation the green LED above the key will light up. When
the appliance is off a singe dash lights up on the service display ( - ) to indicate that
supply voltage is present. In this operating mode the pressure in the CH installation (in
bar) can also be read on the temperature display.
DHW comfort
The DHW comfort function can be operated with the DHW comfort key
and has the
following settings:
On: ( LED on) The appliances DHW comfort function is switched on continuously.
Th eheat exchanger is kept continuoulsy hot. The appliance always delivershot water
immediately.
Eco: ( LED on) The appliances DHW comfort function is self-learning. The
appliance will adapt to the pattern of use of hot tap water. As a result, the
temperature of the heat exchanger will not be maintained during the night or in the
case of long absence.
Uit: (Both LEDs off.) The temperature of the heat exchanger is not maintained, as a
result of which the delivery of hot tap water takes a little time. If there is no need for
hot tap water or its immediate delivery, the DHW comfort function can be switched
off.
Resetting
When a blocking fault is indicated by means of a flashing LED above the key and a figure on
the display, the appliance can be restarted by pressing the reset key. Check the nature of
the fault on the basis of the fault codes in section 8.1 and resolve the cause of the fault if
possible before resetting the appliance.
DHW temperature
Press the key until the LED at
starts to flash.
With the and keys set the temperature between 40C and 65C (default value 60C).
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starts to flash.
68
With the
and
keys set the temperature between 40C and 65C (default value 57C).
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7.2
The burner manager in the appliance is factory set in accordance with the parameters in section
7.3.
These parameters can only be changed using the service code. Proceed as follows to activate
the program memory:
1.
2.
3.
4.
5.
Press the
and keys simultanously until a 0 appears on the service- and temperature display.
Using the and keys set 15 (service code) on the temperature display.
Using the
key set the parameter to be set on the service display.
Using the and keys set the paramter to the desired value (visible) on the temperature display.
Once all desired changes have been entered, press the
key until a P appears on the service display.
7.3
key in takes you out of the menu without storing the parameter
Parameters
Kombi Kompakt
HRE
24/18 default
-
Para
meter
0
Setting
Servicecode [15]
Installation type
CH-pomp continuous
3
4
5
6
7
8
9
70
99
25
-7
25
1
1
70
99
25
-7
25
1
1
Booster
Step modulation
c
d
E
40
30
40
40
30
40
E.
Minimal CH rpm
Minimal DHW rpm
Min. Supply temperature during OT demand
(OT = OpenTherm thermostat)
OT response
F
H
Start rpm
Max.fan rpm
70
45
70
45
n
o
75
0
75
0
Intergas Verwarming BV
Description
Access to installer settings. The service code must be entered
(=15).
0=Kombi-Kompakt He
1=Kompakt Solo HE + boiler
2=Kompakt Tap HE
3=Kompakt Solo HE
0=only post purge period
1=pump continuously active
2=pump continuously active with MIT-switch
Adjustment range of set value parameter c up to 85%
Adjustment range of set valeu parameter d up to 99%
Adjustment range 10C to 25C
Adjustment range -9C to 10C
Adjustment range 15C to 30C
Adjustment range 0 to 15 minutes
Adjustment range 0 to 15 minutes (N/A. for Kombi appliance)
0=actuated during CH operation
1=actuated during DHW operation
0=off
1=on
0=step modulation off during CH operation
1=step modulation on during CH operation
Adjustment range 25 to 50 % (40=propane)
Adjustment range 25 to 50%. (40=propane)
Adjustment range 10C tot 60C
0=ignore OT if < E
1=limit OT if < E
2=OT on-off
Adjustment range 50 to 99% of the set maximum rpm.
Adjustment range 40 to 50. (40=4000rpm, 50=5000rpm) with this
parameter the maximum rpm can be set.
Adjustment range 60C to 90C
Adjustment range 0 to 15 minutes
Minimal switch-off time in CH operation
Adjustable from 0 to 15 minutes
70
7.4
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The maximum CH power is set at 70% in the factory. If more or less power is necessary
for the CH installation, the maximum CH power can be changed by changing the fan
rpm. See table Setting CH power.
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This table shows the relationship between the fan rpm and the appliance power.
Setting CH power
Desired CH power
Setting on service display
(in kW (aproxx.))
(in % of max. rpm)
Kombi Kompakt HRE
24/18
17.8
85
16,9
80
14,8
70
12,7
60
10,6
50
8,5
40
6,4
30
5.4
25
NB
The power during burning is increased slowly and is reduced as soon as the set supply
temperature is reached (modulatie on Ta).
7.5
The switch for adjusting the pump setting is located on the CH pump connection box. (Factory
setting III)
1. Adjust the pump setting depending on the maximum power set an the water resistance of the installation. See diagram: pressure loss of
appliance and pump water head, positions I, II and III.
2. Check the temperature difference between the appliance supply and return: this must be approximately 20C bedragen.
The minimum flow quantity
155 l/h
510 l/h
Power setting
5.4 kW
17,8 kW
7.6
Weatherdependent adjustment
Outside T in C
Supply T in C
Factory setting
(Tmax CH = 80C, Tmin CH=25C, Tmin out=-7C, Tmax out= 25C)
Example
(Tmax CH = 60C, Tmin CH=25C, Tmin out=-7C, Tmax out= 25C)
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7.7
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If a different type of gas is connected to the appliance than that for which the appliance has
been set by the manufacturer, the gas metering ring should be replaced. Conversion sets for
other types of gas are available to order.
Switch the boiler off and remove the plug from the mains socket.
Close the gas tap.
Remove the front panel from the appliance.
Unscrew the coupling (A) above the gas block and twist the gas mixing rube towards the rear (B).
Replace the O-ring (C) and the gas metering ring (D) with the rings from th econversion set.
Re-assemble in reverse sequence.
Open the gas tap.
Check the gas connections before the gas block for gas-tightness.
Insert the plug back into the wall socket and switch the boiler on.
Check the gas connections after the gas block for gas-tightness(during operation).
Now check the setting of the gas/air ratio. (See section 7.9 )
Place a sticker for the gas type set over the existing sticker next to the gas block.
Place a sticker for the gas type set next to the identification plate.
Fit the appliance front panel.
7.8
Gas-/air adjustment
The gas-/air adjustment has been set in the factory and in principle requires no
adjustments.
The setting can be checked by measuring the CO2 percentage in the combusion gases or by
measurement of the pressure difference.
In the case of possible disturbance of the adjustment, replacement of the gas block or
conversion to another gas type the adjustment must be checked and if necessary set in
accordance with the table below.
Gastype
Gas category
CO2% at low setting (L) ( and
)
With opened casing
CO2% at high setting(H) (
and 2x)
With opened casing
Gas supply pressure (mBar)
gas metering ring (mm)
Minimum rpm (% of max) (parameter d)
Min. start rpm (% of max) (parameter F)
Intergas Verwarming BV
Natural gas
L
2L
G25
25mBar
3P
G31(propaan)
29mBar
9,0 0,2
9,5 0,2
9,1 0,5
20-30
6,95
25
70
Propane P
10,0
0,5
25-35
4.90
40
50
75
7.9
A CO2 measurement nipple must have been fitted or must now be fitted in the flue
pipe.
A a fd e k d o p
to rx T 4 0
B s te ls c h r o e f
to rx T 4 0
C m e e tn ip p e l
-5 P a
(- 0 .0 5 m B a r )
D v o o r d r u k m e e tn ip p e l
(2 0 -3 0 m B a r)
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A.
B.
C.
D.
1. Switch the appliance off with the on/off key. ( - on service display).
2. Unscrew the CO2 measuring nipple and connect the measuring hose.
3. Switch the appliance on with the on/off key.
4. Adjust the appliance to the lowest power by simultaneously pressing the keys
and and on the operating panel until an L.
appears on the display.
5. Measrue the CO2 value. If the CO2 value does not correspond with the in the table in section 7.8 proceed with setting as follows:
6. Remove the front panel from the apppliance..
7. Remove the cover cap (A).
8. Adjust the set screw (B) to the correct CO2 value (clockwise higher and anti-clockwise lower).
9. After measurement and setting replace the cover cap (A) and close the CO2 measurement nipple.
10. Press simultaneously on the and keys to leave the test program.
11. Fit the front panel to the appliance.
NB
Check that the measurement nipples used are gas-tight.
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FAULTS
8.1
Fault codes
If the fault LED is flashing, the burner manager has detected a fault. A fault code will be
indicated on the temperature display.
Once the fault has been rectified the burner manager can be restarted:
Press the reset
key on the operating panel.
The following faults are distinguished
Temperatuur
display
10, 11, 12,
13, 14
20, 21, 22,
23, 24
0
1
Omschrijving
Mogelijke oorzaak/oplossing
Sensor fault S1
Sensor fault S2
Sensor fault after self check
Temperature too high
S1 and S2 interchanged
No flame signal
29,30
8.2
Other faults
8.2.1
Possible causes:
Oplossing:
Ja
Ja
Ja
Ja
Ja
Check the cabling. Check the spark plug cap. Replace the ignition unit.
Ja
Ja
Check the wiring. Check the fuse , if necessary, replace the fan.
Ja
Ja
Replace the gas block. Re-adjust the gas block, see gas/air adjustment
Nee
Air in the gas pipe.
Nee
Gas supply pressure to low.
Nee
No ignition.
Nee
No spark. Ignition unit on gas block faulty.
Nee
Gas/air adjustment not correctly set.
Nee
Fan faulty
Nee
Fan dirty.
Nee
Gas block faulty.
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8.2.2
Possible causes:
Solution:
Ja
Ja
Ja
Ja
Nee
Incorrect ignition gap.
Nee
Gas/air adjustment not correctly set.
Nee
Weak spark.
8.2.3
Burner resonating
Possible causes:
Solution:
Ja
The house pressure switch may be faulty. Contact the gas company.
Ja
Ja
Nee
Recirculation of combustion gasses.
Nee
Gas/air adjustment not correctly set.
8.2.4
No heating (CH)
Possible causes:
Room thermostat / weather-dependent
adjustment not closed or faulty.
Ja
Solution:
Check the wiring.
Replace the thermostat.
Replace the weather-dependant adjustment.
Nee
No current (24 V).
Ja
Ja
Ja
Ja
Nee
Pump not running.
Nee
Burner not firing on CH: sensor S1 or S2 faulty.
Nee
Burner does not ignite.
8.2.5
Possible causes:
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Solution:
79
8.2.6
Ja
Possible causes:
Solution:
Ja
Ja
Increase the CH temperature. See Operating CH . Check esternal sensor for shortcircuiting. Rectify.
Ja
Ja
Ja
Ja
Nee
Temperature is too low.
Nee
Pump not running correctly. Pump setting is too
low.
Nee
No circulation in the installation.
Nee
The boiler power has not been correctly set for
the installation.
Nee
No heat transfer as a result of lime scale or
fouling in the heat exchanger.
8.2.7
Possible causes:
Flow switch not switching.
Ja
Solution:
DHW flow < 2.0 l/min.
Replace the flow switch.
Nee
No current at the flow switch (5V DC).
Ja
Ja
Replace S3.
Ja
Nee
Burner not firing on DHW: S3 faulty.
Nee
Burner does not ignite
8.2.8
Possible causes:
Solution:
Ja
Ja
Ja
Ja
Nee
Temperature setting for water circuit too low.
Nee
No heat transfer as a result of lime scale or
fouling in the heat exchanger DHW side.
Nee
Cold water temperature <10C.
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MAINTENANCE
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The appliance and the installation should be checked and if necessary cleaned every year by a
registered expert.
CAUTION
9.1.1
Disassembly
9.1.2
1.
2.
3.
4.
Cleaning
Clean the stem strips and plates of the heat exchanger from top to bottom with a brush or compressed air..
Clean the underside of the heat exchanger.
Clean the condensate drain pan with water.
Clean the siphon with water. (if necessary, the side branch on the siphon may be sawn off.)
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5.
9.1.3
Assembly
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 ar still correctly positioned.
Failure to fit the sensors S1 and/or S2, or the stem strips, or to fit
them correctly, can result in serious damage.
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10
TECHNICAL SPECIFICATIONS
Appliance category
Gas supply pressure
Suitable for gas type
Technical data
DHW
Nom. Power rating lower value
Rated power*
DHW threshold
DHW flow 60C
DHW flow 40C (gemengd)
DHW temperature
Effective appliance waiting time*
DHW-side pressure loss
kW
kW
l/min
l/min
l/min
C
sec
kPa
5,6 22,1
6,1 21,0
2
6
10
60
<1
Zie 5.2
7.1 28.0
7.8 27.0
2.0
7.5
12.5
60
<1
Zie 5.2
7.2 32.7
8.0 31.5
2.0
9.0
15,0
60
<1
Zie 5.2
CH
Nom. Power rating lower value**
Rated power at 80/60C**
Rated power at 50/30C**
Max. CH-water pressure
Max. CH-water temperature
kW
kW
kW
bar
C
5,6 18,7
5,4 17,8
5,9 18,5
3
90
7.1 23.7
6.9 22.8
7.6 - 23.4
3,0
90
7.2 27.3
7.1 26.3
7.8 27.1
3,0
90
Other data
Gas consumption (G20)
Appliance pressure loss (CH)
m3/h
mWk
0,59 2,30
See section 7.5
0,75 2.90
See section 7.5
0.75 - 3.40
See section 7.5
Elektrical data
Mains power
Safety class
Power consumption : full load
Power consumption: partial load
Power consumption: stanby
V
IP
W
W
W
230
IP20
105
40
2,4
230
IP20
105
40
2,4
230
IP20
105
40
2,4
mm
mm
mm
kg
590
450
240
30
650
450
240
33
710
450
240
36
* Time required from start of drawing water to achieve a temperature increase of 40K at the DHW outlet of the appliance,
based on the CW (Comfort hot water) DHW flow.
**The maximum CH power is factory set at 70% of the highest value. (See section 7.4 Setting maximum CH power).
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10.1
Electrical diagram
10.2
NTC resistances
NTC 12kOhm
T [C]
-15
-10
-5
0
5
10
15
20
R[ohm]
76020
58880
45950
36130
28600
22800
18300
14770
T [C]
25
30
35
40
45
50
55
60
Intergas Verwarming BV
R[ohm]
12000
9805
8055
6653
5522
4609
3863
3253
T [C]
65
70
75
80
85
90
95
100
R[ohm]
2752
2337
1994
1707
1467
1266
1096
952
87
11
WARRANTY PROVISIONS
With due regard for the conditions indicated below Intergas Heating
BV guarantees to the registered installer the soundness of the
materials used, as well as the effective operation of its Central
Heating products, when used for the purpose for which they are
supplied. As the case arises we should be given the opportunity
where necessary to ascertain in situ the soundness of the warranty
claim.
The warranty comprises:
The warranty is limited to re-supplying free of charge the parts that
entirely in our judgement display material or manufacturing faults
during the warranty period, which are not the result of normal wear
etc. Such parts should be sent to us carriage paid with an indication
of the defect and after replacement will become our property.
1. The warranty period on parts is 2 years, calculated from the
date of installation. However, the following parts are excluded from
warranty: ignition and ionisation pin, glass fuse, thermocouple and
air bleed
2. The warranty period on the sealing of the appliance heat
exchanger is 15 years provided, however, that, if in our view locally
unavoidable leakages occur as a result of corrosion, we supply
solely this boiler component on the basis of reimbursement of old
for new calculated from the date of installation at the time of
replacement: the first 5 years free, the 6th year 10%, the 7th year
20%, and so on up to the 14th year 90% of the current price of the
boiler part to be replaced.
3. The warranty ceases to apply if it is determined that the
defects, damage or excessive wear are attributable to improper use
or injudicious handling or inexpert repair, adjustment, installation or
maintenance, by unauthorised installers or to exposure to
substances containing aggressive chemicals (including hair
lacquer) and other harmful substances.
4. The warranty also ceases to apply if pipes and couplings have
been used in the installation which can cause oxygen diffusion or if
the defect is the result of boiler scale deposits (harmful to the
appliance and the installation).
Surface damage and transport damage are not covered by the
warranty. The right to warranty lapses if it cannot be demonstrated
that, following commissioning, the central heating boiler or central
heating stove has been subjected to a service at least once a year
by an installer authorised for that purpose by or on behalf of the gas
company. The installation and operating instructions that we issue
for the appliances and stoves concerned should be fully adhered to.
5. The manufacturers liability under the agreement is expressly
limited to fulfilment of the warranty obligations described in this
article. Any claim for compensation with the exception of those
relating to non-fulfilment of the warranty obligations is excluded.
With due regard for the mandatory legal provisions regarding
liability and product liability, no rights may ever be derived with
regard to any consequential loss, purely final loss or any loss
whatsoever arising from defects in materials supplied or work
undertaken by the manufacturer. Furthermore all offers of and
agreements regarding products to be supplied and/or services to be
Intergas Verwarming BV
Use as intended.
The appliance, as described in this documentation, is intended for
heating rooms via a central heating installation and/or for supplying
hot water. Any other use lies outside the intended use of the
appliance. No liability can be accepted for loss or damage arising
from incorrect use.
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CE- VERKLARING
Intergas Verwarming BV
Holwert 1, 7741 KC COEVORDEN
H. Bosscher Directeur
88
Intergas Verwarming BV
269215096.doc
De Holwert 1
Postbus 6
7740 AA Coevorden
Tel: 0524-512345
Fax: 0524-516868
www.intergasverwarming.nl
Intergas Verwarming BV
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