Intergas Xclusive 24 Manual

The complete boiler guide
High Efficiency Wall-Mounted Gas Boilers
Smart Opentherm™
Readthisserviceprocedurethoroughlytoensurecontinuedsafetyandefficient
operationoftheboiler.
ShouldyourequirefurtherinformationpleasecontactourService&Technical
departmentbycalling01527888000
Boiler Service
Procedure
BOILERS
Smart Opentherm™
Boiler Service
Procedure
The complete boiler guide
High Efficiency Wall-Mounted Gas Boilers
Readthisserviceprocedurethoroughlytoensurecontinuedsafetyandefficient
operationoftheboiler.
ShouldyourequirefurtherinformationpleasecontactourService&Technical
departmentbycalling01527888000
Xclusive 30
Xclusive 36
Xclusive 24 (G.C. 47-291-13)
(G.C. 47-291-14)
(G.C. 47-291-15)
Xtreme 24
Xtreme 30
Xtreme 36
(G.C. 47-291-10)
(G.C. 47-291-11)
(G.C. 47-291-12)

Introduction 2
Annual service A ..............................................................................................................6
Service procedure explanation 4
Inspection of seals & unions (X-Range boilers)...................................................................................11
Removing / replacing the room sealed cover (X-Range boiler) .................................................................... 5
CONTENTS
INTRODUCTION
During a survey of existing Intergas boilers installed we have noted that many are not being serviced correctly. To ensure the appliance
continues to operate safely and efficiently it is essential that the annual servicing is completed correctly. Any work undertaken must be
performed by a competent, suitably qualified Gas safe registered engineer.
Please ensure the workspace is suitably protected and that PPE is worn at all times during this procedure.
2
Annual Service Checklist 3
12
Measuring the flue gas at Maximum output
Annual Service
Annual Service 6
13
Measuring the flue gas at Minimum output
14
Gas valve adjustment procedure
15
HRE & Eco RF Service Procedure
19
Rapid Service Procedure
23
Service & Interim record
Service variations ............................................................................................................16
Annual service B ..............................................................................................................8
Reassemble 17
.................................................................................................................
Inspection of seals & unions (HRE & ECO RF boilers) 18
............................................................................
Service variations ...........................................................................................................
Internal maintenance ....................................................................................................... 21
Inspection of seals & unions (HRE & ECO RF boilers)
............................................................................22
Annual service (Cleaning)......................................................................................................8
Annual service (Re-assemble)..................................................................................................
10
20
24
Intergas Heating contact details

Annual service checklist
No. Activity
Inspection and
service procedure
A (Every year)
1Isolate the boiler from the fused spur and make safe (ref TB118) check
the correct 3amp fuse has been fitted.
2Carry out inspection of boiler for dust and dirt and clean where
necessary.
3Visually inspect the front plate and heat exchanger for signs of
damage. (If damaged contact Intergas service department or replace).
4Check the gas inlet working pressure and Input rating on HIGH rate
"H" (DHW mode).**
5Check combustion by measuring CO & CO2
6Close the boiler gas isolation valve.
7
Isolate flow and return valves and drain boiler via the flushing valve on
the Intergas system filter (remove the magnet on the filter prior to
draining, as this will flush out and clean the filter as required).
8Remove the front plate and clean the inside of the heat exchanger.
9
Replace the front plate seal every
or if the front plate has been removed using the Intergas OEM black
 years or if damaged, degraded
Viton seal (Red silicon type seals must be replaced regardless of age).
10 Check the burner has not delaminated also check the burner seal.
11 Check the ignition electrode for clearance, debris & seal integrity.
12 Check the condensate trap & seal, clean and refill.
13
Open the isolation valves on flow and return & recharge the pressure
between 1.2 & 1.5 bar via the filling loop, (replace system filter magnet).
14
Open the gas isolation valve, reconnect the power to the boiler via
fused spur.
15
Check visually the ignition and burner performance (If possible).
16
Check the boiler for leaks of any kind (gas, flue gas, water,
condensate) rectify if necessary.
17
Recheck the CO,CO2and adjust CO if necessary (at LOW fire only).
2
18
Complete the Benchmark Service Record on the back pages of the
Installation manual.
3
**Whenin "H"highratethe gasinletworking pressuremust bechecked viaP1of the
gasvalve andthegas meterwhen required.
Theminimum permissiblepressureat P1is 17mbar(with allconnectedappliances operating
atfull rate)basedon thefollowing calculation..
Gasmeter (GM)21mb+/- 2mb(GM min19mb pipework-1mbar,boiler -1mbar= 17mbarat P1)
Systemor Openventboilers shouldbe checkedat highrate"h" (CHmode) forInput rating.
Check the expansion vessel air pressure via the Schrader valve (with
no system pressure) it should be 0.75 to 1.0bar
◊
◊
Theflushing valveshouldconnected toa suitabledrain hoseorterminated intoa bucket
takingcare asthesystem watercan containchemicals orironoxides (magnetite)which
canstain ordamagesurfaces /carpets etc,PPE shouldbeworn toprotect youreyes and
skin.
Thesystem Inhibitormustbe checkedand ifnecessary toppedupto therequired
concentration(as pertheBuilding Regulations& BS7593:2019). IntergasrecommendFernox
InhibitorTest stripscombinedwith thefree todownload Fernoxwatertest App.
Inspection and
service procedure
B (Every 2 years)
IMPORTANT
See Inspection of seals & unions pages 11, 18 or 22 for model specific seal replacement schedules.
Replace room sealed cover and complete flue integrity test.
19
20

Service procedure explanation.
4
►
►
COMMENT
►There are 2 types of service procedures
A = Interim service to be completed annually.
B = Internal service to be completed bi-annually
in conjunction with Interim service A.
NOTE every year extra seals need to be replaced.
Theboiler mustbeserviced annuallyby completingservice procedureAwhichis a
nonintrusive safetycheck.
Serviceprocedure Aistovisually inspectfor anysigns ofdistress,leaking, basiccleaning
andto completeallgas safetychecks (Seepage 6,7,16 or20 forboiler specificvariations).
Serviceprocedure Bistocomplete serviceprocedure Aandthen continuewiththe
internalmaintenance whichincludescleaning theheat exchanger
►Tohelp understandtheservice intervals....
Year1 (12monthsafter theinstallation date)complete serviceprocedureA
Year2 (24monthsafter theinstallation date)complete serviceprocedureA+ B (replacefront plateseal)
Year3 completeserviceprocedure A
Year4 completeserviceprocedure A+B and replaceseals notedwithinboiler specificpages 11,18, or22
including thefrontplate seal.
A = Interim service to be completed annually.
B = Internal service to be completed bi-annually
►
(Seepage 8,9& 10for
allboiler variants).
Year 1,3, 5,7 etcfollow procedure A
Year2, 6etcfollow procedureA+B
Year4, 8etcfollow procedureA+Bandreplace sealsnotedwithin boilerspecific pages11, 18or22
includingthe plateseal.
4th
IMPORTANT
► When carrying out the flue gas analysis checks
in service procedure (A), should the CO be
the immediately proceed to service procedure (B).
If no proof of service history is available then complete
service procedure (A) + (B), if the boiler is years or
older then also replace the relevant seals as stated on
pages 11, 18 or 22 including the front plate seal.
≥ 160ppm
4
►

Removing/Replacing the Room Sealed Cover (X-Range)
►The front cover of the boiler must be removed to perform
various maintenance activities however you must be a
competent Gas Safe registered engineer before carrying out
the following procedure!
►Loosen both screws (1) under the boiler by using a 5 mm
allen key. (They are captive and therefore will not drop out
of the lower housing).
►Slide the front cover (2) upward and then remove it by
pulling it towards you.
1
2
Replacing the room sealed front cover.
To replace the front panel, proceed as follows:
►Position the front panel (3) against the boiler and slide
it downwards until it is correctly connected to the
lower fascia panel.
►Hand tighten screws under the boiler using a 5 mm
allen key (do not over tighten).
3
COMMENT
►The front cover has a rubber seal around
the inner edge sometimes making it
very sti to slide o so please ensure the
boiler is secured to the wall correctly
before attempting this procedure!
CAREFUL
►This is a room sealed cover and therefore
extremely important that it is fitted
correctly, failure to do so could lead to
products of combustion entering the
room / environment where it is situated.
Removing the room sealed front cover.
5

Annual service procedure (A)
Annual service (A) continued (syphon maintenance).
The boiler and the system must be inspected annually by an qualified competent gas safe registered engineer.
The boilers heat exchanger should be cleaned and inspected as stated below at the correct service interval.
►Detach the syphon cup (1) by rotating it a quarter turn to the
le and then pulling it out downwards.
►Remove the flexible hose (2) from the syphon base and the
waste connection.
►Empty the syphon cup (3).
►Detach the syphon base (3) by pressing the three securing
clips in, while simultaneously pushing the syphon base
downwards (4).
►Remove the circlip and the plastic ball from the syphon base (5).
►Clean the following components with water:
◉the inside of syphon base
◉plastic ball
◉circlip
◉syphon cup
◉opening of the exhaust manifold
2
1
1
1
1
2
3
4
5
CAREFUL
►Aer completion of the Annual service
procedure all 26 (9) safety checks must be
performed and the results recorded within
the service & interim boiler work pages, at
the back of the installation manual.
(see example page 23)
►Some components can be very hot during and
just aer operating the appliance.
►For Health & Safety reasons the use of PPE is
recommended during the below procedure.
►Switch o the appliance and isolate the power supply at the fuse
spur, make safe the appliance before continuing (Ref TB118).
►Close the boiler gas isolation valve (test for let-by).
►Remove the room sealed cover of the boiler by loosening the two
Allen screws (A) and then liing the panel up and forward (B)
►Wait until the boiler has cooled down. This can be done by
opening a domestic hot water tap (with the power switched o).
A
B
ANNUAL SERVICE (A)
6

IMPORTANT
►Make sure that the syphon base is
returned to its original position, firmly
locked into the bottom with no gaps.
Incorrectly attaching the syphon base
(or not attaching it at all) will result in
products of combustion leaking into the
room creating a dangerous situation.
►Return the plastic ball to the syphon base and attach the
circlip.
►Check that the ball and circlip have been installed correctly
(6). Make sure that the top of the circlip is about 6 cm below
the edge of the syphon base.
►Replace the O-ring (art. no. 086154) at the bottom of the
exhaust manifold, every 4 years or if damaged (see page 11).
►Attach the syphon base to the bottom by pushing it high
enough so that the securing clips click over the lip (7).
►Make sure that the syphon cup is filled with ¾ water (8) before
placing it back, slide it into the syphon base and rotate it a
quarter turn to the right (clockwise) so that it is correctly
secured (9).
►Slide the ribbed hose onto the syphon base and back into the
waste connection.
–
C
L
I
C
K
!
–
ca. 6 cm
6
7
8
3/4
9
NOTE
►To assist the replacement of the syphon base and syphon cup
silicone lubricant is recommended on the following seals,
◉ Exhaust manifold O-ring seal
◉ Syphon base outer seal
◉ Syphon cup O-ring seal
►Li and rotate the expansion vessel to the le side.
►
►
►
Annual service (A) continued
COMMENT
► The expansion vessel must be inspected and
tested at each annual service and if required
repressurised between 0.75 & 1.0 bar (cold
and with no system pressure). Ensure the
flexible hose is not kinked, leaking or
damaged (Replace if required).
10
Open the gas isolation valve and check both of the gas
unions for tightness.
Check and repair any water leaks within the boiler.
►Turn the expansion vessel back to its original position. Make
sure the vessel is secured by the lip on the cable cover.
►Check a 3amp fuse is fitted before re-establishing the
power.
Switch on the boiler.
► Check the front plate, the fan seal, fan connection to the
front plate, also check the flue components for leakage,
repair or replace as required.
►Check the gas/air control and also test the gas outlet
union on the gas valve for tightness.
►
Check the domestic hot water facility for correct operation.
Turn to page 1 " measuring the flue gas at maximum output"
then continue through the procedure.
I01.000.09.0001
►
7
2

►Clean the slats of the heat exchanger from top to bottom with a
brush or Intergas comb (use a vacuum cleaner to remove debris).
►Clean the underside of the heat exchanger.
►Only clean the lower metal heat shield of the front panel.
CAREFUL
►The integrated insulation panel and
burner seal contain ceramic fibres use the
appropriate P.P.E dust mask & gloves.
►Li and rotate the expansion vessel to the le side.
►Disconnect the electrical connector to the fan assembly.
►Loosen both unions and the electrical connector then remove
the gas valve.
►Unscrew the 6mm Allen key shoulder bolts of the front plate
and remove it along with the fan (Being careful not to
damage any components). Lay the removed front plate face
down onto its foot supports, this is best achieved on a flat heat-
proof surface.
►The burner and the integrated insulation panel do not require
cleaning only inspecting. Therefore, never use a brush or
compressed air to clean these components (dust hazard).
Annual service (B) (Internal maintenance)
Annual service (B) (cleaning)
SlidetheIntergascombbetweenthefins MovetheIntergascombin-outandup-down
repeatforallcontaminatedpartsoftheexchanger
COMMENT
► The expansion vessel must be inspected and
tested at each annual service and if required
repressurised between 0.75 & 1.0 bar (cold
and with no system pressure). Ensure the
flexible hose is not kinked, leaking or
damaged (Replace if required).
8

Annual service (B) continued (cleaning)
Atypicalheatexchangerthatrequirescleaning Heatexchangeraftercleaning
Ensuretheoxideresiduehasalsobeenremoved
aftercleaningthefins Watercanbeusedtoassistcleaningthefinsusing
afinemistatomiserspray(Warningyoumustprotect
thePCBandanyelectricalconnectionsfrompotential
waterdamage).
WaterAtomisertriggerspray
BrassorNylonbristled
brushonly(notsteel)
IntergasHeatexchangercomb
Partnumber460067
►
►
►
Whencleaningtheheatexchanger
surfacetopreventdamageonly
usethesuggestedtools.
ABrassorNylonbristledbrushcan
beusedtocleanthesurfacefollowed
byamistspraytowashitdown.
TheIntergascombhasbeendesigned
toassistintheremovalofanyhardened
areasofAluminiumoxide.
HO
2
Intaclean
Vacuumcleaner 9
Brassbristles

I01.000.09.0001
I01.000.09.0001
1
2
3
4
5
6
7
8
9
10
11
IMPORTANT
►Replace the Viton front plate O-ring at least
every 2 years or if damaged/ discoloured and
Art.no: (Black Viton) — Xtreme 24/30
(Black Viton) — Xtreme 36
►
Check and replace any other worn gaskets
(see page 11, 18 & 22) check they are
correctly located.
Annual service (B) (re-assemble)
A
►Check whether there is a thin layer of ceramic grease both
sides of the front plate where the shoulder bolts protrude
especially between the flange of the shoulder bolts and
the front plate. itself
►If there is insuicient grease present, extra must be applied
using the foam application tool (A) within the kit (ceramic
grease kit available to order, part number 9587).
►Ensure the Viton O-ring seal is pushed fully into the
O-ring chamber around the whole front plate.
Place the front panel back on the heat exchanger and
attach it with the 6mm Allen key shoulder bolts.
Tighten the shoulder bolts (1 to 11)* by hand, working
diagonally. The order of tightening is shown in the diagram.
►Fully tighten the Allen shoulder bolts with a torque wrench
set at 10-12 Nm when available to ensure uniformity.
►Check and tighten the burner bolts diagonally by hand.
►Replace the gas valve and when necessary replace the seals
►Reinstate the electrical connector to the gas valve and fan.
►Open the gas isolation valve and check both of the gas
unions for tightness.
►Check and repair any water leaks within the boiler.
►Turn the expansion vessel back to its original position. Make
sure the vessel is secured by the lip on the cable cover.
►Check a 3amp fuse is fitted before re-establishing the
power.
►Switch on the boiler.
►Check the front panel, the fan seal, fan connection to the
front panel, also check the flue components for leakage,
repair or replace as required.
►Check the gas/air control and also test the gas outlet
union on the gas valve for tightness.
►
Check the domestic hot water facility for correct operation.
* Do not overtighten
Clicking noise (expansion) during operation is normally due
to overtightening of the front panel bolts or lack of ceramic
grease.
Please check suicient ceramic grease has been applied and
the correct torque settings adhered to before calling the
Intergas service team.
086474
086504
10
►
►
IMPORTANT
Once the boiler has been serviced or
the front plate seal has been replaced
a seal integrity test must be completed
by operating the boiler in high fire 'H'
then using your calibrated E.F.G.A to
sweep around the entire outer edge of
the front plate.
Analyser readings should not be
above that of the ambient room or
compartment the boiler is sited within.
All red Silicon front plate seals must be
replaced, regardless of age with the below
or if the front plate has been removed.

11
Frontplateseal(Viton)
partnumber
Large086474
Medium086504
BurnerEarthspring
FanNonreturnvalve
Fanseal(rubber)
partnumber877807
Venturigas'O'ring
partnumber875737
Gasvalvetopunion
Gasrestrictordisc'O'ring
partnumber875827
Gasrestrictordisc
Gasvalvelowerseal
partnumber875757
Burnerfibreseal(fragile)
Partnumber877847
INSPECTION OF SEALS & UNIONS (X-range boilers)
†
†
†
†
†
†
replaceevery 4yearsregardless ofcondition.
=Front platesealmust bereplaced every2 yearsorif thefront plate
hasbeen removedforinspection.
=Inspect every2years minimumreplace ifdamaged ordegradedor
Partnumber875917(x4)
Burnerretainingscrewseal
†
PLEASE
NOTE
FrontPlate Seal
Replacedon
Date......................................
Syphoncupseal
partnumber875664
†
Fluecollectorseal
partnumber086154
†
(From2203serial numbers)
¶
¶

12
Having cleaned the heat exchanger and boiler components
and whilst the boiler is still safely isolated.....
A.
Remove the cap of the flue gas sampling test point (3) on the
appliance connector or bend on top of the boiler.
B.
Place the sampling probe of the calibrated electronic flue gas
analyser into the flue gas sampling point (3).
IMPORTANT
►Make sure that the flue gas analyser is
calibrated. The start-up procedure of
the flue gas analyser must be completed
before the analyser probe is placed in the
flue gas measurement point.
►The analyser probe must completely seal
o the flue gas measurement point to
provide a reliable measurement.
►The end of the analyser probe must be
located entirely in the flue gases (middle
of the flue gas pipe).
IMPORTANT
►Make sure that the capital letter HH
appears on the right display. This
provides assurance that the boiler is
operating at maximum load.
D. Switch on the boiler by touching above the power light for 2
seconds.
E. Switch the boiler to maximum output. To do this, hold the
Service symbol and at the same time tap the Plus symbol
twice until the capital letter HHappears on the right display.
F. Wait until the readout of the flue gas analyser is stable (at
least 10 minutes).
G. Note the measured CO2(H) value.
CO2(H) = measured maximum output CO2value
H. Check according to Table 2 whether the measured
maximum output CO2(H) % is between the indicated upper
and lower limits.
MEASURING THE FLUE GAS AT MAXIMUM OUTPUT
Cap
Flue gas
analyser
3
C. Re-establish the power by switching on the fused spur.
Test program ‘H’
Service menu
Value limits
Gas category
Natural gas
G20
LPG
G31
CO2[%] CO2[%]
Upper limit 9.6 10.8
Lower limit 8.6 9.8
Table 2: Allowed CO2(H) limits at maximum output (open casing)
I. The flue gas performance measurement must also be
checked at minimum output
IMPORTANT
►Any readings that are out of tolerance
during maximum output cannot be
corrected by adjusting the gas valve.
The boiler must be meticulously
inspected for gas quality / type, correct
components used (especially the gas
restriction ring and the fan including
venturi).

13
Before measuring the flue gases at minimum output, the
measurement at maximum output must be completed,
as previously detailed..
The measured CO2(H) % at maximum output is
important to determine equilibrium, this must be
completed before checking the minimum output %.
A. Switch on the boiler at minimum output. To do this, tap
simultaneously the Service symbol and the Minus
symbol until the capital letter
L
Lappears on the right
display.
B. Wait until the readout of the flue gas analyser is stable (at
least 10 minutes).
C. Note the measured CO2(L) value.
CO2(L) = measured minimum output CO2value
D. Check according to Table 3 whether the measured
minimum output CO2(L) value is between the indicated
upper and lower limits.
E. If the minimum output measurement falls outside the limits
given in Table 4a or 4b, refer to the Gas valve adjustment
page detailing how to adjust the gas valve.
If the setting is correct, continue to Step F.
►The CO2upper limit is the CO2(H) value that
was noted during the maximum output
measurement.
Table 3 : Allowed CO2(L) limits at minimum output (open casing).
Value limits
Gas category
Natural gas
G20
LPG
G31
CO2[%] CO2[%]
Upper limit CO2(H) CO2(H) - 0.3
Lower limit 8.4 9.4
Service menu
Test program ‘L’
MEASURING THE FLUE GAS AT MINIMUM OUTPUT
IMPORTANT
►The gas air control is correctly set if the
measured value at minimum output falls
within the indicated upper and lower
limits. Adjustment of the gas air control is
not necessary in this case. The setting at
minimum output can be adjusted using
the method described but only if the
measured value is outside the indicated
limits.
F. Reattach the room sealed cover and tighten the 2 x 5mm
Allen screws by hand (do not over tighten).
G. Switch the boiler to maximum output. To do this, hold
the Service symbol and at the same time tap the Plus
symbol twice until the capital letter
H
Happears on the
right display. Check the CO value at maximum output. The
maximum allowed CO measurement value is 160ppm.
H. Switch o the boiler.
I. Remove the probe of the flue gas analyser from the flue gas
sampling point and carefully replace the cap on the adapter
above the boiler.
J. Switch on the boiler again.
K. Check the gas integrity of the flue gas sampling point.
L. Carry out a flue integrity test via the air sampling point on
the boiler adaptor or bend (The boiler must be set to maximum
output ). O readings must be between .6 & .9%
H
H

Before the minimum output correction is performed, the
maximum output and minimum output measurements must
be completed. The measured CO2(H) value at maximum output
is important for determining the correct value for the setting at
minimum output.
A. Remove the dust cap of the gas valve so that the adjustment
screw is accessible.
B. Switch on the boiler at minimum output. To do this, tap
simultaneously the Service button and the Minus button
until the capital letter
L
Lappears on the right display.
C. Wait until the readout of the flue gas analyser is stable (at
least 3 minutes).
D. Measure the CO2(L) value.
E. Using the adjustment screw B, set the correct CO2(L) value.
For the correct CO2(L) setting value, see Tables 4a or 4b.
F. Reattach the cover screw of the gas valve so that the
adjustment screw is sealed.
G. Check the measurements at both maximum output and
minimum output to ensure the correct flue gas emission
levels are obtained.
GAS VALVE ADJUSTMENT (at minimum output)
Adjustment screw
Dust cap
►Select the correct table depending on the
applicable gas category:
4a: natural gas (G20)
4b: LPG (G31)
►The maximum output measurement
value is important for a correct
adjustment. This measurement value
was noted during the maximum output
measurement CO2(H)
►Turning the adjustment screw to the right
increases CO2.
Turning to the le decreases CO2.
►Turn the adjustment screw with small
steps and wait aer each turn until the
measurement stabilises.
Use a T15 Torx drive for the dust cap
removal & oset adjustments
Clockwise to
increase CO2
Anticlockwise to
decrease CO2
Table 4a: Checking CO2(L) levels for Natural gas
(open casing)
Table 4b: Checking CO2(L) levels for LPG (open
casing)
LPG G31 (37 mbar)
Measured value at
maximum output
(see §9.10.1, Step H)
Setting value minimum
output
(= CO2(H) - 0.3)
CO2(H) [%] CO2(L) [%]
10.8 10.5 ± 0.1
10.6 10.3 ± 0.1
10.4 10.1 ± 0.1
10.2 9.9 ± 0.1
10.0 9.7 ± 0.1
9.8 9.5 ± 0.1
**Example (when using natural gas G20)
►During maximum output, a CO2(H) level of
9.0% is measured. In this instance a minimum
output CO2value must be 8.7 ± 0.1%.
Natural Gas G20 (20 mbar)
Measured value at
maximum output
(see §9.10.1, Step H)
Setting value minimum
output
(= 0.5 x CO2(H) + 4.2)
CO2(H) [%] CO2(L) [%]
9.6 9.0 ± 0.1
9.4 8.9 ± 0.1
9.2 8.8 ± 0.1
9.0 8.7 ± 0.1
8.8 8.6 ± 0.1
8.6 8.5 ± 0.1
**
14

Smart Opentherm™
Boiler Service
Procedure
BOILERS
HRE & Eco RF
Service
Procedure
HRE 24/18
(G.C. 47-291-01)
HRE 28/24
(G.C. 47-291-02)
HRE 36/30
(G.C. 47-291-03)
HRE 36/40
(G.C. 47-291-04)
HRE SB18
HRE SB24
HRE SB30
HRE SB40
HRE OV24
HRE OV30
HRE OV18
(G.C. 41-291-01)
(G.C. 41-291-02)
(G.C. 41-291-03)
(G.C. 41-291-07)
(G.C. 41-291-04)
(G.C. 41-291-05)
(G.C. 41-291-06)
Eco RF 30
Eco RF 36
Eco RF 24 (G.C. 47-291-05)
(G.C. 47-291-06)
(G.C. 47-291-07)

16
A
B
1
2
3
6
5
4
Service variations (HRE & ECO RF)
AllIntergasboilers usethe same Bithermicheat exchanger technology
withonlyslight variationsthroughout the modelrange.
TheHRE& Ecoboiler variations areshown in thissection howevertherelevant
servicetype(Service (A)page 6, orservice (B) page8) mustbefollowed withthe
CO2settingsasper thoseset out inthe previous tables4a &4bpage 14.
Disassemble
Switchthe boiler off andisolatethe boiler from the mains power.
Closethegas isolation valve (check fortightness andlet-by).
Openthedisplaycover and loosenthe twoscrewson bothsides of thedisplay
andthenpull forward andslide down toremove thecasing.
Wait until the appliance has cooled down.
Unscrewthe coupling nutatthebase of theblack fluepipe (anti-clockwise).
Slidethe flue pipe upwards (1) turningitanti-clockwise until the bottom ofthe
pipeis above thecondensate drain pan connection.Pull thebottom of thepipe
forwards(2) andremove the pipedownwards (3)turning it anti-clockwise.
Liftthecondensatedrainpanonthe left-hand sidefrom the connectionto the
condensate trap(4) andturn ittothe rightwith the condensatetrap connection
over theedge ofthebase tray(5). Pushthe back ofthe condensate drain pan
downwardfrom the connectionto the heat exchanger (6) andremove it from the
appliance.
Removethe electrical connections fromthe fan assembly andthe ignition
module mounted onthe gas valve.
Unscrewthe union below the gasvalve, removethevalve &cover pipe openend.
Unscrewthe shoulder bolts fromthe frontplate andremovethis complete
with gasvalveandfan assemblyattached.
Thefrontplate shouldbe placed burnerside down sothat itsitson itsresting
pegstoensurethat theburner andinsulationpaneldo notgetdamaged. Care
shouldalsobe takennot to damagedthe gas valvemanifoldpipework and fan
assembly.
Itisrecommended tocheck the fannon-return valve (A)and fanseal(B)
duringtheannual service,replace if damagedin any way.
Note
Thecombiandsystemappliancesmaybeconnected toourspecificallydesignedrear
jigwhichincorporatesabuilt-inexpansion vessel.
Theseboilermodelscanalsobeinstalledwitharemoteexpansion vessel of the
correctcapacityandspecification.
Theexpansionvessel(whicheverdesign)mustbeinspectedateachservice interval
toensuretherearenoleaksandthatthepre-chargepressure is correct.
Thesystemmustbecoldanddepressurisedwhencheckingthevessel pressure which
shouldbe0.75to1.0bar(Rechargewithasuitablefootpump or compressor viathe
Schradervalve,thencheckthevalvewithLDFforleaksand replace if required).
Cleaning
Removeandclean outthe condense trapensuring the outletpipework isclear.
Cleantheheat exchangerfrom top tobottom as perthe previoussectionspage 9
usingtherecommended tools,then turn topage 17 tocontinue.
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17
Refit the condensate drain by sliding itonto theexchanger outlet sump withthe
condensate trapconnection still in frontof the blackbasetray.Then turnit tothe left
andpush itdownwards intothe condensate trap connection ensurewhen
doing this that the back of thecondensate drainpan comesto restonthe lug at the
backof the blackbase tray lubricatesealswith siliconegrease to easeconnection.
Fillthe condensate trapwith waterand fitit tothe connectionbelowthe
condensatedrain pan.
Slidethe flue pipe, turning it anti-clockwise, withthe toparound theflue adapter,
intothe top cover.Insertthebottom into thecondensatedrain panandtightenthe
couplingnut clockwise.
Openthegastapand check thegasconnectionsbelow the gas valve andon the
mounting bracketfor leakageusing LDFor a calibratedelectronic leak detector.
Check the CHand the waterpipes for leakage.
Switchon themains power.
Switchthe appliance onwiththe key.
Checkthefront plate,the fanconnectionon thefront plate andthe flue pipe
components for leakage.
Checkthegas/airadjustmentatMaximum &minimumoutputs, settingsasdescribed
inpages12, 13,and 14
Fitthe casing,tighten the two screws leftandright ofthedisplay and closethe
display cover.
Checktheheatingand thehotwateroperation.
usingcalibratedequipment andcomplete all 26(9)safety checks.
1
2
3
A
Reassemble
Replacethefront plateseal as detailedin the previoussection ensureitis
thecorrectsize andlocated correctly withinthe front platechannel.
IMPORTANT Allredsilicon frontplate seals mustbe replaced, regardlessof age,
withthenew blackViton type.
HRE 24/18, SB 18, OV 18 & Eco RF 24 = Viton seal 086514
HRE 28/24, SB 24, OV 24 & Eco RF 30 = Viton seal 086504
HRE 36/30, 36/40, SB 30, 40, 0V 30 & Eco RF 36 = Viton seal 086474
Refitthefront platefollowing the re-assmbleprocedure on page8 1
23
A
Program description
Button
combinations
Display reading
and
L
and (1x)
h
and
(2x)
H
and
Burneroperatingat minimumpower
Burneroperatingat maximumCHpower
setting(See parameter3)
Burneroperating atmaximum DHWpower
setting(See parameter4)
Switchoff /cancel testprogram Boilerstatus
Operational codes
3= Fanoperating
4= Ignitiongenerated
5= Centralheating demand
6= Domestichot waterdemand
7= Pre-Heatoperating
TEST PROGRAMS
Uponcompletion please filloutthe relevant sectionofthe
Benchmarkservice record.
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IMPORTANT
►Replace the front plate O-ring seal at least
every 2 years or if damaged/ discoloured and
or if the front plate has been removed.
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Check or replace the seals and gaskets
detailed in the following page at the requested
intervals .
►The outer casing is a room sealed cover and
therefore extremely important that it is fitted
correctly, failure to do so could lead to
products of combustion entering the
room / environment where it is situated.
All red Silicon front plate seals must be
replaced, regardless of age with the black Viton.
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Frontplateseal(Viton)
partnumber
Large086474
Medium086504
Small086514
BurnerEarthspring
FanNonreturnvalve
Fanseal(rubber)
partnumber877807
Venturigas'O'ring
partnumber875737
Gasvalvetopunion
Gasrestrictordisc'O'ring
partnumber875827
Gasrestrictor
disc
Gasvalvelowerseal
partnumber875757
Burnerfibreseal(fragile)
Partnumber877847
INSPECTION OF SEALS & UNIONS (HRE & ECO RF boilers)
†
†
†
†
†
†
replaceevery 4yearsregardless ofcondition.
=Inspect every2years minimumreplace ifdamaged ordegradedor
Partnumber875917(x4)
Burnerretainingscrewseal
†
PLEASE
NOTE
FrontPlate Seal
Replacedon
Date......................................
Flueseal70x82
Partnumber
878547
O-Ringseal
partnumber878537
Condensecollectorseal
partnumber878147
†
†
†
†Condensesyphonseal
partnumber878577
=Front platesealmust bereplaced every2 yearsorif thefront plate
hasbeen removedforinspection.
¶
18
¶

Smart Opentherm™
Boiler Service
Procedure
BOILERS
Rapid Service
Procedure
Rapid 32
Rapid 25 (G.C.47-291-08)
(G.C. 47-291-09)

openinga domestichotwatertap(withthepower switchedoff).
► Waituntilthe boiler hascooleddown.This canbedone by
► Removetheroomsealedcoverof theboilerby looseningthetwo
► Closethe boiler gasisolationvalve(testforlet-by).
spur, makesafe theappliancebeforecontinuing(RefTB118).
► Switchofftheapplianceandisolatethe powersupplyat thefuse
◉
The syphon seal
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The inside of syphon
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Cleanthefollowing componentswithwater:
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Emptythesyphoncup (3).
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Inspectand if damagedreplacedthe rubber seal( )
4
(anticlockwise)and then pullingitout downwards.
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Detachthe syphon cup(3)byrotatingit tothe left
Syphon maintenance
screws(1) and thensliding thepanelupandforward(2).
1
2
3
4
The syphon cup
Flush the condense pipework
►Replacethe syphon cupandensurethatis filled¾full of water.
Always fill the condensate trap with water then
attach it to the boiler before powering it up.
CAREFUL
20
Service variations (Rapid).
Tofillthecondensatetrap the hose between the
trapandPRVshouldbe removed(from the trap side).
The hose must be re-attached after filling the trap !
Not replacing or filling up the condensate trap can
result in products of combustion entering the room
leading to a potentially dangerous situation.
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TheRapidboiler variationsare shown inthis section howeverthe relevant
servicetype(Service (A)page 6, orservice (B) page8) mustbefollowed withthe
CO2settingsasper thoseset out inthe previous tables4a &4bpage 14.
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