broag SEAGOLD 1A HR, Manual

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Page 82: ...Atmospheric gas boiler 92 372 kW remeha Gas 3c Technical information ...

Page 83: ...elines 8 7 1 General 8 7 2 Boiler assembly 8 7 3 Water connections 8 7 4 Pocket for instrument panel 8 7 5 Water pressure 8 8 Gas supply 9 8 1 General 9 8 2 Gas pressure 9 9 Electrical supply 9 9 1 General 9 9 2 Control panel 9 9 3 Electrical connections 9 9 4 Electrical data 9 9 5 Wiring diagram for the instrument panel 9 9 5 1 Simple instrument panel 9 9 5 2 Complete instrument panel On Off or H...

Page 84: ...1 General Boiler block of cast iron sections are joined together with conical nipples Gas train and water connections can be fitted on either side of the boiler The gas train should as standard always be fitted on the same side as the instrumental panel thermostat pocket and the flow Instrument panel is fitted in the front casing Cleaning of the cast iron block from top of the boiler If you have a...

Page 85: ...5 19 24 29 34 40 46 52 59 16 24 36 48 60 76 96 116 136 160 186 208 236 Water resistance 114 142 170 200 228 258 286 315 343 369 399 426 454 5 6 7 8 9 10 11 12 13 14 15 16 17 92 115 138 162 186 210 234 256 280 301 325 348 372 1015 1015 1040 1040 1040 1040 1065 1065 1065 1065 1090 1090 1090 675 775 875 975 1075 1175 1275 1375 1475 1575 1675 1775 1875 200 200 200 250 250 250 300 300 300 300 350 350 3...

Page 86: ...DM2 Important The remeha Gas 3c is certified appliance and must not be modified or installed in any way contrary to these Installation and Servicing Instructions Manufacturers instructions must NOT be taken in any way as overriding statutory obligations 93 m3 h This minimum flow must be maintained for 5 minutes af ter the burner stops firing to avoid high temperature shut down due to residuel heat...

Page 87: ...ler room back to back Fig 04 Installation 3 Number of sections 5 6 7 8 9 10 11 12 13 14 15 16 17 1015 675 200 1220 1015 775 200 1220 1040 875 200 1220 1040 975 250 1220 1040 1075 250 1220 1040 1175 250 1220 1065 1275 300 1320 1090 1875 350 1320 1090 1775 350 1320 1090 1675 350 1320 1065 1575 300 1320 1065 1475 300 1320 1065 1375 300 1320 Dimensions mm A B Ø D E ...

Page 88: ...lugs The capillaries from the control panel should be fitted in the pocket of the boiler wich is fitted in the top front of the end section The instrument panel pocket and the flow should always be fitted at one side of the boiler either left or right and standard on the same side as the gas train Fig 05 Layout of the complete instrument panel B D E C A 1 3 5 4 2 6 8 7 9 11 10 The modules contain ...

Page 89: ... pressure for the assembled boiler block is 6 bar Operating pressure between 0 8 bar and 6 bar 7 ASSEMBLY AND INSTALLATION GUIDELINES 6 3 Standard electronic gas train On Off or High Low 6 3 1 Schematic construction 6 3 2 Specification 1 Gas multibloc 5 12 sections 2 Safety shut off valves 13 17 sections 1 Gas governor 13 17 sections 1 Pilot gas valve 1 Pilot gas governor 1 Ignition transformer 5 ...

Page 90: ... should be conform to the British Gas safety regulations 8 2 Gas pressure Maximum gas pressure at inlet 100 mbar Burner pressure full load 11 8 mbar 100 part load High Low version only 4 2 mbar 60 injector size 4 4 mm Ø Legend CT Control thermostat HLT High limit thermostat H LT High Low thermostat S Plug Connector 9 1 General The electrical installation must conform to the IEE regulations and als...

Page 91: ...10 remeha Gas 3c 9 5 2 Complete instrument panel On Off or High Low Fig 09 Wiring diagram for the complete instrument panel Only High Low ...

Page 92: ...11 Fig 10 Wiring diagram for the boiler with simple instrument panel 9 6 Wiring diagram boiler 9 6 1 Complete wiring diagram for On Off boiler with simple instrument panel ...

Page 93: ...12 remeha Gas 3c 9 6 2 Complete wiring diagram for On Off boiler with complete instrument panel High Low thermostat will not be used Fig 11 Wiring diagram for the boiler with complete instrument panel ...

Page 94: ...13 9 6 3 Complete wiring diagram for High Low boiler with simple instrument panel Fig 10 Wiring diagram for the boiler with simple instrument panel ...

Page 95: ...14 remeha Gas 3c 9 6 4 Complete wiring diagram for High Low boiler with complete instrument panel Fig 11 Wiring diagram for the boiler with complete instrument panel ...

Page 96: ...ler is on 9 Leave the boiler on for a couple of minutes to get rid of air in the gas pipe 10 Set the correct burner pressure 11 Check the thermostats for correct operation 12 Check the flame protection start the boiler with disconnected ionisation probe 10 3 Switching off the boiler 1 Switch off the electrical supply 2 Turn off the gas cock 10 COMMISSIONING 11 1 General It is essential for a good ...

Page 97: ...chnical descriptions furnished by us remain our property and shall not be multiplied without our prior consent in writing ISO 9001 since 1988 Broag Ltd Head office Remeha house Molly Millars Lane Wokingham Berkshire RG41 2QP Tel 0118 9783434 Fax 0118 9786977 Branch office Unit 3 Kestrel Close Quarry Hill Ind Estate Ilkeston Derbyshire DE7 4RD Tel 0115 9440778 Fax 0115 9440588 ...

Page 98: ...1 remeha Gas 3c ECO Fully condensing atmospheric gas boiler 101 407 kW Technical information ...

Page 99: ... 5 1 Simple instrument panel 10 10 5 2 Complete instrument panel 11 10 6 Wiring diagram boiler 12 10 6 1 Complete wiring diagram for boiler with simple instrument panel 12 10 6 2 Complete wiring diagram for boiler with complete instrument panel 13 11 Commisioning 14 11 1 Technical information 14 11 2 Commissioning 14 11 3 Switch off the boiler 14 12 Maintenance 15 12 1 General 15 12 2 Maintenance ...

Page 100: ...ler block primary heat exchanger of cast iron sections connected with conical nipples Economiser secondary heat exchanger of anodised aluminium Gas train can be fitted on the left or right hand side of the boiler Water connections can be fitted on the left or right hand side of the boiler The return is fitted as standard on the left hand side of the economiser The gas train should always be fitted...

Page 101: ... 1195 1195 1195 1195 1195 1195 1195 1195 1225 1225 1225 1610 1610 1610 1610 1710 1710 1710 1740 1740 1740 1800 1800 1800 1425 1425 1425 1425 1435 1435 1435 1435 1435 1435 1500 1500 1500 85 85 85 85 107 107 107 131 131 131 131 131 131 736 736 736 736 736 736 736 736 736 736 769 769 769 600 600 800 800 1000 1000 1200 1200 1400 1400 1600 1600 1800 143 143 139 139 134 134 134 123 123 123 116 116 116 6...

Page 102: ...ter is untreated The boiler contains an aluminium heat exchanger and the system will also contain a variety of metals Ferrous metals cast iron and steel and non ferrous metals copper brass and gunmetal may be present so it is essential that treatment is suitable for all of them Suitable chemicals and the extent of treatment should be discussed with specialist manufacturers prior to any work commen...

Page 103: ... room back to back Fig 03 Boiler installations 1875 350 1800 1498 131 1775 350 1800 1498 131 1675 350 1800 1498 131 15 16 17 1575 300 1737 1435 131 14 1475 300 1737 1435 131 13 1375 300 1737 1435 131 12 11 1075 200 250 1710 1435 107 9 1175 200 250 1710 1435 107 10 8 975 200 250 1710 1435 107 7 6 675 200 250 1710 1435 107 775 200 250 1710 1435 107 875 200 250 1710 1435 107 B Ø D G H K 1275 200 250 ...

Page 104: ...ve male connectors The capillary from the control panel should be fitted in the pocket of the boiler which is located in the top front of the sections The instrument panel pocket and the flow should be always fitted to the same side of the boiler either left or right and standard on the same side as the gas train A B C D E 11 10 9 8 7 6 5 4 2 1 3 Fig 04 Instrument panel The modules contain Module ...

Page 105: ...tection lock out Moniterers by ionisation flame detection 7 4 2 Thermostats Control thermostat On Off T G 35 95 C High Limit lock out at 110 C 7 4 3 Air pressure switch lock out An air pressure switch checks the function of the flue fan If a failure is detected the boiler is shut down 7 3 Standard electronic gas train Fig 05 5 12 sections Fig 06 13 17 sections Legend A Gas cock PB Pilot burner DR ...

Page 106: ...e connection for welding Ø 70 mm to the installation The top blind flange has an integral cast 1 tapping to accept a safety valve The end sections have a 3 4 tapping to accept a drain off cock Tapping BSP The economiser has at the bottom a 1 2 tapping for a drain off cock 8 4 Pocket for instrument panel The pocket should be fitted in the top front end section of the boiler and at that side of the ...

Page 107: ...installation must conform to the IEE Regu lations and also to Local Authority Requirements 10 2 Control panel A control panel is fitted on the gas train 10 3 Electric connections The boiler is pre wired Only the mains supply should be connected to the control panel 10 4 Electric data Main supply 240 V 50 Hz L N Installed fuse 6 Amp Running current Legend CT Control thermostat HLT High limit thermo...

Page 108: ...mostat DK Reset button F Fuse FD Flame detector FF Flue fan H Lock out Operating light HLT High limit thermostat IT Ignition transformator LD2 Air pressure switch MB Multi bloc MS Main switch PGV Pilot gas valve SSV Safety shut off valve S1 Boiler switch Connector O Connection screws control box Ø Connection screws control panel ...

Page 109: ... remeha Gas 3c ECO Fig 10 Complete wiring diagram for the boiler with simple instrument panel 10 6 Wiring diagram for the boiler 10 6 1 Complete wiring diagram for the boiler with simple instrument panel ...

Page 110: ...13 10 6 2 Complete wiring diagram for the boiler with complete instrument panel High Low thermostat will not be used Fig 11 Complete wiring diagram for the boiler with complete instrument panel ...

Page 111: ...njector size main burner Ø 4 4 mm Burner pressure full load 12 3 mbar Pilot burner pressure 13 mbar 11 2 Commissioning 1 Check gas connections 2 Check electrical supply L N and earth The control box operates on a neutral phase supply 3 Check water connections and release the air out of the ECO and boiler Fill the syphon with water 4 Switch on circulation pump and check rotation direc tion 5 Open m...

Page 112: ...aned by using the nylon clea ning brush In that case remove the rear panel and then the intermediate panel Clean the aluminium pipes using the special nylon cleaning brush avai lable from Broag Clean the condensate collector Never use the nylon brush for the cast iron sec tions and the economiser 3 Remove the lit of the siphon trap and clean it 4 Clean the burners internally and externally 5 Clean...

Page 113: ...main our property and may not be multiplied without our prior consent in writing Subject to alterations Art nr 50 455 1000 06 96 Bo ISO 9001 since 1988 Broag Ltd Head office Remeha House Molly Millars Lane Wokingham Berkshire RG 41 2QP Tel 0118 9783434 Fax 0118 9786977 Branch office Unit 3 Kestrel Close Quarry Hill Ind Estate Ilkeston Derbyshire DE7 4RD Tel 0115 9440778 Fax 0115 9440588 ...

Page 114: ...Technical information remeha Gas 3d Atmospheric gas boiler with reminox Low NOx burners 90 360 kW ...

Page 115: ...2 Down draught thermostat 8 6 4 3 Thermostats 8 7 Assembly and installation guidelines 9 7 1 General 9 7 2 Boiler assembly 9 7 3 Water connections 9 7 4 Pocket for instrument panel 9 7 5 Water pressure 9 8 Gas supply 9 8 1 General 9 8 2 Gas pressure 9 9 Electrical supply 10 9 1 General 10 9 2 Control panel 10 9 3 Electrical connections 10 9 4 Electrical data 10 9 5 Wiring diagram for the instrumen...

Page 116: ... cast iron sectional boiler with atmospheric burners Suitable for all qualities of natural gas cat I 2 H 20 mbar The boiler meets the requirements of the CE regulations at the following directives Gas appliance directive no 90 396 EEC Efficiency directive no 90 42 EEC Electrical low voltage directive no 73 23 EEC Machinery directive no 89 392 EEC E M C directive no 89 336 EEC Classification type f...

Page 117: ...320 1320 51 58 65 71 78 85 91 98 105 111 118 125 131 1 1 1 1 11 4 11 4 11 4 11 4 11 2 11 2 11 2 11 2 11 2 E mm Ø d 200 200 200 250 250 250 300 300 300 300 350 350 350 Ø D mm B mm 675 775 875 975 1075 1175 1275 1375 1475 1575 1675 1775 1875 Boiler weight dry 425 490 555 620 685 755 820 885 950 1020 1085 1150 1215 kg l 111 139 167 194 222 250 279 306 333 361 389 417 Mass flue rate 211 264 316 369 42...

Page 118: ...erature is so low that the chim ney must be in accordance with the guidelines of British Gas and BS 6644 4 3 Installation standards The following instructions must be adhered to when the remeha Gas 3d is installed Gas safety installation and use Regulations 1984 as amended All gas appliances must by law be installed by compe tent persons e g Corgi in accordance with the above regulations Failure t...

Page 119: ...ler room back to back Fig 04 Installation 3 Number of sections 5 6 7 8 9 10 11 12 13 14 15 16 17 1015 675 200 1220 1015 775 200 1220 1040 875 200 1220 1040 975 250 1220 1040 1075 250 1220 1040 1175 250 1220 1065 1275 300 1320 1090 1875 350 1320 1090 1775 350 1320 1090 1675 350 1320 1065 1575 300 1320 1065 1475 300 1320 1065 1375 300 1320 Dimensions mm A B Ø D E ...

Page 120: ...ontrol panel should be fitted in the pocket of the boiler wich is fitted in the top front of the end section The instument panel pocket and the flow should always be fitted at one side of the boiler either left or right and standard on the same side as the gas train B D E C A 1 3 5 4 2 6 8 7 9 11 10 Fig 05 Layout of the complete instrument panel Module D 9 Warning light 10 Analogue thermometer wat...

Page 121: ... 4 1 Flame protection Flame protection by means of UV flame detection 6 4 2 Down draught thermostat The boiler is fitted with a down draught thermostat If there is down draught the thermostat will switch off the boiler Fixed setpoint is 70 C 6 4 3 Thermostats Control thermostat On Off 35 95 C Control thermostat High Low 35 95 C High limit thermostat locks out at 110 C Fig 06 5 12 sections Fig 07 1...

Page 122: ...et and the flow 7 4 Pocket for instrument panel The pocket should be fitted in the top front end section of the boiler and at that side of the boiler where the gas train is fitted Other end section tapping 1 should be sealed 7 5 Water pressure Each section is hydraulically tested to at least 12 bar Maximum test pressure for the assembled boiler block is 6 bar Operating pressure between 0 8 bar and...

Page 123: ...lectrical connections The boiler is pre wired Only the main supply should be wired to this control panel 9 4 Electrical data Main supply 240 V 50Hz L N Running current 120 W Installed fuse 6 Amp 9 5 Wiring diagram for the instrument panel 9 5 1 Simple instrument panel Fig 08 Wiring diagram for the simple instrument panel Legend CT Control thermostat HLT High limit thermostat H LT High Low thermost...

Page 124: ...11 9 5 2 Complete instrument panel Fig 09 Wiring diagram for the complete instrument panel ...

Page 125: ...remeha Gas 3d 12 9 6 Wiring diagram boiler 9 6 1 Complete wiring diagram for the boiler with simple instrument panel Fig 10 Wiring diagram for the boiler with simple instrument panel ...

Page 126: ...13 9 6 2 Complete wiring diagram for the boiler with complete instrument panel Fig 11 Wiring diagram for the boiler with complete instrument panel ...

Page 127: ...rth 3 Check water connections and if the installation is filled 4 Switch on circulation pump and check rotation direc tion 5 Open main gas cock release air in gas pipe work 6 Switch on electrical supply 7 Set the control thermostats at about 85 C 8 After a waiting time of about 72 seconds you will get ignition At a minimum UV current of 100 µAmp the safety gas valve will open and the pilot gas val...

Page 128: ...e hood 2 Clean the burners internally and externally 3 Clean boiler room and the floor underneath the boiler 4 Clean the boiler casings 5 Clean the gas train ignition pilot burner UV thermo stats and wiring 6 Check start program ignition time and safety times 7 Check flame protection and thermostats 8 Check the boiler input at 100 and 60 load 9 Make a combustion efficiency calculation 10 Check the...

Page 129: ...chnical descriptions furnished by us remain our property and shall not be multiplied without our prior consent in writing ISO 9001 since 1988 Broag Ltd Head office Remeha house Molly Millars Lane Wokingham Berkshire RG41 2QP Tel 0118 9783434 Fax 0118 9786977 Branch office Unit 3 Kestrel Close Quarry Hill Ind Estate Ilkeston Derbyshire DE7 4RD Tel 0115 9440778 Fax 0115 9440588 ...

Page 130: ...Remeha Gas 350 Atmospheric gas boiler 64 174 kW Technical information R e m e h a G a s 3 5 0 ...

Page 131: ... Specification control box 9 6 4 1 Specification Ignition transformer 9 6 5 Functions 9 6 5 1 General 9 6 5 2 Flame control lock out 9 6 5 3 Thermostats shutdown lock out 9 6 5 4 Water pressure switch optional shut down 9 6 5 5 Gas pressure switch LD optional shut down 9 6 5 6 Down draught thermostat optional shut down 9 7 Assembly and installation guidelines 9 7 1 General 9 7 2 Boiler assembly 9 ...

Page 132: ... and pro pane cat II2H3B P The Remeha Gas 350 central heating boiler is approved according to the following European directives Gas appliance directive no 90 396 EEC Efficiency directive no 92 42 EEC E M C directive no 89 336 EEC Low voltage directive no 73 23 EEC Remeha Gas 350 PIN 0063AS3842 Classification type for evacuation of the combustion pro ducts B11BS B 11 For further advice or informati...

Page 133: ... mm 165 165 165 215 215 215 table 01 Dimensions Front view Side view Rear view 3 2 Technical data Number of sections 4 5 6 7 8 9 Nominal heat output kW 64 87 109 130 152 174 Nominal heat input Hi NCV kW 72 97 121 145 169 193 Hs GCV kW 80 108 134 161 188 214 Gas consumption m3 h 7 6 10 3 12 8 15 3 17 9 20 4 Flue temperature C 154 152 146 138 138 142 Water resistance t 10 C mbar 5 13 21 30 41 52 t 2...

Page 134: ...w through the boiler on shut down is Output boiler in kW m3 h 93 This minimum flow must be maintained for approximate ly 5 minutes after the burner stops firing to avoid high temperature shut down due to residual heat gain Due to the design and manufacture of the boiler no specific minimum water flow requirements exist other then for overheating protection 4 1 4 Water treatment The system should b...

Page 135: ...about 50 dBA Noise levels taken at 1 meter from the boiler 4 2 Chimneys The average flue gas temperature is so low 108 173 C that the chimney must be made in accordance with the guidelines of British Gas BS 6644 and IG 10 4 3 Installation standards The following instructions must be adhered to when the Remeha Gas 350 is installed Gas Safety installation and use Regulations 1984 as amended In addit...

Page 136: ...ue outlet W min 0 5D 50 mm with horizontal flue outlet 1 Boiler in boiler room fig 02 One boiler 5 2 Installation 2 Recommended layout for two boiler installation meas urements in mm 2 Boilers in boiler room fig 03 Two boilers number of sections Dimensions A B C Ø D E 4 640 280 905 200 1030 5 740 330 905 200 1030 6 840 380 905 200 1030 7 940 430 930 200 1080 8 1040 480 930 250 1080 9 1140 530 930 ...

Page 137: ...ed in the pocket of the boiler which is fitted in the flow connection of the boiler fig 04 Instrument panel The instrument panel contains 1 Operating switch On Off 2 Control thermostat On Off range 35 C 95 C 3 Control thermostat High Low range 35 C 95 C 4 Hour run meter total running hours option 5 Hour run meter full load hours option 6 Analogue thermometer for flow temperature 7 High limit therm...

Page 138: ... 0 8 bar the boiler will shut down When the water pressure returns to 1 bar the boiler will resume opera tion again Type SIT 340 6 5 5 Gas pressure switch LD optional shut down The boiler can be fitted with an optional gas pressure switch LD If the supply gas pressure drops below the set value 12 mbar for natural gas only the boiler will shut down When the supply gas pressure returns above this se...

Page 139: ...supports Use our conversion kit for propane and follow the fitting and commissioning instructions Technical data for operation on propane are shown in table 03 Note Place the sticker from the conversion kit to indi cate that the boiler has been changed for propane firing Number of sections Heat output Heat input Hi Burner pressure1 Gas consumption2 Injector size main burner Injector size pilot bur...

Page 140: ...signals contact 230V 1Amp min Remove link to control boiler using an external Volt free 16 17 External control High Low volt free switch 7 8 External control On Off volt free switch Optional 1 2 Ignition transformer Control box STAGE HIGH STAGE LOW 230V Power supply F 230V 10 Lock out indication 230V 13 Boiler On 230V 19 Boiler High fire 230 P Tmx VA TR TB MK LD DK DS CA BM H IE K F BS Hour run me...

Page 141: ...arning control box is phase neutral sensitive 3 Check the water connections and whether the instal lation is full and under system pressure 4 Switch on the circulation pump and check the rota tion direction 5 Open the main gas cock purge gas pipeline 6 Switch on the electrical supply 7 Set both the thermostats to about 85 C 8 If a control system is built in put the selector switch on manual operat...

Page 142: ...on the pilot gas valve must close imme diately The boiler will lock out Reset by pressing the reset button on the control box 16 Water level control Check the water level Check the operation of the water level control by disconnecting the electrode The boiler should go to lock out Create a shortcut between the electrode and earth The boiler should go to lock out Reset by pressing the reset button ...

Page 143: ...Check start program ignition time and safety times Check flame protection and thermostats Check boiler input at 100 full load and 60 part load load Carryout combustion efficiency test Check the boiler and immediate installation connec tions for water leaks seals Check gas train and gas pipe for gas leaks Check flue connections Clean boiler casings Complete a commissioning report and fill in the bo...

Page 144: ...ck out table 05 Error messages long pulse short pulse short pause 12 2 Fault causes In case of a failure the LED is permanently illuminated Every 10 seconds the illumination is interrupted by a flash code In case of all failures the gas supply is interrupted Fault Possible cause Burner not working shut down no heat demand no mains supply voltage 187 V continuously tension on terminal A 2 3 seconds...

Page 145: ...t or whole without our prior consent in writing Subject to alterations ISO 9001 since 1988 51247 0303 Broag Ltd Remeha House Molly Millars Lane RG41 2QP WOKINGHAM Berks United Kingdom Tel 0118 9783434 Fax 0118 9786977 uk remeha com boilers broag remeha com Midlands Branch Office Unit 3 Kestrel Close Quarry Hill Industrial Estate Ilkeston Derbyshire DE7 4RD Tel 0115 944 0778 Fax 0115 944 0588 R e m...

Page 146: ...1 Remeha Gas 450 Atmospheric gas boiler with reduced NOx emission 217 344 kW Technical information R e m e h a G a s 4 5 0 ...

Page 147: ...7 6 3 1 Schematic 7 6 3 2 Specification 7 6 3 3 Control panel behind front panel 7 6 4 Functions 7 6 4 1 Flame protection 7 6 4 2 Down draught thermostat 7 6 4 3 Thermostats 7 7 Assembly and installation guidelines 8 7 1 General 8 7 2 Boiler assembly 8 7 3 Water connections 8 7 4 Pocket for instrument panel 8 7 5 Water pressure 8 8 Gas supply 8 8 1 General 8 8 2 Gas pressure 8 9 Electrical supply ...

Page 148: ...ing to the following European directives Gas appliance directive no 90 396 EEC Efficiency directive no 92 42 EEC E M C directive no 89 336 EEC and complies with the following directives Low voltage directive no 73 23 EEC Machine directive no 89 392 EEC Classification type for evacuation of the combustion pro ducts B11 BS For further advice or information contact Broag Ltd The Remeha Gas 450 is sup...

Page 149: ... B mm t 10 C l 1365 1565 1763 1963 682 5 782 5 881 5 981 5 300 300 350 350 Boiler weight Dimensions Water resistance Water content Ø D mm 84 120 164 208 t 20 C 21 30 41 52 91 105 118 131 725 835 950 1060 kg h Mass flue rate 544 654 752 831 kg Connections can also be assembled on the other side Flow R 2 Return R 2 Gas connection R 1 Note Right hand execution is shown instrument panel gas and water ...

Page 150: ... flow through the boiler is Output boiler in kW m3 h 93 This minimum flow must be maintained for 5 minutes after the burner stops firing to avoid high temperature shut down due to residuel heat gain Due to the design and manufacture of the boiler no specific minimum water flow requirement exists other than high temperature protection 4 APPLICATION 4 1 4 Water treatment Water treatment under normal...

Page 151: ...let W min 0 5D 50 mm with horizontal flue outlet free access to rear of boiler Note Right hand execution is shown instrument panel gas and water connections on the right hand side left hand execution is mirror image free access to rear of boiler Note Both right and left hand execu tion are shown left boiler instrument panel gas and water connections on the right hand side right boiler instrument p...

Page 152: ...tion Flame protection by means of ionisation flame detection 6 4 2 Down draught thermostat Optional the boiler can be fitted with a down draught thermostat When there is down draught of the flue gases this thermostat will switch off the boiler Fixed setpoint is 70 C 6 4 3 Thermostats Control thermostat On Off 35 95 C Control thermostat High Low 35 95 C High Limit thermostat locks out at 110 C 6 3 ...

Page 153: ...anel 9 4 Electrical data Main supply 230 V 50Hz L N Running current 155 VA Installed fuse 6 Amp 7 4 Pocket for instrument panel The thermostat pocket is fitted in the flow connection of the boiler 7 5 Water pressure Each section is hydraulically tested to at least 10 bar Maximum test pressure for the assembled boiler block is 8 bar Operating pressure between 0 8 bar and 6 bar Optional the boiler c...

Page 154: ...9 9 5 Wiring diagram boiler Fig 06 Wiring diagram ...

Page 155: ...sioning the boiler 1 Check gas connections 2 Check electrical supply L N and earth 3 Check water connections and if installation is filled 4 Switch on circulation pump and check rotation direc tion 5 Open main gas cock release air in gas pipe work 6 Switch on electrical supply 7 Set the control thermostats at about 85 C 8 After a waiting time of about 3 seconds you will get ignition At a minimum i...

Page 156: ... 4 Clean the boiler room and the floor underneath the boiler 5 Clean the burners internally and externally and check the kanthal bars 11 MAINTENANCE 6 Clean the boiler casings 7 Clean the gas train ignition pilotburner thermostats and wiring 8 Check the gas train and pipe for gas leakage 9 Check the start program ignition time and safety times 10 Check flame protection and thermostats 11 Check the...

Page 157: ...rt or whole without our prior consent in writing ISO 9001 since 1988 Subject to alterations 53899 1 500 0401 Ho Broag Ltd Head office Remeha house Molly Millars Lane Wokingham Berkshire RG41 2QP Tel 0118 978 3434 Fax 0118 978 6977 E mail address boilers broag remeha com Branch office Unit 3 Kestrel Close Quarry Hill ind Estate Ilkeston Derbyshire DE7 4RD Tel 0115 944 0778 Fax 0115 944 0588 R e m e...

Page 158: ...1 Atmospheric gas boiler 278 1058 kW R e m e h a G a s 5 5 0 5 5 0 D u o Technical information Remeha Gas 550 550 Duo ...

Page 159: ...ol box 11 6 3 4 Specification Ignition transformer 12 6 4 Functions 12 6 4 1 Flame control lock out 12 6 4 2 Thermostats shutdown lock out 12 6 4 3 Water level control lock out 12 6 4 4 Valve leakage control optional lock out 12 6 4 5 Gas pressure switch LD optional shut down 12 6 4 6 Gas pressure switch HD optional lock out 12 6 4 7 Down draft thermostat optional shut down 12 7 Assembly and insta...

Page 160: ... burners suitable for natural gas cat I 2 H 20 mbar It is supplied in sections for delivery and on site assem bly The boiler meets the requirements of the CE regulations at the following directives Gas appliance directive no 90 396 EEC Efficiency directive no 92 42 EEC E M C directive no 89 336 EEC And is correspondent with Electrical low voltage directive no 73 23 EEC Remeha Gas 550 Duo reference...

Page 161: ...Remeha Gas 550 550 Duo 4 3 DIMENSIONS AND TECHNICAL DATA 3 1 Dimensions Remeha Gas 550 Fig 01 Dimensions Remeha Gas 550 00 05F 79 00002 Flow Ø107 int Return Ø107 int Gas 2 Flue gas Ø ...

Page 162: ...460 1680 1900 2120 2340 2560 Ø D mm 300 350 400 450 450 500 500 E mm 1295 1295 1295 1295 1295 1295 1245 Dimensions H mm 1730 1730 1730 1610 1730 1610 1730 Flue temperature C 154 152 146 138 138 142 142 t 10 C mbar 64 72 80 128 160 180 196 Water resistance t 20 C mbar 16 18 20 32 40 45 49 Water contents litre 291 349 407 465 523 581 639 Boiler weight dry kg 1450 1695 1940 2185 2430 2675 2920 Flue g...

Page 163: ...Remeha Gas 550 550 Duo 6 3 2 Dimensions Remeha Gas 550 Duo Fig 02 Dimensions Remeha Gas 550 Duo 00 05F 79 00003 Flow Ø107 int Return Ø107 int Gas 2 Flue gas Ø ...

Page 164: ... working temperature of 95 C 4 1 3 Water flow The minimum water flow through the boiler on shut down is Output boiler in kW m3 h 93 This minimum flow must be maintained for approxima tely 5 minutes after the burner stops firing to avoid high temperature shut down due to residual heat gain Due to the design and manufacture of the boiler no specific minimum water flow requirements exist other then f...

Page 165: ...ives Maximum chlorine content of 200 mg l Take advice on the suitability of inhibitors 4 1 5 Noise level The noise level measured around the boiler depending on boiler room construction is about 50 55 dBA Noise levels taken at 1 meter from the boiler 4 2 Chimneys The average flue gas temperature is so low that the chimney must be made in accordance with the guide lines of British Gas BS 6644 4 3 I...

Page 166: ... centre of nipple holes floor area Fig 03 Remeha Gas 550 00 05F 79 00004 number of sections 10 12 14 16 18 20 22 Size A 965 1185 1405 1625 1845 2065 2285 Size Ø D 300 350 400 450 450 500 500 Size B 1240 1460 1680 1900 2120 2340 2560 Size E 1295 1295 1295 1295 1295 1295 1245 Size H 1730 1730 1730 1610 1730 1610 1730 ...

Page 167: ...d layout for boiler installation measure ments in mm centre of nipple holes floor area number of sections Fig 04 Remeha Gas 550 Duo 00 05F 79 00005 size A size ØD number of sections 10 12 14 16 18 Size A 965 1185 1405 1625 1845 Size Ø D 450 500 600 650 650 ...

Page 168: ...load hours option 6 Analogue thermometer for flow temperature 7 High limit thermostat preset to 110 C 8 Lock out warning lamp 9 Option for rematic weather compensator 10 Reset for water level control The Instrument panel mounted in the front casing also contains circuit boards for Water level control see 9 6 Common alarm and operating signal 6 3 Standard electronic gas train High Low 6 3 1 Schemat...

Page 169: ...ed that the temperature also falls Type Honeywell L6068A fixed setpoint is 70 C Note The Gas 550 Duo requires two 6 3 3 Specification control box Control box Satronic MMI 816 Main supply 230 V 50 Hz Minimum ionisation current min 3 µA DC Reaction time flame protection 1 sec Safety time 10 sec Maximum ambient temperature 60 C Injector size pilot burner Ø 1 0 mm Injector size main burner Ø 5 4 mm Bu...

Page 170: ...ter pressure Each section is hydraulically tested at 10 bar Maximum test pressure for the assembled boiler block is 7 8 bar Minimum working pressure is 0 8 bar at a maximum working temperature of 110 C or 0 3 bar at a maximum working temperature of 95 C Maximum working pres sure is 6 bar 8 GAS SUPPLY 8 1 General The instrument panel mounted in the front casing must be mounted on the same side of t...

Page 171: ...550 Duo has two control panels and requires two sets of operating controls and has two sets of function indication 9 4 Electrical connections The boiler is pre wired Only the main supply should be wired to the instrument panel 9 5 Electrical information Main supply 230 V 50 Hz L N Running current 150 VA Maximum fuse 6 A slow acting Note The Gas 550 Duo requires two sets of power supplies 9 6 Water...

Page 172: ...15 9 7 Wiring diagrams Fig 08 Electrical principle diagram 04 05F SC 00001 ...

Page 173: ...control system is built in put the selector switch on manual operation 9 Switch on the boiler If a valve leakage control is installed the following will take place A membrane pump will create overpressure between safety valves VA1 VA2 which are inside the multibloc gas valve When within 27 sec an overpressure of 30 mbar compared to the inlet pressure is reached the electric supply is released to t...

Page 174: ...witch until the pressure control operates The control box shuts down the gas supply and will restart 15 Adjustment of the gas pressure switch HD optional Switch the boiler to full load Connect a pressure gauge to manifold Set the pressure switch to the value detailed in the documentation supplied with the gas pressure switch Check whether the gas pressure switch HD comes to action at the set value...

Page 175: ...er controls and gas supply Remove front top casings and flue hood covers Remove gas manifold Remove the burners and floor plates Clean the internal flue ways of the boiler Clean the floor underneath the boiler and boiler room Clean the burners internally and externally using a soft brush Clean the gas train ignition pilot burner thermostats and wiring Check and re set re place ignition electrode a...

Page 176: ...me signal of pilot burner no spark red zone failing or unstable flame of pilot burner end of yellow zone begin of green zone no flame signal of main burner Green zone end of green zone failing or unstable flame of main burner 12 1Fault causes In case of all disturbances the gas supply is interrupted and the color disc stops rotating Check the position of the color disc for a indication of the caus...

Page 177: ...se Quarry Hill Ind Estate Ilkeston Derbyshire DE7 4RD Tel 0115 9440778 Fax 0115 9440588 Copyright All technical and technological information contained in these technical instructions as well as any drawings and technical descriptions furnisched by us remain our property and may not be multiplied without our prior consent in writing Subject to alterations 56267 1500 0601 Ho R e m e h a G a s 5 5 0...

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Page 216: ...1 Atmospheric gasboiler 276 1044 kW remeha Gas 5a 5a Duo Technical information ...

Page 217: ... 5 2 2 Specification 8 5 3 Functions 8 5 3 1 Flame protection 8 5 3 2 Down draught thermostat 8 5 3 3 Thermostats 8 6 Assembly and installation guidelines 9 6 1 General 9 6 2 Boiler assembly 9 6 3 Water connections 9 6 4 Water pressure 9 7 Gas supply 10 7 1 General 10 7 2 Gas pressure 10 8 Electric supply 11 8 1 General 11 8 2 Electric connections 11 8 3 Electric data 11 8 4 Wiring diagram 12 9 Co...

Page 218: ...ols and strictly observe the instruc tions given The Broag remeha Gas 5a boiler is a cast iron sectional boiler with atmospheric burners Suitable for all qualities of natural gas The Broag remeha Gas 5a boiler is fitted with electric ignition and is supplied with an insulated casing 1 BOILER DESCRIPTION 2 CONSTRUCTION 2 1 General Boiler block consists of cast iron sections nippled together with co...

Page 219: ...emeha Gas 5a 22 Front view Side view Top view Cross section ø 100 ø 100 Fig 01 Dimensions of the Broag remeha Gas 5a Nominal output kW Input G C V kW Dimensions 276 306 338 368 398 430 460 522 582 644 345 383 422 460 498 537 575 652 728 805 Resistance L mm Ø D mm Ø d t 20 C mbar t 10 C mbar Water content l 940 940 940 940 940 940 940 940 940 940 350 400 400 400 450 450 450 500 500 600 2 2 2 2 2 2 ...

Page 220: ... Model Front view Side view Top view Cross section Fig 02 Dimensions of the Broag remeha Gas 5a Duo Nominal output kW B mm 690 766 844 920 996 1074 1150 1304 Input G C V kW 552 612 676 736 796 860 920 1044 1240 1350 1460 1570 1680 1790 1900 2120 ø 100 ø 107 ø D Weight dry kg 582 640 698 756 814 872 920 1046 Water content l 2900 3150 3390 3640 3880 4130 4270 4860 Ø D mm L mm 940 940 940 940 940 940...

Page 221: ...of older existing systems must be carefully considered The removal of debris flux residue grease metal swarf etc from new systems and any black magnetic iron exide sludge and other corrosive residue from old systems is essential 3 1 L P H W system 3 1 1 Water temperature Maximum water temperature is 110 C high limit thermostat Highest operating flow temperature is 95 C control thermostat Minimum r...

Page 222: ... boilers in boiler room Installation 3 Duo arrangement B Ø D Ø D duo 1240 350 500 1350 400 600 1460 400 600 1570 400 600 1680 450 600 1790 450 600 1900 450 650 2120 500 700 2340 500 700 2560 600 800 12 13 15 18 20 22 16 14 11 10 Dimensions mm Number of sections Fig 03 Boiler installations ...

Page 223: ...tat set at 70 C 5 3 Functions 5 3 1 Flame protection 5 3 2 Down draught thermostat The boiler is fitted with a thermo down draught thermostat If there is a down draught in the chimney the thermostat will switch off the boiler Fixed setpoint is 70 C 5 3 3 Thermostats Control thermostat On Off 35 95 C Control thermostat High Low 35 95 C High Limit thermostat locks out at 110 C Fig 04 Schematic layou...

Page 224: ...iler with a pipe connection for welding Ø 107 114 mm The flow water connection is a cast iron bend flanged on the boiler and comes complete with a welding neck flange Ø 107 114 mm according BS10 table D The flow bend has 1 2 tappings to accept a dual control limit boiler thermostat and the high low thermostat The end sections have a 3 4 tapping to accept drain off cocks BSP Tapping 6 4 Water press...

Page 225: ...e pressure and supply is available at the boilers maximum output To minimise risk of sediment or foreign particles entering the control valves an approved filter may be fitted into the pipework downstream The gas supply should be conform to the British Gas safety regulations 7 2 Gas pressure Maximum gas pressure at inlet 100 mbar Burner pressure full load 8 7 mbar 100 part load 3 5 mbar 60 ...

Page 226: ...thin the control box illuminates in the event of control malfunction A 240 volts 50 Hz single phase supply should be connected to the live and neutral terminals in the junction box The control box operates on a neutral phase supply The earth conductor should be connected to the earth bar using the screw provided with an anti spread washer These conductors should be entered via one of the cable ent...

Page 227: ...12 remeha Gas 5a 5a Duo 8 4 Wiring diagram Fig 05 Wiring diagram ...

Page 228: ...lot Gas valve opens At a minimum ionisation current of 5 m Amp the safety shut off valves will open after a waiting time of 15 seconds The boiler is on 9 Let the boiler on for a couple of minutes to get rid of air in the gas pipe 10 Set the correct burner pressure High flame adustment by means of the gas governor Low flame adjustment by means of the safety shut off valve Details of safety shut off...

Page 229: ...asing and top of the flue hood 2 Clean the burners internally and externally 3 Clean the floor underneath the boiler and boiler room 4 Clean boiler casings 5 Clean the gas train ignition pilot burner thermostats and wiring 6 Check start program ignition time and safety times 7 Check flame protection and thermostats 8 Check boiler input at 100 and 60 load 9 Check the combustion efficiency 10 Check ...

Page 230: ...tion of the ignition electrode and flame electrode setting If spark does not occur the ignition transformer is faulty and should be replaced If electro de setting is incorrect replace complete assembly No ignition gas at pilot burner pilot safety shut off valve fails to open Check voltage 240 V at the terminals on the pilot safety shut off valve If there is no voltage the automatic control box is ...

Page 231: ...main our property and may not be multiplied without our prior consent in writing Subject to alterations Art nr 46 836 2000 01 95 Ho Broag Ltd Head office Molly Millars Lane Wokingham Berks RG11 2PY Tel 01734 783434 Telex 849 137 Fax 01734 786977 Branch office Unit 3 Kestrel Close Quarry Hill Industrial Estate Ilkeston Derbyshire DE7 4QQ Tel 01159 440778 Fax 01159 440588 ISO 9001 since 1988 ...

Page 232: ...1 Remeha Gas 5c 5c Duo Atmospheric gas boiler 278 1058 kW Technical information R e m e h a G a s 5 c 5 c D u o ...

Page 233: ...Switching off the boiler 15 11 Maintenance 15 11 1 General 15 11 2 Maintenance 15 Preface 3 1 Boiler description 3 2 Construction details 3 2 1 General 3 2 2 Burners 3 2 3 Boiler floor 3 2 4 Assembly 3 3 Technical data and dimensions 4 3 1 Dimensions Remeha Gas 5c 4 3 2 Dimensions Remeha Gas 5c Duo 5 4 Application information 6 4 1 L P H W system 6 4 1 1 Water temperature 6 4 1 2 Water pressure 6 4...

Page 234: ...e important instructions are given to prevent accidents and serious damage before commissioning and during operation of the boiler to ensure safe and trouble free boiler operation Read these instructions carefully before putting the boiler into operation familiarize yourself with its operation and control and strictly observe the instructions given The Remeha Gas 5c boiler is a cast iron sectional...

Page 235: ... 653 365 730 404 809 444 888 Nom heat input kW NCV kW GCV 2 2 2 2 2 2 2 2 2 21 2 21 2 Ø d B Dimensions mm 1240 1350 1460 1570 1680 1790 1900 2120 2340 2560 2780 Ø D mm 300 350 350 400 400 400 450 450 500 500 500 L mm 850 850 850 850 850 850 850 985 985 1170 1170 Table 1 Technical data Remeha Gas 5c 154 152 150 148 146 142 138 138 142 142 142 Flue temp C 64 68 72 76 80 84 128 160 180 196 208 mbar t...

Page 236: ...6 Number of sections Nom heat input Nom heat output 155 618 173 690 189 756 207 828 224 896 241 964 259 1036 294 1176 kW kW NCV kW GCV Dimensions mm L kg 2900 3150 3390 3640 3880 4130 4370 4620 Boiler weight litre Table 2 Technical data Remeha Gas 5c Duo Water contents 1385 1590 1694 1966 2066 2160 2478 2752 m3 h 66 74 80 88 94 102 110 124 Gas consump tion kg h Flue gas flow rate 850 850 850 850 8...

Page 237: ...798 BS 6891 and BG DM2 Important The Remeha Gas 5c 5c Duo is a certified appliance and must not be modified or installed in any way con trary to these Installation and Servicing Instructions Manufacturers instructions must NOT be taken in any way as overriding statutory obligations m3 h 4 1 L P H W system 4 1 1 Water temperature Maximum water temperature is 110 C high limit ther mostat Highest boi...

Page 238: ...7 5 TYPICAL BOILER INSTALLATIONS Recommended layout for boiler installation measure ments in mm Installation 1 Remeha Gas 5c Fig 03 Boiler installation Remeha Gas 5c ...

Page 239: ...Remeha Gas 5c 5c Duo 8 Recommended layout for boiler installation measure ments in mm Fig 04 Boiler installation Remeha Gas 5c Duo Installation 2 Remeha Gas 5c Duo ...

Page 240: ...ronic control and safety equipment with ionisation flame detection 6 2 Instrument panel The Remeha Gas 5c is supplied with an instrument panel that is fitted in the front of the boiler either left or right The instrument panel can be delivered in two models simple instrument panel High Low complete instrument panel High Low The boiler is supplied as standard with the simple instru ment panel All con...

Page 241: ...ultibloc VDK Valve leakage control box option Not supplied as standard 6 3 3 Control panel on gas train 1 Main switch 1 Control box Satronic 1 Fuse Brusk Signal lamps 1 Water level control 6 4 Functions 6 4 1 Flame protection Flame protection by means of ionisation flame detection 6 4 2 Down draught thermostat Type B11 Bs The boiler is fitted with a thermo down draught ther mostat When there is do...

Page 242: ... pressure and supply is available at the boilers maximum output To minimise risk of sediment or foreign particles entering the control valves an approved filter may be fitted into the pipework downstream The gas supply should be conform to the British Gas safety regulations 7 1 General The boiler is suitable for operating at a maximum working pressure of 6 bar and a minimum pressure of 0 8 bar Boile...

Page 243: ...ed on the gas train 9 3 Electrical connections The boiler is pre wired Only the main supply should be wired to this control panel 9 4 Electrical information Main supply 230 V 50 Hz L N Running current 120 W Maximum fuse 6 Amp 9 5 Water level control lock out a Water level control Dungs DWEB 34 2 Main supply 230V 50 Hz Running current 5 W Electrode current 42 V AC Working area 0 5 to 15 mA AC Elect...

Page 244: ...13 9 6 2 Complete instrument panel Fig 08 Scheme complete instrument panel For legend see page 12 ...

Page 245: ...Remeha Gas 5c 5c Duo 14 9 7 Wiring diagram boiler Fig 09 Wiring diagram boiler For legend see page 12 ...

Page 246: ...rotection start the boiler with the ionisation probe disconnected 13 Check the water level control 10 3 Switching off the boiler 1 Switch off the electric supply 2 Shut off the gas cock Be aware of the possibility of the danger of frost Note Commissioning to only be carried out by a qualified engi neer with the relevant training and certification i e Acops Corgi and a commissioning data sheet comple...

Page 247: ...nit 3 Kestrel Close Quarry Hill Ind Estate Ilkeston Derbyshire DE7 4RD Tel 0115 9440778 Fax 0115 9440588 Copyright All technical and technological information contained in these technical instructions as well as any drawings and technical des criptions furnished by us remain our property and shall not be multiplied without our prior consent in writing Ours is a policy of continuous development We ...

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