remeha W40/60-m ECO High-efficiency condensing boiler for free standing (frame mounted) or wall mounted installation Suitable for room sealed fanned flue or open flue fan assisted operation Installation and maintenance instructions
remeha W40/60-m ECO CONTENTS Preface 7. Installation instructions 7.1 General 7.2 Location 7.3 Dimensions of wall mounting bracket 7.4 Ventilation requirements 7.5 Flue gas discharge and air supply 7.5.1 General 7.5.2 Single boiler, non room sealed applications 7.5.3 Single boiler, room sealed applications 7.5.4 Cascade configurations 7.6 Installation details 7.6.1 Condensate discharge 7.6.2 Cold feed and expansion tank height for open vented systems 7.6.3 Water treatment 7.6.4 Safety valve 7.6.
8. Electrical installation 8.1 General 8.2 Electrical supply 8.3 Connection to the control system 8.3.1 Modulating control 8.3.2 Room thermostat 24V 8.3.3 Room thermostat in combination with an outdoor temperature sensor 8.3.4 Two-stage external weather compensator 8.3.5 D.H.W. control 8.3.6 Frost protection 8.3.7 Signals 8.4 Water temperature control 8.5 Low-water protection 8.6 High limit temperature protection 8.7 Differential air pressure switch (LD2) 8.8 Control box 8.9 Fuse specification 8.
remeha W40/60-m ECO PREFACE These technical instructions contain useful and important information for the correct operation and maintenance of the remeha central heating boiler, models W40/60-m ECO. Furthermore, important instructions are given 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.
3. TECHNICAL DATA AND DIMENSIONS 3.1 Dimensions remeha W40-m ECO Top view Side view 1 2 3 4 5 6 Flow boiler Return boiler Gas Condensate discharge Flue gas discharge Combustion air supply * Low loss header for single boiler only Flow/return connections 11/4 BSP (F) Front view 28 mm dia. 28 mm dia. 3/4" male thread 32 mm dia. 100 mm dia. 100 mm dia. Fig. 01 remeha W40-m ECO remeha W60-m ECO Top view Side view Front view Fig.
remeha W40/60-m ECO 3.2 Technical data Boiler type remeha W40-m ECO modulating high - low on - off 12,4 41.0 14.0 44.3 14.1 47.0 12.7 42.3 II 2H 3P 17 - 30 1.3 - 4.5 51 29 0,8 71 B23, C13, C33, C43, C53, C63 240/50 150 2 20 100 20 - 90 0.3 3 5 400 350 67 Load control: adjustable Output Input (GCV) Input (NCV) (80/60˚C) (40/30˚C) - min. - max - min.
4. EFFICIENCY INFORMATION 4.2 Heat to water efficiency a. Up to 99.0% (NCV), 89.1% (GCV) at an average water temperature of 76.5˚C. b. Up to 110.4% (NCV), 99.4% (GCV) at an average water temperature of 45˚C. 4.1 Annual efficiency a. 103.3% (NCV), 93.0% (GCV) at an average water temperature of 45˚C (55/35˚C). 5. INSTALLATION APPLICATIONS 5.
remeha W40/60-m ECO 5.1.2 Installation of multiple boilers Multiple boilers are idealy suited for use in larger commercial buildings and offer a wide variety of application possibilities (see principle drawing). D.H.W. Fig. 05 Principle drawing multiple boilers For further advice or information refer to the Technical Information "Multiple Units". Contact Broag Ltd. Table 1. rematic® 4-step weather compensator (Master) Step 1 till 4 2. rematic® 4-step modular controller (Slave) Step 5 till 8 3.
6. BOILER LAYOUT 6.1 Equipment diagram 2 1 1. Air supply 2. Flue gas discharge 3. Measure point O2 /CO2 4. Air box 5. Slide connector 6. Differential air pressure switch 7. Spring loaded damper 8. Gas injector (behind fan) 9. Fan 10. Automatic vent 11. Burner 12. Ignition/ionisation probe 13. Sight glass 14. Manual air vent 15. Gas combi-block 16. Heat exchanger 17. Flow temperature sensor 18. Inspection cover 19. Return temperature sensor 20. Condense collector 21. Instrument panel 22.
remeha W40/60-m ECO 6.3 Control panel The remeha W40/60-m ECO is equipped with an advanced control system comprising: a. an automatic microprocessor control system b. a control panel with setting keys and read-out display. 6.2 Operating principle The appliance is equipped with a closed air box. Via a fan, air is drawn in. On the intake side of the fan, an intake unit has been mounted where the gas is injected.
6.4 Control system 6.4.1 General Press the 'mode'-key Press the 'step'-key 'Code'-display Operating mode (see para. 6.4.2) Temperature display 0-9 H,L Flow temperature digit Setting mode (see para. 6.4.3) . digit and dot 1. 2. 3. A. Required flow temperature Pump setting D.H.W. setting Boiler control operation On service level (C 12): Read-out mode (see para. 6.4.4) . digit and blinking dot 6. 7. 8. 9. b. C. d. E. F. G. H. I. J. L. n. P.
remeha W40/60-m ECO 6.4.2 Operating mode During operation the 'code'-display shows the status (position in cycle) of the boiler, while the temperature displays indicates the measured water temperature. 5 Waiting mode; the fan runs and the boiler waits until this has been proved or waits until the three-way valve has returned to the central heating position.
6.4.3 Setting mode (with dot) Various settings can be changed as required in the setting mode. a. on user level - Select the setting mode by pressing the 'mode'-key until 1. appears in the 'code' read-out display. - Now select the required code, using the 'step'-key. Code Description Setting 1. 2. Required flow temperature Pump setting 3. A. D.H.W. setting Boiler control operation ( X = don't care) - 20 - 00 01 99 - 20 - 1X - 2X - X0 - X1 - X2 - X3 Preset - 9 0 ˚C pump operation 10 sec.
remeha W40/60-m ECO 6.4.4 Read-out mode (with blinking dot) Various values can be read in the read-out mode. On user level. - Select the read-out mode by pressing the 'mode'-key until 1. (blinking dot) appears in the 'code'-display. - Now select the required code, using the 'step'-key. Code Description Read-out (example) 1. 2. 3. 4. 5. 6. 7. Flow temperature Return temperature D.H.W.
6.4.9 Service code Only for the heating contractor. To avoid incorrect settings several operation levels have protection codes. For service purposes you can program code C 1 2 . - Press the 'mode'- and 'step'-keys simultaneously and the 'code'-display now shows C . - Holding both keys pressed, set the temperature display to 1 2 , using the '▲'- and '▼'-keys. 6.4.8 Failure mode (blinking 'code' display) Only for the heating contractor.
remeha W40/60-m ECO 3. D.H.W. setting (basic setting 65˚C). Only with sensor. - Press the 'mode'-key until the digit 1. (with dot) appears in the 'code'-display. - Press the 'step'-key until the digit 3. appears in the 'code'-display. - Set the required value, using the '▲'- and '▼'-keys. 6.4.10 User settings The user can set the following parameters to the required values. 1. Flow temperature (basic setting 80˚C). - Press the 'mode'-key until the digit 1. (with dot) appears in the 'code'-display.
7. INSTALLATION INSTRUCTIONS 7.3 Dimensions of wall mounting bracket 7.1 General All gas appliances must, by law, be installed by competent persons (e.g. Corgi). Failure to install appliances correctly could lead to prosecution. It is in your own interest and that of safety to ensure that the law is complied with. The following instructions must be adhered to when the remeha W40/60-m ECO is installed: Gas Safety (Installation and Use) Regulations 1984 (as amended). Current I.E.E.
remeha W40/60-m ECO 7.4 Ventilation requirements a. Open flue installations The requirements for high and low level ventilation openings which MUST be provided are contained in detail within BS 6644. Openings must be permanent, communicate direct to outside and be positioned so as to avoid blockage, flooding or high velocity draughts within the boilerhouse. The minimum free area of openings are shown in the table: b.
7.5 Flue gas discharge and air supply Purpose designed flue and air systems for all applications are available from: - Rite-Vent Ltd Crowther Industrial Estate Washington NE 38 OAB Tel.no.: 0191 - 4161150 Fax.no.: 0191 - 4151263 7.5.1 General The remeha W40/60-m ECO is suitable for room sealed fanned flue or open flue fan assisted operation. Separate flue discharge and combustion air inlet connections are located on top of the appliance.
remeha W40/60-m ECO 7.5.2 Single boiler, non room sealed applications H Construction of flue gas discharge duct 1 = flue gas discharge duct without bends 2 = flue gas discharge duct with two 45˚ bends 3 = flue gas discharge duct with two 90˚ bends 4 = flue gas discharge duct with T inlet and 90˚ bend, or flue gas discharge duct with two 45˚ bends Fig. 12 Examples of flue gas discharge duct, single boiler, non room sealed applications. remeha W40-m ECO D (in mm) Min. and max.
7.5.
remeha W40/60-m ECO 7.6.2 Cold feed and expansion tank height for open vented systems The cold feed and expansion tank heights for all open vented systems must comply with the requirements laid down in the Health and Safety Executive publication PM5. For the remeha W40/60-m ECO installations this requirement is met providing the tank height is at least 3 meters above the highest circulating point of the system (see para. 7.7.2, fig. 15). 7.6 Installation details 7.6.
7.6.4 Safety valve A safety valve should be fitted in the flow pipe between the boiler and any isolating valves but in any case within 0.5 m of the appliance. The safety valve should be sized according to the requirements given in the current edition of BS 6644. 7.7 D.H.W. application An indirect calorifier can be connected to the remeha W40/60-m ECO in accordance with the schematic sketch shown (fig. 15 and 16) and the wiring diagram in para. 8.10. 7.7.1 D.H.W.
remeha W40/60-m ECO 7.7.2 Schematic sketch of connections ▼ HR Fig. 15 Schematic sketch of an open system Fig.
8. ELECTRICAL INSTALLATION 8.1 General The remeha W40/60-m ECO is equipped with electronic control and safety equipment, and flame ionisation control. A microprocessor is at the heart of the remeha W40/60-m ECO. The boiler is pre-wired as shown in the wiring diagram in para. 8.10. All controls on the boiler are 24V. Installation and connection 1a. rematic® SR 5240 C1 (no possibility for post-regulation of central heating groups) Installation in the boiler or in a reference room.
remeha W40/60-m ECO 8.3.2 Room thermostat 24V The remeha W40/60-m ECO is suitable for a 2- or 4wire standard room thermostat. Proceed as follows: a. Connect the room thermostat to terminals 1 and 2 of the 16-pole wire connector. 8.3.4 Two-stage external weather compensator The remeha W40/60-m ECO can be connected to a twostage external weather-compensator. The boiler can run on high/low. Proceed as follows: a.
8.3.6 Frost protection Install the boiler in a frost-free room. If the temperature of the central heating water drops too low, the built-in frost protection is activated. Water temperature: - below 7˚C - circulation pump is switched on; - below 3˚C - boiler is switched on; - higher than 10˚C - boiler and circulation pump are switched off. Attention: This is only a protection of the boiler.
remeha W40/60-m ECO 8.4 Water temperature control The remeha W40/60-m ECO is supplied with an electronic temperature control (basic setting 80˚C) with flow and return temperature sensors. The flow temperature can be adjusted between 20 and 90˚C. 8.9 Fuse specification Fuse: F1 3.15 A T F2 3.15 A T F3 2 A F (sand-filled) 8.5 Low-water protection The remeha W40/60-m ECO is supplied with a lowwater protection device. Protection is provided in this appliance on the basis of temperature measurement.
8.10 Electrical wiring diagram Fig.
remeha W40/60-m ECO 9. INSTALLATION INSTRUCTIONS FOR THE GAS INSTALLER 9.1 Gas connection The boiler is suitable for firing on natural gas and propane. Category II2H 3P. Connect the boiler to the incoming gas in accordance with the requirements of the Gas supply company. Install the main gas cock near the boiler. The gas connection is located at the bottom of the boiler (see fig. 6, para. 6.1, item 29). Fit a gas filter in the gas supply piping to avoid fouling of the gas control unit. 9.
10. COMMISSIONING 10.1 Initial lighting 1. Check that the electric power to the boiler is switched off. 2. Remove the front panel and the two side panels. 3. Check that the gas supply is correctly fitted. 4. Check that the electrical connections are correct. 5. Open the cap of the automatic air vent (fig. 6, no 10). 6. Fill the boiler and the installation with water and check the water pressure (recommended 1.5 bar). 7. Only remeha W40-m ECO: Check the pump; this may be stuck.
remeha W40/60-m ECO 17d.Run the appliance at part-load (forced mode ‘LOW’, see par. 6.4.6) - Press the 'mode' and '▼' keys simultaneously. 17e.Once the part-load speed is reached, compare the measured result with the table above (see 17c). If necessary, correct the gas to air ratio using screw B on the gas combination block (see fig. 21). Check via the inspection opening: - the flame (should not blow out) - the burner surface (should show a regular flame distribution). 17f.
10.3 Settings 10.3.6 Setting the burner control Setting mode, step A. The basic setting is modulating burner control. To alter burner control, you should carry out the following actions. - Press the 'mode' key to call up setting mode. The dot in the ‘code’ window will light up continuously. 10.3.1 General In this paragraph a number of further setting options are explained briefly. In most cases reference is merely made to the diagram in par. 6.4.1. 10.3.
remeha W40/60-m ECO 10.3.7 Setting D.H.W. temperature Setting mode, step 3. Setting this value is only important if a remeha D.H.W. sensor is used. The basic setting is: D.H.W. operation with a D.H.W. temperature of 65°C. To make alterations, see para. 6.4.1 and 6.4.10. - Press the 'reset' key to return to operating mode. ⇑ 10.3.8 Switching D.H.W. operation on and off Setting mode, step A. The basic setting is: boiler operation on. To switch off the D.H.W.
11. FAULT-FINDING 11.1 General This chapter differentiates between appliances with the modulating rematic® weather-compensated control and appliances controlled in some other way. In those cases where a modulating room control (Honeywell Chronotherm Modulation with relevant interface) is used, follow par. 11.2. 11.2 Faults in appliances in combination with the rematic® weather-compensated boiler control Carry out the steps listed below in the order given: 1. No figures appear in the appliance display.
remeha W40/60-m ECO 0 0. 0 1. 0 2. Description Flame simulation Short-circuit 24V No flame or no ionisation (after 3 starts) 0 4 0 8. Control fault Air transport 1 1 1 2 Control fault Max. water temperature Temperature sensor fault 2. 8. 9. 4. 2 5. Maximum water temperature 2 8. Fan does not run 2 9. Fan keeps running 3 3 3 3 3 4 Max. water temp. Temp.sensor fault 0. 1. 2. 6. 7. 3. 6 1. Parameters out of reach Air transport Cause/checkpoints Check ionisation probe (distance 3 - 4 mm).
12. INSPECTION AND SERVICING INSTRUCTIONS 12.1 General The remeha W40/60-m ECO is practically maintenancefree. Once a year, the appliance should be checked and if necessary cleaned. 12.2 Inspection The annual inspection of the remeha W40/60-m ECO can be limited to: - inspection of the boilers combustion characteristics - cleaning the siphon - setting the ignition electrode - check for leaks (water side, flue gas side and gas side) - water pressure check.
remeha W40/60-m ECO 12.3 Maintenance If the appliance is checked for technical combustion problems and the result is that either combustion or heat exchanger are no longer at the optimum level, maintenance should be carried out. This maintenance will consist of: - cleaning the heat exchanger with a nylon brush or compressed air and possibly rinsing with water - cleaning the fan - cleaning the siphon. A2 A1 Work order (see fig.
E A B M B D C G I G H G F J K A B C D E F G H I J K L M Fig. 26 Servicing points remeha W40/60-m ECO - To inspect or clean the fan, it must be disconnected from the gas injector. - Remove the screws at the rear of the fan. For cleaning purposes, use a plastic brush; remove any loose dust particles from the fan, before reassembling the system. - Reassemble all parts removed in reverse order.
remeha W40/60-m ECO ISO 9001 since 1988 Broag Ltd. Head Office Remeha house, Molly Millars Lane, Wokingham, Berkshire RG 41 2QP. Tel. 0118 9786977 Fax 0118 9783434 Email address: boilers@broag.ltd.uk. © Copyright All technical and technological information contained in these technical instructions, as well as any drawings and technical descriptions furnished by us remain our property and shall not be multiplied without our prior consent in writing. Subject to alterations Art. nr. 51.794/2500/05.97/Ho.
