Remeha Gas 3002 ECO Remeha Gas 3002 ECO Technical information • High efficiency condensing boiler with Low NOx emission • Range 177 - 531 kW • mbc 3.
Remeha Gas 3002 ECO CONTENTS Preface 3 1. Description of the boiler 4 2. Constructional data 2.1 General 2.2 Burners 5 5 5 3. Technical data and dimensions 6 4. Efficiency information 4.1 Combustion efficiency 4.2 Efficiency 4.3 Standing losses 4.4 Annual efficiency 7 7 7 7 7 5. Application data 5.1 Delivery and positioning 5.1.1 General 5.1.2 Location 5.1.3 Support 5.2 L.P.H.W. configuration 5.2.1 Water temperature 5.2.2 Water pressure 5.2.3 Water circulation 5.2.4 Water treatment 5.2.
PREFACE These technical instructions contain useful and important information for the correct operation and maintenance of the Remeha central heating boiler, model Gas 3002 ECO. Furthermore, 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.
Remeha Gas 3002 ECO 1. DESCRIPTION OF THE BOILER 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 - Electrical low voltage directive no. 73/ 23/EEC - Machinery directive no. 89/392/EEC - E.M.C. directive no. 89/336/EEC. Suitable for all qualities of natural gas (category I 2 H 17 - 30 mbar). Classification type for evacuation of the combustion products: B23, C33, C53 or C63.
2. CONSTRUCTIONAL DATA 2.1 General - The first heat exchanger consists of cast iron sections assembled with conical nipples. - The second heat exchanger (economiser) is constructed from finned tubes and made of aluminium. - A fan supplies the combustion air and transports the exhaust gases through the boiler and flue. - The control and safety equipment is fitted behind the casings. - The boiler is entirely prewired. - The casings are clear of the ground to avoid any corrosion as a result of moisture.
Remeha Gas 3002 ECO 3. TECHNICAL DATA AND DIMENSIONS Cross section Top view 1) Left side view Front view Fig. 02 Dimensions Flue Number Input Water Water Assembly Output Dimensions gas contents weight of resistance 80/60 40/30 (Hs) mass ∆ t = 20°C ∆ t = 10°C sections ˚C ca. A B C ØD/Ød 1) E X F Y 2) L ˚C kg kW mm mm mm mbar mm kg/h mm mm mm inch ltr.
4. EFFICIENCY INFORMATION 4.1 Combustion efficiency Up to 98.5% at Hi (88.7% at Hs) at 80/60°C. 4.3 Standing losses On average 0.38% at Hi (0.34% at Hs) at an average boiler water temperature of 45°C. 4.2 Efficiency Up to 98% at Hi (88.3% at Hs) at 80/60°C and up to 108.1% at Hi (97.4% at Hs) at 40/30°C. 4.4 Annual efficiency On average 108% at Hi (97.2% at Hs) at an average boiler water temperature of 35°C.
Remeha Gas 3002 ECO 5. APPLICATION DATA 5.1 Delivery and positioning 5.1.2 Location The drawings on the next page show a number of possible arrangements with the required space all round. The Remeha Gas 3002 ECO is supplied as standard with connections at the top left side. If specified when ordering, it is possible to have the connections installed top right. 5.1.1 General All parts to be assembled on the site can be transported using normal access doors. The vulnerable parts are packed.
Installation 1 One boiler in the boiler room Number of sections 7 9 11 13 15 17 19 A mm 1235 1790 1790 2035 2345 2495 2645 L mm 313 235 235 312 156 233 110 Installation 2 Two boilers in the boiler room Installation 3 Two boilers in the boiler room, back to back ** When using the seperate connections for the ECO, this distance + 2 x L Fig.
Remeha Gas 3002 ECO 5.1.3 Support The drawing below shows the support surface of the boiler with connections to the left (standard construction). This drawing can be mirrored for the model with connections to the right (specify when ordering). 5.2 L.P.H.W. configuration 5.2.1 Water temperature The maximum water temperature is 110°C (sealed installation). The maximum operating temperature is 95°C. The minimum return water temperature is 20°C with a waterflow corresponding to a ∆t of 20°C at rated output.
5.2.3 Water circulation The water flow through the boiler is limited to an amount corresponding with a differential temperature across the boiler of 45°C. If the differential temperature exceeds 45°C the boiler is turned off and blocked. See also para. 7.5.3. As soon as the flow is again sufficient, the boiler will automatically restart.
Remeha Gas 3002 ECO 5.3 Hydraulic circuits with Low Loss Header 5.4 Installation instructions The following instructions must be adhered to when the Remeha Gas 3002 ECO is installed: Gas Safety (Installation and Use) Regulations 1984 (as amended). All gas appliances must, by law, be installed by competent persons (e.g. Corgi) in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution.
5.6 Flue gas discharge and air supply 5.6.1 General The Remeha Gas 3002 ECO is available in either a conventional room ventilated or a room sealed (Type B13, C33, C53 or C63) construction. Specify at the time of ordering if the boiler is required to be supplied for room sealed operation. In that case, the boiler will be supplied with an air supply connection and a clamping band. This connection must be fixed to the fan inlet (remove the cover plate on the rear top casing).
Remeha Gas 3002 ECO 5.6.4 Room sealed operation Maximum allowable lengths of flue gas discharge and air supply piping in (L) m D (in mm) 7 sect. Ø 180 * Ø 200 Ø 250 Ø 300 9 sect. Ø 200 Ø 250 Ø 300 11 sect. Ø 200 Ø 250 Ø 300 13 sect. Ø 200 Ø 250 Ø 300 15 sect. Ø 200 Ø 250 Ø 300 Fig. 08 Room sealed operation 5= 6= Air supply and flue gas discharge piping without bends Air supply and flue gas discharge piping with two 90° bends, maximum connection length to vertical length 1.
For room sealed operation combined vertical roof outlets (GVRS) are available as outlined below (fig. 09). 175 50 øD 3 (ext.) øD 4 Dimensions øD 3 øD 4 --- Not supplied and mounted by Broag * Correct lengths for 11 and 19 sections; for the 9, 13, 15 and 17 sections, the pipe supplied must be shortened. This pipe is not suitable for the 7 section boiler.
Remeha Gas 3002 ECO 6. PRINCIPLE OF THE BOILER INSTALLATION provided with a distribution plate. This slotted plate serves to distribute the mixture over the burner (6). The burners have a metal fibre cover in which a burner pattern is punched. The gas/air mixture is ignited and combustion takes place. Premix combustion ensures a very low NOx emission.
7. CONTROL AND SAFETY EQUIPMENT 7.1 General The Remeha Gas 3002 ECO comes complete with electronic control and safety equipment, with ionization flame protection. As a standard procedure, the boiler has been designed to meet the CE and other relevant inspection requirements. The boiler can be controlled either high/low or modulating. 7.2.2 Lay-out of the instrument panel The instrument panel consists of the following components: 1. main switch 2.
Remeha Gas 3002 ECO 7.3.3 Service level To prevent unwanted settings by non-experts the service level can only be accessed after entering a security code. The security code for this level is 0012. After entering this code using the ' ' and ' ' buttons in menu 5 and confirming it by pressing the ' ' button, the service level is accessed. Now, a selection can be made from 4 options: 1) Service settings 2) Service test 3) History data 4) Service level II (factory level).
Option 2 Language: A choice of English, Dutch, French or German. Option 3 Setpoint hysteresis: Using this parameter, the switch hysteresis can be set at the flow temperature. As standard, this value is set at 10°C. The boiler will always issue a control stop when the flow temperature equals the preset maximum flow temperature +5°C. The switch hysteresis determines when the boiler will switch on.
= xxC = xxC = xxxPa = x.xuA = xxC = xxxxH = xxxxH = xxxxH heatexch. temp. flue temp. air pressure flame sign. 2 max. oper. temp. hours total hours low hours high 20 Step forward with ' '-button Return step with ' '-button Command with ' '-button enter code for factory level code = 0000 1) lockout data 2) shutdown data 1) boiler on 2) fan on 3) 4) ignition on service settings service test history data factory data Service level 1) 2) 3) 4) ▲ Fig.
7.4 Standard electronic gas train 7.5 Functions 7.4.1 Schematic construction 7.5.1 General The equipment supplied ensures that the following functions are monitored and locked or blocked in case a failure has occured. 7.5.2 Flame protection (lock out) Flame protection with two ionization probes. VA1 VA2 7.5.
Remeha Gas 3002 ECO 8. ASSEMBLY GUIDELINES AND INSTALLATION INSTRUCTIONS FOR THE HEATING ENGINEER 8.1 General The Remeha Gas 3002 ECO is delivered unassembled. The dimensions allow for transportation of all parts to the boiler room through normal access doors. The casing and equipment parts are packed. 8.4 Safety valve The size and location of the safety valve must comply with the relevant requirements.
10. ELECTRICAL SUPPLY 10.1 General The electrical installation must be conform to the I.E.E. regulations and also to the local authority requirements. There are several options to set the required flow temperature and the start command to the boiler. A1. Start/stop through a volt free contact. Select in the service level the option 'Input selection: relay contacts'. The start command to the boiler comes free when relay contacts close. The power for this input is supplied by the boiler at a level of 24V DC.
Remeha Gas 3002 ECO 10.5.2 Blocking inputs The control system is equipped with two blocking inputs which can switch off the boiler. These inputs can be used, for example, in combination with the limit switches of throttling valves, minimum gas pressure switches, etc. Blocking input 1 is fitted on terminals 29 and 30, whilst blocking input 2 is fitted on terminals 31 and 32. The symbol for both inputs is: The input resistance at the analog input is approx. 10 kΩ (see also electrical wiring diagram at para.
10.6 Outputs 10.7 Building Management System 10.6.1 Alarm output The boiler is fitted with a potential-free two-way contact for the alarm or ready message. When the boiler is locked or dead, contact 11 and 12 will be made. When the boiler is ready, contacts 11 and 10 will be made. The maximum load on the contact is 250V/2A. This output is indicated by the following symbol: For connection to a Building Management System the Remeha Gas 3002 ECO is delivered as standard with a RS 232 connection.
Remeha Gas 3002 ECO 10.9 Electrical wiring diagram Fig.
Fig.
Remeha Gas 3002 ECO 11. COMMISSIONING 11.1 Technical data Control box: Remeha mbc 3.0 Mains voltage: 230V - 50Hz Minimum ionization current: 1.0 µA DC Reaction time of flame protection: 1 sec. Safety time: 3 sec. Max. allowable ambient temperature: 60°C Number of start attempts: 5 Cut-out differential pressure: 50 Pa. The control box is sensitive to phase/neutral! The control panel comes with an alphanumeric LCDdisplay. The entire starting cycle can be followed on this display.
the menu with the selecting option "Service settings". 11. Now select the option "Fan on?" and confirm with Select this option and confirm with the ' '-button. the ' '-button. The fan will start now. Switch the fan to maximum speed by selecting this option. Now select "Boiler on?"; confirm with the ' '-button. Confirm with the ' '-button. Now press the ' '-button. The boiler now will make a start attempt without igniSelect the option "Service settings" and confirm tion.
Remeha Gas 3002 ECO Gas distribution pipe blue black burner Gas multi-block blue ∆P gas = PF+PG ∆P air = PL+PF black Fig. 20 Differential pressure measuring points (boiler with 11 to 19 sections) 14. Measure the CO2 percentage at full load, in the flue gas discharge pipe, directly above the casing. The measured value must be compared with the value indicated in the table.
16. Switch the boiler to full load by selecting option "Load maximum" with the ' ' button and confirming it with the ' ' button. Compare the CO2 percentage with the value men tioned in the table. Adjust, if necessary, this CO2 percentage with the V-controller. Switch the boiler to part load, measure and compare the CO2 percentage with the value mentioned in the table and adjust, if necessary, the value with the N-controller. 17.
Remeha Gas 3002 ECO Failure message on LCD-display Instructions live and neutral inversion switch off power, and change connections. Switch off power and change connections. code not valid. check wiring. The control unit does not recognize the boiler through the code connector. Check the wiring. code not accepted. please contact qualified personnel. A wiring error has been made or a failure has occurred in the control unit. Contact our service department. flow sensor short circuit.
false flame at flame guard 1 Check: - if the gas valve circuit is interrupted - if the electrode is not in contact with the burner false flame at flame guard 2 flame 1 lost during burning flame 2 lost during burning Check: - wiring of the first and second ionization electrode - position of the first and second ionization electrode; distance from electrode to burner: approx.
Remeha Gas 3002 ECO Controlstop Instructions boiler diff. temp. too high Boiler temperature differential is getting too high. Check: - boiler/installation water flow - boiler water level - working pressure (min. 0.8 bar) heat exch. temp. rise too fast Boiler temperature rise faster than usual. Check: - boiler/installation water flow - boiler water level - working pressure (min. 0.8 bar) flow temp. rise too fast flue gas temp.
13. INSPECTION AND SERVICING 13.1 General To ensure optimal combustion, the boiler, associated equipment and the boiler room must be cleaned at least once a year. This is to avoid fouling of the burners and the boiler during operation as a consequence of dust in-take, especially with the Remeha Gas 3002 ECO in room ventilated form. This will ultimately result in poor combustion and the possible formation of soot. - Checking the burners. The burner surface must not be mechanically cleaned.
Remeha Gas 3002 ECO 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 Web site: www.broag-remeha.com Branch office Unit 3, Kestrel Close, Quarry Hill ind. Estate, Ilkeston Derbyshire DE7 4RD Tel.
