Remeha GAS 3002 ECO User Manual
Technical information
Remeha Gas 3002 ECO
• High efficiency condensing
boiler with Low NOx
Remeha Gas 3002 ECO
emission
• Range 177 - 531 kW
• mbc 3.0
CONTENTS
Remeha
Gas 3002 ECO
Preface 3
1. Description of the boiler 4
2. Constructional data 5
2.1 General 5
2.2 Burners 5
3. Technical data and dimensions 6
4. Efficiency information 7
4.1 Combustion efficiency 7
4.2 Efficiency 7
4.3 Standing losses 7
4.4 Annual efficiency 7
5. Application data 8
5.1 Delivery and positioning 8
5.1.1 General 8
5.1.2 Location 8
5.1.3 Support 10
5.2 L.P.H.W. configuration 10
5.2.1 Water temperature 10
5.2.2 Water pressure 10
5.2.3 Water circulation 11
5.2.4 Water treatment 11
5.2.5 Noise levels 11
5.3 Hydraulic circuits with Low Loss Header 12
5.3.1 Single boiler installation 12
5.3.2 Modular boiler installation 12
5.4 Installation instructions 12
5.5 Condensate discharge 12
5.6 Flue gas discharge and air supply 13
5.6.1 General 13
5.6.2 Requirements 13
5.6.3 Conventional room ventilated 13
5.6.4 Room sealed operation 14
6. Principle of the boiler installation 16
7. Control and safety equipment 17
7.1 General 17
7.2 Instrument panel 17
7.2.1 General 17
7.2.2 Lay-out of the instrument panel 17
7.3 The control unit 17
7.3.1 General 17
7.3.2 User level 17
7.3.3 Service level 18
7.3.4 Overview of the different menus 20
7.4 Standard electronic gas train 21
7.4.1 Schematic construction 21
7.4.2 Specification 21
7.5 Functions 21
7.5.1 General 21
7.5.2 Flame protection (lock out) 21
7.5.3 Low-water protection 21
7.5.4 Temperature protection 21
7.5.5 Flue gas transport protection 21
8. Assembly guidelines and installation
instructions for the heating engineer 22
8.1 General 22
8.2 Water connections 22
8.3 Water pressure 22
8.4 Safety valve 22
8.5 Filling, refilling and venting of
the installation 22
8.6 Boiler draining 22
9. Gas supply 22
9.1 General 22
9.2 Pressure test of the gas installation 22
9.3 Gas pressures 22
10. Electrical supply 23
10.1 General 23
10.2 Electrical connections 23
10.3 Electrical data 23
10.4 Boiler control 23
10.4.1 General 23
10.4.2 Modulating 23
10.4.3 High/low control 24
10.5 Connections 24
10.5.1 Other inputs 24
10.5.2 Blocking inputs 24
10.5.3 Locking inputs 24
10.5.4 Gas leak check 24
10.6 Outputs 25
10.6.1 Alarm output 25
10.6.2 Operating message 25
10.6.3 External gas valve 25
10.6.4 Shunt pump connection 25
10.6.5 Extra 230V connection 25
10.7 Building Ma na ge ment System 25
10.8 Frequency changer 25
10.9 Electrical wiring diagram 26
11. Commissioning 28
11.1 Technical data 28
11.2 Initial lighting 28
11.3 Shut down the boiler 31
12. Fault-Finding 31
12.1 General 31
12.2 Faults 31
13. Inspection and servicing 35
13.1 General 35
13.2 Servicing 35
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.
Read these instructions carefully before putting the boiler into operation, familiarize yourself with its operation
and control and strictly observe the instructions given.
If you have any questions, or if you need more information about specific subjects relating to this boiler, please
do not hesitate to contact us.
The data published in these technical instructions is
based on the latest information and is subject to revisions. We reserve the right to modify the design and/or
construction of our products at any moment, without
being obliged to adjust earlier supplies accordingly.
3
1. DESCRIPTION OF THE BOILER
Remeha
Gas 3002 ECO
The Remeha Gas 3002 ECO is a high efficiency condensing boiler with a very low NOx emission.
The boiler consists of two heat exchangers, the first
being made of cast iron and the second of aluminium.
The latter is suited for recovering both the sensible and
the latent (condensation) heat. Premix burners ensure a
very low NOx emission (< 25 ppm at O
mg/kWh at O2 = 3%) and low level noise production.
It is supplied disassembled and has a red and grey sheet
steel casing. Its compact construction and the fact that
the boiler is suitable for room sealed or room ventilated
operation, makes it suitable for an unprecedented range
of applications.
= 0%, or < 43
2
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.
For further advice or information contact Broag Ltd.
4
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 construc ted 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 corro sion as a result of moisture.
- The boiler is provided with an integrated instrument
®
panel in which a rematic
weather-compensated boiler
control can be incorporated.
- The boiler is available for either "room sealed" or con ventionally "room ventilated" operation.
- It is supplied disassembled, to facilitate transportation.
- A modulating or high/low load control by means of a
gas/air ratio control always ensures optimal combus
tion.
- Advanced menu-driven microprocessor boiler control,
with extensive operational and fault diagnostics.
- RS232-connection for a two-way connection to a
computer, modem or Building Management System.
2.2 Burners
The premix burners have a metal fibre cover and
guarantee low-noise operation and a very low NOx emission.
Fig. 01 Remeha Gas 3002 ECO
5
3. TECHNICAL DATA AND DIMENSIONS
Remeha
Gas 3002 ECO
Fig. 02 Dimensions
Number
of
sections
7
9
11
13
15
17
19
Output
80/60
˚C
kW
177
235
294
354
413
471
531
40/30
˚C
kW
193
256
320
382
445
507
570
Input
(Hs)
kW
201
268
335
402
469
536
603
Cross section
Left side view
Dimensions
1)
AB X
mm mm
683
1235
960
1790
960
1790
1083
2035
1238
2345
1360
2495
1483
2645
C
mm
618
895
895
1018
1173
1295
1418
ØD/Ød
mm
200
200
200
250
250
250
250
E
F
mm inch mbar
mm kg/h
20
20
60
60
60
60
60
1
1 1/
2
2
2
2
2
450
550
720
820
920
1060
1160
1
/
2
2
1)
2)
Y
NW 65
NW 65
NW 65
NW 80
NW 80
NW 80
NW 80
L
mm
313
235
235
312
156
233
110
Top view
Front view
Flue
gas
mass
∆ t = 20°C ∆ t = 10°C
320
427
535
641
747
853
961
80
95
119
145
177
220
285
Water
resistance
mbar
1140
320
380
476
580
708
880
Water
contents
ca.
ltr.
90
108
121
141
158
171
188
Assembly
weight
kg
893
1092
1228
1380
1520
1659
1799
Return NW Y
Flow NW Y
Gasconnection Rp X” int.
Cabel trough 40 x 40 mm
Flue gas connection Ø D int.
Air supply connection only for room sealed operation
(specify when ordering.
Knockouts in the right and left sides of the boiler for
condensate discharge, Ø 32 mm.
Return Eco NW 65, with option for seperate connec-
tions for second heat exchanger (ECO)
Flow Eco NW65, with option for seperate connec-
tions for second heat exchanger (ECO), or second
return with “second return” option.
1) 11/
connection for installation of a safety valve.
4
2) Flanges according to DIN 2576
6
4. EFFICIENCY INFORMATION
4.1 Combustion efficiency
Up to 98.5% at Hi (88.7% at Hs) at 80/60°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.
4.3 Standing losses
On average 0.38% at Hi (0.34% at Hs) at an
ave ra ge boiler water temperature of 45°C.
4.4 Annual efficiency
On average 108% at Hi (97.2% at Hs) at an
ave ra ge boiler water temperature of 35°C.
7
5. APPLICATION DATA
Remeha
Gas 3002 ECO
5.1 Delivery and positioning
5.1.1 General
All parts to be assembled on the site can be transported
using normal access doors.
The vulnerable parts are packed. If required, the casings
can be mounted after the boiler block has been connected on water side and after any temporary start-up (construction phase), without it being necessary to drain the
boiler block.
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
or de ring, it is possible to have the connections installed
top right.
8
Installation 1
One boiler in the boiler room
Number of
sections
7
9
11
13
15
17
19
A
mmLmm
1235
1790
1790
2035
2345
2495
2645
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
Fig. 03 Typical boiler installations
** When using the seperate connections for the ECO,
this distance + 2 x L
* When using the seperate connections for the ECO,
this distance + L
9
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).
Minimum required floor surface
Support surface boiler
* Only for 7, 11, 15 and 19 sections.
Fig. 04 Support surface Remeha Gas 3002 ECO
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.
With optimised installations the installation water temperature can drop below 20°C during the night or the weekend. In this situation, for heat supply to the installation
the return water temperature of the boiler must first be
restored to at least 25°C before releasing it to the rest
of the installation.
5.2.2 Water pressure
Each boiler section undergoes a test pressure of 12 bar.
The boiler can operate at an operating pressure from 0.8
up to 6 bar.
Number of
sections
7
9
11
13
15
17
19
A
1235
1790
1790
2035
2345
2495
2645
B
745
944
1143
1342
1541
1740
1939
C
240
418
318
341
397
420
443
10
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.The minimum
water circulation in the boiler is determined by the
following formula:
Output boiler in (kW) = ..... m3/h
81
This circulation prevents, for example, activation of the
high limit thermostat when the mixing valves of the installation close when the boiler is in operation (to dissipate
residual heat).
The maximum water circulation in the boiler is
determined by the formula:
Output boiler in (kW) = ..... m3/h
9.3
5.2.4 Water treatment
The system should be filled with mains cold water (for the
UK this will usually have a pH of between 7 and 8).
Pressurised installations with a boiler/system content
ratio of 1:10 or less should not require water treatment,
provided that the following conditions apply:
1. The system is flushed thoroughly to remove all fluxes
and debris and filled completely once.
2. Make up water is limited to 5% per annum.
3. The hardness of the water does not exceed 360 ppm.
(200D).
All scale deposits will reduce the efficiency of the boiler
and should be prevented. However provided the above
is complied with any scale produced will not be too
detrimental to the boiler efficiency and will not reduce the
anticipated life expectancy of the boiler.
NOTE: Scale desposits in excess of 5mm will reduce
boiler efficiency and greatly increase the risk of
premature casting failure
As most systems contain a variety of metals wich can
react with each other to cause corrosion. It is considered
good practice to provide some form of water treatment
(especially in open vented systems) in order to prevent or
reduce the following.
a) Metallic corrosion
b) Formation of scale and sludge
c) Microbiological contamination
d) Chemical changes in the untreated system
water
Suitable chemicals and their use should be discussed
with a specialist water treatment company prior to
carrying out any work.
The specification of the system and manufacturers recommendations must be taken into account, along with
the age and codition of the system. New systems should
be flushed thoroughly to remove all traces of flux, debris,
grease and metal swarf generated during installation.
Care to be taken with old systems to ensure any black
metallic iron oxide sludge and other corrosive residues
are removed, again by thoroughly flushing, ensuring that
the system is drained completely from all low points.
NOTE: Please ensure that the new boiler plant is not in
circuit when the flushing takes place, especially if
cleansing chemicals are used to assist the proces.
Under no circumstances is the boiler to be operated
with cleaning chemicals in the system
To Summarise: Minimise water loss
Prevent pumping over in open vented
systems
Provide adequate air venting at all high
points
Maximum chlorine content of 200 mg/1
Take advice on suitability of inhibitors
for use with aluminium
MAX pH of 9 when using additives
If water treatment is used then we recommend that the
following products be used:
‘Copal’ manufactured by
Fernox Manufacturing Company Ltd.
Britannia Works
Clavering
Essex, CB1L 4QZ
Tel No: 0179 955 0811
Fax No: 0179 955 0853
or
Sentinal ‘X100’ manufactured by
BetzDearborn
Sentinal
Foundry Lane
Widnes
Cheshire WA8 8UD
Tel No: 051 495 5351
Fax No: 0151 420 5447
For the correct dosage and for further information on
water treatment or system cleaning we advise direct
contact either of the above companies.
5.2.5 Noise levels
The noise level in the boiler house, measured at a distance of 1 meter around the boiler, is approx. 60 dBA,
which means that it is usually not necessary to use
sound absorbent material.
11
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