How it Works
Remeha
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Gas 360
Technical Instruction
20 pgs1.04 Mb0
User Manual
10 pgs677.57 Kb0
Table of contents
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Remeha Gas 360 Technical Instruction

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Control panel Gas 360
Package RD 9
English
22/08/05
Technical
instructions
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1 Presentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Electrical connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1 Terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.1 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2 Installation with optional Rematic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.1 Fitting the Rematic control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.2 Connections optional REMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.3 Mouting of the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3 Connecting a third party control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4 Connecting the harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
5 Connecting the low-water pressure switch alarm indicator (Only NL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
6 Connecting the safety thermostat alarm indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
7 Connecting one or two hour run meters (Package BG 40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
8 Connecting the flue gas thermometer (Package BP 28) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
9 Connecting the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Skeleton Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Starting up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1 Control panel without Rematic control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2 Control panel with optional Rematic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Introduction

The control panel is fitted to Remeha boilers in the Gas 360 ranges.
This product will be marketed in the following European Union member states :
Version L: BE, ES
Version S: GB, HU, ES
Directive 97/23/EC
Gas and oil boilers with a maximum operating temperature of 110°C and hot water tanks with a maximum operating pressure of 10 bar pertain to article 3.3 of the directive, and therefore, cannot be CE­marked to certify compliance with the directive 97/23 ECThe boilers and hot water tanks are designed and manufactured in accordance with the sound engineering practice, as requested in article 3.3 of the directive 97/23/EC; it is certified by compliance with the directives 90/ 396/EC, 92/42/EC, 73/23 EC and 89/336/EC.

1 Presentation

The control panel is used to control boilers with 1 or 2-stage burners.
It may be fitted along with several optional features:
- Rematic control unit for 2-stage burners regulating the burner and 2 mixing valve, for heating only or for heating and domestic hot water.
- Hour run meter/s (Package BG 40)
- Flue gas thermometer (Package BP 28)
Warning
The boiler shall be assembled and installed by a qualified professional only.
For a proper operating of the boiler, follow carefully the instructions.
Z
Symbols used
Caution danger
Specific information Information must be kept in mind to maintain comfort
Reference Refer to another manual or other pages in this instruction manual
Risk of injury and damage to equipment. Attention must be paid to the warnings on
safety of persons and equipment
22/08/05 - 300005192-001-A Control panel RD 9
3

Description

13-position switch Auto / Manual ! / TEST STB
- The switch may be left on either position manual ! or automatic AUTO.
- STB TEST: temporary action to test the safety thermostat.
- Press the TEST STB switch and set pump shut-off switch (2) 9 to the “Summer” position %.
2 Switch Burner / Heating pump:
This button is used to control the burner and the heating pump. Both buttons are in “Winter” . position: Heating and hot water production systems operate (if a hot water tank is included). Both buttons are in “Summer” % position: The burner and the heating pump don't operate. If the boiler is fitted with a control unit, both buttons must be left on the Winter . position.
3 Main ON/OFF switch
4 Location for hour run meter for the first and second stage (optional)
5 Boiler thermostat (30 to 90 °C):
A factory-set stop limits the maximum temperature to 75 °C. The stop may be moved if necessary.
6 Stage one or stage two indicators:
These only go on if the relevant thermostat or control unit require heating and if the safety contact is closed.
7 Boiler thermometer
8 Location for flue gas thermometer (optional)
9 Safety thermostat with manual reset (set to 110 °C).
10 10 A Circuit-breaker: with delayed action and manual reset.
11 Location for optional features or a RC4/RC5 control unit
13 Switch for selecting the number of burner stages
14 Burner alarm indicator + Reset button
4

Operating principle

• Boiler regulation
The boiler may be regulated:
- either by the boiler thermostats,
- or by the Rematic control unit, if any (optional terminal strip present in control panel)
- or by the Rematic control unit of the cascaded installation.
- or by a third party control unit with volt-free contacts for high-low and on-off operation, if any (connection kit necessary).
If the boiler is fitted with a Rematic control unit, the boiler temperature is modulated by the regulator, which controls the burner and the motorised mixing valves depending upon the outside temperature. With a third party control connected, the boiler thermostats are set to the maximum position. Operating security is provided by the safety thermostat with manual reset.

Electrical connections

As the electrical wiring has been carefuly checked in the
factory, the internal connections on the control panel must not be changed in any way.
Electrical connections must match the electrical diagrams delivered with the equipment and comply with the instructions in the manual.
The electrical connections shall comply with standards in force. The equipment must have a power supply equipped with a omnipolar switch with an opening distance above 3 mm.
The earth connections shall comply with local standards.

1 Terminal block

All connections are made with the terminal boxes designed for that purpose on the back of the boiler's command board.
22/08/05 - 300005192-001-A Control panel RD 9
5

1.1 Electrical connections

9
5
4
4
1
85 2N1 7A08
5
4
6
3
7
8
9
5
4
6
3
7
8
9
3
2
Proceed as follows to open the control panel:
Remove the upper casing of the boiler. Take out the heater door. Remove the top front panel. Pull out the connection board cover.
Open the side of the panel. Turn the panel.
Remove the 4 screws . These cables will be fixed on to the control panel with cable clips
(supplied in a separate bag).
Make the connections, respecting the live (L), neutral (N) and
earth terminals.
6

2 Installation with optional Rematic control unit

2.1 Fitting the Rematic control unit

The Rematic control unit is fitted on the left-hand side of the front of the panel.
1. 2.
22/08/05 - 300005192-001-A Control panel RD 9
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3. Installing the supplementary wiring
- Remove the "External Regulation" harness
- Fit the harnesses delivered with the REMATIC RC4/5 option
8

2.2 Connections optional REMATIC

Connection block for Rematic sensors and controls.
See the instructions supplied with the control unit and any remote control unit used.
Separate the extra low voltage sensor wires from 230 V
power wires in order to prevent electromagnetic interference.
Inside the boiler:
- Boilers with one cable channel: Place the 230 V main supply cables on one side of the cable channel and the sensor cables on the other. The cables shall be held in place on either side using plastic ties.
- Boilers with two cable channels: Place the 230 V main supply cables in one cable channel and the sensor cables in the other. The cables shall be held in place on either side using plastic ties.
Outside the boiler:
use 2 pipes or cable guides at least 10 cm apart.
Failure to comply with these instructions could lead to
interference and control unit malfunctioning or even damage to the electronic circuitry.
22/08/05 - 300005192-001-A Control panel RD 9
9

2.3 Mouting of the control unit

1
2
1/4
1/4
4
Bring the blue connectors out through the opening in the control
panel.
Plug the connectors onto the back of the control unit.
10
Push the control unit into the front of the control panel and fix it
with the 2 plastic screws supplied (push and 1/4 turn, clockwise) on the front of the control unit.
Close the control panel.

3 Connecting a third party control unit

3x
Control of the first stage of the burner by volt-free contacts Control of the second stage of the burner by volt-free contacts

4 Connecting the harness

Take out the shunt (bridge) CA  Connect the "External Regulation" harness to the control
panel harness.
22/08/05 - 300005192-001-A Control panel RD 9
11

5 Connecting the low-water pressure switch alarm indicator (Only NL)

1
2x 0, 5 mm 7
2
mi i.n
AL
N
L
Low-water pressure switch alarm indicator

6 Connecting the safety thermostat alarm indicator

Safety thermostat alarm indicator
12

7 Connecting one or two hour run meters (Package BG 40)

One or two optional hour run meters (stage 1 and 2) may be fitted on the front of the control panel. To do so:
- Cut the cover off with a cutter along the edges of the coloured rectangle.
- Pull out the *1 wires standing by in the control panel
- Connect the wires to the hour run meter (the wires are interchangeable):
- Brown and blue wires for stage 1
- Violet and blue wires for stage 2
- Clip the hour run meter into the control panel.
If the burner is a 1-stage burner, the counter displays the burner operating time. If the burner has 2 stages, the first stage hour run meters displays the total burner operating time and the second hour run meter displays the operating time of stage 2.
22/08/05 - 300005192-001-A Control panel RD 9
13

8 Connecting the flue gas thermometer (Package BP 28)

An optional flue gas thermometer may be fitted on the front of the control panel.
To do so:
- Cut the cover off with a cutter along the edges of the coloured rectangle.
- Clip the thermometer into the opening.
- Bring the sensor to the back of the boiler via the cable channel and insert it in the flue gas pipe.
14

9 Connecting the burner

Gas pressostat (bridge factory-fitted)
1
Not used on a Gas 360
2a Gas valve 2nd stage
2b Safety box + Gas valve 1st stage
Anti-backflow thermostat Package RD19 (optional as of 10 section
3
models)
4 Flue damper (only version Gas 360 L, bridge plug factory-fitted)
5 Leak proofing system, Package RD18 (bridge factory-fitted)
22/08/05 - 300005192-001-A Control panel RD 9
15
3
1
11a
SCHEMA DE PRINCIPE - STROMLAUFPLAN - WIRING DIAGRAM - PRINCIPESCHEMA - GAS 360
11a

Skeleton Diagrams

8
1
ECS
1
6
RG
ZT
AUTO
å
STB
TEST
2
1
ZB2
1b
1a
TCH2
2
1
θ
2b2a
9 6
B2
SPL2
s
ECO
9 10
CO
ò
12
4
2
PSG
1
1
TAF
1
1a
BPR-VA
2b
2a
4
COM
NC NO
P
8
93 6 2 7
5
4
10 93178511 6 2
S 4565 ....
B1
CCE
13
A
4
6 7
2
CCE
15
9
14
CA
7
CA
SPL1
4
7 1 6
8
9
11
CO
11
4
2
ECS
2
1
1b1a
9
7
2
1
θ
SPL0
TCH1
TI
TI
DJ4A
1
RG
RG
ZT
1
STB
TEST
å
1b 1a
AUTO
6
ECS
CA
ZEH
12
CA
7
9
11
CA
1
5
8
4
RG
3
6
BA
CS
10
BA
θ
23
CCE
TS
3
ZEH
2
8
2b 2a
CA
ZG
CH2
h
1a
1b
VB2
8 5
CH1
B2
h
1b
VG
1a
ANTITERUGSLAG THERMOSTAATBLOCKED VENT SHUTOFF SYSTEMTAF
REGELINGREGULATORRG
KETELTHERMOSTAAT 1st TRAPBOILER THERMOSTAT 1st STAGETCH1
KETELTHERMOSTAAT 2de TRAPBOILER TH ERMOSTAT 2nd STAGETCH2
SCHEIDINGSTRAFOISOLATING TRANSFORMERTI
LAMPJE WERKING 1st TRAPON/OFF INDICATOR 1st STAGEVB1
VEILIG HEIDS THERMOSTAAT ALARM
LAMPJE
VEILIG HEIDS THERMOSTAATSAFETY THE RMOSTATTS
SAFETY THERMOSTAT ALARM INDICATORVA-TS
BRANDER 2DE TRAP SCHAKELAARBURNER SWITCH 2nd STAGEZB2
VEILIGHEIDSKLEPSAFETY VALVEVS
LAMPJE WERKING 2de TRAPON/OFF INDICATOR 2nd STAGEVB2
TEST SCHAKELAARTEST SWITCHZT
ALGEMENE SCHAKELAARMAIN SWITCHZG
ZOMMER-WINTER SCHAKELAAR
N° : 300005200-001-A
SUMMER-WINTER SWITCHZEH
VB1
VERWARMINGSPOMP KRING AHEATING PUMP CIRCUIT AÄ A
RECYCLAGE POMPSHUNT PUMPÄ Å
BRANDERBURNERB
DRUKKNOP HERBEWAPENING ALARM
LAMPJE
TRAPSGEWIJSCASCADE CONNECTIONCA
CYCLISCH DICHTINGSCONTROLE
CONTROLEUR
UURTELLER 1st TRAPHOUR RUN METER 1st STAGECH1
UURTELLER 2de TRAPHOUR RUN METER 2nd STA GECH2
AFSLUITKLEPFLUE DAMPERCO
VEILIGHEIDSCONTACT SAFETY CONTACTCS
THERMISCHE BEVEILIGINGCIRCUIT BREAKERDJ4A
SANITAIR WARM WATERDOMESTIC HOT WATERECS
FASEPHASEL
NULLEIDERNEUTRALN
GASPRESSIOSTAATGAS PRESSOSTATPSG
SPL3
2
CCE
BURNER RESET BUTTON AND ALARM
INDICATOR
52
1
E
C
O
s
14
BA
1
12
BA
7
BA
4
BA
A
15
KESSEL TEMPERATURREGLER 1.STUFETHERMOSTAT DE CHAUDIERE 1ere
ABGASÜBERWACHUNGSTHERMOSTATTHERMOSTAT ANTIREFOULEURTAF
REGELUNGREGULATIONRG
BA
VS
13
BA
VA-TS
ALLURE
4
TI
2
TI
Å
8
BA
A
Å
5
BA
P2
22a
TCH1
KESSELKREISPUMPE KREIS AACCELERATEUR CIRCUIT AÄ A
KESSELKREISPUMPEPOMPE DE RECYCLAGE CHAUDIEREÄ Å
BRENNERBRULEURB
BPR-VA
KESSEL TEMPERATURREGLER 2.STUFETHERMOSTAT DE CHAUDIERE 2eme
ALLURE
TCH2
BRENNERENTSTÖRUNGSTASTE UND
STÖRLEUCHTE
LEAK PROOFING SYSTEMCCE
TESTSCHALTERINTERRUPTEUR TESTZT
HAUPTSCHALTERINTERRUPTEUR GENERALZG
SOMMER-WINTERSCHALTERINTERRUPTEUR ETE-HIVERZEH
BRENNER SCHALTER 2.STUFEINTERRUPTEUR BRULEUR 2eme ALLUREZB2
MAGNETVENTILVANNE DE SECURITEVS
BETRIEBSLEUCHTE 2.STUFEVOYANT MARCHE 2eme ALLUREVB2
BETRIEBSLEUCHTE 1.STUFEVOYANT MARCHE 1ere ALLUREVB1
SICHERHEITSTEMPERATURBEGRENZER
ALARMLEUCHTE
SICHERHEITSTEMPERATURBEGRENZERTHERMOSTAT DE SECURITETS
TRENNTRAFOTRANSFORMATEUR D'ISOLEMENTTI
VOYANT ALARME THERMOSTAT DE
SECURITE
VA-TS
KASKADENSCHALTUNGCASCADECA
DRUCKDICHTHEITSKONTROLERCONTROLEUR CYCLIQUE D'ETANCHEITECCE
BETRIEBSSTUNDENZEHLER 1.STUFECOMPTEUR HORAIRE 1ere ALLURECH1
BETRIEBSSTUNDENZEHLER 2.STUFECOMPTEUR HORAIRE 2eme ALLURECH2
ABGASKLAPPECLAPET O BTURATEURCO
SICHERHEITSKONTAKTCONTACT DE SECURITECS
LEISTUNGSSCHALTERDISJONCTEURDJ4A
WARMWASSEREAU CHAUDE SANITAIREECS
PHASEPHASEL
NULLEITERNEUTREN
GASDRUCKWAECHTERPRESSOSTAT GAZPSG
ZG
16
NF
BOUTON REARMEMENT ET VOYANT
ALARME BRULEUR
1
BA
2
BA
BPR-VA

1 Control panel without Rematic control unit

9
8
7
6
5
M000154

Starting up and operation

The first start-up is to be performed by your installation
engineer.
Before starting the boiler, check if the installation is filled with water.
Start the boiler in the following order:
• Boiler temperature regulation by means of the thermostats
Place the boiler thermostat 5 in the required position. If the burner has 2 stages, the stage 2 thermostat must always be set to value which is approximately 5°C less than that of the stage 1 thermostat.
If required, move the maximum temperature stop as instructed below.
If there is no control unit, we advise you never to set the
boiler thermostat below mark 4 (approx. 40°C) in order to avoid the risk of combustion products condensing on the walls of the boiler.
• Set switch 1 to the manual ! position.
• Control unit in boiler room electrical cabinet
See the instructions supplied with the control unit and any remote control unit used.
• Check that safety thermostat 9 is properly set. To do so,
unscrew the hexagonal cap and press the reset button with a screwdriver.
• Set the burner and heating pump buttons 2 to the Winter .
position.
• Set main On/Off switch 3 to 8.
Moving the thermostat stop:
A factory-set stop limits the maximum temperature to 75 °C. To move the stop, proceed as follows:
- Pull the thermostat button out carefully (use pliers and a cloth).
- Remove the stop with the pliers.
- Put the stop in the hole of the desired higher temperature (maximum 90°C).
22/08/05 - 300005192-001-A Control panel RD 9
17

2 Control panel with optional Rematic control unit

The first start-up is to be performed by your installation
engineer.
Before starting the boiler, check if the installation is filled with water.
Start the boiler in the following order:
• Set the boiler thermostats 5 on maximum position. If required, move the maximum temperature stop as instructed on the preceding page.
Set the Rematic control unit 12. To do so, operate
according to the control instructions supplied with the unit.
• Set switch 1 to the AUTO position.
• Check that safety thermostat 9 is properly set. To do so, unscrew the hexagonal cap and press the reset button with a screwdriver.
• Set the burner and heating pump buttons 2 to the Winter . position.
• Set main On/Off switch 3 to 8.
18
NL Remeha B.V.
Postbus 32 7300 AA APELDOORN Tel: +31 55 5496969 Fax: +31 55 5496496 Internet: nl.remeha.com E-mail: remeha@remeha.com
GB Broag Ltd.
Remeha House Molly Millars Lane RG41 2QP WOKINGHAM, Berks. Tel: +44 118 9783434 Fax: +44 118 9786977 Internet: uk.remeha.com E-mail: boilers@broag-remeha.com
B J.L. Mampaey BVBA
Uitbreidingstraat 54 2600 ANTWERPEN Tel: +32 3 2307106 Fax: +32 3 2301153 Internet: www.mampaey.be E-mail: info@mampaey.be
B Thema S.A.
6, Avenue de l'expansion 4460 GRACE-HOLLOGNE Tel: +32 4 2469575 Fax: +32 4 2469576 Internet: www.thema-sa.be E-mail: info@thema-sa.be
E D.A.C. S.A.
Tomás A. Edison 29 Poligono Cogullada 50014 ZARAGOZA Tel: +34 76 464076 Fax: +34 76 471311 Internet: www.dac.es E-mail: dac@dac.es
E Norte Comercial Organización S.A.
Bereteage Bidea, 19 48180 LOIU (Vizcaya) Tel: +34 94 471 03 33 Fax: +34 94 471 11 52 E-mail: nco@nco.es
IRL Euro Gas Ltd.
Unit 38, Southern Cross Business Park Boghall Road, Bray, Co WICKLOW Tel: +353 12868244 Fax: +353 12861729 Internet: www.eurogas.ie E-mail: sales@eurogas.ie
H Marketbau - Remeha Kft.
Gyár u. 2. Ipari Park 2040 BUDAÖRS Tel: +36 23 503 980 Fax: +36 23 503 981 Internet: www.remeha.hu E-mail: remeha@remeha.hu
E Termibarna S.A.
C. Zamora 55-59 08005 BARCELONA Tel: +34 3 3000204
Fax: +34 3 3009558
E Cuatrocesa S.A.
c) Sor Angela de La Cruz, 10
- 1º Oficina C 28020 MADRID Tel: +34 91 658 18 88 Fax: +34 91 658 30 77
© Copyright
All technical and technological information contained in these technical instructions, as well as any drawings and technical descriptions supplied, remain our property and shall not be multiplied without our prior consent in writing..
Ours is a policy of continuous development. We reserve the right to alter specifications without prior notification
.
Subject to alterations
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