Remeha Gas 460 Control Technical Guide

Control panel Gas460

Package RE 22

English

18/01/06

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

Control panel RE 22 18/01/06 - 300005257-001-A

Introduction

The control panel is fitted to Remeha boilers in the GAS 460 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

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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

Control panelRE 22 18/01/06 - 300005257-001-A

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.

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1.1 Electrical connections

50B83 8N 24

1

5

4

6

3

7

8

9

5

4

6

3

7

8

9

3

3

3

2

Proceed as follows to open the control panel:

Remove the upper casing of the boiler.
Remove the front casing.
Remove the top front panel.

Pull out the connection board cover.
 Open the side of the panel. Remove the 4 screws . Turn the

panel.
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.

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Control panelRE 22 18/01/06 - 300005257-001-A