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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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
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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5
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.
6
Control panelRE 22 18/01/06 - 300005257-001-A
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.
18/01/06 - 300005257-001-A Control panel RE 22
7
3. Installing the supplementary wiring
- Remove the "External Regulation" harness
- Fit the harnesses delivered with the REMATIC RC4/5 option
8
Control panelRE 22 18/01/06 - 300005257-001-A
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.
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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.
Control panelRE 22 18/01/06 - 300005257-001-A
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
Remove the bridge connector from the control panel wiring
"CA"
Connect the "External Regulation" harness to the control
panel harness.
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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
Control panelRE 22 18/01/06 - 300005257-001-A
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.
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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
Control panelRE 22 18/01/06 - 300005257-001-A
9 Connecting the burner
1 Ignition circuit
2 Gas pressostat
3 Gas valve circuit
4 Leak proofing system (Options RE 30)
18/01/06 - 300005257-001-A Control panel RE 22
15
VA-SCS
17
1b
1
SI
VA
1a
BPR-VA
Skeleton Diagrams
h
2
1
1
3
FA TA
1
DGAI 73
SCS
X3
2
1
10
7
X2
5
1a
4
34
5
3
2
X1
2
7
1
1
8
4
ECS
2
6
RG
7
TCH2
1
1
2
f
ZT
2a
2
ZB
1a
2b
4
15
14
CA
1
CA
8
9
CCE
5 6
CH1
1
2
VB1
13
h
CH2
1b
1a
VEILIGHEIDSKOFFERTJESAFETY CONTROL BOXSCS
IONISATIE SONDEIONISATION PROBESI
ANTITERUGSLAG THERMOSTAATBLOCKED VENT SHUTOFF SYSTEMTAF
KETELTHERMOSTAAT 2de TRAPBOILER THERMOSTAT 2nd STAGETCH2
KETELTHERMOSTAAT 1st TRAPBOILER THERMOSTAT 1st STAGETCH1
SCHEIDINGSTRAFOISOLATING TRANSFORMERTI
LAMPJEINDICATORV
VEILIG HEIDS THERMOSTAAT ALARM LAMPJESAFETY THERMOSTAT ALARM INDICATORVA-TS
LAMPJE WERKING 1st TRAPON/OFF INDICATOR 1st STAGEVB1
LAMPJE WERKING 2de TRAPON/OFF INDICATOR 2nd STAGEVB2
GASKLEP ONTSTEKINGGAS VALVEVG
HOOFDGASKLEPMAIN GAS VALVEVP
BRANDER SCHAKELAARBURNER SWITCHZB
ZOMMER-WINTER SCHAKELAARSUMMER-WINTER SWITCHZEH
ALGEMENE SCHAKELAARMAIN SWITCHZG
TEST SCHAKELAARTEST SWITCHZT
PL 300005300-001-A
VB2
(B)
6
5
4
1
12
VG VP
V
5
9
2
8
2
7
2
1
BRANDERBURNERB
ELEKTRISCHE ONTSTEKINGELECTRIC IGNITORAE
VERWARMINGSPOMPHEATING PUMP
AFSLUITKLEPFLUE DAMPERCO
CYCLISCH DICHTINGSCONTROLE CONTROLEURLEAK PROOFING SYSTEMCCE
TRAPSGEWIJSCASCADE CONNECTIONCA
HERBEWAPENINGSKNOP BRANDERRESET PUSH BUTTONBPR
AANSLUITINGSKLEMMENCONNECTING BOARDBA
VEILIGHEIDSCONTACT SAFETY CONTACTCS
THERMISCHE BEVEILIGINGCIRCUIT BREAKERDJ4A
ONSTORINGS-FILTEREMI SUPPRESSORFA
SANITAIR WARM WATERDOMESTIC HOT WATERECS
FASEPHASEL
GASPRESSIOSTAATGAS PRESSOSTATPSG
RECYCLAGE POMPSHUNT PUMPP2
NULLEIDERNEUTRALN
RELAISRELAYR
REGELINGREGULATORRG
2
1
TI
DJ4A
14
BA
7
2
1
TAF
1
2
1
3
2
3
P
PSG
TCH 1
7
9
1
θ
2
RG
1
CCE
1
?
1
1b 1a
6
CCE
5
4
CCE
6
1
1
θ
2
1
1b1a
ZEH
CA
4
ECS
CA
2
9
12
123
TS
10
BA
11
CS
7
BA
CO
12
1a
BA
VG
VA - TS
15
BA
A
25
2
TESTSCHALTERINTERRUPTEUR TESTZT
HAUPTSCHALTERINTERRUPTEUR GENERALZG
SOMMER-WINTERSCHALTERINTERRUPTEUR ETE-HIVERZEH
BRENNER SCHALTERINTERRUPTEUR BRULEURZB
HAUPTGASVENTILVANNE PRINCIPALEVP
GASVENTILVANNE GAZVG
BETRIEBSLEUCHTE 2.STUFEVOYANT MARCHE 2eme ALLUREVB2
BETRIEBSLEUCHTE 1.STUFEVOYANT MARCHE 1ere ALLUREVB1
SICHERHEITSTEMPERATURBEGRENZER ALARMLEUCHTEVOYANT ALARME THERMOSTAT DE SECURITEVA-TS
LEUCHTEVOYANTV
TRENNTRAFOTRANSFORMATEUR D'ISOLEMENTTI
KESSEL TEMPERATURREGLER 1.STUFETHERMOSTAT DE CHAUDIERE 1ere ALLURETCH1
KESSEL TEMPERATURREGLER 2.STUFETHERMOSTAT DE CHAUDIERE 2eme ALLURETCH2
ABGASÜBERWACHUNGSTHERMOSTATTHERMOSTAT ANTIREFOULEURTAF
IONISATIONSELEKTRODESONDE D'IONISATIONSI
GASFEUERRUNGSAUTOMATCOFFRET DE SECURITESCS
13
1b
**
BA
2
CCE
TI
1 3
2
1
ECS
1
ZG
1a
7
8
9
6
11
CA
6
5
4
RG
3
CA
ZEH
2a
2
8
3
7
1
2b
AP2
BA
4
1
BA
2 4
8
2
UMWAELZPUMPEACCELERATEUR
ELEKTROZÜNDERALLUMEUR ELECTRIQUEAE
BRENNERBRULEURB
ANSCHLUSSLEISTEBARRETTEBA
ENTSTÖRUNGSDRUCKTASTEBOUTON POUSSOIR REARMEMENT BRULEURBPR
KASKADENSCHALTUNGCASCADECA
DRUCKDICHTHEITSKONTROLERCONTROLEUR CYCLIQUE D'ETANCHEITECCE
ABGASKLAPPECLAPET OBTURATEURCO
SICHERHEITSKONTAKTCONTACT DE SECURITECS
LEISTUNGSSCHALTERDISJONCTEURDJ4A
WARMWASSEREAU CHAUDE SANITAIREECS
FUNKENENSTÖRUNGSFILTERFILTRE ANTIPARASITEFA
PHASEPHASEL
NULLEITERNEUTREN
KESSELKREISPUMPEPOMPE DE RECYCLAGE CHAUDIEREP2
GASDRUCKWAECHTERPRESSOSTAT GAZPSG
STEUERRELAISRELAISR
REGELUNGREGULATIONRG
5
2
BA BA
2
ZG
2a
16
1
BA
BA
SCHEMA DE PRINCIPE - STROMLAUFPLAN - PRINCIPLE DIAGRAM - PRINCIPESCHEMA - GAS 460
L
2
BA
N
A
Control panelRE 22 18/01/06 - 300005257-001-A
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).
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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
Control panelRE 22 18/01/06 - 300005257-001-A
Control panel RE 22 18/01/06 - 300005257-001-A
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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