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Gas 460 S
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REMEHA Gas 460 S Technical Instructions

Remeha Gas 460 S
Gas-fired boilers
English
06/02/06
Technical
instructions
Contents
1 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2 Symbols used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2 Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3 Main parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4 Technical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
5 Main dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1 Furnace operation equipped with safety box RV 00 54 / 000 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Adapting to another gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2 Changing the ignition burner injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3 Changing the burner injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4 Setting the injector pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5 Checking the minimum gas pressure switch setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
6 Attaching the label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Commissionning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1 Pressure settings and calibrated injector markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2 Final checks before commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
1 Checking and cleaning the main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Spare parts Gas 460 S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Remeha Gas 460 S 06/02/06 - 300005247-001-B

Introduction

This product will be marketed in the following European Union member states:
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 EC.

1 Regulations

It is in any case imperative to conform to the local
regulations in force.

2 Symbols used

Caution danger
Specific information Information must be kept in mind to maintain comfort
The 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.
We would draw your attention to the danger of corrosion in
boilers located in or close to premises in which the atmosphere may be polluted by chloride or fluoride compounds. For example: Hairdressing salons, industrial premises (solvents), refrigeration units. In this event, we cannot uphold the warranty.
Risk of injury and damage to equipment. Attention must be paid to the warnings on
safety of persons and equipment
Z
Reference Refer to another manual or other pages in this instruction manual
06/02/06 - 300005247-001-B Remeha Gas 460 S
3

1Introduction

Description

Gas 460 S boilers are made of cast iron:
- with atmospheric gas burners
- with 2 operating stages
- with electronic ignition via the ignition burner for hot water central heating
- with a useful output of between 119 and 380 kW

2 Certifications

2.1 Introduction

It is CE approved under the following number : 0085BL0187
The boilers are in compliance with the EC directives:
- Royal Decree dated 8th January 2004
- 90/396/EEC Gas Appliance Directive
- 73/23/EEC Low Voltage Directive Reference Standard : EN 60.335.1
- 89/336/EEC Electromagnetic Compatibility Directive Reference Standard : EN 50.081.1 ; EN 50.082.1 ; EN 55.014
- 92/42/EEC Efficiency Directive ** Low temperature gas boiler

2.2 User country

1
,
They are designed to be connected to a chimney.
The figure given after Gas 460 S indicates the number of sections which make up the boiler.
Gas 460 S boilers are delivered with a K control panel. They can be fitted with an optional RC4 and RC5 control unit (master-slave control unit options).
- Type B11 (B11 discharge control system).
France:
Performance class III boiler according to ATG B 84 recommendations.
Belgium:
The boilers comply with the specifications of the HR+ quality label.
The boilers should be fitted with a 160 VA circuit separation transformer (delivered with the documentation package).
if fitted with the optional combustion products
BS
User country ES HU GB
Category II
Gas type G20G31G20G31G20
Distribution pressure (mbar) 20 37 25 50 20
The boilers leave the factory operating with H natural gas.
2H3P
II
2H3P
II
2H3P
4
Remeha Gas 460 S 06/02/06 - 300005247-001-B

3Main parts

3.1 Boiler

1 Control panel
2 Safety box
The safety control box is fitted to the control panel and controls the burner ignition, function and extinction sequences.
3 Multivalve gas unit:
It includes a safety valve and a 2-stage principal valve with filter and minimum gas pressure switch.
4 Ignition burner valve
5 Ignition burner
6 Flame inspection window
7 Ionisation probe: It detects flame presence on the ignition burner by
flame ionisation.
8 Ignition electrode: This ensures ignition burner ignition using a high
voltage spark.
9 Minimum gas pressure switch
(Minimum pressure: 12.5 mbar)
10 Ignition box
06/02/06 - 300005247-001-B Remeha Gas 460 S
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3.2 Control panel

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
6
Remeha Gas 460 S 06/02/06 - 300005247-001-B

4 Technical characteristics

The boilers can operate on natural gases type H/L.
Boiler Gas 460 S / 8 10 12 14 16 18 20
Useful efficiency
Power input
Number of sections Part 8 101214161820
Mass flue gas flow rate
(1)
Flue gas temperature Tf Boiler temperature 80°C
CO
2
Ionisation current µA 1.0
Required depressurisation at the nozzle
Minimum outlet temperature °C 40
Maximum outlet temperature °C 90
Maximum operating pressure bar 6
Electrical connection V/Hz 230/50
Electrical output W 108 / 114 maximum
Gas connection 20 mbar inch 1" 1" 1" 1"1/4 1"1/4 1"1/4 1"1/2
Heating connection inch 2"
Internal diameter flue gas nozzle mm 250 300 300 350 350 350 400
Water resistance
(1)
Water capacity* l 61 76 91 106 122 137 154
Shipping weight kg 668 807 934 1096 1227 1364 1476
(1)
at 2nd stage
1st stage kW 83-98 107-126 131-154 155-182 179-210 202-238 226-266
2nd stage kW 119-140 153-180 187-220 221-260 255-300 289-340 323-380
1st stage kW
93.1-
108.9
2nd stage kW 131.1-153
kg per sec
0.097 0.127 0.144 0.177 0.191 0.203 0.258
119.4-
139.7
168.2-
196.3
145.6-
170.4
205.2-
239.4
171.9-
201.1
242.2-
282.6
197.9-
231.5
278.8-
325.4
224-262.1
315.7-
368.4
250.1-
292.6
352.4-
411.3
°C 125 123 130 126 133 140 126
1st stage
2nd stage 5.4-6.4 5.3-6.3 5.8-6.8 5.5-6.5 6.0-7.0 6.5-7.5 5.5-6.5
%
3.9-4.9 3.8-4.8 4.3-5.3 4.0-5.0 4.5-5.5 5.0-6.0 4.0-5.0
daPa 0.7
∆ T = 10K
∆ T = 15K 36 59 88 123 164 211 263
mbar
80 133 198 277 369 484 592
∆ T = 20K 20 33 50 69 92 118 148
1 mbar = 10 mmCE = 10 daPa = 100 Pa
06/02/06 - 300005247-001-B Remeha Gas 460 S
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5 Main dimensions

Heating outlet R 2
Heating return R 2
8358N061A
B
E
ø F
1406
J
H
130
3
60
G
A
1006
1
375
410
130
2
Draining Rp 3/4
= =
ø C
D
64
Boiler Gas 460 S /8 /10 /12 /14 /16 /18 /20
A (mm) 1362 1362 1362 1412 1412 1412 1462
B (mm) 970 1146 1322 1498 1674 1850 2026
Ø C (mm) 250 300 300 350 350 350 400
D (mm) 632 808 984 1160 1336 1512 1688
E (mm) 165 165 165 190 190 190 220
Ø F (mm) (20/25 mbar) Rp1 Rp1 Rp1 Rp1 1/4 Rp 1 1/4 Rp 1 1/4 Rp 1 1/2
Ø F (mm) (300 mbar) Rp 3/4
G 447 535 623 704 792 880 963
H 445 445 445 454 454 454 507
J 1094 1094 1094 1194 1194 1194 1194
8
Remeha Gas 460 S 06/02/06 - 300005247-001-B

Operation

1 Furnace operation equipped with safety box RV 00 54 / 000 00

Operating principle
The boiler can operate at either 2nd stage or 1st stage depending on the thermal needs of the installation.
The ignition and burner surveillance sequences are ensured by the safety box.
Behaviour in normal conditions
The box closes the TCH contact when there is a requirement for heat1. The safety control box runs an auto-check of around 1 second(s) by lighting the alarm warning light VA.
In the case of an offset alarm, it is necessary to use a timed
relay in order to prevent an unjustified alarm signal.
After a waiting time tw, the ignition transformer TA produces a series of sparks at the ignition electrode. After a pre-ignition period tvz, the ignition burner valve VG and the safety valve VS open. Formation of flame in ignition burner. The ionisation sensor SF shows a flame signal with a minimum ionisation current of 1 µA and ignition is shut down. After a period of stabilisation tstab, the principal burner ignites at 1st stage BR1 (or at 2nd stage if the 2nd stage thermostat TCH2 is needed).
Behaviour in abnormal conditions
- If a flame is not detected before the safety time ts, the box makes 2 more ignition attempts. If, at the end of the last attempt, there is still no flame signal, the box goes into safety and the safety indicator comes on. To restart the heater, press the reset button on the safety box.
- If there is a loss of flame in normal operation, the box automatically repeats the start up sequence.
Resetting
The box is reset after going into safety by pressing the reset button. If the reset button does not work, wait at least 15 seconds before trying a second time. After activating the reset button, the warning light goes out and the safety control box restarts after a waiting time
of around 1 minute.
Note 1: The box may be on safety on its first start up: press the reset
button to release it.
Note 2: If the reset button is pressed in normal operation, the gas valves close and the box starts a new ignition sequence.
06/02/06 - 300005247-001-B Remeha Gas 460 S
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Normal operating cycle
Operating cycle on safety (start up without flame signal)
8358N016A
Required input signals
Box output signals
Thermostatic request at 2nd stage
Operation 2nd stage
A Start of operation B Formation of flame in ignition burner BR1 1st stage BR2 2nd stage SF Burner flame signal TA Ignition transformer TCH1 Boiler thermostat 1 Speed TCH2 Boiler thermostat 2 Speed VA Safety lockout warning light VG Ignition burner valve + Safety valve VS ts Safety time: maximum 10 seconds tstab Flame stabilisation time: 5 seconds tvz Pre-ignition time: 10 seconds tw Waiting time: 0 seconds
10
Remeha Gas 460 S 06/02/06 - 300005247-001-B

Adapting to another gas

These actions must be carried out by a qualified
technician.

1 Changing gas

The boilers are factory-set to operate on natural gas H (G20 - 20 mbar). To convert it to natural gas L, use the gas L conversion kit (optional). Carry out the operations described below.

2 Changing the ignition burner injector

Operations to be carried out to convert from natural gas H to natural gas L and vice versa:
Belgium: The operations required to switch from one gas
to another must be carried out by a SERV'elite technician.
Remove the gas supply pipe from the ignition burner (13 mm
spanner).
Remove the nozzle + seal.
Natural gas H Natural gas L
Nozzle marking 80 100
Nozzle diameter 0.80 mm 1.00 mm
Unscrew the nozzle using a screwdriver and screw in the new
injector.
- Reassemble the parts
- Carry out a leak tightness check
06/02/06 - 300005247-001-B Remeha Gas 460 S
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