REMEHA P 500 Technical Information

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Technical information

Remeha P 500

Remeha P500

• Pressurized boiler

• Heat output: 635 - 1900 kW

Supplied By www.heating spares.co Tel. [phone]

TABLE OF CONTENT

Remeha P 500

Preface 3

1 Description of the unit 3

1.1 General 3

1.2 Burners 3

2 Construction data 3

2.1 General 3

2.2 Sections 3

2.3 Casing 3

3 Technical data and dimensions 4

3.1 Dimensions 4

3.2 Technical data 4

3.3 Quotation specifi cations 5

4 Output data 5

4.1 Boiler effi ciency 5

4.2 Combustion effi ciency 5

5 Application data 5

5.1 L.P.H.W. version 5

5.1.1 Water temperature 5

5.1.2 Water pressure 5

5.1.3 Flow rate 5

5.1.4 Water treatment 6

5.2 Economisers 6

5.3 Flue gas discharge 6

5.4 Noise production 6

7 Assembly guidelines and installation
requirements 7

7.1 General 7

7.2 Water connections 7

7.3 Boiler assembly 7

8 Instrument panels 8

8.1 Equipment contents 8

8.2 Instrument panel High/Low with hours run
meters 8

8.3 Wiring diagram instrument panel High/Low
with hours run meters 1 9

9 Commissioning 10

9.1 Pressurized boiler with gas burner 10

9.1.1 Commissioning procedure 10

9.1.2 Putting out of operation 10

9.2 Pressurized boiler with oil burner 10

9.2.1 Commissioning procedure 10

9.2.2 Putting out of operation 10

10 Fault Finding 11

11 Maintenance recommendations 11

11.1 General 11

11.2 Maintenance instructions 11

6 Installation requirements 7

6.1 Installation recommendations in the boiler
house 7

2

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PREFACE

These technical instructions contain useful and impor­tant information for the correct operation and maintenan­ce of the Remeha boiler, model P200
Read these instructions carefully before putting the boi­ler into operation; familiarise yourself with its control
functions and operation, strictly observing the instructi­ons given. Failure to do so may invalidate warranty or
prevent the boiler from operating.
A competent Engineer, with the relevant certifi cation (i.e.
CORGI, ACOPS, IEE regs. etc) must carry out the instal­lation and commissioning of the boiler.
On completion a copy of the boiler log / commissioning
sheet should be returned to Broag Ltd for record purpo­ses.

1 DESCRIPTION OF THE UNIT

1.1 General

High effi ciency pressurised boiler, suitable for use with
natural gas and light oil, by means of a pressure jet
burner. Also available with a condensing unit (ECO) (for
natural gas only).
The boiler meets the requirements of the CE regulations
in the following directives:

- Gas appliance directive no. 90/396/EEC

- Electrical low voltage directive no. 73/23/EEC

- E.M.C. directive no. 89/336/EEC

- Effi ciency directive no. 92/42/EEC.
Classifi cation type for evacuation of the combustion pro­ducts: B23.

If you have any questions, or if you need more informa­tion about specifi c subjects relating to this boiler, or it’s
installation please do not hesitate to contact us.
The data published in these technical instructions is
based on the latest information (at date of publication)
and may be subject to revisions.
We reserve the right to continuous development in both
design and manufacture, therefore any changes to the
technology employed may not be retrospective nor may
we be obliged to adjust earlier supplies accordingly.

1.2 Burners

In principle all CE-approved pressure jet burners are sui­table, subject to prior adjustment to the boiler capacity
and boiler construction. The individual boiler satisfi es
inspection requirement for central heating boilers.

2 CONSTRUCTION DATA

2.1 General

The boiler block consists of cast iron sections, which are
assembled by means of tapered nipples. The boiler is a
three-pass design. The boiler block is insulated with a
100-mm thick layer of glass wool.

2.2 Sections

The sections are made of pearlitic cast iron.
Weights and measures of the sections:

- Front section: 220 kg H x W = 1252 x 1130mm

- Intermediate section: 250 kg H x W = 1238 x 1130 mm

- Rear section: 250 kg H x W = 1238 x 1130 mm

2.3 Casing

Steel casing, fi nished with a high-quality insulation. The
front door is suitable for left or right opening as desired.

Fig. 01 Remeha P500

IL50

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3 TECHNICAL DATA AND DIMENSIONS

3.1 Dimensions

Remeha P 500

Front view

Side view Rear view

Flow NG 150 - DIN2633
Return NG 150 - DIN2633
Flue ØD ext.

Flanges in accordance with BS 4505 PN 16

Fig. 02 Dimensions

00.15D.79.00006

3.2 Technical data

Number of sections 9 10 11 12 13 14 15 16 17 18 19 20

Nominal heat output kW 635 750 865 980 1095 1210 1325 1440 1555 1670 1785 1900

Nominal
heat input

Hi /

NCV

Hs /

GCV

A mm 1350 1500 1650 1800 1950 2100 2250 2400 2550 2700 2850 3000

kW 706 834 962 1090 1218 1341 1468 1592 1719 1846 1973 2100

kW 784 926 1068 1210 1352 1488 1630 1767 1908 2049 2190 2331

B mm 1660 1810 1965 2115 2265 2415 2565 2715 2870 3020 3170 3320

Dimensions

C mm 1270 1420 1570 1720 1870 2020 2170 2320 2470 2620 2770 2920

ØD mm 400 400 400 400 500 500 500 500 500 500 500 500

∆ t =

Water

resistance

Water contents litre 495 550 605 660 715 770 825 880 935 990 1045 1100

10°C

∆ t =

20°C

mbar 149 166 180 194 189 200 213 234 262 295 337 382

mbar 37 42 45 47 49 50 53 59 66 74 84 96

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Boiler weight (dry) kg 2650 2910 3175 3435 3695 3955 4220 4480 4740 5005 5265 5525

Combustion chamber

resistance

Combustion gas side

content

Flue gas flow rate kg/h 1102 1302 1502 1702 1901 2081 2292 2485 2683 2882 3080 3278

1)

mbar 1.7 2.3 3.0 3.8 3.9 4.8 5.0 5.9 5.5 6.0 6.5 7.0

3

m

0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9

Table 01 Technical data

1)

Determined with 20 % excess air.

3.3 Quotation specifi cations

- Heat exchanger manufactured from corrosion resi­stant “pearlite” cast iron

- Maximum operating pressure of 6 bar

- Maximum operating temperature of 95°C

- Sectional design with three passes for max effi ciency
(gross 83%) and a generously sized combustion
chamber for minimising NOX production

- Water cooled base and rear sections

- Large insulated door (hinged left or right) allowing
easy access for service operations

- Powder coated enamel steel casing

- 80 - 100 mm thick glass wool insulation

- Suitable for use with a Natural gas, and/or 35 sec oil
fi red pressure jet burner (matched with most popular
burner manufacturers)

- Supplied as standard with on/off switch, temperature
indication, control and high limit thermostats

- Effi ciency 83% (Hs - GCV)

- Manufactured to ISO 9001

- CE approved.

- Supplied in broken down form for ease of delivery and
site access

4 OUTPUT DATA

4.1 Boiler effi ciency

Up to 90.2 % at Hi (81.3 % at Hs) at full load and up to

92.5 % at Hi (83.3 % at Hs) at part load.

Average water temperature 70°C (80/60°C).

5 APPLICATION DATA

5.1 L.P.H.W. version

5.1.1 Water temperature

Maximum water temperature is 110°C.
The minimum acceptable return water temperature is,
both for gas and oil fi red boilers 40°C, at a fl ow rate
corresponding to a ∆t of 20°C at nominal heat output.

5.1.2 Water pressure

Maximum pressure 6 bar.
The boiler is suitable for open and sealed systems up
to a maximum pressure of 6 bar and a minimum pres­sure of 0.8 bar. The boiler is suitable for installation in
basement or rooftop boiler houses.

4.2 Combustion effi ciency

Up to 91.2 % at Hi (82.2 % at Hs) at full load and up to

95.5 % at Hi (86.0 % at Hs) at part load.

Note: Hi = NCV; Hs = GCV

5.1.3 Flow rate

The minimum fl ow rate through the boiler is obtained
from the following formula:

Nominal heat output (kW) = m3/h

70

This minimum fl ow must be maintained for 5 minutes
after the burner stops fi ring to avoid high temperature
shutdown due to residual heat gain. Due to the design
and manufacture of the boiler no specifi c minimum water
fl ow requirement exists other than for over-temperature
protection.

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Remeha P 500

5.1.4 Water treatment

The system should be fi lled 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 fl ushed thoroughly to remove all fl uxes
and debris and then fi lled completely once.

2. Make up water is limited to 5 % per annum.

3. The hardness of the water does not exceed 360 ppm
(20°D).

All scale deposits will reduce the effi ciency 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 effi ciency and will not reduce
the anticipated life expectancy of the boiler.

NOTE: Scale deposits in excess of 3 to 5 mm will
reduce boiler effi ciency and greatly increase the risk of
premature casting failure.

As most systems contain a variety of metals which 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:

- Metallic corrosion;

- Formation of scale and sludge;

- Microbiological contamination;

- 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 specifi cation of the system
and manufacturers recommendations must be taken into
account, along with the age and condition of the system.
New systems should be fl ushed thoroughly to remove all
traces of fl ux, 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
fl ushing, 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 fl ushing takes place, especially if
cleansing chemicals are used to assist the process.

Under no circumstances is the boiler to be operated
with cleaning chemicals in the system.

5.2 Economisers

ECO’s can be delivered upon request (for natural gas
only). For specifi cations please refer to Technical infor­mation ECO 13/14/15.

5.3 Flue gas discharge

For the discharge of the fl ue gases, chimney draught is
not required.
Tests have shown that very good combustion results are
obtained with zero draught at the boiler outlet.

5.4 Noise production

The noise level taken at a distance of 1 m around the
boiler is approximately 75 to 90 dBA. The noise level
at the chimney outlet will, depending on load, type of
burner and chimney situation, vary from 75 to 90 dBA,
measured at a distance of 1 m from the outlet. If
this noise production gives rise to problems in the imme­diate vicinity, then noise reducing or absorbing measu­res should be taken.

100

90

2

N/m

-5

80

dB re 2x10

70

60

50

31,5 63 125 250 500 1000 2000 4000 8000

frequency (Hz)

full load

9

part load

NR 90

NR 80

NR 70

NR 60

Fig. 03 Noise level readings without burner silencer

To summarise:

- Minimise water loss;

- Prevent pumping over in open vented systems;

- Provide adequate air venting at all high points;

The values that have been taken are averages obtained
from various measurements carried out at a distance of
approximately 1 m around the boiler and at a height of
approximately 1 m.

- Keep pH level between 7 - 9 when using additives;

- Maximum chlorine content of 200 mg/l;

- Take advice on the suitability of inhibitors.

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6 INSTALLATION REQUIREMENTS

6.1 Installation recommendations in the boiler
house

The necessary minimum installation space of the boiler
can be seen from Fig. 04.

Fig. 04 Installation recommendations in the boiler
house

04.15D.79.00001

H = 80mm without vibration damper
H = 120mm with vibrationdamper

Fig. 05 Base details

00.15A.78.00001

Number

of

sections

9 1350

10 1500

11 1650

12 1800

13 1950

14 2100

15 2250

16 2400

17 2550

18 2700

19 2850

20 3000

A

mm

7 ASSEMBLY GUIDELINES AND INSTALLATION REQUIREMENTS

7.1 General

The Remeha boiler P 500 is delivered in individual parts.
The sizes of the boiler parts are such that they all can

At the front of the boiler a fl ange is provided with 2
x G ½” threaded holes for the fi tting of the thermostat

pockets.
enter the boiler house through a normal entrance.
The casing and equipment parts are delivered in pac­kaged units. If necessary, the boiler can be put into
operation without casing. The casing can be added at a
later stage without dismantling the water connections.

7.3 Boiler assembly

Assembly and installation of a boiler delivered in indivi-

dual parts should only be undertaken by a recognised

and approved engineer and in accordance with the

assembly manual. Local regulations laid down by the

7.2 Water connections

relevant authorities must be adhered to.
The water connections are at the rear of the boiler.
The fl ow and return connections consist of a fl anged
fl ow elbow and a fl anged return connection in accor­dance with DIN 2633. The return connection is provided
with a G ¾” threaded hole in which a drain off cock is
fi tted.

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8 INSTRUMENT PANELS

Remeha P 500

8.1 Equipment contents

The panels contain all the necessary control and measu­ring instruments required to control the boiler. The con­nections have to be made on a terminal strip. The capil­laries and sensor wires, which come from the control
panel, are placed in the instrument pockets that are
fi tted at the front of the boiler.

12 3 6

9

Fig. 06 Layout of the instrument panel High/Low with hours run meters

00.03F.79.00004

See par. 8.2 for an instrument panel High/Low with hours
run meters. Several extra options can be built into the
panels.
Ask our technical department.

8.2 Instrument panel High/Low with hours run
meters

4 578

1. Operating switch (On/Off)

2. Control thermostat; setting between 35°C - 95°C

3. High/Low thermostat; setting between 35°C - 95°C

4. Hours run meter total running hours

5. Hours run meter full load running hours

6. Analoque thermometer water temperature

7. High limit thermostat 110°C (lock out)

8. Lock out warning lamp

9. Option for rematic® weather compensator

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8.3 Wiring diagram instrument panel High/Low with hours run meters 1

3

1.) External control.

remove link; insert control pair (230 V)

2.) External control High/Low.

remove link; insert control pair (230 V).1

Fig. 07 Wiring diagram instrument panel High/Low with hours run meters

04.13C.SC.00001

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9 COMMISSIONING

Remeha P 500

Note:

Commissioning to only be carried out by a qualifi ed
engineer with the relevant training and certifi cation i.e.
Acops-Corgi and a commissioning data sheet completed
on site for issue to owner.

9.1 Pressurized boiler with gas burner

9.1.1 Commissioning procedure

If the boiler is to be put into operation again following
a period of non-use, then the following procedure must
be carried out :

- Open the main gas cock.

- Switch the weather-compensator (if fi tted) over to

manual operation (h).

- Turn the thermostats to their highest setting.

- Switch on the circulation pump.

- Switch on the main switch.

- Switch on the operation switch in the instrument
panel.

- Consult burner manufacturers commissioning details.

Warning

If the instrument panel is fi tted with a weather compen­sator, set the program switch to ‘manual’ position (h).
The following will now take place:

- The gas burner fan will start running so that during
the purging time the combustion chamber will be ven­tilated with the air damper fully opened.

- The air damper will then go into start position.

- Ignition fl ame lights up and is checked.

- Then the control box gives the all clear signal for the
burner to switch over to full load.

9.1.2 Putting out of operation

It is suffi cient to switch off the operation switch on the
instrument panel. It is important that in the event of
work being carried out on the burner, the boiler/burner
unit must be completely electrically isolated and the
main gas cock must be shut.5

9.2 Pressurized boiler with oil burner

9.2.1 Commissioning procedure

If the boiler is to be put into operation again following
a period of non-use, then the following procedure must
be carried out :

- Open the main oil cock.

- Switch the weather-compensator (if fi tted) over to

manual operation (h).

- Turn the thermostat to their highest setting.

- Switch on the circulation pump.

- Switch on the main switch.

- Switch on the operation switch in the instrument
panel.

- Consult burner manufacturer commissioning details.

Warning

If the instrument panel is fi tted with a weather compen­sator, set the program switch to ‘manual’ position (h).
The following will now take place:

- The oil burner fan will start running so that during the
purging time the combustion chamber will be ventila­ted with the air damper fully opened.

- The air damper will then go into start position.

- Ignition fl ame lights up and is checked.

- Then the control box gives the all clear signal for the
burner to switch over to full load.

9.2.2 Putting out of operation

It is suffi cient to switch off the operation switch on the
instrument panel. It is important that in the event of
work being carried out on the burner, the boiler/burner
unit must be completely electrically isolated and the
main oil cock must be shut.

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10 FAULT FINDING

High Limit thermostat lock out:

- Check the water circulation (circulation pump). Reset
the High Limit thermostat (Reset button is on the
instrument panel under the cover cap of the High
Limit thermostat).

- Advise the installer in the event of continued lockouts.

11 MAINTENANCE RECOMMENDATIONS

11.1 General

Depending on the operational conditions, the block and
the burner must be checked and cleaned at least once a
year for gas and at least twice a year for oil.

11.2 Maintenance instructions

Cleaning of the boiler:

- Put boiler out of operation.

- Open the front door, if necessary after dismantling the
burner.

- Remove the retarders (only for the 9 - 16 sections).

- Clean the combustion chamber and fl ue passes using
a suitable brush.

- Clean the removed retarders ( 9 - 16 sections).

- Remove the rear panel of the boiler and remove the
cleaning cover (underneath the smoke box).

- Vacuum clean the boiler and the combustion cham­ber.

- Renew the front door seals after cleaning the boiler.

- Re-assemble the removed parts and close the front
door.

- Re-assemble the burner (if dismantled).

- Check the boiler combustion side for leakage.

- Check the equipment for proper functioning and if
necessary re-adjust the control and safety equipment.

- Carry out combustion analysis.

- Check the water connections.

11

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Remeha P500

Broag Ltd.

Head office

Remeha house

Molly Millars Lane

Wokingham,

Berkshire RG41 2QP

Tel.: [phone]

Fax: [phone]

E-mail address:

[e-mail]

© Copyright

All technical and technological information contained in these technical instructions,

as well as any drawings and technical descriptions furnished by us remain our

property and shall not be copied in part or whole without our prior consent in writing.

Subject to alterations
52881/1000/0202/Ips.

12

Branch office

Unit 3, Kestrel Close,

Quarry Hill ind. Estate,

Ilkeston

Derbyshire DE7 4RD

Tel.: [phone]

Fax: [phone]