REMEHA CALORA TOWER GAS 15S EX Manual

EN
Floor-standing high efficiency gas boiler
CALORA TOWER GAS 15S EX
CALORA TOWER GAS 25S EX
CALORA TOWER GAS 35S EX
C003589-A
Installation and
Service Manual
300026141-001-07

Declaration of conformity
The device complies with the standard type described in
the EG declaration of conformity. It was manufactured and
commissioned in accordance with European directives.
The original declaration of conformity is available from the
manufacturer.

Contents
1 Safety instructions and recommendations ..............................................6
1.1 General safety instructions .................................6
1.2 Recommendations ................................................7
1.3 Liabilities ...............................................................8
1.3.1 Manufacturer’s liability .............................................8
1.3.2 Installer’s liability .....................................................8
2About this manual ......................................................................................9
2.1 Symbols used .......................................................9
2.1.1 Symbols used in the manual ...................................9
2.1.2 Symbols used on the equipment .............................9
2.2 Abbreviations ......................................................10
3 Technical specifications ..........................................................................11
3.1 Homologations ....................................................11
3.1.1 Certifications .........................................................11
3.1.2 Gas categories ......................................................11
3.1.3 Additional Directives ..............................................11
3.1.4 Factory test ...........................................................11
3.2 Technical specifications ....................................11
4 Technical description ..............................................................................13
4.1 General description ............................................13
4.2 Main parts ............................................................13
4.3 Operating principle .............................................14
4.3.1 Skeleton Diagrams ................................................14
4.3.2 Circulation pump ...................................................15
4.3.3 Water flow rate ......................................................16
5 Installation ................................................................................................17
5.1 Regulations governing installation ...................17
5.2 Package list .........................................................17
5.2.1 Standard delivery ..................................................17
5.2.2 Accessories ...........................................................17
5.3 Choice of the location ........................................18
5.3.1 Type plate .............................................................18
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5.3.2 Positioning of the appliance ..................................19
5.3.3 Ventilation .............................................................20
5.3.4 Main dimensions ...................................................21
5.4 Positioning the appliance ..................................25
5.4.1 Positioning the boiler on its own ............................25
5.4.2 Fitting the boiler to a DHW tank ............................27
5.4.3 Positioning the boiler to the left or right of a DHW
tank .......................................................................28
5.5 Hydraulic connections .......................................28
5.5.1 Flushing the system ..............................................28
5.5.2 Hydraulic connection of the heating circuit ............29
5.5.3 Connection of the water circuit for domestic
use ........................................................................29
5.5.4 Connecting the expansion vessel .........................29
5.5.5 Connecting the condensate discharge pipe ..........30
5.5.6 Filling the condensate trap ....................................31
5.6 Gas connection ...................................................31
5.7 Flue gas system connections ............................32
5.7.1 Classification .........................................................32
5.7.2 Lengths of the air/flue gas pipes ...........................33
5.8 Electrical connections ........................................35
5.8.1 Control unit ............................................................35
5.8.2 Recommendations ................................................35
5.8.3 Access to the connection terminal ........................36
5.8.4 Position of the PCBs .............................................38
5.8.5 Heating circuit with boiler alone ............................38
5.8.6 Connecting a direct heating circuit and a domestic hot
water tank ..............................................................39
5.9 Optional electrical connections ........................42
5.9.1 Position of the optional PCBs ................................42
5.9.2 Position of the connections on the PCU
board .....................................................................43
5.9.3 c-Mix PCB .............................................................43
5.9.4 0-10 V (IF-01) PCB ...............................................44
5.9.5 Connection possibilities for the PCB (SCU-
S02) .......................................................................46
5.9.6 Connection possibilities for the PCB (SCU-
S03) .......................................................................49
5.9.7 Connection possibilities for the PCB (SCU-
X01) .......................................................................50
5.10 Electrical diagram ...............................................52
5.11 Filling the system ...............................................53
5.11.1 Water treatment ....................................................53
5.11.2 Filling the system ..................................................53
6 Commissioning ........................................................................................55
6.1 Control panel .......................................................55
6.1.1 Functions of the keys ............................................55
Contents
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6.1.2 Meaning of the symbols on the display .................55
6.2 Check points before commissioning ................56
6.2.1 Preparing the boiler for commissioning .................56
6.2.2 Gas circuit .............................................................56
6.2.3 Hydraulic circuit .....................................................58
6.2.4 Electrical connections ...........................................58
6.3 Putting the appliance into operation ................58
6.4 Gas settings ........................................................60
6.4.1 Adapting to another gas type ................................60
6.4.2 Checking and setting combustion .........................60
6.4.3 Basic setting for the gas/air ratio ...........................64
6.5 Checks and adjustments after
commissioning ...................................................64
6.5.1 Finalizing work ......................................................64
6.6 Reading out measured values ...........................65
6.6.1 Reading out measured values ..............................65
6.6.2 Readout from the hour counter and percentage of
successful starts ....................................................67
6.6.3 Status and sub-status ...........................................67
6.7 Changing the settings ........................................68
6.7.1 Parameter descriptions .........................................68
6.7.2 Modification of the installer-level parameters ........73
6.7.3 Setting the maximum heat input for central heating
operation ...............................................................73
6.7.4 Return to the factory settings Reset Param ..........74
6.7.5 Carrying out an auto-detect ...................................75
7 Switching off the appliance .....................................................................76
7.1 Installation shutdown .........................................76
7.2 Antifreeze protection ..........................................76
8 Checking and maintenance .....................................................................77
8.1 Preventive maintenance with automated service
message ..............................................................77
8.1.1 Resetting the automatic maintenance
message ................................................................77
8.1.2 Dealing with the next maintenance message and
starting the new maintenance period ....................78
8.2 Standard inspection and maintenance
operations ...........................................................78
8.2.1 Checking the hydraulic pressure ...........................78
8.2.2 Checking the expansion vessel .............................79
8.2.3 Checking the ionization current .............................79
8.2.4 Checking the tightness of the flue gas evacuation and
air inlet connections ..............................................79
8.2.5 Checking combustion ............................................79
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8.2.6 Checking the automatic air vent ............................80
8.2.7 Checking the safety valve .....................................80
8.2.8 Checking the condensate trap ..............................80
8.2.9 Checking the burner and cleaning the heat
exchanger .............................................................81
9 Troubleshooting .......................................................................................82
9.1 Error codes ..........................................................82
9.2 Shutdowns and lock-outs ..................................87
9.2.1 Lock out .................................................................87
9.2.2 Blocking .................................................................87
9.3 Error memory ......................................................90
9.3.1 Error readout memorised ......................................91
9.3.2 Deletion of the error display ..................................92
10 Spare parts ................................................................................................93
10.1 General ................................................................93
10.2 Spare parts ..........................................................94
10.2.1 Casing ...................................................................94
10.2.2 Water unit ..............................................................95
10.2.3 Control panel .........................................................96
10.2.4 Casing ...................................................................96
10.2.5 Spare parts list ......................................................97
11 Appendix – Information on the Ecodesign and Energy Labelling
Directives ..................................................................................................99
Contents
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1 Safety instructions and
recommendations
1.1 General safety instructions
DANGER
This appliance can be used by children aged
from 8 years and above and persons with
reduced physical, sensory or mental capabilities
or lack of experience and knowledge if they have
been given supervision or instruction concerning
use of the appliance in a safe way and
understand the hazards involved. Children shall
not play with the appliance. Cleaning and user
maintenance shall not be made by children
without supervision.
DANGER
If you smell gas:
1. Do not use a naked flame, do not smoke, do
not operate electrical contacts or switches
( doorbell, light, motor, lift, etc..).
2. Shut off the gas supply.
3. Open the windows.
4. Trace possible leaks and seal them
immediately.
5. If the gas leak is before the gas meter,
contact the gas supplier.
DANGER
If you smell flue gases:
1. Switch the appliance off.
2. Open the windows.
3. Trace possible leaks and seal them
immediately.
1. Safety instructions and recommendations CALORA TOWER GAS 15S EX CALORA TOWER GAS 25S EX
CALORA TOWER GAS 35S EX
622/04/2016 - 300026141-001-07

1.2 Recommendations
WARNING
4Installation and maintenance of the boiler
must be carried out by a qualified
professional in compliance with prevailing
local and national regulations.
4When working on the boiler, always
disconnect the boiler from the mains and
close the main gas inlet valve.
4After maintenance or repair work, check all
installations to ensure that there are no
leaks.
CAUTION
The boiler must be installed in a frost-free
environment.
Keep this document close to the place where the
boiler is installed.
Casing components
Only remove the casing for maintenance and repair
operations. Put the casing back in place after
maintenance and repair operations.
Instructions stickers
The instructions and warnings affixed to the appliance
must never be removed or covered and must remain
legible during the entire lifespan of the appliance.
Immediately replace damaged or illegible instructions and
warning stickers.
Modifications
Modifications may only be made to the boiler after the
written permission of Remeha to do so.
CALORA TOWER GAS 15S EX CALORA TOWER GAS 25S EX
CALORA TOWER GAS 35S EX
1. Safety instructions and recommendations
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1.3 Liabilities
1.3.1. Manufacturer’s liability
Our products are manufactured in compliance with the
requirements of the various applicable European
Directives. They are therefore delivered with [ marking
and all relevant documentation.
In the interest of customers, we are continuously
endeavouring to make improvements in product quality.
All the specifications stated in this document are therefore
subject to change without notice.
Our liability as the manufacturer may not be invoked in the
following cases:
4Failure to abide by the instructions on using the
appliance.
4Faulty or insufficient maintenance of the appliance.
4Failure to abide by the instructions on installing the
appliance.
1.3.2. Installer’s liability
The installer is responsible for the installation and
commissioning of the appliance. The installer must
respect the following instructions:
4Read and follow the instructions given in the manuals
provided with the appliance.
4Carry out installation in compliance with the prevailing
legislation and standards.
4Perform the initial start up and carry out any checks
necessary.
4Explain the installation to the user.
4If a maintenance is necessary, warn the user of the
obligation to check the appliance and maintain it in
good working order.
4Give all the instruction manuals to the user.
1. Safety instructions and recommendations CALORA TOWER GAS 15S EX CALORA TOWER GAS 25S EX
CALORA TOWER GAS 35S EX
822/04/2016 - 300026141-001-07

2 About this manual
2.1 Symbols used
2.1.1. Symbols used in the manual
In these instructions, various danger levels are employed to draw the
user’s attention to particular information. In so doing, we wish to
safeguard the user’s safety, highlight hazards and guarantee correct
operation of the appliance.
DANGER
Risk of a dangerous situation causing serious physical
injury.
WARNING
Risk of a dangerous situation causing slight physical
injury.
CAUTION
Risk of material damage.
Signals important information.
¼Signals a referral to other instructions or other pages in the
instructions.
2.1.2. Symbols used on the equipment
4Protective earthing
~Alternating current
Before installing and commissioning the device, read
carefully the instruction manuals provided.
Dispose of the used products in an appropriate recovery
and recycling structure.
This appliance must be connected to the protective earth.
D000241-C
CALORA TOWER GAS 15S EX CALORA TOWER GAS 25S EX
CALORA TOWER GAS 35S EX
2. About this manual
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Caution: danger, live parts.
Disconnect the mains power prior to any operations.
2.2 Abbreviations
43CE: Collective conduit for sealed boiler
4DHW: Domestic hot water
4HRU: Heat Recovery Unit
4HL: High Load - DHW tank with plate exchanger
4SL: Standard Load - DHW tank with coil
4SHL: Solar High Load - Solar DHW tank with plate exchanger
1 2
M002628-A
2. About this manual CALORA TOWER GAS 15S EX CALORA TOWER GAS 25S EX
CALORA TOWER GAS 35S EX
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3 Technical specifications
3.1 Homologations
3.1.1. Certifications
CE identification no CE-0085CM0178
NOx classification 5 (EN 15502-1, EN 15502-2-1)
Type of connection
(Flue gas outlet)
B23, B23P, B33, C13, C33, C43, C53, C63, C83, C93
3.1.2. Gas categories
Gas category Gas type Connection pressure (mbar)
II2H3P G20 (Gas H) 20
G31 (Propane) 37/50
3.1.3. Additional Directives
Apart from the legal provisions and Directives, the additional
Directives described in these instructions must also be observed.
For all provisions and Directives referred to in these instructions, it is
agreed that all addenda or subsequent provisions will apply at the
time of installation.
3.1.4. Factory test
Before leaving the factory, each boiler is set for optimum performance
and tested to check the following items:
4Electrical safety
4Adjustment (CO2)
4Domestic hot water mode
4Water tightness
4Gas tightness
4Parameter settings
3.2 Technical specifications
CALORA TOWER GAS 15S EX CALORA TOWER GAS 25S EX
CALORA TOWER GAS 35S EX
3. Technical specifications
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Boiler type CALORA TOWER
GAS 15S EX
CALORA TOWER
GAS 25S EX
CALORA
TOWER GAS
35S EX
General
Nominal output (Pn)
Heating System (80/60 °C)
minimum-
maximum
kW 3,0 - 14,9 5,0 - 24,8 6,3 - 34,8
Nominal output (Pn)
Heating System (50/30 °C)
minimum-
maximum
kW 3,4 - 15,8 5,6 - 25,5 7,0 - 35,9
Nominal output (Pn)
Heating System (40/30 °C)
minimum-
maximum
kW 3,4 - 16,0 5,6 - 25,9 7,0 - 36.4
Nominal input (Qn)
Heating System (Hi)
minimum-
maximum
kW 3,1 - 15,0 5,2 - 25,0 6,5 - 35,1
Nominal input (Qn)
Heating System (Hs)
minimum-
maximum
kW 3,4 - 16,7 5,8 - 27,8 7,2 - 39,0
Nominal input (Qnw)
DHW System (Hi)
minimum-
maximum
kW 3,1 - 15,0 5,2 - 29,3 6,5 - 35,1
Nominal input (Qnw)
DHW System (Hs)
minimum-
maximum
kW 3,4 - 16,7 5,8 - 32,6 7,2 - 39,0
Heating efficiency under full
load (Hi) (80/60 °C)
- % 99,3 99,2 99,1
Heating efficiency under full
load (Hi) (50/30 °C)
- % 105,3 102,0 102,2
Heating efficiency under partial
load (Hi) (Return temperature
60°C)
- % 94,9 96,1 96,3
Heating efficiency under partial
load (EN 92/42) (Return
temperature 30°C)
- % 110,2 110,1 110,6
Data on the gases and combustion gases
Gas consumption - Natural gas
H (G20)
minimum-
maximum
m3/h 0,33 - 1,59 0,55 - 3,10 0,69 - 3,71
Gas consumption - Natural gas
L (G25)
minimum-
maximum
m3/h 0,38 - 1,85 0,64 - 3,61 0,80 - 4,32
Gas consumption - Propane
G31
minimum-
maximum
m3/h 0,13 - 0,61 0,21 - 1,20 0,27 - 1,44
Mass flue gas flow rate minimum-
maximum
kg/h 5,3 - 25,2 8,9 - 49,3 11,1 - 57,3
Flue gas temperature minimum-
maximum
°C 30 - 65 30 - 80 30 - 75
Maximum counter pressure Pa 80 130 140
Characteristics of the heating circuit
Water content (ex expansion
vessel)
l 1,9 1,9 2,5
Water operating pressure minimum kPa (bar
(MPa))
80 (0,8) 80 (0,8) 80 (0,8)
Water operating pressure
(PMS)
maximum kPa (bar
(MPa))
300 (3,0) 300 (3,0) 300 (3,0)
Water temperature maximum °C 110 110 110
Operating temperature maximum °C 90 90 90
Electrical characteristics
Power supply voltage VAC 230 230 230
Power consumption - Full load maximum W 101 116 132
Electrical protection index IP21 IP21 IP21
Other characteristics
Weight (empty) kg 56 59 59
3. Technical specifications CALORA TOWER GAS 15S EX CALORA TOWER GAS 25S EX
CALORA TOWER GAS 35S EX
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4 Technical description
4.1 General description
Gas fired floor-standing condensing boiler
4High efficiency heating.
4Low pollutant emissions.
4Optional domestic hot water production in combination with a
DHW tank.
The boiler is fitted with an interior light. The interior light
comes on in the following cases:
4The boiler is switched on: The lighting is switched on
for 10 minutes.
4The boiler is switched off: The lighting is switched on
for 30 minutes.
4.2 Main parts
1Flue gas discharge pipe
2Flue gas measuring point
3Heat exchanger
4Ignition/ionization electrode
5Box for the control PCBs
6Control panel
7Command module
8Water pressure sensor
9Circulation pump
10 Hydroblock
11 3-way valve
12 Safety valve
13 Casing
14 Expansion vessel
15 Combined venturi and gas valve unit
16 Fan
17 Air intake silencer
18 Mixer pipe
19 Automatic air vent
C003072-C
18
19
16
17
15
14
13
12
11
1234
10
9
5
6
7
8
CALORA TOWER GAS 15S EX CALORA TOWER GAS 25S EX
CALORA TOWER GAS 35S EX
4. Technical description
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4.3 Operating principle
4.3.1. Skeleton Diagrams
nBoiler self-standing
1Heat exchanger
2Hydroblock
3Heating flow
4Primary DHW tank flow
5Primary DHW tank return
6Heating return
73-way valve
8Circulation pump
9Expansion vessel
nBoiler with 100HL / 220SHL type domestic hot water
tank
1Heat exchanger
2Hydroblock
3Heating flow
4Plate exchanger inlet
5Plate exchanger outlet
6Heating return
73-way valve
8Circulation pump
9Expansion vessel
10 Domestic hot water outlet
11 Domestic cold water inlet
12 Plate heat exchanger
13 Domestic hot water pump
14 Domestic hot water tank
19 Safety valve
C003073-C
1
2
8
9
7
3 4 5 6
M002513-F
1
2
8
9
7
3
10
12
13
14
456
11
19
4. Technical description CALORA TOWER GAS 15S EX CALORA TOWER GAS 25S EX
CALORA TOWER GAS 35S EX
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nBoiler with 100SL / 160SL / 200SSL type domestic hot
water tank
1Heat exchanger
2Hydroblock
3Heating flow
4Coil exchanger inlet
5Coil exchanger outlet
6Heating return
73-way valve
8Circulation pump
9Expansion vessel
15 Domestic hot water outlet
16 Domestic cold water inlet
17 Domestic hot water tank
18 Domestic water coil
19 Safety valve
4.3.2. Circulation pump
nPump specifications
15 - 25 kW boilers
HManometric height available for the heating circuit
QWater flow
Useful output (ΔT 20 K)
A10 kW
B15 kW
C20 kW
D25 kW
M002514-D
1
2
8
9
7
3
15 16
17
18
456
19
H (mbar)
C003452-E
Q (l/h)
0 200 400 600 800 1000 1200
0
100
200
300
400
500
600
700
800
B
A
C
D
1037834623440
CALORA TOWER GAS 15S EX CALORA TOWER GAS 25S EX
CALORA TOWER GAS 35S EX
4. Technical description
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35 kW boilers
HManometric height available for the heating circuit
QWater flow
AUseful output 35 kW (ΔT 20 K)
4.3.3. Water flow rate
The boiler’s modulating control system limits the maximum difference
in temperature between the heating flow and return and the maximum
speed at which the flow temperature increases. In this way, the boiler
does not require a minimum water flow rate.
00 200 400 600 800 1000 1200 1400
1465
1600
100
200
300
400
500
600
700
H (mbar)
Q (l/h)
A
L000697-A
4. Technical description CALORA TOWER GAS 15S EX CALORA TOWER GAS 25S EX
CALORA TOWER GAS 35S EX
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5 Installation
5.1 Regulations governing installation
WARNING
Installation of the appliance must be done by a qualified
engineer in accordance with prevailing local and national
regulations.
5.2 Package list
5.2.1. Standard delivery
The delivery includes:
4The boiler, fitted with an earthed mains plug
4Attachment for C-mix optional PCB
4Sticker with details on gas type
4Installation and Service Manual
4User Guide
5.2.2. Accessories
Various options are available depending on the configuration of the
installation.
4Boiler - DHW tank connection kits
4Central connection kit - right / left
4Mixing valve kit for integration DHW tank
4Connection kit for external mixing valve
4Fitting for circulating pipe
4Flue kit
4Flue gas adapters for concentric 80/125 mm or eccentric 80/80
mm connection
4iSense programmable control system for modulating boiler
control (Cable on RF)
4C-mix control PCB
4Outside sensor
4Flue gas temperature sensor
4Electronic boards for extension
4DHW expansion vessel
4Propane conversion kit
CALORA TOWER GAS 15S EX CALORA TOWER GAS 25S EX
CALORA TOWER GAS 35S EX
5. Installation
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4Cleaning tools
5.3 Choice of the location
5.3.1. Type plate
The data plates provide important information on the
appliance: serial number, model, gas category, etc.
1This data plate is affixed to the inside side panel of the
appliance in the factory.
2When installation has been completed, affix the data plate
provided in the instructions bag to the casing of the
appliance in a position where it can be seen.
C003074-E
AufERDGAS H eingestellt
fürDE: Erdgas E
Régléau gaz naturel H
Geregeldvoor aardgas H
Presetfor natural gas H
G20-20 mbar
8366-4038
1 2
5. Installation CALORA TOWER GAS 15S EX CALORA TOWER GAS 25S EX
CALORA TOWER GAS 35S EX
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