REMEHA GAS 210-80 ECO PRO Manual

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High efficiency Low Nox gas boiler
Types:
210-80
210-120
210-160
210-200
EN
English
Technical
information
GAS 210 ECO PRO

GAS 210 ECO PRO
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Preface 6
1. EC declaration 7
2. Introduction 8
2.1 Pictograms used 8
2.2 Important instructions 8
3. Safety 9
4. Installation 10
4.1 Scope of delivery and installation 10
4.2 Dimensions 11
4.3 Installation and service clearances 12
5. Water-side connections 13
5.1.1 Condensed water discharge 13
5.1.2 Water treatment 13
5.1.3 Pressure relief valve 14
5.1.4 Circulation pump 14
5.1.5 Water flow 14
6. Gas-side connections 15
6.1 Gas connection 15
6.2 Gas pressure 15
6.3 Gas/air ratio control 15
7. Connecting the flue gas discharge and air supply 16
7.1 General 16
7.2 Conventional open flue installation 16
7.2.1 Possible lengths for the flue gas discharge pipe 17
7.3 Room sealed installation 18
7.3.1 Possible lengths for the air supply and flue gas discharge 18
7.3.2 Discharge in different pressure areas 20
7.3.3 Connection of flue gas discharge and choice of material 21
7.3.4 Air supply connection and choice of material 21
8. Control and electrical connections 22
8.1 General 22
8.1.1 Boiler control 22
8.1.2 Modulating controls general 22
8.1.3 Modulating room control 22
8.1.4 Modulating weather-compensated control rematic® 22
8.1.5 Modulating cascade controller MC4 23
8.2 Electrical specifications 23
8.2.1 Mains voltage 23
8.2.2 Control box 23
8.2.3 Fuse ratings 24
8.3 Electrical connection options 24
8.3.1 Connection options of standard control unit (PCU-01) 24
8.3.2 On/off control (OT) 24
8.3.3 Modulating controls (OT) 24
8.3.4 External interlock (BL) 24
8.3.5 Input release (RL) 25
8.3.6 Circulation pump (Pump) 25
8.3.7Connecting a PC 25
8.3.8 Connection options for the PCB - SCU - X01 25
Table of contents
Table of contents

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8.4 Connection options for the optional 0 - 10 V control PCB (IF-01) 26
8.4.1 Connection status (Nc) 26
8.4.2 OTm connection 26
8.4.3 Analogue input (0 - 10 V) 27
8.4.4 Analogue output (0 - 10 V) 27
8.5 Connection options of the optional expanded control/protection PCB (SCU-S01) 28
8.5.1 Flue gas damper control (FgV) 28
8.5.2 Hydraulic valve control (HdV) 28
8.5.3 External gas valve control (EgV) 28
8.5.4 Operation signal and failure signal (Nc / No) 28
8.5.5 Water pressure sensor (Wps) 28
8.5.6 Outside temperature sensor (Tout) 29
8.5.7 Minimum gas pressure switch (Gps) 29
8.5.8 Gas leakage control (VPS; only for 210- 160 and 210- 200 boilers) 29
8.5.9 Wiring diagram 30
9 Commissioning 31
9.1 Control panel 31
9.1.1 Normal start-up procedure 31
9.1.2 Fault during start-up procedure 32
9.1.3 Reading current values 33
9.1.3.1 Status and sub status 34
9.1.4 Adjusting the boiler to the system 34
9.1.5 Changing parameters at user level (without access code) 35
9.1.6 Changing parameters at service level (with access code) 35
9.1.7 Resetting factory settings 38
9.1.8 Setting manual operation  (˜ symbol) 39
9.2 Commissioning 39
9.3 Taking the boiler out of operation 42
9.3.1 Boiler with frost protection, out of operation for a long time 42
9.3.2 Boiler without frost protection, out of operation for a long time 42
10. Inspection and maintenance 43
10.1 General 43
10.2 Combustion check of the boiler 43
10.2.1 Corrective maintenance 43
10.2.2 Cleaning the fan 44
10.2.3 Cleaning the heat exchanger (flue gas side) 46
10.2.4 Cleaning the burner 47
10.3 Cleaning the trap 48
10.4 Checking the ignition electrode 48
10.5 Checking for leaks 48
10.6 Checking water pressure 48
10.7 Putting boiler back into operation 48
11. Control stops and faults 49
1 1.1 General 49
11.2 Control stops and faults 49
11.3 Control stop codes 49
11.4 Fault codes 51
11.5 Control stop - and fault memory 54
1 1.5.1 Reading faults 55
11.5.2 Deleting control stops or faults 55
Table of contents

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Table of contents
12. Service parts 56
12.1 General 56
12.2 Exploded view 57
13. Regulations 58
13.1 General 58
13.2 Standards 58
13.3 Remeha factory test 58
13.4 Supplementary guidelines 59
14. Technical specifications 60
14.1 Technical data 60
15. Efficiency data and gas inspection labels 61
15.1 Unit usable efficiency (HR efficiency) 61
15.2 Water-side efficiency 61
15.3 Zero-load losses 61
15.4 Description of specifications 61
15.5 Accessories 62
15.6 Services 62
15.7 Type of unit 63
15.8 Operating principle 64
15.9 Boiler Control 64
15.9.1 Temperature control 64
15.9.2 Low water level protection 64
15.9.3 Maximum protection 65
15.9.4 Frost protection 65
16. Application data 66
16.1 General 66
16.2 Air and flue gas application options 66
16.3 Hydraulic application options 66
16.4 Cascade application 66
16.5 Control options 69
16.6 Gas application options 69
17. Checklists (records) 70
17.1 Checklist for commissioning (Commissioning record) 70
17.2 Checklist for annual inspection (inspection record) 70
17.3 Checklist for maintenance (maintenance record) 71

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Table of contents

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Preface
Preface
PREFACE
This technical information , which contains a lot of practical infor-
mation about the Remeha Gas 210 ECO PRO, a High efficiency
central heating unit, is mainly intended for installers. It contains
important instructions for safe and trouble-free operation of the
boiler before commissioning and during operation.
Read these instructions carefully before putting the boiler into
operation, familiarise yourself with its control functions, operation
and strictly observe the instructions given. Failure to do so may
invalidate warranty or prevent the boiler from operating. The boiler
is available in the following types:
- Gas 210 ECO PRO 80 (3 sections; 87 kW)
- Gas 210 ECO PRO 120 (4 sections; 120 kW)
- Gas 210 ECO PRO 160 (5 sections; 166 kW)
- Gas 210 ECO PRO 200 (6 sections; 200 kW)
The installation, commissioning, inspection and servicing of the
boiler must be carried out by a competent Corgi registered engi-
neer who holds valid A.C.S. certification and in accordance with
current gas safety (installation and use) regulations, the building
regulations and all other relevant codes of practice.
All electrical work must be carried out by a competent engineer
and to be installed in accordance with the current IEE regulations.
If you have any questions, require an engineer to call on site, or if
you need more information about specific subjects relating to this
boiler, or it's installation please do not hesitate to contact our tech-
nical help line 0118 978 3434.

When contacting Broag with a problem on the boiler , please have
available the boiler type, Serial No (located on the bottom of the
casing), and the symptoms or fault code (the fault code is a series
of flashing digits in the display panel).
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 materials or tech-
nology employed may not be retrospective nor may we be obliged
to adjust earlier supplies accordingly.

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1. EC declaration
1. EC declaration
EC - DECLARATION OF CONFORMITY
Manufacturer : Remeha B.V.
Address : Kanaal Zuid 110
City, Country : Postbus 32, NL-7300 AA Apeldoorn, Holland
- this is to declare that the following product(s) : Remeha Gas 210 ECO PRO
is/are in conformity with the following EEC-directives:
EEC- Directive: 90/396/EEC tested and examined to the following norms:
EN 656 A1(2006), EN 15417(2006)
15240
(2006)
92/42/EEC
73/23/EEC DIN EN 50165(2001), EN 50165(1997 + A1: 2001)
DIN EN 60335-1(2003), EN 60335-1(2002) 07
89/336/EEC EN 55014-1(2000+A1:2001), 55014-2(1997+A1:2001)
EN 61000-3-2(2000+A2:2005), 61000-3-3(1995+A1:2001)
97/23/EEC (article 3, sub 3)
Apeldoorn, aug. 2007
W.F. Tijhuis
Approval manager

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2. Introduction
2. Introduction
The following pictograms are used in this document to emphasise
certain instructions. This is in order to increase your personal
safety and to safeguard the technical reliability of the boiler . The
pictograms used are:
 Useful advice.
 Important instruction for carrying out an action.
 Possible risk of bodily injury or material damage to boiler ,
building or environment.
 Possible risk of electrical shocks. Serious bodily injury may
occur .
2.1 Pictograms used
2.2 Important instructions
The boiler must be installed in a frost-free area.

Work on the boiler
Installation, commissioning, maintenance and repair work may
only be carried out by suitably qualified specialist installers in
accordance with the applicable national and local standards and
guidelines.Always disconnect the mains supply and close the main
gas cock when working on the boiler. Check the entire system for
leaks after maintenance and servicing work.
Casing panels may only be removed for maintenance and servic-
ing purposes. Refit all panels on completion of maintenance and
servicing work.
Instruction and warning labels on the boiler must never be
removed or covered and must be clearly legible throughout the
entire service life of the boiler. Replace damaged or illegible
instruction and warning labels immediately. Generally applicable
safety instructions related to accident prevention must be con-
sulted in addition to the information supplied in this technical docu-
mentation.
Boiler modifications
Modifications to the boiler require the written approval of Broag.

Keep this document near to the installation.

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3. Safety
3. Safety
Adhere strictly to the specific safety instructions.

Can you smell gas? Proceed as follows:
• do not smoke and avoid fire and sparks
• do not operate electrical switches.
• close the gas cock.
• open doors and windows.
• trace possible leaks and seal them of f.
• if the leak is upstream of the gas meter , notify National Gas
Emergency Service tel: [phone].

Can you smell flue or combustion gases? Proceed as follows:
• isolate the mains power supply from the boiler.
• open doors and windows.
• trace possible leaks and seal them of f.

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4. Installation
4. Installation
The boiler is supplied fully assembled and protected. The boiler
is placed on a pallet (70 x 130 cm, 145 cm high), which can be
transported with a pallet truck, hand truck, forklift truck or 4-wheel
transport boards. The packaging passes through all standard
doors (minimum width of 74.5 cm).
The boiler is installed as follows:
- Position the pallet with the boiler in the boiler room;
- Remove the fixing bands and all other packaging (some
components are packaged in the polystyrene cap);
- Lift the boiler from the pallet;
- Slide the boiler into the required position, using the recessed
handles in the boiler base;
- Cover the boiler and do not operate it whilst dust creating
construction processes or insulation to the pipe work etc. are
carried out in the plant room.
4.1 Scope of delivery and installation