REMEHA Gas 310 ECO Manual

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• High efficiency condensing
boiler with low NOX emission
• Heat outputs: 51 - 573 kW
Remeha Gas 310 ECO
Technical Information
Remeha Gas 310 ECO

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INHOUD
Preface 5
1 Safety instructions 6
1.1 Symbols 6
2 General description of boiler 7
3 Design 8
3.1 Boiler version 8
3.2 Operating principle 9
4 Technical data 10
4.1 Dimensions 10
4.2 Technical data 11
4.3 Quotation specification 12
4.4 Delivery options 12
4.5 Accessories 13
5 Efficiency information 14
5.1 Annual efficiency 14
5.2 Heat to water efficiency 14
5.3 Standing losses 14
6 Application data 14
7 Installation instructions for heating installer 15
7.1 General 15
7.2 Delivery and installation 15
7.3 Flue gas discharge and air supply 17
7.3.1 General 17
7.3.2 Classification due to discharging
flue gases 17
7.3.3 Connection options 17
7.3.4 Inlets/Outlets 17
7.3.5 Other requirements 17
7.3.6 Single boiler conventional flue 18
7.3.7 Single boiler, room sealed flue 18
7.3.8 Different pressure zones 20
7.3.9 Header flue systems 20
7.4 Installation details 20
7.4.1 Water pressure 20
7.4.2 Condensate discharge 20
7.4.3 Water treatment 20
7.4.4 Safety valve 21
7.4.5 Water circulation 21
7.4.6 Thermostat pocket 21
7.4.7 Noise production 21
7.5 Multiple boiler installation 21
8 Installation instructions for ELECTRICAL
installer 24
8.1 General 24
8.2 Electrical specifications 24
8.2.1 Mains voltage 24
8.2.2 Control unit 24
8.2.3 Power consumption 24
8.2.4 Fuse ratings 24
8.2.5 Temperature control 25
8.2.6 Low water level protection
(flow and content) 25
8.2.7 High limit protection 25
8.2.8 Air pressure differential
sensor (LDS) 25
8.3 Connections 26
8.4 Wiring diagram 27
8.5 Switch sequence diagram 27
8.6 Boiler control 27
8.6.1 Introduction 27
8.6.2 Modulating controls general
(two wire control) 28
8.6.3 BMS Analog control
(0-10 Volt DC) 28
8.6.4 On/ off control (1 x no volt
switched pair) 28
8.6.5 High/ low control (2 x no volt
switched pairs) 29
8.7 Other inputs 29
8.7.1 Shut down input 29
8.7.2 Lock-out input 29
8.7.3 External interlock 29
8.7.4 Other outputs 29
8.7.5 Analog output Depending on the
option settings in the service level
(see section 13.2.13), the analog
output signal is able to transmit
the following values: 29
8.7.6 Operation signal 29
8.7.7 Common alarm (lock-out) 29
8.7.8 External gas valve control 29
8.8 Options/ accessories 30
8.8.1 System pressure sensor 30
8.8.2 Gas valve leak proving system
(VPS) 30
8.8.3 Minimum gas pressure switch 30
8.8.4 Flue gas damper 30
8.8.5 Return butterfly valve (not Broag
supply) 30
8.9 Other connections 30
8.9.1 Boiler or System pump control 30
8.9.2 Frost protection 30

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9 Installation instructions for gas installer 31
9.1 Gas connection 31
9.2 Gas pressures 31
9.3 Gas/ air ratio control 31
10 Commissioning 31
10.1 Initial lighting 31
10.2 Shutdown 33
11 control and safety equipment 34
11.1 General 34
11.1.1 Instrument panel layout 34
11.1.2 LED indicators 35
11.2 Switch function keys 35
11.2.1 Manual/automatic operation 35
11.2.2 Forced mode ‘high’ (h[[) 35
11.2.3 Forced mode ‘low’ (l[[) 35
11.3 Display of values 35
12 Operating mode 36
12.1 Operating mode (x[[) 36
12.2 Read-out mode (X[[) 36
12.3 Control strategy c 37
12.4 Shut-off (bxx) 37
12.4.1 Shut-off 37
12.4.2 Shut-off mode 37
12.5 Counter mode (1, ,and .)
(service level) 38
12.5.1 General 38
12.5.2 Reading out counter mode 38
13 Setting mode 39
13.1 User level setting mode (X[[) 39
13.1.1 Flow temperature (!) 39
13.1.2 Pump run on time (@) 40
13.1.3 Boiler control (A) 40
13.2 Setting mode service level (only for
the qualified service engineer) (X[[) 40
13.2.1 Minimum fan speed ($and 5) 42
13.2.2 Maximum fan speed (^and 7) 42
13.2.3 Forced part load time (*) 42
13.2.4 Cycling prevention delay
time (() 42
13.2.5 Required flow temperature
at 0 - 10 volts (aand B) 42
13.2.6 High operation signal
switch point (C) 42
13.2.7 Shunt pump post-circulation
time (D) 42
13.2.8 dT from control stop point to
start point (E) 42
13.2.9 Maximum flue gas tempera-
ture (F) 42
13.2.10 Maximum temperature
setting (G) 42
13.2.11 Modulation start point at dT (H) 43
13.2.12 Minimum water pressure (I) 43
13.2.13 Adjustments options/ acces-
sories (J) 43
13.2.14 “Low” speed with H/L control (L) 43
13.2.15 Boiler type (P) 43
14 Fault-finding 44
14.1 General 44
14.2Failure mode (1[[) (service level) 44
14.3 Cooling mode 44
14.4 Summary of failures (lock-out) 44
15 Inspection and maintenance instructions 48
15.1 General 48
15.2 Cooling mode 48
15.3 Annual Inspection 48
15.4 Maintenance 48
15.4.1 Inspection of air box and dirt trap 49
15.4.2 Cleaning the non return valve 49
15.4.3 Cleaning the venturi 49
15.4.4 Cleaning the fan 49
15.4.6 Cleaning the burner assembly 50
15.4.5 Cleaning the heat exchanger 50
15.4.7 Cleaning the condensate collector 50
15.4.8 Cleaning the syphon 50
15.4.10 Cleaning the inspection glass 51
15.4.9 Cleaning/Replacing the Ignition/
Ionisation electrode 51
15.5 Exploded view and spare parts list 52
16 appendices 55
16.1 Control menu 55
16.2 Shut-off codes 56

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PREFACE
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 pre-
vent the boiler from operating.
The installation and commissioning of the boiler must be
carried out by a competent Engineer, with the relevant
certification i.e.: CORGI, ACOPS, IEE regs. On com-
pletion a copy of the commissioning sheet should be
returned to Broag Ltd. for record purposes.
fig. 01 Artist impression Gas 310 ECO
3D.AL.31H.000.S.01
If you have any questions, or if you need more informa-
tion about specific subjects relating to this boiler or its
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.

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Remeha Gas 310 ECO
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1 SAFETY INSTRUCTIONS
1.1 Symbols
The following symbols are used in this document to
emphasise certain instructions. This is in order to
increase your personal safety and to safeguard the tech-
nical reliability of the boiler.
gInstructions must be followed closely to avoid
personal injury or serious damage to the unit or the
environment.
gImportant!! Instructions are of essential
importance for the correct functioning of the unit.
wIndicates possible danger of electric shock. Seri-
ous personal injury may occur.
iInstructions contain useful information.
Read and familiarise yourself with these instruc-
tions.
General Instructions
Keep unauthorised personnel away from the boiler. Do
not place objects on or against the boiler. Do not touch
hot water connections or the flue outlet when the boiler
is operating – burn hazard.
wDanger
This boiler is connected to a 230v mains supply. An
improper installation or attempts to repair electrical com-
ponents or controls may result in life threatening situa-
tions.
gBe aware of gas escapes
If you smell gas, close the (main) gas cock and contact
the emergency gas leak telephone number for your
area. DO NOT ISOLATE THE POWER SUPPLY TO
THE BOILER OR ANY OTHER APPLIANCE.
gBe aware of flue gas leaks
If you smell flue gas fumes, turn the boiler off and con-
tact your service company or installer.
gBe aware of water leaks
If you see water leaking from the boiler, turn it off and
contact your Service Company or installer.
gWorking on the boiler
Installation, commissioning, maintenance and repair
work must only be carried out by suitably qualified spe-
cialist. Engineer in accordance with all relevant national/
local standards and certifications.
Always disconnect the mains supply and close the main
gas cock before working on the boiler.
Casing panels should only be removed for mainte-
nance and servicing purposes.
Refit all panels on completion of maintenance or servic-
ing before putting the boiler back into service.
Instruction and warning labels on the boiler must
never be removed or covered and must be clearly leg-
ible throughout the entire service life of the boiler. Dam-
aged or illegible instruction and warning labels must be
replaced immediately.
Generally applicable safety instructions related to acci-
dent prevention must be consulted in addition to the
information supplied in this technical documentation.
Boiler modifications and spare parts
The boiler must not be modified or non-Remeha spare
parts fitted without the express written approval of
Remeha.

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2 GENERAL DESCRIPTION OF BOILER
The Remeha Gas 310 ECO boiler is a fully assembled,
free standing, gas fired (Natural gas only), fully modu-
lating high efficiency condensing boiler and is supplied
plastic wrapped, crated on a pallet.
The sectional cast aluminium heat exchanger and other
major components are contained within a rigid steel
frame with removable casing parts for maintenance
purposes. The Gas 310 ECO frame is fitted with a set
of casters to enable the assembled unit to be easily
manoeuvred into position within the plant room on site
with the minimum of effort. All major electrical and elec-
tronic controls are contained within the instrument panel
mounted on top of the boiler at the opposite end to the
connections facing to the front (long side) but can be
rotated 90otowards the short side to suit site location.
The boiler is available with flow and return connections
on the left or right hand end of the boiler (THIS MUST
BE DECIDED AT TIME OF ORDER), with the gas con-
nection on the top of the boiler. The flue gas outlet c/w a
condensate connection will be at low level on the same
side as the connections. Combustion air inlet (for room
sealed operation) is located at the top of the boiler.
The boiler is suitable for room sealed or open flue
applications and has been designed for central heat-
ing and indirect hot water production at working pres-
sures not exceeding 6 bar. It must be installed on a fully
pumped system and is designed for operating pressures
between 0.8 and 6 bar.
The pre-mix gas burner (NG only) with its gas/ air ratio
control system ensures clean, trouble free operation
with higher than average efficiencies of up to 109% Hi
(NCV) in the condensing mode combined with ultra low
NOx and minimum CO emissions.
The standard control package allows for external On/
Off, High Low (volt free switch/s) or modulating control
(0-10V input). The built in digital display shows normal
operating/ fault code indication and allows actual and
set values to be read and adjusted.
The intelligent, advanced boiler control (‘abc®’) continu-
ously monitors the boiler operating conditions, varying
the heat output to suit the system load. The control is
able to react to external “negative” influences in the
rest of the system (flow rates, air/ gas supply problems)
maintaining boiler output for as long as possible with-
out resorting to a lock out condition. At worst the boiler
will reduce its output and/ or shut down (shut off mode)
awaiting the “negative” conditions to return to normal
before re-starting.
The ‘abc®’ control cannot override the standard flame
safety controls.
All Gas 310 boilers are live fired after assembly to
ensure the boiler and controls comply with our strict
quality policy.
The unit has been inspected for compliance with the
essential requirements of the following directives:
- Gas Appliances Directive, no. 90/ 396/ EEC
- Efficiency Directive, no. 92/ 42/ EEC
- EMC Directive, no. 89/ 336/ EEC
- Electrical Low Voltage Directive, no. 73/ 23/ EEC
- Pressure Equipment Directive, no. 97/ 23/ EEC,
art. 3, item 3
CE identification number (PIN) : 0063BP3474
NOXClass : 5
Type classification of flue gas discharg : B23, C33,
C43, C53, C63, C83

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Remeha Gas 310 ECO
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3 DESIGN
3.1 Boiler version
fig. 02 Cross-section Remeha Gas 310 ECO (Left
hand boiler illustrated)
00.31H.79.00002
The service side of the boiler (with the heat exchanger
inspection cover) is the front.
1. Pressure gauge
2. Pocket for external temperature sensor (7mm i/d
plain pocket)
3. Flow connection
4. 2nd Return connection (Optional)
5. Return connection
6. Filling/ drain cock
7. Condensate collector
8. Flue gas temperature sensor
9. Condensate drain
10. O2/ CO2measuring point
11. Positioning wheels
12. Jacking bolts
13. Condensate drain hose
14. Flue gas discharge
15. Inspection hatch
16. Adapter ø 250/ ø 200 (optional)
17. Heat exchanger
18. Flow temperature sensor
19. Air supply
20. Adapter ø 200/ ø 250 (optional)
21. Air supply grille
22. Gas connection
23. Inspection glass
24. Ignition/ionisation electrode
25. Return temperature sensor
26. Boiler block temperature sensor
27. Frame
28. Steering castor
29. Fan
30. Venturi
31. Gas valve multiblock
32. Non return valve
33. Gas filter
34. Air pressure differential sensor (LDS)
35. Air box
36. Instrument panel
37. Control keys
38. Read-out window
39. Weather compensator installation (optional)
40. On/ off switch

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3.2 Operating principle
Combustion air is drawn into the inlet connection from
the plant room (room ventilated version) or from outside
via the eccentric flue system (room sealed) by an air
supply fan.
On the inlet side of the fan is a specially designed
chamber (venturi unit) which takes gas from the multi-
block and mixes it in the correct proportions with the
incoming air. This mixing system ensures that the cor-
rect gas/ air ratio is delivered to the pre-mix burner at all
times.
Depending on demand (under the dictates of flow/return
sensor and other external/internal control inputs) the
‘abc®’ system determines the required boiler output.
The ‘abc®’ control then varies the speed of the air sup-
ply fan which alters the volume of air being drawn into
the venturi, this change in volume is measured using air
pressure differential which directly controls the volume
of gas also being delivered to the venturi. The resultant
controlled mixture is delivered to the premix burner.
This mixture is initially ignited by the combined ignition/
ionisation probe, which monitors the state of the flame.
Should the flame be unstable or not ignite within the
pre-set safety time cycle the controls will (after 5
attempts) shut the boiler down requiring manual inter-
vention to reset the boiler. The digital display will indi-
cate a flashing fault code confirming the reason for the
failure.
The products of combustion in the form of hot flue gases
are forced through the heat exchanger transferring their
heat to the system water, (the flue gas temperature is
reduced to approximately 5/ 8°above the temperature
of the system return water) then discharged via the con-
densate collector, to the flue gas outlet connection, to
atmosphere.
Because of the low flue gas exit temperature there will
be a vapour cloud formed at the flue gas terminal -this
is not smoke-, simply water vapour formed during the
combustion process.
If the flue gas temperature falls below dew point (55°),
water vapour (created during the combustion process)
will begin to condense out in the boiler, transferring its
latent heat into the system water, thereby increasing the
output of the boiler without increasing the gas consump-
tion.
Condensation formed within the boiler and flue system
is discharged from the boiler to an external drain via the
drain pan and siphon supplied.
The boiler can be supplied, as an option with a
second (constant temperature) return connection. This
additional connection enables the boiler to make full use
of its condensing ability whilst accepting both fixed and
variable temperature returns from the same system.

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4 TECHNICAL DATA
4.1 Dimensions
fig. 03 Elevation drawings (left-hand version shown)
04.31H.79.00002
ÉFlow connection NW 80, DIN 2576
ÊReturn connection NW 80, DIN 2576
ÏGas connection 2” BSP (F)
ÒCondensate drain 1 ¼” nb plastic waste
ÑFlue gas discharge 250 mm i/d
ÐCombustion air supply 250 mm i/d
ÌSecond return connection
(optional) NW 65, DIN 2576
Boiler type A B C E L
5 sections 1600 1463 1590 1004 1312
6 sections 1600 1463 1590 901 1312
7 sections 1990 1853 1980 1110 1702
8 sections 1990 1853 1980 1007 1702
9 sections 1990 1853 1980 904 1702
table 01 Dimensions in mm

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4.2 Technical data
Boiler type Unit Remeha Gas 310 ECO
5 sections 6 sections 7 sections 8 sections 9 sections
General
Boiler control options - Modulating, high/ low or on/ off
Nominal output Pn (80/ 60°)min kW 51 65 79 92 106
max kW 261 327 395 462 531
Nominal output Pn (50/ 30°)min kW 56 71 84 98 113
max kW 282 353 427 499 573
Nominal input Qn (GCV/ Hs) min kW 60 75 91 105 121
max kW 298 372 448 523 598
Nominal input Qn (NCV/ Hi) min kW 54 68 82 95 109
max kW 269 336 404 471 539
Efficiency (Hi)
Combustion (Hi) at 80/ 60°% up to 99
Heat to water (Hi) at 80/ 60°% up to 98,5
Standing losses (Taverage = 45°)% < 0.3
Annual efficiency (Hi) % 108,9
Gas and flue gas side
Gas category - Natural gas only
Inlet pressure gas (boiler running) min mbar 17
max mbar 100
Gas consumption m03/h 2936435057
NOXemission (annual emissions) mg/ kWh < 60
NOXemission
(annual emissions, O2= 0%, dry) ppm < 35
Residual fan duty Pa 150 150 150 150 150
Flue gas mass min kg/ h 91 114 138 160 183
max kg/ h 453 565 680 793 907
Flue gas temperature at 80/ 60°min °57
max °65
Type classification due to discharging flue
gasses - B23, C33, C43, C53, C63, C83
Water side
High limit temperature °110
Flow temperature operating °20 - 90
Operating pressure min bar 0.8
max PMS bar 6
Water contents litres 49 60 71 82 93
Water resistance at 11°dT mbar (kPa) 374 (37.4) 364 (36.4) 397 (39.7) 364 (36.4) 413 (41.3)
Water resistance at 20°dT mbar (kPa) 113 (11.3) 110 (11) 120 (12) 110 (11) 125 (12.5)
Electrical
Mains supply V/Hz 230/ 50
Power consumption min Watt 12 12 12 12 12
max Watt 303 340 470 600 858
Insulation class IP 20
Other
Weight dry kg 360 410 460 510 560
Floor area m21.2 1.2 1.4 1.4 1.4
Noise level at a distance of 1 m from the
boiler (average) dB(A) 60
Colour of casing RAL 2002 (red); 9023 (grey)
table 02 Technical data Remeha Gas 310 ECO