REMEHA Gas 310 ECO Manual

1
 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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Remeha
Gas 310 ECO
TABLE OF CONTENTS
Preface 4
1 SAFETY instructions 5
1.1 Symbols 5
2 General description of boiler 6
3 DESIGN 7
3.1 Boiler version 7
3.2 Operating principle 8
4 Technical data 9
4.1 Dimensions 9
4.2 Technical data 10
4.3 Quotation specification 11
4.4 Delivery options 11
5 Efficiency information 12
5.1 Annual efficiency 12
5.2 Heat to water efficiency 12
5.3 Standing losses 12
6 Application data 12
7 Installation instructions for heating installer 13
7.1 General
7.2 Delivery and installation 13
7.3 Flue gas discharge and air supply 14
7.3.1 General 14
7.3.2 Classification due to discharging
flue gases 14
7.3.3 Connection options 15
7.3.4 Inlets/Outlets 15
7.3.5 Other requirements 15
7.3.6 Single boiler conventional flue 15
7.3.7 Single boiler, room sealed flue 16
7.3.8 Different pressure zones 18
7.3.9 Header flue systems 18
7.4 Installation details 18
7.4.1 Water pressure 18
7.4.2 Condensate discharge 18
7.4.3 Water treatment 18
7.4.4 Safety valve 19
7.4.5 Water circulation 19
7.4.6 Thermostat pocket 19
7.4.7 Noise production 19
7.5 Multiple boiler installation 19
8 Installation instructions for ELECTRICAL \
installer 22
8.1 General 22
8.2 Electrical specifications 22
8.2.1 Mains voltage 22
8.2.2 Control unit 22
8.2.3 Power consumption 22
8.2.4 Fuse ratings 22
8.2.5 Temperature control 23
8.2.6 Low water level protection
(flow and content) 23
8.2.7 High limit protection 23
8.2.8 Air pressure differential
sensor (LDS) 23
8.3 Connections 23
8.4 Wiring diagram 24
8.5 Switch sequence diagram 25
8.6 Boiler control 25
8.6.1 Introduction 25
8.6.2 Modulating controls general
(two wire control) 26
8.6.3 BMS Analog control (0-10 Volt DC) 26
8.6.4 On/ off control (1 x no volt
switched pair) 26
8.6.5 High/ low control (2 x no volt
switched pairs) 27
8.7 Other inputs 27
8.7.1 Shut down input 27
8.7.2 Lock-out input 27
8.7.3 External interlock 27
8.7.4 Other outputs 27
8.7.5 Analog output 27
8.7.6 Operation signal 27
8.7.7 Common alarm (lock-out) 27
8.7.8 External gas valve control 27
8.8 Options/ accessories 28
8.8.1 System pressure sensor 28
8.8.2 Gas valve leak proving system VPS 28
8.8.3 Minimum gas pressure switch \
(suitable for gas pressures up to
30 mbar) 28
8.8.4 Flue gas damper 28
8.8.5 Return butterfly valve (not Broag
supply) 28
8.9 Other connections 28
8.9.1 Boiler or System pump control 28
8.9.2 Frost protection 28
9 Installation instructions for gas installer 29
9.1 Gas connection 29
9.2 Gas pressures 29
9.3 Gas/ air ratio control 29
10 Commissioning 29
10.1 Initial lighting 29
10.2 Shutdown 31
11 control and safety equipment 32
11.1 General 32
11.1.1 Instrument panel layout 32
11.1.2 LED indicators 33
11.2 Switch function keys 33
11.2.1 Manual/automatic operation 33
11.2.2 Forced mode ‘high’ (h[[) 33
11.2.3 Forced mode ‘low’ (l[[) 33
11.3 Display of values 33
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12 Operating mode 34
12.1 Operating mode (x[[) 34
12.2 Read-out mode (X[[)
12.3 Control strategy c35
12.4 Shut-off (bxx)
12.4.1 Shut-off 35
12.4.2 Shut-off mode 35
12.5 Counter mode (1,, and .)
(service level) 36
12.5.1 General 36
12.5.2 Reading out counter mode 36
13 Setting mode 37
13.1 User level setting mode (X[[) 37
13.1.1 Flow temperature (!) 37
13.1.2 Pump run on time (@) 38
13.1.3 Boiler control (A) 38
13.2 Setting mode service level (only for the
qualified service engineer) (X[[) 38
13.2.1 Minimum fan speed ($and 5) 39
13.2.2 Maximum fan speed (^and 7) 39
13.2.3 Forced part load time (*) 40
13.2.4 Cycling prevention delay time (() 40
13.2.5 Required flow temperature at
0 - 10 volts (aand B) 40
13.2.6 Switch point high/low operation signal
(C) 40
13.2.7 Shunt pump post-circulation
time (D) 40
13.2.8 dT from control stop point to start
point (E) 40
13.2.9 Maximum flue gas temperature
(F) 40
13.2.10 High limit temperature setting (G) 40
13.2.11 Modulation start point at dT (H) 40
13.2.12 Minimum water pressure (I) 41
13.2.13 Adjustments options/
accessories (J) 41
13.2.15 Boiler type (P) 41
14 FAULT-FINDING 42
14.1 General 42
14.2 Failure mode (1[[) (service level) 42
14.3 Cooling mode 42
14.4 Summary of failures (lock-out) 42
15 Inspection and maintenance instructions 46
15.1 General 46
15.2 Cooling mode 46
15.3 Annual Inspection 46
15.4 Maintenance
15.4.1 Inspection of air box and dirt trap 47
15.4.2 Cleaning the non return valve 47
15.4.3 Cleaning the venturi 47
15.4.4 Cleaning the fan
15.4.5 Cleaning the heat exchanger 47
15.4.6 Cleaning the burner assembly 48
15.4.7 Cleaning the condensate collector 48
15.4.8 Cleaning the syphon 48
15.4.9 Cleaning/Replacing the Ignition
Ionisation electrode 48
15.4.10 Gas filter check 49
15.4.11 Cleaning the inspection glass 49
15.5 Exploded view and spare parts list 50
16 appendices 53
16.1 Control menu 53
16.2 Shut-off codes 54
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Remeha
Gas 310 ECO
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.
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.
fig. 01 Artist impression Gas 310 ECO
3D.AL.31H.000.S.01
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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.
g
Instructions 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.
w
Indicates possible danger of electric shock. Serious per-
sonal injury may occur.
i
Instructions 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, act as follows:
- Do not smoke and make no fire or sparks;
- Do not operate electrical switches;
- Close the (main) gas cock;
- Open windows and doors;
- Search for a possible leak and seal it up;
Warning! If the gas leak is before the gas meter, alert
your gas supplier (Transco 0800 - 111 999).
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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Remeha
Gas 310 ECO
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
front or “service side” of the boiler provides access to
the heat exchanger inspection hatch and other service
items, see fig. 02 and fig. 04.
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
NOXand 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 discharge : B23, C33, C43, C53,
C63, C83
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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 (7 mm
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 mm (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
3 DESIGN
3.1 Boiler version
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Remeha
Gas 310 ECO
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 65, 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
* Second return water connection for highest return temperature level. Further information:
please contact Broag Technical Dept.
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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Remeha
Gas 310 ECO
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 17 17 17 17
max mbar 30 30 100 100 100
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
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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
4.3 Quotation specification
- Cast aluminium - sectional pre-mix gas fired fully
condensing, modulating floor standing boiler
- Sectional heat exchanger manufactured from cast
aluminium
- Maximum operating pressure of 6 bar
- Maximum operating temperature of 90°C
- Ultra low NOX(max. 35 ppm at 0% O2)
- Pre-mix, fully modulating (20-100%) gas burner with
unique gas/ air ratio control for maximum efficiency
- Intelligent advanced boiler control ‘abc®’ c/w a com-
prehensive operating, service and fault diagnostic
facility
- No minimum flow requirement (see section 7.4.5)
- Available as conventional flue or room sealed opera-
tion
- Capable of remote BMS control (0 -10V modulating,
on/ off or high/ low option)
- Socket for advanced service diagnostics (for PC/ PDA
connection)
- Supplied fully factory assembled and tested
- Powder coated enamel steel casing BS; RAL colour:
2002 (red); 9023 (grey)
Gas 310 ECO
Execution ‘left-hand’
Gas 310 ECO
Execution ‘right-hand’
fig. 04 Installation options
04.31H.79.00004
I = Front (service side)
A = Short side (alternative orientation of the instrument
panel)
- Rigid steel box frame
- Suitable for use with Natural gas only
- Supplied as standard with on/ off switch, temperature
indication, flow, return, heat exchanger block and flue
gas sensors
- Supplied as standard with indicating module No. 1
lock-out indication (Volt free), shut down indication
(Volt free), boiler on indication (24 Volt AC)
- Efficiencies up to 109% (NCV/ Hi)
- Manufactured to ISO 9001
- CE approved
4.4 Delivery options
Available in 5 section sizes, in “left-hand” or “right-hand”
versions each with 2 instrument panel positions:
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Remeha
Gas 310 ECO
The service side with the inspection cover on the heat
exchanger is considered to be the front of the boiler.
With a “left-hand” version, the flow, return and flue
connections are on the left of the boiler as you face
the front (service side). On a “right-hand” version, the
flow, return and flue connections are on the right of the
boiler as you face the front (service side). The boiler
instrument panel can be rotated to face the front or the
short side of the boiler (front will be standard unless
stated on the purchase order) (see fig. 04).
gImportant!! When ordering a Remeha Gas
310 ECO, it is essential that the number of sections and
whether a “left-hand” or “right-hand” connection version
is required as well as the orientation of the instrument
panel (short or front side). The boiler comes entirely
assembled and tested and will include, as far as possi-
ble, all accessories ordered.
5 EFFICIENCY INFORMATION
5.1 Annual efficiency
Up to 108.9% at Hi (up to 97% at Hs) at an average
water temperature of 40°C (50/ 30°C).
5.2 Heat to water efficiency
a. Up to 98.5% at Hi (88% at Hs) at an average water
temperature of 70°C (80/ 60ºC).
b. Up to 106.4% at Hi (98% at Hs) at an average water
temperature of 40°(50/ 30°).
5.3 Standing losses
Less then 0.3% at Hi (0.33% at Hs) at an average water
temperature of 45°C
Note: NCV = Hi, GCV = Hs
6 APPLICATION DATA
The Gas 310 ECO can be used on all new and refur-
bishment projects in both single and multiple configu-
rations. Conventional and room sealed flue system
capability means that the boiler can be sited almost any-
where within a building.
The Remeha rematic®and “OpenTherm” weather com-
pensators (option) are able to communicate directly with
the boiler/s controls to make full use of their fully modu-
lating features, ensuring that the boiler closely matches
the system demand at all times.
External control systems (BMS) can be interfaced with
the boiler to provide on/ off - high/ low or modulating (0
-10V) control options.
4.5 Accessories
- Modulating “OpenTherm” weather compensators,
‘’Open Therm’’ for single or rematic®’ for multi boiler
configurations
- Second return connection
- System pressure sensor
- Flue adapter 250 mm to 200 mm i/d (stainless steel)
- Air supply adapter 250 mm to 200 mm i/d (stainless
steel)
- Vertical room sealed terminal VRS 200/300 or VRS
250/350
- Condensate neutralisation box
- Condensate neutralisation granules
- Recom communication set with CD-ROM, interface
and wiring
- Interfaces for communication with various controllers
(see section 8.6)
- Gas leak proving control
- Minimum gas pressure switch
- Automatic flue gas damper for pressurised flue
system
- Cleaning tools
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7 INSTALLATION INSTRUCTIONS FOR HEATING INSTALLER
7.1 General
All gas appliances must, by law, be installed by com-
petent persons (e.g. Corgi registered). Failure to install
appliances correctly could lead to prosecution.
It is in your own interest and that of safety to ensure that
the law is complied with.
The following instructions must be adhered to when the
Remeha Gas 310 ECO is installed:
- Gas Safety (Installation and Use) Regulations 1984
(as amended).
In addition to the above regulations, this boiler must be
installed in compliance with:
- Current I.E.E. Regulations for electrical installations
- Local building regulations
- The Building Standards (Scotland)
- (Consolidation) Regulations
- By-laws of the local water undertaking
- Health and Safety Document No 635 ‘The Electricity
at Work Regulations 1989’
It should also be in accordance with the relevant recom-
mendations in the current edition of the following British
Standards and Codes of Practice, viz. BS 6644, BS5978
Part 1 & 2, BS 5449, BS 5446, BS 6798, BS 6891 and
BG DM2.
Important:
The Remeha Gas 310 ECO is a CE certified boiler and
must not be modified or installed in any way contrary to
these “Installation and Maintenance Instructions”.
Manufacturers Instructions must NOT be taken as over-
riding statutory obligations.
7.2 Delivery and installation
The Remeha Gas 310 ECO is supplied fully assembled
plastic wrapped and packed in a crate on a pallet.
The overall dimensions of the crate are 80 cm wide and
175 cm high with the length dependant on the number
of sections (5 & 6 sections: 170 cm, 7 to 9 sections:
209 cm). The base of the packaging is a 76-cm wide
pallet to enable it to be transported with a pallet truck,
forklift truck or 4-wheel transport boards.
Excluding the crate the boiler is 72-cm wide c/w cas-
ing panels and 70 cm without casing and will fit through
most standard doors (minimum door opening width 80
cm). The boiler itself has wheels so that, once the pack-
aging has been removed, it can easily be moved around
on a smooth surface. The packaging lid includes a rock-
ing ramp, which can be used to negotiate obstacles
such as doorsteps and small plinths. Once in position
the boiler is fixed into position using the fitted jacking
bolts which both raise the wheels of the ground and
level the boiler. Technical documentation is supplied
with the boiler in a holder on the inside of the boiler cas-
ing (beneath the instrument panel). A number of small
loose components, such as the 4 support pads and the
syphon for the boiler have been placed in the flue gas
discharge.
It is advisable (preferable) to install the Remeha Gas
310 ECO as follows:
- Place the crate c/w the boiler in the boiler room. Make
sure there is enough room at one end of the crate for
the boiler and ramp and clearance for the crate to be
removed (at least 3 M).
gImportant!! Always transport the boiler in
the protective packaging wherever possible.
- Remove fixing strips, packaging lid and all other pack-
aging leaving the boiler on the pallet.
- Place the packaging lid on the end of the pallet (cre-
ating a ramp - secure with screw).
- Roll the boiler on its wheels off the pallet down the
ramp to the boiler room floor.
gWARNING! Use retaining straps to control
the rate of travel - Do not stand in front of the boiler!
- Manoeuvre the boiler to required final position.
iThe pallet lid can be used as a rocking ramp to
convey the boiler over obstacles, such as thresholds
etc.
gImportant!! The wheels are designed for
transport purposes only and MUST NOT be used when
the boiler is in its final position!
- Place the 4 support pads under the adjustment bolts.
- Use the adjusting bolts to jack up the boiler lifting it
clear of the wheels and with the top of the conden-
sate collector level.
- Fit the siphon assembly.
Use the plastic packaging to protect the boiler until
required for use.
gImportant!! Additional protection may be
required if site conditions warrant it – overhead builders
working, insulation etc.
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14
Remeha
Gas 310 ECO
fig. 05 Layout in the boiler room
04.31H.79.00005
Number of
sections C in mm
51590
61590
71980
81980
91980
Clearance of at least 800 mm is required at the front
(service side) of the boiler. However, we recommend a
clearance of 1 m. A clearance of at least 400 mm above
the boiler and at least 300 mm on both ends (800 mm
if the instrument panel is rotated to face the short end).
An isolating gas main cock must be installed near the
boiler, within hand’s reach.
fig. 06 shows the boiler’s support area including the
position of the support pads (shaded boxes) supplied.
fig. 06 Support area Remeha Gas 310 ECO
00.31H.79.00005
Number of sec-
tions C in mm D in mm
51590 1118
61590 1118
71980 1508
81980 1508
91980 1508
table 03 Base dimensions
7.3 Flue gas discharge and air supply
7.3.1 General
The Remeha Gas 310 ECO is suitable for both conven-
tional room ventilated or eccentric room sealed opera-
tion.
Room sealed terminals should comply with the Gastec
QA-requirements for vertical outlet constructions.
Any horizontal pipework in the flue gas discharge sys-
tem should slope towards the boiler.
Horizontal pipework in the air supply system should
slope towards the supply opening and may require a
drain point at the low point.
Care should be taken when siting flue exit positions as
a vapour plume will be visible when the boiler is opera-
tional (flue gas temperature will be less than < 77°
resulting in the water vapour condensing out on contact
with the air).
7.3.2 Classification due to discharging flue gases
Classification according to CE:
Type B23: Conventional room ventilated appliance with-
out draft diverter. Air supply from boiler room; flue gas
discharge on roof.
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15
Type C33: Room sealed appliance, connected to com-
bined roof outlet.
Type C43: Room sealed appliance in cascade configu-
ration, connected via two ducts to a common duct sys-
tem serving more than one appliance.
Type C53: Room sealed appliance, connected to sepa-
rate ducts for the air supply and flue gas discharge, ter-
minated in zones of different pressure.
Type C63: Room sealed appliance, supplied without the
terminal or the air supply and flue gas discharge ducts.
Type C83: Boiler with room sealed operation, connected
to separate air supply and flue gas discharge duct, with
flue gas discharge duct always in depression.
Conventional flue or room ventilated installations:
A room-ventilated boiler takes the required combustion
air from the plant room. Combustion air for the boiler
must be provided to the room/ compartment in accord-
ance with BS 6644. A table showing the maximum
discharge lengths for the room ventilated version of the
Remeha Gas 310 ECO can be found in section 7.3.6.
Room sealed installations:
It is unnecessary to provide separate combustion air to
the room/compartment as this is supplied direct to the
boiler via the eccentric flue and air inlet system to the
vertical terminal unit (see fig. 09,VRS 200/250 options
available from Broag).
Additional ventilation will be required to the room/com-
partment in accordance with BS 6644 (compartment
ventilation).
For installations where supply and discharge points are
in two different pressure zones CLV system please con-
tact Broag Technical Dept. for further details and advice.
Note: The boilers can also be installed on a flue dilu-
tion system, but must incorporate a total flue break to
avoid boiler gas/air ratio controls being affected by the
flue dilution fan pressures. For full details please contact
Broag.
A table showing maximum air supply/ flue gas discharge
lengths for the room sealed version of the Remeha Gas
310 ECO can be found in section 7.3.7.
7.3.3 Connection options
The Remeha Gas 310 ECO is available in a room venti-
lated and a room sealed version. If the room-sealed ver-
sion is used, the grille must be removed before installing
the air supply pipe.
7.3.4 Inlets/Outlets
For conventional flue systems the flue terminal exit point
should discharge vertically and be c/w a tapered cone
and bird guard. For room sealed options use the Broag
VRS 200/250 vertical terminal.
7.3.5 Other requirements
Flue gas discharge materials:
Single wall, rigid: stainless steel, thick-walled aluminium
(to comply with building regulations).
Flexible: stainless steel (to comply with building
regulations).
Flue gas discharge structure:
The flue gas discharge pipe must have airtight and
watertight joints and connections and should be seam-
less. Horizontal sections in the flue gas discharge pipe
must slope down towards the boiler (at least 5-cm per
meter).
Flue liners:
If flue liners are used they must be manufactured from
stainless steel or flexible plastic (continuous temperature
rating of 120oC) and be gas and water tight.
Air supply materials:
Single wall, rigid or flexible: aluminium, stainless steel.
Air supply structure:
The air supply pipe must also be airtight. Horizontal sec-
tions in the air supply must slope away from the boiler
towards the supply opening and incorporate a drain con-
nection if the route rises from a lower point that could
flood.
7.3.6 Single boiler conventional flue
fig. 07 Flue gas discharge duct without bends, single
boiler, conventional flue.
00.31H.79.00011 (afb 1)
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16
Remeha
Gas 310 ECO
Flue diameter 200 mm * 250 mm
Model Gas 310 ECO sections
56789
max eq. length L m 103 65 145 105 78
eq. length
bend 45°, R=D m1.6 2
eq. length
bend 90°, R=D m 2.8 3.5
table 04 Calculation data conventional flue
* When flue gas discharge pipes with a diameter of 200
mm are used, an optional adapter is required for con-
nection to the Remeha Gas 310 ECO from ø250 - ø
200 mm.
Example: Gas 310 ECO, 6 sections, total length 27 m,
diameter 200 mm, 2 bends 90°.
27 m + 2 x 2.8 = 32.6 < 65 m →flue OK.
Note: If the design parameters are outside the val-
ues shown in the above table or there is any doubt
over the flue system, please contact our technical
department for calculation to be undertaken.
7.3.7 Single boiler, room sealed flue
fig. 08 Flue gas discharge duct without bends, single
boiler, room sealed application.
00.31H.79.00011 (nr 6)
Example:
Gas 310 ECO, 8 sections, total length flue and air inlet
each 32 m, each 2 bends 90°.
32 m + 2 x 3.5 = 39.0 < 49 m; flue and air inlet OK.
Note: If the design parameters are outside the val-
ues shown in the above table or there is any doubt
over the flue system, please contact our technical
department for calculation to be undertaken.
Combined vertical terminal sets, and roof sealing plates
for flat roofs, are available for the room-sealed version
with diameters of ø200 and ø250 in accordance with
fig. 09.
Flue/ air inlet diam-
eter 250/ 250 mm
Model Gas 310 ECO sections
56789
max eq. length L m 172 108 71 49 34
eq. length
bend 45°, R=D m2
eq. length
bend 90°, R=D m3.5
table 05 Calculation data room sealed applications
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17
Exc.
fig. 09 Vertical terminal for room sealed operation
pdf
Number of øD EHLG
ød1 ød2 øD3 ext. øD4 int.
sections mm mm mm mm mm mm mm mm mm
5200 459 2350 nvt nvt 300 320 318 640
250 459 2500 nvt nvt 350 370 368 690
6200 562 2350 42 142 300 320 318 640
250 562 2500 2 102 350 370 368 690
7200 743 2350 223 323 300 320 318 640
250 743 2500 183 283 350 370 368 690
8200 846 2350 326 426 300 320 318 640
250 846 2500 286 386 350 370 368 690
9200 949 2350 429 529 300 320 318 640
250 949 2500 389 489 350 370 368 690
table 06 Dimensions vertical terminal in mm
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18
Remeha
Gas 310 ECO
7.3.8 Different pressure zones
ÑFlue gas discharge
ÐCombustion air supply
fig. 10 Different pressure zones
00.31H.79.00012
The Remeha Gas 310 ECO boilers are capable of oper-
ating with the air inlet and flue outlet in different pres-
sure zones (CLV System).
The max height difference between air inlet and flue gas
outlet is 36 meters and the maximum total length of air
inlet and flue gas outlet pipe work L is shown in table
07.
Flue/ air inlet diameter 250/ 250 mm
Model Gas 310 ECO sections
56789
maximum total
length of air inlet
and flue gas outlet
pipework L
m
262
158
98
62
40
bend 45°, R=D m 2
bend 90°, R=D m 3.5
table 07 Different pressure zones
Note: this system may not be used in areas with
adverse wind conditions (i.e. in some coastal regions).
Note: If the design parameters are outside the values
shown in the above table or there is any doubt over the
flue system, please contact our technical department for
calculation to be undertaken.
7.3.9 Header flue systems
For multiple boiler installations with common flue sys-
tems please refer to Broag for advice.
7.4 Installation details
7.4.1 Water pressure
The individual boiler sections are each subjected to a
test pressure of 10 bar. On assembly the complete block
is subjected to a factory pressure test using compressed
air at 2 bar for 1 minute.
The boiler is suitable for a maximum working pressure
of 6 bar.
7.4.2 Condensate discharge
Discharge the condensate via a tundish, directly into
a drain. Only use synthetic material for the connecting
pipework because of the acidity (pH 2 - 5) and allow a
min. of 30 mm per meter fall to ensure a good flow rate.
Fill the siphon with clean water before firing the boiler.
It is not advisable to discharge into an outside gutter,
because of the risk of freezing.
7.4.3 Water treatment
The system should be filled 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 flushed thoroughly to remove all fluxes
and debris and filled 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 efficiency of the boiler
and should be prevented. However provided the above
is complied with any scale produced will not be too det-
rimental to the boiler efficiency and will not reduce the
anticipated life expectancy of the boiler.
NOTE: Scale deposits in excess of 5 mm will reduce
boiler efficiency and increase the risk of premature cast-
ing failure.
As most systems contain a variety of metals it is consid-
ered good practice to provide some form of water treat-
ment (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 car-
rying out any work. The specification of the system and
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19
manufacturers recommendations must be taken into
account, along with the age and condition of the system.
New systems should be flushed thoroughly to remove all
traces of flux, 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
flushing, 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 flushing 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.
To summarise:
- Minimise water loss
- Prevent pumping over in open vented systems
- Provide adequate air venting at all high points
- Maximum chlorine content of 200 mg/ 1
Take advice on the suitability of inhibitors for use with
aluminium boilers
MAX pH of 8.5 when using additives (max. pH of 9
without additives).
If water treatment is used, we recommend the following
products:
‘Copal’ manufactured by:
Fernox Manufacturing Company Ltd.
Britannia Works
Clavering
Essex, CB1L 4QZ
Tel No: 0179 955 0811
Fax No: 0179 955 0853
or:
Sentinal ‘X100’ manufactured by:
BetzDearborn Ltd
Sentinal
Foundry Lane
Widnes
Cheshire WA8 8UD
Tel No: 0151 424 5351
Fax No: 0151 420 5447
For the correct dosage and for further information on
water treatment or system cleaning we advise direct
contact with either of the above companies.
7.4.4 Safety valve
A safety valve should be fitted in accordance with BS
6644. The flow pipe on the Remeha Gas 310 ECO
includes a fitting, which can be used for a safety valve;
size 1½” BSP (F).
7.4.5 Water circulation
Provided that the factory pre-set high limit and flow
temperatures are not altered and the Remeha modulat-
ing controls are used no minimum flow rate is required
as the ‘abc®’ system will monitor these conditions and
reduce the boiler output, finally shutting down until flow
conditions improve. As a result, the boiler is virtually
unaffected by low water flow.
7.4.6 Thermostat pocket
A thermostat pocket (7 mm i/d plain pocket) is supplied
as standard in the flow pipe for an external control/ BMS
temperature sensor.
7.4.7 Noise production
The average noise level measured at 1-m distance
around the boiler is < 60 dBA at full output, avoiding the
need for additional acoustic measures.
7.5 Multiple boiler installation
The Remeha Gas 310 ECO can be installed individually
or in a multiple boiler installation. The narrow width and
depth of the boiler and its ability to be mounted closely
together provides a high output within a small floor area
(see fig. 05)
We recommend that boilers that are not in service are
disconnected from the water supply by means of throttle
valves or non-return valves.
A “DUO” version the Gas 610 (6 to 9 section only) will
also be as a dual cascade unit.
Advice and schematic drawings are available on
request, contact Broag Technical Dept.
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20
Remeha
Gas 310 ECO
Boiler side Installation side
1. OpenTherm or rematic®modulating cascade
controller
2. boiler pump
3. safety valve
4. non return valve
6. isolating valve
7. automatic air vent
8. low loss header
9. drain cock
10. system pump
11. expansion vessel system
12. flow temperature sensor
13. outside temperature sensor
fig. 11 Example hydraulic diagram cascade
configuration
pdf
fig. 12 Low loss header >500kW
00.W20.79.00040
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