REMEHA GAS 460 S Manual

GAS 460 S
Gas-fired boilers
Installation and
Service Manual
300005247-001-E
EN

2GAS 460 S 04/01/11 - 300005247-001-E
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.1 Used symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.2 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.3 Homologations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2 Safety instructions and recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.2 Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3 Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.2 Technical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.3 Main parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.4 Operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.1 Regulations governing installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.2 Package list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.3 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
4.4 Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.5 Gas connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.6 Connection to a chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.7 Electrical connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4.8 Skeleton Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
5 Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5.1 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5.2 Check points before commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5.3 Gas settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5.4 Checks and adjustments after commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
6 Stopping the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
6.1 Precautions to take if there is a danger of frost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
6.2 Precautions to take in the event of prolonged shutdown (one year or more) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
7 Checking and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
7.1 Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
7.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
8 Spare parts Gas 460 S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
8.1 Boiler body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
8.2 Base frame + Draught diverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
8.3 Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8.4 Control panel K. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
8.5 Control panel K + Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
8.6 Metal casing for control panel K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
8.7 Gas line 20 mbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
8.8 Circuit separation transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
8.9 Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

3
04/01/11 - 300005247-001-E GAS 460 S
1Introduction
1.1 Used symbols
Caution danger
Risk of injury and damage to equipment. Attention must be
paid to the warnings on safety of persons and equipment.
Specific information
Information must be kept in mind to maintain comfort.
ZReference
Refer to another manual or other pages in this instruction
manual.
DHW: Domestic hot water
1.2 General
Congratulations on your choice of a high quality product. We
strongly advise you to read the following instructions in order to
guarantee the optimal operation of your appliance. We are sure
that it will be entirely to your satisfaction and will meet with all
of your expectations.
`Keep these instructions in a safe place close to the appliance.
`For a proper operating of the boiler, follow carefully the
instructions.
`The manufacturer is not liable for any improper use of the
appliance or failure to maintain or install the unit correctly (the
user shall take care to ensure that the system is installed by a
qualified engineer).
`In the interest of customers, REMEHA are continuously
endeavouring to make improvements in product quality. All the
specifications stated in this document are therefore subject to
change without notice.

4GAS 460 S 04/01/11 - 300005247-001-E
1.3 Homologations
It is CE approved under the following number : 0085BL0187
The boilers are in compliance with the EC directives:
- Royal Decree dated 8th January 2004
- 90/396/EEC Gas Appliance Directive
- 2006/95/EC Low Voltage Directive
Reference Standard: EN 60.335.1
- 2004/108/EC Electromagnetic Compatibility Directive
Reference Standard: EN 50.081.1 ; EN 50.082.1 ; EN 55.014
- 92/42/EEC Efficiency Directive ** 1,
Low temperature gas boiler
- Type B11 (B11BS if fitted with the optional combustion products
discharge control system).
France:
Performance class III boiler according to ATG B 84
recommendations.
Belgium:
The boilers comply with the specifications of the HR+ quality label.
The boilers should be fitted with a 160 VA circuit separation
transformer (delivered with the documentation package).
1.3.1 Directive 97/23/EC
Gas and oil boilers with a maximum operating temperature of 110°C
and hot water tanks with a maximum operating pressure of 10 bar
pertain to article 3.3 of the directive, and therefore, cannot be CE-
marked to certify compliance with the directive 97/23 EC.
The boilers and hot water tanks are designed and manufactured in
accordance with the sound engineering practice, as requested in
article 3.3 of the directive 97/23/EC; it is certified by compliance with
the directives 90/396/EC, 92/42/EC, 2006/95/EC and 2004/108/EC.
1.3.2 User country
The boilers leave the factory operating with H natural gas.
User country ES, GB HU
Category I2H I2H
Gas type G20 G20
Distribution pressure (mbar) 20 25

5
04/01/11 - 300005247-001-E GAS 460 S
2 Safety instructions and recommendations
2.1 Safety instructions
Fire hazard
Do not stock products of an inflammable nature close to
the appliance.
If you smell gas, do not use a naked flame, do not smoke,
do not operate electrical contacts or switches (doorbell,
lights, motor, lift, etc.).
1.Isolate the gas supply
2.Open the windows
3.Extinguish all flames
4.Evacuate the premises
5.Contact a qualified professional
6.Inform the gas supplier
Risk of intoxication
Do not obstruct the air inlets in the room (even partially).
If you smell flue gases
1.Switch the appliance off
2.Open the windows
3.Evacuate the premises
4.Contact a qualified professional
Risk of being burnt
Avoid direct contact with the flame viewport.
Depending on the settings of the appliance:
- The temperature of the flue gas conduits may exceed 60°C
- The temperature of the radiators may reach 95°C
- The temperature of the domestic hot water may reach 65°C
Risk of damage
Do not stock chloride or fluoride compounds close to the
appliance.
Install the appliance in frost-free premises.
Do not neglect to service the appliance: Contact a qualified
professional or take out a maintenance contract for the annual
servicing of the appliance.
2.2 Recommendations
Only qualified professionals are authorised to work on the
appliance and the instalation.
Before any work, switch off the mains supply to the
appliance.
Check regularly that the installation contains water and is
pressurised.
Keep the appliance accessible at all times.
Avoid draining the installation.
The appliance should be on Summer or Antrifreeze mode rather than
switched off to guarantee the following functions:
- Frost protection
- Protection against corrosion on domestic hot water tanks fitted
with a titanium anode

6GAS 460 S 04/01/11 - 300005247-001-E
3 Technical description
3.1 General description
Gas 460 S boilers are made of cast iron:
- with atmospheric gas burners
- with 2 operating stages
- with electronic ignition via the ignition burner for hot water central
heating
- with a useful output of between 119 and 380 kW
They are designed to be connected to a chimney.
The figure given after Gas 460 S indicates the number of sections
which make up the boiler.
Gas 460 S boilers are delivered with a K control panel. They can be
fitted with an optional RC4 and RC5 control unit (master-secondary
control unit options).
3.2 Technical characteristics
The boilers can operate on natural gases type H/L.
(1) at 2nd stage
1 mbar = 10 mmWG = 10 daPa = 100 Pa
Boiler Gas 460 S / 810 12 14 16 18 20
Useful output 1st stage kW 83-98 107-126 131-154 155-182 179-210 202-238 226-266
2nd stage kW 119-140 153-180 187-220 221-260 255-300 289-340 323-380
Power input
1st stage kW 93.1-
108.9
119.4-
139.7
145.6-
170.4
171.9-
201.1
197.9-
231.8 224-262.1 250.1-
292.6
2nd stage kW 131.1-153 168.2-
196.3
205.2-
239.4
242.2-
282.6
278.8-
325.4
315.7-
368.4
352.4-
411.3
Numberofsections Part 8 101214161820
Mass flue gas flow rate (1) kg per
sec 0.097 0.127 0.144 0.177 0.191 0.203 0.258
Flue gas temperature Tf
Boiler temperature 80°C °C 125 123 130 126 133 140 126
CO2
1st stage %3.9-4.9 3.8-4.8 4.3-5.3 4.0-5.0 4.5-5.5 5.0-6.0 4.0-5.0
2nd stage 5.4-6.4 5.3-6.3 5.8-6.8 5.5-6.5 6.0-7.0 6.5-7.5 5.5-6.5
Ionization current µA 1.0
Required depressurisation at the
nozzle daPa 0.7
Minimum outlet temperature °C 40
Maximum outlet temperature °C 90
Maximum operating pressure bar 6
Electrical connection V/Hz 230/50
Electrical power W 108 / 114 maximum
Gas connection 20 mbar inch 1" 1" 1" 1"1/4 1"1/4 1"1/4 1"1/2
Heating connection inch 2"
Internal diameter flue gas nozzle mm 250 300 300 350 350 350 400
Water resistance (1)
∆T = 10K
mbar
80 133 198 277 369 474 592
∆T = 15K 36 59 88 123 164 211 263
∆T = 20K 20 33 50 69 92 118 148
Water content* l 61 76 91 106 122 137 154
Shipping weight kg 668 807 934 1096 1227 1364 1476

7
04/01/11 - 300005247-001-E GAS 460 S
3.3 Main parts
1Control panel
2Safety box
The safety control box is fitted to the control panel and controls the
burner ignition, function and extinction sequences.
3Multivalve gas unit:
It includes a safety valve and a 2-stage principal valve with filter and
minimum gas pressure switch.
4Ignition burner valve
5Ignition burner
6Flame inspection window
7Ionization probe: It detects flame presence on the ignition burner by
flame ionization.
8Ignition electrode: This ensures ignition burner ignition using a high
voltage spark.
9Minimum gas pressure switch
(Minimum pressure: 12.5 mbar)
10 Ignition box

8GAS 460 S 04/01/11 - 300005247-001-E
3.4 Operating principle
3.4.1 Furnace operation equipped with safety box RV 00 541 400 00
Operating principle
The boiler can operate at either 2nd stage or 1st stage depending on
the thermal needs of the installation.
The ignition and burner surveillance sequences are ensured by the
safety box.
Behaviour in normal conditions
The box closes the TCH contact when there is a requirement for
heat1. The safety control box runs an auto-check of around 1
second(s).
After a waiting time tw, the ignition transformer TA produces a series
of sparks at the ignition electrode. After a pre-ignition period tvz, the
ignition burner valve VG and the safety valve VS open. Formation of
flame in ignition burner. The ionization sensor SF shows a flame
signal with a minimum ionization current of 1 µA and ignition is shut
down. After a period of stabilisation tstab, the principal burner ignites
at 1st stage BR1 (or at 2nd stage if the 2nd stage thermostat TCH2
is needed).
Behaviour in abnormal conditions
- If a flame is not detected before the safety time ts, the box makes
2 more ignition attempts. If, at the end of the last attempt, there is
still no flame signal, the box goes into safety and the safety
indicator comes on. To restart the heater, press the reset button on
the safety box.
- If there is a loss of flame in normal operation, the box automatically
repeats the start up sequence.
Resetting
The box is reset after going into safety by pressing the reset button.
If the reset button does not work, wait at least 15 seconds before
trying a second time. After activating the reset button, the warning
light goes out and the safety control box restarts after a waiting time
of around 1 minute.
Note 1: The box may be on safety on its first start up: press the reset
button to release it.
Note 2: If the reset button is pressed in normal operation, the gas
valves close and the box starts a new ignition sequence.
Required input signals
Box output signals
Thermostatic request at 2nd stage
Operation 2nd stage
AStart of operation
BFormation of flame in ignition burner
BR1 1st stage
BR2 2nd stage
SF Burner flame signal
TA Ignition transformer
TCH1 Boiler thermostat 1 stage
TCH2 Boiler thermostat 2 stage
VA Safety lockout warning light
VG Ignition burner valve + Safety valve VS
ts Safety time: maximum 10 seconds
tstab Flame stabilisation time: 5 seconds
tvz Pre-ignition time: 10 seconds
tw Waiting time: 0 seconds
8358N016B
8358N017C

9
04/01/11 - 300005247-001-E GAS 460 S
4 Installation
4.1 Regulations governing installation
4.1.1 Other countries
Installation and maintenance of the boiler must be carried out by a
qualified professional in compliance with prevailing local and national
regulations.
4.2 Package list
ZAssembly Instructions

10 GAS 460 S 04/01/11 - 300005247-001-E
4.3 Mounting
4.3.1 Position of the boiler
* Water connection side
- The combustive air must reach the burner from the front.
- The dimensions (in mm) correspond to the minimum
recommended dimensions needed to ensure adequate
accessibility around the boiler.
- Dimensions aand bcorrespond to the dimensions to be respected
to ensure clearance of the assembly tool JD-TE Plus.
If a = 1400 mm , b = 500 mm
If a = 500 mm , b = 1400 mm
It is forbidden to store inflammable products and materials
in the boiler room or close to the boiler, even temporarily.
A safety distance of at least 2 metres should be respected.
(1) Thickness of a section
5
0
0
1006
10
0
0
4
00*
20
0
2002 mini
1406
A
1
2
Gas 460 /... 810 12 14 16 18 20
A (mm) 970 1146 1322 1498 1674 1850 2026
B (mm) 938 1114 1290 1466 1642 1818 1994
C(1) (mm) 704 880 792 880 968 1056 1760
D
Side section
(mm) 704 704 704 704 704 704 704
Intermediate
section 720 720 720 720 720 720 720

11
04/01/11 - 300005247-001-E GAS 460 S
4.3.2 Ventilation
The location of air inlets in relation to the high ventilation openings
shall ensure that the air is renewed in the entire volume of the boiler
room.
Please refer to the prevailing regulations in your country.
`France:
Direct air inlet:
• Boiler with nominal output greater than 70 kW in accordance
with DTU 65.4 (NF P 52-221)
Upper and lower air vents compulsory
- Upper air vents

Cross section equal to half the total cross section of the flue gas
pipes with a minimum of 2.5 dm²
- Lower air vents

Direct air inlet:
P = Installed output in kW
Ensure a supply of air through the front of the burner but
avoid serious draughts.
Bottom aeration, even correctly dimensioned but positioned to the
rear of the boiler close to the draught diverter, may turn out to be
totally ineffective.
Incoming air is directly drawn in by the draught cut off without
reaching the burner.
An indirect air inlet through descending conduits presenting serious
airotic losses of load or input of meteorological conditions influencing
their draw should be avoided.
4.3.3 Main dimensions
Heating outlet R 2
Heating return R 2
Draining Rp 3/4
4.3.4 Assembling the appliance
ZSee assembly instructions
Sdm
2
()
086P,
20
--------------
≥
1406
B
H
= =
ø C
D
64
G
J
410
375
130
A
1006
130
E
60
ø F
8358N061A
1
2
3
Boiler Gas 460 S /8 /10 /12 /14 /16 /18 /20
A (mm) 1362 1362 1362 1412 1412 1412 1462
B (mm) 970 1146 1322 1498 1674 1850 2026
Ø C (mm) 250 300 300 350 350 350 400
D (mm) 632 808 984 1160 1336 1512 1688
E (mm) 165 165 165 190 190 190 220
Ø F (mm) (20/25 mbar) Rp1 Rp1 Rp1 Rp1 1/4 Rp 1 1/4 Rp 1 1/4 Rp 1 1/2
Ø F (mm) (300 mbar) Rp 3/4
G 447 535 623 704 792 880 963
H 445 445 445 454 454 454 507
J 1094 1094 1094 1194 1194 1194 1194

12 GAS 460 S 04/01/11 - 300005247-001-E
4.4 Hydraulic connections
4.4.1 Regulations
Installation must be carried out in accordance with the prevailing
regulations, the codes of practice and the recommendations in these
instructions.
Installing the boiler in new installations
(installations less than 6 months old)
- Clean the installation with a universal cleaner to eliminate debris
from the appliance (copper, flaxen thread, flux).
- Thoroughly flush the installation until the water runs clear and
shows no impurities.
Installing the boiler in existing installations
- Remove sludge from the installation.
- Flush the installation.
- Clean the installation with a universal cleaner to eliminate debris
from the appliance (copper, flaxen thread, flux).
- Thoroughly flush the installation until the water runs clear and
shows no impurities.
4.4.2 Hydraulic connection of the heating circuit
GDraining Rp 3/4
HHeating outlet R 2" (1)
IHeating return R 2" (1)
(1) Welded connection possible after sawing off the threading.
The hydraulic connections must be made on the same side (either
right or left) but never in quincunx.
Install a sludge decanting pot on the return pipe, very close to the
boiler.
H
I
G

13
04/01/11 - 300005247-001-E GAS 460 S
4.5 Gas connection
Gas connection is possible to the right or left of the boiler.
It is necessary to abide by the prevailing instructions and regulations.
Each time, a blocking tap will be located as near as possible to the
heater. A gas filter must be fitted to the boiler inlet.
Other countries
The diameters of the pipes must be defined in accordance with the
standards in force in your country.
4.6 Connection to a chimney
Good
Poor
A40 mm (minimum)
The appliance must be installed in accordance with the Codes of
Practice using a leak proof pipe made of a material capable of
withstanding hot combustion gases and any acidic condensation.
The pipe must be laid out to allow any likely condensation to drain.
It must be in accordance with existing regulations for pipes used for
this purpose. Standard meshed connection pipes are to be avoided.
The pipe connecting the outlet conduit must also be as short as
possible and without a reduced diameter.
The vertical section of the draught diverter outlet must be a minimum
length 3x the diameter of the nozzle before an elbow joint is fitted.
The pipe must have a diameter not less than the heater's nozzle
diameter along its whole length. This pipe must be able to be easily
disassembled and must not have a sudden change in diameter.
The outlet conduit must be maintained in a good condition, checked
and cleaned at least once a year.
12
A

14 GAS 460 S 04/01/11 - 300005247-001-E
4.7 Electrical connections
Only qualified professionnals may carry out electrical
connections, always with the power off.
Do not modify the connections inside the control panel.
Make the electrical connections of the appliance according to:
- the instructions of the prevailing standards,
- the instructions on the circuit diagrams provided with the
appliance,
- the recommendations in the instructions.
Standards to be respected
Other countries: The electrical connections shall comply with
standards in force.
Rules to be respected
- Power the appliance via a circuit which includes a remote
omnipolar switch with a gap of more than 3 mm.
- Connect all of the cables to the terminal blocks in the control panel.
Keep to the polarity shown on the terminals: phase (L),
neutral (N) and earth 4.
The available output per outlet is 450 W (2 A, with cos ϕ=
0.7) and the inrush current must be lower than 16 A.
If the charge exceeds one of these values, relay the
command using a contactor (fitted outside the control
panel).
Separate the sensor cables from the 230 V cables.
Outside the boiler : Use 2 pipes or cable guides at least
10 cm apart.
For the 230 V electrical connections, use 3-wire cables with a cross-
section of 0.75 mm². For other electrical connections, use the 3 wire
cable with a diameter of 0.75 mm².
Make the electrical connections:
ZControl panel instructions.
ZOptions brochure.
4.8 Skeleton Diagrams
ZControl panel instructions

15
04/01/11 - 300005247-001-E GAS 460 S
5 Start-up
Initial commissioning must be done by a qualified
professional.
5.1 Control panel
ZControl panel instructions
5.2 Check points before commissioning
The first start-up is to be performed by your installation/
commissioning engineer.
Make the gas line setting before commissioning.
Check the following points before starting the heater:
Hydraulic circuit:
`Check that the installation and boiler are adequately filled with
water and correctly irrigated and bled.
`Check that there are no leaks on the hydraulic connections.
Gas circuit:
`Check the adjustment of the gas line:
- Connect a manometer to the pressure socket located on the
manifold.
- Check that the nozzle pressure and the start-up pressure match
the pressures given in the relevant chapter: Pressure settings and
calibrated injector markings.
If necessary, adjust the pressure as shown in the relevant
chapters: Setting the injector pressure.
Electrical connectors:
Check that the connectors under the control panel are correctly fitted:
5.3 Gas settings
The boilers are factory-set to operate on natural gas H (G20 - 20
mbar).
To convert it to natural gas L, use the gas L conversion kit (optional).
Carry out the operations described below.
1 Ignition circuit
2 Gas pressure switch
3 Gas valve circuit
4 Leak proofing system (Options RE 30)

16 GAS 460 S 04/01/11 - 300005247-001-E
5.3.1 Changing the burner injectors
- Close the gas valve.
- Lift out the injector with a number 12 spanner assemble the new
injectors with their new joint.
First tighten the injectors by hand and carefully lock them using
a spanner.
- Carry out a leak tightness check.
Natural gas H Natural gas L
Nozzle marking 390A 450A
Nozzle diameter 3.9 mm 4.5 mm

17
04/01/11 - 300005247-001-E GAS 460 S
5.3.2 Changing the ignition burner injector
Operations to be carried out to convert from natural gas H to natural
gas L and vice versa:
Remove the gas supply pipe from the ignition burner (13 mm
spanner).
Remove the nozzle + seal.
Unscrew the nozzle using a screwdriver and screw in the new
injector.
- Reassemble the parts
- Carry out a leak tightness check
Natural gas H Natural gas L
Nozzle marking 80 100
Nozzle diameter 0.80 mm 1.00 mm

18 GAS 460 S 04/01/11 - 300005247-001-E
5.3.3 Setting the injector pressure
•Setting the pressure 2nd stage
The pressure must be set by a qualified professional.
The boiler must be commissioned after having checked the points
covered in this chapter: Check points before commissioning.
- Connect a manometer to the pressure outlet.
- Run the boiler at 2nd stage, activating the thermostat(s).
- Set the pressure at the injectors as follows:
- Free the cylindrical split head screw C by around one turn. Fully
unscrew the setting button
D (anti-clockwise). Tighten the screw
C .
- Set the pressure at the injectors by turning the screw on the
regulator
B . By turning to the right, you increase and, by turning to
the left, you decrease the principal flow.
If you find you cannot tighten screw Bany further before
reaching the desired pressure, unscrew Bagain by a quarter
turn and continue the setting by turning Dafter freeing the
inhibitor screw C.
- On propane, the regulator Bis fully tightened. It is not used.
• Setting the pressure 1st stage
- Run the boiler at 1st stage by activating the burner on selector
switch on the boiler control panel.
- Set the flow in such a way as to obtain pressure at the injectors (0.5
x Pressure 2nd stage):
- Set the 1st stage flow with the ring E .
- By turning to the right, you increase and, by turning to the left, you
decrease the principal flow.
- Tighten the inhibitor screw
C .

19
04/01/11 - 300005247-001-E GAS 460 S
•Setting the start-up progressivity (or initial flow)
In the factory, the progressivity is set to minimum (low start-up
pressure).
Depending on the installation conditions, adjust the progressivity
setting in order to guarantee optimum boiler start-up.
- Unscrew the protection cap G. Use like a spanner to turn the
setting rod Huntil you obtain the desired initial flow.
- Put the cap back in place.
5.3.4 Setting the gas pressure switch
The minimum gas pressure switch on the safety valve is set in the
factory to a value of 12.5 mbar, which corresponds to the setting for
natural gas.
If there is a drop in the gas supply pressure, the minimum pressure
switch shuts down the boiler.
5.3.5 Attaching the label
Affix the label which indicates for which type of gas the boiler is fitted
and set.
A0026
02
10
15

20 GAS 460 S 04/01/11 - 300005247-001-E
5.3.6 Pressure settings and calibrated injector markings
1 mbar = 10 mmWG = 10 daPa = 100 Pa
mmWG = mm of Water Gauge
15 °C - 1013 mbar
5.4 Checks and adjustments after commissioning
Carry out all the checks mentioned in the chapter "Checking and
maintenance".
Boiler type Gas 460 S / 810 12 14 16 18 20
Useful output
1st stage kW 83-98 107-126 131-154 155-182 179-210 202-238 226-266
2nd stage kW 119 - 140 153 - 180 187 - 220 221 - 260 255 - 300 289 - 340 323 - 380
Power input
1st stage kW 93.1-108.9 119.4-139.7 145.6-170.4 171.9-201.1 197.9-231.8 224-262.1 250.1-292.6
2nd stage kW 131.1-153 168.2-196.3 205.2-239.4 242.2-282.6 278.8-325.4 315.7-368.4 352.4-411.3
Nozzle
Diameter, principal burner injector
Gas H mm 3.9
Diameter, principal burner injector
Gas L mm 4.5
Diameter, ignition
burner injector
Gas H mm 0.8
Gas L mm 1.0
Gas flow rate
Gas H 1st stage m3/h 9.85-11.52 12.63-14.78 15.41-18.03 18.19-21.28 20.94-24.53 23.70-27.74 26.47-30.96
2nd stage 13.87-16.19 17.80-20.77 21.71-25.33 25.63-29.91 29.50-34.43 33.41-38.98 37.29-43.52
Gas L 1st stage m3/h 11.46-13.40 14.70-17.19 17.92-20.97 21.16-24.75 24.36-28.53 27.57-32.26 30.78-36.01
2nd stage 16.14-18.83 20.70-24.16 25.26-29.46 29.81-34.78 34.31-40.05 38.86-45.34 43.37-50.62
Downstream gas pressure
Gas H 1st stage mmWG Pressure 1st stage = 0.5 x 2nd stage pressure set
2nd stage 90-120
Gas L 1st stage mmWG Pressure 1st stage = 0.5 x 2nd stage pressure set
2nd stage 74-100