REMEHA Gas 550 Manual

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• Atmospheric gas boiler
• 278 - 1058 kW
Remeha Gas 550/550 Duo
echnical information
Remeha Gas 550/550 Duo

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Remeha Gas
550/550 Duo
2
ABLE OF CON EN
Preface 3
1 Boiler description 3
2 Construction details 3
2.1 General 3
2.2 Burners 3
2.3 Assembly 3
3 dimensions and echnical data 4
3.1 Dimensions Remeha Gas 550 4
3.2 Dimensions Remeha Gas 550 Duo 6
4 Application information 7
4.1 L.P.H.W. sys em 7
4.1.1 Wa er empera ure 7
4.1.2 Wa er pressure 7
4.1.3 Wa er flow 7
4.1.4 Wa er rea men 7
4.1.5 Noise level 8
4.2 Chimneys 8
4.3 Ins alla ion s andards 8
5 ypical boiler installations 9
5.1 Ins alla ion 1 9
5.2 Ins alla ion 2 10
6 Control and safety equipment 11
6.1 General 11
6.2 Ins rumen panel 11
6.3 S andard elec ronic gas rain High/Low 11
6.3.1 Schema ic 11
6.3.2 Con rol panel on gas rain 11
6.3.3 Specifica ion con rol box 11
6.3.4 Specifica ion Igni ion ransformer 12
6.4 Func ions 12
6.4.1 Flame con rol (lock ou ) 12
6.4.2 Thermos a s (shu down / lock ou ) 12
6.4.3 Wa er level con rol (lock ou ) 12
6.4.4 Valve leakage con rol - op ional
( lock ou ) 12
6.4.5 Gas pressure swi ch LD - op ional
(shu down) 12
6.4.6 Gas pressure swi ch HD - op ional
(lock ou ) 12
6.4.7 Down draf hermos a ;
(op ional, shu down) 12
7 Assembly and installation guidelines 13
7.1 General 13
7.2 Boiler assembly 13
7.3 Wa er connec ions 13
7.4 Pocke for he hermos a capillaries 13
7.5 Wa er pressure 13
8 Gas supply 13
8.1 General 13
8.2 Gas pressure 13
8.3 Injec ors 13
9 Electrical supply 14
9.1 General 14
9.2 Ins rumen panel 14
9.3 Con rol panel 14
9.4 Elec rical connec ions 14
9.5 Elec rical informa ion 14
9.6 Wa er level con rol 14
9.7 Wiring diagrams 15
10 Commissioning 16
10.1 Swi ching off he boiler 18
11 Maintenance 18
12 rouble shooting 19
12.1 Faul causes 19

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PREFACE
These echnical ins ruc ions con ain useful and impor-
an informa ion for he correc opera ion and main enan-
ce of he Remeha boiler, model Gas 550 and Gas 550
Duo.
Read hese ins ruc ions carefully before pu ing he boi-
ler in o opera ion, familiarise yourself wi h i ’s con rol
func ions and opera ion, s ric ly observing he ins ruc i-
ons given. Failure o do so may invalida e warran y or
preven he boiler from opera ing.
The ins alla ion and commissioning of he boiler mus be
carried ou by a compe en Engineer, wi h he relevan
cer ifica ion i.e.: CORGI, ACOPS, IEE regs. e c.
On comple ion a copy of he boiler log / commissioning
shee should be re urned o Broag L d for record purpo-
ses.
If you have any ques ions, or if you need more informa-
ion abou specific subjec s rela ing o his boiler, or i ’s
ins alla ion please do no hesi a e o con ac us.
The da a published in hese echnical ins ruc ions is
based on he la es informa ion (a da e of publica ion)
and may be subjec o revisions.
We reserve he righ o con inuous developmen in bo h
design and manufac ure, herefore any changes o he
echnology employed may no be re rospec ive nor may
we be obliged o adjus earlier supplies accordingly.
1 BOILER DESCRIP ION
The Remeha Gas 550 series boiler is a cas iron
sec ional boiler, wi h a powder coa ed enamel s eel
casing complee wi h glass fibre insula ion.I has high /
low a mospheric gas burners, sui able for na ural gas,
ca . I 2 H - 20 mbar.
I is supplied in sec ions for delivery and on si e assem-
bly.
The boiler mee s he requiremen s of he CE regula ions
a he following direc ives:
- Gas appliance direc ive no. 90/396/EEC;
- Efficiency direc ive no. 92/42/EEC;
- E.M.C. direc ive no. 89/336/EEC.
And is corresponden wi h:
- Elec rical low vol age direc ive no. 73/23/EEC.
Remeha Gas 550 (Duo)-reference number: 0063AP6520
Classifica ion ype for evacua ion of he combus ion pro-
duc s, according: EN-656: B11, B11BS.
For fur her advice or informa ion con ac Broag L d.
2 CONS RUC ION DE AILS
2.1 General
The Remeha Gas 550 / 550 Duo is a floor s anding
boiler comple e wi h empera ure and safe y con rols.
The cas iron sec ional hea exchanger is assembled
using conical nipples and join ing compound.The boiler
has a buil in draf diver er. I has wa er connec ions a
he side wi hin he casing dimensions and a gas rain
o one side.
Note: Bo h wa er and gas connec ions can be handed
on si e during assembly. Bu he ins rumen panel,
moun ed in he fron casing should always be fi ed on
he same side as he flow connec ion.
The casings can be fi ed af er he flue and pipework o
he boiler have been ins alled and connec ed.
2.2 Burners
The burners are s ainless s eel, a mospheric ype wi h a
hea reflec ing floor pla e providing he correc ven ila ion
dis ribu ion. Fron and op access is required for service
work o be carried ou .
Note: The Gas 550 Duo has wo comple e boiler uni s
wi hin one casing using a common flue connec ion.
2.3 Assembly
The boiler canno be supplied pre-assembled and mus
be assembled on si e.

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3 DIMENSIONS AND ECHNICAL DA A
3.1 Dimensions Remeha Gas 550
Fig. 01 Dimensions Remeha Gas 550
00.05F.79.00002
Flow Ø107 int.
Return Ø107 int.
Gas 2"
Flue gas Ø

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Number of sections 10 12 14 16 18 20 22
Nominal heat
output kW 139-278 170-340 202-403 233-466 265-529 296-592 328-656
Hi /
NCV kW 160-309 195-378 232-448 266-518 301-588 337-657 372-728
Nominal
heat input Hs /
GCV kW 177-343 217-420 256-498 296-576 335-653 374-730 414-809
Gas consumption m3/h 33 40 47 55 62 70 77
B mm 1240 1460 1680 1900 2120 2340 2560
Ø D mm 300* 350* 400* 450 450* 500 500*
E mm 1295 1295 1295 1295 1295 1295 1245
Dimensions
H mm 1730 1730 1730 1610 1730 1610 1730
Flue temperature °C 154 152 146 138 138 142 142
=
10°C mbar 64 72 80 128 160 180 196
Water
resistance =
20°C mbar 16 18 20 32 40 45 49
Water contents li re 291 349 407 465 523 581 639
Boiler weight (dry) kg 1450 1695 1940 2185 2430 2675 2920
Flue gas flow rate kg/h 692 847 1033 1239 1376 1560 1678
Table 01 Technical data Remeha Gas 550
Supplied with a flue gas pipe adapter
∆
∆

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550/550 Duo
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3.2 Dimensions Remeha Gas 550 Duo
Fig. 02 Dimensions Remeha Gas 550 Duo
00.05F.79.00003
Flow Ø107 int.
Return Ø107 int.
Gas 2"
Flue gas Ø

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Number of sections 2 x 10 2 x 12 2 x 14 2 x 16 2 x 18
Nominal heat
output kW 139-556 170-680 202-806 233-932 265-1058
Hi /
NCV kW 160-618 195-756 232-896 266-1036 301-1176
Nominal
heat input Hs /
GCV kW 177-686 217-840 256-996 296-1152 335-1306
Gas consumption m3/h 66 80 94 110 124
B mm 1240 1460 1680 1900 2120
Dimensions
Ø D mm 450* 500* 600* 650 650*
Water contents litr 582 698 814 930 1046
Boiler weight dry) kg 2900 3390 3880 4370 4620
Flue gas flow rate kg/h 1385 1694 2066 2478 2752
Table 02 Technical data Remeha Gas 550 Duo
Supplied with a flue gas pipe adapter
4 APPLICATION INFORMATION
4.1 L.P.H.W. system
4.1.1 Water temperature
Maximum wa er empera ure is 110°C (high limi her-
mos a ).
Highes boiler wa er empera ure is 95°C (con rol her-
mos a ).
Minimum re urn wa er empera ure is 20°C a a flow ra e
rela ed o a ∆ of 20°C (flow/re urn emp).
4.1.2 Water pressure
Boiler sec ions are fac ory pressure es ed a 10 bar.
Maximum pressure es boiler block is 7,8 bar.
Maximum working pressure is 6 bar
Minimum working pressure is 0,8 bar a a maximum
working empera ure of 110°C or 0,3 bar a a maximum
working empera ure of 95°C.
4.1.3 Water flow
The minimum wa er flow hrough he boiler on shu down
is:
Ou pu boiler in kW = m3/h
93
This minimum flow mus be main ained for approxima-
ely 5 minu es af er he burner s ops firing o avoid high
empera ure shu down due o residual hea gain.
Due o he design and manufac ure of he boiler no
specific minimum wa er flow requiremen s exis o her
hen for overhea ing pro ec ion.
4.1.4 Water treatment
The sys em should be filled wi h mains cold wa er (for
he UK his will usually have a pH of be ween
7 and 8).
Pressurised ins alla ions wi h a boiler/sys em con en
ra io of 1:10 or less should no require wa er rea men ,
provided ha he following condi ions apply:
1. The sys em is flushed horoughly o remove all fluxes
and debris and hen filled comple ely once.
2. Make up wa er is limi ed o 5 % per annum.
3. The hardness of he wa er does no exceed 360 ppm
(20°D).
All scale deposi s will reduce he efficiency of he boiler
and should be preven ed. However provided he above
is complied wi h any scale produced will no be oo
de rimen al o he boiler efficiency and will no reduce
he an icipa ed life expec ancy of he boiler.
Note: Scale deposi s in excess of 3 o 5 mm will reduce
boiler efficiency and grea ly increase he risk of prema-
ure cas ing failure.

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550/550 Duo
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As most syst ms contain a vari ty of m tals which can
r act with ach oth r to caus corrosion. It is con-
sid r d good practic to provid som form of wat r
tr atm nt ( sp cially in op n v nt d syst ms) in ord r to
pr v nt or r duc th following:
- M tallic corrosion;
- Formation of scal and sludg ;
- Microbiological contamination;
- Ch mical chang s in th untr at d syst m wat r.
Suitabl ch micals and th ir us should b discuss d
with a sp cialist wat r tr atm nt company prior to car-
rying out any work. Th sp cification of th syst m
and manufactur rs r comm ndations must b tak n into
account, along with th ag and condition of th syst m.
N w syst ms should b flush d thoroughly to r mov all
trac s of flux, d bris, gr as and m tal swarf g n rat d
during installation. Car to b tak n with old syst ms
to nsur any black m tallic iron oxid sludg and oth r
corrosiv r sidu s ar r mov d, again by thoroughly
flushing, nsuring that th syst m is drain d compl t ly
from all low points.
Note: Pl as nsur that th n w boil r plant is not
in circuit wh n th flushing tak s plac , sp cially if
cl ansing ch micals ar us d to assist th proc ss.
Under no circumstances is the boiler to be operated
with cleaning chemicals in the system.
To Summarise:
- Minimis wat r loss;
- Pr v nt pumping ov r in op n v nt d syst ms;
- Provid ad quat air v nting at all high points;
- K p pH l v l b tw n 7 - 9 wh n using additiv s;
- Maximum chlorin cont nt of 200 mg/l;
Tak advic on th suitability of inhibitors.
4.1.5 Noise level
Th nois l v l m asur d around th boil r d p nding
on boil r room construction is about 50-55 dBA. Nois
l v ls tak n at 1 m t r from th boil r.
4.2 Chimneys
Th av rag flu gas t mp ratur is so low that th
chimn y must b mad in accordanc with th guid -
lin s of British Gas (BS 6644).
4.3 Installation standards
Th following instructions must b adh r d to wh n th
R m ha Gas 550/550 Duo is install d:
Gas Saf ty (installation and us ) R gulations 1984 (as
am nd d).
In addition to th abov r gulations, this boil r must b
install d in complianc with:
- Curr nt I.E.E. R gulations for l ctrical installations
- Local building r gulations
- Th Building Standards (Scotland)
- (Consolidation) R gulations
- By-laws of th local wat r und rtaking
- H alth and Saf ty Docum nt No 635 ‘Th El ctricity
at Work R gulations 1989’.
It should also b in accordanc with th r l vant r com-
m ndations in th curr nt ditions of th following British
Standards and Cod s of Practic , viz. BS 5440 Pt 1 and
2, BS 5449, BS 5546,
BS 6798, BS 6891 and BG.DM2.
Lawfully all gas applianc s must b install d by comp -
t nt p rsons ( .g. Corgi, ACOPS).
Failur to install applianc s corr ctly could l ad to
pros cution.
It is in your own int r st and that of saf ty to nsur that
th law is compli d with.
Important:
Th R m ha Gas 550/550 Duo is a c rtifi d applianc
and must not b modifi d or install d in any way con-
trary to th s ‘Installation and S rvicing Instructions’.
Manufactur r instructions must NOT b tak n in any way
as wh n ov rriding statutory obligations.

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5 TYPICAL BOILER INSTALLATIONS
5.1 Installation 1
R comm nd d layout for boil r installation, m asur -
m nts in mm.
centre of nipple
holes
floor area
Fig. 03 Remeha Gas 550
00.05F.79.00004
number of sections 10 12 14 16 18 20 22
Size A 965 1185 1405 1625 1845 2065 2285
Size Ø D 300 350 400 450 450 500 500
Size B 1240 1460 1680 1900 2120 2340 2560
Size E 1295 1295 1295 1295 1295 1295 1245
Size H 1730 1730 1730 1610 1730 1610 1730

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550/550 Duo
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5.2 Installation 2
R comm nd d layout for boil r installation, m asur -
m nts in mm.
centre of nipple holes
floor area
number of
sections
Fig. 04 Remeha Gas 550 Duo
00.05F.79.00005
size A
size ØD
number of sections 10 12 14 16 18
Size A 965 1185 1405 1625 1845
Size Ø D 450 500 600 650 650

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6 CONTROL AND SAFETY EQUIPMENT
6.1 General
Th R m ha Gas 550 is suppli d with l ctronic control
and saf ty quipm nt with ionisation flam d t ction.
6.2 Instrument panel
Th R m ha Gas 550 is suppli d with an instrum nt
pan l mount d in th front of th boil r, ith r l ft or
right. All conn ctions ar pr -wir d and fitt d with plugs.
Th capillari s from th instrum nt pan l should b
fitt d in th th rmostat pock t of th boil r flow con-
n ction, which is fitt d in th top front of th nd s ction.
Th instrum nt pan l and th flow conn ction with th r-
mostat pock t should always b fitt d on th sam sid
of th boil r, ith r l ft or right.
Fig. 05 Instrument panel
04.05F.79.00001
Th instrum nt pan l contains:
1. Op rating switch (On/Off);
2. Control th rmostat On/Off, rang 35°C-95°C;
3. Control th rmostat High-Low, rang 35°C-95°C;
4. Hour run m t r total running hours (option);
5. Hour run m t r full load hours (option);
6. Analogu th rmom t r for flow t mp ratur ;
7. High – limit th rmostat pr s t to 110°C;
8. Lock out warning lamp;
9. Option for rematic® w ath r comp nsator;
10. R s t for wat r l v l control.
Th Instrum nt pan l mount d in th front casing also
contains circuit boards for:
- Wat r l v l control (s §9.6);
- Common alarm and op rating signal.
6.3 Standard electronic gas train High/Low
6.3.1 Schematic
Fig. 06 Schematic layout gas train
04.05F.AP.00001
L g nd
A Gas cock
AB Pilot burn r
DR Gas pr ssur r gulator
F Gas filt r
HB Burn rs
MK Pilot gas valv
MP M asuring point
VA Saf ty shut off valv
OT Ignition transform r
VB Ionisation prob
MB Gas multibloc valv
- - - Not suppli d as standard
6.3.2 Control panel on gas train
Th instrum nt pan l is link d to th control pan l on
gas train by m ans of a cabl and conn ctor. If r quir d
th control pan l (and gas train) can b fitt d on th
opposit sid of th boil r by using xt nsion cabl s
(option).
Fig. 07 Front of Control panel
04.05F.79.00002
1. Control box Satronic MMI 816;
2. Ignition transform r Satronic ZT 870;
3. Op ration r port circuit board.
12
3

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6.4.3 Water level control lock out)
Th boil r is quipp d with a wat r l v l s nsor to
pr v nt boil r from op rating without wat r. Th boil r
will lock out. Manual int rv ntion is r quir d to r s t th
boil r (on th instrum nt pan l) onc th caus of th
probl m has b n r ctifi d.
Note: Th Gas 550 Duo has two s ts.
6.4.4 Valve leakage control - optional lock out)
Th gas train can b combin d with a valv l akag
control, which ch cks for gas l akag b tw n th val-
v s at v ry start. Th boil r will lock out. Manual int r-
v ntion is r quir d to r s t th boil r (on th valv
l akag control) onc th caus of th probl m has
b n r ctifi d.
Typ : Dungs VPS 504.
Note: Th Gas 550 Duo r quir s two s ts.
6.4.5 Gas pressure switch LD - optional shut down)
If th supply gas pr ssur drops b low th s t valu
(12mbar; for natural gas, cat. I2H only), th boil r will shut
down. Wh n th supply gas pr ssur r turns abov this
s t valu th boil r will r sum op ration again.
Typ : Dungs GW50 A5.
Note: Th Gas 550 Duo r quir s two.
6.4.6 Gas pressure switch HD - optional lock out)
If th gas arrival pr ssur ris s abov th s t valu
(10mbar; for natural gas, cat. I2H only), th boil r will lock
out. Manual int rv ntion is r quir d to r s t th boil r
(on th gas pr ssur switch) onc th caus of th
probl m has b n r ctifi d.
Typ : Dungs UB 50 A2.
Note: Th Gas 550 Duo r quir s two.
6.4.7 Down draught thermostat; optional, shut
down)
If th th mp ratur in th draft div rt r ris s abov th
down draught th rmostat s t point, th boil r will shut
down. It automatically r s ts aft r 3 minut s, provid d
that th t mp ratur also falls.
Typ : Hon yw ll L6068A; fix d s tpoint is 70°C.
Note: Th Gas 550 Duo r quir s two.
6.3.3 Specification control box
Control box : Satronic MMI 816
Main supply : 230 V – 50 Hz
Minimum ionisation curr nt : min 3 µA (DC)
R action tim flam prot ction : 1 s c.
Saf ty tim : ≤ 10 s c.
Maximum ambi nt t mp ratur : 60 °C
Inj ctor siz pilot burn r : Ø 1.0 mm
Inj ctor siz main burn r : Ø 5.4 mm
Burn r pr ssur full load
(high calorific gas) : 8.4 mbar (100%)
Burn r pr ssur part load
(high calorific gas) : 2.2 mbar (50%)
Burn r pr ssur pilot burn r
(high calorific gas) : 13 mbar
Warning: control box is phas n utral s nsitiv .
6.3.4 Specification Ignition transformer
Ignition transform r : Satronic ZT 870
Ignition voltag : 16 kV
Distanc l ctrod s : 3,5 ± 1 mm.
6.4 Functions
General
Th following functions (standard and optional) will,
wh n activat d, ith r lock out or shut down th boil r.
For all options full fitting instructions ar includ d in th
option pack.
6.4.1 Flame control lock out)
Th flam is monitor d using ionisation flam d t ction.
In th v nt of a flam failur th boil r will lock out.
Manual int rv ntion is r quir d to r s t th boil r (on
th control pan l) onc th caus of th probl m has
b n r ctifi d.
Note: Th Gas 550 Duo has two s ts.
6.4.2 Thermostats shutdown / lock out)
- Control thermostat On/Off: shutdown (35°C-95°C);
Th boil r will automatically r sum op ration wh n
th flow t mp ratur falls b low th s t point.
- Control thermostat High/Low: shutdown (35°C-95°C);
Th boil r will automatically r sum op ration wh n
th flow t mp ratur falls b low th s t point.
- High Limit thermostat: lock out at 110°C.
Th boil r will lock out. Manual int rv ntion is r quir d
to r s t th boil r (on th instrum nt pan l) onc th
caus of th probl m has b n r ctifi d.
Note: Th Gas 550 Duo has two s ts.

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7 ASSEMBLY AND INSTALLATION GUIDELINES
7.1 General
Th boil r is suitabl for op rating at a maximum wor-
king pr ssur of 6 bar. It can b install d in op n v nt d
or s al d syst ms with a minimum pr ssur of 0.8 bar
s al d and 0.3 bar op n v nt d.
7.2 Boiler assembly
Th boil r is suppli d with full ass mbly instructions. On
r qu st sp cial ass mbly tools can b hir d from Broag
on a daily basis.
How v r, Broag (or a Broag approv d boil r r ction
ngin r) can provid boil r ass mbly s rvic s and / or
building sup rvision.
7.3 Water connections
Th boil r flow and r turn conn ctions can b fitt d
on ith r sid of th boil r (l ft or right hand sid )
d p ndant on d sign or sit conditions.
Th boil r com s with four flang s, 2 x blank and 2 x Ø
107 mm (int.) w ld n ck.
Th nd s ctions hav a 3/4 “ BSP tapping to acc pt th
suppli d drain cock.
Note: Th Gas 550 Duo has two s ts.
7.4 Pocket for the thermostat capillaries
Th multi pock t for th th rmostat capillari s should b
fitt d in th top front- nd s ction of th boil r and on
th sam sid of th boil r as th instrum nt pan l. Th
wat r l v l control l ctrod should b fitt d in th 1”
tapping of th oth r nd s ction.
Note: Th Gas 550 Duo has two s ts.
7.5 Water pressure
Each s ction is hydraulically t st d at 10 bar. Maximum
t st pr ssur for th ass mbl d boil r block is 7.8 bar.
Minimum working pr ssur is 0.8 bar at a maximum
working t mp ratur of 110°C or 0.3 bar at a maximum
working t mp ratur of 95°C. Maximum working pr s-
sur is 6 bar.
8 GAS SUPPLY
8.1 General
Th instrum nt pan l (mount d in th front casing) must
b mount d on th sam sid of th boil r as th flow
conn ction, ith r l ft or right (choic on ass mbly). As
standard th gas train must also b on th sam sid as
th flow conn ction. How v r an xt nsion cabl can b
suppli d (option) to allow th gas train to b mount d on
th opposit sid to th instrum nt pan l.
Th local Gas authority should b consult d to nsur
that an ad quat pr ssur and supply is availabl at th
boil rs maximum output. To minimis risk of s dim nt or
for ign particl s nt ring th control valv s, an approv d
filt r can b fitt d into th pip syst m downstr am.
Th gas supply should b conforming to th British Gas
saf ty r gulations.
Note: Th Gas 550 Duo r quir s two gas suppli s.
8.2 Gas pressure
Natural gas, cat. I2H (20mbar)
Maximum gas pr ssur at inl t 100 mbar.
Main burn r pr ssur s ttings :
- full load : 8.4 mbar
- part load : 2.2 mbar
Pilot burn r pr ssur s ttings : 13 mbar
Gas inl t pr ssur : 17 - 25 mbar
8.3 Injectors
Inj ctor siz main burn r : 5.4 mm
Inj ctor siz ignition burn r : 1.0 mm
Note: Th Gas 550 Duo has two s ts.

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9 ELECTRICAL SUPPLY
9.1 General
Th l ctrical installation must conform to th IEE r gu-
lations and also to local authority r quir m nts.
9.2 Instrument panel
Th Gas 550 is suppli d with an instrum nt pan l that
is fitt d in th front of th boil r, ith r l ft or right
(d p ndant on flow and gas conn ction).
Note: Th Gas 550 Duo has two instrum nt pan ls and
r quir s two s ts of pow r suppli s.
9.3 Control panel
A control pan l is fitt d on th gas train.
Note: Th Gas 550 Duo has two control pan ls and
r quir s two s ts of op rating controls and has two s ts
of function indication.
9.4 Electrical connections
Th boil r is pr -wir d. Only th main supply should b
wir d to th instrum nt pan l.
9.5 Electrical information
Main supply : 230 V-50 Hz (L/N)
Running curr nt : 150 VA
Maximum fus : 6 A (slow acting)
Note: Th Gas 550 Duo r quir s two s ts of pow r suppli s.
9.6 Water level control
Wat r l v l control : Dungs DWEB 53E
Main supply : 230 V – 50 Hz
Running curr nt : 5 W
El ctrod voltag : 42 V (AC)
Working ar a : 100 – 10.000 mA (AC)
El ctrod r sistanc : max. 20 kOhm; min. 1 kOhm
El ctrod : Dungs FLE ½”
Must b fitt d in on of th nd s ctions (s 7.4).
Note: Th Gas 550 Duo has two s ts.

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9.7 Wiring diagrams
Fig. 08 Electrical principle diagram
04.05F.SC.00001

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Remeha Gas
550/550 Duo
16
10 COMMISSIONING
Note: Commissioning must only b carri d out by a
qualifi d ngin r with th r l vant training and c rtifica-
tion i. . Acops - Corgi. A commissioning data sh t /
boil r logbook must b compl t d on sit for issu to
own r.
1. Ch ck th gas conn ctions.
2. Ch ck th l ctrical supply (L/N and arth).
3. Ch ck th wat r conn ctions and wh th r th instal-
lation is full and und r syst m pr ssur .
4. Switch on th circulation pump and ch ck th rota-
tion dir ction.
5. Op n th main gas cock (purg gas pip lin ).
6. Switch on th l ctrical supply.
7. S t both th th rmostats to about 85°C.
8. If a control syst m is built in, put th s l ctor switch-
on manual op ration.
9. Switch on th boil r.
- If a valve leakage control is install d th following
will tak plac :
A m mbran pump will cr at ov rpr ssur
b tw n saf ty valv s VA1 & VA2, which ar
insid th multibloc gas valv . Wh n, within 27
s c, an ov rpr ssur of 30 mbar (compar d to th
inl t pr ssur ) is r ach d, th l ctric supply is
r l as d to th control box.
10. Aft r a waiting tim of about 13 s conds th ignition
starts. Th magn tic valv MK op ns and ignition
burn r lights. At a minimum ionisation curr nt of 3
µA th ignition stops. Aft r 5 s conds th main gas
valv s VA1 n VA2 will op n. Th boil r runs.
11. L t th boil r run for a coupl of minut s on high fir
to cl ar any air still in th gas pip .
Fig. 09 Electric connection central alarm
00.03F.60.00042

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12. S t th corr ct full load burner pressure by m ans
of th pr ssur r gulator on th gas multibloc gas
valv (s Fig. 10, pos. 1).
Warning: Wh n th r quir d burn r pr ssur can
not b r ach d b caus of low inl t pr ssur , nsu-
r that th pr ssur r gulator r mains within it’s
op rating rang .
Now do th following:
• S t th burn r pr ssur to th high st possibl
valu (but not ov r th r quir d full load burn r
pr ssur ).
• Turn th pr ssur r gulator anticlockwis until th
burn r pr ssur is aff ct d.
• Th burn r pr ssur is now limit d, this will pr -
v nt th boil r from b ing ov r gass d should th
inl t gas pr ssur incr as .
13. S t th corr ct part load burner pressure:
• Turn th high/low th rmostat to it’s minimum s t-
ting (35°C). Wh n th flow t mp ratur is ov r
35°C, th boil r will burn at part load.
• S t th part load burn r pr ssur by turning th
adjustm nt ring (Fig. 10, pos. 2).
• To ch ck th th high fir s tting: Turn th
high/low th rmostat to 85°C and ch ck th full
load burn r pr ssur (if n c ssary r -adjust).
Th sp d of op ning of th main gas valv can
also b adjust d to nsur a smooth light up. S t-
ting th hydraulic brak on th main gas valv as
follows:
• R mov th s tting cap (Fig. 10, pos.3) and turn it
upsid down on th hydraulic brak .
• Turn it clockwis to slow down, anticlockwis to
sp d up.
• Ch ck both burn r pr ssur s again and if n c s-
sary r -adjust.
14. Adjustm nt of th gas pressure switch LD (optional):
• Switch th boil r to full load.
• Conn ct a pr ssur gaug to m asuring point LD.
• Turn th adjustm nt disc of th pr ssur switch to
it’s minimum s tting.
• Now clos th main gas cock slowly until th inl t
pr ssur drops to th valu d tail d in th docu-
m ntation suppli d with th gas pr ssur switch.
• Slowly turn th adjustm nt disc of th pr ssur
switch until th pr ssur control op rat s.
• Th control box shuts down th gas supply and
will r start.
15. Adjustm nt of th gas pressure switch HD (optional):
• Switch th boil r to full load.
• Conn ct a pr ssur gaug to manifold.
• S t th pr ssur switch to th valu d tail d in
th docum ntation suppli d with th gas pr ssur
switch.
• Ch ck wh th r th gas pr ssur switch HD com s
to action at th s t valu by incr asing (Fig. 10,
pos.1) th full load burn r pr ssur to that valu .
Th boil r will lock out.
• R s t by pr ssing th r s t button on th gas
pr ssur switch HD. Th boil r will r sum op ra-
tion.
• S t th corr ct full load burn r pr ssur again
according §10.2.12.
16. Valve leakage control (optional)
• R mov plug Pa during boil r start up (s §10.2.
9).Th plug Pa is locat d opposit th valv l a-
kag control on th multibloc.Th boil r will lock
out.
• R s t by pr ssing th r s t button on th valv
l akag control.Th boil r will r sum normal op -
ration.
17. Ch ck th thermostats for th corr ct op ration s t-
ting.
18. Ch ck th flame control on the control box
• Start th boil r with disconn ct d ionisation prob ,
aft r th ignition phas th pilot gas valv must
clos . Th boil r will lock out.
• R s t by pr ssing th r s t button on th control
box.
• Th n disconn ct th ionisation prob during op ra-
tion, th pilot gas valv must clos imm diat ly.
Th boil r will lock out.
• R s t by pr ssing th r s t button on th control
box.
19. Water level control:
• Ch ck th wat r l v l.
• Ch ck th op ration of th wat r l v l control by
disconn cting th l ctrod . Th boil r should go
to lock out
• Cr at a shortcut b tw n th l ctrod and
arth. Th boil r should go to lock out
• R s t by pr ssing th r s t button on th instru-
m nt pan l. Th boil r will r sum op ration
20. Ch ck th down draft thermostat by pr ssing th
bim tallic strip on th th rmostat. Th boil r will shut
down for 3 minut s. Aft r that th boil r will r sum
op ration.
21. S nd th initial commissioning r port CE to Broag.

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Remeha Gas
550/550 Duo
18
12
3
1. pr ssur r gulator
2. part load adjustm nt
ring
3. hydraulic brak
(s tting cap)
Fig. 10 Dungs MB-ZRDLE 415 / 420 S22.
10.1 Switching off the boiler
1. Switch off th l ctric supply.
2. Shut off th gas cock.
Warning: Wh n switch d off and full of wat r th boil r
could b damag d if th t mp ratur falls b low fr zing
point.
Note: Commissioning must only b carri d out by a
qualifi d ngin r with th r l vant product training and
c rtification i. . Acops - Corgi. A commissioning data
sh t / logbook must b compl t d on sit for issu to
own r.
11 MAINTENANCE
To maintain maximum ffici ncy it is ss ntial to s rvic
th boil r, ch ck saf ty param t rs and r -s t combus-
tion onc a y ar.
Normal Service Maintenance
- Isolat pow r , controls and gas supply.
- R mov front, top casings and flu hood cov rs.
- R mov gas manifold.
- R mov th burn rs and floor plat s.
- Cl an th int rnal flu ways of th boil r.
- Cl an th floor und rn ath th boil r and boil r room.
- Cl an th burn rs int rnally and xt rnally using a
soft brush.
- Cl an th gas train, ignition, pilot burn r, th rmostats
and wiring.
- Ch ck and r -s t/r -plac ignition l ctrod and ioni-
sation prob as found n c ssary.
- R -ass mbl boil r.
- Ch ck ignition and ionisation cabl s for conn ctions
and continuity.
- R stor pow r, controls and gas supply.
- Ch ck start program, ignition tim and saf ty tim s.
- Ch ck flam prot ction and th rmostats.
- Ch ck boil r input at 100% (full load) and 50% (part
load) load.
- Carryout a combustion ffici ncy t st.
- Ch ck th boil r and imm diat installation conn cti-
ons for wat r l aks (s als).
- Ch ck gas train and gas pip for gas l aks.
- Ch ck flu conn ctions.
- Cl an boil r casings.
- Compl t a commissioning r port.

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12 TROUBLE SHOOTING
Fig. 11 Switch diagram
04.05F.SC.00001
Fig. 12 Switch diagram with valve leakage control (optio-
nal)
04.05F.SC.00001
Indication mark at: Possible cause:
nd of gr n zon ;
(no rotation of color disc)
- no t nsion
- no h at d mand
nd of y llow zon ;
b gin of r d zon
- no flam (signal) of pilot burn r
- no spark
r d zon failing or unstabl flam of pilot burn r
nd of y llow zon ;
b gin of gr n zon
no flam (signal) of main burn r
Gr n zon ;
nd of gr n zon
failing or unstabl flam of main burn r
12.1 Fault causes
In cas of all disturbanc s th gas supply is int rrupt d
and th color disc stops rotating.
Ch ck th position of th color disc for a indication of
th caus . Th color disc is situat d at th sid of th
control box.
-
Table 03 Trouble shooting

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Broag Ltd
Head Office
Remeha House,
Molly Millars Lane,
Wokingham,
Berkshire RG41 2Q .
Tel.: [phone]
Fax: [phone]
Email: [email protected]
Internet: www.broag-remeha.com
Branch Office
Unit 3, Kestrel Close,
Quarry Hill Ind. Estate,
Ilkeston,
Derbyshire DE7 4RD
Tel. [phone]
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© Copyright
All technical and technological information contained in these technical instructions, as well as any
drawings and technical descriptions furnisched by us remain our property and may not be multiplied
without our prior consent in writing.
Subject to alterations
56267/1500/0601/
Ho .
Remeha Gas 550/550 Duo