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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550/550 Duo
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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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Remeha Gas
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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Remeha Gas
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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Remeha Gas
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