REMEHA P 320-4 Owner's manual

Remeha P 320
Fuel oil/gas boilers
Technical
instructions
English
06/04/06
63184
UK

Contents
Remeha P 320 06/04/06 - 300008452-001-C
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1 Technical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2 Main dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Installing the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1 Boiler location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2 Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1 Important recommendations on connecting the heating circuit to the boiler and the drinking water system . . . . . . . . . . . . . . . . . . . . .9
2 Important recommendations for connecting the boiler to the heating circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3 Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4 Sludge removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Chimney connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1 Flue size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2 Chimney connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Fuel-oil or gas connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Electrical connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1 Sweeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2 Cleaning the casing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3 Precautions required in the case of long boiler stops (one or more years) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
4 Precautions required if the heating is stopped when there is a risk of freezing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Burner maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
System maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
1 Water level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2 Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Spare parts - P 320. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

3
06/04/06 - 300008452-001-C Remeha P 320
Introduction
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, 73/23 EC and 89/336/EC.
Warning
The boiler shall be assembled and installed by a qualified
professional only.
For a proper operating of the boiler, follow carefully the instructions.
Symbols used
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

4Remeha P 320 06/04/06 - 300008452-001-C
Description
The boilers of the P 320 range are pressurised hot water boilers
designed for connecting to a flue pipe which require a separate
automatic fuel-oil or gas burner.
The useful power of P 320 boilers is between 70 and 330 kW.
Models available
Boiler with control panel, which may be fitted with an optional
Rematic 2945 C3K control unit for heating only or heating and
domestic hot water production.

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06/04/06 - 300008452-001-C Remeha P 320
1 Technical characteristics
Maximum operating pressure : 6 bar
Boiler thermostat setting : 30 to 90°C
Safety thermostat setting : 110 °C
(1)Nominal operation (top boiler power)
(2)CO2= 13.1 to 13% with fuel oil and 9.5% with natural gas.
(3)Boiler temperature : 80 °C, Ambient temperature : 20 °C
1 mbar = 10mmWC = 10 daPa
In order for the boiler to operate correctly, it is imperative
to respect the draught at the nozzle: 0 at the nozzle.
Boiler P 320-4 P 320-5 P 320-6 P 320-7 P 320-8 P 320-9
Useful output kW 70-105 105-140 140-180 180-230 230-280 280-330
Power input kW 79.5-119.3 119.3-159.1 159.1-204.5 204.5-261.4 261.4-318.2 318.2-375.0
Number of sections 456789
Water capacity l 96 116 136 156 176 196
Water resistance ∆T = 15K (1) mbar 6.2 10.9 20.4 30 44.5 63.8
Pressure in the furnace for
nozzle pressure = 0 mbar +0.3 +0.6 +1.1 +1.6 +2.2 +2.5
Smoke temperature (1) (3) °C < 210 < 210 < 210 < 210 < 210 < 210
Mass flue gas flow rate (1) Fuel oil Kg/h 178 238 306 391 475 560
Gas Kg/h 187 250 321 410 499 588
Combustion chamber
Recorded diameter mm 377 377 377 377 377 377
Depth mm 621 781 941 1101 1261 1369
Volume m30.096 0.122 0.148 0.174 0.200 0.226
Maintenance consumption by 50°C % 0.17 0.14 0.13 0.11 0.10 0.09
Shipping weight kg 610 739 845 980 1101 1228

6Remeha P 320 06/04/06 - 300008452-001-C
2 Main dimensions
(a) Rp 1 1/2 socket for the safety control unit
(b) 2 1/2 heating outlet (flange + counter flange)
(c) Sludge removal hole Ø Rp 2 1/2
(d) 2 1/2 heating return (flange + counter flange)
(e) Rp 1 1/2 draining outlet (supplied with plug)
P 320-4 P 320-5 P 320-6 P 320-7 P 320-8 P 320-9
L (mm) 991 1151 1311 1471 1631 1791
P (mm) 490 650 810 970 1130 1290
R (mm) 180 180 180 200 200 200

7
06/04/06 - 300008452-001-C Remeha P 320
Installing the boiler
1 Boiler location
The P320 boiler does not require a special base for its assembly.
Their closed furnace system means that the floor need not have
refractory properties. All you have to ensure is that the floor can
support the weight of the boiler when it is fitted for operation. If the
boiler location is not determined precisely, leave enough space
around the boiler to facilitate monitoring and maintenance
operations.
Pay attention to the overall volume of the burner when the
door is open. To install several boilers in cascade, these
dimensions should be adapted accordingly.
Boiler P 320-4 P 320-5 P 320-6 P 320-7 P 320-8 P 320-9
A 840 1000 1160 1320 1480 1640

8Remeha P 320 06/04/06 - 300008452-001-C
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.
It is in any case imperative to conform to the local regulations in force.
Warning:
In order to avoid damage to the boilers, it is necessary to prevent the
contamination of combustion air by chlorine and/or fluoride
compounds, which are particularly corrosive.
These compounds are present, for example, in aerosol sprays,
paints, solvents, cleaning products, washing products, detergents,
glues, snow clearing salts, etc.
Therefore:
• Do not suck in air evacuated from premises using such
products: hairdressing salons, dry cleaners, industrial premises
(solvents), premises containing refrigeration systems (risk of
refrigerant leakage), etc.
• Do not stock such products close to the boilers.
If the boiler and/or peripheral equipment are corroded by such
chloride or fluoride compounds, the contractual guarantee
cannot be applied.
Mounting
ZFor mounting instructions, see installation instructions.

9
06/04/06 - 300008452-001-C Remeha P 320
Hydraulic connections
1 Important recommendations on connecting the heating circuit to the boiler and the drinking water system
Installation must be carried out in accordance with the prevailing
regulations, the codes of practice and the recommendations in these
instructions.
The expansion tank must be connected directly to the boiler without
valves or stop valves.
Likewise, the safety valve must be connected directly to the boiler
without valves or stop valves.
Example of an installation:
The example of an installation shown below does not cover every
possible configuration. Its sole aim is to draw your attention to the
basic rules to be respected. Comply at all times with the codes of
practice and the prevailing national or local regulations.
P 320 boiler with domestic hot water production using an independent tank
1. Heating outlet
2. Heating return
3. 3 bar safety valve + manometer
5. Flow switch
6. Air separator
7. Automatic bleed valve
9. Isolation valve
10. 3-way mixing valve
11. Boiler pump
12. Sludge decanting pot (particularly recommended on older
installations)
13. Flush valve
14. Water low safety pressure-sensitive switch
15. Recycling pump
16. Expansion chamber
17. Drain cock
18. Heating circuit filling (with disconnector depending on prevailing
regulations)
19. Water treatment if TH > 25°
20. Water meter
26. DHW load pump
27. Non-return valve
28. Domestic cold water inlet
29. Pressure reducer (if mains pressure 5.5 bar)
30. Sealed safety unit calibrated to 7 bar with indicator type discharge
31. Independent domestic hot water tanks
32. Domestic hot water loop pump (optional)
56. Domestic hot water circulation return loop
57. Domestic hot water outlet
8219N008C
92
14
12
17
11
27
9
56
32
9
10
1
9
57
9
27
26
15
9
17
18
919 20 9
17
16
13
3
79
7
30
28
9
29
27
9
31
56
9
9
9

10 Remeha P 320 06/04/06 - 300008452-001-C
2 Important recommendations for connecting the boiler to the heating circuit
Installation must be carried out in accordance with the prevailing
regulations, the codes of practice and the recommendations in these
instructions.
`Minimum safety valve flowrate as a function of maximum boiler nominal output :
Minimum relieving capacity
Maximum gross boiler output
Example
Maximum boiler nominal output is 200 kW.
Minimum safety valve flowrate must be 1500 Kg/h
`Water flow in the boiler :
The water flow in the boiler when the burner is operating must correspond with the following formulae:
- Nominal water flow Qn = 0.86 Pn/20
- Minimum flow Qmin = 0.86 Pn/45 (this flow also corresponds with the minimum recycle flow in the boiler)
- Maximum water flow Qmax = 0.86 Pn/5
Qn = flow in m3/h
Pn = Nominal output (full boiler output) in kW.
`Operation in cascade
After stopping the burner:
- Timeout required before the order to close a butterfly valve: 3 min
- Switch a possible shunt pump (located between the boiler and a butterfly valve) off via the end of run contact of the butterfly valve
`Operation with 2-stage burner
- The water temperature in the boiler is maintained at 50°C or more ; the first stage must be set to a minimum of 30% of the nominal stage
- Operation at modulated low temperature (minimum outlet temperature: 30°C) ; the first stage must be set to a minimum of 50% of the nominal
stage

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06/04/06 - 300008452-001-C Remeha P 320
`Operation with modulating burner
- The water temperature in the boiler is maintained at 50°C or more: the burner can modulate down to 30% of the nominal stage
- Operation at modulated low temperature (minimum outlet temperature: 30°C) ; the burner can modulate down to 50% of the nominal stage
3 Filling the system
Filling shall be performed with a low flow rate from a low point in the
boiler room in order to ensure that all the air in the boiler is bled from
the high point of the system.
Always stop the pump before filling.
VERY IMPORTANT : Instructions for starting up the boiler
for the first time after the system is fully or partly drained :
If all the air is not bled naturally to an expansion vessel
which opens out onto the air, the system must include
manual bleeder valves, in addition to automatic bleeder
valves with the capability to bleed the system by
themselves when it is operating; the manual bleeder valves
are used to bleed all the high points of the system and to
make sure that the filled system is free of air before the
burner is turned on.
Do not add cold water suddenly into the boiler when it is
hot.
4 Sludge removal
A tapped Ø 1’’ 1/2 hole with a plug has been provided on the bottom
of the front of the boiler.. Fit a 1/4 turn valve (not supplied) on the
opening to remove the sludge.
Sludge removal leads to the draining of large quantities of water, so
remember to refill the system after the operation.
Comments :
never replace a boiler in an existing system without carefully rinsing
the system first. Install a sludge decanting pot on the return pipe, very
close to the boiler.

12 Remeha P 320 06/04/06 - 300008452-001-C
Chimney connection
The high-performance features of modern boilers and their use in
specific conditions as a result of the advance in burner technology
(e.g. first-stage or low modulation range operation) lead to very low
flue gas temperatures (<160°C).
For this reason :
- Use flue gas pipes designed to enable the flow of condensates
which may result from such operating modes in order to prevent
damage to the chimney.
- Install a draining tee at the bottom of the chimney.
The use of a draught moderator is recommended as well.
1Fluesize
Refer to applicable regulations while determining the size of the flue.
Please note that P 320 boilers have pressurised and tight furnaces
and that the pressure at the nozzle must not exceed 0 mbar, unless
special sealing precautions have been taken, for instance in order to
connect a static condenser/regenerator.
2 Chimney connection
The connection shall be removable, and offer minimum load losses,
i.e. it must be as short as possible with no sudden change in section.
Its diameter shall always be at least equal to that of the boiler outlet,
i.e. :
Ø 180 mm : for 4 to 6 sections
Ø 200 mm : for 7 to 9 sections
Fit a measuring point (Ø 10 mm hole) on the flue, in order to adjust
the burner (combustion check).

13
06/04/06 - 300008452-001-C Remeha P 320
Fuel-oil or gas connections
ZRefer to the instructions supplied with the burner. The burner head deflector must be flush with the insulation
of the burner door.
A: Furnace door insulation
B: 4 markings on Ø 170
C : 4 markings on Ø 200
D: 4 markings on Ø 220
Electrical connections
ZRefer to the connection instructions supplied with the control
panel.

14 Remeha P 320 06/04/06 - 300008452-001-C
Maintenance
The operations described below shall only be performed
with the boiler and power supply off.
1 Sweeping
The boiler will only operate efficiently if the exchange surfaces
are kept clean.
The boiler should be cleaned as soon as required and as the
chimney, at least once a year or more, depending upon applicable
regulations and specific needs.
Cleaning the flue gas circuit
- Cut the power supply to the boiler.
- Unhook the front panel.
- Open the cleaning door (top door) by unscrewing the 4 closing nuts
(17 mm spanner),
- Remove the baffle plates,
- Carefully sweep the four flue ways with the brush supplied for that
purpose,
- Also sweep the baffle plates and the front panel,
- If possible, use a vacuum cleaner,
- Replace the baffle plates,
- Close the door.
Cleaning the combustion chamber
- Unscrew the 4 closing nuts and open the furnace door
- Brush out the inside of the furnace
- Use a vacuum cleaner to remove any soot which has accumulated
in the combustion chamber
- Close the door and replace the front panel.
-

15
06/04/06 - 300008452-001-C Remeha P 320
Positioning of the baffles
The first two baffles on the two lower flue ways are fitted
with stops to position them in the right place.
(1) Stop
Cleaning the flue gas box
- Remove the left and right cleaning hatches from the flue gas box
(2 butterfly nuts) and use a vacuum cleaner to remove any soot
which has accumulated
- Replace the cleaning hatches.
Maintenance of the burner
ZRefer to the instructions supplied with the burner
2 Cleaning the casing material
Use a soapy solution and a sponge only. Rinse with clean water and
dry with chamois leather or a soft cloth.
3 Precautions required in the case of long boiler stops (one or more years)
- The boiler and the chimney must be swept carefully.
- Close all the doors of the boiler to prevent air from circulating inside
the boiler.
- We advise removing the pipe which connects the boiler to the
chimney and to close off the nozzle with a cover.
4 Precautions required if the heating is stopped when there is a risk of freezing
We recommend the use of a correctly dosed antifreeze agent to
prevent to the heating circuit from freezing. If this cannot be done,
drain the system completely.
Baffle plates Flue ways P 320-4 P 320-5 P 320-6 P 320-7 P 320-8 P 320-9
upper 410 mm A + B - 8 8 - - -
570 mm A + B 4 - - 4 4 4
interior 412 mm C 2 2 2 2 2 2

16 Remeha P 320 06/04/06 - 300008452-001-C
Burner maintenance
Refer to the instructions supplied with the burner.
System maintenance
1 Water level
Regularly check the level of water in the system and top up if
required, taking care that cold water is not added suddenly into the
boiler when it is hot.
This operation should be required only a few times in each heating
season, with very low quantities of water; otherwise, look for the leak
and repair it.
2 Draining
We advise you against draining the system unless it is absolutely
necessary.
Identification plate
The identification plate fixed on the side of the boiler during
installation is used to identify the boiler correctly and also provides
the main specifications of the boiler.
A: Boiler type
B: Year of manufacture
C: Week of manufacture
D: Serial no. of the appliance

17
06/04/06 - 300008452-001-C Remeha P 320
Spare parts - P 320
To order a spare part, quote the reference number next to the part required.
06/04/06 - UK300004553-002-A
Boiler body

18 Remeha P 320 06/04/06 - 300008452-001-C
Insulation
Base frame

19
06/04/06 - 300008452-001-C Remeha P 320
Cladding
Table - RC 1

Markers Code no. Description
Boiler body
182198912 Complete rear section
28219-8966 Special intermediate section
38219-8976 Complete front section
48116-0571 Nipple
58219-8968 Complete assembly rod, 4 sections
58219-8969 Complete assembly rod, 5 sections
58219-8970 Complete assembly rod, 6 sections
58219-8971 Complete assembly rod, 7 sections
58219-8972 Complete assembly rod, 8 sections
58219-8973 Complete assembly rod, 9 sections
6.1 8202-0028 Plug 2 1/2" - 1/2"
6.2 8209-0049 Plug 2 1/2" - 1/2" - NL
6.3 94948080 Nipple N 241 - 1/2"x1/4"
79536-5611 Rp 1/2 pocket
880013-0028 Solid plug 2" 1/2
98553-5513 Flow flange, 3 to 9 sections
10.1 8553-5514 Return flange, 4 to 5 sections
10.2 8553-5515 Return flange + distribution pipe, 6 to 8
sections
10.3 8553-5516 Return flange + distribution pipe, 9
sections
10.4 9754-9178 Counter flange
11 9495-0249 Male plug 290 T9 - R 1 1/2
11.1 9501-4122 Flange gasket
12 8104-8984 Hinge
13 8219-8916 Sweeping door
14 9425-0306 Inner protection, sweeping door
15 9425-0305 Insulation, sweeping door
16 9508-6032 10 Ø thermocord gasket
17 9756-0203 Pin Ø 12x350
18 8219-8913 Ø 180 complete nozzle
18 8219-8914 Ø 200 complete nozzle
19 8219-0206 Right hand nozzle cover
20 8219-0207 Left hand nozzle cover
21 8219-8953 Complete combustion chamber door, ø
135
22 9425-0303 Internal protection, combustion chamber
door
23 9425-0302 Furnace door guard
24 9425-0301 Furnace door insulation
25 8015-7700 Sight glass + gaskets
26 9757-0027 Inspection flange
27 9495-0050 Plug 1/4"
28 8219-0539 Guide rail for combustion chamber door
29 8219-0017 Upper baffle plate, 410 mm
29 8219-0018 Upper baffle plate, 570 mm
30 8219-0019 Lower baffle plate, 412 mm
30 8219-0020 Lower baffle plate, 572 mm
31 8219-7724 Body screws packet
32 8219-8957 Bag of screws for furnace door
33 9430-5027 0.3 kg can nipple lubricant
34 9432-0214 Mastic Novasil S 17
Miscellaneous
50 9750-5025 Brush
51 9750-5076 1000 mm brush rod
51 9750-5060 1300 mm brush rod
Base frame
70 8553-7060 Complete frame 4 sections
Package FD 30
70 8553-7061 Complete frame 5 sections
Package FD 31
70 8553-7062 Complete frame 6 sections
Package FD 32
70 8553-7063 Complete frame 7 sections
Package FD 33
70 8553-7064 Complete frame 8 sections
Package FD 34
70 8553-7065 Complete frame 9 sections
Package FD 35
Insulation
90 8553-5507 Complete boiler body insulation, 4
sections
90 8553-5008 Complete boiler body insulation, 5
sections
90 8553-5509 Complete boiler body insulation, 6
sections
90 8553-5510 Complete boiler body insulation, 7
sections
90 8553-5511 Complete boiler body insulation, 8
sections
90 8953-5512 Complete boiler body insulation, 9
sections
Markers Code no. Description