REMEHA P 500 Manual

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Remeha P 500
• Pressurized boiler
• Heat output: 635 - 1900 kW
Te hni al information
Remeha P500

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Remeha P 500
2
Prefa e 3
1 Des ription of the unit 3
1.1 General 3
1.2 Burners 3
2 Constru tion data 3
2.1 General 3
2.2 Sections 3
2.3 Casing 3
3 Te hni al data and dimensions 4
3.1 Dimensions 4
3.2 Technical data 4
3.3 Quotation specifi cations 5
4 Output data 5
4.1 Boiler e fi ciency 5
4.2 Combustion e fi ciency 5
5 Appli ation data 5
5.1 L.P.H.W. version 5
5.1.1 Water temperature 5
5.1.2 Water pressure 5
5.1.3 Flow rate 5
5.1.4 Water treatment 6
5.2 Economisers 6
5.3 Flue gas discharge 6
5.4 Noise production 6
6 Installation requirements 7
6.1 Installation recommendations in the boiler
house 7
7 Assembly guidelines and installation
requirements 7
7.1 General 7
7.2 Water connections 7
7.3 Boiler assembly 7
8 Instrument panels 8
8.1 Equipment contents 8
8.2 Instrument panel High/Low with hours run
meters 8
8.3 Wiring diagram instrument panel High/Low
with hours run meters 1 9
9 Commissioning 10
9.1 Pressurized boiler with gas burner 10
9.1.1 Commissioning procedure 10
9.1.2 Putting out o operation 10
9.2 Pressurized boiler with oil burner 10
9.2.1 Commissioning procedure 10
9.2.2 Putting out o operation 10
10 Fault Finding 11
11 Maintenan e re ommendations 11
11.1 General 11
11.2 Maintenance instructions 11
TABLE OF CONTENT

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PREFACE
These technical instructions contain use ul and impor-
tant in ormation or the correct operation and maintenan-
ce o the Remeha boiler, model P200
Read these instructions care ully be ore putting the boi-
ler into operation; amiliarise yoursel with its control
unctions and operation, strictly observing the instructi-
ons given. Failure to do so may invalidate warranty or
prevent the boiler rom operating.
A competent Engineer, with the relevant certifi cation (i.e.
CORGI, ACOPS, IEE regs. etc) must carry out the instal-
lation and commissioning o the boiler.
On completion a copy o the boiler log / commissioning
sheet should be returned to Broag Ltd or record purpo-
ses.
I you have any questions, or i you need more in orma-
tion about specifi c subjects relating to this boiler, or it’s
installation please do not hesitate to contact us.
The data published in these technical instructions is
based on the latest in ormation (at date o publication)
and may be subject to revisions.
We reserve the right to continuous development in both
design and manu acture, there ore any changes to the
technology employed may not be retrospective nor may
we be obliged to adjust earlier supplies accordingly.
1 DESCRIPTION OF THE UNIT
1.1 General
High e fi ciency pressurised boiler, suitable or use with
natural gas and light oil, by means o a pressure jet
burner. Also available with a condensing unit (ECO) ( or
natural gas only).
The boiler meets the requirements o the CE regulations
in the ollowing directives:
- Gas appliance directive no. 90/396/EEC
- Electrical low voltage directive no. 73/23/EEC
- E.M.C. directive no. 89/336/EEC
- E fi ciency directive no. 92/42/EEC.
Classifi cation type or evacuation o the combustion pro-
ducts: B23.
1.2 Burners
In principle all CE-approved pressure jet burners are sui-
table, subject to prior adjustment to the boiler capacity
and boiler construction. The individual boiler satisfi es
inspection requirement or central heating boilers.
2 CONSTRUCTION DATA
2.1 General
The boiler block consists o cast iron sections, which are
assembled by means o tapered nipples. The boiler is a
three-pass design. The boiler block is insulated with a
100-mm thick layer o glass wool.
2.2 Se tions
The sections are made o pearlitic cast iron.
Weights and measures o the sections:
- Front section: 220 kg H x W = 1252 x 1130mm
- Intermediate section: 250 kg H x W = 1238 x 1130 mm
- Rear section: 250 kg H x W = 1238 x 1130 mm
2.3 Casing
Steel casing, fi nished with a high-quality insulation. The
ront door is suitable or le t or right opening as desired.
Fig. 01 Remeha P500
IL50

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Remeha P 500
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3 TECHNICAL DATA AND DIMENSIONS
3.1 Dimensions
Front view Side view Rear view
Flow NG 150 - DIN2633
Return NG 150 - DIN2633
Flue ØD ext.
Flanges in accordance with BS 4505 PN 16
Fig. 02 Dimensions
00.15D.79.00006
3.2 Te hni al data
Number of sections 9 10 11 12 13 14 15 16 17 18 19 20
Nominal heat output kW 635 750 865 980 1095 1210 1325 1440 1555 1670 1785 1900
Hi /
NC kW 706 834 962 1090 1218 1341 1468 1592 1719 1846 1973 2100
Nominal
heat input Hs /
GC kW 784 926 1068 1210 1352 1488 1630 1767 1908 2049 2190 2331
Amm 1350 1500 1650 1800 1950 2100 2250 2400 2550 2700 2850 3000
Bmm 1660 1810 1965 2115 2265 2415 2565 2715 2870 3020 3170 3320
Cmm 1270 1420 1570 1720 1870 2020 2170 2320 2470 2620 2770 2920
Dimensions
ØDmm 400 400 400 400 500 500 500 500 500 500 500 500
∆ t =
10°C mbar 149 166 180 194 189 200 213 234 262 295 337 382
Water
resistance ∆ t =
20°C mbar 37 42 45 47 49 50 53 59 66 74 84 96
Water contents litre 495 550 605 660 715 770 825 880 935 990 1045 1100

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Boiler weight (dry) kg 2650 2910 3175 3435 3695 3955 4220 4480 4740 5005 5265 5525
Combustion chamber
resistance1) mbar 1.7 2.3 3.0 3.8 3.9 4.8 5.0 5.9 5.5 6.0 6.5 7.0
Combustion gas side
content m30.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9
Flue gas flow rate kg/h 1102 1302 1502 1702 1901 2081 2292 2485 2683 2882 3080 3278
Table 01 Technical data
1) Determined with 20 excess air.
3.3 Quotation specifi cations
- Heat exchanger manufactured from corrosion resi-
stant “pearlite” cast iron
- Maximum operating pressure of 6 bar
- Maximum operating temperature of 95°C
- Sectional design with three passes for max effi ciency
(gross 83 ) and a generously sized combustion
chamber for minimising NOX production
- Water cooled base and rear sections
- Large insulated door (hinged left or right) allowing
easy access for service operations
- Supplied in broken down form for ease of delivery and
site access
- Powder coated enamel steel casing
- 80 - 100 mm thick glass wool insulation
- Suitable for use with a Natural gas, and/or 35 sec oil
fi red pressure jet burner (matched with most popular
burner manufacturers)
- Supplied as standard with on/off switch, temperature
indication, control and high limit thermostats
- Effi ciency 83 (Hs - GCV)
- Manufactured to ISO 9001
- CE approved.
4 OUTPUT DATA
4.1 Boiler effi ciency
Up to 90.2 at Hi (81.3 at Hs) at full load and up to
92.5 at Hi (83.3 at Hs) at part load.
Average water temperature 70°C (80/60°C).
4.2 Combustion effi ciency
Up to 91.2 at Hi (82.2 at Hs) at full load and up to
95.5 at Hi (86.0 at Hs) at part load.
Note: Hi = NCV; Hs = GCV
5 APPLICATION DATA
5.1 L.P.H.W. version
5.1.1 Water temperature
Maximum water temperature is 110°C.
The minimum acceptable return water temperature is,
both for gas and oil fi red boilers 40°C, at a fl ow rate
corresponding to a ∆t of 20°C at nominal heat output.
5.1.2 Water pressure
Maximum pressure 6 bar.
The boiler is suitable for open and sealed systems up
to a maximum pressure of 6 bar and a minimum pres-
sure of 0.8 bar. The boiler is suitable for installation in
basement or rooftop boiler houses.
5.1.3 Flow rate
The minimum fl ow rate through the boiler is obtained
from the following formula:
Nominal heat output (kW) = m3/h
70
This minimum fl ow must be maintained for 5 minutes
after the burner stops fi ring to avoid high temperature
shutdown due to residual heat gain. Due to the design
and manufacture of the boiler no specifi c minimum water
fl ow requirement exists other than for over-temperature
protection.

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Remeha P 500
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5.1.4 Water treatment
The system should be fi lled with mains cold water (for
the UK this will usually have a pH of between 7 and 8).
Pressurised installations with a boiler/system content
ratio of 1:10 or less should not require water treatment,
provided that the following conditions apply:
1. The system is fl ushed thoroughly to remove all fl uxes
and debris and then fi lled completely once.
2. Make up water is limited to 5 per annum.
3. The hardness of the water does not exceed 360 ppm
(20°D).
All scale deposits will reduce the effi ciency of the boiler
and should be prevented. However provided the above
is complied with any scale produced will not be too
detrimental to the boiler effi ciency and will not reduce
the anticipated life expectancy of the boiler.
NOTE: Scale deposits in excess of 3 to 5 mm will
reduce boiler effi ciency and greatly increase the risk of
premature casting failure.
As most systems contain a variety of metals which can
react with each other to cause corrosion. It is consid-
ered good practice to provide some form of water treat-
ment (especially in open vented systems) in order to
prevent or reduce the following:
- Metallic corrosion;
- Formation of scale and sludge;
- Microbiological contamination;
- Chemical changes in the untreated system water.
Suitable chemicals and their use should be discussed
with a specialist water treatment company prior to car-
rying out any work. The specifi cation of the system
and manufacturers recommendations must be taken into
account, along with the age and condition of the system.
New systems should be fl ushed thoroughly to remove all
traces of fl ux, debris, grease and metal swarf generated
during installation. Care to be taken with old systems
to ensure any black metallic iron oxide sludge and other
corrosive residues are removed, again by thoroughly
fl ushing, ensuring that the system is drained completely
from all low points.
NOTE: Please ensure that the new boiler plant is not
in circuit when the fl ushing takes place, especially if
cleansing chemicals are used to assist the process.
Under no circumstances is the boiler to be operated
with cleaning chemicals in the system.
To summarise:
- Minimise water loss;
- Prevent pumping over in open vented systems;
- Provide adequate air venting at all high points;
- Keep pH level between 7 - 9 when using additives;
- Maximum chlorine content of 200 mg/l;
- Take advice on the suitability of inhibitors.
5.2 Economisers
ECO’s can be delivered upon request (for natural gas
only). For specifi cations please refer to Technical infor-
mation ECO 13/14/15.
5.3 Flue gas discharge
For the discharge of the fl ue gases, chimney draught is
not required.
Tests have shown that very good combustion results are
obtained with zero draught at the boiler outlet.
5.4 Noise production
The noise level taken at a distance of 1 m around the
boiler is approximately 75 to 90 dBA. The noise level
at the chimney outlet will, depending on load, type of
burner and chimney situation, vary from 75 to 90 dBA,
measured at a distance of 1 m from the outlet. If
this noise production gives rise to problems in the imme-
diate vicinity, then noise reducing or absorbing measu-
res should be taken.
50
60
70
80
90
100
31,5 63 125 250 500 1000 2000 4000 8000
NR 60
NR 70
NR 80
NR 90
frequency (Hz)
dB re 2x10-5 N/m2
full load
part load
9
Fig. 03 Noise level readings without burner silencer
The values that have been taken are averages obtained
from various measurements carried out at a distance of
approximately 1 m around the boiler and at a height of
approximately 1 m.

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6 INSTALLATION REQUIREMENTS
6.1 Installation recommendations in the boiler
house
The necessary minimum installation space of the boiler
can be seen from Fig. 04.
Fig. 0 Installation recommendations in the boiler
house
04.15D.79.00001
H = 80mm without vibration damper
H = 120mm with vibrationdamper
Fig. 05 Base details
00.15A.78.00001
7 ASSEMBLY GUIDELINES AND INSTALLATION REQUIREMENTS
7.1 General
The Remeha boiler P 500 is delivered in individual parts.
The sizes of the boiler parts are such that they all can
enter the boiler house through a normal entrance.
The casing and equipment parts are delivered in pac-
kaged units. If necessary, the boiler can be put into
operation without casing. The casing can be added at a
later stage without dismantling the water connections.
7.2 Water connections
The water connections are at the rear of the boiler.
The fl ow and return connections consist of a fl anged
fl ow elbow and a fl anged return connection in accor-
dance with DIN 2633. The return connection is provided
with a G ¾” threaded hole in which a drain off cock is
fi tted.
At the front of the boiler a fl ange is provided with 2
x G ½” threaded holes for the fi tting of the thermostat
pockets.
7.3 Boiler assembly
Assembly and installation of a boiler delivered in indivi-
dual parts should only be undertaken by a recognised
and approved engineer and in accordance with the
assembly manual. Local regulations laid down by the
relevant authorities must be adhered to.
Number
of
sections
A
mm
9 1350
10 1500
11 1650
12 1800
13 1950
14 2100
15 2250
16 2400
17 2550
18 2700
19 2850
20 3000

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Remeha P 500
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8 INSTRUMENT PANELS
8.1 Equipment contents
The panels contain all the necessary control and measu-
ring instruments required to control the boiler. The con-
nections have to be made on a terminal strip. The capil-
laries and sensor wires, which come from the control
panel, are placed in the instrument pockets that are
fi tted at the front of the boiler.
See par. 8.2 for an instrument panel High/Low with hours
run meters. Several extra options can be built into the
panels.
Ask our technical department.
8.2 Instrument panel High/Low with hours run
meters
Fig. 06 Layout of the instrument panel High/Low with hours run meters
00.03F.79.00004
1. Operating switch (On/Off)
2. Control thermostat; setting between 35°C - 95°C
3. High/Low thermostat; setting between 35°C - 95°C
4. Hours run meter total running hours
5. Hours run meter full load running hours
6. Analoque thermometer water temperature
7. High limit thermostat 110°C (lock out)
8. Lock out warning lamp
9. Option for rematic® weather compensator
12 3 6
578
9

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8.3 Wiring diagram instrument panel High/Low with hours run meters 1
3
Fig. 07 Wiring diagram instrument panel High/Low with hours run meters
04.13C.SC.00001
1.) External control. remove link; insert control pair (230 V) 2.) External control High/Low. remove link; insert control pair (230 V).1

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9 COMMISSIONING
Note:
Commissioning to only be carried out by a qualifi ed
engineer with the relevant training and certifi cation i.e.
Acops-Corgi and a commissioning data sheet completed
on site for issue to owner.
9.1 Pressurized boiler with gas burner
9.1.1 Commissioning procedure
If the boiler is to be put into operation again following
a period of non-use, then the following procedure must
be carried out :
- Open the main gas cock.
- Switch the weather-compensator (if fi tted) over to
manual operation (h).
- Turn the thermostats to their highest setting.
- Switch on the circulation pump.
- Switch on the main switch.
- Switch on the operation switch in the instrument
panel.
- Consult burner manufacturers commissioning details.
Warning
If the instrument panel is fi tted with a weather compen-
sator, set the program switch to ‘manual’ position (h).
The following will now take place:
- The gas burner fan will start running so that during
the purging time the combustion chamber will be ven-
tilated with the air damper fully opened.
- The air damper will then go into start position.
- Ignition fl ame lights up and is checked.
- Then the control box gives the all clear signal for the
burner to switch over to full load.
9.1.2 Putting out of operation
It is suffi cient to switch off the operation switch on the
instrument panel. It is important that in the event of
work being carried out on the burner, the boiler/burner
unit must be completely electrically isolated and the
main gas cock must be shut.5
9.2 Pressurized boiler with oil burner
9.2.1 Commissioning procedure
If the boiler is to be put into operation again following
a period of non-use, then the following procedure must
be carried out :
- Open the main oil cock.
- Switch the weather-compensator (if fi tted) over to
manual operation (h).
- Turn the thermostat to their highest setting.
- Switch on the circulation pump.
- Switch on the main switch.
- Switch on the operation switch in the instrument
panel.
- Consult burner manufacturer commissioning details.
Warning
If the instrument panel is fi tted with a weather compen-
sator, set the program switch to ‘manual’ position (h).
The following will now take place:
- The oil burner fan will start running so that during the
purging time the combustion chamber will be ventila-
ted with the air damper fully opened.
- The air damper will then go into start position.
- Ignition fl ame lights up and is checked.
- Then the control box gives the all clear signal for the
burner to switch over to full load.
9.2.2 Putting out of operation
It is suffi cient to switch off the operation switch on the
instrument panel. It is important that in the event of
work being carried out on the burner, the boiler/burner
unit must be completely electrically isolated and the
main oil cock must be shut.

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10 FAULT FINDING
High Limit thermostat lock out:
- Check the water circulation (circulation pump). Reset
the High Limit thermostat (Reset button is on the
instrument panel under the cover cap of the High
Limit thermostat).
- Advise the installer in the event of continued lockouts.
11 MAINTENANCE RECOMMENDATIONS
11.1 General
Depending on the operational conditions, the block and
the burner must be checked and cleaned at least once a
year for gas and at least twice a year for oil.
11.2 Maintenance instructions
Cleaning of the boiler:
- Put boiler out of operation.
- Open the front door, if necessary after dismantling the
burner.
- Remove the retarders (only for the 9 - 16 sections).
- Clean the combustion chamber and fl ue passes using
a suitable brush.
- Clean the removed retarders ( 9 - 16 sections).
- Remove the rear panel of the boiler and remove the
cleaning cover (underneath the smoke box).
- Vacuum clean the boiler and the combustion cham-
ber.
- Renew the front door seals after cleaning the boiler.
- Re-assemble the removed parts and close the front
door.
- Re-assemble the burner (if dismantled).
- Check the boiler combustion side for leakage.
- Check the equipment for proper functioning and if
necessary re-adjust the control and safety equipment.
- Carry out combustion analysis.
- Check the water connections.

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© Copyright
All technical and technological information contained in these technical instructions,
as well as any drawings and technical descriptions furnished by us remain our
property and shall not be copied in part or whole without our prior consent in writing.
Subject to alterations
52881/1000/0202/Ips.
Broag Ltd.
Head office
Remeha house
Molly Millars Lane
Wokingham,
Berkshire RG41 2QP
Tel.: [phone]
Fax: [phone]
E-mail address:
[email protected]
Branch office
Unit 3, Kestrel Close,
Quarry Hill ind. Estate,
Ilkeston
Derbyshire DE7 4RD
Tel.: [phone]
Fax: [phone]
Remeha P500