REMEHA P 520-13 Owner's manual

Remeha P 520
Fuel oil/gas boilers
Technical
instructions
English
29/08/05
63115

Contents
Remeha P 520 29/08/05 - 300003791-001-B
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1 Technical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2 Main dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Installing the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1 Boiler location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2 Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1 Dimensional information required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2 Important recommendations for connecting the boiler to the heating circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3 Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4 Sludge removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .12
Chimney connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1 Flue size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2 Chimney connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Fuel-oil or gas connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Electrical connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1 Sweeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2 Cleaning the casing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3 Precautions required in the case of long boiler stops (one or more years) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
4 Precautions required if the heating is stopped when there is a risk of freezing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Burner maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
System maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1 Water level . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2 Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Identification plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

3
29/08/05 - 300003791-001-B Remeha P 520
Introduction
This product will be marketed in the following European Union
member states :
BE - GB - NL - HU
with a gas burner of the associated category.
Directive 97/23/CE
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 tothe 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 520 29/08/05 - 300003791-001-B
Description
The boilers of the P 520 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 520 boilers is between 754 and 1450 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.

5
29/08/05 - 300003791-001-B Remeha P 520
1 Technical characteristics
Maximum operating pressure : 7.5 bar
Boiler thermostat setting : 30 to 90°C
Safety thermostat setting : 110 °C
*Maintenance consumption: total heat emission when the burner is
off as a percentage of the nominal input power when the difference
between the mean boiler temperature and the room temperature is
30 K.
(1)Nominal operation (top boiler power)
(2)CO2= 13.1 to 13.5% with fuel oil and 9.5% with natural gas.
(3)Boiler temperature : 80 °C
Ambient temperature : 20 °C
Boiler P 520-13 P 520-15 P 520-17 P 520-19 P 520-21 P 520-23 P 520-25
Useful efficiency kW 696 to 754 812 to 870 928 to 986 1044 to
1102 1160 to 1218 1276 to 1334 1392 to 1450
Power input kW 773 to 838 902 to 967 1031 to
1096 1160 to 1224 1289 to 1353 1418 to 1482 1547 to 1611
Number of sections 13 15 17 19 21 23 25
Water capacity l 617 693 769 845 943 1019 1095
Water resistance
∆T = 10K mbar 57.6 77.6 30.2 41.4 53.6 64.8 78.4
∆T = 15K 25.8 34.7 13.5 18.5 24 29 35
∆T = 20K 14.4 19.4 7.6 10.4 13.4 16.2 19.6
Pressure in the
furnace for nozzle
pressure = 0 mbar 2.2 2.4 2.6 2.85 3.1 3.3 3.5
Smoke temperature
(1) (3) °K <190 <190 <190 <190 <190 <190 <190
Mass flue gas flow
rate (1) (2) Fuel oil Kg/h 1070 1220 1370 1520 1670 1820 1970
Gas 1120 1280 1440 1590 1750 1910 2070
Combustion chamber
Recorded diameter mm 614 614 614 614 614 614 614
Equivalent diameter mm 694 694 694 694 694 694 694
Depth mm 1372 1594 1816 2038 2300 2522 2744
Volume m30.53 0.61 0.70 0.78 0.88 0.96 1.05
Maintenance
consumption* ∆T = 30K % 0.08 0.07 0.07 0.07 0.06 0.06 0.06
Shipping weight kg 3000 3364 3756 4124 4538 4930 5297

6Remeha P 520 29/08/05 - 300003791-001-B
2 Main dimensions
P 520
Minimum height for sweeping = 850
Flowrate detector
Burner centre line
* Plain plate, requires cutting. Maximum cut-out 500 x 700.
** Dimension representing the end of the 100 mm long chimney
connection.
G = Length required for clearing the water distributing tube.
Nota : with models P 520-21, P 520-23 and P 520-25, a plain plate
which must be cut out is supplied without the 100 mm chimney
connection.
1566
543
496
370
Ø F
815
1080
200
420
616
R
791
17,5
S140
370
240
U
B
MH
K
Ø E
LG
P
D
T
Ø E
223
300
100
C
741
1172
M000032
718
A
*
*
*
50
1
2
3
755
Boiler P 520 P 520-13 P 520-15 P 520-17 P 520-19 P 520-21 P 520-23 P 520-25
A (mm) 1563 1785 2007 2229 2491 2713 2935
B (mm) 1522 1744 1966 2188 2450 2672 2894
C (mm) 1488 1488 1488 1504 1504 1504 1504
D (mm) 256 188 210 257 209 231 253
Ø E (weld) (mm) 139.7 139.7 139.7 159 159 159 159
Ø F (mm) 350 400 400 400 * * *
G (mm) - 150 370 370 650 980 980
H (mm) 37 -31 -9 13 -35 -13 9
K** (mm) 49 -19 3 25 -23 -1 21
L (mm) 1955 2245 2445 2645 2955 3155 3355
M (mm) 275 324 321 299 324 324 303
P (mm) K 355 355 355 355 355 355 355
R (mm) K 175 175 175 175 175 175 175
S (mm) K 1760 1760 1760 1760 1760 1760 1760
T (mm) 1372 1594 1816 2038 2300 2522 2744
U (mm) 2021.5 2243.5 2465.5 2687.5 2949.5 3171.5 3393.5

7
29/08/05 - 300003791-001-B Remeha P 520
Main dimensions - Rear view P 520
565
3/4"
500
Max
700 max
610 M000158

8Remeha P 520 29/08/05 - 300003791-001-B
Installing the boiler
1 Boiler location
For the assembly and because of their design, P 520 boilers require
no special base. Their closed furnace system means that the floor
neednothaverefractoryproperties. Allyouhaveto ensureisthat the
floorcansupporttheweightoftheboilerwhenitisfittedforoperation.
Iftheboilerlocationisnotdetermined precisely, leave enoughspace
around the boiler to facilitate monitoring and maintenance
operations.
Boiler body *
Straight connection (not supplied) *
* 1) In order to facilitate subsequent work on the boiler(replacing the
water distributing tube etc.) use a flanged connection from the boiler
to the system, making sure you comply with minimum clearance
dimension D.
Angled connection (not supplied)
Air inlet
Air outlet
If A = 1.2 m(door opening side), A’ = 0.5 m
If A = 0.5 m, A’ = 1.2 m (door opening side) : adapt the dimensions
on the basis of the dimensions of the burner when the door is open.
B = 1.5 m : adapt the dimensions on the basis of the dimensions of
the burner.
P 520 P 520-13 P 520-15 P 520-17 P 520-19 P 520-21 P 520-23 P 520-25
L1955 2245 2445 2645 2955 3155 3355
M275 324 321 299 324 324 303
C min. 300 436 656 656 936 1266 1266
D min. - 136 356 356 636 966 966

9
29/08/05 - 300003791-001-B Remeha P 520
2 Ventilation
The location of air inlets in relation to the high ventilation openings
shall ensure that the air is renewed in the entirevolume of the boiler
room.
Itisinanycaseimperativetoconformtothelocalregulationsinforce.
Warning:
Inordertoavoiddamage 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
For mounting instructions, see installation instructions.

10 Remeha P 520 29/08/05 - 300003791-001-B
Hydraulic connections
1 Dimensional information required
Draining outlet 3/4’’
Heating return :
- 13 to 17 sections : 139.7 - 5’’
- 18 to 25 sections : 159 - 6’’
weld.
Heating outlet :
- 13 to 17 sections : 139.7 - 5’’
- 18 to 25 sections : 159 - 6’’
weld.
* dimension without connection (see figure on chapter "Boiler
location", straight or angled connection).
C
1080mm
H*
D
M000034
1
2
3
0m20m
P 520 P 520-13 P 520-15 P 520-17 P 520-19 P 520-21 P 520-23 P 520-25
C (mm) 1488 1488 1488 1504 1504 1504 1504
D (mm) 256 188 210 257 209 231 253
H (mm) 37 -31 -9 13 -35 -13 9

11
29/08/05 - 300003791-001-B Remeha P 520
2 Important recommendations for connecting the boiler to the heating circuit
Installation must be carried out in accordance with the prevailing
regulations,the codes ofpracticeand 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 800 kW.
Minimum safety valve flowrate must be 6000 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 aminimum of 30% of the nominal stage
- Operationatmodulatedlowtemperature(minimumoutlettemperature:40°C) ;thefirststagemustbesettoaminimumof50%ofthenominal
stage
0
0
0100 200 300 1000 1300
400 500 600 700 800 1100 1200 1400 1500 1600 1700 1800
900
0
1000
2000
3000
10000
13000
4000
5000
6000
1000
2000
3000
4000
5000
6000
1000 2000 3000 4000 5000 6000
7000
8000
11000
12000
14000
9000
MBtu/h
kW
kg/h
lb/h
M000035
2
1

12 Remeha P 520 29/08/05 - 300003791-001-B
`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: 40°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
themselveswhenit isoperating;themanualbleedervalves
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 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
thesystemfirst.Installasludgedecantingpotonthereturnpipe,very
close to the boiler.
2’’ tapped sludge removal hole
M000036
1
58 mm6
150mm

13
29/08/05 - 300003791-001-B Remeha P 520
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 520 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 300 mm for 13 sections
Ø 400 mm for 14 to 20 sections
Boilers with 21 to 25 sections are supplied with a plain plate. The
maximum cut-out dimensions are 500 x 700 mm.
Fit a measuring point (Ø 10 mm hole) on the flue, in order to adjust
the burner (combustion check).
*Dimension representing the end of the 100 mm long chimney
connection mm.
Nota : with models P 520-21, P 520-23 and P 520-25, a plain plate
which must be cut out is supplied without the 100 mm chimney
connection.
815mm
86mm55mm86
K
M000037
Ø F
P 520 P 520-13 P 520-15 P 520-17 P 520-19 P 520-21 P 520-23 P 520-25
Ø F 350 400 400 400 Plain plate Plain plate Plain plate
K49 -19 3 25 -23* -1* 21*

14 Remeha P 520 29/08/05 - 300003791-001-B
Fuel-oil or gas connections
Refer to the instructions supplied with the burner.
Electrical connections
Refer to the connection instructions supplied with the control panel..
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.
- Cut the power supply to the boiler.
- Remove the upper front panel.
- Remove the retaining upper front crosspiece and then the lower
left and right-hand front panels.
- Remove the lower front panel.
*
- Unfasten the wing nuts and remove the 4 sweeping doors.
M000038
1
1
2
3 3
4
M000039
2

15
29/08/05 - 300003791-001-B Remeha P 520
- Remove the baffle plates from the upper flue ways.
- Carefully sweep the four flue ways with the brush supplied for that
purpose.
- Brush the baffle plates as well.
- If possible, use a vacuum cleaner.
- Unfasten the nuts up to the stop.
- Push in the handles of the sweeping covers.
- Remove the sweeping covers.
- Remove the left and right-hand casing covers.
- Remove the top insulating material.
- Brush the vertical plates.
- Put back the sweeping covers, insulating material and casing
covers by reversing the procedure above.
Comments : chemical sweeping is recommended for such
boilers.
- Put the baffle plates back in place. Interlock them with each other
while fitting them into the flue ways.
- Close the upper sweeping doors.
M000040
3
M000042
5
1
19
2
3
M000041
4
M000043
6

16 Remeha P 520 29/08/05 - 300003791-001-B
- Unscrew the 8 closing nuts and open the furnace door.
These 3 screws must not be unfastened in any event.
- Remove the lower rear panels.
- Remove the lower rear crosspiece.
- Remove the lower insulating material on the rear.
- Brush out the inside of the furnace.
- Clean the soot accumulated in the furnace and lower flue ways
with a vacuum cleaner.
- Close the lower sweeping doors.
- Put back the front casing panels by reversing the removal
procedure.
- Unfasten the wing nuts and remove the lower left and right-hand
sweeping doors.
- Remove any soot deposit with a scraper or a vacuum cleaner.
- Open the lower sweeping cover of the flue gas box (2 H 10 nuts +
Ø 10 washers).
- Remove the soot.
- Put back the sweeping cover and doors.
- Put back the lower insulating material, the crosspiece and panels
by reversing the removal procedure.
19
M000044
7
1
2
M000046
9
M000045
8
M000047
10

17
29/08/05 - 300003791-001-B Remeha P 520
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)
(one or several 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. 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,withvery low quantities of water;otherwise, lookfortheleak
and repair it.
2 Draining
We advise you against draining the system unless it is absolutely
necessary.

18 Remeha P 520 29/08/05 - 300003791-001-B
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.
Boiler type
Power ranges
Thermic output
Spare parts
See next page
M000048
3

19
29/08/05 - 300003791-001-B Remeha P 520
Spare parts
To order a spare part, quote the reference number next to the part required.
13/04/05 - 300003791-002-A
Boiler body
M000049
44
21
19
38
39
2a
22
43
47
37
20
29
28
31
52
30a
16
46
46
40
39
39
46
39
40
15
46
11
13
33
45
60
61
63
30
25
23
21
37 24
38
6
14 36
7
10
12
8
41 42
17
18
9
5
4
35
15
34
49
3
21
21
27
26
48
32
62

Insulation
71
70
M000050