REMEHA Quinta 45 Manual

1
Remeha Quinta 45/65
• High-efficiency
condensing boilers for
wall mounted installation
• Output
Quinta 45 : 9 - 43 kW
Quinta 65 : 13 - 65 kW
Technical information
Remeha Quinta 45
Remeha Quinta 65
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TABLE OF CONTENTS
PREFACE 6
1 General description of the boiler 7
2 Construction 8
2.1 Boiler layout 8
2.2 Operating principle 9
3 Technical data and dimensions 10
3.1 Dimensions 10
3.2 Technical data 11
3.3 General Specification 12
4 Efficiency information 13
4.1 Annual efficiency 13
4.2 Heat to water efficiency 13
5 Application information 14
6 Control and safety equipment 15
6.1 The control panel 15
6.1.1 General 15
6.1.2 Layout of the control panel 15
6.1.3 Combined key functions (in operating mode only) 17
6.1.4 Display of values with more than two digits 18
6.2 Flow diagram control system 18
6.3 Operating mode (x[[) 20
6.4 Shut-off mode (bXX) 21
6.5 Setting mode user level (X[[) 22
6.5.1 Flow temperature set point (!) 23
6.5.2 Pump run on time HTG (@) 23
6.5.3 DHW temperature set point (3) 23
6.5.4 Boiler control setting (A) 24
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6.6 Setting mode service level (X00) 25
6.6.1 Flow temperature set point during forced part load ($) 27
6.6.2 High limit thermostat (%) 27
6.6.3 Fan speed at full load HTG (^) 27
6.6.4 Fan speed at part load (HTG and DHW - &) 27
6.6.5 Starting point modulation (*) 27
6.6.6 Interface selection (() 28
6.6.7 DHW cut-in temperature (B) 28
6.6.8 Fan Speed at DHW full load (C) 28
6.6.9 Forced part load time after start (HTG only - G) 28
6.6.10 DHW control stop set point (I) 29
6.6.11 DHW control option (J) 29
6.6.12 HTG cut in temp (N) 29
6.6.13 Boiler type (P) 29
6.6.14 Maximum delay time (U) 29
6.6.15 Start and end point analog signal (Qand Y) 30
6.7 Read-out mode (X00) 30
6.8 Fan speed mode (<00) 31
6.9 Failure mode (x00) 31
7 Installation instructions 32
7.1 General 32
7.2 Location 32
7.3 Flue gas discharge and air supply 33
7.3.1 General 33
7.3.2 Classification due to discharging flue gases 33
7.3.3 Material and installation 34
7.3.4 Single boiler conventional flue 35
7.3.5 Single boiler, room sealed flue 36
7.3.6 Different pressure zones 37
7.3.7 Modular installations 38
7.4 Hydraulic installation 38
7.4.1 Condensate discharge 38
7.4.2 Water treatment 38
7.4.3 Cold feed and expansion tank height for open vented systems 40
7.4.4 Safety valve 40
7.4.5 Gas connection 40
7.4.6 System pump 41
7.4.7 Waterflow 41
7.5 DHW production 41
7.6 Modular systems 42
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8 Electrical installation 43
8.1 General 43
8.2 Specifications 43
8.2.1 Electrical supply 43
8.2.2 Control box 43
8.2.3 Fuse specification 43
8.2.4 Boiler temperature control 44
8.2.5 High limit temperature protection 44
8.2.6 Low-water protection (flow and content) 44
8.3 External connections 45
8.4 Boiler control 46
8.4.1 Modulating (two wire control) 46
8.4.2 Analog control (0 -10 Volt dc) 48
8.4.3 On / off control (1 x no volt switched pair) 50
8.4.4 High / low control (2 x no volt switched pairs) 50
8.5 DHW control (Broag priority) 50
8.5.1 Temperature control 50
8.5.2 Primary flow control 50
8.6 System pump 50
8.7 Frost protection 50
8.8 Remote alarm and boiler run indication 50
8.9 Safety interlock 51
9 Commissioning 52
9.1 Initial lighting 52
9.2 Shut-down 54
9.2.1 Temporary shut-down with frost protection 54
9.2.2 Permanent shut-down without frost protection 54
10 Fault-finding 55
10.1 General (all installations) 55
10.2 Fault codes 56
11 Inspection and servicing instructions 60
11.1 General 60
11.2 Annual Inspection 60
11.3 Maintenance 61
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PREFACE
These technical instructions contain useful and important information for the correct
operation and maintenance of the Remeha HTG boilers, models Quinta 45 and
Quinta 65.
Read these instructions carefully before putting the boiler into operation, familiarise
yourself with it’s control functions and operation, strictly observing the instructions
given. Failure to do so may invalidate warranty or prevent the boiler from operating.
The installation and commissioning of the boiler must be carried out by a competent
Engineer, with the relevant certification ie: CORGI, ACOPS, IEE regs. etc.
On completion a copy of the commissioning sheet should be returned to Broag Ltd for
record purposes.
If you have any questions, or if you need more information about specific 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 information (at
date of publication) and may be subject to revisions.
We reserve the right to continuous development in both design and manufacture,
therefore any changes to the technology employed may not be retrospective nor may
we be obliged to adjust earlier supplies accordingly.
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1 GENERAL DESCRIPTION OF THE BOILER
The Remeha Quinta 45 and Quinta 65 are wall hung condensing boilers which may be
also installed free standing on a suitable frame (option). The one piece cast aluminium
heat exchanger and other major components are contained within a sealed air box.
This forms the main boiler casing with a removable front section for maintenance
purposes. All electrical and electronic controls are contained within the instrument
panel mounted behind the drop down lower front panel.
The combined flue gas outlet and combustion air inlet are mounted on the top of the
boiler with the flow, return, gas and condensate connections located at the bottom.
The boiler is suitable for room sealed or open flue applications and has been designed
for central heating and indirect hot water production at working pressures not
exceeding 4 bar. It must be installed on a fully pumped system and is suitable for use
on both sealed and open vented installations (minimum operating pressure of 0.3 bar).
The pre-mix, down firing gas burner (NG or LPG) with its gas/air ratio control system
ensures clean, trouble free operation with higher than average efficiencies of 110%
(NCV) in the condensing mode combined with ultra low NOx and minimum CO
emissions. The standard control package allows actual and set values to be read and
adjusted on the built in digital display which also provides normal operating and fault
code indication.
An intelligent, advanced boiler control ‘abc’ continuously monitors the boiler
conditions, varying the heat output to suit the system load. The control is able to react
to external “negative” influences in the rest of the system (flow rates, air / gas supply
problems) maintaining boiler output for as long as possible without resorting to a lock
out condition. At worst the boiler will reduce it’s output and/or shut down (shut-off
mode) awaiting the “negative” conditions to return to normal before re-starting.
The ‘abc’ control cannot override the standard flame safety controls.
The boilers meet the requirements of the EC regulations and directives:
- 90/396EEC Gas appliances directive
- 92/42/EEC Efficiency directive
- 73/23/EEC Electrical low voltage directive
- 89/336/EEC E.M.C. directive
- 97/23/EEC Pressure equipment directive PED (art. 3, sub.3)
Remeha Quinta 45 - reference-number: PIN 0063BL3253
Remeha Quinta 65 - reference-number: PIN 0063BL3253
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2 CONSTRUCTION
2.1 Boiler layout
Fig. 01 Boiler layout Remeha Quinta 45 and Quinta 65
pdf
1. Automatic air vent
2. Air supply fan
3. Gas combi-block (with governor)
4. Gas injector/venturi
5. Cast aluminium heat exchanger
6. Temperature sensor-return
7. Air inlet tube
8. Pressure gauge
9. Control panel
10. Facility for incorporating a rematic®
weather compensated boiler control
11. Heat exchanger inspection cover
12. Sight glass
13. Combined ignition/ionisation probe
14. Temperature sensor-flow
15. Pre-mix burner
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2.2 Operating principle
Combustion air is drawn into the closed air box by a variable speed fan, through the
air inlet connection from the plant room (open flued) or from outside via the concentric
flue system (room sealed). On the inlet side of the fan is a specially designed venturi
which is connected to the outlet side of the gas combi block.
Depending on the demand (under the dictates of flow/return sensor and other external/
internal control inputs) the electronic control unit directly monitors the volume of gas
and air being delivered to the premix burner. This mixture is initially ignited by the
combined ignition/ionisation probe which then monitors the state of the flame. Should
the flame not ignite or is unstable within the pre-set safety time cycle the controls will
shut the boiler down (after 5 attempts) requiring manual intervention to reset the boiler.
The digital display will also indicate a flashing fault code confirming the reason for the
failure.
The products of combustion in the form of hot flue gases are forced through the heat
exchanger transfering their heat to the system water (the flue gas temperature is
reduced to approximately 5°C above the temperature of the system return water) then
discharged via the condensate collector, vertically through the 80/125 mm (Quinta 45)
or 100/150 mm (Quinta 65) combined flue/air connection to atmosphere.
Because of the low flue gas exit temperature there will be a vapour cloud formed
at the flue gas terminal - this is not smoke, simply water vapour formed during the
combustion process.
If the controls allow the flow and therefore return temperature to fall below dew point
(55°C) this water vapour will begin to condense out in the boiler, transfering it’s latent
heat into the system water, increasing the output of the boiler without increasing the
gas consumption.
Condensation formed within the boiler and flue system is discharged from the boiler to
an external drain via the drain pan / siphon supplied.
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3 TECHNICAL DATA AND DIMENSIONS
3.1 Dimensions
Fig. 02 Dimensions Remeha Quinta 45 and Quinta 65
05W4H7900001 + 00W4H7900001
ÊReturn connection 1¼" BSP (m) & 1" BSP (f)
ÉFlow connection 1¼" BSP (m) & 1" BSP (f)
ÏGas connection ¾" BSP (m)
ÒCondensate connection 25 mm Ø o/d (plastic)
ÐCombustion air supply connection 125 mm Ø i/d (Quinta 45) and 150 Ø i/d
(Quinta 65)
** ÐCombustion air supply connection 80 mm Ø i/d (Quinta 45) and 100 Ø i/d
(Quinta 65),see Par. 7.3.1
ÑFlue gas connection 80 mm Ø i/d (Quinta 45) and 100 mm Ø i/d (Quinta 65)
ãHoles for mounting bracket
* Quinta 45 = 120 mm / Quinta 65 = 140 mm
*
**
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3.2 Technical data
Boiler type Quinta 45 Quinta 65
General
Casing Colour BS RAL 9016
Boiler control options (External input)
(Two wire control)
On/off, High/low,
Analog 0 -10V
Communicating Modulation
Nominal output (80/60ºC) kW 8.0 - 40.0 12.0 - 61.0
Nominal output (50/30ºC) kW 8.9 - 43.0 13.3 - 65.0
Nominal input (GCV / Hs) kW 9.1 - 45.7 13.6 - 68.8
Nominal input (NCV / Hi) kW 8.2 - 41.2 12.2 - 62.0
Weight dry kg 57 64
Noise level at 1 m from boiler dB(A) <48
Gas- and flue details
Min/Max Inlet pressure natural gas mbar 17 - 30 17 - 30
Min/Max Inlet pressure propane mbar 37 - 50 37 - 50
Gas consumption (natural gas) m3/h 1.0 - 5.0 1.5 - 7.5
Gas consumption (propane) m3/h 0.3 - 1.7 0.5 - 2.5
NOx-emission *) mg/kWh < 37
NOx-emission (O2= 0%, dry) *) ppm < 21
Residual fan duty Pa 150 100
Mass flue rate kg/h 14 - 69 21 - 104
Classification due to discharging flue gases B23, C13, C33, C43, C53,
C63, C83
Water side
Maximum flow temperature ºC 100 (110)
Operating flow temperature ºC 20 - 90
Operating pressure min. (open vented) bar 0.3
Operating pressure min. (pressurised) bar 0.8
Operating pressure max. bar 4.0
Water contents ltr 5.5 6.5
Water resistance at 11 °C t mbar 300 430
Water resistance at 20 °C t mbar 90 130
Electrical
Main supply V/Hz 230 / 1 / 50
Electric rating W 30 - 85 30 - 90
Insulation class IP 20
Table 01 Technical data remeha Quinta 45 and Quinta 65
*) DIN 4702, part 8
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3.3 General Specification
(to be read with above table)
- One piece cast aluminium heat exchanger
- 1" BSP (f) and 1¼" BSP (m) flow and return connections
- ¾" BSP (m) gas connection
- Maximum operating pressure of 4.0 bar
- Maximum operating temperature of 95°C
- Low NOx (max 21 ppm, O2 = 0%, dry, according to DIN 4702, part 8)
- Pre-mix, fully modulating (18 -100%) gas burner with gas/air ratio control for
maximum efficiency
- Intelligent advanced boiler control 'abc' c/w a comprehensive operating, service and
fault diagnostic facility
- Available for conventional flue or room sealed operation
- Capable of remote BMS (0 -10V, On/off and High/low control options)
- Supplied fully factory assembled
- Powder coated enamel steel casing
- Suitable for use with a Natural gas or propane as standard (choices on
commissioning)
- Supplied as standard with safety interlock facility, temperature indication, control
and high limit sensors, common alarm and boiler run indication
- Efficiency of 99% at 80/60°C (Hi)
- Max efficiency of 105% (Hi) in fully condensing mode
- Manufactured to ISO 9001
- CE approved
Options
- Floor frame
- Two pipe flue/air inlet adapter plate (excentric room sealed)
- DHW-sensor
- Broag-Remeha weather compensating controllers
- Heat exchanger cleaning tool
- EMC filter for boiler sensor or boiler thermostat cables
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4 EFFICIENCY INFORMATION
4.1 Annual efficiency
Up to 109% at Hi(98% at Hs) at an input of 30% and a return temperature of 30°C.
4.2 Heat to water efficiency
a. Up to 99% at Hi(89% at Hs) at an average water temperature of 70°C (80/60°C).
b. Up to 105% at Hi(95% at Hs) at an average water temperature of 40°C (50/30°C).
NOTE: NCV = Hi, GCV = Hs
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5 APPLICATION INFORMATION
The Remeha Quinta can be used on all new and re-furbishment projects in both single
and multiple configurations. Conventional and room sealed flue system capability
means that the boiler can be sited almost anywhere within a building.
The Remeha range of weather compensators (options) are able to communicate
directly with the boiler controls (two wire) to make full use of it’s fully modulating
feature, ensuring that the boiler closely matches the system demand at all times.
External control systems (BMS) can be interfaced with the boiler to provide on/off -
high/low or modulating (0 -10 V) control options.
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6 CONTROL AND SAFETY EQUIPMENT
6.1 The control panel
6.1.1 General
The boiler is supplied with a standard set of defaults pre-programmed for normal
operation but can be tailored by the Engineer to suit most site conditions. These
values are set and read using the built in control panel or with a notebook computer
(with the correct software).
For security the control has three levels of access:
- User level - free access
- Service level - access with service code by qualified personnel
- Factory level - access by PC with factory code (Remeha only)
6.1.2 Layout of the control panel
Fig. 03 Control panel
00W4H7900044
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a. ‘code’-display
Indicates on user level: operating mode: only one digit 1
setting mode: digit with dot !
read-out mode: digit with flashing dot !
shut-off mode: letter b
forced full load: letter h
forced part load: letter l
Additional indication on
service level:
speed mode: alternate half digit <
failure mode: flashing digit 1
b. t-display
Indicates: Temperatures, settings, fault codes (flashing digits),
shut-off codes (flashing dots)
c. reset-key: to reset after a lockout condition
d. ‘m’ -key: Program function: key to select the required mode
e. ‘s’-key: Program function: key to select the required program
within the selected mode
e. ‘s’-key + r-symbol: Switch function: burner switch HTG (manual override)
f. ‘e’-key: Program function: key to save the settings
f. ‘e’-key + k-symbol: Switch function: burner switch DHW (manual override)
g. [+]- key: Program function: to select a higher setting
g. [+]- key + q-symbol: Switch function: pump manual override
h. [-]- key: Program function: to select a lower setting
h. [-]- key + h-symbol: Switch function: manual override (hand/auto)
Table 02 Control panel functions
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6.1.3 Combined key functions (in operating mode only)
When the boiler is in the operating mode, keys with the illuminated symbols above
have a double function (Program and Switch).
To use them for a Program function press the key once - and for a Switch function
(either on or off) press the key and hold for 2 secs. The status of the switch function
will be confirmed by the illuminated symbol as follows:
‘s‘-key and r-symbol:
- (symbol) not illuminated: HTG under normal control
- red (symbol) on: HTG off (manual override)
‘e’-key and k-symbol:
- (symbol) not illuminated: DHW under normal control
- red (symbol) on: DHW off (manual override)
[+]-key and q-symbol:
- green (symbol) on: continuous pump operation
- (symbol) not illuminated: pump under boiler control
[-]-key and h-symbol:
- green (symbol) on: HTG on (manual override)
- (symbol) not illuminated: HTG under normal control
NOTE: In the Switch function, (in order to protect the boiler and the installation) the
flow temperature cannot exceed it’s pre-set maximum. It is also not possible to change
any parameters.
Forced mode ‘high’ (h[[)
By pressing the ‘m’ and [+]-key simultaneously in operating mode, the boiler will burn
at maximum power. The letter hwill now appear on the display.
By pressing the [+] and [-]-keys simultaneously, the boiler will return to operating mode.
Following a manual override the boiler will return to normal (auto control) if no keys are
used within a 15 minute period
Forced mode ‘low’ (l[[)
By pressing the ‘m’ and [-]-key simultaneously in operating mode, the boiler will burn at
minimum power. The letter lwill now appear on the display.
By pressing the [+]and [-]-keys simultaneously, the boiler will return to operating mode.
Following a manual override the boiler will return to normal (auto control) if no keys are
used within a 15 minute period.
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6.1.4 Display of values with more than two digits
The display has only two digits available therefore values over this are displayed as
follows :
- negative values will be indicated by a dot behind the last digit e.g. 1) = -10
- values from 00 to 99 will be indicated without any punctuation marks
- values from 100 to 199 will be indicated by a dot between both digits
e.g. )0 = 100, !0 = 110, (9 = 199.
- values from 200 to 299 will be indicated by a dot behind every digit
e.g. )) = for 200, !) = 210, (( = 299.
6.2 Flow diagram control system
press the ‘m’ -key press the ‘s’-key
‘code’-display tdisplay
Operating mode,
see Par. 6.3
only digit or letter
0- 9,h,l,bFlow temperature or shut-off code
Setting mode,
see Par. 6.5 and
Par. 6.6
digit or letter with
dot
!Flow temperature set point
@Pump run on time HTG
#DHW temperature set point
ABoiler control setting
un/a
service engineer level only:
$Flow temperature set point during forced part
load
%High limit temperature set point
^Fan speed at full load (HTG)
&Fan speed at part load (HTG and DHW)
*Modulation start point Τ(F/R)
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(Interface selection (control option)
BDHW cut-in T
CFan speed at full load (DHW)
Dintern
En/a
Fn/a
GForced part load time after start (HTG)
HFan speed at start
IDHW control stop or boiler modulation set
point (based on parameter #)
JDHW control mode
Ln/a
NHTG cut in T (based on return)
On/a
PBoiler type
Tintern
UMaximum delay time
QStart point for 0 Volt analog signal
YEnd point for 10 Volt analog signal
_intern
Read-out mode,
see Par. 6.7
digit or letter with
flashing dot
!Actual flow temperature
@Actual return temperature
#Actual DHW temperature (with sensor)
$Actual outdoor temperature (with sensor)
%n/a
^Flow temperature (set point)
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&Actual heat demand status
*Calculated HTG cut-in temperature
(Actual flow temperature rise
An/a
service engineer level only:
Speed mode,
see Par. 6.8
alternate half
digit <
Fan speed
Failure mode,
see Par. 6.9
flashing digit
1Failure code
2Operating code during failure
3Flow temperature during failure
4Return temperature during failure
5DHW temperature during failure
6n/a
Table 03 Flow diagram control system
6.3 Operating mode (x[[)
During operation the code-display shows the status (position in cycle) of the boiler,
whilst the t-display indicates the actual flow temperature.
The digits or letters in the code-display have the following meaning:
Code Description
0Standby: there is no heat demand from control system.
1Pre-purge: before start-up, the boiler is purged for 3 seconds.
Post-purge: when the heat demand has been met, the fan continues to
operate for another 10 seconds.
2Ignition: ignition is activated for 2.4 seconds while the gas valve is opened.
3HTG mode; the boiler operates in the HTG mode.
4DHW mode: the three way valve or DHW pump activated (Broag priority only)
5Internal check
6Normal control stop during HTG (flow temperature > set point + 5 °C)
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