Rima ONGAS 300/W Series Instruction manual

ONGAS
300/W SERIES CONDENSING BOILER
·Cast Aluminum Wall Hung Condensing Boilers
REV.01
/2011-OONGAS 300/W
·For Natural Gas
0051 - 11

Index
Safety Instructions
3
Standards & Instructions & Symbols
4
Meaning of the Symbols on packaging
4
Data Plate & Packaging Plate
4
Operating Principle of ONGAS 300/W Series
5
Technical Specification Table
6
Operating Instructions
7
Functional Description of Smart Control Panel
7
Description and functions of the LCD display
8
Operating Modes
10
Description of the Boiler & Delivery Terms
18
Installation Instructions
19
Recommended Minimum Distances
19
Boiler Dimensions for ONGAS Series
20
Boiler De-montage
25
Plumbing Instructions
25
Heating (Radiator) Water
26
Condensate Discharge
26
Gas Connections
27
Electrical Connections
28
ONGAS 303/W Series Electrical Wiring Diagram
30
ONGAS 304/W - 305/W - 306/W - 307/W Series Electrical Wiring Diagram
31
Cascade Configurations
32
Gas rate adjustment instructions
32
Adjustment of the Gas Rate ( ONGAS 306/W & 307/W )
33
Adjustment of the Gas Rate ( ONGAS 303/W & 304/W & 305/W )
34
Chimney Connections
35
Chimney Installation for ONGAS 300/W Series
36
Example Hydraulic Schemes for ONGAS 300/W Series
37
Fault Finding
40
Description of the error codes
41
Cleaning and Maintenance
43
Commissioning Form
44

Safety instructions
Gas Valve (ONGAS 306/W/307/W) , High Voltage Risk
Hig
h voltage in the Ignition transformer , ignition
electrode , and heat exchanger.
Instructions must be followed
carefully to avoid personal injury or
serious damage to the unit or the
environment.
The following symbols are used in this
document to emphasize certain instructions.
This is in order to increase your personal
safety and to safeguard the technical reliability
of the boiler.
Indicates possible danger of electric
shock. Serious personal injury may
occur.
This boiler is connected to a 230v
mains supply. An improper
installation or
attempts to repair
electrical components or controls
may result in life threatening
situations.
Keep unauthorized personnel away
from the boiler. Do not place objects
on or against the boiler. Do not
touch hot water connections or the
flue outlet when the boiler is
operat
ing –burn hazard.
Installation, repair, commissioning,
maintenance and repair work must
only be carried out by suitably
qualified personnel.
Engineer in
accordance with all relevant national
/
local standards and certifications.
Always disconnect the mains supply
and close the main gas cock before
working on the boiler.
The boiler
must not be modified or non
-
RIMA
spare parts fitted without the
express written approval of RIMA.
If you smell gas, close the (main)
gas cock and contact the
emergency
situation
gas leak
telephone number for your
area.
If you smell flue gas fumes,
turn the boiler off and contact your
service company or installer.
Terminal box (ONGAS 300/W Series )High Voltage

Standards & Instructions & Symbols
When installing and operating the boilers it is necessary to keep a safe 200 mm distance from combustible
materials with combustibility degrees B,C1,C2 .
For easily flammable materials with combustibility degree C3 ,which burn quickly and by themselves also after
the ignition source removal the safe distance is doubled it means 400 mm.
Meaning of the Symbols on packaging
FRAGILE TOP SIDE RECYCLE PROTECT AGAINST WATER
All gas appliances must be installed by authorized technicians. Failure to install appliances correctly could lead
to prosecution. RIMA ONGAS
300/W condensing boiler must not be installed or mod
ified in any situations
except written in this manual. Always transport the boiler in the safety packaging , before installation. Additional
protection may be required if site conditions warrant it
–
overhead builders working, insulation etc. Please apply
the regulations and instructions about installation clearances.
Data Plate Packaging Label
Gas Type Plate
The boiler has been set at the
factory for natural gas H/E (G20,
20 mbar).

RIMA ONGAS300/W Series Condensing Boilers
are in compliance with the ; EC Directives
(2009/142/EC) Gas Appliances Directive
(2006/95/EC) Low Voltage Directive
(2004/108/EC) Electromagnetic Compatibility Directive
(92/42/EEC) Efficiency Directive
The boiler may only be installed in a room which
complies w
ith the appropriate ventilation requirements
and which is separated from living rooms.
If not , there is suffocate and poisoning risk .
Read the technical instructions before installing and
lighting the boiler.
ONGAS 300/W Series Wall Hung
Condensing Boilers for Natural Gas
Operating Principle of ONGAS 300/W Series

Operating Instructions

Description of the Boiler & Delivery Terms
The RIMA ONGAS
300/W Series Condensing Boiler is completely assembled , Wall Hung
, fully modulating ,
high efficiency condensing boiler up to (109%) and delivered with steel enamel powder coated casing , shrinked
with film , on a pallet. Cast aluminum heat exchanger and other main components are supplied within boiler
chassis
with easy removable casing for cleaning and maintenance. All main electrical and electronically controls
are supplied in the control panel which is placed on top of the boiler. The RIMA ONGAS
300/W
series
condensing boiler is suitable for room sealed or open flue applications (B and C type) and has been designed
for central heating also optionally domestic hot water. The operating pressure of system is between the 0,8 bar
min. to 6 bar max. The circulation pump must be installed to system. Every boiler has
been tested during the
assembling properly. The pre
-
mix burner with its air/gas system ensures clean mixing , reaches up to 109%
efficiencies without any problem in condensing mode , combined with ultra low NOx and minimum CO
emissions. The control panel
provides the actual and set values to be read and adjusted on the built-
in LCD
display, which also provides normal operating and fault code indication. The control system of the boiler allows
to monitoring all boiler conditions.
Smart
Control
Panel
Fresh Air
Intake
Flue Gas
Measuring
Point
Chimney
Automatic
Air Vent
Condansate
outlet
Water
Outlet
Water
nlet
Gas
Inlet

Installation Instructions
RIMA ONGAS 300/W Series Condensing Boiler should be positioned as follows ;
Place the boiler in the plant room to operation location.
Remove films, straps, pallets, top and sides and all other packaging.
All gas appliances must, by law, be installed by authorized persons. Failure to install appliances correctly could
lead to prosecution. It is in your own interest and that of safety to ensure that the law is complied with.
The boilers must be installed where frost protected place. The water in the radiators must be discharged when
the boiler is not working to avoid from frost.
The boiler must not be installed place that contains humid, vapor, dust. Otherwise , boiler is not working
correctly and efficiently.
The ground where the boiler installed must be stabilized, strong, flat and high from floor level for avoid of
flooding.
Fresh air supply must be refined from halogen hydrocarbons (sprays, paint and some chemical
materials), otherwise this materials can cause corrosion and erosion in the boiler and flue gas chimney.
Do not put flammable materials on top of the boiler or near the boiler.
The fresh air intake, must be according to local gas suppliers and gas connecting instructions, otherwise
there is a risk of poisoning.
Condensing water and chimney connection must be done according to regulations and standards.
800 mm

Boiler Dimensions for ONGAS 300/W
Plumbing Instructions
·Return water inlet, gas inlet and supply water outlet connections placed in rear side of the boiler.
·Every model (ONGAS 303/W,304/W, 305/W, 306/W, 307/W) has a different water and gas connection
size. Boiler connection sizes are given in the technical table.
·Avoiding of the faulty circulation, check valves must be used with circulation pump system. In the new /old
buildings and new/old plumbing systems, strainer (filter) must be used in the return water line.
·Safety valve (max.6 bar), and manometer must be used in the plumbing system. There must not be any
valve between boiler and safety valve, otherwise pipes and the other parts may explode in the over-
pressurized boiler (evaporation harmless).
·RIMA ONGAS 300/W Series Condensing Boilers are only compatible and works with systems which has
circulation pump.
·RIMA ONGAS 300/W Series Condensing Boilers delivered without circulation pump.
·RIMA ONGAS 300/W Series Condensing Boilers are compatible with max. 6 bar systems.
Heating (Radiator) Water
Sanitary water can be used for plumbing and additional
water. Please clean the plumbing system before filling
with water. Chemical materials and softeners can cause
damage to system.
Please consider on the standards and instructions while
the plumbing system are installing, otherwise water
leakage or plumbing problems will occur.
For avoiding the Oxygen diffusion to radiator water ( may cause
from the problem in the heat exchanger), system separator should be used in the system.
Supply
Water
Outlet
Return
Water
Inlet

Lime and chalk can be formed according to the working type of
boiler. Radiators must be heated in min. efficiency with enough
water flow. In cascade systems, all boilers must be worked same
capacity, otherwise chalk and lime may condensed in one boiler.
All plumbing system pipes must be check against leakage before
operating the boiler.
The water quantity in the system, should be determinate by heating
project engineer.
The system should be filled with mains cold water (usually have a pH of between 7 and 8).Pressurized installations
with a boiler / system content ratio of 1:10 or less should not require water treatment.
All scale deposits will reduce the efficiency 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 efficiency and will not reduce the
anticipated life expectancy of the boiler.
Take advice on the suitability of inhibitors for use with aluminum boilers MAX pH of 8.5 when using additives (max.
pH of 9 without additives).
Water Quality
Regarding to quality of water used in central heating and boiler systems, some institutions published instructions as
well as VDI Directive
2035, DIN EN 14868 Standard. Acc
ording to these instructions, for heating systems with
maximum
100 o
C operating temperature, to avoid accumulation of lime (calcium carbonate), below reference
values of water quality are valid;
Total Heating Capacity (kW)
Hardness (°F)
≤ 50
None
50 - 200
≤20
200 - 600
≤15
> 600
< 0,2
Water Rate
Boiler Type
Min. Water Rate (m³/h)
Max. Water Rate (m³/h)
303
2,9
5
304
4,1
7
305
5,2
9
306
6,6
11
307
8,2
13
Condensate Discharge
Unload the condensed water with a pipe, directly into a
drain. Only use plastic material for the connecting piping,
because of the acidity (pH 2 - 5) .(R 3/4 "). Condensing
discharge into an outside gutter, because of the freezing
risk.

Gas Connections
·Gas connections must be done by authorized personnel or gas certificated plumbing
companies.
·Old plumbing systems, must be refined from sediment and debris before installation of
radiator and gas piping.
·Gas side connections must be checked against gas leakage before commissioning.
·Poisoning and explosion risk due to inappropriate gas plumbing materials using and installation
is not made in accordance with the rules.
·Fire protected gas valve must be used in the system, if not, risk of explosion in case of firing.
·Gas connections must be done according to standards and directives.
Perform the gas leakage test, when the check valve is OFF. Gas valves can be exposure max. 150 mbar
pressure. Gas valves and burners may damaged over this pressure and as a result of explosion and
poisoning. In the pressure test of gas side, ball valve in gas device must be closed (OFF position).
Please be careful of gas type that using in the boiler and please consider on the conversion instructions.
Electrical Connections
·Electrical connections must be done by authorized technicians.
·Terminal box, fuse, switches and sensors delivered completely assembled and functionally tested.
·Main supply and other accessories (circulation pump, etc…) must be connected by
authorized technicians.
·Please examine carefully the electrical wiring diagram, before making any connection.
·Please cut off the electrical ( main ) supply , before any operations. The electrical supply is not
cutted, when the ON/OFF switch is at OFF position.
Flue Gas
Measuring
Point
Fresh Air
Intake
Chimney
·In the flue gas discharge connections, only RIMA Original Parts and authorized local gas dealer parts must
be used. Please read carefully instructions before connecting the chimney.
·Local gas distributers may have different directives, because of this, information should be taken from local
gas companies and dealers.
Gas Inlet

Electrical Connection Samples
Remove the screws from control panel for connecting electrical supply and other equipments.
·
To ensure reliable long term operation, mount the boiler control at a position in the appliance with
a low ambient temperature, heat and a low radiation. The boiler control should be externally
fused. High temperatures will strongly affect product life,
please consider on the installation
instructions.
·When first starting the boiler control has a self check time of about 10 seconds.
·Electrical rating of connected controls should be appropriate for the load that is switched by the
boiler control.
·Disconnect the boiler control from mains before performing a dielectric strength test.
·The flame connection pin of all types is not protected against electrical shock.
Terminal Box
Terminal Connections
Mainboard
Safety
Thermostat
Working
Indicator
Energy
Indicator
ON/OFF
Switch

·The modulation function of the boiler control units is checked during the start up safety check. As
a result the gas technical safety of the appliance provided with a boiler control unit can rely on the
proper functioning of the adjustable gas outlet pressure during ignition of
this boiler control unit.
This means that due to a safe ignition pressure level, the safety time of the boiler can be
extended.
·Take care that installer is a trained experienced service person. Disconnect power supply to
prevent electrical shock and/or equipment damage.
·Wiring must be in accordance with local regulations. The appliance manufacturer’s instructions
should always be followed when provided. If such instructions are not provided see the connection
diagrams for typical systems
. Before installing or replacing any control check that type number is
correct for the application. Ensure combustion chamber is free of gas before start up. Conduct a
thorough check out when installation is completed. At the first start the boiler control
can be in
lock-out; depress reset button to free control.
·Do not connect the boiler control to power supply when it is not connected to the gas control.
Flame Sensing
Electrode
Ignition
Electrode
Modulated Fan
Power Cable
Flue Gas
Sensor
Return Water
Temperature
Sensor
Supply Water
Temperature
Sensor
Automatic
Air Vent

ONGAS 300 Series Electrical Wiring Diagram
All electrical connections must be done according the diagrams are given above.

Cascade Configurations
The boiler is also suited for configuration in a cascade
applications. For overpressure flue gas cascade
arrangements,
use our motori
zed flue gas discharge valve (available as an accessory). This prevents
flue gas from flowing back to
boilers that are not in operation. As a
result of the narrow width and depth of the boiler, a heat output of 375
kW (2 x
ONGAS 307/W
) can be provided in a floor area of just
under 2 m2. A floor area of less than 3 m2 is sufficient to
include
room for service and maintenance. If necessary, contact our technical department.
Gas rate adjustment instructions
FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE, SEVERE INJURY OR DEATH !
Gas leak test
·
Paint all pipe connections upstream of the gas control with a rich soap and water solution. Bubbles indicate a
gas leak.
·If a gas leak is detected, tighten the pipe connection.
·
Stand clear while lighting the main burner to prevent injury caused from hidden gas leaks, which could cause
flashback in the appliance vestibule. Light the main burner.
·With the main burner in opera
tion, paint all pipe joints (including adapters) and gas control inlet and outlet
with a rich soap and water solution approved leak detection fluid.
·If another gas leak is detected, tighten adapter screws, joints and pipe connections.
·Replace the part if gas leak cannot be stopped.
Check for gas leaks with a rich soap and water solution any time work is done on a gas control. Keep soap and water
solution away from electrical connections.
Disconnect power supply to prevent electrical shock and/or equipment
damage. Wiring must be in accordance with local regulations. The appliance manufacturer’s instructions should
always be followed. Before installing or replacing any control check that type number is correct for the application.
Ensure combustion chamber is free of gas before start up. Conduct a thorough check out when installation is
completed. At the first start the ignition control can be in lockout; depress reset button to free the ignition control.
Under normal circumstances no maintenance or service i
s required.