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broag REMEHA W40-m ECO, Installation And Maintenance Instructions Manual

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broag REMEHA W40-m ECO Installation And Maintenance Instructions Manual Download Page 2

2

remeha W40/60-m ECO

CONTENTS

Preface

4

1. General description of the boiler

4

2. Construction

4

3. Technical data and dimensions

5

3.1

Dimensions

5

3.2

Technical data

6

3.3

Delivery package

6

4. Efficiency information

7

4.1

Annual efficiency

7

4.2

Heat to water efficiency

7

5. Installation applications

7

5.1

General

7

5.1.1

Installation of single boilers

7

5.1.2

Installation of multiple boilers

8

6. Boiler layout

9

6.1

Equipment diagram

9

6.2

Operating principle

10

6.3

Control panel

10

6.4

Control system

11

6.4.1

General

11

6.4.2

Operating mode

12

6.4.3

Setting mode (with dot)

13

6.4.4

Read-out mode (with blinking dot)

14

6.4.5

Forced 'HIGH' mode

14

6.4.6

Forced 'LOW' mode

14

6.4.7

Speed mode (half digits)

14

6.4.8

Failure mode (blinking 'code' display)15

6.4.9

Service code

15

6.4.10 User settings

16

7. Installation instructions

17

7.1

General

17

7.2

Location

17

7.3

Dimensions of wall mounting bracket

17

7.4

Ventilation requirements

18

7.5

Flue gas discharge and air supply

19

7.5.1

General

19

7.5.2

Single boiler, 
non room sealed applications

20

7.5.3

Single boiler, 
room sealed applications

21

7.5.4

Cascade configurations

21

7.6

Installation details

22

7.6.1

Condensate discharge

22

7.6.2

Cold feed and expansion tank 
height for open vented systems

22

7.6.3

Water treatment

22

7.6.4

Safety valve

23

7.6.5

Circulation pump

23

7.7

D.H.W. application

23

7.7.1

D.H.W. control

23

7.7.2

Schematic sketch of connections

24

Summary of Contents for REMEHA W40-m ECO

Page 1: ...m ECO Installation and maintenance instructions High efficiency condensing boiler for free standing frame mounted or wall mounted installation Suitable for room sealed fanned flue or open flue fan assisted operation ...

Page 2: ...h blinking dot 14 6 4 5 Forced HIGH mode 14 6 4 6 Forced LOW mode 14 6 4 7 Speed mode half digits 14 6 4 8 Failure mode blinking code display 15 6 4 9 Service code 15 6 4 10 User settings 16 7 Installation instructions 17 7 1 General 17 7 2 Location 17 7 3 Dimensions of wall mounting bracket 17 7 4 Ventilation requirements 18 7 5 Flue gas discharge and air supply 19 7 5 1 General 19 7 5 2 Single b...

Page 3: ...t down 32 10 3 Settings 33 10 3 1 General 33 10 3 2 Setting the required flow temperature 33 10 3 3 Setting the required flow temperature when using an outdoor sensor 33 10 3 4 Changing the cut in temperature differential 33 10 3 5 Setting the pump control 33 10 3 6 Setting the burner control 33 10 3 7 Setting D H W temperature 34 10 3 8 Switching D H W operation on and off 34 10 3 9 Changing D H ...

Page 4: ... boiler is suitable for room sealed fanned flue or open flue fan assisted applications The boiler is designed for central heating and indirect hot water supply at working pressures not exceeding 3 bar It should be installed on a pumped water circulation system and is suitable for both open and unvented sys tem operation The remeha W40 60 m ECO is fitted with a top mounted premix gas burner firing ...

Page 5: ...e gas discharge 100 mm dia 6 Combustion air supply 100 mm dia Low loss header for single boiler only Flow return connections 11 4 BSP F Fig 02 remeha W60 m ECO Front view Side view Top view 1 Flow boiler 11 4 male thread 2 Return boiler 11 4 male thread 3 Gas 3 4 male thread 4 Condensate discharge 32 mm dia 5 Flue gas discharge 100 mm dia 6 Combustion air supply 100 mm dia Low loss header for sing...

Page 6: ...0 8 71 B23 C13 C33 C43 C53 C63 240 50 150 2 20 100 20 90 0 3 3 5 400 350 67 kW kW kW kW kW kW kW kW mbar m3 h mg kWh ppm mbar kg h V Hz VA A IP C C bar bar ltr mbar mbar kg remeha W40 m ECO remeha W60 m ECO 3 3 Delivery package circulation pump low loss header pressure gauge filling and drain cock air supply fan electronic control and protection equipment 24V interface for rematic weather compensa...

Page 7: ...heat ing combined with pumped indirect domestic hot water supply systems The remeha W40 60 m ECO is not suitable for systems which include any gravity circulation bathroom installa tions or connection to unlined brick chimneys 5 1 1 Installation of single boilers The low noise level emission of 48 dBA measured at 1 m from the boiler makes the remeha W40 60 m ECO ideal for installation as a single ...

Page 8: ... 4 step weather compensator Master Step 1 till 4 2 rematic 4 step modular controller Slave Step 5 till 8 3 Pump to be set at position 1 4 Safety valve 5 Three way valve 230 V D H W 6 Non return valve 7 Expansion vessel if required 8 Manual isolating valve 9 Automatic vent 10 Open header neutral header 11 Drain cock 12 Installation pump 13 Installation expansion vessel 14 Flow sensor 15 Outdoor sen...

Page 9: ...ass 14 Manual air vent 15 Gas combi block 16 Heat exchanger 17 Flow temperature sensor 18 Inspection cover 19 Return temperature sensor 20 Condense collector 21 Instrument panel 22 Electrical connection strip X15 23 Facility for incorporating a rematic weather compensated boiler control 24 Condensate discharge 25 Setting keys 26 Read out display and reset key 27 Burner switch 28 Interface for rema...

Page 10: ... thus formed is discharged via a siphon at the base of the heat exchanger 6 3 Control panel The remeha W40 60 m ECO is equipped with an advanced control system comprising a an automatic microprocessor control system b a control panel with setting keys and read out display Various values can be set and read using the setting keyboard and read out displays The two levels for setting and read out are...

Page 11: ...an speed at start I Max flow temperature D H W J D H W control L Reserve n Heating cut in temperature differential P Security type 1 Flow temperature 2 Return temperature 3 D H W temperature 4 Outdoor temperature 5 Not applicable 6 Flow temperature setpoint 7 Room thermostat status and air pressure switch status 8 Reserve 9 Not applicable Fan speed blinking digit 1 Failure code 2 Operating mode du...

Page 12: ...ting mode 4 D H W operation the boiler operates when the three way valve serving the calorifier is actuated by a demand from the D H W temperature sensor 5 Waiting mode the fan runs and the boiler waits until this has been proved or waits until the three way valve has returned to the central heating position 7 Continued pump operation in the central heating mode after heat demand is met the pump c...

Page 13: ...the heating contractor Select the service code C 1 2 see para 6 4 9 Select the setting mode by pressing the mode key until 1 appears in the code read out display Now select the required code using the step key Code Description Setting Preset 6 Fan speed at full load 1 0 6 0 hundreds 4 9 7 Fan speed at full load 0 0 9 9 units 0 0 8 Fan speed at part load 1 0 6 0 hundreds 3 0 9 Fan speed at part loa...

Page 14: ...or will switch to that mode automatically after 15 minutes 6 4 7 Speed mode half digits On service level for the heating contractor The fan speed can be read in parts in the speed mode Select the service code C 1 2 see para 6 4 9 Now select the fan speed code using the mode key half digits 6 4 4 Read out mode with blinking dot Various values can be read in the read out mode On user level Select th...

Page 15: ...play of failure code chapter 11 2 0 3 Operating mode during failure para 6 4 2 3 5 3 Flow temperature during failure 4 4 0 Return temperature during failure 5 6 0 D H W temperature during failure 6 1 0 Outdoor temperature during failure Keep both keys pressed and press the store key The temperature display is blinking to acknowledge your access to the service setting Press the store key to store t...

Page 16: ...lay Set the required value using the and keys Code Description 2 0 0 Pump continues to operate for 10 sec 2 X X Pump continues to operate for 1 15 min example X X 05 2 9 9 Continuous pump operation Press the store key to store the new value value will blink twice Press the mode key until the digit without dot appears in the code display Code Description 3 6 5 required temperature Press the store k...

Page 17: ...tic or commercial the requirements of the follow ing publications should be complied with Domestic BS 5449 BS 5546 BS 6644 BS 6891 CP 3006 and BG DM2 Commercial BS 6644 BS 6700 BS 6880 Pts 1 2 and 3 CP 342 2 IM2 IM5 IM11 IM16 and IM22 Manufacturers Instructions must NOT be taken as over riding statutory obligations Important The remeha W40 60 m ECO is a certified appliance and must not be modified...

Page 18: ...irements for high and low level ventilation open ings which MUST be provided are contained in detail within BS 6644 Openings must be permanent communicate direct to outside and be positioned so as to avoid blockage flooding or high velocity draughts within the boilerhouse The minimum free area of openings are shown in the table b Room sealed installations Boilers require no air for combustion but ...

Page 19: ...outside supply opening The flue duct termination must be located such that when exposed to wind it will remain under suction when the appliance is out of operation The flue should be constructed from single walled alu minium or stainless steel 316 and any air supply ducts from either single walled aluminium stainless steel or plastic All seams and joints in the flue shall be air and watertight Whe...

Page 20: ...ns Lengths over 40 metres consult Broag Ltd NB deduct 2 metres of piping length for each 90 bend 1 2 3 4 1 2 3 4 26 40 23 40 13 40 10 40 24 40 21 40 11 40 8 40 80 100 Outlet without Terminal free outlet Outlet with Terminal Min and max allowable lengths of the flue gas discharge piping H in m D in mm Ø 1 2 3 4 1 2 3 4 9 36 7 34 22 18 7 34 5 32 20 16 80 100 Outlet without Terminal free outlet Outle...

Page 21: ... f hf hf hf hf h h h h h h h h hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf hf ...

Page 22: ...avoid sludge and scale information c reduce to a minimum the risk of microbiological contamination of the system d minimise chemical action and changes which take place over a period of time when system water is untreated The boiler contains an aluminium heat exchanger and the system will also contain a variety of metals Ferrous metals cast iron and steel and non ferrous metals copper brass and gu...

Page 23: ...ndirect calorifier can be connected to the remeha W40 60 m ECO in accordance with the schematic sketch shown fig 15 and 16 and the wiring diagram in para 8 10 7 7 1 D H W control The remeha W40 60 m ECO is supplied as standard with a D H W control suitable for activating a 230 V spring loaded three way valve The three way valve is de energized in the central heating position The control features p...

Page 24: ...24 remeha W40 60 m ECO 7 7 2 Schematic sketch of connections Fig 15 Schematic sketch of an open system Fig 16 Schematic sketch of a sealed system HR ...

Page 25: ...ommunication between the modulating control and the protection system is always via an interface PCB The appliance is equipped as standard with an interface for one of the rematic modulating weather compensa ted controls SR 5240 C1 2945 C1 UMU and 2945 C1 MUMU When using a modulating room control Honeywell Chronotherm Modulation the interface must be exchanged Installation and connection 1a remati...

Page 26: ... the sensor is pro tected from direct sunlight Lay the cable to the boiler The cable is supplied in a standard 15 metre length and may not be extended If the cable is extended problem free operation cannot be guaranteed 8 3 4 Two stage external weather compensator The remeha W40 60 m ECO can be connected to a two stage external weather compensator The boiler can run on high low Proceed as follows ...

Page 27: ...ing facility The alarm signal operates via termi nals 6 and 7 and whilst the boiler is operational a 24V AC signal power 4 VA is available to energise a relay In case of failure of any electrical interlock or mains failure the 24V supply will be switched off The alarm which is de activated whilst there is a power supply from the relay during normal operation is now activated by the failure of this...

Page 28: ...r temperature is too high 100 C When the malfunction is corrected the boiler can be restarted by using the reset key on the control panel 8 7 Differential air pressure switch LD2 At the start of a heat demand the appliance first checks whether the LD2 is open If so the fan switches to a monitoring speed and waits until the LD2 is closed Subsequently the LD2 function will no longer be active 8 8 Co...

Page 29: ...29 8 10 Electrical wiring diagram Fig 19 Electrical wiring diagram ...

Page 30: ...sure is 17 30 mbar The burner pressure has been factory set but must be checked and re adjusted to site conditions by an approved engineer Consult our Technical Sales Depart ment for other types of natural gas 9 3 Gas air ratio control The boiler is equipped with a gas air ratio control The purpose of this control is to keep the ratio between gas and air quantities in the burner within safe limits...

Page 31: ...rner 3 Appliance in central heating operation 4 Appliance in boiler operation the three way valve to the boiler or the boiler pump has been activated The following operating situations are now possible 16a Modulating operation The appliance will modulate at the flow temperature requested by the modulating regulator see also Note under 16c 16b High low operation The appliance is operating at part l...

Page 32: ...m thermostat or weather compensator at the required value 21 The boiler is now ready for use Note The remeha W40 60 m ECO is supplied with a number of basic settings burner control on off or modulating flow temperature 80 C post running time pump 5 minutes D H W control operating D H W temperature 65 C D H W cut in temperature differential 5 C If other setting values are required see alteration of...

Page 33: ...s achieved Once the room thermostat has switched the required flow temperature will once again fall by 1 C per minute until the stoking line is regained 10 3 4 Changing the cut in temperature differential Setting mode step n Preset 10 C Change setting see para 6 4 1 and 6 4 3 10 3 5 Setting the pump control Setting mode step 2 Preset 5 minutes Change setting see para 6 4 1 and 6 4 10 10 3 6 Settin...

Page 34: ...entral heating on D H W off X 3 central heating off D H W on Note In the factory the control has been set so that the appli ance will switch off if the measured D H W temperature is 5 C preset value above the preset boiler tempera ture The appliance switches back on at a temperature 5 C below the shutoff point i e at the boiler tempera ture set by yourself This cut in temperature differential can ...

Page 35: ...ace the rematic control If the fault has still not been corrected replace the interface PCB 3 LED A see fig 23 is not flashing Check whether the tape cable connector X7 is cor rectly mounted in the interface PCB and in the control box Then if necessary replace the interface PCB If the fault has still not been corrected replace the control box 4 Both LEDS are flashing This indicates that the instal...

Page 36: ...ective 1 8 Max water Flow temperature too high 1 9 temperature Return temperature too high 2 4 Temperature a Flow and return temperature sensors mixed up sensor fault b Flow and return connections mixed up c Water flow in D H W mode not correct 2 5 Maximum water Rise in flow temperature too fast temperature Check circulation pump position 1 or 2 water flow through the unit sufficient number of rad...

Page 37: ...of approximately 70 C The flue gas temperature can also be taken at P7 This flue gas temperature must not exceed the return water temperature by more than 30 C If this check shows the operation of the unit to have deteriorated clean the boiler as detailed in para 12 3 Fig 24 Measuring points W40 m W60 m boiler model kW input NCV 18 6 62 1 12 7 42 3 4 8 4 8 O2 4 8 4 8 9 0 9 0 CO2 9 0 9 0 fan speed ...

Page 38: ...move the pipes E from the inlet mixer Open the union nut for the gas pipe in the air box A Remember To prevent the flexible gas pipe twisting when slacken ing and tightening the union nut A1 the hexagon nut A2 should be held in place with a spanner see fig 25 Fig 25 Dis assembly of the gas pipe Remove the bolts from the attachment strips B The fastening strips can then be removed Remove the electr...

Page 39: ...ic brush remove any loose dust particles from the fan before reassem bling the system Reassemble all parts removed in reverse order Attention Check that all control hoses are properly fitted following assembly in the event of incorrect assembly it is not possible to guarantee the correct setting of the gas air ratio Check the setting of the ignition electrode between 3 and 4 mm Restart the applian...

Page 40: ...criptions furnished by us remain our property and shall not be multiplied without our prior consent in writing Broag Ltd Head Office Remeha house Molly Millars Lane Wokingham Berkshire RG 41 2QP Tel 0118 9786977 Fax 0118 9783434 Email address boilers broag ltd uk Branch Office Unit 3 Kestrel Close Quarry Hill Industrial Estate Ilkeston Derbyshire DE7 4RD Tel 0115 9440778 Fax 0115 9440588 ISO 9001 ...

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