REMEHA Calenta 25s Installation And Service Manual Download

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4 Installation

4.1

Regulations governing installation

WARNING

Installation of the appliance must be done by a qualified

engineer in accordance with prevailing local and national

regulations.

Installation must also respect the following points:

This instruction manual and any other applicable documentation

NEN 1006: The general provisions for drinking water installations

(AVWI)

NEN 1010: The provisions on safety for low voltage installations

NEN 1078: Gas device with an operating pressure of up to 500

mbar - performance requirements - new construction

NPR 3378: Guide on NEN 1078

NEN 1087: Ventilation of residential buildings

NPR 1088: Explanatory instructions on NEN 1087

NEN 2078: Requirements applicable to industrial gas installations

NEN 2757: Combustive air supply and flue gas discharge for

combustion appliances

NEN 3028: Requirements applicable to incineration installations

NEN 3215: Drainage systems inside residences and residential

buildings

NEN 8078: Gas device with operating pressure of up to 500 mbar

- performance requirements - existing construction

Building Regulations

Local provisions from the fire brigade, public service companies

and the municipality

In the event of application of domestic hot water supply equipment.

Work data sheet Drinking water installations, VEWIN nr. 4.4 B

4.2

Package list

4.2.1.

Standard delivery

The delivery includes:

The boiler, fitted with an earthed mains plug

Mounting rail and mounting accessories for wall mounting

Mounting template

Connection kit comprising sleeves and clamping rings

4. Installation

Calenta 25s - 28c - 35s - 40c

040412 - 7600585-01

Summary of Contents for Calenta 25s

Page 1: ...Netherlands EN High efficiency wall hung condensing gas boilers Calenta 25s 28c 35s 40c Installation and Service Manual 7600585 01...

Page 2: ...ce complies with the standard type described in the EG declaration of conformity It was manufactured and commissioned in accordance with European directives The original of the declaration of complian...

Page 3: ...neral description 12 3 2 Main parts 12 3 3 Operating principle 13 3 3 1 Gas air setting 13 3 3 2 Combustion 14 3 3 3 Heating and domestic hot water production 14 3 3 4 Control system 14 3 3 5 Adjustme...

Page 4: ...nections for the air and exhaust pipes 32 4 8 1 Classification 32 4 8 2 Outlets 33 4 8 3 Lengths of the air flue gas pipes 34 4 8 4 Specific air flue gas applications 36 4 8 5 Additional Directives 36...

Page 5: ...Setting the air gas ratio Part load 59 5 4 4 Basic setting for the gas air ratio 60 5 5 Checks and adjustments after commissioning 60 5 5 1 Finalizing work 60 5 6 Reading out measured values 61 5 6 1...

Page 6: ...city 75 7 3 4 Checking the tightness of the flue gas evacuation and air inlet connections 76 7 3 5 Checking combustion 76 7 3 6 Checking the automatic air vent 77 7 3 7 Checking the safety valve 77 7...

Page 7: ...9 Spare parts 93 9 1 General 93 9 2 Spare parts 93 040412 7600585 01 5...

Page 8: ...y CAUTION Risk of material damage Signals important information Signals a referral to other instructions or other pages in the instructions 1 2 Abbreviations 4 3CE Collective conduit for sealed boiler...

Page 9: ...art up and carry out any checks necessary 4 Explain the installation to the user 4 If a maintenance is necessary warn the user of the obligation to check the appliance and maintain it in good working...

Page 10: ...tes with 120 litres of water at 40 C on average The simultaneity of these functions is not a requirement Parameters for which the performance of the Calenta 28c boiler complies with the Hot Water Comf...

Page 11: ...ype Connection pressure mbar II2L3P I2H G20 Gas H 20 G25 Gas L 25 G31 Propane 30 50 The boiler is preset in the factory to operate on natural gas G25 Gas L 1 4 3 Additional Directives Apart from the l...

Page 12: ...ible leaks and seal them immediately 2 2 Recommendations WARNING 4 Installation and maintenance of the boiler must be carried out by a qualified professional in compliance with prevailing local and na...

Page 13: ...d to the appliance must never be removed or covered and must remain legible during the entire lifespan of the appliance Immediately replace damaged or illegible instructions and warning stickers Modif...

Page 14: ...xer pipe 5 Heating flow hose 6 Air intake silencer 7 Box for the control PCBs accessory 8 Combined venturi and gas valve unit 9 Flow end hydroblock 10 Safety valve outlet pipe 11 Siphon 12 Instrument...

Page 15: ...onization electrode 21 Air intake 3 3 Operating principle 3 3 1 Gas air setting The casing fitted to the boiler is also used as an air box Air is sucked in by the fan and gas injected into the venturi...

Page 16: ...ition The heating water reheats the domestic water in the plate exchanger In comfort mode if there is no hot water draw off the boiler handles the periodic reheating of the plate exchanger Any limesca...

Page 17: ...7 Protection against a shortage of water The boiler is fitted with a safety device to prevent the shortage of water based on temperature measurements By reducing its output when the water flow rate is...

Page 18: ...ating 3 3 10 Shunt pump The boiler is equipped with a circulating pump This energy efficient modulating circulating pump is controlled by the control unit based on T The graph shows the manometric hei...

Page 19: ...ting flow and return and the maximum speed at which the flow temperature increases In this way the boiler does not require a minimum water flow rate If using thermostatic valves see chapter Hydraulic...

Page 20: ...temperature 60 C 96 1 96 1 96 3 96 3 Heating efficiency under partial load EN 92 42 Return temperature 30 C 108 0 108 0 108 2 108 2 Data on the gases and combustion gases Gas categories I2L3P and I2H...

Page 21: ...e 91 4 93 8 Water content l 0 33 0 49 Operating pressure Pmw maximum bar 8 8 Electrical characteristics Power supply voltage VAC 230 Power consumption Full load maximum W 116 124 129 139 Factory setti...

Page 22: ...able to industrial gas installations 4 NEN 2757 Combustive air supply and flue gas discharge for combustion appliances 4 NEN 3028 Requirements applicable to incineration installations 4 NEN 3215 Drain...

Page 23: ...sure gauge Supporting device for feeding pipes behind the appliance Pipe kit for connections behind the appliance in combination with the supporting device Protective cover for the connections Propane...

Page 24: ...quate accessibility to the appliance and facilitate maintenance leave enough space around the boiler WARNING 4 Fix the appliance to a solid wall capable of bearing the weight of the appliance when ful...

Page 25: ...lar switch with an opening gap of at least 3 mm EN 60335 1 4 3 3 Ventilation 1 Distance between the front of the boiler and the internal wall of the casing box 2 Distance to allow on either side of th...

Page 26: ...circuit return Clamping 22 mm x Domestic cold water inlet Clamping 15 mm Gas Gaz Gas connection Clamping 15 mm y Domestic hot water outlet Clamping 15 mm Heating circuit flow Clamping 22 mm T000754 C...

Page 27: ...ustion gas exhaust to protect the boiler and its connections from dust Only remove this protection at the time when these connections are made 2 Drill 2 holes with a of 10 mm Additional holes are prov...

Page 28: ...isable to hydraulically separate the boiler circuit from the central heating circuit by installing a plate heat exchanger Parameters p 8 and p 9 are used to modify the pump settings 4 5 2 Connection o...

Page 29: ...DHW sensor 4 Air vent kit of the hot water tank 5 Safety unit 6 Expansion vessel 7 Heating Installation 8 3 way valve The boiler connection kit must be used to install the three way valve in the boil...

Page 30: ...vent an uncontrolled flow in the heating circuit the return channel to the hot water tank must always be connected directly to the return channel to the boiler and therefore never directly connected t...

Page 31: ...new installations installations less than 6 months old 4 Clean the installation with a universal cleaner to eliminate debris from the appliance copper hemp flux 4 Thoroughly flush the installation unt...

Page 32: ...pe to the heating return connection 4 The boiler is factory fitted with a safety valve mounted on the left hydroblock 4 To facilitate maintenance work we recommend mounting a shut off valve on the hea...

Page 33: ...the heating return pipe z If using a heating and domestic hot water production type boiler on an installation in which the flow can be fully disconnected from the return e g by using thermostatic valv...

Page 34: ...tions 4 8 Connections for the air and exhaust pipes The boiler is suitable for the following types of flue gas connections See chapter Certifications page 7 4 8 1 Classification The table specifies th...

Page 35: ...mbar is possible 4 See table for minimum sizes of duct or sleeving Type Execution Diameter Minimum size of the duct or jacket Without air supply With air supply Channel Channel Channel Channel C93 Ri...

Page 36: ...bustion gas discharge piping with a diameter other than 80 mm a reducer should be used CAUTION 4 The air supply opening must remain open 4 The premises in which the appliance is installed must be fitt...

Page 37: ...ssure C53 C83 Combustion air supply and combustion gas discharge are possible in various pressure zones semi CLV systems With the exception of coastal areas The maximum permissible difference in heigh...

Page 38: ...heat exchanger unit Some boiler settings must be changed for this application of the boiler Full details are provided with the special connection kit accessory component Always use the heat exchanger...

Page 39: ...luminium combustion gas exhaust pipes it is initially necessary to consider the relatively high quantity of corrosive products which are brought together with the condensate from the exhaust pipe The...

Page 40: ...proval according to Gastec QA or KOMO Flexible 1 Stainless steel Approval according to EN 1856 1 Synthetic material T120 Approval according to Gastec QA or KOMO 1 The sealing must conform with pressur...

Page 41: ...Connection of the power supply cable The boiler is fitted with an earthed plug cable length 1 5 m suitable for a 230VAC 50Hz power supply with live neutral earth system The power supply cable is conne...

Page 42: ...l panel 4 Earth the appliance before making any electrical connections Make the electrical connections of the boiler according to 4 The instructions of the prevailing standards 4 The instructions on t...

Page 43: ...nd grommet s on the lower plate of the boiler 3 Tilt the control box forwards by opening the holding clips located at the sides 4 Open the tooling box by opening the clip fastener on the front side 5...

Page 44: ...supplies this temperature with the set value on the boiler as the maximum n Connect on off thermostat Tk ON OFF room thermostat The boiler is suitable for connection to a 2 wire on off room thermosta...

Page 45: ...ermostat If an on off thermostat is used it is advisable to protect any rooms where there is risk of frost by using a frost thermostat The radiator valve in a room where there is a risk of frost must...

Page 46: ...where an outside sensor is used 4 At an outside temperature lower than 10 C can be set with parameter p30 the circulation pump switches on 4 At an outside temperature higher than 10 C can be set with...

Page 47: ...ts Remove the bridge before using the input The behaviour of the input can be changed using parameter p36 See chapter Parameter descriptions page 64 4 9 10 Release input The boiler has a release input...

Page 48: ...rol n Analogue input 0 10 V This control can be based on temperature or heat output The two controls are described briefly below For analogue control the 0 10 V signal must be connected to the interfa...

Page 49: ...Description 0 5 Alarm 1 10 10 100 Delivered temperature Jumper 1 Output signal V Heat output Description 0 0 15 Boiler off 0 5 15 20 Alarm 2 0 10 1 20 100 Heat output supplied 1 Dependent on the minim...

Page 50: ...f the three way valve can be set using parameter p34 The three way valve is connected as follows 4 N neutral 4 C central heating 4 D tank n Control of external sanitary hot water pump 3wV It is also p...

Page 51: ...Tsol The solar boiler temperature is controlled using a sensor Connect this sensor to the connector terminals Tsol n Pressure switch minimum Gps The minimum gas pressure switch shuts the boiler down...

Page 52: ...U X9 2 3 4 5 X91 BK BK BK BK 1 2 4 5 1 BK BK 1 2 X117 P 230V 50Hz L N SCU X2 1 3 2 BL BR GN YW X1 1 2 3 BR BL GN YW DIS 1 10 1 10 X3 4 3 2 1 5 BR BL BR BL GN YW 3 1 4 2 X51 GB PUMP A DV IT FAN S X13 X...

Page 53: ...at least 20 times the volume of the pipes 4 For untreated water the pH value of the water in the installation must be between 7 and 9 and for treated water between 7 and 8 5 4 The maximum hardness of...

Page 54: ...nutes During filling air can escape from the system via the automatic air vent If the water pressure is lower than 0 8 bar the symbol e will appear If necessary top up the water level in the heating s...

Page 55: ...ter p8 Key lock out is activated by setting parameter p6 to 3 If no key is pressed for 3 minutes the display lighting switches off and only the current water pressure the key and the d symbol are disp...

Page 56: ...of the operating hours number of successful starts and hours on mains supply 5 2 Check points before commissioning 5 2 1 Preparing the boiler for commissioning WARNING Do not put the boiler into oper...

Page 57: ...unscrewing the pressure outlet on the gas block Tighten the measurement point when the pipe has been sufficiently purged 8 Check the tightness of the gas connections in the boiler 5 2 3 Hydraulic cir...

Page 58: ...ilation 1 Fan ON 1 Post ventilation Boiler is igniting 5 Burner stop Boiler is igniting 5 Burner stop 6 Post circulation of the pump 6 Post circulation of the pump 3 Heating System 0 Standby 4 Domesti...

Page 59: ...ance with the CW label For operation on another group of gases carry out the following operations 4 Regulate the fan speed as indicated in the table if required The setting can be modified using param...

Page 60: ...lenta 40c 4 8 0 4 9 0 0 2 4 8 0 5 9 0 0 3 O2 CO2 control and setting values at full load for G25 Gas L Boiler type Setting value Checking value O 2 CO 2 O 2 CO 2 Calenta 25s 5 0 0 4 8 8 0 2 5 0 0 5 8...

Page 61: ...r CO2 value 6 Check the flame through the flame inspection window The flame must be stable and blue in colour with orange particles around the edge of the burner O2 CO2 control and setting values at p...

Page 62: ...mixing elbow unit in place on the heat exchanger 7 Completely remove the fan mixing elbow unit For steps 3 to 7 inclusive see chapter Checking the burner and cleaning the heat exchanger page 78 8 Tur...

Page 63: ...ether with the end user fill in the warranty sheet provided 16 Confirm the commissioning with a signature and a company stamp 5 6 Reading out measured values 5 6 1 Reading the various current values T...

Page 64: ...pears on the display 10 Press the key p is displayed alternating with the current modulation percentage 78 for example 11 Press the key The readout cycle starts again with 5t 12 Press the key 2 times...

Page 65: ...trol 31 Limited temperature control T safety 32 Output control 33 Increase protection level 1 Modulate down 34 Increase protection level 2 Part load 35 Increase protection level 3 Blockage 36 Modulate...

Page 66: ...resistance 0 No anticipation resistance for the ON OFF thermostat 1 Anticipation resistance for the ON OFF thermostat 0 p6 Display screen 0 Simple 1 Comprehensive 2 Automatic switching to simple afte...

Page 67: ...with an outside temperature sensor 15 p28 Setting the pump speed Minimum pump speed for central heating operation 2 10 x 10 2 p29 Setting the pump speed Maximum pump speed for central heating operatio...

Page 68: ...ify these factory settings unless absolutely necessary For example for modification of the boiler for G20 H gas or G31 propane high pressure systems WTW coupling or CLV overpressure 5 7 2 Modification...

Page 69: ...s sticker must be affixed to the top of the boiler next to the identification plate CAUTION Modification of the factory settings may be detrimental to the functioning of the appliance 1 Press the two...

Page 70: ...rotation speed rpm Calenta 40c M Maximum heat input F Factory setting Q Power input kW R Fan rotation speed rpm T001848 B 1500 0 5 10 15 20 25 30 2000 2500 3000 3500 4000 4500 5600 5000 5500 6000 F R...

Page 71: ...simultaneously and then key until the symbol flashes on the menu bar 2 Select the installers menu using the key S c0de appears on the display 3 Use keys or to input the installer code 0012 4 Confirm u...

Page 72: ...oiler can be switched to automatic or manual operation under the symbol E To do this proceed as follows 1 Press the two keys f simultaneously and then key until the symbol E flashes on the menu bar 2...

Page 73: ...itself from frost To prevent radiators and the system from freezing in rooms where there is a risk of frost e g a garage or storage room a frost thermostat or outside sensor can be connected to the bo...

Page 74: ...5 The symbol C appears on the display 6 4 Shutting down domestic hot water production The boiler drinking water mode can be deactivated via the quick menu To do this proceed as follows 1 Press the N...

Page 75: ...or c Thanks to the automatically transmitted maintenance message it is possible to carry out preventive maintenance and therefore use the maintenance kits defined by Remeha thus reducing breakdowns t...

Page 76: ...the two keys f simultaneously and then key until the symbol flashes on the menu bar 2 Press the S key hr and the number of hours of boiler operation 3600 for example are displayed alternately 3 Press...

Page 77: ...8 bar the symbol e will appear If necessary top up the water level in the heating system recommended hydraulic pressure between 1 5 and 2 bar 7 3 2 Checking the ionization current Check the ionization...

Page 78: ...Set the boiler to full load Press the two B keys simultaneously The B symbol is visible on the menu bar and h3 appears in the display The boiler is now operating at full load 4 Measure the percentage...

Page 79: ...ater in the small hose on the automatic air vent 7 If any leaks are detected replace the air vent 7 3 7 Checking the safety valve 1 Take out the flow collector located under the boiler 2 Check whether...

Page 80: ...m cleaner again without the top cleaning brush on the endpiece 9 Check using a mirror for example whether any dust can still be seen If so hoover it up 10 The burner does not require any maintenance i...

Page 81: ...n ignition electrode on the ignition transformer 2 Unscrew the 2 screws and remove the ionization ignition electrode 3 Replace the ionization ignition electrode 7 4 2 Cleaning the plate exchanger dome...

Page 82: ...n the heat exchanger side heating circuit 7 Unscrew the 2 hexagonal socket screws located to the right and left of the plate exchanger 8 Slightly turn the plate exchanger and carefully remove it from...

Page 83: ...his be sure that the silencer is left in place 6 Remove the domestic water cartridge 7 Rinse the water filter cartridge with tap water and if need be clean it with a descaling product e g citric acid...

Page 84: ...ide of the hydroblock 6 Remove the heating return hose on the right side of the hydroblock and not on the heat exchanger side heating circuit 7 Unplug the actuator 8 Remove the clip holding the 3 way...

Page 85: ...alve unit 3 Disconnect the connector located under the fan 4 Release the 2 clips holding the fan mixing elbow unit in place on the heat exchanger 5 Completely remove the fan mixing elbow unit 6 Replac...

Page 86: ...mark 3 Put the siphon back in place CAUTION Mount the vent hose above the siphon 4 Carefully open the main water valve fill the installation vent it and if need be top it up with water 5 Check the se...

Page 87: ...and apply the solution If the display does not show J but rather a the boiler must be switched off and then switched on again after 10 seconds before the fault can be reset Error code Description Prob...

Page 88: ...ion 4 Check the wiring 4 Replace the sensor if necessary 4 Vent the air in the heating system 4 Check the circulation direction pump valves 4 Check the water pressure 4 Check that the sensors are oper...

Page 89: ...hot CO2 too high 4 Check the ionization ignition electrode 4 Check the gas valve and replace if necessary 4 Set the CO2 e 17 Problem on the gas valve SU PCB 4 Bad connection 4 Defective SU PCB 4 Chec...

Page 90: ...exist after several start up attempts the boiler will switch into locking mode fault The boiler can only start operating again once the causes of the lock out have been rectified and after pressing th...

Page 91: ...e and neutral of mains supply mixed up 4 Mains supply incorrectly wired 4 Floating or 2 phase network 4 Invert phase and neutral 4 Set parameter p43 to 0 5v 10 Shutdown input is open 4 External cause...

Page 92: ...ully opened 4 Check the supply pressure 4 Check the operation and setting of the gas valve unit 4 Check that the air inlet and flue gas discharge flues are not blocked 4 Check that there is no recircu...

Page 93: ...key to view the following information M 1 Number of times that the error occured hr The number of operating hours 5t State 5v Sub status t1 Supply temperature F C t Return temperature F C t3 Calorifi...

Page 94: ...isplay 5 The fault list or shutdown list can be displayed by pressing the or key 6 Confirm using key S er xx is displayed with xx flashing 7 Press the key several times until er cl is displayed on the...

Page 95: ...general terms and conditions of sale and supply Always ensure that your return package is accompanied by the duly completed return form see attached example In this way Remeha can more easily and mor...

Page 96: ...2019 2029 2022 1004 1001 1002 1006 1003 3004 3002 3011 3012 3008 3001 3008 3006 3010 3005 3003 3007 4011 4010 4014 4012 4013 4009 4004 4001 4014 4003 5010 4009 5009 4002 5037 5017 5014 5015 5008 5020...

Page 97: ...03 5014 5017 5008 5015 2030 5025 2030 2009 5011 2007 2015 4015 2032 5012 2012 2017 2001 2021 2020 2002 2006 4009 5017 5018 5029 5032 5002 5031 4010 4011 4012 4002 2022 2010 5013 5017 5017 5029 5017 50...

Page 98: ...9 Spare parts Calenta 25s 28c 35s 40c 96 040412 7600585 01...

Page 99: ......

Page 100: ...ail remeha remeha com NL Copyright All technical and technological information contained in these technical instructions as well as any drawings and technical descriptions supplied remain our property...

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