REMEHA CALORA TOWER GAS 15S EX Installation And Service Manual Download

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5 Installation

5.1

Regulations governing installation

WARNING

Installation of the appliance must be done by a qualified

engineer in accordance with prevailing local and national

regulations.

5.2

Package list

5.2.1.

Standard delivery

The delivery includes:

The boiler, fitted with an earthed mains plug

Attachment for C-mix optional PCB

Sticker with details on gas type

Installation and Service Manual

User Guide

5.2.2.

Accessories

Various options are available depending on the configuration of the

installation.

Boiler - DHW tank connection kits

Central connection kit - right / left

Mixing valve kit for integration DHW tank

Connection kit for external mixing valve

Fitting for circulating pipe

Flue kit

Flue gas adapters for concentric 80/125 mm or eccentric 80/80

mm connection

iSense programmable control system for modulating boiler

control (Cable on RF)

C-mix control PCB

Outside sensor

Flue gas temperature sensor

Electronic boards for extension

DHW expansion vessel

Propane conversion kit

CALORA TOWER GAS 15S EX CALORA TOWER GAS 25S EX

CALORA TOWER GAS 35S EX

5. Installation

22/04/2016 - 300026141-001-07

Summary of Contents for CALORA TOWER GAS 15S EX

Page 1: ...EN Floor standing high efficiency gas boiler CALORA TOWER GAS 15S EX CALORA TOWER GAS 25S EX CALORA TOWER GAS 35S EX C003589 A Installation and Service Manual 300026141 001 07...

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

Page 3: ...ions 11 3 1 Homologations 11 3 1 1 Certifications 11 3 1 2 Gas categories 11 3 1 3 Additional Directives 11 3 1 4 Factory test 11 3 2 Technical specifications 11 4 Technical description 13 4 1 General...

Page 4: ...hs of the air flue gas pipes 33 5 8 Electrical connections 35 5 8 1 Control unit 35 5 8 2 Recommendations 35 5 8 3 Access to the connection terminal 36 5 8 4 Position of the PCBs 38 5 8 5 Heating circ...

Page 5: ...1 Parameter descriptions 68 6 7 2 Modification of the installer level parameters 73 6 7 3 Setting the maximum heat input for central heating operation 73 6 7 4 Return to the factory settings Reset Pa...

Page 6: ...owns and lock outs 87 9 2 1 Lock out 87 9 2 2 Blocking 87 9 3 Error memory 90 9 3 1 Error readout memorised 91 9 3 2 Deletion of the error display 92 10 Spare parts 93 10 1 General 93 10 2 Spare parts...

Page 7: ...22 04 2016 300026141 001 07 5...

Page 8: ...user maintenance shall not be made by children without supervision DANGER If you smell gas 1 Do not use a naked flame do not smoke do not operate electrical contacts or switches doorbell light motor l...

Page 9: ...e where the boiler is installed Casing components Only remove the casing for maintenance and repair operations Put the casing back in place after maintenance and repair operations Instructions sticker...

Page 10: ...Failure to abide by the instructions on installing the appliance 1 3 2 Installer s liability The installer is responsible for the installation and commissioning of the appliance The installer must res...

Page 11: ...using slight physical injury CAUTION Risk of material damage Signals important information Signals a referral to other instructions or other pages in the instructions 2 1 2 Symbols used on the equipme...

Page 12: ...iler 4 DHW Domestic hot water 4 HRU Heat Recovery Unit 4 HL High Load DHW tank with plate exchanger 4 SL Standard Load DHW tank with coil 4 SHL Solar High Load Solar DHW tank with plate exchanger 1 2...

Page 13: ...ves described in these instructions must also be observed For all provisions and Directives referred to in these instructions it is agreed that all addenda or subsequent provisions will apply at the t...

Page 14: ...emperature 30 C 110 2 110 1 110 6 Data on the gases and combustion gases Gas consumption Natural gas H G20 minimum maximum m3 h 0 33 1 59 0 55 3 10 0 69 3 71 Gas consumption Natural gas L G25 minimum...

Page 15: ...ing is switched on for 30 minutes 4 2 Main parts 1 Flue gas discharge pipe 2 Flue gas measuring point 3 Heat exchanger 4 Ignition ionization electrode 5 Box for the control PCBs 6 Control panel 7 Comm...

Page 16: ...nger 2 Hydroblock 3 Heating flow 4 Plate exchanger inlet 5 Plate exchanger outlet 6 Heating return 7 3 way valve 8 Circulation pump 9 Expansion vessel 10 Domestic hot water outlet 11 Domestic cold wat...

Page 17: ...ank 18 Domestic water coil 19 Safety valve 4 3 2 Circulation pump n Pump specifications 15 25 kW boilers H Manometric height available for the heating circuit Q Water flow Useful output T 20 K A 10 kW...

Page 18: ...n temperature between the heating 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 0 0 200 400 600 800 10...

Page 19: ...nding on the configuration of the installation 4 Boiler DHW tank connection kits 4 Central connection kit right left 4 Mixing valve kit for integration DHW tank 4 Connection kit for external mixing va...

Page 20: ...ctory 2 When installation has been completed affix the data plate provided in the instructions bag to the casing of the appliance in a position where it can be seen C003074 E Auf ERD GAS H eing este l...

Page 21: ...to store inflammable products and materials in the boiler room or close to the boiler even temporarily CAUTION 4 The boiler must be installed in a frost free environment 4 An earthed electrical connec...

Page 22: ...not pull in air evacuated from premises using such products hairdressing salons dry cleaners industrial premises solvents premises containing refrigeration systems risk of refrigerant leakage etc 4 Do...

Page 23: ...G P Domestic cold water inlet G a Domestic hot water outlet G z DHW circulation loop return Pipe G e DHW drain valve on the front of the DHW tank ext 14 mm r Primary solar coil inlet ext 18 mm t Prima...

Page 24: ...B 1408 520 723 70 55 245 70 167 816 715 4 1482 598 818 3 680 132 600 240 74 105 5 87 300 128 5 40 121 5 680 2 1 2 7 8 11 10 13 12 436 16 61 5 Installation CALORA TOWER GAS 15S EX CALORA TOWER GAS 25S...

Page 25: ...1 2 7 8 11 10 13 436 12 1688 1762 1098 1096 994 956 880 16 61 M002519 D 245 70 10 11 12 520 723 87 300 2 13 600 600 520 436 844 917 5 240 74 920 251 105 5 128 5 70 55 167 112 150 254 680 132 1 5 6 7...

Page 26: ...378 1375 1274 1160 1116 1236 40 12 157 115 1968 2042 14 15 M002521 C 2 600 600 520 520 436 844 1201 918 240 74 251 1116 1160 18 5 105 5 128 5 55 112 150 254 680 723 132 7 8 3 4 121 5 1 70 167 1 2 245...

Page 27: ...in place 2 Remove the protective packaging The technical documentation is housed in the protective block 3 Open the access door on the control panel 4 Remove the front panel by pulling firmly from bo...

Page 28: ...e retaining screws 7 Lift the boiler and position it on the ground C003111 D 5 5 C003217 C 6 5 Installation CALORA TOWER GAS 15S EX CALORA TOWER GAS 25S EX CALORA TOWER GAS 35S EX 26 22 04 2016 300026...

Page 29: ...of the appliance 5 4 2 Fitting the boiler to a DHW tank 1 Put the DHW tank in place Refer to the DHW tank s installation use and maintenance instructions 2 Carry out steps 1 to 6 described above See...

Page 30: ...tallations 4 Clean the installation with a universal cleaner to eliminate debris from the system copper hemp flux 4 Thoroughly flush the installation until the water runs clear and shows no impurities...

Page 31: ...tres or the static height of the system exceeds 5 metres an additional expansion vessel must be fitted Refer to the table below to determine the expansion vessel required for the installation Conditio...

Page 32: ...om the siphon j 3 Mount a trap or a siphon in the discharge pipe CAUTION Do not make a permanent rigid connection owing to maintenance work on the condensate trap 4 Do not plug the condensate discharg...

Page 33: ...inlet pipe 2 Fit a gas stop valve to this pipe in such a way that it is visible and easily accessible 3 Connect the gas pipe to the gas shut off valve WARNING 4 Close the main gas valve before starti...

Page 34: ...x 5 7 C43 x C83 x 5 7 C43 x C83 x 5 7 C43 x C83 x C003087 C 1 Configuration B33 Connection to a collective pipe via a concentric pipe combustive air taken from the boiler room All of the pressurised...

Page 35: ...uthorised for connecting the boiler and the terminal 4 The clear section must comply with the standard 4 The chimney must be swept before the installation of the evacuation conduit 5 7 2 Lengths of th...

Page 36: ...imum size of the duct or jacket C93 diameter Channel Without air supply Channel With air supply Channel Without air supply Channel With air supply Rigid 60 mm 110 mm 120 mm 110 x 110 mm 110 x 110 mm 8...

Page 37: ...jority of components in the control panel and the terminal box 4 Power supply cable 5 8 2 Recommendations WARNING 4 Only qualified professionals may carry out electrical connections always with the po...

Page 38: ...n a separate bag Power the appliance via a circuit which includes a remote omnipolar switch with a gap of more than 3 mm The available output per outlet is 450 W 2 A with cos j 0 7 and the inrush curr...

Page 39: ...system module support 4 Pivot the control system module support 5 Remove the 2 retaining screws 6 Remove the top panel C003101 C 2 3 4 C003102 C 5 6 C003103 C CALORA TOWER GAS 15S EX CALORA TOWER GAS...

Page 40: ...emperature sensor Option E Connect a safety thermostat if the heating circuit is for underfloor heating 4 Remove the bridge 4 Connect the wires from the safety thermostat to the connector R Do not con...

Page 41: ...t or OpenTherm controller to the terminals of the connector Option 4 Remove the bridge 4 Connect the wires from the ON OFF thermostat to the connector Z Connect the outside temperature sensor Option E...

Page 42: ...the bridge 4 Connect the wires from the safety thermostat to the connector E Connect the DHW pump R Connect the plate exchanger sensor T Connect the DHW sensor Y Connect the DHW tank anode U Connect...

Page 43: ...is for underfloor heating 4 Remove the bridge 4 Connect the wires from the safety thermostat to the connector E Connect the DHW sensor R Connect a ON OFF thermostat or OpenTherm controller to the term...

Page 44: ...PCU SCU S191 SU PSU IF 01 SCU S03 SCU X01 or or C003817 B SCU S02 c Mix or O T m O T 1 O T 2 T o u t 1 T 1 2 T 2 1 N A B 2 N A B 1 N L 2 N L M a in s N L 5 Installation CALORA TOWER GAS 15S EX CALORA...

Page 45: ...Mix PCB n Installing the PCB c Mix C003818 C O T m O T 1 O T 2 To u t 1 T 1 2 T 2 1 N A B 2 N A B 1 N L 2 N L M a in s N L c Mix PCU 192 SCU S Open Therm X2 BUS X20 X4 X1 HMI On off OT BL RL S EXT S...

Page 46: ...the board Connect the OT and 230 V connectors on the 0 10 V IF 01 board to the PCU board in the boiler CAUTION Do not connect the antifreeze or room thermostat to the boiler if using the 0 10 V IF 01...

Page 47: ...maximum values on the basis of the flow temperature set point calculated by the controller A jumper 2 on the interface is used to select either temperature control or heat output control Jumper 2 Inp...

Page 48: ...per 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 minimum modulation depth set speeds standard 20 5 9 5 Connection...

Page 49: ...VA n Control of external three way valve 3wV The external three way valve 230 VAC can be used when connecting an indirectly heated calorifier The neutral position of the three way valve can be set usi...

Page 50: ...alarm can be transmitted via a potential free contact maximum 230 VAC 1 A on the Nc and C terminals of the connector n Pressure switch minimum Gps The minimum gas pressure switch shuts the boiler dow...

Page 51: ...trol unit of the boiler CAUTION On removing this PCB the boiler will show fault code e 38 To prevent this fault an auto detect must be carried out after removing this PCB See chapter Carrying out an a...

Page 52: ...nit Hru Connect the wires from the heat recovery unit to the Hru terminals of the connector The presence of the heat recovery unit must be set using parameter p4 5 9 7 Connection possibilities for the...

Page 53: ...2 Burning Standby Burning Active 3 Burning inverted Active Burning inverted Standby 4 Burning low Standby Burning low Active 5 Burning high Standby Burning high Active 6 Service report Standby Service...

Page 54: ...SU STEKKER BUITEN VOELER SANITAIR WARM WATER SENSORS EENHEID PRIMARE CONTR LE NULLEIDER FASE AANSLUITKLEM SCU PCU DE INTERFACE MAN MACHINE KETTEL PUMP VOEDING GASKLEP ONTSTEKING SMELTLOOD 6 3A WATER M...

Page 55: ...tives and or inhibitors These may cause faults in the boiler and damage the heat exchanger 4 For untreated water the pH value of the water in the installation must be between 7 and 9 and for treated w...

Page 56: ...p up the water level in the heating system recommended hydraulic pressure between 1 5 and 2 bar CAUTION 4 The filling must be carried out within 30 minutes otherwise the venting program starts and tha...

Page 57: ...rs at user level can be changed D Central heating function Access to central heating temperature parameter C Heating programme deactivated The heating function is deactivated N DHW function Access to...

Page 58: ...the approved gas types Preparatory procedure for boiler commissioning 4 Check that the gas type supplied matches the data shown on the boiler s data plate 4 Check the gas circuit 4 Check the hydraulic...

Page 59: ...n of the tightness gasket when refitting the cover to the sealed chamber n Checking the gas circuit WARNING Ensure that the boiler is switched off 1 Remove the front panel 2 Remove the cover from the...

Page 60: ...p it must be filled with clean water up to the mark 4 Check that there are no leaks on the hydraulic connections 6 2 4 Electrical connections 4 Check the electrical connections particularly the earth...

Page 61: ...y not yet attained The battery will be fully charged once the boiler has been connected to the power for 24 hours Error during the start up procedure 4 No information is shown on the display Check the...

Page 62: ...tion 1 Unscrew the plug of the flue gas measurement point 2 Insert the probe for the flue gas analyser into the measurement opening WARNING Ensure that the opening around the sensor is completely seal...

Page 63: ...ockwise to obtain a lower O2 value 4 Check the flame through the flame inspection window The flame must not be detached Values at full load for G20 Gas H O2 CO2 Ireland CALORA TOWER GAS 15S EX 4 7 5 2...

Page 64: ...splayed on the screen 2 Measure the percentage O2 in the flue gases with the cover of the watertight housing removed 3 If the measured value is outside of the values given in the table correct the gas...

Page 65: ...GAS 35S EX 5 3 1 5 7 1 Nominal value Values at low load for G2 350 Gas Ls O2 CALORA TOWER GAS 15S EX 5 8 1 6 2 CALORA TOWER GAS 25S EX 5 8 1 6 2 1 Nominal value Values at low load for G31 Propane G30...

Page 66: ...nd adjustments after commissioning 6 5 1 Finalizing work 1 Remove the measuring equipment 2 Put the flue gas sampling plug back in place 3 Refit the front panel 4 Push key to return the boiler to norm...

Page 67: ...mperature C 4 t3 Water temperature in the DHW tank C 4 t4 Outside temperature C 4 t5 Solar boiler temperature C 4 t6 Solar panel temperature C 4 5p Internal set point C 4 fl Ionization current A 4 Mf...

Page 68: ...or example 7 Press the key fl is displayed alternating with the current ionization current 70 A for example 8 Press the key Mf is displayed alternating with the current fan rotation speed 3000 rpm for...

Page 69: ...ul starts 92 for example 6 Press the key The display shows N SOLAR and the solar Kwh 45 Kwh for example are displayed alternately 7 Press the key 2 times to return to the current operating mode 6 6 3...

Page 70: ...37 Temperature stabilisation time 38 Cold start 5 Burner stop 40 Burner off 41 Post ventilation 42 Close flue gas damper external gas valve 43 Recirculation protection 44 Stop fan 6 Boiler stop End of...

Page 71: ...98 minutes 99 minutes continuous 3 3 3 p8 Brightness of display lighting 0 Dimmed 1 Bright 1 1 1 p17 Maximum fan speed Heating G25 Gas L 1 x100 rpm 44 53 62 G20 Gas H x100 rpm 45 56 62 G31 Propane x1...

Page 72: ...oning the boiler will operate once a week at 65 C for DHW 3 Management using a programmable thermostat 1 1 1 p32 Set point increase for calorifier 0 to 20 C 20 20 20 p33 DHW cut in temperature DHW sen...

Page 73: ...ifference that the solar pump tries to maintain between the solar DHW sensor and the panel 100 x 0 1 to 200 x 0 1 For example 215 21 5 C 100 100 100 8Z 6 5 Temperature of the panel above which the sol...

Page 74: ...onnected n Maximum flow rate of the solar pump if connected In order for the regulator to calculate the quantity of heat produced by the installation parameter kWh input parameter SO07 The parameter S...

Page 75: ...sing key S p 1 is displayed with 1 flashing 5 Press the S key a second time The value 80 C appears and flashes for example 6 Change the value by pressing the or key In this example using key to 60 C 7...

Page 76: ...appears on the display 3 Use keys or to input the installer code 0012 4 Confirm using key S p 1 is displayed with 1 flashing 5 Press the key several times p df is displayed with df flashing 6 Press th...

Page 77: ...u using the key S c0de appears on the display 3 Use keys or to input the installer code 0012 4 Confirm using key S p 1 is displayed with 1 flashing 5 Press the key several times p Zd is displayed with...

Page 78: ...boiler is too low the integrated boiler protection system starts up This protection functions as follows 4 If the water temperature is lower than 7 C the heating pump starts up 4 If the water tempera...

Page 79: ...enance kits include all of the parts needed for the maintenance concerned such as the gaskets for example 4 When a maintenance message is displayed it must be acted upon within the 2 months following...

Page 80: ...ss key several times until 5c B is displayed with B for example flashing In this example the next service message is KB 8 Press the key a second time cl appears on the display 9 Press the S key cl 0 i...

Page 81: ...s discharge flue To do this proceed as follows 1 Unscrew the plug of the flue gas measurement point 2 Insert the probe for the flue gas analyser into the measurement opening WARNING Ensure that the op...

Page 82: ...ir vent 8 2 7 Checking the safety valve 1 Check whether there is any water in the safety valve flow pipe 2 If any leaks are detected replace the safety valve 8 2 8 Checking the condensate trap 1 Remov...

Page 83: ...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 it is self cleaning Check that there are no cracks...

Page 84: ...cking of the type of problem and for any technical assistance from Remeha 4 Press the J key for 2 seconds If the error code continues to display search for the cause in the error table and apply the s...

Page 85: ...r 4 Replace the sensor if necessary No water circulation 4 Vent the air in the heating system 4 Check the circulation direction pump valves 4 Check the water pressure 4 Check the cleanliness of the he...

Page 86: ...SU PCU Return temperature too high Bad connection 4 Check the wiring between the PCU PCB and the sensor 4 Check that the SU PCB is correctly in place 4 Check that the sensor has been correctly fitted...

Page 87: ...tem 4 Check the circulation direction pump valves 4 Check the water pressure 4 Check the cleanliness of the heat exchanger E 14 SU 5 burner start up failures No ignition 4 Check the wiring between the...

Page 88: ...sensor if necessary Water circulation direction reversed 4 Check the circulation direction pump valves E 36 SU PCU The flame went out more than 5 times in 24 hours while the burner was operating No io...

Page 89: ...lock out have been rectified and after pressing the key 9 2 2 Blocking A temporary blocking mode is a boiler operating function caused by an unusual situation In this case the display gives a code of...

Page 90: ...hat the sensors are operating correctly 4 Check whether the boiler sensor has been correctly fitted Su 08 The RL inlet on the PCU PCB terminal block is open Parameter error 4 Revert to the factory set...

Page 91: ...flue gas discharge flues are not blocked 4 Check that there is no recirculation of flue gases Su 25 Internal error on the SU PCB 4 Replace the SU PCB Su 26 The DHW tank sensor is disconnected or shor...

Page 92: ...nnection 4 Sensor fault Su 34 The sensor in the solar tank is defective 4 Bad connection 4 Sensor fault 9 3 Error memory The boiler control is equipped with an error memory The last 16 errors encounte...

Page 93: ...nformation M 1 Number of times that the error occured hr The number of operating hours 5t State 5v Sub status t1 Flow temperature F C t Return temperature F C t3 Calorifier temperature F C t4 Outside...

Page 94: ...utdown 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 screen 8 Press the S key cl...

Page 95: ...ns of sale and delivery Always ensure that your return package is accompanied by the completed return form see attached example In this way your supplier can fulfil his warranty obligations more easil...

Page 96: ...021 1007 1006 1014 1005 1027 1026 1023 1008 1004 1024 1003 1001 1025 1002 L000202 C 1009 1010 1013 1012 1022 1015 1018 1020 10 Spare parts CALORA TOWER GAS 15S EX CALORA TOWER GAS 25S EX CALORA TOWER...

Page 97: ...2029 2009 2031 2019 2034 2020 2015 2012 2024 2025 2027 2026 2004 2036 2037 2037 2030 2018 2010 2032 2028 2011 2021 2033 2023 2016 2013 L000208 C CALORA TOWER GAS 15S EX CALORA TOWER GAS 25S EX CALORA...

Page 98: ...8 3022 37 3021 3010 3037 3004 3005 3009 3012 3014 3020 3013 3017 3018 3015 3016 SCU S 3038 3006 3002 4002 4003 4001 4006 4005 L000206 D 4007 4004 10 Spare parts CALORA TOWER GAS 15S EX CALORA TOWER GA...

Page 99: ...1023 S100850 Protective plug for the combustion gas evacuation measurement point x5 1024 S100879 Burner 25 kW 198 mm 1025 300024610 Complete siphon 1026 S100906 Siphon gasket Water unit Circulation p...

Page 100: ...3008 300025092 Painted control panel cover 3009 200018121 PCU 192 control board 3010 300025621 2 connector assembled OT Green 3010 300009075 Connector RAST 5 3611 03 F44 K03 M08 P621 3011 200018713 S...

Page 101: ...en Appendix Information on the ecodesign and energy labelling directives...

Page 102: ...Contents 1 Specific information 3 1 1 Recommendations 3 1 2 Ecodesign Directive 3 1 3 Technical data 3 1 4 Circulation pump 4 1 5 Disposal and Recycling 4 Contents 2 300026141 ErP02 03052016...

Page 103: ...emperature regime 1 P1 kW 5 0 8 3 11 6 Seasonal space heating energy efficiency s 94 94 94 Useful efficiency at rated heat output and high temperature regime 2 4 89 5 89 4 89 3 Useful efficiency at 30...

Page 104: ...ons If you need to remove the boiler proceed as follows 1 Switch off the boiler 2 Cut the electrical power to the boiler 3 Close the main gas valve 4 Close the water mains 5 Close the gas valve on the...

Page 105: ...1 Specific information 300026141 ErP02 03052016 5...

Page 106: ...1 Specific information 6 300026141 ErP02 03052016...

Page 107: ......

Page 108: ...com E mail 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 p...

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