REMEHA Gas 220 Ace 160 Installation, User And Service Manual Download

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6.6.5

Connection options for the standard PCB

Standard PCB

The standard PCB can be found in the connection box. Various

thermostats and regulators can be connected to the standard PCB.
Depending on the boiler version chosen, the standard control PCB can be

equipped with additional control PCBs.

Connecting the system pump

1. Connect a system pump to the Pump terminals of the connector.

Important

The maximum power consumption is 300 VA.

The function of the system pump can be changed using parameters

PP015, PP016 and PP018.

Connecting a PWM system pump

A PWM system pump can be connected to the boiler and can be

controlled in a modulating way from the boiler

1. Connect the PWM pump to the PWM terminals of the connector.

Important

Connecting the on/off thermostat

Tk On/off thermostat

The boiler is suitable for connection to a 2-wire on/off thermostat. The

boiler is also suitable for a power stealing thermostat.

1. In the case of a room thermostat: install the thermostat in a reference

room.

2. Connect the two-wire cable of the thermostat to the On/Off OT

terminals of the connector.

Connecting an outdoor sensor

An outdoor sensor can be connected to the Tout terminals of the

connector. In the case of an on/off thermostat, the boiler will control the

temperature with the set point from the internal heating curve.

Fig.36

Standard PCB

AD-3000672-02

Pump

N L

0-10

PWM

Tout

On/off

Fig.37

System pump

AD-3001306-01

Fig.38

PWM system pump

AD-3001307-01

PWM

Fig.39

On/off thermostat

AD-3001308-01

On/off

6 Installation

7665063 - v.05 - 18102018

Summary of Contents for Gas 220 Ace 160

Page 1: ...United Kingdom en Installation User and Service Manual High efficiency floor standing gas boiler Gas 220 Ace 160 200 250 300 HMI S control ...

Page 2: ...using the product and keep it in a safe place for later reference In order to ensure continued safe and efficient operation we recommend that the product is serviced regularly Our service and customer service organisation can assist with this We hope you enjoy years of problem free operation with the product ...

Page 3: ...Protection against shortage of water 19 4 1 7 Water flow 19 4 1 8 Hydraulic pressure sensor 19 4 1 9 Air pressure differential switch 19 4 1 10 Circulating pump 19 4 1 11 Calorifier connection 20 4 2 Main components 20 4 3 Control panel description 21 4 3 1 What each key means 21 4 3 2 Meaning of the symbols on the display 21 4 3 3 Browsing in the menus 22 4 4 Standard delivery 23 4 5 Accessories ...

Page 4: ...tings 52 9 1 List of parameters 52 9 1 1 Parameters FSB WHB HE 150 300 52 9 2 Changing the parameters 55 9 2 1 Configuring the installation parameters 55 9 3 Reading out measured values 56 9 3 1 Reading out counters 56 9 3 2 Reading out signals and software versions 57 9 3 3 Counters FSB WHB HE 150 300 58 9 3 4 Signals FSB WHB HE 150 300 58 9 3 5 Status and sub status FSB WHB HE 150 300 59 10 Main...

Page 5: ...150 300 74 11 1 2 Blocking FSB WHB HE 150 300 75 11 1 3 Lock out FSB WHB HE 150 300 77 11 2 Error memory 80 12 Removal recycling 81 13 Spare parts 82 13 1 General 82 13 2 Parts 83 14 Appendix 85 14 1 ErP information 85 14 1 1 Product fiche 85 14 2 EC Declaration of Conformity 85 14 3 Checklist for commissioning 86 14 4 Checklist for annual maintenance 87 Contents 7665063 v 05 18102018 5 ...

Page 6: ...ly 3 Open the windows 4 Trace possible leaks and seal them off immediately 5 If the leak is upstream of the gas meter notify the gas company Danger If you smell flue gases 1 Switch the boiler off 2 Open the windows 3 Trace possible leaks and seal them off immediately Caution After maintenance or repair work check the entire heating installation to ensure that there are no leaks For the end user 1 ...

Page 7: ... can rise to over 60 C Warning Do not touch radiators for long periods Depending on the boiler settings the temperature of the radiators can rise to over 60 C Warning Be careful when using the domestic hot water Depending on the boiler settings the temperature of domestic hot water can rise to over 65 C Warning The use of the boiler and the installation by you as the end user must be limited to th...

Page 8: ...he appliance Cleaning and user maintenance should not be carried out by children without adult supervision Warning Installation and maintenance of the boiler must be carried out by a qualified installer in accordance with local and national regulations Warning The installation and maintenance of the boiler must be undertaken by a qualified installer in accordance with the information in the suppli...

Page 9: ...e of frost The frost protection does not work if the boiler is out of operation The boiler protection only protects the boiler not the system Check the water pressure in the system regularly If the water pressure is lower than 0 8 bar the system must be topped up recommended water pressure between 1 5 and 2 bar Important Keep this document near to the boiler Important Only remove the casing for ma...

Page 10: ...ns given in this document Our liability as manufacturer may not be invoked in the following cases Failure to abide by the instructions on installing and maintaining the appliance Failure to abide by the instructions on using the appliance Faulty or insufficient maintenance of the appliance 1 4 2 Installer s liability The installer is responsible for the installation and initial commissioning of th...

Page 11: ...anuals provided with the appliance Call on a qualified professional to carry out installation and initial commissioning Get your installer to explain your installation to you Have the required inspections and maintenance carried out by a qualified installer Keep the instruction manuals in good condition close to the appliance 1 Safety 7665063 v 05 18102018 11 ...

Page 12: ... the manual This manual uses various danger levels to draw attention to special instructions We do this to improve user safety to prevent problems and to guarantee correct operation of the appliance Danger Risk of dangerous situations that may result in serious personal injury Danger of electric shock Risk of electric shock Warning Risk of dangerous situations that may result in minor personal inj...

Page 13: ... 200 250 300 Nominal output Pn Central heating operation 80 60 C min max 1 kW 31 5 152 1 152 1 39 4 194 4 194 4 49 2 243 3 243 3 59 0 290 9 290 9 Nominal output Pn Central heating operation 50 30 C min max 1 kW 34 7 161 1 161 1 43 2 209 8 209 8 54 1 261 0 261 0 65 0 310 7 310 7 Nominal load Qnh Central heating operation Hi G20 H gas min max 1 kW 32 0 156 0 156 0 40 0 200 0 200 0 50 0 250 0 250 0 6...

Page 14: ... with Tr 60 C Tab 5 Central heating circuit data Gas 220 Ace 160 200 250 300 Water content l 17 0 33 0 33 0 33 0 Water operating pressure min bar 0 8 0 8 0 8 0 8 Water operating pressure PMS max bar 5 0 6 0 6 0 6 0 Water temperature max C 110 0 110 0 110 0 110 0 Operating temperature max C 90 0 90 0 90 0 90 0 Hydraulic resistance ΔT 20K mbar 190 100 150 200 Tab 6 Electrical data Gas 220 Ace 160 20...

Page 15: ...ƞ1 97 8 97 3 97 5 97 7 Auxiliary electricity consumption Full load elmax kW 0 275 0 204 0 323 0 343 Part load elmin kW 0 047 0 057 0 057 0 048 Standby mode PSB kW 0 005 0 011 0 011 0 009 Other items Standby heat loss Pstby kW 0 191 0 267 0 267 0 267 Ignition burner power consumption Pign kW Annual energy consumption QHE kWh GJ Sound power level indoors LWA dB 67 68 72 72 Emissions of nitrogen oxid...

Page 16: ...gas outlet Gas 220 Ace 160 Ø 150 mm Gas 220 Ace 200 250 300 Ø 200 mm Connecting the air supply Gas 220 Ace Ø 150 mm Gas 220 Ace 200 250 300 Ø 200 mm Gas connection Gas 220 Ace R 1 inch male thread Gas 220 Ace 200 250 300 R 1 inch male thread Flow connection Gas 220 Ace R 1 inch male thread 3 Technical specifications 16 7665063 v 05 18102018 ...

Page 17: ...1 4 X08 1 13 X083 X07 1 4 X071 X06 1 4 X04 X05 1 15 X041 X051 X053 X054 X055 X081 X02 1 9 X03 1 15 X021 X022 X031 X015 X01 1 7 X0141 X014 230V 50Hz X011 X013 X012 X20 X202 X201 EMC X037 Bus 23 23 22 21 20 18 19 17 16 15 14 13 12 11 10 9 8 7 6 5 3 4 2 1 1 Boiler control unit 2 Lighting 3 Ionisation ignition electrode E 4 Ignition transformer IT 5 On Off switch AU 6 Power supply P 7 Service connecto...

Page 18: ...water flowing through the heat exchanger If the temperature of the flue gases is lower than the dew point approx 55 C the water vapour condenses in the heat exchanger The heat released during this condensation process referred to as the latent or condensation heat is also transferred to the central heating water The cooled flue gases are discharged through the flue gas discharge pipe The condensed...

Page 19: ...een the flow temperature and return temperature In addition a heat exchanger temperature sensor is mounted to monitor the minimum water flow This limits the maximum increase in the heat exchanger temperature and monitors the maximum temperature difference between the flow return and heat exchanger temperatures As a result the boiler is not affected by low water flow 4 1 8 Hydraulic pressure sensor...

Page 20: ...4 Temperature sensor for heat exchanger 15 Ignition transformer 16 Hydraulic pressure sensor 17 Heat exchanger inspection hatch 18 Filling drain valve 19 Frame 20 Siphon 21 Adjustment bolt 22 Transport wheel 23 Air intake silencer 24 Condensate collector 25 Gas pressure measuring point 26 Venturi 27 Gas valve unit 28 Control unit CU GH 29 Fan 30 Flue gas connection pipe 31 Flue gas sensor 32 Suppo...

Page 21: ...r level parameters can be configured Installer menu installer level parameter can be configured Manual mode menu manual mode can be configured Error menu errors can be read out Hour counter timer program time display menu Control PCB menu optional control PCBs can be read out The outside temperature sensor is connected The room temperature sensor is connected The burner output level 1 to 5 bars wi...

Page 22: ...on Menu User menu Installer Menu Manual mode menu Failure Menu Hour Run Meters Timer Program Clock menu PCB menu 1 1 The icon is displayed only if an optional control PCB has been instal led 3 Press the key to move the cursor to the right 4 Press the key to move the cursor to the left 5 Press the key to confirm selection of the required menu or parameter 6 Press the or key to modify the value 7 Pr...

Page 23: ...ensate drain hose Sticker This central heating unit is set for The connection box The control panel with a corresponding manual Important This manual only deals with the standard scope of supply For the installation or mounting of any accessories delivered with the boiler refer to the corresponding mounting instructions 4 5 Accessories and options Various accessories can be obtained for the boiler...

Page 24: ...ntenance operations to the boiler are carried out from the front This is also where the inspection ports of the heat exchanger are located The hydraulic connections and the flue gas outlet are located at the front of the boiler The control panel housing is also on the front of the boiler Use the guidelines and the required installation space as a basis for determining the correct place to install ...

Page 25: ...ervice side of the boiler We recommend a clearance of at least 500 mm above the boiler Caution If the power supply cable is permanently connected you must always install a main bipolar switch with an opening gap of at least 3 mm BS EN 60335 1 5 3 Transport The boiler is supplied fully assembled and packaged on a pallet Without the packaging the boiler will fit through all standard doorways The boi...

Page 26: ...he packaging 3 Unscrew the boiler anchorage on the pallet 4 Remove the boiler anchorage 5 Unscrew the loading ramps on the pallet 6 Fit the loading ramps in front of the pallet 7 Move the boiler off the pallet 8 Remove the pallet and the rest of the packaging The boiler can now be moved using the transport wheels Fig 18 Unpacking the boiler AD 0001165 01 8 7 6 5 5 3 4x 4 4x 1 2 5 Before installati...

Page 27: ...position of the adjustment bolts 6 3 Hydraulic connections 6 3 1 Rinsing the system The installation must be cleaned and flushed in accordance with BS 7593 2006 and BSRIA BG 33 2014 Before a new boiler can be connected to an existing or new system the entire system must be thoroughly cleaned and flushed This step is absolutely crucial The flushing helps to remove residue from the installation proc...

Page 28: ...e central heating return connection 3 Fit the outlet pipe for CH water to the CH flow 4 Fit the inlet pipe for CH water to the CH return 5 In the supply directly above the boiler establish a connection for a overpressure valve of sufficient capacity 6 Connect the pump to the boiler s return connection Always connect the boiler in a way that will guarantee the water flow through the unit during ope...

Page 29: ...is securely connected to the drain Danger The siphon must always be filled with water This prevents flue gases from entering the room Caution The drain pipe must slope down at least 30 mm per metre Condensed water must not be discharged into a gutter 6 4 Gas connection Warning Before starting work on the gas pipes turn off the main gas tap Before installing check that the gas meter has sufficient ...

Page 30: ...ab 13 Type of flue gas connection C13 Principle Description Permitted manufacturers 1 AD 3001056 01 Room sealed version Discharge in the outside wall Air supply opening is in the same pressure zone as the dis charge e g a combined outside wall terminal Parallel not permitted Outside wall terminal and con nection material Remeha combined with con nection material from Muelink Grol Muelink Grol 1 Th...

Page 31: ...nd the flue gas outlet must not be placed on opposite walls Minimum permitted pressure difference between the air supply and the flue gas outlet is 200 Pa including 100 Pa wind pressure 1 The material must also satisfy the material property requirements from the relevant chapter Tab 17 Type of flue gas connection C93 Principle 1 Description Permitted manufacturers 2 AD 3001059 01 Room sealed versi...

Page 32: ...ing and connection methods may vary depending on the manufacturer It is not permitted to combine pipes coupling and connection methods from different manufacturers This also applies to roof feed throughs and common channels The materials used must comply with the prevailing regulations and standards Please contact us to discuss using flexible flue gas outlet material Tab 19 Overview of material pr...

Page 33: ...hortened according to the reduction table For adaptation to another diameter use approved transitions The boiler is also suitable for longer chimney lengths and diameters other than those specified in the tables Contact us for more information Room ventilated model B23P L Length of the flue gas outlet channel to roof feed through Flue gas outlet Air supply With a room ventilated version the air su...

Page 34: ...gth it is possible to apply an extra 5 times 90º or 10 times 45º elbows Room sealed model C13 C33 C63 C93 L Combined length of the flue gas outlet and air supply channel to the roof feed through Flue gas outlet Air supply With a room sealed version both the flue gas outlet and the air supply openings are connected in parallel Use adapters when using air supply and flue gas discharge pipes with dia...

Page 35: ...150 220 mm 45 bend 1 0 m 1 0 m 1 5 m 1 5 m 90 bend 2 0 m 2 0 m 3 0 m 3 0 m 6 5 5 Additional guidelines Installation For installing the flue gas outlet and air supply materials refer to the instructions of the manufacturer of the relevant material After installation check at least all flue gas outlet and air supply parts for tightness Warning If the flue gas outlet and air supply materials are not ...

Page 36: ...s sloping down towards the boiler with a slope of 50 mm per metre 6 5 7 Connecting the air supply S Insertion depth 30 mm 1 Fit the air supply pipe to the boiler 2 Fit the successive air supply pipes seamlessly together Caution The pipes must be airtight and corrosion resistant The air supply pipe must be smooth and deburred Connect the pipes so that they are stress free The pipes must not rest on...

Page 37: ...tions in this manual Separate the sensor cables from the 230 V cables 6 6 2 Control unit The table gives important connection values for the control unit Tab 27 Connection values for control unit Supply voltage 230 VAC 50 Hz Main fuse value F1 230 VAC 6 3 AT Fuse value F2 230 VAC 1 6 AT Fan 230 VAC Danger of electric shock The following components of the boiler are connected to a 230 V power suppl...

Page 38: ...ion box The wiring for the external connections is fed through a cable duct to the back of the boiler 6 6 3 Assembly of the control panel The Gas 220 Ace boiler is supplied with a separate control panel The control panel is fitted in the control panel housing The cable behind the control panel with connector X021 must be slid onto the connector pin 5 pins 24V of the PCB B Battery There is also a b...

Page 39: ...ps in the housing 6 Carefully push the connection box downwards over the mounting clips and tighten the two screws 7 Now connect the desired external controllers to the other connectors Proceed as follows 7 1 Unscrew the retaining screw on the cable duct cover 7 2 Remove the cable duct cover 7 3 Route the cable of the external controllers or the sensor through the cable duct 7 4 Lay the cable unde...

Page 40: ...minals of the connector Important Contact us for more information Connecting the on off thermostat Tk On off thermostat The boiler is suitable for connection to a 2 wire on off thermostat The boiler is also suitable for a power stealing thermostat 1 In the case of a room thermostat install the thermostat in a reference room 2 Connect the two wire cable of the thermostat to the On Off OT terminals ...

Page 41: ... Tout of the connector The frost protection works as follows with an outdoor sensor At outside temperatures below 10 C the circulation pump switches on At outside temperatures above 10 C the circulation pump continues to run and then switches off Connecting the modulating regulator OT OpenTherm thermostat The boiler is fitted with an OpenTherm connection as standard As a result modulating OpenTher...

Page 42: ...utput varies between the minimum and maximum value on the basis of the value defined by the controller Tab 29 Control based on heat output Input signal V Heat output Description 0 2 0 0 Boiler off 2 0 2 2 0 Heat demand 2 0 10 0 100 Desired heat output Blocking input The boiler has a blocking input This input is installed on the BL terminals of the connector Change the function of the input using p...

Page 43: ...connector will now be released 5 Pull the interface connector from the connector 6 7 Filling the installation 6 7 1 Water treatment In many cases the boiler and central heating system can be filled with normal tap water and water treatment will not be necessary Warning Do not add chemical agents to the central heating water without consulting Remeha For example antifreeze water softeners pH increa...

Page 44: ...h water This prevents flue gases from entering the room 6 7 3 Filling the system Important In order to be able to read off the water pressure from the control panel the boiler must be switched on If the water pressure is too low the boiler or the boiler pump will not start 1 Fill the central heating system with clean tap water Important The recommended water pressure is between 1 5 and 2 bar 2 Che...

Page 45: ... pressure at the measuring point on the gas pipe 4 Vent the gas supply pipe by unscrewing the measuring point 5 Tighten the measuring point again when the pipe has been fully vented 6 Check all connections for gas tightness The maximum allowable test pressure is 60 mbar For more information see Unit categories page 13 7 1 3 Hydraulic circuit 1 Check the siphon it should be fully filled with clean ...

Page 46: ...up G20 H gas Tab 30 Factory settings G20 H gas Code Description Adjustment range 160 200 250 300 DP003 Maximum fan speed on Domestic Hot Water 1000 Rpm 7000 Rpm 6700 4650 5700 5800 GP007 Maximum fan speed during Central Heating mode 1000 Rpm 8500 Rpm 6700 4650 5700 5800 GP008 Minimum fan speed during Central Heating Domestic Hot Water mode 900 Rpm 8500 Rpm 1900 1450 1550 1650 GP009 Fan speed at ap...

Page 47: ...asurement opening Important During measurement seal the opening around the sensor fully The flue gas analyser must have a minimum accuracy of 0 25 O2 CO2 3 Measure the percentage of O2 CO2 in the flue gases Take measurements at full load and at part load Enable full load 1 Press the two keys on the left simultaneously to select chimney sweep mode The device is now running at part load Wait until L...

Page 48: ...value is outside of the values given in the table correct the gas air ratio 4 Using the adjusting screw A set the percentage of O2 CO2 for the gas type being used to the nominal value This should always be inside the highest and lowest setting limit Important The boilers are supplied with a variety of gas valve units Compare the gas valve unit in the boiler with those in the drawings and see the d...

Page 49: ...9 10 1 1 Gas 220 Ace 250 5 5 1 5 8 9 9 10 1 1 Gas 220 Ace 300 5 5 1 5 8 9 9 10 1 1 1 nominal value Caution The O2 values at low load must be higher than the O2 values at full load The CO2 values at low load must be lower than the CO2 values at full load 3 If the measured value is outside of the values given in the table correct the gas air ratio Important The boilers are supplied with a variety of...

Page 50: ... mentioned above 11 Instruct the user in the operation of the system boiler and controller 12 Inform the user of the maintenance to be performed 13 Hand over all manuals to the user 14 Confirm the commissioning with a signature and a company stamp The boiler is now ready for operation Fig 61 Example filled in sticker AD 3001124 01 Adjusted for Réglée pour Ingesteld op Eingestellt auf Regolato per ...

Page 51: ...rotection does not work if the boiler is out of operation The built in boiler protection is only activated for the boiler and not for the system and radiators Open the valves of all the radiators connected to the system Set the temperature control low for example to 10 C If there is no heat demand the boiler will only switch on to protect itself against frost If the temperature of the central heat...

Page 52: ...r the appliance Tab 37 FSB WHB HE 150 300 Factory settings at user level Code Description Range 160 200 250 300 AP016 Enable central heating heat demand processing 0 Off 1 On 1 1 1 1 AP017 Enable domestic hot water heat demand processing 0 Off 1 On 1 1 1 1 CP080 Room setpoint temperature of the user zone activity 5 C 30 C 16 16 16 16 CP081 Room setpoint temperature of the user zone activity 5 C 30...

Page 53: ...elieved 7 High Low Tariff 8 Photovoltaic HP Only 9 PV HP And backup 10 Smart Grid ready 11 Heating Cooling 1 1 1 1 AP006 Appliance will report low water pressure below this value 0 bar 6 bar 0 7 0 7 0 7 0 7 AP008 The appliance will wait x sec 0 off for the release contact to close in order to start the burner 0 Sec 255 Sec 0 0 0 0 AP009 Burning hours before raising a service notification 100 Hours...

Page 54: ...Max Room Temperature limit of the circuit in reduced mode that allows switching to comfort mode 5 C 30 C 15 15 15 15 CP210 Comfort footpoint of the temperature of heat curve of the circuit 15 C 90 C 15 15 15 15 CP220 Reduced footpoint of the temperature of heat curve of the circuit 15 C 90 C 15 15 15 15 CP230 Heating curve temperature gradient of the zone 0 4 2 5 2 5 2 5 2 5 CP240 Adjustment of th...

Page 55: ...GP010 Gas Pressure Switch check on off 0 No 1 Yes 0 0 0 0 GP021 Modulate back when delta temperature is large then this treshold 5 C 25 C 25 25 25 25 GP024 Valve Proofing System check on off 0 No 1 Yes 0 0 0 0 PP015 Central heating pump post run time 1 Min 99 Min 1 1 1 1 PP016 Maximum central heating pump speed 20 100 100 100 100 100 PP018 Minimum central heating pump speed 20 100 20 20 20 20 PP02...

Page 56: ...alue 11 Press the h key multiple times to go back to the main display 9 3 Reading out measured values 9 3 1 Reading out counters You can read out the counters of the appliance and the connected control boards sensors and so on 1 Navigate to the Counter menu 2 Press the key to open the menu Fig 63 Step 3 MW 3000313 01 Fig 64 Step 4 MW 3000314 01 Fig 65 Step 5 MW 3000406 02 Fig 66 Step 6 MW 3000407 ...

Page 57: ...he key to open the menu 3 Keep pressing the key until the required device control PCB or zone is displayed 4 Press the key to confirm the selection 5 Keep pressing the or key until the required value is displayed At the end of the cycle the software version and parameter version of the selected appliance or control PCB are displayed 6 Press the h key multiple times to go back to the main display F...

Page 58: ...ently in domestic hot water production mode 0 Off 1 On AM010 The current pump speed 0 100 AM012 Current main status of the appliance DeviceState AM014 Current sub status of the appliance DeviceSubStatus AM015 Is the pump running 0 Inactive 1 Active AM016 Flow temperature of appliance 25 C 150 C AM017 The temperature of heat exchanger 25 C 150 C AM018 Return temperature of appliance The temperature...

Page 59: ...ter 0 Winter 1 Frost protection 2 Summer neutral band 3 Summer GM004 Gas valve 1 0 Open 1 Closed 2 Off GM005 Gas valve 2 0 Open 1 Closed 2 Off GM010 Available power in of maximum 0 100 GM044 Possible reason for Controlled Stop 0 None 1 CH Blocking 2 DHW Blocking 3 Wait for burner 4 TFlow absolute max 5 TFlow start temp 6 Theat exch Tstart 7 Avg Tflow Tstart 8 TFlow max setpoint 9 T difference too ...

Page 60: ...alve 11 StartToGlueGasValve 12 CloseFlueGasValve 13 FanToPrePurge 14 WaitForReleaseSignal 15 BurnerOnCommandToSu 16 VpsTest 17 PreIgnition 18 Ignition 19 FlameCheck 20 Interpurge 30 Normal Int Setpoint 31 Limited Int Setpoint 32 NormalPowerControl 33 GradLevel1PowerCtrl 34 GradLevel2PowerCtrl 35 GradLevel3PowerCtrl 36 ProtectFlamePwrCtrl 37 StabilizationTime 38 ColdStart 39 ChResume 40 SuRemoveBur...

Page 61: ...Sub status 63 SetAntiCycleTimer 200 Initialising Done 201 Initialising Csu 202 Init Identifiers 203 Init BL Parameter 204 Init Safety Unit 205 Init Blocking 9 Settings 7665063 v 05 18102018 61 ...

Page 62: ...r preventive maintenance to keep faults to a minimum The service messages show which service kit must be used These service kits contain all parts and gaskets that are required for the relevant service These service kits A B or C put together by Remeha are available from your spare parts supplier Important A service message must be followed up within 2 months Therefore call your installer as soon ...

Page 63: ...skets have been positioned properly absolutely flat in the appropriate groove means they are gas tight During the inspection and maintenance operations water drops splashes must never come into contact with the electrical parts 10 3 1 Checking the water pressure 1 Check the water pressure Important The water pressure is shown on the display of the control panel The water pressure must be at least ...

Page 64: ...side of a pressure gauge 6 Turn on the boiler 7 Push the syringe or bellows in very slowly until the boiler goes into failure mode 8 Make a note of the pressure indicated by the pressure gauge at that point A switch pressure of between 5 5 and 6 5 mbar is fine A lower or higher switch pressure indicates a problem with the air pressure differential switch 9 After taking a measurement detach the sil...

Page 65: ...d 6 5 mbar is fine A lower or higher switch pressure indicates a problem with the air pressure differential switch 5 After taking a measurement detach the silicon hose from the T piece on the side and reconnect the coloured hose that was previously removed 6 Remove any soiling from all connection points for hoses and the air pressure differential switch 7 Check the condition and tightness of the h...

Page 66: ...connect a T piece with a hose connected to the mouth 7 Connect one end of the T piece to measuring point 3 of the gas valve unit 8 Connect the other end of the T piece to a pressure gauge 9 Push the syringe in very slowly until the pressure gauge indicates the minimum inlet gas pressure value 10 Check the measured pressure for about 30 seconds If pressure decreases by more than half this indicates...

Page 67: ...ting plug from the VPS gas leakage control 4 Connect an ohmmeter to terminals 2 and 3 of the VPS 5 Push the syringe in very slowly until the ohmmeter indicates 0 Ohm 6 Make a note of the pressure indicated by the pressure gauge at that point If the measured pressure differs by more than 2 mbar from the VPS set up value set the pressure switch to the correct value or replace it Fig 86 Checking the ...

Page 68: ...r goes into blocking mode 7 Make a note of the pressure indicated by the pressure gauge at that point Compare the measured values with the checking values in the table If the measured pressure is lower set the gas pressure switch to the correct value or replace it Tab 45 Minimum gas pressure switch value Minimum value mbar Gas 220 Ace 160 14 Gas 220 Ace 200 14 Gas 220 Ace 250 14 Gas 220 Ace 300 13...

Page 69: ...Remove the inspection ports to reach the heat exchanger 9 Use a vacuum cleaner to clean the top part of the heat exchanger furnace 10 Check e g using a mirror whether any visible contamination has been left behind If it has remove it with the vacuum cleaner 11 Clean the lower section of the heat exchanger with the special cleaning knife 12 Burner maintenance is almost never required it is self cle...

Page 70: ... 1 Pull the retainer clip of the siphon backwards 2 Carefully pull the siphon and siphon hose downwards 3 Clean the siphon with water 4 Fill the siphon with water up to the mark 5 Push the siphon firmly into the designated opening behind the cover underneath the boiler and install the siphon hose 6 Push the retainer clip of the siphon forwards 7 Check whether the siphon is firmly fitted in the boi...

Page 71: ...therefore may not be removed 2 Unscrew the two screws on the electrode 3 Remove the entire component 4 Fit the new ionisation ignition electrode 5 Reassemble the unit in reverse order 10 4 2 Checking the non return valve Check the condition of the non return valve Replace the non return valve if it is defective there is one in the service kit or if there are traces of condensation on the inside of...

Page 72: ...holder in the event of visible traces of condensation or damage 7 Reassemble in the reverse order Caution Use the specified torques when fitting nuts and bolts Make sure the gaskets are in place when fitting nuts and bolts 10 4 3 Reassembling the boiler 1 Fit all removed parts in the reverse order 2 During inspection or maintenance work always replace all gaskets of the disassembled parts 3 Check ...

Page 73: ...l and national regulations To remove the boiler proceed as follows 1 Switch off the boiler s electrical connection 2 Shut off the gas supply 3 Shut off the water supply 4 Drain the system 5 Remove the siphon 6 Remove the air supply flue gas outlet pipes 7 Disconnect all pipes on the boiler 8 Remove the boiler 10 Maintenance 7665063 v 05 18102018 73 ...

Page 74: ...ng of the code can be found in the various error code tables Make a note of the code displayed Important The error code is needed to find the cause of the error quickly and correctly and for any support from Remeha 11 1 1 Warning FSB WHB HE 150 300 Tab 46 Warning codes Code Description Solution A01 21 Maximum Dhw Temperature Gradient Level3 Exceeded Temperature warning Check the flow A02 06 Water ...

Page 75: ...t exchanger and flow temperature exceeded No flow or insufficient flow Check the circulation direction pump valves Check the water pressure Check the cleanliness of the heat exchanger Check that the installation has been correctly vented to remove air Sensor error Check that the sensors are operating correctly Check that the sensor has been fitted properly H01 07 Maximum difference between heat ex...

Page 76: ... gas outlet system Check the heat exchanger to ensure that the flue gas side is not clogged Faulty sensor replace the sensor H02 00 Reset In Progress Reset procedure active No action H02 02 Waiting For Configuration Number Configuration error or unknown configuration num ber Reset CN1 and CN2 H02 03 Configuration Error Configuration error or unknown configuration num ber Reset CN1 and CN2 H02 05 C...

Page 77: ...ange Flow temperature sensor short circuited Bad connection check the wiring and connectors Incorrectly fitted sensor check that the sensor has been correctly fitted Faulty sensor replace the sensor E00 04 Return temperature sensor is either removed or measures a temperature below range Return temperature sensor open Bad connection check the wiring and connectors Incorrectly fitted sensor check th...

Page 78: ...ss occurs 5 times Vent the gas supply to remove air Check that the gas valve is fully opened Check the gas supply pressure Check the operation and setting of the gas valve unit Check that the air supply inlet and flue gas outlet are not blocked Check that there is no recirculation of flue gases E01 12 Return tempearture has a higher temperature value than the flow temperature Flow and return rever...

Page 79: ...above range Flue gas temperature sensor short circuited Bad connection check the wiring and connectors Incorrectly fitted sensor check that the sensor has been correctly fitted Faulty sensor replace the sensor E04 05 Flue temperature sensor is either removed or measuring a temperature below range Flue gas temperature sensor open Bad connection check the wiring and connectors Incorrectly fitted sen...

Page 80: ...check the wiring and connectors Gas leakage control VPS faulty Replace the GPS Gas valve unit faulty Replace the gas valve unit E04 12 False flame detected before burner start False flame signal The burner remains very hot Set the O2 Ionisation current measured but no flame should be present check the ionisation ignition electrode Faulty gas valve replace the gas valve Faulty ignition transformer ...

Page 81: ...al regulations To remove the boiler proceed as follows 1 Switch off the boiler s electrical connection 2 Shut off the gas supply 3 Shut off the water supply 4 Drain the system 5 Remove the siphon 6 Remove the air supply flue gas outlet pipes 7 Disconnect all pipes on the boiler 8 Remove the boiler 12 Removal recycling 7665063 v 05 18102018 81 ...

Page 82: ...rn boiler parts with original parts or recommended parts Send the part to be replaced to the Remeha Quality Control department if the relevant part is covered by the guarantee see the General Terms of Sale and Delivery 13 Spare parts 82 7665063 v 05 18102018 ...

Page 83: ...2 4005 2020 2027 3012 3003 2012 3004 3006 3015 3005 2023 3001 3016 3004 3007 4003 3009 3011 3010 3005 3011 3005 3008 3002 3008 3013 3017 3011 1013 4035 4036 4037 4012 4024 1006 2025 4020 1002 4003 1001 2014 2003 3004 2002 4004 4001 1003 1002 2021 2001 2024 2024 2047 1005 2053 2034 2032 2035 2017 2027 3013 3005 4002 4019 1010 1012 1012 1012 4018 4033 4028 4017 4005 2006 2013 4006 2019 2004 2010 201...

Page 84: ...2012 3006 3001 3016 3008 3007 3011 3005 3004 3002 3005 3010 3011 3003 3008 3013 3009 3017 3011 1013 4036 4037 4012 4024 1006 2025 2025 1002 1001 2014 2003 3004 2002 4003 2034 2032 2035 3015 4002 4001 3004 3005 3018 4004 4003 1003 2021 2001 2024 2024 1005 2017 2027 3013 3005 4019 4018 4033 4028 2006 2023 2004 2013 2010 2011 2015 2007 2009 2005 2020 2027 2019 2020 2027 2019 4005 4007 4030 4031 4029 ...

Page 85: ...ergy consumption GJ Sound power level LWA indoors dB See For specific precautions in relation to assembly installation and maintenance Safety page 6 14 2 EC Declaration of Conformity The unit complies with the standard type described in the EC declaration of conformity It has been manufactured and commissioned in accordance with European directives The original declaration of conformity is availab...

Page 86: ...e connections and gas pipes 10 Vent the gas supply pipe 11 If installed check the setting of the Gps minimum gas pressure switch 12 If installed check the setting of the Vps pressure switch for gas leakage control 13 Check the electrical connections 14 Check the flue gas outlet air supply connections 15 Check the function and operational status of the boiler 16 Check the air gas ratio 17 Remove th...

Page 87: ...air pressure differential switch 7 Check the VPS gas leakage control if installed 8 Check the GPS minimum gas pressure switch if installed 9 Check the burner and clean the heat exchanger 10 Clean the condensate collector 11 Clean the siphon 12 Replace the ionisation ignition electrode 13 Check the non return valve 14 Install the boiler replace all gaskets removed 15 Put the boiler back into operat...

Page 88: ...14 Appendix 88 7665063 v 05 18102018 ...

Page 89: ...14 Appendix 7665063 v 05 18102018 89 ...

Page 90: ...14 Appendix 90 7665063 v 05 18102018 ...

Page 91: ...chnological information contained in these technical instructions as well as any drawings and technical descriptions supplied remain our property and shall not be multiplied without our prior consent in writing Subject to alterations ...

Page 92: ...Remeha Commercial UK Innovations House 3 Oaklands Business Centre Oaklands Park RG41 2FD Wokingham T 44 0 118 978 3434 F 44 0 118 978 6977 E boilers remeha co uk 7665063 v 05 18102018 7665063 ...

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REMEHA Gas 220 Ace 160, Installation, User And Service Manual

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Summary of Contents for Gas 220 Ace 160

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