Atmospheric Floor Standing Series

User Manual: Atmospheric Floor Standing Series

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remeha Gas 3c
Atmospheric gas boiler

92 - 372 kW

Technical information

remeha Gas 3c
CONTENTS
Preface

1. Boiler description

2. Construction
2.1 General
2.2 Burners
2.3 Boiler base
2.4 Assembly

3
3
3
3
3

3. Technical information and dimensions

4. Application
4.1 L.P.H.W. system
4.1.1 Water temperature
4.1.2 Water pressure
4.1.3 Water flow
4.1.4 Water treatment
4.1.5 Noise level
4.2 Chimneys
4.3 Installation standards

5
5
5
5
5
5
5
5
5

5. Typical boiler installations

6. Regulation and safety equipment
6.1 General
6.2 Instrument panel
6.3 Standard electronic gas train On/Off or
High/Low
6.3.1 Schematic construction
6.3.2 Specification
6.3.3 Control panel on gas train
6.4 Functions
6.4.1 Flame protection
6.4.2 Down draught thermostat
6.4.3 Thermostats

7
7
7

Assembling and installation guidelines
7.1 General
7.2 Boiler assembly
7.3 Water connections
7.4 Pocket for instrument panel
7.5 Water pressure

8
8
8
8
8
8
8
8
8
8
8
8
8
8

8. Gas supply
8.1 General
8.2 Gas pressure

9
9
9

9. Electrical supply
9.1 General
9.2 Control panel
9.3 Electrical connections
9.4 Electrical data
9.5 Wiring diagram for the instrument panel
9.5.1 Simple instrument panel
9.5.2 Complete instrument panel
(On/Off or High/Low)
9.6 Wiring diagram boiler
9.6.1 Complete wiring diagram for
On/Off boiler with simple
instrument panel
9.6.2 Complete wiring diagram for
On/Off boiler with complete
instrument panel
9.6.3 Complete wiring diagram for
High/Low boiler with simple
instrument panel
9.6.4 Complete wiring diagram for
High/Low boiler with complete
instrument panel

9
9
9
9
9
9
9
10
11

10. Commissioning
10.1 Technical information
10.2 Commissioning the boiler
10.3 Switching off the boiler

15
15
15
15

11. Maintenance
11.1 General
11.2 Maintening the boiler

15
15
15

PREFACE
If you have any questions, or if you need more information about specific subjects relating to this boiler, please
do not hesitate to contact us.
The data published in these technical instructions is based on the latest information and is subject to revisions.
We reserve the right to modify the construction and/or
design of our products at any moment, without being
obliged to adjust earlier supplies accordingly.

These technical instructions contain useful and important
information for the proper operation and maintenance of
the remeha Gas 3c central heating boiler.
Furthermore, important instructions are given to prevent
accidents and serious damage before commissioning and
during operation of the boiler, to ensure safe and trouble
free boiler operation. Read these instructions carefully
before putting the boiler into operation, familiarize yourself with its operation and control and strictly observe the
instructions given.
1. BOILER DESCRIPTION
The remeha Gas 3c boiler is a cast iron sectional boiler
with atmospheric burners.
Suitable for all qualities of natural gas, cat. I 2 H (20
mbar).
The boiler meets the requirements of the CE regulations
at the following directives:
- Gas appliance directive
no. 90/396/EEC
- Efficiency directive
no. 90/42/EEC
- Electrical low voltage directive no. 73/23/EEC
- Machinery directive
no. 89/392/EEC
- E.M.C. directive
no. 89/336/EEC.

Classification type for evacuation of the combustion
products: B11 BS.
For further advice or information contact Broag Ltd.
The remeha Gas 3c is supplied with electronic ignition
and insulated casings.
Water connections Ø 70 mm int.

2. CONSTRUCTION
2.1 General
- Boiler block of cast iron sections are joined together
with conical nipples.
- Gas train and water connections can be fitted on either
side of the boiler.
The gas train should as standard always be fitted
on the same side as the instrumental panel,
thermostat pocket and the flow*.
- Instrument panel is fitted in the front casing.
- Cleaning of the cast iron block from top of the boiler.

2.2 Burners
The burners are stainless steel, atmospheric burners.
They guarantee a low noise level.
2.3 Boiler floor
The remeha Gas 3c boiler is supplied as standard with
reflecting floor plates with ventilation underneath.
2.4 Assembling
The boiler must be assembled on site.

* On request extension cables can be delivered, so that
the gas train can be fitted on the opposite side to the
instrument panel, thermostat pocket and the flow.
3

remeha Gas 3c
3. TECHNICAL INFORMATION AND DIMENSIONS

Top view

ø70 int.

Cross section

Left hand side view

Front view

Fig. 01 View figures
Number of
sections

Output

Dimensions

Input
Hs
kW

A
mm

Water
resistance

B
mm

ØD
mm

Ød
"

E
mm

±L
mm

Water Boiler
contents weight

∆t = 10°C ∆t = 20°C
mbar

mbar

114

1015

675

200

1220

670

385

115

142

1015

775

200

1220

670

440

138

170

1040

875

200

1220

670

495

162

200

1040

975

250

1220

670

550

8
9
10

186

228

1040

1075

250

1 /4"

1220

700

605

210

258

1040

1175

250

11/4"

1220

700

665

234

286

1065

1275

300

1 /4"

1320

700

720

256

315

1065

1375

300

11/4"

1320

700

116

775

280

343

1065

1475

300

1320

960

136

105

830

301

369

1065

1575

300

1320

960

160

111

890

325

399

1090

1675

350

1320

960

186

118

945

348

426

1090

1775

350

1320

960

208

125

1000

372

454

1090

1875

350

1320

960

236

131

1055

4. APPLICATION
4.1 L.P.H.W. system

4.2 Chimneys
The average flue gas temperature is so low that the chimney must be in accordance with the guidelines of British
Gas and BS 6644.

4.1.1 Water temperature
Maximum water temperature is 110°C (high limit
thermostat).
Highest boiler water temperature is 95°C (control
thermostat).
Minimum return water temperature is 20°C at a flow rate
related at a ∆t of 20°C (flow/return temperature).

4.3 Installation standards
The following instructions must be adhered to when the
remeha Gas 3c is installed:
Gas safety (installation and use) Regulations 1984 (as
amended).
All gas appliances must, by law, be installed by competent persons (e.g. Corgi) in accordance with the above
regulations. Failure to install appliances correctly could
lead to prosecution.
It is in your own interest and that of safety to ensure that
the law is complied with.
In addition to the above regulations, this appliance must
be installed in compliance with the current I.E.E.
Regulations for electrical installation, local building regulations, the Building Standards (Scotland), Consolidation
Regulations and bye laws of the local water undertaking
and Health and Safety Document No. 635 'The Electricity
at Work Regulations 1989'. It should also be in accordance with the relevant recommendations in the current
editions of the following British Standards and Codes of
Practice, viz.
BS 5540 Pt 1 and 2, BS 5449, BS 5546, BS 6798,
BS 6891 and BG.DM2.

4.1.2 Water pressure
Boiler sections pressure test at 12 bar.
Maximum pressure test for the boiler block is 6 bar.
Minimum working pressure boiler is 0.8 bar.
Maximum working pressure is 6 bar.
4.1.3 Water flow
The minimum water flow through the boiler is:
Output boiler in kW

= ... m3/h
93
This minimum flow must be maintained for 5 minutes after the burner stops firing to avoid high temperature shutdown due to residuel heat gain.
Due to the design and manufacture of the boiler no specific minimum water flow requirement exists other than for
high-temperature protection.
4.1.4 Water treatment
Water treatment under normal circumstances is not
necessary (see our water quality recommendations).

Important:
The remeha Gas 3c is certified appliance and must not
be modified or installed in any way contrary to these
'Installation and Servicing Instructions'.
Manufacturers instructions must NOT be taken in any way
as overriding statutory obligations.

4.1.5 Noise level
The noise level measured around the boiler depending
on boiler room construction is about 50-55 dBA.
(Noise level taken at 1 meter from the boiler)

remeha Gas 3c
5. TYPICAL BOILER INSTALLATIONS
One boiler in boiler room

Fig. 02 Installation 1
Two boilers in boiler room

Fig. 03 Installation 2
Two boilers in boiler room
back to back

Fig. 04 Installation 3

Dimensions
(mm)

A
B
ØD
E

5
1015
675
200
1220

6
1015
775
200
1220

7
1040
875
200
1220

8
1040
975
250
1220

Number of sections
10
11
12
1040 1065 1065
1175 1275 1375
250
300
300
1220 1320 1320

9
1040
1075
250
1220

13
1065
1475
300
1320

14
1065
1575
300
1320

15
1090
1675
350
1320

16
1090
1775
350
1320

17
1090
1875
350
1320

6. REGULATION AND SAFETY EQUIPMENT
6.1 General
The remeha Gas 3c is supplied with electronic control
and safety equipment with flame detection.

All connections are pre-wired and fitted with plugs. The
capillaries from the control panel should be fitted in the
pocket of the boiler, wich is fitted in the top front of the
end section.

6.2 Instrument panel
The remeha Gas 3c is supplied with an instrument panel
that is fitted in the front of the boiler, either left or right.
The instrument panel can be delivered in three models:
- simple instrument panel On/Off;
- simple instrument panel High/Low;
- complete instrument panel High/Low.

The instrument panel, pocket and the flow should
always be fitted at one side of the boiler either left or
right and standard on the same side as the gas
train.***

10
1

8
7

Fig. 05 Layout of the complete instrument panel
Module D
9. Warning light*
10. Analogue thermometer water temperature

The modules contain:
Module A
1. Control thermostat
Setting between 35°-95°C
2. Hour run meter total running hours*

Module E
11. Option for rematic® weather compensating boiler
control*

Module B
3. High-Low thermostat
Setting between 35°-95°C**
4. Hour run meter full load*
Module C
5. High-limit thermostat 110°C (locking)
6. Operating switch (On/Off with optical display)*
7. Switch for circulating pump*
Manual/Off/Automatic
8. Switch for domestic hot water storage pump*
Manual/Off/Automatic

* Absent in simple instrument panels
** Absent in simple instrument panel On/Off
*** On request extension cables can be delivered, so
that the gas train can be fitted on the opposite side to
the instrument panel, thermostat pocket and the flow.
7

remeha Gas 3c
6.3 Standard electronic gas train On/Off or High/Low

6.3.2 Specification
1 Gas multibloc (5-12 sections)
2 Safety shut-off valves (13-17 sections)
1 Gas governor (13-17 sections)
1 Pilot gas valve
1 Pilot gas governor
1 Ignition transformer 5 kV
1 Pilot burner with flame detector
1 Down draught thermostat set at 70˚C

6.3.1 Schematic construction

6.3.3 Control panel on gas train
1 Main switch
1 Control box Satronic
1 Fuse, brusk
1 Signal lamp

Fig. 06 5-12 sections

6.4 Functions
6.4.1 Flame protection
Flame protection by means of ionisation flame detection.
6.4.2 Down draught thermostat
The boiler is fitted with a down draught thermostat
Honeywell (typ L6068A).
If there is down draught the thermostat will switch off the
boiler. Fixed setpoint is 70°C.

Fig. 07 13-17 sections
Legend
A
Gas cock
PB Pilot burner
DR Gas governor
F
Gas filter
HB Main gas burners
MB Gas multibloc
IT
Ignition transformer
PGV Pilot gas valve
MP Measuring point
SSV Safety shut-off valve
FD Flame detector
- - - - Not supplied

6.4.3 Thermostats
Control thermostat On/Off Landis & Gyr 35°-95°C.
Control thermostat High/Low Landis & Gyr 35°-95°C
(High/Low version only).
High-limit thermostat locks out at 110°C.

7. ASSEMBLY AND INSTALLATION GUIDELINES
7.1 General
The boiler is suitable for operating at a maximum working
pressure of 6 bar and a minimum pressure of 0.8 bar.
Boiler can be installated in open or closed systems.

7.4 Pocket for instrument panel
The pocket should be fitted in the top front end section of
the boiler and at that side of the boiler where the gas train
is fitted. Other end section tapping 1" should be sealed.

7.2 Boiler assembly
Broag provides special tools on loan, for the boiler assembly with detailed building instructions. However, building supervision and/or actual boiler erection services
can be provided by Broag or an approved boiler erection
engineer.

7.5 Water pressure
Each section is hydraulically tested to at least 12 bar.
Maximum test pressure for the assembled boiler block is
6 bar.
Operating pressure between 0.8 bar and 6 bar.

8. GAS SUPPLY
8.2 Gas pressure
Maximum gas pressure at inlet 100 mbar.
Burner pressure:
- full load : 11.8 mbar (100%)
- part load (High/Low version only): 4.2 mbar (60%)
- injector size: 4.4 mm Ø.

8.1 General
The gas train can be fitted on the left or right hand side of
the boiler but as standard is always fitted on the same
side of the boiler instrument panel (fitted in the front
casing).*
The local Gas authority should be consulted to ensure
that an adequate pressure and supply is available at the
boilers maximum output. To minimise risk of sediment or
foreign particles entering the control valves, an approved
filter may be fitted into the pipe work downstream.
The gas supply should be conform to the British Gas
safety regulations.
9. ELECTRICAL SUPPLY
9.1 General
The electrical installation must conform to the IEE
regulations and also to local authority requirements.

9.5 Wiring diagram for the instrument panel
9.5.1 Simple instrument panel

9.2 Control panel
A control panel is fitted on the gas train.
9.3 Electrical connections
The boiler is pre-wired. Only the main supply should be
wired to this control panel.
9.4 Electrical data
Main supply: 240V - 50Hz (L/N).
Running current: 120 W.
Installed fuse: 6 Amp.

Only
High/Low

Fig. 08 Wiring diagram for the simple instrument panel
Legend
CT Control thermostat
HLT High limit thermostat
H/LT High/Low thermostat
S
Plug
Connector

On request extension cables can be delivered, so that
the gas train can be fitted on the opposite side to the
instrument panel, thermostat pocket and the flow.
9

9.5.2 Complete instrument panel (On/Off or High/Low)

Fig. 09 Wiring diagram for the complete instrument panel
10

remeha Gas 3c

Only
High/Low

9.6 Wiring diagram boiler
9.6.1 Complete wiring diagram for On/Off boiler with
simple instrument panel

Fig. 10 Wiring diagram for the boiler with simple instrument panel
11

9.6.2 Complete wiring diagram for On/Off boiler with
complete instrument panel (High/Low thermostat will
not be used)

Fig. 11 Wiring diagram for the boiler with complete instrument panel
12

remeha Gas 3c

9.6.3 Complete wiring diagram for High/Low boiler
with simple instrument panel

Fig. 10 Wiring diagram for the boiler with simple instrument panel
13

9.6.4 Complete wiring diagram for High/Low boiler
with complete instrument panel

Fig. 11 Wiring diagram for the boiler with complete instrument panel
14

remeha Gas 3c

10. COMMISSIONING
10.1 Technical information
Control box: Satronic TFI 812 B mod. 10.
Main supply: 240V - 50 Hz.
Minimum ionisation current: 5 µA.
Reaction time flame protection: 1 sec.
Safety time: < 10 sec.
Maximum ambient temperature: 60°C.
Injector size pilot burner: Ø 0.8 mm.
Injector size main burner: Ø 4.4 mm.
Burner pressure full load: 11.8 mbar (100%).
Burner pressure part load: (High/Low version only):
4.2 mbar (60%).

4. Switch on circulation pump and check rotation direction.
5. Open main gas cock (release air in gas pipe work).
6. Switch on electrical supply.
7. Set the control thermostats at about 85°C.
8. After a waiting time of about 12 seconds you will get
ignition. At a minimum ionisation current of 5 µAmp
the ignition stops. 15 sec. later the safety gas valve
will open, the boiler is on.
9. Leave the boiler on for a couple of minutes to get rid
of air in the gas pipe.
10. Set the correct burner pressure.
11. Check the thermostats for correct operation.
12. Check the flame protection, start the boiler with
disconnected ionisation probe.

Warning:
Control box operates on a neutral/phase supply.
10.2 Commissioning the boiler
1. Check gas connections.
2. Check electrical supply (L/N and earth).
3. Check water connections and if the installation is filled.

10.3 Switching off the boiler
1. Switch off the electrical supply.
2. Turn off the gas cock.

11. MAINTENANCE
11.1 General
It is essential for a good combustion, to clean the boiler,
the gas train and boiler room once a year.

4. Clean the boiler casings.
5. Clean the gas train, ignition, pilot burner, thermostats
and wiring.
6. Check start program, ignition time and safety times.
7. Check flame protection, and thermostats.
8. Check the boiler input at 100% and 60% load
(High/Low version only).
9. Make a combustion efficiency calculation.
10. Check the boiler and installation for water leakage.
11. Check gas train and gas pipe for gas leakage.

11.2 Maintening the boiler
1. Clean the internal flue ways of the boiler with a steel
cleaning brush (available from Broag).
Remove top casing and top of the flue hood.
2. Clean the burners internally and externally.
3. Clean boiler room and the floor underneath the boiler.

ISO 9001
since 1988

Broag Ltd.
Head office
Remeha house,
Molly Millars Lane,
Wokingham,
Berkshire RG41 2QP.
Tel. 0118 9783434
Fax 0118 9786977
© Copyright
All technical and technological
information contained in these
technical instructions, as well as any
drawings and technical descriptions
furnished by us remain our property
and shall not be multiplied without
our prior consent in writing.
Subject to alterations
Art.nr. 50.696/1500/10.96/Bo.

Branch office
Unit 3, Kestrel Close,
Quarry Hill Ind. Estate,
Ilkeston
Derbyshire DE7 4RD
Tel. 0115 9440778
Fax 0115 9440588

remeha Gas 3c ECO

Technical information

Fully condensing
atmospheric gas boiler
101 - 407 kW

remeha Gas 3c ECO
CONTENTS
Preface

1. Boiler description

2. Construction
2.1 General
2.2 The burners
2.3 Boiler floor
2.4 Assembly

3
3
3
3
3

3. Boiler efficiency
3.1 General
3.2 Condensation

3
3
3

4. Technical data and dimensions

5. Application
5.1 L.P.H.W. system
5.1.1 Water temperature
5.1.2 Water pressure
5.1.3 Water flow
5.1.4 Water treatment
5.2 Noise level
5.3 Chimney/Flues
5.3.1 General
5.3.2 Fan
5.3.3 Safety equipment

5
5
5
5
5
5
5
5
5
5
5

6. Typical boiler installations

7. Control and safety equipment
7.1 General
7.2 Instrument panel
7.3 Standard electronic gas train
7.3.1 Specification
7.3.2 Control panel on gas train
7.4 Functions
7.4.1 Flame protection (lock out)
7.4.2 Thermostats
7.4.3 Air-pressure switch (lock out)

7
7
7
8
8
8
8
8
8
8

8. Assembly and installation guidelines
8.1 General
8.2 Boiler assembly
8.3 Water connections
8.4 Pocket for instrument panel
8.5 Water pressure
8.6 Condensate drain

9
9
9
9
9
9
9

9. Gas supply
9.1 General
9.2 Gas pressure

9
9
9

10. Electric supply
10.1 General
10.2 Control panel
10.3 Electrical connections
10.4 Electrical data
10.5 Wiring diagram for the instrument panel
10.5.1 Simple instrument panel
10.5.2 Complete instrument panel
10.6 Wiring diagram boiler
10.6.1 Complete wiring diagram for boiler
with simple instrument panel
10.6.2 Complete wiring diagram for boiler
with complete instrument panel

10
10
10
10
10
10
10
11
12

11. Commisioning
11.1 Technical information
11.2 Commissioning
11.3 Switch off the boiler

14
14
14
14

12. Maintenance
12.1 General
12.2 Maintenance instructions

15
15
15

12
13

PREFACE
These technical instructions contain useful and important
information for the correct operation and maintenance of
the remeha Gas 3c ECO gas boiler.
Furthermore, important instructions are given to prevent
accidents and serious damage before commissiong and
during operation of the boiler, to ensure safe and troublefree operation. Read these instructions carefully before
putting the boiler into operation, familiarize yourself with
its operation and controls and strictly observe the instructions given.

If you have any questions, or if you need more information about specific subjects relating to this boiler, please
do not hesitate to contact us.
The data published in these technical instructions is based on the latest information and is given subject to later
revisions.
We reserve the right to modify the design and/or
configuration of our products at any moment, without
being obliged to adjust earlier supplies accordingly.

1. BOILER DESCRIPTION
Classification type for evacuation of the combustion
products: B23
For further advice or information contact Broag Ltd.

The remeha Gas 3c ECO boiler is a fully condensing
atmospheric gas boiler, with stainless-steel atmospheric
burners.
The boiler meets the requirements of the CE regulations
at the following directives:
- Gas appliance directive
no. 90/396/EEC
- Efficiency directive
no. 92/42/EEC
- Electrical low voltage directive
no. 73/23/EEC
- Machinery directive
no. 89/392/EEC
- E.M.C. directive
no. 89/336/EEC.
Suitable for all qualities of natural gas and propane.
Cat. II 2H3p

The remeha Gas 3c ECO boiler is fitted with electronic
ignition and is supplied complete with an insulated
casing. Water connections Ø 70 mm.

2. CONSTRUCTIONS
2.1 General
- Boiler block (primary heat exchanger) of cast iron
sections connected with conical nipples.
- Economiser (secondary heat exchanger) of anodised
aluminium.
- Gas train can be fitted on the left or right hand side of
the boiler.
- Water connections can be fitted on the left or right hand
side of the boiler. The return is fitted as standard on the
left hand side of the economiser.
The gas train should always be fitted on the same side
as the instrument panel and the flow connection*.
- Instrument panel is fitted in the front casing.
- The boiler block (primary heat exchanger) is cleaned
from the top.
The economiser (secondary heat exchanger) is
cleaned from the top rear side.

2.2 The burners
The burners are stainless steel, atmospheric burners.
They guarantee a low noise level.
2.3 Boiler floor
The remeha Gas 3c ECO boiler is supplied as standard
with reflecting floor plates which allows for ventilation
underneath.
2.4 Assembly
The boiler is delivered in sections for assembly on site.

3. BOILER EFFICIENCY
3.1 General
The remeha Gas 3c ECO can operate with exceptionally
low return water temperatures (down to 20°C) and in doing so extracts the maximum efficiency by creating condensation within the economiser so releasing the latent
heat from the flue gases. By raising the return water temperature via the economiser the boiler block is protected
at all times, and heat to water efficiences of 86% (G.C.V.)
are can be attained.
3.2 Condensation
Condensation will take place within the economiser when
return temperature drops below 55°C. Above this temperature no condensing takes place and the latent heat is
not released. Even so, efficiencies well in excess of 95%
are still achieved.

Fig. 01 Relationship between boiler efficiency and return
boiler water temperature

* On request extension cables can be delivered, so that
the gas train can be fitted on the opposite side to the
instrument panel, thermostat pocket and the flow.
3

remeha Gas 3c ECO
4. TECHNICAL DATA AND DIMENSIONS

intern

Condense drain

12-17 sections only

Condense drain
int. Ø 32

Cross section

air-vent.

Automatic

int.

Top view

Front

Left hand side view
Fig. 02 Dimensions of the remeha Gas 3c ECO
Number Output Input
of
sections
Hs
kW
kW
101
5
119
127
6
149
153
7
178
179
8
208
203
9
236
228
10
265
254
11
295
281
12
324
307
13
354
330
14
381
356
15
411
381
16
440
407
17
470

N
mm

M
mm

Water Boiler
Water
content
weight
resistance
∆
t=20
°
C
± L ∆t=10°C
Litres
kg
mbar
mm
mbar

600
600
800
800
1000
1000
1200
1200
1400
1400
1600
1600
1800

143
143
139
139
134
134
134
123
123
123
116
116
116

670
670
670
670
700
700
700
700
960
960
960
960
960

Dimensions
A
mm
1260
1260
1260
1260
1260
1260
1260
1260
1260
1260
1310
1310
1310

B
ØD
mm
mm
675
200
775
200
875
200
975
200
1075 200/250*
1175 200/250*
1275 200/250*
1375
300
1475
300
1575
300
1675
350
1775
350
1875
350

Ød
"
1
1
1
1
11/4
11/4
11/4
11/4
2
2
2
2
2

E
mm
1195
1195
1195
1195
1195
1195
1195
1195
1195
1195
1225
1225
1225

G
mm
1610
1610
1610
1610
1710
1710
1710
1740
1740
1740
1800
1800
1800

H
mm
1425
1425
1425
1425
1435
1435
1435
1435
1435
1435
1500
1500
1500

* Specified when the boiler is ordered

K
mm
85
85
85
85
107
107
107
131
131
131
131
131
131

R
mm
736
736
736
736
736
736
736
736
736
736
769
769
769

44
60
92
116
160
188
220
264
312
360
312
352
400

11
15
23
29
40
47
55
66
78
90
78
88
100

71
78
90
96
108
115
121
134
141
147
158
165
171

445
500
565
620
690
750
805
875
930
990
1050
1105
1160

5. APPLICATION
5.1 L.P.H.W. system

For information on water treatment we advise direct
contact with either:
Fernox Manufacturing Company Ltd.
Britannia Works
Clavering
Essex, CB1L 4QZ
Tel No: 0179 9550811
or:
Sentinal
Grace Dearborne Ltd
Foundry Lane
Widnes
Cheshire WA8 8UD
Tel No: 0151 4951861

5.1.1 Water temperature
Maximum water temperature is 110°C (high limit
thermostat).
Highest operating flow temperature is 95°C (control
thermostat).
Minimum return water temperature is 20°C at a flow rate
related to a ∆t of 20°C (flow/return temperature).
5.1.2 Water pressure
Boiler sections pressure tested to 12 bar.
Maximum test pressure for the boiler block is 6 bar.
Minimum working pressure boiler is 0.8 bar at a maximum water temperature of 110°C or 0.3 bar at a maximum water temperature of 95°C.
Maximum working pressure boiler is 6 bar.

5.2 Noise level
The noise level taken at a distance of 3 m around the
boiler depending on boiler room construction is about
64 dBA.

5.1.3 Water flow
The minimum water flow through the boiler is:
Output boiler in kW
= ... m3/h
81

5.3 Chimney/Flues
5.3.1 General
Consideration of flues for condensing appliances can
conveniently be split between a flue dilution system and
other types of flue.
Please contact our technical department for advice.

This minimum flow must be maintained for 5 minutes
after the burner stops firing to avoid high temperature
shut-down due to residuel heat gain. Due to the design
and manufacture of the boiler no specific minimum water
flow requirements exists other than for over-temperature
protection.
The maximum water flow through the boiler is:
Output in kW
9.3

5.3.2 Fan
At I.D. Fan is supplied with each boiler, this has been
designed to overcome the added resistance through the
heat exchanger and exhaust the combustion gasses
through the relatively cold flues.

= ... m3/h

5.3.3 Safety equipment
An air pressure switch checks the correct functioning of
the flue fan.

5.1.4 Water treatment
Water treatment of all systems, but in particular open
vented systems used with the remeha Gas 3c ECO, is
considered necessary good practice in order to:
- avoid metallic corrosion within the system
- avoid sludge and scale information
- reduce to a minimum the risk of microbiological
contamination of the system
- 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 gunmetal, may be present, so it is
essential that treatment is suitable for all of them.
Suitable chemicals and the extent of treatment should be
discussed with specialist manufacturers prior to any work
commencing. The specification of new systems must be
carefully considered. The removal of debris, flux residue,
grease, metal, swarf etc. from new systems, and any
black magnetic iron oxide sludge and other corrosive
residue from old systems is essential.
5

remeha Gas 3c ECO
6. TYPICAL BOILER INSTALLATIONS
Installation 1
One boiler in boiler room

Condense drain

Installation 2
Two boilers in boiler room

Condense drain

Installation 3
Two boilers in boiler room back to back

Fig. 03 Boiler installations
Number of sections
5
Dimensions
(mm)

B
ØD
G
H
K

675
775
875
975
200/250* 200/250* 200/250* 200/250*
1710*
1710*
1710*
1710*
1435*
1435*
1435*
1435*
107*
107*
107*
107*

1075
200/250
1710
1435
107

1175
200/250
1710
1435
107

* Specified when the boiler is ordered

1375
1275
200/250 300
1737
1710
1435
1435
131
107

1475
300
1737
1435
131

1575
300
1737
1435
131

1675
350
1800
1498
131

1775
350
1800
1498
131

1875
350
1800
1498
131

7. CONTROL AND SAFETY EQUIPMENT
7.1 General
The remeha Gas 3c ECO is supplied with electronic control and safety equipment, with ionisation flame detection.
7.2 Instrument panel
The remeha Gas 3c ECO is supplied with an instrument
panel and it is fitted in the front of the boiler, either left or
right. The panel can be delivered in a simple and a complete version. The instrument panel consists of modules.
The modules contain all the necessary control and measuring instruments required to control the boiler.
All connections are pre-wired and have male connectors.
The capillary from the control panel should be fitted in the
pocket of the boiler, which is located in the top front of the
sections. The instrument panel, pocket and the flow
should be always fitted to the same side of the boiler
either left or right and standard on the same side as the
gas train**.

10
3

7
2

Fig. 04 Instrument panel
The modules contain:
Module A
1. Control thermostat
Setting between 35°C-95°C
2. Hour run meter total running hours*

Module C
5. High-limit thermostat 110°C
6. Operating switch (On/Off) with optical display*
7. Switch for circulating pump*
Manual/Off/Automatic
8. Switch for domestic hot water storage pump*
Manual/Off/Automatic

Module B
3. High-Low thermostat (not connected)*
Setting between 35°C-95°C
4. Hours run meter counter full load hours*

Module D
9. Analogue thermometer (water temperature)
10. Central warning light*
Module E
11. Facility for incorporating rematic® weather
compensator*

* Absent in the simple instrument panel.
** On request extension cables can be delivered, so that
the gas train can be fitted on the opposite side to the
instrument panel, thermostat pocket and the flow.
7

remeha Gas 3c ECO
7.3 Standard electronic gas train

7.3.1 Specification
1 Gas multibloc (5-12 sections)
2 Safety gas valves (13-17 sections)
1 Gas governor (13-17 sections)
1 Pilot gas valve
1 Pilot gas governor
1 Ignition transformer 5 kV
1 Pilot burner with ionisation probe
7.3.2 Control panel on gas train
1 Main switch
1 Control box Satronic
1 Fuse, Brusk
5 Signal lamps

Fig. 05 5-12 sections

7.4 Functions
7.4.1 Flame protection (lock out)
Moniterers by ionisation flame detection
7.4.2 Thermostats
Control thermostat On/Off, T&G 35-95°C.
High Limit lock out at 110°C.

Fig. 06 13-17 sections

7.4.3 Air-pressure switch (lock out)
An air pressure switch checks the function of the flue fan.
If a failure is detected the boiler is shut down.

Legend
A
Gas cock
PB Pilot burner
DR Gas governor
F
Gas filter
HB Main gas burner
PGV Pilot gas valve
MP Measuring point
SSV Safety valve
IT
Ignition electrode
FD Ionisation probe
MB Multibloc
- - - - Not supplied

8. ASSEMBLY AND INSTALLATION GUIDELINES
8.1 General
Boiler can be installed in open or closed systems.

8.6 Condensate drain
A drain pipe with ext. dia. 32 mm can be secured with
adhesive to the siphon trap.
The liquid condensate produced by condensing boilers
must be led away via a pipe to a drain for disposal. This
pipe may be separate from the flue system and incorporate a water- sealed trap allowing condensate to pass but
preventing the escape of flue gases.

8.2 Boiler assembly
Broag provides special tools, on loan, for the boiler
assembly with detailed building instructions. However,
building supervision and/or actual boiler erection services
can be provided by Broag or an approved boiler erection
engineer.
8.3 Water connections
The boiler water connections can be fitted on one side of
the boiler either left or right hand side. The return is fitted
as standard on the left-hand side of the boiler (view from
the front). The return can be fitted on the right; this must
be clearly specified when the boiler is ordered.
The water connection is flanged on the boiler with a pipe
connection for welding Ø 70 mm to the installation.
The top blind-flange has an integral cast 1" tapping to
accept a safety valve. The end sections have a 3/4"
tapping to accept a drain off cock (Tapping BSP). The
economiser has at the bottom a 1/2" tapping for a drain
off cock.

Fig. 07 Siphon trap dimensions

8.4 Pocket for instrument panel
The pocket should be fitted in the top front end section of
the boiler and at that side of the boiler where the gas train
is fitted. Other end section tapping 1" should be plugged.
8.5 Water pressure
Each section is hydraulically tested to at least 12 bar.
Maximum test pressure for the assembled boiler block is
6 bar.
Maximum working pressure is 6 bar.
Minimum working pressure is 0.8 bar at a maximum
working temperature of 110°C or 0.3 bar at a maximum
working temperature of 95°C.
9. GAS SUPPLY
9.1 General
The gas train can be fitted on the left or right hand side of
the boiler but is normally positioned on the same side as
the instrument panel is fitted*.
The local Gas authority should be consulted to ensure
that an adequate pressure and supply is available, at the
boilers maximum output. To minimise risk of sediment or
foreign particles entering the control valves, an approved
filter may be fitted into the pipework downstream. The
gas supply should be conform to the British Gas safety
regulations.

9.2 Gas pressure
Maximum gas pressure at inlet 100 mbar.
(Minimum 20 mbar).
Burner pressure: 12.3 mbar.

On request extension cables can be delivered, so that
the gas train can be fitted on the opposite side to the
instrument panel, thermostat pocket and the flow.
9

remeha Gas 3c ECO
10. ELECTRIC SUPPLY
10.1 General
The electrical installation must conform to the IEE Regulations and also to Local Authority Requirements.

10.5 Wiring diagram for the instrument panel
10.5.1 Simple instrument panel

10.2 Control panel
A control panel is fitted on the gas train.
10.3 Electric connections
The boiler is pre-wired. Only the mains supply should be
connected to the control panel.
10.4 Electric data
Main supply: 240 V-50 Hz (L/N)
Installed fuse: 6 Amp.
Running current:
Number
of
sections

5
6
7
8
9
10
11
12
13
14
15
16
17

500
500
500
500
600
600
600
800
800
800
800
800
800

Fig. 08 Simple instrument panel
Legend
CT Control thermostat
HLT High limit thermostat
S
Plug
Connector

10.5.2 Complete instrument panel
(High/Low thermostat will not be used)

Fig. 09 Complete instrument panel

11
Legend
CT
Control thermostat
DK Reset button
F
Fuse
FD
Flame detector
FF
Flue fan
H
Lock out/Operating-light
HLT High limit thermostat
IT
Ignition transformator

LD2
MB
MS
PGV
SSV
S1
O
Ø

Air-pressure switch
Multi bloc
Main switch
Pilot gas valve
Safety shut-off valve
Boiler switch
Connector
Connection screws control box
Connection screws control panel

10.6 Wiring diagram for the boiler
10.6.1 Complete wiring diagram for the boiler with
simple instrument panel

Fig. 10 Complete wiring diagram for the boiler with
simple instrument panel
12

remeha Gas 3c ECO

10.6.2 Complete wiring diagram for the boiler with
complete instrument panel
(High/Low thermostat will not be used)

Fig. 11 Complete wiring diagram for the boiler with
complete instrument panel
13

remeha Gas 3c ECO
11. COMMISIONING
11.1 Technical information
Control box

11. Let the boiler run for a couple of minutes to get rid of
air in the gas pipe.
12. Set the correct burner pressure.
13. Optimal combustion efficiency can be obtained by
adjusting the plate on the rear of the economiser so
that a CO2 of 7-8% is obtained at a minimum return
water temperature of 60°C.
14. Check that the thermostats are locked in position.
15. Check for flame protection by starting the boiler with
ionisation probe disconnected.
16. Check the operation of the air-pressure switch.

: Satronic TMG 740/2
mod. 45.54.
Main supply
: 240 V-50 Hz.
Minimum ionisation current
: 7 µA.
Reaction time flame protection : 1 sec.
Safety time
: 5 sec.
Maximum ambient temperature : 60°C.
Injector size pilot burner
: Ø 0.8 mm.
Injector size main burner
: Ø 4.4 mm.
Burner pressure full load
: 12.3 mbar.
Pilot burner pressure
: 13 mbar

11.3 Switch off the boiler
1. Switch off the electric supply.
2. Turn off the gas cock.

11.2 Commissioning
1. Check gas connections.
2. Check electrical supply (L/N and earth).
The control box operates on a neutral/phase
supply.
3. Check water connections and release the air out of
the ECO and boiler. Fill the syphon with water.
4. Switch on circulation pump and check rotation direction.
5. Open main gas cock (release air in gas pipe work).
6. Switch on electrical supply.
7. Check rotation direction of the flue fan.
8. Set the control thermostat at about 85°C.
9. Adjust the sliding air inlet (see table).
10. After a waiting time of about 43 seconds you will get
ignition. At a minimum ionisation current of 7 µA the
safety gas valve will open and the pilot gas valve will
close after about 15 seconds. The boiler is on.

Number of
sections
5
6
7
8
9
10
11
12
13
14
15
16
17

Setting 'h'
in mm
34
24
21
27
68
63
43
103
90
86
60
62
65

Flue Fan
E 05-S972- 4mF
E 05-S972- 4mF
E 05-S976- 3mF
E 05-S976- 3mF
E 06-S972- 6mF
E 06-S972- 6mF
E 06-S972- 6mF
E 064-S972- 10mF
E 064-S972- 10mF
E 064-S972- 10mF
E 064-S972- 10mF
E 064-S972- 10mF
E 064-S972- 10mF

Fan power
in kW
0.13
0.13
0.24
0.24
0.30
0.30
0.30
0.63
0.63
0.63
0.63
0.63
0.63

Air-pressure switch
Flue Fan

Air control
Measuring
point CO2
and flue gas temp.

Condense drain connection

Fig. 12 Rear view of 'ECO'
14

Cross section

12. MAINTENANCE
12.1 General
It is essential for a good combustion, to clean the boiler,
the gas train and boiler room once a year.

3.
4.
5.
6.
7.

12.2 Maintenance instructions
1. Clean the internal flue ways of the boiler (cast iron
sections) with a steel cleaning brush (available from
Broag). Remove top casing and the top of the flue
hood.
2. Clean (if necessary) the aluminium economiser.
If it is not too dirty (normal deposition of dust) it is
best be cleaned with water, which can be hosed into
the top of the economiser. This water can be drained
down through the condensate drain. If it is badly
fouled, it should be cleaned by using the nylon cleaning brush. In that case, remove the rear panel and
then the intermediate panel. Clean the aluminium
pipes using the special nylon cleaning brush (available from Broag). Clean the condensate collector.
Never use the nylon brush for the cast iron sections and the economiser.

8.
9.
10.
11.
12.
13.

Remove the lit of the siphon trap and clean it.
Clean the burners internally and externally.
Clean the floor underneath the boiler and boiler room.
Clean boiler casings.
Clean the gas train, ignition, pilot burner, thermostats
and wiring.
Check start program, ignition time and safety times.
Check flame protection and thermostats.
Check boiler input.
Check the combustion efficiency.
Check the boiler and installation for water leakage
(seals).
Check gas train and gas pipe for gas leakage.

remeha Gas 3c ECO

ISO 9001
since 1988

Broag Ltd.
Head office
Remeha House,
Molly Millars Lane,
Wokingham,
Berkshire RG 41 2QP
Tel. 0118 9783434
Fax 0118 9786977
Branch office
Unit 3, Kestrel Close,
Quarry Hill Ind. Estate
Ilkeston,
Derbyshire DE7 4RD
Tel. 0115 9440778
Fax 0115 9440588

© Copyright
All technical and technological information contained in these technical
instructions, as well as any drawings
and technical descriptions furnished
by us remain our property and may
not be multiplied without our prior
consent in writing.
Subject to alterations
Art.nr. 50.455/1000/06.96/Bo.

remeha Gas 3d
Atmospheric gas boiler
with reminox® Low NOx
burners
90 - 360 kW

Technical information

remeha Gas 3d
CONTENTS
Preface

1. Boiler description

2. Construction
2.1 General
2.2 Burners
2.3 Boiler base
2.4 Assembly

3
3
3
3
3

3. Technical information and dimensions

4. Application
4.1 L.P.H.W. system
4.1.1 Water temperature
4.1.2 Water pressure
4.1.3 Water flow
4.1.4 Water treatment
4.1.5 Noise level
4.2 Chimneys
4.3 Installation standards

5
5
5
5
5
5
5
5
5

5. Typical boiler installations

6. Regulation and safety equipment
6.1 General
6.2 Instrument panel
6.3 Standard electronic gas train High/Low
6.3.1 Schematic
6.3.2 Specification
6.3.3 Control panel on gas train
6.4 Functions
6.4.1 Flame protection
6.4.2 Down draught thermostat
6.4.3 Thermostats

7
7
7
8
8
8
8
8
8
8
8

7. Assembly and installation guidelines
7.1 General
7.2 Boiler assembly
7.3 Water connections
7.4 Pocket for instrument panel
7.5 Water pressure
8.

Gas supply
8.1 General
8.2 Gas pressure

9
9
9
9
9
9
9
9
9
10
10
10
10
10
10
10
11
12
12

10. Commissioning
10.1 Technical information
10.2 Commissioning the boiler
10.3 Switching off the boiler

14
14
14
14

11. Maintenance
11.1 General
11.2 Maintening the boiler

15
15
15

These technical instructions contain useful and important
information for the proper operation and maintenance of
the remeha model Gas 3d central heating boiler.
Furthermore, important instructions are given to prevent
accidents and serious damage before commissioning and
during operation of the boiler, to ensure safe and trouble
free boiler operation. Read these instructions carefully
before putting the boiler into operation, familiarize yourself with its operation and control and strictly observe the
instructions given.
1. BOILER DESCRIPTION
The remeha Gas 3d boiler is a cast iron sectional boiler
with atmospheric burners.
Suitable for all qualities of natural gas, cat. I 2 H (20 mbar).
The boiler meets the requirements of the CE regulations
at the following directives:
- Gas appliance directive no. 90/396/EEC
- Efficiency directive no. 90/42/EEC
- Electrical low voltage directive no. 73/23/EEC
- Machinery directive no. 89/392/EEC
- E.M.C. directive no. 89/336/EEC.

Classification type for evacuation of the combustion
products: B11 BS.
For further advice or information contact Broag Ltd.
The remeha Gas 3d is supplied with electronic ignition
and insulated casings.
Water connections: Ø 70 mm int.

2. CONSTRUCTION
2.2 Burners
The burners are cast iron, atmospheric reminox®-burners. They guarantee a low noise level and a low NOxemission.

2.1 General
- Boiler block of cast iron sections are joined together
with conical nipples.
- Gas train and water connections can be fitted on either
side of the boiler.
The gas train should as standard always be fitted
on the same side as the instrumental panel,
thermostat pocket and the flow*.
- Instrument panel is fitted in the front casing.
- Cleaning of the cast iron block from top of the boiler.

2.3 Boiler base
The Broag remeha Gas 3d boiler is supplied as standard
with reflecting floor plates with ventilation underneath.
2.4 Assembly
The boiler must be assembled on site.

* On request extension cables can be delivered, so that
the gas train can be fitted on the opposite side to the
instrument panel, thermostat pocket and the flow.
3

remeha Gas 3d
3. TECHNICAL INFORMATION AND DIMENSIONS

Top view

ø70 int.

Cross section

Left hand side view

Front view

Fig. 01 View figures
Number Output
of
sections

Input
GCV

Water
resistance

Dimensions

± L ∆t = 10°C ∆t = 20°C
mbar
mbar
mm
670
4
16

111

A
mm
1015

113

139

1015

775

200

1220

670

135

167

1040

875

200

1220

670

158

194

1040

975

250

1220

670

B
mm
675

ØD
mm
200

Ød
"
1"

E
mm
1220

Water Boiler
contents weight
dry
l

Mass
flue
rate
kg/h

425

211

490

264

555

316

620

369

180

222

1040

1075

250

1 /4"

1220

700

685

422

203

250

1040

1175

250

11/4"

1220

700

755

475

225

279

1065

1275

300

1 /4"

1320

700

820

527

248

306

1065

1375

300

11/4"

1320

700

100

885

580

270

333

1065

1475

300

1 /2"

1320

1030

120

105

950

633

293

361

1065

1575

300

11/2"

1320

1030

140

111

1020

685

315

389

1090

1675

350

1 /2"

1320

1030

160

118

1085

738

338

417

1090

1775

350

11/2"

1320

1030

184

125

1150

791

1320

1030

208

131

1215

844

360

1090

1875

350

1 /2"

4. APPLICATION
4.1 L.P.H.W. system

4.2 Chimneys
The average flue gas temperature is so low that the chimney must be in accordance with the guidelines of British
Gas and BS 6644.

4.3 Installation standards
The following instructions must be adhered to when the
remeha Gas 3d is installed:
Gas safety (installation and use) Regulations 1984 (as
amended).
All gas appliances must, by law, be installed by competent persons (e.g. Corgi) in accordance with the above
regulations. Failure to install appliances correctly could
lead to prosecution.
It is in your own interest and that of safety to ensure that
the law is complied with.
In addition to the above regulations, this appliance must
be installed in compliance with the current I.E.E.
Regulations for electrical installation, local building regulations, the Building Standards (Scotland), Consolidation
Regulations and bye laws of the local water undertaking
and Health and Safety Document No. 635 'The Electricity
at Work Regulations 1989'. It should also be in accordance with the relevant recommendations in the current
editions of the following British Standards and Codes of
Practice, viz.
BS 5540 Pt 1 and 2, BS 5449, BS 5546, BS 6798,
BS 6891 and BG.DM2.

Important:
The remeha Gas 3d is a certified appliance and must not
be modified or installed in any way contrary to these
'Installation and Servicing Instructions'.
Manufacturers instructions must NOT be taken in any way
as overriding statutory obligations.

4.1.5 Noise level
The noise level measured around the boiler depending
on boiler room construction is about 50 dBA.
(Noise level taken at 1 meter from the boiler)

remeha Gas 3d
5. TYPICAL BOILER INSTALLATIONS
One boiler in boiler room

Fig. 02 Installation 1
Two boilers in boiler room

Fig. 03 Installation 2
Two boilers in boiler room
back to back

Fig. 04 Installation 3

Dimensions
(mm)

A
B
ØD
E

5
1015
675
200
1220

6
1015
775
200
1220

7
1040
875
200
1220

8
1040
975
250
1220

Number of sections
10
12
11
1040 1065 1065
1175 1275 1375
250
300
300
1220 1320 1320

9
1040
1075
250
1220

13
1065
1475
300
1320

14
1065
1575
300
1320

15
1090
1675
350
1320

16
1090
1775
350
1320

17
1090
1875
350
1320

6. REGULATION AND SAFETY EQUIPMENT
6.1 General
The remeha Gas 3d is supplied with electronic control
and safety equipment with UV flame detection.

All connections are pre-wired and fitted with plugs. The
capillaries from the control panel should be fitted in the
pocket of the boiler, wich is fitted in the top front of the
end section.

6.2 Instrument panel
The remeha Gas 3d is supplied with an instrument panel
that is fitted in the front of the boiler, either left or right.
The instrument panel can be delivered in two models:
- simple instrument panel High/Low;
- complete instrument panel High/Low.

The instument panel, pocket and the flow should
always be fitted at one side of the boiler either left or
right and standard on the same side as the gas
train.**

10
1

8
7

Fig. 05 Layout of the complete instrument panel
The modules contain:
Module A
1. Control thermostat
Setting between 35°-95°C
2. Hour run meter total running hours*

Module D
9. Warning light*
10. Analogue thermometer water temperature
Module E
11. Option for rematic® weather compensating boiler
control*

Module B
3. High-Low thermostat
Setting between 35°-95°C
4. Hour run meter full load*
Module C
5. High-limit thermostat 110°C (locking)
6. Operating switch (On/Off with optical display)*
7. Switch for circulating pump*
Manual/Off/Automatic
8. Switch for domestic hot water storage pump*
Manual/Off/Automatic

* Absent in simple instrument panel High/Low
** On request extension cables can be delivered, so
that the gas train can be fitted on the opposite side to
the instrument panel, thermostat pocket and the flow.
7

remeha Gas 3d
6.3 Standard electronic gas train High/Low

6.3.2 Specification
1 Gas multiloc (5-12 sections)
2 Safety shut off valves
1 Gas governor
1 Gas filter
2 Safety shut off valves (13-17 sections)
1 Gas governor
1 Pilot gas valve
1 Ignition transformer 5 kV
1 Pilot burner with UV protection

6.3.1 Schematic

6.3.3 Control panel on gas train
1 Main switch
1 Control box Landis & Gyr
1 Fuse, brusk
1 Signal lamp

Fig. 06 5-12 sections

6.4 Functions
6.4.1 Flame protection
Flame protection by means of UV flame detection.
6.4.2 Down draught thermostat
The boiler is fitted with a down draught thermostat.
If there is down draught the thermostat will switch off the
boiler. Fixed setpoint is 70°C.

6.4.3 Thermostats
Control thermostat On/Off 35°-95°C.
Control thermostat High/Low 35°-95°C.
High-limit thermostat locks out at 110°C.

7.5 Water pressure
Each section is hydraulically tested to at least 12 bar.
Maximum test pressure for the assembled boiler block is
6 bar.
Operating pressure between 0.8 bar and 6 bar.

7.3 Water connections
The boiler water connections can be fitted on either side
of the boiler.
The water connection is flanged on the boiler with a pipe
connection for welding Ø 70 mm to the installation.
The top blind-flange has an integral cast 1" tapping to
accept a safety valve. The end sections have a 3/4"
tapping to accept drain/off cocks (Tapping BSP).
8. GAS SUPPLY
8.1 General
The gas train can be fitted on either side of the boiler but
as standard is always fitted on the same side of the boiler
instrument panel (fitted in the front casing).*
The local Gas authority should be consulted to ensure
that an adequate pressure and supply is available at the
boilers maximum output. To minimise risk of sediment or
foreign particles entering the control valves, an approved
filter may be fitted into the pipe work downstream.
The gas supply should be conform to the British Gas
safety regulations.

8.2 Gas pressure
Maximum gas pressure at inlet 100 mbar.
Burner pressure:
- full load
: 13.0 mbar (100%)
- part load : 4.7 mbar (60%)
- injector size : 2.9 mm Ø

On request extension cables can be delivered, so that
the gas train can be fitted on the opposite side to the
instrument panel, thermostat pocket and the flow.
9

remeha Gas 3d
9. ELECTRICAL SUPPLY
9.1 General
The electrical installation must conform the IEE
regulations and also to local authority requirements.

9.5 Wiring diagram for the instrument panel
9.5.1 Simple instrument panel

9.2 Control panel
A control panel is fitted on the gas train.
9.3 Electrical connections
The boiler is pre-wired. Only the main supply should be
wired to this control panel.
9.4 Electrical data
Main supply: 240 V-50Hz (L/N).
Running current: 120 W.
Installed fuse: 6 Amp.

Fig. 08 Wiring diagram for the simple instrument panel
Legend
CT Control thermostat
HLT High limit thermostat
H/LT High/Low thermostat
S
Plug
Connector

9.5.2 Complete instrument panel

Fig. 09 Wiring diagram for the complete instrument panel
11

9.6 Wiring diagram boiler
9.6.1 Complete wiring diagram for the boiler with
simple instrument panel

Fig. 10 Wiring diagram for the boiler with simple instrument panel
12

remeha Gas 3d

9.6.2 Complete wiring diagram for the boiler with
complete instrument panel

Fig. 11 Wiring diagram for the boiler with complete instrument panel
13

remeha Gas 3d
10. COMMISSIONING
10.1 Technical information
Control box: Landis & Gyr typ LFL 1.638.
Main supply: 240 V-50 Hz.
Minimum UV current: 100 µA.
Reaction time flame protection: 1 sec.
Safety time: 5 sec.
Maximum ambient temperature: 60°C.
Injector size pilot burner: Ø 0.8 mm.
Injector size main burner: Ø 2.9 mm.
Burner pressure full load: 13.0 mbar (100%).
Burner pressure part load: 4.7 mbar (60%).
Burner pressure pilot burner = 16 mbar.

4. Switch on circulation pump and check rotation direction.
5. Open main gas cock (release air in gas pipe work).
6. Switch on electrical supply.
7. Set the control thermostats at about 85°C.
8. After a waiting time of about 72 seconds you will get
ignition. At a minimum UV current of 100 µAmp the
safety gas valve will open and the pilot gas valve will
close after 15 seconds. The boiler is on.
9. Leave the boiler on for a couple of minutes to get rid
of air in the gas pipe.
10. Set the correct burner pressure.
11. Check the thermostats for correct operation.
12. Check the flame protection, start the boiler with
the UV-blindfolded.

10.3 Switching off the boiler
1. Switch off the electrical supply.
2. Turn off the gas cock.

11. MAINTENANCE
4. Clean the boiler casings.
5. Clean the gas train, ignition, pilot burner, UV, thermostats and wiring.
6. Check start program, ignition time and safety times.
7. Check flame protection, and thermostats.
8. Check the boiler input at 100% and 60% load.
9. Make a combustion efficiency calculation.
10. Check the boiler and installation for water leakage.
11. Check gas train and gas pipe for gas leakage.

11.1 General
It is essential for a good combustion, to clean the boiler,
the gas train and boiler room once a year.
11.2 Maintening the boiler
1. Clean the internal flue ways of the boiler with a steel
cleaning brush (available from Broag).
Remove top casing and top of the flue hood.
2. Clean the burners internally and externally.
3. Clean boiler room and the floor underneath the
boiler.

ISO 9001
since 1988

Branch office
Unit 3, Kestrel Close,
Quarry Hill Ind. Estate,
Ilkeston
Derbyshire DE7 4RD
Tel. 0115 9440778
Fax 0115 9440588

3 5 0
G a s

Remeha Gas 350

R e m e h a

Technical information

• Atmospheric gas boiler
• 64 - 174 kW

Remeha Gas 350
TABLE OF CONTENT
Preface

Boiler description

Construction details
2.1 General
2.2 Burners
2.3 Boiler Floor
2.4 Delivery

3
3
3
3
3

Dimensions and technical data
3.1 Dimensions Remeha Gas 350
3.2 Technical data
3.3 Quotation specifications

4
4
4
5

Application information
4.1 L.P.H.W. system
4.1.1 Water temperature
4.1.2 Water pressure
4.1.3 Water flow
4.1.4 Water treatment
4.1.5 Noise level
4.2 Chimneys
4.3 Installation standards

5
5
5
5
5
5
6
6
6

Typical boiler installations
5.1 Installation 1
5.2 Installation 2

7
7
7

Control and safety equipment
6.1 General
6.2 Instrument panel
6.3 Standard electronic gas train High/Low
6.3.1 Schematic
6.4 Specification control box
6.4.1 Specification Ignition transformer
6.5 Functions
6.5.1 General
6.5.2 Flame control (lock out)
6.5.3 Thermostats (shutdown / lock out)
6.5.4 Water pressure switch - optional
(shut down)
6.5.5 Gas pressure switch LD - optional
(shut down)
6.5.6 Down draught thermostat - optional
(shut down)

8
8
8
8
8
9
9
9
9
9
9

9
9
9

Assembly and installation guidelines
7.1 General
7.2 Boiler assembly
7.3 Water connections
7.4 Pocket the thermostat capillaries
7.5 Water pressure

9
9
9
9
9
9

Gas supply
8.1 General
8.2 Gas pressure
8.3 Injectors
8.4 Operation on propane

10
10
10
10
10

Electrical supply
9.1 General
9.2 Control box
9.3 Electrical connections
9.4 Electrical information
9.5 Wiring diagrams

10
10
10
10
11
11

10 Commissioning
10.1 Commissioning the boiler
10.2 Switching off the boiler

12
12
13

11 Maintenance

12 Trouble shooting
12.1 Communication
12.2 Fault causes

14
15
15

PREFACE
These technical instructions contain useful and important information for the correct operation and maintenance of the Remeha boiler, model Gas 350.
Read these instructions carefully before putting the
boiler into operation, familiarise yourself with its control
functions and operation, strictly observing the instructions given. Failure to do so may invalidate warranty or
prevent the boiler from operating.
A competent Engineer, with the relevant certification
(i.e. CORGI, ACOPS, IEE regs. etc.) must carry out the
installation and commissioning of the boiler.
On completion a copy of the boiler log / commissioning
sheet should be returned to Broag Ltd for record purposes.
1

If you have any questions, or if you need more information about specific subjects relating to this boiler, or it’s
installation please do not hesitate to contact us.
The data published in these technical instructions is
based on the latest information (at date of publication)
and may be subject to revisions.
We reserve the right to continuous development in both
design and manufacture, therefore any changes to the
technology employed may not be retrospective nor may
we be obliged to adjust earlier supplies accordingly.

BOILER DESCRIPTION

The Remeha Gas 350 boiler is a cast iron sectional
floor standing gas fired boiler with Class II reduced NOX
burners. Supplied c/w control high/low and high limit
thermostats, automatic ignition and flame failure safety
controls. Suitable for all qualities of natural gas and propane, cat. II2H3B/P. The Remeha Gas 350 central heating
boiler is approved according to the following European
directives:
- Gas appliance directive no. 90/396/EEC,
- Efficiency directive no. 92/42/EEC,
- E.M.C. directive no. 89/336/EEC,
- Low voltage directive no. 73/23/EEC.
2

Remeha Gas 350 PIN: 0063AS3842
Classification type for evacuation of the combustion products: B11BS, B 11.
For further advice or information contact Broag Ltd.
The Remeha Gas 350 is supplied with electronic junction with insulated casings.

CONSTRUCTION DETAILS

2.1 General
The Remeha Gas 350 is a floor standing boiler complete with temperature and safety controls. The cast iron
sectional heat exchanger is assembled using conical
nipples and jointing compounds and ceramic rope. The
finished unit is cased in an insulated enamel coated
steel enclosure. The boiler has a built in draught diverter. It has water and gas connections within the casings
at the rear right hand side (when viewed from the front).
The boiler is supplied prewired requiring only permanent
mains supply and external control connections.

2.3 Boiler Floor
The Remeha Gas 350 boiler is supplied as standard
with reflecting floor plates with ventilation underneath.
2.4 Delivery
The boilers are supplied in sections for on site assembly. The gas train, control panel, burners and casings
supplied loose for fitting one site by others. The 4 - 6
units can also be delivered pre-assembled with the main
block pressure tested.

2.2 Burners
The burners are stainless steel, atmospheric type with
cooling rods to reduce the flame temperature. They guarantee a low noise level and a reduced NOX-emission.
Front and top access is required for service work to be
carried out.

Remeha Gas 350
3
3.1

DIMENSIONS AND TECHNICAL DATA
Dimensions Remeha Gas 350

fig. 01

Rear view

Side view

Front view

Dimensions Remeha Gas 350

É Flow R2” (BSP M)
Ê Return R2”
Ï Gas connection
4 - 6 sections R1”
7 - 9 sections R1¼”
Ñ Flue gas Ø D
Number of sections
A
mm
B
mm
C
mm
ØD
mm
E
mm
F

4
640
280
905
200
1030

5
740
330
905
200
1030

6
840
380
905
200
1030

7
940
430
930
200
1080

8
1040
480
930
250
1080

9
1140
530
930
250
1080

165

215

table 01 Dimensions
3.2

Technical data

Number of sections
Nominal heat output
kW
Hi / NCV
kW
Nominal
heat input
Hs / GCV
kW
Gas consumption
m3/h
Flue temperature
°C
∆t = 10°C
mbar
Water
resistance
∆t = 20°C
mbar
Water contents
litre
Boiler weight (dry)
kg
Flue gas flow rate
kg/h
table 02 Technical data Remeha Gas 350

4
64
72
80
7.6
154
5
2
45
335
219

5
87
97
108
10.3
152
13
3
51
390
239

6
109
121
134
12.8
146
21
5
58
445
255

7
130
145
161
15.3
138
30
8
65
500
271

8
152
169
188
17.9
138
41
10
71
555
398

9
174
193
214
20.4
142
52
13
78
610
407

3.3 Quotation specifications
General specifications:
- Heat exchanger manufactured from corrosion resistant “pearlite” cast iron
- Maximum operating pressure of 6 bar
- Maximum operating temperature of 95°C
- Electronic ignition as standard
- High/low operation as standard
- Reduced NOX burners (CE class 2)
- Built in draft diverter
- Supplied in broken down form, the models 4-6 sections can also be delivered pre-assembled
- Powder coated enamel steel casing
- 80 mm thick glass wool insulation
- Suitable for use with a Natural gas (propane available
as an option)
- Minimum return water temperature 20°C
- Supplied as standard with on/off switch, temperature
indication, control and high limit thermostats
- Efficiency 81.5% (GVC)
- Manufactured to ISO 9001
- CE approved
4
4.1

Optional:
- Hours run meters
- BMS contacts for remote indication
- Water pressure switch
- Down draught thermostat
- rematic® control.

APPLICATION INFORMATION
L.P.H.W. system

4.1.2 Water pressure
Boiler sections are factory pressure tested to 10 bar.
Maximum pressure test boiler block is 8 bar.
Maximum working pressure is 6 bar.
Minimum working pressure is 0.8 (sealed system) or 0.3
(open vented).

4.1.4 Water treatment
The system should be filled with mains cold water (for
the UK this will usually have a pH of between 7 and 8).
Pressurised installations with a boiler/system content
ratio of 1:10 or less should not require water treatment,
provided that the following conditions apply:
1. The system is flushed thoroughly to remove all
fluxes and debris and then filled completely once.
2. Make up water is limited to 5 % per annum.
3. The hardness of the water does not exceed 360
ppm (20°D).
All scale deposits will reduce the efficiency of the boiler
and should be prevented. However provided the above
is complied with any scale produced will not be too detrimental to the boiler efficiency and will not reduce the
anticipated life expectancy of the boiler.

4.1.3 Water flow
The minimum water flow through the boiler on shut
down is:

NOTE: Scale deposits in excess of 3 to 5 mm will
reduce boiler efficiency and greatly increase the risk of
premature casting failure.

4.1.1 Water temperature
Maximum water temperature is 110°C (high limit thermostat).
Highest operating boiler water temperature is 95°C (control thermostat).
Minimum return water temperature is 20°C at a flow rate
related to a ∆t of 20°C (flow/return temp).

Output boiler in kW = m3/h
93

As most systems contain a variety of metals which can
react with each other to cause corrosion. It is considered
good practice to provide some form of water treatment
(especially in open vented systems) in order to prevent
or reduce the following:
- Metallic corrosion;
- Formation of scale and sludge;
- Microbiological contamination;
- Chemical changes in the untreated system water.

This minimum flow must be maintained for approximately 5 minutes after the burner stops firing to avoid high
temperature shut down due to residual heat gain. Due
to the design and manufacture of the boiler no specific
minimum water flow requirements exist other then for
overheating protection.

Remeha Gas 350
4.3 Installation standards
The following instructions must be adhered to when the
Remeha Gas 350 is installed:
Gas Safety (installation and use) Regulations 1984 (as
amended).
In addition to the above regulations, this boiler must be
installed in compliance with:
- Current I.E.E. Regulations for electrical installations;
- Local building regulations;
- The Building Standards (Scotland);
- (Consolidation) Regulations;
- By-laws of the local water undertaking;
- Health and Safety Document No 635 ‘The Electricity
at Work Regulations 1989’.

Suitable chemicals and their use should be discussed
with a specialist water treatment company prior to carrying out any work. The specification of the system and
manufacturers recommendations must be taken into
account, along with the age and condition of the system.
New systems should be flushed thoroughly to remove all
traces of flux, debris, grease and metal swarf generated
during installation. Care to be taken with old systems to
ensure any black metallic iron oxide sludge and other
corrosive residues are removed, again by thoroughly
flushing, ensuring that the system is drained completely
from all low points.
NOTE: Please ensure that the new boiler plant is not in
circuit when the flushing takes place, especially if cleansing chemicals are used to assist the process.

Under no circumstances is the boiler to be operated
with cleaning chemicals in the system.
To Summarise:
- Minimise water loss;
- Prevent pumping over in open vented systems;
- Provide adequate air venting at all high points;
- Keep pH level between 7 - 9 when using additives;
- Maximum chlorine content of 200 mg/l;
Take advice on the suitability of inhibitors.

Lawfully all gas appliances must be installed by competent persons (e.g. Corgi, ACOPS).
Failure to install appliances correctly could lead to prosecution.
It is in your own interest and that of safety to ensure that
the law is complied with.
Important:
The Remeha Gas 350 is a certified appliance and must
not be modified or installed in any way contrary to these
‘Installation and Servicing Instructions’. Manufacturer
instructions must NOT be taken in any way as when
overriding statutory obligations.

4.1.5 Noise level
The noise level measured around the boiler depending
on boiler room construction is about 50 dBA. Noise
levels taken at 1 meter from the boiler.
4.2 Chimneys
The average flue gas temperature is so low (108173°C) that the chimney must be made in accordance
with the guidelines of British Gas, BS 6644 and IG 10.

TYPICAL BOILER INSTALLATIONS

5.1 Installation 1
Recommended layout for one boiler installation, measurements in mm.

1 Boiler in boiler room
V = min. length 0.5 m before elbow, thus avoiding down draught
W = min. 150 mm with vertical flue outlet
W = min. 0.5D + 50 mm with horizontal flue outlet

fig. 02

One boiler
number
of
sections
4
5
6
7
8
9

5.2 Installation 2
Recommended layout for two-boiler installation, measurements in mm.

2 Boilers in boiler room

fig. 03

Two boilers
7

640
740
840
940
1040
1140

280
330
380
430
480
530

Dimensions
C
ØD
905
905
905
930
930
930

200
200
200
200
250
250

E
1030
1030
1030
1080
1080
1080

Remeha Gas 350
6

CONTROL AND SAFETY EQUIPMENT

6.1 General
The Remeha Gas 350 is supplied with electronic control
and safety equipment with ionisation flame detection.

the following options: hour run meters, water pressure
switch, down draught thermostat, simple or complex volt
free modules and/or rematic® control. All connections
are pre-wired and fitted with plugs. The capillaries from
the control panel should be fitted in the pocket of the
boiler, which is fitted in the flow connection of the boiler.

6.2 Instrument panel
The Remeha Gas 350 is supplied with an instrument
panel that is fitted in the front of the boiler. The standard
instrument panel can be extended with the fitting of

1
9

fig. 04

Instrument panel
6.3

The instrument panel contains:
1. Operating switch (On/Off);
2. Control thermostat On/Off, range 35°C-95°C;
3. Control thermostat High/Low, range 35°C-95°C;
4. Hour run meter total running hours (option);
5. Hour run meter full load hours (option);
6. Analogue thermometer for flow temperature;
7. High – limit thermostat pre set to 110°C;
8. Lock out warning lamp;
9. Option for rematic® weather compensator.

Standard electronic gas train High/Low

6.3.1 Schematic

fig. 05

Schematic layout gas train

Legend
A
Gas cock
PB
Pilot burner
DR
Gas pressure governor
F
Gas filter
HB
Main burners
PGV Pilot gas valve
MP
Measuring point
SSV
Safety shut off valve
FD
Ionisation probe
MB
Gas multiblock
IT
Ignition transformer
--Not supplied as standard

6.4 Specification control box
Control box
:
Mains supply
:
Minimum ionisation current
:
Reaction time flame protection :
Safety time
:
Maximum ambient temperature :
Injector size pilot burner
:
Injector size main burner
:
Burner pressure full load
(high calorific gas)
:
Burner pressure part load
(high calorific gas)
:
Start repetitions
:

6.5.3 Thermostats (shutdown / lock out)
- Control thermostat On/Off: shutdown (35°C-95°C);
The boiler will automatically resume operation when
the flow temperature falls below the set point.
- Control thermostat High/Low: shutdown (35°C95°C);
The boiler will automatically resume operation when
the flow temperature falls below the set point.
- High Limit thermostat: lock out at 110°C;
The boiler will lock out. Manual intervention is
required to reset the boiler (on the instrument panel)
once the cause of the problem has been rectified.

Satronic DKG 972-27
230 V – 50 Hz
min 3 µA (DC)
1 sec.
≤ 10 sec.
60 °C
Ø 0.5 mm
Ø 4.0 mm
14.0 mbar (100%)
5.0 mbar (60%)
5x

6.5.4 Water pressure switch - optional (shut down)
The boiler can be fitted with an optional water pressure
switch. If the water pressure drops below the set value
(0.8 bar), the boiler will shut down. When the water
pressure returns to 1 bar, the boiler will resume operation again.
Type: SIT 340

Warning: control box is phase / neutral sensitive.
6.4.1 Specification Ignition transformer
Ignition transformer:
Satronic ZT. 870
Ignition voltage:
16 kV
Distance electrodes:
3,5 ± 1 mm.
6.5

6.5.5 Gas pressure switch LD - optional (shut down)
The boiler can be fitted with an optional gas pressure
switch LD. If the supply gas pressure drops below the
set value (12 mbar; for natural gas only), the boiler will
shut down. When the supply gas pressure returns above
this set value the boiler will resume operation again.
Type: Dungs GW50 A5.

Functions

6.5.1 General
The following functions (standard and optional) will,
when activated, either lock out or shut down the boiler.
For all options full fitting instructions are included in the
option pack.

6.5.6 Down draught thermostat - optional (shut
down)
The boiler can be fitted with an optional down draught
thermostat. When the temperature in the draught diverter rises above the down draught thermostat set point,
the boiler will shut down. It automatically resets after 3
minutes, provided that the temperature also falls.
Type: Honeywell L6068A; fixed set point is 70°C.

6.5.2 Flame control (lock out)
The flame is monitored using ionisation flame detection. In the event of a flame failure the boiler will lock
out. Manual intervention is required to reset the boiler
(on the control box) once the cause of the problem has
been rectified.

ASSEMBLY AND INSTALLATION GUIDELINES

7.1 General
The boiler is suitable for operating at a maximum working pressure of 6 bar. It can be installed in open vented
system with a minimum pressure of 0.3 bar or in sealed
system with a minimum pressure of 0.8 bar.

7.3 Water connections
The boiler water connections (2” male thread) are fitted
at the rear of the boiler (right hand connections only).
The two sections have a ¾” BSP tapping, the right hand
end section to accept a drain/off cock and the left hand
end section to accept a plug.

7.2 Boiler assembly
The boiler is supplied with full assembly instructions. On
request special assembly tools can be hired from Broag
on a daily basis. However, Broag (or a Broag approved
boiler erection engineer) can provide boiler assembly
services and / or building supervision.

7.4 Pocket the thermostat capillaries
The multi pocket for the thermostat capillaries is fitted in
the flow connection of the boiler.
7.5 Water pressure
Each section is hydraulically tested at 10 bar. Operating
pressure between 0.3 and 6 bar. The boiler can be fitted
with an optional water pressure switch, set at 0.8 bar.

Remeha Gas 350
8

GAS SUPPLY

8.1 General
The gas train is fitted behind the front casing.
The local Gas authority should be consulted to ensure
that an adequate pressure and supply is available. To
minimise risk of sediment or foreign particles entering
the control valves, an approved filter can be fitted into
the pipe system downstream. The gas supply should be
conforming to the British Gas safety regulations.

8.4 Operation on propane
The boiler is supplied, as standard set for natural gas,
therefore the boiler must be converted to propane
BEFORE the boiler is fired and commissioned for the
first time on propane.
Important: The boiler can only operate ON/OFF once
converted to propane!
For operation on propane the main burner injectors and
pilot burner injector (Ø 0.25 mm) must be replaced. Also
the burner pressure must be adjusted. It is important
to remove the cooling rods from the burners, including their supports.
Use our conversion kit for propane and follow the fitting
and commissioning instructions.
Technical data for operation on propane are shown in
table 03

8.2 Gas pressure
Natural gas, cat. I2H 3B/P (20 mbar).
Maximum gas pressure at inlet 100 mbar. Recommended min gas pressure required at the boiler is 17 mbar
with it operating at high fire.
Main burner pressure settings:
full load:
14.0 mbar
part load:
5.0 mbar
Pilot burner pressure settings: 13 mbar
Gas inlet pressure:
17 - 100 mbar
8.3 Injectors
Injector size main burner:
Injector size ignition burner:
Number
of
sections
4
5
6
7
8
9

Heat
output
kW
64
87
109
130
152
174

Note: Place the sticker from the conversion kit to indicate that the boiler has been changed for propane firing.

4.0 mm
0.5 mm

Heat
input Hi
kW
72
97
121
145
169
193

Burner
pressure1)
mbar
28
28
28
28
28
28

Gas consumption2)
m3/h
2.9
4.0
4.9
5.9
6.9
7.9

kg/h
5.6
7.5
9.4
11.2
13.1
15.0

Injector size
main burner
Ø mm
2.5
2.5
2.5
2.5
2.5
2.5

Injector size
pilot burner
Ø mm
0.25
0.25
0.25
0.25
0.25
0.25

table 03 Technical data propane
1)
The burner pressure may never vary more than 20% of the inlet pressure
2)
Caloric value propane = 24.44 kWh/m3 = 12.9 kWh/kg
9

ELECTRICAL SUPPLY

9.1 General
The electrical installation must conform to the IEE regulations and also to local authority requirements.

Functions of the basic signalling print:
- general alarm
- operating signals stage 1 and stage 2

9.2 Control box
The Satronic control box is fitted behind the front casing.

Functions of the extended signalling print:
- general alarm
- operating signals stage 1 and stage 2
- no power supply
- valve leakage failure
- burner failure
- low water level
- down draught thermostat
- water level control
- high limit thermostat.

9.3 Electrical connections
The boiler is pre-wired requiring only a mains supply
and external controls connected to the control panel.
The boiler can be fitted as an option, with a basic or an
extended signalling print.

Power supply
230V-50Hz

F
1

Tmx 1
3

* DS
P

* LD

4-2
CA1

1
2

4-4
CA3

*k1
P
1

15
16

2-2

8
7

2-1
7-3

7-4
T

1
5
4

9
1

1.)

TR1
B

R TB

7-9

6
7-6

4-10
CA5

A1
3Min.

7-2

A2 K1

8
2

13
15

VA1

2-4

2-3

Satronic DKG 972-27
5
6
5

Control box
1

Ignition transformer
Satronic ZT.870

16kV

MK 1

4-7
BM- STAGE HIGH
(230V)
19

2.)

TR2

4-8
BM- STAGE LOW (230V)

16
17

VA2

4-5
CA4

1.) & 2.) Remove link to control boiler
using an external Volt free
contact (230V - 1Amp. min.)
Optional

1
2

CA
4-9

1.) 7-8 External control On/Off (volt free switch)
2.) 16-17 External control High/Low (volt free switch)
10
Lock out indication (230V)
13
Boiler On (230V)
19
Boiler High fire (230)

04.03F.SC.00004

Wiring diagrams
9.5

Operating signals
Burner switch
General warning signals
Reset button
Water level switch
Fuse
Disturbance light
Ionisation electrode
Auxilairy relais
Gas pressure switch
Pilot gas valve
Hour run meter
Down draught thermostat
High limit thermostat
Control thermostat
Safety shut-off valve

BM
BS
CA
DK
DS
F
H
IE
K
LD
MK
P
TB
Tmx
TR
VA

1-1 1-2 1-3
K2

Cord numbers
Terminal strip control box
Terminal strip
Connector
Will not be supplied (optional)

Electrical principle diagram

fig. 06

230 V-50 Hz (L/N)
110 W
6.3 A (slow blow)
9.4 Electrical information
Main supply:
Power consumption running:
Maximum fuse:

Remeha Gas 350
CON.4A
4A-8 4A-9

4A-7
CON.4A
4A-8 4A-9

4A-7

4A-1

4A-2

4A-6

4A-5

4A-4

4A-10

4A-3

4A-2

1
2

K10-1 K9-1

5 6

K8-1

K8-2

D7
K10

CGeneral warning
alsignal

4 BOperating signal
5 mstage 2

K10-1 K9-1

6 BOperating signal
7 mstage 1

5 6

K7-1

K6-1

K5-1

K4-1

K3-1

K2-1

K1-1

10 11

12 13

14 15

16 17

18 19

20 21

K8-1

K8-2

2 General warning
signal
3

fig. 07

Optional basic signalling print

4 Operating signal
5 stage 2
6 Operating signal
7 stage 1
8 No power supply
9
10 Valve leakage
11 failure
12 Burner
13 failure
14
15

Low water level

16 Down draught
17 thermostat
18 Water level
19 control
20 High limit stat
21

fig. 08
10

Optional complex signalling print

COMMISSIONING

NOTE: Commissioning must only be carried out by a
qualified engineer with the relevant training and certification i.e. Acops - Corgi and a commissioning data sheet
/ log book completed and left on site for issue to the
owner.

10. After a waiting time of about 3 seconds the ignition
starts. The magnetic valve MK opens and ignition
burner lights. At a minimum ionisation current of 3
µA the safety gas valve will open. The boiler runs.
11. Let the boiler run for a couple of minutes on high fire
to clear any air still in the gas pipe.
12. Set the correct full load burner pressure by means
of the pressure regulator on the gas multiblock gas
valve (see fig. 09, pos. a).
Warning: When the required burner pressure can
not be reached because of low inlet pressure,
ensure that the pressure regulator remains within it’s
operating range.
Now do the following:
• Set the burner pressure to the highest possible
value (but not over the required full load burner
pressure).
• Turn the pressure regulator anticlockwise until
the burner pressure is affected.
• The burner pressure is now limited, this will
prevent the boiler from being over gassed
should the inlet gas pressure increase.

Important: commissioning for propane, first see par.
8.4
10.1 Commissioning the boiler
1. Check the gas connections.
2. Check the electrical supply (L/N and earth).
Warning: control box is phase / neutral sensitive.
3. Check the water connections and whether the installation is full and under system pressure.
4. Switch on the circulation pump and check the rotation direction.
5. Open the main gas cock (purge gas pipeline).
6. Switch on the electrical supply.
7. Set both the thermostats to about 85°C.
8. If a control system is built in: put the selector switch
on manual operation.
9. Switch on the boiler.
12

13. Set the correct part load burner pressure:
• Turn the High/Low thermostat to its minimum
setting (35°C). When the flow temperature is
over 35°C, the boiler will burn at part load.
• Set the part load burner pressure by turning the
adjustment ring (fig. 09, pos. b).
• To check the high fire setting: Turn the High/Low
thermostat to 85°C and check the full load
burner pressure (if necessary re-adjust).
The speed of opening of the main gas valve can
also be adjusted to ensure a smooth light up. Setting the hydraulic brake on the main gas valve as
follows:
• Remove the setting cap (fig. 09, pos. c) and turn
it upside down on the hydraulic brake.
• Turn it clockwise to slow down, anticlockwise to
speed up.
• Check both burner pressures again and if
necessary re-adjust.
14. Check the thermostats for the correct operation
setting.
15. Check the flame control on the control box
• Start the boiler with disconnected ionisation
probe, after the ignition phase the pilot gas
valve must close. The boiler will lock out.
• Reset by pressing the reset button on the
control box.
• Then disconnect the ionisation probe during
operation, the pilot gas valve must close immediately. The boiler will lock out.
• Reset by pressing the reset button on the
control box.
16. Water level control:
• Check the water level.
• Check the operation of the water level control by
disconnecting the electrode. The boiler should
go to lock out
• Create a shortcut between the electrode and
earth. The boiler should go to lock out
• Reset by pressing the reset button on the instrument panel. The boiler will resume operation
17. Check the down draught thermostat by pressing
the bimetallic strip on the thermostat. The boiler will
shut down for 3 minutes. After that the boiler will
resume operation.
18. Send the initial commissioning report CE to Broag.

fig.
a.
b.
c.

09
Dungs MB-ZRDLE 410/412 B01 S52
Pressure regulator
Part load adjustment ring
Hydraulic brake (setting cap)

10.2 Switching off the boiler
1. Set boiler controls to OFF
2. Allow system to cool
3. Switch off the electric supply
4. Turn off the gas cock.
Warning: The boiler can be damaged, when the temperature falls below freezing point and it is switched off
and full of water.
Note:
Commissioning must only be carried out by a qualified
engineer with the relevant product training and certification i.e. Acops - Corgi. A commissioning data sheet / logbook must be completed on site for issue to owner.

Remeha Gas 350
11

MAINTENANCE
-

To maintain maximum efficiency it is essential to service
the boiler, check safety parameters and re-set combustion once a year.

Normal Service Maintenance
- Isolate power, controls and gas supply.
- Remove front and top casings and flue hood covers.
- Remove gas manifold.
- Remove the burners and floor plates.
- Clean the internal flue ways of the boiler.
- Clean the floor underneath the boiler and boiler
room.
- Clean the burners internally and externally using a
soft brush.
- Clean the plates under the burners as well - they
must be fitted and in the correct place for the combustion to be correct
- Clean the gas train, ignition, pilot burner, thermostats and wiring.
12

Check and reset/replace ignition electrode and ionisation probe as found necessary.
Re-assemble boiler.
Check ignition and ionisation cables for connections
and continuity.
Restore power, controls and gas supply.
Check start program, ignition time and safety times.
Check flame protection and thermostats.
Check boiler input at 100% (full load) and 60% (part
load) load.
Carryout combustion efficiency test.
Check the boiler and immediate installation connections for water leaks (seals).
Check gas train and gas pipe for gas leaks.
Check flue connections.
Clean boiler casings.
Complete a commissioning report and fill in the boiler logbook if available.

TROUBLE SHOOTING
Timing diagram begin
duration
VA2 (clamp 6)
37
Ionisation required
27
Waiting time Tw
Ignition valve + VA1 (clamp 5)
17
False flame detection TfIgnition (clamp 3)
7
Main
gas valve
Start
up processor

Pre-ignition time Tvz

Delay 2nd stage Tv2
Safety time Ts
Safety time TsPost ignition Tn
Pre-ignition time Tvz
Delay 2ndFalse
stage Tv2
flame detection Tf
Waiting time Tw
Start up processor

17
17
17
7
7
2
0

Post ignition Tn

Ignition (clamp 3)

duration 2 end
14
24
34
19

20
10
9
10
5
5
2

50
50
50
26
37
27
26
17
12
7
2

Ignition valve + VA1 (clamp 5)
Ionisation required
Main gas valve VA2 (clamp 6)
0

25
seconds

fig. 10

Switch diagram

12.1 Communication
The control box communicates by using a flash code.
An LED inside the reset button of the control box displays this flash code.
flash code
meaning of codes
│││.
waiting time Tw
││││.
pre-ignition (Tvz)
▌│.
safety time (Ts) and post ignition time (Tn)
▌││.
delay time to valve V2 (Tv2)
│.
running
table 04 Program phases
flash code
│▌▌.
│▌.
│▌▌▌▌
││▌▌▌
││▌▌▌▌▌▌▌▌

meaning
low mains voltage (shut down)
Internal fuse defect
lock out
early flame
manual lock out

cause
control box defect
no flame detection within safety time Ts
Ionisation probe may be faulty

table 05 Error messages
▌ = long pulse
│ = short pulse
. = short pause
12.2 Fault causes
In case of a failure the LED is permanently illuminated.
Every 10 seconds the illumination is interrupted by a
flash code.
In case of all failures the gas supply is interrupted.
Fault
Burner not working =>
shut down

Possible cause:
- no heat demand
- no mains supply
- voltage < 187 V
- continuously tension on
terminal A
2-3 seconds after apply- - control box not reset
ing mains =>
lock out
Burner starts, no flame - false flame detected
=> lock out
- no ignition
- no gas supply
Burner starts, flame
- ionisation current < 1,5 µA
established => lock out - phase and neutral
after safety time (Ts)
reversed
- ionisation probe damaged
or dirty
table 06 Trouble shooting

3 5 0
G a s
R e m e h a
Broag Ltd.
Remeha House
Molly Millars Lane
RG41 2QP WOKINGHAM, Berks.
United Kingdom
Tel:

0118 9783434

Fax:

0118 9786977

uk.remeha.com
boilers@broag-remeha.com

Midlands Branch Office
Unit 3 Kestrel Close
Quarry Hill Industrial Estate
Ilkeston

© Copyright
All technical and technological information contained in these technical instructions,
as well as any drawings and technical descriptions furnished by us remain our property and shall not be copied in part or whole without our prior consent in writing.
Subject to alterations

ISO 9001
since 1988

51247-0303

Derbyshire DE7 4RD
Tel:

0115 944 0778

Fax:

0115 944 0588

4 5 0
G a s
R e m e h a

Technical information

Remeha Gas 450

• Atmospheric gas boiler with
reduced NOx emission
• 217 - 344 kW

Remeha Gas 450
CONTENTS
Preface

1. Boiler description

2. Constructions
2.1 General 3
2.2 Burners 3
2.3 Boiler floor
2.4 Delivery 3

3. Technical information and dimensions

4. Application
4.1 L.P.H.W. system
4.1.1
Water temperature
4.1.2
Water pressure
4.1.3
Water flow
4.1.4
Water treatment
4.1.5
Noise level
4.2 Chimneys

5
5
5
5
5
5
5
5

5. Typical boiler installations

6. Regulation and safety equipement
6.1 General
6.2 Instrument panel
6.3 Standard electronic gas train High/Low
6.3.1
Schematic
6.3.2
Specification
6.3.3
Control panel behind front panel
6.4 Functions
6.4.1
Flame protection
6.4.2
Down draught thermostat
6.4.3
Thermostats

7
7
7
7
7
7
7
7
7
7
7

7. Assembly and installation guidelines
7.1 General
7.2 Boiler assembly
7.3 Water connections
7.4 Pocket for instrument panel
7.5 Water pressure

8
8
8
8
8
8

8. Gas supply
8.1 General
8.2 Gas pressure

8
8
8

9. Electrical supply
9.1 General
9.2 Control panel
9.3 Electrical connections
9.4 Electrical data
9.5 Wiring diagram boiler

8
8
8
8
8
9

10. Commissioning
10.1 Technical information
10.2 Commissioning the boiler
10.3 Switching off the boiler

10
10
10
10

11. Maintenance
11.1 General
11.2 Maintaining the boiler

11
11
11

PREFACE
These technical instructions contain useful and important
information for the proper operation and maintenance
of the Remeha central heating boiler, model Gas 450.
Further it contains important directions to prevent accidents
and serious damage before putting it into service and
during operation of the boiler, to allow as far as possible a
safe and trouble free operation. Read these instructions
carefully before putting the boiler into operation, familiarize
yourself with its operation and control and strictly observe
the directions given.

If you have any questions, or if you want more information
about specific items relating to this boiler, please do not
hesitate to contact us.
The data published in these technical instructions is based
on the most recent information and is given subject to
later revisions.
We reserve the right to modify the construction and/or
design of our products at any moment, without obligation
to update earlier supplies accordingly.

1. BOILER DESCRIPTION
The Remeha Gas 450 boiler is a cast iron sectional boiler
with atmospheric burners.
Suitable for all qualities of natural gas and LPG,
cat. II 2H3P (LPG version on request)
The Remeha Gas 450 central heating boiler is approved
according to the following European directives:
- Gas appliance directive
no. 90/396/EEC
- Efficiency directive
no. 92/42/EEC
- E.M.C. directive
no. 89/336/EEC
and complies with the following directives:
- Low voltage directive
no. 73/23/EEC
- Machine directive
no. 89/392/EEC.

Classification type for evacuation of the combustion products: B11 BS.
For further advice or information contact Broag Ltd.
The Remeha Gas 450 is supplied with electronic junction with insulated casings.
Water connections 21/2" BSP.

2. CONSTRUCTIONS
2.1 General
- Boiler block of cast iron sections nippled together with
conical nipples.
- Gas and water connections are at the rear of the boiler.
- Instrument panel is fitted in the front casing and must
be assembled on the same side as the gas and water
connections.
Instrument panel must be assambled on the same
side of gas and water connections.
- Cleaning of the cast iron block from top of the boiler.
- The control and safety equipment is fitted behind the
front casings.
- The boiler is entirely prewired.
- Gas and water connections can be assembled both
left and right.

2.2 Burners
The burners are stainless steel, atmospheric burners
with cooling rods to reduce the flame temperature.
They guarantee a low noise level and a reduced NOxemission.
2.3 Boiler ﬂoor
The Remeha Gas 450 boiler is supplied as standard
with reflecting floor plates with ventilation underneath.
2.4 Delivery
The total range is supplied in parts for site assembly.

Remeha Gas 450
3. TECHNICAL INFORMATION AND DIMENSIONS

Side view

Front view

Flow R 2½"
Return R 2½"
Gas connection: R 1¼"
Note:
Right hand execution is shown: instrument panel,
gas and water connections on the right hand side;
left hand execution is mirror image

Rear view
Fig. 01 Dimensions
Heat
input

Dimensions

Number of
sections

Heat
output

Gasrate

kW
217

Hs
kW
268

Hi
kW
241

m3/h
25.0

A
mm
1365

B
mm
682.5

ØD
mm
300

262

322

290

30.1

1565

782.5

300

120

307

376

338

35.1

1763

881.5

350

344

420

378

39.2

1963

981.5

350

* Connections can also be assembled on the other side
4

Water
resistance
³t = 10°C ³t = 20°C
mbar
mbar
84
21

Water Boiler
content weight

Mass
flue
rate

l
91

kg
725

kg/h
544

105

835

654

164

118

950

752

208

131

1060

831

4. APPLICATION
4.1 L.P.H.W. system

4.1.4 Water treatment
Water treatment under normal circumstances is not
necessary (see our water quality recommendations).

4.1.1 Water temperature
Maximum water temperature is 110°C (high limit
thermostat).
Highest boiler operation water temperature is 95°C
(control thermostat).
Minimum return water temperature is 20°C at a flowrate
related to a ³t of 20°C (flow/return temperature).

4.1.5 Noise level
The noise level measured around the boiler depending
on boiler room construction is about 50 dBA.
(Noise level taken at 1 meter from the boiler).
4.2 Chimneys
The average flue gas temperature is so low that the
chimney must be in accordance with the guidelines of
British Gas and BS 6644.

4.1.2 Water pressure
Boiler sections pressure test at 10 bar.
Maximum pressure test boiler block is 8 bar.
Maximum working pressure is 6 bar.
Minimum working pressure boiler is 0.8 bar.
Optional a water pressure switch set at 0.8 bar can be
supplied with the boiler.
4.1.3 Water ﬂow
The minimum water flow through the boiler is:
Output boiler in kW = ... m3/h
93
This minimum flow must be maintained for 5 minutes after
the burner stops firing to avoid high temperature shut-down
due to residuel heat gain.
Due to the design and manufacture of the boiler no specific
minimum water flow requirement exists other than hightemperature protection.

Remeha Gas 450
5. TYPICAL BOILER INSTALLATIONS
1 boiler in boiler room

V = min. length 0.5 m before
elbow, thus avoiding downdraught
W = min. 150 mm with vertical
flue outlet
W = min. 0.5D + 50 mm with
horizontal flue outlet
= free access to rear of boiler
*Note:
Right hand execution is shown:
instrument panel, gas and
water connections on the right
hand side; left hand
execution is mirror image

Fig. 02 Installation 1
2 boilers in boiler room

free access to rear of boiler

Note:
Both right and left hand execution are shown:
- left boiler: instrument panel,
gas and water connections on
the right hand side;
- right boiler: instrument panel,
gas and water connections on
the left hand side.

Fig. 03 Installation 2

Number of
sections

11
13
15
17

A
1365
1565
1763
1963

Dimensions (mm)
B
682.5
782.5
881.5
981.5

ØD
300
300
350
350

6. REGULATION AND SAFETY EQUIPEMENT
6.1 General
The Remeha Gas 450 is supplied with electronic control
and safety equipment with ionisation flame detection.

All connections are pre-wired and fitted with plugs. The
capillaries from the control panel should be fitted in the
pocket of the boiler, which is fitted in the flow connection
of the boiler.

6.2 Instrument panel
The Remeha Gas 450 is supplied with an instrument
panel that is fitted in the front of the boiler. The standard
instrument panel can be extended with the fitting of
the following options: hour run meters, water pressure
switch, down draught thermostat, no volt contacts and/or
rematic® control.
1

Fig. 04 Layout of the instrument panel, extended with hour counters
1.
2.
3.
4.
5.

Operating switch (On/Off)
Control thermostat On/Off. Setting between 35 - 95°C
Control thermostat high/low. Setting between 35 - 95°C
Hour run meter total running hours (not standard)
Hour run meter full load hours (not standard)

6.
7.
8.
9.

Analogue thermometer for water temperature
High - Limit thermostat 110°C (pre set)
Warning light (lock out)
Option for rematic® weather compensator

6.3.2 Speciﬁcation
1 Gas Multi-Bloc contains:
2 Safety shut off valves
1 Gas governor
1 Gas filter
1 Pilot gas valve
1 Pilot burner with ionisation probe
and ignition probe

6.3 Standard electronic gas train High/Low
6.3.1 Schematic

6.3.3 Control panel behind front panel
1 Control box Satronic
1 Ignition transformer 16 kV
Fig. 05 Gastrain
6.4 Functions
Legend
A
Gas cock
AB
Pilot burner
DR Gas governor
F
Gas filter
HB Main gas burners
MB Gas multibloc
OT Ignition transformer
MK Pilot gas valve
MP Measuring point
VA
Safety shut off valve
VB
Ionisation probe
- - - - Not supplied.

6.4.1 Flame protection
Flame protection by means of ionisation flame detection.
6.4.2 Down draught thermostat
Optional the boiler can be fitted with a down draught
thermostat. When there is down draught of the flue gases
this thermostat will switch off the boiler.
Fixed setpoint is 70°C.
6.4.3 Thermostats
Control thermostat On/Off 35°-95°C.
Control thermostat High/Low 35°-95°C.
High-Limit thermostat locks out at 110°C.
7

Remeha Gas 450
7. ASSEMBLING AND INSTALLATION GUIDELINES
7.4 Pocket for instrument panel
The thermostat pocket is fitted in the flow connection of
the boiler.

7.1 General
The boiler is suitable for operating at a maximum working
pressure of 6 bar and a minimum pressure of 0.8 bar.
Boiler can be installed in open or closed systems.

7.5 Water pressure
Each section is hydraulically tested to at least 10 bar.
Maximum test pressure for the assembled boiler block is
8 bar. Operating pressure between 0.8 bar and 6 bar.
Optional the boiler can be fitted with a water pressure
switch, set at 0.8 bar.

7.2 Boiler assembly
Broag can provide special tools on loan for the boiler
assembly with detailed building instructions. However, building supervision and/or actual boiler erection services
can be provided by Broag or an approved boiler erection
engineer.
7.3 Water connections
The boiler water connections (21/2" BSP) are fitted at
the rear of the boiler (can be assembled either left or
right). The two end sections have a 3/4" BSP tapping
with plug, one end section to accept a drain/off cock
(to be assembled on the same side as the gas/water
connections) and other end section to accept a plug.

8. GAS SUPPLY
8.1 General
The gas train is fitted behind the front casing.
The local Gas authority should be consulted to ensure
that an adequate pressure and supply is available at the
boilers maximum output. To minimise risk of sediment or
foreign particles entering the control valves, an approved
filter may be fitted into the pipe work downstream.
The gas supply should be conform to the British Gas
safety regulations.

8.2 Gas pressure
Cat. I2H
Maximum gas pressure at inlet 100 mbar.
Burner pressure:
- full load
: 14.0 mbar (100%)
- part load : 5.0 mbar (60%)
- injector size: 3.85 mm Ø
Note: LPG version on request.

9. ELECTRICAL SUPPLY
9.1 General
The electrical installation must conform to the IEE
regulations and also to local authority requirements.

9.3 Electrical connections
The boiler is pre-wired. Only the main supply should be
wired to the control panel.

9.2 Control panel
A control panel is fitted behind the front casing on the
same side as the water and gas connections.

9.4 Electrical data
Main supply
: 230 V-50Hz (L/N).
Running current : 155 VA.
Installed fuse : 6 Amp.

9.5 Wiring diagram boiler

Fig. 06 Wiring diagram
9

Remeha Gas 450
10. COMMISSIONING
4. Switch on circulation pump and check rotation direction.
5. Open main gas cock (release air in gas pipe work).
6. Switch on electrical supply.
7. Set the control thermostats at about 85°C.
8. After a waiting time of about 3 seconds you will get
ignition. At a minimum ionisation current of 3 µAmp
the safety gas valve will open. The boiler is on.
9. Let the boiler run for a couple of minutes to get rid
of air in the gas pipe.
10. Set the correct burner pressure.
11. Check the thermostats for correct operation.
12. Check the flame protection, by starting with the
ionisation probe disconnected.
13. Send the commissioning reports to Broag.

Note:
Commissioning to only be carried out by a qualified
engineer with the relevant training and certification i.e.
Acops - Corgi and a commissioning data sheet completed
on site for issue to owner.
10.1 Technical information
Control box: Satronic TFI 812-2 mod. 10.
Main supply: 230 V-50 Hz.
Minimum ionisation current: 3 µA.
Reaction time flame protection: 1 sec.
Safety time: < 10 sec.
Maximum ambient temperature: 60°C.
Injector size pilot burner: Ø 0.5 mm.
Injector size main burner: Ø 3.85 mm.
Burner pressure full load: 14.0 mbar (100%).
Burner pressure part load: 5.0 mbar (60%).

10.3 Switching off the boiler
1. Set boiler controls to off.
2. Allow system to cool.
3. Switch off the electrical supply.
4. Turn off the gas cock.

Warning:
Control box is neutral/phase sensitive: if incorrectly
connected the boiler will not start.
10.2 Commissioning the boiler
1. Check gas connections.
2. Check electrical supply (L/N and earth).
3. Check water connections and if installation is filled.

11. MAINTENANCE
11.1 General
It is essential for efficient operation, to service the boiler,
the gas train and clean the boiler room once a year.

6. Clean the boiler casings.
7. Clean the gas train, ignition, pilotburner, thermostats
and wiring.
8. Check the gas train and pipe for gas leakage.
9. Check the start program, ignition time and safety
times.
10. Check flame protection and thermostats.
11. Check the boiler input at 100% (full load) and 60%
(part load).
12. Make a combustion efficiency calculation.
13. Check the boiler and installation for water leakage.

11.2 Maintaining the boiler
1. Remove the front casing of the boiler.
2. Remove the top casing and the top of the flue hood.
3. Clean the internal flue ways of the boiler with a steel
cleaning brush (available from Broag).
4. Clean the boiler room and the floor underneath the
boiler.
5. Clean the burners internally and externally and
check the kanthal bars.

4 5 0
G a s
R e m e h a
Broag Ltd.
Head office
Remeha house
Molly Millars Lane
Wokingham,
Berkshire RG41 2QP
Tel.: 0118 978 3434
Fax: 0118 978 6977
E-mail address:
boilers@broag-remeha.com

Branch office
Unit 3, Kestrel Close,
Quarry Hill ind. Estate,
Ilkeston
Derbyshire DE7 4RD
Tel.: 0115 944 0778

© Copyright
All technical and technological information contained in these technical instructions,
as well as any drawings and technical descriptions furnished by us remain our
property and shall not be copied in part or whole without our prior consent in writing.

ISO 9001
since 1988

Subject to alterations
53899/1.500/0401/Ho.

Fax: 0115 944 0588

Remeha Gas 550/550 Duo

Technical information

• Atmospheric gas boiler
• 278 - 1058 kW

Remeha Gas
550/550 Duo
TABLE OF CONTENT
Preface

1 Boiler description

2 Construction details
2.1 General
2.2 Burners
2.3 Assembly

3
3
3
3

3 dimensions and Technical data
3.1 Dimensions Remeha Gas 550
3.2 Dimensions Remeha Gas 550 Duo

4
4
6

4 Application information
4.1 L.P.H.W. system
4.1.1 Water temperature
4.1.2 Water pressure
4.1.3 Water flow
4.1.4 Water treatment
4.1.5 Noise level
4.2 Chimneys
4.3 Installation standards

7
7
7
7
7
7
8
8
8

5 Typical boiler installations
5.1 Installation 1
5.2 Installation 2

9
9
10

6 Control and safety equipment
6.1 General
6.2 Instrument panel
6.3 Standard electronic gas train High/Low
6.3.1 Schematic
6.3.2 Control panel on gas train
6.3.3 Specification control box
6.3.4 Specification Ignition transformer
6.4 Functions
6.4.1 Flame control (lock out)
6.4.2 Thermostats (shutdown / lock out)
6.4.3 Water level control (lock out)
6.4.4 Valve leakage control - optional
( lock out)
6.4.5 Gas pressure switch LD - optional
(shut down)
6.4.6 Gas pressure switch HD - optional
(lock out)
6.4.7 Down draft thermostat;
(optional, shut down)

11
11
11
11
11
11
11
12
12
12
12
12

7 Assembly and installation guidelines
7.1 General
7.2 Boiler assembly
7.3 Water connections
7.4 Pocket for the thermostat capillaries
7.5 Water pressure

13
13
13
13
13
13

8 Gas
8.1
8.2
8.3

12
12
12
12

supply
General
Gas pressure
Injectors

13
13
13
13

9 Electrical supply
9.1 General
9.2 Instrument panel
9.3 Control panel
9.4 Electrical connections
9.5 Electrical information
9.6 Water level control
9.7 Wiring diagrams

14
14
14
14
14
14
14
15

10 Commissioning
10.1 Switching off the boiler

16
18

11 Maintenance

12 Trouble shooting
12.1 Fault causes

19
19

PREFACE
These technical instructions contain useful and important information for the correct operation and maintenance of the Remeha boiler, model Gas 550 and Gas 550
Duo.

Read these instructions carefully before putting the boiler into operation, familiarise yourself with it’s control
functions and operation, strictly observing the instructions given. Failure to do so may invalidate warranty or
prevent the boiler from operating.
The installation and commissioning of the boiler must be
carried out by a competent Engineer, with the relevant
certification i.e.: CORGI, ACOPS, IEE regs. etc.
On completion a copy of the boiler log / commissioning
sheet should be returned to Broag Ltd for record purposes.

BOILER DESCRIPTION

The Remeha Gas 550 series boiler is a cast iron
sectional boiler, with a powder coated enamel steel
casing compleet with glass fibre insulation.It has high /
low atmospheric gas burners, suitable for natural gas,
cat. I 2 H - 20 mbar.
It is supplied in sections for delivery and on site assembly.

Remeha Gas 550 (Duo)-reference number: 0063AP6520
Classification type for evacuation of the combustion products, according: EN-656: B11, B11BS.
For further advice or information contact Broag Ltd.

The boiler meets the requirements of the CE regulations
at the following directives:
- Gas appliance directive no. 90/396/EEC;
- Efficiency directive no. 92/42/EEC;
- E.M.C. directive no. 89/336/EEC.
And is correspondent with:
- Electrical low voltage directive no. 73/23/EEC.

CONSTRUCTION DETAILS

2.1 General
The Remeha Gas 550 / 550 Duo is a floor standing
boiler complete with temperature and safety controls.
The cast iron sectional heat exchanger is assembled
using conical nipples and jointing compound.The boiler
has a built in draft diverter. It has water connections at
the side within the casing dimensions and a gas train
to one side.

2.2 Burners
The burners are stainless steel, atmospheric type with a
heat reflecting floor plate providing the correct ventilation
distribution. Front and top access is required for service
work to be carried out.

Note: Both water and gas connections can be handed
on site during assembly. But the instrument panel,
mounted in the front casing should always be fitted on
the same side as the flow connection.
The casings can be fitted after the flue and pipework to
the boiler have been installed and connected.

2.3 Assembly
The boiler cannot be supplied pre-assembled and must
be assembled on site.

Note: The Gas 550 Duo has two complete boiler units
within one casing using a common flue connection.

Remeha Gas
550/550 Duo
3

DIMENSIONS AND TECHNICAL DATA

3.1 Dimensions Remeha Gas 550

Fig. 01 Dimensions Remeha Gas 550
00.05F.79.00002

Flow Ø107 int.
Return Ø107 int.
Gas 2"
Flue gas Ø

Number of sections
Nominal heat
output
Nominal
heat input

Hi /
NCV
Hs /
GCV

139-278

170-340

202-403

233-466

265-529

296-592

328-656

160-309

195-378

232-448

266-518

301-588

337-657

372-728

177-343

217-420

256-498

296-576

335-653

374-730

414-809

Gas consumption

m /h

1240

1460

1680

1900

2120

2340

2560

ØD

300*

350*

400*

450

450*

500

500*

1295

1245

1730

1610

1730

1610

1730

°C

154

152

146

138

142

mbar

128

160

180

196

mbar

Water contents

litre

291

349

407

465

523

581

639

Boiler weight (dry)

1450

1695

1940

2185

2430

2675

2920

Flue gas flow rate

kg/h

692

847

1033

1239

1376

1560

1678

Dimensions

Flue temperature

Water
resistance

∆t =
10°C
∆t =
20°C

Table 01 Technical data Remeha Gas 550
* Supplied with a flue gas pipe adapter

Remeha Gas
550/550 Duo
3.2 Dimensions Remeha Gas 550 Duo

Fig. 02 Dimensions Remeha Gas 550 Duo
00.05F.79.00003

Flow Ø107 int.
Return Ø107 int.
Gas 2"
Flue gas Ø

Number of sections

2 x 10

2 x 12

2 x 14

2 x 16

2 x 18

139-556

170-680

202-806

233-932

265-1058

Hi /
NCV

160-618

195-756

232-896

266-1036

301-1176

Hs /
GCV

177-686

217-840

256-996

296-1152

335-1306

Nominal heat
output
Nominal
heat input

Gas consumption

m /h

110

124

1240

1460

1680

1900

2120

ØD

450*

500*

600*

650

650*

litre

582

698

814

930

1046

Boiler weight (dry)

2900

3390

3880

4370

4620

Flue gas flow rate

kg/h

1385

1694

2066

2478

2752

Dimensions

Water contents

Table 02 Technical data Remeha Gas 550 Duo
* Supplied with a flue gas pipe adapter

APPLICATION INFORMATION
specific minimum water flow requirements exist other
then for overheating protection.

4.1 L.P.H.W. system
4.1.1 Water temperature
Maximum water temperature is 110°C (high limit thermostat).
Highest boiler water temperature is 95°C (control thermostat).
Minimum return water temperature is 20°C at a flow rate
related to a ∆t of 20°C (flow/return temp).

4.1.4 Water treatment
The system should be filled with mains cold water (for
the UK this will usually have a pH of between
7 and 8).
Pressurised installations with a boiler/system content
ratio of 1:10 or less should not require water treatment,
provided that the following conditions apply:
1. The system is flushed thoroughly to remove all fluxes
and debris and then filled completely once.
2. Make up water is limited to 5 % per annum.
3. The hardness of the water does not exceed 360 ppm
(20°D).
All scale deposits will reduce the efficiency of the boiler
and should be prevented. However provided the above
is complied with any scale produced will not be too
detrimental to the boiler efficiency and will not reduce
the anticipated life expectancy of the boiler.

4.1.2 Water pressure
Boiler sections are factory pressure tested at 10 bar.
Maximum pressure test boiler block is 7,8 bar.
Maximum working pressure is 6 bar
Minimum working pressure is 0,8 bar at a maximum
working temperature of 110°C or 0,3 bar at a maximum
working temperature of 95°C.
4.1.3 Water flow
The minimum water flow through the boiler on shut down
is:
Output boiler in kW = m3/h
93

Note: Scale deposits in excess of 3 to 5 mm will reduce
boiler efficiency and greatly increase the risk of premature casting failure.

This minimum flow must be maintained for approximately 5 minutes after the burner stops firing to avoid high
temperature shut down due to residual heat gain.
Due to the design and manufacture of the boiler no
7

Remeha Gas
550/550 Duo
As most systems contain a variety of metals which can
react with each other to cause corrosion. It is considered good practice to provide some form of water
treatment (especially in open vented systems) in order to
prevent or reduce the following:
- Metallic corrosion;
- Formation of scale and sludge;
- Microbiological contamination;
- Chemical changes in the untreated system water.

4.3 Installation standards
The following instructions must be adhered to when the
Remeha Gas 550/550 Duo is installed:
Gas Safety (installation and use) Regulations 1984 (as
amended).
In addition to the above regulations, this boiler must be
installed in compliance with:
- Current I.E.E. Regulations for electrical installations
- Local building regulations
- The Building Standards (Scotland)
- (Consolidation) Regulations
- By-laws of the local water undertaking
- Health and Safety Document No 635 ‘The Electricity
at Work Regulations 1989’.

Suitable chemicals and their use should be discussed
with a specialist water treatment company prior to carrying out any work. The specification of the system
and manufacturers recommendations must be taken into
account, along with the age and condition of the system.
New systems should be flushed thoroughly to remove all
traces of flux, debris, grease and metal swarf generated
during installation. Care to be taken with old systems
to ensure any black metallic iron oxide sludge and other
corrosive residues are removed, again by thoroughly
flushing, ensuring that the system is drained completely
from all low points.

It should also be in accordance with the relevant recommendations in the current editions of the following British
Standards and Codes of Practice, viz. BS 5440 Pt 1 and
2, BS 5449, BS 5546,
BS 6798, BS 6891 and BG.DM2.
Lawfully all gas appliances must be installed by competent persons (e.g. Corgi, ACOPS).
Failure to install appliances correctly could lead to
prosecution.
It is in your own interest and that of safety to ensure that
the law is complied with.

Note: Please ensure that the new boiler plant is not
in circuit when the flushing takes place, especially if
cleansing chemicals are used to assist the process.
Under no circumstances is the boiler to be operated
with cleaning chemicals in the system.

Important:
The Remeha Gas 550/550 Duo is a certified appliance
and must not be modified or installed in any way contrary to these ‘Installation and Servicing Instructions’.
Manufacturer instructions must NOT be taken in any way
as when overriding statutory obligations.

To Summarise:
- Minimise water loss;
- Prevent pumping over in open vented systems;
- Provide adequate air venting at all high points;
- Keep pH level between 7 - 9 when using additives;
- Maximum chlorine content of 200 mg/l;
Take advice on the suitability of inhibitors.
4.1.5 Noise level
The noise level measured around the boiler depending
on boiler room construction is about 50-55 dBA. Noise
levels taken at 1 meter from the boiler.
4.2 Chimneys
The average flue gas temperature is so low that the
chimney must be made in accordance with the guidelines of British Gas (BS 6644).

TYPICAL BOILER INSTALLATIONS

5.1 Installation 1
Recommended layout for boiler installation, measurements in mm.

centre of nipple
holes

floor area

number of sections

Size A

965

1185

1405

1625

1845

2065

2285

Size Ø D

300

350

400

450

500

Size B

1240

1460

1680

1900

2120

2340

2560

Size E

1295

1245

Size H

1730

1610

1730

1610

1730

Fig. 03 Remeha Gas 550
00.05F.79.00004

Remeha Gas
550/550 Duo

centre of nipple holes

5.2 Installation 2
Recommended layout for boiler installation, measurements in mm.

floor area
number of
sections
size A
size ØD

number of sections
Size A
Size Ø D

10
965
450

12
1185
500

Fig. 04 Remeha Gas 550 Duo
00.05F.79.00005

14
1405
600

16
1625
650

18
1845
650

CONTROL AND SAFETY EQUIPMENT
6.3 Standard electronic gas train High/Low
6.3.1 Schematic

6.1 General
The Remeha Gas 550 is supplied with electronic control
and safety equipment with ionisation flame detection.
6.2 Instrument panel
The Remeha Gas 550 is supplied with an instrument
panel mounted in the front of the boiler, either left or
right. All connections are pre-wired and fitted with plugs.
The capillaries from the instrument panel should be
fitted in the thermostat pocket of the boiler flow connection, which is fitted in the top front of the end section.

Fig. 06 Schematic layout gas train
04.05F.AP.00001

The instrument panel and the flow connection with thermostat pocket should always be fitted on the same side
of the boiler, either left or right.

Legend
A
Gas cock
AB
Pilot burner
DR
Gas pressure regulator
F
Gas filter
HB
Burners
MK
Pilot gas valve
MP
Measuring point
VA
Safety shut off valve
OT
Ignition transformer
VB
Ionisation probe
MB
Gas multibloc valve
--Not supplied as standard

Fig. 05 Instrument panel
04.05F.79.00001

The instrument panel contains:
1. Operating switch (On/Off);
2. Control thermostat On/Off, range 35°C-95°C;
3. Control thermostat High-Low, range 35°C-95°C;
4. Hour run meter total running hours (option);
5. Hour run meter full load hours (option);
6. Analogue thermometer for flow temperature;
7. High – limit thermostat preset to 110°C;
8. Lock out warning lamp;
9. Option for rematic® weather compensator;
10. Reset for water level control.

6.3.2 Control panel on gas train
The instrument panel is linked to the control panel on
gas train by means of a cable and connector. If required
the control panel (and gas train) can be fitted on the
opposite side of the boiler by using extension cables
(option).

3
1

The Instrument panel mounted in the front casing also
contains circuit boards for:
- Water level control (see §9.6);
- Common alarm and operating signal.

Fig. 07 Front of Control panel
04.05F.79.00002

1. Control box Satronic MMI 816;
2. Ignition transformer Satronic ZT 870;
3. Operation report circuit board.
11

Remeha Gas
550/550 Duo
6.4.3 Water level control (lock out)
The boiler is equipped with a water level sensor to
prevent boiler from operating without water. The boiler
will lock out. Manual intervention is required to reset the
boiler (on the instrument panel) once the cause of the
problem has been rectified.

6.3.3 Specification control box
Control box
: Satronic MMI 816
Main supply
: 230 V – 50 Hz
Minimum ionisation current
: min 3 µA (DC)
Reaction time flame protection : 1 sec.
Safety time
: ≤ 10 sec.
Maximum ambient temperature : 60 °C

Note: The Gas 550 Duo has two sets.
Injector size pilot burner
Injector size main burner
Burner pressure full load
(high calorific gas)
Burner pressure part load
(high calorific gas)
Burner pressure pilot burner
(high calorific gas)

: Ø 1.0 mm
: Ø 5.4 mm

6.4.4 Valve leakage control - optional ( lock out)
The gas train can be combined with a valve leakage
control, which checks for gas leakage between the valves at every start. The boiler will lock out. Manual intervention is required to reset the boiler (on the valve
leakage control) once the cause of the problem has
been rectified.
Type: Dungs VPS 504.

: 8.4 mbar (100%)
: 2.2 mbar (50%)
: 13 mbar

Warning: control box is phase neutral sensitive.
Note: The Gas 550 Duo requires two sets.
6.3.4 Specification Ignition transformer
Ignition transformer
: Satronic ZT 870
Ignition voltage
: 16 kV
Distance electrodes
: 3,5 ± 1 mm.

6.4.5 Gas pressure switch LD - optional (shut down)
If the supply gas pressure drops below the set value
(12mbar; for natural gas, cat. I2H only), the boiler will shut
down. When the supply gas pressure returns above this
set value the boiler will resume operation again.
Type: Dungs GW50 A5.

6.4 Functions
General
The following functions (standard and optional) will,
when activated, either lock out or shut down the boiler.
For all options full fitting instructions are included in the
option pack.

Note: The Gas 550 Duo requires two.
6.4.6 Gas pressure switch HD - optional (lock out)
If the gas arrival pressure rises above the set value
(10mbar; for natural gas, cat. I2H only), the boiler will lock
out. Manual intervention is required to reset the boiler
(on the gas pressure switch) once the cause of the
problem has been rectified.
Type: Dungs UB 50 A2.

6.4.1 Flame control (lock out)
The flame is monitored using ionisation flame detection.
In the event of a flame failure the boiler will lock out.
Manual intervention is required to reset the boiler (on
the control panel) once the cause of the problem has
been rectified.

Note: The Gas 550 Duo requires two.
Note: The Gas 550 Duo has two sets.
6.4.7 Down draught thermostat; (optional, shut
down)
If the themperature in the draft diverter rises above the
down draught thermostat set point, the boiler will shut
down. It automatically resets after 3 minutes, provided
that the temperature also falls.
Type: Honeywell L6068A; fixed setpoint is 70°C.

6.4.2 Thermostats (shutdown / lock out)
- Control thermostat On/Off: shutdown (35°C-95°C);
The boiler will automatically resume operation when
the flow temperature falls below the set point.
- Control thermostat High/Low: shutdown (35°C-95°C);
The boiler will automatically resume operation when
the flow temperature falls below the set point.
- High Limit thermostat: lock out at 110°C.
The boiler will lock out. Manual intervention is required
to reset the boiler (on the instrument panel) once the
cause of the problem has been rectified.

Note: The Gas 550 Duo requires two.

Note: The Gas 550 Duo has two sets.

ASSEMBLY AND INSTALLATION GUIDELINES
7.4 Pocket for the thermostat capillaries
The multi pocket for the thermostat capillaries should be
fitted in the top front-end section of the boiler and on
the same side of the boiler as the instrument panel. The
water level control electrode should be fitted in the 1”
tapping of the other end section.

7.1 General
The boiler is suitable for operating at a maximum working pressure of 6 bar. It can be installed in open vented
or sealed systems with a minimum pressure of 0.8 bar
sealed and 0.3 bar open vented.
7.2 Boiler assembly
The boiler is supplied with full assembly instructions. On
request special assembly tools can be hired from Broag
on a daily basis.
However, Broag (or a Broag approved boiler erection
engineer) can provide boiler assembly services and / or
building supervision.

Note: The Gas 550 Duo has two sets.
7.5 Water pressure
Each section is hydraulically tested at 10 bar. Maximum
test pressure for the assembled boiler block is 7.8 bar.
Minimum working pressure is 0.8 bar at a maximum
working temperature of 110°C or 0.3 bar at a maximum
working temperature of 95°C. Maximum working pressure is 6 bar.

7.3 Water connections
The boiler flow and return connections can be fitted
on either side of the boiler (left or right hand side)
dependant on design or site conditions.
The boiler comes with four flanges, 2 x blank and 2 x Ø
107 mm (int.) weld neck.
The end sections have a 3/4 “ BSP tapping to accept the
supplied drain cock.
Note: The Gas 550 Duo has two sets.

GAS SUPPLY

8.1 General
The instrument panel (mounted in the front casing) must
be mounted on the same side of the boiler as the flow
connection, either left or right (choice on assembly). As
standard the gas train must also be on the same side as
the flow connection. However an extension cable can be
supplied (option) to allow the gas train to be mounted on
the opposite side to the instrument panel.

8.2 Gas pressure
Natural gas, cat. I2H (20mbar)
Maximum gas pressure at inlet 100 mbar.
Main burner pressure settings :
- full load
: 8.4 mbar
- part load
: 2.2 mbar
Pilot burner pressure settings : 13 mbar
Gas inlet pressure
: 17 - 25 mbar

The local Gas authority should be consulted to ensure
that an adequate pressure and supply is available at the
boilers maximum output. To minimise risk of sediment or
foreign particles entering the control valves, an approved
filter can be fitted into the pipe system downstream.
The gas supply should be conforming to the British Gas
safety regulations.

8.3 Injectors
Injector size main burner
Injector size ignition burner

: 5.4 mm
: 1.0 mm

Note: The Gas 550 Duo has two sets.

Note: The Gas 550 Duo requires two gas supplies.

Remeha Gas
550/550 Duo
9

ELECTRICAL SUPPLY
9.5 Electrical information
Main supply
: 230 V-50 Hz (L/N)
Running current : 150 VA
Maximum fuse : 6 A (slow acting)

9.1 General
The electrical installation must conform to the IEE regulations and also to local authority requirements.
9.2 Instrument panel
The Gas 550 is supplied with an instrument panel that
is fitted in the front of the boiler, either left or right
(dependant on flow and gas connection).

Note: The Gas 550 Duo requires two sets of power supplies.
9.6 Water level control
Water level control
: Dungs DWEB 53E
Main supply
: 230 V – 50 Hz
Running current
:5W
Electrode voltage
: 42 V (AC)
Working area
: 100 – 10.000 mA (AC)
Electrode resistance : max. 20 kOhm; min. 1 kOhm
Electrode
: Dungs FLE ½”
Must be fitted in one of the end sections (see 7.4).

Note: The Gas 550 Duo has two instrument panels and
requires two sets of power supplies.
9.3 Control panel
A control panel is fitted on the gas train.
Note: The Gas 550 Duo has two control panels and
requires two sets of operating controls and has two sets
of function indication.

Note: The Gas 550 Duo has two sets.

9.4 Electrical connections
The boiler is pre-wired. Only the main supply should be
wired to the instrument panel.

9.7 Wiring diagrams

Fig. 08 Electrical principle diagram
04.05F.SC.00001

Remeha Gas
550/550 Duo

Fig. 09 Electric connection central alarm
00.03F.60.00042

COMMISSIONING
9. Switch on the boiler.
- If a valve leakage control is installed the following
will take place:
A membrane pump will create overpressure
between safety valves VA1 & VA2, which are
inside the multibloc gas valve. When, within 27
sec, an overpressure of 30 mbar (compared to the
inlet pressure) is reached, the electric supply is
released to the control box.
10. After a waiting time of about 13 seconds the ignition
starts. The magnetic valve MK opens and ignition
burner lights. At a minimum ionisation current of 3
µA the ignition stops. After 5 seconds the main gas
valves VA1 en VA2 will open. The boiler runs.
11. Let the boiler run for a couple of minutes on high fire
to clear any air still in the gas pipe.

Note: Commissioning must only be carried out by a
qualified engineer with the relevant training and certification i.e. Acops - Corgi. A commissioning data sheet /
boiler logbook must be completed on site for issue to
owner.
1. Check the gas connections.
2. Check the electrical supply (L/N and earth).
3. Check the water connections and whether the installation is full and under system pressure.
4. Switch on the circulation pump and check the rotation direction.
5. Open the main gas cock (purge gas pipeline).
6. Switch on the electrical supply.
7. Set both the thermostats to about 85°C.
8. If a control system is built in, put the selector switchon manual operation.

12. Set the correct full load burner pressure by means
of the pressure regulator on the gas multibloc gas
valve(see Fig. 10, pos. 1).
Warning: When the required burner pressure can
not be reached because of low inlet pressure, ensure that the pressure regulator remains within it’s
operating range.
Now do the following:
• Set the burner pressure to the highest possible
value (but not over the required full load burner
pressure).
• Turn the pressure regulator anticlockwise until the
burner pressure is affected.
• The burner pressure is now limited, this will prevent the boiler from being over gassed should the
inlet gas pressure increase.
13. Set the correct part load burner pressure:
• Turn the high/low thermostat to it’s minimum setting (35°C). When the flow temperature is over
35°C, the boiler will burn at part load.
• Set the part load burner pressure by turning the
adjustment ring (Fig. 10, pos. 2).
• To check the the high fire setting: Turn the
high/low thermostat to 85°C and check the full
load burner pressure (if necessary re-adjust).
The speed of opening of the main gas valve can
also be adjusted to ensure a smooth light up. Setting the hydraulic brake on the main gas valve as
follows:
• Remove the setting cap (Fig. 10, pos.3) and turn it
upside down on the hydraulic brake.
• Turn it clockwise to slow down, anticlockwise to
speed up.
• Check both burner pressures again and if necessary re-adjust.
14. Adjustment of the gas pressure switch LD (optional):
• Switch the boiler to full load.
• Connect a pressure gauge to measuring point LD.
• Turn the adjustment disc of the pressure switch to
it’s minimum setting.
• Now close the main gas cock slowly until the inlet
pressure drops to the value detailed in the documentation supplied with the gas pressure switch.
• Slowly turn the adjustment disc of the pressure
switch until the pressure control operates.
• The control box shuts down the gas supply and
will restart.
15. Adjustment of the gas pressure switch HD (optional):
• Switch the boiler to full load.
• Connect a pressure gauge to manifold.
• Set the pressure switch to the value detailed in
the documentation supplied with the gas pressure
switch.
• Check whether the gas pressure switch HD comes
to action at the set value by increasing (Fig. 10,
pos.1) the full load burner pressure to that value.
The boiler will lock out.
• Reset by pressing the reset button on the gas

16.

17.
18.

19.

20.

21.

pressure switch HD. The boiler will resume operation.
• Set the correct full load burner pressure again
according §10.2.12.
Valve leakage control (optional)
• Remove plug Pa during boiler start up (see §10.2.
9).The plug Pa is located opposite the valve leakage control on the multibloc.The boiler will lock
out.
• Reset by pressing the reset button on the valve
leakage control.The boiler will resume normal operation.
Check the thermostats for the correct operation setting.
Check the flame control on the control box
• Start the boiler with disconnected ionisation probe,
after the ignition phase the pilot gas valve must
close. The boiler will lock out.
• Reset by pressing the reset button on the control
box.
• Then disconnect the ionisation probe during operation, the pilot gas valve must close immediately.
The boiler will lock out.
• Reset by pressing the reset button on the control
box.
Water level control:
• Check the water level.
• Check the operation of the water level control by
disconnecting the electrode. The boiler should go
to lock out
• Create a shortcut between the electrode and
earth. The boiler should go to lock out
• Reset by pressing the reset button on the instrument panel. The boiler will resume operation
Check the down draft thermostat by pressing the
bimetallic strip on the thermostat. The boiler will shut
down for 3 minutes. After that the boiler will resume
operation.
Send the initial commissioning report CE to Broag.

Remeha Gas
550/550 Duo
10.1 Switching off the boiler
1. Switch off the electric supply.
2. Shut off the gas cock.

3
1. pressure regulator
2. part load adjustment
ring
3. hydraulic brake
(setting cap)

Warning: When switched off and full of water the boiler
could be damaged if the temperature falls below freezing
point.
Note: Commissioning must only be carried out by a
qualified engineer with the relevant product training and
certification i.e. Acops - Corgi. A commissioning data
sheet / logbook must be completed on site for issue to
owner.

Fig. 10 Dungs MB-ZRDLE 415 / 420 S22.

MAINTENANCE
- Carryout a combustion efficiency test.
- Check the boiler and immediate installation connections for water leaks (seals).
- Check gas train and gas pipe for gas leaks.
- Check flue connections.
- Clean boiler casings.
- Complete a commissioning report.

To maintain maximum efficiency it is essential to service
the boiler, check safety parameters and re-set combustion once a year.
Normal Service Maintenance
- Isolate power , controls and gas supply.
- Remove front, top casings and flue hood covers.
- Remove gas manifold.
- Remove the burners and floor plates.
- Clean the internal flue ways of the boiler.
- Clean the floor underneath the boiler and boiler room.
- Clean the burners internally and externally using a
soft brush.
- Clean the gas train, ignition, pilot burner, thermostats
and wiring.
- Check and re-set/re-place ignition electrode and ionisation probe as found necessary.
- Re-assemble boiler.
- Check ignition and ionisation cables for connections
and continuity.
- Restore power, controls and gas supply.
- Check start program, ignition time and safety times.
- Check flame protection and thermostats.
- Check boiler input at 100% (full load) and 50% (part
load) load.
18

TROUBLE SHOOTING

Fig. 11 Switch diagram

Fig. 12 Switch diagram with valve leakage control (optional)

04.05F.SC.00001

12.1 Fault causes
In case of all disturbances the gas supply is interrupted
and the color disc stops rotating.
Check the position of the color disc for a indication of
the cause. The color disc is situated at the side of the
control box.
- Indication mark at:
Possible cause:
end of green zone;

- no tension

(no rotation of color disc)

- no heat demand

end of yellow zone;

- no flame (signal) of pilot burner

begin of red zone

- no spark

red zone

failing or unstable flame of pilot burner

end of yellow zone;

no flame (signal) of main burner

begin of green zone
Green zone;

failing or unstable flame of main burner

end of green zone

Table 03

Trouble shooting

Remeha Gas 550/550 Duo
Broag Ltd
Head Office
Remeha House,
Molly Millars Lane,
Wokingham,
Berkshire RG41 2QP.
Tel.: 0118 9783434
Fax: 0118 9786977
Email: boilers@broag-remeha.com
Internet: www.broag-remeha.com

Tel. 0115 9440778

All technical and technological information contained in these technical instructions, as well as any
drawings and technical descriptions furnisched by us remain our property and may not be multiplied
without our prior consent in writing.

Subject to alterations
56267/1500/0601/Ho.

Fax 0115 9440588

remeha
Gas 5a/5a Duo

Technical information

Atmospheric gasboiler
276 - 1044 kW

remeha Gas 5a/5a Duo
CONTENTS
Preface

Boiler description

Construction
2.1 General
2.2 Burners
2.3 Boiler base
2.4 Assembling
2.5 Boiler dimensions and technical data
2.5.1 Broag remeha Gas 5a
2.5.2 Broag remeha Gas 5a Duo

3
3
3
3
3
4
4
5

Application
3.1 L.P.H.W. system
3.1.1 Water temperature
3.1.2 Water pressure
3.1.3 Water flow
3.1.4 Water treatment
3.1.5 Noise level
3.2 Chimneys

6
6
6
6
6
6
6
6

Typical boiler installation

Regulation and safety equipment
5.1 General
5.2 Standard electronic gastrain High/Low
5.2.1 Schematic lay out
5.2.2 Specification
5.3 Functions
5.3.1 Flame protection
5.3.2 Down draught thermostat
5.3.3 Thermostats

8
8
8
8
8
8
8
8
8

Assembly and installation guidelines
6.1 General
6.2 Boiler assembly
6.3 Water connections
6.4 Water pressure

9
9
9
9
9

Gas supply
7.1 General
7.2 Gas pressure

10
10
10

Electric supply
8.1 General
8.2 Electric connections
8.3 Electric data
8.4 Wiring diagram

11
11
11
11
12

Commissioning
9.1 Technical information
9.2 Commissioning the boiler

13
13
13

10. Maintenance
10.1 General
10.2 Maintenance instructions

14
14
14

11. Fault finding chart
11.1 The boiler fails to restart after a normal
shut-down
11.2 No ignition
11.3 Pilot burner ignites but fails immediately
11.4 Pilot burner ignites but gas does not reach
main burners

15
15
15
15
15

PREFACE
These technical instructions contain useful and important
information for the correct operation and maintenance of
the Broag remeha Gas 5a/5a Duo gas boiler. Futhermore, important instructions are given to prevent accidents
and serious damage before commisioning and during
operation of the boiler, to ensure safe and trouble free
operation. Read these instructions carefully before putting the boiler into operation, familiarize yourself with its
operation and controls and strictly observe the instructions given.

If you have any questions, or if you need more information about specific subjects relating to this boiler, please
do not hesitate to contact us.
The data published in these technical instructions is
based on the latest information and is given subject to
later revisions.
We reserve the right to modify the design and/or configuration of our products at any moment, without being
obliged to adjust earlier supplies accordingly.

1. BOILER DESCRIPTION
Water connecties Ø 100 mm.
Output : Gas 5a - 10 to 22 sections
: 276 to 644 kW.
Gas 5a Duo - 2 x 10 sections
to 2 x 18 sections
: 552 to 1044 kW.

The Broag remeha Gas 5a boiler is a cast iron sectional
boiler with atmospheric burners.
Suitable for all qualities of natural gas.
The Broag remeha Gas 5a boiler is fitted with electric
ignition and is supplied with an insulated casing.

2. CONSTRUCTION
2.1 General
- Boiler block consists of cast iron sections nippled
together with conical nipples.
- Gas train can be fitted on the left or right hand side of
the boiler.
- Fitting of the casings is possible after the boiler is
installed.
- The boiler is cleaned from the front.
- Water connections can be fitted on the left or right
hand side of the boiler.

2.2 Burners
The burners are stainless steel, atmospheric burners.
They guarantee a low noise level.
2.3 Boiler base
The Broag remeha Gas 5a boiler is supplied as standard
with reflecting floor plates wich allows for ventilation
beneath the boiler.
2.4 Assembling
The boiler is assembled on site.

remeha Gas 5a/5a Duo
2.5 Boiler dimensions and technical data
2.5.1 Broag remeha Gas 5a

(only 22 S)

ø 100

Side view

Front view

Cross-section

Top view

Fig. 01 Dimensions of the Broag remeha Gas 5a
Model

Broag remeha Gas 5a-10
Broag remeha Gas 5a-11
Broag remeha Gas 5a-12
Broag remeha Gas 5a-13
Broag remeha Gas 5a-14
Broag remeha Gas 5a-15
Broag remeha Gas 5a-16
Broag remeha Gas 5a-18
Broag remeha Gas 5a-20
Broag remeha Gas 5a-22

Dimensions

Nominal
output
kW

Input
G.C.V.
kW

B
mm

276
306
338
368
398
430
460
522
582
644

345
383
422
460
498
537
575
652
728
805

1240
1350
1460
1570
1680
1790
1900
2120
2340
2560

Resistance
∆t = 10°C
mbar
mbar

Ød
"

∆t = 20°C

ØD
mm

940
940
940
940
940
940
940
940
940
940

350
400
400
400
450
450
450
500
500
600

2"
2"
2"
2"
2"
2"
2"
2"
2"
2"

15
16
17
18
19
20
35
44
50
54

±L

59
63
67
71
75
78
137
172
195
211

Water
content
l

Weight
dry
kg

291
320
349
378
407
436

1450
1575
1695
1820
1940
2065
2185
2430
2675
2920

465
523
581
639

2.5.2 Broag remeha Gas 5a Duo

øD

ø 107

ø 100

Side view

Front view

Cross-section

Top view

Fig. 02 Dimensions of the Broag remeha Gas 5a Duo
Model

Broag remeha Gas 5a Duo-10
Broag remeha Gas 5a Duo-11
Broag remeha Gas 5a Duo-12
Broag remeha Gas 5a Duo-13
Broag remeha Gas 5a Duo-14
Broag remeha Gas 5a Duo-15
Broag remeha Gas 5a Duo-16
Broag remeha Gas 5a Duo-18

Dimensions

Nominal
output
kW

Input
G.C.V.
kW

B
mm

552
612
676
736
796
860
920
1044

690
766
844
920
996
1074
1150
1304

1240
1350
1460
1570
1680
1790
1900
2120

ØD
mm

Ød
"

Water
content
l

Weight
dry
kg

940
940
940
940
940
940
940
940

500
600
600
600
650
650
650
700

2"
2"
2"
2"
2"
2"
2"
2"

582
640
698
756
814
872
920
1046

2900
3150
3390
3640
3880
4130
4270
4860

±L

remeha Gas 5a/5a Duo
3. APPLICATION
For information on water treatment we advise direct
contact with either:
Fernox Manufacturing Company Ltd.
Britannia Works
Clavering
Essex, CB1L 4QZ
Tel No: 0799 550811
or:
Sentinal
Grace Dearborn Ltd
Widnes
Cheshire WA8 8UD
Tel No: 051 495 1861

3.1 L.P.H.W. system
3.1.1 Water temperature
Maximum water temperature is 110°C (high limit
thermostat).
Highest operating flow temperature is 95°C (control
thermostat).
Minimum return water temperature is 20°C at a flowrate
related to a ∆t of 20°C (flow/return temperature).
3.1.2 Water pressure
Boiler sections pressure test at 12 bar.
Maximum pressure test boiler block is 6 bar.
Minimum working pressure boiler is 0.8 bar at a maximum water temperature of 110°C or 0.3 bar at a maximum water temperature of 95°C.
Maximum working pressure boiler is 6 bar.

3.1.5 Noise level
The noise level measured around the boiler depending
on boiler room construction is about 50-55 dBA.
Noise levels taken at 1 meter from the boiler.

3.1.3 Water flow
The minimum water flow through the boiler is:
Output boiler in kW
93

3.2 Chimneys
The average flue gas temperature is so low that the
chimney must be made in accordance with the guidelines
of British Gas.

= ... m3/h

This minimum flow must be maintained for 5 minutes
after the burner stops firing to avoid high temperature
shut-down due to residual heat gain. Due to the design
and manufacture of the boiler no specific minimum water
flow requirement exists other than for over-temperature
protection.
3.1.4 Water treatment
Water treatment of all systems, but in particular open
vented systems used with the Broag remeha Gas 5a, is
considered necessary good practice in order to:
- avoid metallic corrosion within the system
- avoid sludge and scale information
- reduce to a minimum the risk of microbiological contamination of the system
- minimise chemical action and changes which take
place over a period of time when system water is untreated.
The system will contain a variety of metals. Ferrous
metals - cast iron and steel, and non-ferrous metals copper, brass and gunmetal, may be present, so it is
essential that treatment is suitable for all of them.
Suitable chamicals and the extent of treatment should be
discussed with specialist manufactures prior to any work
commencing. The specification of new systems and
general condition of older existing systems must be
carefully considered. The removal of debris, flux residue,
grease, metal, swarf etc. from new systems, and any
black magnetic iron exide sludge and other corrosive
residue from old systems is essential.

4. TYPICAL BOILER INSTALLATION
Installation 1
1 boiler in boiler room

Installation 2
2 boilers in boiler room

Installation 3
Duo arrangement

Fig. 03 Boiler installations
Dimensions
mm

B
ØD
Ø D duo

1240
350
500

1350
400
600

1460
400
600

1570
400
600

Number of sections
15
14
1680
450
600

1790
450
600

1900
450
650

2120
500
700

2340
500
700

2560
600
800

remeha Gas 5a/5a Duo
5. REGULATION AND SAFETY EQUIPMENT
5.1 General
The Broag remeha Gas 5a is supplied with electronic
control and safety equipment with ionisation flame detection.

5.2.2 Specification
2 Safety gas valves
1 Gas governor
1 Pilot gas valve
1 Pilot gas governor
1 Ignition transformer 5 kV
1 Pilot burner with ionisation probe
1 Down draught thermostat set at 70°C

5.2 Standard electronic gastrain High/Low
5.2.1 Schematic lay out

5.3 Functions
5.3.1 Flame protection
5.3.2 Down draught thermostat
The boiler is fitted with a thermo-down draught
thermostat.
If there is a down draught in the chimney the thermostat
will switch off the boiler. Fixed setpoint is 70°C.

Fig. 04 Schematic layout
Legend
A
Gas cock (not supplied)
PB Pilot burner
DR Gas governor
F
Gas filter (not supplied)
HB Main gas burners
IT
Ignition transformer
PGV Pilot gas valve
MP Measuring point
SSV Safety shut off valve
FD Ionisation probe
- - - - Not supplied

5.3.3 Thermostats
Control thermostat On/Off 35-95°C.
Control thermostat High/Low 35-95°C.
High Limit thermostat locks out at 110°C.

6. ASSEMBLY AND INSTALLATION GUIDELINES
6.1 General
Boiler can be installed in open or closed systems.

6.4 Water pressure
Each section is hydraulically tested to at least 12 bar.
Maximum test pressure for the assembled boiler block is
6 bar.
Maximum working pressure is 6 bar.
Minimum working pressure is 0.8 bar at a maximum
working temperature of 110°C or 0.3 bar at a maximum
working temperature of 95°C.

6.2 Boiler assembly
Broag provides special tools on loan, for the boiler
assembly with detailed building instructions. However,
building supervision and/or actual boiler erection services
can be provided by Broag.
6.3 Water connections
The boiler water connections can be fitted on one side of
the boiler either left or right hand side.
The return water connection is flanged on the boiler with
a pipe connection for welding Ø 107/114 mm.
The flow water connection is a cast iron bend flanged on
the boiler and comes complete with a welding neck
flange Ø 107/114 mm according BS10 table D. The flow
bend has 1/2" tappings to accept a dual control/limit
boiler thermostat and the high/low thermostat. The end
sections have a 3/4" tapping to accept drain/off cocks.
(BSP Tapping).

remeha Gas 5a/5a Duo
7. GAS SUPPLY
7.2 Gas pressure
Maximum gas pressure at inlet 100 mbar.
Burner pressure:
- full load : 8.7 mbar (100%)
- part load : 3.5 mbar (60%)

7.1 General
The gas train can be fitted on the left or right hand side of
the boiler.
The local Gas authority should be consulted to ensure
that an adequate pressure and supply is available at the
boilers maximum output. To minimise risk of sediment or
foreign particles entering the control valves, an approved
filter may be fitted into the pipework downstream. The
gas supply should be conform to the British Gas safety
regulations.

8. ELECTRIC SUPPLY
8.1 General
The electrical installation must conform to the IEE
Regulations for Electrical Installations and also to Local
Authority requirements.

The control box operates on a neutral/phase supply. The
earth conductor should be connected to the earth bar
using the screw provided with an anti-spread washer.
These conductors should be entered via one of the cable
entry glands. A wiring diagram is fixed inside the lid of the
junction box and is also included in this manual (see
section 8.4). Time controls and remote thermostats can
be connected across terminals 12 and 13 after removal of
the link. These controls should be BEAB or BSI
approved.

8.2 Electric connections
The Satronic control box for the Broag remeha Gas 5a
series boilers is prewired for the operation of all controls
in the correct ignition and shut-down sequences. These
include high limit protection, flame detection, thermostatic
control and safety shut-off. Provision for manual reset is
made in the event of high limit shut-down and flame failure. An indication lamp within the control box illuminates in
the event of control malfunction. A 240 volts ~ 50 Hz
single phase supply should be connected to the live and
neutral terminals in the junction box.

8.3 Electric data
Main supply: 240 V-50 Hz (L/N).
Running current: 120 W.
Maximum fuse: 6Amp.

8.4 Wiring diagram

Fig. 05 Wiring diagram
12

remeha Gas 5a/5a Duo

9. COMMISSIONING
It is important that the protective plastic coating is removed from the casing prior to commissioning by a competent person.
9.1 Technical information
Control box: Satronic TFI 812.1B Mod 10.
Main supply: 240 V-50 Hz.
Minimum Ionisation I.O. current : 5 m Amp.
Reaction time
: 5 sec.
Maximum ambient temperature : 60°C.
Injector size pilot burner
: Ø 0.8 mm.
Injector size main burners
: Ø 5.4 mm.
Burner pressure full load
: 8.7 mbar (100%).
Burner pressure part load
: 3.5 mbar (60%).
Pilot burner pressure
: 13 mbar.
9.2
1.
2.
3.
4.
5.
6.
7.
8.

9.
10.

Fig. 06 9-16 sections

Commissioning the boiler
Check gas connections.
Check electrical supply (L/N and earth).
Check water connections and if installation is filled.
Switch on circulation pump and check rotation direction.
Open main gas cock (bleed the air in gas pipe work).
Switch on electrical supply.
Set the control thermostats to about 85°C.
After a waiting time of about 10 seconds you will get
ignition and the Pilot Gas valve opens. At a minimum
ionisation current of 5 m Amp the safety shut off
valves will open after a waiting time of 15 seconds.
The boiler is on.
Let the boiler on for a couple of minutes to get rid of
air in the gas pipe.
Set the correct burner pressure.
High flame adustment by means of the gas governor.
Low flame adjustment by means of the safety shutoff valve.
Details of safety shut-off valves:
9-16 sections (Fig. 06):
- Low flame adjustment can be made by loosening
screw 2 and turning knob 1. Turning clockwise
decreases gasflow. Do not touch sealed screw 3
unless solenoid or hydraulic unit (knob 1) is to be
replaced.
- After adjustments screw 2 must be retightened.
17-22 sections (Fig. 07):
Gas rate adjustment can be made by turning the
screw in the junction box on the valve actuator.
- Turn screw V1 to adjust low flame.
- Turn clockwise to increase gas rate.

Fig. 07 17-22 sections
11.Check the thermostats are operating correctly.
12.Check the flame protection, start the boiler with
the ionisation probe disconnected.
To turn off the boiler:
1. Switch off the electric supply.
2. Shut off the gas cock.

remeha Gas 5a/5a Duo
10. MAINTENANCE
4. Clean boiler casings
5. Clean the gas train, ignition, pilot burner, thermostats
and wiring.
6. Check start program, ignition time and safety times.
7. Check flame protection, and thermostats.
8. Check boiler input at 100% and 60% load.
9. Check the combustion efficiency.
10. Check the boiler and installation for water leaks.
11. Check gas train and gas pipework for leaks.

10.1 General
It is essential for a good combustion, to clean the boiler
the gas train and boiler room once a year.
10.2 Maintenance instructions
1. Clean the internal flue ways of the boiler with a steel
cleaning brush (available from Broag).
Remove top casing and top of the flue hood.
2. Clean the burners internally and externally.
3. Clean the floor underneath the boiler and boiler
room.

11. FAULT FINDING CHART
11.1 The boiler fails to restart after a normal shutdown
- Ensure that both gas and electricity supplies are
available at the boiler.
- The automatic control box has gone to lockout because of a fault. Press reset button on control box.
If normal start up does not occur, check whether:
• The appliance manual gas valves are fully open.
• The boiler control thermostat is set at the correct
value. After waiting for two minutes, press the reset
button again, if the boiler does not restart normally,
check as follows.

11.3 Pilot burner ignites but fails immediately
- Check the position of the flame detector probe in relation to the pilot burner. if electrode setting is incorrect,
replace complete assembly.
- Pilot flame too small - incorrect pilot burner nozzle 1 x
0.8 mm for natural gas. Or pilot burner injector/nozzle
blocked.
- Check current in the flame detector probe, removing
shunt between terminals 14 and 16 and connect a D.C.
Micro Ammeter (range 0-50 µA) in series. Check the
current reading with boiler operating. If reading is zero,
check Satronic Control Box. If reading is below 5 µA or
showing wide variations, check stability of gas flame
and state of ionisation probe.
- If the boiler does not fire, replace the automatic Control
Box.

The ignition cycle should be as follows: After 10 seconds
(approx.) sparking at the pilot electrode will be heard
followed by the main burners crosslighting from the pilot.
11.2 No ignition
If there is no ignition sequence, check:
- Electricity supply isolated.
- Thermostat adjusted to a low temperature.
- Check whether the limit thermostat was activated by
excess temperature. Reset to remove fault.
(If fault persists this should be rectified.)
- Check whether the draught diverter thermostat was
activated by down draught. Reset to remove fault.
(If fault persists this should be rectified.)
- Check voltage (240 V ~) at ignition transformer terminals. If no voltage is registered, the automatic control
box is faulty and should be replaced. If there is voltage,
check the position of the ignition electrode and flame
electrode setting. If spark does not occur, the ignition
transformer is faulty and should be replaced. If electrode setting is incorrect, replace complete assembly.
- No ignition gas at pilot burner, pilot safety shut-off valve
fails to open. Check voltage (240 V ~ ) at the terminals
on the pilot safety shut-off valve. If there is no voltage
the automatic control box is faulty and should be replaced. If there is voltage, replace the valve.
- No pilot flame, pilot burner injector/nozzle blocked clean.

11.4 Pilot burner ignites but gas does not reach main
burners
- Check voltage (240 V ~ ) at the terminals of the main
burners safety shut-off valves. If there is voltage, the
coil of one of the main gas valves is faulty and should
be replaced.

remeha Gas 5a/5a Duo

ISO 9001
since 1988

Broag Ltd.
Head office
Molly Millars Lane,
Wokingham, Berks.
RG11 2PY
Tel. 01734-783434
Telex 849 137
Fax 01734-786977
Branch office
Unit 3
Kestrel Close, Quarry Hill
Industrial Estate
Ilkeston, Derbyshire
DE7 4QQ
Tel. (01159) 440778
Fax (01159) 440588

Remeha Gas 5c / 5c Duo

Remeha Gas 5c/5c Duo

Technical information

• Atmospheric gas boiler
• 278 - 1058 kW

Remeha
Gas 5c / 5c Duo
CONTENTS
Preface
1. Boiler description

3
3

2. Construction details
2.1 General
2.2 Burners
2.3 Boiler ﬂoor
2.4 Assembly

3
3
3
3
3

3. Technical data and dimensions
3.1 Dimensions Remeha Gas 5c
3.2 Dimensions Remeha Gas 5c Duo

4
4
5

4. Application information
4.1 L.P.H.W. system
4.1.1 Water temperature
4.1.2 Water pressure
4.1.3 Water ﬂow
4.1.4 Water treatment
4.1.5 Noise level
4.2 Chimneys
4.3 Installation standards

6
6
6
6
6
6
6
6
6

5. Typical boiler installations

6. Control and safety equipment
6.1 General
6.2 Instrument panel
6.3 Standard electronic gas train High/Low
6.3.1 Schematic
6.3.2 Speciﬁcation
6.3.3 Control panel on gas train
6.4 Functions
6.4.1 Flame protection
6.4.2 Down draught thermostat
6.4.3 Thermostats

9
9
9
10
10
10
10
10
10
10
10

7. Assembly and installation guidelines
7.1 General
7.2 Boiler assembly
7.3 Water connections
7.4 Pocket for the instrument panel
7.5 Water pressure

11
11
11
11
11
11

8. Gas supply 11
8.1 General
8.2 Gas pressure

11
11

9. Electrical supply
9.1 General
9.2 Control panel
9.3 Electrical connections
9.4 Electrical information
9.5 Water level control (lock out)
9.6 Wiring diagram for the instrument panel
9.6.1 Simple instrument panel
9.6.2 Complete instrument panel
9.7 Wiring diagram boiler

12
12
12
12
12
12
12
12
13
14

10. Commissioning
10.1 Technical information
10.2 Commissioning
10.3 Switching off the boiler

15
15
15
15

11. Maintenance
11.1 General
11.2 Maintenance

15
15
15

PREFACE
These technical instructions contain useful and important
information for the correct operation and maintenance of
the Remeha central heating boiler, model Gas 5c/5c Duo.
Furthermore, important instructions are given to prevent
accidents and serious damage before commissioning
and during operation of the boiler, to ensure safe and
trouble free boiler operation.
Read these instructions carefully before putting the boiler
into operation, familiarize yourself with its operation and
control and strictly observe the instructions given.

If you have any questions, or if you need more information about speciﬁc subjects relating to this boiler, please
do not hesitate to contact us.
The data published in these technical instructions is
based on the latest information and is subject to revisions.
We reserve the right to modify the design and/or configuration of our products at any moment without being
obliged to adjust earlier supplies accordingly.

1. BOILER DESCRIPTION
The Remeha Gas 5c boiler is a cast iron sectional boiler
with atmospheric burners.
Suitable for all qualities of natural gas, cat. I 2 H (20 mbar).
The boiler meets the requirements of the CE regulations
at the following directives:
- Gas appliance directive no. 90/396/EEC
- Electrical low voltage directive no. 73/23/EEC
- Machinery directive no. 89/392/EEC
- E.M.C. directive no. 89/336/EEC
- Efﬁciency directive no. 92/42/EEC.

Classiﬁcation type for evacuation of the combustion products: B11 BS.
For further advice or information contact Broag Ltd.
The Remeha Gas 5c is supplied with electronic junction
with insulated casings.
Water connections Ø 107 mm int.

2. CONSTRUCTION DETAILS
2.1 General
- Boiler block of cast iron sections joined together with
conical nipples.
- Gas train can be ﬁtted on the left hand or right hand
side of the boiler.
- Water connections can be ﬁtted on the left hand side
or right hand side of the boiler. The gas train should
if possible always be ﬁtted on the same side as the
ﬂow connection. If required it can be ﬁtted opposite
(extension cables can be provided on request).
- The casings can be ﬁtted after the boilers have been
installed.
- Control panel is ﬁtted in the front casing.
- Cleaning of the cast iron block from top of the boiler.

2.2 Burners
The burners are stainless steel, atmospheric type. They
guarantee a low noise level.
2.3 Boiler ﬂoor
The Remeha Gas 5c boiler is supplied with a reﬂecting
ﬂoor plate with ventilation underneath.
2.4 Assembly
The boiler will be assembled on site.

Remeha
Gas 5c / 5c Duo
3. TECHNICAL DATA AND DIMENSIONS

int.

3.1 Dimensions Remeha Gas 5c

Front view

Left hand side view

Top view

Cross section

Fig. 01 Dimensions Remeha Gas 5c
Number Nom. heat
output
of
sections

Nom. heat
input

Gas
consumption
3

Dimensions

Flue Water resistence Water
contents
temp.
t= 10°C t= 20°C

Boiler
weight

Flue gas
flow rate

ØD

±L

Ød

°C

mbar

litre

kg/h

kW-NCV

kW-GCV

m /h

139 - 278

155 - 309

172 - 343

1240 300 *

850

154

291

1450

692

155 - 310

173 - 345

192 - 383

1350 350 *

850

152

320

1575

795

170 - 340

189 - 378

210 - 420

1460 350 *

850

150

349

1695

847

186 - 372

207 - 414

230 - 460

1570 400 *

850

148

378

1820

983

202 - 403

224 - 448

249 - 498

1680 400 *

850

146

407

1940

1033

217 - 434

241 - 482

268 - 535

1790 400 *

850

142

436

2065

1080

233 - 466

259 - 518

288 - 576

1900 450 *

850

138

128

465

2185

1239

265 - 529

294 - 588

327 - 653

2120 450 *

985

138

160

523

2430

1376

296 - 592

329 - 657

365 - 730

2340 500 *

985

142

180

581

2675

1560

328 - 656

364 - 728

404 - 809

2560 500 *

1170

21/2

142

196

639

2920

1678

360 - 720

400 - 799

444 - 888

2780 500 *

1170

21/2

142

208

697

3165

1842

Table 1 Technical data Remeha Gas 5c

* Supplied with a flue gas pipe adaptor
4

int.

3.2 Dimensions Remeha Gas 5c Duo

Front view

Left hand side view

Top view

Cross section

Fig. 02 Dimensions Remeha Gas 5c Duo
Number
of
sections

Nom. heat
output

Nom. heat
input

Gas
consumption

Dimensions
B

ØD

Ød

±L

Water
contents

Boiler
weight

Flue gas
flow rate

kW-NCV

kW-GCV

m /h

litre

kg/h

2 x 10

139 - 556

155 - 618

172 - 686

1240

450 *

850

582

2900

1385

2 x 11

155 - 620

173 - 690

192 - 766

1350

500 *

850

640

3150

1590

2 x 12

170 - 680

189 - 756

210 - 840

1460

500 *

850

698

3390

1694

2 x 13

186 - 744

207 - 828

230 - 920

1570

600 *

850

756

3640

1966

2 x 14

202 - 806

224 - 896

249 - 996

1680

600 *

850

814

3880

2066

2 x 15

217 - 868

241 - 964

268 - 1070

102

1790

600 *

850

872

4130

2160

2 x 16

233 - 932

259 - 1036

288 - 1152

110

1900

650 *

850

930

4370

2478

2 x 18

265 - 1058

294 - 1176

327 - 1306

124

2120

650 *

985

1046

4620

2752

Table 2 Technical data Remeha Gas 5c Duo

* Supplied with a flue gas pipe adaptor

Remeha
Gas 5c / 5c Duo
4. APPLICATION INFORMATION
4.1 L.P.H.W. system

4.2 Chimneys
The average ﬂue gas temperature is so low that the
chimney must be made in accordance with the guidelines of British Gas (BS 6644).

4.1.1 Water temperature
Maximum water temperature is 110°C (high limit thermostat). Highest boiler water temperature is 95°C (control thermostat). Minimum return water temperature is
20°C at a ﬂowrate related to a t of 20°C (ﬂow/return
temp).

4.3 Installation standards
The following instructions must be adhered to when the
Remeha Gas 5c / 5c Duo is installed:
Gas Safety (installation and use) Regulations 1984 (as
amended).
All gas appliances must, by law, be installed by competent persons (e.g. Corgi) in accordance with the above
regulations. Failure to install appliances correctly could
lead to prosecution.
It is in your own interest and that of safety to ensure that
the law is complied with.
In addition to the above regulations, this appliance must
be installed in compliance with the current I.E.E. Regulations for electrical installation, local building regulations, the Building Standards (Scotland), (Consolidation)
Regulations and by laws of the local water undertaking
and Health and Safety Document No 635 'The Electricity
at Work Regulations 1989'. It should also be in accordance with the relevant recommendations in the current
editions of the following British Standards and Codes of
Practice, viz.
BS 5440 Pt 1 and 2, BS 5449, BS 5546, BS 6798, BS
6891 and BG.DM2.

4.1.2 Water pressure
Boiler sections pressure tested at 10 bar.
Maximum pressure test boiler block is 7,8 bar.
Minimum working pressure boiler is 0,8 bar.
Maximum working pressure bar is 6 bar.
4.1.3 Water ﬂow
The minimum water ﬂow through the boiler is:
Output boiler in kW
= m3/h
93
This minimum ﬂow must be maintained for approx. 5
minutes after the burner stops ﬁring to avoid high temperature shut down due to residual heat gain.
Due to the design and manufacture of the boiler no
speciﬁc minimum water ﬂow requirements exist other
then for overtemperature propection.
4.1.4 Water treatment
Water treatment is under normal circumstances not
necessary (see our water quality recommendations)

Important:
The Remeha Gas 5c / 5c Duo is a certified appliance
and must not be modified or installed in any way contrary to these 'Installation and Servicing Instructions'.
Manufacturers instructions must NOT be taken in any
way as overriding statutory obligations.

4.1.5 Noise level
The noise level measured around the boiler depending
on boiler room construction is about 50-55 dBA. Noise
levels taken at 1 meter from the boiler.

5. TYPICAL BOILER INSTALLATIONS
Recommended layout for boiler installation, measurements in mm.
Installation 1
Remeha Gas 5c

Fig. 03 Boiler installation Remeha Gas 5c

Remeha
Gas 5c / 5c Duo
Recommended layout for boiler installation, measurements in mm.
Installation 2
Remeha Gas 5c Duo

Fig. 04 Boiler installation Remeha Gas 5c Duo
8

6. CONTROL AND SAFETY EQUIPMENT
The boiler is supplied as standard with the simple instrument panel. All connections are pre-wired and ﬁtted with
plugs. The capillaries from the control panel should be
ﬁtted in the pocket of the boiler, which is ﬁtted in the top
front of the end section.

6.1 General
The Remeha Gas 5c is supplied with electronic control
and safety equipment with ionisation ﬂame detection.
6.2 Instrument panel
The Remeha Gas 5c is supplied with an instrument
panel that is ﬁtted in the front of the boiler, either left or
right. The instrument panel can be delivered in two models:
- simple instrument panel High /Low;
- complete instrument panel High /Low.

The instrument panel, pocket and ﬂow connection
should always be ﬁtted on the same side of the
boi-ler either left or right. If this is not possible
extension cables are available on request.

10
1

2
A

4
B

7
8

9
D

Fig. 5 Complete instrument panel
The modules contain:
Module D
9. Warning light *.
10. Analog thermometer water temperature.

Module A
1. Control thermostat,
setting between 35°C-95°C.
2. Hour run meter *.

Module E
11. Option for rematic weather compensated boiler.
control *.

Module B
3. High-Low thermostat,
setting between 35°C-95°C.
4. Hour run meter *.
Module C
5. High-limit thermostat 110°C (lock out).
6. Operating switch (On/Off with optical display) *.
7. Switch for domestic hot water storage pump *
Manual/Off/Automatic.
8. Switch for circulating pump *
Manual/Off/Automatic.

* Absent in simple instrument panel.
9

Remeha
Gas 5c / 5c Duo
6.3 Standard electronic gas train High/Low
6.3.1 Schematic

10 - 16 sections

18 - 24 sections
Fig. 06 Schematic construction gas train
6.3.3 Control panel on gas train
1 Main switch
1 Control box Satronic
1 Fuse (Brusk)
Signal lamps
1 Water level control

Legend
A
Gas cock
AB
Pilot burner
DR
Gas governor
F
Gas ﬁlter
HB
Burners
HD
Gas pressure switch
MK
Pilot gas valve
MP
Measuring point
VA
Safety shut off valve
OT
Ignition transformer
VB
Ionisation probe
MB
Gas multibloc
VDK Valve leakage control box (option)
--Not supplied as standard

6.4 Functions
6.4.1 Flame protection
Flame protection by means of ionisation flame detection.
6.4.2 Down draught thermostat
Type B11 Bs.
The boiler is fitted with a thermo-down draught thermostat. When there is down draught of the flue gases
this thermostat will switch off the boiler. Fixed set point is
70°C (automatic reset).

6.3.2 Speciﬁcation
2 Safety gas valves
1 Gas governor
1 Pilot gas valve
1 Pilot gas governor
1 Ignition transformer 5 kV
1 Pilot burner with ionisation probe
1 Down draught thermostat set at 70°C

6.4.3 Thermostats
Control thermostat On/Off 35°C-95°C.
Control thermostat High/Low 35°C-95°C.
High Limit thermostat lock out at 110°C.

7.4 Pocket for the instrument panel
The pocket should be ﬁtted in the top front end section
of the boiler and at that side of the boiler where the
gastrain is ﬁtted. In the other end section tapping 1" the
water level control electrode should be ﬁtted.

7.2 Boiler assembly
Broag provides special tools on loan, for the boiler
assembly with detailed building instructions. However,
building supervision and/or actual boiler erection services
can be provided by Broag or an approved boiler erection
engineer.

7.5 Water pressure
Each section is hydraulically tested to at least 10 bar.
Maximum test pressure for the assembled boiler block is
7,8 bar. Operating pressure between 0.8 bar and 6 bar.

7.3 Water connections
The boiler water connections can be ﬁtted on one side
of the boiler either left or right hand side. The water connection is ﬂanged on the boiler with a pipe connection for
welding Ø 107 mm (int.) to the installation.
The top blind-ﬂange has an integral cast 1" tapping to
accept a safety valve. The end sections have a 3/4 "
tapping to accept a drain/off cock (tapping BSP).

8. GAS SUPPLY
8.1 General
The gas train can be ﬁtted on the left or right hand side
of the boiler and on the same side of the boiler instrument panel (ﬁtted in the front casing).
The local Gas authority should be consulted to ensure
that an adequate pressure and supply is available at the
boilers maximum output. To minimise risk of sediment or
foreign particles entering the control valves, an approved
ﬁlter may be ﬁtted into the pipework downstream. The
gas supply should be conform to the British Gas safety
regulations.

8.2 Gas pressure
Cat. I 2 H.
Maximum gas pressure at inlet 100 mbar.
Burner pressure :
- full load
:
8.4 mbar (100%)
- part load
:
2.2 mbar ( 50%).
Min. gas inlet pressure 20 mbar.

Remeha
Gas 5c / 5c Duo
9. ELECTRICAL SUPPLY
9.1 General
The electrical installation must conform to the IEE regulations and also to local authority requirements.

9.6 Wiring diagram for the instrument panel
9.6.1 Simple instrument panel

9.2 Control panel
A control panel is ﬁtted on the gas train.
9.3 Electrical connections
The boiler is pre-wired. Only the main supply should be
wired to this control panel.
9.4 Electrical information
Main supply
:
Running current
:
Maximum fuse
:

230 V-50 Hz (L/N)
120 W
6 Amp.

9.5 Water level control (lock out)
a. Water level control :
Dungs DWEB 34/2
Main supply
:
230V-50 Hz
Running current
:
5W
Electrode current
:
42 V (AC)
Working area
:
0.5 to 15 mA (AC)
Electrode resistance :
max. 20 kOhm
min. 1 kOhm.
b. Electrode
:
Dungs FLE 1/2"
To be ﬁtted in one of the end sections (see par. 7.4).

Fig. 07 Scheme simple instrument panel

For legend see page 12

9.6.2 Complete instrument panel

Fig. 08 Scheme complete instrument panel
13

Remeha
Gas 5c / 5c Duo

For legend see page 12

9.7 Wiring diagram boiler

Fig. 09 Wiring diagram boiler
14

10. COMMISSIONING
10.1 Technical information
Control box:
Satronic MMI 816
Main supply:
230 V - 50 Hz
Minimum ionisation current:
min 3 µA (DC).
Reaction time ﬂame protection: 1 sec.
Safety time:
10 sec.
Maximum ambient temperature: 60°C
Injector size pilot burner:
Ø 0.8 mm
Injector size main burner:
Ø 5.4 mm
Burner pressure full load:
8.4 mbar (100%)
Burner pressure part load:
2.2 mbar (50%)
Burner pressure pilot burner:
13 mbar

The following will happen:
8. After a waiting time of about 13 seconds you will
get ignition. At a minimum ionisation current of 7
µA the ignition stops. The main gas valve will open.
The boiler runs.
9. Let the boiler run for a couple of minutes to get rid
of air in the gas pipe.
10. Set the correct burner pressure.
11. Check the thermostats for the correct setting.
12. Check the ﬂame protection, start the boiler with the
ionisation probe disconnected.
13. Check the water level control.

Warning
Control box operates on a neutral/phase supply.

10.3 Switching off the boiler
1.
Switch off the electric supply.
2.
Shut off the gas cock.

10.2 Commissioning
1. Check gas connections.
2. Check electrical supply (L/N and earth).
3. Check water connections and if installation is ﬁlled.
4. Switch on circulation pump and check rotation direction.
5. Open main gas cock (release air in gas pipe work).
6. Switch on electrical supply.
7. Set thermostats at about 85°C.

Be aware of the possibility of the danger of frost.
Note:
Commissioning to only be carried out by a qualiﬁed engineer with the relevant training and certiﬁcation i.e. Acops
- Corgi and a commissioning data sheet completed on site
for issue to owner

11. MAINTENANCE
11.1 General
It is essential for a good combustion, to clean the boiler,
the gas train and boiler room once a year. This prevents
dust from being aspired and fouling the burners and boiler during operation, thereby avoiding poor combustion
and possibly build-up of soot deposits.

room.
4. Clean boiler casings.
5. Clean the gas train, ignition, pilot burner, ther
mostats and wiring.
6. Check start program, ignition time and safety times.
7. Check ﬂame protection, and thermostats.
8. Check boiler input at 100% and 50% load.
9. Make a combustion efﬁciency calculation.
10. Check the boiler and installation for water leakage
(seals).
11. Check gas train and gas pipe for gas leaks.

11.2 Maintenance
1. Clean the internal ﬂue ways of the boiler. Remove
front casing and cleaning hatches, and remove the
burners.
2. Clean the burners internally and externally.
3. Clean the ﬂoor underneath the boiler and boiler

Remeha Gas 5c/5c Duo

Remeha
Gas 5c / 5c Duo

Broag Ltd.
Head office
Remeha house,
Molly Millars Lane,
Wokingham,
Berkshire RG41 2QP.
Tel. 0118 9783434
Fax 0118 9786977
Email: boilers@broag-remeha.com

Branch office
Unit 3, Kestrel Close,
Quarry Hill Ind. Estate,
© Copyright
All technical and technological information contained in these
technical instructions, as well as any drawings and technical descriptions furnished by us remain our property and shall not be
multiplied without our prior consent in writing.
Ours is a policy of continuous development. We reserve the right to
alter specifications without prior notification.

Ilkeston
Derbyshire DE7 4RD
Tel. 0115 9440778
Fax 0115 9440588

Subject to alterations
44430/1.000/11,00/Bo.

16 16

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