E C O

3 1 0
Technical Information

G a s
Remeha Gas 310 ECO

R e m e h a
• High efficiency condensing

boiler with low NOX emission

• Heat outputs: 51 - 573 kW

1
 INHOUD

Preface 5 8 Installation instructions for ELECTRICAL

installer 24
1 Safety instructions 6 8.1 General 24
1.1 Symbols 6 8.2 Electrical specifications 24
8.2.1 Mains voltage 24
2 General description of boiler 7 8.2.2 Control unit 24
8.2.3 Power consumption 24
3 Design 8 8.2.4 Fuse ratings 24
3.1 Boiler version 8 8.2.5 Temperature control 25
3.2 Operating principle 9 8.2.6 Low water level protection
(flow and content) 25
4 Technical data 10 8.2.7 High limit protection 25
4.1 Dimensions 10 8.2.8 Air pressure differential
4.2 Technical data 11 sensor (LDS) 25
4.3 Quotation specification 12 8.3 Connections 26
4.4 Delivery options 12 8.4 Wiring diagram 27
4.5 Accessories 13 8.5 Switch sequence diagram 27
8.6 Boiler control 27
5 Efficiency information 14 8.6.1 Introduction 27
5.1 Annual efficiency 14 8.6.2 Modulating controls general
5.2 Heat to water efficiency 14 (two wire control) 28
5.3 Standing losses 14 8.6.3 BMS Analog control
(0-10 Volt DC) 28
6 Application data 14 8.6.4 On/ off control (1 x no volt
switched pair) 28
7 Installation instructions for heating installer 15 8.6.5 High/ low control (2 x no volt
7.1 General 15 switched pairs) 29
7.2 Delivery and installation 15 8.7 Other inputs 29
7.3 Flue gas discharge and air supply 17 8.7.1 Shut down input 29
7.3.1 General 17 8.7.2 Lock-out input 29
7.3.2 Classification due to discharging 8.7.3 External interlock 29
flue gases 17 8.7.4 Other outputs 29
7.3.3 Connection options 17 8.7.5 Analog output Depending on the
7.3.4 Inlets/Outlets 17 option settings in the service level
7.3.5 Other requirements 17 (see section 13.2.13), the analog
7.3.6 Single boiler conventional flue 18 output signal is able to transmit
7.3.7 Single boiler, room sealed flue 18 the following values: 29
7.3.8 Different pressure zones 20 8.7.6 Operation signal 29
7.3.9 Header flue systems 20 8.7.7 Common alarm (lock-out) 29
7.4 Installation details 20 8.7.8 External gas valve control 29
7.4.1 Water pressure 20 8.8 Options/ accessories 30
7.4.2 Condensate discharge 20 8.8.1 System pressure sensor 30
7.4.3 Water treatment 20 8.8.2 Gas valve leak proving system
7.4.4 Safety valve 21 (VPS) 30
7.4.5 Water circulation 21 8.8.3 Minimum gas pressure switch 30
7.4.6 Thermostat pocket 21 8.8.4 Flue gas damper 30
7.4.7 Noise production 21 8.8.5 Return butterfly valve (not Broag
7.5 Multiple boiler installation 21 supply) 30
8.9 Other connections 30
8.9.1 Boiler or System pump control 30
8.9.2 Frost protection 30

3
 Remeha Gas 310 ECO

9 Installation instructions for gas installer 31 13.2.9 Maximum flue gas tempera-
9.1 Gas connection 31 ture (F) 42
9.2 Gas pressures 31 13.2.10 Maximum temperature
9.3 Gas/ air ratio control 31 setting (G) 42
13.2.11 Modulation start point at dT (H) 43
10 Commissioning 31 13.2.12 Minimum water pressure (I) 43
10.1 Initial lighting 31 13.2.13 Adjustments options/ acces-
10.2 Shutdown 33 sories (J) 43
13.2.14 “Low” speed with H/L control (L) 43
11 control and safety equipment 34 13.2.15 Boiler type (P) 43
11.1 General 34
11.1.1 Instrument panel layout 34 14 Fault-finding 44
11.1.2 LED indicators 35 14.1 General 44
11.2 Switch function keys 35 14.2Failure mode (1 [[) (service level) 44
11.2.1 Manual/automatic operation 35 14.3 Cooling mode 44
11.2.2 Forced mode ‘high’ (h [[) 35 14.4 Summary of failures (lock-out) 44
11.2.3 Forced mode ‘low’ (l [[) 35
11.3 Display of values 35 15 Inspection and maintenance instructions 48
15.1 General 48
12 Operating mode 36 15.2 Cooling mode 48
12.1 Operating mode (x [[) 36 15.3 Annual Inspection 48
12.2 Read-out mode (X [[) 36 15.4 Maintenance 48
12.3 Control strategy c 37 15.4.1 Inspection of air box and dirt trap 49
12.4 Shut-off (b xx) 37 15.4.2 Cleaning the non return valve 49
12.4.1 Shut-off 37 15.4.3 Cleaning the venturi 49
12.4.2 Shut-off mode 37 15.4.4 Cleaning the fan 49
12.5 Counter mode (1, , and .) 15.4.6 Cleaning the burner assembly 50
(service level) 38 15.4.5 Cleaning the heat exchanger 50
12.5.1 General 38 15.4.7 Cleaning the condensate collector 50
12.5.2 Reading out counter mode 38 15.4.8 Cleaning the syphon 50
15.4.10 Cleaning the inspection glass 51
13 Setting mode 39 15.4.9 Cleaning/Replacing the Ignition/
13.1 User level setting mode (X [[) 39 Ionisation electrode 51
13.1.1 Flow temperature (!) 39 15.5 Exploded view and spare parts list 52
13.1.2 Pump run on time (@) 40
13.1.3 Boiler control (A) 40 16 appendices 55
13.2 Setting mode service level (only for 16.1 Control menu 55
the qualified service engineer) (X [[) 40 16.2 Shut-off codes 56
13.2.1 Minimum fan speed ($ and 5) 42
13.2.2 Maximum fan speed (^ and 7) 42
13.2.3 Forced part load time (*) 42
13.2.4 Cycling prevention delay
time (() 42
13.2.5 Required flow temperature
at 0 - 10 volts (a and B) 42
13.2.6 High operation signal
switch point (C) 42
13.2.7 Shunt pump post-circulation
time (D) 42
13.2.8 dT from control stop point to
start point (E) 42

4
 PREFACE

Read these instructions carefully before putting the If you have any questions, or if you need more informa-
boiler into operation, familiarise yourself with its control tion about specific subjects relating to this boiler or its
functions, operation and strictly observe the instructions installation please do not hesitate to contact us.
given. Failure to do so may invalidate warranty or pre- The data published in these technical instructions is
vent the boiler from operating. based on the latest information (at date of publication)
and may be subject to revisions.
The installation and commissioning of the boiler must be We reserve the right to continuous development in both
carried out by a competent Engineer, with the relevant design and manufacture, therefore any changes to the
certification i.e.: CORGI, ACOPS, IEE regs. On com- technology employed may not be retrospective nor may
pletion a copy of the commissioning sheet should be we be obliged to adjust earlier supplies accordingly.
returned to Broag Ltd. for record purposes.

fig. 01 Artist impression Gas 310 ECO

3D.AL.31H.000.S.01

5
 Remeha Gas 310 ECO

1 SAFETY INSTRUCTIONS

1.1 Symbols g Be aware of flue gas leaks

The following symbols are used in this document to If you smell flue gas fumes, turn the boiler off and con-
emphasise certain instructions. This is in order to tact your service company or installer.

g
increase your personal safety and to safeguard the tech-
nical reliability of the boiler. Be aware of water leaks

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If you see water leaking from the boiler, turn it off and
Instructions must be followed closely to avoid contact your Service Company or installer.

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personal injury or serious damage to the unit or the
environment. Working on the boiler

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Installation, commissioning, maintenance and repair
Important!! Instructions are of essential work must only be carried out by suitably qualified spe-
importance for the correct functioning of the unit. cialist. Engineer in accordance with all relevant national/

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local standards and certifications.
Indicates possible danger of electric shock. Seri- Always disconnect the mains supply and close the main
ous personal injury may occur. gas cock before working on the boiler.

i Instructions contain useful information. Casing panels should only be removed for mainte-
nance and servicing purposes.
Read and familiarise yourself with these instruc- Refit all panels on completion of maintenance or servic-
tions. ing before putting the boiler back into service.

General Instructions Instruction and warning labels on the boiler must

Keep unauthorised personnel away from the boiler. Do never be removed or covered and must be clearly leg-
not place objects on or against the boiler. Do not touch ible throughout the entire service life of the boiler. Dam-
hot water connections or the flue outlet when the boiler aged or illegible instruction and warning labels must be
is operating – burn hazard. replaced immediately.

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Generally applicable safety instructions related to acci-
Danger dent prevention must be consulted in addition to the
This boiler is connected to a 230v mains supply. An information supplied in this technical documentation.
improper installation or attempts to repair electrical com-
ponents or controls may result in life threatening situa- Boiler modifications and spare parts
tions. The boiler must not be modified or non-Remeha spare

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parts fitted without the express written approval of
Be aware of gas escapes Remeha.
If you smell gas, close the (main) gas cock and contact
the emergency gas leak telephone number for your
area. DO NOT ISOLATE THE POWER SUPPLY TO
THE BOILER OR ANY OTHER APPLIANCE.

6
 2 GENERAL DESCRIPTION OF BOILER

The Remeha Gas 310 ECO boiler is a fully assembled, The standard control package allows for external On/
free standing, gas fired (Natural gas only), fully modu- Off, High Low (volt free switch/s) or modulating control
lating high efficiency condensing boiler and is supplied (0-10V input). The built in digital display shows normal
plastic wrapped, crated on a pallet. operating/ fault code indication and allows actual and
The sectional cast aluminium heat exchanger and other set values to be read and adjusted.
major components are contained within a rigid steel The intelligent, advanced boiler control (‘abc®’) continu-
frame with removable casing parts for maintenance ously monitors the boiler operating conditions, varying
purposes. The Gas 310 ECO frame is fitted with a set the heat output to suit the system load. The control is
of casters to enable the assembled unit to be easily able to react to external “negative” influences in the
manoeuvred into position within the plant room on site rest of the system (flow rates, air/ gas supply problems)
with the minimum of effort. All major electrical and elec- maintaining boiler output for as long as possible with-
tronic controls are contained within the instrument panel out resorting to a lock out condition. At worst the boiler
mounted on top of the boiler at the opposite end to the will reduce its output and/ or shut down (shut off mode)
connections facing to the front (long side) but can be awaiting the “negative” conditions to return to normal
rotated 90o towards the short side to suit site location. before re-starting.
The ‘abc®’ control cannot override the standard flame
The boiler is available with flow and return connections safety controls.
on the left or right hand end of the boiler (THIS MUST All Gas 310 boilers are live fired after assembly to
BE DECIDED AT TIME OF ORDER), with the gas con- ensure the boiler and controls comply with our strict
nection on the top of the boiler. The flue gas outlet c/w a quality policy.
condensate connection will be at low level on the same
side as the connections. Combustion air inlet (for room The unit has been inspected for compliance with the
sealed operation) is located at the top of the boiler. essential requirements of the following directives:
The boiler is suitable for room sealed or open flue - Gas Appliances Directive, no. 90/ 396/ EEC
applications and has been designed for central heat- - Efficiency Directive, no. 92/ 42/ EEC
ing and indirect hot water production at working pres- - EMC Directive, no. 89/ 336/ EEC
sures not exceeding 6 bar. It must be installed on a fully - Electrical Low Voltage Directive, no. 73/ 23/ EEC
pumped system and is designed for operating pressures - Pressure Equipment Directive, no. 97/ 23/ EEC,
between 0.8 and 6 bar. art. 3, item 3
The pre-mix gas burner (NG only) with its gas/ air ratio
control system ensures clean, trouble free operation CE identification number (PIN) : 0063BP3474
with higher than average efficiencies of up to 109% Hi NOX Class :5
(NCV) in the condensing mode combined with ultra low Type classification of flue gas discharg : B23, C33,
NOx and minimum CO emissions. C43, C53, C63, C83

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 Remeha Gas 310 ECO

3 DESIGN

3.1 Boiler version

fig. 02 Cross-section Remeha Gas 310 ECO (Left

hand boiler illustrated)
00.31H.79.00002

The service side of the boiler (with the heat exchanger

inspection cover) is the front.
1. Pressure gauge 21. Air supply grille
2. Pocket for external temperature sensor (7mm i/d 22. Gas connection
plain pocket) 23. Inspection glass
3. Flow connection 24. Ignition/ionisation electrode
4. 2nd Return connection (Optional) 25. Return temperature sensor
5. Return connection 26. Boiler block temperature sensor
6. Filling/ drain cock 27. Frame
7. Condensate collector 28. Steering castor
8. Flue gas temperature sensor 29. Fan
9. Condensate drain 30. Venturi
10. O2/ CO2 measuring point 31. Gas valve multiblock
11. Positioning wheels 32. Non return valve
12. Jacking bolts 33. Gas filter
13. Condensate drain hose 34. Air pressure differential sensor (LDS)
14. Flue gas discharge 35. Air box
15. Inspection hatch 36. Instrument panel
16. Adapter ø 250/ ø 200 (optional) 37. Control keys
17. Heat exchanger 38. Read-out window
18. Flow temperature sensor 39. Weather compensator installation (optional)
19. Air supply 40. On/ off switch
20. Adapter ø 200/ ø 250 (optional)

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3.2 Operating principle The boiler can be supplied, as an option with a
Combustion air is drawn into the inlet connection from second (constant temperature) return connection. This
the plant room (room ventilated version) or from outside additional connection enables the boiler to make full use
via the eccentric flue system (room sealed) by an air of its condensing ability whilst accepting both fixed and
supply fan. variable temperature returns from the same system.
On the inlet side of the fan is a specially designed
chamber (venturi unit) which takes gas from the multi-
block and mixes it in the correct proportions with the
incoming air. This mixing system ensures that the cor-
rect gas/ air ratio is delivered to the pre-mix burner at all
times.
Depending on demand (under the dictates of flow/return
sensor and other external/internal control inputs) the
‘abc®’ system determines the required boiler output.
The ‘abc®’ control then varies the speed of the air sup-
ply fan which alters the volume of air being drawn into
the venturi, this change in volume is measured using air
pressure differential which directly controls the volume
of gas also being delivered to the venturi. The resultant
controlled mixture is delivered to the premix burner.
This mixture is initially ignited by the combined ignition/
ionisation probe, which monitors the state of the flame.
Should the flame be unstable or not ignite within the
pre-set safety time cycle the controls will (after 5
attempts) shut the boiler down requiring manual inter-
vention to reset the boiler. The digital display will indi-
cate a flashing fault code confirming the reason for the
failure.
The products of combustion in the form of hot flue gases
are forced through the heat exchanger transferring their
heat to the system water, (the flue gas temperature is
reduced to approximately 5/ 8° above the temperature
of the system return water) then discharged via the con-
densate collector, to the flue gas outlet connection, to
atmosphere.
Because of the low flue gas exit temperature there will
be a vapour cloud formed at the flue gas terminal -this
is not smoke-, simply water vapour formed during the
combustion process.
If the flue gas temperature falls below dew point (55°),
water vapour (created during the combustion process)
will begin to condense out in the boiler, transferring its
latent heat into the system water, thereby increasing the
output of the boiler without increasing the gas consump-
tion.
Condensation formed within the boiler and flue system
is discharged from the boiler to an external drain via the
drain pan and siphon supplied.

9
 Remeha Gas 310 ECO

4 TECHNICAL DATA

4.1 Dimensions

fig. 03 Elevation drawings (left-hand version shown)

04.31H.79.00002

É Flow connection NW 80, DIN 2576

Ê Return connection NW 80, DIN 2576
Ï Gas connection 2” BSP (F)
Ò Condensate drain 1 ¼” nb plastic waste
Ñ Flue gas discharge 250 mm i/d
Ð Combustion air supply 250 mm i/d
Ì Second return connection
(optional) NW 65, DIN 2576

Boiler type A B C E L
5 sections 1600 1463 1590 1004 1312
6 sections 1600 1463 1590 901 1312
7 sections 1990 1853 1980 1110 1702
8 sections 1990 1853 1980 1007 1702
9 sections 1990 1853 1980 904 1702
table 01 Dimensions in mm

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4.2 Technical data

Remeha Gas 310 ECO

Boiler type Unit
5 sections 6 sections 7 sections 8 sections 9 sections
General
Boiler control options - Modulating, high/ low or on/ off
Nominal output Pn (80/ 60°) min kW 51 65 79 92 106
max kW 261 327 395 462 531
Nominal output Pn (50/ 30°) min kW 56 71 84 98 113
max kW 282 353 427 499 573
Nominal input Qn (GCV/ Hs) min kW 60 75 91 105 121
max kW 298 372 448 523 598
Nominal input Qn (NCV/ Hi) min kW 54 68 82 95 109
max kW 269 336 404 471 539
Efficiency (Hi)
Combustion (Hi) at 80/ 60° % up to 99
Heat to water (Hi) at 80/ 60° % up to 98,5
Standing losses (Taverage = 45°) % < 0.3
Annual efficiency (Hi) % 108,9
Gas and flue gas side
Gas category - Natural gas only
Inlet pressure gas (boiler running) min mbar 17
max mbar 100
Gas consumption m 0 3/ h 29 36 43 50 57
NOX emission (annual emissions) mg/ kWh < 60
NOX emission ppm < 35
(annual emissions, O2 = 0%, dry)
Residual fan duty Pa 150 150 150 150 150
Flue gas mass min kg/ h 91 114 138 160 183
max kg/ h 453 565 680 793 907
Flue gas temperature at 80/ 60° min ° 57
max ° 65
Type classification due to discharging flue - B23, C33, C43, C53, C63, C83
gasses
Water side
High limit temperature ° 110
Flow temperature operating ° 20 - 90
Operating pressure min bar 0.8
max PMS bar 6
Water contents litres 49 60 71 82 93
Water resistance at 11° dT mbar (kPa) 374 (37.4) 364 (36.4) 397 (39.7) 364 (36.4) 413 (41.3)
Water resistance at 20° dT mbar (kPa) 113 (11.3) 110 (11) 120 (12) 110 (11) 125 (12.5)
Electrical
Mains supply V/Hz 230/ 50
Power consumption min Watt 12 12 12 12 12
max Watt 303 340 470 600 858
Insulation class IP 20
Other
Weight dry kg 360 410 460 510 560
Floor area m2 1.2 1.2 1.4 1.4 1.4
Noise level at a distance of 1 m from the dB(A) 60
boiler (average)
Colour of casing RAL 2002 (red); 9023 (grey)
table 02 Technical data Remeha Gas 310 ECO

11
 Remeha Gas 310 ECO

4.3 Quotation specification - Powder coated enamel steel casing BS; RAL colour:
- Cast aluminium - sectional pre-mix gas fired fully 2002 (red); 9023 (grey)
condensing, modulating floor standing boiler - Rigid steel box frame
- Sectional heat exchanger manufactured from cast - Suitable for use with Natural gas only
aluminium - Supplied as standard with on/ off switch, temperature
- Maximum operating pressure of 6 bar indication, flow, return, heat exchanger block and flue
- Maximum operating temperature of 90°C gas sensors
- Ultra low NOx (max. 35 ppm at 0% O2) - Supplied as standard with indicating module No. 1
- Pre-mix, fully modulating (20-100%) gas burner with lock-out indication (Volt free), shut down indication
unique gas/ air ratio control for maximum efficiency (Volt free), boiler on indication (24 Volt AC)
- Intelligent advanced boiler control ‘abc®’ c/w a compre- - Efficiencies up to 109% (NCV/ Hi)
hensive operating, service and fault diagnostic facility - Manufactured to ISO 9001
- No minimum flow requirement (see section 7.4.5) - CE approved
- Available as conventional flue or room sealed operation
- Capable of remote BMS control (0 -10V modulating, 4.4 Delivery options
on/ off or high/ low option) Available in 5 section sizes, in “left-hand” or “right-hand”
- Socket for advanced service diagnostics (for PC/ PDA versions each with 2 instrument panel positions:
connection)
- Supplied fully factory assembled and tested

Gas 310 ECO Gas 310 ECO

Execution ‘left-hand’ Execution ‘right-hand’

fig. 04 Installation options

04.31H.79.00004

I = Front (service side) The service side with the inspection cover on the heat
A = Short side (alternative orientation of the instrument exchanger is considered to be the front of the boiler.
panel) With a “left-hand” version, the flow, return and flue
connections are on the left of the boiler as you face
the front (service side). On a “right-hand” version, the
flow, return and flue connections are on the right of the
boiler as you face the front (service side). The boiler
instrument panel can be rotated to face the front or the
short side of the boiler (front will be standard unless
stated on the purchase order) (see fig. 04).

12
g Important!!
When ordering a Remeha Gas 310 ECO, it is essential
that the number of sections and whether a “left-hand”
or “right-hand” connection version is required as well
as the orientation of the instrument panel (short or front
side).

4.5 Accessories
- Modulating “OpenTherm” weather compensators,
‘’Open Therm’’ for single or rematic®’ for multi boiler
configurations
- Second return connection
- System pressure sensor
- Flue adapter 250mm to 200mm i/d (stainless steel)
- Air supply adapter 250mm to 200mm i/d (stainless
steel)
- Vertical room sealed terminal VRS 200/300 or VRS
250/350
- Condensate neutralisation box
- Condensate neutralisation granules
- Recom communication set with CD-ROM, interface
and wiring
- Interfaces for communication with various controllers
(see section 8.6)
- Gas leak proving control
- Minimum gas pressure switch
- Automatic flue gas damper for pressurised flue sys-
tem
- Cleaning tools

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 Remeha Gas 310 ECO

5 EFFICIENCY INFORMATION

5.1 Annual efficiency

Up to 108.9% at Hi (up to 97% at Hs) at an average
water temperature of 40°C (50/ 30°C).

5.2 Heat to water efficiency

a. Up to 98.5% at Hi (88% at Hs) at an average water
temperature of 70°C (80/ 60ºC).
b. Up to 106.4% at Hi (98% at Hs) at an average water
temperature of 40° (50/ 30°).

5.3 Standing losses

Less then 0.3% at Hi (0.33% at Hs) at an average water
temperature of 45°C

Note: NCV = Hi, GCV = Hs

6 APPLICATION DATA

The Gas 310 ECO can be used on all new and refur-
bishment projects in both single and multiple configu-
rations. Conventional and room sealed flue system
capability means that the boiler can be sited almost any-
where within a building.
The Remeha rematic® and “OpenTherm” weather com-
pensators (option) are able to communicate directly with
the boiler/s controls to make full use of their fully modu-
lating features, ensuring that the boiler closely matches
the system demand at all times.
External control systems (BMS) can be interfaced with
the boiler to provide on/ off - high/ low or modulating (0
-10V) control options.

14
 7 INSTALLATION INSTRUCTIONS FOR HEATING INSTALLER

7.1 General Once in position the boiler is fixed into position using the
All gas appliances must, by law, be installed by com- fitted jacking bolts which both raise the wheels of the
petent persons (e.g. Corgi registered). Failure to install ground and level the boiler. Technical documentation is
appliances correctly could lead to prosecution. supplied with the boiler in a holder on the inside of the
It is in your own interest and that of safety to ensure that boiler casing (beneath the instrument panel). A number
the law is complied with. of small loose components, such as the 4 support pads
and the syphon for the boiler have been placed in the
The following instructions must be adhered to when the flue gas discharge.
Remeha Gas 310 ECO is installed:
- Gas Safety (Installation and Use) Regulations 1984 It is advisable (preferable) to install the Remeha Gas
(as amended). 310 ECO as follows:
In addition to the above regulations, this boiler must be - Place the crate c/w the boiler in the boiler room. Make
installed in compliance with: sure there is enough room at one end of the crate for
- Current I.E.E. Regulations for electrical installations the boiler and ramp and clearance for the crate to be
- Local building regulations removed (at least 3 M).

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- The Building Standards (Scotland)
- (Consolidation) Regulations Important!! Always transport the boiler in
- By-laws of the local water undertaking the protective packaging wherever possible.
- Health and Safety Document No 635 ‘The Electricity - Remove fixing strips, packaging lid and all other
at Work Regulations 1989’ packaging leaving the boiler on the pallet.
It should also be in accordance with the relevant recom- - Place the packaging lid on the end of the pallet (cre-
mendations in the current edition of the following British ating a ramp - secure with screw).
Standards and Codes of Practice, viz. BS 6644, BS5978 - Roll the boiler on its wheels off the pallet down the
Part 1 & 2, BS 5449, BS 5446, BS 6798, BS 6891 and ramp to the boiler room floor.

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BG DM2.
WARNING! Use retaining straps to control
Important: the rate of travel - Do not stand in front of the boiler!
The Remeha Gas 310 ECO is a CE certified boiler and - Manoeuvre the boiler to required final position.

i
must not be modified or installed in any way contrary to
these “Installation and Maintenance Instructions”. The pallet lid can be used as a rocking ramp to
Manufacturers Instructions must NOT be taken as over- convey the boiler over obstacles, such as thresholds
riding statutory obligations. etc.

7.2 Delivery and installation g Important!! The wheels are designed for
The Remeha Gas 310 ECO is supplied fully assembled transport purposes only and MUST NOT be used when
plastic wrapped and packed in a crate on a pallet. the boiler is in its final position!
The overall dimensions of the crate are 80 cm wide and - Place the 4 support pads under the adjustment bolts.
175 cm high with the length dependant on the number - Use the adjusting bolts to jack up the boiler lifting it
of sections (5 & 6 sections: 170 cm, 7 to 9 sections: clear of the wheels and with the top of the conden-
209 cm). The base of the packaging is a 76-cm wide sate collector level.
pallet to enable it to be transported with a pallet truck, - Fit the siphon assembly.
forklift truck or 4-wheel transport boards. Use the plastic packaging to protect the boiler until
Excluding the crate the boiler is 72-cm wide c/w cas- required for use.

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ing panels and 70 cm without casing and will fit through
most standard doors (minimum door opening width 80 Important!! Additional protection may be
cm). The boiler itself has wheels so that, once the pack- required if site conditions warrant it – overhead builders
aging has been removed, it can easily be moved around working, insulation etc.
on a smooth surface. The packaging lid includes a rock-
ing ramp, which can be used to negotiate obstacles
such as doorsteps and small plinths.

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 Remeha Gas 310 ECO

fig. 05 Layout in the boiler room

04.31H.79.00005

* Free space 800 mm, if instrument panel is facing the

short side.

Number of sections C in mm
5 1590
6 1590
7 1980
8 1980
9 1980

Clearance of at least 800mm is required at the front fig. 06 Support area Remeha Gas 310 ECO
(service side) of the boiler. However, we recommend a 00.31H.79.00005

clearance of 1 m. A clearance of at least 400mm above

the boiler, at least 300mm on both ends (800mm if the Number of sec-
C in mm D in mm
instrument panel is rotated to face the short end). tions
5 1590 1118
fig. 06 shows the boiler’s support area including the
position of the support pads (shaded boxes) supplied. 6 1590 1118
7 1980 1508
8 1980 1508
9 1980 1508
table 03 longitudinal dimensions

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7.3 Flue gas discharge and air supply Note: The boilers can also be installed on a flue dilu-
tion system, but must incorporate a total flue break to
7.3.1 General avoid boiler gas/air ratio controls being affected by the
The Remeha Gas 310 ECO is suitable for both conven- flue dilution fan pressures. For full details please contact
tional room ventilated or eccentric room sealed opera- Broag.
tion. Room sealed terminals should comply with the
Gastec QA-requirements for vertical outlet constructions. A table showing maximum air supply/ flue gas discharge
Any horizontal pipework in the flue gas discharge sys- lengths for the room sealed version of the Remeha Gas
tem should slope towards the boiler with a drain connec- 310 ECO can be found in section 7.3.7.
tion positioned approx. 300mm from the boiler connec-
tion. Horizontal pipework in the air supply system should 7.3.3 Connection options
slope towards the supply opening and may require a The Remeha Gas 310 ECO is available in a room venti-
drain point at the low point. lated and a room sealed version. If the room-sealed ver-
Care should be taken when siting flue exit positions as sion is used, the grille must be removed before installing
a vapour plume will be visible when the boiler is opera- the air supply pipe.
tional (flue gas temperature will be less than < 77°
resulting in the water vapour condensing out on contact 7.3.4 Inlets/Outlets
with the air). For conventional flue systems the flue terminal exit point
should discharge vertically and be c/w a tapered cone
7.3.2 Classification due to discharging flue gases and bird guard. For room sealed options use the Broag
Classification according to CE: VRS terminals.
Type B23: Conventional room ventilated appliance with-
out draft diverter. Air supply from boiler room; flue gas 7.3.5 Other requirements
discharge on roof.
Type C33: Room sealed appliance, connected to com- Flue gas discharge materials:
bined roof outlet. Single wall, rigid: stainless steel, thick-walled aluminium
Type C43: Room sealed appliance in cascade configu- (to comply with building regulations).
ration, connected via two ducts to a common duct sys- Flexible: stainless steel
tem serving more than one appliance. (to comply with building regulations).
Type C53: Room sealed appliance, connected to sepa-
rate ducts for the air supply and flue gas discharge, ter- Flue gas discharge structure:
minated in zones of different pressure. The flue gas discharge pipe must have airtight and
Type C63: Room sealed appliance, supplied without the watertight joints and connections, or should be seam-
terminal or the air supply and flue gas discharge ducts. less. Horizontal sections in the flue gas discharge pipe
Type C83: Boiler with room sealed operation, connected must slope down towards the boiler (at least 5-cm per
to separate air supply and flue gas discharge duct, with meter) and incorporate a drain point within 300mm of
flue gas discharge duct always in depression. the boiler connection.

Conventional flue or room ventilated installations: Flue liners:

A room-ventilated boiler takes the required combustion If flue liners are used they must be manufactured from
air from the plant room. Combustion air for the boiler gas and water tight airtight, thick-walled rigid aluminium
must be provided to the room/ compartment in accord- or stainless steel (flexible plastic (with a continuous
ance with BS 6644. A table showing the maximum operating temperature rating of 120°) and stainless
discharge lengths for the room ventilated version of the steel pipe liners are also acceptable provided they are
Remeha Gas 310 ECO can be found in section 7.3.6. water and gas tight).

Room sealed installations: Air supply materials:

It is unnecessary to provide separate combustion air to Single wall, rigid or flexible: aluminium, stainless steel.
the room/compartment as this is supplied direct to the
boiler via the eccentric flue and air inlet system to the Air supply structure:
vertical terminal unit (see 0, VRS 200/250 options avail- The air supply pipe must also be airtight. Horizontal sec-
able from Broag). tions in the air supply must slope away from the boiler
towards the supply opening and incorporate a drain con-
Additional ventilation will be required to the room/ nection if the route rises from a lower point that could
compartment in accordance with BS 6644 (compart- flood.
ment ventilation). For installations where supply and dis-
charge points are in two different pressure zones CLV
system please contact Broag Technical Dept. for further
details and advice.
17
 Remeha Gas 310 ECO

7.3.6 Single boiler conventional flue 7.3.7 Single boiler, room sealed flue

fig. 07 Flue gas discharge duct without bends, single fig. 08 Flue gas discharge duct without bends, single
boiler, conventional flue. boiler, room sealed application.
00.31H.79.00011 (afb 1) 00.31H.79.00011 (nr 6)

Flue diameter 200 mm * 250 mm Flue/ air inlet diam-

250/ 250 mm
eter
sections
Model Gas 310 ECO sections
5 6 7 8 9 Model Gas 310 ECO
5 6 7 8 9
max eq. length max eq. length
m 103 65 145 105 78 m 172 108 71 49 34
L L
bend 45°, R=D m 1.6 2 bend 45°, R=D m 2
bend 90°, R=D m 2.8 3.5 bend 90°, R=D m 3.5
table 04 Calculation data conventional flue table 05 Calculation data room sealed applications

* When flue gas discharge pipes with a diameter of 200 Example:

mm are used, an optional adapter is required for con- Gas 310 ECO, 8 sections, total length flue and air inlet
nection to the Remeha Gas 310 ECO from ø 250 - ø each 32 m, each 2 bends 90°.
200 mm. 32 m + 2 x 3.5 = 39.0 < 49 m; flue and air inlet OK.

Example: Gas 310 ECO, 6 sections, total length 27 m, Note: If the design parameters are outside the val-
diameter 200 mm, 2 bends 90°. ues shown in the above table or there is any doubt
27 m + 2 x 2.8 = 32.6 < 65 m → flue OK. over the flue system, please contact our technical
department for calculation to be undertaken.
Note: If the design parameters are outside the val-
ues shown in the above table or there is any doubt Combined vertical terminal sets, and roof sealing plates
over the flue system, please contact our technical for flat roofs, are available for the room-sealed version
department for calculation to be undertaken. with diameters of ø 200 and ø 250 in accordance with
the drawings below.

18
fig. 09 Vertical terminal for room sealed operation
pdf

Number of L E ØD G* H Ød1 Ød2 ØD 3 ØD 4

sections mm mm mm mm mm mm mm mm mm
7 0 450 200 0 2350 300 320 318 640
9 30 550 200 130 2350 300 320 318 640
11 200 720 200 300 2350 300 320 318 640
13 260 820 250 360 2500 350 370 368 690
15 360 920 250 460 2500 350 370 368 690
17 500 1060 250 600 2500 350 370 368 690
19 600 1160 250 700 2500 350 370 368 690
* Correct lengths for 11 and 19 sections; for the 9, 13, 15 and 17 sections, the pipe supplied must be shortened.
This pipe is not suitable for the 7 section boiler.

19
 Remeha Gas 310 ECO

7.3.8 Different pressure zones 7.3.9 Header flue systems

For multiple boiler installations with common flue sys-
tems please refer to Broag for advice.

Ñ Flue gas discharge 7.4 Installation details

Ð Combustion air supply
7.4.1 Water pressure
The individual boiler sections are each subjected to a
test pressure of 10 bar. On assembly the complete block
is subjected to a factory pressure test using compressed
air at 2 bar for 1 minute.
The boiler is suitable for a maximum working pressure
of 6 bar.

7.4.2 Condensate discharge

Discharge the condensate via a tundish, directly into
a drain. Only use synthetic material for the connecting
pipework because of the acidity (pH 2 - 5) and allow a
min. of 30 mm per meter fall to ensure a good flow rate.
Fill the siphon with clean water before firing the boiler.
It is not advisable to discharge into an outside gutter,
because of the risk of freezing.

7.4.3 Water treatment

fig. 10 Different pressure zones The system should be filled with mains cold water (for
00.31H.79.00012
the UK this will usually have a pH of between 7 and 8).
Pressurised installations with a boiler/ system content
The Remeha Gas 310 ECO boilers are capable of oper- ratio of 1:10 or less should not require water treatment,
ating with the air inlet and flue outlet in different pres- provided that the following conditions apply:
sure zones (CLV System).
The max height difference between air inlet and flue gas 1. The system is flushed thoroughly to remove all fluxes
outlet is 36 meters and the maximum total length of air and debris and filled completely once.
inlet and flue gas outlet pipework L is shown in table 06. 2. Make up water is limited to 5% per annum.
3. The hardness of the water does not exceed 360 ppm
Flue/ air inlet diameter 250/ 250 mm (20°D).
sections All scale deposits will reduce the efficiency of the boiler
Model Gas 310 ECO and should be prevented. However provided the above
5 6 7 8 9 is complied with any scale produced will not be too det-
maximum total rimental to the boiler efficiency and will not reduce the
length of air inlet anticipated life expectancy of the boiler.
m 262 158 98 62 40
and flue gas outlet
pipework L NOTE: Scale deposits in excess of 5mm will reduce
bend 45°, R=D m 2 boiler efficiency and increase the risk of premature cast-
ing failure.
bend 90°, R=D m 3.5
table 06 Different pressure zones As most systems contain a variety of metals it is consid-
ered good practice to provide some form of water treat-
Note: this system may not be used in areas with ment (especially in open vented systems) in order to
adverse wind conditions (i.e. in some coastal regions). prevent or reduce the following.
Note: If the design parameters are outside the values - Metallic corrosion
shown in the above table or there is any doubt over the - Formation of scale and sludge
flue system, please contact our technical department for - Microbiological contamination
calculation to be undertaken. - Chemical changes in the untreated system water

20
Suitable chemicals and their use should be discussed For the correct dosage and for further information on
with a specialist water treatment company prior to car- water treatment or system cleaning we advise direct
rying out any work. The specification of the system and contact with either of the above companies.
manufacturers recommendations must be taken into
account, along with the age and condition of the system. 7.4.4 Safety valve
New systems should be flushed thoroughly to remove all A safety valve should be fitted in accordance with BS
traces of flux, debris, grease and metal swarf generated 6644. The flow pipe on the Remeha Gas 310 ECO
during installation. Care to be taken with old systems to includes a fitting, which can be used for a safety valve,
ensure any black metallic iron oxide sludge and other size 1½” BSP (F).
corrosive residues are removed, again by thoroughly Recommended minimum safety valve size of 25mm for
flushing, ensuring that the system is drained completely the 5 & 6 section, 32mm for the 7 section, 38mm for the
from all low points. 8 section and 50mm for the 9 section (all full bore type).

NOTE: Please ensure that the new boiler plant is not 7.4.5 Water circulation
in circuit when the flushing takes place, especially if Provided that the factory pre-set high limit and flow
cleansing chemicals are used to assist the process. temperatures are not altered and the Remeha modulat-
ing controls are used no minimum flow rate is required
Under no circumstances is the boiler to be operated as the ‘abc®’ system will monitor these conditions and
with cleaning chemicals in the system. reduce the boiler output, finally shutting down until flow
conditions improve. As a result, the boiler is virtually
To summarise: unaffected by low water flow.
- Minimise water loss
- Prevent pumping over in open vented systems 7.4.6 Thermostat pocket
- Provide adequate air venting at all high points A thermostat pocket (7mm i/d plain pocket) is supplied
- Maximum chlorine content of 200 mg/ 1 as standard in the flow pipe for an external control/ BMS
temperature sensor.
Take advice on the suitability of inhibitors for use with
aluminium boilers 7.4.7 Noise production
MAX pH of 8.5 when using additives (max. pH of 9 The average noise level measured at 1-m distance
without additives). around the boiler is < 60 dBA at full output, avoiding the
need for additional acoustic measures.
If water treatment is used, we recommend the following
products: 7.5 Multiple boiler installation
The Remeha Gas 310 ECO can be installed individually
‘Copal’ manufactured by: or in a multiple boiler installation. The narrow width and
depth of the boiler and its ability to be mounted closely
Fernox Manufacturing Company Ltd. together provides a high output within a small floor area
Britannia Works (see fig. 05)
Clavering A “DUO” version the Gas 610 (6 to 9 section only) will
Essex, CB1L 4QZ also be as a dual cascade unit.
Tel No: 0179 955 0811 Advice and schematic drawings are available on
Fax No: 0179 955 0853 request, contact Broag Technical Dept.

or:

Sentinal ‘X100’ manufactured by:

BetzDearborn Ltd
Sentinal
Foundry Lane
Widnes
Cheshire WA8 8UD
Tel No: 0151 424 5351
Fax No: 0151 420 5447

21
 Remeha Gas 310 ECO

1. OpenTherm or rematic® modulating cascade 8. low loss header

controller 9. drain cock
2. boiler pump 10. system pump
3. safety valve 11. expansion vessel system
4. non return valve 12. flow temperature sensor
6. isolating valve 13. outside temperature sensor
7. automatic air vent

13

7
12

10

11
9
6

3
2

fig. 11 Sample hydraulic diagram cascade configuration

pdf

The minimal dimensions of low loss header and various

Boiler side Installation side pipes, based on a ∆T of 20° are represented in table 07
The minimal dimensions of low loss header and various
pipes, based on a ∆T of 11° are represented in table
08. The low loss header has to be sized for the maximal
flow Q required. The Remeha Gas 310 ECO has no
built-in pump.

fig. 12 Low loss header > 500kW

00.W20.79.00040

22
 Output up Flow Q Dø D square d interior H A B
to
KW m3/h inch DN mm inch DN mm mm Mm
550 23,65 8 200 190 2½ 65 614 818 983
625 26,88 10 250 200 2½ 65 654 872 1041
875 37,63 10 250 230 3 80 774 1032 1213
1250 53,75 12 300 280 4 100 925 1233 1431
1500 64,50 14 350 300 4 100 1013 1351 1558
1550 66,65 14 350 310 5 125 1030 1373 1582
2000 86,00 16 400 350 5 125 1170 1560 1783
2275 97,83 18 450 370 5 125 1248 1664 1895
2500 107,50 18 450 390 6 150 1308 1744 1982
2650 113,95 20 500 400 6 150 1347 1796 2038
table 07 Dimensions low loss header, based on a dT of 20°

Output up Flow Q Dø D square d interior H A B

to
KW m3/h inch DN mm Inch DN mm mm Mm
675 52,77 12 300 280 4 100 916 1222 1419
825 64,50 14 350 300 4 100 1013 1351 1558
1100 86,00 16 400 350 5 125 1170 1560 1783
1250 97,73 18 450 370 5 125 1247 1663 1894
1375 107,50 18 450 390 6 150 1308 1744 1982
1825 142,68 20 500 450 6 150 1507 2009 2268
1900 148,55 20 xxx 460 8 200 1538 2050 2312
2100 164,18 21 xxx 480 8 200 1616 2155 2426
2300 179,82 22 xxx 500 8 200 1692 2256 2534
2500 195,46 23 xxx 530 8 200 1764 2352 2638
2650 207,18 24 xxx 540 8 200 1816 2421 2713
table 08 Dimensions low loss header, based on a dT of 11°

23
 Remeha Gas 310 ECO

8 INSTALLATION INSTRUCTIONS FOR ELECTRICAL INSTALLER

8.1 General
The Remeha Gas 310 ECO is supplied as standard with
electronic operating and flame ionisation safety controls
with a specially designed microprocessor at the heart of
the system.
The boiler is pre-wired as shown in the wiring diagram
in fig. 17. All external connections can be made on the
terminal strips (one low voltage 24V AC and one mains
voltage 230V AC).
For lasting installation an all pole main switch with
a contact opening of at least 3 mm, must always be
applied between the boiler and the electricity grid (EN
60335-1, art. 7.12.2.).
fig. 13 Position code-key
8.2 Electrical specifications
8.2.3 Power consumption
8.2.1 Mains voltage Power consumption at stand-by /part load /full load:
The boiler is suitable for a 230V-50Hz supply with - 5 sections: 12 Watt / 53 Watt / 303 Watt
phase/ neutral/ earth. Other connection values are only - 6 sections: 12 Watt / 56 Watt / 340 Watt
acceptable if an isolating transformer is installed. The - 7 sections: 12 Watt / 77 Watt / 470 Watt
boiler is sensitive to phase/neutral and therefore has a - 8 sections: 12 Watt / 77 Watt / 600 Watt
facility to ensure that phase and neutral are correctly - 9 sections: 12 Watt / 80 Watt / 858 Watt
connected. If phase and neutral are crossed, the display
will flash L-n / n-L alternately. 8.2.4 Fuse ratings
The circuit board on the control unit contains the follow-
8.2.2 Control unit ing fuses:
Manufacturer : Honeywell F1 - 2 AF mains voltage fuse (automatic fuse)
Type : MCBA 1458 D F2 - 2 AT for gas valve multiblock
Mains voltage : 230 V/50 Hz F3 - 2 AT for 24 V circuit
Safety time : 3 sec. F10 - 2 AT for shunt pump
F11 - 1 AT for flue gas damper
Each Remeha Gas 310 ECO has a unique “boiler F12 - 1 AT for butterfly valve
code”. These codes, together with other data as boiler F13 - 2 AT for heating pump
type, counter data, etc., are stored in a “code-key” that F14 - 1 AT for external gas valve
belongs to the boiler. If the control unit is replaced this
information remains
stored in the code-key.

fig. 14 Control unit

00.31H.79.00009

24
The boiler fuse Fa is located behind / next to the 230V
terminal strip. This fuse de-energises the whole boiler and
has a rating of 10 AT.
The fan has Power Factor Control (PFC ensures that the
mains supply is distributed more uniformly) and is fused
with a 6.3 AT fuse Fb (behind / next to the 230V terminal
strip).

fig. 15 Position Fuses Fa and Fb

8.2.5 Temperature control 8.2.7 High limit protection

The Remeha Gas 310 ECO is equipped with electronic The high limit temperature protection device switches
temperature control based on flow, return, boiler block off and locks out the boiler (showing a flashing fault
and flue gas temperature sensors. The flow temperature code, see section 14.4 for details) when the flow tem-
is adjustable between 20 and 90° (factory setting 90°). perature exceeds the high limit set point (adjustable
parameter, see section 13.2.10). When the fault is cor-
8.2.6 Low water level protection (flow and content) rected, the boiler can be restarted by using the reset-
The Remeha Gas 310 ECO is equipped with low water key on the control panel.
protection based on temperature differences (dT)
between flow and return. When the dT = 25° (fac- 8.2.8 Air pressure differential sensor (LDS)
tory setting) the boiler starts modulating down so that it At the start of a heat demand the system checks
remains operational as long as possible. When the dT = whether the LDS input is open. If not, there are (max.)
40° the boiler will be at part load. If the dT continues to 4 restarts, before the boiler is locked out (E61).
rise and reaches 45°, the boiler shuts down (not a boiler If the LDS input is open, the fan will speed up and a
failure, see section 12.4) and will restart when conditions pressure difference is built up across the boiler. When
return to normal. the LDS control speed is reached the LDS input must
If the boiler is fired dry, it will go to high temperature lock close. If not, there are (max.) 4 restarts, before the
out, failure code (&. boiler is locked out (E08).
Once started the LDS function is switched off for mod-
ulation purposes.

25
 Remeha Gas 310 ECO

8.3 Connections
The terminal strips and boiler connectors can be seen
once the control box cover is removed. The left-hand
terminal strip (X29) is used for 24-volt connections. The
right-hand terminal strip (X27) is used for 230-volt con-
nections. All external connections (low and high voltage)
are made on these terminal strips (see fig. 16). The
various connection options are detailed in the following
sections.

fig. 16 Terminal strip

04.31H.79.00001

26
8.4 Wiring diagram

fig. 17 Wiring diagram

04.31H.SC.00001

27
 Remeha Gas 310 ECO

8.5 Switch sequence diagram

fig. 18 Switch sequence diagram

04.31H.79.00003

8.6 Boiler control

8.6.1 Introduction
The Remeha Gas 310 ECO can be controlled using one
of the following methods:
Note: when using on/off control the boiler will also
modulate to maintain the flow temp set point (param-
eter !)
- Fully modulating, where the output modulates
between the minimum and maximum value on the
basis of the flow temperature defined by the modulat-
ing controller.
- Analog control (0-10 volts), where the heat output or
temperature is controlled by a 0-10 volt signal.
- On/ off control, (one-volt free relay) where the heat
output modulates between the minimum and maxi-
mum value on the basis of the flow temperature set in
the boiler.
- High/ low control, (two volt free relays) where the
boiler is controlled by means of a 2-stage controller at
part load and full load.
fig. 19 Output control characteristic
In all cases, modulation is based on the required flow pdf

temperature and there is a dT dependent output control

with the following characteristic.
Up to a dT of 25° (factory setting, parameter H) the
boiler operates at full output. Between dTfull load and dTpart
load the output reduces in linear fashion (see fig. 19).

28
8.6.2 Modulating controls general (two wire control)
To make full use of the boiler’s modulating feature, an
OpenTherm® or a rematic® control can be connected.
These controls will provide optimised time and weather
compensation to achieve maximum efficiency and mini-
mum boiler cycling whilst maintaining design condition
within the building. An optional OpenTherm® or remat-
ic® interface must be integrated in the boiler control
box.

A. OpenTherm®
Celcia 20 - An optimising/ weather-compensated boiler
control for single boilers. This compensator can regulate
the boiler output against outside weather conditions, and
provide time and temperature control over the DHW.
The compensator is mounted in a reference room (uses
an internal sensor to monitor room temperature) and is
interfaced to communicate with the boiler’s controls via
the two wire serial interface. On site connection of the
supplied outside and common flow sensors complete fig. 20 Temperature control via analog (0-10 Volt)
the installation. Set the x value of the boiler control signal
operation parameter A to 1.
Note: Please refer to the relevant control leaflet for opti- Output based - fixed parameters (20 to 100%), Set the
mising/ compensation settings. x value of the boiler control setting parameter A to 5
(see fig. 21).
B. rematic® modulating multiple boilers controller - 0 to 1.9 Volt = boiler off
rematic® 2945 C3 K - An optimising/ weather-com- - 2 Volt - 10 Volt = boiler modulates between 20
pensated boiler control for multiple boilers (up to a max and 100% on demand.
of 8). This compensator can regulate the boiler output
against outside weather conditions, and provide time
and temperature control over the DHW. The compensa-
tor is mounted in one of the boilers and is interfaced to
communicate with the boiler’s controls via the supplied
adapter. On site connection of the supplied outside and
common flow sensors complete the installation. Set the
x value of the boiler control operation parameter A to 1.
Note: Please refer to the relevant control leaflet for opti-
mising/ compensation settings.

8.6.3 BMS Analog control (0-10 Volt DC)

Input resistance Rin = 66 kW.
The heat output modulates between the minimum and
the maximum value on the basis of the voltage supplied
by an external analog (0-10V) input. To control the boiler
with an analog signal, the signal has to be connected
on terminals 35 (+) and 36 (-) of the terminal strip in the
instrument panel.

g Important!!! When analog control is opted, the fig. 21 Output control via analog (0-10 Volt) signal
on/off-contact and the high/low-contact have higher pri-
ority (e.g. frost protection). 8.6.4 On/ off control (1 x no volt switched pair)
The heat output modulates between the minimum and
Temperature based (20 to 90 °C) set the x value of the maximum value based on the set flow temperature,
the boiler control operation parameter A to 4. To set terminal connections X29-9 and X29-10.
the ratio between voltage and the desired flow tempera- Set the x value of the boiler control operation param-
ture (see par. 13.2.5 and fig. 20). eter A to 3 (on/ off).
0 to 0.9 Volt = boiler off
1 Volt = Flow temperature set point 10 °
8 Volts = Flow temperature set point 80 °
29
 Remeha Gas 310 ECO

8.6.5 High/ low control (2 x no volt switched pairs) Output

Description
The heat output is controlled between part load (50%, signal
adjustable) and full load, by means of a two-stage 0 volts Boiler off
controller, terminal connections X29-9 and X29-10.low 0.5 volts Alarm signal/lock-out
fire - X29-7 and X29-8.high fire.Set the x value of the
1.0 volts Shut-off
boiler control operation parameter A to 2.The output
percentage on which the boiler runs on low fire, can be 2.0 - 10 volts Output between 20 and 100% or
adjusted with parameter 4 (low fire start point as per- flow temperature of 20 to 100 °
centage) in the setting mode. The ‘high fire’ percentage table 09 Analog output signal
is dependent of the maximal adjusted output, see setting
mode, parameter 6 (maximum output). During this ‘high’ This output relates to terminals X29-13 (+) and X29-14 (-).
state modulation on adjusted flow temperature is released.
8.7.6 Operation signal
8.7 Other inputs As standard the boiler is supplied with internal relays to
indicate boiler run and boiler on high fire.
8.7.1 Shut down input The relay contacts are volt free and close to confirm
As standard the boiler is supplied with a shut down operation.
interlock carrying a 24 Volt AC boiler control circuit. This For the ‘boiler on signal’ connect to terminals X27-6 and
input does not require manual re-set. X27-7.
Any external devices required to stop the boiler (e.g. For the ‘boiler high fire signal’ connect to terminals X27-4
limit switches of throttling valves, minimum gas pressure and X27-5.
switches) should be wired in series and connected to Contact load:
terminals X29-5 and X29-6, breaking the circuit will acti- - Maximum voltage: 230 volts.
vate the safety interlock and put the boiler into a shut-off - Maximum current: 1 Amp.
condition with code b **. If this input is being used,
the wire bridge must first be removed. 8.7.7 Common alarm (lock-out)
As standard the boiler is supplied with an internal
8.7.2 Lock-out input change over relay to indicate common alarm.
As standard the boiler is supplied with a lock out inter- The relay contacts are volt free and can be connected to
lock carrying a 24 Volt AC boiler control circuit. This confirm operation with closed or open contacts.
input requires manual re-set if activated. For the alarm signal indication “closed contacts” connect
Any external devices required to stop the boiler (e.g. to terminals X27-3 and X27-1.
maximum gas pressure switch) must be volt free and For the alarm signal indication “open contacts” connect
should be wired in series and connected to terminals to terminals X27-3 and X27-2.
X29-1 and X29-2. Breaking the circuit will activate the Contact load:
safety interlock and put the boiler into a lock out condi- - Maximum voltage: 230 volts.
tion, failure code 12 requiring manual intervention to - Maximum current: 1 Amp.
re-set it. If this input is being used, the wire bridge must
first be removed. 8.7.8 External gas valve control
As standard the boiler is supplied with an internal
8.7.3 External interlock relay that is energised when there is a heat demand,
As standard the boiler is supplied with an external inter- this applies a 230V supply to terminals X27-15 (live)
lock carrying a 24 Volt AC boiler control circuit. and X27-14 (neutral). The relay is de-energised when
Any external devices required to prevent the boiler from the gas valve multiblock closes at the end of the heat
operating (e.g. boiler room ventilation air flow switch, or demand. Additional external interlocks (by others) may
butterfly valve end switch) must be volt free and should be required in a multi boiler installation.

g
be wired in series and connected to terminals X29-3 and
X29-4, breaking the circuit will prevent the boiler from Important!! This supply cannot be used to con-
starting. Boiler does not go to lockout. trol an external gas valve if it supplies other appliances.
If this interlock is being used, the wire bridge must first Contact load:
be removed. - External gas valve voltage: 230 Volts.
- Maximum current: 1 Amp.
8.7.4 Other outputs

8.7.5 Analog output

Depending on the option settings in the service level
(see section 13.2.13), the analog output signal is able to
transmit the following values:

30
8.8 Options/ accessories The return butterfly valve must be connected to termi-
nals X27-11 (neutral), X27-12 (power close) and X27-13
8.8.1 System pressure sensor (power open) on the 230-volt terminal strip.
The system pressure sensor shuts down the boiler The end switch on the return butterfly valve must be
(with shut-off code b ^@) when the minimum water connected to the external interlock terminals X29-3 and
pressure is reached (adjustable 0.8 to 6.0 bar - factory X29-4 (first remove bridge). After boiler shut-off, the
setting 1.0 bar, see section 13.2.12). The hydraulic pres- power supply will remain on X27-13 keeping the valve
sure sensor must be connected to the 5-pin female plug open during the post-circulation time of the pump (set
X22 on the 24-volt terminal strip. point code 2), then switch to X27-12 to close the valve
Press the s and e keys simultaneously for two sec- (this remains valid even if no pump has been connected
onds to indicate the presence of the hydraulic pressure to the control box).
sensor in the control unit. Also see section 8.9.1 and section 13.1.2

g Important!!! This function is only operational 8.9 Other connections

when a system pressure sensor is connected and acti-
vated (parameter J). 8.9.1 Boiler or System pump control
The Remeha Gas 310 ECO has a facility to provide a
8.8.2 Gas valve leak proving system (VPS) power supply (230V Max 2 amps) to run or control an
The gas valve leak proving system checks and operates external boiler or system pump.
the safety valves on the gas valve multiblock. The test The boiler control will run the pump once every 24 hours
takes place before the boiler pre-ventilation phase. In when the boiler not enabled to prevent sticking and
the event of a leak between the two safety valves in the will also provide a run on period at the end of a heat
gas valve multiblock, the boiler will lock out and show demand (parameter @, see section 13.1.2).

g Important!!
failure code 89 or 90 on the display.
The gas valve leak proving system must be fitted to the phase/ neutral sensitive!

g Important!!
boiler and connected to the 3-pin female plug X21 on
the 24 volt terminal strip and the control set to recog- For multiple boiler installations
nise it using parameter J in setting mode (see section the system pump cannot use this power supply. If the
13.2.13). boiler shuts down the system pump will also shut down.

g Important!!! This function is only operational Contact load terminals X27-9 (neutral) and X27-10 (live):
when a gas valve leak proving system is connected and Voltage : 230 volts
activated (parameter J). Maximum current : 2 A.
The hydraulic resistance of the boiler at a dT of 11°
8.8.3 Minimum gas pressure switch and 20° for the various output variants of the Remeha
The minimum gas pressure switch (set to 17 mbar) Gas 310 ECO can be found in table 02, section 4.2
shuts down the boiler (shut-off code b @^) if the
inlet gas pressure becomes too low. The minimum gas 8.9.2 Frost protection
pressure switch must be connected to the 3-pin female The boiler must be installed in a frost-free area to pre-
plug X21 on the 24-volt terminal strip. The connection is vent freezing of the condensate drain.
automatically detected by the boiler control. If the temperature of the heating water drops too low the
integrated boiler protection activates under the following
8.8.4 Flue gas damper conditions.
In a cascade configuration, the flue gas damper pre- If the boiler flow temperature:
vents flue gases from being discharged through a non- - is below 7°, the external heating pump connected to
operating boiler. Therefore, the boiler can be installed the boiler is switched on by the control unit;
on an over pressure flue system (Over pressure flue - is below 3°, the boiler is switched on at minimum
systems enable much smaller diameter flue ducts to be capacity;
used). - exceeds 10°, the boiler and heating pump are
The flue gas damper must be connected to the 4-pin switched off again. The pump now has a fixed post-
female plug X14 on the 230-volt terminal strip. circulation time of 15 minutes.

8.8.5 Return butterfly valve (not Broag supply) g Important!! This frost protection only pro-
A butterfly valve can be installed in the return for each tects the boiler. Other measures must be employed to
boiler module to ensure that a non-operating boiler mod- protect the building and system and will depend which
ule is hydraulically disconnected from the system. When parameters are set or what form of external controls are
the return butterfly valve is fully open, the valve end in use.
switch contact is closed, allowing the boiler to run.

31
 Remeha Gas 310 ECO

9 INSTALLATION INSTRUCTIONS FOR GAS INSTALLER

9.1 Gas connection 9.3 Gas/ air ratio control

The Gas 310 is suitable for use with natural gas only. The boiler has a pressure differential gas/ air ratio
The gas connection is at the top of the boiler (see fig. control. This gas/ air ratio control maintains the correct
02). The boiler is fitted with a gas filter as standard to balance of gas and air quantities to the burner at a con-
prevent dirt from contaminating the gas valve or burner stant level under variable loads. This ensures clean and
assembly. An isolating main gas cock must be installed reliable combustion and high part load efficiency across
in the vicinity of the boiler. the entire load range.
Minimum airflow is monitored before a start by an air
9.2 Gas pressures pressure differential sensor.
The boiler main gas valve can accept an inlet pressure
up to 100 mbars, but MUST have a Min of 17mbar at
the isolating valve when the boiler is operating at max
output. Pressures below this level can result in lockouts
(for multi gas appliance installations this Min pressure
must be available at each boiler with all gas appliances
firing on max output).

10 COMMISSIONING

10.1 Initial lighting 17.a Check and correct, if necessary, the boiler for

w
correct gas/air ratio set-up. Checking takes
1. Isolate main power supply. place on full and part load, adjustment takes
2. Remove the casings on the inspection side. place only on the gas valve multiblock. For
3. Open the main gas valve. checking and adjusting are required: an elec-
4. Check the electrical connections including earth. tronical CO2-gauge (on the basis of O2) and a
5. Fill the boiler and the system with water gas pressure gauge.
(approximate 1.0 bar). Note that the opening (see fig. 23) around the
6. Vent the system. measuring probe is sealed properly during
7. Fill the siphon with water. measurement.
8. Check the flue gas discharge connection and air Note also that measuring the O2 levels in the
inlet duct or air supply connection. flue gas is necessary, because direct measure-
9. Vent the gas pipe. ment of CO2 can lead to inaccuracies due to
10. Open the gas cock to the boiler. varying CO2 levels in the natural gas.
11. Check the inlet gas pressure PI (see fig. 22). Connect the gas pressure meter between meas-
12. Check the gas connection for gas tightness. uring point PG on the underside of the gas valve
13. Switch on the mains supply to the boiler. multiblock and measuring point PL on the ven-
14. Switch on the boiler operating switch. turi (see fig. 22), ensuring the connections are
15. Switch on the heating pump and check the gas tight.
installation position and direction of rotation. 17.b Run the boiler at full load (forced mode 'high') by
16. Adjust the boiler controls to heat demand. pressing the m- and [+]-key simultaneously for
17. The boiler should start with the run sequence 2 seconds. The letter h will now appear on the
indicated in the code-display: display.
17.c When full load is reached, measure dP gas at
0= Boiler neutral position. measuring point P on the underside of the gas
5= Butterfly valve opens, if connected; valve multiblock and at the measuring point PL
Wait for minimum gas pressure switch to close; on the venturi and compare to the value in table
Neutral position check of air pressure differential sensor; 10. Adjust if necessary using the ß adjust-
Flue gas damper opens (if applicable); The fan runs ment screw on the gas valve multiblock.
and the boiler waits until sufficient air transport is estab- 17.d Check CO2-percentage (O2-percentage) against
lished; the air pressure differential sensor must switch to table 10. If the values exceed the given toler-
guarantee sufficient airflow. ances, adjust according to fig. 22.
t= Gas valve leak proving system (if applicable). Check the flame through the inspection glass,
1= Pre-purging. the flame must not blow off.
2= Heating pump starts running; Ignition of the
gas/air mixture.
3= The burner is firing.
32
17.e Run the boiler at part load (forced mode ‘low’)
by pressing the m and [-] keys simultaneously for
2 seconds. The letter l will now appear on the
display.
17.f When part load is reached, measure dP gas at
measuring point P on the underside of the gas
valve multiblock and at measuring point PL on
the venturi and compare to the value in table
10. Adjust if necessary using the Þ adjustment
screw on the gas valve multiblock.
17.g Check CO2-percentage (O2-percentage) against
table 10. If the values exceed the given toler-
ances, adjust according to fig. 22.
Check the flame through the inspection glass,
the flame must not blow off.
Repeat the check starting from point 17 b. until the
readings match the values in the tables.
Contact our Service Department if deviations cannot be
corrected.

fig. 23 Flue gas measuring point

00.31H.79.00007

Natural gas (G20)

Full load (100%) Part load (±
20%)
Guide value CO2 9.0% 9.0%
Adjust at ± 0.5% ± 0.5%
Set to 9.0 ± 0.15% 9.0 ± 0.15%
Guide value O2 4.8% 4.8%
Adjust at ± 0.5% ± 0.5%
Set to 4.8 ± 0.25% 4.8 ± 0.25%
dP 5 sections 1300 ± 100 60 ± 10
(Pa)
dP 6 sections 1020 ± 100 42 ± 10

dP 7 sections 900 ± 100 50 ± 10

Þ Burner pressure minimum load setting
ß Burner pressure maximum load setting dP 8 sections 1350 ± 100 65 ± 10

dP 9 sections 1650 ± 100 85 ± 10

fig. 22 Gas valve multiblock adjustment points table 10 Setting data CO2 and O2
00.31H.79.00006

33
 Remeha Gas 310 ECO

17. h Remove measuring equipment and seal test 10.2 Shutdown

points. 1. Switch off the on/ off switch of the boiler. With this, a
18. Check gas leakage control and minimum gas possible boiler control will be without tension also.
pressure switch (if installed): 2. Close the gas cock.

g
Parameter J must be set to a value greater than or
equal to 8, depending on the connected options (see Important!! When the boiler is out of opera-
section 13.2.13). tion, it is not protected against frost!
Then set the gas leakage control pressure switch to
a switch pressure equal to 50% of the inlet pressure.
Check that the measured inlet pressure is not the
(higher) closing pressure.
19. Return the boiler to 'user level' by pressing the
reset key.
20. Heat the system to approximately 80ºC and
switch off the boiler.
21. Bleed the system and check the water pressure.
22. The boiler is now ready for operation.
23. Set the boiler controls to the required values.
24. Send the commissioning reports to Broag.

i Note:
The Remeha Gas 210 ECO is supplied with a number
of factory default settings that should be correct for most
installations. If other setting values are required: see
sections 13.1. and 13.2.

The following operating situations are now possible:

25.a Modulating operation: The output of the boiler
modulates on the basis of the flow temperature,
asked by the modulating control (see ‘Note’ in
point 25c and section 8.6.2).
25.b High/low operation: The boiler is operating
at part load or full load, depending on the heat
demand (see section 8.6.5). On the safety
boundaries the boiler is going to modulate.
25.c On/off operation: the boiler modulates between
minimal and maximal output on the basis of the
flow temperature pre-set on the boiler (see sec-
tion 8.6.4).

g Important!! The boiler will initially operate in

forced part load. The factory setting for forced part load
time is 30 seconds. This setting is correct if modulating
controllers are used (see point 25a). A forced part load
time of 3 minutes is recommended for on/off operation
(setting mode, parameter *, see section 13.2.3).
25.d 0-10 V operation: Depending on the adjust-
ments, two situations are possible
(see section 8.6.3):
- The given off output varies linear with the sent signal,
2V = 20%, 10V = 100%
- The given off flow temperature varies linear with the
sent signal (depending on parameters a and B);
example: 0V = 0°, 10V = 100°.
The boiler modulates on the basis of the set flow tem-
perature (setting range 20ºC to 90ºC) and a maximum
∆T protection.

34
 11 CONTROL AND SAFETY EQUIPMENT

11.1 General 11.1.1 Instrument panel layout

The boiler is supplied with a standard set of defaults The instrument panel consists of (see fig. 24):
pre-programmed for normal operation but can be tai- 1 Operation switch
lored by the Engineer to suit most site conditions. These 2 PC/ PDA connection for Recom setting and
values are set and read, using the built-in instrument monitoring
panel or with a notebook computer or PDA (with optional 3 Facility for incorporating a weather compensator
software and interface).
For security the control has three levels of access:
1. User level - free access
2. Service level - access with service code by qualified
personnel
3. Factory level - access by PC with factory code
(Remeha only)

fig. 24 Instrument panel

00.31H.79.00010 (fig. 2)

The functions of the keys and read-out windows (a to h) b. t window displaying:

are explained below. - temperatures

i
- settings
A summary of the key functions can be found in - shut-off or failure codes
section 16.1 that is helpful when stepping through the c. reset key:
modes. - reset/unlock key
a. code window: d. m key (mode key):
display at user level: - program function; use this key to select the
- operating mode 1 only digit or letter required mode
- setting mode ! digit or letter with steady dot e. s key (step key):
- read-out mode ! digit or letter with flashing - program function; use this key to select a param-
dot eter within the mode
- shut-off mode letter b f. e key (store key):
- forced mode 'HIGH' letter h - program function; store key for set data
- forced mode 'LOW' letter l g. [+] key:
- failure mode ! flashing digit (current fault) - program function; increase setting
display at service level: h. [-] key:
- failure mode ! flashing digit - program function; decrease setting
(failure memory) - switch function; manual or automatic operation
- counter mode alternating 1 + , + .
- shut-off mode ! alternating digit and dot in
first section

35
 Remeha Gas 310 ECO

11.1.2 LED indicators This is. Parameters can be changed in this mode.
The instrument panel has 4 indicating LED’s with the fol- By pressing the [+]- and [-]-keys simultaneously, the
lowing functions: boiler will return to operating mode.
- The LED above the [-] key (in the h symbol); when Following a manual override the boiler will return to nor-
illuminated green confirms the boiler is in manual mal (auto control) if no keys are used within a 15-minute
override (see section 11.2). period.
- The LED above the [e] key indicates that “24 hour
pump operation” has activated the heating pump (and 11.2.3 Forced mode ‘low’ (l [[)
the shunt pump if required). By pressing the m and [-]-key simultaneously in operat-
- The LED above the [+] key flashes if the optional ing mode, the boiler will run at minimum power. The
hydraulic pressure sensor detects that the water pres- letter l will now appear on the display. To protect the
sure is too low. boiler and the system, the flow temperature cannot
- The LED above the [s] key flashes if there is no exceed its pre-set maximum value. This is. Parameters
communication with the code key (codekey not con- can be changed in this mode.
nected). By pressing the [+]- and [-]-keys simultaneously, the
- Two LED’s flash green when there is no communica- boiler will return to operating mode.
tion anymore between codekey and control unit. The Following a manual override the boiler will return to nor-
boiler will keep on operating. Only after the power mal (auto control) if no keys are used within a 15-minute
supply was switched off and back on, the boiler will period.
refuse to operate.
11.3 Display of values
11.2 Switch function keys The display has only two digits available therefore val-
Some keys on the instrument panel have dual functions, ues over this are displayed as follows:
i.e. a programming and a switch function. - values from 00 to 99 will be indicated without any
The programming function is described in section 13. punctuation marks
The switch function (on or off) is activated by pressing - values from 100 to 199 will be indicated by a dot
down the relevant key for 2 seconds. Whether the func- between both digits e.g. )0 = 100, !0 = 110,
tion is switched on or off is indicated by the indicator for (9 = 199
the key, which is either lit or not lit, or by the appearance - values from 200 to 299 will be indicated by a dot
of a letter in the code window. behind every digit e.g. )) = for 200, !) = 210,
(( = 299
11.2.1 Manual/automatic operation - values over 300 will be indicated by showing the
If the [-] key is pressed for 2 seconds the boiler will thousands, hundreds, tens and units in separate alter-
switch on, even if there is no heat demand from an nating pairs. (see section 12.2 and 12.5)
external control. The green LED above the key is on - negative values (for instance when using an external
continuously to indicate manual heat demand (central sensor or when sensors are not connected) will be
heating bridged internally). When the [-] key is pressed indicated by a dot behind the last digit, e.g. 1)
for 2 seconds again the boiler will return to automatic indicates -10.
central heating operation (green LED off).

i During manual operation the flow temperature

cannot exceed its pre-set maximum value. This is to
protect the boiler and the system. Parameters can be
changed during manual operation.

g Important!! If an external heating pump is

not connected to the control unit, the pump will not be
switched.

11.2.2 Forced mode ‘high’ (h [[)

By pressing the m and [+]-key simultaneously in oper-
ating mode during 2 seconds, the boiler will run at
maximum power. The letter h will now appear on the
display. To protect the boiler and the system, the flow
temperature cannot exceed its pre-set maximum value.

36
 12 OPERATING MODE

12.1 Operating mode (x [[)

During normal operation the code-display shows the
status (position in cycle) of the boiler, with the t -dis-
play indicating the actual flow temperature.
The digits or letters in the code-display have the follow-
ing meaning:

Code Description
0 Standby; there is no heat demand from control system
1 Pre-ventilation (pre-ventilation time 30 seconds, post ventilation time 3 seconds)
2 Ignition
3 The burner is firing (flame detection)
4 n/a
5 Waiting mode; check for sufficient air flow using fan and air pressure differential sensor (LDS)
Control stop (burner off + post ventilation) :
- flow temperature T1 > setpoint + 5°
6 - flow temperature T1 > desired setpoint modulating control + 5°
- flow temperature T1 > parameter 1
- difference flow T1 and return T2 > 10° (factory setting); Starting condition is [ 10 °.
End of heating demand, pump run on time. During cycling prevention delay-time the boiler will remain in
7 state 7 and will not react to heat demand.
8 n/a
b Shut-off mode (see section 12.4)
h Forced full load (HIGH)
l Forced part load (LOW)
t Gas leakage control
c[l Burner cooling
table 11 Operating codes

12.2 Read-out mode (X [[)

Read-out mode is used to display various values. Press
the m key until ! appears in the code window (dot
flashes). Select the required code using the s key.

Read-out
Code Description Read-out range/comments
(e.g.)
! Flow temperature (°) actual value 80
@ Return temperature (°) actual value 70
# Flue gas temperature (°) actual value 85
% Heat exchanger temperature (°) actual value 75
^ Flow temperature (set point, °) Calculated value 84
0x = on/off-contact open
Heat demand status (1 digit) and air pres-
st 1x = on/off contact closed
& sure differential sensor (LDS, 2nd digit) x0 = air pressure differential sensor open 11
x1 = air pressure differential sensor
closed

37
 Remeha Gas 310 ECO

Switch-on temperature for central heating

* demanded value 40
operation (°)
Requested (and permitted by boiler con-
trol) output (%) is displayed, irrespective of 00 - )0 (=100%)
( 90
boiler control setting. demanded value

A Calculated output (%) 10 - )0 (=100) (actual value) 87

B Analog input voltage (volts) 00 - )0 (=100) ((actual value) 45
C Control strategy (see section 12.3) 01 - 06 02
15(=1.5
00 - 60(÷ 10 for bar), with hydraulic
Current water pressure bar)
D pressure sensor only (optional);
with sensor not connected: 00

E N/a

Fan speed 40
F 06 - 60
00(=4000*)
Ionisation level
G 00 - 99(x 0.1 uA) 03

H Unique boiler code 10 - 98

pressure difference over air pressure dif-
I ferential sensor 00 - 80 (x 0,1 mbar) 13

table 12 Read-out mode user level

* The displayed value has 4 digits. The display alter- 12.4 Shut-off (b xx)
nately flashes from F 40 to . 00 with code indi-
cating the value being read. In this example: fan speed 12.4.1 Shut-off
4000 r.p.m. During shut-off, the code window displays b and the
t window indicates the shut-off code.

g
12.3 Control strategy c
During normal operation, the boiler control can operate Important!! Shut-off is a normal boiler oper-
according to a specific strategy. Most control strategies ating function and does not represent a boiler failure.
are meant to keep the boiler burning for as long as pos- However, this may indicate a system problem or an
sible, regardless of changes in flow or flow problems, incorrect parameter setting.
etc.
The control strategies can be viewed in read-out mode 12.4.2 Shut-off mode
with code c. In shut-off mode last shut-off and corresponding operat-
1 = modulate up (control below ionisation limit) ing codes can be reviewed. With PC (version Recom
2 = modulate down (maximum temperature difference PC and higher) or PDA the last six shut-off’s can be
between flow and return) reviewed.
3 = minimum output (return temperature higher than During this particular mode both dots in the t window
flow temperature) flash.
4 = modulate down (flue gas temperature too high) The last shut-off and corresponding operating codes
5 = pump/ boiler on (frost protection) and applicable temperatures are stored in the micro-
6 = zero-flow protection 2 (minimum output) processor memory and can be read out in shut-off mode
7 = zero-flow protection 1 (modulate down) as follows:
8 = boiler block temperature too high (control stop) - Enter the service code c 12 (see section 13.2).
- Press the m key until b appears in the code window
(flashing digit with flashing dot).
Select the required step with the s key.

38
 Code t Description
1 37 Shut-off code (see table 22)
2 03 Operating code, at shut-off intervention (section 12.1)
3 53 Flow temperature, at shut-off intervention
4 40 Return temperature, at shut-off intervention
5 58 Flue gas temperature, at shut-off intervention
6 63 Boiler block temperature, at shut-off intervention
7+8 00 Time from shut-off intervention (with PC software only)
9 18 Ionisation level (analog), at shut-off intervention
a 11 Operating hours (hundred thousands and ten thousands)
b 80 Operating hours (thousands and hundreds)
c 26 Operating hours (tens and units)
d 26 Fan speed at shut-off intervention (thousands and hundreds)
e 67 Fan speed at shut-off intervention (tens and units)
table 13 Shut-off mode in service level

The letters and numbers in the code window and the t The counter has 6 digits. The code window displays the
window are explained in appendix 16.2. following (in sequence):
code figure, ,, . with a value in the t window.
12.5 Counter mode (1, , and .) (service level)
Meaning of readout in t window
12.5.1 General Code Total number or total number of hours in
The boiler control records various data on the combus- figure hundred thousands and ten thousands
tion trend of the boiler. This data can be read out in
Total number or total number of hours in
counter mode. The following data can be read out: , thousands and hundreds
- Hours run
- Number of successful ignition attempts Total number or total number of hours in
. tens and units
- Total number of start attempts
- Number of shunt pump operating hours table 15 Counter mode readout
- Number of shunt pump starts
- Number of internal resets (control unit) Example:
- Number of hours energised (control unit) code window t window value
1 21 210000
12.5.2 Reading out counter mode , 57 5700
First enter the service code c 12 (see section 13.2). . 53 53
Press the m key until the required code (see table 14) This means 215753 Hours run
appears in the code window.

1 Hours run
2 Number of successful ignition attempts
3 Total number of start attempts
4 Number of shunt pump operating hours
5 Number of shunt pump starts
6 Number of internal resets (control unit)
7 Number of hours energised (control unit)
table 14 Counter mode codes

39
 Remeha Gas 310 ECO

13 SETTING MODE

13.1 User level setting mode (X [[)

Setting mode is used to change various settings to suit individual requirements. The required code is selected by
pressing the m key until ! appears in the code window. Select the required code with the s key. Now press the [+]
key to increase a setting or the [-] key to decrease a setting.
Press the e key to store the new setting. The new value will flash twice in the t window to confirm the setting.

Factory
Code Description Setting range and explanation if necessary
setting

Flow temperature setpoint, see section 20 to 90°

! 13.1.1 (boiler thermostat setting, also top heating 90
curve setting if external sensor is used)
00 = pump run on 10 seconds
@ Pump run on setting, see section 13.1.2 05
01 - 15 = pump run on in minutes
99 = continuous pump operation
A Boiler control setting, see section 13.1.3 51
Control mode (modulating-on/off-etc.)
table 16 Settings mode user level

g Important!! Changing @ and A should only be on design engineers advice.

13.1.1 Flow temperature (!)

The required flow temperature is adjustable from 20 to 90°.
The following diagram shows a typical example of this procedure:

fig. 25 Setting flow temperature

pdf

40
13.1.2 Pump run on time (@) Example: boiler control 41 indicates that the boiler is
Pump run on time can be adjusted (Please refer to controlled by means of a 0 -10 volt signal modulated on
installation contractor). the basis of flow temperature (x = 4). Heat demand is
- Press the m-key until the digit ! (with dot) appears in on (y = 1).
the code-display.
- Press the s-key until the digit @ (with dot) 13.2 Setting mode service level (only for the quali-
appears in the code-display. fied service engineer) (X [[)
- Set the required value, using the [+]- and [-]-keys. To prevent accidental, unauthorised access by non-qual-
- Press the e-key to store the new value (value will ified persons the control system requires an input code
flash twice). to gain access to the second level of boiler control.
- Press the reset-key to return to operating mode. - Press the m- and s-keys simultaneously and hold.
The code-display now shows a letter c with a ran-
Code t Description dom number in the t-display.
- While holding both keys pressed, set the t-display
@ 00 Pump runs on for 10 seconds to 12, using the [+]- or [-]-keys and press the e-
Pump runs on for 1 to 15 minutes key.
@ xx (xx = 01 to 15) - The display will flash twice, confirming acceptance of
the access code.
@ 99 Continuous pump operation
- Release the keys and c12 will disappear from the
table 17 Adjustments pump run on time display.

13.1.3 Boiler control (A) g Important!! Changing the pre-set values

Setting mode, parameter A, can be set to different val- without reference to the tables contained in this manual
ues (see table 18). may result in incorrect boiler operation.
Proceed as follows to change the boiler control:
- Press the m key until the number ! (with dot) - The service settings can now be reached by pressing
appears in the code window. the m-key until the digit ! (with dot) appears in the
- Press the s key until the letter A (with dot) code-display. Set the required value, using the s-
appears in the code window. key.
- Use the [+] and/or [-] keys to specify the required set- - To delete the service code, press the reset-key once.
ting. - If no keys are pressed over a 15-minute period the
- Press the e key to store the new setting (flashes 2x service code will delete automatically.
to confirm).
- Press the reset key once to return to operating mode.

Code t Description
x = 2,
A x0 Heat demand off 3, 4 or
5
x = 2,
x1 Heat demand on 3, 4 or
5

On/off and High/low y = 0

2y
or 1
On/off and modulated on y = 0
3y flow temperature or 1
External 0-10V analog y = 0
4y signal on temperature or 1
External 0-10V analog y = 0
5y signal on output % or 1
table 18 Boiler control settings

41
 Remeha Gas 310 ECO

Code Description Setting range Factory setting

Minimum fan speed (hundreds), see sec- 5 sections: 1500 rpm
$ tion 13.2.1 06 - 60 (x 100 rpm) 6 sections: 1600 rpm
7 sections: 1100 rpm
Minimum fan speed (units), see section 8 sections: 1100 rpm
% 13.2.1 00 - 99 (x 1 rpm)
9 sections: 1200 rpm
Maximum fan speed (hundreds), see sec- 5 sections: 5500 rpm
^ tion 13.2.2 10 - 60 (x 100 rpm) 6 sections: 5600 rpm
7 sections: 3650 rpm
Maximum fan speed (units), see section 8 sections: 4000 rpm
& 13.2.2 00 - 99 (x 1 rpm)
9 sections: 4500 rpm
Forced part load running time, see section
* 13.2.3 01 - 30 (x 10 sec.) 03
Cycling prevention delay-time, see section
( 13.2.4 01 - 30 (x 10 sec.) 02 (=20 sec.)
Required flow temperature at 0 volts (ana-
a log signal), see section 13.2.5 5) (=-50) to 50 (°) 00
Required flow temperature at 10 volts (ana-
B log signal), see section 13.2.5 50 to $( (=249) (°) )0 (= 100)
5 sections: 3500 rpm
6 sections: 3900 rpm
Switch point high/low operation signal, see
C 06 - 60 (x 100 rpm) 7 sections: 2500 rpm
section 13.2.6
8 sections: 2700 rpm
9 sections: 3500 rpm

Shunt pump post-circulation time, see sec- 00 = 10sec

D tion 13.2.7 01 to 15 = min 00
99 = continuous
dT from control stop point to start point,
E 05 - 30 (°) 10
see section 13.2.8
Maximum flue gas temperature, see sec-
F tion 13.2.9 80 - @0 (=120) (°) @0 (= 120)
High limit temperature setpoint, see section
G 13.2.10 90 - !0 (=110) (°) )0= 100)

Modulation start point dT, see section

H 10 - 30 (°) 25
13.2.11
Minimum water pressure, see section
I 13.2.12 00 - 60 (x 0.1 bar) 08 (=0.8 bar)
Adjustments options/accessories, see sec-
J tion 13.2.13 00 - 15 00
5 sections: 1500 rpm
6 sections: 1600 rpm
"Low" fan speed with H/L control
L 06 - 60 (x 100) 7 sections: 1100 rpm
(parameter A = 21, see section 13.2.14
8 sections: 1100 rpm
9 sections: 1200 rpm
Boiler type;
depends on output vari-
P Appears only after replacing the control 50 - 98 ant
unit
table 19 Service level setting mode

42
13.2.1 Minimum fan speed ($ and 5)
Parameter $, adjustable between 06 and 60 (x 100
rpm) and parameter 5, adjustable between 0 and 100
(x 1 rpm).
This setting is only active if setting 21 has been
selected in the boiler control: high/low control (see sec-
tion 13.1.3). The value relates to the percentage output
when the boiler is running at 'low'.
The percentage 'high' position depends on the set maxi-
mum central heating speed.

g Important!! Only make changes after con-

sulting Remeha sales support department.

13.2.2 Maximum fan speed (^ and 7)

Parameter ^, Adjustable between 10 and 60 (x100
rpm) and parameter 7 adjustable between 0 and 100
(x 1 rpm).
The maximum speed can be limited at a lower value in fig. 26 Temperature control via analog (0-10 Volt)
the software by changing parameters ^ and 7. signal

g
pdf

Important!! Only make changes after con-

sulting Remeha sales support department. 13.2.6 High operation signal switch point (C)
Parameter C, adjustable between 0 and 60 (x 100)
13.2.3 Forced part load time (*) rpm.
Parameter Adjustable between 0 and 300 seconds.
The boiler always starts with a specified output for a 13.2.7 Shunt pump post-circulation time (D)
certain time. The boiler can then be sent to the minimum Parameter D, setting 00 = 10 sec; 99 = continu-
position (20% of output) for a specific period, independ- ous and adjustable between 01 and 15 = number
ent of the heat demand. of minutes.
Continuous water circulation is advisable if there is a
13.2.4 Cycling prevention delay time (() danger of the heating system freezing up.
Parameter *, Adjustable between 0 and 300 seconds.
This value sets a minimum off time following a control 13.2.8 dT from control stop point to start point (E)
stop / end of a heat demand to prevent cycling taking Parameter E, adjustable from 5 to 20°.
place. When after this delay time flow temperature lies This value sets the flow temperature at which the boiler
less than 5° above return temperature (check on water will cut back in after a control stop.
flow), the boiler will restart. The boiler will always go to a control stop when the flow
temperature equals the flow setpoint temperature + 5°.
13.2.5 Required flow temperature at 0 - 10 volts (a The dT defines when the burner is switched on again.
and B) A value of 10° indicates that the temperature has to
Start point (0 volts): parameter a, adjustable between drop 5° below the calculated flow temperature set point
-50° and +50°. before the boiler starts to run again.
This value sets the required flow temperature at 0-volt Cut back in temperature = flow setpoint (80) + 5 -
signal input. parameter E (10), i.e. 80 + 5 - 10 = 75°.

End point (10 volts): parameter B, adjustable between 13.2.9 Maximum flue gas temperature (F)
+51° and +249°. Parameter F, adjustable between 80 and 120°.
This value sets the required flow temperature at 10-volt This value sets the maximum operating flue gas tem-
signal input (restricted by the maximum flow tempera- perature - for use with PVC flue systems.
ture setpoint and the maximum output).
13.2.10 Maximum temperature setting (G)
These settings only apply if boiler control 41 has Parameter G, adjustable between 90 and 110°.
been selected: ‘external analog input 0-10V on the basis This value sets the high limit temperature at which the
of flow temperature’. boiler will shutdown in a lockout condition requiring
manual intervention.

43
 Remeha Gas 310 ECO

g Important!! If the factory setting is reduced, a Examples:

corresponding reduction in flow setpoint will be required - Factory setting is 0: the analog output will be in %.
otherwise the min flow rate may be effected. - Water pressure sensor (1) and valve leak proving
system (8) options are connected: parameter J is
13.2.11 Modulation start point at dT (H) set to (1) + (8) = 09.
Parameter H, adjustable between 10 and 30°.
This value sets the flow/ return dT point at which the 13.2.14 “Low” speed with H/L control (L)
control modulation begins. The boiler starts to modu- Parameter L, adjustable between 10 and 60 (x 100)
late at the setpoint and will be at minimum output if the rpm.
dT continues to rise to 40°. At 45° the boiler will shut This setting only applies if the boiler is in High/Low con-
(shut-off code b #)). For installations with low flow trol mode (parameter A = 21).
rates the starting point modulation can be brought for-
ward (i.e. 15°), closer matching boiler output to system 13.2.15 Boiler type (P)
demand. In systems with small volume flows the modu- This code appears only when replacing the control unit.
lation start point can be brought forward. The boiler is After placing the new control unit, code P05 appears
better equipped to anticipate low heat demand. automatically in the display. The value 05 must be
The factory setpoint should be correct for most instal- changed in to the correct value for your boiler type (see
lations. The start point should only be changed if abso- mounting-instructions of the service unit).
lutely necessary.

13.2.12 Minimum water pressure (I)

Parameter I, adjustable between 0 and 6 bar.
This setting only applies if an optional hydraulic pres-
sure sensor has been connected.
This value sets the point at which the boiler will shut-
down if the system pressure falls below it. The boiler will
resume normal operation when pressure is restored.

13.2.13 Adjustments options/ accessories (J)

Parameter J, adjustable between 0 and 15.
This setting is only applicable if options from table 20
are connected to the boiler. The control unit detects
which options have been connected by means of the
value of this parameter and adjusts the boiler control on
this basis.
The required feedback message (as output in % or
as temperature in °) can also be selected here if the
(standard) analog output is used. A list of values that
have been assigned to specific options can be found in
table 20. Adding together the values of the options used
gives the parameter J.

Options Value Sum

Hydraulic pressure sensor 1
Analog output:
Heat output (%) 0
Temperature (°) 4
Gas leakage control VPS 8
Parameter J: …
table 20 Adjustments options/accessories

44
 14 FAULT-FINDING

14.1 General Operating hours (thousands and hun-

If the boiler does not start up, check the following: b 80 dreds)
- Is a 230 V supply present;
c 26 Operating hours (tens and units)
- Is there a heat demand;
- Has the boiler control (parameter 3) been set cor- Fan speed at failure (thousands and
rectly (see section 13.1.3). d 26 hundreds)
e 67 Fan speed at failure (tens and units)
If the above items have been verified and the boiler
does not start, this indicates a failure. table 21 Service level failure mode
In the case of a failure signal, both the code window
and the t window will flash. Except for failure F03 In the above example:
(does not flash). The return temperature sensor is defective (= failure

g
code 37), during burning (= operating code 03)
Important!! with a flow temperature of 53°, return temperature of
Keep a record of the failure code before resetting 40° and a flue gas temperature of 58°.
(numbers, including flashing ones and dots) and quote The boiler block temperature was 63 °, the ionisation
it when asking for support. The failure code is needed level was 1.8 uA, the boiler had 118026 operating hours
to find the cause of the fault quickly and correctly. For and a speed of 2667 rpm.
further details on the various failure codes and possible The time elapsed after the failure can only be read on a
causes refer to table 22. PC or laptop.

i Apart from failure codes (lock-out), the system 14.3 Cooling mode
also knows shut-off codes (see section 12.4). In the lat- This mode enables maintenance on the burner and/ or
ter case only the two dots in the t window will flash the heat exchanger to be carried out more efficiently.
and the code window will display b. A shut-off code In this mode, the fan runs at maximum speed for two
may refer to a system problem or incorrect setting. minutes, which cools down the boiler rapidly. When this
mode is active, the system does not respond to heat
14.2 Failure mode (1 [[) (service level) demands.

g
The latest failure and corresponding operating codes
and applicable temperatures are stored in the micro- Important!! This mode can only be activat-
processor memory and can be read out in failure mode ed if there is no heat demand on the boiler.
as follows: The code c[l indicates that the mode is active (
- Enter the service code c 12 (see section 13.2). c[l for cooling).
- Press the m key until 1 appears in the code window
(digit flashes). The mode is activated by pressing the s and [+] keys
- Select the required step with the s key. simultaneously (during normal operating status with no
heat demand).
Code t Description The mode can be terminated prematurely by pressing
the [+] and [-] keys simultaneously.
1 37 Failure code (see table 22)
Operating code, with failure interven- 14.4 Summary of failures (lock-out)
2 03 tion (section 12.1) In the case of the following failures, note the dots in
Flow temperature, with failure inter- between the numbers ()0 = 100. )1 = 101 and
3 53 vention )2 = 102, see section 11.3).
Return temperature, with failure inter-
4 40 vention
Flue gas temperature, with failure
5 58 intervention
6 63 Boiler block temperature
7+ Time from failure (with PC software
00 only)
8
9 18 Ionisation level (analog)
Operating hours (hundred thousands
a 11 and ten thousands)

45
 Remeha Gas 310 ECO

Failure Description Cause/check points

- Burner glows as a result of a high CO2 percentage.
Flame simulation, (flame - Check the combined ignition/ionisation electrode (gap should be 3 to
00 detected when control is in the 4 mm apart).
off position) - Gas valve multiblock is leaking or is stuck in the open position.
Check and replace valve.
Check:
01 Short circuit in 24V circuit - Wiring to sensors
- Wiring to gas valve multiblock.
a. No ignition spark. Check:
- Connection of ignition cable and spark plug cover
- Ignition cable and electrode for 'breakdown'
- For 'flash over' between spark plug cover and earth
- Electrode distance, should be 3 to 4 mm between pins
- Condition of burner set (burner set/ electrode seal)
- Earth.

b. Ignition spark present, but no flame. Check the following:

- The gas cock is open
No flame or ionisation (after 5 - There is sufficient inlet gas pressure (20 - 30 mbar)
02 start attempts) - The gas pipe has been bled
- The gas valve multiblock is energised during ignition and actually
opens
- The electrode is clean and fitted correctly
- The gas pipe is not blocked/ fitted incorrectly
- The air supply or flue gas discharge is not blocked/fitted incorrectly
- The gas/ air mixture is set correctly.

c. There is a flame, but there is insufficient ionisation (< 2 uA). Check:

- The condition of the electrode and earth
- The temperature sensors for leakage current
Control unit does not recognise gas valve multiblock.
Check the following:
03 Gas valve multiblock defective - The wiring on the gas valve multiblock has been connected (cor-
rectly)
- The gas valve multiblock is not defective (burnt out/ short-circuit).
F03
(does Fuse 3 defective Replace fuse 3
not flash)
Mains voltage has been disconnected during lock-out.
04 Permanently locked out
Solution: reset (original lock-out usually returns automatically).
Fault in control unit or fault due to EMC influences
No processor handshake (or
05 Reset first, if fault persists replace control unit.
external influences)
If fault still persists, locate and remove possible external EMC sources.
Check the wiring of the temperature sensors.
Input failure; sensors are short
06 If fault persists, replace control unit.
circuiting
If fault still persists, locate and remove possible EMC sources.
07 Gas valve multiblock relay fault Gas valve multiblock defective or not connected
Check:
Air pressure differential sensor
08 - The air supply or flue gas discharge for blockages/ installation faults
does not maintain check level
- The air pressure differential switch and connections.
Check:
Fault on internal communica-
- The multiple wire cable in the instrument panel for short circuit
11 tion bus (I2C-bus) when reading
- For moisture on the display
EPROM
- Find and remove any EMC sources.

46
 - Maximum thermostat (= external protection), connected to terminals
X29-1 and X29-2 on the terminal strip, has tripped or wire bridge has
12 Locked input open
been removed
- Fuse F3 on automatic burner unit is defective.
17 Gas valve multiblock protection Gas valve multiblock defective or not connected

Check:
Flow temperature too high - Flow
18 - System has been correctly bled
- Temperature sensors for deviations
- Water pressure in the system.
Check:
- Parameters
20 Excessive fan speed
- Whether fan cable is defective or making poor contact.
If failure persists, fan or control unit may be defective.
- Fan defective
28 Fan not operating - Fan cable or connector is corroded, resulting in absence of voltage
or control signal.
- Check the fan cable connectors on both the fan and the automatic
Fan keeps running or signal is burner unit side
29 incorrect - Fan electronics defective
- High natural draught.
Check:
- Flow
30 Max. dT exceeded - System has been correctly bled
- Water pressure in the system.
31 Temperature sensor fault Short circuit of flow temperature sensor.
32 Temperature sensor fault Short circuit of return temperature sensor.
35 Temperature sensor fault Short circuit of flue gas temperature sensor.
36 Temperature sensor fault Flow temperature sensor not connected or defective.
37 Temperature sensor fault Return temperature sensor not connected or defective.
Air pressure differential sensor - Check the connecting cable of the air pressure differential sensor
38 short circuited - The air pressure differential sensor is defective or not connected
- Check the air pressure differential sensor connecting cable for short-
Air pressure differential sensor
39 circuiting, etc.
open
- Air pressure differential sensor is defective
40 Temperature sensor fault Flue gas temperature sensor not connected or defective.
One or more parameters are
43 The input of the parameter (s) is incorrect.
out of limits
- Check the hydraulic pressure sensor connecting cable for short cir-
Hydraulic pressure sensor
45 cuit etc.
short circuited
- Hydraulic pressure sensor is defective
Hydraulic pressure sensor - Check the connecting cable of the hydraulic pressure sensor
46 open - The hydraulic pressure sensor is defective or not connected
Maximum flue gas temperature
52 Check the heat exchanger for fouling on the flue gas side.
exceeded
Air pressure differential sensor not opening. Check the following:
- Is the air pressure differential switch defective
Air pressure differential sensor
61 - Has the wiring short circuited
not opening
- Check for signs of external thermal draught in the flue gas discharge
duct.

47
 Remeha Gas 310 ECO

- Flue gas recirculation. Check flue gas discharge system for installa-
Lack of ionisation during opera-
tion faults and heat exchanger for possible leaks
77 tion (after 4 restarts during 1
- Insufficient air flow due to blockage
heat demand)
- Check the boiler settings.
Check:
Boiler block temperature too - The heating pump is running
83 high - There is sufficient water flow through the boiler
- The water pressure is > 0.8 bar.
The VPS gas leakage control unit has detected a leak. Check for exter-
89 Gas leak VA1 (optional)
nal leaks, otherwise replace gas valve multiblock.

The VPS gas leakage control unit has detected a leak. Check for exter-
90 Gas leak VA2 (optional)
nal leaks, otherwise replace gas valve multiblock.

Air pressure differential sensor fault during pre-ventilation (after 4

restarts).
Check the following:
Air pressure differential sensor
91 - Is the air pressure differential switch defective
fault
- Has the wiring short circuited
- Check for signs of external thermal draught in the flue gas discharge
duct.
Check:
Boiler block temperature > flow - The heating pump is operating
94 temperature + hysteresis - There is sufficient water flow through the boiler
- The water pressure is > 0.8 bar.
95 Temperature sensor fault Short circuit of boiler block sensor.
96 Temperature sensor fault Boiler shut-off sensor not connected or defective.
Check:
Boiler block temperature too - The heating pump is operating
97 high - There is sufficient water flow through the boiler
- The water pressure is > 0.8 bar.
Proceed as follows with all non-listed codes:
Other - Press reset once
Control unit fault
codes - Check that the wiring is not short circuited
- If the fault persists, contact our Service Department.
table 22 Failure codes

48
 15 INSPECTION AND MAINTENANCE INSTRUCTIONS

15.1 General If ionisation level < 3 µA dc or not present, check:

The Remeha Gas 310 ECO has been designed to need - Is flame shape stable and colour as described in
minimum maintenance, but to ensure optimum efficiency commissioning instructions.
we advise that once a year the boiler should be checked - Check ignition probe earth.
and if necessary cleaned and reset. - Check condition of ignition/ ionisation probe replace if
All service and maintenance must be carried out by a necessary.
qualified Engineer with the relevant training and certifi- - Replace electrode at least every 2 years.
cation (ie CORGI - ACOPS - etc.). - Clean any oxides/deposits with sandpaper or fine
emery cloth.
15.2 Cooling mode - Check shape of probe and ignition gap, i.e. 3 to 4 mm
This mode enables maintenance on the burner and/ or (see fig. 35).
the heat exchanger to be carried out more efficiently. - Check temperature sensors for resistance values
In this mode, the fann runs at maximum speed for two against fig. 27 (humidity on sensors).
minutes, which cools down the boiler rapidly. When this - Check and clean if necessary the gas filter.
mode is active, the system does not respond to heat - Check air box and dirt trap (see section 15.4.1).
demands.

g Important!! This mode can only be activat-

ed if there is no heat demand on the boiler.
The code c[l indicates that the mode is active
(c[l for cooling; c in the left-hand display section,
[ in the middle section and l in the right-hand section).

The mode is activated by pressing the s and [+] keys

simultaneously (during normal operating status with no
heat demand).
The mode can be terminated prematurely by pressing
the [+] and [-] keys simultaneously.

15.3 Annual Inspection

The annual inspection of the Remeha Gas 310 as fol-
lows:
- Check combustion characteristics, full and part load fig. 27 Sensor resistance graph
(see section 10.1).
Note: When checking combustion the C02 levels should 15.4 Maintenance
be in accordance with the values in table 10 with a If during the annual inspection combustion results
tolerance of +/- 0.5%. If the levels are outside these indicate that the boiler is no longer operating at the
tolerances, adjustment to the levels must be made in optimum level, additional maintenance should be
accordance with a tolerance of +/- 0.15%. carried out as follows:
- Check flue gas temperature. If flue gas temperature
is more than 30°C above the boiler return water tem- NOTE:
perature the heat exchanger must be cleaned (see Please ensure that the gas supply and mains power
par. 15.4.5). supply is isolated before any maintenance work is car-
- Check/clean the condensate siphon (refill with clean ried out on the boiler.
water). Care should be taken when stripping the boiler for main-
- Check for leaks (waterside, flue gas side and gas tenance making sure that all parts nuts, washers and
soundness). gaskets etc. are kept safe, clean and dry for re-assem-
- Check flue and air inlet system is clear and gas/ bly. Following maintenance/ cleaning, the boiler should
water tight. be re-assembled in the reverse order re-placing gaskets
- Check system pressure. and joints where found necessary.
- Check control settings.
- Check boiler parameters.
- Check ionisation level, minimum 3 µA dc (see 12.2,
parameter G).

49
 Remeha Gas 310 ECO

All general cleaning should be carried out with 15.4.3 Cleaning the venturi
compressed air, a soft brush or damp cloth to avoid Use compressed air or a synthetic brush to clean venturi
damaging components. (Solvents must not be – Make sure that the silicon hose between gas valve
used). and venturi is clear and in good condition.
Remove front and end casing panels – lift casing panel
slightly upwards and tilt toward you lift again clear of the
bottom rail.

15.4.1 Inspection of air box and dirt trap

The air box has a dirt trap on the inlet side. Check this
for dirt, leaves, etc. If the boiler is closed, the clamp-
ing strip under the casing must be removed first, check
using a mirror if necessary.
There is an inspection glass on the air box on the fan
side. Check the air box for dirt using a lamp. If the air
box is dirty, it must be dismantled and blown clean.
If the air box is dirty, the following components must
also be dismantled and blown clean:
- non return valve
- venturi
- fan

g
fig. 29 venturi being cleaned with soft brush
Important!! Ensure that the balancing clips
in the impeller stay in place!
- burner 15.4.4 Cleaning the fan

g
Use compressed air or a synthetic brush to clean fan,
Important!! The sealing between the burner be careful not to disturb the balance clips on the
and the mixing bend may be sticky. Prevent the seal- vanes
ing from tearing. Damaged or hardened sealing must
always be replaced.
- mixing bend

15.4.2 Cleaning the non return valve

Use compressed air or a synthetic brush to clean the
non return valve

fig. 30 fan being cleaned with soft brush

fig. 28 non return valve being cleaned with soft brush

50
15.4.5 Cleaning the heat exchanger 15.4.7 Cleaning the condensate collector
Release the retaining nuts from heat exchanger cover Clean the condensate collector by removing the inspec-
plate, remove plate, be careful not to damage the gas- tion cover (next to the flue gas discharge) and then rins-
ket, store safely. ing the collector with water.
Heat exchanger can be washed with clean water, if
badly contaminated, clean with a small stiff bristle “bot-
tle type” brush or use the special cleaning tool (supplied
optional). Care should be taken when using water in the
confined space of the boiler casing to avoid contaminat-
ing the electrical controls. Compressed air can also be
used but care should be taken to ensure disturbed dust
etc does not contaminate the rest of boiler and controls.
Replace the heat exchanger front plate after the clean-
ing and tighten the retaining nuts.

fig. 33 condensate collector inspection cover

15.4.8 Cleaning the syphon

Remove the complete siphon (located underneath con-
densate collector beneath the flue connection)
Remove siphon, clean and refill with clean water and
re-fit.

fig. 31 heat exchanger opened up for cleaning

15.4.6 Cleaning the burner assembly

Clean the burner assembly by using compressed air
only - between 2 and 5 bar with the nozzle positioned a
min of 10mm away and towards the face of the burner.
Check that the retaining bolts are tight.
If the burner is removed from the front plate ensure
burner-retaining screws are tight on re-assembly.

fig. 34 siphon being emptied

fig. 32 burner attached to plate with air nozzle

cleaning the surface
51
 Remeha Gas 310 ECO

15.4.9 Cleaning/Replacing the Ignition/Ionisation Re-assemble boiler in reverse order, check front plate
electrode gasket and insulation piece, replace if required. Also
Remove safety bracket from the heat exchanger then check the gasket on fan and on gas valve, replace if
remove the two retaining screws on the electrode necessary. Ensure that all cables are routed correctly
assembly, remove assembly and examine for wear and using existing clips and ties were possible to ensure that
dirt, clean and re-gap electrode (3mm) re-fit if in good they do not touch any hot parts of the boiler.

g
condition (replace gasket if necessary).
Replace electrode assembly if necessary - then discard Important!! Ensure that wires do not
screws and gasket and fit replacement assembly c/w come into contact with hot boiler parts
new gasket and screws making sure that the earth con-
nection is in good condition and in contact with the base Commission boiler in accordance with section 10.1;
plate. Re-fit safety bracket. complete site report and/or boiler log book if present.

fig. 35 ignition electrode

00.31H.79.00013

15.4.10 Cleaning the inspection glass

Remove the two retaining screws on the inspection
glass holder, clean and replace.

fig. 36 inspection glass removal

52
15.5 Exploded view and spare parts list

fig. 37 Exploded view

53
 Remeha Gas 310 ECO

Pos. nr. Part description Pos. nr. Part description

1 Teflon tape 51 O-ring Ø 183
2 Loctite 52 Fan (for 7, 8, 9 sections)
3 PVC glue 53 Nut M8
4 Cleaning tool 54 Sealing plate fan/ mixing elbow (for 7, 8, 9
sections)
55 Mixing elbow
56 Bolt M8 x 30
7 Air box 57 Nut M12
8 Nut M8 58 Protection bracket
9 Bolt M6 x 16 59 Sealing plate
60 Measuring nipple
11 Air box support 61 Burner
12 Flue gas damper 62 Nut M12
13 Controller (option) 63 Stud bolt M12 x 35
14 Printed circuit display 64 Blind flange flow
15 Adapter (for pos. 13) 65 O-ring Ø 107
16 Interface (for pos. 13) 66 Bolt M4 x 8
17 Printed circuit control unit 67 Inspection glass holder
18 On/off switch 68 Sealing inspection glass holder
19 Gas supply pipe 69 Inspection glass
20 Gas filter 70 Ignition cable
21 Reducing nipple 71 Ignition electrode
22 Gas valve multiblock 72 Sealing ignition electrode
23 Pressure compensation measurement tube 73 Cover plate ignition electrode
24 Air pressure sensor 74 Silicone sealant
25 Air measurement tube 75 Locking pin Ø 12
26 Gas measurement tube
77 Intermediate section
28 Gas valve leak control system (option) 78 Sealing plate
29 Minimum gas pressure control (option) 79 Cover plate burner entry
80 Bolt M12 x 40
31 Screw nipple 81 Temperature sensor
32 Gasket ring Ø 56 x Ø 42 x2 82 Air valve tube
33 Gas supply elbow 83 Pressure gauge
34 Venturi connecting piece (for 7, 8, 9 sections) 84 Thermostat pocket Ø 7
35 Bolt M8 x 16 85 Flow tube
36 O-ring Ø 142 (for 7, 8, 9 sections) 86 Second return water distribution pipe
37 Nut M8 87 Return water distribution pipe
38 Bolt M8 x 16 88 Blind flange return
39 Venturi (for 7, 8, 9 sections) 89 Filling and drain cock
40 Sealing plate venturi 90 O-ring Ø 82
41 Bolt M5 x 20 91 End section left
42 Venturi connecting piece (for 5 and 6 sections) 92 Sealing cable Ø 10
43 O-ring Ø 110 (for 5 and 6 sections) 93 Frontplate heatexchanger
44 Nut M5 94 Stud bolt M8 x 10
45 Venturi (for 5 and 6 sections) 95 Nut M8

47 Nut M8 97 End section right

48 Fan (for 5 and 6 sections) 98 Bolt M12 x 180
49 Sealing plate fan/ mixing elbow (for 5 and 6 99 Washer
sections)
50 Mounting plate fan (for 5 and 6 sections) 100 Flue gas adapter

54
 Pos. nr. Part description Pos. nr. Part description
101 Inspection cover 121 Plug À"
102 Bolt M6 x 16
103 Sealing cable Ø 10 123 Return blind pipe
104 Flue gas sensor jacket 124 Second return distribution pipe
125 Straight connecting flange
105 Flue gas sensor 126 Straight connecting flange
127 Cover plate controller
107 Condensate collector 128 Front panel
108 Sheet-metal screw 4,2 x 9,5 129 Front panel support
109 Adapter Ø 32 / 40

111 Plinth set (side and front) 132 Davel Ø 4 x 14

112 Siphon 133 Toothed spring ring
134 Bolt M4 x 8
135 Nut M5
115 Lambda pipe (for 5 sections only) 136 Bollt M5 x 20
137 Bolt M8 x 16
117 Return distribution pipe
118 Water seal (for pos. 119)
119 Hydraulic pressure sensor (option)
120 Cable bundle (for pos. 119)
table 23 Part list

55
 Remeha Gas 310 ECO

16 APPENDICES

16.1 Control menu

fig. 38 Control menu flow chart

pdf

56
16.2 Shut-off codes

Code Description Cause/Check

- Air supply or flue gas discharge for
Insufficient air transport during pre-ventilation.
blockages/ installation faults
b )* The boiler is locked after 5 restarts (6 starts) with code 08 - Air pressure differential switch and
(see section 14.4).
connections.
Treturn is higher than Tflow + 2° (e.g. 93°, if Treturn is 90°) for - Flow and return sensors have been
more than 10 minutes (and the boiler has been running at swapped
b @$ - Flow and return pipes have been
minimum load for 10 minutes).The shut-off is lifted when Treturn
is less than or equal to Tflow + 3°, e.g. 92°. swapped.
Maximum acceptable ascension speed of the boiler block
temperature has been exceeded. The boiler shuts down for
- Whether heating pump is running
10 minutes, after 5 consecutive start attempts within one
b @% heat demand command the shut-off is recorded in the failure - The water flow through the boiler
- Water pressure.
register as a fault, the boiler does not lock out/go into failure
mode.
If minimum gas pressure switch LD is connected (optional): - Gas supply (is gas valve open?)
b @^ minimum gas pressure undershot. The shut-off is lifted when - Is switch set correctly?
the gas pressure returns. - Wiring.
- Fan defective
- Fan cable or connector is corroded,
b @8 Fan not running resulting in absence of voltage or
control signal
- Check the fan cable connectors on
both the fan side and the automatic
b @9 Fan continues to run or signal incorrect control unit side
- Fan electronics defective
- High natural draught
Maximum acceptable difference between flow and return
temperature has been exceeded. The boiler shuts down for - Whether the heating pump is operat-
150 seconds, after 20 consecutive start attempts within one ing
b #) heat demand command the shut-off is recorded in the failure - The water flow through the boiler
register as a fault, the boiler does not lock out/go into failure - Water pressure
mode.
- Check the connecting cable of the
Air pressure differential sensor short circuited; after 4 restarts air pressure differential sensor
b 38 the shut-off goes into failure mode - The air pressure differential sensor
is defective or not connected
- Check the air pressure differential
sensor connecting cable for short-
Air pressure differential sensor open; after 4 restarts the shut-
b 39 off goes into failure mode circuiting, etc.
- Air pressure differential sensor is
defective
The parameters in the memory of the
b $# One or more parameters are out of limits. control unit are incorrect.
- Check the hydraulic pressure sensor
connecting cable for short-circuiting,
b $5 Hydraulic pressure sensor short circuited etc.
- Hydraulic pressure sensor is defec-
tive

57
 Remeha Gas 310 ECO

- Check the connecting cable of the

hydraulic pressure sensor
b $6 Hydraulic pressure sensor open - The hydraulic pressure sensor is
defective or not connected
Maximum flue gas temperature has been exceeded. The
- The set maximum flue gas tempera-
boiler shuts down for 150 seconds, followed by a restart. If
ture
b %@ the flue gas temperature rises 5° above the maximum flue - Boiler adjustment
gas temperature, a lockout follows with code 52 (see sec-
- Boiler for fouling.
tion 14.4).
Air pressure differential sensor not
opening Check the following:
- Is the air pressure differential switch
defective
b 61 Air pressure differential sensor not opening - Has the wiring short circuited
- Check for signs of external thermal
draught in the flue gas discharge
duct.
- Refill boiler/system to the correct
If hydraulic pressure sensor has been connected (optional):
pressure
water pressure is too low. The control unit shuts down when
- Sensor defective
b ^@ the minimum water pressure is reached. The shut-off is lifted - Wiring defective
when the water pressure returns and the control unit returns
- Hydraulic pressure sensor not con-
to normal operating status.
nected but has been activated.
Shut-off input is open. When the input is closed, the shut-off
b 88 is lifted. Remove the cause of the shut-off.

Maximum acceptable difference between boiler shut-off

temperature and flow temperature has been exceeded. The
- Flow
boiler shuts down for 10 minutes, after 5 consecutive start
b ($ attempts within one heat demand command the shut-off is - Pumps
- Three-way valves
recorded in the failure register as a fault, the boiler does not
go into failure mode.
- Boiler release contact on butterfly
valve not made
Boiler release contact is open.
b (( - Boiler release contact on terminal
strip not connected (if boiler release
contact is not used)
table 24 Shut-off codes

58
 E C O
3 1 0
G a s
R e m e h a

Broag Ltd.
Remeha House
Molly Millars Lane
RG41 2QP WOKINGHAM, Berks.
Tel: +44 118 9783434
© Copyright
Fax: +44 118 9786977
All technical and technological information contained in these technical instructions, as
well as any drawings and technical descriptions furnisched by us remain our property Internet: uk.remeha.com
and may not be multiplied without our prior consent in writing. E-mail: boilers@broag-remeha.com

59011-0904 Subject to alterations