REMEHA Gas 120 ACE Series Installation And Service Manual
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REMEHA Gas 120 ACE Series Installation And Service Manual

Floor-standing condensing gas boiler
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Installation and Service Manual
Floor-standing condensing gas boiler
Gas 120 ACE
Gas 120 ACE - 65
Gas 120 ACE - 90
Gas 120 ACE - 115

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Summary of Contents for REMEHA Gas 120 ACE Series

  • Page 1 Installation and Service Manual Floor-standing condensing gas boiler Gas 120 ACE Gas 120 ACE - 65 Gas 120 ACE - 90 Gas 120 ACE - 115...
  • Page 2 Dear Customer, Thank you very much for buying this appliance. Please read through the manual carefully before using the product, and keep it in a safe place for later reference. In order to ensure continued safe and efficient operation we recommend that the product is serviced regularly. Our service and customer service organisation can assist with this.

  • Page 3: Table Of Contents

    Contents Contents Safety ................... . 5 General safety instructions .
  • Page 4 Contents Maintenance ..................38 General .

  • Page 5: Safety

    1 Safety Safety General safety instructions For the installer and end user: Danger This appliance can be used by children aged from 8 years and above and persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge if they have been given supervision or instruction concerning use of the appliance in a safe way and understand the hazards involved.
  • Page 6 1 Safety Danger If you smell gas: 1. Do not use a naked flame, do not smoke, do not operate electrical contacts or switches (doorbell, light, motor, lift, etc.). 2. Shut off the gas supply. 3. Open the windows. 4. Locate the probable leak and seal it immediately.

  • Page 7: Recommendations

    1 Safety Recommendations Danger For safety reasons, we recommend fitting smoke and CO detectors and alarms at suitable places in your home. Caution The boiler must always be connected to the protective earthing. Earthing must comply with the prevailing installation standards. Earth the appliance before making any electrical connections.

  • Page 8: Liabilities

    1 Safety Caution The frost protection function only protects the boiler, not the heating system. Caution The frost protection function does not work if the boiler is powered off. Caution The appliance should be switched to Summer or Frost Protection mode rather than be switched off in order to guarantee the following functions: Avoidance of pumps blocking Frost Protection...

  • Page 9: Installer's Liability

    1 Safety Failure to abide by the instructions on installing and maintaining the appliance. Failure to abide by the instructions on using the appliance. Faulty or insufficient maintenance of the appliance. 1.3.2 Installer's liability The installer is responsible for the installation and initial commissioning of the appliance.

  • Page 10: Symbols Used

    2 Symbols used Symbols used Symbols used in the manual This manual uses various danger levels to draw attention to special instructions. We do this to improve user safety, to prevent problems and to guarantee correct operation of the appliance. Danger Risk of dangerous situations that may result in serious personal injury.

  • Page 11: Technical Specifications

    3 Technical specifications Technical specifications Homologations 3.1.1 Directives This product has been manufactured and put into circulation in accordance with the requirements and standards of the following European Directives: Gas Appliances Regulation (EU) (2016/426) Pressure Equipment Directive 2014/68/EU Electromagnetic Compatibility Directive (2014/30/EU). Low Voltage Directive (2014/35/EU).

  • Page 12: Factory Test

    3 Technical specifications Type of flue gas connection Chimney : Forced flue: C43X 3.1.5 Factory test Before leaving the factory, each boiler is optimally set and tested for: Electrical safety, Settings (CO Water tightness, Gas tightness, Parameter setting. Technical data Tab.3 General Gas 120 ACE...
  • Page 13 3 Technical specifications Gas 120 ACE Gas 120 ACE - Gas 120 ACE - Gas 120 ACE - mbar Gas resistance G20 (H gas) BREAM NOx mg/kWh Flue gas quantity min–max 18 - 90 22 - 125 30 - 160 Flue gas temperature min–max °C...

  • Page 14: Erp Technical Parameters

    3 Technical specifications 3.2.1 ErP technical parameters Tab.9 Technical parameters for boiler space heaters Product name Gas 120 ACE Gas 120 ACE Gas 120 ACE - 65 - 90 - 115 Condensing boiler Low-temperature boiler B1 boiler Cogeneration space heater Combination heater Prated Rated heat output...

  • Page 15: Sensor Specifications

    3 Technical specifications Tab.10 Minimum flow to be guaranteed Minimum flow to be guaranteed in the boiler Unit Gas 120 ACE - Gas 120 ACE - Gas 120 ACE - Minimum flow rate litres/hour Fig.2 Pressure drops for Gas 120 ACE - A Dynamic head in mWc B Water flow rate (m C Pressure drops...

  • Page 16: Dimensions And Connections

    3 Technical specifications Boiler sensor, return sensor Tab.12 Boiler sensor, return sensor Temperature 100 110 in °C Resistance 98932 58879 36129 22804 14773 10000 9804 6652 4607 3252 2337 1707 1266 952 726 in Ω Circuit flow sensor, domestic hot water sensor and system sensor Tab.13 Circuit flow sensor, domestic hot water sensor and system sensor...

  • Page 17: Electrical Diagram

    3 Technical specifications Gas 120 ACE - 65 Gas 120 ACE - 90 Gas 120 ACE - 115 E (mm) F (mm) G (mm) Electrical diagram 3.4.1 Electrical diagram of boiler Fig.6 12 11 230V GR BK RE YE BL OR BK RE YE BL N’...
  • Page 18 3 Technical specifications BR Brown PI Pink G/Y Green/Yellow GY Grey YE Yellow RD Red OR Orange WH White GR Green Gas 120 ACE 7717202 - v03 - 24062019...

  • Page 19: Description Of The Product

    4 Description of the product Description of the product General description Gas 120 ACE floor-standing condensing gas boilers have the following characteristics: Low polluting emissions High-efficiency heating Electronic control panel Flue gas discharge by a forced flue or chimney type connection with bi- flow option The boilers are perfectly suited to cascade installation.

  • Page 20: Main Boiler Components

    4 Description of the product Main boiler components Fig.7 1 Control unit 2 Flow sensor 3 Light 4 Ignition/ionization electrode 5 Non-return valve 6 Gas valve 7 Heat exchanger (heating circuit) 8 Return sensor 9 Pressure gauge sensor 10 CU-GH-08 PCB housing 11 Siphon 12 Flue gas circuit 13 Intake silencer...

  • Page 21: Installation

    5 Installation Installation Installation regulations Caution Installation of the boiler must be done by a qualified professional in accordance with prevailing local and national regulations. Caution A disconnection device must be fitted to the permanent pipes in accordance with the installation rules. Caution Respect the maximum water inlet pressure to ensure correct operation of the appliance, referring to the Technical...

  • Page 22: Ventilation

    5 Installation Fig.9 Keep the boiler accessible at all times. Place the boiler on a base to make it easier to clean the room. 1 1 0 The boiler can be located along a partition on one of its sides, provided 5 0 0 there is a 500 mm space on the opposite side.

  • Page 23: Fitting The Outdoor Sensor

    5 Installation If the boiler is installed in closed premises, respect the minimum dimensions given in the diagram below. Also allow for openings to obviate the following hazards: Accumulation of gas Overheating of the premises Great Britain: Minimum cross section of openings: see BS 5440 Part 1 and Part 2, and BS 6644.

  • Page 24: Transport

    5 Installation Fig.12 MW-3000014-2 Transport Transport the boiler pallet with a manual or electric pallet truck. Unpacking and preparing the boiler Caution Wear gloves to handle the boiler. Transport the boiler pallet with a manual or electric pallet truck. Use carrying bars (not provided) to move the boiler. Important To fit the boiler, position the pallet with the package 2.5 m in front of the desired location for the installation.
  • Page 25 5 Installation Fig.14 3. Using a long tool, unlock and remove the boiler's front door. Disconnect the earth wire. MW-6000761-01 Fig.15 4. Remove the mounting bolts from the unloading ramps and the boiler (4 bolts at the rear and 4 bolts at the front). MW-6000737-01 Fig.16 5.
  • Page 26 5 Installation Fig.17 7. Lock the ramps correctly onto the pallet. 8. Screw the unloading ramps onto the pallet. 9. Fold down the ends of the ramp so that they rest on the ground. MW-6000770-01 Fig.18 MW-6000739-02 10. Tilt the boiler backwards until it is resting on the castor wheels, then remove it from the pallet.

  • Page 27: Hydraulic Connections

    5 Installation 12. Level the boiler using the adjustable feet. Fig.19 (1) Factory setting: 30 mm, adjustment range: 20 to 40 mm Caution The rear castor wheels must no longer be in contact with the ground. MW-6000773-01 Hydraulic connections 5.5.1 Water treatment In many cases, the boiler and the heating system can be filled with mains water, without treating the water.

  • Page 28: Flushing New Installations And Installations Less Than 6 Months Old

    5 Installation Important If water treatment proves necessary, Remeha recommends the following manufacturers: Cillit Climalife Fernox Permo Sentinel 5.5.2 Flushing new installations and installations less than 6 months old Before filling the heating installation, it is essential to remove any debris (copper, caulking, soldering flux) from the installation.

  • Page 29: Filling The Siphon

    5 Installation Fig.20 The condensate discharge pipe is located at the rear of the boiler. Do not block the condensate discharge pipe. Tilt the discharge pipe by at least 30 mm per metre and make sure there are no low points that could cause the accumulation of water or deposits.

  • Page 30: Gas Supply

    5 Installation 5. Close the gas supply valve before testing the pressure on the gas supply pipe to avoid damage caused by excessive pressure on the gas regulator. Decompress before reopening the valve. 5.6.1 Gas supply Before mounting, check that the gas meter has sufficient capacity (in /h).
  • Page 31 100 °C. The terminal part of the flue gas pipe must be certified as complying with the EN 1856-1 Standard. If installing discharge and intake pipes not supplied by Remeha, these must be certified for the intended type of use and their maximum pressure drop must be compliant.
  • Page 32 5 Installation Configuration Principle Description Flue gas connection to a collective flue for sealed boilers. The air supply is in­ dividual via a terminal coming from outside the building. A concentric pipe can be used to both supply the boiler with combustion air and connect to the collective flue gas discharge system.

  • Page 33: Lengths Of The Air/Flue Gas Pipes

    5 Installation 5.7.2 Lengths of the air/flue gas pipes The maximum lengths (Lmax) given in the table are valid for pipes in which the horizontal sections do not exceed one metre in total. For each additional metre of horizontal pipe, a multiplication coefficient of 1.2 must be applied when calculating the total length L.

  • Page 34: Dimensions Of Flue Gas Outlet Pipe

    5 Installation Configura­ Description Materials Diameter Gas 120 Gas 120 Gas 120 tion ACE - 65 ACE - 90 ACE - 115 Concentric pipes in the boiler 80/125 mm room 80 mm Single flexible pipes in the chim­ ney (combustion air in counter- current) Concentric pipes in the boiler 110/150 mm...

  • Page 35: Connection To The Flue Gas Pipe

    5 Installation Fig.25 Dimensions of concentric External dimensions of flue gas outlet pipe connection External dimensions of air supply pipe Length difference between flue gas outlet pipe and air supply pipe Tab.26 Dimensions of pipe (min-max) (min-max) (min-max) 80/125 mm 79.3 - 80.3 mm 124 - 125.5 mm 0 - 15 mm...
  • Page 36 5 Installation Fastening the coaxial pipes Fig.28 Fastening the coaxial pipes using Fasten the intake pipes with two galvanised Ø 4.2 mm screws with a screws maximum length of 16 mm. Caution Before fixing the screws, make sure that at least 4.5 cm of pipe is inserted in the gasket of the other pipe.

  • Page 37: Operation

    6 Operation Operation Settings To configure the installation and use the boiler, please refer to the control unit manual. 7717202 - v03 - 24062019 Gas 120 ACE...

  • Page 38: Maintenance

    7 Maintenance Maintenance General We recommend having the boiler inspected and serviced at regular intervals. Caution Do not neglect to service the boiler. Contact a qualified professional or take out a maintenance contract for the obligatory annual servicing of the boiler. Failure to service the appliance voids the warranty.

  • Page 39: Checking The Ionisation Current

    7 Maintenance Fig.31 4. Pull the siphon downwards to disengage it and pivot it to release it. 90° MW-2000905-01 Fig.32 5. Flush the siphon. 6. Drain the siphon. MW-2000843-01 Fig.33 7. Fill the siphon with clean water up to the mark. 8.

  • Page 40: Replace The Ionization/Ignition Electrode

    7 Maintenance 7.2.3 Replace the ionization/ignition electrode Fig.34 The ionization/ignition electrode must be replaced if: The ionization current is < 4 µA. The electrode is damaged or worn. 1. Remove the plug of the electrode from the igniter. Important The ignition cable is fixed to the electrode and therefore may not be removed.
  • Page 41 7 Maintenance Fig.36 Removing the front plate, fan and 6. Remove the front plate from the heat exchanger. burner 7. Carefully lift the front plate, including the burner and fan, away from the heat exchanger. AD-3001179-01 Fig.37 Cleaning the heat exchanger 8.

  • Page 42: Checking The Non-Return Valve

    7 Maintenance 7.2.6 Checking the non-return valve Fig.38 Disconnecting the fan 1. Remove the air inlet pipe from the venturi. 2. Unscrew the gland of the gas valve unit. 3. Disconnect the fan plugs (on the front and rear). 4. Remove the screwed-on plug from the gas valve unit. 5.

  • Page 43: Decommissioning

    8 Decommissioning Decommissioning Decommissioning procedure Caution Only qualified professionals are authorised to carry out maintenance work on the boiler and the heating system. To switch off the boiler temporarily or permanently, proceed as follows: 1. Switch the boiler off. 2. Cut the electrical power to the boiler. 3.

  • Page 44: Disposal And Recycling

    9 Disposal and recycling Disposal and recycling Caution Only qualified professionals are permitted to remove and dispose of the boiler, in accordance with local and national regulations. Fig.40 If you need to remove the boiler, proceed as follows: 1. Switch off the boiler. 2.

  • Page 45: 10 Environmental

    10 Environmental 10 Environmental 10.1 Energy savings Energy-saving advice: Do not block ventilation outlets. Do not cover the radiators. Do not hang curtains in front of the radiators. Install reflective panels behind the radiators to prevent heat losses. Insulate the pipes in rooms that are not heated (cellars and lofts). Close the radiators in rooms not in use.

  • Page 46: 11 Warranty

    11 Warranty 11 Warranty 11.1 General We would like to thank you for buying one of our appliances and for your trust in our product. In order to ensure continued safe and efficient operation, we recommend that the product is regularly inspected and maintained. Your installer and our service department can assist with this.

  • Page 47: 12 Spare Parts

    12 Spare parts 12 Spare parts 12.1 General If inspection or maintenance work bring to light the need to replace a component in the boiler: Provide the reference number given in the spare parts list when ordering a spare part. Caution Only genuine spare parts may be used.

  • Page 48: Gas Circuit

    12 Spare parts Gas 120 Gas 120 Gas 120 Markers Reference Description ACE - 65 ACE - 90 ACE - 115 S101564 Exchanger front plate S54731 Exchanger inspection hatch insulation S57241 Exchanger inspection hatch gasket S100052 M4x10 self-locking screw (x20) S54754 FUR.Q65 burner S57477...
  • Page 49 12 Spare parts Tab.28 Markers Reference Description Gas 120 Gas 120 Gas 120 ACE - 65 ACE - 90 ACE - 115 S101543 Silencer S101520 Silencer S101578 Silencer S54777 Venturi gasket (x5) S59215 Gas valve-venturi gasket (x5) S101593 Gaskets (kit) S101726 Fan RG 148/1200-3633 S100036...

  • Page 50: Hydraulic Circuit

    12 Spare parts 12.2.3 Hydraulic circuit Fig.43 MW-6000745-01 Tab.29 Markers Reference Description Gas 120 Gas 120 Gas 120 ACE - 65 ACE - 90 ACE - 115 7680598 Complete flow pipe 7670807 Complete flow pipe 7672557 Complete return pipe 7674076 Complete gas pipe 7680434 Complete gas pipe...

  • Page 51: Boiler Body

    12 Spare parts 12.2.4 Boiler body Fig.44 MW-6000746-01 Tab.30 Markers Reference Description Gas 120 Gas 120 Gas 120 ACE - 65 ACE - 90 ACE - 115 7686377 Assembled frame 7686139 Assembled frame 7679958 117x34 handle, diameter 6.5 mm 7676037 Wheel 7688301 Frame lateral gasket...

  • Page 52: Casing

    12 Spare parts 12.2.5 Casing Fig.45 MW-6000747-01 Tab.31 Markers Reference Description Gas 120 Gas 120 Gas 120 ACE - 65 ACE - 90 ACE - 115 7701400 Complete front panel 7701417 Complete front panel S100419 Casing handle 7701326 Top panel 7701326 Top panel 7701403...

  • Page 53: Boiler Pcb Housing

    12 Spare parts 12.2.6 Boiler PCB housing Fig.46 MW-6000748-02 Tab.32 Markers Reference Description 7673447 PCB unit 7673548 PCB unit cover 7616673 CSU-01 configuration key 7685144 230 V internal cable harness 7685823 24 V internal cable harness + sensor 7654253 24 V lighting system 7697709 CU-GH-08 PCB 7608040...

  • Page 54: 13 Appendix

    13 Appendix 13 Appendix 13.1 Package fiche - Boilers Fig.47 Package fiche for boilers indicating the space heating energy efficiency of the package Seasonal space heating energy effi ciency of boiler ‘I’ Temperature control Class I = 1%, Class II = 2%, Class III = 1.5%, Class IV = 2%, Class V = 3%, Class VI = 4%, from fi...

  • Page 55: Product Fiche - Temperature Controls

    Product D Temperature control X Temperature control Y 13.2 Product fiche - Temperature Controls Tab.35 Product fiche for temperature controls Remeha - Gas 120 ACE HMI T-control Class Contribution to space heating energy efficiency 13.3 Product fiche Tab.36 Product fiche for boiler space heaters...
  • Page 56 13 Appendix Gas 120 ACE 7717202 - v03 - 24062019...
  • Page 57 13 Appendix 7717202 - v03 - 24062019 Gas 120 ACE...
  • Page 58 13 Appendix Gas 120 ACE 7717202 - v03 - 24062019...
  • Page 59 © Copyright All technical and technological information contained in these technical instructions, as well as any drawings and technical descriptions supplied, remain our property and shall not be multiplied without our prior consent in writing. Subject to alterations.
  • Page 60 E info@remeha.es EST Systems Oy T +358 50 554 3068 Kujamatintie 16 E toimisto@estsystems.fi 48720 Kotka Marketbau - Remeha Kft. T +36 23 503 980 Gyár u. 2. F +36 23 503 981 2040 Budaors E remeha@remeha.hu Euro Gas Ltd.

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Gas 120 ace - 65Gas 120 ace - 90Gas 120 ace - 115

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