Floor Standing Warm Air Heater series PK

Transcription

1 User, Installation and Maintenance and Maintenance Guide Guide Capacities from 26 to 1170 kw Efficiency up to 99%. Reduction of Thermal Stratification 150 Standard Models in our Price List 1 code KG GB ed.a-1611

2 EC Approval Certificate 2 code KG GB ed.a-1611

3 3 code KG GB ed.a-1611

4 - Dichiarazione di Conformità Statement of Compliance APEN GROUP S.p.A Pessano con Bornago (MI) Via Isonzo, 1 Tel r.a. Fax Internet: With this document we declare that the unit: Floor standig heater PK-N, PK-K, PK-R, has been designed and manufactured in compliance with the prescriptions of the following EC Directives: Direttiva macchine 2006/42/CE Machinery Directive 2006/42/CE Direttive Apparecchi a Gas 2009/142/CE (ex 90/396/CE) Gas Appliance Directive 2009/142/CE (ex 90/396/CE) Direttiva compatibilità elettromagnetica (EMC) 2014/30/CE Electromagnetic Compatibility Directive 2014/30/CE Direttiva Bassa Tensione 2014/35/CE Low Voltage Directive 2014/35/CE If the unit is to be installed into an equipment (combined), the manufacturer disclaims any responsibility if this equipment is not previously declared compliant with the requirements specified in IIB Enclosure of above said Machinery Directive. Pessano con Bornago Apen Group S.p.A. Un Amministratore Code serial number 4 code KG GB ed.a-1611

5 TABLE OF CONTENTS SECTION 1. GENERAL WARNINGS 7 SECTION 2. SAFETY WARNINGS Fuel Gas leaks Voltage Use Ventilation Openings Maintenance Transport and Handling Unpacking How to Identify the Heater 10 SECTION 3. TECHNICAL FEATURES Main Components Choosing the Heater Diagrams of Output Heat/Efficiency Ratio of PK-N Heaters Diagrams of Output Heat/Efficiency Ratio of PK-K Heaters Technical Data Noise Level Dimensions of PKA Vertical Heater Dimensions of PKA Horizontal Heater Dimensions of PKE Vertical Heater Dimensions of PKE Horizontal Heater 25 SECTION 4. USER S INSTRUCTIONS Maintenance and Faults 28 SECTION 5. INSTRUCTIONS TO THE INSTALLER Where to Install the Heater Wiring to Power Supply Electrical Wiring Burner Electrical Wiring Optional Accessories 34 SECTION 6. INSTRUCTIONS TO SERVICE STAFF Electrical Wiring and Diagrams Burner Matching Gas Oil Burners Gas Burners Tables for Burner Matching 60 SECTION 7. MAINTENANCE Controls at First Start-up Routine Maintenance Spare Part List 65 5 code KG GB ed.a-1611

6 1. General Warnings This manual is an essential component of the product and must always accompany it. If this equipment is sold or transferred to another owner, ensure that the manual follows it, to enable the new installer/owner to consult it. The manufacturer disclaims any liability (under contract provisions or otherwise) for damage to persons, animals, or objects resulting from wrong installation or misuse, and/or non compliance with the manufacturer s instructions. This unit is intended only and exclusively for the use for which it has been built. Any different, wrong, or unreasonable use is to be considered improper and therefore dangerous. For the installation, the operation and the maintenance of the unit, the user shall strictly follow the instructions stated in this manual. Any installation, maintenance or servicing operations shall be performed only by authorised personnel, with technical skills specific for the heating field. APEN GROUP's business organization can count on a wide - spread network of approved Technical Support Centres. Please contact us for information on the Centre that is closest to your area. Si ricorda che la legge 10/91 stabilisce l'obbligatorietà della manutenzione annuale degli apparecchi e il controllo con frequenza periodica del rendimento termico (in dipendenza della portata termica dell'apparecchio). The unit is covered by a guarantee whose conditions and validity are specified on the relevant certificate. The manufacturer declares that the unit is workmanlike built in compliance with UNI, UNI-CIG, and EC technical provisions, and according to the relevant laws and to the Directive on Appliances burning gaseous fuels 2009/142/EEC, Directive on Machines 06/42/CE and subsequent modifications. Reference regulations: -- - UNI-CIG 7129 regulating appliances fired with natural gas 2. Safety Warnings The following symbol is used in this Manual whenever it is necessary to draw the operator s attention on a safety issue. Safety rules for users or operators of the equipment and for nearby workers. This section contains safety rules to be followed for installation room and ventilation opening. 2.1 Fuel The heater must be matched to a suitable burner, using the fuel chosen for the equipment. The burner shall use the type of fuel it is set for, which is specified on the equipment plate and in technical specifications in burner s Manual. If the burner is fuelled with gas, gas supply pressure shall not exceed the range specified in the accompanying Manual. Gas oil burners can be used only with PK-N heaters, while on PK-K condensation heaters, only gas burners can be installed. Before starting the burner/heater, check that: Gas supply specifications match those written on the rating plate; The grid of combustion air intake system is free from debris, leaves, etc.; The gas seal of the feeding system has been tested and approved in compliance with the law. The heater's fuel is the one specified for the unit; The unit is correctly sized to match required flow rate and includes all safety and control devices required by the law; Gas pipes and air distribution ducts for ducted heaters have been properly cleaned; Fuel rate of flow matches heater's rated input; Gas feeding pressure matches values on rating plate. When connecting gas supply pipe to gas valve, do not over tight so as to protect seals. 2.2 Gas Leaks If you smell gas: Do not operate electrical switches, the telephone or any other object or device that can cause sparks. Immediately open doors and windows to ventilate the room. Close gas valves. call for qualified personnel. 6 code KG GB ed.a-1611

7 2.3 Power Supply The heater shall be correctly wired to an efficient grounding system, complying with existing regulations (CEI 64-8). WARNING: Check the grounding system or have it checked by qualified personnel, if necessary. Make sure network wire gauge suits the unit rated input shown on rating plate and in this Manual. The heater can be plugged into mains using a plug-socket only if the latter prevents any mixing up of phase and neutral wires. The system wire gauge in general, and cable section in particular, must suit the unit rated input shown on equipment data plate and in this Manual. Do not pull electrical wires and keep them far from heat sources. NOTE. A multipole switch with fuses and contact opening greater than 3 mm should be installed before the supply cable. The switch must be in a visible and accessible position and within a 3-meter radius from the control board. Any operations involving electrical components shall be performed by specifically trained and certified personnel. 2.4 Use Children and inexperienced people shall not be allowed to use any electrical appliance. The following precautions shall be adopted: Do not touch the unit with wet or damp parts of the body and/or barefoot; Do not leave the unit exposed to adverse weather conditions (rain, sunshine, etc.) unless the unit has been expressly designed to; Do not use gas pipes to ground electrical devices; Do not wet the unit either with water or other liquids; Do not put any objects on the unit; Do not touch moving parts of the heater while it is working. Avoid contact with hot heater surfaces. Such surfaces, generally located near the flame, overheat during operation and remain hot for some time after the burner has stopped. When use of the unit is to be discontinued, open the electric switch and close the manual valve on burner fuel piping. When the unit is to be finally decommissioned, ask professionally qualified personnel to do the following: disconnect supply cable from mains; shut manual valve on burner fuel supply and lock or remove its control hand wheel. 2.5 Ventilation Openings The room where a gas fuelled heater is installed must comply with relevant regulations as to the number and dimensions of venting openings, in order to guarantee optimum combustion and safety. Number, dimensions, and position of these openings vary according to national regulations. Please check with your installer.the heater, if not built for outdoor installation, shall be sheltered from rain, snow, and frost. If air is pulled from outdoor, the inlet must be protected by a rain deflector or similar device that prevents water from spilling into the heater. The room where the heater-burner group is installed must be clean and deprived of volatile substances that can be drawn by the fan and obstruct burner inner hoses or combustion head. Dust itself can be a problem if it is left depositing on fan blades, thus reducing fan flow rate and making combustion polluting. Moreover dust can deposit on the back of flame stability disk in combustion head, degrading air-fuel mixing ratio. 2.6 Maintenance Before executing any servicing or cleaning, disconnect power and gas supply by means of main ON/OFF switch and/or appropriate detection devices. In case of failure and/or insufficient running standards, switch off the heater and do not attempt to repair it directly. Contact the authorized Service Centre. Use only original spare parts for repairs. Failure to comply with above instructions could compromise the unit safety and shall void the warranty. 7 code KG GB ed.a-1611

8 2.7 Transport and Handling Vertical heaters are delivered fastened to a pallet. Horizontal heaters have their own base. Unload the heater from truck and move it to the installation place using a convenient system, suited to the weight of the load. Any lifting and transport operations must be accomplished by skilled personnel, adequately trained on working procedures and safety rules. Instructions in this Manual shall have to be followed when handling the exchanger. Based on their weight and dimensions, heaters can be lifted with lift trucks or wheel-mounted crane. If a crane is to be used, insert in holes in heater base rods with a suitable lifting resistance and install protections to prevent crane ropes from damaging heater body. Once the unit is placed in the right spot, you can start unpack - ing it. In the first case, use fork extensions as long as heater width. 2.8 Unpacking Unpack the heater using suitable tools and protections, where necessary. Materials resulting from unpacking shall be disposed of according to relevant regulations. While unpacking the unit, check its integrity and its compliance to the order. Should damages or missing pieces result, immediately inform the supplier. The manufacturer is not liable for any damages occurred during transport, handling, or unpacking. KG0100 C3 020 KG0100 C3 022 KG0100 C code KG GB ed.a-1611

9 2.9 How to Identify the Heater PK warm air heaters can be identified using their data plate, stuck on the front of the unit. This plate shows all identification information for the model. When required by Service Centre, read the heater model and serial number on the data table, which identify your unit. The plate shows also main thermal, aeraulic and electrical parameters of the heater, together with Manufacturer s data and the country the equipment was built for. KG0100 C3 025 Heater Code PK A 250 N - 2 H A Heater Version: A (indoor) E (outdoor) Capacity Series: N (No condensation) K (Condensation) R condensation series at high efficiency Available Head Pressure (values are shown in tables with technical features): 0 - Low Head Pressure 1 - Medium Head Pressure 2 - High Head Pressure Installation: H - Horizontal O - Vertical 9 code KG GB ed.a-1611

10 3. TECHNICAL FEATURES 3.1 Main Components Warm air heaters include: stainless steel heat exchanger frame and body centrifugal fan and electrical motor control panel and settings safety controls Stainless steel heat exchanger The leading-edge design of furnace and heat exchanger, the balancing of pressure drops and the extended surface guarantee optimum efficiency and durability. Furnace and flue collectors are entirely built with stainless steel (AISI 430), while contact surfaces (tube bundle) are made of steel with low carbon content (AISI 441), thus guaranteeing higher resistance to corrosion. Tube bundle design is patented (# MI94U00260, April 8, 1994). Characteristics of steel types used The following table shows naming correspondence of the steel types used to manufacture our exchangers: USA -AISI EN - N Composition AISI X6 Cr17 AISI X2 CrTiNb 18 AISI 310 * X8 CrNi AISI 304 * X5 CrNi * Exchangers built with different materials, such as AISI 310 or 304, can be taken into account for special applications. The heat exchanger can be used also in presence of condensation. In this case, suitable accessories must be provided and the coupled burner can only burn gaseous fuel. Frame and body The frame consists of solid anodised aluminium bars. The frame is a multi-piece assembly and can be fully disassembled, if required. Body panels are formed by: - On the exchanger side: double-layered panels with inner galvanized steel sheet, high-density glass fibre insulation, external painted galvanized steel sheet. The three layers are riveted to allow safe removal or the panel during maintenance. - On the fan side: painted galvanized steel sheet with inner layer for thermal and sound isolation, securely fastened to steel panel. All panels are gasketed to ensure perfect sealing. Centrifugal Fan Standard centrifugal fans installed are made of galvanised steel sheet with forward curved blades and low noise of operation. Fans rotate on autoaligned sealed ball bearings, isolated in rubber buffers. Three types of fan are used: Direct drive fan: the motor operates the fan directly. It is used on heaters with single phase electric supply (up to PKA060-00A) Fans for rectangular duct: driven by means of fixed diameter pulleys and belts, three-phase motor, models up to PKA420-20A Fans for square duct: same as previous, they are used on heaters from PKA550-00A upward. No lubrication is required on standard fans. For special fans, check specific requirements. Running Temperatures: A- direct drive -20 C +40 C B- belt drive -20 C +85 C The following fans are available on demand: backward curved blades plug fan, directly driven by the motor and controlled through inverter fans for temperatures lower than -20 C Electrical Motor All motors used, except those with direct drive to the fan, have the following characteristics: Supply 400Vac - Three-phase - 50 Hz Structure B3 - with terminal board above Protection degree IP55 Isolation level cl.f Efficiency EFF2 For more model-related information on motors, see further in this Manual. If required, motors with the following characteristics can be supplied: Efficiency class EFF1 Various supply voltages, electrical features and physical shapes Motors for low temperatures (below -30 C) Motors with class H isolation Tropicalised motors Motors with internal heat protection, thermostat, or PT100 or PTC probe. Control Panel and Settings Standard control panel includes: Oven-varnished metal box Lockable quadripolar switch Protection from overheat and short circuit for each motor Fuse-protected wiring board to control heater, safety devices and burner. For motors with an output from 5.5 kw onward, a soft starter is built in. For motors with lower output, soft starters are available on demand. The standard panel does not allow room temperature setting. The setting the user can ask for depends on the burner installed. The following types are available: ON/OFF, two stages, high/low flame or modulating. Safety Devices and Controls All heaters are supplied with the following thermostats: - STB safety thermostat with manual reset. It immediately stops the burner. The activation is signalled by a red lamp lit on the panel. - TR Fan start-up thermostat. It postpones fan switch on and off as referred to the burner. It prevents cold air to be blown into the room at start up and allows the exchanger to be cooled down. - TW Burner limit thermostat (only on models up to PKA320). It stops the burner and anticipates STP thermostat activation. 10 code KG GB ed.a-1611

11 3.2 Choosing the Heater Heaters are available with condensation (Series K) or without condensation (Series N). They can be installed indoor or in a sheltered position outdoor (PKA) and include exchanger, fan assembly and control panel. Another series (PKE) is conceived for outdoor installation and include a suitably conceived exchanger, fan assembly, control panel and burner casing. A work field has been tested and approved for each heater. This field allows the heater to be used at different power and efficiency levels based on effective output power. When choosing a heater model, the following criteria have to be taken into account: its use (heating, process plant, or other), service type (season or all year long), matching burner type (on-off, two stages or modulating). For example, if a capacity of 160 kw is required, you could choose among the following models: 140 (88.5% efficiency), 190 ( 92% efficiency), and 250 (93.8% efficiency). If the heater is used for heating purposes only and and ON-OFF burner is installed, model 190 should be chosen. If the burner is two-stage or modulating, the best would be model 140 (burner and heater would work at maximum capacity for short periods only). If the heater is used in process plants and works all year long, model 250 would suit (the highest efficiency of a heater with greater capacity would balance higher cost). Curves for PKA032 and PKA100 correspond to curves for PKA035 and PKA120, up to 32kW and 100kW of heat output. 3.3 Diagrams of Output Heat/Efficiency Ratio of PK-N Heaters 95 Output Potenze Heat / -Rendimenti Efficency Rendimento % Efficency % Output Potenza Heat kwtermica kw Output Potenze Heat -Rendimenti / Efficency KG0100 EG Efficency Rendimento % % rendimento % M KG0100 EG 011 Output Potenza Heat termica kw kw 11 code KG GB ed.a-1611

12 3.4 Diagrams of Output Heat/Efficiency Ratio of PK-K Heaters 104 Efficiency/Output Heat Efficency Efficiency % % Minimum Heat Output kw KG0100 EG Efficiency/Output Potenze -Rendimenti Heat Efficency rendimento % % M2 KG0100 EG Minimum Potenza Heat termica Output kw kw 12 code KG GB ed.a-1611

13 3.5 Grafici Potenza Termica resa / Rendimento PK serie R 104 Potenze -Rendimenti Efficency Rendimento % % Minimum Potenza Heat termica Output kw kw KG0100 EG Efficiency/Output Potenze -Rendimenti Heat Efficency Rendimento % rendimento % % Potenza termica kw 13 code KG GB ed.a KG0100 EG 010

14 3.6 Technical data table for PKA, PKE Series N. Technical data for PKA-N and PKE-N models are the same. Heat Input and Efficiency Data Model PKA032 PKA035 PKA060 PKA100 PKA120 Type of appliance EC Approval B BP0758 NOx Class 4-5 with LOW NOx GAS BURNERS MIN MAX MIN >91% MAX MIN >91% MAX MIN MAX MIN >91% MAX Furnace Heat Input kw 24,8 34,8 24,8 34,0 49,5 43,0 61, ,5 110,7 68,5 100,5 137,0 Useful Heat kw 23,5 31,6 23,5 31,0 43,6 40,4 56,0 75,2 64,4 100,4 64,3 91,9 120,1 Combustion Efficiency % 94,8 90,8 94,8 91,2 88,1 94,0 91,3 87,9 94,0 90,7 94,0 91,4 87,7 Chimney loss - Burner ON % 5,2 9,2 5,2 8,8 11,9 6,0 8,7 12,1 6,0 9,3 6,0 8,6 12,3 Chimney loss - Burner OFF % <0,1 <0,1 <0,1 <0,1 <0,1 Casing losses * % 2,61 1,83 1,64 1,81 1,46 Furnace pressure Pa Furnace volume m 3 0,06 0,06 0,12 0,24 0,24 Model PKA140 PKA190 PKA250 PKA320 PKA420 Type of appliance B23 EC Approval 0694BP0758 NOx Class 4-5 with LOW NOx GAS BURNERS MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX Furnace Heat Input kw 96,0 195, ,0 154,0 310,0 185,0 380, Useful Heat kw 90,2 171,0 108,1 205,9 145,0 275,0 173,9 335, Combustion Efficiency % 94,0 87,7 94,0 89,5 94,0 88,7 94,0 87,7 94,4 88,6 Chimney loss - Burner ON % 6,0 12,3 6,0 10,5 6,0 12,3 6,0 12,3 5,6 11,4 Chimney loss - Burner OFF % < 0,1 <0,1 <0,1 < 0,1 < 0,1 Casing losses * % 1,26 1,16 1,17 1,02 1,03 Furnace pressure Pa Furnace volume m 3 0,37 0,52 0,76 1,06 1,55 Model PKA550 PKA700 PKA900 PKA1M2 Type of appliance B23 EC Approval 0694BP0758 NOx Class 4-5 with LOW NOx GAS BURNERS MIN MAX MIN MAX MIN MAX MIN MAX Furnace Heat Input kw Useful Heat kw ,7 1049,5 Combustion Efficiency % 94,3 88,4 94,3 89,3 94,4 89,5 94,6 89,7 Chimney loss - Burner ON % 5,7 11,6 5,7 10,7 5,6 10,5 5,6 10,5 Chimney loss - Burner OFF % < 0,1 < 0,1 < 0,1 < 0,1 Casing losses * % 0,97 1,00 1,01 1,01 Furnace pressure Pa Furnace volume m 3 1,79 4,78 5,58 5,58 * Heat loss of the casing must be considered only when heater is installed outdoor or in a thermal station. If the heater is installed into a building, heat is irradiated inside, so losses are zero. 14 code KG GB ed.a-1611

15 Technical data table for PKA, PKE Series K. Technical data for PKA-K and PKE-K models are the same. Heat Input and Efficiency Data Model PKA032K PKA060K PKA100K PKA140K PKA190K PKA250K PKA320K Type of appliance B23 EC Approval 0694BP0758 NOx Class 4-5 with LOW NOx GAS BURNERS MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX Furnace Heat Input kw 14 34,6 22,0 72,0 26, ,0 152,0 48,0 200,0 61,0 270,0 74,0 347,0 Useful Heat kw 14,3 32,0 22,5 66,5 27,1 105,4 38,5 140,8 48,3 182,2 61,6 248,9 74,8 319,8 Combustion Efficiency % 102,5 92,5 102,4 92,4 102,4 92,5 101,2 92,6 100,5 92,6 101,0 92,2 101,0 92,2 Chimney loss - Burner % 7,5 7,6 7,5 ON 7,4 7,4 7,8 7,8 Chimney loss - Burner % < 0,1 < 0,1 < 0,1 OFF < 0,1 <0,1 < 0,1 < 0,1 Casing losses * % 2,61 1,64 1,81 1,26 1,16 1,17 1,17 Furnace pressure Pa Furnace volume m 3 0,06 0,12 0,24 0,37 0,52 0,76 0,76 Model PKA420K PKA550K PKA700K PKA900K PKA1M2K Type of appliance B23 EC Approval 0694BP0758 NOx Class 4-5 with LOW NOx GAS BURNERS MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX Furnace Heat Input kw 83,0 455,0 95,0 595,0 126,0 756,0 175,0 974,0 175,0 1130,0 Useful Heat kw 83,8 419,4 96,1 549,1 127,6 697,2 179,7 900,0 186,0 1057,7 Combustion Efficiency % 101,0 92,2 101,2 92,3 101,3 92,2 102,7 92,4 106,3 93,6 Chimney loss - Burner % ON 7,8 7,7 7,8 7,6 7,6 Chimney loss - Burner % OFF < 0,1 < 0,1 < 0,1 < 0,1 < 0,1 Casing losses * % 1,03 0,97 1,00 1,01 1,01 Furnace pressure Pa Furnace volume m 3 1,55 1,79 4,78 5,58 5,58 * Heat loss of the casing must be considered only when heater is installed outdoor or in a thermal station. If the heater is installed into a building, heat is irradiated inside, so losses are zero. 15 code KG GB ed.a-1611

16 Technical data table for PKA, PKE Series R. Technical data for PKA-R and PKE-R models are the same. Heat Input and Efficiency Data Modell PKA032R PKA060R PKA100R PKA140R PKA190R PKA250R Type of appliance EC Approval B BP0758 NOx Class 4-5 con BRUCIAT ORI GAS LOW NOx MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX Furnace Heat Input kw 14,0 32,0 22,0 58,0 26,5 90,0 38,0 122,0 48,0 162,0 61,0 217,0 Useful Heat kw 14,3 29,6 22,5 53,8 27,1 84,8 38,5 113,4 48,3 150,6 61,6 205,5 Combustion Efficiency % 102,5 93,2 102,4 93,6 102,4 94,1 101,2 94,2 100,5 94,5 101,0 94,7 Chimney loss - Burner ON % 7,5 7,6 7,5 7,4 7,4 7,8 Chimney loss - Burner OFF % < 0,1 < 0,1 < 0,1 < 0,1 <0,1 < 0,1 Casing losses * % 2,61 1,64 1,81 1,26 1,16 1,17 Furnace pressure Pa Furnace volume m 3 0,06 0,12 0,24 0,37 0,52 0,76 Modello PKA320R PKA420R PKA550R PKA700R PKA900R Type of appliance B23 EC Approval 0694BP0758 NOx Class 4-5 con BRUCIAT ORI GAS LOW NOx MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX Furnace Heat Input kw 74,0 275,0 83,0 345,0 95,0 450,0 126,0 599,0 175,0 760,0 Useful Heat kw 74,8 256,5 83,8 325,8 96,1 430,1 127,6 571,4 179,7 723,4 Combustion Efficiency % 101,0 94,9 101,0 95,2 101,2 95,3 101,3 95,4 102,7 95,4 Chimney loss - Burner ON % 7,8 7,7 7,8 7,6 Chimney loss - Burner OFF % < 0,1 < 0,1 < 0,1 < 0,1 < 0,1 Casing losses * % 1,03 1,03 0,97 1,00 1,01 Furnace pressure Pa Furnace volume m 3 1,06 1,55 1,79 4,78 5,58 16 code KG GB ed.a-1611

17 Technical Data on Air Flow Rate, Head e Installed Power Supply Values are the same in PKA and PKE series and in N, K and R series Model PKA032 PKA035 PKA060 PKA100 PKA120 Version 00A 10A 00A 10A 00A 10A 20A 00A 10A 20A 00A 10A 20A Air Flow Rate - 15 C m 3 /h Available Head Pressure Pa Heat Jump Min e Max* K 26,8 26,8 26,0 28,3 28,3 Power Supply V 230M 230M 230M 400T 400T 400T Frequency Hz 50 Motor max. capacity ** kw 0,25 0,56 0,25 0,56 0,75 1,1 1,5 1,1 1,5 2,2 1,1 1,5 2,2 Max absorbed power*** kw 0,25 0,56 0,25 0,56 0,75 1,44 1,91 1,44 1,91 2,72 1,44 1,91 2,72 Protection degree IP PKA Series = IP20, PKE Series = IP24; PKA Control Panel = IP44, PKE = IP54 Running Temperature C From -20 C to + 40 C (check running temperature of matching burner) Model PKA140 PKA190 PKA250 PKA320 PKA420 Version 00A 10A 20A 00A 10A 20A 00A 10A 20A 00A 10A 20A 00A 10A 20A Air Flow Rate - 15 C m 3 /h Available Head Pressure Pa Heat Jump Min e Max* K 23,8-45,2 23,4-40,8 22,4-42,4 21,1-40,5 22,3-40,9 Power Supply V 400T 400T 400T 400T 400T Frequency Hz 50 Motor max. capacity ** kw 3,0 3,0 4,0 3,0 3,0 4,0 2x2,2 2x2,2 2x3,0 2x2,2 2x3,0 2x4,0 2x4,0 2x5,5 2x5,5 Max absorbed power*** kw 3,63 3,63 4,73 3,63 3,63 4,73 5,43 5,43 7,26 5,43 7,26 9,46 9,46 12,8 12,8 Protection degree IP PKA Series = IP20, PKE Series = IP24; PKA Control Panel = IP44, PKE = IP54 Running Temperature C From -20 C to + 40 C (check running temperature of matching burner) Model PKA550 PKA700 PKA900 PKA1M2 Version 00A 10A 20A 00A 10A 20A 00A 10A 20A 00A 10A 20A Air Flow Rate - 15 C m 3 /h Available Head Pressure Pa Heat Jump Min e Max* K 21,0-41,0 19,9-38,8 18,8-38,5 24,4-43,9 7,8-44,3 (Serie K) Power Supply V 400T 400T 400T 400T Frequency Hz 50 Motor max. capacity ** kw 2x3,0 2x4,0 2x5,5 2x4,0 2x5,5 2x7,5 2x5,5, 2x9,2 2x11,0 2x9,2 2x11,0 2x15,0 Max absorbed power*** kw 7,26 9,46 12,8 9,46 12,8 17,1 12,8 20,7 24,8 20,7 24,3 32,8 Protection degree IP PKA Series = IP20, PKE Series = IP24; PKA Control Panel = IP44, PKE = IP54 Running Temperature C From -20 C to + 40 C (check running temperature of matching burner) * Minimum heat drop is referred to minimum heat input, while maximum heat drop refers to maximum heat input. ** Maximum capacity is the maximum output the motor can deliver. For a heater, real motor output depends on the fan working point as referred to losses of air distribution system (pressure drops). *** Maximum absorbed power refers to maximum motor output multiplied by the efficiency of standard motor supplied (EFF2). The value shown in the table must be added to the power absorbed by matched burner. Note: Motors with an output from 5.5 kw onward, have a soft starter built in. For motors with lower output, soft starters are available on demand. 17 code KG GB ed.a-1611

18 3.7 Noise Level HEATERS INSTALLED INDOOR The following table shows sound pressure values (LpA), issued by PK-A heaters 00A version, installed as follows: Standard distribution plenum Air intake turned towards a wall, without filters Indoor installation. Sound pressure value is referred to a standard heater installation with one long side along a wall and plenum with louvres on one long and two short sides. The estimated value only refers to the amount of sound directly produced by the heater. Any sound source in a closed surrounding produces a sound level that is the sum of direct and diffuse sounds. Direct sound is the output from the source while diffuse sound depends on the acoustic characteristics of the installation room (size, average sound absorption, etc.) Obviously, the incidence of diffuse sound over direct sound is greater as the distance from sound source grows. In PK-A heaters for indoor installation, Lw value (sound output) on intake is the main component of noise produced by the fan, since only a protective grid is installed. The value on delivery is lower since exchanger, panelling and plenum help reducing it. Detection distance for sound pressure in the table changes according to heater size. KG0100 C3 026 Noise level is the same in both N and K series. Model Distance LpA - Sound Pressure Level [db(a)] meters db(a) PKA032-00A ,6 32,6 38,5 43,2 47,0 46,6 39,2 32,5 51,3 PKA060-00A 6 24,3 38,8 44,0 46,0 48,7 48,1 43,1 36,0 53,7 PKA100-00A ,8 43,3 48,5 50,5 53,2 52,6 47,6 40,5 58,2 PKA120-00A 6 28,8 43,3 48,5 50,5 53,2 52,6 47,6 40,5 58,2 PKA140-00A 9 27,3 41,8 47,0 49,0 51,7 51,1 46,1 39,0 56,8 PKA190-00A 9 29,7 44,2 49,4 51,4 54,7 53,5 48,5 41,4 59,4 PKA250-00A 9 28,1 42,6 47,8 49,8 52,5 51,9 46,9 39,8 57,6 PKA320-00A 9 30,3 44,8 50,0 52,0 54,7 54,1 49,1 42,0 59,8 PKA420-00A 12 35,3 49,8 55,0 57,0 59,7 59,1 54,1 47,0 64,8 PKA550-00A 12 32,0 41,3 47,2 49,0 47,9 47,4 42,6 35,0 54,6 PKA700-00A 12 32,7 40,8 46,5 49,6 50,9 49,9 43,8 34,9 56,0 PKA900-00A 12 39,6 43,2 52,6 51,0 54,8 50,5 44,4 37,5 59,0 PKA1M2-00A 12 43,6 47,5 57,9 56,1 60,3 55,6 48,8 41,3 64,9 18 code KG GB ed.a-1611

19 DUCTED HEATERS The following table shows sound power (LwA) and sound pressure (LpA) values, issued by versions 10A and 20A of PKA/E heaters. These values refer to heaters with ducted air intake and delivery. The values in the table refer to LwA through the sandwich panelling of the heater. Detection distance for sound pressure in the table changes according to heater size. If you need to know noise levels of the fan, ask APEN GROUP Technical Support. Noise level is the same in both N and K series. Ducted heater (both intake and delivery) MODEL LwA - Sound Power Level [db(a)] LwA d i s - LpA tance m e db(a) db(a) ters PK032-10A 37,9 51,9 52,1 52,5 51,4 47,0 37,7 30,1 58,4 4 35,4 PK035-10A 37,9 51,9 52,1 52,5 51,4 47,0 37,7 30,1 58,4 4 35,4 PK060-10A 42,7 57,2 56,7 55,9 54,1 49,3 41,6 33,0 62,5 4 39,4 PK060-20A 44,6 59,1 58,6 57,8 56,0 51,2 43,5 34,9 64,4 4 41,3 PK100-10A 47,4 61,9 61,4 60,6 58,8 54,0 46,3 37,7 67,2 4 44,1 PK100-20A 48,4 62,9 62,4 61,6 59,8 55,0 47,2 38,7 68,2 4 45,1 PK120-10A 47,4 61,9 61,4 60,6 58,8 54,0 46,3 37,7 67,2 4 44,1 PK120-20A 48,4 62,9 62,4 61,6 59,8 55,0 47,2 38,7 68,2 4 45,1 PK140-10A 48,8 63,3 62,8 62,0 60,2 55,4 47,7 39,2 68,6 4 45,5 PK140-20A 50,0 64,5 64,0 63,2 61,4 56,6 48,9 40,3 69,8 4 46,7 PK190-10A 51,6 66,1 65,6 64,8 63,0 58,2 50,5 41,9 71,4 6 44,8 PK190-20A 53,0 67,5 67,0 65,9 64,4 59,6 51,9 43,3 72,7 6 46,1 PK250-10A 49,9 64,4 63,9 63,1 61,3 56,5 48,3 40,2 69,6 6 43,1 PK250-20A 52,4 66,9 66,4 65,7 63,8 59,0 51,3 42,7 72,2 6 45,6 PK320-10A 54,3 68,8 68,3 67,6 65,7 61,0 53,2 44,6 74,1 6 47,5 PK320-20A 55,4 69,9 69,4 68,7 66,8 62,0 54,3 45,7 75,2 6 48,6 PK420-10A 58,9 73,4 72,9 72,2 70,3 65,5 57,8 49,2 78, ,7 PK420-20A 59,9 74,4 73,9 73,2 71,3 66,5 58,8 50,2 79, ,7 PK550-10A 58,3 68,0 64,2 63,5 57,6 53,9 46,1 37,1 71, ,0 PK550-20A 64,7 68,2 64,3 64,5 58,1 53,8 46,5 37,7 72, ,0 PK700-10A 57,8 67,1 65,2 63,2 61,3 56,4 47,4 36,9 71, ,1 PK700-20A 59,7 70,5 67,3 65,8 62,9 57,3 49,1 39,1 73, ,8 PK900-10A 62,5 68,9 70,5 67,3 61,5 57,3 48,3 39,6 74, ,5 PK900-20A 63,1 72,4 70,8 69,8 63,3 58,8 50,1 40,9 76, ,4 PKA1M2-20A 69,4 79,6 77,9 76,8 69,6 64,7 55,1 45,0 84, ,9 19 code KG GB ed.a-1611

20 3.8 Dimensions of PKA Vertical Heater INDOOR VERTICAL HEATER (N, K and R series) R Hb E N H S B L Q KG0100 C2 001 P 20 G D A Model Size Intake Delivery Profile Chimney Burner Weight L B H Hb A E A D P G N Ø R S Ø T kg. PKA (119*) PKA (178*) PKA (251*) PKA (326*) PKA (390*) PKA (517*) PKA (587*) PKA (919*) PKA (1170*) PKA (1587*) PKA900 PKA1M (1975*) * weights of K and R series heaters KG0100 ET code KG GB ed.a-1611

21 Integrated Models All vertical PKA heaters, up to PKA320 included, are integrated. Two-Assembly Models From 420 model onward, heaters are split in two assemblies: fan and exchanger. These two assemblies are to be installed one on top of the other without any fixing. Fan assembly includes slots for sliding the two parts into place. A polarized connector is available to wire the exchanger and its thermostats to the control panel. Air Intake Standard air intake is on the right side of the heater (seen from the burner). The grid can be moved to left side by the installer or Apen Group (on demand). Intake can also be moved to the bottom and/or back side of the unit. AIR DELIVER Y AIR INLET OPTIONAL AIR INLET OPTIONAL KG0100 C3 001 AIR INLET STANDARD AIR INLET OPTIONAL 21 code KG GB ed.a-1611

22 3.9 Dimensions of PKA Horizontal Heater INDOOR HORIZONTAL HEATERS (N, K and R series) A A 450 D KG0100 C2 003 B Lb L KG0100 C2 003 N R 20 G P Model Size Intake Delivery Profile Chimney Burner Weight B H L Lb A E A D P G N Ø R S Ø T kg PKA (121*) PKA (180*) PKA (266*) PKA (350*) PKA (420*) PKA (562*) PKA (649*) PKA (994*) PKA (1252*) PKA (1677*) PKA900 PKA1M (2080*) * weights of K series heaters KG0100 ET 005 **For heaters from model 700 and upwards the bottom frame is 140mm high, models 032/035 and 060 are supplied with metal feet 22 code KG GB ed.a-1611

23 Integrated Models All PKA horizontal heaters, up to PKA320 included, are integrated. Two-Assembly Models From 420 model onward, heaters are split in two assemblies: fan and exchanger. These two assemblies are to be installed one next to the other and fixed with the profile and the screws provided. Fan assembly includes slots for sliding the two parts into place. A polarized connector is available to wire the exchanger and its thermostats to the control panel. Heaters are supplied on a galvanized steel base, prepared for lifting with lift truck or crane. 032 and 035 models only include supporting feet. Air Intake Standard air intake is on the back of the heater. Intake can also be moved to the top or bottom side of the unit. For horizontal heaters, you must specify air flow direction: rightward or leftward (always referred to burner). AIR INLET OPTIONAL LEFT VERSION DELIVER AIR Y AIR INLET STANDARD KG0100 C2 044 AIR INLET OPTIONAL AIR INLET OPTIONAL RIGHT VERSION AIR INLET STANDARD DELIVER AIR Y KG0100 C2 004 AIR INLET OPTIONAL 23 code KG GB ed.a-1611

24 3.10 Dimensions of PKE Vertical Heater (Series N, K and R) OUTDOOR VERTICAL HEATER (Series N, K and R) T Hb E S H ØR N B P A Lg L I Lv G 20 D A KG0100 C2 005 Model Size Intake Delivery Profile Chimney Burner Burner Casing Weight L B H Hb A E A D P G N ØR S ØT LG LV I kg PKE032 PKE (151*) PKE (219*) PKE100 PKE (297*) PKE (384*) PKE (468*) PKE (603*) PKE (673*) PKE (1027*) PKE (1307*) PKE (1737*) PKE900 PKE1M (2145*) * weights of K series heaters 24 code KG GB ed.a-1611

25 Integrated Models All vertical PKE heaters, up to PKE320N included, are integrated and burner casing is built-in. Three-Assembly Models From 420 model onward, heaters are split in three assemblies: fan, exchanger, and burner casing. The first two assemblies are to be installed one on top of the other without any fixing. Fan assembly includes slots for sliding le two parts into place. To install burner casing onto the heater, do the following: Lay transparent silicone on the edges of burner casing Press casing onto the heater and match aluminium profiles. Fix casing support to heater profiles using supplied screws. Then, to ensure waterproof protection of internal components, cover with silicone any slots that may exist in between the two assemblies. A polarized connector is available to wire the exchanger and its thermostats to the control panel. Air Intake Standard air intake is on the right side of the heater (seen from the burner). The grid can be moved to left side by the installer or Apen Group (on demand). Intake can also be moved to the bottom and/or back side of the unit. HEATER BURNER CASING FIXING SCREWS KG0100 C code KG GB ed.a-1611

26 3.11 Dimensions of PKE Horizontal Heater (Series N, K and R) HORIZONTAL HEATERS FOR OUTDOOR INSTALLATION (Series N, K and R) KG0100 C2 006 Type Size Intake Delivery Profile Chimney Burner Burner Casing Weight PKE032 PKE035 B H L A D A D P G N ØR S ØT Bg Bv Lg Lv kg (151*) PKE (219*) PKE100 PKE (312*) PKE (408*9 PKE (498*) PKE (648*) PKE (735*) PKE (1097*) PKE (1392*) PKE (1837*) PKE900 PKE1M (2250*) KG0100 ET 007 * weights of K series heaters **For heaters from model 700 and upwards the bottom frame is 140mm high, models 032/035 and 060 are supplied with metal feet 26 code KG GB ed.a-1611

27 Integrated Models All horizontal PKE heaters, up to PKE320 included, are integrated and burner casing is built-in. Two-Assembly Models From 420 model onward, heaters are split in two assemblies: fan and exchanger, and burner casing is assembled. These two assemblies are to be installed one on top of the other without any fixing. Fan assembly includes slots for sliding the two parts into place. Once the casing is in place, complete by mounting corrugated aluminium roof (supplied separately). For these models, control panel is installed into burner casing, i.e. in exchanger assembly. On fan assembly, a polarized connector is available to wire the exchanger to fan motors. Heaters are supplied on a galvanized steel base, prepared for lifting with lift truck or crane. 032 and 035 models only include feet. Air Intake Standard air intake is on the back of the heater (seen from burner). Intake can also be moved to the top or bottom side of the unit. For horizontal heaters, you must specify air flow direction: rightward or leftward (always referred to burner - see picture on page 17). FAN SECTION EXCHANGER SECTION KG0100 C3 003 BURNER CASING 27 code KG GB ed.a-1611

28 4. User s Instructions 3-FUNCTION THERMOSTAT APEN IMPORTANT: Read Safety Warning on pages 3-4 to discover useful information on how to safely use your equipment. User's operations on the heater are limited to regulating controls on room thermostat (optional). Installation of a room thermostat on a heating system is mandatory. A scheduler can be included in room thermostat. Control Panel The following controls and/or alerts are available on control panel: IG Door lock - On Ø (zero), the whole unit is powered off. C1 Summer/0/Winter switch - It allows choosing the running mode you want. L1 Green lamp - If lit, the control panel is powered. L2 Red lamp - Safety thermostat or fire damper, if installed, has triggered. The user has to manually reset devices. L3 Yellow lamp - The electrical protector of the motor has triggered. The user has to open the control panel and manually reset the device. This feature is installed (but not used) on heaters with single phase supply. Thermostats Two thermostat models can be installed on the heater: 3-function thermostat Apen 3-function thermostat Jumo All versions up to PKA320 included. All versions from PKA420 upward In both types of thermostat, the following functions are available: STB Safety thermostat - When activated, it immediately stops the burner and issues an alert (red lamp on control panel). Reset is manual (see figure). TR Fan ON/OFF thermostat - It delays starting the fan with respect to burner start up, thus avoiding blowing cold air into the room. When turning the system off, the fan is stopped after the burner, so it can cool down the exchanger. TW Only in three-function thermostat. It allows to turn off the burner before the safety thermostat triggers. Reset is automatic. No alerts are issued when it triggers: just the burner is turned off. KG100 C FUNCTION THERMOSTAT JUMO KG0100 C3 035 RESET COMMAND : Unscrew the plug and press to reset the LIMIT thermostat (STB) RESET COMMAND : Unscrew the plug and press to reset the LIMIT thermostat (STB) OPERATION MODES SUMMER In summer mode, only the fan works to ventilate the room. The user must start up and turn off the burner manually. Winter In winter mode, the burner and the fan are started, to blow warm air into the room. Room thermostat makes the burner start and, when the temperature set on TR thermostat is reached, fans are started. Standard contactor for fan motor control is self-holding. This prevents that during start-up, cold air flows cool down TR thermostat and keep stopping the fan. Whet set room temperature is reached, the room thermostat stops the burner. The fan keeps working until room temperature lowers below TR (FAN) thermostat value. D uring cooling, the fan may be re-started if air temperature inside the heater increases because of the exchanger temperature. The burner restarts when a heat request is issued by room thermostat. If C1 switch is turned on 0 (zero), the heater continues to be powered and fans keep cooling the exchanger, provided that TR thermostat is closed. In these conditions, DO NOT execute any maintenance nor other operation on the heater since fans can restart when the heater is powered. 28 code KG GB ed.a-1611

29 CONTROL PANEL AND THERMOSTATS CONTROL PANEL SINGLE PHASE HEATERS FROM 032 T O 060 THREE-FUNCTION THERMOSTAT (STB/ TR/TW) REG C1 L3 L2 IG L1 KG0100 C2 009 LEGEND C1 SUMMER/0/WINTER SWITCH IG MAIN SWITCH L1 LINE LAMP (GREEN) L2 SAFETY THERMOSTAT ACTIVATED LAMP (RED) L3 THERMAL RELAY ACTIVATED LAMP (YELLOW) REG 2-STAGE BURNER REGULAT OR (OPTIONAL) STB SAFETY THERMOSTAT DO NOT power off the heater while it is running because this would prevent the heat exchanger from being cooled down, thereby reducing its life and jeopardising its efficiency. The STB safety thermostat triggers to stop the heater when abnormal overheat occurs. In order to reset it, push RESET command. This thermostat triggers in exceptional conditions, thus revealing a fault. This may be caused by several reasons: a surplus of heat input because the burner has been wrongly set up, insufficient air flow because air grids and filters are clogged, wrong pipe sizing, or wrong fan rotation. If, after multiple reset attempts, the problem continues, turn IG switch to 0 (OFF) and contact APEN Group s Service Center. 4.1 Maintenance and Faults The heater and burner have to undergo a full maintenance cycle at least once a year in order to continue assuring top reliability and lowest running cost. Only specifically trained personnel can service the unit. If any abnormal noise is heard during operation, contact your Service Centre. At the end of any repairing or maintenance call by technical service, a dated and signed report shall be issued. The report shall be filed with other documents concerning the equipment. If the system is left unused for a long period, turn IG main switch IG on 0 (OFF) and shut fuel supply valve. If a failure and/or ill functioning occurs, switch off the heater and do not attempt to repair it yourselves. Contact your Service Center. Any repair shall be executed by trained personnel, approved by burner s manufacturer. Failure to follow above instructions could compromise the safety of burner and heater. 29 code KG GB ed.a-1611

30 5. Instructions to the installer 5.1 Where to install the heater The place of installation shall be chosen by the project manager or by an expert, considering technical and regulatory requirements in the country the unit is installed. Generally, specific authorisations are required. Therefore, before installing the heater, check that all authorizations are available or have them issued. Install the heater on a flat surface that can firmly and safely bear the weight. Minimum safety distance for correct air circulation shall be kept all around the unit. This will also ease maintenance and control operations. In any case, and in full compliance with the rules in force in the country of installation, it is recommended to leave at least one meter clearance around the unit, to perform all the necessary actions of ordinary and extraordinary maintenance Connecting Air Ductwork Ducts for air delivery and intake shall be sized based on aeraulic performance of the unit (shown in Technical Data section of this Manual). A vibration damping joint should be installed on air delivery duct so as to prevent vibration transmission from the heater to ductwork. Special attention should be paid to comply with noise level standards. If required, a sound absorber shall be installed in air delivery ductwork. When air inlet is from outdoor, rain deflectors are required. Connecting Fuel Supply Fuel connection shall be performed by qualified personnel only. Follow instructions in User Manual of the burner installed on the heater and comply with existing regulations. Fuel and power supplies shall be easily accessible. Any wiring and assembling tasks shall be executed by adequately trained and qualified personnel. The heater SHALL NOT be modified in ANY part without the manufacturer s written authorisation. KG0100 C code KG GB ed.a-1611

31 KG0100 C3 024 Installation outdoor Installation indoor KG0100 C code KG GB ed.a-1611

32 5.2 Wiring to Power Supply Warm air heaters come with a main switch with door lock (IG) shown in the figure. Wire power supply directly to that switch. Wiring type changes based on type of device: Cables Use flexible, flame-retardant, double-coating cables for the wiring. Cable section must be suited to heater absorption and to the distance between heater and connection point. Single phase Threephase 230V 400V+N Wire phase to L3 terminal and Neutral to N terminal Wire three phases to L1, L2, and L3 terminals and Neutral to N terminal For both types ground wire is mandatory. Connect it to relevant terminal. Note: In order to access terminals, unscrew white cover on the upper part of the switch. When finished, reinstall protection cover. PK Model Rated current In Breakaway starting current Is/In Wire diameter mm A; A 4,5 6,5 2x1, A; A 6,0 6,5 2x1, A 7,5 6,5 2x1, A; A; A 4,0 6 4x1, A; A; A 5,1 6 4x1, A A 6,9 6 4x1, A; A 8,7 6 4x2, A; A 8,7 6 4x2, A; A 9,8 6 4x2, A, A; A 12,0 6 4x2, A; A 16,0 7 4x4, A; A 19,8 7 4x4, A; A 23,8 2-4* 4x6, A 16,2 7 4x4, A; A 20,2 7 4x6, A; A 24,2 2-4* 4x6, A; A 34,0 2-4* 4x10, A; A; 47,0 2-4* 4x16,0 63 1M2-00A; 1M2-10A 1M2-20A 52,0 2-4* 4x16,0 63 A protection KG0100 IM 001 Notes: Determine cable section in compliance with EN and IEC /20001 specifications; PVC insulation; room temperature 30 C; surface temperature <70 C; length below 20m. Rated current: current absorbed by gas or gas oil burner. Add ground cable to the number of cables. * Models with soft starter: Breakaway starting current depends on soft starter settings. Electrical Protections N L1 L2 L3 IMPORTANT: A main switch must be installed before the control panel of the heater. This switch must include a protection (fuses or automatic) and must comply with existing regulations. CHECKS All APEN GROUP heaters undergo electrical tests. Safety devices are tested as well, and if two fans are installed, they are checked to verify they are phased. At first start up of three-phase models, the following checks are mandatory: - Fan rotation sense. If two fans are installed, both have to be checked. - Actual absorption of each motor. It must be lower than rated absorption (see values in Technical Data section). - Adjust trigger threshold of thermal relay to the absorption measured. Increase value by 5-10% over measured value. Never exceed motor rated value. Fuse type, if used, must be rapid. If automatic switch are used, the characteristic curve for their triggering must be of type "K" or D" or "C". Automatic switches with "A" or "B" trigger curve are not allowed since they are not suitable for electrical motor protection. 32 code KG GB ed.a-1611

33 5.3 Electrical Wiring All control panels of 1-phase or 3-phase PKA/E heaters, include a wiring electronic card that allows to easily and safely connect common components such as: Fire damper and discharge shutter, if installed Room thermostat, timer, and high/low flame control of the burner, if installed. Fire Damper Wire microswitch (NC contact with activat - ed damper) to terminals 51 and 52 of CN6 connector on the heater control card. If microswitch triggers, the burner stops while the fan keeps working to cool down the exchanger. Heat in excess will be dispersed through a discharge shutter. When the heater is installed outdoor and no shutter is installed, and if the fan needs to be stopped, install a relay that powers off fan motor. Discharge Shutter Wire servomotor (spring-engaged and 230Vac voltage) to terminals 53 and N of CN6 connector on the heater control card. If fire damper triggers, servomotor is powered down and the spring opens the shutter to discharge heat outside the equipment. Wire room thermostat to terminals 41 and 42 of CN7 connector on the heater control card. This thermostat starts the burner only when room temperature lowers under set value. Timer Wire timer contact in series with room thermostat to terminals 41 and 42 of CN7 connector of heater control card. The timer starts the burner at scheduled time intervals. High/Low Flame Control Wire this control to terminals 43, 44, and 45 of CN7 connector of heater control card. Room Thermostat KG0100 C2 045 SHUTTER SER VO- MOT OR DISCHARGE 230V - 1A FIREPROOF DAMPER TIMER ROOM THERMOSTAT HIGH/LOW REGULAT OR LOW HI Important: are closed. If no fire damper is installed, create a jumper on terminals 51, 52 of CN6 connector. The installation of a room thermostat is mandatory. The burner works only if terminals 41 and 42 High/low flame wiring is required only if a two-stage burner is installed. If you have no two-stage regulator but do have a two-stage burner, create a jumper on 44, 45 terminals of CN7 connector. 33 code KG GB ed.a-1611

34 5.4 Wiring the Burner A specific connector (CN2) on wiring card is dedicated to connecting the burner. CN2 connector shows standard numbering for one- or twostage burners. You only need to wire the burner respecting numbering. If burner terminal board is not standard, do the wiring as follows: Line - 230V Thermostat series Lock signal Operation burner* High/low flame From terminals L1, N From terminals T1 and T2 To terminal S3 To terminal B4 To terminals T6 (common), T7 (low flame), T8 (high flame) * If no connection is provided for burner operation, the selfholding function of the fan is not enabled. Therefore, at start-up or when room air is cold, the fan could repeat multiple ON/ OFF cycles. Three-phase Burner On control panels of models from PKA/E 250 onward, an automatic switch is installed that controls 3-phase burner power supply. 3-phase burners always have two supplies: - 400V Three-phase for electrical motor - 230V single-phase for the control section. With 3-phase motors, remember to verify that rotation sense of burner motor is correct. Connection point of 3-phase motors is under the switch. Installed switch has the following characteristics: Magnetic protection 6,3 A Unlatch current 78 A Breaking capacity 100 KVA X3 X7 X4 Legend of burner plug X7 7-pole plug for burner connection: L1 line supply (230V); T ground; N neutral; T1,T2 series of thermostats; S3 lock signal; B4 ON signal; X4 4 pole plus for high/low flame connection: B5 High flame lit signal; T6,T7,T8 high/low flame thermostat. SC heater wiring card IB 3-phase burner switch X3 3-phase burner terminal board l1 l2 l3 l1 T n T1 T2 s3 B4 B5 T6 T7 T8 IA IB SC KG0100 C code KG GB ed.a-1611

35 5.5 Optional Accessories APEN GROUP has developed a range of accessories to ease heater installation in different contexts and environments KG0100.C LEGEND 1. Vibration damping joint 2. Fireproof Damper 3. Regulation shutter on intake 4. Shutter joint kit 5. Shutter servomotor 6. Manual control for shutter 7. Filter group 8. Controller for two-stage burner 9. Inverter for air flow rate/pressure regulation 10. Burner 11. Rain Deflector Grid 12. Mixing box 13. Duct adapter joint 14. Duct bend 15. Plenum for air delivery 16. Duct temperature sensor 17. Regulation shutter on delivery 18. Chimney Tee Manifold for chimney condensate 20. Chimney bend Flue exhaust module 22. Straight chimney pipe 1 meter 23. Chimney terminal (cover) 24. Kit of tie rods for securing the chimney to the heater 25. Ring for chimney assembly 26. Room temperature sensor (not specified) 27. Regulation shutter on delivery (not specified) 35 code KG GB ed.a-1611

36 HF Floor Standing Warm Air Heater series PK AIR FILTER An air filter can be installed on heater s frame, if required. On vertical versions, no adapters are required. Follow instructions in following paragraph. For horizontal heaters up to 320, an adapter kit is available to adapt intake section to filter section. For models from 420, a specific horizontal filter is provided. Air filters quoted in price list are sized to allow air intake from one side only. For intake on both sides and/or different from standard, contact APEN GROUP Customer Support to know correct sizing. Supplied filters are made of modacrylic fibre. Their fire resistance rating is M1, and they can be used for continuous operation up to 80 C. Their checkweighted efficiency (Am) is 87% (ASHRAE), which corresponds to class G3 (ex EU3) EN779. G4 filters are available upon request, with 90% Am, or filters with metallic media (G1). You can regenerate filters by cleaning them as follows: - Dry dust: scroll, suck or blow with compressed air the filter, or wash it with an air jet; - Greasy dust: plunge the filter in lukewarm water and mild detergent (do not brush nor twist filter pads). BF MODELS KG0100 C3 008 AF HF MODELS KG0100 C3 009 BF HF PK Model Dimensions Δ P AF HF BF [mm] [mm] [mm] Pa xHA M2-xHA 80 KG0100 C3 010 MODELS 420 1M2 AF KEEP RAISED FROM FLOOR AF BF 36 code KG GB ed.a-1611

37 Filter loss ( P) is referred to a clean filter. Deduct this loss from heater static pressure. A dirty filter can reach a loss of 400 Pa, thus compromising heater efficiency. The installation of a pressure switch is recommended to stop the heather when threshold is exceeded. To clean filters, remove them by unscrewing fixing screws. Before this operation, make sure the heater is powered off and disconnected from mains. Code of spare filters The table in this page shows filter codes, cell thickness and codes, and the number of cells. Filters are the same for any versions. They only differ according to heater size Installing the Filters Three filter models are available. See figures in this page. Remove intake ducts before installing the filter. Use supplied brackets to fix the filter group to aluminium heater frame (see 3rd figure). Then fill gaps with silicone. This is especially required if the heater is installed outdoor. Filter code s p mm cell code # cell code FLXPKA032NA 48 G FLXPKA035NA 48 G FLXPKA060NA 48 G FLXPKA100NA 48 G FLXPKA120NA 48 G FLXPKA140NA 48 G FLXPKA190NA 48 G FLXPKA250NA 48 G G FLXPKA320NA 48 G FLXPKA420NA 96 G FLXPKA550NA 96 G FLXPKA700NA 96 G G FLXPKA900NA 96 G G FLXPKA420NA-H 96 G FLXPKA550NA-H 96 G FLXPKA700NA-H 96 G G FLXPKA900NA-H FLXPKA1M2NA-H 96 G G # 37 code KG GB ed.a-1611

38 MIXING BOX Apen provides a mixing box accessory that includes the following components: Aluminium frame; Prepainted, insulated sheet panelling; Air filter G3 or G4 (upon request); Mixing box can include the following components: motor-assisted regulation shutters; rain deflector; manual controls or servocontrols for shutters; controls for servocontrols; Shutters, dampers and servocontrols must be purchased if needed. Their order codes are the same both for PKA and PKE. No mounting kits are required for their installation. Boxes dimensions, either horizontal or vertical, are the same Mixing box code is the following: M550-G3HE-00 M: mixing box code; 550: the type of heater it will be matched to; G3: filter type (G4 as an alternative); H: horizontal installation. It includes feet; V: vertical installation (without feet); E: outdoor equipment (roofed); I: indoor equipment. 00: it indicates the layout of air inlet openings; Available layout are the following: 00: standard, two openings at 90 (bottom and back or top and back) 01: openings on top and bottom 02: one opening on the back only 03: One opening on top or bottom only KG0100 C3 033 Model Size L B H M M M M M M M M M M M900 M1M KG0100 C3 032 L * For heaters from model 700 and upwards the bottom frame is 140mm high B H 100* 38 code KG GB ed.a-1611

39 AIR SHUTTER Air shutter is installed on the filter or the heater using ad adapter kit. All shutters include a control that can either be motorised or remain manual. Any of the two has to be requested separately. 100 H Model PK Code B H P F* [mm] [mm] [mm] [mm] G G G G G G G G G G M2 G B KG0100 C3 012 P F*: Flange size KG0100 ET AIR REGULATION SHUTTERS SERVOCOMMANDS FOR AIR SHUTTERS The air shutter supplied has no control. The following control kits are available: - Manual control - Servomotor for ON/OFF control(230v) - Servocontrol for modulating control 0-10 Vdc (24V) If a motor-assisted control is installed, a control is needed in addition to servomotor. This control can be of the following types: ON-OFF - You can control ON-OFF models using a simple switch that opens or closes the shutter. Mechanical stops can be used to reduce the range. Modulating - Modulating controls need a controller that regulates the shutter based on the output (0-10 Vdc signal) from a value such as temperature, humidity, air flow rate, and so on. As an alternative, you can also use a potentiometer (0-10 Vdc), to manually set the shutter based on your needs. Modulating servomotors require 24V supply while ON/OFF servomotors need 230V supply. Inverter: This picture is for reference only. Brand and model of supplied device can change without notice. Manual control. Model PK Code Description G09901 Manual control for shutters (pitch 100 mm) G01112 Modulation servomotor 0-10Vdc - 24V supply - 4 Nm G01162 ON-OFF servomotor - 230V supply - 4 Nm G09901 Manual control for shutters (pitch 100 mm) G09980 Modulation servomotor 0-10Vdc - 24V supply - 8 Nm G07208 ON-OFF servomotor - 230V supply - 8 Nm 420-1M2 G09902 G09980 G07208 Manual control for shutters (pitch 150 mm) Modulation servomotor 0-10Vdc - 24V supply - 18 Nm ON-OFF servomotor - 230V supply - 18 Nm All models G17745 Shutter spacer Vdc - for modulation servomotors (24V power supply unit) 39 code KG GB ed.a-1611

40 FIRE DAMPER APEN provides two installation places for fire dampers: on intake and on delivery. Dampers differ only for dimensions. Dampers on intake have the same size as air regulation shutter. They are installed directly on this shutter or, if this is not installed, on the filter/heater by means of adapting kits. Dampers on delivery are slightly smaller, the same size as the straight pipe+bend assembly (see further in this Manual). All dampers have the following specifications: - Reaction to fire REI120 - Galvanized sheet body (500 mm deep) mm plasterboard shutter - Thermal cut-out with fuse set on 72 C; - Microswitch, IP55, supplied as a standard and installed on damper - Supplied dampers are certified. NOTE: Depth of open damper equals the height of the blade. Dampers higher than 500 mm stick out on both sides for half the difference of height less depth (500 mm for any models). That is, for a 600mm-high damper, the shutter sticks out on each side for 50 mm. If a 800 mm damper is installed over a regulation shutter, a spacer is required (packaged with the shutter) to allow the blade to rotate. The fire damper too requires an adapter kit to be directly mounted on heater frame or on air filter. ON INTAKE Model PK Code B H P F G G G G G G G ON DELIVERY Model PK Code B H P F G G G G G G G F P H B KG0100 C3 014 DISCHARGE SHUTTER G Apen provides a motor-assisted shutter kit with return spring. Its code is: G Dimensions of discharge shutter are 300x300 mm. Shutter blades are gasketed to prevent air leaks during operation. Discharge shutter is mandatory when the heater is installed in a dedicated room or in a heat central. Wire servomotor to terminals 53 and N of CN6 connector on the heater control card (see page 27 of this Manual). How it works: when fire damper microswitch is closed and the shutter is open, the servomotor is powered and discharge shutter is closed. When fire damper triggers, it closes, its microswitch opens, powers down the servomotor, and the spring mechanism opens the discharge shutter. KG0100 C code KG GB ed.a-1611

41 KG0100 C3 013 Floor Standing Warm Air Heater series PK VIBRATION DAMPING JOINT When correctly assembled on intake or delivery assemblies, the vibration damping joint reduces vibrations on air delivery pipes, thus avoiding their propagation and consequent noise. These joints are made of neoprene and metal and have a galvanized steel framework. They can endure temperatures of 100 C max. and their fire rating is M2. F H B P KG0100 C3 011 Model PK Code B H P F shutter [mm] [mm] [mm] [mm] G G G G G G G G G G M2 G KG0100.ET VIBRATION DAMPING JOINTS RAIN DEFLECTOR If intake air is drawn from outdoor, a rain deflector is available. It also includes a net to prevent animal intrusion. To install the deflector, an adapter kit is required, as for shutters. You can install the regulating shutter in between the adapter kit and the rain deflector. Model PK Code B H P F G G H G G G G G G G G G M2 KG0100 ET PROTECTION GRID B P 41 code KG GB ed.a-1611

42 ACCESSORIES FOR AIR DELIVERY Duct bend When installing a ducted system, the installer will have to provide connections and bends. When connecting PKA/PKE heaters and our air delivery shutters, please follow the specifications below. Sizing is referred to an air speed in ducts ranging from 8 9 m/s. Shapes and dimensions can obviously differ from those stated. Values in the table are referred to inner dimensions. APEN GROUP can supply, if requested, a straight pipe + bend kit correctly dimensioned for heater and fire dampers. Components are made of non-insulated galvanized sheet. Flange size is 25 mm. B Y H A D X KG0100 C3 015 PK Model Code Heater Duct Flange Height Distance A D B H F X Y G G G G G G G G KG0100 ET DUCT BENDS 42 code KG GB ed.a-1611

43 PLENUM FOR AIR DELIVERY Air distribution plenum is to be installed when air is directly blown in the room. It is laid directly on the heater and does not require any fixing. Our plenums have two ranks of louvres and are suitable for use in industrial and commercial buildings. Louvres deliver high volumes of air and guarantee long blows and low pressure drops. Louvres are made of aluminium for models, and of galvanised steel for other models. Louvre pitch ranges from 25 to 50 mm. Standard plenums blow air on three sides (two short and one long). If required, custom plenums can be supplied, blowing air on two long and one short side. In tables below, the following data are shown: Code: the code used to order the plenum. Short side: the number and size of louvres on short side. Long side: the number and size of louvres on long side. H: total height of plenum. Height and width dimen sions are the same as those of corresponding heater. VK: blown air speed when louvre slats deflection is 0 (zero). If deflection is 22, increase VK value by 16%, if deflection is 45, increase VK value by 30%. Deflection means the horizontal angle of blown air. Blow distance: The distance in meters the air is blown to. This value is referred to a residual speed of 0,3 m/s. With deflection angle of 22, multiply blow distance by For angles of 45, multiply by P: pressure drop of the plenum referred to the output speed VK (slats deflected by 0 ). STANDARD VERSION - 2 SHOR T SIDES - 1 LONG SIDE PLENUM Code Short Side Long Side H VK Blow Distance # Louvre size # Louvre size mm m/s m Pa PLXPKA032NA PLXPKA035NA 2 300x x , PLXPKA060NA 2 500x x , PLXPKA100NA PLXPKA120NA 2 400x x , PLXPKA140NA 2 500x x , PLXPKA190NA 2 600x x , PLXPKA250NA 2 600x x , PLXPKA320NA 2 800x x , PLXPKA420NA 2 800x x , PLXPKA550NA x x PLXPKA700NA 4 600x x , PLXPKA900NA PLXPKA1M2NA 4 800x x , ΔP CUST OM VERSION - 1 SHOR T SIDE - 2 LONG SIDES PLENUM Code Short Side Long Side H VK Blow Distance # Louvre size # Louvre size mm m/s m Pa PLXPKA032NA-1 PLXPKA035NA x x , PLXPKA060NA x x , PLXPKA100NA-1 PLXPKA120NA x x , PLXPKA140NA x x , PLXPKA190NA x x , PLXPKA250NA x x , PLXPKA320NA x x , PLXPKA420NA x x , PLXPKA550NA x x , PLXPKA700NA x x , PLXPKA900NA-1 PLXPKA1M2NA x x , KG0100 C3 016 KG0100 ET PLENUM 43 code KG GB ed.a-1611 ΔP

44 ACCESSORIES FOR VENTILATION Apen can supply, if requested, the following accessories: - Soft starter - Motors with isothermal protection - Inverter - Double polarity motors Note: If double polarity motors and/or inverter are used, it is mandatory to install a two-stage or modulating burner with flame mode control depending on fan speed. SOFT STARTER APEN supplies soft starters as a standard for motors with an output equal or higher than 5.5 kw. Soft starter has the following advantages: - In installations where air distribution ducts are made of textiles (or similar), it prevents the initial splash effect and guarantees longer life to ducts. - It balances motor breakaway starting current - It helps reducing belt wear and extending the life of motor and fan bearings. A soft starter for 3-phase motors with capacity below 5.5 kw is also available. G soft starter for motors up to 2.2 kw G soft starter for motors up to 4.0 kw MOTORS WITH ISOTHERMAL PROTECTION This kind of motor have a thermostat in their coil to measure the temperature in the coil itself. If set temperature is exceeded, the thermostat opens up. This protection is required as additional protection of the installation in some European countries. This kind of protection is a default of APEN 1-phase heaters. When the thermostat triggers, the fan stops. For 3-phase motors this protection is optional and must be expressly requested. The wiring of this safety is shown in the figure below. LED power on LED end of cycle Start up time Default=C Start-up voltage Default=C DOUBLE POLARITY MOTORS APEN can supply heaters with double polarity motors (4/6 or 4/8 poles), according to modifications required. Double polarity motors have the following limits: - Air flow rates are in direct proportion to the number of poles based on the following ratio: V2=V1*(n2/n1) - Air flow rates are in direct proportion to the square of poles based on the following ratio: HT2=HT1*(n2/n1)2 2 This change requires the use of specific control panels, larger motors and, if required, a modification of heater frame. We recommend installing an inverter. -Q Move KM1 command from terminal 16 to terminal KM L1 3L2 5L3 KM1 A1 A2 14 KM KM1 l n KG0100 C2 058 CN1 F1 CN2 C.U. 2T1 4T2 6T3 -M2 01 TM1 CN4 CN3 CN9 44 TM1= Isothermal protection on terminals 28 & 29. If two motors are installed, protections are wired in series 4 code KG GB ed.a-1611

45 INVERTER Special applications that require variable air flow rates can also be met by supplying heaters with fan control through inverter. Using an inverter requires an understanding of its control system. Available control types are the following: A B C Speed selector: from 2 to 8 default speeds that can be selected through an electrical switch or a potentiometer. Modulation control using an external signal (generally 0-10V or 4-20 ma). Control of a variable (air pressure, temperature or other) A - Control through a speed selector It s the easiest. It is manually operated by the user and/or electrically operated through free contacts of a relay or other device. Default speeds can be modified by the user. Another option is to use a resistive potentiometer: the shift is within a minimum and a maximum set values. B - Modulation control Before the inverter, a controller sends an analogue signal to the inverter based on the value to be monitored (pressure, temperature, other). The inverter varies its speed according to the input received within max and min values set. C - Control of a variable Almost identical to B. The only difference is that the inverter can directly regulate the monitored variable: its values, its max and min values can be directly programmed and managed through the inverter. For this configuration, a sensor is required to monitor the variable. Inverters can be useful for the following applications: Installations where pressure drop is unknown or difficult to calculate. During installation it is possible to fine tune air flow rate. Buildings where set temperature should be rapidly reached, in order to reduce speed and minimise noise. Variable air flow rate: multi-area air distribution systems where each area has its own temperature setting. Air supported structures and domes: this method maintains optimum pressure value within the dome (supported by a wind speed sensor) and consistently reduces electrical consumption. Single-phase supply for 3-phase units (up to 4kW motors). NOTES: With standard motors, minimum speed must be higher than 20 Hz to guarantee cooling down motor coil. If this threshold is too high, special motors are available and can be requested to APEN GROUP Technical Support. The main switch protecting the heater through an inverter must have a residual current to the ground of 0,3A (300 milliampere). Switches with residual current of 0,03A (30 milliampere) are not suitable. Inverter: This picture is for reference only. Brand and model of supplied device can change without notice. Item Surcharge INVER VVPK060-10A VVPK060-20A VVPK100-00A VVPK100-10A VVPK100-20A VVPK140-00A VVPK140-10A VVPK140-20A VVPK190-00A VVPK190-10A VVPK190-20A VVPK250-00A VVPK250-10A VVPK250-20A VVPK320-00A VVPK320-10A VVPK320-20A VVPK420-00A VVPK420-10A VVPK420-20A VVPK550-00A VVPK550-10A VVPK550-20A VVPK700-00A VVPK700-10A VVPK700-20A VVPK900-00A VVPK900-10A VVPK900-20A VVPK1M2-00A VVPK1M2-10A VVPK1M2-20A TER 45 code KG GB ed.a-1611

46 TEMPERATURE SETTING G09921 A digital electronic regulator is available to control air temperature. The regulator is delivered already wired and tested on front of control panel. It includes a room sensor or a duct probe, based on installation. This regulator can only be used matched to a two-stage burner. Both delivery and intake room temperatures can be checked. Modifying Set Point To change set point 1 (Default =20 C): Press SET key: the screen displays ST1, then the current value of ST1; Press UP and DOWN keys to modify the value; Press SET again to confirm new ST1 value. The following sensors or probes can be matched to the regulator: Code Features Temperature range G07202 NTC - Room sensor -10 C to 60 C G07203 NTC - Duct probe -10 C to 90 C G17675 NTC - Wire probe -50 C to 450 C G16170 PT100 - Ø6x C to 450 C G16195 PT100 - Ø6x C to 450 C Settings: The following parameters must be set: ST1 (set point) and P1 (tolerance). The regulator operates 1st stage (ON-OFF Burner) or 2nd stage (high/low flame burner) depending on how far set point is. Example: ST1=20 C P1=2 C Cold room to be heated: up to 19 C burner is ON with high flame, between 19 C and 20 C burner is ON with low flame, over 20 C burner is OFF. Warm room cooling down: below 19 C burner turns ON with low flame, below 18 C burner turns to high flame. You can get the operation you need by changing ST1 and P1 values. If probe is on delivery, set ST1= C and P1=3-5 C. ST2 set point and P2 range are not used. Process plant installations can require fine tuning P1 range asymmetrically with reference to set point. In such case, contact APEN GROUP Technical Support. Screen The screen shows the following information: Temperature detected by the sensor Stage reached (LEDs 1 to 4) Reverse operation mode (R) - Heating Alarms are indicated by ERR + error number. Modifying P1 parameter To modify P1 parameter (Default =2 C): Press PRG-mute key for more than 5 seconds: the screen displays P1 Press SET to display P1 value; Press UP and DOWN keys to modify the value; Press SET again to store new ST1 value. Press again PRG-mute key for more than 5 seconds to confirm changes and exit the program. Reset of alarms The reset for all alarms with manual reset can be done pressing contemporarily the PRG and UP buttons for at least 5 sec. 46 NOTE: If no key is pressed for 10 seconds, the screen starts flashing and after 1 minute restores standard display, without storing any changes. code KG GB ed.a-1611

47 POSIZIONE HIGH/LOW - Temperature controls SU QUADRO general KG0100 C (230) (0) dig.input supply out1 out2 (M) (+10) (out) ProBe TeMP.-nTC TEMPERATURE SENSOR FOR ROOM OR DUCT. T O BE INSTALLED BY AN INSTALLER TEMPERATURE REGULAT OR TERMI - NAL BOARD SEEN FROM INSIDE THE CONTROL PANEL 47 code KG GB ed.a-1611

48 ACCESSORIES FOR THE CHIMNEY Components supplied for flue system are made of stainless steel AISI316L. They are single walled and suitable for indoor or outdoor installation. If required, double-walled stainless steel chimneys can be supplied. Components have male/female rotating facing. Clamps are only required for chimneys longer than 2 meters. Silicone rubber seals are supplied. Running temperature with dry/wet operation and negative pressure is 400 C. In case of wet operation under pressure, the temperature is 250 C. Chimneys are suitable for working either under pressure or negative pressure. Maximum pressure allowed is 1,000 Pa. Flue sampling element is 300 mm long and it includes a thermometer. Straight pipe (1 meter) Model Code Ø [mm] G G G G G G M2 G Conical rain protection Model Code Ø [mm] G G G G G G M2 G Fastening ring Model Code Ø [mm] G G G G G G M2 G bend Model Code Ø [mm] G G G G G G M2 G KG0100 C3 017 Chimney kit Model Code Ø [mm] G G G G G Flue exhaust module Model Code Ø [mm] G G G G G G M2 G Tee joint Model Code Ø [mm] G G G G G G M2 G Condensate Drain Model Code Ø [mm] G G G G G G M2 G KG0100 ET code KG GB ed.a-1611

49 All components are certified in compliance with EN and EN standards. They are identified by an ID plate showing their features. Some examples: 0051-CPD-0042 AN T600 N1 W V2 L50050 G 0051-CPP-0042 AN T600 N1 W V2 L50050 G CPD-0007 AN T160 P1 W V2 L50050 O 30 Certificate # Product Description Regulation # Temperature Level: T80/T100/T120/T140/T160/T200/T250/T300/T400/T450/T600 Noise Level: N=Negative,P=Positive, H=High Pressure, 1 and 2 indicate allowed loss. 1 is the most restrictive value Condensate Resistance Class: D = dry use, W = wet use Corrosion Resistance Class: V1 - Gaseous fuels, natural gas, LPG, and manufactured gas 50 mg/m³; V2 - Liquid fuels, natural gas, LPG, and manufactured gas 50 mg/m³; V3 - Solid fuels, natural gas, LPG, and manufactured gas 50 mg/m³; Gas oil with sulphur >0.2% Vm - Resistance category without test, only with minimum thickness of material Material and thickness: If INOX AISI316 steel 0.5 mm thick is used, category is L50050 i.e. L50=INOX AISI316, 050=0.4mm thick Inner resistance to fire (G=Yes, O=No) and distance (in mm) from combustible materials 49 code KG GB ed.a-1611

50 ACCESSORIES FOR CONDENSATE HANDLING If a heater with modulating and/or two-stage burner is installed, high air flow rates and low heat drop can result in condensate production. It is necessary to drain this condensate from the exchanger using a suitable system. All PKA/E heaters include a kit for condensate drain. For horizontal heaters, air flow direction (rightward or leftward) must be specified at order to install fittings in the correct position. No condensate should form into front manifold because the gaskets installed are not waterproof. In order to avoid this, burner heat input should be adjusted to a value at least equal to heater minimum heat input (see table with technical data). If condensation is not drained from the exchanger, it could seriously damage it. The warranty of the exchanger does not cover damages caused by condensate. The picture below shows examples of horizontal and vertical installation. In both cases, it is better to install the exchanger with a slight inclination in order to ease the drain. Standard installa - tion of condensate drain has its outlet on chimney side. Materials to be used for condensate drain Any plastics should be avoided for condensate drain system since flue temperature is too high. Suitable materials are stainless steel and aluminium (only outside the heater). Galvanized steel is not recommended since it can be corroded by acid condensate. KIT codes are the following: G00740-xxx-H (horizontal) G00740-xxx-H (vertical) Replace xxx with heater size code. REMARK: Heaters of K and R series have condensate drain installed by default on the back side. If necessary, for horizontal heaters, the condensate drain can be installed on the front. Horizontal conden - sate drain If an oil burner is matched, it is mandat or y to prevent any condensate. Ver tical conden - sate drain Draining using a Siphon [G14551] If the heater is installed indoor and a condensate drain system is provided, the siphon must be smoke proof. The siphon includes a float that prevents any flue leaks, even when the siphon is empty. Fill manually the siphon with water at first start-up. KIT G14303 Apen can supply a kit for deacidifying acid condensate. This kit is suitable for heaters of any size. 50 code KG GB ed.a-1611

51 6. Instructions to Service Staff These instructions provide information on electrical wiring, thermostat settings and checks on motor electrical absorption. 6.1 Electrical Wiring and Diagrams The use of an electronic wiring card eases and makes consistent the wiring scheme of all models. The card includes the following connectors: Connector CN1 CN2 CN3 CN4 CN5 CN6 CN7 CN8 CN9 Feature Power supply inlet; L2 and N terminals are reserved to single-phase burner with separate supply to the motor Connector reserved for the burner Connector for wiring contactors of fan motor Connector for control panel wiring Connector for STB, TW, and TR thermostat wiring (these thermostats are installed into the heater) Connector for fire damper and discharge shutter wiring Connector for room thermostat, high/low flame thermostat and/or temperature regulator wiring Connector for room or delivery air sensor wiring (when temperature regulator is installed) Connector for remote control of alarms or operation status signals (power-free contacts) REMOTELY CONTROLLING FUNCTIONS - CN9 CONNEC- TOR This connector is useful to remotely control alarms and the status of various components of heater and burner. As you can see in the drawing, the connector is not powered and the user can choose to use low tension (24V) or high tension (230V). The following signals are available: Terminal Meaning when contact is closed 31 Common 32 Fan working 33 Thermal relay OK. If the contact is open, thermal relay alarmed. 34 Locked burner 35 Burner working 36 Damper OK. If contact is open, damper is alarmed and closes 37 Safety thermostat (STB) OK. If contact is open, thermostat has triggered. All heaters have the same components. Data listed in the following tables are referred to standard products. KG0100 C code KG GB ed.a-1611

52 CONTROL PANEL - CN4 CONNECTOR Control panel is wired to CN4 connector as follows: Terminal Feature 21 Summer control: it starts the fan 22 S1 Common Winter / 0 / Summer switch 23 Winter control: it starts the burner 24 H3 Red lamp. STB or fire damper alarm 25 H2 Green lamp. Line signal 26 H1 Yellow lamp. Thermal relay alarm 27-N - Neutral 28 and - Terminals for isothermal motor 29 S1 selector allows to choose required operation mode. Summer it starts the fan directly Winter if room thermostat is closed, it starts the burner and, when fan thermostat (TR or FAN) closes, it starts the fan. Note: when the switch is turned on "0", if fan thermostat is closed, the fan will keep working. Before accessing the fans, it is mandatory to power off the heater. It is not enough to turn the switch on "0". -H H2 -H1 X2 X S1 X2 l n CN1 CN N CN4-G10050 CN5 CN4 CN3 -SCH1 CN9 CN6 CN7 CN8 52 KG0110 C2 055 code KG GB ed.a-1611

53 90 40 Floor Standing Warm Air Heater series PK THERMOSTAT WIRING - CONNECTOR CN5 The Heaters are certified with the thermostat groups. All the models series GH and EMS (both N and K) include the 3-function thermostats TR+TW+STB - STB: The STB (or Limit) thermostat, (safety thermostat with manual reset) stops the burner if the exchanger reaches an excessive temperature. If STB thermostat triggers, it has to be manually reset following procedures describes in User section of this Manual. This thermostat cuts the power to the burner by controlling KAS relay of wiring card. - TW: The TW thermostat is installed on thermostat series of the burner (T1 - T2). If triggered, it turns burner off when the temperature inside the burner exceeds threshold. This thermostat is similar to a safety control but should not be used as a regulation thermostat. - TR: The TR thermostat allows the fan to start only when air temperature threshold is reached. When burner turns off, it allows cooling down the exchanger. Tr TW P1 2 1 P1 2 1 GREEN GREEN BLACK BLACK BROWN BROWN stb Wiring for three-function thermostat The three thermostats installed in the box are set to the following temperature values: TR is set to 40 C; TW is set to 90 C; STB default setting is 100 C. To change settings for TR and TW thermostats, turn regulat - ing screws. Note: A jumper must be installed on terminals 3 and 4 to operate the burner correctly. This contact (230V) can be used to connect a device that, if opened, stops the burner. (This is wired in series to STB thermostat and is has the same function). THERMOSTAT SET - TING SCREWS GREEN THERMOSTAT SET - TING SCREWS For models 420 and upwards TR: brown cables- terminals 1 and 2 TW: green cables- terminals 3 and 4 STB: black cables- terminals 5 and 6 GREEN GREEN BLACK BLACK BROWN BROWN KG0100 C code KG GB ed.a-1611

54 MOTOR WIRING - CONNECTOR CN3 Single-phase Motor In PKA/E heaters with single-phase motor, power lines output from main switch and feed directly the overheat protection (Q2) and the wiring card, which is protected by F1 fuse (6.3A - 250V - Rapid). From overheat protection le line feeds KM1 contactor. Motor is directly connected to KM1 contactor. Fan logical control comes from CN3 connector and has the following outputs: Terminal Feature With jumper This terminal of KM1 contactor has a withholding function to prevent repeated ST OP & GO cycles of the fan at first start. 15-N Neutral 16 Fan start-up control 17 Fan start-up control if motor is isothermal In standard PK heaters, single-phase motors directly drive the fan. Built-in isothermal protection is located in the coil and is wired in series to fan supply. No other wiring is required for this safety. Motors have three speeds: maximum speed is used. In specific cases, when a lower air flow rate and/or noise level are required, intermediate speed can be used by moving a wire on the fan. This operation requires reducing heat input by 20% of maximum input. Use of minimum speed is not allowed. l1 -Q1 T1 l n n n LEGEND: Q1 Door lock main switch; Q2 Magnetic switch for motor protection fan - 10A; KM1 Relay, contactor, fan motor start-up; M1 Fan motor - 230V/1F; SCH1 Heater management electronic card; F1 Card protection fuse - 5x20-6,3A SF (rapid) -Q2 9 n n KM1 5 8 A2 A1 KM1 7 KM1 CN5 CN4 CN3 CN1 F1 KG0100 C2 053 CN2 CN9 -SCH1 FAN WIRING DIAGRAM 6 4 CN6 CN7 CN8 B n -M1 +Qd code KG GB ed.a-1611

55 Three-phase Motors - Direct start up In PK heaters with tree-phase motors, power lines output from main switch and directly feed KM1 starter and the wiring card, which is protected by F1 fuse (6.3A - 250V - Rapid). Motor is directly connected to KM1 contactor. Fan logical control comes from CN3 connector and has the following outputs: Terminal Feature Thermal relay. If two motors are installed, thermal relays are wired in series This terminal of KM1 contactor has a withholding function to prevent repeated ST OP & GO cycles of the fan at first start. If two motors are installed, only KM1 is to be wired. 15-N Neutral 16 Fan start-up control. If two motors are installed, coils are wired in parallel. 17 Fan start-up control if motor is isothermal The starter used by APEN in its control panels is "TeSys Model U" by Schneider Electric. It helps protecting against short circuits and overheat. 3-phase motors in standard PKE heaters have 230/400V power supply up to 4 kw included. Over 4 kw, supply is 400/690V. Therefore, for motors up to 4 kw, a star connection is required, while from 5.5 kw onward, a delta connection is required. -Q Mot or star con - nection -KM L1 3L2 5L3 -KM L1 3L2 5L3 KM2 A1 KM1 A2 A1 A2 14 KM KM KM1 17 l n KG0100 C2 059 CN1 F1 CN2 C.U. C.U. F1 connection Mot or del ta connec - tion 2T1 4T2 6T3 2T1 4T2 6T3 CN5 CN4 CN3 -SCH1 CN9 CN6 CN7 CN8 LEGEND: Q1 Door lock main switch; KM1 Fan motor contactor 1; M1 Fan motor 400V/3F/50Hz; SCH1 Heater management electronic card; F1 Card protection fuse - 5x20-6.3A (rapid) -M M code KG GB ed.a-1611

56 Three-phase Motors with Soft Starter In PK heaters with tree-phase motors over 5.5 kw, power lines output from main switch and directly feed KM1 and KM2 starter and the wiring card, which is protected by F1 fuse (6.3A - 250V - Rapid). Motor is directly wired to soft starter, which is wired to the starter. Fan logical control comes from CN3 connector and has the following outputs: Terminal Feature Thermal relay. If two motors are installed, thermal relays are wired in series This terminal of KM1 contactor has a withholding function to prevent repeated ST OP & GO cycles of the fan at first start. If two motors are installed, only KM1 is to be wired. 15-N Neutral 16 Fan start-up control. If two motors are installed, coils are wired in parallel. 17 Fan start-up control if motor is isothermal The starter used by APEN in its control panels is "TeSys Model U" by Schneider Electric. It helps protecting against short circuits and overheat. ATS01N2 by Schneider Electric is the soft starter used. Its start-up time and voltage value can be set through its front potentiometers. The only wiring required by this soft starter is a jumper between terminals LI+ and LI2. 3-phase motors in standard PKA/E heaters with soft starter have 230/400V power supply up to 4 kw included. Over 4 kw, supply is 400/690V. Therefore, for motors up to 4 kw, a star connection is required, while from 5.5 kw onward, a delta connection is required. Starter and additional block scheme LUA1-C11 (thermal) -Q KM2 A1 KM1 A2 A1 A2 14 KM1 18 KM2 17 -KM L1 3L2 5L3 -KM L1 3L2 5L KM1 17 l n KG0100 C2 054 CN1 F1 CN2 C.U. C.U. F1 2T1 4T2 6T3 1/L1 3/L2 5/L3 BoosT lo1 CoM li+ A1 li1 ATs01n2 2/T1 4/T2 6/T3 r1c r1a li2 2T1 4T2 6T3 1/L1 3/L2 5/L3 BoosT lo1 CoM li+ A2 li1 ATs01n2 2/T1 4/T2 6/T3 r1c r1a li2 CN5 CN4 CN3 -SCH1 CN9 CN6 CN7 CN8 -M M code KG GB ed.a-1611

57 Wiring Diagram of PK Card Code G10050 KG0100 C2 060 LEGEND F1 KAV 6,3 A fuse Fan control relay KAR thermal relay control kab kaf burner lock relay burner operation relay KAT Relay closed damper kas Relay STB closed (safety thermostat ) 57 code KG GB ed.a-1611

58 6.2 Burner Matching The burner nosepiece must penetrate for a length not exceeding min and max values of X. Important. Nosepiece length must be greater than "X" min value. Shorter nosepieces could damage the exchanger and void the guarantee. The value of ØT indicates maximum nosepiece diameter for a specific heater. If the installed nosepiece is larger, the exchanger will have to be changed at an extra cost. Contact Apen Group Customer Service if you need to use a low NOx rate burner with flue gas recirculation outside the combustion head. Standard heaters supplied include standard burner plates sized as shown in the table below. If standard burner plate is not suitable for the burner to be installed, a plate with custom holes can be ordered (specify burner brand and model). A B d C P T X M e Model PK X ØT P A B ØC ØD ØM E min max max [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] M M M M M M M M KG0100 ET code KG GB ed.a-1611

59 6.3 Gas Oil Burners If a oil burner is used, its heat output depends on: nozzle size Burner pump pressure. Oil burners can be used only with PK-N heaters, while on PK-K and R condensation heaters, only gas burners can be installed. The table below shows the nozzles and pressures allowed for each heater model. For each nozzle, heat output (kw) and consumption (kg/h) values are reported with reference to pressure. To calculate consumption in liter/hour, just multiply the kg/h value * 1.14 [density = 0.87 kg/l]. If a two-stage burner is used, the sum of the two nozzles is reported in the table. First stage nozzle cannot be smaller than the nozzle listed in first column. This is to avoid condensate in flue. Condensate in flue is not allowed for oil burner. The use of nozzles with spray angle of 60 or 80 is mandatory. It is forbidden to use nozzles with an angle of 45 both on first and second stage. Nozzle matching to PKA/E heaters table Heater Pressure NOZZLE GPH Model Oil kw kg/h kw kg/h kw kg/h kw kg/h kw kg/h kw kg/h bar 0,65 0,75 0,85 1 1, ,4 2,5 33,9 2,8 38,4 3,2 45,2 3,8 49,7 4, ,4 2,7 37,4 3,1 42,4 3,6 49,9 4, ,8 2,9 40,1 3,4 45,5 3,8 bar 1,10 1,25 1,50 1,65 1, ,5 4,7 67,8 5,7 74,6 6,3 79,1 6, ,9 4,6 62,4 5,2 74,9 6,3 82,3 6,9 87,3 7, ,9 4,9 66,9 5,6 80,3 6,7 bar 1,50 1,65 1,75 2,00 2,25 2, , , , ,9 87 7, , , , ,7 88 7,4 94 7, , , ,2 bar 2,00 2,25 2,50 3,00 3,50 4, , , , , , , , , , , , , , , ,7 bar 2,75 3,00 3,50 4,00 4,50 5, , , , , , , , , , , , , , , , ,2 bar 3,50 4,00 4,50 5,00 5,50 6, , , , , , , , , , , , , , , , , ,7 bar 4,00 5,00 6,00 6,50 7,00 8, , , , , , , , , , , , , , , , ,5 bar 6,00 7,00 8,00 8,50 9,00 9, , , , , , , , , , , , , , , , , , ,7 bar 7,50 8,50 9,50 10,50 11,50 13, , , , , , , , , , , , , , , , ,7 bar 9,00 10,50 12,00 14,00 16,00 18, , , , , , , , , , , , , , , , ,9 bar 11,00 13,00 15,00 17,00 19,00 21, , , , , , , , , , , , , , , , ,4 bar 13,00 15,00 17,00 19,00 21,00 23,00 1M , , , , , , , , , , , , , , , ,8 59 code KG GB ed.a-1611

60 6.4 Gas Burners PK heaters must be matched to gas burners certified by an EC mark as compliant to 90/396/EEC Directive concerning appliances burning gaseous fuels. Heaters can work either with natural gas, G20, G25, and G25.1, or with L.P.G., G30, and G31 gas. All models are designed, manufactured and tested to match the burners produced by main burner manufacturers on the market. Correct matches are shown in the product section of Apen Group price list. First start up shall be executed exclusively by authorized service centres complying with relevant laws existing in the Country where the unit is installed. During first start up, the combustion efficiency must be analysed. Gas Flow Rate Table PK N Heaters / GAS U.M. consumption min max min max min max min max min max min max G20 mc/h 2,6 3,7 2,6 5,2 5,3 9,1 8,4 14,4 10,1 20,5 13,2 24,2 G25 mc/h 3,0 4,3 3,0 6,1 6,2 10,6 9,8 16,9 11,8 24,0 15,4 28,3 G30 kg/h 2,0 2,9 2,0 4,0 4,0 6,9 6,4 11,0 7,7 15,6 10,0 18,4 G31 kg/h 2,0 2,8 2,0 4,0 4,1 7,0 6,5 11,1 7,8 15,9 10,2 18, M2 GAS U.M. consumption min max min max min max min max min max min max min max G20 mc/h 16,2 32,6 19,5 40,0 27,4 53,5 33,7 70,5 41,8 86,1 50,2 108,2 62,82 116,63 G25 mc/h 18,9 38,1 22,8 46,7 32,0 62,5 39,4 82,4 48,8 100,6 58,7 126,4 73,46 136,24 G30 kg/h 12,3 24,8 14,8 30,4 20,8 40,6 25,6 53,6 31,8 65,4 38,2 82,2 47,80 88,76 G31 kg/h 12,5 25,2 15,0 30,9 21,1 41,3 26,0 54,5 32,3 66,5 38,8 83,6 48,55 90,11 Gas Flow Rate Table per PK K heaters GAS U.M. consumption min max min max min max min max min max min max G20 mc/h 1,44 3,57 2,29 7,60 2,73 11,97 3,91 15,88 4,91 20,96 6,23 28, M2 GAS U.M. consumption min max min max min max min max min max min max G20 mc/h 7,49 36,08 8,52 46,48 9,78 63,04 12,83 78,07 17,93 101,11 17,97 108,0 Gas Flow Rate Table per PK R heaters GAS U.M. consumption min max min max min max min max min max min max G20 mc/h 1,44 3,32 2,29 5,99 2,73 9,40 3,91 12,43 4,91 16,59 6,23 22, GAS U.M. consumption min max min max min max min max min max G20 mc/h 7,49 28,11 8,52 35,70 9,78 47,19 12,83 62,48 17,93 78,57 60 code KG GB ed.a-1611

61 6.5 Burner Matching Tables In the following pages burner matching between PK heaters and gas burners by main European manufacturers are listed. Please remember that any burner must be accompanied by an EC certificate valid for the Country it is destined to; it must be certified for the gas type that is going to be used and accompanied by localized documentation. Gas oil burners are listed in APEN GROUP column. Some burner models are undersized if compared to maximum heat input of matching exchanger. Please, always check data supplied by burner manufacturer. Remember that burner nosepiece length must always be the one indicated in table on page 51, and that the heat output set must be lower than heater maximum heat input. REMARK: Oil burners can only be matched to heaters of N series. On K and R series condensation heaters, only gas burners can be installed. HEATER MODEL APEN GROUP RIELLO WEISHAUPT CIB UNIGAS BAL TUR Gas oil Gas Gas Gas Gas GAS LO0041-1L00I MG0041-1L10I BS 1 WG5 NG35 M-.TN.L.IT.A.0.15 BTG 3 L 200 LO0060-1L00I MG0075-1L10I BS 1 D NG70 M-.TN.L.IT.A.0.10 BTG 6 L300 LO0060-1L00I MG0075-1L10I BS 2 WG20/0 NG70 M-.TN.L.IT.A.0.10 BTG 6 L M2 LO0085-1L00I MG0090-1L15I BS 2 D WG20/0/Z NG90 M-.TN.L.IT.A.0.15 BTG 11 L300 BTG 11 P L300 LO0168-1L00I MG0120-1L15I BS 3 WG20/1 NG120 M-.TN.L.IT.Y.0.20 BTG 15 LO0168-2L00I MG0168-1L20I BS 3 D WG20/1/Z NG140 M-.TN.L.IT.Y.0.20 BTG 15 P LO0212-1L00I MG0168-2L20I NG140 M-.AB.L.IT.Y.0.20 LO0212-2L00I MG0212-1L25I NG200 M-.TN.L.IT.Y.0.25 MG0212-2L25I NG200 M-.AB.L.IT.Y.0.25 LO0212-1L00I MG0212-1L25I BS 3 WG20/1 NG200 M-.TN.L.IT.Y.0.25 BTG 15 LO0212-2L00I MG0212-2L25I BS 3 D WG30/1 NG200 M-.AB.L.IT.Y.0.25 BTG 15 P LO0280-2L00I MG0300-1L25I WG20/1/Z NG350 M-.TN.M.IT.A.0.25 BTG 15 ME MG0300-2L25I WG30/1/ZM NG350 M-.PR.M.IT.A.0.32 BTG 20 MG0355-1M32I NG350 M-.MD.M.IT.A.0.32 BTG 20 P MG0355-PM32I BTG 20 ME MG0355-MM32I LO0280-2L00I MG0300-1L25I BS 3 WG30/1 NG350 M-.TN.L.IT.A BTG 28 LO0420-2M00I MG0300-2L25I BS 4 WG30/1/ZM NG350 M-.PR.M.IT.A BTG 28 P BS 3 D NG350 M-.MD.M.IT.A.0.32 BTG 28 ME BS 4 D LO0420-2M00I MG0355-1M32I RS5 WG30/1 NG350 M-.TN.L.IT.A.0.25 BTG 28 MG0355-PM32I RS5 D WG30/1/ZM NG350 M-.PR.M.IT.A.0.32 BTG 28 P MG0355-MM32I RS25/M BLU NG350 M-.MD.M.IT.A.0.32 BTG 28 ME TBG 35 TBG 35 P TBG 35 PN LO0420-2M00I MG0355-1M32I RS5 WG30/1 NG350 M-.TN.L.IT.A.0.25 TBG 35 MG0355-PM32I RS5 D WG40/1 NG350 M-.PR.M.IT.A.0.32 TBG 35 P MG0355-MM32I RS25/M BLU WG30/1/ZM NG350 M-.MD.M.IT.A.0.32 MG0420-1M32I RS35/M BLU WG40/1/ZM NG400 M-.TN.M.IT.A.0.25 MG0420-PM32I NG400 M-.PR.M.IT.A.0.32 MG0420-MM32I NG400 M-.MD.M.IT.A.0.32 LO0570-2L00I MG0570-PL40I RS35/M BLU WG40/1 NG550 M-.PR.L.IT.A.0.40 TBG 45 LO0570-ML00I MG0570-ML40I RS45/M BLU WG40/1/ZM NG550 M-.MD.L.IT.A.0.40 TBG 45 PV TBG 60 TBG 60 PV LO0570-2L00I MG0570-PL40I RS45/M BLU WG40/1 NG550 M-.PR.L.IT.A.0.40 TBG 60 M0698-2L00I MG0800-2L50I RS68/M BLU G5/1-E/ZM P60 M-.AB.L.IT.A.0.50 TBG 60 PV M0698-PL00I MG0570-ML40I WG40/1/ZM NG550 M-.MD.L.IT.A.0.40 M0698-ML00I MG0800-ML50I G5/1-E/ZM P60 M-.MD.L.IT.A.0.50 M0698-2L00I MG0800-2L50I RS 70 LP tl G5/1-E/ZM P60 M-.AB.L.IT.A.0.50 TBG 85 PV M1047-2L00I MG0970-2L50I RS 70/M tl G5/1-E/ZMD P65 M-.AB.L.IT.A.0.50 TBG 85 ME M0698-PL00I MG0800-ML50I P60 M-.MD.L.IT.A.0.50 M1047-PL00I MG0970-ML50I P65 M-.MD.L.IT.A.0.50 M0698-ML00I M1047-ML00I M1047-2L00I MG0970-2L50I RS 100 LP tl G5/1-E/ZM P65 M-.AB.L.IT.A.0.50 TBG 85 PV M1047-PL00I MG0970-2L65I RS 100/M tl G7/1-E/ZM P65 M-.AB.L.IT.A.0.65 TBG 85 ME M1047-ML00I MG1200-2L50I G5/1-E/ZMD P72 M-.AB.L.IT.A.0.50 TBG 120 P MG1200-2L65I G7/1-E/ZMD P72 M-.AB.L.IT.A.0.65 TBG 120 ME MG0970-ML50I P65 M-.MD.L.IT.A.0.50 MG0970-ML65I P65 M-.MD.L.IT.A.0.65 MG1200-ML50I P72 M-.MD.L.IT.A.0.50 MG1200-ML65I P72 M-.MD.L.IT.A.0.65 MG1200-ML50I MG1200-ML65I RS 100/M tl WMG10/4-A P72 M-.MD.L.IT.A.0.65 TBG 120 ME 61 code KG GB ed.a-1611

62 FINTERM/ HEATER CUENOD ECOFLAM LAMBORGHINI SANT'ANDREA GIERSCH ELCO JOANNES MODEL Gas Gas Gas Gas Gas oi Gas Gas NC 4 AZUR 0 EM 3 AZ 3 EURO 6 CG10/1 - LN12 E 01B.4 G/F-T C5 AZUR 40 EM 6 AZ5 RG1 E 01B.6 G/F-T C8 AZUR 60 EM6 AZ9 EURO 6 CG10/2 - LN20 E 01B.6 G/F-T 060 C10 AZUR 80 EM9 AZ12 EURO 9 RG20 EGC.90R-2 C10 BLU 120 P EM 16 AZ12 EURO 9 CG10/2 - LN20 EGC.90R-2 C14 BLU 120 PAB EM16/2 AZ18 EURO 15 RG20 EGC.200R BLU 170 P EURO 15/2 RG30 BLU 170 PAB C14 BLU 170 P EM 16 AZ18 EURO 15 RG30 EGC.200R-2 C20 BLU 250 P EM 26 G28 EURO 25 MG10/1-LN BLU 170 PAB EM16/2 G28/2 KB 22 G 140 BLU 250 PAB EM26/2 EURO 15/2 EM 26 M EURO 25/2 KB 22 2G C20 BLU 250 P EM 26 G28 EURO 25 RG30 EGC.200R-2 C24 BLU 250 PAB EM 26/2 G28/2 KB 22 G MG10/1-LN EGC.350R EM 26 M EURO 25/2 KB 25 MOG C28 BLU 350 P EM 35 GAS35 KB 36 MOG RG30 EGC.350R BLU 350 PAB EM 40/2 GAS P45/2 KB 40 G MG10/1-LN EK 4.70G-RU(A) EM40/M GAS P45/M MG10/2-LN C28 BLU 350 P EM 40/2 GAS35 KB 36 MOG MG10/1-LN EK 4.70G-RU(A) C34 BLU 500 P 55 PM/2 GAS50 KB 40 G MG10/2-LN 320 BLU 350 PAB EM40/M GAS P45/2 BLU 500 PAB 55 PM/2 GAS P45/M MODULAIR P40 C34 BLU 500 PAB 55 PM/2 GAS50 OSA 55 MOG MG10/2-LN EK 4.70G-RU(A) 420 C70 MODULAIR P40 55 PM/M GAS P45/2 OSA 60 G MG20/1-LN MODULAIR P55 GAS P45/M BLU 700 PAB 70 PM/2 GAS P55/2 OSA 55 MOG MG10/2-LN EK 4.70G-RU(A) MODULAIR P55 70 PM/M GAS P55/M OSA 85 MOG MG20/1-LN EK 4.90G-RU(A) 550 C70 OSA 60 G OSA 90 G C100 BLU 1000 PAB 70 PM/2 GAS P75/2 OSA 110 G MG20/1-LN EK 4.90G-RU(A) MODULAIR P PM/2 GAS P75/M EK 4.135G-RUA PM/M 140 PM/M C100 BLU 1000 PAB 140 PM/2 GAS P100/2 OSA 110 G MG20/1-LN EK 4.90G-RU(A) 900 C120 BLU 1600 PAB 140 PM/M GAS P100/M OSA 125 G MG3.1-ZM-L EK 4.135G-RUA MODULAIR P90 1M2 C PM/M OSA 125 G 62 code KG GB ed.a-1611

63 Tables for Gas Burner Matching (Switzerland) HEATER ELCO WEISHAUPT CTC-GIERSCH MODEL Gas Gas Gas SVGW-N SVGW-N SVGW-N G1.40 GG 10/ WG GG10/ G1.55 WG20/1 GG 10/1 G WG20/1/Z GG 10/2 060 RG 20-L-Na RG 20-Z-L-Na RG 20-M-L-Na G WG20/1 RG 20-Z-L-Nb G WG20/1/Z RG 20-M-L-Nb EGC 140 R RG 30-Z-L-Na RG 30-M-L-Na G WG20/1 RG 30-Z-L-Nb G WG30/1 RG 30-M-L-Nb 140 WG20/1/Z WG30/1/ZM 190 G WG30/1 RG 30-Z-L-Nb WG30/1/ZM RG 30-M-L-Nb EGC 350-R-2 WG30/1 MG10/1-Z-L-N 250 WG30/1/ZM MG10/1-M-L-N MG10/1-ZM-L-N EGC 350-R WG30/1 MG10/1-Z-L-N 320 WG40/1 MG10/1-M-L-N WG30/1/ZM MG10/1-ZM-L-N WG40/1/ZM MG10/1-DZM-L-N WG40/1 MG10/2-Z-L-N 420 WG40/1/ZM MG10/2-M-L-N MG10/2-ZM-L-N MG10/2-DZM-L-N WG40/1 550 G5/1-D/ZM WG40/1/ZM G5/1-D/ZM 700 G5/1-D/ZM G5/1-D/ZMD G5/1-D/ZM 900 G7/1-D/ZM G5/1-D/ZMD G7/1-D/ZMD 63 code KG GB ed.a-1611

64 7. MAINTENANCE 7.1 Controls at First Start Up During first start-up, the following items need to be checked: Electrical Checks Supply voltage Fan rotation direction Motor absorption and air flow rate Combustion Length of burner nosepiece Fuel capacity of the burner Combustion parameters Safety Checks Check if STB+TW or LIMIT safety thermostat triggers Microswitch for fire dampers (if installed) Room thermostat TR or FAN thermostat Electrical Controls Before powering the unit on, make sure actual voltage matches the rated voltage specified. In 3-phase units it is mandatory to check fan rotation direction. If the heater has two fans, check both rotate in the required direction. Verify each motor s absorption with a suitable amperometric analyser. The table on page 26 shows maximum absorption values for each heater. The table on page 59 shows absorption values for each motor. An absorption rate lower (<15%) than max value means that air flow rate is lower than rated. If necessary, restore air flow rate by changing one of the pulleys to increase number of fan revs or by reducing pressure drops in air distribution system. A higher absorption than rated value means that aeraulic circuit resistance is lower than expected. To restore rated value, local pressure drops should be created to reduce electrical absorption by the motors. Combustion Checks We recommend checking that burner nosepiece is suitable for use (see relevant paragraph) A fuel capacity check must be performed: - At the meter, in case of a gas burner - By comparing nozzle capacity/pressure with values in specific tables, in case of a oil burner. When fuel capacity cannot be measured, adjust the burner by checking combustion parameters. Reference values for CO2 content and therefore for CO2 excess air for different fuels are listed below: CO2 values shown above can surely be improved without producing unburned products. However, a high quantity of excess air should be maintained in order to balance possible working variations in time. Flue temperature is to be measured to set thermal output after combustion has been adjusted. Nominal heat output is reached when net flue temperature ranges from 200 to 220 C; maximum output is reached when net flue temperature ranges from 270 to 290 C; and minimum output is reached when net flue temperature ranges from 120 to 140 C. During first start up, the following checks are recommended: If combustion efficiency is known and CO2 content is included in the above range, check in charts on page 9 the useful heat "set" for the heater. Checks on Safety Controls All heaters and their safety devices have been electrically tested before delivery. However, their correct operation depends on how they are actually wired and installed. When first starting the appliance, the following checks must be performed: STB+TW or LIMIT Safety Thermostat If a double thermostat (STB+TW ) is installed, you only need to reduce TW value until the burner is turned off, then restore TW value. If a LIMIT thermostat is installed, turn the ring clockwise until the right knob exceeds set reference. Check the burner is off, then release the ring that will return to the measured temperature. A red lamp indicates that safety thermostat has triggered. Fire Damper If fire dampers are installed, you need to check that its closure actually stops the burner. A red lamp indicates that the damper has triggered. Room Thermostat Make sure that room thermostat and/or the timer turn off ONL Y the burner, not the cooling fan. The fan shall stop only when the exchanger has cooled down. TR or FAN Thermostat Make sure the thermostat starts the fan on time, before the safety thermostat triggers, and that it prevents blowing cold air from louvres at turn off. Natural gas CO2 content 2 9.7% ± 0.2 LPG CO2 10.2% ± 0.2 Gas oil CO2 12.5% ± code KG GB ed.a-1611

65 7.2 Routine Maintenance We recommend execute maintenance operations using the following schedule: Air Filter Belts Clean it every 30 days After 8 hours from first start-up. Then, every 60 days. Electrical Motor Check electrical absorption every 90 days Fan Check cleaning every 90 days Combustion Analysis Once per season Safety Thermostat At the beginning of each season Fireproof Damper At the beginning of each season Every 5 years with gas burner Cleaning the Exchanger Every 3 years with gas oil burners By using a pressure regulator for the filters, an air flow switch or similar controls, you can check air filter and belts every 90 days. Checking Transmission Belts About 7 8 hours after first start up, check tension and state of belts between motor and fan. If belts are loose, stretch them. To check correct belt tensioning, verify that in the central area between pulleys, belt oscillation does not exceed 20 30mm. To tension belts and align pulleys, adjust belt tightener screws. Turn clockwise to tighten and counter-clockwise to loose. During this operation, verify if pulleys are aligned using a rod long enough to join the pulleys. Cleaning the Exchanger Correct operation and long life of the exchanger depend on its design but also on proper maintenance. The following checks must be performed at regular intervals: Check of burner combustion Check of safety device operation Visual inspection of the exchanger Check that heat exchanger is clean Controlling burner combustion values Check at least once a year burner combustion values. Parameters to check are CO2 content, flue temperature and C0 value. Note these values at first start up and at every subsequent maintenance check. If consistent changes occur, investigate on the causes. For oil and LPG burners, also smoke density must be analysed. The test should return a value below 2 on Bacharach scale. An increase in smoke density value would require cleaning the exchanger. Checking Safety Device Status Check every year that safety devices are working properly. See procedures to follow in the page next to "Safety Controls section. Inspecting the exchanger Inspect every year the exchanger to make sure no component is overheated and/or damaged. If you see any overheated areas, investigate on possible causes: Insufficient or badly distributed ventilation Dirty air filters Partially closed dampers Burner capacity higher than exchanger specifications If any of the exchanger parts is damaged, it should be replaced and the cause of the damage removed. X KG0100 C3 030 Cleaning the Exchanger It s hard to specify the period after which the exchanger must be cleaned. A safe method is to note the pressure value in the furnace at first start up, after completing all burner settings. Near the peep-hole, a tapping point is available to make this measure. The resulting value already includes pressure drops in the chimney, if any. Repeat this measure every year during combustion check and compare the result with the initial value: if they differ by more than 35%, the exchanger is to be cleaned. Generally, if natural gas burners are installed, cleaning is not required for 5-6 years. If burners are fuelled with oil and/or LPG, the cleaning should occur every 3 years. 65 code KG GB ed.a-1611

66 7.3 Spare Part List Spare Parts for Control Panel KG0100 C code KG GB ed.a-1611

67 TABLE OF CONTROL PANEL COMPONENTS Position Description Code Regulation Use Door lock G A All 032 and 035 models A 1 main G A From A to A; switch G A Models A & 20A; all 900 models 2 Neutral G /40A All models up to A included disconnect switch G /80A A & 20A models; all 900 models 3 Wiring card G10050 Any heaters, any models 4 Card fuse X ,3A Any heaters, any models 5 1 pole selector G10065 Ø 22 Any heaters, any models 6 Green lamp G V Any heaters, any models 7 Red lamp G V Any heaters, any models 8 Yellow lamp G V Any heaters, any models 9 Undecal relay X V All 032 and 035 models A Relay base X All 032 and 035 models A 10 1P autoswitch G A All 032 and 035 models A 11 3P autoswitch G ,3A All models from 250 to Starter LUB12 G ,5 kw All models with 3-phase motor up to 5.5 kw included Starter LUB32 G kw All models with 3-phase motor from 7.5 kw to 15kW Thermal relay LUCA05 G ,2-5A All models with 3-phase motor up to 1.5 kw included 13 Thermal relay LUCA12 G A All models with 3-phase motor from 2.2 kw to 5.5 kw included Thermal relay LUCA18 G ,5-18A All models with 7.5 kw 3-phase motor Thermal relay LUCA32 G A All models with 3-phase motor (9.2, 11 & 15 kw) 14 Contact LUA1C20 G02271 NO + NO All models with 3-phase motor starting from A 15 Soft starter block G All Models with soft starter G kw Special models on demand G kw Special models on demand 16 Soft starter G ,5 kw A, A, A G kw A, A, A, A, 1M2-00A, 1M2-10A G kw 1M2-20A 17 Temperature regulator G03470 IR33 Optional for all models Motor KW CurrentIn 400V-50Hz Efficiency % Rev. # 1,1 2,7 81, ,5 3,7 82, ,2 4,9 84, ,0 6,5 85, ,0 8,1 86, ,5 10,9 87, Thermal relay 1,2-5A 3-12A 7,5 14,6 88, ,5-18A 9,2 17,1 89, ,0 20,2 90, ,0 27, A Thermal relay setting 67 code KG GB ed.a-1611