REMKO CLK 20 Mobile Heaters

REMKO CLK 20 Mobile Heaters Operation Technology Spare Parts Edition GB M08 REMKO powerful like a bear

Operating Instructions Before commissioning/use of the equipment, these operating instructions must be read carefully! Our guarantee becomes null and void if the unit is used, set up, or maintained improperly or if modifications are made to the supplied unit without our prior consent. Subject to alterations! Mobile Heaters REMKO CLK 20 Contents Page Contents Page Safety Notices 4 Description of Unit 4 Regulations for Hot Air Heaters 5 Installation Regulations 6 Safety Devices 6 Chimney 7 Before Commissioning 7 Commissioning 8 Shutdown 9 Maintenance and Service 9 Trouble Shooting 11 Customer Service and Guarantee 11 Technical Data 12 Wiring Diagram 13 Exploded View 14 Spare Parts List 15 Commissioning of Forced-Air Oil Burner 16 Maintenance Log 18 EC Declaration of Conformity 19 Always keep these operating instructions in the direct vicinity of the installation site or unit. 3

Safety Notices Make sure to observe relevant local building and fire protection codes and abide by the regulations of the employers' liability insurance associations. The equipment may be operated only by persons who have received proper training in its operation. The equipment must be set up and operated in such a way that people are not endangered by exhaust fumes, hot air, and radiated heat and no fires can break out. The equipment may be operated only in room with a sufficient amount of air for the combustion. The equipment may be operated without a chimney in well-ventilated rooms. In this case, people may not constantly be in the mounting room. Corresponding prohibition signs must be posted at the entryways. A safety zone of 1.5 m around the equipment is to be maintained, even for non-flammable objects. The equipment is to be installed only on a noncombustible foundation. The equipment may be set up and operated only in an environment not at risk of fire or explosion. Mobile fuel containers may only be installed in compliance with technical regulations for flammable liquids TRBF 210 and 280. Any additional building ordinances of the country in which it is installed are to be observed. The intake guard grille must always be kept free of dirt and loose objects. Never insert foreign objects into the equipment. The equipment may not be exposed to direct water jets. All electrical lines of the equipment must be protected from damage (e.g. due to animals). Before all work on the device, the mains plug must be removed from the mains socket on principle. Safety devices may not be bypassed or blocked. Repair work on the electrical installation and on the burner may be carried out only by authorised, expert personnel for safety-technical reasons. The unit may never be disconnected from the power mains before the entire cool-down phase is up (except in emergency situations). Description of Unit The units are mobile, directly combusted hot air heaters (WLE) with heat exchangers and a chimney connection for commercial use. They are directly combusted with EL heating oil or diesel fuel and designed for fully automatic, universal, problem-free use. The units are only operated with a separate forced-air oil burner. The units are equipped with an electrical oil preheater via the nozzle stock. The units are equipped with a low-noise, maintenancefree, high-performance axial ventilator, a room thermostat socket, a connection cable with a plug, and a drum fitting. The units correspond with the basic safety and health requirements of all pertinent EU regulations and are easy to operate. Areas of application The units are mobile, directly combustible hot air heaters that supply instantaneous heat. They are only used for commercial purposes. Among other things, the units can be used in the following areas: Drying of new structures Spot heating of outdoor workstations Spot heating of workstations in open production rooms and halls not at risk of fire Heating of closed and open rooms, on a permanent or temporary basis De-icing of machines, vehicles, and non-flammable warehouse goods Temperature control of parts at risk of frost and greenhouses Function If the unit is switched to heating mode, the forced-air oil burner starts automatically. In fully automatic heating mode, the forced-air oil burner starts only when heat is required. After the burner has run for a short time, the temperature control thermostat "TR" (set temperature between 35 C and 40 C) automatically switches on the air supply fan. Hot air is blown out. When the room thermostat is in operation, the process above is automatically repeated depending on the amount of heat required. The temperature monitor "TW" (set temperature between 80 C and 85 C) monitors the internal temperature of the unit. After the unit has been shut down using the operating switch or by the room thermostats, the air supply fan continues to run for a certain period of time to cool the combustion chamber and the heat exchanger and then shuts down. This process may repeat several times. 4

Monitoring unit operation All functions of the unit are fully automatic and monitored for safety by the safety devices and the automatic burner relay (part of the forced-air oil burner). If the flame burns irregularly or goes out, the unit is switched off by the automatic burner relay. The control lamp on the control panel and the malfunction lamp of the automatic burner relay light up. Before the unit can be restarted, the automatic burner relay must be released manually by pressing the external reset button on the control panel or the reset button on the automatic burner relay. The temperature control thermostat (TR) regulates the operation of the fan. The temperature monitor (TW) limits or regulates the temperature of the unit in heating mode. The safety temperature limiter (STB) interrupts the heating mode when extreme overheating occurs or if the temperature monitor (TW) breaks down or becomes defective. The STB can be released manually only after Before the STB is released to begin operation again, the causes for the activation of the STB must be localised. Regulations for Hot Air Heaters When using the equipment, the following directives must be observed: Feuerungsanlagenverordnung (FeuVo) (Furnace Installation Ordinances) of the individual states Unfallverhütungsvorschrift (UVV) (Accident Preven tion Regulation) "Heiz-, Flämm- und Schmelzgeräte für Bau- und Montagearbeiten" (Heating, Burning, and Melting Equipment for Construction and Mounting Work) (VBG 43) Arbeitsstättenrichtlinien ASR 5 (Workstation Guidelines) Arbeitsstättenverordnung (Workstation Ordinance) 5 and 14 Ordinances regarding the execution of the Bundes- Immissionsschutzgesetzes (BImSchG) (Law Concerning the Protection against Harmful Effects on the Environment through Air Pollution, Noise, Vibrations, and Similar Factors) and the legal regulations enacted as a result (ENEG) Excerpt from the Unfallverhütungsvorschrift (VBG 43) 37 Operating personnel The equipment may be operated only by persons who have received proper training in its operation. 38 Installation (1) The equipment must be installed in a stable location. (2) The equipment must be set up and operated in such a way that people are not endangered by exhaust fumes, hot air, and radiated heat and no fires can break out. (3) The equipment may be operated only in rooms with a sufficient amount of air for the combustion and the exhaust fumes are conducted outside via chimneys. A natural air supply that suffices for combustion is present if the following applies: The room volume in m³ corresponds to at least 10 times the nominal heating capacity in kw of all equipment being operated in the room and a natural exchange of air is guaranteed by windows and doors. (4) Deviating from Section 3, the equipment may be operated without a chimney in rooms that are well aerated and ventilated and the amount of pollutants in the breathing air that is hazardous to health do not reach an unreasonable concentration. Natural aeration and ventilation is present if one of the following applies: 1. The room volume in m³ corresponds to at least 30 times the nominal heating capacity of all equipment being operated in the room and a natural exchange of air is guaranteed by windows and doors. 2. Air openings for supply and outlet air in the ceiling and floor exist and cannot be closed. The size of these openings in m 2 corresponds to at least 0.003 times the nominal capacity in kw of all equipment being operated in the room. (5) The equipment may be set up and operated only in rooms and areas not at risk of fire or explosion. 44 Room drying (2) Deviating from 38 Sect. 3, heaters may be used to dry rooms with a sufficient air supply for combustion without the exhaust fumes having to be conducted outside via chimneys. People may not constantly be in these rooms. Prohibition signs should be hung at the entrances of these rooms. 53 Testing (2) According to the conditions for use, the equipment should be tested by an expert for its proper working order as required, but at least once a year. The exhaust emission specifications of the burner must be checked. 54 Monitoring (1) The persons assigned with the operation of the equipment must check for noticeable defects of the operating controls and safety devices and for the existence of protective mechanisms before starting work. (2) If defects are discovered, the supervisor must be informed. (3) In case of defects that endanger the operating safety of the unit, it must be shut down. 55 Rule infringements Whoever violates the regulations of VBG 43, whether deliberately or due to negligence, is acting contrary to regulations according to 710 Sect. 1 of Reichsversicherungsordnung (RVO) (Reich Insurance Code). 5

Installation Regulations When the equipment is in use, the safety guidelines of the employers' liability insurance associations, the respective country construction ordinances, and the burning appliance regulations basically apply. Avoid underpressure or overpressure in mounting rooms since these states always lead to combustion-technical problems. Make sure the fresh air supply has been adapted to the respective fan output (see model plate). The forced-air oil burner must be equipped with a separate combustion air supply if necessary. Outdoor installation Due to the operation of the equipment, no dangers or unreasonable nuisances may arise. The equipment operator must guarantee that unauthorised persons cannot manipulate the equipment or the energy supply. Because rain and snow can be pulled in through the supply air fan, a suitable protective covering should be used. Installation in closed, well-ventilated rooms without a chimney The equipment may only be operated when the minimum amount of air required for combustion according to 38 Sect. 4 (page 5) is supplied. A safe exhaust of the waste gases is to be ensured to exclude an inadmissible pollution of the room air. Fresh air is supplied from below. Waste gases are expelled upwards. Safety distances To guarantee safe equipment operation and maintenance, a safety distance of 1.5 metres around the device must be observed. The floor and ceiling must be fire-resistant. Heating rooms The equipment may be used for room heating only with a room thermostat (accessory). The supply of the fresh air required for proper combustion must be guaranteed. Electrical connection The equipment is operated at 1~ 230 V/50 Hz. The electrical connection of the equipment must be performed at a certain supply point with an earthleakage circuit breaker according to VDE 0100 55. Suitable cable extensions may be used only when unrolled. Safety Devices The equipment has the following safety or monitoring devices: Temperature control thermostat (TR) Temperature monitor (TW) Safety temperature limiter (STB) Temperature control thermostat (TR) The temperature control thermostat switches the circulating fan on and off. The switching point is set in the switch box using the "Scale 21 60" controller. Setpoint approx. 35 40 C. Temperature monitor (TW) In heating mode, the temperature monitor limits both the temperature of the unit and of the air being blown out. The switching point is set in the switch box using the "Scale 34 110" controller. Setpoint approx. 80 85 C. Safety temperature limiter (STB) The STB controls the temperature monitor. The switching point has a permanent setting. The burner is prevented from being restarted if the STB is activated. After the cover next to the control panel is removed, the reset button must be pressed from the outside. After the STB has been reset, the cover must be remounted. Before an STB reset, check the operating conditions to ensure that the STB temperature is not exceeded again. Information on the safety devices The safety devices are equipped with a sensor monitoring feature and are resistant to cold down to -20 C. Below -20 C, it switches off; when the temperature rises above this temperature, it switches on again. When the sensor or capillary tube is damaged or when an excess temperature of approximately 220 C is reached, the filling medium is emptied and the safety device switches off. The controller is no longer operable and must be replaced. If it is necessary to replace the STB, only the original REMKO spare part should be used. Make sure to install and mount the device carefully. Do not bend the capillary tubes in the direct vicinity of solder points. When installing the capillary tubes, be careful not to damage or bend them too sharply. The sensors may only be mounted in the mounting strap. The sensors must always be free of dust and dirt. 6

Max. 1 metre Over 1 metre Chimney When the units are operated outside or in open spaces, you do not need a chimney. We recommend using a onemetre-long chimney pipe with a rain cover at the top to (see Example 2) to prevent the penetration of rainwater and dirt. If the unit is used as a room heater, the waste gases must be conducted outside. Make absolutely sure that counterpressure is not created by an improperly installed chimney. The chimney pipe parts must be laid in such a way that no counterpressure can arise. The unit operates without malfunctions if the chimney has been installed at an incline and assembled with vertical end pipes. The chimney must reach at least beyond the gutters, but preferably above the top of the roof to prevent counterpressure caused by weather conditions (e.g. wind). All chimney pipe parts must be securely fastened. They may not be smaller in diameter than the chimney connection of the unit. A minimum distance of 0.6 m to flammable objects must be maintained. Chimney pipe parts and fasteners are available as accessories if required. When a chimney is used, the adjustment of the burner must be adapted accordingly. Before Commissioning Before commissioning, the equipment should be checked for noticeable defects of the operating and safety devices, as well as for proper mounting and correct electrical connection. In any case, observe the following: Install the device on a stable surface. Guarantee a sufficient combustion air supply. Make sure the air intake and outlet is unobstructed. Avoid overpressure and underpressure in the room where the unit has been installed. Make sure that enough fuel is supplied. Use only clean EL heating oil or diesel. Do not use biodiesel. Flexible fuel lines must be particularly protected from damage, e.g. by forklifts, animals, and so on. Paraffin formation at low outside temperatures Even in case of low outside temperatures, free-flowing heating oil must be available in sufficient quantities. Paraffin formation can already take place at temperatures below 5 C. Corresponding measures must be taken to prevent it. Winterproof EL heating oil or diesel. Electrical connection The equipment is operated at 1~ 230 V/50 Hz. The electrical connection takes place using an installed mains cable with a safety plug. The electrical connection of the equipment must be performed at a certain supply point with an earthleakage circuit breaker according to VDE 0100 55. Example 1 Example 2 Example 3 Operation with extended chimney. Requires condensate trap. Operation without extended chimney. Max. 1 metre Inadmissible installation Important information To prevent damage to the combustion chamber caused by moisture build-up (condensation) (see Example 3), make sure that the chimney pipe has a properly installed condensation trap (see Example 1). Extension cords may be extended only by authorised electricians depending on the length of the cable and the connected load of the unit and under consideration of the local use. All cable extensions may be used only when unrolled. Additional information The exhaust emission specifications of the forced-air oil burner must be checked or set by authorised personnel according to the respective local conditions. 7

Commissioning Someone who has been sufficiently trained in the corresponding handling of the unit must be assigned with its operation and monitoring. Important notice before the startup of a cold unit The preheating of the nozzle stock delays the start of the unit dependent on temperature. Control panel Safety temperature limiter Operating 4 3. Place the room thermostat in a suitable spot. The thermostat sensor may not be located within the flow of warm air and may not be directly attached to a cold foundation. 4. Adjust the desired temperature on the room thermostat. 5. Switch the operating switch to the "I" position (heating). If heat is needed, the forced-air burner switches on automatically and the unit functions fully automatically. Connecting the unit to the power supply 1. Switch the operating switch to the "0" position (off). 2. Connect the mains plug of the unit only to a properly installed and sufficiently secured mains socket. 3. Open all shut-off fittings in the oil supply. When operating the unit for the first time, air in the oil supply can cause the burner to shut down due to a malfunction. Heating without room thermostat The equipment works in continuous operation. 2 1 1. Connect the jumper plug (2) included in delivery with the thermostat socket (1) on the unit. 2. Switch the operating switch to the "I" position (heating). Fully automatic heating with room thermostat The unit operates fully automatically depending on the room temperature. 3 1 Jumper plug Thermostat socket Burner reset button Burner Fault red control lamp Operation green control Note about the "Operation" control lamp The control lamp indicates that the unit is in "Heating" mode. When the unit is in "Ventilation" mode, nothing is displayed 1. Disconnect jumper plug 2. 2. Connect the plug (3) of the room thermostat (4) together with the thermostat socket (1) of the device. Ventilation In this switch position, only the supply air fan runs and the unit can be used for air circulation. 1. Turn the operating switch to the "II" position (ventilation). 2. Please note: in this mode, regulation of the thermostat and heating mode are not possible. Hot air distribution The units are equipped with a high-performance axial fan. This fan has been designed to transport the hot air directly and effectively. The distribution of the air should preferably take place using the on-site outlet nozzle. If necessary, pipes or special hot-air or foil hoses for air distribution in the possible area of fan output (observe the channel resistance/equipment compression). Use only hot air hoses (accessories) approved by Remko. In the process, pay attention to the air direction! To prevent heat from building up, the pipes and hoses may not have sharp kinks and bends. Counterpressure may not be allowed to build up when using hoses to heat enclosed spaces. If suction temperatures increase or if there is resistance at the air output opening, the forced-air burner can be switched off at short notice by the temperature monitor (TW) during heating. When the temperature falls, the burner restarts automatically. If the intervals are too short, the length of the hot air pipes and hoses should be checked. Avoid starting the burner in frequent cycles (run times under five minutes). If the temperature becomes too high, the heating mode is interrupted permanently by the STB! 8

Shutdown 1. Switch the operating switch to the "0" position (off). 2. Shut off the fuel supply. Important information about the equipment's cooldown phase The supply air fan runs to cool off the combustion chamber and the heat exchanger further and does not switch off till later. The fan may run several times until it switches off permanently! Never (except in emergency situations) interrupt the mains connection before the entire cooldown phase comes to an end. Our guarantee does not cover damages caused to the unit by overheating. Maintenance and Care The regular care and observance of some basic prerequisites guarantee malfunction-free operation and a long service life of the unit. Before all work on the device, the mains plug must be removed from the mains socket. Keep the unit free of dust and other deposits. For cleaning, use a clean, slightly moistened cloth with which you can wipe off the dirt from the surface. Do not use a water jet. Do not use caustic cleaning agents or cleaning agents containing solvents. Even in case of extreme soiling, only use suitable cleaning agent. Use only clean EL heating oil or diesel as fuel. Look for paraffin formation. Do not use biodiesel. Check the fuel filter for soiling at regular intervals. Dirty filters must be replaced. Check the unit for mechanical damage and have defective parts replaced by an expert. Check the fan blades and combustion chamber with the heat exchanger for soiling at regular intervals and clean them when necessary. Check on-site oil tanks for soiling and foreign bodies regularly and clean them when necessary. Always make sure the chimney and combustion air duct are always in perfect working order. Regularly check safety devices to ensure that they are working properly. Always keep the sensors of the safety devices free of dust and dirt. Have the exhaust emission values of the forced-air oil burner checked regularly by authorised personnel. For safety reasons, we recommend the conclusion of a maintenance contract. Observe the maintenance and service intervals. Adjustment and maintenance tasks may be performed only by authorised expert personnel! Cleaning After every heating period or even earlier, depending on the operating conditions, the equipment, including the heat exchanger, combustion chamber, and forced-air oil burner, must be cleaned of dust and dirt. Parts subject to wear, such as waste gas suppressors, seals, oil filter inserts, and oil nozzles, should be checked and exchanged if necessary. Cleaning the heat exchanger 1. Set the operating switch to the "0" position and pull the plug from the mains socket.. 2. Remove the blow-out cone (1) after unscrewing the four fixing screws. Any hot air hoses or pipes must be dismantled as well if pertinent. 3. Remove the revision cover (2) and take the waste gas suppressor (4) out of the unit. 4. Clean all waste gas flues (5). A special cleaning is available as an accessory under EDP No. 1103110. 5 4 3 2 1 5. Clean the waste gas suppressors and replace any damaged ones if necessary. 6. Check the seals (3) of the revision cover and replace any damaged seals. 7. Please observe the notices on the next page. 9

Important information about mounting the revision cover Make sure that the seals and revision cover are correctly placed. When mounting the revision cover, make sure the fixing nuts are tightened evenly. Uneven tightening of the fixing nuts may result in leakage. Cleaning the combustion chamber 1. Set the operating switch to the "0" position and pull the plug from the mains socket. 2. Remove the combustion chamber cover. 3. Pull the burner plug. 4. Unscrew the four quick-release fasteners of the mounting base plate from the mount (1). The quick-release fasteners and the mounting base plate are not shown in the drawing below. 5. Carefully remove the complete mounting base plate from the front of the unit. The fuel line does not have to be dismantled. 6. Place the mounting base plate next to the unit. 7. Unscrew both cylinder head studs (2) from the housing (3). 8. Remove the housing from the front of the combustion chamber and set it aside. Assembling the burner seal and the burner 1. Check the burner seal (4) and replace it if necessary. 2. Push the burner seal onto the flame tube of the housing. 3. Mount the burner seal (4) and the housing (3) to the combustion chamber flange using both cylinder head studs (2). 4. Attach the mounting base plate using the four quick-release fasteners. 5. Insert the burner plug again and close the combustion chamber cover. After all work on the device, perform an electrical safety test according to VDE 0701. Additional maintenance information Maintenance work on the forced-air oil burner may only be performed by authorised personnel. The exhaust emission limits must be observed in accordance with 11 of the small furnace ordinance (1. BImSchV). The exhaust emission analysis may be perfomed only when the combustion chamber cover is closed. Trouble Shooting 4 3 Important safety notices Repair work on the electrical installation and on the forced-air oil burner may be carried out only by authorised, expert personnel for safety-technical reasons. Before all work on the device, the mains plug must be removed from the mains socket. 9. Remove the burner seal (4). 10. Do not damage the burner seal. A damaged burner seal may lead to faulty air intake. 11. Clean the combustion chamber using a vacuum cleaner through the opening of the burner. A special boiler cleaning set for the REMKO industrial vacuum cleaner is available as an accessory. 1 2 The unit does not start 1. Check the mains connection. 1~ 230 V. 2. Switch the operating switch to the "I" position. 3. Check whether the "Operation" control lamp on the control panel has lit up. It must indicate that the unit is in "Heating" mode. 4. Check that the jumper plug or the thermostat plug has been plugged in correctly. 5. Check the room thermostat setting. The temperature set on the room thermostat must be higher than the room temperature. 6. Check whether the safety temperature limiter (STB) has activated. You must remove the protective cover next to the control panel. 10

Customer Service and Guarantee 7. Before resetting the STB, you must determine the reason it was activated and take appropriate measures. The following are possible reasons: The unit could not cool down because the power supply was interrupted. The temperature of the air being blown out is too high because hoses are not directing air properly. Air intakes and outlets are blocked. 8. Check whether the "Burner Fault" control lamp on the control panel has lit up. If so, release the automatic burner relay by pressing the reset button. 9. Switch the operating switch to the "II" position. If the supply air fan now starts, look for the malfunction in the vicinity of the burner. Forced-air burner and power supply 1. Check the oil filter for soiling. Replace the dirty filter. 2. Make sure the shut-off valve on the oil filter is open. 3. Make sure there is enough fuel in the fuel container. 4. Check whether paraffin has accumulated in the heating oil. This can occur at temperatures as low as 5 C already. 5. Check oil tubes for damage. 6. Check the sensors and capillary tubes of the safety devices for damage or soiling. 7. Make sure the temperature monitor (TW) is working properly using suitable equipment. 8. Check the forced-air oil burner for any soiling of the nozzle, baffle plates, filters, and so on. The prerequisite for any warranty claims is that the customer or its recipient has returned the completed "Warranty Document" included in delivery to REMKO GmbH & Co. KG at the time of the sale and commissioning of the equipment. The devices were tested several times at the factory for proper function. If any malfunctions should occur, however, which cannot be eliminated by trouble shooting measures performed by the operator, please consult your specialised dealer or contract partner. Another operation other than that described in these operating instructions is not permitted. Nonobservance leads to the extinguishment of any liability and warranty claims. Proper use Due to their conception and equipping, the devices are designed solely for heating and ventilation purposes in industrial or commercial use. The manufacturer is not liable for damage that occurs due to nonobservance of manufacturer instructions or the legal requirements or due to unauthorised changes to the device. Supply air fan does not start 1. Check whether the fan blade is running smoothly. 2. Check the power cord on the air supply fan for damage. 3. Check the operating capacitor of the fan. It is located in the switch box of the unit. 4. Make sure the temperature control thermostat (TR) is working properly using suitable equipment. Important information about unlocking the burner If the burner shuts down again due to a malfunction during the starting phase, it may not be unlocked again until a five-minute wait has passed. Further unlocking procedures must not be performed. A danger of explosion exists. 11

Technical Data Model CLK 20 Max. nominal heat load kw 22 Nominal heat output kw 20 Nominal air volume flow m³/h 1.860 Pressure (max. total) Pa 95 Fuel EL heating oil or diesel according to DIN 51603 or diesel fuel Max. fuel consumption L/h 2.20 Oil nozzle (Danfoss) 2) USG 0.5/60 S Pump pressure, approx. 2) bar 10.5 11.0 Max. chimney loss % 9 Chimney volume, approx. kg/h 35 Furnace resistance, approx. (start/operation) Pa 140/40 Required chimney draft Pa 0 Electrical connection V/Hz 1~ 230/50 Max. power consumption (ges. Gerät) W 320 Max. nominal current (ges. Gerät) A 1.45 Max. power consumption (Ventilator) W 130 Max. nominal current (Ventilator) A 0.6 Operating capacitor of the fan µf 3 Fuse protection (on site) A 10 Temperature increase ( t ) K 41 Sound pressure level L pa 1m 3) db (A) 60 Air outlet ø mm 300 Chimney adapter Ø mm 130 Total unit length mm 1.180 Total unit width/with wheel attachment mm 510/580 Total unit height/with wheel attachment mm 735/880 Weight with forced-air oil burner kg 94 2) The listed nozzle sizes and pump pressures were determined on the basis of adjustment tests on a test stand. The oil throughput was measured out. (The specifications serve only as standard values due to product-specific nozzle and pressure tolerances and oil temperatures.) 3) Noise measurement according to DIN 45635-01 Cl. 3 (without burner operation) We reserve the right to make changes in dimensions and design in the interest of technical advances. 12

Wiring Diagram TR TW STB RT 3 1 2 S1 2 4 1 1 1 4 2 2 1A 4B 2A 0 5B 3A II 6B C H2 H1 S2 KL 10 9 8 7 6 5 4 3 2 1 N N M braun Brown Orange orange Black schwarz Blue blau S3 IB4 T2 T1 N L1 #2 #3 #4 N L1 PE WS HW 04.03 C = Capacitor S1 = Operating switch H1 = Control lamp (green) S2 = Reset button (burner) H2 = External control lamp (red) STB = Safety temperature limiter KL = Terminal strip TR = Temperature control thermostat M = Fan motor TW = Temperature monitor RT = Thermostat socket WS = Burner plug, 7-pole We reserve the right to make changes in dimensions and design in the interest of technical advances. 13

Exploded View 61 17 65 64 50 18 1 56 63 10 2 45 3 4 57 60 11 57 8 47 5 49 48 9 26 STB sensor TW sensor TR sensor 39 38 Ansicht View Bedienungstableau of control panel 6 36 37 7 15 35 16 28 29 30 55 27 32 33 66 67 68 69 70 71 72 34 19 We reserve the right to make changes in dimensions and design in the interest of technical advances. 14

Spare Parts List No. Description Ref. No. 1 Cover plate 1104890 2 Insulation, top 1104891 3 Insulation, right 1104892 4 Side cover, right top 1104893 5 Side cover, right bottom 1104894 6 Base plate 1104895 7 Insulation, bottom 1104896 8 Side cover, left top 1104897 9 Side cover, left bottom 1104898 10 Insulation, left 1104899 11 Rear panel, cpl. 1104900 15 Partition 1104901 16 Burner seal 1104902 17 Switch box, cpl. 1104903 18 Seal for switch box 1104904 19 Front panel 1104905 26 Angle support, oil filter 1104721 27 Oil filter, cpl. 1102526 28 O-ring 1108464 29 Filter insert 1108462 30 Oil filter cup 1108463 32 Blow-out cone 1104906 33 Burner compartment cover 1104907 34 Lock for burner compartment cover 1104908 35 Support base 1104910 36 Axle 1104911 37 Wheel 1101621 38 Wheel cap 1101623 39 Circlip 1101622 45 Combustion chamber, complete 1104912 47 Waste gas suppressor (set) 1104913 48 Revision cover 1104914 49 Seal for revision cover 1104915 50 Rosette for chimney connection 1104916 55 Transport handle, front 1104917 56 Transport handle, rear 1104918 57 Transport handle, centre 1104919 60 Fan, cpl. 1108169 61 Capacitor (fan) 1102516 63 Safety temperature limiter (STB) 1101197 64 Temperature control thermostat (TR) 1103166 65 Temperature monitor (TW) 1103146 66 Operating switch 1101188 67 Control lamp, green (operation) 1105514 68 Control lamp, red (burner fault) 1105363 69 Reset button (burner) 1103408 70 Thermostat socket 1101018 71 Jumper plug 1101019 72 Mains cable with plug 1104701 Not shown Burner plug, 7-pole 1102537 Forced-air oil burner, cpl. 944015 Drum fitting, cpl. 1002524 Cleaning brush, cpl. 1103110 When ordering spare parts, please indicate the reference number and the machine number (see model plate)! 15

Commissioning of the Forced-Air Oil Burner The forced-air oil burner may be commissioned only by expert personnel! Preparation Before starting with the adjustment of the forced-air oil burner, perform the following tasks: 1. Remove the cover of the burner compartment. 2. Remove the fuel line from the burner and pull the burner plug. 3. Unscrew the four quick-release fasteners of the mounting base plate (1) at Position A. A Adjusting the air flap Adjust the air flap using the adjusting screw (7) in such a way that Distance A between the air flap (8) and the stop (9) amounts to approx. 6 mm. 7 8 9 A To adjust the necessary distance, proceed as follows: 1. Loosen the knurled nut (10) and turn the adjusting screw (7) accordingly. Clockwise rotation: Distance A becomes smaller Counterclockwise rotation: Distance A be comes larger A 1 4. Carefully remove the complete mounting base plate from the front of the unit. 5. Place the mounting base plate somewhere suitable for the further tasks. Required nozzle sizes Selecting the required oil nozzle depends on the pump pressure and the unit capacity. You may only use an oil nozzle that is suitable for the shape of the respective burner chamber with corresponding spray angle, cone properties, and throughput. You can find the necessary nozzle size in the technical data. Setting the ignition electrode and baffle plate 3 D D E 4 4 2. After adjusting the distance, retighten the adjusting screw using the knurled nut (10). The optimum setting must be adapted to the local conditions and the respective chimney. Mounting base plate After the ignition electrode, baffle plate, and air inlet nozzle are adjusted, the mounting base plate is remounted. 1. Attach the mounting base plate using the four quick-release fasteners. 2. Mount the fuel line to the burner. 3. Reinsert the burner plug. 7 10 All dimensions are approx. 5 Mount the baffle plate (D) in such a way that the hole (E) is flush with the photo cell. 16

Secondary air setting (nozzle stock) 1. Set the nozzle stock (2) to the approx. 1.5 marking using the adjusting screw (1). 1 2 Measuring the combustion gases Every stationary combustion plant must be check by measuring the exhaust emission values according to the first Bundesimmissionsschutzverordnung (1.BImSchV) (German Air Pollution Act). The owner is obliged to have the combustion plant monitored by measurements performed by the local chimney sweep up to four weeks after commissioning. In addition, according to 9 and 15 of 1. BImSchV, the emission values must be checked annually by the local chimney sweep (oil derivatives, soot, exhaust emissions). Adjusting the air inlet nozzle 1. Lock the adjust lever (3) of the air inlet nozzle in the locking position (3) (see arrow). 3 Setting the pump pressure For initial burner operation and after each time the burner is serviced, the oil pressure must be adjusted or Never operate the pump without oil! 1. Remove the stopper on the "P" measuring connection and mount the oil manometer (seal!). 2. Open all oil shut-off fittings.. 3. Switch on the burner using the operating switch. 4. Set the required oil pressure via the adjusting screw (4) after loosening the counter nut (5). Clockwise: Increase pressure Counterclockwise: Reduce pressure 5. After making the pressure setting, secure the adjusting screw using the counter nut (5). 4 5 Important information All specifications only serve as presettings and must be readjusted or adapted according to the local conditions during the exhaust emission analysis. The settings can be made only if the chimney has been properly installed! On principle, the equipment must be operated at the nominal load. To guarantee the optimum function of the burner, please note that annual maintenance must be performed according to DIN 4755. For this purpose, you should conclude a maintenance contract. 6. Switch on the unit using the operating switch. 7. Dismantle the oil manometer and replace the stopper (seal!). Additional pump information Perfect fuel quality is absolutely necessary for the lubrication of the pump gear. Never suction up water residue or fine dust that tends to harden (such as cement). Never let the unit run with a dry pump for a longer period of time. P 17

Maintenance Log Model :... Model No. :... Burner :... Burner No. :... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Clean unit surface Clean unit interior Clean fan blade Clean combustion chamber Clean heat exchanger Replace waste gas suppressors Replace seals - revision cover Replace seals - burner Replace filter - fuel Check safety devices Check electric safety Check protective mechanisms Check unit for damage Maintenance burner *) Test run Comments:...... 1. Date: 2. Date:... 3. Date:... 4. Date:... 5. Date: 18......... Signature Signature Signature Signature Signature 6. Date: 7. Date:... 8. Date:... 9. Date:... 10. Date:......... Signature Signature Signature Signature Signature 11. Date: 12. Date:... 13. Date:... 14. Date:... 15. Date:......... Signature Signature Signature Signature Signature 16. Date: 17. Date:... 18. Date:... 19. Date:... 20. Date:......... Signature Signature Signature Signature Signature *) Maintenance work may be performed on the forced-air oil burner only by authorised expert personnel; settings and adjustments must comply with the legal regulations (1. BImSchV. (German Air Pollution Control Act). A corresponding test log must be kept.

EC Declaration of Conformity We hereby declare that the following hot air heater corresponds to the pertinent basic requirements of the respective EC directive (s) due to its conceptual design and construction in the version in which we have brought it on the market. Important Note: This declaration becomes null and void if the unit is used, set up, or maintained improperly or if modifications are made to the supplied unit without our prior consent. Name of manufacturer: : REMKO GmbH & Co. KG Air Conditioning and Heating Technology Im Seelenkamp 12 32791 Lage, Germany Unit (machine) design Series : REMKO CLK 20 Serial number : 594... : Mobile hot air heater for operation with a separate forced-air burner Valid regulations : MA - RL 89/392/EEC Machinery Directive [98/37/EC] NS - RL 73/23/EEC Low Voltage Directive EMC RL 89/336/EEC EMC Directive Applied standards : EN 292-1; EN 292-2; EN 294; EN 349; EN 60204-1; DIN VDE 0116; DIN 30697-2; DIN 45635-1 EN 55014-1; EN 55014-2; EN 55104; EN 61000-3 - 2; EN 61000-3 - 3; Lage, 5 August 2003 REMKO GmbH & Co. KG ppa.... Signature (Technical Management) 19

REMKO GmbH & Co. KG Air Conditioning and Heating Technology Im Seelenkamp 12 32791 Lage, Germany Postfach 1827 32777 Lage, Germany Phone +49-5232-606-0 Fax +49-5232-606-260