ENHANCED PKE-K-SPORT CONDENSATION HEATERS Output from 100 to 550 kw Efficiency up to 102.4% Reduction of Thermal Stratification 1 code HG0150.05GB ed.c-1509 rev.05
2 code HG0150.05GB ed.c-1509 rev.05
Dichiarazione di Conformità Statement of Compliance - 20060 Pessano con Bornago (MI) - ITALY Via Isonzo, 1 Ph. +39 02 9596931 Fax +39 02 95742758 Website: http://www.apengroup.com Il presente documento dichiara che la macchina: With this document we declare that the unit: APEN GROUP S.p.A. Model: Floor Standing Warm Air Heaters PK-N, PK-K, PK-R Floor standig heater PK-N, PK-K, PK-R è stata progettata e costruita in conformità con le disposizioni delle Direttive Comunitarie: have 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 2004/108/CE Electromagnetic Compatibility Directive 2004/108/CE Direttiva Bassa Tensione 2006/95/CE Low Voltage Directive 2006/95/CE Qualora la macchina dovesse essere integrata in un impianto (macchine combinate), il costruttore declina ogni responsabilita se prima, l'impianto di cui farà parte non verrà dichiarato conforme alle sopracitate disposizioni (Allegato IIB della Direttiva Macchine). 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. The General Manager CODE SERIAL NUMBER 3 code HG0150.05GB ed.c-1509 rev.05
EC APPROVAL CERTIFICATE 4 code HG0150.05GB ed.c-1509 rev.05
5 code HG0150.05GB ed.c-1509 rev.05
TABLE OF CONTENTS SECTION 1. GENERAL WARNINGS... 7 SECTION 2. SAFETY WARNINGS... 7 2.1 Fuel... 7 2.2 Gas Leaks... 7 2.3 Power Supply... 8 2.4 Use... 8 2.5 Venting Openings... 8 2.6 Maintenance... 8 2.7 Transport and Handling... 9 2.8 Unpacking... 9 2.9 How to Identify the Heater... 9 SECTION 3. TECHNICAL FEATURES... 10 3.1 Main Components... 10 3.2 Table of PK-SPORT Technical Data 3.3 Noise... 13 3.4 Dimensions of PK-SPORT Heater... 14 SECTION 4. USER S INSTRUCTIONS... 16 4.1 Maintenance and Faults... 17 SECTION 5. INSTRUCTIONS TO THE INSTALLER... 18 5.1 Where to Install... 18 5.2 Wiring to Power Supply... 19 5.3 Electrical Wiring... 20 5.4 Wiring the Burner... 21 5.5 Optional Accessories... 22 SECTION 6. INSTRUCTIONS FOR SERVICE CENTER... 35 6.1 Electrical Wiring and Diagrams... 35 6.2 Burner Matching... 41 6.3 Oil Burners... 42 6.4 Gas Burners... 43 6.5 Burner Matching Tables... 44 SECTION 7. MAINTENANCE... 46 7.1 Controls at First Start Up... 46 7.2 Routine Maintenance... 47 7.3 Spare Part List... 48 SEZIONE 8. SOME ADVICES FOR THE INSTALLATION OF THE CONNECTION SLEEVES... 55 6 code HG0150.05GB ed.c-1509 rev.05
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, make sure 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 authorized personnel, with technical skills specific for the heating field. APEN GROUP's business organization can count on a widespread network of approved Technical Support Centers. Please contact us for information on the Center that is closest to your area. 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 -- UNI-CIG 7131 regulating appliances fired with L.P.G. 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. 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. 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. 7 code HG0150.05GB ed.c-1509 rev.05
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 Venting 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 running 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 follow above instructions could compromise the unit safety and shall void the warranty. 2.7 Transport and Handling The heater includes supports and lifting rings. 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. In the first case, use fork extensions as long as heater width. Pay attention to dampers, in installed on the heater. 8 code HG0150.05GB ed.c-1509 rev.05
2.9 How to Identify the Heater PK warm air heaters can be identified using their data plate, stuck into burner enclosure on the front of the unit. This plate shows all identification information for the model. When required by Service Center, 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. HG0150 C3 001 HG0150 C3 001 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. HG0150 C3 002 9 code HG0150.05GB ed.c-1509 rev.05
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 and their wide 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 and chemical composition of steel types used in exchanger manufacturing: USA -AISI EN - N Composition AISI 430 1.4016 X6 Cr17 AISI 441 1.4509 X2 CrTiNb 18 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 aluminum 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 fiber 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 galvanized steel sheet with forward curved blades and low noise of operation. Fans rotate on autoaligned sealed ball bearings, isolated in rubber buffers. Two types of fan are used: Fans for rectangular duct: driven by means of fixed diameter pulleys and belts, three-phase motor, models up to PKE250N-P00. Fans for square duct: same as previous, they are used on heaters from PKE320N-P00 upward. No lubrication is required on standard fans. For special fans, check specific requirements. Running Temperatures: - 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 have the following characteristics: Supply 400Vac - 3-phase - 50 Hz Structure B3 - with terminal board above Protection degree IP55 Isolation level cl.f Efficiency IE2 For more model-related information on motors, see further in this Manual. If required, motors with the following characteristics can be supplied: Higher efficiency class 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 signaled by a red lamp lit on the panel. - TR Fan start-up thermostat. Il 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. 10 code HG0150.05GB ed.c-1509 rev.05
3.2 Table of PK-SPORT Technical Data Heat Input and Efficiency Data of PKE-N heaters All vertical PK heaters, up to PK320N included, are integrated and burner enclosure is built-in. Model PKE100N PKE120N PKE140N PKE190N Type of appliance EC Approval NOx Class B23 0694BP0758 4-5 with LOW NOx GAS BURNERS MIN >91% MAX MIN >91% MAX MIN >91% MAX MIN >91% MAX Combustion Chamber Heat Input kw 68.5 100.5 110.7 68.5 100.5 137.0 96.0 131.4 195.0 115 202.5 230.0 Useful Heat kw 64.4 91.9 90.7 64.3 91.9 120.1 90.2 120.3 171.0 108.1 184.7 205.9 Combustion Efficiency % 94.0 91.4 87.7 94.0 91.4 87.7 94.0 91.4 87.7 94.0 91.2 89.5 Chimney loss - Burner ON % 6.0 8.6 12.3 6.0 8.6 12.3 6.0 8.6 12.3 6.0 8.8 10.5 Chimney loss - Burner OFF % < 0.1 < 0.1 < 0.1 <0.1 Enclosure losses % 1.81 1.46 1.26 1.16 Combustion chamber pressure Pa 14 30 40 14 30 40 13 28 50 10 32 40 Combustion chamber volume m 3 0.37 0.24 0.37 0.52 Model PKE250N PKE320N PKE420N PKE550N Type of appliance EC Approval NOx Class B23 0694BP0758 4-5 with LOW NOx GAS BURNERS MIN >91% MAX MIN >91% MAX MIN >91% MAX MIN >91% MAX Combustion Chamber Heat Input kw 154.0 252.0 310.0 185.0 309.0 380.0 260 398 508 320 515 670 Useful Heat kw 145.0 230.2 275.0 173.9 282.1 335.9 245 364 450 301 471 592 Combustion Efficiency % 94.0 91.3 88.7 94.0 91.3 87.7 94.4 91.5 88.6 94.3 91.5 88.4 Chimney loss - Burner ON % 6.0 8.7 12.3 6.0 8.7 12.3 5.6 8.5 11.4 5.7 8.5 11.6 Chimney loss - Burner OFF % <0.1 < 0.1 < 0.1 < 0.1 Enclosure losses % 1.17 1.02 1.03 0.97 Combustion chamber pressure Pa 10 36 50 15 45 60 28 85 120 21 80 110 Combustion chamber volume m 3 0.76 1.06 1.55 1.79 11 code HG0150.05GB ed.c-1509 rev.05
Heat Input and Efficiency Data of PKE-K and PKE-R heaters All vertical PK heaters, up to PK320N included, are integrated and burner enclosure is built-in. Model PKE100K PKE140K PKE190K PKE250K Type of appliance EC Approval NOx Class B23 0694BP0758 4-5 with LOW NOx GAS BURNERS MIN MAX MIN MAX MIN MAX MIN MAX Combustion Chamber Heat Input kw 26.5 114.0 38.0 152.0 48.0 200.0 61.0 270 Useful Heat kw 27.1 105.4 38.5 40.8 48.3 185.2 61.6 248.9 Combustion Efficiency % 102.4 92.5 101.2 92.6 100.5 92.6 101.1 92.2 Chimney loss - Burner ON % - 8.6-8.6-8.8-8.7 Chimney loss - Burner OFF % < 0.1 < 0.1 <0.1 <0.1 Enclosure losses * % 1.81 1.26 1.16 1.17 Combustion chamber pressure Pa 14 100 13 140 10 130 10 175 Combustion chamber volume m 3 0.37 0.37 0.52 0.76 Model PKE320K PKE420K PKE550K Type of appliance EC Approval NOx Class B23 0694BP0758 4-5 with LOW NOx GAS BURNERS MIN MAX MIN MAX MIN MAX Combustion Chamber Heat Input kw 74.0 347.0 83.0 455.0 95.0 595.0 Useful Heat kw 74.8 319.8 83.8 419.4 96.1 549.1 Combustion Efficiency % 101.0 92.2 101.0 92.2 101.2 92.2 Chimney loss - Burner ON* % - 8.7-8.5-8.5 Chimney loss - Burner OFF* % < 0.1 < 0.1 < 0.1 Enclosure losses % 1.02 1.03 0.97 Combustion chamber pressure Pa 15 225 28 275 21 365 Combustion chamber volume m 3 1.06 1.55 1.79 12 code HG0150.05GB ed.c-1509 rev.05
Model PKE100R PKE140R PKE190R PKE250R Type of appliance B23 EC Approval 0694BP0758 NOx Class 4-5 with LOW NOx GAS BURNERS MIN MAX MIN MAX MIN MAX MIN MAX Combustion Chamber Heat Input kw 26,5 90,0 38,0 122,0 48,0 162,0 61,0 217,0 Useful Heat kw 27,1 84,8 38,5 113,4 48,3 150,6 61,6 205,5 Combustion Efficiency % 102,4 94,1 101,2 94,2 100,5 94,5 101,0 94,7 Chimney loss - Burner ON % 7,5 7,4 7,4 7,8 Chimney loss - Burner OFF % < 0,1 < 0,1 <0,1 < 0,1 Enclosure losses * % 1,81 1,26 1,16 1,17 Combustion chamber pressure Pa 14 100 15 140 15 130 19 175 Combustion chamber volume m 3 0,24 0,37 0,52 0,76 Model PKE320R PKE420R PKE550R Type of appliance B23 EC Approval 0694BP0758 NOx Class 4-5 with LOW NOx GAS BURNERS MIN MAX MIN MAX MIN MAX Combustion Chamber Heat Input kw 74,0 275,0 83,0 345,0 95,0 450,0 Useful Heat kw 74,8 256,5 83,8 325,8 96,1 430,1 Combustion Efficiency % 101,0 94,9 101,0 95,2 101,2 95,3 Chimney loss - Burner ON % 7,8 7,7 Chimney loss - Burner OFF % < 0,1 < 0,1 < 0,1 Enclosure losses * % 1,03 1,03 0,97 Combustion chamber pressure Pa 19 175 30 275 40 365 Combustion chamber volume m 3 1,06 1,55 1,79 All vertical PK heaters, up to PK320N included, are integrated and burner enclosure is built-in. Model PKE100K PKE140K PKE190K PKE250K PKE320K PKE420K PKE550K Version P00 P00 P00 P00 P00 P00 P00 Air Flow Rate - 15 C m 3 /h 7.000 9.800 13.400 18.200 21.800 30.000 35.000 Available Head Pressure Pa 300 300 300 300 300 300 300 Heat Jump Min e Max* K 10,9-46,7 11,1-44,5 10,3-42,8 9,6-42,5 9,7-45,6 7,9-43,5 7,8-48,7 Power Supply V 400T Frequency Hz 50 Motor max. capacity ** kw 3,0 4,0 4,0 7,5 7,5 11 15 Max absorbed power*** kw 3,51 4,61 4,61 8,45 8,45 12,19 16,48 Protection degree IP PKE = IP24; PKE control panel = IP55 Running Temperature C From -20 C to + 40 C (check running temperature of matched burner) Technical Data on Air flow rate, Head e Installed Power Supply *Chimney losses at minimum output for condensation heaters are zero since efficiency exceeds 100% (calculated with reference to NCV - net calorific value of natural gas). ** 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 (IE2). The value shown in the table must be added to the power absorbed by matched burner. 13 code HG0150.05GB ed.c-1509 rev.05
3.3 Noise Level DUCTED HEATERS If you need to know noise levels of the fan, ask APEN GROUP Technical Support. The following table shows sound power (LwA) and sound pressure (LpA) values, issued by PK-SPORT heaters. These values refer to heaters with ducted air intake and delivery installed indoor. In such applications, sound power levels for fan, intake and delivery ducts have to be summed. Then, sound insulation assured by multilayered paneling must be deducted from the total. The values in the table refer to LwA through the sandwich paneling of the heater. HG0150 C3 003 Ducted heater (both intake and delivery) MODEL LwA - Sound Power Level [db(a)] LwA distance LpA 63 125 250 500 1000 2000 4000 8000 db(a) meters db(a) PKE100-120N 57.3 63.4 66.1 67.4 71.5 71.4 69.0 61.2 76.9 6 56.4 PKE140N 55.1 61.5 65.5 70.2 72.4 72.9 71.0 63.4 78.3 6 57.8 PKE190N 59.6 61.1 66.4 68.2 72.2 72.4 70.3 60.9 77.7 6 57.2 PKE250N 62.3 64.9 69.9 73.6 78.6 78.0 76.9 68.9 83.6 6 63.1 PKE320N 69.5 67.4 68.2 71.3 72.3 71.7 67.9 60.0 78.7 6 58.1 PKE420N 75.7 72.3 70.2 74.8 74.0 72.6 68.4 60.8 81.6 6 61.1 PKE550N 74.3 70.2 71.8 72.7 75.1 72.5 67.8 59.0 81.1 6 60.5 14 code HG0150.05GB ed.c-1509 rev.05
3.4 Dimensions of PK-SPORT Heater Integrated Models All vertical PK heaters, up to PK320N included, are integrated and burner enclosure is built-in. Three-compartment Models From 420N model onward, heaters are split in three compartments: fan, exchanger and burner enclosure. The first two compartments are to be installed one on top of the other without any fixing. Fan compartment includes slots for sliding the two parts into place. To install burner enclosure onto the heater, do the following: Lay transparent silicone on the edges of burner enclosure Press enclosure onto the heater and match aluminum profiles. Fix enclosure 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 compartments. A polarized connector is available to wire the exchanger and its thermostats to the control panel. AIR RECIRCULATION AND DELIVERY Standard intake of recirculation air and air delivery are on the right side of the heater (seen from the burner). Outside air introduction and smoke damper (if present) are always located on the side opposite to air delivery. In required, a heater with return air intake and air delivery on left side can be supplied. HG0150 C2 001 Model PKE100N PKE120N Size Intake Delivery Chimney Burner L B H LG LV E G HB BA HA BM HM N ØR S ØT kg 1,955 800 2,120 1,455 500 875 290 540 500 800 500 800 1,760 180 1,190 190 445 PKE140N 2,170 920 2,180 1,570 600 990 290 540 500 800 500 800 1,800 180 1,155 190 525 PKE190N 2,480 1,060 2,330 1,750 730 1,070 340 540 600 800 600 800 1,960 250 1,190 190 650 PKE250N 2,760 1,140 2,430 1,960 800 1,180 390 540 700 800 700 800 2,020 250 1,180 190 845 PKE320N 3,110 1,140 2,610 2,310 800 1,430 440 540 800 800 800 800 2,040 250 1,180 230 990 PKE420N 3,310 1,340 3,100 2,460 850 1,205 500 700 900 1,100 900 1,100 2,780 300 1,740 230 1,200 PKE550N 3,600 1,340 3,270 2,600 1,000 1,600 500 745 900 1,190 900 1,190 2,900 300 1,830 230 1,450 15 code HG0150.05GB ed.c-1509 rev.05
Accessories PK-SPORT heaters can be integrated with a wide range of accessories. Clients can choose their preferred setup based on system layout. The following table lists dimensions and codes of available accessories. For more details, see paragraph 5.5 on page 20. LEGEND 1. Square/round fitting kit 2. Fire damper kit. 3. Kit for recirculated air regulation damper. 4. Kit for outside air regulation damper. 5. Flue exhaust damper kit 6. Single-wall flue exhaust kit 7. Double-wall flue exhaust kit HG0150 C3 004 16 Model PKE100 PKE120 1- Square to round transition 2- Fire Damper 3 - Recirculation air damper 4- Outside air damper 5- Flue exhaust damper 6- Single wall flue exhaust 7- Double wall flue exhaust code L1 code L2 code L3 code L4 code L5 code code G12833 450 G12830 670 G12834 130 G12831 130 G12832 130 G04065-180 G04065-180-DP PKE140 G12833 450 G12830 670 G12834 130 G12831 130 G12832 130 G04560-180 G04065-180-DP PKE190 G12843 450 G12840 670 G12844 130 G12841 130 G12842 130 G04560-250 G04065-250-DP PKE250 G12853 450 G12850 670 G12854 130 G12851 130 G12852 130 G04560-250 G04065-250-DP PKE320 G12863 450 G12860 670 G12864 130 G12861 130 G12862 130 G04560-250 G04065-250-DP PKE420 G12873 600 G12870 820 G12874 130 G12871 130 G12872 130 G04560-300 G04065-300-DP PKE550 G12883 600 G12880 870 G12884 130 G12881 130 G12882 130 G04560-300 G04065-300-DP code HG0150.05GB ed.c-1509 rev.05
4. USER S INSTRUCTIONS 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 C1 L1 L2 L3 Door lock - On Ø (zero), the whole unit is powered off. Summer/0/Winter switch - It allows choosing the running mode you want. Green lamp - If lit, the control panel is powered. Red lamp - Safety thermostat or fire damper, if installed, has triggered. The user has to manually reset devices. 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 Heaters include a double thermostat formed by: STB Safety thermostat - When activated, it immediately stops the burner and issues an alert (red light on control panel). Reset is manual (see figure). TW: The thermostat TW is located in the thermostat series of the burner and intervenes, on switching off the burner, when the temperature inside the generator exceeds the calibration value. The thermostat TW is similar to a safety device and must not be used as a regulation thermostat. 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. 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. During 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. 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. REMARK: Heaters working in air domes must guarantee continuous ventilation. See pages for wiring instructions. RESET COMMAND PRESS TO UN- LOCK LIMIT THERMOSTAT (STB) 17 code HG0150.05GB ed.c-1509 rev.05
CONTROL PANEL AND THERMOSTATS CONTROL PANEL HEATER TWO-FUNCTION THERMOSTAT (STB/ TR) KG0100 C2 009 LEGEND C1 SUMMER/0/WINTER SWITCH IG MAIN SWITCH L1 LINE LED (GREEN) L2 WINTER MODE LED (RED) L3 THERMAL RELAY OPERATION (YELLOW) REG 2-STAGE BURNER REGULATOR (OPTIONAL) 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. 18 code HG0150.05GB ed.c-1509 rev.05
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 authorizations 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. 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 authorization. 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. 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. Proper installation requires that a net or another device is installed to avoid reduction of the canal size during operation. HG0150 C3 003 19 code HG0150.05GB ed.c-1509 rev.05
5.2 Power Wiring Warm air heaters come with a main switch with door lock (IG) shown in the figure. Wire power supply directly to that switch. Supply of all PK-SPORT heaters is 3-phase 400V +N. Wiring is as follows: 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. Threephase 400V+N Wire three phases to T1, T2, and T3 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. Electrical Protections Model PKE Rated current In Breakaway starting current Is/In Wire diameter mm 2 100/120 6.9 7 4x1.5 10 140/190 8.7 7 4x2.5 16 250/320* 17.1 2-4 4x4.0 25 420* 23.8 2-4 4x6.0 40 550* 31.5 2-4 4x10.0 63 Notes: Determine cable section in compliance with EN60204-1 and IEC60364-5-2/20001 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. A protection CHECKS All APEN GROUP heaters undergo severe electrical and safety tests. 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. N T1 T2 T3 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. 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. 20 code HG0150.05GB ed.c-1509 rev.05
5.3 Electrical Wiring All control panels of PK-SPORT heaters include a wiring electronic card that allows to easily and safely connect common components such as: Fire Damper Room thermostat, timer, and high/low flame control of the burner, if installed. Fire Damper Wire microswitch (NC contact with activated 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. High/Low Flame Control Wire this control to terminals 43, 44, and 45 of CN7 connector of heater control card. 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. Room Thermostat 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. KG0100 C2 045 2 3 TIMER ROOM THERMOSTAT HIGH/LOW REGULATOR SRV Expulsion damper servomotor FIREPROOF DAMPER LOW HI HG0150 C2 007 Important: 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 & 42 are closed. 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 43, 44 terminals of CN7 connector. 21 code HG0150.05GB ed.c-1509 rev.05
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 two-stage 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 250N 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. The 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 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 IA IB SC KG0100 C2 046 22 code HG0150.05GB ed.c-1509 rev.05
5.5 Continuous ventilation In the case of combining generators with pressure switch structures which require continuous ventilation to support the structure it is necessary to bridge terminals 7-8 of the terminal block CN5 on the wiring board contained in the electrical panel. Bridging these contacts inhibits the FAN function of the thermostats TR (see thermostat connections page 41) 5.6 Emergency. In the case of combing the generators with plants that require the use of UPS systems it is possible to use contacts available on the KM1 remote switch inside the electrical panel to sustain the structure. When the thermal protection of the KM1 is triggered the contact between the 13-14 terminals (NO) closes while the contact between the 21-22 terminals (NC) opens. (see motor connection page 42) Schema avviatore e blocco aggiuntivo LUA1-C11 (termico) 23 code HG0150.05GB ed.c-1509 rev.05
5.7 Optional Accessories APEN GROUP has developed a range of accessories to ease heater installation in different contexts and environments. HG0150 C3 004 LEGEND 1. Square/round fitting kit 2. Firel damper kit. 3. Kit for recirculated air regulation damper. 4. Kit for outside air regulation damper. 5. Flue exhaust damper kit 6. Single wall flue exhaust kit 7. Double wall flue exhaust kit 8. Dry-system kit (not specified) 9. Servocommands for air dampers (not specified) 10. Controller for two-stage burner (not specified) 11. Inverter for air flow rate/pressure regulation (not specified) 12. Room temperature sensor (not specified) 13. Room thermostat ON/OFF, G11280 (not specified) 14. Two-stage controller, G09921 (not specified) 24 code HG0150.05GB ed.c-1509 rev.05
AIR DAMPERS Two types of air dampers are available: - Recirculation air damper, including a regulation damper on heater intake and a duct with equal depth and section installed on delivery. - Outside air damper, including a regulation damper installed on the opposite side of intake. Kit for outside air regulation damper. Model Code B H P F shutter [mm] [mm] [mm] [mm] PKE100-120 G12831 500 800 125 30 PKE140 G12831 500 800 125 30 PKE190 G12841 600 800 125 30 PKE250 G12851 700 800 125 30 PKE320 G12861 800 800 125 30 PKE420 G12871 900 1.100 125 30 PKE550 G12881 900 1.200 125 30 KG0100 C3 012 Kit for regulating air recirculation damper Model Code B H P F shutter [mm] [mm] [mm] [mm] PKE100-120 G12834 500 800 125 30 PKE140 G12834 500 800 125 30 PKE190 G12844 600 800 125 30 PKE250 G12854 700 800 125 30 PKE320 G12864 800 800 125 30 PKE420 G12874 900 1.100 125 30 PKE550 G12884 900 1.200 125 30 All dampers include a control that can either be motorized or remain manual. Any of the two has to be requested separately. REMARK: heaters come with regulation damper kit already installed. SQUARE TO ROUND TRANSITION KIT This kit allows to adapt delivery or recirculation square section duct to flexible ducting with round section. This kit includes: - galvanized steel molded duct - clamps - screws for pipe fixing. SQUARE TO ROUND TRANSITION KIT Model Code B H P F Ø D joint [mm] [mm] [mm] [mm] [mm] PKE100-120 G12833 500 800 450 30 600 PKE140 G12833 500 800 450 30 600 PKE190 G12843 600 800 450 30 700 PKE250 G12853 700 800 450 30 700 PKE320 G12863 800 800 450 30 800 PKE420 G12873 900 1.070 600 35 900 PKE550 G12883 900 1.170 600 35 1.000 REMARK: Square to round transition kits are supplied in a separate package. HG0150 C3 005 25 code HG0150.05GB ed.c-1509 rev.05
FIRE DAMPER KIT The fire damper kits can be installed at the inlet or delivery since the dimensions of its sections are identical. The fire dampers consist of a galvanised iron plate structure, partition blade and seal and the blade closure device. All the fire dampers have the following characteristics: - Reaction to fire EI120S - thermal breaker with fuse calibrated to 72 C; - microswitch, IP55, supplied as a standard component and installed on the damper - the dampers are supplied with certificate. HG0150 C3 005 HG0150 C3 005 The dampers which are 800 mm high have a single blade (PKE100-320), while those more than 800 mm in height have a double blade (PKE420/550). The damper, when open, is as deep as the blade is high: dampers higher than 510 protrude from both sides by an amount equal to the height minus the depth (510 mm for all models) divided by two. In the single blade dampers of height 800 mm the blade protrudes from both sides by 145 mm, and for 1,070 double blade dampers the blade protrudes 25 mm on each side. Fire damper kits, when necessary, are supplied complete with spacer bar (length L) to allow installation between the fire damper and generator or shutter. The geometry of the round square fitting kit always makes it possible to install the latter downstream from the fire damper while for all other types of installation and spacer bar of length "L" is required downstream from the fire damper in order to allow the blade to rotate completely. Fire Damper Model Code B H P L F shutter [mm] [mm] [mm] [mm] [mm] PKE100-120 G12830 500 800 510 170 35 PKE140 G12830 500 800 510 170 35 PKE190 G12840 600 800 510 170 35 PKE250 G12850 700 800 510 170 35 PKE320 G12860 800 800 510 170 35 PKE420 G12870 900 1.070 510-35 PKE550 G12880 900 1.170 510 125 35 NB: the fire damper accessory kit is always supplied installed on the generator. INSTALLATION OF THE FIRE DAMPER ON A RIGID WALL 1 2 3 HG0150_C3_010 1. make a hole in the wall having a base and height 85 mm larger than the nominal measurements of the damper; for walls constructed in concrete blocks or bricks it is advisable to insert a reinforcing lintel above the opening; 2. insert the damper in the opening so that the anchoring flange rests on the surface of the wall; 3. anchor the damper to the wall using the holes in the anchoring flange using self-threading screws or expansion bolts of diameter 6 mm; For further information see the manual enclosed with the dampers. 26 code HG0150.05GB ed.c-1509 rev.05
USE OF THE FIRE DAMPER To set the damper turn the control lever anticlockwise. To release the damper press the button shown in the figure. IMPORTANT: make sure that you do not turn the lever energetically in the wrong direction as this could break the closure device. IMPORTANT: After installation check that there are no obstructions to the correct rotation of the blade. FUME EXPULSION DAMPER KIT The fume expulsion dampers are used in combination with the fire damper kit and make it possible to expel fumes outside the generator. The wings, connected to each other by internal levers are held in the closed position by a servomotor powered electrically from the wiring board (see electrical connections on page 24). In the case that the fire damper is triggered the servomotor forces the wings to open the damper rapidly. The frame and wings are made of extruded aluminium. FUME EXPULSION DAMPER KIT HG0150_C3_011 Model Code B H P F serranda [mm] [mm] [mm] [mm] PKE100-120 G12832 500 310 125 30 PKE140 G12832 500 310 125 30 PKE190 G12842 600 310 125 30 PKE250 G12852 700 310 125 30 PKE320 G12862 800 310 125 30 PKE420 G12872 900 310 125 30 PKE550 G12882 900 310 125 30 KG0100 C3 012 NB: the fume expulsion accessories kit are always supplied installed on the generator. OVERPRESSURE DAMPER KIT Overpressure dampers are positioned on the external air intake side or the side of the external air regulation damper. they do not regulate the air flow rate but guaranty the intake of new air from outside as long as the fans are working; when the ventilation stops the overpressure dampers close hermetically due to gravity. OVERPRESSURE DAMPER KIT Modello Codice B H P F serranda [mm] [mm] [mm] [mm] PKE100-120 G12831-SP 500 800 125 30 PKE140 G12831-SP 500 800 125 30 PKE190 G12841-SP 600 800 125 30 PKE250 G12851-SP 700 800 125 30 PKE320 G12861-SP 800 800 125 30 PKE420 G12871-SP 900 1.100 125 30 PKE550 G12881-SP 900 1.200 125 30 NB: the fume expulsion accessories kit are always supplied installed on the generator. KG0100 C3 012 27 code HG0150.05GB ed.c-1509 rev.05
SERVOCOMMANDS FOR AIR DAMPERS The air damper supplied can be motorized but comes with 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. Servomotor: This picture is for reference only. Brand and model of supplied device can change without notice. Type Code Description All models G09901 Manual control for shutters (pitch 100 mm) PKE100-320 G01162 ON-OFF servomotor - 230V supply - 4 Nm G01112 Modulation servomotor 0-10Vdc - 24V supply - 4 Nm PKE420-550 G06642 ON-OFF servomotor - 230V supply - 8 Nm G07240 Modulation servomotor 0-10Vdc - 24V supply - 8 Nm All models G17745 Shutter spacer - 0-10 Vdc - for modulation servomotors (24V power supply unit) FLUE EXHAUST KIT Components supplied for flue system are made of stainless steel AISI316 and are suitable for indoor or outdoor installation. This kit includes: - Tee joint - Two straight pipes (1,000 mm long each) - Conical rain protection - One condensate drain tank - Tie rods for anchoring the upper part of the heater. 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 Kit for flue gas outlet Model Code Ø D single wall double wall [mm] PKE100-140 G04065-180 G04065-180-DP 180 PKE190-320 G04065-250 G04065-250-DP 250 PKE420-500 G04065-300 G04065-300-DP 300 Flue gas module Model Code Ø D single wall double wall [mm] PKE100-140 G04061-180 G04061-180-DP 180 PKE190-320 G04061-250 G04061-250-DP 250 PKE420-500 G04061-300 G04061-300-DP 300 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 exhaust kits can be supplied with single-wall or doublewall chimneys. If necessary, a flue exhaust kit can integrate single-hole flue drawing pipe, or one or more straight pipes, each one 1,000 mm long. Straight chimney (1,000 mm long) Model Code Ø D single wall double wall [mm] PKE100-140 G04052-180 G04052-180-DP 180 PKE190-320 G04052-250 G04052-250-DP 250 PKE420-500 G04052-300 G04052-300-DP 300 REMARK: Flue exhaust kits are supplied in a separate package. 28 code HG0150.05GB ed.c-1509 rev.05
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 minimize 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. NOTES: - With standard motors, minimum speed must be higher than 22 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. Note: If motors including an inverter are used, it is mandatory to install a two-stage or modulating burner with flame mode control depending on fan speed. Inverter: This picture is for reference only. Brand and model of supplied device can change without notice. 29 code HG0150.05GB ed.c-1509 rev.05
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. G04700-06 soft starter for motors up to 2.2 kw G04700-09 soft starter for motors up to 4.0 kw Power ON lamp End of cycle lamp Start up time Default=C Start-up voltage Default=C Room Thermostat Setting ON/OFF G11280 G11280 kit includes an electronic room thermostat equipped with NTC temperature sensor. The temperature sensor is already installed into the heater intake duct. Thermostat and sensor must be wired according to the following diagram: HG0150 C3 006 HG0150 C2 002 30 code HG0150.05GB ed.c-1509 rev.05
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 105 C G16170 PT100 - Ø6x100-50 C to 450 C G16195 PT100 - Ø6x100-50 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= 38-45 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. 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. 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. ALARM RESET All manual reset alarms can be reset by pressing PRG and UP buttons simultaneously for at least 5 seconds. NOTE: If no key is pressed for 10 seconds, the screen starts flashing and after 1 minute restores standard display, without storing any changes. 31 code HG0150.05GB ed.c-1509 rev.05
TEMPERATURE REGULATOR ON GENERAL PANEL KG0100 C2 052 TEMPERATURE SENSOR FOR ROOM OR DUCT. TO BE INSTALLED BY AN INSTALLER TEMPERATURE REGULATOR TERMI- NAL BOARD SEEN FROM INSIDE THE CONTROL PANEL 32 code HG0150.05GB ed.c-1509 rev.05
DRY-SYSTEM KIT Dry-system kit allows controlling ambient humidity level by regulating the mix between recirculated and outside air. This setting means that humidity set point=st2. If sensor value falls below set point value because of heating, outside air damper This kit includes: - a Carel regulator (IR32DR3W) - two ON/OFF servomotors - a regulation damper on recirculation air system - a humidity and temperature sensor IMPORTANT: This kit should always be integrated by an outside air damper kit (to be ordered separately) REMARK: heaters come with dry-system kit already installed and tested. The installer shall wire the ambient humidity sensor according to the wiring in the following page. Ambient humidity control: IR32DR3W regulator controls humidity level into the room where the sensor is installed. It uses ST1 set point to control ambient humidity in summer while ST2 value is used to monitor dry-system operation while the burner is working in winter mode. How to set the IR32W control ST1 65% summer moisture set point ST2 30% winter humidity set point P1 5% ST1 differential P2 5% ST2 differential P3 2% neutral area - not used C0 6 operation with double set point opens and outside air is introduced to increase ambient humidity. Recirculation air damper closes when outside air damper opens. To guarantee a minimum of outside air, mechanical stopper of outside air damper servomotor should be adjusted to prevent it closes completely. Changing the set point To change ST1, press SEL button, modify displayed value using "+" & "- keys, then press again SEL button to confirm. To access P1 and P settings, press simultaneously PRG and SEL buttons for 5 seconds, use "+ & "-" keys to set 22 [password], then press again SEL button to confirm. Scroll parameters using "+" & "-" keys till you reach the parameter you would like to edit, press SEL button to confirm, edit value using "+" & -, then press again SEL. Press PRG button to exit menu. CO=6 setting is as follows: DIG1 contact open, summer operation, burner OFF This setting means that set point is ST1. If sensor value exceeds set point value, outside air damper opens and outside air is introduced to decrease ambient humidity. Direct operation, green lamp is flashing. Temperature Regulator IR32DR3W DIG1 contact closed, winter mode ON, burner ON, reverse operation. 33 code HG0150.05GB ed.c-1509 rev.05
WIRING DIAGRAM FOR DRY-SYSTEM KIT HEATER CONTROL PANEL HG0150 C2 003 Servomotor ON/OFF outside air Servomotor ON/OFF inside air Ambient humidity sensor Temperature Regulator IR32DR3W 34 code HG0150.05GB ed.c-1509 rev.05
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] 032 035 G04052-120 120 060 G04052-150 150 100 140 G04052-180 180 190 320 G04052-250 250 420 550 G04052-300 300 700 G04052-350 350 900 G04052-400 400 Conical rain protection Model Code Ø [mm] 032 035 G04053-120 120 060 G04053-150 150 100 140 G04053-180 180 190 320 G04053-250 250 420 550 G04053-300 300 700 G04053-350 350 900 G04053-400 400 Fastening ring Model Code Ø [mm] 032 035 G04055-120 120 060 G04055-150 150 100 140 G04055-180 180 190 320 G04055-250 250 420 550 G04055-300 300 700 G04055-350 350 900 G04055-400 400 90 bend Model Code Ø [mm] 032 035 G04054-120 120 060 G04054-150 150 100 140 G04054-180 180 190 320 G04054-250 250 420 550 G04054-300 300 700 G04054-350 350 900 G04054-400 400 KG0100 C3 017 Chimney kit Model Code Ø [mm] 032 035 G01822-120 120 060 G01822-150 150 100 140 G01822-180 180 190 320 G01822-250 250 420 550 G01822-300 300 Flue gas module Model Code Ø [mm] 032 035 G04057-120 120 060 G04057-150 150 100 140 G04057-180 180 190 320 G04057-250 250 420 550 G04057-300 300 700 G04057-350 350 900 G04057-400 400 Tee joint Model Code Ø [mm] 032 035 G04050-120 120 060 G04050-150 150 100 140 G04050-180 180 190 320 G04050-250 250 420 550 G04050-300 300 700 G04050-350 350 900 G04050-400 400 Condensate Drain Model Code Ø [mm] 032 035 G04051-120 120 060 G04051-150 150 100 140 G04051-180 180 190 320 G04051-250 250 420 550 G04051-300 300 700 G04051-350 350 900 G04051-400 400 KG0100 ET 021 35 code HG0150.05GB ed.c-1509 rev.05
All components are certified in compliance with EN 1856-1 and EN1856-2 standards. They are identified by an ID plate showing their features. Some examples: 0051-CPD-0042 AN 1856-2 T600 N1 W V2 L50050 G 0051-CPP-0042 AN 1856-2 T600 N1 W V2 L50050 G 500 0051-CPD-0007 AN 1856-1 T160 P1 W V2 L50050 O 30 Certificate # Product Description Rule # 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 36 code HG0150.05GB ed.c-1509 rev.05
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 PKE-N-SPORT heaters include a kit for condensate drain. 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 installation 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 aluminum (only outside the heater). Galvanized steel is not recommended since it can be corroded by acid condensate. This kit is identified by code G00740-xxx-V Replace xxx with heater size code. REMARK: in PKE-K heaters, front condensate drain is built-in. IF AN OIL BURNER IS MATCHED, IT IS MANDATORY TO PREVENT ANY CONDENSATE. VERTICAL CONDENSATE DRAIN ON THE BACK 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. 37 code HG0150.05GB ed.c-1509 rev.05
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, TG, and TR thermostat wiring (these thermostats are installed into the heater) Connector reserved for fire dampers 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 31 Common Meaning when contact is closed 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. KG0100 C2 056 38 code HG0150.05GB ed.c-1509 rev.05
CONTROL PANEL - CN4 CONNECTOR Control panel is wired to CN4 connector as follows: Terminal 21 Feature 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 29 - Terminals for isothermal motor 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". KG0110 C2 055 39 code HG0150.05GB ed.c-1509 rev.05
THERMOSTAT WIRING - CONNECTOR CN5 The PKE-P00 is fitted with two thermostat units: the triple thermostat TR+TW+STB, located in the top part of the generator inside the burner cavity, and the dual thermostat TW + TR in the delivery. STB: The STB thermostat or Limit switch, (safety thermostat with manual reset) stops the burner if an excessively high temperature for the heat exchanger is reached; if the STB is triggered it is necessary to reset the thermostat manually following the procedures explained in the user section of this manual. The thermostat acts on the KAS relay of the wiring board cutting off the voltage to the burner. TW: The TW thermostat is located in the series of burner thermostats (T1 - T2) and acts by switching off the burner when the inside the generator exceeds the calibration value. The TW thermostat is similar to a safety device and must not be used as a regulation thermostat. TR: The TR thermostat allows the fan to start only when the air reaches the temperature set. When the burner is switched off it allows the exchanger to cool down. The three thermostats installed inside the box are calibrated to the following temperature values: the TR is set to 40 C; the TW is set to 90 C; the STB is set permanently to 100 C. To adjust the settings of the TR and TW thermostats turn the relative screws. STB + TW + TR TW + TR THERMOSTATS ON DELIVERY HG0150_C3_012 The dual thermostat TW+TR located in the delivery line of the generator can be adjusted by opening the box that contains the thermostats and turning the screw with a screwdriver. The TW thermostat is set to 65 C and, being connected in series with the TW thermostat of the triple thermostat, acts by switching off the burner to prevent triggering the fire damper. The TR thermostat is set to 40 C and is connected in parallel with the TR thermostat of the triple thermostat. This thermostat switches off the fans when the delivery temperature falls below 40 C. Note: For the burner to work terminals 3-4 must be bridged. The contact (230V) can be used for connecting a devices which, in the event of opening, stops the burner removing the electrical power supply (it is in series with the STB thermostat and has the same function red light on). Thermostat setting screws TR TW STB CONTINUOUS VENTILATION To enable continuous ventilation, create a jumper for fan thermostat on 7-8 terminals of CN5 board TW + TR 1 2 3 4 5 6 THERMOSTATS ON DELIVERY TR TW HG0150 C3 009 GREEN GREEN BLACK BLACK BROWN BROWN STB: black cables TR: brown cables TW: green cables 40 code HG0150.05GB ed.c-1509 rev.05
MOTOR WIRING - CONNECTOR CN3 Three-phase Motors - Direct start up In PK-SPORT 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 11-12 Thermal relay. If two motors are installed, thermal relays are wired in series. 13-14 This terminal of KM1 contactor has a withholding function to prevent repeated STOP & GO cycles of the fan at first start. 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 PK-SPORT 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. Starter and additional block scheme LUA1-C11 (thermal) EMERGENCY GROUP To enable emergency group, use 13-14 contacts (NO) or 31-22 contacts (NC) of KM1 contactor MOTOR STAR CON- NECTION CONNECTION MOTOR DELTA CONNEC- TION HG0150 C2 004 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) 41 code HG0150.05GB ed.c-1509 rev.05
Three-phase Motors with Soft Starter In PK-SPORT 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 ways out: Terminal Feature 11-12 Thermal relay. If two motors are installed, thermal relays are wired in series. 13-14 This terminal of KM1 contactor has a withholding function to prevent repeated STOP & GO cycles of the fan at first start. 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 PK-SPORT heaters with soft starter have 230/400V power supply, so motor connection must be of star type. LEGEND: Q1 Door lock main switch; KM1,2 Fan motor contactor 1 & 2; M1,2 Fan motor 400V/3F/50Hz; A1, 2 Motor soft starters 1 & 2 SCH1 Heater management electronic card; F1 Card protection fuse - 5x20-6.3A (rapid) HG0150 C2 005 42 code HG0150.05GB ed.c-1509 rev.05
Wiring Diagram of PK-SPORT Code G10050 LEGEND F1 KAV KAR KAB KAF KAT KAS 6,3 A FUSE FAN CONTROL RELAY THERMAL RELAY CONTROL BURNER LOCK RELAY BURNER OPERATION RELAY CLOSED DAMPER RELAY RELAY STB CLOSED (SAFETY THERMOSTAT) 43 code HG0150.05GB ed.c-1509 rev.05
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). KG0100 C3 005 Type X ØT P A B ØC ØD ØM E PKE: min max max [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] 100-120 150 220 135 150 270 382 133 170 M8 120 140 270 350 190 175 414 454 140 175 M8 124 190-250 270 350 190 175 414 454 160 223 M8 158 320 270 350 230 230 464 484 160 223 M8 158 420-550 270 350 230 230 464 484 190 269 M8 190 KG0100 ET 011 44 code HG0150.05GB ed.c-1509 rev.05
6.3 Gasoil Burners If a gasoil burner is used, its heat output depends on: Nozzle size Burner pump pressure. 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 litre/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. Table for nozzle-heater matching. 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 1.50 1.65 1.75 2.00 2.25 2.50 100-120 10 90 7.6 102 8.5 113 9.5 12 82 6.9 87 7.3 100 8.4 112 9.4 125 10.5 14 80 6.7 88 7.4 94 7.9 107 9.0 120 10.1 134 11.2 bar 2.00 2.25 2.50 3.00 3.50 4.00 120 10 102 8.5 113 9.5 136 11.4 158 13.3 181 15.2 12 100 8.4 112 9.4 125 10.5 150 12.6 175 14.7 14 107 9.0 120 10.1 134 11.2 161 13.5 187 15.7 bar 2.75 3.00 3.50 4.00 4.50 5.00 140 10 124 10.4 136 11.4 158 13.3 181 15.2 203 17.1 226 19.0 12 137 11.5 150 12.6 175 14.7 200 16.8 225 18.9 14 147 12.4 161 13.5 187 15.7 214 18.0 241 20.2 bar 3.50 4.00 4.50 5.00 5.50 6.00 250 10 158 13.3 181 15.2 203 17.1 226 19.0 249 20.9 271 22.8 12 175 14.7 200 16.8 225 18.9 250 21.0 274 23.1 299 25.2 14 187 15.7 214 18.0 241 20.2 268 22.5 294 24.7 bar 4.00 5.00 6.00 6.50 7.00 8.00 320 10 181 15.2 226 19.0 271 22.8 294 24.7 316 26.6 362 30.4 12 200 16.8 250 21.0 299 25.2 324 27.3 349 29.4 14 214 18.0 268 22.5 321 27.0 348 29.2 375 31.5 bar 6.00 7.00 8.00 8.50 9.00 9.50 420 10 271 22.8 316 26.6 362 30.4 384 32.3 407 34.2 429 36.1 12 299 25.2 349 29.4 399 33.5 424 35.6 449 37.7 474 39.8 14 321 27.0 375 31.5 428 36.0 455 38.2 482 40.5 508 42.7 bar 7.50 8.50 9.50 10.50 11.50 13.00 550 10 339 28.5 384 32.3 429 36.1 475 39.9 520 43.7 588 49.4 12 374 31.4 424 35.6 474 39.8 524 44.0 574 48.2 14 401 33.7 455 38.2 508 42.7 562 47.2 615 51.7 Legend for data reported on oil nozzle labels: EN : Compliant with European rules 1,90 kg/h : Flow rate at a pressure of 10 bars 0.50 GPH : Gallon/hour flow rate at a pressure of 7 bars (100PSI) 80 W : Spray angle and cone type 100 II : Spray angle index and cone type index (EN) CT j3 : Manufacturing date 45 code HG0150.05GB ed.c-1509 rev.05
6.4 Gas Burners PK heaters must be matched to gas burners certified by an EC mark as compliant to 2009/142/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 centers complying with relevant laws existing in the Country where the unit is installed. During first start up, the combustion efficiency must be analyzed. Gas Flow Rate Table PK N Heaters 032 035 060 100/120 140 190 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 18,7 250 320 420 550 GAS U.M. consumption 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 G25 mc/h 18,9 38,1 22,8 46,7 32,0 62,5 39,4 82,4 G30 kg/h 12,3 24,8 14,8 30,4 20,8 40,6 25,6 53,6 G31 kg/h 12,5 25,2 15,0 30,9 21,1 41,3 26,0 54,5 Gas Flow Rate Table per PK K heaters 032 060 100 140 190 250 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 28,52 320 420 550 GAS U.M. consumption min max min max min max G20 mc/h 7,49 36,08 8,52 46,48 9,78 63,04 Gas Flow Rate Table per PK R heaters 032 060 100 140 190 250 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 22,52 320 420 550 GAS U.M. consumption min max min max min max G20 mc/h 7,49 28,11 8,52 35,70 9,78 47,19 46 code HG0150.05GB ed.c-1509 rev.05
6.5 Burner Matching Tables In the following pages burner matching between PK-SPORT 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. 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. HEATER MODEL 100 120 140 250 320 420 550 APEN GROUP RIELLO WEISHAUPT CIB UNIGAS BALTUR Oil Gas Gas Gas Gas GAS LO0168-1L00I MG0120-1L15I BS 3 WG20/1 NG120 M-.TN.L.IT.Y.0.20 BTG 11 LO0168-2L00I MG0168-1L20I BS 3 D WG20/1/Z NG140 M-.TN.L.IT.Y.0.20 SPARKGAS 20 LO0212-1L00I MG0168-2L20I NG140 M-.AB.L.IT.Y.0.20 BTG 11 P LO0212-2L00I MG0212-1L25I NG200 M-.TN.L.IT.Y.0.25 SPARKGAS 20 P 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 SPARKGAS 20 LO0212-2L00I MG0212-2L25I BS 3 D WG30/1 NG200 M-.AB.L.IT.Y.0.25 SPARKGAS 20 P LO0280-2L00I MG0300-1L25I WG20/1/Z NG350 M-.TN.M.IT.A.0.25 BGN 17 DSPGN MG0300-2L25I WG30/1/ZM NG350 M-.PR.M.IT.A.0.32 MG0355-1M32I NG350 M-.MD.M.IT.A.0.32 MG0355-PM32I MG0355-MM32I LO0280-2L00I MG0300-1L25I BS 3 WG30/1 NG350 M-.TN.L.IT.A. 0.25 SPARKGAS 30 LO0420-2M00I MG0300-2L25I BS 4 WG30/1/ZM NG350 M-.PR.M.IT.A. 0.32 SPARKGAS 30 P BS 3 D NG350 M-.MD.M.IT.A.0.32 BGN 26 DSPGN BS 4 D LO0420-2M00I MG0355-1M32I RS5 WG30/1 NG350 M-.TN.L.IT.A.0.25 SPARKGAS 30 MG0355-PM32I RS5 D WG30/1/ZM NG350 M-.PR.M.IT.A.0.32 SPARKGAS 30 P MG0355-MM32I RS25/M BLU NG350 M-.MD.M.IT.A.0.32 BGN 34 DSPGN LO0420-2M00I MG0355-1M32I RS5 WG30/1 NG350 M-.TN.L.IT.A.0.25 BGN 40 P MG0355-PM32I RS5 D WG40/1 NG350 M-.PR.M.IT.A.0.32 BGN 40 DSPGN 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 BGN 60 P LO0570-ML00I MG0570-ML40I RS45/M BLU WG40/1/ZM NG550 M-.MD.L.IT.A.0.40 BGN 60 DSPGN LO0570-2L00I MG0570-PL40I RS45/M BLU WG40/1 NG550 M-.PR.L.IT.A.0.40 M0698-2L00I MG0800-2L50I RS68/M BLU G5/1-E/ZM P60 M-.AB.L.IT.A.0.50 M0698-PL00I MG0570-ML40I WG40/1/ZM NG550 M-.MD.L.IT.A.0.40 BGN 60 P M0698-ML00I MG0800-ML50I G5/1-E/ZM P60 M-.MD.L.IT.A.0.50 BGN 60 DSPGN 47 code HG0150.05GB ed.c-1509 rev.05
HEATER MODEL 100 120 140 250 320 420 550 CUENOD ECOFLAM LAMBORGHINI FINTERM/ JOANNES SANT'ANDREA GIERSCH ELCO Gas Gas Gas Gas Oil Gas Gas 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-2 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 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-2 EM 26 M EURO 25/2 KB 25 MOG C28 BLU 350 P EM 35 GAS35 KB 36 MOG RG30 EGC.350R-2 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 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) 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) C70 OSA 60 G OSA 90 G Tables for Gas Burner Matching (Switzerland) HEATER MODEL 100-120 140 190 250 320 420 550 ELCO RIELLO WEISHAUPT CTC-GIERSCH Gas SVGW-N Gas SVGW-N Gas SVGW-N Gas SVGW-N G02-120 BS 3 WG20/1 RG 20-Z-L-Nb 06-045-4 G02-160 BS 3 D WG20/1/Z RG 20-M-L-Nb EGC 140 R-2 92-146-4 RG 30-Z-L-Na RG 30-M-L-Na G02-160 BS 3 WG20/1 RG 30-Z-L-Nb G02-210 BS 3 D WG30/1 RG 30-M-L-Nb 00-005-4 06-045-4 WG30/1/ZM WG20/1/Z G02-210 BS 3 WG30/1 RG 30-Z-L-Nb BS 3D WG30/1/ZM RG 30-M-L-Nb BS 4 BS 4 D 11-007-4 EGC 350-R-2 RS5 WG30/1 MG10/1-Z-L-N RS5 D WG30/1/ZM MG10/1-M-L-N RS25/M BLU 08-009-4 MG10/1-ZM-L-N EGC 350-R-2 92-146-4 RS5 WG30/1 MG10/1-Z-L-N RS5 D WG40/1 MG10/1-M-L-N RS25/M BLU WG30/1/ZM MG10/1-ZM-L-N 08-017-4 RS35/M BLU 08-009-4 WG40/1/ZM MG10/1-DZM-L-N RS35/M BLU WG40/1 MG10/2-Z-L-N RS45/M BLU WG40/1/ZM MG10/2-M-L-N MG10/2-ZM-L-N MG10/2-DZM-L-N RS45/M BLU WG40/1 RS68/M BLU 10-076-4 G5/1-D/ZM WG40/1/ZM G5/1-D/ZM 48 code HG0150.05GB ed.c-1509 rev.05
7. MAINTENANCE 7.1 Controls at First Start Up Before / 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 Checks Length of burner nosepiece Fuel capacity of the burner Combustion parameters Safety Checks Check if STB+TG or LIMIT safety thermostat triggers Microswitch for fires 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 analyzer. 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 Check 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 CO 2 content and therefore for O 2 excess air for different fuels are listed below: 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 392 to 428 F (200 to 220 C); maximum output is reached when net flue temperature ranges from 518 to 554 F (270 to 290 C); and minimum output is reached when net flue temperature ranges from 248 to 284 F (120 to 140 C). During first start up, the following checks are recommended: If combustion efficiency is known and CO 2 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 controls must be performed: STB + TW Safety thermostat Lower the value of TW until the burner is switched off then reset the value of TW. To verify the action of the STB it is necessary to disconnect the thermostat electrically and check that the burner switches off and the red light comes on. After testing make sure that the thermostat is reconnected correctly. Fire Dampers 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 Check that room thermostat and/or the timer turn off ONLY 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 louvers at turn off. Control on delivered air temperature. Make sure that temperature of delivered air does not exceed 65 C and that there is no danger that safety devices trigger while the heating is normally operating. Natural gas CO 2 content 9.7% ± 0.2 L.P.G CO 2 content 10.2% ± 0.2 Fuel oil CO 2 content 12.5% ± 0.3 CO 2 values shown can surely be improved without producing unburnt products. However a high quantity of excess air should be maintained in order to balance possible working variations in time. 49 code HG0150.05GB ed.c-1509 rev.05
7.2 Routine Maintenance We recommend execute maintenance operations using the following schedule: Air Filter Belts Electrical motor Fan Combustion Analysis Safety Thermostat Fire Damper Cleaning the Exchanger Clean it every 30 days After 8 hours from first start-up. Then, every 60 days. Check electrical absorption every 90 days Check cleaning every 90 days Once per season At the beginning of each season At the beginning of each season See paragraph 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. Checking the Cleanliness of 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 analyzed. 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. 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. 50 code HG0150.05GB ed.c-1509 rev.05
7.3 Spare Part List Spare Parts for Control Panel STB + TW + TR HG0150 C3 007 51 code HG0150.05GB ed.c-1509 rev.05
TABLE OF CONTROL PANEL COMPONENTS 1 2 Description Code Regulation Main switch Door Lock Disconnect switch Neutral Use G10067 32A from PKE100 to PKE320 G10068 63A PKE420 and PKE550 G10074 20/40A from PKE100 to PKE320 G10075 63/80A PKE420 and PKE550 3 Wiring card G10050 Any heaters, any models 4 Card fuse X02150 6.3 A Any heaters, any models 5 1 pole selector G10065 Ø 22 Any heaters, any models 6 Green lamp G14991.01 230V Any heaters, any models 7 Red lamp G14992.01 230V Any heaters, any models 8 Yellow lamp G02756 230V Any heaters, any models 9 3P autoswitch G10078 6.3 A All models from 250 to 550 10 11 Starter LUB12 G02215 5.5 kw All models with 3-phase motor up to 5.5 kw included Starter LUB32 G02225 15 kw All models with 3-phase motor from 7.5 kw to 15kW Thermal relay LUCA12 G02217 3-12 A All models with 3-phase motor from 2.2 kw to 5.5 kw included Thermal relay LUCA18 G02218 4.5-18A All models with 7.5 kw 3-phase motor Thermal relay LUCA32 G02219 8-32 A All models with 3-phase motor (9.2, 11 & 15 kw) 12 Contact LUA1C20 G02271 NO + NO All models 13 Soft starter block G10076 - All Models with soft starter 14 Soft starter G02801 3 kw Special models on demand G02801 4 kw Special models on demand G18034 5.5 kw Special models on demand G18035 11 kw from PKE250 to PKE420 G18043 15 kw PKE550 15 Temperature Regulator G03470 IR33 Optional for all models 16 Threethermostat Jumo G04750 - All models 17 18 Plug for two-function thermostat connection Two-function thermostat on delivery TG + FAN G03486 - All models G10165 - All models Motor KW Current In 400V-50Hz Efficiency % Number of rounds 1.1 2.7 81.4 1,420 1.5 3.7 82.8 1,425 2.2 4.9 84.3 1,445 3.0 6.5 85.5 1,440 4.0 8.1 86.6 1,430 5.5 10.9 87.7 1,450 Thermal Relay 1.2-5A 3-12A 7.5 14.6 88.7 1,455 4.5-18A 9.2 17.1 89.5 1,460 11.0 20.2 90.2 1,465 15.0 27.8 91.0 1,470 8-32A Thermal Relay regulation 52 code HG0150.05GB ed.c-1509 rev.05
Ventilation Spare Parts HG0150 C3 008 6 TRANSMISSION BELT 5 DRIVEN PULLEY 4 FAN 3 DRIVING PULLEY 2 ELECTRICAL MOTOR 1 BELT TIGHTENER REFERENCE DESCRIPTION VENTILATION SPARE PARTS TABLE Heater Model PKE100-120 Fan code G02324 # Transmission Driven pulley Electrical motor Driving pulley Belt tightener belt code Pulley Grip Pulley Grip code # code # G07232 G07406 G01260-IE2 G00393 G00392 G07377 2 PKE140 G01440 G00708 G07406 G00391 2 G00137-IE2 G00419 G00392 PKE190 G01619 G07406 G00696 2 G04133 PKE250 1 G00878 G01468 G07356 G01954 G00863 2 G01022-IE2 PKE320 G07260 G01990 G01906 G00834 G01954 G00863 3 PKE420 G00731 G01955 G01957 G00837-IE2 G01904 G00130 G00868 3 PKE550 G01893 G00290 G01957 G01973-IE2 G07356 G00833 G01899 2 G08604 4 53 code HG0150.05GB ed.c-1509 rev.05
Exchanger Spare Parts POS. Description Code Use 1 Flue System Gasket X01415 Any heaters, any models; in meters G01190 From model 032 to model 120 included 2 Burner plate gaskets G07819 From model 140 to model 250 included G08119 From model 320 to model 550 included 3 Peep-hole G02317 Any heaters, any models 4 Peep-hole Gasket X00397 Any heaters, any models 5 Peep-hole locknut X01822 Any heaters, any models 6 Combustion Chamber Pressure Inlet C00060 Any heaters, any models 7 Flue inspection gasket G14242 From model 032 to model 550 included 8 Flue inspection panel G11142.08 From model 032 to model 550 included KG0100 C3 027 54 code HG0150.05GB ed.c-1509 rev.05
CONSIGLI PER L'INSTALLAZIONE DELLE MANICHE DI COLLEGAMENTO CON LA STRUTTURA SOME ADVICES FOR THE INSTALLATION OF THE CONNECTION SLEEVES Sì YES NO ESP - DATA MODIFICA MODIFICA DISEGNATA DA - - - MODIFICA APPROVATA DA DESCRIZIONE MODIFICA - DETTAGLIO: Le maniche di collegamento devono essere di misura idonea e opportunamente tese DETAIL: The connection sleeves have to be correctly measured and stretched DETTAGLIO: Le maniche di collegamento NON devono afflosciarsi e ostruire il passaggio/ridurre l'area di transito dell'aria durante il funzionamento DETAIL: The connecting sleeves DO NOT wilt and obstruct the area for the air transit when the system is ON. Quote senza indicazione di tolleranza: Classe di Tolleranza ISO 2768 - M per lavorazioni in tranciatura ISO 2768 - C ApenGroup Heating and Conditioning Solutions MATERIALE DESCRIZIONE SCALA 1:2 CONSIGLI PER L'INSTALLAZIONE DELLE MANICHE DISEGNATO DA NVilla - APPROVATO DA - DISEGNO KS0062IT DATA 09/06/14 DISEGNO DI PROPRIETA' APEN GROUP spa E' VIETATA LA RIPRODUZIONE E LA DIFFUSIONE ANCHE PARZIALE SENZA L'AUTORIZZAZIONE DELL'APEN GROUP spa ESP - CARTIGLIO cod. X07003 ed.0411 55 code HG0150.05GB ed.c-1509 rev.05