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PCH
User,
Installation,
and
Maintenance Manual
Pag. 1
APEN GROUP reserves the right to change products and documents as required.
It is forbidden to totally or partially copy or reproduce this document for disclosure to third parties without written consent by Apen Group S.p.A.
CONDENSATION
Air Heater Module
SUMMARY
SECTION
SECTION
SECTION
SECTION
1.
2.
2.1
2.2
2.3
2.4
2.5
2.6
Fuel ......................................................................................................... 3
Gas Leaks .............................................................................................. 3
Power Supply .......................................................................................... 4
Use ......................................................................................................... 4
Maintenance ........................................................................................... 4
Transport and Handling .......................................................................... 4
3.
3.1
3.2
3.3
3.4
3.5
3.6
Efficiency ................................................................................................. 6
Technical Data ........................................................................................ 6
Operation cycle ....................................................................................... 8
Air/Gas Premix ........................................................................................ 9
Dimensions ............................................................................................ 10
Supply of PCH modules ......................................................................... 11
4.
4.1
4.2
5.
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
6.
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
SECTION
7.
TROUBLESHOOTING ................................................................... 36
SECTION
8.
SECTION
9.
SECTION
10.
SECTION
SECTION
APEN GROUP reserves the right to change products and documents as required.
1.
GENERAL WARNINGS
2.
SAFETY WARNINGS
2.1
Fuel
2.2
Gas Leaks
Reference regulations:
- UNI-CIG 7129 regulating appliances fired with natural gas.
Pag. 3
APEN GROUP reserves the right to change products and documents as required.
2.3
Power Supply
2.4
Use
30
00
HG
1
00
IM
2.5
2.6
Maintenance
APEN GROUP reserves the right to change products and documents as required.
3.
TECHNICAL FEATURES
HG0040 C2 003
HG0106 C2 033
Pag. 5
APEN GROUP reserves the right to change products and documents as required.
3.1
Efficiency
Technical data
Description
Type of Appliance
CE Approval
Nominal Capacity
Nominal Power Output
Efficiency
Condensation produced
gas connection
of air inlet/exhaust pipes
Available flue pressure
Power supply
Power absorbed
Minimum air flow *
Exchanger Pressure Drop
Max. applicable pressure
Minimum running temperature
Weight
PCH032
min max
U.M.
PCH035
min max
P.I.N.
kW 10,1 34,85 11,3 38,8
kW 10,2 32,8 11,7 36,5
% 101,0 94,1 103,5 94,1
l/h
0,77
0,84
PCH043
min
max
PCH054
PCH072
PCH092
PCH150
PCH200
min max min max min
max
min
max
min
max
C13 - C33 - C43 - C53 - C63 - B23
0694BM3433
14,8 47,5 15,5
58
22
78
30
98
44
155
53
215
15,54 44,8 16,28 54
23,1 73,2 31,5 93,4 46,3
145
55,7
197
105,0 94,3 105,0 93,1 105,0 93,8 105,0 95,3 105,2% 93,5% 105,1% 91,6%
3,87
4,9
1,45
1,45
2,20
2,60
UNI ISO 7/1- 3/4" M UNI ISO 7/1- 3/4" M UNI ISO 7/1- 3/4" M UNI ISO 7/1- 3/4" M
mm
Pa
V
W
m3/h
Pa
Pa
C
kg
80/80
70
230V/50Hz
70
1900 *
80/80
80
230V/50Hz
70
2100 *
80/80
120
230V/50Hz
70
2600 *
1.200
-15
85
1.200
-15
85
1.200
-15
100
80/80
100/100
120
120
230V/50Hz
230V/50Hz
90
120
3100 *
4200 *
vedi grafico
1.200
1.200
-15
-15
100
140
100/100
120
230V/50Hz
120
5400 *
130/130
100
230V/50Hz
400
130/130
140
230V/50Hz
400
8500*
11500*
1.200
-15
170
1.200
-15
210
1.200
-15
210
Note: Minimum air flow has been calculated for a t value of 50C, which is suitable for process plants or special applications.
AIR FLOW RATE / THROUGHPUT SPEED CHART
In air treatment, roof-top, and heating installations, use modules within a speed range from 3.0 to 7 m/s. Lower speeds require
an accurate control of output temperature to prevent the safety thermostat from triggering. Higher speeds can be used depending
on pressure drops generated in the module.
10
9
032/035
043/054
072
092
150/200
6
5
4
3
2
1
0
-
5.000
10.000
15.000
20.000
25.000
30.000
35.000
40.000
45.000
APEN GROUP reserves the right to change products and documents as required.
speed [m/s]
3.2
270
043/054
240
092
210
150/200
Dp [Pa]
032/035
072
180
150
120
90
30
5.000
10.000
15.000
20.000
25.000
30.000
35.000
40.000
106
105
104
103
102
efficiency [%]
101
100
032 035
99
98
043
092
200
150
97
054
072
96
95
94
93
92
91
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
Pag. 7
APEN GROUP reserves the right to change products and documents as required.
200
60
3.3
Working Cycle
Burner operation
When heating is required, terminals 7/9 of CN6 [A] board close
and the remote control launches modulation card working
cycle. This card triggers the flame control device. The new
CPU-PLUS card enables start up when the 0-10 Vdc signal
exceeds minimum startup threshold (see Electrical Wiring
section).
The flame control device starts the burner fan [A], beginning to
pre-wash the combustion chamber for a default period. Once
this phase is over, the start-up cycle is initialised: the EV1
electrical valve opens simultaneously with the EVP valve,
feeding the pilot burner [B].
A BC
5/6 terminal
Control device
Burner fan
Burner group
EVP
After detecting the pilot flame, the device causes the EV2 main
gas valve [C] to open and feed the main burner.
Pilot and main burner work together for a short period, then the
modulation card closes the EVP electrical valve, turning pilot
burner [D] off.
A single electrode assures flame detection both for pilot and
main burner.
Detection
electrode
Start-up
electrode
pilot burner
Flue
HG0106 C2 026
nozzle
EV2
EV1
Gas
Condensation
drain
Cooling fans
If cooling fans are remotely controlled, they start according to
the default time set in APEN GROUP modulation card.
Default time set by the manufacturer is 60 seconds. This value
can be changed to a value ranging from 0 to 256 seconds by
means of a remote control.
When no more heating is required, 7/9 contacts of CN6 board
open (or 0-10 Vdc lowers), the modulation card turns off the
burner while cooling fans, if controlled, keep working for the
default period in order to cool down the exchanger.
EVP
HG0105 C2 001
APEN GROUP reserves the right to change products and documents as required.
EV1
The fan can be started together with the burner [G] or about 60
seconds later [H], in order to prevent cold air to be blown into
the room. If an electrical protection device and/or an air flow
control is installed on the fan, it must be connected in series
to the burners ON position on 8/9 terminals of CN6 board.
Turn off
- When heating is no more required, the burner must be turned
off (7/9 contacts of CN6 board) [I] and cooling fans must keep
working for at least three minutes [L]. This will allow the heat
exchanger to properly cool down. If post-washing phase is too
short and the exchanger is not correctly cooled down, the
following problems may arise:
- Shorter life of the heat exchanger
- The safety thermostat triggers and will require manual reset.
If, during the cooling cycle, a new heat request arises, the
modulation card waits for the fan to stop, zeroes any counts,
and starts a new cycle.
The minimum interval between a turn off and the subsequent
start up depends on the value of one parameter of the
modulation card which must be set in a range from 0 to 256
seconds.
G H
Burner
Cooling fan
HG0106 C2 034
Safety thermostats
Two safety thermostats with manual reset and positive safety
are installed on the heating module. The breaking of the
sensible element causes a safety state. Two thermostats, one
before and one after the exchanger, are always assembled in
order that the heater be installed either with rightward or
leftward air flow.
The thermostats are wired in series.
When the thermostat triggers, the flame detection device locks,
turning the burner off.
This lock is displayed on the remote control (F2).
The heater is equipped with an air pressure switch controlling
possible obstructions of flue and/or air intake pipes. This
pressure switch is wired in series to the safety thermostats and
operates identically, thereby causing the F2 lock on the remote
control.
3.4
modified
curve
1:1 curve
Pag. 9
APEN GROUP reserves the right to change products and documents as required.
Start up
Fx locks
3.5
Dimensions
HG0106 C2,001
DIMENSIONS
PCH032
PCH035
PCH043
PCH054
B1
H1
L1
L2
L3
H2
H3
H4
H5
B2
(2)
(3)
(3)
(2)
(2)
(1)
(1)
(3)
(1)
(2)
(3)
(3)
(3)
530
95
32
79
32
29
68
29
900
713
PCH072
1410
1950
PCH200
Heater Model
833
650
722
1230
PCH092
PCH150
505
1970
335
860
798
898
735
788
978
1108
920
1012
25
1050
1590
1568
310
610
90
377
870
71
N
(1)
P
(4)
GAS
R
(4)
W
(1)
80
204
373
60
3/4"
100
100
204
343
66
1"
130
130
360
168
178
1"
E
(4)
F
(4)
106
180
75
195
80
119
180
45
195
171
239
99
347
Heater Model
PCH035
PCH043
PCH054
PCH072
PCH092
PCH150
PCH200
(1)
(2)
(3)
(4)
PCH032
APEN GROUP reserves the right to change products and documents as required.
3.6
HG0106 C2,035
Pag. 11
APEN GROUP reserves the right to change products and documents as required.
4.
USERS INSTRUCTIONS
4.2 Resetting
Modulation and control card automatically runs a set of re-start
attempts (4 reset attempts max, A 17 parameter).
During startup cycle, an ignition failure of the burner causes the
unit to lock up and the F1 fault to be displayed on remote control
screen. Only after completion of the automatic restart set, the
external lockup lamp lights up (red light) on the module and an
output signal is issued on the digital line.
If, during heater operation, one safety thermostat or control
pressure switch is engaged, the unit immediately locks up, the
F2 alarm is displayed on remote control screen, a red lamp
light up on the module, and the digital output signal is issued.
F1 and/or F2 alarms, as well as F3 and F8, can only be manually
reset.
To unlock the unit, press simultaneously the two arrow buttons
for at least 3 seconds.
REMARK: only 15 seconds after burner motor stops, the unit
can be reset.
WARNING: Besides storing all possible alarm conditions (F1
to F8), the modulation card runs an further partial count for F1
and F2 errors: after 5 manual reset operations, the
microprocessor itself must be reset in order to continue.
To reset the microprocessor, use the Reset switch on the card
or turn power off and on by using 0/1 main switch.
NOTE: another microprocessor is installed on the control card.
It independently checks maximum number of flame control
unlocks. If this number exceeds maximum value allowed, this
microprocessor prevents flame control unlock and indicates
the fault by turning on a red led on the card.
To restart the system, reset the microprocessor by means of
the Reset switch on the card or turn power off by using 0/1 main
switch.
A fault is displayed
APEN GROUP reserves the right to change products and documents as required.
5.
5.1
Indoor installation
For this kind of installation modules of either C type (sealed
combustion chamber) or B type (open combustion chamber)
can be used.
However, some additional cares have to be taken besides
preventing water from leaking into burner casing.
The hollow space between the units outer panel and the
module must be suitably vented since the gas supply system
is placed in it.
The outer panel must therefore have vents whose surface is
no less than 2% of the larger internal section (see drawing
below). These vents must be equally split between the top and
the bottom of the panel (EN525).
The air to be handled must flow in a sealed duct and must never
mix with the air in this hollow space. In B-type heaters,
combustion air can be sucked from the hollow space.
But, if so, the greatest attention is to be paid to the sealing of
this space, especially when the fan is installed after the PCH
module.
It is mandatory to avoid any depression in the hollow space
caused by fan operation since this would determine a hottest
air flow from the exchanger through the burner fan to this space,
after the burner is off. This hot flow would permanently damage
the burner fan.
Internal installation
C type appliance
External installation
B type appliance
Vents
Ho
llow
spa
ce
Air to
d
andle
be h
HG0106 C2,037
HG0106 C2,046
Pag. 13
APEN GROUP reserves the right to change products and documents as required.
5.2
HG0106 C2 038
air flow
direction
air flow
direction
HG0106 C2 032
APEN GROUP reserves the right to change products and documents as required.
5.3
HG0106 C2 047
Serial assembly
This type of installation requires that the
output temperature of the first module
does not affect data detection of the
thermostat installed on the intake of the
second module. If it does, the second unit
thermostat can be bypassed. The only
thermostat working on the second module
will then be the one on the outlet.
This type of installation is suitable when
reduced air flows and high temperature
differentials are required (process
installations). Pressure drops of all
modules will obviously have to be
summed.
The fan can be installed either before or
after the module.
HG0106 C2 048
HG0106 C2 049
Parallel assembly
Choose this type of installation when high air
flows and low temperature differentials are
required. Check that air flow is balanced through
all the modules.
Pag. 15
APEN GROUP reserves the right to change products and documents as required.
Flue Connections
Combined Venting Systems
Individual flue system is to be preferred, whenever possible.
Since PCH modules are pressurised, a wrongly-sized collective
flue system would cause problems to the unit.
HG0105 C2 004
1-3
HG0106 C2 010
5.4
HG0106 C2 004
HG0106 C2 009
Important
Horizontal flue pipes must be installed with a slight inclination
(1-3) towards the heater, so that condensation water can flow
into the drainage system.
APEN GROUP reserves the right to change products and documents as required.
m o d e lli PCH
Pressure available on outlet
032
70
035
80
4,1
3,8
5,1
4,5
043
054
072
092
120
120
120
120
Pressure drop [Pa]
7,3
13
22
36
5,5
7,5
10
13
23
10
2,8
23
10
2,8
2,2
2
28
13
3,4
28
13
3,4
2,8
2,5
42
21,3
4,9
42
21,3
4,9
4
3
62
34,5
7
62
34,5
7
7
4,2
111
70,3
11,9
111
70,3
11,9
12
5,7
181
128
18,6
181
128
18,6
20
7,3
8,2
5
9,7
5,8
13,6
7,2
19,4
9,7
33,8
15
54
21,3
2,3
2
2,9
2,5
4,3
3
6,4
4,2
11,7
5,7
19,2
7,3
3,9
1,5
4,8
1,8
7,3
2,7
11
4
19,6
7,3
32,3
12
2
0,7
2,4
0,8
3,6
1,3
5,4
1,9
9,8
3,4
16,1
5,6
2
1,5
2
1,5
2
1,5
2
1,5
2,5
2
2,5
2
Component
C13 Horizontal s ingle terminal 80/80
C13 Horizontal s ingle terminal 100/100
C13 Horizontal s ingle terminal 130/130
C13 Horizontal coaxial terminal 80/80
C13 Horizontal coaxial terminal 100/100
C13 Horizontal coaxial terminal 130/130
C33 Vertical coaxial terminal 80/80
C33 Vertical coaxial terminal 100/100
C33 Vertical coaxial terminal 130/130
B23 Horizontal terminal 80
B23 Horizontal terminal 100
B23 Horizontal terminal 130
B23 Vertical terminal 80
B23 Vertical terminal 100
B23 Vertical terminal 130
80 Pipe (1 meter)
100 Pipe (1meter)
130 Pipe (1meter)
80 bend 90 w ide radius
100 bend 90 w ide radius
130 bend 90 w ide radius
80 bend 45 w ide radius
100 bend 45 w ide radius
130 bend 45 w ide radius
Bonnet 80
Bonnet 100
Bonnet 130
Grid 80
Grid 100
Grid 130
Pag. 17
0,8
150
100
200
140
15,2
29,3
44,7
80,2
44,7
80,2
15
27
3,8
7,3
9,2
17,7
3,9
7,5
0,8
[Pa]
Code
G14305
G14315
G05567
G14505
G01942
G01941
C04790-A
G14525
G01944
G05580
G14500
G05582
G05581
G14535
G05583
/
/
/
G01337
G14502
G01339
G01366
G14501
G01276
G05596
G14517
G14517
C04787
G14513
G05589
APEN GROUP reserves the right to change products and documents as required.
5.5
Upon request, Apen Group will supply a suitable kit for each
installation. The kit includes:
- siphon and float
- silicone hose ( 16 x 21)
- various holders for silicone hose.
The system can drain condensation water in the following
ways:
- Free drainage
- Using a siphon
- Into a water pipe
- Into the unit itself (collecting tank)
Precautions
Materials to be used for the condensation drainage system:
- for hot pipes (i.e. flue pipes),
aluminum, stainless steel, silicone tube, or Viton;
- for cold pipes (water pipes), PVC and any materials suitable
for hot pipes.
Do not use copper nor galvanised iron pipes.
Free Drainage
If the unit is installed outdoor and temperatures are never too
cold, you can choose not to connect the water drain tube to any
piping. You only need to make sure the water doesnt stagnate
by the unit.
If a collecting hose is to be installed, do not seal it directly to the
outlet drain tube (see drawing below). In fact, if water freezes
into the tube, ice will block the drain and condensation water
will accumulate into the exchanger.
When the heater works at maximum power, the heat of the flue
will cause the ice in the tube to melt, freeing the drain outlet.
HG0106 C2,022
HG0106 C2,002
HG0103 C2,017
Condensation
drain
APEN GROUP reserves the right to change products and documents as required.
Hood
for flue
collection
HG0105 C2,003
Plug
for siphon
filling
NO
Siphon
connecting
filling
Drain tube
(supplied)
Pag. 19
APEN GROUP reserves the right to change products and documents as required.
5 mm MAX
Siphon for
condensation
collection
Electrical Wiring
400V connection with
400/230 V transformer
230V connection
Power Supply
The heater shall be correctly wired to an efficient grounding
system, complying with existing regulations.
Single-phase 230 Vac supply with neutral. Do not reverse
neutral and phase
or the flame control device will lock the unit for safety reasons
(F1 fault).
If power supply is shunted from a 400V triphase line, use an
insulation transformer and ground a pole of the secondary.
This pole will be used as neutral.
The heater can be plugged into mains using a plug-socket only
if the latter prevents any mix up of phase and neutral wires.
The system wire gauge in general, and cable section in
particular, must suit the unit rated input (see technical data
table).
Keep cables far from heat sources.
HG0106 C2,024
230V-50Hz
5.6
T
N
L
230V-50Hz
Remote Control
The remote control is already installed into burner casing. As
explained above, it controls the heater and can easily be moved
far from the heater, if necessary.
DO NOT BRIDGE THE TERMINALS THE REMOTE CONTROL IS
CONNECTED TO.
If you want remove this control from the heater and install it
elsewhere, remember the following:
- Do not use a multipole cable carrying both the electrical
supply and the remote control, since this would interfere on
control signals, jeopardising heater operation.
- No polarity to be respected when connecting the control.
06
01
HG
5
,02
C2
HG0103 C2 021
400V-50Hz
Diameter of
phase, neutral & ground
wires:
1,5 mm
Chronothermostat
wire
Power supply
supply
Hose or pipe
NO!
Wire diameter:
Max length:
Warning:
YES
untwisted bipolar wire resistance 25 Ohm
50 meters
Where electrical interference is high, use a
twisted or shielded double wire
HG0106 C2,051
ON/OFF WIRING
Diagram for switching on/off multiple modules from a single
control.
APEN GROUP reserves the right to change products and documents as required.
0V
0V
10 V
10 V
CN6 connector
modulation
electronic card
Cascade Regulation
The 0-10 Vdc signal can be used to cascade turn on and off
multiple modules by means of threshold converter relays.
You can connect the 0-10 Vdc signal in parallel to the modules
and, by setting convenient parameters, you can obtain progressive start-ups which will increase the modulation range of
PCH modules.
For information on setting up parameters and values, please
refer to Maintenance chapter.
Check that total absorption of PCH modules does not exceed
available voltage at regulator outlet.
Remote Signals
The following signals can be remotely obtained from PCH
modules:
- Locked unit
- Burner on
Locked unit
If a fault occurs, a free contact (NC or NO) is available. It can be
used to report a fault to a remote console.
Use the remote control to unlock the unit.
To remotely unlock the appliance, remote control must be
remotely controlled.
Burner on
A 230Vac line is available on 8-9 terminals, to report to a remote
console a signal for burner on.
230 Vac
230Vac line to
report unit operation
No-voltage line
to report a lock of the unit
Pag. 21
APEN GROUP reserves the right to change products and documents as required.
5.7
HG0103 C2,022
VGE
NO
NC
R
C
Legend:
L
Line
N
Neutral
R
Relay coil
VGE External Gas Valve
APEN GROUP reserves the right to change products and documents as required.
5.8
To be installed by the
installer
HG0103 C2,016
For PCH150/200
Pag. 23
APEN GROUP reserves the right to change products and documents as required.
6.
County
Category
Gas
Pressure
Gas
Pressure
AT
II2H3B/P
G20
20 mbar
G30/G31
50 mbar
BE <70kW
I2E(S)B,I3P
G20/G25
20/25 mbar
G31
37 mbar
BE >70kW
I2E(R)B,I3P
G20/G25
20/25 mbar
G31
37 mbar
CH
II2H3B/P
G20
20 mbar
G30/G31
50 mbar
DE
II2ELL3B/P
G20/G25
20 mbar
G30/G31
50 mbar
II2H3B/P
G20
20 mbar
G30/G31
30 mbar
II2H3P
G20
20 mbar
G31
37 mbar
IT
II2H3B/P
G20
20 mbar
G30/G31
30 mbar
FR
II2Esi3P
G20/G25
20/25 mbar
G31
37 mbar
LU
II2E3P
G20/G25
20 mbar
G31
37/50 mbar
NL
II2L3B/P
G25
25 mbar
G30/G31
30 mbar
NO
II2H3B/P
G20
20 mbar
G30/G31
30 mbar
HU
II2HS3B/P
G20/G25.1
25 mbar
G30/G31
30 mbar
CZ
II2H3B/P
G20
20 mbar
G30/G31
30 mbar
CY, MT
I3B/P
G30/G31
30 mbar
EE, LT, LV
II2H3B/P
G30/G31
30 mbar
IS
I3P
G31
37 mbar
SK
II2H3B/P
G20
20 mbar
G30/G31
30 mbar
SI
II2H3B/P
G20
20 mbar
G30/G31
30 mbar
BG, RO, TR
II2H3B/P
G20
20 mbar
G30/G31
30 mbar
PL
II2E3B/P
G20/GZ350
20/13 mbar
G30/G31
36 mbar
G20
20 mbar
On the packaging of each heater the following information are clearly marked: Target country, Gas category and Unit code.
The code shows the factory setting for the unit.
Codes without extension:
- PCH043IT
No extension means that the unit has been prepared and tested for [G20] natural gas.
Codes with extension:
the fourth letter identifies
- PCH043FR-xxx0
- PCH043MT-xxx1
- PCH043NL-xxx2
- PCH043HU-xxx3
- PCH043PL-xxx4
Another label on the unit, placed near fuel supply, clearly states which gas type and supply pressure the unit has been set and
tested for.
APEN GROUP reserves the right to change products and documents as required.
6.2
G20 GAS
UNIT TYPE
CATEGORY
SUPPLY PRESSURE
OF PILOT NOZZLE
CARBON DIOXIDE CO2
PCH072
PCH092
PCH150 PCH200
[mbar]
[mm]
[%]
1,64 - 6,14
2,33 - 8,25
PCH072
PCH092
G25 GAS
UNIT TYPE
CATEGORY
SUPPLY PRESSURE
OF PILOT NOZZLE
CARBON DIOXIDE CO2
PCH150 PCH200
[mbar]
[mm]
[%]
G30 GAS
UNIT TYPE
PCH032 PCH035 PCH043 PCH054
PCH072
PCH092
Based on target Country - see previous table
CATEGORY
[mbar]
SUPPLY PRESSURE
30 [min 25 - max 35] - 50 [min 42,5 - max 57,5]
[mm]
OF PILOT NOZZLE
0,51
[%]
CARBON DIOXIDE CO2
9,6 0,2
[kg/h] 0,65 - 2,24 0,73 - 2,50 0,95 - 3,06 1,00 - 3,73
1,42 - 5,02
1,93 - 6,31
GAS CONSUMPTION (15C-1013mbar)
PCH150 PCH200
G31GAS
UNIT TYPE
PCH032 PCH035 PCH043 PCH054
PCH072
PCH092 PCH150 PCH200
Based on target Country - see previous table
CATEGORY
[mbar]
SUPPLY PRESSURE
30 [min 25 - max 35] - 37 [min 25 - max 45] - 50 [min 42,5 - max 57,5]
[mm]
OF PILOT NOZZLE
0,51
[%]
CARBON DIOXIDE CO2
9,4 0,2
[kg/h] 0,64 - 2,21 0,72 - 2,46 0,94 - 3,01 0,98 - 3,68
1,40 - 4,95
1,90 - 6,21 2,79 - 9,83 3,36 - 13,63
GAS CONSUMPTION (15C-1013mbar)
G25.1 * GAS
PCH032 PCH035 PCH043 PCH054
PCH072
PCH092
PCH150 PCH200
[mbar]
[mm]
[%]
2,70 - 9,58
PCH072
PCH150
PCH200
[m3/h] 1,50 - 5,16 1,67 - 5,75 2,19 - 7,04 2,30 - 8,15 ** 3,26 - 10,22 *** 6,52 - 22,96 7,85 - 31,85
GAS CONSUMPTION (15C-1013mbar)
* For Poland only
** For P054 model min. thermal output is 15,5 KW, while max thermal output is 55 KW.
** For P072 model min. thermal output is 22 KW, while max thermal output is 69 KW.
Pag. 25
APEN GROUP reserves the right to change products and documents as required.
UNIT TYPE
CATEGORY
SUPPLY PRESSURE
OF PILOT NOZZLE
CARBON DIOXIDE CO2
6.3
First Start-up
6.4
At delivery, the heater is set and tested for using the type of gas
as noted on the rating plate. Before starting the heater, go
through the following checklist:
Make sure the available gas matches the type the heater is
set for.
Check that electrical wiring complies with requirements
shown in this manual or in other diagrams attached to the
heater.
Using the IN pressure tap on the gas valve, verify that the inlet
pressure to the valve matches the value required for the type
of gas used.
Power on the heater using the main switch and the switch on
the control board.
Check that the remote control displays 0-10 Vdc voltage value
at the modules inlet.
To turn the heater on, do the following:
1. Press the ON-OFF button
2. Check that the green light on the remote control is on. If
heating is required, the red light must turn on, too.
3. If the red light doesnt turn on, check that the bridge on 7/9
terminals of CN6 board is closed and verify remote control
bridge. If you chose to switch the unit on using a 0-10 Vdc signal,
check that incoming value (displayed) exceeds Von value. Wait
at least for the period set in A9 parameter.
When the red light turns on, the heater launches the start-up
cycle.
At this stage, the pilot burner is not likely to start because of the
presence of air in gas pipes and the heater locks up.
To unlock the unit, repeat the procedure until the burner lights
up.
Combustion Analysis
HG0106 IM 001
CALIBRATED
VENTURI
HG0103 IM 003
CO2 REGULATION
CALIBRATED
VENTURI
GAS INLET TO THE
BURNER (OUT)
GAS INLET TO THE
BURNER (OUT)
OFFSET
SETTING
150/200 models
032/092 models
CO2 REGULATION
GAS INLET PRESSURE
TAP (IN)
OFFSET
SETTING
6.5
Diaphragm installation
032-035-043-054 models
HG0106 C2,027
Diaphragm installation
072 models
HG0106 C2,028
Pag. 27
APEN GROUP reserves the right to change products and documents as required.
Diaphragm installation
HG0106 C2,029
Diaphragm installation
MODEL
OF PILOT NOZZLE
mm
OF GAS DIAPHRAGMmm
5,1
6,0
6,5
6,5
blind
10
APEN GROUP reserves the right to change products and documents as required.
14
HG0106 C2,053
6.6
6.7
Pag. 29
APEN GROUP reserves the right to change products and documents as required.
6.8
Maintenance
HG0106 C2,018
Keep
detection
electrode tangent to pilot
burner head
APEN GROUP reserves the right to change products and documents as required.
9) Ionisation Current
Carry out this operation using a device capable of testing direct
current microAmperes. Do the following:
- Disconnect the unit from power supply.
- Disconnect flame control device cable and connect it to the
negative pole of the tester.
- Use a wire to connect the positive pole of the tester and the
flame control device of the unit.
- Power on the device and wait for the burner to start up.
- Check ionisation value.
This value must not be lower than 2 micro Amperes. Lower
values would indicate that the detection electrode is misplaced,
oxidised or it is going to break down.
6.9
Detection electrode
DC Micro Ammeter
mod.032/092
Flame
device
HG0106 C2,014
HG0106 C2,019
control
A
HG0106 C2,054
6.10 Demolition
mod.150/200
flame detection
Pag. 31
APEN GROUP reserves the right to change products and documents as required.
HG0106 C2,058
User
It allows read-only access to modulation values, percentage
of thermal power output for instant operation, and error log.
It is up to the manufacturer to choose whether the setup option
of set point and ST & P parameters should be passwordprotected or not.
Since operation of PCH modules does not require using ST
& P parameters, they can be password-protected [A32
parameter=1].
Operation
It allows to choose the operative mode required. Basic
parameters start with C.
Essential parameters for PCH models are:
- C0 - it depends on the type of modulation signal required. The
unit must be idle (i.e. green light on and red light off) to change
this parameter.
- C2 - if set to zero (), it turns the burner off when signal is below
Voff value and turns it on when signal exceeds Von value. If set
to 1, 0-10 VDC signal is used for modulation only (see related
flow chart).
ON/OFF SWITCH
GREEN
LIGHT ON
NO
CLOSED BRIDGE ON
7/9 TERMINALS
NO
YES
C2 = 1 ?
NO
YES
YES
C0
C1
C2
C3
C4
C5
C6
C7
C8
C9
Default range
5
1-9
0
0-1
0
0-1
20s
0-255s
20s
0-255s
0
0-1
10s
0-255s
80C 10-80C
0
0-1
0
0-1
Meaning
0-10 VDC input
not used
Burner ON-OFF with 0-10VDC
not used
not used
not used
OFF / ON timeout
not used
not used
not used
RED LIGHT
ON
BURNER ON
APEN GROUP reserves the right to change products and documents as required.
Manufacturer
It allows to optimize heater operation according to specific
needs. Parameter names start with an A. Some of the
parameters are general purpose, others depend on the type
of operation you have chosen with the setting of C parameters.
General purpose parameters
Default
A1** 0
A2** 0
A3
70%
A6
2
A7
10s
A10 90s
washing
A11 25s
A17 4
A31* 2
A32 0
range
Meaning
0-100 min. modulation value
0-100 max. modulation value
0-100 start-up power value
1-255 failure display delay
0-255s
pilot working time
0-255s
combustion chamber
HG0106 C2,059
1st heater
post-
0-255s
flame stabiliser time
0-4
number of F1 auto-resets
2-3
see note
0-1
password-protected ST & P param.
Pag. 33
2nd heater
Default Values
A25
A15
A26
A8*
2.5V
1
0.5V
20s
0.1-9.9V
0-16
0.1-9.9
1-255s
A27
A9*
1
20s
0.1-9.9
1-255s
* A8 and A9 parameters avoid multiple burner start ups and turning offs
when Vin signal is irregular.
APEN GROUP reserves the right to change products and documents as required.
bridge on VAN
VAN switch =
ON
A1
18
19
18
19
23
22
20
18
A2 A3
68 70
82 70
80 70
93 70
100 70
100 70
100 50
100 50
A7
10
10
10
10
10
10
8
8
A31
2
2
2
2
2
2
3
3
HG0103 C2,055
APEN GROUP reserves the right to change products and documents as required.
HG0103 IM 003
MOD.032/092
OFFSET
SETTING
MOD.150/200
Pag. 35
APEN GROUP reserves the right to change products and documents as required.
7. TROUBLESHOOTING
PCH MODULE
OPERATION
IS BURNER
WORKING?
YES
NO
IS GREEN LIGHT
ON ?
IS AIR DELIVERED AT
CORRECT
TEMPERATURE ?
NO
SI
NO
IS Fx LOCK
DISPLAYED?
YES
10.0V IS DISPLAYED
NO
NO
LOCKED UNIT
IS RED LIGHT
ON ?
REGULATE UNIT
SETTINGS
YES
NO
YES
CHECK THAT:
a) A2 VALUE MATCHES THE ONE
SHOWN IN THE TABLE
b) P1 VALUE IS THE SAME AS
A2 VALUE
c) UNSUFFICIENT THERMAL
OUTPUT
UNLOCK THE
UNIT
CHECK THAT:
a) BRIDGE ON 7-9 TERMINALS OF
CN6 BOARD IS CLOSED
b) BRIDGE ON 1-2 TERMINALS ON
REMOTE CONTROL IS CLOSED
YES
SEE LOCK
REASONS
C2 = 1 ?
YES
NO
YES
NO
REGULAR
OPERATION
CHECK:
a) THAT C0 = 5
b) FAULTY CARD
HG0106 VI 003
APEN GROUP reserves the right to change products and documents as required.
F1
F2
SAFETY THERMOSTAT
- NO GAS SUPPLY
- PHASE/NEUTRAL EXCHANGE
- NO GROUNDING
- PHASE/PHASE CONNECTION WITHOUT NEUTRAL
- BROKEN OR WRONGLY INSTALLED START-UP ELECTRODE
- BROKEN OR WRONGLY INSTALLED DETECTION
ELECTRODE
- THE DETECTION ELECTRODE IS NOT FIXED OR GROUNDS
WHEN HEATED
- PILOT NOZZLE IS DIRTY OR ITS DIAMETER IS WRONG
F3
F4
F5
F6
F7
FAULTY SERIAL
COMMUNICATION
F8
FLAME CONTROL
DEVICE
ERR
WRONG WIRING OF
REMOTE CONTROL
HG0106 VI 004
Pag. 37
APEN GROUP reserves the right to change products and documents as required.
8.
APPROVAL CERTIFICATE
APEN GROUP reserves the right to change products and documents as required.
9.
WIRING DIAGRAMS
LEGEND
ACF FLAME CONTROL DEVICE
SEM MODULATION ELECTRONIC CARD
B1
PILOT BURNER SOLENOID VALVE
CR
REMOTE CONTROL
EA
STARTUP ELECTRODE
ER
DETECTION ELECTRODE
EV1 GAS VALVE 1ST COIL
EV2 GAS VALVE 2ND COIL
IG
MAIN SWITCH
F1
4 AT FUSE
F2
2.5 AT FUSE
Pag. 39
Lock on LED
CABLE COLOUR
BLACK
PHASE 230V
BLUE
NEUTRAL 230V
RED
24V
YELLOW/GREEN GROUND
Pag. 40 code HG0106.07GB ed.C-0611 rev.07
APEN GROUP reserves the right to change products and documents as required.
HG0106 C2,056
main switch
X01011
R relay
X00859
base
C02780
F2 - 2.5A fuse
X04058
modulation electronic
card
G14900.03
F1 - 4A fuse
X00519
Pag. 41
external
connection
terminal board
(SF,SB)
X00574
APEN GROUP reserves the right to change products and documents as required.
Gas valve
G14067 (032/035/043/054)
G14281 (072)
G14456 (092)
G15535 (150)
G15635 (200)
gas valve venturi
G14068 (032/035)
G14154 (043/054/072/092)
G15536 (150)
G15636 (200)
HG0106 C2,041
air/gas fan
G14069 (032/035/043)
G14070.01 (054)
G14282 (072/092)
G15534 (150/200)
start-up wire
G04123.02
detection wire
G14063
glass
G16324
glass gasket
G16329
fan gasket
G14086 (032/035/043/054)
G14400(072/092)
G15533 (150/200)
start-up electrode
G16333
torch gasket
G14086 (032/035/43/054)
G14450 (072/092)
G15531 (150/200)
HG0106 C2,030
pilot nozzle
G14626 (natural
gas)
G14779 (LPG)
detection electrode
G16334
APEN GROUP reserves the right to change products and documents as required.
110C thermostat
G14298
HG0106 C2,044
HG0106 C2,057
remote control
G14950
Pag. 43
APEN GROUP reserves the right to change products and documents as required.
APEN GROUP reserves the right to change products and documents as required.