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Summary of Contents for ApenGroup AQUAKOND AKY
- Page 1 Installation, Commissioning, and Maintenance Manual Condensation Boilers AKY Efficiency rate up to 109% **** Efficiency Class: NOx Class: code HC0048.01GB ed.B-1406...
- Page 2 AQUAKOND AKY CONDENSATION BOILER code HC0048.01GB ed.B-1406...
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Page 3: Dichiarazione Di Conformit
AQUAKOND AKY CONDENSATION BOILER Dichiarazione di Conformità Statement of Compliance APEN GROUP S.p.A. 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:... - Page 4 AQUAKOND AKY CONDENSATION BOILER Approval Certificate code HC0048.01GB ed.B-1406...
- Page 5 AQUAKOND AKY CONDENSATION BOILER code HC0048.01GB ed.B-1406...
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Page 6: Table Of Contents
AQUAKOND AKY CONDENSATION BOILER TABLE OF CONTENTS SECTION GENERAL WARNINGS SECTION SAFETY WARNINGS Fuel Gas Leaks Power Supply Maintenance SECTION TECHNICAL FEATURES 3.1. Models and Efficiency 3.2. Data Sheet 3.3. Features of Hydraulic System 3.4. Ispesl Components 3.5. Boiler Dimensions 3.6. -
Page 7: General Warnings
AQUAKOND AKY CONDENSATION BOILER GENERAL WARNINGS SAFETY WARNINGS This manual is an essential component of the product and must The following symbol is used in this Manual whenever it is always accompany it. necessary to draw the operator’s attention on a safety issue. -
Page 8: Power Supply
AQUAKOND AKY CONDENSATION BOILER 2.3. Power Supply arning: To properly and safely The heater shall be properly wired to an efficient grounding operate the equipment, glycol shall system, complying with the laws of the Country where the ap- be added to water in the hydraulic circuit in pliance is installed. -
Page 9: Technical Features
AQUAKOND AKY CONDENSATION BOILER TECHNICAL FEATURES 3.1. Models and Efficiency Rates AKY boilers are condensation equipment with modulation burner. AKY condensation boilers burn natural gas or LPG. They are Two boiler series are available: designed to meet heating requirements in industrial and com- mercial buildings. -
Page 10: Data Sheet
AQUAKOND AKY CONDENSATION BOILER 3.2. Data Sheet Boiler - Series 00X0 AKY032-00X0 Type of appliance B23P*-B53P-C43-C53-C63-C83 EC Approval P.I.N. 0694BT1623 Efficiency class [Hi] [EC 92/42 Directive] **** NOx Class [EN 483] Boiler efficiency Combustion Chamber Heat Output [Hi] [75/55°C] 31.0 Useful heat output for water [Hi] [75/55°C] **... - Page 11 AQUAKOND AKY CONDENSATION BOILER BOILER - Standard series AKY034 AKY050 AKY070 Type of appliance B23P*-B53P-C43-C53-C63-C83 EC Approval P.I.N. 0694BT1623 Efficiency class [Hi] **** [EC 92/42 Directive] NOx Class [EN 483] Boiler efficiency Combustion chamber heat output [Hi] [72/45°C] 34.8 49.0 65.0...
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Page 12: Boiler Technical Data
AQUAKOND AKY CONDENSATION BOILER Boiler technical data Available Head-Flow Rate Curve for Boilers Required water flow rates in the AquaKond boilers are the following: • 32 Flow rate from 900 to 1,300 l/h; • 34 Flow rate from 1,000 to 1,400 l/h;... - Page 13 AQUAKOND AKY CONDENSATION BOILER Duct pressure losses The table below shows pressure loss in ducts by flow rate multiple values. Losses are measured in kPa per 1 meter of pipe length. Measure to be considered is the equivalent length of the hydraulic circuit.
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Page 14: Features Of Hydraulic System
AQUAKOND AKY CONDENSATION BOILER 3.3. Features of the Hydraulic System Hydraulic systems of AKY boilers are similar. However, AKY050/070 boilers have some additional components if compared to AKY032/034 models. If more than one boiler is installed, you only need to sum their heat output values when the hydraulic circuit is shared by multiple boilers. -
Page 15: Ispesl Components
AQUAKOND AKY CONDENSATION BOILER 3.4. ISPESL COMPONENTS SAFETY, CONTROL AND PROTECTION DEVICES Component Code Model Description Hydrometer PB3204BB06 Manometer class UNI2.5, range 0-4bar WATTS INDUSTRIES +25% f.s., T=-20/90°C ISPESL-compliant max, ex. Limit pressure switch IPMAX PMR/5-R2 Pressure switch p=1-3bar ITALTECNICA ISPESL-compliant certificate N°... -
Page 16: Boiler Dimensions
AQUAKOND AKY CONDENSATION BOILER 3.5. Dimensions of Boilers AKY032/034 AKY050/070 AKY050/070 AKY032/034 Dimension Description 032/034 050/070 GAS SUPPLY G3/4" WATER RETURN G3/4" G1" WATER DELIVERY G3/4" G1" SAFETY VALVE G1/2" SAFETY VALVE G3/4" SYSTEM FILLING VALVE G1/2" CONDENSATE DRAIN Ø14 mm... -
Page 17: Operation And Accessories
AQUAKOND AKY CONDENSATION BOILER 3.6. Operation and Accessories Operation Mode B: SmartControl Chronothermostat (G20800IT) The boiler includes a standard LCD multifunction panel that This chronothermostat can be used in a system to control one enables the user to manage, zone where the units installed range from 1 to 30. The units setup and diagnose all the op- work at the same temperature and only one control is needed. -
Page 18: User's Instructions
AQUAKOND AKY CONDENSATION BOILER USER'S INSTRUCTIONS 4.1.4. Antilock System of Varying Speed Circulator This feature, enabled by default, starts the circulator after 24 ead General and Safety Warnings on page 6. Users shall consecutive hours of non operation. The circulator works for only use commands on remote control or room devices. -
Page 19: Control Panel
AQUAKOND AKY CONDENSATION BOILER 4.2. Control Panel with LCD Display 4.2.2. Navigation Menu The menu has three levels: the first requires no password while The control panel includes an three-digit LCD with four function for the second and third, a password is required. - Page 20 AQUAKOND AKY CONDENSATION BOILER 4.2.4. Second Level Menu Flue temperature exceeds expected values. Verify if the boiler needs cleaning. This lock requires manual reset. Second and third level menus are reserved to Service Staff and The boiler did not exceed flue temperature threshold but are password protected.
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Page 21: Instructions To The Installer
AQUAKOND AKY CONDENSATION BOILER INSTRUCTIONS TO THE INSTALLER Instructions for installing and setting the boiler are intended for authorized personnel only. Read safety rules first. N.B.: The installer shall train the user on how to use the equipment 5.1. General Installation Rules... - Page 22 AQUAKOND AKY CONDENSATION BOILER 5.4.2. Room Temperature Regulation does not interfere with other thermostats, such as 35°C. If available head in the the boiler is not enough for hydraulic Room temperature regulation depends on the type of installation. circuit, an additional circulator should be installed in the system, •...
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Page 23: Electrical Wiring
AQUAKOND AKY CONDENSATION BOILER 5.5. Electric Wiring 5.5.1. Power Supply of the Boiler The boiler shall be properly wired to an efficient ground- ing system, complying with existing regulations. Single-phase 230 Vac supply with neutral. Do not re- verse neutral and phase As a safety precaution, when phase and neutral wires are reversed, flame control device locks the unit (F11 lock). - Page 24 AQUAKOND AKY CONDENSATION BOILER 5.5.3. Smartcontrol remote control connection dresses go from 1 to N without gaps. Each board address, if different from zero, is displayed on LCD screen as Axx, where Use supplied connector to connect the SmartControl. Wire xx is the address.
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Page 25: Gas Connections
AQUAKOND AKY CONDENSATION BOILER 5.6. Gas Connections For this system, use CE-approved and certified components only. At delivery AKY boilers include: • Double gas valve • Gas stabilizer • Gas cock All components are assembled into the boiler but the cock To complete installation in compliance with the law, the following components have to be installed: •... -
Page 26: Stack Piping
AQUAKOND AKY CONDENSATION BOILER 5.7. Flue Piping EQUIPMENT SET FOR G20 [Natural gas] Flue Flow Temperature Content The outdoor unit is supplied with a flue outlet (B23P type) in Model Rate flue [°C] white polypropylene that consists of: [kg/h] •... - Page 27 AQUAKOND AKY CONDENSATION BOILER 5.7.1. “C”-type Installation If installation layout is type C, do the following: • Open a hole of Ø80 in the top of the boiler • Close air intake in the boiler with the cover supplied C09349;...
- Page 28 AQUAKOND AKY CONDENSATION BOILER Connecting the Condensate Drain System Antifreeze Protection AKY boilers are condensation units. Their pipe fitting for con- If the boiler is to be installed outdoor and temperature may lower densate drain has a diameter of Ø14.
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Page 29: Filling The Hydraulic System
AQUAKOND AKY CONDENSATION BOILER 5.8. Filling the Hydraulic System AKY032/034 At delivery, AKY032/034 boilers are filled with water/glycol mixture and have two shut-off cocks on hydraulic system. AKY070 boilers do not. Use the same type of glycol for all models. -
Page 30: Instructions To Service Staff
AQUAKOND AKY CONDENSATION BOILER INSTRUCTIONS TO SERVICE STAFF First start-up must be performed by an APEN GROUP Authorized Service Centre. During first start up, the combustion efficiency must be analyzed. This appliance is certified for EC and Extra-EC countries for the gas categories listed below. -
Page 31: Gas Setting Data Table
AQUAKOND AKY CONDENSATION BOILER 6.2. Gas Setting Data Table FOR ANY TYPE OF GAS TYPE OF APPLIANCE Values of gas offset valve -1.0±0.8 G20 GAS TYPE OF APPLIANCE CATEGORY Depending on target country - see table 6.1 20 [min 17 - max 25]... -
Page 32: First Start-Up
AQUAKOND AKY CONDENSATION BOILER 6.3. First Start-up 6.4. Combustion Analysis At delivery, the boiler is set and tested for using the type of gas Wait until the boiler reaches maximum power. reported on the rating plate. Before starting the equipment, go... -
Page 33: Conversion To Lpg
AQUAKOND AKY CONDENSATION BOILER 6.5. Conversion to LPG While the burner works at maximum output: Check that inlet pressure of the valve matches the one This conversion is strictly forbidden in Countries such as required for the gas used Belgium, where double category for gas is not allowed. -
Page 34: Replacing The Modulation Board
AQUAKOND AKY CONDENSATION BOILER 6.7. Replacing Modulation Board 6.8. Configuring with LCD Display When replacing the board, some checks have to be carried out Parameters are shown and can be changed only if they have and some parameters have to be set using the LCD display or been enabled using Abi menu password. -
Page 35: Maintaining The Exchanger
AQUAKOND AKY CONDENSATION BOILER Parameter Menu sulphur content, i.e. maximum peak for short periods, 150 Through Par submenu you can access "b" and "d” parameters: mg/m , year average lower than 30 mg/m from b1 to b15 burner parameters • Combustion air shall not contain chlorine, ammonia, or alkalis. -
Page 36: Modulation Board Parameters
AQUAKOND AKY CONDENSATION BOILER MODULATION BOARD PARAMETERS The table below reports all accepted values for parameters in CPU-PLUS board for each model of boiler. Parameters of CPU-SMART board Version 7.00.xx PARAMETER AKY032 AKY034 AKY050 AKY070 DESCRIPTION Flame modulation: 2=NTC1; 5=0÷10Vdc; 7=Modbus (SmartControl &... - Page 37 AQUAKOND AKY CONDENSATION BOILER Parameters of CPU-SMART board Version 7.00.xx PARAMETER AKY032 AKY034 AKY050 AKY070 DESCRIPTION Control of circulator outlet - Only standard series with electronic circulator 0=output disabled;1=Y1 analog output enabled (PWM2); 2=Y2 analog output enabled (0÷10Vdc) Y2 minimum output voltage: 0÷10 10.0...
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Page 38: Lock Analysis - Fault Reporting
AQUAKOND AKY CONDENSATION BOILER LOCK ANALYSYS - FAULT REPORTING CPU-SMART board manages two types of locks: - Precautionary: customer is warned that maintenance is required - Operational: boiler is stopped for safety reasons. Some of the locks require manual reset, others are automatically resolved when their cause is removed. - Page 39 AQUAKOND AKY CONDENSATION BOILER LOCK DESCRIPTION REASON UNLOCK Faulty or missing NTC sensors Error in NTC1 sensor, water temperature on delivery No signal from sensor or faulty sensor Autoreset Error in NTC3 sensor, flue temperature Overtemperatures • Excessive minimum heat output of the boiler com-...
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Page 40: Wiring Diagrams
AQUAKOND AKY CONDENSATION BOILER WIRING DIAGRAMS For connections, see section on Installation. Wiring diagrams and operating principle are the same for all AKY boilers. Differences are listed below. AKY070 boilers have an additional safety device installed on max water pressure. If this device triggers, an F21 error is issued and manual reset is required. -
Page 41: Electrical Wiring For Aky032/034/050/070
AQUAKOND AKY CONDENSATION BOILER 9.1. Electrical Wiring for AKY032/034/050/070 POWER SUPPLY 230 V - 50 HZ 00X0 boilers differ from standard boilers as they lack the circulator with flow rate variation. Therefore, Y1-GND ter- minals are not wired for these boilers. -
Page 42: Spare Part List
AQUAKOND AKY CONDENSATION BOILER SPARE PARTS C09230 AKY032 C09034.01 AKY034 C09350 (AKY050) C09265 AKY070 EXCHANGER ASSEMBLY C05119.01 C09041.01 PRESSURE SWITCH 1÷3bar EXPANSION VESSEL AKY050/070 C08096 85°C NC MICRO- THERMOSTAT G12930 C08025 GAS VALVE I S P E S L S H E AT H... - Page 43 AQUAKOND AKY CONDENSATION BOILER EXCHANGER ASSEMBLY C09303 GASKET FOR FLUE EXHAUST C09260 ADAPTER FOR FLUE OUTLET C09235 Ø80÷Ø60 NTC FLUE SENSOR C09306 EXCHANGER THERMAL CUT-OUT C09304 FURNACE BACK GASKET C09258 IONIZATION ELECTRODE C09313 GASKET FOR IONIZATION ELECTRODE C09255 CABLE FOR IONIZATION...
- Page 44 AQUAKOND AKY CONDENSATION BOILER code HC0048.01GB ed.B-1406...
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