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Summary of Contents for ApenGroup AermaxLine LRP-RAPID PRO Series
- Page 1 Use, Installation and Maintenance Manual MODULATING WARM AIR HEATER LRP - RAPID PRO AND CONDENSING WARM AIR HEATER LK - KONDENSA 2021 Compliant EU/2016/2281 TRANSLATION OF ORIGINAL Manual LRP - RAPID PRO and LK - KONDENSA code HG0141.00GB ed.A-2008...
- Page 2 APEN GROUP S.p.A. 20060 Pessano con Bornago (MI) Via Isonzo, 1 Tel +39.02.9596931 r.a. Fax +39.02.95742758 Internet: http://www.apengroup.com Il presente documento dichiara che la macchina: With this document we declare that the unit: Modello: Generatore d’aria calda LRP, LK, LKC Model: Warm Air Heater LRP, LK, LKC è...
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Page 3: Table Of Contents
LRP and LK WARM AIR HEATER INDEX SECTION GENERAL CAUTIONS ............4 SECTION SAFETY-RELATED WARNINGS ........4 Fuel ....................4 Gas Leaks ..................4 Power Supply ................. 5 Use ....................5 Maintenance .................. 5 Transport and Handling ..............5 Unpacking ..................6 Disposal and Demolition .............. -
Page 4: General Cautions
LRP and LK WARM AIR HEATER GENERAL CAUTIONS SAFETY-RELATED WARNINGS This manual is an integral part of the product and must always This chapter describes the safety instructions to be followed accompany it. by machine operators. Should the equipment be sold or passed on to someone else, always make sure that this manual is supplied with the equipment 2.1. Fuel for future reference by the new owner and/or installer. -
Page 5: Power Supply
LRP and LK WARM AIR HEATER 2.3. Power supply If the heater is to be put out of service, in addition to the above operations, potential sources of hazard on the unit must be The heater must be correctly connected to an effective earthing disabled. system, made in compliance with current regulations (IEC 64-8, It is strictly forbidden to obstruct the Venturi pipe inlet, located applies to Italy only). -
Page 6: Unpacking
LRP and LK WARM AIR HEATER 2.7. Unpacking INFORMATION FOR DISPOSAL valid abroad (EU COUN- TRIES except Italy). The unpacking operation must be carried out by using suitable The European Directive 2012/19/EC shall be implemented in tools or safety devices where required. Recovered packaging every EU member state. There may be different application materials must be separated and disposed of according to ap- modalities for the various member states, even in terms of plicable regulations in the country of use. -
Page 7: Technical Features
LRP and LK WARM AIR HEATER TECHNICAL FEATURES Inherent Safety The efficiency increase at minimum power is achieved by using The LRP-RAPID PRO and LK-KONDENSA series modulating a sophisticated air/gas mixing technique and by regulating at warm air heaters have been designed to heat industrial and the same time the combustion air flow and the fuel gas flow. commercial environments. This technology increases the heater safety as the gas valve The heater PCB continually modulates the heat output between supplies the fuel according to the air flow. Unlike atmospheric the minimum and maximum power, according to heating re-... -
Page 8: Technical Data
LRP and LK WARM AIR HEATER 3.1. Technical Data Model* LRP018 LRP028 LRP035 LRP045 LRP055 LRP075 LRP102 Type of equipment B23 - B23P - C13 - C33 - C43 - C53 - C63 EC approval PIN. 0476CQ0451 NOx class [EN1020:2009] Type of fuel Gaseous Heater Performance Burner heat output (Hi) - Page 9 LRP and LK WARM AIR HEATER Model LK020 LK034 LK045 LK065 LK080 LK105 Type of equipment B23 - B23P - C13 - C33 - C43 - C53 - C63 EC approval PIN. 0476CQ0451 NOx class [EN1020:2009] Type of fuel Gaseous Heater Performance Burner heat output (Hi) 4.75 19.00*...
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Page 10: Technical Data Of Centrifugal Models
LRP and LK WARM AIR HEATER 3.2. Technical data of centrifugal models Model* LKC034 LKC045 LKC065 Type of equipment B23 - B23P - C13 - C33 - C43 - C53 - C63 EC approval PIN. 0476CQ0451 NOx class [EN1020:2009] Type of fuel Gaseous Heater Performance See LK034... - Page 11 LRP and LK WARM AIR HEATER Following is a graph reading example: 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 60,0 Model LKC045 Available pressure: 100 Pa 50,0 Air flow rate: 4800 m ΔT: 28°C 40,0 30,0 20,0 10,0 2000...
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Page 12: Regulation (Eu) 2016/2281
LRP and LK WARM AIR HEATER 3.3. REGULATION (EU) 2016/2281 Product Information in accordance with Annex 2 point 5 a) Model: See table Warm air heaters B1 [yes/no]: Warm air heaters C2 [yes/no]: Warm air heaters C2 [yes/no]: Type of fuel Gaseous [gaseous/liquid/electricity]: Consumption of... -
Page 13: Noise
LRP and LK WARM AIR HEATER LRP035 3.4. Noise Sound power 66,9 The sound power of a source (energy emitted per unit time) is a 61,4 61,4 60,0 characteristic of the same source and does not depend on the 58,2 environment in which the sound is emitted: this measurement 53,4 53,1... -
Page 14: Air Flow Performance
LRP and LK WARM AIR HEATER 3.5. Air flow performance The air flow range, or air throw, is the distance reached by the air jet before its speed decreases and equals the reference speed, assumed to be 0.2 m/s. The throw depends on the speed of the air leaving the heater, which in turn depends on the air flow rate and on the section of the heater air passage. Below is a graph showing the air speed as a function of the distance from the heater outlet. The curves shown in the graph refer to isothermal air throw conditions (i.e. with the warm air heater switched off and therefore at constant air temperature over the entire supply surface) and with horizontal and parallel supply fins. -
Page 15: Dimensions
LRP and LK WARM AIR HEATER 3.6. Dimensions HG0140.00_C2_001 HG0140.00_C2_001 HG0140.00_C2_007 HG0140.00_C2_007 HG0140.00_C2_007 HG0140.00_C2_007 HG0140.00_C2_001 HG0140.00_C2_001 Mod. Overall dimensions Louver Shelf Supply GAS Packaging LRP and LK IS IS ID ID ØG ØG Bi Bi Li Li Hi Hi LRP018,LRP028, LK020 LRP035,LRP045, LK034... - Page 16 LRP and LK WARM AIR HEATER HG0140.00_C2_001 HG0140.00_C2_001 HG0140.00_C2_001 HG0140.00_C2_001 Mod. Mod. Vertical drains (OPT.) Horizontal exhausts (STD) LRP and LK LRP and LK LRP018, LRP018, LRP028, LRP028, LK020 LK020 LRP035, LRP035, LRP045, LRP045, LK034 LK034 LRP055, LRP055, LK045 LK045 LRP075, LRP075, LK065...
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Page 17: User Instructions
LRP and LK WARM AIR HEATER USER'S INSTRUCTIONS 4.2. Interface Panel The LRP and LK heaters are fitted as standard with a multifunction LCD panel located on the front panel of the suspended heater, 4.1. Operating Cycle which is used to control, configure and diagnose all operating parameters of the equipment. The wall mounted LRP and LK heaters operation is fully au- This panel cannot be remotely controlled. tomatic; they are equipped with electronic equipment with self check facility that manages all the burner control and monitoring The panel is fitted with a red 3-digit LCD display and with four... -
Page 18: Reset And Fault Index
LRP and LK WARM AIR HEATER 4.3. Reset and Fault index To confirm a change in parameters, press ENTER for at least 3 seconds. A change in the parameter is indicate by the display In case of lockout, the modulation PCB of the heater allows flashing. the operator to identify about thirty different causes of lockouts All submenus can be scrolled from the bottom to the top, and with a code. -
Page 19: Accessories
LRP and LK WARM AIR HEATER 4.4. Adjustment 4.5. Accessories Ambient temperature adjustment The LRP or LK heaters have three heat output regulation modes: • 0-10 Vdc; The LRP and LK heaters are supplied without remote control • ModBus; and/or thermostat to regulate the room temperature as they can •... - Page 20 LRP and LK WARM AIR HEATER Operation with chronothermostat (OPTIONAL) a voltage of 12 Vdc +10%/-15%. The heater operation is entirely automatic and, by using a An integrated temperature probe allows the management of the chronothermostat, the ambient temperatures can be regulated. room temperature of the controlled area;...
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Page 21: Installation Instructions
LRP and LK WARM AIR HEATER INSTALLATION INSTRUCTIONS Fixed shelves To install the fixed shelves to the walls: Instructions for installing and setting the heater are intended for • fix it to the wall and level the bracket with a spirit level; suitably qualified personnel only. • use the paper template supplied with the heater to correctly position the brackets on the wall; 5.1. - Page 22 LRP and LK WARM AIR HEATER Suspended heater Vertical heater FOR ALL LRP and LK HEATERS The heater can be installed with air intake from top to bottom by To install a suspended heater by using chains or threaded bars, requesting the kit code G27940 (installation with chains). The a kit containing supporting pins is available as an accessory;...
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Page 23: Condensate Drain
LRP and LK WARM AIR HEATER 5.3. Condensate drain The trap, installed inside the heater, has a condensate detection electrode that shuts down the generator in case the condensate The LK series heaters are flue gas condensing appliances. The does not flow out correctly from the drain, in order to prevent lowering of the flue gas temperature in the tube bundle of the condensate from remaining inside the heat exchanger. A pos- heat exchanger causes the formation of condensate that must sible cause of condensate drain failure is the freezing of the be duly drained outside the heat exchanger. - Page 24 LRP and LK WARM AIR HEATER CAUTIONS Special attention must be paid to the condensate drain; an incorrectly installed draining system, in fact, could jeopardize the correct operation of the appliance. The main factors to be taken into account are: •...
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Page 25: Connections To The Flue
LRP and LK WARM AIR HEATER 5.4. Connections to the Flue Selection Guide The table showing the fume exhaust system calculation data The LRP and LK heaters are fitted with a watertight combustion can be found in Paragraph 7.2 "Gas settings data table". circuit and with a fan located upstream of the heat exchanger. The maximum permitted recirculation percentage is 11%. - Page 26 LRP and LK WARM AIR HEATER LRP models Pressure available at the exhaust [Pa] Component Pressure drop [Pa] Code Ø80 SMOOTH PIPE [l=1m] 10.7 18.2 G15820-08-XXX BEND Ø80 WIDE RADIUS 90° 10.0 18.1 31.0 G15810-08-90 BEND Ø80 WIDE RADIUS 45° 14.6 G15810-08-45 Ø80 WALL-MOUNTED TERMINAL FROM SEPARATE TO COAX...
- Page 27 LRP and LK WARM AIR HEATER Fume exhaust and rear air intake Installing the terminals The LRP and LK heaters are fitted with a top and bottom pro- vision for air inlet and fume exhaust. According to installation requirements, the terminals can be fitted at the back or at the top. The exhaust and drainage castings are normally installed on the back of the machine;...
- Page 28 LRP and LK WARM AIR HEATER Type C53 terminal Fumes OUT Combustion circuit watertight to the environment. One of the ducts is connected to the roof, the other to the wall. of the pipe routing made with the Ø shown, excluding the terminal.
- Page 29 LRP and LK WARM AIR HEATER Horizontal coaxial C13 terminal Combustion circuit watertight to the environment. The ducts go directly through the wall. of the pipe routing made with the Ø shown, excluding the 1max terminal. HG140.00_IM_024 The terminal consists of: •...
- Page 30 LRP and LK WARM AIR HEATER C33 type coaxial roof-mounted terminal Combustion circuit watertight to the environment. The ducts are connected to the outside with a coaxial terminal. of the pipe routing made with the Ø shown, excluding the terminal. The terminal consists of: •...
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Page 31: Electrical Connections
LRP and LK WARM AIR HEATER 5.5. Electrical Connections Power supply The heater must be correctly connected to an effective earthing system, fitted in compliance with current legislation. Single phase 230VAC power supply with neutral; do not swap the neutral with the live wire. For safety reasons, the flame monitoring device prevents oper- ation if phase and neutral are swapped, fault F10. The heater can be connected to the mains power supply with a plug-socket only if the latter does not allow live and neutral to be swapped. - Page 32 LRP and LK WARM AIR HEATER Smart Web/Easy connection Summer ventilation The Smart Web/Easy must be connected by using the connec- To enable the fans only (summer ventilation with burner off), tor provided. Connect the power supply, making sure polarity three types of controls are available: is correct. • the ID3-IDC2 contact;...
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Page 33: Modulation Pcb Parameters
LRP and LK WARM AIR HEATER 5.6. Modulation PCB Parameters All values of the parameters of the CPU-SMART PCB are shown for all LRP and LK heater models. (1) parameters that could be modified with "001” Password via remote LCD control (even with modbus address ≠ 0). (2) parameters that could be modified with a second level Password, which can be requested to the manufacturer's Service Centre (even with modbus ≠ 0 address). (3) parameters that could be modified only with a Smart Web/Easy or via modbus. Parameters of CPU-SMART PCB version 7.03.xx LRP018 LRP035 LRP055... - Page 34 LRP and LK WARM AIR HEATER Parameters of CPU-SMART PCB version 7.03.xx LRP018 LRP035 LRP055 LRP075 LRP102 PARAMETER DESCRIPTION LRP028 LRP045 LK105 LK045 LK065 LK080 LK020 LK034 Heat input and fuel instantaneous consumption calculation parameters Qmin (3) see table in Par. 3.1 “Technical Data" Minimum heat input (ref. Lower calorific value - Hi) Qmax (3) see table in Par.
- Page 35 LRP and LK WARM AIR HEATER Parameters of CPU-SMART PCB version 7.03.xx LRP018 LRP035 LRP055 LRP075 LRP102 PARAMETER DESCRIPTION LRP028 LRP045 LK105 LK045 LK065 LK080 LK020 LK034 0=PWM (Y1) or 0/10V (Y2) output according to "direct" logic; 1=PWM (Y1) or 0/10V (Y2) output according to "reverse" logic; 2= PWM (Y1) "reverse" and 0/10V (Y2) "direct” output;...
- Page 36 LRP and LK WARM AIR HEATER Parameters of CPU-SMART PCB version 7.03.xx LRP018 LRP035 LRP055 LRP075 LRP102 PARAMETER DESCRIPTION LRP028 LRP045 LK105 LK045 LK065 LK080 LK020 LK034 Hydraulic circuit WATER FLOW control - NOT USED ON LRP and LK Flow sensor B3 output enabling: 0=disabled 1=enabled as ON/OFF input without F85 fault autoreset 2=enabled as ON/OFF input with F85 fault autoreset 3=enabled as pulsed input without F85 and F86 fault autoreset...
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Page 37: Analysis Of Lockouts- Faults
LRP and LK WARM AIR HEATER 5.7. Analysis of lockouts- faults The CPU-SMART manages two types of lockouts: • preventive, it warns the customer that the LRP and LK heaters require maintenance; • operational, it stops the LRP or LK heater for safety reasons or to ensure its correct operation. Some operational faults require manual reset; others reset themselves when the problem that caused them is solved. Below is a complete list of faults, possible causes and possible solutions. FAULT DESCRIPTION CAUSE... - Page 38 LRP and LK WARM AIR HEATER FAULT DESCRIPTION CAUSE UNLOCK • Contact ID6 open/closed when b17 ≠ 0; Alarm from ID6 input • Contact open when b17 = 1; contact close when Manual reset b17 = 2. NTC probes broken or missing Probe NTC1 error, air intake temper- Auto-reset ature •...
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Page 39: Gas Connection
LRP and LK WARM AIR HEATER GAS CONNECTION NOTE: For ease of maintenance, connect the heater by means of a seal and swivel gasket. Use the gas line connections only with CE certified components. Avoid using threaded connections directly on the gas connection. The heater is supplied complete with: Current legislation allow a maximum pressure inside the - a dual gas valve;... -
Page 40: Servicing Instructions
LRP and LK WARM AIR HEATER SERVICING INSTRUCTIONS The first start-up must be carried out only by authorised service centres. The first start-up also includes a combustion analysis, which is compulsory. The equipment is certified in the EC and non-EC countries, according to the gas categories shown below. 7.1. Country Table - Gas Category Country Category Pressure Pressure AT, CH II2H3B/P 20 mbar G30/G31 50 mbar BE <70kW I2E(S)B, I3P G20/G25 20/25 mbar 37 mbar BE >70kW I2E(R)B, I3P G20/G25 20/25 mbar... -
Page 41: Gas Settings Table
LRP and LK WARM AIR HEATER 7.2. Gas Settings Table LRP-RAPID PRO Table TYPE OF GAS G20 - Cat. E-H TYPE OF MACHINE LRP018 LRP028 LRP035 LRP045 LRP055 LRP075 LRP102 CATEGORY according to the country of destination - see reference table SUPPLY PRESSURE [mbar] 20* [min 15-max 25]... - Page 42 LRP and LK WARM AIR HEATER TYPE OF GAS G2.350 - Cat. Ls (Only for PL-Poland) TYPE OF MACHINE LRP018 LRP028 LRP035 LRP045 LRP055 LRP075* CATEGORY according to the country of destination - see reference table SUPPLY PRESSURE [mbar] 13 [min 10-max 16] PILOT NOZZLE Ø...
- Page 43 LRP and LK WARM AIR HEATER TYPE OF GAS G30 - Cat. 3B-P TYPE OF MACHINE LRP018 LRP028 LRP035 LRP045 LRP055 LRP075 RLP102* CATEGORY according to the country of destination - see reference table SUPPLY PRESSURE [mbar] 30 [min 25-max 35] - 37 [min 42.5-max 57.5] - 50 [min 42.5-max 57.5] PILOT NOZZLE Ø...
- Page 44 LRP and LK WARM AIR HEATER LK-KONDENSA Table TYPE OF GAS G20 - Cat. E-H TYPE OF MACHINE LK020 LK034 LK045 LK065 LK080 LK105 CATEGORY according to the country of destination - see reference table SUPPLY PRESSURE [mbar] 20* [min 17-max 25] PILOT NOZZLE Ø...
- Page 45 LRP and LK WARM AIR HEATER TYPE OF GAS G2.350 - Cat. Ls (Only for PL-Poland) TYPE OF MACHINE LK020 LK034 LK045 LK065* according to the country of destination - see refer- CATEGORY ence table SUPPLY PRESSURE [mbar] 13 [min 10-max 16] PILOT NOZZLE Ø...
- Page 46 LRP and LK WARM AIR HEATER TYPE OF GAS G30 - cat. 3B-P TYPE OF MACHINE LK020 LK034 LK045 LK065 LK080* LK105** CATEGORY according to the country of destination - see reference table SUPPLY PRESSURE [mbar] 30 [min 25-max 35] - 50 [min 42.5-max 57.5] PILOT NOZZLE Ø...
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Page 47: Configuring With Lcd Display
LRP and LK WARM AIR HEATER 7.3. Configuring with LCD Display I/O menu - Inputs outputs From I/O menu it is possible to display the values measured The parameters can be changed only if they have been enabled by the sensors. by entering the password from Abi menu. - Page 48 LRP and LK WARM AIR HEATER Navigation map of LCD display menu Level Level Level Viewing the ENTER ENTER machine status ENTER At the bottom of the 1 level ENTER ENTER ENTER ENTER type of “Confirm” operation ENTER “Confirm” ENTER ESt (summer) “Confirm”...
- Page 49 LRP and LK WARM AIR HEATER - “fault event log” ENTER ENTER “Value-Mod.” “Confirm” “Value” “Value” ENTER “Value” - - - “Value” “Value” - “sensor values” “Value” ENTER “Value” (NTC1) “Value” (NTC2) “Value” (NTC3) “Value” - “setpoint” (Anal. Input B1) ENTER “Value” (water pressure) “Value” (water flow) ENTER “Value”...
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Page 50: Starting Up For The First Time
LRP and LK WARM AIR HEATER 7.4. Starting up for the first time Wait until the heater is switched on. Check that the heater reaches its maximum power: from the LCD display, access the The LRP and LK heaters are supplied with settings entered and REG menu, then use the Hi and Lo controls to force operation tested for the gas specified on the nameplate. Before turning at maximum or minimum output. -
Page 51: Conversion To Lpg
LRP and LK WARM AIR HEATER 7.7. Conversion to gas G25 - G25.1 - G25.3 7.6. Conversion to LPG - G27 Conversion is strictly prohibited in some countries, such as Belgium, which do not allow the double gas category. Conversion for gasses from G20 to G25 or G25.1 or G25.3 or G27 is allowed only in countries of category II2ELL3B/P [Ger- The unit is supplied already set for natural gas and with the kit many], II2Esi3P [France], II2E3P [Luxembourg] and category... -
Page 52: Conversion To Gas G2.350
LRP and LK WARM AIR HEATER 7.8. Conversion to gas G2.350 7.9. Replacing the Gas Valve Conversion is allowed only for Poland. If the gas valve must be replaced, it is required to proceed with Conversion from one type of gas to another can only be per- an inspection and possibly calibrate the CO level through the formed by authorised service centres. -
Page 53: Replacing The Modulation Pcb
LRP and LK WARM AIR HEATER 7.11. Replacing the modulation PCB MAINTENANCE When replacing the PCB, it is required to carry out a few checks To keep the heater efficient and guarantee a long lifetime of the and set a few parameters through the LCD command or Smart same, it is advisable to run some inspections at regular intervals: Web/Easy. 1) check the status of start-up and detection electrodes, pilot Every LRP and LK heater has a list of pre-programmed default flame and relevant seal;... - Page 54 LRP and LK WARM AIR HEATER 1) Inspection of electrodes sure there are no traces of metallic residue. If metallic residue Dismantle the complete pilot flame and use a jet of compressed air has formed, increase the number of inspections. to clean the mesh and nozzle. Check the integrity of the ceramic Remove the cover retaining screws and clean the internal part and use sandpaper to remove any oxidation on the metal parts of the trap and the relevant float (it is possible to clean the trap...
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Page 55: Wiring Diagrams
LRP and LK WARM AIR HEATER WIRING DIAGRAM Wiring diagram LRP018/LRP102 LK020/LK105 (code JG0350.05) CN14 CN12 CN11 C 13 N.O. N.C. IDC1 +28V R 42 CN05 R 44 R 13 R 16 R103 R100 IDC2 R 12 R 15 CN15 C 44 C 48 C 43... -
Page 56: List Of Spare Parts
LRP and LK WARM AIR HEATER LIST OF SPARE PARTS 10.1. Parts for the control panel CPU PCB case G16881 Base G16882 Cover ModBus Connector G10054 Burner Fan Modulation Connector CPU-SMART Display cable G10054 G16791 ON/OFF Connector NTC1 Connector G10051 G04763 ALARM Connector G10052... -
Page 57: 10.2. Parts For The Burner Unit
LRP and LK WARM AIR HEATER 10.2. Parts for the burner unit Gas valve Gas valve Venturi Pilot solenoid valve G14067 LRP018-075 G14898 LRP018 G14378 For all models LK020-080 LK020 G14281-R LRP102 G14899 LRP028 Butterfly gasket LK105 G14990 LRP035 G14129 LRP018-075 LK034 LK020-080 G14068... - Page 58 LRP and LK WARM AIR HEATER Water trap complete with condensation detection electrode RVK cable G27810 For all models condensation detection G28303 (only for LK) Water trap pipe G27576 For all models Condensation detection electrode G27806 For all models Gasket Condensate trap G28827 Tabs...
- Page 59 LRP and LK WARM AIR HEATER Pessano con Bornago, 12/10/2020 MANUFACTURER'S DECLARATION pursuant to MD 06/08/2020 - Annex A - par. 4.1 "Technical requirements for access to tax deductions for the energy upgrading of buildings - also known as Ecobonus" [Official Journal no.
- Page 60 LRP and LK WARM AIR HEATER Notes _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ LRP - RAPID PRO and LK - KONDENSA code HG0141.00GB ed.A-2008...
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