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Summary of Contents for ApenGroup Aermax PCH
- Page 1 Maintenance and service manual of PCH condensing warm air heater module 2021 Compliant EU/2016/2281 HG0130.00 A 001 code HG0131.05GB ed.A-2010...
- 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: Модели: Generatore d’aria calda: modulante a condensazione PCH Model: Warm Air Heater: PCH modulating and condensing è...
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Page 3: Table Of Contents
condensing warm air heater module INDEX SECTION GENERAL CAUTIONS ..............4 SECTION SAFETY INSTRUCTIONS ............4 Fuel ......................4 Gas Leaks ....................4 Power Supply .................... 4 Operation ....................5 Maintenance ....................5 Transport and handling ................5 Dismantling and demolition ............... 5 Installation .................... -
Page 4: General Cautions
condensing warm air heater module 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. -
Page 5: Operation
condensing warm air heater module --------------------------------------------------------------------------------- applicable regulations in the country of use. While unpacking NOTE: IT is compulsory to install, upstream of the power the unit, check that the unit and all its parts have not been cable, a fused multipole switch with contact opening wider damaged during transport and match the order. -
Page 6: Technical Data
condensing warm air heater module TECHNICAL DATA A - PCH single modules (A System) They consist of a single heat exchanger; the range includes six There are 3 configurations of PRH/PCH, listed below: models, i.e.: PCH020, 034, 045, 065, 080 and 105. The heat • Single module (A System); output ranges from 5 to 97.2 kW produced. - Page 7 condensing warm air heater module B - PCH Horizontally combined modules (B System) The heat output ranges from 13.4 to 388.8 kW produced. They consist of two or more heat exchangers; the number of Module operation is cascaded by means of 0/10 Vdc signal and/ burners, gas equipment and flues is equal to the number of or ON/OFF signal taken to the single module.
- Page 8 condensing warm air heater module C- PCH Vertically combined modules (C System) The heat output ranges from 13.4 to 194.4 kW produced. They consist of two heat exchangers; the number of burners, gas Module operation is cascaded by means of 0/10 Vdc signal and/ equipment and flues is equal to the number of heat exchangers.
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Page 9: Regulation (Eu) 2016/2281
condensing warm air heater module 3.1. 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]: Power... -
Page 10: Operating Cycle
condensing warm air heater module OPERATING CYCLE The ignition program turns the burner on at an intermediate heat output, which corresponds to approx. 30% of the maximum Burner operation output. Once the flame is stabilised at the ignition power for a On heat request, from the 0/10 Vdc signal to the terminals B1/ few seconds, the burner starts modulating its output reaching GND of the CN06 terminal board, the modulation PCB starts the maximum value, if requested, in a variable time set in the... -
Page 11: Air/Gas Premixing Operation
condensing warm air heater module ----------------------------------------------------------------------------------- NOTE: In the devices where the cooling fan management Lockouts Fxx is carried out separately, it is necessary to comply with the The modulation PCB can identify more than 30 different types time setting indicated in the following paragraphs. of lockout. This ensures accurate diagnostics. ---------------------------------------------------------------------------------- Codes and possible causes of lockouts are listed later in the manual. -
Page 12: User Instructions
condensing warm air heater module USER'S INSTRUCTIONS and that the small cable RJ11 is securely held in the connector. Please read the safety warnings described in the previous Navigating the menu pages. The operations that the user must carry out are The menu has three levels. The first is accessible without entering limited to the use of the controls placed on the LCD display a password, the second and third require entering second and... -
Page 13: Reset
condensing warm air heater module First level menus For the meaning and the default values, please refer to the table The following menus are available on the first level: In Paragraph 5.4 “Modulation PCB parameters”. Besides "b" and "d" parameters, the following parameters can Machine provides information about PCH operation (e.g. be changed: status rdy, ON, etc.);... -
Page 14: Modulation Pcb Parameters
condensing warm air heater module 5.4. Modulation PCB Parameters All values of the parameters of the CPU-SMART PCB are shown for all PCH 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 PARAMETER DESCRIPTION PCH020 PCH034 PCH045 PCH065 PCH080 PCH105 Control parameters Flame modulation: 2=NTC1 or 3;... - Page 15 condensing warm air heater module Parameters of CPU-SMART PCB version 7.03.xx PARAMETER DESCRIPTION PCH020 PCH034 PCH045 PCH065 PCH080 PCH105 ST1 (1) °C NTC1 setpoint: -10÷140 SP1 (2) °C SP1 hysteresis: 0÷10 XD1 (3) % Proportional band from 4 to 100 TN1 (3) sec Integral coefficient: 1÷255 AC1 (3)
- Page 16 condensing warm air heater module Parameters of CPU-SMART PCB version 7.03.xx PARAMETER DESCRIPTION PCH020 PCH034 PCH045 PCH065 PCH080 PCH105 ST2 (1) °C NTC2 setpoint: -10÷90 P2 (2) °C ST2 hysteresis: 0÷40 XD2 (3) Neutral area, proportional modulation band divided by 100: 4 ÷100 TN2 (3) sec Integration time: 1÷255 ANTIFREEZE control - active with D8=1 - NOT USED ON PCH...
- Page 17 condensing warm air heater module Parameters of CPU-SMART PCB version 7.03.xx PARAMETER DESCRIPTION PCH020 PCH034 PCH045 PCH065 PCH080 PCH105 PRESSURE control - PID parameters for ventilation of Pressostatic structures - NOT USED ON PCH kp % (3) Proportional Gain % (3) Integral Gain kd % (3) Derivative Gain...
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Page 18: Analysis Of Lockouts - Faults
condensing warm air heater module 5.5. Analysis of Lockouts - Faults The CPU-SMART manages two types of lockouts: • preventive, it warns the customer that the PCH heater requires maintenance; • operational, it stops the PCH heater for safety reasons or to ensure its correct operation. Some operational faults require manual resets;... - Page 19 condensing warm air heater module FAULT DESCRIPTION CAUSE UNLOCK Probe NTC1 error, air intake temper- ature No signal from probe or broken probe Auto-reset Probe NTC3 error, flue gas temperature Over-temperature • Check the TH1 parameter - air intake set point. The temperature of the air intake probe Autoreset when •...
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Page 20: Connections To The Flue
condensing warm air heater module 5.6. Connections to the Flue The PCH heater module is fitted with a watertight combustion circuit and with the burner fan located upstream of the heat exchanger. Connection to the flue, according to how the heater is installed, can be made as "C" type, with combustion air being drawn from outside, or as "B" type with combustion air being drawn from the heater installation site. - Page 21 condensing warm air heater module Selection Guide If the terminal is not directly connected to the heater and, therefore, extra routing is required, according to the length of the ducting, the diameter of the selected terminals, extensions and bends must be checked. After establishing the routing, the pressure drops of individual components must be calculated; each component has a different pressure drop value as the flue gas flow rate is different.
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Page 22: Condensate Drain
condensing warm air heater module Free drainage 5.7. Condensate drain If the unit is installed outdoors, unless the temperatures never Special attention must be paid to the condensate drain; an drops below freezing, the water could be drained directly outside, incorrectly installed drain, in fact, could jeopardize the correct without any connections to other pipes. -
Page 23: Gas Connection
condensing warm air heater module 5.8. GAS Connection ---------------------------------------------------------------------------------- IMPORTANT: For proper maintenance, connect the PCH Use the gas line connections only with CE certified components. module by means of a seal and swivel gasket. ---------------------------------------------------------------------------------- The PCH module is supplied complete with: Avoid using threaded connections directly on the gas connection. •... - Page 24 condensing warm air heater module 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 37 mbar II2ELL3B/P G20/G25 20 mbar...
- Page 25 condensing warm air heater module Gas Settings Table TYPE OF GAS G20 - Cat. E-H TYPE OF MACHINE PCH020 PCH034 PCH045 PCH065 PCH080 PCH105 Output CATEGORY according to the country of destination - see reference table SUPPLY PRESSURE [mbar] 20 [min 17-max 25] * PILOT NOZZLE Ø...
- Page 26 condensing warm air heater module TYPE OF GAS G2.350 - Cat. Ls (Only for PL-Poland) TYPE OF MACHINE PCH020 PCH034 PCH045 PCH065* Output according to the country of destination - see refer- CATEGORY ence table SUPPLY PRESSURE [mbar] 13 [min 10-max 16] PILOT NOZZLE Ø...
- Page 27 condensing warm air heater module TYPE OF GAS G30 - Cat. 3B-P TYPE OF MACHINE PCH020 PCH034 PCH045 PCH065 PCH080* PCH105** Output 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 28: Starting Up For The First Time
condensing warm air heater module 5.9. Starting up for the first time 5.10. Analysis of combustion The PCH heater module is supplied already set up and tested Wait until the heater is switched on. Check that the heater for the gas specified on the nameplate. Before turning on the is running at maximum power by using one of the two PCH module check the following: methods below: •... -
Page 29: Conversion To Lpg
condensing warm air heater module 5.11. Conversion to LPG 5.12. Conversion to gas G25 - G25.1 - G25.3 - 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 30: 5.13. Conversion To Gas G2.350
condensing warm air heater module 5.13. Conversion to gas G2.350 5.14. 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 31: 5.15. Replacing The Modulation Pcb
condensing warm air heater module MAINTENANCE 5.15. Replacing the modulation PCB 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. - Page 32 condensing warm air heater module 1) Inspection of electrodes Dismantle the complete pilot flame and use a jet of compressed air to clean the mesh and nozzle. Check the integrity of the ceramic and use sandpaper to remove any oxidation on the metal parts of the electrodes. Check the correct position of the electrodes (see drawing below).
- Page 33 condensing warm air heater module 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 34 condensing warm air heater module - “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” (Anal. Input B1) - “setpoint” ENTER Password required to edit “Value”...
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Page 35: Wiring Diagrams
condensing warm air heater module WIRING DIAGRAM Single PCH wiring diagram: PCH020 - PCH105 (code JG0385.01_A) 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... -
Page 36: Analysis Of Faults
condensing warm air heater module ANALYSIS OF FAULTS PCH OPERATION Read T Is the burner on? Act on the roof-top or Value = 10? AHU regulator Set the control to On Is display OFF? Read delivery air tem- Ignition enabling perature on NTC1 Is display in rDY? missing... -
Page 37: List Of Spare Parts
condensing warm air heater module LIST OF SPARE PARTS 9.1. Parts for the control panel CPU PCB LCD Display G16790 ModBus Connector Burner Fan Modulation Connector G10054 G10054 ON/OFF Connector G10051 NTC1 Connector G04763 ALARM Connector G10052 CPU-SMART PCB G16800.03 0-10Vdc Connector G10052 Burner Fan Power Supply Connector... -
Page 38: Parts For The Burner Unit
condensing warm air heater module 9.2. Parts for the burner unit Gas valve G14456 For all models Gas valve gasket C02000 For all models Butterfly gasket 2x X01133 For all models Burner torch G14534-P PCH020-034 G14375.01-P PCH045 G16340.01-P PCH065 G27618-PF PCH080-105 Pilot solenoid valve G14378 For all models... -
Page 39: Other Spare Parts Available
condensing warm air heater module 9.3. Other spare parts available Condensation detection electrode G27806 Detection electrode Supply gasket Round gasket G28826 G27194 Exhaust casting G27816 Flue gas drainage casting G27815 Type "B" terminal G28814 Door closure X04511 Housing black seal X01495 Gasket Condensate trap... - Page 40 condensing warm air heater module code HG0131.05GB ed.A-2010 APEN GROUP SPA reserves the right to make changes deemed to be required to its products or documentation...
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