ApenGroup PCH Series Maintenance And Service Manual
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ApenGroup PCH Series Maintenance And Service Manual

Condensing warm air heater module
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Maintenance and service manual of
EN
PCH condensing warm air heater module
NEW VERSION
CPU G26800
ErP
2021
Compliant
EU/2016/2281
TRANSLATION OF ORIGINAL Manual
PCH
1
cod. HG0131.10GB ed.A-2205

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Summary of Contents for ApenGroup PCH Series

  • Page 1 Maintenance and service manual of PCH condensing warm air heater module NEW VERSION CPU G26800 2021 Compliant EU/2016/2281 TRANSLATION OF ORIGINAL Manual cod. HG0131.10GB ed.A-2205...
  • 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...
  • Page 3 Via Isonzo, 1 - ITALY Tel +39.02.9596931 r.a. Fax +39.02.95742758 Internet: http://www.apengroup.com With this document we declare that the unit: Model: Warm Air Heater: PCH modulating and condensing has been designed and manufactured in compliance with the prescriptions of the following Regulations: ...

  • Page 4: Table Of Contents

    Condensing warm air heater module INDEX SECTION GENERAL CAUTIONS ..............5 SECTION SAFETY INSTRUCTIONS ............5 Fuel ......................5 Gas Leaks ....................5 Power Supply .................... 6 Use ......................6 Maintenance ....................6 Transport and handling ................6 Unpacking ....................7 Disposal and demolition ................

  • Page 5: General Cautions

    Technical Service Centres that the user can contact to have the first start-up, adjustment and maintenance of the product carried out according to law 37/2007 (ex 46/90) For more information, visit our website www.apengroup.com or contact Apen Group directly. The warranty conditions are specified on the warranty certificate supplied with this equipment. cod. HG0131.10GB ed.A-2205...

  • Page 6: Power Supply

    Condensing warm air heater module 2.3. Power supply If the equipment is not used for long periods, shut the gas supply off through the gas stopcock and disconnect it from the The heater must be correctly connected to an effective earthing power supply. system, made in compliance with current regulations (IEC 64-8, If the heater is to be put out of service, in addition to the above applies to Italy only).

  • Page 7: Unpacking

    Condensing warm air heater module 2.7. Unpacking INFORMATION FOR DISPOSAL valid abroad (EU COUNTRIES 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 modalities for the various member states, even in terms of...

  • Page 8: 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 9 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 10 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.

  • Page 11: 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 12: Operating Cycle

    Condensing warm air heater module OPERATING CYCLE Flame detection is carried out by a single electrode for both the pilot burner and the main burner. Burner operation The ignition program turns the burner on at an intermediate On heat request, from the 0/10 Vdc signal to the terminals B1/ heat output, which corresponds to approx.

  • Page 13: Air/Gas Premixing Operation

    Condensing warm air heater module Management from AHU / ROOF-TOP control unit 0/10 Vdc input signal. The probe monitors the heat output/ cooling air flow ratio. NOTE: In the devices where the cooling fan management It is not advisable to change the ST1 value (R12) without is carried out by means of AHU or ROOF-TOP control consulting the APEN GROUP Service Centre.

  • Page 14: User Instructions

    Condensing warm air heater module USER'S INSTRUCTIONS During normal operation, the display will show the wording HEA if the burner is on; rdy or Sty when the boiler is being switched Please carefully read the safety warnings described in the off or the room temperature has been reached.
  • Page 15 Condensing warm air heater module Second level menu Output - Out Menu The following menus are available on the second level: Allows to display the value and/or status of analogue and digital outputs. For the meaning and the default values, please refer to Allows to select the type of functioning from Aut or OFF the table CPU PCB Parameters of Paragraph 5.4 "Modulation Allows to force the burner at minimum or maximum...

  • Page 16: Reset

    Condensing warm air heater module 5.3. Reset The modulation PCB allows the operator to identify more than 30 different causes of lockouts. This allows a precise diagnostics managing each event very accurately. To reset a lockout, press both ↑ and ↓ arrows simultaneously for a few seconds. It is possible to operate the lockout reset remotely using one of the following solutions: •...
  • Page 17 Condensing warm air heater module Navigation map of LCD display menu - CPU G26800 Level Level Level ENTER ENTER ENTER “Confirm” type of operation ENTER “Confirm” ENTER ENTER “Confirm” adjustment burner display machine status ENTER “Confirm” ENTER ENTER “Axx” “Confirm” PCB address function degasser...
  • Page 18 Condensing warm air heater module - "input management" - "output management" ENTER ENTER “Value” “Value” “Value” “Value” “Value” “Value” ENTER “Value” “Value” “Value” “Value” ENTER “Value” “OPn/CLS” “Value” “OPn/CLS” “OPn/CLS” “OPn/CLS” “OPn/CLS” “OPn/CLS” “OPn/CLS” “OPn/CLS” “OPn/CLS” “OPn/CLS” - “PCB parameters” ENTER “PWD”...

  • Page 19: Modulation Pcb Parameters

    Condensing warm air heater module 5.5. Modulation PCB Parameters All values of the parameters of the CPU PCB are shown for all PCH heater models. The “LCD” column shows the parameters that can be edited with "007” Password via remote LCD control (even with modbus address ≠ 0).
  • Page 20 Condensing warm air heater module Parameters of G26800 CPU PCB version 8.00.xx Parameter Name Smart U.M. DESCRIPTION Defines the analogue input to be used for calculation 1 = NTC1 ING1A 2 = NTC2 3 =NTC3 REG 02 rGL R20 Flue Gas Temperature Probe NTC Control - ONLY ON PCH - 0Fxx Adjustment enabling REG_02 0 = disabled...
  • Page 21 Condensing warm air heater module Parameters of G26800 CPU PCB version 8.00.xx Parameter Name Smart U.M. DESCRIPTION CTRL 03 CrL C30 Burner Compartment Antifreeze Control Control enabling CTRL_03 0 = disabled 1 = enabled ST_Van °C Burner compartment antifreeze setpoint °C Hysteresis on antifreeze setpoint ING_Van...
  • Page 22 Condensing warm air heater module Parameters of G26800 CPU PCB version 8.00.xx Parameter Name Smart U.M. DESCRIPTION FUNC 04 Fnu P40 Function 04 - NOT USED ON PCH Function Enabling FN_04 0 = disabled FUNC 05 Fnu P50 Function 05 - NOT USED ON PCH Function enabling 0 = disabled FUNC 08 Fnu P80...
  • Page 23 Condensing warm air heater module Parameters of G26800 CPU PCB version 8.00.xx Parameter Name Smart DESCRIPTION Digital Input Configurations ID1 digital input enabling 0 = disabled 1 = N.C input (Fault with input Open) with manual reset 2 = N.C input (Fault with input Open) with Autoresolve 3 = N.O.

  • Page 24: Analysis Of Lockouts - Exx

    Condensing warm air heater module 5.6. Analysis of Lockouts - Exx The CPU 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 reset;...
  • Page 25 Condensing warm air heater module CODE DESCRIPTION CAUSE RESET Alarms for safety device activation • Excess air temperature due to lack of air circulation/ Activation of safety thermostat STB flow; Manual • Safety thermostat broken or not connected • Frost or temperature below -20°C; STB safety thermostat activation in •...
  • Page 26 Condensing warm air heater module CODE DESCRIPTION CAUSE RESET Parameter configuration error alarms No input enabling for functions or controls (e.g. no Input configuration error Autoresolve activation of NTC1 input combined with REG_01) No activation of compulsory functions for the product Function configuration error type (e.g. no activation of CTRL_04 for product type Autoresolve "PCH") EEPROM alarms...

  • Page 27: Connections To The Flue

    Condensing warm air heater module 5.7. Connections to the Flue In case of installation of ducts different from those supplied by the manufacturer, always make sure that they are suitable The PCH heater module is fitted with a watertight combustion for the type of application and the type of equipment on which circuit and with the burner fan located upstream of the heat they are installed.
  • Page 28 Condensing warm air heater module Flue gas data The table to be used to calculate the flue gas exhaust system with commercially available pipes can be found in paragraph 5.9 "GAS connection" within the Gas regulation data. The maximum permitted recirculation percentage is 10%. 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.

  • Page 29: Condensate Drain

    Condensing warm air heater module 5.8. Condensate drain Free drainage 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 30: Gas Connection

    Condensing warm air heater module 5.9. GAS Connection IMPORTANT: For proper maintenance, connect the PCH module 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 PCH module is supplied complete with: Current legislation allows a maximum pressure inside the •...
  • Page 31 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 G30/G31...
  • Page 32 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 33 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 reference CATEGORY table SUPPLY PRESSURE [mbar] 13 [min 10-max 16] PILOT NOZZLE Ø...
  • Page 34 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] - 37 [min 25-max 45] - 50 [min 42.5-max 57.5] PILOT NOZZLE Ø...

  • Page 35: Starting Up For The First Time

    Condensing warm air heater module 5.10. Starting up for the first time ATTENTION: IT IS FORBIDDEN to loosen the gas connections, the pressure connectors, the pilot burner The PCH heater module is supplied already set up and tested duct, or any other gas connection point located inside for the gas specified on the nameplate. Before turning on the the burner housing, to purge the air or inert gas that may PCH module check the following:...

  • Page 36: Combustion Analysis

    Condensing warm air heater module 5.11. Analysis of combustion 5.12. Conversion to LPG Conversion is strictly prohibited in some countries, such Wait until the heater is switched on. Check that the heater is as Belgium, which do not allow the double gas category. running at maximum power by using one of the two methods below: •...

  • Page 37: Conversion To Gas G25 - G25.1 - G27

    Condensing warm air heater module 5.13. Conversion to gas G25 - G25.1 - G25.3 - G27 5.14. Conversion to gas G2.350 Conversion for gasses from G20 to G25 or G25.1 or G25.3 or G27 Conversion is allowed only for Poland. is allowed only in countries of category II2ELL3B/P [Germany], Conversion from one type of gas to another can only be performed II2Esi3P [France], II2E3P [Luxembourg] and category II2HS3B/P...

  • Page 38: Cpu Modulation Pcb Replacement

    Condensing warm air heater module MAINTENANCE 5.16. CPU modulation PCB replacement When replacing the CPU modulation PCB, it is required to carry To keep the heater efficient and guarantee a long lifetime of the out some essential operations, described below. same, it is advisable to run some inspections at regular intervals: 1.
  • Page 39 Condensing warm air heater module 6) Inspection of intake gas pressure Verify that the start-up Check that the intake pressure at the valve corresponds to the electrode discharges on the external edge of the pilot value required for the type of gas that you are using. burner.

  • Page 40: Wiring Diagrams

    Condensing warm air heater module WIRING DIAGRAM Single PCH wiring diagram: PCH020 - PCH105 (code JG0386.00) CN20 CN20 CN05A CN05A CN01 CN01 Q1-NC Q1-NC Q1-NO Q1-NO Q1-C Q1-C +24V +24V CN05B CN05B F2 5A - T F2 5A - T +24V +24V CN02...

  • Page 41: Analysis Of Faults

    Condensing warm air heater module ANALYSIS OF FAULTS PCH OPERATION Read An1 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 Ignition enabling temperature on NTC1 Is display in rDY? missing Air flow rate insufficient,...

  • Page 42: 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 Modulation Connector ModBus Connector Burner fan ON/OFF Connector G10054 G10054 G04763 Connector G11099 NTC1 Connector G04763 Connector G11101 ALARM Connector G10054 0-10Vdc Connector G10052...

  • Page 43: 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 44: 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...

This manual is also suitable for:

Pch020Pch034Pch045Pch065Pch080Pch105 ... Show all

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