ApenGroup AKN-0X00 Use, Installation And Maintenance Manual
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ApenGroup AKN-0X00 Use, Installation And Maintenance Manual

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Use, Installation and Maintenance Manual
EN
AKN-0X00 condensing boiler
Thermal Account for
Public Authorities
Tax deduction
Yield up to
108%
Energy Efficiency Class
A
NOx Class:
6
AKN
1
code HC0200.03GB ed.A-2312
TRANSLATION OF ORIGINAL Manual

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  • Page 1 Use, Installation and Maintenance Manual AKN-0X00 condensing boiler Thermal Account for Public Authorities Tax deduction Yield up to 108% Energy Efficiency Class NOx Class: code HC0200.03GB ed.A-2312 TRANSLATION OF ORIGINAL Manual...
  • Page 2 APEN GROUP S.p.A. 20042 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: Caldaia AKN: AKN032, AKN034, AKN050, AKN070, AKN100 Model: Hot Water Boiler AKN: AKN032, AKN034, AKN050, AKN070, AKN100 è...

  • Page 3: Table Of Contents

    CONDENSING BOILER TABLE OF CONTENTS 1. GENERAL CAUTIONS ................................5 1.1. Graphic symbols used in this manual ..............................5 2. SAFETY-RELATED WARNINGS ............................5 2.1. Fuel ........................................5 2.2. Gas Leaks ......................................5 2.3. Personal protective equipment ................................6 2.4. Safety signals ......................................6 2.5.
  • Page 4 CONDENSING BOILER 5.7.4. AB fan heater electric connections ............................31 5.7.5. AX-EC electronic fan heater electric connections and operating parameters ............... 32 5.8. GAS Connections ....................................33 5.9. Connections to the Flue ..................................34 5.9.1. Selection Guide..................................34 5.9.2. Tips for the installation ................................35 5.9.3.

  • Page 5: General Cautions

    37/2007 (ex 46/90). 2.2. Gas Leaks For more information, visit our website www.apengroup.com or contact Apen Group directly. If you smell gas: ONLY FOR ITALY: We remind that Presidential Decree no. •...

  • Page 6: Personal Protective Equipment

    CONDENSING BOILER 2.3. Personal protective equipment 2.6. While using and maintaining the units, personal protective These units are manufactured for water heating. A different equipment must be used, i.e.: application, not expressly authorised by the manufactured, is considered improper and therefore not permitted. The fluid to be used is exclusively water or a mixture of water and glycol in Clothing: The operator that carries out maintenance case of low water temperatures.

  • Page 7: Unpacking

    CONDENSING BOILER 2.9. Disposal and demolition We recommend to check the water and glycol Should the machine be dismantled or demolished, the person content inside the circuit by means of a refractometer on in charge with the operation shall proceed as follows. a yearly basis.

  • Page 8: Technical Features

    According to the model, the different remote controls (optional) The documentation required to access current tax allow operation parameter setting, ambient temperature control, bonuses is available at www.apengroup.it. time programming, working phase and fault display. Inherent Safety For AKN032, AKN034, AKN050 and AKN070, the "cold The efficiency increase at minimum power is achieved by using door"...

  • Page 9: Technical Data

    CONDENSING BOILER 3.2. Technical Data: BOILER AKN032 AKN034 AKN050 AKN070 AKN100 Type of equipment B23P - C63 EC approval P.I.N. 0476CR1226 Seasonal space heating energy efficiency - 91.8 92.2 92.8 92.3 [Reg.813/2013/EC] Energy efficiency class [Reg.811/2013/EC] NOx class [EN 15502-1] Boiler yields Symbol* Burner heat output [Hi]...

  • Page 10: Flow Rate Curve - Boiler Available Head

    CONDENSING BOILER 3.2.1. Flow rate curve - boiler available head For its proper operation, the AKN system requires the following water flow rates through the boiler: FLOW RATE RANGE BOILER AKN032 AKN034 AKN050 AKN070 AKN100 Min. Max. Min. Max. Min. Max.

  • Page 11: Hydraulic Circuit Characteristics

    ISO 2768 - M per lavorazioni in tranciatura DESCRIZIONE DATA ISO 2768 - C NTC water delivery modulation temperature Safety valve [VS1] FOGLIO ApenGroup ® SCALA DISEGNATO DA APPROVATO DA DISEGNO probe [NTC1] Pressure probe [PREX] Heating and Conditioning Solutions...

  • Page 12: Akn050, Akn070 And Akn100

    Classe di Tolleranza 0.00 ISO 2768 - M per lavorazioni in tranciatura DESCRIZIONE DATA ISO 2768 - C GRUP. AKN032 SCAMB.ISO PR 3+1 BJET 18/10/21 FOGLIO ApenGroup ® APPROVATO DA DISEGNO SCALA DISEGNATO DA C12032 System pump (circulator) [P] Filling tap Sermeta...

  • Page 13: Pipe Pressure Drops

    CONDENSING BOILER 3.4. Pipe pressure drops The table below contains pressure drop values of pipes for flow rate multiple values of fan heaters. The drop is indicated in kPa per 1 metre of linear length; the calculation must be made by calculating the equivalent length of the pipe.

  • Page 14: Equivalent Lengths Of Possible Applications

    CONDENSING BOILER Check that the minimum water content of pipes for the system is equal to or higher than what indicated in paragraph 3.2.2. Example of pressure drop calculation Multilayer DN32 pipe, Flow rate = 1,800 l/h, Heat loss = 0.12 kPa/m: Pipe length = 3+2+2 = 7 metres Corresponding length of fittings used = 0.30 (A) + 2.60 (B) = 2.90 metres Total circuit length (pipes + fittings) = 7 (pipe) + 2.90 (fittings) = 9.90 metres...

  • Page 15: Inail Components - Akn050, Akn070 And Akn100

    CONDENSING BOILER 3.5. INAIL components - AKN050, AKN070 and AKN100 Technical implementation specification of Title II of Italian Ministerial Decree 1/12/75 - “Collection R” ed. 2009 INAIL Component Abbreviation Model Description PB3204BB06 Pressure gauge, UNI 2.5 class, scale 0-4 bar Hydrometer IDROM WATTS INDUSTRIES...

  • Page 16: Boiler Size

    Materiale <non specificato> 19/10/21 Classe di Tolleranza ISO 2768 - C per lavorazioni in tranciatura CALDAIA AKY070NEW CONDENSAZIONE per lavorazioni in tranciatura 21/10/21 25566.30 FOGLIO ApenGroup FOGLIO ApenGroup DESCRIZIONE ® CALDAIA AKY070NEW CONDENSAZIONE DESCRIZIONE 21/10/21 CALDAIA AKY070NEW CONDENSAZIONE DATA ISO 2768 - M ®...

  • Page 17: Operation And Accessories

    Operation B) - Smart X chronothermostat Smart X touchscreen control has been designed to control The boiler is fitted as standard several ApenGroup units for heating, ventilation and cooling. with a multifunction LCD panel The control facilitates programming when several systems are...

  • Page 18: User's Instructions

    CONDENSING BOILER USER'S INSTRUCTIONS 4.1.2. Lockout and Reset Any operation fault is signalled on the C09660 remote control by means of a red light. The light indicates an alarm, but it does not indicate the type Please read the safety warnings described in the of alarm occurred.

  • Page 19: Multifunction Lcd Panel

    CONDENSING BOILER 4.2. Multifunction LCD panel Navigating the menu The menu has three levels. The first and the second are The panel is fitted with a red 3-digit LCD display and with four accessible without entering a password, the third requires function keys: ↑...
  • Page 20 CONDENSING BOILER Degasser - dEG Menu Parameters - PAr Menu Allows to activate the system deaeration function, i.e. the function Allows to display, and edit, the value of the main parameters of to eliminate any air contained within the system itself. The cycle the CPU PCB.

  • Page 21: Flame Indication Led

    CONDENSING BOILER 4.3. Flame indication LED The flame monitoring equipment stores the number An orange LED is present on board the CPU PCB, indicating of manual resets that are performed remotely over time. the opening of the gas valve and the presence of flame. If ignition fails with more than 5 resets performed in 15 minutes it switches to "timed"...
  • Page 22 CONDENSING BOILER Navigation map of LCD display menu CPUE G26800 Level Level Level ENTER ENTER ENTER “Confirm” type of operation ENTER “Confirm” ENTER ENTER “Confirm” adjustment burner ENTER “Confirm” display machine status ENTER ENTER “Confirm” function degasser “Axx” PCB address ENTER “Confirm”...
  • Page 23 CONDENSING BOILER - "input management" - "output management" ENTER ENTER “Value” “Value” “Value” “Value” “Value” “Value” ENTER “Value” “Value” “Value” “Value” ENTER “Value” “Value” “Value” “OPn/CLS” “OPn/CLS” “OPn/CLS” “OPn/CLS” “OPn/CLS” “OPn/CLS” “OPn/CLS” “OPn/CLS” “OPn/CLS” - “PCB parameters” ENTER “PWD” “Value-Mod./PWD” ENTER “Value-Mod./PWD”...

  • Page 24: Installation Instructions

    CONDENSING BOILER INSTALLATION INSTRUCTIONS 5.3. Accessories and standard equipment The supply of the equipment includes Instructions for installing and setting the boiler are intended for suitably qualified personnel only. Please read the safety warnings. AKY boilers • no. 1 paper template to position the external module; The installer must instruct the user about the use •...

  • Page 25: Boiler And Fan Heater Installation

    Classe di Tolleranza 24129.67 ISO 2768 - M per lavorazioni in tranciatura DESCRIZIONE DATA ISO 2768 - C ApenGroup FOGLIO ® ground within a radius of 4 m of the installed boiler. CARTIGLIO cod. X07003 ed.0411 SCALA DISEGNATO DA APPROVATO DA...

  • Page 26: Fan Heater Installation Procedure

    CONDENSING BOILER 5.4.2. Fan heater installation procedure Make two holes, centre distance 130 mm, on the wall where It is compulsory to install a Y-shaped filter (on the the fan heater must be fixed. return pipe from the system) with metal mesh of no more To fix the shelf (1) use dowels suitable for the type of wall than 1 mm on the water inlet to the boiler, to prevent the with maximum screw diameter of M10.

  • Page 27: Special Installations

    Classe di Tolleranza 27090.34 ISO 2768 - M per lavorazioni in tranciatura DESCRIZIONE DATA ISO 2768 - C FOGLIO ApenGroup ® SCALA DISEGNATO DA APPROVATO DA DISEGNO Heating and Conditioning Solutions DISEGNO DI PROPRIETA' APEN GROUP spa E' VIETATA LA RIPRODUZIONE E LA DIFFUSIONE ANCHE PARZIALE SENZA L'AUTORIZZAZIONE DELL'APEN GROUP spa...

  • Page 28: Ambient Temperature Adjustment

    CONDENSING BOILER 5.6.3. Ambient temperature adjustment If the boiler available head is not sufficient for the hydraulic system circuit, supply the system with another circulator compatible with We can discriminate between two different types of installation the boiler circulator flow rate. and, therefore, ambient temperature adjustment: To install another circulator, the boiler and the circulator must •...

  • Page 29: Connecting The Ambient Thermostat And The C09660 Remote Control

    CONDENSING BOILER 5.7.2. Connecting the ambient thermostat and the C09660 The thermostat, switch and lamp contacts are supplied by low voltage. remote control The thermostat contact must be “dry”, i.e. have zero voltage. The boiler must be compulsorily connected to an ambient Should the installer decide to fit a lockout warning light, its thermostat;...

  • Page 30: Smart X Remote Control Connection

    CONDENSING BOILER 5.7.3. Smart X remote control connection Use a twisted cable of the AWG20/22 type with a cross-section between 0.25 and 1.5 mm2. Use the CN04 terminal to connect the Smart X. Connect the power supply, making sure polarity is correct. Connect the RS485 Modbus network, making sure polarity is The correct address for each PCB must then be set up.

  • Page 31: Ab Fan Heater Electric Connections

    CONDENSING BOILER 5.7.4. AB fan heater electric connections The electrical system, and more specifically the cable section, Keep electric cables away from heat sources. must be suitable for the equipment maximum power consumption (see technical features table). It is compulsory to fit, upstream of the fan heater, a Fan heater connection: multipole isolator fitted with a suitable electric protection Carry out the connections according to the diagram below.

  • Page 32: Ax-Ec Electronic Fan Heater Electric Connections And Operating Parameters

    CONDENSING BOILER 5.7.5. AX-EC electronic fan heater electric connections The AX-EC fan heaters must be connected directly to the boiler and operating parameters with a 0-10 Vdc connection to terminals Y2-GND (refer to the wiring diagram supplied with AX-EC fan heaters). AX-EC electronic fan heaters require a single-phase 230 Vac The CPU PCB is pre-set at the factory for operation with electronic power supply.

  • Page 33: Gas Connections

    Classe di Tolleranza ISO 2768 - M per lavorazioni in tranciatura ONLY FOR ITALY: DESCRIZIONE ISO 2768 - C BRUC.POLIDORO IN FIBRA 80/100KW L=27 FOGLIO ApenGroup Ministerial Decree 1-12-75 and the corresponding technical ® APPROVATO DA DISEGNO SCALA DISEGNATO DA G276 specifications ["R"...

  • Page 34: Connections To The Flue

    CONDENSING BOILER 5.9. Connections to the Flue Connection to the flue, according to where the heater is installed, If the sum of the pressure drops is higher than the can be made as "C" type, with combustion air being drawn from available pressure, ducting with higher diameter must outside, or as "B"...

  • Page 35: Tips For The Installation

    ISO 2768 - C FOGLIO DESCRIZIONE ISO 2768 - C PESO G PESO G Quote senza i to or greater than 3° to allow for proper flow. FOGLIO ApenGroup PESO G MATERIALE Quote senza indicazione di ® tolleranza: FOGLIO ApenGroup Materiale <non specificato>...

  • Page 36: C" Type Installation

    CONDENSING BOILER Recommended maximum equivalent lengths 5.9.3. "C” TYPE installation If the duct routing requires the use of bends, their length must The boiler is C63 certified; therefore, accessories compliant with be subtracted from the available length: current regulations must be used to manufacture the customer's Bend Ø...

  • Page 37: Connection To The Condensate Drain

    CONDENSING BOILER 5.10. Connection to the condensate drain The AKN boilers are flue gas condensing appliances. The CAUTIONS lowering of the flue gas temperature in the heat exchanger Special attention must be paid when making the condensate drain causes the formation of condensate that must be duly drained system;...

  • Page 38: Hydraulic Circuit And Water Treatment

    CONDENSING BOILER 5.11. Hydraulic circuit and water treatment The table below contains the freezing temperatures of water and glycol mixes. GLYCOL AKN boiler models are NOT pre-filled (check the Quantity capacity of the expansion reservoir according to the water Freezing temperature -3°C -8°C -11°C...

  • Page 39: Water-Glycol Mix Restoration

    CONDENSING BOILER For systems with burner heat output >100 kW (for example To identify the delivery, return and filling position, cascading systems) and in the presence of supply water with refer to paragrafo 3.6 “Boiler dimensions”. total hardness >15 French degrees, a system water softening treatment is mandatory.

  • Page 40: Servicing Instructions

    CONDENSING BOILER 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. 6.1.

  • Page 41: Gas Settings Table

    CONDENSING BOILER 6.2. Gas Settings Table If a Hydrogen-ready installation is provided for H2 percentages up to 20% (referred to gas distributed in the network), all gas valve calibration operations must refer to the O2 values in table G20 TYPE OF GAS G20 AKN032 AKN 034 AKN 050...
  • Page 42 CONDENSING BOILER TYPE OF GAS G30** AKN032* AKN 034 AKN 050 AKN 070 AKN 100 TYPE OF MACHINE According to the country of destination CATEGORY See previous table SUPPLY PRESSURE [mbar] 30 [min 25 - max 35] - 37 [min 25 - max 45] - 50 [min 42.5 - max 57.5] Ø...

  • Page 43: First Start-Up

    DESCRIZIONE DATA Classe di Tolleranza ISO 2768 - C 23552.04 GRUP. AKN050 CALDAIA ASSEMBLATA 11/12/23 ISO 2768 - M per lavorazioni in tranciatura FOGLIO ApenGroup ® DESCRIZIONE DATA ISO 2768 - C APPROVATO DA DISEGNO SCALA DISEGNATO DA C12250.05 GRUP. AKN070 CALDAIA ASSEMBLATA...

  • Page 44: Conversion To Lpg

    CONDENSING BOILER 6.5. Conversion to LPG If the unit runs on G30 [Butane], it is necessary to verify and possibly adjust settings for CO value as shown in table paragrafo Conversion is strictly prohibited in some countries, such 6.2. It is also necessary to change the "RPM" parameter value as Belgium, which do not allow the double gas category.

  • Page 45: Eeprom Board

    CONDENSING BOILER Check the hardware configuration of the PCB Enables FUNC_01 - burner with FUNC01 Modify the address of the PCB with the switch selector, copying that of the PCB that was just replaced. Enables FUNC_03 - electronic FUNC03 Optional fan control or STD (Blower) Enables FUNC_05 - water flow FUNC05...

  • Page 46: Maintenance Of Components And Devices

    CONDENSING BOILER NOTE: Every time the burner or parts of it (e.g.: electrodes, NOTE: Every time the condensate drain trap or parts of it pilot, flue fan) are removed, it is necessary to replace all (e.g.: electrodes) are cleaned, it is necessary to replace the gaskets involved.

  • Page 47: Modulation Pcb Parameters

    CONDENSING BOILER MODULATION PCB PARAMETERS All values of the parameters of the CPU PCB are shown for all boiler models. The “LCD” column shows the parameters that could be modified with “007” Password via remote LCD control (even with modbus address ≠ 0). The “Smart”...
  • Page 48 CONDENSING BOILER Parameters of G26800 CPU PCB version 8.03.xx Smart U.M. DESCRIPTION REG_03 rGL R30 Probe NTC Control for ACS (DHW) Function - NOT USED ON AKN Adjustment enabling 0 = disabled REG_03 2= enabled by SMART through “Domestic water” request; not active in heating and/or conditioning mode.
  • Page 49 CONDENSING BOILER Parameters of G26800 CPU PCB version 8.03.xx Smart U.M. DESCRIPTION CTRL_02 CrL C20 Water Antifreeze Control Control enabling CTRL_02 0 = disabled 1 = enabled ST_Ant °C Water antifreeze setpoint: °C Hysteresis on antifreeze setpoint ING_Ant Analogue input Percentage burner heat output CTRL_03 CrL C30 Control 03 - NOT USED ON AKN...
  • Page 50 CONDENSING BOILER Parameters of G26800 CPU PCB version 8.03.xx Smart U.M. DESCRIPTION FUNC_03 Fnu-P30 Ventilation Management Function (EC-AC Fans) Function enabling 0 = disabled 1 = proportional POT%_OUT enabled FN_03 2 = proportional enabled to PID%_PRESS, value of REG_04_05 3 = start and modulation with temperatures TIN3, TFN3 and TCD3 4 = proportionally enabled to analogue input ING3A T_ON Seconds of delay for fan start...
  • Page 51 CONDENSING BOILER Parameters of G26800 CPU PCB version 8.03.xx Smart X DESCRIPTION RS485 Serial Communication Configurations Slave serial baud rate (SMART X) D_SL 0= baud rate 19,200 - Even Parity NTC input configuration NTC1 Activates or deactivates NTC1 input NTC2 Activates or deactivates NTC2 input NTC3 Activates or deactivates NTC3 input...
  • Page 52 CONDENSING BOILER Parameters of G26800 CPU PCB version 8.03.xx Smart X DESCRIPTION Digital Input Configurations ID1 digital input enabling 0 =disabled 1 = N.C input (Fault activated with input Open) with manual reset 2 = N.C input (Fault activated with input Open) with Autoresolve 3 = N.O.
  • Page 53 CONDENSING BOILER Parameters of G26800 CPU PCB version 8.03.xx Smart X DESCRIPTION Y2 Analogue Outputs Configuration Direct/reverse output configuration 0 = direct output: the maximum calculation value (100%) corresponds to the maximum output value 1 = reverse output: the maximum calculation value (100%) corresponds to the minimum output value Minimum voltage (or PWM in %) output value Maximum voltage (or PWM in %) output value...

  • Page 54: Analysis Of Lockouts - Errors

    CONDENSING BOILER ANALYSIS OF LOCKOUTS - ERRORS The CPU manages two types of lockouts: • preventive, it warns the customer that the boiler requires maintenance • operational, it stops the boiler for safety or warranty reasons. Some operational faults require manual reset; others reset themselves when the problem that caused them is solved. CODE DESCRIPTION CAUSE...
  • Page 55 CONDENSING BOILER CODE DESCRIPTION CAUSE RESET Alarms for safety device activation • Excess water temperature due to lack of Activation of safety thermostat STB water circulation Manual • Safety thermostat broken or not connected • Excess air or water temperature due to lack of water circulation/air flow •...
  • Page 56 CONDENSING BOILER CODE DESCRIPTION CAUSE RESET • FAN electric cables interrupted, not connected or wrongly connected • Faulty burner fan or CPU board not receiving speed signal from the flue gas fan (HALL). To check possible Flue Gas Fan failure: a) Keep the cables connected to the flue gas fan;...
  • Page 57 CONDENSING BOILER CODE DESCRIPTION CAUSE RESET Water flow and water pressure alarms Decrease of the pressure value within the Insufficient water pressure in the water circuit below the Pressure and Hysteresis hydraulic circuit. Water pressure is < set (ST_H20 and TL_H20). If this happens Autoresolve ST_H20 - TL_H20 frequently, check the presence of leakages in...

  • Page 58: Wiring Diagrams

    CONDENSING BOILER WIRING DIAGRAMS Connection details are described in the installation chapter. AKN boilers have the same wiring diagram and operating principle. Differences concern some points indicated in the notes below. AKN050/070/100 boilers have an additional protection located on water maximum pressure. The activation of this device causes error E25.

  • Page 59: Akn032 Electric Connection

    CONDENSING BOILER 9.2.1. AKN032 electric connection JC0300.00IT_B code HC0200.03GB ed.A-2312...

  • Page 60: Akn034 Electric Connection

    CONDENSING BOILER 9.2.2. AKN034 electric connection JC0301.00IT_C POWER SUPPLY 230 V - 50 HZ code HC0200.03GB ed.A-2312...

  • Page 61: Akn050 Electric Connection

    CONDENSING BOILER 9.2.3. AKN050 electric connection JC0302.00IT_C code HC0200.03GB ed.A-2312...

  • Page 62: Akn070 Electric Connection

    CONDENSING BOILER 9.2.4. AKN070 electric connection JC0303.00IT_B code HC0200.03GB ed.A-2312...

  • Page 63: Akn100 Electric Connection

    CONDENSING BOILER 9.2.5. AKN100 electric connection JC0304.01IT code HC0200.03GB ed.A-2312...
  • Page 64 CONDENSING BOILER code HC0200.03GB ed.A-2312...

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