ApenGroup Aermax PCH Manual
1code HG0131.05GB ed.A-2010
PCH
HG0130.00 A 001
ErP
2021
Compliant
EU/2016/2281
EN Maintenance and service manual of
PCH condensing warm air heater module
This manual cannot be copied in part or in full for disclosure to third parties without the prior written consent by Apen Group s.p.a.
PCH condensing warm air heater module
APEN GROUP SPA reserves the right to make changes deemed to be required to its products or documentation
2
code HG0131.05GB ed.A-2010 PCH 3code HG0131.05GB ed.A-2010
PCH
VER. 01.2020
CODE SERIAL NUMBER
Dichiarazione di Conformità
Statement of Compliance
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:
Model:
Generatore d’aria calda: modulante a condensazione PCH
Warm Air Heater: PCH modulating and condensing
è stata progettata e costruita in conformità con le disposizioni delle Direttive Comunitarie:
has been designed and manufactured in compliance with the prescriptions of the following EC Directives:
Regolamento Apparecchi a Gas 2016/426/UE
Gas Appliance Regulation 2016/426/UE
Direttiva compatibilità elettromagnetica 2014/30/UE
Electromagnetic Compatibility Directive 2014/30/UE
Direttiva Bassa Tensione 2014/35/UE
Low Voltage Directive 2014/35/UE
Regolamento ErP 2281/2016/UE
ErP Regulation 2281/2016/UE
Direttiva ROHS II 2011/65/UE e ROHS III 2015/863/UE
ROHS II 2011/65/UE and ROHS III 2015/863/UE Directives
è stata progettata e costruita in conformità con le norme:
has been designed and manufactured in compliance with the standards:
EN17082:2019
EN60335-1
EN60335-2-102
EN60730-1
EN 60068-2-1
EN 60068-2-2
EN55014-1
EN55014-2
EN61000-3-2
EN61000-3-3
Organismo Notificato:
Notified body:
Kiwa Cermet Italia S.p.A
0476
PIN 0476CQ0451
La presente dichiarazione di conformità è rilasciata sotto la responsabilità esclusiva del fabbricante
This declaration of conformity is issued under the sole responsibility of the manufacturer
Pessano con Bornago
01/10/2020 Apen Group S.p.A.
Un Amministratore
Mariagiovanna Rigamonti
APEN GROUP SPA reserves the right to make changes deemed to be required to its products or documentation
PCH condensing warm air heater module
2
code HG0131.05GB ed.A-2010 PCH 3code HG0131.05GB ed.A-2010
PCH
INDEX
SECTION 1. GENERAL CAUTIONS ................................................................. 4
SECTION 2. SAFETY INSTRUCTIONS ............................................................ 4
2.1 Fuel ........................................................................................................... 4
2.2 Gas Leaks ................................................................................................. 4
2.3 Power Supply ............................................................................................ 4
2.4 Operation .................................................................................................. 5
2.5 Maintenance .............................................................................................. 5
2.6 Transport and handling.............................................................................. 5
2.7 Dismantling and demolition ....................................................................... 5
2.8 Installation ................................................................................................. 5
SECTION 3. TECHNICAL DATA........................................................................ 6
3.1 Regulation (EU) 2016/2281 ....................................................................... 9
SECTION 4. OPERATING CYCLE .................................................................... 10
4.1 Air/gas premixing operation....................................................................... 11
SECTION 5. USER INSTRUCTIONS................................................................. 12
5.1 Operation of the Heater ............................................................................. 12
5.2 Interface Panel .......................................................................................... 12
5.3 Reset ......................................................................................................... 13
5.4 Modulation PCB parameters ..................................................................... 14
5.5 Analysis of Lockouts - Faults..................................................................... 18
5.6 Connections to the Flue............................................................................. 20
5.7 Condensate drain ...................................................................................... 22
5.8 Gas Connection......................................................................................... 23
....................................................................... 28
5.10 Combustion Analysis ................................................................................. 28
5.11 Conversion to LPG .................................................................................... 29
5.12 Conversion to gas G25 - G25.1 - G27....................................................... 29
5.13 Conversion to gas G2.350......................................................................... 30
5.14 Replacing the gas valve ............................................................................ 30
5.15 Replacing the modulation PCB.................................................................. 31
SECTION 6. MAINTENANCE ............................................................................ 31
SECTION 7. WIRING DIAGRAMS..................................................................... 35
SECTION 8. ANALYSIS OF FAULTS ................................................................ 36
SECTION 9. LIST OF SPARE PARTS............................................................... 37
9.1 Parts for the electrical panel ...................................................................... 37
9.2 Parts for the burner unit............................................................................. 38
9.3 Other spare parts available ....................................................................... 39
PCH condensing warm air heater module
APEN GROUP SPA reserves the right to make changes deemed to be required to its products or documentation
4
code HG0131.05GB ed.A-2010 PCH 5code HG0131.05GB ed.A-2010
PCH
1. GENERAL CAUTIONS
This manual is an integral part of the product and must always
accompany it.
Should the equipment be sold or passed on to someone else,
always make sure that this manual is supplied with the equipment
for future reference by the new owner and/or installer.
The manufacturer shall not be held civilly or criminally respon-
sible for injuries to people or animals or damages to things
caused by incorrect installation, calibration and maintenance
or by failure to follow the instructions contained in this manual
This product must be used only for the applications for which
it was designed or approved. Any other use must be regarded
as hazardous.
During the installation, operation and maintenance of the equip-
ment described in this manual, the user must always strictly
follow the instructions given in all the chapters of this use and
instruction manual.
----------------------------------------------------------------------------------
The condensing warm air heater must be installed in com-
pliance with current regulations, according to the manu-
facturer's instructions and by qualied sta, technically
specialised in the heating eld.
----------------------------------------------------------------------------------
maintenance operations must be carried out only by suitably
Technical Service Centres certied by current
and older standards prevailing in the installation country and
in compliance with the issued authorisation.
2. SAFETY-RELATED WARNINGS
This chapter describes the safety instructions to be followed
by machine operators.
2.1. Fuel
Before starting up the heater, make sure that:
• the gas mains supply data are compatible with the data
stated on the nameplate;
•
• the combustion air is supplied in such a way as to avoid
even partial obstructions of the intake grille (caused by
leaves etc.);
• the gas seal of the feeding system has been tested and
approved in compliance with the applicable standards;
• the heater is supplied with the same type of fuel it has
been designed for;
•
applicable standards;
• the inside of the gas pipes and air distribution ducts for
ducted heaters have been thoroughly cleaned;
•
heater;
•
on the nameplate.
2.2. Gas Leaks
If you smell gas:
• do not operate electrical switches, telephones or any other
object or device that could produce sparks;
•
to vent the gas out of the room;
• close the gas valves;
• call for qualied sta.
------------------------------------------------------------------------------
NOTE: supplying the gas circuit with pres-
sure greater than 60 mbar is strictly prohibited.
Such pressures could cause the valve to break.
---------------------------------------------------------------------------------
2.3. Power supply
system, made in compliance with current regulations (IEC 64-8).
Cautions.
•
• Check that the mains power supply is the same as the
power input stated on the equipment nameplate and in
this manual.
• Do not mistake the neutral for the live wire.
• 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.
•
section, must be suitable for the equipment maximum
power input, shown on the nameplate and in this manual.
Do not pull electric cables and keep them away from heat sources.
APEN GROUP SPA reserves the right to make changes deemed to be required to its products or documentation
PCH condensing warm air heater module
4
code HG0131.05GB ed.A-2010 PCH 5code HG0131.05GB ed.A-2010
PCH
---------------------------------------------------------------------------------
NOTE: IT is compulsory to install, upstream of the power
cable, a fused multipole switch with contact opening wider
than 3mm.
The switch must be visible, accessible and less than 3m
away from the control board.
All electrical operations (installation and maintenance)
must be carried out by qualied sta.
---------------------------------------------------------------------------------
2.4. Use
Do not allow children or inexperienced people to use any elec-
trically powered equipment.
The following instructions must be followed:
• do not touch the equipment with wet or damp parts of your
body and/or with bare feet;
• do not leave the equipment exposed to the elements (rain,
sun etc...) unless it is adequately protected;
• do not use the gas pipes to earth electrical equipment;
•
gas duct;
•
• do not place any object over the equipment;
• do not touch the moving parts of the heater.
2.5. Maintenance
---------------------------------------------------------------------------------
Maintenance operations and combustion inspections must
be carried out in compliance with current standards.
---------------------------------------------------------------------------------
Before carrying out any cleaning and maintenance operations,
isolate the boiler from the mains power supply using the switch
located on the electrical system and/or on the shut-out devices.
and do not attempt to repair it yourself, but contact our local
Technical Service Centre. All repairs must be carried out by
using genuine spare parts. Failure to comply with the above
instructions could compromise the safety of the equipment and
invalidate the warranty. If the equipment is not used for long
disconnect it from the 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 disabled. It is strictly forbidden to
obstruct the Venturi pipe inlet, located on the burner-fan unit,
with your hands or with any other objects. Any obstruction could
2.6. Transport and handling
The heater is delivered fastened to a pallet and covered with a
suitably secured cardboard box.
Unload the heater from the truck and move it to the site of in-
stallation by using means of transport suitable for the shape of
the load and for the weight. If the unit is stored at the customer’s
premises, make sure a suitable place is selected, sheltered
from rain and from excessive humidity, for the shortest possible
time. Any lifting and transport operations must be carried out
procedures and safety regulations. Once the equipment is moved
to the correct position, the unpacking operation can be started.
The unpacking operation must be carried out by using suitable
tools or safety devices where required. Recovered packaging
materials must be separated and disposed of according to
applicable regulations in the country of use. While unpacking
the unit, check that the unit and all its parts have not been
damaged during transport and match the order. If damages
have occurred or parts are found to be missing, immediately
contact the supplier.
The manufacturer is not liable for any damages occurred
during transport, handling and unloading.
2.7. Dismantling and demolition
Should the machine be dismantled or demolished, the person
in charge with the operation will have to:
• remove the electric wiring
• remove all plastic parts
-----------------------------------------------------------------------------
--NOTE: All materials recovered will be processed and
disposed of according to what provided for by the laws
in force in the country of use and/or according to the
standards indicated in the safety sheets of the chemicals.
----------------------------------------------------------------------------------
2.8. Installation
The LK and LP heat exchanger must be used in the following
conditions:
• The fuel used must have a sulphur content according to the
European standard, namely: maximum peak, for short periods,
150 mg/m3, annual average lower than 30 mg/m3;
• Combustion air must not contain chlorine, ammonia or alkalis;
installation near swimming pools or laundries exposes the heater
DO NOT COVER IT WITH YOUR HAND OR OTHER OBJECTS!
PCH condensing warm air heater module
APEN GROUP SPA reserves the right to make changes deemed to be required to its products or documentation
6
code HG0131.05GB ed.A-2010 PCH 7code HG0131.05GB ed.A-2010
PCH
Model PCH020 PCH034 PCH045 PCH065 PCH080 PCH105
Type of equipment B23P - C13 - C43 - C53 - C63
EC approval PIN. 0476CQ0451
NOx Class Val 5
Type of fuel Gaseous
Heater Performance
min max min max min max min max min max min max
Nominal heat input (Hi) kW 4.75 19.00 7.60 34.85 8.50 42.00 12.40 65.00 16.40 82.00 21.00 100.00
Useful heat output [Pmin, Prated]* kW 4.97 18.18 8.13 33.56 8.97 40.45 13.40 62.93 17.77 80.03 22.77 97.15
ƞpl, ƞnom]* % 104.63 95.68 106.97 96.30 105.50 96.30 108.06 96.82 108.35 97.60 108.40 97.15
ƞpl, ƞnom]* % 94.26 86.20 96.37 86.76 95.07 86.76 97.36 87.22 97.62 87.93 97.68 87.52
Flue losses with burner on (Hi) % 0.4 4.3 0.6 3.7 0.5 3.7 0.2 3.2 0.3 2.4 0.2 2.8
% <0,1 <0,1 <0,1 <0,1 <0,1 <0,1
Max. condensation (1) l/h 0.4 0.9 1.1 2.1 3.3 2.7
Flue gas emissions
Carbon monoxide - CO - (0% of O2) (2) ppm < 5 < 5 < 5 < 5 < 5 < 5
Emissions of nitrogen oxides - NOx*
(0% of O2) (Hi) (3)
29 mg/kWh -
16 ppm
51 mg/kWh -
29 ppm
36 mg/kWh -
20 ppm
45 mg/kWh -
25 ppm
31 mg/kWh -
18 ppm
40 mg/kWh -
23 ppm
Emissions of nitrogen oxides - NOx*
(0% of O2) (Hs) (4)
26 mg/kWh -
15 ppm
46 mg/kWh -
26 ppm
32 mg/kWh -
18 ppm
41 mg/kWh -
23 ppm
28 mg/kWh -
16 ppm
36 mg/kWh -
20 ppm
Pa 80 90 100 120 120 120
Flue gas temperature, CO2
following pages
Electrical Characteristics
Supply voltage V 230 Vac - 50 Hz single-phase
Rated power [elmin - elmax ]* kW 0.011 0.045 0.011 0.074 0.024 0.082 0.015 0.097 0.020 0.123 0.020 0.130
Protection Rating IP IP X5D
Operating Temperatures °C from -15°C to +40°C - for lower temperatures, a burner housing heating kit is required (6)
Connections
Ø gas connection UNI/ISO 228/1-
G 3/4"
UNI/ISO 228/1-
G 3/4"
UNI/ISO 228/1-
G 3/4"
UNI/ISO 228/1-
G 3/4"
UNI/ISO 228/1-
G 3/4"
UNI/ISO 228/1-
G 3/4"
Intake/exhaust pipes Ø mm 80/80 80/80 80/80 80/80 80/80 80/80
Air ow rate
(5) m3/h 2700 4300 4500 7800 9000 11100
Weight
Net Weight kg 39 48 58 72 98 118
3. TECHNICAL DATA
• A Single module (A System);
• B Horizontally combined modules (B System);
• C Vertically combined modules (C System).
A - PCH single modules (A System)
They consist of a single heat exchanger; the range includes six
models, i.e.: PCH020, 034, 045, 065, 080 and 105. The heat
output ranges from 5 to 97.2 kW produced.
The modules can be installed both horizontally and vertically,
NOTES:
* Symbol of conformity with Reg.EU/2281/2016.
(1) Max. condensation produced acquired from testing at 30%Qn.
(2) Value referred to cat. H (G20).
(6) If the burner housing heater kit is installed, add 105 W (230V) per module to the rated power value on the nameplate.
APEN GROUP SPA reserves the right to make changes deemed to be required to its products or documentation
PCH condensing warm air heater module
6
code HG0131.05GB ed.A-2010 PCH 7code HG0131.05GB ed.A-2010
PCH
Model PCH130 PCH160 PCH210 PCH320 PCH420
Type of equipment B23P - C13 - C43 - C53 - C63
EC approval PIN. 0476CQ0451
NOx Class Val 5
Heater Performance
min max min max min max min max min max
Nominal heat input (Hi) kW 12.40 130.00 16.40 164.00 21.00 200.00 21.00 300.00 21.00 400.00
Useful heat output [Pmin, Prated]* kW 13.40 125.86 17.77 160.06 22.77 194.30 22.77 291.45 22.77 388.60
ƞpl, ƞnom]* % 108.06 96.82 108.35 97.60 108.40 97.15 108.40 97.15 108.40 97.15
ƞpl, ƞnom]* % 97.36 87.22 97.62 87.93 97.68 87.52 97.68 87.52 97.68 87.52
Flue losses with burner on (Hi) % 0.2 3.2 0.3 2.4 0.2 2.8 0.2 2.8 0.2 2.8
% <0,1 <0,1 <0,1 <0,1 <0,1
Max. condensation (1) l/h 4.2 6.6 5.4 8.1 10.8
Flue gas emissions
Carbon monoxide - CO - (0% of O2) (2) ppm < 5 < 5 < 5 < 5 < 5
Emissions of nitrogen oxides - NOx*
(0% of O2) (Hi) (3)
45 mg/kWh -
25 ppm
31 mg/kWh -
18 ppm
40 mg/kWh -
23 ppm
40 mg/kWh -
23 ppm
40 mg/kWh -
23 ppm
Emissions of nitrogen oxides - NOx*
(0% of O2) (Hs) (4)
41 mg/kWh -
23 ppm
28 mg/kWh -
16 ppm
36 mg/kWh -
20 ppm
36 mg/kWh -
20 ppm
36 mg/kWh -
20 ppm
Pa 120 120 120 120 120
Flue gas temperature, CO2
22 and on the following pages
Electrical Characteristics
Supply voltage V 230 Vac - 50 Hz single-phase
Rated power [elmin - elmax ]* kW 0.015 0.194 0.020 0.246 0.020 0.260 0.020 0.390 0.020 0.520
Protection Rating IP IP X5D
Operating Temperatures °C from 15°C to +40°C - for lower temperatures, a
burner housing heating kit is required (6)
Connections
Ø gas connection UNI/ISO 228/1-
G 1½"
UNI/ISO 228/1-
G 1½"
UNI/ISO 228/1-
G 1½"
UNI/ISO 228/1-
G 3/4"
UNI/ISO 228/1-
Intake/exhaust pipes Ø mm 2 x 80/80 2 x 80/80 2 x 80/80 3 x 80/80 4 x 80/80
Air ow rate
(5) m3/h 15600 18000 22200 33300 44400
Weight
Net Weight kg 154 206 250 375 500
B - PCH Horizontally combined modules (B System)
They consist of two or more heat exchangers; the number of
heat exchangers.
The gas and electrical connection is the same for all modules.
The range includes two module models, PCH130, 160 and
210, the three module model, PCH320, and four module model
PCH420.
The heat output ranges from 13.4 to 388.8 kW produced.
Module operation is cascaded by means of 0/10 Vdc signal and/
or ON/OFF signal taken to the single module.
The modules can be installed both horizontally and vertically, ac-
NOTE: For single module -00H0 B models refer to the technical
data of the corresponding size of A modules.
NOTES:
* Symbol of conformity with Reg.EU/2281/2016.
(1) Max. condensation produced acquired from testing at 30%Qn.
(2) Value referred to cat. H (G20).
(6) If the burner housing heater kit is installed, add 105 W (230V) per module to the rated power value on the nameplate.
PCH condensing warm air heater module
APEN GROUP SPA reserves the right to make changes deemed to be required to its products or documentation
8
code HG0131.05GB ed.A-2010 PCH 9code HG0131.05GB ed.A-2010
PCH
Model PCH132 PCH162 PCH212
Type of equipment B23P - C13 - C43 - C53 - C63
EC approval PIN. 0476CQ0451
NOx Class Val 5
Heater Performance
min max min max min max
Nominal heat input (Hi) kW 12.40 130.00 16.40 164.00 21.00 200.00
Useful heat output [Pmin, Prated]* kW 13.40 125.86 17.77 160.06 22.77 194.30
ƞpl, ƞnom]* % 108.06 96.82 108.35 97.60 108.40 97.15
ƞpl, ƞnom]* % 97.36 87.22 97.62 87.93 97.68 87.52
Flue losses with burner on (Hi) % 0.2 3.2 0.3 2.4 0.2 2.8
% <0,1 <0,1 <0,1
Max. condensation (1) l/h 4.2 6.6 5.4
Flue gas emissions
Carbon monoxide - CO - (0% of O2) (2) ppm < 5 < 5 < 5
Emissions of nitrogen oxides - NOx*
(0% of O2) (Hi) (3)
45 mg/kWh -
25 ppm
31 mg/kWh -
18 ppm
40 mg/kWh -
23 ppm
Emissions of nitrogen oxides - NOx*
(0% of O2) (Hs) (4)
41 mg/kWh -
23 ppm
28 mg/kWh -
16 ppm
36 mg/kWh -
20 ppm
Pa 120 120 120
Flue gas temperature, CO2
following pages
Electrical Characteristics
Supply voltage V 230 Vac - 50 Hz single-phase
Rated power [elmin - elmax ]* kW 0.015 0.194 0.020 0.246 0.020 0.260
Protection Rating IP IP X5D
Operating Temperatures °C from -15°C to +40°C - for lower temperatures, a burner
housing heating kit is required (6)
Connections
Ø gas connection UNI/ISO 228/1-
G 1½"
UNI/ISO 228/1-
G 1½"
UNI/ISO 228/1-
G 1½"
Intake/exhaust pipes Ø mm 2 x 80/80 2 x 80/80 2 x 80/80
Air ow rate
(5) m3/h 15600 18000 22200
Weight
Net Weight kg 148 200 240
C- PCH Vertically combined modules (C System)
They consist of two heat exchangers; the number of burners, gas
The gas and electrical connection is the same for all modules.
These modules have a reduced width and low pressure drops
when air goes through.
The range includes two module models, PCH132, 162 and 212.
The heat output ranges from 13.4 to 194.4 kW produced.
Module operation is cascaded by means of 0/10 Vdc signal and/
or ON/OFF signal taken to the single module.
NOTES:
* Symbol of conformity with Reg.EU/2281/2016.
(1) Max. condensation produced acquired from testing at 30%Qn.
(2) Value referred to cat. H (G20).
(6) If the burner housing heater kit is installed, add 105 W (230V) per module to the rated power value on the nameplate.
APEN GROUP SPA reserves the right to make changes deemed to be required to its products or documentation
PCH condensing warm air heater module
8
code HG0131.05GB ed.A-2010 PCH 9code HG0131.05GB ed.A-2010
PCH
Model
Capacity Other elements Power
consumption
Rated heating capacity
Minimum capacity
heating capacity
-
mum capacity
Casing loss factor
Ignition burner consump-
tion
Emissions of nitrogen
oxides
Seasonal space heating
At rated heating capacity
At minimum capacity
In stand-by mode
Prated,h Pmin ƞnom ƞpl Fenv Pign NOxƞs,ow ƞs,h elmax elmin elsb
kW kW % % % kW
mg/
kWh
ref.
GCV
% % kW kW kW
PCH020 19.0 4.8 86.2 94.3 0.0 0.0 26 97.5 90.5 0.045 0.011 0.005
PCH034 34.9 7.6 86.8 96.4 0.0 0.0 43 97.3 92.1 0.074 0.011 0.005
PCH045 42.0 8.5 86.8 95.1 0.0 0.0 32 97 90.8 0.082 0.024 0.005
PCH065 65.0 12.4 87.2 97.4 0.0 0.0 41 97.4 93.2 0.097 0.015 0.005
PCH080 82.0 16.4 87.9 97.6 0.0 0.0 28 97.1 93.2 0.123 0.02 0.005
PCH105 100.0 21.0 87.5 97.7 0.0 0.0 36 97.0 93.1 0.13 0.02 0.005
PCH130
PCH132 130.0 12.4 87.2 97.4 0.0 0.0 41 98.1 93.8 0.194 0.015 0.01
PCH160
PCH162 164.0 16.4 87.2 97.4 0.0 0.0 28 97.9 94.0 0.246 0.02 0.01
PCH210
PCH212 200.0 21.0 87.5 97.7 0.0 0.0 36 97.9 93.9 0.26 0.02 0.01
PCH320 300.0 21.0 87.5 97.7 0.0 0.0 36 98.1 94.2 0.39 0.02 0.015
PCH420 400.0 21.0 87.5 97.7 0.0 0.0 36 98.3 94.3 0.52 0.02 0.02
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]: No
Warm air heaters C2 [yes/no]: No
Warm air heaters C2 [yes/no]: No
Type of fuel
[gaseous/liquid/electricity]: Gaseous
PCH condensing warm air heater module
APEN GROUP SPA reserves the right to make changes deemed to be required to its products or documentation
10
code HG0131.05GB ed.A-2010 PCH 11 code HG0131.05GB ed.A-2010
PCH
HG0106 C2 034
HG0131.00 A 001
ID2-IDC2
HG105 C2 001
The ignition program turns the burner on at an intermediate
heat output, which corresponds to approx. 30% of the maximum
few seconds, the burner starts modulating its output reaching
the maximum value, if requested, in a variable time set in the
modulation PCB program.
During the operation, the modulation PCB will adjust the heat
output of the burner proportionally to the voltage value (0-10
Vdc) present at the terminals. In case of multiple modules the
modules in cascading operation.
The voltage value will have to be sent via an external regulator
that is not supplied in the standard version by APEN GROUP.
Burner switch-o
Once the heat request is over, voltage signal lower than set limit
(0.5 Vdc, Parameter H52), the modulation PCB will turn the burner
after the wash, for a set time [F]. The opening of the ID2/IDC2
contact (indicated in the terminal board M1 at contacts 7 and 8)
always causes the stop of the burner without generating any fault.
but with fault signal (F21). This contact is supplied with jumper.
4. OPERATING CYCLE
Burner operation
On heat request, from the 0/10 Vdc signal to the terminals B1/
GND of the CN06 terminal board, the modulation PCB starts
(TER) [A] activation.
Other prerequisites to start the cycle are: terminals ID2/IDC2 of
terminal board CN08 closed and terminals ID1/IDC1 of terminal
board CN02 with jumpers.
----------------------------------------------------------------------------------
NOTE: The indicated terminals refer to the single PCB. On
the interface terminal board M1 the correspondences are:
1=D+, 2=D-, 3=GND, 4=B1, 5=COM; 6=NO, 7=IDC2, 8=ID2.
----------------------------------------------------------------------------------
The equipment will immediately start the burner [A] fan pre-wash-
ing the combustion chamber for a set time. After the pre-wash,
the ignition phase will begin: the equipment opens the solenoid
valve EV1 and in parallel the solenoid valve EVP that supplies
the pilot burner [B].
gas valve EV2 [C] supplying the main burner.
After the operation overlapping time of the two burners (pilot and
Flame detection is carried out by a single electrode for both the
pilot burner and the main burner.
Cooling fans
For the devices that require the control of the cooling fans,
their activation is managed with a timer via the APEN GROUP
modulation PCB.
The default time is 1 second and can be edited, through the
LCD display of the CPU PCB on the machine, from 1 to 255
seconds (parameter D3).
When the heat request is over, low 0-10 Vdc signal or contact
cooling fans, if managed, will continue operating for a set time
(D4), editable through the LCD display of the CPU PCB on the
machine, enough to cool the exchanger down.
EVP
EV1 and EV2 Gas valve
Pilot burner
Detection
electrode
Ignition
electrode
Burner unit
APEN GROUP SPA reserves the right to make changes deemed to be required to its products or documentation
PCH condensing warm air heater module
10
code HG0131.05GB ed.A-2010 PCH 11 code HG0131.05GB ed.A-2010
PCH
Pressione (Portata) gas
HG0106 EG 004 IT_ed.0507
HG106 C2 034_bis
HG106 EG004
Safety thermostats
A safety thermostat with automatic reset and positive safety
setting is installed on the heater module; the breakage of the
sensitive element corresponds to a safety intervention.
The lockout of the equipment, caused by the safety thermostat
triggering, is indicated on the LCD display of the CPU PCB on
the machine with F20.
reset.
Near the safety thermostat, there is an NTC1 probe set to the
value of the ST1 parameter, which reduces the burner's heat
output when the set point is reached, regardless of the 0/10
Vdc input signal. The probe monitors the heat output/cooling
It is not advisable to change the ST1 value without consulting
the APEN GROUP Service Centre.
-----------------------------------------------------------------------------------
NOTE: In the devices where the cooling fan management
is carried out separately, it is necessary to comply with the
time setting indicated in the following paragraphs.
----------------------------------------------------------------------------------
Start-up
The fan can be started together with burner [G] or it can be
delayed for maximum 60 seconds [H], to prevent cold air from
entering the room. If a fan electrical protection control and/or a
burner ON enabling and to ID2/IDC2 contacts of terminal board
CN08 (indicated in the terminal board M1 at contacts 7 and 8).
Switch-o
At the end of the heat request the cooling ventilation must
be kept for a time above three minutes [L]; this is to allow the
correct cooling of the heat exchanger. Failure to perform the
post-cooling operations on the exchanger will cause:
• a shorter lifetime of the exchanger and the guarantee will
be null and void;
• the safety thermostat to trigger and the relevant manual
reset.
If, during the cooling cycle, there is a new demand for heat, the
modulation PCB will wait for the cooling fans to shut down and
then reset the counters and start a new cycle.
Parameter d6 of the modulation PCB, which can be programmed
from 0 to 256 seconds, controls the minimum interval between
----------------------------------------------------------------------------------
IMPORTANT: Powering o the unit before completing the
cooling cycle and with machine set to ON is strictly prohib-
ited. Failure to follow these instructions shall invalidate the
warranty and cause early deterioration of the heat exchanger.
------------------------------------------------------------------------------------
Lockouts Fxx
of lockout. This ensures accurate diagnostics.
Codes and possible causes of lockouts are listed later in the
manual.
For the more serious lockouts, where necessary, proceed with
the manual reset, which can be performed via the LCD display
of the CPU PCB on the machine by pressing the arrows at the
same time.
4.1. Air/gas premixing operation
The PCH heater is equipped with a burner with complete air/gas
premixing. Air is mixed with gas inside the motor-fan impeller.
The air suctioned by the impeller will run though the calibrated
Venturi pipe creating a vacuum. The vacuum in the Venturi is
balanced by the gas valve, which is of the pneumatic control type.
The air pressure - gas pressure ratio of the valve is 1:1. This
adjusted and screw sealed.
A second adjustment is provided by the screw placed on the
determines the carbon dioxide level (CO2
is also a default setting. The screw is not sealed to allow the
CO2see the chapter dedicated to the service.
rotation speed (in cc) according to the heat output requested by
the environment. By changing the rotation speed of the motor,
-
mum and maximum rotation values of the fan are programmed
on the PCB and cannot be edited by the user and/or installer.
PCH condensing warm air heater module
APEN GROUP SPA reserves the right to make changes deemed to be required to its products or documentation
12
code HG0131.05GB ed.A-2010 PCH 13 code HG0131.05GB ed.A-2010
PCH
5. USER'S INSTRUCTIONS
Please read the safety warnings described in the previous
pages. The operations that the user must carry out are
limited to the use of the controls placed on the LCD display
of the CPU PCB on the machine.
5.1. Operation of the heater
handling unit, and its management is demanded to the control
The user will have to follow what stated in the manual of the
The instructions that follow are intended for the PCH operator.
Heater operation is fully automatic; it is equipped with electronic
equipment with self-check function that manages all the burner
control and monitoring operations and with a microproces-
sor-based electronic PCB which, together with the LCD display
of the CPU microprocessor PCB on the machine, controls the
heat output regulation.
The ignition request is carried out by adjusting the machine in
5.2. Interface Panel
panel located inside the burner housing, and is used to con-
equipment.
the user to display the heater operating mode and its Faults.
It also allows the service centre to change the main operating
parameters.
Changing parameters requires a password.
Viewing the machine status
The machine status is shown on the display by the following
wordings:
rdy
for the ON control and/or the heat demand from the
thermostat;
On
phase;
OFF
Any heat demands will be ignored.
To light the burner, the LCD must show the wording
"heater ON";
Fxx Fault detected.
During normal operation, the display will show the wording On
if the burner is on; rdy
the room temperature has been reached.
Air EST operation HAS been selected by mistake
under the FUN menu; set FUN to ON or OFF;
Axx PCH module address;
If the module has an address other than Ø, the display
will show, alternating it with the operation in progress,
the address assigned to the module.
In the event of communication problems between CPU-SMART
PCB and LCD panel, the word CPU
displayed if the problem is caused by the display PCB. If needs
be, check that the display and the PCB are correctly connected
and that the small cable RJ11 is securely held in the connector.
Navigating the menu
a password, the second and third require entering second and
third level passwords to change the parameters.
If the PCH PCB is connected to a Smart Web or Easy, and
The service centre requiring to work on such parameters must
enter the relevant level password.
arrow). Press ENTER to select the menu, and again to select the
the change by pressing ENTER.
To exit the parameter or menu, press ESC. If you exit the pro-
gramming function, after about 10 minutes the program will exit
the menu and go back to the "machine status" display.
reduces it by 1. When the arrow keys are pressed for at least
three seconds, the parameter scrolling speed is increased.
seconds. A change in the parameter is indicate by the display
All submenus can be scrolled from the bottom to the top, and
they start over when the end of the menu is reached.
Entering the password
•
hold down the ENTER key for 3 seconds;
•
ENTER; hold it down for approximately 3 seconds (the
stored);
•
to the initial screen (ON/OFF/rdy/FXX); press ENTER for
3 seconds;
•
(Flt, I/O, SET, PAR);
• Press ENTER to access the function;
•
displayed and edited;
• Press ENTER to display the parameter value;
•
and PAR);
•
• To exit the parameter and the menu, press ESC until the
initial screen is displayed (ON/OFF/rdy/FXX).
APEN GROUP SPA reserves the right to make changes deemed to be required to its products or documentation
PCH condensing warm air heater module
12
code HG0131.05GB ed.A-2010 PCH 13 code HG0131.05GB ed.A-2010
PCH
First level menus
Machine
status
provides information about PCH operation (e.g.
rdy, ON, etc.);
FUn from FUN it is possible to select ON, OFF or EST
operation (do not select EST);
rEg this menu allows the user to force the burner to
the minimum or the maximum for combustion
tests; it returns to automatic mode at the end of
the preset time (10 minutes);
tin allows the user to read the value of the 0/10 Vdc
signal to the PCH input;
PrA not used;
Abi used to enter the PWD to access and modify the
second and third level menus.
FRC not used;
Prt it provides indications on the heat input in kW
Con it provides indications on gas consumption in m3/h
Setpoint Menu
For the meaning and the default values please refer to the
table CPU-SMART PCB PARAMETERS of Paragraph 4.4
"Modulation PCB Parameters".
H51 Select the 0/10 Vdc adjustment operation;
H52 IS the OFF value on the 0/10 Vdc signal;
H53 IS the ON value on the 0/10 Vdc signal;
ST1 Delivery air modulation temperature;
ST2 Not used;
H43 Not used;
H44 Not used;
H45 Not used;
ST5 Not used;
ST6 Not used;
I/O menu - Inputs outputs
From I/O menu it is possible to display the values measured
by the sensors.
NTC1 Air delivery temperature;
NTC2 Not used;
NTC3 Not used;
An1 0/10 V input voltage display;
PRH Not used;
FLH Not used;
rPu no. of FAN revolutions;
PU2 Not used;
uSA Not used;
IOn Measures the ionization current; 0 to 100 for currents
0 to 2 microAmperes, 100 above 2 microAmperes.
Enter the second password to access the third level and, besides
the previous menus, it is also possible to view the PAR and FLT
menus. The technical service centres will need this password
which must be requested to Apen Group.
PAR menu - Parameters
The Par submenu allows the access to "b" and "d" parameters:
from b1 to b17 burner parameters;
from d0 to d10
For the meaning and the default values, please refer to the table
In Paragraph 5.4 “Modulation PCB parameters”.
Besides "b" and "d" parameters, the following parameters can
be changed:
S1 Modulation probe enabling;
SP1 ST1 hysteresis (only if the probe is used as temperature
limit);
tH1 Maximum temperature of the modulation probe, switch-
from S2 Not used.
to H41
Flt Menu (Fault)
It displays the fault event log; use the arrow keys to scroll the
list of error codes and press ENTER to display the historical
value of the selected fault.
operation must not be performed by the user but by the service
centre. The reset operation can be carried out by changing the
parameter d7
ENTER for at least 3 seconds. After the reset, d7 returns to 0.
The list and meanings of all faults are shown in the FAULT table
in Paragraph 4.5 "Analysis of Lockouts - Faults".
5.3. Reset
The modulation PCB allows the operator to identify more than
manage each event very accurately.
To reset the lockouts, press both arrows simultaneously for a
few seconds.
Lockouts may be remotely controlled by using:
• the digital input ID4-IDC4 - button N.O.;
• the Smart Web/Easy control - optional;
• the ModBus protocol, if implemented by the manufacturer
of the machine containing the PCH module.
four times. After four failed attempts, it will lock out and will
display the code F10.
The lockout codes and their cause are shown in the FAULT table
in Paragraph 4.5 “Analysis of Lockouts - Faults".
F10 to F20), it can be reset by using the button on the equip-
ment itself. This lockout is shown by a LED that lights up on
the equipment.
----------------------------------------------------------------------------------
ATTENTION: The ame monitoring equipment memorises
the number of manual resets that are performed during its
lifetime. In case of ve resets performed in a period of 15
minutes, without a ame being ignited and detected, the
equipment will go into a "timed" lockout (F13). In this case,
it is required to wait another 15 minutes before resetting
it again.
Press the reset button on the equipment to immediately
reset this lockout condition.
----------------------------------------------------------------------------------
NOTE: SHOULD THE SAFETY THERMOSTAT (STB) BE
OPEN BEFORE STARTING THE START-UP CYCLE (THIS
COULD BE CAUSED, FOR EXAMPLE, BY LOW TEMPER-
ATURES), THE FLAME MONITORING EQUIPMENT WILL
BE KEPT IN "STAND-BY" INDICATING LOCKOUT F22.
----------------------------------------------------------------------------------
PCH condensing warm air heater module
APEN GROUP SPA reserves the right to make changes deemed to be required to its products or documentation
14
code HG0131.05GB ed.A-2010 PCH 15 code HG0131.05GB ed.A-2010
PCH
Parameters of CPU-SMART PCB version 7.03.xx
PARAMETER PCH020 PCH034 PCH045 PCH065 PCH080 PCH105 DESCRIPTION
Control parameters
d0 (2) 5 Flame modulation: 2=NTC1 or 3; 5=0÷10Vdc; 7=Modbus (Smart
Easy/Web in PID mode)
d1 (2) 5 Type of equipment: 0=heater; 2=boiler; 5=PCH; 8=PKA/E;
10=Queen; 12=Fan heater
d2 (2) 1 Remote lockout signal output (Q1): 0=disabled; 1=enabled
d3 (2) sec 5 Fan delay time ON (RL2): 0÷255
d4 (2) sec 180 Fan delay time OFF (RL2): 0÷255 (1=5seconds 60=300 seconds)
d5 (2) 0 Flue gas T control enabling (NTC3): 0=disabled; 1=enabled NOT
USED
d6 (2) sec 5
d7 (2) 0 1= Fault reset counter; 2= Burner hour-meter reset
d8 (2) 0 Boiler antifreeze enabling (NTC1): 0=disabled; 1=enabled NOT
USED
d9 (2) 0 Dampers enabling: 0=disabled; Do Not Change
d10 (2) 0
Continuous ventilation: 0= disabled; 1= enabled (fans always active);
2= enabled with delay par.d3 upon remote heat request - active in
Fault in case of heat request
Burner parameters
b1 (2) rpm 213 210 168 182 172 195 Motor RPM MINIMUM value (PWM1): 90÷999 (1=10 RPM)
b2 (2) rpm 660 710 580 651 655 635 Motor RPM MAXIMUM value (PWM1): 90÷999 (1=10RPM)
b3 (2) rpm 320 300 345 340 355 240 Motor RPM START-UP value (PWM1): 90÷999 (1=10RPM)
b4 (2) 2 HALL signal divider: 2÷3
b5 (2) rpm 50 Error F3x; no. of revolutions x10 (50=500rpm): 0÷300
b6 (2) sec 20 Error F3x; error dwell time before fault F3x: 0÷255
b7 (2) sec 20 Pre-cleaning time with maximum output: 0÷255. DO NOT CHANGE
THE PRESET VALUE.
b8 (2) sec 10 Flame stabilisation time (ignition): 0÷255
b9 (2) sec 90 Combustion chamber post-cleaning time (FAN ON): 0÷255
b10 (2) % 5 Motor rpm % increase for each b11 seconds: 1÷100
b11 (2) sec 1 Time interval for motor rpm increase: 1÷100
b12 (2) % 30 Antifreeze mode FAN motor modulation % value: 30÷100
b13 (2) pwm 65 Integral factor value (ki_pwm) for PWM1 calculation - (exA36):0÷249
b14 (2) pem 45 Proportional factor value (kp_pwm) for PWM1 calculation - (exA37):
0÷249
b15 (2) sec 0
b16 (2) 0
ID5 - Blower fan control: 0=input disabled; 1=enabled with N.C. input
required; 2=enabled with N.O. input required; 3= enabled with N.C.
input required with auto-reset;
b17 (2) 0
ID6 - Blower fan control: 0=input disabled; 1=enabled with N.C. input
required; 2=enabled with N.O. input required; 3= enabled with N.C.
input required with auto-reset;
Limit NTC1 control (with D0=5 or 7)
SEL (2) 1 Probe used for modulation 1=NTC1; 3=NTC3 - DO NOT CHANGE
S1 (2) 1 NTC1 probe enabling: 0=disabled; 1=enabled
5.4. Modulation PCB Parameters
All values of the parameters of the CPU-SMART PCB are shown for all PCH heater models.
(1)001
APEN GROUP SPA reserves the right to make changes deemed to be required to its products or documentation
PCH condensing warm air heater module
14
code HG0131.05GB ed.A-2010 PCH 15 code HG0131.05GB ed.A-2010
PCH
Parameters of CPU-SMART PCB version 7.03.xx
PARAMETER PCH020 PCH034 PCH045 PCH065 PCH080 PCH105 DESCRIPTION
ST1 (1) °C 45 NTC1 setpoint: -10÷140
SP1 (2) °C 5 SP1 hysteresis: 0÷10
XD1 (3) % 16 Proportional band from 4 to 100
TN1 (3) sec 6
AC1 (3) 0 0=only modulation; 1= modulation and ON/OFF
TH1 (2) °C 60 Upper Temperature limit for fault F51 activation: 10÷95 autoreset if
NTC1<TH1-15°C
S3 (2) 0 NTC3 probe enabling: 0=disabled; 1=enabled DO NOT CHANGE
TH3 (2) °C 95 Upper temperature limit for F53 fault activation (auto-reset if
NTC3<TH3): 0÷140
Control 0/10 Vdc - D0=5
H51 (1) 1 Active only with D0=5 (0/10V) 0=modulation only; 1=modulation and
ON/OFF
H52 (1) V 0.5
1Module = 0.5; 2Modules = 1.5; 3Modules = 2.5; 4Modules = 3.5.
H53 (1) V 0.5 Voltage Delta with burner ignition ON
1Module = 0.5; 2Modules = 1.0; 3Modules = 1.5; 4Modules = 1.5.
H54 (3) sec 10 Lower input dwell time: 0÷255
H55 (3) sec 10 Upper input dwell time: 0÷255
Circulator output control - NOT USED ON PCH
H11 (2) 0
0=output disabled;
1=analogue output Y1 enabled (PWM);
2=analogue output Y2 enabled (0÷10Vdc);
3=outputs Y1 (PWM) and Y2 (0÷10Vdc) enabled;
4=outputs Y1 (PWM) and Y2 (0÷10Vdc) enabled for pressostatic
structures;
5=analogue output Y2 (0÷10Vdc) enabled for operating mode
d1=10/12;
6=Y1 (PWM) and Y2 (0÷10Vdc) outputs enabled for boiler summer
ventilation with EC fan heater;
H12 (3) V 4 Y2 output minimum voltage: 0÷10
H13 (3) V 10 Y2 output maximum voltage: 0÷10
H14 (3) % 80 PWM2 minimum value: 0÷100
H15 (3) % 100 PWM2 maximum value: 0÷100
H16 (3) 2
0, 1=not used;
2=modulation of the blower proportional to FAN (do not change);
3=modulation of the blower proportional to input B1 (0-10V);
4 proportional to B2 input for pressure check in pressostatic
structures;
5= proportional NTC1 for checking Queen fans/Fan heaters (only
output Y2).
H17 (3) 1
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" output and 0/10V (Y2) "direct” output;
3= PWM (Y1) "direct" output and 0/10V (Y2) "reverse” output;
H18 (1) 8 Y2 output voltage in summer ventilation;
H19 (3) 32 Reading of NTC1 to which the minimum value of Y2 output
corresponds - NOT USED
H20 (3) 65 Reading of NTC1 to which the maximum value of Y2 output
corresponds - NOT USED
NTC2 control - USED ON PCH WITH OPTIONAL PROBE
S2 (2) 0 0=NTC2 disabled; 1=NTC2 enabled; 2=blower output activation for
compartment heating function (only with d1=5)
PCH condensing warm air heater module
APEN GROUP SPA reserves the right to make changes deemed to be required to its products or documentation
16
code HG0131.05GB ed.A-2010 PCH 17 code HG0131.05GB ed.A-2010
PCH
Parameters of CPU-SMART PCB version 7.03.xx
PARAMETER PCH020 PCH034 PCH045 PCH065 PCH080 PCH105 DESCRIPTION
ST2 (1) °C 0 NTC2 setpoint: -10÷90
P2 (2) °C 1 ST2 hysteresis: 0÷40
XD2 (3) 40 Neutral area, proportional modulation band divided by 100: 4 ÷100
TN2 (3) sec 5 Integration time: 1÷255
ANTIFREEZE control - active with D8=1 - NOT USED ON PCH
STA (3) °C 2.0 Antifreeze setpoint: -10÷+20
PA (3) °C 1.0 Antifreeze setpoint hysteresis: 0÷10
FLUE GAS TEMPERATURE control - active with D5=1 - NOT USED ON PCH
H41 (2) °C 5 Flue gas temperature (NTC3); neutral band from 1÷50
H42 (3) sec 5
H43 (1) °C 95 Flue gas temperature at maximum capacity (Tmax with PT%=100):
0÷140
H44 (1) °C 85 Flue gas temperature at medium capacity (Tmed with PT%=50):
0÷140
H45 (1) °C 75 Flue gas temperature at minimum capacity (Tmin with PT%=0):
0÷140
H46 (3) 0 Flue gas temperature operation: 0=modulation only - 1=burner OFF
PRESSURE control - NOT USED ON PCH
S5 (2) 0
Pressure probe B2 output enabling:
0=disabled;
1=enabled as ON/OFF input;
2=enabled as analogue input without F83 fault auto-reset;
3=enabled as analogue input with F83 fault auto-reset;
4=enabled as air pressure control analogue input without F80 auto-
reset;
5=enabled as air pressure control analogue input with F80 fault auto-
reset;
6=enabled in read-only mode (no Fault) for pressure control via
Modbus;
ST5 (1) bar 0.70 B2 setpoint: 0÷9.99
P5 (2) bar 0.30 ST5 hysteresis: 0÷9.99
XA5 (3) V 1.18 B2 pressure probe signal input minimum voltage: 0÷9.99
XB5 (3) V 2.72 B2 pressure probe signal input maximum voltage: 0÷9.99
YA5 (3) bar 0.10 Pressure matching the B2 probe input minimum voltage
YB5 (3) bar 2.90 Pressure matching the B2 probe input maximum voltage
TH5 (3) V 2.50 Upper pressure limit for fault F82 activation: 0÷9.99
Hydraulic circuit WATER FLOW control - NOT USED ON PCH
S6 (2) 0
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
4=enabled as pulsed input with F85 and F86 fault autoreset
ST6 (1) From
l/h 56 Flowmeter setpoint - in l/h (x10)
P6 (2) 5 ST6 hysteresis: - in l/h (x10)
XA6 (3) Hz 14 B3 pressure probe signal input minimum frequency: 0÷999
XB6 (3) Hz 229 B3 pressure probe signal input maximum frequency: 0÷999
YA6 (3) l/h 29 Flow rate matching the B3 probe inlet minimum frequency
YB6 (3) l/h 500 Flow rate matching the B3 probe inlet maximum frequency
TR6 (3) sec 2 Fault F85/F86 indication time delay (1=1second): 0÷250. During the
ignition stage, the b15 value is used.
APEN GROUP SPA reserves the right to make changes deemed to be required to its products or documentation
PCH condensing warm air heater module
16
code HG0131.05GB ed.A-2010 PCH 17 code HG0131.05GB ed.A-2010
PCH
Parameters of CPU-SMART PCB version 7.03.xx
PARAMETER PCH020 PCH034 PCH045 PCH065 PCH080 PCH105 DESCRIPTION
PRESSURE control - PID parameters for ventilation of Pressostatic structures - NOT USED ON PCH
kp % (3) 25 Proportional Gain
ki % (3) 5 Integral Gain
kd % (3) 10 Derivative Gain
li % (3) 100 Maximum limit of integral part
Heat input and fuel instantaneous consumption calculation parameters
Qmin kW (3) 4.8 7.6 8.5 12.4 16.4 (1) 21 (1)
Qmax kW (3) 19 34.85 42 65 (2) 82 (1) (4) 99.9
(1) (3)
LCV kW/
m3
see table of "Gas-type parameters” here
below
NOTES:
(1) Models PCH105 and PCH080 MBQ are not approved for operation with gas G2.350 (Poland)
(2) Set 57 (kW) for operation with gas G2.350 or G27 (Poland)
(3) Set 94 (kW) for operation with gas G25.1 (Hungary) or G27 (Poland)
(4) Set 75 (kW) for operation with gas G27 (Poland)
Table of "Gas-type parameters"
PARAMETER G20 G25 G25.3 G25.1 G27 G2.350 G30 G31 DESCRIPTION
LCV (3) kW/m39.45 8.13 8.31 8.14 7.75 6.75 12.4
PCH condensing warm air heater module
APEN GROUP SPA reserves the right to make changes deemed to be required to its products or documentation
18
code HG0131.05GB ed.A-2010 PCH 19 code HG0131.05GB ed.A-2010
PCH
FAULT DESCRIPTION CAUSE UNLOCK
F10
performed by the equipment.
• No gas
• Live and neutral reversed
• Earth wire not connected
• Phase-phase connection without neutral
• Start-up electrode failed or badly positioned
• Detection electrode failed or badly positioned
• Detection electrode that moves or disperses to the
earthing system when hot
• Condensation detection electrode defective or
earthed
• Gas supply pressure too high (>60mbar)
Manual reset
F11
F12
Ignition failure; not visible.
The count, displayed in the history,
indicates whether the heater has had
problems with ignition.
Auto-reset
F13 The TER equipment does not accept
the reset command from CPU-SMART
•
of 15 minutes.
Wait for 15 minutes
or use the equip-
ment reset device
F14
Lack of communication between TER
equipment and CPU for more than 60
seconds
• TER equipment or CPU-SMART PCB broken
• Connections on the STB thermostat to earth
• Capillary of the STB thermostat that discharges on
the earth faston of the thermostat body
Auto-reset
F15
The CPU-SMARTPCB sent the ignition
signal to the TER equipment which, after
300 seconds and with no lockout, has
not communicated its correct operation
status.
• Poor gas mains pressure
• Low CO2value
• Faulty TER equipment
Manual reset, au-
to-reset after 5 min-
utes
F16 Generic equipment lockout
• It indicates that if the heat request has remained
active for more than 24 consecutive hours, the
TER equipment has performed a control cycle
switching temporarily to stand-by mode
Manual reset, au-
to-reset after 5 min-
utes
F17
Internal malfunction of TER equipment
that does not accept reset command
from CPU-SMART
• Faulty TER equipment
Manual reset, au-
to-reset after 5 min-
utes
Lockouts caused by temperature (safety lockouts)
F20 Activation of safety thermostat STB • Excess air temperature due to lack of air circulation
• Safety thermostat broken or not connected Manual reset
F21 (NOT USED - Jumped)
Input ID1 open • ID1 - IDC1 jumper missing Manual reset
F22 Opening of safety thermostat STB or
• Frost or temperature below -20°C
•
or not connected
Auto-reset
F35 Input ID5 open (NOT used) • ID5 - IDC5 jumper missing
F38 DDMP fan fault - ID6 input (NOTUSED) • DDMP fan fault
FAN lockout - burner fan
F30 Fan speed too low in start up phase
- VAG
• Burner fan broken.
• FAN electric cables interrupted, not connected or
wrongly connected
Manual reset
F31 Fan speed too high in start up phase
- VAG
F32
Fan speed, during operation, outside
minimum and maximum set parame-
ters - VAG
Manual reset, au-
to-reset after 5 min-
utes
NTC probes broken or missing
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; others reset themselves when the problem that caused them is solved.
Below is a complete list of faults, possible causes and possible solutions.
APEN GROUP SPA reserves the right to make changes deemed to be required to its products or documentation
PCH condensing warm air heater module
18
code HG0131.05GB ed.A-2010 PCH 19 code HG0131.05GB ed.A-2010
PCH
FAULT DESCRIPTION CAUSE UNLOCK
F41 Probe NTC1 error, air intake temper-
ature No signal from probe or broken probe Auto-reset
F43
Over-temperature
F51 The temperature of the air intake probe
NTC1>TH1
• Check the TH1 parameter - air intake set point.
• Cooling fan(s) inoperative
•
Autoreset when
if NTC1< TH1-15
F53 NTC3 > TH3 (NOT USED)
•
setpoint.
• Cooling fan(s) inoperative
•
Auto-reset
when
NTC3< TH3
Check ModBus communication
F60
Communication error between CPU-
SMART PCB and ModBus, Smart Web
or SMART Easy network
• ModBus network is disconnected.
• The address of the PCB is wrong and/or not con-
Auto-reset
No voltage
F75
No voltage during operation cycle (ex-
cluding stand-by);
the fault is not visible on remote control
but only counted.
• No voltage during operation Auto-reset
F80 - F82 (NOT USED)
F80 Pressure gauge error • Pressure gauge at fault or not connected
• Input signal at B2 is < 0.2 Vdc Auto-reset
F81 Pressure less than B2 setpoint • Input signal at B2 is < ST5 setpoint Auto resolve
F82 Higher pressure at B2 setpoint • Input signal at B2 is < ST5 setpoint + TH5 Auto resolve
F99 CPU parameter programming error
• S1=0 with SEL=1 and D0=2
• S3=0 with SEL=3 and D0=2
•
• D10=1 with D8=1
Auto resolve
Internal malfunction of CPU-SMART PCB
F00 Internal malfunction of CPU-SMART
PCB
• One or more parameters of the CPU PCB have a
value outside of the expected range.
Perform a manual
reset of the PCB
by interrupting the
power supply
CPU CPU-SMARTPCB communication error • RJ11 cable disconnected or faulty Auto resolve
... CPU-SMARTPCB communication error • RJ11 cable disconnected or faulty Auto resolve
In the event of communication problems between CPU-SMART
PCB and LCD panel, the word CPU
displayed if the problem is caused by the display PCB. If needs
be, check that the display and the PCB are correctly connected
and that the small cable RJ11 is securely held in the connector.
----------------------------------------------------------------------------------
NOTE: Axx is not a Fault indication, but corresponds to the
machine address, see Paragraph 5.2.
----------------------------------------------------------------------------------
PCH condensing warm air heater module
APEN GROUP SPA reserves the right to make changes deemed to be required to its products or documentation
20
code HG0131.05GB ed.A-2010 PCH 21 code HG0131.05GB ed.A-2010
PCH
HG0130.00 A 025b HG0130.00 A 029b
PCHXX0-0FV0
HG0130.00 A 061
PCHXX0-0F00
HG0130.00 A 060
5.6. Connections to the Flue
circuit and with the burner fan located upstream of the heat
exchanger.
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.
If the heater is installed outdoor, a "B" type installation is also
a "C" type.
types, please refer to current regulations.
----------------------------------------------------------------------------------
NOTE: A "C" type exhaust is compulsory for PCH heaters
tted inside an Air Handling or Roof Top unit installed indoor.
----------------------------------------------------------------------------------
into account that for PCH condensate modules the following
materials must be used:
- aluminium with a thickness of at least 1.5 mm;
- stainless steel with a thickness of at least 0.6 mm; the steel
must have a carbon content equal to or lower than 0.2 %.
Sealed pipes must be used to prevent condensate from leaking
temperature ranging between 25°C and 120°C.
For the air intake, use:
- aluminium with a thickness of at least 1.0 mm;
- stainless steel with a thickness of at least 0.4 mm.
----------------------------------------------------------------------------------
IMPORTANT: The horizontal sections of ue must be in-
stalled with a slightly incline (1°- 3°) towards the heater, in
order to prevent the build up of condensation in the exhaust.
----------------------------------------------------------------------------------
Common exhausts
Where possible, it is always preferable to use independent
exhausts; PCH module exhausts are pressurised, therefore in
this way it is possible to prevent incorrect sizing from causing
a system malfunction.
-
venting a module from discharging its own combustion gases
inside another module.
Apen Group can provide common exhausts for the "B-System"
plastic non-return valve, it is necessary to request the version
-
perature control by thermostat and temperature sensor.
Flue gas data
with commercially available pipes can be found in paragraph
5.8 "GAS connection" within the Gas regulation data.
The maximum permitted recirculation percentage is 10%.
This manual suits for next models
18
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