REMKO GPS Series User manual

Operating and
installation instructions
Edition EN - Q07 Read the instructions prior to performing any task!
GPS 15, GPS 25, GPS 35, GPS 55, GPS 75
REMKO GPS series
Wall heater with 2-stage gas burner

3
Contents
Safety notes 4
Unit installation 5
Unit description 6-11
Intended use 12
Customer service and guarantee 12
Environmental protection and recycling 12
Installation 13-16
Flue gas connection 17-21
Electrical wiring 22-24
Electrical wiring diagram 25
Gas connection 26
Commissioning 27-28
Maintenance 29-30
Replacement of the control board 30
Replacement of the STB 31
Chimney sweep 31
Replacement of the gas valve 30
Conversion to liquid gas 32
Troubleshooting 34-35
Unit dimensions 36
Exploded view of the unit 35739
Spare parts list 40
Country table of gas types 41
Technical data 42-43
Carefully read this operating manual prior to commissioning /using
the unit!
This operating manual is a translation of the German original.
These instructions are an integral part of the unit and must always be
kept in the vicinity of the installation location or on the unit itself.
Subject to modifications; no liability accepted for errors or misprints!

4
REMKO GPS series
Safety notes
The units have been subjected to extensive material,
functional and quality inspections prior to delivery.
However, dangers can arise from the units if they
are used improperly or not as intended by untrained
personnel!
Please observe the following notes:
■ The units may only be operated by persons
that have been instructed in their operation
■ In case of defects that endanger the operational
safety of the units, operation must be discontinued
■ The units must be installed and operated
so that the emerging flow of warm air does
not have harmful effects on either the units or
the surroundings
■ Do not expose the units to atmospheric influences
(rain, sun, etc.)
■ Do not touch the units with damp or wet body
parts, e.g. hands
■ Protect the units from spray water or other liquids
■ Do not use gas lines for the grounding of electrical
devices
■ Do not touch hot parts of the units, such as the flue
gas pipe
■ Do not touch moving parts of the units
■ Never stick foreign objects into the units
■ The units may only be mounted on stable structures
or ceilings made of non-flammable construction
materials and with sufficient bearing capacity
■ The mounting of the units may only be
executed at the points provided for this purpose
in the factory
■ The units may not be installed or operated in
potentially flammable or explosive environments
Always observe the respective local building
code and fire prevention guidelines as well as
the guidelines of the accident prevention and
insurance associations when using the units.
■ The units must be installed away from traffic
zones - by crane, for example. A safety zone with
a clearance of 1 m must be ensured
■ The protective grid of the intake must always be
kept free of dirt and loose objects
■ The units may not be exposed to direct jets of
water
■ The units must be inspected by a service technician
at least once yearly
■ Safety devices must not be bypassed or disabled!
■ Prior to maintenance or repair work, the gas
supply must be sealed off and the unit must
be disconnected from the mains at all poles.
(Remove fuse and switch off customer-provided
main/emergency shut-off switch)
Preventative measures
with odour of gas
1. Immediately switch off the unit.
2. Close the gas shut-off device(s).
3. Warn all directly endangered persons.
4. Open windows and doors.
5. Do not actuate electrical equipment such as light
switches or electrical plug-in contacts.
6. If the room in which the gas odour has emerged
cannot be entered, immediately contact the fire
brigade, police and the local responsible municipal
gas supplier.
CAUTION
Assembly, adjustment and maintenance work may
only be carried out by authorised and qualified
technicians.
CAUTION
Safety devices may not be bypassed or disabled
during operation.
NOTE
The units are used exclusively for industrial and
commercial applications. They are not intended
for the heating of living spaces or the like.

5
Selection of the installation location
With determination of the installation location,
the requirements must be coordinated in regard to:
■ Fire protection and operational hazard
■ Function: Space heating, underpressure and/or
overpressure in the installation space, etc.
■ Operational concerns, heat requirement, nominal
air flow rate, air recirculation requirement,
humidity, room temperature, air distribution, spatial
requirements
■ Installation, repair and maintenance possibilities.
The units must be installed in such a way that they
are always easily accessible for maintenance and
repair work.
With improper installation and operation, hazards
may arise from the units. Prior to the planning and
during the unit installation, the following points must
absolutely be observed.
■ The units must be installed and operated in such a
way that personnel are not endangered by flue gas
and radiant heat and no fires may occur
■ During installation of the units it must be ensured
that the flow of warm air does not have damaging
effects on the surroundings
■ Fire hazards must be eliminated through
the selection of materials for the installation
and position surfaces. For this purpose, see TRGI,
Section 5.1.3.3
■ The wall or ceiling intended for installation must
also consist of non-flammable materials. Its load
capacity must be checked; reinforcements must
be installed when necessary
■ Brackets must be securely anchored to the wall
or ceiling and the units must be attached to
the brackets at the points provided for this purpose
in the factory
■ Appropriate maintenance possibilities for heat
exchangers, burners, fan and flue gas evacuation
must be planned for
■ It must be possible to actuate control elements
for the units and fuel supply from the ground.
Maintenance and repair possibilities must be
ensured by the operator
Unit installation
Application area
With the REMKO gas wall heaters from the GPS
range, it is possible to heat small rooms, such
as workshops, right through to large spaces such
as industrial warehouses, sports halls, etc.
For efficient heating it is therefore essential to
determine the necessary heat output by professionally
calculating the heat requirement for the respective
space.
General prerequisites
With the installation of the units, the local and
country-specific provisions and guidelines must
be observed in the respective valid version as a basic
rule.
Work such as the following:
■ gas and electrical installation
■ conversion of the gas type
■ commissioning
■ adjustments or maintenance may only be carried
out by qualified technicians
In addition to a faultless electrical and gas installation,
it is also ensured through this measure that all
necessary measurements and test are conducted.
■ The units must be inspected by an authorised
service technician at least once yearly.
For this purpose, concluding a service contract with
a service company is recommended
■ During planning and installation of the flue gas
routeing, the structural possibilities as well as the
applicable local and country-specific regulations
must be consistently adhered to
■ In heavily soiled environments, care and
maintenance measures must be carried out
in accordance with the respective conditions.
The combustion air must be fed from outside
as a basic rule
CAUTION
The units must not be set up or installed in areas
with explosive or corrosive atmospheres.

6
REMKO GPS series
the cable passages for the electrical lines as well as
the plug connection for the power supply. In the right-
hand side section the necessary components for the
control and safety are found behind the inspection
door, including e.g.:
- the electrical circuitry with the cabling
- the control electronics
- the gas valve
- the modulating gas burner
In the interior of the unit, directly in the circulation air
flow, is the combustion chamber with heat exchanger.
The combustion chamber is manufactured entirely
from Inox stainless steel, AISI 430. For the purpose
of higher resistance to corrosion from damp vapours,
Inox stainless steel, AISI 441 is used for the heat
exchanger.
The special form and the large surface area
of the combustion chamber and heat exchanger
guarantee a high level of efficiency and long service
life.
The gas burner is likewise manufactured entirely from
special, mechanically-processed stainless steel.
Function of the units
The 2-stage gas wall heaters of the GPS series have
been developed for the heating of industrial and
commercial spaces.
The electronic control of the unit regulates the heat
output between minimum and high-output according
to the set NTC1 temperature.
With the pre-mix and modulation technology,
efficiency of up to 94% can be achieved.
The nominal heating capacity of the REMKO GPS
series lies between 13.0 and 73.5 kW.
The units consist primarily of the combustion chamber
with heat exchanger and the fan(s).
The ambient air is suctioned in by the fan(s) and
efficiently channelled through the combustion
chamber with heat exchanger. The combustion
chamber is heated by the gas burner operation and
releases its heat to the air flowing past. The air heated
in this manner is blown out of the front side
of the unit through an adjustable outlet grid.
Operation of the unit as intended is only possible
with a connected temperature controller, e.g. ATR-10
(accessory).
Unit description
Definition of the unit
Pursuant to EU Directives, the unit is defined as:
"Gas fan-assisted heater (WLE) without flow-
operated safety device, equipped with a fan in front
of the heat exchanger".
The unit is a fully-automatic, directly-fired fan-assisted
air heater for wall and ceiling installation.
It can be fuelled with natural gas or liquid gas.
The unit is used for continuous and temporary
heating of open and closed spaces, e.g. in:
halls, workshops,
greenhouses,
storage rooms, etc.
Classification of the units
The units have been classified by the European
standardised
regulations EN 437 and EN 1020 according to:
The gas category:
determination according to the type of gases with
which they may be operated.
For Germany DE II2ELL3B/P
The gas type:
the burner can be operated with gases of the second
family (natural gas - group H and L) and with gases
of the third family (butane and propane).
The type of gas fireplace:
differentiation according to the possibilities
of the discharge of the combustion products
or the supply of the combustion air.
(ambient-air-dependent/independent)
Additional notes can be found in the chapter
"Installation of the flue gas evacuation and
the combustion air supply".
Design of the units
The exterior cladding of the units is made from coated
steel sheet, which guarantees durability.
The outlet grid is found in the front section.
In order to ensure an optimal distribution of warm
air in the installation location, the horizontal fins of
the outlet grid can be manually adjusted. On the rear
side of the unit you will find the fan(s) with protection
grid, the connection nozzles for the removal of
the flue gas and supply of the combustion air, the gas
connection nozzles,

7
Safety thermostat(s) with vertical air flow
A safety thermostat (STB) is installed on the units
for each fan, for manual resetting.
If the safety thermostats are triggered then a safety
shutdown is also triggered.
The thermostat is installed in the area of the heat
exchanger in order to monitor the temperature
at its output.
The disabling of the unit caused by the triggering
of the safety thermostat is displayed by the error
indicator light on the front of the unit.
Air/gas premix
The units are equipped with a burner with complete
air/gas premix.
This mixing process takes place in the fan
of the burner motor. The air suctioned in by
the fan flows through the Ventura tube, where an
underpressure is created, which draws in the gas.
In the process, a constant air/gas mixture is created.
The ratio of air and gas pressure is 1:1.
This value can be changed through the offset
regulating screw found on the gas valve.
The amount of gas is already adjusted upon delivery
of the units and the screw is sealed.
With the adjusting screw located at the Venturi tube,
a fine adjustment can take place, which regulates
the maximum gas flow rate and thus determines
the carbon dioxide (CO2) content of the flue gases
The screw is not sealed in order to enable conversion
of the fan-assisted air heater to another type of gas.
PLEASE NOTE:
For the offset and CO2adjustment.
The control board of the units enables the speed
regulation of the burner motor with DC depending
on the heat output required in the space.
By changing the speed the air flow rate and thus
the gas flow rate are changed.
Minimum and maximum speeds of the fan are
two values that cannot be changed.
Fans
The switching on of the fans is time-controlled
by the control board, whereby the timing begins with
the switching-on of the main burner.
The delayed switch-on prevents cold air from being
blown into the room.
Switching off the unit
If there is no longer a heat requirement (room
temperature above the adjusted setpoint value),
the control board switches off the burner.
The burner fan runs for the secondary ventilation
of the combustion chamber for a fixed, pre-set time.
The fan(s) likewise run afterwards on a time-
controlled basis until the heat exchanger is cooled.
If a new heat requirement should take place during
the follow-up phase, the control board will wait for
the fans to switch off and then proceed with a reset
and begin a new cycle.
CAUTION
Before resetting safety equipment, the cause
of the trigger must be identified and rectified.
NOTE
Safety devices may not be bypassed or disabled
during operation of the unit!
IMPORTANT NOTE!
The interruption of the current supply during burning
operation or in the follow-up cooling phase is not
permitted, because lack of a secondary ventilation
of the heat exchanger can lead to significant damage:
■ Overheating of the unit with the resulting
expiration of the guarantee
■ Damage to the fan of the burner and its
components
■ Tripping of the safety thermostat and the
associated lock-out of the safety thermostat (STB).
Therefore no new unit start without manual
resetting
■ Damage to electrical lines
NOTE
The model with vertical air flow must be specified
at the time of order placement, because the probe
is not installed as standard.

8
REMKO GPS series
Cycle of operation
The units from the GPS range are fully-automatic hot
air heaters, which are equipped with an electronic
device with self-testing. This guarantees a high degree
of reliability and safety.
Burner operation
The burner is ignited when the following
preconditions are fulfilled:
■ The unit is supplied with power and is not in a fault
shut-down state (lock-out)
■ The gas supply valve is open
■ The toggle switch on the control panel is switched
to the “I=Winter” position
■ The thermostat contact is closed
■ The contact between terminal 34 and 35
on the GPS board is closed
Under these conditions, the burner fan starts
immediately. After the pre-flushing process is
complete, the flame is ignited with an ignition
output that is 30 % of the maximum output. After
subsequently waiting for the stabilisation phase to
pass, the burner runs up to maximum output.
If the flame cannot be ignited then 4 further
ignition attempts take place. With the fifth ignition
attempt, the GPS board triggers a fault shut-down.
If the burner ignites, the cooling fan starts up after
30 seconds and conveys the warm air into the room.
In order to switch the hot air heater off, the switch
on the control panel must be set to the “0” position.
It is prohibited to switch off the unit by disconnecting
the power supply. This process must be used
exclusively in emergencies. With an instructed switch-
off of the hot air heater, the burner fan continues
to operate for a further 90 seconds, in order to flush
the burner chamber of flue gases. The cooling fan
runs on for 120 seconds after the switch-off, to
ensure that the heat exchanger “cool down” takes
place. If the cool down process is not completed then
this reduces the service life of the heat exchanger and
therefore also invalidates the guarantee. Furthermore,
the safety thermostat may also be triggered and
necessitate a manual reset.
If, during the cool down phase, a new heating request
is issued then the unit waits until the cooling fan has
switched off, performs a reset and then starts a new
heating cycle.
Efficiency
The advantages of the units lie in the 2-stage mode
of operation, meaning the heat output created and
thus the gas flow (consumption of fuel) are changed
corresponding to the heating stage.
With a reduced heat requirement of the room,
the fan-assisted heater consumes less fuel, whereby
its efficiency is increased by up to 94%.
Intrinsic safety:
The increase in efficiency with minimum output is
achieved through the use of a modern air/gas mixture
technology and the simultaneous flow rate regulation
of combustion air and gas.
This technology increases the safety of the unit,
because the gas valve feeds the fuel depending on
the amount of air in accordance with its factory
settings.
Unlike atmospheric burners, the CO2content
remains the same through the entire operating range
and allows an increase in efficiency with reduction
of the heat output.
With no combustion air, the valve does not release
gas.
With reduction of the combustion air, the gas valve
automatically reduces the amount of gas and keeps
the combustion parameters at an optimal level.
Luft
Abgase
Gas
EV1EV2
EVP
HW080909
Flue gases
Air
Gas

9
Modulation
The gas wall heaters are units with 2-stage gas burner
modulation, whereby outputs between the minimum
and maximum settings are possible during operation.
The highest output serves for raising the room
temperature quickly when switching on the units.
The second stage enables a slower heat-up speed
of the space, which means that the burner is required
to switch on and off less often. Furthermore, the air is
heated less heavily due to the lower heat output,
which limits the physical emergence of layer formation
(tendency of the warm to rise).
These results can only be achieved through a precise
monitoring of the climactic spatial conditions and an
optimal control of the unit.
With the dimensioning of heating systems with
fan-assisted air heaters, it is important to observe
the number of hourly air renewals.
In this regard, please note the following: Gas wall
heaters should, in general, be arranged so that the air
flow rate ensures air recirculation at least twice hourly,
even if this would not be necessary for the heat
output.
Minimal pollutant emissions:
The premix burner provides for "clean" burning with
low pollutant emissions with the air/gas valve.

10
REMKO GPS series
Control panel
The hot air heaters from the GPS series are fitted as
standard with a control panel on the front of the unit.
All unit information or fault indications are displayed
on this control panel.
General notes
Toggle switch
ZSummer / dWinter
Reset key
GREEN LED
RED LED
Safety thermostat
High or low flame
The units are serially equipped with a room
temperature probe NTC1 on the rear side of the unit
so that the intake temperature of the fans is
monitored. The operation of the two stages takes
place depending on the temperature value measured
by the probe compared to the value set inside
the thermostat housing. The thermostat can be
set to the desired temperature value via a screw.
This value should be set a few degrees above
the desired room temperature. If the temperature rises
above the set value then the burner is set at a lower
flame, which reduces the heat output. In this way
the air blown into the room is heated less heavily.
However, the thermostat for controlling the high
or low flame is by no means a replacement for a room
thermostat, which must be installed in all instances.
The optimisation of the temperature value must take
place during operation of the system and depends on
the distance of the fan-assisted air heater to the floor
and the required temperature conditions. The gas wall
heater is normally installed at a distance of 2.5 - 4 m
from the floor.
The GPS unit series is equipped with a safety
thermostat with automatic reset function and positive
safety device as standard. This means that the safety
equipment also triggers with a breakage.
If the thermostat is tripped, the burner is stopped
via the flame monitoring unit and a subsequent
fault shut-down of the flame monitoring unit is
triggered. The thermostat probe is located behind
the top outflow fins, in the centre of the housing.
The fault shut-down is displayed on the control panel
by the red indicator light.
Because this is a safety-relevant error, the fault shut-
down is permanent and requires a manual reset.
The illumination of the green LED means that
the unit is connected to the mains.
The illumination of the red LED indicates
a malfunction of the unit.
Using the malfunction diagnostics, the cause
of the malfunction can be identified by the different
types of flashing signals of the red LED.
Summer/winter toggle switch
Also, a manually-operated toggle switch d/ 0 / Z
is installed on the front of the unit, which enables
switching the unit from winter operation dto summer
mode Z(continuous ventilation).
In the central position [0] all unit functions are
switched off.
Reset key
A manually-actuated reset key is installed on the front
of the unit, which enables the unlocking of the unit
after the malfunctions F1, F2, F5, F6 or F8.
CAUTION
Before resetting safety equipment, the cause
of the trigger must be identified and rectified.