ApenGroup RA035, RA015, RA043, RA054, RA024 User, Installation, And Maintenance Manual

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Page 1

APEN GROUP reserves the right to change products and documents as required.

code HG0109.12GB ed.C-1106 rev.12

WARM AIR HEATER SERIES RAPID

RAPID

Warm Air Heater

ON-OFF

It is forbidden to totally or partially copy or reproduce this document for disclosure to third parties without written consent by Apen Group s.p.a.

User,

Installation,

and

Maintenance Manual

NEW SERIES

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code HG0109.12GB ed.C-1106 rev.12

APEN GROUP reserves the right to change products and documents as required.

WARM AIR HEATER SERIES RAPID

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code HG0109.12GB ed.C-1106 rev.12

WARM AIR HEATER SERIES RAPID

Statement of Compliance

APEN GROUP S.p.A.

20060 Pessano con Bornago (MI) - ITALY Via Isonzo, 1 Ph. +39.02.9596931 Fax +39.02.95742758 Website: http://www.apengroup.com

With this document we declare that the unit:

Model: Suspended Heater RA- RAC

has been designed and manufactured in compliance with the prescriptions of the following EC Directives:

Machinery Directive 2006/42/CE

Gas Appliance Directive 90/396/CEE

Electromagnetic Compatibility Directive 2004/108/CE

Low Voltage Directive 2006/95/CE

If the unit is to be installed into an equipment (combined), the manufacturer disclaims any responsibility if this

equipment is not previously declared compliant with the requirements specied in IIB Enclosure of above said

Machinery Directive.

Pessano con Bornago

Apen Group S.p.A.

The General Manager

CODE

SERIAL NUMBER

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WARM AIR HEATER SERIES RAPID

TABLE OF CONTENTS

SEZIONE 1. GENERAL WARNINGS................................................ 3

SECTION 2. SAFETY WARNINGS ................................................... 3

2.1 Fuel ........................................................................................ 3

2.2 Gas Leaks ............................................................................. 3

2.3 Power Supply .................................................................... 3

2.4 Use ........................................................................................ 4

2.5 Maintenance .......................................................................... 4

2.6 Transport and Handling ......................................................... 4

SECTION 3. TECHNICAL FEATURES ............................................. 5

3.1 Technical Data ....................................................................... 6

3.2 Noise ..................................................................................... 7

3.3 Dimensions ............................................................................ 8

SECTION 4. USER’S INSTRUCTIONS ............................................ 10

4.1 Description of the Heater ....................................................... 10

4.2 Heater Operation ................................................................... 10

4.3 Accessories ........................................................................... 11

SECTION 5. INSTRUCTIONS FOR THE INSTALLER ..................... 12

5.1 General Installation Rules ..................................................... 12

5.2 Installing the Heater ............................................................... 12

5.3 Chimney Piping ..................................................................... 15

5.4 Terminal Layout ..................................................................... 17

5.5 Electrical Wiring ..................................................................... 20

5.6 Gas Supply System ............................................................... 23

SECTION 6. INSTRUCTIONS FOR SERVICE STAFF ..................... 24

6.1 Country Table - Gas Category ............................................... 24

6.2 Gas Setting Data Table .......................................................... 25

6.3 First Startup ........................................................................... 26

6.4 Combustion Analysis ............................................................. 26

6.5 Converting the Unit to LPG .................................................... 26

6.6 Conversion to G25 - G25.1 - G2.350 gas .............................. 27

6.7 Maintenance .......................................................................... 27

6.8 Cleaning the Exchanger ........................................................ 28

6.9 Demolition .............................................................................. 28

SECTION 7. DIAGNOSTICS ............................................................. 29

SECTION 8. WIRE DIAGRAMS ........................................................ 30

SECTION 9. APPROVAL CERTIFICATE .......................................... 32

SECTION 10. SPARE PART LIST ...................................................... 34

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1. GENERAL WARNINGS

This manual is an essential component of the product and must always accompany it. If this equipment is sold or transferred to another owner, ensure that the manual follows it, to enable the new installer/owner to consult it. The manufacturer disclaims any liability (under contract provisions or otherwise) for damage to persons, animals, or objects resulting from wrong installation or misuse, and/or non compliance with the manufacturer’s instructions. This unit is intended only and exclusively for the use for which it has been built. Any different, wrong, or unreasonable use is to be considered improper and therefore dangerous. For installing, running and maintaining the unit, the user shall strictly follow the instructions stated in this manual and shall comply with existing national laws and regulations. Any installation, maintenance or servicing operations shall be performed only by authorized personnel, with technical skills

specic for the heating eld.

First start-up, conversion to another gas type and maintenance

must be exclusively carried out by qualied personnel appointed

by Apen Group authorized Service Centers, in compliance with National laws and regulations.

Installation and maintenance operations shall comply with the laws and regulations existing in the Country where the appliance is installed.

APEN GROUP's business organization can count on a widespread network of approved Technical Support Centers. For information, contact your local Representative or directly the Manufacturer. The unit is covered by a guarantee whose conditions and validity

are specied on the relevant certicate.

The manufacturer declares that the unit is workmanlike built in compliance with UNI, UNI-CIG, and EC technical provisions, and according to the relevant laws and to the Directive on Appliances burning gaseous fuels 90/396/EEC.

European Directives referenced:

- Gas Directive 2009/142/CE.

- Low Voltage Directive 2006/95/EEC.

- Machinery Directive 2006/42/CE

- Electromagnetic Compatibility Directive 2004/108/CE.

2. SAFETY WARNINGS

This section describes the safety rules for operators.

2.1 Fuel

Before starting the heater, check that:

Gas supply specications match those written on the rating plate;

- Combustion air inlet pipes (if installed) and ue discharge pipes are exclusively those specied by the manufacturer

- The grid of combustion air intake system is free from debris, leaves, etc.

- The gas seal of the feeding system has been tested and approved in compliance with the law.

- The heater's fuel is the one specied for the unit

- The unit is correctly sized to match required ow and includes

all safety and control devices required by the law

- Gas pipes and air distribution ducts for ducted heaters have been properly cleaned

- Fuel rate of ow matches heater's rated input.

- Gas feeding pressure matches values on rating plate.

2.2 Gas Leaks

If you smell gas:

- Do not operate electrical switches, the telephone or any other object or device that can cause sparks.

- Immediately open doors and windows to vent the room.

- Close gas valves.

- Call for qualied personnel.

2.3 Power Supply

The heater shall be correctly wired to an efcient grounding

system, complying with existing regulations (CEI 64-8).

WARNING:

- Check the grounding system or have it checked by qualied

personnel, if necessary.

- Make sure network wire gauge suits the unit rated input shown on rating plate and in this Manual.

- Do not mistake neutral and phase wires. The heater can be plugged into mains using a plug-socket only if the latter prevents any mistake between phase and neutral wires.

- The system wire gauge in general, and cable section in particular, must suit the unit rated input shown on equipment rating plate and in this Manual. Do not pull electrical wires and keep them far from heat sources. NB: A multipole switch with fuses and contact opening greater than 3 mm should be installed before the supply cable, in a visible and accessible position and within 3 meters from the control board. Any installation or maintenance operation concerning the electrical system must be accomplished by qualied personnel.

2.4 Use

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HG0030 IM 001

Children and inexperienced people shall not be allowed to use any electrical appliance. The following precautions shall be adopted:

- Do not touch the unit with wet or damp parts of the body and/ or barefoot.

- Do not leave the unit exposed to adverse weather conditions (rain, sunshine, etc.) unless the unit has been expressly designed to.

- Do not use gas pipes to ground electrical devices.

- Do not touch hot surfaces of the heater, such as ue pipes.

- Do not wet the unit either with water or other liquids.

- Do not put any objects on the unit.

- Do not touch moving parts of the heater while it is working.

2.5 Maintenance

Before running any servicing or cleaning, disconnect power and gas supply by means of main ON/OFF switch and/or appropriate detection devices.

In case of failure and/or insufcient running standards, switch

off the heater and do not attempt to repair it directly. Contact the authorized Service Centre. Use only original spare parts for repairs. Failure to follow above instructions could compromise the unit safety and shall void the warranty. If the unit is not used for long periods, shut the gas off through gas cocks and disconnect the unit from power supply.

If the unit is to be denitively decommissioned, in addition to

above suggestions, any potential source of hazard shall have to be made inoffensive. It is mandatory that the inlet of the Venturi tube on the burnerfan assembly is kept free from any debris or obstructions (see

gure in this page). In case it is not, a backre from the pre-mix burner might occur.

2.6 Transport and handling

The heater is delivered fastened to a pallet and packed with paperboard. If required, the heater can be delivered packed on a pallet, in a crate or in other forms. Unload the heater from truck and move it to the installation place using a convenient system, suited to the weight of the load. If the unit is stored at the customer’s premises, make sure a suitable place is chosen, sheltered from rain and excessive humidity. Any lifting and transport operations must be accomplished by skilled personnel, adequately trained on working procedures and safety rules. Once the unit is placed in the right spot, you can start unpacking it Unpack the heater using suitable tools and protections, where necessary. Materials resulting from unpacking shall be disposed of according to relevant regulations. While unpacking the unit, check its integrity and its compliance

to the order. Should damages or missing pieces result, immediately inform the supplier. The manufacturer is not liable for any damages occurred during transport, handling, or unpacking.

KEEP FREE AND UNCLOGGED!

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code HG0109.12GB ed.C-1106 rev.12

WARM AIR HEATER SERIES RAPID

HG0109.09_D_001 IT_ed.0902

Attencion:before commissioning the heater, open louvers of at least 45°

3. TECHNICAL FEATURES

Modulating air heaters series RAPID have been designed to serve as heating units in industrial and commercial environments. The control devices installed inside the control board allow to fully manage the heater.

Pre-mix technology allows obtaining high efciency levels and

keep NOx emissions low. The heater works as a standalone unit. In order to start it up, just connect it to power and gas supply. The unit's heat output ranges from 15.3 to 53.4 kW. The heat exchanger complies with production requirements for gas equipment set by EN1020 regulations. The combustion chamber is entirely built in AISI 430 stainless steel while tube bundles are made of AISI 441, in order to assure

high resistance to corrosion of wet ue.

The leading-edge design and the wide surface of the furnace

and tube bundle guarantee optimum efciency and durability.

The burner is entirely built with stainless steel, and it takes advantage of special mechanical solutions to guarantee optimal reliability and performance rates, as well as high thermal and mechanical resistance. The security level of the equipment is IP X0D [IP20] according to EN 60529. RAPID heaters work in ON/OFF mode, i.e. thermal output, and therefore thermal input and fuel consumption, remain steady and are based on heat request.

When the heater is turned on, the burner starts working at maximum capacity.

Low Pollution

Pre-mix burners equipped with an air/gas valve allow "clean" combustion with very low polluting emissions. Nox Class 4 - EN1020

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3.1 Technical data

Models with axial fan

Models with centrifugal fan

RA015 RA024 RA032 RA035 RA043 RA054

TECHNICAL DATA UOM max

Type of appliance

C13 - C33 - C53 - C63 - B23

EC Approval P.I.N. 0694BN4077 Protection degree IP20 Rated thermal output kW 16,5 26,5 34,8 38,7 47,5 58,0 Rated thermal input kW 15,3 24,3 31,7 34,9 43,6 53,4

Efciency % 92,6% 91,8% 91,2% 90,2% 91,8% 92,1% Ø of gas tting UNI ISO 7/1 - 3/4" M Ø of inlet air/ue exhaust pipe mm 80/80 Press. available on ue exhaust Pa 50 90 110

Supply Voltage V 230V/50Hz Input power W 220 260 330 520 620 Air Flow Rate at T=15°C m3/h 1.600 3.050 3.050 3.800 5.000 6.250 Temp. increase Air °C 27,4 22,9 29,8 26,3 25,0 24,5 N° and Ø of fan 1 x 350 1 x 400 1 x 420 2 x 400 2 x 420

Fan speed g/1' 1.050 1.270 1.270 1.350 1.270 1.350 NOISE LEVEL UOM max Noise level (Lw) dB(A) 66,4 70,9 74,1 73,9 77,1 Noise level in free eld 6m (Lp) dB(A) 39,9 44,4 47,5 47,4 50,5

Minimum operating temperature °C -15,0 / +60,0

Heater net weight (unpacked) Kg 59 65 69 75 92 97

Heater gross weight (packed) Kg 70 80 84 90 112 117

RAC024 RAC032 RAC035 RAC043 RAC054

TECHNICAL DATA UOM max

Type of appliance C13 - C33 - C53 - C63 - B23

EC Approval P.I.N. 0694BM3433

Nox Class val. 5

Rated thermal output kW 26,5 34,8 38,7 47,5 58,0

Rated thermal input kW 24,3 31,7 34,9 43,6 53,4

Efciency % 91,8% 91,2% 90,2% 91,8% 92,1%

Ø of gas tting

UNI ISO 7/1 - 3/4" M

Ø of inlet air/ue exhaust pipe mm 80/80

Press. available on ue exhaust Pa 50 90 110 120

Supply Voltage V 230V/50Hz

Input power W 245 500 490 1000

Air Flow Rate m3/h 2.250 2.800 2.800 4.500 5.600

AVAILABLE STATIC PRESSURE Pa 120

Fan number 1 2

Temp. increase Air °C 31,0 0,0 32,5 0,0 35,7 0,0 27,8 0,0 27,3 0,0

Min/max operating temperature °C -15 / +60

Weight kg 84 96 101 134 140

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3.2 Sound Power - Noisiness

Noise level

It is known that the sound power level of a source (energy radiated/time unit) is a characteristic measure of the source itself and does not depend on the surrounding environment. This level allows comparisons between different appliances. As to measuring the sound power level of a machine (not in a workshop), please refer to the following document:

- ISO 3744 (1994)

The method proposed by the document applies to any kind of noise and device, provided it is installed on a solid and

reecting surface (the wall

behind, in case of a blower). ISO 3744 regulations require that test environment is deprived of reflecting surfaces, except for the one the device is placed upon. This simulates as much as

possible free eld conditions.

(These conditions can be found outdoor, away from walls or obstacles, or in a semi-anechoic chamber). The accuracy of the measurement depends on the engineering method used (2nd degree. The reproducibility of the results (obtained in different test environments) can be expressed with a standard deviation below 1,5 dB.

APEN GROUP has chosen to use one-speed fans, in

order to increase the air ow rate and the output efciency

of the equipment, thereby decreasing air layering in the room. This also reduces the time required to heat the environment.

RA015

1 speed

35,3

40,0

50,8

61,0

62,3

59,3

55,6

43,7

66,4

63Hz

125Hz

250Hz

500Hz

1000Hz

2000Hz

4000Hz

8000Hz

Totale

Noise level dB(A)

RA024 - RA032 - RA043

RA024, 032

52,8

55,6

60,9

63,7

65,0

65,5

60,8

53,0

70,9

RA043

55,8

58,6

63,9

66,7

68,0

68,1

63,8

56,0

73,9

63Hz

125Hz

250Hz

500Hz

1000Hz

2000Hz

4000Hz

8000Hz

Totale

Noise level dB(A)Noise level dB(A)

RA035 - RA054

RA035

58,1

67,3

67,0

67,5

66,3

65,3

60,4

50,8

74,1

RA054

59,8

68,7

72,3

70,8

68,9

66,9

62,6

53,7

77,1

63Hz

125Hz

250Hz

500Hz

1000Hz

2000Hz

4000Hz

8000Hz

tot.

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3.3 Dimensions

HG0109.12_C2_002

HG0109.12_C4_004_IT

HG0107.08_C2_003 IT_ed.0609

HG0109.12_ET_003

HG0109.12_ET_004

A Combustion Air Inlet Pipe F Flue Pipe

HG0109.12_ET_002

HEATER SIZE LOUVER BRACKETS GAS SUPPLY

MODEL L B H V HB LB IM IS ID DM GAS GO GV

RA015

720

640

650

140

530

415

450

116 174

475 3/4"

186 263

RA024

900 595 206 264

RA032

RA035

RA043

1240 935 780 228 252

RA054

740 620 183 352

HEATER STANDARD HORIZONTAL OUTLETS

MODEL A F AV TV S

RA015

80 80

367

204 105

RA024

RA032

RA035

RA043

RA054

457

HEATER OPT. VERT. OUTLETS TOP HOLES

MODEL A F AO TO S D1 D2 D3 D4 D5 D6

RA015

80 80

305

120

105

244 450 206 290 232 118

RA024

RA032

RA035

RA043

230 780 228 290 232 122

RA054

310 100

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Dimensions with eased frame

Shutters, brackets and lters for heaters with eased frame

are considered accessories and are not supplied with the equipment.

HEATER DIMENSIONS DELIVERY SHUTTERS/INTAKE FILTERS

MODEL

T DM C N M HM LM BS HS

LS BF HF LF

024

1225 260 520 102 155 500 600

410 510

105

400 500

032

035

043

1315 200 580 90

125 550

950

460

710

450

700

054

145 650 510 500

HEATER BRACKETS

MODEL IS IM ID

024

595 252032

035

043 910 277

054 960 227

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4. USER'S INSTRUCTIONS

Read General and Safety Warnings on page 3.

The user shall only use the room thermostat controls and possibly the commands installed on the unit.

4.1 Description of the heater

Suspended warm air heaters of RAPID series heat air by direct exchange, with a combustion circuit sealed from the room they are installed into. Their patented heat exchanger, furnace and premix burner are entirely made of stainless steel. Therefore, you can install our heaters in any of the industrial or residential environments where the existing regulations allow air recirculation in the room. The heater works in fully automated mode. It includes a selfchecking electronic device that regulates all burner controls and commands, thereby ensuring top reliability and safety.

4.2 Heater Operation

In order to ensure proper operation, the heater shall be connected to a room thermostat and/or a timer that automatically starts the working cycle. Apen Group can provide suitable accessories for unit control.

WINTER: heating mode

To operate the heater, please do the following:

- Make sure gas supply cock is open

- Check the green LED is on (it indicates the unit is powered.)

- Turn the I/0/II switch on “I = Winter”;

- Close room thermostat contact and make sure that the timer, if installed, is OFF. These are the prerequisites to launch burner start-up cycle.

The ame control device starts up the burner that launches the furnace pre-washing phase. The ame is lit about 30 seconds

afterwards.

A detection electrode checks the burner has actually red. In

case it has not, the start up sequence is repeated 4 times before locking the unit.

30 seconds after the burner is red, the fan automatically starts

to blow air in the room. In winter mode, the burner and the fan work continuously without stopping. When the set temperature is reached, the room thermostat turns the burner off. The fan keeps working for 120 seconds to cool the exchanger down while the fan in the burner post-washes the furnace for 60 seconds. The burner restarts when a heat request is issued by room thermostat.

The heater shall not be turned off by disconnecting it from the mains while it is running. In such case, the exchanger would not be cooled down, its durability would be jeopardized and the guarantee would be void.

Locking the heater

On the front of the heater a red LED is installed to show if the equipment is locked. This LED can light up for two reasons:

- The burner locks up (no ame)

- Safety controls lock up

In case of a lock, you can reset the unit manually by pressing the button on the front of the heater for longer than 1 second. This button can also be remotely controlled (see wiring diagrams in the section reserved for the installer).

If the units locks up again after 35/40 seconds If after two or three reset attempts the lock is not resolved, do not insist and contact your Support Center for a repair call.

Summer /0 /Winter switch

Line and lock LEDs

Reset button

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Burner lock:

If the ame control device detects an ignition failure of the burner,

the start-up cycle is automatically repeated up to 4 times. If the lock continues, the red LED on the front of the heater turns on.

Safety thermostat locked (STB):

A safety thermostat (STB) for each cooling fan is installed on the heater. The STB thermostat is a safety device that triggers if a fault occurs. Thermostat is automatically reset by AGP card. When the STB thermostat triggers, the red LED on the front of the heater is lit (the same as for burner lock).

Diagnostics

To nd out the reason of the lock, refer to "Diagnostics" section in paragraph 7.

SUMMER : operation in ventilation mode

The heater can be used also in summer to have air ow in

the room. To enable summer ventilation, turn I/O/II switch on “II = Summer”.

REMARK: If you want to remotely control the Summer/Winter mode, please leave the switch on the heater turned on Winter [ pos. I ]. If you power off the unit before cooling cycle is completed and then power it on again, fans star immediately.

HG0100 C2 012

4.3 Accessories

To ease the use of the heater, APEN can supply two accessories that allow to remotely control heater's commands. Available commands are described below. Please refer to the "instructions to the installer" section for electrical wiring instructions.

Remote Control G12800

G12800 remote control includes ON/OFF [0/I] command, summer/winter switch, and reset button. You do not power off the unit by turning the 0/I switch off. You

simply have the ame extinguished while the exchanger is

properly cooled down. However it is necessary to reset the safety thermostat (STB) is on the remote control.

Remote control code G00094

This command enables to:

- Set room temperature

- Switch Summer/Winter operation

- Turn off the heater without powering it down

- Display burner lock

- Reset the burner With this command too, the only way to reset the safety thermostat (STB) is on the remote control.

HG0107.08_C2_005 IT

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HG0103 C2 009

HG0103 C2 008

HG0103.C2 007

5. INSTRUCTIONS TO THE INSTALLER

Instructions for installing and setting the heater are intended for authorized personnel only.

Read safety rules rst.

5.1 General Installation Rules

If possible, the heater should be installed directly in the room to be heated. For indoor installation, different laws and regulations apply according to the fuel that is used and the Country where the appliance is installed. The installer shall strictly follow the laws and regulations existing in the Country where the appliance is installed.

Venting Openings

The room where a gas-red heater is installed must comply with

relevant regulations as to the number and dimensions of venting openings, in order to guarantee optimum combustion and safety. These openings shall comply with existing relevant national and international regulations.

- a lo del softto per i gas con densità inferiore a 0.8;

- a lo del pavimento per gas con densità superiore o uguale a 0,8.

Le aperture devono essere eseguite su pareti attestate su spazi a cielo libero. Le sezioni vanno dimensionate in Feature della Heat Ouput installata.

5.2 Installing the Heater

The diagram on the right shows installation height and clearance

of the heater from walls and oor. Minimum clearance (in mm)

indicates the space required to assure proper maintenance. Height (2,500 mm) is the minimum value required by the law for wall-mounted heaters. In front of the heater, a clearance of at least 3 meters shall be provided. Behind the unit the space must be equal or greater than "DM" value shown in "Dimensions" paragraph on page 7 of the Manual. Two types of brackets are

available on demand: xed and revolving. With RAC models, only xed brackets can be used.

Codes for available brackets are the following: G15200-0N00 Fixed brackets for RA015/054 G15650-0N00 Revolving brackets for RA015/035 G15610-0N00 Revolving brackets for RA043/054

G13600 Kit for xed bracket RAC024/054

FIXED BRACKETS Installation procedure:

- Place drilling template on the wall and mark the holes to drill.

- Assemble the brackets as shown in gure below, using supplied parts.

- Use screw anchors with outer M10 screw.

REMARK: Make sure screw and anchor size and type are

suitable for holding the heater on the specic wall type.

- When assembling brackets, insert an elastic locking washer between bracket and locknut.

- Place heater on brackets, taking care to centre it. Make also sure panel boring coincide with bracket holes. Bracket ends must not lean out from the heater edge.

- Lock the heater using M8 screws supplied and inserting an elastic locking washer between the screw and the bracket.

MINIMUM CLEARANCE

HG0107.10 C2 005

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HG0107.08_C2_006 IT_ed.0609

HG0107.08_C2_007 IT_ed.0609

HG0107.08_C2_008 IT_ed.0609

HG0100C2 011

REVOLVING BRACKETS

Assembly instructions for revolving brackets are enclosed in the package. Revolving brackets are recommended in the following cases: a) Installation in a corner b) Installation on a pillar

c) Perpendicular installation to the wall the heater is hanged on

HEATER WITH BIFILAR LOUVERS

The available accessory kits have the following codes: G15101 Vertical louvers for RA015 G15102 Vertical louvers for RA054, RA032, RA035 G15103 Vertical louvers for RA043 G15104 Vertical louvers for RA054 Install the louvers using pre-drilled holes in heater upper and lower panel.

WALL-MOUNTED HEATER

To install the heater using eye-bolts, a kit is available G14444.08. Simply replace upper screws with eye-bolts.

VERTICAL HEATER

Rapid heaters can be installed with downwards air blow (vertical

air ow).

This type of heater is not standard as it includes G14437.08 kit and additional thermostats for air fan control. These devices are already assembled in the delivered heater. If the G14437.08 kit is to be installed on the outside, have the installer read the technical sheet included in the kit.

REMARK: Kit G14437.08 does not include suspension eyebolts. Ask for G14444.08 kit, if required (see above).

REMARK: Additional thermostats checking fan operation are installed and connected in series to STB1 and STB2 thermostats (see wiring diagram).

Note: Make sure screw and anchor size and type suit wall type and are adequate to hold the heater.

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FilterFireproof

Power

connection

cable

ASSEMBLING EASED FRAME AND ACCESSORIES

In order to assemble the heater to eased frame, fan compartment

shall be mounted on the heater using supplied screws (see gure). To fasten shutters or lters to eased frame, tighten M8 screws supplied in the kit to the nuts on eased frame. To fasten lters

to the shutter, both nuts and M8 screws are needed.

WIRING THE EASED FRAME

Inside burner compartment, a relay is already wired to wiring card. The wire from eased frame shall be wired to this relay

as described in the gure. No problem if brown and grey wires

are reversed.

Contact NO

14-5

Contact

44 -8

Gray wire

(Neutral)

Brown wire

(Phase)

Yellow/green wire

(Ground)

Wire from

eased frame

Connection from the card to A1- A2 terminals of the

relay

(already wired)

code X01061

code X01076

(230V)

Page 17

APEN GROUP reserves the right to change products and documents as required.

code HG0109.12GB ed.C-1106 rev.12

WARM AIR HEATER SERIES RAPID

CO and NOx values are correct if O2=0%.

HG0109_12_ET_007

VALUES MEASURED WITH G20 [Natural gas]

Model CO NOx NOx Class

ppm ppm EN1020

RA015 1 42 4

RA024 1 40 4

RA032 1 44 4

RA035 1 41 4

RA043 1 50 4

RA054 1 44 4

5.3 Chimney Piping

RAPID heaters have sealed combustion circuits, and the fan is installed before the exchanger.

The ue system can have different layouts: type C (combustion

air taken in from outdoor) or type B (combustion air coming from indoor).

RAPID heaters are certied for the following ue types: C13-

C33-C53-C63-B23.

Use approved pipes and terminals for ue systems. Intake and ue piping shall avoid the entry of objects having

one dimension larger than or equal to 12 mm.

APEN GROUP certies its own air intake and ue terminals,

which shall be installed with RAPID heaters.

The standard version of RAPID heaters is equipped with hori-

zontal ttings for connecting the heater to the chimney and to air intake system. These ttings are on the back of the heater

but they can be moved to the top during installation in order to ease exhaust from the roof. Flue piping for non condensing RAPID heaters must be built using the following materials:

- Aluminum with minimum thickness of 1.0 mm.

- Stainless steel with minimum thickness of 0.4 mm. The carbon content of the steel must not exceed 0.2%.

Use gasketed tubes to avoid any ue leaks. The gasket must be suited to ue temperature ranging from 120°C to 220°C

(248°F to 428°F).

Plastic components SHALL NOT be used for building ue system because ue temperatures are higher than those

allowed by these materials.

Condensate

With ue layouts longer than 8 meters if running indoor, or longer

than 5 meters if running outdoor, condensate may appear in

ue pipes. If so, a condensate manifold (code G15825-08-HV) should be installed between the heater and the ue system to

collect condensation water. This kit can be used both on horizontal and on vertical pipes and should be installed close to the heater. The manifold shall be connected to the siphon (code G14551)

to prevent the ue from leaking with the condensate.

G14303 kit is also available to treat condensation's acidity. Condensation can then be disposed of anywhere. Contact your Apen Group Support Centre for more information.

Combined Flue Systems

An independent ue system is to be preferred, whenever possible. Since RAPID heater ue systems are pressurized, a wrongly-sized collective ue would cause problems to the unit.

However, if a combined system is required, it will have to be carefully designed and sized, so that chimney always works

in depression. This will prevent a unit from venting its ue gas

into another unit.

FLUE SYSTEM - C63 TYPE

For Countries where C63 ue systems are allowed, the following

table shows how to calculate the layout of the system using pipes

available in the market. Available pressure at ue is reported in

the table in the following page.

HG0109_12_ET_005

HG0109_12_ET_006

EQUIPMENT SET FOR G20 [Natural gas]

Model Flue temp. Content Flue ow rate

[°C] CO2 [kg/h]

RA015 190 9,1 26,3

RA024 200 9,1 42,2

RA032 210 9,1 55,1

RA035 210 9,0 61,8

RA043 195 9,2 74,9

RA054 195 9,1 92,4

EQUIPMENT SET FOR G31 [Liquid propane gas]

Model Flue temp. Content Flue ow rate

[°C] CO2 [kg/h]

RA015 190 9,7 24,8

RA024 200 9,7 39,7

RA032 210 9,7 52,3

RA035 210 9,8 57,9

RA043 195 9,7 71,4

RA054 195 9,8 86,2

Page 18

code HG0109.12GB ed.C-1106 rev.12

APEN GROUP reserves the right to change products and documents as required.

WARM AIR HEATER SERIES RAPID

*Equivalent length for wide radius elbows. ** The loss refers to one meter of pipe. When you specify the code, indicate the length in cm instead of xxx.

HG0109.12_ET_008

Guidelines to Component Selection

The following table lists pressure drops of more commonly used terminals and piping. If the terminal is not directly connected to the heater and a distance is to be covered, check that diameters of terminals, extensions and elbows are correct. Refer to the table below to assess pressure drops for each component according to the heater model that was chosen. Sum pressure drops of each component and make sure the result does not exceed the available value for the heater to use. If an air intake pipe is used, sum its pressure drop to that

of ue outlet.

If the result is higher, use pipes with larger diameter and check again the sum. A pressure drop higher than the pressure avai-

lable on ue system would reduce the thermal power output

of the heater.

Note: The gures in the following pages show examples of

venting and air intake piping built using standard kits. The table below shows maximum lengths of layouts that can be built between the unit and the terminal. If elbows are included in the layout, the equivalent length of each elbow must be deducted from the available length. Elbow Ø 80 90° EL 1.7 m Elbow Ø 80 45° EL 0.8 m Elbow Ø 100 90° EL 1.9 m Elbow Ø 100 45° EL 0.9 m

Heater Model RA015 RA024 RA032 RA035 RA043 RA054

Pressure available at discharge 50 50 90 90 11 0 110 [Pa]

Component Pressure Drop [Pa] Code

Ø 80 horizontal separate C13 terminal 2,9 4,5 6,2 7,3 10,1 13,9 TC13-08-HS3

Ø 80 horizontal C13 separate terminal + adapter Ø100 3,3 5,7 8,2 9,7 13,7 19,3 TC13-08-HS3M

Ø 100/100 horizontal C13 separate terminal 2,4 2,9 3,4 3,8 4,5 5,9 TC13-10-HS3

Ø 80/80 horizontal C13 concentric terminal 5,5 14 23 28 42 62 TC13-08-HC3

Ø 100/100 horizontal C13 concentric terminal 2 5,5 10 13 21,8 34,5 TC13-10-HC3

Ø 100/100 horizontal C13 concentric terminal (small) 2,4 6,7 12 15,4 25,4 39,9 TC13-10-HC3R

Ø 130/130 horizontal C13 concentric terminal 1 2 2,8 3,5 4,9 7 TC13-13-HC3

Ø 130/130 horizontal C13 concentric terminal (small) 1,2 2,6 4 4,9 7,1 10,2 TC13-13-HC3R

Ø 80/80 horizontal C33 concentric terminal 5,5 14 23 28 42 62 TC33-08-VC1

Ø 100/100 vertical C33 concentric terminal 2 5,5 10 13 21,8 34,5 TC33-10-VC3

Ø 100/100 vertical C33 concentric terminal (small) 2,4 6,7 12 15,4 25,4 39,9 TC33-10-VC3R

Ø 130/130 vertical C33 concentric terminal 1 2 2,8 3,5 4,9 7 TC33-13-VC3

Ø 130/130 vertical C33 concentric terminal (small) 1,2 2,6 4 4,9 7,1 10,2 TC33-13-VC3R

Ø80 B23 horizontal terminal 1,5 2,4 3,4 4 5,6 7,8 TB23-08-HS0

Ø80 horizontal intake only 1,4 2,1 2,8 3,3 4,5 6,1 TC00-08-HS0

Ø100 horizontal B23 terminal 1,2 1,5 1,8 2 2,4 3,2 TB23-10-HS0

Ø100 horizontal intake only 1,2 1,4 1,6 1,8 2,1 2,7 TC00-10-HS0

Ø80 vertical B23 terminal 3,4 5,8 8,6 10,1 14,2 20,1 TB23-08-VS0

Ø100 vertical B23 terminal 2,5 3,4 4,3 4,9 6,2 8,4 TB23-10-VS0

Ø80 pipe ** 0,5/m 1,4/m 2,4/m 3/m 4,6/m 6,8/m G15820-08-xxx

Ø100 pipe ** 0,2/m 0,5/m 0,8/m 1/m 1,4/m 2,2/m G15820-10-xxx

Ø80 elbow wide radius 90° 0,9 2,4 4,1 5,1 7,6 11,3 G15810-08-90

Ø80 elbow wide radius 45° 0,5 1,2 2 2,5 3,8 5,7 G15810-08-45

Ø100 elbow wide radius 90° 0,3 0,9 1,5 1,9 2,8 4,2 G15810-10-90

Ø100 elbow wide radius 45° 0,2 0,4 0,7 0,9 1,3 2 G15810-10-45

Adapter Ø80 - 80/100 0,2 0,6 1 1,2 1,8 2,7 G15815-08-10

Adapter Ø80 - 100/80 0,2 0,6 1 1,2 1,8 2,7 G15815-10-08

Adapter Ø100/130 0,1 0,3 0,6 0,7 1,1 1,6 G15815-10-13

Adapter Ø130/100 0,1 0,3 0,5 0,6 0,9 1,3 G15815-13-10

Horizontal and vertical Ø80 condensate manifold 0,8 0,8 0,8 0,8 0,8 0,8 G15825-08-HV

Horizontal and vertical Ø100 condensate manifold 0,8 0,8 0,8 0,8 0,8 0,8 G15825-10-HV

Ø80 rain protection 2 2 2 2 2 2 G15830-08-V

Ø100 rain protection 1,5 1,5 1,5 1,5 1,5 1,5 G15830-10-V

Ø130 rain protection 1 1 1 1 1 1 G15830-13-V

Ø80 grid 1 1 1 1 1 1 C04787

Ø100 grid - - - - - - G14513

Page 19

APEN GROUP reserves the right to change products and documents as required.

code HG0109.12GB ed.C-1106 rev.12

WARM AIR HEATER SERIES RAPID

HG0109.12_ET_009

Terminal includes:

-Straight pipe L=900mm with grid

-Outer and inner wall plates

-Fastening accessories

B23 TYPE horizontal

HG0103 C2 011

Terminal includes:

-Rain protection

-Male/female extension L=1000mm

-Elbow 90°

B23 TYPE vertical

HG0103 C2 010

Max L1 of layout,

terminal excluded

Terminal Ø80 TB23-08-HS0

Pipes and elbows Ø80

Model meters

RA015 30

RA024 30

RA032 29

RA035 26

RA043 22

RA054 17

Max L1 of layout,

terminal excluded

Terminal Ø80 TB23-08-HS0

Pipes and elbows Ø80

Model meters

RA015 29

RA024 29

RA032 26

RA035 24

RA043 20

RA054 15

HG0109.12_ET_009-A

5.4 Terminal Layout

B23 TYPE

Open combustion circuit, combustion air intake from indoor, ue

are exhausted outdoor. In this case, UNI-CIG 7129 and 7131 rules require that suitable openings in the walls are provided. REMARK: This layout requires an IP20 protection grid to be installed. The grid [locations 28 and 29] must have a minimum pitch of 8 mm and must prevent the inlet of any object with a diameter greater than 12 mm into air intake.

Page 20

code HG0109.12GB ed.C-1106 rev.12

APEN GROUP reserves the right to change products and documents as required.

WARM AIR HEATER SERIES RAPID

Terminals include:

• TC13-08-HS3

-Intake and ue straight pipes Ø80/80 with grid

-Outer and inner wall plates

-Fastening accessories

HG0103 C2 013

80/80->Ø125 100/100->Ø150 130/130->Ø200

HG0109.12_ET_011

C13 TYPE independent horizontal

C13 TYPE, Combustion circuit sealed from the room. Pipes go outdoor through the wall.

HG0109.12_ET_010

HG0103 C2 012

160

500

203

C13 TYPE concentric horizontal

** using Ø80/100 MALE/FEMALE ADAPTERS AND Ø100 PIPES

Max L1 + L2 of layout, terminal excluded

Term. Ø80/80

TC13-08-HC3 Term. Ø100/100 TC13-10-HC3

Pipes and elbows Ø80 Pipes and elbows Ø100

Model Meters

RA015 10 + 10

RA024 10 + 10

RA032 10 + 10

RA035 9 + 9

RA043 7 + 7 9 + 9**

RA054 4,5 + 4,5 10 + 10**

REMARK: Max possible length was equally divided between intake and discharge. Different ratios are allowed, provided the maximum value shown in the table is not exceeded.

Max L1 + L2 of layout, terminal excluded

Term. Ø80/80TC13-08-HS3

Pipes and elbows Ø80

Model meters RA015 15 + 15 RA024 14 + 14 RA032 14 + 14 RA035 12,5 + 12,5 RA043 10 + 10 RA054 8 + 8

REMARK: Max possible length was equally divided between intake and discharge. Different ratios are allowed, provided the maximum value shown in the table is not exceeded.

Terminals include:

• TC13-08-HC3

- Terminal including 0uter and inner wall plates, Ø 80/80 back ttings

• TC13-10-HC3

- Terminal including outer and inner wall plates, back ttings

Page 21

APEN GROUP reserves the right to change products and documents as required.

code HG0109.12GB ed.C-1106 rev.12

WARM AIR HEATER SERIES RAPID

** using Ø100/80 male/female adapters *** using Ø80/100 male/female adapters

Terminals include:

• TB23-08-VS0 -Rain protection Ø80

-Extension Ø80 L=1000mm

-Elbow Ø80 90°

• TC00-08-HS0 -Intake terminal Ø80 with grid

-Outer and inner wall plates

-Fastening accessories

• TB23-10-VS0 --Rain protection Ø100

-Extension Ø100 L=1000mm

-Elbow Ø100 90°

• TC00-10-HS0 --Intake terminal Ø100 with grid

-Outer and inner wall plates

-Fastening accessories

HG0103 C2 015

C53 TYPE Sealed combustion circuit from the room. Pipe systems are connected one to the roof and the other to the wall.

HG0109.12_ET_012

Max L1 + L2 of layout, terminal excluded

Discharge Ø80 TB23-

08-VS0

Intake Ø80 TC00-08-HS0

Discharge Ø100 TB23-08-

VS0

Intake Ø100 TC00-08-HS0

Pipes and elbows Ø80 Pipes and elbows Ø100

Model Meters

RA015 14 + 14

RA024 13 + 13

RA032 13 + 13

RA035 11,5 + 11,5

RA043 9 + 9

RA054 7 + 7 12,5 + 12,5***

REMARK: Max possible length was equally divided between intake and discharge. Different ratios are allowed, provided the maximum value shown in the table is not exceeded.

Page 22

code HG0109.12GB ed.C-1106 rev.12

APEN GROUP reserves the right to change products and documents as required.

WARM AIR HEATER SERIES RAPID

** using Ø80/100 male/female eccentric adapters code G15835-08-10 (to be ordered separately)

Terminals include:

• TC33-08-VC1 - Complete terminal, Ø 80/80 ttings - Centre distance 120

• TC33-10-VC2 - Complete terminal, Ø 100/100 ttings - Centre distance 140

This layout requires that ttings be moved from the back to the top of the

heater. For more details, see instructions below.

HG0103 C2 016

To disassemble:

1) Cut "A" covers from upper panel

2) Pull "C" ue pipe

3) Disassemble the intake joint "D"

4) Disassemble the ue joint "B"

5) Remove internal covers "E" installed one on burner casing

and the other over ue hood

How to assemble:

1) Install one "E" cover (and its seal) on the side hole of the exchanger.

2) Install "B" ue junction on upper hole of the exchanger

3) Insert intake junction "D" on burner compartment

4) Cut to length "C" pipe and install it on "D" air junction

reaching same height as ue outlet

5) Install pre-cut covers "A" and their seals on the hole for air intake

6) Install "E" cover without seal on back hole of the ue

Disassembling

Assembling

80/80->Ø125 100/100->Ø150 130/130->Ø200

HG0109.12_ET_012

HG0109.12_C2_009

C33 TYPE (ROOF) Combustion circuit is sealed from the room. Pipes end outdoor with a concentric terminal.

Max L1 + L2 of layout, terminal excluded

Term. Ø80/80

TC33-08-VC1 Term. Ø100/100 TC33-10-VC2

Pipes and elbows Ø80 Pipes and elbows Ø100

Model meters

RA015 11 + 11

RA024 11 + 11

RA032 10 + 10

RA035 9 + 9

RA043 7 + 7

RA054 4,5 + 4,5 10 + 10**

REMARK: Max possible length was equally divided between intake and discharge. Different ratios are allowed, provided the maximum value shown in the table is not exceeded.

Page 23

APEN GROUP reserves the right to change products and documents as required.

code HG0109.12GB ed.C-1106 rev.12

WARM AIR HEATER SERIES RAPID

5.5 Electrical Wiring

HG0109.12_C2_005

Room Thermostat Wiring

It is mandatory to install a room thermostat or a timer to turn the burner off without powering off the unit. No spare jumper

supplied with the heater.

Connect the thermostat to terminals No. 34 and 35 of the board on the electronic card installed into the control panel housing of RAPID heater (it replaces the jumper, see diagram in this page). If the burner can be turned off by multiple switches, they must be wired in series. A remote button can be installed and wired to terminals No. 29 and 30 of the board [WARNING: current is 230V]. The type of the button must be Normally Open. .

Power Supply

The heater shall be properly wired to an efcient grounding

system, complying with existing regulations. Single-phase 230 Vac supply with neutral. Do not mistake neutral and phase wires If phase and neutral wires are exchanged, the unit will automatically lock. The heater can be plugged into mains using a plug-socket only if the latter prevents any mistake between phase and neutral wires. The system wire gauge in general, and cable section in particular, must suit the unit rated input (see technical data table). Keep cables far from heat sources.

REMARK: A multipole cut-out switch must be installed before the heater with suitable electric protection. The section of supply cables must be at least 1.5 mm²

The unit shall be plugged into the mains using the plug supplied. Always unplug the unit during maintenance operations.

Reset button

Summer Ventilation

You can enable only the fans (summer ventilation while the burner is off) in the following ways:

1) Turn the switch on the heater on " =SUMMER". In this way, the fans can be turned on or off by rotating the switch or by powering off the appliance (this latter is not allowed in Winter mode).

2) Use remote control - see G12800 and G00094 accessories

3) Remotely control the CN3 connector command through terminals No. 34,35, and 36 as indicated in the wiring diagram for G12800 accessory [see diagram in the following page]. When the summer ventilation command is remotely controlled, the switch on the heater shall be turned on " =WINTER".

HG0109.09_C2_007

Summer /0 /Winter switch

HG0109.12 C2 001

RESET

ROOM THERMOSTAT

Page 24

code HG0109.12GB ed.C-1106 rev.12

APEN GROUP reserves the right to change products and documents as required.

WARM AIR HEATER SERIES RAPID

HG0100 C2 012

Wiring G12800 remote control

G12800 remote control includes an I/O switch, a summer/ winter switch, a reset and lock signaling LED and is delivered with a multipole, numbered cable already wired. To wire the control to the heater, do the following:

- Wire remote control numbered wires (1 to 6) to 31-36 terminals of relevant board (see diagram in this page).

- Make sure the summer/winter switch installed on the heater is turned on "I=WINTER".

HG0109.12 C2 003

Wiring G00094 remote control

G00094 remote control includes a room thermostat, a summer/ winter switch, a reset and lock signaling LED and is delivered with a multipole, numbered cable already wired. To wire the control to the heater, do the following:

- Wire remote control numbered wires (2 to 6) to 31-36 terminals of relevant board (see diagram in this page).

- Make sure the summer/winter switch installed on the heater is turned on "I=WINTER".

HG109.12 C2 002

REMARK: Do not use a multipole cable conducting both electrical supply and chronothermostat control, since this would interfere with control signals, jeopardizing heater operation.

DO NOT CONNECT

AND

ISOLATE POWER

CABLE

REMARK: Do not use a multipole cable conducting both electrical supply and chronothermostat control, since this would interfere with control signals, jeopardizing heater operation.

HG0109.12_C2_026

Page 25

APEN GROUP reserves the right to change products and documents as required.

code HG0109.12GB ed.C-1106 rev.12

WARM AIR HEATER SERIES RAPID

5.6 Gas Supply System

For this system, use CE-approved and certied components only.

RAPID heaters are supplied with a double gas valve

and a gas lter and stabilizer already installed.

All components are assembled into the burner compartment. To complete installation in compliance with the law, the installer shall install the following components:

- Vibration damping joint

- Gas cock

We recommend installing a gas lter with a high ow rate and no pressure stabilizer. In fact, the standard lter installed before

the gas valve has a limited surface.

Do not use threaded joints directly on gas tting. A vibration

damping joint with seat lift on heater side is to be preferred, in

order to ease maintenance. The law allows a maximum pressure of 40 mbar inside the building or thermal plant. Higher pressure values shall be reduced before the room where the heater is installed.

LEGEND 1 Main burner gas solenoid valve 2 Pressure stabilizer 3 Safety solenoid valve

4 Gas lter (small section)

5 Vibration damping joint

6 Gas lter (large section)

7 Gas cock

Supplied with RAPID heater

1 2 3 4 5 6 7

To be installed by the installer

HG0109 C2 006

Connecting Multiple Heaters to One Remote Control

If you need to connect multiple RAPID heaters to just one thermostat, chronothermostat or timer, make sure the following conditions are met:

- Each unit must have its own unpowered contact wired to terminals No. 34 and 35 of the board.

-The load capacity of this contact must be 4A at 250V

- Do not wire in parallel multiple units to just one contact

- Let I/0/II switch on the unit turned on "I=WINTER".

LEGEND:

- TA Room thermostat or chronothermostat

- KA1 Auxiliary contactor

- RAxxx RAPID heater

- CN3 RAPID heater connector

HG0109.12_C02_017

EXTERNAL POWER SUPPLY BASED ON CONTACTOR COIL

Page 26

code HG0109.12GB ed.C-1106 rev.12

APEN GROUP reserves the right to change products and documents as required.

WARM AIR HEATER SERIES RAPID

6. INSTRUCTIONS TO SERVICE STAFF

First start-up must be performed by an APEN GROUP Authorized Service Centre.

During rst start up, the combustion efciency must be analyzed. This appliance is certied for EC and Extra-EC countries for the gas categories listed below.

6.1 Country Table - Gas Category

HG0109.12_ET_014

On the packaging of each heater the following information are clearly marked: Destination Country, gas category, and appliance code translated into the language of destination Country. The code shows the factory setting for the unit:

Codes without extension:

- RA043IT no extension means that the unit has been set and tested for using natural gas [G20]

Codes with extension:

the fourth letter identies the gas for which the unit has been set:

- RA043FR-xxx0 0 indicates the unit has been set and tested for natural gas [G20]

- RA043MT-xxx1 1 indicates the unit has been set and tested for Liquid Propane [G31]

- RA043NL-xxx2 2 indicates the unit has been set and tested for natural gas 'L’ [G25]

- RA043HU-xxx3 3 indicates the unit has been set and tested for natural gas [G25.1]

- RA043PL-xxx4 4 indicates the unit has been set and tested for [G2.350] gas

Another label on the unit, placed near fuel supply, clearly states which gas type and supply pressure the unit has been set and tested for.

County Category Gas Pressure Gas Pressure

AT II2H3B/P G20 20 mbar G30/G31 50 mbar

BE <70kW I2E(S)B,I3P G20/G25 20/25 mbar G31 37 mbar

CH II2H3B/P G20 20 mbar G30/G31 50 mbar

DE II2ELL3B/P G20/G25 20 mbar G30/G31 50 mbar

DK, FI, GR, SE, NO II2H3B/P G20 20 mbar G30/G31 30 mbar

ES, GB, IE, PT, SK II2H3P G20 20 mbar G31 37 mbar

IT, CZ II2H3B/P G20 20 mbar G30/G31 30 mbar

FR II2Esi3P G20/G25 20/25 mbar G31 37 mbar

LU II2E3P G20/G25 20 mbar G31 37/50 mbar

NL II2L3B/P G25 25 mbar G30/G31 30 mbar

HU II2HS3B/P G20/G25.1 25 mbar G30/G31 30 mbar

CY, MT I3B/P G30/G31 30 mbar

EE, LT, SI, II2H3B/P G20 20 mbar G30/G31 30 mbar

AL, MK II2H3P G20 20 mbar G30/G31 37 mbar

LV I2H G20 20 mbar

IS I3P G31 37 mbar

BG, RO, HR, TR II2H3B/P G20 20 mbar G30/G31 30 mbar

PL II2ELwLs3B/P G20/G27/G2.350 20/13 mbar G30/G31 37 mbar

Page 27

APEN GROUP reserves the right to change products and documents as required.

code HG0109.12GB ed.C-1106 rev.12

WARM AIR HEATER SERIES RAPID

HG0109.12_ET_015

G20 GAS TYPE

TYPE OF APPLIANCE RA015 RA024 RA032 RA035 RA043 RA054

CATEGORY

Based on target country - see table 6.1

SUPPLY PRESSURE [mbar] 20 [min 17 - max 25] [for Hungary 25 mbar]

Ø GAS DIAPHRAGM [mm] 3,5 5,1 6,5 6,5 8,5 -

Ø AIR DIAPHRAGM [mm] 13,0 18,0 23,0 24,0 28,0 29,0

CARBON DIOXIDE CO

[%] 9,1 ±0,2 [cat. H] - 9,3 ±0,2 [cat. E]

GAS CONSUMPTION (15°C-1013mbar) [m3/h] 1,75 2,8 3,68 4,1 5,03 6,14

G25 GAS TYPE [cat L-LL]

TYPE OF APPLIANCE RA015 RA024 RA032 RA035 RA043 RA054

CATEGORY

Based on target country - see table 6.1

SUPPLY PRESSURE [mbar] 25 [min 20 - max 30] [for Germany 20 mbar]

Ø GAS DIAPHRAGM [mm] 3,5 5,1 6,5 6,5 8,5 -

Ø AIR DIAPHRAGM [mm] 13,0 18,0 23,0 24,0 28,0 29,0

CARBON DIOXIDE CO

[%] 8,9 ±0,2

GAS CONSUMPTION (15°C-1013mbar) [m3/h] 2,03 3,26 4,28 4,76 5,84 7,13

G30 GAS TYPE

TYPE OF APPLIANCE RA015 RA024 RA032 RA035 RA043 RA054

CATEGORY

Based on target country - see table 6.1

SUPPLY PRESSURE [mbar] 30 [min 25 - max 35] - 50 [min 42,5 - max 57,5]

Ø GAS DIAPHRAGM [mm] 2,5 3,5 5,1 5,1 6,0 6,5

Ø AIR DIAPHRAGM [mm] 13,0 18,0 23,0 24,0 28,0 29,0

CARBON DIOXIDE CO

[%] 10,8 ±0,2

GAS CONSUMPTION (15°C-1013mbar) Kg/h 1,06 1,71 2,24 2,49 3,06 3,73

G31 GAS TYPE

TYPE OF APPLIANCE RA015 RA024 RA032 RA035 RA043 RA054

CATEGORY

Based on target country - see table 6.1

SUPPLY PRESSURE [mbar] 30 [min 25 - max 35] - 37 [min 25 - max 45] - 50 [min 42,5 - max 57,5]

Ø GAS DIAPHRAGM [mm] 2,5 3,5 5,1 5,1 6,0 6,5

Ø AIR DIAPHRAGM [mm] 13,0 18,0 23,0 24,0 28,0 29,0

CARBON DIOXIDE CO

[%] 9,8 ±0,2

GAS CONSUMPTION (15°C-1013mbar) Kg/h 1,05 1,68 2,21 2,45 3,01 3,68

G25.1 * GAS TYPE [cat Ls] - [only for Hungary]

TYPE OF APPLIANCE RA015 RA024 RA032 RA035 RA043 RA054

CATEGORY

Based on target country - see table 6.1

SUPPLY PRESSURE [mbar] 25 [min 20 - max 30]

Ø GAS DIAPHRAGM [mm] - - - - - -

Ø AIR DIAPHRAGM [mm] 13,0 18,0 23,0 24,0 28,0 29,0

CARBON DIOXIDE CO

[%] 10,1 ±0,3

GAS CONSUMPTION (15°C-1013mbar) [m3/h] 2,03 3,26 4,28 4,75 5,84 7,13

G2.350 * GAS TYPE [cat Lw] [only for Poland]

TYPE OF APPLIANCE RA015 RA024 RA032 RA035 RA043 RA054

CATEGORY

Based on target country - see table 6.1

SUPPLY PRESSURE [mbar] 13

Ø GAS DIAPHRAGM [mm] - - - - - -

Ø AIR DIAPHRAGM [mm] 13,0 18,0 23,0 24,0 28,0 29,0

CARBON DIOXIDE CO

[%] 8,7 ±0,3

GAS CONSUMPTION (15°C-1013mbar) [m3/h] 2,44 3,93 5,16 5,73 7,04 8,59

6.2 Gas Setting Data Table

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CO2 REGULATION

GAS INLET TAPPING POINT (IN)

HG0103 IM 003

6.3 First Start Up

First start-up must be performed by an APEN GROUP Authorized Service Centre.

At delivery, the heater is set and tested for using the type of gas reported on the rating plate. Before starting the heater, go through the following checklist:

• Make sure the available gas matches the type the heater is

set for.

• Using the “IN” pressure tap on the gas valve, verify that the

inlet pressure to the valve matches the value required for the type of gas used.

• Make sure electrical wiring match the requirements supplied

in this manual or in other wiring diagrams enclosed with the delivered unit. Make sure the unit is powered and the green LED is ON.

• Close the room thermostat contact and make sure that the

switch on the back of the unit is turned on "I=WINTER". After checking previous conditions, and if the unit is not locked, the start-up sequence is launched. This sequence includes pre-washing the furnace, igniting the burner start-up and then starting cooling fans. At this stage, the pilot burner is not likely to start because of air in gas pipes. The heater locks up. Start-up sequence will be automatically repeated 4 times. After 4 attempts, the heater locks up (red LED on) and a reset is required to repeat the start-up sequence.

6.4 Combustion Analysis

Start the unit and check that the inlet pressure to the valve matches the one required by the gas type. If it doesn't, adjust it.

Wait a couple of minutes, then connect a ue gas content

analyzer to the chimney and check CO2 value, comparing it to the one listed in the Gas Setting Data (point 6.2) table referred to the kind of fuel used.

- If this value is not included in the required range, regulate CO2 value by adjusting the screw on the Venturi: turn it clockwise to

decrease gas ow (thereby decreasing also CO2 value), and

counter clockwise to increase it.

6.5 Converting the Unit to LPG

This conversion is strictly forbidden in Countries such as Belgium, where double category for gas is not allowed.

This Kit is not supplied in Countries where conversion is not allowed. The conversion to another type of gas shall be carried out

exclusively by an APEN GROUP certied Service Centre.

The heater is supplied to use natural gas. The kit for converting it into Liquid Propane is supplied as a standard and includes:

- One calibrated diaphragm

- One sticker "Appliance converted to.." Once the conversion and the setting have been made, replace the label "Appliance set for Natural Gas" with the one "Appliance converted to…", enclosed in the kit.

To convert the heater, do the following:

- Disconnect the unit from power supply

- Replace the supplied calibrated diaphragm between the gas valve and the Venturi

- Power the heater on and make it ready for start up When the burner is working, check the following:

1) The inlet pressure to the valve matches the one required for the gas used

2) The CO2 value does not exceed the values corresponding to the used gas. Should the value be different, change it by turning the regulation screw: screw to decrease the value and unscrew to increase it. Check again that gas circuit does not leak.

REMARK: The heater supplied for using LPG is adjusted for G31 gas. In order to use G30, the CO2 value must be checked and adjusted according to table 6.2, if necessary.

Gas diaphragm replacement

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6.7 MAINTENANCE

To keep the unit perfectly efcient and guarantee its durability,

we recommend to go through the following checklist at least once a year, before restarting the heater:

1) Check the condition of start-up and detection electrode

2) Check ue and air intake terminals and ducts

3) Check the Venturi

4) Check the exchanger is clean (every 3/4 years)

5) Check the inlet pressure of the gas valve

6) Check the operation of ame control device and air pressure

switch

7) Check the safety thermostat/s

8) Check ionization current REMARK: Checks in steps 1, 2, 3, and 4 must be carried out after power and gas supplies have been cut off. Checks in steps 5, 6, 7, and 8 must be carried out while the heater is running.

1) Checking the electrodes

Check proper operation of start-up system and detection device every year. In case of anomalies, uninstall the electrodes. Check the integrity of the ceramic and use emery paper to remove any oxidation on metal parts of the electrodes. Verify proper position of electrodes (see picture in this page). The detection electrode must be installed 20 ±2 mm from burner torch. The start-up electrode must release on the outer edge of the burner at a suitable distance from detection electrode (see diagram underneath).

If the burner is disassembled, check the ceramic ber gasket

and replace it, if necessary.

2) Flue and Air Inlet Systems

Check duct status looking into them or using suitable tools. Remove dust from air intake terminal.

3) Checking and cleaning the Venturi

If necessary, use a brush to remove dust on the Venturi inlet, taking care not to let it drop inside.

6.6 Conversion to G25 - G25.1 - G2.350 Gas

The conversion to another type of gas shall be carried out

exclusively by an APEN GROUP certied Service Centre.

Conversion from G20 into G25 is only allowed for Countries in Cat. 2

ELL

[Germany] and in Cat. 2HS [Hungary]. The conversion to G25 gas, if possible, does not require any change for the heater. The only exception is the RA054 model, where the gas diaphragm is to be removed. The conversion to G25.1 gas (Hungary only) requires the removal of gas diaphragm from all models of RA series. In Countries in Cat. "2L" [Holland], the unit is supplied set and tested for G25. For Cat. 2E Countries [France, Belgium and Luxembourg] where conversion from G20 to G25 is not allowed the appliance is supplied already set to use both G20 and G25 gases. Therefore, conversion is not needed. Conversion to G2.350 gas is allowed only in Poland. The conversion to G2.350 gas requires the removal of gas diaphragm from all models of RA series. After completing the conversion, turn the burner on and:

- Check that CO2 value does not exceed the accepted range for gas type [see table 6.2]. If it does, change it by turning the Venturi adjustment screw: screw to decrease and unscrew to increase. Stick the label "Appliance converted to G25 gas" over the previous label "Appliance set for ... ".The new sticker is enclosed in the kit. Special care should be paid to COCO2 value of G25.1 gas.

Electrodes

must

be parallel

External edges

must

coincide

Start-up electrode

Detection electrode

HG0109.11 C2 004

HG0109.12_C2_027

Air Diaphragm

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Detection electrode

Bottom view of the burner

DC Micro Ammeter

Flame control device

HG0109.12_C2_007

Start-up electrode

4) Checking and cleaning the exchanger (every 3/4 years)

Optimal combustion efciency in RAPID heaters prevents residual combustion products. However, in time, some dirt could

settle inside exchanger pipes, due to the ne dust drawn through

the combustion air duct. It is not possible to schedule a precise timetable for cleaning the heat exchanger. A sensible decrease

in gas ow could indicate there is dirt inside the heat exchanger.

5) Inlet Gas Pressure

Check that the inlet pressure to the valve corresponds to the one required for the available gas. This check is to be carried out while the heater is running at maximum capacity.

6) Flame Control Device

While the heater is running, close the gas tap and verify that the unit locks. Reopen gas tap, reset, and wait for the heater to restart.

7) Safety thermostat/s

Run this test while the heater is working. Heat the thermostat bulb using a hot air gun or a gas lighter and check that the unit locks. Cool the bulb, then reset: this procedure must be carried out on each thermostat assembled on the unit.

8) Ionization Current

Carry out this operation using a device capable of testing direct current microamperes. Do the following:

- Disconnect the unit from power supply.

- Disconnect ame control device cable and connect it to the

negative pole of the tester.

- Use a wire to connect the positive pole of the tester and the

ame control device of the unit.

- Power on the device and wait for the burner to start up.

- Check ionization value. This value must not be lower than 2 micro Amperes. Lower values would indicate that the detection electrode is misplaced, oxidized or it is going to break down.

6.8 Cleaning the Exchanger

The following operations must be carried out when the unit is cold and disconnected from power supply:

• Open the heater door.

• Disconnect the unit from power supply

• Remove the screws that x the ue hood cover.

• Use a suitable brush to clean pipes all along their length,

pushing dirt towards the outlet to collect it.

• Re-install the ue hood cover, taking care to check components

remain sealed.

6.9 Demolition

Should the unit be dismantled or demolished, please take care to:

• remove wires and cables;

• remove all plastic components.

Note: Any recovered material shall be treated and disposed of according to existing regulations and/or rules given in safety technical sheets accompanying chemical products.

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7. DIAGNOSTICS

Heaters include a diagnostic system that is activated in case of ill functioning. A steady red LED lights up on heater front panel when a fault occurs.

To reset the fault, press RESET button for more than 1 sec. RESET button is on front panel (see gure on page 21).

Maximum number of RESET attempts allowed is 3. If the failure persists, call Service Center for assistance.

To activate diagnostics and nd out fault type, press RESET button for more than 5 secs. Red LED will start ashing in sequences separated by a pause of 2 secs. The number of ashes in each sequence indicates the fault number. Check in the following

table fault numbers and relevant meaning.

Fault Codes Meaning

Number of ashes Possible reason

1. Flash

No detection of ame signal and timeout of safety card exceeded:

- Detection electrode wrongly positioned

- No fuel

- Fuel valves not working properly

- Faulty start-up transformer

- Burner damper wrongly set

2 Flashes

Safety Thermostat Opening:

- Activation of Safety Thermostat

- Faulty Safety Thermostat

3 ashes

Not applicable

4 ashes

Not applicable

5 ashes

Faulty Hall sensor of Burner Motor:

- Motor revolutions per minutes are less than set value

6 ashes

Secondary ames at startup

7 ashes

Not applicable

8 ashes

Generic fault

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8. WIRING DIAGRAM

RA015 - RA054 Wiring Diagram (code JG0400.00)

For connections, see section on Installation.

Component Legend IG Voltage disconnect switch (not included) SP1 Socket/plug to power the unit ACF Flame control device EVG Gas solenoid valve STB1-2 Safety thermostat (manual reset). TR-AC Start-up transformer EA Start-up electrode ER Detection electrode TR 230/24V - 63 VA transformer VAG Burner fan LV Green LED 230V [unit powered] LR Red LED 230V [lock] D1 Summer/winter switch SB Reset Button SB Air fans F1 4 AT fuse on board (delayed) R1 Relays of air fans

Wire colors

1 BLACK 2 BLUE/LIGHT BLUE 3 RED - ROSE 4 BROWN 5 YELLOW/GREEN 6 GREY 7 GREEN 8 WHITE 9 ORANGE

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NOTES:

- Dotted lines of fan burner wirings [VAG] are only valid for RA054 model

- VA2, STB2 and R1 components are only for RA043 and RA054 models

- TA*: The installer shall mount a room thermostat [TA] in between terminals No. 34 and 35 of CN3 board.

RAC024 - RAC054 Wiring Diagram (code JG0402.00)

For connections, see section on Installation.

Component Legend IG Voltage disconnect switch (not included) SP1 Socket/plug to power the unit

ACF ame control device

EVG Gas solenoid valve STB1-2 Safety thermostat (manual reset TR-AC Start-up transformer EA Start-up electrode ER Detection electrode TR 230/24V - 63 VA transformer VAG Burner fan LV Green LED 230V [unit powered] LR Red LED 230V [lock] ] D1 Summer/winter switch SB Reset Button VA1-2 Air fans F1 4 AT fuse on board (delayed) R1 Relays of air fans KA1 Relays of air fans

VA2, STB2 and R1 components are only for RA043 and RA054 models

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9. APPROVAL CERTIFICATE

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10. SPARE PART LIST - EXPLODED DRAWINGS

HG0107.08_C2_021

GAS TUBE SEAL

Code Model

C03430 (015/054)

GAS PIPE

Code Model

G14169.08 (015/054)

PANEL GASKET

Code Model

C00520 (015/054)

TUBE LOCKNUT

Code Model

X00630 (015/054)

GAS VALVE

Code Model

G12930 (015/054)

BURNER FAN Model Code G22803 (015/054)

BURNER FLANGE GASKET

Code Model

G16332 (015/054)

BURNER GASKET

Code Model

G14086 (015/054)

BURNER HEAD

Code Model

G14534-P (015/024) G14375.01-P (032/035) G16340.01-P (043) G14370.01-P (054)

Ø 8 GASKET

Code Model

G02285 (015/054)

FLANGE FUSION

Code Model

G16160 15/054)

FAN GASKET

Code Model

G14086 (015/054)

AIR/GAS VENTURI

Code Model

G14898 (015) G14899 (024) G14068 (032/035) G14154 (043/054)

START-UP GROUP WITH ELECTRODES

Code Model

G15020.02 (015/054)

GASKET

Code Model

G16331 (015/054)

PEEPHOLE GASKET

Code Model

G16329 (015/054)

PEEPHOLE GLASS

Code Model

G16324 (015/054)

PEEPHOLE FLANGE

Code Model

G16328 (015/054)

START-UP ELECTRODE CODE MODEL

G16347 (015/054)

DETECTION ELECTRODE

Code Model

G16334 (015/054)

HG0109.08_C2_008

GASKET CODE MODEL

X01257 (015/054)

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FLUE TERMINAL

Code Model

G14161.08 (015/054)

DETECTION WIRE

Code Model

G14993 (015/054)

START-UP TRANSFORMER

Code Model

G12905.01 (015/054)

START-UP WIRE

Code Model

G14994 (015/054)

FLAME CONTROL DEVICE

Code Model

G04600 (015/054)

FUSE - 6.3A - ST

Code Model

X00519 (015/035)

CLOSING HANDLE

Code Model

G14531 (015/054)

GASKET Ø 80

Code Model

G04378 (015/054)

REMOVABLE PLUG

Code Model

G12063 (015/054)

HG0109.09_C2_007

AIR TERMINAL

Code Model

G01239 (015/054)

HINGE

Code Model

X00536 (015/054)

FIXED PLUG

Code Model

G12064.01 (015/054)

MODEL Fan

RA015 C09250 Hidria #1 RA024/32 G03270 Hidria #1 RA035 G14890 Hidria #1 RA043 G03270 Hidria #1 RA054 G14890 Hidria #2

THERMOSTAT (STB)

Code Model

G16300 1X RA015/032 2X RA043/054

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HORIZONTAL LOUVER

Code Model

G15213 -S (015) G15313 -S (024/032/035) G15333 -S (043) G15353 -S (054)

HG0109.12_C2_015.pdf

LEDs

Code Model

G14992.01 015/054) Red G14991.01 (015/054) Green

SUMMER/0 /WINTER SWITCH

Code MODEL G12209.01 (015/054)

RESET BUTTON Code MODEL G13268 (015/054)

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Note 

_________________________________________________________________________________________

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APEN GROUP S.p.A.

Capitale sociale E 928.800 interamente versato 20060 Pessano con Bornago - Milan Via Isonzo, 1 - Tel. +39 2 9596931 Fax +39 2 95742758 Website: http://www.apengroup.com E-mail: [email protected] Tax Registration Number 08767740155