REMKO CLK170-RV, CLK Series, CLK 80-RV Assembly And Operating Instructions Manual

Assembly and operating instructions
REMKO CLK 170-RV
Oil heating unit
0013-2012-08 Version 2, en_GB
Read the instructions prior to performing any task!
Read these operating instructions carefully before commis­sioning / using this device!
These instructions are an integral part of the system and must always be kept near or on the device.
Subject to modifications; No liability accepted for errors or mis­prints!
Installation and operating instructions (translation of the orig­inal)

Table of contents

1 Safety instructions and user manual.................................................................................................. 4
1.1 General safety notes....................................................................................................................... 4
1.2 Identification of notes...................................................................................................................... 4
1.3 Personnel qualifications.................................................................................................................. 4
1.4 Dangers of failure to observe the safety notes................................................................................ 4
1.5 Safety-conscious working............................................................................................................... 4
1.6 Safety instructions for the operator................................................................................................. 5
1.7 Safety notes for installation, maintenance and inspection.............................................................. 5
1.8 Unauthorised modification and changes......................................................................................... 5
1.9 Intended use................................................................................................................................... 5
1.10 Warranty........................................................................................................................................ 5
1.11 Transport and packaging.............................................................................................................. 6
1.12 Environmental protection and recycling........................................................................................ 6
2 Technical data....................................................................................................................................... 7
2.1 Unit data.......................................................................................................................................... 7
3 Standards and regulations................................................................................................................... 8
3.1 Specifications for fan-assisted heaters........................................................................................... 8
4 Design and function.............................................................................................................................. 9
4.1 Unit description............................................................................................................................... 9
4.2 Installation instructions.................................................................................................................... 9
4.3 Safety equipment.......................................................................................................................... 10
4.4 Exhaust ducting............................................................................................................................. 11
5 Electrical connection.......................................................................................................................... 13
5.1 Electrical connection diagram....................................................................................................... 13
6 Before commissioning....................................................................................................................... 14
7
Commissioning................................................................................................................................... 16
7.1 Commissioning the unit................................................................................................................. 16
7.2 Commissioning the forced-air oil burner....................................................................................... 17
8 Decommissioning............................................................................................................................... 20
9 Troubleshooting and customer service............................................................................................ 21
10 Care and maintenance........................................................................................................................ 22
10.1 General....................................................................................................................................... 22
10.2 Maintenance protocol.................................................................................................................. 25
11 Exploded view and replacement parts.............................................................................................. 26
11.1 Exploded view of the unit............................................................................................................ 26
11.2 Replacement parts list................................................................................................................. 27
12 Index..................................................................................................................................................... 30
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REMKO CLK
1
1.1
Carefully read the operating manual before com­missioning the units for the first time. It contains useful tips and notes such as hazard warnings to prevent personal injury and material damage. Failure to follow the directions in this manual not only presents a danger to people, the environment and the system itself, but will void any claims for liability.
Keep this operating manual and the refrigerant data sheet near to the units.
1.2
This section provides an overview of all important safety aspects for proper protection of people and safe and fault-free operation.The instructions and safety notes contained within this manual must be observed in order to prevent accidents, personal injury and material damage.
Notes attached directly to the units must be observed in their entirety and be kept in a fully legible condition.
Safety notes in this manual are indicated by sym­bols. Safety notes are introduced with signal words which help to highlight the magnitude of the danger in question.

Safety instructions and user manual

General safety notes

Identification of notes

DANGER!
CAUTION!
This combination of symbol and signal word warns of a potentially hazardous situation, which if not avoided may cause injury or mate­rial and environmental damage.
NOTICE!
This combination of symbol and signal word warns of a potentially hazardous situation, which if not avoided may cause material and environmental damage.
This symbol highlights useful tips and recom­mendations as well as information for efficient and fault-free operation.
1.3

Personnel qualifications

Personnel responsible for commissioning, opera­tion, maintenance, inspection and installation must be able to demonstrate that they hold a qualifica­tion which proves their ability to undertake the work.
Contact with live parts poses an immediate danger of death due to electric shock. Damage to the insulation or individual components may pose a danger of death.
DANGER!
This combination of symbol and signal word warns of a situation in which there is immediate danger, which if not avoided may be fatal or cause serious injury.
WARNING!
This combination of symbol and signal word warns of a potentially hazardous situation, which if not avoided may be fatal or cause serious injury.
Dangers of failure to observe
1.4 the safety notes
Failure to observe the safety notes may pose a risk to people, the environment and the units. Failure to observe the safety notes may void any claims for damages.
In particular, failure to observe the safety notes may pose the following risks:
n The failure of important unit functions. n The failure of prescribed methods of mainte-
nance and repair.
n Danger to people on account of electrical and
mechanical effects.
1.5

Safety-conscious working

The safety notes contained in this installation and operating manual, the existing national regulations concerning accident prevention as well as any internal company working, operating and safety regulations must be observed.
4
Safety instructions for the oper-
1.6 ator
The operational safety of the units and compo­nents is only assured providing they are used as intended and in a fully assembled state.
n The units and components may only be set up,
installed and maintained by qualified per­sonnel.
n Protective covers (grills) over moving parts
must not be removed from units that are in operation.
n Do not operate units or components with
obvious defects or signs of damage.
n Contact with equipment parts or components
can lead to burns or injury.
n The units and components must not be
exposed to any mechanical load, extreme levels of humidity or extreme temperatures.
n All housing parts and device openings, e.g. air
inlets and outlets, must be free from foreign objects.
n The units must be inspected by a service tech-
nician to ensure that they are safe to use and fully functional at least once annually. Visual inspections and cleaning may be performed by the operator when the units are disconnected from the mains.
Safety notes for installation,
1.7 maintenance and inspection
n Appropriate hazard prevention measures must
be taken to prevent risks to people when per­forming installation, repair, maintenance or cleaning work on the units.
n The setup, connection and operation of the
units and its components must be undertaken in accordance with the usage and operating conditions stipulated in this manual and comply with all applicable regional regulations.
n Regional regulations and laws as well as the
Water Ecology Act must be observed.
n The units must be installed and operated in
such a way that personnel are not endangered by exhaust gases, hot air and radiant heat and no fires may occur
n The units must then only be operated in areas
where the units can be supplied with an ade­quate amount of air for the combustion
n If the units are being operated without exhaust
gas routing then they may only be operated in well ventilated areas. Under such circum­stances it is forbidden for personnel to remain in these areas for extended periods. Appro­priate prohibition signs should be put up at the entrances
n A safety zone of 1.5 m should be maintained
around the units - incl. non-combustible items
n The power supply should be adapted to the
requirements of the units.
n Mobile units must be set up securely on suit-
able non-combustible surfaces.
n The equipment and components should not be
operated in areas where there is a heightened risk of damage. Observe the minimum clear­ances.
n The units and components must be kept at an
adequate distance from flammable, explosive, combustible, abrasive and dirty areas.
n The units must not be exposed to direct jets of
water, e.g. pressure washers etc.
n Portable fuel containers must only be set up
and used in observance of the technical rules for combustible liquids "TRbF 20".
n Safety devices may not be modified or
bypassed.
Unauthorised modification and
1.8 changes
Modifications or changes to units and components are not permitted and may cause malfunctions. Safety devices may not be modified or bypassed. Original replacement parts and accessories authorised by the manufactured ensure safety. The use of other parts may invalidate liability for resulting consequences.
1.9

Intended use

The units are designed exclusively for heating and ventilation purposes in industrial or commercial use (no living space heating in private use) on the basis of their structural design and equipment. The units must only be operated by appropriately instructed personnel.
Any different or additional use is a non-intended use. The manufacturer/supplier assumes no lia­bility for damages arising from a non-intended use. The user bears the sole risk in such cases. Intended use also includes working in accordance with the operating and installation instructions and complying with the maintenance requirements.
The threshold values specified in the technical data must not be exceeded.
1.10
For warranty claims to be considered, it is essential that the ordering party or its representative com­plete and return the "certificate of warranty" to REMKO GmbH & Co. KG at the time when the units are purchased and commissioned.

Warranty

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REMKO CLK
The warranty conditions are detailed in the "Gen­eral business and delivery conditions". Further­more, only the parties to a contract can conclude special agreements beyond these conditions. In this case, contact your contractual partner in the first instance.
1.11
The devices are supplied in a sturdy shipping con­tainer. Please check the equipment immediately upon delivery and note any damage or missing parts on the delivery and inform the shipper and your contractual partner. For later complaints can not be guaranteed.
Plastic films and bags etc. are dangerous toys for children!
Why:
- Leave packaging material are not around.
- Packaging material may not be accessible to children!
1.12
Disposal of packaging
All products are packed for transport in environ­mentally friendly materials. Make a valuable contri­bution to reducing waste and sustaining raw mate­rials. Only dispose of packaging at approved collection points.

Transport and packaging

WARNING!

Environmental protection and recycling

Disposal of equipment and components
Only recyclable materials are used in the manufac­ture of the devices and components. Help protect the environment by ensuring that the devices or components (for example batteries) are not dis­posed in household waste, but only in accordance with local regulations and in an environmentally safe manner, e.g. using certified firms and recy­cling specialists or at collection points.
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2
2.1

Technical data

Unit data

Unit type CLK 170-RV
Max. nominal heating capacity kW 155
Nominal heating capacity kW 143
Nominal air flow volume
1)
m³/h 10 340
(Max. total) pressure Pa 520
Fuel
Heating oil EL acc. to DIN
51603 or diesel fuel
Max. fuel consumption l/h 15.5
Danfoss oil nozzle
2)
Pump pressure, approx.
2)
USG 3.00 / 80°S
bar 13
Max. exhaust gas loss % 9
Exhaust gas flow, approx. kg/h 240
Combustion chamber resistance, approx. Pa 110
Required chimney draft Pa 0
Power supply V/Hz 400 / 3~N / 50
Max. power consumption (complete unit) kW 3.4
Max. nominal current (complete unit) A 8.0
Max. power consumption (Multiflex oil preheating) W 30
Customer-provided electrical protection A 16
Temperature increase (∆t) K 54
Sound-pressure level, LpA 1m
3)
dB (A) 65
Air outlet Ø mm 500
Air intake Ø
4)
mm 2 x 500
Exhaust gas nozzles Ø mm 200
Dimensions (length/width/height) mm 2380/920/1350
Weight with forced-air oil burner kg 385
1)
At ∆t 45K / 1.2 kg/m3.
2)
The specified nozzle sizes and pump pressures are based on test bench results. The oil flow rate was derived from this. Based on the product-specific nozzle and pressure tolerances as well as the oil tempera­ture, the specifications should only be considered guidelines.
3)
Noise level measurement (with hose and without burner operation) DIN 45635 - 01 - KL 3
4)
Only with intake ports (accessories, ref. no: 1072355) for recirculating or mixed air operation.
We reserve the right to modify the dimensions and design as part of the ongoing technical development process.
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REMKO CLK
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3.1
When using the units the respective applicable guidelines must always be observed.
n Combustion plant order (FeuVo) for the indi-
n Accident prevention regulations (UVV)
n Workplace directives ASR 5 n Workplace regulations §§ 5 and 14 n Ordinance for implementation of federal emis-
Extract from the accident prevention regula­tions (VBG 43)
§ 37 Operating personnel
The units may only be operated by persons that have been instructed in the operation of the equip­ment

Standards and regulations

Specifications for fan-assisted heaters

vidual state
"Heating, flaming and melting devices for con­struction and installation work" (VBG 43)
sion control regulations (BImSchG) and the subsequently issued legislation (ENEG).
2nd. there are non-closable openings for incoming and outgoing air in the vicinity of the ceiling and floor whose size in m2 is at least 0.003 times the nominal heating capacity of all of the units oper­ating in the space.
(5) The units may not be installed or operated in potentially flammable or explosive environments or areas.
§ 44 Space drying
(2) In derogation from § 38 section 3 heating units can be used for drying areas with adequate air supply for combustion without having to route the exhaust gases through exhaust gas ducting to the outside. It is forbidden for personnel to remain in these areas for extended periods. Appropriate pro­hibition signs should be put up at the entrances.
§ 53 Testing
(2) In accordance with the operating conditions, the units must, if necessary, be checked at least yearly by a specialist to ensure that they are in a condition that is safe to use The exhaust gas values for the burners must be checked.
§ 38 Installation
(1) The units must be installed in a stable position. (2) The units must be installed and operated in
such a way that personnel are not endangered by exhaust gases and radiant heat and no fires may occur.
(3) The units must then only be installed and oper­ated in areas where the units can be supplied with an adequate amount of air for the combustion and the exhaust gases can be routed to the outside via exhaust gas ducting. There is enough natural air supply for the combustion if, for example, the space in m3 is at least 10 times the nominal heating capacity in kW of all of the units operating in the space and if the natural change of air is guaranteed by windows and doors.
(4) In derogation from point 3, the units may be operated in a space without exhaust gas routing if this is well ventilated (both incoming and outgoing air) and the proportion of health endangering sub­stances in the breathing air does not reach a detri­mental concentration. There is good natural venti­lation if, for example,
§ 54 Monitoring
(1) The personnel tasked with operating the units must check the units for visible defects on the operating and safety devices as well as the pres­ence of the protective devices at the start of work.
(2) If defects are discovered these must be reported to the supervisor.
(3) In the case of defects that endanger the opera­tional safety of the unit, it must be taken out of service immediately.
§ 55 Infringements
Infringements in the sense of § 710 section 1 of the Imperial Insurance Code (RVO) pertain to an intentional or negligent breach of the provisions of VBG 43.
1st. the room volume in m3 is at least 30 times the nominal heating capacity of all of the units oper­ating in the space and if the natural change of air is guaranteed by windows and doors or
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4
4.1
The units are portable, directly fired fan-assisted heaters (WLE) with heat exchanger and exhaust gas connections exclusively for commercial appli­cations.
The units can be directly fired with EL heating oil or Diesel fuel.
The units can be operated with or without exhaust gas pipe. They have been designed for universal and straightforward use.
The units are exclusively operated with separate type-approved forced-air burners.
The units are equipped with a noise-optimised and low-maintenance, high performance radial fan, a room thermostat receptacle and a main cable with 400 V CEE connector.
The units are equipped with a device for automati­cally checking the turning direction of the fan motor, as standard.
With factory fitted forced-air oil burners the units have integrated Multiflex oil pre-heating fitted as standard.
The units conform to the fundamental health and safety requirements of the appropriate EU stipula­tions.

Design and function

Unit description

For optimum operation the units should not be operated above an ambient temperature of 25 °C.
Locations at which units are used
As mobile, directly fired fan-assisted heaters, the units deliver instant heat. They are designed exclu­sively for commercial use.
The units may be used for the heating, tem­perature adjustment or drying of:
n Warehouses n Exhibition halls n Trade fairs n Lightweight construction halls n Large tents / marquees n Large construction sites
Operating sequence
If the units are set to heating mode, then the forced-air burner starts automatically. In fully auto­matic heating mode with room thermostat the forced-air burner starts only when heat is required.
After the burner has run for a short time the tem­perature controller "TR" (target temperature 35 to 40°C) switches the supply air fan on automatically. Warm air is blown out.
When operating with a room thermostat this process is repeated automatically depending on the heat demand.
The temperature monitor "TW" (target temperature 80 to 85°C) monitors the internal temperature of the unit.
After switching off the units via the operating switch or the room thermostats the supply air fan runs to cool the combustion chamber with the heat exchanger for a certain time and then switches off. This process may be repeated several times if necessary.
4.2

Installation instructions

NOTICE!
The units may never be disconnected from the mains prior to the completion of the follow-up cooling phase (except in emergencies).
NOTICE!
Only type-approved forced-air oil burners in WLE design per DIN EN 230 and DIN EN 267 should be used.
9
The safety regulations of the accident preven­tion and insurance associations, the respective regional building regulations and the combus­tion appliances regulations apply in principle to the operation of the unit.
Overpressure and underpressure in the instal­lation area should be avoided as this will inevi­tably lead to combustion-related faults.
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REMKO CLK
n Make sure that there is an adequate fresh air
supply appropriate to the respective forced-air burner capacity (see type plate). The forced-air oil burner may need to be fitted with a separate air supply for combustion
Installation outside
n The operation of the units must not present a
hazard or unreasonable loading
n The unit operator must ensure that it is not
possible for unauthorised persons to be able to manipulate either the unit or the power supply.
n Precipitation such as rain or snow can be
sucked in through the supply air fan. For this reason suitable weather protection should be provided.
DANGER!
The units must only be installed in well venti­lated spaces and not in living areas or similar recreational areas.
Installation in closed, well ventilated areas without exhaust gas connection
Safety distances
n In order to guarantee safe operation and main-
tenance of the units, 1.5 m safety distance should be maintained around the unit.
n Flooring and ceilings must be fire retardant n Intake and outlet diameters must not be nar-
rowed or blocked with foreign objects.
4.3

Safety equipment

Safety temperature limiter (STB)
The heating function is permanently interrupted by the safety temperature limiter (STB) in the event of the units overheating or malfunctioning.
Manually resetting of the STB can only be imple­mented after the units have cooled down.
The resetting of the STB is implemented by actuating the reset button 2.
NOTICE!
If the safety temperature limiter has been tripped then the cause of the fault should be identified and rectified before resetting it.
n The operation of the units is permissible if the
minimum air quantity cited in § 38 section 4 for combustion is supplied.
n Reliable extraction of the combustion gases
must be guaranteed in all cases in order to exclude impermissible contamination of the room air with hazardous substances.
Fresh air is fed from below.
Exhaust gases are routed upwards.
Room heating
n The units may only be operated for room
heating with a room thermostat (accessory).
n The fresh air supply required for trouble-free
combustion must be guaranteed. It is practical to have the fresh air supply provided by win­dows and doors or through appropriately dimensioned openings in the outside wall
1. Unscrew protective cap [1].
2. Carefully press in the reset button [2] with a
suitable tool.
3. Screw the protective cap [1] back on again.
Fig. 1: Safety temperature limiter (STB)
NOTICE!
Safety devices must not be bypassed or disa­bled.
10
In order to prevent a renewed exceedance of the triggering temperature the operating condi­tions of the unit should be checked before resetting the STB.
Regulating device
The temperature sensor of the controller is self­monitoring.
The sensors are cold-resistant to -25 °C. At tem­peratures below -25 °C the controller current flow will be interrupted - if the temperature rises above
-25 °C the current flow will be released again. In the event of the sensor or the capillary tube
being damaged, as well as if an overtemperature of ca. 220 °C is reached, the fill medium will be emptied and the safety device is permanently trig­gered. Resetting is no longer possible. The con­troller is no longer fully functional and must be replaced.
NOTICE!
Only "REMKO original replacement parts" must be used when replacing safety devices.
Temperature monitor (TW)
The temperature monitor limits the unit or outlet temperature in heating mode via the burner. The switch point is set via the "Scale 34-110°" con­troller in the switching cabinet. Target value ca. 80
- 85 °C.
Safety temperature limiter (STB)
The unit is permanently switched off by the safety temperature limiter (STB) in the event of the unit overheating or a temperature monitor malfunction. Manual resetting is required.
Automatic burner
The unit is permanently switched off by the auto­matic burner through the optical flame monitoring in the event of irregularities in the combustion, the flame extinguishing, fuel deficiencies etc.
Manual resetting is required.
4.4

Exhaust ducting

It is also possible to operate the units outside or in open spaces without exhaust gas routing. How­ever, we recommend fitting a 1m exhaust gas duct with a rain hood on top (example 2), in order to exclude the ingress of rainwater and dirt.
If the units are used for room heating then the combustion gases must be routed away, to the outside if necessary.
n Ensure that the device is fitted properly n The capillary tubes must not be kinked or bent
in the immediate vicinity of the soldering points
n The capillary tubes must not be damaged or
kinked during installation
n The sensors must only be fitted at the fas-
tening points provided by the factory
n The sensors must always be free of dust and
dirt in order to be sure of their correct func­tioning
The units have the following control or safety equipment:
Temperature controller (TR)
The temperature controller controls the switching on and off of the recirculating fan. The switch point is set via the "Scale 21-60°" controller in the switching cabinet. Target value ca. 35 - 40 °C.
n The exhaust gas routing must be designed
such that the thermal lift of the exhaust gases is guaranteed at all times
n The exhaust gas routing must be designed
such that there can be no counter-pressure
n Fault-free operation is guaranteed if the
exhaust gas routing is fitted in a rising arrange­ment and with a vertical end pipe
n The exhaust gas routing should end at least
above the height of the eaves but ideally above the height of the ridge, in order to prevent any counter-pressure being caused by poor weather conditions (e.g. wind)
n The minimum distance of 0.6 m to combustible
parts must not be infringed
n Exhaust gas ducting parts and fastening mate-
rials are available as accessories
n All parts of the exhaust gas routing must be
reliably fastened. Its diameter must not be smaller than the outlet nozzle of the unit.
11
> 1 Meter
max. 1 Meter
1
2
3
REMKO CLK
Notes for implementing the 1st. BImSchV
Units that are not expected to be operated for longer than 3 months in the same location are not subject to any approvals or monitoring per the 1st. BImSchV. (§1, section 3)
Fig. 2: Examples of permissible and impermissible exhaust gas ducting
Example 1
Operation with extended exhaust gas ducting
Condensate trap required.
Example 2
Operation without extended exhaust gas ducting.
Max. 1 metre
Example 3
Impermissible layout
In order to avoid the combustion chamber being damaged due to condensation of mois­ture (condensate) in example 3, make sure that the exhaust gas ducting is correctly installed with a condensate trap as shown in example 1.
WARNING!
There must be no counter pressure arising from incorrect installation of exhaust gas ducting under any circumstances.
After installing an exhaust gas system the set­tings on the burner should be adapted to suit the new conditions.
12
SKR
LKR
NET
L A H
2 3
PE
1
1 221
4
1
2
4B
5B
6B
0
2 4
6
1 3
5
2 4
6
1 3
5
2 4
6
1 3
5
1 3
5
2 4
6
L1 L2
L3
16 18
15
22
21
22
21
22
21
22
21
11
14 12
95
96
S1
S2
ÖV
WS
PE N L1 L2 L3PEN4321
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5.1

Electrical connection

Electrical connection diagram

Fig. 3: Electrical connection diagram (see next page for legend)
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REMKO CLK
NET Power supply L,A,H Ventilate, Off, Heat LKR Load circuit SKR Control circuit S1 Operating switch S2 Reset button (burner) H1 Operating lamp (green) H2 External burner fault lamp (red) TR Temperature controller TW Temperature monitor STB Safety temperature limiter X1 Terminal strip M Fan motor
We reserve the right to modify the dimensions and design as part of the ongoing technical development process.
6
The units should be checked for visible defects on the operating and safety devices as well as proper installation and correct electrical connections before commissioning.
It is essential that the following points be observed:
n Set up the units in a stable position n Ensure there is sufficient supply of combustion
n Check that the inlet and outlet are free n Prevent overpressure or underpressure in the
n Ensure that there is sufficient fuel supply and
n Only use clean EL heating oil or Diesel fuel. Do
n The suction line in the base of the tank must be

Before commissioning

air
installation area
that it complies with the respective local regula­tions
not use Bio-Diesel!
fitted with a foot valve as a matter of principle
After fulfilling the respective local regulations as well as a professional installation of the unit, the exhaust values for the forced-air burner must be checked and adjusted if necessary by authorised specialists.
WS Burner connector, 7-pole RT Thermostat receptacle ÖV Multiflex oil pre-heating 1F3.1 Controller fuse 2K2.1 Mains fuse 2K2.2 Time relay 2K3.1 Mains fuse 2K5.1 Delta contactor 2K5.2 Star contactor 1K6.1 Phase sequence relay 2K6.1 Star-delta relay 1Q3.1 Motor protection switch
n Use hot air hoses approved by us (accesso-
ries) exclusively
n Observe the air flow direction of the hoses with
this! The inner overlapping on the seams of the hot air hoses must point in the direction of the air flow.
n Make sure that the hose or ducting is securely
fastened onto the unit outlet nozzle and any connection pieces that may be being used
n Only suitable air distributors or air distributors
approved by ourselves should be used for the air distribution
The hot air hoses must only be used in fully extended form and without any constrictions.
n Enclosed spaces being heated via hoses must
not present any overpressure
n The forced-air burner can be switched off
briefly during operation by the temperature monitor (TW) in the event of there being increased intake temperatures or resistance at the unit's outlet.
After the temperature drops again the burner starts anew automatically!
Air feeds on the intake side must always be implemented by means of non-distorting hoses/ducts (no unstable hoses).
Air distribution
The units are equipped with a high performance radial fan, which has been designed to transport the heated air efficiently and effectively over large distances.
The distribution of the air is preferably imple­mented via ducting or special hot air or membrane hoses.
n If the cycle intervals are too short the length
and layout of the hot air routing should be checked
14
NOTICE!
Cycled operation of the forced-air burner with run times under 5 min. should certainly be avoided.
n There should be no kinks or bends in the
layout of the hoses in order to prevent hot­spots forming. Membrane hoses must not be twisted
If a build-up of heat should occur then the heating operation will be interrupted by the STB permanently.
Suction air
Fresh air, mixed air or circulated air operating modes can be selected on the unit. The following information refers to the installation of the unit out­side the space to be heated.
Fresh air operation:
The air intake is implemented in the factory through 2 intake grills, right / left.
Mixed air operation:
For operation of the unit in mixed air mode it is necessary to fit the intake nozzles, available as accessories. In order to guarantee adequate air throughput the second intake grill must not be cov­ered.
Circulated air operation:
For operation of the unit with 100% recirculated air it is necessary to fit two intake nozzles, available as accessories, in place of the 2 factory-fitted intake grills.
Paraffin formation with low outside tempera­tures
Even at low outside temperatures it is necessary to ensure that there is an adequate supply of heating oil that is capable of flowing.
n Paraffin formation can start with temperatures
as high as 5 °C
n To avoid this appropriate preventative meas-
ures must be implemented.
e.g. winter-proof EL heating oil or winter Diesel, heated oil tank, insulated oil lines etc.
n Note that fault-free operation of the Multiflex oil
pre-heating can only be guaranteed if the unit has been supplied with electrical power for a long period of time before starting
n It is not possible to rectify paraffin separation
that has already occurred with the heating. If paraffin has already formed it is necessary to clean out the complete fuel system
Paraffin formation can start with temperatures as high as 5 °C. To avoid this appropriate pre­ventative measures must be implemented, e.g. winter Diesel.
15
A
B C
1
2
3
4
5
6
7
2
1
REMKO CLK
7
7.1
One person, who has been adequately trained in the handling of the unit, should be tasked with the operation and monitoring of the unit.
Connecting the units with the electrical power supply
The electrical connection 400V/3~N is imple­mented via an integrated mains cable with a 16 A CEE connector.

Commissioning

Commissioning the unit

The units are equipped with a device for auto­matically checking the turning direction of the fan motor, as standard.
Fig. 4: Operating mode switch positions
Control panel
1. Move the operating switch to the "0" (off)
position. (see fig. [A] in Fig. 4)
2. Connect the mains plug with a properly installed and appropriately safeguarded mains socket 400V/3~N/50Hz
The electrical connection for the units must be made at a separate feedpoint with a residual current device in accordance with VDE 0100, Section 55.
3. Open all of the oil supply shut-off devices. With the initial commissioning, air in the lines can lead to a fault shut-down of the burner.
CAUTION!
All cable extensions must only be used in fully un-reeled or reeled off condition.
Fig. 5: Control panel
1 Thermostat receptacle 2 Strapping plug 3 Operating switch 4 Indicator lamp " green" "Operation" 5 Indicator lamp " red" "Burner fault" 6 Reset button "Burner" 7 Mains cable with plug
Heating without room thermostat
The units are operating in permanent operating mode.
1. Connect the strapping plug supplied [2] with the thermostat receptacle [1] on the unit. (See Fig. 6)
2. Move the operating switch to the "I" (on) position. (see fig. [B] in Fig. 4)
Fig. 6: Strapping plug and thermostat receptacle
16
Heating with room thermostat (accessory)
3
1
4
M
G
The units operate fully automatically and in accord­ance with the room temperature.
1. Pull out the strapping plug [2].
2. Connect the room thermostat [4] plug [3] with
the thermostat receptacle [1] on the unit.
Indicator lamp "Operation"
The indicator lamp signals the "Heating" oper­ating mode. There is no display in the " Venti- late" operating mode or with the room thermo­stat switched off and when the STB has been triggered.
Commissioning the
7.2 forced-air oil burner
Preparatory tasks
3. Place the room thermostat [4] at a suitable
location in the room. The thermostat sensor must not be located directly in the warm air flow and should also not be placed directly on the cold floor.
4. Set the desired temperature on the room thermostat [4].
5. Move the operating switch to the "I" (Heating) position. (see fig. [B] in Fig. 4)
The unit starts automatically after a brief burner pre-ventilation if heat is required and then runs fully automatically.
Ventilate
In this switch position the supply air fan runs per­manently. The units can be used for air recircula­tion or ventilation purposes.
Move the operating switch to the "II" (Venti­late) position. (see fig. [C] in Fig. 4)
NOTICE!
The commissioning of the forced-air oil burner may only be carried out by trained specialists.
After loosening the 6 fastening bolts (note marking arrows) the mounting baseplate [M] is pulled off the housing [G] (see Fig. 7).
Because the air flap is sprung this should be closed beforehand with the help of the adjust­ment screw [3] (turn adjusting screw approx. as far as scale value 1).
The most important functional parts for the installa­tion / maintenance are now immediately acces­sible, as per the respective requirements.
Thermostatic control as well as heating operation is not possible in this operating mode.
Fig. 7: Removing the fastening screws
For maintenance work or for installing / replacing
17
the oil nozzle, the mounting baseplate [M] can be positioned on the burner housing [G] in 2 ways (see Fig. 7 and Fig. 8).
M
G
B
A
1
2
REMKO CLK
Fig. 8: Positioning the mounting baseplate on the burner housing
The baseplate can be positioned in the desired / possible position on the special mounting points in accordance with the unit-specific options.
Air inlet nozzle
The required blower pressure can be adjusted with the adjustable air inlet nozzle [A] in accordance with the combustion chamber resistance and chimney draft, without having to change the output diameter.
1. Loosen the Allen screw [B].
2. Turn the air inlet nozzle [A] to the desired
position (note arrows!).
"min" = Smaller blower pressure "max" = Larger blower pressure
Adjusting the ignition electrode and baffle plate
Fig. 9: Adjusting the ignition electrode and baffle plate
Size / dimensions A B C D
CLK 170-RV 7 8 5 3
All sizes are approximate values and are in mm. The optimum setting must be adapted to the unit­specific and structural conditions.
Required nozzle size
The selection of the required oil nozzle is dependent on the pump pressure and the unit capacity. Only a nozzle that is approved for the respective combustion chamber geometry with cor­responding spray angle and cone characteristics may be used. Refer to the technical data for the required oil nozzle size.
Fig. 10: Adjustment of the blower pressure by means of the air inlet nozzle
Mounting baseplate
After having replaced the nozzle and carried out any adjustments required to the air inlet nozzle [A], the mounting baseplate [M] is re-fitted in reverse order.
Adjusting the secondary air (nozzle fitting adjustment)
Fig. 11: Adjusting the secondary air
Carry out the presetting of the secondary air as fol­lows:
Set the nozzle fitting [2] to the desired value with the adjusting screw [1].
(Turns see Fig. 12)
18
3
4
Turning to the left (+)
= larger scale value smaller pressure behind the baffle plate upper power range
Turning to the right (-)
= smaller scale value larger pressure behind the baffle plate lower power range
Fig. 12: Turns of the adjusting screw
Air flap
Fig. 13: Adjustment of the air flap by means of the adjusting screw
The quantity of combustion air required is adjusted by means of the adjusting screw [3]. The air flap is set according to the unit capacity and the further burner settings.
Additional notes
n If the flame should give off sooty smoke or
break away with a fully opened air flap, reduce the pressure behind the baffle plate with the help of the secondary air setting
n It may also be necessary to open the air inlet
nozzle further
Setting the pump pressure
The pump pressure should be adjusted, and checked if necessary, during burner commis­sioning and during every service.
NOTICE!
Never let the pump run for extended periods without any fuel. Never leave the units for extended periods with a pump that has run dry.
Adjust the pump pressure as follows:
1. Remove the plug on the measurement nozzle "P".
2. Fit a suitable oil pressure manometer here.
3. Open all oil shut-off devices.
4. Switch on the burner.
5. Set the required oil pressure in accordance
with the nozzle size and the unit capacity.
6. Switch off the burner after completing the adjustments.
7. Remove the oil pressure manometer again. Re-fit plug incl. seal.
NOTICE!
Adjusting the air flap
Adjust the air flap as follows:
If the burner should carry out a fault shut-down once again after the start phase, then another reset should be carried out after a waiting period of 5 minutes has passed. Further reset
1. Loosen the knurled nut [4].
2. Set the adjusting screw [3] accordingly.
procedures must be prohibited as there is a danger of deflagration.
Turn to the right = Less air
Turn to the left = More air
3. After having set the adjusting screw [3] lock it
again with the knurled knob [4].
19
All values provided are only preliminary set­tings and must be adapted or calibrated in accordance with the exhaust gas analysis.
A
B C
REMKO CLK
8
1. Set the operating mode switch to the "0" (Off)
2. Shut off fuel supply (see fig. [B] in Fig. 14).
3. With longer periods of inactivity, disconnect
Fig. 14: Decommissioning
The supply air fan runs on to cool the combustion chamber and the heat exchanger and only switches off after the cooling down phase is com­plete. The fan can switch on and run several times before the final shutdown.

Decommissioning

position (see fig. [A] in Fig. 14).
the units from the mains power supply (see fig. [C] in Fig. 14).
NOTICE!
Never interrupt the mains connection prior to the completion of the follow-up cooling phase. There is no warranty claim for damage to the units from overheating.
The burner setting should be checked after every change of location and adapted to the new environmental conditions and atmospheric conditions if necessary.
20
9
The unit has been manufactured using state-of­the-art production methods and has been tested several times to ensure that it works properly. However, in the event that malfunctions should occur, the device should be checked against the following list. Please inform your dealer if the unit is still not working correctly after all of the functional checks have been performed.
The unit does not start
1. Check mains connection. 400 V/3~N/50Hz.
2. Move the operating switch to the "I" (Heating)
3. The "Operating" indicator lamp on the control
4. Check the strapping connector or the room
5. Check the setting of the room thermostat.
6. Check whether the safety temperature limiter
7. Before an STB reset ensure that the causes
8. Check whether the "Burner fault" indicator

Troubleshooting and customer service

DANGER!
Before undertaking any work on the units, the mains plug must be removed from the mains socket.
position.
panel must illuminate.
thermostat connector, if fitted, is seated prop­erly and making good contact.
The temperature set must be higher than the current room temperature.
(STB) has tripped. To do so, remove the pro­tective cap next to the control panel.
have been analysed and rectified. The fol­lowing causes are possible:
- The units were not able to cool down because the electrical connection was inter­rupted.
- Too high an outlet temperature due to incor­rectly implemented air routing when oper­ating with hoses.
- Air inlets or outlets are not free or are inad­equate.
lamp on the control panel is illuminated. If this is the case, then reset the automatic burner.
9. Move the operating switch to the "II" (Venti­late) position. If the supply air fan now starts up the fault may well be in the burner area.
Forced-air burner and power supply
1. Check the oil filter(s) for contamination.
Replace contaminated oil filter(s).
2. Check whether the shut-off cock on the oil filter is open.
3. Check the fuel tank for sufficient fuel level.
4. Check the heating oil for paraffin separation. Possible from 5 °C!
5. Check the oil hoses for damage.
6. Check the safety devices' capillary tubes and
sensors for damage or contamination.
7. Use appropriate means to check that the temperature monitor (TW) is functioning properly.
8. Check the forced-air burner for possible damage to the nozzles, baffle plate, filter etc.
The supply air fan does not start
1. Check the fan can move freely.
2. Check the controller fuse in the switching
cabinet.
3. Check whether the motor protection switch in the switching cabinet has tripped.
4. Use appropriate means to check that the temperature controller (TR) is functioning properly.
21
1
2
3
4
5
REMKO CLK
10
10.1
Regular care and observation of some basic points will ensure trouble-free operation and a long service life.
Before undertaking any work on the units, the mains plug must be removed from the mains socket.
Adjustment and maintenance work may only be carried out by authorised qualified techni­cians.
n Keep the units free of dust and other debris n Only clean the units with a dry or moistened
cloth
n Never subject to direct jets of water such as a
high-pressure cleaner etc.
n Never use abrasive or solvent-based cleaners n Even with heavy contamination, use only suit-
able cleaners
n Only use clean EL heating oil or Diesel fuel.
Watch for paraffin formation!
n Check the fuel filter for contamination at reg-
ular intervals. Replace contaminated filter if necessary
n Check the units for mechanical damage and
have defective parts properly replaced
n Check the fan blades and combustion chamber
with heat exchanger for contamination at reg­ular intervals and clean these if necessary
n Check the on-site oil tank regularly for contami-
nation and foreign bodies and clean this if necessary
n Inspect V-belt pre-tensioning. The press-down
deflection depth for the V-belts should be ca. 10 mm (a thumb width)
n Check that the safety devices are operating
correctly at regular intervals
n Keep the sensors for the safety devices free of
dust and dirt
n Have the exhaust gas values for the forced-air
burner checked by authorised specialists at regular intervals. For safety reasons we recom­mend the conclusion of a maintenance con­tract.
n Observe maintenance and care intervals

Care and maintenance

General

DANGER!
NOTICE!
Cleaning tasks
The units, including the heat exchanger, combus­tion chamber and forced-air burner must be cleared of dust and dirt after every heating period, or possibly earlier depending on the operating con­ditions. Wearing parts, such as exhaust gas sup­pressors, seals, V-belts, oil filter inserts and oil nozzles for example, should be checked and replaced if necessary.
Cleaning the heat exchanger
1. Set the operating switch to the "0" position
and remove the mains plug from the mains socket.
2. Take off the exhaust hood [1] after removing the 4 fastening screws. Hot air hoses present need not necessarily be removed.
3. Remove the inspection cover [2] and with­draw the exhaust gas suppressors [4].
4. Clean the flue [5]. A special cleaning brush is available as an accessory with ref. no.
1103110.
Fig. 15: Cleaning the heat exchanger
5. Clean the exhaust gas suppressors or replace damaged exhaust gas suppressors.
6. Check the seal [3] for the inspection cover and replace any damaged seals.
7. After the maintenance work is complete all parts should be carefully re-fitted in reverse order.
22
NOTICE!
1
2
3
4
5
6
30
6
7
Always check that the seal is correctly seated in the inspection cover. When fitting the inspec­tion cover ensure that the fastening screws are tightened evenly.
Cleaning the combustion chamber
1. Set the operating switch to the "0" position
and remove the mains plug from the mains socket.
2. Remove the burner cladding [1] after opening the two quick couplings [2].
3. Loosen the 2 lower fastening screws on the burner flange [6].
4. Loosen the clamping screw [7] on the burner flange [6] and withdraw the burner towards the front.
Fig. 16: Cleaning the combustion chamber
5. Withdraw the burner and carefully set it down beside the unit.
6. Remove the burner flange [6].
7. Take care not to damage the flange seals, as
far as is possible.
NOTICE!
Damaged flange seals can result in incorrect air induction.
Installation of the burner flange and the burner
Fig. 17: Installation of the burner flange and the burner
1. Check the flange seal and replace if neces­sary.
2. Fasten the burner flange to the unit housing with the four fastening screws.
Note the "UP" marking!
3. Tighten the top 2 fastening screws firmly.
4. Tighten the lower 2 fastening screws gently
and with only light force so that the burner flange can still be pulled together.
5. Slide the flame tube of the burner into the burner flange.
Observe the dimensions in Fig. 17
!
6. Clamp the flame tube firmly into place with
the clamping screw [7] whilst lifting the burner slightly (3° tilt).
7. Lastly, tighten the bottom 2 fastening screws firmly.
8. Check the fuel filter insert [3] for leaks and replace if necessary.
9. Re-fit burner cladding and fasten with the quick couplings.
Additional notes for unit maintenance
n All work must be carried out exclusively by
authorised specialists with the appropriate equipment. A log should be created and kept safely by the operator
n It is essential that the forced-air burner is serv-
iced and adjusted by authorised specialists
8. Clean the combustion chamber through the burner opening with a vacuum cleaner. A special boiler cleaning set for the REMKO industrial vacuum cleaner is available as an accessory.
23
WARNING!
Repair work on the electrical installation and on the burner must be performed exclusively by authorised specialists for safety reasons.
8
7
9
REMKO CLK
WARNING!
An electrical safety check must be carried out in accordance with VDE 0701 after any work on the units.
WARNING!
The restrictions on exhaust gas losses per §11 of the ordinance on small furnace systems (1st. BImSchV) must be observed.
Tensioning the V-belt
1. Remove the two air intake grills.
2. Loosen the screws [7]. The screw on the
opposite side is not shown.
3. Set the pre-tension of the V-belt with the (size 17) nuts [8] and [9].
4. The press-down deflection depth for the V­belts should be ca. 10 mm (a thumb width)
5. Counter-lock the nuts [8] and [9] and then tighten the two fastening screws [7] again.
6. Re-fit the two air intake grills.
NOTICE!
The thermal overcurrent relay must be oper­ated exclusively in the "Manual resetting" posi­tion. It is not permitted for the relay to be able to switch itself back on again after the cooling down phase.
NOTICE!
If the overcurrent relay is operated in the "Automatic resetting" position, then motor damage cannot be excluded. Warranty claims
are voided!
NOTICE!
Check the function and setting of the thermal overcurrent relay in the switching cabinet. (Set­ting 3.6 A)
Fig. 18: Tensioning the V-belt
24
10.2
Unit type:
--------------------------------
010203040506070809101112131415161718192
Unit cleaned - outside -
Unit cleaned - inside -
Fan blade cleaned
Combustion chamber cleaned
Heat exchanger cleaned
Exhaust gas suppressors replaced
Inspection cover seal replaced
Fuel filter insert replaced
Safety equipment checked
Safety devices checked
Unit checked for damage

Maintenance protocol

Unit number:
---------------------------------------
0
Electrical safety check
Burner maintenance *)
Test run
Comments: ...................................................................................................................................................
.............................................................................................................................................................................
01. Date: .............
...............................
Signature
06. Date: ............
...............................
Signature
11. Date: ............
...............................
Signature
16. Date: ............
...............................
Signature
02. Date: .............
...............................
Signature
07. Date: .............
...............................
Signature
12. Date: .............
...............................
Signature
17. Date: .............
...............................
Signature
03. Date: .............
...............................
Signature
08. Date: .............
...............................
Signature
13. Date: .............
...............................
Signature
18. Date: .............
...............................
Signature
04. Date: .............
...............................
Signature
09. Date: .............
...............................
Signature
14. Date: .............
...............................
Signature
19. Date: .............
...............................
Signature
05. Date: .............
...............................
Signature
10. Date: .............
...............................
Signature
15. Date: .............
...............................
Signature
20. Date: .............
...............................
Signature
*) Have the forced-air burner maintained and adjusted only by authorised specialists and in accordance with the legal provisions (1st BImSchV.). A corresponding measurement log should be generated.
Unit to be maintained only by authorised specialists in accordance with the statutory regulations.
25
44
43
61
62
60
1
5
6
7
9
8
11
21 22
23
10
25
26
27
38
28
30
31
33
45
48
46
40
41
62
60
60
66
67
696871
72
4
36
60
20
3
2
12
13
32
34
35
42
46
47
50
52
51
53
54
55
70
12
61
A
REMKO CLK
11
11.1

Exploded view and replacement parts

Exploded view of the unit

Fig. 19: Exploded view of the unit CLK 170-RV
A Temperature sensor
26
We reserve the right to modify the dimensions and design as part of the ongoing technical development process.
11.2
No. Description CLK 170-RV
1 Cover panel 1104851
2 Upper insulation 1104852
3 Insulation right / left 1104853
4 Upper side cover (right / left) 1104854
5 Lower side cover (right / left) 1104855
6 Lower insulation 1104872
7 Front base plate 1104856
8 Rear base plate 1104857
9 Support foot 1104790
10 Front wall cmpl. 1104858
11 Front wall insulation 1104786
12 Guide bracket 1104787
13 Hose pass-through 1104722

Replacement parts list

20 Multiflex oil pre-heating 1071411
21 O-ring 1108464
22 Filter insert 1108462
23 Oil filter cup 1108463
25 Outlet nozzle 1104788
26 Burner cladding cmpl. 1104789
27 Axle 1104791
28 Wheel 1108369
30 Combustion chamber, cmpl. 1104806
31 Exhaust gas suppressor (set) 1104809
32 Inspection cover 1104794
33 Seal for inspection cover 1104795
34 Sealing cap 1104784
35 Centre wall 1104862
36 Intake grill, right / left 1104863
40 Back wall 1104864
41 Switching cabinet cmpl. 1104865
42 Seal for switching cabinet 1104866
43 Crane eye 1102554
27
REMKO CLK
No. Description CLK 170-RV
44 Exhaust gas nozzle collar 1104796
45 Transportation bracket, front 1104867
46 Transportation bracket, middle 1104868
47 Transportation bracket, rear 1104869
48 Spacing roller 1104849
50 Radial fan 1108607
51 Fan belt pulley 1102831
52 V-belt 1102802
53 Motor belt pulley 1102784
54 Electric motor IE2 1102733
55 Motor bracket with clamp 1104870
60 Temperature controller (TR) 1103166
61 Safety temperature limiter (STB) 1101197
62 Temperature monitor (TW) 1103146
66 Operating switch 1101188
67 Indicator lamp, green (Operation) 1105514
68 Indicator lamp, red (Burner fault) 1105363
69 Reset button (Burner) 1103408
70 Thermostat receptacle 1101018
71 Strapping plug 1101019
72 Mains cable with plug CEE 16A 1105100
Spare parts not illustrated
Intake nozzles, recirculating / mixing operation 1072355
Burner connector, 7-pole 1102537
Drum fitting, cmpl. 1002544
Cleaning brush, cmpl. 1103110
Locking ring 1101622
Hubcap 1101623
Combination reversing contactor 1105101
Contactor 1105104
Overcurrent relay 1102779
Controller fuse (Automat) 1105105
Controller fuse (Neozet) 1108182
Time relay 1105106
Phase sequence relay 1105415
When ordering spare parts, please state the computerised part no., unit number and type (see identification plate) !
28
29
REMKO CLK
12
A
Adjusting the air flap.......................................... 19
Adjusting the secondary air................................ 18
Adjust the baffle plate........................................ 18
Adjust the ignition electrode............................... 18
Air distribution.................................................... 14
Air flap................................................................ 19
Air inlet nozzle.................................................... 18
Automatic burner................................................ 11
C
Cleaning
Control panel...................................................... 16
D
Disposal of equipment......................................... 6
E
Environmental protection..................................... 6
F
Fit burner flange................................................. 23
M
Mounting baseplate............................................ 18
N
Nozzle fitting adjustment.................................... 18
O
Oil nozzle sizes.................................................. 18
P
Paraffin formation............................................... 15
R
Regulating device.............................................. 11
Room thermostat......................................... 16, 17

Index

Combustion chamber.................................... 23
Heat exchanger
............................................. 22
S
Safety
Dangers of failure to observe the safety
notes............................................................... 4
General........................................................... 4
Identification of notes...................................... 4
Instructions for the operator............................ 5
Note for inspection work................................. 5
Note for installation work................................. 5
Note for maintenance work............................. 5
Personnel qualifications.................................. 4
Safety-conscious working............................... 4
Unauthorised modification ............................. 5
Unauthorised replacement part manufacture.. 5
Safety temperature limiter.................................. 10
Setting the pump pressure................................. 19
STB.................................................................... 10
Suction air
Circulated air operation................................. 15
Fresh air operation........................................ 15
Mixed air operation....................................... 15
T
Temperature controller (TR) ............................. 11
Temperature monitor (TW)................................ 11
Tensioning the V-belt......................................... 24
V
Ventilate............................................................. 17
W
Warranty.............................................................. 5
30
Consulting
Thanks to intensive training, our consultants are always completely up-to-date in terms of technical knowledge. This has given us the reputation of being more than just an excellent, reliable supplier: REMKO, a partner helping you find solutions to your problems.
Distribution
REMKO offers not just a well established sales network both nationally and internationally, but also has exceptionally highly­qualified sales specialists. REMKO field staff are more than just sales representatives: above all, they must act as advisers to our customers in air conditioning and heating technology.
SFlbCustomer Service
Our equipment operates precisely and reliably. However, in the event of a fault, REMKO customer service is quickly at the scene. Our comprehensive network of experienced dealers always guarantees quick and reliable service.
REMKO INTERNATIONAL
… and also right in your neighbourhood! Make use of our experience and advice
We reserve the right to make technical changes, and provide no guarantee as to the accuracy of this data!
REMKO GmbH & Co. KG Air conditioning and heating technology
Im Seelenkamp 12 D-32791 Lage Postfach 1827 D-32777 Lage Telephone +49 5232 606-0 Telefax +49 52 32 606-2 60 E-mail info@remko.de Website www.remko.de
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