REMKO HTK
Mobile oil-fired heating centers
Operation
Technology
Spare Parts
Ausgabe GB – M05
REMKO - powerful like a bear.
Operating Instructions
Read these instructions carefully before setting up/operating the unit!
Our guarantee becomes null and void if the unit is used, set up
or maintained improperly,
or if modifications are made to the supplied unit without our prior consent.
Subject to alterations!
Mobile oil-fired Heating Centers
REMKO HTK
Contents Page
Safety Instructions 4
Description of Device 4
Installation Requirements 5
Safety Device 6
Waste Gas Pipes 6
Hot Air Distribution 7
Before Starting 7
Starting 8
Unit Shut Down 8
Troubleshooting 9
Always keep these operating instructions near or on the unit!
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Contents Page
Service and Guarantee 9
Maintenance and Service 10
Wiring Diagram HTK 100 12
Wiring Diagram HTK 160 13
Exploded View 14
Spare Part List 15
Initial Operation of the Forced-Air Burner 16
Technical Data 18
Maintenance Log 19
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3
Safety Instructions
Make sure to observe relevant local building and
fire protection codes and abide by professional association regulations when the units are in operation.
à The unit may only be operated by persons who have
received proper training in the operation of the unit.
à The unit is to be installed and operated in such a
way as to ensure that people are not endangered by
waste gases and radiation heat and fires cannot occur.
à The unit may only be installed and operated in
rooms, when the air-rate fed to the unit is sufficient
for combustion.
à Units without an exhaust system may be operated
only in well-ventilated rooms.
Persons may not remain permanently in the room
where the unit has been installed. Warning signs are
to be posted at the entrances.
à A safety zone of 1.5 m around the unit is to be main-
tained even for non-flammable objects.
à The unit is to be installed only on a non-combustible
ground.
à The unit may not be set up or operated in surround-
ings susceptible to fire or explosions.
à Mobile fuel containers may only be installed in com-
pliance with technical regulations for flammable liquids.
à The protective air suction grille must always be kept
free of dirt and loose objects.
à Do not insert foreign objects into the unit at any time.
à Do not expose the unit to a direct stream of water.
à All electrical cables outside the unit are to be pro-
tected from damage (e.g. caused by animals, etc.).
à Make sure always to pull the mains plug out of the
mains socket when maintenance and repairs are
carried out.
à While the unit is in operation, the safety mechanisms
may not be bypassed or blocked!
à Never interrupt (except in emergency situations) the
power supply until the cool-down phase is completely
finished.
Before doing any maintenance or repair work,
make sure to unplug the unit from the power supply.
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Use prototype-tested WLE-type oil burners only.
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Description of Device
The units are mobile, warm air heaters with heatexchangers and an exhaust connection for commercial
use.
The unit is fired directly with heating oil or diesel. It is
designed for fully-automatic, universal and reliable use.
The units are only operated with separate forced-air
burners.
The unit is equipped with a quiet, high-performance axial ventilator requiring little maintenance, a connection
cable with plug and a room thermostat socket.
The units have an automatic rotating field control of the
fan motor as standard.
Units with a factory fitted forced-air burner have a separate oil preheater as standard. Additionally, model HTK
100 has got an integrated nozzle stock oil preheater.
The unit complies with the basic safety and health requirements of the relevant EU regulations and is reliable
and simple to operate.
Areas of application
The units supply instant heat as directly fired heaters. The
units are used for mobile application in industrial area for
individual heating and temperature conditioning of e.g.:
− Warehouses
− Fair halls
− Light weight construction halls
− Open-plan tents
− Building sites
Device functionality
If the unit is switched to heating mode, the forced-air
burner starts automatically. In fully-automatic heating
mode, the forced-air burner starts only when the room
thermostats determined that heat is necessary.
After the burner has run for a short time, the temperature
control thermostat “TR” (rated temperature 35 to 40 °C)
automatically switches the air supply fan on. Warm air is
blown out.
When the room thermostat is in operation, the process
above is automatically repeated depending on the
amount of heat required
The temperature monitor “TW” (rated temperature 80 to
85 °C) monitors the internal temperature of the unit.
After the device is switched off with the operating switch
or the room thermostat, the air supply fan runs for a certain amount of time to cool the combustion chamber with
heat-exchanger and then switches off. This process can
be repeated several times.
Never interrupt the power supply (except in emergency situations) before the unit has reached the
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end of the cool-down phase.
.
4
Monitoring operation of device
All functions of the unit are fully automatic and monitored for safety by the safety facility and the automatic
burner relay (part of the forced-air burner).
If the flame burns irregularly or goes out, the unit is
switched off by the automatic burner relay. The control
lamp on the control panel and the malfunction lamp of
the automatic burner relay light up.
Before the unit can be restarted, the automatic burner relay
must be released by pressing the external reset button on
the operating panel or the reset button on the automatic
burner relay.
The fan control (TR) regulates operation of the fan. The
temperature monitor (TW) limits or regulates the temperature of the unit in heating mode.
The safety temperature limiter (STB) interrupts heating
mode when extreme overheating occurs or if the temperature monitor (TW) stops working or is defective.
The STB can only be manually released after the unit
has cooled down.
Before the STB is released to begin operation
again, the reason the STB was activated must be
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determined.
Installation in closed, well aerated rooms without
connection to a chimney
à The units may only be operated when the minimum
amount of air required for combustion is supplied.
à A safe exhaustion of the waste gases is to be en-
sured to exclude inadmissible pollution.
- Fresh air is supplied from below.
- Waste gases are expelled upwards.
Outside installation
à Operation of the unit may not have any harmful ef-
fects or cause any unreasonable problems.
à The unit operator must ensure that unauthorised per-
sons are prevented from manipulating the unit or its
power supply.
à Because rain and snow can be sucked in by the air
supply fan, a suitable protective covering should be
used.
Heating Rooms
While the unit is in operation, the safety features
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may not be bypassed or blocked!
Installation Requirements
The heaters may only be installed in compliance with
the relevant regulations, in particular, regulations governing the installation and operation of fireplaces and
furnaces.
Any national/regional emission control laws or regulations must also be observed.
à Avoid under- or overpressure in the room where the
unit is installed, as this would result in combustion
troubles.
à Make absolutely sure that the opening for air intake
and output is adjusted to the fan power (see model
plate).
If this is not possible, the burner has to be equipped
with a separate air supply device to ensure optimum
combustion.
à Warm air generators may only be operated with a
room thermostat when heating rooms.
Accessories.
à Make sure that there is enough fresh air to ensure
optimum combustion.
Electrical Connection
à The units are operated with 400 V / 3~N / 50 Hz.
à The units have an automatic rotating field control of
the fan motor as standard.
à The unit must be connected to the power source at a
special terminal equipped with a switch to protect
against faulty currents.
à Extension cable may only be laid by authorised elec-
tricians based on the capacity of a unit, the length of
the cable and in accordance with local requirements.
à All extension cable may only be used once they have
been unrolled.
Safety zones
à To ensure safe operation and guarantee unhindered
access to the unit for maintenance work, a safety
zone of 1.5 m should be maintained around the unit.
à Floors and ceilings must be fire-resistant.
5
Safety Device
The device has 3 safety functions:
à Fan control (TR)
à Temperature monitor (TW)
à Safety temperature limiter (STB)
Fan control (TR)
The fan control switches the circulating air fan off and
on. The point at which the device is switched on or off is
set in the control box via the temperature control thermostat “Scale 21 – 60”.
Rated value approx. 35 to 40°C.
Temperature Monitor (TW)
When the unit is in heating mode, the temperature
monitor limits both the temperature of the unit and the
air being blown out. The switching point is set via the
temperature control thermostat “Scale 34 – 110” in the
control box.
Rated value approx. 80 to 85°C.
Safety Temperature Limiter (STB)
The STB controls the temperature monitor. The switching point is fixed. The burner is prevented from being restarted if the STB is activated.
After the cover next to the control panel is removed, the
reset button must be pressed from the outside.
After the STB has been reset, the cover must be replaced.
Waste Gas Pipes
When the units are operated outside or in open rooms
you do not need a waste gas pipe. However, we recommend using a waste gas pipe 1 m long (see example 2)
with a rain cover on top to prevent the penetration of
rainwater and dirt.
If the units are used as room heaters, it is necessary to
route the waste gases to the outside.
Make absolutely sure that counter pressure is not
created by improperly laid waste gas pipes.
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à The unit generally operates properly when the waste
gas pipes have been laid at an incline and assembled with vertical end pipes.
à The waste gas pipes must reach at least beyond the
gutters but preferably above the top of the roof to
prevent counter pressure caused by weather conditions (e.g. wind).
à All waste gas pipe components must be securely
fastened. They may not be smaller in diameter than
the waste gas connection.
à A minimum distance of 0.6 m must be maintained
from flammable objects.
à Waste gas components incl. fasteners can be pur-
chased as accessories.
When using an waste gas connection, the burner
must be adjusted accordingly.
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Before a STB reset, check the operating conditions
to ensure that the STB temperature is not ex-
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ceeded again.
Information on the Safety Device
The device is equipped with a sensor monitoring feature
and is resistant to cool down to temperatures of -20°C;
below -20°C the device switches off; when the temperature rises above this temperature, it switches on again.
When the sensor or capillary tube is damaged, or when
an excess temperature of approximately 220°C is
reached, the liquid contained in the thermostat is emptied and the device switches off for safety purposes.
The device is no longer operable and must be replaced
If it is necessary to replace the STB, only the original
REMKO part may be used.
à Make sure to install and mounting the device care-
fully.
à Do not bend the capillary tubes near to solder points.
à When installing the capillary tubes, be careful not to
damage or bend them too sharply.
à The sensors may only be mounted in the mounting
brackets supplied by the manufacturer.
à The sensors must always be free from dust and dirt.
max.1 m
Example 1 Example 2 Example 3
Operation with
exhaust gas pipe
extended.
Requires conden-
sation trap
Important Information.
To prevent damage to the combustion chamber caused
by moisture build-up (condensation) (see example 3),
make sure that the waste gas pipes have a properly installed condensation trap (see example 1).
Operation without
exhaust gas pipe
extended.
max. 1 meter
more than 1 m.
Inadmissible in-
stallation.
6
Hot Air Distribution
The units are equipped with a high-performance axial
fan. This fan has been designed to transport the hot air
directly and effectively.
It is preferable to distribute air by means of pipes or
special hot air hoses. Warm air may only be distributed
in accordance with the fan capacity of the unit in operation. Please follow these instructions when attaching
warm air hoses:
à Use only warm air hoses approved by our company.
à The internal overlapping at the seams must point at
air direction.
à Make sure that the hoses and/or pipes are securely
attached to the unit’s air outlet connection.
à To prevent heat from building up, the pipes and
hoses may not have sharp kinks and bends.
à Counter pressure may not be allowed to build up
when using hoses to heat closed rooms.
à If suction temperatures increase or if there is resis-
tance on the air output opening, the forced-air burner
can be switched off at short notice by the temperature monitor (TW) in heating mode.
When the temperature falls, the burner restarts automatically.
à If the intervals are too short, the length of the warm
air hoses should be checked.
à Avoid starting the burner in frequent cycles.
Under 5 min.
When the temperature is too high on the unit’s
outgoing air side, the heating-operation is inter-
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rupted automatically by the STB!
Directing the incoming air.
Before Starting
Prior to initial operation, check the unit for any visual defects on the control and safety devices, that the unit has
been installed correctly and that it has been properly
connected to the mains.
Observe the following points:
à Install the unit in a stable position.
à Make sure that air is supplied for combustion and
avoid overpressure and underpressure in the room
where the unit has been installed.
à Make sure that the air can be sucked in and be ex-
hausted freely.
à Make sure that enough fuel is supplied.
à Please note: the multifilex oil preheater will only func-
tion properly if voltage is supplied to the unit for a
longer time prior to initial operation.
à Use only clean heating oil or diesel.
Do not use bio diesel.
à Note that the cross-section of the fuel line must be
designed in accordance with the total line resistance,
the suction height and increased viscosity at lower
temperatures.
In some cases, an oil transport aggregate must be
used.
à Tightly seal the suction line at the bottom of the tank
with a foot valve.
à The waste gas values of the oil-burner are to be
checked and properly adjusted by authorised personnel to ensure compliance with local requirements.
Flexible fuel tubes must be protected from being
damaged, e.g. from forklifts, animals, etc.
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There are three optional modes for unit operation: fresh air
mode, mixed air mode and circulation mode. The following
information is applicable, when the unit is installed outside
of the room to be heated.
Fresh air mode:
Air is suctioned in through the two air suction grilles fit-
ted at the factory
Mixed air operation:
To operate the unit with mixed air, it is necessary to
mount an air suction connection instead of an air suction grille. This connection can be purchased as an accessory. To ensure an adequate air supply, make sure
that the second air suction grille is not covered.
Circulation mode:
To operate the unit in 100 % circulation mode, it is nec-
essary to mount air suction connections (can be purchased as accessories) instead of the air suction grille
supplied with the unit.
Air lines attached to the air intake side must always
have a form-resistant (no unstable hoses) design.
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Paraffin accumulation at low outside temperatures
A sufficient amount of heating oil must be able to flow
freely even when temperatures are low.
à Paraffin can accumulate even at temperatures below
5 °C.
à Appropriate measures must be taken to prevent this.
Use winterised heating oil or winter diesel.
Important hint about the motor protection relay
The motor protection relay made only be operated when
set to “Manual Reset“. The relay may not automatically
switch on again after cooling off.
If the motor protection relay is operated when set to
“Automatic Reset“, the motor may be damaged.
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This is not covered by the guarantee!
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Starting
Only those persons who have been trained in operation
of the unit may be responsible for operating and monitoring it.
Important information about starting the cold unit
The preheating of the nozzle stock delays the temperature depending start of the HTK 100 units delivered with
forced-air burners.
Control Panel
safety temperature limiter
operating switch
bridge circuit plug
thermostat socket
reset button (burner)
control lamp, red (burner malfunction)
control lamp, green (in operation)
Fully automatic heating with room thermostat
The unit runs fully automatically with the temperature
which has been pre-selected on the room thermostat.
1 3
4
Ventilation
In this position only the supply air fan runs and the unit
can be used for air circulation.
1. Remove the bridge circuit plug 2.
2. Plug the thermostat plug 3 of the
room thermostat (accessories) into
the thermostat socket 1.
3. Put room thermostat 4 in a suitable
place.
The thermostat sensor may not be
placed directly in the warm air
stream or attached to a cold surface.
4. Pre-select desired room temperature on the room thermostat.
5. Set the operating switch to “I”.
When heat is required, the forcedair burner switches on automatically; operation of the unit is fullyautomatic.
Note about the green control lamp (in operation).
The control lamp indicates that the unit is in
mode.
When the unit is in
played if the room thermostat is switched off or if the
STB was activated.
Connecting the unit to the power supply
1. Set the operating switch to “0” (OFF).
2. Connect the unit plug to a properly connected power
socket.
3. Open all shut-off fittings in the oil supply.
When operating the unit for the first time, air in the oil
supply can cause the burner to malfunction.
Extension cables may only be used once they are
unrolled.
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Heating without a room thermostat
The unit runs in continuous operation.
1 2
“ventilation” mode, nothing is dis-
1. Plug the supplied bridge circuit plug
2 into the thermostat socket 1 of the
control panel.
2. Set the operating switch to “I“.
Heating.
“heating”
1. Set operating switch to “II”.
Ventilation.
2. Please note: in this mode, it is not
possible to use the thermostat nor
can the unit be operated in heating
mode.
Unit Shut Down
1. Set the operating switch to “0”
OFF.
2. Shut off the fuel supply.
Important information about the unit’s cool-down
phase
The air supply fan continues running to cool down the
combustion chamber and then stops at a later time.
The fan can run several times before the unit is finally
switched off.
Never interrupt (except in emergency situations)
the power supply until the cool-down phase is
completely finished.
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Our guarantee does not cover damages caused to
the unit by overheating.
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Troubleshooting
Prior to doing any work on the unit, unplug it from
the power supply!
Unit does not start:
1. Check power supply.
400 V / 3~N.
2. Set operating switch to “I”.
3. Ensure that the “operation” lamp on the control
panel is illuminated.
It must indicate that the unit is in “heating” mode.
4. Check that the bridge circuit plug or the thermostat
plug has been plugged in correctly.
5. Check the room thermostat setting.
The temperature set on the room thermostat must
be higher than the room temperature.
6. Check whether the safety temperature limiter (STB)
was activated.
You must remove the protective cover next to the
control panel.
7. Before resetting the STB, it is absolutely necessary
to determine the reason it was activated and take
appropriate measures.
The following are possible reasons:
− Unit could not cool down because the power sup-
ply was interrupted.
− Temperature of air being blown out is too high be-
cause hoses are not directing air properly.
− Air intakes and outlets are blocked.
8. Check whether the “burner malfunction” control
lamp on the control panel is illuminated.
If so, release the automatic burner relay by pressing
the reset button.
9. Set operating switch to “II”.
If the fan now starts running, look for the malfunction in the burner.
Forced-air burner and power supply
1. Check whether fuel filter is dirty.
Replace dirty filters.
2. Check that all shut-off fittings in the oil supply are
open.
3. Check that there is enough fuel in the fuel container.
4. Check whether paraffin has accumulated in the
heating oil.
This can occur even at 5 °C.
5. Check oil tubes for damage.
6. Check the sensors and capillary pipes of the safety
devices for damage or dirt.
7. Check that the temperature monitor (TW) is working
properly.
8. Check the forced-air burner for any dirt in the nozzle, air flow plate, filters, etc.
Fan does not start:
1. Check whether the vane wheel is running smoothly.
2. Check whether the controller fuse in the control
panel box was activated.
3. Check whether the motor protection relay in the
control panel box was activated.
4. Check that the fan control thermostat (TR) is working properly.
For safety purposes, repair work on the electrical
components and the burner may only be per-
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formed by authorised personnel.
Important information about resetting the burner
à If, during the start phase, the unit is switched off
again due to a malfunction, it may only be restarted
after 5 minutes have elapsed.
à Take any steps necessary to prevent another reset.
Danger of deflagration.
After working on the unit, conduct an electrical
safety test.
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Service and Guarantee
For the guarantee to be valid, the customer must completely fill out the “guarantee certificate” enclosed with
all heating units and send it back to REMKO GmbH &
Co. KG in a timely manner after purchasing of the unit
and putting it into operation.
The units have undergone several tests to ensure
proper functioning at the factory. If there are still malfunctions that cannot be fixed by the operator using the
troubleshooting instructions, please contact your dealer
or contract partner.
An operation/use other than indicated in these instructions is prohibited!
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In the case of non-compliance, we assume no liability and our guarantee becomes null and void.
Proper Use
These units have been designed and equipped exclusively to be used for heating and ventilation for industrial
and commercial purposes.
The manufacturer is not liable for any damage resulting
from non-adherence to manufacturer specifications, legal requirements or any modifications to the units.
9
Maintenance and Service
Regular maintenance and observance of some basic
principles are required to ensure a long service life and
to keep the unit functioning properly.
Prior to doing any work on the unit, make sure to
unplug it from the power source!
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à The unit must be maintained and cleaned at regular
intervals.
à The unit must be kept free of dust and other deposits
and may only the cleaned using a dry or damp cloth.
Do not use a direct stream of water
à Do not use any aggressive cleaning agents or those
which are harmful to the environment.
à Do not use cleaning agents which contain solvents.
Use only clean heating oil or diesel.
Make sure to keep paraffin from accumulating.
Adjustments and maintenance work may only be
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performed by authorised personnel.
à Check oil filters regularly for dirt and foreign objects.
Replace dirty ones.
à Check the unit for mechanical damage; replace de-
fective parts when necessary.
à Check vane wheel and combustion chamber with
heat-exchanger at regular intervals and clean when
dirty.
à Check the initial tension of the fan belt.
The impression depth of the fan belt should be approx. 10 mm (thickness of your thumb).
à Check oil tanks regularly for dirt and foreign objects
and clean when necessary.
à Make sure that the waste gas and combustion air
can always be properly expelled.
à Regularly check safety devices to ensure that they
are working properly.
à Always keep safety devices free of dust and dirt.
Have the waste gas values of the burner checked
regularly by authorized personnel.
For safety purposes, we recommend entering into a
maintenance contract!
Stretching the fan belt
1. Disassemble the two both air suction grilles.
2. Loosen the screws 7.
The screw on the opposite side is not shown below.
7
8
9
3. With screws 8 and 9, adjust the initial tension of the
fan belt.
4. Please note that the impression depth of the V-belt
should be approximately 10 mm.
Thickness of your thumb.
5. Secure screws 8 and 9 and tighten both fixing
screws 7 again.
6. Assemble both air suction grills.
Cleaning
The complete unit including heat exchanger, combustion chamber and forced-air burner, is to be cleaned
from dust and dirt after every heating period, or before if
necessary, depending on the operating conditions.
Parts subject to wear and tear, such as waste gas suppressors, gaskets, oil filter inserts, and oil nozzles are to
be checked and replaced if necessary.
Cleaning the heat exchanger
1. Unplug the unit from the power source.
3 2 4 1
5
Additional maintenance information.
à Maintenance work on the burner may only be done
by authorised personnel.
à Make sure to comply with waste gas emission limits
in accordance with regulations.
à After maintenance work is complete, conduct an
electrical safety test.
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2. Unscrew the 4 fixing screws and remove the blow-out
cone 1.
If there are warm air hoses, they do not have to be
removed.
3. Remove revision cover 2 and take the waste gas
suppressor 4 out of unit.
4. Clean waste gas passes 5.
A special cleaning brush (Ref. No. 1103110) can be
purchased as an accessory.
5. Clean waste gas suppressors or replace them if
necessary.
6. Check gaskets 3 and revision cover 2 and replace
them if necessary.
7. Reassemble the unit in the reverse order.
Important information about the revision cover
à Make sure that the gaskets and the revision covers
are placed correctly.
à During assembling take care of uniform tightening
of the fixing nuts for clamping of the revision cover.
Uneven tightening may result in leakages of waste
gas.
Cleaning the combustion chamber
1. Unplug unit from the power source.
2. Remove the burner cover 6 after opening the two quick
release fasteners.
6. Place the burner next to the unit.
7. Disassemble the burner flange.
8. Do not damage the flange gasket 10.
Damaged flange gasket can cause air to be suctioned in incorrectly.
8. Clean combustion chamber through the burner
opening using a vacuum cleaner.
Special cleaning sets can be purchased as accessories for the REMKO industrial vacuum cleaner.
10. Assemble the burner flange and burner as described in the following section.
Assembling the burner flange and the burner.
1. Check the flange gasket 10 and replace it if necessary.
2. Attach the burner flange to the unit housing with the
four bolts.
Pay attention to the “UP“ (UP, HAUT) label!
3. Tighten the upper fixing screws.
4. Turn the lower fixing screws but do not tighten them
so that the burner flange can still be put together.
5. Slide the flame tube of the burner into the burner
flange.
Take note of measurement X in the diagram.
8
9
10
7
6
3. Pull the plug 7 from the burner 8.
4. Loosen the 2 lower fixing screws on the burner
flange 9.
5. Loosen the tightening bolt 11 on the burner flange 9
and remove the burner by pulling it towards you.
Burner HTK 100: X = 20 mm
Burner HTK 160: X = 30 mm
X
11
6. Attach the flame tube with the tightening bolt 11 to
the flange by lifting the burner slightly
(3° incline)
.
Use a hexagon socket screw key.
7. Finally, tighten the lower fixing screws.
8. Replace the burner cover and attach securely with
the quick release fasteners.
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Wiring Diagram HTK 100
control circuit load circuit
1F3.1
S1
Lüften
Ventilation
1K7.2
1K5.1
1K8.1
1K7.1
1Q3.1
Aus
OFF
ÖV
WS
Heizen
Heating
95
96
1+3
24
11
12 14
21
22
L1
N
T1T2
S3
B4
1K7.1
1K8.1
TW STBTR
RT
3 2
1K8.1 1K7.1
1PE
53641
2
S2
21
M
3
97
98
22
1234NPE
X1
1 3 4 5 2
H1H2
PE L1 L2 L3N
X1
1Q3.1
X1
UVWPE
53641
2
L1 L2 L3
1K5.1
95
96
Legend HTK 100 and HTK 160
S1 = operating switch
S2 = external reset button (burner)
H1 = control lamp, green (in operation)
H2 = control lamp, red (burner malfunction)
TR = fan control thermostat
TW = temperature monitor thermostat
STB = safety temperature limiter
X1 = terminal strip
M = fan motor
WS = plug to burner, 7-pole
RT = room thermostat socket
ÖV = oil preheater
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Legend only HTK 100
1F3.1 = controller fuse
1Q3.1 = motor protection relay
1K5.1 = phase sequence relay
1K7.1 = main contactor
1K7.2 = time relay
1K8.1 = main contactor
Wiring Diagram HTK 160
control circuit
95
1Q3.1
96
TR
1F3.1
S1
Lüften
Ventilation
2K2.2
1K6.1
2K3.1
2K2.1
Aus
OFF
Heizen
Heating
1+3
24
11
12 14
21
22
2K2.1
2K3.1
TW STB
15
2K6.1
16 18
21
22
2K5.1
21
21
2K5.2
22
22
RT
3 2
S2
1PE
H1H2
2K5.2
2K5.1
2K6.1
1234NPE
X1
Einspeisung
power supply
PE L1 L2 L3N
X1
ÖV
1 3 4 5 2
L1
N
WS
T1T2
S3
B4
Legend only HTK 160
1F3.1 = controller fuse
2K2.1 = main contactor
2K2.2 = time relay
2K3.1 = main contactor
2K5.1 = delta contactor
2K5.2 = star contactor
1K6.1 = phase sequence relay
2K6.1 = star-delta relay
1Q3.1 = motor protection relay
53
2K3.1 2K2.1
6412
2K5.1 2K5.2
97
95
1Q3.1
96
98
W1
V1
M
3
U1
load circuit
53641
2
53641
2
V2
U2
W2
L1 L2 L3
1K6.1
53641
2
13
Exploded View
41
61
62
43
44
47
40
48
54
8
35
55
60
50
42
51
52
53
46
36
34
6
7
1
2
30
31
3
sensor STB
sensor TW
sensor TR
4
5
33
32
45
view
control panel
70 71 72
66 67 68 69
11
We reserve the right to make changes to dimensions and design in the interest of technical progress.
12 13
27
10
20
21
22
23
25
26
14
Spare Part List
No.
Description
1 cover plate 1104830 1104851
2 insulation, top 1104831 1104852
3 insulation, right / left 1104832 1104853
4 side cover, top (right / left) 1104833 1104854
5 side cover, bottom (right / left) 1104834 1104855
6 insulation, bottom 1104871 1104872
7 base plate, front 1104835 1104856
8 base plate, rear 1104836 1104857
10 front panel, cpl. 1104837 1104858
11 insulation, front panel 1104756 1104786
12 guide angle 1104757 1104787
13 lead-through, tube 1104722 1104722
20 oil-preheater 1071410 1071410
21 rubber seal, O-ring 1108464 1108464
22 filter insert 1108462 1108462
23 oil filter cup 1108463 1108463
25 blow-out cone 1104758 1104788
26 burner cover, cpl. 1104759 1104789
27 transportation skid, right / left 1104838 1104859
30 combustion chamber, cpl. 1104839 1104860
31 waste gas suppressor (set) 1104840 1104861
32 inspection cover 1104763 1104794
33 gasket for inspection cover 1104764 1104795
34 lock cap 1104728 1104784
35 separating plate 1104841 1104862
36 air suction grille, right / left 1104842 1104863
40 rear panel, cpl. 1104843 1104864
41 control panel, cpl. 1104844 1104865
42 rubber seal, control panel 1104845 1104866
43 crane eye 1102554 1102554
44 rosette for waste gas connection 1104732 1104796
45 transport handle, front 1104846 1104867
46 transport handle, centre 1104847 1104868
47 transport handle, rear 1104848 1104869
48 roller 1104849 1104849
50 radial fan, cpl. 1108603 1108607
51 pulley, fan 1102798 1102801
52 belt, fan 1102698 1102802
53 pulley, motor 1102800 1102784
54 motor 1102769 1102799
55 bracket, motor 1104850 1104870
60 safety temperature limiter (STB)
61 fan control thermostat (TR) 1103166 1103166
62 temperature monitor (TW)
66 operating switch
67 control lamp, green (in operation)
68 control lamp, red (burner malfunction)
69 external reset button (burner)
70 thermostat socket
71 bridge circuit plug 1101019 1101019
72 connecting cable with plug 1105100 1105100
not plug to burner, 7-pole 1102537 1102537
shown fitting for oil reservoir, cpl. 1002524 1002524
cleaning brush, cpl. 1103110 1103110
Ref.-No. HTK 100 Ref.-No. HTK 160
1101197
1103146
1101188
1105514
1105363
1103408
1101018
1101197
1103146
1101188
1105514
1105363
1103408
1101018
When ordering spare parts please indicate ref. no. and machine no. (see model plate)!
15
Initial Operation of the
Forced – Air Burner
Preparation
After loosening the 4 housing bolts, remove the mounting base plate of the housing so that it is suspended to
the side.
There are 6 housing bolts to disassemble for the HTK
160 model (look for the arrows).
The operating parts are immediately accessible and can
now be serviced.
To service, insert or replace the nozzle, the base plate
must be suspended horizontally by hooks.
Proceed as follows:
1. Hold base plate horizontally.
2. Push right-hand mounting laterally into hook device.
3. Hook left-hand side into the lug.
Setting ignition electrode and device
A
D
size \ dimension A B C D
HTK 100 2 - 4 4 - 6 7 2,5
HTK 160 13 - 15 12 - 14 5 3
All measurements are approx. values in mm. The optimum setting must be adjusted to local and structural requirements.
Air slide plate
The adjustable air slide plate is used to adjust the
burner pressure to the amount of resistance in the combustion chamber and the chimney draught without having to make changes to the original cross-section.
1. Loosen socket screw.
2. Turn air slide plate to desired setting.
Pay attention to the arrows.
Turn to “min” = reduced burner pressure
Turn to “max” = increased burner pressure
C
B
Required nozzle sizes
Selecting the required oil nozzle depends on the pump
pressure and the unit capacity.
You may only use an oil nozzle that is suitable for the
shape of the respective burner chamber with a corresponding spray angle, cone properties and throughput.
You can find the required oil nozzle sizes under Technical Data.
16
Base plate
After changing the nozzle and setting the air slide plate,
reassemble the base plate in the reverse order.
Secondary air setting
(Setting the nozzle stock)
1
2
Proceed as follows to preset the secondary air:
Use the adjusting screw 1 to adjust the nozzle 2 to the
value you want.
HTK 100
Counter clockwise (-) = lower scale values
increased pressure behind the air flow plate
lower performance range
Clockwise (+) = higher scale values
lower pressure behind the air flow plate
upper performance range.
HTK 160
Counter clockwise (+) = higher scale values
reduced pressure behind the air flow plate
upper performance range
Counter clockwise (-) = lower scale values
increased pressure behind the air flow plate
lower performance range
Air flap
The adjustment screw 3 is used to set the required
quantity of air.
The air flap is opened or closed until the soot profile displays an oil-free colour “0 - 1”.
.
Adjusting the air flap
Proceed as follows to adjust the air flap:
1. Loosen the knurled nut 4.
2. Rotate the adjustment screw 3 accordingly.
3. Keep the following in mind:
Right rotation = less air
Left rotation = more air
4. After the adjustment is completed, retighten the ad-
justment screw with the knurled nut.
Additional Information
à If the air flap is completely open and the flame emits
smoke or flickers, use the secondary air setting to
lower the pressure behind the air flow plate.
à It might be necessary to open the air slide plate even
further.
Setting the pump pressure
For initial burner operation and after each time the
burner is serviced, the oil pressure must be adjusted
and/or checked.
Never operate the pump without fuel!
G
Proceed as follows to adjust the pump pressure
1. Remove the stopper on the “P” measuring connec-
tion.
2. Mount the oil manometer.
3. Open all shut-off fittings in the oil supply.
4. Switch the burner on.
5. Set the required oil pressure in accordance with the
size of the nozzle and the unit performance.
6. Switch the burner off.
7. Disassemble the oil manometer.
8. Replace the stopper and its seal.
Important information
à
The forced-air burner may only be put into operation by
trained personnel
à All specifications only serve as presets and must be
3
4
set or adjusted after the waste gas has been analysed.
à Exhaust emissions must be restricted in accordance
with the ordinance on small furnace systems.
The control lamp of the burner unit blinks during
à
operation. This blinking only indicates the operating state of the burner and does not indicate a malfunction.
.
17
Technical Data
Model
HTK 100 HTK 160
rated heat power max. kW 88 160
rated heat output kW 80 146
rated air output 1) m³/h 6,260 12.780
pressure, max. complete Pa 480 680
fuel heating oil or diesel (DIN 51603)
fuel consumption, max. L/h 8,6 15,7
oil nozzle (Danfoss) 2) USG 1,75 / 60°S 3,00 / 80°S
pump pressure, approx. 2) bar 12,5 13,5
waste gas emissions, max. % 9 9
waste gas volume, approx. kg/h 138 250
furnace resistance, approx. Pa 100 110
required chimney draught Pa 0 0
electrical connection V/Hz 400 / 3~N / 50
power consumption max. kW 2,45 4,4
rated current max. A 6,6 10
power consumption (oil preheater ) W 30 30
fuse protection (supplied) A 16 16
increase of temperature (∆t)
sound pressure level LpA 1m
3)
K 42 41
dB (A) 62 66
air outlet Ø mm 400 500
waste gas connection Ø mm 150 200
length, total mm 1.905 2.380
width, total mm 660 785
height, total mm 1.070 1,245
weight with burner kg 240 385
1) ∆t 45K / 1,2 kg/m³)
2) The mentioned nozzle-sizes and pump pressures were determined on the basis of adjustment tests on test units. The oil throughput had been
measured out. The specifications serve only as guidelines due to product-specific differences in nozzle and pressure tolerances and oil temperature.
3) Noise measuring (with hose / and without burner)
18
We reserve the right to make changes to dimensions and design in the interest of technical progress.
Maintenance Log
Maintenance Log
Model: : ................................ Model No.: : ......................................
Burner : ................................ Burner No.: : ......................................
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Clean unit -surfaceClean unit -interiorClean fan
Clean combustion chamber
Clean heat exchanger
Clean/replace waste gas suppressor
Replace seals -inspection coverReplace seals –burnerClean/replace filter -fuelCheck safety mechanisms
Electric safety inspections
Check protective mechanisms
Check unit for damage
Maintenance –burner
Test run
Remarks: ......................................................................................................................................................................
......................................................................................................................................................................................
1. Date: ...................... 2. Date: ...................... 3. Date: ...................... 4. Date: ...................... 5. Date: ......................
................................... ................................... ................................... ................................... ...................................
Signature Signature Signature Signature Signature
6. Date: ...................... 7. Date: ...................... 8. Date: ...................... 9. Date: ...................... 10. Date: ....................
................................... ................................... ................................... ................................... ...................................
Signature Signature Signature Signature Signature
11. Date: .................... 12. Date: .................... 13. Date: .................... 14. Date: .................... 15. Date: ....................
................................... ................................... ................................... ................................... ...................................
Signature Signature Signature Signature Signature
16. Date: .................... 17. Date: .................... 18. Date: .................... 19. Date: .................... 20. Date: ....................
................................... ................................... ................................... ................................... ...................................
Signature Signature Signature Signature Signature
Maintenance work may only be performed by authorised personnel; settings must comply
with legal specifications. A corresponding test log must be kept.
19
REMKO GmbH & Co. KG
Klima- und Wärmetechnik
D-32791 Lage • Im Seelenkamp 12
D-32777 Lage • PO Box 1827
Phone +49 (5232) 606 - 0
Fax +49 (5232) 606260
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