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!
Stationary Warm Air Heating Systems
REMKO VRS 25-I to VRS 200-I
vertical Unit horizontal Unit
Contents Page
Safety Instructions 4
Description of the Unit 4
Safety Device 5
Prior to Setup 6
Exhaust Connection 9
Setup and Assembly 10
Starting 11
Unit Shut Down 12
Maintenance and Service 13
Technical Data 14
Always keep these operating instructions near or on the unit!
G
Contents Page
Exploded View 16
Spare Part List 17
Wiring Diagram 230 V 18
Wiring Diagram 400V Direct Start 19
Wiring Diagram 400V
Wiring Diagram 400V
Troubleshooting 22
Service and Guarantee 22
Maintenance Log 23
Y / ∆ 20
Y / ∆Fan motor 21
G
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 Before performing any maintenance or repair work,
make sure to unplug the units from the power supply!
Remove fuses or switch off the customer-supplied
main switch.
It is not sufficient to switch off the units with the
operating switch!
G
à The units may only be operated by persons who
have received proper training in their operation.
à The units must be installed and operated in such a
way that people are not exposed to radiant heat and
fires cannot occur.
à The units may only be installed and operated in
closed rooms where the units have adequate air
supply for combustion.
If this cannot be guaranteed, a separate burnerdriven device that sucks in fresh air from the outside
must be installed.
à The units may only be set up on a non-flammable
surface.
à The units may only be attached to non-flammable,
sturdy structures or ceilings made from the materials
with sufficient load-bearing capacity.
à The units are to be attached with sturdy mounts
which are fixed on the unit.
à The units may not be set up or operated in surround-
ings susceptible to fire or explosions.
Description of the Unit
The units (automatic heaters) have been designed for
universal, fully-automatic and smooth operation. They
are fired directly with heating oil, diesel or natural/liquid
gas.
Function and Design
The units have been designed for operation with a
separate forced-air burner in single-stage operation.
2-stage burners may only be operated to prevent condensation from accumulating during startup in partial
load range.
It is essential to connect the units to an exhaust system
approved by the state building authorities.
The units are equipped with single setting, quiet radial
ventilators with drive motors requiring little maintenance
and with integrated switches and control devices depending on the type of unit.
The units meet the basic safety and health requirements found in the relevant EU regulations. They are
safe and easy to operate.
The robust design and clean processing of these highquality units ensure a long service life and smooth operation. They can also be assembled quickly, easily and
affordably and are easy to service.
Operating Locations of the Units
The units are direct-fired devices that supply instantaneous heat. They are only used for industrial and commercial purposes. There are generally no restrictions as to
where they can be used.
à The units must be set up outside of traffic zones,
e.g. away from cranes.
à A safety zone of 1 m is to be maintained around the
units.
à The protective air suction grille must always be kept
free of dirt and loose objects.
à Never insert foreign objects into the units.
à Do not expose the units to a direct stream of water.
à Never let water get inside the units.
à All of the units’ electrical cords are to be protected
from damage (e.g. caused by animals, etc.).
Do not bypass or block safety mechanisms while
G
the unit is in operation.
These units have not been designed for heating
G
private residences or similar spaces.
REMKO automatic heaters supply heat or regulate the
temperature of:
à Workshops
à Warehouses
à Exhibition spaces
à Trade show spaces
à Temporary structures for warehousing
à Showrooms
à Greenhouses etc.
Proper Use
The units have been designed and equipped exclusively
for industrial and commercial heating and ventilation
purposes.
The manufacturer assumes no liability for damage resulting from non-compliance with manufacturer specifications and legal requirements, or if modifications are
made to the units.
4
Operation
Safety Device
Triple combination control
After switching on the unit by setting the operating
switch to „I” or “Heizen” (heating), the forced-air burner
turns on automatically.
For the 400 V model, the “burner“ operating light is illuminated on the control box for monitoring purposes. The
combustion chamber with heat-exchanger now heats up
until the target temperature is reached.
After the set target temperature is reached, the air supply fan switches on automatically. The “Fan” operating
light on the control box also lights up on the 400 V
model for monitoring purposes. Warm air is blown out.
Depending on how much heat is required, the process
described is repeated.
If heating mode is controlled via a room thermostat or
other temperature regulating device (operating switch
set to „I” or “Heizen” (heating), the units function fullyautomatically based on amount of heat required.
All of the unit functions are performed automatically and
monitored by the triple combination control and the
automatic burner relay (part of the forced-air burner).
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.
The device has 3 safety functions:
à Fan control thermostat (TR)
à Temperature monitor (TW)
à Safety temperature limiter (STB)
Fig. Without housing cover
Never interrupt (except in emergency situations)
the power supply until the cool-down phase is
completely finished.
G
Our guarantee does not cover damages caused to
the unit by overheating.
If the flame burns irregularly or goes out, the unit is
switched off by the automatic burner relay.
The automatic burner relay’s malfunction light as well as
the “Burner” malfunction light (the 400 V mode only) on
the control box light up. The unit may only be restarted
after the automatic burner relay has been manually released.
The safety temperature limiter (STB) interrupts operation of the unit or burner when extreme overheating occurs or if the TW ceases functioning. The STB can only
be manually released after the unit has cooled.
For units in the 400 V series, the fan motor is also monitored by a thermal overcurrent relay.
If the motor becomes overloaded, operation is interrupted by the relay and the red malfunction lamp
“Ventilator” (fan) on the control box lights up. Release is
only possible after the control box has been opened.
Before releasing the overcurrent relay, the possible
G
causes of the malfunction must be investigated.
The 3 functions of the triple combination control
1. Fan control thermostat (TR)
The fan control thermostat switches the circulating
air fan off and on. The switching point is set via the
temperature control thermostat “TR”.
Rated value approx. 40°C.
2. 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 “TW”.
Rated value approx. 80 to 85°C.
3. 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. The reset button is operated from
outside.
Before the STB is released (to restart operation),
the reason the STB was activated must be deter-
G
mined.
5
Important information about the triple combination
control
The device is equipped with a sensor monitoring feature
and is cold-resistant down to -20°C; below -20°C the device switches off; when the temperature rises above this
temperature, it switches on again.
When the sensor or the capillary tube is damaged, or
when an overtemperature of approximately 220°C is
reached, the filling medium is emptied and the device
performs a safety switch-off operation.
The device is no longer operable and must be replaced.
The triple combination control may only be re-
G
placed with an original REMKO spare part!
Installation and assembly must be performed safely
G
and properly.
Make sure to observe the following general instructions
as well.
à When the safety facility has to be replaced, take care
not to damage or excessively bend the capillary
tubes.
à Bends may only occur on the capillary tubes and not
on the sensor.
à To ensure that the unit functions properly, the sen-
sors must always rest loosely in the warm air current.
à The sensors must always be free from dust and dirt.
à When mounting, the sensor and the capillary tubes
may not be damaged or bended sharply edged.
à The sensors may not come into contact with the
combustion chamber or other metal parts.
à The sensors must be fixed in the mounting brackets
provided by the factory.
Do not bypass or block safety mechanisms while
G
the unit is in operation.
Prior to Setup
When setting up the units, the relevant regional building
and fire protection codes of the respective region must
be observed.
Selecting the Setup Location
When selecting a location to set up the units, the requirements must be adjusted with respect to:
1. Fire protection and operating hazards.
2. Function.
When the units are used to heat rooms, when it is
necessary to adjust to the amount of pressure in the
room, etc.
3. Operating needs.
Heating requirements, rated air output, need for circulation or outside air, humidity, room temperature,
air distribution, space needs, etc.
4. How the unit is connected to the exhaust system.
Oil and gas-fired warm air generators (including those
with a rated heat capacity of more than 50 kW) may
generally be set up outside of heating rooms in compliance with the German fire ordinance.
For rooms where slightly flammable materials or mixtures are processed, stored or produced that could be
dangerous if ignited, exceptions may be made if appropriate measures are taken to ensure that the materials
or mixtures cannot catch fire.
The unit must be set up and assembled in such a
way that it is easily accessible for monitoring, re-
G
pair and maintenance work.
Air Supply for Combustion
An adequate supply of air for combustion must be ensured by meeting the relevant building requirements.
Excerpts from the German fire ordinance:
(1) For furnaces with a total rated heat output of up to
35 kW that are dependent on the air in the room,
evidence of an adequate air supply for combustion
has been provided if the furnaces are set up in a
room that has:
1. A minimum of one door to the outside or a window that can be opened (rooms with a connection to the outside) and a room capacity of at
least 4 m
2. An opening leading to the outside with a crosssection of at least 150 cm
which are each 75 cm
with equivalent cross-sections for air flow.
(2) For furnaces with a total rated heat output of more
than 35 kW and less than 50 kW that are dependent on the air in the room, evidence of an adequate
air supply for combustion has been provided if the
furnaces are set up in rooms that meet the requirements of Para. 1, No. 2.
3
per kW of total rated hear output or
2
or two openings
2
or lines to the outside
6
(3) For furnaces with a total rated heat output of more
than 50 kW that are dependent on the air in the
room, evidence of an adequate air supply for combustion has been provided if the furnaces are set up
in rooms that have an opening or a line leading to
the outside.
The cross-section of the opening must be at least
150 cm² plus and additional 2 cm²
rated heat output which is above 50 kW.
The lines’ cross-sections must have equivalent
measurements for air flow. The required crosssection may not divided among any more than 2
openings or lines.
(4) Combustion air openings and lines may not be
closed or blocked unless the safety mechanisms
can ensure that the furnace can only be operated
when the flap is closed. The required cross-section
may not be constricted by the flap or the grille.
(5) As an exception to Paras. 1 to 3, for furnaces de-
pendent on air in the room, evidence of an adequate air supply for combustion can be provided
other ways.
For example by:
A continuous line to the outside with a sufficient
cross-section that is attached to the burner or its lining. This must be adjusted to the suction capacity of
the burner and the line resistances (including the
protective air suction grille) so that combustion is
assured.
for each kW of
à The units must be set up and operated in such a way
that people are not exposed to exhaust or radiant
heat and fires cannot occur.
à The units must be set up in such a way that they do
not cause any hazards or unreasonable annoyances,
e.g. tremors, vibrations or noise.
à The units must be set up and installed in such a way
that they are easily accessible for monitoring, repair
and maintenance work.
à Operating elements which can result in dangerous
operating conditions when used improperly must be
protected from unauthorised operation if they are
generally accessible.
à We do not recommend suctioning in outside air di-
rectly with the standard combustion chamber. When
mounting the mixed air flaps (accessories), they
must be attached in the opposite direction. The percentage of fresh air supplied may not exceed 30%.
à The units may not be set up or operated in rooms or
areas susceptible to fire or explosions.
The units are suitable for operation when accesso-
G
ries are attached to the air intake or outlet sides.
The units are not suitable exclusively for use
G
as air supply units.
Important Information about Safe Setup
à The units may only be set up and operated in rooms
where there is enough air for combustion and the expelled air is guided to the outside via an exhaust system.
à Units dependent on air in the room may only be set
up in rooms or buildings from which air is suctioned
out by means of fans (such as ventilation or exhaust
systems) if:
1. Safety mechanisms prevent the units and the air
suctioning system(s) from operating simultaneously.
2. The expulsion of exhaust is monitored by special
safety devices.
3. The exhaust produced by the units is expelled by
means of the air suctioning system(s).
4. The design or dimensions of the system ensure
that no dangerous negative pressure can be produced.
à The units must be placed firmly on a suitable, non-
flammable surface outside of traffic zones, for example, away from cranes.
Heating Rooms
The units only may be operated in closed rooms or
warehouses if they have been equipped with a suitable
room temperature control thermostat (room thermostat).
Setup on the Ground
The units must be placed firmly on non-flammable surface outside of traffic zones, e.g. away from cranes.
A safety zone of 1 m must be maintained around the
units to protect them from damage in commercial
rooms, to ensure unhindered access for maintenance
and repair work on the unit and burner and, if necessary, to prevent air intakes and outlets from blockage.
This safety zone is to be identified with a warning sign
that says:
Maintain a Safety Zone of 1 m
We recommend clearly marking heavily trafficked areas.
7
Wall Assembly
Fuel Supply
The wall where the unit is to be assembled may not be
made of flammable materials. Its load-bearing capacity
must be tested and, if necessary, reinforced.
Consoles must be anchored firmly to the wall and the
units attached here. There must be adequate room to
perform maintenance work on the heat-exchanger,
burner, fan and exhaust system.
You must observe the following.
à Operating mechanisms for the unit and the combus-
tion air supply must be able to be operated from the
ground.
à Tools needed for monitoring, service and repair work
must be supplied by the operator.
Assembling Suspended Units
The units may only be attached to sturdy structures or
ceilings that are made of non-flammable materials and
have adequate load-bearing capacity.
Sturdy mounts fixed on the unit are used to attach it. In
addition, the requirements listed in the section “Wall Assembly” must be observed.
Outside Setup
Units that are set up outside must be adequately protected from weather conditions so that they do not have
any harmful effects or cause any unreasonable annoyances during operation.
The units may only be equipped with armatures and
control devices that are suitable for outside use. If not,
the control devices and switches must be protected accordingly.
Power Supply
Prior to performing the electrical installation in line with
local requirements, check whether it is possible for even
a temporary power overload to cause an impermissible
undervoltage.
Particularly for heating oil lines, make sure that the
cross-section of the lines corresponds to the suction
height, the total line resistance and increased viscosity
at lower temperatures and, if necessary, it is possible to
connect an oil transport device.
The lines must be placed in such a way that they are
easily ventilated and are protected from corrosion and
mechanical damage.
The measured pressure of the suction line should
G
not exceed -0.3 bar. It may be a maximum of -0.4 bar.
Annual Inspection and Service
The operator must have the unit checked and serviced
as necessary, at least once a year, by a representative
of the manufacturing company or another authorised individual in accordance with the operating conditions.
The units must be checked for operational readiness,
functional safety, efficiency and compliance with emission limits.
The operator must be informed if defects are found. He
must then have the unit serviced immediately or its
components replaced.
The following applies:
Maintenance work on limiting devices, selfadjusting devices and flame monitoring devices as
well as on other safety mechanisms may only be
performed by the respective manufacturer or his
representatives.
On the other hand, the individual contracted to
service the unit may only replace components or
assemblies with those provided by the manufacturer or his representatives.
The units are intended to be used exclusively for
industrial and commercial purposes. They are not
G
intended to heat residences or similar rooms.
To connect the units, the line cross-sections are to be
placed in such a way that they do not caused the burner
voltage to lower to an impermissible level when the fan
is started.
When connecting the units in the 400 V series, make
sure that the phase sequence of the rotational field is
correct. The fan could rotate in the wrong direction if this
connection is not correct.
An easily accessible emergency switch must be attached in the setup room, but not close to hazardous areas.
All generally accessible switches must be
G
protected against damage and unauthorised use!
8
Exhaust Connection
The unit is to be connected to suitable exhaust systems
whose design has been approved.
Installation of an exhaust system always requires
a permit.
G
Exhaust systems are structural systems located either
in or on buildings whose sole purpose is to expel exhaust from heating appliances safely above the roof.
When planning for the exhaust system, please observe
the following:
à The exhaust system must be installed and assem-
bled properly and in accordance with the relevant
regulations.
Examples of Use
Double-sided exhaust system / stainless-steel / outside
assembly.
Upright unit assembly
AS-ME-D
à The dimensions of the exhaust lines must be ad-
justed to the capacity of the unit and the construction
height.
à The dimensions of the exhaust systems must ensure
that the exhaust is expelled to the outside regardless
of the operating conditions and guarantee that no
positive pressure is produced in the rooms. These
dimensions are based on the cross-section and
height, and to the extent required, the heat penetrability resistance and internal surface.
à The exhaust system openings must stick out at least
40 cm beyond the top of the roof or be at least 1 m
away from the surface of the roof.
à If impact pressures, e.g. from fall winds or neigh-
bouring buildings, are anticipated, the top of the
chimney should be shaped accordingly.
à The exhaust system must be attached securely and
properly according to the manufacturer’s specifications.
à In roof structures, the exhaust system must be led
through a pipe casing or a chute to allow the exhaust
line to expand when heated.
à The unit connection must be impermeable and se-
cured with rivets or screws from becoming accidentally loose.
à It is preferable to have a horizontal exhaust line that
is as short as possible.
Incline 2 % = 2 cm/m.
à You should plan to have a closable opening for per-
forming measurements at a distance of 2 x
haust pipe behind the unit connection.
Under certain circumstances, it is possible to measure the exhaust opening.
à The double-walled, REMKO stainless steel exhaust
systems have been approved by the Institut für Bautechnik (German Institute for Construction Engineering) in accordance with DIN 18160 Part 1.
∅ ex-
AS-1000-D
WS-ÜGI-D
WS-1000-E
AS-T90-D
AS-RT-D
AS-GI-D
AS-WK-D
Assembly of the unit on its side
AS-ME-D
AS-1000-D
AS-RB90-E
AS-ÜGI-D
AS-500-E
AS-T90-D
AS-RT-D
AS-GI-D
AS-WK-D
Wallconsole
Make sure to maintain a safe distance to flammable materials!
G
9
Setup and Assembly
Unit Setup
Thermostat Connection
When setting up the units, the regional provisions and
regulations must be observed.
The units may only be operated with accessories that
have either been approved by the manufacturer or supplied with the units.
Proceed as follows to set up the units:
1. Remove the transport pallets or crates or other
packaging material before set up/assembly.
à Check the units for any damage.
à When assembling, place the units securely on the
ground, preferably on a separate platform and ensure that they are current-free.
à Make sure that the fan capacity (rated pressure) has
been adjusted to the corresponding resistance on
the air side.
Measure rated current.
à Make sure that air can flow freely into and out of the
units.
à Make sure that there is a sufficient supply of air for
combustion.
à If there are unfavourable pressure conditions in the
setup room or strong air impurities, install a burnerdriven device that sucks in fresh air from the outside.
à Guide the suctioned air via appropriate filters
(accessories) if the air in the setup room is expected
to be quite dirty.
Pay attention to the resistance on the air intake side
and adjust the fan capacity accordingly.
Air may only be suctioned in via the air intake
openings for this purpose. If the bottom of the unit
G
has not been equipped for air intake, it must be
closed to prevent the incorrect intake of air.
Exhaust Connection
The exhaust connection must be made properly in accordance with the relevant regulations.
à Proper exhaust expulsion must be ensured.
à The exhaust connection may only be made to a pre-
viously approved exhaust system.
The room thermostat (accessory) or day/night regulator
(accessory) is connected via special connections. You
must observe the following.
à The room thermostat (accessory) must be placed in
the most ideal location in the room for regulating
temperature.
à The thermostat sensor may not be exposed directly
to a particularly cold or warm air current.
à The process is the same for installation of an auto-
matic day/night temperature regulator (accessory).
230 V/1~ model
For the control boxes of the 230 V / 1~ model, a room
thermostat or a day/night temperature control mechanism is connected to the thermostat sockets standard
for this series .
The connection is made as follows.
1
2
400 V / 3~ models
The connection of a room thermostat or a day/night
temperature control mechanism is made to the corresponding terminal strips.
The connection is made as follows:
Remove the bridge and assign the terminal strips with
the corresponding wires of the control mechanism.
400 V / 3~, Direkt Start
Terminal strip X2
400 V / 3~, Y / ∆ Start
Unplug the existing bridge plug and connect the Thermostat plug 2 to the Thermostat socket 1 on the control box.
When using control units without a standard series thermostat plug, it can be
purchased as an accessory.
Ref. no. 1101020.
1
2
Bridge
Electrical Installation
The electrical connection of the units may only be performed by authorised personnel in accordance with the
relevant regulations (including any local ones).
à An easily accessible emergency switch must be at-
tached in the setup room.
10
Terminal strip X2
1
2
Bridge
Fan Motor Connection
Starting
Fan Motor Operation
The units are completely wired at the factory.
If modifications are made or the fan motors are re-
placed, make sure that the motor is properly connected.
Burner Installation
The forced-air burner supplied by the manufacturer is
attached to the front of the unit with a clamp flange.
You must observe the following:
à Only forced-air burners with automatic burners that
have a 5 sec. safety period may be used.
à It is not necessary to limit the capacity in single-
stage burner operation for the warm air generator.
à The burner must be adjusted to the full heat load of
the unit.
à The combustion chamber may not be operated be-
low capacity.
à The exhaust temperature may not fall below 160 de-
grees Kelvin above the room temperature.
Condensation accumulation.
à Follow the operating instructions of the burner sup-
plied by the manufacturer.
à If burners from other manufacturers are used, they
must be checked for compatibility with the unit.
Heating Oil Connection
Check the drive.
1. Check that the tightening screws of the complete
drive are secure.
2. Check the initial tension of the drive belt.
3. Check the rotational direction of the fan.
Measuring the rated current and current consumption
1. To prevent inaccurate measurements, open the grille
in the air duct or the blow-out cover and attach all air
suction grilles to the unit.
2. Check the available power supply.
3. Measure the current.
– Rated current for direct start
The measured rated current may not exceed the
value on the type plate of the motor.
The thermal overcurrent relay must be adjusted to
the rated current of the drive motor.
– Rated current for Y / ∆ start.
The measured rated current may not exceed the
value on the type plate of the motor.
Multiply the rated current of the drive motor by a
factor of 0.58 and adjust the thermal overcurrent
relay to the calculated value.
Each phase should be measured separately to prevent inaccurate measurements.
G
Make sure that there is an adequate supply of fuel.
à The suction line must be equipped with a valve at the
end of the hose in the tank.
à Even when outside temperatures are low, a sufficient
amount of heating oil must be able to flow freely.
Paraffin can accumulate at temperatures starting at
approximately 5 °C depending on the quality of the
heating oil.
Appropriate measures must be taken to prevent this
from happening.
Gas Connection
Depending on the capacity of the unit, the required
quantity of gas must always be available and the necessary gas pressure present during unit operation.
à The installation of the gas connection must be per-
formed by authorised personnel.
à Gas pressure regulators and shut-off valves are to
be supplied by the manufacturer.
à The line cross-section must correspond to the con-
nection values of the units, the total line resistance
and the gas pressure.
Prior to initial operation, the gas supply line must be
G
thoroughly cleaned and tested for impermeability!
Thermal Overcurrent Relay
To check the function of the overcurrent relay or its set
value, remove a fuse. If the unit is functioning and set
properly, the relay should activate after approximately
30 seconds.
Important Hints about the Thermal Overcurrent Relay
The thermal overcurrent relay may only be operated
when the relay is set to manual (H). The relay may not
automatically switch on again after it has cooled.
When the relay is set to automatic (A), the possibility
that damage will occur cannot be ruled out.
There is no guarantee claim!
Current Consumption too High
If the motor is consuming too much current despite a
proper electrical connection and adequate power
supply, the thermal overcurrent relay may not be set
higher or bypassed under any circumstances.
To correct the problem, the air intakes and outlets
(possible air compression) must be checked and
appropriate action taken.
11
Initial operation
Heating Mode
Initial operation of the unit and its forced-air burner must
be performed by the manufacturer or one of its authorised service representatives. During this process, all
regulating, control and safety mechanisms must be
checked to ensure that they are functioning properly and
set correctly.
à Oil and gas-fired units may only be put into initial op-
eration by authorised personnel.
à Make sure that the fan’s screws and bolts and
burner attachments are secure.
à Open the blow-out grille if necessary and adjust it as
required.
à Check the settings of the triple combination control.
à Switch the customer-supplied main switch or fuse on.
à Set the room thermostat to a higher value than the
current room temperature.
à Open the fuel supply and set the operating switch to
“Heizen” (heating).
If the oil burner was supplied by the manufacturer,
(up to VRS 50) the burner start is delayed as a result
of the standard oil preheating process.
à Adjust the throughput for the heating oil or gas to
meet the heating capacity of the unit.
See the unit’s type plate.
à Set the burner to the optimum values in accordance
with the manufacturer’s specifications.
à Measure the chimney draught when cold and hot.
à Keep a protocol of measurements and submit it to
the operator for safekeeping. Familiarise the operator with the system
à Give the statement confirming the authorised com-
pany status and the company certificate of the respective installation company to the relevant authorities.
.
The unit runs fully automatically with the temperature
which has been pre-selected on the room thermostat.
Proceed as follows to put the unit into heating mode.
1. Turn the customer-supplied main switch or the fuse
on.
2. Open the fuel supply.
3. Set the operating switch to
“Heizen” (heating) or “I”.
4. Adjust the room thermostat
to the room temperature
you want.
When heat is necessary, the forced-air burner switches
on automatically. The air supply fan only switches on
once the target temperature has been reached. This
prevents cold air from being blown out.
Ventilation
In this position only the supply air fan runs and the unit
can be used for air circulation.
1. Set the operating switch to
“Lüften” (fan) or “II”.
2. Keep in mind that the unit’s
fan runs continuously.
It is not possible to control it
with a thermostat
Unit Shut Down
Important information about corrosion in the heatexchanger
à The exhaust gas temperature difference may not
fall below 160 Kelvin.
This keeps the temperature from falling below the dew
point and prevents the resulting corrosion in the heatexchanger.
à If the unit is not set to its rated heat load or it is too
large for the necessary heat requirements, the
burner only runs in cyclical operation. Because the
required operating temperature is not reached in cyclical operation, more condensation accumulates
and there is more corrosion in the heat-exchanger.
12
.
Set the operating switch to “0”.
Keep in mind that the air supply fan continues running
to cool down the heat-exchanger and 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.
G
Our guarantee does not cover damages caused to
the unit by overheating.
If the unit is taken out of operation for a
longer period of time, the customersupplied main switch or the fuse should
be switched off and the fuel supply
closed off.
Maintenance and Service
The operator must have the unit checked and serviced
as necessary, at least once a year, by a representative
of the manufacturing company or another authorised individual in accordance with the operating conditions.
Prior to doing any maintenance or repair work on
the unit, unplug it from the power supply. It is not
G
adequate to switch off the unit with the operating
switch!
Adjustments or maintenance work on the unit or
forced-air burner may only be performed by
G
authorised personnel!
à Dust and dirt must be cleaned from the unit including
from the heat-exchanger, combustion chamber and
forced-air burner. Combustion residue in the combustion chamber and in the heat-exchanger must be
removed.
à The V-belt tension and the motor mount must be
checked on a regular basis.
à Parts that wear out, e.g. flue gas brakes, oil nozzles,
oil filter inserts, seals etc. must be checked, cleaned
and replaced if necessary.
à Make sure to comply with waste gas emission limits
in accordance with regulations.
Cleaning the Combustion Chamber and the HeatExchanger
1. Unplug the unit from the power supply.
2. Disassemble the burner with burner plate 6 and the
seal 7.
3. Disassemble the following parts:
– Lining plate(s), front top (not shown),
– Inspection cover, front 1,
– Lining plate, side top (not shown),
– Inspection cover, side 4.
4. Remove the flue gas brakes 3 on both sides from the
heat-exchanger lines and clean the flue gas brakes.
Replace them if necessary!
5. Clean the combustion residue from the heatexchanger lines with a suitable cleaning brush.
6. Remove the accumulated combustion residue with
a industrial vacuum cleaner from the front and side
collection boxes.
A special cleaning set for the REMKO industrial vacuum cleaner can be purchased as an accessory.
7. Clean the combustion residue from the furnace
through the burner opening.
With cleaning brush and industrial vacuum cleaner.
Important Information on Servicing the Unit
à If the cleaning and burner adjustment intervals are
not observed, the guarantee becomes null and void.
à It is therefore absolutely necessary to keep records
that work has been performed by authorised personnel in addition to creating standard protocols.
à We recommend entering into a maintenance con-
tract for the regularly scheduled maintenance and
service work.
Soot deposits
Even when there is only a small amount of soot buildup,
the heating surfaces become insulated and the firing efficiency falls.
A 1 mm thick layer of soot causes an increase in the
exhaust gas temperature of approx. 50 K (see diagram).
5
6+7
4
3
8. Reassemble all parts in the reverse order.
9. Make sure that the heat-exchanger lines are connected properly and that seals 2 and 5 are positioned correctly.
Seals that have been damaged or malformed must
be replaced.
10. Attach the burner with burner plate 6.
Replace seal 7 if necessary.
11. Service the burner in accordance with the separate
operating instructions.
1
2
shown VRS 130
Increase in exhaust temp. [K]
Thickness of soot layer [mm]
Loss of efficiency [%]
Check the burner and all regulating devices to ensure that they are functioning properly and set
30Belt disc, Fan
31Fan motor 400V / 3~/ N
32V-belt
33
Belt disc, Motor
34
Fan
dependent on the unit model and compression
Control box, cpl.
-
When ordering spare parts please indicate ref. no. and machine no. (see model plate)!
We reserve the right to make modifications in dimensions and construction in the interests of technical progress.
17
Wiring Diagram 230 V
/
Fan motor: 230 V / 1~
Burner motor: 230 V / 1~
230V
50 Hz
L1N
4B1A
5B
6B3A
S
SK
2A
12345678
KL
#1
#2
#3
#4
1
2
3
RT
schw.1
schw.2
black 1
black 2
1
23456
2
4
4
2
1
1
TR TWSTB
KB
black 4
schwarz
blau
blue
black
braun
schw.4
schw.3
black 3
2
4
1
brown
blau
blue
M
WS
L1
L1
N
T1 T2
NT1T2S3 B4
Burner cable
Prepared at the factory for connection to
the wieland socket
Wieland plug
S3 B4
Included with purchase of burner.
Wieland socket
from the burner
C Capacitor
KB REMKO Triple Combination Control
KL Terminal strip in the control box
M Fan motor
RT Thermostat socket
S Operating switch
SK Control box
STB Safety temperature limiter
TR Fan control thermostat
TW Temperature monitor
WS Wieland plug
(Only for factory-installed burner
We reserve the right to make modifications in dimensions and construction in the interests of technical progress.
18
An easily accessible emergency switch must be attached in the setup room, but not close to hazardous
areas.
This switch must be protected from damage and unauthorised use!
The electrical connections should only be made by
authorised personnel.
G
)
Wiring Diagram 400 V Direct Start
b
Fan motor: 400 V / 3~ (up to 2,2 kW)
Burner motor: 230 V / 1~
1 2 3PE4
X1
L1 L2 L3
400 V / 50 Hz /
3~ N PE
N PE
12345
F1
12345
K1
12345
F2
5 6 7 PE
X2
U V
W
M
Motor Optional:
1
F3
6
2
6
95
97
6
9698
1
H1
2
1
Aus
S1
Off
23
A1
A2
Heat Fan
H2
LüftenHeizen
K1
1
2
RT
Room thermostat or
day / night regulator
C°
X2
1 2 PE
TWSTB
KB
1
H3
2
43
C°C°C°
Triple combination control
TR
5 6
Optional
Optional
P
H4
PE
7 89 10 PE
# 1
# 2
L1 N T1 T2S3B4 PE
Wieland plug
Included with purchase
of burner.
h
1
2
# 3
# 4
X1 1 2
3
auseitige Zuleitung
Supply line
56
4
UVWPEL1 L2 L3 N
Fan motor
Ventilatormotor
PE7PE
PE
F1 Fuse block, fan motor
F2 Thermal overcurrent relay, fan motor
F3 Control fuse
H1 Malfunction lamp, fan
H2 Operating lamp, fan
H3 Operating lamp, burner
H4 Malfunction lamp, burner
K1 Contactor, fan motor
KB REMKO triple combination control
M Fan motor
P Running hour meter (optional)
If a room therm ostat or a day/
night control mec hanism is
connected, the factor y-installed
bridge between terminals 1 and
2 of the termi nal strip X2 must
be removed.
RT Room thermostat or regulator (optional)
S1 Operating switch
STB Safety temperature limiter
TR Fan control thermostat
TW Temperature monitor
X1 Terminal strip 1 in the control box
X2 Terminal strip 2 in the control box
G
X2 1 23 4
PEPE
Raumthermostat bzw.
Tag / Nacht Regelung
Room thermostat or
day / night regulator
5
678910
S3 B4 PEL1 N
nummeriertes
Dreifach
Triple
Kombinationsregler
combination control
Brennerkabel
Prepared at the factory
numbered
burner cable
PE
Werkseitig vorbereitet zum
Anschluß des Wielanssteckers
for connection to the
wieland socket
The electrical connections should only be made by
authorised personnel.
We reserve the right to make modifications in dimensions and construction in the interests of technical progress.
19
Wiring Diagram 400 V Y / ∆
Fan motor: 400 V / 3~ (over 3,0 kW)
Burner motor: 230 V / 1~
1
F4
2
L1
Fan
Aus
Off
Heat
95
F3
96
23
24
13
14
97
F3
98
Lüften
S1
Heizen
Optional
h
15
P
K4
18
16
21
K2
X1
H1
X1
X2
X2
A1
K1
A2
22
A1
K3
A2
21
K3
22
A1
K2
A2
A1
K4
A2
H3
1
1
H4
2
2
N
PE
1 2
X2
C°
RT
Optional:
Room thermostat or
day / night regulator
PE
TW
3
C°
STB
4
C°
TR
6
C°
7 89 10
PE5
# 1
# 2
L1 N T1T2 S3 B4 PE
KB
Triple combination control Wieland plug
Included with purchase
of burner
PE
# 3
# 4
.
X1 1 2 3 46 7 PE
U1 V1 W1PEL1 L2 L3 N
bauseitige Zuleitung
Supply line
We reserve the right to make modifications in dimensions and construction in the interests of technical progress.
PE
20
89PE 510 11 12
V2 U2 W2
Ventilatormotor
Fan motor
Terminal strips in the control box
If a room therm ostat or a day/
13 14
Überstromrelais
Brenner
Thermal overcurrent
PE
PEL1 L2 L3 N
relay, burner
night control mec hanism is
connected, the factor y-installed
bridge between terminals 1 and
2 of the termi nal strip X2 must
be removed.
X2 1 2
345
PEPE
Raumthermostat bzw.
Room thermostat or
Tag / Nacht Regelung
day / night regulator
Dreifach
Triple
7
6
Kombinationsregler
combination control
8910
S3 B4 PEL1 N
nummeriertes
Brennerkabel
Werkseitig vorbereitetzum
Anschluß des Wielanssteckers
Prepared at the factory
for connection to the
numbered
burner cable
PE
wieland socket
Wiring Diagram 400 V Y / ∆ Fan motor
L1
E
Fan motor: 400 V / 3~ (over 3,0 kW)
Burner motor: (400 V / 3~ optional)
N
PE
13 5
F1F2
2
46
13 5
K1K2K3
24 6
13 5
F3
24 6
12 34PE56 789 10PE11 12 13 14 P
X1
PEL1 L2 L3 N
400V / 50 Hz / 3~ N PE Fan motor400V / 50 Hz / 3~ N PE
M1
9895
9796
W1
V1
U1
13 5
24 6
PE
V2
U2
W2
13 5
24 6
13 5
2
46
L1 L2 L3 N PE
for optional
3~ burner motor
F1 Fuse block, fan motor
F2 Fuse block, burner motor (optional)
F3 Thermal overcurrent relay, fan motor
F4 Control fuse
H1 Malfunction lamp, fan
H2 Operating lamp, fan
H3 Operating lamp, burner
H4 Malfunction lamp, burner
KB REMKO triple combination control
K1 Contactor, power supply
K2 Contactor, delta connection
K3 Contactor, star connection
K4 Timing relay
M1 Fan motor
RT Room thermostat or regulator (optional)
We reserve the right to make modifications in dimensions and construction in the interests of technical progress.
P Running hour meter (optional)
S1 Operating switch
STB Safety temperature limiter
TR Fan control thermostat
TW Temperature monitor
X1 Terminal strip 1 in the control box
X2 Terminal strip 2 in the control box
An easily accessible emergency switch must be attached in the setup room, but not close to hazardous
areas.
This switch must be protected from damage and unauthorised use!
The electrical connections should only be made by
G
authorised personnel.
21
Troubleshooting
For safety purposes, repair work on the electrical
components and the burner may only be per-
G
formed by authorised personnel.
The unit does not start
à Check the power supply.
à Check the fuses in the control box.
Only for units in the 400 V, 3 phase current series.
à Check the temperature monitor .
à Check the safety temperature limiter.
à Keep in mind: before resetting the STB, it is abso-
lutely necessary to determine the reason it was activated and take appropriate measures.
The following are possible causes:
– The unit could not cool down because the power
supply was interrupted. Even short interruptions
can activate the STB.
– The temperature of the air being blown out is too
high because the grilles have not been properly
adjusted.
– The fan was overloaded and the thermal overcur-
rent relay of the 400 V series was activated or the
thermal contacts in the fan motor of the 230 V se-
ries were activated.
– The V-belt of the fan drive is loose or defective
– Air intakes and outlets are blocked.
à Check the operating and/or main switch.
à Check the room thermostat setting.
The room thermostat must be set higher than the
room temperature..
à Set the operating switch to “Lüften” (fan) or “II”.
If the air supply fan starts now, look for the problem
in the burner.
The burner does not start
à Check whether the fuel filter is dirty.
à Check that all shut-off valves in the fuel supply are
open.
à Check that there is enough fuel in the fuel container.
à Check whether paraffin has accumulated in the heat-
ing oil or in the fuel filter.
This can occur at temperatures below 5 °C.
à Check oil lines for damage.
Leaks can cause air intake.
à Use suitable means to ensure that the safety tem-
perature limiter (STB) and the temperature monitor
(TW) are functioning properly.
à Check the sensors and capillary pipes of the triple
combination control for damage and ensure that the
sensor has been properly positioned.
à Check whether the burner malfunction control lamp
on the automatic burner relay is illuminated.
à Release the automatic burner relay by pressing the
malfunction button if the malfunction lamp lights up.
The malfunction light goes out and the burner tries to
start.
à Keep in mind that the units up to VRS 50 have a de-
layed start due to the oil preheating process.
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.
The air supply fan does not start
à Set the operating switch to “Lüften” (fan) or “II”.
The air supply fan should now start.
à Check that the fan and the fan drive are running
smoothly.
à Check the V-belt on the fan drive.
à Check the electric cord on the fan motor for damage.
à Check whether the capacity of the fan was ex-
ceeded.
The thermal overcurrent relay (400 V series) or the
thermal contacts (230 V series) in the fan motor have
been activated.
à Check the operating capacitor of the fan.
Only for the 230 V series.
à Use suitable means to ensure that the fan control
thermostat (TR) are functioning properly.
Please carry out an electrical safety test after having finished service on the unit.
G
Should the unit still not function properly after performing these checks, please contact an author-
G
ised service centre.
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.
22
Maintenance Log
Model: : ................................ Model No.: : ......................................
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