ApenGroup AQUAKOND AKY, Installation And Maintenance Manual

Page 1: ...GB Installation Commissioning and Maintenance Manual Condensation Boilers AKY 1 code HC0048 01GB ed B 1406 AKY Efficiency Class NOx Class 5 Efficiency rate up to 109 ...

Page 2: ...CONDENSATION BOILER AQUAKOND AKY 2 code HC0048 01GB ed B 1406 AKY ...

Page 3: ...ecchi a Gas 2009 142 CE ex 90 396 CE Gas Appliance Directive 2009 142 CE formerly 90 396 EC Direttiva compatibilità elettromagnetica 2004 108 CE Electromagnetic Compatibility Directive 2004 108 CE Direttiva Bassa Tensione 2006 95 CE Low Voltage Directive 2006 95 EC Direttiva Erp 2009 125 CE Erp Directive 2009 125 EC Qualora la macchina dovesse essere integrata in un impianto macchine combinate il ...

Page 4: ...CONDENSATION BOILER AQUAKOND AKY 4 code HC0048 01GB ed B 1406 AKY 3 7 Approval Certificate ...

Page 5: ...CONDENSATION BOILER AQUAKOND AKY 5 code HC0048 01GB ed B 1406 AKY ...

Page 6: ...allation Rules 21 5 2 Transport and Handling 21 5 3 Installation Accessories 21 5 4 Installation of Boiler and Blower 21 5 5 Electrical Wiring 23 5 6 Gas Connections 25 5 7 Stack Piping 26 5 8 Filling the Hydraulic System 29 SECTION 6 INSTRUCTIONS TO SERVICE STAFF 30 6 1 Country Table Gas Category 30 6 2 Gas Setting Data Table 31 6 3 First Start up 32 6 4 Combustion Analysis 32 6 5 Conversion to L...

Page 7: ...d on the relevant certificate The manufacturer declares that the unit is workmanlike built in compliance with UNI UNI CIG and EC technical provisions and according to the relevant laws and to the Directive on Ap pliances burning gaseous fuels 2009 142 EEC 2 SAFETY WARNINGS The following symbol is used in this Manual whenever it is necessary to draw the operator s attention on a safety issue Safety...

Page 8: ...leaning disconnect power and gas supply by means of main ON OFF switch and or appropri ate detection devices In case of failure and or insufficient running standards switch off the unit and do not attempt to repair it yourself Contact the local authorized Service Centre Only use original spare parts for repairs Failure to follow above instructions could compromise the unit safety and shall void th...

Page 9: ...mixingandthesimultaneous adjustment of combustion air and gas flows provide an increase in efficiency at minimum output This technique makes the unit safer since the ratio between the gas flow through the gas valve and the air flow always corresponds to the manufacturer s setting As opposed to atmospheric burners in premix units the CO2 content does not change throughout the operative range of the...

Page 10: ...42 Directive NOx Class EN 483 5 Boiler efficiency MAX MIN Combustion Chamber Heat Output Hi 75 55 C kW 31 0 5 0 Useful heat output for water Hi 75 55 C kW 30 1 5 3 Useful heat to water Hi 80 60 C 96 5 96 7 Useful heat to water Hi 75 55 C 97 1 106 0 Useful heat at 39 of load Hi 50 30 C 104 5 107 3 Stack loss with burner on 80 60 C 3 7 1 4 Stack loss with burner off 0 1 Enclosure loss average T 60 C...

Page 11: ... Useful heat to water 72 45 C kW 35 2 8 6 48 9 8 2 65 3 11 8 Useful heat to water Hi 50 30 C 105 8 108 9 104 8 105 5 104 5 107 4 Output to water Hi 72 45 C 101 1 107 5 99 7 100 8 100 5 107 5 Useful heat to water Hi 80 60 C 98 3 96 8 95 7 97 5 97 4 Stack loss with burner on 72 45 C 2 6 1 4 2 7 1 0 2 7 0 9 Stack loss with burner off 0 1 Enclosure loss average T 60 C 0 35 0 40 0 40 Condensate max qua...

Page 12: ...Flow rate from 1 600 to 2 000 l h 70 Flow rate from 2 000 to 2 400 l h The boiler can normally work also with lower flow rates In such case to reach maximum thermal output you need to increase delivery temperature and consequently heat drop 0 10 20 30 40 50 60 70 80 0 500 1000 1500 2000 2500 prevalenza KPa Portata l h Curva Prevalenza disponibile Portata acqua per Caldaie serie AKY AKY050 AKY034 A...

Page 13: ... 1 22 APEN GROUP recommends for itsAKY boilers the use of mixtures of water and monopropylene glycol FERNOXALPHI11 Different types of glycol might void the warranty Losses are measured in kPa per 1 meter of pipe length Water flow rate Steel tubes Copper tubes l h 3 4 1 1 1 4 1 1 2 2 20 22 25 28 32 35 39 42 51 54 600 0 15 0 05 0 18 0 06 0 02 900 0 31 0 10 0 03 0 35 0 12 0 04 1 200 0 55 0 18 0 05 0 ...

Page 14: ...r limit pressure switch manual reset IPMIN Minimun water pressure switch manual reset NTC Modulation temperature sensor PDIFF Differential pressure switch water flow switch PI System pump circulator PIT Well for temperature check PMIN Water minimum pressure switch PZI Housing for fuel shut off valve R3VIE Three way control valve EV1 EV2 STF U E HC0047 C2 034 3 3 Features of the Hydraulic System Hy...

Page 15: ...VAL CERTIFICATE N VS 319 00 Safety thermostat TS 1NT08L NC terminal of thermostat opening T 87 4 C Sensata Tes 20 180 C KEMA certificate 2014531 16 NOTE Test on Water Circuit ISPESL standards require that the boiler body is tested at a pressure of 4 5 bars i e one and a half times its maximum working pressure NOTE Distance between expansion tank and safety valve only AKY050 070 According to ISPESL...

Page 16: ... 1 AKY032 034 AKY032 034 AKY050 070 3 5 Dimensions of Boilers Description Dimension 032 034 050 070 1 GAS SUPPLY G3 4 2 WATER RETURN G3 4 G1 3 WATER DELIVERY G3 4 G1 4 SAFETY VALVE G1 2 5 SAFETY VALVE G3 4 6 SYSTEM FILLING VALVE G1 2 7 CONDENSATE DRAIN Ø14 mm 8 WIRING PG 09 9 FUEL DETECTION VALVE Ø14mm 10 FLUE GAS STACK 60 mm ...

Page 17: ...odulation concerns delivery water whose temperature remains steady at default value 72 or 80 C based on the series If more room units are connected and one of these is turned off the boiler automatically reduces output without decreasing water tem perature Lock and reset alerts available on the boiler can be transferred to remote control if APEN control C09660 is used Operation Mode B SmartControl...

Page 18: ...emperature must be set on the thermostat This kind of installation requires a remote control code C09660 to enable the user to check locks and remotely reset the boiler if necessary without inspecting the boiler outdoor 4 1 2 Lock and Reset Messages A red lamp on C09660 remote control alerts the user when a problem occurs The red lamp only warns about the existence of the problem but gives no indi...

Page 19: ...re in the circuit It is used when filling the system and checking the pressure in the boiler and the hydraulic circuit If 01 6 is displayed the pressure in the circuit is 1 60 bars 6 Abi From Abi menu you can access submenus using second and third level passwords Note To view water pressure value press Enter when Pra is displayed 4 2 Control Panel with LCD Display The control panel includes an thr...

Page 20: ...equired F80 Lack of water in the circuit Refill the boiler Normal PrA value must be higher than 50 0 50 bars but lower than 220 2 20 bars The lock is automatically removed when the boiler is full No manual reset is required F81 Water pressure is low but still enough to operate the boiler This is a warning to the user Check water pres sure F82 Water pressure is too high This is a warning The boiler...

Page 21: ... plastic flue terminal Ø60 L 400mm with hole for flue test 1 gas cock G3 4 with copper pipe and gaskets for gas valve connection 5 4 Boiler installation We recommend installing the boiler in the lowest point of its hydrauliccircuit Thiswillpreventairbubblecreationinthecircuit 5 4 1 Installation procedure for the boiler Place drilling template on the wall and make sure it is cor rectly leveled Dril...

Page 22: ... parallel connection with other contacts of other relays if any This means the boiler will turn on when a thermostat issues a heat request Water circulates to all room units and partially heats also unwanted rooms Note If all thermostats are OFF the boiler is OFF too In the second case Install a zone valve and a room thermostat chrono thermostat SmartControl in each room Use the stop of zone valve...

Page 23: ... Y1 GND Q2 COM N C N O N N L GND 7Vdc 24Vac 24Vdc CLK DAT NC IDC1 ID1 LBW HC0047 C2 009 YELLOW GREY GREEN BROWN ROSE Supply plug HC0047 C2 007 5 5 Electric Wiring 5 5 1 Power Supply of the Boiler The boiler shall be properly wired to an efficient ground ing system complying with existing regulations Single phase 230 Vac supply with neutral Do not re verse neutral and phase As a safety precaution w...

Page 24: ...3 IDC4 ID4 IDC5 ID5 IDC6 ID6 V GND A B NTC NTC I1 I2 I3 A B GND 1 SW1 2 3 4 5 6 7 8 HC0047 C2 010 CPU SMART Switch for boiler address MOD_BUS Connection Respect polarity SmartControl supply voltage Respect polarity Binary code is used for setting the address Codes are are following 1st 1 2nd 2 3rd 4 4th 8 5th 16 6th 32 Therefore to configure address 13 move to ON switches 4th 3rd 1st Corresponding...

Page 25: ...n burner gas solenoid valve 2 Pressure stabilizer 3 Safety solenoid valve 4 Gas filter on gal valve small section 5 Gas cock supplied by APEN GROUP 6 Vibration damping joint 7 Gas filter 8 Fuel detection valve AKY032 034 Installation Diagram Included at delivery Already installed on the boiler To be installed by the installer 5 6 Gas Connections For this system use CE approved and certified compon...

Page 26: ...e used deduct from max length 1 5 m per each PP 90 bend Ø60 wide radius 1 0 m per each PP 45 bend Ø60 wide radius We recommend orienting horizontal flue terminal towards the front of the boiler see drawing in this page to avoid flue con densation on the wall of the building WARNING Install a shelter on boiler flue outlet to prevent rain from dropping into the unit If flue system is longer than 4 m...

Page 27: ...9 HC0047 C2 032 C09026 splitter 5 7 1 C type Installation If installation layout is type C do the following Open a hole of Ø80 in the top of the boiler Close air intake in the boiler with the cover supplied C09349 Install C09026 accessory and or coaxial discharge as required Ask Apen Group SPA Service Centre for kit documentation ...

Page 28: ...Apen Group Service Centre for more information Antifreeze Protection If the boiler is to be installed outdoor and temperature may lower so that the condensate might freeze condensate drain system should be protected from freezing We recommend building the drain system inside heated rooms using a siphon If the system runs outdoor do not close the drain tube after the siphon but leave it open to pre...

Page 29: ...m For AKY050 070 models After removing cover of C inlet valve connect it to a test pump though a 1 2 flexible hose while the tank is full of water glycol mixture Increase mixture pressure to about 2 bars For any models Vent the pipes When done check on display that the pressure inside the circuit is higher than 1 bar Lower values would make minimum water pressure switch adjusted at 0 4 bars issue ...

Page 30: ...cates the unit has been set and tested for Liquid Propane G31 AKY070NL xxx2 2 indicates the unit has been set and tested for natural gas G25 AKY070HU xxx3 3 indicates the unit has been set and tested for natural gas G25 1 Another label on the unit placed near fuel supply clearly states which gas type and supply pressure the unit has been set and tested for Country Category Gas Pressure Gas Pressur...

Page 31: ...80 0 64 4 21 0 88 5 82 1 02 7 70 1 37 G30 GAS TYPE OF APPLIANCE 032 034 050 070 CATEGORY Depending on target country see table 6 1 SUPPLY PRESSURE mbar 30 min 25 max 35 50 min 42 5 max 57 5 Ø GAS DIAPHRAGM mm 4 0 5 9 5 9 5 9 CARBON DIOXIDE CO2 10 5 0 2 11 2 0 2 GAS CONSUMPTION 15 C 1013 mbar Kg h 1 87 0 31 2 26 0 54 3 64 0 60 4 15 0 68 G31 GAS TYPE OF APPLIANCE 032 034 050 070 CATEGORY Depending o...

Page 32: ...act on elec tronic board closes and start up cycle is launched If APEN remote control a Smartcontrol or a SMART NET application is used se relevant manual to find out start up procedure then do the following It is possible that the burner does not start because of the pres ence of air in gas pipes This would cause the boiler to lock up To unlock the unit use the button on boiler display then repea...

Page 33: ...leaks exist While the burner works at maximum output 1 Check that inlet pressure of the valve matches the one required for the gas used 2 Execute combustion analysis as described in paragraph 6 4 3 Check that CO2 value does not exceed the values corre sponding to the used gas Should the value be different changeitbyturningtheregulationscrew screwtodecrease the value and unscrew to increase it 4 Ma...

Page 34: ...just replaced Setting up parameters Parameters that must necessarily be set are the following d0 d1 and d5 they identify the type of appliance b1 b2 and b3 they regulate the number of revolutions of the motor of flue fan S1 enables NTC1 sensor on hot water delivery S3 enables flue control S5 enables B2 sensor to control water pressure S6 enables B3 sensor to control water flow rate H11 enables Y1 ...

Page 35: ... exceeds the set range D5 1 to enable If NTC3 sensor is not installed the board is sues F43 error If d5 0 the board issue configuration error F99 6 9 Maintaining the Exchanger Precautions Heat exchanger of AKY boilers should be used in the following conditions The fuel used shall comply with European standards as to sulphur content i e maximum peak for short periods 150 mg m3 year average lower th...

Page 36: ... sec 20 F3x lock error holding time before F3x lock is issued 0 255 b7 sec 0 Pre washing time at max power 0 255 b8 sec 5 Duration of flame stabilization start up 0 255 b9 sec 15 Furnace post washing time FAN ON 0 255 b10 5 Increase of motor revs in every b11 sec 1 100 b11 sec 2 Time range for increase of motor revs 1 100 b12 30 of FAN motor modulation in antifreeze mode 30 100 b13 pwm 65 Integral...

Page 37: ...emperature of flue 0 Modulation only 1 Burner OFF TH3 C 103 Higher temperature limit autoreset if NTC3 TH3 0 140 Control of Hydraulic Circuit Pressure S5 3 Enabling B2 output for pressure sensor 0 Disabled 1 Enabled as ON OFF input 2 Enabled as analog input without autoreset Lock F83 3 Enabled as analog input with autoreset Lock F83 ST5 bar 0 60 B2 set point 0 9 99 P5 bar 0 30 ST5 hysteresis 0 9 9...

Page 38: ...ce Manual reset F16 Generic lock Faulty ACF device Manual reset F17 Internal problem with ACF device that failstoacceptCPU SMARTboardreset Faulty ACF device Manual reset of de vice Temperature locks safety locks F20 STB safety thermostat triggers Excessive water temperature because of insuf ficient circulation Faulty or not connected safety thermostat Faulty temperature sensor NTC1 on water delive...

Page 39: ...ST5 Restore water pressure of hydraulic circuit Errors are shown on LCD panel without stopping the unit F82 Alert water pressure PRH TH5 Excessive pressure in water circuit check hydraulic circuit load o expansion vessel F85 Lack of water circulation FLH value is zero Water circuit is clogged valves are closed or the cir culator is not working Disconnected or faulty flow meter Autoreset F86 Water ...

Page 40: ...evice installed on max water pressure If this device triggers an F21 error is issued and manual reset is required STB Safety thermostat has manual reset If it triggers an F20 lock is issued that needs to be manually reset from electronic board using reset button on flame control device ON OFF A room thermostat must be installed on each boiler If a SmartControl G22800IT is used create a jumper on I...

Page 41: ...48 01GB ed B 1406 AKY POWER SUPPLY 230 V 50 HZ 00X0 boilers differ from standard boilers as they lack the circulator with flow rate variation Therefore Y1 GND ter minals are not wired for these boilers 9 1 Electrical Wiring for AKY032 034 050 070 ...

Page 42: ...FLUE FAN C09041 01 EXPANSION VESSEL C09042 ISPESL SAFETY VALVE 2 7 bars AKY050 070 C09230 AKY032 C09034 01 AKY034 C09350 AKY050 C09265 AKY070 EXCHANGER ASSEMBLY C09239 FLOW METER C09240 AKY032 00X0 C09245 AKY032 034 C09275 AKY005 070 CIRCULATOR C09273 CONDENSATE DRAIN SIPHON C09730 TEMPERATURE SENSOR ON WATER DELIVERY G12064 POWER SUPPLY PLUG G12930 GAS VALVE G14899 AKY032 G14068 AKY034 G14154 AKY...

Page 43: ... IONIZATION ELECTRODE C09313 GASKET FOR IONIZATION ELECTRODE C09255 CABLE FOR IONIZATION ELECTRODE C09257 START UP ELECTRODE C09312 GASKET FOR START UP ELECTRODE C09254 CABLE FOR START UP ELECTRODE C09309 BURNER FLANGE INSULATOR C09308 GASKET FOR BURNER FLANGE C09256 AKY032 BURNER FLANGE ASSEMBLY C09302 AKY034 BURNER FLANGE ASSEMBLY C09331 AKY050 BURNER FLANGE ASSEMBLY C09301 AKY070 BURNER FLANGE ...

Page 44: ...CONDENSATION BOILER AQUAKOND AKY 44 code HC0048 01GB ed B 1406 AKY ...