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e r

eserve the right to make technical changes and pr

ovide no warranty as to the accuracy of this data!

Edition GB – J11

REMKO GPC 20-80

Gross calorific value wall-mounted automatic 
heaters with modulating gas burner 
with condensing design

Operation · Technology · Spare parts

Summary of Contents for GPC 20-80

Page 1: ...Edition GB J11 REMKO GPC 20 80 Gross calorific value wall mounted automatic heaters with modulating gas burner with condensing design Operation Technology Spare parts ...

Page 2: ......

Page 3: ...D display 37 40 Maintenance 41 42 Replacement of the STB 42 Replacement of boards 43 Replacement of the gas valve 44 Conversion to liquid gas 45 Unit dimensions 46 Exploded view of the unit 47 49 Spare parts list 50 Country table of gas types 51 Technical data 52 Carefully read this operating manual prior to commissioning or using the units This operating manual is a translation of the German orig...

Page 4: ...ed Always observe the respective local building code and fire prevention guidelines as well as the guidelines of the accident prevention and insurance associations when using the units Do not set down any objects on the unit The protective grille of the intake must always be kept free of dirt and loose objects The units may not be exposed to direct jets of water The units must be inspected by a se...

Page 5: ...hangers burners fan and flue gas evacuation must be planned for It must be possible to actuate control elements for the units and fuel supply from the ground Maintenance and repair possibilities must be ensured by the operator Unit installation Application area With the REMKO gas wall heaters from the GPC range it is possible to heat small rooms such as workshops right through to large spaces such...

Page 6: ...s manner is blown out of the front side of the unit through an adjustable outlet grille Operation of the unit as intended is only possible with a connected temperature controller e g ATR 10 accessory Unit description Definition of the unit Pursuant to EU Directives the unit is defined as Gas fan assisted heater WLE without flow operated safety device equipped with a fan in front of the heat exchan...

Page 7: ...fans is time controlled by the control board whereby the timing begins with the switching on of the main burner The delayed switch on prevents cold air from being blown into the room Switching off the unit If there is no longer a heat requirement room temperature above the adjusted setpoint the control board switches off the burner The burner fan runs for the secondary ventilation of the combustio...

Page 8: ...itional switch in addition to a thermostat the thermostat is to be switched off or the OFF option in the function menu of the control panel should be selected It is prohibited to switch off the unit by disconnecting the power supply This process must be used exclusively in emergencies With an instructed switch off of the hot air heater the burner fan continues to operate for a further 90 seconds i...

Page 9: ...g operation The highest output serves for raising the room temperature quickly when switching on the units If the room temperature approaches the desired value the unit begins to continuously reduce the heat output so that only the actual requirement is covered The air is heated less heavily due to the lower heat output which limits the physical emergence of layer formation tendency of the warm to...

Page 10: ...a remote control Room temperature control The hot air generators of the GPC series are delivered without a remote control or room thermostat as various room thermostats available for the devices For optimum operation the use of ATR Smart Basic or ATR Smart Web electronic room temperature controllers is recommended For correct use of the accessories please read the corresponding operating manual Op...

Page 11: ...n selected in the Fun menu set Fun to On or OFF Axx Address of the GPC hot air generator If the address of the hot air generator is not zero the current operating mode andthe address assigned to the hot air generator are shown alternately on the display In the event of a connection problems between the board and the CPU indicator flashes on the LCD display if the problem is with the CPU three flas...

Page 12: ...the arrow keys and ENTER to change the value SEt and Par only Press ENTER to confirm the change To quit the parameter and menu press ESC until the start screen On OFF rdy Fxx appears Switch to be reset as before Scrolling through menu The menu is divided into three levels the first is displayed without password input the second and the third require the input of a second and third level password I...

Page 13: ...blished the lock out is cancelled manual unlocking is not required For the directory and explanation of all faults see the FAULT table in Faults and fault analysis Resets The modulation board supports the detection of over 30 different lock out causes This means that the causative event can be dealt with perfectly To reset a lock out press both arrow buttons simultaneously for a couple of seconds ...

Page 14: ...at can be connected to a remote control probe for control The ATR Smart Basic Web have an internal temperature probe and can be supplemented by three additional remote control probes The remote probes can be programmed as a main or additional element to the internal probe to obtain a mean value between both measurements When an ATR Smart Controller panel the following is also required for control ...

Page 15: ... the desired setpoint in the room or of the preheat must be set The switch on times must be set For further information on remote operation of the controllers via ATR Smart Basic or Web please refer to the operating manuals The ATR Smart Basic or Web calculate the percentage modulation via the PID control and transmit this value to the individual modules The percentage modulation transmitted to th...

Page 16: ... stable transport packaging and if applicable on a wooden pallet The packaging materials are environmentally friendly and can be recycled By recycling packaging materials you make a valuable contribution to the reduction of waste and conservation of raw materials Therefore only dispose of packaging material at appropriate collection points Disposal of the old unit The manufacturing process for the...

Page 17: ...te must be observed The first enactment of the German Federal Emission Control Act 1st BlmSchG and the statutory provisions of the ordinance governing small combustion plants 1st BlmSchV must also be applied The installation of fan assisted heaters operated with gas burners is prohibited in the following spaces In public function rooms or in rooms with a concentration of persons greater than 0 4 p...

Page 18: ... the screws are appropriate for the type of masonry in order to bear the weight of the unit Position the unit on the brackets so that the holes of the unit line up with those of the brackets whereby the corners of the brackets must be flush with the front edge of the unit Fasten the units with the M8 screws provided in the process insert a locking ring between the screw and bracket 225 225 560 90 ...

Page 19: ...ng brackets is appropriate for the following cases a Installation of the unit in a corner b Installation of the unit at a right angle to the wall it is mounted on c Installation of the unit on a column The unit should be affixed decoupled The spider must be mounted with the flush socket side below the unit s base A counterplate must be used if necessary The bracket must be screwed to the wall so t...

Page 20: ...it When fastening to the ceiling with chains or ropes provided by the customer use appropriate fastening materials that are appropriate for the weight of the unit Detailed view A Horizontal air flow A NOTE Small guide holes are provided for correct arrangement of the suspension brackets These must be aligned at the top edge of the unit Refer to corresponding figure here ...

Page 21: ...less steel silicone Viton or EPDM hoses for hot pipes through which smoke is discharged For cold pipes through which only water flows PVC pipes Do not use copper or galvanized iron Anti freeze protection The condensate disposal system must be effectively protected against the freezing of the circulating condensate It is recommended to install the condensate collection system within heated rooms In...

Page 22: ...tralisation of the condensate The condensate produced by the combustion of natural gas has a pH of 3 5 3 8 If neutralization of the condensate is necessary the corresponding articles are available as accessories The following articles are available as accessories Neutralization box including calcium carbonate EDP no 260400 Acid resistant condensate pump EDP no 260410 Further information can be obt...

Page 23: ... end piece seals The scope of supply includes two seals to seal the end pieces with the flue gas pipe and fresh air line These are fitted on the end pieces of the GPC units for correct sealing Flue gas connection Since the automatic heaters are GPC condensing devices the following material must be used for the exhaust gas line Aluminium with a wall thickness of at least 1 5 mm Stainless steel with...

Page 24: ...ON Installation work may only be carried out by authorised qualified technicians Guide to selection If the flue gas end piece is not connected directly to the unit but rather longer flue gas sections must be overcome ensure according to the total length and geometry of the flue gas ducting that the end and extension pieces as well as the elbows exhibit the correct diameter After fastening the flue...

Page 25: ... to In particular DVGW TRGI 2008 Sec 5 2 2 and TRF Sec 7 2 2 should also be observed The combustion air supply must be made from the outside as a basic rule With mechanical suction plants in the installation space If over or underpressure can occur in the installation space If the unit is installed in environments with large amounts of dust In operations working with motor vehicles Protection grid...

Page 26: ...ally through the roof L1 L2 Installation height 2 5 3 5 m Type C13 Room air independent combustion system Exhaust and combustion air are led through an LAS end piece through the outside wall Type B23 vertical L1 maximum duct length without end pieces ø 80 ø 100 Model Metres GPC 20 30 GPC 40 30 GPC 60 15 GPC 80 30 Type C13 horizontal coaxial L1 L2 maximum duct length without end pieces ø 80 ø 100 M...

Page 27: ... connections to the unit must be changed meaning they must be repositioned from behind to above This variant is executed at the factory and must be indicated when ordering NOTE Condensate drainage connection KO M 30 external thread NOTE The installation of the exhaust gas routeing through the outside wall must correspond to the regulations of DVGW TRGI and TRF as a basic rule and must be approved ...

Page 28: ...ign as part of the ongoing technical development process CAUTION A multi pole isolator with appropriate electrical protection must be connected upstream to the units This must placed in a highly visible and accessible location within 3 m of the control box The wire cross section must be at least 1 5 mm NOTE Phase and neutral lines must not be interchanged during connection because the flame monito...

Page 29: ...or activating only the fans ventilation in summer with the burner switched off Est mode with the contact ID3 IDC2 with ATR Smart Basic Web manually via the LCD switch on the unit NOTE Est mode can be accessed via the Fun menu of the LCD display See Programming via the LCD display and the navigation card for more information NOTE The hot air generator always conducts follow up ventilation before th...

Page 30: ...t GAS solenoid valve EV2 GAS main solenoid valve EVP GAS ignition valve IONO Flame detection electrode KOND Monitoring electrode NTC1 Temperature sensor P1 Connector plug socket TER Flame monitoring unit VAG Burner fan TS Safety thermostat CABLE COLOURS WT white OR orange RD red PK pink BL blue GR green YG yellow green BW brown GY grey BK black YL yellow ...

Page 31: ...ar rpm see table MINIMUM motor speed PWM1 90 999 1 10 rpm b2 2 Par rpm see table MAXIMUM motor speed PWM1 90 999 1 10 rpm b3 2 Par rpm see table IGNITION motor speed PWM1 90 999 1 10 rpm b4 2 Par 2 Divider HALL signal 2 3 b5 2 Par rpm 50 Fault F3x speed x10 50 500 rpm 0 300 b6 2 Par Sec 20 Fault F3x persistence of fault before fault F3x 0 255 b7 2 Par Sec 20 Pre breathing time at maximum output 0 ...

Page 32: ...for fault F51 10 95 Control 0 10 Vdc d0 5 H51 1 Set 1 Only on at D0 5 0 10 V 0 modulation only 1 modulation and ON OFF H52 1 Set V 0 5 OFF voltage burner shut down if H51 1 H53 1 Set V 0 5 Difference in voltage when burner start ON H54 3 Sec 10 Voltage maintained at lower input 0 255 H55 3 Sec 10 Voltage maintained at upper input 0 255 Parameters of GPC board Symbol Level Menu Unit Value Descripti...

Page 33: ...e TER unit but the unit has not switched to Operation status after 300 seconds and no lockout occurred Safety thermostat open on ignition Pressure of mains gas is insufficient Low CO2 value Check contact connection F16 General device lockout Defective TER unit Manual reset automatic reset after 5 minutes F17 Internal defect of the TER device that does not allow resetting by the GPC board Defective...

Page 34: ...t air generator module is too high in relation to the heat output required in space Check parameter TH1 supply air setpoint Fan does not function functions if NTC1 TH1 15 Automatic reset if NTC1 TH1 15 F60 Transmission error between GPC board and ModBus network The Modbus network is not connected The board address is incorrect or not configured in the ModBus network Automatic reset F75 Power failu...

Page 35: ...a suitable removable screw connection free of voltage and vibration The components described in the applicable gas guidelines as well as the locally required components in the gas supply such as gas pressure regulators isolation devices etc are not included in the scope of delivery and must be provided by the customer Installing a high output compatible gas filter without pressure regulator is als...

Page 36: ...ry to which the unit is adjusted For commissioning of the burner proceed as follows Commissioning 1 Loosen the lock screw in the pressure tap of the burner Do not unscrew completely 2 Connect a suitable pressure measurement device e g U pipe pressure gauge min resolution 0 1 mbar 3 Open the gas shut off devices 4 Switch on the main emergency switch 5 Check whether the display shows the statusrdy i...

Page 37: ...low the CO2 value of the high flow rate up to 0 3 With deviating values use the offset screw To change the values pull out the metal plug and use the regulating screw When loosening the CO2 value is reduced When tightening it increases After any changes to the offset regulation the CO2 value at the high output must be checked again through the steps indicated above After these steps set the temper...

Page 38: ... is not pressed within 10 minutes ofpassword input the program automatically returns to the operating state Setpoint menu The meaning and the standard values can be seen if relevant in the parameter table H51 controller 0 10 Vdc H52 controller 0 10 Vdc H53 controller 0 10 Vdc St1 modulation temperature St2 not used H43 not used H44 not used H45 not used ST5 not used ST6 not used Programming via LC...

Page 39: ...checks whether the flue gas temperature during flame modulation remains within a range of a characteristic curve corresponding to an assigned heat output To enable the control the parameter d5 1 must be set If the NTC3 probe is not present the fault F43 is displayed If the probe is present and the value d5 0 the fault F99 configuration error is displayed Flue chimney inspector The unit must be set...

Page 40: ...St summer Hi Lo Value Value Value Mod ESC ENTER ESC ENTER ESC ENTER ESC ENTER ESC ENTER ESC ENTER Below at 1st level Top at 1st level ESC ENTER ESC ENTER ESC ENTER ESC ENTER ENTER ENTER ENTER Confirm Confirm Confirm ENTER ENTER Confirm Confirm ENTER Confirm A B C D For the below diagrams see overleaf A Fault history B Sensor values C Setpoint D Board parameters Navigation map of LCD display ...

Page 41: ...H53 St1 St2 H43 H44 H45 St5 St6 Set ESC ENTER Value Mod Value Mod Value Mod Value Mod Value Mod Value Mod Value Mod Value Mod Value Mod Value Mod Confirm Confirm Confirm Confirm Confirm Confirm Confirm Confirm Confirm Confirm ENTER ESC ENTER D Board parameters Par ESC ENTER b1 b2 b3 b13 b14 b15 d0 d2 d8 d9 Value Mod Value Mod Value Mod Value Mod Value Mod Value Mod Value Mod Value Mod Value Mod Va...

Page 42: ...eason 1 Check condition of the ignition and monitoring electrodes as well as the ignition gas burner 2 Check condition of the supply and flue gas lines as well as the end pieces 3 Inspect Venturi tube for dirt 4 Inspect heat exchanger for dirt 5 Check the siphon of the condensate collecting container and clean it 6 Check gas pressure at the inlet to the gas valve 7 Check function of the flame moni...

Page 43: ...he value is displayed as a percentage Thus the value from 0 to 100 corresponds to the value of 0 to 2 microamps If a value of 100 is displayed the value is over 2 microamps and is thus sufficient for device operation A value of 35 corresponds to 0 7 microamps and also represents the lower value which can be detected by the flame monitoring device The value of the ionisation current must exceed 2 m...

Page 44: ...rameters Programming of parameters Following values must be programmed in each case d0 d1 and d5 to identify the unit b1 b2 b3 for speed control of the flue gas fan drive S1 for enabling NTC1 probe of warm air supply ST1 is the setpoint for NTC1 H51 H52 and H53 for control via 10 Vdc if present S2 ST2 and P2 for the heating of the switching cabinet if present Procedure for parameter setting The pa...

Page 45: ... low temperature Wait until the minimum output at the burner has stabilised and check that the CO2 value is the same or slightly below the CO2 value of the high flow rate up to 0 3 With deviating values use the offset screw To change the values pull out the metal plug and use the regulating screw When loosening the CO2 value is reduced When tightening it increases After any changes to the offset r...

Page 46: ...ay only be carried out by authorised and qualified technicians CAUTION The fan assisted heater supplied for operation with liquid gas is adjusted for the gas G31 When operating with G30 the CO2 must be checked and possibly adjusted Re connect the power supply of the unit and prepare the unit to start Make sure during the ignition process that no gas emerges at the copper pipe connection to the out...

Page 47: ...zontal discharge A F AV TV S GPC 20 80 80 430 120 155 GPC 40 80 80 430 120 155 GPC 60 80 80 505 120 155 GPC 80 100 100 560 140 185 Series Vertical discharge A F AO TO S GPC 20 80 80 145 120 155 GPC 40 80 80 145 120 155 GPC 60 80 80 145 120 155 GPC 80 100 100 145 140 185 A Supply line F Flue gas line We reserve the right to modify the dimensions and design as part of the ongoing technical developme...

Page 48: ...48 REMKO GPC When ordering spare parts please state the EDP no unit number and type see name plate Exploded view of the unit 6 27 35 33 30 32 31 34 28 29 29 ...

Page 49: ...49 10 17 16 21 25 26 23 15 10 13 22 19 11 Venturi burner We reserve the right to modify the dimensions and design as part of the ongoing technical development process 20 14 18 24 ...

Page 50: ...50 REMKO GPC 5 4 3 2 ...

Page 51: ...nozzle 20 Ignition cable 21 Ignition electrode 22 Ionisation electrode 23 Burner fan seal 24 Burner flange seal 25 Burner pipe seal 26 Gas lance 27 Air outlet fins 28 Electrical connection bush 29 Cable connections 30 Flue gas connection 31 Closure 32 Air supply connection 33 Door hinge 34 Temperature probe NTC1 35 Recirculating fan Not shown Safety temperature limiter Not shown Gas valve seal Not...

Page 52: ...0 20 mbar G30 G31 30 mbar Country table of gas types Gas type G20 G25 G30 G31 Category according to country of destination see table above Supply pressure mbar 20 min 15 max 25 25 min 18 max 30 30 50 min 25 max 57 5 30 50 min 25 max 57 5 Ignition gas nozzle Ø mm 0 70 0 70 0 51 0 51 Carbon dioxide CO2 8 7 0 1 cat H 8 7 0 1 cat E 8 8 0 2 9 9 0 4 9 7 0 2 Model Ø Gas diaphragm mm GPC 20 4 4 5 3 3 0 3 ...

Page 53: ...4 G 3 4 G 3 4 Gas flow rate natural gas H 5 m3 h 2 01 3 69 6 88 8 68 Gas flow rate natural gas L 5 m3 h 2 34 4 29 8 00 10 1 Gas flow rate liq gas G31 5 kg h 1 58 2 90 5 39 6 80 Condensate max l h 0 4 0 9 2 1 3 3 Flue gas flow 1 m Af kg h 31 57 107 135 Flue gas flow 3 m Af kg h 24 45 84 107 Available flue gas pressure Pa 80 90 120 120 Exhaust gas temperature approx tAf C 111 94 86 70 reqd draft int...

Page 54: ...y consumption elmax kW 0 045 0 074 0 097 0 123 Min auxiliary energy consumption elmin kW 0 011 0 011 0 015 0 040 Auxiliary energy consumption in sb elsb kW 0 005 0 005 0 005 0 005 Sound pressure level LpA 7 dB A 44 49 51 54 Combustion air connection Ø mm 80 80 80 100 8 Flue gas connection Ø mm 80 80 80 100 8 Installation variants Type B23 B23P C13 C33 C43 C53 C63 EC approval No 0476CQ0451 Weight k...

Page 55: ...55 ...

Page 56: ...y must be advisers to our customers in air conditioning and heating technology Customer service Our units operate precisely and reliably However in the event of a malfunction REMKO customer service is quickly on the scene Our extensive network of experienced dealers guarantees quick and reliable service REMKO INTERNATIONAL and also right in your neighbourhood Take advantage of our experience and a...

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