ROBUA G Series Installation, Use And Maintenance Manual Download Page 3

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Installation, use and maintenance manual – G gas unit heater

I Introduction

..........................................................................

p. 4

I.1 Recipients ................................................................

p. 4

I.2

Control device .......................................................

p. 4

II Symbols and definitions

.........................................

p. 4

II.1

Key to symbols ......................................................

p. 4

II.2

Terms and definitions .........................................

p. 4

III Warnings

...................................................................................

p. 4

III.1 General and safety warnings ............................

p. 4

III.2 Conformity ..............................................................

p. 6

III.3 Exclusions of liability and warranty ...............

p. 6

1 Features and technical data

................................

p. 7

1.1 Features ....................................................................

p. 7

1.2 Dimensions .............................................................

p. 8

1.3

Electrical wiring diagram .................................

p. 11

1.4 Controls ..................................................................

p. 12

1.5

Technical data ......................................................

p. 13

2 Transport and positioning

..................................

p. 14

2.1 Warnings ................................................................

p. 14

2.2 Handling ................................................................

p. 14

2.3

Appliance positioning ......................................

p. 14

2.4

Minimum clearance distances .......................

p. 15

2.5

Support bracket ..................................................

p. 15

3 Heating engineer

...........................................................

p. 17

3.1 Warnings ................................................................

p. 17

3.2

Fuel gas supply ....................................................

p. 17

3.3

Combustion products exhaust ......................

p. 18

3.4

Flue gas condensate discharge .....................

p. 22

4 Electrical installer

.........................................................

p. 23

4.1 Warnings ................................................................

p. 23

4.2

Electrical systems ...............................................

p. 23

4.3

Electrical power supply ....................................

p. 23

4.4

Control system.....................................................

p. 24

4.5

Remote the fault signals ..................................

p. 25

4.6

Remote the error reset .....................................

p. 26

5 First start-up

.......................................................................

p. 26

5.1

Preliminary checks .............................................

p. 26

5.2

Combustion parameters check .....................

p. 27

5.3

Gas changeover ..................................................

p. 28

6 Normal operation

.........................................................

p. 28

6.1 Warnings ................................................................

p. 28

6.2

Switch on and off ................................................

p. 28

6.3 Chronothermostat .............................................

p. 29

6.4

Gas unit heater operating modes.................

p. 36

6.5

Operating diagrams ..........................................

p. 39

6.6

Setting range .......................................................

p. 41

7 Maintenance

.......................................................................

p. 41

7.1 Warnings ................................................................

p. 41

7.2

Scheduled routine maintenance ..................

p. 42

7.3

Resetting the temperature limit

thermostat ............................................................

p. 42

7.4 Troubleshooting .................................................

p. 42

7.5

Periods of inactivity ...........................................

p. 42

8 Appendices

...........................................................................

p. 44

8.1

Product fiche ........................................................

p. 44

INDEX OF CONTENTS

Summary of Contents for G Series

Page 1: ...2021 ready ErP G Condensing gas unit heaters for use in industrial and commercial installations Installation use and maintenance manual Powered by natural gas LPG ...

Page 2: ...d within this publication are not affected With the aim of continuously improving the quality of its products Robur S p A reserves the right to modify the data and contents of this Installation use and maintenance manual without prior notice Revision N Code D LBR565 DISPOSAL The appliance and all its accessories must be disposed of separately in accordance with the regulations in force Use of theW...

Page 3: ...p 17 3 1 Warnings p 17 3 2 Fuel gas supply p 17 3 3 Combustion products exhaust p 18 3 4 Flue gas condensate discharge p 22 4 Electrical installer p 23 4 1 Warnings p 23 4 2 Electrical systems p 23 4 3 Electrical power supply p 23 4 4 Control system p 24 4 5 Remote the fault signals p 25 4 6 Remote the error reset p 26 5 First start up p 26 5 1 Preliminary checks p 26 5 2 Combustion parameters che...

Page 4: ... the Country of installation Declaration of conformity Upon completing installation the installing firm shall issue to the owner client the appliance s workmanlike conformity declaration according to national local regulations in force and the manu facturer s instructions provisions Misuse The appliance must only be used for the purpos es for which it has been designed Any other use is deemed haza...

Page 5: ...iance and in stalled according to the regulations in force Air flow Do not obstruct the fan intake or the warm air outlet Distance from combustible or flammable mate rials Do not deposit flammable materials paper dilu ents paints etc near the appliance Comply with current regulations Aggressive substances in the air The air of the installation site must be free from ag gressive substances Acid flu...

Page 6: ...try and location and in accordance with the manufacturer s instructions In particular regulations regarding the fol lowing shall be complied with Gas systems and equipment Electrical systems and equipment Heating systems Environmental protection and combustion products exhaust Fire safety and prevention Any other applicable law standard and regulation III 3 EXCLUSIONS OF LIABILITY AND WARRANTY Any...

Page 7: ...he power supply to the gas valve and drives the blower and the fan at maximum speed If the temperature should increase further the limit ther mostat trip causes the gas unit heater to switch off A blower upline of the burner mixes the air and gas and expels the combustion fumes In the event of obstructions in the intake or exhaust duct or in the event of malfunction of the blower the electron ic b...

Page 8: ...IONS Figure 1 1 G30 G45 G60 gas unit heater dimensions 1 Flue gas exhaust 2 Combustion air inlet 3 Power supply cables input 4 Gas connection 3 4 F 5 Condensate drain siphon supplied as standard C Q I F D B W 1 T R 2 3 X Y 4 5 Z H L N J E G A M ...

Page 9: ...anual G gas unit heater 9 1 Figure 1 2 G100 gas unit heater dimensions 1 Flue gas exhaust 2 Combustion air inlet 3 Power supply cables input 4 Gas connection 3 4 F 5 Condensate drain siphon supplied as standard H L N J E G A M C Q I F D B 1 2 3 4 5 T R W 540 X Y Z ...

Page 10: ...800 800 800 D 570 570 570 570 E 370 370 510 1010 F 405 405 405 405 G 440 490 580 1080 H 536 536 536 536 I 157 2 157 2 157 2 157 2 J 307 327 371 507 L 180 180 180 180 M 20 20 20 20 N 223 223 223 223 Q 360 360 360 360 R 340 340 340 340 T 720 720 720 720 W 380 480 500 520 X 80 80 80 80 Y 80 80 80 80 Z 120 120 120 120 ...

Page 11: ...F Flue gas temperature probe TL Limit thermostat AC Ignition electrodes TRF1 Fan autotransformer P1 Earthing CR Chronothermostat 1 Brown 2 Red 3 Blue 4 Pink 5 Grey 6 Yellow 7 Green 8 White 9 Black 10 Purple 1 2 3 4 5 6 N X12 CR N SF L 1 5 X15 X3 X17 X16 X22 X18 N TR P3 N X19 FUSE 2A T3 T3 T2 T1 L1 N1 X7 P1 T5 X7 EV RLZ AC FUSE 6 3A X13 L N GND X5 X6 X3 X1 K4 K3 K2 X7 X10 X9 X11 X8 C 1 2 3 4 F1 K1 ...

Page 12: ...thermostat 1 Brown 2 Red 3 Blue 4 Pink 5 Grey 6 Yellow 7 Green 8 White 9 Black 10 Purple 1 2 3 4 5 6 N X12 CR N SF L 1 5 X15 X3 X17 X16 X22 X18 N TR P3 N X19 FUSE 2A T3 T3 T2 T1 L1 N1 X7 P1 T5 X7 EV RLZ AC COM MIN MED MIN MED MAX MAX FUSE 6 3A X13 L N GND X5 X6 X3 X1 L N K4 K3 K2 X7 X10 X9 X11 X8 C 1 2 3 4 F1 K1 X9 SCH1 SCH2 IN 230V 50Hz GND V1 V2 TL S STF LD1 1 4 CONTROLS 1 4 1 Control device The...

Page 13: ... m h 3 69 5 54 7 14 11 45 G25 1 nominal m h 3 69 5 53 7 13 11 43 G25 3 nominal m h 3 16 5 42 6 98 11 19 G27 nominal m h 3 87 5 81 7 49 G2 350 nominal m h 4 41 6 62 8 53 G30 nominal kg h 2 37 3 55 4 57 7 33 G31 nominal kg h 2 33 3 55 4 51 7 22 Air flow nominal m h 2840 3850 5050 8250 minimum m h 2050 2900 4000 5200 Gas connection type F thread 3 4 Flue gas exhaust diameter Ø mm 80 residual head Pa ...

Page 14: ... the appliance The wall or structure on which the unit is to be in stalled must be load bearing or in any case suit able for supporting its weight Installation must not be made on walls with poor strength that do not guarantee adequate resist ance to the stresses produced by the unit The manufacturer does not assume any responsibility if the appliance is installed on surfaces or walls that are not...

Page 15: ...stalling the gas unit heaters at heights below 2 5 m from the floor 2 5 SUPPORT BRACKET Robur provides easy mounting support brackets as an optional suitably designed for G series gas unit heaters which allow simplifying the wall fixing The following support brackets are available O19800020 revolving wall support bracket G30 G45 models O19800024 revolving wall support bracket G60 mod el O19800028 ...

Page 16: ...Transport and positioning 16 2 Table 2 1 Support bracket dimensions G30 G45 G60 G100 A 370 370 510 1010 B 840 ...

Page 17: ...red Provide a three piece pipe union Perform connection in compliance with applicable regulations 3 2 3 Gas pipes sizing The gas pipes must not cause excessive pressure drops and consequently insufficient gas pressure for the appliance 3 2 4 Supply gas pressure This appliance is equipped for a maximum gas supply pressure of 50 mbar The appliance s gas supply pressure both static and dy namic must ...

Page 18: ...r installations where the air and or flue gas exhaust ducts follow linear paths as shown in the respec tive Figures Otherwise you must proceed with the calculation of the pressure drop Paragraph 3 3 4 p 20 If ducts other than those supplied by the manufac turer are used make sure that they are suitable for the unit on which they are installed In particular the temperature class of the duct must be...

Page 19: ...s Indicative maximum lengths m Air pipe Flue gas exhaust pipe Ø 80 Ø 100 Ø 110 Ø 80 Ø 100 Ø 110 G30 17 30 30 17 30 30 G45 12 30 30 12 30 30 G60 9 30 30 9 30 30 G100 6 21 20 6 21 20 3 3 3 4 C13 type installation with wall coaxial terminal Figure 3 4 C13 type installation with wall coaxial terminal A View from above A Table 3 5 C13 type maximum allowed length with 80 125 wall coaxial terminal and Ø ...

Page 20: ... Ø 100 flue and air pipes in aluminium available on the market The pressure drops of the coaxial pipes available as Robur optional are shown in Table 3 14 p 21 Resistance from the separate terminals are negligible since they are very low When designing it must be checked that the total pres sure drop of the piping system is lower than the maximum pressure drop allowed for the unit Table 3 11 p 20 ...

Page 21: ...100 mm Pipe 1 m Pa 0 3 0 7 1 0 2 4 Elbow 90 Pa 0 5 1 2 2 0 4 9 Tee Pa 1 0 2 0 3 1 7 3 Table 3 14 Data for the calculation of the air fumes system with coaxial pipes available as optional G30 G45 G60 G100 Coaxial exhaust pipe pressure drop Ø 80 125 mm wall Pa 21 2 40 3 60 8 132 4 roof Pa 23 8 50 5 Ø 130 180 mm wall 1 Pa 14 0 22 4 31 2 60 8 Ø 100 150 mm roof Pa 9 7 21 3 35 3 90 5 Ø 130 210 mm roof P...

Page 22: ...S CONDENSATE DISCHARGE The G unit is a condensing appliance and therefore pro duces condensation water from combustion flue gases Condensate acidity and exhaust regulations The flue gas condensate contains aggressive acid substances Refer to applicable regulations in force for condensate exhaust and disposal If required install an acidity neutraliser of ade quate capacity Do not use gutters to dis...

Page 23: ...lectrical connections ensure not to work on live components Earthing The appliance must be connected to an effective earthing system installed in compliance with reg ulations in force It is forbidden to use gas pipes as earthing Cable segregation Keep power cables physically separate from signal ones Do not use the power supply switch to turn the appliance on off Never use the power supply switch ...

Page 24: ...hermostat must be installed on the wall in a suitable position using expansion screws The chronothermostat is supplied already connect ed to the electronic board of the gas unit heater by means of a 5 metre long cable Figure 4 2 p 24 For lengths longer than 5 meters use an unshielded 2x0 75 mm2 cable with 5 Ω maximum resistance for each conductor use a shielded cable if the installa tion has stron...

Page 25: ...ration enable of the gas unit heaters S Summer winter selector switch SCH1 Control board SCH2 Motor board G1 3 Gas unit heater CR Chronothermostat WARNING Each gas unit heater must be connected to the respective chronothermostat SCH1 SCH2 G3 CR R3 R3 SCH1 SCH2 G2 SCH1 SCH2 R2 R2 R1 R1 S E 0 I E 0 I E I CR CR G1 L N 4 5 REMOTE THE FAULT SIGNALS Any faults that may occur during normal operation of t...

Page 26: ...y out preliminary checks described in Paragraph 5 1 p 26 5 1 PRELIMINARY CHECKS Paragraph dedicated to the installer 5 1 1 Preliminary checks for first start up Upon completing installation before contacting the TAC the installer must check Electrical and gas systems suitable for the required ca pacities and equipped with all safety and control de vices required by the regulations in force Absence...

Page 27: ...onothermostat to set the minimum capacity flow rate level 1 5 Using the IP key enter the INFO menu and with the OK key select the RPM string and check that the blower speed at level 1 minimum output corresponds to the value indicated in Table 5 1 p 27 6 Turn the offset adjustment screw until the nominal offset pressure value shown in the following Tables is obtained with a tolerance of 1 Pa 7 Ensu...

Page 28: ...pplied to all values of CO2 percentage in fumes Table 5 5 G100 gas valve setting table Gas Gas network pressure Offset pressure CO2 percentage in fumes nominal Minimal heat input Nominal heat input Type mbar Pa G20 See Table 3 1 p 17 5 8 6 9 5 G25 5 8 5 9 4 G25 1 5 9 8 10 6 G25 3 5 8 2 9 0 G27 G2 350 G30 5 10 6 10 9 G31 5 10 0 10 7 LPG 5 9 7 10 1 A tolerance of 0 3 is applied to all values of CO2 ...

Page 29: ...l show the RUN sliding text for a few seconds INFO menu press the key for at least 3 seconds the display will show the sliding INFO text for a few seconds to exit the INFO menu briefly press the key again the display will show the sliding RUN text for a few seconds TIME key allows you to set the timed operations for further information see Paragraph 6 3 7 p 32 TEMP key allows you to select the com...

Page 30: ...ress the or key and set the time and tempera ture level as previously done for each daily profile it is possible to set up to 8 setpoints 10 In the example of Figure 6 4 p 30 for Monday 7 set points have been set as specified below Setpoint 1 at 00 00 antifreeze temperature Setpoint 2 at 07 00 econm temperature Setpoint 3 at 08 00 comfr temperature Setpoint 4 at 11 00 econm temperature Setpoint 5 ...

Page 31: ...le see Table 6 1 p 32 7 To confirm press the key Confirming with the key causes the loss of the daily profile previously set for the same day 8 Press the key to exit the programming mode 6 3 6 Choice of a preset weekly profile on the chronothermostat 1 Enter programming mode by shortly pressing the key 2 Press the key repeatedly 3 WEEK will appear in the lower left corner of the display 4 On the t...

Page 32: ... 06 13 07 07 07 07 07 07 07 14 08 08 08 08 08 08 08 15 09 09 09 09 09 09 09 16 10 10 10 10 10 10 10 6 3 7 Timed functions of the chronothermostat There are 3 timed operating modes Forced automatic operation indicated by the pres ence of both automatic and manual icons Figure 6 7 p 33 Timed off holiday program operation indicated by the presence of both the hourglass and airplane icons Figure 6 8 p...

Page 33: ...itch to the au tomatic operating mode To activate timed manual operation proceed as follows 1 Select manual operation using the key 2 Use the and keys to set the desired temperature 3 Press the key the hourglass and hand icons will appear on the display 4 Use the and keys to set the duration of the manual function The time can be expressed in minutes from 10 to 90 reading MM nn can be in creased o...

Page 34: ...lation percentage refer to the specific clarification note below 2 The antifreeze function is the function that allows the gas unit heater to be activated if the temperature of the room in which it is installed drops below the set anti freeze temperature for further details see Paragraph 6 3 3 p 29 If the value set for the antifreeze temperature is higher than the setpoint value set it is this val...

Page 35: ...place electrodes The flame sensor is broken or incorrectly positioned or touches the appliance metal structure Check the position or replace the electrode Failure of the electronic board or its electri cal connections Check the electrical connection of the board and replace it if necessary Failure of the gas valve or its electrical connections Check the electrical connection of the gas valve and r...

Page 36: ...Failure of the Interface card with the chronothermostat Check the electrical connection of the board and replace it if necessary The electrical bridge on the electronic board is open Check that the electrical bridge is closed 6 3 12 Meaning chronothermostat display icons Table 6 7 Meaning chronothermostat display icons Icon Meaning Gas unit heater is in standby mode Winter operation enabled Fault ...

Page 37: ...t 1 2 or 3 and keys the gas unit heater will have fixed operation at the heat output flow rate level set 1 low 2 medi um 3 maximum The gas unit heater will operate until the required temperature is achieved without any modulation Fixed ventilation with constant ventilation at maximum speed 1 By selecting the flow rate level at 4 and keys the air flow rate remains constant at maximum speed and the ...

Page 38: ... 7 For operation during summer fan operation only close the contact X7 marked with the symbol placed on the SCH2 board This way the fan will run at maximum speed 8 To remote the fault signals refer to the Paragraph 4 5 p 25 6 4 2 2 Air renewal operation ventilation priority Air renewal operation is only possible without the chronothermostat This gas unit heater operating mode allows on off oper at...

Page 39: ... Operation WITH chronothermostat SUMMER operation VENTILATION only Operation WITHOUT chronothermostat SUMMER operation VENTILATION only Automatic scheduled Fixed ventilation programmable Fixed ventilation programmable Fixed ventilation MAX level unchangeable Manual Manual level 2 MED level 3 MAX level 1 MIN level 2 MED level 3 MAX level 1 MIN ...

Page 40: ...odulation level 0 Fixed heat output max ventilation max level WINTER operation HEATING WINTER operation HEATING AIR RENEWAL operation VENTILATION PRIORITY see specific diagram SUMMER operation VENTILATION only see specific diagram Manual ON OFF operation Modulating operation level 2 MED level 3 MAX level 1 MIN Fixed ventilation programmable Total modulation level 0 level 2 MED level 3 MAX level 1 ...

Page 41: ...Heat input kW Combustion blower speed rpm Heat input kW Combustion blower speed rpm Heat input kW 100 3500 30 0 4850 45 0 5650 58 0 6000 93 0 95 3420 29 3 4693 43 5 5468 56 1 5803 89 9 90 3340 28 6 4535 42 1 5285 54 3 5605 86 9 85 3260 27 9 4378 40 6 5103 52 4 5408 83 8 80 3180 27 3 4220 39 2 4920 50 5 5210 80 8 75 3100 26 6 4063 37 7 4738 48 6 5013 77 7 70 3020 25 9 3905 36 2 4555 46 8 4815 74 6 ...

Page 42: ...ostat has not been trig gered If this is the case check the overheating cause remove it and reset the limit thermostat procedure Paragraph 7 3 p 42 Check the presence of voltage at the blower If the voltage is present but the blower does not start disconnect blower control cable If it still does not start replace the blower condenser If this also does not solve the problem replace the blower itsel...

Page 43: ...oid this it is nec essary to leave the generator electrically powered even during prolonged periods of inactivity How to reactivate the appliance after long pe riods of inactivity Before reactivating the appliance the operator maintenance technician of the system must first of all Check whether any maintenance operations are re quired contact the TAC see Paragraph 7 2 p 42 Ensure that the flue gas...

Page 44: ...es no G30 no no no Not required for electric warm air heaters Capacity Useful eﬃciency Electric power consump on Other items Figure 8 2 Item Symbol Value Unit Item Symbol Value Unit Rated hea ng capacity Prated h 43 3 kW Useful eﬃciency at rated hea ng capacity ηnom 86 9 Minimum capacity Pmin 15 6 kW Useful eﬃciency at minimum capacity ηpl 94 0 At rated hea ng capacity elmax 0 330 kW Envelope loss...

Page 45: ... air heater yes no G60 no no no Not required for electric warm air heaters Capacity Useful eﬃciency Electric power consump on Other items Figure 8 4 Item Symbol Value Unit Item Symbol Value Unit Rated hea ng capacity Prated h 90 2 kW Useful eﬃciency at rated hea ng capacity ηnom 87 4 Minimum capacity Pmin 33 5 kW Useful eﬃciency at minimum capacity ηpl 95 2 At rated hea ng capacity elmax 1 000 kW ...

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Page 48: ...ingonia BG Italy 39 035 888111 F 39 035 884165 www robur it robur robur it Robur is dedicated to dynamic progression in research development and promotion of safe environmentally friendly energy efficiency products through the commitment and caring of its employees and partners Revision N 21MCLSDC021 Robur mission ...

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