Robur GA ACF60-00 Installation, Use And Maintenance Manual Download Page 3

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Foreward

Ed. 04/2012

FOREWARD

This manual is designed to be an installation and user’s guide for the Robur series
ACF60-00 absorption chiller.

This manual especially applies to the plumbing and electrical installers for the hook-up of
the ACF and the initial configuration, and also for the end user regarding its use.

This manual also has a section regarding the operations that must be done before the first
start-up and the primary maintenance operations.

References

If the appliance is to be connected to a Direct Digital Controller (DDC), refer to the
following documentation with which it is supplied:

Installation technician manual - book 1: for installation and service technicians.

Final user manual - book 2: for the user of the DDC.

Definitions, terms and icons

Appliance

: this term indicates the gas chiller with absorption cooling cycle and air

condenser/absorber - serie: ACF, line: GA.

DDC

: digital control panel (Direct Digital Controller).

CAT

(or

TAC

): Technical Assistance Centre (authorised by Robur S.p.A.).

Icon Definitions

The icons present in the margins of the manual have the following meanings.

Danger

Warning

Note

Begin operational procedure

Reference to another part of the manual or to a different
manual/booklet

Table 1 –

Descriptive Icons

Summary of Contents for GA ACF60-00

Page 1: ...GA Line ACF Series Gas fired absorption chiller for cooling medium large areas Natural gas LPG fired Installation use and maintenance manual ...

Page 2: ...Any use of this manual other than for personal consultation must be previously authorised by Robur S p A The rights of those who have legitimately filed the registered trademarks contained 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 manual without prior notice ...

Page 3: ...igital Controller DDC refer to the following documentation with which it is supplied Installation technician manual book 1 for installation and service technicians Final user manual book 2 for the user of the DDC Definitions terms and icons Appliance this term indicates the gas chiller with absorption cooling cycle and air condenser absorber serie ACF line GA DDC digital control panel Direct Digit...

Page 4: ......

Page 5: ...LER 39 3 1 GENERAL INSTALLATION PRINCIPLES 39 3 2 POSITIONING OF THE ACF60 00 40 3 3 WATER CONNECTIONS 42 3 4 GAS SUPPLY SYSTEM 47 3 5 FILLING OF THE WATER CIRCUIT 48 3 6 SETTING OF THE WATER PARAMETERS 50 SECTION 4 ELECTRICAL INSTALLER 53 4 1 OPERATION WITH CONTROL SWITCH 53 4 2 APPLIANCE PUMP CONTROL 55 4 3 PUMP AND ELECTRICAL WIRING DIAGRAMS 56 4 4 USE OF A DIRECT DIGITAL CONTROLLER DDC 60 4 5 ...

Page 6: ...ACF60 00 Installation User s and Maintenance Manual 2 Ed 04 2012 ...

Page 7: ...ted for tightness by the manufacturer In case of coolant leaks switch off the electrical power and gas supplies only if this can be done in total safety Contact your Authorised Service Centre Frequent topping up of the plumbing circuit with water can result in damage due to scale and corrosion depending on the quality of the water being used Make sure the system is hermetically sealed and that the...

Page 8: ...necessary contact your Authorised Service Centre The appliance has a sealed circuit classified as pressure equipment i e with internal pressure higher than atmospheric pressure The fluids contained in the sealed circuits are harmful if swallowed or inhaled or if they come into contact with the skin Do not carry out any operation on the sealed circuit or on its valves ELECTROCUTION HAZARD Use only ...

Page 9: ...agraph 1 4 TECHNICAL SPECIFICATIONS on page 11 Installation and regulatory references When the appliance arrives at the installation site before beginning the stages requi red to move it in order to position it on the site perform a visual check to ascertain that there are no evident signs of breakage or damage to the packaging or to the external panels which would be signs that damage occurred du...

Page 10: ... on the data plate the gas supply system and the water distribution system are sealed the gas supplied to the appliance is of the type for which it is designed the pressure of the gas supplied falls within the range of values specified by the manufacturer the gas and electricity supply systems are correctly rated for the capacity required by the appliance and that they are equipped with all safety...

Page 11: ...if possible and if no dangerous condition exists through the controls DDC or permissive switch and wait for the end of the cooling down cycle around 7 minutes remove electrical power by shutting off the main power switch and close the gas valve If it is decided not to use the appliance for a prolonged period disconnect the appliance following the instructions provided in Paragraph PROLONGED INACTI...

Page 12: ...atures It has a nominal cooling capacity of 17 12 kW Data Table Table 6 page 15 ACF60 00 LB Low temperature Designed to provide refrigerated water down to 10 C It has a nominal cooling capacity of 13 30 kW Data Table Table 8 page 17 ACF60 00 HR Heat Recovery This is an ACF60 00 with a heat recovery system able to provide 17 72 kW of nominal cooling capacity when operating without the heat recovery...

Page 13: ...Digital Controller DDC The DDC available as an option monitors and controls each ACF in a more precise manner and can support and manage up to 16 chillers on a water circuit regulating start up in relation to the requested need Figure 2 Direct Digital Controller DDC For the connection of a DDC to the ACF go to the APPLIANCE PUMP CONTROL paragraph on page 55 The ACF s include the following cooling ...

Page 14: ...ety devices S61 electronic board with integrated microprocessor LCD display and encoder in Figure 1 plant water flow switch manually resettable generator limit thermostat differential exhaust gas pressure switch on the combustion circuit automatically resettable exhaust gas thermostat pressure safety valve on the sealed circuit by pass valve between the high and low pressure circuits plant water a...

Page 15: ... SPECIFICATIONS OPERATIONAL WEIGHT kg 340 360 INTERNAL WATER CAPACITY OF ACF L 3 WIDTH 850 DEPTH 1230 DIMENSIONS 10 HEIGHT mm 1290 1540 9 Table 2 ACF60 00 and ACF60 00 S Technical Specifications Remarks 1 Nominal conditions 1013 mbar 15 C Effective conditions 1000 mbar 20 C 2 Nominal running conditions external air temperature 35 C chilled water temperature delivery 7 2 C return 12 7 C For conditi...

Page 16: ... factors for external air temperatures and water flow rates different from the nominal values reported in the table WATER DELIVERY TEMPERATURE C EXTERNAL AIR TEMPERATURE C 3 0 5 0 7 0 9 0 0 0 98 0 99 1 01 1 03 5 0 98 0 99 1 01 1 03 10 0 98 0 99 1 01 1 03 15 0 98 0 99 1 01 1 03 20 0 98 0 99 1 01 1 03 25 0 97 0 99 1 01 1 03 30 0 90 0 98 1 01 1 03 35 0 67 0 87 1 00 1 02 40 0 88 0 93 45 0 67 0 78 ...

Page 17: ...CATIONS OPERATIONAL WEIGHT kg 350 380 INTERNAL WATER CAPACITY OF ACF L 3 WIDTH 850 DEPTH 1230 DIMENSIONS 10 HEIGHT mm 1290 1540 9 Table 4 ACF60 00 TK and ACF60 00 TK S Technical Specifications Remarks 1 Nominal conditions 1013 mbar 15 C Effective conditions 1000 mbar 20 C 2 Nominal running conditions external air temperature 35 C chilled water temperature delivery 7 2 C return 12 7 C For condition...

Page 18: ...0 10 1 18 1 18 1 18 1 19 8 1 17 1 17 1 18 1 19 6 1 16 1 16 1 17 1 18 4 1 16 1 16 1 16 1 18 2 1 15 1 15 1 16 1 17 0 1 15 1 15 1 15 1 16 2 1 14 1 14 1 15 1 16 4 1 14 1 14 1 14 1 15 6 1 13 1 13 1 14 1 15 8 1 12 1 13 1 13 1 14 10 1 12 1 12 1 12 1 13 12 1 12 1 12 1 12 1 13 14 1 11 1 11 1 11 1 12 16 1 11 1 11 1 12 1 12 18 1 10 1 10 1 11 1 11 20 1 09 1 09 1 11 1 11 22 1 08 1 08 1 10 1 10 24 1 06 1 06 1 1...

Page 19: ...UM FILLING PRESSURE bar 3 PHYSICAL SPECIFICATIONS OPERATIONAL WEIGHT kg 350 380 INTERNAL WATER CAPACITY OF ACF L 3 WIDTH 850 DEPTH 1230 DIMENSIONS 9 HEIGHT mm 1290 1540 9 Table 6 ACF60 00 HT and ACF60 00 HT S Technical Specifications Remarks 1 Nominal conditions 1013 mbar 15 C Effective conditions 1000 mbar 20 C 2 Nominal running conditions external air temperature 35 C chilled water temperature d...

Page 20: ...03 4 1 02 1 02 1 02 1 02 1 03 6 1 02 1 02 1 02 1 02 1 03 8 1 02 1 02 1 02 1 02 1 03 10 1 02 1 02 1 02 1 02 1 03 12 1 02 1 02 1 02 1 02 1 03 14 1 02 1 02 1 02 1 02 1 03 16 1 02 1 02 1 02 1 02 1 03 18 1 02 1 02 1 02 1 02 1 03 20 1 02 1 02 1 02 1 02 1 03 22 1 02 1 02 1 02 1 02 1 03 24 1 02 1 02 1 02 1 02 1 03 26 1 01 1 02 1 02 1 02 1 03 28 1 01 1 02 1 02 1 02 1 03 30 1 01 1 02 1 02 1 02 1 03 32 0 99 ...

Page 21: ...bar 3 PHYSICAL SPECIFICATIONS OPERATIONAL WEIGHT kg 350 380 INTERNAL WATER CAPACITY OF ACF L 3 WIDTH 850 DEPTH 1230 DIMENSIONS 9 HEIGHT mm 1290 1540 9 Table 8 ACF60 00 LB and ACF60 00LB S Technical Specifications Remarks 1 Nominal conditions 1013 mbar 15 C Actual conditions 1000 mbar 20 C 2 Nominal running conditions external air temperature 35 C chilled water temperature with addition of glycol a...

Page 22: ...1 15 1 15 1 16 1 17 1 1 14 1 15 1 15 1 16 1 17 2 1 14 1 15 1 15 1 16 1 17 3 1 14 1 15 1 15 1 16 1 17 4 1 14 1 15 1 15 1 16 1 17 5 1 14 1 15 1 15 1 16 1 17 6 1 14 1 15 1 15 1 16 1 17 7 1 14 1 15 1 15 1 16 1 17 8 1 14 1 15 1 15 1 16 1 17 9 1 14 1 15 1 15 1 16 1 17 10 1 14 1 15 1 15 1 16 1 17 11 1 14 1 15 1 15 1 16 1 17 12 1 14 1 15 1 15 1 16 1 17 13 1 14 1 15 1 15 1 16 1 17 14 1 14 1 14 1 15 1 16 1 ...

Page 23: ...NAL AIR TEMPERATURE C 10 0 7 0 5 0 2 0 0 27 1 04 1 07 1 10 1 13 1 15 28 1 02 1 06 1 09 1 12 1 15 29 1 01 1 05 1 08 1 11 1 14 30 0 99 1 03 1 07 1 10 1 14 31 0 97 1 02 1 06 1 09 1 13 32 0 95 1 00 1 05 1 08 1 12 33 0 93 0 98 1 03 1 07 1 11 34 0 90 0 96 1 02 1 06 1 10 35 0 88 0 94 1 00 1 04 1 08 36 0 85 0 92 0 98 1 02 1 07 37 0 82 0 89 0 96 1 01 1 05 38 0 79 0 87 0 94 0 99 1 04 39 0 76 0 84 0 92 0 97 ...

Page 24: ...URE MAXIMUM C 45 OUTLET WATER TEMPERATURE MINIMUM C 3 HEAT RECOVERY SYSTEM SPECIFICATIONS HEAT CAPACITY 8 kW 21 RECOVERY SYSTEM HOT WATER FLOW RATE T 18 C 8 L hr 1000 PRESSURE DROP INSIDE RECOVERY SYSTEM NOMINAL mCA bar 1 3 0 12 ELECTRICAL CHARACTERISTICS VOLTAGE V phases Neutral Hz 230 1N 50 TOTAL ELECTRICAL LOAD 9 W 820 870 WATER CONNECTIONS CHILLED WATER DELIVERY AND RETURN 1 F RECOVERY WATER D...

Page 25: ...system water temperature delivery 58 0 C return 40 0 C For conditions other than the nominal conditions apply the cooling capacity correction factors seen in Table 14 Table 15 page 22 and page 23 9 10 in relation to the power supply and tolerance on the power draw of the electrical motors 10 Nominal running conditions return water temperature 12 7 C chilled water flow rate 2700 L hr For deliveries...

Page 26: ...for chilled water delivery 7 2 C output 500 L hr Empty grey boxes outside operational range OPERATIONAL MODE AIR CONDITIONING HEAT RECOVERY WATER DELIVERY TEMPERATURE C EXTERNAL AIR TEMPERATURE C 3 0 5 0 7 0 9 0 0 0 97 0 98 1 00 1 02 5 0 97 0 98 1 00 1 02 10 0 97 0 98 1 00 1 02 15 0 97 0 98 1 00 1 02 20 0 97 0 98 1 00 1 02 25 0 96 0 98 1 00 1 02 30 0 89 0 97 1 00 1 02 35 0 73 0 91 1 00 1 02 40 0 8...

Page 27: ...r at 40 nominal conditions Figure 3 Pressure drop ACF60 00 LB also silenced version In case of glicole use see also Table 22 at pag 49 HEAT CAPACITY kW Output 1000 L hr EXTERNAL AIR TEMPERATURE C RECOVERY SYSTEM HOT WATER RETURN TEMPERATURE C 15 20 25 30 35 40 45 20 27 00 29 00 30 10 31 30 32 00 30 21 00 22 90 24 48 25 11 26 22 28 00 30 00 40 14 05 16 00 18 00 19 08 21 00 23 00 25 06 50 8 13 9 98 ...

Page 28: ...lso silenced version ACF operation with heat recovery unit hot water return 20 C Figure 5 Heat recovery unit pressure drop ACF60 00 HR also silenced version In case of glicole use see also Table 22 at pag 49 0 000 0 020 0 040 0 060 0 080 0 100 0 120 0 140 0 160 0 250 500 750 1000 1250 1500 1750 2000 2250 2500 PRESSURE DROP bar RECOVERY UNIT WATER FLOW L hr 0 22 0 24 0 26 0 28 0 30 0 32 0 34 0 36 0...

Page 29: ...ERISTICS FLUID CONTENT H2O NH3 CHARGE kgH2O kgNH3 10 7 5 10 7 5 10 8 5 10 5 7 5 10 5 7 2 FLUID GROUP 1 PRESSURE MAXIMUM ALLOWABLE PRESSURE bar 35 SAFETY VALVE CALIBRATION PRESSURE bar 35 TEST PRESSURE in air bar 55 VOLUME GENERATOR litres 18 6 LEVELING CHAMBER litres 11 5 SOLUTION PUMP litres 3 3 SCA litres 6 3 EVAPORATOR litres 3 7 RECOVERY UNIT litres 3 7 COOLANT VOLUME VARIATOR litres 4 5 TARE ...

Page 30: ... dimensions in mm 1230 850 700 100 975 1290 Figure 6 Dimensions of the ACF Standard TK HT and LB versions See Figure 9 on page 28 for the measurements of the service panels ACF HR version with standard ventilation dimensions in mm 1230 850 700 100 975 1290 Figure 7 Dimensions of the ACF60 00 HR For the measurements of the HR service panels see Figure 10 on page 28 ...

Page 31: ... in mm 975 1230 1540 1280 700 850 100 260 Figure 8 Dimensions of the ACF60 00 TK HT LB HR silenced ventilation The measurements of the service panels do not vary According to the ACF type see Figure 9 or Figure 10 page 28 NOTE the service panel represented does not pertain to the ACF HR For this chiller see Figure 10 page 28 ...

Page 32: ...CF60 00 HR Service panel The indicated measurements are expressed in mm and are also valid for the corresponding silenced version 79 200 150 250 108 181 170 303 59 Figure 10 Dimensions of the service panel for the ACF60 00 HR and ACF60 00 HR S Some details have been removed for clarification purposes KEY A WATER DELIVERY TO APPLIANCE Ø 1 F B WATER RETURN TO UNIT Ø 1 F G GAS SUPPLY Ø F A B G KEY Ch...

Page 33: ... supplying or removing electrical power directly from the main power switch in that this could be dangerous and also damage the ACF and the systems connected to it Before turning on the ACF check that The gas valve is open The ACF has electrical power the main power switch must in the ON position The installer has ensured electrical power to the hydraulic system under the correct conditions If the...

Page 34: ... ACF has been started it is controlled by the electronic circuit board inside the electrical panel as explained in the next paragraph 2 2 ON BOARD ELECTRONICS The descriptions reported below make reference to the electrical circuit board with version 3 021 firmware If the ACF60 00 is connected to a Direct Digital Controller DDC its ignition and control are done exclusively through the DDC In this ...

Page 35: ...ted into menus on the electrical circuit board MENU MENU DESCRIPTION ON THE DISPLAY Menu 0 DISPLAY OF DATA TEMPERATURE VOLTAGE PUMP SPEED Menu 1 DISPLAY OF ALL THE ACF PARAMETERS Menu 2 FLAME CONTROL UNIT RESET AND ERROR RESET Menu 3 END USER SETTINGS THERMOSTAT SETTING SET POINT T DIFFERENTIAL Menu 4 INSTALLER SETTINGS Menu 5 SERVICE CENTER SETTINGS Menu 6 SERVICE CENTER SETTINGS MACHINE TYPE Men...

Page 36: ... 5 6 and 7 only pertain to the installer and to Robur Authorized Technical Service Centres Menu 8 can be selected but is not used Display and Knob encoder The display of the S61 circuit board can be seen from the opening in the front panel of the ACF At start up all the LED s on the display light up for approximately 3 seconds then the circuit board name will appear S61 If the control switch is in...

Page 37: ...o access the knob 4 Through the hole turn the knob using the special wrench The knob on the electrical circuit board can be turned using the special wrench without opening the cover of the electrical panel so that one can work safely without being exposed to the electrical components When the necessary settings have been made put the special wrench back where it came from replace the plug in the e...

Page 38: ...tes how to access the circuit board menu s The information given is used to access display only menu s 0 1 and 7 to access the other menu s if authorized additional information is needed which can be found in the dedicated paragraphs see paragraph S61 menu description on page 31 To access the menu s and see the current parameter values 1 Push the knob the first menu can be seen on the display menu...

Page 39: ...he unit for different reasons the error does not necessarily mean that there is a breakdown or that the ACF has malfunctioned The cause of the error could be temporary air in the gas line or temporary electrical blackout are some examples in these situations go to menu 2 of the electronic circuit board to reset the ACF returning it to normal operation The two reset options available in menu 2 are ...

Page 40: ...et any warnings or errors that may arise during ACF operation Requirements Accessibility to the electrical panel see Display and Knob encoder page 32 To reset circuit board errors go to menu 2 as described in Access to the circuit board menu s on page 34 then 1 appears on the display press the knob to access the menu The display shows option 0 first 2 Turn the knob in a clockwise direction until o...

Page 41: ... running of the ACF through probes and sensors The electronic circuit board display shows the operational machine codes which can be of two types a WARNING event identified by the green flashing letter U b ERROR event identified by the green flashing letter E c In the case of a WARNING event U the flashing letter U will appear on the display followed by a number which corresponds to the nature of ...

Page 42: ...ter that may imply the additional introduction of oxygen and the consequent dilution of the used inhibitor for ex glycol In case of precence of glycol Robur advices to use inhibited glycol Galvanized pipes are not recommended as they are not compatible with glycol ACF start up after an extended period of inactivity Requirements The ACF must be off with no supply of gas or electricity To start up t...

Page 43: ... of air and does not require any special protection from the elements In no case should the ACF60 00 be installed indoors The flow of air exiting the upper portion of the ACF must not be obstructed in any way Do not install the ACF near the exhaust flue chimneys of other similar elements in order to avoid the intake of hot or polluted air by the fan to the condenser Clean air must be used for the ...

Page 44: ...ible for any damage that may occur during the commissioning of the ACF Figure 12 Example of bar and cables in the correct position for the lifting of the ACF60 00 ACF positioning and required clearances The ACF must be installed outside the buildings and in an area with a good circulation of air Installation inside a room of any type is not allowed The ACF can be installed at ground level on a pla...

Page 45: ... 000 m3 h of air for heat exchange with the finned battery Make sure that the installation and position allow for sufficient flow of air to the batteries and prevent the air issuing from the fans recirculating which would reduce the efficiency of the units and force them to switch off Install the ACF away from water falling from rain gutters or similar If the ACF is installed on a terrace or on a ...

Page 46: ...ses where reverberations are confirmed such as on rooftops or on a terrace use flexible connections anti vibrational connectors between the machine and the water and gas piping Supports and levelling The ACF must be correctly levelled This is checked by placing a level on the upper part of the machine If necessary metal shims can be placed in the appropriate positions below the ACF until it is lev...

Page 47: ...l or physical above mentioned parameters Reintegration should not exceed 5 per year of the total amount of water It is advised to check regularly the water quality especially in case of automatic or periodic top up In case water treatment is needed this operation should be carried out by a professional or competent person following strictly the instructions by the manufacturer or supplier of the c...

Page 48: ...agram chosen for the characteristics of the plant SAFETY VALVE 3 bar eventual PLANT FILLING system If an automatic filling system is used the percentage of monoethylene glycol in the plant should be checked every season DRAIN VALVE approximately Ø to be installed on the piping to facilitate emptying when necessary Devices for the RELEASE OF AIR in the tubes EXPANSION VESSEL of appropriate volume f...

Page 49: ...tion tank must be used as shown in Figure 15 on page 46 This tank must have the capacity to hold the minimum amount of water required as mentioned in the note below If more than one ACF is used add the minimum contents required for each ACF The size of the pump and the tubing must be sufficient to supply the nominal water flow needed for the correct functioning of the ACF To calculate the internal...

Page 50: ... secondary division of the circuit Figure 15 Example of accumulation tank uses as in line accumulation above and division of the system into primary and secondary circuits below Connection of more than one ACF60 00 ACF60 00 chillers are designed both for individual operation and for use in a many unit system when a higher heat capacity is required than the output of just one ACF The figure below i...

Page 51: ...pply tubes must be done in conformance with the UNI CIG regulations as well as any other regulations in force For the ACF to run on L P G a primary pressure reducer must be installed near the LP tank to reduce the pressure to 1 5 bar A secondary pressure reducer must be installed near the ACF to lower the pressure from 1 5 bar to 0 03 bar before intake into the valve 1 3 4 5 7 8 P P 2 P P 9 DDC KE...

Page 52: ... remove any residue which could effect the functioning of the chillers After all the water gas and electrical supply connections have been made contact an electrician for the electrical connections with water circuit can then be filled Requirements All the electrical and water connections on the ACF must already be connected The filling of the water circuit must be done respecting the following st...

Page 53: ...istics of the water in the appliance and in particular the density viscosity and the average specific heat Always check the technical specifications of the antifreeze used as well as the degradation data of the product which can be obtained from the supplier Table 22 on page 49 reports the freezing temperatures of water and the resulting pressure drop incrementation of the ACF60 00 and the circuit...

Page 54: ...ER TEMPERATURE DIFFERENTIAL RETURN TO PREVIOUS MENU Table 23 ACF hydraulic configuration parameters set from menu 3 Parameter descriptions Selection of water delivery return thermostat parameter 73 this parameter can be either 0 or 1 0 the temperature that controls ignition shutdown of the ACF is detected by the ACF s RETURN water sensor 1 the temperature that controls ignition shutdown of the ACF...

Page 55: ...rn the knob clockwise to scroll through the parameters the last parameter seen is the letter E 2 Press the knob when the desired parameter appears or select E to exit the menu 3 For example to modify parameter 75 water Set Point proceed as follows Select the parameter turn the knob until appears on the display Press the knob to access the parameter value the previously set value will be flashing o...

Page 56: ...ACF60 00 Installation User s and Maintenance Manual 52 Ed 04 2012 ...

Page 57: ...essory see ACCESSORIES on page 81 The wiring diagrams for ACF60 00 connection can be found in paragraph 4 3 PUMP AND ELECTRICAL WIRING DIAGRAMS on page 56 The wiring diagrams for HR circulator pump connection can be found Heat recovery circulator pump control only for HR model on page 55 If you would like to hook up a DDC to the ACF60 00 see also the wiring diagrams in paragraph USE OF A DIRECT DI...

Page 58: ...c switch near the cable see detail GS on Figure 17 3 Connect the control switch to the R and Y connection terminals of the ACF control circuit see detail IC of Figure 18 on page 54 For the ACF to function properly a control switch must ALWAYS be installed The ACF must not be turned on and shut off using the main power switch of the electrical power line 4 Finish the installation by connecting the ...

Page 59: ...19 on page 56 and make sure the Jumper J10 located at the lower left of the electronic circuit board above the NO CONTACT contacts is CLOSED as seen in the Jumper Closed detail Direct control of the electronic circuit board with a pump that draws more than 700W In the case in which the power draw of the pump is equal to or higher than 700W perform the connection as shown in Figure 20 on page 56 us...

Page 60: ...ontrolled by the ACF with control relay power draw 700W Figure 20 Pump wiring with draw 700W controlled by circuit board through a relay For the pump connections see Figure 14 on page 45 KEY SCH1 CIRCUIT BOARD J10 CLOSED JUMPER NO CONCTAT N O VOLTAGE FREE CONTACTS MA UNIT TERMINAL BLOCK L PHASE N NEUTRAL Components NOT SUPPLIED PM WATER PUMP 700W KEY SCH1 CIRCUIT BOARD J10 OPEN JUMPER NO CONCTAT N...

Page 61: ... KP UNIT RELAY FOR HEAT RECOVERY CIRCULATOR PUMP PERMISSIVE KPt DHW TANK THERMOSTAT not supplied KPS DHW TANK THERMOSTAT SET AT 35 C WITH CAPILLARY PUT ON THE LOWER TANK REGION not supplied to be install in case the heating recovery water flow is higher than the nominal of 1000 l h IP BIPOLAR DISCONNECTING DEVICE FOR HEAT RECOVERY POWER SUPPLY PUMP not supplyed KPc BIPOLAR RELAY HEAT RECOVERY CIRC...

Page 62: ...ANK THERMOSTAT not supplied KPs DHW TANK THERMOSTAT SET AT 35 C WITH CAPILLARY PUT ON THE LOWER TANK REGION not supplied to be install in case the heating recovery water flow is higher than the nominal of 1000 l h IP BIPOLAR DISCONNECTING DEVICE FOR HEAT RECOVERY POWER COMMON PUMP SUPPLY not supplyed KPc BIPOLAR RELAY HEAT RECOVERY COMMOMN CIRCULATOR PUMP not supplied PMR1 HEAT RECOVERY COMMOMN CI...

Page 63: ...TANK THERMOSTAT not supplied KPs DHW TANK THERMOSTAT SET AT 35 C WITH CAPILLARY PUT ON THE LOWER TANK REGION not supplied to be install in case the heating recovery water flow is higher than the nominal of 1000 l h IP BIPOLAR DISCONNECTING DEVICE FOR HEAT RECOVERY POWER COMMON PUMP SUPPLY not supplyed KPc 1 2 BIPOLAR RELAYS HEAT RECOVERY COMMOMN CIRCULATOR PUMP not supplied PMR1 HEAT RECOVERY COMM...

Page 64: ...minal nodes are ACF or DDC that are connected to only one other element KEY SCH1 CIRCUIT BOARD CNT BOX FLAME CONTROL UNIT GV GAS SOLENOID VALVE BLW ASPIRATOR MOTOR C CONDENSER IGN IGNITION ELECTRODES FLS DETECTION ELECTRODES FAN FAN MOTOR LS GAS VALVE OPEN TL MANUALLY RESETTING TEMP LIMIT SWITCH TFA EXHAUST TEMP THERMOSTAT PSW AIR PRESSURE GAUGE FL WATER FLOW GAUGE TA AMBIENT AIR TEMPERATURE PROBE...

Page 65: ...l and intermediate nodes One DDC can control and monitor up to 16 ACF s If there are more than 16 ACF s in the network additional DDC s must be connected up to a maximum of 3 CAN BUS cable The CAN BUS cable must correspond to the Honeywell SDS standard The table below mentions a few types of CAN BUS cable combined together based on the maximum distance covered for each individual type TYPE and MOD...

Page 66: ...e ROBUR NETBUS cable is available as an accessory see ACCESSORIES on page 81 Connection of the CAN BUS cable to the ACF Requirements The ACF or ACF s must be positioned in its final location To connect a CAN BUS cable to an ACF The CAN BUS cable is connected to the appropriate connector on the S61 electronic circuit board on the ACF see Figure 11 page 31 as well as the figure below Proceed as indi...

Page 67: ...range connector as shown in detail A of Figure 27 on page 64 Respect the correct indications L H GND provided in Table 24 on page 61 on the figure and on the diagram at the base of the connector 7 If the appliance is an intermediate node repeat the operations from step 3 to step 6 for the other length of cable required so to will have two cable lengths everyone without the sheath To interlace betw...

Page 68: ...rations have been performed close the electrical panel and remount the front cover of the ACF KEY SCH Elettronic circuit board GND Common data L LOW signal data H HIGHT signal data J1 Board CAN BUS Jumper A Detail for terminal node 3 wires J1 jumpers closed B Detail for intermediate node 6 wires J1 jumpers opened P8 CAN PORT connector ...

Page 69: ...The DDC just as the electronic circuit board of the ACF has jumpers that need to be positioned for either an intermediate or a terminal node The configuration of the jumpers on a new DDC is CLOSED as seen in Figure 29 Figure 29 Direct Digital Controller DDC wiring diagram and partial rear view KEY GND common data A Electrical tape to protect CAN BUS cable shielding L LOW signal data B CAN BUS cabl...

Page 70: ... BUS cables to the DDC THE DDC IS AN INTERMEDIATE NODE Note the position of the wires of the CAN BUS cable and the jumpers OPEN If the DDC is a terminal node on the network there are 3 wires attached to the orange connector position the jumpers on the DDC as shown in Figure 31 CLOSED Figure 31 Connection of 1 CAN BUS cable to the DDC THE DDC IS A TERMINAL NODE Note the position of the wires of the...

Page 71: ...work skip point 6 and go directly to point 8 7 Only for intermediate nodes Repeat the operations from point 1 to point 4 for the remaining section of CAN BUS cable Also perform point 5 but refer to Figure 30 on page 66 for connecting the cable to the connector 8 Pass the wires attached to the appropriate connection terminals on the orange connector through the cover of the DDC then insert it into ...

Page 72: ...ION TERMINAL 4 Not used The DDC has a backup battery used to keep the data in memory even when there is the lack of electrical power The backup battery has a life of approximately 7 years contact a Robur S p A Authorized Technical Service Centre for a replacement Close the rear cover of the DDC after all of the operations have been performed Tighten the 4 screws being careful when tightening the l...

Page 73: ...2 69 Figure 33 Diagram of one ACF connected to a Direct Digital Controller DDC KEY DDC DIRECT DIGITAL CONTROLLER accessory L LOW DATA SIGNAL SCH1 ELECTRONIC CIRCUIT BOARD H HIGH DATA SIGNAL GND COMMON DATA SIGNAL JUMPER CLOSED JUMPER CLOSED ...

Page 74: ...ACF60 00 Installation User s and Maintenance Manual 70 Ed 04 2012 Figure 34 Diagram of two ACF60 s connected to a Direct Digital Controller DDC JUMPER CLOSED JUMPER CLOSED JUMPER OPEN ...

Page 75: ...Vac pump controlled directly by the appliance through a relay and a SELV safety transformer KEY SCH1 CIRCUIT BOARD J10 OPEN JUMPER NO CONTACT N O VOLTAGE FREE CONTACTS MA UNIT TERMINAL BLOCK L PHASE N NEUTRAL Components NOT SUPPLIED PM WATER PUMP KP PUMP RELAY PTR SELV SAFETY TRANSFORMER IP BIPOLAR PUMP SWITCH ...

Page 76: ...e cable to the blind terminals A see Figure 36 The blind terminals are hidden on the rightinside the cable tray To extract them remove the cover of the tray slide the cables out of the provided slots and carefully close the tray again The cable may not be longer than 20 metres Incorrect wiring of the reset button may damage the component irreparably Check the cabling carefully before powering the ...

Page 77: ...installer If these conditions have been satisfied the initial start up of the ACF may begin If there is an error in the start up of the ACF a corresponding code will appear on the circuit board display which can be seen through the window in the front panel See the TABLE OF OPERATING CODES on page 83 for a list of these codes If an IRREGULAR or DANGEROUS situation occurs during the initial start u...

Page 78: ...e by a Robur S p A Authorized Technical Service Centre The end users and installers are NOT authorized to regulate the gas flow on the ACF The ACF60 00 s are pre adjusted by the manufacturer for the requested gas type The gas type for which the ACF is setup is noted on the adhesive label located on the electrical panel The front panel of the ACF must be removed to access the gas valve At the initi...

Page 79: ... Digital Controllerif present until the burner ignites 6 After the burner is lit check that the pressure shown on the pressure gauge is in conformance with that reported in Table 25 on page 75 7 If the gas pressure need to be adjusted keep the burner on and the pressure gauge connected turn raising the upper part of the left lateral panel and previously removing the protective plug screw A on the ...

Page 80: ...s 1 remove the front and left side panel of the appliance 2 unscrew the fixing screw of the gas supply pipe above the electrical panel of the appliance see detail A 3 unscrew the hexagonal nut that connects the brass nozzle mount to the air gas mixer taking care not to damage the circular seal see details B and C use a number 36 spanner for this purpose 4 unscrew and replace the removed nozzle wit...

Page 81: ...correctly supplied as standard with the kit 9 retighten the fixing screw of the gas supply pipe above the electrical panel of the appliance 10 supply gas and electricity to the appliance and restart it 11 regulate the appliance to the pressure indicated in Table 25 on page 75 for the type of gas to be used following the instructions provided in Gas flow adjustment paragraph on page 74 then replace...

Page 82: ...ACF60 00 Installation User s and Maintenance Manual 78 Ed 04 2012 Figure 38 Gas conversion operations DETAIL A DETAIL B DETAIL C DETAIL D DETAIL E DETAIL F DETAIL G DETAIL H ...

Page 83: ...ly Maintenance operations to be done by the end user Cleaning of the condenser coil The ACF takes in air through the condenser coil and delivers the warmer air through the fan on the cover After a certain amount of time in operation dust and dirt present in the air can collect in the cracks between the fins of the condenser coil For areas that are particularly dusty a coil filter can be used see A...

Page 84: ...s of operation Special maintenance The operations described in this paragraph must be performed when necessary Addition of water and antifreeze to the water circuit If water needs to be added to the water circuit ALWAYS ADD and adequate percentage of antifreeze based on the minimum winter temperatures of the zone in which the ACF is installed see Table 22 page 49 and based on the specific requirem...

Page 85: ...UMP Centrifugal pump for the circulation of water in the water system R PCR000 HYDRAULIC SEPARATOR Separator to equilibrate the water systems with automatic air release exhaust valve and insulation For installation go to the WATER CONNECTIONS section on page 42 O SPR000 GLYCOL ANTIFREEZE Glycol antifreeze for hot cold hydraulic plants O GLC001 ACCESSORIES FOR THE ELECTRICAL INSTALLER Name Descript...

Page 86: ...ACF60 00 Installation User s and Maintenance Manual 82 Ed 04 2012 ...

Page 87: ...age 35 or by cutting electrical power to the ACF for more information see the TABLE OF OPERATING CODES reported below TABLE OF OPERATING CODES GENERATED BY THE ELECTRONIC BOARD version 3 021 firmware E 0 FAULT ON RESET CIRCUIT OF FLAME CONTROL UNIT CODE GENERATED BY Fault on reset circuit of flame control unit RESET METHOD Contact authorised Robur TAC U 1 MANUAL RESET OF THERMOSTAT GENERATOR LIMIT...

Page 88: ...erated the code ceases E 7 HIGH CONSENSER INLET TEMPERATURE CODE GENERATED BY U 7 code active for 2 hours or U 7 code generated 12 times in 2 hours of operation RESET METHOD Carry out appropriate checks Reset may be performed via DDC or S61 board via menu 2 parameter 1 If the code persists contact authorised Robur TAC E 8 FLAME CONTROL UNIT ERROR CODE GENERATED BY E 12 on Appliance and condenser i...

Page 89: ... menu 2 parameter 1 If the code persists contact authorised Robur TAC E 28 GAS ELECTROVALVE ON IN CASE OF FLAME CONTROL UNIT ARREST CODE GENERATED BY Flame control box is in arrest mode E12 and the gas electrovalve is ON In this condition the flame control box is switched in OFF E12 enabled RESET METHOD The reset can be done via DDC or S61 electronic board menu 2 parameter 1 If the code error pers...

Page 90: ...er the code is generated E 81 E 82 INVALID BANK 1 DATA INVALID BANK 2 DATA CODE GENERATED BY Invalid Bank 1 data Invalid Bank 2 data RESET METHOD Reset may be performed via the board menu 2 parameter 1 If the code persists contact authorised Robur TAC E 84 FAULTY CONNECTION TRANSFORMER OR FUSES 24 Vac CODE GENERATED BY Damage to one of the 2 24 0 24 Vac transformer fuses or one of 24 0 24 Vac wire...

Page 91: ...APPENDIX Ed 04 2012 87 APPENDIX DECLARATION OF CONFORMITY ...

Page 92: ...ACF60 00 Installation User s and Maintenance Manual 88 Ed 04 2012 ...

Page 93: ...APPENDIX Ed 04 2012 89 ...

Page 94: ...ACF60 00 Installation User s and Maintenance Manual 90 Ed 04 2012 ...

Page 95: ......

Page 96: ...nergy efficiency products through the commitment and caring of its employees and partners Robur Mission Robur Spa advanced heating and cooling technologies Via Parigi 4 6 24040 Verdellino Zingonia Bg Italy T 39 035 888111 F 39 035 4821334 www robur com export robur it Codice D LBR357 rev H 12MCM SDC 008 30 04 2012 ...

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Robur GA ACF60-00, Installation, Use And Maintenance Manual

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