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GAHP-AR – Installation, start-up, use and maintenance manual

80

Edition:

2014-08

GAHP-AR SPARE PARTS

Below are the lists of the spare parts for GAHP-AR appliance. Each list comes after the
respective exploded drawing, which pictures each part in the list with its progressive
number.
Spare parts can be ordered from Robur Corporation.

Exploded drawing n.1: INSULATING, WATER PIPES AND ACCESSORIES

Figure 34 -

Exploded drawing n.1 – see next table for the relative parts list.

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Summary of Contents for GAHP Line AR Series

Page 1: ...GAHP Line AR Series Air Water reversible absorption heat pumps for heating and cooling medium large areas Natural gas LPG fired Installation use and maintenance manual ...

Page 2: ... this manual other than for personal consultation must be previously authorized by Robur Corporation 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 Corporation reserves the right to modify the data and contents of this manual without prior notice ...

Page 3: ...nd user s needs SECTION 3 is for the plumbing installer it provides the necessary indications to the plumber in order to correctly install the GAHP AR SECTION 4 is for the electrical installer it provides the necessary information to the electrician in order to make the GAHP AR electrical connections SECTION 5 provides the instructions to regulate the flow of gas and to perform the gas conversion ...

Page 4: ...anual have the following meanings Danger Warning Note Operational procedure start Reference to another part of the manual or to a different manual book Table 1 Description icons OVERVIEW and technical SPECIFICATIONS End user Plumbing installer Electrical installer First start up and maintenance Optionals and Spare Parts Table 2 Section icons ...

Page 5: ... SUPPLY SYSTEM 37 3 5 FILLING OF HYDRAULIC CIRCUIT to be carried out by installation technician 39 3 6 GAS PRESSURE ADJUSTEMENT 41 3 7 CONNECTION OF COMBUSTION PRODUCT EXHAUST PIPE 43 3 8 PROGRAMMING OF HYDRAULIC PARAMETERS 44 SECTION 4 ELECTRICAL INSTALLER 49 4 1 S61 AND UNIT ELECTRICAL DIAGRAM KEY 50 4 2 OPERATION WITH ON OFF COMMAND SWITCH 52 4 3 CONTROL OF PLANT PUMP 54 4 4 PUMP AND ELECTRICAL...

Page 6: ...GAHP AR Installation start up use and maintenance manual 2 Edition 2014 08 ...

Page 7: ... animals or things due to incorrect installation and improper use of the GAHP AR and also by not observing the indications and instructions provided by the manufacturer Codes and standards The installation of the appliance must conform with local building codes or in the absence of local codes with the National Fuel Gas Code ANSI Z223 1 the Natural Gas Installation Code CAN CGA B149 1 or the Propa...

Page 8: ...ge resulting from improper installation A Qualified Technician is defined as someone having specific technical competence in the air conditioning heating and gas appliances according to international and national standards In particular current laws must be respected with regard to Natural gas equipment Electrically powered equipment Any other standard that regulates the installation of air condit...

Page 9: ...l power to the GAHP AR Call a Qualified Service Engineer using a telephone that is not near the GAHP AR In case of fault during installation and ignition without the smell of natural gas In case of fault or poor functioning of the GAHP AR without the escape of gas immediately shut it down using the appropriate control switch see ACTIVATION AND DEACTIVATION OF THE APPLIANCE page 15 if the shutdown ...

Page 10: ...HP AR is a high efficiency reversible air water heat pump operating by a water ammonia absorption cycle and designed for outdoor use The GAHP AR is able to chill water down to a temperature of 37 4 F or to heat it up to 140 F in heat pump mode with a nominal1 efficiency of 126 The cycle of the GAHP AR is fed by thermal energy provided by a gas burner therefore the required electric energy is limit...

Page 11: ...in coil defrosting Variable summer operations air flow helicoidal fan controlled by microprocessor CONTROL AND SAFETY DEVICES The GAHP AR is controlled and monitored by the S61 control board through the peripheral AR10 card These cards and many other devices compose the control and safety devices set of the GAHP AR listed below S61 control board with integrated microprocessor with LCD display and ...

Page 12: ... optional allows a precise control and monitoring on each single GAHP AR a single DDC supports up to 16 GAHP AR on a single hydraulic plant operating them according to the requested thermal load Figure 2 DDC Direct Digital Controller If up to do a DDC GAHP AR connection see paragraph USE OF THE DIRECT DIGITAL CONTROLLER DDC page 58 KEY A 4 digit DISPLAY for data and codes visualization B KNOB enco...

Page 13: ...t of Head PSIg 10 46 4 50 OPERATIONAL LIMITS HEATING EXTERNAL AMBIENT OPERATING TEMPERATURE DRY BULB MAX MIN F F 95 0 20 0 WATER FLOW MAX MIN GPM 22 0 6 2 INLET TO THE UNIT WATER TEMPERATURE MAX MIN F F 122 0 35 6 OUTLET TO PLANT WATER TEMPERATURE MAX T 27 F F 140 0 OPERATIONAL LIMITS COOLING EXTERNAL AMBIENT OPERATING TEMPERATURE MAX MIN F F 120 0 32 0 WATER FLOW MAX MIN GPM 14 1 11 0 INLET TO TH...

Page 14: ...IMENSIONS 5 WIDTH LENGTH HEIGHT Inches 33 1 2 48 1 2 57 WATER CONNECTIONS INLET OUTLET FPT 1 1 4 GAS INLET CONNECTION FPT 1 2 HEATER GASES DUCT INTERNAL DIAMETER Inches 3 1 8 Table 4 GAHP AR technical data 2 UNITS ARE FACTORY WIRED FOR 208 230 VOLTS OPERATION 3 MAY VARY BY 10 AS A FUNCTION OF BOTH POWER SUPPLY AND ELECTRICAL MOTOR INPUT TOLERANCE 4 REFERRED TO A SOLUTION OF QUALITY TAP WATER AND 1...

Page 15: ... 7 109 9 102 4 44 6 F 129 3 128 0 1 12 20 0 4 4 112 6 50 0 F 131 7 131 0 124 2 117 7 59 0 F 134 1 133 4 128 3 122 2 68 0 F 134 8 134 4 129 3 123 9 77 0 F 134 8 134 4 129 7 126 2 Table 5 Heating mode capacity Nominal value is in bold type CHILLING MODE CAPACITY Btu hr OUTLET TO PLANT CHILLED WATER TEMPERATURE 37 4 F 44 6 F 50 0 F EXTERNAL AMBIENT OPERATING TEMPERATURE DRY BULB T 9 F 59 0 F 64 8 63 ...

Page 16: ...05 3 08 3 15 7 04 3 30 3 32 3 35 7 48 3 58 3 62 3 65 7 93 3 89 3 98 4 05 8 37 4 25 4 35 4 42 8 81 4 64 4 76 4 86 9 25 5 05 5 19 5 28 9 69 5 50 5 66 5 77 10 13 5 96 6 18 6 29 10 57 6 45 6 66 6 83 11 01 6 95 7 16 7 39 11 45 7 47 7 68 7 97 11 89 7 99 8 21 8 57 12 33 8 52 8 76 9 18 12 77 9 06 9 32 9 80 13 21 9 59 9 90 10 43 13 65 10 12 10 50 11 07 14 09 10 64 11 11 11 72 14 53 11 36 11 81 12 60 14 97 ...

Page 17: ...essure drop chilling mode see Table 8 6 8 10 12 14 11 12 13 14 37 4 F Outlet 44 6 F Outlet 50 0 F Outlet PRESSURE DROP CHILLING MODE WATER FLOW GPM P FEET OF HEAD 3 6 9 12 15 18 21 24 27 6 6 8 6 10 6 12 6 14 6 16 6 18 6 20 6 86 F Outlet 104 F Outlet 122 F Outlet WATER FLOW GPM P FEET OF HEAD PRESSURE DROP HEATING MODE ...

Page 18: ...7 3 8 48 1 2 60 7 8 50 1 2 10 1 2 4 5 7 8 50 3 4 Figure 3 GAHP AR external dimensions GAHP AR service plate dimensions Figure 4 GAHP AR service plate dimensions Some details were removed for clarity 6 1 2 12 7 7 8 5 7 8 7 1 8 4 1 4 LEGEND A WATER OUTLET TO PLANT Ø 1 1 4 FPT B WATER INLET TO THE UNIT Ø 1 1 4 FPT G GAS INLET Ø 1 2 FPT E ELECTRICAL KNOCKOUTS Ø 7 8 A B G E ...

Page 19: ...t thermostat a programmable timer or one or more clean contacts controlled by another process For details about the type of on off command installed contact the plant s electrical installation technician A summer winter selector switch W Y for selecting the operating mode of the appliance cooling or heating Activation the on off commands are essential Do not switch the appliance on or off by conne...

Page 20: ... OF OPERATING CODES firmware release 3 027 on page 91 The electronic board see Figure 1 page 8 is located inside the electrical panel of the appliance and the display may be viewed through the viewing hole on the front panel of the unit itself Operating codes generated by the DDC The operating codes generated by the DDC may be viewed only on the display of the DDC and may only be cleared via the D...

Page 21: ...icular manual 2 final user manual book 2 The appliance is equipped with a microprocessor controlled S61 electronic board interconnected with an AR10 satellite board located on the side of the S61 board itself see Figure 1 page 8 The S61 electronic board contained in the electrical panel controls the appliance and displays data messages and codes during operation This is how the S61 appears with it...

Page 22: ...e In menu 1 it is possible to view the parameters that characterise the operation of the appliance and their current values Menu 7 pertains exclusively to Robur s authorised Technical Assistance Centres TAC To view the information contained in these menus proceed as illustrated in the paragraph Access to board menus on page 20 Menu 2 is an action menu it allows the operations of resetting the flam...

Page 23: ...TEMPERATURE Table 10 Example of data visualised on display cold water temperature and differential Table 11 illustrates an example of what is visualised on the display for an appliance that has been started up and is operating in heating mode OPERATING MODE HEATING OPERATING DATA OF GAHP AR THE DISPLAY SHOWS HOT OUTLET WATER TEMPERATURE HOT INLET WATER TEMPERATURE OUTLET WATER TEMPERATURE INLET WA...

Page 24: ...e letter E is displayed return to the previous item Access to the viewing menus menu 0 menu 1 and menu 7 is described in the next paragraph Access to board menus Access to the operating menus for control of the appliance menu 3 setting and for error flame control unit and manual defrosting command menu 2 execution is described in Paragraph 3 8 on page 44 and in Paragraph 2 4 on page 21 Access to b...

Page 25: ...edge and experience in order to operate thus In any case to set new operating parameters for the appliance see Paragraph 3 8 PROGRAMMING OF HYDRAULIC PARAMETERS on page 44 2 4 RESET OPERATIONS AND MANUAL DEFROSTING COMMAND There are several possible reasons why the appliance may have error status and therefore its operation arrested such an error situation does not necessarily correspond to damage...

Page 26: ...reset operation has been performed 4 To exit the menu turn the knob clockwise until is displayed then press it to return to the menu selection 5 To exit the menu selection and return to the normal visualisation of the parameters of the appliance turn the knob clockwise until is displayed and press it to exit Parameter 1 other appliance warnings errors reset This is required to reset any warnings a...

Page 27: ...ify the appropriate requirements You will need access to the electrical panel see Display and knob encoder on page 19 To execute the manual defrosting command select menu 2 as described in Access to board menus on page 20 then proceed as follows 1 The display shows press the knob to access the menu The display initially shows Parameter 0 2 Turn the knob clockwise to display Parameter 22 3 Press th...

Page 28: ...ternal disconnection switch GS see Figure 17 page 53 provided in the appropriate panel by the installation technician in the OFF closed position 4 close the gas valve Do not leave the appliance connected to power and gas supply if it is to remain inactive for a long period If the appliance is to be switched off in view of the winter period make sure that the hydraulic plant connected to the applia...

Page 29: ...ea of installation see Table 13 page 40 bring the plant to the correct pressure making sure that the pressure of the water in the plant is not less than 14 5 PSIg and not over 29 0 PSIg You will need the appliance disconnected from the gas electricity supply 5 open the plant gas supply valve and check that there is no smell of gas indicating possible leaks if you smell gas close the gas valve agai...

Page 30: ...GAHP AR Installation start up use and maintenance manual 26 Edition 2014 08 ...

Page 31: ...as supply and distribution network exists according to the manufacturer s indications see GAS SUPPLY SYSTEM on page 37 for the correct gas supply pressures The appliance must be installed on the outside of buildings in an area in which air circulates naturally and which does not require any particular protection from weather phenomena In no case must the appliance be installed inside a room No obs...

Page 32: ...ices braces cables bars must be suitable sized for the load to be lifted For the weight of the appliance consult Table 4 page 10 The manufacturer cannot be held responsible for any damage arising during the set up stage of the appliance Figure 6 Moving the appliance example The appliance can be installed at ground level on a terrace or on a roof if compatible with its dimensions and weight The dim...

Page 33: ...is unavailable see also SUPPORTS and LEVELLING on page 30 it is necessary to create a flat level base in concrete which is larger than the dimensions of the base of the appliance by at least 4 6 on each side The dimensions of the appliance are given in Table 4 page 10 Provide a containing step and a suitable drainage channel for the water Figure 7 Suggested dimensions of the unit bed Installation ...

Page 34: ... resonance phenomena may arise In addition it is advisable to use flexible connections vibration dampings between the appliance and the hydraulic and gas supply pipes Avoid positioning the appliance directly above places of rest or places which require quiet SUPPORTS and LEVELLING The appliance must be correctly leveled by placing a level on the top part of the appliance If necessary level the app...

Page 35: ...mum clearances dimensions expressed in inches There MUST NOT be any obstructions or structural overhangs roof edges balconies over the top of the unit The re circulation of the air discharged from the condenser results in a poor unit performance When the unit is installed in close proximity to buildings keep the unit away from the roof edge drip line In no case should the unit be placed within 6 f...

Page 36: ...ect See the following figure Figure 10 Location of the unit 3 3 HYDRAULIC CONNECTIONS General indications The hydraulic plant may be created using pipes in stainless steel black steel copper or cross linked polyethylene for heating cooling plants All water pipes and pipe connections must be adequately insulated in accordance with current regulations to prevent heat loss and the formation of conden...

Page 37: ...igure 12 on page 36 installed in the appliance water outlet pipe primary side Provide a plant expansion tank in any case secondary side installed in the appliance water outlet pipe The appliance is not equipped with an expansion tank therefore it is necessary to install a suitable expansion tank sized in relation to the maximum heat excursion and maximum operating pressure of the water in the plan...

Page 38: ...ph 3 5 on page 39 and in any case the technical specifications of the glycol that is to be used The sizing of the tubes and of the pump must guarantee the nominal water flow rate necessary for the correct operation of the appliance for calculation of internal pressure drops of the appliance refer to the TECHNICAL DATA paragraph on page 9 The operations necessary for the first activation or regulat...

Page 39: ...ample of hydraulic plant diagram for connection of 1 appliance KEY 1 ANTIVIBRATION JOINTS 2 MANOMETER RANGE 0 60 PSIg 3 FLOW REGULATION VALVE 4 WATER FILTER 2 filter mesh MIN 0 7 mm MAX 1 mm 5 CUT OFF VALVE 6 PLANT WATER CIRCULATION PUMP 7 PLANT EXPANSION TANK 8 SAFETY RELIEF VALVE 45 PSIg 9 DIRECT DIGITAL CONTROLLER DDC available as optional ...

Page 40: ...TER RANGE 0 60 PSIg 3 FLOW REGULATION VALVE 4 WATER FILTER 2 filter mesh MIN 0 7 mm MAX 1 mm 5 SINGLE APPLIANCE EXPANSION TANK 6 RETAINING VALVE 7 SINGLE APPLIANCE WATER CIRCULATION PUMP 8 CUT OFF VALVE 9 STORAGE TANK WITH ANTIMIXING SEPARATORS COMPLETE WITH 45 PSIg 10 PLANT EXPANSION TANK SAFETY RELIEF VALVE AIR BLEEDER VALVE AND DRAIN TAP 11 PLANT WATER CIRCULATION PUMP 12 DIRECT DIGITAL CONTROL...

Page 41: ...Figure 4 on page 14 Supplying gas to the appliance at higher pressures than those indicated above can damage the gas valve giving rise to a situation of danger The installation of gas supply pipes must be carried out in compliance with norms and current regulations L P G may cause corrosion The connectors between the pipes must be made of a material that is resistant to this corrosive action Verti...

Page 42: ...nance manual 38 Edition 2014 08 In any case provide a cut off valve tap on the gas supply line to isolate the appliance if required Figure 13 Typical gas connection APPROVED UNION SEDIMENT TRAP APPROVED GAS SHUT OFF VALVE TO UNIT FROM GAS SUPPLY ...

Page 43: ...ormation into acids increases the corrosive nature of the fluid contained in the circuit For this reason mixtures that are commercially available almost always contain inhibiting substances that are able to control the pH of the solution A necessary condition for the oxidation of the glycol and therefore its degradation is the presence of an oxidizing agent such as oxygen In closed circuits in whi...

Page 44: ...pliances Robur heating and cooling systems operate with grid water of good quality In order to prevent any possible problem of operation or reliability caused by filling or top up water please refer to codes and norms about water treatment for thermo hydraulic installations in civil or industrial applications Parameters indicated in Table 14 must be complied with CHEMICAL AND PHYSICAL PARAMETERS O...

Page 45: ...perly rinsed in order to remove any residue of chemical substances from the pipes Robur is not liable for ensuring that water quality is always compliant with what reported in Table 14 is not s Non compliance with indications above may jeopardize the proper operation integrity and reliability of Robur appliances invalidating the warranty For any further detail please contact directly Robur Corpora...

Page 46: ...osition 2 Remove the plug on Outlet end of gas valve and attach pressure tap and manometer 3 Turn power ON and close control switch 4 Wait for the burner to start up Due to the presence of air inside the piping it may be that the burner does not start at the first three attempts and failing to do so the ignition system is locked out If this happens reset the ignition system see dedicated procedure...

Page 47: ...ow EXHAUST FLUE FLOW TEMPERATURE AND CO2 NATURAL GAS COMBUSTION FLUE FLOW FLUE TEMPERATURE CO2 SCF F 1750 293 9 2 LPG COMBUSTION FLUE FLOW FLUE TEMPERATURE CO2 SCF F 1522 284 11 3 Table 17 Exhaust gas flow and temperatures The appliance shall not be connected to a chimney flue serving a separate appliance designed to burn solid fuel Each unit of the appliance is supplied complete with an exhaust a...

Page 48: ...o the side panel of the unit 5 position the exhaust terminal and fix it with 1 hose clamp 6 fix the hose adaptor condensate drain pipe and the relative silicon tube 7 complete the operation checking carefully that all components are correctly fixed in place Figure 15 Components of exhaust air duct kit 3 8 PROGRAMMING OF HYDRAULIC PARAMETERS The operations described in this paragraph are necessary ...

Page 49: ...activation of the appliance is detected by the sensor on the INLET water i e water flowing into the appliance 1 the temperature that affects the activation and deactivation of the appliance is detected by the sensor on the OUTLET water i e water flowing out of the appliance Water set point parameters 75 and 161 these parameters set the water temperature that when reached causes the appliance to be...

Page 50: ...on again Example Thermostating reading from inlet sensor Set point 104 0 F Differential 3 6 F The appliance is functioning the water in the plant heats up until it reaches the set point temperature 104 0 F The appliance switches off the water in the plant returning from use becomes progressively cooler until it reaches a temperature of 100 4 F 104 0 F 3 6 F The appliance switches on again and the ...

Page 51: ...lay shows the previously set value which flashes for example 44 6 F Turn the knob to modify the value of the parameter for example 47 3 F Press the knob to confirm the value selected The display shows the current parameter again The new value for this parameter has been set 4 If other parameters are to be modified proceed as described previously and then exit from the menu by pressing the knob on ...

Page 52: ...GAHP AR Installation start up use and maintenance manual 48 Edition 2014 08 ...

Page 53: ...e to people animals or things Robur Corporation is not responsible for any damage caused by installation or that is incorrect or that does not comply with current legislation Control of the operation of the appliance may take place in one of the following ways 1 By means of specific on off commands an on off switch and a summer winter selector switch for selecting the operation mode This on off co...

Page 54: ... PROBE MAIN 230V L N POWER SUPPLY TERMINAL TA EXTERNAL AMBIENT IGN BOX L N IGNITION BOX TERMINAL TEMPERATURE PROBE J10 N O CONTACT JUMPER TG GENERATOR TEMPERATURE PROBE P7 R W Y O CONSENT TERMINAL TA1 EVAPORATOR OUTLET Left and Right edge PROBE TEMPERATURE TA2 NOT USED F2 FUSE SRT1 OLEODYNAMIC PUMP OPERATION FS5 24V AC BOARD FEEDING TERMINAL REED SENSOR FL FLOW METER SENSOR SRT2 NOT USED CONNECTOR...

Page 55: ...PY W Chiller Heater Pump 2 pipe systems PWRTR Board Power Transformer DDCTR DDC Power Transformer IGNTR Ignition Transformer PTR Pump Transformer MV Motor Valve DV Defrosting Valve GV Gas Valve DDC Direct Digital Controller CNTBOX Flame Control Box BLW Blower PSW Air Pressure Switch IGN Ignition Electrode FLS Flame sensor FAN Condenser Fan TER Terminal Board PMP Pump KP Relay for Water Pump Contro...

Page 56: ...gulations Do not use gas pipes to ground electrical appliances Connecting the appliance To connect the appliance to the mains supply and to connect the appropriate on off commands You will need the appliance in its permanent location 3 Prepare a cable of the 3x16 AWG type for the power supply to the appliance Ground cable is conventionally yellow green colored 4 Connect the appliance to the mains ...

Page 57: ...tion Ed 2014 08 53 Figure 17 Example of connection of appliance to 208 230 V 1 N 60 Hz electricity supply fuse type T type 2x5A or 1x10A Figure 18 Example of electrical connection of on off commands and summer winter selector ...

Page 58: ...the bottom left of the electronic board above the NO Contact contacts is CLOSED as shown in the detail jumper closed Direct control from the electronic board with power absorbed by the pump of more than 4 A If the power absorbed by the pump is less than or equal to 4 A make the connection as shown in Figure 20 page 55 using a control relay In this case it is necessary to OPEN the jumper J10 locate...

Page 59: ...igure 20 Example of pump appliance electrical connection with 230 Vac pump with absorbed power of 4 A controlled directly by the appliance through a relay GROUND CABLE HAS TO BE CONNECTED BY A SUITABLE EYELET TO THE GROUND PIN INTO THE ELECTRICAL BOX AND FIXED TO IT BY THE PROPER PRESET NUT L N WIRING TO THE TERMINAL BOARD MUST BE DONE RESPECTING THE CORRECT POLARITY GROUND CABLE HAS TO BE CONNECT...

Page 60: ...shut off these contacts could still remain fed Figure 21 Example of pump appliance electrical connection with 208 230 Vac pump controlled directly by the appliance through a relay and a SELV safety transformer GAHP AR WIRING If any of the original wire as supplied with the unit must be replaced this must be done with thermoplastic 221 F wire except ground high temperature and pressure switch wires...

Page 61: ...Electrical installer section Ed 2014 08 57 Figure 22 Internal electrical wiring diagram ...

Page 62: ...appliance is connected to 1 DDC The two elements appliance and DDC are terminal nodes of the network as they are each connected to one other element only b 2 appliances are connected to each other and to 1 DDC Appliance B and the DDC are terminal nodes while appliance A is an intermediate node as it is connected to 2 elements which are appliance B and the DDC It is possible to place one DDC at any...

Page 63: ...tion purchase the correct cable As shown in the table the CAN connection requires a CAN bus cable with 3 wires If the cable available has more than three colored wires choose which colors to use and cut the other unnecessary ones The ROBUR NETBUS cable is available as an accessory see Optionals and Spare Parts page 79 Connection of the CAN BUS cable to the appliance The CAN BUS cable is connected ...

Page 64: ...ng in the area adjacent to the unsheathed part approximate diameter required 12 13 mm 5 Pull back the shielding in the sheathe apply electrician s tape to the end of the shielding as pulled back letter A of Figure 24 page 59 6 If the appliance is a terminal node of the network connect the three coloured wires to the orange connector as shown in detail A of Figure 25 on page 61 Respect the correct ...

Page 65: ...n the board set the jumpers as shown in detail B of Figure 25 Figure 25 Connection CAN PORT S61 electronic board After having carried out all the above operations close the electrical panel and refit the front panel of the appliance Connection of the CAN bus cable to the DDC The CAN bus cable has to be connected to the specific orange connector P8 supplied with the DDC illustrated in Figure below ...

Page 66: ...ers that must be moved so that it can be configured as an intermediate or terminal node The position of the jumpers on a new DDC is CLOSED as illustrated in Figure 27 on page 62 Figure 27 Direct Digital Controller DDC wiring diagram and partial rear view KEY GND Common data A Insulating tape protecting CAN bus cable shield L LOW data signal B CAN bus wires H HIGH data signal C CAN bus cable shield...

Page 67: ...an intermediate node of the network there are 6 wires in the orange connector position the jumpers on the DDC as illustrated in Figure 28 OPEN Figure 28 Connection of 2 CAN bus cables to the DDC the DDC IS AN INTERMEDIATE NODE The diagram shows the positions of the wires of the CAN bus cable and the jumpers OPEN If the DDC is a terminal node of the network i e there are 3 wires in the orange conne...

Page 68: ...he other length of CAN bus cable necessary Follow also point 5 but refer to Figure 28 page 63 instead of Figure 29 for the connection of the cable to the connector Then proceed to point 8 8 Insert the orange connector with the wires first into the opening in the cover of the DDC then into the specific socket of the DDC taking care to insert it correctly 9 Use the fixing screw of the rear cover loc...

Page 69: ...7 years To replace it contact an authorised Robur Technical Assistance Centre TAC After having carried out all of the above operations close the rear cover of the DDC if opened and tighten the 4 screws taking care to fasten the eyelet or eyelets of the CAN bus cable shield with the screw at the bottom right as illustrated in Figure 27 on page 62 Figure 30 Example of connection between 1 appliance ...

Page 70: ...GAHP AR Installation start up use and maintenance manual 66 Edition 2014 08 Figure 31 Example of connection between 2 appliances and 1 DDC ...

Page 71: ...a on board electronic board or via a DDC if the appliance is connected to a DDC Indications regarding maintenance operations of the appliance Paragraph 5 2 general observations and warnings general indications regarding checks controls and cleaning operations to perform At the end of the section you will find instructions for changing the type of gas an operation for technical assistance Before pr...

Page 72: ...sign following the instructions supplied by the manufacturer and respecting current legislation The project must have been drawn up by a qualified self employed professional person check personally that all of the connections hydraulic gas and electrical of the appliance and of the Direct Digital Controller if connected to the appliance have been made correctly check that the necessary conditions ...

Page 73: ...irst activation appliance installed in a closed room appliance installed too near combustible surfaces or in any case in conditions that do not permit access and maintenance operations in safety control of switching on and off of the appliance not via the DDC or consent switch CS but via the internal disconnecting switch GS inside the general electrical panel situations attributable to defects or ...

Page 74: ... via the DDC if connected point 11 of the specific procedure if the appliance is connected to the DDC for this operation consult the specific final user manual book 2 Proceed with regulation of the gas pressure to the burner of the appliance as in the specific procedure set out further on from point 13 onwards Check the dynamic gas mains pressure if possible on the appliance that is furthest from ...

Page 75: ...hed off with the gas valve closed and the front panel removed Check the static gas mains pressure 1 Unscrew the fixing screw of the gas pressure intake detail B in Figure 32 on page 72 2 Connect the manometer to the gas intake mains pressure 3 Open the gas valve 4 Read the value of the static gas mains pressure on the manometer and check that the value read is correct 7 inWC for natural gas G20 11...

Page 76: ... fixing screw of the gas pressure outlet detail C Figure 32 17 Check for possible leaks on the gas network with a solution of soap and water Figure 32 Gas valve SIT 830 of the appliance GAS TYPE NATURAL GAS LP GAS MANIFOLD PRESSURE 2 8 WC INCHES 5 1 WC INCHES NOZZLE DIAMETER 0 21 0 14 Table 21 Gas pressure to the burner air diaphragm and nozzle diameters Regulation of plant operating parameters Re...

Page 77: ...f the unit is subjected to particularly heavy use for example in processing plants or in other conditions of continuous operation these maintenance operations must be performed more often Maintenance operations that may be performed by the user Cleaning the finned coil If the installation environment is particularly dusty it is advisable to fit a filter for the finned coil see the Optionals and Sp...

Page 78: ... the opening see Figure 23 5 Look at the air intake chute for combustion air and clear any debris that may be obstructing the opening 6 Reinstall front door 7 Turn on gas and electric supply to the unit 8 Start unit to check for correct operation Inspection and cleaning of the burner You will need the unit shut off Tools Needed Fiber Bristle Brush Dust Mask 3M 8710 or equal Safety Goggles Hand Too...

Page 79: ...generator housing is properly sealed 10 Turn on gas and electric supply to unit 11 Start unit and check for correct operation Extraordinary maintenance The operations described in this paragraph must be carried out as and when necessary Adding water and antifreeze to the hydraulic plant If it should be necessary to add water to the plant add a suitable quantity making sure that it contains the min...

Page 80: ...oved nozzle with one of the suitable diameter for the gas that is to be used see detail C positioning the new o ring seal supplied between electro valve and nozzle use a 9 64 hex key wrench to fix again the screws 6 reconnect the brass nozzle to the mixer tightening the hexagonal nut taking care to position the new circular seal supplied with the kit correctly 7 retighten the fixing screw of the g...

Page 81: ... 2014 08 77 Figure 33 Operations for change of gas type A B C D E F G F G C H B gas valve air gas mixer LEGEND A 24 Vac GAS CONTROL VALVE B GAS VALVE FLANGE C GAS NOZZLE D O RING E GASKET G BURNISHED SCREW n 4 F GAS SUPPLY PIPE H HEXAGONAL NUT ...

Page 82: ...GAHP AR Installation start up use and maintenance manual 78 Edition 2014 08 ...

Page 83: ... the holes already provided on the beams of the base O NTV003 For the position of the fixing holes see Figure 3 on page 14 HYDRAULIC SEPARATOR Separator to balance hydraulic circuits with automatic air discharge outlet valve and insulation O SPR000 GLYCOL ANTIFREEZE GLYCOL ANTIFREEZE for hot cold hydraulic plants O GLC001 10 litre can OPTIONALS FOR ELECTRICAL SYSTEM INSTALLATION TECHNICIAN Name De...

Page 84: ...parts for GAHP AR appliance Each list comes after the respective exploded drawing which pictures each part in the list with its progressive number Spare parts can be ordered from Robur Corporation Exploded drawing n 1 INSULATING WATER PIPES AND ACCESSORIES Figure 34 Exploded drawing n 1 see next table for the relative parts list ...

Page 85: ...IDE INSULATING 1 6 C CBN092 ABSORBER REAR SIDE INSULATING 1 7 R TBO418 WATER DELIVERY PIPE 1 8 R TBO420 WATER RETURN PIPE 1 9 K MNM002 DIFFERENTIAL MANOMETER KIT 1 10 J TRS007 IGNITER TRANSFORMER 1 11 E LMP013 SIGNAL LIGHT 230V WITH FAST ON 1 12 G VLV032 PRESSURE RELIEF VALVE 1 13 R GFS001 FLOWSWICH CLAMPING RING NUT 1 14 L STF189 AIR BREATHER VALVE BRACKET 1 15 H VLV000 AUTOMATIC AIR BREATHER VAL...

Page 86: ...GAHP AR Installation start up use and maintenance manual 82 Edition 2014 08 Exploded drawing n 2 ELECTRICAL BOX AND PUMP Figure 35 Exploded drawing n 2 see next table for the relative parts list ...

Page 87: ...1 7 E CNT031 24 Vac 60Hz MICROPROCESSOR BASED HSI CONTROL 1 8 J TLT020 COMBUSTION CHAMBER THERMOSTAT 1 9 E SLT031 S61 CF24 ELECTRICAL BOARD 1 10 E CND011 CONDENSER 12 5 µF 450 V 1 11 G PRS000 AIR PRESSURE SWITCH ACF60 2 60 Hz 1 12 E MRS020 9 STUD TERMINAL BOARD WITH REED 1 13 L CQD011 ELECTRIC BOX COVER 1 14 C 12100960 INSPECTION HOLE GLASS 1 15 N TPP019 D 25 PROTECTION CAP 1 16 N CRN000 ELECTRIC ...

Page 88: ...AHP AR Installation start up use and maintenance manual 84 Edition 2014 08 Exploded drawing n 3 COMBUSTION CHAMBER AND GAS SYSTEM Figure 36 Exploded drawing n 3 see next table for the relative parts list ...

Page 89: ...ION 2 13 C CBN041 COMB CHAMBER GENERATOR INSULATION 1 14 J CBN029 BURNER INSULATION 1 15 J BRC017 BOILER BURNER 1 16 J GRN028 BURNER UNION TRIMMING 2 17 R DFF009 INCLINED AIR GAS MIXER 1 18 J LTT047 SPARKLING ELECTRODE 1 19 C GRN086 SENSOR FLAME ELECTRODE GASKET 1 20 J LTT046 SENSOR FLAME ELECTRODE 1 21 N GRG006 2075 NB 70 O RING 1 22 J CSL000 D 11 16 x 50 CERAMIC INSULATION 1 23 G VLV052 24 VAC G...

Page 90: ...GAHP AR Installation start up use and maintenance manual 86 Edition 2014 08 Exploded drawing n 4 PANELS KIT Figure 37 Exploded drawing n 4 see next table for the relative parts list ...

Page 91: ...1 5 C 12100960 INSPECTION HOLE GLASS 1 6 L PST068 SILK SCREENED SERVICE PLATE 1 7 N MNG000 PANELS HANDLE 1 8 E MTR056 60 Hz FAN MOTOR 1 9 V PRT000 60 Hz MOTOR RAIN SHIELD 1 10 L STF210 60 Hz FAN MOTOR BRACKET 4 11 V VNT025 BLADE ASSEMBLY FAN 26 Ø 60 Hz 1 12 P CPR048 PAINTED SUPERIOR PANEL 1 13 N TPP061 Ø33 4 H 25 VINYL CAP 1 14 C CBN028 380X840 SUPERIOR PANEL INSULATION 1 15 J GPR000 FAN GRID 1 Ta...

Page 92: ... blower starts normal operation a pre purge delay begins and the ignition sequence continues Next the ignition control box energizes an ignition transformer that generates a high intensity spark at the igniter to ignite the gas air mixture Simultaneously the gas valve is energized allowing the flow of gas to the burner As soon as the ignition period ends the flame sensor checks for flame presence ...

Page 93: ...stallation technician manual book 1 follow the instructions given in it strictly contacting the authorized Robur Technical Assistance Centre TAC when required If after these operations have been carried out the appliance does not start first perform the following simple checks verify that the on off command controls CS W Y see Figure 18 on page 53 or that the DDC if connected and in controller mod...

Page 94: ...tored automatically when the cause ceases If code U 601 persists it becomes E 601 E 601 MANUAL RESET OF THERMOSTAT GENERATOR LIMIT TEMPERATURE CODE GENERATED BY U 601code active for 1 hour or U 601 code generated 3 times in 2 hours of operation RESET METHOD Contact Robur TAC U 602 EXHAUST GAS THERMOSTAT AUTOMATIC RESET CODE GENERATED BY High temperature detected by exhaust gas thermostat T 473 F R...

Page 95: ...er 1 or via DDC If the code persists contact Robur TAC E 608 FLAME CONTROL UNIT ERROR CONDIZIONI DI INTERVENTO E612 code on GAHP AR in and inlet temperature increasing by over 18 F within 1 hour RESET METHOD Carry out appropriate checks Reset may be performed via S61 board menu 2 Parameter 1 or via DDC If the code persists contact Robur TAC U 610 WATER CIRCUIT FLOWMETER Insufficient water flow COD...

Page 96: ...u 2 Parameter 1 or via DDC If the code persists contact Robur TAC E 628 GAS SOLENOID VALVE EXCITED WHEN THE FLAME CONTROL BOX IS LOCKED CODE GENERATED BY The flame control box is locked E 612 but the gas solenoid valve is excited In this case the flame control box is reset E 612 resets RESET METHOD Reset may be performed via S61 board menu 2 Parameter 1 or via DDC If the code persists contact Robu...

Page 97: ...erated If the code persists code E648 may occur in this case contact Robur TAC E 648 HIGH HOT WATER DIFFERENTIAL TEMPERATURE CODE GENERATED BY U 648 code is generated 2 times in 2 hours of operation RESET METHOD Reset may be performed via S61 board menu 2 Parameter 1 or via DDC If the code persists contact Robur TAC E 649 AR10 SATELLITE BOARD NOT PRESENT CODE GENERATED BY Satellite board not prese...

Page 98: ...mperature returns to above 41 0 F in this case the circulator switches off or if also the flame control unit has switched on when this temperature reaches 64 4 F in this case the flame control unit and then the circulator switch off U 680 INCOMPLETE PARAMETERS CODE GENERATED BY Incomplete parameters RESET METHOD The code remains until operating parameters are entered and completed Contact Robur TA...

Page 99: ...DE GENERATED BY Processor error RESET METHOD Contact Robur TAC E 690 AMBIENT TEMPERATURE SENSOR DEFECTIVE CODE GENERATED BY Interruption or short circuit of ambient temperature sensor RESET METHOD Reset may be performed via S61 board menu 2 Parameter 1 or via DDC If the code persists contact Robur TAC E 691 BOARD DEFECTIVE CODE GENERATED WHEN One of the following is absent serial number of board h...

Page 100: ...ducts through the commitment and caring of its employees and partners Robur Mission Robur Corporation advanced heating and cooling technologies 827 E Franklin Street Evansville Indiana 47711 USA P 812 424 1800 F 812 422 511 7 www robur com us rhalbig servel sbcglobal net Codice D LBR364 rev F 14 MCMSDC 015 25 08 2014 sales robur com ...

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