Robur GAHP-GS, GAHP-WS, GAHP-A HT S1, GAHP-A HT S, GAHP-A HT Installation, User And Maintenance Manual

...

Download

Page 1

Installation, user and maintenance manual

GAHP-GS/WS

water/water gas absorption heat pump

Page 2

Revision: M Code: D-LBR509

This manual has been drawn up and printed by Robur S.p.A.; whole or partial reproduction of this manual is prohibited. The original is ﬁled at Robur S.p.A. 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

Installation, user and maintenance manual – GAHP-GS/WS

Index of Contents

1 PRefACe ��4 2 sAfetY WARnInGs ��5 3 oVeRVIeW And teCHnICAL feAtURes ��8

3.1 GENERAL INFORMATION ............................................................................................................................................................8

3.2 NOTES ON OPERATION OF THE APPLIANCE ......................................................................................................................10

3.3 TECHNICAL MANUFACTURING CHARACTERISTICS.........................................................................................................11

3.4 TECHNICAL DATA ........................................................................................................................................................................12

3.5 DIMENSIONS AND SERVICE PANEL .......................................................................................................................................15

4 noRMAL oPeRAtIon ��17

4.1 START UP (AND SHUT DOWN) ................................................................................................................................................17

4.2 ON-BOARD ELECTRONICS ........................................................................................................................................................19

4.3 RESET OPERATIONS ....................................................................................................................................................................22

4.4 OPERATING SETTINGS ...............................................................................................................................................................23

4.5 PROLONGED PERIODS OF DISUSE ........................................................................................................................................24

5 HYdRAULIC InstALLAtIon ��26

5.1 GENERAL INSTALLATION PRINCIPLES ..................................................................................................................................26

5.2 POSITION OF THE APPLIANCE ................................................................................................................................................26

5.3 HYDRAULIC CONNECTIONS ....................................................................................................................................................28

5.4 GAS SUPPLY...................................................................................................................................................................................30

5.5 CONDENSATE DISCHARGE .......................................................................................................................................................31

5.6 FILLING OF HYDRAULIC CIRCUIT ...........................................................................................................................................34

5.7 EXHAUST FLUE GAS ....................................................................................................................................................................37

5.8 PROGRAMMING OF HYDRAULIC PARAMETERS................................................................................................................42

5.9 SAFETY VALVE DISCHARGE ROUTING ..................................................................................................................................43

6 eLeCtRICAL InstALLAtIon ��45

6.1 ELECTRICAL DIAGRAM OF THE APPLIANCE .......................................................................................................................49

6.2 HOW TO CONNECT THE APPLIANCE ELECTRICALLY .......................................................................................................50

6.3 TYPE A (COMFORT CONTROL PANEL) ..................................................................................................................................50

6.4 TYPE B (DDC) ................................................................................................................................................................................60

6.5 TYPE C (Consent switch) ...........................................................................................................................................................70

6.6 HOW TO RESET THE FLAME CONTROLLER FROM REMOTE ..........................................................................................71

7 InItIAL ACtIVAtIon And MAIntenAnCe ��73

7.1 PROCEDURE FOR FIRST START UP .........................................................................................................................................73

7.2 MAINTENANCE .............................................................................................................................................................................77

7.3 CHANGE OF GAS TYPE ..............................................................................................................................................................78

8 ACCessoRIes ��81 9 oPeRAtInG Codes/tRoUBLesHootInG ��82

9.1 OVERVIEW AND OPERATING CODES/TROUBLESHOOTING ..........................................................................................82

DECLARATION OF CONFORMITY ��95

Page 4

1 PREFACE

This Installation, user and maintenance manual is a guide to the installation and operation of the Air-Water gas absorption heat pump GAHP-GS/WS. This manual is speciﬁcally intended for:

ﬁnal users for the operation of the appliance according to their own • requirements; Installation technicians (hydraulic and electrical) for a correct installation of the • appliance.

The manual also contains:

a section that describes all the operations necessary for the “ﬁrst start-up” and for • the “gas change” of the appliance, as well as the main maintenance operations; an "ACCESSORIES" section with a description of accessories available and their re-• spective reference codes. (IN CASE) one or more APPENDIX sections in which are reported some "speciﬁc" • information for a particular country.

References

If the appliance is connected to a Comfort Control Panel (see detail CCP in Figure 6.4 Comfort Control Panel e Accessory → 48) it is switched on and controlled by the Comfort Control Panel. In this case, refer to the manual supplied with it. If the appliance is connected to a Direct Digital Controller (see Figure 6.3 CCI/DDC → 47) and the DDC is in controller mode, activation and control of the appliance will occur exclusively by operating the DDC. In this case, refer to the manual supplied with it.

Deﬁnitions, terms and icons

APPLIANCE: this term refers to the gas absorption heat pump GAHP-GS and/or gas absorption heat pump GAHP-WS. CCP: "Comfort Control Panel". CCI: "Comfort Control Interface" device. DDC: digital control panel (Direct Digital Controller). TAC: Technical Assistance Centre (authorised by Robur S.p.A.). SYSTEM COLD SIDE: this term refers to the renewable source plant (geothermal probes or ground water). SYSTEM HOT SIDE: this term refers to the primary hot water distribution system. The icons in the edge of the manual have the following meanings:

= DANGER

= WARNING

= NOTE

= START OF OPERATING PROCEDURE

= REFERENCE to another part of the manual or other document

Page 5

Installation, user and maintenance manual – GAHP-GS/WS

2 SAFETY WARNINGS

Packing items (plastic bags, polystyrene foam, nails, etc.) must be kept out of the reach of children, as they are potentially dangerous.

The appliance must only be used for the purposes for which it has been designed. Any other use is considered inappropriate and therefore dangerous. The manufacturer does not accept any contractual or extra-contractual liability for any damage caused by improper use of the appliance.

The appliance is not intended to be used by persons (including children) whose physical, sensory and mental capacities are impaired, or who lack the necessary experience and knowledge, unless they are supervised or instructed in its use by persons responsible for their safety. Children must be supervised to ensure that they do not play with the appliance.

The unit uses a water/ammoniac absorption cycle for hot/cold water production. The ammoniac is in water solution inside a sealed circuit tested 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.

If installed indoors, the safety valve must be ducted. Refer to Chapter 5.9 SAFETY VALVE DISCHARGE ROUTING → 43 of this manual for instructions. The unit MAY NOT BE OPERATED if the safety valve is not ducted.

Frequent topping up of the hydraulic 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 water tight and that the expansion tank is operational.

Concentrations of chlorides or free chlorine in the circuit above the values given in Table

5.1 Chemical and physical parameters of water → 29 will damage the unit's water/ammonia exchanger.

Close the gas supply before working on the gas circuit. On completing work on the gas circuit, check for leakages as required by established regulations.

Do not operate the appliance if dangerous conditions exist: odour of gas in the grid or near the appliance; problems with the electrical/gas grid or hydraulic circuit; parts of the appliance submerged in water or otherwise damaged; controls or safety components bypassed or defective. In these cases, ask for assistance to professionally qualiﬁed personnel.

If you smell gas:

Page 6

do not use electrical devices such as telephones, multimeters or other equipment • that can cause sparks next to the appliance; shut oﬀ gas supply closing the isolation valve;• cut oﬀ electrical power opening the main breaker upstream of the appliance (to be • provided by the electrical installer in an appropriate panel); ask for assistance to professionally qualiﬁed personnel from a telephone distant • from the appliance.

Moving parts, also during the appliance's start-up and shut-down cycles. Do not remove guards. Make sure the appliance cannot be started up inadvertently.

POISONING HAZARD

Make sure the ﬂue gas components are tight and compliant with established regulations. After any intervention on these parts, check for tightness.

If the appliance is installed indoors, insuﬃcient or non-conforming ventilation (see installation instructions) can result in hazardous leaks of combusted gases.

Make sure the ventilation and aeration outlets conform to the installation • instructions. If the non-conformity cannot be resolved immediately, do not start up the • appliance. Notify the plant operator of the non-conformity and any attendant hazards.•

BURN HAZARD

The appliance contains numerous hot parts. Do not open up the appliance or touch the fumes outlet pipe. If necessary, contact your Technical Assistance 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 approved components for the electrical connections, as speciﬁed by the • manufacturer. Disconnect the electrical power supply before working on the appliance's internal • electrical equipment (electrical panel, motors, control board, etc.). Make sure the appliance cannot be started up inadvertently.•

The electrical safety of the appliance is ensured only when it is correctly connected to an eﬃcient grounding system, compilant with current safety regulations.

DAMAGE DUE TO AGGRESSIVE SUBSTANCES IN THE AIR SUPPLY

Hydrogenated hydrocarbons, which contain chlorine and ﬂuorine compounds, will increase the corrosion of the unit.

Page 7

Installation, user and maintenance manual – GAHP-GS/WS

Make sure the air supply is free of aggressive substances.

ACID CONDENSATE

Drain out the condensate produced during combustion as indicated in paragraph 5.5 CONDENSATE DISCHARGE → 31.

EXPLOSIVE/FLAMMABLE MATERIALS HAZARD

Do not use or store ﬂammable materials (paper, solvents, paint, etc.) in the vicinity of the appliance.

SUGGESTIONS FOR THE CLIENT

Stipulate a maintenance contract with an authorised specialist contractor for the annual inspection of the appliance and maintenance when needed. Maintenance and repairs may only be done a contractor legally authorised to work on gas appliances and equipment. Only accept and use original spare parts.

Page 8

3 OVERVIEW AND TECHNICAL FEATURES

In this section you will ﬁnd general information, hints on the operating principle of the appliance and its manufacturing features. This section also contains technical data and dimensional drawings of the appliance.

3.1 GENERAL INFORMATION

This manual is an integral and essential part of the product and must be delivered to the user together with the appliance.

Conformity to CE standards

The absorption heat pumps of the GAHP series are certiﬁed as conforming to standard EN 12309-1 and -2 and comply with the essential requirements of the following Directives:

Gas Directive 90/396/EEC and subsequent modiﬁcations and additions.• Eﬃciency Directive 92/42/EEC and subsequent modiﬁcations and additions.• Electromagnetic Compatibility Directive 89/336/EEC and subsequent modiﬁca-• tions and additions. Low Voltage Directive 89/336/EEC and subsequent modiﬁcations and additions.• "Machinery Directive" 2006/42/EC.• Pressurised Equipment Directive 97/23/EEC and subsequent modiﬁcations and • additions. UNI EN 677 Speciﬁc requirements for condensing boilers with nominal thermal ca-• pacity up to 70 kW. EN 378 Refrigerating systems and heat pumps.•

The emission values of nitrogen oxides (NOx) of gas absorption heat pumps of the GAHP series are lower than 60 mg/kWh, in compliance with the requirements of the standard RAL UZ 118 "Blauer Engel".

Information regarding the above EC certiﬁcations is given in Paragraph 3.4 TECHNICAL DATA → 12, as well as on the Nameplate of the appliance itself.

Installation and regulatory references

On receiving the appliance at the installation site, before placing into ﬁnal position, check there are no signs of transportation damages of the external panels or packaging.

Packing materials must be removed only after the appliance has been positioned on site. After removing the packing materials, ensure that the appliance is intact and complete.

Installation of the appliance may only be carried out by professionally qualiﬁed personnel by i.e. ﬁrms qualiﬁed according to the current legislation of the country of installation.

"Professionally qualiﬁed personnel" means personnel with speciﬁc technical competence in the sector of heating/cooling installations and gas appliances.

Installation of the appliance must be carried out in compliance with current local and national regulations regarding the design, installation and maintenance of heating and cooling installations and in accordance with the manufacturer's instructions. In particular, current regulations regarding the following aspects must be respected:

Gas equipment.• Electrical equipment.• Heating installations and heat pumps•

Page 9

Installation, user and maintenance manual – GAHP-GS/WS

Every other standard and regulation concerning the installation of equipment for •

summer and winter air conditioning using gas fuel. The manufacturer does not accept any contractual or extra-contractual liability for any damage caused by errors in installation and/or failure to observe the abovementioned regulations and the instructions supplied by the manufacturer itself.

Once the appliance is installed

The installer must provide the owner with a Declaration stating that the installation has been completed in compliance with state-of-the-art practices, current national and local regulations, and recommendations by the manufacturer.

Before contacting Technical Assistance for commissioning and ﬁrst start-up, the installer must ensure that:

the electricity and gas grids characteristics correspond to the speciﬁcations on the •

nameplate of the appliance;

the gas supply pressure is compliant with the value reported in Table 5.2 Network •

gas pressure → 31 (considering a tolerance of ±15%);

the appliance is fed by the type of gas for which it is designed;•

the gas supply system and water distribution system are sealed;•

the gas and electricity supply systems are properly rated for the capacity required •

by the appliance and are equipped with all safety and control devices required by

current regulations

Check that no safety and control devices are excluded, by-passed or not properly working.

Initial activation procedure

The complete procedure for the ﬁrst start up of the appliance must be carried out by an authorized technician according to the instructions supplied by the manufacturer. To carry out entire procedure correctly, follow the instructions in Paragraph 7.1 PROCEDURE FOR FIRST START UP → 73.

Warranty could be invalidated if the ﬁrst start up is not carried out and validated by an authorized technician.

Operation and maintenance of the appliance

To ensure the correct operation of the appliance and to avoid failures, control of the switching on and oﬀ of the appliance must be done in line with the requirements of the various types of installation.

If the appliance is connected to the Comfort Control Panel (see Figure 6.4 Comfort •

Control Panel e Accessory → 48 detail CCP), the appliance may be switched on and

oﬀ exclusively by the CCP itself.

If the appliance is connected to the DDC (see Figure 6.3 CCI/DDC • → 47), the appli-

ance may be switched on and oﬀ exclusively by the DDC itself.

If the appliance is NOT connected to a CCP/DDC, the appliance may be switched •

on and oﬀ exclusively by a switch on the consent circuit.

Page 10

The appliance must never normally be switched on and oﬀ by shutting oﬀ the power supply upstream of the Controle Device (CCP, DDC or consent switch) before having used the latter ﬁrst and waited for the shutdown cycle to end (approximately 7 minutes). The shutdown cycle terminates when the hydraulic pump switches oﬀ (no parts in motion).

Shutting oﬀ the power supply while the appliance is running can cause permanent damages to internal components!

If the appliance fails to operate correctly, with the consequent indication of the Machine code, follow the instructions of Paragraph 9.1 OVERVIEW AND OPERATING CODES/ TROUBLESHOOTING → 82.

In the event of failure of the appliance and/or breakage of any component, do not attempt to repair and/or restore operation; proceed as follows:

shut oﬀ the appliance immediately (if possible and if no dangerous condition ex-• ists) through the controls (CCP, DDC or permissive switch) and wait for the end of the cooling down cycle (around 7 minutes); immediately get in touch with Technical Assistance.•

Proper ordinary maintenance ensures the eﬃciency and good operation of the appliance over time. Carry out maintenance operations according to the instructions supplied by the manufacturer. For the maintenance of internal components of the appliance, contact Technical Assistance; for other maintenance requirements, see Paragraph 7.2 MAINTENANCE → 77. Any repair of the appliance must be carried out by Technical Assistance, using only original spare parts.

Failure to observe the indications above may compromise the operation and safety of the appliance, and may invalidate warranty.

If the appliance is to be disposed of, contact the manufacturer for its correct disposal.

If the appliance is to be sold or transferred to another owner, ensure that this “Installation, user and maintenance manual” is handed over to the new owner and installer.

3.2 NOTES ON OPERATION OF THE APPLIANCE

The appliance uses the water/ammoniac absorption thermodynamic cycle (H20 – NH3) to produce hot water, drawing the required energy from the ground (GAHP-GS) or, in the case of the GAHP-WS, from ground water. The water/ammonia thermodynamic cycle used in the unit GAHP-GS/WS is realized in a hermitically sealed circuit, directly veriﬁed by the manufacturer to ensure the perfect tightness of all joints, thus making refrigerant top-ups completely unnecessary.

Description and general characteristics

The GAHP-GS/WS is a modulating condensation heat pump: the thermal power modulates from 100% to 50% depending on load, to ensure optimal comfort. The water/water gas absorption heat pump GAHP-WS produces hot water to +65°C for heating purposes and up to +70°C for sanitary hot water. The geothermal absorption heat pump GAHP-GS is available in the following versions:

Page 11

Installation, user and maintenance manual – GAHP-GS/WS

Version • HT: optimised for high temperature heating systems (radiators, fan coils);

it produces hot water to +65°C for heating purposes and up to +70°C for sanitary

hot water.

Version • LT: optimised for low temperature distribution systems (heating ﬂoor, low

temperature radiators); it produces hot water up to +55°C in heating mode and up

to +70°C in Domestic Hot Water mode. The modulating function (both in terms of combustion and ﬂow rate) combined with fumes condensation results in eﬃciencies of up to 172%. The GAHP-GS/WS can operate in ambient temperatures of 0°C to +45°C. The GAHP heat pump can be controlled with the CCP/DDC or with a switch on the consent circuit. During operation, combustion products are exhausted via the discharge terminal at the left side of the appliance (see Figure 3.1 Size → 15). The fumes outlet must be connected to a ﬂue (for further details, see Paragraph 5.7 EXHAUST FLUE GAS → 37). The appliance powered by 230 V 1N 50 Hz electrical power - .

3.3 TECHNICAL MANUFACTURING CHARACTERISTICS

The appliance is supplied with the following technical manufacturing characteristics, control and safety components:

Steel sealed circuit, externally treated with epoxy paint.•

Sealed combustion chamber suited for type C installation.•

Metal mesh radiant burner equipped with ignition electrodes and ﬂame detection •

managed by an electronic ﬂame control box.

Titanium stainless steel shall-and-tube heat exchanger, with external insulation.•

Tube coil heat recovery [AISI 304L] (for acid condensate).•

Control and safety components

S61 electronic board with integrated microprocessor, LCD display and control •

knob, complete with Mod10 auxiliary card to control thermal capacity and prima-

ry pump modulation (see Figures 6.1 Electronic board S61 → 46 and 6.2 Mod10

controller → 47).

Primary circuit water ﬂowmeter (hot side).•

Plant water ﬂowmeter (cold side).•

Sealed circuit high temperature limit thermostat, with manual reset.•

Flue temperature thermostat 120 °C, with manual reset.•

Sealed circuit safety relief valve.•

Safety by-pass valve, between high and low pressure parts of the sealed circuit.•

Antifreeze functions for hydraulic circuit.•

Ionization ﬂame control box.•

Double shutter electric gas valve.•

Condensate discharge sensor.•

Page 12

3.4 TECHNICAL DATA

Table 3.1 – GS HT/LT technical data

GAHP GS LT GAHP GS HT

OPERATION WHEN HEATING

OPERATING POINT B0W50* (Brine inlet 0°C, hot Water outlet +50°C)

G.U.E. gas usage eﬃciency % 150 (1) 149 (1) Thermal power delivered kW 37,7 (1) 37,6 (1) Power recovered from

renewable source

kW 12,4 12,6

OPERATING POINT B0W35* (Brine inlet 0°C, hot Water outlet +35°C)

G.U.E. gas usage eﬃciency % 170 (1) -Thermal power delivered kW 42,6 (1) -Power recovered from

renewable source

kW 17,0 --

OPERATING POINT B0W65* (Brine inlet 0°C, hot Water outlet +65°C)

G.U.E. gas usage eﬃciency % -- 125 (1) Thermal power delivered kW -- 31,5 (1) Power recovered from

renewable source

kW -- 7,9

Thermal capacity

Nominal (1013 mbar - 15°C) kW 25,7

true peak kW 25,2 NOx emission class 5 NOx emission ppm 25 CO emission ppm 36

Hot water delivery temperature

maximum for heating °C 55 65

maximum for DHW °C 70

Hot water return temperature

maximum heating °C 45 55

maximum for DHW °C 60

minimum temperature in

continuous operation**

°C 20 30

Hot water ﬂow rate

nominal l/h 3250 3170

maximum l/h 4000

minimum l/h 1400

Hot water pressure drop

for nominal water ﬂow

(B0W50)

bar 0,49 (2)

Ambient air temperature (dry bulb)

maximum °C 45

minimum °C 0 Thermal diﬀerential nominal °C 10

gas consumption

methane G20 (nominal) m3/h 2,72 (3)

G30 (nominal) kg/h 2,03 (4)

G31 (nominal) kg/h 2,00 (4)

RENEWABLE SOURCE OPERATING CONDITIONS

Renewable source water ﬂow rate (with 25% glycol)

nominal (B0W50) l/h 3020

maximum l/h 4000

minimum l/h 2000 Renewable source pressure drop at nominal ﬂow rate bar 0,51 (2) Renewable source water return temperature maximum °C 45 Renewable source delivery water temperature minimum °C -10 -5

ELECTRICAL SPECIFICATIONS

Power supply

Voltage V 230

TYPE SINGLE PHASE

Frequency

50 Hz

supply

Electrical power absorption nominal kW 0,47 (5) Degree of protection IP X5D

INSTALLATION DATA

Level of acoustic pressure at 10 meters (maximum) dB(A) 39 (7) Minimum storage temperature °C -30 Maximum operating pressure bar 4 Maximum condensation water ﬂow rate l/h 4,0

Water content inside the apparatus

HOT SIDE l 4

COLD SIDE l 3

Water ﬁtting

TYPE F

thread " G 1 1/4

Gas ﬁtting

TYPE F

thread " G 3/4 Safety valve outlet channel ﬁtting " G 1 1/4

Fume outlet

Diameter (∅) mm 80

Residual head Pa 80

Product conﬁguration C63

Page 13

Installation, user and maintenance manual – GAHP-GS/WS

GAHP GS LT GAHP GS HT

Size

width mm 848 (6) height mm 1278 depth mm 690

Weight In operation kg 300

GENERAL INFORMATION

INSTALLATION MODE C13, C33, C43, C53, C63, C83, B23P, B33

COOLING FLUID

AMMONIA R717 kg 7 WATER H2O kg 10

MAXIMUM PRESSURE OF THE COOLING CIRCUIT bar 35

* data tested by VDE and DVGW-Forschungsstelle. ** in transient operation, lower temperatures are allowed

Notes:

As per EN12309-2 evaluated on actual thermal capacity. For operating conditions 1. other than nominal, refer to the Design Manual. For ﬂow rates diﬀerent from the nominal refer to the Design Manual.2. PCI 34.02 MJ/m3 (1013 mbar – 15 ° C).3. PCI 46.34 MJ/kg (1013 mbar – 15 ° C).4. ± 10% depending on power voltage and absorption tolerance of electric motors.5. Overall dimensions excluding fumes pipes (see Figure 3.1 Size 6. → 15). Free ﬁeld, frontal, directionality factor 2.7.

Table 3.2 – WS technical data

GAHP WS

OPERATION WHEN HEATING

OPERATING POINT W10W50

G.U.E. gas usage eﬃciency % 166 (1) Thermal power delivered kW 41,6 (1) Power recovered from

renewable source

kW 16,6

OPERATING POINT W10W65

G.U.E. gas usage eﬃciency % 143 (1) Thermal power delivered kW 35,8 (1) Power recovered from

renewable source

kW 11,5

Thermal capacity

Nominal (1013 mbar - 15°C) kW 25,7

true peak kW 25,2 NOx emission class 5 NOx emission ppm 25 CO emission ppm 36

Hot water delivery temperature

maximum for heating °C 65

maximum for DHW °C 70

Hot water return temperature

maximum heating °C 55

minimum temperature in

continuous operation**

°C 20

Hot water ﬂow rate

nominal l/h 3570

maximum l/h 4000

minimum l/h 1400

Hot water pressure drop

for nominal water ﬂow

rate(W10W50)

bar 0,57 (2)

Ambient air temperature (dry bulb)

maximum °C 45

minimum °C 0 Thermal diﬀerential nominal °C 10

gas consumption

methane G20 (nominal) m3/h 2,72 (3)

G30 (nominal) kg/h 2,03 (4)

G31 (nominal) kg/h 2,00 (4)

RENEWABLE SOURCE OPERATING CONDITIONS

Renewable source water ﬂow rate

nominal (W10W50) l/h 2850

maximum l/h 4700

minimum l/h 2300 Renewable source pressure drop at nominal ﬂow rate bar 0,38 (2) Renewable source water return temperature maximum °C 45 Renewable source delivery water temperature minimum °C 3

ELECTRICAL SPECIFICATIONS

Page 14

GAHP WS

Power supply

Voltage V 230 TYPE SINGLE PHASE

Frequency

50 Hz

supply

Electrical power absorption nominal kW 0,47 (5) Degree of protection IP X5D

INSTALLATION DATA

Level of acoustic pressure at 10 meters (maximum) dB(A) 39 (7) Minimum storage temperature °C -30 Maximum operating pressure bar 4 Maximum condensation water ﬂow rate l/h 4,0

Water content inside the apparatus

HOT SIDE l 4 COLD SIDE l 3

Water ﬁtting

TYPE F thread " G 1 1/4

Gas ﬁtting

TYPE F thread " G 3/4

Safety valve outlet channel ﬁtting " G 1 1/4

Fume outlet

Diameter (∅) mm 80 Residual head Pa 80 Product conﬁguration C63

Size

width mm 848 (6) height mm 1278 depth mm 690

Weight In operation kg 300

GENERAL INFORMATION

INSTALLATION MODE

C13, C33, C43, C53, C63,

C83, B23P, B33

COOLING FLUID

AMMONIA R717 kg 7,7 WATER H2O kg 10

MAXIMUM PRESSURE OF THE COOLING CIRCUIT bar 35

** in transient operation, lower temperatures are allowed.

Notes:

Table 3.3 – PED data

GAHP GS LT GAHP GS HT GAHP WS

PED data

COMPONENTS UNDER PRESSURE

Generator l 18,6 Leveling chamber l 11,5 Evaporator l 3,7 Cooling volume transformer l 4,5 Absorber/condenser l 3,7 Cooling absorber solution l 6,3

Solution pump l 3,3 TEST PRESSURE (IN AIR) bar g 55 SAFETY VALVE PRESSURE CALIBRATION bar g 35

FILLING RATIO

kg of

NH3/l

0,137 0,159

"SEALED SYSTEM" TARE kg 165 FLUID GROUP GROUP 1°

Page 15

Installation, user and maintenance manual – GAHP-GS/WS

3.5 DIMENSIONS AND SERVICE PANEL

Figure 3.1 – Size

LEGEND

A Fumes outlet dia 80 B Combustion air intake dia 80 C Manual reset fumes thermostat D Power cable input E Cooling fan F Appliance on indicator

G Gas ﬁtting dia. ¾" H Hot water return dia. 1"¼ L Renewable source water return dia. 1"¼ M Renewable source water delivery dia. 1"¼ N Hot water delivery dia. 1"¼ Q Safety valve outlet ducting dia. 1"¼

Page 16

Figure 3.2 – Outdoor unit dimensions

LEGEND

A Fumes outlet dia 80 B Combustion air intake dia 80 C Manual reset fumes thermostat D Power cable input E Cooling fan

F Appliance on indicator G Gas ﬁtting dia. ¾" H Hot water return dia. 1"¼ L Renewable source water return dia. 1"¼ M Renewable source water delivery dia. 1"¼ N Hot water delivery dia. 1"¼

Page 17

Installation, user and maintenance manual – GAHP-GS/WS

4 NORMAL OPERATION

In this section you will ﬁnd all the indications necessary for the activation, regulation and control of operation of the appliance depending on the type of installation and control setup.

• TYPE A: controlled by CCP (see Figure 6.4 Comfort Control Panel e Accessory → 48, detail CCP).

• TYPE B: controlled by DDC (see Figure 6.3 CCI/DDC → 47).

• TYPE C: controlled by consent switch (e.g. on-oﬀ switch, ambient thermostat, tim- er, etc.).

4.1 START UP AND SHUT DOWN

Eﬃcient operation and long life of the appliance depend largely on its correct use!

Before activating the appliance, check that:

the gas valve is open;• the appliance is powered electrically: the general electrical switch (GS) must be in • the «ON» position; power supply to the CCP/DDC (if provided) is on;• the installation technician has ensured that the hydraulic circuit is supplied in the • correct conditions.

If these conditions are satisﬁed, it is possible to proceed with activation.

TYPE A: APPLIANCE CONNECTED TO COMFORT CONTROL PANEL (CCP)

The appliance must never normally be switched on and oﬀ by shutting oﬀ the power supply upstream of the Comfort Control Panel before having used the latter ﬁrst and waited for the shutdown cycle to end (approximately 7 minutes). The shutdown cycle terminates when the hydraulic pump switches oﬀ (no parts in motion).

Shutting oﬀ the power supply while the appliance is running can cause permanent damages to internal components!

TYPE B: APPLIANCE CONNECTED TO A DIRECT DIGITAL CONTROLLER (DDC)

If the appliance is connected to a Direct Digital Controller (see Figure 6.3 CCI/DDC → 47) and the DDC is in controller mode, activation and control of the appliance will occur exclusively by operating the DDC. In this case, refer to the manual supplied with it.

The appliance must never normally be switched on and oﬀ by shutting oﬀ the power supply upstream of the DDC before having used the latter ﬁrst and waited for the shutdown cycle to end (approximately 7 minutes). The shutdown cycle terminates when the hydraulic pump switches oﬀ (no parts in motion).

Shutting oﬀ the power supply while the appliance is running can cause permanent damages to internal components!

Page 18

TYPE C: STANDALONE APPLIANCE

Standalone appliances must be activated and deactivated only by means of the consent switch provided by the electrical installation technician. According to requirements, this consent switch may be an on/oﬀ button, an ambient thermostat, a programmable timer, or one or more voltage free contacts controlled by another process. For details about the type of on/oﬀ command installed, contact the plant’s electrical installation technician.

Shutting oﬀ the power supply while the appliance is running can cause permanent damages to internal components!

Start up

Switch on the appliance by means of the on/oﬀ command (placing it in the "ON" position).

Shut down

Switch oﬀ the appliance via the on/oﬀ command (placing it in the "OFF" position).

The shutdown cycle takes approximately 7 minutes to complete.

The on/oﬀ command is essential! Do not switch the appliance on or oﬀ by connecting it to or disconnecting it from the power supply directly, as this may be a source of danger and in any case damage the appliance or the plants connected to it.

Visualising and clearing of operating codes

Operating codes can be generated:

by the S61 on-board controller;•

by the CCP/DDC (if present).• The operating codes generated by the S61 controller are displayed on its screen and can also be viewed on the CCI (if present) or DDC (if present). Operating codes generated by the controller can be cleared through the board itself or from the CCI/DDC (if ﬁtted and allowed).

For a description of the operating codes generated by the electronic board and how to reset them, refer to the list of operating codes contained in Table 9.1 TABLE OF OPERATING CODES generated by the S61 electronic board (ﬁrmware version 3.024) → 82.

The controller (see Figure 6.1 Electronic board S61 → 46) 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.

The Machine Codes generated by the CCI/DDC may only be viewed on the display of the CCI/DDC and may be cleared only through the CCI/DDC.

Page 19

Installation, user and maintenance manual – GAHP-GS/WS

For the operating codes generated by the CCP/DDC, refer to the manuals supplied with the unit.

Operating codes generated by the electronic board during the start-up of the appliance

If the appliance remains inactive for a prolonged period, it is possible that air is present in the gas pipes. In this case, activation fails and the appliance reports the operating code: "u_12" - ﬂame controller arrest (temporary) (see Paragraph 9.1 OVERVIEW AND OPERATING CODES/TROUBLESHOOTING → 82) and after a brief interval the appliance automatically launches the start up procedure again. If code (u_12) is signalled 3 times on successive activation attempts, the code persists, the appliance locks out the ﬂame controller and displays the following operating code: "E_12" - ﬂame controller arrest (see Paragraph

9.1 OVERVIEW AND OPERATING CODES/TROUBLESHOOTING → 82). In this case reset is not automatic. To restore operation of the appliance, carry out a reset of the ﬂame control unit via menu 2 of the controller: the procedure is illustrated in Paragraph 4.3 RESET OPERATIONS → 22. After it is reset, the appliance will make a new attempt to activate. If the appliance locks out several times, contact a Robur TAC by calling the Technical Serv- ice Department of Robur S.p.A. (tel. +39.035.888111). When activation is successful, the appliance is managed by the on-board controller (see following paragraph).

4.2 ONBOARD ELECTRONICS

The following descriptions refer to the S61 controller with ﬁrmware version 3.024.

The appliance is ﬁtted with an S61 microprocessor controller with Mod10 modulation controller mounted above it (see Figure 4.1 On-board controller → 20). The S61 controller, in the electrical panel, controls the appliance and displays data, messages and operating codes. Programming, control and monitoring of the appliance take place by interacting with the display A and knob B shown in Figure 4.1 On-board controller → 20. The CAN-BUS port connects one or several appliances to the CCP (if present) or a DDC (if present). The Mod10 controller (detail D in Figure 4.1 On-board controller → 20) is used for com- bustion modulation and variable rate pump control.

Page 20

Figure 4.1 – On-board controller

S61 + Mod10

LEGEND

A 4 digit display B Knob C CAN port D Mod10 controller

















Description of menu of S61 controller

The parameters and settings of the appliance are grouped in the menus shown on the controller’s display:

Table 4.1 – Menu of electronic board

MENU MENU DESCRIPTION THE DISPLAY SHOWS

Menu 0 VIEW DATA (TEMPERATURE, VOLTAGE, PUMP SPEED, ECC...) 0. Menu 1 VIEW ALL PARAMETERS 1. Menu 2 ENTER ACTIONS 2. Menu 3 USER SET TINGS (THERMOSTATING, SET-POINT, T. DIFFERENTIAL) 3. Menu 4 INSTALLATION TECHNICIAN SETTINGS 4. Menu 5 TECHNICAL ASSISTANCE CENTRE SETTINGS 5. Menu 6 TECHNICAL ASSISTANCE CENTRE SETTINGS (MACHINE TYPE) 6. Menu 7 VIEW DIGITAL IMPUTS 7. Menu 8 (MENU NOT USED) 8. E EXIT MENU E.

Menu list of electronic board

Menus 0, 1 and 7 are Viewing Menus: they only allow the information displayed to be read, and not modiﬁed. Menu 0 shows the appliance operating data in real time. Menu 1 shows the parameters that characterise the operation of the appliance and their current values.

Menu 7 is to be used ONLY by the Robur TAC.

To view the information contained in these menus, proceed as illustrated in the paragraph "How to acces the menus". Menu 2 is an execution menu: it allows the operations of resetting the ﬂame control unit, error reset and the manual defrosting command to be performed. To perform these procedures, see Paragraph 4.3 RESET OPERATIONS → 22. Menu 3 is a Settings Menu: it allows the values displayed to be set. The correct values of these parameters, for optimum performance of the appliance with the plant to be used

Page 21

Installation, user and maintenance manual – GAHP-GS/WS

connected, have already been set during installation. To set new values for the parameters, see Paragraph 5.8 PROGRAMMING OF HYDRAULIC PARAMETERS → 42. Menus 4, 5, 6 and 7 exclusively concern the installation technician and Robur’s authorized Technical Assistance Centre. Menu 8 may currently be selected, but not used.

Display and knob

The controller’s display can be viewed through the glass of the viewing aperture on the front panel of the appliance. Upon activation, all of the LEDs of the display light up for approximately three seconds, and then the name of the board, S61, appears. After around 15 seconds after the appliance powers up, the appliance starts running if the required consent is available. During correct operation the display shows, alternately, the following information: outlet water temperature, inlet water temperature, and the diﬀerence between the two water temperatures (see Table 4.2 Operating information → 21).

Table 4.2 – Operating information

OPERATING MODE: HEATING PARAMETER THE DISPLAY SHOWS

Hot outlet water temperature 50.0 Hot inlet water temperature 40.0 Diﬀerential Temperature (outlet - inlet) 10.0

Example of data visualised on display: water temperature and diﬀerential

If there are operating problems, the display shows, sequentially, the operating codes corresponding to the problem detected. A list of these codes with their description and the procedure to follow to bring the appliance back to correct operation is provided in Paragraph 9.1 OVERVIEW AND OPERATING CODES/TROUBLESHOOTING → 82. The knob is used to display or set parameters, or to execute actions/commands (e.g.: a function or reset), when permitted.

HOW TO ACCESS THE MENUS

To use the knob with the special key supplied with the appliance:•

You will need: the appliance's electrical power switches set to "ON"; the controller's display sequentially shows the operating data (temperature, delta T) regarding the current mode (e.g.: heating) and any active operating codes ("u/E...").

Remove the front panel by removing the ﬁxing screws.1. Remove the cover of the electrical panel to access the knob.2. Use the special key through the hole to operate the knob and access the control-3. ler’s menus and parameters. To display the menus just press the knob once: the display shows the ﬁrst menu: 4. "0." (= menu 0). The display shows “0.”. To display the other menus, turn the knob clockwise; The 5. display will read, in order: "1.", "2.", "3.", "4.", "5.", "6.", "7.", "8." and "E" (see Table 4.1 Menu of electronic board → 20). To display the parameters in a given menu (for example, menu 0), turn the knob 6. until it displays the menu in question (in the example: "0.") and press the knob: the display will show the ﬁrst of the menu’s parameters, in this example "0.0" or "0.40" (= menu 0, parameter "0" or "40").

Page 22

In the same way: 7. turn the knob to scroll through content (menus, parameters, ac-

tions), press the knob to select/conﬁrm the content (access a menu, display/set

a parameter, execute an action, quit or return to the previous level). For example,

to quit the menus, turn the knob to scroll through menus "0.", "1.", "2." etc. until the

controller displays the quit screen "E"; now press the knob to quit.

In the case of menus 0 and 1, the user can view any parameter. For information about menu 2, refer to Paragraph 4.3 RESET OPERATIONS → 22. To set the parameters of me nu 3, refer to Paragraph 5.8 PROGRAMMING OF HYDRAULIC PARAMETERS → 42. The other menus are not for the User: the information in these menus is dealt with in the sections dedicated to the installation technician or Robur TAC.

The special key allows the knob of the electronic board to be operated without opening the cover of the electrical panel, so that operators are protected from live components. When the necessary settings have been completed, put away the special key, replace the cap on the aperture of the electrical panel and reﬁt the front panel of the appliance.

4.3 RESET OPERATIONS

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 or malfunction on the part of the appliance. The cause that has generated the error may be temporary: for example, presence of air in the gas supply line or temporary power failure. The appliance can be reset with controller menu 2, the Comfort Control Panel (if present) or the DDC (if present). In these two latter cases, refer to their documentation.

Reset appliance controller

The Table 4.3 Menu 2 → 22 shows the actions available in menu 2.

For regulatory reasons, the ﬂame controller reset is in a dedicated voice of menu.

Table 4.3 – Menu 2

ACTION REQUIRED FOR EXECUTION SHOWN ON DISPLAY AS

0 Reset ﬂame controller arrest 2. 0 1 Reset other operating codes 2. 1 3 Timed forcing to minimum power 2. 3 4 Timed forcing to maximum power 2. 4 5 Regulation of power 2. 5 E (EXIT MENU) 2. E

The general operating codes of the unit's controller can be reset with actions "0" and "1". Actions "3", "4" and "5" are used to regulate the combustion parameters or for gas type changeovers, and are thus for use only by the installation technician or Robur TAC (for other information refer to Paragraph 7.1 PROCEDURE FOR FIRST START UP → 73).

RESET FLAME CONTROLLER (ACTION "0"):

Reset ﬂame controller arrest; this may be used when the appliance is ﬁrst activated, see Paragraph 4.1 START UP (AND SHUT DOWN) → 17, when the appliance is in a permanent locked condition or after a long period of disuse (see Paragraph 4.5 PROLONGED PERIODS OF DISUSE → 24).

You will need: access to the electrical panel, see Paragraph “Display and knob”.

Page 23

Installation, user and maintenance manual – GAHP-GS/WS

To reset the ﬂame control unit select menu 2, as indicated in the Paragraph "Accessing the Menus"; then proceed as follows:

The display shows: "2." press the knob to access the menu. The display initially 1. shows item "2. 0". Press the knob to display the ﬂashing reset request: "reS1".2. Press the knob again to reset the ﬂame controller. The reset request stops ﬂashing, 3. and again the display shows "2. 0". The reset operation has been performed. To quit the menu, turn the knob clockwise until the "2. E" is displayed. Now press 4. the knob to return to menu selection: "2.". To exit the menu selection and return to the normal visualisation of the parameters 5. of the appliance, turn the knob clockwise until "E" displays; press the knob to quit.

At this point, if the display does not signal any other operating codes, put away the special key, replace the electrical panel cover and reﬁt the front panel.

RESET OTHER OPERATING CODES (ACTION "1"):

Reset other appliance errors; this is required to reset any errors which may occur during operation.

You will need: access to the electrical panel, see Paragraph “Display and knob”.

To reset the controller errors, select menu 2, as indicated in the Paragraph "Accessing the Menus"; Then:

The display shows: "2." press the knob to access the menu. The display initially 1. shows item "2. 0". Turn the knob clockwise to display item "2. 1".2. Press the knob to display the ﬂashing reset request: "rEr1".3. Press the knob again to perform a board error reset. The reset request stops ﬂash-4. ing, and the again display shows "2. 1". The reset operation has been performed. To quit the menu, turn the knob clockwise until the "2. E" is displayed. Now press 5. the knob to return to menu selection: "2.". To exit the menu selection and return to the normal visualisation of the parameters 6. of the appliance, turn the knob clockwise until "E" displays; press the knob to quit.

At this point, if the display does not signal any other operating codes, put away the special key, replace the electrical panel cover and reﬁt the front panel.

4.4 OPERATING SETTINGS

The operations described require basic knowledge of the plant installed and of the S61 controller ﬁtted to the appliance; before proceeding, you must acquire this informa tion, Paragraph 4.2 ON-BOARD ELECTRONICS → 19.

At the moment of installation, the appliance is set up by the installation technician for best operation according to the type of plant installed. Subsequently it is possible to modify the operating parameters, but this is not recommended if not in possession of the necessary knowledge and experience in order to do so. In any case, to set new operating parameters for the appliance see Paragraph 5.8 PROGRAMMING OF HYDRAULIC PARAMETERS → 42.

Page 24

4.5 PROLONGED PERIODS OF DISUSE

When the appliance is to be inactive for a long period, it is necessary to disconnect the appliance before the period of disuse and reconnect it before it is used again. To carry out these operations, contact a reputable hydraulic system installation technician.

Disconnecting the appliance

You will need: the appliance connected to the power/gas supply. Necessary equip ment

and materials.

If the appliance is in operation, switch it oﬀ with the CCP (if present) or DDC (if 1.

present), or the consent switch and wait for the shutdown cycle to terminate com-

pletely (approximately 7 minutes).

Disconnect the appliance from the power supply, putting the external disconnec-2.

tion switch in the OFF position (see GS in Figure 6.6 Electrical wiring diagram → 50)

provided in the appropriate panel by the installation technician.

Close the gas valve.3.

Do not leave the appliance connected to power and gas supply if it is expected to remain inactive for a long period.

If you wish to disconnect the appliance during the winter, one of the following two conditions must be met:

make sure that the hydraulic plant connected to the appliance contains an ad-1.

equate percentage of glycol antifreeze (see Paragraph 5.6 FILLING OF HYDRAULIC

CIRCUIT → 34 and Table 5.3 Technical data for ﬁlling the hydraulic circuit → 36);

activate the antifreeze function, which runs the circulation pumps and the appli-2.

ance when water temperature is below 4°C or in case the outdoor temperature is

lower than 2 °C. To do this, contact your installer. This function requires the appli-

ance to be ALWAYS powered up (electricity and gas) and power failures excluded.

Otherwise the manufacturer declines all contractual and extra-contractual li-

ability for consequent damage. Connecting the appliance before it is used again (to be carried out by the instal ler)

Before starting this procedure, the hydraulic system installation technician must:

ascertain whether the appliance requires any maintenance operations (con-•

tact your authorised Robur Technical Assistance Centre or consult Paragraph 7.2

MAINTENANCE → 77);

check that the water content of the plant is correct; if necessary, top up the cir-•

cuit to at least the minimum quantity (see Paragraph 5.6 FILLING OF HYDRAULIC

CIRCUIT → 34);

if necessary add, to the water of the system (free of impurities), inhibited monoeth-•

ylene glycol antifreeze in a quantity in proportion to the MINIMUM winter temper-

ature in the area of installation (see Table 5.3 Technical data for ﬁlling the hydraulic

circuit → 36);

bring the plant to the correct pressure, making sure that the pressure of the water •

in the plant is not less than 1 bar and not over 2 bar;

Page 25

Installation, user and maintenance manual – GAHP-GS/WS

In case of winter saesonal switch-oﬀ or long period of stopping, we suggest to not empty the hydraulic circuit: in that case possible oxidation process can occur.This oxidation process could damage both the hydraulic system and also the Robur heat pump.It’s important to verify that no leakages occur in the hydraulic circuit that may empty part of the system. The above recommendation is necessary in order to avoid to ﬁll continuously with water 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.

You will need: the appliance disconnected from the electricity/gas supply

open the plant gas supply valve to the appliance and make sure that there is no 1. smell of gas (indicating possible leaks);

if you smell gas, close the gas valve again immediately without operating any other electrical device and, from a safe place, request the assistance of professionally qualiﬁed personnel.

If no smell of gas is detected, connect the appliance to the electricity supply mains 2. via the external circuit breaker provided by the installation technician in the appropriate panel (set the "GS" circuit breaker to the "ON" position, see Figure 6.6 Electrical wiring diagram → 50); power up the CCP (if present) or DDC (if present);3. check that the hydraulic circuit is charged;4. check that the condensate siphon is NOT empty or blocked (see Paragraph 5.5 5. CONDENSATE DISCHARGE → 31); check that inlet/outlet ducts are correctly connected and NOT obstructed.6. switch on the appliance by means of the on/oﬀ command (or DDC if present and 7. in control mode, or via CCP, if present).

Page 26

5 HYDRAULIC INSTALLATION

In this section you will ﬁnd all the instructions necessary for installing the appliance from a hydraulic viewpoint. The hydraulic system installation technician must consult the electrical system installation technician in order to decide upon the correct sequence of the operations to be carried out.

Before realizing hydraulic system and gas supply for the appliance, the professionally qualiﬁed personnel is advised to read Paragraph 3.1 GENERAL INFORMATION → 8, providing important recommendations about safety and references to current regulations.

5.1 GENERAL INSTALLATION PRINCIPLES

Prior to installation, carry out careful internal cleaning of all pipes and every other component to be used both on the hydraulic system and on the fuel supply, in order to remove any debris that may compromise the operation of the appliance.

Installation of the appliance must be carried out in compliance with current regulations regarding design, installation and maintenance of heating and cooling plants and must be undertaken by professionally qualiﬁed personnel in accordance with the manufacturer’s instructions. During the installation stage, observe the following indications:

Check that there is an adequate mains gas supply, in accordance with the manu-•

facturer’s speciﬁcations; see Table 5.2 Network gas pressure → 31 for the correct

supply pressures.

The appliance must be installed inside the building in a suitable room (see EN378). •

The machine room must be protected from freezing.

• The appliance is not designed for outdoors installation. The appliance must

not be exposed to rain and must be installed in a ventilated location in line

with the safety and installation standards applicable to this type of device.

ONLY the outdoor version (see Figure 3.2 Outdoor unit dimensions • → 16) can be

installed outdoor and does not need any speciﬁc protection against the weather

and against freezing.

The front of the appliance must be at least 80 cm away from walls or other ﬁxed •

constructions; the right and left sides must have a minimum clearance of 45 cm;

the minimum rear clearance from walls is 20 cm (see Figure 5.2 Clearances → 28).

The appliance must be installed in such a way that the exhaust ﬂue gas outlet is •

not in proximity of any external air inlet of a building. Respect current regulations

regarding the exhaust ﬂue gas outlet.

Fit a gas cock on the gas supply line.•

Fit antivibration joints on the hydraulic connections.•

5.2 POSITION OF THE APPLIANCE

Lifting the appliance and placing it in position

Do not remove packaging during handling on the installation site.

Packing must only be removed upon ﬁnal installation.

If the appliance has to be lifted, pass slings into the openings in the base supports and use spreader bars to prevent the slings from damaging the casing during handling (see Figure 5.1 Lift GS/WS → 27).

Page 27

Installation, user and maintenance manual – GAHP-GS/WS

The lifting crane and all accessory devices (braces, cables, bars) must be suitable sized for the load to be lifted. For the weight of the appliance, consult Table 3.1 GS HT/LT technical data → 12 and Table 3.2 WS technical data → 13.

The manufacturer cannot be held responsible for any damage occurring during the installation of the appliance.

Figure 5.1 – Lift GS/WS

MOUNTING BASE

Always place the appliance on a levelled ﬂat surface made of ﬁreproof material and able to support the weight of the appliance. If a horizontal support base is unavailable (see also "SUPPORTS and LEVELLING" below), 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 100-150 mm on each side. The dimensions and weight of the appliance are given in Table 3.1 GS HT/LT technical data → 12 and in Table 3.2 WS technical data → 13. Although the appliance produces only moderate vibrations, the use of anti-vibration supports (available as accessories, see SECTION 8 ACCESSORIES → 81) is especially recommended in cases in which resonance phenomena may occur. Moreover, it is advisable to use ﬂexible connections (anti-vibration joints) between the appliance and the hydraulic and gas supply pipes.

SUPPORTS AND LEVELLING

The appliance must be correctly levelled by placing a spirit level on the upper part. If necessary, level the appliance with metal shimming; do not use wooden spacers as these deteriorate quickly.

CLEARANCES AND WARNINGS

Position the appliance so as to maintain minimum clearances from combustible surfaces, walls or other appliances, as illustrated in Figure 5.2 Clearances → 28.

Page 28

Minimum clearances are necessary in order to be able to carry out maintenance operations.

The fumes outlet terminals must be installed in such a way that they do not allow the fumes to collect or return to the circuit in the unit's installation area. The outlet terminal must be constructed in conformity with established regulations.

Figure 5.2 – Clearances

Place the appliance preferably far from environments where silence is required, such as bedrooms, meeting rooms, etc. Evaluate the noise impact of the appliance in consideration of the installation site: avoid installing the appliance in positions that could amplify its running noise (reverb eﬀect).

5.3 HYDRAULIC CONNECTIONS

General indications

The hydraulic installation may be realized using pipes in stainless steel, black steel, •

copper or crosslinked polyethylene for heating/cooling applications. All water

pipes and pipe connections must be properly insulated in compliance with cur-

rent regulations to prevent heat losses and outer condensation.

To prevent icing in the primary circuit during winter time, the appliance is provided •

with antifreeze functions activating the water circulation pump of the primary cir-

cuit (if controlled by the appliance) and the burner of the appliance itself (when

necessary). It is therefore necessary to ensure a permanent supply of electricity

and gas to the appliance throughout the whole winter period. If it is not possible

to ensure a permanent supply of electricity and gas to the appliance, use glycol

antifreeze of the inhibited monoethylene type.

If glycol antifreeze is to be used (see Paragraph 5.6 FILLING OF HYDRAULIC CIR-•

CUIT → 34), DO NOT USE galvanised pipes, as they are potentially subject to corro-

sion phenomena in the presence of glycol.

If using rigid pipes, use vibration damping couplings at the water and gas connec-•

tions on the appliance's service plate to prevent vibration. As other hydronic appliances, 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 5.1 Chemical and physical parameters of water → 29 must be complied with.

Page 29

Installation, user and maintenance manual – GAHP-GS/WS

Table 5.1 – Chemical and physical parameters of water

CHEMICAL AND PHYSICAL PARAMETERS OF WATER IN HEATING/COOLING SYSTEMS PARAMETER UNIT OF MEASUREMENT ALLOWABLE RANGE

pH \ >7

(1)

Chlorides mg/l < 125

(2)

Total hardness (CaCO3)

°f < 15 °d < 8,4

Iron mg/kg < 0,5

(3)

Copper mg/kg < 0,1

(3)

Aluminium mg/l < 1 Langelier’s index \ 0-0,4

HARMFUL SUBSTANCES

Free chlorine mg/l < 0,2

(3)

Fluorides mg/l < 1 Sulphides ABSENT

1 with aluminium or light alloys radiators, pH must also be lower than 8 (in compliance with applicable rules) 2 value referred to the maximum water temperature of 80 °C 3 in compliance with applicable rules

Water quality can be measured through parameters like acidity, hardness, conductivity, chlorides content, chlorine content, iron content and the like.

The presence of free chlorine in the water, in particular, can jeopardize parts of the installation and Robur units. Therefore, please make sure that free chlorine content and total hardness are compliant with the allowable ranges reported in Table 5.1 Chemical and physical parameters of water → 29.

The way the installation is operated can be the cause of possible degradation of water quality. Moreover, abnormally massive water top-up or reintegration can cause a drift of chemical 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 chemical substances for the treatment, since dangers could arise for health, for the environment and for Robur appliances. Several products for water treatment are available on the market. Robur does not perform detailed market surveys. Therefore Robur suggests to contact Companies which are specialized in water treatments. They will be able to suggest the best way how to proceed according to the type of installation. In case washing of the pipes 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 chemical substances for the washing, avoiding the use of substances aggressive for stainless steel or containing/releasing free chlorine. Please make sure the pipes are properly 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 5.1 Chemical and physical parameters of water → 29. 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 S.p.A. (tel.+39 035.888.111). The components below are always to be ﬁtted in proximity to the appliance:

FLEXIBLE JOINTS on water and gas connections of the appliance.• PRESSURE GAGES on the inlet and outlet water pipes.•

Page 30

FLOW REGULATION VALVE on the water inlet pipe (only if the appliance is control-•

led by a CCP/DDC).

WATER FILTER installed on the water inlet pipe.•

ISOLATION BALL VALVE on the water and gas pipes of the installation.•

3 BAR SAFETY VALVE installed on the outlet water pipe.•

PLANT EXPANSION TANK installed in the appliance outlet water pipe.•

EXPANSION TANK for the individual appliance, installed on the water outlet pipe •

(primary side). Provide a plant expansion tank in any case (secondary side), in-

stalled in the water outlet pipe.

The appliance is not equipped with an expansion tank; therefore it is necessary to install a suitable expansion tank, sized for the maximum temperature range and maximum operating water pressure of the plant.

variable rate WATER CIRCULATION PUMP, FOR PLANT WITH A SINGLE APPLIANCE, •

located on the water inlet pipe of the appliance, ﬂowing towards the appliance.

variable rate WATER CIRCULATION PUMP, FOR PLANT WITH A SEVERAL APPLIANCES •

(each appliance have is pump), ﬂowing towards the appliance.

PLANT FILLING SYSTEM: if automatic ﬁlling systems are used, a seasonal check of •

the percentage of monoethylene glycol in the plant is recommended.

For other components to be installed in the system, refer to "Design Manual". For further information or technical support in this regard, contact Robur S.p.A.'s Presales Oﬃce (tel.+39 035.888.111) or visite site www.robur.it.

The operations necessary for the First Activation or Regulation of the appliance must be carried out exclusively by an authorised Robur Technical Assistance Centre (TAC). These operations are described in Section 7 INITIAL ACTIVATION AND MAINTENANCE → 73.

The products' guarantee is void if initial activation is not carried out by a Robur TAC.

5.4 GAS SUPPLY

The installation of gas supply pipes must be compliant with current regulations and norms. The gas supply pressure must be in the range given in Table 5.2 Network gas pressure → 31.

Supplying gas to the appliance at pressures higher than those indicated above can damage the gas valve, resulting in dangerous situations.

LPG systems must be equipped with a ﬁrst stage pressure reducer close to the LPG storage tank, in order to reduce the gas pressure to 1,5 bar, and a second stage pressure reducer, close to the unit, in order to reduce pression from 1,5 bar to the value in agreement with the gas network pressure of the country of installation (see Table 5.2 Network gas pressure → 31).

Exemple for the Italian market: for the G30 gas, from 1,5 bar to 0,030 bar (30mbar); for the G31 gas, from 1,5 bar to 0,037 bar (37mbar).

Page 31

Installation, user and maintenance manual – GAHP-GS/WS

LPG may cause corrosion; piping and ﬁtting materials must be resistant to this corrosion.

Vertical gas pipes must be equipped with a siphon and provided with a drain for the condensate that may form inside the pipe during cold periods. It may also be necessary to insulate the gas pipe to prevent the formation of excessive condensate.

In any case, provide an isolation valve (ball valve) on the gas supply line, to isolate the appliance when required.

Table 5.2 – Network gas pressure

E3-GS; E3-WS; E3-A; GAHP-GS; GAHP-WS; GAHP-A Gas supply pressure Product categories Countries of destination G20 [mbar] G25 [mbar] G30 [mbar] G31 [mbar] G25.1 [mbar] G27 [mbar] G2,350 [mbar]

2H3B/P

AL, BG, CY, CZ, DK, EE, FI, GR, HR, IT, LT, MK, NO, RO, SE, SI, SK, TR

20 30 30

AT, CH 20 50 50

2H3P

AL, BG, CZ, ES, GB, HR, IE, IT, LT, MK, PT, SI, SK, TR

20 37

RO 20 30

2ELL3B/P

DE 20 20 50 50

2Esi3P

FR 20 25 37

2HS3B/P

HU 25 30 30 25

2E3P

LU 20 50

2L3B/P

NL 25 50 50

2E3B/P

20 37 37

2ELwLs3B/P

20 37 37 20 13

2ELwLs3P

20 37 20 13

2E(R)B ; I3P

BE 20 25 37

IS 30

LV 20

3B/P

30 30

For data regarding hourly fuel consumption of the appliance, refer to Tables 3.1 GS HT/LT technical data → 12 and 3.2 WS technical data → 13.

5.5 CONDENSATE DISCHARGE

INDOORS UNITS

The fumes condensate outlet is on the left of the appliance. The appliance is equipped with a siphon with a piece of pipe connected. If you wish to use the pipe supplied with the unit, proceed as follows:

Connect the pipe to a plastic discharge manifold of the proper length.1. The connection between the pipe and the manifold must remain visible.2.

Page 32

Figure 5.3 – Position of condensate discharge and manual reset fumes thermostat

Position of condensate discharge and manual reset fumes thermostat

LEGEND

D Condensate discharge E Hose connecting to condensate siphon F Fumes outlet G Fumes thermostat manual reset

The condensate discharge to the sewer must be:

sized so as to discharge the maximum condensation ﬂow (see Table 3.1 GS HT/LT •

technical data → 12 and Table 3.2 WS technical data → 13 under the respective

heading);

made of materials resistant to acidity with pH 3 to 5;•

sized to ensure a slope of 10 mm per metre of length; if this slope cannot be •

achieved, a condensate pump must be installed near to the discharge;

realized in such a way as to prevent icing of the condensate;•

mixed, for example, with domestic eﬄuents (washing machine, dishwasher, etc.), •

usually alkaline, acting as a buﬀer solution before discharging into the sewer.

Do not discharge the condensate into the guttering, since it may ice and corrode the materials normally used for gutters.

CHARGING THE SIPHON

To charge the siphon, proceed as follows:

Connect the condensate discharge pipe to a drain.1.

Remove the bottom left side panel to access the siphon.2.

3. If no fumes exhaust equipment has been installed: pour 0.2 litres of water di-

rectly into the plastic pipe (detail F in Figure 5.3 Position of condensate discharge

and manual reset fumes thermostat → 32 and check that it is full. Then proceed to

point 6.

4. If the fumes exhaust equipment has already been installed: remove the clamp

securing the plastic pipe E to the siphon (see Figure 5.3 Position of condensate

discharge and manual reset fumes thermostat → 32), disconnect the plastic pipe E

from the siphon and ﬁll it with 0.2 litres of water.

Page 33

Installation, user and maintenance manual – GAHP-GS/WS

Reconnect the plastic pipe E and secure it with its clamp.5. Fit the bottom left side panel.6.

If the appliance is operated with the siphon empty, there is a risk of leaks of exhaust ﬂue gas.

OUTDOORS UNITS

The fumes condensate outlet is on the left of the appliance.

The distance L between the coupling and the base may not exceed 110 mm.

The condensate discharge corrugated pipe, coming out from the side of the un-1. derbase left support, must be connected to a proper discharge header. The connection between the pipe and the manifold must remain visible.2.

Figure 5.4 – Position of condensate discharge outdoors units

Position of condensate discharge outdoors units

LEGEND

A Condensate discharge hose

D Corrugated hose

The condensate discharge to the sewer must be:

sized so as to discharge the maximum condensation ﬂow (see Table 3.1 GS HT/LT • technical data → 12 and Table 3.2 WS technical data → 13 under the respective heading); made of materials resistant to acidity with pH 3 to 5;•

Page 34

sized to ensure a slope of 10 mm per metre of length; if this slope cannot be •

achieved, a condensate pump must be installed near to the discharge;

realized in such a way as to prevent icing of the condensate;•

mixed, for example, with domestic eﬄuents (washing machine, dishwasher, etc.), •

usually alkaline, acting as a buﬀer solution before discharging into the sewer.

Do not discharge the condensate into the guttering, since it may ice and corrode the materials normally used for gutters.

5.6 FILLING OF HYDRAULIC CIRCUIT

After having completed all hydraulic, gas and electrical connections, the installer can proceed ﬁlling the hydraulic circuit, observing the following steps:

You will need: the appliance connected hydraulically and electrically.

COLD CIRCUIT GAHP-GS

Check that the system delivery and return are correctly connected to the appli-1.

ance’s respective ﬁttings (see Figure 3.1 Size → 15).

Activate the automatic air purging valves of the plant and open all thermostatic 2.

valves.

Fill the hydraulic circuit to at least the minimum amount and add inhibited mo-3.

noethylene glycol to a volume percentage of 25% (obligatory minimum required

for correct system operation) or greater depending on the minimum winter tem-

perature in the installation area (see Table 5.3 Technical data for ﬁlling the hydraulic

circuit → 36). Robur recommends using inhibited corrosion resistant monoethyl-

ene glycol.

Check the ﬁlter on the return pipe for impurities; clean it if necessary.4.

Check that the siphon on the drainage condenses has been ﬁlled with water as 5.

indicated in the relative paragraph.

Bring the plant to the correct pressure, making sure that the water pressure is not 6.

less than 1 bar and not over 2 bar, and run the circu lation pump for at least 30 min-

utes. Check the water ﬁlter again and clean it if necessary.

The technical data (Tables 3.1 GS HT/LT technical data → 12 and 3.2 WS technical data → 13) regarding the cold circuit refer to water with 25% glycol content, so that no correction factor need to be applied to Table 5.3 Technical data for ﬁlling the hydraulic circuit → 36.

To facilitate the operation of bleeding air from the hydraulic circuit, the appliance is equipped with an additional manual air bleeding valve.

COLD CIRCUIT GAHP-WS

Check that the system delivery and return are correctly connected to the appli-1.

ance’s respective ﬁttings (see Figure 3.1 Size → 15).

Activate the automatic air purging valves of the plant and open all thermostatic 2.

valves.

Page 35

Installation, user and maintenance manual – GAHP-GS/WS

Fill the hydraulic circuit to at least the minimum amount and add inhibited mo-3. noethylene glycol to a volume percentage in proportion to the minimum winter temperature in the installation area (see Table 5.3 Technical data for ﬁlling the hydraulic circuit → 36). Robur recommends using inhibited corrosion resistant monoethylene glycol.

Glycol antifreeze may not be used on condition that the antifreeze function, which runs the circulation pumps, is activated at the CCI/DDC. This function requires the appliance to be ALWAYS powered up (electricity and gas) and power failures excluded, otherwise the manufacturer declines all contractual and extra-con-

tractual liability for consequent damage.

Check the ﬁlter on the return pipe for impurities; clean it if necessary.4. Bring the plant to the correct pressure, making sure that the water pressure is not 5. less than 1 bar and not over 2 bar, and run the circu lation pump for at least 30 minutes. Check the water ﬁlter again and clean it if necessary.

To facilitate the operation of bleeding air from the hydraulic circuit, the appliance is equipped with an additional manual air bleeding valve.

HOT CIRCUIT (Heating, sanitary hot water)

Check that the system delivery and return are correctly connected to the appli-1. ance’s respective ﬁttings (see Figure 3.1 Size → 15). Activate the automatic air purging valves of the plant and open all thermostatic 2. valves. Fill the hydraulic circuit to at least the minimum amount and add inhibited mo-3. noethylene glycol to a volume percentage in proportion to the minimum winter temperature in the installation area (see Table 5.3 Technical data for ﬁlling the hydraulic circuit → 36). Robur recommends using inhibited corrosion resistant monoethylene glycol.

Glycol antifreeze may not be used on condition that the antifreeze function, which runs the circulation pumps and the appliance, is activated at the CCI/DDC. This function requires the appliance to be ALWAYS powered up (electricity and gas) and power failures excluded, otherwise the manufacturer declines all contractual

and extra-contractual liability for consequent damage.

Check the ﬁlter on the return pipe for impurities; clean it if necessary.4. Check that the siphon on the condensate discharge has been ﬁlled with water as 5. indicated in Paragraph 5.5 CONDENSATE DISCHARGE → 31 under "Loading the siphon". Bring the plant to the correct pressure, making sure that the pressure of the water 6. in the plant is not less than 1 bar and not over 2 bar, and run the circulation pump for at least 30 minutes. Check the water ﬁlter again and clean it if necessary.

Page 36

To facilitate the operation of bleeding air from the hydraulic circuit, the appliance is equipped with an additional manual air bleeding valve.

Use of glycol antifreeze

Glycols, normally used to lower the freezing point of water, are substances in an intermediate state of oxidation which, in the presence of oxidising agents such as oxygen, are transformed into corresponding acids. This transformation 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 condition necessary for the oxidation and degradation of glycol is the presence of an oxidising agent such as oxygen. In closed circuits in which no replenishment of water (and therefore of oxygen) occurs over time, once the oxygen initially present has reacted, the degenerative phenomenon of glycol is hugely inhibited. Most circuits, however, are of the non-sealed type, and therefore receive a more or less continuous supply of oxygen. Therefore it is essential, whatever type of glycol is in question, to verify that it is adequately inhibited and that the necessary checks are regularly performed during its entire period of use.

Antifreeze liquids for cars, which do not contain inhibiting components other than ethylene glycol, are not recommended for cooling and heating plants.

The manufacturer does not accept any contractual or extra-contractual liability for damages caused by the use or disposal of glycol antifreeze.

It is equally important to recall that the use of monoethylene glycol modiﬁes the thermophysical characteristics of the water in the plant, and in particular its density, viscosity and average speciﬁc heat. Always check the date of expiry and/or degradation of the product with the supplier.

The technical data (Tables 3.1 GS HT/LT technical data → 12 and 3.2 WS technical data → 13) regarding the hot circuit refer to non-glycolised water, so that the correction factors of Table 5.3 Technical data for ﬁlling the hydraulic circuit → 36 must be applied to obtain the consequent increased load drop of the system and penalisation of unit efﬁciency in relation to the percentage of monoethylene glycol used.

Table 5.3 Technical data for ﬁlling the hydraulic circuit → 36 should be taken into account for the sizing of the pipes and the circulation pump (for calculation of internal pressure drops of the appliance, refer to Tables 3.1 GS HT/LT technical data → 12 and 3.2 WS technical data → 13). Nevertheless, it is advisable to consult the technical speciﬁcations of the monoethylene glycol used. If automatic loading systems are used, a seasonal check of the quantity of glycol present in the plant is also necessary.

Table 5.3 – Technical data for ﬁlling the hydraulic circuit

% of MONOETHYLENE GLYCOL 10 15 20 25 30 35 40

WATER-GLYCOL MIXTURE FREEZING TEMPERATURE -3°C -5°C -8°C -12°C -15°C -20°C -25°C PERCENTAGE OF INCREASE IN PRESSURE DROPS -- 6% 8% 10% 12% 14% 16% LOSS OF EFFICIENCY OF UNIT -- 0,5% 1% 2% 2,5% 3% 4%

If the percentage of glycol is ≥ 30% (for ethylene glycol) or ≥ 20% (for propylene glycol):

then parameter 182 in menu 4 must be set to “1” (at the installer’s care).•

Page 37

Installation, user and maintenance manual – GAHP-GS/WS

5.7 EXHAUST FLUE GAS

The appliance is homologated for conﬁguration as a type C and B installation. The following installations are possible: C13, C33, C43, C53, C63, C83, B23P and B33. The appliance is supplied in conﬁguration C63. We list below the various types of installation and the necessary accessories.

For the sizing of the fumes exhaust pipe and the combustion air pipe, refer to Table 5.9 Fumes temperature and ﬂow → 41.

In case of installation of more than one unit GS/WS connected to one ﬂue pipe, it’s necessary to insert one clapet valve for each installed unit, in order to avoid the reﬂux of the ﬂue through the unit that is not working.

Figure 5.5 – C13 type installation

Wall mounted co-axial outlet DN80/125 or DN60/100

LEGEND

See table below

The following table indicates which accessories are required for the installation shown in Figure 5.5 C13 type installation → 37

Table 5.4 – C13 type installation: wall mounted co-axial terminal

DN Re f. Description

80/125

A DN80/125 2xDN80 double ﬁtting B Co-axial wall terminal DN80/125

E Co-axial pipe 80/125 L=1 m E Co-axial pipe 80/125 L=2 m F Co-axial bend 90° 80/125 F Co-axial bend 45° 80/125

60/100

A DN60/100 2xDN80 double ﬁtting B Co-axial wall terminal DN60/100

E Co-axial pipe 60/100 L=1 m E Co-axial pipe 60/100 L=2 m F Co-axial bend 90° 60/100 F Co-axial bend 45° 60/100

Page 38

Figure 5.6 – C33 type installation

Roof mounted co-axial outlet DN80/125 or DN60/100

LEGEND

See table below

The following table indicates which accessories are required for the installation shown in Figure 5.6 C33 type installation → 38.

Table 5.5 – C33 type installation: roof mounted co-axial terminal

DN Re f. Description

80/125

A DN80/125 2xDN80 double ﬁtting B Co-axial roof terminal 80/125 C Tile adaptor for sloped roof D Tile adaptor for ﬂat roof E Co-axial roof pipe 80/125 L=1 m E Co-axial roof pipe 80/125 L=2 m F Co-axial bend 90° 80/125 F Co-axial bend 45° 80/125

60/100

A DN60/100 2xDN80 double ﬁtting B Co-axial roof terminal 60/100 C Tile adaptor for sloped roof D Tile adaptor for ﬂat roof E Co-axial roof pipe 60/100 L=1 m E Co-axial roof pipe 60/100 L=2 m F Co-axial bend 90° 60/100 F Co-axial bend 45° 60/100

Page 39

Installation, user and maintenance manual – GAHP-GS/WS

Figure 5.7 – C43 type installation

Fumes/combustion air collective pipes

LEGEND

See table below

The following table indicates which accessories are required for the installation shown in Figure5.7 C43 type installation → 39

Table 5.6 – C43 installation.

DN Re f. Description

80/125

A DN80/125 2xDN80 double ﬁtting B Wall duct DN 80/125 C Flue mount kit DN80 D Flue cover DN80 with terminal

E Co-axial bend 90° 80/125 E Co-axial bend 45° 80/125 F Co-axial pipe DN80/125 L=1 m

F Co-axial pipe DN80/125 L=2 m G Pipe DN 80 L=1 m G Pipe DN 80 L=2 m H Bend 90° DN80

L Bend 45° DN80

60/100

A DN60/100 2xDN80 double ﬁtting B Wall duct DN 60/100 C Flue mount kit DN60 D Flue cover DN60 with terminal

E Co-axial bend 90° DN60/100

E Co-axial bend 45° DN60/100

F Co-axial pipe DN60/100 L=1 m

F Co-axial pipe DN60/100 L=2 m G Pipe DN 60 L=1 m G Pipe DN 60 L=2 m H Bend 90° DN60

L Bend 45° DN60

Page 40

Figure 5.8 – C53 type installation

Roof mounted ﬂue, wall mounted air intake

LEGEND

See table below

The following table indicates which accessories are required for the installation shown in Figure 5.8 C53 type installation → 40

Table 5.7 – C53 type installation: Roof mounted ﬂue, wall mounted combustion air intake

DN Re f. Description

Double intake/exhaust kit DN80B C D Flue cover DN80 with terminal E Flue mount kit DN80 F Pipe DN80 L = 1 m F Pipe DN80 L = 2 m G Bend 90° DN80 H Bend 45° DN80

Page 41

Installation, user and maintenance manual – GAHP-GS/WS

Figure 5.9 – C53 type installation

Double wall mounted exhaust

LEGEND

See table below

The following table indicates which accessories are required for the installation shown in Figure 5.9 C53 type installation → 41

Table 5.8 – C53 type installation

DN Ref Description

Wall mounted terminal kit DN80C

F Pipe DN80 L=1 m

F Pipe DN80 L=2 m G Bend 90° DN80 H Bend 45° DN80

Double wall mounted exhaust

Table 5.9 – Fumes temperature and ﬂow

Gas type Thermal capacity CO2 (%) TF (C°) Fumes ﬂow (kg/h) Prevalenza residua (Pa)

G20

Nominal 9,10 65 42 80

Minimum 8,90 46 21 80

G25

Nominal 9,10 63,6 42 80

Minimum 8,90 45,7 21 80

G25.1

Nominal 10,10 65 45 80

Minimum 9,60 46 23 80

G27

Nominal 9,0 64 42 80

Minimum 8,5 46 21 80

G2.350

Nominal 9,00 62,7 42 80

Minimum 8,70 46,8 22 80

G30

Nominal 10,40 65 43 80

Minimum 10,10 46 22 80

G31

Nominal 9,10 65 48 80

Minimum 8,90 46 24 80

Page 42

5.8 PROGRAMMING OF HYDRAULIC PARAMETERS

The operations described in this paragraph are necessary only if the appliance is not connected to a DDC or to a CCP.

If the appliance is connected to a CCP/DDC, follow the instructions given in the CCP/DDC manuals exclusively.

This paragraph explains how to set the hydraulic parameters on the electronic board of the appliance. Users not familiar with the basic procedures for the use of the board should refer to Paragraph 4.2 ON-BOARD ELECTRONICS → 19. To conﬁgure the appliance, access menu 3 of the electronic board. With regard to the hydraulic conﬁguration, six parameters may be set: select the letter E to exit to the previous menu.

Table 5.10 – Parameters for hydraulic conﬁguration

HYDRAULIC PARAMETER THE DISPLAY SHOWS

Select cold water thermostating 3. 73 Cold water set-point 3. 75 Cold water temperature diﬀerential 3. 76 Hot water thermostat control selection 3.160 Hot water setpoint 3.161 Hot water temperature diﬀerential 3.162 (EXIT MENU) 3. E

Menu 3 parameters.

Description of parameters:

Water thermostat control, parameters 73 and 160. This parameter takes two val-• ues: "0" and "1". Value "0" indicates that the appliance's "activation/deactivation" temperature is to be read by the water probe at the appliance’s INTAKE. Value "1" indicates that the appliance’s "activation/deactivation" temperature is to be read by the water probe at the appliance’s OUTLET. Water set-point, parameters 75 and 161: these parameters set the water tempera-• ture that, when reached, causes the appliance to be deactivated (when the power modulation is not active - parameter 181). Water diﬀerential, parameters 76 and 162: these parameters represent an interval • in degrees that, when added to the set-point, deﬁnes the temperature at which the appliance is reactivated. These parameters are used only if the power modulation

is NOT active (parameter 181). The appliance functions by heating/cooling the water until it reaches the set-point temperature. At this point, if the power modulation is not active (parameter 181), it switches oﬀ. The temperature of the water goes down again until it reaches the temperature corresponding to "set-point + diﬀerential"; when this is reached the appliance switches on again. Example (heating): Thermostating: reading from inlet sensor. Parameter 181: 0 (power modulation NOT active) Set-point: +40.0°C Diﬀerential: - 2.0° C

The appliance is functioning: the water in the plant heats up until it reaches the •

set-point temperature = +40°C.

Page 43

Installation, user and maintenance manual – GAHP-GS/WS

The appliance switches oﬀ: the water in the plant, returning from use, becomes • progressively cooler, until it reaches a temperature of 38°C = 40°C - 2°. The appliance switches on again, and the plant water heats up again.•

The cycle is repeated.• The following procedure illustrates in detail how to conﬁgure the parameters on the electronic board inside the appliance.

If the procedures for how to access the knob and menus are not familiar, see paragraphs "Display and knob" and "How to access the menus" and following.

To set the parameters of menu 3:

You will need: the appliance on and access to the electrical panel, see "Display and knob".

Access menu 3. The display shows the ﬁrst parameter of the menu, number 73.

Turn the knob clockwise to scroll through the parameters: 3.73, 3.75, 3.76, 3.160, 1.

3.161, 3.162; lastly the letter E is shown.

Press the knob when a parameter is displayed to select it, or when E is displayed to 2.

exit the menu.

For example, to set parameter 161 (hot water set-point), proceed as follows:3.

· Select the parameter: turn the knob until the display shows 3.161;

· Press the knob to access the value of the parameter; the display shows the previ-

ously set value, which ﬂashes, for example 40.0 °C;

· Turn the knob to modify the value of the parameter;

· Press the knob to conﬁrm the value selected; the display shows the current pa-

rameter again, 3.161. The new value for this parameter has been set.

If other parameters are to be modiﬁed, proceed as described previously, and then 4.

exit from the menu by pressing the knob on the letter E. To exit the menu, turn the knob clockwise until E is displayed, then press it to conﬁrm. For details regarding the codes displayed by the appliance during operation, see Paragraph

9.1 OVERVIEW AND OPERATING CODES/TROUBLESHOOTING → 82.

5.9 SAFETY VALVE DISCHARGE ROUTING

Standard EN378-3 requires that potential leaks of refrigerant be discharged outside the machine room. To meet this requirement, the appliance has an outlet on its top panel (detail Q of Figure

3.1 Size → 15) to which a pipe can be ﬁtted to route the refrigerant vented by the safety valve on the sealed circuit out of the machine room.

DO NOT ﬁt any check equipment (valve, etc.) between outlet Q (Figure 3.1 Size → 15) and the external discharge of the evacuation pipe. The manufacturer does not accept any contractual or extra-contractual liability for any damage caused by improper use of the said pipe.

The missing right installation of the canalization of the security valve might cause dangerous situations inside the installation room. The unit can be switched-on only if the right canalitation is installed, as indicated in the following.

Install the pipe as instructed below.

Page 44

You will need: the appliance in its permanent location.

Remove the plastic cap on the top panel (detail Q of Figure 3.1 Size 1. → 15). Connect a carbon steel pipe to the Q outlet, which must have an initial straight 2. tract of at least 30 cm. The maximum length of the pipe is indicated in Table 5.11 Maximum coolant pipe length → 44). Fix the pipe to the nut on the outlet (5.10 Over-pressure valve 3. → 44) and make sure to ﬁt the Teﬂon gasket provided with the appliance for this purpose.

Figure 5.10 – Over-pressure valve

Position of the valve

LEGEND

Detail of the refrigerant ﬂexible ducting pipe

The evacuation terminal must be outside the machine room, away from doors, 4. windows and ventilation openings; the terminal must be located at a height such as to prevent any leaks of refrigerant ﬂuid being inhaled by persons walking in the vicinity of the terminal itself.

The refrigerant discharge pipe MUST be in carbon steel. NEVER use copper or derivate alloys such as brass for this purpose.

The missing canalitation of the security valve might cause danger conditions inside the installation room.

Table 5.11 – Maximum coolant pipe length

Diameter DN Maximum length (m) 1" 1/4 32 30 2" 52 60

Maximum coolant pipe length

Page 45

Installation, user and maintenance manual – GAHP-GS/WS

6 ELECTRICAL INSTALLATION

This section illustrates the operations to perform for the correct electrical installation of the appliance, and contains electrical diagrams that may be of use in the event of maintenance operations.

Installation of the appliance may only be carried out by ﬁrms that are qualiﬁed in accordance with current legislation in the country of installation, i.e. by professionally qualiﬁed personnel.

Before proceeding with operations to create the electrical plant of the appliance, the professionally qualiﬁed personnel concerned are advised to read Paragraph 3.1 GENERAL INFORMATION → 8: it provides important information regarding installation safety and references to current norms.

Installation that is incorrect or that does not comply with current legislation may cause damage to people, animals or things; Robur S.p.A. is not responsible for any damage caused by installation that is incorrect or that does not comply with current legislation.

Figure 6.1 Electronic board S61 → 46 and Table 6.1 S61 electronic controller + Mod10 legend → 46 provide details of input and ouput of the S61 electronic board. The auxiliary electronic card Mod10 is shown in detail in Figure 6.2 Mod10 controller → 47. The appliance and the system can be controlled and regulated in one of the following ways depending on the type of installation and control system selected:

• TYPE A: controlled by CCP (see Figure 6.4 Comfort Control Panel e Accessory → 48,

detail CCP).

• TYPE B: controlled by DDC (see Figure 6.3 CCI/DDC → 47).

• TYPE C: controlled by consent switch (e.g. on-oﬀ switch, ambient thermostat, tim-

er, etc.).

In Paragraph 6.1 ELECTRICAL DIAGRAM OF THE APPLIANCE → 49 may be found the Elec- trical diagrams of the appliance.

Page 46

Figure 6.1 – Electronic board S61

SCH S61

LEGEND

See table below

Table 6.1 – S61 electronic controller + Mod10 legend

CODE DESCRIPTION SCH1 Electronic board S61 SCH3 Mod10 electronic controller (see ﬁgure for further details) A1, A2 Auxiliary inputs ENC Knob F1 Fuse T 2A F2 Fuse F 10A F3 Fuse T 2A F4 Fuse T 3.15A FAN (BK, WH, BR) Cooling fan output FL Flow switch input FS5 (24V AC) Controller power 24-0-24 Vac IGN.BOX (L, N) Flame controller power 230 V AC J1 CAN BUS jumper J10 Jumper N.O. contact J82 W10 board connector (on Mod10) JP10 6-pole ﬂame controller connector JP12 Fumes sensor or generator ﬁn sensor input JTA G S61 controller programming connector MAIN 230V (L,N) S61 controller power 230 V AC N.O. contact Pump contact, N.O. P7 (R, W, Y, o) Consent inputs P8 (GND, L, H) CAN BUS connector PUMP 230V (L,N) Hydraulic pump power output SPI Communication port with Mod10 controller SRT1 Hydraulic pump rotation sensor input SRT2 Hot water ﬂowmeter input TA Ambient temperature probe input TA1 Hot water delivery temperature probe input TA2 Hot water return temperature probe input TCN Combustive air temperature probe input TF Exhausted gas thermostat input

Page 47

Installation, user and maintenance manual – GAHP-GS/WS

CODE DESCRIPTION TG Generator temperature probe input THMF Cold water delivery temperature probe input THRF Cold water return temperature probe input TL Generator limit thermostat input

Figure 6.2 – Mod10 controller

Mod10 controller

LEGEND

HFLOW Not used CFLOW Condensation water sensor control J51 SPI connector HPMP Primary circuit hot water pump control

output (0-10 V) [A/GS/WS]

CPMP Cold side water pump control output

[GS/WS] NC1-C1 Status indication of locking warnig/error CN5 Blower control J82 W10 auxiliary controller connector J83 W10 cable shielding connection W10 CN1 Inputs 0-10V (not used)

Figure 6.3 – CCI/DDC

Page 48

Figure 6.4 – Comfort Control Panel e Accessory

LEGEND

CCP Comfort Control Panel Components componing the CCP AVS37 Comfort Control Siemens RVS61 System controller and set-point CCI Comfort Control Interface PLC Programmable Logic Control AVS75 Expansion

Optional components to predict QAA55 Base room unit QAA75 Room unit QAA78 Radio room unit ASV71 Antenna AVS13 Transmitter QAC34 External temperature probe LPS Central communications for remote control

Page 49

Installation, user and maintenance manual – GAHP-GS/WS

6.1 ELECTRICAL DIAGRAM OF THE APPLIANCE

Figure 6.5 – Appliance internal wiring diagram

LEGEND

SCH1 S61 circuit board

SCH2 W10 circuit board

SCH3 Mod10 circuit board

TER Appliance power terminal block

CNTBOX Flame controller

PWRTR Board transformer

BLW Blower

PMP Hydraulic pump

IGNTR Ignition transformer

IGN Ignition electrodes

FLS Flame sensor

LS Gas valve ON indicator lamp

GV Gas solenoid valve

THMF Cold water delivery temperature sensor

THRF Cold water return temperature sensor

TMIX Combustion air temperature sensor

TA Ambient air temperature sensor

TG Generator temperature sensor

THMC Hot water delivery temperature sensor

THRC Hot water return temperature sensor

REED Hydraulic pump rotation sensor

TF Fumes temperature sensor or generator ﬁn sensor

TC Manual fumes thermostat

TL Generator limit thermostat

FM Hot side ﬂowmeter

FL Renewable source water ﬂow switch

CWS Condensation water sensor

MA Terminal block

TK Condensate discharge heating element thermostat

FS Condensate hose heating element

Page 50

6.2 HOW TO CONNECT THE APPLIANCE ELECTRICALLY

Before making electrical connections, make sure not to work on live elements.

You will need: the appliance in its permanent location.

Use a cable type FG7(O)R 3Gx1.5 for the power supply to the appliance.1. Connect power supply with the cable indicated at point 1, ﬁtting close to the appli-2. ance a two-pole isolator switch with 3 mm distance between contacts (see detail «GS» in Figure 6.6 Electrical wiring diagram → 50) and two 5A fuses type T or a 10A magnetothermic breaker. Prepare the electrical connection in such a way that the ground wire is longer than 3. the live wires. In this way it will be the last wire to be torn away if the cable is accidentally pulled oﬀ; this will ensure the ground connection.

Electrical safety is ensured only when the appliance is correctly connected to an eﬃcient grounding system, realized according to current safety regulations. Do not use gas pipes as grounding.

Figure 6.6 – Electrical wiring diagram

Example of connection of appliance to 230 V 1 N - 50 Hz electricity supply

LEGEND

TER terminal board L phase N neutral Components NOT SUPPLIED GS general switch

6.3 TYPE A COMFORT CONTROL PANEL

This paragraph illustrates the operations to be performed when one or more appliances are connected to a Comfort Control Panel (CCP). In particular:

What is the CAN BUS cable.1. How to connect the CAN BUS cable to the appliance's electronic board2. How to connect the CAN BUS cable to the Comfort Control Panel3. How to connect the Comfort Control Panel4. How to connect the system water circulation pumps5.

For speciﬁc information regarding the operation and programming of the CCP, refer to the speciﬁc manuals supplied with it.

The appliance and the CCP communicate with each other via a CAN bus network.

Page 51

Installation, user and maintenance manual – GAHP-GS/WS

The CAN bus network is characterized by a series of elements (appliances or CCPs) called nodes, connected to each other by a three-wire cable. The nodes are of two types: terminal nodes and intermediate nodes.

Terminal nodes are appliances or CCPs that are connected to one other element • only. Intermediate nodes are appliances or controllers which are connected to two other •

elements. The diagram in Figure 6.7 Example of CAN BUS → 51 gives an example of a CAN BUS network: 3 appliances are connected to each other and to 1 CCP. Appliance D and the CCP (A) are terminal nodes, while appliances C and B are intermediate nodes as they are connected to 2 elements.

One CCP can control up to 3 appliances of the same type.

Figure 6.7 – Example of CAN BUS

Terminal nodes and intermediate nodes

LEGEND

A Controller

B-C-D Appliance 1-4 Terminal nodes

2-3 Intermediate nodes

What is the CAN BUS cable

The cable to be used must be suitable for CAN BUS applications.

The following table gives details of some types of CAN BUS cables, grouped according to the maximum distance covered by each single type.

Table 6.2 – CAN BUS cables type

CABLE NAME SIGNAL / COLOR MAX LENGTH Note Robur

Ordering Code O-CVO008

ROBUR NETBUS H= BLACK L= WHITE GND= BROWN 450 m

Honeywell SDS 1620

In all cases the fourth conductor should not be used

BELDEN 3086A

H= BLACK L= WHITE GND= BROWN 450 m

TURCK type 530

DeviceNet Mid Cable

TURCK type 5711 H= BLUE L= WHITE GND= BLACK 450 m

Honeywell SDS 2022

TURCK type 531 H= BLACK L= WHITE GND= BROWN 200 m

Example types of cables used to connect the CAN network.

For total distances lower than 200 m and networks with a maximum of 4 nodes (example: up to 3 GAHP + 1 controller) a simple shielded cable 3x0.75 mm may be used.

Page 52

As shown in Table 6.2 CAN BUS cables type → 51, the CAN connection requires a CAN BUS cable with 3 cores. If the cable available has more than 3 coloured wires, use the wires with the colours indicated in 6.2 CAN BUS cables type → 51 and cut the remaining ones. The ROBUR NETBUS cable is available as an accessory, see Section 8 ACCESSORIES → 81.

How to connect the CAN BUS cable to the appliance's electronic board

The CAN BUS cable must be connected to the dedicated terminals on the appliance’s electronic board, as shown below (see Figure 6.8 CAN BUS cable connection → 52).

Figure 6.8 – CAN BUS cable connection

Example of a single CAN bus cable connected to the board

LEGEND

A protective isolating tape B shielding of CAN BUS cable (pre-

wired to last unit)

C cable bracket (the CAN BUS cables

of an intermediate node are present) D CAN BUS/circuit board connector E wires (6) of the CAN BUS cable

(intermediate node)

Before working on the electrical panel of the appliance, make sure that power supply is oﬀ.

Cut a length of cable long enough to allow installing it without kinking.1. On one end of the cable, remove the jacket for a length of approximately 70-80 2. mm, taking care not to cut the shielding (metal mesh and/or aluminium sheet and, if present, the bare connector in touch with the shield) and the wires contained within. If the cable is too thin to be held in place in the cable holding bracket (detail C in 3. Figure 6.8 CAN BUS cable connection → 52), make it thicker by wrapping insulating tape around the jacket close to the stripped part (to an approximate diameter of 12-13 mm). Pull back the shielding on the jacket; apply isolating tape to the end of the shield-4. ing as pulled back (detail A, Figure 6.8 CAN BUS cable connection → 52). If the appliance is a 5. terminal node of the network connect the three coloured wires to the orange connector as shown in detail "A" of Figure 6.9 Electrical wiring diagram → 53. Respect the correct indications L, H, GND provided in Table 6.2 CAN BUS cables type → 51, on the ﬁgure and on the electronic board below the connector. If the appliance is an 6. intermediate node repeat the operations from step 2 to step 5 for the other cables required (in this way you will have two cable lengths each one without the jacket on one end). Twist together the cores with the same color and connect them to the orange connector, as shown in detail "B" of Figure 6.9 Electrical wiring diagram → 53.

Page 53

Installation, user and maintenance manual – GAHP-GS/WS

Fix the CAN BUS cable (or two cables, according to the type of node being con-7. nected) to the holding bracket in the upper part of the electrical panel so that the pulled-back shielding is in solid touch with the metal bracket. The cables must be ﬁrmly held in place by the bracket if pulled. In order to position the jumpers on the electronic board according to the type of node being conﬁgured: If the appliance is a • terminal node on the network (i.e. 3 wires are inserted in the orange connector on the board): set the jumpers as shown in detail "A" of Figure

Figure 6.9 – Electrical wiring diagram

Connection cable CAN BUS to electronic board: detail A case "terminal node", detail B case "intermediate node"

LEGEND

SCH electronic board GND Common data L Data signal LOW

H Data signal HIGH J1 Jumper CAN-BUS in board A Detail case "terminal node" (3 wires;

J1=jumper "closed")

B Detail case "intermediate node" (6

wires; J1=jumper "open")

P8 Port can/connector

After ﬁnished with all the above operations, close the electrical panel and reﬁt the 8. front panel of the appliance.

How to connect the CAN BUS cable to the Comfort Control Panel

The CAN bus cable is connected to the speciﬁc orange connector (P8) supplied with the CCP in a bag.

Before working on the Comfort Control Panel, make sure that it is oﬀ.

The CCP, like the controller on the appliance, has jumpers that must be moved so that it can be conﬁgured as an intermediate or terminal node. The position of the jumpers on a new CCP is CLOSED.

To connect the CAN bus cable to a CCP:

You will need: the Comfort Control Panel not powered up.

Open the Comfort Control Panel’s electrical panel with the handle on its left.1.

Page 54

Depending on the type of node being conﬁgured, set the CCI’s jumpers J21 as 2. shown in detail "A" or detail "B" in Figure 6.11 Connection of CCI to CAN-BUS network → 55. If necessary, open the CCI’s back panel (4 screws); after jumpers J21 have been correctly positioned, close the cover again and retighten the 4 bolts. Cut a length of cable long enough to allow installing it without kinking.3. Remove the sheath for a length of approximately 70-80 mm, taking care not to cut 4. the shielding (metallic shield and/or aluminium sheet and, if present, the bare connector in contact with the shield) and wires contained inside. Roll the shielding and connect it to a 4-mm eyelet terminal, as illustrated in Figure 5.

6.10 Connection from CAN BUS to connector P8 → 55, details C and D. Now proceed as follows: If the CCP is a 6. terminal node of the network connect the three coloured wires to the orange connector "P8", as shown in detail "A" of Figure 6.11 Connection of CCI to CAN-BUS network → 55. Observe the terminal markings L, H, GND (on the CCI's board at the base of the socket "P8") which are given both in Table 6.2 CAN BUS cables type → 51 and in the example. If the CCP is an 7. intermediate node repeat the operations from step 2 to step 4 for the other length of CAN bus cable required. Connect the six coloured wires to the orange connector "P8", following the instruction provided in detail "B" of Figure

6.11 Connection of CCI to CAN-BUS network → 55. Observe the terminal markings L, H, GND (on the CCI's board at the base of the socket "P8") which are given both in Table 6.2 CAN BUS cables type → 51 and in the example. Insert the orange connector "P8" with the wires ﬁrst into the opening prepared in 8. the cover of the CCI, and then into the appropriate socket on the CCI itself, making sure it is correctly inserted. Use the rear cover bolts located near the CAN BUS socket to secure the 4-mm 9. eyelet (or 2 eyelets) (detail D, Figure 6.10 Connection from CAN BUS to connector P8 → 55). The cable should be secured against pulling out.

The CCI has jumpers J21: the position of the jumpers, depends if the CCI is an intermediate or terminal node, must be as shown in Figure 6.11 Connection of CCI to CAN-BUS network → 55.

The CCI is equipped with a backup battery which retains the memory settings in case of power failure. The backup battery lasts approximately 7 years, after which time it must be replaced by an authorised Robur Technical Assistance Centre.

Page 55

Installation, user and maintenance manual – GAHP-GS/WS

Figure 6.10 – Connection from CAN BUS to connector P8

Connection detail of cable CAN BUS.

LEGEND

A Insulating tape to protect board/shield B CAN BUS cable wires C CAN bus cable shield D terminal and screw for ﬁxing











Figure 6.11 – Connection of CCI to CAN-BUS network

Jumpers J21 closed

LEGEND

CCI Comfort Control Interface P8 Orange connector J21 Jumpers CAN-BUS on CCI board

A detail of "terminal node" case (3 wires; J21=jumper "closed") B Detail of "intermediate node" case (6 wires; J21=jumper "open") H,L,GND Data signal wires

The following wiring diagrams show the connection of the CCI to 1 appliance (Figure 6.12 Connection of CCI to 1 appliance → 56) and 3 appliances (Figure 6.13 Connection of CCI to 3 appliances → 57) respectively.

Page 56

Figure 6.12 – Connection of CCI to 1 appliance

Connection of CCI to 1 appliance

LEGEND

SCH S61 controller

CCI Comfort Control Interface

Page 57

Installation, user and maintenance manual – GAHP-GS/WS

Figure 6.13 – Connection of CCI to 3 appliances

Connection of CCI to 3 appliances

LEGEND

SCH S61 controller

CCI Comfort Control Interface

How to connect the Comfort Control Panel

You will need: the appliance disconnected from the electricity supply

Page 58

The Comfort Control Panel’s power cord must be type tipo FG7 3Gx2.5mm1.

. the power supply is 230V AC 1N 50Hz. Cut a suitable length of cable.2. The cable must be connected to the terminal block on the bottom right of the 3. Comfort Control Panel. First make a hole in the electrical cabinet near to the terminal block and pass the cable through it. Connect the cable to the terminal block as given in Figure 6.6 Electrical wiring dia-4. gram → 50 and ﬁt a 10 A thermal cut out upstream of the Comfort Control Panel.

How to connect the system water circulation pumps

Before making the electrical connections, make sure that work is not carried out on live elements.

To optimise the operation of the appliance install, on the primary circuit, variable rate WILO STRATOS PARA pumps (see Section 8 ACCESSORIES → 81), which are controlled and modulated with the Robur Mod10 controller.

No other models pump are supported.

The instruction for connecting the WILO STRATOS PARA pumps are given below (see Section 8 ACCESSORIES → 81). Each WILO pump includes its power cord (length 1.5 metres) and cable for connection to the appliance’s controller (1.5 metres). For longer cable runs, use a shielded 2x0.75 mm2 0-10V signal cable and a FG7 3Gx2.5mm2 power cord.

You will need: the appliance in its permanent location.

Check that power supply is oﬀ.1. Remove the front panel of the appliance and the cover of the electrical panel.2. Connect the brown wire of the WILO STRATOS PARA pump on the cold side to the 3. terminal "-" of connector CPMP on the Mod10 board. Connect the white wire of the WILO STRATOS PARA pump on the cold side to the terminal "+" of the connector CPMP on the Mod10 board. Insulated black and blue wires (see Figure 6.14 Wiring diagram for connection of Wilo variable rate pumps → 59). Connect the brown wire of the WILO STRATOS PARA pump on the hot side to the 4. terminal "-" of connector HPMP on the Mod10 board. Connect the white wire of the WILO STRATOS PARA pump on the hot side to the terminal "+" of the connector HPMP on the Mod10 board. Insulated black and blue wires (see Figure 6.14 Wiring diagram for connection of Wilo variable rate pumps → 59). Collegare la pompa alla rete elettrica prevedendo a monte un interruttore esterno 5. bipolare (vedi particolare IP di Figura 6.14 Wiring diagram for connection of Wilo variable rate pumps → 59) con fusibile da 2 A ritardato oppure collegarla ai morsetti interni al quadro elettrico dell’unità (vedi particolare MA di Figura 6.15 Wiring diagram for hooking up the Wilo variable rate pump powered by the unit → 60). After ﬁnished with all the above operations, close the electrical panel and reﬁt the 6. front panel of the appliance.

NEVER switch on or oﬀ the WILO STRATOS PARA pump through the switch on the power supply.

Page 59

Installation, user and maintenance manual – GAHP-GS/WS

Figure 6.14 – Wiring diagram for connection of Wilo variable rate pumps

Wiring diagram for connection of Wilo variable rate pumps

LEGEND

IP Two-position pump power switch F Fuse PMW Hot side water circulation pump (primary circuit) PMY Cold side water circulation pump

Pump signal 0-10V wire colours brown connect to -ve white white connect to +ve black isolate blue isolate

Page 60

Figure 6.15 – Wiring diagram for hooking up the Wilo variable rate pump powered by the unit

Wiring diagram for hooking up the Wilo variable rate pump powered by the unit

LEGEND

PMW Hot side water circulation pump

(primary circuit) PMY Cold side water circulation pump MA Unit terminal block

Pump signal 0-10V wire colours brown connect to -ve white connect to +ve black isolate blue isolate

6.4 TYPE B DDC

This paragraph illustrates the operations to be performed when one or more appliances are connected to a Direct Digital Controller (DDC). In particular:

What is the CAN BUS cable.1. How to connect the CAN BUS cable to the appliance's electronic board2. How to connect the CAN BUS cable to the DDC.3. How to connect the DDC.4. How to connect the plant water circulation pump.5.

For speciﬁc information regarding the DDC, refer to the speciﬁc manuals supplied with it.

The appliance and the DDC communicate with each other via a CAN bus network. The CAN bus network is characterized by a series of elements (appliances or DDCs) called nodes, connected to each other by a three-wire cable. The nodes are of two types: terminal nodes and intermediate nodes.

Page 61

Installation, user and maintenance manual – GAHP-GS/WS

Terminal nodes are appliances or DDCs that are connected to one other element • only. Intermediate nodes are appliances or DDCs that are connected to two other •

elements. The diagram in Figure 6.7 Example of CAN BUS → 51 gives an example of a CAN BUS network:3 appliances are connected to each other and to 1 DDC. Appliance D and the DDC (A) are terminal nodes, while appliances C and B are intermediate nodes as they are connected to 2 elements.

It is possible to place one DDC at any point of the CAN bus network: appliances and DDCs may act equally as terminal or intermediate nodes. One DDC can control and monitor up to 16 appliances. If there are more than 16 appliances on the network, it is necessary to connect more than one DDC on the same network, up to a maximum of 3.

What is the CAN BUS cable

The cable to be used must be suitable for CAN BUS applications.

Table 6.2 CAN BUS cables type → 51 gives details of some types of CAN bus cable, grouped according to the maximum distance covered by each single type.

For overall distances to cover of ≤200 m and networks with a maximum of 6 nodes (a typical example: up to 5 GAHP + 1 DDC) a simple shielded cable 3x0.75 mm may be used.

As shown in Table 6.2 CAN BUS cables type → 51, the CAN connection requires a CAN bus cable with 3 wires. If the available cable has more than 3 coloured wires, use the wires with the colours indicated in 6.2 CAN BUS cables type → 51 and cut the remaining ones. The ROBUR NETBUS cable is available as an accessory, see Section 8 ACCESSORIES → 81.

How to connect the CAN BUS cable to the appliance's electronic board

The CAN BUS cable must be connected to the dedicated terminals on the appliance’s electronic board, as shown below (see Figure 6.8 CAN BUS cable connection → 52).

Before working on the electrical panel of the appliance, make sure that power supply is oﬀ.

Cut a length of cable long enough to allow installing it without kinking.1.

On one end of the cable, remove the jacket for a length of approximately 70-80 2.

mm, taking care not to cut the shielding (metal mesh and/or aluminium sheet and,

if present, the bare connector in touch with the shield) and the wires contained

within.

If the cable is too thin to be held in place in the cable holding bracket (detail C in 3.

Figure 6.8 CAN BUS cable connection → 52), make it thicker by wrapping insulat-

ing tape around the jacket close to the stripped part (to an approximate diameter

of 12-13 mm).

Pull back the shielding on the jacket; apply isolating tape to the end of the shield-4.

ing as pulled back (detail A, Figure 6.8 CAN BUS cable connection → 52).

If the appliance is a 5. terminal node of the network connect the three coloured

wires to the orange connector as shown in detail "A" of Figure 6.9 Electrical wir-

ing diagram → 53. Respect the correct indications L, H, GND provided in Table 6.2

CAN BUS cables type → 51, on the ﬁgure and on the electronic board below the

connector.

Page 62

If the appliance is an 6. intermediate node repeat the operations from step 2 to step 5 for the other cables required (in this way you will have two cable lengths each one without the jacket on one end). Twist together the cores with the same color and connect them to the orange connector, as shown in detail "B" of Figure 6.9 Electrical wiring diagram → 53. Fix the CAN BUS cable (or two cables, according to the type of node being con-7. nected) to the holding bracket in the upper part of the electrical panel so that the pulled-back shielding is in solid touch with the metal bracket. The cables must be ﬁrmly held in place by the bracket if pulled. In order to position the jumpers on the electronic board according to the type of node being conﬁgured: If the appliance is a • terminal node on the network (i.e. 3 wires are inserted in the orange connector on the board): set the jumpers as shown in detail "A" of Figure

6.9 Electrical wiring diagram → 53: If the appliance is an • intermediate node on the network (i.e. 6 wires are inserted in the orange connector on the board); set the jumpers as shown in detail "B" of Figure 6.9 Electrical wiring diagram → 53: After ﬁnished with all the above operations, close the electrical panel and reﬁt the 8. front panel of the appliance.

How to connect the CAN BUS cable to the DDC

The CAN bus cable is connected to the speciﬁc orange connector (P8) supplied with the DDC in a bag.

Before working on the DDC, make sure that it is oﬀ.

The DDC, like the controller on the appliance, has jumpers 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.

To connect the CAN bus cable to a DDC

You will need: DDC not powered up.

Depending on the type of node being conﬁgured, set the DDC's jumpers J21 as 1. shown in detail "A" or detail "B" in Figure 6.16 detail wires and jumpers J21 - terminal/intermediate node CCI/DDC → 63. If necessary, open the DDC's back pa nel (4 screws); after jumpers J21 have been correctly positioned, close the cover again and retighten the 4 screws. If the DDC is an • intermediate node on the network (with no. 6 wires in the or- ange connector "P8"): set the jumpers "J21" as shown in detail "B" of Figure 6.16 detail wires and jumpers J21 - terminal/intermediate node CCI/DDC → 63: Jumpers OPEN. If the DDC is an • terminal node on the network (with no. 3 wires in the orange con- nector "P8"): set the jumpers "J21" as shown in detail "A" of Figure 6.16 detail wires and jumpers J21 - terminal/intermediate node CCI/DDC → 63: Jumpers CLOSED. Prepare the orange CAN bus connector, from the supplied sleeve.2. Cut a length of cable long enough to allow installing it without kinking.3. Remove the sheath for a length of approximately 70-80 mm, taking care not to cut 4. the shielding (metallic shield and/or aluminium sheet and, if present, the bare connector in contact with the shield) and wires contained inside.

Page 63

Installation, user and maintenance manual – GAHP-GS/WS

Roll the shielding and connect it to a 4-mm eyelet terminal, as illustrated in Figure 5.

6.10 Connection from CAN BUS to connector P8 → 55, details C and D. Now pro-

ceed as follows:

If the DDC is an 6. terminal node connect the three coloured wires to the orange

connector "P8", following the diagram provided in detail "A" of Figure 6.16 detail

wires and jumpers J21 - terminal/intermediate node CCI/DDC → 63. Observe the

terminal markings L, H, GND (on the DDC at the base of the socket "P8") which are

given both in Table 6.2 CAN BUS cables type → 51 and in the example.

If the DDC is an 7. intermediate node repeat the operations from step 2 to step 4 for

the other length of CAN bus cable required. Connect the six coloured wires to the

orange connector "P8", following the diagram provided in detail "B" of Figure 6.16

detail wires and jumpers J21 - terminal/intermediate node CCI/DDC → 63. Observe

the terminal markings L, H, GND (on the DDC at the base of the socket "P8") which

are given both in Table 6.2 CAN BUS cables type → 51 and in the example.

Insert the orange connector ("P8") with the wires ﬁrst into the opening prepared in 8.

the cover of the DDC, and then into the appropriate socket on the DDC itself, mak-

ing sure it is correctly inserted.

Use the rear cover bolts located near the CAN BUS socket to secure the 4 mm 9.

eyelet (or 2 eyelets) (detail D, Figure 6.10 Connection from CAN BUS to connector

P8 → 55). The cable should be secured against pulling out.

Figure 6.16 – detail wires and jumpers J21 - terminal/intermediate node CCI/DDC

Detail terminal and intermediate node: jumpers position J21: "closed" - "open".

LEGEND

DDC CCI/DDC J21 Jumper CAN-BUS in CCI/DDC board

A detail case "terminal node" (3 wires; J21=jumper "closed") B detail case "intermediate node" (6 wires; J21=jumper "open") H,L,GND data signal wires

How to connect the DDC

The DDC requires a low voltage power supply (24 V) with a 230/24 V AC, 50 Hz safety transformer; the minimum power requirement is 20 VA. For the connection use a cable with the minimum speciﬁcations 2 x 0.75 mm2.

Page 64

Connect the DDC to the transformer via the 4-pole connector provide for this, following the diagram in Figure 6.17 CCI/DDC - electric supply → 64. Pass the cable through the opening in the cover before ﬁxing the wires to the connector. To power up the DDC, proceed as follows.

You will need: the appliance disconnected from the electricity supply

Remove the DDC's back panel by undoing the 4 bolts securing it.1. Cut a suitable length of power cord (minimum 2x0.75 mm2.

). Pass the power cord (DDC side) through the hole in the DDC's cover and hook up 3. as shown in the example, with the following polarities: terminal 1 = 24 V; terminal 2 = 0 V; terminal 3 = ground.

Make the grounding connection on the transformer terminal connected to terminal 2 of the 4-pole connector (EP) of the DDC. Terminal 2 is connected internally to terminal 3, and is thus grounded; if the transformer already has one wire grounded, it must be connected to this terminal. Terminal 3 of the DDC’s 4 pole connector must always be grounded (r ≤ 0.1Ω).

On completion, close the DDC's back panel with the 4 bolts.4.

The DDC is equipped with a backup battery which retains the memory settings in case of power failure. The backup battery lasts approximately 7 years, after which time it must be replaced by an authorised Robur Technical Assistance Centre.

Figure 6.17 – CCI/DDC - electric supply

CCI/DDC electric supply from external transformer.

LEGEND

DDC CCI/DDC AL supply 4 poles connector 1 clamp and wire for 24 Vac supply 2 clamp and wire for 0 Vac supply 3 clamp and wire for ground contact (required connection) DDCTR safety transformer

- (230/24 Vac 50/60 Hz)

The following wiring diagrams show the connection of the DDC to 1 appliance (Figure

6.18 Connexion câble CAN BUS for plants with one unit → 65) and 2 appliances (Figure

6.19 Connexion câble CAN BUS for plants with more unit → 66) respectively.

Page 65

Installation, user and maintenance manual – GAHP-GS/WS

Figure 6.18 – Connexion câble CAN BUS for plants with one unit

Connexion câble CAN BUS between one DDC and one unit

LEGEND

DDC direct digital control SCH electronic board S61 J1 Jumper CAN-BUS in board S61 J21 Jumper CAN-BUS in board DDC A terminal nodes connection - (3 wires; J1 e J21 = "closed") H,L,GND data signal wires (rif. cables table)

Page 66

Figure 6.19 – Connexion câble CAN BUS for plants with more unit

Connexion câble CAN BUS between one DDC and more unit

LEGEND

DDC direct digital control

SCH electronic board S61

J1 Jumper CAN-BUS in board S61

J21 Jumper CAN-BUS in board DDC

A terminal nodes connection - (3 wires; J1 e J21 = "closed")

B intermediate node connection - (6 wires; J1="open")

H,L,Gnd data signal wires (rif. cables table)

How to connect the system water circulation pumps

Control of the plant water circulation pump from the appliance’s controller depends on the power rating of the pump itself. 2 cases may be distinguished:

Page 67

Installation, user and maintenance manual – GAHP-GS/WS

Direct control from the controller with power absorbed by the pump less than 700 • W. If the power absorbed by the pump is less than 700 W, make the connection as shown in Figure 6.20 Electrical wiring diagram → 67 and check that the jumper J10 and J1 are CLOSED, as shown in detail A. Direct control from the controller with power absorbed by the pump of more than • 700 W. If the power absorbed by the pump is more than or equal to 700 W, make the connection as shown in Figure 6.21 Electrical wiring diagram → 68 using a control relay. In this case it is necessary to OPEN the jumper J1 and J10 positioning its as shown in detail A and B of the Figure.

Figure 6.20 – Electrical wiring diagram

Connection of plant water circulation pumps (power absorption less than 700W), controlled directly by the appliance.

LEGEND

SCH electronic board SCH2 electronic board J10 J1 - jumper closed N.O. CONTACT clean exit normally open MA Unit terminal block L phase N neutral Components NOT SUPPLIED PMW Hot side water pump <700W PMY Cold side water pump <700W

Page 68

Figure 6.21 – Electrical wiring diagram

Connection of plant water circulation pumps (power absorption equal or more than 700W), controlled directly by the appliance.

LEGEND

SCH electronic board SCH2 electronic board J10 J1 - jumper open N.O. CONTACT clean exit normally open MA Unit terminal block L phase N neutral Components NOT SUPPLIED PMW Hot side water pump ≥700W PMY Cold side water pump ≥700W KPW Hot side pump control relay KPY Cold side pump control relay

If several appliances are connected on the same hydraulic circuit, it is always necessary to provide a safety transformer (secondary SELV) and a respective control relay; make the connections according to the diagram in Figure 6.22 Electrical wiring diagram → 69.

Page 69

Installation, user and maintenance manual – GAHP-GS/WS

Figure 6.22 – Electrical wiring diagram

Example of pump/appliance electrical connection with 230 Vac pump, controlled directly by the appliance through a relay and a SELV safety transformer

LEGEND

SCH electronic board SCH2 W10 electronic board SCH3 MOD10 electronic board J1 J10 - jumper open N.O. CONTACT clean exit normally open MA Unit terminal block L phase

N neutral Components NOT SUPPLIED PMW Hot side water pump PMY Cold side water pump KPW Hot side pump control relay KPY Cold side pump control relay PTR SELV safety transformer IP bipolar pump switch

Variable ﬂow pumps WILO STRATOS PARA can also be used (see Section 8 ACCESSORIES → 81). In this case, for the electrical wiring of the pumps, please refer to Figure

6.14 Wiring diagram for connection of Wilo variable rate pumps → 59 and the relevant paragraph.

Page 70

The primary circulation pump/s must be controlled by the S61 board, or directly (via “N.O. contact” contacts or 0-10V signal) or indirectly (“OR” use of said contacts by BMS type external systems). Otherwise, the primary circulation pump/s must be running permanently.

6.5 TYPE C CONSENT SWITCH

Before making the electrical connections, make sure that work is not carried out on live elements.

General indications

Check that the power supply voltage is 230 V 1N - 50 Hz power.• Make the electrical connections as given in the following wiring diagrams.• Make the electrical connection in such a way that the ground wire is longer than • the live wires. In this way it will be the last wire to be pulled away if the mains cable should accidentally be pulled, and will thus guarantee the ground connection.

Electrical safety is ensured only when the appliance is correctly connected to an eﬃcient grounding system, realized according to current safety regulations. Do not use gas pipes as grounding.

How to connect the consent switch

You will need: the appliance is not powered electrically (external master power switch

set to OFF)

Connect the permissive (on-oﬀ switch or ambient thermostat or timer, etc.) to ter-1. minals R and W on the appliance’s electronic board as shown in Figure 6.23 Electrical wiring diagram → 70 (detail “CS”).

For the appliance to operate correctly, it is ALWAYS necessary to provide a consent switch. Do not use the general mains external circuit breaker («GS») to switch the appliance on or oﬀ.

Figure 6.23 – Electrical wiring diagram

electrical connections of ON/OFF command switch

LEGEND

SCH Electronic board R Common W Terminal consensus warming Components NOT SUPPLIED CS ON/OFF command switch

How to connect the system water circulation pumps For how to connect the system pumps, see the section with this title in Paragraph

6.4 TYPE B (DDC) → 60.

Page 71

Installation, user and maintenance manual – GAHP-GS/WS

Variable ﬂow pumps WILO STRATOS PARA can also be used (see Section 8 ACCESSORIES → 81). In this case, for the electrical wiring of the pumps, please refer to Figure

6.14 Wiring diagram for connection of Wilo variable rate pumps → 59 and the relevant paragraph.

6.6 HOW TO RESET THE FLAME CONTROLLER FROM REMOTE

The ﬂame controller reset can be controlled remotely by installing a button (not supplied) to the ﬂame controller inside the unit’s electrical panel. Connect the button as instructed below.

You will need: the appliance disconnected from the electricity supply

The cable required to connect the reset button must be 3x0.75mm1.

. Cut a suitable length of cable.2. Connect the cable to the blind terminals A (see Figure 6.24 Button connection for 3. ﬂame controller reset → 72).

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 unit.

Page 72

Figure 6.24 – Button connection for ﬂame controller reset

LEGEND

1 White

2 Grey

3 Orange

4 Green

5 Yellow/Black

6 Black

7 Yellow/Green (Ground)

8 Brown

9 Blue

10 Yellow

11 Violette

12 Pink

PLS Reset button

A Blind terminals

Page 73

Installation, user and maintenance manual – GAHP-GS/WS

7 INITIAL ACTIVATION AND MAINTENANCE

In this section you will ﬁnd the following information:

Indications required by the authorized Robur Technical Assistance Centre (TAC) in • order to carry out the entire procedure of ﬁrst start-up of the appliance. Indications regarding maintenance operations of the appliance.•

At the end of the section you will ﬁnd instructions for changing the type of gas. Before proceeding with the operations described in this section, the installer is invited to read Paragraph 3.1 GENERAL INFORMATION → 8. Please refer to Paragraph 4.1 START UP (AND SHUT DOWN) → 17 for switching the appliance on and oﬀ.

If the appliance is connected to a CCP for the appliance start-up and switch-oﬀ control phases, reference must be made to the two CCP ﬁles dedicated to it.

If the appliance is connected to a DDC (and the DDC is in controller mode), for the phases of activation and deactivation of the appliance it is necessary to refer to the two manuals dedicated to the DDC itself.

7.1 PROCEDURE FOR FIRST START UP

The entire procedure for the initial activation of the appliance must only carried out by an authorised Robur Technical Assistance Centre (TAC). The product's guarantee may be void if the procedure is not carried out by a Robur TAC. Before leaving the factory, the appliance has been thoroughly tested. The entire procedure for initial activation of the appliance consists in carrying out the following (main) operating stages:

preliminary veriﬁcation of plant compliance;1. check/setup of the combustion parameters;2. regulating the plant operating parameters.3.

Preliminary checks of the installation compliance

The authorized technician must:

Check that the whole installation has been realized in accordance with its design, • following the manufacturer's instructions and respecting current legislation. The design must have been drawn up by a professional speciﬁer. Check that all the connections (hydraulic, gas and electrical) of the appliance have • been made correctly. Check that the installation is actually compliant as per the Declaration of Conform-• ity provided by the installer to the owner.

The Declaration of Conformity CERTIFIES that the installation is compliant with current regulations. This Declaration is a mandatory document and as such it must be provided by the installer to the owner.

Check that the water pressure and ﬂow in the hydraulic circuit and the dynamic • gas mains pressure are correct, as indicated by the manufacturer. Check that the electrical power supply is 230V 50Hz• Check that the air/fumes pipes are properly connected to the exterior.• Check that the fumes condensate discharge is properly installed.• Check that the safety clearances given in Figure 5.2 Clearances • → 28 have been observed.

If all the conditions listed above are in place, the authorized technician can proceed with the commissioning and start up of the appliance.

Page 74

If any non-compliance is found during the preliminary checks, the authorized technician may choose not to proceed with the "ﬁrst start up". In this case, the authorized technician must:

Report the user/installer of any installation anomaly.• Report the user/installer of any situation that is potentially hazardous for the appli-• ance and for people. Report of any missing documentation relevant to the installation.• According to the reports made, advise any corrective action to be taken at the in-• staller's care in order to proceed with the "ﬁrst start up".

It is the responsibility of the user/installation technician to carry out any corrective measures on the plant indicated by the authorized technician. After such corrective measures have been completed, the authorized technician will assess the plant again. At this point, if safety and compliance conditions are judged satisfactory, the authorized technician must carry out the "ﬁrst start up".

Plant conditions that are hazardous for people or for the appliance. If any of the following hazardous situations arises, the authorized technician must not carry out the "ﬁrst start up":

appliance installed outdoors inadequately protected against the weather;• appliance installed close to combustible substances or surfaces or in any case in • conditions of bad accessibility or not allowing safe maintenance operations; control of switching on and oﬀ of the appliance not via the CCP/DDC or consent • switch but via the master power switch; damages or failures of the appliance due to transportation or installation;• smell of gas due to probable leaks from the plant itself and in any case all situations • that are due to non-compliant plants, considered potentially hazardous.

Plant anomalies. If any of the following situations exists, the authorized technician may carry out the "ﬁrst start up" at his choice, but the appliance must be left oﬀ until the anomalies are removed:

installations (not potentially hazardous) not carried out according to sound work-• manship practices, installations (not potentially hazardous) not complying with current national and local regulations; installations (not potentially hazardous) not carried out according to good • workmanship practices, not complying with the instructions provided by the manufacturer; installations that can cause operational troubles on the appliance.•

Procedure for checking/setting-up the combustion parameters

During the initial activation procedure, the combustion parameters must be checked and set ONLY by a Robur TAC. In this stage, NEITHER the user NOR the installation technician is authorised to perform such operations, and in so doing may invalidate the guarantee of the appliance.

The appliance is supplied with all of its units already regulated for the type of gas for which the appliance itself is set up.

Page 75

Installation, user and maintenance manual – GAHP-GS/WS

The type of gas for which the appliance is set up can be identiﬁed from the adhesive label located on the unit’s internal gas pipe (detail M, Figure 7.2 Gas changeover → 80).

The nozzles required to change the gas type to G30 and G31 are supplied together with the appliance.

During the ﬁrst start-up procedure it is in any case necessary to:

check the dynamic gas mains pressure• check and adjust the appliance’s combustion parameters•

You will need: the appliance connected to the gas and electricity supply: switched oﬀ and with the gas cock closed; front panel removed.

Check the dynamic gas mains pressure

Connect the manometer to the gas intake (see detail D, Figure 7.1 Gas 1. valve → 75). Open the gas valve and check that the grid static pressure complies to the value 2. reported in Table 5.2 Network gas pressure → 31 (with a tolerance of ±15%).

If the static mains pressure is greater than 50 mbar DO NOT switch on the appliance!

Give the consent signal for operation.3. After some seconds of operation, check that the grid dynamic pressure complies 4. with the value reported in Table 5.2 Network gas pressure → 31 (with a tolerance of ±15%).

Figure 7.1 – Gas valve

Gas valve Honeywell VK 4115V

LEGEND

A Plug B Key Torx TX40 C screw adjustment CO2 D gas pressure intake

Page 76

If the pressure measured by the pressure gage is not complying with the value reported in Table 5.2 Network gas pressure → 31 (with a tolerance of ±15%), it is NOT possible to switch the appliance on!

Proceed with the regulation/veriﬁcation of the combustion parameters as stated 5.

in the next paragraph. Checking and adjusting the combustion parameters After having checked the dynamic mains pressure (see section), you may check and adjust the combustion parameters as follows.

Fit a combustion products probe in one of the points provided for this purpose on 1.

the external fumes equipment or at point L in Figure 7.2 Gas changeover → 80

Give the unit functioning consent and wait for at least 5 minutes for normal com-2.

bustion conditions.

With the appliance running, access menu 2 parameter 4 of the unit's controller: the 3.

display will ﬂash "P_H0", press to conﬁrm forcing maximum thermal power.

Check that the value of CO4.

read on the ﬂue gas analyser coincides with the value given in Table 7.3 Gas nozzles and content of CO2 → 79 at the "Content of CO2 with/MAX modulation" line with +0.2 -0.4 tolerance. Example (G20 gas): the nominal content of CO2 is equal to 9.1%, values in the range between 8.7-9.3% are therefore acceptable. Access menu 2 parameter 3 of the unit's controller inside the electric panel: the 5. display will ﬂash "P_L0", press to conﬁrm forcing minimum thermal power. Now check that the diﬀerence between the value read in point 4 and that now 6. displayed on the ﬂue gas analyser, corresponds to the data given in the Table 7.3 Gas nozzles and content of CO2 → 79 at the "Delta CO2 between MAX and MIN potentiality" line with tolerance of +0.3-0.0. Example (G20 gas): if at point 4 a content of CO2 equal to 9.2% was detected, at point 6 there must be a value of (9.2%-0.4) with tolerance of +0.3 -0.0 on the delta value, i.e. a value in the range of 8.8-8.5%. If this is not the case, remove cap A from the gas valve (see Figure 7.1 Gas valve 7. → 75) and use a Torx TX40 wrench to act on screw C in Figure 7.1 Gas valve → 75. Turn clockwise to increase the percentage of CO2 and anti-clockwise to decrease the percentage of CO2.

1/8 turn of the regulator screw reduces (counterclockwise) or increases (clockwise) the CO2 content by approximately 0.1%. DO NOT turn the screw more than one full turn in either direction.

With the appliance running, access menu 2 parameter 4 of the unit's controller: the 8. display will ﬂash "P_H0", press to conﬁrm forcing maximum thermal power. Check that, also following a regulation intervention on screw C, the value of CO9.

corresponds to the value read in Table 7.3 Gas nozzles and content of CO2 → 79 at the "Content of CO2 with/Max modulation" line with tolerance of +0.2 -0.4.

If you cannot calibrate the CO2 percentage after the second attempt, DO NOT activate the appliance; contact Robur technical service at +39 035/888111.

Page 77

Installation, user and maintenance manual – GAHP-GS/WS

If the check/setup of the combustion parameters has been successful, please enter 10. menu 2, parameter 5, of the electronic board inside the electric box of the appliance: on the display, the message "unF0", will blink; press to remove the operational override previously selected and then return to the normal operational conﬁguration with modulation of the thermal power.

After 30 minutes of operation the appliance automatically cancels the preceding forced power mode. To anticipate this timing, select and execute action "5" in menu 2.

Switch the appliance oﬀ.11. Close the gas valve.12. Reinstall the cap A in Figure 7.1 Gas valve 13. → 75. Reinstall the front panel.14.

7.2 MAINTENANCE

Correct maintenance prevents problems, guarantees maximum operating eﬃciency of the appliance and allows running costs to be contained.

The maintenance operations described in this paragraph must be performed exclusively by the serviceman in charge of the plant or by an authorized CAT Robur.

Any operation that regards internal components of units of the appliance must be carried out by an authorized Robur Technical Assistance Centre (TAC), according to the instructions supplied by the manufacturer.

The "eﬃciency check" and every other "check and maintenance operation" (see Table

7.1 → 78 and 7.2 → 78), must be performed with a frequency in agreement to cur- rent law or, if more restrictive, in respect of what requested by the planner (builder of the system) or by the manufacturer of the unit.

The liability of CHECKING THE EFFICIENCY AS A FUNCTION OF THE SYSTEM, OF THE FUEL IN USE AND OF THE THERMAL POWER, to be carried out with the purpose of containing the energy consumption, is in charge to the responsable of the system.

Before any maintenance operation, switch oﬀ the appliance by means of the permissive contacts (or by means of DDC/CCP) and wait for the completion of the shut-down cycle. When the appliance is oﬀ, switch oﬀ power supply and gas supply (according to antiicing settings), opening the electrical breaker and closing the gas isolation valve.

GUIDELINES FOR THE PREVENTIVE MAINTENACE OPERATIONS

In Table 7.1 → 78 are reported the guidelines for the preventive maintenance operations.

If the unit is subject to particularly heavy duty (for example in process plants or in other conditions of continuous operation), these maintenance operations must be more frequent.

Page 78

Table 7.1

GUIDELINES FOR THE PREVENTIVE MAINTENACE OPERATIONS Check of the unit GAHP-A GAHP-GS/WS AY ACF GAHP-AR

Visually check of the general condition of the unit and of its air heat exchanger.

(1)

√ √ √ √ Check the correct operation of the device used for monitoring the water ﬂow √ √ √ √ √ Check the % value of CO

√ √ √ check gas pressure to the burners √ √ Check that the condensate discharge is clean (clear the condensate discharge hole of any blockages)

[If necessary, frequency of the maintenace operation must be increased]

√ √ √

Replace the belts after 6 years or 12,000 hours of operation √ √ √ √ Check/restore the pressure of the primary hydronic circuit √ Check/restore the air pressure inside of the expansion vessel of the primary hydronic circuit √

Check every CCI or DDC

(2)

DDC o CCI

Check that the plant is able to achive the setpoint temperature √ Download the hystorical events √

1 It is suggested the cleaning of the air heat exchanger once every 4 years [the optimal frequency of this operation is in any case a consequence of the installation site]. 2 Check that the plant is able to achive the setpoint temperature.

ORDINARY SCHEDULED MAINTENANCE Perform the following operations at least once every 2 years.

If the unit is subject to particularly heavy duty (for example in process plants or in other conditions of continuous operation), these maintenance operations must be more frequent.

Table 7.2

SCHEDULED MAINTENANCE OPERATIONS TO BE PERFORMED AT LEAST ONE EVERY TWO YEARS Check of the unit GAHP-A GAHP-GS/WS AY ACF GAHP-AR

Clean the combustion chamber √ √ √ √ √ Clean the burner √ √ √ √ √ Clean the electrodes of ignition and ﬂame sensing √ √ √ √ √

Check that the condensate discharge is clean (clear the condensate discharge hole of any blockages) √ √ √ Replace the silicone gasket √

In Section 5 HYDRAULIC INSTALLATION → 26 are reported suggestions related to the

hydraulic plant.

7.3 CHANGE OF GAS TYPE

This operation must be carried out exclusively by an authorised Robur Technical Assistance Centre (TAC).

If the appliance is to be used with a type of gas other than that indicated on the the adhesive label located on the unit's electric panel, switch oﬀ the appliance, shut oﬀ its power and gas supplies and proceed as follows (see Figure 7.2 Gas changeover → 80):

You will need: the appliance switched oﬀ and disconnected from the gas/electricity supplies

Disconnect the gas pipe from the gas valve.1. Undo the 4 bolts E shown in Figure 7.2 Gas changeover 2. → 80 and remove the gas valve/blower assembly from the burner. Protect the burner from bolts and nuts falling into it.3. Using a CH 4 hex key, undo the 4 bolts G indicated in Figure 7.2 Gas changeo-4. ver → 80 and remove the nozzle D from the gas valve.

Page 79

Installation, user and maintenance manual – GAHP-GS/WS

Replace the nozzle and o-ring B (see Figure 7.2 Gas changeover 5. → 80) with those of the diameter suited to the new type of gas (see Table 7.3 Gas nozzles and content of CO2 → 79). The nozzle code is stamped on the nozzle itself. Check that the o-ring C is ﬁtted (see Figure 7.2 Gas changeover 6. → 80). Reassemble the gas valve to the blower with the 4 bolts G taking care that the red 7. silicon hose between the venturi tube and the gas valve (see detail F of Figure 7.2 Gas changeover → 80) is correctly installed. Replace the white gasket between the blower and the burner.8. Reinstall the blower/gas valve assembly to the burner with the 4 bolts E, taking 9. care not to damage the white gasket. Reconnect the gas pipe to the gas valve.10. Replace the sticker indicating the type of gas for which the appliance was set up 11. with one that indicates the new type of gas used. Check the tightness of the installation as follows:12. Connect a manometer to the gas intake D (Figure 7.1 Gas valve • → 75). Open the gas valve.• Close the gas cock and check that the mains pressure has not dropped.• If there is no gas leak, supply gas and electricity to the appliance and restart it.13. complete the change of gas type by checking that all gas connections are sealed, 14. including those not directly aﬀected by this operation (using soapy water or another suitable method). Now check and adjust the combustion parameters as indicated in the respective 15. paragraph.

Table 7.3 – Gas nozzles and content of CO2

Gas type G20 G25 G25.1 G27 G2.350 G30 G31

Nozzle code 180 181 181 187 184 182 183 Nozzle diameter 4,7 5,2 5,2 5,4 5,9 3,4 3,6 Content CO2 with MAX modulation 9,1% 9,2% 10,1% 9,0% 9,0% 10,4% 9,8% Delta CO2 between Max and Min potential 0,4 0,6 0,8 0,5 0,5 0,5 0,4

Page 80

Figure 7.2 – Gas changeover

Gas changeover

LEGEND

A Gas valve B O-ring C O-ring D Gas nozzle E Mounting holes F Red silicon hose G Mounting holes H Manual reset fumes thermostat L Fumes outlet

Page 81

Installation, user and maintenance manual – GAHP-GS/WS

8 ACCESSORIES

This section contains a list of the accessories that are available for the installation and use of the appliance. To order these accessories, contact Robur S.p.A. on +39 035.888111.

Table 8.1 – Accessories

ACCESSORIES Name Description Code Notes

CIRCULATION PUMPS

Wilo-Stratos Para 25-11. O-PMP004

Variable rate pump for cold and hot water.

Pompa Wilo-Stratos Para 30-12 O-PMP008 Max variable ﬂow pump.

FILTERS Sludge ﬁlter 1" 1/4 O-FLT014

Sludge ﬁlter 1" 1/2 O-FLT015 Air separator ﬁlter 1" 1/4 O-FLT010 Air separator ﬁlter 1" 1/2 O-FLT016

BOILERS AND HYDRAULIC SEPARATORS Sanitary water boiler with oversize coil, 300 l O-SRB004

Sanitary water boiler with oversize coil, 500 l O-SRB005 Sanitary water boiler with oversize coil, 500 l O-SRB006 With integral solar coil. Sanitary water boiler with oversize coil, 750 l O-SRB007 With integral solar coil. Thermal tank, three ﬁttings, 300 l O-SRB000 Thermal tank, three ﬁttings, 500 l O-SRB001 Thermal tank, three ﬁttings, 800 l O-SRB002 Thermal tank, three ﬁttings, 1000 l O-SRB003

VALVES Flow regulator valve O-VLV001

3-way valve DN20 Kvs 6.3 O-VLV004 3-way valve DN25 Kvs 10 O-VLV005 3-way valve DN32 Kvs 16 O-VLV006 3-way zone ball valve 1"1/4 O-VLV002 3-way zone ball valve 1"1/2 O-VLV003

ANTIVIBRATION n.4 anti-vibration mounts O-NTV003 REGULATOR COMPONENTS Radio module (Siemens) O-DSP007

Repeater (Siemens) O-DSP009 Sender (Siemens) O-DSP008 Room unit basic (Siemens) O-DSP004 Room unit cooling (Siemens) O-DSP005 Room unit cooling (Siemens) (radio) O-DSP006 Servocontrol 230V AC for zone valves, on/oﬀ 90 sec O-BBN000 Modulating servocontrol for 3-way valves 230V AC 150 sec O-BBN001 Probe + sender (Siemens) O-DSP010 Contact probe (Siemens) O-SND006 External probe (Siemens) O-SND003 Immersion probe, length 2 m O-SND004 Solar sensor (Siemens) O-SND005 Commissioning tool O-DSP002 Communications switchboard O-DSP003

Robur “NETBUS” CAN BUS CABLE

Cable for data communication networks: for network connection between CCI and appliance.

O-CVO008

Transformer 50VA trasformer O-TRS005

Page 82

9 OPERATING CODES/TROUBLESHOOTING

9.1 OVERVIEW AND OPERATING CODES/TROUBLESHOOTING

Table 9.1 – TABLE OF OPERATING CODES generated by the S61 electronic board (ﬁrmware version 3.024)

CODES DESCRIPTION TRIP CONDITIONS RESET METHOD

E 200

FAULT ON RESET CIRCUIT OF FLAME CONTROL UNIT

Fault on reset circuit of ﬂame control unit. Contact authorised Technical Assistance.

u 201

GENERATOR LIMIT TEMPERATURE THERMOSTAT

High temperature detected by limit thermostat on body of generator

Acknowledge the thermostat manually: reset will be automatic as soon as fault condition is over.

E 201

GENERATOR LIMIT TEMPERATURE THERMOSTAT

u_01 code active for 1 hour, or u_01 code generated 3 times in 2 hours of operation.

Contact authorised Technical Assistance.

u 202 FUMES THERMOSTAT

High temperature detected by exhaust fumes thermostat.

Acknowledge the thermostat manually: reset will be automatic as soon as fault condition is over.

E 202 FUMES THERMOSTAT

u_02 code active for 1 hour, or u_02 code generated 3 times in 2 hours of operation.

Contact authorised Technical Assistance.

u 203

COLD WATER ANTIFREEZE THERMOSTAT

Low temperature detected by cold outlet water sensor.

Reset occurs automatically when the condition that generated the code ceases, with hysteresis of 2 °C.

E 205 HIGH AMBIENT TEMPERATURE

HIGH temperature detected by ambient temperature sensor.

Reset occurs automatically when the condition that generated the code ceases.

u 206 LOW AMBIENT TEMPERATURE

LOW temperature detected by ambient temperature sensor.

Reset occurs automatically when the cause ceases or when the unit is switched oﬀ.

u 207

HIGH CONDENSER INLET TEMPERATURE

Temperature measured by condenser inlet sensor, fumes sensor or generator ﬁn sensor HIGH.

Reset occurs automatically when the condition that generated the code ceases.

E 207

HIGH CONDENSER INLET TEMPERATURE

u_07 code active for 1 hour, or u_07 code generated 12 times in 2 hours of operation.

Carry out appropriate checks. Reset may be performed from the CCI/DDC (or from the S61 board via menu 2, parameter 1). If the code persists, contact authorised TAC.

E 208 FLAME CONTROL UNIT ERROR

E_12 on unit and condenser inlet temperature increasing by over 10 °C within 1 hour.

Carry out appropriate checks. Reset may be performed from the CCI/DDC (or from the S61 board via menu 2, parameter 1). If the code persists, contact authorised TAC.

u 210 INSUFFICIENT COLD WATER FLOW

Insuﬃcient water ﬂow (the circulator is on and the ﬂowmeter is open).

Reset occurs automatically when correct water ﬂow is restored.

E 210 INSUFFICIENT COLD WATER FLOW

u_10 code generated 5 times since appliance powered, or code u_10 is active for 1 hours.

Reset may be performed from the CCI/DDC (or from the S61 board via menu 2, parameter 1). If the code persists, contact authorised TAC.

u 211

INSUFFICIENT ROTATION OF OIL PRESSURE PUMP

Insuﬃcient rotation of oil pressure pump. Reset occurs automatically 20 minutes after the Code is generated.

E 211

INSUFFICIENT ROTATION OF OIL PRESSURE PUMP

u_11 code generated twice in 2 hours of operation.

Reset may be performed from the CCI/DDC (or from the S61 board via menu 2, parameter 1). If the code persists, contact authorised TAC.

u 212 FLAME CONTROL UNIT ARREST Failure to ignite burner.

Reset occurs automatically when the solenoid valve opens again (new ignition attempt), or if the code persists for 5 minutes.

E 212 FLAME CONTROL UNIT ARREST Flame arrest signal.

Reset may be performed from the CCI/DDC (or from the S61 board via menu 2, parameter 0). If the code persists, contact authorised TAC.

E 216

COLD OUTLET WATER TEMPERATURE SENSOR DEFECTIVE

Fault (interruption or short circuit) on outlet water temperature sensor.

Reset may be performed from the CCI/DDC (or from the S61 board via menu 2, parameter 1). If the code persists, contact authorised TAC.

E 217

COLD INLET WATER TEMPERATURE SENSOR DEFECTIVE

Fault (interruption or short circuit) on condenser outlet temperature sensor.

Reset may be performed from the CCI/DDC (or from the S61 board via menu 2, parameter 1). If the code persists, contact authorised TAC.

E 220

CONDENSER INLET TEMPERATURE SENSOR DEFECTIVE

Fault (interruption or short circuit) on condenser inlet temperature sensor.

Reset may be performed from the CCI/DDC (or from the S61 board via menu 2, parameter 1). If the code persists, contact authorised TAC.

E 222 WATER FLOWMETER FAULT Water ﬂowmeter fault.

Reset may be performed from the CCI/DDC (or from the S61 board via menu 2, parameter 1). If the code persists, contact authorised TAC.

E 223 AIR/GAS MIXTURE SENSOR FAULT Air gas mixture sensor fault.

Reset may be performed from the CCI/DDC (or from the S61 board via menu 2, parameter 1). If the code persists, contact authorised TAC.

E 224

FUMES TEMPERATURE SENSOR FAU LT

Fumes temperature sensor fault

Reset may be performed from the CCI/DDC (or from the S61 board via menu 2, parameter 1). If the code persists, contact authorised TAC.

E 225

CONDENSATE DISCHARGE CLOGGED

Condensate discharge clogged

Reset may be performed from the CCI/DDC (or from the S61 board via menu 2, parameter 1). If the code persists, contact authorised TAC.

E 226

GENERATOR FIN TEMPERATURE SENSOR

Generator ﬁn temperature sensor

Reset may be performed from the controller (or from the S61 board via menu 2, parameter 21). If the code persists, contact authorised Technical Assistance.

E 228

GAS SOLENOID VALVE EXCITED DURING FLAME CONTROLLER ARREST

The ﬂame controller is arrested (E_12) but the gas solenoid valve is excited. In this case the ﬂame controller is de-excited (E_12 resets).

Reset may be performed from the CCI/DDC (or from the S61 board via menu 2, parameter 1). If the code persists, contact authorised TAC.

u 229

GAS SOLENOID VALVE WITHOUT ELECTRICAL POWER

Gas solenoid valve is oﬀ for 5 seconds (with central ﬂame control unit on).

Reset occurs automatically if the gas solenoid valve switches on again within 10 minutes (with central ﬂame control unit on).

E 229

GAS SOLENOID VALVE WITHOUT ELECTRICAL POWER

Code u_29 is active for more than 10 minutes (with ﬂame controller unit on).

Carry out appropriate checks. Reset may be performed from the CCI/DDC (or from the S61 board via menu 2, parameter 1). If the code persists, contact authorised TAC.

Page 83

Installation, user and maintenance manual – GAHP-GS/WS

CODES DESCRIPTION TRIP CONDITIONS RESET METHOD

u 236 BLOWER FAULT Blower fault

Reset occurs automatically 20 minutes after the operating code is generated.

E 236 BLOWER FAULT

u_36 code generated three times in 1 hour of operation.

Reset may be performed from the CCI/DDC (or from the S61 board via menu 2, parameter 1). If the code persists, contact authorised TAC.

u 246

HOT INLET WATER TEMPERATURE TOO HIGH

Hot inlet water temperature higher than upper operating limit of the appliance (if the appliance is in operation).

Resets automatically if, with the circulator on, the cause resolves or (with circulator oﬀ) 20 minutes after generation of code.

u 247 LOW HOT WATER TEMPERATURE

Hot water temperature lower than lower operating limit of the appliance (if the appliance is in operation).

Reset occurs automatically when cause resolves or 430 seconds after the code is generated.

E 247 LOW HOT WATER TEMPERATURE

u_47 code generated 3 times in 1 hour of operation of the circulator.

Reset occurs automatically when the condition that generated the code ceases. If the code persists, contact authorised Technical Assistance.

u 248

HOT WATER DIFFERENTIAL TEMPERATURE TOO HIGH

High hot water diﬀerential temperature.

Reset occurs automatically 20 minutes after the operating code is generated.

E 248

HOT WATER DIFFERENTIAL TEMPERATURE TOO HIGH

u_48 code generated twice in 2 hours of operation.

Reset may be performed from the CCI/DDC (or from the S61 board via menu 2, parameter 1).

E 249 SATELLITE BOARD NOT PRESENT Satellite board not present.

Reset occurs automatically when the condition that generated the code ceases.

u 251

ANTIFREEZE FUNCTION ACTIVATED

- COLD SIDE Activation takes place only if the plant water circulator is oﬀ and the antifreeze function is enabled (see menu 1, parameter 77).

Inlet or outlet water temperature of the cold module falls below 4°C (the code generated signals that the antifreeze function has been activated). In this case the antifreeze function activates the plant water circulator.

Reset (deactivation of antifreeze function) occurs automatically when, with only the circulator on, the inlet and outlet water temperatures return to over 5°C (in this case the circulator switches oﬀ), or if the function itself is disabled.

u 275

INSUFFICIENT HOT SIDE WATER FLOW

On the hot side, the circulator is on and the ﬂowmeter is open for 5 seconds (insuﬃcient water ﬂow).

The warning automatically resets when the circulator switches oﬀ or the ﬂow meter closes for 5 seconds.

E 275

INSUFFICIENT HOT SIDE WATER FLOW

At the ﬁfth u_75 from machine power supply, or after two hours of u_75 presence, the error is generated.

Reset may be performed from the CCI/DDC (or from the S61 board via menu 2, parameter 1).

E 276

HOT WATER DELIVERY TEMPERATURE PROBE FAULT.

Fault (interruption or short circuit) on outlet hot water temperature sensor.

Reset may be performed from the CCI/DDC (or from the S61 board via menu 2, parameter 1).

E 277

HOT WATER RETURN TEMPERATURE PROBE FAULT.

Fault (interruption or short circuit) on inlet water temperature sensor.

Reset may be performed from the CCI/DDC (or from the S61 board via menu 2, parameter 1).

u 278

OUTLET HOT WATER TEMPERATURE TOO HIGH

Outlet hot water temperature too high

Reset is automatic and occurs when the condition that generated it ceases to apply.

u 279

DEFROST FUNCTION ACTIVATED HOT SIDE Activation takes place only if the hot module is oﬀ and the antifreeze function is enabled (see menu 1, parameter 163).

Antifreeze function activated (with function enabled: see menu 1, item163; and only with machine oﬀ). In this case the antifreeze function activates the plant water circulator. If this temperature falls further to below 3 °C, the function also activates the ﬂame controller.

Resets automatically (defrost function disabled) if, with only the circulator operating, the hot water inlet/outlet temperature rises above 5°C (at which point the circulator switches oﬀ); or, if also the ﬂame controller is on, when the temperature reaches 18 °C (in this case the ﬂame controller and then the circulator switch oﬀ).

u 280 INCOMPLETE PARAMETERS Incomplete parameters.

The code remains until operating parameters are entered and completed. Contact authorised Technical Assistance. If the board is replaced, Code E 80 may appear; this means that the unit’s characterisation parameters have not been set.

E 80/280 INVALID PARAMETERS

Invalid parameters or damage to parameter memory.

Reset occurs automatically when correct parameters are entered. If the code persists, contact authorised Technical Assistance: if the parameters are incorrect, it is necessary to enter and complete the unit operating and characterisation parameters; if the memory is damaged, the controller must be replaced.

u 281 INVALID BANK 1 PARAMETERS Invalid Bank 1 data - Bank 2 data OK. Reset occurs automatically 5 seconds after the code is generated.

E 281 INVALID BANK 1 PARAMETERS

The program attempts to resolve the problem by writing the second page over the ﬁrst; if after 5 attempts this fails, the error is generated.

Reset may be performed from the CCI/DDC (or from the S61 board via menu 2, parameter 1). If the code persists, contact authorised TAC.

u 282 PARAMETRI BANCO 2NON VALIDI Invalid Bank 2 data - Bank 1 data OK. Reset occurs automatically 5 seconds after the code is generated.

E 282 INVALID BANK 2 PARAMETERS

The program attempts to resolve the problem by writing the ﬁrst page over the second; if after 5 attempts this fails, the error is generated.

Reset may be performed from the CCI/DDC (or from the S61 board via menu 2, parameter 1). If the code persists, contact authorised TAC.

E 284

FAULTY TRANSFORMER CONNECTION OR 24 V AC FUSES

Damage to one of the 2 24-0-24 V AC transformer fuses, or one of 24-0-24 V AC wires to the board not supplying current.

Check fuses and 24-0-24 V AC electrical power connections on the controller. Reset may be performed from the CCI/DDC (or from the S61 board via menu 2, parameter 1). If the code persists or occurs again, contact authorised TAC.

E 285

INCORRECT MODULE TYPES (from menu 6)

The set module type (from menu 6) does not correspond to the one managed by the controller.

Reset occurs automatically when correct parameters are entered. If

the code persists, contact authorised Technical Assistance. E 286 MEMORY TEST UNSUCCESSFUL Processor error. Contact authorised Technical Assistance. E 287 MEMORY TEST UNSUCCESSFUL Processor error. Contact authorised Technical Assistance. E 288 MEMORY TEST UNSUCCESSFUL Processor error. Contact authorised Technical Assistance. E 289 MEMORY TEST UNSUCCESSFUL Processor error. Contact authorised Technical Assistance.

E 290

AMBIENT TEMPERATURE SENSOR DEFECTIVE

Interruption or short circuit of ambient temperature sensor.

Reset may be performed from the CCI/DDC (or from the S61 board

via menu 2, parameter 1). If the code persists, contact authorised

TAC.

E 291 CONTROLLER DEFECTIVE

One of the following is absent: serial number of board, hardware version code or encryption key written during board test.

Contact authorised Technical Assistance.

TABLE OF OPERATING CODES generated by the S61 electronic board (ﬁrmware version 3.024)

Page 84

Page 85

Installation, user and maintenance manual – GAHP-GS/WS

DECLARATION OF CONFORMITY

Figure 1

coscienza ecologica caring for the environment

Robur S.p.A. tecnologie avanzate per la climatizzazione advanced heating and cooling technologies www.robur.it [email protected] via Parigi 4/6 24040 Verdellino/Zingonia (BG) Italy T +39 035 888111 F +39 035 884165 capitale sociale € 2.028.000,00 i.v. iscritta al Registro Imprese di Bergamo n. 154968 codice fiscale/partita iva 00373210160 V.A.T. code IT 00373210160 società soggetta all’attività di direzione e coordinamento di Fin Robur S.a.p.A. di Benito Guerra & C.

EC – DECLARATION OF CONFORMITY

Manufacturer : Robur S.p.A. Address : Via Parigi 4/6 City, Country : Verdellino/Zingonia 24040 (Bg), Italy

This is to declare that the ROBUR Gas Absortion Heat Pump (GAHP) are in conformity with the following ECDirectives:

2006/42/EC

Machinery Directive with subsequent amendments and integrations.

2004/108/EC Electromagnetic Compatibility with subsequent amendments and integrations.

Tested and examined according to the following norms: EN55014-1, EN55014-2, EN61000-3-2, EN61000-3-3, EN62233.

2006/95/EC Low Voltage Directive with subsequent amendments and integrations. Tested and examined according to the following norms: EN50165, EN60335-2-102, EN60335-1.

2009/142/EC Gas Appliance Directive with subsequent amendments and integrations. Tested and examined according to the following norms: EN 12309-1. EN 12309-2, EN 483. As proved whit EC certification number 0964, issued by KIWA Italia S.p.A Via G. Carducci,5 Milan-Italy

97/23/EC Pressure Equipment Directive with subsequent amendments and integrations. As proved with EC Certification number 1370 of all the components under pressure of the III° category, issued by BUREAU VERITAS Italia S.p.A. Viale Monza, 261 Milan-Italy

Jvan Benzoni R&D Director

Robur S.p.A.

Page 86

Figure 2

coscienza ecologica caring for the environment

Robur Spa tecnologie avanzate per la climatizzazione advanced heating and cooling technologies www.robur.it [email protected] via Parigi 4/6 24040 Verdellino/Zingonia (Bg) Italy T +39 035 888111 F +39 035 884165

D-FGL073 rev.F 11 MCM SDC 030 del 14/12/2011

Dichiarazione di Conformita’ n°: Declaration of Conformity n°: Déclaration de conformité n°: Konformitätserklärung N°: Declaración de Conformidad n°: Verklaring van conformiteit n°:

Zingonia, li/den 14/12/2011

Con la presente si dichiara che i circuiti a pressione:

1. del Refrigeratore d’acqua a gas ad Assorbimento prodotto da ROBUR S.p.A., serie GA: ACF60-00

(standard e versioni speciali);

2. delle Pompe di Calore a gas ad Assorbimento prodotte da ROBUR S.p.A., serie GAHP: GS, WS, A, AR (standard e versioni speciali); serie GAS HP: G, W, A (standard e versioni speciali);

rispondono ai requisiti richiesti dalla Direttiva sulle attrezzature a pressione 97/23/CE (PED) come comprovato dal Certificato CE di Valutazione di Conformità nell'Insieme:

 MODULO H, Garanzia Qualità Totale, numero CE-1370-PED-H-ROB001-10-ITA

Rilasciato da:

BUREAU VERITAS ITALIA S.p.A.

Viale Monza 261

20126 Milano – Italy

Si precisa che tali circuiti sono dotati di una valvola di sicurezza (pressione di taratura 35 bar) conforme ai requisiti della stessa Direttiva 97/23/CE (PED).

Page 87

Installation, user and maintenance manual – GAHP-GS/WS

Figure 3

coscienza ecologica caring for the environment

D-FGL073 rev.F 11 MCM SDC 030 del 14/12/2011

We hereby declare that:

1. pressurized circuit of the Gas Absorption Chiller manufactured by ROBUR S.p.A., series GA: ACF60-00

(standard and special versions);

2. pressurized circuit of the Gas Absorption Heat Pump manufactured by ROBUR S.p.A., series GAHP: GS, WS, A, AR (standard and special versions); series GAS HP: G, W, A (standard and special versions);

comply with Pressure Equipment Directive 97/23/EC (PED) requirements, as proofed with EC Certification of all the components under pressure:

 MODULE H for “Total Quality Assurance”, number CE-1370-PED-H-ROB001-10-ITA

Issued by:

BUREAU VERITAS ITALIA S.p.A.

Viale Monza 261

20126 Milan- Italy

In particular, these circuits are equipped with one safety valve (pressure gauge set at 35 bar) conforming to the requirements of 97/23/EC (PED) Directive.

Nous déclarons par la présente que les circuits hermétiques pressurisés:

1. des unités à Absorption à gaz fabriquées par la Société ROBUR S.p.A., série GA: ACF60-00 (standard et versions spéciales);

2. des Pompes à Chaleur à Absorption à gaz fabriquées par la société ROBUR S.p.A., série GAHP: GS, WS, A, AR (standard et versions spéciales); série GAS HP: G, W, A (standard et versions spéciales);

répondent à la Directive sur les appareils sous pression 97/23/EC (PED) comme d’après le Certificat CE d’Evaluation de l’Ensemble sous Pression:

 MODULE H, “GARANTIE QUALITE TOTALE”, numéro CE-1370-PED-H-ROB001-10-ITA

Délivré par:

BUREAU VERITAS ITALIA S.p.A.

Viale Monza 261

20126 Milano – Italy

Nous précisons que ces circuits sont équipés d'une soupape de sécurité (pression de réglage 35 bar) conformément à la Directive 97/23/EC (PED)

Hiermit erklären wir, daß die hermetischen Kreisläufe:

1. der gasbefeuerte Absorptionskältemaschine , produziert durch ROBUR S.p.A., Typ GA: ACF60-00 (Standard und in den verschiedenen Ausführungen);

2. der Gasabsorptionswärmepumpe, produziert durch ROBUR S.p.A., Typ GAHP: GS, WS, A, AR (Standard und in den verschiedenen Ausführungen); Typ GAS HP: G, W, A (Standard und in den verschiedenen Ausführungen);

den Anforderungen der Druckbehälterverordnung 97/23/EC (PED) entsprechen und hiermit die EC Zertifizierung erfüllen im Ganzen:

x MODUL H, umfassende Qualitätssicherung CE-1370-PED-H-ROB001-10-ITA Ausgestellt von:

BUREAU VERITAS ITALIA S.p.A.

Viale Monza 261

20126 Milano – Italy

Hiermit möchten wir klarstellen , daß diese Behälter mit einem Sicherheitsventil (Eichungsdruck 35 bar) nach 97/23/EC (PED) Verordnung ausgerüstet sind.

Page 88

Figure 4

coscienza ecologica caring for the environment

D-FGL073 rev.F 11 MCM SDC 030 del 14/12/2011

Por la presente certificamos que los circuitos herméticos presurizado:

1) de las Máquinas de Absorción con gas fabricadas por la Empresa ROBUR S.p.A., serie GA: ACF60-00 (Standard y versiones especiales);

2) de las bombas de calor por ciclo de absorción con gas fabricadas por la Empresa ROBUR S.p.A., serie GAHP: GS, WS, A, AR (Standard y versiones especiales); serie GAS HP: G, W, A (Standard y versiones especiales);

se adaptan a la Directiva 97/23/EC (PED) sobre aparatos a presión, y han sido probados conforme al procedimiento EC en conjunto:

 MODULO H, control de aseguramiento de calidad total, número CE-1370-PED-H-ROB001-10-ITA

Efectuados por:

BUREAU VERITAS ITALIA S.p.A.

Viale Monza 261

20126 Milano – Italy

Se precisa que estos circuitos están equipados de una válvula de seguridad (presiòn de calibraciòn 35 bar) conforme a lo establecido en la Directiva 97/23/EC (PED).

Hierbij verklaren wij dat de drukcircuiten:

1) van de GasAbsorptie Koelers geproduceerd door ROBUR S.p.A., serie GA: ACF60-00 (standaard e speciale versies);

2) van de Gasabsorptiewarmtepomp geproduceerd door ROBUR S.p.A., serie GAHP: GS, WS, A, AR (standaard en speciale versies); serie GAS HP: G, W, A (standaard en speciale versies);

voldoen aan de voorwaarden van de Pressure Equipment Directive 97/23/EC (PED), zoals gecertificeerd door EC Certificaat voor alle componenten onder druk:

 Module H, Totale Qualiteits Garantie, nummer CE-1370-PED-H-ROB001-10-ITA

Gepubliceerd door:

BUREAU VERITAS ITALIA S.p.A.

Viale Monza 261

20126 Milaan-Italie

In het bijzonder is dit circuit uitgerust met een veiligheidsventiel (drukmeter op 35 bar) volgens de eisen van de 97/23/EC (PED) richtlijn.

ROBUR S.p.A.

Ing. Davide Schiavon

Quality and Safety Manager

Page 89

Installation, user and maintenance manual – GAHP-GS/WS

Page 90

Robur Spa tecnologie avanzate per la climatizzazione Via Parigi 4/6 24040 Verdellino/Zingonia (Bg) Italy T +39 035 888111 F +39 035 884165 www.robur.it [email protected]

Robur Mission

Revision: M Code: D-LBR509 12 MCM SDC 016 19/10/2012

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.