Installation, use and maintenance manual GA Line ACF Series Gas fired absorption chiller for cooling medium-large areas Natural gas/LPG fired
EDITION: 04/2012 Revision: H Code: D-LBR357 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.
Foreward FOREWARD This manual is designed to be an installation and user’s guide for the Robur series ACF60-00 absorption chiller. This manual especially applies to the plumbing and electrical installers for the hook-up of the ACF and the initial configuration, and also for the end user regarding its use. This manual also has a section regarding the operations that must be done before the first start-up and the primary maintenance operations.
Table of contents TABLE OF CONTENTS SECTION 1 GENERAL INFORMATION AND TECHNICAL SPECIFICATIONS ..............3 1.1 1.2 1.3 1.4 1.5 SAFETY WARNINGS .........................................................................................................................3 GENERAL INFORMATION.................................................................................................................5 OPERATION OF THE ACF60-00 ................................................................................
ACF60-00 – Installation, User’s and Maintenance Manual 2 Ed.
Section GENERAL INFORMATION AND TECHNICAL SPECIFICATIONS SECTION 1 GENERAL INFORMATION AND TECHNICAL SPECIFICATIONS In this section you will find the general instructions to follow for the installation of the ACF, and outlines on the running of the unit, constructive characteristics and the technical data. 1.1 SAFETY WARNINGS Packing items (plastic bags, polystyrene foam, nails, etc.) must be kept out of the reach of children, as they are potentially dangerous.
ACF60-00 – Installation, User’s and Maintenance Manual If you smell gas: • • • • 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.
Section GENERAL INFORMATION AND TECHNICAL SPECIFICATIONS 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.
ACF60-00 – Installation, User’s and Maintenance Manual Natural gas equipment Electrically powered equipment Any other standard that regulates the installation of air conditioning devices with gaseous fuel. It excludes the manufacturer from any contractual and non contractual obligations for damages caused to people, animals, or things due to incorrect installation and improper use of the ACF and also by not observing the indications and instructions provided by the manufacturer.
Section GENERAL INFORMATION AND TECHNICAL SPECIFICATIONS 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 carried out exclusively via a switch located on the on/off command circuit.
ACF60-00 – Installation, User’s and Maintenance Manual 1.3 OPERATION OF THE ACF60-00 The ACF60-00 is a gas chiller with absorption cooling cycle and air condenser/absorber. The liquid coolant is ammonia; the cooling cycle is run by thermal energy supplied by the combustion of natural gas, and is therefore characterized as having a limited need for electrical energy. The ACF runs on either natural gas or LPG and requires an electrical power supply of 230 V 1N – 50 Hz.
Section GENERAL INFORMATION AND TECHNICAL SPECIFICATIONS machine codes during operation, see “ON-BOARD ELECTRONICS” on page 30, and “TABLE OF OPERATING CODES “ on page 83. A C B KEY A 4 digit DISPLAY for the visualization of the data and operational codes B KNOB (encoder) for navigating and selecting of operational data C CAN PORT for the connection of the CAN-BUS network cable Figure 1 – The S61 electronic circuit board.
ACF60-00 – Installation, User’s and Maintenance Manual air-based heat exchanger with single-position finned coil, manufactured in steel tubing and aluminium fins; • water-based exchanger of the shell-and-tube type in titanium alloyed stainless steel, externally insulated; • variable-flow microprocessor-controlled axial fan; • control and safety devices: - S61 electronic board with integrated microprocessor, LCD display and encoder (in Figure 1); - plant water flow switch; - manually resettable generator li
Section GENERAL INFORMATION AND TECHNICAL SPECIFICATIONS 1.4 TECHNICAL SPECIFICATIONS ACF60-00, ACF60-00 S - TECHNICAL SPECIFICATIONS UNIT SIZE ACF60-00 ACF60-00 S OPERATIONAL CHARACTERISTICS NOMINAL HEAT CAPACITY AT THE BURNER COOLING CAPACITY (1) (2) 25.30 25.03 17.72 2770 2500 3200 kW kW CHILLED WATER FLOW RATE GAS CONSUMPTION NAT. GAS L.P.G.
ACF60-00 – Installation, User’s and Maintenance Manual ACF60-00, ACF60-00 S – COOLING CAPACITY CORRECTION FACTORS EXTERNAL AIR TEMPERATURE °C 3.0 5.0 7.0 9.0 0 0.98 0.99 1.01 1.03 5 0.98 0.99 1.01 1.03 10 0.98 0.99 1.01 1.03 15 0.98 0.99 1.01 1.03 20 0.98 0.99 1.01 1.03 25 0.97 0.99 1.01 1.03 30 0.90 0.98 1.01 1.03 35 0.67 0.87 1.00 1.02 40 — — 0.88 0.93 45 — — 0.67 0.
Section GENERAL INFORMATION AND TECHNICAL SPECIFICATIONS ACF60-00 TK, ACF60-00 TK S - TECHNICAL SPECIFICATIONS UNIT SIZE ACF60-00 TK ACF60-00 TK S OPERATIONAL CHARACTERISTICS NOMINAL HEAT CAPACITY AT THE BURNER COOLING CAPACITY (1) (2) 25.30 25.03 17.72 2770 2500 3200 kW kW CHILLED WATER FLOW RATE GAS CONSUMPTION NAT. GAS L.P.G.
ACF60-00 – Installation, User’s and Maintenance Manual ACF60-00 TK, ACF60-00 TK S – COOLING CAPACITY CORRECTION FACTORS EXTERNAL AIR TEMPERATURE °C 3.0 5.0 7.0 9.0 -12 1.18 1.18 1.19 1.20 -10 1.18 1.18 1.18 1.19 -8 1.17 1.17 1.18 1.19 -6 1.16 1.16 1.17 1.18 -4 1.16 1.16 1.16 1.18 -2 1.15 1.15 1.16 1.17 0 1.15 1.15 1.15 1.16 2 1.14 1.14 1.15 1.16 4 1.14 1.14 1.14 1.15 6 1.13 1.13 1.14 1.15 8 1.12 1.13 1.13 1.14 10 1.12 1.12 1.12 1.13 12 1.
Section GENERAL INFORMATION AND TECHNICAL SPECIFICATIONS ACF60-00 HT, ACF60-00 HT S - TECHNICAL SPECIFICATIONS UNIT SIZE ACF60-00 HT ACF60-00 HT S OPERATIONAL CHARACTERISTICS NOMINAL HEAT CAPACITY AT THE BURNER COOLING CAPACITY (1) (2) 25.30 25.03 17.12 2675 2500 3200 kW kW CHILLED WATER FLOW RATE GAS CONSUMPTION NAT. GAS L.P.G.
ACF60-00 – Installation, User’s and Maintenance Manual ACF60-00 HT, ACF60-00 HT S – COOLING CAPACITY CORRECTION FACTORS EXTERNAL AIR TEMPERATURE °C 5.0 7.0 10.0 12.5 14.0 0 1.02 1.02 1.02 1.02 1.03 2 1.02 1.02 1.02 1.02 1.03 4 1.02 1.02 1.02 1.02 1.03 6 1.02 1.02 1.02 1.02 1.03 8 1.02 1.02 1.02 1.02 1.03 10 1.02 1.02 1.02 1.02 1.03 12 1.02 1.02 1.02 1.02 1.03 14 1.02 1.02 1.02 1.02 1.03 16 1.02 1.02 1.02 1.02 1.03 18 1.02 1.02 1.02 1.02 1.
Section GENERAL INFORMATION AND TECHNICAL SPECIFICATIONS ACF60-00 LB, ACF60-00 LB S - TECHNICAL SPECIFICATIONS UNIT SIZE ACF60-00 LB ACF60-00 LB S OPERATIONAL CHARACTERISTICS NOMINAL HEAT CAPACITY AT THE BURNER COOLING CAPACITY (1) (2) 25.30 25.03 13.30 2600 2300 2900 kW kW CHILLED WATER FLOW RATE GAS CONSUMPTION NAT. GAS L.P.G.
ACF60-00 – Installation, User’s and Maintenance Manual ACF60-00 LB, ACF60-00 LB S – COOLING CAPACITY CORRECTION FACTORS – 1/2 EXTERNAL AIR TEMPERATURE °C -10,0 -7,0 -5,0 -2,0 0 -5 1.14 1.15 1.15 1.16 1.17 -4 1.14 1.15 1.15 1.16 1.17 -3 1.14 1.15 1.15 1.16 1.17 -2 1.14 1.15 1.15 1.16 1.17 -1 1.14 1.15 1.15 1.16 1.17 0 1.14 1.15 1.15 1.16 1.17 1 1.14 1.15 1.15 1.16 1.17 2 1.14 1.15 1.15 1.16 1.17 3 1.14 1.15 1.15 1.16 1.17 4 1.14 1.15 1.15 1.
Section GENERAL INFORMATION AND TECHNICAL SPECIFICATIONS ACF60-00 LB, ACF60-00 LB S – COOLING CAPACITY CORRECTION FACTORS – 2/2 EXTERNAL AIR TEMPERATURE °C -10.0 -7.0 -5.0 -2.0 0 27 1.04 1.07 1.10 1.13 1.15 28 1.02 1.06 1.09 1.12 1.15 29 1.01 1.05 1.08 1.11 1.14 30 0.99 1.03 1.07 1.10 1.14 31 0.97 1.02 1.06 1.09 1.13 32 0.95 1.00 1.05 1.08 1.12 33 0.93 0.98 1.03 1.07 1.11 34 0.90 0.96 1.02 1.06 1.10 35 0.88 0.94 1.00 1.04 1.08 36 0.85 0.92 0.
ACF60-00 – Installation, User’s and Maintenance Manual ACF60-00 HR, ACF60-00 HR S - TECHNICAL SPECIFICATIONS UNIT SIZE ACF60-00 HR ACF60-00 HR S OPERATIONAL CHARACTERISTICS NOMINAL HEAT CAPACITY AT THE BURNER (1) NOMINAL EFFECTIVE COOLING CAPACITY (2) (AIR CONDITIONING ONLY – NO RECOVERY) COOLING CAPACITY (3) (AIR CONDITIONING + RECOVERY) CHILLED WATER FLOW RATE GAS CONSUMPTION NAT. GAS L.P.G.
Section GENERAL INFORMATION AND TECHNICAL SPECIFICATIONS Remarks (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) Nominal conditions: 1013 mbar, 15 °C; Actual conditions: 1000 mbar, 20 °C Nominal running conditions: external air temperature 35°C; chilled water temperature - delivery 7.2 °C – return 12.7 °C. For conditions other than the nominal conditions, apply the cooling capacity correction factors seen in Table 12, page 21.
ACF60-00 – Installation, User’s and Maintenance Manual OPERATIONAL MODE: AIR CONDITIONING + HEAT RECOVERY EXTERNAL AIR TEMPERATURE °C 3.0 5.0 7.0 9.0 0 0.97 0.98 1.00 1.02 5 0.97 0.98 1.00 1.02 10 0.97 0.98 1.00 1.02 15 0.97 0.98 1.00 1.02 20 0.97 0.98 1.00 1.02 25 0.96 0.98 1.00 1.02 30 0.89 0.97 1.00 1.02 35 0.73 0.91 1.00 1.02 40 — 0.89 0.95 0.96 45 — — 0.80 0.
Section GENERAL INFORMATION AND TECHNICAL SPECIFICATIONS HEAT CAPACITY kW (Output = 1000 L/hr) RECOVERY SYSTEM HOT WATER RETURN TEMPERATURE °C EXTERNAL AIR TEMPERATURE °C 15 20 25 30 35 20 27.00 29.00 30.10 31.30 32.00 30 21.00 22.90 24.48 25.11 40 14.05 16.00 18.00 50 8.13 9.98 60 3.00 4.70 70 40 45 26.22 28.00 30.00 19.08 21.00 23.00 25.06 12.13 13.22 15.52 17.53 19.22 6.28 7.52 10.00 11.80 13.50 2.50 3.50 5.66 7.00 9.
ACF60-00 – Installation, User’s and Maintenance Manual ACF60-00, TK, HT, HR (also silenced version) PRESSURE DROP under nominal conditions 0.38 ACF60-00, PRESSURE DROP bar 0.36 TK, HT, HR 0.34 0.32 0.30 0.28 0.26 0.22 2500 2600 2700 2770 0.24 2800 2900 3000 3100 3200 WATER FLOW RATE L/hr Figure 4 – Pressure drop ACF60-00, TK, HT, HR, also silenced versions In case of glicole use see also Table 22 at pag.49.
Section GENERAL INFORMATION AND TECHNICAL SPECIFICATIONS PED Characteristics The ACF60-00 chiller has a pressurized hermetic circuit and is therefore subject to the to the Pressurized Equipment Directive (PED). The corresponding parameters and value are reported in the following table: PARAMETERS ACF60-00 ACF60-00 HR ACF60-00 TK ACF60-00 HT ACF60-00 LB FLUID CONTENT CHARACTERISTICS FLUID CONTENT kgH2O kgNH3 CHARGE 10 7.5 10 7.5 FLUID GROUP H2O + NH3 10 8.5 1° 10.5 7.5 10.5 7.
ACF60-00 – Installation, User’s and Maintenance Manual 1.5 ACF DIMENSIONS AND SERVICE PANELS 100 1290 ACF (Standard, TK, HT and LB versions) with standard ventilation (dimensions in mm) Figure 6 – 975 (*) 700 (*) 1230 850 Dimensions of the ACF (Standard, TK, HT and LB versions). See Figure 9 on page 28 for the measurements of the service panels.
Section GENERAL INFORMATION AND TECHNICAL SPECIFICATIONS 100 1280 1540 (260) ACF (all versions) with silenced ventilation (dimensions in mm) Figure 8 – 975 700 1230 850 Dimensions of the ACF60-00, TK, HT, LB, HR, silenced ventilation. The measurements of the service panels do not vary. According to the ACF type see Figure 9 or Figure 10, page 28. NOTE: the service panel represented does not pertain to the ACF HR; For this chiller see Figure 10, page 28 Ed.
ACF60-00 – Installation, User’s and Maintenance Manual Service panel for the ACF60-00, TK, HT, LB. The indicated measurements are expressed in mm, and are also valid for the corresponding silenced versions. KEY G A – WATER DELIVERY TO APPLIANCE Ø 1-¼” F B Ø 1-¼” F G – GAS SUPPLY Ø ¾” F 150 200 305 A B – WATER RETURN TO UNIT 108 164 181 Figure 9 – Dimensions of the service panel for the ACF60-00, TK, HT, LB and corresponding silenced versions.
Section END USER SECTION 2 END USER This section illustrates the commissioning of the ACF, its adjustments and the operation control by the circuit board in the electrical panel. 2.1 COMMISSIONING (AND SHUTDOWN) OF THE ACF Efficient functioning and the longevity of the ACF greatly depend on its correct use! If the ACF60-00 is connected to a Direct Digital Controller (DDC), its ignition and control are done exclusively through the DDC. In this case, refer to the manual supplied with the DDC.
ACF60-00 – Installation, User’s and Maintenance Manual arrest, see “TABLE OF OPERATING CODES “ on page 83). In this case, resetting does not occur automatically. To restart the ACF, reset the flame control unit from menu 2 of the electrical circuit board: the procedure is shown in paragraph 2.4, page 35. After resetting, the ACF will attempt another ignition.
Section END USER A C B KEY A 4 digit DISPLAY for the visualization of the data and operational codes B KNOB (encoder) for navigating and selecting of operational data C CAN PORT for the connection of the CAN-BUS network cable Figure 11 – The S61 electronic circuit board. The Display, Encoder and CAN-BUS Port Programming, control and monitoring of the ACF are done through the display and the circuit board encoder.
ACF60-00 – Installation, User’s and Maintenance Manual Menu’s 0, 1 and 7 are Display-Only Menu’s: information is only displayed and cannot be modified. Real-time data coming from the circuit board regarding the functioning of the ACF can be seen from menu 0; the characteristic operational parameters of the ACF and their current values can be seen on menu 1. Menu 7 displays information of use to Robur S.p.A. Authorized Service Centres, see above.
Section END USER Requirements: Installed and running ACF. To use the knob: 1. Remove the front panel by unscrewing the fastening screws. 2. Remove the special wrench from the tube above the electrical panel. 3. Remove the plug from the electrical panel to access the knob. 4. Through the hole, turn the knob using the special wrench.
ACF60-00 – Installation, User’s and Maintenance Manual To access the menu’s mentioned in Table 17 (seen on page 31) while the ACF is functioning, just press the knob once. Requirements: Accessibility to the electrical panel (see previous procedure). To navigate using the knob: 1. Run through the display elements by turning the knob in either direction, clockwise to see the next menu item and counter clockwise for the previous item. 2. Select an item by pressing the knob.
Section END USER 2.3 SETTING OF OPERATING PARAMETERS The operations described require the basic knowledge of both the installed appliance and the S61 electronic circuit board mounted on the ACF; You must be familiar with this information before proceeding, which can be found in paragraph 2.2 ON-BOARD ELECTRONICS on page 30. During the installation process, the ACF is configured by the installer to operate in the most efficient manner for the type of system used.
ACF60-00 – Installation, User’s and Maintenance Manual 1. appears on the display: press the knob to access the menu. The display shows option 0 first, . 2. Press the knob and the reset request will begin flashing: 3. Press the knob again to reset the flame control unit: The reset request stops flashing will again appear on the display. The resetting operation is now and finished. 4.
Section END USER 2.5 WARNING AND ERROR CODES • • • • If the ACF does not function correctly, before contacting a Robur authorized Technical Service Centre, perform the following simple checks: Check that the control switch (see “COMMISSIONING (AND SHUTDOWN) OF THE ACF” on page 29) is in the ON position; Check that the main power switch is in the ON position, or rather the position where the contacts are closed; Check that the gas valve is open.
ACF60-00 – Installation, User’s and Maintenance Manual 2.6 PROLONGED INACTIVITY When the ACF is expected to be inactive for a long period of time, it is best to follow the shutdown and eventual start-up indications reported below. Shutdown for extended period of time Requirements: The ACF must be powered and running. To shut down the ACF for a long period of inactivity, proceed as follows: 1. 2. 3. 4. Turn off the ACF from the control switch and not from the main power switch.
Section PLUMBING INSTALLER SECTION 3 PLUMBING INSTALLER This section describes the operations to be performed for the correct plumbing installation of the ACF60-00. The plumber must consult with the electrician to determine the correct sequence of operations to follow. WARNING: An incorrect installation could cause harm to people, animals or objects: before installation, carefully read the “SAFETY WARNINGS” found on page 3. 3.
ACF60-00 – Installation, User’s and Maintenance Manual 3.2 POSITIONING OF THE ACF60-00 Keep the ACF60-00 in its packaging in which it was delivered throughout all the moving stages. The packaging is only removed at the time of final installation. Lifting the ACF If the ACF must be lifted, connect cables to the openings on the supports at the base of the ACF, and use support bars and spacers so that the cables don’t damage the ACF panels while moving (see Figure 12).
Section PLUMBING INSTALLER 600 600 Also avoid installing the unit in corners to avoid the amplification of the noise due to reverberation. Position the appliance so as to maintain minimum clearances from combustible surfaces, walls or other appliances, as illustrated in Figure 13. Minimum clearances are are required to make maintenance possible Do not install any cover or obstruction to the evacuation of the air issuing from the fan.
ACF60-00 – Installation, User’s and Maintenance Manual Ground installation Place the ACF on a flat, level surface (support base) made of fireproof material. If a horizontal support base is not available, a flat and level base made of cement must be made that is slightly larger than the base of the ACF: at least 100-150 mm per side; the dimensions of the ACF are reported in the “TECHNICAL SPECIFICATIONS” paragraph on page 11.
Section PLUMBING INSTALLER 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 20 must be complied with. Table 20 - Chemical and physical parameters of water.
ACF60-00 – Installation, User’s and Maintenance Manual Robur is not liable for ensuring that water quality is always compliant with what reported in Table 20 is not’s. Non-compliance with indications above may jeopardize the proper operation, integrity and reliability of Robur appliances, invalidating the warranty. For any further detail, please contact directly Robur S.p.A. (tel.+39 035.888.111).
Section PLUMBING INSTALLER The figure below is a diagram of the ACF60-00 water connections: 9 IF USED ® GAS P DELIVERY RETURN P ACF60-00 1 2 3 4 5 6 7 8 KEY 1 FLEXIBLE CONNECTORS 6 PUMP 2 PRESSURE GAUGES 7 EXPANSION VESSEL 3 FLOW CONTROL VALVE 8 ACCUMULATION TANK 4 WATER FILTER 9 DIRECT DIGITAL CONTROLLER 5 SHUT-OFF VALVE Figure 14 – (available as an accessory) Water system diagram for one ACF60-00 Accumulation Tank The configuration of the plant requires a constant circul
ACF60-00 – Installation, User’s and Maintenance Manual However, the use of an accumulation tank is an ideal solution to compensate for sudden pressure changes, especially when the water circuit contains less than 70 litres of water for each ACF installed. Figure 15 shows 2 examples with the use of accumulation tanks: as in-line accumulation and as primary and secondary division of the circuit. GAS ® P DELIVERY P EXPANSION VESSEL FLEX. CONN. ACC.
Section PLUMBING INSTALLER DDC GAS 9 ® ® 1 P P 2 P P 3 4 5 8 7 6 KEY 1 FLEXIBLE CONNECTORS 6 PUMP 2 PRESSURE GAUGES 7 EXPANSION VESSEL 3 FLOW CONTROL VALVE 8 ACCUMULATION TANK (needed for each ACF with plant water content less than 70 litres) 4 WATER FILTER 9 DIRECT DIGITAL CONTROLLER (available as an accessory 5 SHUT-OFF VALVE Figure 16 – Connection diagram between ACF60-00’s 3.4 GAS SUPPLY SYSTEM The ACF60-00 is designed to run on either natural gas or L.P.G.
ACF60-00 – Installation, User’s and Maintenance Manual LPG can have corrosive effects. The pipe connections must be done using materials that resistant to this corrosive action. The vertical gas pipes must have a siphon and a condensation trap due to the formation of condensation in the pipes during the colder months. The gas pipes may need to be thermally insulated to prevent the excessive formation of condensation.
Section PLUMBING INSTALLER which the ACF is installed and to the specific usage requirements in relation to the ACF model installed (see paragraph 1.4 TECHNICAL SPECIFICATIONS, page 11). Antifreeze must also be used to prevent the formation of ice in the ACF’s evaporator during normal operation, which could cause damage if the volume of water in the appliance or in the primary circuit is less than 70 litres for each ACF.
ACF60-00 – Installation, User’s and Maintenance Manual 3.6 SETTING OF THE WATER PARAMETERS The operations described in this paragraph are only necessary if the ACF is not connected to a Direct Digital Controller (DDC). If the ACF is connected to a DDC, refer to the manual provided with the DDC. This paragraph describes the hydraulic parameter settings on the S61 circuit board of the ACF. If you are not familiar with basic usage procedures of the circuit board, refer to paragraph 2.
Section PLUMBING INSTALLER • • • • The ACF is running: the water is chilled until the Set-Point temperature of +7°C is reached. The ACF turns off: the temperature of the water increases until 9°C is reached (7°C + 2°C). The ACF turns on: the water is again chilled. The cycle repeats itself. The following procedure details how to configure the parameters of the electronic circuit board on the ACF.
ACF60-00 – Installation, User’s and Maintenance Manual 52 Ed.
Section ELECTRICAL INSTALLER SECTION 4 ELECTRICAL INSTALLER This section explains the procedures to follow for the correct electrical hook-up of the ACF60-00, and also gives the wiring diagrams which may be useful for any maintenance interventions. The electrical connections must be done by a Qualified Service Engineer in conformance with EU regulations and in accordance with local norms and regulations.
ACF60-00 – Installation, User’s and Maintenance Manual ACF Hook-up Requirements: The ACF must be positioned in its final location. To connect the ACF to the electrical power supply line and to connect a control switch: 1. Obtain a FG7(O)R 3Gx1,5 type cable for the electrical power supply of the ACF. 2.
Section ELECTRICAL INSTALLER 4.2 APPLIANCE PUMP CONTROL The primary circulation pump/s must be controlled by the S61 board, or directly (via “N.O. contact” contacts) or indirectly (“OR” use of said contacts by BMS type external systems). Otherwise, the primary circulation pump/s must be running permanently. Controlling the pump by means of the ACF circuit board The controlling of the water circulation pump by the ACF60-00 electronic circuit board depends on the power of the pump itself.
ACF60-00 – Installation, User’s and Maintenance Manual 4.3 PUMP AND ELECTRICAL WIRING DIAGRAMS Connection of the water circulation pump Pump controlled by the ACF, power draw <700W KEY SCH1 CIRCUIT BOARD J10 CLOSED JUMPER NO CONCTAT N.O. VOLTAGE FREE CONTACTS MA UNIT TERMINAL BLOCK L PHASE N NEUTRAL Components NOT SUPPLIED PM WATER PUMP <700W Figure 19 – Pump wiring with draw < 700W, controlled directly by circuit board.
Section ELECTRICAL INSTALLER Heat recovery circulator pump connection (ONLY for HR model) Pump connection for a single ACF - HR KEY SCH1 MA KP KPt KPS CIRCUIT BOARD UNIT TERMINAL BLOCK UNIT RELAY FOR HEAT RECOVERY CIRCULATOR PUMP PERMISSIVE DHW TANK THERMOSTAT (not supplied) DHW TANK THERMOSTAT SET AT 35°C WITH CAPILLARY PUT ON THE LOWER TANK REGION (not supplied) [to be install in case the heating recovery water flow is higher than the nominal of 1000 l/h] IP BIPOLAR DISCONNECTING DEVICE FOR HEAT RECOVE
ACF60-00 – Installation, User’s and Maintenance Manual Pump connection for n.
Section ELECTRICAL INSTALLER Independent Pump connection for several ACF - HR Under Insaller Responisibility KEY SCH1 MA KP1-2 KPt KPs CIRCUIT BOARD UNIT TERMINAL BLOCK UNIT RELAYS FOR HEAT RECOVERY COMMON CIRCULATOR PUMP PERMISSIVE DHW TANK THERMOSTAT (not supplied) DHW TANK THERMOSTAT SET AT 35°C WITH CAPILLARY PUT ON THE LOWER TANK REGION (not supplied) [to be install in case the heating recovery water flow is higher than the nominal of 1000 l/h] IP BIPOLAR DISCONNECTING DEVICE FOR HEAT RECOVERY POWE
Figure 24 – 60 GAS SOLENOID VALVE GV IGNITION ELECTRODES DETECTION ELECTRODES FAN MOTOR GAS VALVE OPEN MANUALLY RESETTING TEMP. LIMIT SWITCH EXHAUST TEMP. THERMOSTAT AIR PRESSURE GAUGE IGN FLS FAN LS TL TFA PSW ASPIRATOR MOTOR CONDENSER FLAME CONTROL UNIT CNT BOX BLW C CIRCUIT BOARD SCH1 KEY Ed. 04/2012 ACF60-00 HR internal wiring 4.
Section ELECTRICAL INSTALLER The intermediate nodes are ACF or DDC that are connected to two other elements. This concept is illustrated in the following diagram. a) b) ® ® DDC 1 2 CAN-BUS CABLE (NOT SUPPLIED) SEE Table 24, PAG. 61. A Figure 25 – 3 2nd SEGMENT CANBUS CABLE (NOT SUPPLIED) SEE Table 24, PAG. 61. B Examples of CAN BUS networks with: a) 2 nodes = 1 ACF + 1 DDC ® DDC 1 A 2 1st SEGMENT CANBUS CABLE (NOT SUPPLIED) SEE Table 24, PAG. 61.
ACF60-00 – Installation, User’s and Maintenance Manual For a total distance of ≤ 200 m and a network with a maximum of 6 nodes (typical example: up to 5 ACF60-00’s + 1 DDC) a simple 3x0.75 mm shielded cable can be used. Calculate the length necessary for the current installation, then purchase the correct cable. As seen in the table, the CAN connection requires a 3 wire CAN BUS cable. If the cable being used has more than 3 coloured wires, choose the colours to be used and cut the unnecessary wires.
Section ELECTRICAL INSTALLER Before working on the electric panel of the ACF, ensure that the electrical power supply is disconnected. 1. Remove the front panel of the ACF and the cover of the electrical panel. 2. Cut the ideal length of cable for the installation so that it will not undergo bending. 3.
ACF60-00 – Installation, User’s and Maintenance Manual KEY SCH GNDL H J1 A B P8 Elettronic circuit board Common data LOW signal data HIGHT signal data Board CAN BUS Jumper Detail for “ terminal node” (3 wires; J1 = jumpers “closed”) Detail for “ intermediate node” (6 wires; J1 = jumpers “opened) CAN PORT/connector Figure 27 – Connection CAN PORT S61 electronic board After all the operations have been performed, close the electrical panel and remount the front cover of the ACF. 64 Ed.
Section ELECTRICAL INSTALLER Connection of the CAN BUS cable to the DDC The CAN BUS cable is connected to the special orange connector supplied with the DDC, seen in Figure 28. Figure 28 – Orange connector supplied with the DDC for connecting the wires of the CAN BUS cable. Before working on the DDC, make sure that it is off. The DDC, just as the electronic circuit board of the ACF, has jumpers that need to be positioned for either an intermediate or a terminal node.
ACF60-00 – Installation, User’s and Maintenance Manual Requirements: Accessibility to the rear cover of the DDC. To connect a CAN BUS cable to a DDC: 1. Position the jumpers on the DDC according to the type of node being configured: If necessary, open the rear cover of the DDC by loosening the 4 screws; after the jumpers have been correctly configured, close the cover and tighten the 4 screws.
Section ELECTRICAL INSTALLER 4. Choose one end of the cable and remove about 70-80 mm of the protective outer covering being careful not to cut the shielding (metallic screen and/or aluminium foil, and if present, the raw connector in contact with the screen) and the wires inside. 5. Pull back the shielding and connect it to a 4mm eyelet, as seen in Figure 29 on page 65, letters C and D. Then proceed as follows: 6.
ACF60-00 – Installation, User’s and Maintenance Manual OBLIGATORY GROUND Respect polarity Figure 32 – Electrical power supply hook-up of the DDC to the 4 pole connector.
Section ELECTRICAL INSTALLER JUMPER CLOSED JUMPER CLOSED KEY DDC DIRECT DIGITAL CONTROLLER (accessory) SCH1 ELECTRONIC CIRCUIT BOARD GND COMMON DATA SIGNAL Figure 33 – L H LOW DATA SIGNAL HIGH DATA SIGNAL Diagram of one ACF connected to a Direct Digital Controller (DDC). Ed.
JUMPER CLOSED JUMPER OPEN JUMPER CLOSED ACF60-00 – Installation, User’s and Maintenance Manual Figure 34 – 70 Diagram of two ACF60's connected to a Direct Digital Controller (DDC). Ed.
Section ELECTRICAL INSTALLER KEY SCH1 J10 NO CONTACT MA L N CIRCUIT BOARD OPEN JUMPER N.O VOLTAGE FREE CONTACTS UNIT TERMINAL BLOCK’ PHASE NEUTRAL Components NOT SUPPLIED PM KP PTR IP Figure 35 – WATER PUMP PUMP RELAY SELV SAFETY TRANSFORMER BIPOLAR PUMP SWITCH Example of pump/appliance electrical connection with 230 Vac pump, controlled directly by the appliance through a relay and a SELV safety transformer Ed.
ACF60-00 – Installation, User’s and Maintenance Manual 4.5 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: 1. The cable required to connect the reset button must be 3x0,75mm2. 2. Cut a suitable length of cable. 3. Connect the cable to the blind terminals A (see Figure 36).
Section INITIAL STARTUP AND MAINTENANCE SECTION 5 INITIAL STARTUP AND MAINTENANCE This section describes the initial start-up and maintenance operations. 5.1 INITIAL STARTUP AND ADJUSTING Initial start-up The initial start-up of the ACF should by done by a Robur S.p.A. Authorized Technical Service Centre. . Before starting up the ACF, read paragraph 1.1 on page 3 and also paragraph 2.1 on page 29.
ACF60-00 – Installation, User’s and Maintenance Manual DANGEROUS SITUATIONS TO PEOPLE AND THE ACF: The ACF is installed in a closed room. The ACF is installed at an insufficient distance from flammable surfaces, or installed in a manner that does not permit maintenance operations to be carried out safely.
Section INITIAL STARTUP AND MAINTENANCE 4. Read the static pressure value of the network on the pressure gauge and check that it is within the required pressure limits (see "GAS SUPPLY SYSTEM” on page 47). 5. Close the gas supply valve. 6. Disconnect the pressure gauge and replace the seal screw of the gas pressure jack. To adjust the gas flow on the ACF: 1. With the gas valve closed, loosen the sealing screw on the gas pressure outflow jack, letter C in Figure 37 on page 76. 2.
ACF60-00 – Installation, User’s and Maintenance Manual B C A BURNER PRESSURE REGULATION SCREW B INCOMING PRESSURE JACK C OUTGOING PRESSURE JACK A Figure 37 – GAS valve (SIT 830) of the ACF60-00 Setting of the Water Parameters The adjustment of the temperature, set-point and differential of chilled water is done from menu 3 of the electronic circuit board; the procedure is shown in paragraph 3.6 on page 50. 5.
Section INITIAL STARTUP AND MAINTENANCE 7. 8. 9. 10. 11. 12. 13. kit, taking care to centre the manostat pipe with the hole present on the top edge of the diaphragm itself (see detail H); refit the exhaust air extractor nozzle to the exhaust fan, taking care to position the new gasket (supplied) correctly: during this operation, rotate the nozzle so that the crescent-shaped shield is repositioned in the top half (i.e.
ACF60-00 – Installation, User’s and Maintenance Manual DETAIL B DETAIL A DETAIL D DETAIL F Figure 38 – 78 DETAIL C DETAIL E DETAIL G DETAIL H Gas conversion operations. Ed.
Section INITIAL STARTUP AND MAINTENANCE 5.3 MAINTENANCE Proper maintenance prevents problems, guarantees maximum operational efficiency of the ACF and reduces operating costs. Before starting any work on the ACF, turn it off from the control switch that was installed by the electrician: Allow the ACF to complete the shutdown cycle, then shut off the electrical power supply from the main power switch and close the gas valve.
ACF60-00 – Installation, User’s and Maintenance Manual Maintenance operations NOT to be performed by the end user, but by a Robur S.p.A. Authorized Technical Service Centre. .
Section ACCESSORIES SECTION 6 ACCESSORIES This section gives a list of the available accessories for the ACF60-00. To order any of these accessories, contact Robur S.p.A. by calling +39 035 888 111. ACF60-00 Accessories ACCESSORIES FOR THE WATER SYSTEM INSTALLER Name Description Code CONDENSOR COIL FILTER KIT Filters the impurities in the air taken in by the coil and makes cleaning easier.
ACF60-00 – Installation, User’s and Maintenance Manual 82 Ed.
APPENDIX APPENDIX WARNINGS AND ERRORS If the ACF is connected to a DDC, the warnings and errors will be displayed by the DDC and also by the electronic circuit board; for further information see the documentation regarding this issue. Warnings and Errors Two types of machine codes appear on the ACF60-00’s electronic circuit board display: a) Warnings: identified by the green flashing letter “u” on the display, followed by the code of the warning that is occurring.
ACF60-00 – Installation, User’s and Maintenance Manual CODE GENERATED BY: RESET METHOD: U 3 COLD WATER ANTIFREEZE THERMOSTAT Low temperature detected by cold outlet water sensor. Reset occurs automatically when the condition that generated the code ceases. CODE GENERATED BY: RESET METHOD: INADEQUATE VENTILATION / CONDENSER OVERHEATING (TCN - TA) values > limit set. Reset occurs automatically 20 minutes after the code is generated.
APPENDIX CODE GENERATED BY: RESET METHOD: U 12 FLAME CONTROL UNIT ARREST Failure to ignite burner. Reset occurs automatically when the electrovalve opens again (new attempt at ignition), or after code is active for 5 minutes. E 12 FLAME CONTROL UNIT ARREST CODE GENERATED BY: RESET METHOD: Flame arrest signal. Reset may be performed via DDC (or S61 board via menu 2, parameter 0). If the code persists, contact authorised Robur TAC.
ACF60-00 – Installation, User’s and Maintenance Manual MODALITA’ DI RIARMO: U 77 FLOWMETER ON WITH PLANT IN HEATING MODE The flowmeter of the cold circuit detects the presence of water in the circuit, when (and only in this situation) the appliance is configured as a 2-pipe hot-cold system and the plant is operating at that moment in heating mode. The code (U 77) does not intervene when you have the antifreeze function. Reset is automatic and occurs when the condition that generated it ceases to apply.
APPENDIX APPENDIX DECLARATION OF CONFORMITY Ed.
ACF60-00 – Installation, User’s and Maintenance Manual 88 Ed.
APPENDIX Ed.
ACF60-00 – Installation, User’s and Maintenance Manual 90 Ed.
30/04/2012 Codice: D-LBR357 rev.H 12MCM SDC 008 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. Robur Mission Robur Spa advanced heating and cooling technologies Via Parigi 4/6 24040 Verdellino/Zingonia (Bg) Italy T +39 035 888111 F +39 035 4821334 www.robur.com export@robur.
