Installation, user and maintenance manual GITIE` AHAYPDF

Transcription

Installation, Use and
Maintenance Manual
Gitié - AHAY
Integrated group for outdoor installation
with absorption heat pump and condensing boiler
Revision: C
Code: D-LBR723
This manual has been drawn up and printed by Robur S.p.A.; whole or partial reproduction of this manual is
forbidden.
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.

INDEX OF CONTENTS
I. INTRODUCTION��4
II. SYMBOLS AND DEFINITIONS��4
1Key to symbols��4
2Terms and definitions��4
III. WARNINGS��4
1General and safety warnings��4
2Conformity��6
3Exclusions of liability and warranty��6
4ELECTRICAL INSTALLER��32
1FEATURES AND TECHNICAL DATA��6
1.1Features��6
1.2Dimensions��8
1.3Components�� 10
1.4Wiring diagrams�� 14
1.5Electronic boards�� 18
1.6Controls�� 20
1.7Technical characteristics�� 21
3.1Warnings�� 25
3.2Installation�� 25
3.3Hydraulic connections�� 25
3.4Water circulation pumps�� 27
3.5Anti-icing function�� 27
3.6Anti-icing liquid�� 27
3.7System water quality�� 28
3.8Installation filling�� 28
3.9Fuel gas supply�� 28
3.10GAHP-A unit combustion products exhaust�� 29
5.1Preliminary checks�� 37
6NORMAL OPERATION��38
2.2Handling�� 23
2.3Appliance placement�� 24
2.4Minimum clearance distances�� 24
2.5Mounting base�� 25
3HEATING ENGINEER��25
4.2Electrical systems�� 33
4.3Electrical power supply�� 33
4.4Set-up and control�� 33
4.5Water circulation pumps (versions C0)�� 35
5FIRST START-UP��37
2TRANSPORT AND POSITIONING��23
3.11AY00-120 unit combustion products exhaust�� 30
3.12Combustion products exhaust through the flue
�� 31
3.13Flue gas condensate discharge�� 31
3.14Defrosting water drainage�� 32
6.2Switch on and off�� 38
6.3Messages on the display�� 38
6.4Electronic adjustment on the machine – Menus
and parameters of the S61 board and of the
AY10 board�� 38
6.5How to modify settings�� 40
6.6How to restart a locked-down unit - Reset�� 40
6.7Efficiency handbook�� 41
7MAINTENANCE��41
7.2Pre-emptive maintenance�� 41
7.3Scheduled routine maintenance�� 42
7.4Periods of inactivity�� 42
8DIAGNOSTICS��42
8.1Operative codes�� 42
APPENDICES��47
1Declaration of Conformity�� 47
2Product fiche�� 48
Installation, Use and Maintenance Manual – Gitié - AHAY
3
I. Introduction
I. INTRODUCTION
Manual
This Manual is an integral part of the unit Gitié - AHAY
and must be handed to the end user together with it.
Recipients
This Manual is intended for:
▶▶
end user, for appropriate and safe use of the appliance;
▶▶
qualified installer, for correct appliance installation;
▶▶
planner, for specific information on the appliance.
Control device
In order to be able to work, the unit Gitié - AHAY needs a control
device (DDC or external enables), which must be connected by
the installer.
II. SYMBOLS AND DEFINITIONS
1 KEY TO SYMBOLS
DANGER
WARNING
NOTE
PROCEDURE
REFERENCE (to other document)
2 TERMS AND DEFINITIONS
Gitié AHAY Appliance/Package = equivalent terms, both used
to designate the integrated package consisting of a GAHP-A unit
and a condensation boiler AY00-120.
GAHP Appliance/Unit = equivalent terms, both used to designate the gas powered absorption heat pump GAHP (Gas Absorption Heat Pump).
AY00-120 Boiler/Unit = equivalent terms, both used to designate the condensation boiler AY00-120.
CAT = Technical Assistance Centre authorised by Robur.
External enable = generic control device (e.g. thermostat, clock
or any other system) equipped with a NO clean contact and used
as control to start/stop the GAHP unit and the AY00-120 boiler.
DDC Control (Direct Digital Controller) = optional Robur adjustment device to control one or more Robur appliances (GAHP
heat pumps, GA chillers and AY00-120 boilers) in ON/OFF mode.
RB100/RB200 Devices (Robur Box) = optional interface devices complementary to DDC, which may be used to broaden its
functions (heating/cooling/DHW production service demands,
and control of system components such as third party generators, adjustment valves, circulators, probes).
Thermal generator = equipment (e.g. boiler, heat pump, etc..)
for heat production for heating and/or DHW.
GUE (Gas Utilization Efficiency) = efficiency index of gas chillers
and heat pumps, equal to the ratio between the thermal energy
produced and the energy of the fuel used (relative to LCV, lower
calorific value).
First Switch-One = appliance commissioning operation which
may only and exclusively be carried out by a TAC.
S61/Mod10/W10 Boards = electronic boards on the GAHP unit,
to control all functions and to provide interface with other devices and with the user.
S70/AY10 Boards = electronic boards on the AY00-120 boiler, to
control all functions and to provide interface with other devices
and with the user.
III. WARNINGS
1 GENERAL AND SAFETY WARNINGS
Installer's qualifications
Installation must exclusively be performed by a Qualified Firm and by Skilled Personnel, with specific knowledge on heating, cooling, electrical systems and gas
appliances, in compliance with the laws in force in the
Country of installation.
Declaration of Conformity
Upon completing installation, the installing firm shall
issue to the owner/client the appliance's Workmanlike
Conformity Declaration, according to national/local
4
regulations in force and the manufacturer's instructions/
provisions.
Misuse
The appliance must only be used for the purposes for
which it has been designed. Any other use is deemed
hazardous. Incorrect use may affect operation, duration
and safety of the appliance. Adhere to the manufacturer's instructions.
Hazardous situations
▶
o not start the appliance in hazardous conditions,
D
such as: gas smell, problems with the plumbing/electrical/gas system, parts of the appliance under water
III. Warnings
or damaged, malfunctioning, disabling or bypassing
control and safety devices.
▶
▶
▶
In case of danger, request intervention by skilled
personnel.
I n case of danger, switch off the electrical power and
gas supplies only if this can be done in total safety.
o not entrust children, persons with physical, sensoD
ry or mental disabilities or persons with poor knowledge and experience with use of the appliance.
▶
▶
▶
Gas component tightness
▶
efore performing any operation on gas ducting
B
components, close the gas cock.
pon completing any procedure, perform the tightU
ness test according to regulations in force.
If you smell gas:
▶
▶
▶
o not use electrical devices such as telephones,
D
multimeters or other equipment that may cause
sparks next to the appliance.
Shut off the gas supply by turning the cock off.
isconnect electrical power supply by means of the
D
external isolation switch in the power supply electrical panel.
se a telephone away from the appliance to ask for
U
intervention from skilled personnel.
Poisoning
▶
▶
E nsure the flue gas ducts are tightness and compliant with the regulations in force.
pon completing any procedure, ensure compoU
nents are tightness.
Moving parts
The appliance contains moving parts.
▶
▶
isconnect the electrical power supply before any
D
work/procedure on appliance components.
F or electrical connections exclusively use compliant
components and according to the specifications provided by the manufacturer.
Ensure the appliance cannot be accidentally
switched back on.
Earthing
Electrical safety depends on effective earthing system,
correctly connected to the appliance and installed according to the regulations in force.
Gas smell
▶
Request assistance from the TAC.
Electrocution hazard
▶
▶
In the event of coolant leak keep away and disconnect the power and gas supply (only if it is possible
to do so with no danger).
o not remove guards during operation, and in any
D
case prior to disconnecting the power supply.
Burn hazard
Distance from combustible or flammable materials
▶
o not store flammable materials (paper, solvents,
D
paint, etc.) in the vicinity of the appliance.
Limescale and corrosion
Depending on the chemical/physical properties of the
system water, limescale or corrosion may damage the
appliance (Paragraph 3.7 p. 28).
▶
Check system sealing.
▶
Avoid frequent top-ups.
Chloride concentration
The concentration of chlorides or free chlorine in the
system water must not exceed the values in Table
3.2 p. 28.
Aggressive substances in air
Halogenated hydrocarbons containing chlorine and
fluorine compounds cause corrosion. The supply/ventilation air of the appliance must be free from aggressive
substances.
The appliance contains very hot parts.
▶
o not open the appliance and do not touch internal
D
components before the appliance has cooled down.
Acid flue gas condensate
▶
Pressure vessels
The appliance has a sealed circuit classified as pressure vessel, the tightness of which is tested by the
manufacturer.
▶
o not carry out any intervention on the sealed cirD
cuit or on the appliance's valves.
Water-ammonia solution
The GAHP unit uses the ammonia-water absorption
cycle. The water-ammonia solution is contained in the
sealed circuit. The solution is harmful for health if it is
ingested, inhaled or comes in contact with the skin.
ischarge the acid condensate of combustion flue
D
gas, as indicated in Paragraph 3.13 p. 31, in compliance with current exhaust regulations.
Switching the appliance off
▶
▶
E xcept in the case of danger, do not disconnect the
power supply to switch off the appliance, but always
and exclusively act through the control device provided (DDC or external enable).
isconnecting the power supply while the appliance
D
is running may cause permanent damage to internal
components.
In the event of failure
5
1 Features and technical data
▶
In the event of failure of the appliance and/or breakage of any component, do not attempt to repair and/
or restore and immediately contact the TAC.
Operations on internal components and repairs may
exclusively be carried out by a TAC, only using original
parts.
▶▶
▶▶
▶▶
NI EN 677 Specific requirements for condensing boilers
U
with nominal heating capacity up to 70 kW.
EN 378 Refrigerating systems and heat pumps.
NI EN 483 Type C boilers with nominal thermal capacity no
U
greater than 70 kW.
Other applicable provisions and standards
Routine maintenance
Proper maintenance ensures the efficiency and good
operation of the appliance over time.
▶
▶
▶
▶
aintenance must be performed according to the
M
manufacturer's instructions (see Chapter 7 p. 41)
and in compliance with current regulations.
ppliance maintenance and repairs may only be enA
trusted to firms legally authorised to work on gas appliances and systems.
Electrical systems and equipment.
▶▶
Heating and air conditioning systems, and heat pumps.
Environmental protection and combustion products exhaust.
E nter into a maintenance contract with an authorised specialised firm for routine maintenance and for
servicing in case of need.
▶▶
Fire safety and prevention.
Only use original parts.
▶▶
Any other applicable law, standard and regulation.
If the appliance is to be disposed of, contact the manufacturer for its disposal.
Keep the Manual
This "Installation, Use and Maintenance Manual" must
always accompany the appliance and must be handed
to the new owner or installer in the event of sale or
removal.
2 CONFORMITY
EU Directives and standards
The integrated Gitié packages comply with the requirements of
the following Directives:
▶▶ UNI EN 12309-1 and 2:2000, gas absorption heat pumps and
chillers with thermal capacity not exceeding 70 kW.
▶▶
Gas Directive 90/396/EEC as amended and added.
▶▶
Efficiency Directive 92/42/EEC as amended and added.
Electromagnetic compatibility Directive 89/336/EEC as
amended and added.
▶▶
Low Voltage Directive 73/23/EEC as amended and added.
▶▶
Machinery Directive 2006/42/EC.
▶▶
▶▶
▶▶
Decommissioning and disposal
▶▶
The design, installation, operation and maintenance of the systems shall be carried out in compliance with current applicable
regulations, depending on the Country and location, and in accordance with the manufacturer's instructions.
In particular, regulations regarding the following shall be complied with:
▶▶ Gas systems and equipment.
ressurised Equipment Directive (PED) 97/23/EEC as amendP
ed and added.
3 EXCLUSIONS OF LIABILITY AND WARRANTY
Any contractual or extra-contractual liability of the
manufacturer for any damage caused by incorrect installation and/or improper use and/or failure to comply
with regulations and with the manufacturer's directions/instructions shall be disclaimed.
In particular, the warranty on the appliance may be rendered void by the following conditions:
▶
Incorrect installation.
▶
Misuse.
▶
▶
▶
▶
▶
▶
Failure to comply with the manufacturer's indications on installation, use and maintenance.
lteration or modification of the product or any part
A
thereof.
Extreme operational conditions or however outside of the operational ranges set forth by the
manufacturer.
amages caused by external agents such as salts,
D
chlorine, sulphur or other chemical substances contained in the installation water or present in the air of
the installation site.
bnormal actions transmitted by the plant or instalA
lation to the appliance (mechanical stresses, pressure, vibrations, thermal dilations, power surges...).
Accidental damages or due to force majeure.
1 FEATURES AND TECHNICAL DATA
The Gitié AHAY package consists of a heat pump GAHP-A and a
condensation boiler AY00-120.
1.1 FEATURES
1.1.1 GAHP-A Unit features
Operation
Based on the thermodynamic water-ammonia absorption cycle
(H20–NH3), the appliance produces hot water using outdoor air
6
as a renewable energy source (cold source) and natural gas (or
LPG) as primary energy.
The thermodynamic cycle takes place within a hermetically
sealed circuit, in welded construction, perfectly tight, factorytested, which does not require any maintenance or coolant
top-ups.
Mechanical and thermo-hydraulic components
▶▶
▶▶
▶▶
▶▶
▶▶
▶▶
▶▶
▶▶
steel sealed circuit, externally treated with epoxy paint;
sealed combustion chamber (type C) suitable for outdoor
installations;
etal mesh radiant burner equipped with ignition and flame
m
detection device, controlled by an electronic control unit;
Operation
The AY00-120 condensation boiler produces hot water through
a plate heat exchanger on an internal closed circuit.
Mechanical and thermo-hydraulic components
▶▶
▶▶
premixed multigas burner with low NOX and CO emissions;
s tainless steel plate heat exchanger, combining a hydraulic
separator;
▶▶
internal circuit expansion tank;
▶▶
automatic and manual air bleeds on the internal circuit;
ue gas discharge duct with relevant terminal, for type B53P
fl
configuration;
t itanium stainless steel shell-and-tube water heat exchanger, externally insulated;
▶▶
stainless steel, flue gas latent heat recovery exchanger;
▶▶
a ir heat exchanger with single-row finned coil, with steel
pipe and aluminium fins;
Control and safety devices
a utomatic microprocessor-controlled finned coil automatic
defrosting valve;
s tandard or silenced fan S1 (reduction of electrical consumption and reduction of sound emission).
Control and safety devices
▶▶
1.1.2 AY00-120 Unit features
S 61 electronic board with microprocessor, LCD display and
knob;
▶▶
anti-freeze thermostat for the condensate drain trap resistor;
Y10 electronic board with integrated microprocessor, disA
play and knob;
▶▶
S70 electronic board;
▶▶
ionisation flame controller;
▶▶
gas solenoid valve with double shutter;
▶▶
system water antifreeze function;
▶▶
water anti-freeze protection of the machine's internal circuit;
▶▶
a utomatically resettable water temperature limiting thermostat;
▶▶
Mod10 additional electronic board (integrated in S61);
▶▶
auxiliary W10 electronic board
▶▶
flue gas temperature limit thermostat (thermal fuse);
▶▶
installation water flowmeter;
▶▶
system water differential pressure switch;
▶▶
generator limit thermostat, with manual reset;
▶▶
▶▶
manually reset flue gas temperature thermostat;
▶▶
generator fins temperature probe;
▶▶
sealed circuit safety relief valve;
▶▶
by-pass valve, between high and low pressure circuits;
▶▶
ionisation flame controller;
▶▶
gas solenoid valve with double shutter;
The Gitié package is available in the following versions (Figure
1.6 p. 11):
▶▶ Base version
▶▶
anti-icing function for water circuit;
▶▶
Version KIT/4 C1
▶▶
condensate discharge obstruction sensor.
▶▶
Version KIT/2 C0
▶▶
Version KIT/2 C1
▶▶
internal machine circuit water differential pressure switch
with anti-bonding function;
pressure relief valve for internal machine circuit;
1.1.3 AHAY Integrated package features
In all versions units operation may be simultaneous or
independent.
The Table 1.1 p. 7 shows the features of the various versions
in detail.
Table 1.1 – Versions of Gitié integrated package.
Version
Base
KIT/4 C1
KIT/2 C0
KIT/2 C1
Pipes
4
4
2
2
Circulating pumps
No
Yes
No
Yes
Motorised 2-way valves
No
No
Yes
No
Hydraulic circuits
independent
independent
single
single
7
1.2 DIMENSIONS
Figure 1.1 – Size (Standard ventilation)
Front and side views (dimensions in mm).
Figure 1.2 – Dimensions (Silenced ventilation S1)
Front and side views (dimensions in mm).
8
Figure 1.3 – 2 pipe package service plate (KIT/2 C0 and C1)
LEGEND
AWater outlet fitting Ø 1½” F
BWater inlet fitting Ø 1½” F
CBoiler condensate drain AY00-120
GGas fitting Ø ¾” M
Hydraulic/gas unions detail
Figure 1.4 – 4 pipe package service plate (base version and KIT/4 C1)
LEGEND
AAY - Water outlet fitting Ø 1¼” F
BAY - Water inlet fitting Ø 1¼” F
CBoiler condensate drain AY00-120
EGAHP/GA - Water outlet fitting Ø 1¼” F
FGAHP/GA - Water inlet fitting Ø 1¼” F
GGas fitting Ø ¾” M
Hydraulic/gas unions detail
9
1.3 COMPONENTS
Figure 1.5 – Internal components - front view








 











 





 


















LEGEND
1Fan (version S1)
2Flue gas drawing cap
3Gas valve
4Combustion air restart
5Blower
6Ignition transformer
10
7Tmix Probe
8Oil pump
9Water delivery fitting: “G 1”¼ F
10Water return fitting: “G 1”¼ F
11Gas fitting
12TA Probe
Figure 1.6 – Version components





LEGEND
1BASE Version (2 independent circuits without circulating pumps)
2Kit/4 C1 (2 independent circuits with on board circulators)
3Kit/2 C0 (single circuit with two 2-way motorised valves)
4Kit/2 C1 (single circuit with on board circulators)
11
Figure 1.7 – Internal components - left side view






LEGEND
1Flue gas thermostat reset
2Flue gas thermostat bulb
3Flue gas discharge Ø 80mm
4PT 1000 Flue gas Temperature Probe
5Switch on and detection electrodes
6Condensate sensor
7Electrical panel
12


Figure 1.8 – Internal components - right side view









LEGEND
1TG Probe
2Safety valve
3Delivery pipe flow meter
4Delivery temperature probe
5Limit thermostat
6Defrosting valve
7Return temperature probe
8Teva Probe
13
1.4 WIRING DIAGRAMS
Figure 1.9 – Gitié package wiring diagram (GAHP-A unit)
LEGEND
SCH1Controller S61
SCH2W10 circuit board
SCH3Mod10 circuit board
TERAppliance power terminal block
CNTBOXFlame controller
PWRTRBoard transformer
BLWBlower
PMPOil pump
IGNTRIgnition transformer
IGNIgnition electrodes
FLSFlame sensor
LSGas valve ON indicator lamp
14
GVGas solenoid valve
TCManual flue gas thermostat
TLGenerator limit thermostat
FMFlowmeter
CWSCondensate water sensor
VDDefrosting valve
FAN STDStandard fan
FAN S1Low energy consumption fan
CFFilter capacitor
FSCondensate hose heating element
THRCHot water return temperature probe
THMCHot water flow temperature probe
TMIXCombustion air temperature sensor
TAAmbient air temperature sensor
TGGenerator temperature sensor
TFFumes temperature sensor or generator fin sensor
TEVAEvaporator outlet temperature sensor
TKCondensate discharge heating element
thermostat
MATerminal block
REEDOil pump rotation sensor
Figure 1.10 – Gitié package wiring diagram (unit AY00-120)
LEGEND
SCH5electronic boards S70+AY10
TAroom temperature probe
THPCdelivery water temperature probe
(internal machine circuit)
THMCoutput water temperature probe
(system circuit)
THRCinput water temperature probe
(system circuit)
THcombustion unit limit thermostat
TFexhausted gas thermostat
PDdifferential water pressure switch
A2differential water pressure switch
(system circuit)
TLwater limit thermostat
P1water circulator
LSgas valve ON signal lamp
GVgas solenoid valve
IGNTRignition transformer
IGNignition electrodes
FLSflame sensor
CNTBOXflame control unit
BLWblower
MC230Vac power supply terminal box
PWRTRboard transformer
TGantifreeze thermostat for syphon
resistance
RSsyphon resistance
15
Figure 1.11 – Gitié package wiring diagram - base version
LEGEND
MATerminal block
MOD.0GAHP or ACF unit
MOD.1unit AY00-120
SCH1electronic board S61
TERunit power supply terminal box
J2-J10control jumpers of system water pumps ("closed")
Figure 1.12 – Gitié package wiring diagram with KIT/2 C0
LEGEND
MOD.1unit AY00-120
16
J2-J10control jumpers of system water pump ("open")
MAconnection terminal block
V2V0-V2V1motorised valves
Figure 1.13 – Gitié package wiring diagram with KIT/2 C1 or with KIT/4 C1


LEGEND
MOD.1unit AY00-120
J2-J10control jumpers of system water pumps ("closed")
MAconnection terminal block
PM0-PM1system water pumps
APosition of pumps flow rate adjustment screw
Figure 1.14 – CAN connection between AY10 board and S61 (pre-wired in the factory)
LEGEND
SCH5electronic board S70+AY10
J1Jumpers CAN-BUS on AY10 board and
S61 board
Aterminal node connection - (3 wires; J1
jumpers = "closed")
Cterminal node connection - (3 wires; J1
jumpers = "closed")
H,L,GNDdata signal wires (ref. cables table)
17
1.5 ELECTRONIC BOARDS
and operative codes. The appliance is monitored and programmed by interacting with the display and knob.
GAHP-A Unit electronic boards (S61+Mod10+W10)
▶▶
The GAHP-A Unit's electrical panel contains:
▶▶ Electronic Board S61 (Figure 1.15 p. 18), with microprocessor, it controls the appliance and displays data, messages
▶▶
uxiliary Mod10 electronic board (Figure 1.16 p. 19),
A
overlapping S61, it handles power modulation of the burner,
fan and water circulation pump.
atellite W10 electronic board (Figure 1.17 p. 19), interS
connected to the S61 board and located next to it, used to
control defrosting operations of the GAHP unit.
Figure 1.15 – Electronic board S61
LEGEND
SCH1Electronic board S61
SCH3Electronic board Mod10 (see specific
picture for more details)
A1, A2Auxiliary inputs
ENCKnob
F1Fuse T 2A
F2Fuse T 10A
F3Fuse T 2A
F4Fuse T 3,15A
FAN(BK, WH, BR) Fan output
FS5(24V AC) Board power supply 24-0-24
Vac
IGN.BOX (L, N) Flame control unit power supply
230 Vac
SCH S61
18
J1Jumper CAN BUS
J10Jumper N.O. contact
J82Board connector W10 (on Mod10)
JP106 pole flame control unit connector
JP12Flue gas probe input or generator fin
probe
JTAGConnector for board programming S61
MAIN230V (L, N) Board power supply S61
230 Vac
CONTACT Normally open pump contact
P7(R, W, Y, O) Enable input
P8(GND, L, H) Connector CAN BUS
PUMP230V (L, N) Oil hydraulic pump power
supply output
SPICommunication port with board
Mod10
SRT1Oil hydraulic pump rotation sensor
input
SRT2Hot water flow meter input
TAAmbient air temperature probe
TA1Evaporator output probe input
TA2Not used
TCNCombustive air temperature probe
input
TFFlue gas thermostat input
Figure 1.16 – Mod10 controller
LEGEND
HFLOWNot used
CFLOWCondensation water sensor control
J51SPI connector
HPMPPrimary circuit hot water pump control
output (0-10 V)
CPMPLow consumption fan control output
(0-10V)
NC1-C1Status indication of locking warnig/error
CN5Blower control
J82W10 auxiliary controller connector
J83W10 cable shielding connection W10
CN1Inputs 0-10V (not used)
Mod10 controller
Figure 1.17 – W10 electronic controller
LEGEND
FS1Defrosting valve contact
JP1Communication with S61/Mod10
AY00-120 Unit electronic boards (S70+AY10)
The AY00-120 Unit's electrical panel contains:
▶▶ Electronic Board S70 (Figure 1.18 p. 20), with microprocessor, it controls the appliance and displays data, messages
and operative codes. The appliance is monitored and programmed by interacting with the display and knob.
▶▶
Y10 Electronic board (Figure 1.18 p. 20) overlapping
A
the S70 board.
19
Figure 1.18 – Series AY00-120 - electronic boards AY10+S70
LEGEND
ELEMENTS OF BOARD S70
TLlimit thermostat connector
EVgas solenoid valve connector
LSgas valve ON signal lamp connector
P1flame control unit connector
TFexhausted gas thermostat connector
PDsystem water differential pressure switch
A1-A2auxiliary connectors
J2system water circulator control jumper
NoContactsystem water circulator control terminals (max 700W)
V3Vmachine circulator control terminals
MAIN 230Velectrical supply connector
IGN. BOXignition control unit connector
ELEMENTS OF BOARD AY10
P1connector for blower drive
PWM= signal output
GND= earth
THRCinput hot water temperature connector
THMCoutput hot water temperature connector
TA2-TA1auxiliary temperature probes connector
J1CAN BUS jumper
P8CAN port/connector
H=data signal high
L=data signal low
GND=common data signal
P7operation enable connector
R= common terminal
W= Heat enable terminal
0= terminal not used
FS5board supply connector
F1 - F2fuses
Main elements of electronic boards on the machine AY00-120.
1.6 CONTROLS
▶▶
Control device
▶▶
parameter figures display and setting;
▶▶
hourly programming;
▶▶
climate curve control;
▶▶
diagnostics;
▶▶
reset errors;
▶▶
possibility to interface with a BMS;
The appliance may only work if it is connected to a control device, selected from:
▶▶ (1) preconfigured DDC control
▶▶
(2) external enables
1.6.1 Adjustment system (1) with pre-configured DDC
control
The main functions are:
20
a djustment and control of the GAHP/GA unit and AY00-120
unit in cascade (ON/OFF mode);
DDC functionality may be widened with auxiliary Robur devices
RB100 and RB200 (service requests, DHW production, Third Party
generator control, probe control, system valves or circulators, ...).
system functions (1). Control of the cascade between GAHP/GA
and AY00-120 is left to the user.
1.6.2 Adjustment system (2) - control with external enables
For connection of the selected device to the appliance's
electronic board please refer to Paragraph 4.4 p. 33.
The appliance may also be controlled via generic enable devices
(e.g. thermostats, clocks, buttons, contactors...) fitted with NO
clean contacts. This system only provides elementary control
(on/off, with fixed set-point temperature), without the important
1.7 TECHNICAL CHARACTERISTICS
1.7.1 AHAY Integrated package technical specifications
Table 1.2 – Technical specifications Gitié AHAY
TECHNICAL DATA
BURNER FEATURES
Seasonal space heating energy efficiency class medium-temperature application (55 °C)
(ErP)
low-temperature application (35 °C)
Maximum thermal capacity
G20 - G25
G25
Maximum gas consumption
G30
G31
HYDRAULIC FEATURES
GAHP-A
Water flow rate 4 pipes (max/nominal/min)
AY00-120
Water flow rate 2 pipes C0 version (max/nominal/min)
base version- GAHP-A
Pressure loss at nominal flow rate
- AY00-120
version KIT/2 C0 simultaneous operation
version KIT/4 C1 - GAHP-A
Residual pressure head at nominal flow rate
- AY00-120
version KIT/2 C1
maximum
Ambient air temperature (dry bulb)
minimum
ELECTRICAL SPECIFICATIONS
voltage
TYPE
Power supply
frequency
Electrical power input (nominal)
ELECTRICAL PROTECTION RATING
INSTALLATION DATA
Sound power Lw
Sound pressure Lp at 5 metres
Standard fan
Silenced fan S1
Standard fan
Silenced fan S1
Standard fan
Silenced fan S1
Minimum storage temperature
Maximum operating pressure
Water content inside the appliance
Weight in operation/transport
Fittings
Dimensions
Standard fan
Silenced fan S1
delivery/return water (4 pipe version)
delivery/return water (2 pipe version)
gas
flue gas exhaust pipe GAHP-A
flue gas exhaust pipe AY00-120
width
depth
height
AHAY
A++
A+
kW
m3/h
m3/h
kg/h
kg/h
60,1
6.4(1)
7.5(2)
4.8(3)
4.7(3)
l/h
l/h
l/h
bar
bar
bar
bar
bar
bar
°C
°C
4000/2900/1400
3200/2700/1500
7200/5600/2900
0,430
0,395
0,560
0,240
0,280
0,200
40
-15(4)
V
230
Single phase
50 Hz
supply
kW
kW
IP
1,025(5)(6)
0,955(5)(6)
X5D
dB(A)
dB(A)
dB(A)
dB(A)
°C
bar
l
kg
kg
"F
"F
"M
mm
mm
mm
mm
mm
79,6(7)
74(7)
57,6(8)
52(8)
-30
4
6
490/515
500/525
11/4
11/2
3/4
80
80
1457
1260
1630
50
Notes
(1)PCI (G20) 34.02 MJ/m3 (1013 mbar 15 °C).
(2)PCI (G25) 29.25 MJ/m3 (1013 mbar 15 °C).
(3)PCI (G30/G31) 46.34 MJ/kg (1013 mbar 15 °C)
(4)As an option, a special version for operation at -30 °C is available.
21
(5)± 10% depending on power supply voltage and absorption tolerance of electric motors.
(6)Add 280 W in versions with circulating pumps.
(7)Sound power values measured according to EN ISO 9614 standard methods.
(8)Maximum sound pressure values in free field, with directionality factor 2, obtained from sound power level in compliance with EN ISO
9614 standard.
1.7.2 GAHP-A Unit technical data
Table 1.3 – GAHP-A Unit technical data
TECHNICAL DATA
HEATING MODE
GAHP-A
G.U.E. gas usage efficiency
Thermal power
Thermal power
Thermal power
A7W50 OPERATION POINT
A7W65 OPERATION POINT
A-7W50 OPERATION POINT
%
kW
%
kW
%
kW
NOx emission class
NOx emission
CO emission
maximum for heating
maximum for DHW
maximum for heating
maximum for DHW
minimum temperature in continuous
operation
Hot water delivery temperature
Hot water inlet temperature
INSTALLATION DATA
Type of installation
Maximum condensation water flow rate
Fume outlet
Residual head
Maximum pressure of the cooling circuit
PED data
Ammonia R717
Cooling fluid
Water H2O
Generator
Leveling chamber
Evaporator
Components under pressure
Cooling volume transformer
Cooling absorber solution
Solution pump
Test pressure (in air)
Safety valve pressure calibration
Filling ratio
Fluid group
ppm
ppm
°C
°C
°C
°C
152(1)
38,3(1)
124(1)
31,1(1)
127(1)
32,0(1)
5
25
36
65
70
55
60
°C
20(2)
l/h
Pa
bar
B23P, B33, B53P
4
80
32
kg
kg
l
l
l
l
l
l
bar g
bar g
kg of NH3/l
7
10
18,6
11,5
3,7
4,5
6,3
3,3
55
32
0,146
Group 1°
Notes:
(1)As per EN12309-2 standard assessed on actual thermal capacity. For operating conditions other than nominal, refer to the Design Manual.
(2)In transient operation, lower temperatures are allowed.
1.7.3 AY00-120 Unit technical data
Table 1.4 – Technical specifications AY00-120
TECHNICAL DATA
HEATING MODE
OPERATING POINT: Tm80/Tr60
and nominal thermal capacity
and minimal thermal capacity
and nominal thermal capacity
Efficiency classes
NOx emission class
AY00-120
Available power
Efficiency
kW
%
34.4
98.6
Efficiency
%
97.3
Efficiency
%
100,6
°C
°C
°C
****
5
80
25
60
maximum
Hot water delivery temperature minimum
nominal
22
2 Transport and positioning
TECHNICAL DATA
maximum
Hot water inlet temperature
minimum
nominal
INSTALLATION DATA THERMAL YIELD
Efficiency at MEAN thermal capacity Tm80/Tr60
Efficiency at MIN thermal capacity Tm80/Tr60
Efficiency at nominal thermal capacity Tm50/Tr30
Efficiency at 30% of nominal thermal capacity Tr=30°C
Efficiency at 30% of nominal thermal capacity Tr=47°C
Operational heat loss to jacket
Operational heat loss to jacket
Operational heat loss to flue
Operational heat loss to flue
Heat loss in off mode
Heat loss in off mode
INSTALLATION DATA
°C
°C
°C
AY00-120
70
20
50
%
%
%
%
%
kW
%
kW
%
kW
%
98.3
97.3
104.6
107.5
100.3
0,15
0.44
0,86
2.54
0,058
0,2
l/h
Pa
B23P-B33-B53P-C13-C33-C43C53-C63-C83
5,5
100
Type of installation
Maximum condensation water flow rate
Fume outlet
Residual head
2 TRANSPORT AND POSITIONING
2.1 WARNINGS
▶▶
▶▶
Damage from transport or installation
The manufacturer shall not be liable for any damage
during appliance transport and installation.
▶
se lifting beams to avoid damaging the outer panels and
U
finned coil (Figure 2.1 p. 24).
Comply with safety regulations at the installation site.
In the event of handling with forklift or pallet truck comply with the handling methods shown on the packing.
On-site inspection
▶
▶▶
T o lift the appliance use straps or slings inserted in the holes
of the base (Figure 2.1 p. 24).
pon arrival at the site, ensure there is no transport
U
damage on packing, metal panels or finned coil.
fter removing the packing materials, ensure the apA
pliance is intact and complete.
Packing
Only remove the packing after placing the appliance on
site.
Do not leave parts of the packing within the reach of
children (plastic, polystyrene, nails...) since they are potentially dangerous.
Weight
▶
▶
T he crane and lifting equipment must be suitable for
the load.
Do not stand under suspended loads.
2.2 HANDLING
Handling and lifting
▶▶
lways handle the appliance in its packing, as delivered by
A
the factory.
23
2 Transport and positioning
Figure 2.1 – Instruction for lifting
2.3 APPLIANCE PLACEMENT
Defrosting water drainage
In winter, it is normal for frost to form on the finned coil
and for the appliance to perform defrosting cycles.
Do not install inside a room
▶
The appliance is NOT suitable for indoor installation.
▶
▶
o not install inside a room, not even if it has
D
openings.
Acoustic issues
In no event start the appliance inside a room.
▶▶
Unit ventilation
▶
▶
▶
▶▶
▶▶
▶▶
▶▶
24
re-emptively assess the appliance's sound effect in connecP
tion to the site, taking into account that building corners, enclosed courtyards, restricted spaces may amplify the acoustic impact due to the reverberation phenomenon.
T he aerothermic appliance requires a large space,
ventilated and free from obstacles, to enable smooth
flow of air to the finned coil and free air outlet above
the mouth of the fan, with no air recirculation.
2.4 MINIMUM CLEARANCE DISTANCES
Incorrect ventilation may affect efficiency and cause
damage to the appliance.
▶▶
T he manufacturer shall not be liable for any incorrect
choices of the place and setting of installation.
Where to install the unit
▶▶
T o prevent overflowing and damage provide for a
drainage system.
T he appliance may be installed at ground level, on a terrace
or on a roof, compatibly with its dimensions and weight.
I t must be installed outside buildings, in an area of natural air
circulation, outside the dripping path of drainpipes or similar. It does not require protection from weathering.
o obstruction or overhanging structure (protruding roofs,
N
canopies, balconies, ledges, trees) shall interfere either with
the exhaust air flowing from the top of the appliance or with
the exhaust flue gas.
T he appliance's flue gas exhaust must not be immediately
close to openings or air intakes of buildings, and must comply with environmental regulations.
o not install near the exhaust of flues, chimneys or hot
D
polluted air. In order to work correctly, the appliance needs
clean air.
Distances from combustible or flammable materials
eep the appliance away from combustible or flammable
K
materials or components, in compliance with applicable
regulations.
Clearances around the appliance
The minimum clearance distances shown in Figure 2.2 p. 25
(bar any stricter regulations) are required for safety, operation
and maintenance.
3 Heating engineer
2.5 MOUNTING BASE
Figure 2.2 – Clearances
Mounting base constructive features
600
▶▶
lace the appliance on a levelled flat surface made of fireP
proof material and able to withstand its weight.
(1) - installation at ground level
▶▶
450
F ailing a horizontal supporting base, make a flat and levelled
concrete base, at least 100-150 mm larger than the appliance dimensions per side.
(2) - installation on terrace or roof
▶▶
▶▶
450
T he structure of the building must support the total weight
of the appliance and the supporting base.
I f necessary, provide a maintenance walkway around the appliance.
Anti vibration mountings
Although the appliance's vibrations are minimal, resonance
phenomena might occur in roof or terrace installations.
▶▶ Use anti-vibration mountings.
800
▶▶
lso provide anti-vibration joints between the appliance
A
and water and gas pipes.
3 HEATING ENGINEER
3.1 WARNINGS
a hydraulic separator, or possibly by a tank that also acts as
inertial volume/thermal inertia.
General warnings
Minimum water content
Read the warnings in Chapter III p. 4, providing important information on regulations and on safety.
High thermal inertia is conducive to efficient appliance operation. Very short ON/OFF cycles are to be avoided.
▶▶ If necessary, provide for an inertial volume, to be suitably
sized (see design manual).
Compliance with installation standards
Installation must comply with applicable regulations in
force, based on the installation Country and site, in matters of safety, design, implementation and maintenance
of:
▶
heating systems;
▶
cooling systems;
▶
gas systems;
▶
flue gas exhaust;
▶
flue gas condensate discharge.
4-pipe version hydraulic connections
on the right, at the bottom, connection plate (Figure 1.4 p. 9).
▶▶ A (= out) 1"1/4 F - WATER OUTPUT AY (m = delivery AY to the
system)
▶▶
Installation must also comply with the manufacturer's
provisions.
▶▶
▶▶
(= in) 1"1/4 F - WATER INPUT AY (r = return AY from the
B
system)
E (= out) 1"1/4 F - WATER OUTPUT GAHP/GA (m = delivery
GAHP/GA to the system)
F (= in) 1"1/4 F - WATER INTPUT GAHP/GA (r = return GAHP/
GA from the system)
2-pipe version hydraulic connections
3.2 INSTALLATION
Primary and secondary circuit
▶▶
3.3 HYDRAULIC CONNECTIONS
In many cases it is advisable to divide the hydraulic system
into two parts, primary and secondary circuit, uncoupled by
on the right, at the bottom, connection plate (Figure 1.3 p. 9).
▶▶ A (= out) 1"1/2 F - WATER OUTPUT (m = delivery to the system)
▶▶
B (= in) 1"1/2 F - WATER INPUT (r = return from the system)
25
3 Heating engineer
Hydraulic pipes, materials and features
▶▶
se pipes for heating/cooling systems, protected from
U
weathering, insulated for thermal dispersion.
Pipe cleaning
Before connecting the appliance,accurately wash the
water and gas piping and any other system component,
removing any residue.
Minimum components of the primary hydraulic circuit
(2-pipe version or each of the two circuits GAHP-GA/AY00120 of the 4-pipe versions)
on water piping, both output and input (m/r)
▶▶ 2 ANTIVIBRATION JOINTS on water fittings;
▶▶
2 PRESSURE GAUGES;
▶▶
2 ISOLATION BALL VALVES;
on the input water piping (r)
▶▶ WATER CIRCULATION PUMP with thrust towards the unit (for
the C0 version - without circulating pumps)
▶▶
1 DIRT SEPARATOR FILTER
▶▶
1 FLOW REGULATOR VALVE
on the output water piping (m)
▶▶ 1 SAFETY VALVE (3 bar);
▶▶
1 EXPANSION TANK of the individual unit.
Always provide, near the appliance:
Figure 3.1 – Hydraulic diagram Gitié KIT/2 C0 with storage
LEGEND
1Anti-vibration connection
2Pressure gauge
3Flow regulator valve
4Dirt separator filter
5Shut-off valve
INDICATIVE DIAGRAM NOT VALID FOR EXECUTION PURPOSES
26
6Safety valve 3 bar
7Expansion tank
8Hydraulic separator or inertial tank
9Primary external circulator
10Secondary circulator
3 Heating engineer
Figure 3.2 – Hydraulic diagram Gitié KIT/4 C0 DHW
LEGEND
1Anti-vibration connection
2Pressure gauge
3Flow regulator valve
4Water filter
5Shut-off valve
6Safety valve 3 bar
7Unit expansion tank
8Storage tank with anti-mixing baffles
9Secondary circuit circulator
10Check valve
11Separable DHW service activation
thermostat
12DHW storage tank
13Anti-legionella service activation
thermostat
143-way diverter valve
15DDC
16RB100
17External air temperature probe
18Primary boiler external circulator
19Primary GAHP external circulator
AD.H.W.
BWater mains
CHeating system
DGas
INDICATIVE DIAGRAM NOT VALID FOR EXECUTION PURPOSES
3.4 WATER CIRCULATION PUMPS
The active anti-icing self-protection is only effective
if the power and gas supplies are assured. Otherwise,
anti-icing liquid might be required.
3.4.1 Versions C0
Circulation pumps (flows and heads) must be selected and installed based on pressure losses of hydraulic circuits (piping +
components + exchange terminals + appliance).
For the appliance's pressure losses refer to Table 1.2 p. 21.
Circulation pumps will be controlled at constant flow.
3.6 ANTI-ICING LIQUID
Precautions with glycol
The manufacturer disclaims any liability for any damage
caused by improper glycol use.
For pump sizing in the version KIT/2 C0 also consider
the alternate operation case.
▶
For electrical connections of the pumps refer to Paragraph
4.5 p. 35.
▶
3.4.2 Versions C1
Water circulation pumps are supplied on the appliance.
For available water flow and residual head features refer to Table
1.2 p. 21.
lways check product suitability and its expiry date
A
with the glycol supplier. Periodically check the product's preservation state.
o not use car-grade anti-icing liquid (without inhibD
itors), nor zinc-coated piping and fittings (incompatible with glycol).
3.5 ANTI-ICING FUNCTION
Glycol modifies the physical properties of water (density, viscosity, specific heat...).
▶▶ Size the piping, circulation pumps and thermal generators
accordingly.
Active anti-icing self-protection
With automatic system water filling, a periodic check of the glycol content is required.
The appliance is equipped with an active antifreeze self-protection system to prevent freezing. The antifreeze function (activated by default) automatically starts primary circulation pumps
and, if required, the burner too, when the outside temperature
approaches zero.
Electrical and gas continuity
With high glycol percentage (> 20…30%)
If the glycol percentage is ≥30% (for ethylene glycol) or
≥20% (for propylene glycol) the TAC must be alerted before first start-up.
Type of anti-icing glycol
▶▶
I nhibited type glycol is recommended to prevent oxidation
phenomena.
27
3 Heating engineer
Glycol effects
The Table 3.1 p. 28 shows, indicatively, the effects of using glycol depending on the %.
Table 3.1 – Technical data for filling the hydraulic circuit
GLYCOL %
WATER-GLYCOL MIXTURE FREEZING TEMPERATURE
PERCENTAGE OF INCREASE IN PRESSURE DROPS
LOSS OF EFFICIENCY OF UNIT
10
-3°C
---
15
-5°C
6%
0,5%
3.7 SYSTEM WATER QUALITY
Responsibility of the user/operator/installer
The installer, operator and user must assure system water quality (Table 3.2 p. 28). Failure to comply with the
manufacturer's guidelines may affect operation, integrity and life of the appliance, voiding the warranty.
▶
The chemical-physical properties of the system's water may alter
over time, resulting in poor operation or excessive topping up.
▶▶ Ensure there are no leaks in the installation.
▶▶
eriodically check the chemical-physical parameters of the
P
water, particularly in case of automatic topping up.
Chemical conditioning and washing
Water treatment/conditioning or system washing carried out carelessly may result in risks for the appliance,
the system, the environment and health.
▶
▶
▶
28
ontact specialised firms or professionals for water
C
treatment or system washing.
heck compatibility of treatment or washing prodC
ucts with operating conditions.
o not use aggressive substances for stainless steel
D
or copper.
35
-20°C
14%
3%
40
-25°C
16%
4%
Do not leave washing residues.
After completing all water, electrical and gas
connections:
1. P
ressurise (at least 1.5 bar) and vent the hydraulic
circuit.
2. Let water flow (with appliance off ).
3. Check and clean the filter on the inlet pipe.
4. R
epeat items 1, 2 and 3. until the pressure has stabilised (1.5 bar).
Table 3.2 – Chemical and physical parameters of water
Water topping up
30
-15°C
12%
2,5%
How to fill up the system
Free chlorine or water hardness may damage the appliance.
Adhere to the chemical-physical parameters in Table 3.2 p. 28
and the regulations on water treatment for residential and industrial heating systems.
1with aluminium or light alloys radiators, pH must also be lower than 8 (in compliance with applicable rules)
2value referred to the maximum water temperature of 80 °C
3in compliance with applicable rules
25
-12°C
10%
2%
3.8 INSTALLATION FILLING
System water features
CHEMICAL AND PHYSICAL PARAMETERS OF WATER IN HEATING/COOLING
SYSTEMS
UNIT OF
PARAMETER
MEASUREMENT ALLOWABLE RANGE
pH
\
>7 (1)
Chlorides
mg/l
< 125 (2)
°f
< 15
Total hardness (CaCO3)
°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
20
-8°C
8%
1%
3.9 FUEL GAS SUPPLY
Gas connection
▶▶
3/4" M
on the right, at the bottom, connection plate (Figure [Ref ] p. ).
▶▶ Install an anti-vibration connection between the appliance
and the gas piping.
Mandatory shut-off valve
▶▶
▶▶
rovide a gas shut-off valve (manual) on the gas supply line,
P
to isolate the appliance when required.
erform connection in compliance with applicable regulaP
tions.
Gas pipes sizing
The gas pipes must not cause excessive load losses and, consequently, insufficient gas pressure for the appliance.
Supply gas pressure
The appliance's gas supply pressure, both static and dynamic,
must comply with Table 3.3 p. 29, with tolerance ± 15%.
3 Heating engineer
Table 3.3 – Network gas pressure
Gas supply pressure
Product categories
Countries of destination
AL, BG, CY, CZ, DK, EE, FI, GR,
HR, IT, LT, MK, NO, RO, SE,
SI, SK, TR
AT, CH
AL, BG, CZ, ES, GB, HR, IE, IT,
LT, MK, PT, SI, SK, TR
RO
DE
FR
HU
LU
NL
II2H3B/P
II2H3P
II2ELL3B/P
II2Esi3P
II2HS3B/P
II2E3P
II2L3B/P
II2E3B/P
II2ELwLs3B/P
II2ELwLs3P
I2E(S); I3P
I3P
I2H
I3B/P
I3B
G20 [mbar]
G25 [mbar]
G30 [mbar]
G31 [mbar]
20
30
30
20
50
50
20
20
20
20
25
20
PL
BE
IS
LV
G27 [mbar] G2,350 [mbar]
37
20
25
50
30
25
20
20
20
20
G25.1
[mbar]
50
37
37
25
30
50
37
30
50
50
37
37
37
37
30
25
20
20
13
13
20
30
30
MT
30
Non compliant gas pressure (Table 3.3 p. 29) may
damage the appliance and be hazardous.
Vertical pipes and condensate
▶▶
▶▶
ertical gas pipes must be fitted with siphon and discharge
V
of the condensate that may form inside the pipe.
If necessary, insulate the piping.
LPG pressure reducers
With LPG the following must be installed:
▶▶ a first stage pressure reducer, close to the liquid gas tank;
▶▶
a second stage pressure reducer, close to the appliance.
3.10 GAHP-A UNIT COMBUSTION PRODUCTS
EXHAUST
Compliance with standards
The appliance is approved for connection to a combustion products exhaust duct for the types shown in Table
1.3 p. 22.
Flue gas exhaust connection
▶▶
Ø 80 mm (with gasket),
on the left, at the top (Figure 3.3 p. 30).
Flue gas exhaust kit
The appliance is supplied with flue gas exhaust kit, to be fitted
by the installer, including (Figure 3.3 p. 30):
▶▶ 1 pipe Ø 80 mm, length 300 mm, with terminal and socket
for flue gas analysis;
▶▶
1 support collar;
▶▶
1 90° elbow Ø 80 mm;
▶▶
1 rain cover.
29
3 Heating engineer
Figure 3.3 – Fume outlet





LEGEND
ATerminal
BPipe
CRain cover
DFlanged fitting
E90° Elbow
FPipe w/terminal
GRain cover
HCollar




How to install the flue gas kit
in the upper part (Figure 3.3 p. 30).
Flue gas exhaust kit
Figure 3.3 p. 30:
1. Remove the front panel;
2. F asten the collar (H) with its spacer to the left side
panel of the appliance;
3. Fit the terminal/pipe assembly (F) to the elbow (E).
4. Fit the rain cover (G) onto the elbow (E);
5. Remove the protection cover;
1 extension pipe Ø 80 mm, length 209 mm;
▶▶
1 rain cover;
How to install the flue gas kit
Figure 3.3 p. 30:
7. F it the assembly closing the collar (H) and place the
rain cover.
1. Fit the terminal (A) onto the pipe (B);
2. Fit the rain cover (C) onto the pipe (B);
8. Fit the front panel back on.
3. R
emove the protection cover located on the upper
panel;
Compliance with standards
The appliance is approved for connection to a combustion products exhaust duct for the types shown in Table
1.2 p. 21.
Flue gas exhaust connection
30
▶▶
6. Insert the elbow/terminal/pipe assembly into the
flue gas exhaust;
3.11 AY00-120 UNIT COMBUSTION PRODUCTS
EXHAUST
▶▶
The appliance is supplied with flue gas exhaust kit, to be fitted
by the installer, including (Figure 3.3 p. 30).
▶▶ 1 terminal;
Ø 80 mm
4. F it the rain cover/pipe/terminal assembly onto the
flanged fitting (D) and place the rain cover.
The protection cover has the purpose of preventing ingress of water and/or foreign matter into the appliance
before installation of the flue gas kit. It is therefore important to remove the protection only upon completing installation of the kit.
3 Heating engineer
3.12 COMBUSTION PRODUCTS EXHAUST
THROUGH THE FLUE
▶▶
ilute, if possible, with domestic waste water (bathrooms,
D
washing machine, dish washers...), basic and neutralising.
If necessary, the appliance may be connected to a flue.
▶▶ To size the flue refer to Table 1.4 p. 22, Table 1.3 p. 22
and Design Manual.
▶▶
I f the flue gas exhaust of the GAHP and that of the AY00-120
boiler are connected to a single flue, it is mandatory to install
a flap valve on the exhaust of each.
T he flue must be designed, sized, tested and constructed by a
skilled form, with materials and components complying with the
regulations in force in the country of installation.
▶▶ Always provide a socket for flue gas analysis, in an accessible
position.
3.13 FLUE GAS CONDENSATE DISCHARGE
The GAHP-A unit and the AY00-120 unit are condensation appliances which therefore produce condensation water from combustion fumes.
Condensate acidity and exhaust regulations
The fume condensation water contains aggressive acid
substances.
Refer to applicable regulations in force for condensate exhaust
and disposal.
▶▶ If required, install an acidity neutraliser of adequate capacity
(Tables 1.3 p. 22 and 1.4 p. 22).
Do not use gutters to discharge the condensate
Do not discharge the fume condensate water in gutters,
due to the risk of materials corrosion and ice formation.
GAHP-A Unit flue gas condensate fitting
The fitting for flue gas condensate discharge is located on the
left side of the appliance (Figure 3.4 p. 32).
▶▶ The distance L between the sleeve and the base must not
exceed 110 mm.
▶▶
▶▶
T he corrugated condensate discharge pipe must be connected to a suitable discharge manifold.
T he junction between the pipe and the manifold must remain visible.
AY00-120 Unit flue gas condensate fitting
The fitting for flue gas condensate discharge is located on the
right side of the appliance at the service plate (Figure 1.3 p. 9
and Figure 1.4 p. 9).
▶▶ The condensate discharge pipe must be connected to a suitable discharge manifold.
▶▶
T he junction between the pipe and the manifold must remain visible.
Flue gas condensate discharge manifold
If necessary the condensate discharge manifold may be in common between the 2 units the Gitié package consists of.
To make the condensate discharge manifold:
▶▶ Size the ducts for maximum condensation capacity (Tables
1.4 p. 22 and 1.3 p. 22).
▶▶
▶▶
▶▶
Use plastic materials resistant to acidity pH 3-5.
rovide for min. 1% slope, i.e. 1 cm for each m of the length
P
(otherwise a booster pump is required).
Prevent icing.
31
4 Electrical installer
Figure 3.4 – Condensate discharge

LEGEND
ACondensate discharge hose
L≤ 110 mm
3.14 DEFROSTING WATER DRAINAGE
Collection basin and drainage system
▶▶
Defrosting
rovide for a collection basin or containment rim and a disP
charge system of the defrosting water, to avoid overflowing,
icing and damage.
In winter, frost may form on the finned coil and the appliance performs defrosting cycles.
4 ELECTRICAL INSTALLER
4.1 WARNINGS
Earthing
▶
General warnings
Read the warnings in Chapter III p. 4, providing important information on regulations and on safety.
Compliance with installation standards
Installation must comply with applicable regulations in
force, based on the installation Country and site, in matters of safety, design, implementation and maintenance
of electrical systems.
Installation must also comply with the manufacturer's
provisions.
Live components
After placing the appliance in the final position, and prior to making electrical connections, ensure not to work
on live components.
32
▶
T he appliance must be connected to an effective
earthing system, installed in compliance with regulations in force.
It is forbidden to use gas pipes as earthing.
Cable segregation
Keep power cables physically separate from signal ones.
Do not use the power supply switch to turn the appliance on/off.
▶
▶
ever use the external isolation switch (GS) to turn
N
the appliance on and off, since it may be damaged
in the long run (occasional black outs are tolerated).
T o turn the appliance on and off, exclusively use the
suitably provided control device (DDC or external
enable).
Control of water circulation pumps
The water circulation pumps of the hydraulic circuit
must mandatorily be controlled by the unit's electronic boards. It is not admissible to start/stop circulating
pumps with no enable from the appliance.
The switches must also provide disconnector capability,
with min contact opening 4 mm.
How to connect the power supply
4.2 ELECTRICAL SYSTEMS
To connect the three-pole power supply cable (Figure
4.2 p. 33):
Electrical connections must provide:
▶▶ (a) power supply (Paragraph [Ref ] p. );
1. C
onnect the three lead-in wires to the terminal (TER)
in the electrical panel on the machine.
▶▶
2. P
rovide the earth lead-in wire longer than live ones
(last to be torn in the event of accidental pulling).
(b) control system (Paragraph 1.6 p. 20).
How to perform connections
Figure 4.2 – Package power supply wiring diagram
LEGEND
TERterminal
board
Lphase
Nneutral
Components NOT
SUPPLIED
GSgeneral
switch
All electrical connections must be made in the Electrical
Panel of boiler AY 00-120 (Figure 1.7 p. 12, reference
7):
1. Ensure the appliance's Electrical Panel is not live.
2. R
emove the front panel of the boiler and the cover of
the Electrical Panel.
3. Insert the wires through the suitable holes located
on the rear panel of the boiler (Figure 4.1 p. 33).
4. M
ake the connections by running the wires through
the suitable cable glands in the Electrical Panel.
5. C
lose the Electrical Panel.and fit the front panel back
on.
Figure 4.1 – Electrical cables routing holes position

Connecting the appliance to the power supply mains (230V 1N - 50Hz)
4.4 SET-UP AND CONTROL
Control systems, options (1) (2)

Two separate adjustment systems are provided, each with
specific features, components and diagrams (see Paragraph
1.6 p. 20):
▶▶ System (1), with DDC control (with CAN-BUS connection).
▶▶
System (2), with external enables.
4.4.1 Control with DDC
LEGEND
AHoles for electrical cable routing
CAN-BUS communication network
4.3 ELECTRICAL POWER SUPPLY
The CAN-BUS communication network, implemented with the
cable of the same name, makes it possible to connect and remotely control one or more Robur appliances with the DDC control device.
It entails a certain number of serial nodes, distinguished in:
▶▶ intermediate nodes, in variable number;
Power supply line
Provide (by the installer) a protected single phase line (230 V 1-N
50 Hz) with:
▶▶ 1 three-pole cable type FG7(O)R 3Gx1.5;
▶▶
two-pole switch with two 8 A fuses type T , (GS) or one 10A
1
magnetothermic breaker.
▶▶
terminal nodes, always and only two (beginning and end);
Each component of the Robur system, appliance (GAHP, GA,
AY, Gitié, ...) or control device (DDC, RB100, RB200, CCI, ...), corresponds to a node, connected to two more elements (if it is an
intermediate node) or to just one other element (if it is a terminal
33
node) through two/one CAN-BUS cable section/s, forming an
open linear communication network (never star or loop-shaped).
CAN-BUS signal cable
The DDC controller is connected to the appliance through the
CAN-BUS signal cable, shielded, compliant to Table 4.1 p. 34
(admissible types and maximum distances).
Table 4.1 – CAN BUS cables type
CABLE NAME
Robur
ROBUR NETBUS
Honeywell SDS 1620
BELDEN 3086A
TURCK type 530
DeviceNet Mid Cable
TURCK type 5711
Honeywell SDS 2022
TURCK type 531
SIGNAL / COLOR
MAX LENGTH
H= BLACK
L= WHITE
GND= BROWN
450 m
H= BLACK
L= WHITE
GND= BROWN
450 m
H= BLUE
L= WHITE
GND= BLACK
450 m
H= BLACK
L= WHITE
GND= BROWN
200 m
Note
Ordering Code OCVO008
In all cases the fourth conductor should not be used
For lengths ≤200 m and max 4 nodes (e.g. 1 DDC + 1 Gitié), a
simple 3x0.75 mm shielded cable may even be used.
How to connect the CAN BUS cable to the package
To connect the CAN-BUS cable to the AY10 electronic
board (Paragraph 1.5 p. 18), located in the Electrical
Panel inside the AY 00-120 unit, Figure 4.3 p. 34, Details A and B:
2. c onnect the CAN-BUS cable to terminals GND + L
and H (shielding/earthing + two signal conductors)
of the AY10 board;
3. place the Jumper J1, of the AY10 board, OPEN;
4. c onnect the DDC to the CAN-BUS cable to terminals
GND + L and H (shielding/earthing + two signal conductors) of the DDC;
5. the CAN connection between the AY10 board and
the S61 board is pre-wired (Figure 1.14 p. 17);
1. access the Electrical Panel (procedure Paragraph
4.2 p. 33)
Figure 4.3 – CAN-BUS connection between Gitié and DDC
34
LEGEND
DDCDirect Digital Control
SCH5electronic board S70+AY10
J1Jumpers CAN-BUS on board AY10
J21Jumpers CAN-BUS on DDC board
Aterminal node connection - (3 wires; J21
jumpers = "closed")
Bintermediate node connection - (3 wires;
J1 jumpers ="open")
H,L,GNDdata signal wires (ref. cables table)
4.4.2 Control with external enables
How to connect external enables
If you wish the heating enables of the two units to be simultaneous follow the connection diagram shown in Figure 4.4 p. 35.
Should you wish the enables of the two units to be separate follow the connection diagram shown in Figure 4.5 p. 35.
Connection of external enables is effected on the terminal block located in the Electrical Panel inside the AY00120 unit.
Figure 4.4 – Connection diagram of simultaneous hot external enables
Figure 4.5 – Connection diagram of separate hot external enables
LEGEND
IPtwo-pole switch
PTRsafety transformer SELV
CSGgeneral enable
R24V24V relay
LEGEND
CSGgeneral enable
CS0heat enable GAHP-A
CS1heat enable AY00-120
4.5 WATER CIRCULATION PUMPS (VERSIONS C0)
System water pumps will be controlled at constant flow.
35
4-pipe versions
Figure 4.6 – System pump connection diagram Gitie package base version (P
The diagram in Figure 4.6 p. 36 is for pumps < 700 W.
For pumps > 700 W it is necessary to add a control relay
and arrange Jumpers J10 and J2 OPEN.
36
LEGEND
J2-J10control jumpers of system water pumps
("closed")
Components NOT SUPPLIED
PM0water pump (P<700W) unit GAHP or ACF
PM1water pump (P<700W) unit AY00-120
GSgeneral switch
5 First start-up
2-pipe versions
Figure 4.7 – System pump connection diagram Gitié package 2 pipe version (KIT/2 C0)
LEGEND
Components NOT SUPPLIED
PMwater pump
IPtwo-pole switch
PTRsafety transformer SELV
R24Vpump control relay
5 FIRST START-UP
First Switch-On entails checking/adjusting the combustion parameters and must be carried out ONLY by
a Robur TAC. In this stage, NEITHER the user NOR the installation technician is authorised to perform such operations, under penalty of voiding the warranty.
5.1 PRELIMINARY CHECKS
Abnormal or hazardous installation situations
Should any abnormal or hazardous installation situations be
found, the TAC shall not perform First start-up and the appliance
shall not be commissioned.
These situations may be:
▶▶ appliance installed inside a room;
▶▶
▶▶
Preliminary checks for First start-up
Upon completing installation, before contacting the TAC the installer must check:
▶▶ water-heating, electrical and gas systems suitable for the required capacities and equipped with all safety and control
devices required by the regulations in force;
▶▶
absence of leaks in the water and gas systems;
▶▶
type of gas for which the appliance is designed;
▶▶
▶▶
▶▶
▶▶
▶▶
▶▶
▶▶
failed compliance with minimum clearances;
i nsufficient distance from combustible or flammable materials;
c onditions that do not warrant access and maintenance in
safety;
a ppliance switched on/off with the main switch, instead of
the control device provided (DDC, or external enable);
a ppliance defects or faults caused during transport or installation;
▶▶
supply gas pressure complying with the values of Table
3.3 p. 29, with max tolerance ±15%;
gas smell;
▶▶
non-compliant mains gas pressure;
ower supply mains complying with the appliance's rating
P
plate data;
▶▶
non-compliant flue gas exhausts;
▶▶
a ppliance correctly installed, according to the manufacturer's instructions;
s ystem installed in a workmanlike manner, according to national and local regulations.
a ll situations that may involve operation abnormalities or are
potentially hazardous.
Non-compliant system and corrective actions
Should the TAC find any non conformities, the user/installer is
bound to perform any corrective procedures required by the
TAC.
37
6 Normal operation
After performing the remedial actions (the installer's responsibility), if the TAC deems that safety and conformity conditions
are in place, "First start-up" may be effected.
6 NORMAL OPERATION
This section is for the end user.
Although the external enable is in the "ON" position, this
does not mean the appliance will start immediately, but
it will only start when there are actual service demands.
6.1 WARNINGS
General warnings
Prior to using the appliance carefully read the warnings
in Chapter III p. 4, providing important information
on regulations and on safety.
First start-up by TAC
First Switch-on may exclusively be carried out by a
Robur TAC (Chapter 5 p. 37).
6.3 MESSAGES ON THE DISPLAY
4 digit display
The S61 board and the AY10 board (Figures 6.1 p. 39 and
6.2 p. 39) are fitted with a 4-digit display, visible through the
sight glass of the respective front panels.
▶▶ When the appliance is powered on, all the LEDs switch on for
3 sec, then the board name is displayed.
▶▶
After another 15 sec, the appliance is ready to operate.
Signals in normal operation
Never power the appliance off while it is running
NEVER power the appliance off while it is running (except in the event of danger, Chapter p. 4), since the
appliance or system might be damaged.
6.2 SWITCH ON AND OFF
Routine switching on/off
The appliance may exclusively be switched on/off by
means of the suitably provided control device (DDC or
external enable).
Do not Switch On/Off with the power supply switch
Do not switch the appliance on/off with the power supply switch. This may be harmful and dangerous for the
appliance and for the system.
Inspections before switching on
Before switching on the appliance, ensue that:
▶
▶
gas cock open;
a ppliance electrical power supply (main switch (GS)
ON);
▶
DDC power supply (if any);
▶
water circuit ready.
How to switch on/off
▶▶
▶▶
If the appliance is controlled by a DDC, case (1), refer to the
relevant manual.
If the appliance is controlled by external enables (e.g. thermostat, clock, button, ... with clean contact NO), case (2), the
appliance is switched on/off by the ON/OFF positions of the
external control devices.
After switching on with the control, in normal operating conditions, the appliance starts/stops automatically according to the
user's needs, supplying water at the programmed temperature.
38
▶▶
uring normal operation, water temperature values alterD
nate on the display: output,input and the difference between the two.
Signals in the event of fault
In the event of fault the display blinks indicating an operational
code (first letter on the display: "E" = error, or "U" = warning)
▶▶ If it is only a temporary warning, the appliance may continue
working.
▶▶
If it is a permanent error or warning the appliance stops
(Table 8.1 p. 42 and Table 8.2 p. 45)
6.4 ELECTRONIC ADJUSTMENT ON THE
MACHINE – MENUS AND PARAMETERS OF THE
S61 BOARD AND OF THE AY10 BOARD
Firmware
The instructions on the use of the S61 electronic board
concern the firmware version 3.028.
Le istruzioni sull'utilizzo della scheda elettronica AY10
sono relative al firmware versione 3.106.
6 Normal operation
Figure 6.1 – GAHP unit electronic board




LEGEND
A4 digit display
BKnob
CCAN port
DMod10 controller

S61 + Mod10
Figure 6.2 – AY00-120 unit on-board electronics
LEGEND
A4 digit display
BKnob
CCAN port


Controllers AY10 and S70.
Display
▶▶
The 4-digit displays of the boards (Detail A in Figure 6.1 p. 39
and in Figure 6.2 p. 39) are as follows:
▶▶ the first digit on the left, green) indicates the menu number
(e.g. "0.", "1.", "2.", ... "8.");
▶▶
the last three digits (on the right, red) indicate a code or a
value for a parameter, among those included in the selected
menu (e.g. "__6" "_20", "161").
(e.g. menu+parameter "1.__6", "2._20", "3.161").
Knob
One of the following actions may be done with the board knob
(Detail B in Figure 6.1 p. 39 and in Figure 6.2 p. 39):
▶▶ Enter the menu list (by pressing the first time);
▶▶
▶▶
▶▶
▶▶
S croll the menu list, or a series of parameters in a menu (by
turning);
Select a menu or a parameter (by pressing);
odify and confirm the setting of a parameter (turning and
M
pressing);
Execute a command (by pressing);
E xit a menu and go back to the higher level by selecting the
letter “E” which is displayed at the end of the menu list or of
a series of parameters in a menu.
The letter "E" is displayed at the end of the menu list or of a series
of parameters in a menu, and indicates the exit to go back to the
higher level by pressing the knob.
39
6 Normal operation
Menus and Parameters
The menus may be display only (functional data or parameters),
display and setting (parameters) or control (reset)
Menu for the user (but for the installer and TAC as well)
▶▶ the menu "0.", display only, for functional data detected in
real time;
▶▶
▶▶
▶▶
the menu "1.", display only, for current values of appliance
parameters;
enu "2.", control, to execute flame control unit reset operam
tions, reset errors (Paragraph 6.6 p. 40);
enu "3.", display and setting, to set the value of some sysm
tem parameters (e.g. water set point temperature); the values are initialised by the TAC at First Switch-On.
It is accessed without password.
Menu for the installer or TAC (not accessible to the user)
▶▶ Menu "4.", "5." and "6." are password-protected. These are
specific sections, exclusively intended for skilled personnel
(installer or TAC). For information see the technical Assistant
Manual.
▶▶
Menu "7." is display only and intended for the manufacturer.
▶▶
Menu "8." is empty, it may be selected but not used.
Special key for the knob
▶
▶
T o access the menus and parameters of the boards,
use the special standard supplied key (fastened on
the gas pipe above the electrical panel). The key allows the knob to be operated through the suitable
hole in the Electrical Panel cover, operating safely
away from live components.
Always keep the key for future uses.
How to access the Menus and Parameters
Before Starting:
1. Power supply switch "ON";
2. Display of the board showing in sequence the detected
water temperature data (if the appliance is in normal operation), or the flashing malfunction and failure codes (if the appliance is in failure).
To access the menus and parameters of the board, proceed as follows (see also Figure 6.1 p. 39 and Figure
6.2 p. 39).
1. R
emove the front panel by removing the fixing screws.
2. Remove the cover of the electrical panel to access the board
knob.
3. Act on the knob by means of the special key through the
suitable hole.
4. Press the knob once to display the menus: the first menu is
displayed, "0." (= menu 0).
5. Turn the knob clockwise to scroll down and display the other/subsequent menus; the menu numbers will be displayed
in order, "1.", "2.", ... , "6." ... or "E" (= exit).
6. Select the menu of interest (e.g. display "2.___" = menu 2) by
pressing the knob; the first parameter code will be displayed,
in menu order (e.g. display "2._20" = parameter 20 in menu
2).
7. Turn the knob clockwise to scroll down the other parameters
in the menu; the codes will be displayed in order (e.g. display
"2._20", "2._21", ... "2._25" = parameters 20, 21, ... 25 in menu
2), or letter "E" (= exit) at the end of the list. "
8. Select the parameter of interest (e.g. with code 161 in menu
3) by pressing the knob; the figure previously assigned to
the parameter will be displayed, read only or to be set (e.g.
40
the figure "45" for parameter 161 in menu 3 = water temperature set-point at 45 °C); if instead of a figure/setting it is
a command, a flashing code is displayed (e.g. "reS1" for the
flame block reset command).
9. Press the knob to reconfirm the figure; or rotate the knob to
modify the figure, and press at the end to confirm or set the
new figure; if however, it is a matter of controlling an appliance operation, press the knob to execute it.
10. To exit a parameter menu or the menu list and go back to the
higher level, turn the knob to display the letter "E" for exit,
then press the knob again.
11. Place the cover back on the electrical panel opening and fit
the appliance's front panel back on.
6.5 HOW TO MODIFY SETTINGS
Modify settings via the DDC
If the device is connected to the DDC control, refer to
the relevant manual to modify settings.
How to raise/lower the water temperature set-point
The water temperature set-point establishes the delivery temperature to the system (water output from the appliance), or
return from the system (water input in the appliance). The temperature is pre-set by the TAC upon First Switch-On.
If the appliance is not connected to a DDC control, to
raise/lower the water temperature set-point with the
S61 or AY10 board, proceed as follows:
1. A
ccess menu 3 under parameter 161 (= water temperature
set-point) by rotating and pressing the knob; "3.161" must
be displayed (procedure Paragraph 6.4 p. 38);
2. Display the parameter value by pressing the knob; the previously set value is displayed (from 10 to 65 °C); to reconfirm
the pre-existing value press the knob again, otherwise go to
point 3.
3. Turn the knob to modify the value, increasing or decreasing
it, and press it to set the new value;
4. Exit menu 3, and from the menu list, by selecting and pressing letter "E" twice, and go back to the normal display of detected temperature data.
Do not modify complex settings
Specific technical and system knowledge is required for
complex settings. Contact a TAC.
6.6 HOW TO RESTART A LOCKED-DOWN UNIT
- RESET
Fault signals on the display
In the event of locked-down appliance, an operational code
flashes on the display (first green figure on the left, letter "U" =
warning or "E" = error).
▶▶ To restart the appliance you must know and perform the
procedure concerning the issue signalled and identified by
the code (Paragraph 8.1 p. 42).
▶▶
nly act if you are familiar with the issue and with the proO
cedure (technical expertise and professional qualifications
might be required).
▶▶
7 Maintenance
I f you do not know the code, the problem, or the procedure,
or you do not have sufficient skills, and in any case of doubt,
contact the TAC.
Locked-down appliance
An external intervention (reset or repair) is required due to an
appliance fault or problem with the system.
▶▶ A reset may be enough for a temporary and provisional
anomaly.
▶▶
F or a fault or breakdown, alert the maintenance technician
or TAC.
Reset
There are two options for resetting a fault:
(1) If the appliance is connected to a DDC you may act through
the control device, as described in the relevant manual.
(2) You may act directly from the S61 board and/or the AY10
board as described below (if the appliance is controlled with external enable, this is the only option).
1. A
ccess Menu 2 under Parameter "_20", to reset flame block
(Error E_12), or Parameter "_21", for any other generic reset,
turning and pressing the knob; "2._20"/"2._21" must be displayed (procedure Paragraph 6.4 p. 38);
2. Press the knob to display the flashing reset request (e.g.
"reS1" to reset flame block).
3. Press the knob again (the second time) to perform the reset;
the reset request stops flashing, then "2._XX" is displayed
again (e.g. "2._20"). The reset operation has been performed.
4. Exit menu 2 and the menu list, by selecting and pressing letter "E" twice, and go back to the normal display of detected
temperature data.
6.7 EFFICIENCY HANDBOOK
For increased appliance efficiency:
▶▶ Keep the finned coil clean;
▶▶
djust maximum water temperature to the actual system
A
requirement;
▶▶
How to perform reset from the S61 and AY10 boards
Reduce repeated switch-ons to the minimum (low loads);
▶▶
Program appliance activation for actual periods of use;
To perform the reset directly from the board:
▶▶
eep water and air filters on plumbing and ventilation sysK
tems clean.
7 MAINTENANCE
7.1 WARNINGS
The efficiency check and every other "check and maintenance operation" (see Tables 7.1 p. 41 and 7.2 p. 42)
must be performed with a frequency in agreement
to current regulations or, if more restrictive, according
to the provisions set forth by the manufacturer, installer
or TAC.
Correct maintenance prevents problems, assures efficiency and keeps running costs low.
Maintenance operations described herein may exclusively be performed by the TAC or skilled maintenance
technician.
Responsibility for efficiency checks, to be carried out
for the aims of restricting energy consumption, lies
with the system manager.
Any operation on internal components may exclusively
be performed by the TAC.
Before performing any operation, switch off the appliance by means of the control device (DDC or external
enable) and wait for the end of the switching off cycle,
then disconnect power and gas supply, by acting on the
electrical disconnecter and gas cock.
Heavy-duty use
If the unit is subject to heavy duty use (for example
in process plants or in other conditions of continuous
operation), maintenance operations must be more
frequent.
7.2 PRE-EMPTIVE MAINTENANCE
For pre-emptive maintenance, comply with the recommendations in Table 7.1 p. 41.
Table 7.1
GUIDELINES FOR THE PREVENTIVE MAINTENANCE OPERATIONS
Check of the unit
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 CO2
check gas pressure to the burners
Check that the condensate discharge is clean
[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 for every DDC or CCI
GAHP-A
√
√
√
GAHP-GS/WS
AY
√
√
√
√
√
√
√
√
ACF
√
√
GAHP-AR
√
√
√
√
√
√
√
√
√
DDC or CCI
41
8 Diagnostics
GUIDELINES FOR THE PREVENTIVE MAINTENANCE OPERATIONS
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].
7.3 SCHEDULED ROUTINE MAINTENANCE
For scheduled routine maintenance, perform the operations in
Table 7.2 p. 42, at least once every 2 years.
Table 7.2
SCHEDULED MAINTENANCE OPERATIONS
Check of the unit
Clean the combustion chamber
Clean the burner
Clean the electrodes of ignition and flame sensing
TO BE PERFORMED AT LEAST ONE EVERY TWO YEARS
GAHP-A GAHP-GS/WS
AY
ACF
GAHP-AR
√*
√*
√
√
√*
√*
√*
√
√
√*
√
√
√
√
√
Check that the condensate discharge is clean
√
Replace the silicone gasket between the front plate and the exchanger
√
√
√
*Only in case the analysis of combustion products is non-compliant
7.4 PERIODS OF INACTIVITY
4. I f necessary, add water with glycol (if the appliance is disconnected from the power and gas mains, the active antifreeze
protection is missing, Paragraph 3.5 p. 27).
Avoid emptying the installation
Emptying the system may cause damage due to corrosion of the water pipes.
Deactivate the system in winter
Should you intend to stop the appliance in the winter
season, ensure at least one of the following conditions:
How to reactivate the appliance after long periods of
inactivity
Before reactivating the appliance, the operator/maintenance
technician of the system must first of all:
▶▶ Check whether any maintenance operations are required
(contact the TAC; see Paragraphs 7.2 p. 41 and 7.3 p. 42).
▶▶
1. anti-icing function active (Paragraph 3.5 p. 27);
2. sufficient anti-icing glycol (Paragraph 3.6 p. 27).
▶▶
Prolonged periods of inactivity
▶▶
S hould you foresee to leave the appliance inactive for a long
period of time, disconnect it from the electrical and gas
mains. These operations must be performed by Qualified
Personnel.
How to deactivate the appliance for long periods of time
1. S witch the appliance off (Paragraph 6.2 p. 38).
2. Only when the appliance is completely off, power it off with
the main switch/disconnector switch (Detail GS in Figure
[Ref ] p. ).
3. Close the gas valve
heck content and quality of the water in the system, and if
C
necessary top it up (Paragraphs 3.8 p. 28, 3.7 p. 28 and
3.6 p. 27 ).
E nsure the flue gas exhaust duct is not obstructed, and that
the condensate drain is clean.
After completing the above checks:
1. O
pen the gas cock and ensure there are no leaks;
should gas smell be noticed, close the gas cock
again, do not switch any electrical devices on and
request intervention by Skilled Personnel.
2. P
ower on with the main power supply switch (GS,
Figure [Ref ] p. ).
3. S witch on the appliance by means of the provided
control device (DDC or external enable, Paragraph
4.4 p. 33).
8 DIAGNOSTICS
8.1 OPERATIVE CODES
Table 8.1 – Operative Codes
CODES
DESCRIPTION
400
FAULT ON RESET CIRCUIT OF FLAME NA
CONTROL UNIT
401
GENERATOR LIMIT THERMOSTAT
TRIP
FLUE GAS THERMOSTAT TRIP
402
42
Warning (u)
Contact authorised Technical Assistance
Error (E)
Power cycle the appliance.
If the code persists, shows up again or in case of doubt, contact
the TAC.
CODES
8 Diagnostics
Warning (u)
Error (E)
405
DESCRIPTION
AMBIENT TEMPERATURE EXCEEDING OPERATIVE LIMITS
NA
Reset is automatic when the triggering condition ceases.
406
AMBIENT TEMPERATURE LOWER
THAN OPERATIVE LIMITS
Non-blocking Warning (informative code).
The code is reset automatically when the triggering condition ceases.
NA
407
GENERATOR TEMPERATURE HIGH
Reset is automatic when the triggering condition
ceases.
408
FLAME CONTROL UNIT ERROR
NA
410
INSUFFICIENT WATER FLOW
ceases.
411
INSUFFICIENT ROTATION OF OIL
PUMP
Reset occurs automatically 20 minutes after the
code is generated.
412
FLAME CONTROLLER UNIT ARREST
Reset is automatic up to 4 attempts (in about 5
minutes).
416
FAULTY HOT OUTLET WATER TEMPERATURE PROBE
NA
417
FAULTY HOT OUTLET WATER
INLET TEMPERATURE PROBE
NA
420
FAULTY GENERATOR TEMPERATURE
PROBE
NA
422
FAULTY WATER FLOWMETER
NA
423
FAULTY AIR/GAS MIXTURE TEMPERATURE PROBE
NA
424
FUMES TEMPERATURE SENSOR
FAULT
ceases.
425
CONDENSATE DISCHARGE
CLOGGED
NA
426
GENERATOR FIN TEMPERATURE
SENSOR MALFUNCTION
ceases.
428
GAS SOLENOID VALVE EXCITED
DURING FLAME CONTROLLER
ARREST
NA
Power off the appliance.
Contact authorised Technical Assistance.
429
GAS SOLENOID VALVE WITHOUT
ELECTRICAL POWER
Reset occurs automatically if the gas solenoid
valve switches on again within 10 minutes (with
central flame control unit on).
430
GENERATOR FINS TEMPERATURE
HIGH
ceases.
Reset may be performed from the DDC/CCI or from the S61 board
(menu 2, parameter 21).
the TAC.
the TAC.
431
WATER TEMPERATURE EXCEEDING
OPERATIVE LIMITS
434
POSSIBLE SOURCE ANOMALY
436
BLOWER FAULT
the TAC.
Check and clean water filters on the system.
Check for air in the system.
Check water flow pump.
Power cycle the appliance.
the TAC.
the TAC.
Gas supply check.
If the code persists or in case of doubt, contact the TAC.
the TAC.
the TAC.
the TAC.
the TAC.
the TAC.
the TAC.
Check and clean condensate discharge.
the TAC.
the TAC.
Check configuration of other heat generators on
the system.
Check water flow.
NA
Check system thermal load.
ceases.
Check if the fan is rotating freely. Contact the TAC. NA
code is generated.
the TAC.
43
8 Diagnostics
CODES
Warning (u)
Error (E)
437
DESCRIPTION
LOW AIR-GAS MIXTURE
TEMPERATURE
NA
444
FAULTY EVAPORATOR TEMPERATURE PROBE
NA
the TAC.
485
486
487
488
489
Check configuration of other heat generators on
the system.
HIGH HOT INLET WATER
Reset is automatic and occurs if the generating
TEMPERATURE
condition ceases with circulating pump on or 20
minutes after the code is generated with circulating pump off.
Reset occurs automatically when the generating
HOT INLET WATER TEMPERATURE
cause resolves or 430 seconds after the code is
LOWER THAN OPERATIVE LIMITS
generated.
Check water flow.
HIGH HOT WATER DIFFERENTIAL
TEMPERATURE
code is generated.
SATELLITE BOARD NOT PRESENT
NA
DEFROSTING FUNCTION ACTIVATED The code clears automatically when execution of
defrosting ends.
WATER FLOW IN THE PASSIVE HOT
MODULE
ceases.
HIGH HOT OUTLET WATER
TEMPERATURE
ceases.
DEFROST FUNCTION ACTIVATED
The code clears automatically when anti-icing
function execution ends.
INCOMPLETE OR INVALID
PARAMETERS
INVALID P0 PARAMETERS
ceases.
ceases.
FAULTY TRANSFORMER CONNECNA
TION OR 24 V AC FUSES
INCORRECT MODULE TYPES
NA
FAULTY BOARD, ROM
NA
FAULTY BOARD, pRAM
NA
FAULTY BOARD, xRAM
NA
FAULTY BOARD, REG.
NA
490
FAULTY AMBIENT TEMPERATURE
PROBE
NA
491
CONTROLLER DEFECTIVE
NA
446
447
448
449
452
453
478
479
80/480
481
482
484
NA: Not Applicable
44
NA
Reset occurs automatically when the condition that generated the
code ceases.
If the code shows up again or in case of doubt contact the TAC.
Reset occurs automatically when the condition that generated the
code ceases.
If the code shows up again or in case of doubt contact the TAC.
NA
NA
NA
NA
the TAC.
8 Diagnostics
Table 8.2 – Operative Codes AY00-120
CODES
DESCRIPTION
100
FAULT ON RESET CIRCUIT OF FLAME NA
CONTROL UNIT
101
THERMOSTAT TRIP INTERNAL
CIRCUIT LIMIT
FLUE GAS THERMOSTAT AND/OR
INTERNAL EXCHANGER THERMOSTAT TRIP
HEATING BOARD (S70) ABSENT
AMBIENT TEMPERATURE EXCEEDING OPERATIVE LIMITS
AMBIENT TEMPERATURE LOWER
THAN OPERATIVE LIMITS
SYSTEM CIRCUIT WATER PRESSURE
SWITCH TRIP WITH SYSTEM IN COLD
MODE
FLAME CONTROLLER UNIT ARREST
102
103
105
106
107
112
127
128
Warning (u)
FAULTY INTERNAL CIRCUIT WATER
PRESSURE SWITCH OR INSUFFICIENT INTERNAL CIRCUIT WATER
FLOW
GAS SOLENOID VALVE EXCITED
DURING FLAME CONTROLLER
ARREST
Error (E)
• Power cycle the appliance.
the TAC.
NA
NA
NA
The code is reset automatically when the triggering condition
ceases.
ceases.
NA
Reset is automatic up to 4 attempts (in about 5
minutes).
• Gas supply check.
Reset may be performed from the DDC or from the AY10 board
ceases.
NA
• Power off the appliance.
the TAC.
the TAC.
the TAC.
• Check and clean water filters on the system.
• Check for air in the system.
• Check water flow pump.
• Power cycle the appliance.
the TAC.
the TAC.
the TAC.
129
GAS SOLENOID VALVE WITHOUT
ELECTRICAL POWER
Reset occurs automatically if the gas solenoid
valve switches on again within 10 minutes (with
central flame control unit on).
135
FAULTY INTERNAL CIRCUIT DELIVERY TEMPERATURE PROBE
NA
136
BLOWER FAULT
code is generated.
175
INSUFFICIENT SYSTEM CIRCUIT
WATER FLOW
ceases.
176
FAULTY SYSTEM CIRCUIT DELIVERY
TEMPERATURE PROBE
NA
177
FAULTY SYSTEM CIRCUIT RETURN
TEMPERATURE PROBE
NA
178
HIGH HOT OUTLET WATER
TEMPERATURE
179
DEFROST FUNCTION ACTIVATED
ceases.
The code clears automatically when anti-icing
function execution ends.
80
INCOMPLETE OR INVALID
PARAMETERS
81
82
ceases.
ceases.
84
FAULTY TRANSFORMER CONNECTION OR 24 V AC FUSES
INCORRECT MODULE TYPES
FAULTY BOARD, ROM
FAULTY BOARD, pRAM
FAULTY BOARD, xRAM
FAULTY BOARD, REG.
NA
NA
NA
NA
NA
NA
85
86
87
88
89
NA
NA
45
8 Diagnostics
CODES
DESCRIPTION
Warning (u)
90
FAULTY AMBIENT TEMPERATURE
PROBE
NA
91
CONTROLLER DEFECTIVE
NA
NA: Not Applicable
46
Error (E)
the TAC.
Appendices
APPENDICES
1 DECLARATION OF CONFORMITY
Figure 1
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. Via Miramare, 15 Milan-Italy
Jvan Benzoni
R&D Director
Robur S.p.A.
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.
47
Appendices
2 PRODUCT FICHE
Figure 2
Table 8
COMMISSION DELEGATED REGULATION (EU) No 811/2013
Technical parameters for heat pump space heaters and heat pump combination heaters
Model(s):
Gitié AHAY S1
Air-to-water heat pump:
yes
Water-to-water heat pump:
no
Brine-to-water heat pump:
no
Low-temperature heat pump:
no
Equipped with a supplementary heater:
yes
Heat pump combination heater:
no
Parameters shall be declared for medium-temperature application.
Parameters shall be declared for average, colder and warmer climate conditions.
Item
Symbol
Value
Unit
Item
Symbol
Value
AVERAGE CLIMATE CONDITIONS
Prated
66,8
kW
126
Rated heat output (*)
Seasonal space heating
ηs
energy efficiency
Declared coefficient of performance or primary energy
Declared capacity for heating for part load at indoor
ratio for part load at indoor temperature 20 °C and
temperature 20 °C and outdoor temperature T j
outdoor temperature Tj
58,8
kW
Tj = -7 °C
PERd
107
36,1
kW
Tj = +2 °C
PERd
136
23,4
kW
Tj = +7 °C
PERd
134
10,0
kW
Tj = +12 °C
PERd
127
38,7
kW
Tj = bivalent temperature
PERd
134
1,0
°C
394
GJ
COLDER CLIMATE CONDITIONS
Prated
66,0
kW
122
ηs
energy efficiency
Tj = -7 °C
Tj = +2 °C
Tj = +7 °C
Tj = +12 °C
Bivalent temperature
Annual energy consumption
Tj = -7 °C
Tj = +2 °C
Tj = +7 °C
Tj = +12 °C
Tj = operation limit
temperature
For air-to-water heat pumps:
Tj = –15 °C (if TOL < –20 °C)
Pdh
Pdh
Pdh
Pdh
Pdh
T biv
Q HE
Pdh
Pdh
Pdh
Pdh
Pdh
Pdh
40,3
24,4
15,8
7,3
36,3
66,0
kW
kW
kW
kW
kW
kW
Pdh
54,1
kW
Tj = -7 °C
Tj = +2 °C
Tj = +7 °C
Tj = +12 °C
temperature
Tj = –15 °C (if TOL < –20 °C)
Tj = +2 °C
Tj = +7 °C
Tj = +12 °C
48
%
%
%
%
%
%
%
PERd
PERd
PERd
PERd
PERd
PERd
123
132
127
127
129
94
%
%
%
%
%
%
PERd
97
%
T biv
Q HE
-5,0
°C
480
GJ
WARMER CLIMATE CONDITIONS
Prated
72,1
kW
124
ηs
energy efficiency
Unit
Pdh
Pdh
Pdh
Pdh
T biv
Q HE
72,1
46,1
20,9
36,1
9,0
280
kW
kW
kW
kW
°C
GJ
Tj = +2 °C
Tj = +7 °C
Tj = +12 °C
PERd
PERd
PERd
PERd
103
125
129
132
%
%
%
%
%
Appendices
Figure 3
Power consumption in modes other than active mode
0,000
Off mode
P OFF
P TO
0,041
Thermostat-off mode
0,009
Standby mode
P SB
P CK
Crankcase heater mode
Other items
Capacity control
variable
Sound power level, indoors/
outdoors
L WA
- / 74
kW
kW
kW
kW
dB
Operation limit temperature
Heating water operating limit
Supplementary heater
Rated heat output
TOL
-22
°C
WTOL
65
°C
Psup
34,4
Natural gas
kW
__
10000
m³/h
__
-
m³/h
Type of energy input
Rated air flow rate, outdoors
For water- or brine-to-water
heat pumps: Rated brine or
water flow rate, outdoor heat
exchanger
(*) For heat pump space heaters and heat pump combination heaters, the rated heat output Prated is equal to the design load for
heating Pdesignh , and the rated heat output of a supplementary heater Psup is equal to the supplementary capacity for heating
sup(Tj) .
Additional information required by COMMISSION REGULATION (EU) No 813/2013, Table 2:
40
mg/
Emissions of nitrogen oxides:
NO x
kWh
49
Appendices
Figure 4
Table 8
COMMISSION DELEGATED REGULATION (EU) No 811/2013
Technical parameters for heat pump space heaters and heat pump combination heaters
Model(s):
Gitié AHAY STD
Air-to-water heat pump:
yes
Water-to-water heat pump:
no
Brine-to-water heat pump:
no
Low-temperature heat pump:
no
Equipped with a supplementary heater:
yes
Heat pump combination heater:
no
Parameters shall be declared for medium-temperature application.
Parameters shall be declared for average, colder and warmer climate conditions.
Item
Symbol
Value
Unit
Item
Symbol
Value
AVERAGE CLIMATE CONDITIONS
Prated
66,8
kW
125
ηs
energy efficiency
58,8
kW
Tj = -7 °C
PERd
107
36,1
kW
Tj = +2 °C
PERd
135
23,4
kW
Tj = +7 °C
PERd
133
10,0
kW
Tj = +12 °C
PERd
126
38,7
kW
PERd
133
1,0
°C
398
GJ
COLDER CLIMATE CONDITIONS
Prated
66,0
kW
120
ηs
energy efficiency
Tj = -7 °C
Tj = +2 °C
Tj = +7 °C
Tj = +12 °C
Tj = -7 °C
Tj = +2 °C
Tj = +7 °C
Tj = +12 °C
temperature
Tj = –15 °C (if TOL < –20 °C)
Pdh
Pdh
Pdh
Pdh
Pdh
T biv
Q HE
Pdh
Pdh
Pdh
Pdh
Pdh
Pdh
40,3
24,4
15,8
7,3
36,3
66,0
kW
kW
kW
kW
kW
kW
Pdh
54,1
kW
Tj = -7 °C
Tj = +2 °C
Tj = +7 °C
Tj = +12 °C
temperature
Tj = –15 °C (if TOL < –20 °C)
Tj = +2 °C
Tj = +7 °C
Tj = +12 °C
50
%
%
%
%
%
%
%
PERd
PERd
PERd
PERd
PERd
PERd
122
130
126
125
128
94
%
%
%
%
%
%
PERd
97
%
T biv
Q HE
-5,0
°C
488
GJ
WARMER CLIMATE CONDITIONS
Prated
72,1
kW
123
ηs
energy efficiency
Unit
Pdh
Pdh
Pdh
Pdh
T biv
Q HE
72,1
46,1
20,9
36,1
9,0
282
kW
kW
kW
kW
°C
GJ
Tj = +2 °C
Tj = +7 °C
Tj = +12 °C
PERd
PERd
PERd
PERd
103
125
128
131
%
%
%
%
%
Appendices
Figure 5
Power consumption in modes other than active mode
0,000
Off mode
P OFF
P TO
0,041
Thermostat-off mode
0,009
Standby mode
P SB
P CK
Crankcase heater mode
Other items
Capacity control
variable
Sound power level, indoors/
outdoors
L WA
- / 74
kW
kW
kW
kW
dB
Operation limit temperature
Heating water operating limit
Supplementary heater
Rated heat output
TOL
-22
°C
WTOL
65
°C
Psup
34,4
Natural gas
kW
__
10000
m³/h
__
-
m³/h
Type of energy input
Rated air flow rate, outdoors
For water- or brine-to-water
heat pumps: Rated brine or
water flow rate, outdoor heat
exchanger
(*) For heat pump space heaters and heat pump combination heaters, the rated heat output Prated is equal to the design load for
heating Pdesignh , and the rated heat output of a supplementary heater Psup is equal to the supplementary capacity for heating
sup(Tj) .
Additional information required by COMMISSION REGULATION (EU) No 813/2013, Table 2:
40
mg/
Emissions of nitrogen oxides:
NO x
kWh
51
08/09/2015
15MCMSDC013
Revision: C
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.
Code: D-LBR723 Robur mission
Robur Spa
advanced climate
control technologies
Via Parigi 4/6
24040 Verdellino/Zingonia (Bg) Italy
T +39 035 888111⇒F +39 035 884165
www.robur.it [email protected]