ROBUA GA Line ACF Series Service manual

Installation, Use and
Maintenance Manual
GA Line ACF Series
Natural gas/LPG red
Gas red absorption chiller

Revision: M
Code: D-LBR357
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 led 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 led the registered trademarks contained within this publication are not
aected.
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.

Installation, Use and Maintenance Manual – GA Line ACF Series 3
INDEX OF CONTENTS
I INTRODUCTION...............................................4
II SYMBOLS AND DEFINITIONS.........................4
II.1 Key to symbols......................................................................4
II.2 Terms and denitions.........................................................4
III WARNINGS.......................................................4
III.1 General and safety warnings...........................................4
III.2 Conformity .............................................................................6
III.3 Exclusions of liability and warranty...............................6
1 FEATURES AND TECHNICAL DATA ................6
1.1 Features...................................................................................6
1.2 Size............................................................................................7
1.3 Components....................................................................... 10
1.4 Electrical wiring diagram ............................................... 13
1.5 Electronic boards .............................................................. 14
1.6 Controls ................................................................................ 15
1.7 Technical characteristics................................................. 16
2 TRANSPORT AND PLACEMENT ...................17
2.1 Warnings.............................................................................. 17
2.2 Handling............................................................................... 17
2.3 Appliance positioning..................................................... 18
2.4 Minimum clearance distances...................................... 18
2.5 Mounting base................................................................... 19
3 PLUMBING INSTALLER .................................19
3.1 Warnings.............................................................................. 19
3.2 Plumbing system .............................................................. 19
3.3 Hydraulic connections .................................................... 20
3.4 Water circulation pump.................................................. 21
3.5 Antifreeze function........................................................... 21
3.6 Antifreeze liquid................................................................ 21
3.7 System water quality ....................................................... 21
3.8 Water system lling.......................................................... 22
3.9 Combustible gas supply................................................. 22
4 ELECTRICAL INSTALLER ...............................23
4.1 Warnings.............................................................................. 23
4.2 Electrical systems.............................................................. 23
4.3 Electrical power supply................................................... 24
4.4 Adjustment and control ................................................. 25
4.5 Water circulation pump.................................................. 27
5 FIRST SWITCH ON..........................................28
5.1 Preliminary checks............................................................ 28
6 ROUTINE OPERATION...................................29
6.1 Warnings.............................................................................. 29
6.2 Switch on and o.............................................................. 29
6.3 Signals on the display...................................................... 29
6.4 Electronic adjustment on the machine – Menus
and parameters of the S61 board............................... 29
6.5 Modifying settings............................................................ 31
6.6 Restarting a locked-down unit – Reset..................... 31
6.7 Eciency.............................................................................. 32
7 MAINTENANCE..............................................32
7.1 Warnings.............................................................................. 32
7.2 Pre-emptive maintenance............................................. 32
7.3 Scheduled routine maintenance................................. 32
7.4 Periods of inactivity.......................................................... 33
8 DIAGNOSTICS................................................33
8.1 Operative codes................................................................. 33
APPENDICES........................................................35
1 Declaration of Conformity............................................. 35

I Introduction
4
I INTRODUCTION
Manual
This Manual is an integral part of the GA unit and must
be handed to the end user together with the appliance.
Recipients
This Manual is intended for:
▶ end user, for appropriate and safe use of the appliance;
▶ qualied installer, for correct appliance installation;
▶ designer, for specic information on the appliance.
Control device
In order to be able to work, the GA-ACF unit needs a control de-
vice (DDC or external request), which must be connected by the
installer.
II SYMBOLS AND DEFINITIONS
II.1 KEY TO SYMBOLS
DANGER
WARNING
NOTE
PROCEDURE
REFERENCE (to other document)
II.2 TERMS AND DEFINITIONS
GA Appliance/Unit = equivalent terms, both used to designate
the GA Gas Absorption chiller.
TAC = Technical Assistance Centre authorised by Robur.
External request = generic control device (e.g. thermostat, tim-
er or any other system) equipped with a voltage-free NO contact
and used as control to start/stop the GA unit.
DDC Control (Direct Digital Controller) = optional Robur device
to control one or more Robur appliances (GAHP heat pumps, GA
chillers and AY boilers) in ON/OFF mode.
RB100/RB200 Devices (Robur Box) = optional interface devices
complementary to DDC, which may be used to broaden its func-
tions (heating/cooling/DHW production service demands, and
control of system components such as third party generators,
adjustment valves, circulating pumps, probes).
GUE (Gas Utilization Eciency) = eciency index of gas chiller,
equal to the ratio between the chilling energy produced and the
energy of the fuel used (relative to NCV, net caloric value).
First Switch-On = appliance commissioning operation which
may only and exclusively be carried out by a TAC.
S61 Board = electronic board on the GA unit, to control all func-
tions and to provide interface with other devices and with the
user.
III WARNINGS
III.1 GENERAL AND SAFETY WARNINGS
Installer's qualications
Installation must exclusively be performed by a Quali-
ed Firm and by Skilled Personnel, with specic knowl-
edge on heating, cooling, electrical systems and gas
appliances, pursuant to the laws in force in the Country
of installation.
Workmanlike Conformity Declaration
Upon completing installation, the installing rm shall is-
sue to the owner/principal the appliance'sWorkmanlike
Conformity Declaration, according to national/local reg-
ulations 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 aect operation, duration
and safety of the appliance. Adhere to the manufactur-
er's instructions.
Hazardous situations
▶ Do not start the appliance in hazardous conditions,
such as: gas smell, problems with the hydraulic/elec-
trical/gas system, parts of the appliance under water
or damaged, malfunctioning, disabling or bypassing
control and safety devices.
▶ In case of danger, request assistance by skilled
personnel.
▶ In case of danger, switch o the electrical power and
gas supplies only if this can be done in total safety.
▶ Do not entrust children,personswith physical,senso-
ry or mental disabilities or persons with poor knowl-
edge and experience with use of the appliance.
Gas component seal

III Warnings
Installation, Use and Maintenance Manual – GA Line ACF Series 5
▶ Before performing any operation on gas ducting
components, close the gas cock.
▶ Upon completing any procedure, perform the leak
test according to regulations in force.
Gas smell
If you smell gas:
▶ Do not use electrical devices such as telephones,
multimeters or other equipment that may cause
sparks next to the appliance.
▶ Shut o the gas supply by turning the cock o.
▶ Disconnect electrical power supply by means of the
external isolation switch in the power supply electri-
cal panel.
▶ Use a telephone away from the appliance to ask for
assistance from skilled personnel.
Moving parts
The appliance contains moving parts.
▶ Do not remove guards during operation, and in any
case prior to disconnecting the power supply.
Burn hazard
The appliance contains very hot parts.
▶ Do not open the appliance and do not touch internal
components before the appliance has cooled down.
Pressure vessels
The appliance has a sealed circuit classied as pres-
sure vessel, the tightness of which is tested by the
manufacturer.
▶ Do not carry out any operation on the sealed circuit
or on the appliance's valves.
Water-ammonia solution
The GA 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.
▶ In the event of coolant leak keep away and discon-
nect the power and gas supply (only if it is possible
to do so with no danger).
▶ Request assistance from the TAC.
Electrocution hazard
▶ Disconnect the electrical power supply before any
work/procedure on appliance components..
▶ For electrical connections exclusively use compliant
components and according to the specications pro-
vided by the manufacturer.
▶ Ensure the appliance cannot be accidentally
switched back on.
Earthing
Electrical safety depends on eective earthing system,
correctly connected to the appliance and installed ac-
cording to the regulations in force.
Distance from combustible or ammable materials
▶ Do not store ammable materials (paper, solvents,
paint, etc.) in the vicinity of the appliance.
Scale and corrosion
Depending on the chemical-physical features of the
system water, scale or corrosion may damage the appli-
ance (Paragraph 3.7p.21).
▶ 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.22.
Aggressive substances in air
Halogenated hydrocarbons containing chlorine and
uorine compounds cause corrosion. The supply/venti-
lation air of the appliance must be free from aggressive
substances.
Switching the appliance o
Disconnecting the power supply while the appliance
is running may cause permanent damage to internal
components.
▶ Except in the case of danger, do not disconnect the
power supply to switch o the appliance, but always
and exclusively act through the control device pro-
vided (DDC or external enable).
In the event of failure
Operations on internal components and repairs may
exclusively be carried out by a TAC, only using original
parts.
▶ In the event of failure of the appliance and/or break-
age of any component, do not attempt to repair and/
or restore and immediately contact the TAC.
Routine maintenance
Proper maintenance assures the eciency and good
operation of the appliance over time.
▶ Maintenance must be performed according to the
manufacturer's instructions (see Chapter 7 p. 32)
and in compliance with current regulations.
▶ Appliance maintenance and repairs may only be
entrusted to rms legally authorised to work on gas
appliances and systems.
▶ Enter into a maintenance contract with an author-
ised specialised rm for routine maintenance and for
servicing in case of need.
▶ Only use original parts.

1 Features and technical data
6
Decommissioning and disposal
If the appliance is to be disposed of, contact the manu-
facturer for its disposal.
Store the Manual
This "Installation, Use and Maintenance Manual" must
always accompany the appliance and must be hand-
ed to the new owner or installer in the event of sale or
removal.
III.2 CONFORMITY
EU Directives and standards
GA series absorption chillers are certied in compliance to EC
standards and conform with the essential requirements of the
following Directives:
▶ 2009/142/EC "Gas Appliances Directive" as amended and
added.
▶ 2004/108/EC "Electromagnetic Compatibility Directive" as
amended and added.
▶ 2006/95/EC "LowVoltage Directive" as amended and added.
▶ 2006/42/EC "Machine Directive" as amended and added.
▶ 97/23/EEC "Pressure Equipment Directive" as amended and
added.
Furthermore, they comply with the requirements of the follow-
ing standards:
▶ EN 378 Refrigerating systems and heat pumps.
Other applicable provisions and standards
The design, installation, operation and maintenance of the sys-
tems shall be carried out in compliance with current applicable
regulations, depending on the Country and location, and in ac-
cordance with the manufacturer's instructions. In particular, reg-
ulations regarding the following shall be complied with:
▶ Gas systems and equipment.
▶ Electrical systems and equipment.
▶ Heating and air conditioning systems, and chillers.
▶ Fire safety and prevention.
▶ Any other applicable law, standard and regulation.
III.3 EXCLUSIONS OF LIABILITY AND
WARRANTY
Any contractual or extra-contractual liability of the
manufacturer for any damage caused by incorrect in-
stallation and/or improper use and/or failure to comply
with regulations and with the manufacturer's direc-
tions/instructions shall be disclaimed.
In particular, the warranty on the appliance may be ren-
dered void by the following conditions:
▶ Incorrect installation.
▶ Misuse.
▶ Failure to comply with the manufacturer's indica-
tions on installation, use and maintenance.
▶ Alteration or modication of the product or any part
thereof.
▶ Extreme operational conditions or however out-
side of the operational ranges set forth by the
manufacturer.
▶ Damages caused by external agents such as salts,
chlorine, sulphur or other chemical substances con-
tained in the installation water or present in the air of
the installation site.
▶ Abnormal actions transmitted by the plant or instal-
lation to the appliance (mechanical stresses, pres-
sure, vibrations, thermal dilations, power surges...).
▶ Accidental damages or due to force majeure.
1 FEATURES AND TECHNICAL DATA
1.1 FEATURES
Operation
Based on the thermodynamic water-ammonia absorption cycle
(H20–NH3), the appliance produces chilled water using natural
gas (or LPG) as primary energy source and dissipating heat di-
rectly to the external air.
The thermodynamic cycle takes place within a hermetically
sealed circuit, in welded construction, perfectly tight, facto-
ry-tested, which does not require any maintenance or coolant
top-ups.
Mechanical and thermo-hydraulic components
▶ steel sealed cooling circuit, externally treated with epoxy
paint;
▶ Multigas premix burner equipped with ignition and ame
detection device, controlled by an electronic controller;
▶ titanium stainless steel shell-and-tube water exchanger
(evaporator), externally insulated;
▶ air exchanger (condenser) with nned coil, with steel pipe
and aluminium ns;
▶ helical fan motor with variable ow controlled by micro pro-
cessor.
Control and safety devices
▶ S61 electronic board with microprocessor, LCD display and
knob;
▶ circuit water ow switch;
▶ manually reset generator limit thermostat;
▶ automatically resettable ue gas thermostat;
▶ dierential air pressure switch on the combustion circuit;
▶ sealed circuit safety relief valve;
▶ by-pass valve, between high and low pressure circuits;
▶ ionisation-based ame controller;
▶ gas solenoid valve with double shutter;
▶ heat recovery exchanger circulating pump relay (HR version
only)
ACF-HR/TK/HT/LB Versions
The GA unit is available in the following versions:

1 Features and technical data
Installation, Use and Maintenance Manual – GA Line ACF Series 7
▶ ACF standard, for residential/retail/industrial cooling sys-
tems with chilled water up to +3 °C.
▶ HR with heat recovery exchanger, for residential/retail/in-
dustrial cooling systems with chilled water up to +3 °C, plus
recovery exchanger hot water up to +80 °C (e.g. DHW pro-
duction);
▶ TK for heavy duty use, for process systems and applications
with chilled water up to +3 °C, in continuous operation year
round;
▶ HT for very hot climates, for residential/retail/industrial cool-
ing systems with chilled water up to +5 °C, with outside air
up to +50 °C;
▶ LB for negative temperatures, for cooling systems with
chilled water up to -10 °C (glycol indispensable).
Models ACF, TK, LB and HT have 2 chilled water inlet/outlet t-
tings, model HR has 4 chilled water and heat recovery exchanger
hot water inlet/outlet ttings.
Each version may be supplied with standard (STD) or silenced
(S) fan.
1.2 SIZE
Figure 1.1 – GA-ACF standard version dimensions

1 Features and technical data
8
Figure 1.2 – GA-ACF silenced version dimensions
Figure 1.3 – ACF Service plate with plumbing and gas connections
LEGEND
A WATER FLOW TO INSTALLATION 1"1/4 F
B WATER INLET TO UNIT 1"1/4 F
G GAS SUPPLY 3/4" F

1 Features and technical data
Installation, Use and Maintenance Manual – GA Line ACF Series 9
Figure 1.4 – ACF-HR Service plate with plumbing and gas connections
LEGEND
G GAS SUPPLY 3/4" F
Chiller - CHILLED WATER
D WATER FLOW TO INSTALLATION 1"1/4 F
C WATER INLET TO UNIT 1"1/4 F
Recovery exchanger - HOT WATER
A WATER FLOW TO INSTALLATION 1"1/4 F
B WATER INLET TO UNIT 1"1/4 F

1 Features and technical data
10
1.3 COMPONENTS
Figure 1.5 – Internal components - front view
LEGEND
1.Combustion air intake
2.Blower
3. Gas valve
4.Electrical Panel
5.Oil pump
6.Water inlet connection Ø 1"1/4 F
7.Water ow connection Ø 1"1/4 F
8.Gas connection
9.Ambient temperature probe
10.Fan