Robur GA ACF User manual

Installation, use and maintenance manual
gas powered
absorption chiller
GA ACF

This Installation, use and maintenance manual has been drawn up and printed by Robur Corporation; whole or
partial reproduction of this Installation, use and maintenance manual is prohibited.
The original is led at Robur Corporation.
Any use of this Installation, use and maintenance manual other than for personal consultation must be previously
authorised by Robur Corporation.
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 Corporation reserves the right to modify
the data and contents of this Installation, use and maintenance manual without prior notice.
Revision: P
Code: D-LBR323

Installation, use and maintenance manual – GA ACF 3
INDEX OF CONTENTS
I Introduction............................................................................. p.4
I.1 Recipients .......................................................................... p.4
I.2 Control device.................................................................. p.4
II Symbols and denitions............................................... p.4
II.1 Key to symbols................................................................. p.4
II.2 Terms and denitions.................................................... p.4
III Warnings...................................................................................... p.4
III.1 General and safety warnings ...................................... p.4
III.2 Conformity ........................................................................ p.6
III.3 Exclusions of liability and warranty.......................... p.6
1 Features and technical data ...................................... p.7
1.1 Features .............................................................................. p.7
1.2 Dimensions ....................................................................... p.7
1.3 Components..................................................................... p.9
1.4 Electrical wiring diagram ........................................... p.12
1.5 Electronic boards .......................................................... p.12
1.6 Controls ............................................................................ p.13
1.7 Technical data ................................................................ p.14
2 Transport and positioning........................................ p.18
2.1 Warnings .......................................................................... p.18
2.2 Handling........................................................................... p.18
2.3 Appliance positioning................................................. p.19
2.4 Minimum clearance distances.................................. p.19
2.5 Mounting base............................................................... p.20
3 System design....................................................................... p.21
3.1 Warnings .......................................................................... p.21
3.2 Hydraulic system........................................................... p.21
3.3 Hydraulic connections ................................................ p.22
3.4 Water circulation pump.............................................. p.22
3.5 Antifreeze function....................................................... p.23
3.6 Antifreeze liquid............................................................ p.23
3.7 System water quality ................................................... p.23
3.8 System lling .................................................................. p.24
3.9 Fuel gas supply .............................................................. p.24
4 Electrical installer.............................................................. p.25
4.1 Warnings .......................................................................... p.25
4.2 Electrical systems.......................................................... p.25
4.3 Electrical power supply............................................... p.25
4.4 Set-up and control........................................................ p.26
4.5 Water circulation pump.............................................. p.29
4.6 With more than one GA ACF unit............................ p.30
5 First start-up .......................................................................... p.31
5.1 Preliminary checks........................................................ p.31
5.2 First start-up operations............................................. p.31
5.3 Check the static gas mains pressure...................... p.32
5.4 Gas pressure adjustment............................................ p.32
5.5 Gas changeover............................................................. p.33
5.6 Electronic adjustment on the machine – Menus
and parameters of the S61 board ........................... p.33
5.7 Modifying settings........................................................ p.35
6 Normal operation.............................................................. p.36
6.1 Warnings .......................................................................... p.36
6.2 Switch on and o.......................................................... p.36
6.3 Modifying settings........................................................ p.36
6.4 Eciency.......................................................................... p.36
7 Maintenance.......................................................................... p.36
7.1 Warnings .......................................................................... p.36
7.2 Scheduled routine maintenance............................. p.37
7.3 Extraordinary maintenance....................................... p.38
7.4 Messages on the display ............................................ p.38
7.5 Restarting a locked-out unit ..................................... p.38
7.6 Periods of inactivity...................................................... p.39
8 Diagnostics.............................................................................. p.40
8.1 Operative codes............................................................. p.40

Introduction
4
I
I INTRODUCTION
Installation, use and maintenance manual
This Manual is an integral part of the GA ACF unit and
must be handed to the end user together with the
appliance.
I.1 RECIPIENTS
This Manual is intended for:
▶ End user, for appropriate and safe use of the appliance.
▶ Qualied installer, for correct appliance installation.
▶ Planner, for specic information on the appliance.
I.2 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.
AT = Robur Authorised Technician.
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 adjust-
ment 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 func-
tions (heating/cooling/DHW production service demands, and
control of system components such as third party generators,
adjustment valves, circulators, 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 start-up = appliance commissioning operation which may
only and exclusively be carried out by an AT.
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 rm and by skilled personnel, with specic knowl-
edge on heating, electrical systems and gas appliances,
in compliance with the laws in force in the Country of
installation. The manufacturer will not accept responsi-
bility for personal injuries or property damage resulting
from improper installation.
Declaration of conformity
Upon completing installation, the installing rm shall
issue to the owner/client the appliance's workman-
like conformity declaration, according to national/local
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 aect operation, duration
and safety of the appliance. Adhere to the manufactur-
er's instructions. Steps must be taken to avoid improper
use and potential dangers.
Hazardous situations
Do not start the appliance in hazardous conditions, such
as: gas smell, problems with the plumbing/electrical/gas
system, parts of the appliance under water or damaged,
malfunctioning, disabling or bypassing control and safe-
ty devices.
Immediately call a qualied service technician to inspect
the appliance and to replace any part of the control sys-
tem and any gas control, which has been underwater.

Warnings
Installation, use and maintenance manual – GA ACF 5
III
In case of danger, request intervention by qualied per-
sonnel.
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, persons with physical, sensory
or mental disabilities or persons with poor knowledge
and experience with use of the appliance.
Gas component tightness
Before performing any operation on gas ducting compo-
nents, close the gas valve.
Upon completing any procedure, perform the tightness
test according to regulations in force.
Gas smell
If you smell gas:
Do not use electrical devices such as telephones, multi-
meters or other equipment that may cause sparks next
to the appliance.
Shut o the gas supply by turning the valve o.
Switch o the power supply via the external disconnect
switch in the power supply electrical panel.
Use a telephone away from the appliance to ask for inter-
vention from qualied 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 intervention 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 disconnect
the power and gas supply (only if it is possible to do so
with no danger).
It is recommended that no work be performed on the
sealed circuit except by a qualied service technician
or engineer.
Care should be taken not to disturb or handle the valves
of the sealed circuit.
Electrocution hazard
Disconnect the electrical power supply before any op-
eration on appliance components.
For electrical connections exclusively use compli-
ant components and according to the specications
provided by the manufacturer.
Ensure the appliance cannot be accidentally switched
back on.
Grounding
Electrical safety depends on eective grounding system,
correctly connected to the appliance and installed ac-
cording to the regulations in force.
Distance from combustible or ammable materials
Do not deposit ammable materials (paper, diluents,
paints, etc.) near 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.23 ).
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.23 .
Aggressive substances in the air
Halogenated hydrocarbons containing chlorine and u-
orine compounds cause corrosion. The air of the installa-
tion site 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 pow-
er supply to switch o the appliance, but always and ex-
clusively act through the provided control device (DDC
or external request).
In the event of failure
Operations on internal components and repairs may
exclusively be carried out by an AT, using only original
parts.
In the event of failure of the appliance and/or breakage
of any component, do not attempt to repair and/or re-
store and immediately contact the AT.
Routine maintenance
Proper maintenance assures the eciency and good op-
eration of the appliance over time.
Maintenance must be performed according to the man-
ufacturer's instructions (see Chapter 7 p. 36 ) and in
compliance with current regulations.
Appliance maintenance and repairs may only be entrust-
ed to rms legally authorised to work on gas appliances
and systems.
Enter into a maintenance contract with an authorised
specialised rm for routine maintenance and for servic-
ing in case of need.

Warnings
6
III
Use only original parts.
Decommissioning and disposal
If the appliance is to be disposed of, contact the manu-
facturer for its disposal.
Keep the Manual
This Installation, use and maintenance manual must al-
ways accompany the appliance and must be handed to
the new owner or installer in the event of sale or removal.
III.2 CONFORMITY
The installation of the appliance must conform to the require-
ments of the authority having jurisdiction or, in the absence of
such requirements, to the latest edition of the National Fuel
Gas Code, ANSI Z223.1. If the unit is installed in Canada, the
installation must conform to the Canadian Gas Association
Standard CAN1 B149.1 and .2.
The appliance’s electrical connections and grounding must be
in accordance with the latest edition of the National Electrical
Codes, ANSI/NFPA No. 70 (CSA Standard C22.1 when in-
stalled in Canada) and with any local codes. To ensure the elec-
trical safety of this appliance, it must be correctly connected to
an ecient grounding system. The manufacturer is not respon-
sible for any damages caused by the failure of the grounding
system.
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
accordance with the manufacturer's instructions. In particular,
regulations regarding the following shall be complied with:
▶ Gas systems and equipment.
▶ Electrical systems and equipment.
▶ Heating and cooling systems, heat pumps 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 directions/
instructions shall be disclaimed.
The manufacturer cannot be held responsible for any
damages to persons, animals or goods due to improper,
erroneous or irrational installation of these appliances.
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 indications on
installation, use and maintenance.
Alteration or modication of the product or any part
thereof.
Extreme operational conditions or however outside of
the operational ranges set forth by the manufacturer.
Damages caused by external agents such as salts, chlo-
rine, sulphur or other chemical substances contained in
the installation water or present in the air of the instal-
lation site.
Abnormal actions transmitted to the appliance by the
plant or installation (mechanical stresses, pressure, vi-
brations, thermal expansion, electrical surges...).
Accidental damages or due to force majeure.

Features and technical data
Installation, use and maintenance manual – GA ACF 7
1
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 and dissipating heat directly to
the outside air.
The thermodynamic cycle takes place within a hermetically
sealed circuit, in welded construction, perfectly tight, factory-
tested, which does not require any maintenance or coolant
top-ups.
Mechanical and thermo-hydraulic components
▶ Steel sealed circuit, externally treated with epoxy paint.
▶ Multigas pre-mixing burner equipped with ignition and
ame detection managed by an electronic control unit.
▶ Titanium stainless steel shell-and-tube water exchanger
(evaporator), externally insulated.
▶ Air exchanger (condenser) with nned coil, with steel pipe
and aluminium ns.
▶ Variable-ow microprocessor-controlled helicoidal motor-
fan.
Control and safety devices
▶ S61 electronic board with microprocessor, LCD display and
knob.
▶ Circuit water ow switch.
▶ Generator limit thermostat, with manual reset.
▶ Automatically resettable ue gas thermostat.
▶ Dierential air pressure switch on the combustion circuit.
▶ Sealed circuit safety relief valve.
▶ Bypass valve, between high and low-pressure circuits.
▶ Ionization ame control box.
▶ Dual gas valve.
▶ Antifreeze functions for hydraulic circuit.
▶ Heat recovery exchanger circulating pump relay (HR version
only).
Versions
The GA ACF unit is available in the following versions:
▶ ACF standard, for residential/retail/industrial cooling sys-
tems with chilled water down to 37.4 °F.
▶ HR with heat recovery exchanger, for residential/retail/in-
dustrial cooling systems with chilled water down to 37.4 °F,
plus recovery exchanger hot water up to 176 °F (e.g. DHW
production).
▶ TK for heavy duty use, for process systems and applications
with chilled water down to 37.4 °F, in continuous operation
all year round.
▶ HT for very hot climates, for residential/retail/industrial cool-
ing systems with chilled water down to 41 °F, with outside
air up to 131 °F.
▶ LB for negative temperatures, for cooling systems with
chilled water down to 14 °F (with an appropriate concentra-
tion of glycol).
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.
1.2 DIMENSIONS
Figure1.1ACF standard version dimensions
A Position of holes for xing of anti-vibration joints
38-3/8” (A)
48-1/2”
50-3/4”
27-3/8” (A)
33-1/2”

Features and technical data
8
1
Figure1.2ACF Service plate with plumbing and gas connections
A Water outlet connection Ø 1 1/4" F
B Water inlet connection Ø 1 1/4" F
E Electrical knockouts Ø 7/8"
G Gas tting Ø 1/2" F
6-1/2”
4-1/4”
5-7/8”
7-7/8”
12”
7-1/8”
G
E
A
B
Figure1.3ACF-HR Service plate with plumbing and gas connections
G Gas tting Ø 1/2" F
Chiller - CHILLED WATER
D Outlet water tting Ø 1 1/4" F
C Water inlet connection Ø 1 1/4" F
Recovery exchanger - HOT WATER
A Water outlet connection Ø 1 1/4" F
B Water inlet connection Ø 1 1/4" F
7-1/8”
5-7/8”
7-7/8”
9-7/8”
12-3/16”
3-1/8”
4-1/4”
6-11/16”
11-15/16”

Features and technical data
Installation, use and maintenance manual – GA ACF 9
1
1.3 COMPONENTS
Figure1.4Internal components - front view
1 Combustion air intake
2 Combustion blower
3 Gas valve
4 Electrical panel
5 Oil pump
6 Water inlet connection Ø 1 1/4" F
7 Water outlet connection Ø 1 1/4" F
8 Gas connection Ø 1/2" F
9 Room temperature probe
10 Fan

















Features and technical data
10
1
Figure1.5Internal components - left side view
1 Ignition transformer 2 Flue thermostat 3 Ignitor and ame detectors




