Robur G 30 Service manual

Gas unit heatersproduct line
GSeries
Condensing and modulating Gas Fired Unit Heaters
to heat medium large areas
Natural gas/LPG fired
Installation, use and
maintenance manual

EDITION: 09/2018
Code: D-LBR565
This manual has been written and printed by Robur S.p.A.; the reproduction even partial
of this manual is forbidden.
The original isarchived at Robur S.p.A.
Any use ofthis manual other than for personal consultation must be previously authorised
by Robur S.p.A.
The rights ofthose who have legitimately filed the registered trademarks contained within
this publication are not affected.
With the aim of continuously improving the quality of our products, Robur S.p.A. reserves
the right tomodify instructions, drawings and data contained in this manual without prior
notice.

Condensing Gas Fired Unit Heaters – G Series: Manual of installation, use and maintenance
Ed. 09/2018 I
FOREWORD
This manual is intended for those people who need to install and use the Robur G Series
condensing Gas Fired Unit Heaters.
In particular this manual is addressed to the hydraulic installation technician who shall
install the generator, the electrical installation technician who shall connect the generator
to the power supply and the final user who shall check its normal working. This manual is
also addressed to the Technical Assistance Centres for the main service operations.
Summary
This manual is based on five sections
Section 1 is intended for end user, plumber installer , electrical installer and technical
assistance service; it furnishes general instructions, technical data and general
information of the Gas Fired Unit Heaters G series.
Section 2 is intended for end user; it furnishes all information for the correct use of Gas
Fired Unit Heaters G series.
Section 3 is intended for the plumber installer; it furnishes the information for a correct
installation of Gas Fired Unit Heaters Gseries.
Section 4 is intended for electrical installer; it furnishes the information for correct
electrical connections of the Gas Fired Unit Heaters Gseries.
Section 5 is intended for technical assistance service; it furnishes the instructions to set
the gas flow and to change the type of gas. It reports also information about maintenance.
Meaning of Icons
The icons placed on the margin of the pages of this manual have the following meaning:
Danger signal

Warning
Note
Start of operating procedure
Reference to another part of the manual or to another
manual/book
Table 1 – Descriptive Icons.

Condensing Gas Fired Unit Heaters – G Series: Manual of installation, use and maintenance
Ed. 09/2018 1
TABLE OF CONTENTS
Section1: GENERAL INFORMATION AND TECHNICAL CHARACTERISTICS..............2
1.1 GENERAL WARNINGS.....................................................................................................................2
1.2 OPERATION OF THE UNIT ..............................................................................................................3
1.3 CONSTRUCTIVE CHARACTERISTICS............................................................................................5
1.4 TECHNICAL DATA ............................................................................................................................6
1.5 DIMENSIONS OF G SERIES GAS FIRED UNIT HEATER...............................................................7
section 2: END USER........................................................................................................9
2.1 FUNCTIONS OF CHRONOTHERMOSTAT......................................................................................9
2.2 SETTING THE TIME AND DAY ON THE CHRONOTHERMOSTAT............................................. 10
2.3 SETTING THE COMFORT, ECONOMY AND ANTI- FREEZING TEMPERATURES ON THE
CHRONOTHERMOSTAT ............................................................................................................... 10
2.4 PROGRAMMING OF THE DAILY SET POINT ON THE CHRONOTHERMOSTAT...................... 11
2.5 SELECTING A PRESET DAILY PROFILE ON THE CHRONOTHERMOSTAT ............................ 13
2.6 SELECTING A PRESET WEEKLY PROFILE ON THE CHRONOTHERMOSTAT........................ 13
2.7 TIMED FUNCTIONS OF THE CHRONOTHERMOSTAT............................................................... 15
2.8 KEYBOARD BLOCK....................................................................................................................... 17
2.9 INFORMATION SCREEN OF THE CHRONOTHERMOSTAT....................................................... 18
2.10 SELECTION MENU WINDOW ....................................................................................................... 19
2.11 MALFUNCTION WARNINGS ......................................................................................................... 20
2.12 TABLE OF ICON MEANINGS ON CHRONOTHERMOSTAT DISPLAY........................................ 22
2.13 HOW TO USE THE UNIT HEATER................................................................................................ 23
2.14 HOW TO USE THE UNIT WITH THE CHRONOTHERMOSTAT.................................................. 25
2.15 HOW TO USE THE UNIT WITHOUT A CHRONOTHERMOSTAT................................................ 30
2.16 SETTING FIELD.............................................................................................................................. 31
2.17 END OF SEASON........................................................................................................................... 32
section 3: PLUMBER INSTALLER..................................................................................33
3.1 GENERAL RULES FOR INSTALLATION OF THE APPLIANCE................................................... 33
3.2 INSTALLATION SEQUENCE ......................................................................................................... 33
3.3 SIZE AND INSTALLATION OF THE AIR INLET / EXHAUST FLUE.............................................. 35
3.4 CONDENSATE DRAINAGE ........................................................................................................... 44
section 4: ELECTRICAL INSTALLER.............................................................................46
4.1 HOW TO CONNECT THE HEATER TO THE ELECTRICAL SYSTEM......................................... 46
4.2 HOW TO CONNECT THE CHRONOTHERMOSTAT TO THE HEATER ...................................... 46
4.3 UNIT OPERATION WITH EXTERNAL CONSENT......................................................................... 47
4.4 REMOTE SIGNALLING OF THE ANOMALIES.............................................................................. 48
4.5 INSTALLATION WIRING DIAGRAM .............................................................................................. 49
4.6 WIRING DIAGRAM FOR MULTIPLE HEATER WITH ONE PROGRAMMER............................... 50
section 5: ASSISTANCE AND MAINTENANCE.............................................................52
5.1 START UP OF THE UNIT............................................................................................................... 52
5.2 HOW TO REGULATE THE GAS VALVE ....................................................................................... 52
5.3 CONVERSION TO ANOTHER TYPE OF GAS.............................................................................. 54
5.4 MAINTENANCE.............................................................................................................................. 55

Condensing Gas Fired Unit Heaters – G Series: Manual of installation, use and maintenance
2 Ed. 09/2018
SECTION1: GENERAL INFORMATION AND TECHNICAL
CHARACTERISTICS
In this section you can find the general warnings to follow for the installation and use of
the Condensing Gas Fired Unit Heaters G Series, a short description of the heater
operation, design characteristics and technical data.
1.1 GENERAL WARNINGS
This manual is an integral and essential part of the product and must be given to the final
user.
This appliance must be exclusively used for the purpose it was intended. Any other use is
to be considered improper and therefore dangerous.
The unit must not be used by persons (children included) with lack of physical or mental
disease or not experienced. Children must be supervised to be sure that they do not
play with the unit.
The Manufacturer will not be held responsible for damages resulting from installation
errors or failure to comply with the Manufacturer’s instructions.
The appliance must be installed in compliance with the rules and regulations in force.
Do not obstruct the fan intake opening or the air delivery grids.

In case of failure and/or malfunction of the appliance, isolate the unit (disconnect it
from the power supply and close the main gas cock), do not attempt any repair or
direct servicing.
The Manufacturer’s Authorised Service Centres using only original spare parts
must only carry out any repair to the products.
The non-observance of the above-mentioned provisions may compromise the safety of
the unit.
To ensure unit efficiency and correct operation, it is essential that qualified service
engineers carry out annual maintenance following the Manufacturer’s instructions.
By the term Qualified Service Engineers it is meant the personnel having specific
technical skills in the field of heating system components for civil use. In any case for
more information please contact the Technical Assistance Office of ROBUR S.p.A.
(tel. [phone]).
Should the unit be sold or transferred to another owner, please ensure that the manual
remains with the unit for use by the new owner and/or installer.
Before turning the heater on, a qualified service engineer must check:
- that electric and gas supply ratings are the same as those given in the data plate;
-that the exhaust duct operates correctly;
- the correct functioning of the condensate drainage;
-that combustion air feed and exhaust occur correctly according to the existing
standards;

Condensing Gas Fired Unit Heaters – G Series: Manual of installation, use and maintenance
Ed. 09/2018 3
-the internal and external tightness of the fuel supply system;
-fuel flow control according to the heater power requirements;
-that the heater is supplied with the type of fuel for which it is pre-set.;
-that the gas supply pressure is within rating limits;
-that the gas supply system is suitable to the heater and all safety and check-over
devices prescribed by existing standards are duly installed;
Do not use gas pipes to ground the appliance, or any other electrical appliances.

Avoid unnecessary supply when unit is not in use and always clock the main gas
cock. If the appliance is turned off for a longer time period, close the main gas
supply cock and cut off the power supply.
IF YOU SMELL GAS
•Do not operate electric switches, telephones and any other object or device
which may cause sparks.
•Shut-off the gas supply.
•Open immediately doors and windows to create a cross-current of air to purify
the room.
•Call for a qualified service engineer.
1.2 OPERATION OF THE UNIT
The G Series gas fired unit heater is an independent heater appliance with airtight
combustion circuit and forced air draft.
It is designed for an indoor installation - inside the area to be heated.
It is adjustable for the use of Natural Gas (G20) and L.P.G. (G30/G31) (appliance
belonging to the II2H3B/P category according to the Standard EN 1020).
The combustion circuit is airtight with respect for the heated environment and conforms to
the ordinances of regulations EN 1020 and EN 1196 for C type appliances: the air inlet of
the combustion air and the flue exhaust are outdoors and are ensured through the
operation of combustion blower.
A room thermostat, integrated in a chronothermostat, controls the heater operation.
When the thermostat is turned on the flame control box, after the pre-purge period (about
40 seconds), ignites the burner.
The flame sensor controls the ignition of the burner. If the flame does not appear the
flame control unit locks out the heater.
The combustion products pass through the heat exchangers, the air flow given by the
axial fan provides warm air to the room.
The airflow direction is regulated by means of adjustable horizontal louvres.
The fan control thermostat allows the axial-flow fan to start automatically only when the
heat exchangers are hot (after about 60 sec. from the flame detection or when the
temperature of 60°C is reached on the exchanger thermostat) and to turn off when they
are cold. This prevents cool air from being blown into the room.

Condensing Gas Fired Unit Heaters – G Series: Manual of installation, use and maintenance
4 Ed. 09/2018
If heat exchangers overheat due to malfunction, the temperature limit thermostat cuts off
the supply to the gas valve by setting the blower and the fan to the maximum speed;
should the temperature increase further, the limit thermostat comes into operation causing
the switching off of the heater. The limit thermostat reset is manual.

After removing the cause of overheating, Qualified service engineers should carry
out resetting of the temperature.
Ahead of the burner the flue fan is installed which makes the air-gas mixture and forces
draft of the exhaust flues.
In case of obstructions in the exhaust or intake duct or in case of blower malfunction, the
flame control box intervenes immediately with the modulation of the heater. In case of
obstructions or malfunction beyond the allowed limits, the differential pressure switch
closes the gas valve and consequently stops the fuel flow to the burner.
For winter operation the heating unit can be used in either automatic or manual mode. For
further information see paragraph “WINTER OPERATING (HEATING)” at page 25.
In the summer time it is possible to activate only the axial fan to provide pleasant and
refreshing air movement in the room (for more information see Paragraph “SUMMER
OPERATION (VENTILATION ONLY)” at page 29).

Condensing Gas Fired Unit Heaters – G Series: Manual of installation, use and maintenance
Ed. 09/2018 5
1.3 CONSTRUCTIVE CHARACTERISTICS
The G Series gas fired unit heaters are supplied with:
•Premix burner made of stainless steel.
•High head blower, with rotation speed control.
•Cylindrical combustion chamber made of stainless steel.
•Heat exchangers, patented by ROBUR, made of special light alloy, fining horizontally
on the air side and vertically on the flue side with extremely high capacity of thermal
exchange.
•Steel casing painted with epoxy powders.
•High air flow capacity axial fan(s), with rotation speed control.
•SAFETY AND CONTROL DEVICES
Programming electronic board, with microprocessor and filter: it allows the
following functions: start up of the burner, check and modulation of the flame; set
and control of the blower speed, set speed of fan(s); control of the temperature of
the heat exchanger by a probe; control of the minimum temperature of the
exhaust flue by a probe.
•Supply voltage:230 V - 50 Hz.
•Safety time:5 seconds.
•Pre- purge time:40 seconds.
•Model:Bertelli & Partners DIMS03 with ignition
transformer BRAHMA TC2LTCAF.
Limit thermostat 100°C preventing the overheating of the heat exchanger.
Exhaust flue thermostat: in case the exhaust/air intake pipe or the internal
condensing discharge pipe would be obstructed the unit will stop.
Gas valve: in the case that one of the safety devices is activated (limit thermostat,
safety thermostat, etc.) the gas valve is electrically de-energised with
contemporary cut-off of the burner gas supply.
•Supply voltage:230 V - 50 Hz.
•Operating temperature: 0° C up to +60° C.
•Model:SIT 822 Novamix.

Condensing Gas Fired Unit Heaters – G Series: Manual of installation, use and maintenance
6 Ed. 09/2018
1.4 TECHNICAL DATA
MODEL U.M. G 30 G 45 G 60 G 100
APPLIANCE CATEGORY II2H3P
APPLIANCE TYPE C13 - C33 – B23 - C63 - C53
GAS SUPPLY Gas naturale - G.P.L.
NOMINAL HEAT INPUT (Hi)
kW
30
45
58
93
NOMINAL HEAT OUTPUT kW 29,2 43,3 56,2 90,2
MINIMUM HEAT INPUT (Hi) kW 15,0 15,0 19,3 31,7
MINIMUM HEAT OUTPUT kW 15,8 15,6 20,2 33,5
MAX CONDENSATE PRODUCED l/h 4,6 6,9 8,9 14,4
NOMINAL GAS CONSUMPTION (Hi) NATURAL GAS
(15° C – 1013 mbar) L.P.G.G31 m3/h kg/h 3,17 2,33 4,76 3,50 6,14 4,50 9,84 7,22
ECONOMY GAS CONSUMPTION (Hi) NATURAL GAS
(15° C – 1013 mbar) L.P.G.G31 m3/h kg/h 1,58 1,16 1,58 1,16 2,14 1,50 3,35 2,46
EFFICIENCY AT MAXIMUM HEAT INPUT % 97,3 96,5 97 97
EFFICIENCY AT THE MINIMUM HEAT INPUT % 105,3 104,3 104,6 105,7
INLET GAS PRESSURE NATURAL GAS
L.P.G.G31 mbar 20 37
DIAMETER GAS INLET ” 3/4
AIR INLET PIPE DIAMETER mm 80
EXHAUST FLUE DIAMETER mm 80
VOLTAGE
230V - 50Hz
WATTAGE W 210 330 580 1000
OPERATIONAL TEMPERATURE(1) IN AMBIENT ºC 0 +35
FUSE A 6,3
AIR FLOW(2) AT MAXIMUM SPEED
AT MINIMUM SPEED m3/h 2840 2050 3850 2900 5050 4000 8250 5200
TEMPERATURE RISE AT MAXIMUM SPEED
AT MINIMUM SPEED K 29 22 32 15 32 14 31 18
THROW AT THE MAX SPEED
(RESIDUAL AIR SPEED >1m/s) (3) m 18 25 31 40
NOISE LEVEL AT 6 METERS
(MAX SPEED) IN FREE FIELD
IN TYPICAL INSTALLATION dB(A) dB(A) 48,5 55,5 55 62 59 66 59 66
NOISE LEVEL AT 6 M DISTANCE
(MAX SPEED) IN TYPICAL INSTALLATION dB(A) 50 56 60 60
WEIGHT kg 55 65 75 120
Table 2 – Technical data.
1 OPERATIONAL TEMPERATURE OF THE COMPONENTS ON THE APPLIANCE is between 0 °C / +60 °C.
2 AT 20 °C – 1013 mbar.
3 VALUES MEASURED IN FREE FIELD; IN TYPICAL INSTALLATION THE HEAT FLOW COULD REACH BIGGER DISTANCES THAN
THE VALUE INDICATED (DEPENDING ON THE HEIGHT OF THE BUILDING AND THERMAL INSULATION OF THE ROOF).

Condensing Gas Fired Unit Heaters – G Series: Manual of installation, use and maintenance
Ed. 09/2018 7
1.5 DIMENSIONS OF G SERIES GAS FIRED UNIT HEATER
Figure 1 – Dimensions of gas fired unit heater model G 30 – G 45 – G 60.
A
B
C
D
E
F
G
H
I
J
L
M
N
Q
R
T
W
X
Y
G 30
656
710
800
570
370
405
440
536
157,2
307
180
20
223
360
340
720
380
80
80
G 45
706
715
800
570
370
405
490
536
157,2
327
180
20
223
360
340
720
480
80
80
G 60
796
720
800
570
510
405
580
536
157,2
371
180
20
223
360
340
720
500
80
80
LEGEND
1
flue exhaust
2
combustion air
3
power line
4
gas connection
REAR VIEW
FRONT VIEW
SIDE VIEW
TOP VIEW