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Robur Next-G Installation, Use And Maintenance Manual

Condensing gas unit heaters for use in industrial and commercial installations
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Installation, use and maintenance manual
Next-G
Condensing gas unit heaters
for use in industrial and commercial installations
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Summary of Contents for Robur Next-G

  • Page 1 Installation, use and maintenance manual Next-G Condensing gas unit heaters for use in industrial and commercial installations Powered by natural gas/LPG...
  • Page 2 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 Installation, use and maintenance manual without prior notice.

  • Page 3: Table Of Contents

    ................p. 55 Fuel gas supply ............ p. 28 Board codes ............p. 55 Combustion products exhaust ...... p. 29 9 Appendices ................p. 57 Flue gas condensate drain ......p. 34 Air ducting ............p. 35 Product fiche ............p. 57 Installation, use and maintenance manual – Next-G...

  • Page 4: Iintroduction

    End user, for appropriate and safe use of the appliance. ▶ Qualified installer, for correct appliance installation. ▶ This Manual is an integral part of the Next-G appli- Planner, for specific information on the appliance. ▶ ance and must be handed to the end user together with the appliance.
  • Page 5 The appliance contains very hot parts. TAC. „ Do not open the appliance and do not touch inter- nal components before the appliance has cooled Routine maintenance down. Installation, use and maintenance manual – Next-G...

  • Page 6: Iii.2 Compliance

    III.2 COMPLIANCE er's directions/instructions shall be disclaimed. III.2.1 EU directives and standards The Next-G series gas unit heaters are certified in ac- In particular, the warranty on the appliance may be cordance with European regulation GAR 2016/426/EU rendered void by the following conditions:...

  • Page 7: Features And Technical Data

    (Next-G C series) 1.1.3 Mechanical components 1.1.2 Operation Premix stainless steel burner. The Next-G series gas unit heater is an independent heat- ▶ High head blower, with rotation speed modulation. ▶ ing appliance with airtight combustion circuit and forced Cylindrical stainless steel combustion chamber.

  • Page 8: Dimensions

    Features and technical data DIMENSIONS 1.2.1 Axial gas unit heaters 1.2.1.1 G 20 EC Figure 1.1   Unit dimensions 176 (*) 400 (*) Ø 80mm flue gas exhaust Limit thermostat Combustion air inlet Ø 80 mm Flue gas exhaust blind cover, alternative to the rear one (1) Power supply cables input Condensate drain kit Gas connection 3/4"...
  • Page 9 Combustion air inlet Ø 80 mm Flue gas exhaust blind cover, alternative to the rear one (1) Power supply cables input Condensate drain kit Gas connection 3/4" M (*) Holes for fixing to the support bracket Thermoformed door Installation, use and maintenance manual – Next-G...
  • Page 10 Features and technical data 1.2.1.3 G 35 EC Figure 1.3   Unit dimensions 405 (*) 370 (*) Ø 80mm flue gas exhaust Limit thermostat Combustion air inlet Ø 80 mm Flue gas exhaust blind cover, alternative to the rear one (1) Power supply cables input Condensate drain kit Gas connection 3/4"...
  • Page 11 Combustion air inlet Ø 80 mm Flue gas exhaust blind cover, alternative to the rear one (1) Power supply cables input Condensate drain kit Gas connection 3/4" M (*) Holes for fixing to the support bracket Thermoformed door Installation, use and maintenance manual – Next-G...
  • Page 12 Features and technical data 1.2.1.5 G 60, G 60 EC Figure 1.5   Unit dimensions 405 (*) 620 (*) Ø 80mm flue gas exhaust Limit thermostat Combustion air inlet Ø 80 mm Flue gas exhaust blind cover, alternative to the rear one (1) Power supply cables input Condensate drain kit Gas connection 3/4"...
  • Page 13 Combustion air inlet Ø 80 mm Flue gas exhaust blind cover, alternative to the rear one (1) Power supply cables input Condensate drain kit Gas connection 3/4" F (*) Holes for fixing to the support bracket Thermoformed door Installation, use and maintenance manual – Next-G...
  • Page 14 Features and technical data 1.2.1.7 G 90, G 90 EC Figure 1.7   Unit dimensions 405 (*) 1010 (*) 1059 1100 743 (EC) 1320 1017 Ø 80mm flue gas exhaust Limit thermostat Combustion air inlet Ø 80 mm Flue gas exhaust blind cover, alternative to the rear one (1) Power supply cables input Condensate drain kit Gas connection 3/4"...
  • Page 15 Combustion air inlet Ø 80 mm Limit thermostat Power supply cables input Flue gas exhaust blind cover, alternative to the rear one (1) Gas connection 3/4" M (*) Holes for fixing to the support bracket Installation, use and maintenance manual – Next-G...
  • Page 16 Features and technical data 1.2.2.2 G 60 C Figure 1.9   Unit dimensions 405 (*) 620 (*) 1138 Ø 80mm flue gas exhaust Thermoformed door Combustion air inlet Ø 80 mm Limit thermostat Power supply cables input Flue gas exhaust blind cover, alternative to the rear one (1) Gas connection 3/4"...

  • Page 17: Components

    GEN10 board display Gas valve GEN10 electronic board Terminal block Fan terminal block Controller for ignition, adjustment and Limit thermostat 10 Flame sensor / ignition electrodes flame control Ignition transformer 11 Combustion blower Installation, use and maintenance manual – Next-G...

  • Page 18: Electrical Wiring Diagram

    Features and technical data ELECTRICAL WIRING DIAGRAM 1.4.1 G 30, G 45, G 60, G 90, G 30 C, G 60 C Figure 1.11   Electrical wiring diagram...
  • Page 19 Features and technical data 1.4.2 EC models Figure 1.12   Electrical wiring diagram Installation, use and maintenance manual – Next-G...

  • Page 20: Electronic Board

    Depending on the active inputs, the functions described tailed below. in the following Table 1.1  p. 20 are obtained. The Next-G gas unit heater, thanks to the presence of the Table 1.1   Functions available depending on the status of the supplied room probe, modulates the heat output con-...

  • Page 21: Controls

    Paragraph 5.4  p.  48 ) and room temperature meas- with a colour touch screen that allows centralised man- ured by the appliance via the supplied room probe agement of the Next-G gas unit heaters, up to a maximum fixed power heating, with setpoint from 0-10 V input ▶...
  • Page 22 Features and technical data 1.7.4 OCDS012 1-key basic control 1.7.6 OTRG005 thermoregulator Figure 1.14   OCDS012 1-key basic control Figure 1.16   OTRG005 thermoregulator Its functions are: The thermoregulator is a device that can directly manage Light signalling of the presence of errors or warnings. wall-mounted gas unit heaters: the serial interface makes ▶...

  • Page 23: Technical Data

    External request control can be used on the contacts, Summer ventilation mode activation. ▶ available on the terminal block of the Next-G appliance For further details and diagrams see OCDS008 digi- (Figure 1.13  p. 20 ), to realise various functions. In detail: tal chronothermostat instruction sheet and Paragraph The "HEAT."...
  • Page 24 Features and technical data G 30 G 45 G 60 G 90 nominal heat input 33,1 35,6 29,6 28,4 Temperature rise minimal heat input 11,9 12,4 10,1 length of throw (residual speed < 0,5 m/s) (2) 18,0 24,0 28,0 38,0 Outdoor temperature (dry maximum °C...
  • Page 25 2500 5400 Air flow free blowing m³/h 3550 6500 maximum useful pressure head minimum pressure drop on heat flow delivery width Dimensions height depth 1072 1138 Weight in operation Installation, use and maintenance manual – Next-G...

  • Page 26: Transport And Positioning

    Transport and positioning TRANSPORT AND POSITIONING WARNINGS The appliance is not designed for outdoor instal- lation. Damage from transport or installation 2.3.1 Where to install the appliance The manufacturer shall not be liable for any dam- age during appliance transport and installation. The wall or structure on which the unit is to be in- stalled must be load-bearing or, in any case, suit- On-site inspection...

  • Page 27: Minimum Clearance Distances

    G 90 EC Robur provides easy mounting support brackets as an op- G 45 EC tional, suitably designed for Next-G series gas unit heat- 1010 ers, which allow simplifying the wall fixing. If you do not want to use these options, refer to Figure 2.3 ...

  • Page 28: Heating Engineer

    2.5.1 Axial gas unit heaters 1400 For axial gas unit heaters, the support brackets listed in All Robur support brackets are supplied with bolts and Table 2.3  p. 28 below are available as optional. the rear support plate. Table 2.3   Support brackets...

  • Page 29: Combustion Products Exhaust

    The appliance's gas supply pressure, both static and dy- namic, must comply with Table 3.1  p. 29 , with tolerance The Next-G gas unit heaters are also approved for ± 15%. use with I20 gas, i.e. a gas mix with a 20% maxi- mum of hydrogen.
  • Page 30 Ø 80 Ø 100 Ø 110 G 20 EC Gas unit heaters of the Next-G series can be installed to G 30, G 30 EC one of the following ways. G 35 EC 3.3.3.1 B23 type installation with wall flue gas exhaust...
  • Page 31 G 30, G 30 EC G 75 EC G 35 EC G 90, G 90 EC G 45, G 45 EC G 60, G 60 EC G 75 EC G 90, G 90 EC Installation, use and maintenance manual – Next-G...
  • Page 32 (Table 3.11  p. 32 ). Table 3.10   C53 type maximum allowed length with separate The Ø 80, 110 and 130 pipes available as Robur op- ducts tional are made of stainless steel, while the Ø 100...
  • Page 33 If vertical flue gas exhaust pipes longer than 1,5 m are installed, at the base of the vertically mounted Installation, use and maintenance manual – Next-G...

  • Page 34: Flue Gas Condensate Drain

    2-3% FLUE GAS CONDENSATE DRAIN The Next-G unit is a condensing appliance and there- fore produces condensation water from combustion flue gases. Condensate acidity and exhaust regulations The flue gas condensate contains aggressive acid substances.

  • Page 35: Air Ducting

    (with or without siphon mixing chambers) and on the delivery. For this purpose, the delivery outlet of the Next-G C gas unit heaters is provided with fixing flanges for the delivery air ducting.

  • Page 36: Electrical Power Supply

    Electrical installer How to make connections 1. OCDS015 Modbus remote control 2. Generic Modbus controller All electrical connections must be made in the connection 3. OCDS012 1-key basic control terminal block located near the electrical panel: 4. OCDS016 2-keys basic control 1.
  • Page 37 3. Connect the wires to the terminal block as shown in Figure 4.4  p. 37 . 4. If there is an external request for managing start/stop of the gas unit heater (e.g. thermostat, timer, switch, Installation, use and maintenance manual – Next-G...
  • Page 38 "VENT. " white "HEAT. " pink Figure 4.5   Connections between the thermoregulator and the gas unit heater OTRG005 thermoregulator Room temperature probe (supplied) Next-G gas unit heater terminal block J6 electrical bridge NO NC NO NC VENT. HEAT. RESET ALARM ALARM...
  • Page 39 5. For further information refer to the instruction sheet OTRG005 thermoregulator is connected as de- supplied with the OSWR000 Genius software. scribed in Paragraph 4.4.5  p. 37 . The cable may not be longer than 1100 metres. Installation, use and maintenance manual – Next-G...
  • Page 40 Electrical installer Figure 4.7   USB/RS485 converter connection A signal OTRG005 thermoregulator B signal USB/RS485 converter 4.4.8 External request Figure 4.8   Connection of external request for gas unit heater start/stop management Depending on the required operation, it is required to arrange: Request device (e.g. thermostat, timer, switch, ...) ▶...
  • Page 41 4.4.8.3 Operation as destratifier a centralized request. For all Next-G gas unit heaters, it is possible to connect an Installation, use and maintenance manual – Next-G...

  • Page 42: Temperature Probes Inputs

    4.4.9 Positioning the control system TEMPERATURE PROBES INPUTS Install the chosen thermostat/control system accord- In order to extend the available features, the Next-G ing to the positioning instructions given in Paragraph gas unit heater allows up to three NTC 10k temperature 4.5.1 ...
  • Page 43 1. Access the electrical board of the appliance according Outdoor probe to the Procedure 4.2  p. 35 . 2. Connect the destratification probe to the "Tamb2" contact of the terminal block as shown in Figure Installation, use and maintenance manual – Next-G...

  • Page 44: Input

    The cable may not be longer than 30 metres. to the Next-G gas unit heater alternatively via a 0-10 V an- alogue signal. The meaning to be given to the 0-10 V input is chosen by Figure 4.14  ...
  • Page 45 "UAIt" (wait) which indicates that the machine is not message "UAIt" (wait) which indicates that the ma- yet ready for the reading. chine is not yet ready for the reading. 7. After up to 8 minutes the flashing message becomes Installation, use and maintenance manual – Next-G...
  • Page 46 First start-up 13. After a short while, the flashing message becomes "_ Table 5.2   Next-G 20 gas valve setting table GO_" again to indicate that the combustion control at Offset percentage in fumes maximum power can be carried out. pressure network 14.
  • Page 47 First start-up Table 5.5   Next-G 45 gas valve setting table 9. Press the key on the user interface to activate the chimney sweep function at maximum power. Offset percentage in fumes 10. The display shows the letters "CS.HI" (chimney sweep pressure...

  • Page 48: Gas Changeover

    First start-up Table 5.7   Next-G 75 gas valve setting table GAS CHANGEOVER Offset percentage in fumes For gas change instructions, refer to the rele- pressure network Minimal heat Nominal heat vant documentation. pressure nominal input input Type mbar SETTING THE PARAMETERS G25.1...
  • Page 49 (only for EC heaters) the parameters to be configured according to the func- if the difference between the temperature measured by tionality to be obtained. the destratification probe and the room temperature is Installation, use and maintenance manual – Next-G...

  • Page 50: Normal Operation

    First start-up may exclusively be carried out by a Robur TAC (Chapter 5  p. 44 ). 6.2.1 OCDS015 Modbus remote control Never power the appliance off while it is run- Refer to the instructions in the relevant manual.
  • Page 51 Refer to the instructions in the relevant manual. After a long period of unit inactivity or at the first start-up, it may be necessary to repeat the ignition operation due to the presence of air in the gas Installation, use and maintenance manual – Next-G...

  • Page 52: Messages On The Display

    Normal operation 6.2.7 OSWR000 Genius software for remote used to perform one of the following actions: management of gas unit heaters Enter the menu list (by pressing the key the first ▶ time). Refer to the instructions in the relevant manual. Scroll the menu list, or a series of parameters in a menu ▶...

  • Page 53: Modifying Settings

    If an indicator lamp (which is included when using option- al 1- or 2-key basic controls, see Paragraph 1.7.4  p.  22 and 1.7.5  p.  22 ) is connected to this contact, the lamp Installation, use and maintenance manual – Next-G...

  • Page 54: Efficiency

    Perform the operations in the following Table 7.1  p.  54 efficiency and keeps running costs low. on an annual basis. Table 7.1   Scheduled routine maintenance Maintenance operations described herein may ex- Next-G Next-R clusively be performed by the TAC or skilled main- Ordinary scheduled maintenance tenance technician.

  • Page 55: Emergency Mode

    Reset is automatic when the trig- tion error gering condition ceases. If the code persists, shows up again or in case of doubt, contact the TAC. Flame controller not compat- Contact the TAC. ible NA: Not Applicable Installation, use and maintenance manual – Next-G...
  • Page 56 Diagnostics Code Description Warning (u) Error (E) Flame controller parameters Contact the TAC. error Room temperature probe Install the room temperature probe needed and set P45 = 1. The reset may be done following one of procedures shown in Heat exchanger temperature Paragraph 6.6.3 ...

  • Page 57: Appendices

    Seasonal space heating η 90,6 energy e ciency Contact details Robur SPA, Via Parigi 4/6, I-24040 Zingonia (BG) (*) Not required for electric warm air heaters. Figure 9.2 Table 9 Information requirements for warm air heaters Model(s): Information to identify the model(s) to which the information relates:...
  • Page 58 95,6 s, ow Seasonal space heating η 90,2 energy e ciency Robur SPA, Via Parigi 4/6, I-24040 Zingonia (BG) Contact details (*) Not required for electric warm air heaters. Figure 9.4 Table 9 Information requirements for warm air heaters Model(s): Information to identify the model(s) to which the information relates:...
  • Page 59 95,7 s, ow Seasonal space heating η 89,6 energy e ciency Robur SPA, Via Parigi 4/6, I-24040 Zingonia (BG) Contact details (*) Not required for electric warm air heaters. Figure 9.6 Table 9 Information requirements for warm air heaters Model(s): Information to identify the model(s) to which the information relates:...
  • Page 60 94,1 s, ow Seasonal space heating η 89,3 energy e ciency Robur SPA, Via Parigi 4/6, I-24040 Zingonia (BG) Contact details (*) Not required for electric warm air heaters. Figure 9.8 Table 9 Information requirements for warm air heaters Model(s): Information to identify the model(s) to which the information relates:...
  • Page 61 95,6 s, ow Seasonal space heating η 90,2 energy e ciency Robur SPA, Via Parigi 4/6, I-24040 Zingonia (BG) Contact details (*) Not required for electric warm air heaters. Figure 9.10 Table 9 Information requirements for warm air heaters Model(s): Information to identify the model(s) to which the information relates:...
  • Page 62 96,0 s, ow Seasonal space heating η 91,2 energy e ciency Robur SPA, Via Parigi 4/6, I-24040 Zingonia (BG) Contact details (*) Not required for electric warm air heaters. Figure 9.12 Table 9 Information requirements for warm air heaters Model(s): Information to identify the model(s) to which the information relates:...
  • Page 63 η Emission e ciency 95,4 s, ow Seasonal space heating η 89,9 energy e ciency Robur SPA, Via Parigi 4/6, I-24040 Zingonia (BG) Contact details (*) Not required for electric warm air heaters. Installation, use and maintenance manual – Next-G...
  • Page 64 Robur mission Robur is dedicated to dynamic progression in research, development and promotion of safe, environmentally-friendly, energy-efficiency products, through the commitment and caring of its employees and partners. Robur S.p.A. advanced technologies for air conditioning via Parigi 4/6 24040 Verdellino/Zingonia (BG) Italy +39 035 888111 - F +39 035 884165 www.robur.it robur@robur.it...

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