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Robur Next G Series Instructions For 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
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Condensing gas unit heaters
for use in industrial and commercial installations
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Summary of Contents for Robur Next G Series

  • 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

    TABLE OF CONTENTS Introduction �����������������������������������������������������4 Air ducting ................33 4 Electrical installer ������������������������������������������33 Recipients ................4 Control device ...............4 Warnings ................33 Available languages ............4 Electrical systems .............. 33 II Symbols and definitions ���������������������������������4 Electrical power supply ........... 34 Control system ..............34 II.1 Key to symbols ..............4 Temperature probes inputs ...........

  • Page 4: Introduction

    This document is originally written in Italian and English. Any other languages are translations of this document. This Manual is intended for: For versions of this document in other languages, see Robur End user, for appropriate and safe use of the appliance. ▶...
  • Page 5 Warnings derstanding the dangers inherent in it. Children should Wear appropriate protective equipment when handling not play with the appliance. the front grille louvres. Hazardous situations Earthing „ Do not start the appliance in hazardous conditions, such Electrical safety depends on effective earthing system, as: gas smell, problems with the electrical/gas system, correctly connected to the appliance and installed ac- parts of the appliance under water or damaged, mal-...

  • Page 6: Iii.2 Compliance

    Warnings III.2 COMPLIANCE Any other applicable law, standard and regulation. ▶ III.3 EXCLUSIONS OF LIABILITY AND III.2.1 EU directives and standards WARRANTY The Next-G series gas unit heaters are certified in accordance with European regulation GAR 2016/426/EU and meet the es- sential requirements of the following Directives: Any contractual or extra-contractual liability of the man- 2016/426/EU "Gas Appliances Regulation"...

  • Page 7: Features And Technical Data

    Cylindrical stainless steel combustion chamber. ▶ The combustion circuit is room sealed and meets the require- Robur patented heat exchangers, made out of a special alu- ▶ ments for type C appliances: combustion air supply and flue gas minium die-cast alloy, with horizontal finning on the air side...

  • Page 8: Dimensions

    Features and technical data DIMENSIONS 1.2.1 Axial gas unit heaters 1.2.1.1 G 20 Figure 1�1  Unit dimensions 176 (*) 400 (*) 579 (EC) Ø 80mm flue gas exhaust Limit thermostat reset button Combustion air inlet Ø 80 mm Flue gas exhaust blind cover, alternative to the rear one (1) Power supply cables input Condensate drain siphon (supplied as standard) Gas connection 3/4"...
  • Page 9 Features and technical data 1.2.1.2 G 30 Figure 1�2  Unit dimensions 405 (*) 370 (*) 689 (EC) Ø 80mm flue gas exhaust Limit thermostat reset button Combustion air inlet Ø 80 mm Flue gas exhaust blind cover, alternative to the rear one (1) Power supply cables input Condensate drain siphon (supplied as standard) Gas connection 3/4"...
  • Page 10 Features and technical data 1.2.1.3 G 35 Figure 1�3  Unit dimensions 405 (*) 370 (*) 689 (EC) Ø 80mm flue gas exhaust Limit thermostat reset button Combustion air inlet Ø 80 mm Flue gas exhaust blind cover, alternative to the rear one (1) Power supply cables input Condensate drain siphon (supplied as standard) Gas connection 3/4"...
  • Page 11 Features and technical data 1.2.1.4 G 45 Figure 1�4  Unit dimensions 405 (*) 370 (*) 743 (EC) Ø 80mm flue gas exhaust Limit thermostat reset button Combustion air inlet Ø 80 mm Flue gas exhaust blind cover, alternative to the rear one (1) Power supply cables input Condensate drain siphon (supplied as standard) Gas connection 3/4"...
  • Page 12 Features and technical data 1.2.1.5 G 60 Figure 1�5  Unit dimensions 405 (*) 620 (*) Ø 80mm flue gas exhaust Limit thermostat reset button Combustion air inlet Ø 80 mm Flue gas exhaust blind cover, alternative to the rear one (1) Power supply cables input Condensate drain siphon (supplied as standard) Gas connection 3/4"...
  • Page 13 Features and technical data 1.2.1.6 G 75 Figure 1�6  Unit dimensions 405 (*) 810 (*) 1120 Ø 80mm flue gas exhaust Limit thermostat reset button Combustion air inlet Ø 80 mm Flue gas exhaust blind cover, alternative to the rear one (1) Power supply cables input Condensate drain siphon (supplied as standard) Gas connection 3/4"...
  • Page 14 Features and technical data 1.2.1.7 G 90 Figure 1�7  Unit dimensions 405 (*) 1010 (*) 1059 1100 743 (EC) 1320 1017 Ø 80mm flue gas exhaust Limit thermostat reset button Combustion air inlet Ø 80 mm Flue gas exhaust blind cover, alternative to the rear one (1) Power supply cables input Condensate drain siphon (supplied as standard) Gas connection 3/4"...
  • Page 15 Features and technical data 1.2.2 Centrifugal gas unit heaters 1.2.2.1 G 30 C Figure 1�8  Unit dimensions 405 (*) 370 (*) 1072 Ø 80mm flue gas exhaust Limit thermostat reset button Combustion air inlet Ø 80 mm Flue gas exhaust blind cover, alternative to the rear one (1) Power supply cables input Condensate drain siphon (supplied as standard) Gas connection 3/4"...
  • 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 Limit thermostat reset button Combustion air inlet Ø 80 mm Flue gas exhaust blind cover, alternative to the rear one (1) Power supply cables input Condensate drain siphon (supplied as standard) Gas connection 3/4"...

  • Page 17: Components

    Features and technical data COMPONENTS Figure 1�10  Internal components Electrical panel GEN10 board display Gas valve GEN10 electronic board Terminal block Fan terminal block Controller for ignition, adjustment and flame Limit thermostat Flame sensor / ignition electrodes control Ignition transformer Combustion blower Installation, use and maintenance manual –...

  • Page 18: Electronic Board

    ▶ ment with the Modbus mapping for the specific FW version of heating ▶ the GEN10 board, available on request from the Robur technical The features available with each operating mode are detailed service. below. The types of service requests supported will depend on the...
  • Page 19 Features and technical data 1.5.2.1 Contact service request inputs If the room probe is not connected or is disabled (P45 = 0), the room temperature control will be delegated to an external In the presence of the room probe, supplied and enabled as thermostat/chronothermostat and power modulation cannot standard (P45 = 1), room temperature control takes place via the be used, except in the case of control with a 0-10 V power level...

  • Page 20: Controls

    Possibility of temporarily excluding one or more appliances ▶ gency function is not activated, the gas unit heater from operation. remains switched off and warning 819 (Paragraph Possibility of connection to the Robur cloud via LAN. ▶ 8�1  p� 53 ) is reported� 1.6.3 OCDS012 1-key basic control 1.5.4.2.2 Without a Modbus controller...
  • Page 21 0-10 V DC signal. It may be used only in association with the OTRG005 For managing the request signal ("HEAT." contact), Robur thermoregulator. provides as optional different models of thermostats and The main functions are: chronothermostats.

  • Page 22: Technical Data

    ...). chronothermostats For managing the request signal ("HEAT." contact), Robur pro- The document describing the mapping and meaning of vides as optional different models of thermostats and chrono- the Modbus registers implemented on the GEN10 board thermostats, listed below.
  • Page 23 Features and technical data G 20 G 30 G 35 G 45 G 60 G 90 type of heat exchangers pipe tower number of fans Values measured in an open area at maximum air flow. In a real installation, the thermal flow may reach greater distances than those given here (depending on the height of the ceiling and its thermal insulation).

  • Page 24: Transport And Positioning

    Transport and positioning G 30 C G 60 C fan motor Degree of protection appliance Installation data at maximum available head m³/h 2500 5400 Air flow free blowing m³/h 3550 6500 maximum useful pressure head minimum pressure drop on heat flow delivery width Dimensions height...

  • Page 25: Minimum Clearance Distances

    The recommended height from the floor to the gas unit heater base is 2,5 ÷ 3,5 m (Figure 2.2  p. 25 ). We do not Robur provides easy mounting support brackets as an optional, recommend installing the gas unit heaters at heights suitably designed for Next-G series gas unit heaters, which allow below 2,5 m from the floor.

  • Page 26: Heating Engineer

    Table 2�2  Support bracket dimensions for centrifugal gas unit heaters G 30 C G 60 C 1400 All Robur support brackets are supplied with bolts and the rear support plate. Gas unit heater fixing points centre distance Support bracket length For mounting instructions of the brackets, refer to the relevant instruction sheets.

  • Page 27: Combustion Products Exhaust

    Heating engineer 3.2.4 Supply gas pressure Non compliant gas pressure may damage the appliance and be hazardous. This appliance is equipped for a maximum gas supply pressure of 50 mbar. The Next-G gas unit heaters are also approved for use with I20 gas, i.e.
  • Page 28 In any case, use approved ducts according to the type of Table 3�3  B23 type maximum allowed length with roof flue gas exhaust installation to be made. Upon request, Robur can supply pipe suitable rigid pipes, coaxial ducts and terminals.
  • Page 29 Heating engineer 3.3.3.3 C13 type installation with separate ducts Table 3�6  C13 type maximum allowed length with 130/180 wall coaxial terminal (optional OKTC004) Figure 3�3  C13 type installation with Ø 80 separate ducts Indicative maximum lengths (m) Air pipe Flue gas exhaust pipe Next-G Ø...
  • Page 30 Ø 130 G 20 depends on the unit model (Table 3.11  p. 30 ). G 30 The pressure drops of the flue and air pipes available as Robur G 35 optional are shown in Table 3.12  p. 30 . G 45 Table 3.13  p.  31 shows the pressure drops for Ø 100 flue and G 60 air pipes in aluminium, available on the market.
  • Page 31 Heating engineer G 20 G 30 G 35 G 45 G 60 G 75 G 90 Pipe Ø 130 mm Elbow 90° Air intake pressure drop Pipe Ø 80 mm Elbow 90° 13,6 11,5 19,3 27,2 Pipe Ø 110 mm Elbow 90°...

  • Page 32: Flue Gas Condensate Drain

    Heating engineer discharge manifold. Figure 3�8  Wall terminal position The junction between the pipe and the manifold must re- ▶ main visible. 3.4.2 Condensate drain siphon installation A condensate drain siphon is supplied as standard and must be connected (by the installer) to the appropriate outlet in the low- er part of the gas unit heater.

  • Page 33: Air Ducting

    Electrical installer tioned both on the air intake (with or without mixing chambers) Figure 3�10  Opening the gas unit heater grille louvres and on the delivery. For this purpose, the delivery outlet of the Next-G C gas unit heat- ers is provided with fixing flanges for the delivery air ducting. Refer to the Paragraph 1.2.2 ...

  • Page 34: Electrical Power Supply

    Electrical installer Figure 4�1  GEN10 electronic board J20 RS485 connector J21 RS232 connector J40 Board power supply 230 V AC input J61 Alarm signal SPDT relay output SHLD J30 connector "Tamb1" Room probe input J200 "Tamb2" Destratification probe input "Text" Outdoor probe input "0-10V"...
  • Page 35 Electrical installer 1� Access the connection terminal block according to Pro- The cable may not be longer than 20 metres. cedure 4.2  p. 33 . 2� Use FRO-HP 4x0,75 mm cable for connection. For further information refer to the instruction sheet 3�...
  • Page 36 Electrical installer Figure 4�5  Connections between the thermoregulator and the gas unit heater OTRG005 thermoregulator NTC room temperature probe (supplied) Next-G gas unit heater terminal block J6 electrical bridge NO NC NO NC VENT. HEAT. RESET ALARM ALARM AUX OUT AUX OUT MA-BN Table 4�1 ...
  • Page 37 Electrical installer For further information refer to the instruction sheet supplied with the OCDS008 optional. Figure 4�6  OCDS008 digital chronothermostat connection OTRG005 thermoregulator OCDS008 digital chronothermostat 4.4.6 OSWR001 Genius software for remote termediate node. management of gas unit heaters 5� Insert the 120 Ω terminating resistor (detail G Figure 4.7 ...
  • Page 38 Electrical installer Figure 4�7  Modbus network connection diagram RS485 RS485 Signal A, white/green Next-G gas unit heater n° 2 J200 Modbus network termination jumper (open = Signal B, green LAN Cat. 5e FTP cable 4x2xAWG 24/1 intermediate node; closed = terminal node) USB/RS485 converter 120 Ω...
  • Page 39 Electrical installer bottom of the appliance's electronic board. tilation mode. All the contacts for external requests of the terminal block in the electrical panel inside the unit have a The cable may not be longer than 20 metres. 230 V voltage applied to the relative terminals� Figure 4�10 ...
  • Page 40 Electrical installer Figure 4�11  Multiple appliances wiring diagram with one programmable timer and more room thermostats 4.4.9 Generic Modbus controller 3� Place Jumper J200 closed if the gas unit heater is a ter- minal node of the Modbus network or open if it is an in- Connection of the generic Modbus controller is made on the termediate node.

  • Page 41: Temperature Probes Inputs

    (Paragraph 4.4.8  p. 38 ). The document describing the mapping and meaning of the Modbus registers implemented on the GEN10 board for the specific firmware version is available on-demand from Robur technical service. Tamb1 Tamb2 Text 0-10V Figure 4�12  Modbus connection...

  • Page 42: Input

    Appliance correctly installed, according to the manufactur- ▶ Robur TAC. NEITHER the user NOR the installation tech- er's provisions. nician is authorised to perform such operations, under Front grille louvres, if present, correctly opened (Paragraph ▶...

  • Page 43: Combustion Parameters Check

    (x = 0, 1,..) by pressing the key for 5 seconds and then contact Robur. of the chimney sweep function. 5.2.1 All models except G 75 and G 90 type used.
  • Page 44 First start-up ney sweep function at maximum power. according to the model and the type of gas used. 13� The display shows the letters "CS.HI" (chimney sweep high 20� Repeat steps 16 to 18 to complete the procedure. power), alternating once again with the flashing message Figure 5�1 ...
  • Page 45 First start-up Table 5�4  Next-G 35 gas valve setting table Screw pre-adjustment CO₂ percentage in flue gases Gas network pressure Throttle Offset Minimal heat input Nominal heat input Type mbar turns turns -7 ½ -4 ½ full open -4 ½ G25.1 -8 ½...

  • Page 46: Gas Changeover

    First start-up 12� After a short while, the flashing message becomes "_GO_" Table 5�8  Next-G 90 gas valve setting table again to indicate that the combustion control at maximum Screw pre-ad- CO₂ percentage in flue gases power can be carried out. justment network 13�...
  • Page 47 First start-up Measure- Parameter Parameter description Setting Default ment unit Room temperature setpoint 0,0 ÷ 40,0 °C °C 18,0 Fan speed in summer ventilation mode with standalone opera- 1 ÷ 4 tion 0. variable speed Fan mode in heating mode 1.

  • Page 48: Normal Operation

    Prior to using the appliance carefully read the warnings The use of the device by the end user is only per- in Chapter III.1  p.  4 , providing important information mitted after the Robur authorised TAC has completed on regulations and on safety. the first start-up�...

  • Page 49: Switch On And Off

    Normal operation First start-up may exclusively be carried out by a Robur Figure 6�1  1-key basic control TAC (Chapter 5  p. 42 ). Reset button Fault indicator lamp Never power the appliance off while it is running NEVER power the appliance off while it is running (ex- cept in the event of danger, Chapter III.1 ...

  • Page 50: Messages On The Display

    Normal operation 6.2.4.2 Space heating shutdown room temperature, prefix A ▶ flue gas temperature, prefix F 1� Slightly press the summer button so that neither of the ▶ two summer/winter buttons is pressed (Figure 6.2  p.  49 ) 6.3.3 Events reporting or, if there is an external request connected to the OCDS016 When they occur, the display of the GEN10 board shows three 2-key basic control, deactivate the heating request via the...

  • Page 51: Modifying Settings

    Normal operation ic sections, exclusively intended for qualified personnel (in- parameter 21 in menu 2). staller or TAC). For information see the Service manual. 5� Press the key to scroll down the other parameters in the menu; the codes will be displayed in order (e.g. Before accessing menus and parameters display "2._21", ...

  • Page 52: Efficiency

    If frequent stops occur, contact system manager. Robur TAC. SCHEDULED ROUTINE MAINTENANCE Perform the operations in the following Table 7.1  p.  52 on an annual basis.

  • Page 53: Periods Of Inactivity

    Diagnostics time Figure 7�1  Position of the limit thermostat reset 1� Switch the appliance off (Paragraph 6.2  p. 49 ). 2� Only when the appliance is completely off, power it off with the main switch/disconnector switch (detail GS, Fig- ure 4.2  p. 34 ). 3�...
  • Page 54 Diagnostics Code Description Warning (u) Error (E) The reset may be done following one of procedures shown in Paragraph Parasitic flame lockout 6.6.3  p. 52 . If the code persists, shows up again or in case of doubt, contact the TAC. Reset occurs automatically 10 seconds Flame loss after the code is generated.

  • Page 55: Appendices

    Seasonal space heating η 89,6 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: Next-G 30;...
  • Page 56 Seasonal space heating η 89,3 energy e ciency Contact details Robur SPA, Via Parigi 4/6, I-24040 Zingonia (BG) (*) 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: Next-G 45;...
  • Page 57 Seasonal space heating η 90,2 energy e ciency Contact details Robur SPA, Via Parigi 4/6, I-24040 Zingonia (BG) (*) 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 58 Seasonal space heating η 91,3 energy e ciency Contact details Robur SPA, Via Parigi 4/6, I-24040 Zingonia (BG) (*) 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 59 η 95,4 Emission e ciency s, ow Seasonal space heating η 90,0 energy e ciency Contact details Robur SPA, Via Parigi 4/6, I-24040 Zingonia (BG) (*) Not required for electric warm air heaters. Installation, use and maintenance manual – Next-G...

  • Page 60: Eu Declaration Of Conformity (Doc)

    Parigi 4/6 24040 Verdellino/Zingonia (BG) Italy Tel. +39 035.888.111 Fax +39 035.884.165 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.r.l.
  • 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.com export@robur.it...

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