Robur NEXT R Installation, Use And Maintenance Manual

2021

ready

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Installation, use and maintenance manual

Next-R

Powered by natural gas/LPG

Gas unit heaters for use in industrial and commercial

installations

This Installation, use and maintenance manual has been drawn up and printed by Robur S.p.A.; whole or partial

reproduction of this Installation, use and maintenance manual is prohibited.

The original is led at Robur S.p.A.

Any use of this Installation, use and maintenance 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 Installation, use and maintenance manual without prior notice.

Revision: J

Code: D-LBR851

DISPOSAL

The appliance and all its accessories must be disposed of separately in accordance with the regulations in force.

Use of the WEEE symbol (Waste Electrical and Electronic Equipment) indicates that this product cannot be disposed of as house-

hold waste. Proper disposal of this product helps to prevent potential negative consequences for the environment and human

health.

Installation, use and maintenance manual – Next-R

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.8

1.3 Components.........................................................

p.18

1.4 Electrical wiring diagram .................................

p.20

1.5 Operation mode .................................................

p.22

1.6 Controls ..................................................................

p.22

1.7 Technical data ......................................................

p.23

2 Transport and positioning ..................................

p.25

2.1 Warnings ................................................................

p.25

2.2 Handling ................................................................

p.25

2.3 Appliance positioning ......................................

p.25

2.4 Minimum clearance distances .......................

p.26

2.5 Support bracket ..................................................

p.27

3 Heating engineer...........................................................

p.28

3.1 Warnings ................................................................

p.28

3.2 Fuel gas supply ....................................................

p.28

3.3 Combustion products exhaust ......................

p.29

3.4 Air ducting ............................................................

p.35

4 Electrical installer .........................................................

p.35

4.1 Warnings ................................................................

p.35

4.2 Electrical systems ...............................................

p.35

4.3 Electrical power supply ....................................

p.36

4.4 Control system.....................................................

p.36

5 First start-up .......................................................................

p.42

5.1 Preliminary checks .............................................

p.42

5.2 Combustion parameters check .....................

p.42

5.3 Gas changeover ..................................................

p.46

6 Normal operation .........................................................

p.46

6.1 Warnings ................................................................

p.46

6.2 Switch on and o ................................................

p.46

6.3 Eciency ...............................................................

p.48

6.4 Restarting a locked-out unit ...........................

p.48

7 Maintenance .......................................................................

p.49

7.1 Warnings ................................................................

p.49

7.2 Scheduled routine maintenance ..................

p.49

7.3 Resetting the temperature limit

thermostat ............................................................

p.49

7.4 Troubleshooting .................................................

p.50

7.5 Periods of inactivity ...........................................

p.50

8 Appendices ...........................................................................

p.51

8.1 Product che ........................................................

p.51

Introduction

4

I

I INTRODUCTION

Installation, use and maintenance manual

This Manual is an integral part of the Next-R 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 work, the Next-R unit requires a control de-

vice to be connected by the installer (see Paragraph

1.6

p.22

).

II SYMBOLS AND DEFINITIONS

II.1 KEY TO SYMBOLS

DANGER

WARNING

NOTE

PROCEDURE

REFERENCE (to other document)

II.2 TERMS AND DEFINITIONS

Appliance / Unit = equivalent terms, both used to refer to

the gas unit heater.

TAC = Technical Assistance Centre authorised by Robur.

External request = generic control device (e.g.

thermostat, timer or any other system) equipped with a

voltage-free NO contact and used as control to start/stop

the unit.

OCDS012 1-key basic control = control device that sig-

nals the ame lock-out and allows its resetting.

OCTR000 2-key basic control = control device that sig-

nals the ame lock-out and allows its resetting and also

allows selecting winter operation (space heating) or sum-

mer operation (ventilation).

OTRG005 thermoregulator = control device that allows

to manage settings and operation of one Next-R gas unit

heater.

OCDS008 digital chronothermostat = device that in-

tegrates the functions of room temperature control and

remote control of one or more Next-R gas unit heaters,

when connected to the OTRG005 thermoregulator.

OSWR000 Genius software for remote management =

software that allows, through the OTRG005 termoregula-

tors, to centralize the management of up to 100 Next-R

gas unit heaters.

First start-up = appliance commissioning operation

which may only and exclusively be carried out by a TAC.

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 spe-

cic knowledge on heating, electrical systems and

gas appliances, in compliance with the laws in

force in the Country of installation.

Declaration of conformity

Upon completing installation, the installing rm

shall issue to the owner/client the appliance's

workmanlike conformity declaration, according to

national/local regulations in force and the manu-

facturer's instructions/provisions.

Misuse

The appliance must only be used for the purpos-

es for which it has been designed. Any other use is

deemed hazardous. Incorrect use may aect oper-

ation, duration and safety of the appliance. Adhere

to the manufacturer's instructions.

Use of the appliance by children

The device can be used by children over 8 years

old, and by people with reduced physical, senso-

ry or mental capabilities, or lack of experience or

knowledge, only if they are under surveillance or

after they have received instructions regarding

safe use of the appliance and understanding the

dangers inherent in it. Children should not play

with the appliance.

Warnings

Installation, use and maintenance manual – Next-R

5

III

Hazardous situations

 Do not start the appliance in hazardous conditions,

such as: gas smell, problems with the electrical/gas

system, parts of the appliance under water or dam-

aged, malfunctioning, disabling or bypassing con-

trol and safety devices.

 In case of danger, request intervention by qualied

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, persons with physical,

sensory or mental disabilities or persons with poor

knowledge and experience with use of the appli-

ance.

Gas component tightness

 Before performing any operation on gas ducting

components, 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,

multimeters or other equipment that may cause

sparks next to the appliance.

 Shut o the gas supply by turning the valve o.

 Open immediately doors and windows to create a

cross-current of air to purify the room.

 Switch o the power supply via the external dis-

connect switch in the power supply electrical pan-

el.

 Use a telephone away from the appliance to ask for

intervention from qualied personnel.

Poisoning

 Ensure the ue gas ducts are tightness and compli-

ant with the regulations in force.

 Upon completing any procedure, ensure the tight-

ness of the components.

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 inter-

nal components before the appliance has cooled

down.

 Do not touch the ue gas exhaust before it has

cooled down.

Electrocution hazard

 Disconnect the electrical power supply before any

operation on appliance components.

 For electrical connections exclusively use compli-

ant components and according to the specica-

tions provided by the manufacturer.

 Ensure the appliance cannot be accidentally

switched back on.

Earthing

Electrical safety depends on eective earthing sys-

tem, correctly connected to the appliance and in-

stalled according to the regulations in force.

Air ow

Do not obstruct the fan intake or the warm air

outlet.

Distance from combustible or ammable mate-

rials

 Do not deposit ammable materials (paper, dilu-

ents, paints, etc.) near the appliance.

 Comply with current regulations.

Aggressive substances in the air

The air of the installation site must be free from ag-

gressive substances.

Acid ue gas condensate

 Discharge the acid condensate of combustion ue

gas, as indicated in Paragraph 3.3

p.29

, in com-

pliance with current exhaust regulations.

Switching the appliance o

Disconnecting the power supply while the appli-

ance is running may cause permanent damage to

internal components.

 Except in the event of danger, do not disconnect

the power supply to switch o the appliance, but

always and exclusively act through the provided

control device.

In the event of failure

Operations on internal components and repairs

may exclusively be carried out by a TAC, 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 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

Warnings

6

III

manufacturer's instructions (see Chapter 7

p.49

)

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.

 Use only original parts.

Keep the Manual

This Installation, use and maintenance manual

must always accompany the appliance and must

be handed to the new owner or installer in the

event of sale or removal.

III.2 CONFORMITY

EU directives and standards

The Next-R series gas unit heaters are certied in ac-

cordance with European regulation GAR 2016/426/EU

and meet the essential requirements of the following

Directives:

▶

2016/426/EU "Gas Appliances Regulation" as amend-

ed and added.

▶

2014/30/EC "Electromagnetic Compatibility Directive"

as amended and added.

▶

2014/35/EC "Low Voltage Directive" as amended and

added.

▶

2006/42/EC "Machine Directive" as amended and add-

ed.

▶

2281/2016/EU "Ecodesign requirements for air heat-

ing products" as amended and added.

Furthermore, they comply with the requirements of the

following standards:

▶

EN 17082 Domestic and non-domestic gas-red forced

convection air heaters for space heating not exceed-

ing a net heat input of 300 kW.

Other applicable provisions and standards

The design, installation, operation and maintenance of the

systems shall be carried out in compliance with current

applicable regulations, depending on the Country and

location, and in accordance with the manufacturer's in-

structions. In particular, regulations regarding the follow-

ing shall be complied with:

▶

Gas systems and equipment.

▶

Electrical systems and equipment.

▶

Heating systems.

▶

Environmental protection and combustion products

exhaust.

▶

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

installation and/or improper use and/or failure to

comply with regulations and with the manufactur-

er's directions/instructions shall be disclaimed.

In particular, the warranty on the appliance may be

rendered 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 man-

ufacturer.

 Damages caused by external agents such as salts,

chlorine, sulphur or other chemical substances

present in the air of the installation site.

 Abnormal actions transmitted to the appliance by

the system or installation (mechanical stresses,

pressure, vibrations, thermal expansion, electrical

surges...).

 Accidental damages or due to force majeure.

Features and technical data

Installation, use and maintenance manual – Next-R

7

1

1 FEATURES AND TECHNICAL DATA

1.1 FEATURES

1.1.1 Available range

Next-R gas unit heaters are available in three versions:

▶

with horizontal ow, with axial fan (Next-R series, from

14,1 to 76,4 kW)

▶

with horizontal ow, ductables, with centrifugal fan

(Next-R C series, from 25,5 to 76,4 kW)

▶

with vertical downow (Next-R V series, from 14,1 to

44,6 kW)

Choosing the correct ow direction

Due to characteristics and positioning of internal

components, Next-R V vertical downow gas unit

heaters cannot be used for horizontal ow opera-

tion, and vice versa, horizontal ow gas unit heat-

ers cannot under any circumstances be used for

vertical downow operation.

The R15 and R20 gas unit heaters have the possi-

bility, when combined with the adjustable support

bracket OSTF020 (available as an optional), to be

used with horizontal, oblique or vertical throw.

1.1.2 Operation

The Next-R series gas unit heater is an independent heat-

ing appliance with airtight combustion circuit and forced

air draft.

It has been designed to be installed inside the room to be

heated.

The combustion circuit is room sealed and meets the re-

quirements for type C appliances: combustion air supply

and ue gas exhaust discharge take place outdoors and

are ensured by the functioning of a blower inserted in the

combustion circuit.

The appliance is also approved for type B for installations

where it is allowed to take the combustion air directly

from the room to be heated.

The operation of the gas unit heater is controlled by a con-

trol device (not supplied).

The gas unit heater can operate on two burner power lev-

els, with constant fan speed.

Products of gas combustion (natural gas or LPG) ow

internally through the heat exchangers, which are in-

vested externally by the air current produced by the fan,

delivering warm air ow into the room.

The fan operates automatically only when it receives

the enabling signal, depending on the model, from the

fan thermostat or by the electronic board timer, i.e. with

hot heat exchangers, in order to avoid the introduction

of cold air into the room, and it will switch o with cold

exchangers.

The air ow direction is adjustable vertically by means of

the revolving louvres of the grille.

If heat exchangers overheat due to malfunction, a temper-

ature limit thermostat cuts o the supply to the gas valve,

thus interrupting fuel ow and turning o the burner.

A blower upline of the burner mixes the air and gas and

expels the combustion fumes.

In the event of obstructions in the intake or exhaust duct,

or in the event of malfunction of the blower, the gas valve

stops, thus also interrupting the ow of fuel to the burner.

In summer it is possible to operate the fan only in order to

provide a pleasant air ow within the room.

1.1.3 Mechanical components

▶

Premix stainless steel burner.

▶

High head blower.

▶

Control board for brushless motor of the blower.

▶

Cylindrical stainless steel combustion chamber.

▶

Corrugated stainless steel heat exchangers with very

large exchange surface (R15, R20 models).

▶

Robur patented heat exchangers, made out of a spe-

cial aluminium die-cast alloy, with horizontal nning

on the air side and vertical nning on the ue gas ex-

haust side, with a very high heat exchange capacity

(R30, R40, R50, R60, R80 models).

▶

External steel panelling with epoxy powder enamel

nish.

▶

Axial fan(s) with high ow rate.

▶

Centrifugal fan (for the Next-R C series).

1.1.4 Control and safety devices

▶

100 °C limit thermostat with manual reset against heat

exchangers overheating.

▶

Dierential pressure switch for controlling the correct

operation of the blower (all models except R15, R20).

▶

Fan thermostat (for R30, R40, R50, R60, R80 models).

▶

Ventilation timer (for R15, R20 models).

▶

Gas solenoid valve.

▶

Controller for ignition, adjustment and ame control.

Features and technical data

8

1

1.2 DIMENSIONS

1.2.1 Axial gas unit heaters

1.2.1.1 R15/R20

Figure1.1 Unit dimensions

1 Flue gas exhaust

2 Combustion air inlet

3 Power supply cables input

4 Gas connection 3/4" M

5 Thermoformed door

6 Limit thermostat

7 Flue gas exhaust blind cover, alternative to the rear one (1)

(*) Holes for xing to the support bracket

557

419

480

225

678

485

445

138

320

233

252

80

397

403

247

12

3

4

6

5

7

400 (*)

176 (*)

120

Features and technical data

Installation, use and maintenance manual – Next-R

9

1

1.2.1.2 R30

Figure1.2 Unit dimensions

1 Flue gas exhaust

2 Combustion air inlet

3 Power supply cables input

4 Gas connection 3/4" M

5 Thermoformed door

6 Limit thermostat

7 Flue gas exhaust blind cover, alternative to the rear one (1)

8 Blind cover for access to the fan thermostat

(*) Holes for xing to the support bracket

5

731

777

435

593

734

515

475

210

475

257257

80

12

3

4

383

340

690

370 (*)

405 (*)

6

120

76

432

7

8

Features and technical data

10

1

1.2.1.3 R40

Figure1.3 Unit dimensions

1 Flue gas exhaust

2 Combustion air inlet

3 Power supply cables input

4 Gas connection 3/4" M

5 Thermoformed door

6 Limit thermostat

7 Flue gas exhaust blind cover, alternative to the rear one (1)

8 Blind cover for access to the fan thermostat

(*) Holes for xing to the support bracket

731

777

435

593

734

515

475

210

475

257257

80

12

3

4

400

340

690

370 (*)

405 (*)

6

5

120

76

432

7

8

Features and technical data

Installation, use and maintenance manual – Next-R

11

1

1.2.1.4 R50

Figure1.4 Unit dimensions

1 Flue gas exhaust

2 Combustion air inlet

3 Power supply cables input

4 Gas connection 3/4" M

5 Thermoformed door

6 Limit thermostat

7 Flue gas exhaust blind cover, alternative to the rear one (1)

8 Blind cover for access to the fan thermostat

(*) Holes for xing to the support bracket

746

593

435

777

928

709

669

210

475

354354

80

12

3

4

690

340

519

620 (*)

405 (*)

6

5

120

7

8

76

626

Features and technical data

12

1

1.2.1.5 R60

Figure1.5 Unit dimensions

1 Flue gas exhaust

2 Combustion air inlet

3 Power supply cables input

4 Gas connection 3/4" F

5 Thermoformed door

6 Limit thermostat

7 Flue gas exhaust blind cover, alternative to the rear one (1)

8 Blind cover for access to the fan thermostat

(*) Holes for xing to the support bracket

731

593

435

777

1119

900

860

210

475

80

340

690

383

3

4

12

432 234234

810 (*)

405 (*)

6

5

120

7

8

76

817

Features and technical data

Installation, use and maintenance manual – Next-R

13

1

1.2.1.6 R80

Figure1.6 Unit dimensions

1 Flue gas exhaust

2 Combustion air inlet

3 Power supply cables input

4 Gas connection 3/4" F

5 Thermoformed door

6 Limit thermostat

7 Flue gas exhaust blind cover, alternative to the rear one (1)

8 Blind cover for access to the fan thermostat

(*) Holes for xing to the support bracket

746

593

435

777

1319

1100

1060

80

519

340

690

475

210

540 282280

1010 (*)

405 (*)

120

12

3

4

6

5

7

8

76

1017

Features and technical data

14

1

1.2.2 Centrifugal gas unit heaters

1.2.2.1 R30 C

Figure1.7 Unit dimensions

1 Flue gas exhaust

2 Combustion air inlet

3 Power supply cables input

4 Gas connection 3/4" M

5 Thermoformed door

6 Limit thermostat

7 Flue gas exhaust blind cover, alternative to the rear one (1)

8 Blind cover for access to the fan thermostat

(*) Holes for xing to the support bracket

734

777

774

601

431

40

580

157

469

260

595

482

528

40

5

80

12

3

4

6

690

340

389

298

510

1031

601

176

389

212

462

243

405 (*)

370 (*)

120

7

8

76

432

Features and technical data

Installation, use and maintenance manual – Next-R

15

1

1.2.2.2 R40 C

Figure1.8 Unit dimensions

1 Flue gas exhaust

2 Combustion air inlet

3 Power supply cables input

4 Gas connection 3/4" M

5 Thermoformed door

6 Limit thermostat

7 Flue gas exhaust blind cover, alternative to the rear one (1)

8 Blind cover for access to the fan thermostat

(*) Holes for xing to the support bracket

734

777

774

601

472

157

580

40

469

260

40

595

528

482

1072

601

460

134

446

197

80

12

3

4

6

690

340

446

333

550

5

278

405 (*)

370 (*)

120

7

8

76

432

Features and technical data

16

1

1.2.2.3 R50 C

Figure1.9 Unit dimensions

1 Flue gas exhaust

2 Combustion air inlet

3 Power supply cables input

4 Gas connection 3/4" M

5 Thermoformed door

6 Limit thermostat

7 Flue gas exhaust blind cover, alternative to the rear one (1)

8 Blind cover for access to the fan thermostat

(*) Holes for xing to the support bracket

928

777

601

537

968

580 469

260

40

789

722

676

5

85

521

172

1138

601

460

311

538

521

690

340

315

80

12

3

4

6

405 (*)

620 (*)

120

7

8

76

626

Features and technical data

Installation, use and maintenance manual – Next-R

17

1

1.2.2.4 R80 C

Figure1.10 Unit dimensions

1 Flue gas exhaust

2 Combustion air inlet

3 Power supply cables input

4 Gas connection 3/4" F

5 Thermoformed door

6 Limit thermostat

7 Flue gas exhaust blind cover, alternative to the rear one (1)

8 Blind cover for access to the fan thermostat

(*) Holes for xing to the support bracket

1319

40

1180

1113

1067

777

580

157

40

469

260

1359

601

472

1113

108

333 230 333

108

446

278

12

3

4

6

5

80

340

690

446

197

134

461

601

1072

1010 (*)

405 (*)

120

7

8

76

1017

1.2.3 Vertical downow gas unit heaters

The dimensions of the vertical downow gas unit heaters

are identical to those of the corresponding axial models

(Paragraph 1.2.1

p.8

).

Figure 1.11

p.18

below details the centre distances be-

tween the vertical suspension brackets for the dierent

models of vertical downow gas unit heaters.

The R15 and R20 gas unit heaters are not equipped with

vertical suspension brackets, as the installation with ver-

tical downow is carried out by means of the revolving

bracket OSTF020 (available as an optional, Paragraph

2.5.4

p.28

).

Features and technical data

18

1

Figure1.11 Position of vertical downow gas unit heaters brackets

1 Vertical suspension brackets

A Upper brackets centre distance

B Lower brackets centre distance

785

A

B

1 1

Table1.1 Centre distance of the vertical suspension brackets

Model A B

R30 V 494 370

R40 V 494 370

R50 V 688 620

1.3 COMPONENTS

1.3.1 R15/R20

Figure1.12 Internal components

1 Electrical panel

2 Controller for ignition, adjustment and

ame control

3 Terminal block

4 Gas valve

5 Limit thermostat

6 Ignition transformer

7 Combustion blower

8 Flame sensor / ignition electrodes

1

3

4

5

6

78

2

Features and technical data

Installation, use and maintenance manual – Next-R

19

1

1.3.2 R30/R40/R50/R60/R80

Figure1.13 Internal components

1 Electrical panel

2 Controller for ignition, adjustment and

ame control

3 Terminal block

4 Gas valve

5 Limit thermostat

6 Ignition transformer

7 Combustion blower

8 Flame sensor / ignition electrodes

9 Dierential pressure switch

1 93

4

5

6

7

8

2

Features and technical data

20

1

1.4 ELECTRICAL WIRING DIAGRAM

1.4.1 R15/R20

Figure1.14 Electrical wiring diagram

CV Fan condenser

K1 Internal modulation relay

M1 Limit thermostat

M4 Controller for ignition, adjustment and ame control

Q1 Gas valve

RP7 Ignition electrodes

RP8 Flame sensor

S Blower

TR Ignition transformer

V1 Fan

Z9 External request (not supplied)

27 Power level control contact

28 Winter mode activation contact

Ground

T2

T1

M1

K1

Control panel

Ground

bracket

T3

T5

T4

10

2

6

1

2

3

4

5

6

7

FUSE 6.3A

13

14

15

J2

89

11

10

20

1

S2

S1

2 3 5 6 7 N L

NC

CNL

Z92

Z91

V2L

V1N

Q1L

Q1N

T6

230V~50Hz

CV

L

N

S

~

Q1

V1

~

3

4

12 2 4

3

6 10 1

1

3

3 39

9

2 27 811 4

RP8

12

J5

J3

J1

J7

J6

M4

J8

FUSE

4AF

21

TR

RP7

27

28

Z9

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Robur NEXT R Installation, Use And Maintenance Manual

Robur NEXT R Installation, Use And Maintenance Manual

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