Robur NEXT R Installation, Use And Maintenance Manual

Type
Installation, Use And Maintenance Manual
2021
ready
ErP
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: H
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.49
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 plant 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
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
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
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
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
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
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
260
595
482
528
40
5
80
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
260
40
595
528
482
1072
601
460
134
446
197
80
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
260
40
789
722
676
5
85
521
172
1138
601
460
311
538
521
690
340
315
80
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
260
1359
601
472
1113
108
333 230 333
108
446
278
12
3
4
6
5
80
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
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
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

Type
Installation, Use And Maintenance Manual

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