Beruflich Dokumente
Kultur Dokumente
INDEX
SECTION 1 GENERAL WARNINGS 2
SECTION 2 OVERVIEW AND TECHNICAL DATA 4
2.1 OVERVIEW 4
2.2 GAS FIRED CHILLER OPERATION CYCLE 5
2.3 HEATING MODULE OPERATION 9
2.4 VERSIONS AND MODELS 11
2.5 TECHNICAL DATA 12
SECTION 3 INSTALLATION 18
3.1 GENERAL RULES 18
3.2 INSTALLATION OF THE UNIT 19
SECTION 4 HYDRAULIC AND GAS INSTALLATION 23
4.1 WATER PIPING DESIGN AND INSTALLATION 23
4.2 GAS SUPPLY PIPING 27
4.3 DUCT FLUE EXHAUST – AYF 60-108 MODEL 28
SECTION 5 ELECTRICAL CONNECTION 29
5.1 POWER SUPPLY 29
5.2 ELECTRICAL CONNECTIONS FOR THE CONTROL OF THE UNIT 29
SECTION 6 START-UP AND ADJUSTMENT 38
6.1 FILLING THE WATER PIPING 38
6.2 GAS PRESSURE ADJUSTMENT 41
6.3 CHILLED WATER TEMPERATURE REGULATION 44
6.4 HOT WATER TEMPERATURE REGULATION (AYF only) 45
SECTION 7 SERVICING AND MAINTENANCE 46
SECTION 8 TROUBLE-SHOOTING INSTRUCTIONS 48
APPENDIX ADAPTING TO ANOTHER TYPE OF GAS 51
NOTE
Carefully read the information contained in this manual. It contains important instructions regarding installation,
use and maintenance safety. Save this manual for any future needs. The manufacturer cannot be held
responsible for any damages from improper, erroneous or irrational use.
With the aim of continuously improving of quality of our products, manufacturer reserves the right to vary here
reported instructions and drawings without any prior notice.
1 GENERAL WARNINGS
This manual is an integral and essential part of the product and must be given to the user.
Qualified engineers, strictly complying with the manufacturer’s instructions and the local standards,
should carry out the installation. Non-conform installation may result causing personal and animal injuries
or property damage for which the manufacturer will not undertake any responsibility.
Qualified service engineers means those having specific technical competence in the air conditioning and
gas appliances according to the International and National Standards.
This appliance must be exclusively used for the purpose it was intended, that means all chilling and heating
applications must be in full respect of the operating conditions of the unit.
Any other use is considered improper and therefore dangerous. It is recommended to protect properly the
unit against any improper uses, which may lead to a dangerous situation.
The fluids used in the sealed circuit may cause health disturbances if respired, eaten or put in contact with
the skin. It’s recommended not to perform any intervention on the sealed circuit, by the installer or the end-
user, and not to handle the valves of the sealed circuit of the chiller.
The manufacturer will undertake no contractual or non-contractual responsibility for damages resulting from
installation errors, wrong use or not observing all manufacturers’ instructions.
After unpacking the unit, check for unit integrity. Keep all packaging materials (plastic bags, polystyrene
foam, nails, etc.) away from children, since they are potential source of danger.
Before the installation, it’s recommended to purge accurately all chilled water piping and gas supply piping,
in order to guarantee the absence of any residual materials which could obstacle the propre function of the
chiller.
The electrical safety of this appliance is ensured only when it’s correctly connected to an efficient grounding
system, in accordance to the electrical safety standards in force. The manufacturer cannot be held
responsible for any damages caused by the failure of the grounding system.
In case of failure and/or poor unit performance, disconnect it (i.e. cut off the power supply and close the gas
valve), and do not try any repair or direct servicing. The chiller is also to be disconnected if it will be not used
for a longer period of time.
Manufacturer’s authorised service centers, using only original spare parts, must carry out any repair to the
products. Misapplication of the above can compromise the safety of the unit. To ensure unit efficiency and
correct operation, it is essential that qualified service engineers carry out annual maintenance following
the manufacturer’s instructions.
Should the unit be sold or transferred to another owner, please ensure that this manual remains with the unit
for use by the new owner and/or installer.
2 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
Before starting the appliance
WARNING
To guarantee the correct operation of the unit and avoid possible failures, it’s necessary to turn off the unit by
means of the thermostat, or in any case by means of the ignition switch located on the thermostat circuit.
NEVER turn off the unit by cutting off the power supply.
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 3
2 OVERVIEW AND TECHNICAL DATA
2.1 OVERVIEW
The High Efficiency ACF and AYF series (ACF S - Low Noise version) chillers are single-block water chilling
units, equipped with an air-cooled condenser and designed for outdoor installation. The absorption cooling
cycle is based upon a solution of water and ammonia for the production of chilled water at a temperature as
o
low as 3 C. The chilling system is fed by thermal energy provided by a gas burner, therefore the required
electric energy is limited to driving the fan and pump motors (the only moving components of the unit). The
evacuation of combustion gases, occur by mixing them with condenser air using an axial fan of the
appliance.
The heating function, using the High Efficiency appliance, is possible by the operation of the high-
performance heater, which produce warm water up to 80°C (if required chiller and heater can operate
simultaneously and/or separately).
These models enable to meet all demands for cooling and heating as well for hot water production. The
heating appliance is a fan type direct vent furnace. Combustion gases are exhausted using the outlet
terminal positioned on the backside of the unit (if required an exhaust smokestack could be installed).
The combustion fuel is Natural Gas or LPG. Required electric supply is 230V – 50 Hz single phase.
ACF, AYF/2 (2 pipes version) and chiller section of AYF/4 (4 pipes unit) units are 230V 50 Hz single-phase
electrically supplied and could be connected to Remote Control device.
The Remote Control may control up to 16 single units on the same circuit.
WARNING
When Remote Control device (available as optional) is used to control the operation of the units, it
is necessary to consult “Installation and Programming manual or Remote Control device”.
Complete instructions regarding electrical wiring, temperature control and troubleshooting
diagnostic is described in this manual.
4 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
2.2 GAS FIRED CHILLER OPERATION CYCLE
To controls the startup of the chiller, it’s necessary to install a control switch. It could be programmable
timer, room thermostat or any other type of on/off switch. Installation of this switch is to be done by installer.
When the control switch is turned on, the microprocessor on the electronic board starts the appliance. The 3
digit display (detail A Figure 1) on the control board is showing inlet chilled water temperature and the
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 5
temperature difference T, between inlet and outlet chilled water lines. Red numbers are indicating the inlet
water temperature and the green ones temperature difference between chilled water lines (detail B Figure 1)
- Ammonia-water solution pump; the unit will be stopped if 15 seconds after the start-up of the appliance
no signal is received from the hydraulic pump rotation probe (appears error signal E11).
- Fan; the fan’s speed depends on external and condenser temperatures. When external temperature is
above 33°C, the fan is at full speed. Condenser temperature and external temperature are monitored
continuously. The appliance will be stopped if any of these parameters is not correct (condenser
overheating - appears error signal E04 or external temperature below –12°C - appears error signal E06).
- Flame control box; controls the differential pressure switch and starts the combustion fan. After 40
seconds of purging it opens the gas valve and starts the ignition sparking at the burner (10 seconds). The
gas valve will cut the gas supply and the appliance will be stopped if no flame has been established
(appears error signal E12). To restart the appliance, wait at least 3 seconds and than press the reset
button (supplied with the unit).
- Control light, mounted on the left side of the front panel, is always on when gas valve is opened.
- Generator Temperature Probe; controls the generator temperature. If temperature exceeds 160°C the
unit will be shut down. The unit will be automatically restarted when temperature of the generator is below
110°C. If 160°C temperature occurs 3 times in 60 minutes the appliance will be shut down (appears error
signal E 08).
- Water Pump (not supplied with the unit); is used for chilled water circulation. When the pump is
controlled from electronic board the burner will be stopped when the water flow rate is insufficient or
arrested for more than 15 seconds, (appears error signal E10).
- Low Temperature Chilled Water Control; when outlet water temperature is below 2°C the appliance will
be shut down (appears error signal E03). It’s antifreeze protection. The appliance will be automatically
restarted when water temperature reach 4°C. While the unit is shut down the water pump will run
continuously (when controlled from electronic control board).
IMPORTANT
When the appliance is turned off from the control switch (thermostat, programmable timer or similar),
the solution pump, fan and water pump (if controlled from electronic board) will continue to run for
the next 215 seconds.
6 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
Fan: axial type, directly coupled to a 6-poles electrical motor, protected against over heating and equipped
with protecting grid;
Hydraulic pump: alternative volumetric one-piston pump which creates oscillating flow of oil directed to the
solution pump; the pump is driven by an electrical motor using the system of pulley and belts;
Burner: premixed type; multiple-gas design either for Natural gas or LPG operation with high efficiency of
combustion and low emission of NOx (44 ppm);
Casing: made of galvanized sheet metal, with powder epoxy coating, in order to guarantee the best
resistance against the atmospherics agents;
Sealed refrigerating circuit: all the components are assembled by welding and afterwards heat-treated
and airtight tested under a maximum pressure of 70 bar.
Electric gas valve with double shutter electrically connected in parallel;
Electronic Control Board with integrated microprocessor, controls the operation of the appliance:
• display, shows the values of the process parameters: temperature of chilled inlet water and T between
inlet and outlet water;
• fan speed regulator (100% to 30% of full speed) relating both to condensation and external temperatures;
maximum fan speed is reached if external temperature is above 33°C;
• anti-freeze control; it stops the appliance when outlet water temperature is below +2°C;
• thermostat control of outlet water temperature (setting range from 3°C to 13°C);
• hydraulic pump rotation control;
• control of condensation temperature as the function of external ambient temperature;
• condenser air flow control (dirty coil, damaged fan, motor’s malfunction);
• automatic control of unit’s shut down; the fan and hydraulic pump will be stopped 215 seconds after the
burner;
• control of maximum temperature of the generator using a thermistor with an automatic reset;
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 7
C
LEGEND:
8 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
CHILLER’S CONTROL AND SAFETY DEVICES
In addition of the functions foreseen by the electronic control board, the ACF/AYF units are equipped with
the further safety devices:
§ Flow switch controls chilled water flow; it stops the appliance when water flow arrested or drop too low.
This error E10 is displayed on the electronic board (and on Remote Control if installed).
§ High temperature limit Switch: located at the generator wall above the combustion chamber; it open
the contact if the temperature is above 166°C; manually reset. Error E01 displayed at the electronic
board (and on Remote Control if installed);
§ High pressure limit switch stops the appliance when pressure exceeds 25,9 ± 0,69 bar; with manual
reset; Error E02 displayed at the electronic board (and on Remote Control if installed);
§ Safety relief valve on the sealed circuit; set to release ammonia vapor if pressure is over 31 bar; the
valve close automatically when pressure under 31 bar;
§ Differential flue pressure switch: on the combustion circuit; stops the appliance with insufficient
combustion air flow; Error E09 displayed at the electronic board (and on Remote Control if installed);
§ Flame control box: controls the burner ignition; after 40 seconds of purging it opens the gas valve and
starts the ignition sparking at the burner (10 seconds). The gas valve will cut the gas supply and the
appliance will be stopped if no flame has been established or detected (error signal E12 will appear at
the electronic display and on Remote Control if installed). To restart the appliance, wait at least 3
seconds and than press the reset button (supplied with the unit, to be installed by installer);
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 9
HEATER’S CONTROL AND SAFETY DEVICES
Following safety devices are mounted in the heater:
§ Flame control box: After the purging (approx. 10 seconds) it opens the heater’s gas pilot orifice and
starts the ignition sparking (approx. 60 seconds). When flame sensor confirms the flame, flame control
box opens the gas valve to supply the main burner. If no flame has been established on the pilot, flame
control box close the gas supply and appliance will be stopped. To reset the unit, press either the button
on-board the unit or the remote one (to be installed by the installer);
In case of failing gas supply during the normal operation, the control closes the gas valve in less than 1
second. In this case the ignition control will try one more time and then stop the unit;
§ Electric gas valve with double shutter electrically connected in parallel; stage modulator controls the
high and low flame; it includes a pilot outlet;
§ Automatic reset safety thermostat (TL): it is placed at the exit of the primary heat exchanger. It shuts
±4
down the burner by closing the gas valve when the temperature rises above 105°C . It restarts
±7
automatically the burner when temperature is dropped below 65°C ;
§ Flue pressure switch: differential type; this switch controls over the correct operation of the flue fan. In
case of operation failure or obstructed exhaust terminal, it stops the heater until the normal operating
condition is restored;
§ Two-stage thermostat (TC) (adjustable): it permits automatic control of the water temperature and
±3
selects high and low flame level. Temperature adjustable between minimum 44 °C (complete anti-
±3 nd
clockwise rotation) and maximum 84 °C. Differential for the 2 stage intervention is 11°C;
§ Expansion vessel: closed membrane-type with a capacity of 7.5 l; preloaded to 0.8 bar ( in the 4 pipe
unit the expansion vessel is present only in the heater module and therefore for the chiller is to be
foreseen another one in the system; to be done by the user);
§ Water pressure switch (PD); this device prevents the start of the heating module when system is
under the pressure; it will not measure the correct difference between measured points and as the
consequence the adequate water flow;
§ 3 way electric driven valve for the summer/winter commutation;
§ Automatic breather device in the heater circuit;
The units, moreover, are equipped with following components, certified by ISPESL:
§ High temperature automatic limit switch (STB) with manual reset; placed at the outlet pipe if the heat
exchanger flue/water; if temperature reach a 100°C, it stops the main burner and pilot flame; the reset of
this thermostat is by pressing the button on command board of the heater module, by unscrewing first
the protection cap;
§ Regulation automatic thermal switch (TC2) for the outlet hot water temperature regulation; maximum
±3
operating temperature is 90°C with range between 0 - 87 °C. It stops the main burner and the pilot
flame. The burner is automatically restarted when temperature decrease for approximately 4°C.
§ Safety valve (VS) for the hydraulic system with the regulation pressure of 3 bar;
§ Limit pressure switch (IP) with manual reset, prevent the start and operation of the heater if water
pressure is above 3 bar. The reset of the switch is possible only if pressure is decreased under
approximately 2,6 bar;
10 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
2.4 VERSIONS AND MODELS
Model ACF 60-00
This unit is only air conditioning unit (it’s producing only chilled water).
Model AYF 60-108/2 - two pipes version
This unit is air conditioning and heating unit with two pipes for chilled / hot water. It produces only chilled or
only hot water. The appliance is controlled by external control board, which is not delivered with the unit.
Model AYF 60-108/4 - four pipes version
This unit is a cooling and heating unit with four pipes for chilled / hot water. It produces chilled and hot water
separately. The chiller and the heater are two totally independent appliances; all piping and electric work are
separated from each other. The appliance is controlled by an external control board, which is not delivered
with the unit.
CIRCUIT
CHILLED – HOT WATER
VD
LEGEND:
PD
IP
VD THREE WAY EL. DRIVE VALVE
PD DIFFERENTIAL PRESSURE SWITCH
VE IP WATER PRESSURE SWITCH
CHILLER MANUALLY RESET
TC
VE EXPANSION VESSEL 7,5 LIT. PRESSURE 0,8 bar
STB TC2 TC HOT WATER REGULATION THERMOSTAT
VS STB SAFETY THERMOSTAT 100°C
MANUALLY RESET, ISPESL CERTIFIED
TL TC2 THERMAL REGULATION SWITCH
0 – 90°C, ISPESL CERTIFIED
HEATER VS SAFETY VALVE 3 bar, ISPESL CERTIFIED
TL HIGH TEMP. SWITCH – AUTOMATIC RESET
Figure 2 – SIMPLIFIED FUNCTIONAL DIAGRAM OF THE AYF 60-108/2 UNIT (2 PIPE VERSION)
CIRCUIT
CHILLED WATER
CIRCUIT
HOT WATER
PD LEGEND:
IP
PD DIFFERENTIAL PRESSURE SWITCH
VE IP WATER PRESSURE SWITCH
CHILLER
TC
MANUALLY RESET
VE EXPANSION VESSEL 7,5 LIT. PRESSURE 0,8 bar
STB TC2
TC HOT WATER REGULATION THERMOSTAT
VS STB SAFETY THERMOSTAT 100°C
MANUALLY RESET, ISPESL CERTIFIED
TL
TC2 THERMAL REGULATION SWITCH
0 – 90°C, ISPESL CERTIFIED
HEATER VS SAFETY VALVE 3 bar, ISPESL CERTIFIED
TL HIGH TEMP. SWITCH – AUTOMATIC RESET
Figure 3 – SIMPLIFIED FUNCTIONAL DIAGRAM OF THE AYF 60-108/4 UNIT (4 PIPE VERSION)
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 11
2.5 TECHNICAL DATA
1. Characteristics under normal operating conditions: External air temperature 35°C. Chilled water outlet temperature 7.2°C; Chilled
water inlet temperature 12.7°C. Under operating conditions differing from the rated ones refer to Table 1.
2. LOW HEAT VALUE 34,02 MJ/m3 (1013 mbar – 15°C)
3. HIGH HEAT VALUE 46,34 MJ/kg (1013 mbar – 15°C)
4. The fan speed (rpm) is reduced when external temperature is under 33°C;
5. Taken at 5 meters away from the unit with half-reflected basement;
6. +/- 10% as the function of the voltage of electric supply and of absorption tolerance of electric motors
12 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
TECHNICAL CHARACTERISTICS AYF AYF AYF S
60-108/2 60-108/4 LOW
NOISE
CHILLER
THERMAL INPUT (BURNER) kW 23,74
1
COOLING CAPACITY kW 17,49
BTU 60.000
CHILLED WATER FLOW - NOMINAL l/h 2.735
- MINIMAL l/h 2.500/3.200
2 3
GAS CONSUMPTION: NATURAL GAS (G20) m /h 2,51
3
(15°C-1013mbar) LPG. (G30/G31) kg/h 1,86
3
AIR FLOW THROUGH CONDENSER MAXIMUM m /h 10.200
MINIMUM 3
m /h 3.500
45
SOUND PRESSURE LEVEL MAXIMUM dB(A) 58 54
MINIMUM dB(A) 47 47
HEATER
THERMAL INPUT (BURNER) kW 31
HEATING OUTPUT kW 28,4
BTU 97.000
REDUCED HEAT OUTPUT kW 15
HOT WATER FLOW - NOMINAL l/h 2.735 HEATER
2.000 SEE
- MIN/MAX l/h 2.500/3.200
1.400/2.400 BASE
MODEL
2 3
GAS CONSUMPTION: NATURAL GAS (G20) m /h 3,28
3
(15°C-1013mbar) LPG (G30/G31) kg/h 2,42
DROP PRESSURE THROUGH THE UNIT mWS 4,5 CHILLER
SEE
bar 0,44 3,9 / 0,38
BASE
HEATER MODEL
3,9 / 0,38
ELECTRICAL POWER SUPPLY
VOLTAGE 230V-50 Hz single phase
6
WATTAGE CHILLER W 820 920
6
HEATER W 60 60
PIPELINE INSTALLATION
WATER INLET/OUTLET CHILLED “F 1¼ 1¼ SEE
HOT BASE
- “F 1 ¼ “M 1
MODEL
GAS ”M 1
FLUE DIAMETER mm 80
PHYSICAL DATA
WEIGHT (when operating) kg 460
DIMENSIONS LENGTH mm 1.240 1.240
WIDTH mm 1.230 1.230
HEIGHT mm 1.190 1.260
1. Characteristics under normal operating conditions: External air temperature 35°C. Chilled water outlet temperature 7.2°C; Chilled
water inlet temperature 12.7°C. Under operating conditions differing from the rated ones refer to Table 1.
2. LOW HEAT VALUE 34,02 MJ/m3 (1013 mbar – 15°C)
3. HIGH HEAT VALUE 46,34 MJ/kg (1013 mbar – 15°C)
4. The fan speed (rpm) is reduced when external temperature is under 33°C;
5. Taken at 5 meters away from the unit with half-reflected basement;
6. +/- 10% as the function of the voltage of electric supply and of absorption tolerance of electric motors
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 13
®
1170
1190
20
®
1170
1190
20
GAS WATER
67 356 427 310 80 CONNECTIO
1240 1230
14 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
70
®
1170
1260
20
CONNECTION PANEL
67 356 356 71 (see detail)
850 1230
®
1170
1260
20
GAS WATER
67 356 427 310 80 CONNECT.
1240 1230
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 15
HEATING MODULE CHARACTERISTICS
8 °C
5,5 11 °C
13 °C
PRESSURE DROP mWS
17 °C
5
4,5
3,5
3
2.500 2.600 2.700 2.800 2.900 3.000 3.100 3.200 3.300
Table 3 – ACF 60-00 UNIT’S PRESSURE DROP BY DIFFERENT INLET WATER TEMPERATURES
6,5
8 °C
6 11 °C
13 °C
5,5 17 °C
PRESSURE DROP mWS
4,5
3,5
3
2.500 2.600 2.700 2.800 2.900 3.000 3.100 3.200 3.300
WATER FLOW l/h
Table 4 – AYF 60-108/2 UNIT’S PRESSURE DROP (2 PIPE VERSION) BY DIFFERENT INLET WATER TEMPERATURES
16 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
AYF 60-108/4 – CHILLER ONLY PRESSURE DROP
8 °C
5,5 11 °C
13 °C
PRESSURE DROP mWS
17 °C
5
4,5
3,5
3
2.500 2.600 2.700 2.800 2.900 3.000 3.100 3.200 3.300
Table 5 – AYF 60-108/4 CHILLER ONLY PRESSURE DROP (4 PIPE VERSION) BY DIFFERENT INLET WATER TEMPERATURES
5
PRESSURE DROP mWS
0
750 1.000 1.250 1.500 1.750 2.000 2.250 2.500 2.750
WATER FLOW l/h
Table 6 – AYF 60-108/4 HEATER ONLY PRESSURE DROP (4 PIPE VERSION) BY DIFFERENT INLET WATER TEMPERATURES
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 17
3 INSTALLATION
WARNING
The electrical safety of the unit is obtained only when it’s correctly connected to an efficient grounding
system, made according existing applicable safety standards. Never use gas supply piping to ground
the appliances. The grounding wire should be longer than phase wires. It’s required for safety reasons.
If the cables are accidentally stretched the grounding will be last to break. In this way a good grounding
continuity will be assured
18 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
3.2 INSTALLATION OF THE UNIT
Also the installation in building corners, where air turbulence can take place resulting in the accumulation of
leaves or similar which might amplify the unit noise (reverberation), is to be avoided.
Around the unit a free space is to be provided to allow proper intake of the air needed for the unit cooling and
for servicing.
The minimum clearance from walls, obstructions and other units should be as follows (see Figure 10):
• right/left side: 45 cm
• rear side: 60 cm
• front side: 80 cm
Obviously, the national and international norms regarding heater/boiler installation for AYF 60-108 units, are
to be respected.
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 19
GOOD
IDEAL
GARAGE
BEDROOM LIVING
AVOID
ROOM
INSTALLATION IN
THIS AREA
BETTER
600
FRONT
800
800
600
FRONT
800
800
The units MUST NOT be installed where exist obstructions or structural overhangs (roof edges,
balconies) over the top of the unit. The re-circulation of the air discharged from the condenser, which
results in a poor unit performance, must be avoided.
When the unit is installed in proximity to buildings, keep the unit away from the roof edge drip line. In no case
the unit should be placed less than 2 metres from any external air intakes of the building. For installation on
balconies or roofs, the unit should be located not less than 2.5 metres from chimney flues, outlets and other
such vents. In other words, it should not be installed in such a manner that hot or contaminated air may be
drawn into the air intakes of the unit (see Figure 11).
20 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
4m
min
2,5 m min. 2,5 m min. . 2,5 m min.
® ®
Figure 11 –CLEARANCES FROM VENTING OUTLETS, CHIMNEY FLUES AND AIR INTAKE OPENINGS
GROUND INSTALLATION
Place the appliance on duly leveled surface made of fire-retardant material.
The appliance should be at least 20 cm above the surface level in order to permit correct fresh – cooling air
circulation.
When a level surface not available, build a concrete slab; at least 10cm thick and slightly larger than the unit
base - approx. 10cm each side (see Figure 12).
Unit must be elevated above surface by approximately 20cm..
For this purpose there are available steel frames (as accessories), or alternatively:
- for the ACF 60-00 models, place 5 concrete blocks (20x20x40cm) under each corner of the chiller and
one in the centre of the chiller.
- for the AYF 60-108 models, place 7 concrete blocks (20x20x40cm): i.e. four under each chiller corner,
one under the centre of the chiller and two under the corners of the heater module. (see Figure 12).
1100 1500
415
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 21
Provide for a gangway all around the unit for maintenance purposes.
Installation on roofs directly above sleeping quarters should be avoided if possible. If not possible, special
consideration must be given to the transmission characteristics of the building structure, the use of vibration
isolators under the equipment (acoustically insulated bases) and approved flexible connections (vibration-
dampening pipe fittings) between the unit and the system piping is recommended.
The steel frames (available as accessories) are provided with vibration dampening pads.
LEVELING
The unit should be level both front to back and side to side. Placing a level on the top of the unit can check
the level.
If unit is not level, metal shims are recommended for use under proper corners to level. In the event that the
above mentioned optional frame is used, the unit height can be suitably adjusted by means of the vibration-
dampening feet. If the shim thickness exceeds 13mm, one more shim should be inserted under the center of
the unit (AYF 60-108 model only).
22 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
4 HYDRAULIC AND GAS INSTALLATION
- FITTINGS WITH PRESSURE TEST POINTS (available as accessories for ACF and AYF units) or
WELLS and PRESSURE GAUGES at inlet and outlet water line;
- FLEXIBLE JOINTS (HOSES) for the water and gas connections;
- WATER FLOW REGULATION VALVE (2 valves for “4 pipes” unit) – gate valve/s or mitre valve;
- MANOMETERS AND RESPECTIVE WELLS at inlet and outlet chiller water lines;
- THERMOMETERS AND RESPECTIVE WELLS at inlet/outlet chilled water lines (only for AYF 60-
108 model);
- CHILLED WATER FILTER – mounted at water inlet line (2 filters if “4 pipes” unit);
- ON/OFF WATER AND GAS VALVES (ball type);
- WATER CIRCULATION PUMP – mounted on the water inlet line (2 pumps if “4 pipes” unit);
- SAFETY VALVE – 3 bar (if needed);
- WATER CHARGE SYSTEM - (2 systems if “4 pipes” unit);
- DISCHARGE VALVE – to be installed at piping in the case of water discharge (approx. ؽ”);
- EXPANSION VESSEL
ACF 60-00
this model is supplied without expansion vessel. It’s necessary, therefore, to foreseen the expansion
vessel properly calculated (maximum thermic water expansion and maximum water pressure);
AYF 60-108
“2 pipes” appliance is equipped with an expansion vessel with 7,5-liter capacity. This, membrane
type of vessel, is used for both hot and chilled water circuits.
“4 pipes” appliance is equipped an expansion vessel with 7,5-liter capacity only for hot water
circuit. For chilled water the expansion vessel must be foreseen at the piping.
- AIR BREATHING SYSTEM;
In the case that automatic water charge systems are in use, the glycol percentage is to be controlled once a
year.
The correct chilled water flow must be guaranteed both when the appliance is operating and during the shut
off period (215 seconds, between turn-off the burner and complete shut-off of the appliance).
Piping (diameters of tubes etc.) must be calculated in order to guarantee the chilled water flow necessary for
the proper operation of the appliance (for a pressure losses refer to Tables 3 and 4)
When rigid tubes are used its recommended using flexible joints between the appliance and piping in order
to dump the possible vibrations.
All piping must be properly insulated to avoid thermal losses and creation of condenses (in order to be
conform to the norms in force).
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 23
ACF 60-00 UNIT
GAS
P
1 2 3 4 5 6 7
LEGEND:
1 PRESSURE GAUGES 5 ON/OFF VALVES
2 FLEXIBLE HOSES 6 WATER PUMP
3 WATER FILTER 7 EXPANSION VESSEL
4 WATER FLOW REGULATION VALVE
NOTE: ANTIFREEZE GLYCOL MUST BE ADDED TO CHILLED WATER
GAS
P T
P T
1 2 3 4 5 6 7 8
LEGEND:
The AYF 60-108/4 unit does not produce directly the sanitary hot water.
Therefore if the AYF 60-108/4 (4 pipes version) used for air-conditioning, heating and sanitary hot water
production simultaneously, the hot water storage boiler is to be foreseen (see Figure 15).
24 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
T
BOILER
AYF 60-108/4 12
10 11
P 5 T
P T
P 8
GAS
P
9
1 2 3 4 6 7
Figure 15 – AYF 60-108/4 “4 PIPES” SINGLE UNIT; PIPING DIAGRAM WITH REMOTE BOILER FOR HOT WATER PRODUCTION
The connections for water and gas piping are placed on the "connection panel" on the right hand panel of the
appliance ACF 60-00 (see Figure 16 ) and on the rear panel of the appliance AYF 60-108 (see Figure 17
and Figure 18).
WARNING
When AYF 60-108/4 (4 pipes version) is installed with sanitary hot water storage boiler, it is important to
use antifreeze glycol suitable for this type of installation (plant).
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 25
ACF 60 –00
158
Connection Panel
G A OUTLET ∅ 1 ¼” F
B INLET ∅ 1 ¼” F
100
B G GAS ∅ ¾” F
50
A
70
107 70
B A OUTLET ∅ 1 ¼” F
A B INLET ∅ 1 ¼” F
85 40
G G GAS ∅ ¾” M
76 927 90 137
B
A B COOL WATER INLET ∅ 1” M
G C HOT WATER OUTLET ∅ 1 ¼” F
D HOT WATER INLET ∅ 1 ¼” F
G GAS ∅ ¾” M
76 927 90 137
26 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
4.2 GAS SUPPLY PIPING
The installation of the gas supply piping should comply with the rules and standards currently in
force.
The gas inlet pressure to the chiller must not be more than 28 and 30 mbar for LPG (G30/G31), and between
17 and 25 mbar for Natural Gas (see Table 7).)
WARNING
Gas supply pressure higher than prescribed could damage the gas valve and cause the danger.
The connection of the gas piping to the unit must be provided with shut-off valve approved for gas use.
LPG systems a first-stage pressure reducer of the required flow rate close to the liquid gas tank to reduce
pressure to 1.5 bar as well as a second-stage reducer for further pressure reduction to 0.03 bar (30 mbar)
direct upstream the unit.
Be sure to use materials resistant to the LPG corrosive action when making pipe connections.
Vertical gas piping must be provided with a trap and a condense drain which may generate inside the piping
during the cold season. Insulation may also be necessary for the gas pipe to avoid excessive condense
formation.
Below are indicated the gas consumption of the ACF 60-00 and AYF 60-108 units.
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 27
4.3 DUCT FLUE EXHAUST – AYF 60-108 MODEL
The heater installed inside the heating module is a forced-draught Type C53 design. When the installation
requires a flue for the exhaustion of the products of combustion, this shall be done according to the
standards in force.
Close to the combustion air intake duct, under the elbow, 4 diaphragms are placed one on top of another
with decreasing dimensions (hole diameter) from bottom to top.
In the following table are indicated the available heads for the exhaust duct according to the diaphragm
used.
1240
28 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
5 ELECTRICAL CONNECTION
NOTE
- An error in wiring installation could cause the problems during the unit’s operation and
could damage the electrical components of the appliance;
- The unit must be electrically grounded in accordance with the manufacturers and national
requirements. Otherwise, it could cause the problems during the unit’s operation.
- The power supply line must not be used to turn off/on the appliance. For this purpose is to
be used Remote Control device (optional) or ON/OFF switch on R-Y line.
- Disconnect the power supply lines only when assured that unit is completely shut off (the
fan is stopped).
ACF 60-00 wiring consist in of connecting the power supply line to the high voltage terminals
inside the chiller;
AYF 60-108 wiring consists in of connecting the power supply current to the high voltage terminals
inside the heating module; electrical connections between chiller and heater are
already factory wired;
ATTENTION
Do not operate the appliance unless the chilled-hot water system is not filled with water and antifreeze.
WARNING
When Remote Control device (available as optional) is used to control the operation of the units, it
is necessary to consult “Installation and Programming manual or Remote Control device”.
Here reported instructions and diagrams are to be applied when Remote Control device is NOT
USED.
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 29
§ appliance’s on/off switch; could be programmable timer or thermostat or any “clean” contact between R
and Y terminals;
§ pump switch if water pump is controlled by electronic control board; or time delay relay which controls the
pump operation (10 minutes approx.) when electronic board is by-passed;
NOTE
On the electronic board of the unit is mounted Reset Button of the flame control box (detail D Figure 1).
It is possible to remote this function by use of suitable switch which is to be wired as shown on the Figure
19 and Figure 21.
CONNECTION TO BE DONE
ACF 60-00 CONTROL BOARD
BY INSTALLER
LEGEND:
Figure 19 –ACF 60-00 UNIT WITH DIRECT DRIVEN PUMP - CONNECTIONS TO BE DONE BY INSTALLER
30 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
LEGEND:
COLLEGAMENTI A CURA
DELL’INSTALLATORE
Figure 20 – ACF 60-00 WITH PUMP CONTROLLED BY RELAY - CONNECTIONS TO BE DONE BY INSTALLER
NOTE
On the electronic board of the unit is mounted Reset Button of the flame control box (detail D Figure 1)
and Lockout lamp inside the heater module (see PSC Figure 30).
It is possible to remote this function by use of suitable switch which is to be wired as shown on the Figure
30.
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 31
LEGEND
IG - MAIN SWITCH (not supplied)
IC - ON/OFF SWITCH (not supplied: timer, progr. ecc.)
CONNECTION TO BE DONE EI - SUMMER/WINTER SWITCH (not supplied)
BY INSTALLER PSA - CHILLERS RESET BUTTON (not supplied)
PSC - HEATERS RESET BUTTON (not supplied)
SBA - CHILLERS ERROR LOCKOUT LIGHT (not supplied)
SBC - HEATERS ERROR LOCKOUT LIGHT (not supplied)
R3 - TIME DELAY RELAY (10 MINUTES)
FOR THE WATER CIRCULATION PUMP (not supplied)
N.B. - CONNECT THE POWER SUPPLY (230V-50Hz)
BY RESPECTING PHASE AND NULL
- CONNECT A GROUNDING TO THE CORRECT TERMINAL
- MOUNT THE SWITCH AND FUSE CONFORM
TO THE NORMS AND SUITABLE FOR
APPLICATION
CUT THE RESISTANCE RFC PLACED ON THE
ELECTRONIC BOARD
(LOWER LEFT CORNER).
CONNECTION TO BE
DONE BY INSTALLER
Figure 21 –AYF 60-108/2 (2 PIPES VERSION) WITH PUMP CONTROLLED BY RELAY - CONNECTIONS TO BE DONE BY INSTALLER
This model has the separate electrical circuits, in order to control heating and cooling independently.
Electric board is equipped with 2 terminals, which are to be used for the chiller control, and 2 other terminals
to be used for the heater control:
- heater operation control terminals installed at 230V circuit and identified with letters R e W;
- chiller operation control terminals installed at 24 V circuit and identified with letters R24 e Y24.
Another two terminals could be used for pumps control; 9 - 10 heating pump, and 9 – 15 cooling pump (230
V 50 Hz). In this case these pumps are controlled directly by electronic control board. Maximum wattage is
700 W.
Components to be foreseen (see Figure 22 and Figure 23):
§ heater’s on/off switch; programmable timer or room thermostat or the “clean” contact wired at R e W
terminals;
§ chiller’s on/off switch; programmable timer or room thermostat or the “clean” contact wired at R24 e Y24
terminals;
For the pumps (cooling and heating circuits) control:
§ direct driven cooling water pump to 9-15 terminals, and heating pump on the 9-10 terminals with 10
minutes delay relay.
32 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
§ 2 time delay relays which controls the pump operation (10 minutes delay approx.), when electronic board
is by-passed connected to 9-10 terminal for hot water pump and 9-15 terminal for chilled water pump.
NOTE
On the electronic board of the unit is mounted Reset Button of the flame control box (detail D Figure 1)
and Lockout lamp inside the heater module (see PSC Figure 30).
It is possible to remote this function by use of suitable switch which is to be wired as shown on the Figure
24 and Figure 25.
LEGEND
CONNECTION TO BE DONE IG - MAIN SWITCH (not supplied)
BY INSTALLER
IC - ON/OFF SWITCH (not supplied: timer, progr. ecc.)
EI - SUMMER/WINTER SWITCH (not supplied)
PSA - CHILLERS RESET BUTTON (not supplied)
PSC - HEATERS RESET BUTTON (not supplied)
SBA - CHILLERS ERROR LOCKOUT LIGHT (not supplied)
SBC - HEATERS ERROR LOCKOUT LIGHT (not supplied)
R3 - HEATING PUMP TIME DELAY RELAY (10 MINUTES)
FOR THE WATER CIRCULATION PUMP (not supplied)
N.B. - CONNECT THE POWER SUPPLY (230V-50Hz)
BY RESPECTING PHASE AND NULL
- CONNECT A GROUNDING TO THE CORRECT TERMINAL
- MOUNT THE SWITCH AND FUSE CONFORM
TO THE NORMS AND SUITABLE FOR
APPLICATION
CUT THE RESISTANCE RFC PLACED ON THE
ELECTRONIC BOARD
(LOWER LEFT CORNER).
CONNECTION TO BE
DONE BY INSTALLER
Figure 22 – AYF 60-108/4 (4 PIPES VERSION) WITH COOLING PUMP DIRECT DRIVEN AND HEAT PUMP CONTROLLED BY RELAY -
CONNECTIONS TO BE DONE BY INSTALLER
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 33
CONNECTION TO BE DONE LEGEND
BY INSTALLER IG - MAIN SWITCH (not supplied)
IC - ON/OFF SWITCH (not supplied: timer, progr. ecc.)
EI - SUMMER/WINTER SWITCH (not supplied)
PSA - CHILLERS RESET BUTTON (not supplied)
PSC - HEATERS RESET BUTTON (not supplied)
SBA - CHILLERS ERROR LOCKOUT LIGHT (not supplied)
SBC - HEATERS ERROR LOCKOUT LIGHT (not supplied)
R2 - COOLING PUMP TIME DELAY RELAY (10 MINUTES - not supplied)
R3 - HEATING PUMP TIME DELAY RELAY (10 MINUTES)
FOR THE WATER CIRCULATION PUMP (not supplied)
N.B. - CONNECT THE POWER SUPPLY (230V-50Hz)
BY RESPECTING PHASE AND NULL
- CONNECT A GROUNDING TO THE CORRECT TERMINAL
- MOUNT THE SWITCH AND FUSE CONFORM
TO THE NORMS AND SUITABLE FOR
APPLICATION
CUT THE RESISTANCE RFC PLACED ON THE
ELECTRONIC BOARD
(LOWER LEFT CORNER).
CONNECTION TO BE DONE
BY INSTALLER
Figure 23 – AYF 60-108/4 (4 PIPES VERSION) WITH COOLING AND HEATING PUMPS CONTROLLED BY RELAYS -
CONNECTIONS TO BE DONE BY INSTALLER
34 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
LEGEND:
Connection to be done:
IG MAIN POWER SWITCH
IC CHILLER’S ON/OFF SWITCH
PLS EVENTUAL RESET SWITCH
(230 Vac, not supplied)
MT POWER SUPPLY TERMINAL
M PUMP EXTERNAL WATER PUMP
(not supplied)
TRANSFORME
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
R
BRAHMA MT
ACF 60-
35
36
Figure 25 –AYF 60-108/2 (2 PIPES VERSION) UNIT - WIRING DIAGRAM
LEGEND:
S50 ELECTRONIC CONTROL BOARD OF CHILLER B1 ELECTRO VALVE OF PILOT FLAME PD DIFFERENTIAL WATER PRESSURE SWITCH
MT INTERNAL CHILLER ELECTRIC TERMINAL B2 ELECTRO VALVE OF MAIN BURNER PF FLUE FAN PRESSURE SWITCH
RS485 SERIAL CONNECTOR CM32 FLAME CONTROL BOX PSC HEATER RESET BUTTON
EA IGNITER R1 INTERNAL RELAY SUMMER/WINTER SBC HEATER LOCKOUT ERROR LIGHT
ER FLAME SENSOR STB TEMPER. LIMIT SWITCH (MANUAL RESET)
FL CAPACITOR FILTER TC THERMOSTAT FOR HEATER CONTROL
IP PRESSURE SWITCH TC2 AUTOMATIC THERMAL REGULATOR
MCE TERMINAL FOR EXTERNAL COMMANDS TL LIMIT THERMOSTAT
MCI TERMINAL FOR INTERNAL COMMANDS VF FLUE FAN
MOD 2 STAGE VALVE VD 3 WAY ELECTRO VALVE
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
Figure 26 –AYF 60-108/4 (4 PIPES VERSION) - WIRING DIAGRAM
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
LEGEND:
S50 ELECTRONIC CONTROL BOARD OF CHILLER B1 ELECTRO VALVE OF PILOT FLAME PD DIFFERENTIAL WATER PRESSURE SWITCH
MT INTERNAL CHILLER ELECTRIC TERMINAL B2 ELECTRO VALVE OF MAIN BURNER PF FLUE FAN PRESSURE SWITCH
RS485 SERIAL CONNECTOR CM32 FLAME CONTROL BOX PSC HEATER RESET BUTTON
EA IGNITER SBC HEATER LOCKOUT ERROR LIGHT MOD 2 STAGE VALVE
ER FLAME SENSOR STB TEMPER. LIMIT SWITCH (MANUAL RESET) TL LIMIT THERMOSTAT
FL CAPACITOR FILTER TC THERMOSTAT FOR HEATER CONTROL VF FLUE FAN
IP PRESSURE SWITCH TC2 AUTOMATIC THERMAL REGULATOR
MCE TERMINAL FOR EXTERNAL COMMANDS MCI TERMINAL FOR INTERNAL COMMANDS
37
6 START-UP AND ADJUSTMENT
WARNING
This unit should be Started-up by an Authorized Engineers according to the manufacturer
instructions.
The end-user or installer is not authorized to perform start-up and adjustment operations.
The positive result of the first start-up is only related to the good operation of the appliance and involves no
liability as concerns the correct execution of the system.
If during the first start-up an anomalous or dangerous situation is met due non-conform system, neither a
positive report about the first start-up nor the warranty certificate will be handed over.
This user must perform the proper system adjustments indicated by Authorized Engineers.
NOTE
The warranty is applicable only if appliance is started and validated by Authorized Engineers
NOTE
Single ACF units are equipped with breathing device – nipples ¼ “ - mounted on the inlet of chilled
water line into evaporator, in order to ease the filling of the pipeline and the units.
38 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
WARNING
To ensure a correct operation of the unit and avoid water freezing during winter idle times add
the ethyl glycol antifreeze at the circulation water. The quantity of the glycol should be
calculated regarding the minimum external temperature of the installation zone.(see Table 13).
% GLYCOL 10 20 30 35 40
FREEZING TEMPERATURE (°C) - 3,3 °C - 7,8 °C - 13,3 °C - 17,8 °C - 20,8 °C
Table 13 – APPROXIMATELY QUANTITY OF GLYCOL TO BE ADDED INTO THE CHILLED WATER
Table 10 gives the values and correction factor for the water flow as the function of glycol percentage added
at the water. It is important to consider this factor for the calculus of the water pipeline and the water
circulation pump (for the unit's inner pressure drops refer to Table 3 and 4).
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 39
1,2
1,15
CORRECTION FACTOR
1,1
1,05
0,95
0,9
5 10 15 20 25 30 35 40 45
GLYCOL PERCENTAGE %
40 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
6.2 GAS PRESSURE ADJUSTMENT
GAS PRESSURE ADJUSTMENT ACF 60-00 AND CHILLER SECTION OF AYF 60-108
WARNING
This unit should be Started-Up by Authorized Engineers according to the manufacturer
instructions.
The end-user or installer is not authorized to perform start-up and adjustment operations.
The manufacturer supplies the units already adjusted for the type of gas they have been requested. The
latter can be checked and easily identified by looking at the label inside the unit.
Nevertheless, before starting the unit it is advisable to check (and adjust if necessary - see Table 15) the
burner pressure in the following manner:
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 41
§ turn on the heater (close R-W contacts); the presence of the air in the pipes can provoke the problems
regarding the ignition of the burner. In this press the reset button and restart the burner of the heater.
§ with heater on check the pressures (see Table 16)
§ to adjust the pilot flame turn the "Pilot" screw clockwise to reduce the flow rate
§ turn off the heating unit by use of the on/off switch (thermostat, timer etc.) and check the burner arrest;
§ remove the manometer and REPLACE (SCREW) THE GAS TAP "C" ON THE GAS VALVE;
BURNER PRESSURE
GAS TYPE NATURAL GAS LPG (G30) LPG (G31)
MAX PRESSURE 15 mbar 28 mbar 35,5 mbar
MIN PRESSURE 5 mbar 8,7 mbar 11,8 mbar
Table 16 –AYF 60-108 HEATING MODULE - BURNER PRESSURE
A PRESSURE ADJUSTMENT
SCREW
C
B
Figure 27 – GAS VALVE SIT 830 OF ACF 60-00 AND CHILLER SECTION OF AYF 60-108 APPLIANCES
42 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
D C
F A
E
B
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 43
6.3 CHILLED WATER TEMPERATURE REGULATION
Electronic control board permits the regulation of the temperature of the inlet chilled water (ACF 60-00 and
chiller section of AYF 60-108).
For adjust the water temperature use the trimming condenser placed at electronic board (see detail C on the
Figure 29). The range of the outlet water temperature is between 3°C (rotate completely anti-clockwise) and
13°C (rotate completely anti-clockwise).
Temperature difference, ∆t, between inlet and outlet chilled water is 5°C.
The recommended chilled water temperature for commercial/domestic use is 12°C for inlet water
temperature and 7°C for outlet water temperature. The trimmer is in the central position on the scale. Rotate
clockwise to increase the temperature or counterclockwise to decrease it. The new temperature will be
indicated on the electronic display for 15 seconds after the adjustment operation.
The factory default temperature is 7°C.
NOTE
When appliance is turned on, ”CAP” will appear on the display. After few seconds appears “50H”.
When it disappear, the setting temperature of the inlet chilled water thermostat, will be displayed for the
next 15 seconds.
Afterward display shows the real temperature of the inlet water and T between inlet and outlet water
temperature.
The Led diodes (see detail B on the Figure 29) are indicating:
RED LIGHT Inlet water temperature
GREEN LIGHT Temperature difference between inlet and outlet water lines;
LEGEND:
44 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
6.4 HOT WATER TEMPERATURE REGULATION (AYF only)
On the electronic control board of the heating module of AYF 60-108 appliance, is placed the regulation
thermostat in order to adjust the OUTLET HOT WATER temperature.
Use the control button in order to set the desired temperature (see Figure 30).
+3
The temperature ranges of the outlet hot water vary from minimum 44 °C (completely clockwise rotation),
±3
to maximum 84 °C (completely anti-clockwise rotation).
The recommended hot water temperature for commercial/domestic purposes, when fan coil radiators (fan
convectors) used, is approx. 65°C and to set it put the control button in the center of the scale. Rotate the
control button anti-clockwise for increase the hot water temperature and rotate the button for decreases it.
When heating module is operating, using the thermometers installed (by the installer) at the hot water
pipeline, could be checked the hot water temperature.
LEGEND
TC CONTROL BUTTON
HOT WATER ADJUSTMENT
PSC ERROR LIGHT AND
RESET BUTTON
PSC TC
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 45
7 SERVICING AND MAINTENANCE
The correct preventive servicing and maintenance will guarantee the long life of the appliance with high
efficiency and low maintenance costs.
WARNING
Maintenance and servicing of internal components of the appliance are to be carried out ONLY
by an Authorized Engineers strictly complying with the manufacturer’s instructions and the
local standards.
It is recommended to carry out at least once a year the operations described. If appliance is engaged on
heavy-duty installation (industrial plants, 24h-operation etc.) it is necessary to increase the number of annual
checks and services.
NOTE
Before any type of intervention cut-off the power supply on the main switch.
It is recommended to clean the condenser / absorber coils regularly, since the unit cooling capacity
can be seriously reduced by dirt on the coil.
This operation can be carried out directly by user / installer.
46 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
§ Remove the cover panel
§ Use a brush to remove the dirt from outside and inside of the condenser/absorber coil. To clean AYF 60-
108 (see Figure 32) condenser remove the panel between the heating module and chiller.
§ If water jet used for a cleaning move it from in to out and form top to bottom. Insert the water jet between
two coils.
§ Check that all dirt is removed
§ Replace the Casing
REAR VIEW RIGHT HAND SIDE VIEW LEFT HAND SIDE VIEW
ACF 60-00 ACF 60-00 ACF 60-00
REAR VIEW RIGHT HAND SIDE VIEW LEFT HAND SIDE VIEW
AYF 60-108 AYF 60-108 AYF 60-108
NOTE
Do not use the dissolvents for cleaning the condenser because it can damage the coating of the
aluminium fins or aluminium fins itself.
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 47
8 TROUBLE-SHOOTING INSTRUCTIONS
If the appliance is not producing chilled or hot water (if AYF 60-108 unit) check the following items before
calling the Authorized Engineers:
§ Check that power supply exists and that main switch is on "ON" position;
§ Check that gas cock is open;
§ Check that all on/off switches (timer, thermostat ON/OFF switch etc.) are in the position which requires
the function on the appliance;
§ Check that appliance is not in ignition error mode (stopped): the burner stop is shown with the red error
light on the reset button, installed by the installer of electrical wiring. When reset switch pressed the error
light will turn off and the appliance will restart the ignition operation. In the case when frequent burner
stops are occurring call the Authorized Engineers.
If after all these operations the appliance not starts, do not try to repair the unit but call Authorized
Engineers.
When the chiller is in ERROR mode (stopped), electronic board’s display will indicate the error code. The
blinking character E, followed by two numbers composes error code. This error code is visible from the
opening on the protection shield of the electronic control board.
48 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
CODE ALARM DESCRIPTION
E05 EXTERNAL TEMPERATURE IN EXCESS OF 45°C
Limit thermostat located at the rear right corner on the bottom of the chiller. If the external temperature
is under 45°C, check:
- Natural air circulation (roof overhang or overhead obstructions could provoke the problems)
- The correct position of sensing bulb;
- Sensing bulb; damaged (to be exchanged)
E06 EXTERNAL TEMPERATURE BELOW -12°C
Limit thermostat located at the upper rear right corner of the chiller. If the external temperature is above
–10°C, check:
- Thermostat; damaged (to be exchanged)
E07 GENERATOR LIMIT TEMPERATURE OVER 160°C
Sensed by Generator Temperature Probe, located at the generator, close to the Limit temperature
Thermostat. It’s a warning alarm. Could be caused by black - out or start of the appliance at low
temperatures (under 10°C). Survey the machine next 30 minutes. The third E07 alarm in 60 minutes
will stop the chiller and E08 error will appear on display.
E08 GENERATOR LIMIT TEMPERATURE 160°C REACHED 3 TIMES WHITIN 1 HOUR
Sensed by Generator Temperature Probe, located at the generator, close to the Limit temperature
Thermostat.
Check:
- Tightness of generator’s safety valve
- Gas pressure on the burner;
- Generator Temperature Probe position;
- Combustion Gases blow-by;
- Turn on the chiller and using the gauges measure the pressures of sealed refrigeration unit;
E09 BURNER MALFUNCTION
This alarm is generated by Generator Temperature Probe.
Check:
- Combustion blower motor;
- Combustion Pressure switch; check the air tubes, connection to the probes and functionality;
- Flame control box fuse 3,15 A;
- Flame control box power supply (from electronic board);
- Connection, location and functionality (damage) of Generator Temperature Probe;
E10 CHILLED WATER FLOW SWITCH;
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 49
CODE ALARM DESCRIPTION
E12 FLAME CONTROL BOX LOCKOUT
Water temperature probe is located at chiller water outlet tube (thermometer well).
Check:
- Wiring to the electronic board;
- Before exchange the probe, check with the new probe that error disappear from display (connect
the wires to THM ;connector at electronic board);
E17 INLET CHILLER WATER TEMPERATURE PROBE FAILURE
Water temperature probe is located at chiller water inlet tube (thermometer well).
Check:
- Wiring to the electronic board;
- Before exchange the probe, check with the new probe that error disappear from display (connect
the wires to THR ;connector at electronic board);
E18 CONDENSER TEMPERATURE PROBE FAILURE
The condenser temperature probe is located at condenser outlet tube.
Check:
- Wiring to the electronic board;
- Before exchange the probe, check with the new probe that error disappear from display (connect
the wires to TCN ;connector at electronic board);
E19 EXTERNAL TEMPERATURE THERMOSTAT FAILURE
Limit thermostat located at the rear upper right corner of the chiller.
Check:
- Wiring to the electronic board;
- Before exchange the thermostat, check with the new probe that error disappear from display
(connect the wires to TA ;connector at electronic board);
E20 GENERATOR TEMPERATURE PROBE FAILURE
Generator Temperature Probe is located at the generator, close to the Limit temperature Thermostat.
Check:
- Wiring to the electronic board;
- Before exchange the thermostat, check with the new probe that error disappear from display
(connect the wires to TG ;connector at electronic board);
Note: After the exchange of the defective component, the display will be automatic reset, if the power supply is
interrupted for at least 5 seconds.
Error Codes are hierarchically ordered (when several errors are to be displayed the greater Codes will appear
first at the display).
50 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
APPENDIX - ADAPTING TO ANOTHER TYPE OF GAS
NOTE
All operation described in this Appendix are to be carry out ONLY by an Authorized Engineers.
ACF 60-00 AND CHILLER SECTION OF AYF 60-108 - ADAPTING TO ANOTHER TYPE OF GAS
If the type of gas indicated does not correspond to the type to be used (Natural gas or LPG) by unit, it
must be converted and adapted to the type of gas to be used. The nozzle and diffuser must be
exchanged.
For this operation proceed as follows (see Figure 33):
§ Turn off the gas and electrical supply;
§ Remove the front panel;
§ Remove the gas inlet pipe from gas valve by removing the 4 screws from the valve flange (use 3mm
socket head wrench);
§ Remove the air diffuser between blower fan and air inlet tube; remove 4 screws (7mm wrench) of blower
fan and 3 screws of air inlet tube;
§ Remove 2 nuts of gas valve support (use 8mm wrench)
§ Replace the nozzle with those having suitable diameter for the gas to be used (see Table 15). Use
wrench 12mm;
§ Replace the air diffuser with one suitable for the type of gas to be used. Put particular attention on the
correct installation of the gaskets between diffuser-air intake tube and diffuser-blower fan.
§ Adjust the unit pressure according to the Table 15 for the gas to be used, following the instructions
reported in "Gas pressure adjustment";
§ Replace the stickers indicating the type of gas for which the unit is preset with the new one which
indicates the type actually used
LEGEND:
C AIR-GAS DIFFUSER
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 51
HEATING MODULE OF AYF 60-108 - ADAPTING TO ANOTHER TYPE OF GAS
§ Turn off the gas and electrical supply;
§ Remove the front and right hand side panel of the boiler chamber
§ unscrew the gas pipe union A (see Figure 34) connecting the burner ramp B
§ loosen the two side screws C that retain the nozzle holding ramp B (the use of a hexagon wrench is
recommended)
§ withdraw ramp B
§ remove all nozzles E and replace them with those having a diameter suitable for the gas to be used (see
Table 18);
§ be sure the nozzles are not obstructed not even in part from impurities; this will result in a variation in
combustion;
§ check that the diameter stamped on the nozzles corresponds to that required for the gas to be used;
§ besides nozzles, also the nozzle aluminium gaskets should ALWAYS be replaced;
§ mount nozzle holding ramp B again;
§ connect the gas pipe union A again by fitting a new gasket;
§ shunt together the three pressure switch contacts (see detail PF Figure 25 o Figure 26);
§ ignite the burner with sealed chamber front panel removed;
§ check gaskets for proper sealing;
§ remove the pressure switch shunts;
§ adjust the burner gas pressure as illustrated in the Section "Gas pressure adjustment";
NOZZLES
GAS TYPE NATURAL GAS (G20) LPG (G30) LPG (G31)
Burner nozzles N° and ∅ 28 x 0,89 28 x 0,53 28 x 0,53
Pilot nozzle hole N° and ∅ 2 x 0,27 1 x 0,24 1 x 0,24
Table 18 –AYF 60-108 HEATING MODULE - BURNER NOZZLES NUMBER AND DIAMETER
E A B
52 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108
To replace the Pilot nozzle:
§ remove the front panel M placed under the valve (see Figure 34)
§ using a hexagon wrench, loosen the nut F securing the small pipe which supplies the pilot burner (see
Figure 34);
§ take the pipe from its housing
§ remove the existing nozzle G and fit the new nozzle maintaining the same position
§ insert the gas pipe with its double cone and tighten the hexagonal head nut F fully
§ check the gas leakage with soapy foam;
§ mount the front panel;
§ connect gas and power supply;
Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108 53
54 Installation, Start-Up, Use and Maintenance Manual – Models ACF 60-00 and AYF 60-108