Acf Ayf S50

ACF 60-00 AND AYF 60-108 (S50) INSTALLATION MANUAL
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
A qualified service engineer must verify that:

The electric and gas supply ratings are the same as indicated on the type plate;
The fuel supply and the water distribution systems are water tight;
The appliance is supplied with the type of fuel for which it is preset;
The gas supply pressure is conform to the one indicated on type plate;
The gas supply system is appropriately designed for the gas rate needed by the unit, and equipped by all
safety and control devices prescribed by standards in force;
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 (available as optional) consists of a

control box (that may be fixed on the wall or built in the main
electric board) with a display (4 lines, 20 characters each)
that shows all the operating conditions and faults of all the
each single connected unit.
Remote control device:
• includes timer in order to program the operation of
the units
• controls inlet and outlet chilled water temperature
• allows modular flexibility of cooling/heating capacity
in order to meet requested cooling/heating demands
• displays operating parameters of each connected
unit (temperatures, error codes) and gives the
possibility to reset the units
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.
2.2 GAS FIRED CHILLER OPERATION CYCLE
DESCRIPTION OF THE ABSORPTION REFRIGERANT CYCLE

The fluid used for the cooling system is a solution of water and ammonia. The ammonia is the refrigerant
and the water is the absorbing fluid. In chiller’s generator, the ammonia-water solution is heated until
reaching the boiling temperature, producing on one hand a vapor with a strong concentration of ammonia
and on the other a liquid solution with a low concentration of ammonia.
Ammonia vapor passes into the rectifier where it is separated from the water it contains. The hot and
pressurized ammonia vapor exiting the rectifier enters the condenser, where it’s liquefied after being cooled
down to external temperature.
Low temperature ammonia liquid enters in the accumulator of refrigerant, which, concerning the chiller’s
operational parameters (air temperature, fluid temperature in the evaporator etc.) optimizes the system. This
tank of the liquid ammonia permits the reduction of the ammonia evaporation pressure.
Liquid ammonia is then brought to a lower pressure by means of a restrictor, further cooled in a “tube in
o
tube” heat exchanger and finally brought to a pressure of 2.7 to 4 bars and a temperature lower than +3 C by
way of a further restrictor.
Under these low pressure and low temperature conditions, liquid ammonia enters the evaporator, where it
evaporates by removing heat from water flowing from the users (thermal blowers, fan-coils, etc.) within the
air conditioning system and thus cooling it down.
The cold and low-pressure ammonia vapor exiting the evaporator flows into a «tube-in-tube» exchanger (by
exchanging heat with the liquid ammonia coming from the condenser). Then passes into the “solution cooled
absorber”, where it enters into touch with the poor solution coming from the generator and brought to a low
pressure by a special restrictor.
Inside the “solution cooled absorber” the absorption process starts, i.e. the dilution of ammonia vapor into the
«poor solution». The absorption is an exothermic process, therefore to absorb completely the vapor by the
solution, the solution exiting the “solution cooled absorber” must be further cooled down in a portion of the
condenser-absorber coils.
Once the absorption process is ended, the liquid solution contains a high concentration of ammonia, also
called the «rich solution». It’s pumped back to the generator at high pressure using a diaphragm pump
(operated by a hydraulic pump).
The solution is preheated both inside the coil of the rectifier and the solution cooled absorber (the GAX
section) and returned to the generator where a new cycle starts.
DESCRIPTION OF THE CHILLER OPERATIONS

- All chiller functions and its operations are monitored and controlled by the internal microprocessor
incorporated at the electronic control board
- The temperature probes, placed at the system in order to monitor the operation of the chiller, are
transferring the operating temperatures to the microprocessor:
- outlet chilled water temperature probe;
- inlet chilled water temperature probe;
- probe at ammonia outlet from condenser;
- external ambient temperature probe;
- generator temperature probe;
- Further control of the chiller’s operation is carried out by:
- high limit temperature switch
- sealed circuit limit pressure switch;
- water flow switch;
- flue pressure switch;
- chilled water thermostat;
- hydraulic pump rotation probe;
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
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).
- When chiller is running, its operation is continuously monitored by:

- temperature probes ; in the case of the short circuit or missing signal form the probe the appliance will
be immediately stopped and respective error code will be displayed at the electronic control board.
- high limit thermostat generator thermostat and limit pressure switch, both with manual reset. The
intervention of any of these safeties cause immediate arrest of the appliance and respective error
code will be displayed at the 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.
CHILLER’S COMPONENTS AND MAIN CONSTRUCTIVE FEATURES

Generator: made of mild steel, packaged baffle column type, vapor rectifier integrated, externally finned on
the combustion chamber portion in order to improve the heat exchange characteristics.
Condenser – Absorber: two integrated circuits made of steel tubes, with induction-welded elbows and
aluminum fins. Front surface is designed to ensure condensation at external temperatures up to 45°C.
Evaporator: tube in shell type heat exchanger; titanium stainless steel; high efficiency heat exchange which
guarantee excellent performances of the unit, in a wide conditions of operation; thermal dispersions are
reduced by polystyrene insulation.
Accumulator of refrigerant: made of Stainless steel AISI 304 and it is mounted after the evaporator. The
“tank” of accumulator guarantees the optimization of the chiller’s parameters even with high ambient
temperatures or low refrigerant fluid evaporation temperatures and it reduces/controls the evaporation
pressure of the refrigerant in order to optimize the system.
Solution pump: volumetric pump with Teflon diaphragm, operated by one-piston oil pump;
Solution Cooled Absorber: mild steel tube in shell heat exchanger;
Refrigerant Heat Exchanger: stainless steel “tube in tube” heat exchange;
Restrictors for ammonia and “poor solution”: stainless steel “drilled steel disk” type;
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;
C
LEGEND:
A DISPLAY - SHOWS OPERATIONAL PARAMETERS

B SIGNAL LED DIODES:
- RED LIGHT: Inlet water temperature
- GREEN LIGHT Temperature difference between inlet and outlet water lines
- YELLOW LIGHT Communication with Remote Control
- 2nd RED LIGHT Electrical Power Supply ON
C CONTROLLER OF OUTLET WATER TEMPERATURE
D RESET OF FLAME CONTROL BOX
Figure 1 – ELECTRONIC CONTROL BOARD
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);
2.3 HEATING MODULE OPERATION

The heating function of AYF units is provided by the high - performance heater. The heating module is
integrated with the chiller into a single package.
The forced draft flue gases are exhausted through the special exhaust terminal located at the back of the
unit. When requested, a proper connection with a flue can be provided.
Two-stage thermostat allows an automatic reduction of the heat output of the unit.
HEATER’S COMPONENTS AND MAIN CONSTRUCTIVE FEATURES

§ Air tight chamber, thermally insulated;
§ Forced draft of exhausting gases by centrifugal fan;
§ Finned copper water-air heat exchanger;
§ Atmospheric gas burner; multiple gas type; stainless steel construction; low NOx and CO emission.
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;
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)
2.5 TECHNICAL DATA
TECHNICAL CHARACTERISTICS ACF 60-00 ACF 60-00 S

THERMAL INPUT (BURNER) kW 23,74
1
COOLING CAPACITY kW 17,49
BTU 60.000
CHILLED WATER FLOW NOMINAL l/h 2.735
MAXIMUM l/h 3.200
MINIMUM l/h 2.600
PRESSURE DROP THROUGH THE UNIT (NOMINAL) mWS 3,9
bar 0,38
2 3
GAS CONSUMPTION: NATURAL GAS (G20) m /h 2,51
3
(15°C-1013 mbar) LPG (G30/G31) kg/h 1,86
3
AIR FLOW THROUGH CONDENSER MAXIMUM m /h 10.200
3
MINIMUM m /h 3.500
45
SOUND PRESSURE LEVEL MAXIMUM dB(A) 58 54
MINIMUM dB(A) 47 47
ELECTRICAL POWER SUPPLY
VOLTAGE 230V-50 Hz single phase
6
WATTAGE W 820 920
PIPELINE INSTALLATION
CHILLED WATER INLET/OUTLET “F 1¼
GAS ”F ¾
PHYSICAL DATA
REFRIGERANT COMPONENTS H2O kg 10
NH3 kg 6,7
WEIGHT (when operating) Kg 350
DIMENSIONS LENGTH mm 850 850
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
Chilled Water External Temperature (°C)

Outlet Temperature (°C) < 32 35 38 41
Correction parameter of cooling capacity
3,0 1,000 0,969 0,838 0,612
4,0 1,004 0,976 0,853 0,652
5,0 1,011 0,983 0,876 0,708
6,0 1,017 0,993 0,915 0,786
7,0 1,021 1,000 0,946 0,838
8,0 1,023 1,005 0,964 0,880
9,0 1,024 1,009 0,974 0,913
10,0 1,025 1,011 0,978 0,938
Table 1 –CORRECTION PARAMETERS FOR CHILLER CAPACITY
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
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
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
®
1170
1190
20
67 356 356 71 CONNECTION PANEL

(see detail Figure 16)
850 1230
FRONT VIEW RIGHT HAND SIDE VIEW

ACF 60-00 ACF 60-00
Figure 4 – DIMENSIONS OF THE ACF 60-00 UNIT
®
1170
1190
20
GAS WATER
67 356 427 310 80 CONNECTIO
1240 1230
FRONT VIEW SIDE VIEW

AYF 60-108/2-4 AYF 60-108/2-4
Figure 5 – DIMENSIONS OF THE AYF 60-108/2-4 UNIT
70
®
1170
1260
20
CONNECTION PANEL
67 356 356 71 (see detail)
850 1230

ACF 60-00 S ACF 60-00 S
Figure 6 – DIMENSIONS OF ACF 60-00 S (LOW NOISE VERSION) UNIT

70
®
1170
1260
20
GAS WATER
67 356 427 310 80 CONNECT.
1240 1230

AYF 60-108/2-4 AYF 60-108/2-4
Figure 7– DIMENSIONS OF ACF 60-108 S (LOW NOISE VERSION) UNIT
HEATING MODULE CHARACTERISTICS
NOMINAL HEATING OUTPUT kW 28,4

HEATING EFFICIENCY BY NORMAL HEATING INPUT % 91,6
HEATING EFFICIENCY BY 30% OF NORMAL HEATING INPUT % 86,2
THERMAL LOSSES AT THE FLUE WHEN THE BURNER IS ON % 7,8
THERMAL LOSSES AT THE FLUE WHEN THE BURNER IS OFF % 0,4
THERMAL LOSSES THROUGH THE GENERATOR’S CASING % 0,6
Table 2 – CHARACTERISTIC OF THE HEATING MODULE
ACF 60-00 – UNIT’S PRESSURE
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
WATER FLOW l/h
Table 3 – ACF 60-00 UNIT’S PRESSURE DROP BY DIFFERENT INLET WATER TEMPERATURES
AYF 60-108/2 – UNIT’S PRESSURE DROP
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
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
WATER FLOW l/h
Table 5 – AYF 60-108/4 CHILLER ONLY PRESSURE DROP (4 PIPE VERSION) BY DIFFERENT INLET WATER TEMPERATURES
AYF 60-108/4 – HEATER ONLY PRESSURE DROP
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
3 INSTALLATION
3.1 GENERAL RULES

ACF and AYF units must be installed in accordance with international and nationals regulations in force
relative to the design, installation and maintenance of heating/cooling systems and carried out by qualified
engineers following the instructions of the manufacturer.
The manufacturer cannot be held responsible for any damages to persons, animals or goods due to
improper, erroneous or irrational installation of these appliances
The following rules should be followed to ensure a good installation and best performance of the system:
- Unpack the unit carefully, checking that it has not suffered damage during transport. Each unit is factory
tested before shipping, if damage is found report this immediately to the haulage contractor.
- Each unit must be installed outdoors in an area of natural air circulation and does not require
particular weather protection.
In no case must the unit be installed in a room.
- No overhead obstructions should block the outlet of air from the unit top.
- Avoid installing the unit near flues, chimneys, air outlets, and similar, so as to prevent hot or
polluted air being sucked by the condenser fan
- The unit can be installed on combustible surfaces as long as fire retardant material is placed on the
support or it is lifted at least 20 cm from the bearing face.
- The front and rear sides of the unit must have a minimum clearance of 80 cm and 60 cm respectively (for
maintenance or servicing) from either walls or other stationary constructions. The other sides need a
minimum distance of 45 cm, which is required for the cooling air to flow toward the condenser.
- The unit shall be connected to the electric supply line by using an omnipolar switch having a
minimum contact opening of 3 mm. A so called »omnipolar switch» is a switch that permits both
phase and neutral opening to be obtained.
This means that when the switch opens, both contacts open too.
- The electrical connection to the unit should be carried out so that its operation may be adjusted
according to the real inside climate needs. This connection is to be made by switching off the unit without
cutting out the power supply. This condition is mandatory for the good operation of the unit
- Remote Control device is available as optional. When possible install the Remote Control inside the air-
conditioned building.
- Perform the electrical connection according to the attached diagrams, making sure that the supply
voltage is 230V/50 Hz single-phase.
- Be sure that an adequate gas supply from the mains is provided, according to the manufacturer’s
instructions.
- A gas tap and a flexible hose should be installed in the gas supply line.
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
3.2 INSTALLATION OF THE UNIT
HANDLING OF THE UNIT ON SITE

When arriving at the installation site, visually inspect the unit for any signs of breaking or damage to the
package, which may indicate a possible unit damage.
The units must he handled on site maintaining the same packaging conditions as the factory ones. The unit
is to be unpacked only at the moment of definitive installation.
Before locating and unpacking the unit, make a hole in the package and smell to be sure there is no
ammonia.
If the unit is to be lifted by hoist for installation, leave it on crate base. Attach hoist lines to crate base and
use and use spreader bars to prevent hoist lines from damaging unit Casing.
FRONT VIEW FRONT VIEW SIDE VIEW

ACF AYF ACF - AYF
Figure 8 – HANDLING OF ACF AND AYF UNITS
LOCATION AND CLEARANCES

The chillers (chillers/heaters) must be installed outdoors in an area of free natural air circulation.
The installation inside a room is not allowed.
The units can be installed at ground level, on a platform or on the roof (if this can withstand its weight).
The noise generated by the condenser/absorber fan during summertime when the unit is operating is not
excessive. However, avoid locating the unit in an area adjacent to sleeping quarters of neighbouring
buildings (see Figure 9).
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.
GOOD
IDEAL
GARAGE
BEDROOM LIVING
AVOID
ROOM
INSTALLATION IN
THIS AREA
BETTER
Figure 9 – LOCATION OF THE UNIT

600
600
FRONT
800
800
450 450 450 450 450
ACF SINGLE UNIT CONNECTION OF SEVERAL ACF UNITS

600
600
FRONT
800
800
450 450 450 450 450
AYF SINGLE UNIT CONNECTION OF SEVERAL AYF UNITS
Figure 10 –CLEARANCES FOR CORRECT INSTALLATION OF THE UNITS
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).
4m
min
2,5 m min. 2,5 m min. . 2,5 m min.
® ®
ROOF/ TERRACE INSTALLATION GROUND INSTALLATION
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
64 354 354 68 64 354 400 332 80

415
1500
415
CONCRETE BLOCKS CONCRETE SUPPORT

40 cm x 20 cm WIDTH 20 cm WIDTH 10 cm
ACF 60-00 AYF 60-108
Figure 12 –DIMENSIONS AND THE POSITION OF THE CONCRETE SUPPORTS
ROOF / TERRACE INSTALLATION

Position the unit on the duly leveled surface (support base) made out of fire retardant material.
Both the unit and the supporting base weight should be sufficiently supported by the roof joists.
The unit installed on the roof should be provided with supporting blocks of sufficient size, depth and
resistance in order to permit necessary air circulation (see Figure 12).
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).
4 HYDRAULIC AND GAS INSTALLATION
4.1 WATER PIPING DESIGN AND INSTALLATION

Piping for High Efficiency appliances are to be designed and installed as close circuits hydraulic installations.
No specific demands are required for these applications.
The following must be installed close to appliance, as per Figure 13 and Figure 14:
- 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. Ø½”);
- 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).
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
Figure 13 – ACF 60-00 UNIT - PIPING DIAGRAM SINGLE UNIT
GAS
P T
AYF 60-108/2 UNIT
P T
1 2 3 4 5 6 7 8
LEGEND:
1 PRESSURE GAUGES 5 WATER FLOW REGULATION VALVE
2 FLEXIBLE HOSES 6 ON/OFF VALVES
3 WATER FILTER 7 WATER PUMP
4 THERMOMETER WELLS 8 EXPANSION VESSEL (when necessary)
NOTE: ANTIFREEZE GLYCOL MUST BE ADDED TO CHILLED WATER
Figure 14 – ACF 60-108/2 UNIT - PIPING DIAGRAM SINGLE UNIT (2 PIPES)
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).
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).
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
Figure 16 – ACF 60–00 UNIT - POSITION OF THE WATER / GAS CONNECTIONS
AYF 60 –108/2 (2 PIPES)

Connection Panel
B A OUTLET ∅ 1 ¼” F
A B INLET ∅ 1 ¼” F
85 40
G G GAS ∅ ¾” M
76 927 90 137
Figure 17 – AYF 60–108/2 (2 pipes) - POSITION OF THE WATER / GAS CONNECTIONS
AYF 60 –108/4 (4 PIPES)

Connection Panel
D C
A COOL WATER OUTLET ∅ 1” M
85 40 110
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
Figure 18 – AYF 60 –108/4 (4 pipes); POSITION OF THE WATER / GAS CONNECTIONS
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.
GAS NATURAL GAS LPG
SUPPLY PRESSURE G20 between 17 and 25 mbar G30 28-30 mbar

G31 28-30 mbar
Table 7 –GAS SUPPLY PRESSURE
Below are indicated the gas consumption of the ACF 60-00 and AYF 60-108 units.
MODEL OPERATION NATURAL GAS LPG

1 2
CONSUMPTION CONSUMPTION
3
m /h kg/h
ACF 60-00 COOLING 2,51 1,86
AYF 60-108 COOLING 2,51 1,86
AYF 60-108 HEATING 3,28 2,42
Table 8 – GAS CONSUMPTION PER HOUR
3
1 PCI 34,02 MJ/m (1013 mbar – 15 ° C)
2 PCI 46,34 MJ/kg (1013 mbar – 15 ° C)
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.
DIAPHRAGM (mm) AVAILABLE HEAD (Pa)

41 (standard) 0 (free exhaust) (elbow and pipe supplied)
43 30
46 50
49 65
Table 9 – DUCT FLUE - HEAD TABLE
Data necessary for the calculus of the flue exhaust duct:

3
Flue flow Nm /h 53
NATURAL GAS COMBUSTION
Flue temperature °C 125
3
Flue flow Nm /h 44,4
LPG COMBUSTION
Flue temperature °C 130
Table 10 –AYF 60-108 UNIT - HEATING MODULE'S FLUE FLOW AND TEMPERATURE
FLUE EXHAUST TERMINAL OF THE HEATER SECTION

DIAMETER 80 mm
170
930
1240
REAR VIEW AYF
Figure 11 – AYF – FLUE EXHAUST TERMINAL OF THE HEATER SECTION
5 ELECTRICAL CONNECTION
5.1 POWER SUPPLY

All wiring should be installed in accordance with the EN standards and any existing national and international
standards.
The electrical system is pre-wired for single-phase, 230 V – 50 Hz single phase. Main ON/OFF switch is to
be installed close to the unit.
Power supply line is to be wired on the internal electric board of the unit.
It is necessary to foreseen the electrical switch (main – ON/OFF) with an appropriate fuse on the power
supply line.
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.
5.2 ELECTRICAL CONNECTIONS FOR THE CONTROL OF THE UNIT
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.
ACF 60-00 MODEL

All components need for the controls of the unit are to be connected to the terminals: R and Y inserted in the
control circuit 24V of the appliance.
It’s possible to connect to a “clean” contact for the water circulation pump directly from the appliance
(terminals N.O. CONTACT CIRC). The maximum power of installed pump is 700W (230V – 50 Hz, single
phase).
The components necessary for the correct electrical installation are: (see Figure 19):
§ 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:
S50 - ELECTRONIC CONTROL BOARD

IG - MAIN SWITCH (not supplied)
IC - ON-OFF SWITCH (not supplied)
MT - INTERNAL TERMINAL POWER SUPPLY
PR - ERROR LOCKOUT LAMP AND RESET
SWITCH (230 Vac, not supplied)
POMPA - EXTERNAL WATER 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
Figure 19 –ACF 60-00 UNIT WITH DIRECT DRIVEN PUMP - CONNECTIONS TO BE DONE BY INSTALLER
LEGEND:
S50 - ELECTRONIC CONTROL BOARD

IC - ON-OFF SWITCH (not supplied)
MT - INTERNAL TERMINAL POWER SUPPLY
R2 - PUMP CONTROL RELAY
PR - ERROR LOCKOUT LAMP AND RESET SWITCH
(230 Vac, not supplied)
POMPA - EXTERNAL WATER PUMP ((not supplied)
- CONNECT A GROUNDING TO THE CORRECT
TERMINAL
APPLICATION
CUT THE RESISTANCE RFC PLACED ON THE
ELECTRONIC BOARD
(LOWER LEFT CORNER).
COLLEGAMENTI A CURA
DELL’INSTALLATORE
Figure 20 – ACF 60-00 WITH PUMP CONTROLLED BY RELAY - CONNECTIONS TO BE DONE BY INSTALLER
AYF 60-108/2 MODEL

Inside the unit, at electric board are 3 terminals which are to be used for the switch on/off of the appliance
(chiller and heater). It’s 230V-50Hz circuit:
R Common
W Heater on
Y Chiller on
Using the relay (not supplied) could use terminals 9 - 10 (230 V – 50 Hz) for control of the circulation water
pumps. In this case the water pump is controlled directly by electronic control board
Components to be foreseen (see Figure 21):
§ appliance’s on/off switch; programmable timer or room thermostat or the “clean” contact wired at R and
common to “summer/winter” switch;
§ switch summer/winter; wired to the R,Y and W terminals;
§ time delay relay (10 minutes) by using terminals 9 - 10 for control of the circulation water pumps;
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).
30.
LEGEND
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)
- CONNECT A GROUNDING TO THE CORRECT TERMINAL
APPLICATION
ELECTRONIC BOARD
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
AYF 60-108/4 MODEL
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.
§ 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).
24 and Figure 25.
LEGEND
CONNECTION TO BE DONE IG - MAIN SWITCH (not supplied)
BY INSTALLER
EI - SUMMER/WINTER SWITCH (not supplied)
PSA - CHILLERS RESET BUTTON (not supplied)
R3 - HEATING PUMP TIME DELAY RELAY (10 MINUTES)
APPLICATION
ELECTRONIC BOARD
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
CONNECTION TO BE DONE LEGEND
BY INSTALLER IG - MAIN SWITCH (not supplied)
EI - SUMMER/WINTER SWITCH (not supplied)
PSA - CHILLERS RESET BUTTON (not supplied)
R2 - COOLING PUMP TIME DELAY RELAY (10 MINUTES - not supplied)
R3 - HEATING PUMP TIME DELAY RELAY (10 MINUTES)
APPLICATION
ELECTRONIC BOARD
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
LEGEND:
S50 ELECTRONIC CONTROL BOARD

CNT FLAME CONTROL BOX
Q ELECTRIC GAS VALVE
M ASP FLUE FAN
C1 FLUE FAN CONDENSER 1µF
ACN IGNITOR ELECTRODE
RLZ FLAME SENSOR
M FAN FAN MOTOR
C2 FAN MOTOR CONDENSER12,5 µF
L SIGNAL GAS VALVE OPENING
M1 HIGH TEMPERATURE LIMIT SWITCH
NPH HIGH TEMPERATURE LIMIT SWITCH M.R.
P AIR PRESSURE SWITCH
SRT SOLUTION PUMP ROTATION PROBE
FL WATER FLOW SWITCH
TA AMBIENT TEMPERATURE PROBE
TCN CONDENSER TEMPERATURE PROBE
TG GENERATORE TEMPERATURE PROBE
Figure 24 –ACF 60-00 UNIT (S) - WIRING DIAGRAM

TH2M OUTLET WATER TEMP. PROBE
TH2R RETURN WATER TEMP. PROBE
CNT
TR TRANSFORMER 230/24 V (AC)
M PUMP HYDRODYNAMIC PUMP MOTOR
HTres RESET FLAME CONTROL BOX
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
Figure 26 –AYF 60-108/4 (4 PIPES VERSION) - 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 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
DANGEROUS SITUATIONS CONDITION FOR THE UNIT AND/OR PERSONS

If during the first start-up one of the following conditions is found:
- Appliance installed indoors
- Turn on/off of the of the unit by using the main electrical switch (not used R-Y terminals)
- Antifreeze not added into the water
- Appliance damaged or defective due to the non conform transport and/or installation
ANOMALOUS INSTALLATION CONDITIONS FOR THE UNIT AND/OR THE PERSONS

All situations in contradiction to the directions/instructions of the manufacturer in part or fully, which result or
may result as a defective unit operation.
6.1 FILLING THE WATER PIPING

Connect the water pipeline, gas supply and power supply and than start with filling the water piping.
This operation is to be done as follows:
§ Activate the air breathing valves at the water pipeline system;
§ Fill the system with the water. Add the ethyl glycol antifreeze at the water. The percentage of antifreeze
depends on the minimum temperature that is achieved in winter (see Table 13).
§ Turn on the appliance and check that pressure of inlet/return water is above 1 bar.
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.
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).
The glycol antifreeze allows to:

§ avoid eventual damages due to frost of the water inside the pipeline;
§ avoid to empty the pipeline at the end of the cooling season and consequent water refilling at the
beginning of the next season (with obvious difficult to guarantee that the pipeline is completely dry);
§ avoid the possible freezing of evaporator due to unpredictable electrical black-out; in this case it is
necessary to wait until unit is defrosted (sometimes several hours);
It is mandatory to add the glycol into the water when heating/cooling unit (AYF or AY) is installed.
Ethyl Glycol added into the water changes its thermal-physical properties, particularly its density,
viscosity and mean specific heat.
Table 14 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 Tables 3 and 4).
When the appliance ACF 60-00 (S) or chiller section of AYF 60-108 (S) has to operate at the
external temperatures lower than +10°C, ADD ALWAYS at least 10% of antifreeze at the
circulation water.
MODEL WATER QUANTITY INSIDE THE CHILLERS

ACF 60-00 3 liters
AYF 60-108/2 6 liters
AYF 60-108/4 (cooling section) 4 liters
AYF 60-108/4 (heating section) 5 liters
Table 12 – WATER QUANTITY INSIDE THE CHILLERS
% 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).
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 %
Table 14 – CORRECTION PARAMETER FOR THE CALCULATION OF WATER FLOW (PUMP)
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:
§ Connect the manometer to the gas pressure tap to gas valve;

§ Supply power to the unit.
§ Start the unit by closing the contact at the room thermostat;
§ Wait for the burner to start up. Due to the presence of air inside the piping, it may be that the burner does
not start at the first attempt and failing to do so the ignition system is locked out. If this happens, reset the
ignition system until all the air is purged from the piping and the burner ignites;
§ When the burner is ignited, check pressure at the manometer and compare it with one shown Table 15;
§ If necessary to regulate the gas pressure you have to proceed as follows for all types of gas: keeping
the burner ignited and the manometer connected, turn the gas valve screw (see Figure 27) until a correct
pressure, shown on the Table 15 is obtained;
§ Turn unit off at the room thermostat. Make sure the burner is off;
§ Remove the manometer and REPLACE THE GAS PRESSURE TAP SEAL SCREW;
§ Check all gas pipe connection for leaks using soapy water;
GAS TYPE NATURAL GAS LPG (G30) LPG (G31)

BURNER PRESSURE 6,2 mbar 13 mbar 17,2 mbar
NOZZLE DIAMETER 4,9 mm 3 mm
Table 15 – ACF 60-00 AND CHILLER SECTION OF AYF 60-108 - BURNER PRESSURES AND NOZZLE DIAMETERS
GAS PRESSURE - HEATING UNIT OF AYF 60-108

The units are factory adjusted for the type of gas to be used, which can be easily identified by the label
attached inside the unit.
Nevertheless, before starting the appliance it is advisable to check (and adjust if necessary - see Table 16)
the burner pressure in the following manner:
§ select the maximum temperature on the hot water temperature thermostat
§ remove the pressure regulator protective cap (see Figure 28)
§ connect the manometer to the pressure tap at the valve exit
§ 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)
§ if necessary to adjust burner pressure:

set the maximum burner pressure to the required value by means of nut B (see Figure 28) turning it
clockwise to increase it and anti-clockwise to reduce the pressure (wrench 10mm to be used)
to set the minimum burner pressure the flame modulating coil F (see Figure 28) must be electrically
disconnected (see the electrical wiring diagram). Holding the nut B, turn the screw A clockwise to
increase or anti-clockwise to reduce pressure (the use of a screwdriver is recommended). After
adjustment electrically reconnect the flame modulating coil F (see Figure 28).
§ replace the protection cap;
§ 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;
§ check eventual gas leakage with soapy foam;
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
B INLET GAS PRESSURE TAP
C OUTLET GAS PRESSURE TAP
C
B
Figure 27 – GAS VALVE SIT 830 OF ACF 60-00 AND CHILLER SECTION OF AYF 60-108 APPLIANCES
D C
F A
E
B
A REDUCED PRESSURE ADJUSTMENT D OUTLET GAS PRESSURE TAP

SCREW
B MAXIMUM PRESSURE ADJUSTMENT E INLET GAS PRESSURE TAP
NUT
FLAME REGULATION COIL
C PROTECTION CAP F
Figure 28 – GAS VALVE SIT 836 - AYF 60-108 HEATING MODULE
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:
A DISPLAY - SHOWS OPERATIONAL PARAMETERS

B SIGNAL LED DIODES:
- RED LIGHT: Inlet water temperature
- GREEN LIGHT Temperature difference between inlet and outlet water lines
- YELLOW LIGHT Communication with Remote Control
- 2nd RED LIGHT Electrical Power Supply ON
C CONTROLLER OF OUTLET WATER TEMPERATURE
D RESET OF FLAME CONTROL BOX
Figure 29 – ELECTRONIC CONTROL BOARD
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
Figure 30 –AYF 60-108 HEATING MODULE - CONTROL BOARD
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.
SERVICING OF ACF 60-00 AND CHILLER UNIT OF AYF 60-108 APPLIANCE

§ Cleaning of the condenser /absorber coils;
§ Check of the combustion circuit
- cleaning of the burner and generator (eventually);
- igniter and flame sensor system;
§ Hydrodynamic oil pump
- oil level (after first operational season and than every five years)
- check belts (to be repalced every 5 years or 10.000 working hours)
§ Control eventual presence on non-condensable gases;
SERVICING OF HEATING MODULE OF AYF 60-108 APPLIANCE
§ Check of the combustion circuit, function and heat exchange:

- check the burner and flue exhaust duct;
- cleaning of the burner and flue/water heat exchanger (eventually)
- igniter and flame sensor system;
§ Check the function of intern components:
- expansion vessel
- three way valve
- safety and control components
§ Flue analyses
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.
To clean condenser / absorber coil proceed as follows:

§ Cut off the power and gas supply;
§ 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
Figure 31 –FINNED CONDENSER / ABSORBER OF ACF 60-00 UNIT
REAR VIEW RIGHT HAND SIDE VIEW LEFT HAND SIDE VIEW
AYF 60-108 AYF 60-108 AYF 60-108
Figure 32 – FINNED CONDENSER / ABSORBER OF AYF 60-108 UNIT
NOTE
Do not use the dissolvents for cleaning the condenser because it can damage the coating of the
aluminium fins or aluminium fins itself.
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.
CODE ALARM DESCRIPTION
E01 HIGH TEMPERATURE LIMIT SWITCH – MANUAL RESET

Located at the Generator.
Check:
- Thermostat; when “open” (released) press the reset button;
- Wires; Disconnected or damaged. Check the wiring and continuity (disconnect the wires from the
board);
E02 HIGH PRESSURE SWITCH – SEALED REFRIGERATION UNIT – MANUAL RESET
Located at rear side of the Rectifier.
Check:
- Pressure switch; When “open” (released) reset it manually;
- Wires; Disconnected or damaged. Check the wiring and continuity (disconnect the wires from the
board);
E03 LOW TEMPERATURE LIMIT THERMOSTAT
Located at the upstream chilled water line.
Check:
- The chilled water flow rate;
- Regulation of chilled antifreeze thermostat on electronic board (particularly if minimum thermostat
temperature set to 3°C)
E04 CONDENSER / ABSORBER OVERHEATING – INADEQUATE VENTILATION
Safety based on relation between condenser/absorber temperature (sensor located on the condenser
outlet tube) and external temperature (sensor located at the upper rear right corner of the chiller).
Check:
- Fan operation (smooth rotation, blade position, fastening)
- Condenser/absorber’s state; Clean the condenser/absorber;
- Natural air circulation (roof overhang or overhead obstructions could provoke the problems);
- Sensors damaged or not gauged (to be exchanged or gauged);
- Fan power supply; control the voltage (white and black wires on the fan) which must be at least
200 V before alarm signal (if different exchange electronic control box);
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;
Flow switch is located at returning chilled water line

Check:
- Pump is operating properly; Pump position. Circulation pump must be located before the chiller (at
the chilled water return line);
- Check the circulation pump parameters;
- Installation’s water flow rate;
- If the water in evaporator is frozen (missing antifreeze); turn off the power supply of the unit and
wait 15 to 30 minutes (when possible with circulation pump on);
- Flow switch failure (to be removed and controlled);
E11 SOLUTION PUMP ROTATION
Pump rotation probe is located at pump’s body.
Check:
- Proper operation of pump’s electric motor;
- Probe’s connection wires;
- Closing of switch “REED” by rotating the gear (use the electrical tester at the probe connection on
the electronic board);
- If the pump is blocked because of mechanical failure or belts breakage;
E12 FLAME CONTROL BOX LOCKOUT
Flame control box is located at the left-hand panel of the chiller.

Check:
- Spark ignitor (state of wire, position, location, distance between electrodes);
- Gas manifold orifice; check the gas pressure on the burner);
- Gas supply; check the gas valves and gas supply pressure before the gas manifold orifice;
- Flame sensor (state of wire, position, location, distance between electrodes);
E16 OUTLET CHILLER WATER TEMPERATURE PROBE FAILURE
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:
the wires to THR ;connector at electronic board);
E18 CONDENSER TEMPERATURE PROBE FAILURE
The condenser temperature probe is located at condenser outlet tube.
Check:
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:
- 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:
- Before exchange the thermostat, check with the new probe that error disappear from display
(connect the wires to TG ;connector at electronic board);
Table 17 – ERROR CODES
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).
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:
A GAS INLET TUBE BEFORE THE GAS

A
B VALVE
B GAS VALVE SUPPORT
C AIR-GAS DIFFUSER
Figure 33 – GAS VALVE, AIR INTAKE TUBE AND BLOWER FAN
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
Figure 34 –AYF 60-108 UNIT - HEATING MODULE
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;

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ACF 60-00 AND AYF 60-108 (S50) INSTALLATION MANUAL

A qualified service engineer must verify that:

The Remote Control (available as optional) consists of a

DESCRIPTION OF THE ABSORPTION REFRIGERANT CYCLE

DESCRIPTION OF THE CHILLER OPERATIONS

- When chiller is running, its operation is continuously monitored by:

CHILLER’S COMPONENTS AND MAIN CONSTRUCTIVE FEATURES

A DISPLAY - SHOWS OPERATIONAL PARAMETERS

Figure 1 – ELECTRONIC CONTROL BOARD

2.3 HEATING MODULE OPERATION

HEATER’S COMPONENTS AND MAIN CONSTRUCTIVE FEATURES

TECHNICAL CHARACTERISTICS ACF 60-00 ACF 60-00 S

Chilled Water External Temperature (°C)

67 356 356 71 CONNECTION PANEL

FRONT VIEW RIGHT HAND SIDE VIEW

Figure 4 – DIMENSIONS OF THE ACF 60-00 UNIT

FRONT VIEW SIDE VIEW

Figure 5 – DIMENSIONS OF THE AYF 60-108/2-4 UNIT

FRONT VIEW SIDE VIEW

Figure 6 – DIMENSIONS OF ACF 60-00 S (LOW NOISE VERSION) UNIT

FRONT VIEW SIDE VIEW

Figure 7– DIMENSIONS OF ACF 60-108 S (LOW NOISE VERSION) UNIT

NOMINAL HEATING OUTPUT kW 28,4

ACF 60-00 – UNIT’S PRESSURE

WATER FLOW l/h

AYF 60-108/2 – UNIT’S PRESSURE DROP

WATER FLOW l/h

AYF 60-108/4 – HEATER ONLY PRESSURE DROP

3.1 GENERAL RULES

HANDLING OF THE UNIT ON SITE

FRONT VIEW FRONT VIEW SIDE VIEW

Figure 8 – HANDLING OF ACF AND AYF UNITS

LOCATION AND CLEARANCES

Figure 9 – LOCATION OF THE UNIT

450 450 450 450 450

ACF SINGLE UNIT CONNECTION OF SEVERAL ACF UNITS

450 450 450 450 450

AYF SINGLE UNIT CONNECTION OF SEVERAL AYF UNITS

Figure 10 –CLEARANCES FOR CORRECT INSTALLATION OF THE UNITS

ROOF/ TERRACE INSTALLATION GROUND INSTALLATION

64 354 354 68 64 354 400 332 80

CONCRETE BLOCKS CONCRETE SUPPORT

ACF 60-00 AYF 60-108

Figure 12 –DIMENSIONS AND THE POSITION OF THE CONCRETE SUPPORTS

ROOF / TERRACE INSTALLATION

4.1 WATER PIPING DESIGN AND INSTALLATION

Figure 13 – ACF 60-00 UNIT - PIPING DIAGRAM SINGLE UNIT

AYF 60-108/2 UNIT

1 PRESSURE GAUGES 5 WATER FLOW REGULATION VALVE

2 FLEXIBLE HOSES 6 ON/OFF VALVES

3 WATER FILTER 7 WATER PUMP

4 THERMOMETER WELLS 8 EXPANSION VESSEL (when necessary)

NOTE: ANTIFREEZE GLYCOL MUST BE ADDED TO CHILLED WATER

Figure 14 – ACF 60-108/2 UNIT - PIPING DIAGRAM SINGLE UNIT (2 PIPES)

Figure 16 – ACF 60–00 UNIT - POSITION OF THE WATER / GAS CONNECTIONS

AYF 60 –108/2 (2 PIPES)

Figure 17 – AYF 60–108/2 (2 pipes) - POSITION OF THE WATER / GAS CONNECTIONS

AYF 60 –108/4 (4 PIPES)

Figure 18 – AYF 60 –108/4 (4 pipes); POSITION OF THE WATER / GAS CONNECTIONS

GAS NATURAL GAS LPG

SUPPLY PRESSURE G20 between 17 and 25 mbar G30 28-30 mbar

MODEL OPERATION NATURAL GAS LPG

DIAPHRAGM (mm) AVAILABLE HEAD (Pa)