Robur AY Installation, Use & Maintenance Manual Download Page 1

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Installation, use and maintenance manual

Outdoor condensing boiler

for heating

Summary of Contents for AY

Page 1: ...Powered by natural gas LPG Installation use and maintenance manual AY Outdoor condensing boiler for heating ...

Page 2: ... within this publication are not affected With the aim of continuously improving the quality of its products Robur S p A reserves the right to modify the data and contents of this Installation use and maintenance manual without prior notice Revision A Code D LBR885EN DISPOSAL The appliance and all its accessories must be disposed of separately in accordance with the regulations in force Use of the...

Page 3: ...er p 17 3 1 Warnings p 17 3 2 Hydraulic connections p 18 3 3 Fuel gas supply p 21 3 4 Combustion products exhaust p 23 3 5 Flue gas condensate drain p 24 4 Electrical installer p 25 4 1 Warnings p 25 4 2 Electrical systems p 25 4 3 Electrical power supply p 26 4 4 Adjustment and control p 26 5 First start up p 30 5 1 Preliminary checks p 30 5 2 How to access the boiler p 30 5 3 Electronic board pa...

Page 4: ...ary to DDC which may be used to broaden its functions heating cooling DHW production service demands and control of system components such as third party generators adjustment valves circulators probes First start up appliance commissioning operation which may only and exclusively be carried out by a TAC III WARNINGS III 1 GENERAL AND SAFETY WARNINGS Installer s qualifications Installation must ex...

Page 5: ...ppliance and do not touch inter nal components before the appliance has cooled down Do not touch the flue gas exhaust before it has cooled down Electrocution hazard Disconnect the electrical power supply before any operation on appliance components For electrical connections exclusively use compli ant components and according to the specifica tions provided by the manufacturer Ensure the appliance...

Page 6: ... added Furthermore they comply with the requirements of the following standards EN 15502 Gas fired central heating boilers III 2 2 Other applicable provisions and standards The design installation operation and maintenance of the systems shall be carried out in compliance with cur rent applicable regulations depending on the Country and location and in accordance with the manufacturer s instructio...

Page 7: ...The limit thermostat has manual reset 1 1 2 Mechanical and thermo hydraulic components Integrated spiral single tube stainless steel heat ex changer Premix modulating burner with 1 9 ratio AY 35 1 10 AY 50 1 20 AY 100 Automatic air vent valve High efficiency water pump System drain tap Water temperature probes Condensate drain siphon Check valve only for AY 100 Flue gas exhaust duct with relevant ...

Page 8: ... 720 572 1184 1284 140 185 219 320 A Figure 1 6 Service plate Hydraulic gas connections detail OUT Water outlet connection Ø 1 1 2 F IN Water inlet connection Ø 1 1 2 F SC Condensate discahrge connection outside diameter 25 mm inside 20 mm GAS Gas connection Ø 1 M 160 91 44 238 437 100 IN GAS OUT SC Figure 1 7 Service plate Detail of bottom plate A Boiler safety valve drain external Ø 20 mm intern...

Page 9: ...hermostat TA Connector for optional room thermostat TF Flue gas thermofuse TS Safety thermostat Tra Ignition transformer VG Gas valve ar Orange bi White ce Light blue gi Yellow gr Grey ma Brown ne Black EA VG Tra ER 11 10 9 8 7 12 13 14 15 16 17 M12 M9 M7 M5 M2 M4 M8 M10 M15 M16 1 2 3 4 57 61 60 59 58 38 31 30 29 28 27 26 62 63 64 65 66 67 68 51 52 53 54 55 56 5 6 M13 M14 PM SRi M6 GND PWM HS 24V ...

Page 10: ...room thermostat TF Flue gas thermofuse TS Safety thermostat Tra Ignition transformer VG Gas valve ar Orange bi White ce Light blue gi Yellow gr Grey ma Brown ne Black EA VG Tra ER 11 10 9 8 7 12 13 14 15 16 17 M12 M9 M7 M5 M2 M4 M8 M10 M15 M16 1 2 3 4 57 61 60 59 58 38 31 30 29 28 27 26 62 63 64 65 66 67 68 51 52 53 54 55 56 5 6 M13 M14 PM SRi M6 GND PWM HS 24V 32 33 34 35 36 37 39 40 41 42 43 44 ...

Page 11: ...y probe SRi Heating return probe Ta Antifreeze thermostat TF Flue gas thermofuse TS Safety thermostat Tra Ignition transformer VG Gas valve ar Orange bi White ce Light blue gi Yellow gr Grey ma Brown ne Black EA Tra ER 11 10 9 8 7 12 13 14 15 16 17 M12 M9 M7 M5 M2 M4 M8 M10 M15 M16 1 2 3 4 57 61 60 59 58 38 31 30 29 28 27 26 62 63 64 65 66 67 68 51 52 53 54 55 56 5 6 M14 PM M6 GND PWM HS 24V 32 33...

Page 12: ... room thermostat for module 1 TA2 Connector for optional room thermostat for module 2 TF Flue gas thermofuse TS Safety thermostat Tra Ignition transformer VG Gas valve ar Orange bi White ce Light blue gi Yellow gr Grey ma Brown ne Black EA VG Tra ER 11 10 9 8 7 12 13 14 15 16 17 M12 M9 M7 M5 M2 M4 M8 M10 M15 M16 1 2 3 4 57 61 60 59 58 38 31 30 29 28 27 26 62 63 64 65 66 67 68 51 52 53 54 55 56 5 6...

Page 13: ...r switch contactor fitted with voltage free NO contact This system only provides elementary control hence without the important func tions of the DDC control It is advisable to possibly lim it its use to simple applications only and with a single appliance In the case of the AY 100 appliance two separate requests must be provided for the two thermal modules that make up the appliance For connectio...

Page 14: ...length of exhaust duct m 15 14 14 4 maximum water pressure in operation bar 3 0 maximum flow rate of flue gas condensate l h 3 4 5 0 10 0 water content inside the appliance l 8 11 22 expansion tank volume l 10 minimum storage temperature C 30 Dimensions width mm 465 720 depth mm 575 height mm 1284 Weight in operation kg 77 87 131 1 Relative to NCV net calorific value 2 Gas not available for AY 35 ...

Page 15: ...ad AY 35 AY 50 AY 100 Installation data Circulating pump data nominal flow at the maximum available head l h 2600 2350 4700 Residual pressure head at nominal flow rate boiler only bar 0 44 1 6 3 1 AY 35 Figure 1 17 Available head and pressure drop of the boiler A Boiler pressure drop with 20 glycol water B Boiler pressure drop with no glycol in water 0 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 500 100...

Page 16: ... Packing Only remove the packing after placing the appli ance on site Do not leave parts of the packing within the reach of children plastic polystyrene nails since they are potentially dangerous Weight The lifting equipment must be suitable for the load Do not stand under suspended loads 2 2 INSTALLATION KIT 2 2 1 AY 35 The installation kit supplied with the boiler includes 1 AY 35 condensing boi...

Page 17: ... MINIMUM CLEARANCE DISTANCES 2 5 1 Distances from combustible or flammable materials Keep the appliance away from combustible or flammable materials or components in compliance with applicable regulations 2 5 2 Clearances around the appliance The minimum clearance distances shown in Figure 2 1 p 17 bar any stricter regulations are required for safety operation and maintenance Figure 2 1 Clearances...

Page 18: ... Depending on the water content of the system assess the need for additional expansion tanks 3 2 4 System filling For the calculation of the total water content to be loaded in the system it is necessary to add the water content of the boiler Table 1 1 p 13 and of the distribution terminals to the water content in the pipes and in other elements that make up the system tanks hydraulic separators e...

Page 19: ...ions a decrease in system wa ter pressure is observed open again the system filling valve until the system pressure reaches 1 5 bar 12 Repeat items 9 10 11 until the pressure has stabilised at least 1 5 bar 13 After the operation close the filling tap Once the filling operation has been completed close the cap of the jolly valve on the condensing block to avoid water leaks To start the circulation...

Page 20: ...al continuity The pump anti lock function is only effective if the power supply is guaranteed 3 2 6 Antifreeze liquid Precautions with glycol The manufacturer disclaims any liability for any damage caused by improper glycol use Always check product suitability and its expiry date with the glycol supplier Periodically check the product s preservation state Do not use car grade antifreeze liquid wit...

Page 21: ...poor operation or exces sive topping up Ensure there are no leaks in the installation Periodically check the chemical physical parameters of the water particularly in case of automatic topping up Chemical conditioning and washing Water treatment conditioning or system washing carried out carelessly may result in risks for the ap pliance the system the environment and health Contact specialised fir...

Page 22: ...ues in the Table with a tolerance of 15 1 Gas not available for Caldaia 35 Tech Caldaia 35 Tech ACS Caldaria 35 AY 35 Before proceeding with the construction of the system the installer must Check that the gas used corresponds to that for which the appliance has been designed see nameplate Check that the flow rate of the gas meter is such as to ensure the simultaneous use of all the devices con ne...

Page 23: ...e the flue gas exhaust kit is double and the kit must be installed on both thermal modules Figure 3 4 Flue gas exhaust kit A Gasket of the flanged socket B Flanged socket Ø 60 80 mm C Fixing screws of the flanged socket D Rain cover E Flue gas exhaust pipe F Roof terminal A B C D E F 3 4 2 1 How to install the flue gas kit The protection cover has the purpose of preventing ingress of water and or ...

Page 24: ...outside an appropriate UV ray protection must be assured if the valve is in plastic as well as protection from potential winter freezing of condensate backflow into the siphon The connection of the discharge to the sewerage system must be made at atmospheric pressure i e by dripping into a siphoned container connected to the sewerage system Figure 3 6 Flue gas condensate drain 300 mm 3 4 3 1 Maxim...

Page 25: ...rough the siphon It is advisable after the first few months of operation of the appliance to clean the siphon which collects also any deposits resulting from the first passage of the conden sate inside the components of the appliance These de posits could cause the siphon itself to malfunction 4 ELECTRICAL INSTALLER Do not power and or start the boiler before filling the hydraulic system as this m...

Page 26: ...ure 4 3 Power supply connection L Phase N Neutral Components NOT SUPPLIED GS Two pole switch L N 10 0 Ta Ta L N 230V 50 Hz GS 4 4 ADJUSTMENT AND CONTROL 4 4 1 Control systems Two separate control systems are provided each with specific features components and diagrams Figures 4 6 p 28 4 9 p 29 DDC control with CAN bus connection External request 4 4 2 CAN bus communication network The CAN bus comm...

Page 27: ...d of the appliance ac cording to the Procedure 4 2 p 25 2 Turn the control panel 90 outwards using the side latches to access the CAN NDG board Figure 4 4 p 27 3 Connect the CAN bus cable to terminals 0 L and H 4 Place the CLOSED J11 jumpers Detail A if the node is terminal one connected CAN bus cable section only or OPEN Detail B if the node is intermediate two connected CAN bus cable sections 5 ...

Page 28: ...gle units DDC Direct Digital Controller SCH CAN NDG board J11 CAN bus jumper on CAN NDG board J21 CAN bus jumper on DDC panel GND Common data 0 Common data H Data signal HIGH L Data signal LOW A Terminal node connection 3 wires J11 and J21 closed B Intermediate node connection 6 wires J11 and J21 jumpers open C CAN bus cable shield D Insulating tape to protect the shield of the CAN bus cable E Eye...

Page 29: ...tted with a voltage free NO contact How to connect the external request The connection of the external request is made on the terminal block located in the electrical panel inside the appliance Figure 4 9 p 29 1 Access the electrical board of the appliance ac cording to the Procedure 4 2 p 25 2 Connect the two non polarised conductors to the Ta Ta contacts Use a cable with a cross section between ...

Page 30: ...ues of Table 3 3 p 21 Correct operation of the flue exhaust duct Power supply mains complying with the appliance s rating plate data Appliance correctly installed according to the manu facturer s provisions System installed in a workmanlike manner according to national and local regulations 5 1 2 Abnormal or hazardous installation situations Should any abnormal or hazardous installation situations...

Page 31: ...he message P10 and release the and keys 3 Use the and keys of the heating circuit to select the parameter to be edited 4 Use the keys and of the DHW circuit to change the value of the parameter 5 Press the key to confirm and wait for the dis play to stop blinking to make the adjustment effective 6 To exit the parameter menu hold down the and keys simultaneously and wait for the symbol to appear on...

Page 32: ...d off due to the intervention of the room thermostat 0 90 36 Value in multiples of 5 s default 36 x 5 180 s P62 Minimum blower speed adjustment for heating It is possible to set the minimum speed of the blower for the heating service which corresponds to the minimum power of the burner during a heating request see Figure 5 4 p 36 The value is preset according to the boiler model P10 and the Mod1 t...

Page 33: ...cording to the line passing through the points 3 V minimum power and 10 V maximum power A voltage lower than 3 V corre sponds to no service request 5 3 2 AY 50 and AY 100 The parameters and their values refer to the firm ware 1 001 for the CAN NDG board and to the firm ware A 10 for the MIAH410 board For AY 100 all parameters must be set edited inde pendently on each of the two control panels Tabl...

Page 34: ...C 0 1 30 0 0 disabled The numbering of the value corresponds to the Kd curves of the graph Figure 5 3 p 35 P68 1 3 0 10V industrial bus drive enable The 0 10 V industrial bus input can be enabled or disabled to set burner power or delivery temperature via the external bus 0 2 0 0 disabled 1 temperature control mode 2 power control mode P69 Min heating setpoint It is possible to set the minimum use...

Page 35: ...cies Table 5 3 Minimum and maximum blower frequencies Boiler Gas type Measurement unit Frequency heating DHW 1 minimum maximum Caldaria 35 AY 35 G20 Hz 53 203 G25 Hz 53 203 G25 3 Hz 53 203 G30 Hz 55 195 G31 Hz 55 203 Caldaria 55 1 Caldaria 100 2 AY 50 AY 100 G20 Hz 53 247 G25 Hz 53 247 G25 1 Hz 53 247 G25 3 Hz 53 247 G2 350 Hz 53 247 G27 Hz 53 247 G30 Hz 55 230 G31 Hz 53 240 1 Caldaria 35 Caldaria...

Page 36: ...G31 0 5 10 15 20 25 30 35 40 45 50 55 35 50 65 80 95 110 125 140 155 170 185 200 215 230 245 Ti kW Freq Hz 5 4 COMBUSTION PARAMETERS CHECK The ignition system will automatically activate the system venting cycle function shown in the display with code F33 lasting 2 minutes except for the first start up where the duration is 5 minutes during which the pump will be started and switched off in altern...

Page 37: ...tail PF Figure 5 7 p 37 For the AY 100 model each thermal module has its own flue gas outlet and consequently its own flue gas analysis socket The checks of each module must be carried out separately Figure 5 6 Gas valve A Protection screw 1 Gas flow adjustment screw 2 Offset adjustment screw 1 2 A Figure 5 7 Socket for flue gas analysis PF Flue gas analysis socket PF Table 5 4 AY combustion param...

Page 38: ...e operation is completed 3 Make sure that the circulator is not locked 4 If it is locked wait for the circulator to perform the au tomatic unlocking function duration 3 minutes 5 If the circulator is still locked reactivate the automatic unlocking function of the circulator a further 3 min utes by power cycling the boiler 6 At the end of the above operations open the gas tap 7 To switch the boiler...

Page 39: ... be activated for a continuous period of 10 minutes 6 Display 1 2 3 4 5 6 Figure 6 2 Boiler display icons 1 Parameter number indication or displayed info code 2 Parameter programming function active 3 Not used 4 Not used 5 Not used 6 Installed outdoor probe Outdoor temperature display 7 Temperature display setpoint parameter value 8 OpenTherm communication present remote control 9 Insufficient sys...

Page 40: ...ing to the operating mode indicates that the function has been activated The burner is only ignited when there is a heating service request from the provided con trol device e g thermostat timer switch con tactor After a long period of unit inactivity or at the first start up it may be necessary to repeat the ignition operation a few times due to the presence of air in the gas piping 6 3 1 2 Switc...

Page 41: ...Outdoor probe temperature C d3 Inlet temperature C d4 Combustion blower speed RPM x 10 d5 Water flow rate l h x 10 d6 Delivery temperature C d7 Water setpoint C 6 6 EFFICIENCY For increased appliance efficiency Set water temperature to the actual system require ment Reduce repeated switch ons to the minimum low loads Program appliance activation for actual periods of use Keep water and air filters...

Page 42: ...d are sent to the DDC only if any The faults generated by the boiler board are exclusively errors and consequently on the DDC panel if any they will always be displayed as E either temporary i e with automatic reset or permanent i e with manual reset For faults requiring manual reset this can be done by pressing the reset button on the boiler or alternative ly through the appropriate functions of ...

Page 43: ...tic when the triggering condition ceases NA 77 Hot water inlet temperature probe fault Reset is automatic when the triggering condition ceases NA 83 Invalid functional parameters NA Power off the appliance Contact the TAC 84 Incorrect supply voltage Reset is automatic when the triggering condition ceases NA 86 Internal boiler board error NA Power off the appliance Contact the TAC 87 No communicati...

Page 44: ... minutes a series of cycles in which the pump is turned on for a period of 40 seconds and then turned off for a period of 20 seconds Regular operation is only permitted at the end of the function It can also be activated during normal operation of the boiler in the event that the enable of the water pressure switch is lacking when the contact is closed a 2 minute venting cycle is performed F79 Hea...

Page 45: ...eat loss P stby 0 059 kW At part load elmin 0 017 kW Ignition burner power consumption P ign 0 kW In standby mode P SB kW Annual energy consumption Q HE 266 8 GJ Sound power level indoors outdoors L WA 52 4 dB Contact details Robur SPA Via Parigi 4 6 I 24040 Zingonia BG Additional information required by COMMISSION REGULATION EU No 813 2013 Table 1 Emissions of nitrogen oxides NO x 52 mg kWh COMMI...

Page 46: ...elmin 0 017 kW Ignition burner power consumption P ign 0 kW In standby mode P SB kW Annual energy consumption Q HE 393 1 GJ Sound power level indoors outdoors L WA 52 4 dB Contact details Robur SPA Via Parigi 4 6 I 24040 Zingonia BG Additional information required by COMMISSION REGULATION EU No 813 2013 Table 1 Emissions of nitrogen oxides NO x 52 mg kWh COMMISSION DELEGATED REGULATION EU No 811 2...

Page 47: ... 0 100 kW At part load elmin 0 023 kW Ignition burner power consumption P ign 0 kW In standby mode P SB kW Annual energy consumption Q HE 785 3 GJ Sound power level indoors outdoors L WA 52 0 dB Contact details Robur SPA Via Parigi 4 6 I 24040 Zingonia BG Additional information required by COMMISSION REGULATION EU No 813 2013 Table 1 Emissions of nitrogen oxides NO x 52 mg kWh COMMISSION DELEGATED...

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