1. Manuals
  2. Brands
  3. Robur Manuals
  4. Boiler
  5. Caldaria 35 Condensing+ export
  6. Installation, use and maintenance manual

Robur Caldaria 35 Condensing+ export Installation, Use And Maintenance Manual

Outdoor condensing boiler
Hide thumbs
Table of Contents

Advertisement

Quick Links

Installation, use and maintenance manual
Caldaria Condensing+ export
Outdoor condensing boiler
Powered by natural gas/LPG

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Caldaria 35 Condensing+ export and is the answer not in the manual?

Questions and answers

Related Manuals for Robur Caldaria 35 Condensing+ export

Summary of Contents for Robur Caldaria 35 Condensing+ export

  • Page 1 Installation, use and maintenance manual Caldaria Condensing+ export Outdoor condensing boiler Powered by natural gas/LPG...
  • Page 2 The rights of those who have legitimately filed the registered trademarks contained 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.

  • Page 3: Table Of Contents

    INDEX OF CONTENTS Introduction Electrical power supply ..........p. 29 ................p. 4 Control device ..............p. 30 Recipients ................p. 4 Operation via centralised external request ..p. 32 II Symbols and definitions ..........p. 4 DHW production ............p. 32 II.1 Key to symbols ..............p. 4 5 First start-up ................

  • Page 4: Iintroduction

    Boiler/External module = equivalent terms, both used to des- ignate the part of the appliance to be installed outside the room DANGER to be heated. TAC = Technical Assistance Centre authorised by Robur. Remote control = optional control device with chronothermo- WARNING stat function.

  • Page 5: Iii.2 Conformity

    Warnings Limescale and corrosion personnel. „ In case of danger, switch off the electrical power and gas Depending on the chemical/physical properties of the supplies only if this can be done in total safety. system water, limescale or corrosion may damage the „...

  • Page 6: Iii.3

    Warnings III.3 EXCLUSIONS OF LIABILITY AND added. 2014/30/EC "Electromagnetic Compatibility Directive" as WARRANTY ▶ amended and added. 2014/35/EC "Low Voltage Directive" as amended and added. ▶ Any contractual or extra-contractual liability of the man- 2006/42/EC "Machine Directive" as amended and added. ▶...

  • Page 7: Features And Technical Data

    Features and technical data FEATURES AND TECHNICAL DATA FEATURES DIMENSIONS Operation 1.2.1 Caldaria 35 The Caldaria Condensing+ export units have been designed and Figure 1.1   Caldaria 35 dimensions built to meet the needs of space heating. These boilers (external modules) can also be installed outdoors. Part of the boiler casing is in sheet metal and part in ABS, but it is anyway approved to withstand atmospheric agents with par- ticular attention to the mechanical action of the UV rays of the...
  • Page 8 Features and technical data Figure 1.2   Caldaria 35 hydraulic connections (bottom view) Figure 1.4   Caldaria 55.1 hydraulic connections (bottom view) P1 P2 SVS SC 95 83 55 144 G SC Outlet Ø 3/4" M Outlet Ø 1 1/4" M System filling Ø 1/2" M Gas Ø...

  • Page 9: Components

    Features and technical data Figure 1.6   Caldaria 100.2 hydraulic connections (bottom view) Outlet Ø 1 1/4" M Gas Ø 1" M Inlet Ø 1 1/4" M Condensate drain Ø 25 mm M SPF Female socket SVS Safety valve drain Ø 19 mm M COMPONENTS 1.3.1 Caldaria 35...
  • Page 10 Features and technical data Figure 1.8   Internal hydraulic plan of Caldaria 35 Outlet Ø 3/4" M System filling Ø 1/2" M Gas inlet Ø 3/4" M Inlet Ø 3/4" M System drain tap Ø 10 mm M Condensate drain Ø 25 mm M SVS Safety valve drain Ø...
  • Page 11 Features and technical data Figure 1.10   Internal hydraulic plan of Caldaria 55.1 Outlet Ø 1 1/4" M Gas Ø 3/4" M Inlet Ø 1 1/4" M Condensate drain Ø 25 mm M SVS Safety valve drain Ø 19 mm M Flue safety thermal fuse Heat exchanger Burner unit Combustion blower...

  • Page 12: Technical Data

    Features and technical data Figure 1.12   Internal hydraulic plan of Caldaria 100.2 Outlet Ø 1 1/4" M Gas Ø 1" M Inlet Ø 1 1/4" M Condensate drain Ø 25 mm M SVS Safety valve drain Ø 19 mm M Flue safety thermal fuse Slave unit heat exchanger Burner unit Combustion blower...
  • Page 13 Features and technical data Caldaria 35 Caldaria 55.1 Caldaria 100.2 type Gas connection thread “ diameter (Ø) Flue gas exhaust residual head emission class Residual pressure head at nominal flow rate boiler only m w.c. Circulating pump data nominal flow at the maximum available head 1400 2150 4300...
  • Page 14 Features and technical data 1.4.2.1 Caldaria 35 Figure 1.15   Available head and pressure drop of Caldaria 35 [l/h] 1000 1250 1500 1750 2000 Pump characteristic curve Boiler pressure drop with no glycol in water Boiler pressure drop with 35,5% glycol water 1.4.2.2 Caldaria 55.1 Figure 1.16  ...
  • Page 15 Features and technical data 1.4.2.3 Caldaria 100.2 Figure 1.17   Available head and pressure drop of Caldaria 100.2 11,0 10,0 [l/h] 1000 2000 3000 4000 5000 6000 Pump characteristic curve Boiler pressure drop with no glycol in water Boiler pressure drop with 35,5% glycol water Installation, use and maintenance manual –...

  • Page 16: Electrical Wiring Diagram

    Features and technical data ELECTRICAL WIRING DIAGRAM 1.5.1 Caldaria 35 Figure 1.18   Caldaria 35 electrical connections diagram 220 V 50 Hz Pacq CON OT/Modbus interface (optional ODSP040) RS1 Heating resistance of condensate drain siphon Connector for optional room thermostat Remote control (optional OCDS006) DHW buffer tank probe (optional OSND011) Ignition transformer Standby contact...
  • Page 17 Features and technical data 1.5.2 Caldaria 55.1 Figure 1.19   Caldaria 55.1 electrical connections diagram T2 T1 Pacq 220 V 50 Hz CON OT/Modbus interface (optional ODSP040) DHW buffer tank probe (optional OSND011) Connector for optional room thermostat Remote control (optional OCDS006) Outdoor probe (optional OSND009) Ignition transformer Standby contact...
  • Page 18 Features and technical data 1.5.3 Caldaria 100.2 Figure 1.20   Caldaria 100.2 electrical connections diagram - slave board eBus +24 V RX IN TX OUT Connection to master board of the slave module Orange Ignition electrode Manifold probe White Flame detector SM OT/Modbus interface Light blue Blower Heating delivery probe...
  • Page 19 Features and technical data Figure 1.21   Caldaria 100.2 electrical connections diagram - master board eBus +24 V RX IN TX OUT Pacq 220 V 50 Hz • Connection to slave board DHW buffer tank probe (optional OSND011) Safety thermostat Remote control (optional OCDS006) Outdoor probe (optional OSND009) Connector for optional room thermostat Standby contact...

  • Page 20: Transport And Positioning

    Transport and positioning TRANSPORT AND POSITIONING WARNINGS Figure 2.1   Minimum clearance distances Damage from transport or installation The manufacturer shall not be liable for any damage dur- ing appliance transport and installation. On-site inspection „ Upon arrival at the site, ensure there is no transport dam- age on packing or boiler panels.

  • Page 21: Heating Engineer

    Heating engineer HEATING ENGINEER WARNINGS 3. Hang the boiler using the slots on the frame (Figure 3.3  p. 22 ). 3.1.1 General warnings In order to avoid condensation stagnation inside the boiler, it is necessary to tilt the boiler outwards by 1÷1.5° Read the warnings in Chapter III.1 ...

  • Page 22: Hydraulic Connections

    Heating engineer HYDRAULIC CONNECTIONS Figure 3.2   Caldaria 100.2 mounting jig The hydraulic installer must make the hydraulic connection cir- cuit to the heating system. To facilitate the connection to the system, the boiler is standard supplied with a kit of hydraulic fittings, located under the fitting cover.
  • Page 23 Heating engineer Table 3.1   % of glycol, correction factor for pressure drop Low roughness pipes Medium roughness pipes (copper, stainless steel and plastic) (black and galvanized steel) % of antifreeze glycol Protection temperature (°C) Correction factor for pressure drop Correction factor for pressure drop 1,06 1,08 1,08...
  • Page 24 Heating engineer Figure 3.7   Cap of the jolly valve on condensing block powered, press the button (Figure 6.1  p.  47 ): the symbol will appear on the display; after a few seconds turn off the boiler by pressing the button again (the symbol will appear on the display).

  • Page 25: Combustion Products Exhaust

    Heating engineer 3.3.4 Condensate drain siphon filling outlet of the combustion chamber. 3. Check that the gasket G is correctly positioned on the When switching on for the first time, the condensate siphon combustion chamber (Figure 3.11  p. 26 ). must be filled to prevent the combustion gases from backflow- 4.
  • Page 26 Heating engineer Figure 3.11   Correct gasket positioning Figure 3.13   Horizontal flue gas exhaust Gasket 3.4.2 How to realize the flue gas exhaust In case of flue gas discharge in correspondence of the boil- er, connect to the flue gas connection provided on the upper part of the casing the special rainproof terminal, available as an option (code OTRM031 for Caldaria 35 and Caldaria 55.1, code 3.4.3...

  • Page 27: Pump Antifreeze And Anti-Lock Function

    Heating engineer into a siphoned container connected to the sewerage falls below +4 ºC (antifreeze temperature ON) the control board system. starts the circulation pump and the burner ignition at minimum power. When the water temperature of the DHW buffer tank reaches 8 Maximum exhaust length ºC the control board will turn off the burner.
  • Page 28 Heating engineer Gas supply pressure [mbar] Product category Countries of destination G25.3 AL, BE, BG, CH, CZ, ES, FR, GB, GR, HR, IE, IT, LT, NL, LV, MK, PL, PT, SI, SK, TR 2H3P AT, BE, CH, CZ, DE, ES, FR, GB, HU, NL, SK AT, CZ, DE, NL, RO 2ELL3B/P 2Esi3P...

  • Page 29: Electrical Installer

    Electrical installer ELECTRICAL INSTALLER ELECTRICAL POWER SUPPLY Do not power and/or start the boiler before filling the hydraulic system, as this may damage the internal hy- draulic components. 4.2.1 Caldaria 35 How to connect the power supply WARNINGS 1. Remove the fitting cover and the ABS casing (Paragraph 5.2 ...

  • Page 30: Control Device

    Electrical installer CONTROL DEVICE Figure 4.2   Boiler power supply The Caldaria Condensing+ export is supplied as standard with an electrical bridge mounted on the Ta-Ta terminals (Caldaria 35) or on the T1-T2 terminals (Caldaria 55.1 and Caldaria 100.2), so that it can meet the service requests even without any oth- er control device, based solely on the board parameter settings and the operating mode set via the control panel on board the boiler.
  • Page 31 Electrical installer and stopping of the system can be avoided and optimal Figure 4.4   Connection of external request/room thermostat/OCDS006 comfort in the heated space can be guaranteed. remote control to Caldaria 55.1 and 100.2 4.3.2 Connection of external request/room thermostat/OCDS006 remote control To make the electrical connections of the room thermostat (TA) or of the remote control (optional OCDS006) or of an external request, proceed as described below.

  • Page 32: Operation Via Centralised External Request

    For further information on the operation and use of boilers in this mode, please contact the Robur technical service. DHW PRODUCTION The Caldaria Condensing+ export appliances can manage au-...
  • Page 33 Electrical installer The DHW buffer tank thermostat must be used as an alternative Figure 4.7   Connection of DHW diverter valve to the DHW buffer tank probe (Paragraph 4.5.2  p. 33 ). The cable may not be longer than 50 metres, with a minimum cable cross-section of 0,5 mm Figure 4.9  ...

  • Page 34: First Start-Up

    Figure 5.1  p. 34 . Robur TAC. NEITHER the user NOR the installation tech- 2. Remove the fastening screws 2 located on the upper and...

  • Page 35: How To Access The Control Panel

    First start-up 5.2.2 Caldaria 55.1 and 100.2 the four hooks 2. 4. Remove the C casing upwards. To work on the front side of the boiler (Figure 5.2  p. 35 ): 1. Open locks 1 with a triangle key. Figure 5.3   Accessing the control panel 2.
  • Page 36 First start-up simultaneously and wait for the symbol to appear on the Figure 5.4   Caldaria 100.2 - Control panels position display. Only for Caldaria 100.2 All parameters must be set/modified from the master control panel. Parameters P00, P10, P11, P12, P13 and P14 must also be set/modified from the slave control panel (Figure 5.4 ...
  • Page 37 First start-up 0 = disabled Heating run-up 1 = 50 s It is possible to set the time, during the start-up phase, that the boiler takes to reach 0 ÷ 4 2 = 100 s the maximum set power (for the space heating service). 3 = 200 s 4 = 400 s Anti-water hammer function...
  • Page 38 First start-up Modulating pump maximum speed It is possible to set the maximum speed value of the modulating pump during a 70 ÷ 100 Value in percentage request for space heating operation. DHW buffer tank setpoint differential It is possible to set the differential value with respect to the DHW setpoint at which the DHW buffer tank charge is activated.
  • Page 39 First start-up DHW position holding function By enabling this function it is possible to keep the DHW diverter valve in the DHW 0 = disabled 0 ÷ 1 position for a time equal to the DHW post-circulation (parameter P09), in order to 1 = enabled exploit this heat as well.
  • Page 40 First start-up Modbus address P26 (3) Do not modify Not used Modbus communication baud rate P27 (3) Do not modify Not used Modbus mode P28 (3) Do not modify Not used Post-circulation heating Δt It is possible to set the temperature difference from the main burner shut down due 0 ÷...
  • Page 41 First start-up Minimum blower speed adjustment for DHW It is possible to set the minimum speed of the blower for the DHW service, which P10 (1) (2) corresponds to the minimum power of the burner during a DHW request (see Figure 38 ÷...
  • Page 42 First start-up Modbus communication baud rate P33 (4) Do not modify Not used Status of the additional solar board Do not modify Not used Activation of the auxiliary relay on the SVZ additional board Do not modify Not used Water flow control enable during start-up 0 = disabled 0 ÷...

  • Page 43: Combustion Parameters Check

    First start-up 5.4.5.1 Caldaria 35 Figure 5.7   Heat input/blower frequency diagram G25.3 Freq (Hz) Thermal input Freq Frequency 5.4.5.2 Caldaria 55.1 and 100.2 Figure 5.8   Heat input/blower frequency diagram G25.3 Freq (Hz) Thermal input Freq Frequency 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 CO...
  • Page 44 First start-up ignition request is disabled. The regular operation of the Figure 5.9   Gas valve boiler is allowed only when the operation is completed. To check and calibrate the CO value at maximum and minimum power, proceed as follows, referring to Figure 5.9  p. 44 . The CO values and other parameters useful to verify combus- tion are summarized in Table 5.5 ...

  • Page 45: Gas Changeover

    First start-up 5.5.2 Maximum heating power Figure 5.11   Gas changeover 1. Press the key of the heating side for the calibration of the maximum heating power. 2. Check that the CO value complies to the value shown in Table 5.5  p. 44 . 3.

  • Page 46: Anti-Legionella Service Settings

    First start-up enable is closed, the burner ignition will start. (Figure 6.1  p. 47 ). In this way the appliance is in standby mode 9. In case of lack of flame, the board repeats the ignition opera- symbol appears on the display). tions again after the post-ventilation (20 seconds).

  • Page 47: Normal Operation

    Normal operation NORMAL OPERATION This section is for the end user. after the Robur authorised TAC has completed the first start-up. The use of the device by the end user is only permitted Figure 6.1   External module control panel Heating temperature adjustment keys...

  • Page 48: Warnings

    1. If the boiler does not start up, the relative error will be indi- cated both on the remote control and on the internal panel First start-up may exclusively be carried out by a Robur of the boiler. It will be possible to reset the boiler either re- TAC (Chapter 5 ...

  • Page 49: Remote Control Operation (Optional)

    Maintenance of 30 °C to a maximum of 80 °C. control. 6.3.6 Setting the DHW temperature INFO MENU DISPLAY The temperature is adjusted using the keys of the DHW circuit (Figure 6.1  p. 47 ): To view the boiler data from Info menu you have to: 1.
  • Page 50 Maintenance When all the water has drained off, close the drain tap. ▶ Figure 7.3   Caldaria 100.2 - Drain tap position Figure 7.1   System drain tap position Drain tap Drain tap Figure 7.2   Caldaria 55.1 - Drain tap position Drain tap...

  • Page 51: Diagnostics

    Diagnostics DIAGNOSTICS In the event of a malfunction of the appliance, before contacting To scroll through the list of stored faults, use the ▶ the TAC, make sure that: keys of the heating side There is a full electricity supply. ▶...
  • Page 52 Diagnostics Code Fault Possible cause Remedial action Reset Probe fault or out of calibration (nominal resist- Replace ance 10 KΩ at 25 °C) Return probe fault Automatic Probe connector wet or disconnected Check the electrical connection Blower board fault Replace Blower fault Broken blower Replace...

  • Page 53: Appendices

    (**) Low temperature means for condensing boilers 30 °C, for low-temperature boilers 37 °C and for other heaters 50 °C return temperature (at heater inlet). Contact details Robur SPA, Via Parigi 4/6, I-24040 Zingonia (BG) Additional information required by COMMISSION REGULATION (EU) No 813/2013, Table 1: mg/kWh Emissions of nitrogen oxides: Installation, use and maintenance manual –...
  • Page 54 (**) Low temperature means for condensing boilers 30 °C, for low-temperature boilers 37 °C and for other heaters 50 °C return temperature (at heater inlet). Contact details Robur SPA, Via Parigi 4/6, I-24040 Zingonia (BG) Additional information required by COMMISSION REGULATION (EU) No 813/2013, Table 1: mg/kWh Emissions of nitrogen oxides: 9.1.3...
  • Page 56 Robur mission Robur is dedicated to dynamic progression in research, development and promotion of safe, environmentally-friendly, energy-efficiency products, through the commitment and caring of its employees and partners. Robur S.p.A. advanced technologies for air conditioning via Parigi 4/6 24040 Verdellino/Zingonia (BG) Italy +39 035 888111 - F +39 035 884165 www.robur.it robur@robur.it...

This manual is also suitable for:

Caldaria 55.1 condensing+ exportCaldaria 100.2 condensing+ exportCaldaria condensing+ exportCaldaria 35Caldaria 55.1Caldaria 100.2

Table of Contents