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Summary of Contents for Robur AY
- Page 1 Installation, use and maintenance manual Outdoor condensing boiler for heating 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.
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Page 3: Table Of Contents
System pressure restore ........p. 42 Warnings ..............p. 17 Error codes ............p. 42 Hydraulic connections ........p. 18 Fuel gas supply ............ p. 21 9 Appendices ................p. 45 Combustion products exhaust ...... p. 23 Product fiche ............p. 45 Installation, use and maintenance manual – AY... -
Page 4: Iintroduction
▶ and must be handed to the end user together with the appliance. CONTROL DEVICE In order to work, the AY appliance requires a control de- RECIPIENTS vice to be connected by the installer. This Manual is intended for: SYMBOLS AND DEFINITIONS II.1... - Page 5 „ Do not touch the flue gas exhaust before it has may exclusively be carried out by a TAC, using only cooled down. original spare parts. „ In the event of failure of the appliance and/or Electrocution hazard Installation, use and maintenance manual – AY...
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Page 6: Iii.2 Compliance
Warnings breakage of any component, do not attempt to Furthermore, they comply with the requirements of the repair and/or restore and immediately contact the following standards: TAC. EN 15502 Gas-fired central heating boilers. ▶ III.2.2 Other applicable provisions and standards Routine maintenance The design, installation, operation and maintenance of Proper maintenance assures the efficiency and... -
Page 7: Features And Technical Data
Figure 1.2 Unit dimensions ble of producing hot water up to 88 °C. The range includes three models: AY 35, AY 50, AY 100. The boiler casing is approved to resist weathering with particular regard to the action of UV rays. - Page 8 GAS Gas connection Ø 1" M Figure 1.7 Service plate - Detail of bottom plate Boiler safety valve drain external Ø 20 mm, internal Ø 14 mm 1.2.2 AY 100 Figure 1.5 Unit dimensions Boiler safety valve drain external Ø 20 mm, internal Ø 14 mm...
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Page 9: Electrical Wiring Diagram
Light blue Line SRi Heating return probe Yellow MP Control panel terminal block Antifreeze thermostat Grey Neutral TA Connector for optional room thermostat ma Brown PM Water pump TF Flue gas thermofuse ne Black Installation, use and maintenance manual – AY... - Page 10 Features and technical data 1.3.2 AY 50 Figure 1.12 Boiler electrical connections diagram JUMPER SHIELD BN-MA BU-BL BN-MA BU-BL BN-MA BU-BL BN-MA BU-BL YE-GI WH-BI BN-MA GN-VE SCH2 YE-GI GN-VE YE-GI GN-VE Pacq connett. SAux CAN bus connection Pacq Water pressure switch...
- Page 11 Light blue EV Blower SR Heating delivery probe Yellow FM Flowmeter SRi Heating return probe Grey Line Antifreeze thermostat ma Brown Neutral TF Flue gas thermofuse ne Black PM Water pump TS Safety thermostat Installation, use and maintenance manual – AY...
- Page 12 Features and technical data Figure 1.14 Boiler electrical connections diagram - Module 1 BN-MA BU-BL JUMPER SHIELD BN-MA BU-BL BN-MA BU-BL BN-MA BU-BL BN-MA BU-BL YE-GI WH-BI BN-MA GN-VE SCH2 Pacq connett. SAux Connection of TA2 connector to module PM Water pump TF Flue gas thermofuse Pacq Water pressure switch TS Safety thermostat...
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Page 13: Electronic Boards
▶ appliance. 1.5.2 DDC Controller The DDC control is able to manage one or more Robur ap- In the case of the AY 100 appliance, two separate pliances in ON/OFF mode (GAHP heat pumps, GA chillers) requests must be provided for the two thermal or modulating mode (AY boilers). - Page 14 1.6.1 Circulating pump characteristic curves Figure 1.15 Oversized pressure head circulating pump characteristic curves p/kPa max. 25/10, 30/10 1~230 V - Rp 1, Rp 1¼ Q/m³/h max. Q/m³/h Q/m³/h 2,5 Q/l/s Q/l/s There are two water pumps in the AY 100 appliance.
- Page 15 1.6.3.1 AY 35 Figure 1.17 Available head and pressure drop of the boiler [bar] [l/h] 1000 1500 2000 2500 3000 3500 Boiler pressure drop with 20% glycol water Boiler pressure drop with no glycol in water Installation, use and maintenance manual – AY...
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Page 16: Transport And Positioning
3500 Boiler pressure drop with 35% glycol water Boiler pressure drop with no glycol in water For AY 100 the curve is the same, as the boiler consists of pump. two thermal modules in parallel, each with its own water... -
Page 17: Handling And Lifting
Read the warnings in Chapter III.1 p. 4 , pro- tion and maintenance of: viding important information on regulations and „ heating systems on safety. „ gas systems „ flue gas exhaust „ flue gas condensate discharge Compliance with installation standards Installation, use and maintenance manual – AY... -
Page 18: Hydraulic Connections
1.2 p. 7 ). 2. Open the system filling valve (to be provided on the 3.2.1.1 AY 35 and AY 50 system) and let out all the air. 3. Check with pressure gauge that system pressure Water outlet connection Ø... - Page 19 3. Connect a rubber hose to the drain tap (detail 2, Figure 3.2 p. 19 ). How to vent the water pumps of AY appliances 4. Open the drain tap (detail 2, Figure 3.2 p. 19 ) 1. Turn off the system by means of provided control de- counterclockwise.
- Page 20 Pump anti-lock function the circulation pumps. In order to prevent the circulation pump from lock- Figure 3.3 Pump/Roma valve assembly on AY appliances ing, the boiler is equipped with an anti-lock func- tion which, every 24 hours of inactivity, operates the circulation pump for 30 seconds.
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Page 21: Fuel Gas Supply
The appliance gas supply pressure, both static and dynamic, must comply with the values in the Table, with a tolerance of ± 15%. Gas not available for Caldaia 35 Tech, Caldaia 35 Tech ACS, Caldaria 35, AY 35. Installation, use and maintenance manual – AY... - Page 22 The appliance gas supply pressure, both static and dynamic, must comply with the values in the Table, with a tolerance of ± 15%. Gas not available for Caldaia 35 Tech, Caldaia 35 Tech ACS, Caldaria 35, AY 35. Before proceeding with the construction of the system, appliance.
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Page 23: Combustion Products Exhaust
C. 4. Poistion the flanged socket B over the gasket A and se- For the AY 100 appliance, the flue gas exhaust kit is double and the kit must be installed on both thermal modules. -
Page 24: Flue Gas Condensate Drain
45° Ø 80 mm the boiler. T connector Ø 80 mm 17,4 AY 50/AY 100 In case the check valves are installed outside, an extension pipe Ø 80 mm, length 1000 appropriate UV ray protection must be assured (if the valve is in plastic) as well as protection from elbow 90°... -
Page 25: Electrical Installer
1. Ensure the appliance is not live. 2. Remove the appliance front panel (Figure Earthing 5.1 p. 31 ). 3. Unscrew the two screws and remove the electrical Installation, use and maintenance manual – AY... -
Page 26: Electrical Power Supply
CAN bus signal cable, shielded, compliant to Table 4.1 p. 27 (admissible types and maximum distances). How to connect the power supply For lengths ≤200 m and up to 4 nodes (e.g. 1 DDC + 3 AY), a simple 3x0,75 mm shielded cable may be used. - Page 27 Paragraphs and in the DDC manual. Figure 4.5 Connection of the CAN bus cable to the electronic For the AY 100 appliance, the CAN bus connection board between the two modules is factory wired. Back of the electrical panel...
- Page 28 Electrical installer Figure 4.6 CAN bus connection for systems with one unit JUMPER SHIELD 0 L H SHIELD DDC Direct Digital Controller Common data CAN bus cable shield SCH CAN-NDG board Data signal HIGH Insulating tape to protect the shield of the J11 CAN bus jumper on CAN-NDG board Data signal LOW CAN bus cable...
- Page 29 Use a cable with a cross-section between 0,5 and 1,5 mm², with a maximum length of 50 metres. External request/room thermostat For the AY 100 appliance, two separate requests must be provided, one for each of the Ta1-Ta2 con- 4.4.5.1 Thermostat/chronothermostat location...
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Page 30: First Start-Up
0-10 V Control via 0-10 V signal is alternative to control via DDC panel or external request. The 0-10 V signal connection is only available on AY 35 and AY 50 models. Either the water temperature setpoint or the power value can be communicated alternatively via a 0-10 V analogue signal. -
Page 31: Electronic Board Parameters Setting
1.001 for the CAN-NDG board and to the firmware A.10 for the MIAH410 board. The parameters and their values refer to the Table 5.1 AY 35 electronic board parameters Parameter Description Range Default Setting Installation, use and maintenance manual – AY... - Page 32 First start-up Boiler model selection 17 ÷ 18 17. AY 35 Mod0 type Do not change Not used Serial number Mod0 - 3 most significant digits 000 ÷ 999 Do not change Not used Serial number Mod0 - 3 intermediate digits 000 ÷...
- Page 33 P69 and P70 based on the line passing For AY 100 all parameters must be set/edited inde- through the points (3 V, P69) and (10 V, P70). A volt- pendently on each of the two control panels.
- Page 34 V, maximum power). A voltage lower than 3 V corre- the Kd value set in parameter P66 (Figure 5.3 p. 35 ). sponds to no service request. Control via 0-10 V input 3. With 0-10 V input active in temperature control mode, is not available for AY 100.
- Page 35 G2.350 AY 100 Caldaria 35, Caldaria 55.1, Caldaria 100.2: check parameters P10 and P11 for DHW, P12 and P13 for heating. AY 35, AY 50, AY 100: check parameters P62 and P63 for heating. Installation, use and maintenance manual – AY...
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Page 36: Combustion Parameters Check
First start-up 5.3.4.1 AY 35 Figure 5.4 Heat input/blower frequency diagram G25.3 Freq (Hz) Ti Thermal input Freq Frequency 5.3.4.2 AY 50 and AY 100 Figure 5.5 Heat input/blower frequency diagram G25.1 G25.3 G2.350 Freq (Hz) Ti Thermal input Freq Frequency COMBUSTION PARAMETERS CHECK... - Page 37 (detail PF, Figure 5.7 p. 37 ). Figure 5.7 Socket for flue gas analysis 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.
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Page 38: Gas Changeover
ONLY the antifreeze function (system water) and the 6. Deactivate the chimney sweep function by switching boiler pump anti-lock function remain active. For AY 100, remember to act on both modules. the boiler to OFF mode using the button ( symbol appears on the display). -
Page 39: Normal Operation
NORMAL OPERATION This section is for the end user. The use of the device by the end user is only per- mitted after the Robur authorised TAC has com- pleted the first start-up. Figure 6.1 Boiler control panel Heating temperature adjustment... -
Page 40: Preliminary Checks
Normal operation 4. The fixed symbol that appears on the display, corre- First start-up may exclusively be carried out by a Robur TAC (Chapter 5 p. 30 ). sponding to the operating mode, indicates that the function has been activated. Never power the appliance off while it is run-... -
Page 41: Operation With Ddc Control
„ Water temperature probes maintenance operation" must be performed with Periodic analysis of combustion, in accordance with ▶ a frequency according to current regulations or, regulations in force if more restrictive, according to the provisions set Installation, use and maintenance manual – AY... -
Page 42: Hydraulic Boiler Emptying
Diagnostics HYDRAULIC BOILER EMPTYING Figure 7.1 Drain tap position Whenever there is a need to empty the boiler, proceed as follows: Switch off the boiler by pressing the button. ▶ Only after the water pump has completed its post-cir- ▶ culation cycle, cut off the power supply via the main switch. - Page 43 Incompatibility of boiler board FW version Contact the TAC. NA: Not Applicable The special functions listed below are also shown on the DDC control, if any, as warnings, always adding the hun- dreds digit "1" to the code. Installation, use and maintenance manual – AY...
- Page 44 Diagnostics Table 8.2 Function codes Code Function Description It is activated by pressing the reset key for 7 seconds and it is deactivated by turning off the boiler. Chimney sweep Brings the boiler to the minimum and maximum power for 15 minutes by deactivating the modulation function. function active Generally used for combustion and calibration tests.
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Page 45: 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 46 (**) 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: Emissions of nitrogen oxides:...
- Page 47 (**) 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 48 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...
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