Robur Caldaria Tech Export Installation, Use And Maintenance Instruction Manual

Outdoor condensing boiler for heating medium and large buildings and production of domestic hot water with a buffer tank

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Installation, use and maintenance manual

Caldaria Tech Export

Outdoor condensing boiler

for heating medium and large buildings

and production of domestic hot water with a buffer tank

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Page 1 Installation, use and maintenance manual Caldaria Tech Export Outdoor condensing boiler for heating medium and large buildings and production of domestic hot water with a buffer tank Powered by natural gas/LPG/H2NG...
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
Pump antifreeze and anti-lock function �� 27 Product fiche �� 54 Fuel gas supply �� 28 EU Declaration of conformity (DoC) �� 56 4 Electrical installer �� 29 Warnings �� 29 Installation, use and maintenance manual – Caldaria Tech Export...
Page 4: Iintroduction
▶ Qualified installer, for correct appliance installation. ▶ Planner, for specific information on the appliance. This Manual is an integral part of the Caldaria Tech Export ▶ appliance and must be handed to the end user together with the appliance.
Page 5: Iii.2
Efficiency Directive 92/42/EEC and subsequent modifica- ▶ paints, etc.) near the appliance. tions and additions. 2016/426/EU "Gas Appliances Regulation" as amended and ▶ Limescale and corrosion added. 2014/30/EC "Electromagnetic Compatibility Directive" as ▶ Installation, use and maintenance manual – Caldaria Tech Export...
Page 6: Iii.3
Warnings amended and added. ufacturer for any damage caused by incorrect installa- 2014/35/EC "Low Voltage Directive" as amended and added. tion and/or improper use and/or failure to comply with ▶ 811/2013/EU "Energy-Related Products regulation" as regulations and with the manufacturer's directions/in- ▶...
Page 7: Features And Technical Data
1.1.1 Operation 1.2.1 Caldaria 35 Tech The Caldaria Tech Export units have been designed and built to Figure 1.1 Caldaria 35 dimensions meet the needs of space heating. These boilers (external mod- ules) can also be installed outdoors. Part of the boiler casing is in sheet metal and part in ABS, but it...
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
System drain tap Safety thermostat Heating delivery probe Ignition electrode Expansion tank Ignition transformer Air intake pipe Venturi Water pressure switch Condensate drain siphon System filling tap Safety valve drain Condensate drain Installation, use and maintenance manual – Caldaria Tech Export...
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 Ignition transformer Venturi Safety valve Pressure gauge Manifold probe Master unit heat exchanger Air pressure switch Expansion tank System drain tap Water pressure switch Condensate drain siphon Condensate drain Safety valve drain Installation, use and maintenance manual – Caldaria Tech Export...
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 Figure 1.14 Water pump characteristic curves Figure 1.13 Water pump characteristic curves p/kPa 5%/100% 15%/89,1% 25%/78,3% 35%/67,4% 45%/56,6% 55%/45,7% 65%/34,8% 75%/24,0% Q/m³/ h Q/l/s Q/Igpm In Caldaia 100.2 Tech there are 2 circulators. max. Q/m³/ h Installation, use and maintenance manual – Caldaria Tech Export...
Page 14 Features and technical data 1.4.2 Pressure drops and residual head Table 1.2 Nominal flow rate and residual head Caldaria 35 Tech Caldaria 55.1 Tech Caldaria 100.2 Export Export Tech Export Installation data nominal flow at the maximum available head 1400 2150 4300 Water pump data Residual pressure head at nominal flow rate...
Page 15 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 – Caldaria Tech Export...
Page 16: Electrical Wiring Diagram
Features and technical data ELECTRICAL WIRING DIAGRAM 1.5.1 Caldaria 35 Tech 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 Antifreeze thermostat Grey PM Modulating water pump DHW thermostat (alternative to SB probe) ma Brown Pacq Water pressure switch Flue gas thermofuse Black RS1 Heating resistance of condensate drain siphon Safety thermostat Installation, use and maintenance manual – Caldaria Tech Export...
Page 18 Features and technical data 1.5.3 Caldaria 100.2 Tech 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...
Page 19 Yellow PM Modulating water pump Antifreeze thermostat Grey Pacq Water pressure switch DHW thermostat (alternative to SB probe) ma Brown RS1 Heating resistance of condensate drain siphon Flue gas thermofuse Black Installation, use and maintenance manual – Caldaria Tech Export...
Page 20: Transport And Positioning
Transport and positioning TRANSPORT AND POSITIONING WARNINGS 2. reductions from Ø 1 1/4" M to Ø 1" F. 2. gaskets for fittings. 1. instruction sheet for fitting assembly. Damage from transport or installation 2.2.3 Caldaria 100.2 Tech The manufacturer shall not be liable for any damage dur- The installation kit supplied with the boiler includes: ing appliance transport and installation.
Page 21: Heating Engineer
(Ø 80 mm) indicated on the jig. 4. Unscrew the fixing screws of the lower bracket ensuring the Installation, use and maintenance manual – Caldaria Tech Export...
Page 22: Hydraulic Connections
Heating engineer free sliding of the bracket with respect to the boiler (Figure Figure 3.3 Installation of the wall frame and of the boiler 3.4 p. 22 ). 5. Tilt the boiler about 1÷1.5° vertically (Figure 3.4 p. 22 ). To lock the boiler position, tighten the fixing screws of the low- er bracket.
Page 23 1, Figure 3.5 p. 24 ) to let the air out of the system. 2. Slightly loosen the cap of the jolly valve placed on the top of When using the antifreeze glycol available as a Robur op- the condensing block (Figure 3.7 p. 24 ) to release the air tional, the characteristics can be found in the Instruction from the top of the boiler.
Page 24 Heating engineer Figure 3.7 Cap of the jolly valve on condensing block off the boiler by pressing the key again (the symbol will appear on the display). The water pump will remain in operation for a few minutes. Repeat the operation several times until the pressure of the circuit remains unchanged.
Page 25: Combustion Products Exhaust
When the boiler arrives at the building site, the flanged socket Installation, use and maintenance manual – Caldaria Tech Export...
Page 26 Heating engineer is resting on the flue outlet of the combustion chamber, but it Figure 3.11 Correct gasket positioning is not fixed, and cannot therefore be used if it is not correctly Gasket positioned and fixed. Mounting the flanged socket (Ø 60/80 mm) 1.
Page 27: Pump Antifreeze And Anti-Lock Function
When the water temperature of the DHW buffer tank The connection of the discharge to the sewerage system reaches 8 ºC the control board will turn off the burner. must be made at atmospheric pressure, i.e. by dripping Installation, use and maintenance manual – Caldaria Tech Export...
Page 28: Fuel Gas Supply
Heating engineer Electrical and gas continuity and the gas piping. 3.6.2 Mandatory shut-off valve The antifreeze function is only effective if the power and gas supplies are assured. Otherwise, antifreeze fluid in Provide a gas shut-off valve (manual) on the gas supply line, ▶...
Page 29: Electrical Installer
(Figure 4.1 p. 30 ). ing system, installed in compliance with regulations in 3. Perform connections as shown in Figure 4.1 p. 30 . force. 4. The ground wire to the terminal marked with the ground Installation, use and maintenance manual – Caldaria Tech Export...
Page 30: Control Device
CONTROL DEVICE 4.2.2 Caldaria 55.1 and 100.2 Tech The Caldaria Tech Export is supplied as standard with an elec- trical bridge mounted on the Ta-Ta terminals (Caldaria 35 Tech How to connect the power supply Export) or on the T1-T2 terminals (Caldaria 55.1 Tech Export and Caldaria 100.2 Tech Export), which must be removed when the...
Page 31 Remove the electrical bridge on the Ta-Ta contacts and then connect the two non-polarized conductors on the Ta-Ta contacts (Figura 4.3 p. 31 ). After the operation, reassemble the plate A, the front panel, the ABS casing and the fitting cover. Installation, use and maintenance manual – Caldaria Tech Export...
Page 32: Dhw Production
4.3.4 Connection of OSND009 outdoor probe The OSND009 outdoor probe must be connected as described The Caldaria Tech Export appliances can manage autonomously below. the production of buffer tank DHW, through the control of an ex- The cable may not be longer than 30 metres.
Page 33: Operation Via Centralised External Request
(Caldaria 35 Tech Export and Caldaria 55.1 Tech Export) or 1 board for Caldaria 100.2 Tech Export) (Figure 4.9 p. 33 ). (Caldaria 100.2 Tech Export) (Paragraph 5.4 p. 36 ), when Installation, use and maintenance manual – Caldaria Tech Export...
Page 34: First Start-Up
CS terminal block located inside the MP panel terminal block (Figures For further information on the operation and use of 1.19 p. 17 and 1.20 p. 18 ). boilers in this mode, please contact the Robur technical service. FIRST START-UP 5.1.3...
Page 35: How To Access The Control Panel
4. Remove the fixing screws 5 located in the front and bottom edge of the side panel E. 5. Grab the base of panel E and, after moving it downwards, rotate it outwards and remove it. Installation, use and maintenance manual – Caldaria Tech Export...
Page 36: Electronic Board Parameters Setting
First start-up Figure 5.3 Accessing the control panel 4. Use the keys of the DHW circuit to change the value of the parameter. 5. Press the key to confirm and wait for the display to stop flashing, to make the adjustment effective. 6.
Page 37 It is possible to set the operating time of the pump, for the DHW service, after the 0 ÷ 90 5 = 120 s) setpoint in the DHW buffer tank has been reached. Installation, use and maintenance manual – Caldaria Tech Export...
Page 38 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 corresponds to the minimum power of the burner during a DHW request (see Figure 45 ÷ P11 Value in hertz (1 Hz = 30 RPM) 5.7 ...
Page 39 45 ÷ P11 Value in hertz (1 Hz = 30 RPM) 5.8 p. 44 ). The value is preset according to the set power (parameter P00) and the type of gas (parameter P02). Installation, use and maintenance manual – Caldaria Tech Export...
Page 40 First start-up Maximum blower speed adjustment for DHW It is possible to set the maximum speed of the blower for the DHW service, which corresponds to the maximum power of the burner during a DHW request (see Figure P10 ÷ 203 Value in hertz (1 Hz = 30 RPM) 5.8 ...
Page 41 38 ÷ P13 Value in hertz (1 Hz = 30 RPM) Figure 5.8 p. 44 ). The value is preset according to the set power (parameter P00) and the type of gas (parameter P02). Installation, use and maintenance manual – Caldaria Tech Export...
Page 42 First start-up Maximum blower speed adjustment for heating It is possible to set the maximum speed of the blower for the heating service, which P13 (1) corresponds to the maximum power of the burner during a heating request (see P12 ÷ 290 Value in hertz (1 Hz = 30 RPM) Figure 5.8 ...
Page 43 Caldaria 35 Tech Export, Caldaria 55.1 Tech Export, Caldaria 100.2 Tech Export: 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 – Caldaria Tech Export...
Page 44: Combustion Parameters Check
First start-up 5.4.5.1 Caldaria 35 Tech Figure 5.7 Heat input/blower frequency diagram G25.3 G2.350 Freq (Hz) Ti Thermal input Freq Frequency 5.4.5.2 Caldaria 55.1 and 100.2 Tech Figure 5.8 Heat input/blower frequency diagram G25.1 G25.3 G2.350 Freq (Hz) Ti Thermal input Freq Frequency COMBUSTION PARAMETERS CHECK The ignition system will automatically activate the system...
Page 45 For the Caldaria 100.2 Tech Export model, the flue gas analysis socket must be provided on the flue gas exhaust pipe. It is already provided on the rainproof terminal, available as optional OTRM009. Installation, use and maintenance manual – Caldaria Tech Export...
Page 46: Gas Changeover
First start-up Table 5.5 Caldaria combustion parameters Caldaria 35 Tech Caldaria 55.1 Tech Caldaria 100.2 Tech Export Export Export Installation data 9,45 ÷ 9,25 9,3 ÷ 9,1 9,35 ÷ 9,15 9,3 ÷ 9,1 G25.1 - (1) 10.5 ÷ 10,3 G25.3 9,3 ÷ 9,1 Nominal heat input G2.350 9,4 ÷...
Page 47: Anti-Legionella Service Settings
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 completed the first start-up. Installation, use and maintenance manual – Caldaria Tech Export...
Page 48: Warnings
This may be harmful and dangerous for the appliance and for the system. First startup by TAC PRELIMINARY CHECKS First start-up may exclusively be carried out by a Robur TAC (Chapter 5 p. 34 ). Checks before switching on Never power the appliance off while it is running...
Page 49: Operation Without Remote Control
3. Whenever there is a request for space heating, the automatic trol. ignition system will ignite the burner; the operation is repre- Installation, use and maintenance manual – Caldaria Tech Export...
Page 50: Info Menu Display
Maintenance INFO MENU DISPLAY Combustion blower speed Not used temperature To view the boiler data from Info menu you have to: Return probe temperature 1. Press the key (Figure 6.1 p. 48 ). The info code will be d5 - dE Not-operating data displayed on the left side of the screen and its value will be Table 6.2 ...
Page 51: Diagnostics
E(x), where (x) will be the number of the chron- ure 6.1 p. 48 ) and press and hold the key for 5 seconds. ological order in the last 5 reports. Installation, use and maintenance manual – Caldaria Tech Export...
Page 52 Diagnostics Table 8.1 Error codes Code Fault Possible cause Remedial action Reset Without flame ignition No gas supply Check the gas supply network Broken or badly positioned ignition electrode Replace Gas valve fault Replace Manual reset (press Adjust the minimum pressure to the burner or Slow ignition set too low key) (1) slow ignition...
Page 53 It is activated or deactivated by holding down the reset keys of the DHW circuit for 7 seconds. Only for boilers with DHW production. Only for boilers with instantaneous production of DHW. Installation, use and maintenance manual – Caldaria Tech Export...
Page 54: 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...
Page 55 (**) 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 – Caldaria Tech Export...
Page 56: Eu Declaration Of Conformity (Doc)
Parigi 4/6 24040 Verdellino/Zingonia (BG) Italy Tel. +39 035.888.111 Fax +39 035.884.165 capitale sociale € 2.028.000,00 i.v. iscritta al Registro Imprese di Bergamo n.154968 codice fiscale/partita iva 00373210160 V.A.T. code IT 00373210160 società soggetta all'attività di direzione e coordinamento di Fin Robur S.r.l.
Page 60 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.com export@robur.it...

This manual is also suitable for:

Caldaria 35 tech export Caldaria 55.1 tech export Caldaria 100.2 tech export