Robur AY00-120 Installation, User And Maintenance Manual
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Robur AY00-120 Installation, User And Maintenance Manual

4 star condensation boiler for heating ay condensing line, ay series
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Installation, user and
maintenance manual
AY Condensing line, AY Series
4 star condensation boiler
for heating
gas fired

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  • Page 1 Installation, user and maintenance manual AY Condensing line, AY Series 4 star condensation boiler for heating gas fired...
  • Page 2 Revisione: J Codice: D-LBR531 This manual has been drawn up and printed by Robur S.p.A.; whole or partial reproduction of this manual is prohibited. The original is filed at Robur S.p.A. Any use of this manual other than for personal consultation must be previously authorised by Robur S.p.A.

  • Page 3: Table Of Contents

    INDEX OF CONTENTS 1 PREFACE �������������������������������������������������������������������������������������������������������������������������������������������������� 4 2 SAFETY WARNINGS �������������������������������������������������������������������������������������������������������������������������������� 5 3 OVERVIEW AND TECHNICAL FEATURES ���������������������������������������������������������������������������������������������� 7 GENERAL INFORMATION ......................................7 OVERVIEW OF OPERATION ......................................8 TECHNICAL MANUFACTURING CHARACTERISTICS ............................9 TECHNICAL DATA ........................................9 DIMENSIONS AND SERVICE PANEL ..................................11 4 NORMAL OPERATION �������������������������������������������������������������������������������������������������������������������������� 13 START UP (AND SHUT DOWN) .....................................

  • Page 4: Preface

    This "Installation, user and maintenance manual" is a guide to the installation and operation of the AY Condensing Line base-mounted gas boiler. In particular, the manual deals with the AY00-120 model, hereinafter called "appliance", of the AY Series, and is intended for use by: final users for the operation of the appliance according to their own requirements;...

  • Page 5: Safety Warnings

    SAFETY WARNINGS SAFETY WARNINGS Packing items (plastic bags, polystyrene foam, nails, etc.) must be kept out of the reach of children, as they are potentially dangerous. The appliance must only be used for the purposes for which it has been designed. Any other use is considered inappropriate and therefore dangerous.
  • Page 6 SAFETY WARNINGS Stipulate a maintenance contract with an authorised specialist contractor for the annual inspection of the appliance and mainte- nance when needed. Maintenance and repairs may only be done a contractor legally authorised to work on gas appliances and equipment. Only accept and use original spare parts.

  • Page 7: Overview And Technical Features

    Before contacting your authorised Robur Technical Assistance Centre (TAC) for the initial activation, the firm must ensure that: the electricity and gas mains specifications correspond to the specifications on the nameplate;...

  • Page 8: Overview Of Operation

    Carry out maintenance operations according to the instructions supplied by the manufacturer (see Paragraph 7.2   53). → For maintenance of the appliance’s internal components, contact a Robur TAC or qualified technician; for other maintenance require- ments, see Paragraph 7.2   53.

  • Page 9: Technical Manufacturing Characteristics

    OVERVIEW AND TECHNICAL FEATURES Figure 3�1 – CCI/DDC AY00-120: description and general characteristics the appliance (see Figure 3.2   11) is a B53P type high efficiency boiler ( star efficiency class as per Directive 92/42/CEE). → The appliance is a Range Rated boiler: the power delivery of the appliance can be adapted to the real system requirements by regu- lating the nominal gas flow (nominal thermal input).
  • Page 10 Weight In operation AY00-120 operational and installation technical characteristics. Table 3�2 – Table of pressure drop of a single unit - AY serie PRESSURE DROP OF A SINGLE AY00-120 CONDENSING UNIT WATER TEMPERATURE Water flow rate 20°C [l/h] [bar]...

  • Page 11: Dimensions And Service Panel

    0,469 3�5 DIMENSIONS AND SERVICE PANEL Figure 3�2 – Dimensional drawing of model AY00-120 LEGEND Series AY model AY00-120 AY00-120 - front and RH side views (dimensions in mm). Installation, user and maintenance manual – AY Condensing line, AY Series...
  • Page 12 OVERVIEW AND TECHNICAL FEATURES Figure 3�3 – SERVICE PANEL: Series AY - AY Condensing line LEGEND gas fitting ("G 3/4 M) outlet water fitting ("G 1 1/4 F) inlet water fitting ("G 1 1/4 F) condensate drain fitting (ext. dia. 25 mm) Series AY - service plate (dimensions in mm).

  • Page 13: Normal Operation

     15. After it is reset, the appliance will make a new attempt to activate. → If the appliance locks out several times, contact a Robur TAC by calling the Technical Service Department of Robur S.p.A. (tel. +39.035.888111). When activation is successful, the appliance is managed by the on-board controller (see following paragraph).

  • Page 14: On-Board Electronics

    Menu 1 shows the parameters that characterise the operation of the appliance and their current values. Menu 7 is to be used ONLY by the Robur TAC. To view the information contained in these menus, proceed as illustrated in the procedure explained below: HOW TO ACCESS THE MENUS.

  • Page 15: Reset Operations

    NORMAL OPERATION Menus 4, 5, 6 and 7 exclusively concern the installation technician and Robur’s authorized Technical Assistance Centre. Menu 8 may currently be selected, but not used. Display and knob The controller’s display can be viewed through the glass of the viewing aperture on the front panel of the appliance.

  • Page 16: Operating Settings

    → Actions "23", "24" and "25" are used to regulate the combustion parameters or for gas type changeovers, and are thus for use only by the installation technician or Robur TAC. Reset flame controller (parameter "20"): You will need: the display reads "2.20" (as per step "3").

  • Page 17: Prolonged Periods Of Disuse

    In case of precence of glycol, Robur advices to use inhibited glycol.

  • Page 18: Hydraulic Installation

    HYDRAULIC INSTALLATION HYDRAULIC INSTALLATION In this section you will find all the instructions necessary for the hydraulic installation. Before realizing hydraulic system and gas supply for the appliance, the professionally qualified personnel is advised to read Paragraph 3.1   7, providing important recommendations about safety and references to current regulations. →...

  • Page 19: Hydraulic Connections

    As other hydronic appliances, Robur heating and cooling systems operate with grid-water of good quality. In order to prevent any possible problem of operation or reliability caused by filling or top-up water, please refer to codes and norms about water treatment for thermo-hydraulic installations in civil or industrial applications.
  • Page 20 The presence of free chlorine in the water, in particular, can jeopardize parts of the installation and Robur units. Therefore, please make sure that free chlorine content and total hardness are compliant with the allowable ranges reported in Table 5.1 ...
  • Page 21 Active and passive modules If the Robur appliances are not controlled by a DDC. In appliances with only hot and only cold modules (e.g.: AY series) or appliances of the 4 pipe type with two distinct cold and hot modules, the module is ALWAYS "active". in 2 pipe type (hot and cold) appliances, the “cctive”...
  • Page 22 Figure 5�2 – Diagram of hydraulic system (type with single appliance) LEGEND anti-vibration coupling pressure gauge flow regulator valve water filter check valve system water circulator system expansion tank AY00-120 stand-alone Example of hydraulic plant diagram for connection of no. 1 AY00-120 unit.

  • Page 23: Gas Supply

    AY00-120 stand-alone Example of hydraulic plant diagram for connection of no. 2 AY00-120 units. 5�4 GAS SUPPLY The installation of gas supply pipes must be compliant with current regulations and norms. For the pressure of the gas supplied by the mains see Table 5.2 ...

  • Page 24: Condensate Discharge

    It may also be necessary to insulate the gas pipe to prevent the formation of excessive condensate. In any case, provide an isolation valve (ball valve) on the gas supply line, to isolate the appliance when required. Table 5�2 – Network gas pressure AY00-120; E3 AY00-120 Gas supply pressure G25�1...

  • Page 25: Filling The System Circuit (Appliance)

    HYDRAULIC INSTALLATION 5�6 FILLING THE SYSTEM CIRCUIT (APPLIANCE) After having completed all hydraulic, gas and electrical connections, the installer can proceed filling the hydraulic circuit, observing the following steps: Activate the automatic air vent valves on the system circuit. ▶ Fill the hydraulic circuit, ensuring the minimum water content in the plant, and adding, if necessary, to the plant water (free of ▶...

  • Page 26: Exhaust Flue Gas

    HYDRAULIC INSTALLATION Connect the volumetric charging pump to the union with a hose. Open the filler cock (Figure 5.4   26, detail C), with a flathead screwdriver, and charge the circuit with enough glycol solution → to achieve the specified optimal pressure. Take care not to allow air to enter the circuit.
  • Page 27 HYDRAULIC INSTALLATION Figure 5�5 – AY Condensing line, AY series Fumes outlet fitting (dimensions in mm) - seen from above. FUMES EXHAUST EQUIPMENT FOR EXTERNAL INSTALLATION (installation technician only) Install the equipment externally as follows (see Figure 5.6   28). → You will need: the appliance in its permanent location.
  • Page 28 HYDRAULIC INSTALLATION Figure 5�6 – Fumes evacuation pipe kit LEGEND roof mounting terminal (DN80) extension tube (DN80) rain cover (DN80) flanged fitting (DN80) on top panel A+B+C fumes evacuation pipe kit fumes kit for exterior configuration (B53P). SIZING FUMES PIPES FOR TYPE B INSTALLATIONS If the installation requires the combustion products to be conveyed in a type B configuration, the flue must be sized with reference to the following table.

  • Page 29: Programming Of Hydraulic Parameters

    HYDRAULIC INSTALLATION Table 5�5 – Ducting for fumes evacuation and air intake pipes (type C) Gas type G25�1 G2�350 Useful residual head Mass of fumes at nominal thermal capacity 55.0 62,0 49.0 55.0 56.0 49.0 49.0 56.0 kg/h Mass of fumes at minimal thermal capacity 13.0 15.0 12.0...
  • Page 30 To modify a parameter in menu 4, to access the menu (installation technician only) you are first prompted for a password. For the password, contact the Robur TAC or Technical Service Department of Robur S.p.A. (Tel. +39.035.888111). The special key allows the knob of the electronic board to be operated without opening the cover of the electrical panel, so that operators are protected from live components.
  • Page 31 (parameter "156") and the intake (parameter "157"), accessible in menu 5 (and hence for the Robur TAC only). For example, if the appliance is used on a system for underfloor heating, parameters "156" and "157" must be set to limit the user's options in setting temperature setpoint parameter "161"...

  • Page 32: Electrical Installation

    ELECTRICAL INSTALLATION ELECTRICAL INSTALLATION In this section you will find all the instructions necessary to connect electrically the appliance. The procedures to follow in order to complete the entire process of electrical installation of the appliance are the following: CONNECTING THE APPLIANCE TO THE MAINS. ELECTRICAL CONNECTIONS FOR THE SYSTEM CIRCULATOR.
  • Page 33 ELECTRICAL INSTALLATION CONTROLLER COMPONENT LEGEND CODE DESCRIPTION blower control connector PWM= signal output GND= ground THRC input hot water temperature probe connector THMC output hot water temperature probe connector TA2-TA1 auxiliary temperature probes connector CAN BUS jumper CAN port / connector P8 [GND-L-H] H= high data signal L= low data signal...

  • Page 34: Connecting The Appliance To The Mains

    ELECTRICAL INSTALLATION Figure 6�2 – Functional diagram Electric diagram single unit AY00-120. 6�1 CONNECTING THE APPLIANCE TO THE MAINS The examples of connection of the appliance to the mains in this paragraph refer to: single appliance plants ▶...
  • Page 35 ELECTRICAL INSTALLATION multiple appliance plants ▶ SINGLE APPLIANCE PLANTS The appliance must be connected to a 230 V 1N - 50 Hz power supply, as follows (see example in Figure 6.3   35): → You will need: the appliance connected hydraulically; external electrical panel configured by the installation technician. Necessary equipment and materials.

  • Page 36: Electrical Connections For The System Circulator

    ELECTRICAL INSTALLATION The insertion of relays or other electrical components inside the General Electrical Panel of the appliance is not permitted. Do not activate the appliance if the hydraulic plant has not been filled. Figure 6�4 – connection to electrical mains (230 V 1N - 50 Hz) LEGEND power terminal block Master 2-pole power switch...
  • Page 37 ELECTRICAL INSTALLATION Make sure the ground cable is longer than the live cables. In this way it will be the last wire to be pulled away if the mains cable should accidentally be pulled, and will thus guarantee the ground connection. Do not use gas pipes to ground electrical appliances.
  • Page 38 ELECTRICAL INSTALLATION On each appliance, remove the front panel and open the electrical panel by removing the bolts securing it. Prepare a suitable cable for the connection. Locate the "NO Contact" terminals on the S70 controller of each appliance and hook up as shown in the Figure. Make sure the ground cable is longer than the live cables.

  • Page 39: Connections For Consent Switch Operation

    ELECTRICAL INSTALLATION Figure 6�6 – Direct control of shared circulator Example of electrical connection of a shared three-phase circulator (400 V AC). 6�3 CONNECTIONS FOR CONSENT SWITCH OPERATION To operate, the appliance requires: consent switch for starting up and shutting down the appliance. ▶...

  • Page 40: Use Of The Cci/Ddc

    ELECTRICAL INSTALLATION The consent switch (installation technician) can be an on/off switch, ambient thermostat, programmable timer, or other such device. To make the connection, proceed as follows (references to Figure 6.7   40): → You will need: the appliance connected hydraulically; consent switch. Necessary equipment and materials. Remove the appliance's front panel and open the electrical panel by removing the bolts securing it.
  • Page 41 ELECTRICAL INSTALLATION Figure 6�8 – CCI/DDC LEGEND CAN network connector (orange) ambient temperature probe - 2-pole connector 232 serial connection to PC - 9-pole connector external alarm systems - 3-pole connector mounting holes CCI/DDC power supply 24 V AC - 4-pole connector Encoder external consents - 6-pole connector Display...
  • Page 42 The DDC is equipped with a backup battery which retains the memory settings in case of power failure. The battery has a service life of around 7 years, after which it must be replaced by the Robur TAC. 3) How to connect the CCI/DDC to the appliance The appliance and the DDC communicate with each other via the CAN network (data network), which is characterised by a number of nodes, connected by the CAN BUS cable.
  • Page 43 → wires, use the wires with the colours indicated in 6.2   43 and cut the remaining ones. → The ROBUR NETBUS cable is available as an accessory (see Section 8   58). → > CONNECTION PROCEDURE Instructions for the specific operations to be carried out for the connection of the CAN bus cable follow: Step A: connect the CAN-BUS cable to the CCI/DDC.
  • Page 44 ELECTRICAL INSTALLATION Figure 6�12 Orange connector for CAN-BUS connection to CCI/DDC (supplied with CCI/DDC). The DDC is equipped with jumpers that must be moved in order to take on the configurations of terminal node and interme- diate node (Figure 6.14   45).
  • Page 45 ELECTRICAL INSTALLATION Figure 6�14 – detail wires and jumpers J21 - terminal/intermediate node CCI/DDC LEGEND detail case "terminal node" (3 wires; J21=jumper "closed") CCI/DDC detail case "intermediate node" (6 wires; J21=jumper "open") Jumper CAN-BUS in CCI/DDC board H,L,GND data signal wires Detail terminal and intermediate node: jumpers position J21: "closed"...
  • Page 46 ELECTRICAL INSTALLATION Figure 6�15 – Connection of CAN BUS cable to connector P8 on controller AY10 LEGEND example of connection of 2 CAN BUS cables (the appliance is an intermediate node) insulating tape to protect board/screen CAN BUS cable shielding cable bracket (for 2 CAN BUS cables) orange connector for CAN BUS cable terminals...
  • Page 47 ELECTRICAL INSTALLATION Figure 6�16 – detail of wires and jumpers J1 - appliance terminal/intermediate node LEGEND detail of "terminal node" case (3 wires; J1=jumper "closed") controller (AY10+S70) detail of "intermediate node" case (6 wires; J1=jumper "open") CAN BUS jumper on AY10 controller H,L,GND data signal wires Detail of terminal and intermediate node, jumper position J1: "closed"...
  • Page 48 ELECTRICAL INSTALLATION Figure 6�17 – CAN BUS connection for single appliance systems LEGEND CAN BUS jumper on DDC board digital control panel terminal node connection (3 wires; J1 and J21 = "closed") controller (AY10+S70) H,L,GND data signal wires CAN BUS jumper on AY10 controller CAN BUS cable connection between DDC and one appliance.
  • Page 49 ELECTRICAL INSTALLATION Figure 6�18 – CAN BUS connection for multiple appliance systems CAN BUS cable connection between 1 DDC and multiple appliances. Installation, user and maintenance manual – AY Condensing line, AY Series...

  • Page 50: Initial Activation And Maintenance

    INITIAL ACTIVATION AND MAINTENANCE In this section you will find the following information: Indications required by the authorized Robur Technical Assistance Centre (TAC) in order to carry out the entire procedure of first ▶ start-up of the appliance (see Paragraph 7.1 ...
  • Page 51 Step 2: verification/regulation of combustion parameters and first ignition During the initial activation procedure, the combustion parameters must be checked and set ONLY by a Robur TAC. In this stage, NEITHER the user NOR the installation technician is authorised to perform such operations, and in so doing may in- validate the guarantee of the appliance.
  • Page 52 INITIAL ACTIVATION AND MAINTENANCE With reference to Table 7.1   53 and the fumes analyser reading, check that the difference between the CO percentage ob- → served in step “15” and the current reading corresponds to the 2 characteristic of the gas being used. delta CO Example: having set, in step "15", a CO content of 9.5% for G20 gas, at step "18"...

  • Page 53: Maintenance

    Correct maintenance prevents problems, guarantees maximum operating efficiency of the appliance and allows running costs to be contained. The maintenance operations described in this paragraph must be performed exclusively by the serviceman in charge of the plant or by an authorized CAT Robur. Installation, user and maintenance manual – AY Condensing line, AY Series...

  • Page 54: Change Of Gas Type

    INITIAL ACTIVATION AND MAINTENANCE Any operation that regards internal components of units of the appliance must be carried out by an authorized Robur Tech- nical Assistance Centre (TAC), according to the instructions supplied by the manufacturer.  54), must be per- The "efficiency check"...
  • Page 55 INITIAL ACTIVATION AND MAINTENANCE To convert the appliance to operation with a different type of gas from that indicated on the sticker on the appliance's internal panel and the packaging, proceed as follows. You will need: appliance not powered up: master power switch and gas cock set to OFF. provided envelope containing the spare nozzles and sticker.
  • Page 56 INITIAL ACTIVATION AND MAINTENANCE Restore the appliance by screwing the gas intake seal screw back in. Close the appliance's internal panel (E). Fit a combustion products probe in one of the points provided fro this purpose on the external fumes equipment. Switch the appliance on and wait for it to stabilise (3 minutes).
  • Page 57 INITIAL ACTIVATION AND MAINTENANCE Figure 7�3 – Gas type conversion LEGEND tube/valve connection nut tube/air-gas mixer connection nut gas valve gas nozzle gasket (large) on tube/valve fitting gasket (small) on tube/air-gas mixer fitting air-gas mixer Details of gas changeover procedure. Installation, user and maintenance manual –...

  • Page 58: Accessories

    ACCESSORIES ACCESSORIES This section contains a list of the accessories that are available for the installation and use of the appliance. To order these accessories, contact Robur S.p.A. on +39.035.888111. Table 8�1 – AVAILABLE ACCESSORIES ACCESSORIES FOR INSTALLATION TECHNICIAN Name...

  • Page 59: Operating Codes/Troubleshooting

    ▶ At this point, if the appliance still does not start: refrain from proceeding by trial and error; instead request the direct assistance of an authorised Robur Technical Assistance Cen- ▶ tre (TAC), informing it of the Machine Code that has arisen;...
  • Page 60 OPERATING CODES/TROUBLESHOOTING CODES DESCRIPTION TRIP CONDITIONS RESET METHOD The flame controller is arrested (E_12) but the gas FLAME CONTROLLER ON AND Reset via DDC (or via the controller, menu 2, parameter 20). If the E 128 solenoid valve is excited. In this case the flame ARRESTED code persists, contact authorised TAC.
  • Page 64 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 Spa tecnologie avanzate per la climatizzazione Via Parigi 4/6 24040 Verdellino/Zingonia (Bg) Italy T +39 035 888111∅F +39 035 884165...

This manual is also suitable for:

E3 ay00-120

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