Robur Caldaia 35 Tech Instructions For Installation, Use And Maintenance Manual

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Installation, use and maintenance manual

Caldaia 35 Tech

Outdoor condensing boiler

DISPOSAL

The appliance and all its accessories must be disposed of separately in accordance with the regulations in force.

Use of the WEEE symbol (Waste Electrical and Electronic Equipment) indicates that this product cannot be disposed of as household waste. Proper disposal of this product helps to prevent potential negative consequences for the environment and human health.

Revision: B Code: D-LBR749EN

This Installation, use and maintenance manual has been drawn up and printed by Robur S.p.A.; whole or partial reproduction of this Installation, use and maintenance manual is prohibited.

The original is led at Robur S.p.A. Any use of this Installation, use and maintenance manual other than for personal consultation must be previously

authorised by Robur S.p.A. The rights of those who have legitimately led the registered trademarks contained within this publication are not

aected. 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.

INDEX OF CONTENTS

I Introduction .............................................................................

I.1 Recipients ..........................................................................

II Symbols and denitions ...............................................

II.1 Key to symbols .................................................................

II.2 Terms and denitions ....................................................

III Warnings......................................................................................

III.1 General and safety warnings ......................................

III.2 Conformity ........................................................................

III.3 Exclusions of liability and warranty ..........................

1 Features and technical data ......................................

1.1 Features ..............................................................................

1.2 Dimensions .......................................................................

1.3 Components .....................................................................

1.4 Technical characteristics ...............................................

1.5 Electrical wiring diagram ...........................................

2 Transport and positioning ........................................

2.1 Warnings ..........................................................................

2.2 Handling ...........................................................................

2.3 Minimum clearance distances..................................

3 Heating engineer ...............................................................

3.1 Warnings ..........................................................................

3.2 Boiler installation ..........................................................

3.3 Hydraulic connections ................................................

3.4 Combustion products exhaust ................................

3.5 Pump antifreeze and anti-lock function ...............

3.6 Fuel gas supply ..............................................................

4 Electrical installer ..............................................................

4.1 Warnings ..........................................................................

4.2 Electrical power supply ...............................................

p.4 p.4

p.4 p.5 p.6

p.7 p.7

p.7 p.8 p.9

p.11 p.12

p.12 p.12 p.12

p.12 p.12

p.12 p.13 p.15 p.16 p.17

p.18 p.18

p.18

4.3 Control device ................................................................

4.4 Control through optional OCDS006 remote

control - recommended solution ............................

4.5 Positioning the control system ................................

4.6 Operation via centralised external request .........

4.7 Operation with external temperature probe

(optional)..........................................................................

5 First start-up ..........................................................................

5.1 Preliminary checks ........................................................

5.2 How to access the boiler ............................................

5.3 Electronic board parameters setting .....................

5.4 Combustion parameters check ................................

5.5 Gas changeover .............................................................

5.6 Commissioning ..............................................................

5.7 Switching o ...................................................................

5.8 Prolonged periods of inactivity ...............................

6 Normal operation ..............................................................

6.1 Warnings ..........................................................................

6.2 Preliminary checks ........................................................

6.3 Operation without remote control .........................

6.4 Remote control operation (optional) .....................

Info menu display .........................................................

7 Maintenance ..........................................................................

7.1 Hydraulic boiler emptying .........................................

8 Diagnostics ..............................................................................

8.1 System pressure restore .............................................

8.2 Error codes .......................................................................

9 Appendices..............................................................................

9.1 Product che...................................................................

p.19

p.19 p.19 p.20

p.20 p.20

p.20 p.20 p.21 p.24 p.25 p.25 p.26 p.26

p.26 p.27

p.27 p.27 p.28 p.28

p.28 p.28

p.29 p.29

p.29 p.31

p.31

Installation, use and maintenance manual – Caldaia 35 Tech

Introduction

I INTRODUCTION

Manual

This Manual is an integral part of the Caldaia 35 Tech unit and must be handed to the end user together with the appliance.

II SYMBOLS AND DEFINITIONS

II.1 KEY TO SYMBOLS

DANGER

WARNING

NOTE

PROCEDURE

REFERENCE (to other document)

I.1 RECIPIENTS

This Manual is intended for:

▶

End user, for appropriate and safe use of the appliance.

▶

Qualied installer, for correct appliance installation.

▶

Planner, for specic information on the appliance.

Caldaia 35 Tech. Boiler/External module = equivalent terms, both used to designate the part of the appliance to be installed outside the room to be heated.

TAC = Technical Assistance Centre authorised by Robur. Remote control = optional control device with chronothermo-

stat function. External request = generic control device (e.g. thermostat, timer or any other system) equipped with a voltage-free NO contact and used as control to start/stop the Caldaia 35 Tech unit. First start-up = appliance commissioning operation which may only and exclusively be carried out by a TAC.

II.2 TERMS AND DEFINITIONS

Appliance/Unit = equivalent terms, both used to refer to the

III WARNINGS

III.1 GENERAL AND SAFETY WARNINGS

Installer's qualications

Installation must exclusively be performed by a qualied rm and by skilled personnel, with specic knowledge on heating, electrical systems and gas appliances, in compliance with the laws in force in the Country of installation.

Declaration of conformity

Upon completing installation, the installing rm shall issue to the owner/client the appliance's workmanlike conformity declaration, according to national/local regulations in force and the manufacturer's instructions/ provisions.

Packing

Packing items (plastic bags, polystyrene foam, nails, etc.) must be kept out of the reach of children, as they are potentially dangerous.

Misuse

The appliance must only be used for the purposes for

which it has been designed. Any other use is deemed hazardous. Incorrect use may aect operation, duration and safety of the appliance. Adhere to the manufacturer's instructions.

Use of the appliance by children

The device can be used by children over 8 years old, and by people with reduced physical, sensory or mental capabilities, or lack of experience or knowledge, only if they are under surveillance or after they have received instructions regarding safe use of the appliance and understanding the dangers inherent in it. Children should not play with the appliance. Cleaning and maintenance that must be performed by the user must not be performed by unsupervised children.

Hazardous situations

 Do not start the appliance in hazardous conditions, such

as: gas smell, problems with the plumbing/electrical/gas system, parts of the appliance under water or damaged, malfunctioning, disabling or bypassing control and safety devices.

 In case of danger, request intervention by qualied per-

sonnel.

 In case of danger, switch o the electrical power and gas

supplies only if this can be done in total safety.

III

Warnings

 Do not entrust children, persons with physical, sensory

or mental disabilities or persons with poor knowledge and experience with use of the appliance.

Gas component tightness

 Before performing any operation on gas ducting compo-

nents, close the gas valve.

 Upon completing any procedure, perform the tightness

test according to regulations in force.

Gas smell

If you smell gas:

 Do not use electrical devices such as telephones, mul-

timeters or other equipment that may cause sparks next

to the appliance.  Shut o the gas supply by turning the valve o.  Disconnect electrical power supply by means of the

external isolation switch in the power supply electrical

panel.  Use a telephone away from the appliance to ask for inter-

vention from qualied personnel.

Poisoning

 Ensure the ue gas ducts are tightness and compliant

with the regulations in force.  Upon completing any procedure, ensure components

are tightness.

Moving parts

Switching the appliance o

Disconnecting the power supply while the appliance is running may cause permanent damage to internal components.

 Except in the event of danger, do not disconnect the

power supply to switch o the appliance, but always and exclusively act through the provided control device.

In the event of failure

Operations on internal components and repairs may exclusively be carried out by a TAC, using only original parts.

 In the event of failure of the appliance and/or breakage

of any component, do not attempt to repair and/or restore and immediately contact the TAC.

Routine maintenance

Proper maintenance assures the eciency and good operation of the appliance over time.

 Maintenance must be performed according to the man-

ufacturer's instructions (see Chapter 7

p. 28

) and in

compliance with current regulations.

 Appliance maintenance and repairs may only be entrust-

ed to rms legally authorised to work on gas appliances and systems.

 Enter into a maintenance contract with an authorised

specialised rm for routine maintenance and for servicing in case of need.

 Use only original parts.

The appliance contains moving parts.  Do not remove guards during operation, and in any case

prior to disconnecting the power supply.

Burn hazard

The appliance contains very hot parts.  Do not open the appliance and do not touch internal

components before the appliance has cooled down.  Do not touch the ue gas exhaust before it has cooled

down.

Electrocution hazard

 Disconnect the electrical power supply before any oper-

ation on appliance components.  For electrical connections exclusively use compliant

components and according to the specications provid-

ed by the manufacturer.  Ensure the appliance cannot be accidentally switched

back on.

Earthing

Electrical safety depends on eective earthing system,

correctly connected to the appliance and installed ac-

cording to the regulations in force.

Acid ue gas condensate

 Discharge the acid condensate of combustion ue gas in

compliance with current exhaust regulations.

Decommissioning and disposal

If the appliance is to be disposed of, contact the manufacturer for its disposal.

Keep the Manual

This Installation, use and maintenance manual must always accompany the appliance and must be handed to the new owner or installer in the event of sale or removal.

III.2 CONFORMITY

EU Directives and standards

The appliance is certied in accordance with European regulation GAR 426/2016/EU and meet the essential requirements of the following Directives:

▶

Eciency Directive 92/42/EEC and subsequent modications and additions.

▶

2016/426/EU "Gas Appliances Regulation" as amended and added.

▶

2014/30/EC "Electromagnetic Compatibility Directive" as amended and added.

▶

2014/35/EC "Low Voltage Directive" as amended and added.

▶

2006/42/EC "Machine Directive" as amended and added. Furthermore, they comply with the requirements of the following standards:

▶

EN 677 Specic requirements for condensing boilers with

nominal heat input up to 70 kW.

▶

EN 483 Type C boilers of nominal heat input not exceeding

70 kW.

▶

EN 15502 Gas-red central heating boilers.

Installation, use and maintenance manual – Caldaia 35 Tech

Warnings

III

Other applicable provisions and standards

The design, installation, operation and maintenance of the systems shall be carried out in compliance with current applicable regulations, depending on the Country and location, and in accordance with the manufacturer's instructions. In particular, regulations regarding the following shall be complied with:

▶

Gas systems and equipment.

▶

Electrical systems and equipment.

▶

Heating systems employing condensing boilers.

▶

Environmental protection and combustion products exhaust.

▶

Fire safety and prevention.

▶

Any other applicable law, standard and regulation.

III.3 EXCLUSIONS OF LIABILITY AND

WARRANTY

Any contractual or extra-contractual liability of the manufacturer for any damage caused by incorrect installation and/or improper use and/or failure to comply with regulations and with the manufacturer's directions/

instructions shall be disclaimed.

In particular, the warranty on the appliance may be rendered void by the following conditions:

 Incorrect installation.  Misuse.  Failure to comply with the manufacturer's indications on

installation, use and maintenance.

 Alteration or modication of the product or any part

thereof.

 Extreme operational conditions or however outside of

the operational ranges set forth by the manufacturer.

 Damages caused by external agents such as salts, chlo-

rine, sulphur or other chemical substances contained in the installation water or present in the air of the installation site.

 Abnormal actions transmitted to the appliance by the

plant or installation (mechanical stresses, pressure, vibrations, thermal expansion, electrical surges...).

 Accidental damages or due to force majeure.

162

1 FEATURES AND TECHNICAL DATA

Features and technical data

1.1 FEATURES

Operation

The Caldaia 35 Tech units have been designed and built to meet the needs of space heating. These boilers (external modules) can also be installed outdoors. The boiler casing is made of ABS, and is approved to resist weathering with particular regard to the action of UV rays. The appliance operation will be controlled by an external request (chronothermostat, room thermostat or another operation request) or by the remote control to be installed inside the heated room. When the heating service is requested, detected by the external request or by the remote control, the electronic board starts the circulation pump, the blower and then the burner. When the burner starts up, the ame detector checks that the burner has ignited; in the event of a lack of ame, the electronic control unit stops the appliance and indicates the block. Resetting is manual.

1.2 DIMENSIONS

Figure1.1 Boiler dimensions

140

In the event of abnormal overheating of the delivery, the boiler is switched o. The limit thermostat has manual reset.

Mechanical and thermo-hydraulic components

▶

Integrated spiral single tube stainless steel heat exchanger.

▶

Premix modulating burner with 1:9 ratio.

▶

Automatic air vent valve.

▶

High eciency modulating water pump.

▶

System drain tap.

▶

Water temperature probe.

▶

Condensate drain siphon.

Control and safety devices

▶

Flue safety thermal fuse.

▶

3 bar safety valve.

▶

Gas solenoid valve.

▶

Safety thermostat.

▶

Expansion tank.

▶

Water dierential pressure switch.

420

R Water inlet connection Ø 3/4" M G Gas connection Ø 3/4" M F System lling connection Ø 1/2"

370

710

110

R G F A

A Water outlet connection Ø 3/4" M B Flue gas outlet Ø 80 mm

148 80 102 37

Installation, use and maintenance manual – Caldaia 35 Tech

Features and technical data

1 2

6 7 8

10 11 12

1.3 COMPONENTS

Figure1.2 Boiler internal front view

5 6

7 8

16 17

18 19

1 SYstem lling tap 2 Heat exchanger 3 Burner unit 4 Flame detector 5 Heating return probe 6 Blower 7 Safety valve 8 Air vent valve 9 Modulating circulator 10 Gas valve 11 System drain tap 12 Heating delivery probe 13 Safety thermostat 14 Ignition electrode 15 Expansion tank 16 Ignition transformer 17 Air intake pipe 18 Venturi 19 Water pressure switch 20 Condensate drain siphon

Figure1.3 Hydraulic plan of boiler inside

F A

R Heating return G Gas inlet SC Condensate drain F Cold water inlet A Heating delivery 1 Flue safety thermal fuse 2 Heat exchanger 3 Burner unit 4 Blower 5 Gas valve 6 Air vent valve 7 Modulating circulator 8 Safety valve 9 System drain tap 10 Heating delivery probe 11 Safety thermostat 12 Expansion tank 13 Air intake pipe 14 Venturi 15 Water pressure switch 16 Condensate drain siphon 17 Bypass 18 SYstem lling tap

Features and technical data

1.4 TECHNICAL CHARACTERISTICS

Table1.1 Technical characteristics

Caldaia 35 Tech

Heating mode seasonal space heating energy eciency class (ErP) A

Heat input

Operating point 80/60 Nominal heat input

Operating point 50/30 Nominal heat input eciency % 106,4 Operating point Tr = 30 °C Heat input 30% eciency % 108,6 Operating point Tr = 47 °C Heat input 30% eciency % 102,1

Heat loss

Hot water delivery temperature maximum °C 80 Ambient air temperature (dry

bulb) eciency class **** Electrical specications

Power supply

Electrical power absorption nominal kW 0,08 Degree of protection IP - X5D Installation data

Gas consumption

Water tting

Gas connection

Flue gas exhaust

CO2 percentage in fumes

Flue temperature Nominal heat input G20 °C 69,4

Fumes ow rate

CO emission ppm 75,0 NOx emission class - 6

Circulating pump data

type of installation - B23P, B33 maximum equivalent length of exhaust duct m 15 maximum water pressure in operation bar 3,0 maximum ow ue condensate l/h 3,4 Water content inside the apparatus l 6 expansion tank volume l 8

Dimensions

Weight in operation kg 44

(1) Relative to NCV (net caloric value).

nominal (1013 mbar - 15 °C) (1) kW 34,0 minimum (1) kW 4,1

eective power kW 33,4 eciency % 98,1

to jacket in operation % 0,25 to ue in operation % 2,40 in o mode % 0,03

maximum °C 40 minimum °C -10

voltage V 230 type - SINGLE PHASE frequency Hz 50

G20 natural gas (nominal) m³/h 3,60 G25 (nominal) m³/h 4,18 G25.3 (nominal) m³/h 4,09 G30 (nominal) kg/h 2,68 G31 (nominal) kg/h 2,64 type - M thread “ 3/4 type - M thread “ 3/4 diameter (Ø) mm 80 residual head Pa 91

G20 % 9,3 G25 % 9,2

Nominal heat input

Minimal heat input

Nominal heat input G20 kg/h 54 Minimal heat input G20 kg/h 7

Residual pressure head at nominal ow rate boiler only m w.c. 1,5 nominal ow at the maximum available head l/h 1400

width mm 420 depth mm 370 height mm 787

G25.3 % 9,2 G30 % 11,3 G31 % 10,4 G20 % 9,0 G25 % 8,9 G25.3 % 8,9 G30 % 10,8 G31 % 9,9

Installation, use and maintenance manual – Caldaia 35 Tech

Features and technical data

0 0,4 0,8 1,2 1,6 2,0 2,4

p/kPa

H/m

Q/m³/ h

1.4.1 Circulating pump characteristic curves

Figure1.4 Circulating pump characteristic curves

85%

75%

65%

55%

45%

35%

25%

15%

0 0,4 0,8 1,2 1,6 2,0 2,4

0 0,1 0,2 0,3 0,4 0,5 0,6 0,7

0 2 4 6 8

max.

Q/m³/ h

Q/l/s

Q/Igpm

1.5 ELECTRICAL WIRING DIAGRAM

Figure1.5 Boiler electrical connections diagram

Features and technical data

SRi

SeSe

TaTa

220 V 50 Hz

M8 3 2

M10

Tra

M15

66 65 64 63 62

59 58

M16

M14

55 54 53 52 51

M13

M12

4443424140

3736353433

14 15

16 17

+24V

GND

PWM

ER Flame detector EA Ignition electrode PM Modulating circulator VG Gas valve Tra Ignition transformer TS Safety thermostat Pacq Water pressure switch SR Heating delivery probe EV Blower

Pacq

TF Flue gas thermofuse SRi Heating return probe MP Control panel terminal block Se Connector for optional outdoor temperature

probe Ta Connector for optional room thermostat CS Standby contact

ne Black ce Light blue ma Brown ar Orange gi Yellow bi White

gr Grey L Line N Neutral

Installation, use and maintenance manual – Caldaia 35 Tech

Transport and positioning

2 TRANSPORT AND POSITIONING

2.1 WARNINGS

Damage from transport or installation

The manufacturer shall not be liable for any damage during appliance transport and installation.

On-site inspection

 Upon arrival at the site, ensure there is no transport dam-

age on packing or boiler panels.

 After removing the packing materials, ensure the appli-

ance is intact and complete.

Packing

 Only remove the packing after placing the appliance 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.

2.3 MINIMUM CLEARANCE DISTANCES

Keep the appliance away from combustible or ammable materials or components, in compliance with applicable regulations.

In order to allow periodic maintenance of the boiler, the installation must take place outside, respecting the distances indicated in Figure 2.1

height from the oor of no more than 3 metres.

Figure2.1 Clearances

p.12

and in any case at a

2.2 HANDLING

Handling and lifting

▶

Always handle the appliance in its packing, as delivered by the factory.

▶

Comply with safety regulations at the installation site.

In the event of handling with forklift or pallet truck, comply with the handling instructions shown on the packing.

3 HEATING ENGINEER

3.1 WARNINGS

3.1.1 General warnings

Read the warnings in Chapter III.1 portant information on regulations and on safety.

Compliance with installation standards

Installation must comply with applicable regulations in force, based on the installation Country and site, in matters of safety, design, implementation and maintenance

of:  heating systems  gas systems  ue gas exhaust

p. 4

, providing im-

A 250 mm B min 300 mm, max 3000 mm X 60 mm

 ue gas condensate discharge

Installation must also comply with the manufacturer's provisions.

3.2 BOILER INSTALLATION

1. Fix the mounting jig of the external module to the instal-

lation wall, matching, if already present, the Ø 80 mm hole for the passage of water pipes and electrical cables with the shape of the relative hole (Ø 80 mm) indicated on the jig. At this point, in correspondence with the relative shapes of the holes indicated on the jig, trace the following points for drilling on the wall: 3 xing holes (Ø 10 mm) and 1 lower hole (moved to the right) Ø 10 mm.

2. Remove the mounting jig from the wall and drill the holes

marked out in the previous point: for the 3 upper holes (Ø

Y 60 mm H 1000 mm

Heating engineer

10 mm) for xing the support bracket and the one for the frame of the external module, a depth of 90 mm is sucient; the hole (Ø 80 mm) must be drilled for the entire thickness of the wall.

3. Insert a plastic pipe through the wall into the hole (Ø 80

mm), cut to size.

4. Position the support bracket of the external module in corre-

spondence with the upper holes made (Ø 10 mm, depth 90 mm) and secure it with the supplied wall plugs.

5. Lift the boiler and hook it to the support bracket.

6. Secure the boiler permanently to the wall, fastening the rear

panel by means of the third wall plug supplied.

3.3 HYDRAULIC CONNECTIONS

The hydraulic installer must make the hydraulic connection circuit to the heating system. To facilitate mounting, the boiler is equipped with a kit of hydronic ttings (Figure 3.1 after removing the tting cover (Figure 5.1

Figure3.1 Hydronic tting kit

p.13

) to be connected to the boiler

p.21

weathering and freezing, insulated for thermal dispersion.

 Sizing of the pipes, according to the standard circulator,

must grant the nominal water ow required for the correct operation of the heating system.

B. of the following data:

 nominal ow at the maximum available head = 1400 l/h  Residual pressure head at nominal ow rate = 1,5 m w.c.

3.3.1 System connections

Connect the water pipes between the boiler and the system as follows:

1. After having removed the tting cover (Figure 5.1

connect the copper 90° ttings supplied to the hydraulic connections of the boiler service plate, taking care to orient them towards the wall hole (hole Ø 80 mm, made during the installation phases of the boiler on the wall).

2. Connect the hydraulic hoses to the water delivery and return

connections (Figure 1.1 gaskets on each connection and taking care to avoid the entry of foreign bodies.

3. Connect a hose connected to a system test pump to the sys-

tem lling tap (Figure 3.3 hydraulic circuit with water; the air in the circuit and in the pipes will be automatically vented by the venting device on the boiler.

p. 7

), interposing appropriate

p.14

) on the boiler and ll the

p. 21

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

A Delivery R Return

The installer must provide for the construction of a suitably sized hydraulic connection circuit, taking into account: A. of the following indications:

 Use pipes for heating/cooling systems, protected from

Table3.1 % of glycol, correction factor for pressure drop

% of antifreeze glycol Protection temperature (°C) Correction factor for pressure drop Correction factor for pressure drop

15% -5 1,08 1,06 20% -8 1,11 1,08 25% -12 1,15 1,10 30% -15 1,19 1,12

Connect the boiler safety drains (heating circuit safety valve) to a drain funnel. The manufacturer is not responsible for any damage due to the opening of the safety valve in case of overpressure of the system.

3.3.2 System lling

Proceed with the lling of the system as follows.

1. Slightly loosen the cap of the jolly valve on the circulator to

release the air from the system (Figure 3.2

2. Slightly loosen the cap of the jolly valve placed on the top of

the condensing block (Figure 3.4

p.14

p. 14

) to release the air

bution terminals to the water content in the pipes.

In order to ensure correct operation of the unit and avoid freezing of the water during the winter periods (with possible damage to the unit and the system), it is necessary to add antifreeze glycol to the water in a quantity proportional to the minimum winter temperatures of the installation site (see Table 3.1

Low roughness pipes

(copper, stainless steel and plastic)

from the top of the boiler.

3. Open the lling tap (Figure 3.3

4. Check with pressure gauge (Figure 3.3

pressure reaches 1,2 bar (Figure 3.5

5. Open the automatic air purging valves on the system, if any,

and check the air purging process.

6. Make sure that the unit is energized.

7. Send an operating request to the unit for a few seconds. The

circulating pump will be immediately activated.

8. Remove the request before the burner is activated. The cir-

culating pump will continue to circulate the water for the post-circulation time.

9. If, after the above operations, a decrease in system water

pressure is observed, open again the system lling valve

p. 9

) and of the distri-

p.13

Medium roughness pipes

(black and galvanized steel)

p.14

) and let out all the air.

p. 14

) that system

p.14

Installation, use and maintenance manual – Caldaia 35 Tech

Heating engineer

until the system pressure reaches 1,2 bar.

10. Repeat steps 7, 8 and 9 until the pressure has stabilised (at

least 1,2 bar).

11. After the operation, make sure that the system lling tap

(Figure 3.3

p.14

) is tightly closed.

Once the lling operation has been completed, re-

member to close the cap of the jolly valve on the circula-

tion pump, to avoid water leaks.

To start the circulation pump only, with the boiler pow-

ered, press the button (Figure 6.1

symbol will appear on the display; after a few sec-

onds turn o the boiler by pressing the button

again (the symbol will appear on the display). The

circulation pump will remain in operation for a few min-

utes. Repeat the operation several times until the pres-

sure of the circuit remains unchanged.

The rst time the unit is switched on, an automatic

system venting cycle is activated (see note in Paragraph

5.6

p.25

p. 26

): the

Figure3.3 Pressure gauge and system lling tap

Figure3.2 Cap of the jolly valve on ciculating pump

1 Cap of the jolly valve

M Pressure gauge R System lling tap

Figure3.4 Cap of the jolly valve on condensing block

Figure3.5 Pressure gauge

Heating engineer

3.3.2.1 System water characteristics

Responsibility of the user/operator/installer

The installer, operator and user must assure system water quality (Table 3.2 manufacturer's guidelines may aect operation, integrity and life of the appliance, voiding the warranty.

In order to avoid any scale or deposits on the primary exchanger, the water in the system must be treated in accordance with the applicable standards. This treatment is absolutely essential in cases where there are frequent episodes of water supply or partial or total emptying of the system.

The hardness of the lling and top-up water brings a certain amount of calcium into the system. This is attached to the hot parts including the heat exchanger, thus creating pressure losses and thermal insulation on the active parts. This can lead to damage. If the lling and top-up water of the system is outside the values indicated below, it must be softened. Additives may also be added to keep the calcium in solution. Hardness should be checked regularly and recorded. If the above limits are exceeded, a water chemical treatment must be carried out. The choice of the type of treatment must be made according to the characteristics of the water to be treated, the type of plant and the limits of purity required. Adhere to the chemical-physical parameters in Table 3.2 and the regulations on water treatment for residential and industrial heating systems.

Table3.2 Chemical and physical parameters of water

Acidity 7 < pH < 8,5 Conductivity < 400 μS/cm (at 25°C) Chlorides < 125 mg/l Iron < 0,5 mg/l Copper < 0,1 mg/l

p.15

). Failure to comply with the

p.15

3.3.3 Condensate drain siphon lling

When switching on for the rst time, the condensate siphon must be lled to prevent the combustion gases from backowing through the siphon. It is advisable, after the rst few months of operation of the appliance, to clean the siphon, which collects also any deposits resulting from the rst passage of the condensate inside the components of the boiler. These deposits could cause the siphon itself to malfunction. For charging the siphon proceed as follows (Figure 3.6

1. Unscrew screw P, remove the siphon and ll it with water to

the top point T.

2. Replace the siphon and fasten it with the screw P.

3. Connect the specically designed exible condensate drain

hose to a drainage system.

p.15

Figure3.6 Condensate drain siphon

P Fastening screw T Top point

3.4 COMBUSTION PRODUCTS EXHAUST

Installation types

For this type of boiler the ue gas exhaust conguration B23P, B33 can be used.

3.4.1 Flue gas exhaust connection

▶

Ø 80 mm, on the upper side of the boiler (Figure 1.1 The Caldaia 35 Tech is supplied with a anged socket, equipped with a socket for ue gas analysis (detail PF in Figure 5.6 which must be connected to the combustion chamber after having interposed the silicone gasket, supplied, for the protection against weathering.

After installing the anged socket, it is important to check the correct positioning of the gasket G positioned on the combustion chamber (Figure 3.7

Incorrect positioning of the gasket G can compromise the correct discharge of the ue gas outside and consequently damage the appliance.

Figure3.7 Correct gasket positioning

p.15

G Gasket

p.7

p.24

The combustion air is drawn from the outside of the casing by

Installation, use and maintenance manual – Caldaia 35 Tech

Heating engineer

means of special louvres located in the lower part of the casing.

3.4.2 How to realize the ue gas exhaust

For the ue gas exhaust without a chimney, the special rainproof terminal (code OTRM031) is available as an option.

It is not recommended to install the ue terminal near the boiler if it is close to a wall. This condition could cause condensation to form on the terminal and on the wall that would fall on the boiler.

To avoid this type of problem, it is recommended to take the ue terminal beyond the roof of the building as shown in Figure 3.8 exhaust horizontally as shown in Figure 3.9 specting the indications given in Paragraph 3.4.3

Figure3.8 Roof vertical ue gas exhaust

p. 16

or to carry out the ue

p. 16

p.16

, re-

3.4.3 Possible ue

In case of extension of the duct, follow the instructions below:

▶

Use ducts and terminals (Ø 80 mm) suitable for forced draft condensing appliances.

▶

For vertical ducts longer than 1,5 m, a curve and a Tee (Figure

3.10

p. 16

) for condensate collection and drainage must be provided. The condensate must then be evacuated in accordance with the regulations in force, at the same time as that coming from inside the boiler.

Figure3.10 Flue gas condensate discharge

> 300 mm

Figure3.9 Horizontal ue gas exhaust

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.

Maximum exhaust length

▶

Pipe Ø 80 mm: 15 m

▶

Blower available head: 91 Pa

The maximum exhaust length (or equivalent linear length) is obtained by adding the length of the linear duct to the equivalent length of each additional curve. The equivalent lengths of the curves are given in Table

3.3

p.16

Table3.3

Elbow Ø 80 mm

90° elbow 1,5 m 45° elbow 1,2 m

3.5 PUMP ANTIFREEZE AND ANTILOCK

FUNCTION

Antifreeze function

If the delivery temperature detected by the temperature probe falls below +12 ºC (antifreeze temperature ON), the control board starts the circulation pump and the ignition of the burner at the minimum power. When the delivery water temperature reaches +30 ºC (antifreeze temperature OFF), the control board will switch the burner o.

Heating engineer

Electrical and gas continuity

The antifreeze function is only eective if the power

on the bottom of the boiler (Figure 1.1

▶

Install an anti-vibration connection between the appliance

and the gas piping. and gas supplies are assured. Otherwise, antifreeze uid might be required.

Pump anti-lock function

In order to prevent the circulation pump from locking, the Caldaia 35 Tech is equipped with an anti-lock function which, every 24 hours of inactivity, operates the circulation pump for 30 seconds.

Mandatory shut-o valve

▶

Provide a gas shut-o valve (manual) on the gas supply line,

next to the appliance, to isolate it when required.

▶

Perform connection in compliance with applicable regula-

tions.

Gas pipes sizing

The gas pipes must not cause excessive pressure drops and, consequently, insucient gas pressure for the appliance.

Electrical continuity

Supply gas pressure

The pump anti-lock function is only eective if the power supply is guaranteed.

This appliance is equipped for a maximum gas supply pressure of 50 mbar.

3.6 FUEL GAS SUPPLY

The appliance's gas supply pressure, both static and dynamic, must comply with Table 3.4

Gas connection

▶

3/4" M

Table3.4 Gas network pressure

Product category Countries of destination

AL, AT, BG, CH, CY, CZ, DK, EE, FI, GR, HR, IT, LT, LV, MK, NO, RO, SE,

2H3B/P

2H3P

2ELL3B/P

2Esi3P

2E(R)3P

2E(S)3P

2E3P

2E3B/P

2L3B/P

2L3P

2EK3P

2EK3B/P

2EK

2ELL

2E(S)

2E(R)

2Esi

3B/P

The appliance gas supply pressure, both static and dynamic, must comply with the values in the Table, with a tolerance of ± 15%.

SI, SK, TR AT, CH 20 50 HU 25 30 AL, BE, BG, CH, CZ, ES, FR, GB, GR, HR, IE, IT, LT, NL, LV, MK, PL, PT,

SI, SK, TR AT, BE, CH, CZ, DE, ES, FR, GB, HU, NL, SK 20 50 AT, CZ, DE, NL, RO 20 30 DE 20 20 50 FR 20 25 37

LU 20 50 DE, PL, RO 20 30 RO 20 30 FR 25 37 RO 20 37

DE 20 20

FR 20 25 AL, AT, BG, CH, CY, CZ, DK, EE, ES, FI, GB, GR, HR, IE, IT, LT, LV, MK,

NO, PT, RO, SE, SI, SK, TR FR 20 HU 25 FR 25 RO 20 DE, PL, RO 20 AL, AT, BG, BE, CY, CZ, DE, DK, EE, FI, FR, GB, GR, HR, HU, IT, LT, MT,

NL, NO, RO, SE, SI, TR PL 37 AT, CH, DE, SK, CY, CZ 50 FR 50

Non compliant gas pressure (Table 3.4 damage the appliance and be hazardous.

G20 G25 G25.3 G30 G31

20 30

20 37

20 37 20 37

20 25 30 20 25 30 20 25

20 20

p.7

p.17

, with tolerance ± 15%.

Gas supply pressure [mbar]

p. 17

) may

Installation, use and maintenance manual – Caldaia 35 Tech

Electrical installer

Product category Countries of destination

AT, BE, CH, CZ, DE, ES, FR, GB, HU, IS, NL, SK 50

The appliance gas supply pressure, both static and dynamic, must comply with the values in the Table, with a tolerance of ± 15%.

AL, BE, BG, CH, CZ, ES, FR, GB, GR, HR, IE, IT, LT, NL, LV, MK, PL, PT, SI, SK, TR

AT, CZ, DE, NL, RO 30

Before proceeding with the construction of the system, the in-

G20 G25 G25.3 G30 G31

external temperatures.

staller must:

▶

Check that the gas used corresponds to that for which the appliance has been designed (see nameplate).

▶

Check that the ow rate of the gas meter is such as to ensure the simultaneous use of all the devices connected to it.

If it is necessary to change the type of gas supply to the boiler, contact the TAC that will make the necessary changes.

Although it is normal for the inlet pressure to decrease during the operation of the appliance, it is important to check that there are no excessive uctuations in the inlet

Under no circumstances shall the installer be authorised to carry out such operations.

pressure. In order to limit the extent of these variations, it is necessary to appropriately dene the diameter of the gas inlet pipe to be adopted based on the length and pressure drop of the pipe itself, from the gas meter to the boiler.

If uctuations in the gas distribution pressure happen, it is advisable to insert a special pressure stabiliser upstream of the gas inlet to the boiler. In case of LPG supply, all necessary precautions must be taken to avoid

Vertical pipes and condensate

▶

Vertical gas pipes must be tted with siphon and discharge of the condensate that may form inside the pipe.

▶

If necessary, insulate the piping.

LPG pressure reducers

With LPG the following must be installed:

▶

A rst stage pressure reducer, close to the liquid gas tank.

▶

A second stage pressure reducer, close to the appliance.

freezing of the combustible gas in case of very low

Gas supply pressure [mbar]

4 ELECTRICAL INSTALLER

Do not power and/or start the boiler before lling the hydraulic system, as this may damage the internal hydraulic components.

4.1 WARNINGS

General warnings

Read the warnings in Chapter III.1 portant information on regulations and on safety.

Compliance with installation standards

Installation must comply with applicable regulations in force, based on the installation Country and site, in matters of safety, design, implementation and maintenance of electrical systems.

Installation must also comply with the manufacturer's provisions.

Live components

 After placing the appliance in the nal position, and pri-

or to making electrical connections, ensure not to work on live components.

p. 4

, providing im-

Earthing

 The appliance must be connected to an eective earth-

ing system, installed in compliance with regulations in force.

 It is forbidden to use gas pipes as earthing.

Cable segregation

Keep power cables physically separate from signal ones.

Do not use the power supply switch to turn the appliance on/o

 Never use the external isolation switch to turn the appli-

ance on and o, since it may be damaged in the long run (occasional blackouts are tolerated).

 To switch the appliance on and o, use only the control

device provided for this purpose (remote control or external request).

4.2 ELECTRICAL POWER SUPPLY

The cables inside the boiler must be routed through the P1 and P2 cable glands (Figure 4.2 make a hole in the cable gland, slightly smaller than the cable, so that the air does not pass through.

p. 19

). To do this,

1 2 3

Electrical installer

How to connect the power supply

1. Remove the ABS casing, the tting cover and the front panel

(Paragraph 5.2

2. Unscrew the two screws and remove the terminal block cov-

er plate (Figure 4.1

3. Perform connections as shown in Figure 4.1

4. The ground wire to the terminal marked with the ground

symbol.

5. The neutral cable to the terminal marked with the letter N.

6. The line cable to the terminal marked with the letter L.

Figure4.1 Electrical power supply

p.20

p.19

SeSe

TaTa

Figure4.2 Cable gland position and remote control connection detail

to the external module

P1 P2

SeSe

TaTa

A Plate B Terminal block 1 Neutral

2 Yellow/Green 3 Line

4.3 CONTROL DEVICE

To make the electrical connections of the room thermostat (TA) or of the remote control (optional OCDS006) or of an external request, proceed as follows (Figure 4.2

1. Remove the bridge on the Ta-Ta contacts and then connect

the two non-polarized conductors on the Ta-Ta contacts.

2. After the operation, reassemble the plate, the front panel,

the tting cover and the ABS casing.

p.19

P1 - P2 Cable glands A Plate B Terminal block CR Room thermostat or remote control (OCDS006)

4.4 CONTROL THROUGH OPTIONAL

OCDS006 REMOTE CONTROL  RECOMMENDED SOLUTION

The use of the remote control allows you to adjust the operation of the boiler to the desired temperature, in the time programming chosen, provides a series of information on the status of operation and/or boiler lock and also allows the resetting of some locks. For the electrical connection of the remote control, follow the instructions given in Paragraph 4.3

The remote control is electrically connected to the boiler by means of two non-polarized conductors through which it receives the power supply necessary for its operation and carries out communication between the two devices.

p.19

4.5 POSITIONING THE CONTROL SYSTEM

Install the chosen thermostat/control system according to the following guidelines:

▶

At about 1,5 m from the oor, protected against air draughts,

direct exposure to sun rays and direct heat sources (lamps,

hot air ow from the unit itself, etc.).

Installation, use and maintenance manual – Caldaia 35 Tech

First start-up

▶

If possible, do not place the control system on walls bordering the outside, to avoid false temperature readings and therefore aect system operation. If this is not possible, shield the control system by placing a sheet of insulating material (cork, polystyrene or other similar) between the control system and the wall.

contact between the terminals must be closed. When these are closed, the boiler will stop, while when they are reopened, the boiler can be activated according to what has been set on the other controls (room thermostat or remote control).

By following the above guidelines, unwanted starting and stopping of the system can be avoided and optimal comfort in the heated space can be guaranteed.

4.6 OPERATION VIA CENTRALISED

EXTERNAL REQUEST

The unit's operation can also be controlled by means of an external request. This request, activated for example by a programmable timer or another system, can be used for the centralised activation or deactivation of several boilers. For the electrical connection of the external request, follow the instructions below:

1. Remove the ABS casing, the tting cover and the front panel

(Paragraph 5.2

p.20

2. Access the CS terminal block on the left side of the control

panel (Figure 1.5

p.11

3. Connect the external request to the terminal block.

4. After the operation, reassemble the plate, the front panel,

the tting cover and the ABS casing.

The terminals have open contacts from the factory (active request). If the boiler is to be switched o, the

5 FIRST START-UP

In the case of centralized management of several boilers, each request must be connected through the interposition of a relay.

For further information on the operation and use of boilers in this mode, please contact the Robur technical service.

4.7 OPERATION WITH EXTERNAL

TEMPERATURE PROBE OPTIONAL

It is possible to operate the boiler with a variable water ow temperature depending on the outdoor temperature. To do this, it is necessary to install an outdoor temperature probe (available as OSND007 optional) and connect it to the SE terminals of the boiler terminal block (Figure 1.5 The outdoor temperature probe provides the temperature value of the outdoor air and according to this the electronic board of the boiler will change the water supply temperature. The extent of the temperature correction depends on the temperature control value Kd set (using the board parameter P16 - see Figure

5.4

p.23

p.11

First start-up entails checking/setting up the combustion parameters and may exclusively be carried out by a Robur TAC. NEITHER the user NOR the installation technician is authorised to perform such operations, under penalty of voiding the warranty.

5.1 PRELIMINARY CHECKS

5.1.1 Preliminary checks for rst start-up

Upon completing installation, before contacting the TAC the installer must check:

▶

Water, electrical and gas systems suitable for the required capacities and equipped with all safety and control devices required by the regulations in force.

▶

Absence of leaks in the water and gas systems.

▶

Type of gas for which the appliance is designed (natural gas or LPG).

▶

Supply gas pressure complying with the values of Table

3.4

p.17

▶

Power supply mains complying with the appliance's rating plate data.

▶

Appliance correctly installed, according to the manufacturer's instructions.

▶

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 be found, the TAC shall not perform rst start-up and the appliance

shall not be commissioned. These situations may be:

▶

Failed compliance with minimum clearances.

▶

Insucient distance from combustible or ammable materials.

▶

Conditions that do not warrant access and maintenance in safety.

▶

Appliance switched on/o with the main switch, instead of the provided control device.

▶

Appliance defects or faults caused during transport or installation.

▶

Gas smell.

▶

Non-compliant mains gas pressure.

▶

Non-compliant ue gas exhaust.

▶

All situations that may involve operation abnormalities or are potentially hazardous.

5.1.3 Non-compliant system and corrective actions

Should the TAC nd any non conformities, the user/installer is bound to perform any corrective procedures required by the TAC. After performing the remedial actions (the installer's responsibility), if the TAC deems that safety and conformity conditions are in place, rst start-up may be eected.

5.2 HOW TO ACCESS THE BOILER

For all check and maintenance operations it is necessary to remove the front panel of the boiler as follows (Figure 5.1

1. Remove the fastening screws 1 located to the side of the

casing ange, and pull it out as shown in Figure 5.1

p.21

First start-up

2. Remove the fastening screws 2 located on the upper and

lower side of the casing, grasp the ABS casing and pull it out towards you.

3. Remove the fastening screws 3 located on the lower side of

the boiler and remove the tting cover.

To work on the front side of the boiler, proceed as follows:

1. Remove the fastening screws 4 located in front of the front

panel.

2. Grab the front panel and pull it out towards you. To work on the side panels of the boiler, proceed as follows:

1. Remove the fastening screws 5 located in the front edge of

the side panel.

2. Grab the base of the panel and, after moving it sideways, pull

it out by lifting it up.

Figure5.1 Accessing the boiler

Figure5.2 Accessing the control panel

A ABS casing ange B ABS casing C Fitting cover D Front panel E Side panel

1 Flange fastening screws 2 Casing fastening screws 3 Fitting cover fastening screws 4 Front panel fastening screws 5 Lateral panel fastening screws

To work on the internal electrical connections of the control panel, proceed as follows (Figure 5.2

p.21

1. Simultaneously grab the control panel support brackets by

widening them and turn the panel upside down by rotating it down.

2. Unscrew the four xing screws 1 and remove the cover

upwards.

5.3 ELECTRONIC BOARD PARAMETERS

SETTING

Before commissioning the operation of the device to the user, the operating parameters must be set or simply checked.

To access the parameters menu and adjust the value of the desired parameter, follow the procedure described below (refer to Figure 5.3

1. Press key to select the OFF mode, displayed with the

2. Hold at the same time the and keys and wait until on

3. Use the keys and of the space heating circuit to

4. Press the and keys of the 'S' side to change the pa-

5. Press the key to conrm and wait for the display to

6. To exit the parameter menu, hold down the and keys

p.22

symbol.

the display appears the symbol with the message ‘P00’,

and release the and keys.

select the parameter to be edited.

rameter value.

stop blinking, to make the adjustment eective.

simultaneously and wait for the symbol to appear on the

Installation, use and maintenance manual – Caldaia 35 Tech

First start-up

display.

The operating parameters are shown in Table 5.1

p.22

and are

visible on the internal display of the boiler.

Figure5.3 Access and setting of boiler parameters

Table5.1 Electronic board parameters

Parameter Description Range Default Setting

P00 Boiler model selection 0 - 10 9 9 = Caldaia 35 Tech P01 Boiler type selection 0 - 5 5 5 = heating only

Gas type selection

P02

WARNING: before changing the parameter value, read the instructions in Paragraph 5.5

p.25

P03 Heating temperature setting 0 - 1 0

Heating run-up

P04

It is possible to set the time, during the start-up phase, that the boiler takes to reach the maximum set power (for the space heating service).

Heating timing

P07

You can set the minimum time in which the burner is kept o once the heating temperature has reached the setpoint.

Post-circulation heating timing

It is possible to set the operating time of the pump, in heating mode, after the

P08

main burner has been switched o due to the intervention of the room thermostat.

Heating blower minimum speed adjustment

It is possible to set the minimum speed of the fan for the heating service, which

P12

corresponds to the minimum power of the burner during a heating request (see Figure 5.5

p.24

and the type of gas (parameter P02).

Heating blower maximum speed adjustment

It is possible to set the maximum speed of the fan for the heating service, which

P13

corresponds to the maximum power of the burner during a heating request (see Figure 5.5 and the type of gas (parameter P02).

Starting step adjustment

P14

It is possible to set the fan speed during the start-up phases. The value is preset according to the set power (parameter P00) and the type of gas (parameter P02).

Setting the climate curve (only with outdoor probe connected)

An outdoor temperature probe may be connected and acts by automatically changing the delivery temperature according to the measured outdoor temperature. The extent of the correction depends on the set Kd heating control value

P16

(see Figure 5.4 delivery temperature Tm and the minimum outdoor temperature Te, taking into account the degree of insulation of the house. The values of the delivery temperatures Tm refer to standard systems 30-80 °C or oor systems 25-45 °C. The type of system can be set using parameter P03.

). The value is preset according to the set power (parameter P00)

p.24

). The value is preset according to the set power (parameter P00)

p.23

). The choice of the curve is determined by the maximum

0 - 1 0

0 - 4 1

0 - 90 36

45 - P13 -- Value in hertz (1 Hz = 30 RPM)

P12 - 203 -- Value in hertz (1 Hz = 30 RPM)

P10 - 203 -- Value in hertz (1 Hz = 30 RPM)

0 - 30 15

0 = G20, G25, G25.3 1 = LPG, G30, G31

0 = standard (30-80 °C) 1 = reduced (25-45 °C) 0 = disabled 1 = 50 s 2 = 100 s 3 = 200 s 4 = 400 s

Value in multiples of 5 s (default 36 x 5 = 180 s)

The numbering of the value corresponds to the 'Kd' curves of the graph (see Figure 5.4

p.23

)

Te (°C)

Tm (°C)

First start-up

0-10 V industrial bus drive enable

P18

The 0-10 V industrial bus input can be enabled or disabled to set burner power or delivery temperature via the external bus.

Min heating setpoint

P19

It is possible to set the minimum user-adjustable heating temperature.

Max heating setpoint

P20

It is possible to set the maximum user-adjustable heating temperature.

Δt delivery-return setpoint

P22

It is possible to set the temperature dierence between delivery and return.

Modulating pump minimum speed

P23

It is possible to set the minimum speed value of the modulating pump during a request for space heating operation.

Modulating pump maximum speed

P24

It is possible to set the maximum speed value of the modulating pump during a request for space heating operation.

Modbus address

P26

Not used

Modbus communication baud rate

P27

Not used

Modbus mode

P28

Not used

Post-circulation heating Δt

P29

It is possible to set the temperature dierence from the main burner shutdown due to the room thermostat, to the pump shutdown for the heating service.

Heating antifreeze temperature setting

P31

It is possible to set the temperature of the water in the heating system at which the antifreeze protection is activated.

Flowmeter enable

P32

Not used

Minimum water ow setting

P33

Not used

0 - 2 0

20 - 40 30 Value in °C

40 - 90 85 Value in °C

10 - 40

50 - 70 60 Value in percentage

70 - 100 100 Value in percentage

0 - 25 10 Value in °C

5 -12 8 Value in °C

0 = disabled 1 = temperature control mode 2 = power control mode

0 = disabled

Value in °C

Figure5.4 Climatic curves

5 MAX

MIN

Tm Delivery temperature Te Outdoor temperature

Kd = 10

Kd = 5

Kd = 0

Kd = 25

-10

Kd = 20

-5

Kd = 15

-15-20

Kd = 30

Kd Heating control value

3025201510

Installation, use and maintenance manual – Caldaia 35 Tech

First start-up

G25.3

Ti (kW)

Freq (Hz)

Figure5.5 Heat input/blower frequency diagram

35 55 75 95 115 135 155 175

Ti Thermal input Freq Frequency

Table5.2 Minimum and maximum blower frequencies in heating mode

Gas type

G20 Hz 45 186 G25 Hz 53 203 G25.3 Hz 53 203 G30 Hz 45 176 G31 Hz 45 184

Frequency in heating mode

Minimum maximum

Figure5.6 Socket for ue gas analysis and gas valve

G30

G20 G25

G31

5.4 COMBUSTION PARAMETERS CHECK

The CO2 value should be checked with casing assembled, while the gas valve should be adjusted with the casing open.

To check and calibrate the CO power, proceed as follows, referring to Figure 5.6

▶

Power the boiler.

▶

Open the gas valve on the boiler and check that the valves connecting to the system are open.

▶

Activate the heating request to the boiler, through the control devices provided, and provide an adequate thermal load for carrying out the verication operations.

▶

Insert the ue gas analyser into the ue gas analyser socket PF (Figure 5.6

p.24

value at maximum and minimum

) and turn it on.

p.24

PF Flue gas analysis socket A Protection screw

1 Gas ow adjustment screw 2 Oset adjustment screw

5.4.1 Minimum heating power

1. Activate the chimney sweep function by pressing for 7 sec-

onds the fore being forced out of the function is 15 minutes.

2. Check that the CO2 value complies with Table 1.1

otherwise unscrew protection screw A and adjust screw 2 of

key (Figure 6.1

p.26

). The maximum time be-

p. 9

First start-up

the oset regulator with a 4 hex key. To increase the value of CO2 it is necessary to turn the screw clockwise and vice versa if you want to decrease it.

3. Once completed the adjustment, tighten the protection

screw A on the oset adjuster.

5.4.2 Maximum heating power

1. Press the key of the heating side for the calibration of

the maximum heating power.

2. Check that the CO2 value complies to the value shown in Ta-

ble 1.1

p.9

3. If this is not the case, adjust the gas ow adjuster using the

screw 1 (Figure 5.6 the screw counterclockwise and vice versa if you want to decrease it.

4. After each adjustment on screw 1 of the gas ow adjuster,

you have to wait about 30 seconds for the boiler to stabilize itself to the set value.

5. Press the key of the space heating circuit and check

that CO2 value at minimum power has not changed. If so, repeat the calibration described in previous Paragraph

5.4.1

p.24

6. Deactivate the chimney sweep function by switching the

boiler to OFF mode using the button ( symbol appears on the display).

7. Disconnect the ue gas analyzer and screw the cap of the

ue gas analysis socket back on.

8. Replace the boiler front panel.

p. 24

). To increase the CO2 value turn

Figure5.7 Gas changeover

5.5 GAS CHANGEOVER

Paragraph reserved exclusively to TACs.

The following instructions apply to both the conversion from natural gas (G20) to any other gas and vice versa.

Check that the gas supply line is suitable for the new fuel type used to supply the unit.

How to change gas (Figure 5.7

1. Loosen the two screws 1 from the xing bushing, and re-

move the air intake pipe.

2. Unscrew the pipe connection connecting the gas valve to

the venturi.

3. Unscrew the three xing screws 2 of the venturi V with a 10

mm wrench.

4. Unscrew the two screws 3 and press on the back side of the

venturi body C.

5. Replace the venturi with the one suitable for the type of gas

to be used and make sure that the orientation of tooth D is downwards on the aluminium body.

6. Reassemble the components, proceeding in the opposite se-

quence to the disassembly operations, making sure that the gasket G is reassembled.

7. Set the boiler to operate with the new type of gas, chang-

ing the value of parameter P02 (gas type selection) from the control panel (Paragraph 5.3

8. Proceed to the adjustment of the CO2 value, as described in

Paragraph 5.4

p.24

9. Replace the sticker indicating the gas type on the appliance

with the sticker for the new gas type.

p.21

p.25

)

1 Bushing xing screw 2 Venturi fastening screws 3 Venturi fastening screws

V Venturi G Gasket C Venturi backside

5.6 COMMISSIONING

1. Remove the ABS casing of the boiler (see Paragraph

5.2

p.20

2. Power the boiler.

The ignition system will automatically activate the system venting cycle function shown in the display with the code F33, which lasts 2 minutes (except the rst time the appliance is switched on, where the duration is 5 minutes).

When function F33 is active, the pump is activated at intervals and the burner ignition request is disabled. The regular operation of the boiler is allowed only when the operation is completed.

3. Make sure that the circulator is not locked.

4. If it is locked, wait for the circulator to perform the automatic

unlocking function (duration 3 minutes).

5. If the circulator is still locked, reactivate the automatic un-

locking function of the circulator (a further 3 minutes) by

power cycling the boiler.

6. At the end of the above operations, open the gas tap.

7. To switch the boiler to the heating operating mode, press

the key; the xed symbol will appear on the dis-

play, indicating that the function has been activated.

Installation, use and maintenance manual – Caldaia 35 Tech

Normal operation

2 3 4

8. When the room thermostat contact or the remote control

enable is closed, the burner ignition will start.

9. In case of lack of ame, the board repeats the ignition opera-

tions again after the post-ventilation (20 seconds).

10. It may be necessary to repeat the ignition operation sever-

al times to remove any air in the gas pipe. Before repeating the operation, wait about 5 seconds from the last ignition attempt and unlock the boiler from error code E01 by pressing the reset key.

11. Check the system pressure. if a decrease is observed, open

the lling tap again until the pressure reaches 1,2 bar. When done, close the lling tap again.

5.7 SWITCHING OFF

To switch o the unit, select the OFF mode using the key (Figure 6.1 mode ( symbol appears on the display), ONLY the antifreeze function (system water) and the boiler pump anti-lock function remain active.

As it is harmful to the appliance, it is essential to avoid

p.26

). In this way the appliance is in standby

6 NORMAL OPERATION

switching o the appliance by removing the power supply to the external module.

For the antifreeze and pump anti-lock functions to be active, the boiler must be left powered.

5.8 PROLONGED PERIODS OF INACTIVITY

To switch o the unit, select the OFF mode using the key (Figure 6.1 ( symbol appears on the display). Switch o the power using the main switch, outside the boiler, and close the gas tap upstream of the appliance.

p.26

). In this way the appliance is in standby mode

By removing the power supply, the automatic antifreeze and pump anti-lock functions will be disabled. If it is expected that during the period of inactivity the external temperature may fall below zero, it is therefore advisable NOT to cut o the electrical and gas supply to the appliance.

This section is for the end user.

The use of the device by the end user is only permitted

Figure6.1 External module control panel

1 Heating temperature adjustment keys 2 INFO key: press once to view the temperatures and other informations - hold for 5 seconds, in o operating mode, to view the last 5 faults 3 Operating mode selection key: heating only / OFF 4 RESET key: faults reset - chimney sweep function activation (hold for 7 seconds) 5 Parameter value adjustment keys / hold the keys at the same time for 5 seconds to activate display backlighting for 10 minutes 6 Display

after the Robur authorised TAC has completed the rst start-up.

4 5 6 7

121314

Figure6.2 Boiler display icons

Normal operation

1 Parameter number indication or displayed info code 2 Parameter programming function active 3 Not used 4 Not used 5 Not used 6 Not used 7 Temperature display / setpoint / parameter value 8 OpenTherm communication present (remote control)

6.1 WARNINGS

General warnings

Prior to using the appliance carefully read the warnings in Chapter III.1 on regulations and on safety.

First start-up by TAC

First start-up may exclusively be carried out by a Robur TAC (Chapter 5

Never power the appliance o while it is running

p. 4

, providing important information

p.20

≤ 33% >33%<66% > 66% <100%

9 Insucient system water pressure signal 10 Flame presence signal / it also indicates, on 3 percentage levels, the

modulating power level of the boiler 11 Operation in DHW mode enabled (only for boilers having this function) 12 Resettable error signal 13 O operating mode 14 Non resettable error signal 15 Operation in heating mode enabled

ll the system according to the instructions in Paragraph

3.3.2

p.13

and 3.3.3

 Check on the pressure gauge that the system pressure

is 1,2 bar.

If there is no water in the system or if the system pressure

is less than 1,2 bar, appears on the display of the control panel (Figure 6.2 the remote control (if any). When the correct pressure is restored, the error code disappears.

p.15

p.27

), while error E04 appears on

6.3 OPERATION WITHOUT REMOTE

CONTROL

NEVER power the appliance o while it is running (except in the event of danger, Chapter III.1 the appliance or system might be damaged.

Routine switching on/o

The appliance may exclusively be switched on/o by means of the suitably provided control device.

Do not switch on/o with the power supply switch

Do not switch the appliance on/o with the power supply switch. This may be harmful and dangerous for the appliance and for the system.

6.2 PRELIMINARY CHECKS

Checks before switching on

Before switching on the appliance, ensue that:  Gas valve open.  Appliance electrical power supply (main switch ON).  The fumes exhaust duct is free and correctly connected

to the fumes exhaust system.  The hydraulic circuit has been lled. If this is not the case,

p. 4

), since

6.3.1 Turning the external boiler on and o

1. Open the gas tap and provide electrical power.

2. Switch on the appliance by closing the two-pole switch (to

be provided by the installer).

3. Press the key on the control panel of the boiler (Fig-

ure 6.1

p.26

) and select the desired operating mode.

4. The xed symbol that appears on the display, corresponding

to the operating mode, indicates that the function has been activated.

6.3.2 Heating mode

In this operating mode the boiler provides heating:

1. Press the key (Figure 6.1

bol will appear on the display, indicating that the function has been activated.

2. Whenever there is a demand for space heating, the auto-

matic ignition system will ignite the burner; the operation is represented by the ignition of the symbol with an intermittent signal on the display.

After a long period of unit inactivity or at the rst start-up, it may be necessary to repeat the ignition operation a few times due to the presence of air in the gas piping.

p.26

), the xed sym-

Installation, use and maintenance manual – Caldaia 35 Tech

Maintenance

3. If the boiler does not start up, the relative error will be indi-

cated both on the remote control and on the internal panel of the boiler. It will be possible to reset the boiler either remotely or directly on the boiler panel.

4. Program the operation according to your needs.

For operation of the remote control refer to the instructions supplied with it.

6.3.3 Adjust the heating temperature

The temperature is adjusted using the and keys of the heating side (Figure 6.1

p.26

1. Pressing the key decreases the temperature.

2. Pressing the key increases the temperature.

3. The heating temperature control range is from a minimum

of 30 °C to a maximum of 80 °C.

6.3.4 OFF mode

In this operating mode the boiler no longer provides heating, but the antifreeze and pump anti-lock systems remain active. To switch the boiler to the OFF operating mode, press the

key; the xed symbol will appear on the display, indicating that the function has been activated. If the boiler was previously in operation, it is switched o and the post-ventilation and post-circulation functions are activated. If you decide to shut down the boiler for a long period of time, secure it by operating in one of the following two ways:

1. Call the TAC that will empty the water system, where there

is no provision for the use of antifreeze, and disconnect the power supply, water and gas.

2. Leave the boiler in the OFF operating mode, keeping the

power and gas supply active, so that the antifreeze function

and the pump anti-lock function can be activated.

6.3.5 Pump antifreeze and anti-lock function

Refer to Paragraph 3.5

p.16

6.4 REMOTE CONTROL OPERATION

OPTIONAL

For switching on, adjusting and switching o the boiler, refer to the instructions supplied with the remote control.

INFO MENU DISPLAY

To view the boiler data from Info menu you have to:

1. Press the key (Figure 6.1

displayed on the left side of the screen and its value will be displayed on the centre of the screen.

2. To scroll through the list of displayable data, use the and

keys of the heating side .

3. Press the key to exit the Info menu. Table 6.1

p.28

shows the list of Info menu displayable data.

Table6.1 List of displayable data from menu Info

Info code Description

d0 Not used temperature d1 Outdoor probe temperature d2 Blower speed d3 Not used temperature d4 Return probe temperature

d5 - d9 Not used temperatures

p. 26

). The info code will be

7 MAINTENANCE

Correct maintenance prevents problems, assures e-

ciency and keeps running costs low.

Maintenance operations described herein may exclu-

sively be performed by the TAC or skilled maintenance

technician.

Any operation on internal components may exclusively

be performed by the TAC.

Before performing any operation, switch o the appli-

ance by means of the control device and wait for the end

of the shutdown cycle, then disconnect power and gas

supply, by acting on the electrical disconnector and gas

valve.

It is recommended that the following operations and checks be carried out each year:

▶

Combustion circuit functionality and heat exchange control:

 Burner and ue exhaust duct inspection  Cleaning of burner and water/ue exchanger (if applica-

ble)

 Flame ignition/detection system control

▶

Hydraulic circuit and internal components functionality check:

 Hydraulic circuit control (pipes, gaskets)  Expansion tank  Control and safety devices  Water temperature probe

▶

Periodic analysis of combustion, in accordance with regulations in force

7.1 HYDRAULIC BOILER EMPTYING

Whenever there is a need to empty the boiler, proceed as follows:

▶

Switch o the boiler by pressing the button.

▶

Turn o the main power switch.

▶

Wait until the boiler has cooled down.

▶

Connect a hose emptying point and connect the other end of the hose to a suitable drain.

▶

Open the drain tap (Figure 7.1

▶

When all the water has drained o, close the drain tap.

p.29

Figure7.1 System drain tap position

RS Drain tap

Diagnostics

8 DIAGNOSTICS

In the event of a malfunction of the appliance, before contacting the TAC, make sure that:

▶

There is a full electricity supply.

▶

The gas is supplied.

▶

The gas pressure is within the indicated limits.

▶

The remote control (if any) is set so that the appliance is switched on and the appliance does not signal a fault.

8.1 SYSTEM PRESSURE RESTORE

In case of malfunction of the appliance, with pressure inside the hydraulic circuit lower than 0,3 bar, which can be seen through the pressure gauge located on the instrument panel inside the boiler, it is necessary, after having identied and solved any leaks

Table8.1 Error codes

Code Fault Possible cause Remedial action Reset

Without ame ignition

No gas supply Check the gas supply network Broken or badly positioned ignition electrode Replace Gas valve fault Replace Slow ignition set too low Adjust the minimum or slow ignition Inlet pressure of gas valve too high (only for LPG

E01 Flame lockout

Safety thermostat trip

E02

(95 °C)

Flue safety thermal

E03

fuse (102 °C)

supply)

With ame ignition

Power supply with phase and neutral inverted Connect the power supply correctly Flame detector fault Replace Detection electrode cable disconnected Check the electrical connection

Phase-to-phase electric current

Hydraulic circuit overheating Remove the cause of the lack of heat exchange Thermostat cable broken or disconnected Check the electrical connection Thermostat fault Replace Hydraulic circuit overheating Remove the cause of the lack of heat exchange Thermal fuse fault Replace Thermal fuse cable disconnected Check the electrical connection

on the circuit, to proceed with the restoring the correct amount of water (with glycol, if needed), as indicated in Paragraph

3.3

p.13

8.2 ERROR CODES

To display the last 5 fault codes, from the most recent in chronological order, activate the o mode using the key (Figure

6.1

p.26

) and press and hold the key for 5 seconds.

▶

To scroll through the list of stored faults, use the and keys of the heating side .

▶

To reset the fault history, press the reset key .

▶

To exit the display press the key.

Manual reset (press key) (1)

Check the maximum calibration pressure

If the voltage measured between neutral and earth is almost the same as the one measured between phase and earth, eliminate the dispersions

Manual reset (press key) (1)

Installation, use and maintenance manual – Caldaia 35 Tech

Diagnostics

Code Fault Possible cause Remedial action Reset

Insucient water pressure in the system (less

Low system water

E04

pressure

E05 Heating probe fault

E06 (2) DHW probe fault

E10 (4) False safety trip Incorrect setting of parameter P32 to value 1 Set parameter P32 to 0 Automatic

E14 (3) Air pressure switch

E15 Return probe fault

E16 Blower fault

E18 Low water ow

Generic internal elec-

E21

tronic board error Parameter program-

E22

ming request Not compatible

E31

remote control Communication error

E32

between boiler board and Modbus board

E35 Parasitic ame

Wrong power supply

E40

voltage

than 0,3 bar) Water pressure cable disconnected Check the electrical connection Water pressure switch fault Replace Probe fault or out of calibration (nominal resistance 10 KΩ at 25 °C) Probe connector wet or disconnected Check the electrical connection Probe fault or out of calibration (nominal resistance 10 KΩ at 25 °C)

Exhaust duct obstructed Check the ue exhaust duct Pressure switch disconnected Check the electrical connection Pressure switch fault Replace Probe fault or out of calibration (nominal resistance 10 KΩ at 25 °C) Probe connector wet or disconnected Check the electrical connection Blower board fault Replace Blower fault Replace Power supply cable fault Replace Clogged exchanger Clean the heat exchanger or replace it Circulator fault or dirty impeller Clean the impeller or replace the circulator Wrong recognition of a signal by the microprocessor of the modulation board

Microprocessor memory loss Parameter reprogramming

The remote controller connected to the boiler is not compatible with the electronic board No electrical connection Check the electrical connection

Modbus board fault Replace Flame detector fault Clean or replace

Flame detector cable fault Replace Modulation board fault Replace

Supply voltage out of operating range (≤160 Volts)

Load the system at the required pressure.

Automatic

Replace

Replace Automatic

Replace

If the modulation board does not reset the error automatically, replace it

Replace with a compatible one Automatic

Check the power supply (the error is automatically reset as soon as the power supply voltage returns to the required limits)

Automatic

Manual reset (press key) (1)

Automatic

Manual reset (disconnect the power supply)

Automatic

Manual reset (press key) (1)

Automatic

1 For model 100.2 boilers, press the key on the master control panel. 2 Only for boilers with DHW production. 3 Only for 100.2 boiler. 4 Not applicable to 100.2 boilers.

Table8.2 Signalling codes (visible ONLY on the boiler display)

Code Function Description

F07

F08

F09 (1)

F33 (2)

FH (1) Fast H2O

1 Only for boilers with DHW production. 2 Not applicable to 100.2 boilers.

Chimney sweep

function active

Heating antifreeze

function

DHW antifreeze

function

System air purge cycle

in progress

It is activated by pressing the reset key for 7 seconds and it is deactivated by turning o the boiler. Brings the boiler to the minimum and maximum power for 15 minutes by deactivating the modulation function. Generally used for combustion and calibration tests. It is automatically activated when the heating probe detects a temperature of 12 °C. The boiler operates at minimum power and is deactivated when a temperature of 30 °C is detected. It is automatically activated when the DHW probe detects a temperature of 4 °C. The boiler operates at minimum power with diverter valve in summer position. It is deactivated when a temperature of 8 °C is detected. It automatically starts when the boiler is rst turned on, running for 5 minutes a series of cycles in which the pump is turned on for a period of 40 seconds and then turned o 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.

It is activated or deactivated by holding down the reset and keys of the DHW side for 7 seconds.

Table 7

9 APPENDICES

9.1 PRODUCT FICHE

Figure9.1

COMMISSION DELEGATED REGULATION (EU) No 811/2013

Technical parameters for boiler space heaters, boiler combination heaters and cogeneration space heaters

Rated heat output

For boiler space heaters and boiler combination heaters: Useful heat output

Prated 33,35 kW

Appendices

53 airadlaC:)s(ledoM sey:reliob gnisnednoC sey:reliob )**( erutarepmet-woL

on:reliob 11B

on:retaeh noitanibmoC

Seasonal space heating



energy efficiency

For boiler space heaters and boiler combination heaters: Useful efficiency

92,81 %

on:retaeh yratnemelppus a htiw deppiuqe ,sey fIon:retaeh ecaps noitarenegoC

tinUeulaVlobmySmetItinUeulaVlobmySmetI

At rated heat output and high-temperature regime (*) At 30 % of rated heat output and low-temperature regime (**)

33,4 kW At rated heat output and

high-temperature regime (*)

10,2 kW At 30 % of rated heat output



and low-temperature regime (**)

smeti rehtOnoitpmusnoc yticirtcele yrailixuA

At full load elmax 0,038 kW Standby heat loss P

At part load elmin 0,016 kW Ignition burner power

stby

ign

consumption

In standby mode P

(*) High-temperature regime means 60 °C return temperature at heater inlet and 80 °C feed temperature at heater outlet.

(**) 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).

0,004

kW Annual energy consumption Q

Sound power level, indoors

- / 52,4 dB

Additional information required by COMMISSION REGULATION (EU) No 813/2013, Table 1: Emissions of nitrogen oxides: NO

55 mg/

kWh

88,3 %

97,8 %

0,059 kW

0 kW

105,5 GJ

Installation, use and maintenance manual – Caldaia 35 Tech

Robur mission

Robur is dedicated to dynamic progression in research, development and promotion of safe, environmentally-friendly, energy-eciency products, through the commitment and caring of its employees and partners.

23/07/2019

19 MCM SDC 022

Code: D-LBR749EN

Robur S.p.A. advanced technologies for climate conditioning via Parigi 4/6 24040 Verdellino/Zingonia (BG) Italy +39 035 888111 - F +39 035 884165 www.robur.it robur@robur.it

Revision: B

Robur Caldaia 35 Tech Instructions For Installation, Use And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual