Robur AY00-120, E3 AY00-120 Installation, User And Maintenance Manual

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Installation, user and maintenance manual

AY Condensing line, AY Series

gas red

4 star condensation boiler for heating

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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 led at Robur S.p.A. Any use of this 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 manual without prior notice.

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Installation, user and maintenance manual – AY Condensing line, AY Series

INDEX OF CONTENTS

1 PREFACE �� 4 2 SAFETY WARNINGS �� 5 3 OVERVIEW AND TECHNICAL FEATURES �� 7

3.1 GENERAL INFORMATION ..........................................................................................................................................................................................7

3.2 OVERVIEW OF OPERATION ......................................................................................................................................................................................8

3.3 TECHNICAL MANUFACTURING CHARACTERISTICS .........................................................................................................................................9

3.4 TECHNICAL DATA ........................................................................................................................................................................................................9

3.5 DIMENSIONS AND SERVICE PANEL ....................................................................................................................................................................11

4 NORMAL OPERATION �� 13

4.1 START UP (AND SHUT DOWN) .............................................................................................................................................................................13

4.2 ON-BOARD ELECTRONICS ..................................................................................................................................................................................... 14

4.3 RESET OPERATIONS .................................................................................................................................................................................................15

4.4 OPERATING SETTINGS ............................................................................................................................................................................................ 16

4.5 PROLONGED PERIODS OF DISUSE ..................................................................................................................................................................... 17

5 HYDRAULIC INSTALLATION �� 18

5.1 GENERAL INSTALLATION PRINCIPLES ............................................................................................................................................................... 18

5.2 POSITION OF THE APPLIANCE ............................................................................................................................................................................. 18

5.3 HYDRAULIC CONNECTIONS ................................................................................................................................................................................. 19

5.4 GAS SUPPLY ................................................................................................................................................................................................................23

5.5 CONDENSATE DISCHARGE .................................................................................................................................................................................... 24

5.6 FILLING THE SYSTEM CIRCUIT (APPLIANCE) ...................................................................................................................................................25

5.7 FILLING THE APPLIANCE’S INTERNAL CIRCUIT ..............................................................................................................................................25

5.8 EXHAUST FLUE GAS .................................................................................................................................................................................................26

5.9 PROGRAMMING OF HYDRAULIC PARAMETERS.............................................................................................................................................29

6 ELECTRICAL INSTALLATION ��32

6.1 CONNECTING THE APPLIANCE TO THE MAINS .............................................................................................................................................. 34

6.2 ELECTRICAL CONNECTIONS FOR THE SYSTEM CIRCULATOR ................................................................................................................... 36

6.3 CONNECTIONS FOR CONSENT SWITCH OPERATION ................................................................................................................................... 39

6.4 USE OF THE CCI/DDC ..............................................................................................................................................................................................40

7 INITIAL ACTIVATION AND MAINTENANCE ��50

7.1 PROCEDURE FOR FIRST START UP ......................................................................................................................................................................50

7.2 MAINTENANCE .......................................................................................................................................................................................................... 53

7.3 CHANGE OF GAS TYPE............................................................................................................................................................................................54

8 ACCESSORIES �� 58 9 OPERATING CODES/TROUBLESHOOTING �� 59

9.1 OVERVIEW AND OPERATING CODES/TROUBLESHOOTING .......................................................................................................................59

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1 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:

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nal users for the operation of the appliance according to their own requirements;

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installation technicians (hydraulic and electrical) for the carrying out of a correct installation of the appliance and of the Direct Digital Controller (DDC).

The manual also contains:

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a section that describes all the operations necessary for the “rst start-up” and for the “gas change” of the appliance, as well as the main maintenance operations;

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an "ACCESSORIES" section with a description of accessories available and their respective reference codes;

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(IN CASE) one or more APPENDIX sections in which are reported some "specic" information for a particular country.

Denitions, meaning of terms and icons

APPLIANCE: 4 star condensation boiler, Robur model "AY00-120". CCI: "Comfort Control Interface" device. Not applicable. DDC: digital control panel (Direct Digital Controller). TAC: Technical Assistance Centre (authorised by Robur S.p.A.). ACS: sanitary (domestic) hot water. UTA: air handler. The icons used in the manual have the following meanings:

= DANGER

= WARNING

= NOTE

= START OF OPERATING PROCEDURE

= REFERENCE to another part of the manual or other document

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2 SAFETY WARNINGS

Installation, user and maintenance manual – AY Condensing line, AY Series

2 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. The manufacturer does not accept any contractual or extra-contractual liability for any damage caused by improper use of the appliance.

Frequent topping up of the hydraulic with water can result in damage due to scale and corrosion, depending on the quality of the water being used. Make sure the system is water tight and that the expansion tank is operational.

Concentrations of chlorides or free chlorine in the circuit above the values given in Table 5.1→19 will damage the unit's water/ammonia exchanger.

Close the gas supply before working on the gas circuit. On completing work on the gas circuit, check for leakages as required by established regulations.

Do not operate the appliance if dangerous conditions exist: odour of gas in the grid or near the appliance; problems with the electrical/gas grid or hydraulic circuit; parts of the appliance submerged in water or otherwise damaged; controls or safety components bypassed or defective. In these cases, ask for assistance to professionally qualied personnel.

If you smell gas:

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do not use electrical devices such as telephones, multimeters or other equipment that can cause sparks next to the appliance;

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shut o gas supply closing the isolation valve;

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cut o electrical power opening the main breaker upstream of the appliance (to be provided by the electrical installer in an appropriate panel);

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ask for assistance to professionally qualied personnel from a telephone distant from the appliance.

Moving parts, also during the appliance's start-up and shut-down cycles. Do not remove guards. Make sure the appliance cannot be started up inadvertently.

POISONING HAZARD

Make sure the ue gas components are tight and compliant with established regulations. After any intervention on these parts, check for tightness.

BURN HAZARD

The appliance contains numerous hot parts. Do not open up the appliance or touch the fumes outlet pipe. If necessary, contact your Technical Assistance Centre.

ELECTROCUTION HAZARD

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Use only approved components for the electrical connections, as specied by the manufacturer.

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Disconnect the electrical power supply before working on the appliance's internal electrical equipment (electrical panel, motors, control board, etc.).

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Make sure the appliance cannot be started up inadvertently.

The electrical safety of the appliance is ensured only when it is correctly connected to an ecient grounding system, compilant with current safety regulations.

DAMAGE DUE TO AGGRESSIVE SUBSTANCES IN THE AIR SUPPLY

Hydrogenated hydrocarbons, which contain chlorine and uorine compounds, will increase the corrosion of the unit. Make sure the air supply is free of aggressive substances.

ACID CONDENSATE

Drain out the condensate produced during combustion as indicated in paragraph 5.5→24.

EXPLOSIVE/FLAMMABLE MATERIALS HAZARD

Do not use or store ammable materials (paper, solvents, paint, etc.) in the vicinity of the appliance.

SUGGESTIONS FOR THE CLIENT

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2 SAFETY WARNINGS

Stipulate a maintenance contract with an authorised specialist contractor for the annual inspection of the appliance and maintenance 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.

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3 OVERVIEW AND TECHNICAL FEATURES

Installation, user and maintenance manual – AY Condensing line, AY Series

3 OVERVIEW AND TECHNICAL FEATURES

In this section you will nd general information, hints on the operating principle of the appliance and its manufacturing features. This section also contains technical data and dimensional drawings of the appliance.

3.1 GENERAL INFORMATION

This manual is an integral and essential part of the product and must be delivered to the user together with the appliance.

Conformity to CE standards

The appliance is CE certied and conforms with all essential requirements of:

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Gas Directive 90/396/EEC and subsequent modications and additions.

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

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Electromagnetic Compatibility Directive 89/336/EEC and subsequent modications and additions.

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Low Voltage Directive 89/336/EEC and subsequent modications and additions.

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Machinery Directive 2006/42/EC.

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UNI EN 677 Specic requirements for condensing boilers with nominal thermal capacity up to 70 kW.

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UNI EN 483 Type C boilers with nominal thermal capacity no greater than 70 kW.

Information regarding the above EC certications is given in Paragraph 3.4→9, as well as on the Nameplate of the appliance itself.

Installation and regulatory references

When the appliance arrives at the installation site, before beginning the stages required to move it in order to position it on the site, perform a visual check to ascertain that there are no evident signs of breakage or damage to the packaging or to the external panels, which would be signs that damage occurred during transport.

Packing materials must be removed only after the appliance has been positioned on site. After removing the packing materials, ensure that the appliance is intact and complete.

Installation of the appliance may only be carried out by professionally qualied personnel by i.e. rms qualied according to the current legislation of the country of installation.

"Professionally qualied personnel" means personnel with specic technical competence in the sector of heating/cooling installations and gas appliances.

Installation of the appliance must be carried out in compliance with current local and national regulations regarding the design, installation and maintenance of heating and cooling installations and in accordance with the manufacturer's instructions. In particular, current regulations regarding the following must be observed:

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Gas equipment.

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Electrical equipment.

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Heating systems employing condensation boilers.

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Every other standard and regulation concerning the installation of equipment for summer and winter air conditioning using gas fuel.

The manufacturer does not accept any contractual or extra-contractual liability for any damage caused by errors in installation and/ or failure to observe the abovementioned regulations and the instructions supplied by the manufacturer itself.

Once the appliance is installed

The installer must provide the owner with a Declaration stating that the installation has been completed in compliance with state-of-the-art practices, current national and local regulations, and recommendations by the manufacturer.

Before contacting your authorised Robur Technical Assistance Centre (TAC) for the initial activation, the rm must ensure that:

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the electricity and gas mains specications correspond to the specications on the nameplate;

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the gas supply pressure is compliant with the value reported in Table 5.2→24 (considering a tolerance of ±15%);

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the appliance is fed by the type of gas for which it is designed;

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the gas supply system and water distribution system are sealed;

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the gas and electricity supply systems are properly rated for the capacity required by the appliance and are equipped with all safety and control devices required by current regulations

Check that no safety and control devices are excluded, by-passed or not properly working.

Initial activation procedure

The complete procedure for the rst start up of the appliance must be carried out by an authorized technician according to the instructions supplied by the manufacturer. To carry out entire procedure correctly, follow the instructions in Paragraph 7.1→50.

Warranty could be invalidated if the rst start up is not carried out and validated by an authorized technician.

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3 OVERVIEW AND TECHNICAL FEATURES

Operation and maintenance of the appliance

To ensure the correct operation of the appliance and to avoid failures, control of the switching on and o of the appliance must be carried out exclusively via a switch located on the on/o command circuit. If the appliance is to be connected to a Direct Digital Controller (DDC, available as an accessory), control of activating and deactivating the appliance must be performed exclusively through the DDC itself.

The appliance must never normally be switched on and o by shutting o the power supply upstream of the on/o commands (DDC or other switch) before having operated these rst. With the appliance running, also wait for the shutdown cycle to end (approximately 3 minutes) before shutting o the power supply power.

If the appliance fails to operate correctly, with the consequent indication of the Machine code, follow the instructions of Paragraph

9.1→59. In the event of failure of the appliance and/or breakage of any component, do not attempt to repair and/or restore opera-

tion; proceed as follows:

▶

deactivate the appliance immediately (if permitted and if no condition of danger exists) by starting the shutdown cycle via the on/o command (or DDC) and waiting for it to terminate (approximately 3 minutes);

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disconnect the appliance from the gas and electricity mains, cutting o gas supply by means of the appropriate valve and the power supply by means of the external circuit breaker provided by the electrical system installation technician on the appropriate panel;

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contact your local Robur TAC.

If it is decided not to use the appliance for a prolonged period, disconnect the appliance following the instructions provided in Paragraph 4.5→17. Proper ordinary maintenance ensures the eciency and good operation of the appliance over time. 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 qualied technician; for other maintenance requirements, see Paragraph 7.2→53. Any repair of the appliance must be carried out by Technical Assistance, using only original spare parts.

Failure to observe the indications given above may compromise the operation and safety of the appliance, and may invalidate its guarantee, if active.

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

If the appliance is to be sold or transferred to another owner, ensure that this “Installation, user and maintenance manual” is handed over to the new owner and installer.

3.2 OVERVIEW OF OPERATION

The appliance powered by 230 V 1N 50 Hz electrical power - . During operation, combustion products are exhausted via the discharge terminal, with vertical outlet, at the top of the appliance. Combustion product condensate is discharged via the special pipe which passes through the service plate (see Figure 3.3→12). The appliance is equipped with a plate exchanger which separates the following hydraulic circuits:

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the internal circuit dedicated to the combustion unit and factory charged to enable storage down to -30°C;

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the system circuit. The section of circuit running from the exchanger to the hydraulic unions on the service plate is itself a part of the system circuit.

Control and management of operation of the appliance occurs via the on-board electronics through the microprocessor control board (see Figure 4.1→14). Control and management of operation of the appliance may also take place via the Direct Digital Controller (see Figure 3.1→9) available as an accessory.

For instructions regarding the use, conguration and programming of the DDC, refer to the two manuals supplied with the unit.

DDC conguration/programming operations must be carried out by an authorised Robur Technical Assistance Centre (TAC) during initial activation procedures and according to the instructions supplied by the manufacturer.

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3 OVERVIEW AND TECHNICAL FEATURES

Installation, user and maintenance manual – AY Condensing line, AY Series

Figure 3.1 – CCI/DDC

AY00-120: description and general characteristics

the appliance (see Figure 3.2→11) is a B53P type high eciency boiler ( star eciency 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 regulating the nominal gas ow (nominal thermal input). The appliance, which can produce hot water up to 80°C, is suited to installation in all hot water production systems for heating, sanitary use (ACS), process needs, air handlers, etc. Since the appliance is of the 2 pipe variety (water inlet and outlet), it can be adapted to a variety of purposes (e.g.: both heating and ACS) by bleeding the system.

3.3 TECHNICAL MANUFACTURING CHARACTERISTICS

The appliance is supplied with the following technical manufacturing characteristics, control and safety components:

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premixed multigas burner with low NOX and CO emissions;

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stainless steel plate exchanger, acting as a hydraulic separator;

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AY10 microprocessor controller with LCD display and control knob (Figure 4.1→14);

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S70 controller (Figure 4.1→14);

▶

ionisation-based ame controller;

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gas solenoid valve with double shutter;

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system water antifreeze function;

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internal circuit antifreeze function;

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automatically resettable water temperature limiting thermostat;

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single-use fumes limiting thermostat (thermal cutout);

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system circuit water dierential pressure switch (PD1);

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internal circuit water dierential pressure switch (PD2) with anti-sticking function;

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overpressure valve on internal circuit, set to trip at 3 bar;

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internal circuit expansion tank;

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automatic and manual air bleeds on the internal circuit;

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fumes pipe with terminal, for type B53P conguration.

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condensate discharge siphon (with antifreeze function);

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anti-freezing thermostat used for the activation of the heating element on the condensate drain.

3.4 TECHNICAL DATA

Table 3.1 – TECHNICAL CHARACTERISTICS

AY00-120

OPERATION WHEN HEATING

Thermal capacity

Nominal (1013 mbar - 15°C) kW 34,9 MEAN kW 21.5 MIN kW 8.0

OPERATING POINT: Tm80/Tr60 and nominal thermal capacity

Available power kW 34.4 Eciency % 98.6

OPERATING POINT: Tm80/Tr60 and minimal thermal capacity

Eciency % 97.3

OPERATING POINT: Tm70/Tr50 and nominal thermal capacity

Eciency % 100,6

Eciency classes ****

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3 OVERVIEW AND TECHNICAL FEATURES

AY00-120

NOx emission class 5

Hot water delivery temperature

maximum °C 80 minimum °C 25 nominal °C 60

Hot water return temperature

maximum °C 70 minimum °C 20 nominal °C 50

Hot water ow rate

nominal l/h 2950 maximum l/h 3200 minimum l/h 1500

Hot water pressure drop at nominal water ow bar 0,395

Ambient air temperature (dry bulb)

maximum °C 45 minimum °C -20

gas consumption

methane G20 (nominal) m3/h 3.69 methane G20 (MIN) m3/h 0.85 G25 (nominal) m3/h 4,35 G25 (MIN) m3/h 1,00 G30 (nominal) kg/h 2.75 G30 (MIN) kg/h 0.63 G31 (nominal) kg/h 2.71 G31 (MIN) kg/h 0.62

THERMAL EFFICIENCIES

Eciency at MEAN thermal capacity Tm80/Tr60 % 98.3 Eciency at MIN thermal capacity Tm80/Tr60 % 97.3 Eciency at nominal thermal capacity Tm50/Tr30 % 104.6 Eciency at 30% of nominal thermal capacity Tr=30°C % 107.5 Eciency at 30% of nominal thermal capacity Tr=47°C % 100.3 Operational heat loss to jacket kW 0,15 Operational heat loss to jacket % 0.44 Operational heat loss to ue kW 0,86 Operational heat loss to ue % 2.54 Heat loss in o mode kW 0,058 Heat loss in o mode % 0,2

ELECTRICAL SPECIFICATIONS

Power supply

Voltage V 230 TYPE single-phase

Frequency 50 Hz supply 50 Electrical power absorption nominal kW 0.185 Degree of protection IP X5D

INSTALLATION DATA

Minimum storage temperature °C -30 Maximum operating pressure bar 3 Water content inside the apparatus HOT SIDE l 1,0

Water tting

TYPE F

thread " G 1 1/4

Gas tting

TYPE M

thread " G 3/4

Fume outlet

Type of installation B23P-B33-B53P-C13-C33-C43-C53-C63-C83

Diameter (∅) mm 80

Residual head Pa 100

Product conguration B53P

Size

width mm 410

height mm 1280

depth mm 530 Weight In operation kg 71

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 ow rate

WATER TEMPERATURE

20°C

[l/h] [bar]

1008 0,066 1198 0,085 1398 0,106

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3 OVERVIEW AND TECHNICAL FEATURES

Installation, user and maintenance manual – AY Condensing line, AY Series

PRESSURE DROP OF A SINGLE AY00-120 CONDENSING UNIT

Water ow rate

WATER TEMPERATURE

20°C

[l/h] [bar]

1608 0,136 1801 0,165 2007 0,204 2199 0,234 2400 0,269 2601 0,312 2797 0,353 2958 0,395 3000 0,406 3201 0,469

3.5 DIMENSIONS AND SERVICE PANEL

Figure 3.2 – Dimensional drawing of model AY00-120

AY00-120 - front and RH side views (dimensions in mm).

LEGEND

Series AY model AY00-120

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3 OVERVIEW AND TECHNICAL FEATURES

Figure 3.3 – SERVICE PANEL: Series AY - AY Condensing line

Series AY - service plate (dimensions in mm).

LEGEND

G gas tting ("G 3/4 M) A outlet water tting ("G 1 1/4 F) B inlet water tting ("G 1 1/4 F) C condensate drain tting (ext. dia. 25 mm)

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4 NORMAL OPERATION

Installation, user and maintenance manual – AY Condensing line, AY Series

4 NORMAL OPERATION

In this section you will nd all the indications necessary for the activation, regulation and control of operation of the appliance via the controller present in the electrical panel.

4.1 START UP AND SHUT DOWN

Ecient operation and long life of the appliance depend largely on its correct use!

Before activating the appliance, check that:

▶

the gas valve is open;

▶

the appliance is powered electrically: the general electrical switch (GS) must be in the «ON» position;

▶

the installation technician has ensured that the hydraulic circuit is supplied in the correct conditions.

If these conditions are satised, it is possible to proceed with activation. If the appliance is not connected to a DDC, it may be activated and deactivated only by means of the on/o command provided by the electrical installation technician. According to requirements, this on/o command may be an on/o button, an ambient thermostat, a programmable timer, or one or more voltage free contacts controlled by another process.

For details about the type of on/o command installed, contact the plant’s electrical installation technician.

Start up

Switch on the appliance by means of the on/o command (placing it in the "ON" position).

Shut down

Switch o the appliance via the on/o command (placing it in the "OFF" position).

The shutdown cycle takes approximately 3 minutes to complete.

The on/o command is essential! Do not switch the appliance on or o by connecting it to or disconnecting it from the power supply directly, as this may be a source of danger and in any case damage the appliance or the plants connected to it.

If the appliance is connected to a DDC running in controller mode, the appliance is started up and controlled exclusively by the DDC.

For instructions regarding the use of the DDC, refer to the two manuals supplied with it, and in particular: "Final user manual

- manual 2"

Visualising and clearing of operating codes

Operating codes can be generated by the controller or by the DDC. The operating codes generated by the controller are visualised on its display and may also be visualised on the display of the DDC (if tted). Operating codes generated by the controller can be reset with the controller itself or from the DDC (if tted or where possible).

For a description of the operating codes generated by the electronic board and how to reset them, refer to the list of operating codes contained in Table 9.1→59.

The controller (see Figure 4.1→14) is located inside the electrical panel of the appliance and the display may be viewed through the viewing hole on the front panel of the unit itself.

The Machine Codes generated by the DDC may only be viewed on the display of the DDC and may be cleared only through the DDC.

Operating codes generated by the electronic board during the start-up of the appliance

If the appliance remains inactive for a prolonged period, it is possible that air is present in the gas pipes. In this case, activation fails and the appliance reports the operating code: "u_12" - ame controller arrest (temporary) (see Paragraph 9.1→59) and after a brief interval the appliance automatically launches the start up procedure again. If code (u_12) is signalled 4 times on successive activation attempts, the code persists, the appliance locks out the ame controller and displays the following operating code: "E_12" – ame controller arrest (see Paragraph 9.1→59). In this case reset is not automatic. To restore operation of the appliance, carry out a reset of the ame control unit via menu 2 of the controller: the procedure is illustrated in Paragraph 4.3→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).

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4 NORMAL OPERATION

4.2 ONBOARD ELECTRONICS

The following descriptions refer to the controller with rmware version 3.106.

The appliance is tted with an AY10 controller connected to an auxiliary S70 controller (see Figure 4.1→14). The AY10 is installed over the S70 and is located in the machine’s internal electrical panel. The AY10 controller controls the appliance and displays data, messages and codes during operation. Programming, control and monitoring of the appliance take place by interacting with the display and encoder of the controller. The CAN BUS port connects one or several appliances to a DDC.

Figure 4.1 – On-board electronics

Controllers AY10 and S70.

LEGEND

A 4 digit display for data and

operating codes.

B Knob for scrolling through/

selecting operating data

Description of menu of AY10 controller

The parameters and settings of the appliance are grouped in the menus shown on the controller’s display:

Table 4.1 – Menu of electronic board

MENU MENU DESCRIPTION THE DISPLAY SHOWS

Menu 0 VIEW DATA (TEMPERATURE, VOLTAGE, PUMP SPEED, ECC...) 0. Menu 1 VIEW ALL PARAMETERS 1. Menu 2 ENTER ACTIONS 2. Menu 3 USER SETTINGS (THERMOSTATING, SET-POINT, T. DIFFERENTIAL) 3. Menu 4 INSTALLATION TECHNICIAN SETTINGS 4. Menu 5 TECHNICAL ASSISTANCE CENTRE SETTINGS 5. Menu 6 TECHNICAL ASSISTANCE CENTRE SETTINGS (MACHINE TYPE) 6. Menu 7 VIEW DIGITAL IMPUTS 7. Menu 8 (MENU NOT USED) 8. E EXIT MENU E.

Menu list of electronic board

Menus 0, 1 and 7 are Viewing Menus: they only allow the information displayed to be read, and not modied. Menu 0 shows the appliance operating data in real time. 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. Menu 2 is an Action Menu: it is used to reset the ame controller and errors. To perform these procedures, see Paragraph 4.3→15. Menu 3 is a Settings Menu: it allows the values displayed to be set. The correct values of these parameters, for optimum performance of the appliance with the plant to be used connected, have already been set during installation. To set new values for the parameters, see Paragraph 5.9→29.

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4 NORMAL OPERATION

Installation, user and maintenance manual – AY Condensing line, AY Series

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. Upon activation, all display’s LED’s light up, and then the name of the controller displays. Subsequently (if the on/o command switch is set to ON), the appliance begins to operate. During correct operation the display shows, alternately, the following information: outlet water temperature, inlet water temperature, and the dierence between the two water temperatures (see Table 4.2→15).

Table 4.2 – Operating information

OPERATING MODE: HEATING PARAMETER THE DISPLAY SHOWS

Hot outlet water temperature 50.0 Hot inlet water temperature 40.0 Dierential Temperature (outlet - inlet) 10.0

Example of data visualised on display: water temperature and dierential

If there are operating problems, the display shows, sequentially, the operating codes corresponding to the problem detected. A list of these codes with their description and the procedure to follow to bring the appliance back to correct operation is provided in Paragraph 9.1→59. The knob is used to display or set parameters, or to execute actions/commands (e.g.: a function or reset), when permitted.

HOW TO ACCESS THE MENUS

▶

To use the knob with the special key supplied with the appliance:

You will need: the appliance's electrical power switches set to "ON"; the controller's display sequentially shows the operating data (temperature, delta T) regarding the current mode (e.g.: heating) and any active operating codes ("u/E...").

1. Remove the front panel by removing the xing screws.

2. Remove the cover of the electrical panel to access the knob.

3. Use the special key through the hole to operate the knob and access the controller’s menus and parameters.

4. To display the menus just press the knob once: the display shows the rst menu: "0." (= menu 0).

5. The display shows “0.”. To display the other menus, turn the knob clockwise; The display will read, in order: "1.", "2.", "3.", "4.", "5.", "6.", "7.", "8." and "E" (see 4.1→14).

6. To display the parameters in a given menu (for example, menu 0), turn the knob until it displays the menu in question (in the example: "0.") and press the knob: the display will show the rst of the menu’s parameters, in this example "0.0" or "0.40" (= menu 0, parameter "0" or "40").

7. In the same way: turn the knob to scroll through content (menus, parameters, actions), press the knob to select/conrm the content (access a menu, display/set a parameter, execute an action, quit or return to the previous level). For example, to quit the menus, turn the knob to scroll through menus "0.", "1.", "2." etc. until the controller displays the quit screen "E"; now press the knob to quit.

In the case of menus 0 and 1, the user can view any parameter. For how to access to menu 2, refer to Paragraph 4.3→15. To set the parameters of me nu 3, refer to Paragraph 5.9→29. The other menus are not for the User: the information in these menus is dealt with in the sections dedicated to the installation technician or Robur TAC.

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. When the necessary settings have been completed, put away the special key, replace the cap on the aperture of the electrical panel and ret the front panel of the appliance.

4.3 RESET OPERATIONS

Table 4.3→15 shows the actions available in menu 2.

Table 4.3 – Menu 2 of the AY10 controller

ACTION REQUIRED FOR EXECUTION SHOWN ON DISPLAY AS

20 Reset ame controller arrest 2. 20 21 Reset other operating codes 2. 21 23 Timed forcing to minimum power 2. 23 24 Timed forcing to maximum power 2. 24 25 Stop power forcing 2. 25 E (EXIT MENU) 2. E

Menu 2 actions.

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4 NORMAL OPERATION

The general operating codes of the controller can be reset with functions "20" and "21" or via the DDC, if running in controller mode. These operations can be run by the TAC and (some of them) by the user, as indicated in Table 9.1→59. When the DDC is running in controller mode, these operations can be run only with the DDC itself.

▶

To access menu 2:

You will need: the controller display shows the operating data (temperatures, delta T°, etc.) or operating codes ("u/E...") corresponding to the signal in question (u/E..) in sequence.

1. See procedure "HOW TO ACCESS THE MENUS" (Paragraph 4.2→14) and proceed as described in steps "1" to "5".

2. The display will now ash "0.". Turn the knob until menu 2 displays: the display shows “2”.

3. Press the knob to access menu 2: the display shows the rst of its actions "2.0" or "2.20" (= menu 2, action "0" or "20"). Turn the knob to scroll through the other actions."

The user must now only run the action relating to the command indicated in the operating code description in TABLE

9.1→59. Two commands are available: “reset ame controller" (action "20") or "reset other codes" (action "21").

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 ame controller (parameter "20"):

You will need: the display reads "2.20" (as per step "3").

1. Press the knob to display the ashing reset request: "reS1".

2. Press the knob again to reset the ame controller. The reset request stops ashing, and the display shows “2.20” again. The reset operation has been performed.

3. To exit the menu, turn the knob clockwise until “2.E” displays, and press it to return to the menu selection: "2.".

4. To exit the menu selection, turn the knob clockwise until “E” displays, and press it to exit.

At this point, if the display does not signal any other operating codes, put away the special key, replace the electrical panel cover and ret the front panel.

Reset other operating codes (parameter "21"):

You will need: the display reads "2.20" (as per step "3").

1. Turn the knob clockwise until action "2.21" displays.

2. Press the knob to display the ashing reset request: "rEr1".

3. Press the knob again to reset the operating code. The reset request stops ashing, and the display shows “2.21” again. The reset operation has been performed.

4. To exit the menu, turn the knob clockwise until “2.E” displays, and press it to return to the menu selection: "2.".

5. To exit the menu selection, turn the knob clockwise until “E” displays, and press it to exit.

At this point, if the display does not signal any other operating codes, put away the special key, replace the electrical panel cover and ret the front panel.

4.4 OPERATING SETTINGS

At the moment of installation, the appliance is set up by the installation technician for best operation according to the type of plant installed. Subsequently it is possible to modify the operating parameters, but this is not recommended if not in possession of the necessary knowledge and experience required to ensure the appliance’s performance.

The user modiable parameters (only if the appliance is not controlled by a DDC) are those in menu 3 of the controller, as follows:

▶

parameter "160": thermostat control.

▶

parameter "161": setpoint.

▶

parameter "162": dierential.

These are hydraulic parameters and expert knowledge is required to set them.

To modify these parameters, refer to Paragraph 5.9→29.

If the appliance is connected to a DDC, follow the instructions given in the DDC manuals exclusively.

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4 NORMAL OPERATION

Installation, user and maintenance manual – AY Condensing line, AY Series

4.5 PROLONGED PERIODS OF DISUSE

When the appliance is to be inactive for a long period, it is necessary to disconnect the appliance before the period of disuse and reconnect it before it is used again. To carry out these operations, contact a reputable hydraulic system installation technician.

Disconnecting the appliance before the period of disuse

You will need: the appliance connected to the power/gas supply. Necessary equipment and materials.

1. if the appliance is in operation, switch it o with the DDC (or other consent switches) and wait for the shutdown cycle to terminate completely (approximately 3 minutes).

2. Close the gas cock (if compatible with the antifreeze functions) (Paragraphs 5.6→25 and 5.7→25).

3. Switch o the DDC (if present).

4. Disconnect the appliance from the mains (if compatible with antifreeze functions, Paragraphs 5.6→25 and 5.7→25), and set the external power switch in the electrical panel to "OFF" (GS - see Paragraph 6.1→34).

Do not leave the appliance connected to the power and gas supply if it is expected to remain inactive for a long period.

If the appliance is disconnected in the run up to winter, make sure that there is a sucient glycol concentration in the internal and system circuits: see "Possible use of glycol antifreeze" and Table 5.3→25.

Connecting the appliance before it is used again (to be carried out by the installation technician)

Before starting this procedure, the hydraulic system installation technician must:

▶

Ascertain whether the appliance requires any maintenance (contact your authorised Robur Technical Assistance Centre or refer to Paragraph 7.2→53);

▶

check that the water content of the plant is correct; if necessary, top up the circuit to at least the minimum quantity (see Paragraph 5.6→25);

▶

if necessary, add inhibited monoethylene glycol antifreeze (free of impurities) in a quantity in proportion to the MINIMUM winter temperature in the area of installation (see Table 5.3→25);

▶

bring the plant to the correct pressure, making sure that the pressure of the water in the plant is not less than 1 bar and not over 2 bar.

In case of winter saesonal switch-o or long period of stopping, we suggest to not empty the hydraulic circuit: in that case possible oxidation process can occur.This oxidation process could damage both the hydraulic system and also the Robur heat pump.It’s important to verify that no leakages occur in the hydraulic circuit that may empty part of the system. The above recommendation is necessary in order to avoid to ll continuously with water that may imply the additional introduction of oxygen and the consequent dilution of the used inhibitor, for ex glycol. In case of precence of glycol, Robur advices to use inhibited glycol. Galvanized pipes are not recommended, as they are not compatible with glycol.

You will need: the appliance disconnected from the electricity and gas supply. Necessary equipment and materials.

1. Open the gas supply tap to the plant and ascertain that there is no smell of gas (indicating possible leaks);

if you smell gas, close the gas valve again immediately without operating any other electrical device and, from a safe place, request the assistance of professionally qualied personnel.

1. If no smell of gas is detected, connect the appliance to the electricity supply mains via the external disconnecting switch provided by the installation technician in the appropriate panel (set the "GS" disconnecting switch to the "ON" position - see Paragraph 6.1→34).

2. Power up the DDC (if present).

3. Check that the hydraulic plant is suitably sized to guarantee the correct water ow.

4. Switch the appliance on with the DDC (or other consent switches).

5. Ascertain whether the appliance requires any maintenance (refer to Paragraph 7.2→53). In particular, check the operation of the condensate siphon.

Icing of condensate during the period of disuse can lead to a permanent locked condition. In this case, the rst symptom would be a lack of condensate draining in condensation mode (outlet water temperature less than 50 °C).

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5 HYDRAULIC INSTALLATION

In this section you will nd all the instructions necessary for the hydraulic installation.

Before realizing hydraulic system and gas supply for the appliance, the professionally qualied personnel is advised to read Paragraph 3.1→7, providing important recommendations about safety and references to current regulations.

5.1 GENERAL INSTALLATION PRINCIPLES

Prior to installation, carry out careful internal cleaning of all pipes and every other component to be used both on the hydraulic plant and the fuel supply plant, in order to remove any residues that may compromise operation of the appliance.

Installation of the appliance must be carried out in compliance with current regulations regarding design, installation and maintenance of heating and cooling plants and must be undertaken by professionally qualied personnel in accordance with the manufacturer’s instructions. During the installation stage, observe the following indications:

▶

Check that there is an adequate mains gas supply, in accordance with the manufacturer’s specications; for the correct supply pressure, refer to Paragraph 5.4→23.

▶

The appliance may be installed both indoors and outdoors; in case of outdoors installation, the appliance must be located in an area in which air circulates naturally and which does not require any particular protection from the weather.

▶

No obstruction or overhanging structure (protruding roofs, eaves, balconies, ledges, trees) may obstruct the exhaust fumes outlet at the top of the appliance.

▶

Do not install the appliance, in conguration B, in the immediate vicinity of ue outlets, chimneys or other such features, so as to prevent warm or polluted air from being drawn in by the combustion fan. In order to function correctly the appliance must use clean air from the environment.

▶

If the appliance is installed near buildings, make sure it is not on the dripping line from gutters or similar.

▶

A cut-o valve and vibration damping coupling must be tted on the gas supply.

5.2 POSITION OF THE APPLIANCE

Lifting the appliance and placing it in position

Do not remove packaging during handling on the installation site.

Packing must only be removed upon nal installation.

When unpacking the appliance, do not remove the protective cap on the top panel as this can allow dirt and water to enter the interior of the appliance.

The appliance can be installed at ground level, or on a terrace or roof (if they are able to sustain its "dimensions" and "weight"). The

appliance must be installed in an area which is always accessible.

The dimensions and weight of the appliance are given in Paragraph 3.4→9.

Supporting base

Always place the appliance on a levelled at surface made of reproof material and able to support the weight of the appliance.

▶

Installation at ground level

If a horizontal base is not available (see also "Supports and levelling"), it is necessary to create a at level base in concrete at least 100-150 mm larger than the dimensions of the base of the appliance on each side. For the dimensions refer to the tables in Paragraph 3.4→9.

▶

Installation on a terrace or roof

Position the appliance on a levelled at surface made of reproof material (see also "Supports and levelling"). The structure of the building must be able to sustain the weight of the appliance added to that of the supporting base. For the weight refer to the tables in Paragraph 3.4→9. In addition, it is advisable to use exible connections (anti-vibration joints) between the appliance and the hydraulic and gas supply pipes.

Avoid placing the appliance on the roof directly above locals requiring quietness.

Supports and levelling

The appliance must be correctly levelled by placing a spirit level on the upper part. If necessary, level the appliance with metal shimming; do not use wooden spacers as these deteriorate quickly.

CLEARANCES AND WARNINGS

Position the appliance so as to maintain minimum clearances from combustible surfaces, walls or other appliances, as illustrated in Figure 5.1→19.

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5 HYDRAULIC INSTALLATION

Installation, user and maintenance manual – AY Condensing line, AY Series

Minimum clearances are required for maintenance accessibility.

The fumes outlet terminals must be installed in such a way that they do not allow the fumes to collect or return to the circuit in the unit's installation area. The outlet terminal must be constructed in conformity with established regulations. Position the appliance preferably out of range of rooms and/or environments where strict silence is required, such as bedrooms, meeting rooms, etc.

Figure 5.1 – Clearances

sample minimum clearances.

LEGEND

* dimensions in mm.

5.3 HYDRAULIC CONNECTIONS

General indications

▶

The hydraulic plant may be created using pipes in stainless steel, black steel, copper or crosslinked polyethylene suitable for heating and cooling plants. All water pipes and connections must be adequately insulated in accordance with current norms, to prevent heat dispersion and the formation of condensate.

▶

If glycol antifreeze is to be used (see Paragraph 5.6→25), DO NOT USE galvanised pipes or pipe ttings as they are subject to potential corrosion phenomena when glycol is present.

▶

If using rigid pipes, use vibration damping couplings at the water and gas connections on the appliance's service plate to prevent vibration.

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 lling or top-up water, please refer to codes and norms about water treatment for thermo-hydraulic installations in civil or industrial applications. Parameters indicated in Table 5.1→19 must be complied with.

Table 5.1 – Chemical and physical parameters of water

CHEMICAL AND PHYSICAL PARAMETERS OF WATER IN HEATING/COOLING SYSTEMS PARAMETER UNIT OF MEASUREMENT ALLOWABLE RANGE

pH \ >7

(1)

Chlorides mg/l < 125

(2)

Total hardness (CaCO

°f < 15 °d < 8,4

Iron mg/kg < 0,5

(3)

Copper mg/kg < 0,1

(3)

Aluminium mg/l < 1 Langelier’s index \ 0-0,4

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5 HYDRAULIC INSTALLATION

CHEMICAL AND PHYSICAL PARAMETERS OF WATER IN HEATING/COOLING SYSTEMS PARAMETER UNIT OF MEASUREMENT ALLOWABLE RANGE HARMFUL SUBSTANCES

Free chlorine mg/l < 0,2

(3)

Fluorides mg/l < 1 Sulphides ABSENT

1 with aluminium or light alloys radiators, pH must also be lower than 8 (in compliance with applicable rules) 2 value referred to the maximum water temperature of 80 °C 3 in compliance with applicable rules

Water quality can be measured through parameters like acidity, hardness, conductivity, chlorides content, chlorine content, iron content and the like.

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→19.

The way the installation is operated can be the cause of possible degradation of water quality. Moreover, abnormally massive water top-up or reintegration can cause a drift of chemical or physical above-mentioned parameters. Reintegration should not exceed 5% per year of the total amount of water. It is advised to check regularly the water quality, especially in case of automatic or periodic top-up. In case water treatment is needed, this operation should be carried out by a professional or competent person, following strictly the instructions by the manufacturer or supplier of the chemical substances for the treatment, since dangers could arise for health, for the environment and for Robur appliances. Several products for water treatment are available on the market. Robur does not perform detailed market surveys. Therefore Robur suggests to contact Companies which are specialized in water treatments. They will be able to suggest the best way how to proceed according to the type of installation. In case washing of the pipes is needed, this operation should be carried out by a professional or competent person, following strictly the instructions by the manufacturer or supplier of the chemical substances for the washing, avoiding the use of substances aggressive for stainless steel or containing/releasing free chlorine. Please make sure the pipes are properly rinsed in order to remove any residue of chemical substances from the pipes. Robur is not liable for ensuring that water quality is always compliant with what reported in Table 5.1→19. Non-compliance with indications above may jeopardize the proper operation, integrity and reliability of Robur appliances, invalidating the warranty. For any further detail, please contact directly Robur S.p.A. (tel.+39 035.888.111). The components described below, to be tted in proximity to the appliance, are illustrated in the typical hydraulic plant schemes in Figures 5.2→22 and 5.3→23.

▶

VIBRATION DAMPING COUPLINGS

▶

PRESSURE GAUGES (range 0-3 bar).

▶

FLOW REGULATION VALVE (shutter or balancing).

▶

WATER FILTER with mesh MIN 0.7 mm and MAX 1 mm.

▶

BALL CHECK VALVE (also to be tted on the gas supply line).

▶

EXPANSION TANK on system common circuit or each individual appliance:

the appliance is equipped with its own expansion tank on the machine’s internal circuit. the system circuit thus requires a separate expansion tank, sized in relation to the maximum heat range and the maximum operating pressure of the water in the plant (see the gures for reference mentioned above).

▶

WATER CIRCULATOR on system common circuit or each individual appliance: chosen to meet the system specications.

▶

INERTIAL TANK (OPTIONAL) or accumulator tank:

By the nature of its operating characteristics, the appliance does not strictly require the installation of an inertial tank on the hydraulic plant. The use of an inertial tank is, however, recommended in order to compensate for sudden variations in load, in particular when the plant has a water content of less than 70 litres per appliance.

▶

ACCCUMULATOR BOILER (OPTIONAL) for hot sanitary water (ACS):

The appliance does not itself produce hot water for sanitary (domestic) applications). If it is to be used for this purpose, a remote accumulator tank must be provided. In this case, any use of glycol in the heating circuit must be FOODSAFE.

▶

Systems for BLEEDING AIR from the pipes.

▶

DRAIN COCK (usually dia. ½”) for system water.

▶

PLANT FILLING SYSTEM:

if automatici lling systems are used, it is advisable to carry out a seasonal check of the percentage of monoethylene glycol contained in the plant (if present).

Antifreeze

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5 HYDRAULIC INSTALLATION

Installation, user and maintenance manual – AY Condensing line, AY Series

To prevent the water freezing in the internal and system circuits, the appliance is equipped with an antifreeze function. There are two antifreeze functions, both of which operate only on active modules. The hydraulic circuit is protected from icing by an electronical anti-freezing function; it operates by activating the water pump (if directly managed by the unit) ed eventually the burner of the units. The function, already factory activated on every unit, can be deactivated only by adding an adequate amount of anti-freezing glycole in the hydraulic circuit or by emptying the hydraulic circuit at the beginning of the winter season. The second antifreeze function protects the internal circuit against freezing; it runs the internal circuit water circulator. This function may not be deactivated inasmuch it is also used to protect the machine’s electronics during normal operation.

The machine is factory charged to 2 bar with a water/glycol mix which enables the machine to be safely stored down to

-30°C.

The antifreeze function, in order to protect the internal circuit, actuates the dedicated water circulator so as to keep the water in the circuit at a temperature of more than -10°C and hence the electrical components at more than -20°C. Make sure that the machine's internal circuit is always charged with an adequate glycol solution.

It is therefore necessary to ensure a continuous supply of electricity and gas to the appliance throughout the whole of the winter period. If it is not possible to ensure a continuous supply of electricity and gas to the appliance, use glycol antifreeze of the inhibited monoethylene type.

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” module is the one that operated the last shutdown; the other module will be the “passive” module.

If the appliances are controlled by a DDC. If the DDC manages a 2 pipe type plant (only hot, or only cold), or a 4 pipe type plant (hot and cold), the appliance module is ALWAYS “active”. If the DDC is controlling a 2 pipe hot/cold system, the active module is the one set as such on the DDC. As an example, if heatingis set on the DDC, all the hot modules managed by the DDC will be “active”; all the cold modules controlled by the DDC will be “passive”.

If glycol antifreeze is to be used in the hydraulic circuit, DO NOT USE galvanised pipes and connections. Consult the notes on "Possible use of glycol antifreeze" contained in Paragraph 5.6→25 and in any case the technical specications of the glycol to be used. The sizing of the pipes and pump must guarantee correct operation of the appliance (for calculation of pressure drops in the appliance, refer to the technical data, Paragraph 3.4→9).

The operations necessary for the rst activation or regulation of the appliance and of the Direct Digital Controller must be carried out exclusively by an authorized Robur Technical Assistance Centre (TAC). These operations are described in Section 7→50.

The products’ guarantee is void if initial activation is not carried out by a Robur TAC.

The following gures show examples of typical hydraulic circuits, composed of a single or multiple appliances.

For further information and technical support regarding other congurations, contact Robur S.p.A. Presales. (tel. 035

888.111).

Page 22

5 HYDRAULIC INSTALLATION

Figure 5.2 – Diagram of hydraulic system (type with single appliance)

Example of hydraulic plant diagram for connection of no. 1 AY00-120 unit.

LEGEND

1 anti-vibration coupling 2 pressure gauge 3 ow regulator valve 4 water lter 5 check valve 6 system water circulator 7 system expansion tank 8 DDC 9 AY00-120 stand-alone

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5 HYDRAULIC INSTALLATION

Installation, user and maintenance manual – AY Condensing line, AY Series

Figure 5.3 – Diagram of hydraulic system (type with several appliances)

Example of hydraulic plant diagram for connection of no. 2 AY00-120 units.

LEGEND

1 anti-vibration coupling 2 pressure gauge 3 ow regulator valve 4 water lter 5 check valve 6 system expansion tank 7 system water circulator 8 DDC 9 AY00-120 stand-alone

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→24.

Supplying gas to the appliance at pressures higher than those indicated above can damage the gas valve, resulting in dangerous situations.

LPG systems must be equipped with a rst stage pressure reducer close to the LPG storage tank, in order to reduce the gas pressure to 1,5 bar, and a second stage pressure reducer, close to the unit, in order to reduce pression from 1,5 bar to the value in agreement with the gas network pressure of the country of installation (see Table 5.2→24).

Exemple for the Italian market: for the G30 gas, from 1,5 bar to 0,030 bar (30mbar); for the G31 gas, from 1,5 bar to 0,037 bar (37mbar).

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5 HYDRAULIC INSTALLATION

LPG may cause corrosion; piping and tting materials must be resistant to this corrosion.

Vertical gas pipes must be equipped with a siphon and provided with a drain for the condensate that may form inside the pipe during cold periods. 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 Product categories Countries of destination G20 [mbar] G25 [mbar] G30 [mbar] G31 [mbar]

G25.1

[mbar]

G27 [mbar] G2,350 [mbar]

2H3B/P

AL, BG, CZ, DK, EE, FI, GR, LT, NO, SE, SI, SK, TR

20 30 30

AT, CH 20 50 50 HR, MK, RO 25 30 30

IT 20 28-30 37

2H3P

AL, BG, CZ, ES, GB, IE, LT, PT, SI, SK

20 37

HR, MK, RO 25 37 37

2HS3B/P

HU 25 30 30 25

2E3P

LU 20 50

2ELL3B/P

DE 20 20 50 50

2Esi3P *

FR 20 25 37

2L3B/P

NL 25 50 50

2E3B/P

20 37 37

2ELwLs3B/P

20 37 37 20 13

2ELwLs3P

20 37 20 13

2E(S); I3P

BE 20 25 37

LV 20

MT 30

3B/P

CY, MT 30 30

IS 30

Note: values reported in table are the nominal one, it is in any case accepted a value within the tollerance range of ±15% (Pmin/Pmax).

For data regarding hourly fuel consumption of the appliance, refer to Table 3.1→9.

5.5 CONDENSATE DISCHARGE

The fumes exhaust pipe is located on the right of the appliance on the service plate. To install/connect the condensate discharge pipe, proceed as follows: The condensate discharge to the sewer must be:

▶

made of materials resistant to acidity with pH 3 to 5;

▶

sized to ensure a slope of 10 mm per metre of length; if this slope cannot be achieved, a condensate pump (available as an accessory) must be installed near to the discharge - see Section 8→58);

▶

realized in such a way as to prevent icing of the condensate;

▶

mixed, for example, with domestic euent (washing machine, dishwasher, etc.), usually of base pH, so as to form a buer solution before discharge into the sewer.

Do not discharge the condensate into the gutter drains, given the risk of icing and degradation of the materials usually used for such drains.

CHARGING THE SIPHON

In case of residential installation, to prevent an initial discharge of combustion products from the condensate drain, charge the siphon itself as follows:

1. remove the appliance's front panel and open the interior panel to access the siphon;

2. if the fumes exhaust equipment has not yet been installed, pour 0.2 litres of water directly into the plastic fumes exhaust pipe accessible from the top panel (see Figure 5.6→28 - detail "D") and visually check that the siphon is full, then go to step 5. Otherwise, proceed as follows;

3. remove the clamp, disconnect the plastic siphon pipe and ll it with 0.2 litres of water;

4. reconnect the plastic pipe and secure it with its clamp;

5. restore the appliance.

If the appliance is operated with the siphon empty, there is a risk of leaks of combusted gas.

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Installation, user and maintenance manual – AY Condensing line, AY Series

5.6 FILLING THE SYSTEM CIRCUIT APPLIANCE

After having completed all hydraulic, gas and electrical connections, the installer can proceed lling 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 impurities) a quantity of monoethylene glycol in proportion with the minimum winter temperature in the installation zone (see table 5.3→25).

▶

Bring the plant to the correct pressure, making sure that the pressure of the water in the plant is not less than 1 bar and not over 2 bar.

Possible use of glycol antifreeze

Glycols, normally used to lower the freezing point of water, are substances in an intermediate state of oxidisation which, in the presence of oxidising agents such as oxygen, are transformed into corresponding acids. This transformation into acids increases the corrosive nature of the uid contained in the circuit. For this reason, mixtures that are commercially available almost always contain inhibiting substances that are able to control the pH of the solution. A necessary condition for the oxidisation of the glycol, and therefore its degradation, is the presence of an oxidising agent such as oxygen. In closed circuits in which no replenishment of water, and therefore of oxygen, occurs over the course of time, once the oxygen initially present has reacted, the degenerative phenomenon of glycol is hugely inhibited. Most circuits, however, are of the non-sealed type, and therefore receive a more or less continuous supply of oxygen. Therefore it is essential, whatever type of glycol is in question, to verify that it is adequately inhibited and that the necessary checks are regularly performed during its entire period of use.

Antifreeze liquids for cars, which do not contain inhibiting components, are not recommended for cooling and heating plants. The manufacturer does not accept any contractual or extra-contractual liability for damage caused by the use

or incorrect disposal of glycol antifreeze.

It is equally important to recall that the use of monoethylene glycol modies the thermophysical characteristics of the water in the plant, and in particular its density, viscosity and average specic heat. Always check the date of expiry and/or degradation of the product with the supplier. Table 5.3→25gives the approximate freezing temperature of the water and consequent increased drop in pressure of the appliance and of the circuit of the plant, according to the percentage of monoethylene glycol. This table should be borne in mind when sizing the pipes and water circulator: for pressure drop calculations, see the data in paragraph 3.4→9). Nevertheless, it is advisable to consult the technical specications of the monoethylene glycol used. If automatic loading systems are used, a seasonal check of the quantity of glycol present in the plant is also necessary.

Table 5.3 – Technical data for lling the hydraulic circuit

% of MONOETHYLENE GLYCOL 10 15 20 25 30 35 40

WATER-GLYCOL MIXTURE FREEZING TEMPERATURE

-3°C -5°C -8°C -12°C -15°C -20°C -25°C

PERCENTAGE OF INCREASE IN PRESSURE DROPS -- 6% 8% 10% 12% 14% 16%

5.7 FILLING THE APPLIANCE’S INTERNAL CIRCUIT

The machine is factory charged to 2 bar with a water/glycol mix which enables the machine to be safely stored down to

-30°C.

Remove the front panel of the appliance to read the internal circuit charging pressure of the appliance on the external lling pressure gauge (Figure 5.4→26, detail B). The optimal pressure value is in the range 1 and 2 bar. If the internal circuit must be recharged, proceed as follows:

The internal circuit is hermetically sealed. If the circuit is empty (this is a fault), identify the leak and restore the seal (for example, by replacing defective gaskets) before proceeding.

You will need: 50-50 glycol solution; volumetric charging pump capable of pressuring the circuit to 2 bar; hose to connect to the provided D.13 union; provided union.

1. Remove the front panel.

2. Open the internal front panel.

3. Remove the cap closing the ller cap and connect the provided D.13 union (Figure 5.4→26, detail D).

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5 HYDRAULIC INSTALLATION

4. Connect the volumetric charging pump to the union with a hose.

5. Open the ller cock (Figure 5.4→26, detail C), with a athead screwdriver, and charge the circuit with enough glycol solution to achieve the specied optimal pressure.

Take care not to allow air to enter the circuit.

1. Open the cap on the automatic bleed valve on the internal circuit and run the machine for 3 minutes to bleed the circuit.

2. If the circuit gurgles during operation, this indicates that air is present in the circuit; connect a hose to the manual bleed cock on the top of the combustion unit (Figure 5.4→26, detail A), open the cock by turning it counterclockwise and bleed the circuit. Once the circuit has stopped gurgling, close the cock and remove the hose.

During manual bleeding, any liquid which has been bled out of the circuit must be replaced with the charging pump. Make sure that the circuit pressure is 1-2 bar on completion of the following procedure.

1. Stop the circuit operating, close the charging cock with a athead screwdriver and close the automatic bleed valve on the circuit.

2. Disconnect the volumetric pump, remove the union and replace the ller cap.

3. Close the front panel with its retainer bolts.

4. Restore the appliance and put away the union.

Figure 5.4 – Filling the machine's internal circuit

Detailed description of lling procedure.

LEGEND

A manual air vent cock B pressure gauge C ller cock * D hose tting D.13 standard supply * notch in horizontal position: cock closed;

notch in vertical position: cock open.

5.8 EXHAUST FLUE GAS

The appliance, which is supplied in the B53P conguration for installation in the open, is equipped as standard supply with a DN80 fumes kit (nominal diameter 80 mm). The supplied fumes kit must be installed by the installation technician. The DN80 union for connecting the fumes kit to the appliance is located at the top of the latter (see Figure 5.5→27) with a vertical outlet.

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5 HYDRAULIC INSTALLATION

Installation, user and maintenance manual – AY Condensing line, AY Series

Figure 5.5 – AY Condensing line, AY series

Fumes outlet tting (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. Necessary equipment and materials.

1. Fit the DN80 roof terminal (detail A) inside the cone on the end of the DN80 extension pipe (detail B).

2. Fit the DN80 rain guard (detail C) to the DN80 extension pipe (B), with the rain guard lip turned towards the exterior of the kit (A+B+C).

3. Remove the protective cap on the top panel.

The cap prevents water and foreign bodies entering the appliance before the fumes kit is installed. The cap should thus be removed only when the kit itself has been fully assembled and installed.

4. Fit the DN80 extension pipe (assembly A+B+C) into the cone of the DN80 anged union which can be accessed via the appliance’s top panel (detail D). Take care to position the rain guard properly so that it prevents foreign bodies entering the hole in the top panel.

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5 HYDRAULIC INSTALLATION

Figure 5.6 – Fumes evacuation pipe kit

fumes kit for exterior conguration (B53P).

LEGEND

A roof mounting terminal (DN80) B extension tube (DN80) C rain cover (DN80) D anged tting (DN80) on top panel A+B+C fumes evacuation pipe kit

SIZING FUMES PIPES FOR TYPE B INSTALLATIONS

If the installation requires the combustion products to be conveyed in a type B conguration, the ue must be sized with reference to the following table.

Table 5.4 – Fumes evacuation pipe ducting (type B)

Useful residual head 100 Pa Maximum length of straight DN80 pipe sections 31.0 m Equivalent DN80 curve length at 90° 2.0 m

Data for sizing type B installation ues.

Example: to install a horizontal fumes pipe using n. 1 DN80 90° curve, the maximum extension possible with DN80 straight pipe sections is 29 m.

The following other type B congurations are also possible: B23P and B33 (for specications, see Table 5.6→29).

Exhaust pipes exposed to atmospheric agents must be made of black polypropylene or an equivalent weather resistant material. For sizing, refer to the established regulations and the manufacturer’s instructions.

SIZING AIR/FUMES PIPES FOR TYPE C INSTALLATIONS

The appliance is homologated for conguration as a type C installation. The following congurations are permitted: C13, C33, C43, C53, C63 and C83 (for specications, see Table 5.6→29). To install the appliance in a type C conguration refer to the following technical data table for the sizing of the combustion fumes outlet and combustion air intake pipes.

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5 HYDRAULIC INSTALLATION

Installation, user and maintenance manual – AY Condensing line, AY Series

Table 5.5 – Ducting for fumes evacuation and air intake pipes (type C)

Gas type G20 G25 G25.1 G27 G2.350 G30 LPG G31

Useful residual head Pa 120 Mass of fumes at nominal thermal capacity

kg/h

55.0 62,0 49.0 55.0 56.0 49.0 49.0 56.0 Mass of fumes at minimal thermal capacity 13.0 15.0 12.0 13.0 13.0 12.0 12.0 13.0 Temperature of fumes at nominal thermal capacity

°C

72.5 72,0 72,0 72,0 72,0 71.5 71.5 72.5 Temperature of fumes at minimal thermal capacity 71.6 72,0 71,0 71.5 72,0 71.5 71.5 71.5 CO

2 content at nominal thermal capacity

9.4 9.4 10,7 9,35 9,15 12,4 11.4 10.6

2 content at minimal thermal capacity

8.9 8.9 10.2 8,90 8,80 11,5 10,5 10.2

Data for sizing type C air/fumes installation pipes.

Examples of the two principal type C congurations:

▶

C13 - using a concentric DN60/100 90°C curve, the maximum permitted extension with concentric DN60/100 straight pipe sections is 5.75 m, while the minimum permitted extensions is 0.75 m.

▶

C33 - the maximum permitted extension with concentric DN60/100 straight pipe sections is 6.25 m.

The following table gives a brief description of the possible installation congurations.

Table 5.6 – Installation conguration (types B and C)

TYPE CONFIGURATION B23P

The combustion products are exhausted outside, from the wall or roof, while the combustion air is drawn directly from the room in which the appliance is installed. This conguration can ONLY be installed in open areas or areas suciently well ventilated and free of combustible powders.

B33

Evacuation of combusted gas into the ue, combustion air drawn directly from the room in which the appliance is installed. This conguration can ONLY be installed in open areas or areas suciently well ventilated and free of combustible powders.

B53P

Boiler designed for connection, via its own pipe, to a dedicated combustion product evacuation terminal. The air is drawn from the installation room and the combustion products are evacuated outside the room. This conguration can ONLY be installed in open areas or areas suciently well ventilated and free of combustible powders.

C13

Type C boiler connected, via its own pipes, to a terminal installed horizontally on the wall or roof. The outlets of the pipes are concentric or suciently close to each other to be exposed to analogous wind conditions.

C33

Type C boiler connected, with its pipes, to a vertical terminal. The outlets of the pipes are concentric or suciently close to each other to be exposed to analogous wind conditions.

C43

Type C boiler connected, via its pipes and optionally with a tting, to a collective piping system composed of a pipe for combustion air supply and a pipe for combustion product evacuation. The outlets of the system of collective pipes are concentric or suciently close to each other to be exposed to analogous

wind conditions. C53 Type C boiler connected, via its separate pipes, to two terminals which can be installed in zones at dierent pressures. C63 Type C boiler designed for connection to a system for combustion air supply and combustion product evacuation which is approved and sold separately. C83 Type C boiler connected, via its pipes, and optionally via a tting, to an air supply terminal and connected to a dedicated or collective ue.

Description of possible appliance installation congurations.

5.9 PROGRAMMING OF HYDRAULIC PARAMETERS

The hydraulic parameters can be set according to the procedure described in this paragraph only when the appliance is not connected to a DDC.

If the appliance is connected to a DDC, follow the instructions given in the DDC manuals exclusively.

To congure the hydraulic parameters, access menu 3 of the controller.

For the use of the controller, refer to procedure "HOW TO ACCESS THE MENUS" in Paragraph 4.2→14.

Table 5.7→29 gives the three parameters used for hydraulic conguration.

Table 5.7 – Menu 3 parameters

HYDRAULIC PARAMETER THE DISPLAY SHOWS

Hot water thermostat control selection 3.160 Hot water setpoint 3.161 Hot water temperature dierential 3.162 (EXIT MENU) 3. E

Description of parameters

▶

Hot water thermostat control: parameter "160". This parameter takes two values: "0" and "1". Value "0" indicates that the appli- ance's "activation/deactivation" temperature is to be read by the water probe at the appliance’s INTAKE. Value "1" indicates that the appliance’s "activation/deactivation" temperature is to be read by the water probe at the appliance’s OUTLET.

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5 HYDRAULIC INSTALLATION

▶

Hot water setpoint: parameter "161". this parameter sets the water temperature that, when reached, causes the appliance to be deactivated.

▶

Hot water dierential: parameter "162". This parameter represents an interval in degrees that, when added to the set-point, de- nes the temperature at which the appliance is reactivated.

Heating mode:

The appliance heats the water until it reaches the setpoint temperature. The appliance then switches o. This means that the water temperature slowly drops to the setpoint + dierential temperature. At this point, the appliance turns back on. For example, if we set the following values:

▶

Thermostat control: "0" (= read INTAKE water temperature).

▶

Setpoint: +40.0 °C.

▶

Dierential: -2.0 °C.

The appliance will behave as follows:

1. the water temperature rises (heating);

2. the intake water temperature reaches +40 °C (= setpoint);

3. The appliance switches o;

4. the system water temperature slowly drops (loses heat to the environment);

5. the intake water temperature reaches +38 °C (= setpoint + dierential);

6. the appliance turns back on: heating starts again. The cycle is repeated. The following instructions give a detailed description of how to congure the hydraulic parameters in menu 3 (or menu 4) on the machine’s controller.

Hydraulic parameter settings

You will need: the controller’s display sequentially shows the operating data (temperature, delta T°) regarding the current

mode (e.g.: heating). Special key provided with the appliance.

1. See procedure "HOW TO ACCESS THE MENUS" (Paragraph 4.2→14) and proceed as described in steps "1" to "5".

2. The display will now ash "0.". Turn the knob until menu 3 displays (the display shows "3.") or menu 4 (the displays shows "4.").

▶

For example: to set the parameters of menu 3:

1. The display shows “3.”. Press the knob to access the menu. the display shows the rst of the menu parameters: "3.73" or "3.160" (= menu 3, parameter "73" or "160").

2. The display shows "3.73" or "3.160". To access a parameter, press the knob: the displays shows the preset value (e.g. "1"), ashing, to indicate that it can be modied.

3. Press again to conrm "1" (= outlet water thermostat control); to modify the value, turn the knob until "0" displays: press to conrm "0" (= intake water thermostat control).

4. The display now shows the current parameter "3.73" or "3.160" again: the parameter has been set to its new value.

5. Turn the knob to display the next parameter. The display shows: "3.75" or "3.161". To access a parameter, press the knob: the displays shows the preset value (e.g. "60"), ashing, to indicate that it can be modied.

6. Press again to conrm "60" (= water temperature setpoint); to modify the value, turn the knob until the desired value displays (e.g. "40"): press again to conrm "40" (= water temperature setpoint);

7. The display now shows the current parameter "3.75" or "3.161" again: the parameter has been set to its new value.

8. Turn the knob to display the next parameter. The display shows: "3.76" or "3.162". To access a parameter, press the knob: the displays shows the preset value (e.g. “-10"), ashing, to indicate that it can be modied.

9. Press again to conrm “-10" (= water temperature dierential); to modify the value, turn the knob until the desired value displays (e.g. “-2"): Press again to conrm “-2" (= water temperature dierential).

10. The display now shows the current parameter "3.76" or "3.162" again: the parameter has been set to its new value.

11. To quit menu 3, turn the knob clockwise until the quit screen displays: "E". The display shows “3.”. E": press the knob. The display will now show the current menu "3.". To exit the menu selection screen, turn the knob clockwise until “E” displays: press to conrm.

The controller’s display now sequentially shows, as at the beginning, the operating data (temperature, delta T) regarding the current mode (e.g.: heating).

To modify a parameter in menu 4, to access the menu (installation technician only) you are rst prompted for a password. For the password, contact the Robur TAC or Technical Service Department of Robur S.p.A. (Tel. +39.035.888111).

SPECIAL PARAMETER SETTINGS

The appliance is a Range Rated boiler: the power delivery of the appliance can be adapted to the real system requirements by regulating the nominal gas ow (nominal thermal input). The thermal input can be regulated with parameter "180" in menus 4 and 5. The parameter has a range from maximum (34.9 kW) to minimum (8.0 kW) thermal capacity (see also Table 3.1→9).

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If multiple appliances are connected to the system, the value of parameter "180" must be the same for all appliances.

To prevent errors in setting the hydraulic parameters available to the user in menu 3, we recommend setting the maximum water temperature setpoint, both at the outlet (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 underoor heating, parameters "156" and "157" must be set to limit the user's options in setting temperature setpoint parameter "161" (also available in menu 3) and thus prevent operational settings outside the installation design limits. The appliance’s internal circuit is factory charged, ad hoc, with a monoethylene glycol solution sucient to enable storage down to

-30°C. Any topping up of the initial charge must restore the optimal water/glycol mix (50/50). However, parameter "180" allows the appliance to be congured for operation with pure water or a non-optimal glycol solution (value “0”: no glycol in the machine’s internal circuit); in this case the antifreeze function will activate the internal water circulator to keep the water temperature above +4°C. Within the limits of the design minimum ambient temperature it may be necessary, in such cases, to ensure continuous electrical power to the appliance even during periods of disuse.

Parameter "156" is to be used ONLY by the Robur TAC; parameters "180" and "182" are also available to the installation technician. These special parameters may be congured, when so required, only by the Robur TAC or the installation technician, when authorised to do so.

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6 ELECTRICAL INSTALLATION

In this section you will nd 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:

1. CONNECTING THE APPLIANCE TO THE MAINS.

2. ELECTRICAL CONNECTIONS FOR THE SYSTEM CIRCULATOR.

3. CONNECTIONS FOR CONSENT SWITCH OPERATION.

Before proceeding with operations to create the electrical plant of the appliance, the professionally qualied personnel concerned are advised to read Paragraph 3.1→7: it provides important information regarding installation safety and references to current regulations.

Before making the electrical connections or any checks, make sure that work is not carried out on live elements.

Figure 6.1→32 illustrates, in their main parts, the on-board electronics: controller AY10 overlaying the auxiliary controller S70 (for the legend, see Table 6.1→32). Figure 6.2→34 detail plant of the appliance.

Figure 6.1 – Series AY - AY10+S70 controllers

Main components of the on-board controller.

LEGEND

see table below

Table 6.1 – AY10 and S70 controller components

CONTROLLER COMPONENT LEGEND CODE DESCRIPTION

COMPONENTS OF CONTROLLER S70 TL limit thermostat connector EV gas solenoid valve connector LS gas valve ON indicator lamp connector P1 ame controller connector TF fumes thermostat connector PD circuit water dierential pressure switch connector A1 - A2 auxiliary connectors J2 circuit water circulator controller jumper No Contact system water circulator controller terminal clamps (max 700W) V3V (1-2-N) machine circulator terminal clamps MAIN 230V (L-N) power supply connector IGN. BOX (N-L) ignition controller connector COMPONENTS OF CONTROLLER AY10

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6 ELECTRICAL INSTALLATION

Installation, user and maintenance manual – AY Condensing line, AY Series

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 J1 CAN BUS jumper

P8 [GND-L-H]

CAN port / connector

H= high data signal L= low data signal GND= common data signal

P7 (R-W-0)

operation consent connector

R= common terminal W= HOT consent terminal 0= terminal not used FS5 [24ac1-0V-24ac2] controller power connector F1 - F2 fuses

Controller component legend.

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6 ELECTRICAL INSTALLATION

Figure 6.2 – Functional diagram

Electric diagram single unit AY00-120.

LEGEND

SCH controllers (AY10/S70)

TA ambient temperature probe

THPC delivery water temperature probe

(appliance internal circuit)

THMC outlet water temperature probe

(system circuit)

THRC inlet water temperature probe

(system circuit)

TH combustion unit limit thermostat

(appliance internal circuit)

TF exausted gas thermostat

A2 dierential water pressure switch

(appliance internal circuit)

PD dierential water pressure switch

(system circuit)

TL water limit thermostat

P1 water circulator

(appliance internal circuit)

LS gas valve ON indicator lamp

GV gas solenoid valve

IGNTR ignition transformer

IGN ignition electrodes

FLS ame sensor

CNTBOX ame controller

BLW blower

MC power terminal block 230Vac

PWRTR controller transformer

TG antifreezing thermostat for siphon heating element

RS siphon heating element

P * water circulator (system circuit)

* only for LINK's unit in "CC" conguration

(n.1 circulator for single module)

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

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6 ELECTRICAL INSTALLATION

Installation, user and maintenance manual – AY Condensing line, AY Series

▶

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 congured by the installation technician. Necessary equipment and materials.

Make sure that the electrical panel congured by the technician is equipped with a 2 pole circuit breaker with minimum air gap of 3 mm, and a 2A type T fuses.

1. Remove the appliance's front panel and open the electrical panel by removing the bolts securing it.

2. Prepare a cable of the FG7(O)R 3Gx1.5 type for the power supply to the appliance.

3. Locate terminal block "MC" inside the panel and hook up as shown in the gure.

4. On completion, restore the appliance to its fully assembled condition. 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 lled.

Figure 6.3 – connection to electrical mains (230 V 1N - 50 Hz)

Example of connection of no. 1 appliance to the mains.

LEGEND

MC power terminal block GS Master 2-pole power switch F Fuse/s N Neutral terminal Ground ground terminal L single-phase line terminal

Disconnect the appliance from the electrical power supply via the external disconnecting switch only after having performed the shutdown cycle (via the DDC or consent switch) and having waited for it to terminate (approximately 3 minutes).

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.

A wiring error, as well as impeding the correct operation of the appliance, could also damage the electrical apparatus that it contains.

MULTIPLE APPLIANCE PLANTS

The appliance must be connected to a 230 V 1N - 50 Hz power supply, as follows (see example in Figure 6.4→36):

You will need: the appliances hydraulically connected; the external electrical panel congured by the installation technician. Necessary equipment and materials.

Make sure that the electrical panel congured by the technician is equipped with a 2 pole circuit breaker with minimum air gap of 3 mm, and two type T fuses of suitable rating.

1. On each appliance, remove the front panel and open the electrical panel by removing the bolts securing it.

2. For each appliance, provide a FG7(O)R 3Gx1.5 type cable.

3. Locate terminal block "MC" inside the panel of each appliance and hook up as shown in the gure.

4. On completion, restore the appliances to their fully assembled condition.

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6 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 lled.

Figure 6.4 – connection to electrical mains (230 V 1N - 50 Hz)

Example of connection of more than one appliance to the mains.

LEGEND

MC power terminal block GS Master 2-pole power switch F Fuse/s N Neutral terminal Ground ground terminal L single-phase line terminal

A wiring error, as well as impeding the correct operation of the appliance, could also damage the electrical apparatus that it contains.

6.2 ELECTRICAL CONNECTIONS FOR THE SYSTEM CIRCULATOR

The primary circulation pump/s must be controlled by the S70 board, or directly (via “N.O. contact” contacts) or indirectly (“OR” use of said contacts by BMS type external systems). Otherwise, the primary circulation pump/s must be running permanently.

CONNECTION FOR CONTROLLING INDEPENDENT CIRCULATORS

This connection applies to hydraulic circuits which have a primary circuit circulator for each appliance (independent circulators) installed on the plant. For example: 1 circulator/1 appliance; 5 circulators/5 appliances. In such cases, for each appliance it may be sucient to install a single-phase water circulator (230 V AC), with power absorption less than 700 W. To make the circulator-appliance connections, proceed as follows (references to Figure 6.5→37):

You will need: the appliance connected hydraulically; single-phase water circulator (230 V AC), with power absorption less than 700 W. Necessary equipment and materials.

In this case, the circulator’s 230 V AC power can be taken directly o the appliance’s internal terminal block (on the electrical panel).

1. Remove the appliance's front panel and open the electrical panel by removing the bolts securing it.

2. Prepare a suitable cable for the connection.

3. Locate terminal block MC and the "NO Contact" terminals on controller S70 (SCH) inside the electrical panel, and hook up as shown in the example.

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Installation, user and maintenance manual – AY Condensing line, AY Series

A wiring error, as well as impeding the correct operation of the appliance, could also damage the electrical apparatus that it contains.

The "NO Contact" terminals are no voltage contacts with maximum power capacity of 700 W. These contacts control the circulator shutdown delay (2 minutes after appliance shutdown). Check the position of jumper "J2", as follows:

4. Locate, on the appliance’s controller (SCH), jumper "J2" on the S70 (bottom right, below the "NO Contact" contacts) and make sure that it is set as shown in detail "A" (jumper closed) of the gure.

5. On completion, restore the appliance to its fully assembled condition.

Figure 6.5 – Direct control of independent circulator

Example of "circulator-appliance" electrical connection with single-phase circulator (230 V AC), power less than 700 W.

LEGEND

SCH controller (AY10+S70) NO contact system water circulator control

terminals (voltage free NO contact,

maximum power absorption 700 W) J2 system water circulator control jumper A detail of "closed" jumper MC 230 V AC power terminal block PW system water circulator (230 V AC;

<700 W)

If the circulator’s power is equal to or greater than 700 W, the installation technician must make the following modications (see gure):

▶

(point 3) <<... make the connections as shown in the example, but installing a relay for the control of the pump, managed via NO-contact>>. Then:

▶

(point 4) <<Locate and open jumper "J2" as shown in detail "A" (jumper open) in the next gure 6.6→39>>.

Fit the relay inside the external electrical panel provided by the installation technician.

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 lled.

CONNECTIONS FOR CONTROLLING A SHARED CIRCULATOR

This connection applies to hydraulic circuits which have a single primary circuit circulator for multiple appliance (shared circulator) installed on the plant. For example: 1 circulator/3 appliances. In such cases, a three-phase water circulator (400 V AC) may be required.

The choice of water circulator depends on the number of appliances being served as the specications of the system (water ow rate, head, etc.) which are determined during the design process. Always follow the specications of the system design documentation.

The following procedure refers to Figure 6.6→39, which gives an example of a three-phase circulator (400 V AC) connection.

To make the circulator-appliance connection, proceed as follows (references to Figure 6.6→39):

You will need: the appliances hydraulically connected; water circulator in line with the system specications (e.g.: threephase/400 V AC); external electrical panel congured by the installation technician. Necessary equipment and materials.

Make sure that the external electrical panel is equipped with a power switch (4-pole) with suitable motor thermal switch, a secondary SELV safety transformer and control relay.

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6 ELECTRICAL INSTALLATION

1. On each appliance, remove the front panel and open the electrical panel by removing the bolts securing it.

2. Prepare a suitable cable for the connection.

3. 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. 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.

A wiring error, as well as impeding the correct operation of the appliance, could also damage the electrical apparatus that it contains.

1. Locate, on each appliance's controller (SCH), jumper "J2" on the S70 (bottom right, below the "NO Contact" contacts) and make

sure that it is set as shown in detail "A" (jumper open) of the gure.

2. On completion, restore the appliances to their fully assembled condition. 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 lled.

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Installation, user and maintenance manual – AY Condensing line, AY Series

Figure 6.6 – Direct control of shared circulator

Example of electrical connection of a shared three-phase circulator (400 V AC).

LEGEND

SCH controller (AY10+S70)

NO contact system water circulator control terminals (voltage free NO contact, maximum power ab-

sorption 700 W )

J2 system water circulator control jumper

A detail of "open" jumper

MC 230 V AC power terminal block.

RST/N PHASE/NEUTRAL terminals for three-phase power (400 V AC)

ground ground terminal

IP system water circulator power switch

KQ motor protector or maximum current dierential circuit breaker for system water circulator

(400 V AC)

PTR SELV secondary safety transformer

KP NO (normally open) system water circulator control relay

PW system water circulator

6.3 CONNECTIONS FOR CONSENT SWITCH OPERATION

To operate, the appliance requires:

▶

consent switch for starting up and shutting down the appliance.

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6 ELECTRICAL INSTALLATION

The consent switch (installation technician) can be an on/o 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.

1. Remove the appliance's front panel and open the electrical panel by removing the bolts securing it.

2. Prepare a suitable cable for the connection.

3. Locate, on the appliance’s electrical panel, the consent terminals "R,W,0" (connector "P7") on the AY10 controller, and make the

connections between the consent switch and the R and W terminals as shown in the gure.

To start up and shut down the appliance in normal operation, always use the consent switch. Do not use the external power switch.

4. On completion, restore the appliance to its fully assembled condition. 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 lled.

If you intend to use a DDC, available as an accessory, refer to Paragraph 6.4→40.

Figure 6.7 – Series AY - operated by on-o consent switch

Example of operation consent connection.

LEGEND

SCH controller (AY10+S70) W HOT consent terminal R common terminal CS consent switch

6.4 USE OF THE CCI/DDC

This paragraph is dedicated to the installation of the Direct Digital Controller (DDC). It gives full information on the installation and connection of the device to the appliances. Proceed as follows (qualied installation technician only):

1) How to t the CCI/DDC.

2) How to supply power to the CCI/DDC.

3) How to connect the CCI/DDC to the appliance.

Figure 6.8→41 gives rear and front views of the DDC along with its electrical connections. The following connectors are required:

▶

4 pole connector (part reference "AL") for 24 V AC power.

▶

6 pole CAN BUS connector (part reference "P8") for connecting the DDC with the appliance.

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6 ELECTRICAL INSTALLATION

Installation, user and maintenance manual – AY Condensing line, AY Series

Figure 6.8 – CCI/DDC

Front and rear views with detail of electrical connections.

LEGEND

STA ambient temperature probe - 2-pole connector SAE external alarm systems - 3-pole connector AL power supply 24 V AC - 4-pole connector CE external consents - 6-pole connector

P8 CAN network connector (orange) SPC 232 serial connection to PC - 9-pole connector A mounting holes CCI/DDC E Encoder D Display

For instructions regarding other connections (optional: to be done by the electrical installation technician in accordance with the user's requirements) and, in general, for the DDC installation and user instructions, see the two booklets in question.

Before installing the DDC, disconnect the appliance from its power supply with the power switch in its electrical panel.

1) How to t the CCI/DDC

The DDC in indoor installations must be applied to a panel as follows (see Figure 6.9→41):

You will need: the appliance and the DDC disconnected from the electricity supply. Necessary equipment and materials.

1. Make a rectangular opening 155 mm wide and 151 mm high;

2. Locate the DDC on this hole and mark the 4 points where the holes are to be made to x it. See the gure.

3. Drill no. 4 holes of dia. 4 mm.

4. Proceed with the operation of making fast the DDC on the opening of the panel using the screws and nuts supplied.

Figure 6.9

Centre distances of mounting holes for CCI/DDC.

LEGEND

Holes for mounting CCI/DDC’s to panel

horizontal: 168 mm vertical: 158 mm

The DDC's operating temperature range is 0 - 50 °C. If the temperature of the room where the DDC is installed falls below zero, it continues to operate correctly to -10 °C. However, its LCD display may not be able to display data.

2) How to supply power to the CCI/DDC

The DDC requires a low voltage power supply (24 V) with 230/24 V AC, 50/60 Hz safety transformer; the minimum power requirement is 20 VA.

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6 ELECTRICAL INSTALLATION

To power the DDC (o a transformer located in an external panel), proceed as follows (see example in Figure 6.10→42):

You will need: the appliance disconnected from the electricity supply; the external electrical panel congured by the installation technician. Necessary equipment and materials.

Make sure that the external electrical panel is equipped with a 230/24 V AC - 50/60 Hz safety transformer, of at least 20 VA power.

1. Remove the DDC's back panel by undoing the 4 bolts securing it (detail "A" - Figure 6.8→41).

2. Use an electrical power cord (minimum cross section: 2x0.75 mm2).

3. Pass the power cord (DDC side) through the hole in the DDC's cover and hook up as shown in the example, with the following

polarities: terminal 1 = 24 V; terminal 2 = 0 V; terminal 3 = ground.

Terminal 3 of the DDC's 4-pole connector (AL) must be, in any case, connected to a ground plant (r≤0,1Ω). Terminal 2 of the DDC is connected internally to terminal 3, and is thus also connected to ground. Make the grounding connection on the transformer terminal connected to terminal 2 of the DDC. if the transformer already has one wire grounded, it must be connected to this terminal.

4. On completion, close the DDC's back panel with the 4 bolts.

Figure 6.10 – CCI/DDC - electric supply

CCI/DDC electric supply from external transformer.

LEGEND

DDC CCI/DDC AL supply 4 poles connector 1 clamp and wire for 24 Vac supply 2 clamp and wire for 0 Vac supply 3 clamp and wire for ground contact (required connection) DDCTR safety transformer

- (230/24 Vac 50/60 Hz)

If the CAN BUS cable has already been connected to the DDC (next procedure "3) How to connect the CCI/DDC to the appliance"), take care with the 4 mm CAN BUS cable shielding eyelet (or two eyelets): use the retainer screw next to the CAN BUS socket (bottom right) to secure the eyelet (or both eyelets) as shown in Figure 6.13→44.

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.

By a node of the data network we mean any device (DDC, appliance or individual module) connected to it. Each network consists of 2 terminal nodesand, if required, a certain number of intermediate nodes. A device is considered to be a terminal node when it is connected to only one other device. A device is considered to be an intermediate node when it is connected to two other devices. Appliances, individual modules and DDC's may act equally as terminal or intermediate nodes. See Figure 6.11→43.

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Installation, user and maintenance manual – AY Condensing line, AY Series

The CAN network can link together a maximum of: 3 DDC's, each of which is in turn connected to 16 hot only modules + 16 cold only modules or 16 hot/cold modules.

Figure 6.11 – CAN network

Example of network with 4 nodes (1 DDC + 3 appliances).

LEGEND

A appliance (GA/GAHP) B appliance (AY) C appliance (GA/GAHP) D DDC

1 CAN-BUS network terminal node 2 CAN-BUS network intermediate node 3 CAN-BUS network intermediate node 4 CAN-BUS network terminal node

> CHARACTERISTICS OF THE CAN BUS CABLE

The cable to be used must be suitable for CAN BUS applications. The following table gives details of some types of CAN bus cable, grouped according to the maximum distance covered by each single type.

Table 6.2 – CAN BUS cables type

CABLE NAME SIGNAL / COLOR MAX LENGTH Note Robur

Ordering Code O-CVO008

ROBUR NETBUS H= BLACK L= WHITE GND= BROWN 450 m

Honeywell SDS 1620

In all cases the fourth conductor should not be used

BELDEN 3086A

H= BLACK L= WHITE GND= BROWN 450 m

TURCK type 530

DeviceNet Mid Cable

TURCK type 5711 H= BLUE L= WHITE GND= BLACK 450 m

Honeywell SDS 2022

TURCK type 531 H= BLACK L= WHITE GND= BROWN 200 m

Example types of cables used to connect the CAN network.

For overall distances to cover of ≤200 m and networks with a maximum of 6 nodes (a typical example: 1 DDC + 5 devices), a simple 3 x 0.75 mm2 shielded cable may be used.

As shown in Table 6.2→43, the CAN connection requires a CAN bus cable with 3 wires. If the available cable has more than 3 coloured 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 specic 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.

▶

Step B: connect the CAN-BUS cable to the appliance.

The two steps must done in both cases illustrated in Figure 6.17→48 (wiring diagram for 1 DDC connected to a single appliance) and Figure 6.18→49 (wiring diagram for 1 DDC connected to multiple appliances).

Step A: connect the CAN-BUS cable to the CCI/DDC

The CAN bus cable connects to the specic orange connector supplied with the DDC, as shown in Figure 6.12→44.

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6 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 congurations of terminal node and interme- diate node (Figure 6.14→45). The DDC is supplied with the jumpers CLOSED (detail "A" Figure 6.14→45).

Figure 6.13 – Connection from CAN BUS to connector P8

Connection detail of cable CAN BUS.

LEGEND

A Insulating tape to protect board/shield B CAN BUS cable wires C CAN bus cable shield D terminal and screw for xing









To connect a CAN BUS cable to a DDC, proceed as follows (references in Figure 6.14→45):

You will need: DDC not powered up. Necessary equipment and materials.

1. Depending on the type of node being congured, set the DDC's jumpers as shown in detail "A" or detail "B" in the gure. If

necessary, open the DDC’s back panel (4 bolts); after the jumpers have been correctly positioned, close the cover again and retighten the 4 bolts;

▶

if the DDC is an intermediate node on the network (with no. 6 wires in the orange connector): set the jumpers as shown in detail "B" of the gure: Jumpers OPEN;

▶

if the DDC is a terminal node on the network (with no. 3 wires in the orange connector): set the jumpers as shown in detail "A" of the gure: Jumpers CLOSED.

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6 ELECTRICAL INSTALLATION

Installation, user and maintenance manual – AY Condensing line, AY Series

Figure 6.14 – detail wires and jumpers J21 - terminal/intermediate node CCI/DDC

Detail terminal and intermediate node: jumpers position J21: "closed" - "open".

LEGEND

DDC CCI/DDC J21 Jumper CAN-BUS in CCI/DDC board

A detail case "terminal node" (3 wires; J21=jumper "closed") B detail case "intermediate node" (6 wires; J21=jumper "open") H,L,GND data signal wires

2. Prepare the orange connector (remove from envelope).

3. Cut a length of cable, long enough to allow it to be installed without kinking.

4. Having chosen one end of the length of cable, remove the sheath from a length of approximately 70-80 mm, taking care not to cut the wires contained inside, the shielding (metallic shield and/or aluminium sheet) and, if present, the bare connector in contact with the shield and the wires contained within.

5. Roll the shielding and connect it to a 4-mm eyelet terminal, as illustrated in Figure 6.13→44, details C and D. Now proceed as follows:

6. Connect the three coloured wires to the orange connector, as shown in detail "A" in the gure. Observe the terminal markings L, H, GND (on the DDC at the base of the socket "P8") which are given both in Table 6.2→43, and in the gure:

▶

if the DDC is an intermediate node on the network, also complete step "7";

▶

if the DDC is a terminal node, skip directly to step "8".

7. Intermediate nodes only: repeat the operations from step "1" to step "4" for the other length of CAN bus cable required. Now proceed with step "5" and, to connect the cable to orange connector, refer to detail "B" in the gure. Then proceed to point "8".

8. Fit the orange connector, with the wires attached, rst through the slot in the DDC’s cover and then into the socket on the DDC itself.

9. Use the rear cover bolts located near the CAN BUS socket to secure the 4-mm eyelet (or 2 eyelets) (detail D, Figure 6.13→44). The cable should be secured against pulling out.

Step B: connect the CAN-BUS cable to the appliance

The CAN BUS cable must be connected to the orange socket on the machine’s on-board controller (see detail "D" in Figure 6.15→46).

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6 ELECTRICAL INSTALLATION

Figure 6.15 – Connection of CAN BUS cable to connector P8 on controller AY10

Detail of cabling of CAN BUS cable to controller AY10.

LEGEND

example of connection of 2 CAN BUS cables (the appliance is an intermediate node) A insulating tape to protect board/screen B CAN BUS cable shielding C cable bracket (for 2 CAN BUS cables) D orange connector for CAN BUS cable

terminals

E wires (no. 6) of CAN BUS cables

To connect the CAN BUS cable to the DDC, proceed as follows (references in Figure 6.15→46):

You will need: appliance not powered up. Necessary equipment and materials.

1. Remove the front panel of the appliance and the cover of the electrical panel.

2. Cut a length of cable, long enough to allow it to be installed without kinking.

3. Having chosen one end of the length of cable, remove the sheath from a length of approximately 70-80 mm, taking care not to cut the wires contained inside, the shielding (metallic shield and/or aluminium sheet) and, if present, the bare connector in contact with the shield and the wires contained within.

4. If the cable is too thin to be held in place in the cable holder bracket (detail C), make it thicker by wrapping insulating tape around it on the sheath in the area adjacent to the stripped part (to an approximate diameter of 12-13 mm).

5. Pull back the shielding in the sheathe; apply electrician’s tape to the end of the shielding as pulled back (detail A).

6. Pull the orange connector (detail D) out of socket "P8" on the controller.

7. Connect the three coloured wires to the orange connector, as shown in detail "A" in Figure 6.16→47. Observe the terminal markings L, H, GND (on the board at the base of the socket "P8") which are given both in Table 6.2→43, and in Figure 6.16→47:

▶

if the appliance is an intermediate node on the network, also complete step 8;

▶

if the appliance is a terminal node, skip directly to step 9.

8. Intermediate nodes only: repeat the operations from point 2 to point 5 for the other length of CAN bus cable required. Now proceed with step 7 and, to connect the cable to connector P8, refer to detail "B" in Figure 6.16→47. Then proceed to point 9.

9. Fit the orange connector, with wires attached, into the P8 socket on the board.

10. Fix the CAN BUS cable (or two cables, according to the type of node being connected) to the cable xing bracket so that the rolled-back sheathing makes solid contact with the metal bracket. The cable should be secured against pulling out.

11. Now, depending on the type of node being congured, set the jumpers on the appliance’s controller as shown in detail "A" or detail "B" in Figure 6.16→47. Proceed as follows:

▶

If the appliance is an intermediate node on the network (with no. 6 wires in the orange connector): set the jumpers as shown in detail "B" of the gure: Jumpers OPEN.

▶

If the appliance is a terminal node on the network (with no. 3 wires in the orange connector): set the jumpers as shown in detail "A" of the gure: Jumpers CLOSED.

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6 ELECTRICAL INSTALLATION

Installation, user and maintenance manual – AY Condensing line, AY Series

Figure 6.16 – detail of wires and jumpers J1 - appliance terminal/intermediate node

Detail of terminal and intermediate node, jumper position J1: "closed" - "open".

LEGEND

SCH controller (AY10+S70) J1 CAN BUS jumper on AY10 controller

A detail of "terminal node" case (3 wires; J1=jumper "closed") B detail of "intermediate node" case (6 wires; J1=jumper "open") H,L,GND data signal wires

12. Now close the electrical panel and ret the front panel of the appliance.

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6 ELECTRICAL INSTALLATION

Figure 6.17 – CAN BUS connection for single appliance systems

CAN BUS cable connection between DDC and one appliance.

LEGEND

DDC digital control panel SCH controller (AY10+S70) J1 CAN BUS jumper on AY10 controller

J21 CAN BUS jumper on DDC board A terminal node connection (3 wires; J1 and J21 = "closed") H,L,GND data signal wires

Page 49

6 ELECTRICAL INSTALLATION

Installation, user and maintenance manual – AY Condensing line, AY Series

Figure 6.18 – CAN BUS connection for multiple appliance systems

CAN BUS cable connection between 1 DDC and multiple appliances.

LEGEND

DDC digital control panel

SCH controller (AY10+S70)

J1 CAN BUS jumper on AY10 controller

J21 CAN BUS jumper on DDC board

A terminal node connection (3 wires; J1 and J21 =

"closed")

B intermediate node connection (6 wires; J1="open")

H,L,Gnd data signal wires

Page 50

7 INITIAL ACTIVATION AND MAINTENANCE

In this section you will nd the following information:

▶

Indications required by the authorized Robur Technical Assistance Centre (TAC) in order to carry out the entire procedure of rst start-up of the appliance (see Paragraph 7.1→50);

▶

Indications regarding maintenance operations of the appliance (Paragraph 7.2→53): general information and warnings; general indications regarding checks, controls and cleaning.

▶

Instruction for the Robur TAC or gas type conversion (Paragraph 7.3→54).

Before proceeding with the operations described in this section, the installation technician concerned is invited to read Paragraph 3.1→7. in regard to switching the appliance on and o, refer to Paragraph 4.1→13. If the appliance is connected to a DDC (and the DDC is in controller mode), for the phases of activation and deactivation of the appliance it is necessary to refer to the two manuals dedicated to the DDC itself.

7.1 PROCEDURE FOR FIRST START UP

The initial activation procedure is composed of the following (main) steps. Step 1: preliminary verication of plant compliance. Step 2: verication/regulation of combustion parameters and rst ignition. Step 3: regulation of plant operating parameters.

The entire procedure for the initial activation of the appliance must only carried out by an authorised Robur Technical Assistance Centre (TAC). The product's guarantee may be void if the procedure is not carried out by a Robur TAC.

Before leaving the factory, the appliance has been thoroughly tested.

Step 1: preliminary verication of plant compliance

The Robur TAC technician must:

▶

Check that the whole installation has been realized in accordance with its design, following the manufacturer's instructions and respecting current legislation. The design must have been drawn up by a professional specier.

▶

Check personally that all of the connections (hydraulic/gas and electrical) of the appliance (and of the Direct Digital Controller, if connected to the appliance) have been made correctly.

▶

Check that the installation is actually compliant as per the Declaration of Conformity provided by the installer to the owner.

The Declaration of Conformity CERTIFIES that the installation is compliant with current regulations. This Declaration is a mandatory document and as such it must be provided by the installer to the owner.

▶

Check that the water pressure and ow in the hydraulic circuit and the static gas supply network pressure are correct, as indicated by the manufacturer.

▶

Check that the electrical power supply is 230V 50Hz

▶

Check that the air/fumes pipes are properly connected.

▶

Check that the fumes condensate discharge is properly installed.

▶

Check that the safety clearances have been observed, as shown in Figure 5.1→19.

If all the conditions listed above exist, the TAC can proceed with the operations, performing the "initial activation" of the appliance. If any non-compliant elements arise during the initial verication, the TAC may choose not to proceed with the operation of "initial activation". In this case, the Robur TAC technician must:

▶

Report the user/installer of any installation anomaly.

▶

Report the user/installer of any situation that is potentially hazardous for the appliance and for people.

▶

Report of any missing documentation relevant to the installation.

▶

According to the reports made, advise any corrective action to be taken at the installer's care in order to proceed with the "rst start up".

It is the responsibility of the user/installation technician to carry out any corrective measures on the plant indicated by the TAC. Following such corrective measures performed by the installation technician, the TAC will assess the plant again. At this point, if, in the opinion of the TAC, safety and compliance conditions exist, the TAC must carry out the "initial activation".

Plant situations that are hazardous for people and for the appliance. If one of the following hazardous situations arises, the TAC must not carry out the "initial activation":

▶

appliance installed in improper conguration (e.g.: type B in closed and insuciently ventilated area);

▶

appliance installed close to combustible substances or surfaces or in any case in conditions of bad accessibility or not allowing safe maintenance operations;

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7 INITIAL ACTIVATION AND MAINTENANCE

Installation, user and maintenance manual – AY Condensing line, AY Series

▶

control of switching on and o of the appliance not via the DDC but via the external switch connecting the appliance to the power supply mains ("GS", tted by the electrical installation technician on a suitable panel);

▶

damages or failures of the appliance due to transportation or installation;

▶

smell of gas due to probable leaks from the plant itself and in any case all situations that are due to non-compliant plants, considered (after on-site evaluations) potentially hazardous.

Plant anomalies. If any of the following situations exists, the authorized technician may carry out the "rst start up" at his choice, but the appliance must be left o until the anomalies are removed:

▶

installations (not potentially hazardous) not carried out according to sound workmanship practices, installations (not potentially hazardous) not complying with current national and local regulations;

▶

installations (not potentially hazardous) not carried out according to good workmanship practices, not complying with the instructions provided by the manufacturer;

▶

installations that can cause operational troubles on the appliance.

Step 2: verication/regulation of combustion parameters and rst 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 invalidate the guarantee of the appliance.

The appliance is delivered already regulated for the type of gas requested. Anyway, the combustion parameters must ALWAYS be checked and set during the rst start up.

The type of gas for which the appliance is set is given on the sticker on the internal panel and on the appliance's original packaging.

To check and set the combustion parameters, proceed as follows, with reference to Figures 7.1→52 and 7.2→52 and Table 7.1→53.

You will need: appliance not powered up: master power switch and gas cock set to OFF. outer front panel (H) removed. Necessary equipment and materials. DDC (if installed) already connected electrically.

1. Open the internal panel (E) by undoing its bolts.

2. Open the plant gas supply valve to the appliance and make sure that there is no smell of gas (indicating possible leaks). In case of gas leaks, go back over Step 1 above and restore the system to compliancy.

3. Once you are sure there are no gas leaks, close the gas cock. Now check the static and dynamic mains gas pressure: if the system has multiple appliances, this check (steps "4" to "10")

need only be done once, so long as it is done with the appliance furthest from the mains connection; for the other appliances, skip directly from step "3" to step "12".

4. Undo the bolt sealing the inlet gas pressure socket (D).

5. Connect the manometer to the gas intake (mains pressure).

6. Open the gas valve.

7. Read the value of the static network pressure on the manometer and check that the value read is equal to that stated in Table

5.2→24 (with tollerance ±15%).

8. Close the master power switch (GS) on the external electrical panel.

9. Switch the appliance on. Wait for the appliance to stabilise (3 minutes from switching on) and then proceed to step "10". If the appliance does not switch on, remove the side panel (N), remove the cap (L) and use a athead screwdriver through

hole (G) to turn the ow regulator screw 3 turns counterclockwise ; reinstall the cap (L) and repeat step "9".

10. Read the dynamic mains pressure on the pressure gauge and check that the value is in the range specied at step "7". Now

switch the appliance o.

If the dynamic network pressure does not corresponde to the value stated in Table 5.2→24 (with tollerance ±15%), write down the fault and, at the end of the procedure, notify the installer/user. Received the notify, the user must not operate the appliance until the fault has been solved and the manufacturer's specications are met (see Step 1 once again).

11. Restore the appliance by screwing the gas intake seal screw back in.

12. Close the appliance's internal panel (E).

13. Fit a combustion products probe in one of the points provided fro this purpose on the external fumes equipment.

14. Switch the appliance on and wait for it to stabilise (3 minutes).

15. With reference to Table 7.1→53 and the fumes analyser reading, check that the CO2 content percentage of the combustion

products is within ±0,2 of the characteristic value for the gas being used.

16. If the value is in the correct range, go to step "17". Otherwise, remove the side panel (N) and follow the instructions given in

steps "25" and "26", including the note, in the procedure given in Paragraph 7.3→54.

17. Enter menu 2 and execute action "23": timed forcing of the appliance to minimum power (8.0 kW). The procedure to run the

actions of menu 2 is specied in this Paragraph “Step 2".

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7 INITIAL ACTIVATION AND MAINTENANCE

18. With reference to Table 7.1→53 and the fumes analyser reading, check that the dierence between the CO2 percentage observed in step “15” and the current reading corresponds to the

delta CO

2 characteristic of the gas being used.

Example: having set, in step "15", a CO2 content of 9.5% for G20 gas, at step "18" the reading should be 9.0% (=9.5%-0.5%).

19. If the dierence satises the

delta CO

2 requirement, go to the next step. Otherwise, follow the instructions given in steps "30" and

"35", including the note, in the procedure given in Paragraph 7.3→54.

20. Enter menu 2 and execute action "25": forced stop to cancel the preceding forced operation and return to the initial operational conguration.

After 30 minutes of operation the appliance automatically cancels the preceding forced power mode. To anticipate this timing, select and execute action "25" in menu 2.

21. Switch o and completely restore the appliance.

Figure 7.1 – Checking and adjusting the combustion parameters

Procedure for checking and adjusting the combustion parameters.

LEGEND

E front panel interior F access hole for OFFSET regulator G access hole for ow rate regulator H front panel exterior L access plug for ow rate regulator M access plug for OFFSET regulator N external side panel

Figure 7.2 – Gas valve

Gas valve Honeywell VK 4115V

LEGEND

A Cap B Torx wrench TX40 C CO2 adjuster screw D Mains gas pressure tting

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7 INITIAL ACTIVATION AND MAINTENANCE

Installation, user and maintenance manual – AY Condensing line, AY Series

Table 7.1 – Gas nozzles and content of CO2

Gas type G20 G25 G25.1 G27 G2.350 G30 LPG G31

Nozzle code - 176 179 178 178 - 177 177 177 Nozzle diameter mm 6.20 7,30 7,60 7,60 - 4.45 4.45 4.45 Parameter value "45" - 0 0 0 0 0 1 1 0 CO2 content % 9.4 9.4 10,7 9,35 9,15 12,4 11.4 10.6 Delta CO2 between Max and Min potential % 0,5 0,5 0,5 0,45 0.35 0,9 0,9 0,4

In the rst start-up stage, on the display of the controller of the appliance (and/or on the display of the DDC, if connected), an operating code might be visualized. If the operating code is generated by the controller of the appliance, see the list of codes in Table 9.1→59; if the operating code is generated by the DDC, see the list of codes given in the "installation technician manual - manual 1" of the DDC (supplied with the unit).

Successful rst start-up ONLY certies the correct operation of the appliance (and of the DDC, if connected). It does NOT certify that the plant complies with current regulations.

OPERATIONS IN MENU 2

▶

FORCING TO MINIMUM POWER (ACTION "23"):

You will need: the display showing "2.20" (see point "3" of procedure "HOW TO ACCESS THE MENUS" - Paragraph "4.3→15").

1. Turn the knob clockwise until the display shows parameter "2.23".

2. Press the knob to display the ashing force to minimum power request: "P_L1".

3. Press the knob again to execute the forcing. The request stops ashing, and the display shows “2.23” again. The forcing operation has been performed.

4. To exit the menu, turn the knob clockwise until “2.E” displays, and press it to return to the menu selection: "2.".

5. To exit the menu selection, turn the knob clockwise until “E” displays, and press it to exit.

▶

FORCING TO MAXIMUM POWER (ACTION "24"):

You will need: the display showing "2.20" (see point "3" of procedure "HOW TO ACCESS THE MENUS" - Paragraph "4.3→15").

1. Turn the knob clockwise until the display shows parameter: "2.24".

2. Press the knob to display the ashing force to minimum power request: " P_H1".

3. Press the knob again to execute the forcing. The request stops ashing, and the display shows "2.24" again. The forcing operation has been performed.

4. To exit the menu, turn the knob clockwise until “2.E” displays, and press it to return to the menu selection: "2.".

5. To exit the menu selection, turn the knob clockwise until “E” displays, and press it to exit.

▶

CANCELLING POWER FORCING (ACTION "25"):

You will need: the display showing "2.20" (see point "3" of procedure "HOW TO ACCESS THE MENUS" - Paragraph "4.3→15").

1. Turn the knob clockwise until the display shows parameter: "2.25".

2. Press the knob to display the ashing cancel forcing request: "UnF1".

3. Press the knob again to execute the cancel operation. The request stops ashing, and the display shows "2.25" again. The cancel operation has been performed.

4. To exit the menu, turn the knob clockwise until “2.E” displays, and press it to return to the menu selection: "2.".

5. To exit the menu selection, turn the knob clockwise until “E” displays, and press it to exit.

Step 3: regulation of plant operating parameters

Regulation of operating parameters of the plant occurs via the controller (see Paragraph 5.9→29) or via the DDC (if connected).

In this phase it may be necessary to check the settings of parameters "156", "180" and "182", which are closely linked to the system requirements (see instructions "SPECIAL PARAMETER SETTINGS" in Paragraph 5.9→29).

If the appliance is connected to a Direct Digital Controller (DDC), for operations regarding the regulation of plant operating parameters according to the user's requirements, refer to the DDC’s manual (nal user manual - manual 2) supplied with the unit.

7.2 MAINTENANCE

Correct maintenance prevents problems, guarantees maximum operating eciency 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.

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7 INITIAL ACTIVATION AND MAINTENANCE

Any operation that regards internal components of units of the appliance must be carried out by an authorized Robur Technical Assistance Centre (TAC), according to the instructions supplied by the manufacturer.

The "eciency check" and every other "check and maintenance operation" (see Table 7.2→54 and 7.3→54), must be per- formed with a frequency in agreement to current law or, if more restrictive, in respect of what requested by the planner (builder of the system) or by the manufacturer of the unit.

The liability of CHECKING THE EFFICIENCY AS A FUNCTION OF THE SYSTEM, OF THE FUEL IN USE AND OF THE THERMAL POWER, to be carried out with the purpose of containing the energy consumption, is in charge to the responsable of the system.

Before carrying out any operation on the appliance, switch it o via the appropriate on/o command (or via the DDC, if connected and in controller mode) and wait for the shutdown cycle to terminate. When the appliance is o, disconnect it from the gas and electricity mains, bearing in mind the antifreeze settings, via the external circuit breaker (GS) and the gas valve.

GUIDELINES FOR THE PREVENTIVE MAINTENACE OPERATIONS In Table 7.2→54 are reported the guidelines for the preventive maintenance operations.

If the unit is subject to particularly heavy duty (for example in process plants or in other conditions of continuous opera- tion), these maintenance operations must be more frequent.

Table 7.2

GUIDELINES FOR THE PREVENTIVE MAINTENACE OPERATIONS Check of the unit GAHP-A GAHP-GS/WS AY ACF GAHP-AR

Visually check of the general condition of the unit and of its air heat exchanger.

(1)

√ √ √ √ Check the correct operation of the device used for monitoring the water ow √ √ √ √ √ Check the % value of CO

√ √ √ check gas pressure to the burners √ √ Check that the condensate discharge is clean (clear the condensate discharge hole of any blockages)

[If necessary, frequency of the maintenace operation must be increased]

√ √ √ Replace the belts after 6 years or 12,000 hours of operation √ √ √ √

Check/restore the pressure of the primary hydronic circuit √ Check/restore the air pressure inside of the expansion vessel of the primary hydronic circuit √

Check every CCI or DDC(2) DDC o CCI

Check that the plant is able to achive the setpoint temperature √ Download the hystorical events √

1 - It is suggested the cleaning of the air heat exchanger once every 4 years [the optimal frequency of this operation is in any case a consequence of the installation site]. 2 - Check that the plant is able to achive the setpoint temperature.

ORDINARY SCHEDULED MAINTENANCE Perform the following operations at least once every 2 years.

If the unit is subject to particularly heavy duty (for example in process plants or in other conditions of continuous opera- tion), these maintenance operations must be more frequent.

Table 7.3

SCHEDULED MAINTENANCE OPERATIONS TO BE PERFORMED AT LEAST ONE EVERY TWO YEARS Check of the unit GAHP-A GAHP-GS/WS AY ACF GAHP-AR

Clean the combustion chamber √* √* √ √ √* Clean the burner √* √* √ √ √* Clean the electrodes of ignition and ame sensing √ √ √ √ √

Check that the condensate discharge is clean (clear the condensate discharge hole of any blockages) √ √ √ Replace the silicone gasket √

*Only in case the analysis of combustion products is non-compliant

In Section 5→18 are reported suggestions related to the hydraulic plant.

7.3 CHANGE OF GAS TYPE

The following procedure must be done by a Robur TAC or professionally qualied technician.

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7 INITIAL ACTIVATION AND MAINTENANCE

Installation, user and maintenance manual – AY Condensing line, AY Series

To convert the appliance to operation with a dierent 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. Necessary equipment and materials.

The appliance must be tted with the sticker (in the conversion kit) giving the specications of the new gas type in replacement of the existing sticker. The sticker must bear the markings required by UNI EN 483 (par. 8.2.3).

- CHECK THE NOZZLE DIAMETER.

Refer to Table 7.1→53 and Figure 7.3→57; if the diameter of the nozzle to be used with the gas with which the appliance is to be operated corresponds to the diameter of the existing nozzle, skip directly to the step checking the value of parameter "45": step "8" onwards. If on the other hand the diameter is dierent from that of the existing nozzle, the latter must be replaced:

1. Remove the outer front panel (H - Figure 7.1→52) and open the internal panel (E - Figure 7.1→52) by undoing the screws securing it.

2. Undo the nut (A) connecting the gas pipe to the gas valve (C).

3. Slacken o the nut (B) connecting the gas pipe to the air/gas mixer (G).

4. Turn the gas pipe so as to enable access to the gas nozzle (D) inside the anged union on the gas valve outlet (C).

5. Replace the nozzle (D).

Each nozzle is stamped with a code to identify it (see Table 7.1→53).

6. Restore the appliance making sure to reposition (and replace if damaged) the gaskets (E, F) aected by the procedure.

During the procedure a number of broken seals must be restored and regulators sealed.

At this point, open the system gas cock and check for gas leaks at the two pipe unions (A, B); close the gas cock.

7. Close the appliance's internal panel (E).

- CHECK THE VALUE OF PARAMETER "45".

8. Turn on the master power switch (GS).

9. Enter menu 1 (accessible to everyone) and check the setting of parameter "45".

10. If the value of the parameter "45" doesn't match the value specied for the type of gas with which the appliance is intended to operate(see Table 7.1→53), enter in menu 4 of the electronic board and set the correct value for parameter "45" (see Table

7.1→53). To enter menu 4 and make the required changes, refer to the instructions "Hydraulic parameter settings" in

Paragraph 5.9→29.

If the setting of parameter "45" coincides with the value specied for the type of gas with which the appliance is to be

operated, skip step "10".

- CHECK/ADJUST THE COMBUSTION PARAMETERS.

Refer to Figures 7.1→52 and 7.2→52, and Table 7.1→53.

You will need: appliance not powered up: master power switch and gas cock set to OFF. external front panel (H) and side panel (N) removed. Necessary equipment and materials. DDC (if installed) already connected electrically.

Now check the static and dynamic mains gas pressure: if the system has multiple appliances, this check (steps "11" to "18") need only be done once, so long as it is done with the appliance furthest from the mains connection; for the other appliances, skip directly from step "11" to step "20".

11. Open the internal panel (E) by undoing its bolts.

12. Undo the bolt sealing the inlet gas pressure socket (Figure 7.2→52 - detail D).

13. Connect the manometer to the gas intake (mains pressure).

14. Open the gas valve.

15. Read the value of the static network pressure on the manometer and check that the value read is equal to that stated in Table

5.2→24 (with tollerance ±15%).

16. Close the master power switch (GS) on the external electrical panel.

17. Switch the appliance on. Wait for the appliance to stabilise (3 minutes from switching on) and then proceed to step "18".

If the appliance fails to switch on, remove the access cap (L) on the ow regulator and use a athead screwdriver through hole (G) to turn the regulator screw 3 turns counterclockwise. Replace the cap (L).

18. Read the dynamic mains pressure on the pressure gauge and check that the value is in the range specied at step "15". Now switch the appliance o.

If the dynamic pressure does not corresponde to the value stated in Table 5.2→24 (with tollerance ±15%), perform the necessary checks (see Step 1 del Paragrafo 7.1→50) and solve the fault.

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7 INITIAL ACTIVATION AND MAINTENANCE

19. Restore the appliance by screwing the gas intake seal screw back in.

20. Close the appliance's internal panel (E).

21. Fit a combustion products probe in one of the points provided fro this purpose on the external fumes equipment.

22. Switch the appliance on and wait for it to stabilise (3 minutes).

23. With reference to Table 7.1→53 and the fumes analyser reading, check that the CO2 content percentage of the combustion products is within ±0,2 of the characteristic value for the gas being used.

24. If the value is in the correct range, go to step "27"; otherwise proceed as follows:

25. remove the access cap (L) on the ow regulator and use a athead screwdriver through the hole (G) to adjust the ow regulator so that the value falls in the correct CO2 content range.

26. Reinstall the cap (L).

1 full turn of the ow regulator screw reduces (clockwise) or increases (counterclockwise) the percentage of CO2 by approximately 0.1%.

27. Enter menu 2 of the electronic board and execute action "23": timed forcing of the appliance to minimum power (8.0 kW). The

procedure to run the actions of menu 2 is specied in the Paragraph 7.1→50, at the end of "Step 2".

28. With reference to Table 7.1→53 and the fumes analyser reading, check that the dierence between the CO2 percentage observed in step “15” and the current reading corresponds to the delta CO2characteristic of the gas being used.

Example: having set, in step "23", a CO2 content of 9.5% for G20 gas, at step "28" the reading should be 9.0% (=9.5%-0.5%).

29. If the dierence satises the delta CO2 requirement, go to step "34", otherwise proceed as follows:

30. Open the access (F) to the OFFSET regulator, which is part of the gas valve, by removing the access cap (M) on the internal panel (E).

31. Open the internal panel (E) and, using a Torx TX40 wrench (B) remove the cap (A) on the OFFSET regulator (C). Close the internal panel (E).

32. Through hole (F) on panel (E), use a Torx TX40 wrench (B) on the OFFSET regulator to achieve a value of CO2 content whose value relative to the value red at step "23" satises the requirement of the Table regarding the characteristic delta CO2 for the gas being used (see example above and observe the following instructions):

1/8 turn of the OFFSET regulator screw reduces (counterclockwise) or increases (clockwise) the CO2 content by approximately 0.1%.

33. Once the correct CO2 content has been achieved, open the internal panel (E) and restore the cap (A), close the panel (E) and reinstall the cap (M).

34. Enter menu 2 and execute action "24": timed forcing of the appliance to maximum power (34.9 kW).

35. Check that the CO2 content percentage of the combustion products is within ±0.2 of the characteristic value for the gas being used. If this condition is not met, repeat the procedure from step "25", otherwise proceed with the next step.

36. Enter menu 2 and execute action "25": forced stop to cancel the preceding forced operation and return to the initial operational conguration.

After 30 minutes of operation the appliance automatically cancels the preceding forced power mode. To anticipate this timing, select and execute action "25" in menu 2.

37. Switch o and completely restore the appliance.

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7 INITIAL ACTIVATION AND MAINTENANCE

Installation, user and maintenance manual – AY Condensing line, AY Series

Figure 7.3 – Gas type conversion

Details of gas changeover procedure.

LEGEND

A tube/valve connection nut B tube/air-gas mixer connection nut C gas valve D gas nozzle E gasket (large) on tube/valve tting F gasket (small) on tube/air-gas mixer tting G air-gas mixer

Page 58

8 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 Description Code Notes

ANTIVIBRATION MOUNT kit FOR BASE

Kit of 4 non-adjustable anti-vibration feet for installation on the beams of the base.

ONTV008

For multiple units ONLY. For the mount positioning spacings, see the dimensional drawings.

PLANT ELECTRICAL PUMP

Centrifugal pump for the circulation of water in the hydraulic plant

OPMP000 For cold and hot water

HYDRAULIC SEPARATOR

Separator for balancing hydraulic circuits; with automatic air vent, drain valve and insulation.

OSPR000 Maximum water ow rate 15 m

3/h.

WATER/GLYCOL MIX

Glycol water solution (water/glycol mix 50+50) for hot/cold hydraulic systems.

OGLC007

10 liters tank (50%÷50%). Glycol water solution for machine internal circuit.

CONDENSATE PUMP

Pump for the condensate obtained from combustion products.

OPMP006 Handles up to 20 units.

Direct Digital Controller (DDC)

Provides remote control of one or more units.

OCRM007

No. 1 DDC per a maximum of 16 units in the same installation. NB: with multiple units, the DDC is standard supply.

RB100

Controller for handling sliding temperatures and remote ACS production.

ODSP001

Can be used in combination with the DDC.

WISE (Web Invisible Service Employee)

Communications system for remote handling, control and supervision of installation.

ODSP000

Can be used in combination with the DDC. The WISE unit has an integral antenna; 1 RS232 serial cable; 1 cable with telephone jack; 1 CD-ROM.

Robur “NETBUS” CAN BUS CABLE

Cable for data communication networks: for network connection between DDC and appliance.

OCVO008

Maximum length: 450 m (for details, see the electrical connections section).

List of appliance accessories.

Page 59

9 OPERATING CODES/TROUBLESHOOTING

Installation, user and maintenance manual – AY Condensing line, AY Series

9 OPERATING CODES/TROUBLESHOOTING

9.1 OVERVIEW AND OPERATING CODES/TROUBLESHOOTING

If, during the operation of the appliance, the display of the controller of the appliance (or also of the display of the Direct Digital Controller, if connected) signals an operating code, it is necessary to:

▶

make a note of the indications shown on the display;

▶

consult the (specic) list of machine operating codes.

For the operating codes generated by the controller of the appliance, refer to Table 9.1→59. If the appliance is connected to a DDC, a list of the operating codes generated by the DDC is provided in the DDC's manual (see "installation technician manual - manual 1").

▶

carry out the instructions contained in it scrupulously (contact your Authorised Robur Technical Assistance Centre when instructed to do so).

If, after performing these operations, the appliance does not start, rst carry out the following simple checks:

▶

ensure that the external disconnecting switch tted by the electrical installation technician on a suitable panel (see Section 6→32) is set to ON;

▶

check that the consent switches (see Paragraph 6.3→39) or the DDC (if connected and in controller mode) are set for operation of the appliance;

▶

check that the gas supply valve is open;

▶

determine that no further indications are given on the display.

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 Centre (TAC), informing it of the Machine Code that has arisen;

▶

disconnect the appliance from the gas and electricity supply, cutting o the gas supply by means of the appropriate tap and electrical power via the external master power switch. Wait for the TAC sta to arrive.

For how to reset the machine operating code with the on-board controller, refer to Paragraph 4.3→15.

We list below the operating codes generated by the appliance's controller (rmware version 3.106). The following codes can also be displayed by the DDC, if connected.

Table 9.1 – TABLE OF OPERATING CODES generated by the electronic board (rmware version 3.106)

CODES DESCRIPTION TRIP CONDITIONS RESET METHOD

E 100 FLAME RESET FAULTY The ame control unit reset circuit is faulty. Contact authorised Technical Assistance.

E 101 LIMIT THERMOSTAT

The limit thermostat is open. This only happens if the ame controller is on and the gas solenoid valve is excited (the thermostat is connected in series with the solenoid valve power supply).

Contact authorised Technical Assistance.

u 102

FUMES THERMOSTAT AND/ OR INTERNAL EXCHANGER THERMOSTAT

The fumes thermostat and/or the internal exchanger thermostat are interrupted.

Contact authorised Technical Assistance.

E 102

FUMES THERMOSTAT AND/ OR INTERNAL EXCHANGER THERMOSTAT

"u 102" persistent for 1 hour. Contact authorised Technical Assistance.

E 103

HEATING CONTROLLER NOT PRESENT

The auxiliary controller (S70) is not present. Contact authorised Technical Assistance.

E 105 HIGH AMBIENT TEMPERATURE

The ambient temperature is HIGH. This only happens when the appliance is operating.

Automatic (on termination of originating event).

E 106 LOW AMBIENT TEMPERATURE

The ambient temperature is LOW. This only happens when the appliance is operating.

Automatic (on termination of originating event).

u 107

WATER PRESSURE SWITCH (HOT ONLY CIRCUIT)

The system water dierential pressure switch is closed while the appliance is running in cooling mode. This only happens when the appliance is installed in a "hot/cold" system.

Automatic (on termination of originating event).

u 112 FLAME CONTROLLER FAULT The burner does not light.

Automatic when the ame controller attempts ignition again (solenoid valve excited - maximum 4 attempts); or after 5 minutes of persistence: in this case, ignition has failed and a new event has occurred after "u112" was reset (run checks).

E 112

ARREST OF FLAME CONTROL UNIT

Flame controller arrested - failure to ignite burner: all possible attempts to ignite the burner have failed.

Reset via the controller, menu 2, parameter 20 (or via DDC). If the code persists, contact authorised TAC.

u 127

MACHINE INTERNAL CIRCUIT WATER PRESSURE SWITCH

Lo stato del pressostato non corrisponde allo stato del circolatore acqua del circuito interno della macchina.

Automatico ed avviene se si ha corrispondenza di stato tra il circolatore e il pressostato dierenziale.

E 127

MACHINE INTERNAL CIRCUIT WATER PRESSURE SWITCH

"u 127" persistent for 10 minutes.

Carry out appropriate checks. Reset via the controller, menu 2, parameter 21 (or via DDC). If the code persists, contact authorised TAC .

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9 OPERATING CODES/TROUBLESHOOTING

CODES DESCRIPTION TRIP CONDITIONS RESET METHOD

E 128

FLAME CONTROLLER ON AND ARRESTED

The ame controller is arrested (E_12) but the gas solenoid valve is excited. In this case the ame controller is de-excited.

Reset via DDC (or via the controller, menu 2, parameter 20). If the code persists, contact authorised TAC.

u 129

GAS SOLENOID VALVE WITHOUT ELECTRICAL POWER

Gas solenoid valve is o for 5 seconds (with ame controller on).

Automatic, when at least of the following conditions obtains (and only if the "E 101" condition has not been forced): ame controller o, or solenoid valve excited.

E 129

GAS SOLENOID VALVE WITHOUT ELECTRICAL POWER

The gas solenoid valve has been o for more than 10 minutes (with the ame controller on), or "E 101" is keeping the ame controller on. Or also in the case that, with the ame o (but ame controller on) "E 101" obtains when generation of "u/E" is enabled.

Reset via the controller, menu 2, parameter 21 (or via DDC). If the code persists, contact authorised TAC.

E 135

DELIVERY WATER TEMPERATURE PROBE FAULT (MACHINE CIRCUIT)

The delivery water probe on the internal circuit (machine circuit) is faulty.

Contact authorised Technical Assistance.

u 136 MODULATING BLOWER FAULT The blower speed is out of range.

Reset occurs automatically 20 minutes after the operating code is generated.

E 136 MODULATING BLOWER FAULT

u_36 code generated three times in 1 hour of operation.

Contact authorised Technical Assistance.

u 175

SYSTEM CIRCUIT WATER PRESSURE SWITCH - Insucient water ow

The system circuit water circulator is on and the system circuit water dierential pressure switch is open.

Automatico ed avviene se il circolatore si spegne, oppure se il pressostato dierenziale si chiude.

E 175

SYSTEM CIRCUIT WATER PRESSURE SWITCH - Insucient water ow

Event u_175 has been generated 5 times since the appliance was powered up, or code u_175 has been active for 1 hour.

Carry out appropriate checks. Reset via the controller, menu 2, parameter 21 (or via DDC). If the code persists, contact authorised TAC .

E 176

OUTPUT WATER (SYSTEM) TEMPERATURE PROBE FAULT

Fault (interruption or short circuit) on outlet system water temperature sensor.

Reset via the controller, menu 2, parameter 21 (or via DDC). If the code persists, contact authorised TAC.

E 177

INPUT WATER (SYSTEM) TEMPERATURE PROBE FAULT

Fault (interruption or short circuit) on inlet system water temperature sensor.

Reset via the controller, menu 2, parameter 21 (or via DDC). If the code persists, contact authorised TAC.

u 178

DELIVERY WATER TEMPERATURE (MACHINE CIRCUIT) HIGH

The water temperature on the internal circuit (machine circuit) is too high.

Automatic (on termination of originating event).

u 179 DEFROST FUNCTION ACTIVATED

The temperature of the water has reached values which could result in icing. In such cases, to prevent the appliance arresting, the defrost function may activate only the system circuit circulator or also the ame controller.

The defrost function is de-activated automatically when the ame controller switches o and/or the circulator switches o. These switch o when the water temperature has reached the values required to ensure operation of he appliance. The defrost function can also be de-activated manually via the controller, menu 4, parameter 163.

u 80 INCOMPLETE PARAMETERS

Incomplete functional parameters (menus 3, 4 and 5).

The code persists until operating parameters are entered and completed. Contact authorised TAC.

E 80 INVALID PARAMETERS

Invalid parameters (menu 6) or damage to parameter memory.

Reset occurs automatically when correct parameters are entered. If the code persists, contact authorised TAC: if the memory is damaged, the controller must be replaced.

u 81; u 82

"BANK 1" AND "BANK 2" PARAMETERS: INVALID

Bank 1 data invalid - Bank 2 data invalid: in both cases, one of the two parameter memory pages contains invalid values.

Automatic (on termination of originating event).

E 81; E 82

"BANK 1" AND "BANK 2" PARAMETERS: INVALID

Bank 1 data invalid - Bank 2 data invalid: the program has failed to copy the data from the correct page to the other page.

Contact authorised Technical Assistance.

E 84

FAULTY TRANSFORMER CONNECTION OR 24 V AC FUSES

Danneggiamento dei 2 fusibili di ingresso 240-24 Vac oppure interruzione del lo centrale dell’alimentazione 24-0-24 Vac verso la scheda

Check fuses and 24-0-24 V AC electrical power connections on the controller. Reset via the controller, menu 2, parameter 21 (or via DDC). If the code persists or returns, contact authorised TAC.

E 85

INCORRECT MODULE TYPES (from menu 6)

The set module type (from menu 6) does not correspond to the one managed by the controller.

Contact authorised Technical Assistance.

E 86; E 87; E 88 ; E 89

MEMORY TEST UNSUCCESSFUL Processor error. Contact authorised Technical Assistance.

E 90

AMBIENT TEMPERATURE SENSOR DEFECTIVE

Interruption or short circuit of ambient temperature sensor.

Contact authorised Technical Assistance.

E 91 CONTROLLER DEFECTIVE

Numero seriale di scheda assente e/o codice di versione hardware assente e/o chiave di criptazione assente o errata; oppure i dati di calibrazione sono assenti o inconsistenti.

Contact authorised Technical Assistance.

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Robur mission

Robur Spa tecnologie avanzate per la climatizzazione Via Parigi 4/6 24040 Verdellino/Zingonia (Bg) Italy T +39 035 888111∅F +39 035 884165 www.robur.it [email protected]

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.

Revisione: J Codice: D-LBR531 14 MCM SDC 007 10/03/2014