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Installation, user and maintenance manual AY Condensing

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2. 090900000090000900909090000920000090990000000000900000900900000900900009000000009000000000000000000900000909900000909000000000000000000900009 Detailed description of filling procedure 5 8 EXHAUST FLUE GAS The appliance which is supplied in the B53P configuration 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 OFACIESLJFT HYDRAULIC INSTALLATION Figure 5 5 AY Condensing line AY series 09099090090909009000099099000900000000090900090090009090900000000909000000009090000900900090 sc ARA SE 1 900900000000900000909090000009000009000000000000000090090000000909000000900000000000000000090000090900000900000000000900000000000000290 Fumes outlet fitting dimensions in mm seen from above FUMES EXHAUST EQUIPMENT FOR EXTERNAL INSTALLATION installation technician only Install the equipment externally as follows see Figure 5 6 28 You will need the appliance in its permanent location Necessary equipment and materials T Fit the DN80 roof terminal detail A inside the cone on the end of the DN80 extension pipe detail B 2 Fit
3. 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 A The following procedure must be done by a Robur TAC or professionally qualified technician OFICIESLJFT 7 INITIAL ACTIVATION AND MAINTENANCE To convert the appliance to operation with a different type of gas from that indicated on the sticker on the appliance s internal panel and the packaging proceed as follows You will need appliance not powered up master power switch and gas cock set to OFF provided envelope containing the spare nozzles and sticker Necessary equipment and materials i The appliance must be fitted with the sticker in the conversion kit giving the specifications of the new gas type in replace 2 ment ofthe 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 different from that of the existing nozzle the la
4. 200 n T N e il 2 4 T 174 6 p 217 6 Series AY service plate dimensions in mm LEGEND G A B C gas fitting G 3 4 M outlet water fitting G 1 1 4 F inlet water fitting G 1 1 4 F condensate drain fitting ext dia 25 mm 00900000000990000900990000009090000009000000000900000090099000009009000000000000900900000000000000000900000900000000000000009000000090900009 OFAICIESLIJFT 4 NORMAL OPERATION 4 NORMAL OPERATION In this section you will find 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 i Efficient operation and long life of the appliance depend largely on its correct use bh Before activating the appliance check that the gas valve is open theappliance is powered electrically the general electrical switch GS must be in the ON position theinstallation technician has ensured that the hydraulic circuit is supplied in the correct conditions If these conditions are satisfied 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 off command provided by the electrical installation technician According to requirements this on off command may be an on off button an ambient therm
5. Checkthat the water pressure and flow in the hydraulic circuit and the static gas supply network pressure are correct as indi cated by the manufacturer gt Check that the electrical power supply is 230V 50Hz gt Check that the air fumes pipes are properly connected Checkthat the fumes condensate discharge is properly installed gt 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 verification the TAC may choose not to proceed with the operation of initial activation In this case the Robur TAC technician must gt Report the user installer of any installation anomaly gt 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 first start up i It is the responsibility of the user installation technician to carry out any corrective measures on the plant indicated by the 2 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 com
6. 29 lii If the setting of parameter 45 coincides with the value specified 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 gt 52 and 7 2 52 and Table 7 1 53 2 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 Ll 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 appli ances skip directly from step 11 to step 20 11 Openthe internal panel E by undoing its bolts 12 Undothe 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 Ifthe appliance fails to switch on remove the access cap L on the
7. i 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 cir cuit Once the circuit has stopped gurgling close the cock and remove the hose 1 During manual bleeding any liquid which has been bled out of the circuit must be replaced with the charging pump Make 2 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 flathead screwdriver and close the automatic bleed valve on the circuit 2 Disconnect the volumetric pump remove the union and replace the filler 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 000000090000000900900000000000009090900000009000000900090000090000000000000009000000000909000000000000000900000090000000009000000090000009 LEGEND A manual air vent cock B pressure gauge C filler cock D hose fitting D 13 standard supply notch in horizontal position cock closed notch in vertical position cock open
8. Diagram of hydraulic system type with single appliance 090009090000000009090009000900090090090009000000000990090009090900009009000000900000909000000000900000090000000900000000900909009009090900909 LEGEND l g 1 anti vibration coupling o pressure gauge flow regulator valve water filter check valve system water circulator system expansion tank DDC AY00 120 stand alone O0 00 Ov Ui 4 UC h2 IIFt lt tr GAS gt I c E y 1 2 3 4 5 6 Example of hydraulic plant diagram for connection of no 1 AY00 120 unit OFICIESLIJIFT 5 HYDRAULIC INSTALLATION Figure 5 3 Diagram of hydraulic system type with several appliances LEGEND 8 1 anti vibration coupling 2 pressure gauge 3 flow regulator valve 4 water filter 5 check valve 6 system expansion tank 7 system water circulator IIlIH gt lt GAS pos m 9 AY00 120 stand alone 5 w 9 ui gt lt XX Dj iors lI gt lt GAS 6 B Hl Dj i a ee KX gt lt 1 2 3 4 5 gt lt 7 009090000090999000099090900000090000090000000900000000009000000000000009090000000000000900000000900000000900000000009000009209000000900990 Example of hydraulic plant diagram for connection of no 2 AY00 120 units 5 4 GAS SUPPLY The installation of gas supply pipes must be compliant with current regulations and norms For the pressure of the g
9. 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 Gas equipment gt Electrical equipment Heating systems employing condensation boilers gt 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 3 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 firm must ensure that the electricity and gas mains specifications correspond to the specifications on the nameplate the gas supply pressure is compliant with the value reported in Table 5 2 24 considering a tolerance of 15 theappliance is fed by the type of ga
10. When the necessary settings have been completed put away the special key replace the cap on the aperture of the electrical panel and refit the front panel of the appliance CIAL PARAMETER SETTINGS appliance is a Range Rated boiler the power delivery of the appliance can be adapted to the real system requirements by regu lating the nominal gas flow nominal thermal input The min thermal input can be regulated with parameter 180 in menus 4 and 5 The parameter has a range from maximum 34 9 kW to imum 8 0 kW thermal capacity see also Table 3 1 9 OFICIESLJFT S HYDRAULIC INSTALLATION i If multiple appliances are connected to the system the value of parameter 180 must be the same for all appliances hm 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 underfloor 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 sufficient to enable storage down to 30 C Any topping up of the
11. actuates the dedicated water circulator so as to keep the 2 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 Remove the front panel of the appliance to read the internal circuit charging pressure of the appliance on the external filling 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 i The internal circuit is hermetically sealed If the circuit is empty this is a fault identify the leak and restore the seal for ex 2 ample by replacing defective gaskets before proceeding i 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 filler cap and connect the provided D 13 union Figure 5 4 26 detail D Installation user and maintenance manual AY Condensing line AY Series 25 26 5 HYDRAULIC INSTALLATION 4 Connect the volumetric charging pump to the union with a hose 5 Open the filler cock Figure 5 4 26 detail C with a flathead screwdriver and charge the circuit with enough glycol solution to achieve the specified optimal pressure
12. 6 11 CAN network 090000090000990000009000090900000000090000090000000000000009009000000000000009000000090000000090009000000000000900090000000900000099999 CAN BUS network terminal node LEGEND 1 A appliance GA GAHP 2 CAN BUS network intermediate node B appliance AY 3 CAN BUS network intermediate node C appliance GA GAHP 4 CAN BUS network terminal node D DDC Example of network with 4 nodes 1 DDC 3 appliances 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 0900000900009900000900909000900000000000000009000000000900000009000000000900000009000000000090000000000000000000000900000000000900000090990 Robur ROBUR NETBUS H BLACK L WHITE GND BROWN 450m Ordering Code O CVO008 Honeywell SDS 1620 BELDEN 3086A TURCK type 530 DeviceNet Mid Cable In all cases the fourth conductor should not be used TURCK type 5711 H BLUE L WHITE GND BLACK 450m Honeywell SDS 2022 H BLACK L WHITE GND BROWN 450m TURCK type 531 H BLACK L WHITE GND BROWN 200m Example types of cables used to connect the CAN network T For overall distances to cover of lt 200 m and networks with a maximum of 6 nodes a typical example 1 DDC 5 devices a s
13. 7 INITIAL ACTIVATION AND MAINTENANCE Table 7 1 Gas nozzles and content of CO2 Nozzle code Nozzle diameter Parameter value 45 CO2 content Delta CO2 between Max and Min potential t In the first 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 techni cian manual manual 1 of the DDC supplied with the unit Successful first start up ONLY certifies 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 FORCINGTO 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 Turnthe knob clockwise until the display shows parameter 2 23 2 Press the knob to display the flashing force to minimum power request P L1 3 Press the knob again to execute the forcing The request stops flashing and the display shows 2 23 again The forcing opera tion has been performed 4 To exit the menu turn the knob clockwise until 2 E displays and press it to return to the menu sele
14. NO SE SI SK TR AT CH HR MK RO IT AL BG CZ ES GB IE LT PT SI SK HR MK RO 2HS3B P HU 2E3P LU lusgjp 2ELL3B P DE 2Esi3P FR 2E3B P PL l llar3sp NL l l l 2ELwLs3P bas I3P BE lg P lp 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 acces sory 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 effluent washing machine dishwasher etc usually of base pH so as to form a buffer solution before discharge into the sewer dp 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
15. 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 Installation user and maintenance manual AY Condensing line AY Series 13 14 4 NORMAL OPERATION 4 2 ON BOARD ELECTRONICS LH The following descriptions refer to the controller with firmware version 3 106 The appliance is fitted with an AY70 controller connected to an auxiliary 70 controller see Figure 4 1 14 The AY70 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 LEGEND A 4 digit display for data and operating codes B Knob for scrolling through selecting operating data Controllers AY10 and S70 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 VIEW DATA TEMPERATURE VOLTAGE PUMP SPEED ECC VIEW ALL PARAMETERS ENTER ACTIONS USER SETTINGS THERMOSTATING SET POINT T DIFFERENTIAL INSTALLATION TECHNICIAN SETTINGS TECHNICAL ASSISTANCE CENTRE SETTINGS
16. TECHNICAL ASSISTANCE CENTRE SETTINGS MACHINE TYPE VIEW DIGITAL IMPUTS MENU NOT USED EXIT MENU mes o emnt mI 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 modified Menu 0 shows the ap pliance operating data in real time Menu 1 shows the parameters that characterise the operation of the appliance and their current values A 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 flame 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 ofthe 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 OFICIESLJFT 4 NORMAL OPERATION Menus 4 5 6 and 7 exclusively concern the installation technician and Robur s authorized Technical Assistance Centre Menu 8 may currently be selected but not used Display and knob The controller s display can be viewed through the glass of the viewing aperture on the front panel of the appliance Upon activation all display s LED s light up and then the name o
17. To modify these parameters refer to Paragraph 5 9 29 gt If the appliance is connected to a DDC follow the instructions given in the DDC manuals exclusively OFICIESLJFT 4 NORMAL OPERATION 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 fM i You will need the appliance connected to the power gas supply Necessary equipment and materials 1 if the appliance is in operation switch it off with the DDC or other consent switches and wait for the shutdown cycle to ter minate 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 off 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 A Do not leave the appliance connected to the power and gas supply if it is expected to remain inactive for a long period i If the appliance is disconnected in the run up to winter make sure that there is a sufficient glycol concentration in the inter 2
18. circolatore si spegne oppure se il pres sostato differenziale si chiude Carry out appropriate checks Reset via the controller menu 2 parameter 21 or via DDC If the code persists contact authorised TAC OUTPUT WATER SYSTEM TEM PERATURE 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 INPUT WATER SYSTEM TEM PERATURE 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 DELIVERY WATER TEMPERATURE MACHINE CIRCUIT HIGH The water temperature on the internal circuit machine circuit is too high Automatic on termination of originating event DEFROST FUNCTION ACTIVATED The temperature of the water has reached values which could result in icing In such cases to pre vent the appliance arresting the defrost function may activate only the system circuit circulator or also the flame controller The defrost function is de activated automatically when the flame controller switches off and or the circulator switches off These Switch off 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
19. f SaM uon euuoo epou jeur V jaued ouo je 6p ddd saumjeubls eep puo TH preoq Jaq uo saduinf sng NYD Ler GNaD31 p N N IVL ZVL IWHL IHHL r4 ifs soo n IVL 2VL OWHL OBHL 31615 Ei o OJO 1 w3dwnrX Cll ir w3dWnr LLOJ SW CAN BUS cable connection between 1 DDC and multiple appliances 49 Installation user and maintenance manual AY Condensing line AY Series 50 7 INITIAL ACTIVATION AND MAINTENANCE 7 INITIAL ACTIVATION AND MAINTENANCE In this section you will find the following information gt Indications required by the authorized Robur Technical Assistance Centre TAC in order to carry out the entire procedure of first start up of the appliance see Paragraph 7 1 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 i Before proceeding with the operations described in this section the installation technician concerned is invited to read 2 Paragraph 3 1 7 in regard to switching the appliance on and off refer to Paragraph 4 1 gt 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
20. filled 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 1 D The choice of water circulator depends on the number of appliances being served as the specifications of the system water 2 flowrate head etc which are determined during the design process Always follow the specifications of the system design documentation T 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 dk You will need the appliances hydraulically connected water circulator in line with the system specifications e g three phase 400 V AC external electrical panel configured 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 Installation user and maintenance manual AY Condensing line AY Series 37 38 6 ELECTRICAL INSTALLATION 1 On each appliance remove the front panel and open the electrical panel by remo
21. flow regulator and use a flathead 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 specified at step 15 Now switch the appliance off E If the dynamic pressure does not corresponde to the value stated in Table 5 2 24 with tollerance 15 perform the nec essary checks see Step 1 del Paragrafo 7 1 50 and solve the fault Installation user and maintenance manual AY Condensing line AY Series 55 56 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 Fita 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 CO content percentage of the combustion products is within 0 2 of the characteristic value for the gas being used 24 Ifthe value is in the correct range go to step 27 otherwise proceed as follows 25 removethe access cap L on the flow regulator and use a flathead screwdriver through the hole G to adjust the flow regulator so that the value falls in the correct CO content range 2 Reinstall the cap L 6 1 1fullturn of the flow regula
22. following technical manufacturing characteristics control and safety components premixed multigas burner with low NO and CO emissions stainless steel plate exchanger acting as a hydraulic separator AY10 microprocessor controller with LCD display and control knob Figure 4 1 14 S70 controller Figure 4 1 14 ionisation based flame controller gas solenoid valve with double shutter system water antifreeze function internal circuit antifreeze function automatically resettable water temperature limiting thermostat single use fumes limiting thermostat thermal cutout system circuit water differential pressure switch PD1 internal circuit water differential pressure switch PD2 with anti sticking function overpressure valve on internal circuit set to trip at 3 bar internal circuit expansion tank automatic and manual air bleeds on the internal circuit fumes pipe with terminal for type B53P configuration condensate discharge siphon with antifreeze function V WV WV NW NN NON NON ON ON ON ON ON YV V iy anti freezing thermostat used for the activation of the heating element on the condensate drain 3 4 TECHNICAL DATA Table 3 1 TECHNICAL CHARACTERISTICS Nominal 1013 mbar 15 C Thermal capacity MEAN MIN OPERATING POINT Tm80 Tr60 and nominal thermal Available power Capacity Efficiency 96 98 6 OPERATING POINT Tm80 Tr60 and minimal thermal capacity Efficiency 96 97 3 OP
23. initial charge must restore the optimal water glycol mix 50 50 However parameter 180 allows the appliance to be configured 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 i Parameter 156 is to be used ONLY by the Robur TAC parameters 180 and 182 are also available to the installation tech 3 nician These special parameters may be configured when so required only by the Robur TAC or the installation technician when authorised to do so Installation user and maintenance manual AY Condensing line AY Series 31 32 6 ELECTRICAL INSTALLATION 6 ELECTRICAL INSTALLATION In this section you will find all the instructions necessary to connect electrically the appliance The procedures to follow in order to complete the entire process of electrical installation of the appliance are the following 1 CONNECTING THE APPLIANCE TO THE MAINS 2 ELECTRICAL CONNECTIONS FOR THE SYSTEM CIRCULATOR 3 CONNECTIONS FOR CONSENT SWITCH OPERATION ap Before proceeding with operations to create the electrical plant of the appliance the professionally qualified person
24. local regulations installations not potentially hazardous not carried out according to good workmanship practices not complying with the in structions provided by the manufacturer installations that can cause operational troubles on the appliance Step 2 verification regulation of combustion parameters and first ignition A During the initial activation procedure the combustion parameters must be checked and set ONLY by a Robur TAC In this stage NEITHER the user NOR the installation technician is authorised to perform such operations and in so doing may in validate the guarantee of the appliance The appliance is delivered already regulated for the type of gas requested Anyway the combustion parameters must ALWAYS be checked and set during the first start up ill 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 i 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 A In case of
25. naland 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 Para graph 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 gt 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 off 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 fill continuously with water that may imply the additional introduc tion of oxygen and the consequent dilution of the used inh
26. of operation or reliability caused by filling or top up water please refer to codes and norms about water treatment for thermo hydraulic installations in civil or industrial applications Parameters indicated in Table 5 1 19 must be complied with Table 5 1 Chemical and physical parameters of water an gt 70 Chlorides mg l 1259 f 15 Total hardness CaCO d lt 84 Iron mg kg 059 Copper mg kg 019 Aluminium mg l 1 Langelier s index 0 0 4 Installation user and maintenance manual AY Condensing line AY Series 19 20 5 HYDRAULIC INSTALLATION HARMFUL SUBSTANCES Free chlorine Fluorides 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 A 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 5 19 The way the installation is operated can be the cause of possible degradation of water quality Moreover abnormally massive water top up or reintegra
27. the DDC itself 7 1 PROCEDURE FOR FIRST START UP The initial activation procedure is composed of the following main steps Step 1 preliminary verification of plant compliance Step 2 verification regulation of combustion parameters and first ignition Step 3 regulation of plant operating parameters A The entire procedure for the initial activation of the appliance must only carried out by an authorised Robur Technical As sistance Centre TAC The product s guarantee may be void if the procedure is not carried out by a Robur TAC iE Before leaving the factory the appliance has been thoroughly tested Step 1 preliminary verification of plant compliance The Robur TAC technician must gt 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 specifier Checkpersonally 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 gt Check that the installation is actually compliant as per the Declaration of Conformity provided by the installer to the owner 3 The Declaration of Conformity CERTIFIES that the installation is compliant with current regulations This Declaration is a 27 mandatory document and as such it must be provided by the installer to the owner
28. 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 ie 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 flanged union which can be accessed via the appli ance 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 Installation user and maintenance manual AY Condensing line AY Series 27 28 5 HYDRAULIC INSTALLATION Figure 5 6 Fumes evacuation pipe kit i LEGEND A A roof mounting terminal DN80 S B extension tube DN80 C rain cover DN80 D flanged fitting DN80 on top panel A B C fumes evacuation pipe kit 000000000000009009900000099000000090900000000900000000900000900090000900000000000000000000000090000000090000000000000000000000090900009 fumes kit for exterior configuration B53P SIZING FUMES PIPES FOR TYPE B INSTALLATIONS If the installation requires the combustion products to be conveyed in a type B configuration the flue must be sized with reference to the following table Table 5 4 Fumes evacuation pipe ducting type B 000000090000009090090000009
29. uerdde sienna ada vane aqodd ainjesadiua 1972M Alaaljap 2dHL XOINI qo d aunjejeduue1 juerquue YL 0ZS 0 LAY 54 01 U02 HDS QN3911 ir pealor Sron Pajo w S ves s r 8400 Electric diagram single unit AYOO 120 CONNECTING THE APPLIANCE TO THE MAINS The examples of connection of the appliance to the mains in this paragraph refer to 6 1 single appliance plants 34 6 ELECTRICAL INSTALLATION multiple appliance plants SINGLE APPLIANCE PLANTS The appliance must be connected to a 230 V 1N 50 Hz power supply as follows see example in Figure 6 3 35 56 j You will need the appliance connected hydraulically external electrical panel configured by the installation technician Necessary equipment and materials 1 Make sure that the electrical panel configured by the technician is equipped with a 2 pole circuit breaker with minimum air 7 29 gap of 3mm anda 2A typeT fuses Remove the appliance s front panel and open the electrical panel by removing the bolts securing it Prepare a cable of the FG7 O R 3Gx1 5 type for the power supply to the appliance Locate terminal block MC inside the panel and hook up as shown in the figure On completion restore the appliance to its fully assembled condition BOWN i The insertion of relays or other electrical components inside the General Electrical Panel of the appliance is not permitted 2 Donotactivate
30. user and maintenance manual AY Condensing line AY Series 17 18 5 HYDRAULIC INSTALLATION 5 HYDRAULIC INSTALLATION In this section you will find all the instructions necessary for the hydraulic installation 1 Before realizing hydraulic system and gas supply for the appliance the professionally qualified personnel is advised to read Paragraph 3 1 5 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 hy 2 draulic 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 mainte nance of heating and cooling plants and must be undertaken by professionally qualified personnel in accordance with the manu facturer 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 specifications for the correct supply pressure refer to Paragraph 5 4 23 Theappliance 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 requi
31. 0 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 mm 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 rx0 10O Terminal 2 of the 2 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 con nected to this terminal 4 On completion close the DDC s back panel with the 4 bolts Figure 6 10 CCI DDC electric supply fe N LEGEND S 9 DDC CCI DDC Y AL supply 4 poles connector B 1 clamp and wire for 24 Vac supply 2 clamp and wire for 0 Vac supply g H 3 clamp and wire for ground contact o B required connection DDCTR safety transformer z 230 24 Vac 50 60 Hz 1234 12345662 pppoj 000000 685 o o N I 3 DDC CCI DDC electric supply from external transformer dis Mem iia ids j T If th
32. 0909000009000000000090000000000000909090000900990000090000000000900000000900000900000000000000090000000909090009 Useful residual head Maximum length of straight DN80 pipe sections Equivalent DN80 curve length at 90 Data for sizing type B installation flues 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 T The following other type B configurations are also possible B23P and B33 for specifications see Table 5 6 29 dp 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 configuration as a type C installation The following configurations are permitted C13 C33 C43 C53 C63 and C83 for specifications see Table 5 6 29 To install the appliance in a type C configuration refer to the following technical data table for the sizing of the combustion fumes outlet and combustion air intake pipes SRAOBUF S HYDRAULIC INSTALLATION Table 5 5 Ducting for fumes evacuation and air intake pipes type C Useful residual head Mass of fumes at nominal thermal capacity Mass of fumes at minimal thermal capacity Temperature of fumes at nominal thermal capacity Temperature of fumes at minimal ther
33. 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 off via the appropriate on off command or via the DDC if con nected and in controller mode and wait for the shutdown cycle to terminate When the appliance is off disconnect it from the gas and electricity mains bearing in mind the antifreeze settings via the external circuit breaker GS and the gas valve gt gt gt GUIDELINES FOR THE PREVENTIVE MAINTENACE OPERATIONS In Table 7 2 54 are reported the guidelines for the preventive maintenance operations A 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 09000000000000909000000000000009000000000000000000000000000000900090000000000000900000000900000000000000000000009000000000090090009 Check of the unit GAHP GS WS Visually check of the general condition of the unit and of its air heat exchanger Check the correct operation of the de
34. 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 t 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 final user manual manual 2 supplied with the unit 7 2 MAINTENANCE Correct maintenance prevents problems guarantees maximum operating efficiency of the appliance and allows running costs to be contained i The maintenance operations described in this paragraph must be performed exclusively by the serviceman in charge of the plant or by an authorized CAT Robur Installation user and maintenance manual AY Condensing line AY Series 53 54 7 INITIAL ACTIVATION AND MAINTENANCE b Ele Any operation that regards internal components of units of the appliance must be carried out by an authorized Robur Tech nical Assistance Centre TAC according to the instructions supplied by the manufacturer The efficiency check and every other check and maintenance operation see Table 7 2
35. ERATING POINT Tm70 Tr50 and nominal thermal capacity Efficiency 96 100 6 KEKE Efficiency classes Installation user and maintenance manual AY Condensing line AY Series 10 3 OVERVIEW AND TECHNICAL FEATURES NOx emission class Hot water delivery temperature maximum minimum nominal Hot water return temperature maximum minimum nominal Hot water flow rate nominal maximum minimum Hot water pressure drop at nominal water flow Ambient air temperature dry bulb maximum minimum gas consumption Efficiency at MEAN thermal capacity Tm80 Tr60 methane G20 nominal methane G20 MIN G25 nominal G25 MIN G30 nominal G31 nominal G30 MIN G31 MIN Efficiency at MIN thermal capacity Tm80 Tr60 Efficiency at nominal thermal capacity Tm50 Tr30 Efficiency at 30 of nominal thermal capacity Tr 30 C Efficiency at 30 of nominal thermal capacity Tr 47 C Operational heat loss to jacket Operational heat loss to jacket Operational heat loss to flue Operational heat loss to flue Heat loss in off mode Heat loss in off mode Power supply Voltage 230 TYPE single phase Frequency 50 Hz supply 50 Electrical power absorption Degree of protection Minimum storage temperature nominal 0 185 Maximum operating pressu
36. 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 Pos sible use of glycol antifreeze contained in Paragraph 5 6 25 and in any case the technical specifications 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 appli ance refer to the technical data Paragraph 3 4 9 e 1 The operations necessary for the first activation or regulation of the appliance and of the Direct Digital Controller must be 2 carried out exclusively by an authorized Robur Technical Assistance Centre TAC These operations are described in Section 7550 i The products guarantee is void if initial activation is not carried out by a Robur TAC r The following figures show examples of typical hydraulic circuits composed of a single or multiple appliances m For further information and technical support regarding other configurations contact Robur S p A Presales tel 035 888 111 Installation user and maintenance manual AY Condensing line AY Series 21 22 5 HYDRAULIC INSTALLATION Figure 5 2
37. LJFT blower control connector ELECTRICAL INSTALLATION PWM signal output GND ground input hot water temperature probe connector output hot water temperature probe connector auxiliary temperature probes connector P8 GND L H CAN BUS jumper 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 Controller component legend fuses Installation user and maintenance manual AY Condensing line AY Series 33 OFACIESLIFT ELECTRICAL INSTALLATION 6 9900909009900000090900009000900000090000090000000009090090009090000090000000090000090900000000009000099090000000900000000000090090900909000909 Figure 6 2 Functional diagram
38. ROBUR caring for the environment Installation user and maintenance manual AY Condensing line AY Series 4 star condensation boiler for heating gas fired Revisione J Codice D LBR531 This manual has been drawn up and printed by Robur S p A whole or partial reproduction of this manual is prohibited The original is filed at Robur S p A Any use of this manual other than for personal consultation must be previously authorised by Robur S p A The rights of those who have legitimately filed the registered trademarks contained within this publication are not affected With the aim of continuously improving the quality of its products Robur S p A reserves the right to modify the data and contents of this manual without prior notice INDEX OF CONTENTS OVERVIEW AND TECHNICAL FEATURES eere e ee en seen sese en ssa s sesso sse enss sese enses sesnsssssessssesesssseess 7 3 1 GENERALINEQRIMATIOIN e 32 OVERVIEW OF OPERATION 3 3 TECHNICAL MANUFACTURING CHARACTIERISTICS sicesscssiccsssssssscssssisvecsssisssenssadeetossenisacessoasasnsesd ssooseibcasossssteseecdodenceonsdssensetsbsuscsensincosisnenieseesae 9 34 TECHNICAL DATA n H 9 3 5 DIMENSIONS AND SERVICEIPANEL c 11 4 1 START UP AND SHUT DOWN 4 2 ie ose tpi2laepioec 4 3 RESET OPERATIONS mee a
39. a tures 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 an tenna 1 RS232 serial cable 1 cable with telephone jack 1 CD ROM Robur NETBUS CAN BUS CABLE List of appliance accessories Cable for data communication networks for network connection between DDC and appliance OFICIESLJFT OCVO008 Maximum length 450 m for details see the electrical connections section g OPERATING CODES TROUBLESHOOTING 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 makea note of the indications shown on the display consult the specific list of machine operating codes iil 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 Robu
40. acteristic of the gas being used Example having set in step 15 a CO content of 9 5 for G20 gas at step 18 the reading should be 9 096 9 5 0 5 19 If the difference satisfies the goraco2 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 opera tional configuration After 30 minutes of operation the appliance automatically cancels the preceding forced power mode To anticipate this tim ing select and execute action 25 in menu 2 21 Switch off and completely restore the appliance Figure 7 1 Checking and adjusting the combustion parameters 09000000900000090000000000000000000000000000000900000000000000000900000000000000900000000090000000000000000009000000000900000090000 LEGEND E front panel interior F access hole for OFFSET regulator G access hole for flow rate regulator H front panel exterior L access plug for flow rate regulator M access plug for OFFSET regulator N external side panel Procedure for checking and adjusting the combustion parameters Figure 7 2 Gas valve LEGEND A Cap B Torx wrench TX40 C CO2 adjuster screw D Mains gas pressure fitting Gas valve Honeywell VK 4115V OFACIESLIJIFT
41. ance ACCCUMULATOR BOILER OPTIONAL for hot sanitary water ACS E 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 gt Systems for BLEEDING AIR from the pipes gt DRAIN COCK usually dia for system water PLANT FILLING SYSTEM if automatici filling systems are used it is advisable to carry out a seasonal check of the percentage of monoethylene glycol contained in the plant if present AJ Antifreeze OFICIESILJFT S HYDRAULIC INSTALLATION 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 ina
42. as supplied by the mains see Table 5 2 24 A Supplying gas to the appliance at pressures higher than those indicated above can damage the gas valve resulting in dan gerous situations LPG systems must be equipped with a first 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 Installation user and maintenance manual AY Condensing line AY Series 23 24 5 HYDRAULIC INSTALLATION A LPG may cause corrosion piping and fitting 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 dur ing cold periods It may also be necessary to insulate the gas pipe to prevent the formation of excessive condensate 1 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 0900000900000090900900000000000009090000000900000900900000090000000900090000009009000000000000000000000090000000009000909000900000000000009 AL BG CZ DK EE Fl GR LT
43. ate node e 9 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 o E wires no 6 of CAN BUS cables 2 O 9 Oo O a 5 9 A A EEO eA j E E L c Em n z w Fildes L JBN e Om c O a B Detail of cabling of CAN BUS cable to controller AY10 To connect the CAN BUS cable to the DDC proceed as follows references in Figure 6 15 46 56 2 You will need appliance not powered up Necessary equipment and materials 1 2 3 Remove the front panel of the appliance and the cover of the electrical panel Cut a length of cable long enough to allow it to be installed without kinking 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 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 Pull back the shielding in the sheathe apply electrician s tape to the end of the shielding a
44. cate 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 figure A 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 1 The insertion of relays or other electrical components inside the General Electrical Panel of the appliance is not permitted Do not activate the appliance if the hydraulic plant has not been filled 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 off consent switch a LEGEND SCH controller AY10 S70 Ww HOT consent terminal GEI IN L R common terminal CS consent switch 18 HE H Lj v se 2 v PI THRC THMC TA2 TAL Example of operation consent connection 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 qualified installation technician only 1 How to fit 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 elec
45. contact a Robur TAC or qualified technician for other maintenance require ments see Paragraph 7 2 53 Any repair of the appliance must be carried out by Technical Assistance using only original spare parts l i Failure to observe the indications given above may compromise the operation and safety of the appliance and may invali 2 date 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 gt theinternal circuit dedicated to the combustion unit and factory charged to enable storage down to 30 C 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 microp
46. ction 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 id You will need the display showing 2 20 see point 3 of procedure HOW TO ACCESS THE MENUS Paragraph 4 3 15 1 Turnthe knob clockwise until the display shows parameter 2 24 2 Press the knob to display the flashing force to minimum power request P_H1 3 Press the knob again to execute the forcing The request stops flashing and the display shows 2 24 again The forcing opera tion 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 27 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 Turnthe knob clockwise until the display shows parameter 2 25 2 Press the knob to display the flashing cancel forcing request UnF1 3 Press the knob again to execute the cancel operation The request stops flashing and the display shows 2 25 again The can cel 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 27 5 To exit the menu selection turn the knob clockwise until
47. detail case intermediate node 6 wires J21 jumper open J21 Jumper CAN BUS in CCI DDC board H L GND data signal wires 000000000000000000000009000000000000000000000000000000000000000000000000000000000000000000000000000000000000000900000000090990 Detail terminal and intermediate node jumpers position J21 closed open 2 Prepare the orange connector remove from envelope 3 Cuta 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 figure 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 figure ifthe DDCisan intermediate node on the network also complete step 7 gt ifthe 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
48. e CAN BUS cable has already been connected to the DDC next procedure 3 How to connect the CCI DDC to the appli ance 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 il 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 E 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 OFICIESLJFT 6 ELECTRICAL INSTALLATION 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
49. e 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 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 in directly 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 sufficient 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 i You will need the appliance connected hydraulically single phase water circulator 230 V AC with power absorption less than 700 W Nec
50. eed as described in steps 1 to 5 2 The display will now flash 0 Turn the knob until menu 2 displays the display shows 2 3 Press the knob to access menu 2 the display shows the first of its actions 2 0 or 2 20 menu 2 action 0 or 20 Turn the knob to scroll through the other actions i The user must now only run the action relating to the command indicated in the operating code description in TABLE Ba 9 1 59 Two commands are available reset flame controller action 20 or reset other codes action 21 i Actions 23 24 and 25 are used to regulate the combustion parameters or for gas type changeovers and are thus for use only by the installation technician or Robur TAC Reset flame controller parameter 20 ig You will need the display reads 2 20 as per step 3 1 Press the knob to display the flashing reset request reS1 2 Press the knob again to reset the flame controller The reset request stops flashing and the display shows 2 20 again The reset operation has been performed To exit the menu turn the knob clockwise until 2 E displays and press it to return to the menu selection 27 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 refit the front panel w Reset other operati
51. en areas or areas sufficiently well ventilated and free of combustible powders 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 configuration can ONLY be installed in open areas or areas sufficiently well ventilated and free of combustible powders 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 sufficiently close to each other to be exposed to analogous wind conditions Type C boiler connected with its pipes to a vertical terminal The outlets of the pipes are concentric or sufficiently close to each other to be exposed to analogous wind conditions Type C boiler connected via its pipes and optionally with a fitting 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 sufficiently close to each other to be exposed to analogous wind conditions Type C boiler connected via its separate pipes to two terminals which can be installed in zones at different pressures Type C boiler designed for connection to a system for combustion air supply and combustion product evacuation which is approved and sold separately Type C boiler connected via its pipes and optional
52. ent and materials o 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 fix it See the figure 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 9 168 LEGEND Holes for mounting CCI DDC to panel horizontal 168 mm vertical 158 mm O 9 9 Centre distances of mounting holes for CCI DDC 99 TheDDCs 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 1 The DDC requires a low voltage power supply 24 V with 230 24 V AC 50 60 Hz safety transformer the minimum power 72 requirement is 20 VA Installation user and maintenance manual AY Condensing line AY Series 41 42 6 ELECTRICAL INSTALLATION To power the DDC off a transformer located in an external panel proceed as follows see example in Figure 6 10 42 ide You will need the appliance disconnected from the electricity supply the external electrical panel configured by the instal lation technician Necessary equipment and materials i Make sure that the external electrical panel is equipped with a 23
53. er for system water circulator 400 V AC NO normally open system water circulator control relay system water circulator power switch system water circulator SELV secondary safety transformer ground terminal o 8 cc EQ 52 x ave NO contact system water circulator control terminals voltage free NO contact maximum power ab PHASE NEUTRAL terminals for three phase power 400 V AC 2 oa 2 E g 3 E S a S sas o tt IS EVE n 2597 a coz _ 2 Svc vy gt cosy ZHOS NE AD00v o2g8 roeooad En c FuYU 5 ox o BE E 2 7z o s SRERER 9 92508 a z uc war aan N lt 2e Example of electrical connection of a shared three phase circulator 400 V AC 6 3 CONNECTIONS FOR CONSENT SWITCH OPERATION To operate the appliance requires consent switch for starting up and shutting down the appliance Installation user and maintenance manual AY Condensing line AY Series 40 6 ELECTRICAL INSTALLATION The consent switch installation technician can be an on off switch ambient thermostat programmable timer or other such device To make the connection proceed as follows references to Figure 6 7 40 Soe 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 Lo
54. erate the knob and access the controller s menus and parameters 4 Todisplay the menus just press the knob once the display shows the first menu 0 menu 0 5 The display shows 0 To display the other menus turn the knob clockwise The display will read in order 17 27 37 47 57 67 77 8 and E see 4 1 14 6 Todisplay 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 first 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 confirm 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 i 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 gt 15 To set the parameters of menu 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 i The special key allows the knob of the electronic board to be operated without opening
55. es counterclockwise or increases clockwise the CO content by approxi 2 mately 0 1 33 Once the correct CO 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 CO 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 opera tional configuration After 30 minutes of operation the appliance automatically cancels the preceding forced power mode To anticipate this tim ing select and execute action 25 in menu 2 37 Switch off and completely restore the appliance OFICIESLJFT Figure 7 3 Gas type conversion tube valve connection nut tube air gas mixer connection nut gas valve gas nozzle gasket large on tube valve fitting gasket small on tube air gas mixer fitting air gas mixer INITIAL ACTIVATION AND MAINTENANCE My 00000000000000009000000009000009009000000000000000000000000000000000000000000000000000000900000000000000000000000000000000090 Details of gas changeove
56. essary equipment and materials In this case the circulator s 230 V AC power can be taken directly off 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 OFICIESLJFT 6 ELECTRICAL INSTALLATION A 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 5 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 i The NO Contact terminals are no voltage contacts with maximum power capacity of 700 W These contacts control the 2 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 figure 5 On completion restore the appliance to its fully assembled condition Figure 6 5 Direct con
57. f the controller displays Subsequently if the on off 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 tempera ture and the difference between the two water temperatures see Table 4 2 15 Table 4 2 Operating information Hot outlet water temperature 50 0 Hot inlet water temperature 40 0 Differential Temperature outlet inlet Example of data visualised on display water temperature and differential 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 Tousethe 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 operat ing data temperature delta T regarding the current mode e 9 heating and any active operating codes u E i Remove the front panel by removing the fixing screws 2 Remove the cover of the electrical panel to access the knob 3 Use the special key through the hole to op
58. f the on off com dA mands DDC or other switch before having operated these first With the appliance running also wait for the shutdown cycle to end approximately 3 minutes before shutting off 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 5 59 1 In the event of failure of the appliance and or breakage of any component do not attempt to repair and or restore opera t tion proceed as follows gt deactivate the appliance immediately if permitted and if no condition of danger exists by starting the shutdown cycle via the on off command or DDC and waiting for it to terminate approximately 3 minutes disconnect the appliance from the gas and electricity mains cutting off 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 appropri ate panel gt 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 efficiency 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
59. 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 P Now check the static and dynamic mains gas pressure if the system has multiple appliances this check steps 4 to 10 L need only be done once so long as it is done with the appliance furthest from the mains connection for the other appli ances 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 Ifthe appliance does not switch on remove the side panel N remove the cap L and use a flathead screwdriver through hole G to turn the flow 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 specified at step 7 Now switch the appliance off If the dynamic network pressure does not corresponde to the value stated in Table 5 2 24 with tollerance 15 write dow
60. 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 flashing to indicate that it can be modified 9 Press again to confirm 10 water temperature differential to modify the value turn the knob until the desired value dis plays e g 2 Press again to confirm 2 water temperature differential 10 Thedisplay 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 37 To exit the menu selection screen turn the knob clockwise until E displays press to confirm 0900 H The controller s display now sequentially shows as at the beginning the operating data temperature delta T regarding the current mode e g heating x To modify a parameter in menu 4 to access the menu installation technician only you are first prompted for a password For Ll J the password contact the Robur TAC or Technical Service Department of Robur S p A Tel 39 035 888111 ND SPE The 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
61. ibitor 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 op 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 qualified personnel 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 Power up the DDC if present Check that the hydraulic plant is suitably sized to guarantee the correct water flow Switch the appliance on with the DDC or other consent switches Ascertain whether the appliance requires any maintenance refer to Paragraph 7 2 53 In particular check the operation of the condensate siphon Dn ds pr NO Icing of condensate during the period of disuse can lead to a permanent locked condition In this case the first symptom would be a lack of condensate draining in condensation mode outlet water temperature less than 50 C Installation
62. ications and additions Electromagnetic Compatibility Directive 89 336 EEC and subsequent modifications and additions Low Voltage Directive 89 336 EEC and subsequent modifications and additions Machinery Directive 2006 42 EC UNI EN 677 Specific requirements for condensing boilers with nominal thermal capacity up to 70 kW vvvvvyvyy UNI EN 483 Type C boilers with nominal thermal capacity no greater than 70 kW Information regarding the above EC certifications 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 1 Packing materials must be removed only after the appliance has been positioned on site After removing the packing mate z rials ensure that the appliance is intact and complete Installation of the appliance may only be carried out by professionally qualified personnel by i e firms qualified according to the cur rent legislation of the country of installation Professionally qualified personnel means personnel with specific technical competence in the sector of heating cooling installations and gas appliances
63. imple 3 x 0 75 mm 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 L The ROBUR NETBUS cable is available as an accessory see Section 8 58 CONNECTION PROCEDURE Instructions for the specific operations to be carried out for the connection of the CAN bus cable follow Step A connect the CAN BUS cable to the CCI DDC Step B connect the CAN BUS cable to the appliance E The two steps must done in both cases illustrated in Figure 6 17 48 wiring diagram for 1 DDC connected to a single appli ance 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 specific orange connector supplied with the DDC as shown in Figure 6 12 44 Installation user and maintenance manual AY Condensing line AY Series 43 44 6 ELECTRICAL INSTALLATION Figure 6 12 Orange connector for CAN BUS connection to CCI DDC supplied with CCI DDC ap The DDC is equipped with jumpers that must be moved in order to take on the configurations of terminal node and interme diate node Figure 6 14 45 The DDC is supplied with the jumpers CLOSED detail A Figure 6 14 45 Figure 6 13 Connection from CAN BUS to connec
64. ing the isolation valve vovv cut off electrical power opening the main breaker upstream of the appliance to be provided by the electrical installer in an ap propriate panel gt ask for assistance to professionally qualified personnel from a telephone distant from the appliance i Moving parts also during the appliance s start up and shut down cycles Do not remove guards Make sure the appliance 39 cannot be started up inadvertently A POISONING HAZARD Make sure the flue gas components are tight and compliant with established regulations After any intervention on these parts check for tightness A 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 A ELECTROCUTION HAZARD Use only approved components for the electrical connections as specified by the manufacturer Disconnect the electrical power supply before working on the appliance s internal electrical equipment electrical panel motors control board etc Make sure the appliance cannot be started up inadvertently i The electrical safety of the appliance is ensured only when it is correctly connected to an efficient grounding system com pilant with current safety regulations i DAMAGE DUE TO AGGRESSIVE SUBSTANCES IN THE AIR SUPPLY Hydrogenated hydrocarbons which contain chlorine and fluorine compounds will increase the cor
65. 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 remove the clamp disconnect the plastic siphon pipe and fill it with 0 2 litres of water reconnect the plastic pipe and secure it with its clamp restore the appliance A If the appliance is operated with the siphon empty there is a risk of leaks of combusted gas A ed OFICIESLJFT S HYDRAULIC INSTALLATION 5 6 FILLING THE SYSTEM CIRCUIT APPLIANCE After having completed all hydraulic gas and electrical connections the installer can proceed filling the hydraulic circuit observing the following steps Activate the automatic air vent valves on the system circuit Fill the hydraulic circuit ensuring the minimum water content in the plant and adding if necessary to the plant water free of impurities a quantity of monoethylene glycol in proportion with the minimum winter temperature in the installation zone see table 5 3 25 gt Bring the plant to the correct pressure making sure that the pressure of the water i
66. liances hydraulically connected the external electrical panel configured by the installation techni cian Necessary equipment and materials i Make sure that the electrical panel configured by the technician is equipped with a 2 pole circuit breaker with minimum air 2 gap of 3mm and two type T fuses of suitable rating On each appliance remove the front panel and open the electrical panel by removing the bolts securing it For each appliance provide a FG7 O R 3Gx1 5 type cable Locate terminal block MC inside the panel of each appliance and hook up as shown in the figure On completion restore the appliances to their fully assembled condition S N Installation user and maintenance manual AY Condensing line AY Series 35 36 6 JJ ELECTRICAL INSTALLATION 3 The insertion of relays or other electrical components inside the General Electrical Panel of the appliance is not permitted Do not activate the appliance if the hydraulic plant has not been filled Figure 6 4 connection to electrical mains 230 V 1N 50 Hz LEGEND MC GS F N Ground L 230V 50 Hz power terminal block Master 2 pole power switch Fuse s Neutral terminal ground terminal single phase line terminal Example of connection of more than one appliance to the mains 1 Disconnect the appliance from the electrical power supply via the external disconnecting switch only after having per formed the shutdown cycle via th
67. ly via a fitting to an air supply terminal and connected to a dedicated or collective flue Description of possible appliance installation configurations 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 5 9 b If the appliance is connected to a DDC follow the instructions given in the DDC manuals exclusively To configure the hydraulic parameters access menu 3 of the controller b 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 configuration Table 5 7 Menu 3 parameters Hot water thermostat control selection Hot water setpoint Hot water temperature differential EXIT MENU Description of parameters gt 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 Installation user and maintenance manual AY Condensing line AY Series 29 30 HYDRAULIC INSTALLATION gt Hot water setpoint parameter 161 this parameter sets
68. mal capacity co content at nominal thermal capacity Data for sizing type C air fumes installation pipes Examples of the two principal type C configurations C13 using a concentric DN60 100 90 C curve the maximum permitted extension with concentric DN60 100 straight pipe sec tions 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 i 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 The following table gives a brief description of the possible installation configurations Table 5 6 Installation configuration types B and C 0090000090900009000009090900009090000000000000009000000000000000009000000000000000000000000000000000000009000000900000000000000099090 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 configuration can ONLY be installed in open areas or areas sufficiently well ventilated and free of combustible powders Evacuation of combusted gas into the flue combustion air drawn directly from the room in which the appliance is installed This configuration can ONLY be installed in op
69. menu 4 parameter 163 COMPLETE PARAMETERS Incomplete functional parameters menus 3 4 and 5 The code persists until operating parameters are entered and completed Contact authorised TAC E80 VALID PARAMETERS Invalid parameters menu 6 or damage to param eter memory Reset occurs automatically when correct parameters are entered If the code persists contact authorised TAC if the memory is dam aged the controller must be replaced u81 u 82 BANK 1 AND BANK 2 PARAM ETERS 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 E81 82 BANK 1 AND BANK 2 PARAM ETERS INVALID Bank 1 data invalid Bank 2 data invalid the pro gram has failed to copy the data from the correct page to the other page Contact authorised Technical Assistance E84 FAULTY TRANSFORMER CON NECTION OR 24 V AC FUSES Danneggiamento dei 2 fusibili di ingresso 24 0 24 Vac oppure interruzione del filo 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 E85 INCORRECT MODULE TYPES from menu 6 The set module type from menu 6 does not cor respond to the one managed b
70. n 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 specifications 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 Fita 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 CO content percentage of the combustion products is within 0 2 of the characteristic value for the gas being used 16 Ifthe 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 specified in this Paragraph Step 2 Installation user and maintenance manual AY Condensing line AY Series 51 Z INITIAL ACTIVATION AND MAINTENANCE 18 With reference to Table 7 1 53 and the fumes analyser reading check that the difference between the CO percentage ob served in step 15 and the current reading corresponds to the gets 52 char
71. n 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 pres ence of oxidising agents such as oxygen are transformed into corresponding acids This transformation into acids increases the corrosive nature of the fluid 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 ini tially 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 dp 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
72. na A ARAE AORAR 4 4 4 5 5 1 GENERAL INSTALLATION PRINCIPLES 518 5 2 POSITION OF THE APPLIANCE 16 5 3 HYDRAULIC CONNECTIONS 4 19 5 4 GAS SUPPLY eren 23 5 5 CONDENSATE DISCHARGE 4 24 5 6 FILLING THE SYSTEM CIRCUIT APPLIANCE 4 25 5 7 FILLING THE APPLIANCE S INTERNAL CIRCUIT 425 5 8 EXHAUST FLUE GAS B GGG Gv vB R S 26 5 9 PROGRAMMING OF HYDRAULIC PARAMETERS csssscssscossssscosssastcssaccassasscnssscotosasnsuesntasnssosissactossessoacsonasesteboacbisesdasoaseoiorscesonstosssebbashcebbsegieasene 29 ELECTRICAL INSTALLATION scccssssssoees 32 6 1 CONNECTING THE APPLIANCE TO THE MAINS 34 6 2 ELECTRICAL CONNECTIONS FOR THE SYSTEM CIRCULATOR 30 6 3 CONNECTIONS FOR CONSENT SWITCH OPERATION 39 6 4 USE OF THE CCI DDO iicet trees 40 INITIAL ACTIVATION AND MAINTENANCE 50 7 1 PROCEDURE FOR FIRST START UP s 50 7 2 MAINTENANCE eee 53 7 3 ap tzelc mee 54 OPERATING CODES TROUBLESHOOT ING eene eene eene enero sense en eos en eene soe en esse enesosesseses ese DO 9 1 OVERVIEW AND OPERATING CODES TROUBLESHOOTING Installation user and maintenance manual AY Condensing line AY Series 1 PREFACE 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
73. nel con cerned are advised to read Paragraph 3 1 7 it provides important information regarding installation safety and references to current regulations A 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 AY70 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 LEGEND see table below QA AY 10 A GND L H n n n n O O Olpg ENC amp 9 eL SJ oda oa nn na P THRC THMC TA2 TAI Main components of the on board controller Table 6 1 AY10 and S70 controller components COMPONENTS OF CONTROLLER S70 limit thermostat connector gas solenoid valve connector gas valve ON indicator lamp connector flame controller connector TF fumes thermostat connector PD circuit water differential pressure switch connector Al 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 AY 10 OFICIES
74. ng codes parameter 21 ide You will need the display reads 2 20 as per step 3 1 Turnthe knob clockwise until action 2 21 displays 2 Press the knob to display the flashing reset request rEr1 3 Press the knob again to reset the operating code The reset request stops flashing 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 Toexitthe menu selection turn the knob clockwise until E displays and press it to exit il At this point if the display does not signal any other operating codes put away the special key replace the electrical panel cover and refit the front panel 4 4 OPERATING SETTINGS 1 At the moment of installation the appliance is set up by the installation technician for best operation according to the type 2 ofplantinstalled Subsequently it is possible to modify the operating parameters but this is not recommended if not in pos session of the necessary knowledge and experience required to ensure the appliance s performance The user modifiable parameters only if the appliance is not controlled by a DDC are those in menu 3 of the controller as follows gt parameter 160 thermostat control parameter 161 setpoint gt parameter 162 differential H These are hydraulic parameters and expert knowledge is required to set them b
75. onic board and how to reset them refer to the list of operat z ing codes contained in Table 9 1 59 t 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 t 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 flame 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 flame controller and displays the following operating code E 12 flame 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 flame control unit via menu 2 of the controller the procedure is illus trated 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
76. or incorrect disposal of glycol antifreeze It is equally important to recall that the use of monoethylene glycol modifies the thermophysical characteristics of the water in the plant and in particular its density viscosity and average specific heat Always check the date of expiry and or degradation of the product with the supplier Table 5 3 5 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 specifications 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 filling the hydraulic circuit 0900000909009900000909000090900000000090000009000000000000000900000000000000009000000000000000000900000000000000000000000000009909900 WATER GLYCOL MIXTURE FREEZING 3 C TEMPERATURE PERCENTAGE OF INCREASE IN PRESSURE DROPS _ 5 7 FILLING THE APPLIANCE S INTERNAL CIRCUIT L 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 i The antifreeze function in order to protect the internal circuit
77. ostat a programmable timer or one or more voltage free contacts controlled by another process For details about the type of on off command installed contact the plant s electrical installation technician Start up Switch on the appliance by means of the on off command placing it in the ON position Shut down Switch off the appliance via the on off command placing it in the OFF position i The shutdown cycle takes approximately 3 minutes to complete hm A The on off command is essential Do not switch the appliance on or off 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 i If the appliance is connected to a DDC running in controller mode the appliance is started up and controlled exclusively by 2 the DDC gt 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 fitted Operating codes generated by the controller can be reset with the controller itself or from the DDC if fitted or where possible i For a description of the operating codes generated by the electr
78. pliance conditions exist the TAC must carry out the initial activation A 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 gt appliance installed in improper configuration e g type B in closed and insufficiently ventilated area gt appliance installed close to combustible substances or surfaces or in any case in conditions of bad accessibility or not allowing safe maintenance operations OFICIESLJFT d INITIAL ACTIVATION AND MAINTENANCE control of switching on and off of the appliance not via the DDC but via the external switch connecting the appliance to the power supply mains GS fitted by the electrical installation technician on a suitable panel damagesor failures of the appliance due to transportation or installation gt smell of gas due to probable leaks from the plant itself and in any case all situations that are due to non compliant plants con sidered after on site evaluations potentially hazardous X Plant anomalies If any of the following situations exists the authorized technician may carry out the first start up at his choice but the appliance must be left off 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
79. port the weight of the appliance gt Installation at ground level If a horizontal base is not available see also Supports and levelling it is necessary to create a flat 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 gt Installation on a terrace or roof Position the appliance on a levelled flat surface made of fireproof 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 flexible connections anti vibration joints between the appliance and the hydraulic and gas supply pipes 1 Avoid placing the appliance on the roof directly above locals requiring quietness M 4 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 OFICIEILJIFT 5 HYDRAULIC INSTALLATION Minimum clearances are required for maintenance accessibility The fumes outlet terminals must be in
80. 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 flash 07 Turn the knob until menu 3 displays the display shows 3 or menu 4 the displays shows 4 Forexample to set the parameters of menu 3 1 The display shows 3 Press the knob to access the menu the display shows the first 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 flash ing to indicate that it can be modified 3 Press again to confirm 1 outlet water thermostat control to modify the value turn the knob until 0 displays press to confirm 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 flashing to indicate that it can be modified 6 Press again to confirm 60 water temperature setpoint to modify the value turn the knob until the desired value displays e g 40 press again to confirm 40 water temperature setpoint 7 The display now shows the current parameter 3 75 or 3 161 again the parameter
81. r Technical Assistance Centre when in structed to do so If after performing these operations the appliance does not start first carry out the following simple checks ensure that the external disconnecting switch fitted 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 checkthat 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 Cen tre TAC informing it of the Machine Code that has arisen disconnect the appliance from the gas and electricity supply cutting off the gas supply by means of the appropriate tap and electrical power via the external master power switch Wait for the TAC staff 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 firmware 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 firmware version 3 106 E 100 FLAME RESET FAULTY The flame cont
82. r procedure Installation user and maintenance manual AY Condensing line AY Series 58 8 ACCESSORIES 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 ANTIVIBRATION MOUNT kit FOR BASE Kit of 4 non adjustable anti vibration feet for installation on the beams of the base ONTVO008 For multiple units ONLY For the mount positioning spacings see the dimen sional drawings PLANT ELECTRICAL PUMP Centrifugal pump for the circulation of water in the hydraulic plant OPMPO00 For cold and hot water HYDRAULIC SEPARATOR Separator for balancing hydraulic cir cuits with automatic air vent drain valve and insulation OSPROOO Maximum water flow rate 15 m 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 OCRMO007 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 temper
83. re Water content inside the apparatus HOT SIDE Water fitting TYPE thread 11 4 Gas fitting TYPE M thread 3 4 Fume outlet Type of installation B23P B33 B53P C13 C33 C43 C53 C63 C83 Diameter X 80 Residual head 100 Product configuration B53P width 410 height 1280 depth 530 In operation AYO0 120 operational and installation technical characteristics Table 3 2 Table of pressure drop of a single unit AY serie 71 0900000000000090900000000000000000090000000000000000000000000000900900000000000000900000000900000000900000000000000000900000000000009 1008 0 066 1198 0 085 1398 0 106 OFICIESLJFT 3 OVERVIEW AND TECHNICAL FEATURES 3 5 DIMENSIONS AND SERVICE PANEL Figure 3 2 Dimensional drawing of model AYOO 120 Hi E ip o Y I i en N n iN E e E N o 3 Co i h f y ofi v i nj m Y Y 530 L 410 LEGEND Series AY model AY00 120 AYOO 120 front and RH side views dimensions in mm Installation user and maintenance manual AY Condensing line AY Series 3 OVERVIEW AND TECHNICAL FEATURES Figure 3 3 SERVICE PANEL Series AY AY Condensing line
84. re any particular protection from the weather Noobstruction or overhanging structure protruding roofs eaves balconies ledges trees may obstruct the exhaust fumes out let at the top of the appliance Donotinstall the appliance in configuration B in the immediate vicinity of flue 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 Ifthe appliance is installed near buildings make sure it is not on the dripping line from gutters or similar Acut off valve and vibration damping coupling must be fitted 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 3 Packing must only be removed upon final installation hm 3 When unpacking the appliance do not remove the protective cap on the top panel as this can allow dirt and water to enter theinterior 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 T The dimensions and weight of the appliance are given in Paragraph 3 4 9 Supporting base Always place the appliance on a levelled flat surface made of fireproof material and able to sup
85. rocessor 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 avail able as an accessory For instructions regarding the use configuration and programming of the DDC refer to the two manuals supplied with the unit e 1 DDC configuration programming operations must be carried out by an authorised Robur Technical Assistance Centre TAC 32 during initial activation procedures and according to the instructions supplied by the manufacturer SRAOBUFT 3 OVERVIEW AND TECHNICAL FEATURES Figure 3 1 CCI DDC AY00 120 description and general characteristics the appliance see Figure 3 2 11 is a B53P type high efficiency boiler star efficiency class as per Directive 92 42 CEE The appliance is a Range Rated boiler the power delivery of the appliance can be adapted to the real system requirements by regu lating the nominal gas flow nominal thermal input The appliance which can produce hot water up to 80 C is suited to installation in all hot water production systems for heating sani tary 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
86. rol unit reset circuit is faulty Contact authorised Technical Assistance The limit thermostat is open This only happens if the flame controller is on and the gas solenoid E101 LIMIT THERMOSTAT valve is excited the thermostat is connected in Contact authorised Technical Assistance series with the solenoid valve power supply FUMES THERMOSTAT AND OR INTERNAL EXCHANGER The fumes thermostat and or the internal ex u 102 THERMOSTAT changer thermostat are interrupted Contact authorised Technical Assistance FUMES THERMOSTAT AND E102 ORINTERNAL EXCHANGER u 102 persistent for 1 hour Contact authorised Technical Assistance THERMOSTAT E103 PEANG CONTROLLER NOT The auxiliary controller S70 is not present Contact authorised Technical Assistance E105 HIGH AMBIENTTEMPERATURE The ambient temperature is HIGH This only haP Automatic on termination of originating event pens when the appliance is operating The ambient temperature is LOW This only hap me E E 106 LOW AMBIENT TEMPERATURE pens when the appliance is operating Automatic on termination of originating event The system water differential pressure switch is WATER PRESSURE SWITCH HOT closed while the appliance is running in cooling u107 ONLY CIRCUIT mode This only happens when the appliance is Automatic on termination of originating event installed in a hot cold system Automatic when the flame controller attempts igni
87. roper 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 fitted 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 fitted on the gas supply line EXPANSION TANK on system common circuit or each individual appliance vv wv NN Yy the appliance is equipped with its own expansion tank on the machines 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 figures for reference mentioned above gt WATER CIRCULATOR on system common circuit or each individual appliance chosen to meet the system specifications p gt 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 appli
88. rosion of the unit Make sure the air supply is free of aggressive substances i ACID CONDENSATE Drain out the condensate produced during combustion as indicated in paragraph 5 5 24 i EXPLOSIVE FLAMMABLE MATERIALS HAZARD hm Do not use or store flammable materials paper solvents paint etc in the vicinity of the appliance i SUGGESTIONS FOR THE CLIENT be Installation user and maintenance manual AY Condensing line AY Series 2 SAFETY WARNINGS Stipulate a maintenance contract with an authorised specialist contractor for the annual inspection of the appliance and mainte nance when needed Maintenance and repairs may only be done a contractor legally authorised to work on gas appliances and equipment Only accept and use original spare parts OFICIESLJFT 3 OVERVIEW AND TECHNICAL FEATURES 3 OVERVIEW AND TECHNICAL FEATURES In this section you will find 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 certified and conforms with all essential requirements of Gas Directive 90 396 EEC and subsequent modifications and additions Efficiency Directive 92 42 EEC and subsequent modif
89. s for which it is designed the gas supply system and water distribution system are sealed 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 A Check that no safety and control devices are excluded by passed or not properly working Initial activation procedure The complete procedure for the first 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 i Warranty could be invalidated if the first start up is not carried out and validated by an authorized technician Installation user and maintenance manual AY Condensing line AY Series 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 off of the appliance must be carried out exclusively via a switch located on the on off command circuit If the appliance is to be connected to a Direct Digital Controller DDC available as an accessory control of activating and deactivat ing the appliance must be performed exclusively through the DDC itself 1 The appliance must never normally be switched on and off by shutting off the power supply upstream o
90. s pulled back detail A Pull the orange connector detail D out of socket P8 on the controller 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 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 Fit the orange connector with wires attached into the P8 socket on the board Fix the CAN BUS cable or two cables according to the type of node being connected to the cable fixing bracket so that the rolled back sheathing makes solid contact with the metal bracket The cable should be secured against pulling out Now depending on the type of node being configured 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 figure Jumpers OPEN If the appliance is a terminal node on the network wi
91. smuch it is also used to protect the machine s electronics during normal operation L 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 i The antifreeze function in order to protect the internal circuit actuates the dedicated water circulator so as to keep the 27 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 i It is therefore necessary to ensure a continuous supply of electricity and gas to the appliance throughout the whole of the 2 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 E 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 E 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
92. stalled 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 e LEGEND e x ME RI dimensions in mm o oO CO 0909000090900009000000900009000000000090000009090000000000000000900900000090000000900000009000000009000900000009000000900900000000090000009909909 sample minimum clearances 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 gt If glycol antifreeze is to be used see Paragraph 5 6 25 DO NOT USE galvanised pipes or pipe fittings as they are subject to potential corrosion phenomena when glycol is present gt fusing 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
93. t be kept out of the reach of children as they are potentially dangerous i The appliance must only be used for the purposes for which it has been designed Any other use is considered inappropriate 2 and therefore dangerous The manufacturer does not accept any contractual or extra contractual liability for any damage caused by improper use of the appliance 1 Frequent topping up of the hydraulic with water can result in damage due to scale and corrosion depending on the quality C39 ofthe water being used Make sure the system is water tight and that the expansion tank is operational i Concentrations of chlorides or free chlorine in the circuit above the values given in Table 5 1 19 will damage the unit s 29 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 A 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 qualified personnel If you smell gas gt do not use electrical devices such as telephones multimeters or other equipment that can cause sparks next to the appliance shut off gas supply clos
94. th no 3 wires in the orange connector set the jumpers as shown in detail A of the figure Jumpers CLOSED OFACIESLJFT 6 ELECTRICAL INSTALLATION Figure 6 16 detail of wires and jumpers J1 appliance terminal intermediate node LEGEND A detail of terminal node case 3 wires J1 jumper closed SCH controller AY 104 570 B detail of intermediate node case 6 wires J1 jumper open J CAN BUS jumper on AY10 controller H L GND data signal wires Detail of terminal and intermediate node jumper position J1 closed open 12 Now close the electrical panel and refit the front panel of the appliance Installation user and maintenance manual AY Condensing line AY Series 47 48 6 ELECTRICAL INSTALLATION Figure 6 17 CAN BUS connection for single appliance systems SE AEE FEDE z 5 a 8 2 6 _9 Fai P THRC THMC TA2 TAL LEGEND J21 CAN BUS jumper on DDC board DDC digital control panel A terminal node connection 3 wires J1 and J21 closed SCH controller AY104 S70 H L GND data signal wires J1 CAN BUS jumper on AY10 controller CAN BUS cable connection between DDC and one appliance OFACIEILIFT ELECTRICAL INSTALLATION Figure 6 18 CAN BUS connection for multiple appliance systems Ter Se aadwnr 7 xd N _ UadO f S8JIM 9 uoneuuoo epou p w1 U q J9 04 U0D OL AY UO Jaduun sng NYD ur paso 0ZS 0 LAY J9 o11u05 HDS Zf pue
95. the appliance if the hydraulic plant has not been filled Figure 6 3 connection to electrical mains 230 V 1N 50 Hz d LEGEND N MC power terminal block i GS gs Master 2 pole power switch i te 3 jf Fuse s y eS o N ee N Neutral terminal l i oi Ground ground terminal I E i oo zL single phase line terminal l o gt p 4 S eu l DOO MII C DWN L l uc ANE E 0090000090009900090090900009000009000009000000900900000090000000000000000090000000009000000000000000000000000000090000000000000000990990 Example of connection of no 1 appliance to the mains i D Disconnect the appliance from the electrical power supply via the external disconnecting switch only after having per 2 formed the shutdown cycle via the DDC or consent switch and having waited for it to terminate approximately 3 minutes A 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 app
96. the cable to orange connector refer to detail B in the figure Then proceed to point 8 8 Fit the orange connector with the wires attached first 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 Installation user and maintenance manual AY Condensing line AY Series 45 46 6 ELECTRICAL INSTALLATION Figure 6 15 Connection of CAN BUS cable to connector P8 on controller AY10 0900900090009000909000909900090000090900900090900000000009009000900900000900000000900000900900000009000000090000000900000000000090090900909090009 LEGEND example of connection of 2 CAN BUS cables the appliance is an intermedi
97. 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 refit 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 099000000090000900900000900909000009090000090090000000900000900900009009090000000900900009000900000900090000000900000900090000000000000090909 Reset flame controller arrest Reset other operating codes Timed forcing to minimum power Timed forcing to maximum power Stop power forcing EXIT MENU Menu 2 actions Installation user and maintenance manual AY Condensing line AY Series 15 16 4 NORMAL OPERATION i The general operating codes of the controller can be reset with functions 20 and 21 or via the DDG if running in controller i 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 Toaccess menu 2 ide You will need the controller display shows the operating data temperatures delta T etc or operating codes u E cor responding to the signal in question u E in sequence 1 See procedure HOW TO ACCESS THE MENUS Paragraph 4 2 14 and proc
98. the manual deals with the AYOO 120 model hereinafter called appliance of the AY Series and is intended for use by gt final users for the operation of the appliance according to their own requirements 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 asection that describes all the operations necessary for the first start up and for the gas change of the appliance as well as the main maintenance operations gt an ACCESSORIES section with a description of accessories available and their respective reference codes IN CASE one or more APPENDIX sections in which are reported some specific information for a particular country Definitions meaning of terms and icons APPLIANCE 4 star condensation boiler Robur model AYOO 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 A DANGER 3 WARNING hm 09999 NOTE id START OF OPERATING PROCEDURE REFERENCE to another part of the manual or other document OFICIESLJFT 2 SAFETY WARNINGS 2 SAFETY WARNINGS A Packing items plastic bags polystyrene foam nails etc mus
99. the water temperature that when reached causes the appliance to be deactivated gt Hot water differential parameter 162 This parameter represents an interval in degrees that when added to the set point de fines the temperature at which the appliance is reactivated Heating mode The tem appliance heats the water until it reaches the setpoint temperature The appliance then switches off This means that the water perature slowly drops to the setpoint 4 differential temperature At this point the appliance turns back on For example if we set the following values Thermostat control 0 read INTAKE water temperature gt Setpoint 40 0 C Differential 2 0 C The ANAWN gt The appliance will behave as follows the water temperature rises heating the intake water temperature reaches 40 C setpoint The appliance switches off the system water temperature slowly drops loses heat to the environment the intake water temperature reaches 38 C setpoint differential the appliance turns back on heating starts again The cycle is repeated following instructions give a detailed description of how to configure the hydraulic parameters in menu 3 or menu 4 on the machine s controller Hydraulic parameter settings E io You will need the controller s display sequentially shows the operating data temperature delta T regarding the current mode e g heating Special key
100. tion again solenoid valve excited maximum 4 attempts or after 5 minutes Uia FLAME CONTROLLER FAULT The burner does not light of persistence in this case ignition has failed and a new event has occurred after u112 was reset run checks Flame controller arrested failure to ignite burner ARREST OF FLAME CONTROL e Reset via the controller menu 2 parameter 20 or via DDC If the E112 UNIT ae attempts to ignite the burner have code persists contact authorised TAC Lo stato del pressostato non corrisponde allo F y MACHINE INTERNAL CIRCUIT ae Automatico ed avviene se si ha corrispondenza di stato tra il circo WU WATER PRESSURE SWITCH stato del circolatore acqua del circuito interno itor e il pressostato differenziale della macchina Carry out appropriate checks Reset via the controller menu 2 E127 Weste tH iei d u 127 persistent for 10 minutes parameter 21 or via DDC If the code persists contact authorised Installation user and maintenance manual AY Condensing line AY Series 59 60 9 OPERATING CODES TROUBLESHOOTING FLAME CONTROLLER ON AND ARRESTED The flame controller is arrested E 12 but the gas solenoid valve is excited In this case the flame controller is de excited Reset via DDC or via the controller menu 2 parameter 20 If the code persists contact authorised TAC GAS SOLENOID VALVE WITHOUT ELECTRICAL POWER Gas solenoid valve is off for 5 seconds with flame con
101. tion can cause a drift of chemical or physical above mentioned parameters Reintegration should not exceed 596 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 aggres sive 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 p
102. tor P8 000000000000009000000000000000000000000000000000000009000000000000000000000000000000009000000000000000000000000000000000000009 LEGEND A Insulating tape to protect board shield B CAN BUS cable wires C CAN bus cable shield D terminal and screw for fixing E E Aira 00000000000009090900000000000000000000000000000000000000000000000000090000000000000009000000000090000000000000000000000009000009 Connection detail of cable CAN BUS To connect a CAN BUS cable to a DDC proceed as follows references in Figure 6 14 45 id You will need DDC not powered up Necessary equipment and materials 1 Depending on the type of node being configured set the DDC s jumpers as shown in detail A or detail B in the figure 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 gt ifthe 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 figure Jumpers OPEN gt 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 figure Jumpers CLOSED OFICIEILJFT 6 ELECTRICAL INSTALLATION Figure 6 14 detail wires and jumpers J21 terminal intermediate node CCI DDC JUMPER JUMPER A J21 J21 LEGEND A detail case terminal node 3 wires J21 jumper closed DDC CCI DDC B
103. tor screw reduces clockwise or increases counterclockwise the percentage of CO by approxi mately 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 specified 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 difference between the CO percentage ob served in step 15 and the current reading corresponds to the delta CO characteristic of the gas being used Example having set in step 23 a CO content of 9 5 for G20 gas at step 28 the reading should be 9 0 9 5 0 5 29 Ifthe difference satisfies the delta CO 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 Opentheinternal 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 CO content whose value relative to the value red at step 23 satisfies the requirement of the Table regarding the characteristic delta CO for the gas being used see example above and observe the following instructions 1 j 1 8 turn of the OFFSET regulator screw reduc
104. trical connections The following connectors are required 4pole connector part reference AL for 24 V AC power gt 6 pole CAN BUS connector part reference P8 for connecting the DDC with the appliance OFACIESLJFT 6 ELECTRICAL INSTALLATION Figure 6 8 CCI DDC STA el 183456 Pe9 pBooooo 0000 000000 D D E AL GE P8 LEGEND P8 CAN network connector orange STA ambient temperature probe 2 pole connector SPC 232 serial connection to PC 9 pole connector SAE external alarm systems 3 pole connector A mounting holes CC DDC AL power supply 24 V AC 4 pole connector E Encoder CE external consents 6 pole connector D Display 0000000000000009000000000090000009000000000000000000900000000000000000000000000000000000000000000000000000090000000000000009090 Front and rear views with detail of electrical connections 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 A Before installing the DDC disconnect the appliance from its power supply with the power switch in its electrical panel 1 How to fit the CCI DDC The DDC in indoor installations must be applied to a panel as follows see Figure 6 9 41 ide You will need the appliance and the DDC disconnected from the electricity supply Necessary equipm
105. trol of independent circulator dux 2 c ML LEM LL cM a LEGEND SCH controller AY10 S70 NO contact system water circulator control terminals voltage free NO contact em M ema HAHA o Bes maximum power absorption 700 W B 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 lglg olga 1 1 1 1 D 1 1 1 1 1 1 1 Pi THRCTHMC TAS TAL 1 D T 1 1 1 j 1 1 1 j 1 1 1 1 1 i 1 1 1 PW Example of circulator appliance electrical connection with single phase circulator 230 V AC power less than 700 W e If the circulator s power is equal to or greater than 700 W the installation technician must make the following modifica tions see figure gt point 3 lt lt make the connections as shown in the example but installing a relay for the control of the pump managed via NO contact gt gt Then gt point 4 Locate and open jumper J2 as shown in detail A jumper open in the next figure 6 6 39 gt gt i D Fit the relay inside the external electrical panel provided by the installation technician w 4 i D The insertion of relays or other electrical components inside the General Electrical Panel of the appliance is not permitted 2 Do not activate the appliance if the hydraulic plant has not been
106. troller on Automatic when at least of the following conditions obtains and only if the E 101 condition has not been forced flame controller off or solenoid valve excited GAS SOLENOID VALVE WITHOUT ELECTRICAL POWER The gas solenoid valve has been off for more than 10 minutes with the flame controller on or E 101 is keeping the flame controller on Or also in the case that with the flame off but flame 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 DELIVERY WATER TEMPERA TURE PROBE FAULT MACHINE CIRCUIT MODULATING BLOWER FAULT The delivery water probe on the internal circuit machine circuit is faulty The blower speed is out of range Contact authorised Technical Assistance Reset occurs automatically 20 minutes after the operating code is generated MODULATING BLOWER FAULT u_36 code generated three times in 1 hour of operation Contact authorised Technical Assistance SYSTEM CIRCUIT WATER PRES SURE SWITCH Insufficient water flow SYSTEM CIRCUIT WATER PRES SURE SWITCH Insufficient water flow The system circuit water circulator is on and the system circuit water differential pressure switch is open Event u_175 has been generated 5 times since the appliance was powered up or code u_175 has been active for 1 hour Automatico ed avviene se il
107. tter 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 Undo the nut A connecting the gas pipe to the gas valve C Slacken off the nut B connecting the gas pipe to the air gas mixer G Turn the gas pipe so as to enable access to the gas nozzle D inside the flanged union on the gas valve outlet C Replace the nozzle D P Each nozzle is stamped with a code to identify it see Table 7 1 53 RUN 6 Restore the appliance making sure to reposition and replace if damaged the gaskets E F affected by the procedure A During the procedure a number of broken seals must be restored and regulators sealed i 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 Ifthe value of the parameter 45 doesn t match the value specified 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
108. vice used for monitoring the water flow Check the 96 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 y Download the hystorical events y y 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 A 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 090009000090000900900000000900000900000000009000000090000000000000009000000900000000090900000900000000000000009000000900900000009000009 Check of the unit Clean the combustion chamber Clean the burner Clean the electrodes of ignition and flame sensing
109. ving 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 A 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 i The NO Contact terminals are no voltage contacts with maximum power capacity of 700 W These contacts control the 32 circulator shutdown delay 2 minutes after appliance shutdown Check the position of jumper J2 as follows 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 figure 2 On completion restore the appliances to their fully assembled condition i The insertion of relays or other electrical components inside the General Electrical Panel of the appliance is not permitted 2 Do notactivate the appliance if the hydraulic plant has not been filled OFICIESLJFT 6 ELECTRICAL INSTALLATION Figure 6 6 Direct control of shared circulator motor protector or maximum current differential circuit break
110. y the controller Contact authorised Technical Assistance E 86 E87 E88 E89 MEMORY TEST UNSUCCESSFUL Processor error Contact authorised Technical Assistance E90 AMBIENT TEMPERATURE SEN SOR DEFECTIVE Interruption or short circuit of ambient tempera ture sensor Contact authorised Technical Assistance E91 CONTROLLER DEFECTIVE Numero seriale di scheda assente e o codice di versione hardware assente e o chiave di criptazi one assente o errata oppure i dati di calibrazione sono assenti o inconsistenti OFICIESLJFT Contact authorised Technical Assistance ISO 9001 2000 VERSION ISO 14001 Robur mission Robur is dedicated to dynamic progression in research development and promotion of safe environmentally friendly energy efficiency products through the commitment and caring of its employees and partners GFICELIF caring for the environment Robur Spa tecnologie avanzate per la climatizzazione Via Parigi 4 6 24040 Verdellino Zingonia Bg Italy T 39 035 88811 1KF 39 035 884165 www robur it robur robur it 10 03 2014 Codice D LBR531 14 MCM SDC 007 Revisione J

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