Robur AY00-120, Installation, User And Maintenance Manual

Page 1: ...Installation user and maintenance manual AY Condensing line AY Series gas fired 4 star condensation boiler for heating ...

Page 2: ...e 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 ...

Page 3: ...NSTALLATION PRINCIPLES 18 5 2 POSITION OF THE APPLIANCE 18 5 3 HYDRAULIC CONNECTIONS 19 5 4 GAS SUPPLY 23 5 5 CONDENSATE DISCHARGE 24 5 6 FILLING THE SYSTEM CIRCUIT APPLIANCE 25 5 7 FILLING THE APPLIANCE S INTERNAL CIRCUIT 25 5 8 EXHAUST FLUE GAS 26 5 9 PROGRAMMING OF HYDRAULIC PARAMETERS 29 6 ELECTRICAL INSTALLATION 32 6 1 CONNECTING THE APPLIANCE TO THE MAINS 34 6 2 ELECTRICAL CONNECTIONS FOR TH...

Page 4: ...ecessary for the first start up and for the gas change of the appliance as well as the main maintenance operations 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 b...

Page 5: ...t off gas supply closing the isolation valve cut off electrical power opening the main breaker upstream of the appliance to be provided by the electrical installer in an ap propriate panel ask for assistance to professionally qualified personnel from a telephone distant from the appliance Moving parts also during the appliance s start up and shut down cycles Do not remove guards Make sure the appl...

Page 6: ...n authorised specialist contractor for the annual inspection of the appliance and mainte nance when needed Maintenance and repairs may only be done a contractor legally authorised to work on gas appliances and equipment Only accept and use original spare parts ...

Page 7: ...hnical competence in the sector of heating cooling installations and gas appliances Installation of the appliance must be carried out in compliance with current local and national regulations regarding the design installation and maintenance of heating and cooling installations and in accordance with the manufacturer s instructions In particular current regulations regarding the following must be ...

Page 8: ...ding to the instructions supplied by the manufacturer see Paragraph 7 2 53 For maintenance of the appliance s internal components contact a RoburTAC 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 Failure to observe the indications given above may compromise the ...

Page 9: ...eparator 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 diff...

Page 10: ...acityTr 47 C 100 3 Operational heat loss to jacket kW 0 15 Operational heat loss to jacket 0 44 Operational heat loss to flue kW 0 86 Operational heat loss to flue 2 54 Heat loss in off mode kW 0 058 Heat loss in off mode 0 2 ELECTRICAL SPECIFICATIONS Power supply Voltage V 230 TYPE single phase Frequency 50 Hz supply 50 Electrical power absorption nominal kW 0 185 Degree of protection IP X5D INST...

Page 11: ...120 CONDENSING UNIT Water flow rate WATERTEMPERATURE 20 C l h bar 1608 0 136 1801 0 165 2007 0 204 2199 0 234 2400 0 269 2601 0 312 2797 0 353 2958 0 395 3000 0 406 3201 0 469 3 5 DIMENSIONS AND SERVICE PANEL Figure 3 2 Dimensional drawing of model AY00 120 AY00 120 front and RH side views dimensions in mm LEGEND Series AY model AY00 120 ...

Page 12: ...S 12 Figure 3 3 SERVICE PANEL Series AY AY Condensing line Series AY service plate dimensions in mm LEGEND G gas fitting G 3 4 M A outlet water fitting G 1 1 4 F B inlet water fitting G 1 1 4 F C condensate drain fitting ext dia 25 mm ...

Page 13: ... 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 contr...

Page 14: ...VOLTAGE PUMP SPEED ECC 0 Menu 1 VIEW ALL PARAMETERS 1 Menu 2 ENTER ACTIONS 2 Menu 3 USER SETTINGS THERMOSTATING SET POINT T DIFFERENTIAL 3 Menu 4 INSTALLATIONTECHNICIAN SETTINGS 4 Menu 5 TECHNICAL ASSISTANCE CENTRE SETTINGS 5 Menu 6 TECHNICAL ASSISTANCE CENTRE SETTINGS MACHINETYPE 6 Menu 7 VIEW DIGITAL IMPUTS 7 Menu 8 MENU NOT USED 8 E EXIT MENU E Menu list of electronic board Menus 0 1 and 7 are ...

Page 15: ...l to access the knob 3 Use the special key through the hole to operate the knob and access the controller s menus and parameters 4 To display the menus just press the knob once the display shows the 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 1 2 3 4 5 6 7 8 and E see 4 1 14 6 To display the parameters in a given menu ...

Page 16: ...nd press it to return to the menu selection 2 4 To exit the menu selection turn the knob clockwise until E displays and press it to exit At this point if the display does not signal any other operating codes put away the special key replace the electrical panel cover and refit the front panel Reset other operating codes parameter 21 You will need the display reads 2 20 as per step 3 1 Turn the kno...

Page 17: ...e MINIMUM winter temperature in the area of installation see Table 5 3 25 bring the plant to the correct pressure making sure that the pressure of the water in the plant is not less than 1 bar and not over 2 bar In case of winter saesonal switch 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 coul...

Page 18: ... dripping line from gutters or similar A cut 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 Packing must only be removed upon final installation When unpacking the appliance do not remove the protective cap on the top panel as th...

Page 19: ...nce with current norms to prevent heat dispersion and the formation of condensate If glycol antifreeze is to be used see Paragraph 5 6 25 DO NOT USE galvanised pipes or pipe fittings as they are subject to potential corrosion phenomena when glycol is present If using rigid pipes use vibration damping couplings at the water and gas connections on the appliance s service plate to prevent vibration A...

Page 20: ...r stainless steel or containing releasing free chlorine Please make sure the pipes are properly rinsed in order to remove any residue of chemical substances from the pipes Robur is not liable for ensuring that water quality is always compliant with what reported in Table 5 1 19 Non compliance with indications above may jeopardize the proper operation integrity and reliability of Robur appliances i...

Page 21: ...ifreeze of the inhibited monoethylene type Active and passive modules If the Robur appliances are not controlled by a DDC In appliances with only hot and only cold modules e g AY series or appliances of the 4 pipe type with two distinct cold and hot modules the module is ALWAYS active in 2 pipe type hot and cold appliances the cctive module is the one that operated the last shutdown the other modu...

Page 22: ...with single appliance Example of hydraulic plant diagram for connection of no 1 AY00 120 unit LEGEND 1 anti vibration coupling 2 pressure gauge 3 flow regulator valve 4 water filter 5 check valve 6 system water circulator 7 system expansion tank 8 DDC 9 AY00 120 stand alone ...

Page 23: ...ent regulations and norms For the pressure of the gas supplied by the mains see Table 5 2 24 Supplying gas to the appliance at pressures higher than those indicated above can damage the gas valve resulting in 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...

Page 24: ...ht 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 rea...

Page 25: ...eze 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 25gives the approximate freezing temperature of the water and consequent increased drop in press...

Page 26: ...rging pump Make sure that the circuit pressure is 1 2 bar on completion of the following procedure 1 Stop the circuit operating close the charging cock with a 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 uni...

Page 27: ... the end of the DN80 extension pipe detail B 2 Fit the DN80 rain guard detail C to the DN80 extension pipe B with the rain guard lip turned towards the exterior of the kit A B C 3 Remove the protective cap on the top panel The cap prevents water and foreign bodies entering the appliance before the fumes kit is installed The cap should thus be removed only when the kit itself has been fully assembl...

Page 28: ...ues Example to install a horizontal fumes pipe using n 1 DN80 90 curve the maximum extension possible with DN80 straight pipe sections is 29 m The following other type B configurations are also possible B23P and B33 for specifications see Table 5 6 29 Exhaust pipes exposed to atmospheric agents must be made of black polypropylene or an equivalent weather resistant material For sizing refer to the ...

Page 29: ...he room This configuration can ONLY be installed in open areas or areas sufficiently well ventilated and free of combustible powders C13 Type C boiler connected via its own pipes to a terminal installed horizontally on the wall or roof The outlets of the pipes are concentric or sufficiently close to each other to be exposed to analogous wind conditions C33 Type C boiler connected with its pipes to...

Page 30: ...arameter 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 ...

Page 31: ...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 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 ...

Page 32: ...ried out on live elements Figure 6 1 32 illustrates in their main parts the on board electronics controller AY10 overlaying the auxiliary controller S70 for the legend see Table 6 1 32 Figure 6 2 34 detail plant of the appliance Figure 6 1 Series AY AY10 S70 controllers Main components of the on board controller LEGEND see table below Table 6 1 AY10 and S70 controller components CONTROLLER COMPONE...

Page 33: ...ter temperature probe connector THMC output hot water temperature probe connector TA2 TA1 auxiliary temperature probes connector J1 CAN BUS jumper P8 GND L H CAN port connector H high data signal L low data signal GND common data signal P7 R W 0 operation consent connector R common terminal W HOT consent terminal 0 terminal not used FS5 24ac1 0V 24ac2 controller power connector F1 F2 fuses Control...

Page 34: ... PD differential water pressure switch system circuit TL water limit thermostat P1 water circulator appliance internal circuit LS gas valve ON indicator lamp GV gas solenoid valve IGNTR ignition transformer IGN ignition electrodes FLS flame sensor CNTBOX flame controller BLW blower MC power terminal block 230Vac PWRTR controller transformer TG antifreezing thermostat for siphon heating element RS ...

Page 35: ...rminal Ground ground terminal L single phase line terminal Disconnect the appliance from the electrical power supply via the external disconnecting switch only after having per formed the shutdown cycle via the DDC or consent switch and having waited for it to terminate approximately 3 minutes Make sure the ground cable is longer than the live cables In this way it will be the last wire to be pull...

Page 36: ...HE 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 f...

Page 37: ... modifica tions see figure point 3 make the connections as shown in the example but installing a relay for the control of the pump managed via NO contact Then point 4 Locate and open jumper J2 as shown in detail A jumper open in the next figure 6 6 39 Fit the relay inside the external electrical panel provided by the installation technician The insertion of relays or other electrical components in...

Page 38: ...impeding the correct operation of the appliance could also damage the electrical apparatus that it contains The NO Contact terminals are no voltage contacts with maximum power capacity of 700 W These contacts control the circulator shutdown delay 2 minutes after appliance shutdown Check the position of jumper J2 as follows 1 Locate on each appliance s controller SCH jumper J2 on the S70 bottom rig...

Page 39: ...er circulator control jumper A detail of open jumper MC 230 V AC power terminal block RST N PHASE NEUTRAL terminals for three phase power 400 V AC ground ground terminal IP system water circulator power switch KQ motor protector or maximum current differential circuit breaker for system water circulator 400 V AC PTR SELV secondary safety transformer KP NO normally open system water circulator cont...

Page 40: ...sertion 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 Example of operation consent connection LEGEND SCH controller AY10 S70 W H...

Page 41: ...it the CCI DDC The DDC in indoor installations must be applied to a panel as follows see Figure 6 9 41 You will need the appliance and the DDC disconnected from the electricity supply Necessary equipment and materials 1 Make a rectangular opening 155 mm wide and 151 mm high 2 Locate the DDC on this hole and mark the 4 points where the holes are to be made to fix it See the figure 3 Drill no 4 hole...

Page 42: ...tric supply from external transformer LEGEND DDC CCI DDC AL supply 4 poles connector 1 clamp and wire for 24 Vac supply 2 clamp and wire for 0 Vac supply 3 clamp and wire for ground contact required connection DDCTR safety transformer 230 24 Vac 50 60 Hz If the CAN BUS cable has already been connected to the DDC next procedure 3 How to connect the CCI DDC to the appli ance take care with the 4 mm ...

Page 43: ...TURCK type 530 DeviceNet Mid Cable TURCK type 5711 H BLUE L WHITE GND BLACK 450 m Honeywell SDS 2022 TURCK type 531 H BLACK L WHITE GND BROWN 200 m Example types of cables used to connect the CAN network For overall distances to cover of 200 m and networks with a maximum of 6 nodes a typical example 1 DDC 5 devices a simple 3 x 0 75 mm2 shielded cable may be used As shown inTable 6 2 43 the CAN co...

Page 44: ...w for fixing To connect a CAN BUS cable to a DDC proceed as follows references in Figure 6 14 45 You will need DDC not powered up Necessary equipment and materials 1 Depending on the type of node being 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 ...

Page 45: ...strated 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 if the DDC is an intermediate node on the network also complete step 7 if the DDC is a terminal node skip di...

Page 46: ...pe to the end of the shielding as pulled back detail A 6 Pull the orange connector detail D out of socket P8 on the controller 7 Connect the three coloured wires to the orange connector as shown in detail A in Figure 6 16 47 Observe the terminal markings L H GND on the board at the base of the socket P8 which are given both inTable 6 2 43 and in Figure 6 16 47 if the appliance is an intermediate n...

Page 47: ...ediate node Detail of terminal and intermediate node jumper position J1 closed open LEGEND SCH controller AY10 S70 J1 CAN BUS jumper on AY10 controller A detail of terminal node case 3 wires J1 jumper closed B detail of intermediate node case 6 wires J1 jumper open H L GND data signal wires 12 Now close the electrical panel and refit the front panel of the appliance ...

Page 48: ...pliance systems CAN BUS cable connection between DDC and one appliance LEGEND DDC digital control panel SCH controller AY10 S70 J1 CAN BUS jumper on AY10 controller J21 CAN BUS jumper on DDC board A terminal node connection 3 wires J1 and J21 closed H L GND data signal wires ...

Page 49: ...tiple appliance systems CAN BUS cable connection between 1 DDC and multiple appliances LEGEND DDC digital control panel SCH controller AY10 S70 J1 CAN BUS jumper on AY10 controller J21 CAN BUS jumper on DDC board A terminal node connection 3 wires J1 and J21 closed B intermediate node connection 6 wires J1 open H L Gnd data signal wires ...

Page 50: ... correctly Check that the installation is actually compliant as per the Declaration of Conformity provided by the installer to the owner The Declaration of Conformity CERTIFIES that the installation is compliant with current regulations This Declaration is a mandatory document and as such it must be provided by the installer to the owner Check that the water pressure and flow in the hydraulic circ...

Page 51: ...ell of gas indicating possible leaks In case of gas leaks go back over Step 1 above and restore the system to compliancy 3 Once you are sure there are no gas leaks close the gas cock Now check the static and dynamic mains gas pressure if the system has multiple appliances this check steps 4 to 10 need only be done once so long as it is done with the appliance furthest from the mains connection for...

Page 52: ...ction 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 Procedure ...

Page 53: ...Turn the 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 2 5 T...

Page 54: ...the unit and of its air heat exchanger 1 Check the correct operation of the device used for monitoring the water flow Check the value of CO2 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 operati...

Page 55: ...the setting of parameter 45 10 If the 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...

Page 56: ...ep 28 the reading should be 9 0 9 5 0 5 29 If the difference satisfies the delta CO2 requirement go to step 34 otherwise proceed as follows 30 Open the access F to the OFFSET regulator which is part of the gas valve by removing the access cap M on the internal panel E 31 Open the internal panel E and using aTorxTX40 wrench B remove the cap A on the OFFSET regulator C Close the internal panel E 32 ...

Page 57: ...densing line AY Series 57 Figure 7 3 Gas type conversion Details of gas changeover procedure LEGEND A tube valve connection nut B tube air gas mixer connection nut C gas valve D gas nozzle E gasket large on tube valve fitting F gasket small on tube air gas mixer fitting G air gas mixer ...

Page 58: ...ater glycol mix 50 50 for hot cold hydraulic systems OGLC007 10 liters tank 50 50 Glycol water solution for machine internal circuit CONDENSATE PUMP Pump for the condensate obtained from combustion products OPMP006 Handles up to 20 units Direct Digital Controller DDC Provides remote control of one or more units OCRM007 No 1 DDC per a maximum of 16 units in the same installation NB with multiple un...

Page 59: ...PTION TRIP CONDITIONS RESET METHOD E 100 FLAME RESET FAULTY The flame control unit reset circuit is faulty Contact authorisedTechnical Assistance E 101 LIMITTHERMOSTAT The limit thermostat is open This only happens if the flame controller is on and the gas solenoid valve is excited the thermostat is connected in series with the solenoid valve power supply Contact authorisedTechnical Assistance u 1...

Page 60: ...e code persists contact authorisedTAC u 178 DELIVERYWATERTEMPERATURE MACHINE CIRCUIT HIGH The water temperature on the internal circuit machine circuit is too high Automatic on termination of originating event u 179 DEFROST FUNCTION ACTIVATED The temperature of the water has reached values which could result in icing In such cases to pre vent the appliance arresting the defrost function may activa...

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Page 64: ... T 39 035 888111 F 39 035 884165 www robur it robur robur it 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 Revisione J Codice D LBR531 14 MCM SDC 007 10 03 2014 ...