Robur AY Installation, Use & Maintenance Manual

Installation, use and maintenance manual AY Outdoor condensing boiler for heating

reproduction of this Installation, use and maintenance manual is prohibited. The original is filed at Robur S.p.A. Any use of this Installation, use and maintenance manual other than for personal consultation must be previously authorised by Robur S.p.A. The rights of those who have legitimately 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 Installation, use and maintenance manual without prior notice. Revision: A Code: D-LBR885EN DISPOSAL The appliance and all its accessories must be disposed of separately in accordance with the regulations in force. Use of the WEEE symbol (Waste Electrical and Electronic Equipment) indicates that this product cannot be disposed of as house- hold waste. Proper disposal of this product helps to prevent potential negative consequences for the environment and human health.

3 INDEX OF CONTENTS I Introduction ..........................................................................p. 4 I.1 Recipients ................................................................ p. 4 I.2 Control device ....................................................... p. 4 II Symbols and definitions .........................................p. 4 II.1 Key to symbols ...................................................... p. 4 II.2 Terms and definitions ......................................... p. 4 III Warnings ...................................................................................p. 4 III.1 General and safety warnings ............................ p. 4 III.2 Compliance ............................................................. p. 6 III.3 Exclusions of liability and warranty ............... p. 6 1 Features and technical data ................................p. 7 1.1 Features .................................................................... p. 7 1.2 Dimensions ............................................................. p. 7 1.3 Electrical wiring diagram ................................... p. 9 1.4 Electronic boards ................................................p. 13 1.5 Controls ..................................................................p. 13 1.6 Technical data ......................................................p. 13 2 Transport and positioning ..................................p. 16 2.1 Warnings ................................................................p. 16 2.2 Installation kit ......................................................p. 16 2.3 Handling and lifting ..........................................p. 17 2.4 Where to install the appliance .......................p. 17 2.5 Minimum clearance distances .......................p. 17 2.6 Mounting base ....................................................p. 17 3 Heating engineer...........................................................p. 17 3.1 Warnings ................................................................p. 17 3.2 Hydraulic connections ......................................p. 18 3.3 Fuel gas supply ....................................................p. 21 3.4 Combustion products exhaust ......................p. 23 3.5 Flue gas condensate drain ..............................p. 24 4 Electrical installer .........................................................p. 25 4.1 Warnings ................................................................p. 25 4.2 Electrical systems ...............................................p. 25 4.3 Electrical power supply ....................................p. 26 4.4 Adjustment and control ...................................p. 26 5 First start-up .......................................................................p. 30 5.1 Preliminary checks .............................................p. 30 5.2 How to access the boiler ..................................p. 30 5.3 Electronic board parameters setting ...........p. 31 5.4 Combustion parameters check .....................p. 36 5.5 Gas changeover ..................................................p. 38 5.6 Commissioning ...................................................p. 38 5.7 Switching off ........................................................p. 38 5.8 Prolonged periods of inactivity .....................p. 38 6 Normal operation .........................................................p. 39 6.1 Warnings ................................................................p. 39 6.2 Preliminary checks .............................................p. 40 6.3 Operation with external request ..................p. 40 6.4 Operation with DDC control ...........................p. 41 6.5 Info menu display ...............................................p. 41 6.6 Efficiency ...............................................................p. 41 7 Maintenance .......................................................................p. 41 7.1 Hydraulic boiler emptying ..............................p. 42 8 Diagnostics ...........................................................................p. 42 8.1 System pressure restore ...................................p. 42 8.2 Error codes ............................................................p. 42 9 Appendices ...........................................................................p. 45 9.1 Product fiche ........................................................p. 45

This Manual is an integral part of the AY appliance and must be handed to the end user together with the appliance. I.1 RECIPIENTS This Manual is intended for: ▶ End user, for appropriate and safe use of the appliance. ▶ Qualified installer, for correct appliance installation. ▶ Planner, for specific information on the appliance. I.2 CONTROL DEVICE In order to work, the AY appliance requires a control de- vice to be connected by the installer. II SYMBOLS AND DEFINITIONS II.1 KEY TO SYMBOLS DANGER WARNING NOTE PROCEDURE REFERENCE (to other document) II.2 TERMS AND DEFINITIONS DHW = domestic hot water. Appliance/Unit AY = equivalent terms, both used to des- ignate the AY series condensing boiler. TAC = Technical Assistance Centre authorised by Robur. External request = generic control device (e.g. thermo- stat, timer or any other system) equipped with a volt- age-free NO contact and used as control to start/stop the AY unit. DDC Control (Direct Digital Controller) = optional Robur control device to manage one or more Robur appliances in ON/OFF mode (GAHP heat pumps, GA chillers) or in modulating mode (AY boilers). RB100/RB200 Devices (Robur Box) = optional interface devices complementary to DDC, which may be used to broaden its functions (heating/cooling/DHW production service demands and control of system components such as third party generators, adjustment valves, circulators, probes). First start-up = appliance commissioning operation which may only and exclusively be carried out by a TAC. III WARNINGS III.1 GENERAL AND SAFETY WARNINGS Installer's qualifications Installation must exclusively be performed by a qualified firm and by skilled personnel, with spe- cific knowledge on heating, electrical systems and gas appliances, in compliance with the laws in force in the Country of installation. Declaration of conformity Upon completing installation, the installing firm shall issue to the owner/client the appliance's workmanlike conformity declaration, according to national/local regulations in force and the manu- facturer's instructions/provisions. Packing Packing items (plastic bags, polystyrene foam, nails, etc.) must be kept out of the reach of chil- dren, as they are potentially dangerous. Misuse The appliance must only be used for the purpos- es for which it has been designed. Any other use is deemed hazardous. Incorrect use may affect oper- ation, duration and safety of the appliance. Adhere to the manufacturer's instructions. Use of the appliance by children The appliance can be used by children over 8 years old, and by people with reduced physical, senso- ry or mental capabilities, or lack of experience or

5 III knowledge, only if they are under surveillance or after they have received instructions regarding safe use of the appliance and understanding the dangers inherent in it. Children should not play with the appliance. Hazardous situations � Do not start the appliance in hazardous conditions, such as: gas smell, problems with the plumbing/ electrical/gas system, parts of the appliance under water or damaged, malfunctioning, disabling or bypassing control and safety devices. � In case of danger, request intervention by qualified personnel. � In case of danger, switch off the electrical power and gas supplies only if this can be done in total safety. Gas component tightness � Before performing any operation on gas ducting components, close the gas valve. � Upon completing any procedure, perform the tightness test according to regulations in force. Gas smell If you smell gas: � Do not use electrical devices such as telephones, multimeters or other equipment that may cause sparks next to the appliance. � Shut off the gas supply by turning the valve off. � Switch off the power supply via the external dis- connect switch in the power supply electrical pan- el. � Use a telephone away from the appliance to ask for intervention from qualified personnel. Poisoning � Ensure the flue gas ducts are tight and compliant with the regulations in force. � Upon completing any procedure, ensure the tight- ness of the components. Moving parts The appliance contains moving parts. � Do not remove guards during operation, and in any case prior to disconnecting the power supply. Burn hazard The appliance contains very hot parts. � Do not open the appliance and do not touch inter- nal components before the appliance has cooled down. � Do not touch the flue gas exhaust before it has cooled down. Electrocution hazard � Disconnect the electrical power supply before any operation on appliance components. � For electrical connections exclusively use compli- ant components and according to the specifica- tions provided by the manufacturer. � Ensure the appliance cannot be accidentally switched back on. Earthing Electrical safety depends on effective earthing sys- tem, correctly connected to the appliance and in- stalled according to the regulations in force. Distance from combustible or flammable mate- rials Do not deposit flammable materials (paper, dilu- ents, paints, etc.) near the appliance. Limescale and corrosion Depending on the chemical/physical properties of the system water, limescale or corrosion may dam- age the appliance. � Check system sealing. � Avoid frequent top-ups. Chloride concentration The concentration of chlorides or free chlorine in the system water must not exceed the values in Table 3.2 p. 21. Aggressive substances in the air Halogenated hydrocarbons containing chlorine and fluorine compounds cause corrosion. The air of the installation site must be free from aggressive substances. Acid flue gas condensate Discharge the acid condensate of combustion flue gas in compliance with current exhaust regulations. Switching the appliance off Disconnecting the power supply while the appli- ance is running may cause permanent damage to internal components. � Except in the event of danger, do not disconnect the power supply to switch off the appliance, but always and exclusively act through the provided control device. In the event of failure Operations on internal components and repairs may exclusively be carried out by a TAC, using only original spare parts. � In the event of failure of the appliance and/or

repair and/or restore and immediately contact the TAC. Routine maintenance Proper maintenance assures the efficiency and good operation of the appliance over time. � Maintenance must be performed according to the manufacturer's instructions (see Chapter 7  p.  41) and in compliance with current regulations. � Appliance maintenance and repairs may only be entrusted to firms legally authorised to work on gas appliances and systems. � Enter into a maintenance contract with an author- ised specialised firm for routine maintenance and for servicing in case of need. � Use only original parts. Decommissioning and disposal If the appliance is to be disposed of, contact the manufacturer for its disposal. Keep the Manual This Installation, use and maintenance manual must always accompany the appliance and must be handed to the new owner or installer in the event of sale or removal. III.2 COMPLIANCE III.2.1 EU directives and standards The appliance is certified in accordance with European regulation GAR 426/2016/EU and meet the essential re- quirements of the following Directives: ▶ Efficiency Directive 92/42/EEC and subsequent modifi- cations and additions. ▶ 2016/426/EU "Gas Appliances Regulation" as amend- ed and added. ▶ 2014/30/EC "Electromagnetic Compatibility Directive" as amended and added. ▶ 2014/35/EC "Low Voltage Directive" as amended and added. ▶ 2006/42/EC "Machine Directive" as amended and add- ed. ▶ 811/2013/EU "Energy-Related Products regulation" as amended and added. ▶ 813/2013/EU "Ecodesign requirements regulation" as amended and added. Furthermore, they comply with the requirements of the following standards: ▶ EN 15502 Gas-fired central heating boilers. III.2.2 Other applicable provisions and standards The design, installation, operation and maintenance of the systems shall be carried out in compliance with cur- rent applicable regulations, depending on the Country and location, and in accordance with the manufacturer's instructions. In particular, regulations regarding the fol- lowing shall be complied with: ▶ Gas systems and equipment. ▶ Electrical systems and equipment. ▶ Heating systems employing condensing boilers. ▶ Environmental protection and combustion products exhaust. ▶ Fire safety and prevention. ▶ Any other applicable law, standard and regulation. III.3 EXCLUSIONS OF LIABILITY AND WARRANTY Any contractual or extra-contractual liability of the manufacturer for any damage caused by incorrect installation and/or improper use and/or failure to comply with regulations and with the manufactur- er's directions/instructions shall be disclaimed. In particular, the warranty on the appliance may be rendered void by the following conditions: � Incorrect installation. � Misuse. � Failure to comply with the manufacturer's indica- tions on installation, use and maintenance. � Alteration or modification of the product or any part thereof. � Extreme operational conditions or however out- side of the operational ranges set forth by the man- ufacturer. � Damages caused by external agents such as salts, chlorine, sulphur or other chemical substances contained in the installation water or present in the air of the installation site. � Abnormal actions transmitted to the appliance by the system or installation (mechanical stresses, pressure, vibrations, thermal expansion, electrical surges...). � Accidental damages or due to force majeure.

Installation, use and maintenance manual – AY 7 1 1 FEATURES AND TECHNICAL DATA 1.1 FEATURES 1.1.1 Operation The AY appliances are outdoor condensing boilers capa- ble of producing hot water up to 88 °C. The range includes three models: AY 35, AY 50, AY 100. The boiler casing is approved to resist weathering with particular regard to the action of UV rays. The operation of the appliance is managed by one of the following controls (Paragraph 1.5 p. 13): ▶ DDC control ▶ external request (chronothermostat, room thermostat or other operating request) When the heat supply is requested, the electronic board starts the system water pump, the blower and then the burner. When the burner starts up, the flame detector checks that the burner has ignited; in the event of a lack of flame, the electronic control unit retries ignition several times and if this fails, it stops the appliance and displays the lock-out. The reset is manual. In the event of abnormal overheating of the delivery, the boiler is switched off. The limit thermostat has manual reset. 1.1.2 Mechanical and thermo-hydraulic components ▶ Integrated spiral single tube stainless steel heat ex- changer. ▶ Premix modulating burner with 1:9 ratio (AY 35), 1:10 (AY 50), 1:20 (AY 100). ▶ Automatic air vent valve. ▶ High efficiency water pump. ▶ System drain tap. ▶ Water temperature probes. ▶ Condensate drain siphon. ▶ Check valve (only for AY 100). ▶ Flue gas exhaust duct with relevant terminal, for type B53P configuration. In the AY 100 the above components are double. 1.1.3 Control and safety devices ▶ Flue safety thermal fuse. ▶ Gas solenoid valve. ▶ Safety thermostat. In the AY 100 the above components are double. ▶ Safety valve. ▶ Water differential pressure switch. ▶ Expansion tank. ▶ Outdoor temperature probe. 1.1.4 INAIL safety appliances The kit is only available on appliances intended for the Italian market. 1.2 DIMENSIONS 1.2.1 AY 35 and AY 50 Figure 1.2   Unit dimensions A Flue gas outlet Ø 80 mm 465 572 1184 1284 141 235 A Figure 1.3   Service plate - Hydraulic/gas connections detail OUT Water outlet connection Ø 1 1/4" F IN Water inlet connection Ø 1 1/4" F SC Condensate discahrge connection (outside diameter 25 mm, inside 20 mm) GAS Gas connection Ø 3/4" M 459 305 100 100 355 43 160 59 119 185 IN GAS OUT SC

8 1 Figure 1.4   Service plate - Detail of bottom plate A Boiler safety valve drain external Ø 20 mm, internal Ø 14 mm 159 Ø22 266 A 1.2.2 AY 100 Figure 1.5   Unit dimensions A Flue gas outlet Ø 80 mm 720 572 1184 1284 140 185 219 320 A Figure 1.6   Service plate - Hydraulic/gas connections detail OUT Water outlet connection Ø 1 1/2" F IN Water inlet connection Ø 1 1/2" F SC Condensate discahrge connection (outside diameter 25 mm, inside 20 mm) GAS Gas connection Ø 1" M 160 91 44 238 437 100 IN GAS OUT SC Figure 1.7   Service plate - Detail of bottom plate A Boiler safety valve drain external Ø 20 mm, internal Ø 14 mm 74 378 Ø22 A

Installation, use and maintenance manual – AY 9 1 1.3 ELECTRICAL WIRING DIAGRAM 1.3.1 AY 35 Figure 1.11   Boiler electrical connections diagram A CAN bus connection CS Heating cable EA Ignition electrode ER Flame detector EV Blower FM Flowmeter L Line MP Control panel terminal block N Neutral PM Water pump Pacq Water pressure switch RS1 Heating resistance condensate drain 1 SCH Control board SCH2 CAN-NDG board SE Outdoor temperature probe SR Heating delivery probe SRi Heating return probe Ta Antifreeze thermostat TA Connector for optional room thermostat TF Flue gas thermofuse TS Safety thermostat Tra Ignition transformer VG Gas valve ar Orange bi White ce Light blue gi Yellow gr Grey ma Brown ne Black EA VG Tra ER 9 10 11 8 7 12 13 14 15 16 17 M12 M9 M7 M5 M2 M4 M8 M10 M15 M16 1 2 3 4 57 61 60 59 58 38 31 30 29 28 27 26 62 63 64 65 66 67 68 51 52 53 54 55 56 5 6 M13 M14 PM SRi M6 GND PWM HS +24V 32 33 34 35 36 37 39 40 41 42 43 44 Pacq SR TF TS MP L N TA TA +10 0 0 L H SHIELD E-SLT088 CAN-NDG E-SLT088 CAN-NDG CS 1 1 RS1 230V-50Hz SE connett. SAux 1 Ta 1 EV SCH SCH2 FM YE-GI GN-VE YE-GI GN-VE YE-GI BN-MA WH-BI GN-VE GN/YE BN-MA BU-BL BN-MA BU-BL BU-BL BN-MA BN-MA BU-BL BN-MA BN-MA BU-BL BU-BL BN-MA BU-BL BN-MA JUMPER J11 J11 A

10 1 1.3.2 AY 50 Figure 1.12   Boiler electrical connections diagram A CAN bus connection CS Heating cable EA Ignition electrode ER Flame detector EV Blower FM Flowmeter L Line MP Control panel terminal block N Neutral PM Water pump Pacq Water pressure switch RS1 Heating resistance condensate drain 1 SCH Control board SCH2 CAN-NDG board SE Outdoor temperature probe SR Heating delivery probe SRi Heating return probe Ta Antifreeze thermostat TA Connector for optional room thermostat TF Flue gas thermofuse TS Safety thermostat Tra Ignition transformer VG Gas valve ar Orange bi White ce Light blue gi Yellow gr Grey ma Brown ne Black EA VG Tra ER 9 10 11 8 7 12 13 14 15 16 17 M12 M9 M7 M5 M2 M4 M8 M10 M15 M16 1 2 3 4 57 61 60 59 58 38 31 30 29 28 27 26 62 63 64 65 66 67 68 51 52 53 54 55 56 5 6 M13 M14 PM SRi M6 GND PWM HS +24V 32 33 34 35 36 37 39 40 41 42 43 44 Pacq SR TF TS 0 L H SHIELD E-SLT088 CAN-NDG E-SLT088 CAN-NDG CS 1 1 RS1 230V-50Hz SE connett. SAux 1 Ta 1 EV SCH SCH2 FM YE-GI GN-VE YE-GI GN-VE YE-GI BN-MA WH-BI GN-VE GN/YE BN-MA BU-BL BN-MA BU-BL BU-BL BN-MA BN-MA BU-BL BN-MA BU-BL BU-BL BN-MA BU-BL BN-MA JUMPER J11 J11 BN-MA A MP L N TA TA +10 0

Installation, use and maintenance manual – AY 11 1 1.3.3 AY 100 Figure 1.14   Boiler electrical connections diagram - Module 2 A Connection from TA2 connector B Connection from module 1 C CAN bus connection from module 1 EA Ignition electrode ER Flame detector EV Blower FM Flowmeter L Line N Neutral PM Water pump Pacq Water pressure switch RS2 Heating resistance condensate drain 2 SE Outdoor temperature probe SCH Control board SCH2 CAN-NDG board SR Heating delivery probe SRi Heating return probe Ta Antifreeze thermostat TF Flue gas thermofuse TS Safety thermostat Tra Ignition transformer VG Gas valve ar Orange bi White ce Light blue gi Yellow gr Grey ma Brown ne Black EA Tra ER 9 10 11 8 7 12 13 14 15 16 17 M12 M9 M7 M5 M2 M4 M8 M10 M15 M16 1 2 3 4 57 61 60 59 58 38 31 30 29 28 27 26 62 63 64 65 66 67 68 51 52 53 54 55 56 5 6 M14 PM M6 GND PWM HS +24V 32 33 34 35 36 37 39 40 41 42 43 44 SR TF TS EV Pacq connett. SAux VG E-SLT088 CAN-NDG E-SLT088 CAN-NDG Ta RS2 1 0 L H SHIELD M13 SRi 1 FM SE 1 BN-MA BU-BL YE-GI BN-MA BU-BL BN-MA BN-MA BU-BL BU-BL BN-MA BN-MA BU-BL WH-BI GN-VE GN/YE GN/YE L N SCH JUMPER J11 J11 BU-BL BN-MA BU-BL BN-MA A B C SCH2

12 1 Figure 1.14   Boiler electrical connections diagram - Module 1 A Connection of TA2 connector to module 2 B Connection to module 2 C CAN bus connection to module 2 D CAN bus connection CS Heating cable EA Ignition electrode ER Flame detector EV Blower FM Flowmeter L Line MP Control panel terminal block N Neutral PM Water pump Pacq Water pressure switch RS2 Heating resistance condensate drain 2 SCH Control board SCH2 CAN-NDG board SE Outdoor temperature probe SR Heating delivery probe SRi Heating return probe Ta Antifreeze thermostat TA1 Connector for optional room thermostat for module 1 TA2 Connector for optional room thermostat for module 2 TF Flue gas thermofuse TS Safety thermostat Tra Ignition transformer VG Gas valve ar Orange bi White ce Light blue gi Yellow gr Grey ma Brown ne Black EA VG Tra ER 9 10 11 8 7 12 13 14 15 16 17 M12 M9 M7 M5 M2 M4 M8 M10 M15 M16 1 2 3 4 57 61 60 59 58 38 31 30 29 28 27 26 62 63 64 65 66 67 68 51 52 53 54 55 56 5 6 M13 M14 PM SRi M6 GND PWM HS +24V 32 33 34 35 36 37 39 40 41 42 43 44 Pacq ne ne ce ma ma ce SR TF TS ma ce 0 L H SHIELD E-SLT088 CAN-NDG E-SLT088 CAN-NDG CS 1 1 RS1 230V-50Hz connett. SAux 1 FM SE 1 GN/YE BU-BL BN-MA BN-MA BU-BL BN-MA BU-BL BU-BL BN-MA BN-MA BU-BL YE-GI BN-MA WH-BI GN-VE BN-MA BN-MA BN-MA BU-BL L N BU-BL BN-MA BU-BL BN-MA SCH SCH2 JUMPER J11 J11 A B C D L N TA1 TA1 TA2 TA2 MP

Installation, use and maintenance manual – AY 13 1 1.4 ELECTRONIC BOARDS The unit's electrical board contains: ▶ Electronic board MIAH410, with microprocessor, it controls the appliance and displays data, messages and operative codes. The appliance is monitored and programmed by interacting with the control panel on the boiler. ▶ CAN-NDG electronic board, controls CAN bus com- munication with the DDC panel. 1.5 CONTROLS 1.5.1 Control device The appliance may only work if it is connected to a control device, selected from: ▶ DDC control ▶ external request 1.5.2 DDC Controller The DDC control is able to manage one or more Robur ap- pliances in ON/OFF mode (GAHP heat pumps, GA chillers) or modulating mode (AY boilers). The main functions are: ▶ Adjustment and control of one (or more) Robur units of the absorption line (GAHP, GA, AY). ▶ Data display and parameters setting. ▶ Hourly programming. ▶ Climatic curve control. ▶ Diagnostics. ▶ Errors reset. ▶ Possibility to interface with a BMS. DDC functionality may be extended with auxiliary Robur devices RB100 and RB200 (e.g. service requests, DHW pro- duction, third party generator control, probe control, sys- tem valves or circulating pumps, ...). For further details refer to the DDC, RB100, RB200 manuals and the design manual. 1.5.3 External request The appliance may also be controlled via generic request devices (e.g. thermostat, timer, switch, contactor...) fitted with voltage-free NO contact. This system only provides elementary control, hence without the important func- tions of the DDC control. It is advisable to possibly lim- it its use to simple applications only and with a single appliance. In the case of the AY 100 appliance, two separate requests must be provided for the two thermal modules that make up the appliance. For connection of the selected device to the appli- ance's electronic board please refer to Paragraph 4.4.5 p. 29. 1.6 TECHNICAL DATA Table 1.1   Technical data AY 35 AY 50 AY 100 Heating mode seasonal space heating energy efficiency class (ErP) - A - Heat input nominal (1013 mbar - 15 °C) (1) kW 34,0 50,0 99,8 minimum (1) kW 4,1 5,0 Operating point 80/60 Nominal heat input effective power kW 33,4 49,2 98,4 efficiency % 98,2 98,4 98,5 Operating point 50/30 Nominal heat input efficiency % 106,4 106,8 Operating point Tr = 30 °C Heat input 30% efficiency % 108,6 108,8 Operating point Tr = 47 °C Heat input 30% efficiency % 102,1 102,8 Heat losses to casing in operation % 0,25 0,10 0,47 to flue in operation % 2,40 2,10 with burner off % 0,03 0,05 0,03 Heating water flow nominal l/h 2600 2350 4700 minimum l/h 1200 1500 Hot water outlet temperature maximum °C 88 Outdoor temperature (dry bulb) maximum °C 45 minimum °C -25 Electrical specifications Power supply voltage V 230 type - single-phase frequency Hz 50 Electrical power absorption nominal kW 0,22 0,25 0,49 (1) Relative to NCV (net calorific value). (2) Gas not available for AY 35. (3) 2 independent flue gas exhausts. (4) For each of the independent flue gas exhausts.

14 1 AY 35 AY 50 AY 100 Degree of protection IP - X5D Installation data Gas consumption G20 natural gas (nominal) m³/h 3,60 5,29 10,58 G25 (nominal) m³/h 4,18 6,15 12,30 G25.1 (nominal) m³/h - (2) 5,97 11,94 G25.3 (nominal) m³/h 4,09 6,01 12,03 G27 (nominal) m³/h - (2) 6,32 12,64 G2.350 (nominal) m³/h - (2) 7,09 14,18 G30 (nominal) kg/h 2,68 3,94 7,88 G31 (nominal) kg/h 2,64 3,88 7,77 Water fitting type - F thread “ 1 1/4 1 1/2 Gas connection type - M thread “ 3/4 1 Flue gas exhaust diameter (Ø) mm 80 80 (3) residual head Pa 91 100 100 (4) NOx emission class - 6 Circulating pump data Residual pressure head at nominal flow rate boiler only bar 0,44 nominal flow at the maximum available head l/h 2600 2350 4700 type of installation - B23, B23P, B33, B53 maximum equivalent length of exhaust duct m 15 14 14 (4) maximum water pressure in operation bar 3,0 maximum flow rate of flue gas condensate l/h 3,4 5,0 10,0 water content inside the appliance l 8 11 22 expansion tank volume l 10 minimum storage temperature °C -30 Dimensions width mm 465 720 depth mm 575 height mm 1284 Weight in operation kg 77 87 131 (1) Relative to NCV (net calorific value). (2) Gas not available for AY 35. (3) 2 independent flue gas exhausts. (4) For each of the independent flue gas exhausts. 1.6.1 Circulating pump characteristic curves Figure 1.15   Oversized pressure head circulating pump characteristic curves 0 2 4 6 8 0 0,5 1,0 1,5 2,0 2,5 0 2 4 6 8 10 0 20 40 60 80 100 max. p/kPa H/m Q/l/s 0 0,5 1,0 1,5 2,0 2,5 Q/l/s Q/m³/h 25/10, 30/10 1~230 V - Rp 1, Rp 1¼ 0 2 4 6 8 0 50 100 150 Δp-c P1/W Q/m³/h max. max. 6m 7m 8m 9m 10m 5m 4m 3m 2m 1m 0,5m Q/m³/h Δp-v P1/W 0 2 4 6 8 0 50 100 150 6m 7m 8m 9m 10m 5m 3m 1,5m 4m There are two water pumps in the AY 100 appliance.

Installation, use and maintenance manual – AY 15 1 1.6.2 Pump selector switch setting Figure 1.16   AY pump selector switch setting 1.6.3 Pressure drops and residual head Table 1.2   Nominal flow rate and residual head AY 35 AY 50 AY 100 Installation data Circulating pump data nominal flow at the maximum available head l/h 2600 2350 4700 Residual pressure head at nominal flow rate boiler only bar 0,44 1.6.3.1 AY 35 Figure 1.17   Available head and pressure drop of the boiler A Boiler pressure drop with 20% glycol water B Boiler pressure drop with no glycol in water 0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 500 1000 1500 2000 2500 3000 3500 A B [bar] [l/h]

16 2 1.6.3.2 AY 50 and AY 100 Figure 1.18   Pressure drop AY 50 and AY 100 A Boiler pressure drop with 35% glycol water B Boiler pressure drop with no glycol in water 0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1 1,1 1,2 1,3 500 1000 1500 2000 2500 3000 3500 [bar] [l/h] A B For AY 100 the curve is the same, as the boiler consists of two thermal modules in parallel, each with its own water pump. 2 TRANSPORT AND POSITIONING 2.1 WARNINGS Damage from transport or installation The manufacturer shall not be liable for any dam- age during appliance transport and installation. On-site inspection � Upon arrival at the site, ensure there is no transport damage on packing or boiler panels. � After removing the packing materials, ensure the appliance is intact and complete. Packing � Only remove the packing after placing the appli- ance on site. � Do not leave parts of the packing within the reach of children (plastic, polystyrene, nails...) since they are potentially dangerous. Weight � The lifting equipment must be suitable for the load. � Do not stand under suspended loads. 2.2 INSTALLATION KIT 2.2.1 AY 35 The installation kit supplied with the boiler includes: 1. AY 35 condensing boiler. 1. flanged socket Ø 60/80 mm. 1. gasket of the flanged socket. 8. fixing screws of the flanged socket. 1. rain cover. 1. flue gas exhaust kit. 2.2.2 AY 50 The installation kit supplied with the boiler includes: 1. AY 50 condensing boiler. 1. triangle key for opening the front panel. 1. flanged socket Ø 60/80 mm. 1. gasket of the flanged socket. 8. fixing screws of the flanged socket. 1. rain cover. 1. flue gas exhaust kit. 2. 2.2.3 AY 100 The installation kit supplied with the boiler includes: 1. AY 100 condensing boiler. 1. triangle key for opening the front panel. 2. flanged socket Ø 60/80 mm.

17 3 2. gasket of the flanged socket. 16. fixing screws of the flanged socket. 2. rain cover. 2. flue gas exhaust kit. 3. 2.3 HANDLING AND LIFTING ▶ Always handle the appliance in its packing, as deliv- ered by the factory. ▶ Do not remove the protective cap on the top panel as this can allow dirt and water to enter the interior of the appliance. ▶ Comply with safety regulations at the installation site. In the event of handling with forklift or pallet truck, comply with the handling instructions shown on the packing. 2.4 WHERE TO INSTALL THE APPLIANCE ▶ The appliance may be installed at ground level, on a terrace or on a roof, compatibly with its dimensions and weight. ▶ The appliance's flue gas exhaust must not be immedi- ately close to openings or air intakes of buildings, and must comply with safety and environmental regula- tions. ▶ No obstruction or overhanging structure (e.g. protrud- ing roofs, eaves, balconies, ledges, trees) may obstruct the exhaust fumes outlet at the top of the appliance. ▶ Do not install near the exhaust of flues, chimneys or hot polluted air. In order to work correctly, the appli- ance needs clean air. ▶ In the case of indoor installation, meet all require- ments set forth by laws, standards and regulations of the Country and place of installation concerning gas appliances. 2.5 MINIMUM CLEARANCE DISTANCES 2.5.1 Distances from combustible or flammable materials Keep the appliance away from combustible or flammable materials or components, in compliance with applicable regulations. 2.5.2 Clearances around the appliance The minimum clearance distances shown in Figure 2.1  p.  17 (bar any stricter regulations) are required for safety, operation and maintenance. Figure 2.1   Clearances 200 300 300 300 800 2.6 MOUNTING BASE 2.6.1 Mounting base constructive features Place the appliance on a level flat surface made of fire- proof material and able to withstand its weight. 2.6.2 Installation at ground level Failing a horizontal supporting base, make a flat and level concrete base, at least 100-150 mm larger than the appli- ance size per side. 2.6.3 Installation on terrace or roof ▶ The structure of the building must support the total weight of the appliance and the supporting base. ▶ If necessary, provide a maintenance walkway around the appliance. 2.6.4 Anti-vibration connections It is advisable to use flexible connections (anti-vibration joints) between the appliance and the hydraulic and gas supply pipes. 3 HEATING ENGINEER 3.1 WARNINGS Read the warnings in Chapter III.1  p.  4, pro- viding important information on regulations and on safety. Compliance with installation standards Installation must comply with applicable regula- tions in force, based on the installation Country and site, in matters of safety, design, implementa- tion and maintenance of: � heating systems � gas systems � flue gas exhaust � flue gas condensate discharge

er's provisions. 3.2 HYDRAULIC CONNECTIONS The hydraulic installer must make the hydraulic connec- tion circuit to the heating system. The installer must provide for the construction of a suita- bly sized hydraulic connection circuit, taking into account: A. of the following indications: � Use pipes for heating/cooling systems, protected from weathering and freezing, insulated for ther- mal dispersion. � Sizing of the pipes, according to the standard circu- lator, must grant the nominal water flow required for the correct operation of the heating system. � When using glycol water, take this into account when selecting the pipe material and calculating the additional pressure drop generated by the presence of glycol (Table 3.1 p. 20). B. of the residual head and pressure drop data reported in Paragraph 1.6.3 p. 15. Connect the outlet of the boiler safety valve (Paragraph 1.2  p.  7) to a suitable drain. The manufacturer is not liable for any damage caused by the opening of the safety valve in the event of system overpressure. 3.2.1 Hydraulic connections on the right, at the bottom, connection plate (Paragraph 1.2 p. 7). 3.2.1.1 AY 35 and AY 50 OUT Water outlet connection Ø 1 1/4" F IN Water inlet connection Ø 1 1/4" F 3.2.1.2 AY 100 OUT Water outlet connection Ø 1 1/2" F IN Water inlet connection Ø 1 1/2" F 3.2.2 Pipe cleaning Pipe cleaning Before connecting the appliance,accurately wash the water and gas piping and any other system component, removing any residue. 3.2.3 Minimum components of water circuit Always provide, near the appliance: ▶ on water piping, both outlet and inlet � 2 antivibration joints on water fittings � 2 pressure gauges � 2 isolation ball valves ▶ on the inlet water piping � 1 separator filter The appliance is equipped with its own 10 l internal expansion tank and with a safety valve. Depending on the water content of the system, assess the need for additional expansion tanks. 3.2.4 System filling For the calculation of the total water content to be loaded in the system it is necessary to add the water content of the boiler (Table 1.1  p.  13) and of the distribution terminals to the water content in the pipes and in other elements that make up the system (tanks, hydraulic separators, etc.). Proceed with the filling of the system as follows. A filling tap on the system must be provided for fill- ing the system. At the first power supply and each time the power supply is restored, an automatic system venting cycle is activated. The display will show the code F33 for the entire duration of the cycle (5 minutes for the first power supply, 2 minutes for the fol- lowing ones). To access the display, remove the front panel of the boiler, as shown in Figure 5.1 p. 31. 3.2.4.1 AY 35 1. Slightly loosen the cap of the jolly valve placed on the top of the condensing block (Figure 3.1 p. 19) to re- lease the air from the top of the boiler. 2. Open the system filling valve (to be provided on the system) and let out all the air. 3. Check with pressure gauge that system pressure reaches 1,5 bar. 4. Open the automatic air vent valves on the system, if any, and check the air venting process. 5. Make sure that the unit is energized. 6. Send an operating request to the unit for a few sec- onds. The circulating pump will be immediately activated. 7. Remove the request before the burner is activated. The circulating pump will continue to circulate the wa- ter for the post-circulation time. 8. If, after the above operations, a decrease in system wa- ter pressure is observed, open again the system filling tap until the system pressure reaches 1,5 bar. 9. Repeat items 6, 7, 8 until the pressure has stabilised (at least 1,5 bar). 10. After the operation, make sure that the system filling tap is tightly closed. Once the filling operation has been completed, close the cap of the jolly valve on the condensing block, to avoid water leaks. To start the circulation pump only, with the boiler

19 3 powered, press the key (Figure 6.1 p. 39): the symbol will appear on the display; after a few seconds turn off the boiler by pressing the key again (the symbol will appear on the display). The circulation pump will remain in operation for a few minutes. Repeat the operation several times until the pressure of the circuit re- mains unchanged. Figure 3.1   Cap of the jolly valve on condensing block 3.2.4.2 AY 50 and AY 100 1. Slightly loosen the cap of the jolly valve located at the top of the condensing block (detail 1, Figure 3.2 p. 19) to let the air out from the highest point of the boiler. 2. Check that the air vent valves in the system are not blocked. 3. Connect a rubber hose to the drain tap (detail 2, Figure 3.2 p. 19). 4. Open the drain tap (detail 2, Figure 3.2  p.  19) counterclockwise. 5. Open the system filling tap (to be provided on the sys- tem) and let all the air out. Close it when the air is all out, replaced by a constant water flow. 6. Operations 1 to 5 are to be carried out on both con- densation blocks of the AY 100 model. 7. Pressurize the hydraulic system, making sure that the water pressure indicated by the pressure gauge is not less than 1,5 bar. 8. Make sure that the unit is energized. 9. Send an operating request to the unit for a few sec- onds. The circulating pump will be immediately activated. 10. Remove the request before the burner is activated. The circulating pump will continue to circulate the wa- ter for the post-circulation time. 11. If, after the above operations, a decrease in system wa- ter pressure is observed, open again the system filling valve until the system pressure reaches 1,5 bar. 12. Repeat items 9, 10, 11 until the pressure has stabilised (at least 1,5 bar). 13. After the operation, close the filling tap. Once the filling operation has been completed, close the cap of the jolly valve on the condensing block, to avoid water leaks. To start the circulation pump only, with the boiler powered, press the key (Figure 6.1 p. 39): the symbol will appear on the display; after a few seconds turn off the boiler by pressing the key again (the symbol will appear on the display). The circulation pump will remain in operation for a few minutes. Repeat the operation several times until the pressure of the circuit re- mains unchanged. Figure 3.2   Air-vent valve 1 Cap of the jolly valve 2 Tap 2 1 3.2.4.3 Water pump air vent How to vent the water pumps of AY appliances 1. Turn off the system by means of provided control de- vices and wait for the water pumps to stop. 2. Disassemble the front panel of the unit. 3. Close the shut-off valve on the outlet and open the up- per vent valve (Figure 3.3 p. 20, detail B). 4. When the air is all out, replaced by a constant flow of water, close the upper vent valve and open the shut- off valve on the outlet. 5. Close the shut-off valve on the inlet and open the low- er vent valve (Figure 3.3 p. 20, detail C). 6. When the air is all out, replaced by a constant flow of water, close the lower vent valve and open the shut-off valve on the inlet. 7. Reactivate the system and let water flow (with burner off). 8. If the air vent has been properly completed, reassem- ble the front panel of the unit. If not, repeat the proce- dure from step 3. The correct filling and air venting of the hydraulic

time of the mechanical components, in particular the circulation pumps. Figure 3.3   Pump/Roma valve assembly on AY appliances A Roma valve B Air vent (internal circuit) C Air vent (system) D Flexible hose E Circulator F Return pipe G Delivery pipe A G E F B C D 3.2.5 Pump antifreeze and anti-lock function Heating antifreeze function If the outlet water temperature detected by the water temperature probe inside the boiler falls below the antifreeze activation value (default 12 °C, settable via parameter P81), the control board starts the water pump and the ignition of the burn- er at minimum power. When the outlet water temperature reaches 30 ºC or the inlet water temperature reaches 20 °C (anti- freeze temperature OFF) the control board will turn off the burner. Electrical and gas continuity The antifreeze function is only effective if the power and gas supplies are assured. Otherwise, antifreeze fluid in the system water might be required. Pump anti-lock function In order to prevent the circulation pump from lock- ing, the boiler is equipped with an anti-lock func- tion which, every 24 hours of inactivity, operates the circulation pump for 30 seconds. Electrical continuity The pump anti-lock function is only effective if the power supply is guaranteed. 3.2.6 Antifreeze liquid Precautions with glycol The manufacturer disclaims any liability for any damage caused by improper glycol use. � Always check product suitability and its expiry date with the glycol supplier. Periodically check the product's preservation state. � Do not use car-grade antifreeze liquid (without inhibitors), nor zinc-coated piping and fittings (in- compatible with glycol). � Glycol modifies the physical properties of water (density, viscosity, specific heat...). Size the piping, circulation pump and thermal generators accord- ingly. � With automatic system water filling, a periodic check of the glycol content is required. In the presence of glycol In the presence of glycol it is necessary to warn the TAC before the first start-up and to set parameter P52 correctly. When producing DHW by DHW buffer tank, use propylene glycol only. 3.2.6.1 Type of antifreeze glycol Inhibited type glycol is recommended to prevent oxida- tion phenomena. 3.2.6.2 Glycol effects The Table 3.1 p. 20 shows, indicatively, the effects of us- ing a glycol depending on its %. Table 3.1   Technical data for filling the hydraulic circuit Glycol % Water-glycol mixture freezing temperature Percentage of increase in pressure drops Loss of efficiency of unit 10 -3 °C - - 15 -5 °C 6,0% 0,5% 20 -8 °C 8,0% 1,0% 25 -12 °C 10,0% 2,0% 30 -15 °C 12,0% 2,5% 35 -20 °C 14,0% 3,0% 40 -25 °C 16,0% 4,0%

21 3 3.2.7 System water quality Responsibility of the user/operator/installer The installer, operator and user must assure system water quality (Table 3.2  p.  21). Failure to comply with the manufacturer's guidelines may affect op- eration, integrity and life of the appliance, voiding the warranty. 3.2.7.1 System water characteristics In order to avoid any scale or deposits on the pri- mary exchanger, the water in the system must be treated in accordance with the applicable stand- ards. This treatment is absolutely essential in cases where there are frequent episodes of water supply or partial or total emptying of the system. The filling and top-up water brings a certain amount of calcium into the system. This is attached to the hot parts including the heat exchanger, thus creating pressure drops and thermal insulation on the active parts. This can lead to damage. If the filling and top-up water of the system is outside the values indicated below, it must be softened and/or chem- ically treated. Additives may also be added to keep the calcium in solution. Hardness should be checked regularly and recorded on the system logbook. The choice of the type of treatment must be made accord- ing to the characteristics of the water to be treated, the type of plant and the limits of purity required. Adhere to the chemical-physical parameters in Table 3.2  p.  21 and the regulations on water treatment for residential and industrial heating systems. Table 3.2   Chemical and physical parameters of water Acidity 7 < pH < 8,5 Conductivity < 400 μS/cm (at 25°C) Chlorides < 125 mg/l Iron < 0,5 mg/l Copper < 0,1 mg/l 3.2.7.2 Water topping up The chemical-physical properties of the system's water may alter over time, resulting in poor operation or exces- sive topping up. ▶ Ensure there are no leaks in the installation. ▶ Periodically check the chemical-physical parameters of the water, particularly in case of automatic topping up. Chemical conditioning and washing Water treatment/conditioning or system washing carried out carelessly may result in risks for the ap- pliance, the system, the environment and health. � Contact specialised firms or professionals for water treatment or system washing. � Check compatibility of treatment or washing prod- ucts with operating conditions. � Do not use aggressive substances for stainless steel or copper. � Do not leave washing residues. 3.3 FUEL GAS SUPPLY 3.3.1 Gas connection ▶ AY 35: 3/4" M ▶ AY 50: 3/4" M ▶ AY 100: 1" M on the right, at the bottom, connection plate (Paragraph 1.2 p. 7). ▶ Install an anti-vibration connection between the ap- pliance and the gas piping. 3.3.2 Mandatory shut-off valve ▶ Provide a gas shut-off valve (manual) on the gas sup- ply line, next to the appliance, in a visible and easy ac- cessible position, to exclude it when required. ▶ Perform connection in compliance with applicable regulations. 3.3.3 Gas pipes sizing The gas pipes must not cause excessive pressure drops and, consequently, insufficient gas pressure for the appliance. 3.3.4 Supply gas pressure This appliance is equipped for a maximum gas supply pressure of 50 mbar. The appliance's gas supply pressure, both static and dy- namic, must comply with Table 3.3 p. 21, with tolerance ± 15%. Non compliant gas pressure (Table 3.3  p.  21) may damage the appliance and be hazardous. Table 3.3   Network gas pressure Product category Country of destination Gas supply pressure [mbar] G20 G25 G25.1 (1) G25.3 G2.350 (1) G27 (1) G30 G31 II2H3B/P AL, BG, CY, CZ, DK, EE, FI, GR, HR, IT, LT, MK, NO, RO, SE, SI, SK, TR 20 30 AT, CH 20 50 HU 25 30 The appliance gas supply pressure, both static and dynamic, must comply with the values in the Table, with a tolerance of ± 15%. 1 Gas not available for Caldaia 35 Tech, Caldaia 35 Tech ACS, Caldaria 35, AY 35.

Gas supply pressure [mbar] G20 G25 G25.1 (1) G25.3 G2.350 (1) G27 (1) G30 G31 II2H3B/P HU 25 30 II2HS3B/P 25 II2H3P AL, BE, BG, CH, CZ, ES, FR, GB, GR, HR, IE, IT, LT, NL, MK, PL, PT, SI, SK, TR 20 37 AT, BE, CH, CZ, DE, ES, FR, GB, HU, NL, SK 20 50 AT, CZ, DE, NL, RO 20 30 II2ELL3B/P DE 20 20 50 II2Esi3P FR 20 25 37 II2E(R)3P BE 20 37 II2E(S)3P 20 37 II2E3P LU 20 50 II2E3B/P DE, PL, RO 20 30 II2ELwLs3B/P PL 13 20 II2ELwLs3P 13 20 II2L3B/P RO 20 30 II2L3P FR 25 37 RO 20 37 II2EK3P NL 20 25 30 II2EK3B/P 20 25 30 I2EK 20 25 I2ELL DE 20 20 I2E(S) BE 20 I2E(R) 20 I2Esi FR 20 25 I2H AL, AT, BG, CH, CY, CZ, DK, EE, ES, FI, GB, GR, HR, IE, IT, LT, LV, MK, NO, PT, RO, SE, SI, SK, TR 20 FR 20 HU 25 I2L FR 25 RO 20 I2E DE, PL, RO 20 I3B/P AL, AT, BG, BE, CY, CZ, DE, DK, EE, FI, FR, GB, GR, HR, HU, IT, LT, MT, NL, NO, RO, SE, SI, TR 30 PL 37 AT, CH, DE, SK, CY, CZ 50 FR 50 I3P AT, BE, CH, CZ, DE, ES, FR, GB, HU, IS, NL, SK 50 AL, BE, BG, CH, CZ, ES, FR, GB, GR, HR, IE, IT, LT, NL, LV, MK, PL, PT, SI, SK, TR 37 AT, CZ, DE, NL, RO 30 The appliance gas supply pressure, both static and dynamic, must comply with the values in the Table, with a tolerance of ± 15%. 1 Gas not available for Caldaia 35 Tech, Caldaia 35 Tech ACS, Caldaria 35, AY 35. Before proceeding with the construction of the system, the installer must: ▶ Check that the gas used corresponds to that for which the appliance has been designed (see nameplate). ▶ Check that the flow rate of the gas meter is such as to ensure the simultaneous use of all the devices con- nected to it. Although it is normal for the inlet pressure to de- crease during the operation of the appliance, it is important to check that there are no excessive fluc- tuations in the inlet pressure. In order to limit the extent of these variations, it is necessary to appro- priately define the diameter of the gas inlet pipe to be adopted based on the length and pressure drop of the pipe itself, from the gas meter to the appliance. If fluctuations in the gas distribution pressure happen, it is advisable to insert a special pressure stabiliser upstream of the gas inlet to the appliance. In case of LPG supply, all necessary precautions must be taken to avoid freezing of the combustible gas in case of very low external temperatures. If it is necessary to change the type of gas supply to the appliance, contact the TAC that will make the necessary changes.

23 3 Under no circumstances shall the installer be au- thorised to carry out such operations. 3.3.5 Vertical pipes and condensate ▶ If needed, vertical gas pipes must be fitted with siphon and discharge of the condensate that may form inside the pipe. ▶ If needed, insulate the piping. 3.3.6 LPG pressure reducers With LPG the following must be installed: ▶ A first stage pressure reducer, close to the liquid gas tank. ▶ A second stage pressure reducer, close to the appli- ance. 3.4 COMBUSTION PRODUCTS EXHAUST Installation types The appliance is approved for connection to a combustion products exhaust duct for the types shown in Table 1.1 p. 13. 3.4.1 Flue gas exhaust connection ▶ AY 35: Ø 80 mm ▶ AY 50: Ø 80 mm ▶ AY 100: Ø 80 mm (2 independent flue gas exhausts) on the upper side of the boiler (Paragraph 1.2 p. 7). The rain cover, supplied, must be mounted on the flue gas exhaust pipe to protect the internal components of the boiler (detail E, Figure 3.4 p. 23). The combustion air is drawn from the outside of the cas- ing by means of special louvres. 3.4.2 Flue gas exhaust kit The appliance, supplied in B53P configuration, is stand- ard supplied with a DN80 flue gas kit, to be set up by the installer. For the AY 100 appliance, the flue gas exhaust kit is double and the kit must be installed on both thermal modules. Figure 3.4   Flue gas exhaust kit A Gasket of the flanged socket B Flanged socket Ø 60/80 mm C Fixing screws of the flanged socket D Rain cover E Flue gas exhaust pipe F Roof terminal A B C D E F 3.4.2.1 How to install the flue gas kit The protection cover has the purpose of preventing ingress of water and/or foreign matter into the ap- pliance before installation of the flue gas kit. It is therefore important to remove the protection only upon completing installation of the kit. Figure 3.4 p. 23: 1. Remove the protective cap on the top panel of the appliance. 2. Check that the gasket G is correctly positioned on the combustion chamber (Figure 3.5 p. 24). 3. Position the gasket A of the flanged socket B at the ap- propriate holes for the fixing screws C. 4. Poistion the flanged socket B over the gasket A and se- cure the assembly with the appropriate fixing screws C. 5. Position the rain cover D on the flanged socket B, mak- ing sure that it fits underneath the flue gas analysis socket. 6. Insert the flue gas exhaust pipe E into the flanged socket B. 7. Fit the terminal F on the extension pipe E inside the dedicated socket. Take care to fit the rain cover below the flue gas analysis socket on the flanged socket in such a way that it is still accessible. It is important to check the correct positioning of the gasket G positioned on the combustion chamber (Figure 3.5 p. 24).

mise the correct discharge of the flue gas outside and consequently damage the appliance. Figure 3.5   Correct gasket positioning G Gasket G 3.4.3 Possible flue If required, the appliance may be connected to a flue ap- propriate for condensing appliances. ▶ To size the flue refer to Table 3.4  p.  24 and design manual. ▶ Use ducts and terminals suitable for forced draft con- densing appliances. ▶ If several appliances are connected to a single flue, it is obligatory to install a check valve on the flue gas ex- haust of each. ▶ The flue must be designed, sized, tested and con- structed by a skilled firm, with materials and compo- nents complying with the regulations in force in the country of installation. ▶ Always provide a socket for flue gas analysis, in an ac- cessible position. ▶ The horizontal sections for flue gas exhaust must al- ways be mounted on a slope towards the appliance (3° slope = 5 mm per metre of pipe). ▶ For vertical ducts longer than 1,5 m, a curve and a Tee (Figure 3.6  p.  24) for condensate collection and drainage must be provided. The condensate must then be evacuated in accordance with the regulations in force, at the same time as that coming from inside the boiler. In case the check valves are installed outside, an appropriate UV ray protection must be assured (if the valve is in plastic) as well as protection from potential winter freezing of condensate backflow into the siphon. The connection of the discharge to the sewerage system must be made at atmospheric pressure, i.e. by dripping into a siphoned container connected to the sewerage system. Figure 3.6   Flue gas condensate drain > 300 mm 3.4.3.1 Maximum exhaust pipe length Table 3.4   Characteristics of flue gas exhaust AY 35 AY 50 AY 100 Installation data Flue gas exhaust residual head Pa 91 100 100 (1) diameter (Ø) mm 80 80 (2) maximum equivalent length of exhaust duct m 15 14 14 (1) (1) For each of the independent flue gas exhausts. (2) 2 independent flue gas exhausts. The maximum exhaust length (or equivalent linear length) is obtained by adding the length of the linear duct to the equivalent length of each additional curve. The equivalent lengths of linear ducts and curves are giv- en in Table 3.5 p. 24. Table 3.5   Pressure drop of flue pipes Equivalent length (m) Pressure drop (Pa) AY 35 extension pipe Ø 80 mm, length 1000 mm 1 5,8 elbow 90° Ø 80 mm 1,5 8,7 elbow 45° Ø 80 mm 1,2 7,0 T connector Ø 80 mm 3 17,4 AY 50/AY 100 extension pipe Ø 80 mm, length 1000 mm 1 7,0 elbow 90° Ø 80 mm 2,5 17,5 elbow 45° Ø 80 mm 1,4 7,8 T connector Ø 80 mm 3 21,0 3.5 FLUE GAS CONDENSATE DRAIN The provided condensate drain hose must be connected to a suitable collection and disposal system in accordance with the applicable regulations in force.

25 4 It will be the responsibility of the designer and/or the in- staller and/or the person in charge of the system, depend- ing on the power of the system and intended use of the building, to assess the adoption of systems for the neu- tralization of acid condensate. The system must be designed in such a way as to prevent condensation from freezing. Before commissioning the appliance, check that the condensate is drained correctly. To do this, disconnect the hose from the siphon outlet and pour water into it, making sure that it is correctly and com- pletely drained from the downstream drainage system. Do not use gutters to discharge the condensate Do not discharge the flue condensate in gut- ters, due to the risk of materials corrosion and ice formation. 3.5.1 Flue gas condensate connection The fitting for flue gas condensate drain is located on the right side of the appliance (Paragraph 1.2  p.  7) at the connection plate. The connection of the discharge to the sewerage system should be made at atmospheric pressure, i.e. by dripping into a siphoned container connected to the sewerage system. 3.5.2 Flue gas condensate drain manifold To make the condensate drain manifold: ▶ Size the ducts for maximum condensation flow rate (Table 1.1 p. 13). ▶ Use plastic materials resistant to acidity pH 3-5. ▶ Provide for min. 1% slope, i.e. 1 cm for each m of the length (otherwise a booster pump is required). ▶ Prevent freezing. ▶ Dilute, if possible, with domestic waste water (e.g. bathrooms, washing machines, dish washers...), basic and neutralising. 3.5.3 Condensate drain siphon filling When switching on for the first time, the condensate si- phon must be filled to prevent the combustion gases from backflowing through the siphon. It is advisable, after the first few months of operation of the appliance, to clean the siphon, which collects also any deposits resulting from the first passage of the conden- sate inside the components of the appliance. These de- posits could cause the siphon itself to malfunction. 4 ELECTRICAL INSTALLER Do not power and/or start the boiler before filling the hydraulic system, as this may damage the in- ternal hydraulic components. 4.1 WARNINGS General warnings Read the warnings in Chapter III.1  p.  4, provid- ing important information on regulations and on safety. Compliance with installation standards Installation must comply with applicable regula- tions in force, based on the installation Country and site, in matters of safety, design, implementa- tion and maintenance of electrical systems. Installation must also comply with the manufactur- er's provisions. Live components After placing the appliance in the final position, and prior to making electrical connections, ensure not to work on live components. Earthing � The appliance must be connected to an effective earthing system, installed in compliance with reg- ulations in force. � It is forbidden to use gas pipes as earthing. Cable segregation Keep power cables physically separate from signal ones. Do not use the power supply switch to turn the appliance on/off � Never use the external isolation switch to turn the appliance on and off, since it may be damaged in the long run (occasional blackouts are tolerated). � To turn the appliance on and off, exclusively use the suitably provided control device. 4.2 ELECTRICAL SYSTEMS Electrical connections must provide: ▶ power supply (Paragraph 4.3 p. 26) ▶ control system (Paragraph 4.4 p. 26) How to make connections All electrical connections must be made in the ap- pliance's electrical panel (Figure 4.1 p. 26): 1. Ensure the appliance is not live. 2. Remove the appliance front panel (Figure 5.1 p. 31). 3. Unscrew the two screws and remove the electrical

4. Run the cables through the appropriate holes at the rear of the appliance (Figure 4.2 p. 26). 5. Identify the appropriate connection terminals. 6. Make the connections. 7. Replace the terminal block cover plate, securing it with its screws, and refit the front panel. Figure 4.1   Access to AY terminal block A Electrical panel B Terminal block C Plate B A C Figure 4.2   Cable glands position A Detail of cable glands position A 4.3 ELECTRICAL POWER SUPPLY Provide (by the installer) a protected single phase line (230 V 1-N 50 Hz) with: ▶ 1 three-pole cable type FG7(O)R 3Gx1,5 ▶ 1 two-pole switch with 2 2 A type T fuses, (GS) or 1 4 A magnetothermic breaker. The switches must also provide disconnect capa- bility, with min contact opening 3 mm. How to connect the power supply To connect the three-pole power supply cable (Figure 4.3 p. 26): 1. Access the electrical board of the appliance ac- cording to the Procedure 4.2 p. 25. 2. Connect the three wires to the terminal block in the electrical panel on the appliance. 3. Provide the earth lead-in wire longer than live ones (last to be torn in the event of accidental pulling). Figure 4.3   Power supply connection L Phase N Neutral Components NOT SUPPLIED: GS Two-pole switch L N 10 0 Ta Ta L N 230V - 50 Hz GS 4.4 ADJUSTMENT AND CONTROL 4.4.1 Control systems Two separate control systems are provided, each with specific features, components and diagrams (Figures 4.6 p. 28, 4.9 p. 29): ▶ DDC control (with CAN bus connection). ▶ External request. 4.4.2 CAN bus communication network The CAN bus communication network, implemented with the cable of the same name, makes it possible to connect and remotely control one or more Robur appliances with the DDC or CCP/CCI control devices. It entails a certain number of serial nodes, distinguished in: ▶ intermediate nodes, in variable number ▶ terminal nodes, always and only two (beginning and end) Each component of the Robur system, appliance (GAHP, GA, AY, ...) or control device (DDC, RB100, RB200, ...), corre- sponds to a node, connected to two more elements (if it is an intermediate node) or to just one other element (if it is a terminal node) through two/one CAN bus cable sec- tion/s, forming an open linear communication network (never star- or loop-shaped). 4.4.3 CAN bus signal cable The DDC controller is connected to the appliance through the CAN bus signal cable, shielded, compliant to Table 4.1 p. 27 (admissible types and maximum distances). For lengths ≤200 m and up to 4 nodes (e.g. 1 DDC + 3 AY), a simple 3x0,75 mm2 shielded cable may be used.

27 4 Table 4.1   CAN bus cables type Cable name Signals / Color Maximum length Note Robur Optional code OCVO008 ROBUR NETBUS H = BLACK L = WHITE GND = BROWN 450 m Honeywell SDS 1620 In all cases the fourth conductor should not be used BELDEN 3086A H = BLACK L = WHITE GND = BROWN 450 m TURCK type 530 DeviceNet Mid Cable TURCK type 5711 H = BLUE L = WHITE GND = BLACK 450 m Honeywell SDS 2022 TURCK type 531 H = BLACK L = WHITE GND = BROWN 200 m How to connect the CAN bus cable to the appli- ance To connect the CAN bus cable to the CAN-NDG electronic board, located at the rear of the electri- cal panel inside the appliance: 1. Access the electrical board of the appliance ac- cording to the Procedure 4.2 p. 25. 2. Turn the control panel 90° outwards, using the side latches, to access the CAN-NDG board (Figure 4.4 p. 27). 3. Connect the CAN bus cable to terminals 0, L and H. 4. Place the CLOSED J11 jumpers (Detail A) if the node is terminal (one connected CAN bus cable section only), or OPEN (Detail B) if the node is intermediate (two connected CAN bus cable sections). 5. Connect the DDC to the CAN bus cable according to the instructions in the following Paragraphs and in the DDC manual. For the AY 100 appliance, the CAN bus connection between the two modules is factory wired. Figure 4.4   Access to CAN-NDG board A CAN-NDG board B CAN bus port A B Figure 4.5   Connection of the CAN bus cable to the electronic board C Back of the electrical panel D CAN-NDG board E Jumper J11 F CAN bus port C D F E 4.4.4 AY + DDC configuration System (1) see also Paragraph 1.5 p. 13.

DDC Direct Digital Controller SCH CAN-NDG board J11 CAN bus jumper on CAN-NDG board J21 CAN bus jumper on DDC panel GND Common data 0 Common data H Data signal HIGH L Data signal LOW A Terminal node connection - (3 wires; J11 and J21 = "closed") B CAN bus cable shield C Insulating tape to protect the shield of the CAN bus cable D Eyelet terminal and fixing screw P8 CAN port/connector JUMPER J11 H 1 2 3 4 1 2 3 4 5 6 L H GND JUMPER J21 A GND L 0 L H SHIELD E-SLT088 CAN-NDG E-SLT088 CAN-NDG J11 A DDC SCH B C D P8 0 L H SHIELD A Figure 4.7   CAN bus connection for systems with multiple single units DDC Direct Digital Controller SCH CAN-NDG board J11 CAN bus jumper on CAN-NDG board J21 CAN bus jumper on DDC panel GND Common data 0 Common data H Data signal HIGH L Data signal LOW A Terminal node connection - (3 wires; J11 and J21 = "closed") B Intermediate node connection - (6 wires; J11 and J21 jumpers = "open") C CAN bus cable shield D Insulating tape to protect the shield of the CAN bus cable E Eyelet terminal and fixing screw P8 CAN port/connector JUMPER J11 H 1 2 3 4 1 2 3 4 5 6 L H GND JUMPER J21 A GND L 0 L H SHIELD E-SLT088 CAN-NDG E-SLT088 CAN-NDG J11 A DDC SCH C D E P8 JUMPER J11 0 L H SHIELD E-SLT088 CAN-NDG E-SLT088 CAN-NDG J11 B SCH 0 L H SHIELD 0 L H SHIELD A B Place the CLOSED J21 Jumpers (Detail A) if the node is terminal (one connected CAN bus cable section only), or OPEN (Detail B) if the node is intermediate (two connect- ed CAN bus cable sections).

29 4 Figure 4.8   Connection of the CAN bus cable to the control panel DDC Direct Digital Controller GND Common data L Data signal LOW H Data signal HIGH J21 CAN bus jumper on DDC board A Detail of "terminal node" case (3 wires; J21 = jumper "closed") B Detail of "intermediate node" case (6 wires; J21 = jumper "open") P8 CAN port/connector DDC GND H L JUMPER J21 P8 B A DDC GND H L JUMPER J21 P8 4.4.5 External request System (2), see also Paragraph 1.5.3 p. 13. The following Table 4.2  p.  29 summarizes the features associated with the different control devices. Table 4.2   Available features depending on controls Control devices Description External request Heating at fixed temperature, based on the parameters set on the control panel onboard the boiler. Activation/deactivation based on an external request, connected to the Ta-Ta terminals. Room thermostat Heating at fixed temperature, based on the parameters set on the control panel onboard the boiler. Activation/deactivation based on the temperature detected by the room thermostat and its settings. It is required to arrange: ▶ Enable device (e.g. thermostat, timer, switch, ...) fitted with a voltage-free NO contact. How to connect the external request The connection of the external request is made on the terminal block located in the electrical panel inside the appliance (Figure 4.9 p. 29). 1. Access the electrical board of the appliance ac- cording to the Procedure 4.2 p. 25. 2. Connect the two non-polarised conductors to the Ta-Ta contacts. Use a cable with a cross-section between 0,5 and 1,5 mm², with a maximum length of 50 metres. For the AY 100 appliance, two separate requests must be provided, one for each of the Ta1-Ta2 con- tacts in the electrical panel, which correspond to the two separate thermal modules of the appli- ance. Figure 4.9   External request connection CR External request/room thermostat L N 10 0 Ta Ta CR 4.4.5.1 Thermostat/chronothermostat location Install the thermostat/chronothermostat according to the following guidelines: ▶ Place it inside the heated room, in an area that is rep- resentative of the room temperature, at about 1,5 m from the floor, protected from draughts, direct expo- sure to sunlight, influence by direct heating sources (lamps, hot air flows, etc.). ▶ Avoid installation on walls bordering the outside, to avoid distortion on the detected temperature and therefore affect system operation. Otherwise, shield the control system by placing a sheet of insulating ma- terial (cork, polystyrene or other) between it and the

starting and stopping of the system can be avoided and optimal comfort in the heated space can be guaranteed. 4.4.5.2 0-10 V input Control via 0-10 V signal is alternative to control via DDC panel or external request. The 0-10 V signal connection is only available on AY 35 and AY 50 models. Either the water temperature setpoint or the power value can be communicated alternatively via a 0-10 V analogue signal. The meaning to be given to the 0-10 V input is chosen by appropriately configuring the boiler board parameters (Paragraph 5.3 p. 31). The 0-10 V signal should be connected to the 0-10 terminals as shown in Figure 4.10 p. 30. The cable may not be longer than 30 metres. Figure 4.10   0-10 V input connection L N 10 0 Ta Ta - +0-10 V 5 FIRST START-UP First start-up entails checking/setting up the com- bustion parameters and may exclusively be carried out by a Robur TAC. NEITHER the user NOR the in- stallation technician is authorised to perform such operations, under penalty of voiding the warranty. 5.1 PRELIMINARY CHECKS 5.1.1 Preliminary checks for first start-up Upon completing installation, before contacting the TAC the installer must check: ▶ Water, electrical and gas systems suitable for the re- quired capacities and equipped with all safety and control devices required by the regulations in force. ▶ Absence of leaks in the water and gas systems. ▶ Type of gas for which the appliance is designed (natu- ral gas or LPG). ▶ Supply gas pressure complying with the values of Table 3.3 p. 21. ▶ Correct operation of the flue exhaust duct. ▶ Power supply mains complying with the appliance's rating plate data. ▶ Appliance correctly installed, according to the manu- facturer's provisions. ▶ System installed in a workmanlike manner, according to national and local regulations. 5.1.2 Abnormal or hazardous installation situations Should any abnormal or hazardous installation situations be found, the TAC shall not perform first start-up and the appliance shall not be commissioned. These situations may be: ▶ Failed compliance with minimum clearances. ▶ Insufficient distance from combustible or flammable materials. ▶ Conditions that do not warrant access and mainte- nance in safety. ▶ Appliance switched on/off with the main switch, in- stead of the provided control device. ▶ Appliance defects or faults caused during transport or installation. ▶ Gas smell. ▶ Non-compliant mains gas pressure. ▶ Non-compliant flue gas exhaust. ▶ All situations that may involve operation abnormali- ties or are potentially hazardous. 5.1.3 Non-compliant system and corrective actions Should the TAC find any non conformities, the user/install- er is bound to perform any corrective procedures required by the TAC. After performing the remedial actions (the installer's re- sponsibility), if the TAC deems that safety and conformity conditions are in place, first start-up may be effected. 5.2 HOW TO ACCESS THE BOILER For all control and maintenance operations, it is necessary to remove the front panel of the boiler as described below. The other panels cannot be removed as they are structural. Remove the front panel of the boiler as follows: 1. Open lock A with the triangle key supplied with the appliance. 2. Remove front panel B by tilting it outwards and pulling it upwards.

31 5 Figure 5.1   Accessing the boiler A Front panel lock B Front panel A B 5.3 ELECTRONIC BOARD PARAMETERS SETTING Before commissioning the operation of the device to the user, the operating parameters must be set or simply checked. Modify settings via the DDC If the device is connected to the DDC control, refer to the relevant manual to modify settings. To access the parameters menu and adjust the value of the desired parameter, follow the procedure described below (refer to Figure 5.2 p. 31): 1. Press key to select the OFF mode, displayed with the symbol. 2. Hold at the same time the and keys and wait until on the display appears the symbol with the message ‘P10’, and release the and keys. 3. Use the and keys of the heating circuit to select the parameter to be edited. 4. Use the keys and of the DHW circuit to change the value of the parameter. 5. Press the key to confirm and wait for the dis- play to stop blinking, to make the adjustment effective. 6. To exit the parameter menu, hold down the and keys simultaneously and wait for the symbol to appear on the display. The operating parameters are shown in the following Tables and are visible on the internal display of the boiler. Only for AY 100 All parameters must be set/edited independently on each of the two control panels. Figure 5.2   Access and setting of boiler parameters 5.3.1 AY 35 The parameters and their values refer to the firmware 1.001 for the CAN-NDG board and to the firmware A.10 for the MIAH410 board. Table 5.1   AY 35 electronic board parameters Parameter Description Range Default Setting

17 ÷ 18 17 17. AY 35 P20 Mod0 type Not used -- -- Do not change P22 Serial number Mod0 - 3 most significant digits Not used 000 ÷ 999 -- Do not change P23 Serial number Mod0 - 3 intermediate digits Not used 000 ÷ 999 -- Do not change P24 Serial number Mod0 - 3 least significant digits Not used 000 ÷ 999 -- Do not change P30 Mod1 type 31 ÷ 32 31 31. AY 35 P32 Serial number Mod1 - 3 least significant digits 000 ÷ 999 -- Do not change P33 Serial number Mod1 - 3 intermediate digits 000 ÷ 999 -- Do not change P34 Serial number Mod1 - 3 least significant digits 000 ÷ 999 -- Do not change P40 Board CAN address It is possible to set the CAN bus address of the CAN-NDG board for connect- ing the boiler to the DDC panel. 0 ÷ 478 0 The address must be unique for each appliance on the same CAN bus network. P45 Gas type selection WARNING: before changing the parameter value, read the instructions in Paragraph 5.5 p. 38. 0 ÷ 1 0 0. G20, G25, G25.1 (1), G25.3, G2.350 (1), G27 (1) 1. LPG, G30, G31 P46 Special function 0 ÷ 5 0 Do not change P50 Mod1: hydraulic system ID It is possible to set the system ID to which the DDC panel considers the boiler to be connected. 0 ÷ 15 0 The code must be the same for all the appliances on the same hydraulic system P51 Mod1: group of belonging (DHW) It is possible to set the group of belonging to which the DDC panel consid- ers the boiler to be connected. 0 ÷ 1 0 0. base group 1. separable group P52 Glycol percentage It is possible to set the percentage of glycol in the system water. 0 ÷ 60 0 Value in percentage P54 Heating run-up It is possible to set the time, during the start-up phase, that the boiler takes to reach the maximum set power (for the space heating service). 0 ÷ 4 1 0. disabled 1. 50 s 2. 100 s 3. 200 s 4. 300 s P58 Post-circulation heating timing It is possible to set the operating time of the pump, in heating mode, after the main burner has been switched off due to the intervention of the room thermostat. 0 ÷ 90 36 Value in multiples of 5 s (default 36 x 5 = 180 s) P62 Minimum blower speed adjustment for heating It is possible to set the minimum speed of the blower for the heating service, which corresponds to the minimum power of the burner during a heating request (see Figure 5.4 p. 36). The value is preset according to the boiler model (P10) and the Mod1 type (P30). 33 ÷ min between 133 and P63 53 Value in hertz (1 Hz = 30 RPM) P63 Maximum blower speed adjustment for heating It is possible to set the maximum speed of the blower for the heating service, which corresponds to the maximum power of the burner during a heating request (see Figure 5.4 p. 36). The value is preset according to the boiler model (P10) and the Mod1 type (P30). maximum between 40 and P62 ÷ 290 203 Value in hertz (1 Hz = 30 RPM) P64 Starting step adjustment It is possible to set the blower speed during the start-up phases. The value is preset according to the boiler model (P10) and the Mod1 type (P30). 33 ÷ 255 110 Value in hertz (1 Hz = 30 RPM) P66 (2) (3) Setting the climatic curve The appliance is equipped with an outdoor temperature probe (located onboard the appliance) that acts by automatically changing the outlet tem- perature according to the measured outdoor temperature. The extent of the correction depends on the set heating control value Kd (Figure 5.3 p. 35). The choice of the curve is determined by the maximum outlet temperature Tm and the minimum outdoor temperature Te, taking into account the degree of insulation of the building. The values of the outlet temperatures Tm refer to standard systems 30÷80 °C. 0 1 ÷ 30 0 0. disabled The numbering of the value corresponds to the 'Kd' curves of the graph (Figure 5.3 p. 35) P68 (2) (4) 0-10 V industrial bus drive enable The 0-10 V industrial bus input can be enabled or disabled to set burner power or delivery temperature via the external bus. 0 ÷ 2 0 0. disabled 1. temperature control mode 2. power control mode P69 Min heating setpoint It is possible to set the minimum user-adjustable heating temperature. 20 ÷ 40 30 Value in °C

33 5 P70 Max heating setpoint It is possible to set the maximum user-adjustable heating temperature. 40 ÷ 88 80 Value in °C P72 Δt delivery-return setpoint It is possible to set the temperature difference between delivery and return. 0 5 ÷ 40 20 0. disabled Value in °C P73 Modulating pump minimum speed 50 ÷ 70 60 Do not change P74 Modulating pump maximum speed 70 ÷ 100 100 Do not change P78 Control mode It is possible to set the control mode of the boiler. 0 ÷ 2 0 0. CAN bus 1. do not use 2. external request P81 Heating antifreeze temperature setting It is possible to set the temperature of the water in the heating system at which the antifreeze protection is activated. 5 ÷ 12 12 Value in °C P82 Flowmeter type 0 ÷ 2 2 Do not change P83 Minimum water flow setting 20 ÷ 68 30 Do not change 1. Gas not available for AY 35. 2. The climatic curve and the use of the 0-10 V input are alternative functions. If both functions are configured as active, the climatic curve is used. These functions are only used in the case of control via external re- quest (P78 = 2). 3. With the climatic curve active, the outlet water setpoint temperature is set to a value between that of param- eters P69 and P70 based on the outdoor temperature measured by the probe inside the appliance and on the Kd value set in parameter P66 (Figure 5.3 p. 35). 4. With 0-10 V input active in temperature control mode, the outlet water setpoint is set to a value between that of parameters P69 and P70 based on the line passing through the points (3 V, P69) and (10 V, P70). A volt- age lower than 3 V corresponds to no service request. With 0-10 V input active in power control mode, the thermal output is set to a value between the minimum and maximum power according to the line passing through the points (3 V, minimum power) and (10 V, maximum power). A voltage lower than 3 V corre- sponds to no service request. 5.3.2 AY 50 and AY 100 The parameters and their values refer to the firm- ware 1.001 for the CAN-NDG board and to the firm- ware A.10 for the MIAH410 board. For AY 100 all parameters must be set/edited inde- pendently on each of the two control panels. Table 5.2   AY 50 and AY 100 electronic board parameters Parameter Description Range Default Setting P10 Boiler model selection 17 ÷ 18 18 18. AY 50 (and each of the two modules of AY 100) P20 Mod0 type Not used -- -- Do not change P22 Serial number Mod0 - 3 most significant digits Not used 000 ÷ 999 -- Do not change P23 Serial number Mod0 - 3 intermediate digits Not used 000 ÷ 999 -- Do not change P24 Serial number Mod0 - 3 least significant digits Not used 000 ÷ 999 -- Do not change P30 Mod1 type 31 ÷ 32 32 32. AY 50 (and each of the two modules of AY 100) P32 Serial number Mod1 - 3 least significant digits 000 ÷ 999 -- Do not change P33 Serial number Mod1 - 3 intermediate digits 000 ÷ 999 -- Do not change P34 Serial number Mod1 - 3 least significant digits 000 ÷ 999 -- Do not change P40 Board CAN address It is possible to set the CAN bus address of the CAN-NDG board for connect- ing the boiler to the DDC panel. 0 ÷ 478 0 The address must be unique for each appliance on the same CAN bus network. P45 Gas type selection WARNING: before changing the parameter value, read the instructions in Paragraph 5.5 p. 38. 0 ÷ 1 0 0. G20, G25, G25.1, G25.3, G2.350, G27 1. LPG, G30, G31 P46 Special function 0 ÷ 5 0 Do not change P50 Mod1: hydraulic system ID It is possible to set the system ID to which the DDC panel considers the boiler to be connected. 0 ÷ 15 0 The code must be the same for all the appliances on the same hydraulic system P51 Mod1: group of belonging (DHW) It is possible to set the group of belonging to which the DDC panel consid- ers the boiler to be connected. 0 ÷ 1 0 0. base group 1. separable group

0 ÷ 60 0 Value in percentage P54 Heating run-up It is possible to set the time, during the start-up phase, that the boiler takes to reach the maximum set power (for the space heating service). 0 ÷ 4 1 0. disabled 1. 50 s 2. 100 s 3. 200 s 4. 300 s P58 Post-circulation heating timing It is possible to set the operating time of the pump, in heating mode, after the main burner has been switched off due to the intervention of the room thermostat. 0 ÷ 90 36 Value in multiples of 5 s (default 36 x 5 = 180 s) P62 Minimum blower speed adjustment for heating It is possible to set the minimum speed of the blower for the heating service, which corresponds to the minimum power of the burner during a heating request (see Figure 5.5 p. 36). The value is preset according to the boiler model (P10) and the Mod1 type (P30). 33 ÷ min between 133 and P63 53 Value in hertz (1 Hz = 30 RPM) P63 Maximum blower speed adjustment for heating It is possible to set the maximum speed of the blower for the heating service, which corresponds to the maximum power of the burner during a heating request (see Figure 5.5 p. 36). The value is preset according to the boiler model (P10) and the Mod1 type (P30). maximum between 40 and P62 ÷ 290 247 Value in hertz (1 Hz = 30 RPM) P64 Starting step adjustment It is possible to set the blower speed during the start-up phases. The value is preset according to the boiler model (P10) and the Mod1 type (P30). 33 ÷ 255 130 Value in hertz (1 Hz = 30 RPM) P66 (1) (2) Setting the climatic curve The appliance is equipped with an outdoor temperature probe (located onboard the appliance) that acts by automatically changing the outlet tem- perature according to the measured outdoor temperature. The extent of the correction depends on the set heating control value Kd (Figure 5.3 p. 35). The choice of the curve is determined by the maximum outlet temperature Tm and the minimum outdoor temperature Te, taking into account the degree of insulation of the building. The values of the outlet temperatures Tm refer to standard systems 30÷80 °C. 0 1 ÷ 30 0 0. disabled The numbering of the value corresponds to the 'Kd' curves of the graph (Figure 5.3 p. 35) P68 (1) (3) 0-10 V industrial bus drive enable The 0-10 V industrial bus input can be enabled or disabled to set burner power or delivery temperature via the external bus. 0 ÷ 2 0 0. disabled 1. temperature control mode 2. power control mode P69 Min heating setpoint It is possible to set the minimum user-adjustable heating temperature. 20 ÷ 40 30 Value in °C P70 Max heating setpoint It is possible to set the maximum user-adjustable heating temperature. 40 ÷ 88 80 Value in °C P72 Δt delivery-return setpoint It is possible to set the temperature difference between delivery and return. 0 5 ÷ 40 20 0. disabled Value in °C P73 Modulating pump minimum speed 50 ÷ 70 60 Do not change P74 Modulating pump maximum speed 70 ÷ 100 100 Do not change P78 Control mode It is possible to set the control mode of the boiler. 0 ÷ 2 0 0. CAN bus 1. do not use 2. external request P81 Heating antifreeze temperature setting It is possible to set the temperature of the water in the heating system at which the antifreeze protection is activated. 5 ÷ 12 12 Value in °C P82 Flowmeter type 0 ÷ 2 2 Do not change P83 Minimum water flow setting 20 ÷ 68 30 Do not change 1. The climatic curve and the use of the 0-10 V input are alternative functions. If both functions are configured as active, the climatic curve is used. These functions are only used in the case of control via external re- quest (P78 = 2). 2. With the climatic curve active, the outlet water setpoint temperature is set to a value between that of param- eters P69 and P70 based on the outdoor temperature measured by the probe inside the appliance and on the Kd value set in parameter P66 (Figure 5.3 p. 35). 3. With 0-10 V input active in temperature control mode, the outlet water setpoint is set to a value between that of parameters P69 and P70 based on the line passing through the points (3 V, P69) and (10 V, P70). A volt- age lower than 3 V corresponds to no service request. With 0-10 V input active in power control mode, the thermal output is set to a value between the minimum and maximum power according to the line passing through the points (3 V, minimum power) and (10 V, maximum power). A voltage lower than 3 V corre- sponds to no service request. Control via 0-10 V input is not available for AY 100.

35 5 5.3.3 Climatic curves Figure 5.3   Climatic curves Tm Delivery temperature Te Outdoor temperature Kd Heating control value Te (°C) 35 30 25 20 15 10 75 80 45 MAX Tm (°C) 5 0 -5 -10 65 55 60 50 40 45 35 30 30 -15 -20 25 MIN 35 70 Kd = 0 Kd = 5 Kd = 15 Kd = 20 Kd = 25 Kd = 30 Kd = 10 5.3.4 Blower frequencies Table 5.3   Minimum and maximum blower frequencies Boiler Gas type Measurement unit Frequency (heating/DHW) (1) minimum maximum Caldaria 35 AY 35 G20 Hz 53 203 G25 Hz 53 203 G25.3 Hz 53 203 G30 Hz 55 195 G31 Hz 55 203 Caldaria 55.1 Caldaria 100.2 AY 50 AY 100 G20 Hz 53 247 G25 Hz 53 247 G25.1 Hz 53 247 G25.3 Hz 53 247 G2.350 Hz 53 247 G27 Hz 53 247 G30 Hz 55 230 G31 Hz 53 240 1 Caldaria 35, Caldaria 55.1, Caldaria 100.2: check parameters P10 and P11 for DHW, P12 and P13 for heating. AY 35, AY 50, AY 100: check parameters P62 and P63 for heating.

Figure 5.4   Heat input/blower frequency diagram Ti Thermal input Freq Frequency G31 G20 G25 G25.3 G30 2 6 10 14 18 22 26 30 34 35 55 75 95 115 135 155 175 Ti (kW) Freq (Hz) 5.3.4.2 AY 50 and AY 100 Figure 5.5   Heat input/blower frequency diagram Ti Thermal input Freq Frequency G30 G20 G25 G25.1 G25.3 G2.350 G27 G31 0 5 10 15 20 25 30 35 40 45 50 55 35 50 65 80 95 110 125 140 155 170 185 200 215 230 245 Ti (kW) Freq (Hz) 5.4 COMBUSTION PARAMETERS CHECK The ignition system will automatically activate the system venting cycle function shown in the display with code F33, lasting 2 minutes (except for the first start-up, where the duration is 5 minutes), during which the pump will be started and switched off in alternate cycles. When the function is active, the pump is activated and the burner ignition request is disabled. The regular operation of the boiler is

37 5 allowed only when the operation is completed. To check and calibrate the CO2 value at maximum and minimum power, proceed as follows, referring to Figure 5.6 p. 37. The CO2 values and other parameters useful to verify com- bustion are summarized in Table 5.4 p. 37. ▶ Power the boiler. ▶ Open the gas valve on the boiler and check that the valves connecting to the system are open. ▶ Activate the heating request to the boiler, through the control devices provided, and provide an adequate thermal load for carrying out the verification opera- tions. ▶ Insert the flue gas analyser into the flue gas analyser socket and turn it on. The flue gas analysis socket is positioned on the flanged socket (detail PF, Figure 5.7 p. 37). For the AY 100 model, each thermal module has its own flue gas outlet and consequently its own flue gas analysis socket. The checks of each module must be carried out separately. Figure 5.6   Gas valve A Protection screw 1 Gas flow adjustment screw 2 Offset adjustment screw 1 2 A Figure 5.7   Socket for flue gas analysis PF Flue gas analysis socket PF Table 5.4   AY combustion parameters AY 35 AY 50 AY 100 Installation data CO2 percentage in fumes Nominal heat input G20 % 9,45 ÷ 9,25 9,3 ÷ 9,1 G25 % 9,35 ÷ 9,15 9,3 ÷ 9,1 G25.3 % 9,3 ÷ 9,1 G30 % 11,4 ÷ 11,2 11,3 ÷ 11,1 G31 % 10,55 ÷ 10,35 10,3 ÷ 10,1 Minimal heat input G20 % 9,05 ÷ 8,85 9,0 ÷ 8,8 G25 % 9,0 ÷ 8,8 G25.3 % 9,0 ÷ 8,8 G30 % 10,75 ÷ 10,55 10,9 ÷ 10,7 G31 % 9,9 ÷ 9,7 Flue temperature Nominal heat input G20 °C 69,4 66,4 Minimal heat input G20 °C 61,3 56,8 Fumes flow rate Nominal heat input G20 kg/h 54 80 80 (1) Minimal heat input G20 kg/h 7 8 8 (1) CO emission ppm 75,0 68,0 (1) Data refers to each thermal module.

1. Activate the chimney sweep function (F32) by press- ing for 7 seconds the key (Figure 6.1 p. 39). The maximum time before being forced out of the func- tion is 15 minutes. 2. Check that the CO2 value conforms to that reported in Table 5.4 p. 37. 3. If this is not the case, unscrew the protection screw A and adjust with a 4 hex key the screw 2 of the offset adjuster (Figure 5.6  p.  37). To increase the value of CO2 turn the screw clockwise and vice-versa if you want to decrease it. 4. Once completed the adjustment, tighten the protec- tion screw A on the offset adjuster. 5.4.2 Maximum heating power 1. Press the key of the heating side for the cali- bration of the maximum heating power. 2. Check that the CO2 value complies to the value shown in Table 5.4 p. 37. 3. If this is not the case, adjust the gas flow adjuster using the screw 1 (Figure 5.6  p.  37). To increase the CO2 value turn the screw counterclockwise and vice versa if you want to decrease it. 4. After each adjustment on screw 1 of the gas flow ad- juster, you have to wait about 30 seconds for the boiler to stabilize itself to the set value. 5. Press the key of the heating side and check that CO2 value at minimum power has not changed. If so, repeat the calibration described in previous Paragraph 5.4.1 p. 38. 6. Deactivate the chimney sweep function by switching the boiler to OFF mode using the button ( symbol appears on the display). 7. Disconnect the flue gas analyzer and screw the cap of the flue gas analysis socket back on. 8. Replace the boiler front panel. 5.5 GAS CHANGEOVER Contact a TAC for the gas change operation. 5.6 COMMISSIONING 1. Remove the boiler front panel (Paragraph 5.2 p. 30). 2. Power the boiler. The ignition system will automatically activate the system venting cycle function shown in the display with the code F33, which lasts 2 minutes (except the first time the appliance is switched on, where the duration is 5 minutes). When function F33 is active, the pump is activated at intervals and the burner ignition request is disa- bled. The regular operation of the boiler is allowed only when the operation is completed. 3. Make sure that the circulator is not locked. 4. If it is locked, wait for the circulator to perform the au- tomatic unlocking function (duration 3 minutes). 5. If the circulator is still locked, reactivate the automatic unlocking function of the circulator (a further 3 min- utes) by power cycling the boiler. 6. At the end of the above operations, open the gas tap. 7. To switch the boiler to the heating operating mode, press the key; the fixed symbol will ap- pear on the display, indicating that the function has been activated. 8. When there is a request for service from the provided control device, the burner ignition will start. 9. In case of lack of flame, the board repeats the igni- tion operations again after the post-ventilation (20 seconds). 10. It may be necessary to repeat the ignition operation several times to remove any air in the gas pipe. Before repeating the operation, wait about 5 seconds from the last ignition attempt and unlock the boiler from error code E12 by pressing the reset key . 11. Check the system pressure. If a decrease is observed, open the filling tap again until the pressure reaches 1,5 bar. After the operation, close the filling tap again. 5.7 SWITCHING OFF To switch off the unit, select the OFF mode using the key (Figure 6.1  p.  39). In this way, the appli- ance is in standby mode ( symbol appears on the dis- play), ONLY the antifreeze function (system water) and the boiler pump anti-lock function remain active. For AY 100, remember to act on both modules. As it is harmful to the appliance, it is essential to avoid switching off the appliance by removing the power supply to the external module. For the antifreeze and pump anti-lock functions to be active, the boiler must be left powered. 5.8 PROLONGED PERIODS OF INACTIVITY To switch off the unit, select the OFF mode using the key (Figure 6.1 p. 39). In this way, the appliance is in standby mode ( symbol appears on the display). For AY 100, remember to act on both modules. Switch off the power using the main switch, outside the boiler, and close the gas tap upstream of the appliance. By removing the power supply, the automatic antifreeze and pump anti-lock functions will be disabled. If it is expected that during the period of inactivity the external temperature may fall below zero, it is therefore advisable NOT to cut

39 6 off the electrical and gas supply to the appliance. 6 NORMAL OPERATION This section is for the end user. The use of the device by the end user is only per- mitted after the Robur authorised TAC has com- pleted the first start-up. Figure 6.1   Boiler control panel 1 Heating temperature adjustment keys 2 INFO key: press once to view the temperatures and other informa- tions - hold for 5 seconds, in off operating mode, to view the last 5 faults 3 Operating mode selection key: win- ter / space heating / summer / OFF 4 RESET key: faults reset - chimney sweep function activation (hold for 7 seconds) 5 Keys for setting DHW temperature / parameter values / by pressing the keys simultaneously for 5 seconds, the display backlighting can be activated for a continuous period of 10 minutes 6 Display 1 2 3 4 5 6 Figure 6.2   Boiler display icons 1 Parameter number indication or displayed info code 2 Parameter programming function active 3 Not used 4 Not used 5 Not used 6 Installed outdoor probe / Outdoor temperature display 7 Temperature display / setpoint / parameter value 8 OpenTherm communication present (remote control) 9 Insufficient system water pressure signal 10 Flame presence signal / it also indicates, on 3 percentage levels, the modulating power level of the boiler 11 Operation in DHW mode enabled (only for boilers having this function) 12 Resettable error signal 13 Off operating mode 14 Non resettable error signal 15 Operation in heating mode enabled 4 5 6 7 9 10 11 12 13 14 15 1 2 3 8 ≤ 33% >33%<66% >66%<100% 6.1 WARNINGS General warnings Prior to using the appliance carefully read the warnings in Chapter III.1  p.  4, providing impor- tant information on regulations and on safety. First startup by TAC

Robur TAC (Chapter 5 p. 30). Never power the appliance off while it is run- ning NEVER power the appliance off while it is running (except in the event of danger, Chapter III.1 p. 4), since the appliance or system might be damaged. Routine switching on/off The appliance may exclusively be switched on/off by means of the suitably provided control device. Do not switch on/off with the power supply switch Do not switch the appliance on/off with the power supply switch. This may be harmful and dangerous for the appliance and for the system. 6.2 PRELIMINARY CHECKS Checks before switching on Before switching on the appliance, ensue that: � Gas valve open. � Appliance electrical power supply (main switch ON). � The fumes exhaust duct is free and correctly con- nected to the fumes exhaust system. � The hydraulic circuit has been filled. If this is not the case, fill the system according to the instructions in Paragraph 3.2.4 p. 18 and 3.5.3 p. 25. � Check on the pressure gauge that the system pres- sure is 1,5 bar. If there is no water in the system or if the system pressure is lower than the minimum required pres- sure, and error E73 appear on the display of the control panel (Figure 6.2  p.  39), while error E173 appears on the DDC panel (if any). When the correct pressure is restored, the error code disap- pears. 6.3 OPERATION WITH EXTERNAL REQUEST 6.3.1 Turning the boiler on and off 6.3.1.1 Switching on 1. Open the gas tap and provide electrical power. 2. Supply the boiler with electric power by closing the omnipolar switch (to be provided by the installer). 3. Press the key on the control panel of the boil- er (Figure 6.1 p. 39) and select the desired operating mode. 4. The fixed symbol that appears on the display, corre- sponding to the operating mode, indicates that the function has been activated. The burner is only ignited when there is a heating service request from the provided con- trol device (e.g. thermostat, timer, switch, con- tactor ...). After a long period of unit inactivity or at the first start-up, it may be necessary to repeat the ignition operation a few times due to the presence of air in the gas piping. 6.3.1.2 Switching off The burner switches off automatically when the heating service request from the provided control device (e.g. thermostat, timer, switch, contactor ...) is switched off or when the setpoint is achieved. To switch off the boiler, press the button on the boiler (Figure 6.1 p. 39) until the symbol appears on the display. 6.3.2 Heating mode In this operating mode the boiler provides heating only: To switch the boiler to the space heating operating mode: 1. Press the key (Figure 6.1  p.  39), the fixed symbol will appear on the display, indicating that the function has been activated. 2. Adjust the heating water temperature as described in Paragraph 6.3.3 p. 40. 3. Whenever there is a request for space heating, the au- tomatic ignition system will ignite the burner; the op- eration is represented by the ignition of the sym- bol with an intermittent signal on the display. 6.3.3 Setting the heating temperature The temperature is adjusted using the and keys of the heating circuit (Figure 6.1 p. 39): 1. Pressing the key decreases the temperature. 2. Pressing the key increases the temperature. 3. The heating temperature control range is from a mini- mum of 30 °C to a maximum of 80 °C. In order to change the heating temperature con- trol range, parameters P69 (minimum heating set- point) and P70 (maximum heating setpoint) must be changed, Paragraph 5.3 p. 31. 6.3.4 OFF mode In this operating mode the boiler no longer provides heat- ing and DHW, but the antifreeze and pump anti-lock sys- tems remain active. To switch the boiler to the OFF operating mode, press the key; the fixed symbol will appear on the

41 7 display, indicating that the function has been activated. If the boiler was previously in operation, it is switched off and the post-ventilation and post-circulation functions are activated. If you decide to shut down the boiler for a long period of time, secure it by operating in one of the following two ways: 1. Call the TAC that will empty the water system, where there is no provision for the use of antifreeze, and dis- connect the power supply, water and gas. 2. Leave the boiler in the OFF operating mode, keeping the power and gas supply active, so that the antifreeze function and the pump anti-lock function can be activated. 6.3.5 Pump antifreeze and anti-lock function Refer to Paragraph 3.2.5 p. 20. 6.4 OPERATION WITH DDC CONTROL Modify settings via the DDC If the device is connected to the DDC control, refer to the relevant manual to modify settings. Do not modify complex settings Specific technical and system knowledge is re- quired for complex settings. Contact a TAC. 6.5 INFO MENU DISPLAY To view the boiler data from Info menu you have to: 1. Press the key (Figure 6.1 p. 39). The info code will be displayed on the left side of the screen and its value will be displayed on the centre of the screen. 2. To scroll through the list of displayable data, use the and keys of the heating side . 3. Press the key to exit the Info menu. Table 6.1  p.  41 shows the list of Info menu displayable data. Table 6.1   List of displayable data from menu Info Info code Description Measure- ment unit d0 AUX temperature (if not present “--”) °C d1 Manifold temperature (only if the appli- ance is connected to DDC control) °C d2 Outdoor probe temperature °C d3 Inlet temperature °C d4 Combustion blower speed RPM x 10 d5 Water flow rate l/h x 10 d6 Delivery temperature °C d7 Water setpoint °C 6.6 EFFICIENCY For increased appliance efficiency: ▶ Set water temperature to the actual system require- ment. ▶ Reduce repeated switch-ons to the minimum (low loads). ▶ Program appliance activation for actual periods of use. ▶ Keep water and air filters on plumbing and ventilation systems clean. 7 MAINTENANCE Correct maintenance prevents problems, assures efficiency and keeps running costs low. Maintenance operations described herein may ex- clusively be performed by the TAC or skilled main- tenance technician. Any operation on internal components may exclu- sively be performed by the TAC. Before performing any operation, switch off the appliance by means of the control device and wait for the end of the shutdown cycle, then disconnect power and gas supply, by acting on the electrical disconnector and gas valve. The efficiency checks and every other "check and maintenance operation" must be performed with a frequency according to current regulations or, if more restrictive, according to the provisions set forth by the manufacturer, installer or TAC. Responsibility for efficiency checks, to be carried out for the aims of restricting energy consumption, lies with the system manager. It is recommended that the following operations and checks be carried out each year: ▶ Combustion circuit functionality and heat exchange control: � Burner and flue exhaust duct inspection � Cleaning of burner and water/flue exchanger (if applicable) � Flame ignition/detection system control ▶ Hydraulic circuit and internal components functional- ity check: � Hydraulic circuit control (pipes, gaskets) � Expansion tank � Control and safety devices � Water temperature probes ▶ Periodic analysis of combustion, in accordance with regulations in force

Whenever there is a need to empty the boiler, proceed as follows: ▶ Switch off the boiler by pressing the button. ▶ Only after the water pump has completed its post-cir- culation cycle, cut off the power supply via the main switch. ▶ Wait until the boiler has cooled down. ▶ Connect a hose emptying point and connect the other end of the hose to a suitable drain. ▶ Open the drain tap (Figure 7.1 p. 42). ▶ When all the water has drained off, close the drain tap. Figure 7.1   Drain tap position RS Drain tap RS 8 DIAGNOSTICS In the event of a malfunction of the appliance, before con- tacting the TAC, make sure that: ▶ There is a full electricity supply. ▶ The gas is supplied. ▶ The gas pressure is within the indicated limits. ▶ The DDC control (if any) is set so that the appliance is switched on and the appliance does not display a fault. 8.1 SYSTEM PRESSURE RESTORE In case of malfunction of the appliance, with pressure in- side the hydraulic circuit lower than 0,3 bar, which can be seen through the pressure gauge located on the instru- ment panel inside the boiler, it is necessary, after having identified and solved any leaks on the circuit, to proceed with the restoring the correct amount of water (with gly- col, if needed), as indicated in Paragraph 3.2 p. 18. 8.2 ERROR CODES Most faults are generated directly by the MIAH410 boil- er electronic board and are consequently shown on the boiler display (and sent to the DDC control, if any), while faults generated by the CAN-NDG board are sent to the DDC only (if any). The faults generated by the boiler board are exclusively errors (and consequently on the DDC panel, if any, they will always be displayed as E), either temporary (i.e. with automatic reset) or permanent (i.e. with manual reset). For faults requiring manual reset, this can be done by pressing the reset button on the boiler or, alternative- ly, through the appropriate functions of the DDC control, if any. Specifically, codes 01, 02, 12 and 41 are reset by the DDC control via the reset button of the flame controller. Errors can be blocking (i.e. implying burner shutdown) or non-blocking. Even with a non-blocking error, it is not guaranteed that the burner can be switched on in the event of a service request. To display the last 5 fault codes, from the most recent in chronological order, activate the OFF mode using the key (Figure 6.1  p.  39) until the fixed sym- bol appears on the display, then press and hold the key for 5 seconds. ▶ To scroll through the list of stored faults, use the and keys of the heating side . ▶ To reset the fault history, press the reset key . ▶ To exit the display press the key. The fault codes listed below are also shown on the DDC control, if any, by adding the hundreds digit "1" to the code. The code 01 will then be displayed as 101 on the DDC control. Table 8.1   Error codes Error codes generated by the MIAH410 boiler electronic board (displayed both on the boiler display and on the DDC control, if any) Code Description Temporary error Permanent error 01 Limit thermostat trip Contact authorised Technical Assistance 02 Flue gas thermostat trip Contact authorised Technical Assistance 09 Ignition failure Reset is automatic up to 3 attempts. NA NA: Not Applicable

43 8 12 Flame controller lockout NA Check gas supply. The reset can be carried out from DDC or from the boiler panel by pressing the key. If the code persists or in case of doubt, contact the TAC. 31 No CAN bus communication Contact authorised Technical Assistance NA 36 Blower fault Reset occurs automatically 20 minutes after the code is generated. The reset can be carried out from DDC or from the boiler panel by pressing the key. If the code persists, shows up again or in case of doubt, contact the TAC. 41 Flame controller error NA The reset can be carried out from DDC or from the boiler panel by pressing the key. If the code persists, shows up again or in case of doubt, contact the TAC. 73 Insufficient water pressure Reset is automatic when the triggering condition ceases. NA 74 AUX temperature probe fault Reset is automatic when the triggering condition ceases. NA 75 Low hot water flow Reset is automatic when the triggering condition ceases. Check and clean water filters on the system. Check for air in the system. Check water flow pump. Power cycle the appliance. The reset can be carried out from DDC or from the boiler panel by pressing the key. If the code persists, shows up again or in case of doubt, contact the TAC. 76 Hot water delivery temperature probe fault Reset is automatic when the triggering condition ceases. NA 77 Hot water inlet temperature probe fault Reset is automatic when the triggering condition ceases. NA 83 Invalid functional parameters NA Power off the appliance. Contact the TAC. 84 Incorrect supply voltage Reset is automatic when the triggering condition ceases. NA 86 Internal boiler board error NA Power off the appliance. Contact the TAC. 87 No communication with CAN-NDG board Reset is automatic if communication is restored within 60 seconds. Otherwise, a reset of the CAN-NDG board is forced and W182 is raised. Contact the TAC. 90 Outdoor temperature probe fault Reset is automatic when the triggering condition ceases. NA NA: Not Applicable Error codes generated by the CAN-NDG board (displayed only on the DDC control, if any) Code Description Warning (u) Error (E) 180 Incomplete functional parameters Contact the TAC. 181 Error in storing configuration parameters on CAN-NDG board Reset is automatic when the triggering condition ceases. Contact the TAC. 182 CAN-NDG board reset Reset is automatic when the triggering condition ceases. NA 185 Invalid module type configuration param- eters NA Contact the TAC. 188 Boiler parameters reading error Reset is automatic the next time the parameters are read correctly. NA 189 Boiler parameters writing error NA Run parameter writing again. 192 Incompatibility of boiler board FW version NA Contact the TAC. NA: Not Applicable The special functions listed below are also shown on the DDC control, if any, as warnings, always adding the hun- dreds digit "1" to the code.

Code Function Description F32 Chimney sweep function active It is activated by pressing the reset key for 7 seconds and it is deactivated by turning off the boiler. Brings the boiler to the minimum and maximum power for 15 minutes by deactivating the modulation function. Generally used for combustion and calibration tests. F33 System air purge cycle in progress It automatically starts when the boiler is powered up, running for 5 minutes a series of cycles in which the pump is turned on for a period of 40 seconds and then turned off for a period of 20 seconds. Regular operation is only permitted at the end of the function. It can also be activated during normal operation of the boiler, in the event that the enable of the water pressure switch is lacking, when the contact is closed, a 2-minute venting cycle is performed. F79 Heating antifreeze function It is automatically activated when the heating probe detects an outlet temperature lower than the value of P81. The boiler operates at minimum power and is deactivated when a water temperature of 30 °C is detected on the outlet or 20 °C on the inlet.

45 9 9 APPENDICES 9.1 PRODUCT FICHE 9.1.1 AY 35 Figure 9.1 Table 7 Model(s): AY 35 Condensing boiler: yes Low-temperature (**) boiler: yes B11 boiler: no Cogeneration space heater: no If yes, equipped with a supplementary heater: no Combination heater: no Item Symbol Value Unit Item Symbol Value Unit Rated heat output Prated 33,4 kW Seasonal space heating energy efficiency η s 92,7 % At rated heat output and high- temperature regime (*) P 4 33,4 kW At rated heat output and high- temperature regime (*) η 4 88,3 % At 30 % of rated heat output and low-temperature regime (**) P 1 10,0 kW At 30 % of rated heat output and low-temperature regime (**) η 1 97,8 % Auxiliary electricity consumption Other items At full load elmax 0,088 kW Standby heat loss P stby 0,059 kW At part load elmin 0,017 kW Ignition burner power consumption P ign 0 kW In standby mode P SB kW Annual energy consumption Q HE 266,8 GJ Sound power level, indoors/outdoors L WA - / 52,4 dB Contact details Robur SPA, Via Parigi 4/6, I-24040 Zingonia (BG) Additional information required by COMMISSION REGULATION (EU) No 813/2013, Table 1: Emissions of nitrogen oxides: NO x 52 mg/kWh COMMISSION DELEGATED REGULATION (EU) No 811/2013 (**) Low temperature means for condensing boilers 30 °C, for low-temperature boilers 37 °C and for other heaters 50 °C return temperature (at heater inlet). Technical parameters for boiler space heaters, boiler combination heaters and cogeneration space heaters For boiler space heaters and boiler combination heaters: Useful heat output For boiler space heaters and boiler combination heaters: Useful efficiency 0,004 (*) High-temperature regime means 60 °C return temperature at heater inlet and 80 °C feed temperature at heater outlet.

Figure 9.2 Table 7 Model(s): AY 50 Condensing boiler: yes Low-temperature (**) boiler: yes B11 boiler: no Cogeneration space heater: no If yes, equipped with a supplementary heater: no Combination heater: no Item Symbol Value Unit Item Symbol Value Unit Rated heat output Prated 49,2 kW Seasonal space heating energy efficiency η s 93 % At rated heat output and high- temperature regime (*) P 4 49,2 kW At rated heat output and high- temperature regime (*) η 4 88,1 % At 30 % of rated heat output and low-temperature regime (**) P 1 14,8 kW At 30 % of rated heat output and low-temperature regime (**) η 1 98,0 % Auxiliary electricity consumption Other items At full load elmax 0,113 kW Standby heat loss P stby 0,059 kW At part load elmin 0,017 kW Ignition burner power consumption P ign 0 kW In standby mode P SB kW Annual energy consumption Q HE 393,1 GJ Sound power level, indoors/outdoors L WA - / 52,4 dB Contact details Robur SPA, Via Parigi 4/6, I-24040 Zingonia (BG) Additional information required by COMMISSION REGULATION (EU) No 813/2013, Table 1: Emissions of nitrogen oxides: NO x 52 mg/kWh COMMISSION DELEGATED REGULATION (EU) No 811/2013 (**) Low temperature means for condensing boilers 30 °C, for low-temperature boilers 37 °C and for other heaters 50 °C return temperature (at heater inlet). Technical parameters for boiler space heaters, boiler combination heaters and cogeneration space heaters For boiler space heaters and boiler combination heaters: Useful heat output For boiler space heaters and boiler combination heaters: Useful efficiency 0,004 (*) High-temperature regime means 60 °C return temperature at heater inlet and 80 °C feed temperature at heater outlet.

47 9 9.1.3 AY 100 Figure 9.3 Table 7 Model(s): AY 100 Condensing boiler: yes Low-temperature (**) boiler: yes B11 boiler: no Cogeneration space heater: no If yes, equipped with a supplementary heater: no Combination heater: no Item Symbol Value Unit Item Symbol Value Unit Rated heat output Prated 98,4 kW Seasonal space heating energy efficiency η s 93,1 % At rated heat output and high- temperature regime (*) P 4 98,4 kW At rated heat output and high- temperature regime (*) η 4 88,1 % At 30 % of rated heat output and low-temperature regime (**) P 1 30,0 kW At 30 % of rated heat output and low-temperature regime (**) η 1 98,0 % Auxiliary electricity consumption Other items At full load elmax 0,225 kW Standby heat loss P stby 0,100 kW At part load elmin 0,023 kW Ignition burner power consumption P ign 0 kW In standby mode P SB kW Annual energy consumption Q HE 785,3 GJ Sound power level, indoors/outdoors L WA - / 52,0 dB Contact details Robur SPA, Via Parigi 4/6, I-24040 Zingonia (BG) Additional information required by COMMISSION REGULATION (EU) No 813/2013, Table 1: Emissions of nitrogen oxides: NO x 52 mg/kWh COMMISSION DELEGATED REGULATION (EU) No 811/2013 (**) Low temperature means for condensing boilers 30 °C, for low-temperature boilers 37 °C and for other heaters 50 °C return temperature (at heater inlet). Technical parameters for boiler space heaters, boiler combination heaters and cogeneration space heaters For boiler space heaters and boiler combination heaters: Useful heat output For boiler space heaters and boiler combination heaters: Useful efficiency 0,004 (*) High-temperature regime means 60 °C return temperature at heater inlet and 80 °C feed temperature at heater outlet.

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