ApenGroup Aquakond AKY Series Technical manual

GB Use, Installation and Maintenance Manual
AKY condensing boiler
1code HC0048.10GB ed.B-1811
AKY
Energy Efciency Class A
NOx Class: 6
Yield up to 109%
Tax deduction
Thermal Account for
Public Authorities

AQUAKOND AKY CONDENSING BOILER
2
code HC0048.10GB ed.B-1811 AKY

AQUAKOND AKY CONDENSING BOILER
3code HC0048.10GB ed.B-1811
AKY
VER. 00.00.2017
CODE SERIAL NUMBER
Dichiarazione di Conformità
Statement of Compliance
APEN GROUP S.p.A.
20060 Pessano con Bornago (MI)
Via Isonzo, 1
Tel [phone] r.a.
Fax [phone]
Internet: http://www.apengroup.com
Il presente documento dichiara che la macchina:
With this document we declare that the unit:
Modello:
Model:
Caldaia AKY
: AKY032, AKY034, AKY050, AKY070
, AKY100
Hot Water Boiler AKY: AKY032, AKY034, AKY050, AKY070, AKY100
è stata progettata e costruita in conformità con le disposizioni delle Direttive Comunitarie:
has been designed and manufactured in compliance with the prescriptions of the following EC Directives:
Regolamento Apparecchi a Gas 2016/426/UE
Gas Appliance Regulation 2016/426/UE
Direttive Rendimenti 92/42/CE
Efficiency Requirements Directive 92/42/CE
Regolamento UE 813/2013
EU Regulation 813/2013
Regolamento UE 811/2013
EU Regulation 811/2013
Direttiva compatibilità elettromagnetica 2014/30/UE
Electromagnetic Compatibility Directive 2014/30/UE
Direttiva Bassa Tensione 2014/35/UE
Low Voltage Directive 2014/35/UE
è stata progettata e costruita in conformità con le norme:
has been designed and manufactured in compliance with the standards:

EN15502-1: 2012
EN15502-2-1 :2012

EN60335-1
EN60335-2-102
EN60730-1
EN 60068-2-1
EN 60068-2-2
Organismo Notificato:
Notified body:
Kiwa Cermet Italia S.p.A
0476
PIN 0476CR1226
La presente dichiarazione di conformità è rilasciata sotto la responsabilità esclusiva del fabbricante
This declaration of conformity is issued under the sole responsibility of the manufacturer
Pessano con Bornago, 01/03/2018
Apen Group S.p.A.
Un Amministratore

AQUAKOND AKY CONDENSING BOILER
4
code HC0048.10GB ed.B-1811 AKY

AQUAKOND AKY CONDENSING BOILER
5code HC0048.10GB ed.B-1811
AKY
INDEX
SECTION 1. GENERAL CAUTIONS 6
SECTION 2. SAFETY-RELATED WARNINGS 6
2.1. Fuel 6
2.2. Gas Leaks 6
2.3. Power supply 7
2.4. Use 7
2.5. Maintenance 7
2.6. Unpacking 8
2.7. Dismantling and disposal 8
SECTION 3. TECHNICAL FEATURES 9
  3.1. ModelsandEfciency 9
3.2. Technical Data: 10
3.3. Hydraulic circuit characteristics 14
3.4. INAIL components 15
3.5. Boiler size 16
3.6. Operation and accessories17
SECTION 4. USER'S INSTRUCTIONS 18
4.1. Boiler operation 18
  4.2. LCDinstrumentpanel 19
SECTION 5. INSTALLATION INSTRUCTIONS 20
5.1. General Installation Instructions (ITALY) 20
5.2. Transport and Handling 20
5.3. Accessories for installation 21
5.4. Boiler installation 21
5.5. Electrical Connections 22
5.6. GAS Connections24
5.7. Connections to the Flue 25
  5.8. Hydrauliccircuitlling 27
SECTION 6. SERVICING INSTRUCTIONS 29
  6.1. CountryTable-GasCategory 29
6.2. Gas Settings Table 30
6.3. First start-up 31
6.4. Analysis of combustion 31
6.5. Conversion to LPG 32
6.6. Replacing the Gas Valve 32
6.7. Replacing the modulation PCB 33
6.8. Programming with LCD Display 33
  6.9. Exchangermaintenance 34
SECTION 7. MODULATION PCB PARAMETERS 35
SECTION 8. ANALYSIS OF LOCKOUTS - FAULT 37
SECTION 9. WIRING DIAGRAMS 39
  9.1. AKY032/034/050/070electricconnection 40
  9.2. AKY100electricconnection 41
SECTION 10. SPARE PARTS 42

AQUAKOND AKY CONDENSING BOILER
6
code HC0048.10GB ed.B-1811 AKY
1. GENERAL CAUTIONS
This manual is an integral part of the product and must always
accompany it.
Should the equipment be sold or passed on to someone else,
always make sure that this manual is supplied with the equipment
for future reference by the new owner and/or installer.
The manufacturer shall not be held civilly or criminally responsible
for injuries to people or animals or damages to things caused
by incorrect installation, calibration and maintenance or by
failure to follow the instructions contained in this manual or by
operations carried out by unqualied staff.
This product must be used only for the applications for which
it was designed or approved. Any other use must be regarded
as hazardous.
During the installation, operation and maintenance of the
equipment described in this manual, the user must always strictly
follow the instructions given in this use and instruction manual.
The equipment must be installed in compliance with current
regulations and according to the manufacturer's instructions
by qualied staff, technically specialised in the heating eld.
First start-up, conversion between different types of gas and
maintenance operations must be carried out only by staff of
Authorised Service Centres (for Italy, authorised by Apen
Group Spa).
APEN GROUP has a large network of authorised Service
Centres. For more information, refer to the telephone directories
or contact the manufacturer directly.
The warranty conditions are specied on the warranty certicate
supplied with this equipment.
The manufacturer declares that the equipment has been
workmanlike manufactured in compliance with UNI, UNI-CIG, IEC,
EN technical standards and with all relevant legislation, as well as
with Gas Directive 2009/142/EEC.
For Swiss market, reference standards are:
• SSIGA G1 Directive: Directive for natural gas equipment
in buildings;
• Cantonal requirements (AICAA- Fireghting directives,
Thermal technical systems (2015)).
2. SAFETY-RELATED WARNINGS
The following symbol is used in this manual to attract machine
operators’ attention.
Accident prevention rules for the operator
and the personnel operating nearby.
Please nd below the safety regulations for the installation room
and the air vents.
2.1. Fuel
Before starting up the boiler, make sure that:
• the gas mains supply data are compatible with the data
stated on the nameplate;
• the combustion air intake ducts and the fume exhaust pipes
are only those specied by Apen Group;
• the gas seal of the feeding system has been tested and
approved in compliance with the applicable standards;
• the boiler is supplied with the same type of fuel it has been
designed for;
• the system is correctly sized for such ow rate and is tted
with all safety and monitoring devices required by applicable
standards;
• the internal cleaning of gas pipes has been correctly carried out;
• the fuel ow rate is suitable for the power required by the boiler;
• the fuel supply pressure is between the range specied on
the nameplate.
2.2. Gas Leaks
If you smell gas:
• do not operate electrical switches, telephones or any other
object/device that could produce sparks;
• immediately open doors and windows to create an air ow
to vent the gas out of the room;
• close the gas valves;
• call for qualied staff.

AQUAKOND AKY CONDENSING BOILER
7code HC0048.10GB ed.B-1811
AKY
Warning: in order to ensure the correct operation of the equipment, preventing
its damage or problems for persons, it is
mandatory to add a percentage of glycol to
the lling water, proportional to the minimum
winter temperature of the area where the
boiler is installed.
It is strictly FORBIDDEN to connect a system
lling circuit to the waterworks mains.
We recommend to check the water and glycol content inside the boiler by
means of a refractometer on a yearly basis.
Attention: Using galvanised iron pipes may
bring about corrosive phenomena when
using antifreeze. Therefore we DO NOT suggest
using this material.
2.3. Power supply
The equipment must be correctly connected to an effective
earthing system, made in compliance with current regulations
(IEC 64-8).
Cautions
• With the help of qualied personnel, check the efciency
of the earthing system;
• Check that the mains power supply is the same as the
power input stated on the equipment nameplate and in
this manual;
• Do not mistake the neutral for the live wire. The equipment can
be connected to the mains power supply with a plug-socket
only if the latter does not allow live and neutral to be swapped;
• The electrical system and, more specically, the cable
section, must be suitable for the equipment maximum
power input, shown on the nameplate and in this manual;
• The electric cables must be kept away from heat sources.
IMPORTANT: an omnipolar switch having fuses with contact opening greater than 3 mm must be installed
upstream of the power cable. The switch must be visible,
accessible and positioned at a distance lower than 3 metres
from the equipment. All electrical operations (installation
and maintenance) must be carried out by qualied staff.
2.4. Use
Do not allow children or inexperienced people to use any
electrically powered equipment.
The following instructions must be followed:
• do not touch the equipment with wet or damp parts of your
body and/or with bare feet;
• do not use the gas pipes to earth electrical equipment;
• do not touch the hot parts of the equipment, such as the
fume exhaust duct;
• do not place any object over the equipment;
• do not touch the moving parts of the equipment.
2.5. Maintenance
Before carrying out any cleaning and maintenance operations,
isolate the boiler from the mains power supply using the switch
located on the electrical system and/or on the shut-out devices.
If the equipment is faulty and/or incorrectly operating, switch it
off and do not attempt to repair it yourself, but contact our local
Technical Service Centre.
All repairs must be carried out by using genuine spare parts.
Failure to comply with the above instructions could compromise
the safety of the equipment and invalidate the warranty.
If the equipment is not used for long periods, shut the gas
supply off through the gas stopcock and disconnect it from the
power supply.
If the boiler is to be put out of service, in addition to the above operations, potential sources of hazard on the unit
must be disabled.
For itsAKY boilers,APEN GROUPtested and recommends
to use ALPHI 11 glycol by Fernox; the following KITS
contain packs with different capacity:
code capacity
C07200-05 5 litres
C07200-25 25 litres
Warnings for glycol use
In case of direct intake of high doses, the
product may cause effects on the central
nervous system, respiratory diseases and
kidney damage. Avoid contact with skin and
eyes – protect the respiratory tract.
Do not allow the product to enter sewers,
surface water and groundwater, ground.
Use gloves, rubber boots and normal tight
working clothing. Wear tight goggles.
For further information, refer to the safety data
sheet of
Cookson Electronics, Alpha Metals S.p.A.,
Via Ghisalba 1, 20021 Bollate, Milano, Italy
Tel: [phone] Fax: [phone]
e-mail: fernox_italy@cooksonelectronics.
com www.fernox.com

AQUAKOND AKY CONDENSING BOILER
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code HC0048.10GB ed.B-1811 AKY
2.6. Unpacking
The unpacking operation must be carried out by using suitable
tools or safety devices where required. Recovered packaging
materials must be separated and disposed of according to
applicable regulations in the country of use.
While unpacking the unit, check that the unit and all its parts
have not been damaged during transport and match the order.
If damages have occurred or parts are found to be missing,
immediately contact the supplier.
The manufacturer is not liable for any damages occurred
during transport, handling and unloading.
Packing material disposal
The packing safeguards the product from transport damages.
All the materials used are environmentally friendly and
recyclable. Please contact a specialised distributor or your local
administration for more information on waste disposal.
2.7. Dismantling and disposal
Should the machine be dismantled or demolished, the person
in charge with the operation shall proceed as follows:
Disposal of end-of-life products
This equipment is marked in compliance with
European Directive 2012/19/EU on waste
electrical and electronic equipment (WEEE).
This Directive denes the rules for collecting and
recycling waste equipments throughout the entire
territory of the European Union.
WEEE contain both pollutants (which may affect
the environment negatively) and raw materials (which may be
re-used). Therefore WEEE must undergo specic treatment
operations to remove and dispose of the pollutants in a safe
manner and extract and recycle the raw materials. It is forbidden to
dispose of WEEE in unsorted municipal waste. These operations
facilitate recovery and recycling of the materials, thus reducing
the environmental impact.
NOTE: All materials recovered will be processed and
disposed of according to what provided for by the laws
in force in the country of use and/or according to the
standards indicated in the safety sheets of the chemicals.
INFORMATION FOR DISPOSAL valid in ITALY (Legislative
Decree 49/2014)
The condensing boilers series AKY and fan heaters mod. AB at
the end of their life are considered “waste electrical and electronic
equipment”, classied as “professional WEEE”. According to
Decree 49/2014 the “professional WEEE” classication sets forth
the obligation to dispose of the products in treatment facilities
suitable for this kind of waste.
Apen Group is part of a collective system (Union Ecoped/
Ridomus) for the sorted waste management of professional
WEEE according to art. 13 of Legislative Decree 49/2014.
Please contact the Apen Group for end-of-life products so as
to obtain all the information necessary for their correct waste
disposal, which is possible thanks to the Collective System
(Union) to which the company is associated.
Please remember that product disposal without complying with
the mode described above is a violation liable to administrative
and penal sanctions.
INFORMATION FOR DISPOSAL valid abroad
(EU COUNTRIES except Italy).
The European Directive 2002/96/EC shall be implemented in
every EU member state. There may be different application
modalities for the various member states, even in terms of
modality for waste disposal depending on its type (House-hold
or Professional WEEE). To this regard at the end of the life of
the product, we highly recommend you call the distributor or
installer so as to obtain information on the correct disposal, in
compliance with the existing laws of the installation country.

AQUAKOND AKY CONDENSING BOILER
9code HC0048.10GB ed.B-1811
AKY
3. TECHNICAL FEATURES
AquaKond thermal unit, running with natural gas or LPG, has
been designed to meet heating requirements of environments
such as garages, body shops, carpenter’s shops, industrial and
commercial buildings, etc..
AquaKond system consists of a boiler module, to be installed
outside the room to be heated, and one or more fan units to be
positioned inside the room.
The system combustion circuit, located in the boiler, is completely
outside. Therefore, both the gas circuit and the combustion
fume circuit [B23P in standard conguration] are outside the
room to be heated.
The system can operate independently. To start up the unit,
simply connect it to the gas mains and to the mains power supply.
The boiler is equipped with the antifreeze protection, which is of
course operated by power supply; to prevent any frost problem
in the absence of power supply, rell the system with a water-
glycol mix in a percentage that varies according to external
operating temperatures [see below].
Upon delivery, AKY032 andAKY034 models have already been
relled with a 30% water-glycol mix, in order to avoid liquid
freezing in case of external temperatures up to -15°C.
AKY050, AKY070 and AKY100 models have not been relled as
the size of the boiler expansion reservoir is not able to contain
the whole volume of the circuit liquid.
AKY boilers are compliant with regulations EN15502-1 and
EN15502-2-1.
Condensing and premixing technology, together with ame
modulation, allow achieving efciency above 108%.
The boiler exchanger, made of stainless steel, ensures a high
yield and a high corrosion resistance.
The burner is made entirely of stainless steel with special
mechanical solutions to ensure optimal reliability and performance
levels, as well as high thermal and mechanical resistance.
According to the model, the different remote controls (optional)
allow operation parameter setting, ambient temperature control,
time programming, working phase and fault display.
Inherent Safety
The efciency increase at minimum power is achieved by using
a sophisticated air/gas mixing technique and by regulating at
the same time the combustion air ow and the fuel gas ow.
This technology increases the equipment safety as the gas valve
supplies the fuel according to the air ow, based on an adjustment
preset in the factory. Unlike atmospheric burners, the CO2content
remains constant throughout the boiler operating range, allowing
the boiler to increase its efciency when the heat output reduces.
If there is no combustion air, the valve will not supply gas; if
the combustion air ow reduces, the valve will automatically
reduce the gas ow yet will keep its combustion parameters
at optimal levels.
Low emissions
The premixed burner, in combination with the air/gas valve,
ensures "clean" efcient combustion having low emissions.
3.1. Models and Efciency
AKY boilers are of condensing type with modulating burner.
All the boilers are condensing type with seasonal efciency
ErP ≥90% (corresponding to a Class A Energy Efciency). AKY
series boilers are in compliance with the efciency demand set
forth by all regional resolutions, even the strictest ones.
Water operating temperature is 72°C.
Efciency with maximum heat output is greater than 100%.
All models are supplied as standard with an electronic circulator
characterised by variable speed and low electrical consumption.
Control accessories, such as ordinary remote control,
SmartEASY/WEB, may be used with all models.
All models have been designed to achieve efciency above 100%
with respect to the lower caloric value, when the boiler supplies
maximum heat output, and 108% with minimum heat output.
The boiler efciency, with water delivery at 72/75°C, has been
tested and certied by the certication body.
By means of the SmartEASY/WEB remote control [optional], it
is possible to use the "ambient compensation" function (PID)
that allows to reduce water delivery temperature, "sliding
temperature", in inverse proportion to ambient temperature
increase, thereby reaching boiler efciency above 108% [Hi].
Note: to gain access to nancing allowed for by the current budget, concerning single thermal systems
with heat output above 100kW, an ambient thermostat with
ambient compensation function, or sliding temperature, and
the circulator characterised by variable ow must be used.
AKY032, AKY034, AKY050 and AKY070 use the "cold door"
exchanger, which allows to further reduce the heat losses in
the housing, increasing the boiler yield.

AQUAKOND AKY CONDENSING BOILER
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code HC0048.10GB ed.B-1811 AKY
3.2. Technical Data:
* Abbreviation compliant with reg. EU/811/2013.
1 The boiler is supplied as standard with B23P terminal; other congurations are possible using accessories.
2 Reg. EU/813/2013 art.2 point 20. It is calculated starting from the weighted average of useful efciency to the rated heat output and of
the useful efciency at 30% of rated heat output, expressed in %. For calculation purposes, the efciency value is referred to the higher
caloric value [Hs].
3 CO and NOX values refer to the average weighted value of emission between maximum and minimum rated heat output according to the
product standard [EN15502]. Values referred to cat. H (gas G20).
BOILER AKY032
HC00046 ET 012
Type of equipment B23P¹-B53P-C43-C53-C63-C83
EC approval P.I.N. 0476CR1226
Seasonal space heating energy efciency - [Reg.813/2013/EC]² hs91.5
Energy efciency class [Reg.811/2013/EC] A
NOx class [EN 15502-1] 6
Boiler yields
Symbol* MAX MIN
Burner heat output [Hi] Qn kW 31.0 5.0
Useful heat output [Hi] [80/60°C] P4 kW 29.9 4.8
Useful heat output [Hi] [50/30°C] kW 32.4 5.3
Useful heat output at 30% of load [Hi] [50/30°C] P1 kW 10
Useful heat output [Hi] [72/45°C] Pn kW 30.8 5.2
Useful efciency [Hi] [80/60°C] η4 %96.5 96.7
Useful efciency [Hi] [50/30°C] % 104.5 106.8
Useful efciency at 30% of Pn [Hi] [50/30°C] η1 %107.3
Useful efciency [Hi] [72/45°C] % 99.5 104.5
Flue losses with burner on [80/60°C] % 2.6 1.4
Heat loss in standby [EN15502-2;EN15316-1-4] Pstand-by kW 0.112
Flue losses with burner off %0.1
Housing losses [Taverage=60°C] % 0.4
MAX condensation l/h 0.8
Flue gas emissions
Carbon monoxide - CO - [0% of 02]ppm 44ppm
Nitrogen oxides - NOx - [Hi] [0% of 02]330ppm - 54mg/kWh
Nitrogen oxides - NOx - [Hs] [0% of 02]327ppm - 48mg/kWh
Fumes temperature °C 75 48
Pressure available at the ue Pa 120
Electrical Characteristics
Supply voltage V 230V-50 Hz single-phase
Rated power W 101 68
Electric power of auxiliary components (excluding circulator) elmax W 48 12
Electric power of auxiliary components at 30% of load (excluding circulator) elmin W 14
Electric power of auxiliary components in standby PSB W 5
Operating Temperatures °C -15°C to +50°C
Protection Rating IP IPX5D
Hydraulic connections
Maximum working pressure PMS bar 3
Boiler water content l 4.5
Delivery/return connections - UNI ISO 7/1 - Ø G 3/4" M
Gas connection Ø G 3/4" M
Operating weight (water included) kg 32
Weight with packaging kg 37

AQUAKOND AKY CONDENSING BOILER
11 code HC0048.10GB ed.B-1811
AKY
* Abbreviation compliant with reg. EU/811/2013.
1 The boiler is supplied as standard with B23P terminal; other congurations are possible using accessories.
2 Reg. EU/813/2013 art.2 point 20. It is calculated starting from the weighted average of useful efciency to the rated heat output and of the useful
efciency at 30% of rated heat output, expressed in %. For calculation purposes, the efciency value is referred to the higher caloric value [Hs].
3 Value referred to cat. H (gas G20) with Burner for Switzerland setting. For further details refer to page 34 table 6.2 (gas settings).
4 CO and NOX values refer to the average weighted value of emission between maximum and minimum rated heat output according to the product
standard. Values referred to cat. H (gas G20).
5 The boiler is supplied as standard with C63 conguration; other congurations are possible using accessories available from our catalogue.
6 AKY100 for Switzerland is weakened: Burner heat output [Hi] [72/45°C] MAX: 92 kW and MIN: 20.5 kW.
BOILER AKY034 AKY050 AKY070 AKY100
HC00046 ET 012
Type of equipment B23P¹-B53P-C43-C53-C63-C83 B23P -C635
EC approval P.I.N. 0476CR1226
Seasonal space heating energy efciency -
[Reg.813/2013/EC]² hs92.6 90.8 91.3 92.5
Energy efciency class [Reg.811/2013/EC] A -
NOx class [EN 15502-1] 6
Boiler yields
Symbol* MAX MIN MAX MIN MAX MIN MAX MIN
Burner heat output [Hi] Qn kW 34.8 8.0 49.0 8.1 65.0 11.0 96.0 6 21.0 6
Useful heat output [Hi] [80/60°C] P4 kW 34.2 7.9 47.4 7.8 63.4 10.7 92.8 21.2
Useful heat output [Hi] [50/30°C] kW 36.8 8.6 51.4 8.5 67.9 11.8 100.1 23.1
Useful heat output at 30% of load [Hi] [50/30°C] P1 kW 11.4 15.7 21.0 31.1
Useful heat output [Hi] [72/45°C] Pn kW 35.2 8.3 48.9 8.3 65.3 11.4 96.2 22.2
Useful efciency [Hi] [80/60°C] η4 %98.3 98.2 96.8 95.7 97.5 97.4 96.7 98.6
Useful efciency [Hi] [50/30°C] % 105.8 106.9 104.8 105.5 104.5 107.4 104.3 107.6
Useful efciency at 30% of Pn [Hi] [50/30°C] η1 %108.9 106.7 107.5 108.1
Useful efciency [Hi] [72/45°C] % 101.1 103.3 99.7 101.9 100.5 103.8 100.2 103.3
Flue losses with burner on [80/60°C] % 2.6 1.4 2.7 1.0 2.7 0.9 3.3 1.4
Heat loss in standby [EN15502-2;EN15316-1-4] Pstand-by kW 0.112 0.574 0.694 0.127
Flue losses with burner off %0.1
Housing losses [Taverage=60°C] % 0.35 0.40 0.40 0.50
MAX condensation l/h 0.8 1.6 2.2 3.5
Flue gas emissions
Carbon monoxide - CO - [3% of 02] - [80/60°C] - Pn³ 78ppm-97mg/kWh 76ppm-95mg/kWh 73ppm-91mg/kWh 71ppm-89mg/kWh
Carbon monoxide - CO - [0% of 02]4ppm 34 30 44 27
Nitrogen oxides - NOx - [Hi] [0% of 02]422ppm-39mg/kWh 15ppm-27mg/kWh 34ppm-61mg/kWh 24ppm-43mg/kWh
Nitrogen oxides - NOx - [Hs] [0% of 02]420ppm-35mg/kWh 14ppm-24mg/kWh 32ppm-56mg/kWh 22ppm-39mg/kWh
Fumes temperature °C 75 48 75 40 75 40 83 35
Pressure available at the ue Pa 120 100 150 90
Electrical Characteristics
Supply voltage V 230V-50 Hz single-phase
Rated power W 101 68 152 54 180 64 235 95
Electric power of auxiliary components (excluding
circulator) elmax W 48 12 88 10 104 12 110 13
Electric power of auxiliary components at 30% of load
(excluding circulator) elmin W 14 14 17 18
Electric power of auxiliary components in standby PSB W 5
Operating Temperatures °C -15°C to +50°C
Protection Rating IP IPX5D
Hydraulic connections
Maximum working pressure PMS bar 3.0
Boiler water content l 5.0 6.3 7.0 10.0
Delivery/return connections - UNI ISO 7/1 - Ø G 3/4" M G 1" M G 1 1/2" M
Gas connection Ø G 3/4" M
Operating weight (water included) kg 35 45 47 90
Weight with packaging kg 40 43 45 106

AQUAKOND AKY CONDENSING BOILER
12
code HC0048.10GB ed.B-1811 AKY
Flow rate curve - boiler available head
For its proper operation, AquaKond system requires the following water ow rates through the boiler:
• 32 ow rate within 900 and 1,300 l/h;
• 34 ow rate within 1,000 and 1,400 l/h;
• 50 ow rate within 1,600 and 2,000 l/h;
• 70 ow rate within 1,800 and 2,000 l/h;
• 100 ow rate within 3,100 and 3,400 l/h.
The boiler can operate correctly even with lower water ow rates; in this case, to reach the maximum heat output, increase hot
water delivery temperature, thereby increasing its thermal difference.
0
10
20
30
40
50
60
70
80
90
100
500 1000 1500 2000 2500 3000 3500
Prevalenza [kPa]
Portata [l/h]
Curva Prevalenza disponibile/Portata acqua per Caldaie serie AKY
AKY050
AKY034
AKY032
AKY070
AKY100

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Pipe pressure drop
The table below contains pressure drop values of pipes for ow rate multiple values.
The drop is indicated in kPa per 1 metre of linear length; the calculation must be made by calculating the equivalent length of
the pipe. Drops are given for glycol-free 70-75°C water; for water glycol mix, multiply the drops by the given factor. The last line
contains the volume in litres per 1 metre of pipe.
Pressure drops identied due to the various components inserted in the hydraulic system must be added up to the pipe length,
according to the values indicated in the table below.
Glycol coefcients
The table below contains the freezing temperatures of water and glycol mixes.
Using a water and glycol mix, it is necessary to increase pressure drops of pipes according to the following coefcients:
• for a glycol mix equal to 10% of volume multiply by 1.07
• for a glycol mix equal to 20% of volume multiply by 1.15
• for a glycol mix equal to 30% of volume multiply by 1.22
All data refer to a FERNOX ALPHI11 monopropylene glycol and water mix recommended by APEN GROUP for AQUAKOND
systems.
Other types of glycol, different from the recommended one, invalidate the product warranty.
Pressure drops in kPa for 1 metre of linear length
Water ow rate Steel pipes Copper pipes
l/h 3/4" 1" 1"1/4 1"1/2 2" 20/22 25/28 32/35 39/42 51/54
600 0.15 0.05 0.18 0.06 0.02
900 0.31 0.10 0.03 0.35 0.12 0.04
1,200 0.55 0.18 0.05 0.02 0.60 0.20 0.07 0.03
1,500 0.82 0.26 0.07 0.03 0.30 0.10 0.04
1,800 0.36 0.10 0.04 0.01 0.42 0.13 0.05 0.01
2,100 0.49 0.13 0.06 0.02 0.52 0.17 0.07 0.02
2,400 0.65 0.16 0.08 0.03 0.70 0.21 0.09 0.03
3,000 0.24 0.11 0.04 0.27 0.12 0.04
3,600 0.34 0.16 0.06 0.35 0.17 0.06
4,200 0.45 0.21 0.07 0.53 0.22 0.07
4,800 0.59 0.21 0.08 0.28 0.08
Water content l/m 0.37 0.59 1.20 1.39 2.22 0.31 0.49 0.80 1.19 2.04
Equ ivalen t
length in m Steel pipes
3/4" 1" 1"1/4 1"1/2 2"
45° bend 0.3 0.3 0.6 0.6 0.6
90° bend 0.6 0.6 0.9 1.2 1.5
90° bend with wide radius 0.6 0.6 0.6 0.6 0.9
T-shaped tting 1.5 1.5 1.8 2.4 3.0
check valve 1.5 1.5 2.1 2.7 3.3
gate valve 0.3 0.3 0.3 0.3 0.3
Table of freezing temperatures
Glycol % 25 30 35 40
Freezing temperature -11°C -15°C -18°C -22°C

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* These components are included in the whole AKY range. For
AKY050/070/100 models, they are compliant with or certied
according to INAIL standard.
** Components included forAKY050/070/100 models only, they
are compliant with or certied according to INAIL standard.
VS1 AKY032/034 safety valve
VS2* AKY050/070/100 safety valve
VSC boiler vent valve
U.I. Internal unit [fan heater]
FAN air fan
VSB battery vent valve
TERM** INAIL thermometer
TV fan thermostat
Key
U.E. External unit [boiler]
EV1 main gas solenoid valve
EV2 secondary solenoid valve
VG gas valve (EV1+EV2)
FLUX water ow gauge (owmeter)
IDROM* hydrometer
IPMAX** limit water pressure switch [manual reset]
IPMIN** minimum water pressure switch [manual reset]
NTC1 water delivery modulation temperature probe
PFLUE ue gas pressure switch
P system pump (circulator)
PIT** temperature inspection well
PMIN/PREX pressure probe
PZI** well for fuel cut-off valve
R3VIE** 3-way control valve
RBC lling tap
TFUMI ue gas thermal fuse
TF exchanger protection thermal fuse
TDOOR AKY100 burner door thermostat
VAG burner fan
TS safety thermostat 90°C
VE expansion reservoir
3.3. Hydraulic circuit characteristics
AKY boilers have similar hydraulic circuitry; AKY050/070/100 models are characterised by some additional components with
respect to AKY032/034 models, which have heat output below 35kW and therefore do not need INAIL declaration.
When several systems are installed, the sum of the heat outputs is allowed only if the hydraulic circuit is shared among
several boilers.
AKY050/070/100 models, with rated heat output above 35 kW, are included in INAIL standard; therefore, the components of the
boiler and the system must comply with this directive.
A declaration must be submitted to the competent body. We suggest sending the declaration at the time of installation.

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3.4. INAIL components
SAFETY, PROTECTION AND CONTROL DEVICES
component abbreviation model description
hydrometer IDROM PB3204BB06 pressure gauge class UNI2.5, scale 0-4bar
WATTS INDUSTRIES pmax,es.=+25% f.s., T=-20/90°C compliant with INAIL
limit pressure switch IPMAX PMR/5-R2 pressure switch p=1÷3bar
ITALTECNICA INAIL approval certicate No. 0605/10/EC
minimum pressure switchIPMIN LPR/5 pressure switch p=0,5÷1.7bar
ITALTECNICA INAIL approval certicate No. 0206/08/EC
ITALTECNICA INAIL approval certificate No. PS/001/10
inspection well PIT PGUA0TT003 control well L=45mm, 1/2” connection
WATTS INDUSTRIES compliant with INAIL
3-way control valve R3VIE 403R14 3-way valve, 1/4” connection,
WATTS INDUSTRIES Tmax,es=90°C, Pmax,es=15bar compliant with INAIL
thermometer TERM PT4A507011 1/2" connection with well
WATTS INDUSTRIES T=0/120°C accuracy class UNI 2, compliant with INAIL
expansion reservoir VE 13S6001006 10-litre capacity, 3/4” connection,
pre-charge 0.75bar
ZILMET Pmax,es=3bar, Tmax,es=99°C certied 97/23/EC directive
safety valve VS 527427 1/2"Fx3/4"Fconnections,2.7barcalibration,15-mmdiameter,
CALEFFI 152.2 kW drain output. Tmax=110°CV
INAIL approval certicate No.VS/319/00
safety thermostat TS 2BD NC contact thermostat, opening T=90±3°C,
T&P closing T=80±4°C,
IMQ CA02.02231 certied
NOTE: Water circuit test
According to INAIL standard, the boiler body is tested at a pressure of 4.5 bar, i.e. 1.5 times the maximum working pressure.
NOTE: Distance between the expansion reservoir and the safety valve [AKY050/070/100 only].
According to INAIL standard, the distance between the expansion reservoir centreline surface and the safety valve centreline
surface is 450mm.
NOTE: Fuel cut-off valve [AKY050/070/100 only].
In case of equipment above 35kW, INAIL standard compulsorily requires that a fuel cut-off valve must be used. The boiler is
equipped with the well for the sensitive component of the fuel cut-off valve: the valve kit is available as an accessory (code C09073).
This well is suitable for the Calef fuel cut-off valve; to use other valves it is necessary to check their coupling.
NOTE: Expansion reservoir
All boilers are equipped with a 10-litre expansion reservoir, whose pre-charge is 1.0 bar (1.3 bar for AKY050/070/100).
When the system water content exceeds 65-70 litres, an expansion reservoir with suitable capacity must be added.
Boiler water contents are summarised below; as far as pipes are concerned, refer to page 17 in this manual.
WATER CONTENT
Boiler AKY032 3.5 litres
Boiler AKY034 4.0 litres
Boiler AKY050 6.3 litres
Boiler AKY070 7.0 litres
Boiler AKY100 9.0 litres

AQUAKOND AKY CONDENSING BOILER
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code HC0048.10GB ed.B-1811 AKY
500
755
HC0047 C2 002
455
AKY050/070
310
10
8
9
4
2 6 3 7 5 1
AKY032/034
AKY032/034 AKY050/070
AKY100
3.5. Boiler size
Description Dimension
032/034 050/070 100
1 GAS SUPPLY G3/4"
2 WATER RETURN G3/4" G1" G1 1/2"
3 WATER DELIVERY G3/4" G1" G1 1/2"
4 SAFETY VALVE G1/2" - -
5SAFETY VALVE - G1/2" G1/2"
6SYSTEM FILLING TAP G1/2"
7CONDENSATE DRAIN Ø18 mm
8 ELECTRICAL CONNECTIONS PG 09
9 FUEL CUT-OFF VALVE PASSAGE Ø14mm
10 FLUE GAS DISCHARGE CHIMNEY 60mm 100 mm

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AKY
ON/OFF boiler
switch
Reset button
Lockout
indicator
light
The boiler is supplied without remote control and/or ambient
thermostat as it can operate with different remote controls, some
of which are supplied by APEN GROUP as accessories, whilst
others are commercially available.
Operating modes:
A) ordinary thermostat, or chronothermostat, with a clean digital
contact to be connected to the boiler ID2/IDC2 terminals;
B) SmartEASY/WEB code G23500/G23700.
This manual will describe "A” operation, providing information
about Aquakond system modes. Instructions on how to operate
the SmartEASY/WEB chronothermostats can be found in
manuals supplied with the accessory.
Equipment main functions
The system is equipped with the following functions:
• Circulator anti-lock and variable speed;
• Antifreeze.
A operation: ordinary remote control
The Customer must install a chronothermostat or an ambient
thermostat with a voltage free dry contact, between ID2/IDC2
terminals; the boiler will switch on when the contact is open and it
will switch off when the contact is closed.The modulation occurs
on the delivery water temperature, which remains xed to the
factory value pre-set to 72°C. When several ambient units are
connected and one of them is turned off, the boiler automatically
reduces the heat output while keeping the delivery temperature
xed. Boiler lockout and reset, available inside it, can be remotely
indicated with the APEN remote control code C09660.
3.6. Operation and accessories
The boiler is tted as standard
with a multifunction LCD
panel located inside it, and
is used to control, congure
and diagnose all operating
parameters of the equipment.
The "LCD control” paragraph
explains its operation.
This panel cannot be remotely
controlled.
Ambient Temperature
adjustment
Operation B: G23500/G23700 SmartEASY/WEB
SmartEASY/WEB touchscreen control has been designed to
control several ApenGroup equipment for heating, ventilation
and cooling.
The control facilitates programming when several systems are
installed (possibility to connect up to 32 systems), allows to have
a view of the whole system, to reset the systems directly from
the panel, as well as to control and manage lockouts.
Main features:
• Simultaneous management of all devices connected to it
(switching on and switching off)
• Simplied connection by means of two polarised cables
and two power cables
• A temperature probe installed on the control
• Possibility to connect up to three remote temperature probes
• Multilingual 4.3” touchscreen colour display
• Complete management of the operating parameters
• Built-in or ush with the wall installation
• In the SMART WEB version, complete management of the
control and its functions through the network
For operating instructions and installation diagrams, please
refer to the manual of SmartEASY/WEB control.

AQUAKOND AKY CONDENSING BOILER
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ON/OFF boiler
switch
reset button
Lockout
indicator
light
C09660 remote control
LCD panel G16890
4. USER'S INSTRUCTIONS
Please read the safety warnings described in the previous pages. The operations that the user must carry out
are limited to the use of the controls placed in the remote
control and/or on the ambient.
4.1. Boiler operation
Boiler operation is fully automatic; it is equipped with electronic
equipment with self check facility that manages all the burner
control and monitoring operations and with a microprocessor
based electronic PCB that controls the heat output regulation.
As mentioned above, the explanation focuses on the boiler
without accessories; for information about Smart EASY/WEB
operation, refer to the manuals supplied with the accessory.
The boiler is switched on when the following two conditions
are met:
• the boiler is powered on and has not been locked out;
• when the contact is closed on ID2/IDC2 terminals of the
boiler PCB
In these conditions the burner circulator and fan will be immediately
started; after pre-cleaning time has elapsed, the ame will light up
with an ignition power equal to approximately 50% of its maximum
output. Once the ame stabilising time has expired, the burner
will start to modulate its heat output according to the delivery
temperature: water delivery temperature setpoint is set to 72°C.
If a lockout occurs because there is no ame during the ignition
phase, the boiler will make other 4 ignition attempts; at the fth
attempt, if ignition is not successful, the boiler will be locked out.
The boiler will be switched off when the ID2/IDC2 contact opens
on the boiler terminal box; disconnecting the boiler power
supply is prohibited, except for emergencies, because, when
the boiler is switched off, the circulator will continue to work for
approximately 3÷5 minutes so as to eliminate any residual heat in
the boiler (water post-circulation); the fume fan too will continue
to work for approximately 15 seconds to clean up the combustion
chamber (combustion chamber post-cleaning phase).
4.1.1. Ambient temperature setting
Connecting an ambient thermostat (chronothermostat) or an
ON/OFF switch is compulsory.
If a thermostat supplied by third parties is installed, the ambient
temperature must be programmed on the thermostat.
In this type of installation, we recommend that a C09660
remote control is used to allow users to check the conditions
for the lockout and, if necessary, to remotely reset it without
accessing the external boiler.
4.1.2. Lockout and Reset
Any operation fault is signalled on the C09660 remote control
by means of a red light.
The light indicates an alarm, but it does not indicate the type
of alarm occurred. To reset, press the button below the light.
The error code, from F10 to F99, is signalled by the display located
inside the boiler and/or by the SmartEASY/WEB, if connected.
Using the LCD panel located inside the boiler, unlock by pressing
the two arrows simultaneously for a few seconds.
The error codes are described below.
4.1.3. Boiler temperature setting
When the boiler is delivered, the ST1 value, water delivery
temperature setpoint, has already been set to 72°C; the
parameter can be modied by means of the LCD panel inside
the boiler or through SmartEASY/WEB.
4.1.4. Circulator anti-lock and variable speed
The function, which is enabled by default, starts the circulator
when it fails to operate for twenty-four hours in a row; the
circulator works for 120 seconds and then it stops.
The circulator modies its speed according to the heat output;
two parameters set the level under which the minimum speed
is activated.
4.1.5. Antifreeze
The function is enabled by default (d8=1) and operates on two
levels: when water temperature drops below a rst value, the
circulator is activated in order to circulate water around the
system; when it drops below a second value, the burner too is
switched on for the time required to warm up the system water.

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the parameter scrolling speed is increased.
To conrm a change in parameters, press ENTER for at least
3 seconds. A change in the parameter is indicate by the display
ashing.
All submenus can be scrolled from the bottom to the top, and they
start over when the end of the menu is reached and vice versa.
4.2.3. Entering the password
• From the initial screen (ON/OFF/rdy/FXX) use the ↑ (up arrow)
and ↓ (down arrow) keys to reach the ABI function; hold down
the ENTER key for 3 seconds;
• Set the password inside the ABI menu and conrm it with
ENTER; hold it down for approximately 3 seconds (the
ashing display will conrm that the parameter has been
stored);
• Press ESC and, by using the ↑ and ↓ arrow keys, return
to the initial screen (ON/OFF/rdy/FXX); press ENTER for
3 seconds;
• Use the ↑ and ↓ arrow keys to reach the desired menu item
(Flt, I/O, SET, PAR);
• Press ENTER to access the function;
• Use the ↑ and ↓ arrow keys to select the parameters to be
displayed and edited;
• Press ENTER to display the parameter value;
• Use the ↑ and ↓ arrow keys to edit the value (only SET
and PAR);
• Press ENTER to conrm the change made;
• To exit the parameter and the menu, press ESC until the
initial screen is displayed (ON/OFF/rdy/FXX).
4.2.4. Level 1 menu
The rst level in the menu consists of the following items:
1. machine status: ON, rdy, OFF;
2. FUn, it allows to force the ON, OFF operation type; this menu
can be accessed only in case of Stand-Alone conguration
(ModBus address equal to Ø); when the address is different
from Ø, this menu cannot be accessed;
3. rEg, it allows to force the burner at minimum (Lo) or maximum
(Hi) output in order to perform combustion tests;
4. tin, it shows the input voltage value (0/10Vdc) if the boiler
is connected to a cascade management control unit;
5. PrA, it shows water pressure inside the hydraulic circuit. It
is used to load, and to control, the pressure inside the boiler
and the hydraulic circuit. If the 01.6 value is displayed, the
pressure inside the circuit is 1.60 bar;
6. Abi. Entering the second or third level password allows to
switch from the Abi menu to the underlying menus.
7. FRC allows to operate the circulator manually. Selecting
the key for 3 sec will provide access to BLO submenu.
Pressing the UAR key (up arrow ↑) starts the circulator.
Releasing the UAR key (up arrow ↑) stops the circulator.
Note: To display water pressure value, press Enter when PrA is shown.
4.2. LCD instrument panel
The instrument panel is tted with a red 3-digit LCD display and
with four function keys: ↑, ↓, ESC and ENTER;
The screen allows the user to display the boiler operating mode,
the Faults, water pressure inside the hydraulic circuit and the
reading of probe values.
It also allows the service centre to change the main operating
parameters.
Changing parameters requires a password.
4.2.1. Viewing the machine status
The machine status is shown on the display by the following
wordings:
rdy the machine is on without burner ame, it is waiting for the
ON control and/or the heat demand from the thermostat
On the machine is on with burner ame on;
OFF the machine has been switched off through the LCD
control; any heat demands will be ignored. To light the
boiler, the LCD must show the wording "operation ON";
Fxx Fault detected.
During normal operation, the display will show the wording On
if the burner is on; rdy when the boiler is being switched off or
the room temperature has been reached.
If the boiler is connected to a SmartEASY/WEB, the PCB address
must be set to a value different from Ø. In this case, every 30
seconds and for the following 5 seconds, the display shows the
PCB modbusaddress asAxx, where xxis theprogrammed address.
In the event of communication problems between CPU-SMART
PCB and LCD panel, the word CPU will ash on the display if
the problem is caused by the CPU; three ashing dots will be
displayed if the problem is caused by the display PCB.
If needs be, check that the display and the PCB are correctly
connected and that the small cable RJ11 is securely held in
the connector.
4.2.2. Menu Navigation
The menu has three levels and all levels can be accessed in
display mode. The rst is accessible without entering a password,
the second and third require entering passwords in write mode,
as described in paragraph 4.2.5.
With modbus address other than Ø the following SETS can be
edited: ST1, ST2, ST5, ST6.
If the boiler PCB is connected to a SmartEASY/WEB, and
therefore with an address different from Ø, parameters can be
viewed but cannot be modied.
The Service Centre that is required to use all menus must follow
these instructions:
- disconnect the power supply;
- set the PCB address to Ø;
- restore power;
- after nishing the work, please remember to reset the switches
to the previously set position.
Use the arrows to scroll the menus: UAR (up arrow ↑) and DAR
(down arrow ↓). Press ENTER to select the menu, and again
to select the parameter. Change the parameter with the arrows
and conrm the change by pressing ENTER.
To exit the parameter or menu, press ESC. If you exit the
programming function, after about 10 minutes the program
will exit the menu and go back to the "machine status" display.
To change the parameter, press the arrow keys: pressing UAR
↑ increases the parameter by 1, pressing DAR ↓ reduces it by
1. When the arrow keys are pressed for at least three seconds,

AQUAKOND AKY CONDENSING BOILER
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4.2.5. Second level menu
Second and third level menus are dedicated to the technical
Service Centre. PAR and SET editing in the second level
menu is allowed only with a password to be requested to the
manufacturer’s Assistance Service.
4.2.6. FAULT list
In the event of a lockout, the boiler PCB will display a code,
which indicates what problem has occurred.
To reset the boiler, simply press the LCD panel 2 arrow keys
simultaneously for at least 3 seconds or operate one of the
remote controls provided.
Faults are classied according to the type of error and are
indicated on page 41 Par.8.ANALYSIS OF LOCKOUTS - FAULT.
4.2.7. Antifreeze Function
The function is activated as a precaution to avoid any fuel cut-off
valve activation when temperatures are near zero. Filling the
system with the right amount of water and glycol is deemed the best
antifreeze method (it protects the system even in case of blackout).
To activate the antifreeze function, set d8=1 according to water
temperature, STA antifreeze setpoint and PA hysteresis; the
circulator and, if necessary, the burner too will be activated.
When the antifreeze function is on, the boiler behaves as follows:
NTC1>(STA+PA): system in standby;
NTC1<(STA+PA): water circulation on;
NTC1<(STA-PA): water circulation and burner on.
5. INSTALLATION INSTRUCTIONS
Instructions for installing and setting the boiler are intended for
suitably qualied personnel only. Please read the safety warnings.
N.B.: the installer must instruct the user about the use of the
machine and inform him/her about the presence, in this manual,
of a chapter fully intended for the nal user.
5.1. General Installation Instructions (ITALY)
The boiler installation must be carried out in compliance with
the current regulations concerning design, installation and
maintenance of thermal systems.
Reference standards:
• Ministerial Decree of 12 April 1996 containing the re
prevention rules for design, construction and operation of
thermal systems red with gaseous fuels;
• Presidential Decree no.412/93 which regulates design,
installation, operation and maintenance of thermal systems;
• Law no.10/91: rules for implementing the national energy plan
in the eld of the rational use of energy, energy savings and
the development of renewable energy sources;
• Standard UNI-CIG 7129 regarding the installation of natural
gas equipment;
• Standard UNI-CIG 7131 regarding the installation of LPG
equipment;
• Law 186 of 01 March 1986 regarding the installation of
electrical systems;
• Legislative Decree no. 192/05 of 19/08/05;
• Ministerial Decree no. 37 of 22/01/2008;
and subsequent amendments and/or integrations.
5.2. Transport and Handling
The boiler and the internal units making up AquaKond system
are packaged individually inside cardboard boxes.
Unload the equipment from the truck and move it to the site of
installation by using means of transport suitable for the shape
of the load and for its weight.
If the thermal unit is stored at the customer’s premises, make
sure a suitable place is selected, sheltered from rain and from
excessive humidity, for the shortest possible time.
Any lifting and transport operations must be carried out by
skilled staff, adequately trained and informed on the working
procedures and safety regulations.
Recovered packaging materials must be separated and disposed
of according to applicable regulations in the country of use.
While unpacking the unit, check that the unit and all its parts
have not been damaged during transport and match the order.
If damages have occurred or parts are found to be missing,
immediately contact the supplier.
Note The manufacturer is not liable for any damages occurred during transport, handling, unloading, etc.