ROBUA AY00-120 User manual

AY00-120
Condensing boiler
for heating
gas powered
Installation, Use and Maintenance
Manual

Revision: K
Code: D-LBR531
This Installation, use and maintenance manual has been drawn up and printed by Robur S.p.A.; whole or partial reproduction of this
Installation, use and maintenance manual is prohibited.
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Installation, use and maintenance manual without prior notice.

Installation, use and maintenance manual – AY00-120 3
INDEX OF CONTENTS
I Introduction............................................................................. p.4
I.1 Recipients .......................................................................... p.4
I.2 Control device.................................................................. p.4
II Symbols and denitions............................................... p.4
II.1 Key to symbols................................................................. p.4
II.2 Terms and denitions.................................................... p.4
III Warnings...................................................................................... p.4
III.1 General and safety warnings...................................... p.4
III.2 Conformity ........................................................................ 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.10
1.5 Controls ............................................................................ p.10
1.6 Technical characteristics............................................. p.11
2 Transport and positioning........................................ p.12
2.1 Warnings.......................................................................... p.12
2.2 Handling........................................................................... p.12
2.3 Appliance positioning................................................. p.12
2.4 Minimum clearance distances.................................. p.12
2.5 Mounting base............................................................... p.13
3 Heating engineer............................................................... p.13
3.1 Warnings.......................................................................... p.13
3.2 Installation....................................................................... p.13
3.3 Hydraulic connections ................................................ p.13
3.4 Water circulation pump.............................................. p.14
3.5 Anti-icing function........................................................ p.14
3.6 Anti-icing liquid............................................................. p.14
3.7 System water quality ................................................... p.15
3.8 Installation lling .......................................................... p.15
3.9 Fuel gas supply .............................................................. p.16
3.10 Combustion products exhaust ................................ p.17
3.11 Flue gas condensate discharge................................ p.17
4 Electrical installer.............................................................. p.18
4.1 Warnings.......................................................................... p.18
4.2 Electrical systems.......................................................... p.18
4.3 Electrical power supply............................................... p.19
4.4 Set-up and control........................................................ p.19
4.5 Water circulation pump.............................................. p.21
5 First start-up .......................................................................... p.22
5.1 Preliminary checks........................................................ p.22
6 Normal operation.............................................................. p.23
6.1 Warnings.......................................................................... p.23
6.2 Switch on and o.......................................................... p.23
6.3 Messages on the display ............................................ p.23
6.4 Electronic adjustment on the machine – Menus
and parameters.............................................................. p.23
6.5 Modifying settings........................................................ p.24
6.6 Restarting a locked-down unit................................. p.25
6.7 Eciency.......................................................................... p.25
7 Maintenance.......................................................................... p.25
7.1 Warnings.......................................................................... p.25
7.2 Pre-emptive maintenance......................................... p.26
7.3 Scheduled routine maintenance............................. p.26
7.4 Periods of inactivity...................................................... p.26
8 Diagnostics.............................................................................. p.28
8.1 Operative codes............................................................. p.28
9 Appendices.............................................................................. p.29
9.1 Product che................................................................... p.29

Introduction
4
I
I INTRODUCTION
Manual
This Manual is an integral part of the AY00-120 unit
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;
▶ qualied installer, for correct appliance installation;
▶ planner, for specic information on the appliance.
I.2 CONTROL DEVICE
In order to be able to work, the AY00-120 unit needs a control
device (DDC, CCP/CCI or external requests), which must be con-
nected 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
Appliance/Unit AY = equivalent terms, both used to designate
the AY00-120 gas red condensing boiler.
TAC = Technical Assistance Centre authorised by Robur.
External request = generic control device (e.g. thermostat, tim-
er or any other system) equipped with a voltage-free NO contact
and used as control to start/stop the AY00-120 unit.
CCI Controller (Comfort Controller Interface) = optional Robur
control device which lets you manage up to three modulating
heat only GAHP units (A, WS, GS).
CCP Controller (Comfort Control Panel) = Robur control de-
vice which lets you manage in modulation mode up to three
GAHP units and all system components (probes, diverter/mixing
valves, circulating pumps), including any integration boiler.
DDC Control (Direct Digital Controller) = optional Robur device
to control one or more Robur appliances (GAHP heat pumps, GA
chillers and AY boilers) in ON/OFF mode.
RB100/RB200 Devices (Robur Box) = optional interface devices
complementary to DDC, which may be used to broaden its func-
tions (heating/cooling/DHW production service demands, and
control of system components such as third party generators,
adjustment valves, circulators, probes).
Heat generator = equipment (e.g. boiler, heat pump, etc..) pro-
ducing heating and/or DHW.
First Switch-On = appliance commissioning operation which
may only and exclusively be carried out by a TAC.
AY10/S70 boards = electronic boards on the AY00-120 unit, to
control all functions and to provide interface with other devices
and with the user.
III WARNINGS
III.1 GENERAL AND SAFETY WARNINGS
Installer's qualications
Installation must exclusively be performed by a Qualied
Firm and by Skilled Personnel, with specic knowledge
on heating, cooling, electrical systems and gas applianc-
es, in compliance with the laws in force in the Country of
installation.
Declaration of Conformity
Upon completing installation, the installing rm shall
issue to the owner/client the appliance's Workmanlike
Conformity Declaration, according to national/local reg-
ulations in force and the manufacturer's instructions/
provisions.
Misuse
The appliance must only be used for the purposes for
which it has been designed. Any other use is deemed
hazardous. Incorrect use may aect operation, duration
and safety of the appliance. Adhere to the manufactur-
er's instructions.
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 safe-
ty devices.
In case of danger, request intervention by skilled person-
nel.
In case of danger, switch o the electrical power and gas
supplies only if this can be done in total safety.
Do not entrust children, persons with physical, sensory
or mental disabilities or persons with poor knowledge

Warnings
Installation, use and maintenance manual – AY00-120 5
III
and experience with use of the appliance.
Gas component tightness
Before performing any operation on gas ducting compo-
nents, close the gas cock.
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, mul-
timeters or other equipment that may cause sparks next
to the appliance.
Shut o the gas supply by turning the cock o.
Disconnect electrical power supply by means of the
external isolation switch in the power supply electrical
panel.
Use a telephone away from the appliance to ask for inter-
vention from skilled personnel.
Poisoning
Ensure the ue gas ducts are tightness and compliant
with the regulations in force.
Upon completing any procedure, ensure components
are tightness.
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 internal
components before the appliance has cooled down.
Do not touch the ue gas exhaust before it has cooled
down.
Electrocution hazard
Disconnect the electrical power supply before any work/
procedure on appliance components.
For electrical connections exclusively use compliant
components and according to the specications provid-
ed by the manufacturer.
Ensure the appliance cannot be accidentally switched
back on.
Earthing
Electrical safety depends on eective earthing system,
correctly connected to the appliance and installed ac-
cording to the regulations in force.
Distance from combustible or ammable materials
Do not store ammable materials (paper, solvents, paint,
etc.) in the vicinity of the appliance.
Limescale and corrosion
Depending on the chemical/physical properties of the
system water, limescale or corrosion may damage the
appliance (Paragraph 3.7 p.15 ).
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.15 .
Aggressive substances in air
Halogenated hydrocarbons containing chlorine and u-
orine compounds cause corrosion.The air of the installa-
tion site must be free from aggressive substances.
Acid ue gas condensate
Discharge the acid condensate of combustion ue gas,
as indicated in Paragraph 3.11 p. 17 , in compliance
with current exhaust regulations.
Switching the appliance o
Disconnecting the power supply while the appliance
is running may cause permanent damage to internal
components.
Except in the case of danger, do not disconnect the pow-
er supply to switch o the appliance, but always and ex-
clusively act through the control device provided (DDC,
CCP/CCI or external request).
In the event of failure
Operations on internal components and repairs may
exclusively be carried out by a TAC, only using original
parts.
In the event of failure of the appliance and/or breakage
of any component, do not attempt to repair and/or re-
store and immediately contact the TAC.
Routine maintenance
Proper maintenance assures the eciency and good op-
eration of the appliance over time.
Maintenance must be performed according to the man-
ufacturer's instructions (see Chapter 7 p. 25 ) and in
compliance with current regulations.
Appliance maintenance and repairs may only be entrust-
ed to rms legally authorised to work on gas appliances
and systems.
Enter into a maintenance contract with an authorised
specialised rm for routine maintenance and for servic-
ing in case of need.
Only use original parts.
Decommissioning and disposal
If the appliance is to be disposed of, contact the manu-
facturer for its disposal.
Keep the Manual
This "Installation, Use and Maintenance Manual" must al-
ways accompany the appliance and must be handed to
the new owner or installer in the event of sale or removal.

Warnings
6
III
III.2 CONFORMITY
EU Directives and standards
The appliance is CE certied and conforms with all essential re-
quirements of the following Directives:
▶ Eciency Directive 92/42/EEC and subsequent modica-
tions and additions.
▶ 2009/142/EC "Gas Appliances Directive" as amended and
added.
▶ 2014/30/EC "Electromagnetic Compatibility Directive" as
amended and added.
▶ 2014/35/EC "LowVoltage Directive" as amended and added.
▶ 2006/42/EC "Machine Directive" as amended and added.
Furthermore, they comply with the requirements of the follow-
ing standards:
▶ UNI EN 677 Specic requirements for condensing boilers
with nominal heating capacity up to 70 kW.
▶ UNI EN 483 Type C boilers with nominal thermal capacity no
greater than 70 kW.
Other applicable provisions and standards
The design, installation, operation and maintenance of the sys-
tems shall be carried out in compliance with current applicable
regulations, depending on the Country and location, and in ac-
cordance with the manufacturer's instructions. In particular, reg-
ulations regarding the following shall be complied with:
▶ Gas systems and equipment.
▶ Electrical systems and equipment.
▶ Heating systems employing condensing boilers.
▶ Environmental protection and combustion products ex-
haust.
▶ 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 man-
ufacturer for any damage caused by incorrect installa-
tion and/or improper use and/or failure to comply with
regulations and with the manufacturer's directions/in-
structions shall be disclaimed.
In particular, the warranty on the appliance may be ren-
dered void by the following conditions:
Incorrect installation.
Misuse.
Failure to comply with the manufacturer's indications on
installation, use and maintenance.
Alteration or modication of the product or any part
thereof.
Extreme operational conditions or however outside of
the operational ranges set forth by the manufacturer.
Damages caused by external agents such as salts, chlo-
rine, sulphur or other chemical substances contained in
the installation water or present in the air of the instal-
lation site.
Abnormal actions transmitted by the plant or installa-
tion to the appliance (mechanical stresses, pressure, vi-
brations, thermal dilations, power surges...).
Accidental damages or due to force majeure.

Features and technical data
Installation, use and maintenance manual – AY00-120 7
1
1 FEATURES AND TECHNICAL DATA
1.1 FEATURES
AY00-120 unit is a high eciency condensing boiler suitable for
supply hot water up to 80 °C. The appliance is provided with an
internal heat exchanger to separate internal hydraulic circuit
from system hydraulic circuit.
Mechanical and thermo-hydraulic components
▶ premixed multi-gas burner with low NOx and CO emissions;
▶ stainless steel plate heat exchanger, combining a hydraulic
separator;
▶ automatic and manual air bleeds on the internal circuit;
▶ ue gas discharge duct with relevant terminal, for type B53P
conguration;
▶ condensate discharge siphon (with antifreeze function).
Control and safety devices
▶ electronic board with microprocessor;
▶ automatically resettable water temperature limiting ther-
mostat;
▶ ue gas limit thermostat, for single use (thermal switch);
▶ system circuit water dierential pressure switch (PD1);
▶ internal circuit water dierential pressure switch (PD2) with
anti-sticking function;
▶ overpressure valve on internal circuit, set to trip at 3 bar;
▶ internal circuit expansion tank;
▶ ionisation ame controller;
▶ gas solenoid valve with double shutter;
▶ antifreeze function for water circuit;
▶ anti-freezing thermostat used for the activation of the heat-
ing element on the condensate drain.
1.2 DIMENSIONS
Figure1.1Dimensions (front and right side views)

Features and technical data
8
1
Figure1.2Service plate - Hydraulic/gas unions detail
G Gas connection Ø 3/4" M
A Water outlet connection Ø 1 1/4" F
B Water inlet connection Ø 1 1/4" F
C Condensate discharge connection (ext. D. 25
mm)

Features and technical data
Installation, use and maintenance manual – AY00-120 9
1
1.3 ELECTRICAL WIRING DIAGRAM
Figure1.3Wiring diagram AY00-120 unit
SCH Electronic boards AY10/S70
TA Ambient air temperature sensor
THPC Delivery water temperature probe (appliance internal circuit)
THMC Hot water ow temperature probe
THRC Hot water return temperature probe
TH Combustion unit limit thermostat (appliance internal circuit)
TF Flue gas thermostat
A2 Dierential water pressure switch (appliance internal circuit)
PD Dierential water pressure switch (system circuit)
TL Water limit thermostat
P1 Water circulating pump (appliance internal circuit)
LS Gas valve ON indicator lamp
GV Gas solenoid valve
IGNTR Ignition transformer
IGN Ignition electrodes
FLS Flame sensor
CNTBOX Flame controller
BLW Blower
MC Appliance power terminal block
PWRTR Board transformer
TS Safety thermostat
TG Antifreeze thermostat for syphon resistance
RS Syphon resistance

Features and technical data
10
1
1.4 ELECTRONIC BOARDS
Electronic boards (AY10+S70)
The unit's electrical board contains:
▶ AY10 Electronic Board (Figure 1.4 p. 10 ), with micropro-
cessor, it controls the appliance and displays data, messages
and operative codes. The appliance is monitored and pro-
grammed by interacting with the display and the knob.
▶ Auxiliary S70 electronic board (Figure 1.4 p.10 ).
Figure1.4AY10+S70 electronic boards
TL limit thermostat connector
ENC Knob
EV gas solenoid valve connector
LS gas valve ON signal lamp connector
P1 6 pole ame controller connector
TF exhausted gas thermostat connector
PD system water dierential pressure switch
A1, A2 Auxiliary inputs
J2 system water circulating pump jumper
N.O. CONTACT System water circulating pump control terminals (max 700W)
V3V (1-2-N) appliance circulating pump connecting terminals
MAIN 230V (L, N) Board power supply 230Vac
IGN.BOX (L, N) Flame controller power supply 230 Vac
P1 connector for blower drive
THRC Return hot water temperature connector
THMC Delivery hot water temperature connector
TA2-TA1 auxiliary temperature probes connector
J1 CAN BUS Jumper
P8 (GND, L, H) CAN BUS connector
P7 (R,W, 0) Enable input
FS5 board supply connector
F1-F2 fuses
1.5 CONTROLS
Control device
The appliance may only work if it is connected to a control de-
vice, selected from:
▶ (1) DDC control
▶ (2) CCP/CCI control
▶ (3) external request
1.5.1 Adjustment system (1) with DDC control (ON/
OFF unit)
The DDC controller is able to control appliances, a single
AY00-120 unit, or even several Robur GAHP/GA/AY units in cas-
cade, only in ON/OFF mode (non modulating). For more details
refer to the DDC, RB100, RB200 Manuals and the Design Manual.
DDC Controller
The main functions are:
▶ setup and control of one (or more) Robur units of the ab-
sorption line (GAHP, GA, AY);
▶ parameter gures display and setting;
▶ hourly programming;
▶ climate curve control;
▶ diagnostics;
▶ reset errors;
▶ possibility to interface with a BMS;
DDC functionality may be extended with auxiliary Robur devices
RB100 and RB200 (e.g. service requests, DHW production, Third
Party generator control, probe control, system valves or circulat-
ing pumps, ...).

Features and technical data
Installation, use and maintenance manual – AY00-120 11
1
1.5.2 Adjustment system (2) with CCP/CCI
(modulating GAHP unit)
The CCP/CCI control is able to control up to 3 GAHP units in mod-
ulating mode (therefore A/WS/GS only, excluding AR/ACF/AY),
plus any AY00-120 integration ON/OFF boiler. For additional de-
tails and diagrams refer to the CCP/CCI Manual and the Design
Manual.
CCP/CCI Control
See CCP/CCI device Manual.
1.5.3 Adjustment system (3) with external request
(GAHP unit ON/OFF)
The appliance may also be controlled via generic request de-
vices (e.g. thermostats, clocks, buttons, contactors...) tted with
voltage-free NO contact. This system only provides elementary
control (on/o, with xed set-point temperature), thus without
the important system functions (1). It is advisable to limit its pos-
sible use only to simple applications and with a single appliance.
For connection of the selected device to the appliance's
electronic board please refer to Paragraph 4.4 p.19 .
1.6 TECHNICAL CHARACTERISTICS
Table1.1Technical specications AY00-120
AY00-120
Heating mode
Seasonal space heating energy eciency class (ErP) A
Operating point 80/60
Nominal thermal capacity eective
power kW 34,4
eciency % 98,6
Mean thermal capacity eciency % 98,3
Minimal thermal capacity eciency % 97,3
Operating point 70/50 Nominal thermal capacity eciency % 100,6
Operating point 50/30 Nominal thermal capacity eciency % 104,6
Operating pointTr = 30 °C Thermal capacity 30% eciency % 107,5
Operating pointTr = 47 °C Thermal capacity 30% eciency % 100,3
Heating capacity
nominal (1013 mbar - 15 °C) kW 34,9
average kW 21,5
minimum kW 8,0
Hot water delivery temperature
maximum °C 80
minimum °C 25
nominal °C 60
Hot water inlet temperature
maximum °C 70
minimum °C 20
nominal °C 50
Heating water ow
nominal l/h 2950
maximum l/h 3200
minimum l/h 1500
Pressure drop heating mode at nominal water ow bar 0,40 (1)
Eciency class ****
Heat loss
to jacket in operation kW 0,15
to jacket in operation % 0,44
to ue in operation kW 0,86
to ue in operation % 2,54
in o mode kW 0,058
in o mode % 0,17
Ambient air temperature (dry bulb) maximum °C 45
minimum °C -20
Electrical specications
Power supply
voltage V 230
type - single-phase
frequency 50 Hz supply 50
Electrical power absorption nominal kW 0,18
Degree of protection IP - XSD
Installation data
Gas consumption
methane G20 (nominal) m³/h 3,69
methane G20 (min) m³/h 0,85
G25 (nominal) m³/h 4,35
G25 (min) m³/h 1,00
G30 (nominal) kg/h 2,75
G30 (min) kg/h 0,63
G31 (nominal) kg/h 2,71
G31 (min) kg/h 0,62
(1) For ows other than nominal see Design Manual, Pressure losses Paragraph.

Transport and positioning
12
2
AY00-120
NOxemission class - 5
NOxemission ppm 19,5
CO emission ppm 8,4
Minimum storage temperature °C -30
Maximum water pressure in operation bar 4
Maximum ow ue condensate l/h 5,5
Water content inside the apparatus hot side l 1
Water tting type - F
thread “ G 1 1/4
Gas connection type - M
thread “ G 3/4
Fume outlet
diameter (Ø) mm 80
residual head Pa 100
product conguration B53P
Type of installation - B32P, B33, B35P, C13, C33, C34, C53, C63, C83
Dimensions
width mm 410
depth mm 530
height mm 1278
Weight in operation kg 71
(1) For ows other than nominal see Design Manual, Pressure losses Paragraph.
2 TRANSPORT AND POSITIONING
2.1 WARNINGS
Damage from transport or installation
The manufacturer shall not be liable for any damage dur-
ing appliance transport and installation.
On-site inspection
Upon arrival at the site, ensure there is no transport dam-
age on packing or metal panels.
After removing the packing materials, ensure the appli-
ance is intact and complete.
Packing
Only remove the packing after placing the appliance on
site.
Do not leave parts of the packing within the reach of
children (plastic, polystyrene, nails...) since they are po-
tentially dangerous.
Weight
The crane and lifting equipment must be suitable for the
load.
Do not stand under suspended loads.
2.2 HANDLING
Handling and lifting
▶ Always handle the appliance in its packing, as delivered 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 appli-
ance.
▶ 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.
2.3 APPLIANCE POSITIONING
Where to install the appliance
▶ It can be installed either inside a suitable technical room, or
outside buildings, out of the dripping line of rain gutters or
the like. It does not require protection from weathering.
▶ The appliance may be installed at ground level, on a terrace
or on a roof, compatibly with its dimensions and weight.
▶ The appliance's ue gas exhaust must not be immediately
close to openings or air intakes of buildings, and must com-
ply with environmental regulations.
▶ No obstruction or overhanging structure (e.g. protruding
roofs, eaves, balconies, ledges, trees) may obstruct the ex-
haust fumes outlet at the top of the appliance.
▶ Do not install near the exhaust of ues, chimneys or hot
polluted air. In order to work correctly, the appliance needs
clean air.
▶ The installation premises must meet all requirements set
forth by laws, standards and regulations of the Country and
place of installation concerning gas appliances.
2.4 MINIMUM CLEARANCE DISTANCES
Distances from combustible or ammable materials
▶ Keep the appliance away from combustible or ammable
materials or components, in compliance with applicable
regulations.
Clearances around the appliance
The minimum clearance distances shown in Figure 2.1 p.13
(bar any stricter regulations) are required for safety, operation
and maintenance.

Heating engineer
Installation, use and maintenance manual – AY00-120 13
3
Figure2.1Clearances 2.5 MOUNTING BASE
Mounting base constructive features
▶ Place the appliance on a levelled at surface made of re-
proof material and able to withstand its weight.
(1) - installation at ground level
▶ Failing a horizontal supporting base, make a at and levelled
concrete base, at least 100-150 mm larger than the appli-
ance dimensions per side.
(2) - 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 ap-
pliance.
Anti-vibration connections
▶ It is advisable to use exible connections (anti-vibration
joints) between the appliance and the hydraulic and gas
supply pipes.
3 HEATING ENGINEER
3.1 WARNINGS
General warnings
Read the warnings in Chapter III.1 p. 4 , providing im-
portant information on regulations and on safety.
Compliance with installation standards
Installation must comply with applicable regulations in
force, based on the installation Country and site, in mat-
ters of safety, design, implementation and maintenance
of:
heating systems;
gas systems;
ue gas exhaust;
ue gas condensate discharge.
Installation must also comply with the manufacturer's
provisions.
3.2 INSTALLATION
Primary and secondary circuit
The appliance is provided with an internal heat exchanger who
separates the system in two parts:
▶ water circuit inside the appliance (inside);
▶ system water circuit (primary).
In many cases it is advisable to divide the hydraulic system into
two parts, primary and secondary circuit, uncoupled by a hy-
draulic separator, or possibly by a tank that also acts as inertial
volume/thermal inertia.
3.3 HYDRAULIC CONNECTIONS
Plumbing ttings
on the right, at the bottom, connection plate (Figure 1.2 p.8 ).
▶ A (= out) 1 1/4" F - WATER OUTLET (m = outlet to the system);
▶ B (= in) 1 1/4" F - WATER INLET (r = return from the system).
Hydraulic pipes, materials and features
▶ Use pipes for heating/cooling systems, protected from
weathering, insulated for thermal dispersion.
Pipe cleaning
Before connecting the appliance,accurately wash the
water and gas piping and any other system component,
removing any residue.
Minimum components of primary water circuit
▶ Always provide, near the appliance:
on water piping, both output and input (m/r)
2 ANTIVIBRATION JOINTS on water ttings;
2 PRESSURE GAUGES;
2 ISOLATION BALL VALVES;
on the input water piping (r)
1 SEPARATOR FILTER;
1 FLOW ADJUSTMENT VALVE, if the circulating pump is
constant ow;
1 WATER CIRCULATION PUMP, towards the appliance;
on the output water piping (m)
1 EXPANSION TANK of the individual unit.

Heating engineer
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Figure3.1Hydraulic plan
A Gas connection
1 Anti-vibration connection
2 Pressure gauge
3 Flow regulator valve
4 Water lter
5 Shut-o valves
6 Water pump (primary circuit)
7 Safety valve (3 bar)
8 Expansion tank
9 Hydraulic separator / inertial tank with 4
ttings
10 Water pump (secondary circuit)
11 Water circuit inside the appliance
A
1 2 3 4 5
78
10
9
6
11
P
P
The appliance is equipped with its own expansion tank
and safety valve exclusively dedicated to the machine’s
internal circuit. The system circuit thus requires a suit-
able expansion tank to be installed.
3.4 WATER CIRCULATION PUMP
The circulation pump (ow and head) must be selected and
installed based on pressure losses of plumbing/primary circuit
(piping + components + exchange terminals + appliance).
For the appliance's pressure losses refer to Table 1.1 p.11 and
Design Manual.
3.5 ANTIICING FUNCTION
Active anti-icing self-protection
The appliance is equipped with an active antifreeze self-protec-
tion system to prevent icing. The anti-icing function (activated
by default) automatically starts the primary circulation pump
and, if required, the burner too, when the outside temperature
approaches zero.
The function is double, both for the water circuit inside the ap-
pliance, and for the system’s water circuit.
The function concerning the internal circuit cannot be disabled
as it is also used to protect the electronic components.
Electrical and gas continuity
The active anti-icing self-protection is only eective if
the power and gas supplies are assured. Otherwise, an-
ti-icing liquid might be required.
3.6 ANTIICING 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 pres-
ervation state.
Do not use car-grade anti-icing liquid (without inhibi-
tors), nor zinc-coated piping and ttings (incompatible
with glycol).
Glycol modies the physical properties of water (densi-
ty, viscosity, specic heat...). Size the piping, circulation
pump and thermal generators accordingly.
With automatic system water lling, a periodic check of
the glycol content is required.
With high glycol percentage (> 20…30%)
If the glycol percentage is ≥30% (for ethylene glycol) or
≥20% (for propylene glycol) the TAC must be alerted be-
fore rst start-up.
When producing DHW by DHW buer tank, use pro-
pylene glycol only.
Type of anti-icing glycol
▶ Inhibited type glycol is recommended to prevent oxidation
phenomena.
Glycol eects
The Table 3.1 p. 14 shows, indicatively, the eects of using a
glycol depending on its %.
Table3.1Technical data for lling 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%

Heating engineer
Installation, use and maintenance manual – AY00-120 15
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Water circuit inside the appliance
The water circuit inside the appliance is factory charged to 2 bar
with a water/glycol mix which enables the appliance to be safely
stored down to -30 °C.
You must always ensure adequate glycol antifreeze content.
3.7 SYSTEM WATER QUALITY
Responsibility of the user/operator/installer
The installer, operator and user must assure system water quali-
ty (Table 3.2 p.15 ). Failure to comply with the manufacturer's
guidelines may aect operation, integrity and life of the appli-
ance, voiding the warranty.
System water features
Free chlorine or water hardness may damage the appliance.
Adhere to the chemical-physical parameters in Table 3.2 p.15
and the regulations on water treatment for residential and in-
dustrial heating systems.
Table3.2Chemical and physical parameters of water
CHEMICAL AND PHYSICAL PARAMETERS OF WATER IN HEATING/
COOLING SYSTEMS
PARAMETER UNIT OF
MEASUREMENT ALLOWABLE RANGE
pH / > 7 (1)
Chlorides mg/l < 125 (2)
Total hardness (CaCO3)°f < 15
°d < 8.4
Iron mg/kg < 0,5 (3)
Copper mg/kg < 0,1 (3)
Aluminium mg/l < 1
Langelier’s index / 0-0,4
HARMFUL SUBSTANCES
Free chlorine mg/l < 0,2 (3)
Fluorides mg/l < 1
Sulphides ABSENT
(1) with aluminium or light alloys radiators, pH must also be lower than 8 (in compliance
with applicable rules).
(2) value referred to the maximum water temperature of 80 °C.
(3) in compliance with applicable rules.
Water topping up
The chemical-physical properties of the system's water may alter
over time, resulting in poor operation or excessive 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 car-
ried out carelessly may result in risks for the appliance,
the system, the environment and health.
Contact specialised rms or professionals for water treat-
ment or system washing.
Check compatibility of treatment or washing products
with operating conditions.
Do not use aggressive substances for stainless steel or
copper.
Do not leave washing residues.
3.8 INSTALLATION FILLING
How to ll up the system
Aftercompletingallwater,electricalandgasconnections:
1. Pressurise (at least 1.5 bar) and vent the hydraulic circuit.
2. Let water ow (with appliance o).
3. Check and clean the lter on the inlet pipe.
4. Repeat items 1, 2 and 3 until the pressure has stabilised (at
least 1.5 bar).
To vent the system do not use the appliance's vent, ex-
clusively intended for the internal exchanger (see detail
A Figure 3.2 p.16 ).
Water circuit inside the appliance
The water circuit inside the appliance is factory charged to 2 bar
with a water/glycol mix which enables the appliance to be safely
stored down to -30 °C.
The pressure gauge (detail B) will display the charging pressure
when the front panel of the appliance is removed. The optimal
pressure value is between 1 and 2 bar.
How to restore the charge of the water circuit inside
the appliance
Figure 3.2 p.16
1. Remove the front panel.
2. Identify any leakage points and restore the tightness
(e.g. seal replacement).
3. Remove the cap closing the lling cock and x the sup-
plied hose tting (detail D).
4. Open the lling cock, with a athead screwdriver, and
charge the circuit with enough glycol solution to achieve
the specied optimal pressure range.
5. Open the cap on the automatic bleed valve on the inter-
nal circuit and run the machine for 3 minutes to bleed
the circuit.
6. If there still is air, manually open the venting valve.
7. Stop the circuit operating, close the charging cock with
a athead screwdriver and close the automatic bleed
valve on the circuit.
8. Remove the hose tting and reposition the cap of the
lling cock.
9. Close the front panel with its retainer bolts.
10. Restore the appliance and put away the union.

Heating engineer
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Figure3.2Filling the appliance’s internal circuit - Detail of lling op-
erative stages
A manual air vent cock
B pressure gauge
C lling cock *
D D.13 hose tting supplied
* cut in horizontal position: cock closed;
cut in vertical position: cock open.
3.9 FUEL GAS SUPPLY
Gas connection
▶ 3/4" M
on the right, at the bottom, connection plate (Figure 1.2 p.8 ).
▶ Install an anti-vibration connection between the appliance
and the gas piping.
Mandatory shut-o valve
▶ Provide a gas shut-o valve (manual) on the gas supply line,
next to the appliance, to isolate it when required.
▶ Perform connection in compliance with applicable regula-
tions.
Gas pipes sizing
The gas pipes must not cause excessive load losses and, conse-
quently, insucient gas pressure for the appliance.
Supply gas pressure
The appliance's gas supply pressure, both static and dynamic,
must comply with Table 3.3 p.16 , with tolerance ± 15%.
Non compliant gas pressure (Table 3.3 p. 16 ) may
damage the appliance and be hazardous.
Table3.3Gas network pressure
AY00-120 Gas supply pressure
Product category Countries of destination G20
[mbar] G25 [mbar] G30 [mbar] G31 [mbar] G25.1 [mbar] G27 [mbar] G2,350 [mbar]
II2H3B/P
AL, BG, CZ, DK, EE, FI, GR, LT, NO, SE, SI, SK, TR 20 30 30
AT, CH 20 50 50
HR, MK, RO 25 30 30
IT 20 28-30 37
II2H3P
AL, BG, CZ, ES, GB, IE, LT, PT, SI, SK 20 37
HR, MK, RO 25 37 37
II2HS3B/P HU 25 30 30 25
II2E3P LU 20 50
II2ELL3B/P DE 20 20 50 50
II2Esi3P* FR 20 25 37
II2E3B/P
PL
20 37 37
II2ELwLs3B/P 20 37 37 20 13
II2ELwLs3P 20 37 20 13
I2E(S); I3P BE 20 25 37
I2H LV 20
I3B MT 30
I3B/P CY, MT 30 30
I3P IS 30
Vertical pipes and condensate
▶ Vertical gas pipes must be tted with siphon and discharge
of the condensate that may form inside the pipe.
▶ If necessary, insulate the piping.

Heating engineer
Installation, use and maintenance manual – AY00-120 17
3
LPG pressure reducers
With LPG the following must be installed:
▶ a rst stage pressure reducer, close to the liquid gas tank;
▶ a second stage pressure reducer, close to the appliance.
3.10 COMBUSTION PRODUCTS EXHAUST
Flue gas exhaust kit
The appliance, supplied in B53P conguration, is standard sup-
plied with a DN80 ue gas kit, to be set up by the installer.
The tting (DN80) for connecting the ue gas kit is located in the
upper part of the appliance with vertical outlet.
How to install the ue gas kit
Figure 3.3 p.17 :
1. Fix the terminal (detail A) on the DN 80 extension pipe (detail
B) inside the dedicated socket.
2. Fit the rain cover (detail C) onto the DN 80 extension pipe
(detail B).
3. Remove the protective cap on the top panel of the appliance.
4. Fix the kit (details A+B+C) into the dedicated socket of the
DN 80 anged union which can be accessed via the appli-
ance's top panel (detail D).
The cap prevents water and foreign bodies entering
the appliance before the fumes kit is installed. The cap
should thus be removed only when the kit itself has
been fully assembled and installed.
Figure3.3Flue gas exhaust kit
A roof terminal (DN80)
B extension pipe (DN80)
C rain cover (DN80)
D anged tting (DN80) on upper panel
A+B+C ue gas exhaust duct kit
Possible ue
If necessary, the appliance may be connected to a ue.
▶ To size the ue refer to Table 1.1 p.11 and Design Manual.
▶ If several appliances are connected to a single ue, it is oblig-
atory to install a check valve on the exhaust of each.
▶ The ue must be designed, sized, tested and constructed by
a skilled form, with materials and components complying
with the regulations in force in the country of installation.
▶ Always provide a socket for ue gas analysis, in an accessible
position.
3.11 FLUE GAS CONDENSATE DISCHARGE
The AY00-120 unit is a condensing appliance and therefore pro-
duces condensation water from combustion ue gases.
Condensate acidity and exhaust regulations
The ue gas condensate contains aggressive acid sub-
stances. Refer to applicable regulations in force for con-
densate exhaust and disposal.
If required, install an acidity neutraliser of adequate ca-
pacity.
Do not use gutters to discharge the condensate
Do not discharge the fume condensate in gutters, due to

Electrical installer
18
4
the risk of materials corrosion and ice formation.
Flue gas condensate connection
The tting for ue gas condensate discharge is located on the
right side of the appliance (Figure 1.2 p. 8 ) at the connection
plate.
Flue gas condensate discharge manifold
To make the condensate discharge manifold:
▶ Size the ducts for maximum condensation capacity (Table
1.1 p.11 ).
▶ 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 icing.
▶ Dilute, if possible, with domestic waste water (e.g. bath-
rooms, washing machines, dish washers...), basic and neu-
tralising.
Charging the siphon
Robur uses condensate collection siphons with oat, which
blocks the passage of fumes and odours deriving therefrom
in case the equipment remains turned o for a long time and
the liquid contained in the siphon evaporates or in case of
commissioning.
Thanks to this system, it is not necessary to ll the siphon at
commissioning.
4 ELECTRICAL INSTALLER
4.1 WARNINGS
General warnings
Read the warnings in Chapter III.1 p. 4 , providing im-
portant information on regulations and on safety.
Compliance with installation standards
Installation must comply with applicable regulations in
force, based on the installation Country and site, in mat-
ters of safety, design, implementation and maintenance
of electrical systems.
Installation must also comply with the manufacturer's
provisions.
Live components
After placing the appliance in the nal position, and pri-
or to making electrical connections, ensure not to work
on live components.
Earthing
The appliance must be connected to an eective earth-
ing system, installed in compliance with regulations 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 ap-
pliance on/o
Never use the external isolation switch (GS) to turn the
appliance on and o, since it may be damaged in the
long run (occasional black outs are tolerated).
To turn the appliance on and o, exclusively use the suit-
ably provided control device (DDC, CCP/CCI or external
request).
Control of water circulation pump
The water circulation pump of the water/primary cir-
cuit must mandatorily be controlled by the appliance's
electronic boards (AY10 + S70). It is not admissible to
start/stop the circulating pump with no request from
the appliance.
4.2 ELECTRICAL SYSTEMS
Electrical connections must provide:
▶ (a) power supply (Paragraph 4.3 p.19 );
▶ (b) control system (Paragraph 4.4 p.19 ).
How to perform connections
All electrical connections must be made in the appli-
ance's Electrical Board (Figure 4.1 p.19 ):
1. Ensure the appliance's Electrical Panel is not live.
2. Remove the front panel of the appliance and the cover of the
Electrical Board.
3. Run the cables through the suitable holes in the Connection
Plate.
4. Run the cables through the suitable cable glands in the Elec-
trical Board.
5. Identify the appropriate connection terminals.
6. Perform the connections.
7. Close the Electrical Panel.and t the front panel back on.

Electrical installer
Installation, use and maintenance manual – AY00-120 19
4
Figure4.1Electrical Panel
A Transformer 230/23V AC
B AY10+S70 electronic boards
C MC terminal block
D Power supply cable gland
E Circulating pump cable gland
F CAN-BUS cable gland
G Flame control box
4.3 ELECTRICAL POWER SUPPLY
Power supply line
Provide (by the installer) a protected single phase line (230V 1-N
50 Hz) with:
▶ 1 three-pole cable type FG7(O)R 3Gx1.5;
▶ 1 two-pole switch with 2 2A type T fuses, (GS) or 1 4A mag-
netothermic breaker.
The switches must also provide disconnect capability,
with min contact opening 3 mm.
How to connect the power supply
To connect the three-pole power supply cable (Figure
4.2 p.19 ):
1. Access the Electrical Board of the appliance according to the
Procedure 4.2 p.18 .
2. Connect the three wires to terminal board (MC) in the elec-
trical panel on the machine.
3. Provide the earth lead-in wire longer than live ones (last to
be torn in the event of accidental pulling).
Figure4.2Electrical wiring diagram - Example of connection of appli-
ance to 230 V 1 N - 50 Hz electricity supply
MC power terminal block
GS General switch
F Fuse(s)
N Neutral terminal
Ground Earth terminal
L Single phase line terminal
4.4 SETUP AND CONTROL
Control systems, options (1) (2) (3)
Three separate adjustment systems are provided, each with
specic features, components and diagrams (see 4.4 p. 20 ,
4.5 p.21 ):
▶ System (1), with DDC control (with CAN-BUS connection).
▶ System (2), with CCP/CCI control (with CAN-BUS connec-
tion).
▶ System (3), with an external request.
CAN-BUS communication network
The CAN-BUS communication network, implemented with the
cable of the same name, makes it possible to connect and re-
motely 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, CCI, ...), corresponds to
a node, connected to two more elements (if it is an intermedi-
ate node) or to just one other element (if it is a terminal node)
through two/one CAN-BUS cable section/s, forming an open lin-
ear communication network (never star or loop-shaped).
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. 20
(admissible types and maximum distances).
For lengths ≤200 m and max 4 nodes (e.g. 1 DDC + 3 GAHP), a
simple 3x0.75 mm shielded cable may even be used.

Electrical installer
20
4
Table4.1CAN BUS cables type
CABLE NAME SIGNALS / COLOR MAX LENGTH Note
Robur Ordering 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 appliance
To connect the CAN-BUS cable to the AY10 electronic board
(Paragraph 1.4 p.10 ), located in the Electrical Panel inside the
appliance (Figure 4.3 p.20 ):
1. Access the Electrical Board of the appliance according to the
Procedure 4.2 p.18 );
2. Connect the CAN-BUS cable to terminals GND, L and H
(shielding/earthing + two signal conductors);
3. Place the CLOSED J1 Jumpers (Detail A) if the node is termi-
nal (one connected CAN-BUS cable section only), or OPEN
(Detail B) if the node is intermediate (two connected CAN-
BUS cable sections);
4. Connect the DDC to the CAN-BUS cable according to the in-
structions of the following Paragraphs and DDC Manual.
Figure4.3Electrical wiring diagram - Connection cable CAN BUS to electronic board
SCH Electronic board
J1 Jumper CAN-BUS in board
A detail of "terminal node" case
(3 wires; J1=jumper "closed")
B Detail of "intermediate node"
case (6 wires; J1=jumper
"open")
GND Common data
L Data signal LOW
H Data signal HIGH
P8 CAN port/connector
AY conguration (AY10) + DDC
(System (1) see also Paragraph 1.5 p.10 )
Figure4.4Connexion câble CAN BUS for plants with one unit
DDC Direct Digital Control
SCH electronic board (AY10+S70)
J1 CAN-BUS Jumper on AY10 board
J21 Jumper CAN-BUS in board DDC
A terminal node connection (3 wires; J1 and J21 = "closed")
H,L,GND data signal wires