Robur AY Quick start guide

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

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.
The original is led at Robur S.p.A.
Any use of this Installation, use and maintenance manual other than for personal consultation must be previously
authorised by Robur S.p.A.
The rights of those who have legitimately led the registered trademarks contained within this publication are not
aected.
With the aim of continuously improving the quality of its products, Robur S.p.A. reserves the right to modify the
data and contents of this Installation, use and maintenance manual without prior notice.
Revision: A
Code: D-LBR885EN
DISPOSAL
The appliance and all its accessories must be disposed of separately in accordance with the regulations in force.
Use of theWEEE symbol (Waste Electrical and Electronic Equipment) indicates that this product cannot be disposed of as house-
hold waste. Proper disposal of this product helps to prevent potential negative consequences for the environment and human
health.

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

Introduction
4
I
I INTRODUCTION
Installation, use and maintenance manual
This Manual is an integral part of the AY appliance
and must be handed to the end user together with
the appliance.
I.1 RECIPIENTS
This Manual is intended for:
▶ End user, for appropriate and safe use of the appliance.
▶ Qualied installer, for correct appliance installation.
▶ Planner, for specic information on the appliance.
I.2 CONTROL DEVICE
In order to work, the AY appliance requires a control de-
vice to be connected by the installer.
II SYMBOLS AND DEFINITIONS
II.1 KEY TO SYMBOLS
DANGER
WARNING
NOTE
PROCEDURE
REFERENCE (to other document)
II.2 TERMS AND DEFINITIONS
DHW = domestic hot water.
Appliance/Unit AY = equivalent terms, both used to des-
ignate the AY series condensing boiler.
TAC = Technical Assistance Centre authorised by Robur.
External request = generic control device (e.g. thermo-
stat, timer or any other system) equipped with a volt-
age-free NO contact and used as control to start/stop the
AY unit.
DDC Control (Direct Digital Controller) = optional Robur
control device to manage one or more Robur appliances
in ON/OFF mode (GAHP heat pumps, GA chillers) or in
modulating mode (AY boilers).
RB100/RB200 Devices (Robur Box) = optional interface
devices complementary to DDC, which may be used to
broaden its functions (heating/cooling/DHW production
service demands and control of system components such
as third party generators, adjustment valves, circulators,
probes).
First start-up = appliance commissioning operation
which may only and exclusively be carried out by a TAC.
III WARNINGS
III.1 GENERAL AND SAFETY WARNINGS
Installer's qualications
Installation must exclusively be performed by a
qualied rm and by skilled personnel, with spe-
cic knowledge on heating, electrical systems and
gas appliances, in compliance with the laws in
force in the Country of installation.
Declaration of conformity
Upon completing installation, the installing rm
shall issue to the owner/client the appliance's
workmanlike conformity declaration, according to
national/local regulations in force and the manu-
facturer's instructions/provisions.
Packing
Packing items (plastic bags, polystyrene foam,
nails, etc.) must be kept out of the reach of chil-
dren, as they are potentially dangerous.
Misuse
The appliance must only be used for the purpos-
es for which it has been designed. Any other use is
deemed hazardous. Incorrect use may aect oper-
ation, duration and safety of the appliance. Adhere
to the manufacturer's instructions.
Use of the appliance by children
The appliance can be used by children over 8 years
old, and by people with reduced physical, senso-
ry or mental capabilities, or lack of experience or

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

Warnings
6
III
breakage of any component, do not attempt to
repair and/or restore and immediately contact the
TAC.
Routine maintenance
Proper maintenance assures the eciency and
good operation of the appliance over time.
Maintenance must be performed according to the
manufacturer's instructions (see Chapter 7 p. 41 )
and in compliance with current regulations.
Appliance maintenance and repairs may only be
entrusted to rms legally authorised to work on
gas appliances and systems.
Enter into a maintenance contract with an author-
ised specialised rm for routine maintenance and
for servicing in case of need.
Use only original parts.
Decommissioning and disposal
If the appliance is to be disposed of, contact the
manufacturer for its disposal.
Keep the Manual
This Installation, use and maintenance manual
must always accompany the appliance and must
be handed to the new owner or installer in the
event of sale or removal.
III.2 COMPLIANCE
III.2.1 EU directives and standards
The appliance is certied in accordance with European
regulation GAR 426/2016/EU and meet the essential re-
quirements of the following Directives:
▶ Eciency Directive 92/42/EEC and subsequent modi-
cations and additions.
▶ 2016/426/EU "Gas Appliances Regulation" as amend-
ed and added.
▶ 2014/30/EC "Electromagnetic Compatibility Directive"
as amended and added.
▶ 2014/35/EC "Low Voltage Directive" as amended and
added.
▶ 2006/42/EC "Machine Directive" as amended and add-
ed.
▶ 811/2013/EU "Energy-Related Products regulation" as
amended and added.
▶ 813/2013/EU "Ecodesign requirements regulation" as
amended and added.
Furthermore, they comply with the requirements of the
following standards:
▶ EN 15502 Gas-red central heating boilers.
III.2.2 Other applicable provisions and standards
The design, installation, operation and maintenance of
the systems shall be carried out in compliance with cur-
rent applicable regulations, depending on the Country
and location, and in accordance with the manufacturer's
instructions. In particular, regulations regarding the fol-
lowing shall be complied with:
▶ Gas systems and equipment.
▶ Electrical systems and equipment.
▶ Heating systems employing condensing boilers.
▶ Environmental protection and combustion products
exhaust.
▶ Fire safety and prevention.
▶ Any other applicable law, standard and regulation.
III.3 EXCLUSIONS OF LIABILITY AND
WARRANTY
Any contractual or extra-contractual liability of the
manufacturer for any damage caused by incorrect
installation and/or improper use and/or failure to
comply with regulations and with the manufactur-
er's directions/instructions shall be disclaimed.
In particular, the warranty on the appliance may be
rendered void by the following conditions:
Incorrect installation.
Misuse.
Failure to comply with the manufacturer's indica-
tions on installation, use and maintenance.
Alteration or modication of the product or any
part thereof.
Extreme operational conditions or however out-
side of the operational ranges set forth by the man-
ufacturer.
Damages caused by external agents such as salts,
chlorine, sulphur or other chemical substances
contained in the installation water or present in the
air of the installation site.
Abnormal actions transmitted to the appliance by
the system or installation (mechanical stresses,
pressure, vibrations, thermal expansion, electrical
surges...).
Accidental damages or due to force majeure.

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

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

Features and technical data
Installation, use and maintenance manual – AY 9
1
1.3 ELECTRICAL WIRING DIAGRAM
1.3.1 AY 35
Figure1.11Boiler electrical connections diagram
A CAN bus connection
CS Heating cable
EA Ignition electrode
ER Flame detector
EV Blower
FM Flowmeter
L Line
MP Control panel terminal block
N Neutral
PM Water pump
Pacq Water pressure switch
RS1 Heating resistance condensate drain 1
SCH Control board
SCH2 CAN-NDG board
SE Outdoor temperature probe
SR Heating delivery probe
SRi Heating return probe
Ta Antifreeze thermostat
TA Connector for optional room thermostat
TF Flue gas thermofuse
TS Safety thermostat
Tra Ignition transformer
VG Gas valve
ar Orange
bi White
ce Light blue
gi Yellow
gr Grey
ma Brown
ne Black
EA
VG
Tra
ER
11
10
98
7
12
13
14
15
16
17
M12 M9 M7 M5
M2
M4
M8
M10
M15
M16
1
2
3
4
57
61
60
59
58
38
31 30
29 28
27 26
62
63
64
65
66
67
68
51
52
53
54
55
56
56
M13
M14
PM
SRi
M6
GND
PWM
HS
+24V
32 33
34 35 36 37
39
40 41 42 43 44
Pacq SR
TF
TS
MP
LN
TA TA +10
0
0LH
SHIELD
E-SLT088 CAN-NDGE-SLT088 CAN-NDG
CS
1 1
RS1
230V-50Hz
SE
connett. SAux
1
Ta
1
EV
SCH
SCH2
FM
YE-GI
GN-VE
YE-GI
GN-VE
YE-GI
BN-MA
WH-BI
GN-VE
GN/YE
BN-MA
BU-BL
BN-MA
BU-BL
BU-BL
BN-MA
BN-MA
BU-BL
BN-MA
BN-MA
BU-BL
BU-BL
BN-MA
BU-BL
BN-MA
JUMPER
J11
J11
A

Features and technical data
10
1
1.3.2 AY 50
Figure1.12Boiler electrical connections diagram
A CAN bus connection
CS Heating cable
EA Ignition electrode
ER Flame detector
EV Blower
FM Flowmeter
L Line
MP Control panel terminal block
N Neutral
PM Water pump
Pacq Water pressure switch
RS1 Heating resistance condensate drain 1
SCH Control board
SCH2 CAN-NDG board
SE Outdoor temperature probe
SR Heating delivery probe
SRi Heating return probe
Ta Antifreeze thermostat
TA Connector for optional room thermostat
TF Flue gas thermofuse
TS Safety thermostat
Tra Ignition transformer
VG Gas valve
ar Orange
bi White
ce Light blue
gi Yellow
gr Grey
ma Brown
ne Black
EA
VG
Tra
ER
11
10
98
7
12
13
14
15
16
17
M12 M9 M7 M5
M2
M4
M8
M10
M15
M16
1
2
3
4
57
61
60
59
58
38
31 30
29 28
27 26
62
63
64
65
66
67
68
51
52
53
54
55
56
56
M13
M14
PM
SRi
M6
GND
PWM
HS
+24V
32 33
34 35 36 37
39
40 41 42 43 44
Pacq SR
TF
TS
0LH
SHIELD
E-SLT088 CAN-NDGE-SLT088 CAN-NDG
CS
1 1
RS1
230V-50Hz
SE
connett. SAux
1
Ta
1
EV
SCH
SCH2
FM
YE-GI
GN-VE
YE-GI
GN-VE
YE-GI
BN-MA
WH-BI
GN-VE
GN/YE
BN-MA
BU-BL
BN-MA
BU-BL
BU-BL
BN-MA
BN-MA
BU-BL
BN-MA
BU-BL
BU-BL
BN-MA
BU-BL
BN-MA
JUMPER
J11
J11
BN-MA
A
MP
LN
TA TA +10
0

Features and technical data
Installation, use and maintenance manual – AY 11
1
1.3.3 AY 100
Figure1.14Boiler electrical connections diagram - Module 2
A Connection fromTA2 connector
B Connection from module 1
C CAN bus connection from module 1
EA Ignition electrode
ER Flame detector
EV Blower
FM Flowmeter
L Line
N Neutral
PM Water pump
Pacq Water pressure switch
RS2 Heating resistance condensate drain 2
SE Outdoor temperature probe
SCH Control board
SCH2 CAN-NDG board
SR Heating delivery probe
SRi Heating return probe
Ta Antifreeze thermostat
TF Flue gas thermofuse
TS Safety thermostat
Tra Ignition transformer
VG Gas valve
ar Orange
bi White
ce Light blue
gi Yellow
gr Grey
ma Brown
ne Black
EA
Tra
ER
11
10
98
7
12
13
14
15
16
17
M12 M9 M7
M5
M2
M4
M8
M10
M15
M16
1
2
3
4
57
61
60
59
58
38
31 30
29 28
27 26
62
63
64
65
66
67
68
51
52
53
54
55
56
56
M14
PM
M6
GND
PWM
HS
+24V
32 33 34 35 36 37
39
40 41 42 43 44
SR
TF
TS
EV
Pacq
connett. SAux
VG
E-SLT088 CAN-NDGE-SLT088 CAN-NDG
Ta
RS2
1
0LH
SHIELD
M13
SRi
1
FM
SE
1
BN-MA
BU-BL
YE-GI
BN-MA
BU-BL
BN-MA
BN-MA
BU-BL
BU-BL
BN-MA
BN-MA
BU-BL
WH-BI
GN-VE
GN/YE
GN/YE
L
N
SCH
JUMPER
J11
J11
BU-BL
BN-MA
BU-BL
BN-MA
A
B
C
SCH2

Features and technical data
12
1
Figure1.14Boiler electrical connections diagram - Module 1
A Connection of TA2 connector to module
2
B Connection to module 2
C CAN bus connection to module 2
D CAN bus connection
CS Heating cable
EA Ignition electrode
ER Flame detector
EV Blower
FM Flowmeter
L Line
MP Control panel terminal block
N Neutral
PM Water pump
Pacq Water pressure switch
RS2 Heating resistance condensate drain 2
SCH Control board
SCH2 CAN-NDG board
SE Outdoor temperature probe
SR Heating delivery probe
SRi Heating return probe
Ta Antifreeze thermostat
TA1 Connector for optional room thermostat
for module 1
TA2 Connector for optional room thermostat
for module 2
TF Flue gas thermofuse
TS Safety thermostat
Tra Ignition transformer
VG Gas valve
ar Orange
bi White
ce Light blue
gi Yellow
gr Grey
ma Brown
ne Black
EA
VG
Tra
ER
11
10
98
7
12
13
14
15
16
17
M12 M9 M7 M5
M2
M4
M8
M10
M15
M16
1
2
3
4
57
61
60
59
58
38
31 30
29 28
27 26
62
63
64
65
66
67
68
51
52
53
54
55
56
56
M13
M14
PM
SRi
M6
GND
PWM
HS
+24V
32 33 34 35 36 37
39
40 41 42 43 44
Pacq
ne ne
ce
ma ma
ce
SR
TF
TS
ma
ce
0LH
SHIELD
E-SLT088 CAN-NDGE-SLT088 CAN-NDG
CS
1 1
RS1
230V-50Hz
connett. SAux
1
FM
SE
1
GN/YE
BU-BL
BN-MA
BN-MA
BU-BL
BN-MA
BU-BL
BU-BL
BN-MA
BN-MA
BU-BL
YE-GI
BN-MA
WH-BI
GN-VE
BN-MA
BN-MA
BN-MA
BU-BL
L
N
BU-BL
BN-MA
BU-BL
BN-MA
SCH
SCH2
JUMPER
J11
J11
A
B
CD
LN
TA1 TA 1 TA2
TA2
MP

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

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

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

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

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

Heating engineer
18
3
Installation must also comply with the manufactur-
er's provisions.
3.2 HYDRAULIC CONNECTIONS
The hydraulic installer must make the hydraulic connec-
tion circuit to the heating system.
The installer must provide for the construction of a suita-
bly sized hydraulic connection circuit, taking into account:
A. of the following indications:
Use pipes for heating/cooling systems, protected
from weathering and freezing, insulated for ther-
mal dispersion.
Sizing of the pipes, according to the standard circu-
lator, must grant the nominal water ow required
for the correct operation of the heating system.
When using glycol water, take this into account
when selecting the pipe material and calculating
the additional pressure drop generated by the
presence of glycol (Table 3.1 p.20 ).
B. of the residual head and pressure drop data reported
in Paragraph 1.6.3 p.15 .
Connect the outlet of the boiler safety valve
(Paragraph 1.2 p. 7 ) to a suitable drain. The
manufacturer is not liable for any damage caused
by the opening of the safety valve in the event of
system overpressure.
3.2.1 Hydraulic connections
on the right, at the bottom, connection plate (Paragraph
1.2 p.7 ).
3.2.1.1 AY 35 and AY 50
OUT Water outlet connection Ø 1 1/4" F
IN Water inlet connection Ø 1 1/4" F
3.2.1.2 AY 100
OUT Water outlet connection Ø 1 1/2" F
IN Water inlet connection Ø 1 1/2" F
3.2.2 Pipe cleaning
Pipe cleaning
Before connecting the appliance,accurately wash
the water and gas piping and any other system
component, removing any residue.
3.2.3 Minimum components of water circuit
Always provide, near the appliance:
▶ on water piping, both outlet and inlet
2 antivibration joints on water ttings
2 pressure gauges
2 isolation ball valves
▶ on the inlet water piping
1 separator lter
The appliance is equipped with its own 10 l internal
expansion tank and with a safety valve. Depending
on the water content of the system, assess the
need for additional expansion tanks.
3.2.4 System lling
For the calculation of the total water content to
be loaded in the system it is necessary to add the
water content of the boiler (Table 1.1 p. 13 ) and
of the distribution terminals to the water content
in the pipes and in other elements that make up
the system (tanks, hydraulic separators, etc.).
Proceed with the lling of the system as follows.
A lling tap on the system must be provided for ll-
ing the system.
At the rst power supply and each time the power
supply is restored, an automatic system venting
cycle is activated. The display will show the code
F33 for the entire duration of the cycle (5 minutes
for the rst power supply, 2 minutes for the fol-
lowing ones).
To access the display, remove the front panel of the
boiler, as shown in Figure 5.1 p.31 .
3.2.4.1 AY 35
1. Slightly loosen the cap of the jolly valve placed on the
top of the condensing block (Figure 3.1 p.19 ) to re-
lease the air from the top of the boiler.
2. Open the system lling valve (to be provided on the
system) and let out all the air.
3. Check with pressure gauge that system pressure
reaches 1,5 bar.
4. Open the automatic air vent valves on the system, if
any, and check the air venting process.
5. Make sure that the unit is energized.
6. Send an operating request to the unit for a few sec-
onds. The circulating pump will be immediately
activated.
7. Remove the request before the burner is activated.
The circulating pump will continue to circulate the wa-
ter for the post-circulation time.
8. If, after the above operations, a decrease in system wa-
ter pressure is observed, open again the system lling
tap until the system pressure reaches 1,5 bar.
9. Repeat items 6, 7, 8 until the pressure has stabilised (at
least 1,5 bar).
10.After the operation, make sure that the system lling
tap is tightly closed.
Once the lling operation has been completed,
close the cap of the jolly valve on the condensing
block, to avoid water leaks.
To start the circulation pump only, with the boiler

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

Heating engineer
20
3
system are fundamental to ensure reliability over
time of the mechanical components, in particular
the circulation pumps.
Figure3.3Pump/Roma valve assembly on AY appliances
A Roma valve
B Air vent (internal circuit)
C Air vent (system)
D Flexible hose
E Circulator
F Return pipe
G Delivery pipe
AG
E
F
B
C
D
3.2.5 Pump antifreeze and anti-lock function
Heating antifreeze function
If the outlet water temperature detected by the
water temperature probe inside the boiler falls
below the antifreeze activation value (default 12
°C, settable via parameter P81), the control board
starts the water pump and the ignition of the burn-
er at minimum power.
When the outlet water temperature reaches 30 ºC
or the inlet water temperature reaches 20 °C (anti-
freeze temperature OFF) the control board will turn
o the burner.
Electrical and gas continuity
Theantifreezefunction isonly eectiveif the power
and gas supplies are assured. Otherwise, antifreeze
uid in the system water might be required.
Pump anti-lock function
In order to prevent the circulation pump from lock-
ing, the boiler is equipped with an anti-lock func-
tion which, every 24 hours of inactivity, operates
the circulation pump for 30 seconds.
Electrical continuity
The pump anti-lock function is only eective if the
power supply is guaranteed.
3.2.6 Antifreeze liquid
Precautions with glycol
The manufacturer disclaims any liability for any
damage caused by improper glycol use.
Always check product suitability and its expiry
date with the glycol supplier. Periodically check the
product's preservation state.
Do not use car-grade antifreeze liquid (without
inhibitors), nor zinc-coated piping and ttings (in-
compatible with glycol).
Glycol modies the physical properties of water
(density, viscosity, specic heat...). Size the piping,
circulation pump and thermal generators accord-
ingly.
With automatic system water lling, a periodic
check of the glycol content is required.
In the presence of glycol
In the presence of glycol it is necessary to warn the
TAC before the rst start-up and to set parameter
P52 correctly.
When producing DHW by DHW buer tank, use
propylene glycol only.
3.2.6.1 Type of antifreeze glycol
Inhibited type glycol is recommended to prevent oxida-
tion phenomena.
3.2.6.2 Glycol eects
The Table 3.1 p.20 shows, indicatively, the eects of us-
ing 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 eciency 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%