Robur AY00-120 User manual

Installation, use and maintenance manual
AY00-120
Condensing boiler
for heating
gas powered

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: M
Code: D-LBR531
DISPOSAL
The appliance and all its accessories must be disposed of separately in accordance with the regulations in force.
Use of the WEEE symbol (Waste Electrical and Electronic Equipment) indicates that this product cannot be disposed of as household waste.
Proper disposal of this product helps to prevent potential negative consequences for the environment and human health.

Installation, use and maintenance manual – AY00-120 3
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 data ................................................................ 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.13
2.5 Mounting base............................................................... p.13
3 Heating engineer............................................................... p.13
3.1 Warnings.......................................................................... p.13
3.2 Hydraulic system........................................................... p.13
3.3 Hydraulic connections ................................................ p.14
3.4 Water circulation pump.............................................. p.14
3.5 Antifreeze function....................................................... p.14
3.6 Antifreeze liquid............................................................ p.14
3.7 System water quality ................................................... p.15
3.8 System lling .................................................................. p.15
3.9 Fuel gas supply .............................................................. p.16
3.10 Combustion products exhaust ................................ p.17
3.11 Flue gas condensate discharge................................ p.18
4 Electrical installer.............................................................. p.18
4.1 Warnings.......................................................................... p.18
4.2 Electrical systems.......................................................... p.19
4.3 Electrical power supply............................................... p.19
4.4 Adjustment and control ............................................. p.19
4.5 Water circulation pump.............................................. p.23
5 First start-up .......................................................................... p.23
5.1 Preliminary checks........................................................ p.24
5.2 Electronic adjustment on the machine – Menus
and parameters.............................................................. p.24
5.3 Modifying settings........................................................ p.25
6 Normal operation.............................................................. p.25
6.1 Warnings.......................................................................... p.25
6.2 Switch on and o.......................................................... p.26
6.3 Modifying settings........................................................ p.26
6.4 Eciency.......................................................................... p.26
7 Maintenance.......................................................................... p.26
7.1 Warnings.......................................................................... p.26
7.2 Pre-emptive maintenance......................................... p.26
7.3 Scheduled routine maintenance............................. p.27
7.4 Messages on the display ............................................ p.27
7.5 Restarting a locked-out unit..................................... p.27
7.6 Periods of inactivity...................................................... p.28
8 Diagnostics.............................................................................. p.28
8.1 Operative codes............................................................. p.28
9 Appendices.............................................................................. p.30
9.1 Product che................................................................... p.30
INDEX OF CONTENTS

Introduction
4
I
I INTRODUCTION
Installation, use and maintenance 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 adjust-
ment device to control one or more Robur appliances (GAHP
heat pumps, GA chillers and AY00-120 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 start-up = 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
rm and by qualied 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 qualied per-
sonnel.
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
and experience with use of the appliance.

Warnings
Installation, use and maintenance manual – AY00-120 5
III
Gas component tightness
Before performing any operation on gas ducting compo-
nents, 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, mul-
timeters 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 disconnect
switch in the power supply electrical panel.
Use a telephone away from the appliance to ask for inter-
vention from qualied personnel.
Poisoning
Ensure the ue gas ducts are tightness and compliant
with the regulations in force.
Upon completing any procedure, ensure the tightness 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 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 oper-
ation 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 deposit ammable materials (paper, diluents,
paints, etc.) near 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 the 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. 18 , 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 provided control device (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, using only 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. 26 ) 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.
Use only 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 certied in accordance with European regula-
tion GAR 426/2016/EU and meet the essential requirements of
the following Directives:
▶ Eciency Directive 92/42/EEC and subsequent modica-
tions and additions.
▶ 2016/426/EU "Gas Appliances Regulation" 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:
▶ EN 15502 Gas-red central heating boilers.
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 to the appliance by the
plant or installation (mechanical stresses, pressure, vi-
brations, thermal expansion, electrical surges...).
Accidental damages or due to force majeure.

Features and technical data
Installation, use and maintenance manual – AY00-120 7
1
1 FEATURES ANDTECHNICAL 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
▶ Premix multigas burner with low NOx and CO emissions.
▶ Stainless steel plate heat exchanger, which also acts as a hy-
draulic separator.
▶ Automatic and manual air vent devices on the appliance in-
ternal circuit.
▶ Flue gas exhaust duct with relevant terminal, for type B53P
conguration.
▶ Condensate discharge siphon (with antifreeze protection).
Control and safety devices
▶ Electronic board with microprocessor.
▶ Automatically resettable water temperature limit thermo-
stat.
▶ Flue gas limit thermostat, for single use (thermal switch).
▶ System circuit water dierential pressure switch (PD1).
▶ Appliance internal circuit water dierential pressure switch
(PD2) with anti-welding function.
▶ Overpressure valve for the appliance internal circuit, set to
trip at 3 bar.
▶ Appliance internal circuit expansion tank.
▶ Ionization ame control box.
▶ Double shutter electric gas valve.
▶ Antifreeze functions for hydraulic circuit.
▶ Antifreezing thermostat for the heating element on the con-
densate siphon.
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 Power supply 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.
▶ S70 auxiliary 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 circulator jumper
N.O. CONTACT System water circulating pump control terminals (max 700W)
V3V (1-2-N) Appliance circulation 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:
▶ DDC controller
▶ CCP/CCI controller
▶ external request
1.5.1 Control 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).
▶ 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 production, Third
Party generator control, probe control, system valves or circula-
tion pumps, ...).