Robur Caldaia 100.2 Tech User manual

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Installation, use and maintenance manual
Outdoor condensing boiler
for heating medium and large buildings
Caldaia 55.1 and 100.2 Tech

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-LBR861EN
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 – Caldaia 55.1 and 100.2 Tech 3
I Introduction............................................................................. p.4
I.1 Recipients .......................................................................... 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.5
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 Components..................................................................... p.9
1.4 Technical characteristics............................................. p.13
1.5 Electrical wiring diagram ........................................... p.15
2 Transport and positioning........................................ p.18
2.1 Warnings.......................................................................... p.18
2.2 Handling........................................................................... p.18
2.3 Minimum clearance distances.................................. p.18
3 Heating engineer............................................................... p.18
3.1 Warnings.......................................................................... p.18
3.2 Boiler installation .......................................................... p.18
3.3 Hydraulic connections ................................................ p.19
3.4 Combustion products exhaust ................................ p.21
3.5 Pump antifreeze and anti-lock function............... p.22
3.6 Fuel gas supply .............................................................. p.22
4 Electrical installer.............................................................. p.24
4.1 Warnings.......................................................................... p.24
4.2 Electrical power supply............................................... p.24
4.3 Control device................................................................ p.24
4.4 Control through optional OCDS006 remote
control - recommended solution............................ p.25
4.5 Positioning the control system................................ p.25
4.6 Operation via centralised external request......... p.25
4.7 Operation with external temperature probe
(optional).......................................................................... p.25
5 First start-up .......................................................................... p.25
5.1 Preliminary checks........................................................ p.26
5.2 How to access the boiler............................................ p.26
5.3 How to access the control panel............................. p.27
5.4 Electronic board parameters setting..................... p.27
5.5 Combustion parameters check................................ p.32
5.6 Gas changeover............................................................. p.33
5.7 Commissioning.............................................................. p.33
5.8 Switching o................................................................... p.34
5.9 Prolonged periods of inactivity ............................... p.34
6 Normal operation.............................................................. p.34
6.1 Warnings.......................................................................... p.35
6.2 Preliminary checks........................................................ p.35
6.3 Operation without remote control......................... p.35
6.4 Remote control operation (optional)..................... p.36
6.5 Info menu display......................................................... p.36
7 Maintenance.......................................................................... p.36
7.1 Hydraulic boiler emptying......................................... p.36
8 Diagnostics.............................................................................. p.37
8.1 System pressure restore ............................................. p.37
8.2 Error codes....................................................................... p.37
9 Appendices.............................................................................. p.40
9.1 Product che................................................................... p.40
INDEX OF CONTENTS

Introduction
4
I
I INTRODUCTION
Manual
This Manual is an integral part of the
Caldaia 55.1 and 100.2 Tech units 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.
II SYMBOLS AND DEFINITIONS
II.1 KEY TO SYMBOLS
DANGER
WARNING
NOTE
PROCEDURE
REFERENCE (to other document)
II.2 TERMS AND DEFINITIONS
Appliance/Unit = equivalent terms, both used to refer to
Caldaia 55.1 and 100.2 Tech.
Boiler/External module = equivalent terms, both used to des-
ignate the part of the appliance to be installed outside the room
to be heated.
TAC = Technical Assistance Centre authorised by Robur.
Remote control = optional control device with chronothermo-
stat function.
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 Caldaia 55.1 and 100.2Tech
unit.
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 specic knowl-
edge 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 reg-
ulations in force and the manufacturer's instructions/
provisions.
Packing
Packing items (plastic bags, polystyrene foam, nails, etc.)
must be kept out of the reach of children, as they are po-
tentially dangerous.
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.
Use of the appliance by children
The device can be used by children over 8 years old,
and by people with reduced physical, sensory or mental
capabilities, or lack of experience or knowledge, only if
they are under surveillance or after they have received
instructions regarding safe use of the appliance and un-
derstanding the dangers inherent in it. Children should
not play with the appliance. Cleaning and maintenance
that must be performed by the user must not be per-
formed by unsupervised children.
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.

Warnings
Installation, use and maintenance manual – Caldaia 55.1 and 100.2 Tech 5
III
Do not entrust children, persons with physical, sensory
or mental disabilities or persons with poor knowledge
and experience with use of the appliance.
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.
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 qualied 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 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.
Check system sealing.
Avoid frequent top-ups.
Acid ue gas condensate
Discharge the acid condensate of combustion ue gas 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 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
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. 36 ) 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.
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

Warnings
6
III
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 677 Specic requirements for condensing boilers with
nominal heat input up to 70 kW.
▶ EN 483 Type C boilers of nominal heat input not exceeding
70 kW.
▶ 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 – Caldaia 55.1 and 100.2 Tech 7
1
1 FEATURES AND TECHNICAL DATA
1.1 FEATURES
Operation
The Caldaia 55.1 and 100.2 Tech units have been designed and
built to meet the needs of space heating. These boilers (external
modules) can also be installed outdoors.
The appliance operation will be controlled by an external re-
quest (chronothermostat, room thermostat or another opera-
tion request) or by the remote control to be installed inside the
heated room.
When the heating service is requested, detected by the external
request or by the remote control, the electronic board starts the
circulation 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 stops the appliance and indicates the block. Reset-
ting is manual.
In the event of abnormal overheating of the delivery, the boiler
is switched o. The limit thermostat has manual reset.
Mechanical and thermo-hydraulic components
▶ Integrated spiral single tube stainless steel heat exchanger
(2 heat exchangers for Caldaia 100.2 Tech).
▶ Premix modulating burner with 1:9 ratio.
▶ Automatic air vent valve.
▶ High eciency modulating water pump.
▶ System drain tap.
▶ Water temperature probe.
▶ Condensate drain siphon.
Control and safety devices
▶ Flue safety thermal fuse.
▶ Gas solenoid valve.
▶ Safety thermostat.
▶ Safety appliances kit approved by INAIL; for further details
see specic Paragraph at  p.7 .
INAIL safety appliances
The boiler is supplied with an INAIL approved safety applianc-
es kit (see Figure 1.2 p. 8 and Figure 1.7 p. 11 ), created in
order to meet the requirements of Italian regulations, with the
exception of the installation of any expansion tank in addition to
that already supplied and the gas shut-o valve.
The installation of the devices and the connection to the
electrical network must be subject to the safety regula-
tions for devices containing hot liquids under pressure in
compliance with the provisions regulations in force.
It is not allowed to reuse any type of device previously
disassembled from another plant.
The calibration report of the approved safety valve and the cer-
ticates of the control, regulation and safety devices are con-
tained in the packaging of the components themselves.
The kit is composed as follows:
▶ INAIL approved safety valve calibrated at 2,5 bar, positive
action, depending on the installed power, accompanied by
INAIL calibration report and EC approval mark.
▶ Well for INAIL control thermometer.
▶ INAIL approved manual reset lock thermostat.
▶ Thermal switch with declaration of conformity, copy of the
INAIL type approval certicate and instructions.
▶ Sensitive element thermowell for gas shut-o valve.
▶ INAIL approved thermometer with scale 0-120 °C.
▶ INAIL approved pressure lock switch, working range: 1÷5
bar; standard operating pressure 3 bar, acting on the pres-
sure of the relative circuit, accompanied by a document in-
cluding a declaration of conformity, a copy of the INAIL ap-
proval certicate and instructions.
▶ Pressure gauge connection tap with ange for control pres-
sure gauge.
▶ Shock absorber pipe.
▶ INAIL-compliant pressure gauge, working range: 0÷4 bar.
▶ INAIL approved 0,5 bar minimum pressure switch, acting on
the pressure of the relevant circuit, accompanied by a doc-
ument including a declaration of conformity, a copy of the
INAIL approval certicate and instructions.
1.2 DIMENSIONS
Figure1.1Caldaia 55.1 dimensions
480
870
582
240
144

Features and technical data
8
1
Figure1.2Caldaia 55.1 hydraulic connections (bottom panel view)
A Delivery Ø 1 1/4" M
R Return Ø 1 1/4" M
G Gas Ø 1" M
SC Condensate drain
V Safety valve drain
1 Side resting on the installation wall
273
93
82
89,5
166
172
227 241
R
G
A
SC
V
1
Figure1.3Caldaia 100.2 dimensions
350
160
590
977
730
Figure1.4Caldaia 100.2 hydraulic connections (bottom panel view)
A Delivery Ø 1 1/2" M
R Return Ø 1 1/2" M
G Gas Ø 1" M
SC Condensate drain
V Safety valve drain
1 Side resting on the installation wall
R
SC
93
162
67
155 180 85 310
215
195 320
SC
G A
1
V

Features and technical data
Installation, use and maintenance manual – Caldaia 55.1 and 100.2 Tech 9
1
1.3 COMPONENTS
Figure1.5Caldaia 55.1 internal components
1 Flue safety thermal fuse
2 Heat exchanger
3 Burner unit
4 Flame detector
5 Heating return probe
6 Blower
7 Modulating circulator
8 Gas valve
9 Air vent valve
10 System drain tap
11 Heating delivery probe
12 Safety thermostat
13 Ignition electrode
14 Air intake pipe
15 Ignition transformer
16 Venturi
17 Condensate drain hose
18 Water pressure switch
19 Condensate drain siphon
20 Expansion tank
21 System drain tap
22 Inspection well
23 Gas shut-o valve sensing bulb thermowell
24 INAIL approved manual reset lock thermostat
25 INAIL approved maximum pressure lock switch
26 INAIL approved minimum pressure lock switch
27 Pressure gauge connection tap with test ange
and shock absorber pipe
28 INAIL-compliant pressure gauge
29 In-line shut-o valve
30 System delivery connection
31 System return connection
32 Control panel
33 INAIL approved safety valve
28
27
25
15
18
13
12
20
14
4
3
2
22
29
23
7
19
5
24
2
18
26
29
29
29
6
32
20
31
30
33
11
7
8
9
10
9
10
11
16
17
21

Features and technical data
10
1
Figure1.655.1 boiler hydraulic diagram
1 Flue safety thermal fuse
2 Heat exchanger
3 Burner unit
4 Flame detector
5 Heating return probe
6 Blower
7 Modulating circulator
8 Gas valve
9 Air vent valve
10 System drain tap
11 Heating delivery probe
12 Safety thermostat
13 Ignition electrode
14 Air intake pipe
15 Ignition transformer
16 Venturi
17 Safety valve
18 Water pressure switch
19 System drain tap
20 Condensate drain siphon
21 INAIL approved manual reset lock thermostat
22 INAIL approved thermometer
23 INAIL approved minimum pressure lock switch
24 INAIL approved maximum pressure lock switch
25 Pressure gauge connection tap with test ange
and shock absorber pipe
26 INAIL-compliant pressure gauge
27 System delivery connection
28 System return connection
29 INAIL approved safety valve
30 Expansion tank
31 Gas shut-o valve sensing bulb thermowell
32 Inspection well
33 In-line shut-o valve
A Heating outlet
B Condensate discharge
C Gas
D Heating return
PB
TB
PM
30
14
12
11
9
13
15
16
6
20
1
3
21
18
29
22
21
26
25
23
24
31
32
33
27
28
33
10
5
7
19
6
4
2
17
8
D
C
A
B

Features and technical data
Installation, use and maintenance manual – Caldaia 55.1 and 100.2 Tech 11
1
Figure1.7Caldaia 100.2 internal components
1 Flue safety thermal fuse 2 Slave unit heat exchanger 3 Burner unit 4 Flame detector 5 Heating return probe 6 Blower 7 Modulating circulator 8 Gas valve 9 Air vent valve 10 System drain tap 11 Heating delivery probe 12 Safety thermostat 13 Ignition electrode 14 Air intake pipe 15 Ignition transformer
16 Venturi 17 Condensate drain hose 18 Water pressure switch 19 Manifold probe 20 Master unit heat exchanger 21 Condensate drain siphon 22 System drain tap 23 Expansion tank 24 INAIL approved safety valve 25 Inspection well 26 Gas shut-o valve sensing bulb thermowell 27 INAIL approved manual reset lock thermostat 28 INAIL approved maximum pressure lock switch 29 INAIL approved minimum pressure lock switch 30 Pressure gauge connection tap with test ange and shock absorber
pipe
31 INAIL-compliant pressure gauge 32 In-line shut-o valve 33 System delivery connection 34 System return connection 35 Delivery manifold 36 Return manifold 37 Gas manifold 38 Master control panel 39 Slave control panel 40 Flue gas manifold 41 Electrical connection terminal 42 Integrated ue gas check valve
9
11 12 13
6
19
1 2 3 4 8 8
14 13 4
20
11
12
91
36 37 39 38 34 32 33
25 26 32 24 28 29 30 31
15 17
5 76
16 14
14
18
22 22 21 17
2
10 9 1 23 28 40 41
25 32 32 40
40
15 27 35
42
42

Features and technical data
12
1
Figure1.8100.2 boiler hydraulic diagram
1 Flue safety thermal fuse
2 Slave unit heat exchanger
3 Burner unit
4 Flame detector
5 Heating return probe
6 Blower
7 Modulating circulator
8 Gas valve
9 Air vent valve
10 System drain tap
11 Heating delivery probe
12 Safety thermostat
13 Ignition electrode
14 Air intake pipe
15 Ignition transformer
16 Venturi
17 Condensate drain hose
18 Water pressure switch
19 Manifold probe
20 Master unit heat exchanger
21 Condensate drain siphon
22 System drain tap
23 Expansion tank
24 INAIL approved safety valve
25 Inspection well
26 Gas shut-o valve sensing bulb thermowell
27 INAIL approved manual reset lock thermostat
28 INAIL approved thermometer
29 INAIL approved minimum pressure lock
switch
30 INAIL approved maximum pressure lock
switch
31 Pressure gauge connection tap with test
ange and shock absorber pipe
32 INAIL-compliant pressure gauge
33 In-line shut-o valve
34 System delivery connection
35 System return connection
36 Delivery manifold
37 Return manifold
38 Gas manifold
39 Flue gas manifold
A Heating outlet
B Condensate discharge
C Gas
D Heating return
D
C
PB
TB
PM
A
B
1
2
4
3
6
13
16
15
21
5
7
7
8
8
9
12
11
14
22
14
12
11
9
13
4
15
16
6
21
37
1
20
3
36
38
18
19
24
28
27
32
31
29
30 23
26
25
33
34
35
33
10
5
22
10
17
39

Features and technical data
Installation, use and maintenance manual – Caldaia 55.1 and 100.2 Tech 13
1
1.4 TECHNICAL CHARACTERISTICS
Table1.1Technical data of external modules
Caldaia 55.1 Tech Caldaia 100.2 Tech
Heating mode
seasonal space heating energy eciency class (ErP) A -
Heat input nominal (1013 mbar - 15 °C) (1) kW 50,0 99,8
minimum (1) kW 5,0
Operating point 80/60 Nominal heat input
eective
power kW 49,2 98,2
eciency % 98,4
Operating point 50/30 Nominal heat input eciency % 106,8
Operating point Tr = 30 °C Heat input 30% eciency % 108,8
Operating point Tr = 47 °C Heat input 30% eciency % 102,8
Heat loss
to jacket in operation % 0,10 0,47
to ue in operation % 2,10
in o mode % 0,05 0,03
Hot water delivery temperature maximum °C 80
Ambient air temperature (dry bulb) maximum °C 40
minimum °C -10
eciency class ****
Electrical specications
Power supply
voltage V 230
type - SINGLE PHASE
frequency Hz 50
Electrical power absorption nominal kW 0,11 0,22
Degree of protection IP - X5D
Installation data
Gas consumption
G20 natural gas (nominal) m³/h 5,29 10,59
G25 (nominal) m³/h 6,15 12,30
G25.3 (nominal) m³/h 6,01 12,03
G30 (nominal) kg/h 3,94 7,88
G31 (nominal) kg/h 3,88 7,77
Water tting type - M
thread “ 1 1/4 1 1/2
Gas connection type - M
thread “ 1
Flue gas exhaust diameter (Ø) mm 80 100
residual head Pa 100
CO2percentage in fumes
Nominal heat input
G20 % 9,3 9,2
G25 % 9,2 9,1
G25.3 % 9,2 9,1
G30 % 11,3
G31 % 10,5 10,3
Minimal heat input
G20 % 9,1 8,8
G25 % 8,9
G25.3 % 8,9
G30 % 10,7
G31 % 9,7 9,6
Flue temperature Nominal heat input G20 °C 66,4
Fumes ow rate Nominal heat input G20 kg/h 80 161
Minimal heat input G20 kg/h 8
CO emission ppm 68,0
NOxemission class - 6
Circulating pump data
Residual pressure head at
nominal ow rate boiler only m w.c. 2,5
nominal ow at the maximum available head l/h 2150 4300
type of installation - B23P, B33
maximum equivalent length of exhaust duct m 17 12
maximum water pressure in operation bar 3,0
maximum ow ue condensate l/h 5,0 6,0
Water content inside the apparatus l 9 18
expansion tank volume l 10
Dimensions
width mm 558 730
depth mm 515 590
height mm 903 977
(1) Relative to NCV (net caloric value).

Features and technical data
14
1
Caldaia 55.1 Tech Caldaia 100.2 Tech
Weight in operation kg 56 95
(1) Relative to NCV (net caloric value).
1.4.1 Circulating pump characteristic curves
Figure1.9Circulating pump characteristic curves
In Caldaia 100.2 Tech there are 2 circulators.
0 0,5 1,0 1,5 2,0 2,5 3,0 3,5
0 0,2 0,4 0,6 0,8 1,0
20 4 6 8 10 12 14
0
1
2
3
4
5
6
7
8
0
10
20
30
40
50
60
70
80
0 0,5 1,0 1,5 2,0 2,5 3,0 3,5
4,0
4,0
0
20
40
60
3780/ 25PWM1
4270/ 15 PWM1
4770/ ≤5PWM1
3280/ 35PWM1
2780/ 45PWM1
2280/ 55PWM1
1780/65 PWM1
1290/ 75PWM1
max.
p/kPa
H/m
P1/W
Q/m³/h
Q/l/s
Q/Igpm
Q/m³/h
max.
790/ 85
PWM1
Figure1.10Boiler pressure drop curve (boiler + INAIL equipment)
0,0
10,0
20,0
30,0
40,0
50,0
60,0
70,0
00,5 11,5 22,5
[kPa]
[m3/h]

Features and technical data
Installation, use and maintenance manual – Caldaia 55.1 and 100.2 Tech 15
1
1.5 ELECTRICAL WIRING DIAGRAM
Figure1.1155.1 boiler electrical connections diagram
ER Flame detector
EA Ignition electrode
CRE Modulating circulator
VG Gas valve
Tra Ignition transformer
TF Flue gas thermofuse
TS Safety thermostat
Pacq Water pressure switch
SR Heating delivery probe
EV Blower
MP Standby contact
SE Connector for optional outdoor tempera-
ture probe
TA Connector for optional room thermostat
SRi Heating return probe
SPM Male plug
INAIL INAIL safety appliances
PRM Minimum pressure switch
PB Maximum pressure switch
TB Lock thermostat
L Line
N Neutral
ne Black
ce Light blue
ma Brown
ar Orange
gi Yellow
bi White
gr Grey
11
10
98
7
12 13 14 15 16 17
M12 M9 M7 M5
M2
M4
M8
M10
M15
M16
1234
57
61
60
59
58
44
43 42 41 40
39 38
37
36 35 34 33 32
31 30
29 28
26 27
EV
EA
VG
Tra
ER
TS
TF
SR
Pacq
1 C1 C
PB
p>
t>
TB
p<
PRM
C1
N T LS3B4 T2 T1
N LTS3B3 T2 T1
SPM
SE TA
ce
ma
ce
ma
ne ne
ce
ma ma
ce
ar ar
ma
ce
GND
PWM
HS
+24V
ce
ma
ce
ma
220 V
50 Hz
LN
MP
ma
ce
SRi
gi/ne
ne
ma ce
ma gi
bi gr
68
67
62
64
65
66
63
CRE
INAIL

Features and technical data
16
1
Figure1.12100.2 boiler electrical connections diagram - slave board
ER Flame detector
EA Ignition electrode
CRE Modulating circulator
VG Gas valve
Tra Ignition transformer
SM Modbus card
SPM Male plug
SE Connector for optional outdoor
temperature probe
TA Connector for optional room thermostat
L Line
N Neutral
TS Safety thermostat
SR Heating delivery probe
SC Manifold probe
EV Blower
PA Air pressure switch
TF Flue gas thermofuse
SRi Heating return probe
ce Light blue
ma Brown
gi Yellow
bi White
gr Grey
ma
ce
ma
ce
ma
ce
ma
gi
bi
gr
EV
ce
ma
ce
ma
EA
VG
Tra
ER
TS
TF
SR
ce
ma ma
ce
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
44 43 42 41 40
39 38
37 36 35 34 33 32
31 30
29 28
27 26
62
63
64
65
66
67
68
51
52
53
54
55
56
56
M13
M14
+24V
HS
PWM
GND
CRE
SRi
ma
ce
M6
12
6
5
eBus GND
TXOUT RXIN GND +24V
SC
L
N
SM
SPM
SE TA
220 V
50 Hz
L
N
B3 S3T2 T1 N T LB3 S3 T2 T1 N T L
PA
2
11
3
3
ma
ce

Features and technical data
Installation, use and maintenance manual – Caldaia 55.1 and 100.2 Tech 17
1
Figure1.13100.2 boiler electrical connections diagram - master board
ER Flame detector
EA Ignition electrode
CRE Modulating circulator
MP Standby contact
VG Gas valve
Tra Ignition transformer
SM Modbus card
TS Safety thermostat
Pacq Water pressure switch
SR Heating delivery probe
EV Blower
TF Flue gas thermofuse
SRi Heating return probe
SPF Female socket
INAIL INAIL safety appliances
PRM Minimum pressure switch
PB Maximum pressure switch
TB Lock thermostat
ne Black
ce Light blue
ma Brown
ar Orange
gi Yellow
bi White
gr Grey
2Schema elettric o_R 1 K1 00 RAI N_formato
ma
ce
ma
ce
ma
ce
ma
gi
bi
gr
EV
ce
ma
ce
ma
EA
VG
Tra
ce
ma
ER
TS
TF
SR
ar ar
ce
ma ma
ce
ne ne
Pacq
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
44 43 42 41 40
39 38
37 36 35 34 33 32
31 30
29 28
27 26
62
63
64
65
66
67
68
51
52
53
54
55
56
56
M13
M14
+24V
HS
PWM
GND
CRE
SRi
ma
ce
M6
12
6
5
eBus GND
TXOUT RXIN GND +24V
SM
INAIL
1
C
1
C
PB
p >
t >
TB
p <
PRM C
1
B4 S3 T2 T1 N T L B4 S3 T2 T1 N T L
SPF
MP

Transport and positioning
18
2
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 boiler 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 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.
▶ 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 MINIMUM CLEARANCE DISTANCES
Keep the appliance away from combustible or am-
mable materials or components, in compliance with ap-
plicable regulations.
In order to allow periodic maintenance of the boiler, the
installation must take place outside, respecting the dis-
tances indicated in Figure 2.1 p.18 and in any case at a
height from the oor of no more than 3 metres.
Figure2.1Minimum clearance distances
A 200 mm
B 500 mm
H 1000 mm
X 200 mm
Y 200 mm
3 HEATING ENGINEER
3.1 WARNINGS
3.1.1 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 BOILER INSTALLATION
To facilitate assembly, the boiler is equipped with a jig and a
frame that allow you to prepare in advance the connections to
the pipes with the possibility of installing the boiler when the
masonry work is complete.
Follow the instructions below for installation:
1. Using a spirit level, x the jig to the wall where the boiler is to
be installed and mark the points for inserting the plugs and
the points of the system's delivery and return connections.
2. Drill the holes and x the frame to the wall (Figure 3.1 p.19 ).
3. Hang the boiler using the slots on the frame (Figure
3.1 p.19 ).
In order to avoid condensation stagnation inside the

Heating engineer
Installation, use and maintenance manual – Caldaia 55.1 and 100.2 Tech 19
3
condensation module, it is necessary to tilt the boiler to-
wards the wall by 1÷1,5° (Figure 3.2 p.19 ).
4. Unscrew the xing screws of the lower bracket ensuring the
free sliding of the bracket with respect to the boiler (Figure
3.2 p.19 ).
5. Tilt the boiler about 1÷1.5° vertically (Figure 3.2 p.19 ). To
lock the boiler position, tighten the xing screws of the low-
er bracket.
6. Make sure that the boiler is rmly xed to the wall.
7. For the Caldaia 55.1 Tech model, install the hydraulic
connections.
8. Make the hydraulic and electrical connections as specied in
the relevant paragraphs.
9. Mount the tting cover.
Figure3.1Boiler installation
Figure3.2Detail of the inclination of the boiler
A Lower bracket
1-1.5°
A
A
3.3 HYDRAULIC CONNECTIONS
The hydraulic installer must make the hydraulic connection cir-
cuit to the heating system.
The installer must provide for the construction of a suitably 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 thermal disper-
sion.
Sizing of the pipes, according to the standard circulator,
must grant the nominal water ow required for the cor-
rect operation of the heating system.
B. of the following data:
Caldaia 55.1 Tech: nominal ow at the maximum availa-
ble head = 2150 l/h
Caldaia 100.2 Tech: nominal ow at the maximum avail-
able head = 4300 l/h
Residual pressure head at nominal ow rate = 2,5 m w.c.
3.3.1 System connections
Connect the water pipes between the boiler and the
system as follows:
▶ Connect the hydraulic pipes to the water delivery and return
connections of the boiler, equipped with the appropriate
valves, interposing appropriate gaskets on each connection
and taking care to avoid the entry of foreign bodies.
▶ Then connect the heating system terminals to the hydraulic
pipe coming from the boiler.
▶ Fill the hydraulic circuit with water through the lling tap,
adding antifreeze glycol to the water in a quantity propor-
tional to the minimum winter temperature of the installation
site (see Table 3.1 p. 19 ); the air in the circuit and in the
pipes will be vented by the venting devices located in the
upper parts of the system.
Table3.1% of glycol, correction factor for pressure drop
Low roughness pipes
(copper, stainless steel and plastic) Medium roughness pipes (black and galvanized steel)
% of antifreeze glycol Protection temperature (°C) Correction factor for pressure drop Correction factor for pressure drop
15% -5 1,08 1,06
20% -8 1,11 1,08
25% -12 1,15 1,10
30% -15 1,19 1,12

Heating engineer
20
3
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 distri-
bution terminals to the water content in the pipes.
In order to ensure correct operation of the unit and avoid
freezing of the water during the winter periods (with
possible damage to the unit and the system), it is nec-
essary to add antifreeze glycol to the water in a quantity
proportional to the minimum winter temperatures of
the installation site (see Table 3.1 p.19 ).
Connect the boiler safety drains (heating circuit safety
valve) to a drain funnel. The manufacturer is not respon-
sible for any damage due to the opening of the safety
valve in case of overpressure of the system.
Connect the boiler safety drains (heating circuit safety
valve) to a drain funnel. The manufacturer is not respon-
sible for any damage due to the opening of the safety
valve in case of overpressure of the system.
3.3.2 System lling
Proceed with the lling of the system as follows.
▶ Slightly loosen the cap of the jolly valve placed on the top of
the condensing block (Figure 3.3 p. 20 ) to release the air
from the top of the boiler.
▶ Check that the air vent valves in the system are not blocked.
▶ Connect a rubber hose to the drain tap 2.
▶ Open the drain tap 2 counterclockwise.
▶ Open the system lling valve (to be provided on the system)
and let out all the air.
▶ Bring the hydraulic system under pressure, making sure that
the water pressure indicated by the pressure gauge is not
less than 1,5 bar.
▶ To facilitate the venting of the system, it is suggested to
activate the water circulation pump several times with the
boiler o, so that the air can be purged by the vent valves
located on the boiler and on the system. To start the circu-
lation pump only, with the boiler electrically powered, press
the key to turn on the boiler and after a few seconds
turn o the boiler. The circulation pump will remain in oper-
ation for a few minutes. Repeat the operation several times
until the pressure of the circuit remains unchanged.
▶ After the operation, close the lling tap.
Figure3.3System lling
1 Cap of the jolly valve
2 Tap
2
1
3.3.2.1 System water characteristics
Responsibility of the user/operator/installer
The installer, operator and user must assure system wa-
ter quality (Table 3.2 p.20 ). Failure to comply with the
manufacturer's guidelines may aect operation, integri-
ty and life of the appliance, voiding the warranty.
In order to avoid any scale or deposits on the primary
exchanger, the water in the system must be treated in ac-
cordance with the applicable standards. This treatment
is absolutely essential in cases where there are frequent
episodes of water supply or partial or total emptying of
the system.
The hardness of the lling and top-up water brings a certain
amount of calcium into the system. This is attached to the hot
parts including the heat exchanger, thus creating pressure loss-
es and thermal insulation on the active parts. This can lead to
damage.
If the lling and top-up water of the system is outside the values
indicated below, it must be softened. Additives may also be add-
ed to keep the calcium in solution. Hardness should be checked
regularly and recorded.
If the above limits are exceeded, a water chemical treatment
must be carried out.
The choice of the type of treatment must be made according to
the characteristics of the water to be treated, the type of plant
and the limits of purity required.
Adhere to the chemical-physical parameters in Table 3.2 p.20
and the regulations on water treatment for residential and in-
dustrial heating systems.
Table3.2Chemical and physical parameters of water
Acidity 7 < pH < 8,5
Conductivity < 400 μS/cm (at 25°C)
Chlorides < 125 mg/l
Iron < 0,5 mg/l
Copper < 0,1 mg/l
3.3.3 Condensate drain siphon lling
When switching on for the rst time, the condensate siphon
must be lled to prevent the combustion gases from backow-
ing through the siphon.
It is advisable, after the rst few months of operation of the ap-
pliance, to clean the siphon, which collects also any deposits re-
sulting from the rst passage of the condensate inside the com-
ponents of the boiler. These deposits could cause the siphon
itself to malfunction.
For charging the siphon proceed as follows (Figure 3.4 p.21 ):
1. Unscrew screw P, remove the siphon and ll it with water to
the top point T.
2. Replace the siphon and fasten it with the screw P.
3. Connect the specically designed exible condensate drain
hose to a drainage system.