Robur Caldaia 35 Tech Service manual

Powered by natural gas/LPG
Installation, use and maintenance manual
Caldaia 35 Tech
Outdoor condensing boiler

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: B
Code: D-LBR749EN
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 35 Tech 3
INDEX OF CONTENTS
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.8
1.4 Technical characteristics............................................... p.9
1.5 Electrical wiring diagram ........................................... p.11
2 Transport and positioning........................................ p.12
2.1 Warnings.......................................................................... p.12
2.2 Handling........................................................................... p.12
2.3 Minimum clearance distances.................................. p.12
3 Heating engineer............................................................... p.12
3.1 Warnings.......................................................................... p.12
3.2 Boiler installation .......................................................... p.12
3.3 Hydraulic connections ................................................ p.13
3.4 Combustion products exhaust ................................ p.15
3.5 Pump antifreeze and anti-lock function............... p.16
3.6 Fuel gas supply .............................................................. p.17
4 Electrical installer.............................................................. p.18
4.1 Warnings.......................................................................... p.18
4.2 Electrical power supply............................................... p.18
4.3 Control device................................................................ p.19
4.4 Control through optional OCDS006 remote
control - recommended solution............................ p.19
4.5 Positioning the control system................................ p.19
4.6 Operation via centralised external request......... p.20
4.7 Operation with external temperature probe
(optional).......................................................................... p.20
5 First start-up .......................................................................... p.20
5.1 Preliminary checks........................................................ p.20
5.2 How to access the boiler............................................ p.20
5.3 Electronic board parameters setting..................... p.21
5.4 Combustion parameters check................................ p.24
5.5 Gas changeover............................................................. p.25
5.6 Commissioning.............................................................. p.25
5.7 Switching o................................................................... p.26
5.8 Prolonged periods of inactivity ............................... p.26
6 Normal operation.............................................................. p.26
6.1 Warnings.......................................................................... p.27
6.2 Preliminary checks........................................................ p.27
6.3 Operation without remote control......................... p.27
6.4 Remote control operation (optional)..................... p.28
Info menu display......................................................... p.28
7 Maintenance.......................................................................... p.28
7.1 Hydraulic boiler emptying......................................... p.28
8 Diagnostics.............................................................................. p.29
8.1 System pressure restore ............................................. p.29
8.2 Error codes....................................................................... p.29
9 Appendices.............................................................................. p.31
9.1 Product che................................................................... p.31

Introduction
4
I
I INTRODUCTION
Manual
This Manual is an integral part of the Caldaia 35 Tech
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.
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 the
Caldaia 35 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 35 Tech 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 35 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.
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. 28 ) 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
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.

Warnings
6
III
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
manufacturer for any damage caused by incorrect in-
stallation and/or improper use and/or failure to comply
with regulations and with the manufacturer's directions/
instructions 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 35 Tech 7
1
1 FEATURES AND TECHNICAL DATA
1.1 FEATURES
Operation
The Caldaia 35 Tech units have been designed and built to meet
the needs of space heating.These boilers (external modules) can
also be installed outdoors.
The boiler casing is made of ABS, and is approved to resist
weathering with particular regard to the action of UV rays.
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.
▶ 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.
▶ 3 bar safety valve.
▶ Gas solenoid valve.
▶ Safety thermostat.
▶ Expansion tank.
▶ Water dierential pressure switch.
1.2 DIMENSIONS
Figure1.1Boiler dimensions
R Water inlet connection Ø 3/4" M
G Gas connection Ø 3/4" M
F System lling connection Ø 1/2"
A Water outlet connection Ø 3/4" M
B Flue gas outlet Ø 80 mm
140
162
710
420
370
53 148 80 102 37
110
R G F A
B

Features and technical data
8
1
1.3 COMPONENTS
Figure1.2Boiler internal front view
1 SYstem lling tap
2 Heat exchanger
3 Burner unit
4 Flame detector
5 Heating return probe
6 Blower
7 Safety valve
8 Air vent valve
9 Modulating circulator
10 Gas valve
11 System drain tap
12 Heating delivery probe
13 Safety thermostat
14 Ignition electrode
15 Expansion tank
16 Ignition transformer
17 Air intake pipe
18 Venturi
19 Water pressure switch
20 Condensate drain siphon
2
3
4
5
7
9
10
11
12
13
14
15
17
16
18
19
20
1
8
6
Figure1.3Hydraulic plan of boiler inside
R Heating return
G Gas inlet
SC Condensate drain
F Cold water inlet
A Heating delivery
1 Flue safety thermal fuse
2 Heat exchanger
3 Burner unit
4 Blower
5 Gas valve
6 Air vent valve
7 Modulating circulator
8 Safety valve
9 System drain tap
10 Heating delivery probe
11 Safety thermostat
12 Expansion tank
13 Air intake pipe
14 Venturi
15 Water pressure switch
16 Condensate drain siphon
17 Bypass
18 SYstem lling tap
R
F A
G
1
2
3
4
6
7
8
9
6
10
11
12
13
14
15
17
18
sc
5
16

Features and technical data
Installation, use and maintenance manual – Caldaia 35 Tech 9
1
1.4 TECHNICAL CHARACTERISTICS
Table1.1Technical characteristics
Caldaia 35 Tech
Heating mode
seasonal space heating energy eciency class (ErP) A
Heat input nominal (1013 mbar - 15 °C) (1) kW 34,0
minimum (1) kW 4,1
Operating point 80/60 Nominal heat input eective power kW 33,4
eciency % 98,1
Operating point 50/30 Nominal heat input eciency % 106,4
Operating point Tr = 30 °C Heat input 30% eciency % 108,6
Operating point Tr = 47 °C Heat input 30% eciency % 102,1
Heat loss
to jacket in operation % 0,25
to ue in operation % 2,40
in o mode % 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 0,08
Degree of protection IP - X5D
Installation data
Gas consumption
G20 natural gas (nominal) m³/h 3,60
G25 (nominal) m³/h 4,18
G25.3 (nominal) m³/h 4,09
G30 (nominal) kg/h 2,68
G31 (nominal) kg/h 2,64
Water tting type - M
thread “ 3/4
Gas connection type - M
thread “ 3/4
Flue gas exhaust diameter (Ø) mm 80
residual head Pa 91
CO2percentage in fumes
Nominal heat input
G20 % 9,3
G25 % 9,2
G25.3 % 9,2
G30 % 11,3
G31 % 10,4
Minimal heat input
G20 % 9,0
G25 % 8,9
G25.3 % 8,9
G30 % 10,8
G31 % 9,9
Flue temperature Nominal heat input G20 °C 69,4
Fumes ow rate Nominal heat input G20 kg/h 54
Minimal heat input G20 kg/h 7
CO emission ppm 75,0
NOxemission class - 6
Circulating pump data Residual pressure head at nominal ow rate boiler only m w.c. 1,5
nominal ow at the maximum available head l/h 1400
type of installation - B23P, B33
maximum equivalent length of exhaust duct m 15
maximum water pressure in operation bar 3,0
maximum ow ue condensate l/h 3,4
Water content inside the apparatus l 6
expansion tank volume l 8
Dimensions
width mm 420
depth mm 370
height mm 787
Weight in operation kg 44
(1) Relative to NCV (net caloric value).

Features and technical data
10
1
1.4.1 Circulating pump characteristic curves
Figure1.4Circulating pump characteristic curves
0 0,4 0,8 1,2 1,6 2,0 2,4
0 0,1 0,2 0,3 0,4 0,5 0,6 0,7
0 2 4 6 8
0
1
2
3
4
5
6
7
8
0
10
20
30
40
50
70
60
80
0 0,4 0,8 1,2 1,6 2,0 2,4
0
10
20
30
40
15%
25%
5%
p/kPa
H/m
P
1
/W
Q/m³/ h
Q/l/s
Q/Igpm
Q/m³/ h
max.
max.
35%
45%
55%
65%
75%
85%