Robur CALDARIA CONDENSING 100 Operating and maintenance manual

D-LBR571 rev.B 15 MCM SDC 006
CALDARIA CONDENSING 100
Instruction manual.
Installation and use

92/42/CEE
UNI EN ISO 9001:2000
UNI EN ISO 14001:2004

Installation and user manual
Contents
Contents ............................................................................................................................................................ 2
1Introduction ............................................................................................................................................... 3
1.1 Introduction and referenced European laws .................................................................................... 3
1.2 Warnings .......................................................................................................................................... 3
2Technical features..................................................................................................................................... 4
2.1 Dimensions....................................................................................................................................... 4
2.2 Main advantages.............................................................................................................................. 4
2.3 Construction details.......................................................................................................................... 5
3Installer instruction.................................................................................................................................... 6
3.1 Packing and product identification ................................................................................................... 6
3.2 Mounting........................................................................................................................................... 7
3.2.1 Installation room........................................................................................................................... 7
3.2.2 Wall mounting .............................................................................................................................. 7
3.3 System cleaning............................................................................................................................... 8
3.4 Gas system ...................................................................................................................................... 8
3.5 Flue gas system ............................................................................................................................... 8
3.5.1 Pipe maximum length .................................................................................................................. 8
3.5.2 Installation of one single thermal assembly with flue gas exhaust pipe running inside a cavity
for pipe routing (open chamber operation) ............................................................................................... 8
3.5.3 Connection to a flue gas manifold ............................................................................................... 9
3.6 Condensate discharge ................................................................................................................... 10
3.6.1 Siphon along the discharge piping............................................................................................. 11
3.7 Hydraulic connection...................................................................................................................... 11
3.7.1 Operating pressure .................................................................................................................... 12
3.7.2 Filling and emptying................................................................................................................... 12
4Installation drawings ............................................................................................................................... 12
5Power supply system.............................................................................................................................. 15
5.1 Power supply.................................................................................................................................. 15
5.2 Warnings ........................................................................................................................................ 16
5.3 Electrical connections..................................................................................................................... 16
5.3.1 5.3.1 Connection to temperature regulation devices................................................................. 16
5.3.2 Antifreeze protection.................................................................................................................. 16
5.3.3 Pump connection ....................................................................................................................... 16
5.3.4 Room Thermostat connection (on/off))...................................................................................... 18
5.3.5 External probe connection......................................................................................................... 18
5.3.6 Connection of an external regulation 0-10v............................................................................... 18
5.3.7 Connection of an alarm device .................................................................................................. 18
5.3.8 Connection of a remote control.................................................................................................. 18
5.3.9 Emergency mode....................................................................................................................... 18
5.3.10 Battery installation ................................................................................................................. 19
6Regulation............................................................................................................................................... 20
6.1 Digital control panel: keys description............................................................................................ 20
6.2 Display during normal operation .................................................................................................... 20
6.2.1 Functioning values display......................................................................................................... 21
6.3 User’s parameter change............................................................................................................... 21
6.4 Monitor mode ................................................................................................................................. 22
7Assistance............................................................................................................................................... 24
7.1 Gas change –Methane-LPG conversion....................................................................................... 24
7.1.1 Introduction ................................................................................................................................ 24
7.1.2 Operating instruction.................................................................................................................. 24
7.1.3 Gas valve regulation .................................................................................................................. 25
7.2 Slave boards setting....................................................................................................................... 25
7.2.1 Example of configuration of a battery with seven burner in cascade ........................................ 26
8Safety devices......................................................................................................................................... 27
9Parameter list.......................................................................................................................................... 28
10 Error list................................................................................................................................................... 33
10.1 Master board error.......................................................................................................................... 33
10.2 Slave board error............................................................................................................................ 33
11 Electrical wiring diagram......................................................................................................................... 34
Technical data ................................................................................................................................................. 36

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1 Introduction
1.1 Introduction and referenced European laws
Dear Customer,
Congratulations for your choice and thank you for the trust you place in our products.
With your purchase you have chosen a technology which is the best combination of energy saving and
functionality, compliant with the strictest European safety standards.
We kindly ask you to read the content of this manual carefully, as you will find useful advice and directions
which will help you operate the boiler effectively and efficiently, increasing its lifespan and your comfort.
We also ask you to preserve these instructions and make them available, when required, to the technician or
installer, to ensure easier and correct boiler installation, operation and maintenance.
For the realization of this product Robur SpA follows these European and Italian laws and standards:
COUNCIL DIRECTIVE 92/42/EEC of 21 May 1992 on efficiency requirements for new hot-water boilers fired
with liquid or gaseous fuels.
PROJECT CIG E.01.08.929.0 –Gas fired condensing heating appliances with nominal heat input more than
35 kW.
D.P.R. 412 of 26 August 1993 and D.P.R. 551 of 21 December 1999 –These Italian laws specify the
requirements for the projecting, working and maintenance for rational use of energy.
D.M. 12.04.1996 –Technical standard for fire prevention and for the projecting, working and maintenance for
hot-water boilers fired with gaseous fuels.
R COLLECTION (ISPESL) –Italian safety standard for hot-water boilers plants with temperature not
exceeding 110° C.
UNI 10845 –Italian standard for flue gas venting system for hot-water boilers fired with gaseous fuels.
The company Robur S.p.A. has the certification UNI EN ISO 9001/2000.
CALDARIA CONDENSING 100 has:
European conformity mark (from the directive 92/42/CEE) issued from the German homologater
The higher energetic efficiency class (from the directive 92/42/CEE) shown with the symbol ;
The better class for NOx emissions (the fifth for the EN 297).
1.2 Warnings
INSTALLATION In order to ensure safety and correct operation, the installation shall always take place in
full compliance with the applicable Law and with the instructions provided by the Manufacturer, and will
always be carried out by professionally qualified technical personnel only. The equipment shall be installed in
a suitable area, and connected to the heating system in accordance with the applicable Law.
WARRANTY Full warranty assistance will be ensured only if the appliance is commissioned by Robur Spa
commissioning engineers, please see Terms and Conditions for full details.
The Manufacturer disclaims any and all responsibility resulting from damage due to tampering, improper use
or mistakes made during equipment installation, operation and maintenance. In the event of failure or
breakdown, isolate the equipment and do not try to repair it.
START UP The boiler shall be switched on for the first time by approved Corgy registered only. During start-
up, the engineer shall complete the commissioning certificate and leave you a copy, thus starting the
warranty period, whose conditions are specified in the Terms and Conditions available on request.
INSTALLATION AND USER MANUAL This manual shall be read carefully, in order to use the boiler
correctly and safely, and shall always be kept safely.

92/42/CEE

92/42/CEE

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2 Technical features
2.1 Dimensions
CALDARIA CONDENSING 100 is a wall-mounted, modular, condensing, pre-mixed and blown thermal assembly,
consisting of two thermal element installed in series.
The useful power of each thermal element reaches 48.5 kW (100%, 50°C-30°C) and is modulating from 30%
to 100%.
.
The efficiency of each generator reaches 108.7% in relation
to the lower heating power of methane gas (Hi); thanks to
the low temperatures of flue gas, an integrated flue gas
collector entirely in plastic can be used, having a 50mm
diameter and a glass-shaped connection, which can reach a
height of 30 metres.
Caldaria Condensing 100 thermal assembly series is a
great achievement as regards management, cost-
effectiveness, reliability, and flexibility. Indeed, thanks to the
last-generation electronic management, modularity and
versatility that for more than ten years have characterised
Caldaria Condensing 100 products, this assembly can be
rapidly connected to any type of heating system and system
for the production of sanitary hot water with accumulation,
simultaneously managing three different systems operating
at three different temperatures.
Caldaria Condensing 100 is fitted with an electronic management system, making it possible to combine
several thermal assemblies in cascade, to create thermal stations which can reach an installed power
exceeding 3000 kW.
Individual thermal units can be installed in cascade, besides applying the traditional ignition rotation, by
means of a variable load factor, so that when the first unit reaches a certain power percentage (e.g. 30%),
the following units start already, all with the same load factor.
This makes it possible to divide supplied power onto several heat exchangers with a power/exchange
surface which is particularly useful to exploit latent condensation heat.
2.2 Main advantages
Total pre-mixing blown air burner
Condensing exchanger with efficiency until
108.7% (see Figure 2);
Power from 16 to 100 kW
Possibility to manage 60 thermal units
(burners) in series
Flue gas maximum temperature 80°C
Plastic flue gas collector (self-extinguishing
PPS) (see par. 3.5 ”Flue gas system “)
Figure 1
L –Width
600 mm
H –Height
1000 mm
P –Depth
380 mm
Water pipe (in)
1”
Water pipe (out)
1”
Gas pipe
¾”
Condensate pipe
18 mm
Figure 2

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Pre-mixing unit consisting of a modulating gas valve integrated with
a high-head fan. The system ensures a constant mixing ratio in all
operating conditions, and flue gas discharge through a plastic (PP)
exhaust pipe, up to 30 linear metres long.
High-efficiency burnt 50 kW heat exchanger fitted with bi-metal
corrugated internal coil:
water side: copper
flue gas side: stainless steel
The micro-flame burner is located high, at the centre of the
exchanger, and is a grid-type, with one single ignition electrode
Digital control panel. The panel includes several adjustment
functions and is equipped with a double display, which, depending
on the circumstances, shows either the operation status or the
error codes related to the most common failures
The Master/Slaves adjustment system is located behind the front
panel. It consists of a master control unit that manages two Slave-
type control units. Each slave card controls the operation and of
the individual unit to which it is connected. The Master card can
manage up to 60 Slave cards and is set for tele-management,
temperature regulation, and remote control.
Ø 50mm flue gas exhaust for each thermal unit (see fig. 8)
Flue pipe until 30 meters
Standard condensate discharge system in the boiler
Fast connection of water, condensate and gas (optional) collectors, with right and left outlet
Various thermal modules and the Master control station
Standard outside temperature regulation
Modulating and modular regulation of the power of individual thermal units;
Automatic inversion (adjustable time interval) of the burners' ignition order
Selection of the burner's cascade ignition criterion (power %)
Management of sanitary function and circuits at different temperatures, with or without operation priority;
Important safety devices, like a water differential pressure switch to control flux minimum flux for each unit
2.3 Construction details
Caldaria Condensing 100 thermal assemblies have two thermal units inside the metal cabinet, respectively.
Each thermal unit is connected to the hydraulic system and the gas supply in parallel to the others and
consists of the following main components:
Heat exchanger
Pre-mixing assembly
Control and management slave card
Safety kit
50 mm polypropylene flue gas pipe
Each Caldaria Condensing 100 series may be combined, in series, with other similar generators, to create
modular thermal station where the various thermal units are managed by one single Master card, which can
be installed on any of the thermal assemblies making up the station.
It is necessary to install in each unit a two way valve or a pump. For more information see par. 3.7 and the
section 4.
Figure 3 :Caldaria Condensing 100
1
2
3
4

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3 Installer instruction
3.1 Packing and product identification
Figure 4
Caldaria Condensing 100 series heat generators are
supplied on pallets, packed and protected with strapped
cardboard.
It is important immediately to check for product integrity
and correspondence with the order.
Product features are specified on the outer part of the
packing: model, power, version, and fuel type.
Should the product not match with the order, immediately
contact the point of sale where the product was
purchased.
NUM.
DESCRIPTION
1
Packing
2
Product plate
3
Information about model/gas type
4
Information about EC mark/symbols
5
Lower support structure in polystyrene
6
Boiler
7
Upper support structure in polystyrene
8
Polystyrene angulars
9
Wall fixing plate
10
Envelope with warranty and manual
11
Envelope with dowels
12
Box with external probe (only in the models 100
Master)
The product rating plate includes the following data:
Product name
Registration number
Product identification code
Efficiency as per Directive EEC92/42
Gas type and feed pressures
CE certificate No.
Data on power supply
Primary circuit maximum pressure and temperature
Thermal power
Efficiency values
Hourly condensate production
Figure 5

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3.2 Mounting
3.2.1 Installation room
Caldaria Condensing 100 thermal assemblies
shall be installed in accordance with the most
recent applicable standards and technical
regulations on thermal stations and condensing
boilers, as with any other applicable provision.
3.2.2 Wall mounting
WARNING: Thermal assemblies Caldaria
Condensing 100 series could be installed
outdoor.
3.2.2 Wall mounting
The boiler must be installed on a solid masonry
wall by means of hooks supplied together with
the boiler, inside the packing (see Figure 4).
In particular, use the 4 expansion fixings (2 for
each side) to fix the boiler plate to the wall (see
Figure 6).
The boiler should be installed at a height
ensuring that its upper part cannot be reached
with your hands.
WARNING: Thermal assemblies Caldaria
Condensing 100 series could be installed
outdoor.
Figure 6

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3.3 System cleaning
This preventive measure is absolutely required whenever a heat generator needs to be replaced in existing
systems, but it is in any case recommended also on new systems, in order to remove any waste, dirt,
working residues, etc.
To clean the system, if the old generator is still present in the system, it is advisable to:
- Add a descaling additive, such as FERNOX Superfloc 2%, to the system water;
- Have the system operate with the operating generator for approximately 7 days;
- Discharge the system's dirty water and wash once or several times using clean water. If the system is very
dirty, repeat the last procedure one more time.
If the old generator is not present or available, use a pump to circulate the water + additive through the
system for about 10 days and perform a final washing as described in the previous paragraph.
At the end of cleaning operations, before installing boiler Caldaria Condensing 100, it is advisable to add
protection fluid FERNOX MB-1 AT 4% to the system water.
3.4 Gas system
The boiler is prepared for the gas type shown on the data plate that is inside the shell. It’s important to verify
the real match between available gas type and the type required by the boiler.
If your gas is a LPG it’s important to verify the regulation of the pressure on the gas line.
The gas change procedure is shown in par. 7.1 “Gas change –Methane-LPG conversion”
3.5 Flue gas system
Each heat generator (unit) inside thermal assemblies Caldaria
Condensing 100 has been validated equipped with a self-
extinguishing polypropylene flue gas exhaust system (letter A
in Figure 7) with glass-shaped connections.
As for the air supply system, since thermal assemblies
Caldaria Condensing 100 have been validated as type B or
type C assemblies, air can be taken directly from the boiler
room through specific vacuum pipes (letter B in Figure 7).
In any case the air supply system has to be made in
compliance with the applicable standards.
3.5.1 Pipe maximum length
Each 50 mm exhaust pipe maximum equivalent length is 30 metres with a maximum 4-metre flow resistance
for each 90° bend.
3.5.2 Installation of one single thermal assembly with flue gas exhaust pipe running inside a cavity
for pipe routing (open chamber operation)
For this type of operation, it should be checked that the cavity's size complies with the applicable standards
(see par. 3.6).
Figure 8 shows the cavity's minimum size for the routing of two flue gas exhaust pipes.
A
Figure 7
A
A
B
B

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Figure 8
Should it be necessary to extend the vertical or the horizontal section of the discharge piping to over 4
metres, create a siphon for condensate drainage at the foot of the pipe. The siphon's useful length must be
at least 30 cm. (see par. 3.6).
3.5.3 Connection to a flue gas manifold
The flue gas venting system for two or more Caldaria Condensing 100 installed in series can be realized with
the installation of a polypropylene manifold (it’s optional) with a diameter of 125 mm, with male/female
connections.
The collector was conceived to collect the flue gas from the two 50mm pipes of a Caldaria Condensing 100,
each of which contains a flue gas non-return device.
If you want to use the collector when several thermal assemblies are installed in series, the minimum
distance required between the assemblies (150 mm) (see Figure 9) must be complied with.
In this way, the male end of one of the two collectors will connect more easily to the female connection of the
nearby collector.

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Figure 9
1
DN125 manifold
2
Non-return device (Clapet)
3
45° bend
4
DN125 Tap
5
DN125 joint
3.6 Condensate discharge
Figure 10
CALDARIA CONDENSING 100 allow the
condensate discharge using the two little pipes
shown in Figure 10. In the packing these pipes are
in the shell (as indicated in Figure 10) so, first of all,
it’s necessary to extract them by using the two
holes and then fix them with the two screwed rings.
The condensate water produced by thermal
assembly Caldaria Condensing 100 during its
normal operation shall be discharged at
atmospheric pressure, i.e. by dripping into a
siphon-shaped container (
) connected as described in the following procedure:
- Create a drip pan under the condensate discharge
system (see position on the installation template);
- Connect the drip pan to the sewage system by
means of a siphon.
- Insert a neutraliser if required by the applicable
law.
The drip pan shall be created and installed in
accordance with the applicable technical standards
(see par. 1.1).
It is advisable to use plastic pipes (PP) to create the
condensate discharge system. Never use copper
pipes, as the condensate would rapidly damage
them.

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Figure 11
3.6.1 Siphon along the discharge piping
Should it be necessary to extend the vertical or
the horizontal section of the discharge piping to
over 4 metres, create a siphon for condensate
drainage at the foot of the pipe. The siphon's
useful length must be at least 30 cm (see
Figure 12). The siphon discharge shall then be
connected to the sewage system.
Condensate maximum production (50°C-30°C)
100% : ……………………...............14,4 Kg / h
Figure 12
3.7 Hydraulic connection
In Figure 6 at page 7 there are the hydraulic connections for Caldaria Condensing 100. The connection sizes
are:
Gas 3/4” (G in Figure 6)
System delivery 1” (M in Figure 6)
System return 1” (R in Figure 6)
To create the hydraulic connection, two kits are available:
the first one can be used for the installation of one Caldaria Condensing 100;
the second one is designed for the battery installation of maximum four Caldaria Condensing 100 (in this
case the system has a power of 400 kW). It is necessary to complete the connection to the hydraulic set
using a two way valve or a pump (see also par. 4).
In the following pictures is
shown the kit for a Caldaria
Condensing 100
composed by the following
items:
N°1 gas collector Ø45 mm
N°1 delivery collector. Ø45
mm
N°1 Return collector. Ø45
mm
Each collector is fitted with
2 branch pipe, at whose
ends are two 1' taps for
delivery and return
collectors, and two ¾' taps
for the gas collector. In
Figure 13 we have a
Figure 13
Figure 14
connection using the two way valve kit and in
Figure 14 a connection using the pump.

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In
Figure 15 and
Figure 16 is shown the kit for two
Caldaria Condensing 100 composed
by the following items :
N°1 gas collector Ø3”
N°1 delivery collector Ø3”
N°1return collector Ø3”
The collectors arrive until 400 kW in
an installation of four Caldaria
Condensing 100. Each collector is
fitted with 2 branch pipe, at whose
ends are two 1' taps for delivery and
return collectors, and two ¾' taps for
the gas collector.
In this case it is also possible to
complete the connections using a
two way valve kit (see
Figure 15) or using a pump kit (see
Figure 16).
Figure 15
Figure 16
3.7.1 Operating pressure
The maximum operating pressure is
6 bar, its minimum operating
pressure is 0.5 bar. Each unit has a
safety valve at 5.5 bar
3.7.2 Filling and emptying
The boiler should be filled
connecting the water network to any
system point.
The boiler should be emptied using
the relevant valves in the relevant
system points.
4 Installation drawings
A plant scheme must be fit for the technical boiler features: so it’s possible to utilize in the better way boiler’s
efficiency and to keep the plant in good conditions for a long time. The figures below show some possible
solutions for Caldaria Condensing 100 installations schemes.
In the following schemes we can use a connection with a pump for each unit or a connection with a two way
valve for unit. In the first case the unit pump supplies the adequate flow for each unit and the system pumps
are dimensioned for the pressure drops of the system. Figure 17 shows a 150 kW installation with a pump
for each unit. In Figure 18 it is shown a similar system with a header.

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Figure 17
Figure 18
In Figure 19 and in Figure 20 we have two schemes with a two way valve for each unit. In the system shown
in Figure 19 it is necessary to calculate the three pumps (for high temperature, low temperature and sanitary
hot water) to guarantee in any case an adequate flow for each circuit and for each unit. The choice of an
adequate pump is easier when we have a header between the units and the system as shown in Figure 20.
In this case the pump between the header and the units supplies only the adequate flow for the units and the
header.

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Figure 19
Figure 20

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To help the designer choose
the correct pump, Figure 21
shows the curve of flow
resistance values inside the
boiler (for a Caldaria
Condensing 100)
In the case of an installation in
series the designer could use
the curve flow shown on
Figure 22, where there is the
pressure drop curve for a
general installation with n
burners: changing the n value
(n=1, 2, 3….) the designer
could obtain different flow
resistance value.
COROLLA 501 / 502
0
100
200
300
400
500
600
700
800
01000 2000 3000 4000 5000
l/h
mbar
Figure 21
For example if we have one Caldaria Condensing 100 master and two Caldaria Condensing 100 slave
connected (with a total power of 300 kW) on the x we have a flow rate of 2000 x 6 =12000 l/h (12 m3/h) and
the correspondent value for the pressure drop.
0
100
200
300
400
500
600
700
800
0 x n 500 x n 1000 x n 1500 x n 2000 x n 2500 x n 3000 x n
l/h
mbar
Figure 22
We have to remember that the pump has to supply 2000 l/h with a pressure drop of 6 meters. To assure a
correct performance of the pump, it is necessary to use a pump with a curve flow/pressure-drop as plate as
possible.
5 Power supply system
5.1 Power supply
The electrical drawing of the Caldaria Condensing 100 series thermal assembly is shown in detail in chapter
11.
Some important electrical features of the thermal assembly are specified on the appliance's rating plate.
(Figure 5)
Boiler installation requires the connection to a 230 v - 50 Hz mains. The connection should be made in full
compliance with the applicable electrical standards.
However, it is always advisable to install a magneto thermal differential switch along the boiler's power
supply line.
In Figure 23 is shown the terminal block of the master board. In Figure 24 is shown an example of an
electrical connection of some external device.

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5.2 Warnings
Always check the effectiveness of the earthing of the electrical system to which the thermal assembly is
going to be connected. Indeed, should the earthing be inefficient, the correct operation of the
ignition/detection electrode might be affected.
Warnings
230 V voltage cables must be separated from the 24 V ones using independent PVC conduits.
Before connecting external electrical components (regulators, electrical valves, outside temperature
probes, etc.) to the thermal assembly, make sure that their electrical features (voltage, absorption,
pickup voltage) are compatible with the available inputs and outputs.
Never switch off the boiler during its normal operation (when the burner is on), suddenly cutting off the
power supply by means of the on-off button. This may cause an anomalous overheating of the primary
exchanger. To switch off the boiler (during the heating stage) use an environment thermostat or a remote
control
To connect external devices, use the adequate relays (see the electrical schema at pag. 34 ). In this way
it is possible to use the external devices also in emergency mode (see par 5.3.9)
Do not touch electrical appliances with wet or humid body parts.
Do not expose the appliance to the elements (rain, sun, wind, etc.).
Do not pull the electrical cables.
Do not let the appliance be operated by non-expert people. Should the power supply cable break, switch
off the thermal assembly. To replace it, contact qualified personnel.
5.3 Electrical connections
5.3.1 5.3.1 Connection to temperature regulation devices
Caldaria Condensing 100 series thermal assemblies are fitted with a very versatile control and management
system, which can manage up to three independent circuits operating at different temperatures.
5.3.2 Antifreeze protection
The thermal assembly's management electronics includes an antifreeze function. When the delivery
temperature drops below a minimum limit (programmable), the burners switch on at minimum power, as set
in the operation parameters. The antifreeze function is activate also when the external probe is not
connected. The parameter 14 (high temperature zone Ch1) and the parameter 22 (low temperature zone
Ch2) are by default in climatic mode. If you wan to disconnect the external probe, it is necessary to change
the value of the parameters 14 and 22. Only a Robur authorized Technical Support Service can operate this
parameter variation.
5.3.3 Pump connection
Caldaria Condensing 100 series regulation system includes the simultaneous management of up to three
circulators.
Therefore, if it is necessary to use a general pump to assure the circulation (P3 in Figure 24) and there is a
low temperature circuit, the pump of this circuit (P4 in Figure 24) will be managed directly by a room
thermostat .This operation is carried out by setting the parameter n° 34.
The pumps shall be installed using an adequate relay/commutator, (see also par. 5.2)
With this device we can supply pumps directly from the electrical system, not using the fusible present in the
board.

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Figure 23
Code
N. Jumper
Description
S1
J11 (1-2)
Flow temperature probe
(High)
SB
J11 (3-4)
Sanitary temperature probe
S2
J11 (5-6)
Flow temperature probe
(Low)
SE
J11 (7-8)
External temperature probe
T1
J12 (9-10)
Room thermostat (High)
T2
J12 (11-12)
Room thermostat (Low)
AI
J12 (13-14)
Analogical device 0-10V
CR
J12 (15-17)
Remote control
AL
J8 (18-19)
Alarm device
VM
J9 (20-22)
Mixing valve
P3
J10 (23-24)
Low temperature circuit
pump
P1
J10 (25-26)
High temp. circuit pump
P2
J10 (27-28)
Sanitary pump
Figure 24

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5.3.4 Room Thermostat connection (on/off))
Connect the high temperature system's environment thermostat to terminals no. 9 and 10 (Figure 23).
The low temperature system's thermostat shall be connected to terminals no. 11 and 12 (Figure 23).
5.3.5 External probe connection
If outside temperature regulation is to be used, the outside probe (optional) needs to be connected to
terminals no. 7 and 8 (Figure 23).
The outside probe shall be installed on an outer wall, North or North/East, at a minimum height of 2.5
metres, away from windows, door, and ventilation grids.
Never install the probe in a position exposed to the sun. If it is necessary to modify the climatic curve set,
please contact a Robur Technical Support Service.
5.3.6 Connection of an external regulation 0-10v
It is possible to use the terminals n. 13 and n. 14 (Figure 23) for an external power or set-point regulation.
The input signal is a DC voltage with a range of 0-10 V. It is important to connect the positive input to the
terminal n. 13.
5.3.7 Connection of an alarm device
A 220 V clear contact block output on the boiler's terminal strip allows to connect an outside sound or visual
alarm device, capable of highlighting any technical anomalies.
The alarm device must be connected to terminals no. 18 and 19 (Figure 23)
5.3.8 Connection of a remote control
If the remote control is to be used, it must be connected to terminals no. 15, 16, and 17 (Figure 23).
5.3.9 Emergency mode
Caldaria Condensing 100 series electronic
management system includes an operation mode
called "Emergency" mode, which can be activated in
case of malfunctioning of the Master card.
Indeed, to ensure continuous operation of the
thermal assembly, the master card can be disabled
in such a way as to have the system operate at a
default delivery temperature set by the
Manufacturer.
To enable the "Emergency" function, carry out the
following procedure:
a. Disconnect the 4-pole connector J14 from
the Master card (see Figure 25);
b. Set all four J17 switches located on each
Slave of the thermal assembly on the Off position
(Figure 26);
c. Supply all system circulators with mains
current, using the appropriate switches;
d. terminal X1 or terminal X2 which are part of
the cabling of the J14 connector disconnected in
point a) of this procedure must be connected to a
24V ac power supply (see Figure 27).
Figure 25

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Figure 26
Figure 27
Warning: if several Caldaria Condensing 100 are installed in series, one of the two terminals (X1
or X2) or both may be connected to the adjacent thermal group or groups. If this is the case,
supply the free terminal with 24 V, (see par. 5.3.10).
5.3.10 Battery installation
On of the many functions included in Caldaria Condensing 100 electronics allows for the installation of
several modules in series, to create thermal assemblies having an overall power exceeding 75 kW.
This type of system requires on single Caldaria Condensing 100 series equipped with a Master control unit,
while all other Caldaria Condensing 100 will have no control unit.
The cabling of some electronic components present on the system should be carried out as illustrated in
Figure 28.
The setting of the electronic components is explained in chapter 7.2
Figure 28

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6 Regulation
6.1 Digital control panel: keys description
Caldaria Condensing 100 digital Master control panel (Figure 29) is located in the front, low and left, of the
boiler’s shell.
The panel includes several adjustment functions and is equipped with a double display, which, depending on
the circumstances, shows either the operation status or the error codes related to the most common failures.
Each key has a particular meaning, because there are many use modes.
Figure 29
KEY
LEGEND
KEY DESCRIPTION
S1
Reset
It is necessary to unblock the electronic board after a permanent block
S2
Set / esc
It is necessary to enter into parameters and monitor mode for the
singles units
S3
Arrow
It is necessary to display the functioning state of master circuits
S4
Increment
It is necessary to increase a value
S5
Decrement
It is necessary to decrease a value
S6
Prog/OK
It is necessary to store a value
U2
Luminous display
Display information about boiler condition
U3
Luminous display
Display information about boiler condition
D4
Green led
If lighted, it indicates that the system has power supply
D5
Red led
If lighted, it indicates an anomaly
6.2 Display during normal operation
The red led, D5, is turned on in case of anomalies which imply the permanent block-out on any unit (only the
Mater or Slave reset button will restore normal functioning).
The green led, D4, shows power on. The 3 7 segment displays shall visualize:
:
SYSTEM STATUS
DISPLAY
No demand from the heating and sanitary circuit
(figures on the right display the T1 e.g. T1=30°C)
0 30
Demand from circuit N°1 or simultaneous functioning the 1° and 2°.
(figures on the right display the T1 e.g. T1=80°C)
1. 80
Demand from sanitary circuit or simultaneous functioning.
(figures on the right display the T1 e.g. T1=80°C) the dot after the first figure must be
flashing
180
Demand from 2° circuit
(figures on the right display the T1 e.g. T1=80°C)
1'80