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 Safety

FA ROTEX A1 BOe - 02/2014

5

2.5 Instructions for operating safety

2.5.1 Before working on the heating system

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Work on the heating system (such as installation, connection 
and initial start-up) may only be carried out by authorised, 
trained heating technicians.

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Switch off the main switch and secure it against unintended 
switching on when carrying out any work on the heating 
system.

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Seals must not be damaged or removed.

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Make sure that the safety valves comply with the require-
ments of EN 12828 when connecting on the heating side, and 
with the requirements of EN 12897 when connecting on the 
domestic water side.

2.5.2 Electrical installation

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Electrical installations must only be conducted by electrical 
engineers and in compliance with valid electrical guidelines 
as well as the specifications of the energy supply company.

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Before completing the mains connection, compare the mains 
voltage, indicated on the type plate (230 V, 50 Hz) with the 
supply voltage.

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Before beginning work on live parts, disconnect them from the 
power supply (switch off main switch, remove fuse) and 
secure against unintentional restart.

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Equipment covers and service panels must be replaced as 
soon as the work is completed.

2.5.3 Installation room

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Operate ROTEX A1 BO only if sufficient combustion air 
supply is ensured. If you operate the ROTEX A1 BO in a 
room-air independent manner with a concentric air/flue gas 
system (LAS) dimensioned as per ROTEX standard, this is 
fulfilled automatically and there are no other conditions for the 
equipment erection room. With installation in residential 
rooms, this method of operation applies exclusively.

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Make sure that, with installation in a room-air dependent or 
limited room-air independent manner, an inlet air opening to 
the outside of at least 150 cm

2

 is provided.

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Do not operate the ROTEX A1 BO by the ambient air 
dependent method in rooms with aggressive vapours (e.g. 
hair spray, perchloroethylene, carbon tetrachloride), strong 
dust formation (e.g. workshop) or high humidity (e.g. laundry). 

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Strictly keep the minimum distances to walls and other 
objects (see chapter 4.1).

2.5.4 Requirements for the heating water

Avoid damage caused by deposits and corrosion:

 Observe 

the relevant regulations of technology to prevent creation of cor-
rosion products and deposits.

Measures for desalination, softening or hardness stabilization are 
necessary, if the filling and top-up water have a high total 
hardness (>3 mmol/l - sum of the calcium and magnesium con-
centrations, calculated as calcium carbonate.

Using filling water and top-up water which does not meet the 
stated quality requirements can cause a considerably reduced 
service life of the equipment. The responsibility for this is entirely 
that of the operator.

2.5.5 Heating system and sanitary connection

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Create a heating system according to the safety requirements 
of EN 12828.

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With sanitary connection, you must observe;
– EN 1717 - Protection of domestic water from contamina-

tion in domestic water installations and general require-
ments concerning safety equipment for the prevention of 
domestic water contamination by back-flow

– EN 806 - Technical regulations for domestic water instal-

lations (TRWI)

– and, in addition, the country-specific legal regulations.

During operation of the ROTEX A1 BO, the storage tank temper-
ature may exceed 60 °C, particularly when solar power is used.

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Therefore, incorporate scald protection during the installation 
of the system (domestic hot water mixing construcion, e.g. 
VTA32,  

15 60 16

).

2.5.6 Fuel

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Use only the approved heating oils as fuel (see chapter 12 
"Technical data").

2.5.7 Operation

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Operate ROTEX A1 BO only with closed silencer hoods.

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Only operate the ROTEX A1 BO if all the prerequisites as per 
the checklist in chapter 5.2 are fulfilled.

2.5.8 Instructing the user/owner

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Before you hand over the heating system, explain to the 
owner how he/she can operate and check the heating 
system.

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Hand over the technical documentation (at least the operating 
instruction manual and operating handbook) to the user and 
advise him that these documents must be made available at 
all times and be stored in the immediate vicinity of the unit.

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Make a record of the handover by filling out and signing the 
installation and instruction forms jointly with the user/owner.

Summary of Contents for Rotex A1 BO 15-e

Page 1: ...ROTEX A1 BO Installation and maintenance instructions Oil condensing boiler Types A1 BO 15 e A1 BO 20 e A1 BO 27 e A1 BO 34 e GB Output 02 2014 0035 BM 105 3 For certified companies...

Page 2: ...flue gas temperature sensor 27 6 5 3 Changing the storage tank temperature sensor 27 6 6 Replacing the fuse or control panel circuit board 28 6 7 Wiring diagram 28 7 Oil burner 30 7 1 Design and brie...

Page 3: ...sole responsibility that the products Product Order No Product Order No ROTEX A1 BO 15 e 15 49 60 ROTEX A1 BO 27 e 15 49 62 ROTEX A1 BO 20 e 15 49 61 ROTEX A1 BO 34 e 15 49 63 with the product ID No C...

Page 4: ...an arrow 2 3 Avoid danger ROTEX Oil condensing boiler conforms to the state of the art and meets all recognised technical requirements However improper use may result in serious physical injuries or...

Page 5: ...p the minimum distances to walls and other objects see chapter 4 1 2 5 4 Requirements for the heating water Avoid damage caused by deposits and corrosion Observe the relevant regulations of technology...

Page 6: ...9 Heating return flow cold 10 Heating flow hot 11 Pressure sensor 12 Flue gas supply air connection 13 Condensate treatment unit 14 Condensate drain 15 Air supply hose 16 Flame tube 17 Combustion cham...

Page 7: ...1 15 70 68 can be used to connect and regulate one or more mixed circuits All settings displays and functions are carried out by the RoCon B1 controller The display and operating elements offer con ve...

Page 8: ...ined heating experts Fig 4 1 Dimensions of model variants side view legend see tab 4 1 1 Boiler return 1 AG 2 Boiler flow 1 AG 3 Filling line connection on the KFE cock 1 AG 4 Flue gas air intake conn...

Page 9: ...n the floor on the sub tank on the boiler frame on the floor on the sub tank on the boiler frame on the floor on the sub tank on the boiler frame a 400 b 720 c 135 15 785 15 500 15 135 15 785 15 500 1...

Page 10: ...b Set up variant for limited room air independent operation flue gas air inlet separate c Set up variant for room air dependent operation d Longitudinally ventilated shaft with fire resistance durati...

Page 11: ...ufficient fire resistance or be structurally sepa rated from the roof truss 4 2 2 Operation partially independent of ambient air If the flue gas pipe is too high see tab 4 4 it may be advisable to suc...

Page 12: ...as in section 4 2 2 A ventilation opening to the outside of 150 cm2 is imperative Set up version 2 Combustion air supply from the installation room Flue gas dissipation to the outdoors is via the chim...

Page 13: ...0 4 bar the oil must be supplied to the burner using a separate pump ROTEX strongly recommends using a suction aggregate The minimum height of the flue gas pipe must be 2 m in order to avoid malfuncti...

Page 14: ...ith a suitable test adapter for checking and setting the combustion values The ROTEX LAS construction sets each include a test adapter D8 PA 15 50 79 00 93 Installation position and line height The ma...

Page 15: ...ue gas mass flow P Burner output Fig 4 6 Flue gas mass flow in relation to the burner output Basically any flue gas line that complies with the minimum requirements according to the EN 14471 and that...

Page 16: ...16 FA ROTEX A1 BOe 02 2014 4 x Set up and installation 4 5 3 Flue gas system kits Fig 4 8 Flue gas system components if necessary...

Page 17: ...BO can be hinged open without any problems after installation fig 4 10 CAUTION If the ROTEX A1 BO is connected to a heating system in which the pipelines or heating elements are made of steel or non...

Page 18: ...the flue gas pipe and fill the condensate box by using a hose held in the flue gas pipe Check the condensate drain section for leakage 4 8 Establish connection and electrical equipment 4 8 1 Instruct...

Page 19: ...ect to the ROTEX A1 BO controller Connect the external temperature sensors with a dual core cable minimum cross section 1 mm2 Storage tank temperature sensor The storage tank temperature sensor is inc...

Page 20: ...Adjusting the pressure gauge Before the initial filling of the system you must set the correct minimum pressure mark on the glass of the pressure gauge in safety group SGB A1 15 60 18 Rotate the pres...

Page 21: ...r the start phase Open the venting screw on the oil filter Vent oil line and measure the oil pressure on vacuum meter The vacuum may be maximum 0 4 bar better 0 2 bar Start up Switch on the mains swit...

Page 22: ...nd heating system vented yes 15 In case of systems with a hot water storage tank a Storage tank filled yes b Is the 3 way diverter valve correctly mounted on the flow connection and PCB plug inserted...

Page 23: ...und in the documentation of the ROTEX RoCon BF Controller Reglator 1 Mains switch 2 Operating part RoCon B1 3 Clear text display 4 Rotary switch 5 Setting Info 6 Setting Operating Mode 7 Setting Set T...

Page 24: ...chapter 9 2 1 3 Remove both top heat insulation shells see chapter 9 2 1 4 Unscrew the switching panel cover and remove fig 6 3 5 Pull out all plugs from the switchboard PCB fig 6 4 6 Pull out the se...

Page 25: ...are con nected to the circuit board connectors and cannot be released They can be released from the respective compo nents where they are plugged in The cables for external components e g external tem...

Page 26: ...Do not force the connector WARNING Live parts can cause an electric shock on contact and cause life threatening burns and injuries Before beginning work on the ROTEX A1 BO disconnect therom the power...

Page 27: ...sensor is connected directly to the connection terminals 9 and 10 of the 12 pin sensor connector J8 in the boiler control panel 1 Open the boiler control panel and pull connector J8 off the circuit bo...

Page 28: ...the electrical system Have a professional electrician remedy the cause of the short circuit before putting in a new fuse 1 Mains switch 2 Operating part RoCon B1 16 Switchboard PCB 17 Communication ca...

Page 29: ...6 x Control unit FA ROTEX A1 BOe 02 2014 29 Fig 6 16 Wiring diagram ROTEX A1 BO for legend see tab 6 1...

Page 30: ...inary ventilation Ignition switches on Solenoid valve opens Flame formation Ignition switches off Burner runs as long as there is demand for burner by the con trol and the flame monitor enables the bu...

Page 31: ...perature sensor does not provide a valid value short circuit interruption fault code 12 the flow temperature exceeds the return temperature by more than 35 K fault code 17 the flow temperature rises t...

Page 32: ...rottle Fan pressure Conversion kit kW mm USgal h GpH bar kg h Dimension Y mm mbar Type A1 BO 15 e oil blue burner BLB 15e 12 17 5 0 30 10 5 1 05 0 10 5 3 URS12 13 17 5 0 30 12 5 1 14 0 14 6 5 14 17 5...

Page 33: ...determine the CO2 O2 content of the flue gas Connect up the flue gas analysis unit To reduce air quantity Turn air throttle adjusting screw to the left lower scale value O2 CO2 To increase air quanti...

Page 34: ...st loosen the fixing screw and push the mixing device on the nozzle rod also refer to fig 9 16 in chapter 9 2 8 1 Adjustment screw recirculation tube 2 Scale recirculation gap Fig 7 6 Positioning reci...

Page 35: ...ew fig 7 10 pos 1 6 Rotate burner counter clockwise out of the bayonet lock and lift out upwards WARNING Live parts can cause an electric shock on contact and cause fatal burns or injuries Switch off...

Page 36: ...e see section 7 4 1 working steps 3 6 6 Unscrew four fixing screws from the burner flange 7 Lift burner flange with recirculation tube and flame tube out of the burner chamber Install the burner in re...

Page 37: ...oring 7 8 Oil burner pump and oil filter The oil burner pump is a self suctioning gear pump which is con nected as a two strand pump through a venting oil filter Suction filters and oil pressure contr...

Page 38: ...g system must be connected to the return line There should be no hydraulic blocking ele ments between the heat generator and the safety valve Locate the diaphragm expansion vessel in an easily accessi...

Page 39: ...to centre position with hand lever fig 8 4 pos 3 3 only possible if the valve drive is already in Heating position 1 T Piece 3x1 2 Ball cock 1 2x 3 3 way diverter valve 3UV1 3 1 Valve drive 3 2 Unloc...

Page 40: ...valves 3UV1 3 way switch valve DHW A1 A1 oil or gas condensing boiler CW Cold water DHW Domestic hot water S O Hot water storage tank SC 538 16 0 H1 H2 Hm Heating circuits MAG Diaphragm expansion ves...

Page 41: ...it For the maintenance activities sound insulation hood boiler pan elling and heat insulation layers must be removed After removing the rear and two side securing screws you can easily remove the soun...

Page 42: ...d or if the condensate preparation adequately neutralised 1 Open the combustion chamber and lift up the combustion chamber insert see section 9 2 5 2 Check the combustion chamber and clean if needed s...

Page 43: ...condensate box contains acidic condensate that can lead to injury upon contact with the skin or eyes Wear protective clothing safety glasses rubber gloves when working on the condensate box If your sk...

Page 44: ...boiler control panel rotary switch in position Info on the measuring piece of the flue gas pipe by using a flue gas thermometer If the flue gas temperature exceeds the boiler temperature by over 20 K...

Page 45: ...e gap Special tool Cleaning brush and scraper fixed on the inside of the boiler panels included in the supply Remove dry residue mostly in the upper combustion chamber half Loosen the dirt and soot on...

Page 46: ...n includes Opening the combustion chamber If there is damage around the combustion chamger the burner must be removed see chapter 7 4 Clean the burner surface cloth plastic brush Visual inspection of...

Page 47: ...open end or ring spanner SW 16 on the nozzle rod Hold back the nozzle rod with an open end wrench SW 16 2 Fitting mixing device Thereby position the light tube fig 9 16 pos 4 between the guide pins i...

Page 48: ...switched off e g timer is in economy phase outside temperature too high Check operating mode setting 1 Check requirement parameter1 e g timer programme Heating does not warm up enough Heating charact...

Page 49: ...cient Change oil pump Clutch defective Change clutch Oil atomisation not uniform heavy soot deposit in flame tube Oil nozzle loose clogged or worn out Check tighten change oil nozzle Oil nozzle sprayi...

Page 50: ...ion Possible cause Possible solution Code Component Designation Fault E1 Automatic firing unit Interlocking fault Safety temperature limit Flow temperature 105 C return temperature 95 C E4 No flame de...

Page 51: ...a brief push of the rotary switch The ROTEX A1 BO operates manually at the set flow tem perature 5 Cancelling and jump back by pushing the Exit button again Code Component Designation Fault Possible f...

Page 52: ...the filling and draining sockets KFE cock 11 2 Final shutdown and disposal For the final shutdown the ROTEX A1 BO must be taken out of service disconnected from all electrical oil and water connection...

Page 53: ...with EN 15034 kW 12 4 15 3 12 4 21 1 20 6 27 7 25 8 34 4 Set rated thermal output P upon delivery kW 15 18 25 30 Setting range burner with series configura tion kW 15 15 20 25 27 27 32 Output range fo...

Page 54: ...iler type A1 BO 15 e A1 BO 20 e A1 BO 27 e A1 BO 34 e Burner type BLB 15e BLB 20e BLB 27e BLB 34e Automatic firing unit Elster CM165 R1 Ignition transformer with flame monitor Federal Mogul ZT No 0 09...

Page 55: ...tage V 230 Frequency power supply Hz 50 Maximum power consumption W 4 3 Protection type IP X0B Turnaround time S 6 Tab 12 4 Technical details of the integrated heating circulation pump and the 3 way d...

Page 56: ...tance characteristics of the temperature sensor Temperature sensor Measured temperature in C Type Specification 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 Sensor resistance in Ohm according to sta...

Page 57: ...x Notes FA ROTEX A1 BOe 02 2014 57 13 Notes...

Page 58: ...x Notes 58 FA ROTEX A1 BOe 02 2014...

Page 59: ...urement 60 Exit button 23 F Fault codes 50 Filling the heating system 20 Filling water 18 21 Firing program 30 Flame tube 37 Flow rate 55 Flue gas mass flow 15 Flue gas temperature probe 27 Check 44 F...

Page 60: ...Selection of a different menu using the rotary switch and confirmation Unit type Nominal boiler heat output in kW Flue gas mass flow humid in g s Flue gas temperature in C Available pumping pressure...

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