Rotex A1 BO Installation And Maintenance Instructions Manual Download

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For certified companies

ROTEX A1 BO

Oil condensing boiler

Installation and maintenance

instructions

Type

Rated thermal output

ROTEX A1 BO 15bio 12–15 kW

ROTEX A1 BO 20i

12–20 kW

ROTEX A1 BO 27i

20–27 kW

ROTEX A1 BO 35i

25–35 kW

Serial number

Customer

0645 BM

GB
Edition 10/2007

Summary of Contents for A1 BO

Page 1: ...condensing boiler Installation and maintenance instructions Type Rated thermal output ROTEX A1 BO 15bio 12 15 kW ROTEX A1 BO 20i 12 20 kW ROTEX A1 BO 27i 20 27 kW ROTEX A1 BO 35i 25 35 kW Serial numb...

Page 2: ...arranty Improper use tampering with the unit and unqualified modifications immediately invalidate the warranty Dispatch and transport damage are excluded from the warranty The warranty explicitly excl...

Page 3: ...lue gas pipe to the oil condensing boiler 18 3 5 3 Flue system kits 19 3 6 Water connection 20 3 7 Connecting the condensate treatment unit 20 3 8 Connect the 3 way diverter valve 21 3 9 Connecting co...

Page 4: ...of supply 50 8 Inspection and maintenance 52 8 1 General overview of inspection and maintenance 52 8 2 Service and maintenance tasks 52 8 2 1 Removing panelling and cleaning it 52 8 2 2 Checking the c...

Page 5: ...ly before proceeding with the installation or modification of the heating system Relevant documents ROTEX A1 BO Instruction manual for the user owner The document is included in the scope of delivery...

Page 6: ...f the contents of this manual the relevant accident prevention regulations and the recognised safety related and occupational medical rules 1 4 Proper use The oil condensing boiler ROTEX A1 BO can onl...

Page 7: ...nstallation room Make sure that there is a supply air opening to the open air of at least 150 cm2 with ambient air dependent operation Do not operate the oil condensing boiler dependent on ambient air...

Page 8: ...with heat and sound insulation 7 Type plate with manufacture number 8 Circulation pump 9 3 way diverter valve 10 Heater return flow cold 11 Heating flow hot 12 Manometer 13 Filling and draining cock 1...

Page 9: ...a storage tank charging circuit All settings displays and functions are carried out by the ROTEX control The ROTEX THETA 23R control or the ROTEX ALPHA 23R control can be used according to the equipme...

Page 10: ...ensions and connection dimensions WARNING Units which have been set up and installed incorrectly may not operate properly and can be a health and safety risk endangering human life Set up and installa...

Page 11: ...T G IT 11 Heat exchanger return flow 12 Sensor immersion sleeve 13 Heat exchanger flow 14 Cold water 15 Air flue system LAS Connection piece 16 Air supply hose 17 Condensate drainage hose A ROTEX A1 B...

Page 12: ...ergy rating of the building Fig 3 4 Different set ups for the oil condensing boiler in the series A1 BO 1 8 Different set ups Description see section 3 2 1 to 3 2 3 1 Set up version for ambient air in...

Page 13: ...the roof truss The combustible air supply and the flue gas discharge run through a concentric dual tube as in set up version 5 In the area of the roof truss the dual tube for the combustible air supp...

Page 14: ...ansport and delivery The oil condensing boiler is delivered on a pallet All industrial trucks such as lifting trucks and forklift trucks are suitable for transporting it Scope of delivery Oil condensi...

Page 15: ...and high atmospheric humidity e g utility room Set up in the attic If the A1 condensing boiler is installed in the attic and the oil is stored in the rooms below it the oil pump of the burner is gene...

Page 16: ...Position the oil condensing boiler such that it can be folded out without any restrictions Check the horizontal position and the correct installation height of the oil condensing boiler You can adjus...

Page 17: ...gas pipe must be 2 m in order to avoid malfunction when starting or while operating the burner Tab 3 3 Maximum permitted height of the flue gas pipe in m when operating in the nominal output range 1...

Page 18: ...They satisfy all requirements and are also fitted with special acid proof seals Fig 3 6 Connection dimensions LAS Twin skin flue of oil condensing boiler of series A1 BO A Boiler connection B Flue gas...

Page 19: ...3 x Set up and Installation 19 FA ROTEX A1 BO 10 2007 3 5 3 Flue system kits Tab 3 5 Plastic PP flue system kits If required...

Page 20: ...lue gas connecting piece of the boiler The connection to the wastewater network is designed for HT piping DN 40 Lay the condensate drain sloping down from the boiler so that condensation will not accu...

Page 21: ...re located in the control panel on the switchboard PCB Only the optional applications e g mixer circuit circulation pump still have to be connected to the boiler control panel 1 Boiler flow 2 Heating...

Page 22: ...ow and return flow temperature sensor flue gas temperature sensor are used for the output control of the burner and for fault detection The temperature sensors are already factory connected and can be...

Page 23: ...ter such that the oil hoses are connected without tension and the top half of the boiler can be opened without hindrance Insert the supplied spare Universal Micro filter insert MC 7 in the venting oil...

Page 24: ...emperature values and operating modes of the control unit THETA 23R central unit can be displayed and changed through the room station THETA RS 15 70 18 Apart from the chimney sweep and manual operati...

Page 25: ...upplied see chapter 4 2 Log the test results on the checklist The oil condensing boiler can only be provisionally put into service if all points on the checklist can be answered with Yes Bleeding the...

Page 26: ...n the rotary button Set the rotary switch default settings to position and press and simultaneously Check burner settings using flue gas analyser and adjust if necessary see chapter 6 3 Press Manual b...

Page 27: ...carried out Yes 13 Is the system water pressure within the green range Yes 14 Are boiler and heating system vented Yes 15 In case of systems with a hot water storage tank Is the storage container fill...

Page 28: ...topping up the system The ROTEX Oil condensing boiler A1 BO can be operated with the THETA 23R control or only with the ALPHA 23R control The electronic digital controls are to be used for controllin...

Page 29: ...ot available if a room temperature controller THETA RFF is connected or if the operating mode of the control has been set at different settings for the individual heating circuits Setting automatic ti...

Page 30: ...s over to heating c Reset If the display shows RESET press the Manual button In case of repeated malfunction the cause must be rectified see chapter 6 Oil burner and chapter 9 Faults and malfunctions...

Page 31: ...uses of the system components can be shown on the display If there is a malfunction a fault code is displayed Default display in normal operation Flow temperature NORMAL OPERATING MODE Controller work...

Page 32: ...sure that the connecting pins are not damaged Tighten the fixing screws right handed threads Close the bayonet lock 90 rotation WARNING Live parts can cause an electric shock on contact and cause life...

Page 33: ...over fig 5 5 and remove the cable duct cover 5 Pull all connectors from the switchboard PCB fig 5 6 6 Pull out the sensor and the connection cables from the cable ducts of the control panel fig 5 7 WA...

Page 34: ...nected to the circuit board connectors and cannot be released They can be released from the respective components where they are plugged in The cables for external components e g external temperature...

Page 35: ...the connector WARNING Live parts can cause an electric shock on contact and cause life threatening burns and injuries Before beginning work on the oil condensing boiler disconnect it from the power s...

Page 36: ...emperature sensor is connected directly to the connection terminals 11 and 12 of the 12 pin sensor connector J8 in the boiler control panel 1 Open boiler control panel and remove plug J8 from the swit...

Page 37: ...tors on the switchboard PCB Close boiler control panel WARNING Live parts can cause an electric shock on contact and cause life threatening burns and injuries Before beginning work on the oil condensi...

Page 38: ...connector with valve cable J3 6 pin circuit board connector with clamped burner cable J3A Standard connector oil burner 7 pin J3B 2 pin plug for remote burner unlocking J4 Communication connection in...

Page 39: ...der for service position 11 Blue Flame Meter 12 Service Allen key 13 Burner flange with seal 14 Flame tube 15 Flame monitor 16 Connection for remote unlocking 17 Connector socket 7 pin 18 Fan rigid in...

Page 40: ...times independent of the fluctuations in the mains voltage or ambient temperature Operating safety even in the event of power failures The automatic firing unit switches off in the event of a power fa...

Page 41: ...14 3 2 Y68 Y4 4 14 19 0 35 10 0 1 23 4 2 Y70 Y5 0 Series status 15 19 0 35 12 5 1 32 4 2 Y77 Y6 2 A1 BO 20i Oil blue burner BL 20 12 19 0 30 12 0 1 05 3 2 Y10 Y4 5 URS12 13 19 0 30 13 5 1 14 3 2 Y11 Y...

Page 42: ...8 0 to 20 bar To increase pressure Adjusting screw fig 6 4 pos 2 for oil pressure to be turned to the right To reduce the pressure Adjusting screw fig 6 4 pos 2 for oil pressure to be turned to the le...

Page 43: ...mbient air and is equipped with a concentric flue gas supply air connection DN 80 125 If it is operated depending on the ambient air and it is only connected to a single wall flue gas pipe the setting...

Page 44: ...ance Tools required Feeler gauge Blue Flame Meter fixed on the holder for the service position Put burner in service position see chapter 6 4 Check electrode distance and position with feeler gauge Bl...

Page 45: ...nd cleaning jobs or if there is damage in the combustion chamber area Move the burner to service position 1 Switch off main heater switch 2 Take off the sound insulation hood and boiler panels remove...

Page 46: ...r clockwise by 1 8 rotation Install the flame tube in reverse sequence Removing the burner 1 Switch off main heater switch 2 Remove flame tube 3 Disconnect air supply hose remote unlocking connector a...

Page 47: ...er directly before the oil nozzle which prevents pre and post dripping when starting and switching off the burner To protect the oil pump and LE membrane valve either insert the enclosed micro replace...

Page 48: ...turn to the left and remove The 3 way diverter valve is set to the Heating position Note the following for the temporary manual parallel operation of the heating circuit and the hot water storage tan...

Page 49: ...r storage tank 4 1 Storage tank 4 2 Storage tank charging heat exchanger stainless steel corrugated pipe in SC538 16 0 4 3 Domestic water heat exchanger stainless steel corrugated pipe 5 Storage tempe...

Page 50: ...5 x 61 5 x 159 79 x 79 x 159 cm 79 x 79 x 159 cm 79 x 79 x 159 cm 100 x 66 x 66 cm Max permitted storage water temperature 85 C 85 C 85 C 85 C 90 C Standby heating power 2 3 kWh 24h 1 4 kWh 24h 1 4 k...

Page 51: ...SCS 538 16 0 SCS 580 1 US 150 Efficiency characteristic NL according to DIN 4708 on recharging at 35 kW TKW 10 C TWW 45 C TSP 65 C Tv 80 C 2 2 4 1 2 3 3 5 2 2 Continuous output QD according to DIN 470...

Page 52: ...required 8 2 Service and maintenance tasks 8 2 1 Removing panelling and cleaning it For the maintenance activities sound insulation hood boiler panelling and heat insulation layers must be removed Hav...

Page 53: ...neutralisation box outlet 2 Remove the indicator strips after about 1 minute and compare the colour of the indicator strip with the accompanying colour table The numerical value above the colour combi...

Page 54: ...burns The condensate treatment unit contains acid which can cause injury on skin contact Wear protective clothing when working on condensate treatment unit protective goggles rubber hand gloves If yo...

Page 55: ...e boiler body remove the combustion chamber insert and hold a water hose in the combustion boiler fig 8 10 Rinse condensate treatment unit several times with flowing water counter current until clear...

Page 56: ...ory combustion values are detected the combustion chamber must be cleaned and readjusted If necessary reset the burner Opening the combustion chamber Special tool Combustion chamber key fixed on the i...

Page 57: ...ing scraper included in scope of supply Remove dry residue mostly in the upper boiler half cup Loosen the dirt and soot on the combustion chamber ribs by using the cleaning brush and cleaning scraper...

Page 58: ...t burner and with the Control measurement setting see chapter 14 allow to run for approx 10 min Check combustion values Flue gas temperature at measuring sockets of the flue gas pipe Target value 120...

Page 59: ...r 6 3 3 Plug on ignition cable on the ignition electrodes WARNING Danger of burning on hot surfaces Before starting work on burners and combustion chamber allow them to cool down sufficiently Wear pro...

Page 60: ...ol unit q a Malfunction Possible cause Possible solution Heating system not functioning main switch not illuminated no display No mains voltage Switch on boiler main switch Turn on main switch of heat...

Page 61: ...s Insulating body cracked Change ignition electrodes Ignition transformer defective Replace ignition transformer Ignition cable burnt Change ignition cable and determine the cause Automatic firing uni...

Page 62: ...Check correct burner setting Oil nozzle is wrong size Check change nozzle type Combustion air quantity wrong Measure fan pressure correct burner setting Suction line draws air leakage Seal suction lin...

Page 63: ...Storage tank charging position first On reaching the maximum adjustable storage tank temperature the 3 way diverter valve is switched to the Heating position If the 3 way diverter valve is faulty the...

Page 64: ...ockets KFE cock 10 2 Final shutdown and disposal For final shutdown the oil condensing boiler must be taken out of service disconnected from all electrical oil and water connections disposed off in a...

Page 65: ...fficiency according to efficiency guidelines CO emission class acc to EN 303 2 3 NOx emission class acc to EN 303 2 3 Diameter of flue gas connection air supply connection 80 125 mm Voltage supply 230...

Page 66: ...052 F0077 2x 7 5 kV 20 kHz Solenoid valve Danfoss Type 071 N 0051 Oil pump pumping capacity Danfoss Type BFP 21 L3 LE No 071 N2110 Oil preheating Danfoss Type FPHB LE PTC 70 No 030 N4101 or Danfoss Ty...

Page 67: ...C Sensor Temperature sensor Measured temperature in C 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 Sensor resistance in Ohm according to standard or manufacturer s indications PTC Outside temperatur...

Page 68: ...k Fig 11 5 Remaining pumping height A1 BO 35i pR Remaining pumping height mH Flow heating network 0 100 200 300 400 500 600 0 200 400 600 800 1000 1200 1400 1600 1800 2000 I II III m L h H p mbar D R...

Page 69: ...sensor t R Return flow temperature sensor t V Flow temperature sensor STL Safety temperature limiter Connection cable colours bl blue br brown ge yellow gn green gr grey rt red sw black ws white n b C...

Page 70: ...Minimum requirements 16 Piping height 17 Flue system kits 19 Fuel 9 Fuse 37 H Heating circuit expansion module Cascading 24 Hot water storage tank 50 Target temperature 29 31 Technical data 50 Thermal...

Page 71: ...he flue gas connection Cleaning of the combustion chamber Cleaning and inspection of the burner Oil nozzle change Used nozzles Manufacturer Type Rechecking burner setting Checking distance ignition el...

Page 72: ...nstruction manual for ROTEX Control Control ROTEX THETA 23R 1 Press Manual button fig 5 1 pos 13 The oil condensing boiler controls the maximum boiler temperature for a period of 20 minutes 2 Press Ma...

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