Rotex GasCompactUnit Series Page 59 Installation And Maintenance Instructions Manual Download

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Fig. 8.4: Permissible burner loads for GSU/GCU, the details highlighted in white represent factory settings

Fig. 8.3: Required flow rate subject to the heating output and the design temperature spread

Summary of Contents for GasCompactUnit Series

Page 1: ...high performance domestic hot water cylinder I n s t a l l a t i o n a n d m a i n t e n a n c e i n s t r u c t i o n s f o r c o n t r a c t o r s Type Rated thermal load ROTEX GSU 25 5 25 kW modulating ROTEX GSU 35 8 35 kW modulating ROTEX GCU 25 5 25 kW modulating ROTEX GCU 35 8 35 kW modulating Serial number Customer GB 0085 BM0065 ...

Page 2: ...this the user must be instructed in the operation and control of the heating equipment The handover should be recorded by jointly completing and signing the installation and training form supplied The symbol and further warning symbols highlight safety information The symbol identifies text passages that are particularly important to achieve an optimum utilisation adjustments monitoring etc Chapte...

Page 3: ...n the minimum clearances towards walls and other objects as detailed in chapter 3 When installing the ROTEX GasSolar Unit GasCompactUnit ensure that the floor can bear a load of at least 1050 kg m2 and provides a sufficiently sizeable safety margin Check the correct installation of the temperature sensor and the pressure gauge prior to commissioning The GasSolarUnit GasCompactUnit must only be ope...

Page 4: ...ruction form supplied is completed and returned to ROTEX Warranty periods The warranty period commences with the date of installation invoice date of the installing contractor but no later than six months after the date of manufacture invoice date The warranty period will not be extended by the return of the equipment for repair or replacement Warranty 2 years Warranty exclusions Non authorised in...

Page 5: ...um 5 8 to maximum 25 35 kW The GSU GCU flexibly matches its output to changing conditions The internal microprocessor control manages the output The flue gas temperature remains below 90 C at all times The energy contained in the fuel gas is utilised to its optimum by the condensing technology In this process the flue gas inside the boiler and with balanced flue operation in the flue gas system co...

Page 6: ...eated according to the instantaneous water heater principle This has already been proven as a perfect solution in the DHW cylinder ROTEX Sanicube for more than 20 years Excellent corrosion resistance low susceptibility to scaling and most of all optimum water hygiene are the hallmarks of this heating principle Extensive research by the Hygiene Instituts of the university Tübingen have shown that t...

Page 7: ...linder sensor 13 Sensor well for Solaris return temperature sensor 14 Condensate safety overflow connection Tr 32x3 male 14 a Upper fill connection alternative condensate safety overflow connection to the front Tr 32x3 male 15 Condensate drain hose on site 16 Condensate pipe 17 Heating heat exchanger boiler body 18 DHW heat exchanger DHW HE 19 Heat exchanger for cylinder heating CH HE 20 Heat exch...

Page 8: ... safety overflow connection Tr 32x3 male 14aUpper fill connection alternative condensate safety overflow connection to the front Tr 32x3 male 23 Heating circulation pump 24 Modulating pressure jet gas burner see chapter 5 25 Three way diverter valve 26 Flow temperature sensor 27 Return temperature sensor 28 Flue gas temperature sensor 29 Safety valve Blow off line connection 3 4 female 30 Optional...

Page 9: ...5 Drain for removing the condensate created during the combustion condensing operation connection either at the back 14 or at the front 14 a The operation must proceed without faults Route the condensate drain hose on site provision with a constant slope to the drainage system Check the condensate drain annually for contamination and unrestricted flow During operation the cylinder pos B must const...

Page 10: ...ter valve 5 1 Valve servomotor 5 2 Reset button of the servomotor lock 5 3 Lever Pos 26 27 Flow 26 and return 27 temperature sensor The sensors type NTC are screwed into the waterways of the boiler body The sensor leads can be plugged in The sensors are directly connected to the gas burner control unit This also safeguards the low water indicator and high limit safety cut out functions Pos 28 Flue...

Page 11: ...e system pressure is too low Connect the filling hose and top up the system until the pressure gauge indicates in the upper part of the green range generally 2 0 to 2 5 bar Pos 38 Automatic air vent valve Open the screw cap to vent the GSU GCU This air vent valve is generally insufficient to vent the entire heating system Pos 39 Ball shut off valve During operation the shut off valves must remain ...

Page 12: ...rs or deflectors for the whole system 3 2 Installation options Generally a balanced flue connection is required for the ROTEX GasSolarUnit Gas CompactUnit A concentric balanced flue DN 80 125 certified for condensing operation is available DIBT certificate Z 7 2 1051 Z 7 2 3061 Z 7 2 3062 The GSU GCU can be installed in 4 different ways see Fig 3 2 2 Installation version 1 The chimney or service d...

Page 13: ...ence is made to the respectively applicable fire prevention regulations and DIN 18160 or local regulations Generally speaking the system can be connected to any flue with Building Regulation approval subject to the follow ing conditions leaning on DIN 18160 1 being met suitable for at least 120 C temperature class T 120 or higher withstands at least 200 Pa positive pressure pressure class P1 or H1...

Page 14: ... gas routing 14 Fig 3 2 2 Installation versions for the ROTEX GasSolarUnit GasCompactUnit linear ventilated duct with a 90 min fire resistance for low domestic buildings 30 min fire resistance Air Flue gas ...

Page 15: ...em is to be installed must be solid level and horizontal Where necessary install a suitable plinth Route all connecting cables leads so that the silencer hood Fig 2 2 1 pos 34 can be removed The GSU GCU flue can be connected in three different ways Standard connection is the direct flue connection out the back Fig 3 3 1 set H PPD H part no 15 50 79 08 If there is a chimney adjacent to the GSU GCU ...

Page 16: ...anced flue inspection bend 87 DN 80 125 4 Cover plates white DN 125 5 PP balanced flue wall outlet DN 80 125 6 PP balanced flue pipe PPD L50 DN 80 125 Fig 3 4 2 Flue connection out the side with the balanced flue connection set K top view Fig 3 4 1 Flue connection to the back with the balanced flue connection set H top view 3 4 Connecting the GasSolarUnit Connection of the flue gas and ventilation...

Page 17: ... 17 Fig 3 4 3 Flue gas system sets ...

Page 18: ... to the cold water supply ensure that the maximum mains pressure should be around 6 bar Never exceed 10 bar Install a pressure reducer if higher mains pressure prevails For connection work EN 806 and DIN 1988 or local regulations apply The heating connections are fitted with female threads those for DHW with male threads Position and dimension can be found in Fig 3 4 4 Please note Risk of corrosio...

Page 19: ...nnection hose is factory fitted so that the burner can be removed for maintenance work without needing to be disconnected from the gas mains Install a thermally activated shut off valve TAE and a gas flow limiter GSW with DVGW test symbol check local regulations on site The TAE must comply with the test standard according to DVGW VP 301 or local regula tions Size the GSW in accordance with the max...

Page 20: ...thorised electrician who must observe all local and national regulations as well as those specified by the local electricity supply company The ROTEX GasSolarUnit GasCompactUnit is designed for connection to a 230 Volt 50 Hz AC supply Prior to connecting the ROTEX GasSolarUnit GasCompactUnit ensure that the supply voltage is that stated on the type plate To prevent an interchange between the mains...

Page 21: ...ntrol cable for the burner fan via a common plug at the burner control unit CVBC of the pressure jet burner The flue gas temperature sensor Pt resistor is connected directly at the control panel The temperature sensors can be directly plugged in at the individual sensors to ease replacement To regulate a mixer circuit connect a mixer circuit flow sensor accessories TMKF part no 15 60 62 PTC resist...

Page 22: ...extension module THETA HEM1 part no 15 60 61 The heating circuit extension module THETA HEM1 communicates via the BUS with the central controller in the GSU GCU Cascading the THETA HEM1 enables the system to be extended to up to five mixer circuits and or cylinder primary circuits Order the temperature sensors required in connection with a heating circuit extension module separately mixer circuit ...

Page 23: ...ure that all three electrodes of the level sensor are immersed in water Only this ensures that the electronic can register the ade quate level and enable the burner opera tion The burner will be locked out if the level is too low 3 Heating and DHW primary circuit Lock the three way valve in its central position for filling a stable central valve position can only be assured in a zero volt conditio...

Page 24: ... Fig 4 1 1 to test the high limit safety cut out The hold down the rotary selector pos 6 in Fig 4 1 1 until the high limit safety cut out has responded The display pos 14 in Fig 4 1 display STB test see Fig 3 6 2 After a successful test reset the high litres capacity manually after the boiler has cooled down open the ball valve at the heating flow connection again by pressing the manual key briefl...

Page 25: ...mixer installation option is the mixer circuit sensor mixer motor and the mixer circuit pump Yes No connected to he correct plug in position and are the corresponding plugs plugged in to the respective position on the PCB 14 Is the room station correctly terminated A B and plugged in Yes No 15 Is the gas supply correctly connected and correctly installed Yes No 16 Is the gas line correctly vented ...

Page 26: ...fault The user can restart the burner after a burner fault by pressing the rest button pos 13 and display RESET pos 14 Remove the cause if the burner fault occurs repeatedly see also chapter 5 1 Gas burner Faults are generally displayed with fault code For troubleshooting information see chapter 7 3 Legend to identify the equipment type This type immediately indicates whether the boiler is a GasSo...

Page 27: ...rol unit Note All details concerning the ROTEX THETA 23R control unit adjustment programming parameter etc are contained in the separate Operating instructions for contractors ROTEX control unit that is supplied with the GSU GCU 6 Rotary selector The rotary selector enables control settings to be selected and set values to be changed changes are saved by lightly pressing the selector afterwards Tu...

Page 28: ...e immersed in water A burner demand will only be enabled if the level is adequate 18 Level warning indicator for low water level This indicator shows that the cylinder is insuf ficiently full of water It is switched ON when not at least two of the three electrodes of the level probe pos 42 in Fig 2 1 1 Fig 2 1 2 and Fig 2 2 1 are immersed in The unpressurised sector of the cylinder needs to be ful...

Page 29: ...fill drain valve pos 37 in Fig 2 2 1 and release the water pressure from the boiler 3 Remove the capillary pipe from the pressure gauge Fig 4 4 1 Remove the small volume of water released when undoing the pipe with a kitchen towel 4 Undo the control panel cover Fig 4 4 2 5 Pull all plugs from the PCB Fig 4 4 3 All PCB plugs are coded to prevent errors during reconnection 6 Lift the sensor leads an...

Page 30: ...ndoing the boiler control panel fixing screws 4 5 Replacing the cables leads and sensors Fig 4 4 4 Removing leads cables Fig 4 5 1 Replacing the return 38 and flow sensor 37 Fig 4 4 3 Pulling coded plugs from the PCB ...

Page 31: ...d or connecting cable from the cable duct with strain relief chicanes inside the control panel Fig 4 4 4 4 Pull all associated plugs from the PCB Fig 4 4 3 All PCB plugs are coded to prevent errors during reconnection 5 Separate the opposite end of the lead cable from the component concerned undo plug in connection 6 Replace the cable lead Re assemble in reverse order Sensors inside the equipment ...

Page 32: ...ified electrician Fuse type Only use fuses type 250 V 6 3 A slow Note A spare fuse is clipped into the upper part of the enclosure 4 7 Replacing the PCB It is possible that the PCB has developed a fault if there is a fault that cannot be removed neither by replacing the ROTEX THETA 23R control unit chapter 4 3 nor by replacing the sensors and cables leads in the control panel chapter 4 5 After pul...

Page 33: ...iverter valve 26 4 PIN PCB plug with valve cable 27 6 PIN PCB plug with connected burner cable power supply for burner control unit and burner fan 28 Modulating gas burner burner control unit 29 7 PIN PCB plug for connecting a mixer motor and a mixer circuit pump 30 3 PIN PCB plug with communication cable 31 12 PIN PCB plug for connecting sensors the BUS and control cable 32 Outside temperature se...

Page 34: ...ology Fig 5 1 1 Gas burner of the GSU 25 GCU 25 front view Fig 5 1 3 Gas burner of the GSU GCU rear view Fig 5 1 2 Gas burner of the GSU 35 front view Fig 5 1 4 Gas burner of the GSU GCU view from the left 5 1 Gas burner ...

Page 35: ...ectrode 14 2 Ionisation cable 15 1 Ignition electrodes 15 2 Ignition cable 16 Flame tube insert 17 Burner flange gasket O ring 18 Flame tube gasket graphite flat packing 19 Fan flange gasket silicone flat packing 20 Locking plates never undo these 21 Air inlet hose 22 Lid with strain relief for burner cable pos 27 30 and 36 in Fig 4 8 1 and safety screw for gas burner control unit 23 Power supply ...

Page 36: ...allowed to work on gas equipment Check the gas type selected at the factory After the system has successfully passed its test run check the burner output during emissions test operation at maximum full load and minimum standard load burner output using a flue gas analyser for emissions test operation see chapter 8 Adjust the burner if the actual carbon dioxide concentration deviates by more than 0...

Page 37: ...100 25 5 11 3 3 8 100 36 1 11 5 3 5 80 20 2 11 1 4 1 80 28 6 11 2 3 9 STANDARD LOAD 33 7 9 10 6 4 9 33 11 1 10 6 4 9 24 5 5 10 5 5 0 26 8 5 10 5 5 0 FULL LOAD 100 25 5 11 5 3 8 100 36 1 11 7 3 5 80 20 2 11 3 4 1 80 28 6 11 4 3 9 STANDARD LOAD 33 7 9 10 8 4 9 33 11 1 10 8 4 9 24 5 5 10 7 5 0 26 8 5 10 7 5 0 1 Observe warning information The details in the plain fields correspond to the ROTEX factor...

Page 38: ... Fig 6 4 Open the heating valves 5 Start the GSU GCU at the mains isolator 6 Start the emissions test function to ramp up to full load see chapter 8 Note Carry out a new standard burner adjustment if the burner fails to start even though the power and gas supply are OK and the flue path is unrestricted Turn the mixture adjusting screw pos 11 clockwise up to its end stop do not tighten The open the...

Page 39: ...eps 9 to 13 Important The gas valves are preset at the factory Generally the gas pressure governor requires no further adjustment The adjusting screw is hidden under a cover If the adjusted value deviates excessively from the set value and the burner tends to whistle alter the adjustment only in small steps maximum 1 2 turn per adjustment After each adjustment wait a while at least two minutes unt...

Page 40: ...abel below the type plate on the equipment front and confirm the work by signature Affix the equipment label for the natural gas or natural gas LL L adjustment request the label from ROTEX to the burner fan casing 40 Limiting the maximum burner output The maximum burner output can be limited at the boiler control panel by entering an appropriate parameter After entry of the contractor access code ...

Page 41: ...ugated stainless steel pipe that is located inside the cylinder and is fully surrounded by the cylinder water The specific hygienic water properties of the GasSolarUnit GasCompactUnit are based on the separation of the unpressurised cylinder water and the DHW flowing through the corrugated pipe heat exchanger The DHW zone pos D is a combination of DHW cylinder and instantaneous water heater The re...

Page 42: ...al handling of the applied heating energy Stratification inside the cylinder The spiral shape of the heat exchanger and the direction of flow in the countercurrent principle create a distinct temperature stratification inside the cylinder every time heat is drawn off or when the cylinder is heated up A high DHW flow rate can be achieved even is large volumes of DHW are drawn off as high temperatur...

Page 43: ...hown makes no claim as to its completeness and is no replacement for careful system engineering Please note Risk of scalding During the operation of the Gas SolarUnit particularly when utilising solar energy cylinder temperatures in excess of 60 C can occur Therefore install an anti scalding device on site DHW mixing facility The same applies to the Gas CompactUnit if cylinder temperatures above 6...

Page 44: ... 44 Fig 5 3 2 Standard connection diagram ROTEX GasCompactUnit 1 1 The connection diagram shown makes no claim as to its completeness and is no replacement for careful system engineering ...

Page 45: ...he connection diagram shown makes no claim as to its completeness and is no replacement for careful system engineering Convert the Solaris control and pump unit RPS 2 Remove the PS2 The PS2 can be used as solar circuit pump It is connected electrically in parallel to the PS1 Separating the standard connection Remove UV1 and reconnect it outside the equipment ...

Page 46: ... 46 Fig 5 3 5 Hydraulic system connection with heating circuit extension 1 Fig 5 3 6 Hydraulic system connection GSU with higher solar output proportion 1 2 ...

Page 47: ...no claim as to its completeness and is no replacement for careful system engineering 2 Note The mechanical level indicator in the Sanicube Solaris cannot indicate with this type of control since the overflow connection on the GSU is arranged lower down thereby determining the fill level of the overall control ...

Page 48: ...ris control and pump unit Accessories 164105 PS1 Operating pump Part of the standard RPS2 delivery PS2 Pressure pump Part of the standard RPS2 delivery tS R Solaris return temperature sensor Part of the standard RPS2 delivery tS Solaris cylinder temperature sensor Part of the standard RPS2 delivery tS V Solaris flow temperature sensor Part of the standard RPS2 delivery tK Solaris collector tempera...

Page 49: ...stment To safeguard that this is done regularly we recommend you take out a maintenance contract Specifically the following work should be carried out annually 1 Removing the silencer hood Inspection and maintenance require the removal of the silencer hood from the ROTEX GasSolarUnit Caution Risk of burning Burner and boiler components below the silencer hood can be very hot Let the equipment cool...

Page 50: ...oves Caution Risk of electric shock Only work on the burner after switching the mains isolator OFF or after interrupting the power supply and after the boiler body has cooled down sufficiently Only work on the burner after switching the mains isolator OFF or after interrupting the power supply and after the boiler body has cooled down sufficiently Fig 6 1 3 Prior to burner removal Pull off the ven...

Page 51: ...ion Where a Solaris system is connected the system can also be drained via the boiler fill drain valve attached to the Solaris return Draining the heating circuit heat exchanger and the DHW heat exchanger To drain both heat exchangers separate the heating flow and return as well as the cold water supply and the hot water outlet Then connect hoses routed downwards so that the hose opening is as clo...

Page 52: ...rner control unit CVBC that lead to the burner being locked out are not only indicated on the control unit display but also by a fault indicator on the boiler control panel pos 2 in Fig 4 1 1 These faults may be reset five times within one hour by lightly pressing the manual key pos 13 in Fig 4 1 1 For such faults always investigate and remove the respective cause Faults recognised by the CVBC bur...

Page 53: ...ontrol unit CVBC Interlocking fault Fault in the flame monitoring routine E 10 Burner control unit CVBC Interlocking fault EEPROM communication error E 11 Burner control unit CVBC Interlocking fault Faulty sensor adjustment procedure for the electronic high limit safety cut out function or return temperature longer than 3 minutes more than 3K higher than the flow temperature E 19 Burner control un...

Page 54: ... fully in Fan motor faulty bearing seized Replace the burner fan no ignition Ignition electrodes short circuited adjust or replace Ignition electrodes are too far apart Adjust Ignition electrodes are contaminated and or damp Clean Ignition electrodes burned out Replace Insulation body cracked Replace ignition electrode Ignition cable burned out 1 Replace the cable 2 Identify and remove the cause B...

Page 55: ... 55 ...

Page 56: ...0 1040 1950 Solar central heating backup stainless steel Heat exchanger surface area m2 0 43 0 43 Average specific output W K 200 200 Thermo technical performance data stainless steel Performance factor NL to DIN 4708 1 2 1 2 3 4 0 4 4 D value spec water flow rate to EN 625 2 l min 27 29 33 39 Continuous output to DIN 4708 Qn kW 25 29 25 35 Max draw off rate for 10 min at TKW 10 C Tcyl 60 C TWW 40...

Page 57: ...20 28 30 30 GB GR IE IT I 2 H I3 20 28 30 37 CH ES PT I 2 H I3 20 28 30 37 NL I 2 L I3 B P 25 28 30 30 LU I 2 E I3 B P 20 50 FR I 2 Esi I3 P 20 25 37 US I 2 E S B I3 P 20 25 37 Table 8 3 Summary of countries of destination equipment categories and associated gas supply pressures Explanations regarding Table 8 1 1 At rated output 80 C flow temperature 65 C cylinder temperature 45 C DHW temperature ...

Page 58: ... 58 Fig 8 1 Residual head GSU 25 GCU 25 heating side Fig 8 2 Residual head GSU 35 GCU 35 heating side ...

Page 59: ... 59 Fig 8 4 Permissible burner loads for GSU GCU the details highlighted in white represent factory settings Fig 8 3 Required flow rate subject to the heating output and the design temperature spread ...

Page 60: ...side the DHW heat exchanger subject to the draw off rate Fig 8 6 Available draw off volume subject to the draw off rate 1 1 Cylinder temperature 60 C draw off temperature 40 C cold water temperature 10 C reheating at rated output ...

Page 61: ...acturer s details PTC 1386 1495 1630 1772 1922 2080 2245 2418 2598 2786 2982 3185 3396 Pt 1000 1000 1039 1077 1116 1155 1194 1232 1270 1308 1347 1385 1423 1461 NTC 98660 56250 33210 20240 12710 8195 5416 3663 2530 1782 1278 932 690 519 395 2 Temperature sensor PTC resistance Outside temperature DHW cylinder temperature mixer circuit temperature Pt 1000 resistance Flue gas temperature NTC resistanc...

Page 62: ...ungsautomat Kesselerdung Netz Abgas1 Speicherfühler Aussenfühler Mischerfühler r Raumstation oder weitere THETA Regler Gasventil Speicher Aussen Mischer Modem BR Sperre Hauptschalter Elektrodenrelais Siehe Blatt 2 2 Masse Max Min Reset Lampe1 Lampe2 Sammelstörung Pegel niedrig Pegel in Ordnung ...

Page 63: ... drain Testing the flue gas connection Cleaning the combustion chamber Cleaning and checking the burner Checking the burner adjustment correct gas type Testing the gap of the ionisation and ignition electrodes Testing the burner inlet pressure Cleaning the cylinder and silencer hood Starting the burner and testing values Carbon dioxide CO2 in the flue Oxygen O2 in the flue Carbon dioxide CO2 in th...

Page 64: ...W in kW in g s in C in Pa 40 30 C 80 60 CNatural gas E HNatural gas LL LLPG 40 30 C 80 60 C 5 5 5 9 5 5 2 31 2 31 2 09 35 65 30 10 0 10 7 10 0 4 20 4 43 3 80 37 68 110 15 0 16 0 14 9 6 30 6 31 5 71 40 72 170 20 0 21 1 19 8 8 40 8 41 7 61 43 74 200 25 5 26 8 25 0 10 71 10 73 9 70 46 78 200 8 5 9 0 8 0 3 57 3 58 3 23 41 71 40 15 0 15 9 14 8 6 30 6 31 5 71 43 74 120 20 0 21 1 19 6 8 40 8 42 7 61 46 7...

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