Rotex GCU compact 315, Installation And Maintenance Instructions Manual

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Table of contents
FA ROTEX GCU2 - 06/2017
3
1 General safety precautions . . . . . . . . . . . . . 5
1.1 Particular safety instructions . . . . . . . . . . . . . . . . 5
1.1.1 Observing the instructions. . . . . . . . . . . . . . . . . . . . 6
1.1.2 Meaning of warnings and symbols . . . . . . . . . . . . . 6
1.2 Safety instructions for installation and operation 7
1.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.2 Use as intended . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.3 Device installation room . . . . . . . . . . . . . . . . . . . . . 8
1.2.4 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.5 Requirements for the heating water . . . . . . . . . . . . 9
1.2.6 Heating system and sanitary connection. . . . . . . . . 9
1.2.7 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.8 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Handover to operator and warranty . . . . . 10
2.1 Instruct the owner . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Warranty conditions . . . . . . . . . . . . . . . . . . . . . 10
3 Product description . . . . . . . . . . . . . . . . . . 11
3.1 Design and components . . . . . . . . . . . . . . . . . . 11
3.1.1 GCU compact 315 / 320 . . . . . . . . . . . . . . . . . . . . 11
3.1.2 GCU compact 515 / 520 / 524 / 528 . . . . . . . . . . . 12
3.2 Brief description . . . . . . . . . . . . . . . . . . . . . . . . 14
4 Set-up and installation . . . . . . . . . . . . . . . . 16
4.1 Dimensions and pipe dimensions . . . . . . . . . . . 16
4.1.1 Connecting dimensions for the heating and

hot water connections . . . . . . . . . . . . . . . . . . . . . . 18
4.2 Installation versions . . . . . . . . . . . . . . . . . . . . . 20
4.2.1 Ambient air-independent mode . . . . . . . . . . . . . . . 20
4.2.2 Partial ambient air-independent mode . . . . . . . . . 21
4.2.3 Ambient air-dependent mode . . . . . . . . . . . . . . . . 21
4.2.4 Additional information on equipment type in
accordance with CEN/TR 1749 . . . . . . . . . . . . . . . 21
4.3 Transport and delivery . . . . . . . . . . . . . . . . . . . 23
4.4 Installing the GCU compact . . . . . . . . . . . . . . . 23
4.4.1 Selecting the installation site . . . . . . . . . . . . . . . . . 23
4.4.2 Installing the unit . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.4.3 Removing the cover and thermal insulation . . . . . 25
4.5 Air/flue gas system (LAS) . . . . . . . . . . . . . . . . . 26
4.5.1 General instructions for the flue gas system . . . . . 26
4.5.2 Connecting a flue gas line . . . . . . . . . . . . . . . . . . . 27
4.5.3 Flue gas system kits . . . . . . . . . . . . . . . . . . . . . . . 29
4.6 Water connection . . . . . . . . . . . . . . . . . . . . . . . 30
4.6.1 Aligning the connections of the heating supply

and return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.6.2 Connecting hydraulic lines . . . . . . . . . . . . . . . . . . 32
4.6.3 Connect the condensate drain . . . . . . . . . . . . . . . 33
4.6.4 Installation of the DB connection kit ( 141590) . . . 33
4.6.5 Installation of the P connection kit ( 141589) . . . . 33
4.7 Electrical connection . . . . . . . . . . . . . . . . . . . . . 34
4.7.1 Opening the control unit housing and establishing
electric connections. . . . . . . . . . . . . . . . . . . . . . . . 34
4.7.2 Integrated heating circulation pump and

3-way valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.7.3 Temperature sensors and further electric

components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.7.4 Connecting the RoCon OT1 external temperature
sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.7.5 Mixer module RoCon M1. . . . . . . . . . . . . . . . . . . . 38
4.7.6 Room controller RoCon U1 . . . . . . . . . . . . . . . . . . 38
4.7.7 Internet gateway RoCon G1 . . . . . . . . . . . . . . . . . 38
4.7.8 Room thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.7.9 External switching contact. . . . . . . . . . . . . . . . . . . 39
4.8 Connect the gas line, check the burner setting

for gas type . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.8.1 Important instructions for gas connection . . . . . . . 39
4.8.2 Connecting the gas line . . . . . . . . . . . . . . . . . . . . . 39
4.8.3 Removing/attaching the heat cell panelling . . . . . . 40
4.8.4 Checking the gas presetting . . . . . . . . . . . . . . . . . 40
4.9 Filling the system . . . . . . . . . . . . . . . . . . . . . . . . 41
4.9.1 Checking the water quality and adjusting the

pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.9.2 Filling the hot water heat exchanger . . . . . . . . . . . 41
4.9.3 Filling the storage tank . . . . . . . . . . . . . . . . . . . . . 41
4.9.4 Filling the heating system . . . . . . . . . . . . . . . . . . . 41
5 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
5.1 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.1.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.1.2 Checks before start-up . . . . . . . . . . . . . . . . . . . . . 42
5.1.3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.1.4 After start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.2 Checklists for start-up . . . . . . . . . . . . . . . . . . . . 44
6 Controller and electronic components . . . .45
6.1 Operating elements on the boiler control panel . 45
6.2 Replacing the RoCon B1 control panel . . . . . . . 46
6.3 Changing sensors . . . . . . . . . . . . . . . . . . . . . . . 46
6.3.1 Replacing the inflow temperature sensor /

return flow temperature sensor and

pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.3.2 Replacing the internal mixer sensor for heating
support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.3.3 Changing the storage tank temperature sensor . . 48
7 Heat cell with gas burner . . . . . . . . . . . . . . .49
7.1 Design and brief description . . . . . . . . . . . . . . . 49
7.2 Safety function . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.3 Burner setting. . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.3.1 Adjustment values . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.3.2 Establishing access to the burner . . . . . . . . . . . . . 52
7.3.3 Checking and setting the burner . . . . . . . . . . . . . . 52
7.3.4 Starting problems - calibrating the firing unit,

setting the burner blower starting output and

gas volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.3.5 Setting ignition and ionisation electrodes . . . . . . . 54
7.4 Dismantling the burner. . . . . . . . . . . . . . . . . . . . 55
8 Hydraulic connection . . . . . . . . . . . . . . . . . .57
8.1 Hydraulic system connection . . . . . . . . . . . . . . . 57
9 Service and maintenance. . . . . . . . . . . . . . .59
9.1 General overview of service and maintenance . 59
9.2 Service and maintenance tasks . . . . . . . . . . . . . 59
9.2.1 Checking the connections and pipes. . . . . . . . . . . 59
9.2.2 Checking and cleaning the condensate drain . . . . 60
9.2.3 Checking and cleaning the burner. . . . . . . . . . . . . 60
9.2.4 Filling, topping up the storage tank . . . . . . . . . . . . 61
9.2.5 Filling, topping up the heating system and storage
tank charging circuit. . . . . . . . . . . . . . . . . . . . . . . . 62
9.2.6 Venting the hydraulic block . . . . . . . . . . . . . . . . . . 63