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Rotex GCU compact 315, Installation And Maintenance Instructions Manual

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Rotex GCU compact 315 Installation And Maintenance Instructions Manual Download Page 49

7 

x

 Heat cell with gas burner

   

7 Heat cell with gas burner

7.1 Design and brief description

Fig. 7-1

GCU compact - heat cell

(for legend, see tab. 7-1)

Fig. 7-2

Components of the GCU compact heat cell:

Gas section – exploded view

(for legend, see tab. 7-1)

Summary of Contents for GCU compact 315

Page 1: ...condensing boiler with integrated heat storage Types GCU compact 315 GCU compact 320 GCU compact 515 GCU compact 520 GCU compact 524 GCU compact 528 GCU compact 315 Biv GCU compact 320 Biv GCU compac...

Page 2: ...r med senere ndringer 11 Direktiv med f retagna ndringar 12 Direktiver med foretatte endringer 13 Direktiivej sellaisina kuin ne ovat muutettuina 14 v platn m zn n 15 Smjernice kako je izmijenjeno 16...

Page 3: ...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...

Page 4: ...posal 71 12 Technical data 72 12 1 Basic data 72 12 1 1 GCU compact 3xx 72 12 1 2 GCU compact 5xx 73 12 1 3 Integrated gas boiler 74 12 1 4 Integrated heating circulation pump 3 way valves 74 12 1 5 I...

Page 5: ...the equipment Cleaning and user maintenance must not be carried out by children without supervision Make up the power supply in accordance with IEC 60335 1 via a separator device which exhibits contac...

Page 6: ...ed in the scope of supply for the individual units 1 1 2 Meaning of warnings and symbols Warnings in this manual are classified according into their severity and probability of occurrence Special warn...

Page 7: ...age The ROTEX GCU compact is suitable for oper ation with natural gas E natural gas LL and liquid gas propane Gases from regenerative sources e g biogas may contain substances that cause corrosion on...

Page 8: ...supply voltage before connecting to the mains Before beginning work on live parts disconnect them from the power supply switch off main switch remove fuse and secure against unintentional restart Equi...

Page 9: ...828 The plumbing connection must comply with the requirements of EN 12897 The require ments of the following must also be observed EN 1717 Protection against pollution of potable water installations a...

Page 10: ...ese documents must be made available at all times and be stored in the immediate vicinity of the device Document the handover by filling out the installation and instruction forms together with the ow...

Page 11: ...act 315 320 Fig 3 1 Design and components of GCU compact 315 320 top view for legend designations see tab 3 1 Fig 3 2 Design and components GCU compact 315 320 front view for legend designations see t...

Page 12: ...components GCU compact 515 520 524 528 top view for legend designations see tab 3 1 Fig 3 5 Design and components GCU compact 515 520 524 528 front view for legend designations see tab 3 1 Fig 3 6 De...

Page 13: ...3 x Product description FA ROTEX GCU2 06 2017 13 Fig 3 7 Design and components diagram for GCU compact 515 520 524 528 for legend designations see tab 3 1...

Page 14: ...even if water is drawn off over a long period of time In the GCU compact 5xx Biv models the SL WT ends approx 40 cm above the floor of the container Only the hot water zone above that point is heated...

Page 15: ...ete storage tank is designed as a hot water zone It is possible to make thermal use of solar energy for hot water preparation The solar component is optimised in combination with an upstream ROTEX Sol...

Page 16: ...perly and are dangerous for the health and safety of individuals The ROTEX GCU compact may only be installed by heating technicians authorised and trained by gas or energy supply companies A Side view...

Page 17: ...ation dimensions of the GCU compact in mm based on fig 4 1 fig 4 2 fig 4 10 fig 4 16 to fig 4 18 Dim GCU compact 3xx GCU compact 5xx h1 1380 h2 1895 h3 1725 1720 hR 2050 r1 165 130 s1 440 370 s2 200 s...

Page 18: ...and hot water connections GCU compact 3xx Fig 4 3 GCU compact 3xx connection dimensions view from the back For legend of position numbers see tab 3 1 A Front B Rear Fig 4 4 Connection dimensions of t...

Page 19: ...on numbers see tab 3 1 A Front B Rear Fig 4 6 Connection dimensions GCU compact 5xx top view For legend of position numbers tab 3 1 To prevent increased cooling losses ROTEX recom mends installation o...

Page 20: ...pe with sufficient fire resistance or be structurally sepa rated from the roof truss Equipment type C33 1 6 Installation versions for the description see chap 4 2 1 to 4 2 3 CA Supply air combustion a...

Page 21: ...o the outside of at least 150 cm2 is required Appropriate measures must be taken to ensure that the burner cannot be operated if the ventilation opening is closed The installation shaft where the flue...

Page 22: ...ent allowed with single assignment not allowed with multiple assignment C93 as for C33 but Connection of the supply air pipe to an existing vertical shaft e g chimney that is part of the building 1 Th...

Page 23: ...risk environment is not permissi ble The electronic controller may never be exposed to the effects of the weather The storage tank may not be exposed to continuous direct sunlight as the UV radiation...

Page 24: ...em B and unscrew the threaded fittings fig 4 9 item F from the openings at which the handles are to be fitted Screw the handles fig 4 9 item A into the now uncovered threaded holes Carefully transport...

Page 25: ...um distances for setting up the GCU compact for dimensions see tab 4 1 and installing a booster heater at low ceiling heights Fig 4 11 Remove the protective cover Fig 4 12 ROTEX GCU compact without pr...

Page 26: ...t adapter for checking and setting the combustion values The ROTEX LAS construction sets each include a test adapter D8PA 15 50 79 00 93 Depending on the local building regulations inspection com pone...

Page 27: ...low of the system depends on the burner output of the ROTEX GCU compact 4 5 2 Connecting a flue gas line Requirements The flue gas system fulfils the requirements described in chap 4 5 1 The flue gas...

Page 28: ...mpact flue gas connection to the side with SET H see chap 4 5 3 for dimensions see tab 4 1 In some cases the resonance in the flue gas system can amplify the noise at the mouth of the flue gas duct Th...

Page 29: ...installation 4 5 3 Flue gas system kits Fig 4 18 Flue gas system kits If needed See tab 4 1 PA Test adapter L Flue gas connection left R Flue gas connection right H Flue gas connection rear O Flue gas...

Page 30: ...e supply lines before filling the device Rinse out the heat distribution network in the existing heating system Install a dirt filter or sludge separator in the heating return flow see chap 1 2 6 CAUT...

Page 31: ...backwards out of its horizontal mounting that the retaining plate fig 4 22 item A can be pushed vertically in between In accordance with EN 12828 a safety valve that limits the maximum permissible op...

Page 32: ...fter assem bly Connect a suitably dimensioned and preset diaphragm expansion vessel for the heating system There may not be any hydraulic blocking elements between the heat generator and the safety va...

Page 33: ...he optional P connection kit for Biv device types allows better access for connecting the supply and return lines of a pressurised solar system or another external heat generator on the storage tank T...

Page 34: ...controller housing and remove the insulation accordingly fig 4 30 WARNING Touching live parts can result in an electric shock and lead to potentially fatal injuries and burns Before beginning work on...

Page 35: ...ont panel fig 4 31 Insert the cables in the controller housing Lay the cabling in the controller housing fig 4 32 and connect the electrical connections in accordance with fig 4 33 and the subsequent...

Page 36: ...or temperature sensors The ROTEX GCU compact can regulate the flow temperature de pendent on the weather The external temperature sensor RoCon OT1 contained in the scope of delivery is required for th...

Page 37: ...evice e g lamp can be connected to the internal switching contact on the J3 circuit board connector terminals A A1 A2 Different connection conditions must be complied with depending on the model of th...

Page 38: ...mobile phones by app 4 7 8 Room thermostat When the ROTEX GCU compact is used as master in a CAN bus system terminal function for remote con trol of other data bus devices the external temperature sen...

Page 39: ...type Natural gas Observe the permitted gas inlet pressure resting pressure see tab 12 6 4 8 2 Connecting the gas line Connect the factory installed corrugated gas connection hose A pipe thread DIN EN...

Page 40: ...as line in a professional manner Connect the pressure gauge measuring hose to the inlet gas pressure measuring connection fig 4 44 item 3 3 Check the inlet gas pressure If the gas inlet pressure lies...

Page 41: ...ding side in accordance with chap 4 6 2 or temporarily installed with filling hose Rotate the pressure gauge glass so that the minimum pressure mark equates to the system height 2 m 1 m water column c...

Page 42: ...215 2 but do not confirm Make sure that heat can dissipate into the heating network during emission measurement In the event of burner starting problems see chap 7 3 4 Automatic calibration of the GC...

Page 43: ...l Load 4 5 5 3 10 3 10 8 Liquid gas setting Compare with the information on the yellow sticker attached to the burner housing Tab 5 1 Start up control values for GCU compact 315 and GCU compact 515 fo...

Page 44: ...iler and heating system vented Yes 14 All sensors connected and correctly positioned Yes 15 Mixer group mixer module and mixer circuit sensor optional connected correctly Yes 16 Room controller option...

Page 45: ...ory components A detailed description is given in the documentation for the ROTEX RoCon BF controller 1 Clear text display 2 Setting Configuration 3 Setting Remote Param 4 Rotary switch 5 Setting Info...

Page 46: ...the front panel 6 3 Changing sensors Most internal sensors fig 6 3 can be replaced without having to open the controller housing To remove the thermal insulation see chap 4 4 3 WARNING Touching live p...

Page 47: ...ternal mixer sensor inflow temperature sensor heating circuit tR Return flow temperature sensor boiler circuit 22 Heating circulation pump 23 Burner blower DS Pressure sensor FLS Flow sensor 3UV DHW 3...

Page 48: ...perature sensor The storage tank temperature sensor is connected directly to connection terminals 9 and 10 of the 12 pin J8 sensor plug on the boiler control panel see chap 12 6 1 Open the boiler cont...

Page 49: ...as burner 7 Heat cell with gas burner 7 1 Design and brief description Fig 7 1 GCU compact heat cell for legend see tab 7 1 Fig 7 2 Components of the GCU compact heat cell Gas section exploded view fo...

Page 50: ...6 Gas connector pipe 7 Gas connection G IG with connected gas hose 8 Safety gas control block 9 Gas valve connection adapter 10 Condensate pipe with overfill protection 11 Flue gas collector 12 Securi...

Page 51: ...tation and the signature of the installer A locking malfunction can only be reset manually on the controller of the GCU compact see chap 10 4 With a temporary fault shutdown the burner is switched of...

Page 52: ...e yellow sticker attached to the burner housing Tab 7 3 Set flue gas setting values for GCU compact 315 and GCU compact 515 for various gas types Type GCU compact 320 520 Biv Gas type test gas Burner...

Page 53: ...troller operating instructions Resetting from Liquid petroleum gas to natural gas 1 Turn the gas air mix setting screw fig 4 44 item 3 1 to position 1 2 Change the gas type in the controller RoCon BF...

Page 54: ...overview is displayed 3 Use the rotary switch to select the parameter Corr qGas start and confirm Current value is displayed 4 Use the rotary switch to adjust the parameter Corr qGas start 5 Confirm t...

Page 55: ...oller fig 7 6 item 4 5 Unscrew the fixing screws on the burner flange fig 7 6 item 6 Remove the burner blower with burner flange from the boiler body Unscrew the burner surface from the burner flange...

Page 56: ...Check the gas line for leakage Start the burner Check the function leak tightness at the burner flange and the settings see chap 7 3 3 1 Securing stirrup 2 Burner flange seal 3 Burner surface 4 Conne...

Page 57: ...ng flow 4 Heating return flow 5 Mixing circuit 6 Circulation 7 Check valve return valve 7a Non return valves 8 Solar circuit 3UV DHW 3 way distribution valve hot water heater 3UVB1 3 way mixer valve h...

Page 58: ...8 x Hydraulic connection Fig 8 1 GCU compact 3xx example with DrainBack solar for legend see tab 8 1 Fig 8 2 GCU compact 5xx Biv with pressurised solar system for legend see tab 8 1...

Page 59: ...aintenance plastic only needs to be cleaned with a soft cloth and a mild detergent Do not use any cleaners with aggressive solvents damage to the plastic surface may occur 9 2 1 Checking the connectio...

Page 60: ...iently Wear protective gloves UK only CAUTION If filling or topping up the storage tank is done by means of the boiler filling and drain valve a temporary filling loop must be used with the appropriat...

Page 61: ...ry KFE BA 16 52 15 to the solar control and pump unit RPS4 Connect the filling hose with non return valve 1 2 to the previously installed KFE cock Fill the storage tank of the GCU compact until water...

Page 62: ...DANGER During the filling process water may escape from any leaking points that can cause an electric shock if it comes into contact with live parts Before the filling process de energise the GCU com...

Page 63: ...the integrated heating circulation pump and various settings of the 3 way changeover valves integrated in the ROTEX GCU compact Any air present can escape via the automatic vent valve during the air p...

Page 64: ...iler Turn on main switch of heating room Check switch on fuse house connection Check renew fuse boiler control panel Only use same type of fuses Heating does not warm up Central heating standby switch...

Page 65: ...and adjust as required Ignition electrodes contaminated or humid Clean ignition electrodes and check burner settings Ignition electrodes burnt out Replace ignition electrodes Insulating body cracked...

Page 66: ...burner blower E158 EEPROM fault manufacturer s parameters E159 EEPROM fault safety parameters E189 Regulation deviation during ionisation process too high from 2nd fault burner earthed in correctly or...

Page 67: ...Firing unit internal fault E4 Firing unit Temporary malfunction device is attempting to restart 1x no flame formation at end of safety time no gas valves do not open no ignition sparks E5 Flame failur...

Page 68: ...s Replace sensor temperature sensor E198 FlowSensor Volume flow too low Check heating circulation pump filter heating network E200 Communication firing unit Communication interrupted between firing un...

Page 69: ...rotary switch Fault is reset 6 Cancellation and jump back by pushing the Exit button again 10 5 Emergency operation Emergency heating operation can be maintained if the electronic controller settings...

Page 70: ...e filling and draining connection fig 11 4 WARNING When opening the solar return connection and the heating and hot water connections there is a danger of scalding and overflooding from escaping hot w...

Page 71: ...e tank charging 9 Remove the hydraulic group 10 Connect the drain hose to the cold water inlet and hot water outlet as well as the heat exchanger for storage tank charging so that the hose opening is...

Page 72: ...Max draw off rate for a period of 10 min at TKW 10 C TWW 40 C TSP 60 C litres 19 20 Hot water quantity without reheating with a draw off rate of 15 l min NewLine TKW 10 C TWW 40 C TSP 60 C litres 200...

Page 73: ...off rate for a period of 10 min at TKW 10 C TWW 40 C TSP 60 C litres 20 21 23 24 Hot water quantity without reheating with a draw off rate of 15 l min NewLine TKW 10 C TWW 40 C TSP 60 C litres 230 Ho...

Page 74: ...lass to EN 15502 1 4 6 NOx output with reference to calorific value Hs mg kWh 23 31 31 31 Boiler body water content litres 1 2 Max permissible operating pressure PMS 12 bar 3 0 Max permissible operati...

Page 75: ...plumbing 14 Max permissible operating pressure PMS heating 15 Max permissible operating temperature Tmax 16 D value EN 15502 17 Serial number specify for complaints and inquiries 18 Production date 1...

Page 76: ...0 8 Hot water storage tank volume L 294 294 477 477 477 477 Controller class of temperature control II II II II II II contribution to seasonal space heating efficiency 2 2 2 2 2 2 Energy efficiency cl...

Page 77: ...II 2N3P 20 25 37 LU I 2E 20 PL II 2E3P 20 37 RO II 2H3P 20 30 Tab 12 7 Countries of destination unit categories and associated gas connection pressures 7 For position numbers see fig 12 1 Component Re...

Page 78: ...d the dimensioned temperature spread RS Sensor resistance T Temperature Fig 12 4 Resistance characteristics of the temperature sensor Measured temperature in C Temperature sensor Type Specification NT...

Page 79: ...12 x Technical data 12 6 Electrical connection diagram Fig 12 5 Wiring diagram ROTEX GCU compact for legend see tab 12 10...

Page 80: ...r coil TRA1 Ignition transformer CM 434 Automatic firing unit J1 3 pin circuit board connector with mains pump cable J2 4 pin PCB connector Connection 3 way mixer valve 3UVB1 J3 6 pin circuit board co...

Page 81: ...13 x Notes 13 Notes...

Page 82: ...13 x Notes...

Page 83: ...ring unit 50 51 69 Flow rate 78 Flow temperature sensor 14 47 FlowSensor 14 47 Flue gas collector 14 50 Flue gas mass flow 27 Flue gas system Design 26 Kits 29 Minimum requirements 26 Piping height 26...

Page 84: ...rner is turned on for 30 min and is regulated at maximum load Select the load type Base Load using the rotary switch but do not confirm it Display Base Load The modulating gas burner runs at minimum o...

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