Daikin Rotex A1 BO Series Installation And Maintenance Instructions Manual Download

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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

Output 02/2014

0035 BM 105.3

For certified companies

Summary of Contents for Rotex A1 BO Series

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: ...e 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 brief description 30 7 2 Safety function 31 7 3 Burner setting 31 7 3 1 Settings 31 7 3 2 Instructions for burner setting 32 7 3 3 Check vacuum in the oil pump and set the oil pump pressure 33 7 3 4 Set ...

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 CE 0035 BM 105 3 comply in its standard design with the following European Directives 2004 108 EC Electromagnetic Compatibility Directive 2006 42 EC EC Machinery Directive 2006 95 EC EC Low Voltage Di...

Page 4: ...ith 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 death as well as property damage Install and operate only ROTEX Oil condensing boiler to avoid danger as stipulated and in perfect condition with an awareness of the safety and hazards involved Thi...

Page 5: ... 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 mm...

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 chamber insert 18 Flue gas temperature sensor 19 Circuit board electrical connections 20 Document pouch 21 Flow temperature sensor 22 Return flow temperature sensor Safety devices Fig 3 1 Constituent par...

Page 7: ...M1 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 venient operating possibilities As an option for increased convenience a digital room controller RoCon U1 15 70 34 is available as an option This can be used as a remote control and a room thermostat U...

Page 8: ...rained 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 connection DN 80 125 5 Connection expansion vessel 1 IG 6 Burner 7 Safety valve 1 IG flue line IG 8 3 way diverting valve 2 1 AG 9 Hot water IG 10 Circulation IG 11 Heat exchanger return AG 12 Sensor im...

Page 9: ...on 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 15 135 15 785 15 500 15 d 230 15 880 15 590 15 230 15 880 15 590 15 230 15 880 15 590 15 e 365 15 1000 15 755 15 425 15 1065 15 815 15 425 15 1065 15 815 15 f 405 15 1045 15 795 15 465 15 1105 15 855 ...

Page 10: ...c 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 duration of 90 min in residential buildings with low headroom 30 min Observe country specific regulations for fire resistance periods e Ventilation opening 1x150 cm or 2x75 cm f Rear ventilation opening 15...

Page 11: ...sufficient 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 suction the supply air through a separate air supply line with lower resistance The ROTEX A1 BO is operated with separately routed inlet air flue gas lines 2 line system Combustion air inlet is routed f...

Page 12: ...y 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 chimney or an installation shaft such as Set up version 1 Set up version 7 The ROTEX A1 BO is connected by the SET A or SET B to a ceramic chimney Combustion air supply from the installation room Cerami...

Page 13: ... 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 malfunction at start or during operation of the burner Surface temperature minimum distance When operating independently of the ambient air with nomi nal output the design does not allow temperatures 70 C on an...

Page 14: ... with 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 maximum permitted flue gas counter pressure is 200 Pa The pressure loss in the supply line must not exceed 50 Pa Angle of entry of the flue gas pipe into the chimney or instal lation shaft 3 Slope for...

Page 15: ... Flue 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 has the CE labelling can be connected see section 4 5 1 Each flue gas line must be installed with a suitable test adapter for checking and setting the combustion values The ROTEX LAS construction s...

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: ...1 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 diffusion sealed floor heating pipes sludge and shavings may enter the boiler and lead to blockage local overheating or corrosion damage Ɣ Rinse out the heat distribution network in the existing heat...

Page 18: ...e flue gas pipe and fill the condensate box by using a hose held in the flue gas pipe Ɣ Check the condensate drain section for leakage 4 8 Establish connection and electrical equipment 4 8 1 Instructions concerning electrical connection All electronic control and safety systems of the ROTEX A1 BO are connected and tested Modifications on the electrical instal lation are dangerous and prohibited Th...

Page 19: ...ect to the ROTEX A1 BO controller Ɣ 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 included in the scope of supply of the connection kit A1 VSA1 15 48 22 or it can be supplied separately as an accessory RoCon DT1 15 60 68 Ɣ Connect the sensor line to the sensor plug J8 connection TWW...

Page 20: ...ting 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 Ɣ Rotate the pressure gauge glass in such a way that the minimum pressure mark corresponds to the system height 2 m 1 m water column corresponds to 0 1 bar Checking the water quality Ɣ Observe the instructions concerning ...

Page 21: ...e start phase Ɣ Open the venting screw on the oil filter Ɣ Vent oil line and measure the oil pressure on vacuum meter Î The vacuum may be maximum 0 4 bar better 0 2 bar Start up Ɣ Switch on the mains switch Wait for the start phase Ɣ Adjust the hand operation on the ROTEX Controller RoCon BF Special Level see documentation ROTEX Controller RoCon BF WARNING If not started up properly a ROTEX A1 BO ...

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 yes 16 Are all sensors connected and correctly positioned yes 17 Mixer group mixer module and mixer circuit sensor optional connected correctly yes 18 Room controller optional correctly connected to t...

Page 23: ...ound 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 Temp Day 8 Setting Set Temp Night 9 Setting DHW Set Temp 10 Setting DHW Reheating 11 Setting Time Program 12 Setting Configuration 13 Not assigned 14 Rotary button 15 Exit button jump back Special Lev...

Page 24: ...see 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 sensor and the connection cables from the cable ducts of the control panel fig 6 5 WARNING Live parts can cause an electric shock on contact and cause life threatening burns and injuries Ɣ Before beg...

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 tempera ture sensors or for components not included in the scope of supply are connected to the circuit board connectors with screw terminals Changing the cables observe sequence 1 Remove the sound insul...

Page 26: ...o not force the connector WARNING Live parts can cause an electric shock on contact and cause life threatening burns and injuries Ɣ Before beginning work on the ROTEX A1 BO disconnect therom the power supply switch off fuse main switch and secure against uninten tional restart 22 Flow temperature sensor 25 Pressure sensor Fig 6 8 Position of the sensors on the boiler 1 23 Return flow temperature s...

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 board see section 6 3 steps 1 to 4 2 Pull out the storage tank temperature sensor from the sensor immersion sleeve at the storage tank 3 Bend the pressing springs on the new sensor and push the new sen...

Page 28: ...in 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 cable switchboard PCB operating section 18 Stickers for connection assignment 19 Heating circulation pump 20 Oil burner 21 Automatic firing CM165 22 Flow temperature sensor 23 Return flow temperature...

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: ...minary 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 burning process When the burner request by the Control ends Solenoid valve closes oil preheating switches off Post ventilation Electric motor switches off 1 Automatic oil firing unit 2 Oil pump 3 Heati...

Page 31: ...ature 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 too rapidly fault code 19 the supply voltage is too low fault code 32 the communication between the automatic firing and the con troller is interrupted for longer than 2 mins fault code 48 A fault is disp...

Page 32: ...rottle Fan pressure Conversion kit kW Ø 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 0 30 14 0 1 23 0 18 7 5 15 17 5 0 35 10 0 1 32 1 18 7 1 Series status A1 BO 20 e oil blue burner BLB 20e 12 19 0 30 10 5 1 05 3 64 4 5 URS12 13 19 0 30 13 0 1 14 3 68 5 0 14 19 0 30 15 5 1 23 4 80 5...

Page 33: ...termine the CO2 O2 content of the flue gas Ɣ Connect up the flue gas analysis unit Ɣ To reduce air quantity Turn air throttle adjusting screw to the left lower scale value Î O2È CO2Ç Ɣ To increase air quantity Turn air throttle adjusting screw to the right higher scale value Î O2Ç CO2È 1 Vacuum meter connection 2 Adjusting screw for oil pres sure 3 Solenoid valves 4 Pump cover 5 Manometer connecti...

Page 34: ...o adjust 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 recirculation tube 1 Recirculation gap 2 Flame tube 3 Recirculation tube Fig 7 7 Flame tube and recirculation gap The scale fig 7 6 pos 2 shows the set width of the recirculation gap in mm If the no...

Page 35: ... 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 Ɣ Switch off the heating main switch before removing the burner and secure it from being unintentionally switched on WARNING Danger of burning on hot surfaces Ɣ Let the burner cool down sufficiently before removin...

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 reverse sequence 8 Start burner check function and settings see section 7 3 7 5 Removing fitting the air nozzle For certain output ranges air nozzles that differ from the series condition must be fitted...

Page 37: ...nitoring 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 controllers are integrated in the pump Fig 7 14 Automatic firing CM165 R1 Connect or Pin Cable colour Function X1 L1 brown Mains connection switched by boiler control ler connection J10 PE green yellow ...

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 accessible place maintenance parts replacement 8 1 2 Connection kit A1 If a heat exchanger is to be connected to the heating system ROTEX recommends fitting the connection kit VSA1 15 48 22 Ɣ Install the com...

Page 39: ...valve 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 Unlocking button of the drive lock 3 3 Hand lever shown in filling position 5 Storage tank temperature sensor 6 Flat seal 1 2x 7 Storage tank return flow 8 Heating return flow 9 Boiler return 10 Boile...

Page 40: ...n 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 vessel MIX 3 way mixer with drive motor MK1 Mixer group with high efficiency pump MK2 Mixer group with high efficiency pump PWM controlled PK Boiler circuit pump PMi Mixing circuit pump PZ Circulation p...

Page 41: ...or 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 sound insulation hood Ɣ Remove the sound insulation hood see fig 9 1 Ɣ Lift and remove the boiler cladding see fig 9 2 Have the service and maintenance carried out by authorised and trained heating engineers ...

Page 42: ...required 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 see section 9 2 5 3 Check condensate drain for free flow and leaks Ɣ Use a hose or bucket to fill a larger amount of water about 5 l into the lower combustion chamber and watch it drain Î The wa...

Page 43: ...ndensate box contains acidic condensate that can lead to injury upon contact with the skin or eyes Ɣ Wear protective clothing safety glasses rubber gloves when working on the condensate box Ɣ If your skin comes in contact with anything wash the affected area immediately with tap water Ɣ If the chemicals come in contact with eyes immediately wash with tap water and consult an ophthalmologist 1 Cond...

Page 44: ...oiler 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 after 10 mins of burner operation the combustion chamber will have to be cleaned see section 9 2 5 Checking the flue gas temperature sensor Ɣ Unscrew the box nut fig 9 10 pos 4 and pull out the flue ga...

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 Ɣ Loosen the dirt and soot on the combustion chamber ribs by using the cleaning brush and cleaning scraper Ɣ Suction off the loosened dirt and soot by using a vacuum cleaner Hard residues may arise in the transition region betw...

Page 46: ...ncludes Ɣ Opening the combustion chamber Î If there is damage around the combustion chamger the burner must be removed see chapter 7 4 Ɣ Clean the burner surface cloth plastic brush Ɣ Visual inspection of the fuel lines for leaks clogging and denting Ɣ Check oil filter of the suction line change the filter set if necessary Ɣ Clean the burner head at fuel exit in the area of baffle plate Ɣ If neces...

Page 47: ...h 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 in the nozzle lid see fig 7 2 pos 21 Distance oil nozzle air nozzle setting see tab 7 1 dimension Y 3 Plug on ignition cable on the ignition electrodes WARNING Danger of burning hot surfaces Ɣ Before ...

Page 48: ... g timer is in economy phase outside temperature too high Ɣ Check operating mode setting 1 Ɣ Check requirement parameter1 e g timer programme Heating does not warm up enough Heating characteristic too low Ɣ Increase parameter value 1 Hot water does not warm up Storage charging standby switched off e g timer is in economy phase Ɣ Check operating mode setting 1 Ɣ Check demand parameters 1 Hot water ...

Page 49: ...ient Ɣ Change oil pump Clutch defective Ɣ Change clutch Oil atomisation not uniform heavy soot deposit in flame tube Oil nozzle loose clogged or worn out Ɣ Check tighten change oil nozzle Oil nozzle spraying angle is wrong Ɣ Replace oil nozzle No oil flow Oil nozzle clogged Ɣ Replace oil nozzle Mixer device has thick layer of oil or heavy carbon deposits Air supply insufficient Ɣ Check air supply ...

Page 50: ...alfunction 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 detection at burner start E5 More than 5 flame interruptions during a continuous burner demand E11 Flame detection before burner start E15 Oil preheater does not switch within a 5 min period E34 ...

Page 51: ... the rotary switch Î 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 fault rectification E75 Outside temperature sensor Measured value outside measuring range temperature sensor defective Ɣ Check cable terminal and plug connec tions Ɣ Replace the temperature sensor E76 Storage tank ...

Page 52: ...he filling and draining sockets KFE cock 11 2 Final shutdown and disposal For the final shutdown the ROTEX A1 BO must be Ɣ taken out of service Ɣ disconnected from all electrical oil and water connections Ɣ disposed off in a professional manner Recommendations for disposal The ROTEX A1 BO is designed to be environmentally friendly During the disposal process the only waste created is that which ca...

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 for burner conversion kW URS12 12 14 URS12 12 14 URS20 20 24 URS25 25 26 URS35 33 34 Maximum permissible flow temperature C 80 Maximum permitted operating overpressure PMS bar 4 Max boiler efficiency u...

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 ZTÜ No 0 096 600 033 2x 7 5 kV 15 20 kHz Solenoid valve Danfoss Type 071 N 0051 Oil pump pumping capacity Danfoss Type BFP 21 L3 No 071 N0185 Oil preheating Danfoss Type FPHB 5 No 030N2057 30 90 W Motor includi...

Page 55: ...age 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 diverter valve from connecting kit A1 ΔpR Remaining pumping height mH Flow heating network Fig 12 2 Residual feed height A1 BO 15 e A1 BO 20 e ΔpR Remaining pumping height mH Flow heating network Fig 12...

Page 56: ...stance 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 standard or manufacturer s indications NTC tV tR tAU tDHW tMi 98660 56250 33210 20240 12710 8195 5416 3663 2530 1782 1278 932 690 519 395 PT 1000 tAG 922 961 1000 1039 1077 1116 1155 1194 1232 1270 1308...

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: ...surement 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 Flue system Dimensioning 14 Kits 16 Minimum requirements 14 Piping height 14 Flue system kits 16 Fuel 7 Fuse 28 H Hydraulic system connection 40 I Inflow temperature sensor 26 Installation area 13 Ins...

Page 60: ...n again or 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 in Pa at 75 60 C at 40 30 C 75 60 C 40 30 C A1 BO 15 e 12 5 32 5 17 70 48 150 15 6 72 6 49 75 52 150 A1 BO 20 e 12 5 32 5 17 70 48 150 15 6 72 6 49 75 52 150 20 9 03 8 67 85 65 150 A1 BO 27 ...

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Daikin Rotex A1 BO Series, Installation And Maintenance Instructions Manual

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