Rotex GCU compact Installation And Maintenance Instructions Manual Download

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ROTEX

GCU compact
Installation and maintenance
instructions

Gas Combi Unit compact

Types

GCU compact 315
GCU compact 324
GCU compact 515
GCU compact 524
GCU compact 533

GCU compact 315 Biv
GCU compact 324 Biv
GCU compact 515 Biv
GCU compact 524 Biv
GCU compact 533 Biv

GB
Edition

0085 CO 0180

Summary of Contents for GCU compact

Page 1: ...maintenance instructions Gas Combi Unit compact Types GCU compact 315 GCU compact 324 GCU compact 515 GCU compact 524 GCU compact 533 GCU compact 315 Biv GCU compact 324 Biv GCU compact 515 Biv GCU c...

Page 2: ...gas line 26 4 9 3 Installing removing the burner trim 26 4 9 4 Checking the gas pre installation 27 4 10 Optional connections 28 4 10 1 Mixer module RoCon M1 28 4 10 2 Room control RoCon U1 28 4 10 3...

Page 3: ...1 4 Integrated heating circulation pump 3 way valve 58 12 2 Gas type connection pressures 59 12 3 Tightening torque 60 12 4 Flow rate and residual feed height 60 12 5 Temperature sensor 60 12 6 Electr...

Page 4: ...antee 4 ROTEX GCU compact 1 Guarantee 1 1 Warranty conditions The legal guarantee conditions fundamentally apply Our war ranty conditions beyond that can be found online on your sales representative s...

Page 5: ...s Combi Unit compact 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 I...

Page 6: ...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 mmol l sum of the calcium and mag...

Page 7: ...ructure and components GCU compact 315 324 plan view for legend designations see tab 3 1 Fig 3 2 Structure and components GCU compact 315 324 front view for legend designations see tab 3 1 89 Fig 3 3...

Page 8: ...U compact 515 524 533 plan view for legend designations see tab 3 1 Fig 3 5 Structure and components GCU compact 515 524 533 front view for legend designations see tab 3 1 Fig 3 6 Structure and compon...

Page 9: ...the container Only the hot water zone about it is heated by the boiler The tank volume below it is heated only on using the solar energy On the GCU compact 315 315 BIV 324 324 BIV 533 533 BIV models...

Page 10: ...in series preheating stage the solar proportion is optimised Safety management The entire safety management of the ROTEX GCU compact is entrusted to electronic control This effects a safety switch off...

Page 11: ...devices may not operate properly and are dangerous for the health and safety of individuals The ROTEX GCU compact must be installed only by heating engineers authorised and trained by gas or energy su...

Page 12: ...1 110 250 r2 380 540 s1 345 s2 350 4701 200 3201 s3 535 3651 2852 500 3301 2502 s4 370 2001 210 401 s5 750 6301 5002 s6 750 6301 5002 750 6301 sD 150 t 615 790 w 595 790 1 When installing the test ada...

Page 13: ...w from behind A Front side B Rear side Gc GCU compact Fig 4 6 Connection dimensions GCU compact 5xx plan view ROTEX recommends the installation of gravity brakes 16 50 70 or syphoning lead the connect...

Page 14: ...ration 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...

Page 15: ...rated from the roof truss Set up version 4 The ROTEX GCU compact with the SET GCU1 and the LAS connection line SET H or SET K is connected to the exterior wall system SET G The combustible air supply...

Page 16: ...ks are suitable for transporting it Scope of delivery ROTEX GCU compact preassembled Bag of accessories see fig 4 8 Outside temperature sensor RoCon OT1 for weather con trolled regulation Document pac...

Page 17: ...nsport the ROTEX GCU compact to the erection site use the handles Install ROTEX GCU compact at the place of installation Recommended distances to the wall s1 s2 s3 s4 see tab 4 1 To the ceiling sD 150...

Page 18: ...flue gas calculations may be needed If the horizontal connecting piece is extended the maximum permitted height of the flue gas pipe is reduced by exactly that length Flexible flue gas lines must not...

Page 19: ...E H G20 B Natural gas LL L G25 C Liquid gas mET Flue gas mass flow P Burner load Fig 4 12 Flue gas mass flow in dependence of the burner load ROTEX GCU compact all types We recommend to use the assoc...

Page 20: ...system kits Fig 4 15 Flue system kits If needed See tab 4 1 L Flue gas connection left R Flue gas connection right H Flue gas connection rear V 3 3 V V 5 3 PP 9 PP 9 PP 9 PP 9 PP 9 PP 9 PP 6 7 6 6 6 6...

Page 21: ...of adequate dimensions and pre set for the heating 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 t...

Page 22: ...construction Avoid damages caused by deposits and corrosion Observe the relevant regulations of technology to prevent creation of corrosion products and deposits Measures for desalination softening or...

Page 23: ...need to be connected to the boiler control panel 4 7 2 Establishing the electrical connection Check the supply voltage 230 V 50 Hz Switch the mains switch on the boiler control panel of the ROTEX GCU...

Page 24: ...35 1 Ensure that the polarity is correct After completing all electrical connection tasks re establish the power supply to the automatic fuse concerned Fig 4 24 Connection diagram of the circuit board...

Page 25: ...ldest side of the building North or North East Thereby exclude the proximity of external heat sources chimney air shafts and direct sunshine Place external temperature sensors in such a way that the c...

Page 26: ...ension to the gas supply line 4 9 3 Installing removing the burner trim Undo the safety screws on the upper burner trim fig 4 31 item 1 Remove the upper burner trim Assembly is carried out in reverse...

Page 27: ...ection inlet gas pressure fig 4 32 item 3 3 Check the inlet gas pressure If the gas inlet pressure lies below the permissible range tab 12 5 inform the responsible gas supply company For liquid gas Ch...

Page 28: ...e tank Without installed solar system Remove the filling hose with backflush prevention 1 2 to the connection Solar inflow fig 4 34 item 20 Fill the storage tank of the GCU compact until water begins...

Page 29: ...4 x Set up and installation ROTEX GCU compact 29 20 Solar inflow 23 Safety overflow Gc GCU compact Fig 4 34 Filling buffer storage tank without connected DrainBack solar system Gc 5xx Gc 3xx...

Page 30: ...illing for the first time and before switching the GCU compact at the mains switch check that all electrical parts and joints are dry WARNING Contamination of drinking water endangers the health When...

Page 31: ...switch off the mains plug on the boiler control panel GCU compact switches off Wait 20 seconds before switching the mains switch on again Wait for the start phase 5 Second automatic calibration and p...

Page 32: ...nly carry out a calibration of the firing unit when the exhaust setting values are not adhered to or when a mechanical change was carried out e g by replacing the component with original ROTEX spare p...

Page 33: ...rrectly positioned Yes 15 Mixer group mixer module and mixer circuit sensor optional connected correctly Yes 16 Room controller optional correctly connected to the PCB Yes 17 Is the gas connection ins...

Page 34: ...found in the documentation of the ROTEX RoCon BF 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...

Page 35: ...an cause an electric shock on contact and cause life threatening burns and injuries Before beginning work on live parts disconnect them from the power supply switch of fuse main switch and secure agai...

Page 36: ...V DHW fig 6 5 to fig 6 7 WARNING There is a danger of scalding from heating water The sensor s are directly connected to the pres surised heating water Before removing the sensor s close the ball cock...

Page 37: ...hing panel PCB see chapter 4 7 2 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 sens...

Page 38: ...urner blower burner flange 13 4x fixing screws burner flange boiler body 14 4x fixing screws burner blower blower adapter 15 Seal burner blower blower adapter 16 Burner flange seal 17 Burner adapter 1...

Page 39: ...fault shutdowns check the heating system e g flue system fuel supply 7 3 Burner setting Tab 7 2 Possible adjustment ranges If changes have been made to the power settings of the burner or if it has be...

Page 40: ...in CO2 content in Set Set Natural gas E H G20 15 7 4 6 0 6 0 2 9 2 0 1 0 3 Natural gas LL L G25 9 0 0 1 0 3 Propane G31 10 7 0 3 0 5 Liquid gas setting Compare with the information on the yellow stick...

Page 41: ...housing 5 Carry out commissioning as per chapter 5 1 3 In the event of starting problems see section 7 3 4 More detailed explanations and possible setting values for these parameters can be found in t...

Page 42: ...ition An overview is displayed 2 Select the SCOT config level with the rotary switch An overview is displayed 3 Using the rotary switch select the parameter Corr qGas start and confirm Current value i...

Page 43: ...see chapter 4 9 3 Remove the safety clamp fig 7 5 item 1 for the Venturi nozzle Disconnect the mains plug for the blower and the plug for the blower controller fig 7 5 item 2 3 Undo 4 fixing screws fi...

Page 44: ...on to the stipulated tightening torque see chapter 12 3 Check the gas line for leakage Start the burner Check for function leakage at the burner flange and the settings see section 7 3 3 1 Safety clam...

Page 45: ...rk 2 Hot water distribution network 3 Heating inflow 4 Heating return flow 5 Mixer circuit 6 Circulation 7 Check valve return valve 7a Non return valves 8 Solar circuit 3UV DHW 3 way distribution valv...

Page 46: ...46 ROTEX GCU compact 8 x Hydraulic connection Fig 8 1 GCU compact 3xx with DrainBack solar for legend see tab 8 1 Fig 8 2 GCU compact 5xx with DrainBack solar for legend see tab 8 1...

Page 47: ...of the condensate drain must be free from impurities If a solar system DrainBack system is connected and is in operation switch it off and empty the solar panels Unscrew the overflow hose Open the co...

Page 48: ...e the burner must be adjusted according to chapter 7 3 Burner setting Fig 9 2 Check condensation water drain The condensate is a weak acid It is added to the de pressurised zone of the hot water stora...

Page 49: ...splay No mains voltage Switch on the main switch for the boiler Turn on main switch of heating room Check switch on fuse house connection Check renew fuse boiler control panel Only use the same type o...

Page 50: ...t as necessary No ignition Ignition electrodes short circuited Check the ignition electrodes adjust or replace as necessary Distance of ignition electrodes too large Check the ignition electrodes and...

Page 51: ...ault manufacturer s parameters E159 EEPROM fault safety parameters E189 Regulation deviation during ionisation process too high as of 2nd fault burner grounded in correctly or faulty supply voltage fi...

Page 52: ...cable E99 Internal fault to firing unit E4 Automatic firing unit Temporary fault unit is at tempting to restart 1x no flame formation at end of safety time no gas valves do not open no ignition spark...

Page 53: ...e combustion controller E129 Pressure sensor Measured value outside measuring range sensor temperature sensor defective Check cable terminal and plug connec tions Replace the sensor temperature sensor...

Page 54: ...n 10 5 1 Requirements and procedures are identical to those in chapter 4 11 4 or b by removing the valve drive of the 3 way valve fig 4 28 item 5 1 from the valve GCU compact 5xx BIV 3UV DHW fig 3 4 P...

Page 55: ...he floor Allow heat exchanger to run idle according to siphon principle 11 2 Final shutdown and disposal For final shutdown of the ROTEX GCU compact decommissioned see section 11 1 disconnect it from...

Page 56: ...10 min at TKW 10 C TSP 60 C TWW 40 C Litres 19 21 Hot water quantity without reheating up to 15 l min tapping rate T KW 10 C TWW 40 C TSP 60 C Litres 200 Domestic hot water quantity with reheating at...

Page 57: ...TKW 10 C TSP 60 C TWW 40 C Litres 20 23 24 Hot water quantity without reheating up to 15 l min tapping rate T KW 10 C TWW 40 C TSP 60 C Litres 230 Domestic hot water quantity with reheating at rated o...

Page 58: ...ermissible operating pressure PMS 12 bar 3 0 Max permissible operating temperature 13 C 85 Max boiler efficiency 110 Flue gas air infeed connection diameter mm DN 60 100 DN 80 125 with SET GCU1 15 50...

Page 59: ...plate bottom Information regarding the positions see tab 12 1 to tab 12 6 Gas type Rated pressure in mbar Min inlet pressure in mbar Max inlet pressure in mbar Natural gas E H 20 17 25 Natural gas LL...

Page 60: ...Thread 1 25 30 Tab 12 7 Tightening torque pR Remaining pumping height mH Flow heating network 1 Modulation range Fig 12 2 Residual feed height GCU compact heater side mH Flow heating network Q Heatin...

Page 61: ...n circuit board connector not occu pied J10 3 pin circuit board connector with mains ca ble for automatic firing CM434 J11 5 pin circuit board connector with mains ca ble for automatic firing CM434 J1...

Page 62: ...62 ROTEX GCU compact 13 x Notes 13 Notes...

Page 63: ...ow temperature sensor 9 FlowSensor 9 35 Flue gas mass flow 19 Flue system Dimensioning 18 Kits 20 Minimum requirements 18 Piping height 18 Flue system kits 20 G Gas connection Execution 26 Gas inlet p...

Page 64: ...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 output for 30 mins Cancellation and j...

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