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Installation and operating instructions

Daikin/ROTEX A2 F
Oil condensing boiler A2 F
008.1546499_02 – 04/2018 – EN

14 For the chimney sweep

14.1

Data for designing the flue gas pipe..........................................

14.2

Emissions measurement ...........................................................

Содержание A2 F 18H

Страница 1: ...ng instructions Oil condensing boiler A2 F English Installation and operating instructions Oil condensing boiler A2 F Daikin ROTEX A2 F 18H A2 F 24H A2 F 32H D9HA2018A D9HA2024A D9HA2032A R9HA2018A R9HA2024A R9HA2032A 04 2018 ...

Страница 2: ...ng Removing the boiler cladding 26 5 Start up 29 5 1 Initial commissioning 29 5 1 1 Requirements 29 5 1 2 Checks before start up 29 5 1 3 Start up 29 5 1 4 After start up 29 5 2 Checklists for start up 30 6 Controller and electronic components 31 6 1 Operating elements on the boiler control panel 31 6 2 Replacing the RoCon B1 control panel 31 6 3 Change cables 32 6 4 Changing sensors 32 6 4 1 Repl...

Страница 3: ...s Installation and operating instructions 3 Daikin ROTEX A2 F Oil condensing boiler A2 F 008 1546499_02 04 2018 EN 14 For the chimney sweep 64 14 1 Data for designing the flue gas pipe 64 14 2 Emissions measurement 64 ...

Страница 4: ...he equipment and under stand the dangers arising therefrom Children must not play with the device Cleaning and user mainten ance must not be carried out by children without supervision Make up the power supply in accord ance with IEC 60335 1 via a separ ator device which exhibits contact separation in all poles with a contact opening distance that provide full disconnection in accordance with over...

Страница 5: ... must be maintained are numbered è Results of actions are identified with an arrow 1 2 Safety instructions for installation and operation 1 2 1 General WARNING Heating devices that have not been set up and installed correctly can impair the function of the heating device and or cause serious or fatal injuries to the user Work on the A2 F such as set up servicing connection and initial start up mus...

Страница 6: ...inst unintentional restart Device covers and service panels must be replaced as soon as the work is completed 1 2 5 Requirements for the heating water Avoid damage caused by deposits and corrosion Comply with the applicable engineering regulations on prevention of corrosion products and deposits VDI 2035 BDH ZVSHK technical information Scale formation Measures for desalination softening or hardnes...

Страница 7: ...rating manual to the operator and advise him that these 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 instruc tion forms together with the owner and sign them 2 2 Warranty conditions The legal guarantee conditions fundamentally apply Our more ex tensive warranty conditions can be found i...

Страница 8: ...2 F 008 1546499_02 04 2018 EN 3 Product description 3 1 Design and components Fig 3 1 Design and components view from above 1 Fig 3 2 Design and components front and rear view 1 Fig 3 3 Design and components view without cladding 1 Fig 3 4 Design and components view of lower part 1 1 For legend see Tab 3 1 ...

Страница 9: ...eating return flow 24 oil filter 3 Storage tank char ging flow optional 25 MAG connection 4 Storage tank char ging return flow op tional 26 Recirculation tube 5 Oil connection 27 KFE cock 6 flue gas connection 28 Flue gas temperature sensor 7 Mains switch 29 Safety pressure relief valve heating circuit 8 Controller control panel 30 Automatic vent valve 9 boiler enclosure 32 Valve kit 10 Height adj...

Страница 10: ...age tank The Smart Start function remains active until the next request for hot water genera tion is pending The Smart Start function is automatically controlled by the RoCon BF controller Safety management The entire safety management of the A2 F is carried out by the elec tronic controller If there is water shortage oil shortage or undefined operating conditions there is a safety shutdown A corr...

Страница 11: ...23 B23P B33 B53 B53P Fig 4 2 Different set ups Item Designation 1 6 Installation versions for a description see Chap 4 2 1 to Chap 4 2 3 CA Supply air combustion air FG Flue gas RV Rear ventilation a Installation version for ambient air independent opera tion flue gas supply air concentric b Installation version for conditional ambient air independ ent operation flue gas supply air separate c Inst...

Страница 12: ...he roof truss the dual pipe for the combustible air supply and the flue gas duct must be laid through a protective pipe with sufficient fire resistance or be structurally separated from the roof truss Device type C33x Installation version 4 The A2 F is connected with the SET K LAS connection line to the SET G outer wall system The combustible air supply from the outside runs through the ring shape...

Страница 13: ... for such systems based on EN 15035 are listed below C13 Horizontal openings for flue gas outlet and supply air inlet Openings within a square of 50 cm x 50 cm C33 vertical openings for flue gas outlet and supply air inlet Openings within a square of 50 cm x 50 cm Spacing of opening levels 50 cm C43 Connection of more than one device to a common air flue gas sys tem that is part of the building ve...

Страница 14: ...em B53 as for B33 but connection to associated flue gas pipe including flue gas opening B53P as for B53 but overpressure operation Spacings of brackets and offsets The distance of the supports of the flue gas line must not be more than 2 m in the vertical area In the horizontal area of the connecting lines the brackets must be installed so tightly that there is no risk of any gradient in the hori ...

Страница 15: ...e A2 F is installed in the attic and the oil is stored in the rooms below it the oil pump of the burner is generally not sufficient If the vacuum on the suction side exceeds the value 0 4 bar the oil must be supplied to the burner through a separate pump We strongly re commend using a suction unit The minimum height of the flue gas conduit must be 2 m in order to avoid malfunction at start or duri...

Страница 16: ...The associated assembly instructions must be observed for installing the flue gas and supply air holding system components or their means of attachment Each flue gas line must be installed with a suitable test ad apter for checking and setting the combustion values The LAS construction sets contain one test adapter each D8PA Depending on the local building regulations inspection compon ents must b...

Страница 17: ...gas system fulfils any required other national or regional safety requirements The A2 F is installed correctly Connection INFORMATION We recommend use of the associated LAS construction sets see Chap 4 5 3 They satisfy all requirements and are also fitted with special acid proof seals The associated assembly instructions must be observed for installing the flue gas and supply air holding system co...

Страница 18: ...137 231 mm 155079 0088 097 W8 WHV32 231 325 mm 155079 0089 091 W8 WKV15 55 147 mm 155079 0084 092 W8 WKV24 147 239 mm 155079 0085 093 W8 WKV33 239 331 mm 155079 0086 SET L XXX α XXX D8 FD15 0 15 049 155079 0082 D8 SD25S 5 25 045 155079 0014 D8 SD45S 25 45 046 155079 0037 D8 SD55S 35 55 047 155079 0012 D8 FD 0 048 155079 0040 xxx SET H 155079 08 DRFLUEGAKITA SET L 155079 10 E8 RR 155079 0107 E8 MSD...

Страница 19: ...in the heating system must be installed on or in the immediate vicinity of the heat generator There may not be any hydraulic block ing elements between the heat generator and the safety valve Any steam or heating water which may escape must be drained by a suitable blow off line with constant gradient in a frost protected safe and observable manner A suitable safety valve is integrated in the A2 F...

Страница 20: ...ith free inflow to the drains connection 2 Lay the condensate drain sloping down from the boiler so that condensation will not accumulate in the flue gas pipe INFORMATION If it is not possible to connect the condensate drain to the waste water system with a sufficient gradient in the install ation room a condensate lifting pump must be installed on site 3 The complete outlet must not be lockable a...

Страница 21: ... a way that the cir cuit board connectors can be connected to the board without voltage Fig 4 11 Cable guiding and strain relief 6 Inserting the cables in the controller housing 7 Insert strain relief clips in the boiler control panel and ensure ef fective strain relief for all cables connected to the A2 F by means of cable ties 8 Check the holding force of the strain relief 9 Lay cabling in the b...

Страница 22: ...cuit board in the boiler control panel and attached to the boiler frame by means of cable ties Slide the mains connection cable through the cable penetration into the rear wall of the boiler Fig 3 2 item 16 and connect to the distribution box on site Use an all pole disconnecting main switch on the junction box of the domestic power supply separator device according to IEC 60335 1 which exhibits c...

Страница 23: ... 6 tV2 The optional storage tank temperature sensor is connected to ter minals 9 10 tDHW The flue gas temperature sensor on the plugged in 6 pin plug is connected to terminals 11 12 tAG WP J3 circuit board connector An external control acquisition or display device e g lamp can be connected to the internal switching contact on the J3 circuit board connector terminals A A1 A2 Depending on the model...

Страница 24: ...ller INFORMATION A separate installation manual is included with this com ponent See the enclosed control system manual for in structions on setting and operation 4 7 6 Room controller RoCon U1 optional A separate RoCon U1 room controller can be connected for each heating circuit to enable remote adjustment of operating modes and target room temperatures from another room INFORMATION A separate in...

Страница 25: ...e Standby 680 Ω 5 Heating 1200 Ω Reducing 1800 Ω Summer 2700 Ω Automatic 1 4700 Ω Automatic 2 8200 Ω Tab 4 11 Resistance values for evaluating the EXT signal INFORMATION The input is not considered for resistance values greater than the value for Automatic 2 4 8 Connect the oil line 4 8 1 Important instructions for oil connection Oil connection Implement the oil connection in the single strand sys...

Страница 26: ...age in accordance with local regula tions DIN 4755 min 5 bar overpressure and 0 3 bar underpres sure 4 9 Filling the system Only fill the A2 F after completion of all installation work in the order shown below 4 9 1 Checking the water quality and adjusting the pressure gauge 1 Comply with the instructions for the water connection see and water quality see Chap 1 2 5 2 Adjust the mechanical pressur...

Страница 27: ...anel and boiler control panel Connect the cables to circuit board con nectors J15 and BU1 on circuit boardRoCon BE 2 and ensure the strain relief of the cables Fig 4 11 Fig 4 23 Installing the boiler cladding inserting the cables 6 5 Close the boiler control panel again Fig 4 24 Installing the boiler cladding closing the boiler control panel 6 6 Guide the front panel to the device and let it engag...

Страница 28: ...erting the front panel 6 7 Move the cover to the end position and screw tight Fig 4 26 Screwing the cover tight Item Designation A Boiler cladding side panel B Boiler cladding side panel C Boiler cladding cover D Boiler cladding front panel E Screws Tab 4 13 Legend for Fig 4 20 to Fig 4 26 Remove boiler cladding The boiler cladding is removed in reverse order 6 For legend see Tab 4 13 ...

Страница 29: ...lled correctly If a pressure unit is used as a sep arate oil pump the installation location is also secured by a sealed tank and a filter cup made of metal The A2 F is fully connected The heating and if necessary the hot water system are filled and charged to the right pressure The oil valves are open and the oil line is topped up 5 1 2 Checks before start up 1 Check all connections for leakage 2 ...

Страница 30: ...ifications and of the requisite size yes 11 Is the safety valve connected to a safe free drain yes 12 Has the quality of the filling water been checked and has any necessary water preparation been carried out yes 13 System water pressure within prescribed range yes 14 Boiler and heating system vented yes 15 All sensors connected and correctly positioned yes 16 Mixer group mixer module and mixer ci...

Страница 31: ...d Control panel for the RoCon B1 The control panel is equipped with a coloured backlit clear text dis play INFORMATION Malfunctions are generally indicated by a fault code and a clear text fault message on the display For troubleshooting instructions refer to Chap 10 The colour of the backlighting indicates the operational status and the programming mode White Standard lighting normal operating di...

Страница 32: ...erminals Changing cables 1 Remove the boiler cladding see Chap 4 10 2 Open the boiler control panel see Chap 4 7 1 3 Remove the strain relief of the affected sensor or connection cable and lift out the cable 4 Pull out the corresponding connector from the circuit board dis connect the cable from the circuit board connector if necessary 5 Separate the other cable end from the component release plug...

Страница 33: ...onnect the sensor cable 4 Unscrew the sensor sleeve from the flue gas duct using an SW 24 wrench Fig 6 5 The flue gas temperature sensor can only be completely changed with the sleeve 5 Screw the new sensor sleeve into the flue gas duct and tighten it carefully using the SW 24 wrench plastic thread 6 Route the sensor cable into the boiler control panel connect the cable to the 6 pole PCB connector...

Страница 34: ...Oil condensing boiler A2 F 008 1546499_02 04 2018 EN 4 Close the boiler control panel INFORMATION If the fuse immediately blows upon switching on again there is a short circuit in the electrical system Have a pro fessional electrician remedy the cause for the short circuit before putting in a new fuse ...

Страница 35: ...led as standard is similar in design and func tion to EN 267 The burner is engaged on the burner flange with a bayonet lock and secured with a service screw The construction of the burner head with internal flue gas recirculation makes high effi ciency low nitrogen oxide combustion possible The burner tube is firmly mounted in the burner flange Oil preheating The heating oil is preheated during th...

Страница 36: ...ault code on the display on the control section Unlocking the burner INFORMATION The cause of the last fault is saved in the device and can be reconstructed even after power failure on restarting the device Locking faults detected by the firing unit can only be released manu ally directly on the boiler Requirements The cause of the malfunction has been rectified the burner is connected to the elec...

Страница 37: ...ads to higher boiler output while reducing the oil pressure leads to lower boiler output The oil pressure is monitored by the oil pump control unit For this purpose fixed values that cannot be changed are stored in the control unit Required tools Allen key SW 4 mm pressure gauge 1 8 0 28 bar 1 To check the oil pressure connect the manometer to the mano meter connection Fig 7 4 item 5 of the oil pu...

Страница 38: ...d CO2 below the tolerance O2 above the tolerance Decrease speed 6 Only change the settings in the respective power levels after the measured value has stabilised 7 The setting mode of a power level can be exited with the Exit key Then select the next power level to be checked within 15 seconds 8 The burner will continue to run for 15 seconds after pressing the Exit button if the Expert Config menu...

Страница 39: ... ELECTROCUTION Touching live parts can result in an electric shock and lead to potentially fatal injuries and burns Before removal of the burner shut off the main switch for the heater and secure against unintentional restart DANGER RISK OF BURNING Danger of burning on hot surfaces Let the burner cool down sufficiently before dismantling Wear protective gloves The burner requires annual maintenanc...

Страница 40: ...amber is open DANGER RISK OF BURNING Danger of burning on hot surfaces Let the burner cool down sufficiently before dismantling Wear protective gloves 1 Switch off the main heater switch 2 Remove the boiler cladding see Chap 4 10 3 Open the combustion chamber see Chap 9 2 3 4 Rotate the recirculation tube turn bayonet lock anticlockwise by 1 8 rotation Install the recirculation tube in reverse ord...

Страница 41: ...sensor 3 4 flow Inflow temperature sensor 5 6 flue Not assigned 7 8 DI2 Safety temperature limiter 9 10 DI3 Not assigned Tab 7 8 Assignment of the connection cables on the firing unit 7 6 Ignition transformer with flame monitor Fig 7 14 Ignition transformer Item Designation 1 Ignition cable connections 2x 7 5 kV 2 Status display LED 3 Flame monitor connection 4 Earth connection 5 Ignition connecti...

Страница 42: ...use paper filters of maximum 25 µm Oil burner pump function Fig 7 15 Oil burner pump function Item Designation Item Designation S Intake manifold NC Oil solenoid valve H Filter E Nozzle connection V Vacuum connection R Return flow connection pipe O Baffle P1 Pressure limiter P Manometer connection PT Pressure transducer Red Pressure Green Suction Yellow Return flow Tab 7 10 Legend for Fig 7 15 Oil...

Страница 43: ...turn valves 3UV DHW 3UV1 3 way distribution valve hot water heater 3UVB1 3 way mixer valve heater internal boiler circuit CW Cold water DHW Domestic hot water DS Pressure sensor FLS FlowSensor flow rate and inflow temperature measurement H 1 H 2 H m 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 e...

Страница 44: ...8 Hydraulic connection Installation and operating instructions 44 Daikin ROTEX A2 F Oil condensing boiler A2 F 008 1546499_02 04 2018 EN Fig 8 3 Connection diagram of A2 F with Smart Start kit ...

Страница 45: ...an the condensate drain Replacement of the wearing parts if required Documentation of the maintenance work in the operating manual Before restarting the A2 F after maintenance work the require ments for start up according to Chap 5 2 must be checked and fulfilled 9 2 Service and maintenance tasks DANGER RISK OF ELECTROCUTION Touching live parts can result in an electric shock and lead to potential...

Страница 46: ...nts must be carried out in accordance with the proper procedures otherwise there may be a danger to the life and health of individuals and the function of the A2 F may be impaired Rectification of damage to live components of the A2 F must only be carried out by heating engineers author ised and recognised by the energy supply company 1 Remove the boiler cladding see Chap 4 10 2 Check all oil and ...

Страница 47: ...ndensate siphon from the flue gas el bow remove the condensate box accessory Fig 9 5 Removing the siphon 4 Place a drip tray underneath Fig 9 6 Placing a drip tray underneath 5 Open the four screws on top of the combustion chamber Fig 9 7 Opening the combustion chamber 6 Remove the combustion chamber cover 7 Remove the turbolators Fig 9 8 Taking out the turbolators 8 Clean the turbolators with a s...

Страница 48: ...tling the burner see Chap 7 4 2 Clean the burner surface lapping plastic brush and check for damage 3 Visual inspection of the fuel lines for leaks clogging and denting 4 Check the oil filter replace filter insert if necessary 5 Clean the burner head at the fuel exit in the area of baffle plate INFORMATION In the course of maintenance work the safety relevant components must also be inspected for ...

Страница 49: ...screw item 6 with Allen key SW 3 Replace the ignition electrodes item 2 Tighten the fixing screw with Allen key SW 3 Dismantling oil nozzles 1 Pull out the ignition cables from the ignition electrodes item 2 2 Loosen the fixing screws item 3 and pull out the mixing device item 1 upwards 3 Unscrew the oil nozzle with a wrench or ring spanner SW 16 Hold back the nozzle linkage item 5 with an open en...

Страница 50: ...perating mode setting 9 Check the request parameter e g timer program 9 Heating does not warm up enough Heating characteristic too low Increase the parameter value 9 Carry out hydraulic balancing Hot water does not warm up Storage charging standby switched off e g time program is in economy phase Check the operating mode setting 9 Check the request parameters 9 Hot water does not warm up enough St...

Страница 51: ...lter not leakproof Replace the filter Oil pump power insufficient Replace the oil pump Oil atomisation not uni form heavy soot de position in flame tube Oil nozzle loose clogged or worn Check tighten change the oil nozzle Oil nozzle spraying angle is wrong Replace the oil nozzle No oil passage Oil nozzle clogged Replace the oil nozzle Mixer device has thick oil layer or heavy car bon deposition In...

Страница 52: ...ing unit On the error display Inside device Heating Module is displayed for the location information Code Component Designation Error E 1 Firing unit Temporary malfunction burner shutdown automatic release when fault condition no longer active Inflow temperature exceeds monitor temperature overtemperature no heat dissipation E 2 Return flow temperature exceeds monitor temperature overtemperature n...

Страница 53: ... Measured value under permissible minimum value Top up the heating water Leak test W8006 Warning message Maximum permissible pressure drop exceeded W8007 Warning message Measured value exceed per missible maximum value Check the diaphragm expansion vessel Drain the heating water Tab 10 4 Fault codes can be detected by the circuit board Inside device Boiler is displayed for location information 10 ...

Страница 54: ...tection functions are active If it is not possible to guarantee the oil and power supply when there is danger of frost then the A2 F must be drained the condensate box must be drained suitable antifreeze measures must be applied to the connected heating system and optional hot water storage tank e g draining Draining the heating circuit and hot water circuit 1 Switch off the main switch and secure...

Страница 55: ...ass as per EN 267 3 3 3 NOX emission class as per EN 267 3 3 3 Diameter of flue gas connection supply air con nection mm 80 125 Voltage V 230 Power supply frequency Hz 50 Max electric power consumption without with circulation pump W 184 242 204 264 228 289 Max electric power consumption in Standby operating mode W 3 4 Protection type IP X0B Tab 12 1 Basic data A2 F Boiler type A2 F 18H A2 F 24H A...

Страница 56: ...mpapst HRG134 Tab 12 3 Type designation of the burner components 12 1 1 Integrated heating circulation pump 3 way valves Parameters Unit Heating circulation pump Type Grundfos UPM3K 25 75 CHBL RT Voltage V 230 Frequency voltage supply Hz 50 Maximum power consumption W 60 Protection type IP X4D Permitted overpressure bar 3 Maximum pumping height m 7 5 Energy efficiency EEI 0 2 EN 16297 3 3 way valv...

Страница 57: ...eating energy efficiency ηS 91 92 93 Annual energy consumption QHE GJ 41 54 68 Noise power level LWA dB A 63 65 66 Tab 12 6 Product data sheet A2 F Type integrated temperature controller RoCon B1 BM2 Parameters Unit Class of the temperature con troller II Contribution to the seasonal space heating energy effi ciency 2 0 Tab 12 7 Product data sheet integrated control RoCon B1 BM2 Type of connected ...

Страница 58: ... In standby mode PSB 0 003 0 003 0 003 Heat loss in standby mode Pstby kW 0 093 0 093 0 093 Annual energy consumption QHE kW GJ 11397 41 15078 54 18953 68 Noise power level indoors LWA dB A 63 65 66 Nitrogen oxide output mg kWh 50 57 66 Tab 12 9 Technical data sheet A2 F 12 1 4 Tightening torque Component Remark Tightening torque in Nm Hydraulic line connections Water Thread 1 25 30 Sensor sleeve ...

Страница 59: ...ng network flow rate Q Heating output S Spread Tab 12 12 Legend for Fig 12 3 12 3 Temperature sensor Fig 12 4 Resistance characteristics of the temperature sensor Item Designation RS Sensor resistance T Temperature Tab 12 13 Legend for Fig 12 4 Measured temperature in C Temperature sensor Type Specification NCT tV1 tR tV2 tAU tDHW tMi PT1000 tAG Sensor resistance in Ohm according to standard or ma...

Страница 60: ... FLS B B1 A A1 A2 CANH CANL Vcc EXT EBA tV2 tAu tDHW tAG WP V B A B A A A B B L2 L1 N tR tV1 CM471 nc nc V1N V1L 1 1 1 X3 X2 X1 DI FI L Th N L L L L L L N N N N N oil mains RJ45 CAN J16 J8 J9 J13 J3 J12 J2 J14 J6 J11 J7 J5 J4 1 1 1 1 1 1 1 1 1 F1 RoCon BE2 1 1 1 1 J10 J1 J15 1 1 1 RoCon B1 1 S3 S5 S3 ON ON ON ON DP DP DP DP 1 1 1 1 2 2 2 2 3 3 3 3 4 4 4 4 N N COM 5V nc nc nc T X T X R X R X 1 1 1 ...

Страница 61: ...ensor boiler circuit J5 3 pin circuit board connector with pressure sensor cable tV2 Internal mixer sensor inflow temperature sensor heating circuit J6 4 pin circuit board connector with clamped mains cable and earthing slots tR Return flow temperature sensor J7 2 pin circuit board connector with PWM signal cable for heating circulation pump tAU External temperature sensor J8 12 pin circuit board ...

Страница 62: ...13 Notes Installation and operating instructions 62 Daikin ROTEX A2 F Oil condensing boiler A2 F 008 1546499_02 04 2018 EN 13 Notes ...

Страница 63: ...53 Flue gas mass flow 17 Flue gas system Measurement 16 Flue gas system Minimum requirements 16 Flue gas system Piping height 16 Fuel Information 10 I Installation area 15 Installation height 15 Installation in garages 15 Installation in the attic 15 Installation room 15 Installation room Requirements 6 Installation site 15 Installation versions Ambient air independent operation 12 Installation ve...

Страница 64: ...ng load types are available for selection Off The emission measurement is switched off any heat generators switched on by the A2 F control functions con tinue to be regulated normally Base load The heat generator is switched on and operated at the minimum output of the heat generator irrespective of the set operating mode Full load The heat generator is switched on and operated at the maximum outp...

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