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8

Hydraulic connection

Installation and operating instructions

51

Gas Combi Unit
Floor-standing gas condensing boiler with integrated heat storage
008.1543899_02 – 04/2019 – EN

8

Hydraulic connection

WARNING

To prevent flue gas from escaping, the storage tank must
be filled to overflowing when commissioning the GCU com-
pact.

DANGER: RISK OF BURNING

High temperatures can occur in the solar storage tank.
Therefore, sufficient scalding protection must be included
when the hot water system is installed (automatic hot water
mixing device).

CAUTION

We recommend equipping the GCU compact with plastic
gravity brakes. They are suitable for maximum operating
temperatures of 95 °C.

8.1

Hydraulic system connection

INFORMATION

A selection of diagrams of the most common systems is
shown below. The arrangements shown are only ex-
amples, and are no substitute for careful system planning.

Further diagrams can be found on the homepage on the
back of this manual.

Short name

Meaning

1

Cold water distribution network

2

Hot water distribution network

3

Heating flow

4

Heating return flow

5

Mixing circuit

6

Circulation

7

Check valve, return valve

7a

Circulation stop valves

8

Solar circuit

3UV DHW

3-way distribution valve (hot water/heater)

3UVB1

3-way mixer valve (heater/internal boiler circuit)

Short name

Meaning

CW

Cold water

DHW

Domestic hot water

DSR1

Pressurised solar system

FLS

FlowSensor - solar 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-efficiency pump (PWM-regu-
lated)

P

K

Boiler circuit pump

P

Mi

Mixing circuit pump

P

S

Solar operating pump

P

S1

Solar operating pump

P

Z

Circulation pump

RDS2

Pressure station

RoCon BF

Control GCU compact

RoCon M1

Mixer circuit control

RPS4

Solar control and pump unit

SK

Solar panel field

SV

Safety overpressure valve

t

AU

Outside temperature sensor

t

DHW

Storage tank temperature sensor

t

Mi

Inflow temperature sensor, mixer circuit

TK

Solaris collector temperature sensor

TR

Solaris return flow temperature sensor

TS

Solaris storage cylinder temp. sensor

TV

Solaris inflow temperature sensor

VS

Burns guard VTA32

Tab. 8-1

Legend for

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Содержание GCU compact Series

Страница 1: ...at storage English Installation and operating instructions GCU compact GCU compact 315 GCU compact 320 GCU compact 515 GCU compact 520 GCU compact 524 GCU compact 528 GCU compact 315 Biv GCU compact 3...

Страница 2: ......

Страница 3: ...onnect the gas line check the burner setting for gas type 36 4 8 1 Important instructions for gas connection 36 4 8 2 Connecting the gas line 36 4 8 3 Removing attaching the heat cell panelling 36 4 8...

Страница 4: ...es 69 12 1 5 Information on the type plate 70 12 1 6 Data sheets according to Ecolabel and Ecodesign regulation EU 811 2013 and EU 813 2013 70 12 2 Gas type connection pressures 72 12 3 Tightening tor...

Страница 5: ...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 Establish the power supply in ac...

Страница 6: ...torque see Chap 12 3 Only applies to devices with unpressurised solar system connection DrainBack Only applies to devices with a bivalent solar system connec tion Biv Handling instructions 1 Handling...

Страница 7: ...further conditions regarding the installation room Only this method of operation is permissible for installation in residential rooms Make sure that there is an outside air opening of at least 150 cm2...

Страница 8: ...t pollution by backflow EN 61770 Electric appliances connected to the water mains Avoidance of backsiphonage and failure of hose sets EN 806 Specifications for installations inside buildings con veyin...

Страница 9: ...tructions and operating 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 fi...

Страница 10: ...grated heat storage 008 1543899_02 04 2019 EN 3 Product description 3 1 Design and components 3 1 1 GCU compact 315 320 Biv Fig 3 1 Design and components of GCU compact 315 320 Biv for legend designat...

Страница 11: ...r with integrated heat storage 008 1543899_02 04 2019 EN 3 1 2 GCU compact 515 520 524 528 Biv Fig 3 3 Design and components of GCU compact 515 520 524 528 Biv for legend designations see Tab 3 1 Fig...

Страница 12: ...l for bivalent storage charging 3 19 Bivalent storage charging inflow 1 3 1 IG 20 Bivalent storage charging return flow 1 3 1 IG 21 Solar inflow layering pipe 22 Heating circulation pump 23 Burner fan...

Страница 13: ...piral shape there is definite temperature stratification within the hot water storage tank As high temperatures can be maintained for a very long time in the upper section of the storage tank a high h...

Страница 14: ...ol and room ther mostat The controller can be connected to the Internet via the optional gate way RoCon G1 This enables remote control of the GCU compact by mobile phone using an app Calorific value e...

Страница 15: ...tion would render the manufacturer s guarantee void If you have questions please contact our Technical Customer Service 4 1 Dimensions and connection dimensions Fig 4 1 Installation dimensions for flu...

Страница 16: ...008 1543899_02 04 2019 EN 4 1 1 Connecting dimensions for the heating and hot water connections GCU compact 3xx Fig 4 3 GCU compact 3xx connection dimensions view from the back For legend of position...

Страница 17: ...Chap 4 2 1 to Chap 4 2 3 CA Supply air combustion air FG Flue gas RV Rear ventilation a Installation variant for ambient air independent operation flue gas supply air concentric b Installation variant...

Страница 18: ...tric dual pipe as in Installation variant 2 In the area of the 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...

Страница 19: ...of 50 cm 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 Vertical opening for the flue gas outlet and supply...

Страница 20: ...the unfilled state and could tip over during transport which could put persons in danger or damage the device Secure the GCU compact well transport carefully use handles The GCU compact is delivered o...

Страница 21: ...component outside the device panels Therefore no minimum distance is specified for components made of flammable materials A minimum distance of 50 mm between the flue gas line and flam mable componen...

Страница 22: ...A consists of pres sure sensitive EPP moulded parts that can be easily dam aged if not handled correctly Only remove the thermal insulation in the order stated below and in the stated directions Do no...

Страница 23: ...rizontal sections of the flue gas line at least 3 Counter slopes are not permissible at any point in the flue gas line so that condensate can drain off without restriction If more than 3 deflections 4...

Страница 24: ...irements 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 components or their means of...

Страница 25: ...ed flue gas pipe LW Double walled exhaust pipe for outdoor use MA Outer wall opening closure MSD Opening silencer PA Test adapter RV Inspection piece SB Support for flue SD Sloping roof tile WA Wall d...

Страница 26: ...e to an ex cessively high inflow temperature at these connections The inflow temperature of the external heater should be limited to max 95 C CAUTION Corrosion may be caused by air entering the heatin...

Страница 27: ...op thermal insulation see Chap 4 4 3 Fig 4 20 Aligning the heating inflow and return flow upwards 2 Pull the two securing clips off the connection couplings Fig 4 20 item C 3 Pull off the two connecti...

Страница 28: ...4 6 2 Connecting hydraulic lines 1 Check the cold water connection pressure maximum 6 bar If a higher pressure is present in the domestic water pipe a pressure reducer will need to be installed 2 Esta...

Страница 29: ...in hoses with hose clamps on connection nozzles 3 The complete outlet must not be lockable and must discharge the condensation and any medium leaking due to damage drinking water buffer or heating wat...

Страница 30: ...to connectors or other electrical equipment components Device covers and service panels must be replaced as soon as the work is completed All GCU compact control and safety devices are connected read...

Страница 31: ...ief in the controller housing by means of cable ties must be ensured for all cables connected to the GCU com pact 10 Check the holding force of the strain relief 11 Open the front panel Fig 4 31 12 In...

Страница 32: ...ction J6 Mains connection J8 Sensors switching contacts J9 FlowSensor FLS1 J12 3UV DHW J13 CAN system bus J14 Circulation pump PZ J16 Room thermostat Cable colours bl Blue br Brown ye Yellow gn Green...

Страница 33: ...CAUTION The use of temperature sensors that are not approved or unsuitable for the device can lead to major malfunctions during controlled operation of the GCU compact and impair the control function...

Страница 34: ...see Chap 4 7 8 A connected room thermostat has to be activated by the Room thermostat parameter on the RoCon BF controller In Heating operating mode and during the active heating phases of the time pr...

Страница 35: ...ting and operation 4 7 8 Room thermostat INFORMATION A separate manual containing instructions about installa tion and operation is included with this component Fig 4 38 Room thermostat connected by c...

Страница 36: ...as connection complies with the technical regulations for gas installations as well as the relevant regulations of the destination country and the gas supply company A thermally triggered blocking dev...

Страница 37: ...9 Filling the system Only fill the GCU compact 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 in...

Страница 38: ...for the start phase In the event of problems when starting see Chap 10 3 Configure the heating system on the RoCon BF controller For configuration and explanation see the enclosed RoCon BF controller...

Страница 39: ...nd GCU compact 515 for various gas types Type GCU compact 320 520 Biv Gas type test gas 10 Burner load O2 content in CO2 content in Natural gas E H G20 Base Load 6 5 7 2 7 7 8 1 Full Load 5 6 6 3 8 2...

Страница 40: ...ary water preparation been carried out Yes 13 System water pressure within prescribed range Yes 14 Boiler and heating system filled vented and charged with the correct pressure Yes 15 All sensors conn...

Страница 41: ...ighting indicates the operational status and the programming mode White Standard lighting normal operating display Red Fault status the boiler continues to operate with restric tions depending on the...

Страница 42: ...al insulation see Chap 4 4 3 DANGER RISK OF ELECTROCUTION Touching live parts can result in electric shock and lead to potentially fatal injuries and burns Before beginning work on the GCU compact dis...

Страница 43: ...3 3 Fold open the front panel of the controller housing see Chap 4 7 1 Remove the plug from connection J8 and dis connect the sensor cable 4 Pull the internal mixer sensor tV2 on the cable out of the...

Страница 44: ...7 Heat cell with gas burner 7 1 Design and brief description Fig 7 1 GCU compact Heat cell legend Tab 7 1 Fig 7 2 Components of the GCU compact heat cell Gas section exploded view for legend see Tab 7...

Страница 45: ...down and fault indicator You can find an overview of locking and temporary fault shutdowns in Chap 10 3 Tab 10 2 to Tab 10 4 INFORMATION A locking fault can only be reset manually on the controller of...

Страница 46: ...etting values for GCU compact 320 and GCU compact 520 for various gas types Type GCU compact 524 Biv Gas type test gas 13 Burner load in kW with Full Load O2 content in CO2 content in Set Set Natural...

Страница 47: ...e specified setting values see Chap 7 3 1 If the O2 CO2 concentrations are within the permissible values No further measures required If the O2 CO2 concentrations are outside the permissible values Ca...

Страница 48: ...adjust the Corr power start parameter 5 Confirm the changes with a brief push of the rotary switch 6 Switch the GCU compact off and then on again 7 Generate a burner demand e g heating operation Burn...

Страница 49: ...correct assembly and dismantling of the burner can cause the gas to escape Always replace the seals Observe the fitting positions DANGER RISK OF BURNING Danger of burning on hot surfaces Let the burne...

Страница 50: ...t on the burner surface remove it carefully from the perforated plate side with a vacuum cleaner Never blow over the burner surface with compressed air This could cause changes to the surface structur...

Страница 51: ...tion network 3 Heating flow 4 Heating return flow 5 Mixing circuit 6 Circulation 7 Check valve return valve 7a Circulation stop valves 8 Solar circuit 3UV DHW 3 way distribution valve hot water heater...

Страница 52: ...52 Gas Combi Unit Floor standing gas condensing boiler with integrated heat storage 008 1543899_02 04 2019 EN Fig 8 1 GCU compact 3xx example with DrainBack Solar For legend see Tab 8 1 Fig 8 2 GCU c...

Страница 53: ...nd lead to potentially fatal injuries and burns Before beginning work on the GCU compact disconnect it from the power supply fuse switch off the main switch and secure against unintentional restart DA...

Страница 54: ...e on heat exchanger tubes 4 Clean the combustion chamber Fig 9 4 Vacuum deposits from combustion chamber INFORMATION Deposits on the heat exchanger tubes must be vacuumed dry Do not flush the combusti...

Страница 55: ...al service life Combustion control 10 years or 250 000 burner starts Safety gas control block 10 years or 250 000 burner starts Overpressure safety valve 10 years 3 If necessary replace any faulty par...

Страница 56: ...ECTROCUTION 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...

Страница 57: ...g 9 8 item A Fig 9 8 Undoing the automatic vent valve cap A Automatic vent valve cap 3 Open the water tap Fig 9 7 item 6 on the feed pipe 4 Open the fill drain cock Fig 9 7 item 2 and observe the pres...

Страница 58: ...ump and various settings of the 3 way switch valves integ rated in the GCU compact Any air present can escape via the automatic vent valve dur ing the ventilation function and the hydraulic circuit co...

Страница 59: ...ch for the boiler Turn on the main switch of the heating room Check switch on the fuse house connection Check renew the boiler control panel fuse Only use the same type of fuses Heating does not warm...

Страница 60: ...heck the ignition electrodes and adjust as required Ignition electrodes contaminated or humid Clean the ignition electrodes and check the burner settings Ignition electrodes burnt out Replace the igni...

Страница 61: ...ure too low E 191 Internal electronic error from 2nd error switch device on off E 192 A value fell below the minimum limit values during calibration flue gas recirculation electrodes oxidised ionisati...

Страница 62: ...period wind effect speed fluctuations blower Tab 10 3 Error codes for temporary faults can be detected by the combustion control Code Component Designation Error Possible error rectification E 72 Int...

Страница 63: ...switch to select the FA failure level Error code and Reset request is displayed 4 Select Yes with the rotary switch 5 Confirm the changes with a brief push of the rotary switch Error is reset 6 Cance...

Страница 64: ...nnec ted heat distribution system 11 1 1 Draining the storage tank 1 Switch off the main switch and secure against restarting 2 Close the gas stop valve 3 Connect the drain hose to the combined fillin...

Страница 65: ...valve insert on the connection bracket so that the path to the drain hose is open see also Fig 11 5 and drain the water content of the storage tank 11 1 2 Draining the heating circuit and hot water c...

Страница 66: ...professional manner Recommendations for disposal The GCU compact has an environmentally friendly design During the disposal process the only waste created is that which can be used for material or th...

Страница 67: ...min 22 23 Continuous output QD according to DIN 4708 kW 15 20 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 up to 15 l m...

Страница 68: ...26 Continuous output QD according to DIN 4708 kW 15 20 24 28 Max draw 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 up to 1...

Страница 69: ...C53 C63 C83 C93 NOx class acc to EN 15502 1 4 30 6 NOx output with reference to calorific value HS mg kWh 23 31 31 31 Boiler body water content litres 0 5 0 8 Max permissible operating pressure 12 30...

Страница 70: ...of destination 20 Appliance category EN 437 21 Nominal connection pressure for natural gas 22 Nominal connection pressure for liquid gas 23 Gas type 24 Minimum burner load 25 Maximum burner load 26 G...

Страница 71: ...010 30 EC For the correct selection of products for your application contact your dealer Boiler type GCU compact Parameters Unit 315 315 Biv 320 320 Biv 515 515 Biv 520 520 Biv 524 524 Biv 528 528 Biv...

Страница 72: ...E II2N3P 20 25 50 DE II2ELL3P 20 50 AT CZ SK II2H3P 20 50 ES FR GB GR HR IE IT LT PT SI SK II2H3P 20 37 BE ES FR GR NL PT SI II2N3P 20 25 37 NL II2L3P 25 37 NL II2EK3P 20 25 37 HU II2H3P 25 30 FR II2E...

Страница 73: ...ion range Fig 12 3 Required flow rates depending on the heating output and the dimensioned temperature spread mH Heating network flow rate Q Heating output 12 5 Temperature sensor Fig 12 4 Resistance...

Страница 74: ...nstallation and operating instructions 74 Gas Combi Unit Floor standing gas condensing boiler with integrated heat storage 008 1543899_02 04 2019 EN 12 6 Electrical connection diagram Fig 12 5 Wiring...

Страница 75: ...er blower speed regulation GMV Voltage supply for gas solenoid valve GPV Voltage supply for plunger coil TRA1 Ignition transformer CM 434 Automatic combustion control J1 3 pin circuit board connector...

Страница 76: ...13 Notes Installation and operating instructions 76 Gas Combi Unit Floor standing gas condensing boiler with integrated heat storage 008 1543899_02 04 2019 EN 13 Notes...

Страница 77: ...13 Notes Installation and operating instructions 77 Gas Combi Unit Floor standing gas condensing boiler with integrated heat storage 008 1543899_02 04 2019 EN...

Страница 78: ...13 Notes Installation and operating instructions 78 Gas Combi Unit Floor standing gas condensing boiler with integrated heat storage 008 1543899_02 04 2019 EN...

Страница 79: ...ng Heating system 37 Storage tank 37 Filling connection 64 Filling water 38 Flow rate 73 Flow temperature sensor 13 43 FlowSensor 13 42 Flue gas collector 13 45 Flue gas mass flow 23 Flue gas system K...

Страница 80: ...splayed 2 Use the rotary button to select the Emissions measurement program 3 Confirm the changes with a brief push of the rotary switch The following load types are available for selection Off The em...

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