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For certified companies

ROTEX
A1 BG
Installation and maintenance
instructions

Gas condensing boiler

For the types

A1 BG 25-e
A1 BG 25F-e
A1 BG 40-e
A1 BG 40F-e

Output 02/2014

0085 AS 0011

Содержание A1 BG Inline

Страница 1: ...For certified companies ROTEX A1 BG Installation and maintenance instructions Gas condensing boiler For the types A1 BG 25 e A1 BG 25F e A1 BG 40 e A1 BG 40F e GB Output 02 2014 0085 AS 0011...

Страница 2: ...ng the operating section RoCon B1 25 6 3 Changing the boiler control panel 25 6 4 Changing cables 26 6 5 Changing the sensors 27 6 5 1 Changing flow return flow temperature sensor 27 6 5 2 Changing th...

Страница 3: ...List of contents FA ROTEX A1 BGe 02 2014 3 14 Notes 60 15 For the chimney sweep 64 15 1 Data for designing the flue gas pipe 64 15 2 Emissions measurement 64...

Страница 4: ...Heating Systems GmbH declare under our sole responsibility that the products Product Order No Product Order No ROTEX A1 BG 25 e 15 59 35 ROTEX A1 BG 25F e 15 59 36 ROTEX A1 BG 40 e 15 59 42 ROTEX A1 B...

Страница 5: ...ROTEX 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 damag...

Страница 6: ...tion 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 mmol l sum of the calc...

Страница 7: ...ing return flow cold 10 Heating flow hot 11 Pressure sensor 12 Flue gas supply air connection 13 Condensate box 14 Condensate drain 15 Air supply hose 16 Flame tube 17 Combustion chamber insert 18 Flu...

Страница 8: ...ing fault signal provides an engineer with all the necessary information for troubleshooting Electronic control An electronic digital controller combined with the intelligent au tomatic firing unit of...

Страница 9: ...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...

Страница 10: ...ler frame and sub tank for legend see tab 4 1 A1 BG 25 F e A1 BG 40 F e Dim on the floor on the sub tank on underframe on the floor on the sub tank on underframe a 400 b 720 c 135 15 785 15 500 15 135...

Страница 11: ...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 durati...

Страница 12: ...e via the ade quately sealed inlet air through the external wall The air inlet line should be sized so that the suction resistance at nomi nal power is less than 50 Pa Flue gas dissipation to the outd...

Страница 13: ...gonal spanner for burner and heat exchanger Recommended accessory Safety group SGB A1 15 60 18 with pressure gauge safety valve automatic bleeding filling cock connection fit tings Connection kit A1 V...

Страница 14: ...system must be recognisable on the in stalled system Place the nameplate of the flue system in the installation room Type of connections Straight directly towards rear SET C 15 50 79 03 Height offset...

Страница 15: ...4 5 1 The flue system fulfils any other required national or regional safety requirements The ROTEX A1 is installed correctly Connection Connect ROTEX A1 to the flue gas system within the place of ins...

Страница 16: ...16 FA ROTEX A1 BGe 02 2014 4 x Set up and installation 4 5 3 Flue gas system kits Fig 4 8 Flue gas system components if necessary...

Страница 17: ...of technology to prevent creation of corrosion products and deposits Measures for desalination softening or hardness stabilization are necessary if the filling and top up water have a high total hard...

Страница 18: ...ncerning electrical connection All electronic control and safety systems of the ROTEX A1 are connected and tested Modifications on the electrical installation are dangerous and prohibited The operator...

Страница 19: ...obe line and connect to the ROTEX A1 controller Connect the external temperature sensors with a dual core cable minimum cross section 1 mm2 Storage tank temperature sensor The storage tank temperature...

Страница 20: ...corrugated hose fig 4 10 Item 3 pipe thread EN 2999 Rp to the gas line without tension 4 9 3 Checking burner pre setting Compare the available gas type with the set gas type sticker on burner housing...

Страница 21: ...ttings KFE cock fig 4 3 item 3 and secure against sliding by using a hose clamp Open water cock on the supply line Open the KFE cock and observe the pressure gauge in safety group SGB A1 15 60 18 Fill...

Страница 22: ...tion ROTEX Controller RoCon BF Check the resistance in the flue gas line see chapter 4 5 1 Check the burner adjustments with a flue gas analyser and readjust if necessary see chapter 7 3 Burner settin...

Страница 23: ...on the flow connection and PCB plug inserted Yes 16 Are all sensors connected correctly positioned and activated Yes 17 Mixer group mixer module and mixer circuit sensor optional connected correctly Y...

Страница 24: ...und 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 8 S...

Страница 25: ...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...

Страница 26: ...in the unit 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...

Страница 27: ...d Do not force the connector WARNING Live parts can cause an electric shock on contact and cause life threatening burns and injuries Before beginning work on the ROTEX A1 disconnect therom the power s...

Страница 28: ...re 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...

Страница 29: ...t 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 Communicati...

Страница 30: ...30 FA ROTEX A1 BGe 02 2014 6 x Control unit Fig 6 16 Wiring diagram ROTEX A1 BG for legend see tab 6 1...

Страница 31: ...ment connection IN input gas pressure 10 Measurement connection OUT output gas pressure 11 Gas air mixture set screw 12 Gas pressure controller set screw beneath cover cap 13 Burner flange 14 1 Ionisa...

Страница 32: ...s automatic firing CM124 R1 controlled by a micropro cessor controls and monitors the firing programme and the temperature sensors for the flow and return temperature It features the following propert...

Страница 33: ...ation is installed The blower type can be read off of the type plate of the blower near the outlet flange on the blower housing If changes have been made to the power settings of the burner or if it h...

Страница 34: ...burner ROTEX Factory settings Tab 7 2 Flue gas set values and speed limits for A1 BG 25 F e for different types of gas A1 BG Type A1 BG 40 F e G1G 126 Blower type Gas type Test gas Setting for control...

Страница 35: ...th the specified setting values see section 7 3 1 11 If the CO2 concentration is outside 0 2 or the O2 concentration is outside 0 3 of the set target values Readjust burner using the adjusting screw f...

Страница 36: ...uri nozzle fig 7 8 step 2 7 Remove the brass bezel between the safety gas control block and the venturi nozzle fig 7 8 step 3 8 Using the 3 screws screw the Venturi nozzle back on the safety gas contr...

Страница 37: ...out by Determining the matching setting values for the desired out put from fig 12 4 to fig 12 7 or tab 7 2 and tab 7 3 Limiting the maximum burner output The limiting of the maximum burner output wou...

Страница 38: ...start power may help For deflagrations Reduce the starting output For starting problems such as burner whistling or flame forming Increase the starting output To change the starting output 1 Enter the...

Страница 39: ...ctrodes are factory set to the optimum value For adjusting see fig 7 10 CAUTION Ignition electrodes can break with cold deformation Dismantle the burner before adjusting the electrodes and make the el...

Страница 40: ...e all electrical plug connections 3 Connect the air supply hose to the burner 4 Open gas intake and check gas line for leaks 5 Turn power supply back on 6 Start the burner Check function and setting s...

Страница 41: ...tem 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 p...

Страница 42: ...to centre position with hand lever fig 8 4 item 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 Unlo...

Страница 43: ...n return 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 expan...

Страница 44: ...ation 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 Remove the sound insulation...

Страница 45: ...ch it drain The water must flow quickly without puddling If the water doesn t drain quickly the condensate box must be cleaned and the drain connector checked see Dismount ing and cleaning the condens...

Страница 46: ...xible connector hose and drain connector and clean if necessary 8 Push condensate box under the boiler 9 Plug flexible connector hose onto the condensate box see fig 4 11 10 Place the connection sleev...

Страница 47: ...ner see chapter 7 3 Opening the combustion chamber Special tool Combustion chamber key fixed on the inside of the boiler panels included in the supply Remove four M10 inner hex screws fig 9 11 Hinge t...

Страница 48: ...and cleaning scraper Rinse off loosened dirt with clean water into the drain Alternatively any residue can be removed with a high pressure cleaner For this Close combustion chamber without combustion...

Страница 49: ...ment operating mode Check combustion values Flue gas temperature at measuring sockets of the flue gas pipe Target value 90 C O2 or CO2 content see chapter 7 3 1 Settings CO content target value 50 ppm...

Страница 50: ...not functioning main switch not illuminated no display 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 f...

Страница 51: ...st or replace if necessary Distance of ignition electrodes too large Check ignition electrodes and adjust if necessary Ignition electrodes contaminated or humid Clean ignition electrodes and check bur...

Страница 52: ...E34 BCC data conflict E35 Necessary BCC not detected E36 BCC data conflict E37 BCC firmware does not match automatic firing firmware E38 Wrong BCC number E39 BCC system fault E99 Safety shutdown E6 A...

Страница 53: ...not actuate The ROTEX A1 operates manually at the set flow temper ature 4 Cancelling and jump back by pushing the Exit button again Code Component Designation Fault Possible fault rectification E75 O...

Страница 54: ...stem at the filling and draining sockets KFE cock 11 2 Final shutdown and disposal For the final shutdown the ROTEX A1 must be Taken out of service Disconnect it from all electrical gas and water conn...

Страница 55: ...permitted operating temperature 90 C Maximum permitted operating overpressure PMS 4 bar Maximum boiler efficiency 109 Energy efficiency according to efficiency guidelines Flue gas temperature 85 C Flu...

Страница 56: ...g circulation pump and the 3 way diverter valve from connecting kit VSA1 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 L...

Страница 57: ...ner load of the ROTEX A1 BG 25 F e Fig 12 3 Permissible burner load of the ROTEX A1 BG 40 F e legend see fig 12 2 pR Remaining pumping height mH Flow heating network Fig 12 4 Residual conveying height...

Страница 58: ...ccording 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...

Страница 59: ...lue gas mass flow 15 Flue gas temperature probe 28 Check 47 Flue system Dimensioning 14 Kits 16 Minimum requirements 14 Piping height 14 Flue system kits 16 Fuel 6 Fuse 29 G Gas connection Execution 2...

Страница 60: ...60 FA ROTEX A1 BGe 02 2014 14 x Notes 14 Notes...

Страница 61: ...14 x Notes FA ROTEX A1 BGe 02 2014 61...

Страница 62: ...62 FA ROTEX A1 BGe 02 2014 14 x Notes...

Страница 63: ...14 x Notes FA ROTEX A1 BGe 02 2014 63...

Страница 64: ...oad type Full Load using the rotary switch but do not confirm it Display Full Load The burner is turned on for 30 min and is regulated at maximum load Select the load type Base Load using the rotary s...

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