Anda di halaman 1dari 76

For certified companies

ROTEX GasSolarUnit
Gas condensing boiler with stratified solar storage tank Installation and Operating Instructions

0085 BM 0065
Type Rated thermal output ROTEX GSU 320(F)-e 3 - 20 kW modulating ROTEX GSU 520S(F)-e 3 - 20 kW modulating ROTEX GSU 530S(F)-e 7 - 30 kW modulating ROTEX GSU 535(F)-e 8 - 35 kW modulating Serial number

GB Edition 04/2012

Customer

Guarantee and conformity


Warranty conditions
The legal guarantee conditions fundamentally apply. Our warranty conditions beyond that can be found online on your sales presentative's webpage.

Declaration of conformity
For the central condensing boiler units ROTEX GasSolarUnit We, ROTEX Heating Systems GmbH, declare under our sole responsibility that the products Product ROTEX GSU 320-e ROTEX GSU 520S-e ROTEX GSU 530S-e ROTEX GSU 535-e Order No. 15 70 31 15 71 13 15 71 25 15 71 43 Product ROTEX GSU 320 F-e ROTEX GSU 520S F-e ROTEX GSU 530S F-e ROTEX GSU 535 F-e Order No. 15 70 32 15 71 14 15 71 26 15 71 48

with the product identification number CE 0085 BM 0065 comply, in their standard design, with the following European Directives: 2004/108/EG 2009/142/EC 2006/95/EC 92/42/EEC Electromagnetic compatibility directive Gas appliances directive EC Low Voltage Directive Boiler efficiency requirements directive

Gglingen, 01.04.2012

Dr.-Ing. Franz Grammling Managing director

FA ROTEX GSU - 04/2012

List of contents
1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 1.2 1.3 1.4 1.5 1.5.1 1.5.2 1.5.3 1.5.4 1.5.5 1.5.6 1.5.7 1.5.8 Refer to the manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warnings and explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Avoid danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Proper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fundamental instructions for operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Before working on the hot water storage tank and the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit installation room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements for the heating water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heating system and sanitary connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instructing the user/owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5 6 6 6 6 6 6 7 7 7 7 7

Product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 2.2 Structure and Components of GasSolarUnit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Set-up and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12


3.1 Dimensions and connection dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Different set-ups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.1 Operation independent of ambient air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.2 Operation partially independent of ambient air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.3 Ambient air dependent operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Transport and delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 Installing the GasSolarUnit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.1 Selecting the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.2 Erecting the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 Air/flue system (LAS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.1 General instructions for flue system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.2 Connect flue gas line to the GSU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.3 Flue gas system kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 Water connection for heating and hot water pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 Connect the condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 Connect valve drive to the 3-way switch valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 Establish connection and electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 Temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.1 General instructions for the temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.2 Connecting the temperature sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11 Connect the gas line, check the burner setting for gas type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11.1 Important instructions for gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11.2 Connecting the gas line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11.3 Checking burner pre-setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12 Optional connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12.1 Mixer circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12.2 Flue gas temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12.3 Room temperature controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12.4 Room station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13 Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 14 15 16 16 16 17 17 18 18 18 20 21 22 23 23 24 25 25 25 26 26 26 27 27 27 27 27 27 28

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.2 Tests prior to start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.4 Setting the heating circulation pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Checklists for start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 29 29 29 30 30

FA ROTEX GSU - 04/2012

List of contents
5 Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.1 5.2 5.3 5.4 5.5 5.6 5.7 Controls on the boiler control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Changing the central unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Changing the boiler control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Changing cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Changing the sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Changing the fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Gas burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.1 6.2 6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7 6.4 Structure and brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Unlocking in the event of malfunction shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Burner setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Setting values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Checking and setting the burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Carrying out the basic setting on the burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Resetting the gas type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Adjusting the output limits and the starting output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Setting the gas pressure controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Setting ignition and Ionisation electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Dismantling the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Hydraulic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.1 Important information on the hydraulic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 7.2 Storage tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 7.3 Hydraulic system connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 7.3.1 Short names in the connection schemes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 7.3.2 ROTEX GasSolarUnit with solar heating support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Service and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56


8.1 General overview of inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 8.2 Service and maintenance tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 8.2.1 Checking the connections and pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 8.2.2 Checking and cleaning the condensate drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 8.2.3 Checking and cleaning the burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Faults and malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59


9.1 9.2 9.3 9.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Fault code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Emergency operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

10

Taking out of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63


10.1 10.2 Temporary shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Final decommissioning and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

11 12 13 14

Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 List of keywords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 For the chimney sweep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

FA ROTEX GSU - 04/2012

1 x Safety
1 1.1 Safety to the manual Refer

This instruction is compiled for authorised and trained heating engineers that have, due to their professional education and their expert knowledge, experiences with the correct installation and maintenance of heating systems as well as with gas installations. All required activities for installation, commissioning, operation and maintenance are described in this operating instruction manual. All heating parameters needed for smooth operation are already factory-set. Please refer to other relevant documents for information on setting the control. Please read this manual carefully and thoroughly before proceeding with the installation or modification of the heating system.

Relevant documents
ROTEX GSU: Operating manual for the user/owner. The document is included in the scope of delivery. The documentation of the installed ROTEX control system. This documentation is included in the scope of delivery.

1.2

Warnings and explanation of symbols


Meaning of the warnings
The warnings are classified in this manual according to their severity and probability of occurrence. DANGER! Draws attention to imminent danger. Disregarding this warning can lead to serious injury or death. WARNING! Indicates a potentially dangerous situation. Disregarding this warning may result in serious physical injury or death. CAUTION! Indicates a situation which may cause possible damage. Disregarding this warning can lead to damage to property and the environment.

This symbol identifies user tips and particularly useful information, but not warnings or hazards.

Special warning signs


Some types of danger are represented by special symbols: Danger of explosion Risk of poisoning Electrical current Danger of burning or scalding

Order number
Notes related to order numbers are identified by the shopping cart symbol .

Handling instructions
Instructions on actions are shown as a list. Actions of which the sequential order must be maintained are numbered. Results of actions are identified with an arrow.

FA ROTEX GSU - 04/2012

1 x Safety
1.3 Avoid danger
The ROTEX GSU is state-of-the-art and is built to meet all recognised technical requirements. However, improper use may result in serious physical injuries or death, as well as property damage. To prevent such risks, install and operate ROTEX GSU only: as stipulated and in perfect condition, with an awareness of safety and the hazards involved. This assumes knowledge and use of the contents of this manual, of the relevant accident prevention regulations as well as the recognised safety-related and occupational health rules.

1.4

Proper use
The ROTEX GSU may be used exclusively as hot water heating system. The GasSolarUnit must be installed, connected and operated only according to the indications in this manual. The ROTEX GSU must only be operated with the integrated circulation pump and only in connection with a control system that has been approved by ROTEX. Any other use outside the above-mentioned use is considered as improper. Any resulting damages will be borne by the user/owner alone. Proper use also includes observing the relevant maintenance and servicing conditions. Spare parts must at least satisfy the technical requirements defined by the manufacturer. This is the case, for example, with original spare parts.

1.5

Fundamental instructions for operational safety


1.5.1 Before working on the hot water storage tank and the heating system
Works at the domestic hot water storage tank and the heating system (such as the installation, the connections and the initial commissioning) must only be conducted by authorised and trained heating engineers. Switch off the mains supply before starting any work on the hot water storage tank and heating system and secure it against unintentional switch-on. Lead tamper-proof seals must not be damaged or removed. Make sure that the safety valves comply with the requirements of EN 12828 when connecting on the heating side, and with the requirements of EN 12897 when connecting on the domestic water side.

1.5.2 Electrical installation


Electrical installations must only be conducted by electrical engineers and in compliance with valid electrical guidelines as well as the specifications of the energy supply company. Before completing the mains connection, compare the mains voltage, indicated on the type plate (230 V, 50 Hz) with the supply voltage. Before beginning work on live parts, disconnect them from the power supply (switch off main switch, remove fuse) and secure against unintentional restart. Equipment covers and service panels must be replaced as soon as the work is completed.

1.5.3 Unit installation room


Operate GasSolarUnit only if sufficient combustion air supply is ensured. If you operate the ROTEX GSU in a room-air independent manner with a concentric air/flue gas system (LAS) dimensioned as per ROTEX standard, this is fulfilled automatically and there are no other conditions for the equipment erection room. With installation in residential rooms, this method of operation applies exclusively. Make sure that, with installation in a room-air dependent or limited room-air independent manner, an inlet air opening to the outside of at least 150 cm2 is provided. Do not operate the burner by the ambient air dependent method in rooms with aggressive vapours (e.g. hair spray, perchloroethylene, carbon tetrachloride), strong dust formation (e.g. workshop) or high humidity (e.g. laundry). Always maintain the minimum distances to walls and other objects (see chapter 3.1 and 3.4).

FA ROTEX GSU - 04/2012

1 x Safety
1.5.4 Requirements for the heating water
Avoid damages caused by deposits and corrosion: To prevent corrosion products and deposits, observe the applicable regulations of technology. 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 magnesium concentrations, calculated as calcium carbonate. Using filling water and top-up water which does not meet the stated quality requirements can cause a considerably reduced service life of the equipment. The responsibility for this is entirely that of the operator.

1.5.5 Heating system and sanitary connection


Create a heating system according to the safety requirements of EN 12828. With sanitary connection, you must observe; EN 1717 - Protection of domestic water from contamination in domestic water installations and general requirements concerning safety equipment for the prevention of domestic water contamination by back-flow EN 806 - Technical regulations for domestic water installations (TRWI) and, in addition, the country-specific legal regulations. During operation of the ROTEX GSU, the storage tank temperature may exceed 60C, particularly when solar power is used. For this reason, install a scald protection (domestic hot water mixing construction, e.g. VTA32, 15 60 16) when installing the system.

1.5.6 Fuel
The ROTEX GSU is factory set to the gas type indicated on the burner sticker and on the settings type plate and adjusted to the gas pressure indicated on the burner sticker. Operate the unit only with the gas type and gas pressure indicated on these stickers. Installation and adaptation of the gas system must only be conducted by personnel qualified for this work and in compliance with valid gas installation related guidelines as well as the applicable regulations of the gas supply company.

1.5.7 Operation
Do not operate the ROTEX GSU if the storage tank is filled to above the overflow edge. Operate ROTEX GSU only with closed silencer hoods. Operate the ROTEX GSU on the sanitary side only with an adjusted pressure reducer (6 bar).

1.5.8 Instructing the user/owner


Before you hand over the heating system, explain to the owner how he/she can operate and check the heating system. Hand over the technical documentation (this document and all supporting documents) to the user and advise him that these documents must be made available at all times and be stored in the immediate vicinity of the unit. Make a record of the handover by filling out and signing the installation and instruction forms jointly with the user/owner.

FA ROTEX GSU - 04/2012

2 x Product description
2 2.1 Product description Structure and Components of GasSolarUnit

Cold water 1) Domestic hot water 1) Domestic hot water-charging exchanger flow Domestic hot water-charging exchanger return flow 5 Heating flow (hot) 6 Heating return flow (cold) 7 Solaris flow 8 Solaris return flow (with valve insert) 9 Flue gas 10 Supply air 11 Immersion sleeve for storage tank sensor and for Solaris return flow temperature sensor 12 Condensate overflow connection 12a Upper filling connection (alternatively: Condensate overflow connection to the front) 1 2 3 4 Fig. 2-1 Components of the ROTEX GSU

21 22 23 24 25 27 28 29 30 31 32 33 34 35 36

Circulation pump for heating Gas-blower burner 3-way switch valve Flow temperature sensor Return flow temperature sensor Safety valve Connection for the diaphragm expansion vessel Boiler control panel Control system Pressure gauge Silencer hood Retaining bolts for silencer hood Air supply hose Filling and drain fittings (KFE-cock) Automatic bleeder

37 38 39 40 41

Ball stopcock Heat-insulating jacket for boiler body Type plate with manufacturing number Settings type plate Connection for equalisation pipe (with valve insert) Safety devices

1)

Prepared for the installation of gravity brakes to prevent losses through cooling.

FA ROTEX GSU - 04/2012

2 x Product description
A B C D E F G 1 2 3 4 Gas condensing boiler Stratified hot water storage tank Unpressurised storage tank water Hot water zone Solar zone Heating support zone RPS control and pump unit (Solaris accessory)

Cold water 1) Domestic hot water 1) Domestic hot water-charging exchanger flow Domestic hot water-charging exchanger return flow 5 Heating flow (hot) 6 Heating return flow (cold) 7 Solaris flow 8 Solaris return flow (with valve insert) 9 Flue gas 10 Supply air 11 Immersion sleeve for storage tank sensor and for Solaris return flow temperature sensor 12 Condensate overflow connection 12a Upper filling connection (alternatively: Condensate overflow connection to the front) 13 Condensate drain hose (building side) 14 Condensate pipe 15 Heater heat exchanger (boiler body) 16 Domestic water heat exchanger (TW-WT) 17 Heat exchanger for storage tank charging (SL-WT) 18 Heat exchanger for solar heating support (HU-WT) 19 Heat insulation sleeve for HU-WT 20 Solaris flow stratifying pipe 21 Circulation pump for heating 22 Gas blower burner 23 3-way switch valve 24 Flow temperature sensor 25 Return flow temperature sensor 26 Flue gas temperature sensor (accessory) 27 Safety valve 28 Connection for diaphragm expansion vessel 41 Connection for equalisation pipe (with valve insert) Safety devices
1)

Prepared for the installation of gravity brakes to prevent losses through cooling.

Fig. 2-2

Schematic assembly of the GSU 520S(F)-e and the GSU 530S(F)-e

FA ROTEX GSU - 04/2012

2 x Product description
A B C D G 1 2 3 4 Gas condensing boiler Stratified hot water storage tank Unpressurised storage tank water Hot water zone RPS control and pump unit (Solaris accessory)

Cold water 1) Domestic hot water 1) Domestic hot water-charging exchanger flow Domestic hot water-charging exchanger return flow 5 Heating flow (hot) 6 Heating return flow (cold) 7 Solaris flow 8 Solaris return flow (with valve insert) 9 Flue gas 10 Supply air 11 Immersion sleeve for storage tank sensor and for Solaris return flow temperature sensor 12 Condensate overflow connection 12a Upper filling connection (alternatively: Condensate overflow connection to the front) 13 Condensate drain hose (building side) 14 Condensate pipe 15 Heater heat exchanger (boiler body) 16 Domestic water heat exchanger (TW-WT) 17 Heat exchanger for storage tank charging (SL-WT) 20 Solaris flow stratifying pipe 21 Circulation pump for heating 22 Gas-blower burner 23 3-way switch valve 24 Flow temperature sensor 25 Return flow temperature sensor 26 Flue gas temperature sensor (accessory) 27 Safety valve 28 Connection for diaphragm expansion vessel 41 Connection for equalisation pipe (with valve insert) Safety devices
1)

Prepared for the installation of gravity brakes to 16 50 70). prevent losses through cooling (

Fig. 2-3

Schematic assembly of the GSU 535(F)-e and the GSU 320(F)-e

10

FA ROTEX GSU - 04/2012

2 x Product description
2.2 Brief description
The ROTEX GasSolarUnit (GSU) is a complete, pre-assembled gas condensing boiler with an integrated domestic hot water storage tank. This integration ensures that there are no external surface and cooling losses. All the heat is passed to the storage tank water, not to the surroundings. The excellent heat insulation properties of the plastic storage tank also ensure that heat losses are kept to a minimum. The very flat cylinder-shaped aluminium boiler body is inserted into the cover of the storage tank. The combustion chamber is arranged centrally. The flue gas is directed in a spiral around the burner chamber and then taken away upwards. The flue gas temperature now always remains below 80C.

Solar utilisation
The hot water storage tank of ROTEX GSU can also be used by solar energy. For the models GSU 520S(F)-e and GSU 530S(F)-e, the gas condensing boiler is specifically used to maintain the temperature only in the upper zone of the storage tank. With solar heating, depending on the available heat from the sun, the entire hot water storage tank can be heated up. The stored heat is now used for hot water generation as well as for the heating support. The high-level total storage tank capacity in the 500 l hot water storage tank, also allows bridging of the periods without sunshine. For the models GSU 320(F)-e and GSU 535(F)-e, the entire storage tank is designed as domestic hot water zone. It is possible to make thermal use of solar energy for hot water preparation. The solar component is optimised in combination with an upstream Solaris system (pre-heating stage).

Operating mode
The ROTEX GSU is designed such that it can be operated independently of the ambient air. The burner suctions the combustion air directly in through an installation shaft or a double-walled flue gas pipe. This operating mode has several advantages: The heating room does not need any ventilation opening into the open air and therefore does not cool down. Lower energy consumption. Additional energy recovery in the flue gas pipe through preheating the combustion air. Additional energy efficiency through the positioning and flow through of the heat exchangers. For all units, a distinct temperature stratification is formed. Contamination from the environment of the burner are not suctioned in. The heating room can thus be used as a workpspace, laundry room etc. at the same time. Possible to install as central roof unit and in garages. The potable water is heated up indirectly with the non-pressurized storage water of the domestic hot water storage tank in a corrosion resistant, stainless steel heat exchanger with corrugated pipes. This heat exchanger stores approx. 24 l (19 l for the GSU 320(F)-e) hot potable water on the temperature level of the domestic hot water zone. If a higher quantity of hot water is tapped, this water is heated by the geyser principle. The precipitating condensation is collected at the lowest point of the boiler body, led to the storage tank through a plastic tube and neutralised there. From there, it is led through the safety overflow connection.

Safety management
The entire safety management of the ROTEX GSU is entrusted to electronic control. This effects a safety switch-off in the event of water shortage, gas shortage or undefined operating states. A corresponding fault signal provides an engineer with all the necessary information for troubleshooting.

Electronic control
A fully electronic digital control combined with the "intelligent" automatic firing unit of the burner controls all heating and hot water functions fully automatically for the direct heating circuit, an optionally available mixed heating circuit as well as a storage tank charging circuit. The continuously modulating control adjusts the heating output flexibly to the changing requirements. All adjustments, displays and functions are carried out through the ROTEX control system THETA 23R+. The display and keyboard make it easy to use. To increase the comfort, a digital room station (ROTEX THETA RS+, (ROTEX THETA RFF, 15 40 70) are optionally available. 15 70 22) or a room temperature controller set

Condensing technology
The calorific value engineering makes optimum use of the energy contained in the heating gas. The flue gas is cooled down in the boiler and in an operating mode, independent from the ambient air to a temperature below the dew point. A part of the water vapour generated on combustion of the gas thus condenses. The condensation heat is fed to the heating, as against the low temperature boilers. This makes an efficiency of over 100% possible.

FA ROTEX GSU - 04/2012

11

3 x Set-up and installation


3 Set-up and installation

WARNING! Incorrectly erected and installed gas devices may not operate properly and are dangerous for the health and safety of individuals. The GasSolarUnit must be installed only by heating engineers authorised and trained by gas or energy supply companies.

Incorrect set-up and installation would render the manufacturer's guarantee for the unit void. If you have questions, please contact our Technical Customer Service.

3.1

Dimensions and connection dimensions

A B

Side view Front view Installation dimensions for flue gas pipe at the rear (for values see tab. 3-1)

Top view

Fig. 3-1

A B

Side view Front view Installation dimensions for flue gas pipe at the side (for values see tab. 3-1)

Top view

Fig. 3-2

12

FA ROTEX GSU - 04/2012

3 x Set-up and installation


Dim. h1 h2 h3 r1 r2 s1 s2 s3 s4 t W
Tab. 3-1

GSU 320(F)-e 1404 1869 1640 202 203 213 228 377 193 615 590

GSU 520S(F)-e 1384 1846 1600 299 284 115 130 295 84 780 780

GSU 530S(F)-e GSU 535(F)-e 1384 1828 1600 264 284 150 165 295 84 780 780

Dimensions table - Installation (refers to fig. 3-1, fig. 3-2)

Connecting dimensions for the heating and hot water connections

1 2 3 4

Cold water (pipe thread 1" AG) Domestic hot water (pipe thread 1" AG) Heater flow (pipe thread with ball cock 1" IG) Heater return flow (pipe thread with ball cock 1" IG)

5 A B

Solaris flow (pipe thread flat sealing 1" M) front back

Fig. 3-3

Pipe dimensions for heating and hot water pipe (top view) (see chapter 3.6)

ROTEX recommends the installation of gravity brakes ( 16 50 70) or syphoning (lead the connection lines straight downward) of the potable water connections to avoid an increased loss through cooling.

FA ROTEX GSU - 04/2012

13

3 x Set-up and installation


3.2 Different set-ups
The ROTEX GasSolarUnits are generally designed for the operation, independent from the ambient air. They are fitted with a concentric flue gas /air supply pipe DN 80/125. ROTEX recommends the use of the gas condensing boiler in room-air independent operation with a concentric flue gas/air inlet. If possible, choose this set-up! In the event of limited room-air independent operation (separate flue gas/ air inlet) and in the event of room-air dependent operation, the installation room must have a ventilation opening of at least 150 cm2 to the outside. This reduces the overall energy efficiency of the building in the framework of the European Guideline 2010/31/EU: EPBD.

Fig. 3-4

Installation variants for the GSU

14

FA ROTEX GSU - 04/2012

3 x Set-up and installation


1-6 CA FG RV Different set-ups (Description, see section 3.2.1 to 3.2.3) Inlet air (combustion air) Flue gas Rear ventilation a b c d e f Tab. 3-2 Legend for fig. 3-4 Set up variant for room-air independent operation (flue gas / inlet air concentric) Set up variant for limited room-air independent operation (flue gas / air inlet separate) Set up variant for room-air dependent operation 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! Ventilation opening (1x150 cm or 2x75 cm) Rear ventilation opening (150 cm)

3.2.1 Operation independent of ambient air


With equipment erection in residential rooms, only one of the set up variants 1 to 4 is permissible.

Set-up version 1
The ROTEX GSU is connected to the chimney or an installation shaft with the concentric LAS connection line SET H or SET K. The combustible air supply from the outside runs through the chimney or through an installation shaft. The flue gas discharge to the outside runs through the same shaft as the air supply. Minimum distance between flue gas exit and crest: 40 cm.

Set-up version 2
The ROTEX GSU is placed directly below the roof. Connection with SET L. The combustible air supply and flue gas discharge run through a concentric dual pipe. The combustible air supply from the outside runs through the outer ring-shaped gap of the dual tube and the flue gas discharge to the outside runs through the inner tube. Minimum distance between flue gas exit and roof surface: 40 cm. Minimum height of the flue gas duct: 2 m.

Installation version 3
The ROTEX GSU is not placed directly below the roof. The dual tube for the combustible air supply and flue gas pipe runs through the roof truss. The combustible air supply and the flue gas discharge run through a concentric dual pipe (as in Installation version 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 resistance or be structurally separated from the roof truss.

Set-up version 4
The ROTEX GSU is connected with the LAS connection line SET H or SET K to the exterior wall system SET G. The combustible air supply from the outside runs through the ring-shaped gap in the dual pipe, through the outer wall (suction from below). The flue gas discharge to the outside runs through a concentric pipe, through the outer wall and then up to at least 40 cm over the roof surface. In the external area, the outer air gap serves as heat insulation for the flue gas pipe. If the wall feedthrough has a height of less than one meter above the plot, ROTEX recommends sending the combustible air through a separate air supply pipe (mounting height: about 2 m). W8 ZR, 15 50 79.00 66 or W11 ZR, 15 50 77.00 30

Information for installation in garages


The ROTEX GSU is basically suitable for installation and operation in garages. Requirements: Ambient air-independent operation, A durable operating manual placed in a very visible place near the boiler, The construction must include a protective device against mechanical damage (vehicle!) for the entire system (e.g. bracket or deflector).

FA ROTEX GSU - 04/2012

15

3 x Set-up and installation


3.2.2 Operation partially independent of ambient air Set-up version 5
The ROTEX GSU is operated with separately routed inlet air/ flue gas lines (2 line system). Combustion air inlet is routed from the outside via the adequately sealed inlet air through the external wall. The air inlet line should be sized so that the suction resistance at nominal power is less than 50 Pa. Flue gas dissipation to the outdoors is via the chimney or an installation shaft. If the connection line between the ROTEX GSU and the installation shaft is single-walled or is not completely surrounded by combustion air, a ventilation opening of at least 150 cm2 is required. Appropriate measures must be taken to ensure that the burner cannot be operated if the ventilation opening is closed. The installation shaft where the flue gas line runs must be rear ventilated. In the lower area there must be a rear ventilation opening of at least 150 cm2 must be provided. The cross-section of the installation shaft must be sized so that between the external wall of the flue gas line and the internal face of the installation shaft the following minimum distance must be maintained: with a rectangular shaft cross-section: 2 cm with round shaft cross-section: 3 cm. The rear ventilation opening must not be in rooms where a positive pressure is generated (e.g. by controlled apartment ventilation, a tumble-drier etc.).

3.2.3 Ambient air dependent operation


The ROTEX GSU can be connected even with ventilation and air-conditioning. Thereby, only the inner flue gas pipe (plastic pipe 80 mm) of the concentric air-flue gas pipe is connected to the flue gas line. The device sucks the combustible air from the installation room through the ring-shaped gap of the jacket pipe. For the flue gas routing to the outdoors, the shaft sizing and the rear ventilation, the same conditions apply as in section 3.2.2. A ventilation opening to the outside of 150 cm2 is imperative. In some cases, the resonance in the flue system can amplify the noise at the mouth of the flue gas pipe. The noise level can be effectively reduced with the application of a silencer (E8 MSD, 15 45 78 or E11 MSD, 15 45 79). Air suction noises are generated in ambient air-dependent operations. The noise level can be effectively reduced with the application of a silencer (G ZLSD, 15 45 77).

3.3

Transport and delivery


WARNING! The ROTEX GSU is top heavy when not filled, it can tilt over during transport. This can pose a risk to persons or damage the machine. Transport the ROTEX GSU carefully, use supporting straps. The ROTEX GSU is delivered on a pallet. All industrial trucks, such as lifting trucks and forklift trucks, are suitable for transporting it.

Scope of delivery
The ROTEX GSU (pre-assembled and ready-to-connect) consisting of the solar storage tank, gas condensing boiler with modulated gas burner, the control system, the integrated circulation pump, 3-way-switch valve, unit internal temperature sensors (flow, return flow, storage tank), exterior temperature sensor, safety group and ball cocks. The documentation folder with installation and operating instructions, operational handbook and installation and training form. The ROTEX GSU cannot function without the central unit of the control system (operation is only permissible with the ROTEX control system).

16

FA ROTEX GSU - 04/2012

3 x Set-up and installation


3.4 Installing the GasSolarUnit
3.4.1 Selecting the installation site
The place of installation for the ROTEX GSU must meet the following minimum requirements.

Installation surface

Supporting ground is solid, flat and horizontal and adequately capable of carrying the weight (>1050 kg/m2). Install a pedestal if necessary. Observe the set-up dimensions (see section 3.1).

Installation room
There are no special conditions for ventilation of the installation room for operation independent of the ambient air (using a concentric air/flue system). In the event of limited room-air independent operation and in the event of room-air dependent operation, the installation room must have a ventilation opening of at least 150 cm2 to the outside. If the flue gas line goes via an installation shaft to the outside, it must be rear ventilated (see section 3.2.2). For partial ambient air-independent and for ambient air-dependent mode, the installation room must be free from aggressive vapours (e.g. hair spray, perchloroethylene, carbon tetrachloride), heavy dust formation and high atmospheric humidity (e.g. washhouse).

Surface temperatures, minimum distance


WARNING! The storage tank plastic wall on the ROTEX GSU can melt under the effects of external heat (>80C) and, in the extreme case, can cause a fire. The ROTEX GSU can only be set up at a minimum distance of 1 m from other sources of heat (>80C, e.g. electric heaters, gas heaters, chimneys). When operating independently of the ambient air with nominal output, the design does not allow temperatures >80C on any component outside the unit panels. Therefore, no minimum distance is required to components made with flammable materials. A minimum distance of 50 mm between the flue gas duct and flammable components should be maintained in a partial ambient air-independent and ambient air-dependent mode. Do not use easily inflammable and easily combustible substances directly next to the ROTEX GSU.

Fig. 3-5

Minimum distances for erecting the GSU

FA ROTEX GSU - 04/2012

17

3 x Set-up and installation


3.4.2 Erecting the unit
WARNING! The ROTEX GSU is top heavy when not filled, it can tilt over during transport. This can pose a risk to persons or damage the machine. Transport the ROTEX GSU carefully, use supporting straps.

Precondition
The installation site complies with the respective country-specific regulations, as well as the minimum requirements described in section 3.4.1.

Set-up
Remove the packing. and dispose of it in an environmentally sound manner. Install ROTEX GSU at the place of installation. Lay connection lines in such a way that the noise insulation hood (fig. 2-1 pos. 32) can be removed.

3.5

Air/flue system (LAS)


3.5.1 General instructions for flue system
WARNING! There will be a risk of poisoning caused by flue gas escaping within enclosed rooms that are inadequately ventilated. Install only approved flue gas systems. The stipulated ventilation and rear ventilation must be ensured, depending on the set up variant.

Minimum requirements
The firing regulations for the country in question and the country-specific standards are applicable for the model and design of the flue gas system. Basically, for the flue gas system, you can use each flue gas pipe according to EN 14471 with EU label, which meets the following minimum requirements: Suitable for gas. Suitable for flue gas temperatures of at least 120C (temperature class T120 or higher). Suitable for at least 200 Pa overpressure (pressure class P1 or H1). Humidity-resistant (condensation resistance class W). Sufficiently corrosion-resistant (corrosion resistance class 1 or 2). The properties of the flue gas system must be identifiable on the installed system (nameplate in the installation room).

Type of connections
Directly backwards (fig. 3-1: SET H, 15 50 79.08). At the side towards the back (fig. 3-2: SET K, 15 50 79.09). Direct roof penetration (fig. 3-4, variant 2 and 3: SET L, 15 50 79.10). For other details and connection dimensions for the three versions of the flue gas pipe, see section 3.5.3. Each flue gas line must be installed with a suitable test adapter for checking and setting the combustion values. The ROTEX LAS construction sets each include a test adapter (D8PA, 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 installation shaft: at least 3. Slope for horizontal parts of the flue gas pipe: at least 3. Counter-slopes are not allowed at any point in the flue gas pipe. If the flue gas duct needs more than 3 deflections >45 for the flue gas duct, the maximum height for the flue gas duct reduces by at least 1 m per deflection (flue gas calculations may be needed). If the horizontal connecting piece is extended, the maximum permitted height of the flue gas duct is reduced by exactly that length. Flexible flue gas lines must not be used in horizontal connection sections. FA ROTEX GSU - 04/2012

18

3 x Set-up and installation


Flue gas system resistance
For a safe burner start and stable setting values in the lower output range, a minimum resistance in the flue gas line is necessary, especially for liquid gas units. If this resistance is not achieved during the max. speed of the burner blower, a silencer must be installed (E8 MSD, 15 45 78 or E11 MSD, 15 45 79). After the initial burner start, the ROTEX GSU switches at first into the storage tank charging mode. In this mode, the burner blower runs with max. speed. Measure the resistance with a differential pressure measuring device at the flue gas measuring piece between the flue gas and the supply air measuring opening (differential pressure for GSU 320(F)-e / GSU 520S(F)-e at least 0.45 mbar, for GSU 530S(F)-e / GSU 535(F)-e at least 1 mbar). The tab. 3-3 indicates the max. permissible height for the flue gas line, in the event that the ROTEX GSU will be operated in the nominal output range. Installation version (according to fig. 3-4) 11) 22) 32) 42)
Tab. 3-3

GSU 320(F)-e 10 12 12 12

GSU 520S(F)-e 10 12 12 12

GSU 530S(F)-e 18 17 17 17

GSU 535(F)-e 20 19 20 20

1) Shaft cross-section at DN80: 135 mm x 135 mm

2) Concentric flue gas/supply line: DN80/125

Maximum height for the flue gas duct in m

Any restriction on the output range may require a recalculation of the maximum permitted height for the flue gas duct. The performance characteristics for the flue gas calculation can be found in fig. 3-6 and in chapter 11 "Technical data" or tab. 14 -1. The flue gas mass flow of the systems depends on the burner output set.
A

P Burner load mET Flue gas mass flow Fig. 3-6

A B

Natural gas E, H Natural gas L, LL

Liquid gas

Flue gas mass flow in relation to the burner load

FA ROTEX GSU - 04/2012

19

3 x Set-up and installation


3.5.2 Connect flue gas line to the GSU
The certified company carrying out the work must come to an agreement with the district chimney sweep before beginning the work. Even in regions where it is not legally specified, we recommend documenting the participation of the district chimney sweep on a form.

Requirements
The flue system fulfils the requirements described in section 3.5.1. The flue system fulfils any other required national or regional safety requirements. The ROTEX GSU is installed correctly.

Connection
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 3.5.1). Each flue gas line must be installed with a suitable test adapter for checking and setting the combustion values. The ROTEX LAS construction sets each include a test adapter (D8PA, 15 50 79.00 93). We recommend to use the associated ROTEX LAS-sets (see fig. 3-9). They satisfy all requirements and are also fitted with special acid-proof seals. Connect ROTEX GSU to the flue gas system within the place of installation (for pipe dimensions, see fig. 3-1 or fig. 3-2).

Pipe dimensions for air/flue gas system (LAS) connection kits

Fig. 3-7

Top view GSU flue gas connection towards the back with SET H (see section 3.5.3)

Fig. 3-8

Top view GSU flue gas connection to the side with SET K (see section 3.5.3)

Dim. s1 s2 s3 t W
Tab. 3-4

GSU 320(F)-e 213 228 377 615 590

GSU 520S(F)-e 115 130 295 780 780

GSU 530S(F)-e 150 165 295 780 780

GSU 535(F)-e

Pipe dimensions for LAS kits (refers to fig. 3-7, fig. 3-8)

Place the nameplate of the flue gas pipe in the installation room. In some cases, the resonance in the flue system can amplify the noise at the mouth of the flue gas pipe. The noise level can be effectively reduced with the application of a silencer (E8 MSD, 15 45 78 or E11 MSD, 15 45 79). Air suction noises are generated in ambient air-dependent operations. The noise level can be effectively reduced with the application of a silencer (G ZLSD, 15 45 77).

20

FA ROTEX GSU - 04/2012

3 x Set-up and installation


3.5.3 Flue gas system kits

* **

Accessories as required For dimensions see tab. 3-1 Plastic (PP) flue system kits

*** The 3 digit numbers on the individual parts correspond to the image numbers that display the individual parts in the ROTEX total price list.

Fig. 3-9

FA ROTEX GSU - 04/2012

21

3 x Set-up and installation


Additional kits
Flue gas connection to a duct system (rigid flue gas line SET E or flexible flue gas line SET O) Flue gas connection for exterior wall line (SET G) If necessary, additionally needed PP-LAS pipes for increased roof or ceiling heights, single wall PP pipes for chimney heights of more than 10 m or additional accessory components must be ordered.

3.6

Water connection for heating and hot water pipes


The connections of the ROTEX GSU are located on top of the unit or at the front (Solaris return flow). Heating circuit and storage charge have a common inflow and return flow. The heating circuit for the storage charge is integrated at the factory and must not be connected separately. Any limescale which results from the water heating process is rinsed out of the stainless steel corrugated pipe heat exchanger with hot water. Observe implicitly the information regarding the corrosion protection in chapter 7.1 "Important information on the hydraulic connection".

Instructions for water connection


CAUTION! If the ROTEX GSU is connected to a heating system with steel pipelines, radiators or non-diffusion-proof floor heating pipes, slurry and chips could enter the boiler and cause blockages, overheating or corrosion. Rinse out the heat distribution network (in the existing heating system). Install a dirt filter into the heating return flow (SFR 28, 15 60 11 for units of up to 28 kW or SFR 50, 15 60 12 for units of up to 50 kW). For potable water lines, the stipulations of the EN 806 and the national regulations for potable water installation that apply additionally must be observed. CAUTION! If the ROTEX GSU is connected to a cold water line, where steel pipes are used, chips can go into the special steel corrugated pipe heat exchanger and remain there. This can lead to contact corrosion damage and subsequently to leakage. Flush the feed pipes before filling the heat exchanger. Install a dirt filter in the cold water supply. Check the cold water connection pressure (maximum 6 bar). At higher pressure in the drinking water line, a pressure reducer must be installed. Position and dimension of the heating pipes are given in fig. 3-3. To prevent heat losses, all hot water pipes must be insulated against heat. To avoid a circulation line, install the hot water storage close to the removal location. If a circulation line is absolutely essential, it must be installed in accordance with the schematics in chapter 7.3 "Hydraulic system connection". Connect the flue gas pipe to the safety valve and the diaphragm expansion basin according to EN 12828. Water shortage protection: The overheating protection of the ROTEX GSU switches off the gas condensing boiler in case of heat deficiency and locks it. No additional water shortage protection is needed in the construction. Avoid damages caused by deposits and corrosion: To prevent corrosion products and deposits, observe the applicable regulations of technology. 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 magnesium concentrations, calculated as calcium carbonate. WARNING! There is a danger of scalding at hot water temperatures over 60C. This is possible, when solar energy is used, when the Legionella protection is activated or when the domestic hot water target temperature is set higher than 60C. Install a scald protection (domestic hot water mixing construction (e.g. VTA32, 15 60 16).

22

FA ROTEX GSU - 04/2012

3 x Set-up and installation


3.7 Connect the condensate drain
The condensate, forming during the cooling of the combustion gases in the boiler and in the flue gas system is dumped through the condensate tube into the storage container. By means of a permanent neutralisation filling it is neutralised and subsequently it is dumped into the sewer system through the safety overflow connection (fig. 3-10).

Connection
Direct condensation drain pipe (not included) with constant slope and with free inflow to the drains pipe. The complete outlet must not be lockable and must discharge the condensation and any medium leaking due to damage (drinking water, buffer or heating water) outwards visibly (e.g. hose to flow drain or transparent outlet pipe). Check the condensate drain section for leakage.

Fig. 3-10

Connection of the condensate overflow pipe

3.8

Connect valve drive to the 3-way switch valve


The ROTEX GSU is fitted with an integrated circulation pump and a 3-way switch valve (3-w SV) as standard. The circulation pump and the 3-way switch valve are connected at the factory, the valve drive is inserted.
1 2 3 4 5.1 5.2 5.3 Boiler flow Heater flow Storage tank flow 3-way switch valve Valve drive Unlock button for the drive locking mechanism Hand lever

Fig. 3-11

3-way switch valve

After commissioning, connect the connector on the cable for the 3-way switch valve to the valve drive. The cable for the circulation pump and the 3-way switch valve are equipped with one connector each and readyinstalled to the boiler control panel.

FA ROTEX GSU - 04/2012

23

3 x Set-up and installation


3.9 Establish connection and electrical equipment
WARNING! Live parts can cause an electric shock on contact and cause fatal burns or injuries. Before beginning work on live parts, disconnect them from the power supply (switch off fuse, main switch) and secure against unintentional restart. The electrical connection should only be performed by electrical engineers in compliance with valid standards and guidelines as well as the specifications of the energy supply company. All ROTEX GSU control and safety devices are connected, tested and ready for use. Modifications on the electrical installation are dangerous and prohibited. Any resulting damages will be borne by the user/owner alone. There are two 3 m flexible cables connected inside the device for the mains connection and for the external temperature sensor; they are located in the control panel on the circuit board. Only the optional applications (e.g. mixer circuit, circulation pump, flue gas temperature probe) still have to be connected to the boiler control panel.

Electrical connection of the control unit


Check the supply voltage (~230 V, 50 Hz). Disconnect the junction box of the domestic installation. Connect the cables for connecting to the mains in the junction box. Ensure that the polarity is correct. Restore power supply to the junction box of the domestic electrical installation.

Switching circuit board

Connections of the circuit board connectors: J1 Pump PK J2 3-way-switch valve or storage tank charging pump PL* J3 Burner - power supply J4 Burner - communication J6 Mains connection J7 Mixer J8 Communication, sensors J10 Sensors J14 Circulation pump PZ
* If an adapter cable is used for the charge pump ( E 1500430)

Cable colours: bl blue br brown ge yellow gn green gr grey rt red sw black ws white n.a. Contact not assigned

Fig. 3-12

Connection diagram of the circuit board connectors and cable colours of the factory-installed connection cables

24

FA ROTEX GSU - 04/2012

3 x Set-up and installation


3.10 Temperature sensor
3.10.1 General instructions for the temperature sensors
The ROTEX GSU comes with a weather-proof control unit of the flow temperature. For this function an exterior temperature sensor (enclosed in the ROTEX GSU scope of delivery) is necessary. The 3 m long flexible cable for the exterior temperature sensor is internally already connected and plugged into the control panel to the connection circuit board. The temperatures captured by the unit's internal temperature probes (inflow and return flow temperature sensor, flue gas temperature probe) are used for the output control of the burner and for fault detection. They are already factory-connected and can be plugged directly to the respective sensor, if they are to be swapped. The storage temperature probe is mounted at the factory and clamped (PTC resistance). The mixer circuit inflow sensor (TMKF, 15 60 62) is required for the control of the mixer circuit . Additional information on the operating state is provided by a flue gas temperature probe (TAGF1, 15 70 52).

The electronic control detects the existing sensor configuration automatically when switching on the ROTEX GSU. Additional information and a detailed description can be found in the documentation "ROTEX control system". This documentation is included in the scope of delivery.

3.10.2 Connecting the temperature sensor


CAUTION! Using unapproved temperature sensors or those which do not match the device can cause considerable malfunctioning in the regular operation of the ROTEX GSU, damaging the device control. Exclusively use the outside temperature probe included with the machine.

External temperature sensor


Choose a location at about one third of the building height (minimum distance from floor: 2 m) at the coldest 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 cable exit points face downwards (prevents humidity ingress). CAUTION! The parallel routing of sensor and mains lines within an installation pipe can cause considerable malfunctioning in the regular operation of the ROTEX GSU. Always lay the sensor line separately. Lay probe line and connect to the ROTEX GSU control panel. Connect the external temperature sensors with a dual core cable (minimum cross section 1 mm2).

Mixer circuit flow probe (accessory)


Connect the sensor line to the sensor plug J8 (see fig. 3-12).

Flue gas temperature probe (Accessory)


Pull out sensor plug J10 with closing resistance. Plug the sensor cable (connection set) onto the circuit board.

FA ROTEX GSU - 04/2012

25

3 x Set-up and installation


3.11 Connect the gas line, check the burner setting for gas type
DANGER OF EXPLOSION! Escaping gas is a direct threat to human health and safety. Even a few sparks can cause major explosions. Before working on gas carrying parts, always close the main gas stop valve of the system. If you smell gas, ventilate the room well. Do not fan any open fire or operate any electrical switches. Only heating specialists authorised and trained by the gas or power supply company should be allowed to work on gas-conducting parts.

3.11.1 Important instructions for gas connection Gas connection


Implement the gas connection according to the technical rules for gas installation, as well as the appropriate regulations of the country of destination and the gas supply company. A thermally triggered blocking device (TAE) and a gas flow monitor (GSW) with a DVGW inspection symbol must be fitted. The TAE must comply with the test basis of DVGW-VP 301. The dimensions of the GSW must comply with the maximum adjustable rated load of the device.

Gas type
The preset gas type and the designated gas inlet pressure are indicated on the yellow sticker placed on the burner housing. Observe permitted gas inlet pressure (Resting pressure). Gas type Natural gas H Liquid gas B/P
1)

Nominal pressure in mbar 1) Min. inlet pressure in mbar Max. inlet pressure in mbar 20 28-30 / 37 17 25 25 35 / 45

The liquid gas unit is factory set to a nominal pressure of 50 mbar. The subsequent burner adjustment must be adapted to the permissible gas input pressure. This adaptation must be appropriately labelled with a suitable burner settings sticker and an entry on the settings sticker (under the type plate. Permitted gas inlet pressure

Tab. 3-5

3.11.2 Connecting the gas line


The standard corrugated gas connection hose can cause a pressure drop of up to 5 mbar. This does not adversely affect the functioning of the gas condensing boiler.

Connect the factory installed corrugated gas connection hose (A) (pipe thread DIN EN 2999 Rp ") without tension to the gas supply line.

Fig. 3-13

Gas connection

26

FA ROTEX GSU - 04/2012

3 x Set-up and installation


3.11.3 Checking burner pre-setting
Compare the available gas type with the set gas type (sticker on burner housing). The two gas types must match. If the burner is not labelled for the available gas type, convert the burner over to the new gas type and label it (see chapter 6.3 "Burner setting"). Check the gas inlet pressure. If the gas inlet pressure lies below the permissible range (tab. 3-5), inform the responsible gas supply company. For liquid gas: Check the pressure reducer or adjust the burner to the permissible gas inlet pressure (see chapter 6 "Gas burner"). This adaptation must be appropriately labelled with a suitable burner settings sticker and an entry on the settings type plate (fig. 2-1, pos. 40).

Fig. 3-14

Check the gas inlet pressure.

3.12 Optional connections


3.12.1 Mixer circuit
A mixer circuit can be connected to the ROTEX GSU directly that is regulated via the electronic boiler control. For this, ROTEX offers: The ready-to-connect mixer group AMK1 ( 15 60 44), which contains a circulation pump integrated in the heat insulated housing, a motor mixer and check valves with temperature displays. The mixer circuit contact sensor TMKF ( 15 60 62).

Cascading
By cascading the heating circuit expansion modules THETA HEM1+ ( 15 60 64), the system can be expanded to up to 5 mixing circuits and/or storage tank charging circuits. The required temperature sensors need to be ordered separately (mixer circuit contact sensor TMKF ( 15 60 62), storage tank temperature sensor TSF ( 15 60 63)). Connection and communication of the heating circuit expansion module THETA HEM1+ via data bus at the central unit.

3.12.2 Flue gas temperature sensor


For an optimal operation monitoring, the flue gas sensor connection set TAGF1 ( 15 70 52) can be installed. Connection to the circuit board connector J10 at the central unit (see section 3.10.2, as well as fig. 3-12).

3.12.3 Room temperature controller


A separate room control THETA RFF ( 15 40 70) can be connected for each heating circuit for a remote setting of modes and room temperature from other rooms. Connection and communication of the room temperature controller THETA REF1 via a data bus on the central unit.

3.12.4 Room station


With the room station THETA RS+ ( 15 70 22), all temperature values and operating modes for the THETA 23R+ control unit (central unit) can be displayed and modified. Apart from the chimney sweep and manual operation function, all operating elements (display, keys, rotary switch and functions (e.g. timer programs) are identical to those of the central unit. The room station THETA RS+ can be installed in a suitable location in the building and be used as a remote control for the boiler control. Connection and communication of the room station THETA RS+ through data bus at the central unit.

FA ROTEX GSU - 04/2012

27

3 x Set-up and installation


3.13 Filling the system
Adjusting the pressure gauge
The correct minimum pressure marking must be set on the pressure gauge glass before filling the system for the first time: Rotate the pressure gauge glass (fig. 2-1, pos. 31) in such a way that the minimum pressure marking corresponds to the system height +2 m (1 m water column corresponds to 0.1 bar). After completing the installation, fill ROTEX GSU in the following sequence:

1. Filling the hot water heat exchanger


Open the shut-off valve of the cold water supply line. Open the withdrawal tap connection for hot water, so that you can set the highest possible tapping quantity. Once water has been discharged from the tap connections, do not interrupt the cold water inflow; this will ensure that the heat exchanger will be fully vented and that any impurities or residue will be discharged.

2. Filling the storage tank


WARNING! Escape of flue gas from the system will be damaging to health. Before commissioning the ROTEX GSU, fill the storage tank container up to the overflow mark. GSU with installed Solaris System Connect the filling hose with return flow inhibitor (") to the KFE cock on the control and pump unit (RPS). Fill the storage container, until water exits out of the condensate overflow. GSU without installed Solaris System Either connect the filler hose to the enclosed hose socket and this socket to the upper lateral container connector (see fig. 2-1, pos. 12a) or insert the hose into the Solaris flow connection (fig. 2-1, pos. 7). Fill storage tank container until water flow out of the condensation overflow drain.

3. Filling the heating system and the storage tank charging circuit
WARNING! Contamination of drinking water endangers the health. When filling the heating system, prevent the boiler water from flowing back into the drinking water line. Engage the hand lever on the 3-way switch valve (see fig. 3-11) in the centre position (only possible when de-energised/in the delivered condition). The centre position is on stable, when the 3-way switch valve has not power. The 3-way-switch valve unlocks automatically, when the voltage at the drive motor for the valve position AB-A is applied (storage tank charging). To ensure a complete ventilation, the 3-way switch valve must be unlocked earliest one hour after commissioning the plant. Connect the filling hose with return prevention device (") to the filling and draining fittings (KFE cock, fig. 2-1, pos. 35) 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 (fig. 2-1, pos. 31). Fill the system with water until the marking of the system overpressure is roughly in the centre of the green range of the pressure gauge display. Shut off the KFE cock. Vent the entire heating network (open the system control valves). Check the water pressure on the pressure gauge again and top up with water if necessary. Close the KFE cock, remove the filling hose with return prevention device from the filling and draining fittings.

28

FA ROTEX GSU - 04/2012

4 x Start-up
4 Start-up

WARNING! A ROTEX GSU that is installed or started incorrectly may not operate properly and is dangerous for the health and safety of individuals. Only heating engineers, authorised and trained by gas and energy supply companies are allowed to start up the ROTEX GSU. CAUTION! A ROTEX GSU not put into operation properly can lead to damage to property and the environment. Observe the regulations in VDI 2035 in order to avoid corrosion and deposits. Measures for desalination, softening or hardness stabilization are necessary, if the filling and top-up water has a high total hardness (>3 mmol/l - sum of the calcium and magnesium concentrations, calculated as calcium carbonate). We recommend Fernox scale and corrosion protection agent KSK ( 15 60 50). During the plant operation, the water pressure at the manometer (green area) must be checked at regular intervals. If necessary, readjust by topping up. Incorrect start-up makes the manufacturer's guarantee for the unit void. If you have questions, please contact our Technical Customer Service.

4.1

Initial start-up
After the ROTEX GSU has been erected and fully connected, it can be put into service by skilled staff.

4.1.1 Requirements
The ROTEX GSU is fully connected. The heating and hot water system are filled and charged with the right pressure. The storage tank is filled to the overflow point. The control valves of the heating system are open.

4.1.2 Tests prior to start-up


Check all connections for leakage. Check all points of the enclosed check list (see section 4.2). Log the test results on the checklist. The gas condensing boiler can only be provisionally put into service if all points on the checklist can be answered with Yes.

4.1.3 Start-up
Switch on the mains switch. Wait for the start phase. Check the resistance in the flue gas line (see chapter 3.5). Set the operating temperature for manual operation. To do so, activate the manual key approx. 5 sec and set the operating temperature on the rotary switch. Check the burner adjustments with a flue gas analyser and readjust if necessary, (see chapter 6.3 "Burner setting").
Fig. 4-1

Press and hold for approx. 5 sec. Target temperature Current value Change Desired target value (flashing) Reset to the original operating mode, basic display, adjusted target value is stored.

Manual operation for THETA 23R+ (adjust heater temperature)

FA ROTEX GSU - 04/2012

29

4 x Start-up
4.1.4 Setting the heating circulation pump
The prerequisite for the most energy-saving method of operation is that a hydraulic balance is carried out and the heating circulation pump is running at the lowest possible necessary stage. The instructions for hydraulic incorporation (see chapter 7.1) and the characteristic curves of the residual feed height (chapter 11, fig. 11-9 and fig. 11-10) must be observed. If the design of the hot water distribution network is appropriate, it is normally adequate to have the pump set to the automatic stage "b".

4.2

Checklists for start-up


Checklist before start-up Is the ROTEX GSU correctly set up according to an admissible set up variant and without visible damages? Combustion air supply secured? Adequate ventilation and exhaust in the heating room with limited room-air independent or room-air dependent operation? Does the mains connection conform to the specifications? Is the mains voltage 230 V, 50 Hz? LAS flue gas line connected with a consistent gradient (at least 3) and no leaks? Storage tank topped up with water to overflow, condensate drain line connected correctly and leakproof? On restoration: Has the heat distribution network been cleaned? Is a dirt filter installed in the heating return flow? Is a membrane expansion tank mounted according to specifications and in the requisite size? Is the safety valve connected to a free outlet? Is the system water pressure within the green range? Are boiler and heating system vented? Are all sensors connected and correctly positioned? Are the mixing unit and the sensor for the mixing circuit (optional) correctly connected to the printed circuit board? Is the room temperature controller (optional) correctly connected to the circuit board? Is the gas connection installed according to regulations, professionally and correctly? Is the gas line vented expertly and leakproof? Do the gas type and gas inlet pressure correspond to the values indicated on the boiler sticker?

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

The system may only be started up if all questions can be answered with "Yes".

A B C D E F

Checklist after start-up When the circulation pump runs, does the heating heat up? Is the flow pressure for the gas type within the permitted range? Have the screws for the gas pressure test points been retightened and are they leakproof? Has the resistance of the flue gas pipe been measured and if so, is the measured resistance higher than the required minimum resistance? Have the burner settings been checked by using a flue gas analyser and readjusted if necessary? Has the 3-way switch valve connector been plugged on following start-up?

Yes Yes Yes Yes Yes Yes

The system may only be handed over to the user/owner if all questions can be answered with "Yes". Fill out the enclosed installation and instruction form as well as the first pages of the operating manual together with the.

30

FA ROTEX GSU - 04/2012

5 x Control
5 5.1 Control Controls on the boiler control panel

The ROTEX GSU can be operated with the THETA 23R+ control system or any other control system that is approved by ROTEX. The electronic-digital control system is used to actuate 2 heating circuits (direct heating circuit, mixing circuit) and a storage charging circuit. The control system has a multi-lingual clear text display. The language selection is located in the programming level "System". A detailed description can be found in the documentation "ROTEX Control system". This documentation is included in the scope of delivery.

1 2 3 4 5 6 7 8

Mains switch Group malfunction lamp Not assigned Pressure gauge Control system: Central unit THETA 23R+ Rotary push button for the selection and adjustment of functions and parameters Selection of the room target temperature for the day Selection of the decreased room target temperature

9 10 11 12 13 14 15 16

Target temperature selection for the domestic hot water storage tank Selecting the operating mode Adjustment of the automatic switching timer programme System information Button for Emission measurement, manual operation, reset function Display Compartment for quick reference instruction manual Fastening bolts for the control system

Fig. 5-1

Control elements at the boiler control panel with integrated THETA 23R+ control system

Mains switch
Switch on and off the ROTEX GSU. When the heating system is on, the mains switch is illuminated green.

Collective fault signal


During normal operation, the collective fault signal is off. If it lights up this indicates a malfunction. Malfunctioning is generally indicated by an error code on the display. For troubleshooting instructions refer to chapter 9.1 "Troubleshooting".

Pressure gauge
Black pointer: Display of the current water pressure in the heating system. Green range: Permitted water pressure range. Red pointer: Indication of the permitted minimum pressure. The black pointer must be in the green range. If it is to the left of the red pointer, the water pressure must be raised by topping up the system.

FA ROTEX GSU - 04/2012

31

5 x Control
Rotary switch
The rotary switch can be used to select operating settings, changing and storing target values. Rotate to the right (+): Increased regulation Rotate to the left (): Reduced regulation Tapping: Save the selected value

Press and hold (3 sec): Enter the programming level (select level)

Day target room temperature


Selection and setting of the target temperature in normal operation. Setting according to individual temperature sensitivity.

Reduced target room temperature


Select and set the target temperature in economy operation (night reduction). Setting according to individual temperature sensitivity.

Target temperature hot water storage tank


Select and set the target hot water storage tank temperature Setting according to specific hot water requirement. It is possible to trigger an unplanned storage tank charge by keeping the key pressed for a long time (during an economy phase).

Selecting the operating mode


Setting the mode by tapping the mode selection key. The mode currently active flashes on the display. Select and activate another operating mode with the rotary switch. A marking on the display through the respective symbol shows the mode currently selected. HOLIDAY ABSENT PARTY AUTOMATIC SUMMER HEATING REDUCED STANDBY
*

Frost-protected shutdown of heating and domestic hot water (e.g. during vacation times). Brief break in the heating mode during absence. Extended heating operation beyond the heating time pre-set in the AUTOMATIC OPERATION. Automatic heating and economy mode according to timer programme. Domestic hot water operation has been shutdown in frost-protected mode according to the switching time programme.* Continuous heating mode without time restriction. Continuous reduced heating mode without time restriction. Frost-protected shutdown of heating and hot water.

This function is not available if a room temperature controller THETA RFF is connected or if the operating mode of the control has been set at different settings for the individual heating circuits.

Setting automatic timer programme


Selection of one of 3 preset timer programs P1, P2 or P3. Additional information and a detailed description can be found in the documentation "ROTEX Control system". This documentation is included in the scope of delivery.
i

System information

Querying all system temperatures and operating statuses of the system components. Tap the system information key. Query the desired information successively by using the rotary switch.

32

FA ROTEX GSU - 04/2012

5 x Control
Emission measurement, manual operation, reset function
You can request 3 functions by using the manual button. Functions for emission measurement for the chimney sweep: press the manual button, 1. Tapping: The burner runs with max. output, 2. Tapping: the burner runs with minimum output. Manual operation: press the manual button for 5 sec. The GSU is controlled according to the set target value (heat generator temperature). The storage tank charges until the maximum adjustable storage tank temperature is reached. It then switches over to heating. Fault clearance: If the display shows "<<RESET", tap the manual button. If a problem recurs, the root cause must be eliminated.

Display
All system temperatures and operating statuses of the system components can be shown on the display. In the event of a fault, the corresponding fault signal is issued. Standard display in normal operation: Current day of the week, current date, current time, heat generator temperature and active operating mode (marking bar).

5.2

Changing the central unit


WARNING! Live parts can cause an electric shock on contact and cause life-threatening burns and injuries. Before starting any maintenance work on the central unit, disconnect it from the power supply (switch off fuse, main switch) and secure it against unintentional restart.

Disassembling the central unit


Loosen fixing screws (fig. 5-2, pos. 16) (anticlockwise rotation), pull out central unit from front.

Assembling the central unit


Push the central unit carefully into the boiler control panel. Ensure that the connecting pins are not damaged. Tighten the fixing screws (right handed threads).

A B 16

Front view Rear view Fastening bolts Assembling / disassembling central unit

C D

Loosen the fastening bolt Tighten the fastening bolt

Fig. 5-2

FA ROTEX GSU - 04/2012

33

5 x Control
5.3 Changing the boiler control panel
WARNING! Live parts can 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 against unintentional restart.

Disassembly (observe sequence)


The position and arrangement of the components described below is shown in fig. 5-15 on page 39. 1. 2. 3. Remove the silencer hood (see also chapter 8.2 "Service and maintenance tasks", page 56). Shut the stop cocks in the heating inflow and in the heating return flow. Connect the hose to the KFE cock and release water pressure from the boiler. Unscrew and remove the pressure gauge-capillary tube with a SW14 spanner (fig. 5-3). Wipe up the escaping water amount that occurs during the removal with a rag. WARNING! There is a danger of scalding from heating water. The capillary tube of the pressure gauge is directly connected to the pressurised heating water. Close the ball cocks on the boiler inflow before removing the pressure gauge and depressurise the system.

Fig. 5-3

Remove pressure gauge capillary tube

Fig. 5-4

Manometer capillary pipe removed

34

FA ROTEX GSU - 04/2012

5 x Control
4. Unscrew the control panel cover (fig. 5-5) and remove the cable duct cover.

Fig. 5-5

Unscrew control panel cover

Fig. 5-6

Pull off the coded connector

5. 6.

Pull all connectors from the circuit board (fig. 5-6). Unscrew and remove the sensor and connector cable from the cable ducts of the boiler control panel (fig. 5-7).

Fig. 5-7

Pull out the cable

Fig. 5-8

Loosen the fixing bolts for the boiler control panel

7.

Remove the boiler control panel fastening bolts (SW8) (fig. 5-8). Remove the control panel.

Installation (observe sequence)


1. 2. 3. 4. 5. 6. 7. 8. Insert the boiler control panel into the attachment. Insert and tighten the fixing screws. Insert all sensor and connecting cables into the cable ducts of the boiler control panel. Ensure the correct cable routing through the strain relief plates. Insert all connectors on the circuit board. The connectors are shape-coded to avoid confusion. Do not force the connector! Mount the control panel cover. Screw in the pressure gauge capillary tube. Ensure the correct seating of the ring seal. Top up with water until the required system pressure is restored. Open the stopcocks for heating. Vent the system again (top up with water if required). Install noise insulation hood.

FA ROTEX GSU - 04/2012

35

5 x Control
5.4 Changing cables
The connection cables can be loosened either on the boiler control panel or on the component in question. The cables for the internal components in the unit are connected to the circuit board connectors and cannot be released. They are connected to the corresponding element with connectors and can be released. The cables for external components (e.g. external temperature sensors), or for components not included in the scope of supply (e.g. mixer), are connected to the circuit board connectors by bolted terminals. WARNING! Live parts can 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 against unintentional restart.

Changing the cables (observe sequence)


1. 2. 3. 4. 5. 6. Remove the silencer hood (see also chapter 8.2 "Service and maintenance tasks", page 56). Unscrew control panel cover and remove cable duct cover. Pull out the corresponding sensor or connection cable from the cable duct of the control panel. Pull out the associated connector from the circuit board. Separate the other cable end from the component (release plug connection or remove the cable from the terminal). Replace the cable. Ensure that the cable cross section is correct.

Install the new cable in reverse order. Whilst doing so, ensure the following: The technical specification of the new cable must correspond to the values of the replaced cables (e.g. conductor cross section). The circuit board connectors are shape-coded. Do not force the connector!

5.5

Changing the sensors


Sensors inside the unit can be changed without having to open the boiler control panel. WARNING! Live parts can cause an electric shock on contact and cause life-threatening burns and injuries. Before work begin at the ROTEX GSU, disconnect the unit from the power supply (fuse, shut off main switch) and secure against unintentional restart.
33 34 Flow temperature sensor Return flow temperature sensor

Fig. 5-9

Position of temperature probe on boiler

36

FA ROTEX GSU - 04/2012

5 x Control
Changing flow / return flow temperature sensor
WARNING! There is a danger of scalding from heating water. Flow and return flow temperature sensors are connected directly to the pressurised heating water. Close the ball cocks on the boiler flow and boiler return flow before removing the sensor, and depressurise the system through the KFE cock.

Fig. 5-10

Pull out the connector on the return flow temperature probe

Fig. 5-11

Unscrew and remove the return flow temperature sensor

1. 2. 3. 4.

Remove sound insulation hoods. Pull out the connectors on the inflow temperature sensor/ return flow temperature sensor. Unscrew and remove the flow temperature sensor/return flow temperature sensor with a socket wrench SW15. Screw in the new inflow /return flow temperature sensor and plug in the cable with connector. The connectors are shapecoded. Do not force the connector!

Changing the storage tank temperature sensor


The storage tank temperature sensor is connected directly to the connection terminals 11 and 12 of the 12-pin sensor connector J8 in the boiler control panel. For more information on installing the storage tank temperature sensor, see the enclosed installation instructions.

1. 2. 3.

Open the boiler control panel and pull out the J8 connector from the circuit board (see section 5.4, steps 1 to 4). Pull out the storage tank temperature sensor from the sensor immersion sleeve at the storage tank. Bend the pressure spring at the new storage tank temperature sensor and slide the temperature sensor up to the marking into the sensor immersion sleeve. Connect the temperature sensor cable at the connector for the connector clamps 11 and 12 of the sensor connector J8, connect the connector to the printed circuit board and install the control panel and the silencer hood.
Fig. 5-12 Storage probe with bent spring

4.

FA ROTEX GSU - 04/2012

37

5 x Control
5.6 Changing the fuse
WARNING! Live parts can cause an electric shock on contact and cause life-threatening burns and injuries. Before work begin at the ROTEX GSU, disconnect the unit from the power supply (fuse, shut off main switch) and secure against unintentional restart. CAUTION! Electrostatic charge can damage the electronic components and connections on the circuit board. Do not touch the electronic components or connections with your bare hands. The fuse is located on the switch circuit board (fuse type: 250 V, 6.3 AT), substitute fuse in the housing upper part. 1. Open the boiler control panel and pull out all connection plugs from the circuit board (see section 5.4, steps 1 to 4).

Fig. 5-13

Remove the locking screws from the control panel housing

Fig. 5-14

Changing the fuse

2. 3. 4.

Remove the 4 locking screws on the control panel casing using a screwdriver (fig. 5-13). Remove the top of the casing. Change the fuse (fig. 5-14). If the fuse immediately blows upon switching on again, there is a short circuit in the electrical system. Have a professional electrician remedy the cause of the short circuit before putting in a new fuse.

38

FA ROTEX GSU - 04/2012

5 x Control
5.7 Wiring diagram

1 2 4 5 20 21 22 23 24 25

Mains switch Group malfunction lamp Pressure gauge capillary tube Control system: Central unit THETA 23R+ 4-Pin circuit board connector with switch cable 4-Pin circuit board connector with error lamp cable 4-Pin mains circuit board connector with clamped mains cable and ground wire 3-Pin circuit board connector with pump cable Circulation pump for heating 3-Pin circuit board to connect a circulation pump Wiring diagram

26 27 28 29 30 31 32

3-way switch valve 4-Pin circuit board connector with valve cable 6-Pin circuit board connector with clamped burner cable (power supply for combustion controller and burner blower) Modulating gas burner combustion controller 7-Pin circuit board connector to connect a mixer motor and a mixing circuit pump 3-Pin circuit board connector with communication cable 12-Pin circuit board connector to connect sensors, BUS and control lines

33 34 35 36 37 38 39 40 41

External temperature sensor Storage tank temperature sensor 8-Pin circuit board connector with terminal resistance or flue gas temperature sensor (optional) 16-Pin MOLEX-connector with cable for flow and return flow temperature sensor and blower control Flow temperature sensor Return flow temperature sensor Burner blower Switchboard PCB Stickers for connection assignment

Fig. 5-15

FA ROTEX GSU - 04/2012

39

6 x Gas burner
6 6.1 Gas burner Structure and brief description

Fig. 6-1

Gas burner of the GSU - Front views

1 2 3 4 5 6 7 8 9 10 11 12 13

Burner surface Blower Safety gas control block Gas-/air interlinked controller Gas solenoid valve (1 x Class B and 1 x Class C) Gas combustion controller ESYS Gas connection G " IG with connected gas hose Venturi orifice with air connection DN 50 Measuring port IN - Input gas pressure Measuring port OUT - Output gas pressure Adjusting screw gas-/air-mixture Adjusting screw gas pressure regulator (under cap) Burner flange Gas burner of GSU - Rear view

14/1 14/2 15/1 15/2 16 17 18 19 20 21 22

Ionisation electrode Ionisation cable Ignition electrode Ignition cable Flame tube insert Burner flange seal (O ring) Flame tube seal (graphite flat seal) Blower flange seal (Silicone flat seal) Clamping plates Air intake pressure hose Cover with strain relief for burner cable and securing screw for gas combustion controller Gas burner of GSU - Side view from left

Fig. 6-2

Fig. 6-3

40

FA ROTEX GSU - 04/2012

6 x Gas burner
Controlling the burner output
The control system determines continually the necessary flow temperature (according to the set operating parameters) and transmits the temperature to the gas burner combustion controller ESYS. The combustion controller calculates the required burner output from the target value and the values from the flow and the return flow temperature sensor. The determined output is passed to the burner fan as a PWM signal. The burner fan immediately adjusts the gas fan speed and as such the combustion air flow. The gas controller controls the gas volume accordingly.

Gas/air compound control


The gas/air compound control (pneumatic compound) ensures that the CO2 flow is maintained at a suitable level for each output and is set by the adjusting screw for the gas/air mix (fig. 6-3, pos. 11) and by the adjusting screw of the gas pressure controller (fig. 6-3, pos. 12) if required. The burner immediately responds to every change in the air flow volume through the gas/air compound control with a corresponding change in the gas flow volume. The gas/air compound control (pneumatic compound) consists of a Venturi nozzle with a ring-shaped gas inlet and a gas pressure controller. A vacuum forms in the centre of the Venturi nozzle depending on the volume flow of the combustible air. This causes the gas to be sucked into the centre of the Venturi nozzle, conveyed through the burner fan to the burner surface and optimally mixed. The gas valve can be adjusted for supply pressures from 5 to 60 mbar (zero pressure controller).

6.2

Unlocking in the event of malfunction shutdown


Safety function
The gas-combustion controller ESYS starts and monitors the firing program process. This is followed by a fault shutdown: if the starting speed of the burner fan is not achieved, if a flame signal is present during pre-ventilation, if no flame is formed at the start (fuel release) after 5 sec (safety period) (5 start attempts), if no flame is able to start or a flame failure during operation, or failed program repetition.

Unlocking the burner


The fault shutdown of the burner is displayed by "E" and a two-digit fault code on the display of the boiler control panel. Unlock the burner by briefly pressing the button on the control panel (fig. 5-1, pos. 13) (max. 5x per hour). If there are several shutdowns due to faults successively, check the heating system (e.g. flue system, fuel supply).

6.3

Burner setting
DANGER OF EXPLOSION! Escaping gas is a direct threat to human health and safety. Even a few sparks can cause major explosions. Before working on gas carrying parts, always close the main gas stop valve of the system. If you can smell gas, air the room thoroughly. Do not fan any open fire or operate any electrical switches. Only heating specialists authorised and trained by the gas or power supply company should be allowed to work on gas-conducting parts. The ROTEX GSU gas burners can be equipped with various blowers ex factory, which are operated with various speed settings. For the device types GSU 530S(F)-e and GSU 535S(F)-e it may also be necessary, to exchange the flame tube insert to adjust the desired burner output. This flame tube insert (FRE, E 15 00 600) Type B, if required, must be ordered separately. The respective modification instruction is enclosed in the scope of delivery for the flame tube insert.

FA ROTEX GSU - 04/2012

41

6 x Gas burner
The following burner configurations are possible: Flame tube insert GSU-Type GSU 320-e GSU 520S-e GSU 320 F-e GSU 520S F-e Blower type (Manufacturer) NRG 118 (ebm-papst) PX 118 (FIME) NRG 118 (ebm-papst) PX 118 (FIME) RG 148 (ebm-papst) GSU 530S-e PX 128 (FIME) RG 148 (ebm-papst) GSU 530S F-e PX 128 (FIME) GSU 535-e GSU 535 F-e
Tab. 6-1

Type A (Series) x x x x x x x x x x

Type B E1500600) x x x x x x

Adjustable load in Burner kW configuration 3.7 - 21.0 5.9 - 21.0 6.2 - 25.6 7.3 - 31.0 6.2 - 24.0 8.0 - 31.0 6.4 - 27.1 8.5 - 31.0 6.8 - 25.8 9.1 - 31.0 7.6 - 30.4 8.9 - 36.1 7.9 - 29.0 9.8 - 36.1 1a 2a 1AF 2AF 3a 3B 4a 4B 3AF 3BF 4AF 4BF 3A5 3B5 3A5F 3B5F

RG 148 (ebm-papst) RG 148 (ebm-papst)

Possible burner configurations with adjustment ranges

Before adjustments to the burner can be made it must be determined, which burner configuration is installed. The blower type can be obtained from the type plate on the blower (in the proximity of the outlet flange at the blower housing). If changes to the performance settings of the burner or a changeover to a new gas type must be made, these changes must be documented in the operating manual and entered onto the settings type plate (fig. 2-1, pos. 40 and fig. 6-4). The changeover must be provided with the date of implementation and the signature of the installer. If the system is changed to a different gas type, a respective unit sticker must be adhered to the red cover of the combustion controller ESYS (see also section 6.3.4).

Fig. 6-4

Settings type plate

42

FA ROTEX GSU - 04/2012

6 x Gas burner
6.3.1 Setting values
Burner configuration / GSU-Type Blower type (Manufacturer) / Flame tube insert Gas type (Test gas)** Setting for control pmeasurement Full load Basic load Full load Basic load Full load Basic load Full load Basic load 1A, 1AF* / GSU 320(F)*-e, GSU 520S(F)*-e NRG 118 (ebm-papst) / Type A Power setting Speed in % in 1/min 100 85 15 0 100 85 15 0 100 85 10 0 94 85 10 0 7500 6600 2400 1500 7500 6600 2400 1500 7200 6450 2610 2100 6900 6450 2610 2100 CO2-content O2-content in % in % Load in kW (0.2%) ( 0.1%) 21.1 18.6 6.7 4.1 21.0 18.5 6.6 4.1 21.3 19.1 7.9 6.4 21.0 19.6 8.2 6.7 9.7 9.6 9.5 9.5 9.5 9.4 9.3 9.3 11.3 11.3 11.2 11.1 11.6 11.6 11.4 11.4 3.7 3.7 4.0 4.0 3.7 3.7 4.0 4.0 3.7 3.7 4.0 4.0 3.7 3.7 4.0 4.0 Speed in % in 1/min 100 85 15 0 100 85 15 0 100 85 10 0 94 85 10 0 7500 6600 2400 1500 7500 6600 2400 1500 7200 6450 2610 2100 6900 6450 2610 2100 2A, 2AF*/ GSU 320(F)*-e, GSU 520S(F)*-e PX 118 (ebm-papst) / Type A Power setting CO2-content O2-content in % in % Load in kW (0.2%) ( 0.1%) 20.8 18.3 6.6 4.1 20.7 18.3 6.7 4.2 21.1 19.8 8.2 6.7 21.0 19.6 8.3 6.8 9.7 9.6 9.5 9.5 9.5 9.4 9.3 9.3 11.3 11.3 11.2 11.1 11.6 11.6 11.4 11.4 3.7 3.7 4.0 4.0 3.7 3.7 4.0 4.0 3.7 3.7 4.0 4.0 3.7 3.7 4.0 4.0

Natural gas E/H (G20) Natural gas LL/L (G25) Propane* (G31)

Butane* (G30)
*

Liquefied petroleum gas design (F)

** Compare with the information on the yellow sticker attached to the burner housing.

ROTEX Factory settings

Tab. 6-2

Flue gas setting values and speed limitations for GSU 320(F)-e and GSU 520S(F)-e, burner 1A/2A for various gas types

Burner configuration / GSU-Type Blower type (Manufacturer) / Flame tube insert Gas type (Test gas)** Setting for control pmeasurement Full load Basic load Full load Basic load Full load Basic load Full load Basic load

3A, 3AF* / GSU 530S(F)*-e RG 148 (ebm-papst) / Type A Power setting Speed in % in 1/min 100 91 10 0 100 91 10 0 100 91 10 0 100 91 10 0 6450 6000 1980 1500 6450 6000 1980 1500 6450 6000 1980 1500 6450 6000 1980 1500 CO2-content O2-content in % in % Load in kW (0.2%) ( 0.1%) 25.6 23.8 8.1 6.2 25.5 23.8 8.4 6.6 27.1 25.2 8.4 6.4 27.8 25.9 8.7 6.7 9.7 9.6 9.5 9.5 9.5 9.5 9.3 9.3 11.3 11.3 11.2 11.1 11.6 11.6 11.4 11.4 3.7 3.7 4.0 4.0 3.7 3.7 4.0 4.0 3.7 3.7 4.0 4.0 3.7 3.7 4.0 4.0 Speed

3B, 3BF* / GSU 530S(F)*-e RG 148 (ebm-papst) / Type B Power setting in % in 1/min 100 91 10 0 97 91 10 0 91 91 10 0 82 79 10 0 6450 6000 1980 1500 6300 6000 1980 1500 6000 6000 1980 1500 5550 5400 1980 1500 CO2-content O2-content in % in % Load in kW (0.2%) ( 0.1%) 31.6 29.4 9.7 7.3 31.2 29.7 9.8 7.5 32.8 32.8 11.1 8.5 31.4 30.6 11.4 8.7 9.7 9.6 9.5 9.5 9.5 9.5 9.3 9.3 11.3 11.3 11.2 11.1 11.6 11.6 11.4 11.4 3.7 3.7 4.0 4.0 3.7 3.7 4.0 4.0 3.7 3.7 4.0 4.0 3.7 3.7 4.0 4.0

Natural gas E/H (G20) Natural gas LL/L (G25) Propane* (G31)

Butane* (G30)
*

Liquefied petroleum gas design (F)

** Compare with the information on the yellow sticker attached to the burner housing.

ROTEX Factory settings

Tab. 6-3

Flue gas setting values and speed limitations for GSU 530S(F)-e with blower RG 148, burner 3A/3B for various gas types

FA ROTEX GSU - 04/2012

43

6 x Gas burner

Burner configuration / GSU-Type Blower type (Manufacturer) / Flame tube insert Gas type (Test gas)** Setting for control pmeasurement Full load Basic load Full load Basic load Full load Basic load Full load Basic load

4A, 4AF* / GSU 530S(F)*-e PX 128 (FIME) / Type A Power setting Speed in % in 1/min 100 88 10 0 100 88 10 0 100 88 10 0 100 88 10 0 6600 6000 2280 1800 6600 6000 2280 1800 6600 6000 2280 1800 6600 6000 2280 1800 CO2-content O2-content in % in % Load in kW (0.2%) ( 0.1%) 24.0 21.8 8.0 6.2 23.9 21.7 7.9 6.1 25.8 23.4 8.7 6.8 26.1 23.7 8.7 6.8 9.7 9.6 9.5 9.5 9.5 9.5 9.3 9.3 11.3 11.3 11.2 11.1 11.6 11.6 11.4 11.4 3.7 3.7 4.0 4.0 3.7 3.7 4.0 4.0 3.7 3.7 4.0 4.0 3.7 3.7 4.0 4.0 Speed in % 100 88 10 0 100 88 10 0 91 88 10 0 91 88 10 0

4B, 4BF* / GSU 530S(F)*-e PX 128 (FIME) / Type B Power setting in 1/min 6600 6000 2280 1800 6600 6000 2280 1800 6150 6000 2280 1800 6150 6000 2280 1800 CO2-content O2-content in % in % Load in kW (0.2%) ( 0.1%) 31.1 28.2 10.3 8.0 31.6 28.7 10.8 8.5 31.4 30.7 11.6 9.1 31.5 30.7 11.7 9.2 9.7 9.6 9.5 9.5 9.5 9.5 9.3 9.3 11.3 11.3 11.2 11.1 11.6 11.6 11.4 11.4 3.7 3.7 4.0 4.0 3.7 3.7 4.0 4.0 3.7 3.7 4.0 4.0 3.7 3.7 4.0 4.0

Natural gas E/H (G20)

Natural gas LL/L (G25)

Propane* (G31)

Butane* (G30)
*

Liquefied petroleum gas design (F)

** Compare with the information on the yellow sticker attached to the burner housing.

ROTEX Factory settings

Tab. 6-4

Flue gas setting values and speed limitations for GSU 530S(F)-e with blower PX 128, burner 4A/4B for various gas types

Burner configuration / GSU-Type Blower type (Manufacturer) / Flame tube insert Gas type (Test gas)** Setting for control pmeasurement Full load Basic load Full load Basic load Full load Basic load Full load Basic load

3A5, 3A5F* / GSU 535(F)*-e RG 148 (ebm-papst) / Type A Power setting Speed in % in 1/min 100 80 10 0 100 80 10 0 100 88 10 0 100 88 10 0 7500 6360 2370 1800 7500 6360 2370 1800 6600 6000 2280 1800 6600 6000 2280 1800 CO2-content O2-content in % in % Load in kW (0.2%) ( 0.1%) 30.4 25.9 9.9 7.6 30.5 26.0 10.2 7.9 29.0 26.4 10.0 7.9 29.3 26.7 10.0 7.9 9.7 9.6 9.5 9.5 9.5 9.4 9.3 9.3 11.3 11.3 11.2 11.1 11.6 11.6 11.4 11.4 3.7 3.8 4.0 4.0 3.7 3.8 4.0 4.0 3.7 3.7 4.0 4.0 3.7 3.7 4.0 4.0 Speed in % 100 80 10 0 92 80 10 0 100 88 10 0 97 88 10 0

3B, 3B5F* / GSU 535(F)*-e RG 148 (ebm-papst) / Type B Power setting in 1/min 7500 6360 2370 1800 7050 6360 2370 1800 6600 6000 2280 1800 6450 6000 2280 1800 CO2-content O2-content in % in % Load in kW (0.2%) ( 0.1%) 36.2 30.7 11.6 8.9 36.3 32.7 12.3 9.4 36.8 33.4 12.5 9.8 36.6 34.0 12.9 10.2 9.7 9.6 9.5 9.5 9.5 9.5 9.3 9.3 11.3 11.3 11.2 11.1 11.6 11.6 11.4 11.4 3.7 3.8 4.0 4.0 3.7 3.7 4.0 4.0 3.7 3.7 4.0 4.0 3.7 3.7 4.0 4.0

Natural gas E/H (G20) Natural gas LL/L (G25) Propane* (G31)

Butane* (G30)
*

Liquefied petroleum gas design (F)

** Compare with the information on the yellow sticker attached to the burner housing.

ROTEX Factory settings

Tab. 6-5

Flue gas setting values and speed limitations for GSU 535(F)-e with blower RG 148, burner 3A/3B for various gas types

44

FA ROTEX GSU - 04/2012

6 x Gas burner
6.3.2 Checking and setting the burner
The gas burner has been factory-set for a certain gas type. The preset gas type and the designated gas inlet pressure are indicated on the yellow sticker placed on the burner housing. Inspecting the burner capacity with a flue gas analyser In chimney sweep mode with maximum (full) load, In chimney sweep mode with minimum (basic) load. With the chimney sweep button, the settings for full load (parameter 02) and basic load (parameter 04) in the parameter level of combustion controller can be actuated. Within the permissible limit values (see tab. 6-2 to tab. 6-5), these settings can be adjusted individually to the respective system requirements.

Auxiliary resources
Flue gas analysis device. Pressure meter for measuring gas pressure.

Checking and setting (observe the sequence)


1. Inspect the pre-settings, so that the burner is set to the correct gas type and the correct gas inlet pressure. If the test gas indication on the yellow sticker on the burner housing varies from the test gas associated to the available gas type or if the stated value deviates from the permissible gas inlet pressure, the burner must be converted to the local conditions (see section 6.3.3 to 6.3.6). 2. 3. 4. Turn the screw in the gas inlet pressure measuring connection (fig. 6-3, pos. 9) anticlockwise by half a turn and push up the measuring hose of the pressure meter. Open the gas stopcock. Measure the gas inlet pressure (idle pressure) and compare it with the target value (according to tab. 11 -5). Leave the measuring instrument connected. If the gas inlet pressure (resting pressure) is outside the set value range: Inform your gas supply company or check the pressure regulator (for liquid gas). 5. 6. 7. Open the heating valves. Switch on ROTEX GSU with main switch. Switch on the chimney sweep function for the full load. If the burner does not start, even with the power and gas supply properly connected and with the flue gas path free, a new burner basic setting must be carried out (see section. 6.3.3). 8. 9. Connect the flue gas analysis unit. Check flow pressure. The gas inlet flow pressure must not fall essentially below the idle pressure minus the pressure loss in the gas connection hose (see chapter 11 "Technical data"). If the flow pressure is too low, the burner output also drops. 10. If the measured flue gas values do not change anymore (for the soonest 3 min after the start of the burner), measure the CO2-content and the O2-content. Compare the measured values with the specified setting values (see section 6.3.1). 11. If the CO2 concentration is outside 0.2% or the O2 concentration is outside 0.1% of the set target values: Readjust burner using the adjusting screw for the gas/air mixture (fig. 6-3, pos. 11): Left turn (counter clockwise) Right turn (clockwise) more gas: O2p, CO2 n less gas: O2n, CO2 p

12. Set the chimney sweep function for minimum load. 13. If the measured flue gas values do not change anymore (for the soonest 2 min after energy change), measure the CO2content and O2-content. Compare the measured values with the specified setting values (see section 6.3.1).

FA ROTEX GSU - 04/2012

45

6 x Gas burner
14. If the CO2 concentration is outside 0.2% or the O2 concentration is outside 0.1% of the set target values or the burner whistles: Readjust the burner using the adjusting screw for the gas pressure controller (fig. 6-3, pos. 12) (see section 6.3.6): Left turn (counter clockwise) Right turn (clockwise) less gas outlet pressure: O2n, CO2 p more gas outlet pressure: O2p, CO2 n Adjustment procedure is finished. Repeat the steps 8-14.

15. Set the chimney sweep function for maximum load and recheck the combustion values. The values adjust according to the specifications (compare step 8) The values adjust not according to the specifications

16. All changes of the output setting values must be entered on the Settings type plate beneath the type plate and in the operating manual.

6.3.3 Carrying out the basic setting on the burner.


If the burner does not start, even with the power and gas supply properly connected and with the flue gas path free, a new burner basic setting must be carried out see section.

Basic setting
Screw in the adjusting screw for the gas/air mixture (fig. 6-3, pos. 11) clockwise up to the stop (do not tighten). Open the adjusting screw for the gas/air mixture according to tab. 6-6 counter clockwise: Number of rotations Gas type Natural gas E/H Natural gas LL/L Propane* Butane*
Tab. 6-6

Associated test gas G20 G25 G31 G30

GSU 320(F)-e 5.5 8.5 6 4

GSU 520S(F)-e GSU 530S(F)-e 5.5 8.5 6 4


*

GSU 535(F)-e 7 10 7 5

9 12 8 6

Number of rotations for adjusting the gas/air mixture

Liquefied petroleum gas design (F)

Restart the burner. If the burner does not start, open the adjusting screw for gas/air mixture further by 2 more turns and restart the burner. After carrying out the basic setting for the burner, the burner must be checked and fine setting should be carried out. (see section 6.3.2).

6.3.4 Resetting the gas type


The burner is factory set to the gas type indicated on the yellow sticker on the burner housing or on the settings type plate (fig. 6-4).

Resetting from natural gas E/H to natural gas LL/L


1. 2. 3. 4. Open adjusting screw for gas/air mixture (fig. 6-3, pos. 11) 3 rotations anticlockwise. Set burner (see section 6.3.2). A gas type changeover and the adjusted thermal load must be entered on the settings type plate and in the operating manual and confirmed with signature. Place the device sticker for LL/L gas setting (in scope of supply) on the fan housing of the burner.

46

FA ROTEX GSU - 04/2012

6 x Gas burner
Resetting from Liquid petroleum gas to natural gas
WARNING! Live parts can cause an electric shock on contact and cause fatal burns or injuries. Before beginning the maintenance work, disconnect the ROTEX GSU from the power supply (fuse, shut off main switch) and secure against unintentional restart. 1. 2. 3. 4. Switch off the ROTEX GSU and secure against restart. Unscrew and remove the cover from the combustion controller (fig. 6-3, pos. 22) and disconnect all cables from the combustion controller. Disconnect the air intake pressure hose (fig. 6-2, pos. 21) from the safety gas control block (fig. 6-2, pos. 3). Unscrew the Venturi nozzle with the safety gas control block from the burner blower (fig. 6-5) and remove it (fig. 6-6).

Fig. 6-5

Unscrew the Venturi nozzle with the safety gas control block

Fig. 6-6

Remove the Venturi nozzle with the safety gas control block

5.

Unscrew and remove the 3 bolts that bolt down the venturi nozzle to the safety gas control block (fig. 6-7, step 1). Take of the venturi nozzle (fig. 6-7, step 2). Remove the brass bezel between the safety gas control block and the venturi nozzle (fig. 6-7, step 3).

6. 7.

Fig. 6-7

Unscrew and remove the venturi nozzle and take off the brass bezel

8. 9.

Using the 3 screws, screw the Venturi nozzle back on the safety gas control block and then onto the burner fan. Connect all cables again to the combustion controller, screw on the cover of the combustion controller and attach the air intake pressure hose to the safety gas control block.

10. Start the burner check for leakage and adjust (see section 6.3.2). If necessary, adapt the output limits (see tab. 6-2 to tab. 6-5). 11. A gas type changeover and the adjusted thermal load must be entered on the settings type plate and in the operating manual and confirmed with signature. 12. Apply the unit sticker for natural gas H/E- or natural gas LL/L (to be ordered from ROTEX) on the red housing cover of the des combustion controller ESYS. FA ROTEX GSU - 04/2012 47

6 x Gas burner
Changeover from natural gas to liquid gas
WARNING! Live parts can cause an electric shock on contact and cause fatal burns or injuries. Before beginning the maintenance work, disconnect the ROTEX GSU from the power supply (fuse, shut off main switch) and secure against unintentional restart. 1. 2. 3. 4. 5. 6. 7. Switch off the ROTEX GSU and secure against restart. Unscrew and remove the cover from the combustion controller (fig. 6-3, pos. 22) and disconnect all cables from the combustion controller. Disconnect the air intake pressure hose (fig. 6-2, pos. 21) from the safety gas control block (fig. 6-2, pos. 3). Unscrew the Venturi nozzle with the safety gas control block from the burner blower (fig. 6-5) and remove it (fig. 6-6). Unscrew and remove the 3 bolts that bolt down the venturi nozzle to the safety gas control block (fig. 6-7, step 1). Take of the venturi nozzle (fig. 6-7, step 2). Insert the brass bezel for liquid gas between the safety gas control block and the Venturi nozzle (fig. 6-7, step 3). GSU 320-e / GSU 520S-e: GSU 530S-e / GSU 535-e: 8. 9. E15 00 605 E15 00 606

Using the 3 screws, screw the Venturi nozzle back on the safety gas control block and then onto the burner fan. Connect all cables again to the combustion controller, screw on the cover of the combustion controller and attach the air intake pressure hose to the safety gas control block.

10. Start the burner check for leakage and adjust (see section 6.3.2). If necessary, adapt the output limits (see tab. 6-2 to tab. 6-5). 11. A gas type changeover and the adjusted thermal load must be entered on the settings type plate and in the operating manual and confirmed with signature. 12. Apply the unit sticker for liquid gas (to be ordered from ROTEX) on the red housing cover of the des combustion controller ESYS.

6.3.5 Adjusting the output limits and the starting output


The burner output is limited by entering parameter data into the control system. The output values are entered relatively to the difference from the absolute max. speed (100%) and the absolute min. speed (0%) of the burner blower. Additional information for the parameter entry can be found in the "ROTEX Control" documentation. This documentation is included in the scope of delivery. A targeted output adjustment is carried out by; Determining the matching burner speed for the desired output, from fig. 11-2 to fig. 11-5 or tab. 6-2 to tab. 6-5.

Q n

Burner load Blower speed Fig. 6-8 Determination process for the burner blower target speed

The values stated in the diagrams and tables have been determined on the test bench. Deviations due to the individual position and installation situation may occur.

48

FA ROTEX GSU - 04/2012

6 x Gas burner
Determining the required parameter setting value FX, from fig. 11-6 to fig. 11-8.

FESYS Output parameter setting value for the control system n Blower speed Fig. 6-9 Determining the value FX for the output setting through the control system

Limiting the maximum burner output


The limiting of the maximum burner output would be advisable, for example, in the event of better sourcing charges for lower installed outputs. Enter the access code for the heating engineering and request the parameter level "Automatic firing unit". Enter the maximum speed of the burner fan for the heating mode (parameter 2). Enter the maximum speed of the burner fan for the hot water charging mode (parameter 3). Enter the output change on the settings type plate and in the operating manual and confirm with signature.

Limiting the minimum burner output


Raising the minimum burner output would be advisable, for example, if the flue gas side resistance were relatively high and the flame became unstable with a minimum load, or if the partial load demands were not fulfilled when designing the flue gas system. Enter the access code for the heating engineering and request the parameter level "Automatic firing unit". Enter the minimum speed for the burner fan (parameter 4). Enter the output change on the settings type plate and in the operating manual and confirm with signature.

Adjusting the starting output


Usually, the burner start is problem free and quiet, if the burner adjustment has been completed correctly (see section 6.3.2) with the factory set starting output. If during the starting process an obvious deflagration or whistling sound occur, or several starting attempts are necessary on a regular basis, a slight change in the starting output may remedy the occurrences. 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: Enter the access code for the heating engineering and request the parameter level "Automatic firing unit". Enter the starting speed for the burner fan (parameter 5). Enter the performance changes in the operational handbook and confirm with your signature.

6.3.6 Setting the gas pressure controller


The gas valves are factory-set. As a rule, no changes should be made to the gas pressure controller. The adjusting screw (fig. 6-3, pos. 12) is hidden under a cover. If the set value for basic load deviates to much from the target value or if the burner tends to whistle: Adjust the adjusting screw for the gas pressure controller (fig. 6-3, pos. 12) in small steps (maximum half a turn per adjustment step). After each adjusting step, wait at least 2 minutes. Check the changes in the combustion quality with a flue gas analyser. If the burner produces noises in the lowest output setting (basic load) (weather based!): set the min. output to a higher value.

FA ROTEX GSU - 04/2012

49

6 x Gas burner
6.3.7 Setting ignition and Ionisation electrodes
CAUTION! Ignition electrodes can break with cold deformation. Dismantle the burner before adjusting the electrodes and make the electrodes glow by using a solder lamp. The electrodes are factory-set. For adjusting: see fig. 6-10.

Fig. 6-10

Adjustment of the ignition and ionisation electrodes

6.4

Dismantling the burner


WARNING! Live parts can cause an electric shock on contact and cause fatal burns or injuries. Before removing the burner, shut off the main switch for the heater and secure against unintentional restart. WARNING! Danger of burning from hot surfaces (flame tube). Let the burner cool down sufficiently before dismantling. Wear protective gloves. The burner works, as a rule, almost without any wear and residue. It may be necessary to dismantle the burner for some cleaning and servicing jobs or if there is damage in the combustion chamber area.

50

FA ROTEX GSU - 04/2012

6 x Gas burner
Burner dismantling
Block gas supply. Disconnect ROTEX GSU from the power supply (fuse, main switch switched off) and secure against unintentional restart. Pull off the air supply hose on the burner and rotate sideways. Pull out the mains plug for the fan and the plug for the fan control. Unscrew and remove the cover with strain relief from the combustion controller and disconnect all 3 connectors (fig. 6-12).

6 Combustion controller ESYS 23 Air supply hose 24 Mains connector for the blower 25 Connector for blower control system Fig. 6-11 Burner

22

Cover with strain relief at the combustion controller

Fig. 6-12

Unscrew and remove the ESYS cover and disconnect the connector

Unscrew and remove the 4 fastening nuts M6 at the burner flange (fig. 6-13). Lift burner from burner chamber (fig. 6-14).

Fig. 6-13

Unscrew the burner flange

Fig. 6-14

Remove the burner

WARNING! An incorrect burner removal and installation can lead to gas leakages. Only loosen the two clamping plates at the burner flange (secured with locking paint), if the flame tube insert must be replaced.

Burner installation
Insert the burner into the combustion chamber and tighten the burner flange with the 4 fastening nuts. Attach and fasten the ground cable under one of the nuts. Restore all electrical plug connections. Connect the air supply hose to the burner. Check the gas line for leakage. Start the burner. Check for function, leakage at the burner flange and the settings (see section 6.3.2).

FA ROTEX GSU - 04/2012

51

7 x Hydraulic connection
7 7.1 Hydraulic connection Important information on the hydraulic connection

To avoid damage to persons and things, please observe the instructions for the hydraulic system connection of the ROTEX GSU.

Protection against scalding


During operation of the ROTEX GSU, the storage tank temperature may exceed 60C, particularly when solar power is used. For this reason, install a scald protection (domestic hot water mixing construction, e.g. VTA32, 15 60 16) when installing the system.

Prevention of emission of exhaust gas


To prevent the emission of exhaust gas, before commissioning the ROTEX GSU, the storage tank container must be filled up to the overflow mark.

Protection against corrosion


In a few regions, the water supply companies supply aggressive drinking water, which can cause corrosion damage, even with high-quality stainless steels. Check with your water supply works whether corrosion problems can occur when using hot water storage made of special steel in your area. Also take into account the requirements of quality of heating water (see chapter 1.5.4). Suitable water treatment may be required.

Maximum energy utilisation


The device achieves the most effective energy utilisation when the return flow temperatures are as low as possible. This requires hydraulic balancing of the heating system, which is often also a prerequisite for conveying equipment.

7.2

Storage tank
Design
All plastic, double shell design (corrosion-free). Space between internal and external tanks foamed up with high heat insulation (low surface losses). External wall 3-4 mm thick (impact-resistant and shockproof).

Method of operation
The pressure-less storage water serves as water storage medium. Useful heat is supplied and led out by completely submerged, helically intertwined stainless steel corrugated tubes (1.4404). The hot water zone in the storage tank container acts as combination of heat accumulator and flow heater (see fig. 2-2 and fig. 2-3). The cold water flowing back after hot water removal is first guided to the bottom of the storage tank container and cools the storage area maximum. The hot water zone is heated up, if necessary, with the gas condensing boiler. Water flows through the heat exchanger for storage charging (SL-WT) from top to bottom. This improves efficiency and the yield of the solar heating system. On its way to the top, the domestic water continuously absorbs the heat of the storage tank water. The flow direction, operating on the principle of counter-flow, and the coil-shaped heat exchanger create a pronounced temperature layering in 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 hot water output is achieved even if water is drawn off over a long period of time. For the models GSU 520S(F)-e and GSU 530S(F)-e the SL-WT ends approx. 40 cm above the container floor. Only the hot water zone above it is heated by the boiler. The tank volume below it is heated only on using the solar energy. For the models GSU 320(F)-e and GSU 535(F)-e the SL-WT is pulled down all the way to the container floor. The total storage volume is heated by the boiler (higher standby hot water capacity).

Water hygiene
The separation of pressure-less storage water and hot water flowing into the corrugated pipe heat exchanger secures the optimum water hygiene of the ROTEX GSU: There are no zones with a low flow rate or zones that are not heated on the hot water side. It is impossible for sludge, rust or other sediments to be deposited, as can be the case with other large volume tanks. The water fed into the system first is also discharged first (first in, first out principle).

52

FA ROTEX GSU - 04/2012

7 x Hydraulic connection
Storage water heating
For the initial start-up, the storage tank will be filled once with unpressurized storage water, which will later on not be exchanged anymore. The storage water can be heated in two different ways: through the integrated gas condensing boiler, by a ROTEX solar installation additionally connected directly to the zero pressure area, through another heat source directly connected to the pressure-less area (e.g. hot water heat pump).

Maintenance
Thermal and pressure expansion and the high flow rates in the heat exchangers cause limescale residue to peel away; this residue is rinsed out and is not deposited. On the storage water side, dissolved lime can result only once in the filled water. Thanks to the smooth surface of the stainless steel corrugated pipe heat exchanger, no limescale crust forms (no reduction in heat transfer performance over time). Corrosion protection devices (e.g. reactive anodes) are not needed. This means that associated maintenance work, e.g. changing the protective anodes or cleaning the storage tank, does not need to be carried out. At the annual boiler inspection, only the water level is checked and topped up if necessary (see chapter 8.2.2).

7.3

Hydraulic system connection


7.3.1 Short names in the connection schemes

Short name

Meaning GasSolarUnit with solar heating support

GSU GasSolarUnit without solar heating support 1 2 3 4 5 6 7 7a 8 AMK1 DTR FLG FLS HEM1+ Mi PMi PK PS1 PS2 PWEx PZ RPS3 SCS 538/0/0 SK Cold water Domestic hot water Heating flow Heating return flow Mixing circuit Circulation circuit Check valve, return valve Gravity brake (for cold/hot water connection) Solar circuit Mixer group Difference temperature regulation Solaris FlowGuard regulation valve with flow indicator Flow sensor (flow and flow temperature measurement) Heating circuit expansion module 3-way-mixer with drive motor Mixer circuit pump Boiler circuit pump Tank circulation pump Solar panel circulation pump Pump for external heat generator circuit Circulation pump Regulation and pump unit Solaris Sanicube as buffer storage for external heat exchanger High-performance flat solar panel

Remark GSU 520S-e GSU 520S F-e GSU 530S-e GSU 530S F-e GSU 320-e GSU 320 F-e GSU 535-e GSU 535 F-e

Order No. 15 71 13 15 71 14 15 71 25 15 71 26 15 70 31 15 70 32 15 71 43 15 71 48

Optional Provided by customer Accessories Optional Accessories Provided by customer

16 50 70 15 60 44

16 41 02 Accessories FlowSensor FLS20 16 41 07 Accessories 15 60 64 Supplied with AMK1. Supplied with GSU. Supplied with RPS3. Supplied with RPS3. Provided by customer Provided by customer Accessories Accessories Solaris V21P Solaris V26P Solaris H26P

16 41 06 15 45 15 16 20 12 16 20 10 16 20 11 53

FA ROTEX GSU - 04/2012

7 x Hydraulic connection
Short name SV t1 t2 tAG tAU tDHW tV tR tMi tK tR tS tV TMV TSF V UV2 VS WEx Meaning Safety pressure relief valve Heating return temperature sensor Buffer storage temperature probe Flue gas temperature sensor Outside temperature sensor Storage tank temperature sensor Heating inflow temperature probe Heating return temperature sensor Mixer circuit flow temperature sensor Solaris panel temperature sensor Solaris return temperature sensor Solaris storage tank temperature sensor Solaris inflow temperature probe Thermostatic 3-way valve for return temperature increase Storage tank temperature sensor Overflow valve 3-way switch valve Burns guard VTA32 External heat generator (e.g. Pellet wooden boiler, other solid matter boiler, heat pump) Separation of the standard connection - PK must be removed from the device and reconnected outside the device. Remark Suitable for DTR Suitable for DTR Accessories Supplied with GSU. Supplied with GSU. Supplied with GSU. Accessories 15 60 62 Supplied with the Solaris roof penetration package. Supplied with RPS3. Supplied with FLS. Provided by customer Accessories Provided by customer Supplied with AMK1. Accessories Provided by customer Provided by customer Order No.

15 70 52

15 60 63

15 60 15

Tab. 7 -1 Short names in hydraulic drawings

7.3.2 ROTEX GasSolarUnit with solar heating support

Fig. 7-1

Standard connecting diagram ROTEX GasSolarUnit with solar heating support

54

FA ROTEX GSU - 04/2012

7 x Hydraulic connection
ROTEX GasSolarUnit without solar heating support

Fig. 7-2

Standard connecting diagram ROTEX GasSolarUnit without solar heating support

Wooden boiler integration to ROTEX GasSolarUnit

Fig. 7-3

Wooden boiler integration to the ROTEX GasSolarUnit

FA ROTEX GSU - 04/2012

55

8 x Service and maintenance


8 8.1 Service and maintenance General overview of inspection and maintenance

Regular inspection and maintenance of the heating system reduces energy consumption and ensures a long life and smooth operation. Have the inspection and maintenance carried out by authorised and trained heating engineers once a year and, if possible, before the heating period. This will avoid malfunctions during the heating period. ROTEX recommends an inspection and maintenance contract to ensure regular inspection and maintenance.

Tests during annual inspection


General condition of the heating system, visual inspection of connections and conduits. Condensate drain, flue gas temperature and possibly optional flue gas temperature sensor. Burner operation and burner settings.

Maintenance work to be carried out annually


Cleaning the burner components, the combustion chamber and the heating surfaces. Cleaning of the storage container and the silencer hood. Replacement of the wearing parts (if required). Documentation of the maintenance work in the operating manual. Before recommissioning the ROTEX GSU after maintenance work the conditions for commissioning as per chapter 4.2 must be checked and fulfilled.

8.2

Service and maintenance tasks


WARNING! Live parts can cause an electric shock on contact and cause fatal burns or injuries. Before beginning the maintenance work, disconnect the ROTEX GSU from the power supply (fuse, shut off main switch) and secure against unintentional restart. CAUTION! Danger of burning - hot surfaces. Let the burner cool down for a reasonably long time before maintenance and service work. Wear protective gloves.

Remove the silencer hood.


For inspection and maintenance, it is necessary to remove the silencer hood placed on the storage tank.
1 2 3 Remove the fixing screws. Tilt the silencer hood. Lift off the silencer hood towards the front.

Fig. 8-1

Remove the sound insulation hood.

Cleaning silencer hood and storage tank


The low-maintenance plastic only needs to be cleaned with a soft cloth and a mild detergent. Do not use any cleaners with aggressive solvents (damage to the plastic surface may occur).

56

FA ROTEX GSU - 04/2012

8 x Service and maintenance


8.2.1 Checking the connections and pipes
WARNING! Incorrect conducted work on live and gas carrying components can endanger the life and health of personnel and impair the function of the GasSolarUnit. Damage repair to live or gas carrying components of the ROTEX GSU must only be conducted by heating engineers that are authorised and approved through the gas or energy supply company. Inspect all (flue) gas and water carrying components and connections for leakages and system integrity. If damaged, determine the cause and replace the damaged parts. Check all components of the flue system for leakage and damage. Repair damaged parts or replace them. Check all electrical components, connections and conduits. Repair damaged parts.

8.2.2 Checking and cleaning the condensate drain.


The connection and leakage line of the condensate drain must be free from impurities. If a Solaris system (Drain-Back-System) is connected and in operation, shut down this system and drain the collectors. Open the condensate drain (connection and drain conduit). Check that the condensate drain is free from blockages and clean if necessary. Unscrew the overflow hose. Visual inspection of container filling level (water level at the overflow rim). If necessary, correct the fill level; determine the reason for the low water level and remedy it. Check the overflow hose connection and drain section for leakage, unobstructed flow and gradient.

Fig. 8-2

Check condensation water drain

The condensation is light acid. It is conducted into the pressureless area of the storage tank. This ensures that the storage container is always completely filled up during the normal system operation. A long-term neutralisation filling in the container ensures that the fluid leaving the container has neutral pH. Any depositions remain in the pressureless area of the container.

8.2.3 Checking and cleaning the burner


DANGER OF EXPLOSION! Escaping gas is a direct threat to human health and safety. Even a few sparks can cause major explosions. Only loosen the two clamping plates at the burner flange, (secured with locking paint), if the flame tube insert must be replaced. When re-installing the burner, attach the ground cable under one of the 4 fastening nuts for the burner flange. Only heating specialists authorised and trained by the gas or power supply company should be allowed to work on gas-conducting parts. As a rule, the burner does not wear. If contaminations or unsatisfactory combustion values are detected, the burner must be removed (see chapter 6.4 "Dismantling the burner"), cleaned and, if necessary, re-adjusted (see chapter 6.3 "Burner setting").

FA ROTEX GSU - 04/2012

57

8 x Service and maintenance


Cleaning the combustion chamber
WARNING! Live parts can cause an electric shock on contact and cause fatal burns or injuries. Before beginning the maintenance work at the burner, disconnect the ROTEX GSU from the power supply (fuse, shut off main switch) and secure against unintentional restart. WARNING! Danger of burning - hot surfaces. Let the burner cool down for a reasonably long time before maintenance and service work. Wear protective gloves. Remove the burner (see chapter 6.4 "Dismantling the burner") Rinse the flue gas path with clean water (hose or steam jet device in the open combustion chamber).

Checking the burner


Checking the burner includes visually inspecting the burner's condition as well as making flue gas measurements. For exact information regarding the checking and setting of the burner, see chapter 6.3 "Burner setting". For exact information regarding the assembly and disassembly of the burner, see chapter 6.4 "Dismantling the burner". The scope of inspection includes: Clean the burner surface (cloth, plastic brush). Conduct a visual inspection of the ignition and ionisation electrodes for damages and correct electrode gap (see chapter 6.3.7 "Setting ignition and Ionisation electrodes"). In the course of maintenance work, the safety relevant components must be additionally inspected for the expiration of their nominal service life: Combustion controller ESYS: 10 years or 250,000 burner starts, Safety gas control block 10 years or 250,000 burner starts, Overpressure safety valve: 10 years. If necessary, replace faulty parts. Mount burner in combustion chamber. Check the gas line for leakage. Put the burner into operation and let it run for about 5 minutes in the chimney sweep position. Check combustion values: Flue gas temperature at measuring sockets of the flue gas pipe. (Target value < 80C), O2- or CO2-content (see chapter 6.3.1 "Setting values"), CO content (target value < 50 ppm). If the combustion values lie not within the target range, the burner must be adjusted according to chapter 6.3 "Burner setting". We recommend, to enter all measured values and the conducted work with the date and signature into the enclosed operating handbook.

58

FA ROTEX GSU - 04/2012

9 x Faults and malfunctions


9 9.1 Faults and malfunctions Troubleshooting

The electronics of the GasSolarUnit detects faults and indicates them: with an error code in the display, if the ROTEX THETA 23R+ boiler control system detects an error, with the general malfunction lamp in the boiler control panel and an error code in the display, if the combustion controller ESYS detects an error that leads to a locking malfunction. Detailed information for the control system and the boiler control panel as well as for the operating modes and parameter settings can be found in the "ROTEX Control system" documentation. This documentation is included in the scope of delivery.

Solving failures
Detecting and remedying the cause of the malfunction. Interlocking fault: Release the lock by briefly pressing the hand button on the boiler control panel (max. 5x per hour). Non-interlocking failures are indicated as long as failure conditions are present. Once the cause has been eliminated, the unit continues to work normally.

9.2

Failures
Failure Possible cause Possible solution Switch on the main switch for the boiler. Switch on the main switch for the boiler room. Switch on the fuse for the house connection. Replace the fuse for the boiler control panel.

No mains voltage Heating system not functioning (main switch not illuminated, no display) Heating does not warm up Heating does not warm up enough Central heating stand-by switched off (e.g. timer is in economy phase, outside temperature too high) Heating characteristic too low

Check the operating mode setting. Check the request parameters. Increase the parameter value.

Hot water does not warm Storage charging standby switched off (e. g. timer is in Check the operating mode setting. up economy phase) Check the request parameters. Hot water does not warm Storage tank charging temperature too low up enough Draw-off rate too high Burner output too low Burner does not start Interlocking failure Increase the target hot water temperature. Reduce the draw-off rate, limit throughput. See malfunction "max. burner output is too low". Determine and repair the cause for the malfunction. Release the lock by briefly pressing the hand button (max. 5x per hour). Connect the 3-pin connector securely to the blower. Connect the 5-pin connector securely to the blower. Check the voltage at the terminals of the connectors. Check the connector in the control panel and at the combustion controller and connect them correctly.

Burner fan not running despite burner demand

No mains voltage on burner fan

Fan motor faulty No ignition Ignition electrodes dirty, faulty or incorrectly set

Replace the burner blower. Clean the ignition electrodes. Adjust the ignition electrodes. Replace burnt or non-adjustable ignition electrodes. Replace ignition electrodes with a defective insulator.

Ignition cable burnt Automatic firing unit faulty

1. Determine and repair the cause for the burnt cable. 2. Replace the ignition cable. Change automatic firing unit

FA ROTEX GSU - 04/2012

59

9 x Faults and malfunctions


Failure Burner fan not starting despite burner demand Possible cause No mains voltage on burner fan Possible solution Connect the 3-pin connector securely to the blower. Connect the 5 pin connector securely to the blower. Check the voltage at the terminals of the connectors. Check the connector in the control panel and at the combustion controller and connect them correctly.

Fan motor faulty No mains voltage on burner

Replace the burner blower. Check the connector in the control panel and at the combustion controller and connect them correctly. Replace the cables. Adjust the ionisation electrode. Clean up oxidized electrode areas on the ionisation electrode (with fine sanding paper). Replace worn ionisation electrodes. Inspect the gas connections. Vent the gas line. Inspect the plug connection between the gas valve and the combustion controller, connect correctly if necessary. Re-align the connecting pins of the plug connection. Check gas valve (vacuum at outlet pressure measuring socket during pre-ventilation, zero pressure during the ignition) Replace the gas valve. Replace the combustion controller. See "No ignition" failure Re-adjust the burner setting. Reduce the max. output. Replace the burner blower. Adjust the output parameter. Check the lines for contaminations. If necessary, install lines with a larger line cross-section for supply air or flue gas.

Flame monitoring switches off

No gas pressure Air in the gas line Gas valve not opening

No ignition Loud operating noises Wrong burner setting Bearing damage on burner fan Maximum burner output Incorrect setting parameters too low Air/flue gas resistance too high

Tab. 9 -1 Possible faults on the ROTEX GSU

60

FA ROTEX GSU - 04/2012

9 x Faults and malfunctions


9.3 Fault code
Component/Designation Outside temperature sensor Interruption Short circuit Mixer circuit flow temperature sensor Interrupt Mixer circuit pump is turned off and the mixer motor is disconnected from power. Short circuit: mixer circuit pump is turned off and mixer motor disconnected from power. Hot water storage tank temperature sensor Modem contact Burner inhibit contact Interruption Short circuit Fault signal Fault signal Fault

Fault code 10-0 10-1 12-0 12-1 13-0 13-1 14-7 15-7 16-0 16-1 16-7 17-0 17-1 30-2 30-3 33-5 70-0 70-1 70-6 Burner

Flue gas temperature sensor (if installed) Short circuit Interruption Fault signal Return flow temperature sensor Interruption Short circuit No switching off No switching on Flue gas temperature Address Activity Communication between the THETA control system and the combustion controller ESYS EEPROM EEPROM faulty Overshooting Address collision of the BUS subscribers No T2B signal, check the BUS-cable and the connections. Interruption

71-0 71-1
Tab. 9 -2

Internal fault Internal fault

Error codes for the ROTEX GSU for the THETA 23R+ control system (can be detected by the central unit)

FA ROTEX GSU - 04/2012

61

9 x Faults and malfunctions


Fault code E 01 E 02 E 03 E 05 E 08 E 11 E 12 E 13 E 21 E 25 E 26 B 09 B 30 B 34 B 37 B 43 B 99 Temporary malfunction combustion controller ESYS Component/Designation Locking error, combustion controller ESYS Fault No flame detection during the 5 possible start attempts Wrong flame signal ionisation current outside the permitted range STL malfunction: Inflow temperature too high No speed signal from burner fan within 10 sec Fault in the flame monitoring routine Sensor equalisation procedure for electronic STB function faulty or return flow temperature higher by 3 K than inflow temperature for more than 3 min. EEPROM communication error 5x RESET within 15 min Analogue-to-digital converter error Internal fault 5x flame break within 4 min Error in gas valve control routine Flow sensor (measuring value outside the operating range) Low voltage (< 185 V) Internal fault Return flow sensor (measuring value outside the operating range) Internal communication between the control system and the combustion controller ESYS is interrupted.

Tab. 9 -3 Error codes for the ROTEX GSU for the THETA 23R+ control system (can be detected by the combustion controller)

9.4

Emergency operation
Note the following for emergency operation if the valve drive is faulty: Press the unlocking button (fig. 3-11, pos. 5.2) and rotate the motor head of the valve drive (fig. 3-11, pos. 5.1) 1/4 turn to the left and remove. The 3-way switch valve is set to the "Heating" position. Note the following for the temporary manual parallel operation of the heating circuit and the hot water storage tank: Pull the 6-pin plug out of the valve drive. Bring switch valve to centre position with hand lever (fig. 3-11, pos. 5.3) (only possible if the valve drive is found in the "Heating" position before). In the event of faults or incorrect settings in the electronic controller, emergency heating operation can be maintained. Press the hand button on the control for approx. 5 seconds. "Manual operation" appears on the display. Adjust the desired temperature with the rotary switch (setting range 5 - 78C). In manual operation, the 3-way switch valve is in the "Storage tank charging" position first. When the adjusted storage tank target temperature has been reached, the 3-way switch valve will be set to the "heating" position.

62

FA ROTEX GSU - 04/2012

10 x Taking out of service


10 10.1 Taking out of service Temporary shutdown

CAUTION! A heating system which is shut down can freeze in the event of frost and may suffer damage. Drain the heating system that is shut down if there is danger of frost. If the heating system is not drained, the gas and power supplies must be secured and the main switch must remain switched on. If no heat and no hot water supply is needed for a long time, the ROTEX GSU can be shut up temporarily. However, ROTEX recommends, to set the system into stand-by operation (see documentation "ROTEX-control") and to logoff the heating and domestic hot water supply. The heating system is then protected from frost. The pumps and valve protection functions are active. If there is a danger of frost, and the gas and power supply cannot be guaranteed, then the GSU must be emptied, suitable antifreeze measures must be adopted for the connected heating system and hot water storage tank (e.g. draining). If there is danger of frost in case of unsafe gas and power supply only for a few days, due to the excellent heat insulation, the emptying of the ROTEX GSU can be dispensed with if the storage temperature is observed regularly and does not drop below +3C. However, there is no frost protection for the connected heat distribution system through this.

Emptying storage tank container


Switch off the main switch and secure against restarting. Close gas stopcock. Connect the hose and hose connection from the accessories set to the rear of the solar panel (only this particular hose will open the foot valve automatically). In the connected Solaris system, use KFE cock on Solaris return. Drain the tank's water content.

Emptying heating circuit and drinking water heat exchanger


Switch off the main switch and secure against restarting. Close gas stopcock. Disconnect the heating flow and return flow, as well as the cold water inflow and the hot water outflow. Connect drain hoses in hoses in such a way that the hose opening is leakproof on the floor. Allow heat exchanger to run idle according to pipette principle.

10.2 Final decommissioning and disposal


For final shutdown of the ROTEX GSU decommissioned (see section 10.1), disconnect it from all electrical, gas and water connections, disposed off in a professional manner.

Recommendations for disposal


The ROTEX GSU has an environmentally friendly design. During the disposal process, the only waste created is that which can be used for material or thermal recycling. The materials used that are suitable for recycling can be sorted into individual types. ROTEX has complied with the standards for environmentally-friendly disposal as a result of the environmentallyfriendly design of the GSU. Proper disposal in compliance with the respective national regulations of the country of use is the responsibility of the user/owner.

FA ROTEX GSU - 04/2012

63

11 x Technical data
11 Technical data

Standard data
(1)* Unit Litres (11)* kg kg cm C C kWh/24h bar 300 86 386 59.5 x 61.5 x 189 1-35C 85 1.7 6 Stainless steel 1.4404 Litres m2 W/K Litres m2 W/K m2 W/K inches inches 19.0 4.1 1820 9.1 2.1 910 1" outer thread 1" female
* Position numbers see fig. 11-1

Type PARAMETER Total storage capacity Empty weight Total filled weight Dimensions (L x B x H) Permissible ambient temperature Maximum permissible storage water temperature Stand-by heating power

GSU 320(F)-e

GSU 520S(F)-e 500 124 624 79 x 79 x 181 1-35C 85 1.8 6 Stainless steel 1.4404 24.5 5.5 2470 10.4 2.3 1040 0.43 200 1" outer thread 1" female

GSU 530S(F)-e 500 128 628 79 x 79 x 181 1-35C 85 1.8 6 Stainless steel 1.4404 24.5 5.5 2470 10.4 2.3 1040 0.43 200 1" outer thread 1" female

GSU 535(F)-e 500 128 628 79 x 79 x 181 1-35C 85 1.8 6 Stainless steel 1.4404 24.5 5.5 2470 19.5 4.3 1950 1" outer thread 1" female

Max. operating pressure for the potable water PMW (14)* Domestic water heat exchanger material Drinking water heating Potable water capacity Domestic water heat exchanger surface Average specific thermal output Storage Tank primary heat exchanger (stainless steel) Water content heat exchanger Heat exchanger surface area Average specific thermal output Solar heating support (stainless steel) Heat exchanger surface area Average specific thermal output Pipe connections Cold and domestic hot water Heating inflow and return flow (with ball cock)
Tab. 11-1 Standard data of ROTEX GSU

64

FA ROTEX GSU - 04/2012

11 x Technical data
Type PARAMETER Efficiency characteristic NL according to DIN 47081) l/min kW l/h Litres D-value (specific Water flow) according to EN 6252) (15)* Continuous rating QD according to DIN 4708 Continuous output1) Hot water quantity without reheating up to 15 l/min tapping rate (TKW = 10C / TWW = 40C / TSP = 60C) Domestic hot water quantity with reheating at rated output and 15 l/min at tapping rate (TKW = 10C / TWW = 40C / TSP = 60C) Short time water quantity in 10 min3)
1) 2)

(1)* Unit

GSU 320(F)-e 2.0 23 20 440 200

GSU 520S(F)-e 2.1 25 20 615 220

GSU 530S(F)-e 2.2 27 30 630 220

GSU 535(F)-e 4.4 39 35 860 412

Litres

360

500

1180

unlimited

Litres

200

210

215

310

3)

Reheating with nominal output, flow temp. TV=80C, starting storage tank temp. TSP=65C, cold water temp. TKW=10C, domestic hot water temp. TWW =45C. The specific water flow according to EN 625 is the potable water flow with a mean temperature increase of 30 K, which the ROTEX GSU is able to deliver in two consecutive tappings of 10 min duration each with a charging temperature of 65C. A delay of 20 minutes between the two draw-off procedures is usually assumed. The ROTEX GSU reaches this value also with shorter waiting periods. Reheating with nominal output, starting storage tank temp. TSP=60C, cold water temp. TKW=10C, domestic hot water temp. TWW=40C.
* Position numbers see fig. 11-1

Tab. 11-2 Thermal output data for ROTEX GSU

Type PARAMETER Water content (heating side) Burner weight Combustion controller Honeywell ESYS Honeywell gas valve Burner fan Nominal output P Rated thermal load Q Electrical power consumption (including heating circulation pump) Device type Product ID (CE number) NOx class Voltage supply Protection type Water content Max. allowable operating pressure: Max. permissible operating temperature Max. boiler efficiency
Tab. 11-3 Heat generator characteristic data

(1)* Unit Litres kg

GSU 320(F)-e 3 3.8

GSU 520S(F)-e 5 3.8

GSU 530S(F)-e 7 4.7

GSU 535(F)-e 5 4.7

S4965 V 2059 ROTEX VK 4115 V2 NRG118 / PX118 (6)* (5)* (9)* (2)* (3)* (4)* (8)* (10)* Litres (12)* (13)* bar C %
* Position numbers see fig. 11-1

RG148 / PX128 6.5-30.0 6.6-30.9 < 111

RG148 8.0-35.0 8.5-36.1 < 148

kW kW W

3.7-20.0 3.7-21.0 < 99

3.7-20.0 3.7-21.0 < 99

B 23, C13 , C33 , C43 , C53 , C63 , C83 CE-0085 BM 0065 5 (<60 mg/kWh) 230 V~, 50 Hz IP X0B 2.0 3.0 85 110 3.6

FA ROTEX GSU - 04/2012

65

11 x Technical data
Gas type, connection pressures
Country of destination Appliance category Natural gas DE AT, CH DK, FI, NO, SE GB, GR, IE, IT CH, ES, PT NL LU FR BE PL HU I 2 ELL I2H I2H I2H I2H I2L I2E I 2 Esi I 2 E(S)B I2E I2H Liquefied petroleum gas I 3 B/P I 3 B/P I 3 B/P I 3+ I 3+ I 3 B/P I 3 B/P I3P I3P I 3 B/P I 3 B/P Nominal connection pressure in mbar Natural gas 20 20 20 20 20 25 20 20/25 20/25 20 25 Liquefied petroleum gas 50 50 28-30/30 28-30/37 28-30/37 28-30/30 50 37 37 37 30

Tab. 11 -4 Countries of destination, unit categories and associated gas connection * Position numbers see fig. 11-1 pressures (7)*

Gas type Natural gas H Liquid gas B/P


1)

Nominal pressure in mbar 1) Min. inlet pressure in mbar Max. inlet pressure in mbar 20 28-30 / 37 17 25 25 35 / 45

The liquid gas unit is factory set to a nominal pressure of 50 mbar. The subsequent burner adjustment must be adapted to the permissible gas input pressure. This adaptation must be appropriately labelled with a suitable burner settings sticker and an entry on the settings sticker (under the type plate.

Tab. 11 -5 Permitted gas inlet pressure

Integrated connection group (GSU - all types)


Heating circulation pump Type Voltage Maximum power consumption Protection type Permitted overpressure Maximum pumping height Basic setting circulation pump 3-way switch valve Voltage Maximum power consumption Protection type Turnaround time
Tab. 11 -6 Technical data of the integrated connection group

Grundfos ALPHA2 L 15-60 CIL 2 230 V, 50 Hz 45 W IP 42 3 bar 6.0 m Stage "b" 230 V, 50 Hz 4.3 W IP 40 6s

66

FA ROTEX GSU - 04/2012

11 x Technical data

1 2 3 4 5 6 7 8

Type Unit type Product-ID (CE-Number) NOx-class Rated thermal load Nominal output Country of destination Voltage supply

9 10 11 12 13 14 15 16

Electr. power input Degree of protection Net weight Max. permissible operating pressure (heater) Max. permissible operating temperature Max. operating pressure (sanitary) D value Serial number (indicate for complaints and inquiries)

17 18 19 20 21 22 23

Burner configuration Gas type Minimum burner load Max. burner load Gas type Minimum burner load Max. burner load

Fig. 11-1

Information on the Type plate (top) and settings type plate (bottom) Information regarding the positions see tab. 11-1 to tab.

Burner load

Blower speed

Fig. 11-2

Permissible burner loads on ROTEX GSU 320(F)-e / GSU 520S(F)-e Burner configuration 1A/1AF (NRG118) and 2A/2AF (PX118) see tab. 6-1

FA ROTEX GSU - 04/2012

67

11 x Technical data

Burner load

Blower speed

Fig. 11-3

Additional burner loads of the ROTEX GSU 530S(F)-e Burner configuration 3A/3AF, 3B/3BF (RG148) see tab. 6-1

Burner load

Blower speed

Fig. 11-4

Additional burner loads of the ROTEX GSU 530S(F)-e Burner configuration 4A/4AF, 4B/4BF (RG148) see tab. 6-1

Burner load

Blower speed

Fig. 11-5

Additional burner loads of the ROTEX GSU 535S(F)-e Burner configuration 3A/3AF, 3B/3BF (RG148) see tab. 6-1

68

FA ROTEX GSU - 04/2012

11 x Technical data

FESYS Fig. 11-6

Output parameter-Setting value for the control system n

Blower speed

Permissible burner loads on ROTEX GSU 320(F)-e / GSU 520S(F)-e Burner configuration 1A/1AF (NRG118) and 2A/2AF (PX118) see tab. 6-1

FESYS Fig. 11-7

Output parameter-Setting value for the control system n

Blower speed

Burner blower speed setting for ROTEX GSU 530S(F)-e Burner configuration 3A/3AF, 3B/3BF (RG148) and 4A/4AF, 4B/4BF (PX128) see tab. 6-1

FA ROTEX GSU - 04/2012

69

11 x Technical data

FESYS Fig. 11-8

Output parameter-Setting value for the control system n Burner blower speed setting for ROTEX GSU 535(F)-e Burner configuration 3A/3AF, 3B/3BF (RG148) see tab. 6-1

Blower speed

'pR Remaining pumping height Fig. 11-9

mH

Flow heating network

Remaining pumping height GSU 320(F)-e and GSU 520S(F)-e (heater side)

70

FA ROTEX GSU - 04/2012

11 x Technical data

'pR Remaining pumping height

mH

Flow heating network

Fig. 11-10 Remaining pumping height GSU 530S(F)-e and GSU 535(F)-e (heater side)

Heating output

mH

Flow heating network

Fig. 11-11 Required throughput volumes dependent on the heating output and the design temperature spread

FA ROTEX GSU - 04/2012

71

11 x Technical data

RS t

Sensor resistance Temperature

PTC-Resistance

Exterior temperature, mixing circuitflow temperature, storage tank temperature NTC- Resistance Flow temperature, return flow temperature Pt 1000 resistance Flue gas temperature

Fig. 11-12 Resistance characteristics of the temperature sensor

Temperature sensor -20 Type PTC NTC PT1000 Specification * tAU, tMi, tDHW tV, tR tAG -10 0 10 20

Measured temperature inC 30 40 50 60 70 80 90 100 110 120 Sensor resistance in Ohm according to standard or manufacturer's indications 1386 1495 1630 1772 1922 2080 2245 2418 2598 2786 2982 3185 3396 98660 56250 33210 20240 12710 8195 5416 3663 2530 1782 1278 922 961 932 690 519 395 1000 1039 1077 1116 1155 1194 1232 1270 1308 1347 1385 1423 1461
* Key see tab. 7 -1

Tab. 11 -7 Resistance values of the temperature sensor

72

FA ROTEX GSU - 04/2012

11 x Technical data
Circuit diagram
Connection cable colours bl blue br brown ge yellow gn green gr grey rt red sw black ws white n.a. Contact not assigned Fig. 11-13 Wiring diagram ROTEX GSU (shown with ROTEX THETA 23R+ control system)

FA ROTEX GSU - 04/2012

73

12 List of keywords
12 A List of keywords

Additional water . . . . . . . . . . . . . . . 7, 29 Annual inspection . . . . . . . . . . . . . . . . . .56 Annual maintenance tasks . . . . . . . . . . .56 Automatic timer programme . . . . . . . . . .32

F
Fault codes . . . . . . . . . . . . . . . . . . . . . . 61 Filling Cylinder charging circuit . . . . . . . . . 28 Heating system . . . . . . . . . . . . . . . . 28 Hot water-heat exchanger . . . . . . . . 28 Outer layer of storage tank . . . . . . . 28 Filling water . . . . . . . . . . . . . . . . . . . . . 29 Flue gas mass flow . . . . . . . . . . . . . . . . 19 Flue gas system kits . . . . . . . . . . . . . . . 21 Flue gas temperature probe . . . . . . . . . 37 Flue gas temperature sensor . . . . . . 25, 27 Flue system Dimensioning . . . . . . . . . . . . . . . . . 18 Kits . . . . . . . . . . . . . . . . . . . . . . . . . 21 Minimum requirements . . . . . . . . . . 18 Piping height . . . . . . . . . . . . . . . . . . 18 Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Gas burner setting . . . . . . . . . . . . . . . . Gas connection Execution . . . . . . . . . . . . . . . . . . . . Gas inlet pressure . . . . . . . . . . . . . . . . . Gas type . . . . . . . . . . . . . . . . . . . . . . . . Gas valve . . . . . . . . . . . . . . . . . . . . . . . General malfunction lamp . . . . . . . . . . . 45 26 26 26 49 31

O
Operating elements . . . . . . . . . . . . . . . . 31 Operating mode Selection . . . . . . . . . . . . . . . . . . . . . 32 Operating safety . . . . . . . . . . . . . . . . . . . 6 Outer layer of storage tank . . . . . . . . . . 52 Output limits . . . . . . . . . . . . . . . . . . . . . 48 Outside temperature sensor . . . . . . . . . 25

Basic setting for burner . . . . . . . . . . . . .46 Boiler control panel . . . . . . . . . . . . . . . .31 Assembly . . . . . . . . . . . . . . . . . . . . .35 Burner Assembly . . . . . . . . . . . . . . . . . . . . .51 Basic setting . . . . . . . . . . . . . . . . . .46 Dismantling . . . . . . . . . . . . . . . . . . .50 Burner flange . . . . . . . . . . . . . . . . . 40, 51 Burner output Control . . . . . . . . . . . . . . . . . . . . . . .41 Limiting . . . . . . . . . . . . . . . . . . . . . .49 Burner setting . . . . . . . . . . . . . . . . . . . .41 Calorific value engineering Instructions . . . . . . . . . . . . . . . . . . .11 Cascading . . . . . . . . . . . . . . . . . . . . . . .27 Changing the central unit . . . . . . . . . . . .33 Circulation pump . . . . . . . . . . . . . . . . . .23 Combustion chamber Cleaning . . . . . . . . . . . . . . . . . . . . . .58 Components GSU . . . . . . . . . . . . . . . . . . .8 Condensate drain Connection . . . . . . . . . . . . . . . . . . . .23 Testing . . . . . . . . . . . . . . . . . . . . . . .57 Connect the power supply . . . . . . . . . . .24 Connecting the mixer circuit . . . . . . . . . .27 Connection cables . . . . . . . . . . . . . . . . .36 Connection dimensions . . . . . . . . . . . . . .12 Connection types - Flue gas . . . . . . . . . .18 Control Connection . . . . . . . . . . . . . . . . . . . .24 THETA 23R+ . . . . . . . . . . . . . . . . . .31 Control panel cover . . . . . . . . . . . . . . . .35

Parallel operation . . . . . . . . . . . . . . . . . 62 PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Pressure gauge . . . . . . . . . . . . . . . . . . . 31 Proper use . . . . . . . . . . . . . . . . . . . . . . . 6 Remove the silencer hood. . . . . . . . . . . Reset function . . . . . . . . . . . . . . . . . . . Resetting the gas type . . . . . . . . . . . . . Resting pressure . . . . . . . . . . . . . . . . . . Room station . . . . . . . . . . . . . . . . . . . . Room temperature controller . . . . . . . . . Rotary switch . . . . . . . . . . . . . . . . . . . . 56 33 46 26 27 27 32

Danger of frost . . . . . . . . . . . . . . . . . . .63 Declaration of conformity . . . . . . . . . . . . .2 Different set-ups Ambient air-dependent mode . . . . . . .16 Ambient air-independent mode . . . . .15 Overview . . . . . . . . . . . . . . . . . . . . .14 Dimensions . . . . . . . . . . . . . . . . . . . . . . .12 Display . . . . . . . . . . . . . . . . . . . . . . . . . .33 Disposal . . . . . . . . . . . . . . . . . . . . . . . . .63 Drinking water heating Technical data . . . . . . . . . . . . . . . . .64 Efficiency . . . . . . . . . . . . . . . . . . . . . . . .11 Electrical Connection . . . . . . . . . . . . . . . . . . . .24 Electrical installation . . . . . . . . . . . . . . .24 Electronic control . . . . . . . . . . . . . . . . . .11 Emergency operation . . . . . . . . . . . . . . .62 Emission measurement . . . . . . . . . . . . . .33

Heating circuit expansion module Cascading . . . . . . . . . . . . . . . . . . . . 27 Heating system Draining . . . . . . . . . . . . . . . . . . . . . 63 Filling . . . . . . . . . . . . . . . . . . . . . . . 28 Hot water storage tanks Target temperature . . . . . . . . . . . . . 32 Technical data . . . . . . . . . . . . . 64, 65 Housing installation room Requirements . . . . . . . . . . . . . . . . . . .6 Hydraulic diagrams Short designations . . . . . . . . . . . . . 53 Hydraulic system connection . . . . . . . . 53 Ignition electrodes . . . . . . . . . . . . . . . . Inflow temperature sensor . . . . . . . . . . Installation area . . . . . . . . . . . . . . . . . . Installation in garages . . . . . . . . . . . . . Installation room . . . . . . . . . . . . . . . . . Installation site . . . . . . . . . . . . . . . . . . . Ionisation electrode . . . . . . . . . . . . . . . 50 37 17 15 17 17 50

Safety management . . . . . . . . . . . . . . . 11 Safety shutdown . . . . . . . . . . . . . . . . . 11 Scope of delivery . . . . . . . . . . . . . . . . . 16 Service . . . . . . . . . . . . . . . . . . . . . . . . . 56 Setting sticker . . . . . . . . . . . . . . . . . . . 46 Setting values . . . . . . . . . . . . . . . . . . . . 43 Settings type plate . . . . . . . .8, 42, 49, 67 Shutdown . . . . . . . . . . . . . . . . . . . . . . . 63 Solar utilisation . . . . . . . . . . . . . . . . . . . 11 Starting output . . . . . . . . . . . . . . . . . . . 49 Start-up . . . . . . . . . . . . . . . . . . . . . . . . 29 Checklist . . . . . . . . . . . . . . . . . . . . . 30 Requirements . . . . . . . . . . . . . . . . . 29 Storage tank temperature sensor . . 25, 37 Storage water Heating . . . . . . . . . . . . . . . . . . . . . . 53 Structure GSU . . . . . . . . . . . . . . . . . . . . 8 Surface temperature . . . . . . . . . . . . . . . 17 Switch valve . . . . . . . . . . . . . . . . . . . . . 23 System information . . . . . . . . . . . . . . . 32 Target room temperature . . . . . . . . . . . Target temperature hot water storage tank . . . . . . . . . . . . . . . . . . . . . Temperature sensor Connection . . . . . . . . . . . . . . . . . . . Transport . . . . . . . . . . . . . . . . . . . . . . . Type plate for the burner setting . . . . . . 32 32 25 16 49

Language selection . . . . . . . . . . . . . . . . 31

Mains switch . . . . . . . . . . . . . . . . . . . . 31 Maintenance . . . . . . . . . . . . . . . . . . . . 56 Make-up water . . . . . . . . . . . . . . . . . . . 22 Malfunctions . . . . . . . . . . . . . . . . . . . . 59 Manual operation . . . . . . . . . . . . . . 29, 33 Mark the gas type changeover . . . . . . . 27 Method of operation . . . . . . . . . . . . . . . 11 Minimum distance . . . . . . . . . . . . . 12, 16 Mixer circuit inflow sensor . . . . . . . . . . 25

Warranty . . . . . . . . . . . . . . . . . . . . . . . . 2 Water hardness . . . . . . . . . . . . . . . . . . . 22 Water pressure . . . . . . . . . . . . . . . . . . . 31 Water shortage protection . . . . . . . . . . 22 Wiring diagram . . . . . . . . . . . . . . . . . . . 39 Wooden boiler integration . . . . . . . . . . . 55

74

FA ROTEX GSU - 04/2012

13 x Notes
13 Notes

FA ROTEX GSU - 04/2011

75

For the chimney sweep


Data for designing flue gas pipe 14 For the chimneythe sweep
Appliance Burner ploading in kW Rated output in kW 40/30C Flue gas mass flow in g/s Flue gas temperature Available delivery inC pressure in Pa 40/30C 80/60C

GSU 320(F)-e GSU 520S(F)-e

GSU 530S(F)-e

GSU 535(F)-e

5.0 10.0 15.0 20.0 20.6 7.0 15.0 20.0 25.0 30.0 8.0 15.0 20.0 25.0 36.0

5.4 10.7 15.8 20.8 21.4 7.6 16.0 21.1 26.3 31.1 8.6 16.0 21.1 26.3 37.3

80/60C Natural gas Natural gas Liquefied E/H LL/L petroleum gas 5.0 2.01 2.10 1.90 9.9 4.20 4.21 3.80 14.7 6.30 6.31 5.70 19.4 8.40 8.42 7.61 20.0 8.65 8.67 7.83 7.0 2.94 2.95 2.67 14.9 6.30 6.31 5.70 19.6 8.40 8.42 7.61 24.4 10.50 10.52 9.51 29.1 12.60 12.62 11.41 8.0 3.36 3.37 3.04 14.9 6.30 6.31 5.70 19.6 8.40 8.41 7.61 24.4 10.50 10.52 9.51 34.9 15.12 15.15 13.69

34 37 40 44 44 37 41 43 45 47 38 41 43 45 48

64 66 68 70 70 63 68 70 72 73 64 68 70 72 74

40 110 170 200 200 40 120 180 200 200 40 120 180 200 200

Tab. 14 -1 Triple values for chimney design

Check measurement ROTEX THETA 23R+


The check measurement can be implemented through a plain selectable automatic function (see the enclosed "quick-reference manual" or the "Operating manual ROTEX-Control system". Press manual button (fig. 5-1, pos. 13). The gas condensing boiler controls the maximum boiler temperature for a period of 20 minutes. Press the manual key again. The gas condensing boiler regulates back to the minimum output. The running time for this setting is also 20 minutes. Pressing the button again within these 20 minutes will prematurely terminate the emission measurement.
Fig. 14-1

Remaining time from activation Abort the emission measurement.

Current heater temperature

Symbolic quick-reference manual for chimney sweep operation control mode THETA 23R+

FA ROTEX GSU - 04/2012

008.1510644_02 Errors and technical changes excepted Original version 008.1510649_02 04/2012 in German ROTEX

Remaining time from activation

Current heater temperature