1. Manuals
  2. Brands
  3. Rotex Manuals
  4. Boiler
  5. GSU 320
  6. Operating instructions manual

Rotex GSU 320 Operating Instructions Manual

Gassolarunit gas condensing boiler with stratified solar storage tank
Hide thumbs
Table of Contents

Advertisement

Quick Links

For the owner
ROTEX GasSolarUnit
Gas condensing boiler with stratified solar storage tank

Operating instructions

0085 BM 0065
Type
Rated thermal output
ROTEX GSU 320
3 - 20 kW modulating
ROTEX GSU 520S
3 - 20 kW modulating
ROTEX GSU 530S
7 - 30 kW modulating
ROTEX GSU 535
8 - 35 kW modulating
Manufacture number
Customer
GB
Edition 09/2007

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the GSU 320 and is the answer not in the manual?

Questions and answers

Related Manuals for Rotex GSU 320

Summary of Contents for Rotex GSU 320

  • Page 1: Operating Instructions

    Gas condensing boiler with stratified solar storage tank Operating instructions 0085 BM 0065 Type Rated thermal output Edition 09/2007 ROTEX GSU 320 3 - 20 kW modulating ROTEX GSU 520S 3 - 20 kW modulating ROTEX GSU 530S 7 - 30 kW modulating...
  • Page 2 The guarantee is only valid if the device has been used properly and it can be proved that it was installed properly by an expert firm. As proof, we strongly recommend completing the enclosed installation and instruction forms and returning them to ROTEX.

  • Page 3: Table Of Contents

    For the chimney sweep..............48 BA ROTEX GSU - 09/2007...

  • Page 4: Safety

    The installation, connection and the initial start-up of the ROTEX GasSolarUnit are carried out by authorised and trained heating engineers. The ROTEX GSU was properly handed over to you by the installer. The handover is documented in the handing over report.

  • Page 5: Danger Prevention

    – As stipulated, and in perfect conditions, – With an awareness of safety and dangers. This assumes the knowledge and use of the contents of this manual and training in the operation of the ROTEX GSU by the installer. Danger of explosion if you smell gas Escaping gas is a direct threat to human health and safety.
  • Page 6 Device installation room • Operate ROTEX GasSolarUnit only if sufficient combustion air supply is ensured. If you operate the ROTEX GSU in ambient- air-independent mode with an air/ flue gas system (LAS) dimensioned according to ROTEX standard, this is guaranteed automatically and there are no further conditions to be met in the device installation room.

  • Page 7: Product Description

    Retaining screws for silencer hood Condensate overflow connection Supply air hose 12a Top filling connection (alternatively: condensate Filling and draining fitting (KFE cock) overflow connection to the front Automatic aspirator Figure 2-1 Components of the ROTEX GasSolarUnit BA ROTEX GSU - 09/2007...
  • Page 8 Flue gas temperature sensor (accessory) Safety valve Connection for diaphragm expansion tank Safety devices Prepares for the installation of gravity brakes to avoid cooling losses. Figure 2-2 Schematic layout of GSU 520S and GSU 530S BA ROTEX GSU - 09/2007...
  • Page 9 Flue gas temperature sensor (accessory) Safety valve Connection for diaphragm expansion tank Safety devices Prepares for the installation of gravity brakes to avoid cooling losses. Figure 2-3 Schematic construction of GSU 535 and of GSU 320 BA ROTEX GSU - 09/2007...

  • Page 10: Brief Description

    Solar utilisation The hot water storage tank of ROTEX GSU can also be heated by solar energy. In the models GSU 520S and GSU 530S, the gas condensing boilers are designed to maintain only the upper zone of the storage tank at the target temperature. In solar heating, the entire storage tank can be heated up, depending on the heat offered by the sun.

  • Page 11: Gas Burner

    Set screw for gas pressure controller (under cover cap) firing unit Burner flange Figure 2-5 Gas burner of ROTEX GSU - View from rear Figure 2-6 Gas burner of ROTEX GSU - Side view from left BA ROTEX GSU - 09/2007...
  • Page 12 Controlling the burner output The controls ROTEX ALPHA 23R and ROTEX THETA 23R determine the requisite flow temperature (corresponding to the set operating parameters) continuously and feed them to the CVBC automatic firing units of the gas burner. The CVBC automatic firing unit calculates the necessary burner output from the target value and the values of the flow and return flow temperature sensors.

  • Page 13: Connections

    Mixer circuit (optional) A mixer circuit can be connected to the ROTEX GSU directly, which is controlled through the electronic boiler control. ROTEX offers the following: –...

  • Page 14: Storage Tank

    Storage tank Important instructions for hydraulic integration Observe the following instructions for hydraulic system integration of the ROTEX GasSolarUnit in order to avoid damage to persons and property. – Protection from scalding: When operating the ROTEX GasSolarUnit, especially when using the solar energy, the storage tank temperature can exceed 60 °C.

  • Page 15: Start-Up

    The following instructions are especially applicable for transport, erection, installation and initial start-up: – Lift the ROTEX GasSolarUnit only by the handles provided for the purpose. Lifting or shifting the ROTEX GSU by the panels can damage the device (see Chapter 3.2).

  • Page 16: Initial Start-Up

    Dirt filter in the heating return flow and cold water inlet If the ROTEX GasSolarUnit is connected to a heating or cold water system, in which piping or radiators made of steel or non- diffusion-proof floor heating pipes are used, sediment and swarf can enter the boiler or the stainless steel corrugated tube heat exchanger and cause blockage, local over-heating or corrosion damage.

  • Page 17: Operation

    The electronic digital controls are to be used for controlling 2 heating circuits (direct heating circuit, mixer circuit) and a storage tank charging circuit. A more detailed description is given in the documentation of the "ROTEX Control". It is part of the scope of supply of the electronic control to be ordered separately.

  • Page 18: System Information

    Selection of one of the 3 pre-installed timer programs P1, P2 or P3. You can find further instructions and a more exact description in the documentation for "ROTEX control“. It is part of the scope of supply of the electronic control to be ordered separately.

  • Page 19: Display And Modification Of Parameters

    – Manual operation: press the manual button for 5 sec. The ROTEX 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.

  • Page 20: Control Alpha 23R

    Operation 4.1.3 Control ALPHA 23R Only the operating and display elements of the central units of the ROTEX Control ALPHA 23R are described below. Refer to Section 4.1.1 for the operating elements of the complete boiler control panel. Mains power switch...
  • Page 21 Switching time programming for the switching time program (I) (for more detailed information, see ROTEX Control ALPHA). Display All system temperatures and operating conditions of the system components can be indicated on the display. If there is a fault, a fault code is displayed.

  • Page 22: Heating Mode

    You can economise on the pump power in this way. The pump fitted in the ROTEX GSU consumes only about 75-80 W in output stage 3, about 55-60 W in output stage 2 and only about 40 W in output stage 1.

  • Page 23: Information On Operating Noises

    Δp Residual discharge head Flow rate Figure 4-6 Residual discharge head of ROTEX GSU heating pump • Determine the hydraulic resistance in the heating network. • Determine the needed output stage of your heating pump by using Fig 4-6. In practice, the hydraulic resistance in the heating network is often not known. By observing the flow and return temperature at the heat generator, you can define whether the pump can still provide sufficient output at a lower speed stage.

  • Page 24: Temporary Shutdown

    • Drain the heat exchanger in siphon mode. Re-commissioning If the ROTEX GasSolarUnit has not been in operation for a long time, you have to carry out a few preparatory jobs and tests before re-commissioning. 4.4.1 Work to be done before re-commissioning 1.
  • Page 25 The gas condensation boiler charges the storage tank until the maximum adjustable storage tank temperature is reached. There fter it switches over to heating mode. • Check all heating lines for leakage in the hot condition. • Set the desired mode (see section 4.1.1 or section 4.1.3). BA ROTEX GSU - 09/2007...

  • Page 26: Checklist For Returning To Service

    Operation 4.4.2 Checklist for returning to service Checklist for returning to service ROTEX GSU installed correctly according to an installation version and without recognisable damage? Combustion air supply secured? Sufficient venting of the heating room in ambient air-dependent operation? Does the mains connection conform to the specifications?

  • Page 27: Inspection And Maintenance

    – Replacement of the wearing parts (if required). ROTEX recommends that you make an inspection and maintenance contract to ensure regular inspection and maintenance. • Have the inspection and maintenance confirmed in the maintenance log. The maintenance log is included in the scope of delivery.

  • Page 28: Checking The Connections And Conduits

    • Only heating engineers authorised and recognised by the gas or energy supply company should replace damaged power or gas-conducting components in the ROTEX GSU. • Check all (flue) gas and water-conducting components and connections for leakage and intactness. Have damage corrected by a specialised agency.

  • Page 29: Checking And Cleaning The Burner

    – Safety gas control block 10 years or 250.000 burner starts, – Overpressure safety valve: 10 years. We recommend completing the service log provided with all the measured values and the tasks performed, with dates and signature. BA ROTEX GSU - 09/2007...

  • Page 30: Faults And Malfunctions

    The electronics of the ROTEX GasSolarUnit detects faults and indicates them: – by a fault code in the display, for faults detected by the ROTEX THETA 23R or ROTEX ALPHA 23R. – by the collective fault signals in the boiler control panel and through a fault code on the display, for faults detected by the CVBC automatic firing unit, which leads to an interlocking failure.
  • Page 31 Air/flue gas resistance too high • Check ducts for dirt. • Use ducts with larger cross section for supply air or flue gas if necessary Tab. 6-1 Possible faults on the ROTEX GSU BA ROTEX GSU - 09/2007...

  • Page 32: Fault Codes

    Communication between control THETA Interruption and CVBC automatic firing unit 71-0 EEPROM Internal fault 71-1 EEPROM faulty Internal fault Tab. 6-2 Fault codes for the ROTEX GSU for control THETA 23R (detected from the central unit) BA ROTEX GSU - 09/2007...
  • Page 33 Return flow sensor interruption B 99 Internal communication between control and CVBC automatic firing unit interrupted. Tab. 6-3 Fault codes for the ROTEX GSU for control THETA 23R (detected from the automatic firing unit) Control ALPHA 23R Fault code Component/name...
  • Page 34 195 V for at least 5 secs restart is triggered. uuuu Interruption of a sensor nnnn Short circuit in a sensor Tab. 6-4 Fault codes for the ROTEX GSU for control ALPHA 23R BA ROTEX GSU - 09/2007...

  • Page 35: Emergency Operation

    • Adjust the desired temperature with the rotary switch (setting range 5 - 80 °C). In manual operation, the 3-way switch valve is in the "Storage tank charging" position first. On reaching the maximum adjustable storage tank temperature, the 3-way switch valve moves to the "Heating" position. BA ROTEX GSU - 09/2007...

  • Page 36: Technical Data

    Figure 7-2 Installation dimensions for flue gas connection on the side (for values, see Tab. 7-1) Dimension GSU 320 GSU 520S GSU 530S GSU 535 1404 1384 1384 1869 1846 1828 1918 1896 1878 Tab. 7-1 Dimensions table for assembly dimensions (relating to Fig 7-1, Fig 7-2) BA ROTEX GSU - 09/2007...
  • Page 37 Figure 7-3 Connecting dimensions for heating and hot water connection (plan view)) ROTEX recommends installing gravity brakes or siphoning (connecting lines leading directly downwards) of the drinking water connection in order to avoid higher cooling losses. BA ROTEX GSU - 09/2007...
  • Page 38 =45 °C. The specific water flow according to EN 625 is the drinking water flow with an average temperature increase of 30 K that the ROTEX GSU can deliver with two consecutive draw-offs each lasting 10 minutes assuming a charging temp. of 65 °C. In this case a 20 minute waiting time between draw-offs is assumed in accordance with the standards.
  • Page 39 IP 44 IP 40 Permitted overpressure 3 bar 4 bar Maximum pumping height 6.2 m — Changeover time — — Tab. 7-5 Technical data of the integrated connection group * Item number see Fig 7-4 BA ROTEX GSU - 09/2007...
  • Page 40 Figure 7-5 Permissible burner loads of ROTEX GSU Δp Residual discharge head Flow rate, heating system Figure 7-6 Residual discharge head GSU 320 and GSU 520S (on heating side) Δp Residual discharge head Flow rate, heating system Figure 7-7 Residual discharge head GSU 530S and GSU 535 (on heating side)
  • Page 41 Technical Data Figure 7-8 Flue gas setpoint values for burner adjustment with reference to burner output P for GSU 320 and GSU 520S, O content or CO content* Figure 7-9 Flue gas setpoint values for burner adjustment with reference to burner output P for GSU 530S, O...
  • Page 42 98660 56250 33210 20240 12710 8195 5416 3663 2530 1782 1278 ature Pt 1000 Flue gas temperature 922 1000 1039 1077 1116 1155 1194 1232 1270 1308 1347 1385 1423 1461 Tab. 7-6 Resistance values of the temperature sensor BA ROTEX GSU - 09/2007...

  • Page 43: Wiring Diagram

    Heating circulation pump 12-pin circuit board connector for clamping Stickers for terminal assignment 3-pin circuit board connector for connecting a sensors, BUS and control lines circulation pump Figure 7-13 Wiring diagram (showing the control THETA 23R) BA ROTEX GSU - 09/2007...
  • Page 44 Technical Data Circuit diagram BA ROTEX GSU - 09/2007...
  • Page 45 Notes BA ROTEX GSU - 09/2007...
  • Page 46 Notes BA ROTEX GSU - 09/2007...

  • Page 47: Glossary

    Safety device which switches the heating boiler off if there is water shortage, to avoid overheating. protection/ overheating protection Timer program Times which you can set on the operating unit to define regular heating, economy and hot water phases. BA ROTEX GSU - 09/2007...

  • Page 48: For The Chimney Sweep

    (see also the supplied "Short • Pressing the and Fig 4-3items 8 and 9 keys simultaneously for the first time instruction manual" or the "Operating manual for ROTEX- ensures that the emission measurement can be conducted within 20 minutes in full load Control“. operation.

This manual is also suitable for:

Gsu 520sGsu 535Gsu 530s

Table of Contents

Save PDF