Rotex A1 BG Installation And Maintenance Instructions Manual
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Rotex A1 BG Installation And Maintenance Instructions Manual

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See also: Operating Manual
For certified companies
ROTEX
A1 BG
Installation and maintenance
instructions
Gas condensing boiler
0085 AS 0011
For the types
A1 BG 25-e
A1 BG 25F-e
A1 BG 40-e
A1 BG 40F-e
GB
Output 02/2014

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Summary of Contents for Rotex A1 BG

  • Page 1 For certified companies ROTEX A1 BG Installation and maintenance instructions Gas condensing boiler 0085 AS 0011 For the types A1 BG 25-e A1 BG 25F-e A1 BG 40-e A1 BG 40F-e Output 02/2014...

  • Page 2: Table Of Contents

    Checking and cleaning the condensate drain. . . 45 4.5.2 Connecting the flue gas line to the ROTEX A1 . . .15 9.2.4 Checking the flue gas temperature ... 47 4.5.3...
  • Page 3 15.1 Data for designing the flue gas pipe ..64 15.2 Emissions measurement....64 FA ROTEX A1 BGe - 02/2014...

  • Page 4: Guarantee And Conformity

    1.2 Declaration of conformity For the central condensing heating units in the boiler range ROTEX A1 BG We, ROTEX Heating Systems GmbH, declare under our sole responsibility that the products Product Order No.

  • Page 5: Safety

    2.4 Proper use Indicates a potentially dangerous situation. Disregarding this warning can result in serious injury The ROTEX A1 may only be used for the heating of hot water or death. heating systems. It must be installed, connected and operated only according to the information in this manual.

  • Page 6: Instructions For Operating Safety

    2.5.6 Fuel as well as the specifications of the energy supply company. The ROTEX A1 is configured at the factory for the gas type Before completing the mains connection, compare the mains shown on the burner sticker and configuration type plate, and is voltage, indicated on the type plate (230 V, 50 Hz) with the configured for the gas pressure specified on the burner sticker.

  • Page 7: Product Description

    Constituent parts of the A1 BG - view from the front + schematic A1 BG 25(F)-e A1 BG 40(F)-e Fig. 3-2 Constituents of the A1 BG - view from the rear for legend see fig. 3-1 FA ROTEX A1 BGe - 02/2014...

  • Page 8: Brief Description

    Product description 3.2 Brief description The ROTEX condensing boiler in the A1 BG series is a fully pre- assembled gas condenser unit. Operating instructions The ROTEX condensing boiler A1 BG is designed to be operated independently of the room air (concentric flue gas/air inlet piping).

  • Page 9: Set-Up And Installation

    Units which have been set-up and installed incorrectly may not operate properly and can be a health and safety risk endangering human life. Erection and installation of the ROTEX heat generator only by authorised and trained heating experts. Incorrect set-up and installation would render the manufacturer's guarantee for the unit void.
  • Page 10 ±15 ±15 1000 1065 ±15 ±15 ±15 ±15 ±15 ±15 1045 1105 1100 1730 1480 1340 1970 1720 1340 1890 1650 1590 2140 1890 ±15 ±15 Tab. 4-2 Installation dimensions A1 BG in mm FA ROTEX A1 BGe - 02/2014...

  • Page 11: Different Set-Ups

    90 min (in residential buildings with low headroom 30 min). Observe country-specific regulations for fire-resistance periods! Ventilation opening (1x150 cm² or 2x75 cm²) Rear ventilation opening (150 cm²) Fig. 4-4 Installation variants for the Gas condensing boiler in series A1 BG FA ROTEX A1 BGe - 02/2014...

  • Page 12: Operation Independent Of Ambient Air

    – The installation shaft where the flue gas line runs must be rear The ROTEX A1 is connected by the Set C or Set D concentric ventilated. In the lower area there must be a rear ventilation LAS connection lines to the SET G exterior wall system.

  • Page 13: Ambient Air Dependent Operation

    Set-up and installation Set-up version 8 4.3 Transport and delivery The ROTEX A1 is connected by the SET A or SET B to a ceramic CAUTION: chimney. – The combustible air supply from the outside runs through a Lifting or pushing the condensing boiler on the separate air supply line through the external wall.

  • Page 14: Setting Up The Unit

    2). The features of the flue system must be recognisable on the in- Fig. 4-5 Minimum distance for the installation of the A1 BG (for legend stalled system. see tab. 4-2) Place the nameplate of the flue system in the installation room.

  • Page 15: Connecting The Flue Gas Line To The Rotex A1

    (D8 PA, 15 50 79.00 93). intake air measurement openings (differential pressure for the A1 BG 25(F)-e at 0.5 mbar, for the A1 BG 40(F)-e at least We recommend the use of the associated ROTEX flue 1 mbar).

  • Page 16: Flue Gas System Kits

    Set-up and installation 4.5.3 Flue gas system kits Fig. 4-8 Flue gas system components (* if necessary) FA ROTEX A1 BGe - 02/2014...

  • Page 17: Water Connection

    10 m or additional accessory components must be ordered. 4.6 Water connection The ROTEX A1 has a common flow and common return for the heating circuit and storage tank filling. The connections are placed on the rear of the unit (refer to fig. 3-2).

  • Page 18: Connect The Condensate Drain

    Fig. 4-11 Connecting the condensate drain hose specifications of the energy supply company. All electronic control and safety systems of the ROTEX A1 are connected and tested. Modifications on the electrical installation are dangerous and prohibited. The operator alone shall bear re- sponsibility for any resulting damage.

  • Page 19: Connecting The Temperature Sensor

    Use only the ROTEX temperature sensor available as an accessory. The ROTEX A1 can regulate the flow temperature, dependent on the weather. For this function, the outside temperature sensor (RoCon OT1, 15 60 70) included in the scope of supply, must be connected to the sensor plug J8 and activated in the con- troller-Configuration.

  • Page 20: Connect The Additional Electrical Components

    ( E 1500430) the PCB plug J2 (see fig. 4-13). Position the gas intake in such a way that the ROTEX A1 can be opened without tension or restriction. Additional optional regulating system components (room con- Connect the factory-mounted gas connection corrugated trollers, mixer modules etc.) are connected to the switching field...

  • Page 21: Filling The Heating System

    Check the water pressure on the pressure gauge again and top up with water if necessary. Close the KFE cock and the water supply cock. Remove the filling hose with backflush prevention from the filling and draining fitting. ZB_RoCon_VentFkt (008.1534699) FA ROTEX A1 BGe - 02/2014...

  • Page 22: Start-Up

    If you have questions, please contact our Technical Customer Service. 5.1 Initial start-up Once the ROTEX A1 is installed and fully connected, it can be put into operation by expert technicians. Requirements – The ROTEX A1 is installed correctly.

  • Page 23: Checklists For Start-Up

    Checklists for start-up Checklist before start-up Is the ROTEX A1 correctly set up according to an admissible set up variant and without visible damages? Combustion air supply secured? Adequate ventilation and extraction in the heating room with limited room-air independent (separate flue...

  • Page 24: Control Unit

    6.1 Operating elements on the boiler control panel The ROTEX A1 is equipped with the ROTEX RoCon BF Regulation. The fitted digital control system serves to actuate a direct heating circuit and a storage tank charging circuit. It can be extended in many ways with accessory components.

  • Page 25: Replacing The Operating Section Rocon B1

    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. Fig. 6-5 Pull out the cable FA ROTEX A1 BGe - 02/2014...

  • Page 26: Changing Cables

    6. Insert all connectors on the switchboard PCB. The connec- tors are colour and shape-coded to avoid confusion. Do not force the connector! 7. Mount the control panel cover. 8. Fit both top heat insulation shells. FA ROTEX A1 BGe - 02/2014...

  • Page 27: Changing The Sensors

    Close the ball cocks on the boiler flow and boiler return flow before removing the sensor, and Before beginning work on the ROTEX A1, depressurise the system through the KFE cock. disconnect therom the power supply (switch off fuse, main switch) and secure against uninten- tional restart.

  • Page 28: Changing The Flue Gas Temperature Sensor

    3. Bend the pressing springs on the new sensor and push the new sensor into the sensor immersion sleeve. The insertion depth is marked on the ROTEX storage tank by a coloured marking, depending on the storage tank type. 4. Clamp the sensor cable on the connector of the connection Fig.

  • Page 29: Replacing The Fuse Or Control Panel Circuit

    (digital demand contact) 2. Remove the 4 locking screws on the control panel casing us- ing a screwdriver (fig. 6-14). Accessories 3. Remove the top of the casing. Tab. 6-1 Legend for fig. 6-16 FA ROTEX A1 BGe - 02/2014...
  • Page 30 Control unit Fig. 6-16 Wiring diagram ROTEX A1 BG (for legend see tab. 6-1) FA ROTEX A1 BGe - 02/2014...

  • Page 31: Gas Burner

    Burner of the A1 BG - front view Fig. 7-2 Burner of the A1 BG - rear view (legend in fig. 7-1) Fig. 7-3 Burner of the A1 BG - left side view (legend in fig. 7-1) FA ROTEX A1 BGe - 02/2014...

  • Page 32: Automatic Firing Cm124-R1

    Ignition brown brown green/yellow Gas valve black HALL brown black Blower speed grey n.a. black Ionisation n.a. Not assigned Tab. 7-1 Assignment and colours of the connection cable on the automatic firing CM124-R1 FA ROTEX A1 BGe - 02/2014...

  • Page 33: Safety Function

    Gas burner 7.2 Safety function The burners of the ROTEX A1 can be equipped at the factory with different blower types, which are operated at different speed set- Fault shutdown and malfunction indicator tings. A locking fault shutdown takes place if: The following settings apply to the blower type –...
  • Page 34 Liquid petroleum gas version (F) ** Compare with the information on the yellow sticker attached to the burner ROTEX-Factory settings Tab. 7-2 Flue gas set values and speed limits for A1 BG 25(F)-e for different types of gas A1 BG-Type A1 BG 40(F)*-e...

  • Page 35: Checking And Setting The Burner

    11) clockwise up to the stop (do not tighten). 5. Open the heating valves. 2. Open the adjusting screw for the gas/air mixture according to 6. Switch on ROTEX A1 with main switch. tab. 7-4 counter clockwise: 7. Switch on the operating mode "Emission Measurement" for Full Load.

  • Page 36: Resetting The Gas Type

    ROTEX A1 from the power supply (switch off fuse, main switch) and secure against uninten- tional restart. 1. Switch off the ROTEX A1 and secure against restart. 2. Remove the plug from the gas regulation block (fig. 7-6, step 1).

  • Page 37: Adjusting The Output Limits And The Starting Output

    "ROTEX Control RoCon BF" documen- tation. This documentation is included in the scope of delivery. 1. Switch off the ROTEX A1 and secure against restart. 2. Remove the plug from the gas regulation block (fig. 7-6, A targeted output adjustment is carried out by: step 1).

  • Page 38: Setting The Gas Pressure Controller

    3. Check the changes in the combustion quality with a flue gas analyser. If the burner creates noises at the least output setting (Base Load), you should (depending on the weather!): set the min. output to a higher value. FA ROTEX A1 BGe - 02/2014...

  • Page 39: Setting Ignition And Ionisation Electrodes

    Dismantle the burner before adjusting the electrodes and make the electrodes glow by using a solder lamp. The electrodes are factory-set to the optimum value. For adjusting: see fig. 7-10. Fig. 7-10 Adjustment of the ignition and ionisation electrodes FA ROTEX A1 BGe - 02/2014...

  • Page 40: Removing/Fitting The Burner

    4. Open gas intake and check gas line for leaks 5. Turn power supply back on. 6. Start the burner. Check function and setting (see section 7.3.2). 7. Attach boiler cladding and noise damping hood. FA ROTEX A1 BGe - 02/2014...

  • Page 41: Hydraulic Connection

    Hydraulic connection 8.1 Connection accessories 8.1.1 Safety group SBG A1 For the hydraulic connection of the ROTEX A1 you must comply with the safety technological regulations in accordance with EN 12828. ROTEX recommends the use of the safety group offered as an accessory (SBG A1, 15 60 18).
  • Page 42 Move diverter valve to centre position with hand lever (fig. 8-4, item 3.3) (only possible if the valve drive is already in "Heating" position). FA ROTEX A1 BGe - 02/2014...

  • Page 43: Hydraulic System Connection

    US 150. Note that the hydraulic circuit shown does not claim to be complete and your system planning must therefore still be carried out thoroughly. As a ROTEX certified company you will find other ex- amples for hydraulic system connection concepts on the ROTEX Homepage.

  • Page 44: Service And Maintenance

    Remove the sound insulation hood. cause fatal burns and injuries. Lift and remove the boiler cladding (see fig. 9-2). Before beginning maintenance work, disconnect the ROTEX A1 from the power supply (switch off fuse, main switch) and secure against uninten- tional restart. WARNING! Danger of burning - hot surfaces.

  • Page 45: Checking The Connections And Pipes

    Rectification of damage to live components on the Wear protective clothing (safety glasses, rubber ROTEX A1 may only be carried out by authorised gloves) when working on the condensate box. and recognised heating experts.
  • Page 46 (insert a wedge if necessary). 13. Fill condensate box with water (see chapter 4.7 "Connect the condensate drain"). Fig. 9-7 Pull out connecting flexible hose FA ROTEX A1 BGe - 02/2014...

  • Page 47: Checking The Flue Gas Temperature

    Checking the flue gas temperature sensor Before beginning maintenance work, disconnect CAUTION! the ROTEX A1 from the power supply (switch off fuse, main switch) and secure against uninten- The fitting position of the flue gas temperature sensors tional restart.
  • Page 48 (fig. 9-15). Fig. 9-13 Lift out the top burner chamber insert (shown A1 BG 25-e) Only on A1 BG 40(F)-e: Remove the cylindrical burner chamber. Remove the lower combustion chamber inset using the combustion chamber wrench (fig. 9-14).

  • Page 49: Checking The Burner

    If the combustion values do not fall within the target range, the burner must be adjusted accordingly (see chapter 7.3) We recommend, to enter all measured values and the conducted work with the date and signature into the enclosed operating handbook. FA ROTEX A1 BGe - 02/2014...

  • Page 50: Faults And Malfunctions

    You will find detailed information on the control unit and the boiler control panel as well as on the operating modes and parameter settings in chapter 6 "Control unit" and in the documentation "ROTEX RoCon BF Controller" as supplied with the associated Control unit. 10.2 Overview of possible malfunctions...
  • Page 51 Switch off storage tank charging circuit Flue gas temperature Flue gas temperature too high Clean the boiler sensor switch off 1) See documentation "ROTEX RoCon BF Controller" Tab. 10-1 Possible faults on the A1 FA ROTEX A1 BGe - 02/2014...

  • Page 52: Fault Codes

    Flow temperature increase too rapid. Supply voltage too low. No communication with the automatic firing for longer than 2 mins. BCC activation BCC conformity Tab. 10-2 Fault codes (can be detected by automatic firing) FA ROTEX A1 BGe - 02/2014...

  • Page 53: Rectifying Burner Faults And Stb Faults

    3. Set the flow temperature with the rotary switch, but do not actuate Fault code and request "Reset" is displayed. The ROTEX A1 operates manually at the set flow temper- 4. Select "Yes" with the rotary switch. ature. 4. Cancelling and jump back by pushing the Exit button again.

  • Page 54: Taking Out Of Service

    Bleed all the water in the entire system at the filling and draining sockets (KFE cock). 11.2 Final shutdown and disposal For the final shutdown, the ROTEX A1 must be: Taken out of service, Disconnect it from all electrical, gas and water connections, Disposed off in a professional manner.

  • Page 55: Technical Data

    ~230 v / 50 hz Electrical power consumption (including heating circulation <85 W <110 W pump) Protection type IP X0B Tab. 12-1 Basic data A1 BG Type Unit type Product-ID (CE-Number) NOx class Nominal heat load Nominal output Country of destination Power voltage supply Electr.

  • Page 56: Heating Circulation Pump And 3-Way Diverter Valve (A1 - All Types)

    GB, GR, IE, IT 28-30/37 CH, ES, PT 28-30/37 28-30/30 3 B/P 3 B/P 20/25 2 Esi 20/25 2 E(S)B 3 B/P 3 B/P Tab. 12-4 Countries of destination, device categories and associated gas connection pressures FA ROTEX A1 BGe - 02/2014...

  • Page 57: Performance Diagrams

    Technical data 12.4 Performance diagrams Fig. 12-3 Permissible burner load of the ROTEX A1 BG 40(F)-e (legend Burner load in kW Maximum permissible burn- see fig. 12-2 Relative burner load in % er load Gas type (test gas) Minimum permissible burner load Fig.

  • Page 58: Temperature Sensor

    Fixing screw (venturi nozzle / safety gas regulation block) Fixing screw (safety gas regulation block / gas connection line) Temperature probe and sensors Max. 10 Hydraulic line connections (Water) Thread 1" 25 - 30 Tab. 12-6 Tightening torque FA ROTEX A1 BGe - 02/2014...

  • Page 59: List Of Keywords

    Output limits ....37 Draining the heating system ..54 Parallel operation ....42 FA ROTEX A1 BGe - 02/2014...

  • Page 60: Notes

    Notes 14 Notes FA ROTEX A1 BGe - 02/2014...
  • Page 61 Notes FA ROTEX A1 BGe - 02/2014...
  • Page 62 Notes FA ROTEX A1 BGe - 02/2014...
  • Page 63 Notes FA ROTEX A1 BGe - 02/2014...

  • Page 64: For The Chimney Sweep

    4-6, page 15) 15.2 Emissions measurement Special Level The check measurement can be made by a simply selectable automatic function (see also "Operating Instructions - ROTEX-RoCon BF Con- Emission Measurement troller"). Manual Operation Depress the exit button for at least 5 secs.

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