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Summary of Contents for Rotex GW
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Page 1: Installation And Operating Instructions
For operation and the operator ROTEX GW Wall-mounted Gas condensing boiler Installation and Operating Instructions 0051 CL 4018 Type Rated thermal output (modulating*) Edition 09/2012 ROTEX GW22C 4.5 - 21.6 kW ROTEX GW26C 5.8 - 26.2 kW Manufacturer's number Customer... -
Page 2: Table Of Contents
6.7.1 Special function emission measurement..32 Wall mounting ROTEX GW ....12 4.4.1 Selecting the installation location ... . .12 Gas burner . - Page 3 15.1 Data for designing the flue gas pipe ..52 15.2 Chimney sweep function....52 FA ROTEX GW - 09/2012...
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Page 4: Guarantee And Conformity
1.2 Declaration of conformity We, ROTEX Heating Systems GmbH, declare exclusive responsibility for the Gas condensing boiler with the product identification number 0051 CL 4018, Product Order No. -
Page 5: Safety
2.3 Avoid danger and maintenance are described in this operating instruction manual. The ROTEX GW is built according to the state of the art and recognised norms on technology. However, improper use may All heating parameters needed for smooth operation are already result in serious physical injuries or death, as well as property factory-set. -
Page 6: Fundamental Instructions For Operational Safety
Electrical installations must only be conducted by electrical engineers and in compliance with valid electrical guidelines The ROTEX GW is set, in the factory, to the type of gas quoted as well as the specifications of the energy supply company. -
Page 7: Product Description
Product description Product description 3.1 Structure and constituents of the GW Fig. 3-3 Constituents of the ROTEX GW - external parts Fig. 3-1 Constituents of the ROTEX GW - inner view Fig. 3-2 Constituents of the ROTEX GW - side view Fig. -
Page 8: Brief Description
Safety management Heating return (cold) Ignition transformer Cold water Ionisation electrode The safety management of the ROTEX GW is handled entirely by Gas connection Ignition electrode the electronic controller. This effects a safety switch-off in the Hot water Flue gas temperature... -
Page 9: Installation
1500 mm 370 mm The ROTEX GW must be erected and installed only by heating technicians authorised and trained 200 mm by gas or energy supply companies. 2500 mm... -
Page 10: Different Set-Ups
Installation Different set-ups The ROTEX GW is principally designed for operation The appropriate test adapter is included. independent of room air. By default, it comes equipped with a concentric DN 60/100 flue gas/intake air connection. 1-10 Different set-ups (Description, see chapter 4.2.1 to 4.2.3) -
Page 11: Operation Independent Of Ambient Air
The ROTEX GW is principally suited for installation and operation within garages. Set-up version 3 Requirements: The ROTEX GW is not mounted on a wall directly under the roof. The dual tube for the combustible air supply and flue gas pipe Requirements: runs through the roof truss. -
Page 12: Operation Partially Independent Of Ambient Air
4.4 Wall mounting ROTEX GW Set-up version 8 4.4.1 Selecting the installation location The ROTEX GW is operated with separately routed inlet air/ flue The place of installation for the ROTEX GW must meet the gas lines (2 line system). -
Page 13: Wall Mounting
Wall breakthrough (Ø 135 mm when using GW1 kit) constructional conditions and the minimum distances (see Fig. 4-7 Creating the drilled holes chapter 4.1). Drill the holes Ø 10 mm for the fixing hooks for the ROTEX GW as per the mounting template. FA ROTEX GW - 09/2012... -
Page 14: Air/Flue System (Las)
Check that the unit is hori- for checking and setting the combustion values. A test adapter zontal. (DN 60/100) is included in the delivery of the ROTEX GW. Installation position and line height – The maximum permitted flue gas counter pressure is 200 Pa. -
Page 15: Connect Flue Gas Line To The Rotex Gw
Installation Permissible height of the flue gas system Tab. 4-2 shows the maximum permissible height of the flue gas line for the case that the ROTEX GW is operated in the nominal output range. Installation version GW 22C GW 26C... -
Page 16: Flue System Kits
Accessories as required xxx 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. 4-11 Plastic (PP) flue system kits FA ROTEX GW - 09/2012... -
Page 17: Hydraulic Connection
4.6 Hydraulic connection tures over 60 °C. This is possible with installed solar The connections of the ROTEX GW are located on the bottom of system (e.g. ROTEX Solaris) or if the hot water the unit. Any limescale which results from the water heating nominal temperature is set to greater than 60 °C. -
Page 18: Connecting The Drain Hoses
The entire blow-off line and the connection to the sewerage system must be executed in accordance with EN 12828. All control and safety systems of the ROTEX GW are connected and tested at the factory. Modifications on the electrical instal- DANGER OF CHEMICAL BURNS! lation are dangerous and prohibited. -
Page 19: Temperature Sensors And Other Sensors
Lay the sensor line (twin core cable, minimum cross section X10/3 3-Way diverter valve - L2 1 mm ) and connect to the controller on the ROTEX GW at X11/1 Burner blower - L the terminal rail X5 to the connections 11 and 12... -
Page 20: Connect The Gas Line, Check The Burner Setting For Gas Type
When changing over to natural gas LL/L, this adaptation must be made clear by an entry on the setting type identification plate (fig. 4-17, item 28). Tab. 4-4 Permitted gas inlet pressure Fig. 4-17 Access to the inside of the unit (key see tab. 3-1) FA ROTEX GW - 09/2012... -
Page 21: Checking Burner Pre-Setting
(fig. 4-17, item 27) and on the set- controller of the ROTEX GW at the terminal rail X5 to the ting type identification plate (fig. 4-17, item 28). connections 1 and 2 (see fig. 4-15). -
Page 22: Start-Up
5.1 Initial start-up Open all the regulating valves on the system. Once the ROTEX GW is installed and fully connected, it can be Connect the filling hose with return flow inhibitor (1/2") at put into operation by expert technicians. - Page 23 Fully open all the radiator thermostats / regulating valves. output stage. On the ROTEX GW set the highest nominal room temper- ature so that the burner and the heating circulation pump operate. In the heating performance diagram (chapter 12 "Technical data", fig.
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Page 24: Checks During Start-Up
5.1.6 Setting parameters When the heating circulation pump runs, does the heating heat up? Adapt the ROTEX GW to the heating system and, if necessary, to the country-specific requirements by adjusting Is the flow pressure for the gas type within the the parameters on the controller (see chapter 6.5). -
Page 25: Operation
Operation Operation The ROTEX GW can only be operated with the Action Result integrated controller or in combination with a different – In basic display: Nominal hot water controller extension approved by ROTEX. briefly temperature – In other display: Setting (+) -
Page 26: Structure Of Display
1st. part of parameter Associated measured value 2nd. part of parameter Tab. 6-3 Explanation info values Fig. 6-2 Structure of display of GW controller 6.3 Basic display The basic display shows information about the current operating status of the boiler. °C... -
Page 27: Operating Modes
"hot water" If an optional room station GW-QAA73 ( 15 00 41) operating mode using the is connected to the ROTEX GW, the operating modes buttons °C are set directly at the room station (see associated The value is saved instructions). -
Page 28: Operating Mode Standby
Anti-blocking function If there is no heat demand for an extended period, the heating circulation pump is switched on briefly every 24 hours and the 3-way diverter valve is opened and closed once. FA ROTEX GW - 09/2012... -
Page 29: End-User Level (E1)
Fig. 6-11 Jump to the heating technician level and setting a parameter value (example: P518 - value changed from "0" to "5") This limits the increase in boiler nominal value temperature on a ramp function with 5 K/min. FA ROTEX GW - 09/2012... -
Page 30: Parameter List
E2 Can only be set by heating technician via operating elements direct on the controller The factory values must not be changed! In the event of other settings, the manufacturer's warranty lapses automatically! Tab. 6-4 List of settable parameters FA ROTEX GW - 09/2012... -
Page 31: Reset
P681 to b7 = on (as described in chapter 6.6.1). Press the button briefly to change the parameter. Use button to change the value from "off" to "on". Push the button briefly to save the change. RESET starts. FA ROTEX GW - 09/2012... -
Page 32: Special Functions (Heating Technician)
8 mins. until the function ends automatically. 8. The code of the special function is displayed in the event of 8 min a manual cancellation. 9. The unit goes back to the basic display. Fig. 6-15 Function sequence emission measurement FA ROTEX GW - 09/2012... -
Page 33: Gas Burner
Ionisation electrode Ignition electrodes Ignition transformer Burner flange seal (sealing cord) Flame tube seal (flat seal ring) Boiler flange seal (lip seal ring) Burner flange channel Venturi nozzle Fig. 7-1 Gas burner on the ROTEX GW FA ROTEX GW - 09/2012... -
Page 34: Burner Setting
** Compare details on type identification plate ROTEX Factory settings Tab. 7-1 Flue setting values and speed limits for ROTEX GW for various different gas types 7.3.2 Checking and setting the burner The gas burner has been factory-set for a certain gas type. The... -
Page 35: Carrying Out The Basic Setting On The Burner
1. Close the gas isolator valve. – The values adjust according to the specifications (com- pare step 7) 2. Switch off the ROTEX GW and secure against restart. Adjustment procedure is finished. 3. Create access to the unit internals (see chapter 4.9.3). -
Page 36: Adjusting The Output Limits And The Starting Output
Push the button briefly to leave the heating technician level and to switch back to the basic display. Enter the output change on the settings type plate and in the operating manual and confirm with signature. FA ROTEX GW - 09/2012... -
Page 37: Setting The Gas Pressure Controller
The electrodes are factory-set. For adjusting: Remove the burner (see chapter 7.4) Check and adjust the electrodes (see fig. 7-5). 6 mm 6 mm Ionisation electrode Ignition electrodes Fig. 7-5 Adjustment of the ignition and ionisation electrodes FA ROTEX GW - 09/2012... - Page 38 Burner installation Close the gas isolator valve. WARNING! Switch off the ROTEX GW and secure against restart. Create access to the unit internals (see chapter 4.9.3). An incorrect burner removal and installation can lead Disconnect the ionisation electrode (fig. 7-6, item 14) at the to gas leakages.
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Page 39: Hydraulic Connection
8.2 Equipment information 8.3.2 Connection schematic ROTEX GW Procedure The burner installed in the ROTEX GW heats the heating water directly via the boiler heat exchanger (direct circuit). In the event of hot water demand, the 3-way diverter valve integrated in the ROTEX GW switches the direct circuit as follows. -
Page 40: Inspection And Maintenance
Troubleshooting of power and gas lines on the authorised and trained heating engineers once a year ROTEX GW may only be carried out by heating and, if possible, before the heating period. This will technicians authorised and trained by the gas or avoid malfunctions during the heating period. -
Page 41: Checking And Cleaning The Burner
Check combustion values: – Flue gas temperature at measuring sockets of the flue gas pipe. (Target value < 75 °C), – O - or CO -content (see chapter 7.3.1), – CO content (target value < 50 ppm). FA ROTEX GW - 09/2012... -
Page 42: Faults And Malfunctions
10 Faults and malfunctions WARNING! Work on power or gas lines can endanger life and health and hinder the operation of the ROTEX GW. Work within the ROTEX GW only by authorised heating technicians. Fig. 10-2 Display of a 3-digit error code (e.g. c133) - Page 43 X10 on the controller and insert correctly. – 3-way diverter valve drive motor defec- Replace the drive motor on the 3-way diverter valve. tive Tab. 10-1 Possible faults on the ROTEX GW FA ROTEX GW - 09/2012...
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Page 44: Fault Codes
Brief mains interruption or voltage too low Cancellation of chimney sweep No fault - special function function Cancellation of emission No fault - special function measurement Tab. 10-2 Fault codes on the controller of the ROTEX GW FA ROTEX GW - 09/2012... -
Page 45: Decommissioning
6.5). If a heating or hot water supply is not to be required for a longer period of time, it is possible to temporarily shut down the ROTEX GW. However, ROTEX recommends leaving the plant in standby mode (see Chapter 6 "Operation") and cancelling the heating and hot water supply functions. -
Page 46: Technical Data
°C Pipe connections Hot and cold water Inch ½" outer thread Heating feed and return flow Inch ¾" outer thread Tab. 12-1 Basic data ROTEX GW * Position numbers see fig. 12-1 Type (1)* GW 22C GW 26C Parameter Unit... - Page 47 Tab. 12-5 Technical data of the integrated connection group Characteristic line GW 26C RQ Relative burner output Characteristic line GW 22C Burner load Fig. 12-2 Relative burner output of the ROTEX GW (see tab. 7-1) FA ROTEX GW - 09/2012...
- Page 48 Fig. 12-3 Residual delivery height ROTEX 22C (heating side) 1000 1200 1400 m / L/h Remaining pumping height I, II, III Pump stages integrated heating circulation pump Flow heating network Fig. 12-4 Residual delivery height ROTEX GW 26C (heating side) FA ROTEX GW - 09/2012...
- Page 49 Kilo-Ohm 55.0 32.0 25.0 19.7 15.0 12.4 10.0 Sensor resistance Temperature Fig. 12-6 Resistance characteristic line of the temperature sensor According to standard or manufacturer's de- tails Tab. 12-7 Resistance values of the temperature sensor FA ROTEX GW - 09/2012...
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Page 50: List Of Keywords
Piping height ....14 Flue system kits ....16 Frost protection function ..28 FA ROTEX GW - 09/2012... -
Page 51: Notes
Notes 14 Notes FA ROTEX GW - 09/2012... -
Page 52: For The Chimney Sweep
8 mins. until the function ends automatically. 5. The code of the special function is displayed in the event of a manual cancellation. 6. The unit goes back to the basic display. Fig. 15-1 Function sequence chimney sweep measurement FA ROTEX GW - 09/2012...
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