General safety precautions General safety precautions 1.1 Particular safety instructions WARNING! Heating devices that have not been correctly set up and installed can impair the function of the heating device and/or cause serious or fatal injuries to the user. ● Work on the GCU compact (such as set-up, servicing, connection and initial start-up) must only be carried out by persons who are authorised and who have successfully completed qualifying technical or vocational training and who have taken part in advanced training sessions recog- nised by the relevant responsible authorities for the specific activity.
– ROTEX GCU compact: – Operating instructions for the operator. Danger of explosion – Operating manual for the operator – ROTEX RoCon BF: operating instructions. Risk of burning or scalding – When additional ROTEX components are connected: the associated installation and Risk of poisoning operating instructions.
1.2.2 Use as intended authorised and who have successfully The ROTEX GCU compact may only be used for completed qualifying technical or the heating of hot water heating systems. It may...
● Make sure that there is an outside air opening of at least 150 cm for ambient-air dependent or partial ambient-air independent operation. ● Do not operate the ROTEX GCU compact in ambient-air dependent operation in rooms with aggressive vapours (e.g. hair spray,...
1.2.7 Fuel cause a considerably reduced service life of the equipment. The responsibility for this lies solely The ROTEX GCU compact is factory set to the with the operator. gas type indicated on the burner sticker and on the settings type plate and adjusted to the gas pressure indicated on the burner sticker.
Handover to operator and warranty Handover to operator and warranty 2.1 Instruct the owner 2.2 Warranty conditions ● Before you hand over the heating system, explain to the The legal guarantee conditions fundamentally apply. Our war- owner how he/she can operate and check the heating ranty conditions beyond that can be found online on your sales system.
Tab. 3-1 Legend for fig. 3-1 to fig. 3-7 3.2 Brief description The ROTEX Gas Combi Unit 2 (GCU compact) is a fully preas- exchanger, which is made from a stainless steel corrugated pipe sembled gas condenser unit integrated in a hot water storage (1.4404), and is completely immersed in the storage tank water.
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There are no low flow or unheated zones on the domestic water The calorific value engineering makes optimum use of the energy side with the ROTEX GCU compact. It is not possible for sludge, contained in the heating gas. The flue gas is cooled down in the rust or other sediments to be deposited, as can be the case with boiler –...
Incorrectly erected and installed gas devices may not operate properly and are dangerous for the health and safety of individuals. ● The ROTEX GCU compact may only be installed by heating technicians authorised and trained by gas or energy supply companies.
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Set-up and installation Dim. GCU compact 3xx GCU compact 5xx 1380 1895 1725 1720 2050 Tab. 4-1 Connection and installation dimensions of the GCU compact in mm (based on fig. 4-1, fig. 4-2, fig. 4-10, fig. 4-16 to fig. 4-18)
Set-up and installation 4.1.1 Connecting dimensions for the heating and hot water connections GCU compact 3xx Front Rear Fig. 4-4 Connection dimensions of the GCU compact 3xx (top view) For legend of position numbers, see tab. 3-1 Fig. 4-3 GCU compact 3xx connection dimensions (view from the ...
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Fig. 4-6 Connection dimensions GCU compact 5xx (top view) For legend of position numbers tab. 3-1 To prevent increased cooling losses ROTEX recom- mends installation of SKB gravity brake systems 16 50 70) or syphoning (lead the connection lines straight downwards) of the drinking water connections.
2x75 cm²) Installation version 3 Rear ventilation opening (150 cm The ROTEX GCU compact is not placed directly below the roof. Fig. 4-7 Installation versions for the GCU compact The dual pipe for the combustible air supply and flue gas duct The ROTEX GCU compact is designed basically for ambient air- runs through the roof truss.
Appropriate measures must be taken to ensure that the burner cannot be operated if the ventilation opening is closed. The ROTEX GCU compact with the SET GCU1 and the LAS – The installation shaft where the flue gas line runs must be rear connection line SET H or SET K is connected to the exterior wall ventilated.
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– as for B , but connection to associated flue gas pipe described in this manual (see chap. 4.5.1), a suitable arith- (ROTEX system) including flue gas opening metical dimensioning verification is required. – For data on dimensioning calculation, see tab. 15-1.
– The GCU compact must be installed protected from frost. Surface temperatures, minimum distance WARNING! The plastic wall of the storage tank of the ROTEX GCU compact can melt under the effects of external heat (>80 °C) and, in the extreme case, can catch fire.
4.4.2 Installing the unit WARNING! The ROTEX GCU compact is top-heavy when unfilled and could tilt over during transport. That could put persons in danger or damage the unit. ● Secure the ROTEX GCU compact well, transport carefully, use handles.
● Unhook the protective cover from the rearward facing holding burls, lift at the back and remove to the front. Fig. 4-11 Remove the protective cover Fig. 4-12 ROTEX GCU compact without protective cover CAUTION! The thermal insulation (fig. 4-12, item A) consists of pressure- sensitive EPP moulded parts that can be easily damaged if not handled correctly.
– 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). – Depending on the local building regulations, inspection com- ponents must be installed in the required locations.
SET H (see chap. 4.5.3) - (for dimensions, see tab. 4-1) fig. 4-15 and chap. 15.1. Natural gas E/H (G20) Flue gas mass flow Natural gas LL/L (G25) Burner load Liquid gas (G31) Fig. 4-15 Flue gas mass flow in relation to the burner load ROTEX GCU compact (all types)
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Set-up and installation Front view Inspection section Test adapter Fig. 4-17 Top view of the GCU compact flue gas connection to the side with SET H (see chap. 4.5.3) - (for dimensions, see tab. 4-1) In some cases, the resonance in the flue gas system can amplify the noise at the mouth of the flue gas duct.
Set-up and installation 4.5.3 Flue gas system kits Fig. 4-18 Flue gas system kits If needed Flue gas connection, left See tab. 4-1 Flue gas connection, right (PA) Test adapter Flue gas connection, rear (O) Flue gas connection, top...
● Install a dirt filter or sludge separator in the heating return flow (see chap. 1.2.6). CAUTION! If the ROTEX GCU compact 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.
1.2.6. ● Install the ROTEX GCU compact close to the withdrawal point to dispense with the need for a circulation line. If a circu- lation line is essential, it must be installed in accordance with the schematic diagrams in chap.
Comply with the stipulated tightening torque (see chap. 12.3). – Install the line in such a way that the protective cover of the ROTEX GCU compact is simple to put on after assem- bly. – Connect the water for filling or refilling the heating system as specified by EN 1717/EN 61770 to avoid contamina- tion of drinking water by return flow.
Set-up and installation WARNING! There is a danger of scalding at hot water temperatures over 60 °C. This is possible when using solar energy if an external heater is connected, the Legionella protection is activated, or the target hot water temperature is set to be greater than 60 °C. ●...
● The equipment covers and maintenance opening covers must be re-fitted immediately after completion of the work. All ROTEX GCU compact control and safety devices are con- nected ready for use and tested. Modifications on the electrical installation are dangerous and prohibited. The operator alone Fig.
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● Effective strain relief in the controller housing by means of cable ties must be ensured for all cables connected to the ROTEX GCU compact. ● Check the holding force of the strain relief. ● Bring the controller housing back into the vertical operating position.
● Close the front panel and screw in the locking screw. The use of temperature sensors that are not approved or unsuitable for the unit can lead to major malfunctions during regular operation of the ROTEX GCU compact and impair the CAUTION! control function of the unit.
- see chap. 4.7.9 and function "Operating chap. 4.7.8). A connected room thermostat has to be activated by mode switchover over EXT input" in the "ROTEX controller parameter [Room thermostat] on the RoCon BF controller. RoCon BF" documentation.
Fig. 4-38 Connect the J8 sensor connector to the PCB control panel ● Close the control panel. 4.7.5 Mixer module RoCon M1 The RoCon M1 mixer module can be connected to the ROTEX GCU compact (J13 circuit board connector) and is controlled by the electronic boiler controller.
The operating mode has an effect on the direct circuit of the a few sparks can cause major explosions. ROTEX GCU compact as well as all other heating circuits con- ● Before working on gas carrying parts, always close the nected to this device as an option.
Set-up and installation 4.8.4 Checking the gas presetting ● Compare the available gas type with the position set for the setting screw on the safety gas control block (fig. 4-44, item 3.1). – 1 = Natural gas – 2 = Liquid gas ...
This adjustment must be appropriately labelled with a suit- able burner settings sticker and an entry on the settings Fill the ROTEX GCU compact only after completion of all instal- type plate (fig. 3-2 / fig. 3-5, item 33). lation work in the order shown below.
– In the event of burner starting problems, see chap. 7.3.4. CAUTION! Automatic calibration of the GCU compact and adjust- If the ROTEX GCU compact is not started up properly, it could ment of the gas valve complete. lead to material or environmental damage. ...
5.1.4 After start-up housing ● Installing the protective cover (see chap. 4.4.3). Tab. 5-1 Start-up control values for GCU compact 315 and ● Check all the points on the "Checklist after start-up" (see GCU compact 515 for various gas types chap.
Start-up Checklists for start-up Checklist before start-up Is the ROTEX GCU compact properly installed in accordance with a permitted set-up and without any discernible damage? Combustion air supply secured? Adequate ventilation and extraction in the heating room with limited ambient air-independent (separate flue gas/air supply line) or ambient air-dependent operation? ...
6.1 Operating elements on the boiler control panel The ROTEX GCU compact is fitted with the ROTEX RoCon BF controller. The integrated digital control system actuates a direct heating circuit and a storage tank charging circuit. It can be extended in many ways with accessory components.
Touching live parts can result in an electric shock and lead to against unintentional restart. potentially fatal injuries and burns. ● Before beginning work on the ROTEX GCU compact, Removing the control panel disconnect it from the power supply (fuse, switch off the main ●...
Controller and electronic components 6.3.1 Replacing the inflow temperature sensor / return flow temperature sensor and pressure sensor WARNING! There is a danger of scalding from heating water. Sensors are connected directly to the pressurised heating water. ● Before removal of the sensors, close the ball cocks on the boiler inflow and boiler return flow, and depressurise the system with the KFE cock.
Guide the cable into The insertion depth is marked on the ROTEX hot water the controller housing, connect to terminals 5 and 6 of PCB storage tank by a coloured marking depending on the storage plug J8 and put on the plug.
Heat cell with gas burner Heat cell with gas burner 7.1 Design and brief description Fig. 7-2 Components of the GCU compact heat cell: Gas section – exploded view (for legend, see tab. 7-1) Fig. 7-1 GCU compact - heat cell (for legend, see tab.
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Heat cell with gas burner Ignition electrodes Ionisation electrode Burner flange Burner blower Venturi nozzle Gas connector pipe Gas connection G ½" IG with connected gas hose Safety gas control block Gas valve connection adapter Condensate pipe with overfill protection Flue gas collector Securing stirrup for gas connection line(2x) Supply air manifold...
Requirements: The cause of the malfunction has been rectified, the burner is connected to the electrical system. 1. Switch on the ROTEX GCU compact. 2. Push the Exit button (fig. 6-1, item 13) for at least 5 s. ...
Compare with the information on the yellow sticker attached to the burner housing housing Tab. 7-3 Set flue gas setting values for GCU compact 315 and Tab. 7-7 Set flue gas setting values at "Base Load" for all GCU compact 515 for various gas types...
Compare the measured values with You can find more detailed explanations and possible setting values for these pa- the specified setting values (see chap. 7.3.1). rameters in the "ROTEX RoCon BF" controller operating instructions. a) If the O concentrations lie within the permissible 7.3.4 Starting problems - calibrating the firing unit,...
Heat cell with gas burner 1. Switch the ROTEX GCU compact off and then on again. 5. Confirm the changes with a brief push of the rotary switch. 2. Set the rotary switch to the "Configuration" position. 6. Switch the ROTEX GCU compact off and then on again.
Removing the burner ● Block gas supply. ● Disconnect the ROTEX GCU compact from the power supply (fuse, main switch switched off) and secure against uninten- tional restart. ● Remove the protective cover (see chap. 4.4.3).
Cold water distribution network WARNING! Hot water distribution network To prevent flue gas from escaping, the storage tank must be Heating flow filled to overflow when starting up the ROTEX GCU compact. Heating return flow Mixing circuit Circulation WARNING! Check valve, return valve Non-return valves High temperatures can occur in the solar storage tank.
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Hydraulic connection Fig. 8-1 GCU compact 3xx (example) with DrainBack solar (for legend, see tab. 8-1) Fig. 8-2 GCU compact 5xx Biv with pressurised solar system (for legend, see tab. 8-1)
ROTEX GCU compact. Tests performed during the annual service ● Damage repair to power and gas lines on the ROTEX – General condition of the heating system, visual inspection of GCU compact may only be carried out by heating techni- connections and pipes.
Service and maintenance 9.2.2 Checking and cleaning the condensate drain 9.2.3 Checking and cleaning the burner WARNING! DANGER OF EXPLOSION! Danger of scalding from hot storage water. Escaping gas is a direct threat to human health and safety. Even ● Before dismantling the condensate drain, allow the storage a few sparks can cause major explosions.
● Fill the storage tank of the GCU compact until water escapes out of the overflow connection (fig. 9-3, item 2). ● Remove the filling hose with non-return valve (1/2"). GCU compact 315 / 320 / 515 / 520 (Biv) GCU compact 524 / 528 (Biv)
Service and maintenance 9.2.5 Filling, topping up the heating system and Filling hose with return flow Water tap storage tank charging circuit inhibitor (and manometer Automatic bleeder KFE cock Pressure gauge Heater ball cock - inflow Heater ball cock - return 3UV DHW DANGER! ...
3-way changeover valves integrated in the ROTEX GCU compact. Any air present can escape via the automatic vent valve during the air purge and the hydraulic circuit connected to the ROTEX GCU compact is evacuated. The activation of this function does not replace correct venting of the heating circuit.
10.1 Troubleshooting Troubleshooting ● Detecting and remedying the cause of the malfunction. The electronics of the ROTEX GCU compact ● Non-interlocking faults (see chap. 10.3) are indicated for as – signal a fault by red backlight in the display, and long as the malfunction exist.
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● Throttle maximum pump output (setting of parameter noises [Max Perform Pump] reduce gradually – not below Badly balanced heat distribution system 65%). ● Carry out hydraulic balancing. 1) See "ROTEX RoCon BF" controller documentation Tab. 10-1 Possible faults on the GCU compact...
Faults and malfunctions 10.3 Fault codes Code Component/Designation Error or t defective (cable break, short circuit). During calibration, difference from prior value was too high (unclean supply air, electrode re- placement, electrode defective). E129 Inflow temperature exceeds limiter temperature (overtemperature, no heat dissipation) E130 Return flow temperature exceeds limiter temperature (overtemperature, no heat dissipation) E132...
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Faults and malfunctions Code Component/Designation Error Return flow temperature exceeds monitor temperature (overtemperature, no heat dissipa- tion) Inflow flow temperature exceeds monitor temperature (overtemperature, no heat dissipation) Undervoltage with 230 V mains voltage or 18 V internal DC voltage (electronic fault, switch device on/off).
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Faults and malfunctions Code Component/Designation Error Possible fault rectification Internal mixer sensor ● Check cable, terminal and plug connec- tions. External temperature sensor Measured value outside measuring range, ● Replace temperature sensor. temperature sensor defective. Storage tank temperature sensor EEPROM ●...
"Manual Operation" special function on the controller (see en- closed "ROTEX controller RoCon BF" operating instructions). When the 3-way valves are intact the ROTEX GCU compact switches to heating operation. The required inflow temperature can be adjusted with the rotary switch.
If no heating and no hot water supply is needed over a long ● When using the KFE filling connection (accessory period the ROTEX GCU compact can be temporarily shut down. KFE BA, 16 52 15): However, ROTEX recommends putting the system into standby Remove the cover panel on the handle and unscrew the mode (see the documentation concerning "ROTEX controller).
1. Switch off the main switch and secure against restarting. 2. Close the gas stop valve. 3. Connect the drain hose to the KFE cock of the ROTEX GCU compact. Fig. 11-3 Completing the KFE fill- Fig. 11-4 Screwing the KFE filling...
= 45 °C. The specif. water flow acc. to EN 15502 is the domestic water flow at an average temperature increase of 30 K, which the ROTEX GCU compact can supply if two draw-off procedures each of 10 minutes duration are performed one after the other, assuming a charging temp. of 65 °C. A delay of 20 minutes between the two draw-off procedures is usually assumed.
= 45 °C. The specif. water flow acc. to EN 15502 is the domestic water flow at an average temperature increase of 30 K, which the ROTEX GCU compact can supply if two draw-off procedures each of 10 minutes duration are performed one after the other, assuming a charging temp. of 65 °C. A delay of 20 minutes between the two draw-off procedures is usually assumed.
Technical data 12.1.3 Integrated gas boiler Type (1)* GCU compact (Biv) Parameters Unit 315 / 515 320 / 520 Permitted ambient temperature °C 1 - 60 Product ID (CE number) (3)* CE-0063 CR 3574 Automatic firing unit Elster QCM434-R1 Safety gas control block Elster CES10 Burner fan ebmpapst NRG 118/0800-3612...
Technical data 12.1.5 Information on the type plate Equipment type Unit type Product ID (CE number) Rated thermal load Q Nominal output P (80/60 °C) Nominal thermal output during condensation operation P (50/30 °C) NOx class (EN 15502) Voltage supply U Electrical power consumption elmax Degree of protection Net weight...
Details and precautions on installation, maintenance and assembly can be found in the installation and or operation manuals. Energy labels and product fiches for additional combinations, packages and other products can be found at www.rotex-heating.com. Sound power in heating mode, measured according to the EN 12102 under conditions of the EN 14825.
Technical data 12.2 Gas type, connection pressures Gas type Nominal pressure in mbar Min. inlet pressure in mbar Max. inlet pressure in mbar Natural gas E/H Natural gas LL/L Liquefied petroleum gas 42.5 57.5 Tab. 12-6 Permitted gas inlet pressure Country of destination Appliance category Nominal connection pressure in...
Technical data 12.4 Flow rate and residual feed height 12.5 Temperature sensor p Sensor resistance Temperature Residual feed height Modulation range Heating network flow Fig. 12-4 Resistance characteristics of the temperature sensor Fig. 12-2 Residual feed height GCU compact (heating side) Temperature sensor Type Specification *...
15.2 Emissions measurement Special Level The check measurement can be made by an easily selectable automatic Emission Measurement function (see also "Operating Instructions ROTEX RoCon BF controller"). Manual Operation ● Push the Exit button for at least 5 s. ...
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