List of contents 4.8.4 Checking the gas presetting ........36 List of contents Filling the system................ 37 4.9.1 Checking the water quality and adjusting the pressure gauge ............37 4.9.2 Filling the hot water heat exchanger ......37 1 General safety precautions 4.9.3 Filling the condensate siphon ........
List of contents 12.1.3 Integrated gas boiler ........... 69 12.1.4 Integrated heating circulation pump, 3-way valves ..69 12.1.5 Information on the type plate ........70 12.1.6 Data sheets according to Ecolabel and Ecodesign regulation (EU) 811/2013 and (EU) 813/2013 .... 70 12.2 Gas type, connection pressures..........
General safety precautions General safety precautions Particular safety instructions ▪ Establish the power supply in ac- WARNING cordance with IEC 60335-1, via a Heaters that have not been set up and separate isolator which separates all installed correctly can impair the func- poles with a contact opening dis- tion of the heater and/or cause serious tance that provides full disconnection...
General safety precautions 1.1.1 Observing the instructions Observe the specified tightening torque (see Chap. 12.3) Only applies to devices with unpressurised solar system ▪ The original documentation is written in German. All other lan- connection (DrainBack). guages are translations. Only applies to devices with a bivalent solar system connec- ▪...
General safety precautions ▪ Do not operate the GCU compact in ambient-air dependent opera- 1.2.2 Intended use tion in rooms with aggressive vapours (e.g. hair spray, perchloro- ethylene, carbon tetrachloride), strong dust formation (e.g. work- The GCU compact may only be used for the heating of hot water shop) or high humidity (e.g.
General safety precautions 1.2.6 Heating system and sanitary connection ▪ Create a heating system according to the safety requirements of EN 12828. ▪ The plumbing connection must comply with the requirements of EN 12897. The requirements of the following must also be ob- served: ▪...
Handover to operator and warranty Handover to operator and warranty Instruct the 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 (at least the operating in- structions and operating manual) to the operator and advise him that these documents must be made available at all times and be stored in the immediate vicinity of the device.
Product description possible. The readiness zone is flowed through and heated from top Item Name to bottom by the heat exchanger for the storage tank charging Inflow temperature sensor (boiler circuit) (SL-WT), which is heated by the gas burner. Internal mixer sensor = inflow temperature sensor On its way to the top, the domestic water continuously absorbs the (heating circuit) heat of the storage tank water.
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Product description One or more mixed circuits can be connected and controlled via op- tionally connected mixer modules RoCon M1. All settings, displays and functions are carried out by the integrated RoCon BF controller. The display and the operating elements make operation easy. A digital room controller (RoCon U1) is optionally available for greater comfort.
Set-up and installation Set-up and installation WARNING Incorrectly erected and installed gas appliances may not operate properly and are dangerous for the health and safety of individuals. ▪ The GCU compact must only be set up and installed by heating engineers authorised and trained by gas or en- ergy supply companies.
Set-up and installation 4.1.1 Connecting dimensions for the heating and hot water connections GCU compact 3xx Fig. 4-4 Connection dimensions of the GCU compact 3xx (top view) For legend of position numbers, see Tab. 3-1 Front side Rear side Fig. 4-3 GCU compact 3xx connection dimensions (view from the back) For legend of position numbers, see Tab.
Set-up and installation GCU compact 5xx INFORMATION To avoid increased cooling losses, we recommend the in- stallation of SKB gravity brakes or the syphoning (connect- ing lines leading directly downwards) of the drinking water connection. Different set-ups Fig. 4-5 Connection dimensions GCU compact 5xx (view from the back) For legend of position numbers, see Tab.
Set-up and installation ▪ In the area of the roof truss, the dual pipe for the combustible air INFORMATION supply and the flue gas duct must be laid through a protective pipe In some cases, the resonance in the flue gas system can with sufficient fire resistance or be structurally separated from the amplify the noise at the mouth of the flue gas duct.
Set-up and installation ▪ The flue gas discharge to the outside runs through the chimney or ▪ Openings within a square of 50 cm × 50 cm an installation shaft. If the connection line between the GCU com- ▪ Spacing of opening levels < 50 cm pact and the installation shaft is single-walled or not completely ▪...
Set-up and installation ▪ Flue gas pipe without flow safeguard – underpressure operation ▪ Properties and application options of the flue gas pipe: ▪ Minimum requirements according to Chap. 4.5.1 fulfilled ▪ Opening for the flue gas outlet to the outside ▪...
Set-up and installation ▪ For ambient air-dependent mode, the installation room must be Pull the cover screens off the storage tank (Fig. 4-9, item B) and free from aggressive vapours (e.g. hair spray, perchloroethylene, unscrew the threaded fittings (Fig. 4-9, item F) from the open- carbon tetrachloride), heavy dust formation and high atmospheric ings at which the handles are to be fitted.
Set-up and installation CAUTION The thermal insulation (Fig. 4-12, item A) consists of pres- sure-sensitive EPP moulded parts that can be easily dam- aged if not handled correctly. ▪ Only remove the thermal insulation in the order stated below and in the stated directions. ▪...
Set-up and installation ▪ If the horizontal connecting piece is extended to more than 2 m, Air/flue gas system (LAS) the maximum permitted height of the flue gas duct is reduced by exactly that length. 4.5.1 General instructions for the flue gas ▪...
Set-up and installation 4.5.2 Connecting a flue gas line INFORMATION Before commencing work, the specialist company carrying out the work must consult the local authority responsible for building law issues relating to the installation of chim- ney systems and record this on a form. Requirements ▪...
Set-up and installation 4.5.3 Flue gas system kits Fig. 4-18 Flue gas system kits If needed Wall lead-through Tab. 4-1 Wall support Flue gas connection, rear Double-walled external wall connection Flue gas connection, left Supply air Flue gas connection, top Exterior wall supply air duct Flue gas connection, right Additional kits Cover panel...
Set-up and installation Water connection INFORMATION In accordance with EN 12828, a safety valve that limits the The GCU compact connections are located on the device top or front maximum permissible operating pressure in the heating solar return flow). The heating circuit and storage tank char- system must be installed on or in the immediate vicinity of ging share the same flow and return flow.
Set-up and installation The following conversion steps are required in order to direct 4.6.1 Aligning the connections of the heating the connections to the rear out of the device: inflow and return flow Remove the protective cover and top thermal insulation The connections of the heating supply and return can be directed (see Chap.
Set-up and installation Carefully pull the manifold (Fig. 4-20, item F) so far backwards out of its horizontal mounting that the retaining plate (Fig. 4-22, item A) can be pushed vertically in between. Fig. 4-24 Tension-free line connection 4.6.2 Connecting hydraulic lines Check the cold water connection pressure (maximum 6 bar). Fig. 4-22 Heating inflow and return flow connections aligned to the ▪...
Set-up and installation WARNING (UK ONLY) If filling or topping up the storage tank is done by means of the boiler filling and drain valve, a temporary filling loop must be used with the appropriate backflow prevention device in accordance with clause G24.2, Guidance to the Water Supply (Water Fittings) Regulations 1999.
Set-up and installation Remove the locking screw at top right on the boiler switch panel (Fig. 4-28). Fig. 4-28 Removing the locking screw Fig. 4-27 P-connection kit for Biv device types (example shows Remove the cable cover from the back of the controller housing GCU compact 5xx Biv ) (Fig.
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Set-up and installation Guide the cables to the controller housing and remove the insu- lation accordingly Fig. 4-30. Fig. 4-31 Open the front panel, install the cabling in the controller and establish the electrical connections 13 Lay the cabling in the controller housing (Fig.
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Set-up and installation Connections of the PCB connectors: 3UVB1 AUX connection Mains connection Sensors, switching contacts FlowSensor (FLS1) 3UV DHW CAN system bus Circulation pump P Room thermostat Cable colours: Blue Brown Yellow Green n.b. Contact not assigned Mains voltage 230 V, 50 Hz Tab. 4-3 Legend for Fig.
Set-up and installation Fig. 4-34 Installing the cable cover 16 Close the front panel and screw in the locking screw. CAUTION Clamped cables can cause short-circuits and malfunctions. ▪ When closing the front panel, make sure that cables are Fig. 4-35 Set-up and position assignment of 3-way valves not jammed.
Set-up and installation ▪ An external operating mode switch-over can be made by a poten- INFORMATION tial-free switching contact connected to terminals 1+2 (EXT). De- Further instructions and a detailed description can be pending on an interconnected resistance and when the switching found in the "RoCon BF controller”...
Set-up and installation 4.7.5 RoCon M1 mixer module The RoCon M1 mixer module can be connected to the GCU com- pact (J13 circuit board connector) and is controlled by the electronic boiler controller. INFORMATION Separate installation instructions are included with this component. See the enclosed control system manual for instructions on setting and operation.
Set-up and installation Connect the factory-installed corrugated gas connection hose INFORMATION (A) (pipe thread DIN EN 2999 Rp ½") without tension to the gas The input is not considered for resistance values greater supply line. than the value for "Automatic 2". INFORMATION The [HZU] function integrated in the RoCon BF controller (see the Controller operating instructions) makes it unne- cessary to connect the EXT connection to the burner...
Set-up and installation Rotate the pressure gauge glass so that the minimum pressure mark equates to the system height + 2 m (1 m water column corresponds to 0.1 bar). 4.9.2 Filling the hot water heat exchanger Open the shut-off valve for the cold water supply pipe. Open the hot water tap connections so that the draw-off volume can be set as high as possible.
Commissioning Configure the heating system on the RoCon BF controller. Commissioning ▪ For configuration and explanation, see the enclosed "RoCon BF controller" operating instructions -> chapter "Initial commission- WARNING ing". If a GCU compact is not properly commissioned, it may not ▪ Enter modified setting values in the corresponding table in the operate properly and can endanger human life and health.
Commissioning In the [Emissions measurement] program, choose the [Base Type GCU compact 528 (BIV) Load] setting (see Emissions measurement), but do not con- Gas type Burner load content in content in firm. (10) (test gas) ▪ Make sure that heat can dissipate into the heating network dur- Natural gas E/H Base Load 5.6 –...
Commissioning Checklists for commissioning Checklist before commissioning Is the GCU compact properly installed in accordance with a permitted set-up variant and without any discernible dam- age? 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? Does the mains connection conform to the specifications? Is the mains voltage 230 V, 50 Hz?
Controller and electronic components In normal system operation the rotary switch should be in the "Info" Controller and electronic position. components The most important system temperatures and operating states are shown on the controller display. Operating elements on the boiler INFORMATION control panel Further instructions and a detailed description can be...
Controller and electronic components Fig. 6-2 Removing/installing the control panel Front view Rear view Control panel for the RoCon B1 Plug connection for communication cable Communication cable Changing sensors Most internal sensors (Fig. 6-3) can be replaced without having to open the controller housing. To remove the thermal insulation, see Chap.
Controller and electronic components 6.3.1 Replacing the inflow temperature sensor / return flow temperature sensor and pressure sensor DANGER: RISK OF BURNING There is a danger of scalding from heating water. Sensors are connected directly to the pressurised heating water. ▪...
Heat cell with gas burner Item Name INFORMATION Gas connection line A locking fault can only be reset manually on the controller of the GCU compact (see Chap. 10.4). Gas connection G ½" IG with connected gas hose Safety gas control block INFORMATION Gas valve connection adapter With a temporary fault shutdown, the burner is switched off...
Heat cell with gas burner Type GCU compact Blower type Adjustable load in Type GCU compact 320 / 520 (Biv) (manufacturer) Gas type Burner load in content content in (13) 315 / 515 NRG118/ 0800‑3612 3.0 - 15.0 (test gas) kW with "Full in % (ebmpapst) Load"...
Heat cell with gas burner Changeover from natural gas to liquid gas The RoCon BF controller can be used to set the GCU compact to the [Emissions measurement] function under [Full Load] and [Base Turn the gas/air mix setting screw (Fig. 4-43, item 3.1) to posi- Load].
Heat cell with gas burner The factory-set starting output usually provides a problem-free, quiet Generate a burner demand (e.g. heating operation). burner start. è Burner starts without problems: Recheck the flue gas values in accordance with Chap. 7.3.3. No further measures are re- The starting output of the burner blower is set at the factory.
Heat cell with gas burner The electrodes are optimally configured at the factory. Dismantling the burner After replacement or for maintenance purposes, it may be necessary DANGER: RISK OF ELECTROCUTION to check the electrode spacing and adjust where necessary (for di- mensions, see Fig.
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Heat cell with gas burner Mains plug, blower (16) (17) × fixing screws (burner flange/boiler body) Remove the burner blower with burner flange from the boiler body. Unscrew the burner surface from the burner flange. When lifting off the burner surface, pay special attention that it is not dam- aged through contact with the electrodes.
Hydraulic connection Short name Meaning Hydraulic connection Cold water WARNING Domestic hot water To prevent flue gas from escaping, the storage tank must DSR1 Pressurised solar system be filled to overflowing when commissioning the GCU com- pact. FlowSensor - solar flow rate and inflow temperature DANGER: RISK OF BURNING measurement 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 (example) with Pressure Solar (For legend, see Tab. 8-1) Installation and operating instructions Gas Combi Unit Floor-standing gas condensing boiler with integrated heat storage 008.1543899_02 – 04/2019 – EN...
Service and maintenance 9.2.1 Checking the connections and pipes Service and maintenance WARNING General information regarding Improperly performed work on power or gas lines can en- danger life and health and impair the operation of the inspection and maintenance GCU compact. Regular inspection and maintenance of the heating system reduces ▪...
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Service and maintenance Fig. 9-2 Visual inspection of the combustion chamber Check the combustion chamber for contamination. INFORMATION Under certain conditions, dry efflorescence may form on the heat exchanger surfaces. These can block the flue gas path and thus reduce the efficiency of the condensing boiler.
Service and maintenance 9.2.3 Checking the storage tank fill level INFORMATION In the course of maintenance work, the safety relevant Visual inspection of the tank fill level (fill level indicator). components must also be inspected for expiration of their If necessary, correct the fill level; determine the reason for the nominal service life: low water level and remedy it.
Service and maintenance Remove the filling hose with non-return valve (1/2"). 9.2.6 Filling, topping up the heating system and storage tank charging circuit DANGER: RISK OF ELECTROCUTION During the filling process, water may escape from any leaking points that can cause an electric shock if it comes into contact with live parts.
Service and maintenance Make sure that the automatic vent valve cap is open (Fig. 9-8, item A). Fig. 9-8 Undoing the automatic vent valve cap Automatic vent valve cap Open the water tap (Fig. 9-7, item 6) on the feed pipe. Open the fill/drain cock (Fig.
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Service and maintenance Activate the ventilation function (see accompanying controller manual). – By activating the ventilation function, the RoCon BF control- ler starts a permanently defined sequence program with start/stop operation of the integrated heating circulation pump and various settings of the 3-way switch valves integ- rated in the GCU compact.
Errors and faults INFORMATION Errors and faults Detailed information on the control and the boiler control panel as well as on the operating modes and parameter 10.1 Troubleshooting settings can be found in Chap. 6 and in the “RoCon BF controller” documentation that is included in the scope of The electronics of the GCU compact delivery.
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Errors and faults Fault Possible cause Possible solution Burner fan not running No mains voltage on burner ▪ Insert X1 connector on combustion control until it clicks in place. despite burner demand ▪ Check voltage at the terminals L-N of the X1 connector. ▪...
Errors and faults 10.3 Error codes Code Component/Designation Error E 12 Combustion control locking or t defective (cable break, short circuit) or safety temperature limiter STBK has tripped (e.g. low water error or pump defective) E 65 During calibration, difference from prior value was too high (unclean supply air, electrode replacement, electrode defective).
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Errors and faults Code Component/Designation Error Automatic combustion con- 1× no flame formation at end of safety time (no gas, valves do not open, no ignition sparks). trol Flame failure in flame stabilisation (ionisation electrode defective or dirty). Temporary fault, device is E 10 Flame failure at end of the safety time (ionisation electrode defective or dirty).
Errors and faults 10.4 Rectifying burner faults and STB faults DANGER: RISK OF BURNING Risk of burns from very hot boiler body for STB malfunc- tion. ▪ Do no let any metallic parts come into contact with the boiler. ▪ Let the boiler cool down. ▪...
Taking out of operation Taking out of operation DANGER: RISK OF BURNING When opening the solar return flow connection and the heating and hot water connections, there is a danger of scalding and flooding from escaping hot water. ▪ Only empty the storage tank or heating system when it has cooled down sufficiently and if it is provided with a suitable device for safely draining off or collecting the es- caping water.
Taking out of operation Insert the combined filling and draining filling connection in the connection bracket and secure with the holding clamp (Fig. 11-6). Fig. 11-3 Completing the combined filling and draining filling con- nection Fig. 11-6 Installing the combined filling and draining filling connec- tion in the connection bracket Open the fill/drain cock on the KFE filling connection.
Taking out of operation 11.2 Final shutdown and disposal For the final shutdown of the GCU compact, it must be taken out of service (see Chap. 11.1), disconnected from all electrical, gas and water connections, disposed of in a professional manner. Recommendations for disposal The GCU compact has an environmentally friendly design.
Technical data Technical data 12.1 Basic data 12.1.1 GCU compact 3xx (22) Type (1) GCU compact Individual Unit 315 / 315 Biv 320 / 320 Biv Permitted ambient temperature °C 1 - 40 Total storage capacity litres (22) Net weight (11) 76 / 78 Total filled weight 370 / 372 Dimensions (W ×...
Technical data 12.1.3 Integrated gas boiler (30) Type (1) GCU compact (Biv) Individual Unit 315 / 515 320 / 520 Permitted ambient temperature °C 1 – 40 (30) Product ID (CE number) (3) CE-0063 CR 3574 Automatic combustion control Elster CM434-R1 Safety gas control block Elster CES10 Burner fan ebmpapst NRG 118/0800-3612...
Technical data 12.1.5 Information on the type plate Device type Device type Product ID (CE number) Rated thermal load Q Nominal output P (80/60 °C) Nominal heat output with condensation P (50/30 °C) NOX class (EN 15502) Voltage supply U Electrical power consumption elmax Protection type Empty weight Total filled weight...
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Class of the temperature controller other products can be found at www.rotex-heating.com https://en- ergylabel.daikin.eu. Contribution to the seasonal space heating energy efficiency Sound power in heating mode, measured according to EN 15036 un- der the conditions of EN ISO 3746, accuracy class 3.
Technical data 12.2 Gas type, connection pressures Country Gas type Nominal pressure in Min. inlet pressure in Max. inlet pressure mbar mbar in mbar AT, CH, CZ, DE, DK, ES, FI, FR, Natural gas E/H (G20) GB, GR, HR, IE, IT, LT, LU, LV, NL, NO, PL, PT, RO, SE, SI, SK, Natural gas LL/L (G25) BE, DE, ES, FR, GR, NL, PT, SI...
Notes Notes Installation and operating instructions Gas Combi Unit Floor-standing gas condensing boiler with integrated heat storage 008.1543899_02 – 04/2019 – EN...
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Notes Gas Combi Unit Installation and operating instructions Floor-standing gas condensing boiler with integrated heat storage 008.1543899_02 – 04/2019 – EN...
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Notes Installation and operating instructions Gas Combi Unit Floor-standing gas condensing boiler with integrated heat storage 008.1543899_02 – 04/2019 – EN...
For the chimney sweep For the chimney sweep 14.1 Data for designing the flue gas pipe Device Burner Rated output in kW Flue gas mass flow in g/s Flue gas temperature in Available pump- load in kW °C ing pressure in 50/30 °C 80/60 °C Natural gas...
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