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Rotex GasSolarUnit Series Installation And Maintenance Instructions Manual

Gas fired condensing boiler
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I n s t a l l a t i o n a n d m a i n t e n a n c e i n s t r u c t i o n s f o r c o n t r a c t o r s .
R O T E X G a s S o l a r U n i t :
Gas fired condensing boiler with solar stratification cylinder.
R O T E X G a s C o m p a c t U n i t :
Gas fired condensing boiler with high performance domestic hot water cylinder.
0085 BM0065
Type
Rated thermal load
ROTEX GSU 25
5–25 kW modulating
ROTEX GSU 35
8-35 kW modulating
ROTEX GCU 25
5–25 kW modulating
ROTEX GCU 35
8–35 kW modulating
Serial number
Customer
GB

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Summary of Contents for Rotex GasSolarUnit Series

  • Page 1 R O T E X G a s C o m p a c t U n i t : Gas fired condensing boiler with high performance domestic hot water cylinder. 0085 BM0065 Type Rated thermal load ROTEX GSU 25 5–25 kW modulating ROTEX GSU 35 8-35 kW modulating ROTEX GCU 25 5–25 kW modulating...

  • Page 2: Table Of Contents

    For even higher highlight safety information. The symbol burner settings convenience, a digital room station (ROTEX identifies text passages that are particularly Connection, condensate drain THETA RS, part no. 15 70 18) and a room important to achieve an optimum utilisation Connection, electrical cables/leads controller set (THETA RFF, part no.

  • Page 3: Safety Instructions

    Specification GSU/GCU detailed in chapter 3. connecting pressure should not exceed Maintenance log When installing the ROTEX GasSolar- 6 bar and must, under no circumstances, Unit/GasCompactUnit ensure, that the be higher than 10 bar. When installing gas Chapter 9: For the flue gas...

  • Page 4: General Warranty Terms

    General warranty terms DECLARATION OF CONFORMITY for the condensing heating centres Only use flue gas systems approved for ROTEX is liable for all material and ROTEX GasSolarUnit and ROTEX GasCompactUnit condensing operation. manufacturing faults in line with this Only use the burner when an adequate statement.

  • Page 5: Chapter 2: General Function And

    DHW zone to make the highest connected via a flange in the lower part of the The ROTEX GSU/GCU is a gas fired condensing DHW output available. Any associated thermal boiler. It is arranged inside a tubular thermal...
  • Page 6 This has already been proven as a perfect solution in the DHW cylinder ROTEX Sanicube for more than 20 years. Excellent corrosion resistance, low susceptibility to scaling and, most of all, optimum water hygiene are the hallmarks of this heating principle.
  • Page 7 Pos./description Gas fired condensing boiler DHW stratification cylinder Unpressurised cylinder water DHW zone Solar zone Heating backup zone Control and pump unit RPS (Solaris accessories) Cold water connection (1” male) with gravity brake Hot water connection (1” male) with gravity brake DHW primary exchanger;...

  • Page 8: Component Description

    13 Sensor well for Solaris return 31 Boiler control panel (see chapter 4) 1 Cold water connection (1” male) temperature sensor 32 ROTEX THETA 23R control unit with gravity brake 14 Condensate safety overflow connection (see separate ROTEX control unit manual) 2 Hot water connection (1”...
  • Page 9 Pos. 7, 8: Solar flow (7) and return (8) hose. Pos. 21: Thermal insulation sleeve For the optional connection of a ROTEX Solaris for HB HE – only GSU system (only GSU) for solar DHW heating and Pos. 16: Condensate pipe For the thermal separation of the heating central heating backup.
  • Page 10 Pos. 22: Solaris flow — Pos. 28: Flue gas temperature sensor stratification pipe – only GSU The sensor (type Pt 1000) is screwed into the The stratification pipe routes the flue gas channel of the boiler body unpressurised cylinder water heated up by the immediately upstream of the flue outlet.
  • Page 11 Pos. 40: Thermal insulation shell for the The control unit operation and functions are Combustion air from the annular gap of the boiler body detailed in the separate ROTEX control unit concentric balanced flue pipe is channelled to To minimise the radiation and standby losses manual.

  • Page 12: Chapter 3: Positioning And Installation

    Caution: Risk of tipping Generally, a balanced flue connection is routed through a concentric twin pipe. Flue gas In their delivered condition, required for the ROTEX GasSolarUnit/Gas- is expelled to atmosphere through the inner ROTEX GasSolarUnit/Gas- CompactUnit. A concentric balanced flue pipe;...

  • Page 13: General Information Regarding The Flue Gas System

    3°. Implement horizontal sections of the flue pipe with an incline of approx. 3°. Nowhere along the length of the flue must a counter-slope occur. Fig. 3.2.1: Flue gas mass flow/burner output ROTEX GasSolarUnit [ 13 ]...
  • Page 14 F l u e g a s ro u t i n g Flue gas * linear ventilated duct with a 90 min fire resistance, for low domestic buildings 30 min fire resistance Fig. 3.2.2: Installation versions for the ROTEX GasSolarUnit/GasCompactUnit [ 14 ]...

  • Page 15: Positioning

    Secure the equipment particularly when moving the equipment up or down stairs. After removing the packaging, the ROTEX GasSolarUnit/GasCompactUnit can be installed at the intended site. The surface where the system is to be installed must be Fig.

  • Page 16: Connecting The Gassolarunit

    We recommend the flue connection at the and ventilation air lines back, we recommend the balanced flue side, if the ROTEX GasSolarUnit/Gas- connections set H that is specifically tailored CompactUnit cannot be connected out the General: The installer must agree the required for the ROTEX GasSolarUnit/GasCompactUnit.
  • Page 17 Fig. 3.4.3: Flue gas system sets [ 17 ]...

  • Page 18: Flue With Roof Outlet

    For All connection lines of the GSU/GCU lead Where a DHW circulation line is a must, this routing flue gas through the roof, ROTEX offers upwards through the cover hood. Only the can be implemented in accordance with the the balanced flue system connection set L.

  • Page 19: Connection Of The Gas Supply Pipe

    static gas inlet pressure (Fig. 3.4.6) and compare it with the values listed in Tab. 3.4.1. The standard gas supply hose can cause a pressure drop of approx. 5 mbar. The supply pressure at the gas valve can therefore be back below the value in the table by that amount.

  • Page 20: Connection, Condensate Drain

    230 Volt, 50 Hz (DHW, buffer or heating water), visibly and AC supply. Prior to connecting the ROTEX safely outside (in accordance with DIN 4743 T. GasSolarUnit/GasCompactUnit ensure that the 11 [or local regulations]) (e.g.

  • Page 21: Temperature Sensor Connection

    DHW cylinder prevent damage to the control unit, use is fitted and terminated (PTC resistor) in the only the original ROTEX sensors supplied. factory. The outside temperature sensor and all internal temperature sensors are part of Fit the outside temperature sensor at a height the standard delivery.

  • Page 22: Pumps, Three-Way Diverter Valve

    For this, ROTEX offers a (remote control). Simultaneously, the heating panel and at the pump/valve servomotor.

  • Page 23: Filling

    Fill the that the electronic can register the ade- Open the fill & drain valve and start to fill the ROTEX GasSolarUnit/GasCompactUnit in the quate level and enable the burner opera- system with water, until the pressure gauge following sequence: tion.

  • Page 24: Initial Start-Up

    3.6 Initial start-up function value (flashing) Return to the original operating mode, standard display, the The ROTEX GasSolarUnit/GasCompactUnit is 3.7 Standards and guidelines selected set value is saved read for operation after all connections have Fig. 3.6.1: Manual mode been made; it can then be commissioned by Apart from the general technical rules, observe your heating contractor.

  • Page 25: Check List Prior To Commissioning

    Check list prior to commissioning 1. Is the combustion air supply assured? 2. Is the adequate venting of the installation room assured? (only for open flue operation) 3. Does the power supply meet all relevant regulations? 4. Is the power supply 230 Volt 50 Hz? 5.

  • Page 26: Brief Description

    5 Central control unit THETA 23R time program Characteristics in case of a fault: The user can The electronic digital control unit ROTEX 12 Info key for system information restart the burner after a burner fault by THETA 23R can regulate 2 heating circuits 13 Key for emissions test and manual mode pressing the rest button (pos.
  • Page 27 1. Temporary operating modes: adjusting the switching times, see the separate “Operating instructions for abridged operating instructions or the contractors - ROTEX control unit” that is HOLIDAY Frost-protected operating instructions “ROTEX control unit”. supplied with the GSU/ GCU.

  • Page 28: Manually Adjusting The Boiler Water Temperature

    (Fig. 4.3.1 and 4.3.2). 18 Level warning indicator for low water level This indicator shows that the cylinder is insuf- Fig. 4.3.1 also shows the back of the ROTEX change Required set Actual value ficiently full of water. It is switched ON when THETA 23R control unit.

  • Page 29: Replacing The Boiler Control Panel

    Fig. 4.3.2: Removing the control unit Fig. 4.4.2: Removing the control panel cover 3) Remove the capillary pipe from the 4.4 Replacing the boiler control panel pressure gauge (Fig. 4.4.1). Remove the small volume of water released when Warning: Electric shocks can undoing the pipe with a kitchen towel.

  • Page 30: Replacing The Cables/Leads And Sensors30

    4.5 Replacing the cables/leads and sensors Fig. 4.4.3: Pulling coded plugs from the PCB Fig. 4.4.4: Removing leads/cables Fig. 4.4.5: Undoing the boiler control panel fixing screws Fig. 4.5.1: Replacing the return (38) and flow sensor (37) [ 30 ]...
  • Page 31 Warning: Electric shocks can 1) Remove the lsilencer hood locking screws The cylinder temperature sensor is directly cause severe burns and life- (pos. 35 in Fig. 2.2.1), and lift off the hood connected at terminals 11/12 of the 12-PIN threatening injuries. Before (pos.

  • Page 32: Replacing The Fuse

    Warning: Electric shocks can fault, if there is a fault that cannot be removed cause severe burns and life- neither by replacing the ROTEX THETA 23R threatening injuries. Before control unit (chapter 4.3) nor by replacing the commencing any maintenance work,...
  • Page 33 1 ON/OFF switch 24 3-PIN PCB plug for connecting a DHW 32 Outside temperature sensor 2 Central fault message indicator circulation pump 33 Cylinder (DHW) temperature sensor 4 Pressure gauge capillary pipe 25 Three-way diverter valve 34 8-PIN PCB plug with flue gas sensor lead 5 Control unit: Central control unit THETA 23R 26 4-PIN PCB plug with valve cable 35 Flue gas temperature sensor...

  • Page 34: Chapter 5: Technology

    C h a p t e r 5 : Te c h n o l o g y 5.1 Gas burner Fig. 5.1.1: Gas burner of the GSU 25/GCU 25 (front view) Fig. 5.1.2: Gas burner of the GSU 35 (front view) Fig.
  • Page 35 Burner surface Fan 230 V/ 50 Hz Safety gas governor Gas:air mixture controller Gas solenoid valve (1x class B and 1x class C) Gas burner control unit CVBC Gas connection G “ female Venturi nozzle with air connection DN 50 Test port “In”...

  • Page 36: Construction

    5 and 25 kW (GSU 25/GCU 25) or between integrated into the control panel constantly Incorrect handling of gas 8 and 35 kW (GSU 35/GCU 35) of the ROTEX determines the required flow temperature equipment can lead to gas GasSolarUnit/GasCompactUnit is...
  • Page 37 10.7 10.7 Observe warning information! The details in the plain fields correspond to the ROTEX factory settings Table 5.1.2: Set flue gas values for different gas types Fig. 5.1.7: Set flue gas values for burner adjustment for GSU 25/GCU 25 Fig.

  • Page 38: Matching The Burner To The Gas Type

    7) Connect the flue gas analyser. Burner adjustment and matching The burner adjustment is checked and 8) The gas inlet supply pressure must not matching the burner to the gas type matched in accordance with the drop substantially below the static following steps: pressure less the pressure drop in the gas At the factory, the burner is preset to the...
  • Page 39 Gas type Inlet pressure in mbar Rated max. pressure Natural gas E, H 20 17.0 25.0 Natural gas LL, L 20 17.0 25.0 42.5 57.5 Table 5.1.3: Gas supply pressure Notify your gas supply company if the gas supply pressure falls outside the stated range. Where the rated pressures deviate, observe the limits in accordance with the regulations of the relevant country.

  • Page 40: Gas Type Conversion

    The minimum burner output can be regulated on the equipment front and confirm the work via the ROTEX THETA 23R control unit by by signature. entering an appropriate parameter. After entry • Affix the equipment label for the natural gas...

  • Page 41: Adjusting The Ignition And Ionisation Electrodes

    5.2 Cylinder The ROTEX GasSolarUnit/GasCompactUnit is a DHW cylinder developed in accordance with the latest know-how regarding water hygiene with an integral gas fired condensing boiler (Fig. 2.1.1 and 2.1.2). The cylinder is a twin-wall plastic construction. The space between the internal and external wall is filled with thermal foam insulation.

  • Page 42: Optimum Water Hygiene

    This may be used in heat is drawn off or when the cylinder is the DHW side offered by the combination with a ROTEX A1 oil or gas heated up. A high DHW flow rate can be GasSolarUnit/GasCompactUnit. fired condensing boiler as an ideal...

  • Page 43: Hydraulic System Connection

    The same applies to the Gas- CompactUnit, if cylinder temperatures above 60 °C can occur. Fig. 5.3.1: Standard connection diagram ROTEX GasSolarUnit 1) The connection diagram shown makes no claim as to its completeness and is no replacement for careful system engineering. [ 43 ]...
  • Page 44 Fig. 5.3.2: Standard connection diagram ROTEX GasCompactUnit 1) The connection diagram shown makes no claim as to its completeness and is no replacement for careful system engineering. [ 44 ]...
  • Page 45 * Separating the standard connection: Remove UV1 and reconnect it outside the equipment. Fig. 5.3.3: Connection of a wood fired boiler to the GSU/ GCU * Convert the Solaris control and pump unit RPS 2: Remove the P The P can be used as solar circuit pump.
  • Page 46 Fig. 5.3.5: Hydraulic system connection with heating circuit extension Fig. 5.3.6: Hydraulic system connection GSU with higher solar output proportion 1) 2) [ 46 ]...
  • Page 47 Fig. 5.3.7: Hydraulic system connection GCU with solar pre-heating The connection diagram shown makes no claim as to its completeness and is no replacement for careful system engineering. Note: The mechanical level indicator in the Sanicube Solaris cannot indicate, with this type of control, since the overflow connection on the GSU is arranged lower down, thereby determining the fill level of the overall control.
  • Page 48 Abbreviation Explanation Comments/Part no. GasSolarUnit GSU 25 15 70 10 GSU 25 F 15 70 20 GSU 35 15 70 21 GSU 35 F 15 70 23 GasCompactUnit GCU 25 15 70 30 GCU 25 F 15 70 35 GCU 35 15 70 40 GCU 35 F 15 70 45...

  • Page 49: Chapter 6: Inspection And Maintenance

    Inspection and maintenance require the completely full. If there is no water at the top correctly installed, i.e. with a constant removal of the silencer hood from the ROTEX edge, top up the cylinder with water. slope. GasSolarUnit.
  • Page 50 Fig. 6.1.3: Prior to burner removal Fig. 6.1.4: Turn the pulled off ventilation Step 1: Undo the drain plug Pull off the ventilation air hose air hose to the side Step 2: Visual control of the connection and level Step 3: Visual check of the drain hose (embrittlement, slope) Step 4: Check the unrestricted draining Fig.

  • Page 51: Temporary Shutdown

    Remove the two M6 fixing nuts from the 6. Clean the cylinder and the silencer Draining the cylinder burner flange. The burner can then be lifted hood out of the combustion chamber (Fig. 6.1.5). The cylinder and silencer hood are made from To drain the cylinder, attach the hose with the To clean the combustion chamber, flush it out - easy to clean plastic.

  • Page 52: Chapter 7: Troubleshooting

    ROTEX Service, always quote control unit CVBC that lead to the burner being the equipment serial number from The integral ROTEX THETA 23R boiler control locked out, are not only indicated on the the type plate (lower r.h. side of the...
  • Page 53 Fault code Description Type of fault Comments 10-0 Outside sensor Cable break 10-1 Outside sensor Short circuit 12-0 Mixer circuit flow sensor Cable break Mixer circuit pump will be switched OFF; the mixer motor goes to zero volt 12-1 Mixer circuit flow sensor Short circuit Mixer circuit pump will be switched OFF;...
  • Page 54 - possibly replace The max. burner output is too low Incorrect parameter setting Adjust the output parameter (see operating instructions “ROTEX control unit“: Burner control unit parameter level) Excessive air/flue gas pressure drop Check lines for contamination poss. use larger cross-section for ventilation air pipe and/ or flue Table 7.2: Fault removal...
  • Page 55 [ 55 ]...

  • Page 56: Specification Gsu/Gcu

    C h a p t e r 8 : S p e c i f i c a t i o n Footnotes regarding Table 8.1 Specification Specification GasSolarUnit and GasCompactUnit GSU 25 GSU 35 GCU 25 GCU 35 1) at rated output, 80 °C flow temp., 65 °C cylinder temp., 45 °C DHW temp. and 10 °C cold water temp. 2) Explanation: The specific water flow rate to EN 625 is the cold water flow rate when raising the average temperature by 30 K, that can be delivered by the GasSolarUnit/GasCompactUnit in the course of two consecutive drawings of 10 minutes duration respectively, starting from a primary temperature of 65 °C.
  • Page 57 Gas type Inlet pressure in mbar Country of destination Equipment category Rated supply pres- Rated sure pressure in mbar Natural gas E, H 20 17.0 25.0 Natural gas Natural gas Natural gas LL 20 17.0 25.0 2 ELL 3 B/P 42.5 57.5 AT, CH...
  • Page 58 Fig. 8.1: Residual head GSU 25, GCU 25 (heating side) Fig. 8.2: Residual head GSU 35, GCU 35 (heating side) [ 58 ]...
  • Page 59 Fig. 8.3: Required flow rate subject to the heating output and the design temperature spread Fig. 8.4: Permissible burner loads for GSU/GCU, the details highlighted in white represent factory settings [ 59 ]...
  • Page 60 Fig. 8.5: Pressure drop inside the DHW heat exchanger subject to the draw-off rate Fig. 8.6: Available draw-off volume subject to the draw-off rate Cylinder temperature 60 °C, draw-off temperature 40 °C, cold water temperature 10 °C, reheating at rated output [ 60 ]...
  • Page 61 Temperature in °C Fig. 8.7: Resistance curves of the temperature sensors Sensor type Actual temperature in °C Sensor resistance in Ohm according to standard or manufacturer’s details 1386 1495 1630 1772 1922 2080 2245 2418 2598 2786 2982 3185 3396 –...
  • Page 62 16 pol. Microfit Vorlauf1 Rücklauf1 Mischer Bauseits Gebläse Feuerungsautomat Kesselerdung Netz Abgas1 Speicherfühler Aussenfühler Mischerfühler Raumstation oder weitere THETA Regler Gasventil Speicher Aussen Mischer Modem BR-Sperre Hauptschalter Elektrodenrelais Siehe Blatt 2/2 Masse Max. Min. Reset Lampe1 Lampe2 Sammelstörung Pegel niedrig Pegel in Ordnung...

  • Page 63: Maintenance Log

    M a i n t e n a n c e l o g Please tick the maintenance work done and enter actual values, as appropriate. Observe the information in chapters 6 and 5.1. Inspection and maintenance work Initial 1. Maintenance 2.

  • Page 64: Flue Sizing Details

    Chapter 9: For the flue gas inspector Flue sizing details Fig. 9.1: Flue gas mass flow/burner output ROTEX GasSolarUnit/GasCompactUnit Burner load Rated output Flue gas mass flow rate Flue gas temperature Available draught in kW in kW in g/s in °C in Pa 40/30 °C...

This manual is also suitable for:

Gsu 35Gcu 25Gcu 35Gascompactunit seriesGsu 25

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