Related Manuals for Daikin Rotex A1 BO Series
Summary of Contents for Daikin Rotex A1 BO Series
- Page 1 For certified companies ROTEX A1 BO Installation and maintenance instructions Oil condensing boiler 0035 BM 105.3 Types A1 BO 15-e A1 BO 20-e A1 BO 27-e A1 BO 34-e Output 02/2014...
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Page 2: Table Of Contents
List of contents Guarantee and conformity ... . . 3 Burner setting ......31 7.3.1 Settings . -
Page 3: Guarantee And Conformity
Guarantee and conformity Guarantee and conformity 1.1 Warranty conditions The legal guarantee conditions fundamentally apply. Our war- ranty conditions beyond that can be found online on your sales representative's webpage. 1.2 Declaration of conformity For the central condensing heating units in the boiler range ROTEX A1 BO We, ROTEX Heating Systems GmbH, declare under our sole responsibility that the products Product Order No. -
Page 4: Safety
Safety Safety 2.1 Observing instructions Special warning signs Some types of danger are represented by special symbols: This instruction is the >> Original Version << in your language. Please read this manual carefully and thoroughly before pro- Electric power ceeding with the installation or modification of the heating system. -
Page 5: Instructions For Operating Safety
Safety 2.5 Instructions for operating safety 2.5.5 Heating system and sanitary connection Create a heating system according to the safety requirements 2.5.1 Before working on the heating system of EN 12828. With sanitary connection, you must observe; Work on the heating system (such as installation, connection –... -
Page 6: Product Description
Product description Product description 3.1 Boiler design and components A1 BO 15-e / A1 BO 20-e A1 BO 27-e / A1 BO 34-e A1 BO Schematic Sound insulation hood Heating return flow (cold) Flue gas temperature sensor Boiler control panel Heating flow (hot) Circuit board (electrical connections) Boiler cladding... -
Page 7: Brief Description
Product description 3.2 Brief description The ROTEX Oil condensing boiler in the A1 BO series is a fully Fuel preassembled oil condenser unit. The ROTEX Oil condensing boiler A1 BO can be operated using standard or low-sulphur heating oil (sulphur content <50 ppm). Operating instructions It is prepared for combustion of heating oil with biogenic content. -
Page 8: Set-Up And Installation
Set-up and installation Set-up and installation Incorrect set-up and installation would render the manufacturer's WARNING! guarantee for the unit void. If you have questions, please contact Units which have been set-up and installed incorrectly our Technical Customer Service. may not operate properly and can be a health and safety risk endangering human life. - Page 9 Set-up and installation Fig. 4-2 Dimensions and connection dimensions - view from the rear (for legend see tab. 4-1) Fig. 4-3 Dimensions and connection dimensions with boiler frame and sub-tank (for legend see tab. 4-1) A1 BO 15-e / A1 BO 20-e A1 BO 27-e A1 BO 34-e Dimen...
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Page 10: Different Set-Ups
Set-up and installation 4.2 Different set-ups Different set-ups (Description, see section 4.2.1 to Set up variant for room-air independent operation (flue gas/ inlet 4.2.3) air concentric) Set up variant for limited room-air independent operation (flue gas/ CA Inlet air (combustion air) air inlet separate) Flue gas Set up variant for room-air dependent operation... -
Page 11: Operation Independent Of Ambient Air
Set-up and installation Set-up version 5 The Oil condensing boiler series A1 BO are basically designed for operation in the room-air independent mode. They are fitted The ROTEX A1 BO is placed directly under the roof. Connected with a concentric flue gas /air supply pipe DN 80/125. with SET F. -
Page 12: Ambient Air Dependent Operation
Set-up and installation Set-up version 7 The cross-section of the installation shaft must be sized so that between the external wall of the flue gas line and the The ROTEX A1 BO is connected by the SET A or SET B to a internal face of the installation shaft the following mini- ceramic chimney. -
Page 13: Installing The Oil Condensing Boiler
Set-up and installation 4.4 Installing the Oil condensing boiler Surface temperature, minimum distance WARNING! 4.4.1 Selecting the installation site The storage tank plastic wall on the ROTEX A1 BO The installation location for the ROTEX A1 BO must meet the fol- can melt under the effects of external heat (>80 °C) lowing minimum requirements. -
Page 14: Setting Up The Unit
Set-up and installation 4.4.2 Setting up the unit Type of connections – Straight, directly towards rear: SET C, 15 50 79.03. Precondition – Height offset, towards rear: SET D, 15 50 79.04. – The installation site complies with the respective country-spe- –... -
Page 15: Connecting The Flue Gas Line To The Rotex A1 Bo
Set-up and installation Connection Set-up A1 BO 34-e version 30 kW 34 kW 34 kW Basically, any flue gas line that complies with the (ref. fig. 4-4) DN 80 DN 80 DN 110 minimum requirements according to the EN 14471 and that has the CE-labelling can be connected (see section 4.5.1). -
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 BOe - 02/2014... -
Page 17: Water Connection
Set-up and installation Additional kits – Flue gas connection to a duct system (rigid flue gas line SET E or flexible flue gas line SET O) – Flue gas connection for exterior wall line (SET G) If necessary, additionally needed concentric LAS pipes for in- creased roof or ceiling heights, single wall PP pipes for chimney heights of more than 10 m or additional accessory components must be ordered. -
Page 18: Connect The Condensate Drain
Set-up and installation – Water shortage protection: The overheating protection of Fill the condensate box with water in order to prevent flue gas the ROTEX A1 BO safely shuts off the Oil condensing boiler from escaping into the installation room. To do this, either: in case of lack of water and locks it. -
Page 19: Connecting The Temperature Sensor
Set-up and installation Switchboard PCB 4.8.3 Connecting the temperature sensor Instructions concerning temperature sensors CAUTION! The use of non-approved temperature sensors or ones which are not suited to the unit can lead to signif- icant malfunctions in the regulation of the ROTEX A1 BO and damage the unit's controller. -
Page 20: Connect The Additional Electrical Components
Set-up and installation 4.8.4 Connect the additional electrical components 4.10 Filling the heating system When using a hot water storage tank you must connect a 3-way Only fill the heating system if all installation work has been com- diverter valve (a) or a storage tank charging pump (b) to the pleted. -
Page 21: Start-Up
Start-up Start-up Bleeding the oil line, checking the oil pressure WARNING! The oil line must be completely vented at the beginning of the If not started up properly, a ROTEX A1 BO can be a start-up and the oil pressure must be checked. health and safety risk endangering human life and its operation may be adversely affected. -
Page 22: Checklists For Start-Up
Start-up Checklists for start-up Checklist before start-up Is the ROTEX A1 BO correctly set up according to an admissible set up variant and without visible damages? When using a pressure assembly: Is the installation site additionally secured (leakproof tray, filter cup of metal)? Combustion air supply secured? Adequate ventilation and extraction in the heating room with limited room-air independent (separate flue gas/intake air) or room-air dependent operation? -
Page 23: Control Unit
Control unit Control unit 6.1 Operating elements on the boiler control panel The ROTEX A1 BO 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 24: Replacing The Operating Section Rocon B1
Control unit 6.2 Replacing the operating section RoCon B1 6.3 Changing the boiler control panel WARNING! WARNING! Live parts can cause an electric shock on contact and Live parts can cause an electric shock on contact and cause life-threatening burns and injuries. cause life-threatening burns and injuries. -
Page 25: Changing Cables
Control unit Installation (observe sequence) 1. Insert the boiler control panel into the holder. Insert and tighten the fixing screws. 2. Hook the cable duct into the contrpol panel. 3. Hook in/fix the internal cables on the guiding elements provid- 4. -
Page 26: Changing The Sensors
Control unit 6.5 Changing the sensors 6.5.1 Changing flow / return flow temperature sensor Sensors inside the unit (fig. 6-8, fig. 6-9) can be changed without WARNING! having to open the boiler control panel. There is a danger of scalding from heating water. WARNING! flow and return flow temperature sensors are con- nected directly to the pressurised heating water. -
Page 27: Changing The Flue Gas Temperature Sensor
Control unit 6.5.2 Changing the flue gas temperature sensor 6.5.3 Changing the storage tank temperature sensor The flue gas temperature sensor is mounted in the flue gas duct The storage tank temperature sensor is connected directly to the of the heat generator using a packing gland and connected to the connection terminals 9 and 10 of the 12-pin sensor connector J8 sensor cable using a floating plug connection. -
Page 28: Replacing The Fuse Or Control Panel Circuit Board
Control unit 6.6 Replacing the fuse or control panel circuit CAUTION! board Electrostatic charges can lead to voltage arcing that can destroy the electronic components. WARNING! Secure potential equalisation before touching the Live parts can cause an electric shock on contact and control panel circuit board (e.g. - Page 29 Control unit Fig. 6-16 Wiring diagram ROTEX A1 BO (for legend see tab. 6-1) FA ROTEX A1 BOe - 02/2014...
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Page 30: Oil Burner
Oil burner Oil burner 7.1 Design and brief description Fig. 7-3 Oil burner - side view from the right Automatic oil firing unit Service Allen key for legend see fig. 7-1 Oil pump Holder for service position Heating oil suction line Setting gauge The blue burner installed as standard is similar in design and Heating oil return line... -
Page 31: Safety Function
Oil burner Automatic firing CM165-R1 Unlocking burner The oil automatic firing CM165-R1 controlled by a micropro- Switching ROTEX A1 BO on. cessor controls and monitors the firing programme and the Push the Exit button (fig. 6-1, pos. 15) for at least 5 secs. temperature sensors for the flow and return temperature. -
Page 32: Instructions For Burner Setting
Oil burner Boiler Oil nozzle Oil pump Distance Conversion Unit type -output nozzle Danfoss pressure throughput oil/air throttle pressure (Burner type) 80°H nozzle Ø / mm USgal/h kg/h Dimension mbar Type (GpH) Y/mm 17.5 0.30 10.5 1.05 A1 BO 15-e 17.5 0.30 12.5... -
Page 33: Check Vacuum In The Oil Pump And Set The Oil Pump Pressure
Oil burner 7.3.3 Check vacuum in the oil pump and set the oil 7.3.4 Set air quantity pump pressure The ROTEX A1 BO is generally designed to be op- erated independently of the ambient air and is equipped with a concentric flue gas / supply air connection DN 80/125. -
Page 34: Recirculation Gap
Oil burner 7.3.5 Recirculation gap 7.3.6 Check and set electrode distance and the distance between oil nozzles and air nozzles Adjustment screw recirculation tube Mixing unit Setting gauge Scale recirculation gap Ignition electrodes Fig. 7-6 Positioning recirculation tube Fixing screw Electrode position BLB 15e, Light tube BLB 20e and BLB 27e... -
Page 35: Removing/Fitting The Burner
Oil burner 7.4 Removing/fitting the burner The burner is normally in operating position. In order to carry out work on the nozzle rod (e.g. changing nozzle or electrodes) or within the flame tube, the burner is moved to the service po- sition. -
Page 36: Removing/Fitting The Flame Tube
Oil burner 7.4.3 Removing/fitting the burner Rotate burner by 180° around the motor axis and put aside on the burner flange. Switch off main heater switch. Hang in the burner through the opening in the holder plate in Remove the noise damping hood and boiler cladding (see the service screw and engage in the bayonet lock. -
Page 37: Automatic Firing Connections
Oil burner 7.6 Automatic firing connections 7.7 Ignition transformer with flame monitor The function mode of the automatic firing is described in section 7.1. Ignition cable connections Earth connection (2x 7.5 kV) Ignition connection (input) Status display (LED) Fig. 7-14 Automatic firing CM165-R1 Connection flame monitor Fig. -
Page 38: Hydraulic Connection
Hydraulic connection Hydraulic connection 8.1 Connection accessories 8.1.1 Safety group SBG A1 For the hydraulic connection of the ROTEX A1 BO 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 39 Hydraulic connection T-Piece 3x1" Flat seal 1" (2x) Ball cock 1" (2x) Storage tank return flow 3-way diverter valve (3UV1) Heating return flow Valve drive Boiler return Unlocking button of the drive Boiler flow lock Boiler flow Hand lever (shown in filling (3UV1: connection AB) position) Heating flow...
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Page 40: Hydraulic System Connection
Hydraulic connection Hydraulic system connection Fig. 8-5 and fig. 8-6 show examples of the integration of a Sanicube inox hot water storage tank and a sub- tank 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. -
Page 41: Service And Maintenance
Service and maintenance Service and maintenance 9.1 General overview of service and 9.2.1 Removing panelling (and cleaning it) maintenance For the maintenance activities, sound insulation hood, boiler pan- elling and heat insulation layers must be removed. Regular inspection and maintenance of the heating system re- duces energy consumption and ensures a long life and smooth After removing the rear and two side securing screws you can operation. -
Page 42: Checking The Connections And Pipes
Service and maintenance 9.2.3 Checking and cleaning the condensate drain. Remove the holding clamps on both upper heat insulation layers (see fig. 9-3). The condensate treatment unit cleans the draining condensation and neutralises its pH-value. The connection and drainage line of the condensate drain must be free from impurities. - Page 43 Service and maintenance Dismounting and regenerating the condensate box 3. Lift the condensate box and empty it through the connection hose (fig. 9-6). DANGER OF CHEMICAL BURNS! The condensate box contains acidic condensate that can lead to injury upon contact with the skin or eyes. Wear protective clothing (safety glasses, rubber gloves) when working on the condensate box.
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Page 44: Checking The Flue Gas Temperature
Service and maintenance 9.2.4 Checking the flue gas temperature 6. Regenerating the condensate box. Rinse condensate box with flowing water against the flow The flue gas temperature can be checked until clear water emerges (fig. 9-8). The condensate box – on the operating panel in the boiler control panel, rotary must be shaken in order to dislodge the deposits. -
Page 45: Checking And Cleaning The Combustion Chamber
Service and maintenance 9.2.5 Checking and cleaning the combustion Only on A1 BO 27-e and A1 BO 34-e: Remove the top burner chamber ring (perforated). chamber Remove the cylindrical burner chamber. If there are impurities, or if unsatisfactory combustion values are Remove the lower combustion chamber inset using the detected, the combustion chamber must be cleaned and combustion chamber wrench (fig. -
Page 46: Checking The Oil Filter And Cleaning The Oil Pump Filter
Service and maintenance 9.2.7 Checking the burner Alternatively, any residue can be removed with a high-pressure cleaner. For exact information regarding the checking and set- For this: ting of the burner, see 7.3. Close combustion chamber without combustion chamber insert. For exact information regarding the assembly and dis- Unscrew burner and burner flange (see chapter 7.4 assembly of the burner, see 7.4. -
Page 47: Replacing The Oil Nozzle And Ignition Electrodes
Service and maintenance 9.2.8 Replacing the oil nozzle and ignition electrodes Fitting oil nozzle Requirement: Burner is in service position (see chapter 7.4). To protect the oil pump, either insert the enclosed micro-replacement filter insert MC-7, ( 15 60 13) for WARNING! short filter cups or the MC-18, ( 15 60 14) for long... -
Page 48: Faults And Malfunctions
Faults and malfunctions 10 Faults and malfunctions 10.1 Troubleshooting Troubleshooting Detecting and remedying the cause of the malfunction. The electronics of the ROTEX A1 BO 10.3 Non-interlocking malfunctions (see section 10.3) are – signals a fault by red backlighting in the display and indicated as long as there is a malfunction. - Page 49 Faults and malfunctions Malfunction Possible cause Possible solution No ignition Ignition electrodes short circuited Set / change ignition electrodes Distance of ignition electrodes too large Adjust the ignition electrodes. Ignition electrodes contaminated or humid Clean ignition electrodes, check oil nozzle and burner setting Ignition electrodes burnt out Change ignition electrodes...
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Page 50: Fault Codes
Faults and malfunctions Malfunction Possible cause Possible solution STL switch off Water throughput too low due to air inclusion Vent system Water flow too low due to valves closing too Use slow closing or timed valves, if needed, install quickly along the entire heating network overflow valve Pump standstill Check mains and PWM control signal connection,... -
Page 51: Rectifying Burner Faults And Stb Faults
Faults and malfunctions Code Component/Designation Fault Possible fault rectification Outside temperature sensor Check cable, terminal and plug connec- Measured value outside measuring range, tions. Storage tank temperature temperature sensor defective. Replace the temperature sensor. sensor EEPROM Total reset Internal fault Replace switching panel PCB in controller. -
Page 52: Taking Out Of Service
Taking out of service 11 Taking out of service 11.1 Temporary shutdown CAUTION! A heating system which is shut down can freeze in the event of frost and may suffer damage. Drain the heating system that is shut down if there is danger of frost. -
Page 53: Technical Data
Technical data 12 Technical data 12.1 Basic Data Oil Boiler Boiler type A1 BO 15-e A1 BO 20-e A1 BO 27-e A1 BO 34-e Parameter Unit Product Identification Number (CE number) CE 0035 BM-105.3 Length Width Height 1100 1100 1220 1340 Weight of the boiler body Transport weight Unit... - Page 54 Technical data Boiler type A1 BO 15-e A1 BO 20-e A1 BO 27-e A1 BO 34-e Burner type BLB 15e BLB 20e BLB 27e BLB 34e Parameter Unit Firing heat output Q 12.2 - 15.1 12.3 - 20.8 20.4 - 27.8 25.7 - 34.9 Oil-throughput kg/h...
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Page 55: Heating Circulation Pump And 3-Way Diverter Valve (A1 Bo - All Types)
Technical data 12.2 Heating circulation pump and 3-way diverter valve (A1 BO - all types) Parameter Unit Heating circulation pump Type Grundfos UPM2 15-70 CES87 Voltage 230 ~ Frequency (power supply) Maximum power consumption Protection type IP 44 Permitted overpressure Maximum pumping height Energy efficiency EEI <... -
Page 56: Temperature Sensor
Technical data 12.4 Temperature sensor Sensor resistance Temperature NTC resistance Flow temperature, return temperature, external temperature, stor- age tank temperature, mixer circuit flow temperature Pt 1000 resistance Flue gas temperature Fig. 12-6 Resistance characteristics of the temperature sensor Temperature sensor Measured temperature in °C Type Specification *... -
Page 57: Notes
Notes 13 Notes FA ROTEX A1 BOe - 02/2014... - Page 58 Notes FA ROTEX A1 BOe - 02/2014...
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Page 59: List Of Keywords
List of keywords 14 List of keywords Numerics Preheating oil ....30 Proper use ..... 4 3-way switch valve Efficiency . -
Page 60: For The Chimney Sweep
15 For the chimney sweep 15.1 Data for designing the flue gas pipe Unit type Nominal boiler Flue gas mass flow (humid) in g/s Flue gas temperature in °C Available pumping heat output in kW pressure in Pa at 75/60 °C at 40/30 °C 75/60 °C 40/30 °C...