Rotex A1 BG Inline Operating Manual
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Rotex A1 BG Inline Operating Manual

Gas condensing boiler
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For the operator
ROTEX A1 BG Inline
Gas condensing boiler

Operating manual

0085 AS 0011
Type
Rated thermal output
ROTEX A1 BG 25i
5 - 25 kW modulating
ROTEX A1 BG 40i
8 - 40 kW modulating
ROTEX A1 BG 25i F
5 - 25 kW modulating
ROTEX A1 BG 40i F
8 - 40 kW modulating
Manufacture number
Customer service
GB
Edition 10/2007

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Summary of Contents for Rotex A1 BG Inline

  • Page 1: Operating Manual

    For the operator ROTEX A1 BG Inline Gas condensing boiler Operating manual 0085 AS 0011 Type Rated thermal output ROTEX A1 BG 25i 5 - 25 kW modulating Edition 10/2007 ROTEX A1 BG 40i 8 - 40 kW modulating ROTEX A1 BG 25i F...
  • Page 2 The guarantee is only valid if the device has been used properly and it can be proved that it was installed properly by an expert firm. As proof, we strongly recommend completing the enclosed installation and instruction forms and returning them to ROTEX.

  • Page 3: Table Of Contents

    For the chimney sweep..............36 ROTEX A1 BG Inline - 10/2007...

  • Page 4: Safety

    The documents listed below are part of the technical documentation of the gas condensing boiler and must therefore be observed. The documents are included in the scope of supply. – ROTEX A1 BG Inline: Installation and maintenance instructions for the heating expert, – ROTEX Control THETA: Operating instructions for the heating engineer.

  • Page 5: Danger Prevention

    • Inform the authorised gas supply company. Proper use The gas condensing boiler ROTEX A1 BG xxi can only be used for the heating of hot water heating systems. The gas condensing boiler must be installed, connected and operated as indicated in this manual.
  • Page 6 • Only operate the gas condensing boiler if sufficient combustible air supply is guaranteed. If operating the gas condensing boiler independently of the ambient air with an air/flue gas system (LAS) with dimensions according to ROTEX-Standard, this is automatically guaranteed and there will be no further conditions required of the device installation room.

  • Page 7: Product Description

    Condensate drain line Ball stopcock Nameplate with manufacture number Condensation discharge Inflow temperature sensor Circulation pump Supply air hoses Return flow temperature sensor 3-way switch valve Flame tube Setting sticker Safety devices BA ROTEX A1 BG Inline - 10/2007...

  • Page 8: Brief Description

    Operating instructions The ROTEX gas condensing boiler A1 BG xxi is designed in such a way that it can be operated independently of ambient air. The burner sucks the combustible air directly from the outside through an installation shaft or a double-walled flue gas duct. This method has several advantages: –...

  • Page 9: Gas Burner

    Measurement connection OUT - outlet gas pressure Air suction pressure hose Adjusting screw gas/air mixture Cover with strain relief for burner cable and locking screw for Setting screw for gas pressure control automatic gas firing unit Burner flange BA ROTEX A1 BG Inline - 10/2007...

  • Page 10: Connection

    Control of the burner output The ROTEX THETA 23R control continually determines the requisite inflow temperature and indicates this to the CVBC automatic firing units of the gas burner. The CVBC automatic firing unit calculates the necessary burner output from the target value and the values of the inflow and return flow temperature sensors.

  • Page 11: Hot Water Storage Tank (Not Included In Scope Of Supply)

    4 types of hot water storage tanks are available for the gas condensing boilers A1 BG 25i and A1 BG 40i (see Tab. 2-1). Furthermore, the ROTEX Solaris System can be included in the hot water preparation. For further information about the hot water tanks, refer to documents for Sanicube INOX, Sanicube PEX and Solaris.
  • Page 12 16 45 16 16 50 06 16 01 50 Tab. 2-1 Basic technical data of the ROTEX hot water storage tank which can be connected to the gas condensing boiler Heating output data for hot water storage tank Type Sanicube INOX...

  • Page 13: Start-Up

    The gas condensing boilers are designed generally for the ambient-air-independent operation. They are fitted with a concentric flue gas /air supply connection DN 80/125. ROTEX recommends using the gas condensing boiler in ambient air-independent mode. If possible, choose this installation version!

  • Page 14: Initial Start-Up

    – Explanation of the necessary cleaning and servicing activities which you can carry out, – Actions to take in the event of failures. The scope of supply includes an installation and instruction form. Document the proper handover by filling-in this form together with the installer. BA ROTEX A1 BG Inline - 10/2007...

  • Page 15: Operation

    The black pointer must be in the green range. If it is to the left of the red pointer, the water pressure must be raised by topping up the system. If water needs to be filled frequently, please find out the reason for it and have the fault correct as soon as possible. BA ROTEX A1 BG Inline - 10/2007...
  • Page 16 Control THETA 23R Electronic digital control ROTEX THETA 23R for controlling 2 heating circuits (direct heating circuit, mixer circuit) and a storage tank charging circuit. It contains a switch clock with three individually configurable timer programs per heating circuit. Three more users can be connected to the THETA 23R control (also refer to chapter 2.4).

  • Page 17: Display And Modification Of The Parameters

    Selection of one of 3 pre-installed timer programs P1, P2 or P3. You can find a detailed description for adjusting the switching time in the "ROTEX Control“ documentation, which is included in the scope of supply of the gas calorific value boiler.

  • Page 18: Heating Mode

    A1 BG 25i condensing boiler A1 BG 25i • Determine the throughput quantity pertaining to a certain heating output in the heat power graph (Fig 4-4), depending on the design scatter. BA ROTEX A1 BG Inline - 10/2007...

  • Page 19: Tips About Operating Noises

    • Drain the shut-down heating system if there is danger of frost. • If the heating system is not drained, the gas and power supplies must be secured and the main switch must remain switched on. BA ROTEX A1 BG Inline - 10/2007...

  • Page 20: Recommissioning

    If no heating and no hot water supply is needed over a long period, the gas condensing boiler can be temporarily shut down. ROTEX recommends, however, that you put the system in the Stand-By mode. The heating system is then protected from frost.

  • Page 21: Checklist For Recommissioning

    Does the gas type and gas inlet pressure correspond to the values featured on the burner sticker? Put the system into operation again only if the answer to all the questions has been "Yes"! BA ROTEX A1 BG Inline - 10/2007...

  • Page 22: Inspection And Maintenance

    – Replacement of the wearing parts (if required). ROTEX recommends that you make an inspection and maintenance contract to ensure regular inspection and maintenance. • Have the inspection and maintenance confirmed in the Maintenance log. The Maintenance log is included in the scope of supply.

  • Page 23: Removing Panelling (And Cleaning It)

    • Insert the condensate drain hose in the wastewater connection. Check the correct path of the condensate drain section (slight slope to the drainage pipeline, no siphon formation). • Check the connection and drain section for leakage. BA ROTEX A1 BG Inline - 10/2007...

  • Page 24: Checking And Cleaning The Burner

    (shown A1 BG 25i) (shown A1 BG 25i) • Remove the top combustion chamber insert by using the combustion chamber key. • Remove the bottom combustion chamber insert by using the combustion chamber key. BA ROTEX A1 BG Inline - 10/2007...
  • Page 25 In the course of maintenance work, safety-relevant components must also be checked for achieving the nominal service life: – CVBC automatic firing unit 10 years or 250,000 burner starts, – Safety gas control block 10 years or 250,000 burner starts, – Overpressure safety valve: 10 years. BA ROTEX A1 BG Inline - 10/2007...

  • Page 26: Faults And Failures

    The electronic system in the gas condensing boiler detects faults and displays them: – through a fault code in the display, for faults detected by the boiler control ROTEX THETA 23R. – through the collective fault signals in the boiler control panel and through a fault code on the display, for faults detected by the CVBC automatic firing unit, which leads to an interlocking failure.

  • Page 27: Failures

    Interruption, mixer circuit pump is switched off; mixer motor is made dead 12-1 Short circuit, mixer circuit pump is switched off, mixer motor is switched de-energised 13-0 Hot water storage tank temperature Interruption sensor 13-1 Short circuit BA ROTEX A1 BG Inline - 10/2007...
  • Page 28 Return flow sensor interruption B 99 Internal communication between THETA 23R control and CVBC automatic firing unit interrupted. Tab. 6-3 Fault code for gas condensing boiler A1 (Automat firing unit recognisable by central unit) BA ROTEX A1 BG Inline - 10/2007...

  • Page 29: Technical Data

    Technical data Technical data Dimensions and connection dimensions Fig. 7-1 Dimensions of the model versions, side view Fig. 7-2 Dimensions and connection dimensions of the model versions, rear view BA ROTEX A1 BG Inline - 10/2007...
  • Page 30 ≥ ≥ ≥ ≥ ≥ ≥ 1340 1890 1650 1590 2140 1890 1100 1730 1480 1340 1970 1720 Tab. 7-1 Installation dimensions for gas condensing boilers A1 BG 25i / A1 BG 40i BA ROTEX A1 BG Inline - 10/2007...
  • Page 31 Name Type CVBC Honeywell automatic firing unit S4965 V 1059 ROTEX Honeywell gas valve VK 4115 V2 Burner fan G1G 126-AA49-61 Tab. 7-3 Type designation components A1 BG 25i / A1 BG 40i BA ROTEX A1 BG Inline - 10/2007...
  • Page 32 Detailed information about burner setting and the flue gas target values are given in the installation manual for the technical operation, which is included in the scope of supply. Fig. 7-4 Residual pumping height A1 BG 25i (on heating side) BA ROTEX A1 BG Inline - 10/2007...
  • Page 33 Technical data Fig. 7-5 Residual pumping height A1 BG 40i (on heating side) Fig. 7-6 Required throughput volumes dependent on the heating output and the design temperature spread BA ROTEX A1 BG Inline - 10/2007...

  • Page 34: Wiring Diagram

    Storage tank (hot water ) temperature sensor mains cable and earthing connection External temperature sensor Flue gas temperature sensor 3-pin circuit board connector with pump cable 12-pin circuit board connector for clamping sensors, BUS and control lines BA ROTEX A1 BG Inline - 10/2007...

  • Page 35: Glossary

    Safety device which switches off the heating boiler automatically if there is a water shortage, in order to avoid over- Over-heating protection heating. Timer program Times which can be set on the operating unit to define regular heating, economy and hot water phases. BA ROTEX A1 BG Inline - 10/2007...

  • Page 36: For The Chimney Sweep

    For the chimney sweep Data for designing the flue gas duct For the chimney sweep Fig. 9-1 Flue gas mass flow / burner output ROTEX gas condensing boiler A1 BG xxi Appliance Burner Rated output in kW Flue gas mass flow in g/s...

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