Rotex A1 BG User Manual

List of contents
2
FA ROTEX A1 BGe - 02/2014
1 Guarantee and conformity . . . . . . . . . . . . . 4
1.1 Warranty conditions . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Declaration of conformity . . . . . . . . . . . . . . . . . . 4
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Observing instructions . . . . . . . . . . . . . . . . . . . . 5
2.2 Warning signs and explanation of symbols . . . . 5
2.3 Avoid danger . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Instructions for operating safety . . . . . . . . . . . . . 6
2.5.1 Before working on the heating system . . . . . . . . . .6
2.5.2 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . .6
2.5.3 Installation room . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.5.4 Requirements for the heating water . . . . . . . . . . . .6
2.5.5 Heating system and sanitary connection . . . . . . . .6
2.5.6 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.5.7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.5.8 Instructing the user/owner. . . . . . . . . . . . . . . . . . . .6
3 Product description. . . . . . . . . . . . . . . . . . . 7
3.1 Boiler design and components. . . . . . . . . . . . . . 7
3.2 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Set-up and installation . . . . . . . . . . . . . . . . 9
4.1 Dimensions and connection dimensions . . . . . . 9
4.2 Different set-ups. . . . . . . . . . . . . . . . . . . . . . . . 11
4.2.1 Operation independent of ambient air. . . . . . . . . .12
4.2.2 Operation partially independent of ambient air . . .12
4.2.3 Ambient air dependent operation . . . . . . . . . . . . .13
4.3 Transport and delivery . . . . . . . . . . . . . . . . . . . 13
4.4 Installing the condensing boiler . . . . . . . . . . . . 13
4.4.1 Selecting the installation site . . . . . . . . . . . . . . . .13
4.4.2 Setting up the unit . . . . . . . . . . . . . . . . . . . . . . . . .14
4.5 Air/flue system (LAS) . . . . . . . . . . . . . . . . . . . . 14
4.5.1 General instructions for flue system . . . . . . . . . . .14
4.5.2 Connecting the flue gas line to the ROTEX A1 . . .15
4.5.3 Flue gas system kits . . . . . . . . . . . . . . . . . . . . . . .16
4.6 Water connection . . . . . . . . . . . . . . . . . . . . . . . 17
4.7 Connect the condensate drain . . . . . . . . . . . . . 18
4.8 Establish connection and electrical equipment 18
4.8.1 Instructions concerning electrical connection . . . .18
4.8.2 Establishing the electrical connection . . . . . . . . . .18
4.8.3 Connecting the temperature sensor . . . . . . . . . . .19
4.8.4 Connect the additional electrical components. . . .20
4.9 Connect the gas line, check the burner
setting for gas type. . . . . . . . . . . . . . . . . . . . . . 20
4.9.1 Important instructions for gas connection . . . . . . .20
4.9.2 Connecting the gas line. . . . . . . . . . . . . . . . . . . . .20
4.9.3 Checking burner pre-setting . . . . . . . . . . . . . . . . .20
4.10 Filling the heating system . . . . . . . . . . . . . . . . 21
5 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2 Checklists for start-up . . . . . . . . . . . . . . . . . . . 23
6 Control unit . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1 Operating elements on the boiler control
panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2 Replacing the operating section RoCon B1 . . . 25
6.3 Changing the boiler control panel . . . . . . . . . . 25
6.4 Changing cables . . . . . . . . . . . . . . . . . . . . . . . 26
6.5 Changing the sensors . . . . . . . . . . . . . . . . . . . 27
6.5.1 Changing flow / return flow temperature sensor . .27
6.5.2 Changing the flue gas temperature sensor . . . . . 28
6.5.3 Changing the storage tank temperature sensor . 28
6.6 Replacing the fuse or control panel circuit
board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.7 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . 29
7 Gas burner . . . . . . . . . . . . . . . . . . . . . . . . . .31
7.1 Design and brief description . . . . . . . . . . . . . . 31
7.1.1 Automatic firing CM124-R1 . . . . . . . . . . . . . . . . . 32
7.1.2 Automatic firing connections . . . . . . . . . . . . . . . . 32
7.2 Safety function . . . . . . . . . . . . . . . . . . . . . . . . 33
7.3 Burner setting . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.3.1 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.3.2 Checking and setting the burner . . . . . . . . . . . . . 35
7.3.3 Carrying out the basic setting on the burner. . . . 35
7.3.4 Resetting the gas type. . . . . . . . . . . . . . . . . . . . . 36
7.3.5 Adjusting the output limits and the starting
output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.3.6 Setting the gas pressure controller . . . . . . . . . . . 38
7.3.7 Setting ignition and Ionisation electrodes . . . . . . 39
7.4 Removing/fitting the burner . . . . . . . . . . . . . . . 40
7.4.1 Burner dismantling . . . . . . . . . . . . . . . . . . . . . . . 40
7.4.2 Burner installation . . . . . . . . . . . . . . . . . . . . . . . . 40
8 Hydraulic connection . . . . . . . . . . . . . . . . .41
8.1 Connection accessories . . . . . . . . . . . . . . . . . 41
8.1.1 Safety group SBG A1 . . . . . . . . . . . . . . . . . . . . . 41
8.1.2 Connection kit A1 . . . . . . . . . . . . . . . . . . . . . . . . 41
8.2 Hydraulic system connection . . . . . . . . . . . . . 43
9 Service and maintenance . . . . . . . . . . . . . .44
9.1 General overview of service and maintenance 44
9.2 Service and maintenance tasks . . . . . . . . . . . 44
9.2.1 Removing panelling (and cleaning it) . . . . . . . . . 44
9.2.2 Checking the connections and pipes. . . . . . . . . . 45
9.2.3 Checking and cleaning the condensate drain. . . 45
9.2.4 Checking the flue gas temperature . . . . . . . . . . . 47
9.2.5 Checking and cleaning the combustion chamber 47
9.2.6 Checking the burner . . . . . . . . . . . . . . . . . . . . . . 49
10 Faults and malfunctions . . . . . . . . . . . . . . .50
10.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 50
10.2 Overview of possible malfunctions . . . . . . . . . 50
10.3 Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
10.4 Rectifying burner faults and STB faults. . . . . . 53
10.5 Emergency operation . . . . . . . . . . . . . . . . . . . 53
11 Taking out of service. . . . . . . . . . . . . . . . . .54
11.1 Temporary shutdown . . . . . . . . . . . . . . . . . . . 54
11.2 Final shutdown and disposal. . . . . . . . . . . . . . 54
12 Technical data . . . . . . . . . . . . . . . . . . . . . . .55
12.1 Basic data condensing boiler . . . . . . . . . . . . . 55
12.2 Heating circulation pump and 3-way diverter
valve (A1 - all types) . . . . . . . . . . . . . . . . . . . . 56
12.3 Gas type, connection pressures . . . . . . . . . . . 56
12.4 Performance diagrams . . . . . . . . . . . . . . . . . . 57
12.5 Flow rate and residual feed height . . . . . . . . . 57
12.6 Temperature sensor . . . . . . . . . . . . . . . . . . . . 58
12.7 Tightening torque . . . . . . . . . . . . . . . . . . . . . . 58
13 List of keywords . . . . . . . . . . . . . . . . . . . . .59

Rotex A1 BG Specifications

General

Brand	Rotex
Model	A1 BG
Category	Boiler
Language	English