ROTEX Gassolarunit Gas Condensing Boiler with Stratified Solar Storage Tank

For specialist technical operation

ROTEX GasSolarUnit Gas condensing boiler with stratified solar storage tank

Installation and maintenance instructions

0085 BM 0065 Type Rated thermal output GB ROTEX GSU 320 3 - 20 kW modulating Edition 09/2007 ROTEX GSU 520S 3 - 20 kW modulating ROTEX GSU 530S 7 - 30 kW modulating ROTEX GSU 535 8 - 35 kW modulating

Manufacture number

Customer Guarantee and conformity

ROTEX accepts the guarantee for material and manufacturing defects according to this statement. Within the guarantee period, ROTEX agrees to have the device repaired by a person assigned by the company, free of charge. ROTEX reserves the right to replace the device. 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.

Guarantee period The guarantee period begins on the day of installation (billing date of the installation company), however at the latest 6 months after the date of manufacture (billing date). The guarantee period is not extended if the device is returned for repairs or if the device is replaced. Guarantee period of burner, boiler body and boiler electronics: 2 years

Guarantee exclusion Improper use, intervention in the device and unprofessional modifications immediately invalidate the guarantee claim. Dispatch and transport damage are excluded from the guarantee offer. The guarantee explicitly excludes follow-up costs, especially the assembly and disassembly costs of the device. There is no guarantee claim for wear parts (according to the manufacturer's definition), such as lights, switches, fuses.

Declaration of conformity For the condensing boiler heating central units ROTEX GasSolarUnit We, ROTEX Heating Systems GmbH, declare under our sole responsibility that the products Product Order No. Product Order No. ROTEX GSU 320 15 70 25 ROTEX GSU 320 F 15 70 26 ROTEX GSU 520S 15 71 10 ROTEX GSU 520S F 15 71 20 ROTEX GSU 530S 15 71 21 ROTEX GSU 530S F 15 71 23 ROTEX GSU 535 15 71 40 ROTEX GSU 535 F 15 71 45 with the product ID number CE 0085 BM 0065, in connection with one of the following controls Product Order No. Product Order No. ROTEX THETA 23R (N) 15 40 52 ROTEX ALPHA 23R 15 40 54 ROTEX THETA 23R (S) 15 40 53 comply, in their standard design, with the following European Directives: 2004/108/EC Electromagnetic compatibility directive 90/396/EEC Gas appliances directive 2006/95/EC Low voltage directive 92/42/EEC Boiler efficiency requirements directive

Güglingen, 1.3.2007 Dr Eng. Franz Grammling Managing Director

2 FA ROTEX GSU - 09/2007 Table of contents

1 Safety ...... 5 1.1 See the manual ...... 5 1.2 Warnings and symbols...... 5 1.3 Danger prevention ...... 6 1.4 Proper use...... 6 1.5 Information on operating safety...... 6

2 Product description...... 8 2.1 Structure and Components of ROTEX GasSolarUnit...... 8 2.2 Brief description ...... 11

3 Erection and installation ...... 12 3.1 Dimensions and pipe dimensions ...... 12 3.2 Installation versions ...... 14 3.2.1 Ambient air-independent mode ...... 15 3.2.2 Ambient air-dependent mode...... 15 3.3 Transport and delivery...... 16 3.4 Installing the ROTEX GasSolarUnit ...... 16 3.4.1 Selecting the installation site ...... 16 3.4.2 Erecting the unit ...... 17 3.5 Air/flue gas system (LAS) ...... 17 3.5.1 General instructions for flue gas system ...... 17 3.5.2 Connect flue gas line to the ROTEX GSU...... 18 3.5.3 Flue gas system kits ...... 20 3.6 Waterconnection for heating and hot water pipes ...... 21 3.7 Connect the condensate drain ...... 22 3.8 Connect valve drive to the 3-way reverse valve ...... 22 3.9 Establish connection and electrical equipment ...... 23 3.10 Temperature sensor ...... 24 3.10.1 General instructions for the temperature sensors ...... 24 3.10.2 Connecting the temperature sensor...... 24 3.11 Connect the gas line, check the burner setting for gas type ...... 25 3.11.1 Important instructions for gas connection ...... 25 3.11.2 Connecting the gas line...... 25 3.11.3 Checking burner pre-setting ...... 26 3.12 Optional connections...... 26 3.12.1 Mixer circuit ...... 26 3.12.2 Flue gas temperature probe...... 26 3.12.3 Room controller ...... 26 3.12.4 Room station ...... 26 3.13 Filling the system ...... 27

4 Start-up ...... 28 4.1 Initial start-up ...... 28 4.2 Checklists for start-up...... 29

5 Control ...... 30 5.1 Operating elements on the boiler control panel...... 30 5.1.1 Control THETA 23R ...... 30 5.1.2 Control ALPHA 23R ...... 32 5.2 Replacing the central unit ...... 34 5.3 Replacing the boiler control panel ...... 35 5.4 Change cables...... 37 5.5 Changing the sensors ...... 37 5.6 Changing the fuse ...... 39 5.7 Wiring diagram ...... 40

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6 Gas burner...... 41 6.1 Structure and brief description ...... 41 6.2 Unlocking in the event of fault shutdown ...... 42 6.3 Burner setting ...... 42 6.3.1 Setting values ...... 43 6.3.2 Checking and setting the burner...... 44 6.3.3 Carrying out the basic settings at the burner...... 45 6.3.4 Resetting the gas type...... 45 6.3.5 Setting the output limits ...... 46 6.3.6 Setting the gas pressure controller...... 46 6.3.7 Setting ignition and Ionisation electrodes ...... 47 6.4 Dismantling the burner ...... 47

7 Hydraulic connection ...... 49 7.1 Important notes on the hydraulic connection ...... 49 7.2 Storage tank container...... 49 7.3 Hydraulic system connection ...... 50 7.3.1 Short names in the connection schemes...... 50 7.3.2 ROTEX GasSolarUnit with solar heating support ...... 51

8 Inspection and maintenance ...... 54 8.1 General overview of inspection and maintenance ...... 54 8.2 Inspection and maintenance tasks ...... 54 8.2.1 Checking the connections and conduits ...... 55 8.2.2 Checking and cleaning the condensate drain...... 55 8.2.3 Checking and cleaning the burner...... 55

9 Faults and malfunctions...... 57 9.1 Troubleshooting ...... 57 9.2 Malfunctions ...... 57 9.3 Fault code ...... 59 9.4 Emergency operation ...... 61

10 Decommissioning ...... 62 10.1 Temporary shutdown ...... 62 10.2 Final decommissioning and disposal ...... 62

11 Technical data...... 63

12 List of keywords...... 70

13 Maintenance log ...... 71

14 For the chimney sweep ...... 72

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1.11Safety See the manual

This instruction manual is intended for use by authorised and trained heating experts who have the necessary experience to carry out the professional installation and maintenance of heating systems and gas installations due to their specialised training and technical knowledge. All necessary installation, commissioning and maintenance tasks as well as basic information on operation and settings are described in this instruction manual. For detailed information on operation and control please refer to the other applicable documents. All the heating parameters required for comfortable operation are set at the factory. To adjust the control please refer to the relevant documents. Please read this instruction manual through carefully before starting the installation or making interventions in the heating system.

Other applicable documents – ROTEX GasSolarUnit: Operating instructions for the operator. This document in included in the scope of delivery. – The documentation of the ROTEX control used is included in the corresponding scope of delivery.

1.2 Warnings and symbols

Meaning of warnings The system used for the warnings in this instruction manual is based on the level of danger and the probability of their occurrence.

DANGER! Draws attention to immediate danger. If the warning is disregarded this will lead to severe injury or death.

WARNING! Draws attention to a potentially dangerous situation. If the warning is disregarded this may lead to severe injury or death.

CAUTION! Draws attention to a potentially harmful situation. If this warning is disregarded this may lead to material and environmental damage.

This symbol denotes tips for the user and especially useful information but is not used to warn against danger.

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Special warning symbols Special symbols are used to denote several types of danger.

Danger of explosion Electric current Danger of combustion or scalding

Validity Some of the information in this instruction manual has a limited validity. This is highlighted by a symbol.

a Valid only for ROTEX control ALPHA 23Rq Valid only for ROTEX control THETA 23R

Order number References to order numbers are indicated by the merchandise symbol .

Handling instructions • Handling instructions are presented as a list. Actions that must be carried out in a specific order are numbered. Î Results of actions are identified with an arrow.

1.3 Danger prevention

ROTEX GasSolarUnit conforms to the state-of-the-art and meets all recognised technical requirements. However, improper use may result in serious physical injuries or death, as well as property damage. To avoid danger the ROTEX GasSolarUnit must be installed and operated as follows: – correctly and in proper working order, – with an awareness of safety and danger. This requires knowledge and application of the contents of this instruction manual, applicable accident prevention regulations and recognised occupational health and safety regulations.

1.4 Proper use

The ROTEX GasSolarUnit may only be used as a hot water heating system. The ROTEX GasSolarUnit must be installed, connected and operated only according to the specifications in this manual. The ROTEX GasSolarUnit may only be used with a control approved by ROTEX (see declaration of conformity in Page 2 of this instruction manual). Any other use outside the above is considered as improper. Any resulting damage will be borne by the owner alone. Proper use also includes compliance with the maintenance and inspection requirements. Spare parts must at least satisfy the technical requirements defined by the manufacturer. These requirements are satisfied by original spare parts, for example.

1.5 Information on operating safety

Prior to carrying out work on the heating system • Work on the heating system (e.g. installation, connection and the initial start up) must only be carried out by authorised and trained heating engineers. • Switch off the main switch and secure it against unintended switching on when carrying out any work on the heating system. • Lead seals must not be damaged or removed.

Electrical installation • The electrical installation should only be carried out by qualified electrical engineers in observance of the technical electrical guidelines and the relevant electrical power supply company regulations. • Before connecting the appliance to the mains check that the mains voltage specified on the type plate (230 V, 50 Hz) corresponds to the power supply at the installation location.

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Unit installation room • Only operate the ROTEX GasSolarUnit if a sufficient combustion air supply can be ensured. This air supply is guaranteed with room air-independent operation of the ROTEX GSU with an air/flue gas system (LAS) and ROTEX standard dimensions, without any further conditions applying for the installation room. • In the case of room air-dependent operation ensure that the supply air opening to the open air is at least 150 cm2. • Room air-dependent operation of the burner must be avoided in rooms with aggressive vapours (e.g. hair spray, perchloroethylene, carbon tetrachloride), where large quantities of dust accumulate (e.g. workshop) or with high humidity (e.g. laundry rooms). • Always maintain the minimum distances from walls and other objects (see Ch. 3.1).

Open or closed heating system • Set up the heating system as an open or closed system in accordance with the safety requirements of EN 12828. • Note that the safety valves used must correspond to the requirements of DIN EN ISO 4126-1 and must be type tested. The safety valves must be installed in the safety inflow.

Hydraulic system connection • When operating the ROTEX GasSolarUnit, particularly, for solar energy utilisation, the storage temperature of 60 °C can be exceeded. Therefore, during the installation of the plant, install a scalding guard (hot water mixer, e.g. VTA32 15 60 16).

Operation • Only operate the ROTEX GasSolarUnit with the storage tank filled to the overflow. • Only operate the ROTEX GasSolarUnit with the silencer hood closed.

Instructing operator • Before you hand over the heating system, show the owner how to operate and control his/her heating system. • Document the handover by filling in and signing the attached installation and instruction form with the owner.

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2.12 StructureProduct description and Components of ROTEX GasSolarUnit

1 Cold water1) 21 Heating circulation pump 37 Ball stop-cock 2 Hot water1) 22 Gas fan burner 38 Heat insulation tray for boiler body 3 Hot water charging heat exchanger flow 23 3-way diverting valve 39 Type plate with manufacturer's number 4 Hot water charging heat exchanger return flow 24 Flow temperature sensor 5 Heating flow (hot) 25 Return flow temperature sensor 6 Heater return flow (cold) 27 Safety valve 7 Solaris flow 28 Connection for diaphragm expansion vessel Safety devices 8 Solaris return flow with valve insert 29 Boiler control panel 9 Flue gas 30 Control 1) Prepared for the installation of gravity brakes for 10 Supply air 31 Pressure gauge the prevention of cooling losses. 11 Immersion sleeve for storage tank sensor and 32 Silencer hood Solaris return flow temperature sensor 33 Retaining screws for silencer hood 12 Condensate overflow connection 34 Supply air hose 12a Upper filling connection (alternative: Condensate 35 Filling and draining fitting (KFE cock) overflow connection at front 36 Automatic venting device Fig.2-1 Components of ROTEX GasSolarUnit

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A Gas condensing boiler B Hot water layered storage tank C Unpressurised storage tank water D Hot water zone E Solar zone F Heating support zone G Control and pump unit RPS (Solaris accessory)

1 Cold water1) 2 Hot water1) 3 Hot water charging heat exchanger flow 4 Hot water charging heat exchanger return flow 5 Heating flow (hot) 6 Heating return flow (cold) 7 Solaris flow 8 Solaris return flow with valve insert 9 Flue gas 10 Supply air 11 Immersion sleeve for storage tank sensor and Solaris return flow temperature sensor 12 Condensate overflow connection 12a Upper filling connection (alternative: condensate overflow connection at front) 13 Condensate discharge hose (by others) 14 Condensate pipe 15 Heating heat exchanger (boiler body) 16 Drinking water heat exchanger (TW-WT) 17 Heat exchanger for storage tank charging (SL-WT) 18 Heat exchanger for solar heating support (HU-WT) 19 Thermal insulation jacket for HU-WT 20 Solaris inflow layering pipe 21 Heating circulation pump 22 Gas fan burner 23 3-way diverting valve 24 Inflow temperature sensor 25 Return flow temperature sensor 26 Flue gas temperature sensor (accessory) 27 Safety valve 28 Connection for diaphragm expansion vessel

Safety devices

1) Prepared for the installation of gravity brakes for the prevention of cooling losses.

Fig.2-2 Schematic layout of the GSU 520S and GSU 530S

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A Gas condensing boiler B Hot water layered storage tank C Unpressurised storage tank water D Hot water zone G Control and pump unit RPS (Solaris accessory)

1 Cold water1) 2 Hot water1) 3 Hot water charging heat exchanger flow 4 Hot water charging heat exchanger return flow 5 Heating flow (hot) 6 Heating return flow (cold) 7 Solaris flow 8 Solaris return flow with valve insert 9 Flue gas 10 Supply air 11 Immersion sleeve for storage tank sensor and Solaris return flow temperature sensor 12 Condensate overflow connection 12a Upper filling connection (alternative: condensate overflow connection at front) 13 Condensate discharge hose (by others) 14 Condensate pipe 15 Heating heat exchanger (boiler body) 16 Drinking water heat exchanger (TW-WT) 17 Heat exchanger for storage tank charging (SL-WT) 20 Solaris inflow layering pipe 21 Heating circulation pump 22 Gas fan burner 23 3-way diverting valve 24 Inflow temperature sensor 25 Return flow temperature sensor 26 Flue gas temperature sensor (accessory) 27 Safety valve 28 Connection for diaphragm expansion vessel

Safety devices

1) Prepared for the installation of gravity brakes for the prevention of cooling losses.

Fig.2-3 Schematic layout of the GSU 535 and GSU 320

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2.2 Brief description

The ROTEX GasSolarUnit is a fully preassembled gas condensing boiler integrated in a hot water storage. Through this integration, there are no external surface and cooling losses. The heat is emitted entirely into the storage water and not to the environment. In addition, the excellent heat insulation of the plastic storage container provides for minimum heat losses. The very flat cylindrical aluminium boiler body is recessed into the cover of the storage tank container. The combustion chamber is arranged centrally. The flue gas is directed in a spiral around the burner chamber and then taken away upwards. The flue gas temperature always remains below 90 °C.

Solar utilisation The hot water storage of the ROTEX GSU can also be heated by solar energy. The GSU 520S and GSU 530S models selectively maintain the upper section of the storage tank at the required temperature when used with the gas condensing boiler. In solar heating, – depending on the heat from the sun – the entire storage is heated. The stored heat is now used both for the hot water preparation and for the heating system support. The high total storage capacity in the 500-l storage also enables the occasional bridging without sunshine. In the GSU 320 and GSU 535 models, the complete storage tank container is designed as domestic water zone. Thermal solar energy utilisation for hot water preparation is possible. In connection with a Solaris plant connected in series (preheating stage), the solar proportion is optimised.

Operating instructions The ROTEX GasSolarUnit is designed in such a way that it can be operated independently of the room air. The burner draws the combustion air directly from the outside through an installation shaft or a double-walled flue gas duct. This method has several advantages: – The heating room does not need any air inlet opening to the outside and therefore does not cool down. – Lower energy consumption. – Additional energy recovery in the flue gas duct by preheating the combustion air. – Additional energy yield from the distinctive temperature layering in all devices, by the arrangement and flow through the heat exchanger. – Dirt from the burner environment is not sucked in. The heating room can thus be used as a workspace, laundry room etc. – Installation possible as central roof unit and in garages. The drinking water is heated indirectly through the pressureless storage water of the hot water storage in a anticorrosion special steel corrugated pipe heat exchanger. Approximately 24 litres (19 l on GSU 320) hot drinking water are stored at the temperature level of the domestic water zone. If a greater hot water quantity is drawn off, this water is heated in the instantaneous heater principle. At the lowest point of the boiler body, the resulting condensation is collected, directed through a plastic pipe into the storage tank container and then neutralised there. From there, it is dissipated through the safety overflow connection.

Safety management The complete safety management of the ROTEX GasSolarUnit is performed by the electronic control. If there is a water shortage, gas shortage or undefined operating conditions, there will be a safety shutdown. A corresponding error message shows the technician all the necessary information needed for troubleshooting.

Electronic control A full electronic digital control panel, together with the "intelligent" automatic firing unit for the burner, controls all the heating and hot water functions fully automatically for the direct heating circuit, an optional connectable mixed heating circuit as well as a storage tank charging circuit. The infinitely variable modulating control adjusts the heat output flexibly to the changing requirements. All settings, indicators and functions are made through the ROTEX control panel THETA 23R or the ROTEX control panel ALPHA 23R. The display and keyboard offer comfortable operating options. q To increase comfort, a digital room station (ROTEX THETA RS, 15 70 18) or a room control set (THETA RFF, 15 40 70) are also available as options. a To increase the comfort, the room temperature regulator (ALPHA RTR-E, 17 51 26) is available as an option.

Condensing technology Condensing technology makes optimum use of the energy contained in the heating gas. The flue gas is cooled in the boiler and, in the case of the ambient air-independent method, in the flue gas system, until the temperature falls below the dew point. Part of the water vapour created on combustion of the gas thereby condenses. Unlike the low temperature boilers, the condensation heat is fed to the heating. This means that efficiency levels over 100% are possible.

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3 Erection and installation WARNING! Incorrectly erected and installed gas devices may not operate properly and are dangerous to the health and life of individuals. • The ROTEX GasSolarUnit must be installed only by heating engineers authorised and trained by gas or energy supply companies.

Incorrect erection and installation would make the manufacturer's guarantee void. Should you have any questions, please do not hesitate to contact our Technical Customer Service.

3.1 Dimensions and pipe dimensions

A View from the side C View from above B View from the front Fig.3-1 Installation dimensions for flue gas pipe at the rear (for values see Tab. 3-1)

A View from the side C View from above B View from the front Fig.3-2 Installation dimensions for flue gas pipe at the side (for values see Tab. 3-1)

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Dimension GSU 320 GSU 520S GSU 530S GSU 535 h1 1404 1384 1384 h2 1869 1846 1828 h3 1918 1896 1878 r1 202 299 264 r2 203 284 284 s1 213 115 150 s2 228 130 165 s3 377 295 295 t 615 780 780 w 590 780 780 Tab. 3-1 Dimensions table - Installation (refers to Fig 3-1, Fig 3-2)

Pipe dimensions for heating and hot water pipes

1 Cold water (pipe thread 1“ male) 5 Solaris flow (pipe thread, flat sealing 1“ SN) 2 Hot water (pipe thread 1“ male) 3 Heating flow (pipe thread with ball valve 1“ female) A front 4 Heating return (pipe thread with ball valve 1“ female) B rear Fig.3-3 Pipe dimensions for heating and hot water connection (view from above) (see Chapter 3.6)

To prevent increased cooling losses ROTEX recommends installation of gravity brake systems ( 16 50 70) or the syphonisation (connection pipes directly leading downwards) of the drinking water pipes.

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3.2 Installation versions

The ROTEX GasSolarUnit are basically designed for operation independent of ventilation and air-conditioning. They are fitted with a concentric flue gas /air supply pipe DN 80/125.

ROTEX recommends using the gas condensing boiler in ambient air-independent mode. If possible, choose this installation version! In partial room air-independent and room air-dependent mode, the installation room must have a ventilation opening of at least 150 cm2 to the outside. As such, the installation room will not be assigned the heated building envelope under the Energy Conservation Ordinance (EnEV), which downgrades the energy rating of the building.

1-4 Installation versions (for description, see Section 3.2.1) Ö Air supply *) Longitudinally ventilated shaft with a fire-resistance period of Î Flue gas 90 minutes (30 minutes in low height residential buildings). Observe country-specific regulations for fire-resistance periods! Fig.3-4 Installation variants for the ROTEX GasSolarUnit

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3.2.1 Ambient air-independent mode

Installation version 1 The ROTEX GSU is connected to the LAS connection line kit H or kit K at the chimney or an installation shaft. – The combustible air supply from the outside runs through the chimney or through an installation shaft. – The flue gas discharge to the outside runs through the same shaft as the air supply. – Minimum distance between flue gas exit and roof crest: 40 cm.

Installation version 2 The ROTEX GSU is located directly under the roof. Connection with kit L. – The combustible air supply and flue gas discharge run through a concentric dual pipe. – The combustible air supply from the outside runs through the outer ring-shaped gap of the dual pipe, and the flue gas discharge to the outside runs through the inner tube. – Minimum distance between flue gas exit and roof surface: 40 cm. – Minimum height of the flue gas duct: 2m.

Installation version 3 The ROTEX GSU is not located directly under the roof. The dual pipe for the combustible air supply and flue gas duct runs through the roof truss. – The combustible air supply and the flue gas discharge run through a concentric dual pipe (as in Installation version 2). – In the area of the roof truss, the dual pipe for the combustible air supply and the flue gas duct must be laid through a protective pipe with sufficient fire resistance or be structurally separated from the roof truss.

Installation version 4 The ROTEX GSU is connected to the LAS connection line kit H or kit K at the outer wall system kit G. – The combustible air supply from the outside runs through the ring-shaped gap in the dual pipe, through the outer wall (drawn in from below). – The flue gas discharge to the outside runs through a concentric pipe, through the outer wall and then up to at least 40 cm above the roof surface. In the external area, the outer air gap serves as heat insulation for the flue gas pipe.

If the wall breakthrough has a height of less than one meter above ground level, ROTEX recommends sending the combustible air through a separate air supply pipe (mounting height: about 2 m). PPW-ZR, 15 50 79.00 66

Information for installation in garages The ROTEX GSU is basically suitable for installation and operation in garages. Requirements: – Ambient air-independent operation mode, – A durable operating manual placed in a very visible place near the boiler, – The construction must include a protective device against mechanical damage (vehicle!) for the entire system (e.g. bracket or deflector).

3.2.2 Ambient air-dependent mode The ROTEX GSU can be connected in room-air dependent mode. Thereby, only the inner flue gas pipe (plastic pipe Ø 80 mm) of the concentric air-flue gas pipe is connected to the flue gas line. The device draws the combustible air from the installation room through the ring-shaped gap of the jacket pipe.

In some cases, the resonance in the flue gas system can amplify the noise at the mouth of the flue gas duct. The noise level can be effectively reduced by using a silencer ( 15 45 78). Air suction noises are generated in ambient air-dependent operations. The noise level can be effectively reduced by using a silencer ( 15 45 77).

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3.3 Transport and delivery

WARNING! The ROTEX GSU is top heavy when empty, it can tip over during transport. This can pose a risk to persons and damage the machine. • Transport the ROTEX GSU carefully, using supporting straps.

The ROTEX GSU is delivered on a pallet. All industrial trucks, such as lifting trucks and forklift trucks, are suitable for its transport.

Scope of delivery – The ROTEX GSU (ready for connection, pre-mounted) consists of solar storage, gas condensing boiler with modulating gas burner, the integrated circulating pump, 3-way reverse valve, device-internal temperature probes (flow, return, storage), outer temperature probe, safety group and ball valves. – The document folder with installation and maintenance manual, installation and instruction form.

The gas condensing boiler will not function without the central control unit. The control unit must be ordered separately in the required model (operation only allowed with ROTEX controller).

3.4 Installing the ROTEX GasSolarUnit

3.4.1 Selecting the installation site The place of installation for the ROTEX GSU must meet the following minimum requirements.

Installation surface – The base must be solid, flat and horizontal, and must have sufficient load bearing strength. Install a pedestal if necessary. – Observe setup dimensions (see Ch. 3.1).

Installation room – There are no special conditions for ventilation of the installation room for ambient air-independent operations (using a concentric air/flue gas system). – In partial ambient air-independent and ambient-dependent mode, the installation room must have a ventilation opening of at least 150 cm2 to the outside. – For partial ambient air-independent and for ambient air-dependent mode, the installation room must be free from aggressive vapours (e.g. hair spray, perchloroethylene, carbon tetrachloride), heavy dust formation and high atmospheric humidity (e.g. a laundry).

Surface temperature – In ambient air-independent mode with rated power, the design does not allow temperatures > 80°C on any component outside the unit panels. Therefore, no minimum distance is required to components made from flammable materials. – A minimum distance of 50 mm between the flue gas duct and flammable components should be maintained in a partial ambient air-independent and ambient air-dependent modes. – Do not store or use highly combustible and flammable materials in the immediate vicinity of the GSU.

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3.4.2 Erecting the unit

WARNING! The ROTEX GSU is top heavy when empty, it can tip over during transport. This can pose a risk to persons or damage the machine. • Transport the ROTEX GSU carefully, using supporting straps.

Prerequisite: – The installation site follows country-specific regulations, as well as the minimum requirements described in section 3.4.1.

Erection: • Remove the packing. Dispose of the packing in an ecological manner. • Install ROTEX GSU at the place of installation. • Lay connection lines in such a way that the noise insulation hood (Fig 2-1 Pos. 32) can be removed.

3.5 Air/flue gas system (LAS)

3.5.1 General instructions for flue gas system

Minimum requirements: The firing regulations for the country in question and the country-specific standards are applicable for the model and design of the flue gas system. Basically, for the flue gas system, you can use any flue gas pipe according to EN 14471 with EU label, which meets the following minimum requirements: – Suitable for gas. – Suitable for flue gas temperatures of at least 120 °C (temperature class T120 or higher). – Suitable for at least 200 Pa overpressure (pressure class P1 or H1). – Humidity-resistant (condensation resistance class W). – Sufficiently corrosion-resistant (corrosion resistance class 1 or 2). The properties of the flue gas system must be identified on the system installed (nameplate in the installation room).

Connection types: – Directly to the back (Fig 3-1 - Kit H: PPD-H, 15 50 79.08). – To the side at the back (Fig 3-2 - Kit K: PPD-K, 15 50 79.09). – Direct roof installation (Fig 3-4 - Kit L: PPD-L, 15 50 79.10). For other details and connection dimensions for the three versions of the flue gas pipe, see section 3.5.3.

Assembled position and piping height: – The maximum permissible flue gas counter pressure is 200 Pa. The pressure loss in the supply line must not be greater than 50 Pa. – Angle of entry of the flue gas pipe into the chimney or installation shaft: ca. 3°. – Slope for horizontal parts of the flue gas duct: ca. 3°. Counter-slopes are not allowed at any point in the flue gas duct. – If the flue gas duct needs more than 3 deflections >45° for the flue gas duct, the maximum height for the flue gas duct reduces by at least 1 m per deflection (flue gas calculations may be needed). – If the horizontal connecting piece is extended, the maximum permitted height of the flue gas duct is reduced by exactly that length.

Resistance of flue gas system: A minimum resistance in the flue gas pipe is required to ensure safe starting of the burner and also stable adjustment values in the lower performance range, particularly with liquid gas appliances. If this is not reached at the maximum rotational speed of the burner fan, a silencer must be installed ( 15 45 78). The first time the burner is started the GSU initially switches to storage tank charging mode. In this case the burner fan runs at maximum speed. • Using a differential pressure gauge, measure the resistance between the flue gas and supply air measuring aperture at the flue gas measuring piece (differential pressure at GSU 320/520S at least 0.45 mbar and at least 1 mbar at GSU 530S/535).

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Tab. 3-2 shows the maximum height for the flue gas duct if the ROTEX GSU is operated in the nominal output range.

Installation version GSU 320 GSU 520S GSU 530S GSU 535 (according to Fig 3-4) 11) 10 10 18 20 22) 12 12 17 19 32) 12 12 17 20 42) 12 12 17 20 Tab. 3-2 Maximum height for the flue gas duct in m 1) Shaft cross-section at DN80: 135 mm x 135 mm 2) Concentric flue gas/supply air line: DN80/125 Any restriction on the output range may require a recalculation of the maximum permitted height for the flue gas duct. The characteristics for the flue gas calculation can be obtained from Fig 3-5 and Chapter 11 "Technical data" or Tab. 14-1. The flue gas mass flow of the systems depends on the set burner output.

P Burner load A Natural gas E, H mAG Flue gas mass flow B Natural gas L, LL C Liquefied petroleum gas Fig.3-5 Flue gas mass flow in relation to the burner load

3.5.2 Connect flue gas line to the ROTEX GSU

The specialised company carrying out the work must come to an agreement with the district chimney sweep before beginning the work. Even in regions where it is not legally specified, we recommend documenting the participation of the district chimney sweep on a form.

Prerequisites: – The flue gas system fulfils the requirements described in section 3.5.1. – The flue gas system fulfils any required other national or regional safety requirements. – The ROTEX GSU is installed correctly.

Connection: Basically, any flue gas pipe approved by the construction supervisor (DIBT permit) that meets the minimum requirements stipulated in EN 14471 and carries the CE mark (see Section 3.5.1) can be connected. We recommend using the associated ROTEX flue gas kits (see Fig 3-8). They satisfy all requirements and are also fitted with special acid-proof seals.

• Connect ROTEX GSU to the flue gas system within the place of installation (for pipe dimensions, see Fig 3-1 or Fig 3-2).

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Pipe dimensions for air/flue gas system (LAS) connection kits

Fig.3-6 Top view ROTEX GSU Flue gas pipe at the back with kit H (see section 3.5.3)

Fig.3-7 Top view ROTEX GSU Flue gas pipe at the side with kit K (see section 3.5.3)

Dimension GSU 320 GSU 520S GSU 530S GSU 535 s1 213 115 150 s2 228 130 165 s3 377 295 295 t 615 780 780 w 590 780 780 Tab. 3-3 Pipe dimensions for LAS kits (refers to Fig 3-6, Fig 3-7) • Place the nameplate of the flue gas duct in the installation room. In some cases, the resonance in the flue gas system can amplify the noise at the mouth of the flue gas duct. The noise level can be effectively reduced by using a silencer ( 15 45 78). Air suction noises are generated in ambient air-dependent operations. The noise level can be effectively reduced by using a silencer ( 15 45 77).

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3.5.3 Flue gas system kits

Fig.3-8 Plastic (PP) flue gas system kits * If needed

Dimension GSU 320 GSU 520S GSU 530S GSU 535 h2 1869 1846 1828 h3 1918 1896 1878 r1 202 299 264 s1 213 115 150 s2 228 130 165 s3 377 295 295 s4 193 84 84 Tab. 3-4 Pipe dimensions for LAS kits (refers to Fig 3-8, )

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Additional kits – Flue gas pipe to a shaft system (rigid flue gas pipe kit E or flexible flue gas pipe kit O) – Flue gas pipe for outer wall line (kit G) If needed, in addition, PP-LAS pipes must be ordered for larger roof or ceiling heights or single-wall PP pipes for chimney heights over 10 m.

3.6 Waterconnection for heating and hot water pipes

The ROTEX GSU connections are located at the top or on the front of the machine (Solaris return flow). Heating circuit and storage charge have a common flow and return flow. The heating circuit for the storage charge is integrated at the factory and must not be connected separately. Any scale which is deposited as a result of water heating is flushed out with the hot water from the special steel corrugated pipe heat exchanger. • Observe the information regarding corrosion protection in Ch. 7.1 without fail.

Instructions for water connection

CAUTION! If the ROTEX GSU is connected to a heating system with steel piping, radiators or non-diffusion-proof floor heating pipes, sediment and swarf could enter the boiler and cause blockages, overheating or corrosion. • Flush the heat distribution network (in the existing heating system). • Install contamination filter in heating return ( 15 60 11 for appliances up to 28 kW, 15 60 12 for appliances up to 50 kW).

• For drinking water lines, comply with the EN 806 and DIN 1988 stipulations.

CAUTION! If the ROTEX GSU is connected to a cold water line, where steel pipes are used, swarf can enter the special steel corrugated pipe heat exchanger and remain there. This can lead to contact corrosion damage and subsequently to leakage. • Flush the supply lines before filling the heat exchanger. • Install a dirt filter in the cold water supply.

• Check cold water pressure (maximum 6 bar). – At higher pressure in the drinking water line, a pressure reducer must be installed. • Position and dimension of the heating pipes are shown in Fig 3-3. • To prevent heat losses, all hot water pipes must be insulated against heat. • To avoid using a circulation line, install the hot water storage close to the draw-off location. If a circulation line is compulsory, then it must be installed according to the schematic diagrams in Ch. 7.3. • Connect the flue gas pipe to the safety valve and the diaphragm expansion basin according to EN 12828.

– Water shortage protection: The overheating protection of the ROTEX GSU switches off the gas condensing boiler in case of heat deficiency and locks it. No additional water shortage protection is needed in the construction. – Avoiding deposits: Observe the regulations in VDI 2035 in order to avoid corrosive products and deposits. If the filling and top-up water has a very high hardness level, measures for hardness stabilisation and softening would be needed.

WARNING! At hot water temperatures of over 60 °C there is a danger of scalding. This is possible where solar energy is used if the legionella protection is activated or if the hot water nominal temperature is set higher than 60 °C. • Install scalding protection (hot water mixer, e.g. VTA32 ( 15 60 16).

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3.7 Connect the condensate drain

The condensation that forms during cooling of combustion gases in the boiler and in the flue gas system is directed to the storage tank container via the condensation pipe where it is neutralised by continuous neutralisation and is ultimately discharged into the sewage system via the safety overflow pipe (Fig 3-9).

Connection • Route the condensation drain pipe (not included) with constant gradient and with free flow into the drain pipe. • The complete outlet must not be lockable and must discharge the condensation and any medium leaking due to damage (drinking water, buffer or heating water) outwards visibly (e.g. hose to flow drain or transparent outlet pipe). • Check the condensate drain section for leakage.

Fig.3-9 Connection of the condensate overflow pipe

3.8 Connect valve drive to the 3-way reverse valve

The ROTEX GSU is fitted with an integrated circulation pump and a 3-way switch valve (3-w SV) as standard. The circulation pump and the 3-way reverse valve are connected at the factory, the valve drive is applied from outside.

1 Boiler inflow 2 Heating inflow 3 Storage tank charging flow 4 3-way diverting valve

5.1 Valve drive 5.2 Release button for drive locking device 5.3 Manual lever

Fig.3-10 3-way diverting valve

• After commissioning, plug the connection plug of the 3-way reverse valve cable to the valve drive.

The circulation pump and the 3-way switch valve have one cable each with a connection plugs. These cables are ready for use.

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3.9 Establish connection and electrical equipment

WARNING! Live parts can cause an electric shock on contact and cause life-threatening burns and injuries. • Before beginning work on live parts, disconnect them from the power supply (switch of fuse, main switch) and secure against unintentional restart. • The electrical connection should only be performed by electrical engineers in compliance with valid standards and guidelines as well as the specifications of the energy supply company.

Up to the central unit, all control and safety devices of the ROTEX GSU are connected and checked ready for operation. Modifications to the electrical installation are dangerous and are prohibited. Any resulting damage will be borne by the owner alone. There are two 3 m flexible cables connected inside the device for the mains connection and for the external temperature sensor; they are located in the control panel on the circuit board. Only the optional applications (e.g. mixer circuit, circulation pump, flue gas temperature probe) need to be connected to the boiler control panel.

Assembling the central unit: The selected control (THETA 23R or ALPHA 23R) is delivered separately. Install central unit as described in Ch. 5.2.

Electrical connection: • Check the supply voltage (~230 V, 50 Hz). • Connect the indoor installation distributor box with the power switched off. • Connect the cables for the mains on the indoor installation distributor box. Ensure that the polarity is correct. • Restore power supply for the indoor installation distributor box.

Switchboard panel:

Connections of the circuit jumpers: Cable colours: J1 Pump Pk bl blue * J2 3-way diverting valve or storage tank charging pump PL br brown J3 Burner - power supply ye yellow J4 Burner - communication gn green J6 Mains connection gr grey J7 Mixer rd red J8 Communication, sensors bl black J10 Sensors wt white J14 Circulation pump PZ n.a. contact not assigned

* If an adapter cable is used for the charge pump ( E 1500430) Fig.3-11 Connection diagram of the circuit board jumpers and cable colours of the factory-installed connection cable

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3.10 Temperature sensor

3.10.1 General instructions for the temperature sensors The ROTEX GSU comes with a weather-proof control unit for the flow temperature. This function requires an external temperature sensor. A 3 m flexible cable is already connected inside the device and placed in the control panel on the circuit board. The temperatures detected by the unit's internal temperature probes (flow and return flow temperature sensor, flue gas temperature probe) are used for the output control of the burner and for fault detection. They are already factory-connected and can be plugged directly to the respective sensor, if they need to be replaced. The storage temperature probe is mounted at the factory and clamped (PTC resistance). The mixer circuit inflow sensor (TMKF, 15 60 62) is required for the control of the mixer circuit . Additional information on the operating state is provided by a flue gas temperature probe (TAGF1, 15 70 52).

The electronic control detects the existing sensor configuration automatically when switching on the ROTEX GSU. Other notes and an exact description are given in the "ROTEX control" documentation. It is included with the electronic control panel that is to be delivered separately.

3.10.2 Connecting the temperature sensor

CAUTION! Using unapproved temperature sensors or those which do not match the device can cause considerable malfunctioning in the regular operation of the ROTEX GSU, damaging the device control. • Use only the outside temperature probe included with the machine.

External temperature sensor • Choose a location at about one third of the building height (minimum distance from floor: 2 m) on the coldest side of the building (North or North-East facing). • Avoid close proximity to external heat sources (chimney, air shafts) and direct sunshine. • Place external temperature sensors in such a way that the cable exit points face downwards (prevents humidity ingress).

CAUTION! Parallel routing of sensor and mains lines within an installation pipe can cause considerable malfunctioning in the regular operation of the ROTEX GSU. • Always lay the sensor line separately.

• Lay the probe line and connect to the ROTEX GSU control panel. • Connect the external temperature sensors with a twin core cable (minimum cross section 1mm2).

Mixer circuit flow probe (accessory) • Connect the probe line to the sensor plug J8 (see Fig 3-11).

Flue gas temperature probe (accessory) • Pull sensor plug J10 with closing resistance out. • Plug probe cable (connection set) onto board.

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3.11 Connect the gas line, check the burner setting for gas type

DANGER OF EXPLOSION! Escaping gas is a serious health and life hazard. Even a few sparks can cause very serious explosions. • Always close the gas stop-cock of the house before working on gas-conducting parts. • If you smell gas, ventilate the room thoroughly. Do not light any open flames or operate any electrical switches. • Only heating specialists authorised and trained by the gas or energy supply company should be allowed to work on gas-conducting parts.

3.11.1 Important instructions for gas connection

Gas connection: – Establish the gas connection in accordance with the technical regulations for gas installations (DE: German technical and scientific association for gas and water (DVGW) work sheet G 600 / TRGI 86, edition 1996 and TRF; CH: Swiss Gas and Water Industry Association (SVGW) gas guidelines G1, EKAS form. 1942 liquefied petroleum gas guideline, part 2, regulations of the cantonal authorities e.g. fire authority regulations) as well as the applicable regulations in the country of operation and the gas supply company. – A thermally triggered blocking device (TAE) and a gas flow monitor (GSW) with a DVGW inspection symbol must be fitted. The TAE must comply with the test basis of DVGW-VP 301. The dimensions of the GSW must comply with the maximum adjustable rated load of the device.

Gas type: – The preset gas type is quoted on the yellow sticker on the burner housing. – Observe permitted gas inlet pressure (Resting pressure). Gas type Rated pressure in mbar Min. inlet pressure in mbar Max. inlet pressure in mbar Natural gas E/H 20.0 17.0 25.0 Natural gas LL/L 20.0 17.0 25.0 Liquid petroleum gas 50.0 42.5 57.5 Tab. 3-5 Permitted gas inlet pressure

3.11.2 Connecting the gas line

The standard corrugated gas connection hose can cause a pressure drop of up to 5 mbar. This does not adversely affect the functioning of the gas condensing boiler.

• Connect gas pipe corrugated hose mounted at the factory (A) (pipe thread DIN EN 2999 Rp ½") to the gas line

Fig.3-12 Gas connection

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3.11.3 Checking burner pre-setting

• Compare the available gas type with the set gas type (sticker on burner housing). The two gas types must match. If the burner is not marked for the available gas type, change the burner over to the new gas type and mark it accordingly (see Ch. 6.3). • Check the gas inlet pressure. If the gas inlet pressure falls outside the permitted range Tab. 3-5, inform the authorised gas supply company.

Fig.3-13 Check the gas inlet pressure.

3.12 Optional connections

3.12.1 Mixer circuit A mixer circuit can be connected to the ROTEX GSU directly that is regulated via the electronic boiler control. ROTEX offers the following: – The ready-to-connect mixer group AMK1 ( 15 60 44), which contains a circulation pump integrated in the heat insulated housing, a motor mixer and check valves with temperature displays. – The mixer circuit contact sensor TMKF ( 15 60 62).

Cascading q By cascading from the heat circuit expansion modules THETA HEM1 ( 15 60 61), the system can be expanded by up to 5 mixer circuits and/or storage tank charging circuits. The required temperature sensors need to be ordered separately (mixer circuit contact sensor TMKF ( 15 60 62), storage tank temperature sensor TSF ( 156063)). – Connection and communication of the heating circuit expansion module THETA HEM1 through a databus on the central unit.

3.12.2 Flue gas temperature probe For optimum operation control, the flue gas probe connection set TAGF1 ( 15 70 52) can be installed. – Connection to the circuit board connector J10 on central unit (see section 3.10.2 and Fig 3-11).

3.12.3 Room controller q A separate room control THETA RFF ( 15 40 70) can be connected for each heating circuit for a remote setting of modes and room temperature from other rooms. – Connection and communication of the room controller THETA REF1 through a databus on the central unit. a A separate room control ALPHA RTR-E ( 17 51 26) can be connected for each heating circuit for a remote setting of modes and room temperature from other rooms. – Connection of the room regulator ALPHA RTR-E to the AB terminal of the circuit board connector J8 on central unit (see Fig 3-11).

3.12.4 Room station q All temperature values and modes of the control unit THETA 23R (central unit) can be displayed and changed through the room station THETA RS ( 15 70 18). Apart from the chimney sweep and manual operation function, all operating elements (display, keys, rotary switch and functions (e.g. timer programs) are identical to those of the central unit. The room station THETA RS can be installed in a suitable place in the building and can be used for the remote operation of the boiler control. – Connection and communication of the room station THETA RS through a databus on the central unit.

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3.13 Filling the system

Adjusting the pressure gauge The correct minimum pressure marking must be set on the pressure gauge glass before the first filling of the system: • Rotate the pressure gauge glass (Fig 2-1, item 31) in such a way that the minimum pressure marking corresponds to the system height + 2 m (1 m water column corresponds to 0.1 bar).

After completing the installation, fill ROTEX GasSolarUnit in the following sequence:

1. Fill hot water heat exchanger • Open isolator in cold water line. • Open draw-off points for hot water so that maximum draw-off volume can be set. • After water flows out of the draw-off points, do not disconnect the cold water flow, so that the heat exchanger is fully drained and any impurities or residue are flushed away.

2. Fill storage tank container

WARNING! Flue gas emitting from the plant endangers the health. • Before commissioning the ROTEX GSU, fill the storage tank container up to the overflow mark.

GSU with installed Solaris system: • Connect filling hose with backflow prevention device (½") to the KFE cock on the control and pump unit (RPS) • Fill storage tank container until water flows out of the condensation overflow drain.

GSU without installed Solaris system: • Either fasten the filling hose to the nozzle supplied then to the container connection on the top at the side (see Fig 2-1 Pos.12a) or insert hose into the Solaris inflow connection (Fig 2-1 Pos.7). • Fill storage tank container until water flows out of the condensation overflow drain.

3. Fill heating system and storage loading circuit

WARNING! Contamination of drinking water endangers the health. • When filling the heating system, prevent the boiler water from flowing back into the drinking water line.

• Locate the hand lever on the 3-way valve (see Fig 3-10) in the central position (only possible in current-fee or as-delivered state). The centre position is stable only on the current-free valve. The valve automatically unlocks when there is voltage on the drive motor for the valve position AB-A (storage loading). To ensure complete ventilation, the 3-way reverse valve must be unlocked at the earliest one hour after commissioning the plant.

• Connect the filling hose with return prevention device (½") to the filling and draining fittings (KFE cock, Fig 2-1, item 35) and secure against coming off with a hose clamp. • Open supply water cock. • Open the KFE cock and observe the pressure gauge (Fig 2-1, item 31). • Fill the system with water until the mark for the system overpressure is roughly in the centre of the green range on the pressure gauge display. • Shut off the KFE cock. • Vent the entire heat network (open the system control valves). • Check the water pressure on the pressure gauge again and top up with water if necessary. • Close the KFE cock, remove the filling hose with return prevention device from the filling and draining fittings.

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4Start-up WARNING! A ROTEX GasSolarUnit erected and installed incorrectly may not operate properly and is dangerous to the health and life of individuals. • The ROTEX GSU must be commissioned only by heating engineers authorised and trained by gas or energy supply companies.

CAUTION! A ROTEX GSU not properly commissioned can lead to damage to property and the environment. • Observe the regulations in VDI 2035 in order to avoid corrosion and deposits. • If the filling and top-up water has a very high hardness level, measures for hardness stabilisation and softening would be needed. – We recommend Fernox scale and corrosion preventative KSK ( 15 60 50). • During the plant operation, the water pressure on the pressure gauge (green area) must be checked at regular intervals. If necessary, readjustment by topping up.

Incorrect start-up makes the manufacturer's guarantee for the device void. Should you have any questions, please do not hesitate to contact our Technical Customer Service.

4.1 Initial start-up

After the ROTEX GSU has been erected and fully connected, it can be put into service by skilled staff.

Prerequisites – The ROTEX GSU has been fully connected. – The heating and hot water system are filled and pressurised to the correct pressure. – The storage tank container has been filled to overflowing. – The control valves of the heating system have been opened.

Tests prior to start-up • Check all connections for leaks. • Check all points on the checklist provided (see Chapter 4.2). Log the test result on the checklist. The gas condensing boiler can only be provisionally put into service if all points on the checklist can be answered by Yes.

Start-up • Switch on the mains switch. Wait for the start phase. • Check resistance of flue gas pipe (see Ch. 3.5).

press for approx. 5 s

Target temperature

Current actual value Change Desired setpoint value (flashing) Return to original operating mode, basic display, adjusted setpoint value is stored Fig.4-1 Manual operating mode for THETA 23R (adjust heater temperature) •q Set the operating temperature for manual operation. To do so, activate the manual key approx. 5 sec and set the operating temperature on the rotary switch. •a Set rotary switch II to position . Press and simultaneously. • Check burner settings using flue gas analyser and adjust if necessary (see Ch. 6.3).

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4.2 Checklists for start-up

Checklist before start-up 1. Is the ROTEX GSU assembled properly according to a permitted assembly variant and without visible damage? Yes 2. Combustion air supply secured? Yes 3. Sufficient venting of the heating room for ambient air-dependent operation? Yes 4. Does the mains connection comply with regulations? Yes 5. Mains voltage 230 Volt, 50 Hz? Yes 6. LAS flue gas conduit connected correctly and leakproof? Yes 7. Storage tank container filled with water to overflowing, condensate drain pipe connected properly and leakproof? Yes 8. For restorations: Has the heat distribution network been flushed out? Is a dirt filter built into the heating return flow? Yes 9. Is a diaphragm expansion tank fitted according to regulations and in the required size? Yes 10. Is the safety valve connected to a free drain? Yes 11. Is the system water pressure in the green range? Yes 12. Are boilers and heating systems vented? Yes 13. Are all sensors connected and correctly positioned? Yes 14. Is the mixer group and the mixer circuit sensor (optional) correctly connected to the circuit board? Yes 15. Is the room temperature controller (optional) correctly connected to the circuit board? Yes 16. Is the gas connection installed according to regulations, professionally and correctly? Yes 17. Is the gas line properly vented and leakproof? Yes 18. Does the gas type and gas inlet pressure correspond to the values featured on the burner sticker? Yes

The system may only be put into service if all questions can be answered with "Yes".

Checklist after the start-up A When the circulation pump runs, does the heating heat up? Yes B Is the flow pressure for the gas type within the permitted range? Yes C Have the screws for the gas pressure test points been retightened and are they leakproof? Yes D Was the resistance of the flue gas pipe measured and is it greater than the minimum resistance? Yes E Have the burner settings been checked using a flue gas analyser and readjusted if necessary? Yes f After commissioning, was the plug of the 3-way reverse valve inserted? Yes

The system may only be handed over to the owner if all questions can be answered with "Yes". • Fill in the supplied installation and instruction form along with the owner.

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5.15 OperatingControl elements on the boiler control panel

The ROTEX GasSolarUnit can be operated with the THETA 23R or ALPHA 23R control unit. The electronic digital controls are used for controlling 2 heating circuits (direct heating circuit, mixer circuit) and a storage tank charging circuit. Other notes and an exact description are given in the "ROTEX control" documentation. It is included with the electronic control panel that is to be delivered separately.

5.1.1 Control THETA 23R

1 Mains switch 9 Selection of the target temperature for the hot water storage tank 2 Common fault indicator lamp 10 Selecting the operating mode 3 Not assigned 11 Setting the automatic timer program 4 Pressure gauge 12 System information 5 Control: Central unit THETA 23R 13 Manual button for emission measurement, manual mode, suppression function 6 Rotary button for selection and adjustment of functions and parameters 14 Display 7 Selection of the target room day temperature 15 Compartment for quick reference operating manual 8 Selection of the reduced target room temperature 16 Fixing bolts for the control Fig.5-1 Controls on the boiler switchboard with integrated THETA 23R control

Mains switch Switch on and off the ROTEX GSU. When the heating system is on, the mains switch is illuminated green.

Collective fault signal During normal operation, the collective fault signal is off. If it lights up this indicates a malfunction.

Malfunctioning is generally indicated by an error code on the display. For information on troubleshooting refer to Ch. 9.1.

Pressure gauge – Black pointer: Indication of the current water pressure in the heating system. – Green range: Permitted water pressure range. – Red pointer: Indication of the permitted minimum pressure. 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.

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Rotary switch The rotary switch can be used for selecting operating settings, changing and storing target values.

• Rotate to the right (+): Increased regulation • Rotate to the left (–): Reduced regulation

• Tapping: Saving the selected value

• Press and hold (3 sec): Enter the programming level (select level)

Day target room temperature Selection and setting of the target temperature in normal operation. Setting according to individual temperature sensitivity.

Reduced target room temperature Selection and setting of the target temperature in economy operation (night reduction). Setting according to individual temperature sensitivity.

Target temperature of the hot water storage tank Selection and setting of the target hot water storage tank temperature Setting according to specific hot water requirement.

It is possible to trigger an unplanned storage tank charge by keeping the key pressed for a long time (during an economy phase).

Selecting the mode Setting the mode by tapping the mode selection key. The mode currently active flashes on the display. Selection and activation of another mode with the rotary switch. A marking on the display through the respective symbol shows the mode currently selected.

HOLIDAY Frost-protected shutdown of heating and hot water (e.g. during holidays).

ABSENT Brief break in the heating mode during absence. Extended heating operation over and above the heating period preset in PARTY AUTOMATIC MODE. AUTOMATIC Automatic heating and economy mode according to timer program.

SUMMER Hot water mode according to timer program, heating switched off with frost-protection.*

HEATING Continuous heating mode without time restriction.

REDUCED Continuous reduced heating mode without time restriction.

STAND-BY Frost-protected shutdown of heating and hot water.

* This function is not available if a room controller THETA RFF is connected or if the operating mode of the control has been set on different settings for the individual heating circuits.

Setting automatic timer program Selection of 3 pre-installed time switching programs P1, P2 or P3. Other notes and an exact description are given in the "ROTEX control" documentation. It is included with the electronic control panel that is to be delivered separately.

System information Calling up all system temperatures and operating conditions of the system components. • Tap the system information key. • Call up the desired information successively by using the rotary switch.

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Emission measurement, manual operation, fault clearance function You can request 3 functions by using the manual button. – Functions for emission measurement for the chimney sweep: Tap the manual button. First tap: the burner runs at maximum output, second tap: the burner runs at minimum output. – Manual operation: press the manual button for 5 sec. The ROTEX GSU is controlled according to the set target value (heat generator temperature). The storage tank charges until the maximum adjustable storage tank temperature is reached. It then switches over to heating. – Fault clearance: If the display shows "RESET", tap the manual button. If a problem recurs, the root cause must be eliminated.

Display All system temperatures and operating conditions of the system components can be indicated on the standard display. In the event of a fault, the relevant fault signal is produced. Standard display in normal operation: Current day of the week, current date, current time, heat generator temperature and active operating mode (marker bar).

5.1.2 Control ALPHA 23R

Only the control and display elements of the ROTEX central control unit ALPHA 23R are described below. For the controls of the complete boiler switchboard, see section 5.1.1.

1 Mains switch 14 Display 2 Common fault indicator lamp 15 Compartment for quick reference operating manual 3 Not assigned 16 Locking bar for control 4 Pressure gauge 17 Button "+" 5 Control: Central unit ALPHA 23R 18 Button "–" 6 Rotary switch II 19 Suppress button 10 Rotary switch I – selection of operating mode Fig.5-2 Controls on the boiler switchboard with integrated ALPHA 23R control

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Rotary switch I The settings of the ALPHA 23R control panel can be selected using rotary switch I.

STAND-BY Frost-protected shutdown of heating and hot water. Continuously reduced heating operation without time restriction — reduced operation for hot REDUCED water. HEATING Continuous heating operation without time restriction — normal operation for hot water.

SUMMER Hot water operation, frost-protected heating shutdown. Automatic heating and lowering mode according to switching time program AUTOMATIC I "business premises" (can be set separately). AUTOMATIC II Automatic heating and economy mode according to timer program "Families".

AUTOMATIC III Automatic heating and economy mode according to timer program "Solar".

Rotary switch II The settings of the ALPHA 23R control can be made with rotary switch II.

HOT WATER TARGET Display and change hot water target temperature. TEMPERATURE NORMAL MODE Normal heating mode, no settings possible. TEMPERATURE Display and modify correction value (parallel displacement of heating curve). ADJUSTMENT STATUS PLANT Read information on the plant status.

WEEKDAY Display and change weekday.

TIME Display and change time.

PARAMETERS Select and change parameters.

Changing values, Navigation – Changing values. – The buttons are used for navigation in the "Parameter", "Information" and "Switching time program (I)" menu items. – Simultaneously pressing the and confirms and/or saves the selected setting.

RESET – Reset the fault message in case of burner fault. – Discard entries within the selection menu. – Return to higher-level selection point within the selection menu. – Acknowledge the fault messages by the operator and return to standard display.

Special functions Rotary switch II in pos. : • Simultaneous pressing of and buttons for longer than 2 s activates the Emission measurement .

• Simultaneous pressing of and buttons activates the Switching time programming for the switching time programs (I) (for more exact information, see ROTEX ALPHA control).

Display All system temperatures and operating conditions of the system components can be displayed on the standard display. In case of fault, an error code is displayed. Standard display in normal operation: Flow temperature.

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5.2 Replacing the central unit

Disassembling the central unit •q Release the fixing screws (Fig 5-3, Pos. 16) (anticlockwise rotation), pull out central unit to the front. •a Release bayonet lock, pull out central unit to the front.

Assembling the central unit • Push the central unit carefully into the boiler control panel. Ensure that the connecting pins are not damaged. •q Tighten fastening screws (clockwise rotation). •a Close bayonet catch (90° rotation).

A View from front C Release fixing bolt B View from behind D Tighten fixing bolt 16 Fixing bolts Fig.5-3 Install/remove central unit (shown in THETA 23R control)

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5.3 Replacing the boiler control panel

Disassembly (observe sequence) The position and arrangement of the components described below is shown in Fig 5-16 on Page 40.

1. Remove silencer hoods.

Fig.5-4 Remove pressure gauge capillary tube Fig.5-5 Pressure gauge capillary pipe removed

2. Shut the stop cocks in the heating flow and in the heating return flow. Connect the hose to the KFE cock and release water pressure from the boiler.

WARNING! There is a danger of scalding from the heating water. The capillary tube of the pressure gauge is directly connected to the pressurised heating water. • Close the ball cocks on the boiler inflow before removing the pressure gauge and depressurising the system.

3. Unscrew the pressure gauge capillary tube with a WS14 spanner (Fig 5-4). Use a cloth to absorb the small amount of water escaping when unscrewing.

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4. Unscrew the control panel cover (Fig 5-6) and remove the cable duct cover.

Fig.5-6 Unscrew control panel cover Fig.5-7 Pull off the coded connector 5. Pull all connectors off the circuit board (Fig 5-7). 6. Extract the sensor and the connection cables from the cable ducts of the control panel (Fig 5-8).

Fig.5-8 Extract the cable Fig.5-9 Release the fixing bolts for the boiler control panel

7. Remove the fixing bolts of the boiler control panel (WS8) (Fig 5-9). Remove the control panel.

Assembly (observe sequence)

1. Insert the boiler control panel into the retainer. Insert and tighten the fixing bolts. 2. Place all sensor and connecting cables in the cable ducts of the control panel. Ensure the correct cable routing through the strain relief plates. 3. Insert all connectors on the circuit board. The connectors are shape-coded to avoid confusion. Do not force the connector! 4. Mount the control panel cover. 5. Screw in the pressure gauge capillary tube. Ensure the correct seating of the ring seal. 6. Top up with water until the required system pressure is restored. 7. Open the stop-cocks for heating. Vent the system again (top up with water if required). 8. Install noise insulation hood.

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5.4 Change cables

The connection cables can be released either on the boiler control panel or on the component in question. – The cables for the internal components in the unit are connected to the circuit board connectors and cannot be released. They are connected to the corresponding element with connectors and can be released. – The cables for external components (e.g. external temperature sensors), or for components not included in the scope of supply (e.g. mixer), are connected to the circuit board connectors by bolted terminals.

Changing the cables (observe sequence)

1. Remove silencer hoods. 2. Unscrew control panel cover and remove cable duct cover. 3. Lift out the corresponding sensor or connection cable from the cable duct of the control panel. 4. Pull out the associated connector from the circuit board. 5. Separate the other cable end from the component (release plug connection or remove the cable from the terminal). 6. Replace the cable. Ensure that the cable cross section is correct. Assemble the new cable in reverse order. Whilst doing so, ensure the following: – The technical specification of the new cable must correspond to the values of the replaced cables (e.g. conductor cross section). – The circuit board connectors are shape-coded. Do not force the connector!

5.5 Changing the sensors

Sensors inside the unit can be changed without having to open the boiler control panel.

WARNING! Live parts can cause an electric shock on contact and cause life-threatening burns and injuries. • Before beginning work on ROTEX GSU, disconnect them from the power supply (switch of fuse, main switch) and secure against unintentional restart.

33 Flow temperature sensor 34 Return flow temperature sensor

Fig.5-10 Position of temperature probe on boiler

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Changing inflow / return flow temperature sensor

WARNING! There is a danger of scalding from heating water. Flow and return flow temperature sensors are connected directly to the pressurised heating water. • Close the ball cocks on the boiler flow and boiler return flow before removing the sensor, and depressurise the system through the KFE cock.

Fig.5-11 Pull out the connector on the return Fig.5-12 Unscrew return flow temperature probe flow temperature probe

1. Remove silencer hoods. 2. Pull out the connectors on the flow temperature sensor/ return flow temperature sensor. 3. Unscrew the flow /return flow temperature sensor using a socket wrench WS15. 4. Screw in the new flow /return flow temperature sensor and plug in the cable with connector. The connectors are shape-coded. Do not force the connector!

Replacing the storage tank temperature sensor The storage tank temperature sensor is connected directly to the connection terminals 11 and 12 of the 12-pin sensor connector J8 in the boiler control panel.

For more information on mounting the storage temperature probe, see the enclosed assembly manual.

1. Open the boiler control panel and pull out the J8 connector from the circuit board (see section 5.4, steps 1 to 4). 2. Pull out the storage temperature probe from the sensor immersion sleeve on the storage tank. 3. Bend pressing springs on the new storage temperature probe and push temperature probe into the probe immersion sleeve up to the mark. 4. Connect temperature probe cable to the plug of connection terminals 11 and 12 on the sensor plug J8, push connector onto circuit board, fit switchboard cover and noise insulation hood. Fig.5-13 Storage probe with bent-over spring

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5.6 Changing the fuse

WARNING! Live parts can cause an electric shock on contact and cause life-threatening burns and injuries. • Before beginning work on ROTEX GSU, disconnect them from the power supply (switch off fuse, main switch) and secure against unintentional restart.

CAUTION! Electrostatic charge can damage the electronic components and connections on the circuit board. • Do not touch the electronic components and connection with bare hands.

The fuse is located on the switch circuit board (fuse type: 250 V, 6.3 AT), spare fuse in the housing upper part.

1. Open boiler control panel and pull all plug connectors off the circuit board (see Ch. 5.4, Steps 1 to 4).

Fig.5-14 Remove the locking screws from the control panel casing Fig.5-15 Changing the fuse

2. Remove the 4 locking screws on the control panel casing using a screwdriver (Fig 5-14). 3. Remove the top of the casing. 4. Replace the fuse (Fig 5-15).

If the fuse immediately blows upon switching on again, there is a short circuit in the electrical system. Have a professional electrician remedy the cause of the short circuit before putting in a new fuse.

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5.7 Wiring diagram

1 Mains switch 26 3-way diverting valve 33 External temperature sensor 2 Common fault indicator lamp 27 4-pin circuit board connector with valve cable 34 Storage tank temperature sensor 4 Capillary tube pressure gauge 28 6-pin circuit board connector with connected 35 8-pin board connector with terminating resistor or 5 Control: Central unit THETA 23R burner cable (voltage supply for automatic firing flue gas temperature sensor (optional) 20 4-pin circuit board connector with switch cable unit and burner fan) 36 16-pin MOLEX plug with cable for inflow and 21 4-pin circuit board connector with fault indicator 29 Modulating gas burner automatic firing unit return flow temperature sensor and blower control lamp cable 30 7-pin circuit board connector for connecting a 37 Flow temperature sensor 22 4-pin mains circuit board connector with clamped mixer motor or mixer circulation pump 38 Return flow temperature sensor mains cable and earthing connection 31 3-pin circuit board connector with communication 39 Burner fan 23 3-pin circuit board connector with pump cable cable 40 Control panel circuit board 24 Heating circulation pump 32 12-pin circuit board connector for connection of 41 Stickers for terminal allocation 25 3-pin circuit board connector for connecting a sensors, BUS and control lines circulation pump Fig.5-16 Wiring drawing (shown in THETA 23R control)

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6.16 StructureGas burner and brief description

Fig.6-1 Gas burner of the ROTEX GasSolarUnit - Front views

1 Burner surface 14/1 Ionisation electrode 2 Fan 14/2 Ionisation cable 3 Safety gas control block 15/1 Ignition electrodes 4 Gas/air compound controller 15/2 Ignition cable 5 Gas solenoid valve (1 x Class B and 1 x Class C) 16 Flue insert 6 Automatic gas firing unit CVBC 17 Burner flange seal (O-ring) 7 Gas connection G ½" female 18 Flame tube seal (flat graphite seal) 8 Venturi nozzle with air connection DN 50 19 Fan flange seal (flat silicon seal) 9 Measurement connection IN - inlet gas pressure 20 Clamp plates Do not loosen! 10 Measurement connection OUT - outlet gas pressure 21 Air suction pressure hose 11 Adjusting screw, gas/air mixture 22 Cover with strain relief for burner cable and locking screw for automatic gas 12 Adjusting screw on gas pressure controller (under cover cap) firing unit 13 Burner flange Fig.6-2 Gas burner of ROTEX GSU - Rear view Fig.6-3 Gas burner of ROTEX GSU - Side view from left

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Controlling the burner output The ROTEX ALPHA 23R and ROTEX THETA 23R controllers constantly determine the required flow temperature (corresponding to the set operating parameters) and pass 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 flow and return flow temperature probes. The determined output is passed to the burner fan as a PWM signal. The burner fan immediately adjusts the gas fan speed and as such the combustion air flow. The gas controller controls the gas volume accordingly.

Gas/air compound control The gas/air compound control (pneumatic compound) ensures that the CO2 flow is maintained at a suitable level for each output and is set by the adjusting screw for the gas/air mix (Fig 6-3, item 11) and by the adjusting screw of the gas pressure controller (Fig 6-3, item 12) if required. The burner immediately responds to each change in the air flow volume through the gas/air compound control with a corresponding change in the gas flow volume. The gas/air compound control (pneumatic compound) consists of a Venturi nozzle with a ring-shaped gas inlet and a gas pressure controller. A vacuum forms in the centre of the Venturi nozzle depending on the volume flow of the combustible air. This causes the gas to be drawn into the centre of the Venturi nozzle, conveyed through the burner fan to the burner surface and mixed in an optimum manner. The gas valve can be adjusted for supply pressures from 5 to 60 mbar (zero pressure controller).

6.2 Unlocking in the event of fault shutdown

Safety function The CVBC automatic gas firing unit starts and monitors the firing program sequence. This is followed by a fault shutdown: – if the starting speed of the burner fan is not reached, – if a flame signal is present during pre-ventilation, – if no flame is produced at the start (fuel release) after 5 sec (safety period) (5 start attempts), – if no flame is able to start, or if a flame fails during operation, or failed program repetition.

Unlocking the burner The fault shutdown of the burner is displayed by "E" and a two-digit fault code on the display of the boiler control panel. •q Unlock the burner by briefly pressing (maximum 5 times/h) on the control panel (Fig 5-1, Pos. 13). •a Unlock the burner by briefly pressing (maximum 5 times/h) on the control panel (Fig 5-2, Pos. 19). • If there are several shutdowns due to faults successively, check the heating system (e.g. flue system, fuel supply).

6.3 Burner setting

DANGER OF EXPLOSION! Escaping gas presents an immediate danger to health and life. Even a few sparks can cause very serious explosions. • Always close the gas stop-cock in the house before working on gas-conducting parts. • If you smell gas, ventilate the room thoroughly. Do not light any open flames or operate any electrical switches. • Only heating specialists authorised and trained by the gas or energy supply company should be allowed to work on gas-conducting parts.

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6.3.1 Setting values

If the ROTEX factory settings are not used for operation, the values from the charts Fig 11-5 to Fig 11-7 in Chapter 11 „Technical data“ apply.

Appliance GSU 320 (F)* GSU 520S (F)*

Setting for Power setting CO2-content O2-content Power setting CO2-content O2-content control in % in % in % in % Gas type Speed in % Load in kW Speed in % Load in measurement ( 0.2%) ( 0.1%) ( 0.2%) ( 0.1%) ± ± kW ± ± Natural gas E/H Full load 100 21.0 9.6 3.8 100 21.0 9.6 3.8 80 16.7 9.5 4.0 80 16.7 9.5 4.0 Basic load 33 6.5 9.2 4.6 33 6.5 9.2 4.6 20 3.7 9.1 4.7 20 3.7 9.1 4.7 Natural gas LL/L Full load 100 21.0 9.5 3.6 100 21.0 9.5 3.6 80 16.7 9.4 4.0 80 16.7 9.4 4.0 Basic load 33 6.5 9.0 4.6 33 6.5 9.0 4.6 20 3.7 8.9 4.7 20 3.7 8.9 4.7 Propane* Full load 100 21.0 11.3 3.7 100 21.0 11.3 3.7 80 16.7 11.2 3.8 80 16.7 11.2 3.8 Basic load 33 6.5 11.1 4.0 33 6.5 11.1 4.0 30 5.9 11.1 4.0 30 5.9 11.1 4.0 Butane* Full load 100 21.0 11.6 3.7 100 21.0 11.6 3.7 80 16.7 11.5 3.8 80 16.7 11.5 3.8 Basic load 33 6.5 11.4 3.9 33 6.5 11.4 3.9 30 5.9 11.4 3.9 30 5.9 11.4 3.9

Appliance GSU 530S (F)* GSU 535 (F)*

Setting for Power setting CO2-content O2-content Power setting CO2-content O2-content control in % in % in % in % Gas type Speed in % Load in kW Speed in % Load in measurement ( 0.2%) ( 0.1%) ( 0.2%) ( 0.1%) ± ± kW ± ± Natural gas E/H Full load 100 31.0 9.6 3.9 100 36.1 9.7 3.6 80 24.8 9.5 4.0 80 28.7 9.6 3.9 Basic load 33 10.2 9.3 4.2 33 11.3 9.2 4.5 20 6.2 9.3 4.3 20 6.5 9.1 4.7 Natural gas LL/L Full load 100 31.0 9.4 3.9 100 36.1 9.5 3.6 80 24.8 9.3 4.0 80 28.7 9.4 3.9 Basic load 33 10.2 9.2 4.2 33 11.3 9.0 4.5 20 6.2 9.2 4.3 20 6.5 8.9 4.7 Propane* Full load 100 31.0 11.3 3.8 100 33.5 11.5 3.5 80 24.7 11.2 3.9 80 27.2 11.4 3.6 Basic load 33 9.8 11.1 4.0 33 12.3 11.1 4.0 30 8.9 11.1 4.0 30 11.3 11.1 4.0 Butane* Full load 100 31.0 11.5 3.8 100 36.1 11.7 3.5 80 24.7 11.5 3.8 80 29.0 11.6 3.6 Basic load 33 9.8 11.5 3.8 33 12.4 11.5 3.8 30 8.9 11.5 3.8 30 11.3 11.5 3.8 Shaded fields: ROTEX factory settings Unshaded fields: Limits Tab. 6-1 Flue setting values and speed limits for various gas types

* Liquid petroleum gas version (F)

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6.3.2 Checking and setting the burner

The gas burner has been factory-set for a certain gas type. The gas type is indicated on the yellow sticker on the burner housing. Check the burner output by using a flue gas analysis device – In chimney sweep mode with maximum (full) load, – In chimney sweep mode with minimum (basic) load. The full load set in the automatic firing unit parameter levels (parameter 02) and the basic load (parameter 04) can be set by means of the chimney sweep key. These settings can be individually adapted within the permitted limits (see Tab. 6-1) to the system requirements.

Auxiliary resources – Flue gas analysis device. – Pressure gauge for measuring gas pressure.

Checking and setting (observe the sequence)

1. Turn the screw in the gas inlet pressure measuring connection (Fig 6-3, item 9) anticlockwise by half a turn and push on the measuring hose of the pressure gauge. 2. Open the gas stop-cock. 3. Measure the gas inlet pressure (rest pressure) and compare with the set value. Leave the measuring instrument connected.

Gas type Rated pressure in mbar Min. inlet pressure in mbar Max. inlet pressure in mbar Natural gas E/H 20.0 17.0 25.0 Natural gas LL/L 20.0 17.0 25.0 Liquid petroleum gas 50.0 42.5 57.5 Tab. 6-2 Nominal gas pressures (valid for Germany) Î If the gas inlet pressure (rest pressure) is outside the set value range: Inform the authorised gas supply company. 4. Open the heating valves. 5. Switch on ROTEX GSU with main switch. 6. Switch on the chimney sweep function for the full load.

If the burner does not start, even with the power and gas supply properly connected and with the flue gas path free, a new burner basic setting must be carried out (see section 6.3.3).

7. Connect the flue gas analysis unit. 8. Check flow pressure. The gas inlet flow pressure must not drop appreciably below the rest pressure minus the pressure drop in the gas connection hose (see Chapter 11 „Technical data“). If the flow pressure is too low, the burner output also drops.

9. If the flue gas measured values no longer change (at the earliest 3 minutes after the start of the burner) measure CO2 and O2 content. Compare the measured values with the specified setting values (see section 6.3.1).

10. If the CO2 concentration is outside ± 0.2 % or the O2 concentration is outside ± 0.1 % of the set target values: Readjust burner using the adjusting screw for the gas/air mixture (Fig 6-3, Pos. 11) : ↓ ↑. – Turn to left (in the anticlockwise direction)Î more gas: O2 , CO2 ↑ ↓. – Turn to right (in the clockwise direction) Î less gas: O2 , CO2 11. Set the chimney sweep function for minimum load.

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12. If the flue gas measured values no longer change (at the earliest 2 minutes after the change in output) measure CO2 content and O2 content. Compare the measured values with the specified setting values (see section 6.3.1).

13. If the CO2 concentration is outside ± 0.2 % or the O2 concentration is outside ± 0.1 % of the set target values or the burner whistles: Readjust the burner using the adjusting screw for the gas pressure controller (Fig 6-3, Pos. 12) (see section 6.3.6): ↑ ↓. – Turn to left (in the anticlockwise direction)Î reduced gas outlet pressure: O2 , CO2 ↓ ↑. – Turn to right (in the clockwise direction) Î more gas outlet pressure: O2 , CO2 14. Set the chimney sweep function for maximum load and recheck the combustion values. – The values are adjusted according to the specifications (cp. Step 8) Î Adjustment procedure is complete. – The values are not adjusted according to the specifications Î Repeat Steps 8-14. 15. Enter all changes in the setting output values on the setting sticker on the control panel cover.

6.3.3 Carrying out the basic settings at the burner. If the burner does not start, even with the power and gas supply properly connected and with the flue gas route open, a new basic setting must be carried out for the burner output.

Basic setting • Screw the adjusting screw for the gas/air mixture (Fig 6-3, item 11) in, in a clockwise direction, up to the stop (do not tighten). • Open adjusting screw for gas/air mixture in accordance with Tab. 6-3 in an anticlockwise direction: Appliance GSU 320 GSU 520S GSU 530S GSU 535 Number of rotations 4 4 15 8 Tab. 6-3 Number of rotations for adjusting the gas/air mixture • Restart the burner. • If the burner does not start, open the adjusting screw for gas/air mixture by 2 more turns and restart the burner.

After carrying out the basic setting for the burner, the burner must be checked and fine setting should be carried out. (see section 6.3.2).

6.3.4 Resetting the gas type The burner is factory-set for the gas type given on the setting sticker located on the control panel cover.

Resetting from natural gas E/H to natural gas LL/L • Open adjusting screw for gas/air mixture (Fig 6-3, Pos. 11) by 3 rotations in an anticlockwise direction. • Set burner (see section 6.3.2). • Enter the gas type changeover and the set thermal load on the setting sticker located on the control panel cover and confirm with a signature. • Place the device sticker for LL/L gas setting (in scope of supply) on the fan housing of the burner.

Resetting from Liquid petroleum gas to natural gas • Unscrew the Venturi nozzle (Fig 6-1, item 8) from the burner fan and also remove the 3 screws holding the Venturi nozzle onto the safety gas control block (Fig 6-1, Pos. 3). • Remove the brass screen between the safety gas control block and the Venturi nozzle. • Using the 3 screws, screw the Venturi nozzle back on the safety gas control block and then onto the burner fan. • Start and set the burner (see section 6.3.2), adjust the output limits if necessary (see Tab. 6-2). • Enter the gas type changeover and the set thermal load on the setting sticker located on the control panel cover and confirm with a signature. • Place the device stickers for natural gas H/E or natural gas LL/L (request from ROTEX) on the fan housing of the burner.

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6.3.5 Setting the output limits

The burner output is limited by the parameter input on the boiler control panel. The output values are entered relative to the maximum speed of the burner fan (in %). Other information for parameter input is given in the "ROTEX Regulation" documentation. It is included with the electronic control panel that is to be purchased separately.

Limiting the maximum burner output The limiting of the maximum burner output would be advisable, for example, in the event of better sourcing charges for lower installed outputs. • Enter the access code for the heating engineering and request the parameter level "Automatic firing unit". • Enter the maximum speed of the burner fan for the heating mode (parameter 2). • Enter the maximum speed of the burner fan for the hot water charging mode (parameter 3). • Enter the output modification on the setting sticker under the type plate and confirm with a signature.

Limiting the minimum burner output Raising the minimum burner output would be advisable, for example, if the flue gas side resistance were relatively high and the flame became unstable with a minimum load, or if the partial load demands were not fulfilled when designing the flue gas system. • Enter the access code for the heating engineering and request the parameter level "Automatic firing unit". • Enter the minimum speed for the burner fan (parameter 4). • Enter the output modification on the setting sticker under the type plate and confirm with a signature.

6.3.6 Setting the gas pressure controller The gas valves are factory-set. As a rule, no changes should be made to the gas pressure controller. The adjusting screw is hidden under a cover. If the set value at base load deviates excessively from the target value and the burner tends to whistle: • Adjust the adjusting screw for the gas pressure controller (Fig 6-3, item 12) in small steps (maximum half a turn per adjustment step). • Wait for at least 2 minutes after each adjustment step. • Check change in the combustion quality with the help of the flue gas analysis device.

If the burner produces noises in the lowest output setting (basic load) (weather-dependent!), set the minimum output to a higher value.

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6.3.7 Setting ignition and Ionisation electrodes

CAUTION! Ignition electrodes can break if deformed in the cold state. • Dismantle the burner before adjusting the electrodes and make the electrodes glow by using a blow-lamp.

The electrodes are factory-set. For adjusting: see Fig 6-4.

Fig.6-4 Adjustment of the ignition and ionisation electrodes

6.4 Dismantling the burner

WARNING! Live parts can cause an electric shock on contact and cause life-threatening burns and injuries. • Switch off the heating main switch before dismantling the burner and secure it from being unintentionally switched on.

WARNING! Danger of burning from hot surfaces (flame tube). • Let the burner cool down sufficiently before dismantling. • Wear protective gloves.

The burner works, as a rule, almost without any wear and residue. It may be necessary to dismantle the burner for some cleaning and servicing jobs or if there is damage in the combustion chamber area.

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Burner dismantling • Isolate the gas supply. • Disconnect ROTEX GSU from the power supply (fuse, main switch switched off) and secure against being unintentionally restarted. • Pull the air supply hose off the burner and rotate sideways. • Pull the mains plug for the fan and the plug for the fan control out. • Unscrew the cover with strain relief from the automatic firing unit and pull all 3 plugs out (Fig 6-6).

6 Automatic firing unit CVBC 22 Cover with strain relief on the automatic firing unit 23 Supply air hose 24 Mains plug for fan 25 Plug for fan control Fig.6-5 Burner Fig.6-6 Unscrew CVBC cover, remove connection plug

• Remove two fixing nuts M6 on burner flange (Fig 6-7). • Lift burner from burner chamber (Fig 6-8).

Fig.6-7 Unscrew the burner flange Fig.6-8 Remove the burner

WARNING! Incorrect assembly and dismantling of the burner can cause the gas to escape. • Never loosen both clamping plates on the burner flange (sealed with sealing paint).

Burner installation • Insert the burner into the combustion chamber, attach the burner flange securely with the two fixing bolts. • Restore all electrical plug connections. • Connect the air supply hose to the burner. • Check the gas line for leakage. • Start the burner. Check function and setting (see section 6.3.2).

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7.17 ImportantHydraulic connection notes on the hydraulic connection

To avoid damage to persons and objects, please observe the instructions for the hydraulic system connection of the ROTEX GasSolarUnit.

Protection against scalding When operating the ROTEX GasSolarUnit, particularly, for solar energy utilisation, the storage temperature of 60 °C can be exceeded. Therefore, during the installation of the plant, install a scalding guard (hot water mixer, e.g. VTA32 15 60 16).

Prevention of emission of exhaust gas To prevent the emission of exhaust gas, before commissioning the ROTEX GasSolarUnit, the storage tank container must be filled to the overflow mark.

Protection against corrosion In some regions, aggressive drinking water is supplied by public utility companies that itself can cause damage through corrosion in high grade special steels. Check with your water supply works whether corrosion problems can occur when using hot water storage made of special steel in your area. If needed, appropriate water treatment is required.

7.2 Storage tank container

Structure – Double wall full plastic construction (corrosion-free). – Space between inner and outer container filled with foam for insulation against high heat (low surface losses). –Outer skin 3-4mm thick (impact strength).

Procedure The pressure-less storage water serves as water storage medium. Useful heat is supplied and dissipated through the fully submerged spiral heat exchanger made of special steel corrugated pipe (1.4404). The hot water zone in the storage tank container acts as combination of heat accumulator and flow heater (see Fig 2-2 and Fig 2-3). The cold water flowing back after hot water removal is first guided to the bottom of the storage tank container and provides maximum cooling of the storage area. The hot water zone is heated with the gas condensing boiler if necessary. The heat exchanger for storage charge (SL-WT) flows through from top to bottom. This increases the efficiency and the yield of the solar system. On the way up, the drinking water continuously collects the storage water heat. The direction of flow in the reverse current principle and the spiral heat exchanger shape causes a distinctive temperature layering in the storage. As high temperatures can be maintained in the upper area for a very long time, a high hot water capacity is achieved in long draw-off processes. – In the GSU 520S and GSU 530S models, the SL-WT ends approx. 40 cm above the container floor. Only the hot water zone above it is heated by the boiler. The container volume below it is heated only in solar applications. – In the GSU320 and GSU 535 models, the SL-WT passes up to the container floor. The total storage volume is heated by the boiler (higher standby hot water capacity).

Water hygiene The separation of pressure-less storage water and hot water flowing into the corrugated pipe heat exchanger secures the optimum water hygiene of the ROTEX GSU: – Low flow or zones not heated through on the hot water side are excluded. – Deposits of sludge, rust or other sediments, which can occur in high volume containers are impossible. – Water fed in first is also removed first (First-in-first-out principle).

Storage water heating During the first commissioning, the storage tank container is filled once with pressure-less storage water that is no longer exchanged later. The storage water can be heated in two different ways: – by the integrated gas condensing boiler, – by an additional solar system directly connected to the pressure-less area (ROTEX Solaris System), – by another heat source directly connected to the pressure-less area (e.g. hot water heat pump).

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Maintenance Heat and pressure expansion and the high flow speeds in the heat exchangers release scale deposits and wash them away, scale does not precipitate. On the storage water side, dissolved scale can only deposit once in the water. No scale incrustations are formed due to the smooth surface of the special steel corrugated pipe heat exchanger (no deterioration of the heat exchanger capacity during the operating period). Corrosion protection devices (e.g. sacrificial anodes) are not needed. Maintenance tasks, such as replacement of protective anodes or cleaning the storage tanks are thus not required. During the annual boiler inspection, just the level is checked and, if needed, water is added (see section 8.2.2).

7.3 Hydraulic system connection

7.3.1 Short names in the connection schemes

Short name Meaning Remark Order No. GSU 520S 15 71 10 GSU 520S F 15 71 20 GSUS GasSolarUnit with solar heating support GSU 530S 15 71 21 GSU 530S F 15 71 23 GSU 320 15 70 25 GSU 320 F 15 70 26 GSU GasSolarUnit without solar heating support GSU 535 15 71 40 GSU 535 F 15 71 45 1Cold water 2Hot water 3 Heating flow 4 Heating return flow PK Boiler circuit pump Included in the GSU scope of delivery. UV1 3-way diverting valve Included in the GSU scope of delivery. tWW Storage tank temperature sensor Included in the GSU scope of delivery. tV Heating flow temperature probe Included in the GSU scope of delivery. tR Heating return flow temperature sensor Included in the GSU scope of delivery. tAG Flue gas temperature probe Accessories 15 70 52 tAU External temperature sensor Included in the GSU scope of delivery. SV Safety pressure relief valve Included in the GSU scope of delivery. 5 Mixer circuit Optional AMK1 Mixer group Accessories 15 60 44 PMi Mixer circuit pump Included in the AMK1 scope of delivery. Mi 3-way-mixer with drive motor Included in the AMK1 scope of delivery. tMi Mixer circuit inflow temperature sensor Accessories 15 60 62 HEM1 Heating circuit extension module Accessories 15 60 61 TSF Storage tank temperature sensor Accessories 15 60 63 6 Circulation circuit Optional PZ Circulation pump on site 7 Check valve, return valve on site 7a Gravity brake (for cold/hot water connection) Accessories 16 50 70 8 Solar circuit Optional SK High capacity flat collector Accessories 15 43 00 RPS3 Regulation and pump unit Solaris Accessories 15 41 06 PS1 Process pump Included in the RPS3 scope of delivery. PS2 Booster pump Included in the RPS3 scope of delivery. Tab. 7-1 Short names in hydraulic drawings (1)

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Short name Meaning Remark Order No. tS, R Solaris return temperature probe Included in the RPS3 scope of delivery. tS Solaris storage temperature probe Included in the RPS3 scope of delivery. tS, V Solaris flow temperature probe Included in the RPS3 scope of delivery. Delivered with collector connection package, Connect t Solaris collector temperature probe K AB. FLS Flow sensor Accessories 15 41 07 VS Scalding protection VTA 32 Accessories 15 60 15 ÜV Overflow valve on site UV2 3-way diverting valve Accessories 15 60 34 WEx External heat generator (e.g. Pellet wood boiler, other solid matter boiler, on site heat pump) SC 538/0/0 Sanicube as buffer storage for external heat exchanger Accessories 15 50 15 PWEx Pump for external heat exchanger circuit on site TMV Thermostatic 3-way valve for return temperature increase on site DTR Difference temperature regulation on site t1 Heating return flow temperature sensor suitable for DTR t2 Buffer storage temperature probe suitable for DTR Separation of standard connection – PK must be removed from the device and on site reconnected outside the device Tab. 7-2 Short names in hydraulic drawings (2)

7.3.2 ROTEX GasSolarUnit with solar heating support

Fig.7-1 Standard connection layout ROTEX GasSolarUnit with solar heating support

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ROTEX GasSolarUnit without solar heating support

Fig.7-2 Standard connection layout ROTEX GasSolarUnit without solar heating support

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Wooden boiler integration in ROTEX GasSolarUnit Fig.7-3 Rotex GasSolarUnit integration in boiler Wooden

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8.18 GeneralInspection and overview maintenance of inspection and maintenance

Regular inspection and maintenance of the heating system reduces energy consumption and ensures a long life and smooth operation.

Have the inspection and maintenance carried out by authorised and trained heating engineers once a year and, if possible, before the heating period. This will avoid malfunctions during the heating period. ROTEX recommends an inspection and maintenance contract to ensure regular inspection and maintenance.

Tests during the annual inspection: – General condition of the heating system, visual inspection of connections and conduits. – Condensate discharge, flue gas temperature and if needed, optional flue gas temperature probe. – Burner operation and burner settings.

Maintenance work to be carried out annually: – Cleaning of the burner components, the combustion chamber and the heating surfaces. – Cleaning of the storage container and the silencer hood. – Replacement of the wear parts (if required).

8.2 Inspection and maintenance tasks

WARNING! Live parts can cause an electric shock on contact and cause life-threatening burns and injuries. • Before beginning maintenance work, disconnect the ROTEX GSU from the power supply (switch off fuse, main switch) and secure against unintentional restart.

WARNING! Danger of burning on hot surfaces. • Let the burner cool down for a reasonably long time before maintenance and inspection work. • Wear protective gloves.

Remove the silencer hood. For inspection and maintenance, it is necessary to remove the noise insulation hood attached on top on the storage tank container.

1 Remove the fixing screws. 2 Tilt the silencer hood. 3 Lift the silencer hood out to the front.

Fig.8-1 Remove the silencer hood.

Cleaning the noise insulation hood and storage tank container • Clean the easy-care plastic only using soft cloths and a mild cleaning agent. • Do not use cleaner with aggressive solvents, damage to KS surface.

54 FA ROTEX GSU - 09/2007 8 x Inspection and maintenance

8.2.1 Checking the connections and conduits

WARNING! Work carried out incorrectly on power or gas-conducting components can cause death and serious physical harm and adversely affect the operation of the GasSolarUnit. • Only heating engineers authorised and recognised by the gas or energy supply company should replace damaged power or gas-conducting components in the ROTEX GSU.

• Check all gas and water-conducting components and connections for leakage and damage. If damaged, determine the cause and replace the damaged parts. • Check all components of the flue gas system for leakage and damage. Recondition the damaged parts or replace them. • Check all electrical components, connections and conduits. Recondition the damaged parts.

8.2.2 Checking and cleaning the condensate drain. The connection and leakage line of the condensate drain must be free from impurities.

• If Solaris system is connected and in operation, switch it off and empty collectors. • Open condensate drain (connection and drain pipe). • Check that the condensate drain is free from blockages and clean if necessary. • Unscrew overflow hose. • Visual inspection of container filling level (water level at overflow mark). • If needed, correct filling level and determine causes for defective filling level and shut off. • Check overflow hose and drainage route for leaks, free flow and slopes. Fig.8-2 Check condensation flow

The condensate is slightly acid. It is directed to the pressure-less area of the storage. During normal plant operation this ensures that the storage container is always full. A long term neutraliser in the container ensures that only pH-neutral liquid flows out of the container. Any precipitants remain in the pressure-less area of the container.

8.2.3 Checking and cleaning the burner

DANGER OF EXPLOSION! Escaping gas is a serious health and life hazard. Even a few sparks can cause very serious explosions. • Never release the two clamping plates on the burner flange (sealed with lacquer). • When reinstalling the burner, always mount the fixing protective conductor cable under the fixing nut. • Only heating specialists authorised and trained by the gas or energy supply company should be allowed to work on gas-conducting parts.

As a rule, the burner does not wear. If impurities or unsatisfactory combustion values are encountered, the burner must be removed (see Ch. 6.4), cleaned and reset (see Ch. 6.3) if necessary.

FA ROTEX GSU - 09/2007 55 8 x Inspection and maintenance

Cleaning the combustion chamber

WARNING! Live parts can cause an electric shock on contact and cause life-threatening burns and injuries. • Before beginning work on the burner, disconnect ROTEX GSU from the power supply (switch off fuse, main switch) and secure against unintentional restart.

WARNING! Danger of burning on hot surfaces. • Let the burner cool down for a reasonably long time before maintenance and inspection work. • Wear protective gloves.

• Remove burner (see Ch. 6.4) • Rinse the flue gas path with clean water (hose or steam jet in the open combustion chamber).

Checking the burner Burner inspection includes visual inspection of the burner condition as well as flue gas measurements.

For detailed information on checking and setting the burner, see Ch.6.3 For detailed information on installing and removing the burner see Ch. 6.4

The scope of inspection includes: • Clean the burner surface (cloth, plastic brush). • Visual inspection of the ignition and ionisation electrodes for damage and electrode gap (see section 6.3.7). 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.

• If necessary, replace faulty parts. • Mount burner in combustion chamber. • Check the gas line for leakage. • Put the burner into operation and let it run for about 5 minutes in the chimney sweep position. • Check combustion values: – Flue gas temperature at measuring sockets of the flue gas duct. (Target value < 120 °C), –O2 or CO2 content (see section 6.3.1), – CO content (target value < 50 ppm). Î If the combustion values do not fall within the target range, the burner must be adjusted accordingly (see Ch. 6.3)

We recommend completing the service log provided with all the measured values and the tasks performed with dates and signature.

56 FA ROTEX GSU - 09/2007 9 x Faults and malfunctions

9.19 TroubleshootingFaults and malfunctions

The electronics of the ROTEX GasSolarUnit detects errors and displays them: – an error detected by the boiler control ROTEX THETA 23R or ROTEX ALPHA 23R through an error code in the display, – 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.

Detailed information on the control and boiler control panel as well as the operating mode and parameter settings can be found in the "ROTEX Control" documentation. It is included with the electronic control panel that is to be delivered separately.

Solving malfunctions • Detecting and solving the cause of the malfunction. • Interlocking fault: Lift the interlocking by briefly pressing the manual button on the boiler control panel (max. 5 times per hour). • Non-interlocking malfunctions are indicated as long as failure conditions are present. If the cause has been eliminated, the unit continues to work normally.

9.2 Malfunctions

Malfunctions Possible cause Possible solution Heating system not No mains voltage • Switch on boiler main switch functioning (main switch • Switch on heating room main switch not illuminated, no • Switch on house connection fuse display) • Replace fuse on boiler control panel

Heating does not heat up Central heating standby switched off (e.g. timer is in • Check operating setting economy phase, outside temperature too high) • Check demand parameters

Heating does not heat up Heating characteristic too low • Raise parameter value enough

Hot water does not heat Storage charging standby switched off (e.g. timer is in • Check operating setting up economy phase) • Check demand parameters

Hot water does not heat Storage tank charging temperature too low • Raise hot water target temperature up enough Tapping rate too high • Reduce the draw-off rate, limit throughput

Burner output too low • See malfunction "Max. burner output too low"

Burner does not start Interlocking failure • Establish cause of malfunction and eliminate it • Lift the interlocking by briefly pressing the manual button (max. 5 times per hour).

Burner fan not running No mains voltage on burner fan • Insert the 3-pin plug on the fan until it clicks in position despite burner demand • Insert the 5-pin plug on the fan until it clicks in position • Check the voltage at the terminals of the plug • Check the plug in the control panel and on the automatic firing unit and insert it correctly

Fan motor faulty • Replace burner fan

FA ROTEX GSU - 09/2007 57 9 x Faults and malfunctions

Malfunctions Possible cause Possible solution No ignition Ignition electrodes dirty, faulty or incorrectly set • Clean ignition electrodes • Set ignition electrodes • Replace burnt out or unadjustable ignition electrodes • Replace ignition electrodes which have faulty insulation

Ignition cable burnt • 1. Establish cause and eliminate it • 2. Replace ignition cable

Automatic firing unit faulty • Replace automatic firing unit

Burner fan not starting No mains voltage on burner • Check the plug in the control panel and on the automatic firing despite burner demand unit and insert it correctly • Replace cable

Flame monitoring switches off • Adjust ionisation electrode • Clean the oxidised electrode surfaces of the ionisation electrode (with fine emery paper) • Replace worn ionisation electrodes

No gas pressure • Check gas connection

Air in the gas line • Vent gas line

Gas valve not opening • Check plug connection between gas valve and automatic firing unit and insert correctly • Realign connecting pins of the plug connection • Check gas valve (vacuum at outlet pressure measuring socket during pre-ventilation, zero pressure during the ignition) • Replace gas valve • Replace automatic firing unit

No ignition • See "No ignition" failure

Loud operating noises Wrong burner setting • Correct the burner setting

Bearing damage on burner fan • Reduce maximum output • Replace burner fan

Maximum burner output Incorrect setting parameters • Adjust output parameters too low Air/flue gas resistance too high • Check ducts for dirt. • Use ducts with larger cross section for supply air or flue gas if necessary Tab. 9-1 Possible faults on the ROTEX GSU

58 FA ROTEX GSU - 09/2007 9 x Faults and malfunctions

9.3 Fault code

Fault code Component/name Fault 10-0 Outside temperature sensor Interruption 10-1 Short circuit 12-0 Inflow temperature sensor, mixer circuit Interruption, mixer circuit pump is switched off, mixer motor is switched de-energised 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 14-7 Modem contact Fault signal 15-7 Burner blockage contact Fault signal 16-0 Flue gas temperature probe (if installed) Short circuit 16-1 Interruption 16-7 Fault signal 17-0 Return flow temperature sensor Interruption 17-1 Short circuit 30-2 Burner No switching off 30-3 No switching on 33-5 Flue gas temperature Overshooting 70-0 Address Address collision of the BUS subscribers 70-1 Activity No T2B signal, check BUS cable and connections 70-6 Communication between THETA control Interruption and CVBC automatic firing unit 71-0 EEPROM Internal fault 71-1 EEPROM faulty Internal fault Tab. 9-2 Error codes for the ROTEX GSU for control THETA 23R (detectable by central unit)

Fault code Component/name Fault 10-0 Outer temperature probe interruption The resistance of the outside temperature probe is high or the computed value is over 130 °C. The plant continues working with constant outside temperature value of 0 °C until measured values are in the correct range. 10-1 Outside temperature probe short-circuit The resistance of the outside temperature probe is zero or the computed value is below -40 °C. The plant continues working with a constant outside temperature value of 0 °C until measured values are in the correct range. 11-0 Flow temperature probe interruption The resistance of the inflow temperature probe is high or the computed value is over 130 °C. The plant goes out of operation. After measured values are available for minimum 1 s, the plant goes into operation again. 11-1 Flow temperature probe short-circuit The resistance of the inflow temperature probe is zero or the computed value is below -40 °C. The plant goes out of operation. Control functions continue. After measured values are available for minimum 1 s, the plant goes into operation again. 12-0 Mixer circuit temperature probe inter- The resistance of the mixer circuit temperature probe is high resistance or the computed value is ruption over 130 °C. The plant goes out of operation. After measured values are available for minimum 1 s, the plant goes into operation again.

FA ROTEX GSU - 09/2007 59 9 x Faults and malfunctions

Fault code Component/name Fault 12-1 Mixer circuit temperature probe short- The resistance of the mixer circuit temperature sensor is zero, or the value calculated is circuit below -40 °C. The plant goes out of operation. After measured values are available for minimum 1 s, the plant goes into operation again. 13-0 Storage temperature probe interruption The resistance of the storage temperature probe is high or the computed value is over 120 °C. (if probe registered) At intervals of 30 min, a hot water requirement is generated with a fixed flow temperature of 40 °C. This is limited to 10 min. After measured values are available for minimum 1 s, the plant goes into normal operation again. 13-1 Storage temperature probe short-circuit The resistance of the storage tank temperature sensor is zero, or the value calculated is (if probe registered) below -40 °C. At intervals of 30 min, a hot water requirement is generated with a fixed flow temperature of 40 °C. This is limited to 10 min. After measured values are available for minimum 1 s, the plant goes into normal operation again. 16-0 Flue gas temperature probe interruption Measured value > 150 °C (if registered through parameters [1]) The plant goes out of operation. After measured values are available for minimum 1 s, the plant goes into operation again. 16-1 Flue gas temperature probe short-circuit Measured value < -10 °C (if registered through parameters [1]) The plant goes out of operation. After measured values are available for minimum 1 s, the plant goes into operation again. 30-3 Burner fault: No switching on There is a burner request. However, after 20 min, no burner counter signal (oil) or no burner flame signal (gas) could be detected. The indicator issues a warning that can be deleted with "RESET". The control functions work normally again. 30-9 Burner fault Gas The heating automatic unit reports a fault via the bus. The burner can be reset by pushing the button. The control functions work normally again. 33-5 Flue gas temperature probe: Warning Measured value > Parameter [23] temperature reached The indicator issues a warning that can be deleted with "RESET". The plant continues to work normally. 33-8 Flue gas temperature probe: Shutoff Measured value ≥ Parameter [22] temperature reached The burner is put out of operation for 10 min. Then, there is a release up to the next temperature excess [22]. The plant works normal after the cooling phase. 70-1 Communication fault ALPHA 23R/CVBC The system is stopped until communication is restored or the fault is rectified. The display can be deleted via "RESET". 99-9 Under voltage The supply voltage drops below 190 V for minimum 1 s. The processor secures all data and goes into sleep mode. All relay contacts drop out. If the supply voltage is over 195 V again for minimum 5 s, restart is initiated. uuuu Interruption of a probe nnnn Short-circuit of a probe Tab. 9-3 Error codes of ROTEX GSU for the control ALPHA 23R (detected through central unit)

60 FA ROTEX GSU - 09/2007 9 x Faults and malfunctions

Fault code Component/name Fault E 01 CVBC automatic firing unit No flame detection during the 5 possible start attempts E 02 interlocking fault Wrong flame signal ionisation current outside the permitted range E 03 STB failure: Flow temperature too high E 05 No speed signal from burner fan within 10 sec E 08 Fault in the flame monitoring routine E 10 EEPROM communication error E 11 CVBC automatic firing unit Sensor equalisation procedure for electronic STB function faulty or return flow temperature higher interlocking fault by 3 K than flow temperature for more than 3 min. E 19 Microprocessor H - I/O error E 20 Microprocessor L - I/O error E 21 Microprocessor H - A/D-converter error E 22 Microprocessor L - A/D-converter error E 25 Internal fault E 26 5 times flame stalling within 4 minutes B 09 CVBC automatic firing unit Error in gas valve control routine B 30 temporary failure Inflow sensor short circuit B 31 Inflow sensor interruption B 34 Low voltage (< 185 V) B 35 Fluctuating mains frequency (more than ±2 Hz) B 37 Internal fault B 43 Return flow sensor short circuit B 44 Return flow sensor interruption B 99 Internal communication between control and CVBC automatic firing unit interrupted. Tab. 9-4 Error codes of ROTEX GSU for the control THETA 23R (detected through heating unit)

9.4 Emergency operation

Note the following for emergency operation if the valve drive is faulty: • Press the unlocking key (Fig 3-10, item. 5.2) and rotate the motor head of the valve drive (Fig 3-10, item 5.1) 1/4 turn to the left and remove. Î The 3-way switch valve is set to the "Heating" position.

Note the following for the temporary manual parallel operation of the heating circuit and the hot water storage tank: • Pull the 6-pin plug off the valve drive. Bring changeover valve to central position with hand lever (Fig 3-10, Pos. 5.3) (only possible if the valve drive is previously in the "Heating" position before).

q In the event of failure or incorrect settings of the electronic control, an emergency heating operation can be maintained. • Press the manual button on the control for about 5 sec. Î The indication "Manual operation" appears on the display. • Adjust the desired temperature with the rotary switch (setting range 5 - 80 °C). In manual operation, the 3-way switch valve is in the "Storage tank charging" position first. On reaching the maximum adjustable storage tank temperature, the 3-way switch valve switches over to the "Heating" position.

FA ROTEX GSU - 09/2007 61 10 x Decommissioning

10.110 TemporaryDecommissioning 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. • If the heating system is not drained, the gas and power supplies must be maintained and the main switch must remain switched on.

If no heat and no hot water supply is needed for a long time, the ROTEX GasSolarUnit can be shut down temporarily. However, ROTEX recommends changing the system to standby mode (see documentation "ROTEX regulation") and disabling the heating and hot water supply. The heating system is then protected from frost. The pumps and valve protection functions are active. If it is not possible to guarantee the gas and power supply when there is danger of frost, then: – the ROTEX GSU must be drained, – suitable antifreeze measures must be adopted for the connected heating system and hot water storage tank (e.g. draining). If there is danger of frost in case of non-secured gas and power supply only for a few days, due to the excellent heat insulation, emptying the ROTEX GSU can be dispensed with if the storage temperature is checked regularly and does not fall below + 3 °C. However, there is no antifreeze protection for the connected heat distribution system when using this process!

Draining the storage tank container • Switch off the main switch and secure against restarting. • Close gas stop-cock. • Connect hose with connection from the accessory set (only this opens the foot valve automatically) to the solar return. In the connected Solaris system, use KFE cock on Solaris return. • Drain water from container.

Draining heating circuit and drinking water heat exchanger • Switch off the main switch and secure against restarting. • Close gas stop-cock. • Disconnect heating inflow and return flow as well as cold water supply and hot water drain. • Connect drain hoses in hoses in such a way that the hose outlet is just above floor level. • Allow heat exchanger to empty on the siphoning principle.

10.2 Final decommissioning and disposal

For final shutdown of the ROTEX GSU • de-commisioning must be carried out. (see Chapter 10.1), • disconnect it from all electrical, gas and water connections, • dispose of it in a professional manner.

Recommendations for disposal The ROTEX GSU is designed to be environmental-friendly. During the disposal process, the only waste accrued is that which can be used for material or thermal recycling. The materials used that are suitable for material recycling can be sorted into different specific types.

Through the environmentally-friendly design of the ROTEX GSU, ROTEX has complied with the standards for environmentally-friendly disposal. Proper disposal in compliance with the respective national stipulations of the country of use is the responsibility of the owner.

62 FA ROTEX GSU - 09/2007 11 x Technical Data

11 Technical data Basic data Type (1)* GSU 320 GSU 520S GSU 530S GSU 535 Parameter Unit Total storage capacity Litres 300 500 500 500 Empty weight (11)* kg 86 124 128 128 Total full weight kg 386 624 628 628 Dimensions (L x B x H) cm 59.5 x 61.5 x 159 79 x 79 x 181 79 x 79 x 181 79 x 79 x 181 Maximum permissible storage water temperature °C 85 85 85 85 Stand-by heating power kWh/24 h 2.4 1.8 1.8 1.8

Max. operating pressure, drinking water PMW (14)* bar6666 Special steel Special steel Special steel Special steel Drinking water heat exchanger material 1.4404 1.4404 1.4404 1.4404 Drinking water heating Drinking water capacity Litres 19.0 24.5 24.5 24.5 Drinking water heat exchanger surface m2 5.5 5.5 5.5 5.5 Average specific heat capacity W/K 1820 2470 2470 2470 Storage tank charging heat exchanger (stainless steel) Water capacity heat exchanger Litres 10.0 10.4 10.4 19.5 Heat exchanger surface area m2 2.1 2.3 2.3 4.3 Average specific heat capacity W/K 910 1040 1040 1950 Solar heating support (stainless steel) Heat exchanger surface area m2 — 0.43 0.43 — Average specific heat capacity W/K — 200 200 — Pipe connections Cold and hot water Inch 1" MT 1" MT 1" MT 1" MT Heating flow pipe and return pipe with ball valve) Inch 1" FT 1" FT 1" FT 1" FT Tab. 11-1 Basic data of ROTEX GasSolarUnit

Type (1)* GSU 320 GSU 520S GSU 530S GSU 535 Parameter Unit

Efficiency characteristic NL according to 2.0 2.1 2.2 4.4 DIN 47081) D value (specif. water flow) according to EN 6252) (15)* l/min27303139

Continuous rating QD according to DIN 4708 kW 20 20 30 35 Continuous output1) l/h 440 615 630 860 Hot water quantity without reheating with Litres 200 220 220 412 15 l/min draw-off rate (TKW = 10°C / TWW = 40°C / TSP = 60°C) Hot water quantity when reheating at nominal Litres 360 500 1180 unlimited output and with 15 l/min draw-off rate (TKW = 10°C / TWW = 40°C / TSP = 60°C) Short-term water quantity in 10 min3) Litres 200 210 215 310 Tab. 11-2 Heat output data of ROTEX GasSolarUnit

1) Recharging with nominal output, flow temp. TV=80 °C, storage tank starting temp. TSP=65 °C, cold water temp. TKW=10 °C, hot water temp. TWW =45 °C. 2) The specific water flow according to EN 625 is the drinking water flow with an average temperature increase of 30 K that the ROTEX GSU can deliver for two consecutive draw-offs each lasting 10 minutes assuming a charging temp. of 65 °C. In this case a 20 minute waiting time between draw-offs is assumed in accordance with the standards. The ROTEX GSU also achieves this value after shorter waiting times. 3) Recharging with nominal output, storage tank starting temp. TSP=60 °C, cold water temp. TKW=10 °C, hot water temp. TWW=40 °C.

* Item number see Fig 11-1

FA ROTEX GSU - 09/2007 63 11 x Technical Data

Type (1)* GSU 320 GSU 520S GSU 530S GSU 535 Parameter Unit CVBC Honeywell automatic firing unit S4965 V 1059 ROTEX Honeywell gas valve VK 4115 V2 Burner fan G1G118/NRG118 G1G126 RG148 Nominal output P (6)* kW 3.7-20.0 3.7-20.0 6.5-30.0 8.0-35.0 Rated thermal load Q (5)* kW 3.7-21.0 3.7-21.0 6.6-30.9 8.5-36.1 Electrical power consumption (including heating (9)* w < 114 < 114 < 135 < 148 circulation pump)

Device type (2)* B23, C13x, C33x, C43x, C53x, C63x, C83x Product ID (CE number) (3)* CE-0085 BM 0065 NOx class (4)* 5 Voltage supply (8)* 230 V~, 50 Hz Protection type (10)* IP 20 Water content Litres 2.0 3.6 Max. permitted operating pressure: (12)* bar 3.0 Max. permissible operating temperature (13)* °C 85 Max. boiler efficiency % 110 Tab. 11-3 Heat generator characteristic data

Gas type, connection pressures Appliance category Nominal connection pressure in mbar Country of destination Liquefied petroleum Liquefied petroleum Natural gas Natural gas gas gas

DE I 2 ELL I 3 B/P 20 50

AT, CH I 2 H I 3 B/P 20 50

DK, FI, NO, SE I 2 H I 3 B/P 20 28-30/30

GB, GR, IE, IT I 2 H I 3+ 20 28-30/37

CH, ES, PT I 2 H I 3+ 20 28-30/37

NL I 2 L I 3 B/P 25 28-30/30

LU I 2 E I 3 B/P 20 50

FR I 2 Esi I 3 P 20/25 37

BE I 2 E(S)B I 3 P 20/25 37

PL I 2 E I 3 B/P 20 37

HU I 2 H I 3 B/P 25 30 Tab. 11-4 Countries of operation, appliance categories and corresponding gas connection pressures (7)*

Gas type Rated pressure in mbar Min. inlet pressure in mbar Max. inlet pressure in mbar Natural gas E/H 20.0 17.0 25.0 Natural gas LL 20.0 17.0 25.0 Liquid petroleum gas 50.0 42.5 57.5

Tab. 11-5 Permitted gas connection pressure

* Item number see Fig 11-1

64 FA ROTEX GSU - 09/2007 11 x Technical Data

Integrated connection group GSU GSU 320/GSU 520S GSU 530S/GSU 535 Heating circulation pump Grundfos UPSO 15-50 CIL 2 Alphaplus 15-60 CIL 2 Voltage 230 V, 50 Hz Maximum power consumption 60 W 75 W Capacity 2.5 µF Protection type IP 44 Permitted overpressure 3 bar Maximum pumping height 5.0 m 6.2 m 3-way diverting valve Voltage 230 V, 50 Hz Maximum power consumption 4.3 W Protection type IP 40 Changeover time 6 sec. Tab. 11-6 Technical data of the integrated connection group

1 Type 6 Nominal output 12 Max. permissible operating pressure 2 Appliance type 7 Country of operation 13 Max. permissible operating temperature 3 Product ID (CE number) 8 Voltage supply 14 Max. operating pressure 4 NOx class 9 Electrical power consumption 15 D value 5 Rated thermal load 10 Protection 16 Manufacturer's number (to be stated in 11 Net weight the event of complaints and queries) Fig.11-1 Information in type plate on bottom right hand side of storage container (for information on items see Tab. 11-1 to Tab. 11-4)

FA ROTEX GSU - 09/2007 65 11 x Technical Data

Q Burner load n Fan speed Fig.11-2 Permissible burner loads of ROTEX GSU

Δ pR Residual head mH Flow rate, heat distribution system Fig.11-3 Residual head GSU 320 and GSU 520S (on heating side)

Δp Residual head R mH Flow rate, heat distribution system Fig.11-4 Residual head GSU 530S and GSU 535 (on heating side)

66 FA ROTEX GSU - 09/2007 11 x Technical Data

Fig.11-5 Flue gas setpoint values for burner adjustment with reference to burner output P for GSU 320 and GSU 520S, O2 content or CO2 content*

Fig.11-6 Flue gas setpoint values for burner adjustment with reference to burner output P for GSU 530S, O2 content or CO2 content*

Fig.11-7 Flue gas setpoint values for burner adjustment with reference to burner output P for GSU 535, O2 content or CO2 content*

* The points filled in identify the factory settings

FA ROTEX GSU - 09/2007 67 11 x Technical Data

Q Heating output mH Flow rate, heat distribution system Fig.11-8 Required throughput volumes dependent on the heating output and the design temperature spread

RS Sensor resistance PTC resistance external temperature, mixer circuit feed t Temperature temperature NTC resistance feed temperature, return temperature Pt 1000 resistance Flue gas temperature Fig.11-9 Resistance characteristics of the temperature sensor

Measured temperature in °C Temperature Sensor -20-100 102030405060708090100110120 sensor Sensor resistance in Ohm according to standard or manufacturer's data Outside temperature, PTC mixer circuit flow 1386 1495 1630 1772 1922 2080 2245 2418 2598 2786 2982 3185 3396 temperature Feed temperature, NTC return flow 98660 56250 33210 20240 12710 8195 5416 3663 2530 1782 1278 932 690 519 395 temperature Pt 1000 Flue gas temperature 922 961 1000 1039 1077 1116 1155 1194 1232 1270 1308 1347 1385 1423 1461 Tab. 11-7 Resistance values of the temperature sensor

68 FA ROTEX GSU - 09/2007 11 x Technical Data

Circuit diagram Connection cable colours blbr blue ye brown gn yellow gr green rd grey bl red wt black n.a. white not assigned contact nted with ROTEX control THETA 23R) ROTEX control panel nted with Fig.11-10 (prese GasSolarUnit drawing Circuit

FA ROTEX GSU - 09/2007 69 12 x List of keywords

A12 List of keywords Flow temperature sensor ...... 38 P Annual inspection ...... 54 Flue gas mass flow ...... 18 Parallel operation ...... 61 Annual maintenance tasks ...... 54 Flue gas system Pipe dimensions ...... 12 Automatic timer program ...... 31, 33 Design ...... 17 Pressure gauge ...... 30 B Kits ...... 20 Proper use ...... 6 Basic setting for burner ...... 45 Minimum requirements ...... 17 R Basic setting for burner output ...... 45 Piping height ...... 17 Remove the silencer hood...... 54 Boiler control panel ...... 30 Flue gas system kits ...... 20 Replacing the central unit ...... 34 Assembly ...... 36 Flue gas temperature probe . 24, 26, 38 Resetting the gas type ...... 45 Burner Frost protection function ...... 33 Resting pressure ...... 25 Basic setting ...... 45 Fuse ...... 39 Reverse valve ...... 22 installation ...... 48 G Room controller ...... 26 the burner ...... 47 Gas connection Room station ...... 26 Burner flange ...... 41, 48 Execution ...... 25 Rotary switch ...... 31 Burner setting ...... 42 Gas inlet pressure ...... 25 Rotary switch I ...... 28, 33 C Gas type ...... 25 Rotary switch II ...... 33 Cascading ...... 26 Gas valve ...... 46 S Circuit board ...... 36 H Safety management ...... 11 Circulation pump ...... 22 Heating circuit expansion module Safety shutdown ...... 11 Collective fault signal ...... 30 Cascading ...... 26 Scope of delivery ...... 16 Combustion chamber Heating system Setting ...... 44 cleaning ...... 56 Draining ...... 62 Setting sticker ...... 45, 46 Components GSU ...... 8 Hot water storage tank Setting values ...... 43 Condensate drain Target temperature ...... 31, 33 Shutdown ...... 62 check ...... 55 Technical data ...... 63, 64 Solar utilisation ...... 11 connection ...... 22 Hydraulic representations Start-up ...... 28 Condensing technology Short names ...... 50 Checklist ...... 29 Instructions ...... 11 Hydraulic system connection ...... 50 Prerequisites ...... 28 Connect the power supply ...... 23 I Storage tank container ...... 49 Connecting the mixer circuit ...... 26 Ignition electrodes ...... 47 Storage tank temperature sensor 24, 38 Connection cables ...... 37 Inspection ...... 54 Storage water Connection types - flue gas ...... 17 Installation in garages ...... 15 Heating ...... 49 Control Installation room ...... 16 Structure GSU ...... 8 ALPHA 23R ...... 32 Installation site ...... 16 Supply voltage ...... 60 Connection ...... 23 Installation surface ...... 16 Surface temperature ...... 16 THETA 23R ...... 30 Installation versions System information ...... 31, 33 Control panel cover ...... 36 Ambient air-dependent mode . . . . 15 T Correction value ...... 33 Ambient air-independent mode . . . 15 Target room temperature ...... 31 D Overview ...... 14 Target temperature, hot water storage tank Danger of frost ...... 62 Integrated connection group ...... 49 ...... 31, 33 Dimensions ...... 12 Ionisation electrodes ...... 47 Temperature adjustment ...... 33 Display ...... 32, 33 L Temperature sensor Disposal ...... 62 Limiting the burner connection ...... 24 Drinking water heating Control ...... 42 Top-up water ...... 21 Technical data ...... 63 output ...... 46 Transport ...... 16 E M U Efficiency ...... 11 Mains switch ...... 30 Unit installation room Electrical Maintenance ...... 54 Requirements ...... 7 Connection ...... 23 Maintenance log ...... 71 W Electrical installation ...... 23 Malfunctions ...... 57 Water hardness ...... 21 Electronic control ...... 11 Manual operation ...... 28, 32 Water shortage protection ...... 21 Emergency operation ...... 61 Mark the gas type changeover ...... 26 Wiring diagram ...... 40 Emission measurement ...... 32, 33 Mixer circuit flow sensor ...... 24 Wooden boiler integration ...... 53 External temperature sensor ...... 24 Mixer circuit inflow sensor ...... 24 F O Fault clearance function ...... 32, 33 Operating elements ...... 30 Fault code ...... 59 Operating instructions ...... 11 Filling storage loading circuit ...... 27 Operating mode Filling the heating system ...... 27 Selection ...... 31, 33 Filling the system ...... 27 Operating safety Filling water ...... 21 Instructions ...... 6

70 FA ROTEX GSU - 09/2007 13 x Maintenance log

Please13 complete Maintenance the maintenancelog log by entering the maintenance work carried out and the measured values recorded.

Maintenance jobs Initial start-up 1st service 2nd service 3rd service 4th service Leakage testing heating pipeconnection Leakage testing hot water pipe

Leakage testing gas connection

Visual inspection of electrical components Inspection of electrical connections for proper fit Cleaning and functionality check of the condensation drain Inspection of the flue gas connection Cleaning of the combustion chamber Cleaning and inspection of the burner Inspection of the burner setting (correct gas type) Distance check ionisation and ignition electrodes Inspection of the initial pressure on burner

Putting the burner into operation and recording measured values

Carbon dioxide (CO2) in the flue gas duct

Oxygen (O2) in the flue gas duct

Carbon dioxide (CO2) in the supply air (ring-shaped gap measurement) Flue gas temperature in the flue gas duct Temperature of the drawn in air

Cleaning of the silencer hood and the boiler panelling Maintenance confirmed

(Company stamp, Date, Signature)

Modifications made to the control setting parameters, other remarks on the heating system Date Signature Remarks

FA ROTEX GSU - 09/2007 71 14 For the chimney sweep

Data13 for For designing the chimney the sweep flue gas duct

Flue gas temperature Rated output in kW Flue gas mass flow in g/s in °C Available Burner loading Appliance Liquefied pumping pressure in kW Natural Natural gas 40/30 °C 80/60 °C petroleum 40/30 °C 80/60 °C in Pa gas E/H LL/L gas 5.0 5.4 5.0 2.01 2.10 1.90 34 64 40 GSU 320 (F) 10.0 10.7 9.9 4.20 4.21 3.80 37 66 110 15.0 15.8 14.7 6.30 6.31 5.70 40 68 170 GSU 520S (F) 20.0 20.8 19.4 8.40 8.42 7.61 44 70 200 20.6 21.4 20.0 8.65 8.67 7.83 44 70 200 7.0 7.6 7.0 2.94 2.95 2.67 37 63 40 15.0 16.0 14.9 6.30 6.31 5.70 41 68 120 GSU 530S (F) 20.0 21.1 19.6 8.40 8.42 7.61 43 70 180 25.0 26.3 24.4 10.50 10.52 9.51 45 72 200 30.0 31.1 29.1 12.60 12.62 11.41 47 73 200 8.0 8.6 8.0 3.36 3.37 3.04 38 64 40 15.0 16.0 14.9 6.30 6.31 5.70 41 68 120 GSU 535 (F) 20.0 21.1 19.6 8.40 8.41 7.61 43 70 180 25.0 26.3 24.4 10.50 10.52 9.51 45 72 200 36.0 37.3 34.9 15.12 15.15 13.69 48 74 200 Tab. 14-1 Triple values for chimney design

Control measurement ROTEX THETA 23R Control measurement ROTEX ALPHA 23R The control measurement can be carried out by using a 1. The rotary switch II (Fig 5-2, Pos. 6) must be turned to position . selectable automatic function (see the supplied "Quick • First simultaneous pressing of keys and (Fig 5-2, Pos. 8 and 9) results in the reference operating instructions" or the "Operating manual emission measurement being accomplished within 20 min in full load mode. ROTEX-control". • Simultaneous pressing again of and buttons results in the emission • Press manual button (Fig 5-1, Pos. 13). measurement being accomplished within 20 min in partial load mode. Î The gas condensing boiler controls the maximum The display changes during the emission measurement between the remaining rest time for boiler temperature for a period of 20 min. the emission measurement and the flow temperature. • Press the manual button. 2. After 20 min, the control switches back automatically to the previous selected operating Î The gas condensing boiler regulates back to the mode for safety reasons. The emission measurement can be started again if needed. minimum output. The running time for this setting To abort the function simply press the and buttons at the same time. is also 20 minutes. Pressing the button again within these 20 minutes will prematurely terminate the emission measurement. · German 106 49

Current heater tem-

perature 09/2007 · 008.15 Time remaining from activation

Current heater temperature

Time remaining manual reservedons · Original from activation End emission measurement prematurely

Fig.14-1 Symbolic quick-reference manual, chimney sweep Fig.14-2 Symbolic brief instruction chimney mode control mode, THETA 23R control panel ALPHA 23R 44· Errors and technical modificati Errors 44· 008.15106

72 FA ROTEX GSU - 09/2007