ROTEX A1 BO - E-santechnika.lt

For certified companies

ROTEX A1 BOOil condensing boiler

Installation and maintenance instructions

Type Rated thermal output

ROTEX A1 BO 15bio 12–15 kW

ROTEX A1 BO 20i 12–20 kW



Serial number

Customer

0645 BM

GBEdition 10/2007

Guarantee and conformity

2 FA ROTEX A1 BO - 10/2007

ROTEX provides a warranty for material and manufacturing defects according to this statement. Within the warranty period, ROTEX undertakes to have the unit repaired free of charge by a person assigned by the company.

ROTEX reserves the right to replace the unit.

The warranty is only valid if the unit is used properly and if it can be proved that it was installed correctly by a specialist company. As proof, we strongly recommend completing the enclosed installation and instruction forms and returning them to ROTEX.

Warranty period

The warranty 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 warranty period is not extended if the unit is returned for repairs or if the unit is replaced.

Guarantee period for the burner and boiler electronics: 2 yearsGuarantee period for the boiler body: 10 years.

Exclusion of warranty

Improper use, tampering with the unit and unqualified modifications immediately invalidate the warranty.

Dispatch and transport damage are excluded from the warranty.

The warranty explicitly excludes consequential costs, especially costs of installing and removing costs the unit.

There is no warranty for consumables (according to the manufacturer's definition), such as lights, switches, fuses.

Declaration of conformity

We, ROTEX GmbH, declare under our sole responsibility that the products

with the product ID No.: CE 0645 BM-105.2 together with one of the following control systems

comply, in their standard design, with the following European Directives:

2004/108/EC Electromagnetic Compatibility Directive

98/37/EC EC Machine Directive

2006/95/EC EC Low Voltage Directive

92/42/EEC EC Efficiency Directive

For the calorific value heating centres of the boiler series ROTEX A1 BO.

Product Order No. Product Order No.

ROTEX A1 BO 15bio 15 48 13 ROTEX A1 BO 27i 15 48 11

ROTEX A1 B0 20i 15 48 10 ROTEX A1 BO 35i 15 48 12

Product Order No.

ROTEX THETA 23R (N) 15 40 52

ROTEX THETA 23R (S) 15 40 53

ROTEX ALPHA 23R 15 40 54

Güglingen, 1.10.2007 Dr Eng. Franz GrammlingManaging Director

Contents

1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.1 Observing Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.2 Warning signs and explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.3 Avoid danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.4 Proper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.5 Instructions for operating safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 Product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1 Boiler design and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 Set-up and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.1 Dimensions and connection dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.2 Different set-ups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.2.1 Operation independent of ambient air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133.2.2 Operation partially independent of ambient air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133.2.3 Ambient air dependent operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.3 Transport and delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143.4 Setting up an oil condensing boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.4.1 Selecting the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153.4.2 Setting up the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.5 Air/flue system (LAS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163.5.1 General instructions for flue system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163.5.2 Connecting the flue gas pipe to the oil condensing boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183.5.3 Flue system kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.6 Water connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203.7 Connecting the condensate treatment unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203.8 Connect the 3-way diverter valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213.9 Connecting control unit and electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213.10 Temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.10.1 General instructions for the temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223.10.2 Connecting the temperature sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.11 Connecting and filling up the oil line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233.12 Optional connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.12.1 Mixer circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243.12.2 Room temperature controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243.12.3 Room station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.13 Filling the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254.1 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254.2 Checklists for start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285.1 Controls on the boiler control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5.1.1 Control THETA 23R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285.1.2 Control ALPHA 23R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.2 Changing the central unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325.3 Changing the boiler control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335.4 Changing cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345.5 Changing the sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355.6 Changing the flue gas temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365.7 Changing the fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375.8 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3FA ROTEX A1 BO - 10/2007

Contents

6 Oil burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396.1 Design and brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396.2 Safety function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406.3 Burner setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.3.1 Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416.3.2 Instructions for burner setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426.3.3 Check vacuum in the oil pump and set the oil pump pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426.3.4 Set air quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436.3.5 Setting recirculation gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436.3.6 Check and set electrode distance and the distance between oil nozzles and air nozzles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

6.4 Removing/Installing burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456.5 Oil burner pump with LE system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

7 Hydraulic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487.1 Integrated connection group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

7.1.1 Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487.1.2 Releasing / restoring electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

7.2 Hydraulic system connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497.3 Hot water storage tank (not included in scope of supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

8 Inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528.1 General overview of inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528.2 Service and maintenance tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

8.2.1 Removing panelling (and cleaning it) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528.2.2 Checking the connections and pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538.2.3 Checking the condensate treatment unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538.2.4 Checking the flue gas temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568.2.5 Checking and cleaning the combustion chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568.2.6 Checking the oil filter and cleaning the oil pump filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588.2.7 Checking the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588.2.8 Replacing the oil nozzle and ignition electrodes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

9 Faults and malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609.2 Overview of possible malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609.3 Control unit fault signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629.4 Burner malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629.5 Rectifying STL fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 639.6 Emergency operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

10 Taking out of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6410.1 Temporary shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6410.2 Final shutdown and disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

11 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

12 List of keywords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

13 Service log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

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

4 FA ROTEX A1 BO - 10/2007

1 x Safety

1 Safety1.1 Observing Instructions

This manual is intended for authorised and trained heating engineers who have experience with the proper installation and mainte-nance of heating systems on account of their technical training and knowledge.

This manual provides all the necessary information for installation, start-up and maintenance, as well as basic information on operation and settings. Please go through the attached documents for a detailed description of operation and control.

All heating parameters needed for smooth operation are already factory-set. Please refer to the documentation of the respective control for setting up the control.

Please read this manual carefully and thoroughly before proceeding with the installation or modification of the heating system.

Relevant documents– ROTEX A1 BO Instruction manual for the user/owner. The document is included in the scope of delivery.– The documentation of the ROTEX Control being used. It is included in the scope of delivery of the Control.

1.2 Warning signs and explanation of symbols

Meaning of the warningsWarnings in this manual are classified according into their severity and probability of occurrence.

DANGER!

Draws attention to imminent danger.

Disregarding this warning can lead to serious injury or death.

WARNING!

Indicates a potentially dangerous situation.

Disregarding this warning can result in serious injury or death.

CAUTION:

Indicates a situation which may cause possible damage.

Disregarding this warning can lead to damage to property and the environment.

This symbol identifies user tips and particularly useful information, but not warnings or hazards.


1 x Safety

Special warning signsSome types of danger are represented by special symbols:

ValiditySome information in this manual has limited validity. The validity is highlighted by a symbol.

Order numberNotes related to Order numbers are identified by the cart symbol .

Handling instructions• Instructions on actions are shown as a list. Actions of which the sequential order must be maintained are numbered.

Results of actions are identified with an arrow.

1.3 Avoid danger

ROTEX oil condensing boilers are state-of-the-art and are built to meet all recognised technical requirements. However, improper use can lead to serious injuries or death, as well as causing material damage. To avoid danger, install and operate ROTEX oil condensing boilers only:– as stipulated and in perfect condition,– with an awareness of the safety and hazards involved.This assumes knowledge and use of the contents of this manual, the relevant accident prevention regulations and the recognised safety-related and occupational medical rules.

1.4 Proper use

The oil condensing boiler ROTEX A1 BO can only be used for heating hot water heating systems. It must be installed, connected and operated only according to the information in this manual.

The oil condensing boiler ROTEX A1 BO may be operated only in combination with a control unit approved by ROTEX (see conformity declaration on page 2 of this manual).

The oil condensing boiler ROTEX A1 BO may be operated only with the integrated circulation pump.

Any other use outside the above-mentioned use is considered as improper. Any resulting damages will be borne by the user/owner alone.

Intended use also includes compliance with the maintenance and inspection conditions. Spare parts must at least satisfy the technical requirements defined by the manufacturer. This is the case, for example, with original spare parts.

Electrical current Danger of burning or scalding

Valid only for ROTEX Control ALPHA 23R Valid only for ROTEX Control THETA 23R� �

6 FA ROTEX A1 BO - 10/2007

1 x Safety

1.5 Instructions for operating safety

Before working on the heating system• Only authorised and trained heating engineers should work on the heating system (e.g. set-up, connection and initial start-up).• Switch off the mains supply before starting any work on the heating system and secure it against unintentional switch-on.

Electrical installation• Electrical installations may only be carried out by qualified electrical technicians under observance of the relevant electrical

guidelines and the regulations of the electric utilities company.• Compare the mains voltage (230 V, 50 Hz) indicated on the nameplate with the supply voltage before connecting to the mains.

Unit installation room• Operate the oil condensing boiler only if sufficient combustible air supply is guaranteed. If operating the oil condensing boiler

independently of the ambient air with an air/flue system (LAS) with dimensions according to ROTEX-Standard, this is automatically guaranteed and there will be no further conditions required of the unit installation room.

• Make sure that there is a supply air opening to the open air, of at least 150 cm2 with ambient air dependent operation.• Do not operate the oil condensing boiler dependent on ambient air in rooms with aggressive vapours (e.g. hair spray, perchlo-

roethylene, carbon tetrachloride), strong dust formation (e.g. workshop) or high atmospheric humidity (e.g. laundry). • Strictly keep the minimum distances to walls and other objects (see chapter 3.1).

Heating system• Create a heating system according to the safety requirements of EN 12828, as an open or closed heating system.• Note that the safety valves must comply with DIN EN ISO 4126-1 and be type tested. The safety valves must be installed

in the safety flow.• Check the correct installation of the temperature sensor and safety temperature controller before the initial start up.• Always operate the oil condensing boiler with the sound insulation hoods closed.

Fuel• Use only the approved heating oils as fuel (see chapter 11 "Technical data").

Instructing the user/owner• Before you hand over the heating system, explain to the owner how he/she can operate and check the heating system.• Make a record of the handover by filling out and signing the installation and instruction forms jointly with the user/owner.


2 x Product description

2 Product description2.1 Boiler design and components

A1 BO 15bio / A1 BO 20i A1 BO 27i/A1 BO 35i A1 Schematic drawing

Fig. 2-1 Boiler components – View from the front Fig. 2-2 Diagram A1-boiler

A1 BO 15bio / A1 BO 20i A1 BO 27i/A1 BO 35i

Fig. 2-3 Boiler components – View from the back

1 Sound insulation hood 2 Boiler control panel3 Boiler panelling4 Burner 5 Controller6 Boiler main body with heat and sound

insulation7 Type plate with manufacture number8 Circulation pump9 3-way diverter valve

10 Heater return flow (cold)11 Heating flow (hot)12 Manometer 13 Filling and draining cock14 Safety valve15 Flue gas/supply air connection16 Condensate treatment unit17 Condensate drain18 Air supply hose19 Flame tube

20 Burner chamber insert21 Flue gas temperature sensor 22 Circuit board (electrical connections)23 Stickers for identification of the usable oil quality24 Document pouch25 Ball stopcock26 Flow temperature sensor27 Return flow temperature sensor

Safety devices

2 4

18

26

149

8

21

15

16172019

25

8 FA ROTEX A1 BO - 10/2007

2 x Product description

2.2 Brief description

The ROTEX oil condensing boiler in the series A1 BO combined with the ROTEX controller to be ordered separately is a premounted oil fired boiler unit.

Operating modeThe ROTEX oil condensing boiler A1 BO is designed in such a way that it can be operated independent of ambient air. The burner suctions the combustion air directly in through an installation shaft or a double-walled flue gas pipe. This operating mode has several advantages:– The heating room does not need any ventilation opening into the open air and therefore does not cool down.– Lower energy consumption.– Additional energy recovery in the flue gas pipe through preheating the combustion air.– Contamination from the environment of the burner are not suctioned in. The heating room can thus be used as a workspace,

laundry room etc. at the same time.– Possible to set up in loft areas or attic.– Possible to set up in garages.The collecting condensate is neutralised in the integrated ROTEX condensate treatment unit and then conducted into the drainage system through a plastic tube.

Safety managementThe entire safety management of the oil condensing boiler is managed through an electronic control panel. If there is water shortage, oil shortage or undefined operating conditions, there is a safety shutdown. A corresponding fault signal provides an engineer with all the necessary information for troubleshooting.

Electronic controlAn electronic digital controller combined with the "intelligent" automatic firing unit of the burner controls all heating and hot water functions automatically for the direct heating circuit, an optionally available mixed heating circuit as well as a storage tank charging circuit.

All settings, displays and functions are carried out by the ROTEX control. The ROTEX THETA 23R control or the ROTEX ALPHA 23R control can be used according to the equipment version. The display and keyboard make it easy to use.

A digital room station (THETA RS, 15 70 18) or a room temperature controller set (THETA RFF, 15 40 70) are available as option for greater convenience.

The room temperature control (ALPHA RTR-E, 17 51 26) is available as option for greater convenience.

Condensing technologyCondensing technology makes optimum use of the energy contained in the heating oil. The flue gas is cooled down in the boiler and in the flue system – when operated independently of ambient air – such that the temperature is below the dew point. Part of the water vapour created on combustion of the oil thereby condenses. The condensation heat is fed to the heating, in contrast to low-temperature boilers, thus making it possible to achieve over 100 % efficiency.

FuelThe ROTEX oil condensing boiler A1 BO can be operated with standard or low sulphur heating oil (sulphur content < 50 ppm). It is prepared for combustion of heating oil with biogenic content. As things currently stand, admixing bio heating oil up to 10 % (B10) is permitted without an additional conversion being required.

The ROTEX oil condensing boiler A1 BO 15bio is equipped with components that allow an admixture of bio-heating oil up to 20 % (B20).

Condensate treatmentThe condensate generated during the combustion in an oil condensing boiler has a pH value of 1.8 to 3.7. It must be neutralised before it enters the drainage system.

The ROTEX condensate treatment unit fulfils the following functions:– Removes floating particles in the settling basin,– Neutralises the condensate in the shell limestone.

ROTEX recommends using EL low sulphur heating oil in order to achieve highest efficiency and to keep maintenance expenditure low.

�

�


3x Set-up and Installation

3 Set-up and installation

Incorrect set-up and installation would make the manufacturer's guarantee void. If you have questions, please contact our Technical Customer Service.

3.1 Dimensions and connection dimensions

WARNING!

Units which have been set-up and installed incorrectly may not operate properly and can be a health and safety risk endangering human life.• Set-up and installation of the oil condensing boiler should only be carried out by authorised and trained

heating engineers.

Fig. 3-1 Dimensions of the model versions, side view

Fig. 3-2 Dimensions and connection dimensions of the model versions, rear view

10 FA ROTEX A1 BO - 10/2007

3 x Set-up and Installation

Tab. 3-1 Installation dimensions for oil condensing boiler A1 B0 in mm

Fig. 3-3 Dimensions and connection dimensions of the different set-ups

1 Boiler return flow2 Boiler flow3 KFE cock connection on the unit filling

line connection on KFE cock4 Flue gas/supply air connection5 Connection expansion vessel6 Burner7 Safety valve8 3-way diverter valve9 Hot water10 Circulation

G 1" IT (Box nut)G 1¼" ET / G 1" ITG ½" ITG ½" ETDN 80/125G ½" IT

G ½" IT (Bleeding line G ¾" IT)G 1" ETG ¾" ITG ¾" IT

11 Heat exchanger return flow12 Sensor immersion sleeve13 Heat exchanger flow14 Cold water15 Air/flue system (LAS) Connection piece16 Air supply hose17 Condensate drainage hose

A ROTEX A1 BOB Boiler frame (KU)C Sub-tank (US 150)

G ¾" ET

G ¾" ETG ¾" ITDN 80/120DN 50DN 40

A1 B0 15bio / A1 B0 20i A1 BO 27i A1 BO 35i

Dim. on the floor on US 150 on stand on the floor on US 150 on stand on the floor on US 150 on stand

a U400

b 720

c Y137 Y785 Y499 Y137 Y785 Y499 Y137 Y785 Y499

d 230F15 880F15 590F15 230F15 880F15 590F15 230F15 880F15 590F15

e 400F15 1040F15 790F15 460F15 1100F15 850F15 460F15 1100F15 850F15

f U1340 U1890 U1650 U1470 U2020 U1770 U1590 U2140 U1890

g 1100 1730 1480 1220 1850 1600 1340 1970 1720

h 625

i 300

11FA ROTEX A1 BO - 10/2007


3.2 Different set-ups

The oil condensing boilers in the series A1 BO are basically designed for operation independent of ambient air. They are fitted with a concentric flue gas/air supply pipe DN 80/125.

ROTEX recommends operating the oil condensing boiler independently of ambient air. If possible, choose this set-up!

In partial ambient air-independent and ambient-dependent operation, the installation room must have a ventilation opening of at least 150 cm2 to the outside. According to some country-specific regulations, this can , which downgrades the energy rating of the building.

Fig. 3-4 Different set-ups for the oil condensing boiler in the series A1 BO

1-8 Different set-ups(Description, see section 3.2.1 to 3.2.3)

1) Set-up version for ambient air-independent mode2) Set-up version for operation partially independent of ambient air3) Set-up version for ambient air-dependent operation

Air supplyFlue gas

a) Longitudinally ventilated shaft with a fire-resistance period of 90 minutes (30 minutes in low height residential buildings). Observe country-specific regulations for fire-resistance periods!

b) Humidity-resistant flue gas pipe in compliance with DIN 14 478 (temperature category T120 or higher, pressure category P1 or H1, condensate resistance category W, corrosion resistance class 2)

c) Ventilation opening 1 x 150 cm2 or 2 x 75 cm2 d) Rear ventilation

12 FA ROTEX A1 BO - 10/2007


3.2.1 Operation independent of ambient air

Set-up version 1The oil condensing boiler is connected to the LAS connection line kit C or kit D 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 using a flue gas pipe to the outside runs through the same shaft as the air supply.– Minimum distance between flue gas exit and roof ridge: 40 cm.

Set-up version 4The oil condensing boiler is connected to the external wall system kit G using the LAS connection pipe kit C or kit D.– The combustible air supply from the outside runs through the ring-shaped gap in the dual tube, through the outer wall (suction

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

over the roof surface. In the external area, the outer air gap serves as heat insulation for the flue gas pipe.

Set-up version 5The oil condensing boiler is located directly under the roof. Connection with kit F.– The combustible air supply from the outside runs through the outer ring-shaped gap of the dual tube 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 pipe: 2 m.

Set-up version 6The oil condensing boiler is not located directly under the roof. The dual tube for the combustible air supply and flue gas pipe runs through the roof truss.– The combustible air supply and the flue gas discharge run through a concentric dual tube (as in set-up version 5).– In the area of the roof truss, the dual tube for the combustible air supply and the flue gas pipe must be laid through

a protective pipe with sufficient fire resistance or be structurally separated from the roof truss.

3.2.2 Operation partially independent of ambient air

If the flue gas pipe is too high (see tab. 3-3, page 17), it may be advisable to suction the supply air through a separate air supply line with a lower resistance.

• Pull off the air supply hose at the air supply connecting manifold of the boiler body and connect the separate air supply line.

Set-up version 3– The combustible air supply from the outside runs through a separate air supply line through the external wall.– The flue gas discharge to the outside runs through the chimney or through an installation shaft (as in set-up version 1).

Set-up version 8The oil condensing boiler is connected to a ceramic chimney by means of kit A or kit B.– The combustible air supply from the outside runs through a separate air supply line through the external wall.– The ceramic chimney for the flue gas discharge should be humidity-resistant, as specified in DIN 18160 and it must have the

corresponding approval (suitability for overpressure operation).– If the ceramic chimney does not have an approval for the flue gas pipe for overpressure operation, it must be possible to

prove, through a flue gas calculation, that there is a vacuum in the shaft when the flue gas enters.

If the wall opening is less than one metre above the ground, ROTEX recommends sending the combustible air through a separate air supply pipe (PPW-ZR, 15 50 79.00 66) at a height of approx. 2 m.

13FA ROTEX A1 BO - 10/2007


3.2.3 Ambient air dependent operation

The oil condensing boiler of series A1 BO can also be connected depending on ambient air. The unit suctions the combustible air from the installation room through the ring-shaped gap in the enveloping pipe.

Set-up version 2– Combustion air supply from the installation room.– The flue gas discharge to the outside runs through the chimney or through an installation shaft (as in set-up version 1).

Set-up version 7The oil condensing boiler is connected to a ceramic chimney by means of kit A or kit C.– Combustion air supply from the installation room.– The ceramic chimney for the flue gas discharge should be humidity-resistant, as specified in DIN and it must have the

corresponding approval (suitability for overpressure operation).– If the ceramic chimney for the flue gas discharge does not have an approval for overpressure operation, it must be possible

to prove, through a flue gas calculation, that there is a vacuum in the shaft when the flue gas enters.

3.3 Transport and delivery

The oil condensing boiler is delivered on a pallet. All industrial trucks, such as lifting trucks and forklift trucks, are suitable for transporting it.

Scope of delivery– Oil condensing boiler (preassembled),– Accessories package (diverter valve, T-piece, ball cocks, external temperature sensor, spare microfilters inserts, seals, double

box nuts),– The document folder with installation and service manual, instruction manual, installation and instruction forms.

Status at the time of deliveryThe following outputs are factory-set:

Tab. 3-2 Factory setting and output range

Ambient air-dependent operation produces air suction noises which raise the operating noise of the boiler. To reduce the noise, you can use an air supply noise damper ( 15 45 77).

CAUTION!

Lifting or moving the oil condensing boiler by the panels can damage the unit.• Only lift the gas condensing boiler using the carrying straps provided for this purpose.

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

Type Pre-set output Output range

A1 BO 15bio 14 kW 12–15 kW

A1 BO 20i 18 kW 12–20 kW

A1 BO 27i 25 kW 20–27 kW

A1 BO 35i 30 kW 25–35 kW

14 FA ROTEX A1 BO - 10/2007


3.4 Setting up an oil condensing boiler

3.4.1 Selecting the installation site

The installation site for the oil condensing boiler must satisfy the following minimum requirements:

Installation heightThe bottom edge of the condensate drain connection on the unit must be higher than the outlet height of the condensate drainage hose, otherwise condensation can accumulate in the drain.• If setting up with an extension storage tank, the boiler pedestal height must be minimum 80 mm.

Installation area– The base must be solid, even and horizontal and must have sufficient load bearing strength. Install a pedestal if necessary.– Observe the installation dimensions (see chapter 3.1).

Installation room in general– There are no special conditions for ventilation of the installation room for operation independent of the ambient air (using a

concentric air/flue system).– When operating partially independent of ambient air and with ambient air dependent operation, the installation room must

have a ventilation opening of at least 150 cm2 to the outside.– When operating partially independent of ambient air and with ambient air dependent operation, 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. utility room).

Set-up in the atticIf the A1 condensing boiler is installed in the attic and the oil is stored in the rooms below it, the oil pump of the burner is generally not adequate. Since the vacuum on the suction side exceeds the value of 0.4 bar, the oil must be supplied to the burner through a separate pump. ROTEX urgently recommends using a suction aggregate.

The minimum height of the flue gas pipe must be 2 m in order to avoid malfunction at start or during operation of the burner.

Set-up in garagesThe oil condensing boilers of series A1 BO are basically suitable for being set-up and operated in garages. Requirements:– Operation independent of ambient air,– A durable instruction 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).

Heating oil storage in the installation room

As a general rule, construction specifications allow up to 5000 litres of heating oil to be stored in the installation room (according to the Firing Ordinance of the state) if the building is in Building Category 1 and the installation room is not a living room.

CAUTION!

If using a pressure aggregate, oil could escape if there is a fault. Escaping oil can cause serious damage to the environment.• Install boiler in a leakproof tray and secure through a float switch (connection through additional plug strip

ZSÖ, 15 40 67).• Use only a metallic filter cup (never Plexiglas).

15FA ROTEX A1 BO - 10/2007


Surface temperature– When operating independently of the ambient air with nominal output, the design does not allow temperatures > 70 °C on

any component outside the unit panels. Therefore, no minimum distance is required to components made with flammable materials.

– A minimum distance of 20 mm between the flue gas pipe and flammable components should be maintained with partial ambient air-independent and ambient-dependent operation.

– Do not store or use highly combustible and flammable materials in the immediate vicinity of the oil condensing boiler.

3.4.2 Setting up the unit

Requirement:– The installation site complies with the respective country-specific regulations, as well as the minimum requirements

described in section 3.4.1.– Install a leakproof tray on site if using a pressure device.

Set-up:• Remove packing and dispose of it in an environment-friendly manner.• Set up the oil condensing boiler at the installation site. Do not lift or move the unit holding the panels.• Position the oil condensing boiler such that it can be folded out without any restrictions.• Check the horizontal position and the correct installation height of the oil condensing boiler. You can adjust the height with

the four height-adjustable feet.

3.5 Air/flue system (LAS)

3.5.1 General instructions for flue system

The Firing Ordinance of the respective state and EN 14 478 are valid for the model and dimensioning of the flue system.

Minimum requirements:Any CE-certified flue gas pipe with technical approval EN 14 478:– 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 2).The features of the flue system must be recognisable on the installed system.

• Place the nameplate of the flue system in the installation room.

A flue gas temperature sensor integrated in the control unit of the oil condensing boiler triggers a safety shutdown if the flue gas temperature is too high.

We recommend using the associated ROTEX flue gas kits. They satisfy all requirements and are also fitted with special acid-proof seals.

16 FA ROTEX A1 BO - 10/2007


Installation position and piping height:– The maximum permitted flue gas counterpressure is 200 Pa. The pressure loss in the supply line must not exceed 50 Pa.– Angle of entry of the flue gas pipe into the chimney or installation shaft: approx. 3°.– Slope for horizontal parts of the flue gas pipe: approx. 3°. Counter-slopes are not allowed at any point in the flue gas pipe.– If the flue gas pipe needs more than 3 deflections > 45°, then the maximum permitted height for the flue gas pipe is reduced

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 pipe is reduced by exactly that

length.– The minimum height of the flue gas pipe must be 2 m in order to avoid malfunction when starting or while operating the

burner.

Tab. 3-3 Maximum permitted height of the flue gas pipe in m (when operating in the nominal output range)

1) Shaft cross section for DN 80: 135 mm x 135 mm; Shaft cross section for DN 110: 160 mm x 160 mm

Any restriction on the output range may require a recalculation of the maximum permitted height for the flue gas pipe. The characteristics for the flue gas calculation can be obtained from fig 3-5 and chapter 11 "Technical data“.

The flue gas mass flow of the systems depends on the burner output set.

Set-up version(ref. fig 3-4)

A1 BO 15bio A1 BO 20i A1 BO 27i A1 BO 35i

DN 80 DN 80 DN 80 30 kWDN 80

33 kWDN 80

35 kWDN 80

35 kWDN 110

11) 16 16 16 20 16 8 24

21) 21 21 21 21 21 21 30

31) 17 17 17 21 21 17 30

4 16 16 16 20 20 20 28

5 17 17 17 11 11 11 23

6 17 17 17 11 11 11 23

Fig. 3-5 Flue gas mass flow in relation to the burner outputmET Flue gas mass flow P Burner output

17FA ROTEX A1 BO - 10/2007


3.5.2 Connecting the flue gas pipe to the oil condensing boiler

Requirements:– The flue system fulfils the requirements described in section 3.5.1.– The flue system fulfils any other required national or regional safety requirements.– The oil condensing boiler is correctly connected.

Connection:

• Connect the oil condensing boiler to the flue system in the installation room (for connection dimensions refer to fig 3-6 and tab. 3-4).

• Place the nameplate of the flue gas pipe in the installation room.

Tab. 3-4 Connection dimensions for the LAS connection of the oil condensing boiler

14 478 (ref. to chapter 3.5.1):

We recommend using the associated ROTEX flue gas kits (see fig 3-5). They satisfy all requirements and are also fitted with special acid-proof seals.

Fig. 3-6 Connection dimensions LAS Twin skin flue of oil condensing boiler of series A1 BO

A Boiler connectionB Flue gas connection

C Flue gas temperature sensorD Connection for condensate drainE Flue gas noise damper (not in A1 BO 35i)

Connection side Connection Connection dimension in mm

A Boiler side A1 Flue gas DN 80 Collar Inner diameter = 80.4 +0.8

A2 Supply air DN 125 Collar Inner diameter = 127.0 –0.5

B Flue gas side B1 Flue gas DN 80 Outer diameter = 80.0 +0.3

B2 Supply air DN 125 Outer diameter = 126.0 ±0.3

In some cases, the resonance in the flue system can amplify the noise at the mouth of the flue gas pipe. The noise level can be effectively reduced by using a noise damper ( 15 45 78).

Air suction noises are generated during ambient air-dependent operation. The noise level can be effectively reduced by using a noise damper ( 15 45 77).

18 FA ROTEX A1 BO - 10/2007


3.5.3 Flue system kits

Tab. 3-5 Plastic (PP) flue system kits

* If required

19FA ROTEX A1 BO - 10/2007


3.6 Water connection

The oil condensing boiler has a joint flow and return flow for the heating circuit and charging the storage tank. The connections are on the back of the units (see fig 3-2 and fig 3-3).

Instructions for water connection

– Water shortage protection: The overheating guard of the oil condensing boiler series A1 BO shuts off the oil condensing boiler in the event of a water shortage and locks it for safety reasons. No additional water shortage protection is needed in the construction.

Notes on water quality– Avoiding deposits: Observe the regulations in VDI 2035 in order to avoid corrosive products and deposits. If filling and

additional water has a high degree of hardness (Sum of alkaline earths > 3 mol/m3), measures need to be taken to stabilise or soften hardness.

– Install dirt filter in the heating return flow (up to 28 kW the SFR 28, 15 60 11; up to 50 kW the SFR 50, 15 60 12).

3.7 Connecting the condensate treatment unit

The condensation in oil condensing technology has a pH value between 1.8 and 3.7.

• Neutralise the condensation in accordance with the local guidelines and discharge into the public drainage system.

ConnectionThe condensate treatment unit is factory-assembled in the boiler cradle and connected to the flue gas connecting piece of the boiler. The connection to the wastewater network is designed for HT piping DN 40.• Lay the condensate drain sloping down from the boiler so that condensation will not accumulate in the flue gas manifold.• In order to avoid accumulation in the flue gas connection of the boiler, make sure that no siphon is formed between the

condensate drainage hose and the connection with the wastewater line.• Fill the condensate pipe with water in order to prevent flue gas from escaping into the installation room. To do this, either :

– Open the boiler body and lift up the combustion chamber insert (see section 8.2.5); top up condensate pipe through a hose (see fig 3-8) or,

– Unscrew the inspection lid of the flue gas pipe and fill the condensate pipe by using a hose held in the flue gas manifold.• Check the condensate drain section for leakage.

CAUTION!

If the oil condensing boiler is connected to a heating system with steel pipelines, radiators or non-diffusion-proof floor heating pipes, slurry and chips could enter the boiler and cause blockages, overheating or corrosion. • Rinse out the heat distribution network (in the existing heating system).• Install a dirt filter in the heating return flow.

Depending on the regulations of the community waste water regulations, neutralisation can be dispensed with, if the condensing boiler is operated exclusively with low-sulphur heating oil EL.

Fig. 3-7 Connection of the condensate treatment unit Fig. 3-8 Fill condensate treatment unit with water

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3.8 Connect the 3-way diverter valve

The oil condensing boiler is fitted with an integrated circulation pump and a 3-way diverter valve (3W-UV) as standard. The circulation pump is already factory-connected; the 3-way diverter valve is supplied as an accessory.

• Mount the 3-way diverter valve on the flow connection. Ensure the correct position: Connect connection B to the heating unit and connection A to the storage tank (see fig 3-9).

• Insert the connection plug to the cable of the 3-way diverter valve to the valve drive.

3.9 Connecting control unit and electrics

Apart from the central unit, all control and safety devices of the oil condensing boiler are connected ready for operation and inspected. Modifications on the electrical installation are dangerous and prohibited. Any resulting damages will be borne by the user/owner alone.

There are two 3 m flexible cables connected inside the unit for the mains connection and for the external temperature sensor; they are located in the control panel on the switchboard PCB. Only the optional applications (e.g. mixer circuit, circulation pump) still have to be connected to the boiler control panel.

1 Boiler flow2 Heating flow3 Storage tank flow4 3-way diverter valve

5.1 Valve drive5.2 Unlocking button of the drive lock5.3 Hand lever

Fig. 3-9 3-way diverter valve

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

If the storage tank charging circuit is to be operated through a charging pump (parallel operation, cascade circuit etc.), a storage tank charge pump will have to be installed in the heating system instead of the 3-way diverter valve. An adapter cable is needed for controlling the storage tank charge pump ( E 1500430).

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 off 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.

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Installing the central unitThe oil condensing boiler can be operated either with the ROTEX Control ALPHA 23R or with the ROTEX Control THETA 23R. The central control unit to be used is supplied separately and must be fitted at the time of installation (also refer to chapter 5.2).• Push the central unit carefully into the boiler control panel. Ensure that the connecting pins are not damaged.

• Tighten the fixing screws (right handed threads).

• Close the bayonet lock (90° rotation).

Establishing the electrical connection• Check the supply voltage (~230 V, 50 Hz).• Disconnect the junction box of the domestic electrical installation.• Connect the cables for connecting to the mains in the junction box. Ensure that the polarity is correct.• Restore power supply to the junction box of the domestic electrical installation.

Switchboard panel:

3.10 Temperature sensor

3.10.1 General instructions for the temperature sensors

The oil condensing boiler has a weather-driven control for the flow temperature. This function requires an external temperature sensor. A 3 m flexible cable is already connected inside the unit and placed in the control panel on the connecting circuit board.

The temperatures captured by the unit's internal temperature sensors (flow and return flow temperature sensor, flue gas temperature sensor) are used for the output control of the burner and for fault detection. The temperature sensors are already factory-connected and can be plugged directly to the respective sensor, if they need to be swapped.

If a hot water storage tank is used, the connected storage tank temperature sensor must be mounted at the suitable position in the hot water storage tank (observe installation instructions for the hot water storage tank). The mixer circuit flow sensor (TMKF, 15 60 62) is required to control the mixer circuit.

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Fig. 3-10 Connection diagram of the circuit board connectors and cable colours of the factory-installed connection cables

Connections of the circuit board connectors:J1 Pump PKJ2 3-way diverter valve or storage tank charging pump PL

*

J3 Burner power supplyJ4 Burner communicationJ6 Mains connectionJ7 MixerJ8 Communication, sensorsJ10 SensorsJ14 Circulation pump PZ

Cable colours:bl bluebr brownge yellowgn greengr greyrt redsw blackws whiten.b. Contact not assigned

* The adapter cable ( E 1500430) is needed for connecting a storage tank charging pump.

The electronic control unit detects the existing sensor configuration automatically when switching on the oil condensing boiler for the first time.

You will find more instructions and an exact description in the documentation "ROTEX Control". It is included in the scope of supply of the particular electronic control to be ordered separately.

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3.10.2 Connecting the temperature sensor

External temperature sensor• Choose a location at about one third of the building height (minimum distance from floor: 2 m) on the coldest side (north or

north-east) of the building (not near other heat sources (chimneys, air shafts) and not subjected to direct sunlight).• Place external temperature sensors in such a way that the cable exit points face downwards (prevents humidity ingress).

• Lay the sensor line and connect it to the control unit of the oil condensing boiler.• Connect the external temperature sensors with a dual core cable (minimum cross section 1 mm2).

Mixer circuit flow sensor• Connect the sensor line to the sensor plug J8 (see fig 3-10).

Storage tank temperature sensor• Disconnect the storage tank temperature sensor for operation without a hot water storage tank.

3.11 Connecting and filling up the oil line

The oil connection must be implemented according to the local regulations in the single strand system with an outlet-side built-in ventilation oil filter.

• Lay oil hoses. Whilst doing so, ensure the following:– that the combustion chamber can be opened without removing the oil hoses,– that oil hoses do not buckle.

• Place the ventilation oil filter such that the oil hoses are connected without tension and the top half of the boiler can be opened without hindrance.

• Insert the supplied spare Universal Micro-filter insert MC-7 in the venting oil filter (generally use only filters with maximum 25 μm).

• Connect oil line Whilst doing so, ensure the following:– The inner diameter of the oil line must not be greater than 8 mm. Use the ROTEX VA-Oil oil feeding line or copper pipes

with diameter between 6 and 8 mm as the oil line.– The total resistance of the suction line (total of height difference, line resistance and individual resistances) must not

exceed 4 m water column (0.4 bar).• Fill up oil line. Suction the oil by using a hand pump.• Check oil line for leaks according to the local regulations .

CAUTION!

Using an unapproved temperature sensor or one which is not calibrated to the unit can cause serious malfunctions in controlled operation of the oil condensing boiler, damaging the unit control.• Only use external temperature sensors and storage tank temperature sensors supplied within the scope

of delivery.

CAUTION!

Parallel routing of sensor and mains lines within an installation pipe can cause serious malfunction in controlled operation of oil condensing boiler.• Always lay the sensor line separately.

ROTEX recommends using EL low sulphur heating oil in order to achieve the highest efficiency and to keep the maintenance expenditure low.

Admixing bio heating oils is possible (see chapter 2.2).

23FA ROTEX A1 BO - 10/2007


3.12 Optional connections

3.12.1 Mixer circuit

A mixer circuit can be connected directly to the oil condensing boiler which is controlled through 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 stop valves with temperature displays.– The mixer circuit contact sensor TMKF ( 15 60 62).

Cascading

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 ( 15 60 63)).– Connection and communication of the heating circuit expansion module THETA HEM1 through a data bus on the central unit.

3.12.2 Room temperature controller

You can connect a separate room temperature controller THETA RFF ( 15 40 70) for each heating circuit to remotely set operating modes and room temperatures from another room.

– Connection and communication of the room temperature controller THETA REF1 via a data bus on the central unit.

You can connect a separate room temperature controller ALPHA RTR-E ( 17 51 26) for each heating circuit to remotely set operating modes and room temperature from another room.

– Connection of the room temperature controller ALPHA RTR-E to the AB terminal of the circuit board connector J8 on central unit (see fig 3-10).

3.12.3 Room station

All temperature values and operating 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 controls (display, buttons, rotary switch and functions (e.g. timer programmes) are identical to those on the central unit.

The room station THETA RS can be installed in a suitable place in the building and can be used to remotely operate the boiler control unit.– Connection and communication of the room station THETA RS through a data bus on the central unit.

3.13 Filling the heating system

Only fill the heating system if all installation work has been completed.

Adjusting the pressure gaugeThe correct minimum pressure marking must be set on the pressure gauge glass before filling the system for the first time:• Rotate the pressure gauge glass (fig 2-1, pos. 12) 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).

Checking the water quality• Observe instructions for water connection according to chapter 3.6.

Filling the system• Connect the filling hose with return flow inhibitor (½") at the filling and draining fittings (KFE cock, fig 3-3, pos. 3) and secure

against sliding by using a hose clamp.• Open the KFE cock and watch the pressure gauge (fig 2-1, pos. 12).• Fill the system with water until the marking of the system overpressure is roughly in the centre of the green range of the

pressure gauge display.• Close the filling & draining cock.• Vent the entire heating 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 and return flow inhibitor from the filling and draining fittings.

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24 FA ROTEX A1 BO - 10/2007

4 x Start-up

4 Start-up

Incorrect start-up makes the manufacturer's guarantee for the unit void. If you have questions, please contact our Technical Customer Service.

4.1 Initial start-up

After the oil condensing boiler has been installed and fully connected, it can be started up by trained staff.

Requirements– The oil condensing boiler is correctly connected. If a pressure device is used as separate oil pump, the installation site must

also be secured by using a leakproof tray and a filter cup made of metal (see section 3.4.1).– The oil condensing boiler is fully connected.– The heating system is filled and charged at the correct pressure.– The oil valves are open and the oil line is topped up.

Tests prior to start-up• Check all connections for leakage.• Check all points on the checklist supplied (see chapter 4.2). Log the test results on the checklist.The oil condensing boiler can only be provisionally put into service if all points on the checklist can be answered with Yes.

Bleeding the oil line, checking the oil pressureThe oil line must be completely vented at the beginning of the start-up and the oil pressure must be checked.

• Connect vacuum meter to the oil pump (Vacuum meter connection, fig 4-2, pos. 2)• Switch on the mains switch. Wait for the start phase.• Open the venting screw on the oil filter.• Vent oil line and measure the oil pressure on vacuum meter.

The vacuum may be maximum 0.4 bar (better: 0.2 bar).

WARNING!

An oil condensing boiler not started up properly can be a health and safety risk endangering human life and adversely affect its operation.• Start-up of the oil condensing boiler may only be carried out by authorised and trained heating engineers.

Fig. 4-1 Oil connection with venting oil filter Fig. 4-2 Oil pump

1 Filter2 Filter cup

1 Manometer connection2 Vacuum meter connection

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4 x Start-up

Start-up• Switch on the mains switch. Wait for the start phase.• Set the operating temperature for manual operation. You can do this by pressing the Manual button for about 5 seconds

and setting the operating temperature on the rotary button.• Set the rotary switch "default settings" to position and press and simultaneously.• Check burner settings using flue gas analyser and adjust if necessary (see chapter 6.3).

Press Manual button for approx. 5 s

Target temperature

Change Desired target value (flashing)

Current actual value

Return to the original operating mode, default display, set target value is saved

Fig. 4-3 Manual mode for control THETA 23R (set heat generator temperature)

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4 x Start-up

4.2 Checklists for start-up

Checklist before start-up

1. Is the boiler properly assembled in an authorised way and without visible damage? Yes

2. When using a pressure assembly: Is the installation site additionally secured (leakproof tray, filter cup of metal)? Yes

3. Is the combustion air supply secured? Yes

4. Is sufficient venting assured for the heating room in ambient air - dependent operation? Yes

5. Does the mains connection conform to the specifications? Yes

6. Is the mains voltage 230 Volt, 50 Hz? Yes

7. Is the LAS flue gas pipe connected correctly and leakproof? Yes

8. Is the condensate treatment unit correctly connected, filled with water and leakproof? Yes

9. On restoration: Has the heat distribution network been cleaned? Is a dirt filter built into the heating return flow? Yes

10. Is a membrane expansion tank mounted according to specifications and in the requisite size? Yes

11. Is the safety valve connected to a free outlet? Yes

12. Has the quality of the filling water been checked and has the required water preparation been carried out? Yes

13. Is the system water pressure within the green range? Yes

14. Are boiler and heating system vented? Yes

15. In case of systems with a hot water storage tank: Is the storage container filled? Yes

16. Are all sensors connected and correctly positioned? Yes

17. Is the 3-way diverter valve correctly mounted and inserted on the flow connection? Yes

18. Are the mixer group and the mixer circuit sensor (optional) correctly connected to the circuit board? Yes

19. Is the room temperature controller or room station (optional) correctly connected to the circuit board? Yes

20. Is the oil connection installed according to regulations, professionally and correctly? Yes

21. Is the oil tank topped up sufficiently and are the oil valves open? Yes

The system may only be started up if all questions can be answered with "Yes".

Checklist after start-up

A Is the circulation pump running? Is the heater heating up? Yes

B Is the oil line vented? Yes

C Is the oil pressure within the permissible range? Yes

D Have the burner settings been checked by using a flue gas analyser and readjusted if necessary? Yes

The system may only be handed over to the user/owner if all questions can be answered with "Yes".

• Fill in the supplied installation and instruction form jointly with the user/owner.

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5 x Control

5 Control unit5.1 Controls on the boiler control panel

5.1.1 Control THETA 23R

Mains switchSwitches the oil condensing boiler on and off. When the heating system is on, the mains switch is illuminated green.

Burner malfunction indicatorDuring normal operation, the burner malfunction indicator is off. When it lights up, it indicates a burner malfunction. For troubleshooting instructions, see chapter 9.4.

STL indicatorThe STL indicator is off during normal operation. When it lights up, it indicates a safety temperature shutoff due to a serious malfunction in the heating system (e.g. pump defect, clogging or air in the system). For troubleshooting instructions, see chapter 9.5.

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.

The ROTEX Oil condensing boiler A1 BO can be operated with the THETA 23R control or only with the ALPHA 23R control. The electronic digital controls are to be used for controlling 2 heating circuits (direct heating circuit, mixer circuit) and a storage tank charging circuit.

You will find an exact description in the respective documentation on the ROTEX Control.

Fig. 5-1 Controls on the boiler control panel

1 Mains switch2 Burner malfunction indicator3 STL indicator4 Manometer5 Controller: Central unit THETA 23R6 Rotary switch for selecting and setting functions

and parameters7 Selecting the target room temperature during day 8 Selection of the reduced target room temperature

9 Selection of the target temperature for the hot water storage tank

10 Selecting the operating mode11 Setting automatic timer programme12 System information13 Manual button for emission measurement, manual operation,

reset function14 Display15 Compartment for quick reference instruction manual16 Fixing screws for the control unit17 safety temperature limiter (STL)

Malfunctions are generally indicated by a fault code on the display.

For troubleshooting instructions refer to chapter 9 "Faults and malfunctions".

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5 x Control

Safety temperature limiter (STL)The safety temperature limiter shuts off the burner if the boiler temperature exceeds the permissible limit and locks it against automatic restart. For manual unlocking, see chapter 9.5.

Rotary switchThe rotary switch can be used to select operating settings, changing and storing target values.

Target room temperature during daySelection and setting of the target temperature in normal operation. Set according to individual temperature sensitivity.

Reduced target room temperatureSelect and set the target temperature in economy operation (night reduction). Set according to individual temperature sensitivity.

Target temperature hot water storage tankSelect and set the target hot water storage tank temperature Set according to specific hot water requirements.

Selecting the operating modeSet the operating mode by tapping the operating mode selector button. The operating mode that is currently active flashes on the display. Select and activate another operating mode with the rotary switch. A marking on the display above the respective symbol shows the mode currently selected.

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

Setting automatic timer programmeSelect one of the 3 pre-installed timer programmes P1, P2 or P3. You can find further instructions and a more exact description in the documentation for "ROTEX controller THETA 23R". It is included in the scope of supply of the particular electronic control to be ordered separately.

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

• Tap: Save the selected value

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

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

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

ABSENT Brief break in the heating mode during absence.

PARTY Extended heating mode over and above the heating period preset in the AUTOMATIC MODE.

AUTOMATIC Automatic heating and economy mode according to timer programme.

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

HEATING Continuous heating mode without time restriction.

REDUCED Continuous reduced heating mode without time restriction.

STANDBY Frost-protected shutdown of heating and hot water.

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5 x Control

System informationQuerying all system temperatures and operating statuses of the system components.• Tap the system information button.• Query the desired information successively by using the rotary switch.

Emission measurement, manual operation, reset functionYou can request 3 functions by using the Manual button.

a) Functions for emission measurement for the chimney sweep: Tap Manual button.

– First tap: The burner is turned on for 20 min. and is regulated at the stipulated maximum temperature. The 3-way diverter valve is at "Storage charge" until the maximum adjustable storage temperature is achieved. Finally, switch to the heating mode.

– Tap a second time: early cancellation.b) Manual operation: Press the Manual button for 5 sec. The oil condensing boiler 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.

c) Reset: If the display shows "<< RESET", press the Manual button. In case of repeated malfunction, the cause must be rectified (see chapter 6 "Oil burner" and chapter 9 "Faults and malfunctions").

DisplayAll system temperatures and operating statuses of the system components can be shown on the display. In the event of a malfunction, the corresponding fault signal is issued.

Standard display in normal operation: Current day of the week, current date, current time, heat generator temperature and active operating mode (marking 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 control panel, see section 5.1.1.

Fig. 5-2 Controls on the boiler control panel with integrated control ALPHA 23R

1 Mains switch2 Burner malfunction indicator3 STL indicator4 Manometer5 Central unit ALPHA 23R6 Rotary switch for the default settings10 Rotary switch for selecting the operating mode

14 Display15 Compartment for quick reference instruction manual16 Locking the control in place17 safety temperature limiter (STL)27 "+" button28 "–" button29 "RESET" button

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5 x Control

"Default settings" rotary switch

Rotary switch "Selecting the operating mode"

Modification of values, Navigation– Changing values.– In the function menus "Parameter", "Status Plant" and "Automatic I", the buttons help with navigation.– Press briefly the and buttons simultaneously to confirm and/or save the selected setting.

RESET– Reset the fault signal in case of burner malfunction.– Cancel the operating mode "Emission".– Reset entries in a function menu.– Return to higher-level selection point within the function menu.– Operator acknowledging fault signals and returns to default display.

Special functionsSimultaneously pressing the and buttons for longer than 2 seconds activates Emission measurement .

Simultaneously pressing the and buttons activates the Switching timer programming for the switching time programme "Automatic I" (for more detailed information, see ROTEX Control ALPHA 23R).

DisplayAll system temperatures and operating statuses of the system components can be shown on the display. If there is a malfunction, a fault code is displayed.

Default display in normal operation: Flow temperature.

NORMAL OPERATING MODE

Controller works according to the operating mode set with the "Selection of operating mode" rotary switch.

TARGET HOT WATER TEMPERATURE

Display and modify target hot water temperature.

TARGET ROOM TEMPERATURE

Display and change target room temperature.

STATUS PLANT Read information on the plant status.

WEEKDAY Display and change weekday.

CLOCK TIME Display and change time.

PARAMETER Select and change parameters.

STANDBY Frost-protected shutdown of heating and hot water.

REDUCED Continuous reduced heating mode without time restriction.

HEATING Continuous heating mode without time restriction.

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

AUTOMATIC IAutomatic heating and lowering mode according to switching timer programme "Out at work"(can be set separately).

AUTOMATIC II Automatic heating and economy mode according to timer programme "Family".

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

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5 x Control

5.2 Changing the central unit

Removing the central unit• Loosen fixing screws (fig. 5-3, pos. 16)

(anticlockwise rotation), pull out central unit from front.

• Release bayonet lock, pull out the central unit forward.

Installing the central unit• Push the central unit carefully into the boiler control panel. Ensure that the connecting pins are not damaged.

• Tighten the fixing screws (right handed threads).

• Close the bayonet lock (90° rotation).

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.

A Front viewB Rear view16 Fixing screws

C Loosen fixing screwsD Tighten fixing screws

Fig. 5-3 Install/remove central unit (shown in THETA 23R control)

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5 x Control

5.3 Changing the boiler control panel

Removal (observe sequence)

The position and arrangement of the components described below is shown in fig. 5-18 on page 38.

1. Remove the sound insulation hood and the boiler panelling. Remove the two heat insulation layers (see section 8.2.1).

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.

3. Unscrew the pressure gauge capillary tube with the key SW 14 (fig. 5-4). Use a cloth to absorb the small amount of water that escape on unscrewing the tube.

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

5. Pull all connectors from the switchboard PCB (fig. 5-6).

6. Pull out the sensor and the connection cables from the cable ducts of the control panel (fig. 5-7).

WARNING!



WARNING!

There is a danger of scalding from heating water.

The capillary tube of the pressure gauge is directly connected to the pressurised heating water.• Close the ball cocks on the boiler flow before removing the pressure gauge and depressurise the system.

Fig. 5-4 Remove pressure gauge capillary tube Fig. 5-5 Unscrew control panel cover

Fig. 5-6 Pull off the coded connector Fig. 5-7 Pull out the cable

33FA ROTEX A1 BO - 10/2007

5 x Control

7. Loosen fixing screw of the cable duct holder with Allan key 6 mm, but do not unscrew completely (fig. 5-8).

8. Remove the fixing screws of the boiler control panel with wrench SW 8 (fig. 5-9). Remove the control panel.

Installation (observe sequence)

1. Insert the boiler control panel into the holder. Insert and tighten the fixing screws.

2. Tighten the fixing bolt for the cable duct holder.

3. Place all sensor and connecting cables into the cable ducts of the control panel. Ensure the correct cable routing through the strain relief plates.

4. Insert all connectors on the switchboard PCB. The connectors are colour and shape-coded to avoid confusion. Do not force the connector!

5. Mount the control panel cover.

6. Screw in the pressure gauge capillary tube. Ensure the correct seating of the ring seal.

7. Top up with water until the required system pressure is restored.

8. Open the stopcocks for heating. Vent the system again (top up with water if required).

9. Mount the heat insulation layers and put on the sound insulation hood.

5.4 Changing cables

The connection cables can be loosened 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 can be released from the respective components where they are plugged in.– 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 with screw terminals.

Changing the cables (observe sequence)

1. Remove sound insulation hoods.

2. Unscrew control panel cover and remove cable duct cover.

3. Pull out the corresponding sensor or connection cable from the cable duct of the control panel.

4. Pull out the associated connector from the switchboard PCB.

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.

Install 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 colour and shape-coded. Do not force the connector!

Fig. 5-8 Loosen cable duct holder Fig. 5-9 Remove the fixing screws for the boiler control panel

WARNING!



34 FA ROTEX A1 B0 - 10/2007

5 x Control

5.5 Changing the sensors

Sensors inside the unit (fig. 5-10, fig. 5-11) can be changed without having to open the boiler control panel.

Changing flow / return flow temperature sensor

1. Remove the sound insulation hood and the boiler panelling. Remove the heat insulation layers for changing the flow temperature sensor (see section 8.2.1).

2. Pull out the connectors on the flow temperature sensor/ return flow temperature sensor (fig. 5-12).

3. Unscrew the flow /return flow temperature sensor using an open-jaw wrench SW 15 (fig. 5-13).

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!

WARNING!

Live parts can cause an electric shock on contact and cause life-threatening burns and injuries.• Before beginning work on the oil condensing boiler, disconnect it from the power supply (switch off fuse,

main switch) and secure against unintentional restart.

Fig. 5-10 Position of the temperature sensor on the boiler (1) Fig. 5-11 Position of the temperature sensor on the boiler (2)

33 Flow temperature sensor 34 Return flow temperature sensor 37 Flue gas 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. 5-12 Pull out the connector on the flow temperature sensor Fig. 5-13 Unscrew the flow temperature sensor

35FA ROTEX A1 BO - 10/2007

5 x Control

5.6 Changing the flue gas temperature sensor

The flue gas temperature sensor is mounted in the flue gas duct of the heat generator using a packing gland and connected to the sensor cable using a floating plug connection.

1. Remove the sound insulation hood and the boiler panelling. Release the plug connection on the sensor cable (fig. 5-14).

2. Unscrew the sensor sleeve from the flue gas duct by using an SW 24 wrench (fig. 5-15).The flue gas temperature sensor can only be completely changed with the sleeve.

3. Screw in the new sensor sleeve into the flue gas duct and tighten it carefully using the SW 24 wrench (plastic thread!).

4. Restore the plug connection on the sensor cable.

Changing the storage tank temperature sensorThe 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.

1. Open boiler control panel and remove plug J8 from the switchboard PCB (see chapter 5.4, Steps 1 to 4).

2. Pull out the sensor from the sensor immersion sleeve on the storage tank.

3. Bend the pressing springs on the new sensor and push the new sensor into the sensor immersion sleeve.The insertion depth is marked on the ROTEX storage tank by a coloured marking, depending on the storage tank type.

4. Clamp the sensor cable on the connector of the connection terminals 11 and 12 of the 12-pin sensor connector J8, plug in the connector on the switchboard PCB and close the boiler control panel.

Fig. 5-14 Release the plug connection for the flue gas temperature sensor

Fig. 5-15 Unscrew the flue gas temperature sensor

For further information on fitting the storage temperature sensor see: "Storage temperature sensor" installation instructions.

36 FA ROTEX A1 B0 - 10/2007

5 x Control

5.7 Changing the fuse

The fuse is in the switchboard PCB. Fuse type: 250 V, 6.3 AT.

1. Open boiler control panel and remove all plugs from the switchboard PCB (see chapter 5.4, steps 1 to 4).

2. Remove the 4 locking screws on the control panel casing using a screwdriver (fig. 5-16).

3. Remove the top of the casing.

4. Change the fuse (fig. 5-17).

5. Replace top of casing.

6. Insert all connectors on the switchboard PCB. Close boiler control panel.

WARNING!

Live parts can cause an electric shock on contact and cause life-threatening burns and injuries.• Before beginning work on the oil condensing boiler, disconnect it from the power supply (switch off fuse,

main switch) and secure against unintentional restart.

Fig. 5-16 Remove the locking screws from the control panel casing

Fig. 5-17 Changing the fuse

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.

37FA ROTEX A1 BO - 10/2007

5 x Control

5.8 Wiring diagram

Fig. 5-18 Wiring diagram for oil condensing boiler A1 BO (shown with ROTEX THETA 23R Control)

1 Main switch2 Burner malfunction indicator3 STL indicator4 Manometer5 Controller: Central unit THETA 23R17 safety temperature limiter (STL)18 Stickers for connection diagram19 Circulation pump for heating20 3-way diverter valve21 Oil burner22 Outside temperature sensor23 Storage tank temperature sensor24 Flue gas temperature sensor

25 Return flow temperature sensor26 Flow temperature sensor27 Switchboard PCB J1 3-pin circuit board connector with pump cableJ2 4-pin circuit board connector with valve cableJ3 6-pin circuit board connector with clamped

burner cableJ3A Standard connector oil burner (7-pin)J3B 2-pin plug for remote burner unlockingJ4 Communication connection internal (not loaded)J5 4-pin circuit board connector with malfunction

indicator cable

J6 4-pin circuit board connector with clamped mains cable and earthing slots

J7 7-pin circuit board connector for clamping a mixer motor and a mixer circulation pump

J8 12-pin circuit board connector for clamping sensors, BUS- and control lines (storage temperature sensor and cable for external sensor are clamped)

J9 5-pin circuit board connector with STL cableJ10 8-pin circuit board connector with flue gas, flow

and return flow sensor cableJ14 3-pin circuit board connector for clamping

a circulation pumpJ15 4-pin circuit board connector with switch cable

38 FA ROTEX A1 B0 - 10/2007

6 x Oil burner

6 Oil burner6.1 Design and brief description

1 Automatic oil firing unit2 Oil pump3 Suction line connection 4 Return line connection5 Adjusting screw for recirculation opening6 Scale of recirculation opening7 Scale of air throttle8 Adjusting screw for air throttle9 Reset button for oil burner10 Holder for service position11 Blue Flame Meter12 Service Allen key13 Burner flange with seal14 Flame tube15 Flame monitor16 Connection for remote unlocking17 Connector socket, 7 pin18 Fan rigid in compression19 Air supply connector20 Electric motor21 Service screw22 Recirculation tube23 Nozzle connection cover

Fig. 6-1 Oil burner top view (rear view)

Fig. 6-2 Oil burner – Side view from left

Fig. 6-3 Oil burner – Side view from right

11

10

12

8

7

6 5 21 15 9

1

20

2

4

3

17

19

18

16

10

12

17

1 16 21 13 22 14

23

4

23

11

10

18

8

7 21 13 22 14

19

39FA ROTEX A1 BO - 10/2007

6 x Oil burner

The blue burner installed as standard is similar in design and function to EN 267. The burner is engaged on the burner flange with a bayonet lock and secured with a service screw. The construction of the burner head with internal flue gas recirculation makes high efficiency, low nitrogen oxide combustion possible. The recirculation tube is firmly mounted in the burner flange.

Preheating oilThe heating oil is preheated during the start phase. For this purpose, the boiler control first switches on the nozzle bar heating (the orange light on the automatic oil firing unit lights up). As soon as the oil preheating temperature is reached, the thermostat of the nozzle bar heating triggers the programme sequence. The heating time with a cold start is 2 to 3 minutes.

Sequence of firing programmeThe firing programme is monitored by the automatic firing unit. It proceeds with the following steps:– Oil preheating.– Electrical motor starts, ignition switches on.– Pre-ventilation.– Solenoid valve opens.– Flame formation (green LED lights up).– Ignition switches off.– Burner runs, as long as there is demand for burner by the Control and the flame monitor enables the burning process.– When the burner request by the Control ends: oil preheating and electrical motor switch off, solenoid valve closes.– Post-ventilation corresponding to the control setting.

Automatic firing unit DKO 974The automatic oil firing unit DKO 974 controlled by a microprocessor controls and monitors the firing programme. It features the following properties:– Stable programme times, independent of the fluctuations in the mains voltage or ambient temperature.– Operating safety, even in the event of power failures. The automatic firing unit switches off in the event of a power failure

without a fault signal and on again once the normal voltage has been resumed.An LED in the reset button of the automatic firing unit indicates the burner control processes. In normal mode, the LED sends a brief flashing signal, followed by a long pause. In the event of malfunction, a flashing code provides information on the cause of the fault (see chapter 9 "Faults and malfunctions").

6.2 Safety function

Fault shutdown and malfunction indicatorA fault shutdown takes place:– if a flame signal is present during pre-ventilation (remote light monitoring),– if no flame is formed on start (fuel release) after 5 seconds (safety period),– if there is a flame failure during operation after unsuccessful programme repetition and no flame is formed.

A fault is displayed:– by the burner malfunction indicator lighting up on the boiler control panel (fig 5-1, pos. 2),– by the LED in the reset button of the automatic firing unit (fig 6-1, pos. 9) being continuously lit up,– by "E" and a two digit fault code on the boiler control panel display.

Unlocking burner• By briefly pressing the Manual button on the boiler control panel (fig 5-1, pos. 13).

• By briefly pressing the Reset button on the boiler control panel (fig 5-2, pos. 29).• If there are several successive fault shutdowns, check the heating system (e.g. flue system, fuel supply).

6.3 Burner setting

�

�

�

CAUTION!

An inappropriate setting of the oil burner can lead to a prohibited level of pollutant emissions, heavy contam-ination and increased oil consumption.• Burner setting should be carried out only by authorised and recognised heating engineers.

40 FA ROTEX A1 BO - 10/2007

6 x Oil burner

6.3.1 Settings

Tab. 6-1 Settings on oil condensing boiler for operation dependent on ambient air

URS12 Conversion kit for the output range 12–14 kW. 15 46 15URS20 Conversion kit for the output range 20–24 kW. 15 46 24URS25 Conversion kit for the output range 25–27 kW. 15 46 28URS35 Conversion kit for the output range 33–35 kW. 15 46 35

The factory-preset values are printed in bold in tab. 6-1.

In the "Air throttle" column, the settings can vary from the specified value depending on the air and flue gas flow. It is therefore absolutely essential to monitor the air surplus (Lambda) by measuring CO2 or O2 (CO2 target value = 12.5–13.0 %). O2 target value = 3.3–4.0 %).

Unit Boiler output

Air nozzle Oil nozzle Danfoss 80°H

Oil pump pressure

Oil through-

put

Distanceoil-air nozzle

Recirculation gap

Air throttle Fan pressure

Conversion kit

kW ∅ / mm USgal/h (GpH) bar kg/h Dimension Y/mm

Scale/mm % mbar Type

A1 BO 15bio(Oil Blue burner BL 15)

12 19 0.30 10.5 1.05 3 2 Y64 Y3.9URS 12

13 19 0.30 13.0 1.14 3 2 Y68 Y4.4

14 19 0.35 10.0 1.23 4 2 Y70 Y5.0 Series status15 19 0.35 12.5 1.32 4 2 Y77 Y6.2

A1 BO 20i(Oil blue burner BL 20)

12 19 0.30 12.0 1,05 3 2 Y10 Y4.5

URS1213 19 0.30 13.5 1.14 3 2 Y11 Y5.0

14 19 0.30 15.5 1.23 4 2 Y13 Y5.7

15 19 0.40 10.0 1.32 4 2 Y20 Y6.3

Series status

16 19 0.40 11.5 1.41 4 2 Y23 Y7.2

17 19 0.40 13.0 1.49 4 2 Y26 Y7.9

18 19 0.40 14.5 1.58 4 2 Y29 Y8.5

19 19 0.40 16.5 1.67 4 2 Y41 Y9.4

20 19 0.40 18.0 1.75 4 2 Y100 Y10.4

A1 BO 27i(Oil blue burner B 27)

20 22 0.50 11.3 1.77 4 3 Y32 Y7.4

URS 20

21 22 0.50 12.7 1.86 4 3 Y40 Y7.9

22 22 0.50 14.0 1.92 4 3 Y60 Y8.6

23 22 0.50 15.4 1.98 4 3 Y90 Y9.2

24 22 0.50 16.8 2.10 4 3 Y100 Y8.6

25 24 0.55 11.5 2.16 4 3 Y44 Y6.9Series status

26 24 0.55 13.0 2.25 4 3 Y66 Y7.8

27 24 0.55 14.0 2.34 4 3 Y100 Y8.9

A1 BO 35i(Oil blue burner BL 35)

25 24 0.55 14.5 2.19 5 2 Y25 Y7.2URS 25

28 24 0.55 16.7 2.28 5 2 Y29 Y7.8

27 24 0.60 11.5 2.37 2 2 Y30 Y6.7

Series status

28 24 0.60 13.0 2.48 4 2 Y34 Y6.5

29 24 0.60 13.5 2.55 4 2 Y46 Y7.0

30 24 0.60 14.5 2.65 4 2 Y50 Y7.5

31 24 0.60 15.5 2.72 4 2 Y70 Y7.8

32 24 0.60 16.5 2.81 4 2 Y78 Y8.1

33 27 0.65 13.0 2.90 4 4 Y36 Y6.2

URS 3534 27 0.65 13.7 2.99 4 4 Y40 Y6.7

35 27 0.65 14.8 3.07 4 4 Y42 Y7.2

41FA ROTEX A1 BO - 10/2007

6 x Oil burner

6.3.2 Instructions for burner setting

The oil burner is factory-set for a certain output range (see tab. 6-1, values printed in bold).

To change the burner output:– Change the pump pressure,– Adjust air quantity,– Regulate the distance of the oil-air nozzles,– If large adjustment to output is made: change oil nozzle and air nozzle.

Conversion kitTo set some output ranges, a conversion kit URS is needed (see tab. 6-1).

Oil nozzlesROTEX recommends using Danfoss Type 80° H oil nozzles to maintain the emission limits as specified in RAL-UZ 46 (see tab. 6-1).

6.3.3 Check vacuum in the oil pump and set the oil pump pressure

Setting oil pressureThe oil pressure on the pump can be varied within the range of 10–18 bar. Increasing the oil pressure leads to higher boiler output, while reducing the oil pressure leads to lower boiler output.Tools required: Screw driver; Allen key SW 4 mm; Manometer 1/8", 0 to 20 bar.

• To increase pressure: Adjusting screw (fig 6-4, pos. 2) for oil pressure to be turned to the right.• To reduce the pressure: Adjusting screw (fig 6-4, pos. 2) for oil pressure to be turned to the left.• To check the oil pressure, connect the manometer to the manometer connection (fig 6-4, pos. 5) of the oil pump.

Check vacuumFor a long and fault-free operation, the oil supply system must be adjusted such that the vacuum does not exceed 0.2 bar.

Tools required: Vacuum meter R 1/8"; Allen key SW 4 mm;

• Connect vacuum meter to the V connection (fig 6-4, pos. 1) and measure vacuum with active burner.

1 Vacuum meter connection2 Adjusting screw for oil pressure3 Solenoid valves4 Pump cover5 Manometer connection6 Flow connection7 Return connection8 Oil pump filter

Fig. 6-4 Oil pump

CAUTION!

If the vacuum at the oil pump is too high, it causes greater wear to the pump and can destroy it.

If the vacuum is greater than 0.4 bar, the heating oil can degasify. There will be whistling noises in the pump, the pump can be destroyed. Vacuum greater than 0.2 bar causes greater pump wear.• Reduce the vacuum, check oil supply if necessary.

42 FA ROTEX A1 BO - 10/2007

6 x Oil burner

6.3.4 Set air quantity

The combustion air quantity is set using the adjusting screw for the air throttle (fig 6-5, pos. 1). The CO2 content in the flue gas must be regulated to 12.5–13.0 %.

Tools required: Flue gas analysis device to determine the CO2 content of the flue gas.

• Connect up the flue gas analysis unit.• To reduce air quantity: Turn air throttle adjusting screw to the left (lower scale value) O2 , CO2• To increase air quantity: Turn air throttle adjusting screw to the right (higher scale value) O2 , CO2

6.3.5 Setting recirculation gap

The recirculation gap is set using the adjusting screw (fig 6-6, Pos. 1) which causes an axial shift in the mixer device in the combustion tube (see fig 6-7).

The oil condensing boiler is generally designed to be operated independently of the ambient air and is equipped with a concentric flue gas / supply air connection DN 80/125. If it is operated depending on the ambient air and it is only connected to a single wall flue gas pipe, the settings can differ considerably from the values given in tab. 6-1.

1 Adjusting screw for air throttle2 Scale air throttle

Fig. 6-5 Setting the air throttle

You can make a rough pilot adjustment to the air quantity by using the values from tab. 6-1. But the rough adjustment cannot replace the fine adjustment with CO2 measurement in any case.

Fig. 6-6 Setting the recirculation gap Fig. 6-7 Flame tube and recirculation gap1 Adjusting screw for recirculation gap2 Scale recirculation gap

1 Recirculation gap2 Flame tube

The scale (fig 6-6, pos. 2) shows the set width of the recirculation gap (in mm). If the nozzle tube or the oil preheater are changed or an oil nozzle type different from the regular production type is used, there can be a difference between the scale display and the actual width of the recirculation gap.

43FA ROTEX A1 BO - 10/2007

6 x Oil burner

Tools required: Flue gas analysis unit for determining the emission values for NOx and CO in the flue gas.

• Connect the flue gas analysis unit.• Adjust the position of the recirculation gap with adjusting screw (for setting, see tab. 6-1).• Shut down and wait for about 5 minutes.• Restart the burner.

Burner does not start or is late: Reduce the width of the recirculation gap (lower scale value).

• Check emission values for NOx and CO (observe country-specific regulations).

6.3.6 Check and set electrode distance and the distance between oil nozzles and air nozzles

Checking and setting electrodes distance

Tools required: Feeler gauge "Blue Flame Meter" (fixed on the holder for the service position);

• Put burner in service position (see chapter 6.4).• Check electrode distance and position with feeler gauge "Blue Flame Meter".• If necessary, readjust electrodes by bending them.

CAUTION!

If the recirculation gap is too small or closed, it will cause a sudden temperature rise in the mixing device and can damage the mixing device.

a Mixing unitb Ignition electrodesc Fixing screwd Light tubee Oil nozzlef Air nozzleg Nozzle rod

X1 Electrode position BL 15, BL 20 and BL 27

X2 Electrode position BL 35Y Distance oil nozzle – air nozzle

Fig. 6-8 Check electrodes setting and distance oil nozzles - air nozzles

If the ignition electrodes are worn out, they must be replaced.

Notes on replacing the ignition electrodes are given in section 8.2.8.

44 FA ROTEX A1 BO - 10/2007

6 x Oil burner

Setting the oil nozzle – air nozzle distance

Tools required: Feeler gauge "Blue Flame Meter" (fixed on the holder for the service position); Allen key SW 4 mm;

• Put burner in service position (see chapter 6.4).• Check distance with the feeler gauge "Blue Flame Meter". For setting values refer to tab. 6-1.• To adjust, loosen the fixing screw and push the mixing device on the nozzle rod (also refer to fig 8-18 on page 59).

6.4 Removing/Installing burner

The burner is normally in operating position. In order to carry out work on the nozzle rod (e.g. changing nozzle or electrodes) or within the flame tube, the burner is moved to the service position.

It may be necessary to remove the burner for maintenance and cleaning jobs or if there is damage in the combustion chamber area.

Move the burner to service position

1. Switch off main heater switch.

2. Take off the sound insulation hood and boiler panels, remove upper heat insulation layers.

3. Pull off the air supply hose from the burner and rotate sideways.

4. Loosen the service screw (fig 6-10, pos. 1).

CAUTION!

Wrong distance setting can cause unclean burning, bad starting behaviour and increased burner wear.• Use the correct side of the feeler gauge.

WARNING!

Live parts can cause an electric shock on contact and cause fatal burns and injuries.• Switch off the heating main switch before removing the burner and secure it from being unintentionally

switched on.

WARNING!

Danger of burning – hot surfaces.• Let the burner cool down sufficiently before removing it.• Wear protective gloves.

Fig. 6-9 Burner in operating position Fig. 6-10 Loosen service screw on the burner1 Service screw2 Bayonet lock

45FA ROTEX A1 BO - 10/2007

6 x Oil burner

5. Rotate burner counter-clockwise from the bayonet lock (fig 6-10, pos. 2) and lift upwards.

6. Rotate burner by 180° around the motor axis and put aside on the burner flange.

7. Hang in the burner through the opening in the holder plate in the service screw and engage in the bayonet lock. Tighten the service screw.

The burner is now in service position.

Removing/Installing flame tubeThe flame tube can be removed with mounted burner and open boiler.


2. Take off the sound insulation hood and boiler panels, remove upper heat insulation layers.

3. Opening the combustion chamber (see section 8.2.5).

4. Rotate flame tube (turn bayonet lock counter clockwise by 1/8 rotation).

Install the flame tube in reverse sequence.

Removing the burner


2. Remove flame tube

3. Disconnect air supply hose, remote unlocking connector and burner plug (7-pin).

4. Unscrew the oil hoses from the oil filter.

5. Unscrew four fixing screws from the burner flange.

6. Lift the burner out of the combustion chamber.

Burner installation

1. Insert the burner into the combustion chamber, attach the burner flange securely with the four fixing screws.

2. Screw on the oil hoses on the oil filter.

3. Restore the electrical plug connections and connect the air supply hose to the burner.

4. Install flame tube.

5. Start burner, check functioning and settings (see chapter 6.3).

Fig. 6-11 Pull off burner Fig. 6-12 Service position

WARNING!

Danger of burning – hot surfaces (flame tube).• Let the burner cool down sufficiently before removing the flame tube.• Wear protective gloves.

46 FA ROTEX A1 BO - 10/2007

6 x Oil burner

6.5 Oil burner pump with LE system

The oil burner pump is a self-suctioning gear pump which is connected as a two-strand pump through a venting oil filter. Suction filters and oil pressure controllers are integrated in the pump.

An LE membrane valve is mounted in the oil preheater directly before the oil nozzle, which prevents pre and post-dripping when starting and switching off the burner.

To protect the oil pump and LE membrane valve, either insert the enclosed micro-replacement filter insert MC-7, ( 15 60 13) for short filter cups or the MC-18, ( 15 60 14) for long filter cups in the ventilation oil filters. Use only filters with a maximum of 25 µm.

A ThermostatB Connection plugC Heat exchangerD PTC heating elementE LE membrane valveF Oil nozzle

Fig. 6-13 Oil preheater with LE membrane valve

47FA ROTEX A1 BO - 10/2007

7 x Hydraulic connection

7 Hydraulic connection7.1 Integrated connection group

7.1.1 Design and function

The integrated connection group is a compact unit for connecting a heating circuit and a hot water tank to the oil condensing boiler ROTEX A1 BO.

The integrated circulation pump allows the required water to flow through the oil condensing boiler and the active circuit (hot water storage tank or heating circuit).

The 3-way diverter valve switches between the heating circuit and the hot water storage tank as required by the boiler control.

7.1.2 Releasing / restoring electrical connections

The integrated connection group is wired into the boiler control panel. The integrated heating circuit pump and the 3-way diverter valve on the unit are connected with plugs.• When changing the boiler control panel or the pump, unplug the pump cable from the terminal box on the pump.• Plug the 6-pin plug into the valve drive socket to connect the 3-way diverter valve (shape-coded).

Note the following for emergency operation if the valve drive is faulty:• Press the unlocking button (fig, 7-1, pos. 2.2) and rotate the motor head of the valve drive (fig, 7-1, pos. 2.1) 1/4 turn to the

left and remove.

The 3-way diverter 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 out of the valve drive.• Move diverter valve to centre position with hand lever (fig, 7-1, pos. 2.3) (only possible if the valve drive is already in

"Heating" position).

If the pumping capacity of the integrated circulation pump is not enough to supply of the heat distribution network (see fig, 11-2 to fig, 11-5), an additional pump can be installed in the heat distribution network. The additional pump must be uncoupled from the boiler circuit (e.g. through a hydraulic switch point).

Fig.7-1 Integrated connection group

1 Circulation pump2 3-way diverter valve2.1 Valve drive2.2 Unlocking button of the drive lock2.3 hand lever (shown in filling position)3 Boiler flow (Connection AB)

4 Heating flow (connection B)5 Storage tank charging flow (connection A)a Heating flow 1" ITb Heating return flow 1" ITc Storage flow 1" ETd Storage tank return flow 1" ET

WARNING!

Live parts can cause an electric shock on contact and cause life-threatening burns and injuries.• Disconnect from the power supply before beginning work on the integrated connection group (remove

fuse, switch off main switch) and secure against unintentional restart.

b

c

d

12

a

X

B

A

AB

4

3

5 2.2 2.12.32

X

48 FA ROTEX A1 BO - 10/2007


7.2 Hydraulic system connection

Fig, 7-2 and fig, 7-3 show examples of the integration of a Sanicube INOX hot water storage tank and a sub-tank US 150. Note that the hydraulic circuit shown does not claim to be complete and your system planning must therefore still be carried out thoroughly.

As a ROTEX certified company you will find other examples for hydraulic system connection concepts on the ROTEX Homepage.

1 Oil condensing boiler A1 BO2 Boiler circuit pump3 3-way diverter valve4 Hot water storage tank4.1 Storage tank4.2 Storage tank charging heat exchanger

(stainless steel corrugated pipe in SC538/16/0)

4.3 Domestic water heat exchanger (stainless steel corrugated pipe)

5 Storage temperature sensor for reloading

6 Cold water connection7 Hot water bleeding point8 Circulation pump (optional)9 Heating flow10 Heating return flow11 Storage tank (stainless steel)12 Storage tank flow13 Storage tank return flow14 Return valve15 Pressure relief valve16 Anti-scalding

(storage tank operating temperature > 60 °C)

17 Cold water distribution network18 Gravity brake (accessories)19 Pipe aspirator

H1...Hm Heating circuits

Fig.7-2 Hydraulic circuit ROTEX A1 BO with Sanicube STAINLESS STEEL

Fig.7-3 Hydraulic circuit ROTEX A1 BO with US 150

49FA ROTEX A1 BO - 10/2007


7.3 Hot water storage tank (not included in scope of supply)

Five types of hot water storage tanks are available for the oil condensing boiler A1 BO (see tab. 7-1). Correct integration of the hot water storage tank into the heating network is shown in fig, 7-2 and fig, 7-3. Alternatively, the ROTEX Solaris System can be integrated for hot water preparation and heating support.

Technical data hot water storage tank

Tab. 7-1 Basic technical data for the ROTEX hot water storage tank which can be connected to the oil condensing boiler

For further information on the hot water tanks, refer to documents for Sanicube INOX, Sanicube PEX and Solaris.

Type Sanicube INOX Sanicube INOX SanicubeSolaris INOX

SanicubeSolaris PEX

Sub-tank for hot water

storage tank

Parameter SCS 328/14/0 SC 538/16/0 SCS 538/16/0 SCS 580/1 US 150

Basic data

Total storage capacity 285 Litres 500 Litres 500 Litres 500 Litres 148 Litres

Empty weight 55 kg 84 kg 87 kg 109 kg 44 kg

Total filled weight 335 kg 584 kg 587 kg 609 kg 192 kg

Dimensions (L x B x H) 59.5 x 61.5 x 159 79 x 79 x 159 cm 79 x 79 x 159 cm 79 x 79 x 159 cm 100 x 66 x 66 cm

Max. permitted storage water temperature 85 °C 85 °C 85 °C 85 °C 90 °C

Standby heating power 2.3 kWh/24h 1.4 kWh/24h 1.4 kWh/24h 1.4 kWh/24h 1.1 kWh/24h

Maximum operating pressure 10 bar 10 bar 10 bar 6 bar 10 bar

Domestic water heat exchanger materialStainless steel

(1.4404)Stainless steel

(1.4404)Stainless steel

(1.4404)PEX

Stainless steel (pressure tank)

Domestic hot water

Domestic water capacity 18.0 Litres 24.5 Litres 24.5 Litres 80.0 Litres 144.0 Litres

Domestic water heat exchanger surface 4.1 m2 5.5 m2 5.5 m2 25.0 m2

Average specific thermal output 1820 W/K 2470 W/K 2470 W/K 1620 W/K

Storage tank charging heat exchanger (stainless steel)

Water content heat exchanger 10.0 Litres 10.4 Litres 10.4 Litres 10.4 Litres 3.3 Litres

Heat exchanger surface area 2.1 m2 2.3 m2 2.3 m2 2.3 m2 0.7 m2

Average specific thermal output 910 W/K 1040 W/K 1040 W/K 1040 W/K 700 W/K

Solar heating support (stainless steel)

Water content heat exchanger 2.0 Litres

Heat exchanger surface area 0.43 m2

Average specific thermal output 200 W/K

Pipe connections

Hot and cold water 1" ET 1" ET 1" ET ¾" IT ¾" IT

Heating flow and return flow 1" ET 1" ET 1" ET 1" ET ¾" ET

Order number 16 50 10 16 50 16 16 45 16 16 50 06 16 01 50

50 FA ROTEX A1 BO - 10/2007


Thermal output data Hot water storage tank

Tab. 7-2 Thermal output data of the ROTEX hot water storage tank which can be connected to the oil condensing boiler

* TKW = Cold water temperatureTWW = Hot water temperatureTSP = Storage temperatureTV = Feed temperature

The plastic gravity brakes recommended as an accessory ( 16 50 70) in the pipe connections are suitable for temperatures up to max. 90 °C.

Type Sanicube INOX Sanicube INOX SanicubeSolaris INOX

SanicubeSolaris PEX

Sub-tank for hot water

storage tank

Parameter SCS 328/16/0 SC 538/16/0 SCS 538/16/0 SCS 580/1 US 150

Efficiency characteristic NL according to DIN 4708 (on recharging at 35 kW, TKW = 10 °C / TWW = 45 °C / TSP = 65 °C / Tv = 80 °C):

2.2 4.1 2.3 3.5 2.2

Continuous output QD according to DIN 4708 27 kW 35 kW 35 kW 35 kW 25 kW

Maximum draw-off rate for the duration of 10 min on recharging at 35 kW (TKW = 10 °C / TWW = 40 °C / TSP = 60 °C)

21 l/min 30 l/min 22 l/min 25 l/min 16 l/min

Hot water quantity without reheating with up to 15 l/min draw-off rate (TKW = 10 °C / TWW = 40 °C / TSP = 60 °C)

200 Litres 412 Litres 220 Litres 335 Litres 250 Litres

Hot water quantity with reheating at 20 kW reheating power and 15 l/min draw-off rate(TKW = 10 °C / TWW = 40 °C / TSP = 60 °C)

400 Litres 837 Litres 442 Litres 600 Litres 300 Litres

Short-term water quantity in 10 min 210 Litres 300 Litres 220 Litres 250 Litres 160 Litres

51FA ROTEX A1 BO - 10/2007

8 x Inspection and maintenance

8 Inspection and maintenance8.1 General overview of inspection and maintenance

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

Tests during the annual service:– General condition of the heating system, visual inspection of connections and pipes.– Flue gas temperature and flue gas temperature sensor.– Functioning of the condensate treatment unit (determination of pH value).– Burner operation and burner settings.

Maintenance work to be carried out annually:– Cleaning the burner components, the combustion chamber and the heating surfaces.– Cleaning the boiler panelling and the sound insulation hood.– Cleaning and regeneration of the Condensate treatment unit.– Replacement of the consumables (if required).

8.2 Service and maintenance tasks

8.2.1 Removing panelling (and cleaning it)

For the maintenance activities, sound insulation hood, boiler panelling and heat insulation layers must be removed.

Have the service and maintenance carried out by authorised and trained heating engineers once a year and, if possible, before the heating period starts. This will avoid malfunctions during the heating period.

ROTEX recommends a service and maintenance contract to ensure regular service and maintenance.

WARNING!

Live parts can cause an electric shock on contact and cause life-threatening burns and injuries.• Before beginning maintenance work, disconnect the oil condensing boiler from the power supply

(switch of 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 service work.• Wear protective gloves.

Fig. 8-1 Remove the sound insulation hood. Fig. 8-2 Remove the holding clamps on the heat insulation layers

52 FA ROTEX A1 BO - 10/2007


1. Remove the sound insulation hood (see fig. 8-1).

2. Lift and remove the boiler panelling.

3. Remove the holding clamps on both upper heat insulation layers (see fig. 8-2). Remove both upper heat insulation layers.

Cleaning panelsThe sound insulation hood and the boiler panels are made of easy-to-maintain plastic. Clean them only using soft cloth and a mild water and soap cleaning solution. Aggressive cleaning agents with solvents can damage the plastic surface.

8.2.2 Checking the connections and pipes

• Check all oil 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 system for leakage and damage. Repair damaged parts or replace them.• Check all electrical components, connections and pipes. Repair damaged parts.

8.2.3 Checking the condensate treatment unit

The condensate treatment unit cleans the draining condensation and neutralises its pH-value. The connection and drainage line of the condensate drain must be free from impurities.

Checking that the condensate treatment unit is working (pH value).

1. Dip the indicator strips (provided with condensate treatment unit) into the water from the neutralisation box outlet.

2. Remove the indicator strips after about 1 minute and compare the colour of the indicator strip with the accompanying colour table.

The numerical value above the colour combination corresponds to the pH value of the water.

pH value = 7F1: condensate treatment neutralised correctly.

pH value <6: condensate treatment not neutralised adequately.

When the condensate treatment is not neutralised adequately:

1. Check the flue gas temperature (see chapter 8.2.4).

2. Check the burner chamber and clean if needed (see chapter 8.2.5).

3. Dismantle and regenerate the condensate treatment unit.

WARNING!

Improper work on live components can be a health and safety risk endangering human life and adversely affect the operation of the oil condensing boiler.• Damage restoration on live components of the oil condensing boiler may be carried out only by authorised

and recognised heating engineers.

CAUTION!

Escaping gases can cause breathing problems and poisoning.• The condensate treatment unit must always be connected and filled up, otherwise flue gases could escape

into the installation room.

The pH value measurement can be dispensed with if low sulphur EL heating oil is used exclusively and the responsible Water Authorities do not specify neutralisation.

A pH value < 5 despite regular maintenance indicates that the neutralisation medium is spent and the filling quantity is no longer sufficient. In such a case, change the neutralisation medium ( 15 45 75).

53FA ROTEX A1 BO - 10/2007


Disassembling and draining the condensate treatment unit

1. Open the fixing belt (fig. 8-3, pos. 3).

2. Lift the stabilising plate (fig. 8-4, pos. 1) and pull out the connecting muff (fig. 8-4, pos. 2) from the condensate drain.

3. Lift up condensate treatment unit and drain through the connecting hose (fig. 8-5).

4. Place collector container under the hose connection. Pull out the flexible connecting hose from the condensate treatment unit (fig. 8-6).

5. Pull the condensate treatment unit out from under the boiler.

CAUTION!

Danger of chemical burns! The condensate treatment unit contains acid which can cause injury on skin contact.• Wear protective clothing when working on condensate treatment unit (protective goggles, rubber hand

gloves).• If your skin comes in contact with anything, wash the affected area immediately with tap water.• If the chemicals come in contact with eyes, immediately wash with tap water and consult an

ophthalmologist.

Fig. 8-3 Connections for condensate treatment unit Fig. 8-4 Condensate treatment unit –Wrapped connections

1 Condensate treatment unit2 Wrapped connection on flue gas arc3 Fixing belt with snap closing4 Flexible connecting hose

2 Wrapped connection on flue gas arc5 Stabilising plate

Fig. 8-5 Draining the condensate treatment unit Fig. 8-6 Pull out connecting flexible hose

25

54 FA ROTEX A1 BO - 10/2007


Regenerate condensate treatment unit.To regenerate the condensate treatment unit, thoroughly rinse and vigourously shake up the shell limestone in it.

Requirement: The condensate treatment unit is dismantled.

Mounting the condensate treatment unit

Filling condensate treatment unit with waterThe condensate treatment unit holds about 2.5 litres of water. It can be filled in several ways.

a) If there is an inspection opening in the connecting piece of the flue gas pipe, the condensate treatment unit can be filled through the flue gas pipe. For this, unscrew the inspection cover and hold a water hose in the inspection opening of the flue gas pipe. The superfluous water flows into the drainage system through the flexible hose (fig. 8-9).

b) The condensate treatment unit is filled through the boiler. For this, open the boiler body, remove the combustion chamber insert and hold a water hose in the combustion boiler (fig. 8-10).

• Rinse condensate treatment unit several times with flowing water (counter current), until clear water emerges.fig. 8-7 Fluff the condensate treatment unit several times so that the deposits will loosen up.

• If necessary, replace the neutralisation medium (shell limestone) ( 15 45 75).

Fig. 8-7 Rinse condensate treatment unit

1. Push the condensate treatment unit under the boiler.

2. Plug the flexible connecting hose to the condensate treatment unit (fig. 8-6).

3. Place connecting sleeve (see fig. 8-4, pos. 2) tight on the condensate drain bracket.

4. Rotate the stabilising plate downwards and snap into place (fig. 8-8).

5. Close and tighten fixing belt (see fig. 8-3, pos. 3). Tighten the belt so much that the wrapped connection cannot loosen itself (insert a wedge if necessary).

6. Fill condensate treatment unit with water.Fig. 8-8 Snap stabilising plate into place

Fig. 8-9 Fill condensate treatment unit through the flue gas pipe Fig. 8-10 Fill condensate treatment unit through the boiler

55FA ROTEX A1 BO - 10/2007


8.2.4 Checking the flue gas temperature

The flue gas temperature can be checked:– on the boiler control panel by using the Info button (see manual "ROTEX Control"),– on the measuring piece of the flue gas pipe by using a flue gas thermometer.If the flue gas temperature exceeds the boiler temperature by more than 40 K after 10 minutes of operating the burner, the combustion chamber should be cleaned (see section 8.2.5).

Checking the flue gas temperature sensor

1. Unscrew the box nut (fig. 8-11, pos. 4) and pull out the flue gas temperature sensor carefully with the guide sleeve (fig. 8-11, pos. 3).

2. Check flue gas temperature sensor for contamination and corrosion. Clean if needed. Do not use any metallic cleaning devices (e.g. wire brush).

8.2.5 Checking and cleaning the combustion chamber

If there are impurities, or if unsatisfactory combustion values are detected, the combustion chamber must be cleaned and readjusted. If necessary, reset the burner.

Opening the combustion chamber

Special tool: Combustion chamber key, fixed on the inside of the boiler panels (included in the supply).

CAUTION!

The fitting position of the flue gas temperature sensors is factory-adjusted by a fixing screw. Modifying the fitting position adversely affects the correct functioning of the flue gas temperature sensor.• Never loosen the fixing screw (fig. 8-11, pos. 2) when inspecting the flue gas temperature sensor.

1 Sensor cable to the boiler control panel2 Fixing screw – Do not loosen!3 Guide bush4 Union nut5 Flue gas temperature sensor

Fig. 8-11 Position of the flue gas temperature sensor

When replacing the flue gas temperature sensor, ensure that the end of the flue gas temperature sensor projects 28±2 mm out of the guide sleeve.

WARNING!

Danger of burning on hot surfaces.• Before starting work on the burners, the combustion chamber and the combustion chamber inserts, allow

them to cool down.• Wear protective gloves.

1

2

3

5

4

56 FA ROTEX A1 BO - 10/2007


• Disconnect the oil condensing boiler from the power supply (fuse, main switch off) and secure against unintentional restart.• Remove four Allan screws M10 (see fig. 8-12).• Tilt the combustion chamber upwards (see fig. 8-13). An air pressure spring keeps the upper half of the combustion chamber

open.

• Only in A1 BO 27i and A1 BO 35i: Remove cylindrical combustion chamber ring.• Remove combustion chamber insert with the help of the combustion chamber key (fig. 8-14 and fig. 8-15).

Cleaning the combustion chamberDepending on the heating oil quality and the operating temperatures, deposits and contamination of varying intensity are formed in the A1 BO.

Requirement:The gap between the boiler half shell in the joint area is covered to prevent residues from the upper boiler half shell from falling into the gap.

Special tool: Cleaning brush, cleaning scraper (included in scope of supply).

Remove dry residue (mostly in the upper boiler half cup):• Loosen the dirt and soot on the combustion chamber ribs by using the cleaning brush and cleaning scraper.• Suction off the loosened dirt and soot by using a vacuum cleaner.

In the transition area between dry and moist combustion chamber areas (mostly in the lower boiler half cup) there is hard residue that can be removed only with wet cleaning. For this:• Loosen dirt and rust under running water spray (fig. 8-16) with cleaning brushes and scrapers.• Rinse off loosened dirt with clean water into the drain.

Always remove any existing residue with high pressure cleaner. For this purpose:• Close combustion chamber without combustion chamber insert.• Unscrew burner incl. burner flange (see chapter 6.4).• Clean combustion chamber through burner flange opening with high pressure cleaner (fig. 8-17).

Fig. 8-12 Opening the combustion chamber Fig. 8-13 Fold the combustion chamber upwards

Fig. 8-14 Attach combustion chamber key(shown A1 BO 20i)

Fig. 8-15 Lift out the bottom combustion chamber insert (shown A1 BG 20i)

57FA ROTEX A1 BO - 10/2007


8.2.6 Checking the oil filter and cleaning the oil pump filter

• Check oil filter for contamination, replace if needed.

The oil pump filter is located under the oil pump cover (see fig. 6-4, page 42).• Loosen screw (fig. 6-4, pos. 8) and remove oil pump lid.• Remove oil pump filter and clean it.• Insert new or cleaned oil pump filter.• Check seal of oil pump cover and replace if needed.• Put the pump lid in place and bolt it down.

8.2.7 Checking the burner

Checking the burner includes visually inspecting the burner's condition as well as making flue gas measurements.Check:• Open the combustion chamber Remove the burner only if the area of the combustion chamber is damaged.• Clean the burner surface (cloth, plastic brush).• Visual inspection of the fuel lines for clogging and denting. • Check oil filter of the suction line, change the filter set if necessary.• Clean the burner head at fuel exit in the area of baffle plate.

• If necessary, replace faulty parts.• Close the combustion chamber.• Start burner and with the "Control measurement" setting (see chapter 14) allow to run for approx. 10 min.• Check combustion values:

– Flue gas temperature at measuring sockets of the flue gas pipe. (Target value < 120 °C),– O2 or CO2 content (see section 6.3.1),– CO content (target value < 50 ppm).– Soot number according to Bacharach-Scale < 1.

If the combustion values do not fall within the target range, the burner must be adjusted accordingly (see chapter 6.3).

Fig. 8-16 Wet clean combustion chamber Fig. 8-17 Clean combustion chamber with high pressure cleaner

To protect the oil pump and LE membrane valve, either insert the enclosed micro-replacement filter insert MC-7, ( 15 60 13) for short filter cups or the MC-18, ( 15 60 14) for long filter cups in the ventilation oil filters. Only use filters of maximum 25 µm.

For more detailed information on checking and setting the burner, see chapter 6.3, on installation and removing the burner, see chapter 6.4.

In the course of the maintenance activities, the automatic firing unit DKO 974 must also be rechecked to see whether it attains the rated life cycle: 10 years or 250,000 burner starts,

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

58 FA ROTEX A1 BO - 10/2007


8.2.8 Replacing the oil nozzle and ignition electrodes

Requirement: Burner is in service position (see chapter 6.4).

Removing oil nozzles

1. Pull out ignition cables from ignition electrodes (fig. 8-18, pos. a).

2. Loosen fixing screws (fig. 8-18, pos. c) and pull out mixing device upwards.

3. Unscrew nozzles with wrench or ring spanner SW 16. Hold back the nozzle rod with an open-end wrench SW 16.

Replacing ignition electrodes

Fitting oil nozzle

1. Screw in the oil nozzle with open end or ring spanner SW 16 on the nozzle rod. Hold back the nozzle rod with an open-end wrench SW 16.

2. Fitting mixing device. Thereby, position the light tube (fig. 8-18, pos. d) between the guide pins in the nozzle lid (see fig. 6-2, pos. 23). Maintain oil-air nozzle distance (Dimension "Y") (see tab. 6-1, chapter 6.3).

3. Plug on ignition cable on the ignition electrodes.

WARNING!

Danger of burning on hot surfaces.• Before starting work on burners and combustion chamber, allow them to cool down sufficiently.• Wear protective gloves.

a Mixing unitb Ignition electrodesc Fixing screwd Light tubeg Nozzle rod (oil preheater)

Fig. 8-18 Mixing head and ignition electrodes

If the LE membrane valve (fig. 6-13, page 47) is clogged and needs to be changed, it can be pulled out after unscrewing the oil nozzle from the nozzle holder of the oil preheater by using a M5 screw.

If the ignition electrodes are worn out, they must be replaced.

• Loosen fixing screw with Allan key SW 3.• Replacing ignition electrodes• Tighten fixing screw with Allan key SW 3.

Fig. 8-19 Fixing screw for the ignition electrodes

To protect the oil pump and LE membrane valve, either insert the enclosed micro-replacement filter insert MC-7, ( 15 60 13) for short filter cups or the MC-18, ( 15 60 14) for long filter cups in the ventilation oil filters. Only use filters of maximum 25 µm.

59FA ROTEX A1 BO - 10/2007

9 x Faults and malfunctions

9 Faults and malfunctions9.1 Troubleshooting

The electronic system in the oil condensing boiler detects faults and displays them:– Through a fault code in the display, for faults detected by the boiler control.– Through the burner malfunction indicator on the boiler control panel and through a fault code on the display, for faults

detected by the DKO automatic firing unit which lead to an interlocking malfunction.– Through the STL indicator in the boiler control panel for a boiler overheating detected by the safety temperature limiter (STL)

that leads to an interlocking malfunction.

Troubleshooting• Detecting and remedying the cause of the malfunction.• Interlocking fault with fault code in the display: Unlock by briefly pressing the Manual button (Reset button ) on the

boiler control panel (see chapter 9.4).• STL malfunction: By unlocking the STL switch (see chapter 9.5).• Non-interlocking malfunctions are indicated as long as there is a malfunction. Once the cause has been eliminated, the unit

continues to work normally.

9.2 Overview of possible malfunctions

Tab. 9-1 Possible malfunctions on the A1 BO (Part 1)

1) see documentation "ROTEX control"

You will find detailed information on the control unit and the boiler control panel as well as on the operating modes and parameter settings in chapter 5 "Control unit" and in the documentation "ROTEX Control" as supplied with the associated Control unit.

� �

Malfunction Possible cause Possible solution

Heating system not functioning (main switch not illuminated, no display)

No mains voltage • Switch on boiler main switch• Turn on main switch of heating room• Check / switch on fuse house connection• Check / renew fuse boiler control panel

Heating does not warm up

Central heating standby switched off (e.g. timer is in economy phase, outside temperature too high)

• Check operating mode setting1)

• Check requirement parameter1) (e.g. timer programme)

Heating does not warm up enough

Heating characteristic too low • Increase parameter value1)

Hot water does not warm up

Storage charging standby switched off (e.g. timer is in economy phase)

• Check operating mode setting1)

• Check requirement parameter1)

Hot water does not warm up enough

Storage tank charging temperature too low • Increase hot water target temperature1)

Draw-off rate too high • Reduce the draw-off rate, limit throughput

Burner output too low • See malfunction "Maximum burner output too low"

Maximum burner output too low

Burner setting wrong Oil nozzle wrong or dirty

• Adjust burner setting (see chapter 6.3)• Replace oil nozzle (see section 8.2.8)

Air/flue gas resistance too high • Check pipes for dirt.• Use pipes with larger cross section for supply air or flue gas if

necessary

Oil filter dirty • Replace oil filter

Burner does not start Interlocking malfunction • Establish cause of malfunction and eliminate it• Unlock by briefly pressing the Manual button

Burner motor not running despite burner demand

No mains voltage on burner • Insert the 7-pin plug on the motor until it engages• Check voltage at the terminals L-N of the 7 pin plug• Check / renew fuse.

60 FA ROTEX A1 BO - 10/2007




Burner motor not running despite burner demand

Plug connections of the control unit are loose • Check/insert plug connections

Heater element or thermostat for preheating of the heating oil defective

• Change oil preheater

Burner motor defective (bearing has seized) • Change burner motor

Condenser defective • Change condenser

Oil pump has seized • Change oil pump

Burner starting is hard Start delay due to bad ignition • Adjust ignition electrodes

Burner starts with blue flame, but tears out at intervals

Recirculation too large • Reduce recirculation slightly

Flame has gold strands, higher NOx-component

Recirculation too low • Raise recirculation further

Flame is all blue and stable in operation, but cold start not possible

Recirculation too large • Reduce recirculation slightly

No ignition Ignition electrodes short circuited • Set/change ignition electrodes

Distance of ignition electrodes too large • Set ignition electrodes

ignition electrodes contaminated or humid • Clean ignition electrodes, check oil nozzle and burner setting

Ignition electrodes burnt out • Change ignition electrodes

Insulating body cracked • Change ignition electrodes

Ignition transformer defective • Replace ignition transformer

Ignition cable burnt • Change ignition cable and determine the cause

Automatic firing unit faulty • Change automatic firing unit

Loud, whistling mechanical noise

Oil pump is suctioning air • Check bolts

Vacuum in the oil line too high • Clean the filter, open valves fully

Burner motor bearing defective • Change burner motor

Oil pump defective • Change oil pump

Oil pump does not pump any oil

Stop valve at oil filter or in suction line closed • Open stop valve

Oil pump gear damaged • Change oil pump

Suction valve has leakage • Clean/change suction valve

Oil line has leakage (pump suctions air) • Check bolts

Filter clogged • Clean the filter

Filter not leakproof • Change filter

Oil pump power insufficient • Change oil pump

Clutch defective • Change clutch

Oil atomisation not uniform – heavy soot deposit in flame tube

Oil nozzle loose, clogged or worn out • Check/tighten/change oil nozzle

Oil nozzle spraying angle is wrong • Replace oil nozzle

No oil flow Oil nozzle clogged • Replace oil nozzle

LE membrane valve clogged • Change LE membrane valve or oil preheater

Mixer device has thick layer of oil or heavy carbon deposits

Air supply insufficient • Check air supply line for clogging• Use air supply lines with larger cross-section• Ambient air dependent operation: Check air supply opening

(min. 150 cm2 unlockable air supply opening)

61FA ROTEX A1 BO - 10/2007



9.3 Control unit fault signals

The control unit detects malfunctions, e.g. sensor disruptions or short-circuits. The type of malfunction is displayed via a fault code. The fault codes are explained in the documentation of the relevant ROTEX control.

9.4 Burner malfunctions

The LED in the reset button of the automatic firing units (fig 6-1, pos. 9) indicates the processes of the burner control. In the normal mode, the LED transmits a brief flashing signal, followed by a long pause.LED display in the event of a malfunction:– LED burns steadily, the burner is shut off and locked.– The continuous lighting is interrupted every 10 seconds and a flash code is broadcast which gives information about the

cause of the last fault.

Fig. 9-1 Fault codes of the automatic firing units

I short signall long signal— Pause


Mixer device has thick layer of oil or heavy carbon deposits

Air supply line contaminated/clogged • Clean air supply line

Flue gas pipe of the LAS is leaking • Seal the flue gas pipe, change seal

Burner setting wrong • Check/correct burner setting

Oil nozzle is wrong size • Check/change nozzle type

Combustion air quantity wrong • Measure fan pressure, correct burner setting

Suction line draws air (leakage) • Seal suction line

Soot formation on the air nozzle

Recirculation too low • Open recirculation slightly

Solenoid valve at oil pump does not open

Coil defective • Change coil

Automatic firing unit faulty • Change automatic firing unit

Automatic flame guard does not actuate

Flame guard contaminated or defective • Clean or change flame guard

Glass on light tube dirty • Clean or change glass or light tube

STL switch off Water throughput too low due to air inclusion • Vent system

Water flow too low due to valves closing too quickly along the entire heating network

• Use slow closing or timed valves, if needed, install overflow valve

Pump standstill • Check network connection, change pump if necessary

Storage tank switched off in operation without hot water storage tank

• Disconnect storage temperature sensor• Switch off storage tank charging circuit

Flue gas temperature sensor switch off

Flue gas temperature too high • Clean the boiler

Flash Code Cause of the fault

l l l l l No flame signal within safety period

l l l l l External light during pre-ventilation time/ pre-ignition time

l l l l l Contact release thermostat does not close within 400 s

l l l l l — l l l l l Manual fault shutdown

62 FA ROTEX A1 BO - 10/2007


Unlocking the automatic firing unit: Requirements: The cause of the malfunction is rectified, the burner is electrically connected.

• Turn on A1 BO.

• Reset by briefly pressing the Manual button on the boiler control (fig 5-1, pos. 13).

• Reset by briefly pressing the Reset button on the boiler control (fig 5-2, pos. 29).

9.5 Rectifying STL fault

When the STL indicator (fig 5-1, pos. 3 and fig 5-2, pos. 3) lights up, it indicates the boiler overheating. The safety temperature limiter (STL) shuts off the system and locks it.

• Before unlocking the STL, determine the cause for the boiler overheating and rectify it (see tab. 9-3).

Unlocking the STL • Remove sound insulation hood (see fig 2-1, pos. 1).• Unscrew STL cover (fig 5-1, pos. 17 and fig 5-2, pos. 17).• Unlock STL switch with pointed object.• Screw on STL switch.• Install sound insulation hood.

9.6 Emergency operation

In manual operation, the 3-way diverter valve is in the "Storage tank charging" position first. On reaching the maximum adjustable storage tank temperature, the 3-way diverter valve is switched to the "Heating" position.

If the 3-way diverter valve is faulty, the motor head of the valve drive can be removed (see section 7.1.2). The diverter valve is on the Heating setting.

Manual parallel operation of the heating circuit and hot water storage tank can be set temporarily (see section 7.1.2).

In the event of a malfunction or incorrect settings of the electronic control, emergency heating operation can be maintained.• Press Manual button (fig 5-1, pos. 13) for approx. 5 s.

The indication "Manual operation" appears on the display.

• Adjust the desired temperature with the rotary switch (setting range 5–80 °C).

The cause of the last fault is saved in the unit and can be reconstructed on restarting the unit, even after power failure.

Further information about operating processes and malfunctions can be obtained from the automatic units by using a reading unit (accessory).

�

�

WARNING!

Risk of burns due to hot boiler body.• Do not touch any metallic parts on the boiler.• Let the boiler cool down.• Wear protective gloves.

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63FA ROTEX A1 BO - 10/2007

10 x Taking out of service

64 FA ROTEX A1 BO - 10/2007

10 Taking out of service10.1 Temporary shutdown

If no heating and no hot water supply is needed over a long period, the oil condensing boiler can be temporarily shut down. ROTEX, however, recommends putting the system on Standby mode (see Documentation "ROTEX Control"). The heating system is then protected from frost. The pumps and valve protection functions are active.If it is not possible to guarantee the oil and power supply when there is danger of frost,– the oil condensing boiler must be drained,– the condensate treatment unit must be drained,– suitable antifreeze measures must be taken for the connected heating system and hot water storage tank (e.g. draining).

Draining the heating system• Switch off the main switch and secure against restarting.• Close the stop valve on the oil filter.• Bleed all the water in the entire system at the filling and draining sockets (KFE cock).

10.2 Final shutdown and disposal

For final shutdown, the oil condensing boiler must be• taken out of service,• disconnected from all electrical, oil and water connections,• disposed off in a professional manner.

Recommendations for disposalThe ROTEX oil condensing boilers are designed to be environmentally friendly. During the disposal process, the only waste accrued is that which can be used for material or thermal recycling. The materials used can be separated into different types.

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 and there is the risk of frost, the oil and power supplies must be secured

and the main switch must remain switched on.

Through the environmentally-friendly design of the oil condensing boiler, ROTEX has complied with the requirements for environmentally-friendly disposal. Proper disposal in compliance with the respective national regulations of the country of use is the responsibility of the user/owner.

11 xTechnical data

11 Technical data Basic data

Tab. 11-1 Basic data oil condensing boiler

Tab. 11-2 Basic data oil burner

Boiler type A1 B0 15bio A1 B0 20i A1 BO 27i A1 BO 35i

Product Identification Number (CE number) CE 0645 BM-105.2

Length 720 mm

Width 625 mm

Height 1100 mm 1100 mm 1220 mm 1340 mm

Weight of the boiler body 49 kg 49 kg 58 kg 67 kg

Transport weight Unit (without panels and condensate preparation)

81 kg 81 kg 96 kg 113 kg

Water content 3.0 l 3.0 l 4.5 l 5.0 l

Rated thermal output (according to DIN-EN 303) 12–15 kW 12–20 kW 20–27 kW 25–35 kW

Set rated thermal output upon delivery 14 kW 18 kW 25 kW 30 kW

Setting range (burner with series configuration) 14–15 kW 15–20 kW 25–27 kW 27–32 kW

Output range for burner conversion URS 12: 12–13 kW URS 12: 12–15 kW URS 20: 20–24 kW URS 25: 25–27 kWURS 35: 33–35 kW

Maximum permissible flow temperature 80 °C

Maximum permitted operating overpressure 4 bar

Boiler efficiency up to 105 %

Energy efficiency according to efficiency guidelines

CO emission class (acc. to EN 303-2) 3

NOx emission class (acc. to EN 303-2) 3

Diameter of flue gas connection/air supply connection

80/125 mm

Voltage supply 230 V~, 50 Hz


Burner type ROTEX BL 15 ROTEX BL 20 ROTEX BL 27 ROTEX BL 35

Burner output 12.4–15.5 kW 12.4–20.8 kW 20.4–27.8 kW 25.5–36.8 kW

Oil-throughput 1.05–1.32 kg/h 1.05 kWh/-1.75h 1.72–2.34 kg/h 2.15–3.10 kg/h

Heating oil Extra light as specified in DIN 51603-1, preferably low sulphur

Maximum bio-heating oil ratioBTL or FAME acc. to DIN V 51 603-6

20 % 10 % (20 % after burner retrofit)

Hydraulic system Single stage with oil preheating

Air regulation Linearised air metering drum

Regulation ratio 1:1

Voltage supply 230 V~ 50 Hz

Electrical power consumption (pre-ventilation) 250 W (10.0 bar) 260 W (14.5 bar) 260 W (11.5 bar) 265 W (14.5 bar)

Electrical power consumption (continuous operation)

225 W (10.0 bar) 230 W (14.5 bar) 225 W (11.5 bar) 250 W (14.5 bar)

Weight 9.5 kg 9.5 kg 9.5 kg 10.5 kg

Test as specified in EN 267 Registration number: 5 G 966/2001

Output electrical motor at 2800 min-1 90 W 90 W 90 W 180 W

Protection type IP 40

65FA ROTEX A1 BO - 10/2007

11 x Technical data

Tab. 11-3 Classification of burner components in the A1 BO

Integrated connection group

Tab. 11-4 Technical data of the integrated connection group


Burner type ROTEX BL 15 ROTEX BL 20 ROTEX BL 27 ROTEX BL 35

Automatic firing unit DKO 974 Mod. 5 (Satronic)

Flame monitor Satronic IRD 1010 red axial or BST Solutions KLC 2002 axial

Ignition transformer Beru Type MKZ 100 No. 0 096 600 017: 2x 7.5 kV, 20 kHzor Danfoss Type EBI No. 052 F0077: 2x 7.5 kV, 20 kHz

Solenoid valve Danfoss Type 071 N 0051

Oil pump, pumping capacity Danfoss Type BFP 21 L3 LE, No. 071 N2110

Oil preheating Danfoss Type FPHB-LE/PTC 70 No. 030 N4101or Danfoss Type FPHB-LE/PTC 50 No. 030 N4257

Motor ACC EB 95C 28/2, 90 W ACC EB 95C 52/2, 180 W

Boiler type A1 BO 15bio A1 BO 20i A1 BO 27i/A1 BO 35i

Heating circulation pump Grundfos ALPHA+15-40 CES Grundfos UPS 15-60 N1 CES 87 Grundfos ALPHA+15-60 N1 CES

Voltage 230 V, 50 Hz

Maximum power consumption 45 W 90 W 80 W

Protection type IP 42 IP 44 IP 42

Permitted overpressure 3 bar

Maximum pumping height 3.8 m 6.0 m 6.2 m

3-way diverter valve

Voltage 230 V, 50 Hz

Maximum power consumption 4.3 W

Protection type IP 40

Turnaround time 6 s

66 FA ROTEX A1 BO - 10/2007

11 xTechnical data

Temperature sensor

Tab. 11-5 Resistance values of the temperature sensor

Remaining pumping height

Fig. 11-1 Resistance characteristics of the temperature sensorRS Sensor resistancet Temperature

PTC-resistance Flow, return flow, hot water, outside temperature, mixer circuit feed temperaturePt 1000 resistance Flue gas temperature

500

1000

1500

2000

2500

3000

3500

t / °C

-20 0 20 40 60 80 100 120

R/

S�

Pt 1000

PTC

Sensor Temperature sensor Measured temperature in °C

–20 –10 0 10 20 30 40 50 60 70 80 90 100 110 120

Sensor resistance in Ohm according to standard or manufacturer's indications

PTC Outside temperature Heat generator (flow temperature, Return flow temperature) Hot water temperature

1383 1511 1644 1783 1928 2078 2234 2395 2563 2735 2914 3098 3287

Pt 1000 Flue gas temperature 922 961 1000 1039 1078 1117 1155 1194 1232 1271 1309 1374 1385 1423 1461

Fig. 11-2 Remaining pumping height A1 BO 15bio

ΔpR Remaining pumping height mH Flow heating network

m / L/hH

p/

mW

s�

R

I II III

0

0,5

1

1,5

2

2,5

3,5

3

4

0 200 400 600 800 1000 1200 1400 1600

min

max

min

max

67FA ROTEX A1 BO - 10/2007

11 x Technical data

Fig. 11-3 Remaining pumping height A1 BO 20i






0

100

200

300

400

500

600

0 200 400 600 800 1000 1200 1400 1600 1800 2000

I II III

m / L/hH

p/

mbar

�R

m / L/hH

p/

mbar

�R

I II III

0

100

200

300

400

500

600

0 200 400 600 800 1000 1200 1400 1600 1800 2000

min

max

min

max

m / L/hH

p/

mbar

�R

min

max

0

100

200

300

400

500

600

0 200 400 600 800 1000 1200 1400 1600 1800 2000

min

max

I II III

68 FA ROTEX A1 BO - 10/2007

11 xTechnical data

SW1

Mai

n sw

itch

S1ST

L fa

ultS2

Burn

er fa

ult

P KPu

mp

P KP Z

Circ

ulatio

n pu

mp

3W-U

V3

way

dive

rter v

alve

P LSt

orag

e ta

nk c

harg

ing p

ump

P MI

Mixe

r circ

uit p

ump

MI

Mixe

r mot

orM

KM

ixer c

ircuit

BUS

Conn

ectio

n for

THE

TA ro

om st

ation

or

othe

r THE

TA co

ntro

ller o

r ALP

HA

room

tem

pera

ture

con

trol

RMRe

sista

nce

for m

odem

con

tact

(v

alue

dep

ends

on

desir

ed fu

nctio

n)t M

IM

ixer c

ircuit

flow

tem

pera

ture

se

nsor

t AU

Outs

ide te

mpe

ratu

re se

nsor

t WW

Stor

age

tem

pera

ture

sens

ort E

TFl

ue g

as te

mpe

ratu

re se

nsor

t RRe

turn

flow

tem

pera

ture

sen

sor

t VFl

ow te

mpe

ratu

re se

nsor

STL

Safe

ty te

mpe

ratu

re lim

iter

Conn

ectio

n ca

ble

colo

urs

blbl

uebr

brow

nge

yello

wgn

gree

ngr

grey

rtre

dsw

blac

kw

sw

hite

n.b.

Cont

act n

ot a

ssig

ned

Fig.

11-6

Circ

uit d

iagra

m fo

r oil c

onde

nsing

boil

er A

1 BO

(sho

wn

with

ROT

EX T

HETA

23R

Con

trol)

gn/ge

gn/ge

gn/gebl

bl

br

br

brswbl

gn/ge

gn/gebl

swws

gr

br

blbr

brbl

bl

bl

bl

br

br

br

bl

br rt

sw

rtgn

bl

n.b.n.b.n.b.

n.b.

n.b.n.b.n.b.n.b.n.b.n.b.n.b.

n.b.n.b.n.b.

n.b.

blbr

n.b.

n.b.n.b.

n.b.n.b.n.b.n.b.n.b.n.b.n.b.

n.b.

ge/gnbrn.b.

rt

sw

J15

J6

J1

J14

J2

J3

J7

J4

J8

J10

J16

J13.B

J13.A

X1

X2

X3

X4

TH

ETA

23R

J9

J5

SW1

S1S2

S1

230V/

50Hz

PK

PZ

PL

PMI

tMI

tAU

tAG

tR

tV

tWW

3W-UV

S2

MKMK

COM

BS

SF

AG

BUS

69FA ROTEX A1 BO - 10/2007

12 x List of keywords

70 FA ROTEX A1 BO - 10/2007

12 List of keywordsAAir nozzle

Distance to oil nozzle . . . . . . . . . .45Air quantity . . . . . . . . . . . . . . . . . . . .43Air supply noise damper . . . . . . . . . . .14Annual maintenance tasks . . . . . . . . .52Annual service . . . . . . . . . . . . . . . . . .52Automatic firing unit . . . . . . . . . 40, 63Automatic timer programme . . . . 29, 31

BBoiler control panel . . . . . . . . . . . . . .28

Installation . . . . . . . . . . . . . . . . . .34Burner

Check . . . . . . . . . . . . . . . . . . . . . .56Clean . . . . . . . . . . . . . . . . . . . . . .56

Burner malfunction indicator . . . . . . .28Burner malfunctions . . . . . . . . . . . . . .62Burner setting . . . . . . . . . . . . . . . . . .40

CCable duct holder . . . . . . . . . . . . . . . .34Cascading . . . . . . . . . . . . . . . . . . . . .24Circulation pump . . . . . . . . . . . . . . . .21Combustion chamber

Clean . . . . . . . . . . . . . . . . . . . . . .57Open . . . . . . . . . . . . . . . . . . . . . . .56

Condensate treatment unit . . . . . . . . .20Check . . . . . . . . . . . . . . . . . . . . . .53Connection . . . . . . . . . . . . . . . . . .20Instructions . . . . . . . . . . . . . . . . . . 9

Condensing technology . . . . . . . . . . . . . 9Connect oil line . . . . . . . . . . . . . . . . . .23Connect the power supply . . . . . . . . .22Connecting the mixer circuit . . . . . . . .24Connection cables . . . . . . . . . . . . . . .34Connection dimensions . . . . . . . . . . . .10Control

ALPHA 23R . . . . . . . . . . . . . . . . .30THETA 23R . . . . . . . . . . . . . . . . .28

Control panel cover . . . . . . . . . . . . . .33Controls . . . . . . . . . . . . . . . . . . . . . . .28

DDanger of frost . . . . . . . . . . . . . . . . .64Design . . . . . . . . . . . . . . . . . . . . . . . . . 8Different set-ups

Ambient air-dependent . . . . . . . . .14Independent of ambient air . . . . . .13Overview . . . . . . . . . . . . . . . . . . .12Partially ambient air-independent .13

Dimensions . . . . . . . . . . . . . . . . . . . . .10Display . . . . . . . . . . . . . . . . . . . . 30, 31Disposal . . . . . . . . . . . . . . . . . . . . . . .64Domestic hot water

Technical data . . . . . . . . . . . . . . .50Draining the heating system . . . . . . . .64

EEfficiency . . . . . . . . . . . . . . . . . . . . . . . 9Electrical installation . . . . . . . . . . . . .21Electrodes distance . . . . . . . . . . . . . .44Electronic control . . . . . . . . . . . . . . . . . 9Emergency operation . . . . . . . . . 48, 63Emission measurement . . . . . . . . 30, 31

FFilling the heating system . . . . . . . . . 24Filling water . . . . . . . . . . . . . . . . . . . . 20Flame tube . . . . . . . . . . . . . . . . . . . . . 47Flow temperature sensor . . . . . . . . . . 35Flue gas mass flow . . . . . . . . . . . . . . 17Flue gas temperature probe . . . . . . . . 36

Check . . . . . . . . . . . . . . . . . . . . . 56Flue system

Dimensioning . . . . . . . . . . . . . . . . 16Kits . . . . . . . . . . . . . . . . . . . . . . . 19Minimum requirements . . . . . . . . . 16Piping height . . . . . . . . . . . . . . . . 17

Flue system kits . . . . . . . . . . . . . . . . . 19Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 37

HHeating circuit expansion module

Cascading . . . . . . . . . . . . . . . . . . 24Hot water storage tank . . . . . . . . . . . 50

Target temperature . . . . . . . .29, 31Technical data . . . . . . . . . . . . . . . 50Thermal data . . . . . . . . . . . . . . . . 51

Hydraulic system connection . . . . . . . 49I

Inspection . . . . . . . . . . . . . . . . . . . . . 52Installation area . . . . . . . . . . . . . . . . . 15Installation dimensions . . . . . . . . . . . . 11Installation height . . . . . . . . . . . . . . . 15Installation room . . . . . . . . . . . . . . . . 15Installation site . . . . . . . . . . . . . . . . . 15Installing the central unit . . . . . . . . . . 22Integrated connection group . . . . . . . 48

LLAS connection

Connection dimensions . . . . . . . . . 18M

Mains switch . . . . . . . . . . . . . . . . . . . 28Maintenance . . . . . . . . . . . . . . . . . . . 52Make-up water . . . . . . . . . . . . . . . . . 20Malfunctions . . . . . . . . . . . . . . . . . . . 60Manual operation . . . . . . . . . . . . .26, 30Mixer circuit flow sensor . . . . . . . . . . 22

OOil nozzle

Distance to air nozzle . . . . . . . . . . 45Oil pump . . . . . . . . . . . . . . . . . . . . . . 47Operating mode . . . . . . . . . . . . . . .9, 29

Selection . . . . . . . . . . . . . . . . . . . 31Operating mode selector button . . . . . 29Operating safety . . . . . . . . . . . . . . . . . 7

PParallel operation . . . . . . . . . . . . . . . . 48PCB . . . . . . . . . . . . . . . . . . . . . . . . . . 33pH value . . . . . . . . . . . . . . . . . . . . . . 20Preheating oil . . . . . . . . . . . . . . . . . . . 40Proper use . . . . . . . . . . . . . . . . . . . . . . 6

RRecirculation . . . . . . . . . . . . . . . . . . . 43Remove the sound insulation hood. . . 52Replacing ignition electrodes . . . . . . . 59Reset . . . . . . . . . . . . . . . . . . . . . . . . 31Reset function . . . . . . . . . . . . . . . . . . 30Room station . . . . . . . . . . . . . . . . . . . 24Room temperature controller . . . . . . . 24Rotary switch . . . . . . . . . . . . . . . . . . 29

"Default settings" . . . . . .26, 30, 31"Selecting the operating mode" . . . . . . . . . . 30, 31

SSafety management . . . . . . . . . . . . . . 9Safety shutdown . . . . . . . . . . . . . . 9, 16Scope of delivery . . . . . . . . . . . . . . . . 14Service log . . . . . . . . . . . . . . . . . . . . 71Service position . . . . . . . . . . . . . . . . . 45Shutdown . . . . . . . . . . . . . . . . . . . . . 64Start-up . . . . . . . . . . . . . . . . . . . . . . 25

Checklist . . . . . . . . . . . . . . . . . . . 27Requirements . . . . . . . . . . . . . . . . 25

Storage tank temperature sensor . . . . . . . . . . . . . . . . . . . . . 22, 36Surface temperature . . . . . . . . . . . . . 16Switching timer programme . . . . . . . . 31System information . . . . . . . . . . . 30, 31

TTarget . . . . . . . . . . . . . . . . . . . . . . . . 29Target room temperature . . . . . . . 29, 31Target room temperature during day . . . . . . . . . . . . . . . . . . . . . . . . . . 29Temperature sensor . . . . . . . . . . . . . . 22

Connection . . . . . . . . . . . . . . . . . 23Three-way diverter valve . . . . . . . . . . 21

UUnit installation room

Requirements . . . . . . . . . . . . . . . . . 7W

Water hardness . . . . . . . . . . . . . . . . . 20Water shortage protection . . . . . . . . . 20Wiring diagram . . . . . . . . . . . . . . . . . 38

13 x Service log

71FA ROTEX A1 BO - 10/2007

13 Service logPlease enter the maintenance work carried out and the measured values in the service log.

Maintenance jobs Initial start-up 1st service 2nd service 3rd service 4th serviceLeakage testing heating pipe connections

Leakage testing hot water pipe connections

Leakage testing oil connection

Visual inspection of electrical components, testing electrical connectionsTesting the pH value in condensate drain (enter value)

Function testing and cleaning condensate treatment unit and drain

Inspection of the flue gas connection

Cleaning of the combustion chamber

Cleaning and inspection of the burner

Oil nozzle change Used nozzles: Manufacturer/Type

Rechecking burner setting

Checking distance ignition electrodes

Cleaning sound insulation hood, boiler panelling, storage tank

Putting the burner into operation and recording measured values

Oil pressure at the burner

Carbon dioxide (CO2) in the flue gas pipe

Oxygen (O2) in the flue gas pipe

Carbon dioxide (CO2) in the supply air (ring-shaped gap measurement)Flue gas temperature in the flue gas pipe

Temperature of the suction air

Carbon monoxide (CO)

Maintenance confirmed

(Company stamp,Date, Signature)

Modifications made to the control setting parameters, other remarks on the heating systemDate Signature Comments

For the chimney sweep

72 FA ROTEX A1 BO - 10/2007

14

008.

15 1

10 4

4_00

· Er

rors

and

tech

nica

l mod

ifica

tions

rese

rved

· Orig

inal

man

ual ·

008.

15 1

10 4

9_00

Ger

man

14 For the chimney sweepData for designing the flue gas pipe

Tab. 14-1 Triple values for chimney design

Unit type Boiler rated output in kW

Flue gas mass flow (humid) in g/s Flue gas temperature in °C Available delivery pressure in Paat 75/60 °C at 40/30 °C 75/60 °C 40/30 °C

A1 BO 15bio12 5.32 5.17 70 48 15015 6.72 6.49 75 52 150

A1 BO 20i12 5.32 5.17 70 48 15015 6.72 6.49 75 52 15020 9.03 8.67 85 65 150

A1 BO 27i20 9.03 8.55 79 53 10023 10.49 9.86 84 61 10027 12.40 11.61 89 68 80

A1 BO 35i25 11.29 10.69 84 58 10030 13.68 12.86 95 66 10035 16.08 15.05 98 74 80

Control measurement

The check measurement can be carried out by an easily selectable automatic function (see also the supplied "Quick reference instruction manual" or the "Instruction manual for ROTEX-Control").

Control ROTEX THETA 23R

1. Press Manual button (fig. 5-1, pos. 13).

The oil condensing boiler controls the maximum boiler temperature for a period of 20 minutes.

2. Press Manual button again within this period.

Premature cancellation of emission measurement, return to the previous active operating mode.

Control ROTEX ALPHA 23R

1. Set the "default settings" rotary switch (fig. 5-2, pos. 6) to position .

2. Simultaneously press the and buttons (fig. 5-2, pos. 8 and 9).

The oil condensing boiler controls the maximum boiler temperature for a period of 20 minutes.

3. Press the and buttons within this period.

End emission measurement prematurely, return to the previous active operating mode.

Remaining time from activation

Current heat generator temperature

End emission measurement prematurely

Fig. 14-1 Brief instructions for chimney sweep operating mode in symbols ROTEX THETA 23R

Fig. 14-2 Brief instructions for chimney sweep operating mode in symbols ROTEX ALPHA 23R

mET Flue gas mass flowP Burner output

Fig. 14-3 Flue gas mass flow in relation to the burner output

�

�

68

4819:59

+

V

ROTEX A1 BO - E-santechnika.lt

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