Daikin RHOBG12AAV1, RHOBG18AAV1 Installation manuals

TABLE OF CONTENTS

Safety instructions 5

Unit description 6

2.1 General ............................................................................................................................................................................................ 6

2.2 Functioning ...................................................................................................................................................................................... 6

2.3 Operating modes ............................................................................................................................................................................. 6

2.4 PC Interface .................................................................................................................................................................................... 8

2.5 Test programs ................................................................................................................................................................................. 8

Main components 9

3.1 Accessories ................................................................................................................................................................................... 10

Installation 11

4.1 Installation measurements ............................................................................................................................................................ 11

4.2 Installation space ........................................................................................................................................................................... 13

4.3 Assembly ....................................................................................................................................................................................... 14

Connecting 16

5.1 Connecting CH installation ............................................................................................................................................................ 16

5.2 Connecting electronically .............................................................................................................................................................. 18

5.3 Connect room thermostat .............................................................................................................................................................. 19

5.4 Connecting gas ............................................................................................................................................................................. 20

5.5 Flue and air supply duct ................................................................................................................................................................ 21

5.6 Outlet systems ............................................................................................................................................................................... 22

5.7 Flue material .................................................................................................................................................................................. 23

5.8 Connection to a flue system without air inlet (B23, B33) .............................................................................................................. 25

5.9 Connection to a sealed flue system. ............................................................................................................................................. 26

Commissioning the unit and the Installation 34

6.1 Filling and air purge of unit and installation ................................................................................................................................... 34

6.2 Commissioning the unit ................................................................................................................................................................. 35

6.3 Switching off the unit ..................................................................................................................................................................... 36

Setting and adjustment 37

7.1 Direct via operating panel .............................................................................................................................................................. 37

7.2 Parameter settings via the service code ....................................................................................................................................... 38

7.3 Setting maximum CH power .......................................................................................................................................................... 40

7.4 Setting pump setting ...................................................................................................................................................................... 40

7.5 Weather dependent regulation ...................................................................................................................................................... 40

7.6 Conversion to different type of gas................................................................................................................................................ 41

7.7 Gas/air regulation .......................................................................................................................................................................... 41

7.8 Setting gas/air regulation ............................................................................................................................................................... 42

Malfunctions 44

8.1 Show last malfunction ................................................................................................................................................................... 44

8.2 Malfunction codes ......................................................................................................................................................................... 44

8.3 Other faults .................................................................................................................................................................................... 45

Maintenance 48

Technical specifications 50

10.1 NTC resistances ............................................................................................................................................................................ 51

10.2 Technical Product Fiche in accordance to CELEX-32013R0811 .................................................................................................. 51

10.3 Electrical diagram .......................................................................................................................................................................... 52

Warranty conditions 53

All rights reserved. The information provided applies to the product in its standard version. Rotex Heating Systems GmbH can therefore not be held liable for any damages arising from any specifications of the product which deviate from the standard version. The available information has been compiled with the greatest possible care, but Rotex Heating Systems GmbH can not be held liable for any mistakes in the information, or for any consequences thereof. Rotex Heating Systems GmbH cannot be held liable for any damage arising from work carried out by third parties.

Subject to change.

These installation instructions

With these installation instructions, you can safely assemble, install and maintain the unit. Carefully follow the instructions.

In case of any doubt, please contact the manufacturer. Keep the installation instructions near the unit.

Abbreviations and terms used

Description To be referred to as

Rotex RHOBG12AAV1, RHOBG18AAV1 Unit Unit with piping for central heating CH installation System with pipes for domestic hot water DHW installation

Symbols

The following symbols are used in this manual:

CAUTION Procedures which - if they are not carried out with the

necessary care - may cause damage to the product, the surroundings, the environment or injury.

IMPORTANT Procedures and/or instructions which, if they are not

followed, will have a negative effect on the functioning of the unit.

Service and technical support for the installer

For information about specific settings, installation, maintenance and repair work, as an installer, please contact your local Rotex dealer.

Identification of the product

You will find the unit details on the type plate on the bottom of the unit. The data plate contains, beside the supplier information and the boiler specification (boiler type and model name) the following information:

******-yymm****** Product code-Serial No.

YY= year of production, mm = month of production

PIN Product Identification Number

Data related to Central Heating

Information regarding electrical power supply Voltage, mains frequency, elmax, IP-class)

PMS Permissible overpressure in CH circuit in bar

Qn HS Input related to gross caloric value in kilowatts

Qn Hi Input related to net caloric value in kilowatts

Pn Output in kilowatts

BE, DE, FR, IT, PL Countries of Destination (EN 437)

I2E(s), I2H, IIELL3P,

II2H3P,

II2Esi3P G20-20 mbar G25-25 mbar

B23, …. C93(x) Approved flue gas category (EN 15502)

Tmax Max. flow temperature in °C

IPX4D Electrical protection class

Approved unit categories (EN 437)

Gas group and gas connection pressure as set at the factory (EN 437)

1 SAFETY INSTRUCTIONS

The manufacturer Rotex Heating Systems GmbH accepts no liability for damage or injury caused by the failure to (strictly) observe the safety instructions, or negligence during the installation of the Rotex RHOBG*AAV1 wall-mounted gas boiler and any associated accessories.

This device is not intended for use by people (including children) with reduced physical, sensory or mental abilities, or lack of experience and knowledge, unless they are given supervision or instructions on the use of the device by a person who is responsible for their safety.

The entire installation must meet the applicable local technical and (safety) instructions, for the gas installation, the electrical installation, smoke extraction installation, drinking water installation, and central heating installation.

IMPORTANT This product is intended for domestic use only.

2 UNIT DESCRIPTION

2.1 General

The Rotex RHOBG*AAV1 wall-mounted gas boiler is a closed unit. The unit is intended to provide heat to the water of a CH-installation and the domestic hot water installation.

The air supply and combustible gas outlet can be connected to the unit by means of two separate pipes. A concentric connection can be supplied upon demand. The unit was tested in combination with the combi feedthrough, but the unit may also be connected to combi feedthroughs which meet the universal test standards for combi feedthroughs.

The unit can be connected to an assembly bracket if required, a frame with top connection, and various installation sets. These are provided separately.

The Rotex RHOBG*AAV1 wall-mounted gas boilers have the CE marking and electrical protection class IP44.

The unit is delivered for natural gas (G20) as a standard. On request, the unit can also be provided for propane (G31).

2.2 Functioning

The Rotex RHOBG*AAV1 wall-mounted gas boiler is a modulating high-efficiency boiler. This means that the power is modulated to suit the required heat demand.

A copper CH circuit is integrated in the aluminum heat exchanger. The water of the DHW installation can be heated by connecting the unit to an indirectly

heated tank using a three-way valve and tank sensor (see par.5.1 and 5.2). The built in tank regulation of the unit ensures the domestic hot water provision takes precedence over the heating. Both cannot work at the same time.

The unit is fitted with an electronic boiler controller, which operates the fan at every heat requirement of the heating or the warm water supply, opens the gas valve, ignites the boiler controller, and continuously monitors and regulates the flame, depending on the requested power.

2.3 Operating modes

The operating mode of the unit is indicated by means of a code on the service display of the operating panel.

Off

The unit is not in operation, but is connected to the electricity supply. No response is given to requests for domestic hot water or CH water. The unit frost protection is active. This means that the pump will start running and the exchanger will be heated up if the temperature of the water in the system drops too far.

If the frost protection intervenes, the code The pressure in the CH installation can also be read from the temperature display in

this operating mode (in bar).

Standby

The LED at the key is lit and possibly one of the LEDs of the tap comfort function. The unit is ready to respond to a request for CH or tap water.

Post-running CH

After the end of the CH-operation, the pump will run for a specified time. The postpumping time is set to the value in par. 7.2 in its factory settings. This setting can be changed. In addition to this, the pump will run automatically 1 time per 24 hours, for 10 seconds, in order to prevent it from getting stuck. This automatic switching on of the pump takes place at the time of the last heating request. In order to change this, the room thermostat needs to be set higher for a moment, at the required time of day.

will be displayed (heating up exchanger).

Requested temperature reached

The boiler controller may temporarily block the heat request. The boiler controller will then be stopped. The block occurs because the required temperature has been reached. When the temperature has sufficiently decreased, the block will be lifted.

Selftest

Once every 24 hours, the boiler controller tests the connected sensors. During the test, the relay will not carry out any other tasks.

Ventilating

When the unit is started, the fan is first brought up to its correct start rpm. When the start rpm is reached, the boiler controller will be ignited. Code 3 is also visible when

there is post-fanning after the boiler controller is stopped.

Igniting

When the fan has reached the start rpm, the burner relay will be ignited by means of electrical sparks. During the ignition, code

not ignite, a new attempt will be made after approximately 15 seconds. If after 4 ignition attempts, the boiler controller has still not been ignited, the controller will go into downtime.

CH operation

An on/off thermostat, an OpenTherm thermostat, an outdoor sensor or a combination thereof can be connected to the controller (see par. 10.3)

When there is a heat request from a thermostat, after the fan has started running (code

), the ignition will take place (code

During CH operation, the rpm of the fan and therefore the power of the unit can be adjusted so the temperature of the CH water to the required CH supply temperature can be controlled. If an on/off thermostat has been connected, this will be the CH supply temperature set on the display. In case of an OpenTherm thermostat, the required CH supply temperature is determined by the thermostat. In case of an outdoor sensor, the required CH supply temperature is determined by the fuel line programmed in the boiler controller. For the last two situations, the temperature set on the display is the maximum.

During CH operation, the requested CH supply temperature will be displayed on the operating panel.

The CH supply temperature can be set between 30 and 90°C (see par. 7.1). Caution: for a low temperature system, a lower maximum setting may be required than the standard setting of 80°C.

You can press the service button during CH operation to read the actual CH supply temperature.

is displayed. If the boiler controller does

) followed by the CH operating mode (code 5 ).

If the tap comfort function is switched on (see code of less than 40 degrees will be generated.

), an OpenTherm heatingrequest

•

freezing. If the temperature of the heat exchanger drops too low, the

Domestic hot water operation

RHOBG*AAV1 in combination with indirectly fired tank

The hot water supply takes precedence over the heating. When a tank sensor is used, any CH request will be interrupted when the tank sensor detects a temperature of

5 degrees lower than the set value. After the fan has switched on (code

has been an ignition (code 4 ), the boiler controller will switch to domestic water

operation (code the thermostat is opened, and it will end when the thermostat closes again. The fan speed , and therefore the power of the unit, is in that case controlled by the boiler controller on the basis of a fixed leaving water temperature. The domestic hot water temperature can be set between 40°C and 65°C. The set tank temperature is displayed on the operating panel during domestic hot water operation. You can press the service button during tap water operation to read the actual tank temperature.

). When a tank thermostat is used, the heat request will start when

) and there

2.4 PC Interface

The boiler controller is provided with an interface for a PC. A PC can be connected by means of a dongle, and the associated software. This facility enables you to follow the behavior of the boiler controller, the unit and the heat installation over a long period.

2.5 Test programs

There is an option in the burner relay, to bring the unit into a test status. Activating a test program, will switch on the unit with a set fan rotations per minute,

without the control functions intervening. The safety functions do remain active.

The test program is ended by pressing and simultaneously.

Test programs

Description of program Button combination Display reading

Burner on with minimum DHW capacity (see parameter d par. 7.2) Burner on with set maximum CH power (see parameter 3 par. 7.2) Burner on with maximum DHW power (see parameter 3 par. 7.2)

Switching off test program and

During test mode the following data can be read :

• By pressing the button continuously in the display the CH water pressure is shown.

• By pressing the button continuously in the display the ionisation current is shown.

and “L”

and (1x)

and (2x)

Current operation

“h”

“H”

situation

2.5.1 Frost protection

The unit is fitted with frost protection in order to prevent it from

pump will start running until the temperature of the heat exchanger is sufficiently high. If the frost protection intervenes, the code

be displayed (heating up exchanger).

• If the installation (or a part thereof) can freeze, the coldest place should be fitted with an (external) frost thermostat on the return pipe. This must be connected in accordance with the electrical diagram (see par. 10.3).

Note When the unit is switched off (

remain active, however a heating request from an (external) frost thermostat will be ignored.

on the service display), the unit frost protection will

will

3 MAIN COMPONENTS

Ignition/ionization pin

0207010009

A. Modulating CH pump K. Flue gas/air inlet concentric adapter B. Gas valve L. Air supply (only when using twin pipe flue system) C. Burner controller (incl. operating panel) M. Connection block / terminal strip X4 D. Sensor S1 (flow) N. Condensate collector E. Sensor S2 (return) O. Siphon F. Fan P. Heat exchanger G. Pressure sensor central heating Q. Operating panel and display H. Connection wire 230 V ~ with earthed plug R. I. Manual air bleed S. Position of data plate J. Inspection glass

3.1 Accessories

Description Article numbers B-pack small EKFJS*AA

B-pack middle EKFJM*AA

B-pack large EKFJL*AA

Valve kit EKVK4AA Cover plate EKCP1AA

Outdoor sensor EKOSK1AA 3-way valve set EK3WV1AA Flue gas adapter Concentric Ø80x125 EKHY090717

Flue gas adapter Parallel 80 mm

EKHY090707

Propane conversion set RHOBG12AAV1 EKPS075917 Propane conversion set RHOBG18AAV1 EKPS075877

4 INSTALLATION

A = Supply CH

G ¾” (ext)

B = Return CH

G ¾” (ext)

C = Gas G ½” (int)

D = Condense outlet

Ø dn25 (flexible)

h =

517mm

RHOBG

AAV1

H =

590mm

RHOBG

AAV1

Z = Flue gas outlet/air inlet

Ø60/100 (concentric)

020601005

161

450

240

135

130 130

4.1 Installation measurements

Boiler mounted directly to the wall:

Unit + mounting bracket

RHOBG18AAV1

A = Supply CH

G ¾” (ext)

B = Return CH

G ¾” (ext)

C = Gas G ½” (int)

D = Condense outlet

Ø dn25 (flexible)

H = 770mm

RHOBG

AAV1

Z = Flue gas outlet/air inlet

Ø60/100 (concentric)

020601006

265

130 130

Unit connected to B-pack:

Unit + B-pack

RHOBG18AAV1

4.2 Installation space

The unit must be installed against a wall with sufficient load bearing capacity. In case of light wall constructions, there is a risk of resonance noises. Within 1 meter of the unit, there must be an earthed wall plug. In order to prevent the condense outlet from freezing, the unit must be installed in a

frost-free room. Preferably ensure there is a space of at least 2 cm next to the boiler. No free space is required due to danger of singeing.

4.2.1 Installing in kitchen cabinet

The unit can be placed between two kitchen cabinets, or inside a kitchen cabinet. Make sure there is sufficient ventilation at the bottom and the top. If the unit is installed inside a cabinet, ventilation openings of at least 50 cm2 are

required.

4.2.2 Removing cover plate and front panel

For various activities on the unit, the cover plate and front panel have to be removed from the unit, if they were installed. Do this as follows:

• If you are using the cover plate (A), remove it to the front.

• Unscrew both screws (1) behind the display window.

• Pull the bottom of the front panel (2) forwards.

Danger: risk of burning

In case of high leaving water set ponts for space heating (eighter a high fixed set point or a high weather-dependent set point at low ambient temperatures), the heat exchanger of the boiler can be very hot, for example 70°C.

Beware that in case of a tapping demand, the water can initially have a higher water temperature than requested.

In this case, it is recommended to install a thermostatic valve to prevent scalding. This can be done according to the schematics below.

a=boiler, b=DHW from boiler, c= cold water inlet,

d=shower, e=thermostatic valve (field supply)

4.3 Assembly

020601020

The boiler can be hung to the wall using :

• the wall suspension strip and a the connection kit EKVK4AA

• a B-pack including an expension vessel and a connection kit.

4.3.1 Assembling suspension strip and assembly bracket

• Make sure the construction of the wall is suitable for hanging the boiler.

• Drill the holes for the suspension strip and the connection kit in the wall

using the template delivered with the boiler.

• Mount the suspension strip and the assembly bracket horizontally on the wall, using the associated attachment materials.

• The boiler can now be placed on the suspension strip simultaniously sliding the pipes of the boiler into the valves in the assembly bracket.

4.3.2 Assembling B-pack

• Make sure the construction of the wall is suitable for hanging the boiler and B-pack.

• Drill the holes for the B-pack kit in the wall using the template delivered with the boiler.

• Mount the B-pack on the wall using the associated attachment materials.

• Place the assembly bracket in the frame as described in the manual

inclued in the B-pack.

• Connect the flexible hose on the expension vessel and the conenction on the return valve. Make sure the seal rings are placed !

• The boiler can now be placed on B-pack simultaniously sliding the pipes of the boiler into the valves in the assembly bracket.

4.3.3 Assembling the unit

1. Unpack the unit.

2. Check the content of the packaging, which consists of:

• Unit (A)

• Suspension strip (B)

• Siphon + flexible hose (C)

• Installation instructions

• Operating instructions

• Warranty card

3. Check the unit for any damage: immediately report damages to the supplier.

4. Install the suspension strip.

5. Check whether the compression rings are positioned straight in the couplings of the assembly bracket.

6. Position the unit: slide it from top to bottom over the suspension strip (B). Make sure the pipes slide into the compression fittings simultaneously.

7. Tighten the compression fittings onto the assembly bracket. The nipples and pipes must not rotate with it!

8. Open the display valve and loosen the two screws on the left and right of the display, and remove the front panel.

9. Assemble the flexible tube (D) onto the outlet of the siphon. Fill the siphon with water, and slide it as far as possible on top of the condense output connector (E) under the unit.

10. Seal flexible tube (D) of the siphon, if possible together with the overflow pipe of the inlet combination and the overflow valve, to the sewage via open connection (F).

11. Assemble the air supply and the burning gas outlet (see par.5.5).

12. Assemble the cover and tighten the two screws to the left and the right of the display, and close the display cover.

4.3.4 Apply cover plate (optional)

Suspend the converted top edge of the cover plate from the washers underneath the bottom of the unit, and slide the cover plate as far back as possible.

Please note: When installing the boiler in combination with a cover plate, the siphon will extend underneath the cover plate.

5 CONNECTING

020601009

020601010

5.1 Connecting CH installation

1. Rinse the CH installation carefully.

2. Fit the supply pipe (A) and return pipe (B) to the connection set.

3. All pipes must be assembled with no electrical current, in order to prevent shocks from the pipes.

4. Existing connections may not be rotated, in order to prevent leakages.

The CH installation must be fitted with:

• A filling/draining tap (A) in the return pipe, immediately underneath the unit.

• A draining tap at the lowest point of the installation.

• An overflow valve (B) of 3 bar in the input pipe at a distance of no more than 500 mm

from the unit. Between the unit and the overflow valve there may be no valve or constriction.

• An expansion vessel in the return pipe (in the B-pack or in the installation).

• A check valve, if there are pipes running up, within close distance of the unit. This

prevents a thermosiphon effect from occurring during tap water operation (a non spring-operated return valve, must be assembled vertically).

5.1.1 Thermostatic radiator taps

If all radiators are fitted with thermostatic or cable radiator taps, a minimum water circulation must be safeguarded. See par. 7.4.

5.1.2 Dividing CH installation in groups in case of additional heat sources

Operating principle

If the room thermostat switches off the boiler because another heat source (wood heater, open fire etc.) heats the room, the other rooms may cool down. This can be resolved by splitting the CH installation into two zones. The zone with the external heat source (Z2) can be shut off from the main circuit by means of an electrical shut-off valve. Both zones are fitted with their own room thermostat.

Please note: This “external heat source” regulation may only be applied if no extra external tank has to be heated up (installation type 1).

Installation instructions

1. Install the valve in accordance with the connection diagram.

2. Connect the room thermostat of zone 1 to X4 – 6/7.

3. Connect the room thermostat of zone 2 to X4 – 11/12.

4. Change parameter A (see Parameter settings via the service code par. 7.2).

Please note: The room thermostat in zone thermostat in zone 2 may be an OpenTherm thermostat or an on/off thermostat.

Connection diagram “external heat source” regulation A. Boiler B. Electrical shut-off valve 230 V ~ C. Radiators T1. Room thermostat zone 1 T2. Room thermostat zone 2 Z1. Zone 1 Z2. Zone 2

1 MUST

be an on/off thermostat. The room

Connecting external tank

For the connection of the RHOBG*AAV1 to an indirectly fired tank, a set is available. This set, EK3WV1AA contains the folowing parst and is delivered upon order:

• Tank sensor

• Locking clip for tank sensor

• Three-way valve set 230V

Connect the tank and three-way valve to the boiler in accordance with the diagram. Remove the through connection between 9 and 10 to connector X4. Connect the threeway valve to connector X2 and connect the tank sensor or thermostat to connector X4 in accordance with the wiring diagram (see par. 10.2).

Connection diagram indirectly fired tank

C. Unit D. Tanks E. CH installation F. Expansion vessel G. Safety valve 3 Bar H. Three-way valve I. Tank sensor or thermostat

Note

When an on/off tank thermostat is used, the heat request will start when the thermostat is opened, and it will end when the thermostat closes again.

In case of old installations or domestic hot water circuits which can contain small particles, install a filter in the domestic hot water circuit. This pollution could cause a fault during domestic hot water operation.

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