Guarantee and conformity
2FA 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 years
Guarantee 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 Grammling
Managing Director
Contents
3
FA ROTEX A1 BO - 10/2007
1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Observing Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Warning signs and explanation of symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Avoid danger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Proper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5 Instructions for operating safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Boiler design and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Set-up and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 Dimensions and connection dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Different set-ups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2.1 Operation independent of ambient air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.2 Operation partially independent of ambient air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.3 Ambient air dependent operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Transport and delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4 Setting up an oil condensing boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4.1 Selecting the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4.2 Setting up the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5 Air/flue system (LAS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5.1 General instructions for flue system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5.2 Connecting the flue gas pipe to the oil condensing boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5.3 Flue system kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.6 Water connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.7 Connecting the condensate treatment unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.8 Connect the 3-way diverter valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.9 Connecting control unit and electrics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.10 Temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.10.1 General instructions for the temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.10.2 Connecting the temperature sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.11 Connecting and filling up the oil line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.12 Optional connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.12.1 Mixer circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.12.2 Room temperature controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.12.3 Room station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.13 Filling the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1 Initial start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2 Checklists for start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.1 Controls on the boiler control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.1.1 Control THETA 23R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.1.2 Control ALPHA 23R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.2 Changing the central unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.3 Changing the boiler control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.4 Changing cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.5 Changing the sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.6 Changing the flue gas temperature sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.7 Changing the fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.8 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Contents
4FA ROTEX A1 BO - 10/2007
6 Oil burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.1 Design and brief description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
6.2 Safety function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
6.3 Burner setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
6.3.1 Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
6.3.2 Instructions for burner setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
6.3.3 Check vacuum in the oil pump and set the oil pump pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
6.3.4 Set air quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
6.3.5 Setting recirculation gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
6.3.6 Check and set electrode distance and the distance between oil nozzles and air nozzles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
6.4 Removing/Installing burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
6.5 Oil burner pump with LE system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
7 Hydraulic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.1 Integrated connection group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
7.1.1 Design and function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
7.1.2 Releasing / restoring electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
7.2 Hydraulic system connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
7.3 Hot water storage tank (not included in scope of supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
8 Inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.1 General overview of inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
8.2 Service and maintenance tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
8.2.1 Removing panelling (and cleaning it). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
8.2.2 Checking the connections and pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
8.2.3 Checking the condensate treatment unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
8.2.4 Checking the flue gas temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
8.2.5 Checking and cleaning the combustion chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
8.2.6 Checking the oil filter and cleaning the oil pump filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
8.2.7 Checking the burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
8.2.8 Replacing the oil nozzle and ignition electrodes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
9 Faults and malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
9.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
9.2 Overview of possible malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
9.3 Control unit fault signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
9.4 Burner malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
9.5 Rectifying STL fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
9.6 Emergency operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
10 Taking out of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
10.1 Temporary shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
10.2 Final shutdown and disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
11 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
12 List of keywords. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
13 Service log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
14 For the chimney sweep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1 x Safety
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FA ROTEX A1 BO - 10/2007
1Safety
1.1 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 warnings
Warnings 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
6FA ROTEX A1 BO - 10/2007
Special warning signs
Some types of danger are represented by special symbols:
Validity
Some information in this manual has limited validity. The validity is highlighted by a symbol.
Order number
Notes 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.
ÎResults 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 page2 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
a
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FA ROTEX A1 BO - 10/2007
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
8FA ROTEX A1 BO - 10/2007
2 Product description
2.1 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
2Boiler control panel
3Boiler panelling
4 Burner
5Controller
6Boiler main body with heat and sound
insulation
7Type plate with manufacture number
8Circulation pump
93-way diverter valve
10 Heater return flow (cold)
11 Heating flow (hot)
12 Manometer
13 Filling and draining cock
14 Safety valve
15 Flue gas/supply air connection
16 Condensate treatment unit
17 Condensate drain
18 Air supply hose
19 Flame tube
20 Burner chamber insert
21 Flue gas temperature sensor
22 Circuit board (electrical connections)
23 Stickers for identification of the usable oil quality
24 Document pouch
25 Ball stopcock
26 Flow temperature sensor
27 Return flow temperature sensor
Safety devices
24
18
26
14
9
8
21
15
16
17
20
19
25
2 x Product description
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FA ROTEX A1 BO - 10/2007
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 mode
The 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 management
The 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 control
An 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 technology
Condensing 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.
Fuel
The 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 treatment
The 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.
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3x Set-up and Installation
10 FA ROTEX A1 BO - 10/2007
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
3 x Set-up and Installation
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FA ROTEX A1 BO - 10/2007
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
1Boiler return flow
2Boiler flow
3KFE cock connection on the unit filling
line connection on KFE cock
4Flue gas/supply air connection
5Connection expansion vessel
6Burner
7Safety valve
83-way diverter valve
9Hot water
10 Circulation
G 1" IT (Box nut)
G 1¼" ET / G 1" IT
G ½" IT
G ½" ET
DN 80/125
G ½" IT
G ½" IT (Bleeding line G ¾" IT)
G 1" ET
G ¾" IT
G ¾" IT
11 Heat exchanger return flow
12 Sensor immersion sleeve
13 Heat exchanger flow
14 Cold water
15 Air/flue system (LAS) Connection piece
16 Air supply hose
17 Condensate drainage hose
AROTEX A1 BO
BBoiler frame (KU)
CSub-tank (US 150)
G ¾" ET
G ¾" ET
G ¾" IT
DN 80/120
DN 50
DN 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
aU400
b 720
cY137 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
fU1340 U1890 U1650 U1470 U2020 U1770 U1590 U2140 U1890
g 1100 1730 1480 1220 1850 1600 1340 1970 1720
h 625
i 300
3x Set-up and Installation
12 FA 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 mode
2) Set-up version for operation partially independent of ambient air
3) Set-up version for ambient air-dependent operation
ÖAir supply
ÎFlue 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
3 x Set-up and Installation
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FA ROTEX A1 BO - 10/2007
3.2.1 Operation independent of ambient air
Set-up version 1
The 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 4
The 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 5
The 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: 2m.
Set-up version 6
The 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 8
The 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.
3x Set-up and Installation
14 FA 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 7
The 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 delivery
The 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
3 x Set-up and Installation
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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 height
The 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 attic
If 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 2m in order to avoid malfunction at start or during operation of the burner.
Set-up in garages
The 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).
3x Set-up and Installation
16 FA 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.
3 x Set-up and Installation
17
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 2m 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 chapter11 "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 kW
DN 80 33 kW
DN 80 35 kW
DN 80 35 kW
DN 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 16161620202028
5 17171711111123
6 17171711111123
Fig. 3-5 Flue gas mass flow in relation to the burner output
mET Flue gas mass flow PBurner output
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18 FA 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 section3.5.1.
– 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
ABoiler connection
BFlue gas connection CFlue gas temperature sensor
DConnection for condensate drain
EFlue 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).
3x Set-up and Installation
20 FA 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.
Connection
The 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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