ROTEX HPSU monobloc compact Installation and maintenance instructions

Transcription

1 For certified companies ROTEX HPSU monobloc compact Installation and maintenance instructions Solar storage tank with heating controller For types RKHWMX300C RKHWMX500C RKHWMXB300C RKHWMXB500C GB Edition 09/2017

2 CE - ATITIKTIES-DEKLARACIJA CE - ATBILST BAS-DEKLAR CIJA CE - VYHLÁSENIE-ZHODY CE - UYUMLULUK-BEYANI CE - IZJAVA O SKLADNOSTI CE - VASTAVUSDEKLARATSIOON CE CE - IZJAVA-O-USKLA ENOSTI CE - MEGFELEL SÉGI-NYILATKOZAT CE - DEKLARACJA-ZGODNO CI CE - DECLARA IE-DE-CONFORMITATE CE - ERKLÆRING OM-SAMSVAR CE - ILMOITUS-YHDENMUKAISUUDESTA CE - PROHLÁENÍ-O-SHOD CE - DECLARAÇÃO-DE-CONFORMIDADE CE CE - OVERENSSTEMMELSESERKLÆRING CE - FÖRSÄKRAN-OM-ÖVERENSTÄMMELSE CE - DECLARACION-DE-CONFORMIDAD CE - DICHIARAZIONE-DI-CONFORMITA CE - H CE - DECLARATION-OF-CONFORMITY CE - KONFORMITÄTSERKLÄRUNG CE - DECLARATION-DE-CONFORMITE CE - CONFORMITEITSVERKLARING 17 m deklaruje na w asn i wy czn odpowiedzialno, e urz dzenia, których ta deklaracja dotyczy: 18 r declar pe proprie r spundere c echipamentele la care se refer aceast declara ie: 19 o z vso odgovornostjo izjavlja, da je oprema naprav, na katero se izjava nanaa: 20 x kinnitab oma täielikul vastutusel, et käesoleva deklaratsiooni alla kuuluv varustus: 21 b,, e : 22 t visika savo atsakomybe skelbia, kad ranga, kuriai taikoma i deklaracija: 23 v ar pilnu atbild bu apliecina, ka t l k aprakst t s iek rtas, uz kur m attiecas deklar cija: 24 k vyhlasuje na vlastnú zodpovednos, e zariadenie, na ktoré sa vz ahuje toto vyhlásenie: 25 w tamamen kendi sorumlulu unda olmak üzere bu bildirinin ilgili oldu u donan m n n a a daki gibi oldu unu beyan eder: 09 u,,, : 10 q erklærer under eneansvarlig, at udstyret, som er omfattet af denne erklæring: 11 s deklarerar i egenskap av huvudansvarig, att utrustningen som berörs av denna deklaration innebär att: 12 n erklærer et fullstendig ansvar for at det utstyr som berøres av denne deklarasjon innebærer at: 13 j ilmoittaa yksinomaan omalla vastuullaan, että tämän ilmoituksen tarkoittamat laitteet: 14 c prohlauje ve své plné odpov dnosti, e za ízení, k n mu se toto prohláení vztahuje: 15 y izjavljuje pod isklju ivo vlastitom odgovorno u da oprema na koju se ova izjava odnosi: 16 h teljes felel ssége tudatában kijelenti, hogy a berendezések, melyekre e nyilatkozat vonatkozik: 01 a declares under its sole responsibility that the equipment to which this declaration relates: 02 d erklärt auf seine alleinige Verantwortung daß die Ausrüstung für die diese Erklärung bestimmt ist: 03 f déclare sous sa seule responsabilité que l'équipement visé par la présente déclaration: 04 l verklaart hierbij op eigen exclusieve verantwoordelijkheid dat de apparatuur waarop deze verklaring betrekking heeft: 05 e declara bajo su única responsabilidad que el equipo al que hace referencia la declaración: 06 i dichiara sotto la propria responsabilità che gli apparecchi a cui è riferita questa dichiarazione: 07 g : 08 p declara sob sua exclusiva responsabilidade que os equipamentos a que esta declaração se refere: 16 megfelelnek az alábbi szabvány(ok)nak vagy egyéb irányadó dokumentum(ok)nak, ha azokat el írás szerint használják: 17 spe niaj wymogi nast puj cych norm i innych dokumentów normalizacyjnych, pod warunkiem e u ywane s zgodnie z naszymi instrukcjami: 18 sunt în conformitate cu urm torul (urm toarele) standard(e) sau alt(e) document(e) normativ(e), cu condi ia ca acestea s fie utilizate în conformitate cu instruc iunile noastre: 19 skladni z naslednjimi standardi in drugimi normativi, pod pogojem, da se uporabljajo v skladu z naimi navodili: 20 on vastavuses järgmis(t)e standardi(te)ga või teiste normatiivsete dokumentidega, kui neid kasutatakse vastavalt meie juhenditele: 21,, : 22 atitinka emiau nurodytus standartus ir (arba) kitus norminius dokumentus su s lyga, kad yra naudojami pagal m s nurodymus: 23 tad, ja lietoti atbilstoi raot ja nor d jumiem, atbilst sekojoiem standartiem un citiem normat viem dokumentiem: 24 sú v zhode s nasledovnou(ými) normou(ami) alebo iným(i) normatívnym(i) dokumentom(ami), za predpokladu, e sa pouívajú v súlade s naim návodom: 25 ürünün, talimatlar m za göre kullan lmas ko uluyla a a daki standartlar ve norm belirten belgelerle uyumludur: 08 estão em conformidade com a(s) seguinte(s) norma(s) ou outro(s) documento(s) normativo(s), desde que estes sejam utilizados de acordo com as nossas instruções: 09, : 10 overholder følgende standard(er) eller andet/andre retningsgivende dokument(er), forudsat at disse anvendes i henhold til vore instrukser: 11 respektive utrustning är utförd i överensstämmelse med och följer följande standard(er) eller andra normgivande dokument, under förutsättning att användning sker i överensstämmelse med våra instruktioner: 12 respektive utstyr er i overensstemmelse med følgende standard(er) eller andre normgivende dokument(er), under forutssetning av at disse brukes i henhold til våre instrukser: 13 vastaavat seuraavien standardien ja muiden ohjeellisten dokumenttien vaatimuksia edellyttäen, että niitä käytetään ohjeidemme mukaisesti: 14 za p edpokladu, e jsou vyuívány v souladu s naimi pokyny, odpovídají následujícím normám nebo normativním dokument m: 15 u skladu sa slijede im standardom(ima) ili drugim normativnim dokumentom(ima), uz uvjet da se oni koriste u skladu s naim uputama: 01 are in conformity with the following standard(s) or other normative document(s), provided that these are used in accordance with our instructions: 02 der/den folgenden Norm(en) oder einem anderen Normdokument oder -dokumenten entspricht/entsprechen, unter der Voraussetzung, daß sie gemäß unseren Anweisungen eingesetzt werden: 03 sont conformes à la/aux norme(s) ou autre(s) document(s) normatif(s), pour autant qu'ils soient utilisés conformément à nos instructions: 04 conform de volgende norm(en) of één of meer andere bindende documenten zijn, op voorwaarde dat ze worden gebruikt overeenkomstig onze instructies: 05 están en conformidad con la(s) siguiente(s) norma(s) u otro(s) documento(s) normativo(s), siempre que sean utilizados de acuerdo con nuestras instrucciones: 06 sono conformi al(i) seguente(i) standard(s) o altro(i) documento(i) a carattere normativo, a patto che vengano usati in conformità alle nostre istruzioni: 07 ( ) ( ) ( ) ( ), : EN , EN : 2006 (+A1: 200 ), EN : 1997 (+A1: A2: 200 ), EN : 20, EN : 20, EN : 2007 (+A1: 2011), 19 Direktive z vsemi spremembami. 20 Direktiivid koos muudatustega. 21,. 22 Direktyvose su papildymais. 23 Direkt v s un to papildin jumos. 24 Smernice, v platnom znení. 25 De i tirilmi halleriyle Yönetmelikler. 10 Direktiver, med senere ændringer. 11 Direktiv, med företagna ändringar. 12 Direktiver, med foretatte endringer. 13 Direktiivejä, sellaisina kuin ne ovat muutettuina. 14 v platném zn ní. 15 Smjernice, kako je izmijenjeno. 16 irányelv(ek) és módosításaik rendelkezéseit. 17 z pó niejszymi poprawkami. 18 Directivelor, cu amendamentele respective. 01 Directives, as amended. 02 Direktiven, gemäß Änderung. 03 Directives, telles que modifiées. 04 Richtlijnen, zoals geamendeerd. 05 Directivas, según lo enmendado. 06 Direttive, come da modifica. 07,. 08 Directivas, conforme alteração em. 09. Low Voltage 20 / 5/E Electromagnetic Compatibility 20 4/ /E 19 ob upotevanju dolo b: 20 vastavalt nõuetele: 21 : 22 laikantis nuostat, pateikiam : 23 iev rojot pras bas, kas noteiktas: 24 odriavajúc ustanovenia: 25 bunun ko ullar na uygun olarak: 10 under iagttagelse af bestemmelserne i: 11 enligt villkoren i: 12 gitt i henhold til bestemmelsene i: 13 noudattaen määräyksiä: 14 za dodrení ustanovení p edpisu: 15 prema odredbama: 16 követi a(z): 17 zgodnie z postanowieniami Dyrektyw: 18 în urma prevederilor: 01 following the provisions of: 02 gemäß den Vorschriften der: 03 conformément aux stipulations des: 04 overeenkomstig de bepalingen van: 05 siguiendo las disposiciones de: 06 secondo le prescrizioni per: 07 : 08 de acordo com o previsto em: 09 :

3 List of contents 1 General Information Refer to the manual Warranty conditions Safety Warnings and symbols Meaning of the warnings Validity Order number Handling instructions Avoiding danger Intended use Instructions for operating safety Before working on the hydraulic system Electrical installation Site of installation Heating system and sanitary connection Requirements for the heating water Operation Instruct the owner Product description Design and components Exterior of the device and interior structure RKHWMX(B)300C Exterior of the device and interior structure RKHWMX(B)500C Upper side of the device Set-up and installation Dimensions and connections RKHWMX(B)300C RKHWMX(B)500C Scope of delivery Installation Removing the cover and thermal insulation Water connection Aligning the connections of the heating supply and return Connecting hydraulic lines Installation of the DB connection kit ( ) Installation of the P connection kit ( ) Electrical connection ROTEX HPSU monobloc compact overall c onnection diagram Position of the printed circuit boards RTX-EHS printed circuit board connection diagram RoCon BM2C printed circuit board connection diagram Mains connection ROTEX HPSU monobloc compact Opening the controller housing and establishing electrical connections Connecting the heat pump outdoor unit Connecting an external switching contact External requirement request (EBA) Connecting an electric ROTEX backup heater (BUxx) Connecting an external heat generator Connecting a ROTEX room thermostat Connecting optional ROTEX RoCon system components Connecting a ROTEX HP convector Connecting switching contacts (AUX outputs) Off-peak mains connection (HT/NT) Connecting an intelligent controller (Smart Grid - SG) Symbols and key names for connection and wiring diagrams Filling the system on the water side Checking the water quality and adjusting the pressure gauge Filling the hot water heat exchanger Filling the storage tank Filling the heating system Start-up Initial start-up Requirements Starting the device Setting commissioning parameters Bleeding the hydraulic system Checking the minimum flow Setting the parameter Screed Program (only when required) Re-commissioning Requirements Start-up Taking out of operation Temporary shutdown Draining the storage tank Draining the heating circuit and hot water circuit Final shutdown Service and maintenance General Activities to be performed annually Filling, topping up the storage tank Filling, topping up the heating system Protecting the water circuit against freezing Filling, topping up steps Errors, malfunctions and messages Recognising errors, correcting malfunctions Current error display Reading out the protocol Troubleshooting Malfunctions Error codes Control and configuration of DIP switches Emergency operation Hydraulic system connection Technical data Equipment data RKHWMX(B)300C RKHWMX(B)500C Characteristic lines Sensor characteristic lines Tightening torque Circuit diagram ROTEX HPSU monobloc compact Notes List of keywords FA ROTEX HPSU monobloc compact 09/2017 3

4 1 x General Information 1 General Information 1.1 Refer to the manual Original Operating Instructions These instructions are a >> translation of the original version << in your language. Please read this manual carefully and thoroughly before proceeding with the installation or modification of the heating system. Target Group These instructions are aimed at people who are authorised and who have successfully completed a qualifying technical or skilled manual training program for the particular work to be carried out and who have participated in professional development seminars recognised by the appropriate responsible authority. This, in particular, includes heating specialists and climate control technicians who have experience, as a result of their technical training and their knowledge of the subject, of proper and appropriate installation and maintenance of heating, climate control and cooling installations and heat pumps. This manual provides all the necessary information for installation, start-up and maintenance, as well as basic information on operation and settings. All parameters needed for trouble-free operation have been configured at the factory. Please see the attached documents for a detailed description of operation and control. Relevant documents ROTEX HPSU monobloc compact: Operating instructions for the user/owner Commissioning checklist the operating manual for the user/owner RoCon mb controller operating instructions Outdoor unit for ROTEX HPSU monobloc compact: the respective installation and operating instructions. On connection of a ROTEX solar system: the respective installation and operating instructions. On connection of a ROTEX HP convector: the respective installation and operating instructions. On connection of a control component available as an accessory (room station, mixer module, etc.): the associated installation and operating instructions. 1.2 Warranty conditions The legal guarantee conditions fundamentally apply. Our warranty conditions beyond that can be found online on your sales presentative's webpage. The guides are included in the scope of supply for the individual units. 4 FA ROTEX HPSU monobloc compact 09/2017

5 2 x Safety 2 Safety 2.1 Warnings and 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 may result in serious physical injury or death. CAUTION! Indicates a situation which may cause possible damage. Disregarding this warning may cause damage to property and the environment. This symbol identifies user tips and particularly useful information, but not warnings or hazards. Special warning signs Some types of danger are represented by special symbols: Electric current Risk of burning or scalding Risk of environmental damage Danger of local freezing up Health impairing or irritant materials Prescribed temperature for continuous use Validity Some information in this manual has limited validity. The validity is highlighted by a symbol. Heat pump outdoor unit Heat pump interior unit HPSU monobloc compact HP convector Observe specified tightening torque (see chap "Tightening torque") Only applicable to the unpressurised solar system (DrainBack). Only applicable for the pressurised solar system Order number References to order numbers can be recognised from the goods symbol Handling instructions Handling instructions are shown as a list. Actions for which the sequential order must be maintained are numbered. Results of actions are identified with an arrow. Entry into a setting procedure Exit from a setting procedure 2.2 Avoiding danger The ROTEX HPSU monobloc compact is built according to the state-of-the-art and the recognised technical rules. However, improper use may result in serious physical injuries or death, as well as property damage. To avoid hazards, only install and operate the ROTEX HPSU monobloc compact: as stipulated and in perfect condition, with an awareness of safety and the hazards involved. This assumes knowledge and use of the contents of this manual, of the relevant accident prevention regulations as well as the recognised safety-related and occupational health rules. Danger of explosion FA ROTEX HPSU monobloc compact 09/2017 5

6 2 x Safety 2.3 Intended use The ROTEX HPSU monobloc compact must only be used to prepare hot water, as a room heating system and as a room cooling system. The ROTEX HPSU monobloc compact must only be installed, connected and operated according to the data in these instructions. Only the use of a suitable outdoor unit approved by ROTEX is permitted. The following combinations are permissible in this respect: * Not all the equipment mentioned here is offered in some countries because of the various different country-specific connection conditions. Tab. 2-1 WARNING! This equipment must only be used by children aged 8 and above and by persons with restricted physical, sensory or mental capabilities or with a lack of experience and knowledge, if they are under supervision or if they have been instructed in the safe use of the equipment and understand the dangers arising therefrom. Children must not play with the equipment. Cleaning or user maintenance must not be carried out by children without supervision. Indoor unit RKHWMX300C RKHWMX500C RKHWMXB300C RKHWMXB500C Outdoor unit RBLQ05C2V3 RBLQ07C2V3 Permissible combinations of ROTEX HPSU monobloc compact solar storage tanks with heating controller and ROTEX HPSU monobloc compact outdoor units Any other use outside the intended use is considered as improper. The operator alone shall bear responsibility for any resulting damage. Intended use also includes compliance with the maintenance and service conditions. Replacement parts must at least satisfy the technical requirements defined by the manufacturer. This is the case, for example, with original spare parts. 2.4 Instructions for operating safety Before working on the hydraulic system Work on the ROTEX HPSU monobloc compact (such as e.g. installation, connection and initial commissioning) must only be carried out by persons who are authorised, who have successfully completed qualifying technical or vocational training for the respective activity and who have taken part in advanced training sessions recognised by the relevant responsible authority. This, in particular, includes heating specialists and climate control technicians who have experience, as a result of their technical training and their knowledge of the subject, of proper and appropriate installation and maintenance of heating, climate control and cooling installations and heat pumps. Switch off the external main switch during all work on the ROTEX HPSU monobloc compact, and secure it to prevent unintentional activation. Seals must not be damaged or removed. Make sure that the safety valves comply with the requirements of EN when connecting on the heating side, and with the requirements of EN when connecting on the domestic water side. Only original ROTEX replacement parts may be used. When working on the hydraulics, you must first drain the water or release the pressure using the internal KFE valve. Otherwise hot water can jet out under pressure and result in injury Electrical installation Electrical installation must only be carried out by specialist personnel with electrical engineering qualifications and subject to compliance with the valid electrical engineering guidelines as well as the regulations of the responsible utility company (EVU). Compare the mains voltage (~230 V, 50 Hz or ~400 V, 50 Hz) indicated on the type plate with the supply voltage before connecting to the mains. Before beginning work on live parts, disconnect all of the systems circuits from the power supply (switch off main switch, disconnect fuse) and secure against unintentional restart. Equipment covers and service panels must be replaced as soon as the work is completed. 6 FA ROTEX HPSU monobloc compact 09/2017

7 2 x Safety Site of installation For safe and fault-free operation, the installation location of the ROTEX HPSU monobloc compact must meet certain criteria. Information on this can be found in chap Information on the installation site of other components can be found in the associated documentation supplied with them Heating system and sanitary connection Create a heating system according to the safety requirements of EN With a sanitary connection you must comply with EN 1717 Protection against pollution of potable water installations and general requirements of devices to prevent pollution by backflow EN 806 Specifications for installations inside buildings conveying water for human consumption and, in addition, the country-specific legal regulations. The connection of a solar installation, an electric heating rod or an alternative heat generator may cause the storage temperature to exceed 60 C. Scalding protection (e.g. VTA Screw set 1" ) must therefore be fitted during installation. If the ROTEX HPSU monobloc compact is connected to a heating system with steel pipes, radiators or non-diffusion-proof floor heating pipes, sludge and swarf can enter the hot water storage tank and cause blockages, local overheating or corrosion damage. To prevent possible damage, fit a dirt filter or sludge separator into the heating return flow of the system. SAS 1 ( ) The dirt filter must be cleaned at regular intervals Requirements for the heating water Observe the relevant regulations of technology to prevent creation of corrosion products and deposits. Minimum requirements regarding the quality of filling and supplementary water: Water hardness (calcium and magnesium, calculated as calcium carbonate): 3 mmol/l Conductivity: 1500 (ideal: 100) μs/cm Chloride: 250 mg/l Sulphate: 250 mg/l ph-values (heating water): Using filling water and top-up water which does not meet the stated quality requirements can cause a considerably reduced service life of the equipment. The responsibility for this lies solely with the operator Operation The ROTEX HPSU monobloc compact: Do not operate until all installation and connection work is completed. Only operate with a completely full storage tank (Level indicator) and heating circuit. Operate at a maximum pressure of 3 bar. Only connect with a pressure reducer on the external water supply (supply line). only operate if the protective cover is installed. The specified servicing intervals should be adhered to and inspection work must be carried out Instruct the owner Before you hand over the ROTEX HPSU monobloc compact, explain to the user how to operate and check the system. Hand over the technical documentation (this document and all supporting documents) to the user and advise him that these documents must be made available at all times and be stored in the immediate vicinity of the unit. Document the handover by filling out the installation and instruction forms together with the owner and sign them. FA ROTEX HPSU monobloc compact 09/2017 7

8 3 x Product description 3 Product description 3.1 Design and components Exterior of the device and interior structure RKHWMX(B)300C UV DHW 33 3UVB AB 32 M 3UV DHW A B 5 4 X SV MAG t V,BH A M AB B 3UVB1 DS 18 RoCon B X 27 AB B M A 26 3UVB1 7a AB A B M 3UV DHW t DHW / Fig. 3-1 RKHWMX(B)300C design and components (exterior view and interior structure) Key names, see tab FA ROTEX HPSU monobloc compact 09/2017

9 3 x Product description Exterior of the device and interior structure RKHWMX(B)500C UV DHW 5 4 X SV MAG 33 3UVB AB 32 M 3UV DHW A B t AB V,BH A B M 3UVB1 DS RoCon B X AB B M A 26 3UVB1 7a AB A B M 3UV DHW t DHW / Fig. 3-2 RKHWMX(B)500C design and components (exterior view and interior structure) Key names, see tab. 3-1 FA ROTEX HPSU monobloc compact 09/2017 9

10 3 x Product description Upper side of the device 3UV DHW A SV 40 DS 3UV DHW 5 (34) 3UV DHW A (34) 3UVB1 t V,BH Fig RKHWMX(300/500)C design and components (upper side of the device) 10 FA ROTEX HPSU monobloc compact 09/2017

11 3 x Product description 1 Solar feed or connection for further heat source (1" IG) 2 Cold water connection (1" AG) 3 Hot water (1" AG) 4 Heating feed (1" AG)* 5 Heating return flow (1" AG)* 7a Recommended accessories: non-return valves (2x), Automatic bleeder 9 Storage tank (double walled jacket made of polypropylene with PUR hard foam heat insulation) 10 Filling and draining connection or solar return flow connection 11 Mount for solar controller or handle 12 Heat exchanger (stainless steel) for domestic hot water heating 13 Heat exchanger (stainless steel) for storage tank charging and heating support 14 Heat exchanger (stainless steel) for pressurised solar system charging (type (B) only) 15 Connection for optional electric backup heater BUxx (R 1½" IG) 16 Solar - inflow layering pipe 17 Fill level indicator (storage tank water) Tab. 3-1 Legend for fig. 3-1 to fig Optional: electric backup heater (BUxx) 19 Sensor immersion sleeve for storage tank temperature sensor t DHW 20 Pressure-free storage tank water 21 Solar zone 22 Hot water zone 23 Safety overflow connection 24 Mount for handle 25 Rating plate 26 Cover 27 Solar return flow 28 Solar feed (3/4" IG + 1" AG) (type (B) only) 29 Solar return flow (3/4" IG + 1" AG) (type (B) only) 30 Discharge fitting cover 31 Outdoor unit water inlet connection (1" AG)* 32 Outdoor unit water outlet connection (1" IG)* 33 Vent valve (manual) 34 Ball cock (heating circuit)* 35 Combined filling and draining valve (heating circuit) 38 Diaphragm expansion vessel connection 39 Controller housing with electr. connector block 40 Holding burls for protective cover 41 RPS4 Optional: pump unit ROTEX solar control and 3UVB1 3-way switch valve (internal heat generator circuit) 3UV DHW 3-way switch valve (hot water / heating) DS Pressure sensor MAG Diaphragm expansion vessel (optional) SV Safety pressure relief valve (heating circuit) t DHW Storage tank temperature sensor t V, BH Backup heater feed temperature sensor RoCon B1 ROTEX HPSU monobloc compact controller control panel Safety devices Observe tightening torque! AG External thread IG Internal thread * Ball cock (1" IG) is supplied. FA ROTEX HPSU monobloc compact 09/

12 4 x Set-up and installation 4 Set-up and installation WARNING! Cooling systems (heating pumps), climate control systems and heating devices that have been set up and installed incorrectly can both endanger life and health of people and be impaired in their function. Work on the ROTEX HPSU monobloc compact (such as e.g. installation, repair, connection and initial commissioning) must only be carried out by persons who are authorised, who have successfully completed qualifying technical or vocational training for the respective activity and who have taken part in advanced training sessions recognised by the relevant responsible authority. This especially includes heating specialists and specialist electricians, who have experience in the proper installation and maintenance of heating systems due to their technical training and specialist knowledge. 12 FA ROTEX HPSU monobloc compact 09/2017

13 4 x Set-up and installation 4.1 Dimensions and connections RKHWMX(B)300C 1 Solar inflow 2 Cold water 3 Hot water 4 Heating flow 5 Heating return flow 6 Outdoor unit water outlet connection Fig. 4-1 RKHWMX(B)300C connections and dimensions 7 Outdoor unit water inlet connection 8 Solar feed (type (B) only) 9 Solar return (type (B) only) A B Front Rear FA ROTEX HPSU monobloc compact 09/

14 4 x Set-up and installation RKHWMX(B)500C 1 Solar inflow 2 Cold water 3 Hot water 4 Heating flow 5 Heating return flow 6 Outdoor unit water outlet connection Fig. 4-2 RKHWMX(B)500C connections and dimensions 7 Outdoor unit water inlet connection 8 Solar feed (type (B) only) 9 Solar return (type (B) only) A B Front Rear 14 FA ROTEX HPSU monobloc compact 09/2017

15 4 x Set-up and installation Scope of delivery ROTEX HPSU monobloc compact Bag of accessories (see fig. 4-3) 4.2 Installation CAUTION! Only install the ROTEX HPSU monobloc compact if a sufficient ground carrying capacity of 1050 kg/m² plus safety margin is ensured. The ground must be flat and level. Outdoor installation is not permissible. Installation in an explosion-risk environment is not permissible. The electronic controller must never be exposed to the effects of weather. The storage tank may not be exposed to continuous direct sunlight, as the UV radiation and the effects of the weather will damage the plastic. The ROTEX HPSU monobloc compact must be installed protected from frost. Make sure that the supply company does not provide corrosive domestic water. Suitable water treatment may be required. A Handles (only required for transport) E F B Cover screen G C Hose connecting piece for safety overflow H I D Spanner J K Fig. 4-3 Contents of bag of accessories Ball cock Flat seal O-ring Cable tie Plug bracket Venting tube Cover drain hose WARNING! The plastic wall of the storage tank of the ROTEX HPSU monobloc compact can melt under the effects of external heat (>80 C) and, in the extreme case, can catch fire. Only install the ROTEX HPSU monobloc compact with a minimum distance of 1 m to other heat sources (>80 C) (e.g. electrical heater, oil heater, chimney) and the material to be combusted. FA ROTEX HPSU monobloc compact 09/

16 4 x Set-up and installation CAUTION! If the ROTEX HPSU monobloc compact is not installed a sufficient distance below the flat solar panels (the top edge of the storage tank is higher than the bottom edge of the solar panels), the unpressurised solar system in the outdoor area will not be able to drain completely. Install the ROTEX HPSU monobloc compact sufficiently low at the flat solar panels (observe minimum gradient in the solar connection lines) in the case of a DrainBack solar connection. Remove packing and dispose of it in an environment-friendly manner. Pull off the cover screens (fig. 4-4, item B) from the storage tank and unscrew the threaded fittings (fig. 4-4, item F) from the openings at which the handles are to be fitted (fig. 3-1 to fig. 3-2, item 24). Screw the handles (fig. 4-4, item A) into the now uncovered threaded holes. A Handle B Cover screen Fig. 4-4 Installing the handles F Threaded piece Install the ROTEX HPSU monobloc compact at the installation site. Recommended clearances (fig. 4-5): From the wall: (s1) 100 mm, (s2) 500 mm. From the ceiling (X): 1200 mm, at least 480 mm. Transport the ROTEX HPSU monobloc compact using the handles. When setting up the unit in a cabinet, behind panels or in other restricted conditions, sufficient ventilation (e.g., using ventilation gratings) must be ensured. If required, install the optional backup heater (BUxx) in the ROTEX HPSU monobloc compact (fig. 4-5). Observe the installation and operating instructions enclosed with the accessories ( tightening torque, see chap. 10.3). 16 FA ROTEX HPSU monobloc compact 09/2017

17 4 x Set-up and installation 4.3 Removing the cover and thermal insulation Raise the cover at the rear and remove forwards <1000 mm >80 C Fig. 4-6 Remove the protective cover s2 s1 If the installation conditions require the hydraulic connection directly upwards, the cover can be cut out along the broken line. X 1. max. 10 Nm 5. X 1200 mm Fig. 4-7 Producing the cover cut-out Fig. 4-5 Installation (shown on RKHWMX(B)500C with installation of the optional backup heater) Fig. 4-8 ROTEX HPSU monobloc compact without protective cover FA ROTEX HPSU monobloc compact 09/

18 4 x Set-up and installation CAUTION! The thermal insulation (fig. 4-8, item A) consists of pressure-sensitive EPP moulded parts that can be easily damaged if not handled correctly. Only remove the thermal insulation in the order stated below and in the stated directions. Do not use force. Do not use tools. Remove the thermal insulation in the following order: Pull the side insulating element off horizontally (fig. 4-9, item A). Pull the rear insulating element off horizontally (fig. 4-9, item B). Pull the front insulating element off horizontally (fig. 4-9, item C). Fig Removing the bottom thermal insulation The thermal insulation is installed in reverse order. 4.4 Water connection Fig. 4-9 Removing the top thermal insulation As required: Remove the bottom thermal insulation in the following order: Pull the side insulating element off vertically (fig. 4-10, item A). Pull the rear insulating element off vertically (fig. 4-10, item B). CAUTION! If the ROTEX HPSU monobloc compact is connected to a heating system with steel pipes, radiators or non-diffusion-proof floor heating pipes, slurry and swarf could enter the hot water storage tank and cause blockages, local overheating or corrosion. Flush the feed pipes before filling the heat exchanger. Rinse out the heat distribution network (in the existing heating system). Install a dirt filter or sludge separator in the heating return flow (see chap ). 18 FA ROTEX HPSU monobloc compact 09/2017

19 4 x Set-up and installation CAUTION! If the ROTEX HPSU monobloc compact is connected to a cold water supply line in which steel pipes are used, swarf can enter the stainless steel corrugated tube heat exchanger and remain there. This can lead to contact corrosion damage and subsequently to leakage. Flush the feed pipes before filling the heat exchanger. Install a dirt filter in the cold water supply (see chap ) Aligning the connections of the heating supply and return The connections of the heating supply and return can be directed upwards or backwards in order to adapt it optimally to the structural conditions of the installation site. The device is supplied with upwards aligned connections as standard. The following conversion steps are required in order to direct the connections to the rear out of the device: Remove the protective cover and top thermal insulation (see chap. 4.3). RKHWMXB300C AND RKHWMXB500C ONLY CAUTION! If the heat exchanger for pressurised solar system charging (fig. 4-1 / fig. 4-2, items 8+9) is connected to an external heater (e.g. woodburning boiler), the ROTEX HPSU monobloc compact can be damaged or destroyed due to an excessively high feed temperature at these connections. The inflow temperature of the external heating unit should be limited to max. 95 C. In accordance with EN a safety valve that limits the maximum permissible operating pressure in the heating system must be installed on or in the immediate vicinity of the heat generator. There may not be any hydraulic blocking elements between the heat generator and the safety valve. Any steam or heating water which may escape must be drained by a suitable blow-off line with constant gradient in a frost-protected, safe and observable manner. A diaphragm expansion vessel suitably sized and preset for the heating system must be connected to the ROTEX HPSU monobloc compact. There may not be any hydraulic blocking elements between the heat generator and the diaphragm expansion vessel. ROTEX recommends installing a mechanical pressure gauge for filling the heating system. Observe the stipulations of EN 806 and DIN 1988 for domestic water pipes. Install the ROTEX HPSU monobloc compact close to the withdrawal point to dispense with the need for a circulation line. If a circulation line is mandatory, it must be installed according to the schematic diagrams in chap. 9 "Hydraulic system connection". Fig Aligning the heating supply and return upwards Pull the two plug brackets off the connection couplings (fig. 4-11, item C). Pull off the two connection couplings (fig. 4-11, item B). CAUTION! When working on the hydraulics, pay attention to the installation position of the O-rings to avoid damaging them and causing leaks. Always place O-rings on the part to be inserted after a plug connection has been removed or before it is installed. Connection of heating lines by plug connection must be without tension. Establish suitable tension relief particularly for connection with flexible lines (not breathable!). Remove the retaining plate (fig. 4-11, item A). Pull off the sealing plug plug bracket (fig. 4-11, item D). Pull out the sealing plug (fig. 4-11, item E). Turn the elbow (fig. 4-11, item H) 90 to the rear. Pull the plug bracket off the manifold (fig. 4-11, item G). Carefully pull the manifold (fig. 4-11, item F) so far backwards out of its horizontal mounting that the retaining plate (fig. 4-12, item A) can be pushed vertically in between. FA ROTEX HPSU monobloc compact 09/

20 4 x Set-up and installation Fig Cut-out in thermal insulation Fig Heating supply and return connections aligned to the rear Slide the retaining plate between the manifold and its horizontal mounting and insert the manifold (fig. 4-12, item F) back into its mounting through the middle hole of the retaining plate. CAUTION! If the plug brackets cannot be put on properly, the couplings can be detached from their mountings to ensure a very strong or continuous escape of liquid can occur. Before putting on a plug bracket, make sure that the plug bracket engages in the coupling groove. To do so, insert the coupling far enough into the mounting that the groove is visible through the plug bracket mounting. Insert the plug bracket up to the end stop. Secure the manifold with plug bracket (fig. 4-12, item G) in its mounting again. Insert the two connection couplings (fig. 4-12, item B) into the lateral mountings through the retaining plate. Secure the two connection couplings with plug brackets (fig. 4-12, item C) in their mountings. Insert the sealing plug (fig. 4-12, item E) into the upper mounting. Secure the sealing plug with plug bracket (fig. 4-12, item D). Cut out side openings in the thermal insulation (fig. 4-13, item A) using a suitable tool Connecting hydraulic lines Prerequisite: optional accessories (e.g. solar, backup heater) are mounted on the ROTEX HPSU monobloc compact as specified in the enclosed instructions. Check cold water pressure (maximum 6 bar). If a higher pressure is present in the domestic water pipe, a pressure reducer will need to be installed. Establish hydraulic connections on the ROTEX HPSU monobloc compact. Refer to fig. 4-1 / fig. 4-2 and tab. 3-1 for the position and dimensions of the heater connections and the outdoor unit connections. Pay attention to the stipulated tightening torque (see chap "Tightening torque"). Install the line so that the sound insulation hood can be positioned easily after installation. Connect the water for filling or refilling the heating system as per EN 1717 so that contamination of the drinking water due to return flow is reliably prevented. Connect the drain line to the safety overpressure valve and diaphragm expansion vessel as per EN Check the seat of the drain hose on the pressure relief valve. If necessary, connect and install a separate hose. Carefully insulate pipework against heat loss and to avoid condensation (insulation thickness at least 20 mm). Water shortage protection: the controller's pressure and temperature monitoring function shuts off the ROTEX HPSU monobloc compact reliably if there is a shortage of water. No additional water shortage protection is needed in the construction. Damage due to deposits and corrosion: observe the relevant technical rules to avoid corrosion products and deposits. Minimum requirements regarding the quality of filling and supplementary water: Water hardness (calcium and magnesium, calculated as calcium carbonate): 3 mmol/l Conductivity: 1500 (ideal: 100) μs/cm Chloride: 250 mg/l Sulphate: 250 mg/l ph-values (heating water): Measures for desalination, softening, hardness stabilisation or other suitable conditioning measures are necessary to adhere to the required water quality if the filling and top-up water have a high overall hardness or other properties that deviate from the minimum requirements. 20 FA ROTEX HPSU monobloc compact 09/2017

21 4 x Set-up and installation WARNING! There is a danger of scalding at hot water temperatures over 60 C. This is possible when using solar energy if an external heater is connected, the Legionella protection is activated, or the target hot water temperature is set to be greater than 60 C. Install scalding protection (hot water mixing facility (e.g. VTA Screw set 1" ) Installation of the DB connection kit ( ) The optional DB connection kit enables better accessibility for connecting the DrainBack line (solar feed). Connect the drain hose to the hose connector for the safety overflow (fig. 3-1 to fig. 3-3, item 23). Use transparent drain hose (draining water must be visible). Connect the drain hose to an adequately dimensioned waste water installation. Drain should not be lockable. A DB pipe connection (solar feed) B FlowSensor (not part of the DB connection kit, but included with RPS4) Fig DB connection kit C Flow limiter (FlowGuard) D Solar feed connection on the storage tank Installation of the P connection kit ( ) Fig Installation of drain hose at safety overflow The optional P connection kit for B device types allows better access for connecting the supply and return lines of a pressurised solar system or another external heat generator on the storage tank. The kit contains two thermally insulated corrugated pipes that are connected to the connections of the storage tank via a union nut. At the other end of the corrugated pipes there is an adapter for different connection sizes of the supply and return pipes. Connect the discharge fitting on the cover (fig. 3-3, item 30) to the waste water installation with the enclosed hose section. A Connection for supply (red) B Connection for return (blue) Fig P connection kit for B device types FA ROTEX HPSU monobloc compact 09/

22 4 x Set-up and installation 4.5 Electrical connection WARNING! Touching live parts can result in an electric shock and lead to potentially fatal injuries and burns. Before beginning work on live parts, disconnect all of the systems circuits from the power supply (switch off external main switch, disconnect fuse) and secure against unintentional restart. The electrical connection and working on the electrical components should only be performed by electrical engineers in compliance with valid standards and guidelines as well as the specifications of the energy supply company. The equipment covers and maintenance opening covers must be re-fitted immediately after completion of the work. CAUTION! Increased temperatures may occur in the ROTEX HPSU monobloc compact control housing during operation. This can result in currently-carrying wires from reaching higher temperatures during operation due to self-heating. For this reason, these lines need to have a continuous use temperature of 90 C. For the following connections, use only cables with a long-term use temperature 90 C: Optional: electric backup heater (BUxx) 22 FA ROTEX HPSU monobloc compact 09/2017

23 4 x Set-up and installation ROTEX HPSU monobloc compact overall connection diagram See tab. 4-2 and tab. 4-3 for an explanation of the symbols and abbreviated designations in this chapter. J13 J3 J3 J8 5-7 kw L N PE 1 2 BUxx 1 ~ 230V BUxx 3 ~ 400V N PE PE N 2,5 mm² /230 V 90 C 2,5 mm² / 230 V 1,5 mm² / sig XAG1 EXT EBA L EXT GND EVU GND PE N PE N L1 A1 A A2 J8 SG EBA GND B B1 J8 t V,BH Smart Grid GND CAN-H CAN-L CAN-VCC CAN-GND J8 J8 HT/NT T AU GND GND GND J14 J16 P Z 0,5 mm² / sig 0,5 mm² / sig 0,75 mm² / sig 0,75 mm² / sig 0,75 mm² / sig 1,5 mm² / 230V P1 P2 BU BU L1 N PE 0,5 mm² / sig 0,5 mm² / sig 0,75 mm² / sig 0,75-1,5 mm² / sig AUX RoCon BM2C RTX - EHS XBUH1 BU BU BU BU L1 L2 L3 N PE 2,5 mm² / 400 V J6 XBUH1 V3 X5M V3 1 ~ 230V 230V 400V? Power surge category III Power surge category III Power surge category III RCD (FI) L1 L2 L3 N PE L1 L2 L3 L1 L2 L3 RCD (FI) Fuse 20A Fuse 16A 1 ~ 230V 1,5 mm² / 230 V PE N RoCon UFH output RoCon U1 RoCon M1 RT Power surge category III L1 L2 L3 RCD (FI) Fuse 16A Fig Overall connection diagram - for electrical connection during device installation FA ROTEX HPSU monobloc compact 09/

24 4 x Set-up and installation Position of the printed circuit boards 1 Controller housing 3 Controller control panel 2 Controller cover Fig Overview of printed circuit boards (inside housing) RTX-EHS printed circuit board connection diagram Fig RTX-EHS printed circuit board (backup heater) - see chap FA ROTEX HPSU monobloc compact 09/2017

25 4 x Set-up and installation RoCon BM2C printed circuit board connection diagram Fig RoCon BM2C printed circuit board (basic controller module) Mains voltage 230 V, 50 Hz (connection diagram in these instructions) Mains connection ROTEX HPSU monobloc compact A flexible cable for the mains connection is already connected inside the device. Check the supply voltage (~230 V, 50 Hz). Disconnect the junction box of the domestic installation. Connect the cable for connecting the ROTEX HPSU monobloc compact to the mains to the domestic installation's junction box (isolator according to EN ) via an all-pole separating main switch to be installed in the building. Ensure that the polarity is correct. The outdoor unit and optional accessories must be connected to the ROTEX HPSU monobloc compact controller separately. To do this, the cover of the ROTEX HPSU monobloc compact must be removed (see chap. 4.3) and the controller housing must be opened if necessary (see chap ). FA ROTEX HPSU monobloc compact 09/

26 4 x Set-up and installation Opening the controller housing and establishing electrical connections Connecting the heat pump outdoor unit A separate manual containing instructions about installation and operation is included with this component. Remove the cover (see chap. 4.3). Connect the heat pump outdoor unit to terminal strip XAG1 (see fig. 4-27, fig. 4-29). Fig Remove the right housing cover. Fig Unlock the front panel. Fig Connecting the heat pump outdoor unit If the heat pump outdoor unit is shut off via a circuit specified by the utility company (EVU), the ROTEX HPSU monobloc compact internal unit is not shut off (see chap ). Fig Open the front panel and place in installation position. Fig Route the wiring in the right housing cover. Fig Install the cabling in the controller and establish the electrical connections. Fig Attach the right housing cover Connecting an external switching contact Connection of an external switching contact (fig. 4-30) enables changeover of the operating mode on the ROTEX HPSU monobloc compact. The current operating mode is switched by a changing resistance value (tab. 4-1). The changeover of the operating mode is only effective for a long as the external switching contact is closed. The operating mode has an effect on the direct circuit of the ROTEX HPSU monobloc compact as well as all other heating circuits connected to this device as an option. The operating mode shown on the controller display may differ from the operating mode activated in rotary switch position. An operating mode activated by the external switching contact is shown on the controller display by "EXT." followed by the symbol for the operating mode (see the operating instructions for the controller). When special functions are activated, for example "Manual Operation", the input is not evaluated. Fig Establish electrical connections at rear of housing (see chap ). Fig Secure cabling to the storage tank. Fig Connection of EXT switching contact 26 FA ROTEX HPSU monobloc compact 09/2017

27 4 x Set-up and installation Tab. 4-1 Operating mode Resistance R V Tolerance Standby < 680 Ω Heating 1200 Ω Reducing 1800 Ω Summer 2700 Ω ± 5 % Automatic Ω Automatic Ω Resistance values for evaluating the EXT signal The input is not considered for resistance values greater than the value for "Automatic 2" Connecting an electric ROTEX backup heater (BUxx) A separate manual containing instructions about installation and operation is included with this component. Connect the power supply for the backup heater at terminal strip X1 of printed circuit board RTX-EHS (fig. 4-19) in the ROTEX HPSU monobloc compact controller housing. Insert connector XBUH1 of the backup heater at the rear of the ROTEX HPSU monobloc compact controller housing. Set parameter [Function Heating Rod] to "1" (see RoCon mb controller operating instructions). Connection variant 1 INFORMATION FOR CONNECTION OF A ROTEX SOLAR SYSTEM The [HZU] function integrated in the RoCon mb controller (see the operating instructions for the controller) makes it unnecessary to connect the EXT connection to the burner blocking contact connection of the ROTEX solar system External requirement request (EBA) By connecting the EBA switching contact to the ROTEX HPSU monobloc compact (fig. 4-31) and corresponding parameterisation in its RoCon mb controller, an external switching contact can be used to generate a heat request. If the switching contact is closed, the ROTEX HPSU monobloc compact switches to heating mode. The feed temperature is regulated to the temperature set in the parameter [T-Flow Day]. The EBA switching contact has priority over a request from the room thermostat. The switching contact is not evaluated in cooling mode, Standby, manual or summer mode. The heating limits are also ignored. Fig Connection of EBA switching contact A Wiring in the building (observe country-specific connection conditions - ask the responsible utility company (EVU))! Fig phase backup heater (BU9c) connection FA ROTEX HPSU monobloc compact 09/

28 4 x Set-up and installation Connection variant 2 Connection variant 3 On connection of a backup heater with a heating element (BUH1 / BUH3), the parameter [Function Heating Rod]=2 must be set. Fig phase backup heater (BU9c) connection (key, see fig. 4-32) Fig Connection of a backup heater with a heating element (BUH1 / BUH3) (key, see fig. 4-32) WARNING! Contact with a damaged backup heater connection cable can result in an electric shock and therefore life-threatening injuries and burns. Do not repair the backup heater's connection cable. Always replace the entire backup heater. 28 FA ROTEX HPSU monobloc compact 09/2017

29 4 x Set-up and installation Connecting an external heat generator For heating support or as an alternative to an electric backup heater (see chap ), an external heat generator (e.g. gasor oil-fired boiler) can be connected to the ROTEX HPSU monobloc compact. The heat supplied by the external heat generator must be fed to the unpressurised storage tank water in the ROTEX HPSU monobloc compact's hot water storage tank. Implement the hydraulic connection according to one of the two following options: a) unpressurised via the connections (solar feed and solar return) of the hot water storage tank or b) in the case of ROTEX HPSU monobloc compact B device types, via the integrated pressurised solar system heat exchanger. Observe notes on hydraulic connections (see chap. 2.4) Examples of hydraulic connection (see chapter 9). The external heat generator request is connected via a relay on printed circuit board RTX-EHS (see fig. 4-35). Electrical connection to the ROTEX HPSU monobloc compact is possible as follows; a) External heat generator has a potential-free switching contact connection for heat request: Connection to K3 if the external heat generator undertakes hot water preparation and heating support (setting of parameter [Function Heating Rod]=2) or Connection to K1 and K3 if two external heat generators are used (setting of parameter [Function Heating Rod]=3). In this case, K1 connects the external heat generator (e.g. gas- or oil-fired boiler) for heating support and K3 connects the external heat generator (BUxx) for hot water preparation. or Connection to AUX connection A (see chap ) b) External heat generator can only be connected via mains voltage: connection (~230 V, maximum load 3000 W) to K1 and K3. CAUTION! Danger of voltage flash-overs. The connections of printed circuit board RTX- EHS must not be used simultaneously for connecting mains voltage (~230 V) and SELV ("Safety Extra Low Voltage"). K1/2/3 Relays for backup heater X1 Terminal strip for backup heater mains connection L Phase X3 Internal wiring plug connection N Neutral conductor to RoCon BM2C printed PE Protective earth conductor circuit board RTX-EHS Printed circuit board (backup heater) Fig Connections on printed circuit board RTX-EHS Refer to the external heat generator's respective installation instructions for a suitable electrical connection. Connect the external heat generator to the ROTEX HPSU monobloc compact (fig. 4-35). Connection X1 is designed as a screw terminal. FA ROTEX HPSU monobloc compact 09/

30 4 x Set-up and installation Connecting a ROTEX room thermostat Connecting optional ROTEX RoCon system components A separate manual containing instructions about installation and operation is included with this component. The optional RoCon devices must be connected to the ROTEX HPSU monobloc compact via a 4-wire CAN bus line (connection J13). For this, ROTEX recommends shielded lines with the following characteristics: Standardisation according to ISO 11898, UL/CSA type CMX (UL 444) PVC outer sheath with flame retardancy according to IEC Up to 40 m, minimum cross-section 0.75 mm 2. Larger conductor cross-section necessary with increasing length. Commercially available junction boxes can be used to connect CAN bus lines of several RoCon devices. Ensure that mains, sensor and data bus lines are routed separately. Use only cable ducts with separators or separate cable ducts spaced at least 2 cm apart. Line crossings are permissible. A maximum of 16 devices with a total line length of up to 800 m can be connected in the entire RoCon system. Fig Connection with wired room thermostat (RT = ROTEX RKRTW, ) ROTEX RoCon U1 room station A separate RoCon U1 room station can be connected for each heating circuit to enable remote adjustment of operating modes and target room temperatures from another room. A separate manual containing instructions about installation and operation is included with this component. Fig Connection of RoCon U1 room station Fig Connection with wireless room thermostat (RT-E = ROTEX RKRTR, ) ROTEX RoCon M1 mixer module It is possible for the ROTEX HPSU monobloc compact to be connected to the RoCon M1 mixer module, which is operated using the RoCon mb electronic controller. The connection of the CAN data bus lines is identical to fig at connection J13 of the ROTEX HPSU monobloc compact. A separate manual containing instructions about installation and operation is included with this component. 30 FA ROTEX HPSU monobloc compact 09/2017

31 4 x Set-up and installation Internet gateway ROTEX RoCon G1 The controller can be connected to the internet with the optional RoCon G1 gateway. This enables remote control of the ROTEX HPSU monobloc compact by mobile phones (by app). A separate manual containing instructions about installation and operation is included with this component Connecting a ROTEX HP convector A separate manual containing instructions about installation and operation is included with this component. Electrical connection of the ROTEX HP convector to the basic module with the following accessories according to fig as a switchover contact (heating/cooling). Connect the original ROTEX connecting cable (HPc-VK ) with ROTEX HPSU monobloc compact (H/C) (with cooling function) so that the ROTEX HP convector switches the operating mode (heating/cooling) together with the ROTEX HPSU monobloc compact. If necessary, install and connect a 2-way valve (2UV) (HPC- RP ) in the ROTEX HP convector. Set its controller so that the 2-way valve (2UV) closes when no request is available from this device. The operating mode (heating/cooling) can only be switched on the ROTEX HPSU monobloc compact. Fig Connection of the ROTEX HP convector (min. 3) to the ROTEX HPSU monobloc compact Connecting switching contacts (AUX outputs) The switching contacts (AUX outputs) can be used for various parameterisable functions. When the ROTEX HPSU monobloc compact is in [Cooling] operating mode, switching contact B-B1 closes. Switching contact B-B1 is used e.g. to connect an external status display ("Cooling mode active") or as a switchover contact (heating/cooling) on the basic module of the ROTEX RoCon UFH floor heating controller. A separate manual containing instructions about installation and operation is included with this component. Switchover contact A-A1-A2 switches under the conditions set in the parameter [AUX Fct] (see controller operating instructions). Fig Connection of the ROTEX HP convector (max. 2) to the ROTEX HPSU monobloc compact Fig Connection of switching contact (AUX output) FA ROTEX HPSU monobloc compact 09/

32 4 x Set-up and installation The relays to be used according to variant 2 (switched output > 15 W) must be suitable for a 100% on time. [HT/NT Contact] = 1 [HT/NT Contact] = 0 Switchover contact A-A1-A2 can be used e.g. to control the heat generators in bivalent heating systems consisting of a ROTEX HPSU monobloc compact and an oil-or gas-fired boiler. Examples of hydraulic system integration are described in chapter 9. If an A1 or G-plus condensing boiler is connected, the parameter [AUX Fct] and the parameter [AUX time] must be set according to the desired function. See "ROTEX RoCon mb controller" operating instructions > Parameter settings chapter. Precise information on electrical connection and the required parameter settings for such bivalent heating systems are available in the Internet or from your service partner Off-peak mains connection (HT/NT) If the outdoor unit is connected to an off-peak mains connection, potential-free switching contact S2S of the receiver, which evaluates the off-peak input signal output by the electricity company (EVU), must be connected to connector J8, EVU connection on the RoCon BM2C printed circuit board (see fig. 4-42). If parameter [HT/NT Function] > 0 is set, certain system components are shut off during peak periods (see controller operating instructions). The following types of off-peak mains connection are common: Type 1: with this type of off-peak mains connection, the power supply to the heat pump outdoor unit is not interrupted. Type 2: with this type of off-peak mains connection, the power supply to the heat pump outdoor unit is interrupted after a certain period of time. Type 3: with this type of off-peak mains connection, the power supply to the heat pump outdoor unit is interrupted immediately. Potential-free switching contact S2S can be implemented as a normally closed or normally open switching contact. a) If implemented as a normally closed switching contact, parameter [HT/NT Contact] = 1 must be set. When the EVU sends the off-peak signal, switching contact S2S is opened. The system switches to "Mandatory OFF". If the signal is sent again, potential-free switching contact S2S closes and the system resumes operation. b) If implemented as a normally open switching contact, parameter [HT/NT Contact] = 0 must be set. When the EVU sends the off-peak signal, switching contact S2S is closed. The system switches to "Mandatory OFF". If the signal is sent again, potential-free switching contact S2S opens and the system resumes operation. 1 Mains connection box for off-peak mains connection 2 Receiver for evaluating the HT/NT control signal 3 Heat pump outdoor unit power supply (see respective installation instructions for the heat pump outdoor unit) 4 Potential-free switching contact for heat pump indoor unit Fig Connection of HT/NT switching contact Connecting an intelligent controller (Smart Grid - SG) As soon as the function is activated through the parameter [SMART GRID] = 1 (see controller operating instructions), the heat pump is switched to Stand-by, standard or a mode with higher temperatures depending on the utility company signal. To do this, the intelligent controller's potential-free switching contacts SG1/SG2 must be connected to connector J8, Smart Grid and EVU connection, on the RoCon BM2C printed circuit board (see fig. 4-43). As soon as the Smart Grid function is active, the HT/NT function is automatically deactivated. The heat pump is operated differently depending on the value of the parameter [Mode SG] (see controller operating instructions). Fig Smart Grid connection 32 FA ROTEX HPSU monobloc compact 09/2017

33 4 x Set-up and installation Symbols and key names for connection and wiring diagrams Symbols Explanation Symbols Explanation Safety earthing Low external voltage earthing External cabling (number of individual cores and the mains voltage are partially quoted.) Pushbutton Connection terminal Plug connection Terminal rail 2-core cabling (non-screened) 4-core cabling (non-screened) 6-core cabling (non-screened) DIP switch Optional component Plug and socket connection 3-core cabling (non-screened) 5-core cabling (non-screened) Screened cabling (e.g. 3-core) Tab. 4-2 Explanation of symbols for connection and wiring diagrams Short designation RRLQ 3UVB1 3UV DHW AUX BUxx DS Key names Explanation Heat pump outdoor unit Indoor unit 3-way switch valve (internal heat generator circuit) 3-way switch valve (hot water / heating) Switching contact outputs (A-A1-A2) + (B-B1) Backup heater Pressure sensor EBA Switching contact for external requirement request EXT Switching contact for external operating mode switchover F1 Fuse 250 V T 2 A (RoCon BM2C) FU1 Fuse 250 V T 3.15 A (A1P in the outdoor unit) Connecting cable between HPSU monobloc HPc-VK-1 compact (with cooling function) and HP convector HT/NT Switching contact for off-peak mains connection P Z Circulation pump RJ45 CAN Internal wiring plug connection (RoCon BM2C) (to RoCon B1) RoCon B1 Controller control panel RoCon BM2C Printed circuit board (basic controller module) Key names Short designation Explanation J1 Not assigned J2 Plug connection3uvb1 J3 AUX switching contact plug connection J4 Plug connection - not assigned J5 Pressure sensor plug connection J6 Plug connection mains voltage J7 Not assigned Plug connectionext Plug connectioneba Smart Grid plug connection EVU switching contact J8 Plug connection t V, BH Storage tank temperature sensor t DHW plug connection HT/NT plug connection EVU switching contact J9 Not assigned J10 Not assigned J11 Internal wiring plug connection to XAG1 J12 Plug connection3uv DHW J13 System bus plug connection (e.g. room station) J14 Circulation pump P Z plug connection J15 Internal wiring plug connection (bridging plug) J16 Room thermostat (RKRTR / RKRTW) plug connection RoCon M1 Mixer module RoCon U1 Room station RoCon UFH Status output for "Cooling" operating mode (RoCon UHF floor heating controller connection) RT Room thermostat (RKRTW) RT-E Receiver for wireless room thermostat (RKRTR) RTX-EHS Printed circuit board (backup heater) RoCon BM2C FA ROTEX HPSU monobloc compact 09/

34 4 x Set-up and installation Key names Short designation Explanation K1 Relay 1 for backup heater K2 Relay 2 for backup heater K3 Relay 3 for backup heater X1 Terminal strip for backup heater mains connection X3 Internal wiring plug connection to J17 (RoCon BM2C) SG Switching contact for Smart Grid (intelligent mains connection) Storage tank temperature sensor 1 t DHW (RoCon BM2C) t V, BH Backup heater feed temperature sensor (RoCon BM2C) XAG1 Heat pump outdoor unit plug connection XBUH1 Backup heater plug connection (BUxx) X2M6 Connecting cable terminal HPc-VK-1 X2M7 Connecting cable terminal HPc-VK-1 X11M Terminal strip in HP convector RTX-EHS Tab. 4-3 Key names for connection and wiring diagrams 4.6 Filling the system on the water side Fill the ROTEX HPSU monobloc compact only after completion of all installation work in the order shown below Checking the water quality and adjusting the pressure gauge Observe the notes on the water connection and water quality according to chap The correct minimum pressure mark must be set on the pressure gauge installed in the building before initially filling the system: Rotate the pressure gauge glass so that the minimum pressure mark corresponds to the system height +2 m (1 m water column = 0.1 bar). To guarantee frost protection in the event of a power failure, glycol can be added to the heating water circuit. Please observe the notes in chap Filling the hot water heat exchanger Open the shutoff valve for the cold water supply pipe. Open the hot water tap connections so that the draw-off volume can be set as high as possible. Once water has been discharged from the tap connections do not interrupt the cold water flow; this will ensure that the heat exchanger will be fully vented and that any impurities or residue will be discharged Filling the storage tank See chap Filling the heating system See chap FA ROTEX HPSU monobloc compact 09/2017

35 5 x Start-up 5 Start-up WARNING! A ROTEX HPSU monobloc compact erected and installed incorrectly may not operate properly and can be dangerous for the health and safety of individuals. The ROTEX HPSU monobloc compact must only be commissioned by authorised and trained heating specialists. CAUTION! If the ROTEX HPSU monobloc compact is not started up properly, it could lead to material or environmental damage. Observe the current technological regulations to prevent corrosion products and deposits. Minimum requirements regarding the quality of filling and supplementary water: Water hardness (calcium and magnesium, calculated as calcium carbonate): 3 mmol/l Conductivity: 1500 (ideally 100) μs/cm Chloride: 250 mg/l Sulphate: 250 mg/l ph value (heating water): We recommend the use of Fernox limescale and corrosion protector KSK ( ). The water pressure must be checked at regular intervals during system operation. If necessary, correct the pressure by topping up with water 5.1 Initial start-up Once the ROTEX HPSU monobloc compact has been installed and completely connected, it must be adapted once to the installation environment by expert personnel (configuration). After this configuration is complete, the installation is ready for operation and the operator can make additional custom configurations on it. The heating technician must familiarise the user, draw up the commissioning log and complete the operating manual. The settings for optional components such as a room thermostat or ROTEX solar system must be carried out on the respective components Requirements The ROTEX HPSU monobloc compact is fully connected. The heating and hot water system has been filled and pressurised to the correct pressure (see chap. 7.4). The storage tank is filled up to the overflow (see chap. 7.3). Optional accessories have been mounted on and connected up. The heating system's control valves are open Starting the device Switch on the power supply to the ROTEX HPSU monobloc compact. After the start phase, the operating language selection is displayed. Use the rotary button to select the desired language. The operating language can be changed again at any time. Confirm the selection with a brief push of the rotary button. The ROTEX HPSU monobloc compact basic configuration is loaded. The "Starting Up" message is displayed. The "Initialization" message is displayed. The standard display for the current rotary switch setting is shown. CAUTION! Make sure that the parameter [Glycol] corresponds to the fluid in the water circuit (0 = water only, 1 = water + glycol). If the glycol setting is NOT correct, the fluid inside the pipes can freeze. If glycol has been added to the system but the glycol concentration is lower than specified, the fluid can still freeze in the pipes. FA ROTEX HPSU monobloc compact 09/

36 5 x Start-up Setting commissioning parameters To set the commissioning parameters, the heating technician must be logged into the controller. Technician login Configuration Configuration Access Rights Setup System Configuration Setup System Configuration System Configuration Power DHW BUH s1 power Setup Language Date Setup Language Date Access Rights User Fig. 5-2 Setting the commissioning parameters Bleeding the hydraulic system Setup Fig. 5-1 Keylock Function Access Rights Outdoor type Access Rights Entering the technician code Access Rights Expert Access Rights Set the required commissioning parameters. The enclosed "Commissioning check list" must be observed and completed for this. Explanation of the operating parameters, see controller operating instructions. Enter the set values in the corresponding tables in the "Notes" chapter of the controller operating instructions. Activate the Legionella protection (parameter [Anti-Legionella day]) if required. If an outside temperature sensor is connected, set the parameter [Tamb Config] to "1". Set further commissioning parameters on the ROTEX HPSU monobloc compact controller depending on system requirements. With glycol in the system, set the parameter [Glycol] to "1". If the storage tank temperature falls below specific minimum values, the ROTEX HPSU monobloc compact's safety settings prevent the heat pump from being operated at low outside temperatures: Outside temperature < -2 C, minimum storage tank temperature = 30 C Outside temperature < 12 C, minimum storage tank temperature = 23 C. Without backup heater: The storage tank water must be heated to the required minimum storage tank temperature with an external heater booster. With backup heater (BUxx): At an outside temperature of < 12 C and a storage tank temperature of < 35 C, the backup heater (BUxx) is automatically switched on to heat the storage tank water to at least 35 C. To speed up the heating process with backup heater, temporarily set parameter [Function Heating Rod] = "1" and parameter [Power DHW] to the maximum value of the backup heater. Set the rotary switch to operating mode, and set the parameter [1x Hot Water] to "On". After heating, set the parameter to "Off" again. 36 FA ROTEX HPSU monobloc compact 09/2017

37 5 x Start-up Make sure that the automatic vent valve cap is open (fig. 5-3, item A). Fig. 5-4 Manual vent valves Checking the minimum flow Fig. 5-3 Automatic vent valve cap Provide the manual vent valve (fig. 5-4, item B) with a hose and direct it away from the unit. Open the valve until water comes out. Fit the second manual vent valve (fig. 5-4, item C) with a hose and open it until water emerges. Activate air purge (see FA RoCon mb). By activating the air purge, the RoCon mb controller starts a permanently defined sequence program with start/stop operation of the integrated heating circulation pump and various settings of the 3-way switch valves integrated in the ROTEX HPSU monobloc compact. Any air present can escape via the automatic vent valve during the air purge and the hydraulic circuit connected to the ROTEX HPSU monobloc compact is evacuated. The activation of this function does not replace correct venting of the heating circuit. The heating circuit must be completely full before activating this function. Check the water pressure and replenish water if necessary (see chap. 7.4). Repeat the venting, checking and replenishing process until: a) It is completely vented. b) There is sufficient water pressure. The minimum flow must be checked with the heating circuit closed. If the minimum flow is too low, an error message may appear and the heating system may shut down. If the minimum flow is inadequate: air may be in the circulation pump. Vent the circulation pump (heat pump outdoor unit). the valve drive of the 3-way switch valves (3UVB1 / 3UV DHW) may be defective. Check the function of the valve drives; replace the valve drive if necessary. Close the valves and adjuster drives of all connected heat distribution circuits. Set "Heating" operating mode on the ROTEX HPSU monobloc compact controller. Read out the information parameter [Flow Rate]. The flow rate must be at least 480 l/h (see controller operating instructions). The ROTEX HPSU monobloc compact controller constantly monitors the flow rate of the internal heat generator circuit. Different minimum flow rate values are required depending on the active operating mode: "Heating", "Cooling" operating mode: 420 l/h Automatic thawing function ( ) active: 780 l/h BUxx support: 780 l/h If an error message regarding an inadequate minimum flow is displayed at a flow rate over 600 l/h, check the actual flow rate in the active operating mode and eliminate possible fault causes Setting the parameter Screed Program (only when required) With the screed program, the feed temperature is controlled according to a pre-set temperature profile. See the controller operating instructions for further information on the screed program, its activation and sequence. After the screed program has ended, the RoCon mb control unit continues to work in the previously set operating mode. If not configured beforehand, the following finishing work is necessary. FA ROTEX HPSU monobloc compact 09/

38 5 x Start-up a) On connection without room station RoCon U1: Set the heating characteristic curve or required T-HS. b) On connection with room station RoCon U1: Activate the room station. Set the heating characteristic curve or required T-HS. If necessary, activate the [Room Influence] parameter and set the room target temperature. 5.2 Re-commissioning Requirements 4. After the start phase has completed, in heating mode, evacuate the heating system, check the installation pressure and adjust if necessary (max. 3 bar, see chap. 7.4). 5. Carry out a visual inspection for leaks on all joints internally. Seal any leaks that occur in a professional manner. 6. Set the rotary switch on the controller to the desired operating mode. 7. If a ROTEX solar system is connected, commission it according to the enclosed instructions. After shutting off the ROTEX solar system, again check the fill level in the buffer storage tank. The ROTEX HPSU monobloc compact is fully connected. The heating and hot water system has been filled and pressurised to the correct pressure (see chap. 7.4). The storage tank is filled up to the overflow (see chap. 7.3) Start-up CAUTION! Setting up in frosty conditions can result in damage to the entire heating system. Commissioning at temperatures below 0 C only if a water temperature of at least 5 C is guaranteed in the heating system and the storage tank. ROTEX recommends not operating the installation in extremely frosty conditions. If the storage tank temperature falls below specific minimum values, the ROTEX HPSU monobloc compact's safety settings prevent the heat pump from being operated at low outside temperatures: Outside temperature < -2 C, minimum storage tank temperature = 30 C Outside temperature < 12 C, minimum storage tank temperature = 23 C. Without backup heater: The storage tank water must be heated to the required minimum storage tank temperature with an external heater booster. With backup heater (BUxx): At an outside temperature of < 12 C and a storage tank temperature of < 35 C, the backup heater (BUxx) is automatically switched on to heat the storage tank water to at least 35 C. To speed up the heating process with backup heater, temporarily set parameter [Function Heating Rod] = "1" and parameter [Power DHW] to the maximum value of the backup heater. Set the rotary switch to operating mode, and set the parameter [1x Hot Water] to "On". After heating, set the parameter to "Off" again. 1. Check the cold water connection and, where necessary, fill the potable water heat exchanger. 2. Switch on the power supply to the ROTEX HPSU monobloc compact. 3. Wait for the start phase. 38 FA ROTEX HPSU monobloc compact 09/2017

39 6 x Taking out of operation 6 Taking out of operation Draining the storage tank WARNING! When opening the solar return connection and the heating and hot water connections, there is a danger of scalding and overflooding from escaping hot water. Only empty storage tanks or the heating system if they have cooled for a sufficient period of time with a suitable fixture for safely draining or collecting the escaping water with suitable protective clothing. Disconnect the ROTEX HPSU monobloc compact from the power supply. Connect a drain hose to the KFE filling connection (accessory KFE BA, ) (fig. 6-1, item A) and lay to a drainage point at least at ground level. If no KFE filling connection is available, the connecting piece (fig. 6-1, item C) can be detached from the safety overflow (fig. 6-1, item B) and used. This must be re-installed after the draining process before the heating system is put back in operation. 6.1 Temporary shutdown CAUTION! A heating system which is shut down can freeze in the event of frost and may suffer damage. Drain the water out of the shutdown heating system if there is a danger of frost. If the heating system is not drained, the power supply must be ensured and the external main switch must remain switched on if there is a danger of frost. If the ROTEX HPSU monobloc compact is not needed for a long time, it can be temporarily decommissioned. However, ROTEX recommends not disconnecting the system from the power supply but merely switching it to "Stand-by mode" (see controller operating instructions). The system is then protected from frost. The pumps and valve protection functions are active. If it is not possible to guarantee the power supply when there is danger of frost, completely drain the ROTEX HPSU monobloc compact on the water side, or suitable antifreeze measures must be applied to the connected heating system and hot water storage tank (e.g. draining). If there is a danger of frost and the power supply cannot be guaranteed for just a few days, the unit's excellent heat insulation means that the ROTEX HPSU monobloc compact does not have to be drained on the water side, provided that the storage tank temperature is monitored regularly and does not fall below +3 C. However, there is no frost protection for the connected heat distribution system through this. Fig. 6-1 A B C D Installing the draining hose KFE filling connection (accessory KFE BA, ) Safety overflow Hose connecting piece for safety overflow Clamping piece Tab. 6-1 Legend for fig. 6-1 to fig. 6-6 Without solar system Remove the cover panel on the filling and draining connection. When using the KFE filling connection (accessory KFE BA, ): Remove the cover panel on the handle and unscrew the threaded piece (fig. 6-2, item E) from the storage tank. Optional: Detaching the connecting piece from the safety overflow Insert the KFE filling connection in the threaded piece (fig. 6-3, item E) and secure with the clamping piece (fig. 6-3, item D). Place a suitable collecting tray under the filling and draining connection. E F G X Fig. 6-2 Threaded piece Sealing plug Connection bracket Valve insert E Unscrewing the threaded piece FA ROTEX HPSU monobloc compact 09/

40 6 x Taking out of operation Unscrew the threaded piece on the filling and draining connection (fig. 6-4, item E), remove the sealing plug (fig. 6-4, item F) and immediately screw in the pre-installed threaded insert with KFE filling connection again into the filling and draining connection (fig. 6-4). Insert the KFE filling connection in the connection bracket and secure with holding clamp (fig. 6-6). Fig. 6-3 CAUTION! After removing the sealing plug, storage tank water surges out. Completing the KFE filling connection Open the KFE cock on the KFE filling connection and drain the water content of the storage tank. Only with solar system Adjust the valve insert on the connection bracket so that the path to the blind plug is blocked off (fig. 6-5). Place a suitable collecting tray and remove the blind plug from the connection bracket (fig. 6-5). 1. E Fig F Screwing the KFE filling connection into the filling and draining connection Fig. 6-6 Installing the KFE filling connection in the connection bracket Open the KFE cock on the KFE filling connection. Adjust the valve insert on the connection bracket so that the path to the drain hose is open (see also fig. 6-5) and drain the water content of the storage tank Draining the heating circuit and hot water circuit Connect the drain hose to the KFE cock of the ROTEX HPSU monobloc compact. Open the combined filling and draining valve on the ROTEX HPSU monobloc compact. Drain the heating and hot water circuits. Disconnect the heating flow and return flow as well as the cold water inflow and the hot water outflow from the ROTEX HPSU monobloc compact. Connect the discharge hose on the heating flow and return flow as well as the cold water inflow and hot water outflow so that the hose opening is at ground level. Allow the individual heat exchangers to run empty one after the other based on the suction lifter method. Fig. 6-5 Shut off the valve insert, remove the blind plug from the connection bracket 40 FA ROTEX HPSU monobloc compact 09/2017