ROTEX Sanicube / HybridCube High-efficiency hot water storage tank

Transcription

1 For certified companies ROTEX Sanicube / HybridCube High-efficiency hot water storage tank Installation and maintenance instructions Type ROTEXSCS 328/14/0 ROTEXSC 538/16/0 ROTEXSC 538/16/16 ROTEXSCS 538/0/0 ROTEXSCS 538/16/0 ROTEXSCS 538/16/16 ROTEXHYC 343/19/0 ROTEXHYC 544/19/0 ROTEXHYC 544/32/0 Continuous heat output up to: 27 kw 35 kw 50 kw 35 kw 35 kw 45 kw 8 kw 8 kw 16 kw GB Edition 10/2009 Serial number Customer

2 Guarantee and conformity Warranty conditions 1. Warranty ROTEX provides, for the hot water storage tank the electric immersion heater element a warranty on material and fabrication faults, in addition to the existing legal guarantee period. 2.. Duration of the warranty The warranty period for the 3 years for the hot water storage tank 2 years for the electric immersion heater element 3. Start of warranty a) The warranty period starts on the day of installation and issue of the installation and instruction certificate concerning the items covered by the warranty. b) The warranty period starts no later than 6 months after the date of manufacture of the items covered by the warranty. 4. Conditions for claims under warranty Claims under the warranty will only be accepted if: the unit has been used as intended and was installed properly in a verifiable manner by a qualified expert company, the "Installation and Instruction Certificate" has been completed in full, the date and legally binding signature has been added and it has been sent back to ROTEX without delay after the installation, the unit has been serviced at regular intervals by an expert company in accordance with the relevant documentation and has been cared for in accordance with the specifications. 5. Scope of warranty a) For the first two years of the warranty period, ROTEX undertakes to repair the unit free of charge, or commission a company or individual to repair the unit, where a material or manufacturing fault has resulted in a malfunction. Should repair not be possible or be uneconomical, ROTEX is prepared to provide a new unit and to pay the removal and installation costs involved. No claim for reimbursement of additional consequential costs or damage may be derived from this. b) For the period after expiry of the first 2 years as per a), up to the expiry of the warranty period in accordance with subparagraph 2, ROTEX undertakes to provide replacement parts for the repair free of charge. The costs for fitting and removal and other consequential costs or damage will not be covered by ROTEX. 6. Exclusions from the warranty a) Improper use, tampering with the unit and unqualified modifications immediately invalidate the warranty. The same applies if the unit has not been verifiably properly maintained or taken care of. b) Dispatch and transport damage are excluded from the warranty. c) Unless agreed otherwise, the warranty does not cover reimbursement of consequential costs, in particular fitting and removal costs or damage. d) Wearing parts (as defined by ROTEX) such as indicators, switches, fuses are not covered by the warranty. 7. Final provisions If certain specific provisions of this warranty declaration are, or become, void, then the validity of the remaining provisions remains unaffected by this. Status of warranty conditions March FA ROTEX SC+HYC - 10/2009

3 Declaration of conformity Guarantee and conformity For the high-efficiency hot water storage tank ROTEX Sanicube / HybridCube We, ROTEX Heating Systems GmbH, declare under our sole responsibility that the products Product Order No. Product Order No. ROTEXSCS 328/14/ ROTEXSC 538/16/ ROTEXSCS 538/0/ ROTEXSC 538/16/ ROTEXSCS 538/16/ ROTEXHYC 343/19/ ROTEXSCS 538/16/ ROTEXHYC 544/19/ ROTEXHYC 544/32/ are ready-for-use products in terms of the EC Construction Products Directive and comply with the requirements of the following guideline. 89/106/EEC Construction Products Directive, Annex lll-2-ii-3 with reference to EN Storage tank water heaters (reference for the type, only applicable in part) Design modifications which have an influence on the technical data for the hot water storage tank quoted in the product description and on the intended use, in other words representing substantial changes, render this declaration of conformity invalid. Güglingen, Dr Eng. Franz Grammling Managing Director FA ROTEX SC+HYC - 10/2009 3

4 Contents 1 Safety Refer to the manual Warning signs and explanation of symbols Avoid danger intended use Instructions for operating safety Product description Design and components Sanicube (SC) / Sanicube Solaris (SCS) HybridCube (HYC) Brief description Advantages Accessories Electric immersion heater elements Non return flow valves Dirt filter Scalding protection Thermometer Set Solaris storage tank extension set Set-up and installation Hydraulic system connection Sanicube (SC) / Sanicube Solaris (SCS) HybridCube (HYC) Set-up Installation Overview of connections Instructions for water connection Hydraulic connection Connection of several Sanicube storage tanks Filling the hot water heat exchanger Filling the storage tank (without Solaris System installed) Filling the storage tank (with Solaris System installed) Filling the heating system and the storage tank charging circuit Connecting the electric immersion heater element (accessories) Commissioning Initial commissioning Operation and maintenance Operation Storage tank Immersion heater EHS/500/1, EHS/500/5, EHS/500/6 (Accessories) Booster heater EHS/500/ Inspection and maintenance Technical data Basic data Sanicube (SC) / Sanicube Solaris (SCS) HybridCube (HYC) Performance diagrams List of keywords FA ROTEX SC+HYC - 10/2009

5 1 x Safety 1.1 Refer Safety to the manual These instructions are intended for authorised and trained heating and sanitation experts who have experience in the proper installation and maintenance of heating systems and hot water storage tanks by virtue of their technical training and know-how. This manual provides all the necessary information for installation, commissioning and maintenance, as well as basic information on operation and settings. Please see the attached documents for a detailed description of operation and control. Please read this manual carefully and thoroughly before proceeding with the installation or modification of the heating system. Relevant documents When connecting to an external heat generator; the appropriate installation and operating instructions. When connecting a ROTEX Solaris system; the appropriate installation and operating instructions. 1.2 Warning signs and explanation of symbols Meaning of the warnings The warnings are classified in this manual according to 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 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: Electrical current Danger of burning or scalding Order number Notes related to Order numbers are identified by the cart symbol. Handling instructions Instructions on actions are shown as a list. Actions during which the sequential order must be maintained are numbered. Results of actions are identified with an arrow. FA ROTEX SC+HYC - 10/2009 5

6 1 x Safety 1.3 Avoid danger The ROTEX SC+HYC is state-of-the-art and is built to meet all recognised technical requirements. However, improper use may result in serious physical injuries or death, as well as property damage. To prevent such risks, install and operate ROTEX SC+HYC only: as stipulated and in perfect condition, with an awareness of safety and the hazards involved. This assumes knowledge and implementation of the contents of this manual, the relevant accident prevention regulations as well as the recognised safety-related and occupational medical rules. 1.4 intended use The ROTEX Sanicube / HybridCube may only be used as a hot water storage tank. The ROTEX SC+HYC must be installed, connected and operated only according to the information in this manual. For connection to an HPSU heat pump, only the specially provided storage tank connecting sets (E-PAC) may be used. Only electric immersion heater elements supplied by ROTEX may be used. Any use above and beyond this is deemed to be improper use. Responsibility for any resulting damage will be borne by the user/owner alone. Intended use also includes the observance of maintenance and inspection conditions. Replacement parts must at least satisfy the technical requirements defined by the manufacturer. This is the case, for example, with the use of original replacement parts. 1.5 Instructions for operating safety Before working on the hot water storage tank and the heating system Work on the hot water storage tank and heating system (e.g. installation, connection and initial commissioning) should only be carried out by authorised and trained heating experts. Switch off the mains supply before starting any work on the hot water storage tank and heating system and secure it against unintentional switch-on. Lead tamper-proof 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. Electrical installation of optional accessories Electrical installation should only be carried out by qualified electrical engineers observing the technical electrical guidelines and regulations of the relevant electric power supply company. Compare the mains voltage indicated on the type plate with the supply voltage before connecting to the mains. Unit installation room Only erect the ROTEX Sanicube / HybridCube if a ground load-bearing capacity of 1050 kg/m² plus safety factor is guaranteed. The ground must be flat and level. Erection outdoors is only possible to a limited extent. The storage tank must not be continuously exposed to direct sunlight. The ROTEX Sanicube / HybridCube must be protected from frost. Corrosion protection In some regions, corrosive drinking water is supplied by public utility companies that can cause damage through corrosion even in high grade stainless steels. Check with your water supply works whether corrosion problems can occur when using hot water storage tanks made of stainless steel in your area. Appropriate water treatment may be required. 6 FA ROTEX SC+HYC - 10/2009

7 Sanitary connection 1 x Safety With sanitary connection, the following must be observed EN Protection of domestic water from contamination in domestic water installations and general requirements concerning safety equipment for the prevention of domestic water contamination by back-flow EN Technical regulations for domestic water installations (TRWI) and, in addition, the country-specific legal stipulations. During operation of the ROTEX Sanicube / HybridCube, the storage tank temperature may exceed 60 C, particularly when solar power is used. Therefore, some form of scalding protection needs to be included when you install the system (hot water mixing device, e. g.vta ). Use a pressure reducer if the cold water connection pressure >6 bar. Operation Operate ROTEX Sanicube / HybridCube only with storage tanks filled up to overflow edges. Operate the ROTEX Sanicube / HybridCube only with a set pressure reducer (max. 6 bar). Instructing the user/owner Before you hand over the heating system and the hot water storage tank, explain to the owner how he/she can operate and check the heating system. Document the hand-over by filling in and signing the checklist in Chapter 4 Commissioning, together with the operator. FA ROTEX SC+HYC - 10/2009 7

8 2 x Product description 2.1 Design Product description and components Sanicube (SC) / Sanicube Solaris (SCS) SCS/SC 538/16/ SCS 328/14/ X X ø mm mm mm mm SCS 538/16/16 SC 538/16/16 SCS 328/14/ Fig. 2-1 Connections and dimensions, Sanicube Hot water storage tank 1 Solaris - flow (1 union nut) (SCS only) 2 Cold water supply (1 male)* 3 Hot water (1" male)* 4 Tank charge feed (SC - "heating 1 ; SCS - "heating 2 ) (1 AG)* 5 Tank charge return flow (SC - "heating 1 ; SCS - "heating 2 ) (1 AG)* 6 Tank charge feed (2nd heat source - "heating 3 ) (1 AG)* 7 Tank charge return flow (2nd heat source - "heating 3 ) (1 AG)* 8 Solar support heating feed (SCS 538/xx/xx only) (1 male)* (Connect to heating return flow to boiler!) 9 Solar support to heating return flow (SCS 538/xx/xx only) (1 male)* (Connect to heating return flow from system!) 10 Storage tank (double-walled jacket made of polypropylene with PUR hard foam thermal insulation) 11 Filling and drain connection (Tr. 32 x3 male) with valve insert (SCS: Solaris return flow) 12 Connection for equalisation pipe (AGL, ) or extension set for another heat source (EWS, ) 13 Corrugated stainless steel pipe heat exchanger for domestic hot water heating 14 Corrugated stainless steel pipe heat exchanger for charging storage tank (SL-WT1) 15 Corrugated stainless steel pipe heat exchanger for charging tank via 2nd heat source (SL-WT2) 16 Corrugated stainless steel pipe heat exchanger solar support to heating system (SCS 538/xx/xx only) 17 Heat exchange sleeve for solar support to heating system heat exchanger (SCS 538/xx/xx only) 18 Connection for electric immersion heater element (R 11/2 female) 19 Solaris - stratifying pipe flow (SCS only) 20 Filling level indicator 21 Electric immersion heater element (optional) 22 Sensor immersion sleeve for storage tank temperature sensor 23 Unpressurised storage tank water 24 Solar zone (SCS 538/xx/xx only) 25 Hot water zone 26 Type plate 27 Safety overflow connection (Tr. 32x3 male) 28 Handle X Recommended wall distance 200 mm * Recommended accessories (non return flow valves (2 pcs.), ) 8 FA ROTEX SC+HYC - 10/2009

9 2 x Product description HybridCube (HYC) Fig.2-2 Connections and dimensions HybridCube hot water storage tank (HYC) 1 Solaris - flow (1 swivel nut) 2 Cold water supply (1 male)* 3 Hot water (1 male)* 4 Tank charge flow (1 male)* 5 Tank charge return flow (1 swivel nut)* 6 Heating support return flow (1 ÜM)* HYC 544 only 7 Heating support return flow (1 AG)* HYC 544 only 10 Storage tank (double-walled jacket made of polypropylene with PUR hard foam thermal insulation) 11 Filling and drain connection (Tr. 32 x3 male) with valve insert (Solaris return flow) 12 Connection for equalising line (AGL, ) 13 Corrugated stainless steel pipe heat exchanger for domestic hot water (TW-WT) 14 Corrugated stainless steel pipe heat exchanger for charging storage tank (SL-WT1) 15 Corrugated stainless steel pipe heat exchanger for solar support (HYC 544 only) 16 Heat insulation shell for heating support - heat exchanger 17 Connection for Booster Heater (EHS) (R 11/2 female) 18 Solaris flow multilayer pipe 19 Filling level indicator 20 Booster Heater (EHS) 21 Dip sensor sleeve for tank temperature sensor 22 Pressure-free storage tank water 23 Solar zone 24 Hot water zone 25 Type plate 26 Safety overflow connection (Tr. 32x3 male) 27 Handle X Recommended wall distance 200 mm * Recommended accessories (non return flow valves (2 pcs), ) 2.2 Brief description The Hot water storage tank is a combination of heat storage tank and instantaneous water heater. The pressureless storage water serves as heat storage medium. Useful heat is supplied and removed via the spiral corrosionresistant heat exchanger, which is made from a corrugated stainless steel pipe (1.4404), and is completely immersed in the storage tank water. In the heat exchanger for heating drinking water, the latter is stored at the temperature level of the standby zone. FA ROTEX SC+HYC - 10/2009 9

10 2 x Product description The cold waterwhich flows in when the hot water is drawn off is first routed to the storage tank at the very bottom of the heatexchanger, where it cools the lower zone of the storage tank down as much as possible. The stand-by zone is heated by an external heat generator (condensing boiler, heating pump, solar system, electric immersion heater element). The flow through the heat exchanger for tank charge (SL-WT) is downwards from above. The drinking water continually absorbs the heat from the storage tank water on its way up. The direction of throughflow by the countercurrent principle and the helical shape of the heat exchanger creates a distinct temperature layering in the storage tank. As high temperatures can continue in the top area of the storage tank, it can achieve a high hot water output even on long tapping cycles. The ROTEX Sanicube Solaris and the ROTEX HybridCube can, in addition to an external heat generator, also be heated by solar power. Depending on how much solar energy is available, the entire storage tank is heated up. The stored heat is used for hot water generation as well as for the heating support. The high total storage capacity also temporarily allows periods when the sun does not shine to be bridged. If an external heat generator is used as a ROTEX heat pump system, only a ROTEX HybridCube is permissible as the primary heat source. 2.3 Advantages Optimum water hygiene Low flow or unheated zones on the domestic water side are completely excluded with the Hot water storage tank. It is impossible for sludge, rust or other sediments to be deposited, as can be the case with other large volume tanks. The water which is fed into the system first is also discharged first (first in, first out principle). Low maintenance and corrosion The Hot water storage tank is made of plastic and is completely corrosion-free. Sacrificial anodes or similar anti-corrosion units are not necessary. This means that associated maintenance work, e.g. changing the protective anodes or cleaning the storage tank, does not need to be carried out on the Hot water storage tank. Only the fill level of the storage tank water needs to be checked. The corrugated stainless steel pipe heat exchangers on the heating and domestic water side are made from high quality stainless steel (1.4404). Low scaling On the storage tank side only one deposition of scale is possible. The immersion heater element therefore remains clean, as do the stainless steel heat exchanger pipes in the storage tank water. This means that no scale can build up which would continuously reduce the efficiency of heat transfer in the course of operation (as is the case with other storage tank designs). The thermal and pressure expansion and high flow rates in the domestic water heat exchanger release any possible scale deposits, which are then flushed away. Economical operation The full-area heat insulation of the storage tank ensures very low heat losses in use and means that the best use is made of the heat energy being applied. Modular extension facility If the heat output of a single Hot water storage tank is not adequate, you can interconnect several storage tanks. Electronic control A control system integrated in the heat generator controls all heating and hot water functions for the direct heating circuit, a mixed heating circuit which can be connected as an option and a tank charge circuit. SCS: Settings, displays and functions of the solar heating are e.g. carried out by the regulating and pump station RPS3. HYC: For the connection to a ROTEX heat pump system, the setting and adjustment of the solar heating, in addition to the control and pump station RPS3, via the controller integrated in the heat pump. 10 FA ROTEX SC+HYC - 10/2009

11 2 x Product description 2.4 Accessories Electric immersion heater elements In addition to the heating possibilities via the corrugated stainless steel pipe heat exchanger from various different heat sources and energy carriers, the Hot water storage tank can also be charged using an electric immersion heater element. Type EHS/500/1 EHS/500/5 EHS/500/6 EHS/500/7 Operating voltage 230 V / 50 Hz 230/400 V / 50 Hz 230/400 V / 50 Hz 230 V / 50 Hz Heating output 2 kw 2, 4, 6 kw 2, 4, 6 kw 3 kw Temperature range 1) C C C C Cable length 1.5 m Heating element length 1.4 m 1.4 m 1.1 m 0.9 m Screw-in thread R 1½" R 1½" R 1½" R 1½" Suitable for all SC + SCS 2) all SC + SCS 2) for SCS only all HYC ) Tab. 2-1 Electric immersion heater elements - overview and technical data 1) Temperature regulation and a safety temperature limiter (STB) are already integrated in the electric immersion heater element. The electric immersion heater element is delivered ready for installation. 2) The longer heating element in the SCS means that the Solar zone is also heated if electric charging is used. This can reduce the efficiency of the Solaris system. 3) The EHS/500/7 is contained in the respective "E-PAC" of the ROTEX HybridCube as standard Non return flow valves In order to prevent heat losses from the connection pipes when the heating pump is switched off and during periods without domestic water being drawn off (gravity circulation), you should fit non return flow valves (set - 2 pcs, ) in the connections to the Hot water storage tank Dirt filter If the Hot water storage tank 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. This can be prevented by fitting a dirt filter. for devices up to 28 kw: SFR 28 ( ) for devices up to 50 kw: SFR 50 ( ) Scalding protection There is a danger of scalding at hot water temperatures over 60 C. Fitting scalding protection enables the hot water temperature to be varied continuously and limited from C. Scalding protection VTA 32 ( ) Screw fittings set 1" ( ) Thermometer Set The thermometer THSS ( ) can be fitted for analogue display of the storage tank temperature Solaris storage tank extension set ROTEX can supply the following components for interconnection of several ROTEX Sanicube Solaris to the ROTEX Solaris installation: Solaris storage tank extension set CON SX ( ) Solaris FlowGuard ( ) Solaris FlowSensor FLS20 ( ), FlowSensor FLS100 ( ) Equalisation pipe for connection of 2 storage tanks AGL ( ) FA ROTEX SC+HYC - 10/

12 3 x Set-up and installation 3.1 Hydraulic Set-up and installation system connection Sanicube (SC) / Sanicube Solaris (SCS) H 1... H m 17 M M SC 538/16/0 Fig. 3-1 Standard connection schematic drawing Hot water storage tank 1) H 1... H m M M SCS 538/16/0 Fig. 3-2 Standard connection schematic drawing Hot water storage tank Solaris 1) Explanation of legend, see Page FA ROTEX SC+HYC - 10/2009

13 3 x Set-up and installation M H 1... M H m SC 1 SC 2 SC n Fig. 3-3 Standard connection schematic diagram for connecting several Hot water storage tank (SC) (large scale installations) 1) H 1... H m M M SCS 1 SCS 2 SCS (n-1) SCS n Fig. 3-4 Standard connection schematic diagram for connecting several Hot water storage tank Solaris (SCS) (large scale installations) 1) Explanation of legend, see Page 14 FA ROTEX SC+HYC - 10/

14 3 x Set-up and installation 1 Boiler (e.g. ROTEX A1) 2 Boiler circuit pump 3 3-way diverter valve heating circuit/storage charging circuit 4 Hot water storage tank 4.1 Storage tank 4.2 Tank primary heat exchanger (stainless steel corrugated pipe) 4.3 Domestic water heat exchanger (stainless steel corrugated pipe) 5 Storage tank sensor (recharge) 6 Cold water connection 7 Hot water draw-off point 8 Circulation pump (optional) 9Heating flow 10 Heating return flow 11 Storage charging pump (only with several storage tanks connected together) 12 Storage tank feed 13 Storage tank return flow 14 Non-return valve 15 Safety overpressure valve cold water feed 16 Scalding protection (at storage tank temperatures >60 C) 17 Cold water distribution network 18 Convection brake (accessory) 19 Air vent (accessory) 20 Control and pump unit for Solaris system 21 Solaris feed 22 Solaris return flow 23 Solaris high-efficiency flat solar panel 24 Safety overflow connection (accessories: Thermometer) SC 1, SC 2, SC n ROTEXSanicube SCS 1, SCS 2, SCS n-1,scs n ROTEX Sanicube Solaris H 1, H mheating circuits 1) No claims are made for the completeness of the installation diagram shown, and it is no substitute for careful installationplanning. Tab. 3-1 Legend from Fig 3-1 to Fig HybridCube (HYC) AB Tmax=55 C A M B RLB Fig. 3-5 Standard connection diagram Hot water storage tank (represented with HPSU heat exchanger, version with only room heating function) 1) 14 FA ROTEX SC+HYC - 10/2009

15 3 x Set-up and installation 1 Fluid line coolant circuit 2 Gas line coolant circuit 3 Heating feed 4 Heating return flow 5 Storage tank feed 6 Storage tank return flow 7 Heating support feed 8 Heating support return flow 9 Solaris feed 10 Solaris return flow 3UV1 3-way diverter valve heating circuit/storage charging circuit 3UV1 3-way diverter valve heating circuit/coolant circuit BV Safety overpressure valve heating C Circulation pump CW Cold water feed DHW Hot water tap point E Expansion valve EHS Booster heater (electric immersion heater element) HP-TR Main controller heat pump HYC HybridCube hot water storage tank P S1 Circulation pump Solaris P S2 Booster pump Solaris RPS3 Control and pump unit for Solaris system RKHB Internal unit of the HPSU heat pump RRHQ External unit of the HPSU Heat pump RT Room thermostat SK Solaris high-efficiency flat solar panel SV Safety overpressure valve cold water feed V Fan VS Scalding protection (at storage tank temperatures >60 C) 1) No claims are made for the completeness of the installation diagram shown, and it is no substitute for careful installationplanning. Tab. 3-2 Legend for Fig 3-5 and Fig 3-6 AB Tmax=55 C A M B RLB Fig. 3-6 Standard connection diagram Hot water storage tank (represented with HPSU heat exchanger, version with room heating and cooling function) 1) FA ROTEX SC+HYC - 10/

16 3 x Set-up and installation 3.2 Set-up CAUTION! Only erect the ROTEX Sanicube / HybridCube if a ground load-bearing capacity of 1050 kg/m² plus safety factor is guaranteed. The ground must be flat and level. Erection outdoors is only possible to a limited extent. 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 Sanicube / HybridCube must be protected from frost. Make sure that the supply company does not provide corrosive domestic water. Appropriate water treatment may be required. HYBRIDCUBE Permitted lengths of the pipes between the HybridCube hot water storage tank and the hydraulic connections on the HPSU heat pump (see Installation and operating instructions for the HPSU heat pump as well as for the respective storage tank connect set "E-PAC"). Incorrect set-up and installation would render the manufacturer's guarantee void. If you have questions, please contact our Technical Customer Service. Prerequisite The installation site meets the applicable national requirements. Remove the packaging Dispose of the packing in an environmentally-responsible manner. Transport the Hot water storage tank carefully, using the handles provided. Install the Hot water storage tank at the installation site. Recommended wall distance of 200 mm must be observed. When using an electric immersion heater element (booster heater) (see Chapter Electric immersion heater elements ), it must be screwed into the cover opening in the Hot water storage tank (see Fig 3-7 and Fig 3-8, Item 18). If headroom is restricted, tilt the Hot water storage tank until the electric immersion heater element can be fitted without damage. 21 Do not switch on the power supply for the electrical immersion heater element until the ROTEX Sanicube / HybridCube is filled. Fig. 3-7 Installation position electric immersion heater element (shown on the Sanicube Solaris) 16 FA ROTEX SC+HYC - 10/2009

17 3 x Set-up and installation 3.3 Installation Overview of connections Sanicube (SC) / Sanicube Solaris (SCS) Fig. 3-8 External connections (shown on Sanicube SCS) 1 Solaris - flow (1 union nut) (SCS only) 2 Cold water supply (1 male)* 3 Hot water (1 male)* 4 Tank charge feed (SC - "heating 1 ; SCS - "heating 2 ) (1 AG)* 5 Tank charge return flow (SC - "heating 1 ; SCS - "heating 2 ) (1 AG)* 6 Tank charge feed (2nd heat source - "heating 3 ) (1 AG)* 7 Tank charge return flow (2nd heat source - "heating 3 ) (1 AG)* 8 Solar support to heating system flow (SCS 538/xx/xx only) (1 male)* (Connect to heating return to boiler!) 9 Solar support to heating system return (SCS 538/xx/xx only) (1 male)* (Connect to heating return from system!) 10 Storage tank (double-walled jacket made of polypropylene with PUR hard foam thermal insulation) 11 Filling and drain connection (Tr. 32 x3 male) with valve insert (SCS: Solaris return flow) 12 Connection for equalising pipe (AGL, ) or extension set for another heat source (EWS, ) 18 Connection for electric immersion heater element (R 11/2 female) 20 Filling level indicator 22 Sensor immersion sleeve for storage tank temperature sensor 26 Type plate 27 Safety overflow connection (Tr. 32x3 male) 28 Handle * Recommended accessories (non return valves (2 pcs), ) HybridCube (HYC) 1 Solaris - flow (1 swivel nut) 2 Cold water supply (1 male)* 3 Hot water (1 male)* 4 Tank charge flow (1 male)* 5 Tank charge return flow (1 swivel nut)* 6 Heating support return flow (1 ÜM)* only HYC Heating support return flow (1 AG)* only HYC Storage tank (double-walled jacket made of polypropylene with PUR hard foam thermal insulation) 11 Filling and drain connection (Tr. 32 x3 male) with valve insert (Solaris return flow) 12 Connection for equalising line (AGL, ) 18 Solaris flow multilayer pipe 19 Filling level indicator 20 Booster Heater (EHS) 21 Dip sensor sleeve for tank temperature sensor 25 Type plate 26 Safety overflow connection (Tr. 32x3 male) 27 Handle * Recommended accessories (non return valves (2 pcs), ) Fig. 3-9 External connections (shown on HYC 544*) FA ROTEX SC+HYC - 10/

18 3 x Set-up and installation Instructions for water connection WARNING! There is a danger of scalding at water temperatures >60 C. This can arise with solar energy utilisation if the Legionella protection is activated or if the target temperature is set to >60 C. Fit scalding protection (see Chapter Scalding protection ). CAUTION! If the Hot water storage tank is connected to a heating system with steel pipes, radiators or non-diffusionproof 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). Fit dirt filter in the heating return pipe (see Chapter Dirt filter ). For domestic water pipes, observe the stipulations of EN 806 and EN The position and dimensions of the connections can be found in Fig 3-8 / Fig 3-9. Carefully lag the hot water pipes to prevent heat loss. The thermal insulation needs to be at least 20 mm thick to prevent condensation from forming on the surface of the insulation material. Check the cold water connection pressure (maximum 6 bar). If a higher pressure is present in the domestic water pipe, a pressure reducer will need to be installed. Connect the pressure relief line to the safety pressure relief valve and the membrane expansion tank as per EN Install the hot water storage tank near to the removal point to dispense with the need for a circulation pipe. If a circulation pipe is essential, then it must be installed in accordance with the schematic drawing in Fig 3-1, Fig 3-2, Fig 3-3 or Fig 3-4. Avoid deposits: Observe the regulations in VDI 2035 in order to avoid corrosive products and deposits. If the filling and additional water has a high degree of hardness, measures must be taken to stabilise this hardness or soften the water. To prevent heat loss from the connection pipes when the heating pump is switched off and during periods when no domestic water is drawn off (gravity circulation), you should fit non return valves (see chapter 2.4.2) in the connections to the ROTEX Hot water storage tank Hydraulic connection 1. Only with connection of a HybridCube hot water tank to an HPSU heat pump: Attach the storage tank connecting set E-PAC" to the HybridCube hot water tank (see the respectively supplied installation and operating instructions of the storage tank connecting set). 2. When using non return valves (see Chapter Non return flow valves ), these should be fitted in the pipe connections on the ROTEX Sanicube / HybridCube. 3. Drainage hose with the connection of the safety overflow (Fig 3-8 / Fig 3-9) to the hot water storage tank. 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. 4. Check the water pressure at the cold water connection (<6 bar). If the pressure in the domestic water supply is greater, then fit a pressure reducer and limit the water pressure to <6 bar. 5. Establish connection to the cold water feed of the hot water storage tank (Fig 3-8 / Fig 3-9, connection 2). 6. Establish connections to the hot water distribution network (Fig 3-8 / Fig 3-9, Connection 3). 18 FA ROTEX SC+HYC - 10/2009

19 3 x Set-up and installation 7. Establish connections to the heating circuit. Sanicube: When the hot water tank is connected on the heating side, it is essential to ensure that the air is properly bled from the tank charge lines (e.g. use of automatic air vents on connections 4 to 9, Fig 3-8). HybridCube: The connection of the hot water tank on the heating side must be established according to the specifications of the installation and operating instructions for the respective storage tank connecting set (E-PAC). It must be ensured that the storage tank charge lines are properly bled of air. 8. Establish connections to the heat generator. Sanicube: Connections should be established according to the corresponding design scheme (Fig 3-1 to Fig 3-4) to the heat generator. HybridCube: In conjunction with an HPSU heat pump, the connection of the hot water storage tank must be set up according to the specifications of the installation and operating instructions of the respective storage tank connecting set (E-PAC). In the case of bivalent firing the connections should be set up in accordance with the connecting diagrams in the installation and operating instructions of the respective controllers. Optional: Establish connections to the Solaris System (see Solaris installation and maintenance instructions) Connection of several Sanicube storage tanks If the heat output of a single ROTEX Sanicube is not adequate to connect several ROTEX Hot water storage tank in a modular fashion. This means that both the stainless steel heat exchangers for post-heating and the hot water heat exchangers are interconnected in accordance with the Tichelmann principle (Fig 3-3 SCS: Fig 3-4). With seasonal variations in demand these individual units can be added or taken out of service accordingly. In this way the total hot water output can be manually matched to the actual demand. In Chapter 6.2 Performance diagrams you can see what efficiency characteristics can be achieved by interconnecting several ROTEX Sanicube / HybridCube units. Only for Sanicube Solaris: 1 Sanicube Solaris 2 Control and pump unit RPS3 3 Solaris - flow manifold 4 T-connecting piece AGL CON SX A CON SX B FLG FLS Equalisation pipe Storage tank extension set (bottom) Storage tank extension set (top) FlowGuard FlowSensor For the interconnection of several Sanicube Solaris units you can purchase thesolaris StorageTank Extension Set CON SX, the equalisation pipe AGL, and the Solaris FlowGuards and the Solaris FlowSensor. For purchasing information see Chapter Solaris storage tank extension set. The fitting and operation of these accessoriesis described in detail in the Solaris operating and installation instructions. Fig Schematic drawing of the Solaris storage tank extension equipment FA ROTEX SC+HYC - 10/

20 3 x Set-up and installation Filling the hot water heat exchanger 1. Open shutoff device of cold water line. 2. Open bleeding point for hot water so that as little bleeding as possible can be set. 3. Once water has been discharged from the tap connections, do not interrupt the cold water feed; this will ensure that the heat exchanger will be fully vented and that any impurities or residue will be discharged Filling the storage tank (without Solaris System installed) 1. Connect the filler hose with back flow preventer (½") via the hose connector provided to the filling and drain connection (Fig Fig 3-9, Item 11). 2. Fill the storage tank of the ROTEX Sanicube / HybridCube until water comes out of the connection of the safety overflow (Fig 3-8 / Fig 3-9) Filling the storage tank (with Solaris System installed) 1. Connect the filling hose with return flow inhibitor (½") to the boiler filling and draining valve on the Solaris control and pump unit (RPS3). 2. Fill storage tank of the ROTEX Sanicube / HybridCube until water flows out of the connection of the safety overflow (Fig 3-8 / Fig 3-9) Filling the heating system and the storage tank charging circuit Fill and bleed the heating system and tank charge circuit in accordance with the installation and operating instructions for the particular heat generator Connecting the electric immersion heater element (accessories) 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 them from the power supply (switch off fuse, main switch) and secure against unintentional restart. Electrical connection and work on electrical components must only be carried out by qualified electricians in compliance with valid standards and guidelines as well as the specifications of the energy supply company. Equipment covers and service flaps must be replaced as soon as the work is completed. EHS/500/1 The EHS/500/1 is delivered ready to plug in. 1. Check the power supply voltage of the mains connection (~230 V, 50 Hz). 2. Insert the mains plug of the electric immersion heater element into the plug socket. EHS/500/5 and EHS/500/6 1. Check the power supply voltage of the mains connection (~230/400 V, 50 Hz). 2. Disconnect the junction box of the domestic electrical installation. 3. Install the electric cabling between the mains connection and the electric immersion heater element. 20 FA ROTEX SC+HYC - 10/2009

21 3 x Set-up and installation 4. Unscrew the cap screws on the electric immersion heater element and remove the cap together with the regulating knob (Fig 3-11) Remove and dispose of the folding sheet for installation (Fig 3-12). 6. Connect the cables to the terminal block K1 (Fig 3-12) in accordance with the connection assignment (Fig 3-13) on the electric immersion heater element. As-delivered condition is "Connection variant l". For Connection variants II + III, the wiring on terminal block K2 and the bridge positions must be adapted to suit. 4x 2. Fig Removing the cap on the electric immersion heater element 7. Check the setting of the safety temperature limiter (STL) (Fig 3-12); if necessary, push the pin in to release the interlock. 8. Place the cap with regulating knob on the immersion heater element. Make sure the regulating knob is located correctly. 9. Screw in the screws for the electric immersion heater element cap. 3. K1 K2 TR STB 10. Connect the cables to the mains connection of the domestic installation. Ensure that the polarity is correct. 11. Restore power supply to the junction box of the domestic electrical installation. K1 K2 STL TR Terminal block (external connections) Terminal block (internal connections) Safety temperature limiter Temperature regulator Fig Electric immersion heater element regulator unit 3 ~400V / 50Hz 6000 W I 3 ~230V / 50Hz 6000 W II 1 ~230V / 50Hz 6000 W III D+E+F, 4+5 A+B, C+D, E+F D+E+F, 1+2+3, 4+5 K2 K2 K2 TR/STB TR/STB TR/STB K1 K1 K1 L1 L2 L3 N L1 L2 L3 L1 N L1 L1 N L2 L3 L2 L3 Fig Connection assignment for EHS/500/5 and EHS/500/6 FA ROTEX SC+HYC - 10/

22 3 x Set-up and installation EHS/500/7 The connection of the electric immersion heater element (booster heater) is only possible in conjunction with an HPSU heat pump. The installation is to be performed in accordance with the associated installation and operating instructions of the HPSU heat pump and of the respective storage tank connection set (E-PAC). 22 FA ROTEX SC+HYC - 10/2009

23 4 x Commissioning 4 Commissioning WARNING! If not commissioned properly, a Hot water storage tank can be a health and safety risk endangering human life and its operation may be adversely affected. The Hot water storage tank may only be commissioned by authorised and trained heating experts. CAUTION! An incorrectly commissioned Hot water storage tank can cause material damage. Observe the regulations in VDI 2035 in order to avoid corrosion and deposits. If the filling and top-up water has a high degree of hardness, measures must be taken to stabilise this hardness or soften the water. Set the pressure reducer on the cold water connection to a maximum of 6 bar. Incorrect commissioning renders the manufacturer's guarantee for the device void. If you have questions, please contact our Technical Customer Service. 4.1 Initial commissioning Requirements The Hot water storage tank is set up and properly connected. The heating and hot water system have been filled and pressurised to the correct pressure. The Hot water storage tank is filled to the overflow point. Checks before commissioning Check all connections for leakage. Commissioning Check all the points on the enclosed checklist. Make a record of the test results and sign it, together with the operator. If an electric immersion heater element is fitted, set the desired storage tank water temperature. Switch on the mains supply switch on the heat generator. Wait for the start phase. Only if all points on the checklist can be answered with Yes may the Hot water storage tank be started up. Check list for commissioning 1. Is Hot water storage tank the properly installed in accordance with a permitted set-up and without any discernible damage? Yes 2. With installed electric immersion heater element. Does the mains connection comply with the regulations and is the mains voltage 230 volts or 400 volts, 50 Hz? Yes 3. Is the storage tank filled with water to the overflow point? Yes 4. When overhauled: Was the heat distribution circuit flushed? Is a dirt filter installed in the heating return flow? Yes 5. Is the safety overflow connection connected to an open drain? Yes 6. Is the water pressure in the system < 6 bar? Yes 7. Are the heat generator and heating system vented? Yes 8. Are all hydraulic connections tight (leaks)? Yes 9. Does the installation operate without faults? Yes 10. With new installation: Has the operating manual been handed over and the owner instructed? Yes Location and date: Signature of installer: Signature of owner: FA ROTEX SC+HYC - 10/

24 5 x Operation and maintenance 5.1 Operation and maintenance Storage tank No separate controller is required to operate the Hot water storage tank. The regulation is effected in each case by the control system of the connected heat generator and, in the case of Solaris installations, by the Regulation and Pump Station. Check the level in the storage tank (see Chapter 2 Product description, Fig. 2-1) at regular intervals and top up with water if required Immersion heater EHS/500/1, EHS/500/5, EHS/500/6 (Accessories) CAUTION! If the electric immersion heater is used when the storage tank is not completely full, this can lead to a reduction in heating efficiency and can cause an electrical fault under certain circumstances. Only use the electric immersion heater when the storage tank is completely full. X B X A D Set the target temperature using the regulating knob on the electric immersion heater. The ranges between positions B, C and D are continuously adjustable. C Switch position Regulating knob X A B C D EHS/500/1 EHS/500/5 EHS/500/6 switched off (no frost protection) frost protection only (~4-18 C) Target temperature ~50 C Target temperature ~65 C Target temperature ~55 C Target temperature ~78 C Fig. 5-1 Operating unit for electric immersion heater Booster heater EHS/500/7 CAUTION! If the booster heater is used when the storage tank is not completely full, this can lead to a reduction in heating efficiency and can cause an electrical fault under certain circumstances. Only use the booster heater when the storage tank is completely full. The booster heater can only be adjusted via the configuration menu of the HPSU heat pump (see respective installation and operating instructions). 24 Company ROTEX hot water storage tank - 10/2009