For certified companies
ROTEX E-SolarUnit
Electric heat generator with
stratified solar storage tank
Installation and maintenance
instructions
Type
Rated thermal output
ROTEX ESU 509
3–9 kW
Serial number
Customer
GB
Edition 07/2008
Guarantee and conformity
ROTEX provides a warranty for material and manufacturing defects according to this statement. Within the warranty period,
ROTEX undertakes to have the unit repaired free of charge by a person assigned by the company.
ROTEX reserves the right to replace the unit.
The warranty is only valid if the unit is used properly and if it can be proved that it was installed correctly by a specialist company.
As proof, we strongly recommend completing the enclosed installation and instruction forms and returning them to ROTEX.
Warranty period
The warranty period begins on the day of installation (billing date of the installation company), however at the latest 6 months
after the date of manufacture (billing date). The warranty period is not extended if the unit is returned for repairs or if the unit is
replaced.
 Warranty period for the heat generator, boiler main body and boiler electronics: 2 years
Exclusion of warranty
Improper use, tampering with the unit and unqualified modifications immediately invalidate the warranty.
Dispatch and transport damage are excluded from the warranty.
The warranty explicitly excludes consequential costs, especially costs of installing and removing costs the unit.
There is no warranty for consumables (according to the manufacturer's definition), such as lights, switches, fuses.
Declaration of conformity
for the ROTEX E-SolarUnit heating system
We, ROTEX Heating Systems GmbH, declare under our sole responsibility that the product(s)
Product
Order No.
ROTEX ESU 509
15 70 50 - 44
do, in their standard version, comply with following European standards:
2004/108/EC
Electromagnetic Compatibility
2006/95/EC
EC Low Voltage Directive
Güglingen, 01.05.2007
2
Dr Eng. Franz Grammling
Managing Director
FA ROTEX ESU - 07/2008
Contents
1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1
1.2
1.3
1.4
1.5
2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
11
11
11
11
12
13
14
15
16
16
16
17
17
17
17
19
Initial start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Checklists for start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Boiler control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1
5.2
5.3
5.4
5.5
5.6
5.7
6
Transport and delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the ROTEX E-SolarUnit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1
Selecting the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2
Installing the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water connection for heating and hot water pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the valve drive to the 3-way diverter valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Establishing an electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7.1
General instructions for the temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7.2
Connecting the temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8.1
Mixer circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8.2
Room thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the heating output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1
4.2
5
Design and components of the ROTEX E-SolarUnit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Brief description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Set-up and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1
3.2
4
5
5
6
6
6
Product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1
2.2
3
Observing Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning signs and explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Avoid danger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Proper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instructions for operating safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating elements on the boiler control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the boiler control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.1
Changing flow/return flow temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.2
Changing the storage tank temperature sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing and removing the central unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
24
26
27
27
29
29
30
31
ROTEX control system ALPHA+ 23R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.1
6.2
6.3
6.4
6.5
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.1
"Selection of operating mode" rotary switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.2
"Default settings" rotary switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.3
Operator keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.4
Special functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COM socket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Default settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.1
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.2
Normal operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.3
Changing the correction value for the flow temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.4
Setting the target hot water temperature for off-peak tariff charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.5
Setting the time and weekday . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.6
Switching timeprogramme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FA ROTEX ESU - 07/2008
32
32
32
33
33
33
34
34
34
34
35
35
35
36
36
3
Contents
6.6
7
Electric heat generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.1
7.2
7.3
7.4
8
General overview of service and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Service and maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9.2.1
Checking the connections and pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.2.2
Checking and cleaning the safety overflow and drain hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
x Faults and malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10.1
10.2
10.3
10.4
11
Important information on the hydraulic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Storage tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Hydraulic system connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.3.1
Short designations used in connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.3.2
ROTEX E-SolarUnit with solar heating support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.3.3
ROTEX E-SolarUnit with integrated wood boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Service and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9.1
9.2
10
Design and brief description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Load compensation of switching contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Fault shutdown of tubular radiators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Fault shutdown of the power circuit board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Hydraulic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.1
8.2
8.3
9
6.5.7
Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.5.8
Querying system information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
System parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.6.1
Setting parameters – Basic procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.6.2
Overview of system parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.6.3
Resetting parameters to factory settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.6.4
Heating technician access code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.6.5
Setting heating characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.6.6
Automatic summer switch-off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.6.7
Setting hot water mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.6.8
Setting the maximum flow temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.6.9
Manual hot water recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.6.10 Legionella protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Detecting faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10.2.1 Individual reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10.2.2 General reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fault codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Taking out of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
11.1
11.2
Temporary shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Final shutdown and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
12
Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
13
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
13.1
13.2
13.3
External temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Mixer circuit docking sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Room temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
14
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
15
List of keywords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
16
Service log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4
FA ROTEX ESU - 07/2008
1 Safety
1.1
1
Safety
Observing Instructions
These instructions are intended for authorised and trained heating experts who have experience in the proper installation and
maintenance of heating systems and electrical installations on account of their technical training and knowledge.
This manual provides all the necessary information for installation, start-up and maintenance, as well as basic information on
operation and settings. Please go through the attached documents for a detailed description of operation and control.
All heating parameters needed for smooth operation are already factory-set. For setting the control, please refer to Chapter 6.
Please read this manual carefully and thoroughly before proceeding with the installation or modification of the heating system.
Relevant documents
– Documentation ROTEX Solaris, if the ROTEX Solar-System is connected.
1.2
Warning signs and explanation of symbols
Meanings of safety information
The safety information contained in these instructions is classified according to severity and probability of occurrence.
DANGER!
Draws attention to imminent danger.
If you disregard this danger notice, it will result in serious injury or even death.
WARNING!
Indicates a potentially dangerous situation.
If you disregard this warning, it could result in serious injury or even death.
CAUTION:
Indicates a situation which may cause possible damage.
If you disregard this warning, it could result in material or environmental damage.
This symbol indicates useful information and instructions.
FA ROTEX ESU - 07/2008
5
1 Safety
Special safety symbols
Some special symbols represent particular types of danger:
Danger of explosion
Electrical current
Danger of burning or scalding
Order number
The cart symbol
indicates information on order numbers.
Handling instructions
• Handling instructions are given in the form of bullet points. Handling sequences where a particular order must be followed
are given in the form of a numbered list.
Î Results of actions are identified with an arrow.
1.3
Avoid danger
The ROTEX E-SolarUnit is state-of-the-art and is built to meet all recognised technical requirements. However, improper use can
lead to serious injuries or death, as well as cause material damage.
To avoid such risks, only install and operate the ROTEX E-SolarUnit:
– as stipulated and in perfect condition,
– with an awareness of the safety and hazards involved.
This assumes knowledge and use of the contents of this manual, the relevant accident prevention regulations and the recognised
safety-related and occupational medical rules.
1.4
Proper use
The ROTEX E-SolarUnit must only be used as a hot water heating system. The ROTEX E-SolarUnit must be set up, connected and
operated in accordance with the stipulations contained in these instructions.
Any other use outside the above-mentioned use is considered as improper. Any resulting damages will be borne by the user/owner
alone.
Proper use also includes observing the relevant maintenance and servicing conditions. Spare parts must at least satisfy the
technical requirements defined by the manufacturer. This is the case, for example, with original spare parts.
1.5
Instructions for operating safety
Before starting up the heating system
• Only authorised and trained heating engineers should work on the heating system (e. g. installation, connection and initial
start-up).
• When carrying out any work on the heating system, switch off the main switch and secure it against being switched on
unintentionally.
• Seals must not be damaged or removed.
Electrical installation
• Electrical installations may only be carried out by qualified electrical technicians under observance of the relevant electrical
guidelines and the regulations of the electric utilities company.
• Compare the mains voltage (400 V, 50 Hz 3-phase current) indicated on the type plate with the supply voltage before
connecting to the mains.
Open or closed heating system
• Install the heating system as an open or closed system in accordance with the safety-related requirements of EN 12828.
• Note that the safety valves must comply with DIN EN ISO 4126-1 and be type tested. They must be installed in the
safety flow.
6
FA ROTEX ESU - 07/2008
1 Safety
Hydraulic system connection
• During operation of the ROTEX E-SolarUnit, 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. VTA32
15 60 16).
Operation
• Do not operate the ROTEX E-SolarUnit if the storage tank is filled to above the overflow edge.
• Do not operate the ROTEX E-SolarUnit if the protective cover is open.
Instructing the user/owner
• Before you hand over the heating system, explain to the owner how he/she can operate and check the heating system.
• Make a record of the handover by filling out and signing the installation and instruction forms jointly with the user/owner.
FA ROTEX ESU - 07/2008
7
2 Product description
2.1
1
2
3
4
5
6
7
8
9
10
11
12
13
2
Productof
description
Design and components
the ROTEX E-SolarUnit
Cold water connection (1" male) *
Hot water connection (1" male) *
Hot water charging heat exchanger flow connection
Hot water charging heat exchanger return
connection
Heating flow connection (1" female)
Heating return connection (1" female)
Solaris flow connection (1" swivel nut)
Solaris return connection (Tr 32x3 male)
with valve set
Connection for compensating line (Tr 32x3 male)
with valve set
Top filling connection (alternative: safety overflow
connection to front – Tr 32x3 male)
Immersion sleeve for storage tank sensor
Immersion sleeve for Solaris return flow
temperature sensor
Safety overflow connection to rear (Tr 32x3 male)
with hose nipple
Fig. 2-1
8
15 Heat exchanger for heating (electric heat generator
with integrated safety temperature limiters
in heat-insulated housing)
18 Heat exchanger for solar heating support (HU-WT)
21 Circulation pump for heating
22 3-way diverter valve
23 Flow temperature sensor
24 Return flow temperature sensor
25 Safety valve – Connection for blow-off pipe (3/4"
female)
26 Option for connecting membrane expansion tank
(3/4" male)
27 Bypass
28 Boiler control panel, see Chapter 5, page 23
29 ROTEX Regelung ALPHA+ 23R, see
Chapter 6, page 32
30
31
32
33
34
35
36
37
38
39
40
41
Heating pressure gauge
Protective cover
Lock screws for protective cover
KFE cock for filling the heating system (1/2" male)
Automatic vent valve
Ball stopcock
Type plate
Terminal box for supply terminals
Electronic fill level probe
Connecting cable for external temperature sensor
Safety temperature limiter heat generator flow
ThermowellSTB
Safety devices
* The connection is ready for installation of a gravity brake, which can
be ordered separately.
Gravity brake 16 50 70
Components of the ROTEX E-SolarUnit
FA ROTEX ESU - 07/2008
2 Product description
A
B
C
D
E
F
G
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Electric heat generator
Stratified hot water storage tank
Unpressurised storage tank water
Hot water zone
Solar zone
Heating support zone
RPS control and pump unit (Solaris accessory)
Hot water connection (1" male)
Heating connection (1" male)
Solaris connection
Domestic water heat exchanger (TW-WT)
Heat exchanger for storage tank charging (SL-WT)
Heat exchanger for solar heating support (HU-WT)
Heat exchanger for heating (electric heat
generator with integrated safety temperature
limiting in heat-insulated housing, see
Chapter 7, page 51)
Heat insulation sleeve for HU-WT
Ready for installation of gravity brakes, not
included in the scope of delivery (165070)
Solaris flow layering pipe
Circulation pump for heating
3-way diverter valve
Safety overflow connection to rear (Tr 32x3 male)
Top filling connection (alternative: safety overflow
connection to front - Tr 32x3 male)
Electronic fill level probe
Safety devices
Gravity brake 16 50 70
Fig. 2-2
Schematic design of the ROTEX E-SolarUnit
FA ROTEX ESU - 07/2008
9
2 Product description
2.2
Brief description
The ROTEX E-SolarUnit is a fully pre-assembled electric heat generator for supplying hot water and heating rooms in buildings
with a heat demand of up to 9 kW. The electric heat generator is placed directly on top of the hot water storage tank, inside
a housing with good heat insulation. There are practically no external surface or cooling losses. All the heat is passed to the
storage tank water, not to the surroundings. The excellent heat insulation properties of the plastic storage tank also ensure that
heat losses are kept to a minimum.
Using solar power
The ROTEX ESU hot water storage tank can use solar power as its heat source, if required. The electric heat exchanger only
maintains the upper zone of the storage tank at a certain temperature. If the sun provides a lot of heat, solar power can be used
to heat the water in the whole of the storage tank. In this case, the stored heat is used to heat hot water and for heating support.
The high overall capacity of the 500 l storage tank means that periods when there is no sunshine can also be bridged.
Operating mode
The potable water is heated indirectly in the ROTEX ESU through the pressureless storage water of the hot water storage tank
in a corrosion resistant stainless steel corrugated pipe-heat exchanger (Figure 2-2, page 9, pos. 4). It stores around 24 litres of
domestic water at the hot water zone temperature level. In case of greater warm water volumes the ROTEX ESU heats this water
using the continuous-flow water heater principle. If there is sufficient solar radiation, the contents of the hot water storage tank
can also be heated using solar power (ROTEX Solaris accessories).
While heating using the electric heater of the ROTEX ESU, specifically only the upper zone of the storage tank is kept on
temperature. If solar power is used, depending on the heat provided by the sun, it may be possible to heat the entire storage tank
in this way, so that stored heat can be used to heat water and for heating support.
The arrangement of the heat exchanger and the flow of water through it results in distinct temperature stratification in the unit,
which leads to improved energy efficiency.
Safety management
The electronic control is responsible for all safety management functions relating to the ROTEX E-SolarUnit. If there is a shortage
of water or if an undefined operating state arises, the control executes a safety shutdown. A corresponding fault signal provides
an engineer with all the necessary information for troubleshooting.
Electronic control
A fully-electronic, digital control is able to automatically control all heating and hot water functions for the direct heating circuit,
a mixed heating circuit which can be connected as an option and a storage tank charging circuit. Using potential-free switching
contact (Chapter 3.6, page 15) provided by the power supply company (PSC) the heat output control can be adjusted to the tariff
offered by the PSC (Chapter 3.10, page 19). The user carries out all settings, displays, and functions using the ROTEX control
system ALPHA+ 23R. The display and keyboard provide user-friendly ways of executing such operations.
10
FA ROTEX ESU - 07/2008
3 Set-up and installation
3
Set-up and installation
DANGER!
Danger of death due to improper installation
Electronic units, which are not set up or installed properly can endanger an individual's life or health and can
also impair the function they are designed to perform.
• The ROTEX E-SolarUnit must be set up and installed by authorised and trained heating experts.
Incorrect set-up and installation would make the manufacturer's guarantee void. If you have questions, please contact our
Technical Customer Service.
3.1
Transport and delivery
WARNING!
Danger of injury from toppling over.
Risk of toppling over: When empty, the ROTEX ESU is top-heavy and topples over easily. This can result in
injury to individuals or damage to the unit.
• Transport the ROTEX ESU carefully, using the handles provided on it.
The ROTEX ESU is delivered on a pallet. All industrial trucks, such as lifting trucks and forklift trucks, are suitable for
transporting it.
Scope of delivery
– ROTEX ESU (pre-assembled and ready to plug in), consisting of a solar storage tank, electric heat generator, integrated
circulation pump, 3-way diverter valve, automatic vent valve, KFE cock, internal temperature sensors (flow, return flow,
storage tank), external temperature sensor, fill level probe, safety group and ball cocks.
– The document folder, containing installation and maintenance instructions, instruction manual, installation and instruction
form.
3.2
Installing the ROTEX E-SolarUnit
3.2.1 Selecting the installation site
The installation site for the ROTEX ESU must meet the minimum requirements below.
Installation area
– The surface must be solid, level, horizontal and have sufficient load capacity. Install a pedestal if necessary.
– Observe the installation dimensions (see Chapter 3.3).
3.2.2 Installing the unit
WARNING!
Danger of injury from toppling over.
Risk of toppling over: When empty, the ROTEX ESU is top-heavy and topples over easily. This can result in
injury to individuals or damage to the unit.
• Transport the ROTEX ESU carefully, using the handles provided on it.
Requirement:
– The installation site complies with applicable country-specific regulations and meets the minimum requirements described in
Chapter 3.2.1.
FA ROTEX ESU - 07/2008
11
3 Set-up and installation
Set-up:
• Remove the packaging and dispose of it in an environmentally sound manner.
• Install the ROTEX ESU at the installation site.
• Lay the connection lines in such a way that the protective cover can be removed (see Figure 3-2).
3.3
Dimensions
Fig. 3-1
12
Mounting dimensions of the ROTEX ESU
FA ROTEX ESU - 07/2008
3 Set-up and installation
Connecting dimensions for the heating and hot water connections
1
2
5
6
Cold water (pipe thread 1" male)
Hot water (pipe thread 1" male)
Heating flow (pipe thread 1" female)
Heating return flow (pipe thread 1" female)
Fig. 3-2
7
25
26
33
Solaris flow (flat-sealing pipe thread 1" swivel nut)
Safety overpressure valve (pipe thread 3/4" female)
Membrane expansion tank (pipe thread 3/4" male)
KFE cock (pipe thread 1/2" male)
Connecting dimensions for the heating and hot water connections (top view)
To avoid temperature losses by warm water circulation, ROTEX recommends the installation of gravity breaks
(
16 50 70) or the siphoning (conducting the pipes straight downwards) of the potable water pipes.
The domestic water connections are ready for gravity brakes to be installed.
3.4
Water connection for heating and hot water pipes
The connectors of the ROTEX ESU are located on the upper rear side of the unit or on the lower front side (optional Solaris-return
flow). The heating circuit and storage tank charging share the same flow and return flow. The heating circuit for the storage tank
charging is integrated at the factory and must not be connected separately. The chalk that probably falls out during water heating
is rinsed from the stainless steel corrugated pipe-heat exchanger by the warm water. See Chapter 8.1, page 53 for important
information on the hydraulic connection.
Instructions for water connection
CAUTION!
If the ROTEX ESU is connected to a cold water input pipe or a heating system, in which steel pipes or radiators
or non diffusion-proof floor heating pipes are installed, slurry and chippings can enter the heat generator and
the heat exchangers and lead to clogging, local overheating, or corrosion damage.
• Rinse out the heat distribution network (in the existing heating system).
• Install a dirt filter in the heating return flow.
FA ROTEX ESU - 07/2008
13
3 Set-up and installation
• Observe the stipulations of EN 806 and DIN 1988 for domestic water pipes.
• 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.
• The positions and dimensions of the heating connections are shown in Figure 3-2, page 13.
• All hot water piping must be properly insulated in order to prevent heat losses.
• Connect the pressure relief line to the safety overpressure valve and the membrane expansion tank acc. to EN 12828.
– Water shortage protection: The ROTEX ESU overheating protection function switches the electric heat generator off
safely if there is a shortage of water, and locks it. No additional water shortage protection is needed in the construction.
– Avoiding 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.
WARNING!
Danger of scalding
Temperatures of over 60 °C present a danger of scalding if solar power is being used, if Legionella protection
is activated or if the target hot water temperature is set to over 60 °C.
• Install scalding protection (hot water mixing device), VTA32 (
3.5
15 60 16).
Connecting the valve drive to the 3-way diverter valve
The ROTEX ESU is equipped with an integrated circulation pump and a 3-way diverter valve (3W-DV) as standard. The circulation
pump and the 3-way diverter valve are connected at the factory; the valve drive is plugged on.
1
2
3
4
Heat generator flow
Heating flow
Storage tank flow
3-way diverter valve
5.1 Valve drive
5.2 Unlocking button of the drive lock
5.3 Hand lever
Fig. 3-3
3-way diverter valve
• Following start-up, insert the connection plug of the 3-way diverter valve's cable into the valve drive.
The circulation pump and the 3-way diverter valve each have one cable with a connection plug. These cables
are ready for use.
14
FA ROTEX ESU - 07/2008
3 Set-up and installation
3.6
Establishing an electrical connection
WARNING!
Danger of death due to electric shock
Live parts can cause an electric shock on contact and cause fatal burns and injuries.
• Before beginning work on live parts, disconnect them from the power supply (switch off fuse, main
switch) and secure against unintentional restart.
• The electrical connection may only be established by qualified electrical technicians with observance of
the relevant standards and guidelines, as well as the regulations of the electric utilities company.
All ROTEX ESU control and safety devices are connected, tested and ready for use. Modifications on the electrical installation
are dangerous and prohibited. Any resulting damages will be borne by the user/owner alone.
The ROTEX E-SolarUnit is intended to be connected to a 400 V, 50 Hz 3-phase supply system. The electric heat generator is
supplied with power via 3 phases, 230 V/50 Hz. With sufficient protection and line dimensioning the ROTEX ESU can also operate
on a 230 V/50 Hz single-phase grid. The ROTEX ESU-adapter 230 V/single-phase (
15 70 51) is available for that.
Before connecting the ROTEX E-SolarUnit, you must ensure that the supply voltage corresponds to the specified mains voltage.
The mains connecting cable must be routed into the terminal box through the large cable gland (A). After the cable has been
connected to the terminals, tighten the cable gland's swivel nut to grip the cable.
Connect to the mains as per Figure 3-4 in the terminal box (see Figure 2-1, pos. 37).
Fig. 3-4
Connection assignment in the terminal box
If a signal is available from the power company at off-peak tariff, a switch cable (hose line minimum 2 x 0.5 mm2) can be wired
through the second cable gland (B) of the terminal box. The switching contact must be connected to terminals 4 and 5 in the
terminal box. The switching contact must be designed as a floating contact. If the contact is open the ROTEX ESU operates with
the standard tariff (ST) settings, if the contact is closed with the settings for off-peak tariff (OT) – see Chapter 3.10, page 19.
CAUTION:
Danger of destroying the relay board
• Design the ST/OT switching contact as a floating contact.
• Do not apply mains voltage under any circumstances, as this would destroy the board.
The mains and sensor connections are coded on the connector circuit board of the boiler control panel in terms of their colour and
shape (see Figure 3-5), to prevent them being mixed up.
FA ROTEX ESU - 07/2008
15
3 Set-up and installation
\All electrical installation work required inside the ROTEX E-SolarUnit has already been completed at the factory. A 3 m flexible
external sensor cable (see Figure 2-1, pos. 39) has already been connected to the terminals inside the unit and plugged onto the
connecting circuit board in the control panel. Only optional extras (such as a mixer circuit) then have to be connected to the boiler
control panel.
Make sure that the mains connection uses the correct phase sequence. If incorrect polarity is used, the mains
switch remains lit even after it has been switched off.
Connections of the circuit board connectors:
J1 Boiler pump Pk
J2 3-way diverter valve or storage tank charging
pump PL*
J6 Mains connection
J7 Mixer
J8 Communication, sensors
J10 Sensors
* If the adapter cable is used for the charging pump (
Fig. 3-5
3.7
Cable colours:
bl blue
br brown
gr grey
rt red
sw black
ws white
n.b. Contact not assigned
E 1500430)
Connection assignment label on the boiler control panel
Temperature sensor
3.7.1 General instructions for the temperature sensors
The ROTEX ESU controls the flow temperature based on the weather. An external temperature sensor is required for this
function. A 3 m flexible cable is already connected inside the unit and placed in the control panel on the connecting circuit board.
The temperatures detected via the internal temperature sensors (flow and return flow temperature sensors) are used to
control the heat generator's output and to detect faults. They are connected in the factory and can be plugged onto the
appropriate sensor directly, should a replacement be needed.
The storage tank temperature sensor is installed and connected to the terminals at the factory (PTC thermistor). The mixer
circuit flow sensor (TMKF,
15 60 62) is required to control a mixer circuit.
3.7.2 Connecting the temperature sensor
CAUTION!
The use of temperature sensors that are not approved or unsuitable for the unit can lead to major malfunctions
during controlled operation of the ROTEX ESU and impair the control function of the unit.
• Only use the external temperature sensor included in the scope of delivery.
16
FA ROTEX ESU - 07/2008
3 Set-up and installation
External temperature sensor
• Choose a location at about one third of the building height (minimum distance from floor: 2 m) on the coldest side of the
building (north or north-east).
• Ensure that the location is not near to any external heat sources (flues, air ducts), nor subject to direct solar radiation.
• Place external temperature sensors in such a way that the cable exit points face downwards (prevents humidity ingress).
CAUTION!
Laying the sensor and mains lines in parallel within a wiring conduit can lead to major malfunctions during
controlled operation of the ROTEX ESU.
• Always lay the sensor line separately.
• Connect the outdoor temperature sensor with a duplex wire (minimum cross-section 1 mm2) with the cable marked "outdoor
temperature sensor".
Mixer circuit flow sensor (accessory)
• Connect the sensor line to the sensor plug J8 (see Figure 3-5, page 16).
3.8
Optional connections
3.8.1 Mixer circuit
A mixer circuit, which is controlled via the electronic boiler control, can be connected to the ROTEX ESU directly.
ROTEX offers the following:
– The AMK1 (
15 60 44) mixer group, which is ready to plug in and consists of a circulation pump integrated into a heatinsulated housing, a motor mixer and stop valves with temperature indicators.
– The TMKF (
15 60 62) mixer circuit docking sensor.
3.8.2 Room thermostat
To remotely set the room temperature from another room, a separate room thermostat ROTEX ALPHA RTR-E (
17 51 26)
can be installed for the direct or the mixed circuit. If you want to use this function, you must activate it in the
ROTEX ALPHA+ 23R control.
– Connection of the room thermostat ROTEX ALPHA RTR-E to the terminal AB of the board connector J8 on main unit
(see Figure 3-5, page 16).
3.9
Filling the system
Adjusting the pressure gauge
Before filling the system for the first time, the minimum pressure marking must be adjusted to the correct setting on the pressure
gauge glass:
• Rotate the pressure gauge glass (Figure 2-1, page 8, pos. 30) so that the minimum pressure marking equates to the height
of the system + 2 m (1 m water column corresponds to 0.1 bar).
Once all installation work has been completed, fill the ROTEX E-SolarUnit by following the sequence below:
1. Filling the hot water heat exchanger
• Open the shutoff valve for the cold water supply pipe.
• Open the hot water bleeder 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 inflow; this will ensure that the
heat exchanger will be fully vented and that any impurities or residue will be discharged.
FA ROTEX ESU - 07/2008
17
3 Set-up and installation
2. Filling the storage tank
ROTEX ESU with Solaris-System installed:
• Connect the filling hose with return flow inhibitor (½") to the KFE cock on the control and pump unit (RPS).
• Fill the storage tank until water is discharged from the safety overflow.
ROTEX ESU without Solaris-System installed:
• Either connect the filling hose to the hose nozzle supplied and then secure this nozzle to the connection on the side of the
tank, at the top (see Figure 2-1, page 8, pos. 10) or insert the hose into the Solaris flow connection (Figure 2-1, page 8,
pos. 7).
• Fill the storage tank until water is discharged from the safety overflow.
3. Filling the heating system and the storage tank charging circuit
WARNING!
Polluted domestic water is hazardous to health.
• When filling the heating system, ensure that water from the boiler cannot flow back into the domestic
water pipe.
• Engage the hand lever on the 3-way diverter valve (see Figure 3-3, page 14) in the centre position (only possible when deenergised/in the delivered condition).
The centre position is only stable when the valve is de-energised. The valve releases automatically if voltage is
applied at the drive motor for valve position AB-A (storage tank charging).
To ensure a complete deaeration, the 3-way diverter valve must be unlocked at the earliest one hour after
equipment start-up by plugging in the power cable.
• Connect the filling hose with return flow inhibitor (½") to the filling and draining fittings (KFE cock, Figure 2-1, page 8,
pos. 33) and secure against sliding by using a hose clamp.
• Open the water tap for the supply pipe.
• Open the KFE cock and watch the pressure gauge (Figure 2-1, page 8, pos. 33).
• Fill the system with water until the marking of the system overpressure is roughly in the centre of the green range of the
pressure gauge display.
• Close the filling & draining cock.
• Vent the entire heating network (open the system control valves).
• Check the water pressure on the pressure gauge again and top up with water if necessary.
• Close the KFE cock, remove the filling hose and return flow inhibitor from the filling and draining fittings.
18
FA ROTEX ESU - 07/2008
3 Set-up and installation
3.10 Setting the heating output
The heater performance of the electric heat generator can be individually set at the boiler control panel according to low-, and
peak tariff of the power company as well as according to heater and water heating. Therefore, the ROTEX electronic control
ALPHA+ 23R must be temporarily removed (see Chapter 5.6, page 30).
The DIP switches on the relay board on the boiler control panel (see Figure 3-6) are used to set the outputs for each
operating mode. For each operating mode (heater, water heating) power settings must be preset in increments of 3 kW according
to Table 3-1, page 19 for HT- and LT times of the power company. Each pair of switches is assigned to a particular operating
mode and tariff time.
The settings for peak tariff are effective with open contact between the terminals 4 and 5 in the power supply terminal box
(Chapter 3.6, page 15). The settings for off-peak tariff are effective, if the contact between the terminals 4 and 5 is closed. The
switching contact between the terminals 4 and 5 must be carried out potential-free.
Fig. 3-6
DIP switches for setting heating output
For example: J3 and J4 can be used to set the output for the hot water preparation operating mode during standard tariff time.
In Figure 3-6, DIP switches 2, 3, 7 and 8 are set to position "1" (pressed down). This means that the following settings have
been made:
•
•
•
•
Heat demand, standard tariff: 6 kW (switches 1 and 2)
Hot water demand, standard tariff: 3 kW (switches 3 and 4)
Heat demand, off-peak tariff: OFF (switches 5 and 6)
Hot water demand, off-peak tariff: 9 kW (switches 7 and 8)
By simultaneously setting both switches of a DIP switch pair to "0" (e. g. switch 5 and 6 for off-peak tariff
time heat request in our example) power for the corresponding operating mode is deactivated! In such cases,
the frost protection function is also disabled for the operating mode concerned.
Heat demand standard
tariff (ST)
Warm water demand
standard tariff (ST)
Heat demand, off-peak
tariff (OT)
Warm water demand
off-peak tariff (OT)
Tab. 3-1
FA ROTEX ESU - 07/2008
P [kW]
J1
J2
J3
J4
J5
J6
J7
J8
OFF
0
0
3
1
0
6
0
1
9
1
1
OFF
0
0
3
1
0
6
0
1
9
1
1
OFF
0
0
3
1
0
6
0
1
9
1
1
OFF
0
0
3
1
0
6
0
1
9
1
1
Assignment of DIP switch settings in terms of heating output
19
4 Start-up
4
Start-up
WARNING!
Danger of death due to improper start-up
A ROTEX E-SolarUnit which is not started up properly can endanger an individual's life or health and can also
impair the function it is designed to perform.
• The ROTEX ESU may only be started up by authorised and trained heating experts.
CAUTION:
If the ROTEX ESU is not started up properly, it could lead to material or environmental damage.
• Observe the regulations in VDI 2035 in order to avoid corrosion 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.
– We recommend the use of Fernox limescale and corrosion protector KSK (
15 60 50).
• During operation of the system, the water pressure must be checked at the pressure gauge at regular
intervals (it must be in the green range). If necessary, correct the pressure by topping up with water.
Incorrect start-up makes the manufacturer's guarantee for the unit void. If you have questions, please contact our Technical
Customer Service.
4.1
Initial start-up
Once the ROTEX ESU has been fully installed and connected, it can be started up by suitably trained staff.
Requirements
–
–
–
–
The ROTEX ESU is fully connected.
The heating and hot water system are filled and subjected to the correct pressure.
The storage tank is filled to the overflow point.
The heating system's control valves are open.
Checks before start-up
• Check all connections for leakage.
• Check all the points on the enclosed checklist (see Chapter 4.2). Log the test results on the checklist.
Only if all points on the checklist can be answered with yes may the electric heat generator be started up temporarily.
Start-up
• Switch the mains switch on (see Figure 5-1, page 23, pos. 1).
Requirements
– The control has been installed in accordance with these instructions.
– All sensors required for normal operating mode (the flow temperature sensor, for example) have been connected
(see Table 4-1).
– Optional sensors have been properly connected.
Unit
Flow
temperature
sensor
Return flow
temperature
sensor
Flue gas
temperature
probe
Hot water
temperature
sensor
External
temperature
sensor
Mixer
temperature
sensor
ROTEX ESU
Yes
Available*
No
Optional
Optional
Optional
* Available in the unit, not evaluated by ROTEX ESU
Tab. 4-1
20
Necessary and optional sensors for ROTEX ESU
FA ROTEX ESU - 07/2008
4 Start-up
Adjusting the control to the unit type
Preinstalled controls are adjusted to the ROTEX boiler at the factory. If you have purchased your control as an accessory or a
spare part for your boiler, it must then be set in accordance with the relevant unit type.
You only adjust the control to the unit type during initial start-up. If you set the wrong unit type by mistake,
you can correct your entry by changing parameter [1] in Table 6-7 in Chapter 6.6 "System parameters".
1.
Set the "Default settings" rotary switch to
2.
Switch the heat generator on.
.
Î The display shows "OIL".
3.
Select the unit type ESU using the
4.
Press the
5.
The ROTEX ESU checks whether all sensors required for normal operating mode and other optional sensors are connected
(see Table 4-1).
OK
key on the main unit.
key on the central unit to confirm your selection.
Î If a sensor required for normal operation is missing, the ROTEX control system ALPHA+ 23R reports a sensor failure
and terminates operation.
Information on the detected sensors is initially stored in the temporary memory. Once the control has been
operational for over 24 hours (changeover from one day to the next) and no sensors have been connected or
disconnected during this period, the existing sensor configuration is permanently stored in the memory.
Fault correction:
•
•
•
•
•
Use the displayed fault code to determine which sensor the fault relates to (see Chapter 10 "x Faults and malfunctions").
Reset the fault signal with RESET: Press the OK key and hold it down for longer than 3 s.
Switch the heat generator off.
Check that the sensor is working (see Chapter 12, Table 12-6) and that it is properly connected.
Switch the heat generator on.
Î If the failure is displayed again, replace the sensor or the sensor cable.
Î If all sensors required for operation have been detected and are free of faults, the system runs in the set operating mode
(depending on the position of the "Selection of operating mode" rotary switch, see 6.2).
6.
Set the time and weekday (see section 6.5.5).
7.
Now adjust the system parameters to the requirements of the heating system according to Table 6-7 and Table 6-8
(see Chapter 6.6.2, page 43).
FA ROTEX ESU - 07/2008
21
4 Start-up
4.2
Checklists for start-up
Checklist before start-up
1.
Is the ROTEX ESU properly installed in accordance with a permitted set-up and without any discernible damage?
‰Yes
2.
Does the mains connection conform to the specifications?
‰Yes
3.
Is the mains voltage 230 V, 50 Hz?
‰Yes
4.
Is the storage tank filled with water to the overflow point; is the overflow pipe properly connected and sealed?
‰Yes
5.
On restoration: Has the heat distribution network been cleaned? Is a dirt filter installed in the heating return flow?
‰Yes
6.
Is a membrane expansion tank mounted according to specifications and in the requisite size?
‰Yes
7.
Is the safety valve connected to a free outlet?
‰Yes
8.
Is the system water pressure within the green range?
‰Yes
9.
Are the heat generator and heating system vented?
‰Yes
10.
Are all sensors connected and correctly positioned?
‰Yes
11.
Are the mixer group and mixer circuit sensor (optional) properly connected to the circuit board?
‰Yes
12.
Is the room thermostat (optional) properly connected and are the corresponding parameters set correctly in the control?
‰Yes
The system may only be started up if all questions can be answered with "Yes"!
Checklist after start-up
A
Is the circulation pump running; is the heating system warming up?
‰Yes
B
Has the 3-way diverter valve connector been plugged on following start-up?
‰Yes
The system may only be handed over to the user/owner if all questions can be answered with "Yes".
• Fill in the supplied installation and instruction form jointly with the user/owner.
22
FA ROTEX ESU - 07/2008
5 Boiler control panel
5.1
5
Boiler
control
panel control panel
Operating elements
on the
boiler
The ROTEX E-SolarUnit is controlled via the central unit on the boiler control panel, the electronic ROTEX
control system ALPHA+ 23R.
You can find a detailed description of this in Chapter 6, page 32.
1
2
3
Mains switch
Group malfunction lamp
Fill level warning lamp (if level too low)
Fig. 5-1
4
5
Pressure gauge
Fill level warning lamp for correct fill level
Control elements on the boiler control panel with integrated ROTEX control system ALPHA+ 23R (middle, see Chapter 6.1, page 32)
Mains switch
Switching the ROTEX ESU on and off: If the heating system is switched on, the mains switch is lit up green.
If the heating system is running without malfunctions in normal operating mode, the green fill level control lamp is also lit. All other
control lamps are off.
Group malfunction lamp
In normal operating mode, the group malfunction lamp (2) is off. If a malfunction occurs, it lights up red.
The ROTEX ALPHA+ 23R displays an onscreen error code in case of a malfunction.
For information on the meanings of fault codes and how to rectify malfunctions, see Chapter 10, page 58.
Pressure gauge
– Black pointer: Indication of the current water pressure in the heating system.
– Green range: Permissible water pressure range.
– Red pointer: Indication of the permitted minimum pressure.
The black pointer must be in the green range. If it is to the left of the red pointer, the water pressure must be increased by topping
up the system (see Chapter 3.9, page 17).
Fill level warning lamp
This indicates that the storage tank is insufficiently filled, i. e. fewer than two of the three electrodes on the fill level probe are
in the water (see Chapter 2.1, page 8, pos. 38).
To ensure hot water is supplied safely and Solaris operates effectively, the unpressurised area of the storage tank must be filled
with water.
FA ROTEX ESU - 07/2008
23
5 Boiler control panel
5.2
Changing the boiler control panel
DANGER!
Danger of death from electric shock
Live parts can cause fatal burns or injuries on contact.
• Before starting any maintenance work on the central unit, disconnect it from the power supply (switch
off fuse, main switch) and secure it against unintentional restart.
Removal (observe sequence)
The location and arrangement of the components described below are shown in Figure 2-1, page 8 and Figure 5-16, page 31.
WARNING!
There is a danger of scalding from heating water.
The capillary tube of the pressure gauge is directly connected to the pressurised heating water.
• Before removing the pressure gauge, close the ball cocks at the boiler flow and return flow, and ventilate
the system.
1.
Remove the lock screws for the protective cover (see Figure 2-1, page 8, pos. 32) and lift it off.
2.
Close the stopcocks (Figure 2-1, page 8, pos. 35) in the heating flow and return flow, connect the hose to the KFE cock
(Figure 2-1, page 8, pos. 33) and discharge the water pressure from the heat generator.
3.
Disconnect the power cable of the return flow temperature sensor (see pos. 24, Figure 5-2) and remove the heat insulation
at the return connection.
4.
Remove the pressure gauge capillary tube (see Figure 5-3, pos. 30). Use kitchen roll to absorb the small amount of water,
which will escape when the tube is unscrewed.
Fig. 5-2
5.
24
Disconnect power cable
Fig. 5-3
Unscrew the capillary tube, open the terminal box
Open the terminal box (see Figure 5-3, pos. 37) and use the supply line to check whether the system is enabled or not.
FA ROTEX ESU - 07/2008
5 Boiler control panel
6.
Disconnect terminals L1, L2, L3, N, PE and 1 to 5 of the cables to the control panel (A + B).
7.
Remove cable glands (C + D) and disconnect cables (A + B) from the power supply terminal box.
8.
Unscrew the control panel cover (see Figure 5-5).
Fig. 5-4
9.
Remove the cable to the control panel from
the terminal, unscrew the cable protective tube
Fig. 5-5
Unscrew control panel cover
Pull all connectors off the circuit board (see Figure 5-6).
All circuit board connectors are coded to prevent them being mixed up when they are reinserted.
10. Lift the sensor and connecting cables out of the cable ducts with strain relief plates on the control panel (see Figure 5-7).
Fig. 5-6
Disconnect coded connectors
and remove cable
Fig. 5-7
Disassemble filling level probe
11. Unscrew the covering cap from the electronic fill level probe and lift the probe out (see Figure 5-8).
12. Pull safety temperature limiter (STL) from immersion tube of the heat generator flow.
13. Unscrew the boiler control panel via the supports on the tank cover (see Figure 5-9), replace the control panel.
Fig. 5-8
FA ROTEX ESU - 07/2008
Pull STL from the immersion tube
Fig. 5-9
Unscrew the fixing screws
for the boiler control panel
25
5 Boiler control panel
Installation (observe sequence)
1.
Insert the boiler control panel into the mounting. Insert and tighten the fixing screws.
2.
Insert the fill level probe, attach the covering cap and screw it on.
3.
Plug safety temperature limiter (STL) into immersion tube of the heat generator flow.
4.
Place all sensor and connecting cables into the cable ducts of the control panel. Ensure the correct cable routing through the
strain relief plates.
5.
Plug all connectors onto the circuit board. The connectors are shape-coded to prevent them being mixed up.
Do not force the connector!
6.
Mount the control panel cover.
7.
Connect cables A + B with the power supply terminal box and tighten cable glands (C + D).
8.
Connect terminals L1, L2, L3, N, PE and 1 to 5 of the cables to the control panel. Close the terminal box.
9.
Screw in the pressure gauge capillary tube. Ensure the correct seating of the ring seal.
10. Install heat insulation at the return connection and connect the return flow temperature sensor cable.
11. Top up with water until the required system pressure is restored.
12. Open the stopcocks for heating. Vent the system again (top up with water if required).
13. Put on cover and tighten safety screws.
5.3
Changing cables
The connecting cables must either be released from the boiler control panel or from the relevant components.
– The cables for the internal components in the unit are connected to the circuit board connectors and cannot be released.
They can be released from the respective components where they are plugged in.
– The cables of external components (e. g. external temperature sensor) or of components that are not included in the scope
of delivery (e. g. mixer), are connected to the circuit board connectors via screw terminals.
DANGER!
Danger of death due to electric shock.
Live parts can cause fatal burns or injuries on contact.
• Before starting any maintenance work on the central unit, disconnect it from the power supply (switch off
fuse, main switch) and secure it against unintentional restart.
Changing the cables (observe sequence)
1.
Remove the protective cover.
2.
Unscrew the control panel cover and remove the cable duct cover.
3.
Pull out the corresponding sensor or connection cable from the cable duct of the control panel.
4.
Pull the relevant connectors off the circuit board.
5.
Separate the other cable end from the component (release plug connection or remove the cable from the terminal).
6.
Replace the cable. Ensure that the cable cross section is correct.
Install the new cable in reverse order. Whilst doing so, ensure the following:
– The technical specification of the new cable must correspond to the values of the replaced cables (e. g. conductor cross
section).
– The circuit board connectors are shape-coded. Do not force the connector!
26
FA ROTEX ESU - 07/2008
5 Boiler control panel
5.4
Changing sensors
DANGER!
Danger of death due to electric shock.
Live parts can cause fatal burns or injuries on contact.
• Before starting any maintenance work on the central unit, disconnect it from the power supply (switch off
fuse, main switch) and secure it against unintentional restart.
If a sensor or connecting cable is faulty, it can be changed as an individual component, provided that it is not grouped together
with other cables on the control panel via a plug-and-receptacle connection that cannot be released. The cables of internal
components are connected to the relevant circuit board connector; this connection cannot be released. However, the associated
cables can be plugged onto the relevant component, so that the component or the cable can always be easily changed without
the need to perform complicated reconnection work.
With the exception of the storage tank sensor, faulty internal sensors can be changed without opening the control panel. External
components (e. g. external sensors) or components that are not included in the scope of delivery as standard (e. g. mixers) are
connected to connectors via screw terminals.
5.4.1 Changing flow/return flow temperature sensors
WARNING!
There is a danger of scalding from heating water.
flow and return flow temperature sensors are connected directly to the pressurised heating water.
• Close the ball valves at the boiler flow and boiler return flow before removing the sensor. Release the
system pressure using a hose connected to the KFE valve and ventilate.
Flow sensor
1.
Open the housing of the electric heat generator unscrewing the two screws on both sides (Figure 5-10 a).
2.
Remove cover, upper heat insulation, and lateral heat insulation around the sensor (Figure 5-10 b and Figure 5-10 c).
3.
Pull the cable off the flow sensor (Figure 5-10 d).
4.
Unscrew and replace the sensor from the heat generator.
Installation is carried out in reverse order.
Return flow sensor
1.
Pull the sensor cable off (Figure 5-11).
2.
Remove insulation of the return flow pipe.
3.
Unscrew and replace the sensor.
Installation is carried out in reverse order.
The sensor plugs are form-coded. Do not force the connector
FA ROTEX ESU - 07/2008
27
5 Boiler control panel
28
Fig. 5-10
Replace the flow sensor
Fig. 5-11
Replace the return flow sensor
FA ROTEX ESU - 07/2008
5 Boiler control panel
5.4.2 Changing the storage tank temperature sensor
The storage tank temperature sensor is connected directly to the connection terminals 11 and 12 of the 12-pin sensor connector
J8 in the boiler control panel.
To replace the storage tank temperature sensor, follow steps 1 to 4 for changing cables (see Chapter 5.3, page 26). When
inserting the sensor into the immersion sleeve, ensure that the pressure spring is bent appropriately (Figure 5-12, page 29) and
that the sensor is installed at the correct depth (note the marking).
Insert the storage tank sensor with bent spring into the sensor immersion sleeve to a depth of 70 cm.
0
For more information on installing the storage tank temperature sensor, see the enclosed installation
instructions.
5.5
1.
Open the boiler control panel and pull connector J8 off the
circuit board (see Chapter 5.3, page 26, steps 1 to 4).
2.
Pull the storage tank temperature sensor out of the sensor
immersion sleeve on the storage tank.
3.
Bend the pressure spring on the new storage tank
temperature sensor appropriately and insert the
temperature sensor into the sensor immersion sleeve up
to the marking.
4.
Connect the temperature sensor cable to the connection
for connection terminals 11 and 12 of the J8 sensor
connector, plug the connector onto the circuit board and
mount the control panel cover and protective cover.
Fig. 5-12 Storage tank sensor with bent spring
Changing the fuse
DANGER!
Danger of death due to electric shock
Live parts can cause fatal burns or injuries on contact.
• Before starting any maintenance work on the central unit, disconnect it from the power supply (switch
off fuse, main switch) and secure it against unintentional restart.
CAUTION!
Electrostatic charging
Electrostatic charging can damage the electronic components and connections on the circuit board.
• Do not touch the electronic components or connections with your bare hands.
FA ROTEX ESU - 07/2008
29
5 Boiler control panel
The fuse is located on the switchboard PCB (fuse type: 250 V, 6.3 AT); a replacement fuse can be found in the top of the housing.
1.
Removing the central unit (Chapter 5.6).
2.
Open the boiler control panel cover and pull all connectors off the circuit board (see Chapter 5.3, page 26, steps 1 to 4).
2.
3.
Fig. 5-13
Remove the locking screws from the
control panel housing
Fig. 5-14
Changing the fuse
3.
Use a screwdriver to remove the 4 locking screws from the control panel housing (see Figure 5-13).
4.
Remove the top of the housing. Mind the cables of the STL.
5.
Replacing the fuse on the upper left on the control panel board (see Figure 5-14).
If the fuse immediately blows upon switching on again, there is a short circuit in the electrical system.
Technicians must eliminate the cause of the short circuit before a new fuse is inserted.
5.6
Installing and removing the central unit
The central unit ROTEX ALPHA+ 23R is designed as built in device. It is inserted from the front into the cut-out on the control
panel.
Installation
• Rotate the locking bolts (pos. 1, Figure 5-15) anticlockwise into the installation position and carefully insert the control into
the cut-out on the central unit, parallel with the front face of the boiler control panel, until the connecting pins are resting on
the PCB receptacle.
• Lock ROTEX ALPHA+ 23R in place into the receptacles applying gentle even pressure on the corners of the control box.
• Rotate the locking bolts clockwise to lock them in place.
• The control is removed by following these steps in reverse order. To remove the ROTEX ALPHA+ 23R lever the central unit
out of the receptacle inserting a flat screwdriver under the frame of the control box.
5 sec
ALPHA+
1
Fig. 5-15
30
1
7
OK
i
3sec. Reset
1
ALPH
+
A
Removing the central unit
FA ROTEX ESU - 07/2008
5 Boiler control panel
5.7
Wiring diagram
1 Mains switch
2 Group malfunction lamp
4 Pressure gauge capillary tube
5 Controller: Central unit ROTEX ALPHA+ 23R
17 Fill level control lamp
18 Fill level warning lamp
19 Switchboard PCB
20 Relay board (power section)
21 Stickers for connection assignment
22 4-pin circuit board connector with switch cable
23 Fill level probe with 3-pin circuit board connector
24 4-pin circuit board connector with malfunction
lamp cable
25 5-pin circuit board connector with jumper
26 Connecting cable to relay board with circuit board
connector
27 ST/OT control cable with 4-pin circuit board
connector for relay board, clamped in terminal box
28 Load control cable between relay board, terminal
box (connected to relevant terminals – cable gland)
and electric heat generator (attached to tubular
radiators by means of push-on receptacles)
Fig. 5-16
29 Power cable between terminal box (cable gland)
and electric heat generator
30 Electric heat generator with three tubular
radiators of 3 kW, each tubular radiator
safeguarded by an STL
31 Terminal box for connecting the power supply and
floating ST/OT contact to terminals
32 Connecting cable for floating ST/OT contact
(provided by customer)
33 Connecting cable for power supply, 3 N ~ 230 V
(provided by customer)
34 4-pin mains circuit board connector with clamped
mains cable and stranded earthing wire,
at terminal box cable gland
35 3-pin circuit board connector with pump cable
36 Circulation pump for heating
38 3-way diverter valve
39 4-pin circuit board connector with valve cable
40 6-pin circuit board connector empty housing
(circuit board terminal not occupied)
41 7-pin circuit board connector for connecting a mixer
motor and a mixer circuit pump to terminals
42 3-pin circuit board connector empty housing (circuit
board terminal not occupied)
43 2-pin circuit board connector for connecting
sensors, BUS lines and control lines to terminals
44 External temperature sensor
45 Storage tank (hot water) temperature sensor
46 8-pin circuit board connector with cable for flow
and return flow temperature sensor
47 Return flow temperature sensor
48 Flow temperature sensor
49 STL heat generator flow
Wiring diagram
FA ROTEX ESU - 07/2008
31
6 ROTEX control system ALPHA+ 23R
6.1
Overview
ROTEX control system ALPHA+ 23R
6
The ROTEX ALPHA+ 23R is a constituent part of the boiler control panel. Therefore, in this section of the
manual only the functions of the control unit and not those of the boiler control panel are explained. Further
information on the boiler control panel can be found in Chapter 5.
The electronic, digital control system ROTEX ALPHA+ 23R automatically controls all heater-, and warm water functions for the
direct heater circuit, an optionally connectable mixed heating circuit and a storage load circuit.
The ROTEX ALPHA+ 23R contains:
– A clock timer with three switching time programmes per heating circuit, one of which can be individually customised
– A frost protection function for all heating circuits
– An integrated PC interface (COM socket) for targeted fault diagnosis
5
4
3
7
8
5 sec
ALPHA+
1
7
OK
3sec. Reset
i
2
6
8
1
1
2
3
4
5
6
7
8
9
"Selection of operating mode" rotary switch
"Default settings" rotary switch
Display
Key
Key
Key OK
COM socket (underneath cover)
Locking bolts
Compartment for quick reference instruction manual
9
Fig. 6-1
6.2
Central unit ROTEX ALPHA+ 23R
Control elements
6.2.1 "Selection of operating mode" rotary switch
STANDBY
Frost-protected shutdown of heating and hot water.
REDUCED
Continuous reduced heating mode without time restriction — hot water reduced mode.
HEATING
Continuous heating mode without time restriction — hot water normal operating mode.
SUMMER
Hot water mode, heating shut down with frost protection.
AUTOMATIC I
AUTOMATIC II
AUTOMATIC III
32
Automatic heating and economy mode according to "Out at work" switching time
programme (can be set separately).
Automatic heating and economy mode according to "Family" switching time
programme.
Automatic heating and economy mode according to switching time programme "Solar".
FA ROTEX ESU - 07/2008
6 ROTEX control system ALPHA+ 23R
6.2.2 "Default settings" rotary switch
TARGET HOT WATER
TEMPERATURE
NORMAL OPERATING
MODE
TEMPERATURE
ADJUSTMENT
i
1
7
Display and modify target hot water temperature.
Default setting. Display the current flow temperature (to display the current external
and hot water temperature, see Chapter 6.5.2, page 35).
Display and modify correction value (parallel shift of the heating curve).
STATUS PLANT
Read out data on equipment status.
WEEKDAY
Display and change weekday.
CLOCK TIME
Display and change time.
PARAMETER
Select and change parameters.
6.2.3 Operator keys
The operator keys can be used to modify and save values.
PLUS
Changing values. The keys are used for navigation within the "Parameter",
"Information" and "Automatic I" menu items.
MINUS
OK/RESET
OK
OK function: Press key briefly
– Confirms or saves selected settings.
– Enters the submenu.
RESET function: Press key and hold it down for longer than 3 s.
– Resets settings to existing values.
– Returns to higher-level selection point within the function menu.
– Operator acknowledging fault signals and returns to default display.
6.2.4 Special functions
+
FA ROTEX ESU - 07/2008
5 sec
+
+
+
OK
>5sec
OK
Manual warm water boost charge (see Chapter 6.6.9, page 49)
manual operation (see Chapter 6.5.7, page 40)
Programming switch switching time programme "automatic I" (see Chapter 6.5.6,
page 36)
Setting heating curve (see Chapter 6.6.5, page 46)
33
6 ROTEX control system ALPHA+ 23R
6.3
Display
The 4-digit display shows system information.
Position of the
"Default settings"
rotary switch
Display
Explanation
48.
L 60
C 0
i
1
Tab. 6-1
6.4
7
d
1
• The current boiler or flow temperature is displayed.
• The point on the lower right designates the heat generator
status. If a point is displayed, the electric pipe heater is
operating.
• If there is no point in the lower right corner of the display,
the heat generator is not operating.
• The currently set hot water temperature is displayed.
• The currently set correction value for the temperature
adjustment is displayed (value range: +20 to –20).
• Current system information is displayed.
The display alternates between showing the info number,
on the left, and the info value, on the right.
• The current weekday is displayed.
• The current time is displayed.
Basic displays
COM socket
The COM socket is used to connect a PC or an external data storage device.
Only ROTEX service engineers may use the COM socket.
6.5
Default settings
6.5.1 General information
• Press the
OK
key to enter the programming level.
Î The point at the second decimal place flashes.
• Turn the "Default settings" rotary switch prior to saving.
Î All changes are lost.
• Press the
OK
key after making changes.
Î The changes are saved.
Î The control confirms that the new value has been saved correctly by means of a programming confirmation on the
display:
.
• Press the
OK
key and hold it down for longer than 3 s.
Î The previous value is restored (only possible if the new value has not already been saved).
34
FA ROTEX ESU - 07/2008
6 ROTEX control system ALPHA+ 23R
6.5.2 Normal operating mode
• Set the "Default settings" rotary switch to position
.
• Set the "Selection of operating mode" rotary switch to the correct
position.
48
Fig. 6-2
• Set the "Default settings" rotary switch to position
• Press the OK key.
Setting normal operating mode
.
48.
Î Calls the info values (current flow temperature,
current storage tank temperature and current external
temperature).
Fig. 6-3
OK
L 60
OK
A -5
Calling info values
6.5.3 Changing the correction value for the flow temperature
The control calculates the target flow temperature in heating mode in accordance with the external temperature and the heating
characteristic that has been set. In the storage loading operation and the special functions "manual warm water boost charge"
as well as "manual operation" constant target flow temperatures are used. If the desired room temperature is not reached despite
the correct heating characteristic being set, the operator can adjust the flow temperature by entering a correction value. The
correction causes the heating characteristic to undergo a parallel shift in accordance with the set value.
OK
1.
Set the "Default settings" rotary switch to position
2.
Press the
3.
Use the
value.
4.
Press the
OK
key.
and
OK
.
keys to increase or decrease the correction
C 0
C . O
C . 1
OK
C
key to save the value.
Fig. 6-4
1
Changing the flow temperature correction
value
The flow temperature is limited by the maximum flow temperature (see Chapter 6.6, page 42).
6.5.4 Setting the target hot water temperature for off-peak tariff charging
The target hot water temperature can be set to any value within a specified temperature range.
A heating output must be set for hot water at the off-peak tariff
(see Chapter 3.10, page 19).
1.
Set the "Default settings" rotary switch to position
2.
Press the
3.
Use the
and
temperature.
4.
Press the
OK
OK
OK
.
key.
keys to increase or decrease the hot water
OK
L 59
key to save the value.
Fig. 6-5
FA ROTEX ESU - 07/2008
L 60
L .60
L .59
Setting the target hot water temperature
35
6 ROTEX control system ALPHA+ 23R
The upper and lower limits of the target hot water temperature range are defined via the maximum hot water
temperature and energy-saving hot water temperature parameters (see Chapter 6.6, page 42).
6.5.5 Setting the time and weekday
The ROTEX ALPHA+ 23R has an integrated clock for time and day. If the unit is disconnected from the mains, the clock has
a reserve power of around 6 hours. The clock must be reset after the unit was disconnected for a longer period.
Setting the time
OK
1.
Set the "Default settings" rotary switch to position
2.
Press the
3.
Use the
and
00:00 and 23:59.
4.
Press the
OK
OK
.
key.
14.20
14.20
14.21
14.19
OK
keys to set the time to a value between
14.19
key to save the value.
Fig. 6-6
Setting the time
Setting the weekday
1
7
OK
1
1.
Set the "Default settings" rotary switch to position
2.
Press the
3.
Use the
and
keys to set the weekday to a value between
1 (= Monday) and 7 (= Sunday).
4.
Press the
OK
OK
7
.
key.
d 1
d . 1
d . 2
OK
d
key to save the value.
Fig. 6-7
2
Setting the weekday
6.5.6 Switching timeprogramme
The ROTEX ALPHA+ 23R has three automatic switching time programmes, which can be selected with the rotary switch
"operating mode selection". The switching time programmes control the heating circuit temperatures (direct circuit, mixer circuit).
The storage tank charging circuit is controlled in accordance with the ST/OT contact.
With the ST/OT contact closed (= off-peak tariff) the ROTEX ESU heats the water to the set warm water target
temperature, with the contact open (= standard tariff) it hold the warm water temperature (applies for automatic
programmes only 1–3).
There are essentially two daily switching cycles available for each heating circuit, with the heating system being controlled
differently during day mode and economy mode. The switching cycles saved differ according to the various days of the week
(Monday to Sunday).
36
FA ROTEX ESU - 07/2008
6 ROTEX control system ALPHA+ 23R
The automatic programmes are preset for different target groups. Table 6-2 to Table 6-4 provide an overview of the factory-set
switching times. In addition, users can adjust the "Automatic I" switching time programme to their individual needs.
AUTOMATIC I
"Out at work"
Day
Switching cycle 1
Switching cycle 2
Direct circuit
(t 1.0)
Mon–Fri
Sat–Sun
05:00–08:00
07:00–23:00
16:00v22:00
–––
Hot water circuit
Mon–Sun
Mixer circuit
(t 3.0)
Mon–Fri
Sat–Sun
Tab. 6-2
Depends on the
ST/OT contact
04:00–08:00
07:00–23:00
15:00 - 22:00
–––
Factory settings for the "Out at work" switching time programme
AUTOMATIC II
"Family"
Day
Switching cycle 1
Switching cycle 2
Direct circuit
Mon–Fri
Sat–Sun
05:00–22:00
07:00–23:00
–––
–––
Hot water circuit
Mon–Sun
Mixer circuit
Mon–Fri
Sat–Sun
Tab. 6-3
Depends on the
ST/OT contact
04:00–22:00
06:00–23:00
–––
–––
Settings for the "Family" switching time programme
AUTOMATIC III
"Solar"
Day
Switching cycle 1
Switching cycle 2
Direct circuit
Mon–Fri
Sat–Sun
05:00–22:00
07:00–23:00
–––
–––
Hot water circuit
Mon–Sun
Mixer circuit
Mon–Fri
Sat–Sun
Tab. 6-4
Depends on the
ST/OT contact
04:00–22:00
06:00–23:00
–––
–––
Settings for the "Solar" switching time programme
If the ST-/OT contact is open (terminals 4 and 5 in the power supply terminal box), the warm water is heated up to the set warm
water saving temperature (parameter 7). If the contact is closed the warm water is heated up to the set target temperature (see
Chapter 6.5.4, page 35). However, heater performances have to be programmed for the respective tariff times (see Chapter 3.10,
page 19).
Adjusting the "Automatic I" switching time programme to user requirements
Four independent switching cycles can be defined for each control circuit (direct circuit, storage tank charging circuit and mixer
circuit). The first two switching cycles define the behaviour of the control Monday to Friday, whilst the third and fourth relate
to Saturdays and Sundays.
The individual switching time programmes and switching times are identified on the display by a number and a point, preceded
by the letter "t", where:
– t1. identifies the direct circuit switching time programme
– t2. identifies the storage tank charging circuit switching time programme If ESU , the times are deactivated, as this circuit
is controlled via the ST/OT contact
– t3. identifies the mixer circuit switching time programme
The third digit on the display, from 1 to 8, defines the time within the switching time program. Figure 6-8 provides a schematic
representation of how a switching time programme is processed.
FA ROTEX ESU - 07/2008
37
12:00
00:00
05:00 08:00
00:00
22:00
16:00
12:00
07:00
1 ... 5
Fig. 6-8
t1.6
t1.5
t1.4
t1.3
t1.2
t1.1
6 ROTEX control system ALPHA+ 23R
6 + 7
00:00
23:00
1
7
Schematic representation of how the "Automatic I" switching time programme is processed
The example shows the factory settings for the switching times for the direct heating circuit. Odd numbers (such as t1.1, t1.3)
define the corresponding switch-on time, whilst even ones (such as t1.2, t1.4) represent the switch-off time. The switching time
must be set to "——.——" for unused switching cycles, (such as t1.7 or t1.8 in the "Automatic I" switching time programme, if
factory settings are to be used).
+
+
Reset /
1
OK
3sec.
7
1 ... 5
OK
t1
OK
t2
OK
t3
OK
3sec.
OK
3sec.
t1.1
5.00
t3.1
4.00
t1.2
8.00
t3.2
8.00
t1.3
16.00
t3.3
16.00
t1.4
22.00
t3.4
22.00
t1.5
7.00
t3.5
6.00
t1.6
23.00
t3.6
23.00
t1.7
--.--
t3.7
--.--
t1.8
--.--
t3.8
--.--
6+ 7
Fig. 6-9
38
Structure of the "Automatic I" switching time programme
FA ROTEX ESU - 07/2008
6 ROTEX control system ALPHA+ 23R
Example of how to set the switching time
In the example the switch-on time for the mixer circuit t3.1 (first cycle, Monday to Friday) is changed from 4:00 h to 4:30 h and
the switch-off time t3.4 (second cycle, Monday to Friday) from 22:00 h to 22:30 h.
Alternating display
OK
Increase value
Decrease value
Fig. 6-10
Press briefly: confirm a selection, enter the displayed parameter
in order to modify it
Press and hold down for longer than 3 s: reset
Adjusting the "Automatic I" switching time programme
1.
Enter the programming level
2.
Selection of the mixer circuit (t3) with
3.
Selection of the first switch-on time t3.1with
4.
Changing the first switch-on time t3.1 from 4:00 h to 4:30 h
using the
and
keys. Saving the changes with OK and returning to the selection level.
5.
Selection of the switch-off time t3.4 with the navigation keys
and
and entering the programming mode with OK .
6.
Changing the switch-off time t3.4 from 22:00 h to 22:30 h.
using the
and
keys. Saving the changes with OK and returning to the selection level.
7.
Returning to the heater circuit level with
8.
Terminating programming by pressing the
FA ROTEX ESU - 07/2008
.
and entering the sub-level with
OK
OK
or
OK
.
and entering the programming mode with
OK
.
longer than 3 s.
key for over 3 s.
39
6 ROTEX control system ALPHA+ 23R
6.5.7 Manual operation
– The heat generator is controlled in accordance with the set target value. It is only limited by the maximum heat generator
temperature (parameter [12]).
– All pumps are operational.
– Any mixers are disconnected and can be controlled manually in accordance with a heat request.
– The hot water is maintained at the absolute minimum temperature (15 °C) and takes precedence over heating mode.
– The burner request is made using the heat generator's standard switching hysteresis.
– If the rotary switch "operating mode selection" is set to "summer" when activating manual operation, the constant
temperature is applied to the storage tank otherwise to the heating system. It is not possible to switch between the heating
system and the storage tank when manual operation is active.
– The adjustable target temperature is represented by a following "H" and changes with the actual flow temperature.
1.
+
Set the "Default settings" rotary switch to position
and press
the
and
keys simultaneously, holding them down for longer
than 5 s.
Use the
and
keys to
set the required target temperature.
3.
Press the
and
38
45 H
Î Manual operation is activated.
2.
5 sec
Ist
Soll
38
55 H
keys simultaneously.
Î Exits the programme.
EXIT
Fig. 6-11
Activate and set manual operation
6.5.8 Querying system information
Info values relating to functions, which have not been activated are not shown.
Certain info values are blocked from the display. The installer can call these values up by entering an access
code (see section 6.6.4).
1.
Set the "Default settings" rotary switch to position
i
i
.
Î The word "INFO" appears on the display for a few seconds,
then left-aligned the info value number and right-aligned the
corresponding info value are alternately displayed.
2.
You can use the
and
keys to select and display the required
information (see Table 6-5 to Table 6-6).
3.
Exit system information by setting the "Default settings" rotary switch
to a different position.
Fig. 6-12
40
InFo
I
21
Querying system information
FA ROTEX ESU - 07/2008
6 ROTEX control system ALPHA+ 23R
Overview of general system information
Info value no.
Info value
Can be viewed by
Installer
Operator
x
Comment
1
External temperature
x
If sensor value is available, otherwise "n. c." or "uuuu"
2
External working temperature
x
3
ACTUAL flow temperature
x
4
TARGET flow temperature
x
5
Return flow temperature
x
6
Condition of the direct heating circuit
pump
x
7
TARGET mixer circuit temperature
x
8
ACTUAL mixer circuit temperature
x
9
Condition of the mixer circuit pump
x
0 = Off, 1 = On
10
Condition of the mixer motor
x
0 = Disconnected, 1 = Mixer open, –1 = Mixer closed
11
Flue gas temperature
x
If sensor value is available, otherwise "n. c." or "uuuu"
12
Hot water temperature
x
13
Condition of the diverter valve
x
0 = Off, 1 = On
14
heat generator status
x
0 = no request from control
1 = request, but no BZ=0
2 = heat generator to (flame signal)
15
Hot water circuit clock timer
x
x
"AcT" = Active, "dEAC" = Inactive
16
Direct circuit clock timer
x
x
"AcT" = Active, "dEAC" = Inactive
17
Mixer circuit clock timer
x
x
"AcT" = Active, "dEAC" = Inactive
If no sensor value is available = 0 °C
x
x
0 = Off, 1 = On
x
x
If sensor value is available, otherwise "n. c." or "uuuu"
0 = Modem input > 3.3 kOhms ±200 ohms
The control is running in the operating mode that is currently set.
1 = Modem input = 3 kOhms ±200 ohms
The control is running in continuous reduced mode for both circuits
(in acc. with parameter [11]).
18
Condition of the modem contact
x
2 = Modem input = 2.2 kOhms ±200 ohms
The control is running in continuous reduced heating mode for both
circuits. The clock timer has no influence here.
3 = Modem input = 0 ohms or undefined
The control is running in standby mode for both circuits. Both
circuits are protected against frost.
Tab. 6-5
19
Condition of the flow heater – lock
x
"STOP"; " "
20
Flow heater – starts
x
Number
21
Flow heater – elapsed hours
x
x
In hours
22
Total elapsed hours, heating system
x
x
In hours
General info values (part I)
FA ROTEX ESU - 07/2008
41
6 ROTEX control system ALPHA+ 23R
Info value no.
Can be viewed by
E01
Fault no. 1 (most recent fault)
E02
Fault no. 2
E03
Fault no. 3
E04
Fault no. 4
E05
Fault no. 5
E06
Fault no. 6
E07
Fault no. 7
E08
Fault no. 8
E09
Fault no. 9
E10
Fault no. 10 (oldest fault)
Tab. 6-6
6.6
Info value
Installer
Operator
x
x
Comment
For fault codes, see the fault code table (Chapter 10.3).
General info values (part II)
System parameters
6.6.1 Setting parameters – Basic procedure
1.
Set the "Default settings" rotary switch to the position
.
Î The display "PArA" lights up briefly. The display then alternates between the parameter number, shown on the left of
the screen (Figure 6-13), and the parameter value, shown on the right (Figure 6-14).
60
P05
Fig. 6-13
Parameter number display
Fig. 6-14
Parameter value display
Parameters reserved for the heating technician are only accessible after entering the access code and thus,
visible for the heating technician (see section 6.6.4).
2.
Use the
3.
Press the
and
OK
keys to select the required parameter.
key to confirm your selection.
Î The parameter value is displayed.
4.
Use the
and
keys to modify the parameter value.
Up until the point when the parameters are saved, you can restore the original value by pressing the OK key and
holding it down for longer than 3 s. If the "Default settings" rotary switch is moved out of position before the
changes are saved, the value entered will be lost.
5.
Press the
OK
key to save your entry.
Î The control confirms that the new value has been saved correctly by means of a programming confirmation on the
display:
.
6.
42
Leave the system parameters by resetting the rotary switch "default configuration" to the position
parameter you want to change (steps 2 to 6).
or select another
FA ROTEX ESU - 07/2008
6 ROTEX control system ALPHA+ 23R
6.6.2 Overview of system parameters
You can tailor the ROTEX ESU to the prevailing installation conditions by setting the parameters. This section provides an
overview of all the available system parameters and their possible settings.
For information about the heating technician access code, see section 6.6.4.
Range
Min.
Max.
Increment
Operator/User
Can be set
by:
Installer
Parameter no.
Parameter name
Factory setting
(FS)
Universal parameters
Meaning
1 Unit type
x
1
4
1
0
0 = undefined, user is requested to set operation mode
1 = oil condensing boiler standard
2 = reserved
3 = gas condensing boiler
4 = ROTEX ESU
2 Hot water on/off,
Legionella protection
x
0
3
1
1
0 = Hot water off
1 = Hot water on, no Legionella protection
2 = Hot water on, Legionella protection every Saturday
3 = Hot water on, Legionella protection every day
4 Max. hot water
temperature, heating
technician
x
15 °C
65 °C
1K
60 °C Maximum settable warm water temperature for heating technician
5 Max. hot water
temperature, operator
x
x
Parameter
[7]
Parameter
[4]
1K
60 °C Maximum settable warm water temperature for user
7 Hot water, energy-saving
x
x
15 °C
Parameter
[5]
1K
40 °C
Warm water temperature at night setback or at standard tariff
8 Hot water switch-on
hysteresis
x
1 °C
20 °C
1K
2K
10 Parallel operation
x
0
1
1
0
A storage tank charging pump is used in place of a three-way valve. The
boiler circuit pump and the storage tank charging pump run in parallel.
11 Heating on
x
0
4
1
2
0 = No heating mode
1 = Heating mode for direct circuit only, ECO function, weather-driven
2 = Heating mode for direct circuit only, economy function,
weather-driven
3 = Heating mode for direct and mixer circuit, ECO function,
weather-driven
4 = Heating mode for direct and mixer circuit, economy function,
weather-driven
x
Request for hot water is generated if:
Target hot water temperature - hot water temperature ≥ hot water
switch-on hysteresis
Note: If a mixer circuit sensor is identified during automatic sensor
detection, the parameter is automatically set to "4".
13 Maximum flow
temperature, heating
technician
x
Parameter
[26]
78 °C
1K
60 °C
15 Assignment of room
temperature control
x
0
3
1
0
Tab. 6-7
Maximum flow temperature during heating mode (e. g. 55 °C for an
underfloor heating system)
0 = Room temperature control off
1 = Room temperature control assigned to direct circuit
2 = Room temperature control assigned to mixer circuit
3 = Room temperature control affects both circuits
Universal system parameters (part I)
FA ROTEX ESU - 07/2008
43
Increment
Range
Meaning
Operator/User
Can be set
by:
Installer
Parameter no.
Parameter name
Factory setting
(FS)
6 ROTEX control system ALPHA+ 23R
16 Night reduction
x
x
17 DCP run-on time after
heating
x
0s
600 s
10 s 180 s Defines the period for which the pump will run on once a heating request
has been deactivated. In case of a warm water demand this time is set
to = 0 and the pump is activated.
18 Follow-up time
DKP+SLP/3UV after
warm water
x
0s
600 s
1s
180 s
19 Heating switch-on
hysteresis
x
1K
20 K
1
7K
Request for burner is generated, if actual flow temperature is < flow
target temperature — switch-on hysteresis.
20 Heating switch-off
hysteresis
x
0K
20 K
1
7K
An active request for burner is stopped, if flow temperature - flow target
temperature is > switch-off hysteresis.
26 Room temperature
the direct circuit is
designed for
x
15 °C
30 °C
29 Summer switch-off
x
31 Charging limit
x
Min.
Max.
0
–80 °C
1K
10 °C Value how much the flow temperature calculated by the control system
is reduced in setback mode.
–
Defines the period for which the pumps and the 3-way diverter valve will
remain active once a hot water request has been deactivated.
1 K +25 °C
Parameter for the calculation of heater curve TR (Figure 6-17, page 47)
x
1 °C
60 °C
1 K +20 °C Value at which the heating system will switch from normal mode to
summer mode.
x
1h
12 h
1h
34 Maximum mixer circuit
temperature
x
15 °C
Parameter
[13] –
[36]
1 K +55 °C
35 Room temperature
the mixer circuit is
designed for
x
30 °C
1 K +20 °C
36 Mixer circuit temperature
increase
x
0K
10 K
1K
37 Pump run-on of the mixer
circuit pump
x
0s
600 s
10 s 180 s
38 Mixer valve runtime
x
10 s
600 s
10 s 180 s Time the mixer valve requires to move from one limit stop to the next.
Adjustable according to the used mixer drive.
84 Filter time for external
temperature
x
0 min
30 min 1 min 15 min
86 Start reset, heating
technician
x
0
1
1
0
88 Start initial run
x
0
1
1
0
98 Entry of access code,
x
x
15 °C
4h
Limits hot water charging to the time (in hours) set in the parameter.
Maximum temperature for the mixer circuit.
Parameter for the calculation of heater curve TR (Figure 6-17, page 47).
4K
This value specifies how far above the target temperature of the mixer
circuit the temperature of the direct circuit must be when the mixer
circuit makes a request.
Follow-up time mixer circuit pump
heating technician
Tab. 6-8
44
Universal system parameters (part II)
FA ROTEX ESU - 07/2008
6 ROTEX control system ALPHA+ 23R
6.6.3 Resetting parameters to factory settings
In certain circumstances it may be necessary to reset the control to its delivery settings using the access code
(see Chapter 6.6.4).
1.
In the "Parameter" menu, use the
2.
Press the
3.
Use the
4.
Press the
OK
keys to select parameter [86].
key to confirm your selection.
and
OK
and
keys to select value "1".
key to confirm your selection.
Î All parameters are reset to factory settings. The control system restarts.
Info values, such as the elapsed-hour meter, are not affected by this procedure.
6.6.4 Heating technician access code
Parameters only intended for use by the heating technician can be enabled for editing by entering the heating technician access
code. The parameters concerned are listed in Table 6-7, page 43 and Table 6-8, page 44.
Entering the access code
1.
In the "Parameter" menu, use the
2.
Press the
OK
and
keys to select parameter [98].
key to confirm your selection.
Î The display shows "0000", with the first digit flashing.
3.
Use the
and
4.
Press the
OK
keys to select the first number of the access code.
key to confirm your selection.
Î The entry is temporarily saved and the next digit begins to flash, indicating that this number can now be entered.
5.
Repeat the two input steps above until all 4 digits of the access code have been entered correctly.
Î If the code has been entered correctly, when the last number is confirmed the display will show "LoG". The protected
parameter levels are now enabled for the heating technician (see Figure 6-15).
Fig. 6-15
. 48
Visual confirmation, "heating technician logged in"
Î If the access code has been entered incorrectly, when the last number is confirmed the display will show "Err". Follow
the entry procedure again from the beginning.
If no entry is made for an extended period (exit time), in the interests of security the parameters intended for the
heating technician will be blocked once more. The decimal point of the left-hand digit on the display indicates
whether technician values can still be accessed (point lit up) or whether they have been blocked again.
The heating technician access code must be entered again. The exit time can be set via parameter [30].
FA ROTEX ESU - 07/2008
45
6 ROTEX control system ALPHA+ 23R
6.6.5 Setting heating characteristics
Heating characteristics can be set for the direct circuit (circuit 1) and the mixed circuit (circuit 2).
The heating characteristics are used to adjust the heating output to the building conditions in accordance with the relevant
external temperature. Generally speaking, the steepness of the heating characteristics describes the ratio of the flow
temperature change to the external temperature change.
The heating characteristics apply within the minimum and maximum temperature limits that have been set for the corresponding
heating circuit.
The room temperature measured in the living area may differ from the desired room temperature; these deviations can be kept to
a minimum by installing a room temperature control.
Do not make any corrections to the set values for 1 – 2 days, and then only make them in small increments.
All radiator thermostat valves must be fully opened prior to making the corrections.
Approximate setting values:
– Radiator and system 70: 1.4 to 1.6 (factory setting 1.5)
– Underfloor heating system: 0.7 to 1.0 (factory setting 1.0)
Example of how to set the heating characteristic
In the example, the steepness of the heating characteristic for the direct circuit is changed from 1.5 to 1.3.
Reset /
+
OK
>5sec
h
1
h
2
1.00
1.50
h
OK
3sec.
1
1.30
OK
OK
1.50
1.30
OK
Reset
OK
3sec.
Fig. 6-16
1.
Setting the heating characteristic for the direct circuit (example using the factory setting)
Set the "Default settings" rotary switch to position
, press the
OK
key and hold it down for longer than 5 s.
Î The first heating circuit (in this example, the direct circuit) is displayed. The display alternates between the heating
circuit and the value representing the steepness of the heating characteristic (1.50 in the example).
2.
Press the
OK
key to confirm your selection.
Î The value 1.50 is displayed for the steepness of the heating characteristic.
3.
Use the
4.
Press the
key to reduce the steepness of the heating characteristic to 1.30.
OK
key to save your entry.
Î The value 1.30 is displayed for the steepness of the heating characteristic.
Set the other heating circuits or exit the setting by pressing the
46
OK
key and holding it down for longer than 3 s.
FA ROTEX ESU - 07/2008
TV (°C)
2,00
2,25
105
2,50
3,50
3,25
3,00
2,75
6 ROTEX control system ALPHA+ 23R
1,75
95
1,50
85
1,25
75
1,00
65
0,75
55
0,50
45
35
30
25
0,20
25
20
20
15
10
-10
-15
-20
TR (°C)
External temperature
Fig. 6-17
-5
0
Ta (°C)
15
Ta
5
10
TV
Flow temperature
TR
Room temperature
Heating characteristic curve
6.6.6 Automatic summer switch-off
This function only has an effect in the
,
and
automatic programmes.
• Set the summer switch-off temperature by changing parameter [29].
If the external temperature exceeds the set summer switch-off temperature, the heating circuits will be
deactivated automatically; i. e. the pumps are switched off, the mixer closed and the switch valve switched
to warm water.
6.6.7 Setting hot water mode
Activating and deactivating hot water mode
• You activate and deactivate hot water mode manually by changing parameter [2].
CAUTION:
If the Legionella protection function is activated, the hot water temperature may temporarily exceed 65 °C.
• If hot water is required during the disinfection phase, it must be mixed with cold water.
If the ROTEX ALPHA+ 23R detects a storage tank sensor on ROTEX ESU start-up, the warm water mode is
activated automatically. If a storage tank sensor is connected subsequently, the hot water function must be
activated via parameter [2].
FA ROTEX ESU - 07/2008
47
6 ROTEX control system ALPHA+ 23R
Setting the maximum hot water temperature
• Set the maximum hot water temperature limit by changing parameter [4].
CAUTION:
If the Legionella protection function is activated, the hot water temperature may temporarily exceed 65 °C.
• If hot water is required during the disinfection phase, it must be mixed with cold water.
Setting the energy-saving hot water temperature
In order to minimise standby losses relating to the hot water storage tank, yet still maintain a comfortable minimum hot water
temperature, it is possible to set a temperature which the hot water storage tank must not fall below during economy mode
phases.
• Set the energy-saving hot water temperature by changing parameter [7].
If the ST/OT contact is open, this temperature is maintained (only applies to automatic programmes 1 – 3 and
"reduced heating mode").
6.6.8 Setting the maximum flow temperature
The flow temperature is the temperature the water is heated to before it is introduced into the heating circuit. Each heating circuit
has its own maximum flow temperature.
• Set the maximum flow temperature by changing the relevant parameter (see Table 6-9).
Direct heating circuit/Mixer circuit
Parameter
Name
Maximum setting limit
Maximum flow temperature
95 °C
[12]*
Flow temperature, manufacturer
≤ Maximum flow temperature
[13]/[34]
Flow temperature, heating technician
≤ Maximum flow temperature, manufacturer
[28]/[35]
Flow heating curve at maximum temperature
≤ Maximum flow temperature, heating technician
(minimum 15 °C)
Note: Mixer temperatures are dealt with in the same way.
Tab. 6-9
* Parameter can only be set by ROTEX.
Dependencies between flow temperatures and the direct circuit
Hot water circuit
Parameter
Name
Maximum setting limit
Maximum hot water temperature
95 °C
[12]*
Flow temperature, manufacturer
[3]*
Hot water temperature, manufacturer
≤ Maximum flow temperature
≤ Maximum flow temperature,
manufacturer + 5 °C
[4]
Hot water temperature, heating technician
[5]
Hot water, user
≤ Maximum hot water temperature, manufacturer
≤ Maximum hot water temperature,
heating technician
[7]
Hot water temperature, energy-saving
[6]*
Absolute minimum hot water temperature
≤ Maximum hot water temperature, user
≤ Maximum hot water temperature,
energy-saving (minimum 2 °C)
* Parameter can only be set by ROTEX.
Tab. 6-10 Dependencies between flow temperatures and the hot water circuit
48
FA ROTEX ESU - 07/2008
6 ROTEX control system ALPHA+ 23R
3
4
5
Hot water, OEM max.
Hot water, HE max.
Hot water, operator
Fig. 6-18
6
7
8
Hot water, absolute min.
Hot water, energy-saving
Switch hysteresis warm water
A
B
t
Ts
Off-peak tariff
Standard tariff
Time
Storage tank temperature
Dependencies between hot water parameters
The temperature can only be maintained if a heating output has been set for hot water at the standard tariff (see Chapter 3.10,
page 19).
6.6.9 Manual hot water recharging
The flow temperature is maintained at the defined maximum boiler temperature during hot water recharging.
The storage tank is heated up to not more than the set warm water temperature.
The heating output for hot water recharging is based on the setting at the ST/OT contact.
The power company charges the warm water boost charge during the standard tariff period (ST-/OT contact
open) at an accordingly higher tariff.
• Set the rotary switch (II) to position
.
• Press the
and
keys simultaneously and perform hot water
recharging within 60 min.
During hot water recharging, the display alternates between the time
remaining for recharging and the flow temperature.
In the interests of safety, after 60 min the control automatically returns to the
previously selected operating mode. Hot water recharging may then have to
be restarted. To abort the function, all you have to do is press the
and
keys simultaneously.
+
V
68
Fig. 6-19
FA ROTEX ESU - 07/2008
48
59:59
Activation of manual hot water recharging
49
6 ROTEX control system ALPHA+ 23R
6.6.10 Legionella protection
Thermal disinfection is carried out to prevent the hot water storage tank becoming contaminated with bacteria.
The storage tank is heated up to a temperature of 65 °C just once. This temperature is then maintained for at least 10 min.
CAUTION:
If hot water is used during the disinfection phase, there is a risk of fluctuations in the hot water storage tank
temperature and, thus, of scalding.
• If hot water is required during the disinfection phase, it must be mixed with cold water.
The maximum hot water temperature set by the user or the heating technician is ignored when hot water is
heated for disinfection purposes.
ESU
It must be ensured that charging can take place at the times specified below.
• Set the disinfection phase by changing parameter [2].
– 2 = The hot water system is disinfected once a week, at the changeover from Friday to Saturday
(day 5 to day 6) at 00:00.
– 3 = Disinfection starts at every changeover from one day to the next.
50
FA ROTEX ESU - 07/2008
7 Electric heat generator
7.1
7
Electric heat generator
Design and brief
description
9 13
9
3
11
14
8
2
12
1
4
14
5
Fig. 7-1
7
9
10
2
6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Stainless steel pipe
Connection cover
Tie-rod
Electric tubular radiator 1 – 3 kW
Electric tubular radiator 2 – 3 kW
Electric tubular radiator 3 – 3 kW
Push-on connections for tubular radiators
Earth connection
Safety temperature limiter (STL) of the tubular
radiator
Return connection
Flow connection
Flow temperature sensor
Return flow temperature sensor
STL heat generator flow
Top view on the ROTEX ESU with open heat generator cover and partially removed heat insulation
The electric heat generator of the E-SolarUnit is installed in a heat-insulated plastic housing behind the boiler control panel on the
cover of the heat storage tank. It consists of a stainless steel pipe surrounded by three tubular radiators. The welded tubular
radiators each heat the heating water with an output of 3 kW.
The tubular radiators are controlled by the heating controller. The ROTEX ALPHA+ 23R electronics monitor the flow and storage
tank temperatures against user settings and transfer a heat request signal to the relay board, if necessary. The relay board then
enables the tubular radiators in accordance with the operating mode, tariff type and corresponding output setting.
Each tubular radiator is protected from overheating by a safety temperature limiter (STL). The flow temperature sensor is
screwed into the flow connection cap, meaning it is positioned directly in the water flow. Thus, even if heat consumption is low,
any increase in temperature is detected quickly enough to switch the tubular radiators off before the safety temperature limiter
function is triggered. In case of a very rapid rise in temperature due to a malfunction, an additional STL cuts the heat generator
flow switching power of the power circuit board of the control panel.
7.2
Load compensation of switching contacts
The ROTEX ESU electronics consider the number of internal relay contacts and stores the operation time of each contact.
Requests made in partial-load operation are assigned to the switching contacts with shorter operating times.
In partial-load operation, the output remains constant but the heating windings switched differ from one
switching operation to the next. This must be taken into account when performing tests on the unit.
7.3
Fault shutdown of tubular radiators
A fault shutdown occurs if the temperature at the tubular radiator exceeds 200 °C.
This situation can arise if
 The heating circuit pump fails
 The heating system is not sufficiently filled with water (water shortage)
 The bypass (see Figure 2.1, page 8, pos. 27) is blocked or
 The tubular radiator is faulty
FA ROTEX ESU - 07/2008
51
7 Electric heat generator
Releasing the safety temperature limiter (STL)
The controller display will not necessarily indicate that a safety fault shutdown has occurred for one or two
tubular radiators. The malfunction is only indicated if the temperature still has not increased a long time after
a heat request was made.
A relatively easy way to check whether a tubular radiator is working or not, without having to open the unit,
is to look at the electricity meter. A tubular radiator consumes 0.05 kWh of power every minute.
1.
Allow the heat generator to cool down sufficiently.
2.
Error detection and elimination.
3.
Open the electric heat generator housing.
4.
On the STL, use a screwdriver, for example, to press
the metal flag that is protruding between the push-on
connections down hard.
Fig. 7-2
7.4
STL with protruding metal flag
Fault shutdown of the power circuit board
A fault shutdown occurs if the temperature exceeds 105 °C in the flow.
This situation can arise if
 the heating circuit pump fails
 if the overflow pipe is clogged
 there is a defect (controller, power circuit board etc.)
 the control parameters are set incorrectly (e.g. incorrect device type)
The STL disconnects the power circuit board from the power supply and thus, the tubular radiators as well. The controls and the
pump continue to operate. The controller does not necessarily display the fault shutdown.
Fault correction
1.
Allow the heat generator to cool down sufficiently.
2.
Error detection and elimination.
3.
Unlock STL on the control panel. By pressing the red
button until a clicking sound can be heard.
Fig. 7-3
52
STL left control panel side
FA ROTEX ESU - 07/2008
8 Hydraulic connection
8.1
8
Hydraulic
connection
Important information
on the
hydraulic connection
In order to prevent injuries and material damage occurring, take note of the precautions below which relate to the hydraulic
system connection of the ROTEX E-SolarUnit.
Scalding protection
During operation of the ROTEX E-SolarUnit, the storage tank temperature may exceed 60 °C, particularly when solar power is
used. To prevent scalding injuries occurring, install scalding protection in the system (hot water mixer device,
e. g. VTA32
15 60 16).
Corrosion protection
In a few regions, the water utility company supplies corrosive domestic water, which can result in corrosion damage even if highquality stainless steel is used. Ask your water utility whether the use of hot water storage tanks made from stainless steel results
in problems with corrosion in your area.
Suitable water treatment may be needed.
8.2
Storage tank
Design
– All plastic, double shell design (corrosion-free).
– Space between the internal and external tank filled with foam to give excellent heat insulation (low surface losses).
– External wall 3 – 4 mm thick (impact-resistant and shockproof).
Method of operation
The pressureless storage water serves as heat storage medium. Useful heat is supplied and removed via the spiral heat exchanger,
which is made from a stainless steel corrugated pipe (1.4404), and is completely immersed in the storage tank water.
The hot water zone in the storage tank acts as a heat storage tank and flow heater combined (see Figure 2-2, page 9). The cold
water which flows out when the hot water is removed is first routed to the storage tank at the very bottom of the heat exchanger,
where it cools the lower area of the storage tank down as much as possible. If necessary, the hot water zone is heated up by the
electric heat generator. Water flows through the heat exchanger for storage charging (SL-WT) from top to bottom. This improves
efficiency and the yield of the solar heating system. On its way to the top, the domestic water continuously absorbs the heat of
the storage tank water. Since the flow direction makes use of the counter flow principle, and the heat exchanger is shaped like
a spiral, there is definite temperature stratification within the storage tank. As high temperatures can be maintained for a very
long time in the upper section of the storage tank, a high hot water output is achieved even if water is drawn off over a long
period of time.
– With the ROTEX ESU the SL-WT ends about 40 cm above the bottom of the tank. Only the hot water zone above that point
is heated by the boiler. The water below that point in the tank is heated by solar power alone.
Water hygiene
Separating the unpressurised storage tank water from the hot water flowing in the corrugated pipe heat exchanger ensures that
the ROTEX ESU delivers optimum levels of hygiene:
– There are no zones with a low flow rate or zones that are not heated on the hot water side.
– 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).
Heating storage tank water
During initial start-up, the storage tank is filled once with unpressurised storage tank water, which is then never changed.
The storage tank water can be heated in various ways:
– By the integrated electric heat generator
– Via an additional solar heating system (ROTEX Solaris system) that is connected directly to the unpressurised area
– Via an additional heat source (e. g. hot water heating pump) that is connected directly to the unpressurised area
Company ROTEX ESU - 07/2008
53
8 Hydraulic connection
Maintenance
Thermal and pressure expansion and the high flow rates in the heat exchangers cause limescale residue to peel away; this residue
is rinsed out and is not deposited. The limescale-causing components that are present in the water can only be released once, in
the water you use to fill the storage tank. Thanks to the smooth surface of the stainless steel corrugated pipe heat exchanger,
no limescale crust forms (no reduction in heat transfer performance over time).
No corrosion protection equipment is required (such as expendable anodes). This means that associated maintenance work,
e.g. changing the protective anodes or cleaning the storage tank, does not need to be carried out. During the yearly inspection
only the filling level is checked and refilled if needed (see Chapter 9).
8.3
Hydraulic system connection
8.3.1 Short designations used in connection diagrams
Short des.
ROTEX ESU 509
1
2
3
4
PK
UV1
tWW
tV
tR
tAU
SV
5
AMK1
PMI
MI
tMI
7
8
SK
RPS3
PS1
PS2
Tab. 8-1
Meaning
E-SolarUnit with solar heating support
Cold water
Hot water
Heating flow
Heating return flow
Boiler circuit pump
3-way diverter valve
Storage tank temperature sensor
Heating flow temperature sensor
Heating return flow temperature sensor
External temperature sensor
Safety pressure relief valve
Mixer circuit
Mixer group
Mixer circuit pump
3-way mixer with drive motor
Mixer circuit flow temperature sensor
Non-return valve, return flow inhibitor
Solar circuit
High-performance flat solar panel
Solaris control and pump unit
Duty pump
Booster pump
Comment
ROTEX ESU 509
Included in the scope of delivery of the ROTEX ESU
Included in the scope of delivery of the ROTEX ESU
Included in the scope of delivery of the ROTEX ESU
Included in the scope of delivery of the ROTEX ESU
Included in the scope of delivery of the ROTEX ESU
Included in the scope of delivery of the ROTEX ESU
Included in the scope of delivery of the ROTEX ESU
Optional
Accessories
15 60 44
Included in the AMK1 scope of delivery
Included in the AMK1 scope of delivery
Accessories
15 60 62
Provided by customer
Optional
Accessories
Accessories
16 41 06 - 44
Included in the RPS3 scope of delivery
Included in the RPS3 scope of delivery
Short designations used in hydraulic diagrams (1)
Short des.
tS, R
tS
tS, V
Meaning
Solaris return flow temperature sensor
Solaris storage tank temperature sensor
Solaris flow temperature sensor
tK
Solaris panel temperature sensor
FLS
VS
ÜV
WE
PWE
tWE
UV2
SCS-TR
Flow sensor
Scalding protection VTA 32
Bypass valve
External heat generator (e. g. wood pellet boiler, heating pump)
Pump for external heat generator circuit
Temperature sensor for external heat generator
3-way diverter valve
Thermostat controller
Disconnecting the standard connection – UV1 and heating pump PK must be
taken out of the unit and reconnected outside it.
Provided by customer
Tab. 8-2
54
Order no.
15 70 50 - 44
Comment
Order no.
Included in the RPS3 scope of delivery
Included in the RPS3 scope of delivery
Included in the RPS3 scope of delivery
Included in the Connect AB panel connection set scope
of delivery
Accessories
16 41 07
Accessories
15 60 15
Provided by customer
Provided by customer
Provided by customer
Included in the SCS-TR scope of delivery
Accessories
15 60 34
Accessories
16 41 30
Short designations used in hydraulic diagrams (2)
Company ROTEX ESU - 07/2008
8 Hydraulic connection
8.3.2 ROTEX E-SolarUnit with solar heating support
tK
2
B
A
tMI
UV1
M
tV
AB
7
PMI
tR
PK
FLS
tS,V
tAU
5
AMK1
1
1300
700
M
SK
8
VS
2
MI
2-5
4
3
tWW
RPS3
tS
PS2
PS1
7
Fig. 8-1
010.000 0442
tS,R
SV
ESU 509
Standard connection diagram for the ROTEX E-SolarUnit with solar heating support
8.3.3 ROTEX E-SolarUnit with integrated wood boiler
tK
2-5
A
2
7
tMI
AMK1
UV1 tR
M
tV
PK
7
7
Fig. 8-2
AB
B
A
UV2
M
tAU
tWE
tWW
SCS-TR
PWE
RPS3
WE
tS
SV
FLS
tS,V
1
1300
M
8
700
PMI
MI
B
AB
5
4
3
VS
PS2
PS1
tS,R
ESU 509
010.000 0471
2
ÜV
SK
Standard connection diagram for the ROTEX E-SolarUnit with integrated wood boiler
Other connection diagrams can be found on the ROTEX Heating Systems GmbH website (see www.rotex.de).
Company ROTEX ESU - 07/2008
55
9 Service and maintenance
9.1
9
and maintenance
General overview
ofService
service
and maintenance
Regular inspection and maintenance of the heating system reduces energy consumption and ensures a long life and smooth
operation.
Authorised and trained heating experts must carry out servicing and maintenance every two years, before
heating if possible, in order to preclude malfunctions which may occur during heating.
To ensure that servicing and maintenance is performed on a regular basis, ROTEX recommends that you enter
into a service and maintenance contract.
At short regular intervals:
– check the storage tank fill level and
– refill water if needed,
– cleaning of the storage tank and the cover.
Checks during bi-yearly inspection:
– Visually inspect, check and test the general condition of the heating system.
– Change worn parts.
9.2
Service and maintenance tasks
DANGER!
Danger of death due to electric shock
Live parts can cause fatal burns or injuries on contact.
• Before starting any maintenance work on the central unit disconnect it from the power supply (switch off
fuse, main switch) and secure it against unintentional restart.
WARNING!
Danger of burning due to hot surfaces
• Allow for sufficient cooling of the ROTEX ESU before performing any maintenance and inspection work.
• Wear protective gloves.
Removing the protective cover
The protective cover on the top of the storage tank must be removed in order to carry out servicing and maintenance work.
1
2
3
Fig. 9-1
Remove the fixing screws.
Tilt the protective cover.
Take the protective cover off by lifting it towards the front
of the tank.
Remove the protective cover
Cleaning the protective cover and storage tank
• The low-maintenance plastic only needs to be cleaned with a soft cloth and a mild detergent.
• Do not use cleaning agents containing aggressive solvents, as this will damage the surface of the boiler control panel.
56
FA ROTEX ESU - 07/2008
9 Service and maintenance
9.2.1 Checking the connections and pipes
WARNING!
Danger of death due to electric shock
All work performed on live components must be carried out in accordance with the proper procedures,
otherwise there may be a danger to the life and health of individuals and the function of the E-SolarUnit may
be impaired.
• Only properly authorised heating engineers may rectify faults on the live components of the electric heat
generator.
• Check all components and connections through which water flows for leakage and ensure that they are sound. If damaged,
determine the cause and change the damaged parts.
• Check all electrical components, connections, and pipes. Repair damaged parts.
9.2.2 Checking and cleaning the safety overflow and drain hose
The safety overflow connection and drain pipe must be free of impurities.
• If the Solaris system is connected and operational,
switch it off and drain the solar panels.
• Open the overflow drain (connection and drain pipe).
• Check that the overflow drain is not blocked and clean it,
if necessary.
• Unscrew the overflow hose.
• Visually inspect the tank fill level (water level at drain
edge).
• If necessary, correct the fill level; determine the reason
for the low water level and remedy it.
• Check the overflow hose connection and drain section
for leakage, unobstructed flow and gradient.
FA ROTEX ESU - 07/2008
Fig. 9-2
Check the safety overflow
57
10 Faults and malfunctions
10
10.1 Detecting faults
Faults and malfunctions
The electronic control detects, saves and displays faults:
– an error detected by the ROTEX ALPHA+ 23R with an error code on the display (explanation of the error codes see
chapter 10.3).
Displaying faults
When a fault occurs, the control's display alternates between showing an "E" and a number on the left, and a fault code on the
right.
16-0
E1
Fig. 10-1
Example error display "E 1" - first error
Fig. 10-2
Example fault display "fault code 16-0"
Reading the fault memory
If multiple faults occur, the integrated fault memory saves the last 10 faults that are still present. These faults can be read via
the info values. You can reach them as follows:
1.
Set the "Default settings" rotary switch to position
2.
Using the
and
i
.
keys to navigate to the info value E1 (Table 6-5, page 41 and Table 6-6, page 42).
Î The display alternates between an "E" with a number on the left, and a fault code on the right.
3.
You can display the ten last error codes using the
and
keys (explanation of the error codes see Table 10-1).
4.
Exit system information by setting the "Default settings" rotary switch to a different position.
10.2 Troubleshooting
• Find and resolve the cause of the malfunction. If you cannot ascertain the cause of the malfunction, contact ROTEX
Technical Customer Services.
WARNING!
Improper malfunction location and correction can represent a health and safety risk endangering human life
and adversely affect the operation of the heating system.
• Only heating experts authorised and trained by a gas or energy utilities company may perform work on
the electrical system or on components that carry gas or flue gas.
10.2.1 Individual reset
• Press the OK key on the control and hold it down for longer than 3 s to reset the fault. If a malfunction reoccurs following
this reset, the heating system must be checked by a heating expert (e. g. flue system, fuel supply).
10.2.2 General reset
The AIpha controller allows to reset the controller to the factory defaults (procedure see Chapter 6.6.3, page 45).
If a malfunction re-occurs after that, the heating system must be inspected by a technician.
58
FA ROTEX ESU - 07/2008
10 Faults and malfunctions
10.3 Fault codes
Fault code
00-X
(X = 0 ... 9)
Tab. 10-1
Designation
Type of fault
Comments
Internal fault
Interruption
The processor has detected an undefined condition. An
entry is added to the fault register. The system shuts down.
10-0
External temperature sensor
Interruption
The system resumes operation with a fixed external
temperature of 0 °C.
10-1
External temperature sensor
Short circuit
The system resumes operation with a fixed external
temperature of 0 °C.
11-0
Flow temperature sensor
Interruption
11-1
Flow temperature sensor
Short circuit
12-0
Mixer circuit flow sensor
Interruption
ROTEX ESU switches the mixer circuit pump and the
mixer motor power off
12-1
Mixer circuit flow sensor
Short circuit
ROTEX ESU switches the mixer circuit pump and the
mixer motor power off
13-0
Hot water (storage tank) sensor
Interruption
13-1
Hot water (storage tank) sensor
Short circuit
16-0
set to incorrect device type (oil)
No switch-on
17-0
Return flow temperature sensor
Interruption
17-1
Return flow temperature sensor
Short circuit
30-2
Heat generator
No switch-off
30-3
Heat generator
No switch-on
70-6
set to incorrect device type (gas)
No switch-on
Change by parameter 1.
99-9
Undervoltage
Interruption
The mains voltage falls below 190 V for at least 1 s.
The processor backs up all data and enters hibernation
mode. All relay contacts are released. If the mains voltage
rises above 195 V again for at least 5 s, this triggers a
restart.
Change by parameter 1.
uuuu
Sensor interruption
nnnn
Sensor short circuit
Error codes of the ROTEX ESU on the ROTEX ALPHA+ 23R
FA ROTEX ESU - 07/2008
59
10 Faults and malfunctions
10.4 Malfunctions
Malfunction
Possible cause
Possible solution
Heating system inoperable
- Main switch not lit up
- No display
No mains voltage
•
•
•
•
Heating does not warm up
Central heating standby mode disabled
- Incorrect controller setting
• Check the operating mode setting.
• Check the timer progr. or request parameters.
No heating mode despite correct
controller settings
Storage tank charging runs for too long
• Check whether storage tank charging is active.
Storage tank charging can be temporarily
interrupted by selecting a lower target hot water
temperature. If this leads to an extended period
where the temperature drops below a
comfortable level, select parallel operation
instead.
Unit in the summer switch-off state
• Correct the summer switch-off temperature or
building type setting.
Heating mode DIP switch is OFF during the tariff time
concerned
• See the "Heat generator output too low"
malfunction.
Turning on ROTEX ESU main switch
Switch the heating room main switch on.
Replace the boiler control panel fuse.
Replace the line connection fuse.
Diverter valve drive inoperable – Storage tank charging • Check the valve drive/insert the connector,
position
change if faulty.
The valve drive can be removed temporarily, but
storage tank charging will then be impossible.
Heating does not warm up enough
Heating pump shutdown – STLs have been triggered
• Release the STLs (see Chapter 7.3, page 51).
• Check the pump/insert the connector, change if
faulty.
Heating characteristic too low
• Increase the parameter value.
Heat generator output too low
• See the "Heat generator output too low"
malfunction.
Hot water does not warm up
Storage charging standby switched off (e. g. timer is in • Check the operating mode setting.
economy phase)
• Check the request parameters.
Hot water does not warm up enough
Storage tank charging temperature too low
• Increase the target hot water temperature.
Draw-off rate too high
• Reduce the draw-off rate, limit throughput
Heat generator output too low
• See the "Heat generator output too low"
malfunction.
DIP switch set incorrectly
• Adjust the output setting.
• Take note of the timer programme and tariff time.
Output limited by DIP switch for standard tariff time
• No fault: ROTEX ESU can require performance
limitation during standard tariff periods.
At least one STL has been triggered. Could have been
caused by pump shutdown, water shortage or blocked
bypass.
• Have an electrician check the electric heat
generator.
Heat demand too high
• Determine the cause of the excessive heat
demand (e. g. windows open all the time, long
storage tank charging times due to high
circulation losses, incorrect dimensioning, etc.)
and remedy it if possible.
Heat generator output too low
Tab. 10-2 Possible malfunctions of the ROTEX ESU
60
FA ROTEX ESU - 07/2008
11 Taking out of service
11
Taking out of service
11.1 Temporary shutdown
CAUTION!
Frost may cause material damage.
A deactivated heating system can freeze due to frost and consequently be damaged.
• Drain the heating system that is shut down if there is danger of frost.
• If there is a danger of frost and your heating system has not been drained, ensure that power is still supplied
to it and leave the main switch switched on.
If the heating and hot water supply will not be needed for a long period, the ROTEX E-SolarUnit can be temporarily shut down.
However, ROTEX recommends to set the ROTEX ESU to standby mode (see Chapter 6.1, page 32) and to sign off heating-, and
warm water supply. The heating system is then protected from frost. The pumps and valve protection functions are active.
If a continued supply of power is not guaranteed when there is a danger of frost, the ROTEX ESU must be drained.
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 ESU does not have to be drained, provided that the storage tank
temperature is monitored regularly and does not fall below +3 °C.
However, using this method means that the connected heat distribution system is not protected from frost.
Draining the storage tank
• Switch off the main switch and secure against restarting.
• Connect the hose and hose connection from the accessories set to the rear of the solar panel (only this particular hose will
open the foot valve automatically). If a Solaris system is connected, use the KFE cock on the rear of the Solaris.
• Drain the tank's water content.
Draining the heating circuit and domestic water heat exchangers
•
•
•
•
Switch off the main switch and secure against restarting.
Disconnect the heating flow and return flow, as well as the cold water inflow and the hot water outflow.
Connect the drain hoses so that the hose opening is located just above the floor of the exchanger.
Drain the heat exchanger using the siphoning technique.
11.2 Final shutdown and disposal
For final shutdown of the ROTEX ESU, it must be
• taken out of service (see Chapter 11.1),
• disconnected from all electrical and water connections,
• disposed off in a professional manner.
Recommendations for disposal
The ROTEX ESU has an environmentally friendly design. During the disposal process, the only waste accrued is that which can
be used for material or thermal recycling. The materials that are suitable for recycling can be separated so that they are unmixed.
Thanks to the environmentally friendly design of the ROTEX ESU, ROTEX has complied with requirements for
environmentally sound disposal. Proper disposal in compliance with the respective national regulations of the
country of use is the responsibility of the user/owner.
FA ROTEX ESU - 07/2008
61
12 Technical data
Basic data
12
Technical data
Pos. in Fig. 12-1
Total storage capacity
Unit
litres
500
kg
110
Total filled weight
kg
610
Dimensions (L x B x H)
cm
79 x 79 x 181
Maximum permissible storage tank water temperature
°C
85
Average hourly temperature drop
K/h
0.1
kWh/24h
1.8
bar
10/10
Empty weight
6
Standby heating power
Maximum operating pressure, heating/domestic water
7/9
Material for all heat exchangers
Stainless steel 1.4404
Domestic hot water
Domestic water capacity
litres
2
24.5
Domestic water heat exchanger surface
m
Average specific thermal output
W/K
2470
Pressure drop in the domestic water heat
exchanger (at a withdrawal rate of 15 l/min)
mbar
185
litres
10.4
5.5
Storage tank charging heat exchanger (stainless steel)
Water content heat exchanger
2
Surface of charging heat exchanger
m
Average specific thermal output
W/K
1040
Pressure drop in heat exchanger 1
(at a flow rate of 1000 l/h)
mbar
96
Heat exchanger surface area
m2
0.43
Average specific thermal output
W/K
200
Pressure drop in heat exchanger
(at a flow rate of 1000 l/h)
mbar
18
2.3
Solar heating support
Tab. 12-1 Basic data for the ROTEX E-SolarUnit
Thermal output data
NL efficiency characteristic acc. to DIN 4708
Pos. in Fig. 12-1
Unit
1)
D value, spec. water flow acc. to EN 6252)
1.8
10
l/min
22
Continuous output QD according to DIN 4708
kW
9
Maximum draw-off rate for a duration of 10 min
(TTK= 10 °C/TWW=40 °C/TSP= 60 °C)
l/min
19
Hot water quantity without reheating with up to 15 l/min
draw-off rate (T KW = 10 °C/TWW = 40 °C/TSP = 60 °C)
litres
220
Hot water volume with reheating at a draw-off rate of 15
l/min (TKW= 10 °C/TWW= 40 °C/TSP= 60 °C)
litres
270
Temporary water volume in 10 min3)
litres
190
Tab. 12-2 Thermal output data for the ROTEX E-SolarUnit
1)
2)
3)
62
Recharging with nominal output, flow temp. TV = 80 °C, initial storage tank temp. TSP= 65 °C, cold water temp. TKW = 10 °C, hot water temp. TWW = 45 °C
The specif. water flow acc. to EN 625 is the domestic water flow, at an average temperature increase of 30 K, which the ROTEX ESU can supply if two draw-off
procedures each of 10 minutes duration are performed one after the other, assuming a charging temp. of 65 °C. A delay of 20 minutes between the two draw-off
procedures is usually assumed. The ROTEX ESU also achieves this value even if the delay is shorter.
Recharging with nominal output, initial storage tank temp. TSP = 60 °C, cold water temp. TKW = 10 °C, hot water temp. TWW = 40 °C
FA ROTEX ESU - 07/2008
12 Technical data
Heat generator characteristic
data
Pos. in Fig. 12-1
Unit
Nominal output
2
kW
Operating voltage
3
3-phase, 230 V/50 Hz
Protection type
5
IP 20
3-9
Tab. 12-3 Heat generator characteristic data
Nominal values ROTEX ALPHA+ 23R
Unit
Mains voltage
Power consumption during standby
230 V, 50 Hz
W
6
Back-up fuse
Max. 6.3 AT
Contact rating of output relay
A
Max. 2
Ambient temperature
°C
0 to 50
Storage temperature
-20 to 60
Protection type
IP 20
Software class
A
Housing dimensions (W x H x D)
mm
144 x 96 x 75
Housing material
Tab. 12-4
ABS with antistatic agent
Technical data ROTEX ALPHA+ 23R
007.1502544
1
2
3
4
5
6
Type
Rated thermal load
Voltage supply
Elec. power consumption
Degree of protection
Empty weight
Fig. 12-1
7
8
9
10
11
Max. permissible operating pressure
Max. permissible operating temperature
Max. operating pressure
D value
Manufacturer number
(to be quoted in the event of complaints or queries)
Data on the type plate at the bottom right of the storage tank (for information on the different points, see Tab. 12-1 to Tab. 12-3)
Pipe connections
Unit
Hot and cold water
inches
1" ET
Heating flow and return flow (with ball cock)
inches
1" IT
Tab. 12-5 Pipe connections
FA ROTEX ESU - 07/2008
63
12 Technical data
700
600
D pR / mbar
500
400
300
200
100
I
0
0
200
400
600
800
II
1000
1200
III
1400
1600
1800
2000
700
800
900
1000
mH / L/h
Δ pR/mbar = Residual delivery head in mbar
mH/ L/h
= Flow through heating system in litres per hour
Fig. 12-2
I = Stage 1
II = Stage 2
III = Stage 3
Residual delivery head ROTEX ESU 509 (heater side)
10
S= 20 K
S= 15 K
9
8
S= 10 K
Q / kW
7
6
5
4
3
2
1
0
0
100
200
300
400
500
600
mH / L/h
mH/ L/h
Q/kW
Fig. 12-3
64
= Flow rate in litres per hour
= Heating output in kW
S = Spread
Required flow rates depending on the heating output and the dimensioned temperature spread
FA ROTEX ESU - 07/2008
12 Technical data
mWW / L/h
1000
0
300
600
900
1200
1500
1800
0
5
10
15
mWW / L/min
20
25
30
D p / mbar
800
600
400
200
0
Δ p / mbar = Pressure drop in mbar
mWW / L/min = Flow in litres per minute
mWW/ L/h = Flow in litres per second
Fig. 12-4
Pressure drop in the hot water heat exchanger depending on the draw-off rate
25
mZ / L/min
20
15
12
10
5
0
VZ/L
mZ/ L/min
Fig. 12-5
FA ROTEX ESU - 07/2008
0
330
500
1000
VZ / L
= Max. draw-off volume in litres
= Draw-off rate in litres per minute
Flow temperature 80 °C
Cold water temperature 10 °C
1500
2000
Storage tank temperature 60 °C
Draw-off temperature 40 °C
Available draw-off volumes depending on the draw-off rate
65
12 Technical data
3500
RS / V
3000
2500
PTC
2000
1500
1000
-20
0
20
40
60
80
100
120
t / °C
t/°C
RS/Ω
Fig. 12-6
= Temperature in degrees Celsius
= Sensor resistance in ohms
Resistance characteristics of the PTC temperature sensors
Measured temperature in °C
Sensor type
–20
–10
0
10
20
30
40
50
60
70
80
90
100
3185
3396
110
120
Sensor resistance in ohms according to manufacturer's specifications
PTC
1386
1495
1630
1772
1922
2080
2254
2418
2598
2796
2982
Tab. 12-6 Resistance values of the PTC temperature sensors
66
FA ROTEX ESU - 07/2008
Fig. 12-7
E-SolarUnit wiring diagram
Connecting
cable colours
bl blue
br brown
ge yellow
gn green
gr grey
rt red
sw black
ws white
n.b. Contact not
assigned
12 Technical data
FA ROTEX ESU - 07/2008
67
13 x Accessories
13
13.1
Accessories temperature sensor
External
The external temperature sensor is supplied with the ROTEX ESU. It is tapped to the prepared sensor line, which is connected in
the control panel by delivery.
If no external temperature sensor is connected, the control sets the external working temperature value to 0 °C
by default.
13.2 Mixer circuit docking sensor
If a mixer circuit is to be connected, the TMKF (
15 60 62) mixer circuit docking sensor is required.
It is connected at the appropriate location on the boiler control panel (see the installation instructions for the heat generator in
question).
13.3 Room temperature control
Installing the RTR E (
17 51 26) room temperature control minimises deviations between the room temperature measured in
the living area and the desired room temperature.
The connection is made in the boiler control panel at the intended point (connector J8, terminals "1, 2"), on the room temperature
controller at the terminals "1" and "2". The "N" terminals are not connected.
°C
0
10
30
25
15
Fig. 13-1
68
RTR E room temperature control
FA ROTEX ESU - 07/2008
14 Notes
14
Notes
Individual settings for the "Automatic I" switching time programme
• Enter your switching time settings in the table below.
Heating circuit
Day
Switching time 1
Switching time 2
On
On
Off
Off
Tab. 14-1 Individual settings made by the user or the heating technician for the "Out at work" switching time programme
Individual parameter changes
• Enter your parameter changes in the table below.
Parameter no.
Old value
New value
Date
Comments
Tab. 14-2 Individual changes made to parameters by the user or the heating technician
FA ROTEX ESU - 07/2008
69
14 Notes
70
FA ROTEX ESU - 07/2008
15 List of keywords
15
A
Flow temperature . . . . . . . 43, 47, 48, 49
adjustment . . . . . . . . . . . . . . . . . . . 35
display . . . . . . . . . . . . . . . . . . 34, 35
Flow temperature sensor . . . . . . . 20, 27
Frost protection function . . . . . . . . . . . 32
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
List of keywords
Access code . . . . . . . . . . . . . . 40, 43, 45
Additional water . . . . . . . . . . . . . . . . . 14
Adjusting . . . . . . . . . . . . . . . . . . . . . . . 17
All . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
B
Bi-yearly inspection . . . . . . . . . . . . . . .
Boiler control panel . . . . . . . . . . . . . . .
installation . . . . . . . . . . . . . . . . . .
upgrade . . . . . . . . . . . . . . . . . . . . .
C
56
23
26
24
Changing . . . . . . . . . . . . . . . . . . . . . . . 29
Changing the central unit . . . . . . . . . . 30
Circulation pump . . . . . . . . . . . . . . . 8, 14
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 56
CLOCK TIME . . . . . . . . . . . . . . . . . 33, 36
COM socket . . . . . . . . . . . . . . . . . . . . 34
Components ROTEX ESU . . . . . . . . . . . . .8
Connecting . . . . . . . . . . . . . . . . . . . . . . .8
Connecting the temperature sensor . . . 16
Connecting the mixer circuit . . . . . . . . 17
Connection cables . . . . . . . . . . . . . . . . 26
Control panel cover . . . . . . . . . . . . . . . 30
G
Group malfunction lamp . . . . . . . . . . . . 23
H
I
D
E
F
Danger of frost . . . . . . . . . . . . . . . . . . 61
Decimal point . . . . . . . . . . . . . . . . . . . 45
Declaration of conformity . . . . . . . . . . . .2
Design ROTEX ESU . . . . . . . . . . . . . . . . .8
Dimensions . . . . . . . . . . . . . . . . . . 12, 62
Direct . . . . . . . . . . . . . . . . . . . . . . . . . 48
Direct heating circuit . . . . . . . . . . . . . . 48
Direct heating circuit pump . . . . . . . . . 41
Display . . . . . . . . . . . . . . . . . . . . . . . . 34
Disposal . . . . . . . . . . . . . . . . . . . . . . . 61
Diverter valve . . . . . . . . . . . . . . . . . . . 14
Domestic hot water technical data . . . 62
Draining . . . . . . . . . . . . . . . . . . . . . . . 61
Electrical
- connection . . . . . . . . . . . . . . . . . . 15
Electrical installation . . . . . . . . . . . . . . 15
Electronic control . . . . . . . . . . . . . 10, 32
Energy-saving hot water
temperature . . . . . . . . . . . . . . . . . . 48
Exit time . . . . . . . . . . . . . . . . . . . . . . . 45
External . . . . . . . . . . . . . . . . . . . . . . . 31
External temperature
sensor . . . . . . . . . . . . . . . . 16, 17, 68
Fault codes . . . . . . . . . . . . . . . . . . . . . 59
Fault shutdown
power circuit board . . . . . . . . . . . . 52
tubular radiators . . . . . . . . . . . . . . 51
Filling of the storage tank . . . . . . . . . . 18
Filling the heating system . . . . . . . 17, 18
Filling the storage tank charging
circuit . . . . . . . . . . . . . . . . . . . . . . 18
Filling water . . . . . . . . . . . . . . . . . . . . 14
FA ROTEX ESU - 07/2008
L
Heating circuit . . . . . . . . . . . . . . . 46, 48
Heating system draining . . . . . . . . . . . . 61
Hot water circuit . . . . . . . . . . . . . 37, 48
Hot water mode . . . . . . . . . . . . . . 32, 47
Hot water storage tank
technical data . . . . . . . . . . . . . . . . . 62
Hot water
temperature . . . . . . . .33, 34, 35, 41, 48
Hydraulic system connection . . 7, 54, 55
If . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Individual
parameters . . . . . . . . . . . . . . . . . . . 69
Individual parameter settings . . . . . . . . 69
Info value . . . . . . . . . .34, 40, 41, 42, 58
Installation area . . . . . . . . . . . . . . . . . . 11
Installation site . . . . . . . . . . . . . . . . . . . 11
Installing the unit . . . . . . . . . . . . . . . . . 11
Legionella protection . . . . . . . . . . . 43, 50
M
Mains switch . . . . . . . . . . . . . . . . 23, 31
Maintenance . . . . . . . . . . . . . . . . . 54, 56
Malfunctions . . . . . . . . . . . . . . . . 58, 60
Maximum flow temperature . . . . . 43, 48
Maximum hot water temperature . . . . . 48
Mixer circuit . . . . . . . . . . . . . . . . . . . . . 17
Mixer circuit docking sensor . . . . . . . . . 68
Mixer circuit flow sensor . . . . 16, 17, 59
Mixer circuit pump . . . . . . . . . . . . 41, 44
N
Normal . . . . . . . . . . . . . . . . . . . . . . . . . 35
Normal operating mode . . . . . . . . . . . . . 33
O
Operating elements . . . . . . . . . . . . 23, 32
Operating mode . . . . . . . . . . . . . . . . . . 10
Operating safety . . . . . . . . . . . . . . . . . . . 6
Operator . . . . . . . . . . . . . . . . . . . . . . . . 33
Optional sensors . . . . . . . . . . . . . . 20, 21
Overview . . . . . . . . . . . . . . . . . . . . . . . 41
R
Remove the protective cover . . . . . . . . 56
Required sensors . . . . . . . . . . . . . . . . . 20
Return flow temperature
sensor . . . . . . . . . . . . . . . 16, 20, 26
Room temperature . . . . . . . . . 17, 46, 68
Room temperature control . . . 43, 46, 68
Room thermostat . . . . . . . . . . . . . . . . . 17
S
Safety management . . . . . . . . . . . . . . . 10
Safety shutdown . . . . . . . . . . . . . . . . . 10
Scope of delivery . . . . . . . . . . . . . . . . . 11
Sensor faults . . . . . . . . . . . . . . . . . . . . 21
Service . . . . . . . . . . . . . . . . . . . . . . 56, 57
Service log . . . . . . . . . . . . . . . . . . . . . . 72
Shutdown . . . . . . . . . . . . . . . . . . . . . . 61
Start-up . . . . . . . . . . . . . . . . . . . . . . . . 20
- Requirements . . . . . . . . . . . . . . . . 20
adjustment . . . . . . . . . . . . . . . . . . . 21
checklist . . . . . . . . . . . . . . . . . . . . . 22
Storage . . . . . . . . . . . . . . . . . . . . . . . . 53
Storage tank . . . . . . . . . . . . . 18, 53, 61
Storage tank temperature
sensor . . . . . . . . . . . . . . . . . . . 16, 29
Storage tank water
heating . . . . . . . . . . . . . . . . . . . . . . 53
Summer switch-off . . . . . . . . . . . . 44, 47
Switching switching time
programme . . . . . . . . . . . . . . . . 32, 36
Switching time programme . . . . . . . . . . 32
switching time programme . . . . . . . . . . 32
Switching timer programme . . . . . . . . . 69
System information . . . . . . . . . . . . . . . 40
T
Target hot water temperature . . . . 33, 35
Target temperature hot water
storage tank . . . . . . . . . . . . . . . 33, 35
The . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Transport . . . . . . . . . . . . . . . . . . . . . . . 11
U
Unscrew . . . . . . . . . . . . . . . . . . . . 25, 26
Using solar power . . . . . . . . . . . . . . . . 10
W
Water connection . . . . . . . . . . . . . . . . . 13
Water hardness . . . . . . . . . . . . . . . . . . 14
Water shortage protection . . . . . . . . . . 14
WEEKDAY . . . . . . . . . . . . . . . 33, 34, 36
Wiring diagram . . . . . . . . . . . . . . . . . . . 31
P
Parameter . . . . . . . . . . . . . . . . . . . . . . . 33
setting . . . . . . . . . . . . . . . . . . . . . . 42
Pressure gauge . . . . . . . . . . . . . . . . . . . 23
Proper use . . . . . . . . . . . . . . . . . . . . . . . 6
71
16 Service log
16
Service log
Please enter the maintenance work carried out and the measured values in the service log.
Maintenance jobs
Initial start-up
1. Maintenance
2. Maintenance
3. Maintenance
4. Maintenance
Date
Checking fill level/
refilling storage tank water
Leakage testing heating pipe
connections
Leakage testing hot water pipe
connections
Checking electrical connections for
proper seating
Cleaning and testing the function
of the safety overflow
Cleaning the storage tank
and protective cover
Changes made to the control's adjustable parameters, plus other comments regarding the heating system
Signature
Comments
008.15 144 44_01 · Errors and technical modifications reserved · Original instructions 08.15 144 49_01 German
Date
72
FA ROTEX ESU - 07/2008
Download PDF
Similar pages