rotex e-solarunit · the rotex e-solarunit must only be used as a hot water heating system. the...

For certified companies

ROTEX E-SolarUnitElectric heat generator withstratified solar storage tank

Installation and maintenance instructions

Type Rated thermal output

ROTEX ESU 509 3–9 kW

Serial number

Customer

GBEdition 07/2008

Guarantee and conformity

2 FA ROTEX ESU - 07/2008

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, 01.05.2007Dr Eng. Franz GrammlingManaging Director

Contents

1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.1 Observing Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.2 Warning signs and explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.3 Avoid danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.4 Proper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.5 Instructions for operating safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1 Design and components of the ROTEX E-SolarUnit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2 Brief description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3 Set-up and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113.1 Transport and delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113.2 Installing the ROTEX E-SolarUnit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2.1 Selecting the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113.2.2 Installing the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.4 Water connection for heating and hot water pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133.5 Connecting the valve drive to the 3-way diverter valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143.6 Establishing an electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153.7 Temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.7.1 General instructions for the temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163.7.2 Connecting the temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.8 Optional connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173.8.1 Mixer circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173.8.2 Room thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.9 Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173.10 Setting the heating output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204.1 Initial start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204.2 Checklists for start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5 Boiler control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235.1 Operating elements on the boiler control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235.2 Changing the boiler control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245.3 Changing cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265.4 Changing sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5.4.1 Changing flow/return flow temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275.4.2 Changing the storage tank temperature sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.5 Changing the fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295.6 Installing and removing the central unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305.7 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6 ROTEX control system ALPHA+ 23R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326.2 Control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6.2.1 "Selection of operating mode" rotary switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326.2.2 "Default settings" rotary switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336.2.3 Operator keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336.2.4 Special functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6.3 Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346.4 COM socket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346.5 Default settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

6.5.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346.5.2 Normal operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356.5.3 Changing the correction value for the flow temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356.5.4 Setting the target hot water temperature for off-peak tariff charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356.5.5 Setting the time and weekday . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366.5.6 Switching timeprogramme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3FA ROTEX ESU - 07/2008

Contents

6.5.7 Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406.5.8 Querying system information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.6 System parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426.6.1 Setting parameters – Basic procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426.6.2 Overview of system parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436.6.3 Resetting parameters to factory settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456.6.4 Heating technician access code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456.6.5 Setting heating characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466.6.6 Automatic summer switch-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476.6.7 Setting hot water mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476.6.8 Setting the maximum flow temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486.6.9 Manual hot water recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496.6.10 Legionella protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

7 Electric heat generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517.1 Design and brief description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517.2 Load compensation of switching contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517.3 Fault shutdown of tubular radiators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517.4 Fault shutdown of the power circuit board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

8 Hydraulic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538.1 Important information on the hydraulic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538.2 Storage tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538.3 Hydraulic system connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

8.3.1 Short designations used in connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548.3.2 ROTEX E-SolarUnit with solar heating support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558.3.3 ROTEX E-SolarUnit with integrated wood boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

9 Service and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569.1 General overview of service and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .569.2 Service and maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

9.2.1 Checking the connections and pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579.2.2 Checking and cleaning the safety overflow and drain hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

10 x Faults and malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5810.1 Detecting faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5810.2 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

10.2.1 Individual reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5810.2.2 General reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

10.3 Fault codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5910.4 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

11 Taking out of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6111.1 Temporary shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6111.2 Final shutdown and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

12 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

13 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6813.1 External temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6813.2 Mixer circuit docking sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6813.3 Room temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

14 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

15 List of keywords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

16 Service log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72


1 Safety

1 Safety1.1 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.


1 Safety

Special safety symbols

Some special symbols represent particular types of danger:

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.

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.

Danger of explosion Electrical current Danger of burning or scalding


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.


2 Product description

2 Product description2.1 Design and components of the ROTEX E-SolarUnit

1 Cold water connection (1" male) *2 Hot water connection (1" male) *3 Hot water charging heat exchanger flow connection4 Hot water charging heat exchanger return

connection5 Heating flow connection (1" female)6 Heating return connection (1" female)7 Solaris flow connection (1" swivel nut)8 Solaris return connection (Tr 32x3 male)

with valve set9 Connection for compensating line (Tr 32x3 male)

with valve set10 Top filling connection (alternative: safety overflow

connection to front – Tr 32x3 male)11 Immersion sleeve for storage tank sensor12 Immersion sleeve for Solaris return flow

temperature sensor13 Safety overflow connection to rear (Tr 32x3 male)

with hose nipple

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 heating22 3-way diverter valve23 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 Bypass28 Boiler control panel, see Chapter 5, page 2329 ROTEX Regelung ALPHA+ 23R, see

Chapter 6, page 32

30 Heating pressure gauge 31 Protective cover 32 Lock screws for protective cover33 KFE cock for filling the heating system (1/2" male)34 Automatic vent valve35 Ball stopcock36 Type plate37 Terminal box for supply terminals38 Electronic fill level probe39 Connecting cable for external temperature sensor40 Safety temperature limiter heat generator flow41 ThermowellSTB

Safety devices

* The connection is ready for installation of a gravity brake, which can be ordered separately.

Gravity brake 16 50 70

Fig. 2-1 Components of the ROTEX E-SolarUnit



A Electric heat generatorB Stratified hot water storage tankC Unpressurised storage tank waterD Hot water zoneE Solar zoneF Heating support zoneG RPS control and pump unit (Solaris accessory)1 Hot water connection (1" male) 2 Heating connection (1" male) 3 Solaris connection4 Domestic water heat exchanger (TW-WT)5 Heat exchanger for storage tank charging (SL-WT)6 Heat exchanger for solar heating support (HU-WT)7 Heat exchanger for heating (electric heat

generator with integrated safety temperature limiting in heat-insulated housing, see Chapter 7, page 51)

8 Heat insulation sleeve for HU-WT9 Ready for installation of gravity brakes, not

included in the scope of delivery (165070)10 Solaris flow layering pipe11 Circulation pump for heating12 3-way diverter valve13 Safety overflow connection to rear (Tr 32x3 male)14 Top filling connection (alternative: safety overflow

connection to front - Tr 32x3 male)15 Electronic fill level probe

Safety devices

Gravity brake 16 50 70

Fig. 2-2 Schematic design of the ROTEX E-SolarUnit



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.


3 Set-up and installation


Incorrect set-up and installation would make the manufacturer's guarantee void. If you have questions, please contact our Technical Customer Service.

3.1 Transport and delivery

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

Requirement:– The installation site complies with applicable country-specific regulations and meets the minimum requirements described in

Chapter 3.2.1.

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.

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.

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.



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 Mounting dimensions of the ROTEX ESU



Connecting dimensions for the heating and hot water connections

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

1 Cold water (pipe thread 1" male)2 Hot water (pipe thread 1" male)5 Heating flow (pipe thread 1" female)6 Heating return flow (pipe thread 1" female)

7 Solaris flow (flat-sealing pipe thread 1" swivel nut)25 Safety overpressure valve (pipe thread 3/4" female)26 Membrane expansion tank (pipe thread 3/4" male)33 KFE cock (pipe thread 1/2" male)

Fig. 3-2 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.

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.



• 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.

3.5 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.

• Following start-up, insert the connection plug of the 3-way diverter valve's cable into the valve drive.

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 ( 15 60 16).

1 Heat generator flow2 Heating flow3 Storage tank flow4 3-way diverter valve

5.1 Valve drive5.2 Unlocking button of the drive lock5.3 Hand lever

Fig. 3-3 3-way diverter valve

The circulation pump and the 3-way diverter valve each have one cable with a connection plug. These cables are ready for use.



3.6 Establishing an electrical connection

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).

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.

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.

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.

Fig. 3-4 Connection assignment in the terminal box

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.



\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.

3.7 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

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 PkJ2 3-way diverter valve or storage tank charging

pump PL*

J6 Mains connectionJ7 MixerJ8 Communication, sensorsJ10 Sensors

Cable colours:bl bluebr browngr greyrt redsw blackws whiten.b. Contact not assigned

* If the adapter cable is used for the charging pump ( E 1500430)

Fig. 3-5 Connection assignment label on the boiler control panel

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.



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).

• 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 heat-

insulated 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 gaugeBefore 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.

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.



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

• Engage the hand lever on the 3-way diverter valve (see Figure 3-3, page 14) in the centre position (only possible when de-energised/in the delivered condition).

• 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.

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.

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.



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.

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)

Tab. 3-1 Assignment of DIP switch settings in terms of heating output

Fig. 3-6 DIP switches for setting heating output

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.

P [kW] J1 J2 J3 J4 J5 J6 J7 J8

Heat demand standard tariff (ST)

OFF 0 0

3 1 0

6 0 1

9 1 1

Warm water demand standard tariff (ST)

OFF 0 0

3 1 0

6 0 1

9 1 1

Heat demand, off-peak tariff (OT)

OFF 0 0

3 1 0

6 0 1

9 1 1

Warm water demand off-peak tariff (OT)

OFF 0 0

3 1 0

6 0 1

9 1 1


4 Start-up

4 Start-up

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.

Tab. 4-1 Necessary and optional sensors for ROTEX ESU

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.

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


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.

1. Set the "Default settings" rotary switch to .

2. Switch the heat generator on.

The display shows "OIL".

3. Select the unit type ESU using the key on the main unit.

4. Press the key on the central unit to confirm your selection.

5. The ROTEX ESU checks whether all sensors required for normal operating mode and other optional sensors are connected (see Table 4-1).

If a sensor required for normal operation is missing, the ROTEX control system ALPHA+ 23R reports a sensor failure and terminates operation.

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 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.

If the failure is displayed again, replace the sensor or the sensor cable.

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).

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".

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.

OK

OK


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.


5 Boiler control panel

5 Boiler control panel5.1 Operating elements on the boiler control panel

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.

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.

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 Mains switch2 Group malfunction lamp3 Fill level warning lamp (if level too low)

4 Pressure gauge5 Fill level warning lamp for correct fill level

Fig. 5-1 Control elements on the boiler control panel with integrated ROTEX control system ALPHA+ 23R (middle, see Chapter 6.1, page 32)

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.



5.2 Changing the boiler control panel

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.

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.

5. Open the terminal box (see Figure 5-3, pos. 37) and use the supply line to check whether the system is enabled or not.

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.

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.

Fig. 5-2 Disconnect power cable Fig. 5-3 Unscrew the capillary tube, open the terminal box



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).

9. 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).

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. 5-4 Remove the cable to the control panel from the terminal, unscrew the cable protective tube

Fig. 5-5 Unscrew control panel cover

Fig. 5-6 Disconnect coded connectors and remove cable

Fig. 5-7 Disassemble filling level probe

Fig. 5-8 Pull STL from the immersion tube Fig. 5-9 Unscrew the fixing screws for the 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.

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!

DANGER!

Danger of death due to electric shock.





5.4 Changing sensors

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

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

DANGER!

Danger of death due to electric shock.



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.



Fig. 5-10 Replace the flow sensor

Fig. 5-11 Replace the return flow sensor



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.

5.5 Changing the fuse

0

For more information on installing the storage tank temperature sensor, see the enclosed installation instructions.

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

DANGER!




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.



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).

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).

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.

Fig. 5-13 Remove the locking screws from the control panel housing

Fig. 5-14 Changing the fuse

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.

2.

3.

Fig. 5-15 Removing the central unit

ALPHA+

17

i

OK3sec. Reset

5 sec

1 1ALPHA

+



5.7 Wiring diagram

1 Mains switch2 Group malfunction lamp4 Pressure gauge capillary tube5 Controller: Central unit ROTEX ALPHA+ 23R17 Fill level control lamp18 Fill level warning lamp19 Switchboard PCB20 Relay board (power section)21 Stickers for connection assignment22 4-pin circuit board connector with switch cable23 Fill level probe with 3-pin circuit board connector24 4-pin circuit board connector with malfunction

lamp cable25 5-pin circuit board connector with jumper26 Connecting cable to relay board with circuit board

connector27 ST/OT control cable with 4-pin circuit board

connector for relay board, clamped in terminal box28 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)

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 cable36 Circulation pump for heating

38 3-way diverter valve39 4-pin circuit board connector with valve cable40 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 terminals42 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 terminals44 External temperature sensor45 Storage tank (hot water) temperature sensor46 8-pin circuit board connector with cable for flow

and return flow temperature sensor47 Return flow temperature sensor48 Flow temperature sensor49 STL heat generator flow

Fig. 5-16 Wiring diagram


6 ROTEX control system ALPHA+ 23R

6 ROTEX control system ALPHA+ 23R6.1 Overview

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

6.2 Control elements

6.2.1 "Selection of operating mode" rotary switch

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.

1 "Selection of operating mode" rotary switch2 "Default settings" rotary switch3 Display4 Key 5 Key 6 Key 7 COM socket (underneath cover)8 Locking bolts9 Compartment for quick reference instruction manual

Fig. 6-1 Central unit ROTEX ALPHA+ 23R

ALPHA+

17

i

OK3sec. Reset

5 sec3

7

8

2

9

45

68

1

OK

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 IAutomatic heating and economy mode according to "Out at work" switching time programme (can be set separately).

AUTOMATIC IIAutomatic heating and economy mode according to "Family" switching time programme.

AUTOMATIC III Automatic heating and economy mode according to switching time programme "Solar".



6.2.2 "Default settings" rotary switch

6.2.3 Operator keys

The operator keys can be used to modify and save values.

6.2.4 Special functions

TARGET HOT WATER TEMPERATURE

Display and modify target hot water temperature.

NORMAL OPERATING MODE

Default setting. Display the current flow temperature (to display the current external and hot water temperature, see Chapter 6.5.2, page 35).

TEMPERATUREADJUSTMENT

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.

PLUS Changing values. The keys are used for navigation within the "Parameter", "Information" and "Automatic I" menu items.

MINUS

OK/RESET 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.

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)

i

17

OK

+ 5 sec

+ + OK

+ OK

>5sec



6.3 Display

The 4-digit display shows system information.

Tab. 6-1 Basic displays

6.4 COM socket

The COM socket is used to connect a PC or an external data storage device.

6.5 Default settings

6.5.1 General information

• Press the key to enter the programming level.

The point at the second decimal place flashes.

• Turn the "Default settings" rotary switch prior to saving.

All changes are lost.

• Press the key after making changes.

The changes are saved.

The control confirms that the new value has been saved correctly by means of a programming confirmation on the display: .

• Press the key and hold it down for longer than 3 s.

The previous value is restored (only possible if the new value has not already been saved).

Position of the "Default settings"

rotary switch

Display Explanation

• 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.

48.

L 60

C 0i

17

d 1

Only ROTEX service engineers may use the COM socket.

OK

OK

OK



6.5.2 Normal operating mode

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.

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.

• Set the "Default settings" rotary switch to position .• Set the "Selection of operating mode" rotary switch to the correct

position.

Fig. 6-2 Setting normal operating mode

• Set the "Default settings" rotary switch to position .• Press the key.

Calls the info values (current flow temperature, current storage tank temperature and current external temperature).

Fig. 6-3 Calling info values

1. Set the "Default settings" rotary switch to position .

2. Press the key.

3. Use the and keys to increase or decrease the correction value.

4. Press the key to save the value.

Fig. 6-4 Changing the flow temperature correction value

The flow temperature is limited by the maximum flow temperature (see Chapter 6.6, page 42).

A heating output must be set for hot water at the off-peak tariff (see Chapter 3.10, page 19).


2. Press the key.

3. Use the and keys to increase or decrease the hot water temperature.


Fig. 6-5 Setting the target hot water temperature

48

OK 48. L 60OK A -5OK

OK

OK

C 0

C . OOK

OK

C . 1

C 1

OK

OK

L 60

L .60

L .59

OK

OK

L 59



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

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.

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).

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).


2. Press the key.

3. Use the and keys to set the time to a value between 00:00 and 23:59.


Fig. 6-6 Setting the time


2. Press the key.

3. Use the and keys to set the weekday to a value between 1 (= Monday) and 7 (= Sunday).


Fig. 6-7 Setting the weekday

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).

OK

OK

14.20

14.20

14.21

14.1914.19

OK

OK

14.19

17

OK

OK

d 11

7

d . 1

d . 2

OK

OK

d 2



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.

Tab. 6-2 Factory settings for the "Out at work" switching time programme

Tab. 6-3 Settings for the "Family" switching time programme

Tab. 6-4 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 , 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.

AUTOMATIC I"Out at work"

Day Switching cycle 1 Switching cycle 2

Direct circuit(t 1.0)

Mon–FriSat–Sun

05:00–08:0007:00–23:00

16:00v22:00– – –

Hot water circuit Mon–Sun Depends on theST/OT contact

Mixer circuit(t 3.0)

Mon–FriSat–Sun

04:00–08:0007:00–23:00

15:00 - 22:00– – –

AUTOMATIC II"Family"


Direct circuit Mon–FriSat–Sun

05:00–22:0007:00–23:00

– – –– – –


Mixer circuit Mon–FriSat–Sun

04:00–22:0006:00–23:00

– – –– – –

AUTOMATIC III"Solar"


Direct circuit Mon–FriSat–Sun

05:00–22:0007:00–23:00

– – –– – –


Mixer circuit Mon–FriSat–Sun

04:00–22:0006:00–23:00

– – –– – –

ESU



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).

Fig. 6-8 Schematic representation of how the "Automatic I" switching time programme is processed

Fig. 6-9 Structure of the "Automatic I" switching time programme

t1.1

t1.2

t1.3

t1.4

t1.5

t1.6

00:0005:00 08:00 16:00

12:00 00:00 00:0012:00

22:00 07:00 23:00

1 5. . . 6 7+7

1

t1.1

t1 t2 t3

t3.1

t1.2 t3.2

t1.3 t3.3

t1.4 t3.4

t1.5 t3.5

t1.6 t3.6

t1.7 t3.7

t1.8 t3.8

5.00 4.00

8.00 8.00

16.00 16.00

22.00 22.00

7.00 6.00

23.00 23.00

--.-- --.--

--.-- --.--

71

3sec.OK

3sec.OKOK OK

Reset /3sec.

OK

+ + OK

1 5...

6 7+



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.

1. Enter the programming level .

2. Selection of the mixer circuit (t3) with and entering the sub-level with .

3. Selection of the first switch-on time t3.1with or and entering the programming mode with .

4. Changing the first switch-on time t3.1 from 4:00 h to 4:30 husing the and keys. Saving the changes with 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 .

6. Changing the switch-off time t3.4 from 22:00 h to 22:30 h. using the and keys. Saving the changes with and returning to the selection level.

7. Returning to the heater circuit level with longer than 3 s.

8. Terminating programming by pressing the key for over 3 s.

Alternating display

Increase value

Decrease value

Press briefly: confirm a selection, enter the displayed parameter in order to modify itPress and hold down for longer than 3 s: reset

Fig. 6-10 Adjusting the "Automatic I" switching time programme

OK

OK

OK

OK

OK

OK

OK

OK



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.

6.5.8 Querying system information

1. Set the "Default settings" rotary switch to position and press the and keys simultaneously, holding them down for longer than 5 s.

Manual operation is activated.

2. Use the and keys to set the required target temperature.

3. Press the and keys simultaneously.

Exits the programme.

Fig. 6-11 Activate and set manual operation

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).


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 Querying system information

38

38

45 H

55 H

+

Soll Ist

EXIT

5 sec

i i

InFo

I

21



Overview of general system information

Info value no. Info value Can be viewed by Comment

Installer Operator

1 External temperature x x If sensor value is available, otherwise "n. c." or "uuuu"

2 External working temperature x If no sensor value is available = 0 °C

3 ACTUAL flow temperature x x

4 TARGET flow temperature x

5 Return flow temperature x x

6Condition of the direct heating circuit pump

x 0 = Off, 1 = On

7 TARGET mixer circuit temperature x

8 ACTUAL mixer circuit temperature x 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 x If sensor value is available, otherwise "n. c." or "uuuu"

13 Condition of the diverter valve x 0 = Off, 1 = On

14 heat generator status x0 = no request from control1 = request, but no BZ=02 = 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

18 Condition of the modem contact x

0 = Modem input > 3.3 kOhms ±200 ohmsThe control is running in the operating mode that is currently set.

1 = Modem input = 3 kOhms ±200 ohmsThe control is running in continuous reduced mode for both circuits (in acc. with parameter [11]).

2 = Modem input = 2.2 kOhms ±200 ohmsThe control is running in continuous reduced heating mode for both circuits. The clock timer has no influence here.

3 = Modem input = 0 ohms or undefinedThe control is running in standby mode for both circuits. Both circuits are protected against frost.

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

Tab. 6-5 General info values (part I)



6.6 System parameters

6.6.1 Setting parameters – Basic procedure

1. Set the "Default settings" rotary switch to the position .

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).

2. Use the and keys to select the required parameter.

3. Press the key to confirm your selection.

The parameter value is displayed.

4. Use the and keys to modify the parameter value.

5. Press the key to save your entry.

The control confirms that the new value has been saved correctly by means of a programming confirmation on the display: .

6. Leave the system parameters by resetting the rotary switch "default configuration" to the position or select another parameter you want to change (steps 2 to 6).

Info value no. Info value Can be viewed by Comment

Installer Operator

E01 Fault no. 1 (most recent fault)

x x For fault codes, see the fault code table (Chapter 10.3).

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 General info values (part II)

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).

Up until the point when the parameters are saved, you can restore the original value by pressing the 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.

P05 60

OK

OK

OK



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.

Universal parameters

Para

met

er n

o.

Parameter name Can be set by:

Range

Incr

emen

t

Fact

ory

sett

ing

(FS)

MeaningIn

stal

ler

Oper

ator

/Use

rMin. Max.

1 Unit type x 1 4 1 0 0 = undefined, user is requested to set operation mode1 = oil condensing boiler standard2 = reserved3 = gas condensing boiler4 = ROTEX ESU

2 Hot water on/off, Legionella protection

x 0 3 1 1 0 = Hot water off1 = Hot water on, no Legionella protection2 = Hot water on, Legionella protection every Saturday3 = Hot water on, Legionella protection every day

4 Max. hot water temperature, heating technician

x 15 °C 65 °C 1 K 60 °C Maximum settable warm water temperature for heating technician

5 Max. hot water temperature, operator

x x Para-meter

[7]

Para-meter

[4]

1 K 60 °C Maximum settable warm water temperature for user

7 Hot water, energy-saving x x 15 °C Para-meter

[5]

1 K 40 °CWarm water temperature at night setback or at standard tariff

8 Hot water switch-on hysteresis

x 1 °C 20 °C 1 K 2 K Request for hot water is generated if:Target hot water temperature - hot water temperature ≥ hot water switch-on hysteresis

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 x 0 4 1 2 0 = No heating mode1 = Heating mode for direct circuit only, ECO function, weather-driven2 = Heating mode for direct circuit only, economy function, weather-driven3 = Heating mode for direct and mixer circuit, ECO function, weather-driven4 = Heating mode for direct and mixer circuit, economy function, weather-driven

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 Para-meter[26]

78 °C 1 K 60 °CMaximum flow temperature during heating mode (e. g. 55 °C for an underfloor heating system)

15 Assignment of room temperature control

x 0 3 1 0 0 = Room temperature control off1 = Room temperature control assigned to direct circuit2 = Room temperature control assigned to mixer circuit3 = Room temperature control affects both circuits

Tab. 6-7 Universal system parameters (part I)


Pa
ram

eter

no.

Parameter name Can be set by:

Range

Incr

emen

t

Fact

ory

sett

ing

(FS)

Meaning

Inst

alle

r

Oper

ator

/Use

r

Min. Max.

16 Night reduction x x 0 –80 °C 1 K –10 °C Value how much the flow temperature calculated by the control system is reduced in setback mode.

17 DCP run-on time after heating

x 0 s 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 0 s 600 s 1 s 180 sDefines the period for which the pumps and the 3-way diverter valve will remain active once a hot water request has been deactivated.

19 Heating switch-on hysteresis

x 1 K 20 K 1 7 K Request for burner is generated, if actual flow temperature is < flow target temperature — switch-on hysteresis.

20 Heating switch-off hysteresis

x 0 K 20 K 1 7 K An active request for burner is stopped, if flow temperature - flow target temperature is > switch-off hysteresis.

26 Room temperaturethe direct circuit is designed for

x x 15 °C 30 °C 1 K +25 °CParameter for the calculation of heater curve TR (Figure 6-17, page 47)

29 Summer switch-off x x 1 °C 60 °C 1 K +20 °C Value at which the heating system will switch from normal mode to summer mode.

31 Charging limit x 1 h 12 h 1 h 4 h Limits hot water charging to the time (in hours) set in the parameter.

34 Maximum mixer circuit temperature

x 15 °C Para-meter[13] – [36]

1 K +55 °C

Maximum temperature for the mixer circuit.

35 Room temperaturethe mixer circuit is designed for

x x 15 °C 30 °C 1 K +20 °CParameter for the calculation of heater curve TR (Figure 6-17, page 47).

36 Mixer circuit temperature increase

x 0 K 10 K 1 K 4 K 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.

37 Pump run-on of the mixer circuit pump

x 0 s 600 s 10 s 180 sFollow-up time mixer circuit pump

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,

heating technician

x

Tab. 6-8 Universal system parameters (part II)



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 and keys to select parameter [86].


3. Use the and keys to select value "1".


All parameters are reset to factory settings. The control system restarts.

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 and keys to select parameter [98].


The display shows "0000", with the first digit flashing.

3. Use the and keys to select the first number of the access code.


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.

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).

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.

Info values, such as the elapsed-hour meter, are not affected by this procedure.

Fig. 6-15 Visual confirmation, "heating technician logged in"

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].

OK

OK

OK

OK

. 48



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.

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.

1. Set the "Default settings" rotary switch to position , press the key and hold it down for longer than 5 s.

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).


The value 1.50 is displayed for the steepness of the heating characteristic.

3. Use the key to reduce the steepness of the heating characteristic to 1.30.

4. Press the key to save your entry.

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 key and holding it down for longer than 3 s.

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)

Fig. 6-16 Setting the heating characteristic for the direct circuit (example using the factory setting)

h 1 h 1h 2

1.50

1.50 1.30

1.301.00

+

Reset

3sec.OK

OK

OK

OK

OK

Reset /3sec.

OK

>5sec

OK

OK

OK

OK



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].

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].

Ta External temperature TV Flow temperature TR Room temperature

Fig. 6-17 Heating characteristic curve

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.

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].

25

35

45

55

65

75

85

95

105

-20-15-10-50510152025

0,50

0,20

0,75

1,00

1,25

1,50

1,75

2,00

2,25

2,50

2,75

3,00

3,25

3,50

T (°C)a

T (°C)R

T(°

C)

V

30

20

15

10



Setting the maximum hot water temperature• Set the maximum hot water temperature limit by changing parameter [4].

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].

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

Tab. 6-9 Dependencies between flow temperatures and the direct circuit

Hot water circuit

Tab. 6-10 Dependencies between flow temperatures and the hot water circuit

CAUTION:

If the Legionella protection function is activated, the hot water temperature may temporarily exceed 65 °C.


If the ST/OT contact is open, this temperature is maintained (only applies to automatic programmes 1 – 3 and "reduced heating mode").

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. * Parameter can only be set by ROTEX.

Parameter Name Maximum setting limit

Maximum hot water temperature 95 °C

[12]* Flow temperature, manufacturer ≤ Maximum flow temperature

[3]* Hot water temperature, manufacturer ≤ Maximum flow temperature, manufacturer + 5 °C

[4] Hot water temperature, heating technician ≤ Maximum hot water temperature, manufacturer

[5] Hot water, user ≤ Maximum hot water temperature, heating technician

[7] Hot water temperature, energy-saving ≤ Maximum hot water temperature, user

[6]* Absolute minimum hot water temperature ≤ Maximum hot water temperature, energy-saving (minimum 2 °C)

* Parameter can only be set by ROTEX.



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

3 Hot water, OEM max.4 Hot water, HE max.5 Hot water, operator

6 Hot water, absolute min.7 Hot water, energy-saving8 Switch hysteresis warm water

A Off-peak tariffB Standard tarifft TimeTs Storage tank temperature

Fig. 6-18 Dependencies between hot water parameters

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.

Fig. 6-19 Activation of manual hot water recharging

V

68

4859:59

+



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.

• 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.

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.


The maximum hot water temperature set by the user or the heating technician is ignored when hot water is heated for disinfection purposes.

It must be ensured that charging can take place at the times specified below.ESU


7 Electric heat generator

7 Electric heat generator7.1 Design and brief description

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.

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 ifThe heating circuit pump failsThe 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

1 Stainless steel pipe2 Connection cover3 Tie-rod4 Electric tubular radiator 1 – 3 kW5 Electric tubular radiator 2 – 3 kW6 Electric tubular radiator 3 – 3 kW7 Push-on connections for tubular radiators8 Earth connection9 Safety temperature limiter (STL) of the tubular

radiator10 Return connection11 Flow connection12 Flow temperature sensor13 Return flow temperature sensor14 STL heat generator flow

Fig. 7-1 Top view on the ROTEX ESU with open heat generator cover and partially removed heat insulation

12

1

28

11

3

9 9 97

10

2

5

6

13

4

14

14

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 Electric heat generator

Releasing the safety temperature limiter (STL)

7.4 Fault shutdown of the power circuit board

A fault shutdown occurs if the temperature exceeds 105 °C in the flow.

This situation can arise ifthe heating circuit pump failsif 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.

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 STL with protruding metal flag

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 STL left control panel side


8 Hydraulic connection

8 Hydraulic connection8.1 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 high-quality 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 operationThe 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 hygieneSeparating 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 waterDuring 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

53Company ROTEX ESU - 07/2008


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

Tab. 8-1 Short designations used in hydraulic diagrams (1)

Tab. 8-2 Short designations used in hydraulic diagrams (2)

Short des. Meaning Comment Order no.ROTEX ESU 509 E-SolarUnit with solar heating support ROTEX ESU 509 15 70 50 - 441 Cold water2 Hot water3 Heating flow4 Heating return flowPK Boiler circuit pump Included in the scope of delivery of the ROTEX ESUUV1 3-way diverter valve Included in the scope of delivery of the ROTEX ESUtWW Storage tank temperature sensor Included in the scope of delivery of the ROTEX ESUtV Heating flow temperature sensor Included in the scope of delivery of the ROTEX ESUtR Heating return flow temperature sensor Included in the scope of delivery of the ROTEX ESUtAU External temperature sensor Included in the scope of delivery of the ROTEX ESUSV Safety pressure relief valve Included in the scope of delivery of the ROTEX ESU5 Mixer circuit OptionalAMK1 Mixer group Accessories 15 60 44PMI Mixer circuit pump Included in the AMK1 scope of deliveryMI 3-way mixer with drive motor Included in the AMK1 scope of deliverytMI Mixer circuit flow temperature sensor Accessories 15 60 627 Non-return valve, return flow inhibitor Provided by customer8 Solar circuit OptionalSK High-performance flat solar panel AccessoriesRPS3 Solaris control and pump unit Accessories 16 41 06 - 44PS1 Duty pump Included in the RPS3 scope of deliveryPS2 Booster pump Included in the RPS3 scope of delivery

Short des. Meaning Comment Order no.tS, R Solaris return flow temperature sensor Included in the RPS3 scope of deliverytS Solaris storage tank temperature sensor Included in the RPS3 scope of deliverytS, V Solaris flow temperature sensor Included in the RPS3 scope of delivery

tK Solaris panel temperature sensorIncluded in the Connect AB panel connection set scope of delivery

FLS Flow sensor Accessories 16 41 07VS Scalding protection VTA 32 Accessories 15 60 15ÜV Bypass valve Provided by customerWE External heat generator (e. g. wood pellet boiler, heating pump) Provided by customerPWE Pump for external heat generator circuit Provided by customertWE Temperature sensor for external heat generator Included in the SCS-TR scope of deliveryUV2 3-way diverter valve Accessories 15 60 34SCS-TR Thermostat controller Accessories 16 41 30

Disconnecting the standard connection – UV1 and heating pump PK must be taken out of the unit and reconnected outside it. Provided by customer

54 Company ROTEX ESU - 07/2008


8.3.2 ROTEX E-SolarUnit with solar heating support

8.3.3 ROTEX E-SolarUnit with integrated wood boiler

Other connection diagrams can be found on the ROTEX Heating Systems GmbH website (see www.rotex.de).

Fig. 8-1 Standard connection diagram for the ROTEX E-SolarUnit with solar heating support

Fig. 8-2 Standard connection diagram for the ROTEX E-SolarUnit with integrated wood boiler

PS2

PS1

tK

tMI

PMI

PK

tV

tR

tAUtS,V

2-5 SK

M

MI AMK15

2

2

34

SV

VS

7

7

FLS

UV1

RPS3

ESU 509

1

8

A

AB

B

M

tWW

tS

1300

700

tS,R

010.

000

0442

010.

000

0471

PS2

PS1

RPS3

ESU 509

tWW

tS

1300

700

tS,R

tK

tMI

PMI

PK

PWE

tV

tR

tAU

tWE

tS,V

2-5 SK

M

MI AMK1

5

2

2

3 4

SV

VS

7

7

7

FLS

UV1

UV2

1

8

A

AB

B

M

ÜV

WE

SCS-TR

A

AB BM

55Company ROTEX ESU - 07/2008

http://www.rotex.de

9 Service and maintenance

9 Service and maintenance9.1 General overview of service and maintenance

Regular inspection and maintenance of the heating system reduces energy consumption and ensures a long life and smooth operation.

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

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.

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.

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.

DANGER!



• 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.

1 Remove the fixing screws.2 Tilt the protective cover.3 Take the protective cover off by lifting it towards the front

of the tank.

Fig. 9-1 Remove the protective cover


9 Service and maintenance

9.2.1 Checking the connections and pipes

• 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.

WARNING!


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.

• 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.Fig. 9-2 Check the safety overflow


10 Faults and malfunctions

10 Faults and malfunctions10.1 Detecting faults

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.

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:


2. Using the and keys to navigate to the info value E1 (Table 6-5, page 41 and Table 6-6, page 42).

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.

10.2.1 Individual reset

• Press the 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.

Fig. 10-1 Example error display "E 1" - first error Fig. 10-2 Example fault display "fault code 16-0"

E1 16-0

i

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.

OK



10.3 Fault codes

Tab. 10-1 Error codes of the ROTEX ESU on the ROTEX ALPHA+ 23R

Fault code Designation Type of fault Comments

00-X(X = 0 ... 9)

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 themixer motor power off

12-1 Mixer circuit flow sensor Short circuit ROTEX ESU switches the mixer circuit pump and themixer 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 Change by parameter 1.

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.

uuuu Sensor interruption

nnnn Sensor short circuit



10.4 Malfunctions

Tab. 10-2 Possible malfunctions of the ROTEX ESU

Malfunction Possible cause Possible solution

Heating system inoperable- Main switch not lit up- No display

No mains voltage • Turning on ROTEX ESU main switch• Switch the heating room main switch on.• Replace the boiler control panel fuse.• Replace the line connection fuse.

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.

Diverter valve drive inoperable – Storage tank charging position

• Check the valve drive/insert the connector, change if faulty.The valve drive can be removed temporarily, but storage tank charging will then be impossible.

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 does not warm up enough 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 economy phase)

• Check the operating mode setting.• 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.

Heat generator output too low 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.


11 Taking out of service


11 Taking out of service11.1 Temporary shutdown

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.

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.

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 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.

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.

12 Technical data

12 Technical data

Tab. 12-1 Basic data for the ROTEX E-SolarUnit

Basic data Pos. in Fig. 12-1 Unit

Total storage capacity litres 500

Empty weight 6 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

Standby heating power kWh/24h 1.8

Maximum operating pressure, heating/domestic water 7/9 bar 10/10

Material for all heat exchangers Stainless steel 1.4404

Domestic hot water

Domestic water capacity litres 24.5

Domestic water heat exchanger surface m2 5.5

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

Storage tank charging heat exchanger (stainless steel)

Water content heat exchanger litres 10.4

Surface of charging heat exchanger m2 2.3


Pressure drop in heat exchanger 1(at a flow rate of 1000 l/h)

mbar 96

Solar heating support

Heat exchanger surface area m2 0.43


Pressure drop in heat exchanger(at a flow rate of 1000 l/h)

mbar 18

Thermal output data Pos. in Fig. 12-1 Unit

NL efficiency characteristic acc. to DIN 47081) 1.8

D value, spec. water flow acc. to EN 6252) 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) 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 °C2) 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.

3) Recharging with nominal output, initial storage tank temp. TSP = 60 °C, cold water temp. TKW = 10 °C, hot water temp. TWW = 40 °C


12 Technical data

Tab. 12-3 Heat generator characteristic data

Tab. 12-4 Technical data ROTEX ALPHA+ 23R

Tab. 12-5 Pipe connections

Heat generator characteristic data

Pos. in Fig. 12-1 Unit

Nominal output 2 kW 3-9

Operating voltage 3 3-phase, 230 V/50 Hz

Protection type 5 IP 20

Nominal values ROTEX ALPHA+ 23R Unit

Mains voltage 230 V, 50 Hz

Power consumption during standby 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 ABS with antistatic agent

1 Type2 Rated thermal load 3 Voltage supply 4 Elec. power consumption 5 Degree of protection 6 Empty weight

7 Max. permissible operating pressure 8 Max. permissible operating temperature 9 Max. operating pressure 10 D value 11 Manufacturer number

(to be quoted in the event of complaints or queries)

Fig. 12-1 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

007.1502544


12 Technical data

Δ pR/mbar = Residual delivery head in mbar I = Stage 1mH/ L/h = Flow through heating system in litres per hour II = Stage 2

III = Stage 3

Fig. 12-2 Residual delivery head ROTEX ESU 509 (heater side)

mH/ L/h = Flow rate in litres per hour S = SpreadQ/kW = Heating output in kW

Fig. 12-3 Required flow rates depending on the heating output and the dimensioned temperature spread

0

100

200

300

400

500

600

700

0 200 400 600 800 1000 1200 1400 1600 1800 2000

m / L/hH

I II III

p/

mbar

�R

0

1

2

3

4

5

6

7

8

9

10

0 100 200 300 400 500 600 700 800 900 1000

Q/

kW

S= 20 K

S= 15 K

S= 10 K

m / L/hH


12 Technical data

mWW / L/min = Flow in litres per minute Δ p / mbar = Pressure drop in mbarmWW/ L/h = Flow in litres per second

Fig. 12-4 Pressure drop in the hot water heat exchanger depending on the draw-off rate

VZ/L = Max. draw-off volume in litres Storage tank temperature 60 °CmZ/ L/min = Draw-off rate in litres per minute Draw-off temperature 40 °C

Flow temperature 80 °CCold water temperature 10 °C

Fig. 12-5 Available draw-off volumes depending on the draw-off rate

0

400

1000

0

300 600 1200 1500 18000

5 10 15 20 25 30

200

600

800

900

m / L/hWW

m / L/minWW

p/

mbar

�

12

0330

500 1000 1500 20000

5

10

15

20

25

m/

L/m

inZ

V / LZ


12 Technical data

Tab. 12-6 Resistance values of the PTC temperature sensors

t/°C = Temperature in degrees CelsiusRS/Ω = Sensor resistance in ohms

Fig. 12-6 Resistance characteristics of the PTC temperature sensors

PTC

1000

1500

2000

2500

3000

3500

-20 0 20 40 60 80 100 120

t / °C

R/

S�

Sensor type

Measured temperature in °C

–20 –10 0 10 20 30 40 50 60 70 80 90 100 110 120

Sensor resistance in ohms according to manufacturer's specifications

PTC 1386 1495 1630 1772 1922 2080 2254 2418 2598 2796 2982 3185 3396


12 Technical data

Conn

ectin

gca

ble

colo

urs

blblu

ebr

brow

nge

yello

wgn

gree

ngr

grey

rtre

dsw

black

ws

whit

en.

b.Co

ntac

t not

assig

ned

Fig.

12-7

E-So

larUn

it w

iring

diag

ram


13 x Accessories


13 Accessories13.1 External temperature sensor

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.

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.

If no external temperature sensor is connected, the control sets the external working temperature value to 0 °C by default.

Fig. 13-1 RTR E room temperature control

°C

0

10

15

25

30

14 Notes

14 Notes Individual settings for the "Automatic I" switching time programme• Enter your switching time settings in the table below.

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.

Tab. 14-2 Individual changes made to parameters by the user or the heating technician

Heating circuit Day Switching time 1 Switching time 2

On Off On Off

Parameter no. Old value New value Date Comments


14 Notes


15 List of keywords


15 List of keywordsAAccess code . . . . . . . . . . . . . . 40, 43, 45Additional water . . . . . . . . . . . . . . . . . 14Adjusting . . . . . . . . . . . . . . . . . . . . . . . 17All . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

BBi-yearly inspection . . . . . . . . . . . . . . . 56Boiler control panel . . . . . . . . . . . . . . . 23

installation . . . . . . . . . . . . . . . . . . 26upgrade . . . . . . . . . . . . . . . . . . . . . 24

CChanging . . . . . . . . . . . . . . . . . . . . . . . 29Changing the central unit . . . . . . . . . . 30Circulation pump . . . . . . . . . . . . . . . 8, 14Cleaning . . . . . . . . . . . . . . . . . . . . . . . 56CLOCK TIME . . . . . . . . . . . . . . . . . 33, 36COM socket . . . . . . . . . . . . . . . . . . . . 34Components ROTEX ESU . . . . . . . . . . . . .8Connecting . . . . . . . . . . . . . . . . . . . . . . .8Connecting the temperature sensor . . . 16Connecting the mixer circuit . . . . . . . . 17Connection cables . . . . . . . . . . . . . . . . 26Control panel cover . . . . . . . . . . . . . . . 30

DDanger of frost . . . . . . . . . . . . . . . . . . 61Decimal point . . . . . . . . . . . . . . . . . . . 45Declaration of conformity . . . . . . . . . . . .2Design ROTEX ESU . . . . . . . . . . . . . . . . .8Dimensions . . . . . . . . . . . . . . . . . . 12, 62Direct . . . . . . . . . . . . . . . . . . . . . . . . . 48Direct heating circuit . . . . . . . . . . . . . . 48Direct heating circuit pump . . . . . . . . . 41Display . . . . . . . . . . . . . . . . . . . . . . . . 34Disposal . . . . . . . . . . . . . . . . . . . . . . . 61Diverter valve . . . . . . . . . . . . . . . . . . . 14Domestic hot water technical data . . . 62Draining . . . . . . . . . . . . . . . . . . . . . . . 61

EElectrical

- connection . . . . . . . . . . . . . . . . . . 15Electrical installation . . . . . . . . . . . . . . 15Electronic control . . . . . . . . . . . . . 10, 32Energy-saving hot water

temperature . . . . . . . . . . . . . . . . . . 48Exit time . . . . . . . . . . . . . . . . . . . . . . . 45External . . . . . . . . . . . . . . . . . . . . . . . 31External temperature

sensor . . . . . . . . . . . . . . . . 16, 17, 68F

Fault codes . . . . . . . . . . . . . . . . . . . . . 59Fault shutdown

power circuit board . . . . . . . . . . . . 52tubular radiators . . . . . . . . . . . . . . 51

Filling of the storage tank . . . . . . . . . . 18Filling the heating system . . . . . . . 17, 18Filling the storage tank charging

circuit . . . . . . . . . . . . . . . . . . . . . . 18Filling water . . . . . . . . . . . . . . . . . . . . 14

Flow temperature . . . . . . . 43, 47, 48, 49adjustment . . . . . . . . . . . . . . . . . . . 35display . . . . . . . . . . . . . . . . . . 34, 35

Flow temperature sensor . . . . . . . 20, 27Frost protection function . . . . . . . . . . . 32Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

GGroup malfunction lamp . . . . . . . . . . . . 23

HHeating circuit . . . . . . . . . . . . . . . 46, 48Heating system draining . . . . . . . . . . . . 61Hot water circuit . . . . . . . . . . . . . 37, 48Hot water mode . . . . . . . . . . . . . . 32, 47Hot water storage tank

technical data . . . . . . . . . . . . . . . . . 62Hot water temperature . . . . . . . .33, 34, 35, 41, 48Hydraulic system connection . . 7, 54, 55

IIf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Individual

parameters . . . . . . . . . . . . . . . . . . . 69Individual parameter settings . . . . . . . . 69Info value . . . . . . . . . .34, 40, 41, 42, 58Installation area . . . . . . . . . . . . . . . . . . 11Installation site . . . . . . . . . . . . . . . . . . . 11Installing the unit . . . . . . . . . . . . . . . . . 11

LLegionella protection . . . . . . . . . . . 43, 50

MMains switch . . . . . . . . . . . . . . . . 23, 31Maintenance . . . . . . . . . . . . . . . . . 54, 56Malfunctions . . . . . . . . . . . . . . . . 58, 60Maximum flow temperature . . . . . 43, 48Maximum hot water temperature . . . . . 48Mixer circuit . . . . . . . . . . . . . . . . . . . . . 17Mixer circuit docking sensor . . . . . . . . . 68Mixer circuit flow sensor . . . . 16, 17, 59Mixer circuit pump . . . . . . . . . . . . 41, 44

NNormal . . . . . . . . . . . . . . . . . . . . . . . . . 35Normal operating mode . . . . . . . . . . . . . 33

OOperating elements . . . . . . . . . . . . 23, 32Operating mode . . . . . . . . . . . . . . . . . . 10Operating safety . . . . . . . . . . . . . . . . . . . 6Operator . . . . . . . . . . . . . . . . . . . . . . . . 33Optional sensors . . . . . . . . . . . . . . 20, 21Overview . . . . . . . . . . . . . . . . . . . . . . . 41

PParameter . . . . . . . . . . . . . . . . . . . . . . . 33

setting . . . . . . . . . . . . . . . . . . . . . . 42Pressure gauge . . . . . . . . . . . . . . . . . . . 23Proper use . . . . . . . . . . . . . . . . . . . . . . . 6

RRemove the protective cover . . . . . . . . 56Required sensors . . . . . . . . . . . . . . . . . 20Return flow temperature

sensor . . . . . . . . . . . . . . . 16, 20, 26Room temperature . . . . . . . . . 17, 46, 68Room temperature control . . . 43, 46, 68Room thermostat . . . . . . . . . . . . . . . . . 17

SSafety management . . . . . . . . . . . . . . . 10Safety shutdown . . . . . . . . . . . . . . . . . 10Scope of delivery . . . . . . . . . . . . . . . . . 11Sensor faults . . . . . . . . . . . . . . . . . . . . 21Service . . . . . . . . . . . . . . . . . . . . . . 56, 57Service log . . . . . . . . . . . . . . . . . . . . . . 72Shutdown . . . . . . . . . . . . . . . . . . . . . . 61Start-up . . . . . . . . . . . . . . . . . . . . . . . . 20

- Requirements . . . . . . . . . . . . . . . . 20adjustment . . . . . . . . . . . . . . . . . . . 21checklist . . . . . . . . . . . . . . . . . . . . . 22

Storage . . . . . . . . . . . . . . . . . . . . . . . . 53Storage tank . . . . . . . . . . . . . 18, 53, 61Storage tank temperature

sensor . . . . . . . . . . . . . . . . . . . 16, 29Storage tank water

heating . . . . . . . . . . . . . . . . . . . . . . 53Summer switch-off . . . . . . . . . . . . 44, 47Switching switching time

programme . . . . . . . . . . . . . . . . 32, 36Switching time programme . . . . . . . . . . 32switching time programme . . . . . . . . . . 32Switching timer programme . . . . . . . . . 69System information . . . . . . . . . . . . . . . 40

TTarget hot water temperature . . . . 33, 35Target temperature hot water

storage tank . . . . . . . . . . . . . . . 33, 35The . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Transport . . . . . . . . . . . . . . . . . . . . . . . 11

UUnscrew . . . . . . . . . . . . . . . . . . . . 25, 26Using solar power . . . . . . . . . . . . . . . . 10

WWater connection . . . . . . . . . . . . . . . . . 13Water hardness . . . . . . . . . . . . . . . . . . 14Water shortage protection . . . . . . . . . . 14WEEKDAY . . . . . . . . . . . . . . . 33, 34, 36Wiring diagram . . . . . . . . . . . . . . . . . . . 31

16 Service log


16 Service logPlease 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 tankand protective cover

Changes made to the control's adjustable parameters, plus other comments regarding the heating system

Date Signature Comments

008.

15 1

44 4

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rotex e-solarunit · the rotex e-solarunit must only be used as a hot water heating system. the...

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