Table Of Contents - Rotex HPSU compact (V5) Installation And Maintenance Manual

1 General Information . . . . . . . . . . . . . . . . . . . 4
1.1 Observing instructions . . . . . . . . . . . . . . . . . . . .4
1.2 Warranty conditions . . . . . . . . . . . . . . . . . . . . . .4
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Warning signs and explanation of symbols. . . . .5
2.1.1 Meaning of the warnings . . . . . . . . . . . . . . . . . . . . 5
2.1.2 Validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1.3 Order number . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1.4 Handling instructions . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Avoid danger. . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.3 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.4 Instructions for operating safety . . . . . . . . . . . . .7
2.4.1 Before working on the hydraulic system . . . . . . . . 7
2.4.2 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . 7
2.4.3 Working on cooling systems (heat pump) . . . . . . . 8
2.4.4 Site of installation . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4.5 Heating system and sanitary connection. . . . . . . . 8
2.4.6 Requirements for the heating water . . . . . . . . . . . 9
2.4.7 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4.8 Instructing the user/owner . . . . . . . . . . . . . . . . . . . 9
3 Product description . . . . . . . . . . . . . . . . . . 10
3.1 Design and components . . . . . . . . . . . . . . . . . .10
3.1.1 Top of unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1.2 Equipment external and internal structure
ROTEX HPSU compact 304/308 DB . . . . . . . . . 11
3.1.3 Equipment external and internal structure
ROTEX HPSU compact 304/308 BIV . . . . . . . . . 12
3.1.4 Equipment external and internal structure
ROTEX HPSU compact 508/516 DB . . . . . . . . . 13
3.1.5 Equipment external and internal structure
ROTEX HPSU compact 508/516 BIV . . . . . . . . . 14
4 Set-up and installation . . . . . . . . . . . . . . . . 16
4.1 Dimensions and connections . . . . . . . . . . . . . .17
4.1.1 ROTEX HPSU compact 304/308 . . . . . . . . . . . . 17
4.1.2 ROTEX HPSU compact 508/516 . . . . . . . . . . . . 18
4.1.3 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
4.3 Remove cover hood and heat insulation. . . . . .21
4.4 Water connection . . . . . . . . . . . . . . . . . . . . . . .22
4.4.1 Aligning the connections of the heating feed
and return flow. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4.2 Connecting hydraulic lines . . . . . . . . . . . . . . . . . 23
4.4.3 Installation of DB connection kit ( 141590) . . . . . 24
4.4.4 Installation of P connection kit ( 141589) . . . . . . 25
4.5 Electrical connection . . . . . . . . . . . . . . . . . . . . .25
4.5.1 Overall connection plan ROTEX HPSU compact 26
4.5.2 Position of the circuit boards . . . . . . . . . . . . . . . . 27
4.5.3 Connection assignment, circuit board A1P . . . . . 27
4.5.4 Terminal assignment for the RTX-AL4 circuit board27
4.5.5 Terminal assignment for the RTX-EHS
circuit board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.5.6 Connection assignment, circuit board RoCon BM128
4.5.7 Mains connection ROTEX HPSU compact . . . . . 28
4.5.8 Open controller housing and making the
electrical connections . . . . . . . . . . . . . . . . . . . . . 29
4.5.9 Connection of exterior heat pump unit RRLQ . . . 29
4.5.10 Connection of external temperature sensor
RoCon OT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.5.11 Connection of an external switching contact . . . . 30
4.5.12 External demand signal (EDS) . . . . . . . . . . . . . . 30
4.5.13 Connection of the electrical ROTEX Backup
Heater (BUxx) . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.5.14 Connection of an external heat generator . . . . . . 32
4.5.15 Connection of the ROTEX room thermostat . . . . 33
FA ROTEX HPSU compact (V5) •
4.5.16 Connection optional ROTEX
RoCon system components. . . . . . . . . . . . . . . . . 34
4.5.17 Connection of the ROTEX HP convector. . . . . . . 34
4.5.18 Connection switch contacts (AUX outputs) . . . . . 35
4.5.19 Low tariff mains connection (HT/NT) . . . . . . . . . . 35
4.5.20 Connection intelligent controller (Smart Grid - SG)36
4.5.21 Symbols and legend keys on connection and
circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.6 Laying coolant lines . . . . . . . . . . . . . . . . . . . . . 39
4.7 Pressure test and filling the coolant circuit. . . . 39
4.8 Filling the system with water . . . . . . . . . . . . . . 39
4.8.1 Checking the water quality and adjusting the
pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.8.2 Filling the hot water heat exchanger . . . . . . . . . . 40
4.8.3 Filling the storage tank . . . . . . . . . . . . . . . . . . . . 40
4.8.4 Filling the heating system . . . . . . . . . . . . . . . . . . 40
5 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.1 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.1.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.1.2 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.1.3 Set the commissioning parameters . . . . . . . . . . . 42
5.1.4 Venting the hydraulics . . . . . . . . . . . . . . . . . . . . . 42
5.1.5 Check the minimum flow rate . . . . . . . . . . . . . . . 43
5.1.6 Configuring Screed Program parameters
(only if necessary) . . . . . . . . . . . . . . . . . . . . . . . . 43
5.2 Re-commissioning . . . . . . . . . . . . . . . . . . . . . . 44
5.2.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.2.2 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6 Decommissioning . . . . . . . . . . . . . . . . . . . . 45
6.1 Temporary shutdown . . . . . . . . . . . . . . . . . . . . 45
6.1.1 Draining the storage tank . . . . . . . . . . . . . . . . . . 45
6.1.2 Draining the heating circuit and hot water circuit . 46
6.2 Final shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 47
7 Service and maintenance. . . . . . . . . . . . . . 49
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.2 Activities to be performed annually . . . . . . . . . 50
7.3 Filling and topping up the storage tank . . . . . . 52
7.4 Filling and topping up the heating system . . . . 53
8 Errors, malfunctions and messages . . . . . 55
8.1 Recognising errors, correcting malfunctions . . 55
8.1.1 Current fault display. . . . . . . . . . . . . . . . . . . . . . . 55
8.1.2 Read Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.1.3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.2 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.3 Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8.4 Monitoring and configuration DIP Switch . . . . . 66
8.5 Emergency operation . . . . . . . . . . . . . . . . . . . . 66
9 Hydraulic system connection . . . . . . . . . . 67
10 Technical data . . . . . . . . . . . . . . . . . . . . . . . 72
10.1 Equipment data . . . . . . . . . . . . . . . . . . . . . . . . 72
10.1.1 ROTEX HPSU compact 304/308. . . . . . . . . . . . . 72
10.1.2 ROTEX HPSU compact 508/516. . . . . . . . . . . . . 75
10.2 Characteristic lines. . . . . . . . . . . . . . . . . . . . . . 77
10.2.1 Sensor characteristic lines. . . . . . . . . . . . . . . . . . 77
10.2.2 Characteristic curves for pumps . . . . . . . . . . . . . 79
10.3 Tightening torque . . . . . . . . . . . . . . . . . . . . . . 79
10.4 Circuit diagram ROTEX HPSU compact . . . . . 80
11 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
12 List of keywords . . . . . . . . . . . . . . . . . . . . . 83
List of contents
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