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Rotex HPSU compact 304 Installation And Maintenance Manual

Hpsu compact solar tank with integrated interior heat pump unit
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Download this manual See also: Instruction Manual
For certified companies
ROTEX HPSU compact
Installation and maintenance
manual
Solar tank with integrated interior heat pump unit
For the types
HPSU compact 304
HPSU compact 308
HPSU compact 508
HPSU compact 516
GB
Output 06/2015

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Summary of Contents for Rotex HPSU compact 304

  • Page 1 For certified companies ROTEX HPSU compact Installation and maintenance manual Solar tank with integrated interior heat pump unit For the types HPSU compact 304 HPSU compact 308 HPSU compact 508 HPSU compact 516 Output 06/2015...

  • Page 2: Table Of Contents

    RoCon OT1 ......23 10.1.1 ROTEX HPSU compact 304/308 ... . 63 4.4.12 Connection of an external switching contact.
  • Page 3 11 Notes ......70 12 List of keywords ..... 71 FA ROTEX HPSU compact 4 - 06/2015...

  • Page 4: Guarantee And Conformity

    1.2 Declaration of conformity for the Solar tank with integrated interior heat pump unit in the HPSU compact series. We, ROTEX Heating Systems GmbH, declare under our sole responsibility that the products Product Order No. Product Order No.

  • Page 5: Safety

    – When connecting to a ROTEX solar system; the associated Danger of explosion installation and operating instructions. – If a ROTEX HP convector is connected; the associated instal- lation and operating instructions. 2.2.2 Validity – In the case of connection to a control component offered as an accessory (room controller, mixer module etc.);...

  • Page 6: Handling Instructions

    The ROTEX HPSU compact must be installed, connected and operated only according to the indications in this manual. Only use of a suitable external unit approved by ROTEX is per- mitted. The following combinations are permissible in this re- spect:...

  • Page 7: Instructions For Operating Safety

    15 60 16). engineers and in compliance with the valid electro-technical If the ROTEX HPSU compact is connected to a heating system guidelines as well as the regulations of the relevant energy with steel pipes, radiators or non-diffusion-proof floor heating supply company (EVU).

  • Page 8: Operation

    The specified servicing intervals should be adhered to and in- spection work must be carried out. 2.5.8 Instructing the user/owner Before you hand over the ROTEX HPSU compact, explain to the user/owner how to operate and check the system. Hand over the technical documentation (this document and...

  • Page 9: Product Description

    Connection for electrical Backup Heater BUxx (R 1½" IG) (Accessory) Plate heat exchanger (PWT) Connection coolant fluid line ROTEX HPSU compact 30x/508: Cu Ø 6.4 mm (1/4"), ROTEX HPSU compact 516: Cu Ø 9.5 mm (3/8") Connection to coolant gas line Cu Ø 15,9 mm (5/8")

  • Page 10: Equipment External And Internal Structure Rotex Hpsu Compact 304/308 Db

    Product description 3.1.2 Equipment external and internal structure ROTEX HPSU compact 304/308 DB Fig. 3-2 Structure and constituents ROTEX HPSU compact 304/308 DB (External appearance and internal structure) Designations of key see tab. 3-1 FA ROTEX HPSU compact 4 - 06/2015...

  • Page 11: Equipment External And Internal Structure Rotex Hpsu Compact 304/308 Biv

    Product description 3.1.3 Equipment external and internal structure ROTEX HPSU compact 304/308 BIV Fig. 3-3 Structure and constituents ROTEX HPSU compact 304/308 BIV (External appearance and internal structure) Designations of key see tab. 3-1 FA ROTEX HPSU compact 4 - 06/2015...

  • Page 12: Equipment External And Internal Structure Rotex Hpsu Compact 508/516 Db

    Product description 3.1.4 Equipment external and internal structure ROTEX HPSU compact 508/516 DB Fig. 3-4 Structure and constituents ROTEX HPSU compact 508/516 DB (External appearance and internal structure) Designations of key see tab. 3-1 FA ROTEX HPSU compact 4 - 06/2015...

  • Page 13: Equipment External And Internal Structure Rotex Hpsu Compact 508/516 Biv

    Product description 3.1.5 Equipment external and internal structure ROTEX HPSU compact 508/516 BIV Fig. 3-5 Structure and constituents ROTEX HPSU compact 508/516 BIV (External appearance and internal structure) Designations of key see tab. 3-1 FA ROTEX HPSU compact 4 - 06/2015...
  • Page 14 Ball cock (1" IG) is supplied with the equip- Optional: Electrical backup heater 3-way diverter valve (internal heat genera- ment (BUxx) tor circuit) 3UV DHW 3 way diverter valve (hot water/heating) Tab. 3-1 Legend from fig. 3-2 to fig. 3-5 FA ROTEX HPSU compact 4 - 06/2015...

  • Page 15: Set-Up And Installation

    Work on the ROTEX HPSU compact (such as setup, servicing, connection and initial start-up) is only to be carried out by persons who are authorised and who have successfully completed qualifying technical or vocational training and who have taken part in advanced training sessions recognised by the relevant responsible authorities for the specific activity.

  • Page 16: Rotex Hpsu Compact 508/516

    Solar - flow (only type ... BIV) Hot water Solar - return (only type ... BIV) Heating feed Heating return flow Front Connection coolant gas line Back Fig. 4-2 Connections and dimensions ROTEX HPSU compact 508/516 (in general) FA ROTEX HPSU compact 4 - 06/2015...

  • Page 17: Scope Of Delivery

    – Suitable water treatment may be required. WARNING! The plastic wall of the storage tank on the ROTEX HPSU compact may melt due to the effects of external heat (>80 °C) and, in the extreme case, can catch fire.

  • Page 18: Water Connection

    Install the dirt filter or sludge separator into the heating return flow (see chapter 2.5.5). CAUTION! If the ROTEX HPSU compact is connected to a cold water line, where steel pipes are used, chips can enter the special steel corrugated pipe heat exchanger and remain there.

  • Page 19: Connecting Hydraulic Lines

    Set-up and installation 4.3.1 Connecting hydraulic lines Requirement: Optional accessories (e.g. Solar, backup heater) mounted on the ROTEX HPSU compact according to the specifi- cations of the instructions included. Check cold water pressure (maximum 6 bar). – At higher pressure in the drinking water line, a pressure reducer must be installed.

  • Page 20: Overall Connection Plan Rotex Hpsu Compact

    Set-up and installation 4.4.1 Overall connection plan ROTEX HPSU compact Explanation of symbols and abbreviations in this Chap- ter see tab. 4-2 and tab. 4-3. Fig. 4-7 Overall connection diagram - for electrical connection during device installation FA ROTEX HPSU compact 4 - 06/2015...

  • Page 21: Position Of The Circuit Boards

    Fig. 4-10 Circuit board RTX-AL4 (interface) 4.4.5 Terminal assignment for the RTX-EHS circuit board Fig. 4-11 Circuit board RTX-EHS (Backup Heater) - see section 4.4.14 Fig. 4-9 Circuit board A1P (basic control of the heat pump) FA ROTEX HPSU compact 4 - 06/2015...

  • Page 22: Rocon Bm1

    The exterior unit and optional accessories must be connected separately to the regulator on the ROTEX HPSU compact. To do so, the cover panel of the ROTEX HPSU compact must be re- Fig. 4-13 Unscrew/loosen screws, lift the cover at the back and remove moved (see section 4.4.8) and, if necessary, the control housing...

  • Page 23: Opening The Control Housing And Establishing Electrical Connections

    4.4.11 Connection of external temperature sensor tion. electrical connections. RoCon OT1 The exterior heat pump unit of the ROTEX HPSU compact has a built-in exterior temperature sensor which is used to regulate the inflow temperature depending on the weather, with frost pro- tection function.

  • Page 24: Connection Of An External Switching Contact

    After connecting the exterior temperature sensor RoCon OT1 to RoCon HP integrierten [HZ Unterstützung] control the regulator RoCon HP of the ROTEX HPSU compact, the pa- unit (see operating manual for the control unit) it is not rameter [SKonfig T-Aussen] must be set to "Ein".

  • Page 25: Connection Of The Electrical Rotex Backup

    X1 of the switch board RTX-EHS (fig. 4-11) in the regulation housing of the ROTEX HPSU compact. Insert the plug XBUH1 of the Backup Heater on the back of the regulation housing of the ROTEX HPSU compact. Set parameter [Funktion EHS] to "1" (see controller operating instructions RoCon HP).

  • Page 26: Connection Of An External Heat Generator

    For heating support or as an alternative to an electrical Backup Heater (see section 4.4.14) you can connect an external heat generator (e.g. gas or oil boiler) to the ROTEX HPSU compact. The heat supplied by the external heat generator must be added to the unpressurised storage tank water in the ROTEX HPSU compact hot water storage tank.

  • Page 27: Connection Of The Rotex Room Thermostat

    Set-up and installation 4.4.16 Connection of the ROTEX room thermostat This component has a separate manual attached, including among other things instructions for installation and operation. Fig. 4-30 Connection with cabled room thermostat (RT = ROTEX RKRTW, 14 10 03)

  • Page 28: Connection Optional Rotex Rocon System

    Ensure power cables, sensor cables and data bus cables are laid separately from each other. Use only cable trunking with sep- – Electrical connection of the ROTEX HP convector with the fol- arate trays or cable trunking with separators that ensure at least lowing accessories in accordance with fig.

  • Page 29: Connection Switch Contacts (Aux Outputs)

    The following types of reduced tariff mains connection are If the ROTEX HPSU compact is in the [Kühlen] operating mode, standard: the switch contact B-B1 closes. The switch contact B-B1 is used, –...

  • Page 30: Connection Intelligent Controller

    Plug and socket connection 2-core cabling (non-screened) 3-core cabling (non-screened) 4-core cabling (non-screened) 5-core cabling (non-screened) 6-core cabling (non-screened) Shielded cabling (for example 3-strand) Tab. 4-2 Symbol explanations for connection and circuit diagrams FA ROTEX HPSU compact 4 - 06/2015...
  • Page 31 Storage tank temperature sensor plug connection switching DHW1 Fuse 250 V T 2 A (RoCon BM1) Plug connection HT/NT switching contact EVU Tab. 4-3 Key names for connections and circuit diagrams - Part 1 FA ROTEX HPSU compact 4 - 06/2015...

  • Page 32: Laying Coolant Lines

    4.5 Laying coolant lines Check whether oil trap arc necessary. Only solder with light nitrogen flow – Required if ROTEX HPSU compact is not installed at (hard soldering only). ground level with the heat pump exterior unit (fig. 4-37, Do not apply heat insulation to joins until after start-up (for 10 m).

  • Page 33: Pressure Test And Filling The Coolant Circuit

    80 cm. DHW2 4.7 Filling the system with water Do not fill the ROTEX HPSU compact until all installation activ- ities have been completed, in the order shown as follows. 4.7.1 Checking the water quality and adjusting the...

  • Page 34: Start-Up

    The settings of the optional components such the room ther- mostat or ROTEX solar installation must be configured on the re- spective components themselves. 5.1.1 Requirements – The ROTEX HPSU compact is fully connected.

  • Page 35: Set The Commissioning Parameters

    – Allow pump wheel to run until water emerges from the Configure additional commissioning parameters depending ventilation screw without bubbles. on the system requirements for the control unit of the ROTEX – Close ventilation screw on the heat circulation pump HPSU compact.

  • Page 36: Activating The Parameter [Entlüftungsfunktion]

    When connecting with a room station RoCon U1: 3-way diverter valve integrated into the ROTEX HPSU compact. Activate the room station. Set the heating characteristic curve or the desired flow Existing air can leak from the automatic venting valve during the temperature.
  • Page 37 1. Check the cold water connection and, where necessary, fill the potable water heat exchanger. 2. Turn power supply to ROTEX HPSU compact on. 3. Wait for the start phase. 4. After the start phase has completed, in heating mode, vent the heating system, check the system pressure and adjust if necessary (max.

  • Page 38: Decommissioning

    If the heating system is not drained and there is a risk of frost, the power supplies must be secured and the external main switch must remain switched If the ROTEX HPSU compact is not needed for a long time, it can Fig. 6-1 Connecting the drain- Optional: Removing the connec- be temporarily decommissioned.

  • Page 39: Draining The Heating Circuit And Hot Water Circuit

    Disconnect the heating flow and return flow as well as the cold connection connection into the fill- water inflow and the hot water outflow from the ROTEX HPSU ing and draining fitting compact. Open the KFE cock on the KFE filling connection and Connect the discharge hose on the heating flow and return drain the water out of the storage tank.

  • Page 40: Final Shutdown

    The ROTEX HPSU compact is designed to be environmentally ROTEX has complied with the standards for environ- friendly and easy to install: the jobs described above can...

  • Page 41: Service And Maintenance

    Improperly carried out work on the ROTEX HPSU must be documented e.g. in the operating manual. compact and its components that have been con- Operators of ROTEX heat pump systems are subject to the nected as an option can endanger human life and following obligations: health and adversely affect the operation of the these components.
  • Page 42 1. Dismount the protective cover (see section 7.2). Never allow coolant to escape into the atmosphere 2. Carry out a functional inspection of the ROTEX HPSU (forms high concentrations). compact, as well as all installed accessory components...

  • Page 43: Filling And Topping Up The Storage Tank

    7.5). water comes out of the connection (fig. 7-2, pos. 23), that 12. Clean plastic surface of ROTEX HPSU compact with a soft has been connected as the safety overflow. cloth and mild cleaning agent. Do not use any cleaners with Disconnect the filling hose with backflush prevention (1/2")

  • Page 44: Filling And Topping Up The Heating System

    7. Switch on the power supply of the HPSU compact. 8. Set rotary switch to position operating mode and select "Heizen". ROTEX HPSU compact runs in the hot water heating mode after the start phase. 9. During the hot water heating mode, continuously check the water pressure at the external pressure gauge.

  • Page 45: Errors, Malfunctions And Messages

    Protokoll 8.1 Recognising errors, correcting malfunctions Handbetrieb Electronic control of the ROTEX HPSU compact: FA Fehler – signals an error by means of the background of the display lighting up red and shows an error code in the display (see tab.

  • Page 46: Malfunctions

    The parameter [SMART GRID] is active and the connections are set incorrectly. The power company has sent the high-cost Wait for the repeat off-peak rate signal which reacti- signal. vates the power supply. FA ROTEX HPSU compact 4 - 06/2015...
  • Page 47 Thermal protection switch (STB) on backup heater Optional backup heater (BUxx) or alternative (BUxx) was triggered. Unlock. heater not switched on. Check parameters [Funktion EHS] and [Leistung EHS Stufe 1] and [Leistung EHS Stufe 2]. FA ROTEX HPSU compact 4 - 06/2015...
  • Page 48 Quantity of coolant in the heating system too low or too high. If the quantity of coolant is too great, recycle the coolant and refill the system with the correct vol- ume. FA ROTEX HPSU compact 4 - 06/2015...

  • Page 49: Fault Codes

    E9004 / 7H. function error (PHE) – Failure of the frost protection function of the plate heat exchanger because there is a lack of coolant in the system. See error code E9015 / E4. FA ROTEX HPSU compact 4 - 06/2015...
  • Page 50 With optional backup heater: check its power supply and fuses. Check the fuses in the control housing of the ROTEX HPSU compact (pump fuse (FU1) on circuit board A1P and printed circuit board fuse (F1) on the RoCon BM1 circuit board).
  • Page 51 – High pressure switch S1PH defective. High pressure switch – Main board in the heat pump exterior unit defective. E9021 HPS-System S1PH in the heat pump – Cabling, poor contact. exterior unit Check, replace. FA ROTEX HPSU compact 4 - 06/2015...
  • Page 52 Temperature sensor of the lamella heat exchanger R4T in the heat pump Aircoil-Fühler E9028 exterior unit Temp (only in 11-16 kW systems) Temperature sensor liq- Fehler Kältefühler E9029 uid-side R6T in the heat pump exterior unit FA ROTEX HPSU compact 4 - 06/2015...
  • Page 53 (only in 11-16 kW Check, correct cause, replace. systems) If necessary contact ROTEX service technician. Power setting for the heat Contact a ROTEX service technician. Einstellung Leis- E9037 pump exterior unit incor- tung rect FA ROTEX HPSU compact 4 - 06/2015...
  • Page 54 FLS or con- Error return flow Return flow temperature nection cable defective. E128 — temperature sen- sensor t Check, replace. Pressure sensor DS defective. Pressure sensor E129 — Pressure sensor DS error Check, replace. FA ROTEX HPSU compact 4 - 06/2015...
  • Page 55 Tab. 8-2 Error codes on the main control unit of HPSU compact Respect the maximum tightening torque of the temper- ature sensor (see chapter 10.3 "Tightening torque"). FA ROTEX HPSU compact 4 - 06/2015...

  • Page 56: Monitoring And Configuration Dip Switch

    ROTEX HPSU compact, adjust where necessary (see tab. 8-4). The factory preset may only be changed if e.g. an optional accessory was connected. Replace the RoCon BM1 switch board, close the control housing and reconnect the power supply. FA ROTEX HPSU compact 4 - 06/2015...

  • Page 57: Emergency Operation

    "Handbetrieb" function on the control unit (see operating manual for the control unit). If the 3-way valves are intact, the ROTEX HPSU compact switches to Heating mode. The necessary flow temperature can be adjusted with the rotary switch: A storage charge can be realised using the special "Handbe-...

  • Page 58: Hydraulic System Connection

    ROTEX matic hot water mixing device). homepage. The ROTEX units can also be optionally fitted with gravity breaks ( 16 50 70) made of plastic to prevent thermal losses caused by gravity flow.These are suita- ble for operating temperatures of maximum 95 °C and...
  • Page 59 Hydraulic system connection Fig. 9-2 ROTEX HPSU compact (BIV types) with pressurised solar (for legend see tab. 9-1) Fig. 9-3 HPSU compact (DB types) parallel bivalent with A1 boiler without solar support (for legend, see tab. 9-1) FA ROTEX HPSU compact 4 - 06/2015...
  • Page 60 HPSU compact (DB types) alternative bivalent with A1 boiler without solar support (for legend, see tab. 9-1) Fig. 9-5 HPSU compact (BIV types) parallel bivalent with A1 boiler and DrainBack Solar (for legend, see tab. 9-1) FA ROTEX HPSU compact 4 - 06/2015...
  • Page 61 Hydraulic system connection Fig. 9-6 ROTEX HPSU compact 508/516 (DB) with wood-burning boiler <8 kW without solar support (for legend, see tab. 9-1) Fig. 9-7 ROTEX HPSU compact 508/516 BIV with wood-burning boiler <8 kW and Drain-Back solar (Legend see tab. 9-1)
  • Page 62 RRLQ External unit for heat pump Room thermostat Storage tank incorporation (A1 condensing SAA1 boiler) Storage tank connection (wood boiler) SAS1 Sludge and magnetic separator SGB A1 Safety module for A1 condensing boiler FA ROTEX HPSU compact 4 - 06/2015...

  • Page 63: Technical Data

    90 l = 3660 Wh (Ø shower draw-off quantity) Cold and hot water inches 1" AG Heating feed and return flow inches 1" IG Pipe connections inches 1" IG Solar connections inches — 3/4" IG / + 1" AG FA ROTEX HPSU compact 4 - 06/2015...
  • Page 64 The cross-section of the individual lines is dependent on the current (charge state before drawing off) load, the length of the connection cable and the respective legal provi- sions. Tab. 10-1 Basic data ROTEX HPSU compact 304/308 FA ROTEX HPSU compact 4 - 06/2015...

  • Page 65: Rotex Hpsu Compact 508/516

    90 l = 3660 Wh (Ø shower draw-off quantity) Cold and hot water inches 1" AG Heating feed and return flow inches 1" IG Pipe connections inches 1" IG Solar connections inches — 3/4" IG + 1" AG FA ROTEX HPSU compact 4 - 06/2015...

  • Page 66: Characteristic Lines

    Hot water storage tank only to be charged using a heat pump, without a Storage target temperature backup heater. (charge state before drawing off) With a reference spacing of 1 m. Tab. 10-2 Basic data ROTEX HPSU compact 508/516 10.2 Characteristic lines 10.2.1 Sensor characteristic lines Temperature sensor Measured temperature in °C Sensor resistance in kOhm according to standard or manufacturer's indications —...
  • Page 67 / l/min Sensor resistance (NTC) Frequency Temperature Flow Storage tank temperature sensor Fig. 10-3 Characteristics of the flow sensor FLS (V1) ROTEX HPSU DHW2 Return flow temperature sensor compact Flow temperature sensor Flow temperature sensor Backup Heater V, BH Fig.

  • Page 68: Characteristic Curves For Pumps

    10 Nm (hand-tight) Tab. 10-4 Tightening torque Water pressure Tension Fig. 10-5 Characteristics of the pressure sensor (DS) ROTEX HPSU compact 10.2.2 Characteristic curves for pumps Residual pumping height of internal heat circulation pump Flow rate of heating system Fig.

  • Page 69: Circuit Diagram Rotex Hpsu Compact

    Technical data 10.4 Circuit diagram ROTEX HPSU compact Fig. 10-8 Circuit diagram ROTEX HPSU compact - For legend see tab. 4-3 FA ROTEX HPSU compact 4 - 06/2015...

  • Page 70: Notes

    Notes 11 Notes FA ROTEX HPSU compact 4 - 06/2015...

  • Page 71: List Of Keywords

    Heating expert log-in ......35 Heating support ......... 26 Hydraulic connection Valve drive ......... 44 Connection examples ....58 Venting function ......... 44 Connections ....... 9 Important information ...... 7 Installation ........18 FA ROTEX HPSU compact 4 - 06/2015...

This manual is also suitable for:

Hpsu compact 516Hpsu compact 308Hpsu compact 508

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