Related Manuals for Rotex E-Solar Unit ESU 509
Summary of Contents for Rotex E-Solar Unit ESU 509
- Page 1 For certified companies ROTEX E-SolarUnit Electric heat generator with stratified solar storage tank Installation and maintenance instructions Type Rated thermal output Edition 07/2008 ROTEX ESU 509 3–9 kW Serial number Customer...
- Page 2 Guarantee and conformity ROTEX provides a warranty for material and manufacturing defects according to this statement. Within the warranty period, ROTEX undertakes to have the unit repaired free of charge by a person assigned by the company. ROTEX reserves the right to replace the unit.
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Page 3: Table Of Contents
Design and components of the ROTEX E-SolarUnit ........ - Page 4 ROTEX E-SolarUnit with integrated wood boiler ........
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Page 5: Safety
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. 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. -
Page 6: Avoid Danger
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. - Page 7 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.
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Page 8: Product Description
2 Product description Design and components of the ROTEX E-SolarUnit Product description Cold water connection (1" male) * 15 Heat exchanger for heating (electric heat generator 30 Heating pressure gauge Hot water connection (1" male) * with integrated safety temperature limiters... - Page 9 13 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 FA ROTEX ESU - 07/2008...
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Page 10: Brief Description
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. -
Page 11: Set-Up And Installation
• Transport the ROTEX ESU carefully, using the handles provided on it. The ROTEX ESU is delivered on a pallet. All industrial trucks, such as lifting trucks and forklift trucks, are suitable for transporting it. -
Page 12: Dimensions
• 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). -
Page 13: Water Connection For Heating And Hot Water Pipes
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. -
Page 14: Connecting The Valve Drive To The 3-Way Diverter Valve
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. -
Page 15: Establishing An Electrical Connection
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. -
Page 16: Temperature Sensor
3 Set-up and installation \All electrical installation work required inside the ROTEX E-SolarUnit has already been completed at the factory. A 3 m flexible external sensor cable (see Figure 2-1, pos. 39) has already been connected to the terminals inside the unit and plugged onto the connecting circuit board in the control panel. -
Page 17: Optional Connections
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). Filling the system... - Page 18 3 Set-up and installation 2. Filling the storage tank ROTEX ESU with Solaris-System installed: ½ • Connect the filling hose with return flow inhibitor ( ") to the KFE cock on the control and pump unit (RPS). • Fill the storage tank until water is discharged from the safety overflow.
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Page 19: 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). -
Page 20: Start-Up
WARNING! Danger of death due to improper start-up A ROTEX E-SolarUnit which is not started up properly can endanger an individual's life or health and can also impair the function it is designed to perform. • The ROTEX ESU may only be started up by authorised and trained heating experts. - Page 21 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.
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Page 22: Checklists For Start-Up
4 Start-up Checklists for start-up Checklist before start-up Is the ROTEX ESU properly installed in accordance with a permitted set-up and without any discernible damage? Does the mains connection conform to the specifications? Is the mains voltage 230 V, 50 Hz? Is the storage tank filled with water to the overflow point;... -
Page 23: 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. -
Page 24: Changing The Boiler Control Panel
Disconnect power cable Fig. 5-3 Unscrew the capillary tube, open the terminal box 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. FA ROTEX ESU - 07/2008... - Page 25 13. Unscrew the boiler control panel via the supports on the tank cover (see Figure 5-9), replace the control panel. Fig. 5-8 Pull STL from the immersion tube Fig. 5-9 Unscrew the fixing screws for the boiler control panel FA ROTEX ESU - 07/2008...
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Page 26: Changing Cables
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! FA ROTEX ESU - 07/2008... -
Page 27: Changing Sensors
1. Pull the sensor cable off (Figure 5-11). 2. Remove insulation of the return flow pipe. 3. Unscrew and replace the sensor. Installation is carried out in reverse order. The sensor plugs are form-coded. Do not force the connector FA ROTEX ESU - 07/2008... - Page 28 5 Boiler control panel Fig. 5-10 Replace the flow sensor Fig. 5-11 Replace the return flow sensor FA ROTEX ESU - 07/2008...
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Page 29: Changing The Storage Tank Temperature Sensor
CAUTION! Electrostatic charging Electrostatic charging can damage the electronic components and connections on the circuit board. • Do not touch the electronic components or connections with your bare hands. FA ROTEX ESU - 07/2008... -
Page 30: Installing And Removing The Central Unit
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. -
Page 31: Wiring Diagram
Pressure gauge capillary tube 30 Electric heat generator with three tubular 40 6-pin circuit board connector empty housing Controller: Central unit ROTEX ALPHA radiators of 3 kW, each tubular radiator (circuit board terminal not occupied) 17 Fill level control lamp... -
Page 32: Rotex Control System Alpha + 23R
Further information on the boiler control panel can be found in Chapter 5. The electronic, digital control system ROTEX ALPHA 23R automatically controls all heater-, and warm water functions for the direct heater circuit, an optionally connectable mixed heating circuit and a storage load circuit. -
Page 33: Default Settings" Rotary Switch
6 ROTEX control system ALPHA 6.2.2 "Default settings" rotary switch TARGET HOT WATER Display and modify target hot water temperature. TEMPERATURE NORMAL OPERATING Default setting. Display the current flow temperature (to display the current external MODE and hot water temperature, see Chapter 6.5.2, page 35). -
Page 34: Display
Tab. 6-1 Basic displays COM socket The COM socket is used to connect a PC or an external data storage device. Only ROTEX service engineers may use the COM socket. Default settings 6.5.1 General information • Press the key to enter the programming level. -
Page 35: Normal Operating Mode
6 ROTEX control system ALPHA 6.5.2 Normal operating mode • Set the "Default settings" rotary switch to position • Set the "Selection of operating mode" rotary switch to the correct position. Fig. 6-2 Setting normal operating mode • Set the "Default settings" rotary switch to position •... -
Page 36: Setting The Time And Weekday
The storage tank charging circuit is controlled in accordance with the ST/OT contact. With the ST/OT contact closed (= off-peak tariff) the ROTEX ESU heats the water to the set warm water target temperature, with the contact open (= standard tariff) it hold the warm water temperature (applies for automatic programmes only 1–3). - Page 37 6 ROTEX control system ALPHA 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.
- Page 38 6 ROTEX control system ALPHA 12:00 00:00 12:00 00:00 00:00 05:00 08:00 16:00 22:00 07:00 23:00 . . . Fig. 6-8 Schematic representation of how the "Automatic I" switching time programme is processed The example shows the factory settings for the switching times for the direct heating circuit. Odd numbers (such as t1.1, t1.3) define the corresponding switch-on time, whilst even ones (such as t1.2, t1.4) represent the switch-off time.
- Page 39 6 ROTEX control system ALPHA 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.
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Page 40: Manual Operation
6 ROTEX control system ALPHA 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. - Page 41 6 ROTEX control system ALPHA Overview of general system information Info value no. Info value Can be viewed by Comment Installer Operator External temperature If sensor value is available, otherwise "n. c." or "uuuu" External working temperature If no sensor value is available = 0 °C...
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Page 42: System Parameters
6 ROTEX control system ALPHA Info value no. Info value Can be viewed by Comment Installer Operator Fault no. 1 (most recent fault) Fault no. 2 Fault no. 3 Fault no. 4 Fault no. 5 For fault codes, see the fault code table (Chapter 10.3). -
Page 43: Overview Of System Parameters
6 ROTEX control system ALPHA 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. - Page 44 6 ROTEX control system ALPHA Parameter name Can be set Range Meaning Min. Max. 16 Night reduction –80 °C 10 °C Value how much the flow temperature calculated by the control system – is reduced in setback mode. 17 DCP run-on time after...
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Page 45: Resetting Parameters To Factory Settings
6 ROTEX control system ALPHA 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 keys to select parameter [86]. -
Page 46: Setting Heating Characteristics
6 ROTEX control system ALPHA 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. -
Page 47: Automatic Summer Switch-Off
• 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]. -
Page 48: Setting The Maximum Flow Temperature
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. Tab. 6-9 Dependencies between flow temperatures and the direct circuit Hot water circuit... -
Page 49: Manual Hot Water Recharging
6 ROTEX control system ALPHA Hot water, OEM max. Hot water, absolute min. Off-peak tariff Hot water, HE max. Hot water, energy-saving Standard tariff Hot water, operator Switch hysteresis warm water Time Storage tank temperature Fig. 6-18 Dependencies between hot water parameters The temperature can only be maintained if a heating output has been set for hot water at the standard tariff (see Chapter 3.10,... -
Page 50: Legionella Protection
6 ROTEX control system ALPHA 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. -
Page 51: Electric Heat Generator
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. -
Page 52: Fault Shutdown Of The Power Circuit Board
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 FA ROTEX ESU - 07/2008... -
Page 53: Hydraulic Connection
– 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. -
Page 54: Hydraulic System Connection
Hot water Heating flow Heating return flow Boiler circuit pump Included in the scope of delivery of the ROTEX ESU 3-way diverter valve Included in the scope of delivery of the ROTEX ESU Storage tank temperature sensor Included in the scope of delivery of the ROTEX ESU... -
Page 55: Rotex E-Solarunit With Solar Heating Support
8.3.3 ROTEX E-SolarUnit with integrated wood boiler ÜV SCS-TR AMK1 RPS3 ESU 509 Fig. 8-2 Standard connection diagram for the ROTEX E-SolarUnit with integrated wood boiler Other connection diagrams can be found on the ROTEX Heating Systems GmbH website (see www.rotex.de). Company ROTEX ESU - 07/2008... -
Page 56: Service And Maintenance
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. -
Page 57: Checking The Connections And Pipes
• 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 FA ROTEX ESU - 07/2008... -
Page 58: Faults And Malfunctions
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. -
Page 59: Fault Codes
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 Tab. 10-1 Error codes of the ROTEX ESU on the ROTEX ALPHA FA ROTEX ESU - 07/2008... -
Page 60: Malfunctions
• 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 •... -
Page 61: Taking Out Of Service
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. -
Page 62: Technical Data
= 45 °C The specif. water flow acc. to EN 625 is the domestic water flow, at an average temperature increase of 30 K, which the ROTEX ESU can supply if two draw-off procedures each of 10 minutes duration are performed one after the other, assuming a charging temp. of 65 °C. A delay of 20 minutes between the two draw-off procedures is usually assumed. - Page 63 IP 20 Software class Housing dimensions (W x H x D) 144 x 96 x 75 Housing material ABS with antistatic agent Tab. 12-4 Technical data ROTEX ALPHA 007.1502544 Type Max. permissible operating pressure Rated thermal load Max. permissible operating temperature Voltage supply Max.
- Page 64 / 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) S= 20 K S= 15 K S= 10 K 1000 m / L/h...
- Page 65 Storage tank temperature 60 °C / L/min = Draw-off rate in litres per minute Draw-off temperature 40 °C Flow temperature 80 °C Cold water temperature 10 °C Fig. 12-5 Available draw-off volumes depending on the draw-off rate FA ROTEX ESU - 07/2008...
- Page 66 Measured temperature in °C Sensor type –20 –10 Sensor resistance in ohms according to manufacturer's specifications 1386 1495 1630 1772 1922 2080 2254 2418 2598 2796 2982 3185 3396 Tab. 12-6 Resistance values of the PTC temperature sensors FA ROTEX ESU - 07/2008...
- Page 67 12 Technical data FA ROTEX ESU - 07/2008...
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Page 68: Accessories
13.1 External temperature sensor Accessories The external temperature sensor is supplied with the ROTEX ESU. It is tapped to the prepared sensor line, which is connected in the control panel by delivery. If no external temperature sensor is connected, the control sets the external working temperature value to 0 °C by default. -
Page 69: Notes
Tab. 14-1 Individual settings made by the user or the heating technician for the "Out at work" switching time programme Individual parameter changes • Enter your parameter changes in the table below. Parameter no. Old value New value Date Comments Tab. 14-2 Individual changes made to parameters by the user or the heating technician FA ROTEX ESU - 07/2008... - Page 70 14 Notes FA ROTEX ESU - 07/2008...
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Page 71: List Of Keywords
Switching switching time Design ROTEX ESU ....8 programme ....32 Dimensions . -
Page 72: Service Log
Cleaning and testing the function of the safety overflow Cleaning the storage tank and protective cover Changes made to the control's adjustable parameters, plus other comments regarding the heating system Date Signature Comments FA ROTEX ESU - 07/2008...
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