Rollo Solar RT 200 Installation Manual
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Rollo Solar RT 200 Installation Manual

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Tubular Motors
RT 200
RT 400

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Summary of Contents for Rollo Solar RT 200

  • Page 1 Installation Manual Tubular Motors RT 200 RT 400...
  • Page 2 As of 05/2018...
  • Page 3 The length of the conduit between the drive and connection box should be max. 3.5 m. • The supply cable between the controller and distribution box must correspond to the ’ ‘ characteristics specified in Rollo Solar s supply table (see the section Rollo Solar supply ’ table ).
  • Page 4 Initial start-up Caution! The qualified specialist performing the installation must start up the system and provide instructions to the operator. The operator must be provided with information regarding all protection regulations and due diligence which must be observed. Scope of delivery The scope of delivery is indicated on the delivery note.
  • Page 5 The motors are to be used in pool water with a quality corresponding to DIN 19643 for non-swimmer pools. The saline concentration agreed with the retailer/customer and Rollo Solar may not be exceeded in the case of swimming pools operated with saline water.
  • Page 6 Symbols on components During the (re)commissioning of the pool cover, the ‘ZU’ (OPEN) and ‘ZU’ (CLOSED) end positions of the swimming pool system must be monitored and adjusted if necessary in accordance with these operating instructions. The distribution box must be installed and must be freely accessible at all times on the edge of the pool;...
  • Page 7 General operating and safety instructions It is important that these instructions are followed to ensure personal safety and prevent damage to property. Keep all safety information and instructions for future reference. • The swimming pool cover may only be used after receiving instructions from the authorised pool retailer.
  • Page 8 • The threshold values/concentration of salt electrolysis/saline, chloride concentration, pH values, etc. specified by the manufacturer must be met at a minimum and must not be exceeded. The operator is responsible for establishing and monitoring these values. • Any change and/or modification to the product by the operator or retailer is prohibited and will invalidate the warranty and guarantee claims.

  • Page 9: Table Of Contents

    Cable gland for drive ......................13 Inserting the cable between the distribution box and technical system ....... 14 Supply cable table – Rollo Solar cable cross sections ............. 15 Grounding the distribution box ..................19 Connecting the drive and connecting cable ..............20 Alternative routing for the cable ..................
  • Page 10 Emergency mode active ....................57 Thermoprotector active ....................57 Motor/pulse generator fault .................... 58 Undervoltage ........................59 Emergency mode ......................60 Maintenance ........................61 Decommissioning ......................61 Disposal ..........................61...

  • Page 11: Installation

    3.5 m. The supply cable between the controller and distribution box must correspond to the characteristics specified in Rollo Solar’s supply table. We recommend using the original extension cable, article no. 6100-0023.

  • Page 12: Installing The Rt 200 In The Shaft

    RT 200 NSTALLING THE IN THE SHAFT (1) Bearing ring (2) Motor with actuator pin (3) Actuator device for actuator pin The plastic disc, actuator and bearing ring are screwed to the shaft. The plastic discs are pre-installed in the shaft.
  • Page 13 (1) Actuator pin (2) Actuator device for actuator pin Installation steps Use the actuator pin (1) to secure the drive in the actuator device (2). Make sure that the actuator pin engages in the pre-installed actuator device in the shaft. Caution! The plastic discs, actuator and bearing rings are already pre-installed with screws.

  • Page 14: Installing The Rt 400 In The Shaft

    RT 400 NSTALLING THE IN THE SHAFT (1) Bearing ring (2) Drive (3) Bearing ring (4) Actuator device with notch for key Page | 4...
  • Page 15 (1) Key (2) Actuator device for key Installation steps Use the key (1) to secure the drive in the actuator device (2). Make sure that the key of the drive engages in the pre-installed actuator device in the shaft. Caution! The plastic discs, actuator and bearing rings are already pre-installed with screws.

  • Page 16: Conversion From K-Motor To Rt Drive

    Use the enclosed screws to mount the adapter illustrated above (1) between the existing pre-assembly component and the RT motor. Mount the POM discs (2) as illustrated above; two POM discs are required for the RT 200 and three POM discs are required for the RT 400. Page | 6...

  • Page 17: Cable Routing Between Drive And Clamping Flange

    ABLE ROUTING BETWEEN DRIVE AND CLAMPING FLANGE (1) Screw fitting (4 pieces) (2) Clamping flange (3) Metric cable gland Installation steps four screw fittings mount drive in the clamping flange (2). Guide the green drive cable through the metric cable gland. Hand-tighten the metric cable gland using a VA universal pliers.
  • Page 18 (1) Screw connection (6 pieces) Variable: Nuts + washers or hexagonal screws + washers Installation steps Lubricate the threaded bolts (1) with ceramic paste. Use a VA ring spanner and the corresponding spanner size (M8 or M10) to tighten the six screw connections (1) in a crosswise sequence. Please note: The screw fittings vary depending on the design of the pre-assembly flange, e.g.

  • Page 19: Installing The Counter Bearing (Locking The Shaft)

    NSTALLING THE COUNTER BEARING LOCKING THE SHAFT (1) Screw fitting (4 pieces) (2) Set collar (3) Counter bearing (4) Locking screw Installation steps Lubricate the threaded bolts (1) with ceramic paste. Use a VA ring spanner and the corresponding spanner size (M8 or M10) to tighten the six screw connections (1) in a crosswise sequence.

  • Page 20: Preparing The Distribution Box

    REPARING THE DISTRIBUTION BOX (1) Grounding (2) Connecting piece with internal cable gland (2 pieces) (3) Screw-type blank cap (optional additional connecting piece with cable gland) Installation steps Install the connecting pieces with internal cable gland (2) Install the screw-type blank cap (3) or, if necessary, a third connecting piece (optionally available) Page | 10...

  • Page 21: Installing The Flexible Tube On The Pre-Assembly Flange

    NSTALLING THE FLEXIBLE TUBE ON THE PRE ASSEMBLY FLANGE (1) Flexible tube (green or transparent) (2) Tube clamp (3) Pre-assembly flange (outside of pool) Caution! Only install the flexible tube (1) on the pre-assembly flange when it is cool (3). If the pre-assembly flange has been welded on in the case of stainless steel pools, for example, it may still be hot and could damage the flexible tube (1)! Installation steps...

  • Page 22: Inserting The Drive Cable

    NSERTING THE DRIVE CABLE (1) Distribution box (2) Connecting piece with internal cable gland (3) Tube clamp (4) Flexible tube with cable (drive direction) Installation steps Remove the internal cable gland (2) Insert the cable through the flexible tube (4) and connecting piece (2) into the distribution box (1) Slide the tube clamp (3) over the flexible tube (4) Tighten the tube clamp (3) with a VA Phillips screwdriver...

  • Page 23: Cable Gland For Drive

    ABLE GLAND FOR DRIVE (1) Cable gland (brass nut + rubber plug) Installation steps Slide the rubber plug (1) onto the cable as shown Hand-tighten the cable gland (1) using a VA universal pliers Page | 13...

  • Page 24: Inserting The Cable Between The Distribution Box And Technical System

    (4) Flexible tube with cable (technical system direction) (5) Flexible tube with cable (drive direction) Caution! The connecting cable (4) (5) must correspond to the cable characteristics specified in Rollo Solar supply cable table! We recommend using the original extension cable, article no. 6100-0023. Installation steps...

  • Page 25: Supply Cable Table - Rollo Solar Cable Cross Sections

    – R UPPLY CABLE TABLE OLLO OLAR CABLE CROSS SECTIONS Page | 15...
  • Page 26 ABLE CONNECTION FROM CORES Page | 16...
  • Page 27 ABLE CONNECTION FROM CORES Page | 17...
  • Page 28 ABLE GLAND FOR DISTRIBUTION BOX AND TRANSFORMER (1) Cable gland (brass nut + rubber plug) Installation steps Slide the rubber plug (1) onto the cable as shown Hand-tighten the cable gland (1) using a VA universal pliers Page | 18...

  • Page 29: Grounding The Distribution Box

    ROUNDING THE DISTRIBUTION BOX (1) Grounding for distribution box Installation steps Ground the distribution box according to the corresponding DIN standards e.g. ‘Protection against electrical shock’. Page | 19...

  • Page 30: Connecting The Drive And Connecting Cable

    ONNECTING THE DRIVE AND CONNECTING CABLE 2– (1) Distribution box (2) – (11) (9 pieces) cable connections between drive cable and connecting cable Caution! The cables should not be interchanged to ensure that the cables are not joined to the controller at the wrong number! Carefully connect the drive cable (2) –...

  • Page 31: Alternative Routing For The Cable

    LTERNATIVE ROUTING FOR THE CABLE The cable can alternatively be routed directly into the technical system; in this case, please put the distribution box in place and guide the cable through the distribution box (see image). (1) Cable gland (2 pieces) Installation steps Slide the rubber plug (1) onto the respective end of the cable as shown Hand-tighten the cable gland (1) using a VA universal pliers.

  • Page 32: Sealing The Distribution Box

    EALING THE DISTRIBUTION BOX Caution! Please follow the instructions for use included with the gel. Caution! Make sure that the cables are completely covered by the gel. Installation steps Pour both of the gel components into a suitable container at the same time. Mix the gel until it turns a uniform blue colour.

  • Page 33: Place The Cover On The Distribution Box

    LACE THE COVER ON THE DISTRIBUTION BOX (1) Cover of the distribution box for final installation + countersunk screws (2) Cover of the distribution box during building period + round-head screws Caution! Make sure that the distribution box is accessible at all times. The distribution box must be installed on the edge of the pool and accessible at all times.

  • Page 34: Transformer And Motor Fuse

    RANSFORMER AND MOTOR FUSE Caution! Electrical connection work may only be carried out by a qualified, skilled electrician! Switch off the power supply to the control board during all electrical work! LED (green) / power light – 24 volt circuit LED (green) / mains switch / power light –...
  • Page 35 A spare fuse can be found in the cover of the transformer. Caution! The fuse of the motor may only be replaced by a fuse with the same rating. If the fuse becomes defective again within a short time, please contact Rollo Solar. Page | 25...

  • Page 36: Connecting The Controller With The Cable

    ONNECTING THE CONTROLLER WITH THE CABLE Caution! Electrical connection work may only be carried out by a qualified, skilled electrician! Caution! Switch off the power supply to the control board during all electrical work! The following images show a completely wired RSC 3 circuit board and a RSC 4 with connected PS1 switch.

  • Page 37: Rsc 3 Circuit Board

    RSC 3 CIRCUIT BOARD Page | 27...

  • Page 38: Rsc 4 Circuit Board + Ps1

    RSC 4 + PS1 CIRCUIT BOARD Page | 28...

  • Page 39: Rsc3/Rsc4 Circuit Diagram

    RSC3/RSC4 CIRCUIT DIAGRAM Page | 29...

  • Page 40: Dip Switch - Public Pools

    – SWITCH PUBLIC POOLS Caution! The kill switch must be configured for public swimming pools; this configuration may not be modified or manipulated. The DIP switch with the number 1 must be move to the ON position for this purpose. Configuration step 1.

  • Page 41: Connecting The Braking Resistor

    ONNECTING THE BRAKING RESISTOR Caution! braking resistor varies depending motor power. Connections are identical acc. to circuit diagram/connection diagram. Caution! Make sure that the red LED on the housing of the braking resistor is illuminated when the roller shutter is closing (‘CLOSED’) Caution! Components are getting hot.
  • Page 42 Compensation resistor for direct drive (RT) Connection directly to brake clamp +/- on the RSC control Connection directly to brake clamp +/- on the RSC-PRO control, parallel to the drive Red LED must light up when Rollo closes pool (Pool Covered), If necessary, replace connecting wires for directional adjustment.

  • Page 43: Status Indicators And Operating Buttons

    TATUS INDICATORS AND OPERATING BUTTONS (1) ‘AUF’ (OPEN) LED (2) LED ‘PROG’ (3) LED ‘CLOSED’ (4) DIP switches (5) Internal programming/operating buttons AUF/PROG/ZU (OPEN/PROG/ZU) Page | 33...
  • Page 44 (1) Status indicators/operating states – AUF/PRG./ZU (OPEN/PRG./ZU) (2) Pulse generator LED – green (name on control board: 24V Imp. Geb.) (3) CPU LED – green (named on control board: CPU) (4) 24 volt LED – green (name on control board: CPU) Component Normal operating state Pulse generator –...
  • Page 45 RSC 3 RSC 4 LED colour LED colour AUF (OPEN) AUF (OPEN) Yellow Yellow CLOSED (ZU) Green CLOSED (ZU) Green BLINKING STATUS ILLUMINATED Error message AUF (OPEN) Illuminated Controller not programmed CLOSED AUF (OPEN) CLOSED Blinking Emergency mode active PROG Blinking Error –...

  • Page 46: Programming The End Positions

    ROGRAMMING THE END POSITIONS The end positions (‘AUF’ (OPEN) and ‘ZU’ (CLOSED)) are configured and then saved on the control board. The settings are retained even if there is a power failure. Caution! Always check that the end positions are configured correctly when restarting the system.
  • Page 47 Configuring the ‘ZU’ end position – cover closed Starting programming: Press and hold the ‘PROG’ and ‘ZU’ (CLOSED) operating buttons until the two LEDs ‘PROG’ and ‘ZU’ (CLOSED) are illuminated. ZU – configuring the end position: Use the ‘AUF’ (OPEN) and ‘ZU’ (CLOSED) operating buttons to move the system to the desired end position;...

  • Page 48: Direction Of Rotation Of The Shaft

    IRECTION OF ROTATION OF THE SHAFT ‘ZU’ (CLOSED) – no swimming ‘AUF’ (OPEN) – ready for swimming ‘ZU’ (CLOSED) means that the swimming ‘AUF’ (OPEN) means that the swimming pool cover is rolled out from the shaft and pool cover is rolled onto the shaft and the the swimming pool is covered as illustrated swimming pool is open as illustrated in the in the image to the left.

  • Page 49: Connecting The Key Switch

    ONNECTING THE KEY SWITCH (1) ‘STOP’ operating switch (2) ‘AUF’ (OPEN) operating switch (3) ‘ZU’ (CLOSED) operating switch (4) Key cylinder Please note: This operating switch is available as shown here, as well as with an emergency stop button. The model is available in both a flush mounted version and in a surface mounted version.
  • Page 50 Installation steps Open the housing of the key switch, and use a VA Phillips screwdriver to unscrew the Phillips screw on the front of the housing Insert the key in the key cylinder and move the key to the 1 o’clock position; then pull on the key cylinder to open the housing and remove the components inside.
  • Page 51 Mount the cable gland on the bottom of the switch and guide the cable through it into the switch housing. Connect your supply cable to the cable terminal in the switch housing and take note of the colours of the cables for the respective labels (2, P and 1) of the cable terminal.
  • Page 52 Connect the key switch cables to the circuit board as shown in the image. Circuit board terminal ‘+’ with the cable terminal position ‘P’ of the key switch b. Circuit board ‘AUF’ (OPEN) with cable terminal position ‘1’ of the key switch Circuit board ‘ZU’...

  • Page 53: Connecting The Ps1 Switch

    ONNECTING THE SWITCH Caution! Switch off the power to the RSC controller prior to installing the receiver board! Caution! Use only supply cables with the following characteristics: Telephone line J-Y(ST)Y 2x2 x 0.6 mm², or identical construction. (1) LED (green) – roller shutter ‘ZU’ (CLOSED) (2) LED (red) –...
  • Page 54 Please note: This operating switch (module) fits in all conventional cover frames in the 55 series. Flush as well as surface mounting are possible. It is operated using the provided customer or service key. Please only provide the customer key to the end customer! This module can be operated with the customer key (short, one ring) or service key (long, two rings).
  • Page 55 Connect the switch connections: A, B, C, D with RSC circuit board: A, B, C, D. Operation with PS1 key switch Switch DIP switch no. 7 on the RSC controller to the ‘ON’ position. Power may be supplied to the RSC circuit board again only after this step. Operation without the PS1 operating switch Leave DIP switch no.

  • Page 56: Connecting The Rsc Wireless Module

    ONNECTING THE WIRELESS MODULE Caution! Switch off the power to the RSC controller prior to installing the receiver board! The remote control consists of several components: • Handheld transmitter with operating buttons for opening, closing and stopping the cover as well as an optional light function (only with version RSC-4) •...
  • Page 57 Installation steps: Please remove the receiver board as well as the mounting bolts from the packaging Insert the three white (or black) mounting pins into the RSC motherboard. Carefully position the radio board on the slot on the RSC controller. The gold coloured connecting pins will engage in the green (or black) sockets.
  • Page 58 If an external antenna is being installed, connect the coaxial cable with inner conductor and shield to the K-1 terminal now. Remove the black jumper if an external antenna is being used. Page | 48...

  • Page 59: Programming For The Radio Receiver/Handheld Transmitter

    ROGRAMMING FOR THE RADIO RECEIVER HANDHELD TRANSMITTER Several handheld transmitters (256) can be taught in for the same system. All handheld transmitters must be taught in on the receiver board. This ensures that the handheld transmitter(s) only respond to your receiver. (1) LED (red) –...
  • Page 60 Step 1: Resetting the receiver: In order to ensure that any existing programming is erased, please perform a ‘RESET’. Do so by pressing and holding any channel button on the receiver module for approx. 10 sec. until all channel LEDs are blinking; then release the channel button. All channels are deleted (memory is empty).

  • Page 61: Connection For Locking The Filter Pump

    ONNECTION FOR LOCKING THE FILTER PUMP Caution! The filter pump only runs once the roller shutter has reached the AUF (OPEN) or ZU (CLOSED) position. The R1 auxiliary relay pulls between the end points and its contact blocks the filter pump. Caution! A maximum of 24 VOLT DC, 500 mA can be connected to the ‘POS AUF’...
  • Page 62 Contact state in ZU (CLOSED) position (auxiliary relay in idle position) RSC CONTROL POS OPEN POS CLOSE KEY SWITCH Auxiliary relay 11 and 12 contacts for pump Contact state in AUF (OPEN) position (auxiliary relay in idle position) RSC CONTROL POS OPEN POS CLOSE KEY SWITCH Auxiliary relay 11 and 12 contacts for pump...

  • Page 63: Connection Between Bus - / Eib - System

    (OPEN)/STOP/ZU (CLOSED)) should be provided on the control panel. The roller cover must be kept within sight at all times! Operating mode settings for the RSC controller are made in automatic mode. Cover control – Rollo Solar RSC Clamps RSC POSITION...

  • Page 64: Course Of Action For Errors

    OURSE OF ACTION FOR ERRORS Read the error messages on the circuit board. We have put together solution guidelines for the individual error messages. Operating states which may be indicated when power is being supplied to the RSC controller. The switch on the transformer for the 230 V mains supply and the LED for the 24 V must be illuminated for this purpose.

  • Page 65: Switch Does Not Respond

    6. 6. Is the LED on the transformer lit up green now? If not, please contact Rollo Solar If yes, continue to point 7. 7. Read and make note of error messages on the circuit board, then perform reset Switch off the transformer mains switch for at least 10 seconds;...

  • Page 66: Handheld Transmitter Does Not Respond

    If not, this is an existing handheld transmitter, continue to point 2. If yes, please teach in new handheld transmitter; see the section ‘CONNECTING THE ROLLO SOLAR RSC WIRELESS MODULE’ 2. Are you within the range of the receiver? If not, move within range of the receiver If yes, continue to point 2.

  • Page 67: Controller Not Programmed

    11. Has the error been corrected? If yes, check that the system works by running ‘AUF’ (OPEN) and ‘ZU’ (CLOSED) at a minimum If not, please contact Rollo Solar ONTROLLER NOT PROGRAMMED Error: The controller is not programmed Troubleshooting: Program the controller...

  • Page 68: Motor/Pulse Generator Fault

    Switch off the transformer mains switch for at least 10 seconds; this will confirm all errors! 4. Has the error been corrected? If yes, check that the system works by running ‘AUF’ (OPEN) and ‘ZU’ (CLOSED) If not, please contact Rollo Solar Page | 58...

  • Page 69: Undervoltage

    Switch off the transformer mains switch for at least 10 seconds; this will confirm all errors! 4. Has the error been corrected? If yes, check that the system works by running ‘AUF’ (OPEN) and ‘ZU’ (CLOSED) at a minimum If not, please contact Rollo Solar Page | 59...

  • Page 70: Emergency Mode

    MERGENCY MODE Caution! The programmed end positions ‘AUF’ (OPEN) and ‘ZU’ (CLOSED) are deactivated in emergency mode. The system is moved manually and must be stopped manually. As a result, there is a risk that the roller shutter could turn over or collide with the wall at the end of the pool.

  • Page 71: Maintenance

    AINTENANCE Rollo Solar underwater drives require no maintenance. ECOMMISSIONING Have the underwater drive decommissioned by a skilled expert. ISPOSAL Please dispose motor household rubbish. Dispose of the motor at a suitable recycling centre or collection point. Page | 61...
  • Page 72 ROLLO® SOLAR Melichar GmbH Josef-Janker-Ring 18 83646 Bad Tölz Deutschland / Germany Fon: +49(0)8041/79265-0 Fax: +49(0)8041/79265-50 info@rollo-solar.de http://www.rollo-solar.de...

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Rt 400

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