Rotex HPSU compact 308 Installation Instructions Manual

ROTEX HPSU compact 308

Solar tank with integrated interior heat

pump unit

Installation instructions

For the qualified installer

Types

HPSU compact 308

Serial Number

Customer

GB

Edition 02/2012

2FA ROTEX HPSU compact 308 - 02/2012

Guarantee and conformity

Warranty conditions

The legal guarantee conditions fundamentally apply. Our warranty conditions beyond that can be found online on your sales

presentative's webpage.

Declaration of conformity

for the Solar tank with integrated interior heat pump unit (ROTEX HPSU compact).

We, ROTEX Heating Systems GmbH, declare under our sole responsibility that the products

Product Order No.

ROTEX HPSU compact 308 14 15 06

comply, in its standard design, with the following European Directives:

2004/108/EC Electromagnetic Compatibility Directive

2006/95/EC EC Low Voltage Directive

Güglingen, 01.09.2011 Dr.-Ing. Franz Grammling

Managing Director

List of contents

3

FA ROTEX HPSU compact 308 - 02/2012

1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1 Refer to the manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.2 Warning signs and explanation of symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.3 Avoiding danger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.4 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.5 Instructions for operating safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Set-up and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1 Dimensions and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.3 Hydraulic connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.4 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.4.1 Installation of cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.4.2 Connection diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.4.3 Connection of exterior heat pump unit RRLQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.4.4 Connection to backup heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.4.5 Connection of room thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.4.6 Connecting the ROTEX HP convector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.4.7 Connection of pulse input, current meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.4.8 Low-cost connector (HT/NT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.4.9 Connection of switching contact (AUX output) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.4.10 Connection of ROTEX Solaris installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.4.11 Symbols, key designations, cable colours and complementing instructions to the connection and electrical circuit diagrams . . . 24

2.5 Laying refrigerant lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.6 Pressure test and vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.1 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.1.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.1.2 Configuration of DIP switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.1.3 Test run and setting of minimum flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.1.4 Set parameters of main control unit HPR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.1.5 Set parameters of the additional control unit HPRA1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.2 Re-commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4 Parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.2 Main control unit (HPR1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.2.1 Displaying and setting parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.2.2 Parameter description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4.2.3 Overview of factory-set parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4.3 Additional control unit (HPRA1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.3.1 Overview of factory-set parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.3.2 Displaying and setting parameters (head technician) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5 Hydraulic system connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

6 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

6.1 Basic data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

6.2 Characteristic lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

6.2.1 Sensor characteristic lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

6.2.2 Characteristic curves for pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6.3 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

7 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

8 List of keywords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

1 x Safety

4FA ROTEX HPSU compact 308 - 02/2012

1Safety

1.1 Refer to the manual

This instruction manual is directed at persons who are authorised and who have successfully completed an enabling technical or

craft training course, as well as having attended a further educational course recognised by the individual authorities concerned.

This, in particular, includes heating specialists and climate control technicians who have experience, as a result of their technical

training and their knowledge of the subject, of proper and appropriate installation and maintenance of heating, climate control

and cooling installations and heat pumps.

This manual provides all the necessary information for installation, start-up and maintenance, as well as basic information on

operation and settings. All parameters needed for trouble-free operation have been configured at the factory. Please see the

attached documents for a detailed description of operation and control.

Please read this manual carefully and thoroughly before proceeding with the installation or modification of the heating system.

Relevant documents

– ROTEX HPSU compact; the associated operating instructions and the operating manual for the operator.

– External unit for ROTEX HPSU compact; the associated installation and operating instructions.

– When connecting a ROTEX Solaris solar installation; the associated installation- and instruction manuals.

– When connecting a ROTEX HP convectors; the associated installation- and instruction manuals.

The guides are included in the scope of supply for the individual units.

1.2 Warning signs and explanation of symbols

Meaning of the warnings

Warnings in this manual are classified according into their severity and probability of occurrence.

DANGER!

Draws attention to imminent danger.

Disregarding this warning can lead to serious injury or death.

WARNING!

Indicates a potentially dangerous situation.

Disregarding this warning can result in serious injury or death.

CAUTION!

Indicates a situation which may cause possible damage.

Disregarding this warning may cause damage to property and the environment.

This symbol identifies user tips and particularly useful information, but not warnings or hazards.

1 x Safety

5

FA ROTEX HPSU compact 308 - 02/2012

Special warning signs

Some types of danger are represented by special symbols:

Electric current Danger of explosion

Danger of local freezing up Danger of burning or scalding

Health impairing or irritant materials Danger of environmental damage

Prescribed temperature for continuous use

Validity

Some information in this manual has limited validity. The validity is highlighted by a symbol.

Pay attention to the stipulated tightening torque (See chapter 6.3 "Tightening torque")

Order number

Notes related to Order numbers are identified by the cart symbol .

Handling instructions

• Handling instructions are shown as a list. Actions of which the sequential order must be maintained are numbered.

ÎResults of actions are identified with an arrow.

1.3 Avoiding danger

The ROTEX HPSU compact is state-of-the-art and is built to meet all recognised technical requirements. However, improper use

may result in serious physical injuries or death, as well as property damage.

To prevent such risks, install and operate ROTEX HPSU compact only:

– as stipulated and in perfect condition,

– with an awareness of safety and the hazards involved.

This assumes knowledge and use of the contents of this manual, of the relevant accident prevention regulations as well as the

recognised safety-related and occupational health rules.

WARNING!

This unit is not intended for use by persons (including children) with impaired physical, sensory or mental

faculties or persons with insufficient experience and/or expertise unless supervised by a person responsible for

ensuring their safety or are given instruction by this person on how to use the unit.

1 x Safety

6FA ROTEX HPSU compact 308 - 02/2012

1.4 Intended use

The ROTEX HPSU compact may only be used for the preparation of hot water, as a room heating system or as a room cooling

system. 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 permitted. The following combinations are permissible in this respect:

Internal unit Order No. External unit Order No.

HPSU compact 308

(Heating/cooling function) 14 15 06

RRLQ006BBV3 14 41 42

RRLQ007BBV3 14 41 43

RRLQ008BBV3 14 41 44

Tab. 1-1 Permissible combinations of ROTEX external units for heat pumps and the ROTEX HPSU compact

Any other use outside the intended use is considered as improper. The operator alone shall bear responsibility for any resulting

damage.

Use as intended also involves compliance with maintenance and inspection conditions. Replacement 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 working on the hydraulic system

• 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 appropriate responsible authorities. This, in particular, includes

heating specialists and climate control technicians who have experience, as a result of their technical training and their

knowledge of the subject, of proper and appropriate installation and maintenance of heating, climate control and cooling

installations and heat pumps.

• Switch off the mains supply before starting any work on the ROTEX HPSU compact and secure it against unintentional

switch-on.

• Lead tamper-proof seals must not be damaged or removed.

• Make sure that the safety valves comply with the requirements of EN 12828 when connecting on the heating side, and with

the requirements of EN 12897 when connecting on the domestic water side.

• Only original ROTEX replacement parts may be used.

Electrical installation

• Electrical installation may be carried out only by electrical engineers and in compliance with the valid electrotechnical guide-

lines as well as the regulations of the relevant energy supply company (EVU).

• Compare the mains voltage (~230 V, 50 Hz) indicated on the nameplate with the supply voltage before connecting to the

mains.

• Before beginning work on live parts, disconnect them from the power supply (switch off main switch, remove fuse) and

secure against unintentional restart.

• Equipment covers and service panels must be replaced as soon as the work is completed.

Working on cooling systems (Heat pump)

For work on stationary refrigeration systems (heat pumps) and air conditioning systems, proof of expertise is

required in the European Community according to the F-Gases Directive (EC) No. 842/2006.

– total overall coolant weight up to 3 kg: expert certificate category 2

– total overall coolant weight in excess of 3 kg: expert certificate category 1

• Always wear safety goggles and protective gloves.

• When working on the refrigerant circuit, ensure that the workplace is well ventilated.

• Never carry out work on the refrigerant circuit in closed rooms or work pits.

• Do not let refrigerant come into contact with open fire, embers or hot objects.

• Never allow refrigerant to escape into the atmosphere (high pressure at the point of the leak).

• When removing the service pipes from the filling connections, never hold the connections in the direction of your body.

Residual refrigerant could escape.

• Components and spare parts must at least satisfy the technical requirements defined by the manufacturer.

1 x Safety

7

FA ROTEX HPSU compact 308 - 02/2012

Corrosion protection

In some regions, corrosive potable water is supplied by public utility companies that can cause damage through corrosion even in

high grade stainless steels. Ask your water utility whether the use of heating components made from stainless steel results in

problems with corrosion in your area.

Observe the relevant rules of technology (VDI 2035) to avoid the formation of corrosion and deposits.

Measures for desalination, softening or hardness stabilization are necessary, if the filling and top-up water have a high total

hardness (>3 mmol/l - sum of the calcium and magnesium concentrations, calculated as calcium carbonate).

Equipment installation location

For safe and fault-free operation, it is necessary that the installation location of the HPSU compact fulfils certain criteria. Related

information can be found in chapter 2.

Information on the installation site of other components can be found in the associated documentation supplied with them.

Hydraulics

• Create a heating system according to the safety requirements of EN 12828.

• For the connection on the heater side, the safety valves must meet the requirements of EN 12828 and must be type-approved.

The connection of a solar installation, an electric heating rod or an alternative heat generator may cause the storage temperature

to exceed 60 °C.

• During installation, therefore, install a scald protector (e.g. VTA32 15 60 15 and 1" screw connection set

15 60 16).

If the ROTEX HPSU compact is connected to a heating system with steel pipes, radiators or non-diffusion-proof floor heating

pipes, slurry and swarf could enter the hot water storage tank and cause blockages, local overheating or corrosion.

• To prevent possible damage, fit a dirt filter in the heating return line of the system.

– For units up to 6-16 kW: SFR 28 ( 15 60 11)

Sanitary connection

With sanitary connection, you must observe;

• EN 1717 - Protection of drinking water from contamination in drinking water installations and general require-

ments for safety equipment for prevention of drinking water contamination by back-flow,

• EN 806 - Technical Regulations for Potable Water Installations (TRWI),

• and, in addition, the country-specific legal stipulations.

Operation

The ROTEX HPSU compact:

• Do not operate until all installation and connection work is completed.

• Only operate with a completely full storage tank (Level indicator) and heating circuit.

• Only connect with a pressure reducer on the external water supply (supply line).

• Operate at a maximum pressure of 3 bar.

• Only operate the with the specified quantity of refrigerant and the type of refrigerant specified.

• Only operate if the protective cover is installed.

The prescribed maintenance intervals must be maintained and the inspection work must be carried out.

Instruct the operator

• Before you hand over the ROTEX HPSU compact, explain to the user/owner how to operate and check the system.

• Document the handover by filling out the installation and instruction forms together with the owner and sign them.

Documentation

• The technical documentation included in the scope of supply is a constituent part of the equipment. It must be stored in such

a way that it can be consulted at any time by the operator or the technicians.

2 x Set-up and installation

8FA ROTEX HPSU compact 308 - 02/2012

2 Set-up and installation

WARNING!

Cooling systems (heating pumps), climate control systems and heating devices that have been set up and

installed incorrectly can both endanger life and health of people and be impaired in their function.

• Work on the 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. These include in particular certified heating engineers, qualified electricians

and HVAC specialists, who because of their professional training and expert knowledge, have

experience in the professional installation and maintenance of heating, cooling and air conditioning

systems and heat pumps.

2.1 Dimensions and connections

1 Solaris feed

2Cold water

3Hot water

4 Heating feed

5 Heating return flow

6 Connection refrigerant gas line

7 Connection refrigerant fluid line

A Front

BBack

Fig. 2-1 Connections and dimensions HPSU compact (General)

1 Solaris - flow (1" swivel nut)

2 Cold water supply (1" outer thread)

3 Hot water (1" outer thread)

4 Heating flow (1" outer thread)*

5 Heating return flow (1" outer thread)*

6 Circulation pump (storage tank circuit)

7 Safety-pressure relief valve (heating circuit)

!

8 Automatic vent

!

18 Assembly position for optional backup heater (R 11/2“ IG)

20 Fill level indicator (tank water)

29 Heat insulation

30 Plate heat exchanger (PWT)

31 Connection refrigerant fluid line CuT, Ø 6.4 mm (1/4")

32 Connection refrigerant gas line CuT, Ø 15,9 mm (5/8")

33 Filling connection for refrigerant

34 Ball cock (heating circuit)

35 Combined filling and draining valve (heating circuit)

37 Storage tank temperature sensor tDHW1 and tDHW2

38 Connection diaphragm expansion vessel (MAG)

3UV1 3-Way switch valve (hot water/heating)

3UVB 3-Way switch valve (temperature limiter)

HPR Control housing with electr. terminal strip

tR1 , V1

Return line and flow sensor

tR2 Return temperature sensor

tV1 , tV2

Flow temperature sensors

tV, BH1 , tV, BH2

Flow temperature sensors, backup-heater

!

Safety devices

Pay attention to the tightening torque

(see chapter 6.3 "Tightening torque")

* Ball cock (1" internal thread) is included in the delivery

Fig. 2-2 Connections and dimensions HPSU compact (top of unit)

2 x Set-up and installation

9

FA ROTEX HPSU compact 308 - 02/2012

1 Solaris - flow (1" swivel nut)

2 Cold water supply (1" outer thread)

3 Hot water (1" outer thread)

4 Heating flow (1" outer thread)*

5 Heating return flow (1" outer thread)*

6Circulation pump

7a Recommended accessories:

Non-return valves (2 pcs.), 16 50 70

8 Storage tank (double-wall polypropylene sleeve

with PUR rigid foam heat insulation)

9 Filling and drain connection (Tr. 32x3 AG) with

valve insert

(When connecting a ROTEX Solaris solar

installation: Solaris - return)

12 Corrugated stainless steel pipe heat exchanger

for domestic hot water heating

13 Corrugated stainless steel pipe heat exchanger

to storage tank charging

14 Stainless steel corrugated pipe heat exchanger

for heating support

17 Connection for optional backup-heater

(R 11/2" internal thread)

19 Solar - flow stratification pipe (for use with

connection of optional ROTEX Solaris solar

installation)

20 Fill level indicator (water circuit)

21 Submersible sensor sleeve for storage tank

temperature sensor tDHW1 and tDHW2

22 Pressure-free storage tank water

23 Solar zone

24 Hot water zone

25 Safety overflow connection (Tr. 32x3 AG)

26 Handle

27 Type plate

28 Protective cover

30 Panel heat exchanger

31 Connection refrigerant fluid line

CuT, Ø 6.4 mm (1/4")

32 Connection refrigerant gas line

CuT, Ø 15.9 mm (5/8")

36 Pressure gauge (heating circuit)

!

3UV1 3-Way switch valve (hot water/heating)

3UVB 3-Way switch valve (temperature limiter)

HPR Control housing with electr. terminal strip

HPR1 Main control

HPRA1

Additional control

RPS3 Optional: Solaris control and pump unit

!

Safety devices

Pay attention to the tightening torque

(see chapter 6.3 "Tightening torque")

* Ball cock (1" internal thread) is included in the

delivery

Fig. 2-3 Connections and dimensions HPSU compact (Side view and interior)

2 x Set-up and installation

10 FA ROTEX HPSU compact 308 - 02/2012

2 x Set-up and installation

11

FA ROTEX HPSU compact 308 - 02/2012

2.2 Installation

• Remove packing and dispose of it in an environment-friendly manner.

• Install the HPSU compact at the installation site.

– Recommended clearances (fig. 2-4):

From the wall (s1):  200 mm

To the ceiling (X):  1200 mm.

– Transport the HPSU compact carefully, using the handles provided on it.

– When setting up the unit in a cabinet, behind panels or in other restricted conditions, sufficient ventilation

(e.g., using ventilation gratings) must be ensured.

Optional backup heater (BUH):

If the heat output of the HPSU compact is insufficient, the optional backup heater (BUH) can provide heating

power to heat the heating circuit. Due to its intelligent storage technology, the backup heater (BUH) can also be

used for the supporting heating of the readiness zone (hot water) (booster function).

If a backup heater is installed, its installation into the HPSU compact must take place before final setup and

filling.

A separate manual, including, among other things, i instructions for installation and operation is attached to this

component ( Pay attention to the tightening torque, see chapter 6.3 "Tightening torque").

Fig. 2-4 Installation HPSU compact

2.3 Hydraulic connection

CAUTION!

If the HPSU compact is connected to a heating system with steel pipes, radiators or non-diffusion-proof

floor heating pipes, slurry and swarf could enter the hot water storage tank and cause blockages, local

overheating or corrosion.

• Ensure that the volume up to the heating circuit or up to the overflow valve is at least 10 L. This results,

for example, from a total line length VA Ø 32 of 24 m or Cu Ø 28 of 20.4 m.

• Flush the feed pipes before filling the heat exchanger.

• Rinse out the heat distribution network (in the existing heating system).

• Install dirt filter in the heating return line (e. g. SFR 28 15 60 11).

2 x Set-up and installation

12 FA ROTEX HPSU compact 308 - 02/2012

Requirement: Optional accessories (e.g. Solaris, backup heater) mounted on the HPSU compact according to the specifications

of the instructions included.

• Establish hydraulic connections at the HPSU compact.

– For the position and dimension of the connections, see section 2.1.

–Pay attention to the tightening torque (see chapter 6.3 "Tightening torque").

• Carefully lag the hot water pipes to prevent heat loss.

– The thermal insulation needs to be at least 20 mm thick to prevent condensation from forming on the surface of the

insulation material.

• Connect the pressure relief line to the safety pressure relief valve and the membrane expansion tank as per EN 12828.

• Check the cold water connection pressure (maximum 6 bar).

ÎIf a higher pressure is present in the domestic water pipe, a pressure reducer will need to be installed.

• Connect drainage hose to the connection on the safety overflow

(fig. 2-3, item 25).

– Use transparent drain hose (draining water must be visible).

– Connect the drain hose to an adequately dimensioned waste

water installation.

– Drain should not be lockable.

Fig. 2-5 Installation of drain hose at

safety overflow

• Open the cold water connection and fill the potable water heat exchanger.

• Fill buffer tank above the fill and discharge connection (fig. 2-3, item 9) until the water emerges from the safety overflow

(fig. 2-3, item 25).

• Fill heating system.

2.4 Electrical connection

WARNING!

Touching live parts can result in an electric shock and lead to potentially fatal injuries and burns.

• 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 and working on the electrical components should only be performed by

electrical engineers in compliance with valid standards and guidelines as well as the specifications of

the energy supply company.

•The equipment covers and maintenance opening covers must be re-fitted immediately after

completion of the work.

CAUTION!

Increased temperatures may arise in the control housing of HPSU compact during operation. This can

result in currently-carrying wires from reaching higher temperatures during operation due to self-heating.

For this reason, these lines must have a temperature for continuous use of 90 °C.

• For the following connections, use only calbes with a long-term use temperature 90 °C:

– Exterior heat pump unit

– Backup-heater (optional)

2 x Set-up and installation

13

FA ROTEX HPSU compact 308 - 02/2012

2.4.1 Installation of cables

Fig. 2-6 1. Remove the protective cover. Fig. 2-7 2. Dismount right housing cover. Fig. 2-8 3. Unlock front panel.

1.

2.

Fig. 2-9 4. Open front panel and place in

assembly position.

Fig. 2-10 5. Route cabling into the regulator

and make the electrical

connections (see section 2.4.2).

Fig. 2-11 6. Lay cables in the right

housing cover.

Fig. 2-12 7. Install the right housing cover. Fig. 2-13 8. Fasten cabling on the storage

container.

2 x Set-up and installation

14 FA ROTEX HPSU compact 308 - 02/2012

2.4.2 Connection diagrams

Overall connection diagram

Fig. 2-14 Overall connection plan - for disconnection of the outdoor and indoor unit by EVU

Fig. 2-15 Overall connection plan - for disconnection of the outdoor unit by the EVU (the HPSU compact interior unit is not disconnected)

2 x Set-up and installation

15

FA ROTEX HPSU compact 308 - 02/2012

2 x Set-up and installation

16 FA ROTEX HPSU compact 308 - 02/2012

Position of the circuit boards

A4P

A1P

XR1P

X1

A1P Circuit board (under XR1P)

A4P Solaris circuit board (accessories)

X1 Terminal strip

XR1P Circuit board

Fig. 2-16 Overview, circuit boards of control unit

Connection assignment, circuit board A1P

The A1P circuit board comes pre-connected to the unit. No assembly or connection work is necessary on the A1P circuit board!

2121

111111

1111

A1PA1P

X4X4

(XRP1)(XRP1)

X3X3

(XRP1)(XRP1)

X2X2

(XRP1)(XRP1)

FU1 (250V T 3,15A)

X13A

SS2

SS1

on

off

X17A X21A X14A X16A X20A

X15AX19AX11AX12A X3A

X4A

X10A X18A

X40A

X5A X6A X7A X8A X9A X33A

X1A

X61A

X60A

Fig. 2-17 Circuit board A1P

2 x Set-up and installation

17

FA ROTEX HPSU compact 308 - 02/2012

Connection assignment, XR1P circuit board

Fig. 2-18 XR1P circuit board 230 V, 50 Hz mains voltage (1= Connection diagram in this manual

(2= Connection diagram in the manual for the part

2 x Set-up and installation

18 FA ROTEX HPSU compact 308 - 02/2012

2.4.3 Connection of exterior heat pump unit RRLQ

This component has a separate manual attached, including among other things instructions for installation and

operation.

Fig. 2-19 Connection to exterior heat pump unit - for disconnection of the outdoor and indoor unit by EVU

Fig. 2-20 Connection to exterior heat pump unit - for disconnection of the outdoor unit by the EVU

(the HPSU compact interior unit is not disconnected)

2 x Set-up and installation

19

FA ROTEX HPSU compact 308 - 02/2012

2.4.4 Connection to backup heater

This component has a separate manual attached, including among other things instructions for installation and

operation.

A1 A2

A On-site cabling

A1 BUH connection variants 3-phase

A2 BUH connection variants 1-phase (observe country-specific

connection conditions - request from responsible power

company (EVU))!

X Minimum clearance contact (>3 mm)

Y Switching contactor

Fig. 2-21 Connecting optional backup heater

2 x Set-up and installation

20 FA ROTEX HPSU compact 308 - 02/2012

2.4.5 Connection of room thermostat

This component has a separate manual attached, including among other things instructions for installation and

operation.

The connection of the room thermostat to a ROTEX HP convector is described in section 2.4.6.

Installation without room thermostat:

The cable bridge- mounted on-site - is recommended by ROTEX as otherwise problems may arise due to the

cyclical circulation pump during heating operation. The DIP switch 3 (see tab. 3-1, chapter 3 "Start-up") must

be set to "ON".

The absence of a summer switch-off on the circulation pump can be compensated for by manually switching off

heating in the summer (key ) when a cable bridge is mounted.

RT

N

RT

C

RT

L

RT

H

PE PE

9

X1 (XR1P)

HPSU compact

RT

N

RT

C

RT

L

RT

H

PE PE

X1M

9

X1 (XR1P)

HPSU compact Rotex

RKRTW

HcomC

RT

N

RT

C

RT

L

RT

H

PE PE

X2M

X1M

9

X1 (XR1P)

HPSU compact Rotex

RKRTR

HC Lcom N

Fig. 2-22 Connection without

room thermostat*

Fig. 2-23 Connection with room thermostat

cable-connected

Fig. 2-24 Connection with radio-controlled room

thermostat

* The cable bridge must be

installed on-site before start-up.

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Rotex HPSU compact 308 Installation Instructions Manual

Rotex HPSU compact 308 Installation Instructions Manual

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