Rotex E-Solar Unit ESU 509 Page 4 Installation And Maintenance Instructions Manual Download | Manualshive

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Contents

4

FA ROTEX ESU - 07/2008

Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Querying system information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

System parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Setting parameters – Basic procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Overview of system parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Resetting parameters to factory settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Heating technician access code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Setting heating characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Automatic summer switch-off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Setting hot water mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Setting the maximum flow temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Manual hot water recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

6.6.10 Legionella protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Electric heat generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Design and brief description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Load compensation of switching contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Fault shutdown of tubular radiators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Fault shutdown of the power circuit board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Hydraulic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Important information on the hydraulic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Storage tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Hydraulic system connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Short designations used in connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

ROTEX E-SolarUnit with solar heating support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

ROTEX E-SolarUnit with integrated wood boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Service and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

General overview of service and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Service and maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Checking the connections and pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Checking and cleaning the safety overflow and drain hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

x Faults and malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Detecting faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

10.2.1 Individual reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10.2.2 General reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Fault codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Taking out of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Temporary shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Final shutdown and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

External temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Mixer circuit docking sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Room temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

List of keywords. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Service log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

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Summary of Contents for E-Solar Unit ESU 509

Page 1: ...mpanies ROTEX E SolarUnit Electric heat generator with stratified solar storage tank Installation and maintenance instructions Type Rated thermal output ROTEX ESU 509 3 9 kW Serial number Customer GB...

Page 2: ...extended if the unit is returned for repairs or if the unit is replaced Warranty period for the heat generator boiler main body and boiler electronics 2 years Exclusion of warranty Improper use tamper...

Page 3: ...3 9 Filling the system 17 3 10 Setting the heating output 19 4 Start up 20 4 1 Initial start up 20 4 2 Checklists for start up 22 5 Boiler control panel 23 5 1 Operating elements on the boiler control...

Page 4: ...tant information on the hydraulic connection 53 8 2 Storage tank 53 8 3 Hydraulic system connection 54 8 3 1 Short designations used in connection diagrams 54 8 3 2 ROTEX E SolarUnit with solar heatin...

Page 5: ...6 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 Syst...

Page 6: ...mentioned use is considered as improper Any resulting damages will be borne by the user owner alone Proper use also includes observing the relevant maintenance and servicing conditions Spare parts mu...

Page 7: ...ot water mixing device e g VTA32 15 60 16 Operation Do not operate the ROTEX E SolarUnit if the storage tank is filled to above the overflow edge Do not operate the ROTEX E SolarUnit if the protective...

Page 8: ...t generator with integrated safety temperature limiters in heat insulated housing 18 Heat exchanger for solar heating support HU WT 21 Circulation pump for heating 22 3 way diverter valve 23 Flow temp...

Page 9: ...r heating support HU WT 7 Heat exchanger for heating electric heat generator with integrated safety temperature limiting in heat insulated housing see Chapter 7 page 51 8 Heat insulation sleeve for HU...

Page 10: ...EX ESU heats this water using the continuous flow water heater principle If there is sufficient solar radiation the contents of the hot water storage tank can also be heated using solar power ROTEX So...

Page 11: ...nts below Installation area The surface must be solid level horizontal and have sufficient load capacity Install a pedestal if necessary Observe the installation dimensions see Chapter 3 3 3 2 2 Insta...

Page 12: ...e 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 Figu...

Page 13: ...e thread 1 female 6 Heating return flow pipe thread 1 female 7 Solaris flow flat sealing pipe thread 1 swivel nut 25 Safety overpressure valve pipe thread 3 4 female 26 Membrane expansion tank pipe th...

Page 14: ...osits If the filling and additional water has a high degree of hardness measures must be taken to stabilise this hardness or soften the water 3 5 Connecting the valve drive to the 3 way diverter valve...

Page 15: ...riff a switch cable hose line minimum 2 x 0 5 mm2 can be wired through the second cable gland B of the terminal box The switching contact must be connected to terminals 4 and 5 in the terminal box The...

Page 16: ...factory and can be plugged onto the appropriate sensor directly should a replacement be needed The storage tank temperature sensor is installed and connected to the terminals at the factory PTC therm...

Page 17: ...om a separate room thermostat ROTEX ALPHA RTR E 17 51 26 can be installed for the direct or the mixed circuit If you want to use this function you must activate it in the ROTEX ALPHA 23R control Conne...

Page 18: ...ing fittings KFE cock Figure 2 1 page 8 pos 33 and secure against sliding by using a hose clamp Open the water tap for the supply pipe Open the KFE cock and watch the pressure gauge Figure 2 1 page 8...

Page 19: ...switching contact between the terminals 4 and 5 must be carried out potential free For example J3 and J4 can be used to set the output for the hot water preparation operating mode during standard tar...

Page 20: ...ed see Table 4 1 Optional sensors have been properly connected Tab 4 1 Necessary and optional sensors for ROTEX ESU WARNING Danger of death due to improper start up A ROTEX E SolarUnit which is not st...

Page 21: ...it down for longer than 3 s Switch the heat generator off Check that the sensor is working see Chapter 12 Table 12 6 and that it is properly connected Switch the heat generator on If the failure is di...

Page 22: ...ve connected to a free outlet Yes 8 Is the system water pressure within the green range Yes 9 Are the heat generator and heating system vented Yes 10 Are all sensors connected and correctly positioned...

Page 23: ...opping up the system see Chapter 3 9 page 17 Fill level warning lamp This indicates that the storage tank is insufficiently filled i e fewer than two of the three electrodes on the fill level probe ar...

Page 24: ...sure gauge capillary tube see Figure 5 3 pos 30 Use kitchen roll to absorb the small amount of water which will escape when the tube is unscrewed 5 Open the terminal box see Figure 5 3 pos 37 and use...

Page 25: ...h strain relief plates on the control panel see Figure 5 7 11 Unscrew the covering cap from the electronic fill level probe and lift the probe out see Figure 5 8 12 Pull safety temperature limiter STL...

Page 26: ...eased from the boiler control panel or from the relevant components The cables for the internal components in the unit are connected to the circuit board connectors and cannot be released They can be...

Page 27: ...g of the electric heat generator unscrewing the two screws on both sides Figure 5 10 a 2 Remove cover upper heat insulation and lateral heat insulation around the sensor Figure 5 10 b and Figure 5 10...

Page 28: ...5 Boiler control panel 28 FA ROTEX ESU 07 2008 Fig 5 10 Replace the flow sensor Fig 5 11 Replace the return flow sensor...

Page 29: ...off the circuit board see Chapter 5 3 page 26 steps 1 to 4 2 Pull the storage tank temperature sensor out of the sensor immersion sleeve on the storage tank 3 Bend the pressure spring on the new stora...

Page 30: ...1 Figure 5 15 anticlockwise into the installation position and carefully insert the control into the cut out on the central unit parallel with the front face of the boiler control panel until the con...

Page 31: ...ar radiators of 3 kW each tubular radiator safeguarded by an STL 31 Terminal box for connecting the power supply and floating ST OT contact to terminals 32 Connecting cable for floating ST OT contact...

Page 32: ...e of the boiler control panel are explained Further information on the boiler control panel can be found in Chapter 5 1 Selection of operating mode rotary switch 2 Default settings rotary switch 3 Dis...

Page 33: ...d change weekday CLOCK TIME Display and change time PARAMETER Select and change parameters PLUS Changing values The keys are used for navigation within the Parameter Information and Automatic I menu i...

Page 34: ...e previous value is restored only possible if the new value has not already been saved Position of the Default settings rotary switch Display Explanation The current boiler or flow temperature is disp...

Page 35: ...ified temperature range 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 Defau...

Page 36: ...during day mode and economy mode The switching cycles saved differ according to the various days of the week Monday to Sunday The upper and lower limits of the target hot water temperature range are...

Page 37: ...d and fourth relate to Saturdays and Sundays The individual switching time programmes and switching times are identified on the display by a number and a point preceded by the letter t where t1 identi...

Page 38: ...7 or t1 8 in the Automatic I switching time programme if factory settings are to be used Fig 6 8 Schematic representation of how the Automatic I switching time programme is processed Fig 6 9 Structure...

Page 39: ...1 from 4 00 h to 4 30 h using the and keys Saving the changes with and returning to the selection level 5 Selection of the switch off time t3 4 with the navigation keys and and entering the programmin...

Page 40: ...nges with the actual flow temperature 6 5 8 Querying system information 1 Set the Default settings rotary switch to position and press the and keys simultaneously holding them down for longer than 5 s...

Page 41: ...valve x 0 Off 1 On 14 heat generator status x 0 no request from control 1 request but no BZ 0 2 heat generator to flame signal 15 Hot water circuit clock timer x x AcT Active dEAC Inactive 16 Direct...

Page 42: ...ch default configuration to the position or select another parameter you want to change steps 2 to 6 Info value no Info value Can be viewed by Comment Installer Operator E01 Fault no 1 most recent fau...

Page 43: ...aving x x 15 C Para meter 5 1 K 40 C Warm water temperature at night setback or at standard tariff 8 Hot water switch on hysteresis x 1 C 20 C 1 K 2 K Request for hot water is generated if Target hot...

Page 44: ...esigned for x x 15 C 30 C 1 K 25 C Parameter for the calculation of heater curve TR Figure 6 17 page 47 29 Summer switch off x x 1 C 60 C 1 K 20 C Value at which the heating system will switch from no...

Page 45: ...code 4 Press the key to confirm your selection The entry is temporarily saved and the next digit begins to flash indicating that this number can now be entered 5 Repeat the two input steps above until...

Page 46: ...position press the key and hold it down for longer than 5 s The first heating circuit in this example the direct circuit is displayed The display alternates between the heating circuit and the value r...

Page 47: ...ture the heating circuits will be deactivated automatically i e the pumps are switched off the mixer closed and the switch valve switched to warm water CAUTION If the Legionella protection function is...

Page 48: ...ction function is activated the hot water temperature may temporarily exceed 65 C If hot water is required during the disinfection phase it must be mixed with cold water If the ST OT contact is open t...

Page 49: ...to not more than the set warm water temperature The heating output for hot water recharging is based on the setting at the ST OT contact The power company charges the warm water boost charge during t...

Page 50: ...once a week at the changeover from Friday to Saturday day 5 to day 6 at 00 00 3 Disinfection starts at every changeover from one day to the next CAUTION If hot water is used during the disinfection ph...

Page 51: ...tional STL cuts the heat generator flow switching power of the power circuit board of the control panel 7 2 Load compensation of switching contacts The ROTEX ESU electronics consider the number of int...

Page 52: ...shutdown has occurred for one or two tubular radiators The malfunction is only indicated if the temperature still has not increased a long time after a heat request was made A relatively easy way to c...

Page 53: ...the storage tank down as much as possible If necessary the hot water zone is heated up by the electric heat generator Water flows through the heat exchanger for storage charging SL WT from top to bot...

Page 54: ...ensor Included in the scope of delivery of the ROTEX ESU tAU External temperature sensor Included in the scope of delivery of the ROTEX ESU SV Safety pressure relief valve Included in the scope of del...

Page 55: ...ction diagram for the ROTEX E SolarUnit with solar heating support Fig 8 2 Standard connection diagram for the ROTEX E SolarUnit with integrated wood boiler PS2 PS1 tK tMI PMI PK tV tR tAU tS V 2 5 SK...

Page 56: ...se cleaning agents containing aggressive solvents as this will damage the surface of the boiler control panel Authorised and trained heating experts must carry out servicing and maintenance every two...

Page 57: ...h the proper procedures otherwise there may be a danger to the life and health of individuals and the function of the E SolarUnit may be impaired Only properly authorised heating engineers may rectify...

Page 58: ...0 1 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...

Page 59: ...witches the mixer circuit pump and the mixer motor power off 12 1 Mixer circuit flow sensor Short circuit ROTEX ESU switches the mixer circuit pump and the mixer motor power off 13 0 Hot water storage...

Page 60: ...drive can be removed temporarily but storage tank charging will then be impossible Heating pump shutdown STLs have been triggered Release the STLs see Chapter 7 3 page 51 Check the pump insert the con...

Page 61: ...e 11 2 Final shutdown and disposal For final shutdown of the ROTEX ESU it must be taken out of service see Chapter 11 1 disconnected from all electrical and water connections disposed off in a profess...

Page 62: ...op in heat exchanger at a flow rate of 1000 l h mbar 18 Thermal output data Pos in Fig 12 1 Unit NL efficiency characteristic acc to DIN 47081 1 8 D value spec water flow acc to EN 6252 10 l min 22 Co...

Page 63: ...perature 20 to 60 Protection type IP 20 Software class A Housing dimensions W x H x D mm 144 x 96 x 75 Housing material ABS with antistatic agent 1 Type 2 Rated thermal load 3 Voltage supply 4 Elec po...

Page 64: ...OTEX ESU 509 heater side mH L h Flow rate in litres per hour S Spread Q kW Heating output in kW Fig 12 3 Required flow rates depending on the heating output and the dimensioned temperature spread 0 10...

Page 65: ...ff rate VZ L Max draw off volume in litres Storage tank temperature 60 C mZ 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...

Page 66: ...ms Fig 12 6 Resistance characteristics of the PTC temperature sensors PTC 1000 1500 2000 2500 3000 3500 20 0 20 40 60 80 100 120 t C R S V Sensor type Measured temperature in C 20 10 0 10 20 30 40 50...

Page 67: ...12 Technical data 67 FA ROTEX ESU 07 2008 Connecting cable colours bl blue br brown ge yellow gn green gr grey rt red sw black ws white n b Contact not assigned Fig 12 7 E SolarUnit wiring diagram...

Page 68: ...nel see the installation instructions for the heat generator in question 13 3 Room temperature control Installing the RTR E 17 51 26 room temperature control minimises deviations between the room temp...

Page 69: ...ual 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 Tab 14 2 Individual ch...

Page 70: ...14 Notes 70 FA ROTEX ESU 07 2008...

Page 71: ...nical data 62 Hot water temperature 33 34 35 41 48 Hydraulic system connection 7 54 55 I If 21 Individual parameters 69 Individual parameter settings 69 Info value 34 40 41 42 58 Installation area 11...

Page 72: ...nk water Leakage testing heating pipe connections Leakage testing hot water pipe connections Checking electrical connections for proper seating Cleaning and testing the function of the safety overflow...

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