Rotex HPSU compact 304 Installation And Maintenance Manual

Table of contents
2
FA ROTEX HPSU compact 4 - 06/2015
1 Guarantee and conformity . . . . . . . . . . . . . 4
1.1 Warranty conditions . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Declaration of conformity . . . . . . . . . . . . . . . . . . 4
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Observing instructions . . . . . . . . . . . . . . . . . . . . 5
2.2 Warning signs and explanation of symbols . . . . 5
2.2.1 Meaning of the warnings. . . . . . . . . . . . . . . . . . . . .5
2.2.2 Validity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.2.3 Order number . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.2.4 Handling instructions. . . . . . . . . . . . . . . . . . . . . . . .6
2.3 Avoid danger . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5 Instructions for operating safety. . . . . . . . . . . . . 7
2.5.1 Before working on the hydraulic system . . . . . . . . .7
2.5.2 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . .7
2.5.3 Working on cooling systems (heat pump) . . . . . . . .7
2.5.4 Site of installation . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.5.5 Heating system and sanitary connection . . . . . . . .7
2.5.6 Requirements for the heating water . . . . . . . . . . . .7
2.5.7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.5.8 Instructing the user/owner. . . . . . . . . . . . . . . . . . . .8
3 Product description. . . . . . . . . . . . . . . . . . . 9
3.1 Design and components . . . . . . . . . . . . . . . . . . 9
3.1.1 Top of unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.1.2 Equipment external and internal structure 
ROTEX HPSU compact 304/308 DB . . . . . . . . . .10
3.1.3 Equipment external and internal structure 
ROTEX HPSU compact 304/308 BIV . . . . . . . . . .11
3.1.4 Equipment external and internal structure 
ROTEX HPSU compact 508/516 DB . . . . . . . . . .12
3.1.5 Equipment external and internal structure 
ROTEX HPSU compact 508/516 BIV . . . . . . . . . .13
4 Set-up and installation . . . . . . . . . . . . . . . 15
4.1 Dimensions and connections . . . . . . . . . . . . . . 15
4.1.1 ROTEX HPSU compact 304/308 . . . . . . . . . . . . .15
4.1.2 ROTEX HPSU compact 508/516 . . . . . . . . . . . . .16
4.1.3 Scope of delivery. . . . . . . . . . . . . . . . . . . . . . . . . .17
4.2 Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3 Water connection . . . . . . . . . . . . . . . . . . . . . . . 18
4.3.1 Connecting hydraulic lines . . . . . . . . . . . . . . . . . .19
4.4 Electrical connection . . . . . . . . . . . . . . . . . . . . 19
4.4.1 Overall connection plan ROTEX HPSU compact .20
4.4.2 Position of the circuit boards. . . . . . . . . . . . . . . . .21
4.4.3 Connection assignment, circuit board A1P . . . . . .21
4.4.4 Terminal assignment for the RTX-AL4 
circuit board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.4.5 Terminal assignment for the RTX-EHS 
circuit board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.4.6 Connection assignment, circuit board 
RoCon BM1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.4.7 Mains connection ROTEX HPSU compact . . . . . .22
4.4.8 Removing the protective cover . . . . . . . . . . . . . . .22
4.4.9 Opening the control housing and establishing 
electrical connections . . . . . . . . . . . . . . . . . . . . . .23
4.4.10 Connection of exterior heat pump unit RRLQ . . . .23
4.4.11 Connection of external temperature sensor 
RoCon OT1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.4.12 Connection of an external switching contact. . . . .24
4.4.13 External demand signal (EDS) . . . . . . . . . . . . . . .24
4.4.14 Connection of the electrical ROTEX Backup 
Heater (BUxx) . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
4.4.15 Connection of an external heat generator. . . . . . .26
4.4.16 Connection of the ROTEX room thermostat . . . . .27
4.4.17 Connection optional ROTEX RoCon system 
components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.4.18 Connection of the ROTEX HP convector . . . . . . 28
4.4.19 Connection switch contacts (AUX outputs) . . . . . 29
4.4.20 Low tariff mains connection (HT/NT). . . . . . . . . . 29
4.4.21 Connection intelligent controller 
(Smart Grid - SG) . . . . . . . . . . . . . . . . . . . . . . . . 30
4.4.22 Symbols and legend keys on connection and 
circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.5 Laying coolant lines. . . . . . . . . . . . . . . . . . . . . 32
4.6 Pressure test and filling the coolant circuit . . . 33
4.7 Filling the system with water . . . . . . . . . . . . . . 33
4.7.1 Checking the water quality and adjusting 
the pressure gauge . . . . . . . . . . . . . . . . . . . . . . . 33
4.7.2 Filling the hot water heat exchanger . . . . . . . . . . 33
4.7.3 Filling the storage tank . . . . . . . . . . . . . . . . . . . . 33
4.7.4 Filling the heating system . . . . . . . . . . . . . . . . . . 33
5 Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
5.1 Initial commissioning . . . . . . . . . . . . . . . . . . . . 34
5.1.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.1.2 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.1.3 Set the commissioning parameters . . . . . . . . . . . 35
5.1.4 Venting the internal heating circulation pump . . . 35
5.1.5 Activating the Parameter [Entlüftungsfunktion] . . 36
5.1.6 Check minimum flow . . . . . . . . . . . . . . . . . . . . . . 36
5.1.7 Configuring Estrichprogramm parameters
(only if necessary) . . . . . . . . . . . . . . . . . . . . . . . . 36
5.2 Re-commissioning. . . . . . . . . . . . . . . . . . . . . . 36
5.2.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.2.2 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6 Decommissioning . . . . . . . . . . . . . . . . . . . .38
6.1 Temporary shutdown . . . . . . . . . . . . . . . . . . . 38
6.1.1 Draining the storage tank . . . . . . . . . . . . . . . . . . 38
6.1.2 Draining the heating circuit and hot water circuit. 39
6.2 Final shutdown . . . . . . . . . . . . . . . . . . . . . . . . 40
7 Service and maintenance . . . . . . . . . . . . . .41
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.2 Removing the protective cover . . . . . . . . . . . . 41
7.3 Activities to be performed annually . . . . . . . . . 41
7.4 Filling and topping up the storage tank . . . . . . 43
7.5 Filling and topping up the heating system. . . . 44
8 Errors, malfunctions and messages . . . . .45
8.1 Recognising errors, correcting malfunctions . . 45
8.1.1 Current fault display . . . . . . . . . . . . . . . . . . . . . . 45
8.1.2 Read Protokoll. . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.1.3 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.2 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.3 Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.4 Monitoring and configuration DIP Switch . . . . 56
8.5 Emergency operation . . . . . . . . . . . . . . . . . . . 57
9 Hydraulic system connection. . . . . . . . . . .58
10 Technical data . . . . . . . . . . . . . . . . . . . . . . .63
10.1 Equipment data. . . . . . . . . . . . . . . . . . . . . . . . 63
10.1.1 ROTEX HPSU compact 304/308 . . . . . . . . . . . . 63
10.1.2 ROTEX HPSU compact 508/516 . . . . . . . . . . . . 65
10.2 Characteristic lines . . . . . . . . . . . . . . . . . . . . . 66
10.2.1 Sensor characteristic lines . . . . . . . . . . . . . . . . . 66
10.2.2 Characteristic curves for pumps . . . . . . . . . . . . . 68
10.3 Tightening torque . . . . . . . . . . . . . . . . . . . . . . 68
10.4 Circuit diagram ROTEX HPSU compact. . . . . 69

Rotex HPSU compact 304 Specifications

General

Brand	Rotex
Model	HPSU compact 304
Category	Controller
Language	English