Daikin Rotex RPS4 User manual

For the qualified installer
ROTEX RPS4
Operating and installation
instructions
Regulation and pump unit for Solaris Solar Systems
Valid for the following components
- ROTEX Solaris RPS4
- Solaris R4 Differential temperature control
GB
Output 04/2016

2FA ROTEX Solaris RPS4 - 04/2016
1 xGuarantee
1Guarantee
1.1 Warranty conditions
The legal guarantee conditions fundamentally apply. Our war-
ranty conditions beyond that can be found online on your sales
representative's webpage.

List of contents
FA ROTEX Solaris RPS4 - 04/2016 3
1Guarantee . . . . . . . . . . . . . . 2
1.1 Warranty conditions . . . . . . . . . . . . . . . . . . . . . .2
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Observing instructions . . . . . . . . . . . . . . . . . . . .4
2.2 Warning signs and explanation of symbols. . . . .4
2.3 Avoid danger. . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.4 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.5 Instructions for working safely. . . . . . . . . . . . . . .5
3 Manual operation . . . . . . . . . . . . . . . . . . . . . 6
3.1 Structure and Components of Solaris system. . .6
3.2 Info parameters. . . . . . . . . . . . . . . . . . . . . . . . . .7
3.3 System components . . . . . . . . . . . . . . . . . . . . . .7
3.3.1 Regulation and pump unit RPS4 . . . . . . . . . . . . . . 7
3.3.2 Optional accessories . . . . . . . . . . . . . . . . . . . . . . . 8
4 Peak output . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 System concepts. . . . . . . . . . . . . . . . . . . . . . . . .9
4.1.1 Parallel connection . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1.2 Serial connection. . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 Installing the control and pump unit . . . . . . . . .10
4.2.1 Installation pump unit . . . . . . . . . . . . . . . . . . . . . 10
4.2.2 Installation of FlowSensor, FlowGuard (optional) 11
4.2.3 Installing temperature sensor . . . . . . . . . . . . . . . 12
4.2.4 Preparing and fitting the control system . . . . . . . 13
4.2.5 Fit the covering hood. . . . . . . . . . . . . . . . . . . . . . 15
5 Start-up and decommissioning . . . . . . . . . 16
5.1 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5.2 Control Brief description . . . . . . . . . . . . . . . . . .17
5.2.1 Temporary shutdown. . . . . . . . . . . . . . . . . . . . . . 17
5.2.2 Final shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6 FlowSensor . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1 Operating and display components . . . . . . . . .19
6.2 Operating mode of control system . . . . . . . . . .20
6.2.1 Pump operation . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2.2 Booster function for high solar panel
temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2.3 Start optimisation. . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2.4 Switch-on block functions . . . . . . . . . . . . . . . . . . 20
6.2.5 Pump kick function . . . . . . . . . . . . . . . . . . . . . . . 21
6.2.6 Manual operation. . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2.7 FlowSensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2.8 Output calculation, maximum values,
and yield count . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.2.9 Speed regulation of the solar operating
pump PS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.2.10 Total Reset Function . . . . . . . . . . . . . . . . . . . . . . 23
6.2.11 Frost protection function . . . . . . . . . . . . . . . . . . . 23
6.2.12 Leak protection function . . . . . . . . . . . . . . . . . . . 23
6.3 Adjustment and menu guide . . . . . . . . . . . . . . .24
6.3.1 Fast access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.3.2 Display during operation . . . . . . . . . . . . . . . . . . . 25
6.3.3 Setup menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.3.4 Password input . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.3.5 Language selection . . . . . . . . . . . . . . . . . . . . . . . 27
6.3.6 Setting and resetting parameters . . . . . . . . . . . . 27
6.3.7 Setting the mounting position of the solar panel
temperature sensor . . . . . . . . . . . . . . . . . . . . . . . 27
6.3.8 Manual setting of the pump speed regulation . . . 28
6.3.9 Correction values for measuring points. . . . . . . . 28
6.3.10 Cylinder temperature sensor . . . . . . . . . . . . . . . . 28
6.4 Recommended settings . . . . . . . . . . . . . . . . . . 29
6.4.1 Standard parameter settings, recommended
setting ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.4.2 Additional settings for your solar system . . . . . . . 30
6.4.3 Setting recommendation for the post-heating via
external heat sources or by the electrical
immersion heater, burner blocking contact . . . . . 31
6.4.4 Tips for optimised user behaviour . . . . . . . . . . . . 31
6.4.5 Domestic water hygiene . . . . . . . . . . . . . . . . . . . 31
7 Faults and malfunctions. . . . . . . . . . . . . . . 32
7.1 Display of events . . . . . . . . . . . . . . . . . . . . . . . 32
7.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 33
8 Hydraulic system connection . . . . . . . . . . 35
8.1 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.2 Connection of a pressure solar panel system . 39
9 Technical data. . . . . . . . . . . . . . . . . . . . . . . 40
9.1 Product Fiche. . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.2 Regulation and pump unit RPS4 . . . . . . . . . . . 40
9.3 Sensor characteristics . . . . . . . . . . . . . . . . . . . 40
9.4 Pump characteristic curve . . . . . . . . . . . . . . . . 41
10 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
11 List of keywords . . . . . . . . . . . . . . . . . . . . . 43

4FA ROTEX Solaris RPS4 - 04/2016
2 xSafety
2 Safety
2.1 Observing instructions
These instructions are a >> translation of the
original version << in your language.
All activities required for installation, commis-
sioning, operation, and adjustment of the heating
system are described in this manual. For de-
tailed information regarding the connected com-
ponents of your heating system, please observe
the respective documents.
ƔWork on the ROTEX RPS4 (such as hydraulic
and electrical 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 appro-
priate responsible authorities for the specific
activity. This includes, in particular, heating
specialists who, as a result of their technical
training and knowledge, have experience with
the proper and appropriate installation and
maintenance of heating systems and solar
systems.
ƔPlease read this manual carefully and
thoroughly before proceeding with the instal-
lation and commissioning or carrying out an
operation on the heating system.
ƔComply strictly with warning instructions!
Relevant documents
Documents listed below are part of the technical
documentation of the ROTEX solar system and
therefore must be observed. The documents are
included in the scope of supply of the individual
components.
– ROTEX high-performance flat solar panels
Solaris V21P, V26P and H26P. Installation
instructions for on-roof, in-roof and flat-roof
mounting
– ROTEX hot water storage tank (Sanicube
Solaris / HybridCube, GCU compact or
HPSU compact): Operating and installation
instructions
When connecting to an external heat generator
or storage tank which is not included in the scope
of delivery, the individual associated operating
and installation instructions apply.
2.2 Warning signs and explanation of
symbols
Meaning of the warnings
Warnings in this manual are classified according
into their severity and probability of occurrence.
Special warning signs
Some types of danger are indicated by special
warning signs.
Order number
Notes related to order numbers are identified by
the shopping cart symbol .
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 may result in serious
physical injury or death.
CAUTION!
Indicates a situation which may cause possible
damage.
Disregarding this warning can lead to damage
to property and the environment.
This symbol identifies user tips and par-
ticularly useful information, but not warn-
ings or hazards.
Electric power
Danger of explosion
Risk of burning or scalding

2 xSafety
FA ROTEX Solaris RPS4 - 04/2016 5
Handling instructions
ƔInstructions on actions are shown as a list.
Actions of which the sequential order must be
maintained are numbered.
ÎResults of actions are identified with an
arrow.
2.3 Avoid danger
ROTEX solar installations are state-of-the-art
and are built to meet all recognised technical
requirements. However, improper use can lead
to serious injuries or death, as well as causing
material damage. Install and operate only
ROTEX solar systems to avoid danger:
– as stipulated and in perfect condition,
– with an awareness of the safety and hazards
involved.
This assumes knowledge and use of the con-
tents of this manual, the relevant accident pre-
vention regulations and the recognised safety-
related and occupational medical rules.
2.4 Intended use
The ROTEX solar system may only be used for
solar-supported heating of hot water systems.
The ROTEX solar system must be installed, con-
nected and operated only according to the in-
structions in this manual.
The regulation and pump unit is not suitable for
use in an explosive atmosphere.
Any other use outside the intended use is con-
sidered as improper. The operator alone shall
bear responsibility for any resulting damage.
Intended use also includes compliance with the
maintenance and service conditions. Spare
parts must at least satisfy the technical require-
ments defined by the manufacturer. This is the
case, for example, with original spare parts.
2.5 Instructions for working safely
Working on the roof
ƔInstallation work on the roof may only be
carried out by authorised and trained persons
(heating technicians, roofers, etc.) under
observance of the relevant Accident
Prevention Regulations.
ƔMaterial and tools must be secured against
falling.
ƔBarriers must be erected to prevent persons
from entering the area below the roof where
the work is being carried out.
Before working on the heating system
ƔAll work on the heating system (such as instal-
lation, connection and commissioning) may
only be carried out by authorised and trained
heating technicians.
ƔSwitch off the main switch and secure it
against unintended switching on when
carrying out any work on the heating system.
Electrical installation
ƔElectrical installation must be carried out only
by qualified electrical experts and in
compliance with the valid electro-technical
guidelines as well as the regulations of the
relevant energy supply company (EVU).
ƔMake up the power supply in accordance with
IEC 60335-1, via an isolator with contact
separation in all poles with a contact opening
distance in accordance with the conditions of
the over-voltage category III for full discon-
nection, and a residual current protection
switch (FCD) having a reaction
time 0.2 secs.
ƔBefore completing the mains connection,
compare the mains voltage, indicated on the
type plate (230 V, 50 Hz) with the supply
voltage.
ƔBefore beginning work on live parts,
disconnect them from the power supply
(switch off main switch, remove fuse) and
secure against unintentional restart.
ƔEquipment covers and service panels must be
replaced as soon as the work is completed.
Instructing the user/owner
ƔBefore you hand over the heating system,
explain to the user/owner how to operate and
check the heating system.
ƔMake a record of the handover by filling out
and signing the installation and instruction
forms jointly with the user/owner.

6FA ROTEX Solaris RPS4 - 04/2016
3 xManual operation
3 Manual operation
3.1 Structure and Components of Solaris
system
Fig. 3-1 Standard design of a ROTEX Solaris solar system (ROTEX recommends a double-sided connection)
1 Cold water connection line
2 Domestic water (hot) distribution line
3 Stainless steel corrugated heat exchanger for domestic water
(hot)
4a Stainless steel corrugated heat exchanger for storage tank charg-
ing
4a Stainless steel corrugated heat exchanger for storage tank charg-
ing and heating support
5 Submersion sleeve for storage, return temperature sensors
6 Fill level display
7 Filling and draining hose (KFE BA, 16 52 15 accessory)
8 Solaris R4 regulator
9 Solar return line (at the bottom on the solar panel)
10 Solar panel array
11 Solar flow line (at the top on the solar panel)
12 Thermal mixing valve (scalding protection, provided by customer)
13 Convection brake (accessory)
14 Solar flow layering pipe
15 Corrugated stainless steel heat exchanger for heating support
16 Thermal insulation sleeve for corrugated stainless steel heat ex-
changer for heating support
17 Solar return connection
18 Safety overflow connection
A Zone with water for domestic use
B Solar zone
FLS Solaris FlowSensor (flow measuring)
PSSolaris operating pump
RPS4
Regulation and pump unit
tDHW Storage temperature sensor
TKSolaris Solar panel temperature sensor
TRSolaris Return flow temperature sensor
TSSolaris Storage tank temperature sensor
TVSolaris Inflow temperature sensor
GCU compact
Gas Combi Unit
HPSU compact
Solar tank with integrated interior heat pump unit
SCS/HYC
Energy store Sanicube Solaris / HybridCube
Tab. 3-1 Legend for fig. 3-1

3 xManual operation
FA ROTEX Solaris RPS4 - 04/2016 7
3.2 Info parameters
The ROTEX solar system is a thermal solar system for supplying
hot water for consumption and solar support.
Password protection
The Solaris V21P, V26P and H26P high-performance solar
panels efficiently convert the sun’s radiation into heat. The heat
transport medium is normal tap water.
As soon as the solar collectors have reached a useful temper-
ature level, the water of the heating jacket in the storage cylinder
(which is not under pressure) is pumped directly through the
collectors. With insufficient collector temperature, the circulation
pump is switched off and the system is drained automatically.
This operating mode has several advantages:
– High operational reliability, as there are no components that
could be damaged or fail (such as expansion vessel, safety
valve, venting valves, etc.).
– Excellent heat transfer and heat storage capacity (system
works without antifreeze agents).
– Minimum maintenance requirements.
– Frost proof.
– Without separate solar heat exchanger.
– No stagnation problems.
Modular design
The system consists of several preassembled modules. Plug-in
technology and a high degree of pre-assembly ensure fast and
simple system installation.
Storage tank
The following storage tanks can be used for the ROTEX solar
system:
– ROTEX Sanicube Solaris (SCS): Thermally insulated, de-
pressurised plastic storage tank (with connection facility for a
ROTEX air-water heat pump).
– ROTEX HybridCube (HYC): Thermally insulated, de-pressur-
ised plastic storage tank (with connection facility for a ROTEX
air-water heat pump).
– ROTEX GCU compact: Solar storage tank with integrated gas
condensing boiler.
– ROTEX HPSU compact: Solar storage tank with integrated
internal unit of an air-water heat pump.
Electronic control
The fully electronic ROTEX Solaris R4 regulator ensures op-
timum utilisation of the solar heat (hot water generation, heating
support) and that all safety-relevant aspects are complied with.
All parameters needed for trouble-free operation have been
preset at factory.
3.3 System components
3.3.1 Regulation and pump unit RPS4
16 41 26
The ROTEX regulation and pump unit RPS4 can only
be installed and operated in the depressurised ROTEX
Solaris System (DrainBack) using the provided installa-
tion material.
The prerequisite for problem-free operation in the DrainBack
system, is that the connection lines are routed with a constant
gradient (at least 2 %), and that the bottom edges on the solar
panels with double-sided connections are mounted with a con-
stant gradient to the return connection, or, with same side con-
nection, are mounted horizontally.
Construction, operating principle, commissioning, and
operation of other Solaris components are not
described in this manual. Detailed information about the
components can be seen in the operating and installa-
tion instructions of the individual units.
The handling instructions and descriptions in this manual are
valid for all ROTEX storage tanks to be used in conjunction with
this solar system, even if only one type (z. B. SCS) is used for
illustrative purposes. Where other cylinders deviate, this will be
pointed out separately.
Consists of:
1Cover
2Connecting pipework to the solar operating pump
3ROTEX Solaris R4 regulator with storage tank temperature sen-
sor, return flow temperature sensor, connecting cable solar panel
temperature sensor, FlowSensor, connection cable 230 V mains
connection (3 m)
4Accessories bag (angle, 4 countersunk head screws, 4 self-tap-
ping screws, sensor plugs, plastic plugs)
5Mounting material (retaining bracket for pump mounting, holding
bar and fixing bracket for controller)
6Solaris Documentation
Fig. 3-2 Regulation and pump unit (RPS4)

8FA ROTEX Solaris RPS4 - 04/2016
3 xManual operation
3.3.2 Optional accessories
KFE Filling connection
For convenient filling and draining of the ROTEX hot water
storage tank, you can connect the KFE filling connection
(KFEBA 165215).
FlowGuard
For setting and display of the flow rate of 2-6 l/min, you can use
the setting valve (FlowGuard FLG 16 41 02).
Solar storage tank extension kit
If the heat output of a single ROTEX hot water storage tank is not
adequate, you can interconnect several Sanicube / HybridCube
as modules.
The following components are offered:
– Solar storage tank extension kit CON SX ( 16 01 20)
– Solar storage tank kit 2 CON SXE ( 16 01 21)
– FlowGuard FLG ( 16 41 02)
The installation and operation of this accessory component is de-
scribed in detail in the individual operating and installation in-
structions provided.
Additional pump kit for tall buildings
If the top edge of the solar panel is more than 12 m above the
erection surface of the solar storage tank, the system can be op-
erated up to a maximum total height of the system of 18 m if the
additional pump kit ZP-RPS4 ( 16 42 43) is installed.

4 xPeak output
FA ROTEX Solaris RPS4 - 04/2016 9
4 Peak output
4.1 System concepts
ROTEX solar systems are usually built according to one of the
following system concepts. Information concerning hydraulic
system incorporation with example schematics can be seen in
section 8 "Hydraulic system connection".
4.1.1 Parallel connection
4.1.2 Serial connection
As an alternative to the parallel mode described in this manual,
and if necessary, a maximum of 3 solar panels can be mounted
one above the other. Solar panels or solar panel fields mounted
one above the other must be connected in series (fig. 4-3).
Fig. 4-1 Solar panel field with a connection at each end
(recommended)
Fig. 4-2 Solar panel field with both connections at one end
(max. 3 solar panels)
T
K
Fig. 4-3 Alternative solar panel arrangement
1Collector connector
2Mounting rail
3Solar panel securing hook
4Solar panel
5Return panel connection
6Flow panel connection
7Collector sealing cap
8Roof penetration boxes for inflow/return flow
9Solar return line
10 Solar flow line
11 Series panel connector
12 Solar panel array (2x2 panels)
Tab. 4-1 Legend for fig. 4-3

10 FA ROTEX Solaris RPS4 - 04/2016
4 xPeak output
4.2 Installing the control and pump unit 4.2.1 Installation pump unit
WARNING!
Live parts can cause an electric shock on
contact and cause life-threatening burns and
injuries.
ƔBefore beginning work on the boiler switching
panel or the solar controller, disconnect the
devices from the power supply (switch off
fuse, main switch) and secure against
unintentional restart.
ƔElectrical installations must always be carried
out by qualified electrical technicians in
conformity with the relevant electrical guide-
lines and the regulations of the electric
utilities company to prevent hazards from
damaged electric wiring.
ƔComply with the relevant safety at work
regulations.
DANGER!
Leaking gas in the immediate proximity of
electrical components can cause an explosion.
ƔThe RPS4 regulating and pump unit and
electrical components should not be installed
in locations where there is a danger of
flammable gas escaping.
ƔObserve the minimum clearances to walls
and in shafts.
CAUTION!
Large volumes of water may come out of the
solar storage tank during installation.
ƔMount the pump unit before filling the solar
storage tank (depressurised range) with
water.
ƔIf the pump unit is to be connected to solar
storage tank that is already in operation, the
depressurised storage area must first be
drained.
If the overall height of the system is greater than 12 m.
the additional pump kit ( 16 42 43) must be installed
after working step 5, in accordance with the instructions
provided.
Fig. 4-4 Work step 1 Fig. 4-5 Work step 2
Fig. 4-6 Work step 3
Fig. 4-7 Work step 4
100
710
ø3,5
<15 mm