Rotex RPS4 User manual

For certified companies
ROTEX RPS4
Operating and installation
instructions
Control and pump unit for Solaris solar systems
Valid for the following components
- ROTEX Solaris RPS4
- Solaris R4 differential temperature regulation
GB
Output 06/2015

List of contents
2FA ROTEX Solaris RPS4 - 06/2015
1 Guarantee and conformity . . . . . . . . . . . . . 3
1.1 Warranty conditions . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Declaration of conformity . . . . . . . . . . . . . . . . . . 3
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Observing instructions . . . . . . . . . . . . . . . . . . . . 4
2.2 Warning signs and explanation of symbols . . . . 4
2.3 Avoid danger . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Instructions for working safely . . . . . . . . . . . . . . 4
3 Product description. . . . . . . . . . . . . . . . . . . 6
3.1 Layout and constituent parts of the Solaris
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 System components. . . . . . . . . . . . . . . . . . . . . . 7
3.3.1 Control and pump unit RPS4 . . . . . . . . . . . . . . . . .7
3.3.2 Filling and draining cock (KFE BA) for RPS4 . . . . .8
3.3.3 Regulating valve FlowGuard FLG. . . . . . . . . . . . . .8
3.3.4 Storage tank extension kit CON SX . . . . . . . . . . . .8
3.3.5 Storage tank extension kit 2 CON SXE. . . . . . . . . .8
4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . 9
4.2.1 Installation pump unit . . . . . . . . . . . . . . . . . . . . . .10
4.2.2 Installation FlowSensor, FlowGuard (optional) . . .11
4.2.3 Installing temperature sensor . . . . . . . . . . . . . . . .12
4.2.4 Preparing and fitting the control system . . . . . . . .12
4.2.5 Fit the covering hood. . . . . . . . . . . . . . . . . . . . . . .14
4.3 Linking several solar storage tanks . . . . . . . . . 15
5 Start-up and decommissioning . . . . . . . . 18
5.1 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2 Decommissioning. . . . . . . . . . . . . . . . . . . . . . . 19
5.2.1 Temporary shutdown . . . . . . . . . . . . . . . . . . . . . .19
5.2.2 Final shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . .20
6 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.1 Operating and display components . . . . . . . . . 21
6.2 Controller operating principle. . . . . . . . . . . . . . 21
6.2.1 Pump operation. . . . . . . . . . . . . . . . . . . . . . . . . . .21
6.2.2 Booster function for high solar panel
temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
6.2.3 Start optimisation . . . . . . . . . . . . . . . . . . . . . . . . .22
6.2.4 Switch-on block functions . . . . . . . . . . . . . . . . . . .22
6.2.5 Pump kick function . . . . . . . . . . . . . . . . . . . . . . . .22
6.2.6 Manual operation . . . . . . . . . . . . . . . . . . . . . . . . .23
6.2.7 FlowSensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
6.2.8 Output calculation, maximum values,
and yield count . . . . . . . . . . . . . . . . . . . . . . . . . . .23
6.2.9 Speed regulation of the solar operating
pump PS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
6.2.10 Total Reset Function. . . . . . . . . . . . . . . . . . . . . . .24
6.2.11 Frost protection function . . . . . . . . . . . . . . . . . . . .25
6.2.12 Leak protection function . . . . . . . . . . . . . . . . . . . .25
6.3 Adjustment and menu guide . . . . . . . . . . . . . . 25
6.3.1 Display during start-up . . . . . . . . . . . . . . . . . . . . .26
6.3.2 Display during operation . . . . . . . . . . . . . . . . . . . .27
6.3.3 Setup menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
6.3.4 Password input . . . . . . . . . . . . . . . . . . . . . . . . . . .29
6.3.5 Language selection. . . . . . . . . . . . . . . . . . . . . . . .29
6.3.6 Setting and resetting parameters . . . . . . . . . . . . 29
6.3.7 Setting the mounting position of the solar
panel temperature sensor . . . . . . . . . . . . . . . . . . 29
6.3.8 Manual setting of the pump speed regulation . . . 30
6.3.9 Correction values for measuring points. . . . . . . . 30
6.3.10 Burner inhibit contact. . . . . . . . . . . . . . . . . . . . . . 30
6.4 Recommended settings . . . . . . . . . . . . . . . . . 31
6.4.1 Standard parameter settings, recommended
setting ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.4.2 Additional settings for your solar system. . . . . . . 32
6.4.3 Setting recommendation for the post-heating
via external heat sources or by the electrical
immersion heater, burner blocking contact . . . . . 33
6.4.4 Tips for optimised user behaviour . . . . . . . . . . . . 33
6.4.5 Domestic water hygiene . . . . . . . . . . . . . . . . . . . 33
7 Faults and malfunctions . . . . . . . . . . . . . . 34
7.1 Display of events. . . . . . . . . . . . . . . . . . . . . . . 34
7.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 35
8 Hydraulic system connection. . . . . . . . . . 37
8.1 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.2 Connection of a pressure solar panel system. 40
9 Technical data . . . . . . . . . . . . . . . . . . . . . . 41
9.1 RPS4 control and pump unit. . . . . . . . . . . . . . 41
9.2 Sensor characteristics. . . . . . . . . . . . . . . . . . . 41
9.3 Connection allocation RPS4 controller . . . . . . 42
10 List of keywords . . . . . . . . . . . . . . . . . . . . 43

1xGuarantee and conformity
FA ROTEX Solaris RPS4 - 06/2015 3
1 Guarantee and conformity
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.
1.2 Declaration of conformity
for the Control and pump unit in the RPS4 series.
We, ROTEX Heating Systems GmbH, declare under our sole responsibility that the products
Product Order No.
ROTEX RPS4 16 41 26
comply, in their standard design, with the following European Directives:
2004/108/EC Electromagnetic Compatibility Directive
2006/95/EC EC Low Voltage Directive
Güglingen, 01.07.2015 Georg Blümel
Managing Director

4FA ROTEX Solaris RPS4 - 06/2015
2xSafety
2 Safety
2.1 Observing instructions
This manual is intended for authorised and trained technicians
who have experience in the proper installation and commis-
sioningof solarsystemsonaccount oftheirtechnical trainingand
knowledge.
All necessary tasks for the installation, initial start-up, operation
and setting of the system are described in this manual. For de-
tailed information regarding the connected components of your
heating system, please observe the respective documents.
Please read this manual carefully and thoroughly before pro-
ceeding with the installation and initial start-up or modification of
the system.
Relevant documents
Documents listed below are part of the technical documentation
ofthe ROTEXsolar system andtherefore mustbeobserved. 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
– ROTEXhot waterstoragetank (SanicubeSolaris/ Hybrid-
Cube, 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 asso-
ciated 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 se-
verity 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 cart
symbol .
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 contents of this manual,
the relevant accident prevention 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, connected and operated only according to the instruc-
tions in this manual.
Any other use outside the intended use is considered as im-
proper. The operator alone shall bear responsibility for any re-
sulting damage.
Use as intended also involves compliance with maintenance and
inspection conditions. Spare parts must at least satisfy the tech-
nical requirements 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.
ƔBarriersmustbeerected toprevent personsfromenteringthe
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 installation,
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.
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 can lead to damage to
property and the environment.
This symbol identifies user tips and particularly useful
information, but not warnings or hazards.
Electric power
Danger of explosion
Risk of burning or scalding

2xSafety
FA ROTEX Solaris RPS4 - 06/2015 5
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).
ƔFor the mains connection, use a separate EN 60335-1
disconnector for all-pole disconnection from the power mains
and a GFCI circuit breaker with a reaction time 0.2 s.
ƔBefore completing the mains connection, compare the mains
voltage, indicated on the type plate (230 V, 50 Hz) with the
supply voltage.
ƔBeforebeginningworkonliveparts,disconnectthemfromthe
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 - 06/2015
3xProduct description
3 Product description
3.1 Layout and constituent parts of the Solaris
system
Fig. 3-1 Standard layout of a ROTEX Solaris installation (ROTEX recommends 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 cock (accessory KFE BA, 16 52 15)
8 Solaris R4 controller
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 measurement)
PSSolaris operating pump
RPS4Control and pump unit
tDHW Storage temperature sensor
TKSolaris solar panel temperature sensor
TRSolaris return flow temperature sensor
TSSolaris storage cylinder temperature sensor
TVSolaris inflow temperature sensor
GCU compact
Gas Combi Unit
HPSU compact
Solar storage tank with integrated interior heat pump unit
SCS/HYC - DB
Energy storage Sanicube Solaris / HybridCube
Tab. 3-1 Legend for fig. 3-1

3xProduct description
FA ROTEX Solaris RPS4 - 06/2015 7
3.2 Brief description
The ROTEX solar system is a thermal solar system for supplying
hot water for consumption and solar support.
Mode of operation
The high-performance flat solar panels Solaris V21P, V26P and
H26P convert the sun's radiation into heat with a high level of ef-
fectivity. Hereby, the heat transport media 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 condensing boiler).
– ROTEX Hybridcube (HYC): Thermally insulated, de-pressur-
isedplastic storage tank(withconnectionfacility foraROTEX
air-water heat pump).
– ROTEXGCUcompact:Solarstoragetankwithintegratedgas
condensing boiler.
– ROTEX HPSU compact: Solar storage tank with integrated
indoor unit of as air-water heat pump.
Electronic control
The fully-electronic ROTEX Solaris R4 controller ensures op-
timumsolarheat exploitation(hotwaterheating, heating support)
and compliance with all operational safety aspects.All param-
eters needed for trouble-free operation have been preset at
factory.
3.3 System components
3.3.1 Control and pump unit RPS4
16 41 26
The ROTEX Control and pump unit RPS4 can only be
installed and operated in the depressurised ROTEX
Solaris System (DrainBack) using the installation mate-
rial provided for the purpose.
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
thebottom edgesonthe solarpanelswith double-sided
connections are mounted with a constant gradient to
the return connection, or, with same side connection,
are mounted horizontally.
The layout, function, commissioning and operation of
other Solaris components are not described in this
instruction manual. Detailed information about the com-
ponents can be seen in the operating and installation
instructions of the individual units.
The handling instructions and descriptions listed in this
manual apply fundamentally to all ROTEX storage
tanks used in this solar system, even if just one type is
described (e.g. SCS) for representative purposes. In
the event of deviations from other storage tanks, a sep-
arate note is provided.
Consists of:
1Cover
2Connection piping with circulation pump and solar operating pump
3ROTEX Solaris R4 controller with storage tank temperature sen-
sor, return temperature sensor, connection cable, solar panel tem-
perature sensor FlowSensor, connection cable 230 V-mains
connection (3 m)
4Accessories pocket (6 fixing screws, 2 plastic plugs, 2 locking
screws, plug fitting and gasket)
5Mounting material (retaining bracket for pump mounting, holding
bar and fixing bracket for controller)
6Solaris documentation
Fig. 3-2 Control and pump unit(RPS4)
4
5
1
2
6
3

8FA ROTEX Solaris RPS4 - 06/2015
3xProduct description
3.3.2 Filling and draining cock (KFE BA) for RPS4
16 52 15
3.3.3 Regulating valve FlowGuard FLG
16 41 02
For setting and display of flow rate of 2 - 16 l/min.
Consists of:
– FlowGuard FLG (a).
– 2x seals (b).
3.3.4 Storage tank extension kit CON SX
16 01 20
For connecting 2 Sanicube Solaris storage tanks or 2 Hy-
bridCube storage tanks.
Consists of:
– Return connection line (a).
– Flow distribution line (b).
3.3.5 Storage tank extension kit 2 CON SXE
16 01 21
Extension for connecting an additional Sanicube Solaris storage
tank or HybridCube storage tank.
Consists of:
– Return connection line (a).
– Flow distribution line (b).
Fig. 3-3 KFE cock (optional)
Fig. 3-4 FlowGuard FLG (optional)
Fig. 3-5 CON SX (optional)
Fig. 3-6 CON SXE (optional)

4xInstallation
FA ROTEX Solaris RPS4 - 06/2015 9
4 Installation
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
chapter 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).
4.2 Installing the control and pump unit
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 so-
lar panels)
Fig. 4-3 Alternative solar panel arrangement
TK
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 (2x 2 panels)
Tab. 4-1 Legend for fig. 4-3
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 guidelines and the
regulations of the electric utilities company to
prevent hazards from damaged electric wiring.
ƔComply with the relevant safety at work regula-
tions.
DANGER!
Leaking gas in the immediate proximity of electrical
components can cause an explosion.
ƔThe Control and pump unit RPS4 and electrical
components should not be installed in locations
where there is a danger of flammable gas
escaping.
ƔPayattentiontominimum distancesfromwallsand
in shafts.

10 FA ROTEX Solaris RPS4 - 06/2015
4xInstallation
4.2.1 Installation pump unit
13.Cut the flow line (VA Solar 15) to length on the storage tank
sideandinsertintotheplugfittingon thesolarflowconnection
(see chapter 4.3 "Linking several solar storage tanks",
FlowSensor, work step 4).
CAUTION!
Large volumes of water may come out of the solar
storage tank during installation.
ƔMountthe pumpunit beforefilling thesolar storage
tank (depressurised range) with water.
ƔIf the pump unit is to be connected to solar storage
tankthat is alreadyin operation, thedepressurised
storage area must first be drained.
Fig. 4-4 Work step 1 Fig. 4-5 Work step 2
Fig. 4-6 Work step 3
Fig. 4-7 Work step 4
Fig. 4-8 Work step 5 Fig. 4-9 Work step 6
100
710
ø3,5
<15 mm
Fig. 4-10 Work step 7 Fig. 4-11 Work step 8
Fig. 4-12 Work step 9 Fig. 4-13 Work step 10
10.Prepare feed line
(VA 15 Solar) with sensor
cable and return line
(VA 18 Solar). Cut open
the twin heat insulation in
the middle.
11.Adapt the return line (VA
18 Solar) accordingly and
route separately after
separatingthetwinthermal
insulation.
Fig. 4-14 Work step 11
12.Insert the pre-curved return
line (VA 18 Solar) into the
plug fitting on the pump
outlet pipe.
Fig. 4-15 Work step 12
Click
Click
1x
007.16 054 99 4PW56022-1
MS MS

4xInstallation
FA ROTEX Solaris RPS4 - 06/2015 11
4.2.2 Installation FlowSensor, FlowGuard (optional)
FlowSensor
The FlowSensor FLS 20 (fig. 4-17) is a measuring device that
simultaneouslydeterminestheflowrateinthesolarpanelandthe
flow temperature. The measuring ranges are 0...20 l/min (flow
quantity) and 0...120°C (inflow temperature). The measured
values are displayed on the Solaris R4 controller. By speed
regulation of the solar operating pump PS, the Solaris R4
controller automatically takes over the setting of the corre-
sponding flow rate.
1. Insert the seal (b) on the solar flow connection (a) of the hot
water storage tank.
2. Screw the FlowSensor (c) onto the solar flow connection (a)
of the hot water storage tank.
3. Insert the seal (e) and fit the plug fitting (f) to the inlet to the
FlowSensor (c).
4. Shortenthe flow line(g) (Ø 15 mm) tothe required length and
insert into the plug fitting (f).
5. Run the FlowSensor cable between the FlowSensor (c) and
the Solaris R4 controller.
6. Insert the cable of the FlowSensor on the FlowSensor (c) and
at the edge of the board of the Solaris R4 controller, at the
position FLS (4-pin, see fig. 4-23).
FlowGuard
The FlowGuard FLG (fig. 4-19, 16 41 02) is available as an
accessory. It is a regulating valve with integrated flow indicator
which can be used to set the flow rate through the solar panel
array. The display range is 2...16 l/min.
1. Insert the seal in the flow connection (see fig. 4-18).
2. Mount the FlowGuard, and screw it tight.
3. Insert the seal and install the plug fitting into the input to the
FlowGuard.
4. Insert a prepared flow pipe into the plug fitting of the
FlowGuard.
CAUTION!
In the case of longer pipe runs with only a minimum
gradient, it is possible for water pockets to develop
due to thermal expansion of the plastic pipes between
the mounting points with siphon action:
ƔUse support cups (TS 16 42 45).
ƔAlways make sure that pipe runs have a
continuous gradient of at least 2 %.
Note the direction of flow when installing the FlowSen-
sor.
Fig. 4-16 Mounting FlowSensor FLS
Fig. 4-17 FlowSensor FLS supplied with 3 m cable
Fig. 4-18 Work step 1+2
Fig. 4-19 Accessory FlowGuard FLG

12 FA ROTEX Solaris RPS4 - 06/2015
4xInstallation
4.2.3 Installing temperature sensor
1. Bend over the contact springs on both sensors (return
temperature sensor, storage tank temperature sensor) and
insert into the sensor tube.
2. Positionthereturnflow temperaturesensorinthe sensortube
at approx. 130 cm insertion depth (cable tie).
3. Position the storage cylinder temperature sensor in the
sensor tube at approx. 70 cm insertion depth (cable tie).
4. Push the sealing plug into the well, and run the cables.
4.2.4 Preparing and fitting the control system
Requirements
– For electrical connections and consumable electrical materi-
als (cable, insulation, etc.), follow all valid country-specific
guidelines.
– For every fixed mains connection, use a separate EN 60335-
1 disconnector for all-pole disconnection from the power
mains and a GFCI circuit breaker with a reaction time 0.2 s.
Permissible cable types at the terminal strip:
– Single core 2.5 mm2
– Multi-core 2.5 mm2
– Multi-core with wire end sleeves with insulating collar
1.5 mm2
– Multi-core with wire end sleeves without insulating collar
2.5 mm2
CAUTION!
On no account may the storage cylinder temperature
sensor of the boiler controller be inserted more than
75 cm into the sensor well. A sensor that is inserted
toodeeply can lead to overheating of the consumption
watersection, as wellas a"hang-up" ofthecontrol unit
during the storage cylinder charging phase.
a Solaris return flow temperature sensor
b Solaris storage cylinder temperature sensor
Fig. 4-20 Work step 1
Fig. 4-21 Work step 2+3
Fig. 4-22 Work step 4

4xInstallation
FA ROTEX Solaris RPS4 - 06/2015 13
Electrical connection
1. Fix the cable supplied to the back of the control system using
theedgeconnectors.Theconnectorsare polarised toprevent
errors. A connecting diagram is provided in the control unit
cover.
2. To ensure reliable tension relief, all cables should be run
through the respective labyrinths.
4. Insert the plug at the edge of the board on the controller, at
position TK (2-pin, see fig. 4-23).
BSK Burner inhibit contact
CONF
Programming socket for
Software update
FLS FlowSensor
TS Storage cylinder temper-
ature sensor
TR Return flow temperature
sensor
TK Collector temperature
sensor
PSSolar operating pump
F1 Fuse
Power
Mains supply
Fig. 4-23 Connection assignment
Fig. 4-24 Work step 1
FLS TRTS TK BSK P1 F1
250V
T2A
POWERCONFPWM
007.16 108 99_00
n.b.
NN LL11111113
322222224 3
Fig. 4-25 Work step 2
3. Connect the solar panel
temperature sensor line
(integrated in the
connection line) to the plug
terminals.
Fig. 4-26 Work step 3
Fig. 4-27 Basic wiring: FlowSensor, storage tank, return, solar panel
sensor, pumps and mains wiring

14 FA ROTEX Solaris RPS4 - 06/2015
4xInstallation
5. Suspend the controller from above in the fixing bracket.
– Make sure that the cable loops (as shown in fig. 4-27 and
fig. 4-28) point downwards.
6. Cabling of the solar operating pump PS:
– Connect the pump cable to the solar operating pump PS.
7. Lay the cable for the control system along the return line and
fix using cable ties.
4.2.5 Fit the covering hood
1. Slide the covering hood in position and align. Slide the
covering hood under the controller housing so that a constant
gap is produced round the controller.
2. Screw the covering hood to the controller housing on both
sides using countersunk head screws.
3. Fix the covering hood to the storage tank connection bracket
that is located underneath. Carefully screw the self-tapping
fixing screw (pre-installed in the covering hood) over the
depression in the lower section of the housing front and then
insert the covering cap.
Fig. 4-28 Work step 5
Fig. 4-29 Work step 6
Fig. 4-30 Work step 7
Fig. 4-31 Work step 1
Fig. 4-32 Work step 2
Fig. 4-33 Work step 3

4xInstallation
FA ROTEX Solaris RPS4 - 06/2015 15
4.3 Linking several solar storage tanks
The ROTEX-storage tank extension is a system of connecting
lines and permits parallel linking of several hot water storage
tanks for use in the ROTEX solar system.
The solar storage tank extension kit CON SX ( 16 01 20) can
be used to link, per Control and pump unit RPS4, 2 hot water
storage tanks used for solar systems (fig. 4-35). It is possible to
linka maximum of3 hot water storage tanksto produce astorage
tank battery (solar storage tank extension kit 2 for a third hot
water storage tank - CON SXE ( 16 01 21).
The optional ROTEX FlowGuard FLG ( 16 41 02) ensures
even filling of the linked hot water storage tanks. One FlowGuard
should be installed per hot water storage tank. The FlowSensor
is installed in the common flow (fig. 4-34).
Operating principle
– The solar return is taken from the solar zone of the linked hot
water storage tanks via the return connection line (fig. 4-35,
item 5).
– The common return is pumped to the solar panel array by the
Control and pump unit RPS4 (fig. 4-35, item 4).
– The water is heated in the solar panel array and is directed,
as the solar flow, to the hot water storage tank via the flow dis-
tribution line (fig. 4-35, item 6).
Installation of storage tank extension for 2 hot water
storage tanks
1. Mounting the Control and pump unit RPS4 without fitting the
hood (see section 4.2).
2. Unscrewthe covering capon thesolar returnconnectionfrom
the second solar storage tank.
Fig. 4-34 Completely installed RPS4
1 Solar storage tank
2 Non-pressurised area
3 Solar panel array
4 Control and pump unit RPS4
5 Return flow connection pipe (non-pressurised area)
6 Solar flow distribution line
7 Solar return line
8 Solar flow line
¨H Level difference in the de-pressurised storage tank area
CON SX Storage tank extension kit
FLS Flow sensor
FLG FlowGuard
Fig. 4-35 Operating principle of the common return flow pipe
WARNING!
Danger of scalding by releasing the connection lines
from the storage tank or when working on the
hydraulics on the Control and pump unit (e.g. when
changing a pump).
ƔEmpty the storage tank (de-pressurised area)
before working on the connecting line or the
hydraulics.
CAUTION!
Large volumes of water may come out of the solar
storage tank during installation.
ƔMount the storage tank extension kit before filling
the hot water storage tank (depressurised range)
with water.
ƔIf the solar system is to be connected to solar
storage tank that is already in operation, the
depressurised storage area must first be drained.

16 FA ROTEX Solaris RPS4 - 06/2015
4xInstallation
3. Aligningthe solar storagetank. The centre-to-centredistance
betweenthestoragecylindersmust be 830mm.Notealsothe
recommended wall distance of 200 mm.
4. Preparation of the storage tank connection bracket (on the
Control and pump unit RPS4).
ƔRemove the holding bar on the extension side and
remove the ball valve or blind plug, depending on the
existing structure.
ƔAdjusting the desired operating position:
– X2: storage tank extension on the right-hand side,
fig. 4-38.
– X4: storage tank extension on the left-hand side, fig. 4-40.
– X1: without storage tank extension, fig. 4-42 (standard ex
works)
5. Mount the removed plug on the return connection line pre-
installed by ROTEX on the second storage tank connection
bracket.
6. Insert the return line, completed in this way, in the free outlet
ofthe storage tankconnection elbow of the Controland pump
unit RPS4 using the free plug fitting (Ø 28).
7. Fix the return line to the return connection of the second hot
water storage tank.
8. Remove the lower covering lid on the relevant side from the
covering hood.
9. Fit the covering hood to the hot water storage tank
(see chapter 4.2.5).
10.Fit a FlowGuard (optional) to the solar flow connections on
the storage tank (see chapter 4.2.2).
Fig. 4-36 Work step 2
Fig. 4-37 Work step 4
4
3
2
1
Fig. 4-38 Operating position with
right-hand storage tank
extension
Fig. 4-39 Storage tank extension on the right-hand side
Fig. 4-40 Operating position with
left-hand storage tank
extension
Fig. 4-41 Storage tank extension on the left-hand side
Fig. 4-42 Operating position with-
out storage tank exten-
sion
4.
3.
1.
2.
X2
5.
4.
3.
1.
2.
5.
X4

4xInstallation
FA ROTEX Solaris RPS4 - 06/2015 17
11.Fit the flow distribution lines left and right to the connection
T-piece (fig. 4-43, item 3 + 4).
12.Place gaskets on both FlowGuards and screw the flow
distribution line to the two FlowGuards using union nuts.
13.Position seal on the connecting t-piece and screw on the
double swivel nut (1").
14.Position seal in double swivel nut (1").
15.Mounting the FlowSensor (see chapter 4.2.2).
1 Solar storage tank
2 Control and pump unit RPS4
3 Solar flow distribution pipe
4 Connecting T-piece
CON SX (A)Storage tank extension kit (bottom)
CON SX (B)Storage tank extension kit (top)
FLS Flow sensor
FLG FlowGuard
Fig. 4-43 Installation of storage tank extension for 2 Solar storage tank
(shown on 2 Sanicube Solaris)
When extending to the maximum three storage tanks,
youmusttake noteofthe installation instructionsforthe
storage tank extension kit 2 CON SXE ( 16 01 21).

18 FA ROTEX Solaris RPS4 - 06/2015
5xStart-up and decommissioning
5 Start-up and decommissioning
5.1 Start-up
All the following work must be carried out in the specified se-
quence.
1. Filling the storage cylinder:
ƔFilling the heat exchanger for domestic water.
ƔFill buffer storage volume via the filling and draining valve
(KFE BA, 16 52 15) on the Control and pump unit
RPS4 until water comes out of the safety overflow.
ƔClose the filling and draining valve (KFE BA,
16 52 15).
2. Switch on the Solaris R4 controller.
ÎThe initialisation phase starts.
3. When the initialisation phase is finished (temperature
display), fill and vent the solar system by simultaneously
pressing both arrow keys (starting manual mode).
ÎThe solar operating pump PSnow runs at full power and
the solar system is exposed to the maximum possible
operatingpressure. The solarsystem fills, theair escapes
through the flow line into the air compartment of the stor-
age tank.
4. Check the entire system for leaky joints (in the building and
on the roof). Seal any leaks that occur in a professional
manner.
5. Switch off the Solaris R4 controller.
6. Check the filling level in the hot water storage tank.
7. Adjusting the filling time:
ƔSwitch the Solaris R4 controller on again (initialisation
phase starts).
ƔWhen the initialising phase is finished (temperature
display), you can start the manual operating mode by
simultaneously pressing both arrow keys.
ƔMeasure the time it takes to fill the solar system
completely. The system is fully filled when you can no
longer hear any air noises and a steady value for the flow
rate is displayed (activate the measuring point "Flow rate"
using the arrow keys).
ƔSet the measured time plus 20 s at the parameter "Time
P2" (see section 6.3.6).
8. Switch the Solaris R4 controller to automatic mode by
simultaneously pushing both arrow keys or by switching off
and on again.
ÎThe solar system is now ready for operation.
9. Only when connecting a Control and pump unit RPS4 to
several solar storage tanks:
– The entire flow rate, measured with the FlowSensor in the
solar flow line, must be distributed evenly to all the con-
nected solar storage tanks. We recommend using a Flow-
Guard (FLG) at each storage tank for regulation pur-
poses.
10.Instruct the user, fill out the acceptance report, and send it to
the address indicated on the rear cover of this manual.
WARNING!
The solar system cannot be started until all hydraulic
and electrical connections have been completed.
Incorrect commissioning will impair the system's
function, and can lead to damage to the entire instal-
lation. Installation and start-up must therefore must
conducted by ROTEX-authorised and trained heating
experts.
CAUTION!
Commissioning in frosty conditions can result in
damage to the entire heating system.
ƔCommissioning at outdoor temperatures below
0°C only with a guaranteed water temperature of
at least 5°C in the solar circuit (e.g. prior heating of
the hot water storage tank).
ROTEX recommends that you avoid operating the
system in extremely frosty conditions.
Withinafew minutesafterswitching off andemptying of
the solar system, the fill level indicator in the hot water
storage tank once again reach almost to the fill level.
– Thereason for a slightly lowerfill level is theremain-
ingof a smallvolume of waterin the lowercollection
pipes in the panels. If the solar panels are correctly
aligned, this volume of water is not dangerous for
the panel, even under the effects of frost, since
there is adequate space for expansion.
– If the fill level remains considerably below the fill
level, this can be an indication of undiscovered
leaks or faulty line routing (water pockets). In this
caseyoumustundertake averycarefulcheck ofthe
system again.
The correct flow rate in the solar circuit is set automati-
cally by regulating the speed of the solar operation
pump PS.

5xStart-up and decommissioning
FA ROTEX Solaris RPS4 - 06/2015 19
5.2 Decommissioning
5.2.1 Temporary shutdown
The ROTEX solar system can be shut down temporarily by
switching the main switch off on the Solaris R4 controller or by
separating the mains plug from the power supply.
If there is a danger of frost:
– the ROTEX solar system must be taken into operation
again
or
– suitable antifreeze measures must be applied to the con-
nected heating system and hot water storage tank
(e.g. draining).
Draining the storage tank
ƔSeparate all power circuits of the solar and heating system
from the power supply and secure against inadvertent
switching on again.
ƔGCU compact only: Close gas stopcock.
ƔConnect the drain hose to the filling and draining valve (KFE
BA, 16 52 15) (fig. 5-1, item A) and run to a drainage
point that is at least soil deep.
ƔAdjust the valve insert on the connecting angle so that the
path to the blind plug is blocked off (fig. 5-2).
ƔRemove the blanking plug from the connecting angle
(fig. 5-2) and place a suitable collection trough beneath the
unit.
ƔOpentheKFEvalveon theKFE filling connection (KFE BA,
16 52 15).
ƔAdjust the valve insert on the connecting angle so that the
flow to the drain hose is opened (also refer to fig. 5-2) and
drain the water content of the storage tank.
CAUTION!
A heating system which is shut down can freeze in the
event of frost and may suffer damage.
ƔDrain the heating system that is shut down if there
is danger of frost.
CAUTION!
Pumpsthatremain switchedoff foranextended period
can seize up.
With temporarily shut-down solar systems, the
protection function from seized pumps (pump kick
function) is also deactivated.
ƔCheck for correct pump function when re-starting.
Seized pumps can normally be released again
manually.
If the danger of freezing will only last for a few days, the
very good heat insulation of the ROTEX means that it
need not be drained, as long as the storage tank tem-
perature is observed regularly and not permitted to fall
below +3°C. This does not, however, provide any pro-
tection against frost for the connected heat distribution
system!
Fig. 5-1 Connecting the drainage hose
Fig. 5-2 Shutting off the valve insert and removing the blanking plug
from the connecting angle
ƔInsert the KFE filling
connection (KFE BA,
16 52 15) into the
connection elbow and
secure with the clamp
(fig. 5-3).
Fig. 5-3 Assembling the KFE fill-
ing connection in the
connecting elbow
1.
2.
X
4
3
2
1
G
X4
X1
X3
X2
X4
4.
3.

20 FA ROTEX Solaris RPS4 - 06/2015
5xStart-up and decommissioning
5.2.2 Final shutdown
ƔTake the ROTEX solar system out of service
(see chapter 5.2.1 "Temporary shutdown").
ƔControl and pump unit RPS4 disconnected from all electrical
and water connections.
ƔControl and pump unit RPS4 to be dismantled in accordance
with the instruction manual (chapter 4 "Installation") in
reverse order.
ƔControl and pump unit RPS4 disposed off in a professional
manner.
Recommendations for disposal
Thanks to the environmentally friendly design of
the solar system, ROTEX has complied with
requirements for environmentally sound disposal.
During the disposal process, the only waste
created is that which can be used for material or
thermal recycling.
The materials used that are suitable for recycling
can be sorted into individual types.
The designation of the product means that
electrical and electronic products may not be
disposed of together with unsorted domestic
waste.
Proper disposal in compliance with the respective
national regulations of the country of use is the
responsibility of the user/owner.
ƔDisassembly of the system, handling of
coolant, oil and other parts may only be carried
out by a qualified fitter.
ƔDisposal may only be carried out by an organi-
zation that specialises in reuse, recycling and
recovery.
Furtherinformationisavailablefromtheinstallation
company or the responsible local authorities.