Rotex E-Solar Unit ESU 509 User manual

For certified companies
ROTEX E-SolarUnit
Electric heat generator with
stratified solar storage tank
Installation and maintenance
instructions
Type Rated thermal output
ROTEX ESU 509 3–9kW
Serial number
Customer
GB
Edition 07/2008

Guarantee and conformity
2FA ROTEX ESU - 07/2008
ROTEX provides a warranty for material and manufacturing defects according to this statement. Within the warranty period,
ROTEX undertakes to have the unit repaired free of charge by a person assigned by the company.
ROTEX reserves the right to replace the unit.
Thewarrantyisonlyvalidiftheunitisusedproperlyandifitcanbeprovedthatitwasinstalledcorrectlybyaspecialistcompany.
As proof, we strongly recommend completing the enclosed installation and instruction forms and returning them to ROTEX.
Warranty period
The warranty period begins on the day of installation (billingdate of the installation company), however at the latest 6 months
afterthedateofmanufacture(billingdate).Thewarrantyperiodisnotextendedif the unit is returned for repairs or ifthe unit is
replaced.
Warranty period for the heat generator, boiler main body and boiler electronics: 2 years
Exclusion of warranty
Improper use, tampering with the unit and unqualified modifications immediately invalidate the warranty.
Dispatch and transport damage are excluded from the warranty.
The warranty explicitly excludes consequential costs, especially costs ofinstalling and removing costs the unit.
There is no warrantyfor consumables (according to the manufacturer's definition), such as lights, switches, fuses.
Declaration of conformity
for the ROTEX E-SolarUnit heating system
We, ROTEX Heating Systems GmbH, declare under our sole responsibility that theproduct(s)
Product Order No.
ROTEX ESU 509 15 70 50 - 44
do, in their standard version, comply with following European standards:
2004/108/EC Electromagnetic Compatibility
2006/95/EC EC Low Voltage Directive
Güglingen, 01.05.2007 Dr Eng. Franz Grammling
Managing Director

Contents
3
FA ROTEX ESU - 07/2008
1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Observing Instructions. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . 5
1.2 Warning signs andexplanation of symbols . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . 5
1.3 Avoid danger. . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . 6
1.4 Proper use. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . .. . 6
1.5 Instructions for operating safety . . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . 6
2 Product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Design and components of the ROTEX E-SolarUnit . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . 8
2.2 Brief description. . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . 10
3 Set-up and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Transport and delivery. . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. 11
3.2 Installing the ROTEX E-SolarUnit . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. 11
3.2.1 Selecting the installation site . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . 11
3.2.2 Installing the unit. . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . 11
3.3 Dimensions . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . 12
3.4 Water connection for heating and hot water pipes. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . 13
3.5 Connecting the valvedrive to the 3-way diverter valve . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. 14
3.6 Establishing an electrical connection. . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . .. 15
3.7 Temperature sensor. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . 16
3.7.1 General instructions for the temperature sensors. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . 16
3.7.2 Connecting the temperature sensor . . . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . 16
3.8 Optional connections . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . 17
3.8.1 Mixer circuit . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . 17
3.8.2 Room thermostat. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 17
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 panel. . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . 23
5.2 Changing the boiler control panel. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . 24
5.3 Changing cables . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 26
5.4 Changing sensors. . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . .. . . . . . . . . . . . 27
5.4.1 Changing flow/return flow temperature sensors. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . 27
5.4.2 Changing the storage tank temperature sensor. . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. 29
5.5 Changing the fuse. . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. 29
5.6 Installing and removing the central unit. . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. 30
5.7 Wiring diagram. . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 31
6 ROTEX control system ALPHA+23R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.1 Overview. . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . 32
6.2 Control elements . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . 32
6.2.1 "Selectionof operating mode" rotary switch . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . 32
6.2.2 "Default settings" rotary switch . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . 33
6.2.3 Operator keys . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . 33
6.2.4 Special functions. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . 33
6.3 Display. . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . 34
6.4 COM socket. . . . .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . 34
6.5 Default settings . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. 34
6.5.1 General information . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . .. . . . 34
6.5.2 Normal operating mode . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . 35
6.5.3 Changing the correction value for the flow temperature. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . 35
6.5.4 Setting the target hot water temperature for off-peak tariff charging . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . 35
6.5.5 Setting the time and weekday . . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. 36
6.5.6 Switching timeprogramme . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . . . . . 36

Contents
4FA ROTEX ESU - 07/2008
6.5.7 Manual operation . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . .40
6.5.8 Querying system information. . . . . .. . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . .40
6.6 System parameters. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . .. . . . . . . . . . .42
6.6.1 Setting parameters – Basicprocedure. . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . .42
6.6.2 Overview of system parameters . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . .43
6.6.3 Resetting parameters to factory settings . . . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . .45
6.6.4 Heating technician access code. . . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . .45
6.6.5 Setting heating characteristics . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . .46
6.6.6 Automatic summer switch-off. . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . .47
6.6.7 Setting hot water mode . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .47
6.6.8 Setting the maximum flow temperature . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . .48
6.6.9 Manual hot water recharging . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . .. . .49
6.6.10 Legionella protection. . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . .50
7 Electric heat generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.1 Design and brief description. . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . .51
7.2 Load compensation of switching contacts . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . .. . .51
7.3 Fault shutdown of tubular radiators . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .51
7.4 Fault shutdown of the power circuit board. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . ..52
8 Hydraulic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.1 Important information on the hydraulic connection. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . .53
8.2 Storage tank . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .53
8.3 Hydraulic system connection . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . .54
8.3.1 Short designationsused in connection diagrams . . . . . .. . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . .54
8.3.2 ROTEX E-SolarUnit with solar heating support . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . .55
8.3.3 ROTEX E-SolarUnit with integrated wood boiler . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . .55
9 Service and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9.1 General overview of service and maintenance. . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . .56
9.2 Service and maintenance tasks . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . .56
9.2.1 Checking the connections and pipes . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . .57
9.2.2 Checking and cleaning the safety overflow and drain hose . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . .57
10 x Faults and malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10.1 Detecting faults. . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .58
10.2 Troubleshooting. . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . .58
10.2.1 Individual reset . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . .. . .58
10.2.2 General reset . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .58
10.3 Fault codes. . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . .59
10.4 Malfunctions . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . .60
11 Taking out of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
11.1 Temporary shutdown . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .61
11.2 Final shutdown and disposal . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .61
12 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
13 Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
13.1 External temperature sensor . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . .68
13.2 Mixer circuit docking sensor . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .68
13.3 Room temperature control . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . .68
14 Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
15 List of keywords. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
16 Service log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

1 Safety
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1Safety
1.1 Observing Instructions
These instructions are intended for authorised and trained heating experts who have experience in the proper installation and
maintenance of heating systems and electrical installationson account of their technical training and knowledge.
This manual provides all the necessary information for installation,start-up and maintenance, as well as basic information on
operation and settings. Please go through the attached documentsfor a detailed description of operationand control.
All heating parametersneeded for smooth operation are alreadyfactory-set. For setting the control, please refer to Chapter 6.
Please read this manual carefully and thoroughlybefore proceeding with the installation or modification of the heating system.
Relevant documents
– Documentation ROTEX Solaris, if the ROTEX Solar-System is connected.
1.2 Warning signs and explanation of symbols
Meanings of safety information
The safety information contained in these instructions is classified according to severity and probability of occurrence.
DANGER!
Draws attention to imminent danger.
If you disregard this danger notice, it willresult in serious injury or even death.
WARNING!
Indicates a potentially dangerous situation.
If you disregard this warning, it could result in serious injury or even death.
CAUTION:
Indicates a situation which may cause possible damage.
If you disregard this warning, it could result in material or environmental damage.
This symbol indicates useful information and instructions.

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Special safety symbols
Some special symbols represent particular types of danger:
Order number
The cart symbol indicates information on order numbers.
Handling instructions
• Handling instructionsare given in the form of bullet points. Handling sequences where a particular order must be followed
are given in the form of anumbered list.
ÎResults of actions are identified with an arrow.
1.3 Avoid danger
TheROTEXE-SolarUnitisstate-of-the-artandisbuilttomeetallrecognisedtechnicalrequirements.However,improperusecan
lead to serious injuries or death, as well as cause material damage.
To avoid such risks, only install and operate the ROTEX E-SolarUnit:
– as stipulated and in perfect condition,
– with an awareness of the safety and hazards involved.
Thisassumesknowledgeanduseofthecontentsofthismanual,therelevantaccidentpreventionregulationsandtherecognised
safety-related and occupational medical rules.
1.4 Proper use
TheROTEXE-SolarUnitmustonlybeusedasahotwaterheatingsystem.TheROTEXE-SolarUnitmustbesetup,connectedand
operated in accordance with the stipulations contained in these instructions.
Anyotheruseoutsidetheabove-mentioneduseisconsideredasimproper.Anyresultingdamageswillbebornebytheuser/owner
alone.
Proper use also includes observing the relevant maintenance andservicing conditions. Spare parts must at least satisfy the
technical requirements defined by the manufacturer. This is the case, for example, with original spare parts.
1.5 Instructions for operating safety
Before starting up the heating system
• Only authorised and trained heating engineers should work on the heating system (e. g. installation, connection and initial
start-up).
• When carrying out any workon the heating system, switch off the mainswitch and secure it against being switched on
unintentionally.
• Seals must not be damaged or removed.
Electrical installation
• Electrical installations may only becarried out by qualified electrical technicians underobservance of the relevant electrical
guidelines and the regulations of the electric utilities company.
• Compare the mainsvoltage (400 V, 50 Hz 3-phase current) indicated on the type plate withthe supply voltage before
connecting to the mains.
Open or closed heating system
• Install the heating system as an open or closed system in accordance with the safety-related requirements of EN 12828.
• Note that the safety valves must comply with DIN EN ISO 4126-1 and be type tested. They must be installed in the
safety flow.
Danger of explosion Electrical current Danger of burning or scalding

1 Safety
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Hydraulic system connection
• Duringoperationof the ROTEXE-SolarUnit,thestoragetanktemperaturemayexceed60°C,particularlywhensolarpower
is used. Therefore, some form of scalding protection needs tobe included whenyou install the system (hot water mixing
device, e. g. VTA32 15 60 16).
Operation
• Do not operatethe ROTEX E-SolarUnit if the storage tank is filledto above the overflow edge.
• Do not operate the ROTEX E-SolarUnit if the protective cover is open.
Instructing the user/owner
• Before you hand over the heatingsystem, explain to the owner how he/she can operate and check the heating system.
• Make a record of the handover by filling out andsigning the installation and instruction forms jointly with the user/owner.

2 Product description
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2 Product description
2.1 Design and components of the ROTEX E-SolarUnit
1Cold water connection (1" male) *
2Hot water connection (1" male) *
3Hotwaterchargingheatexchangerflowconnection
4Hot water charging heat exchanger return
connection
5Heating flow connection (1" female)
6Heating return connection (1" female)
7Solaris flow connection (1" swivel nut)
8Solaris return connection (Tr 32x3 male)
with valve set
9Connection for compensating line (Tr 32x3 male)
with valve set
10 Top filling connection (alternative: safety overflow
connection to front – Tr 32x3 male)
11 Immersion sleeve for storage tank sensor
12 Immersion sleeve for Solaris return flow
temperature sensor
13 Safety overflow connection to rear (Tr 32x3 male)
with hose nipple
15 Heatexchanger forheating(electricheatgenerator
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 temperature sensor
24 Return flow temperature sensor
25 Safety valve – Connection for blow-off pipe (3/4"
female)
26 Option for connecting membrane expansion tank
(3/4" male)
27 Bypass
28 Boiler control panel, see Chapter 5, page 23
29 ROTEX Regelung ALPHA+23R, see
Chapter 6, page 32
30 Heating pressure gauge
31 Protective cover
32 Lock screws for protective cover
33 KFEcock forfilling theheating system(1/2"male)
34 Automatic vent valve
35 Ball stopcock
36 Type plate
37 Terminal box for supply terminals
38 Electronic fill level probe
39 Connecting cable for external temperature sensor
40 Safety temperature limiter heat generator flow
41 ThermowellSTB
Safety devices
*Theconnectionisreadyforinstallationof agravitybrake, whichcan
be ordered separately.
Gravity brake 16 50 70
Fig. 2-1 Components of the ROTEX E-SolarUnit

2 Product description
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AElectric heat generator
BStratified hot water storage tank
CUnpressurised storage tank water
DHot water zone
ESolar zone
FHeating support zone
GRPS control and pump unit (Solaris accessory)
1Hot water connection (1" male)
2Heating connection (1" male)
3Solaris connection
4Domestic water heat exchanger (TW-WT)
5Heat exchanger for storage tank charging (SL-WT)
6Heat exchanger for solar heating support (HU-WT)
7Heat exchanger for heating (electric heat
generator with integrated safety temperature
limiting in heat-insulated housing, see
Chapter 7, page 51)
8Heat insulation sleeve for HU-WT
9Ready for installation of gravity brakes, not
included in the scope of delivery (165070)
10 Solaris flow layering pipe
11 Circulation pump for heating
12 3-way diverter valve
13 Safetyoverflowconnectionto rear (Tr 32x3 male)
14 Topfillingconnection(alternative:safetyoverflow
connection to front - Tr 32x3 male)
15 Electronic fill level probe
Safety devices
Gravity brake 16 50 70
Fig. 2-2 Schematic design of the ROTEX E-SolarUnit

2 Product description
10 FA ROTEX ESU - 07/2008
2.2 Brief description
The ROTEX E-SolarUnit is a fully pre-assembled electric heat generator for supplying hot water and heating roomsin buildings
with a heat demand of up to9 kW. The electric heat generator is placed directly on top of the hot water storage tank, inside
a housing with good heat insulation. There are practically noexternal surfaceor cooling losses.All the heat is passed to the
storagetank water,nottothesurroundings.Theexcellentheatinsulationpropertiesoftheplasticstoragetankalsoensurethat
heat losses are kept to a minimum.
Using solar power
The ROTEX ESU hot water storage tank can use solar power as its heat source, if required. The electric heat exchanger only
maintainstheupperzoneofthestoragetankatacertaintemperature.If the sunprovidesalotofheat,solarpowercanbeused
toheatthewaterinthewholeofthestoragetank.Inthiscase,thestoredheatisusedtoheathotwaterandforheatingsupport.
The high overall capacity of the 500 l storage tank means that periods when there is no sunshine can also be bridged.
Operating mode
The potable water is heated indirectly in theROTEX ESU through the pressureless storage water ofthe hot water storage tank
in a corrosion resistant stainless steel corrugated pipe-heat exchanger (Figure 2-2,page 9, pos. 4).It stores around 24litres of
domesticwateratthehotwaterzonetemperaturelevel.IncaseofgreaterwarmwatervolumestheROTEXESUheatsthiswater
usingthecontinuous-flowwaterheaterprinciple.Ifthereissufficientsolarradiation,thecontentsofthehotwaterstoragetank
can also be heated using solar power (ROTEX Solaris accessories).
While heating using theelectric heaterof the ROTEX ESU, specifically only the upper zone of the storage tankis kept on
temperature.Ifsolarpowerisused,dependingontheheatprovidedbythesun,itmaybepossibletoheattheentirestoragetank
in this way, sothat stored heat canbe used to heat water and for heating support.
Thearrangementoftheheatexchangerandthe flow ofwaterthroughitresultsindistincttemperaturestratificationinthe unit,
which leads to improvedenergy efficiency.
Safety management
TheelectroniccontrolisresponsibleforallsafetymanagementfunctionsrelatingtotheROTEXE-SolarUnit.Ifthereisashortage
ofwaterorifanundefinedoperatingstatearises,thecontrolexecutesa safetyshutdown.Acorrespondingfaultsignalprovides
an engineer with all the necessary information for troubleshooting.
Electronic control
Afully-electronic,digitalcontrolisabletoautomaticallycontrolallheatingandhotwaterfunctionsfor thedirectheatingcircuit,
a mixed heating circuit which can be connected as an option and a storage tank charging circuit. Using potential-free switching
contact(Chapter 3.6, page 15)providedbythepower supplycompany(PSC)theheatoutputcontrolcanbeadjustedtothetariff
offered by the PSC (Chapter 3.10, page 19). The user carries out all settings, displays, and functions using the ROTEX control
system ALPHA+23R. The display and keyboard provide user-friendly ways of executing such operations.