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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6FA ROTEX ESU - 07/2008
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

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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
8FA ROTEX ESU - 07/2008
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

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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.

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3 Set-up and installation
Incorrect set-up and installation would make the manufacturer's guarantee void. If you have questions, pleasecontact our
Technical Customer Service.
3.1 Transport and delivery
The ROTEX ESU is delivered on a pallet. Allindustrial trucks, such as lifting trucks and forklift trucks, are suitable for
transporting it.
Scope of delivery
– ROTEX ESU (pre-assembled and ready to plug in), consisting of a solar storage tank, electric heat generator, integrated
circulation pump,3-way diverter valve, automatic vent valve,KFE cock, internal temperature sensors (flow, return flow,
storage tank), external temperaturesensor, fill level probe, safety group and ball cocks.
– The document folder, containing installation and maintenance instructions,instruction manual, installation and instruction
form.
3.2 Installing the ROTEX E-SolarUnit
3.2.1 Selecting the installation site
The installation site for the ROTEX ESU must meet the minimum requirements below.
Installation area
– The surface must be solid, level, horizontal and have sufficient load capacity. Install a pedestal if necessary.
– Observe the installation dimensions (see Chapter 3.3).
3.2.2 Installing the unit
Requirement:
– Theinstallationsitecomplieswith applicablecountry-specificregulationsandmeetsthe minimum requirementsdescribedin
Chapter 3.2.1.
DANGER!
Danger of death due to improper installation
Electronic units, whichare not setup or installed properly can endanger an individual's life orhealthand can
also impair the function they are designed to perform.
• The ROTEX E-SolarUnit must be set up and installed by authorised and trained heating experts.
WARNING!
Danger of injury from toppling over.
Risk of toppling over: When empty, the ROTEX ESU istop-heavy and topples over easily. This can result in
injury to individuals or damage to the unit.
• Transport theROTEX ESU carefully, using the handles provided on it.
WARNING!
Danger of injury from toppling over.
Risk of toppling over: When empty, the ROTEX ESU istop-heavy and topples over easily. This can result in
injury to individuals or damage to the unit.
• Transport theROTEX ESU carefully, using the handles provided on it.

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12 FA ROTEX ESU - 07/2008
Set-up:
• Remove the packaging and disposeof it in an environmentally sound manner.
• Install the ROTEX ESU at the installation site.
• Lay the connection lines in such a way that the protective cover can be removed (see Figure 3-2).
3.3 Dimensions
Fig. 3-1 Mounting dimensions of the ROTEX ESU

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Connecting dimensions for the heating and hot water connections
3.4 Water connection for heating and hot water pipes
TheconnectorsoftheROTEXESUarelocatedontheupperrearsideoftheunitoronthelowerfrontside(optionalSolaris-return
flow).Theheatingcircuitandstoragetankchargingsharethesameflowandreturnflow.Theheatingcircuitforthestoragetank
chargingisintegratedatthefactoryandmustnotbeconnectedseparately.Thechalkthatprobablyfallsoutduringwaterheating
is rinsed from the stainless steelcorrugated pipe-heat exchanger by the warm water. See Chapter 8.1,page 53 for important
information on the hydraulic connection.
Instructions for water connection
1Cold water (pipe thread 1" male)
2Hot water (pipe thread 1" male)
5Heating flow (pipe thread 1" female)
6Heating return flow (pipe thread 1" female)
7Solaris flow (flat-sealing pipe thread 1" swivel nut)
25 Safety overpressure valve (pipe thread 3/4" female)
26 Membrane expansion tank (pipe thread 3/4" male)
33 KFE cock (pipe thread 1/2" male)
Fig. 3-2 Connecting dimensions for the heating and hot water connections (top view)
Toavoidtemperaturelossesbywarmwatercirculation,ROTEXrecommendstheinstallationofgravitybreaks
(16 50 70) or the siphoning (conducting the pipes straight downwards) of the potable water pipes.
The domestic water connections are ready for gravity brakes tobe installed.
CAUTION!
IftheROTEXESUisconnectedtoacoldwaterinputpipeoraheatingsystem,inwhichsteelpipesorradiators
ornon diffusion-prooffloorheatingpipesare installed,slurry and chippingscanenter the heat generatorand
the heat exchangers and leadto clogging, local overheating, orcorrosion damage.
• Rinse out the heat distribution network (in the existing heating system).
• Install a dirt filter in the heating return flow.

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14 FA ROTEX ESU - 07/2008
• Observe the stipulations of EN 806and DIN 1988 for domestic water pipes.
• Check the cold water connection pressure (maximum 6 bar).
– If a higher pressure is present in the domestic water pipe, a pressure reducer will need to be installed.
• The positions and dimensions of the heating connections are shown in Figure 3-2, page 13.
• All hot water piping must be properly insulated in order to prevent heat losses.
• Connect the pressure relief line to the safety overpressure valve and the membrane expansion tank acc. to EN 12828.
–Water shortage protection: The ROTEX ESU overheating protection function switchesthe electric heat generator off
safely if there is a shortage of water, and locks it. No additional water shortage protection is needed in the construction.
–Avoiding deposits: Observe theregulations inVDI 2035 in orderto avoidcorrosiveproductsand deposits. If the fillingand
additional water has a high degree of hardness, measures must be taken to stabilise this hardness or soften the water.
3.5 Connecting the valve drive to the 3-way diverter valve
TheROTEXESUisequippedwithanintegratedcirculationpumpanda3-waydivertervalve(3W-DV)asstandard.Thecirculation
pump and the 3-way diverter valveare connected atthe factory; the valve drive isplugged on.
• Following start-up, insert the connection plug of the 3-way diverter valve's cable into the valve drive.
WARNING!
Danger of scalding
Temperaturesofover60°Cpresentadangerofscaldingif solarpowerisbeingused,ifLegionellaprotection
is activated or if the target hot water temperature is set to over 60°C.
• Install scaldingprotection(hot water mixing device), VTA32 ( 15 60 16).
1Heat generator flow
2Heating flow
3Storage tank flow
43-way diverter valve
5.1 Valve drive
5.2 Unlocking button of the drive lock
5.3 Hand lever
Fig. 3-3 3-way diverter valve
The circulation pump and the 3-waydiverter valve each have one cable with a connection plug. These cables
are ready for use.

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3.6 Establishing an electrical connection
All ROTEX ESU control and safety devices are connected, tested and ready for use. Modifications on the electrical installation
are dangerous and prohibited. Any resulting damages will be borne by the user/owner alone.
The ROTEX E-SolarUnit is intended to be connected to a 400 V, 50 Hz3-phase supply system. The electric heat generator is
suppliedwithpowervia3phases,230 V/50 Hz.WithsufficientprotectionandlinedimensioningtheROTEXESUcanalsooperate
on a 230 V/50 Hz single-phase grid. The ROTEX ESU-adapter 230 V/single-phase ( 15 70 51) is available for that.
Before connecting the ROTEX E-SolarUnit, you must ensure that the supply voltage corresponds to thespecified mains voltage.
The mains connecting cable must be routed into the terminal box through the large cable gland (A). After the cable has been
connected to the terminals, tighten the cable gland's swivel nut togrip the cable.
Connect to the mains as per Figure 3-4 in the terminal box (see Figure 2-1, pos. 37).
If a signal is available from the power company at off-peak tariff,a switchcable (hose lineminimum2 x0.5 mm2)can be wired
through the second cable gland (B) of theterminal box. The switching contact must be connectedto terminals 4and 5 in the
terminalbox.Theswitchingcontactmustbedesignedasafloatingcontact.IfthecontactisopentheROTEXESUoperateswith
the standard tariff (ST) settings, if the contact is closed with the settings for off-peak tariff (OT)– see Chapter 3.10, page 19.
Themainsandsensorconnectionsarecodedontheconnectorcircuitboardoftheboilercontrolpanelintermsoftheircolourand
shape (see Figure 3-5), to prevent them being mixed up.
WARNING!
Danger of death due to electric shock
Live parts can cause an electric shockon contactand cause fatal burns and injuries.
• Before beginning work on live parts, disconnect them from the power supply (switch off fuse, main
switch) and secure against unintentional restart.
• The electricalconnection may only be establishedby qualified electrical technicianswith observance of
the relevant standards and guidelines, as well as the regulations of the electric utilities company.
Fig. 3-4 Connection assignment in the terminal box
CAUTION:
Danger of destroying the relay board
• Design the ST/OT switching contact asa floating contact.
• Do not applymains voltage under any circumstances, as this would destroy the board.

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\All electrical installation work required inside the ROTEX E-SolarUnithas already been completed at the factory. A 3 m flexible
external sensorcable (see Figure 2-1, pos. 39) has already been connected to the terminals inside the unit andplugged onto the
connectingcircuitboardinthecontrolpanel.Onlyoptionalextras(suchasamixercircuit)thenhavetobeconnectedtotheboiler
control panel.
3.7 Temperature sensor
3.7.1 General instructions for the temperature sensors
The ROTEX ESU controls the flow temperature based on theweather. An external temperature sensor is required for this
function.A3 m flexible cable isalready connected inside theunit andplacedin the control panel onthe connecting circuit board.
The temperatures detected via the internal temperature sensors (flow and return flow temperature sensors) are used to
control the heat generator's output and to detect faults. They are connected in the factory and can be plugged onto the
appropriate sensor directly, should a replacement be needed.
The storage tank temperature sensor is installed and connected to the terminals at the factory (PTC thermistor). The mixer
circuit flow sensor (TMKF, 15 60 62) is required to control a mixer circuit.
3.7.2 Connecting the temperature sensor
Make sure that the mains connection uses the correct phase sequence. If incorrect polarity is used, the mains
switch remains lit even after it has been switched off.
Connections of the circuit board connectors:
J1 Boiler pump Pk
J2 3-way diverter valve or storage tank charging
pump PL*
J6 Mains connection
J7 Mixer
J8 Communication, sensors
J10Sensors
Cable colours:
bl blue
br brown
gr grey
rt red
sw black
ws white
n.b. Contact not assigned
* If the adapter cable is used for the charging pump ( E 1500430)
Fig. 3-5 Connection assignment label on the boiler control panel
CAUTION!
Theuseoftemperaturesensorsthatarenotapprovedorunsuitablefortheunitcanleadtomajormalfunctions
during controlled operation of the ROTEX ESU and impair the control function of the unit.
• Only use the external temperature sensor included in the scope of delivery.

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External temperature sensor
• Choose a location at about one thirdof the building height (minimum distance from floor: 2 m) on the coldest side of the
building (north or north-east).
• Ensure that the location is not near to any external heat sources (flues, air ducts), nor subject to direct solar radiation.
• Place external temperature sensors in such a way that the cable exit points face downwards (prevents humidity ingress).
• Connecttheoutdoortemperaturesensorwithaduplexwire(minimumcross-section1mm
2)withthecablemarked"outdoor
temperature sensor".
Mixer circuit flow sensor (accessory)
• Connect the sensor line to the sensor plug J8 (see Figure 3-5, page 16).
3.8 Optional connections
3.8.1 Mixer circuit
A mixer circuit, which is controlled via the electronic boiler control, canbe connected to theROTEX ESU directly.
ROTEX offers the following:
–TheAMK1 ( 15 60 44) mixer group, which is ready to plug in and consists of a circulationpump integrated into a heat-
insulated housing, a motor mixer and stopvalves with temperature indicators.
–TheTMKF( 156062)mixer circuit docking sensor.
3.8.2 Room thermostat
To remotely set theroom temperaturefrom anotherroom, a separateroom thermostat ROTEX ALPHA RTR-E ( 17 51 26)
can be installedfor the direct or the mixed circuit. If you want to use this function, you must activate it in the
ROTEX ALPHA+23R control.
– Connection ofthe room thermostatROTEX ALPHA RTR-E to the terminal AB of the board connector J8 on main unit
(see Figure 3-5, page 16).
3.9 Filling the system
Adjusting the pressure gauge
Beforefillingthesystemforthefirsttime,theminimumpressuremarkingmustbeadjustedtothecorrectsettingonthepressure
gauge glass:
• Rotate the pressure gauge glass (Figure 2-1, page 8, pos. 30) so that the minimum pressure marking equates to the height
of the system + 2 m (1 m water column corresponds to 0.1 bar).
Once all installation work has beencompleted, fill the ROTEX E-SolarUnit by following the sequence below:
1. Filling the hot water heat exchanger
• Open the shutoff valve for the cold water supply pipe.
• Open the hot water bleeder tap connections so that the draw-off volume can be set as high as possible.
• Once water hasbeen discharged from the tap connections, do not interrupt the cold water inflow; this will ensure that the
heat exchanger will be fully vented and that any impuritiesor residue will be discharged.
CAUTION!
Laying the sensor and mains lines inparallel within a wiring conduit can lead to major malfunctions during
controlled operation of the ROTEX ESU.
• Always lay the sensor line separately.

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18 FA ROTEX ESU - 07/2008
2. Filling the storage tank
ROTEX ESU with Solaris-System installed:
• Connect the filling hose with return flow inhibitor (½") to the KFE cock on the control and pump unit (RPS).
• Fill the storage tank until water is discharged from the safety overflow.
ROTEX ESU without Solaris-System installed:
• Either connect the filling hose to thehose nozzle supplied and then secure this nozzle to theconnection on the side of the
tank, at the top (see Figure 2-1, page 8,pos. 10) or insert the hose into the Solaris flow connection (Figure 2-1, page 8,
pos. 7).
• Fill the storage tank until water is discharged from the safety overflow.
3. Filling the heating system and the storage tank charging circuit
• Engage the hand lever on the 3-way diverter valve (see Figure 3-3, page 14)in the centreposition (only possible when de-
energised/in the delivered condition).
• Connect the filling hose with return flow inhibitor (½") to the filling and draining fittings (KFE cock,Figure 2-1, page 8,
pos. 33) and secure against sliding by using a hose clamp.
• Open the water tap for the supply pipe.
• Open the KFE cock and watch the pressure gauge (Figure 2-1, page 8, pos.33).
• Fill the system with water until the marking of the system overpressure is roughly in the centre of the green range of the
pressure gauge display.
• Close the filling & draining cock.
• Vent the entire heating network (open the system control valves).
• Check the water pressure on the pressure gauge again and top up with water if necessary.
• Close the KFE cock, remove the filling hose and return flow inhibitor from the fillingand draining fittings.
WARNING!
Polluted domestic water is hazardous to health.
• When filling the heating system, ensure that water from the boiler cannot flow back into thedomestic
water pipe.
Thecentrepositionisonlystable when the valveisde-energised.Thevalvereleasesautomaticallyifvoltageis
applied at the drive motor for valve positionAB-A (storage tank charging).
To ensure a complete deaeration, the 3-way diverter valve must be unlocked at the earliest one hour after
equipment start-up byplugging in the power cable.

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3.10 Setting the heating output
The heater performance of the electric heat generator can be individually set at the boiler control panel according to low-, and
peak tariff of thepower company aswell as accordingto heater and water heating. Therefore, theROTEX electronic control
ALPHA+23R must be temporarily removed (see Chapter 5.6, page 30).
The DIP switches on the relay board on the boiler control panel (see Figure 3-6) are used to set the outputsfor each
operating mode.Foreachoperatingmode(heater,waterheating)powersettingsmustbe presetinincrementsof3 kWaccording
to Table 3-1, page 19 for HT- and LT times ofthe power company. Each pair of switches is assigned to a particular operating
mode and tariff time.
The settings for peak tariff are effective with open contact between the terminals 4 and 5 in the power supply terminal box
(Chapter 3.6,page 15). Thesettingsforoff-peaktariffareeffective,ifthecontactbetween the terminals4and5is closed.The
switching contact between the terminals 4 and 5 must be carried out potential-free.
For example: J3 andJ4 can be used to set the output for thehot water preparationoperating mode during standard tariff time.
In Figure 3-6, DIPswitches 2, 3, 7 and8 are set to position "1" (pressed down). This means that the following settings have
been made:
• Heat demand, standard tariff: 6 kW (switches 1 and 2)
• Hot water demand, standard tariff: 3 kW (switches 3 and 4)
• Heat demand, off-peak tariff: OFF (switches 5 and 6)
• Hot water demand, off-peak tariff: 9 kW (switches 7and 8)
Tab. 3-1 Assignment of DIP switch settings in terms of heating output
Fig. 3-6 DIP switches for setting heating output
By simultaneously setting both switches of aDIP switch pair to "0" (e. g. switch5 and 6 for off-peak tariff
time heat request in our example) power for the corresponding operating mode isdeactivated! In such cases,
the frost protection function is also disabled for the operating mode concerned.
P [kW] J1 J2 J3 J4 J5 J6 J7 J8
Heat demand standard
tariff (ST) OFF 0 0
310
601
911
Warm water demand
standard tariff (ST) OFF 0 0
310
601
911
Heat demand, off-peak
tariff (OT) OFF 0 0
310
601
911
Warm water demand
off-peak tariff (OT) OFF 0 0
310
601
911

4 Start-up
20 FA ROTEX ESU - 07/2008
4Start-up
Incorrect start-up makes the manufacturer's guarantee for the unit void. If you have questions, please contact our Technical
Customer Service.
4.1 Initial start-up
Once the ROTEX ESU has been fully installed and connected, it can be started up by suitably trained staff.
Requirements
– The ROTEX ESU is fullyconnected.
– The heating and hot water system are filled and subjected to the correct pressure.
– The storage tankis filled to the overflow point.
– The heating system's control valves are open.
Checks before start-up
• Check all connections for leakage.
• Check all the points on the enclosed checklist (see Chapter 4.2). Log the test results on the checklist.
Only if all points on the checklist can be answered with yes may the electricheat generator be started up temporarily.
Start-up
• Switch the mains switch on (see Figure 5-1, page 23, pos. 1).
Requirements
– The control hasbeen installed inaccordance with these instructions.
– All sensors required for normal operating mode (the flow temperature sensor, for example) have been connected
(see Table 4-1).
– Optional sensors have been properly connected.
Tab. 4-1 Necessary and optional sensors for ROTEX ESU
WARNING!
Danger of death due to improper start-up
AROTEXE-SolarUnitwhich is not startedupproperlycanendangeranindividual'slifeorhealth andcanalso
impair the function it is designed to perform.
• The ROTEX ESU may only be started up by authorised and trained heating experts.
CAUTION:
If the ROTEX ESU is not started up properly, it could lead to materialor environmental damage.
• Observe the regulations in VDI 2035 in orderto avoid corrosion and deposits.
• Ifthefillingand additionalwaterhasahighdegreeofhardness,measuresmust be takentostabilisethis
hardness or soften the water.
– We recommend the use of Fernox limescale and corrosion protector KSK ( 15 60 50).
• During operation of the system, the water pressure must be checkedat the pressure gauge at regular
intervals (it must bein the green range).If necessary, correct the pressure by topping up with water.
Unit Flow
temperature
sensor
Return flow
temperature
sensor
Flue gas
temperature
probe
Hot water
temperature
sensor
External
temperature
sensor
Mixer
temperature
sensor
ROTEX ESU Yes Available* No Optional Optional Optional
* Available in the unit, not evaluated by ROTEX ESU