Rotex Solaris RPS3 25M Specification sheet

For certified companies
ROTEX Solaris
Solar system
Control unit for large-scale installations RPS3 25M
Operating and installation manual
Valid for the following components
ROTEX SolarisRPS3 25M
Solaris R3 temperature difference controller
Sanicube Solaris and HybridCube storage tank
Serial number
Customer
GB
Issue 03/2010

2FA ROTEX Solaris RPS3 25M - 03/2010
Guarantee and conformity
Guarantee conditions
ROTEX accepts the guarantee for material and manufacturing defects according to this statement. Within the warranty period,
ROTEXundertakes to have damaged parts of the installation repaired free of charge by a person assigned by the company.
ROTEX reserves the right to provide substitute replacement parts.
The warranty is only valid if the installation is used properly and if it can be proved that it was installed correctly by a specialist
company. As proof, we strongly recommend completing the enclosed installation and instruction forms and returning them to
ROTEX.
Warranty period
The guarantee period begins on the day of installation (billing date of the installation company), but at the latest 6 months after
the date of manufacture (billing date). The warranty period is not extended if parts of the installation are returned for repairs or
if components are replaced.
• Warranty period for the Control unit: 3 years.
• Warranty for all other parts of the installation according to construction contract procedures.
Exclusion of warranty
Improper use, tampering with system components pre-assembled by ROTEXand improper modifications will immediately inval-
idate the guarantee.
Dispatch and transport damage are excluded from the warranty.
The guarantee explicitly excludes follow-up costs, especially the assembly and disassembly costs of system components.
All ongoing costs, in particular claims for damages, are excluded.
There is no guarantee claim for wear parts (according to the ROTEX definition), such as lights, switches, fuses.
The warranty claim is automatically void if the connecting pipes are not run with continuous gradients and the lower edges of
the collectors are not installed with a constant slope (at least 2 %) towards the return connection in the case of opposite side
connections or installed horizontally in the case of same-side connections.
Declaration of conformity
for the control unit Solaris RPS3 25M.
We, ROTEX Heating Systems GmbH, declare under our sole responsibility that the product
Product Order No.
ROTEX RPS3 25M 16 41 11-49
complies, in its standard design, with the following European Directives:
2004/108/EC Electromagnetic Compatibility Directive
2006/95/EC Low Voltage Directive
Güglingen, 01.03.2010 Dr Eng. Franz Grammling
Managing Director

List of contents
3
FA ROTEX Solaris RPS3 25M - 03/2010
1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Refer to the manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Warning signs and explanation of symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Avoiding danger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5 Instructions for operating safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Design and components of Solaris large-scale systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3.1 Control unit RPS3 25M. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3.2 Flow rate meter and regulating valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3.3 Connecting pipes and extension kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1 System concepts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1.1 Parallel connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1.2 Series connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 System design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3 Preparatory installation work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4 Control unit RPS3 25M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.5 Hydraulic connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.6 FlowGuard, FlowSensor (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.7 Temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.8 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.9 Connecting severalDHW storage tanks together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4 Commissioning and decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.1 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2 Decommissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2.1 Temporary shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2.2 Permanent decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.1 Operating and display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.2 Controller operating principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.2.1 Pump operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.2.2 Booster function for high solar panel temperatures (only if a booster pump is connected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.2.3 Switch-on inhibit functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.2.4 Pump kick function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.2.5 Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.2.6 Solaris FlowSensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.2.7 Output calculation, maximum values, and yield count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.2.8 Overallresetfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.2.9 Frost protectionfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.2.10 Plant leakage protection function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.3 Adjustments and menu guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.3.1 Display during start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.3.2 Display during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.3.3 ESetup menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.3.4 Password protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.3.5 Language selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.3.6 Adjusting and resetting parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.3.7 Correcting values for measurement points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3.8 Burner inhibit contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

List of contents
4FA ROTEX Solaris RPS3 25M - 03/2010
5.4 Recommended settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
5.4.1 Standard parameter values, recommended adjustment ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.4.2 Other adjustments of your Solaris system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.4.3 Recommended settings for auxiliary heating via external heat sources or the electric heater, burner inhibit contact. . . . . . . . . . 41
5.4.4 Tips for optimised user behaviour. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.4.5 Domestic water hygiene. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6 Faults and malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.1 Display of events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7 Hydraulic system integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.1 Schematic diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
7.2 Short designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.3 Connection of a pressurised collector system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
8 Technical data for. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.1 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
8.2 Sensor characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
8.3 Hydraulic resistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.4 Terminal assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9 List of keywords. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

1 xSafety
5
FA ROTEX Solaris RPS3 25M - 03/2010
1Safety
1.1 Refer to the manual
This manual is intended for authorised and trained technicians who have experience of the proper installation and commissioning
of Solaris systems on account of their technical training and knowledge.
All activities required for installation, commissioning, operation, and adjustment of the heating system are described in this
manual. For detailed information on the equipment connected to your heating system, please refer to the corresponding manuals.
Please read this manual carefully and thoroughly before proceeding with the installation and commissioning or carrying out an
operation on the heating system.
Relevant documents
The documents listed below are part of the technical documentation for the ROTEX Solaris system and must also be observed.
The documents are included in the scope of supply of the individual components.
– ROTEX Solaris V21P, V26P and H26P high output flat collectors: Installation instructions for on-roof, in-roof and flat
roof mounting
– ROTEX DHW storage tank (Sanicube Solaris/HybridCube, GasSolarUnit (GSU) or HPSU compact): Operating and installa-
tion instructions
When connecting to an external heat generator or hot water storage tank which is not included in the scope of delivery, the
individual associated operating and installation instructions apply.
1.2 Warning signs and explanation of symbols
Meaning of the warnings
Warnings in this manual are classified according into their severity and probability of occurrence.
Special warning symbols
Some types of danger are indicated by special warning symbols.
Order number
Notes relating to order numbers are identified by the cart symbol .
DANGER!
Draws attention to imminent danger.
Disregarding this warning results in serious physical injury or death.
WARNING!
Indicates a potentially dangerous situation.
Disregarding this warning may result in serious physical injury or death.
CAUTION!
Indicates a potentially damaging situation.
Disregarding this warning may cause damage to property and the environment.
This symbol identifies user tips and particularly useful information, but not warnings or hazards.
Danger of burning or scalding Electric current

1 xSafety
6FA ROTEX Solaris RPS3 25M - 03/2010
Handling instructions
• Handling instructions are shown as a list. Actions for which the sequential order must be maintained are numbered.
Results of actions are identified with an arrow.
Validity
Some of the information in this manual only applies to certain components or software versions of the RPS3 25M differential
temperature controllers. Validity is indicated by the following symbols:
1.3 Avoiding danger
ROTEX Solaris systems are state-of-the-art and are built to meet all recognised technical requirements. However, improper use
may result in serious physical injuries or death, as well as property damage. To avoid danger ROTEX Solaris systems should only
be installed and operated:
– as stipulated, and in perfect condition,
– with an awareness of safety and the hazards involved.
This assumes knowledge and use of the contents of this manual, of the relevant accident prevention regulations as well as the
recognised safety-related and occupational health rules.
1.4 Intended use
The ROTEX Solaris system may only be used for solar-supported heating of hot water heating systems. The ROTEX Solaris
system must be installed, connected and operated according to the information in this manual.
Any use other than or beyond that defined is considered to be improper. Any resulting damages will be borne by the user/owner
alone.
Intended use also includes compliance with the maintenance and service conditions. Replacement 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
Working on the roof
• Installation 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.
• Material and tools must be secured against falling.
• Barriers must be erected to prevent persons from entering the area below the roof where the work is being carried out.
Before working on the heating system
• All work on the heating system (such as installation, connection and commissioning) may only be carried out by authorised
and trained heating technicians.
• Switch off the main switch and secure it against unintended switching on when carrying out any work on the heating
system.
Electrical installation
• Electrical installation should only be carried out by qualified electrical engineers observing the technical electrical guidelines
and regulations of the relevant electric power supply company.
• Before connecting to the mains supply, check that the voltage specified on the type label of the heating system (230 V,
50 Hz) is the same as the available supply voltage.
Instructing the user/owner
• Before you hand over the Solaris system, explain to the user/owner how to operate and check the system.
• Document the handover by filling out the installation and instruction forms together with the owner and sign them.
Valid for all software versions of the Solaris R3 con-
troller
Only valid for the specified software version of the Solaris
R3 controller
3.9
3.9

2 xProduct description
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FA ROTEX Solaris RPS3 25M - 03/2010
2 Product description
2.1 Design and components of Solaris large-scale systems
1 Cold water connection pipe
2 Drinking water (hot) distributor
3 Stainless steel corrugated heat exchanger for
domestic water (hot)
4 Corrugated stainless steel heat exchanger for
heat generator (storage tanks charging)
5 Pocket for storage tanks and return temperature
sensors
6 Fill level display
7 Filling and draining cock
8 Solaris R3 controller
9 Solaris return pipe (bottom of collector)
10 Solaris solar collector field (up to 10 solar
collectors per row)
11 Solaris flow pipe (top of collector)
12 Thermostatic mixer valve (consumer-side scalding
protection)
13 Non-return valve (accessory)
14 Solaris flow layering pipe
15 Corrugated stainless steel heat exchanger for
heating support
16 Thermal insulation of stainless steel heat exchanger
for heating support
17 Solaris return connection (with valve insert)
18 Equalising pipe connection (with valve insert
for storage tank extension)
19 Safety overflow connection
20 Equalising pipe
21 Return flow connection pipe
A Zone with water for domestic use
B Solar zone
C Heating support zone
TRSolaris return flow temperature sensor
TSSolaris storage tank temperature sensor
TKSolaris collector temperature sensor
TVSolaris feed temperature sensor
TDHW Storage tank temperature sensor for heat
generator control
RPS3 25M
Control unit
FLG FlowGuard
FLS Solaris FlowSensor (flow rate measurement)
PS1 Solar circulation pump (on-site)
PS2 Solar booster pump (on-site, optional)
Illustration 2-1 Standard design of a ROTEX Solaris system (double-sided connection is recommended by ROTEX)

2 xProduct description
8FA ROTEX Solaris RPS3 25M - 03/2010
2.2 Brief description
The ROTEX Control unit RPS3 25M is used to control a circulation pump installed on-site and if required also a booster pump in
a Solaris large-scale system (thermal solar system for hot water generation and heating support).
A large-scale system is required when the necessary pump pressure to fill the system and the required flow rate cannot be
achieved in a Solaris Drainback system with the conventional RPS3 control and pump unit.
This is likely to be the case:
– when the height difference between the hot water storage tank and the solar collector is more than 12 m.
– when several collector arrays are connected (e. g. more than 5 solar collectors per system).
– when several hot water storage tanks are connected to form storage batteries.
Mode of operation
The Solaris V21P, V26P and H26P high-performance flat solar panels convert the sun's radiation into heat with high efficiency.
The heat transport medium is normal tap water.
As soon as the solar collectors have reached a useful temperature level, the water of the heating jacket in the storage tank (which
is not under pressure) is pumped directly through the collectors. If this is not the case, the circulation pump switches off and the
system is drained automatically.
Modular design
The majority of the system components offered by ROTEX are pre-assembled parts. Plug-in technology and a high degree of pre-
assembly ensure fast and simple system installation.
Hot water storage tank
The following hot water storage tanks can be used for the ROTEX Solaris system:
– ROTEX Sanicube Solaris (SCS): thermally insulated, unpressurised plastic storage tank (with the facility to connect a ROTEX
condensing boiler).
– ROTEX HybridCube (HYC): thermally insulated, unpressurised plastic storage tank (with the facility to connect a ROTEX air-
water heat pump).
– ROTEX GasSolarUnit (GSU): Sanicube Solaris with integrated gas-fired condensing boiler.
– ROTEX HPSU compact: HybridCube DHW storage tank with integrated indoor unit for an air-water heat pump.
Electronic control
The ROTEX Solaris R3 fully electronic control unit ensures optimum utilisation of the solar heat (hot water generation, heating
support) as well as compliance with all aspects of operating safety. All parameters needed for trouble-free operation have been
preset at the factory.
The ROTEX Control unit RPS3 25M can only be installed and operated in the unpressurised ROTEX Solaris sys-
tem (Drainback), using the assembly material provided.
As a precondition for fault-free operation in the Drainback system, the connection pipes must be routed with a
continuous downward gradient (at least 2 %), the collector arrays must be connected on both sides and the lower
edges of the solar panels must be attached to the return connection with a continuous downward gradient.
Construction, operating principle, commissioning, and operation of the hot water storage tank are not described
in this manual. You will find detailed information on the hot water storage tanks in their respective installation
and operating manuals.
The instructions and descriptions in this manual apply for all ROTEX hot water storage tanks that can be used
with this Solaris system, though for purposes of illustration, only one type may be described (e. g. SCS). Where
other hot water tanks deviate from the specific tank described, this will be pointed out separately.

2 xProduct description
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FA ROTEX Solaris RPS3 25M - 03/2010
2.3 System components
2.3.1 Control unit RPS3 25M
16 41 11
Consists of:
1Cover
2ROTEX Solaris R3 controller with storage tank
temperature sensor, return flow temperature sensor,
terminal connector for collector temperature sensor,
terminal block for mains and pump connection
3Solaris documentation
Illustration 2-2 Control unit RPS3 25M

2 xProduct description
10 FA ROTEX Solaris RPS3 25M - 03/2010
2.3.2 Flow rate meter and regulating valve
FlowSensor FLS100
FlowGuard FLG
2.3.3 Connecting pipes and extension kits
Connection set CON X20 25M
Connection set CON RA 25M
16 41 03
For measuring the flow rate (5 - 100 l/min) and the feed temper-
ature.
Consists of:
– Measuring section (a)
–Sensor(b)
– 3 m connecting cable (c).
– 2x seals (d).
Can be ordered as an option (see Chapter 5.2.6 "Solaris
FlowSensor"):
– FlowSensor FLS20 (1.5 - 20 l/min).
– FlowSensor FLS40 (2.5 - 40 l/min).
Illustration 2-3 FlowSensor FLS100 (optional)
16 41 02
For setting and displaying the flow rate from 2 - 16 l/min.
Consists of:
– FlowGuard FLG (a).
– 2x seals (b).
Illustration 2-4 FlowGuard FLG
16 42 32
For connecting a collector array (V21P, V26P, H26P) to the on-site
rigid copper connection pipes when using roof penetration kits
RCAP, RCRP, RCIP, RCFP.
Consists of:
– Push-in coupling fitting for return line with Ø 28 mm (a).
– Push-in coupling fitting for feed line with Ø 15 mm (b).
– 2 m feed line VA 15 Solar (c).
– 2 m return line VA 18 Solar (d).
Illustration 2-5 CON X20 25M (optional)
16 01 13
For connecting the return of a Sanicube Solaris or HybridCube hot
water storage tank to the on-site copper pump connection pipe.
Consists of:
– Connecting T-piece (a).
– Connection pipe with ball valve and connection fitting to
Ø 28 mm pipe diameter (b).
– Blanking plug with clamp (c).
Illustration 2-6 CON RA 25M (optional)

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FA ROTEX Solaris RPS3 25M - 03/2010
Connection set CON VA 25M
Storage tank extension kit CON SX
Storage tank extension kit 2 CON SXE
Equalising pipe AGL
Equalising pipe extension kit AGLE
16 01 14
For connecting the feed of a Sanicube Solaris or HybridCube hot
water storage tank to the on-site copper feed line.
Consists of:
– 5x push-in fitting flow 1" to Ø 15 mm.
One push-in fitting is included in each roof penetration kit RCAP,
RCRP, RCIP and RCFP. Connection set CON VA 25M is only required if
the number of hot water storage tanks installed in the system exceeds
the number of roof penetration kits.
Illustration 2-7 CON VA 25M (optional)
16 01 07
For connecting 2 Sanicube Solaris or 2 HybridCube hot water
storage tanks in systems with up to 3 hot water storage tanks.
Consists of:
– Return connecting pipe (a).
– Flow manifold (b).
Illustration 2-8 CON SX (optional)
16 01 11
Extension kit for connecting a 3rd Sanicube Solaris or
HybridCube hot water storage tank in systems with up to 3 hot
water storage tanks.
Consists of:
– Return connecting pipe (a).
– Flow manifold (b). Illustration 2-9 CON SXE (optional)
16 01 08
Equalising pipe for preventing differences in level between 2
connected hot water storage tanks (for 2 Sanicube Solaris hot
water storage tanks, 2 HybridCube hot water storage tanks or
for 2 GSU hot water storage tanks).
Consists of:
– Equalising pipe.
Use with CON SX and CON RA 25M.
Illustration 2-10 AGL (optional)
16 01 12
Equalising pipe for preventing differences in level between
connected hot water storage tanks in a row of storage tanks.
Consists of:
– Equalising pipe.
Use with CON SXE and CON RA 25M.
Illustration 2-11 AGLE (optional)

3 xInstallation
12 FA ROTEX Solaris RPS3 25M - 03/2010
3 Installation
3.1 System concepts
ROTEX Solaris systems are usually built according to one of the following system concepts. Information concerning hydraulic
system integration with specimen schematic diagrams can be found in Chapter 7 "Hydraulic system integration".
Careful design of the system is required to ensure that the circulation pump and the connection pipes are adequately dimensioned
(see section 3.2).
In the case of large-scale systems, the hydraulic resistance of the plastic connection pipes available from ROTEX is usually too
high. We recommend that you install connection lines made from rigid copper pipes on-site.
3.1.1 Parallel connection
Illustration 3-1 Double-sided connection in solar collector array
(up to 10 solar panels)
Illustration 3-2 Connection of several rows of solar panels in
accordance with the Tichelmann principle
3.1.2 Series connection
As an alternative to the parallel connection of the solar panels
described in this manual, if required, a maximum of 3 rows of
solar panels can also be installed above one another and
connected in series.
As a rule, parallel connection is preferable.
Illustration 3-3 Same-side connection of solar collector array

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FA ROTEX Solaris RPS3 25M - 03/2010
3.2 System design
Calculation of the piping network is necessary to ensure that the circulation pump and the connection pipes are correctly dimen-
sioned.
We recommend the following data as rough values:
1. Nominal flow rate per solar panel = 100 l/h
2. Size of the collector array and storage tank volume:
– Maximum of 5 solar collectors per 500 l storage tank volume.
– Maximum of 10 solar panels per row.
3. When installing several rows of solar panels, there should be the same number of panels in each row as far as possible, and
they should be connected according to the Tichelmann principle.
4. Route feed connections for several rows of solar panels in a continuous upward gradient to the point where they are
combined to form a common feed pipe.
5. Measuring the pressure drops:
a) Resistance of the collector array (chapter 8.3, Image 8-3).
The diagram shows the pressure drop in a row of solar panels including the connection fittings, with and without the
influence of the connection pipes from connection set CON X20 25M. The influence of the plastic connection pipes
available from ROTEX depending on the required length can be calculated precisely with the help of Image 8-6 in chapter
8.3.
b) Resistance of the flow connection on the hot water storage tank (chapter 8.3, Image 8-4).
The diagram allows you to calculate the pressure drop at a recommended flow connection when the FlowGuard (FLG) is
fully opened. The FlowGuard is required for hydraulic balancing on each flow connection in systems with several hot
water storage tanks.
c) Resistance of the return connection on the hot water storage tank (chapter 8.3, Image 8-5).
The diagram can be used to calculate the pressure drop at a CON RA 25M return connection set fitted to a hot water
storage tank. In the case of several storage tanks connected in series, the pressure drop is calculated as the sum of the
partial resistance values depending on the respective flow rates.
d) Resistance of the feed and return connection pipes.
The pressure drop from the partial lines not already calculated under a) to d) is calculated according to the classical
pipeline network calculation methods, depending on the required pipeline lengths and the individual resistances of
moulding parts.
6. Pump capacity
In order to overcome the sum of all resistance values calculated in point 5, the capacity of the pump must be such that it
supplies a sufficient pressure boost at the required nominal flow rate "Q1" (total number of solar panels x 100 l/h). This total
pressure drop in the collector circuit will ideally be equivalent to the pump delivery "H1" at work step "A" (Image 3-4).
At the same time, the delivery capacity "H0" of the pump must be greater than the maximum static pressure in the system,
which is calculated by taking the total height "H" of the system (see Image 2-1) in metres x 100 mbar.
Under certain conditions, it may be advisable to connect a second pump (booster pump) in series with the circulation pump
to allow faster filling of the system.
Whenever you select a pump, ensure that the pump:
– is suitable for reverse flow in switched-off state.
– is suitable for the permanent transport of water containing oxygen.
– is arranged in such a way that the necessary pre-pressure which may be needed is ensured via the filling level of the
water in the hot water storage tank.
CAUTION!
When solar panels are installed in areas where there is a danger of frost, connection pipes of the Solaris system
which lie outside may freeze, causing malfunctions and damage to the Solaris system.
• Ensure that pipe runs in the open air are kept as short as possible.
• Longer pipe runs in the open air (e. g. in the case of installation on a flat roof) must be specially insulated
or protected against frost by other appropriate means.
• If necessary, a separate feed line must be routed from each row of solar panels affected by the risk to the
respective storage tank battery.

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14 FA ROTEX Solaris RPS3 25M - 03/2010
3.3 Preparatory installation work
• ROTEX Install the Solaris solar panels (see installation manual provided).
• Install the collector temperature sensor on the last solar panel before the common feed line (see installation manual for the
Solaris solar panels).
• ROTEX Set up the hot water storage tanks and heat generators (see the installation and operating manuals provided).
3.4 Control unit RPS3 25M
1 Pump characteristics
2 Mains characteristics
AWorkstep
H Pressure boost through the pump
H1Delivery capacity of the pump in work step "A"
HQDelivery capacity of the pump
Q Flow rate in the collector circuit
Q1Nominal flow rate
Illustration 3-4 Diagram of total pressure drop and pump capacity
WARNING!
Live parts can cause an electric shock on contact and cause life-threatening burns and injuries.
• Before beginning maintenance work on the boiler control panel or the solar control system, disconnect
both units from the power supply (remove fuse, switch off main switch) and secure against unintentional
switch-on.
• To prevent hazards caused by damaged electrical cables, always have them replaced by a qualified
electrician in compliance with the applicable electrical guidelines and the regulations of the responsible
electricity supply company.
• Comply with the relevant safety at work regulations.
DANGER!
Escaping gas in the immediate vicinity of electrical parts can cause explosions.
• Do not install the Control unit RPS3 25M or electrical components in locations where there is a risk of
escaping, inflammable gas.
• Observe the minimum clearances to walls and in shafts.

3 xInstallation
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FA ROTEX Solaris RPS3 25M - 03/2010
Installation on the hot water storage tank
5. Remove the housing baseplate from the hot water storage tank.
6. Drill a hole with a drill bit Ø 7.5 mm, depth <15 mm, at the marked bottom attachment point.
7. Attach the housing baseplate to the hot water storage tank using the 2 screws from the handle (A) at the top and the plastic
rawlplug and screw provided at the bottom.
Installation on a wall
• Unhook the controller from the housing baseplate by
pulling in upward direction.
• Attach the housing baseplate to the wall near the 1st
hot water storage tank using suitable screws.
Select the installation location so that the pre-installed
storage tank and return flow temperature sensors can be
installed in the 1st hot water storage tank without
problems.
Illustration 3-5 Installing the housing baseplate on the wall
1. Unscrew the handle from the hot water storage tank.
2. Unhook the controller from the housing baseplate by pulling in upward
direction.
3. Screw the housing baseplate loosely to the top two attachment points on the
hot water storage tank using 2 screws (A) from the dismantled handle.
4. Align the housing baseplate and mark the third (bottom) attachment point on
the hot water storage tank.
Illustration 3-6 Step 1
Illustration 3-7 Step 2 Illustration 3-8 Step 3 Illustration 3-9 Step 4
WARNING!
If the hole for attaching the housing baseplate to the hot water storage tank is drilled too deep or the screw
used to attach the baseplate is too long, the hot water storage tank may be damaged. When the hot water
storage tank is full, hot water may then emerge from the bore hole, with the danger of scalding.
• Do not drill deeper than 15 mm into the outer shell of the hot water storage tank.
• Use only the plastic rawlplug and fixing screw provided to attach the housing baseplate to the hot water
storage tank.
1
2
1
4x A
2
3
A
4


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16 FA ROTEX Solaris RPS3 25M - 03/2010
3.5 Hydraulic connection
1. Install piping between the collector array(s) and the connections of the hot water storage tank or the storage batteries in
accordance with the planned hydraulic circuit (example circuit in Chapter 7 "Hydraulic system integration").
Use connection set CON X20 25M ( 16 42 32) for roof penetration and to connect the solar panels to the on-site copper
pipes.
2. Screw connecting T-piece from connection set CON RA 25M ( 16 01 13) to the return connection of the Solaris hot
water storage tank.
3. Fit the connection line with ball valve and push-in fitting Ø 28 mm from connection set CON RA 25M to the desired side of
the connecting T-piece.
Illustration 3-10 Step 5 Illustration 3-11 Step 6 Illustration 3-12 Step 7
5
<15mm
Ø 7,5mm
x
6
7
A
CAUTION!
When using plastic pipes, in the case of longer horizontal pipe runs with only a minimum gradient, it is possible
for water pockets with a siphoning effect to develop due to thermal expansion of the plastic pipes between
the mounting points.
• Attach the pipe to a rigid supporting structure (e. g. mounting rail, pipe etc.).
• Always make sure that pipe runs have a continuous gradient of at least 2 %.
• We recommend the use of rigid connection pipes made from copper.
When connecting several hot water storage tanks, fit the end of the connection line to the connecting T-piece
mounted on the extension hot water storage tank.
One CON RA 25M is required per tank (see also section 3.9).
Illustration 3-13 Step 2 Illustration 3-14 Step 3

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FA ROTEX Solaris RPS3 25M - 03/2010
5. Fit equalising pipes AGL ( 16 01 08) to connect 2 hot water storage tanks and AGLE ( 16 01 12) to connect each
further hot water storage tank in a row (max. 4 hot water storage tanks per row).
6. Install circulation pump and where necessary optional booster pump near the return connection (pumps, pipes and
installation materials to be provided on-site).
The circulation pump and the optional booster pump must be of sufficient capacity to ensure the nominal flow rate in the
collector circuit (see section 3.2, Image 3-4).
7. Install pipes from connection set CON RA 25M between the circulation pump and the free push-in fitting on the return
connection line. For preference, the connection pipe between the circulation pump and the hot water storage tank should be
made from copper piping Ø 28 mm.
Install a filling and draining cock in the piping for filling and draining the solar system.
8. Connect circulation pump and optional booster pump to the return piping of the collector array.
9. Fit FlowGuard FLG ( 16 41 02) to the Solaris flow connection of the hot water storage tank (see section 3.6).
10. Fit push-in fitting for flow connection from roof penetration kit RCAP, RCRP, RCIP, RCFP or from connection set CON VA
25M ( 16 01 14) to the FlowGuard.
11. When connecting several hot water storage tanks, establish a flow manifold and connect it to the push-in fitting (see also
section 3.9).
12. Optionally: Install FlowSensor in the common flow manifold.
13. Connect the flow piping of the collector array to the flow manifold.
3.6 FlowGuard, FlowSensor (optional)
FlowGuard
4. Insert blanking plug from connection set CON RA 25M into the free connection
of the T-piece on the last extension hot water tank in a row and secure it with
the retaining bracket.
Illustration 3-15 Step 4
Note the direction of flow when installing the FlowSensor.
The Solaris FlowGuard FLG (Image 3-16), 16 41 02) is available as an accessory.
It is a regulating valve with an integrated flow rate indicator. A FlowGuard must be
installed on every storage tank. It can be used to set the flow distribution over several
storage tanks and the total flow rate through the collector array. The display range is
2...16 l/min.
Illustration 3-16 FlowGuard FLG accessory

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18 FA ROTEX Solaris RPS3 25M - 03/2010
FlowSensor
1. Insert seal (b) in the flow connection (a) (see Image 3-17).
2. Mount the FlowGuard (c) and screw it tight.
3. Fit seal (e) and insert the push-in fitting (f) in the inlet of
the FlowGuard.
4. Insert prepared feed pipe (g) into the push-in fitting (f)
Ø15mm.
Illustration 3-17 Installing the FlowGuard
The Solaris FlowSensor FLS 100 (Image 3-18, 16 41 03), which is available as an
accessory, is a dual-function device that simultaneously measures the flow in the collector
array and the flow temperature. The measuring ranges are 5...100 l/min (flow) and
0...120 °C (flow temperature). Both values are indicated on the Solaris R3 controller.
FlowSensors with lower measuring ranges are available as an alternative.
The FlowSensor is optional. Installing a FlowSensor ensures significantly better monitoring
of functions and higher functional safety and allows heat ouput measurement via the
Control unit RPS3 25M.
The FlowSensor must be installed in the solar flow line created on-site. Where several hot
water storage tanks are used, the FlowSensor is installed in the common flow line. Illustration 3-18 FlowSensor FLS
supplied with 3 m of
cable
The installation position of the FlowSensor and the Control unit RPS3 25M should be such that the 3 m con-
necting cable can be routed easily, without need for an extension.
1. Insert seal (b) in the tank-side screwed connection 1" (a) (see Image 3-19).
2. Screw in the FlowSensor (c).
3. Insert seal (d) in the inlet of the FlowSensor (c).
4. Screw the collector-side connection 1" (e) of the common flow line onto the
FlowSensor (c).
With 15 mm copper pipe or VA 15 solar pipe, the push-in fitting from connecting set
CON VA 25M ( 16 01 14) can be used.
5. Run the FlowSensor cable (f) between the FlowSensor (c) and the Solaris R3
controller.
6. Plug the FlowSensor cable (f) into the FlowSensor (c) and into the FLS position (4-pin,
see Image 3-24) on the edge of the Solaris R3 controller PCB.
Illustration 3-19 Installation of
FlowSensor FLS

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FA ROTEX Solaris RPS3 25M - 03/2010
3.7 Temperature sensor
1. Bend contact springs around both sensors (return and tank sensor of the Solaris R3 controller) and insert into the probe tube.
2. Position the return sensor at a depth of approx. 130 cm in the probe tube (use a cable tie).
3. Position the storage tank sensor at a depth of approx. 70 cm in the probe tube (use a cable tie).
CAUTION!
On no account may the storage tank temperature sensor for the boiler controller be inserted more than 75 cm
into the sensor pocket. A sensor that is inserted too deeply can lead to overheating of the hot water section,
as well as a "hang-up" of the control unit during the storage tank charging phase.
When using several hot water storage tanks and with correct configuration of the system, it does not matter
which hot water storage tank the return flow temperature sensor and the storage tank temperature sensor of
the Control unit RPS3 25M are installed in.
Ensure that the sensor cables can be routed to the Control unit RPS3 25M without problems. If necessary, the
sensor cables can be extended.
Illustration 3-20 Step 1 Illustration 3-21 Steps 2+3 Illustration 3-22 Steps 2+3
4. Push the sealing plug into the well, and run the cables.
Illustration 3-23 Step 4

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20 FA ROTEX Solaris RPS3 25M - 03/2010
3.8 Electrical connection
1. Clamp the collector temperature sensor cable to the connector.
2. Clip the connector onto the edge of the control system circuit board at position "TK" (2-pin, see Image 3-24).
3. Route the collector temperature sensor cable through the labyrinth to prevent strain on the cable.
4. Clip the mains and pump connection cables (premounted on the terminal block) to the edge of the control system circuit board
at positions "Power" and "P1/P2." The connectors are polarised to prevent errors.
5. Place controller into the housing baseplate from above.
• Make sure that the loops in the cable are pointing downwards (as shown in Image 3-27 to Image 3-28).
BSK Burner inhibit contact
CONF Programming socket for
software update
FLS FlowSensor
F1 Fuse
TK Collector temperature sensor
TR Return flow temperature sensor
TS Storage tank temperature sensor
P1 Circulation pump
P2 Optional
Booster pump
Power Mains supply
Illustration 3-24 Terminal assignment controller PCB
The storage tank temperature sensor and the return flow temperature sensor are already connected to the
Solaris R3 controller at the factory.
Illustration 3-25 Step 1 Illustration 3-26 Steps 2+3
Illustration 3-27 Basic cabling: sensors for storage tank, return and
collector sensor, pump supply, mains supply
Illustration 3-28 Additional cabling with FlowSensor