FA solaris panel solar

For specialist technical operation

ROTEX SolarisSolar heating system

Operating and installation manual

Valid for the following components

ROTEX Solaris Version 3.0 and higher

Solaris R3 temperature difference controller

Sanicube Solaris storage cylinder

Solaris flat collector

Serial number

Customer

GBIssue 07/2007

Guarantee

2 FA ROTEX Solaris - 07/2007

ROTEX accepts the guarantee for material and manufacturing defects according to this statement. Within the guarantee period, ROTEX agrees to have the device repaired by a person assigned by the company, free of charge.

ROTEX reserves the right to replace the device.

The guarantee is only valid if the device is used properly and 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.

Guarantee period

The guarantee period begins on the day of installation (billing date of the installation company), however at the latest 6 months after the date of manufacture (billing date). The guarantee period is not extended if the device is returned for repairs or if the device is replaced.

Guarantee period for the controller: 3 years.Guarantee period for the hot water storage cylinder: 3 years.Guarantee period for the collectors: 5 years.

Exclusion of warranty

Improper use, tampering with the device, and unqualified modifications immediately invalidate the guarantee.

Dispatch and transport damage are excluded from the guarantee.

The guarantee explicitly excludes consequential costs, especially the assembly and disassembly costs of the device.

There is no guarantee for wear-prone parts (according to the manufacturer's definition), such as lights, switches, fuses.

Contents

3FA ROTEX Solaris - 07/2007

1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.1 Refer to the manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.2 Warning signs and explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.3 Danger prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.4 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.5 Instructions for working safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.1 Design and components of the Solaris system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.2 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.3 System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.3.1 Control and pump unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.3.2 Optional FlowGuard flow controller and FlowSensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.3.3 Collector accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.1 System concepts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.2 Installing the control and pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.2.1 Mounting the pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133.2.2 Installing the sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173.2.3 Installing the cylinder temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.3 Installing the connecting pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193.3.1 Fitting the connecting pipe to the collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193.3.2 Connect several Sanicube hot water storage tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203.3.3 Installing the common return flow pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.4 Installing the collector components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223.4.1 Installing the supporting structure for subsequent installation on the roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233.4.2 Installing the supporting structure for subsequent installation on a flat roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273.4.3 Installing the supporting structure for subsequent in-roof installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273.4.4 Installing the first collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273.4.5 Installing the other collectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283.4.6 Installing the equipotential bonding terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303.4.7 Running the connecting pipes and the collector temperature sensor cable through the roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303.4.8 Installing the collector temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333.4.9 Uninstalling the collectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343.4.10 Additional notes about connecting pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354.1 Operating Solaris systems without a FlowSensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354.2 Operation of Solaris systems with a FlowSensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385.1 Operating and display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385.2 Controller operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

5.2.1 Pump operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385.2.2 Booster function for high collector temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395.2.3 Switch-on inhibit function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395.2.4 Pump kick function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395.2.5 Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395.2.6 Solaris FlowSensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405.2.7 Output calculation, maximum values, and yield count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405.2.8 Speed control of circulation pump P1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405.2.9 Overall reset function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415.2.10 Frost protection function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415.2.11 System leakage protection function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Contents


5.3 Adjustments and menu guidance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425.3.1 Display during start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425.3.2 Display during operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435.3.3 Setup menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435.3.4 Password protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455.3.5 Language selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465.3.6 Adjusting and resetting parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465.3.7 Burner inhibit contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465.3.8 Manual adjustment of pump speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465.3.9 Correcting values for measurement points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

5.4 Recommended settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475.4.1 Standard parameter values, recommended adjustment ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475.4.2 Other adjustments of your Solaris system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475.4.3 Recommended settings for auxiliary heating via external heat sources or the electric heater, burner inhibit contact . . . . . . . . . . 485.4.4 Tips for optimised user behaviour. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495.4.5 Domestic water hygiene. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

6 Faults and disturbances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506.1 Display of events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

7 Hydraulic system integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

8 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

9 List of keywords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1 x Safety


1 Safety1.1 Refer to the manual

This manual is intended for authorised and trained technicians who have experience with the proper installation and commissioning of heating 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 of the heating system.

Relevant documentsThe documents listed below are part of the technical documentation of the ROTEX Solaris system, and must also be observed. The documents are included in the scope of supply.– ROTEX Solaris: Instruction manual for the operator.

1.2 Warning signs and explanation of symbols

Meaning of the warningsThe warnings are classified in this manual according to their severity and probability of occurrence.

Special warning signsSome types of danger are indicated by special warning signs.

Order numberNotes related to Order numbers are identified by the cart symbol .

Handling instructions• Handling instructions are shown as a list. Actions during which the sequential order must be maintained are numbered.

Results of actions are identified with an arrow.

DANGER!

Indicates a direct threat of danger.

Disregarding this warning can lead to serious injury or death.

WARNING!

Indicates a potentially dangerous situation.

Disregarding this warning can result in serious injury or death.

CAUTION:

Indicates a possibly damaging situation.

Disregarding this warning can lead to damage to property and the environment.

This symbol identifies user tips and particularly useful information, but not warnings or hazards.

Risk of burning or scalding. Electric power

1 x Safety


ValiditySome of the information in this manual only applies/does not apply for certain devices. Validity is indicated by the following symbols:

1.3 Danger prevention

ROTEX Solaris systems are built in accordance with the state of the art and generally accepted engineering practice. However, improper use can lead to serious injuries or death, as well as causing material damage. To avoid danger, ROTEX systems should only be installed and operated:– As stipulated, and in perfect conditions,– With an awareness of safety and possible dangers.This presumes knowledge and application of the information given in this manual, as well as the relevant accident prevention regulations and the accepted rules on safety and occupational health.

1.4 Intended use

The ROTEX Solaris system may only be used for solar-supported heating of hot water systems. The ROTEX Solaris system may only be installed, connected, and operated in accordance with the instructions given in this manual.

Any use other than defined above is considered as non-intended (incorrect). The owner will be solely responsible for any resulting damage.

Intended use also includes the observance of maintenance and inspection specifications. 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 working safely

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 mains supply before starting any work on the heating system, and secure it against unintentional switch-on.

Electrical installation• Electrical installations may only be carried out by qualified electrical technicians under observance of the relevant electrical

guidelines and the regulations of the electric utilities 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 heating system, explain to the user/owner how to operate and check the heating system.• Make a record of the handover by filling out and signing the installation and instruction forms together with the user/owner.

Valid for ROTEX GasSolarUnit GSU Not valid for ROTEX GasSolarUnit GSU

Valid for ROTEX E-SolarUnit ESU Not valid for ROTEX E-SolarUnit ESU

Valid for ROTEX Sanicube Solaris SCS Not valid for ROTEX Sanicube Solaris SCS

2 x Product description


2 Product description2.1 Design and components of the Solaris system

Fig. 2-1 Standard design of a ROTEX Solaris system (ROTEX recommends a two-way connection)

1 Cold water connection pipe2 Drinking water (hot) distributor3 Stainless steel corrugated pipe heat exchanger for drinking water (hot)4 Stainless steel corrugated pipe heat exchanger for generating heat

(storage cylinder charging)5 Well for storage cylinder temperature sensor6 Fill level display7 Filling and draining cock8 Solaris R3 differential temperature control9 Solar return flow pipe (at the bottom of the collector/VA 18 Solar)10 Solaris solar panel11 Solar inflow pipe (at the top of the collector/VA 15 Solar)12 Thermal mixer valve (prevents scalding; installed by the customer)13 Anti-siphon valve14 Solaris inflow multilayer pipe15 Stainless steel corrugated pipe heat exchanger for heating support16 Insulating hose sleeve for stainless steel corrugated pipe heat exchanger for

heating support

17 Solaris return flow connection18 Well for Solaris return flow temperature sensor19 Equipotential bonding terminal cable connection (with valve attachment) for

storage cylinder extension20 Safety overflow connection

A Area with water for domestic useB Solar areaC Heating support areaTR Solaris return flow temperature sensor TS Solaris storage cylinder temperature sensorTK Solaris collector temperature sensorTV Solaris inflow temperature sensorRPS3 Control and pump unitFLS Solaris flow sensor (flow rate measurement) or Solaris FlowGuard

(flow rate setting)PS1 Solaris circulation pumpPS2 Booster pump

wechselseitiger Anschluss - 2 bis 5 Kollektoren

Das gezeigte Anlagenschema erhebt keinen Anspruch auf Vollständigkeit und ersetzt nicht die sorgfältige Anlagenplanung. Änderung und Irrtum vorbehalten!

SCS GSU

≤12

m

I

TK

>2%

2 oder maximal 3 Kollektoren(nur bei Aufdach- und Flachdachmontage)gleichseitiger Anschluss -II

TK

≥0,5 %

M

11

11

11

10

10

12

12

13 13

6

6

1 1

5

20 20

5

A

C C

A

B

16 164 4

B

7 7

8

14 14

19 19

18 18

17 17

8

3 3

15 15

2

2

9

9

9

FLS

FLS

RPS 2 RPS 2PS2

PS2

PS1 PS1

TR

TV

TV

TR

TS TS



2.2 Brief description

The ROTEX Solaris system is a thermal solar system for supplying hot water for consumption and heating support.

Method of operationThe high-performance Solaris flat solar collector Types V21A, V26A, and H26A convert the sun's radiation into heat with high efficiency. Hereby, the heat transport media 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 cylinder (which is not under pressure) is pumped directly through the collectors. With insufficient collector temperature, the circulation pump is switched off and the system is drained automatically. This method has several advantages:– High operational reliability, as there are no components that could be damaged or fail (such as expansion vessel, safety valve,

venting valves, etc.).– Excellent heat transfer and heat storage capacity (system works without antifreeze agents).– Minimum maintenance requirements.– Frost proof.– Without separate solar heat exchanger.

Modular designThe system consists of several pre-assembled modules. Plug-in technology and a high degree of pre-assembly ensure fast and simple system installation.

Storage cylinderThe following storage cylinders can be used for the ROTEX Solaris system:– ROTEX Sanicube Solaris: Thermally insulated, non-pressurised plastic storage cylinder.– ROTEX Gas Solar Unit (GSU): Sanicube Solaris with integrated gas condensing boiler.– ROTEX E-Solar Unit (ESU): Sanicube Solaris with integrated electric water heater.

Electronic controlThe fully electronic control unit ROTEX Solaris R3 ensures optimum utilisation of the solar heat (hot consumption water generation, heating support) as well as the observance of all safety-relevant aspects. All parameters needed for trouble-free operation have been preset at factory.

Construction, operating principle, commissioning, and operation of the storage cylinder are not described in this manual. Detailed information on the storage cylinders is given in the manuals of the respective units.



2.3 System components

2.3.1 Control and pump unit

2.3.2 Optional FlowGuard flow controller and FlowSensor

2.3.3 Collector accessories

CON A and CON R

Fig. 2-2 Scope of supply for pump and control unit (RPS3) ( 16 41 06)1 Cover2 Connection pipe with circulation pump, booster pump, filling and draining cock3 ROTEX Solaris R3 differential temperature control with storage cylinder temperature sensor, return flow temperature sensor,

collector temperature sensor connection cable, connection cable for 230 V mains supply (3 m)4 Accessories case (4 cheese head screws, 4 washers, 3 safety screws)5 Solaris documentation

Fig. 2-3 Flow controller and flow sensor (scope of supply)

1 FlowGuard ( 16 427)2 FlowGuard seal

3 FlowSensor ( 16 41 07)4 FlowSensor seal

Installation-ready connecting pipes between solar panel and pump control unit RPS3, consisting of thermally insulated inflow and return pipes with integrated sensor cable, Pt 1000 collector sensor, installation fittings, and roof penetration boxes for two-way connection.

Anthracite connection pipe (CON A) ( 16 42 11)

Red connection pipe (CON R) ( 16 42 12) Fig. 2-4 CON A and CON R (optional)



CON F

CON I

CON SX

Collector mounting rails

Solaris connection pipe ( 16 47 13) for flat roof installation Fig. 2-5 CON F (optional)

Solaris connection pipe ( 16 46 10) for in-roof installation Fig. 2-6 CON I (optional)

Solaris storage cylinder extension set ( 16 01 07): for connecting two Sanicube Solaris storage cylinders, consisting of a return flow connection pipe and inflow connection pipe. Fig. 2-7 CON SX (optional)

FIX-100 ( 16 42 24):– Two mounting rails for a V21A collectorFIX-130 ( 16 42 25):– Two mounting rails for a V26A collectorFIX-200 ( 16 42 26):– Two mounting rails for one H26A collector

or two V21A collectorsFIX-260 ( 16 42 27): – Two mounting rails for two V26A collectors Fig. 2-8 Collector mounting rails



Rail connector FIX-VB

Solaris flat collectors V21A, V26A and H26A

CON V

FIX-AD

Profile connector ( 16 42 22) for connecting the mounting rails:

– Splicing plate (2x)– Allen wrench– Fixing screws (4x) Fig. 2-9 Rail connector FIX-VB

V21A collector ( 16 43 06):– H x B x T: 2000 x 1006 x 95 mm, weight: approx. 34 kgV26A collector ( 16 43 04):– H x B x T: 2000 x 1300 x 95 mm, weight: approx. 41 kgH26A collector ( 16 43 05):– H x B x T: 1300 x 2000 x 95 mm, weight: approx. 44 kg Fig. 2-10 Solaris flat collector (V26A shown here)

Collector connection kit ( 16 42 13) for immediate connection of an additional collector, incl. installation material for attaching a pair of collectors Fig. 2-11 Collector connecting kit CON V

Kit for installing a collector on a roof ( 16 47 00)

– Roof ties (4x)– Wood screws (Ø 8 x 6 mm, 8x) Fig. 2-12 On-roof mounting brackets FIX-AD

3 x Installation


3 Installation3.1 System concepts

ROTEX Solaris installations are usually built according to one of the following system concepts.

Fig. 3-1 Solaris solar panel with connections on same side, and Sanicube storage cylinder

Fig. 3-2 Solaris solar panel with connections on same side, and Gas Solar Unit (or E-Solar Unit)

Fig. 3-3 Solaris solar panel with connections on opposite sides, and Sanicube storage cylinder

Fig. 3-4 Solaris solar panel with connections on opposite sides, and Gas Solar Unit (or E-Solar Unit)

M

M

3 x Installation


3.2 Installing the control and pump unit

3.2.1 Mounting the pump unit

1. Remove the handle from the storage cylinder, and unscrew the sealing cap of the Solaris return flow coupling.

2. Use the previously removed handle screws to attach the pump holding bracket to the upper plastic inserts of the handle mounting.

3. Attach each pump and storage cylinder coupling nut to the storage cylinder coupling bracket and secure using retainers.

4. Insert the filling & draining cock on the desired side and secure it using a retainer.

5. Insert a blind plug in the opposite side to the filling & draining cock and secure using a retainer.

WARNING!

Live parts can cause an electric shock on contact and cause life-threatening burns and injuries.

• Before beginning work on live parts, disconnect them from the power supply (switch of fuse, main switch) and secure against unintentional restart.

If the RPS3 control and pump unit is to be fitted to an older storage cylinder, this can be done by using the threaded plastic inserts (Wellnut) included in delivery. Use the template on the packaging (see Figure 3-5) to drill the two mounting holes (Ø 7.5 mm). Hereby, the two smaller holes at the top edge are the mounting holes, whilst the slightly larger hole at the bottom edge serves to adjust the template. The exact dimensions are given in Figure 3-6.

– Note: The holes must not be deeper than 15 mm.

Fig. 3-5 Drilling template Fig. 3-6 Spacing dimensions of the holes

Fig. 3-7 Working step 1 Fig. 3-8 Working step 2 Fig. 3-9 Working step 3

3 x Installation


6. Push the two pumps together and secure using a retainer.

7. Mount the pre-assembled pump unit on the storage cylinder coupling bracket together with the supplied seal and screw onto the solar return flow coupling of the storage cylinder. Mounting is simplified, if the retainer is clipped into the holding bracket.

8. Tighten the storage cylinder coupling nut. Use the sickle spanner (included in scope of supply) to do this.

9. Screw the retainer to the holding bracket (necessary to withstand forces).

10. Mount the support bracket for the control unit.

11. Mount the push-in elbow fitting (Ø 22/Ø 18).

12. Prepare the inflow pipe using the sensor cable (VA 15 Solar) and return flow pipe (VA 18 Solar). Cut the Twin-Tube insulation apart in the middle.

Fig. 3-10 Working step 6 Fig. 3-11 Working step 6



3 x Installation


13. Fit the return flow pipe, and install it separately after parting the Twin-Tube insulation.

14. Insert the pre-bent return flow pipe into the push-in fitting of the pump coupling.

Preparing and installing the control unit

1. Plug the edge connectors of the supplied control cables to the circuit board at the rear of the control unit. The connectors are polarised to prevent errors. A connecting diagram is provided in the control unit cover.

2. To ensure reliable tension relief, all cables should be run through the respective labyrinths.

3. Attach the supplied 2-pole edge connector to the sensor cable (pre-installed with the inflow pipe), and plug it into the control unit.

Fig. 3-18 Working step 13 Fig. 3-19 Working step 14

Fig. 3-20 Terminal assignmentCONF Programming connector for control

unit updateFLS Flow sensorTS Storage cylinder temperature sensor

TR Return flow temperature sensorTK Collector temperature sensorBSK Burner inhibit contact

P1/P2 Circulation and booster pumpF1 FusePower Mains supply


The automatic speed regulation of the control and pump unit can only work, if a FlowSensor is included in the system. If not, the circulation pump will run continuously at 100 %.

3 x Installation


4. Insert the control unit into its support bracket from above.

5. Connect the cables to the booster and the circulation pumps. The cable with red marking goes to the lower (circulation) pump, and the other cable to the upper pump.

6. Run the control cables along the return flow pipe, and fix them with cable ties.

Fitting the silencer hood

1. Fit the hood and align it. Make sure that the hood is pushed under the control unit housing so that there is an evenly spaced joint all around control unit.

2. Fix the hood to the control unit on both sides with countersunk screws.

3. Attach cover to storage cylinder connection bracket underneath. To do this, carefully screw in the self-tapping fastening screw (included in scope of supply) above the recess in the lower section of the housing front and then attach the cover cap.

Fig. 3-24 Basic wiring: Sensors for storage cylinder, return flow, and collector, pump supply, mains supply

Fig. 3-25 Additional cable of FlowSensor



3 x Installation


3.2.2 Installing the sensors

FlowSensorThe Solaris FlowSensor (Figure 3-35, 16 41 06), which is available as an accessory, is a dual-function device that simultaneously measures the flow through the solar panel as well as the inflow temperature. The measuring ranges are 0...20 l/min (flow quantity) and 0...120 °C (inflow temperature). Both values are indicated on the Solaris R3 control unit. By controlling the speed of the circulation pump, the Solaris R3 automatically adjusts the optimum flow quantity.

1. Screw the FlowSensor onto the solar inflow coupling of the storage cylinder. Next, fit the sealing ring, and mount the push-in fitting to the inflow of the FlowSensor.

2. Insert the pre-assembled inflow pipe into the push-in fitting of the FlowSensor, and connect the sensor cable from the control unit.

Fig. 3-32 Completely installed RPS3

Note the direction of flow when installing the FlowSensor.

Fig. 3-33 Working step 1 Fig. 3-34 Working step 2 Fig. 3-35 Optional FlowSensor is supplied with 3 m long cable

3 x Installation


FlowGuard

Also available as an accessory is the Solaris FlowGuard (Figure 3-37), ( 16 41 02). It is a regulating valve with integrated flow indicator that is used to adjust the flow through the solar panel. The display range is 2 ...16 l/min.

1. Fit the sealing ring.

2. Mount the FlowGuard, and screw it tight.

3.2.3 Installing the cylinder temperature sensor

1. Bend back the temperature sensor springs (storage cylinder and return flow sensors, as well as the sensor for the boiler controller).

2. Insert the return flow sensor approx. 130 cm (cable tie) into the well of the storage cylinder.

3. Insert both cylinder sensors approx. 70 cm (cable tie) into the well of the storage cylinder.

4. Push the sealing plug into the well, and run the cables.

Fig. 3-36 Working steps 1 + 2 Fig. 3-37 Optional FlowGuard

CAUTION:

On no account may the storage cylinder temperature sensor of the boiler controller be inserted more than 75 cm into the sensor well. A sensor that is inserted too deeply can lead to overheating of the consumption water section, as well as a "hang-up" of the control unit during the storage cylinder charging phase.

Fig. 3-38 Working step 1 Fig. 3-39 Working steps 2 + 3 Fig. 3-40 Working steps 2 + 3

Fig. 3-41 Working step 4

3 x Installation


3.3 Installing the connecting pipes

3.3.1 Fitting the connecting pipe to the collector

1. Run the connecting pipe right up to the collector on the roof, and attach it with pipe clips at suitable points.

2. Shorten the connecting pipe to the required length (Figure 3-43).

3. Deburr the pipe end (protection for the O-ring in the push-in fitting), and attach the fitting.

4. Connect the inflow (at the top of the collector/VA 15 Solar) or outflow connection pipe (at the bottom of the collector/VA 18 Solar) to the connection pipe (Figure 3-44).

CAUTION:

In case of longer pipe runs with minimum gradient, it is possible for water pockets to develop due to thermal expansion of the plastic pipes between the mounting points:

• Either attach the pipe to a rigid supporting structure (e.g. mounting rail, pipe, etc.).• Or run the pipe through a drain pipe with gradient (e.g. HT pipe).

CAUTION:

Siphon action may never be allowed to occur anywhere in the pipe run between storage cylinder and collector. This could lead to functional faults and even material damage.

• Always make sure that pipe runs have a continuous gradient of at least 2 %.

The differences between the connection points and dimensions of the inflow connection pipe (at the top of the collector/VA 15 Solar) and the return flow connection pipe (at the bottom of the collector/VA 18 Solar) make it impossible to confuse one pipe for the other.

• However, you must ensure that the inflow and return flow pipes on the collector are labelled as heat generators.

Fig. 3-42 Mark the connecting pipe Fig. 3-43 Shorten it to length Fig. 3-44 Push the fitting onto the coupling

3 x Installation


3.3.2 Connect several Sanicube hot water storage tanks

The ROTEX connecting pipe system permits the parallel connection of several Solaris Sanicube to obtain large-scale installations with and without solar heating.

By means of the Solaris storage cylinder extension set CON SX ( 16 01 07), 2 Solaris Sanicubes can be connected per control and pump unit RPS3 (Figure 3-45).

Operating principle– The solar return flow is drawn from the common return flow pipe (Figure 3-45, Pos. 5), which connects the solar sections of

both storage cylinders.– The common return flow is pumped to the solar panel by the RPS3 control unit (Figure 3-45, Pos. 4).– After being heated in the solar panel, the water enters both storage cylinders as solar inflow via the inflow distribution pipes

(two equally long flexible and insulated pipes, Pos. 6 Figure 3-45).As the amount of water drawn into and circulated through the solar system can be different in the 2 Sanicubes in spite of the matching provided by the FlowGuard valves (FLG) in the inflow distribution pipes, one of the Sanicubes could overflow if there were no common return flow pipe (Figure 3-45, Pos. 5) as equalisation. This pipe prevents excessive level differences in the two storage cylinders.

The optional ROTEX FlowGuard ( 16 41 02) ensures even filling of both Sanicubes. For this, one FlowGuard must be installed per storage cylinder, with a common inflow pipe to the FlowSensor.

After connecting and starting the system, the filling levels should be observed for at least 2 hours, and the FlowGuards adjusted if necessary.

1 Sanicube Solaris2 Non-pressurised area3 Solar panel4 Control and pump unit RPS35 Return flow connection pipe

(non-pressurised area)6 Solaris inflow distributor7 Solaris return flow pipe8 Solaris inflow pipe

ΔH Difference in level in non-pressurised storage cylinder area

FLS Flow sensorFLG FlowGuard

Fig. 3-45 Operating principle of the common return flow pipe

3 x Installation


3.3.3 Installing the common return flow pipe

1. Mount the RPS3 but do not fit the silencer hood (see Chapter 3.2).

2. Remove the sealing cap from the solar return flow coupling of the 2nd storage cylinder.

3. Align the Sanicube storage cylinder. The centre-to-centre distance between the storage cylinders must be 830 mm. Also observe the necessary clearance of 200 mm to any wall.

4. Mount the return flow connecting pipe.

5. Remove the lower sealing cap on the corresponding side of the silencer hood.

6. Mount the hood on the storage cylinder, and install the sensors (see Chapter 3.2).

7. Fit the optional two FlowGuards (see "FlowGuard" info field) or a dual nipple to the solar inflow coupling.

8. Mount the left-hand inflow distribution pipe.

9. Mount the right-hand inflow distribution pipe.

10. Fit the connecting T-piece.

11. Fit the dual 1-inch union coupling nut.

12. Install the FlowSensor.

WARNING!

Danger of scalding after disconnecting the CON SX from the storage cylinder or during work on the pipework of the control and pump unit (e.g. when replacing a pump).

• Drain the storage cylinder before starting work on the equalisation pipe or other pipework.

CAUTION:

Large amounts of water can escape from the Sanicube during installation.

• Install the Solaris storage cylinder extension set before filling the Sanicubes (non-pressurised area).

Fig. 3-46 Installing the inflow distribution pipe (top)

13

12

11

10

9

3 x Installation


3.4 Installing the collector components

Notes for safe and trouble-free operation• For solar panels with connections on same side (up to 3 collectors permitted), the lower edges of all the collectors must be

absolutely horizontal.• Mount the solar panel with a gradient to the lower collector coupling (return flow).• The entire run of the connecting pipe between the collectors and the storage cylinder must always have a continuous gradient

to prevent siphon action.The upper edge of the collectors may not be more than 12 m above the storage cylinder(s) mounting floor level.

Fig. 3-47 Cylinder extension (lower connecting pipe)

DANGER:

There is an increased accident risk during work on a 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.

WARNING!

After their packaging is removed, the collectors will become hot very quickly if they are exposed to the sun's rays.

• Wear protective gloves.• Remove the protective caps (they are not temperature resistant).

CAUTION:

Frost or overheating can damage the system.

• Permit the system to drain. Make sure that the collectors are installed so that their lower edge is always higher than the inflow coupling of the Solaris storage cylinder.

3 x Installation


3.4.1 Installing the supporting structure for subsequent installation on the roof

Main dimensions of Solaris solar panel for on-roof mounting

Tab. 3-1 Main dimensions of Solaris solar panel for on-roof mounting

Instead of the mounting kit FIX-AD, the roof fixtures FIX-WD ( 16 47 03) are used for corrugated roofs, and the fixtures FIX-BD ( 16 47 04) for trapezoidal roofs.

Number of collectors 1 2 3 4 5Measurement Dim. Dimensions in mm

Width of solar panelV21A

B1100 2150 3250 4300 5400

V26A 1370 2740 4110 5480 6850H26A 2150 4300 6450 — —

Distance from roof penetration box H0 300 to 700

Height of solar panelV21A

h12000

V26A 2000H26A 1303

Distance from lower collector edge to lower mounting rail

Y0 230

Spacing of the mounting railsV21A

Y11400 to 1600

V26A 1400 to 1600H26A 800 to 1000

Distance from lower collector edge to lower edge of the perforated plate of roof mounting bracket

Y2 260 to 290

Max. distance from edge of solar panel to the first roof mounting bracket

X0 450

Spacing of the roof mounting brackets of a collectorV21A

X1400 to 1000

V26A 400 to 1000H26A —

Spacing of roof mounting brackets between two collectors

X2 300 to 900

Distance between solar panel and the first collector securing clip

A0 100 to 300

Spacing of the securing clips of a collectorV21A

A1800 to 1100

V26A 800 to 1100H26A 120 to 1800

Spacing of the securing clips between two collectors A2 200 to 600Distance from collector edge to pipe coupling E0 70

Centre-to-centre distance of the collector couplingsV21A

E11884

V26A 1884H26A 1187

Upper collector edge to collector sensor connection F 175

3 x Installation


Fig. 3-48 Main dimensions of a Solaris solar panel for on-roof mounting (example shows V26A collectors)

1 Roof mounting bracket2 Mounting rail3 Collector securing clip

4 Solaris V26 flat collector5 Return flow connection pipe6 Inflow connection pipe

7 Collector drain plug8 Universal roof penetration boxes

Fig. 3-49 Side view of Solaris collector mounted on a roof

3 x Installation


Installing the roof brackets and mounting rails

Required tool:

– Socket wrench SW13– Jaw wrench SW13– Hammer– Cut-off grinder with diamond cutting wheel– Spirit level– Yard stick– Cordless drill with 6 mm bit

1. Determine the roof space for the solar panel, and mark the mounting location.

2. Remove the row of tiles above the intended lower edge of the collectors.

3. Position the mounting rail horizontally centred on the rafters (for the entire width of the solar panel). If several mounting rails are required for an array, they must first be joined by means of two splicing plates and the Allen screws from the FIX-VB mounting kit.

4. Determine the positions for the roof mounting brackets, whereby the brackets should be spaced evenly under the mounting rail (Figure 3-50 and Figure 3-51). Also note the dimensions X0, X1, and X2 given in Tab. 3-1 for the rafter spacing – if necessary, a suitable supporting structure will have to be provided.

5. Position the perforated plate of the roof mounting bracket so that at least two screw holes are located over the rafter.

6. Place the mounting rail on the perforated plates, and align the mounting brackets parallel to the roof tiles.

7. Fix every roof mounting bracket to a rafter with at least 2 of the wood screws supplied (Figure 3-52).

Each collector requires a specific amount of space on the roof: 2.0 x 1.01 m2 for the V21A, 2.0 x 1.37 m2 for the V26A, and 1.37 x 2.0 m2 for the H26A.

The main dimensions of the solar panel (as shown in Figure 3-48 and Figure 3-49) are summarised in Tab. 3-1.

As the mounting rails will have to be separated again before final installation, only one splicing plate is required for this step.

Fig. 3-50 Determining the distance Y2 Fig. 3-51 Determining the mounting positions of the roof brackets

Fig. 3-52 Attach the roof brackets to the rafters with at least two screws

WARNING!

Insufficiently dimensioned supporting structures can endanger persons, the building, and the solar installation.

• Check the load bearing capacity of the supporting structure. Do not use roofing battens.

Y2

geplanteKollektorunterkante

3 x Installation


8. If several mounting rails are being used: Separate them again.

9. Push the individual mounting rails into the pre-assembled slide blocks of the roof mounting bracket from the side.

10. If several mounting rails are being used: Rejoin the rails, using both splicing plates and all the screws supplied.

11. Tighten the self-locking nuts with which the slide blocks have been attached to the roof mounting brackets. Take care to align the mounting rail parallel to the edges of the roof tiles (Figure 3-53 to Figure 3-55).

12. Height adjustment for levelling the mounting rails

– For solar panels with connections on the same side (up to 3 collectors), the mounting rail must be exactly level (this ensures automatic collector venting and draining when the pump stops).

– For solar panels with connections on opposite sides (more than 3 collectors), the mounting rail must be installed with a slight gradient to the return flow coupling (water inflow at lower collector coupling). Counter-gradients must be avoided.

13. Replace the row of roof tiles.

14. Mark the positions where the roof mounting brackets emerge under the tiles (Figure 3-56).

15. Knock out the lower tile webs at the marked exit points for the mounting brackets, or remove them with the cutting grinder (Figure 3-57).

16. Install the upper mounting rails at a distance Y1 from the lower rails in the same manner as described for the lower mounting rail (Figure 3-58). Make sure that the upper and lower mounting rails provide a plane-parallel mounting surface for the collectors.

The mounting brackets may neither press on the roof tiles below, nor raise the roof tiles above.

Fig. 3-53 Align the mounting rails, and screw tightly to the upper part of the roof mounting brackets

Fig. 3-54 Height adjustment of the mounting bracket

Fig. 3-55 Levelling the mounting rails

Fig. 3-56 Mark the exit position of the mounting bracket on the roof tile

Fig. 3-57 Remove the lower roof tile web

Lightly tighten the self-locking nuts of the slide blocks in the upper mounting rails, so that the rail can be levelled out precisely after mounting the first collector.

3 x Installation


3.4.2 Installing the supporting structure for subsequent installation on a flat roof

More detailed information can be found in the installation manual entitled "ROTEX Solaris installation on a flat roof", supplied with the installation system.

3.4.3 Installing the supporting structure for subsequent in-roof installation

More detailed information can be found in the installation manual entitled "ROTEX Solaris in-roof installation", supplied with the installation system.

3.4.4 Installing the first collector

1. Push the slide blocks (dual or single clip) into the mounting rail in the correct sequence.

2. Observing the clearance applicable to the collector type concerned, hook the collector securing clips into the top lateral guide notch on the lower mounting profile and tilt downwards. After they have been hooked on, the collector securing clips can be moved sideways (see Figure 3-59 and Figure 3-60).

3. Lift the collector onto the roof, e.g. with a crane. If no crane is available, the collector can be hoisted onto the roof with a rope, using a ladder leaning on the roof edge as a slipway. Depending on the installation requirements, the collector can be unpacked and the protective caps for the pipes removed either before or after the collector has been lifted onto the roof.

4. Position the collector above the mounting rails as shown in Figure 3-61, and carefully lower it into the securing clips.

Fig. 3-58 Mounting the upper rails (see Tab. 3-1 for dimension)

CAUTION:

Danger of burns from hot collector couplings and hot collector frame.

• Do not touch hot parts.• Wear protective gloves.

Make sure to lift the collector onto the roof in the correct orientation for mounting (avoids errors during connection or difficult turning operations). The upper side of the collector is marked with a label on the packaging. When aligning the collector, ensure that the nameplate attached to the frame profile is located on the bottom left-hand side and that the sleeve for the collector temperature sensor is on the top right-hand side.

Fig. 3-59 Inserting the collector securing clips

Fig. 3-60 Positioning the collector securing clips

Fig. 3-61 Lowering and aligning the collector

3 x Installation


5. Move the collector sideways until the left-hand ends of the two mounting rails project 35 mm beyond the collector's edge (Figure 3-62).

6. Now push the single clip with the potential bonding terminal into the mounting rail close to the return flow coupling, and secure it with self-locking nuts (Figure 3-63).

7. Then attach the single clip to the upper mounting rail with the self-locking nuts.

3.4.5 Installing the other collectors

1. Insert dual clips into the upper and lower mounting rails, and push them up to the previously installed collector (Figure 3-65).

2. Lubricate both pipe ends of the collector with the supplied lubricant (Figure 3-66).

3. Mount the fitting (Figure 3-67).

4. Lift the next collector onto the mounting rails (see Section 3.4.4, step 2), and lower into the securing clips at a distance from the fittings (Figure 3-68).

5. Lubricate the upper and lower pipe couplings of the next collector with the lubricant supplied (Figure 3-69).

6. Slide the fitting over the new collector connection, leaving a gap between the collectors and start of the fitting, and between the collectors and end of the fitting (to protect the O-ring) (Figure 3-70).

Fig. 3-62 Correct mounting position Fig. 3-63 Securing the equipotential bonding terminal

Fig. 3-64 Clip with equipotential bonding connection

CAUTION:

Careless handling can damage the components, resulting in difficulties during installation.

• Apply a sufficient amount of lubricant to the sealing plug. Only use the lubricant supplied or a type of grease or oil that will provide long-lasting lubrication.

• Never crush or compress collector connection pipes.

Fig. 3-65 Insert the dual mounting clip Fig. 3-66 Apply lubricant to pipe ends of last collector

Fig. 3-67 Push the fitting onto the coupling

3 x Installation


7. Now push the next collector against the fitting and then further up to the previously installed collector (Figure 3-71). The distance between the collectors is determined automatically on the basis of the connection fittings.

8. Tighten the dual clip (Figure 3-72).

9. Insert the mounting clips for the last collector, and tighten them.

Fig. 3-68 Positioning the next collector Fig. 3-69 Apply lubricant to pipe ends of next collector

Fig. 3-70 Position the fitting before pushing the collectors together

CAUTION:

Unless the utmost care is taken when assembling the collector connections (CON V), the fitting could get damaged. This would result in a leaky system. For this reason:

• Be very careful when assembling the connections on the collector (CON V).• When pushing the parts together, move the next collector upwards slightly or align it with the connection

pipes of the previous collector.

Fig. 3-71 Push collectors together Fig. 3-72 Tightening the dual clip

3 x Installation


3.4.6 Installing the equipotential bonding terminal

1. Loosen the slotted screws on the equipotential bonding terminal.

2. Connect the equipotential bonding terminal cable (not included in scope of supply) (Figure 3-74).

3. Tighten the screws of the equipotential bonding terminal.

4. Run the connecting cable to the equipotential bonding rail, secure it with cable ties, and connect it to the rail.

3.4.7 Running the connecting pipes and the collector temperature sensor cable through the roof

WARNING!

The equipotential bonding terminal is not a substitute for a lightning rod. It is merely intended to protect the collector temperature sensor.

If two or more collector rows are installed, they must be connected by means of an equipotential bonding terminal. Equipotential bonding terminals are included in the CON RV ( 16 42 17) kit.

Fig. 3-73 Mounting clip with equipotential bonding terminal

Fig. 3-74 Connecting the equipotential bonding terminal cable

CAUTION:

In the case of longer pipe runs with only a minimum gradient, it is possible for water pockets to develop due to thermal expansion of the plastic pipes between the mounting points: For this reason:

• Either attach the pipe to a rigid supporting structure (e.g. mounting rail, pipe, etc.).• Or run the pipe through a drain pipe with gradient (e.g. HT pipe).

If the 20 m CON A, CON R, CON I or CON F connection pipe is not long enough, it can be lengthened in accordance with the size of the solar panel to bridge the gap between the storage cylinder and the solar panel.

Pipe extension kits CON X 25 (2.5 m), CON X 50 (5 m) and CON X 100 (10 m) are available.

Number of collectors Max. possible total length of pipe

2 45 m3 30 m4 17 m5 15 m

Tab. 3-2 Lengthening options with CON X connection pipes

3 x Installation


Notes on pipe installation• Run the connecting pipe with a continuous gradient between the collectors and the storage cylinder.• Install and connect the pipe to the lower coupling of the Solaris Sanicube as described in Chapter 3.3.• Connect the solar panel alternately, and align it so that the bottom return flow coupling is located at the lowest point of the

solar panel.

1. Remove three roof tiles at each intended roof penetration points (one or two tile rows below the lower collector edge).

2. Run the connecting pipe up to the roof penetration point, and attach it.

3. A slit can be made in the roof heat insulation underneath the roof penetration box, or it can be cut back, so that there is sufficient space for the return flow pipe (VA 18 Solar) to be pulled out and correctly angled in relation to the roof penetration box (Figure 3-75).

4. Run the connecting pipes through the roof at the points provided. To ensure the necessary uninterrupted thermal insulation (also within the roof structure), the insulation must be re-sealed at the penetration points (e.g. with adhesive tape).

5. Remove the thermal insulating hoses of the connecting pipes so that the pipes can be passed through the roof penetration boxes (Figure 3-75).

6. Pull the inflow pipe (at the top of the collector/VA 15 Solar) or return flow pipe (at the bottom of the collector/VA 18 Solar) through the M32 screw connection of the relevant roof penetration box. Following this, push the equipotential bonding terminal/collector temperature sensor cable from the inside through the relevant M16 screw connection (Figure 3-76).

CAUTION:

Leaky vapour barriers can lead to building damage.

• Re-seal the vapour barrier from the inside at the penetration points of the connecting pipes and cable.

CAUTION:

If plastic pipes are damaged, there is a risk that they will break.

• When cutting through the thermal insulation, never damage the outer surface of the VA Solar pipes.

Fig. 3-75 Shorten the plastic connecting pipe to the required length

Fig. 3-76 Run the pipe and the cable through the roof penetration box

Fig. 3-77 Install the roof penetration box

3 x Installation


7. Install the roof penetration boxes (Figure 3-77), remove the protective foil from the corrugated aluminium collar, adapt the collar to the shape of the roof tiles, and fix with adhesive (Figure 3-78).

8. Tighten the ring nuts of the M glands for the pipes and cables (see Figure 3-79).

9. Bend the connecting pipes as necessary, mark the required length (Figure 3-80), and cut off (Figure 3-81).

10. Cut the enclosed insulating hoses to the required length.

11. Push the insulating hose over the connecting pipe and over the push-in fitting on the VA Solar pipe (Figure 3-82).

12. Attach the push-in fitting to the collector connection and push the compressed insulating hose over the fitting until it reaches the collector (Figure 3-83).

CAUTION:

With special roof coverings, such as roof tiles with very pronounced undulations (large differences in height), sealing problems can occur with the universal roof penetration box.

• For these cases, and also with plane tiles or slate roofing, a professional roofer should be consulted.

Fig. 3-78 Removing the protective foil of the corrugated aluminium collar

Fig. 3-79 Tightening the nut of an M gland Fig. 3-80 Marking the required length of a connecting pipe

Fig. 3-81 Cutting the connecting pipe to the required length

Fig. 3-82 Compressing the insulating hose and mounting the fitting

Fig. 3-83 Pushing the insulation hose over the fitting

3 x Installation


3.4.8 Installing the collector temperature sensor

The sleeve for the collector temperature sensor is located on the side of the collector frame, approx. 10 cm underneath the upper connection. The sensor socket is sealed on delivery. The temperature sensor must be installed in the same collector to which the inflow pipe is connected.

1. Cut off the protruding end of the sensor socket (Figure 3-84).

2. Push the collector temperature sensor into the socket as far as it will go (see Figure 3-85). Temperature sensors, on which the marking starts immediately behind the metal sensor sleeve, must be inserted until the marking is no longer visible.

3. Run the silicone-covered sensor cable to the roof penetration box, and secure it to the mounting rail or connecting pipe by means of cable ties (Figure 3-86).

CAUTION:

Plastic connection pipes will not conduct voltages induced by electrical storms. Adverse conditions may cause these voltages to spread to the control unit via the collector sensor, causing damage to both.

• Implement equipotential bonding measures ("earth connection") between the foundation earth and the solar panel.

This should only be performed by an authorised specialist (electrician) in accordance with the local regulations.

If the collector temperature sensor cannot be inserted into the well, it may be that the sensor sleeve has moved in relation to the socket. In this case, the sensor will measure an incorrect temperature. This can be remedied by aligning the well, e.g. with a 5.5 mm Ø spiral drill.

CAUTION:

Moisture ingress can damage the temperature sensor.

• When securing the cable, make sure that no rainwater can run down the cable to the sensor well.

Fig. 3-84 Cutting off the well cover Fig. 3-85 Inserting the temperature sensor up to the specified depth in the well

Fig. 3-86 Secure the sensor cable with cable ties

3 x Installation


3.4.9 Uninstalling the collectors

If the collectors are to be separated, the fittings or the end cap must be removed as follows:

3.4.10 Additional notes about connecting pipes

If on-site conditions make it impossible or very difficult to install the connecting pipes in the manner described above, slight deviations from the specified installation are permitted. Hereby, the inflow pipe may not be larger than 18 x 1 mm.

1. If vertical copper pipes are already installed in the house, they can be used if a continuous connection pipe gradient can be guaranteed.

2. In the case of a two-way collector connection, if a continuous gradient from the second roof penetration box to all of the pipe sections cannot be achieved, this penetration box can be raised in relation to that of the inflow pipe (e.g. by using a ventilating tile). This is possible if:

– The highest point if the inflow pipe is not more than 12 m above the storage cylinder mounting floor level,– The internal diameter of the inflow pipe is not more than 13 mm, and– A continuous rise of the inflow pipe to the highest point, as well as a continuous gradient to the storage cylinder is

ensured.

3. If the required pipe length exceeds the maximum length calculated in Tab. 3-2, a copper connection pipe with larger pipe dimensions may be installed.

4. For pipe runs in which only a limited gradient can be achieved, copper pipe may be used on site. This avoids the need for a rigid supporting structure, and prevents the formation of water pockets due to expansion of the plastic pipes.

CAUTION:

Danger of burns from hot collector couplings and hot collector frame.

• Do not touch hot parts.• Wear protective gloves.

Fig. 3-87 Clip the removal tool behind the fitting Fig. 3-88 Pull the fitting off the collector

4 x Commissioning


4 Start-up

All the following work must be carried out in the specified sequence.

4.1 Operating Solaris systems without a FlowSensor

1. Filling the storage cylinder:

• Filling the heat exchanger for domestic water.• Fill the storage cylinder via the filling & draining cock on the RPS3 until water comes out of the safety overflow.• Close the filling & draining cock.

2. Switch on the Solaris R3 control unit (initialising phase starts).

3. When the initialising phase is finished (temperature display), you can vent the system by simultaneously pressing both arrow keys (starts the manual operating mode).

Both pumps are now running at full capacity, and the system is subjected to the max. possible working pressure. The system is filled with water, and the air escapes through the inflow pipe into the air space of the storage cylinder. A bypass in the FlowGuard regulating valve ensures that the system is vented automatically, even if the valve is fully closed.

4. Close the regulating valve completely. The system is now subjected to the max. possible working pressure.

5. Check the entire system for leaky joints (in the building and on the roof). Any leaks must be repaired by a qualified technician.

6. Adjust the flow in accordance with the number of collectors. For reference valve settings, see Tab. 4-3.

7. Switch off the Solaris control unit.

8. Check the filling level in the Solaris Sanicube.

9. Only if the water in the Solaris Sanicube does not reach the approximate previous filling level:

• Switch the Solaris R3 control unit on again (initialising phase starts).• When the initialising phase is finished (temperature display), you can start the manual operating mode by simultaneously

pressing both arrow keys.• Note the time it takes for the system to be filled completely. The max. filling level is reached, when no sound of escaping

air can be heard, and a stable flow value is indicated (use the arrow keys to select the measuring point "Flow").• Adjust the determined filling time plus 20 seconds as parameter "Time P2" (see Section 5.3.6).

10. Switch the Solaris R3 control unit back to automatic operation either by simultaneously pressing both arrow keys or by switching the unit off/on. The system is now ready for operation.

WARNING!

The Solaris installation may only be commissioned after all the hydraulic and electrical connections have been made.

Incorrect commissioning will impair the system's function, and can lead to damage of the entire system. Therefore, installation and commissioning should only be carried out by heating technicians trained and authorised by ROTEX.

As both pumps are running during commissioning in the manual operating mode, the basic setting should be at the upper limit values.

Within a few minutes, the filling level indicator in the Solaris Sanicube must show a filling level that is slightly lower than before. The reason for this is the small amount of water remaining in the lower pipes of the collectors. This amount of water represents no risk at sub-zero temperatures, as the empty collectors provide sufficient volume for expansion.

4 x Commissioning


11. The thermal insulation can now be applied to the pipe joints (e.g. between Connect SCS and Connect VG).

12. Instruct the user, fill out the acceptance report, and send it to the address indicated on the rear cover of this manual.

Tab. 4-3 Reference values for adjusting the flow on systems without a FlowSensor

4.2 Operation of Solaris systems with a FlowSensor

1. Filling the storage cylinder:

• Filling the heat exchanger for domestic water.• Fill the storage cylinder via the filling & draining cock on the RPS3 until water comes out of the safety overflow.• Close the filling & draining cock.

2. Switch on the Solaris R3 control unit (initialising phase starts).

3. When the initialising phase is finished (temperature display), you can vent the system by simultaneously pressing both arrow keys (starts the manual operating mode).

Both pumps are now running at full capacity, and the system is subjected to the max. possible working pressure. The system is filled with water, and the air escapes through the inflow pipe into the air space of the storage cylinder.

4. Check the entire system for leaky joints (in the building and on the roof). Any leaks must be repaired by a qualified technician.

5. Switch off the Solaris control unit.

6. Check the filling level in the Solaris Sanicube.

7. Only if the water in the Solaris Sanicube does not reach the approximate previous filling level:

• Switch the Solaris R3 control unit on again (initialising phase starts).• When the initialising phase is finished (temperature display), you can start the manual operating mode by simultaneously

pressing both arrow keys.• Note the time it takes for the system to be filled completely. The max. filling level is reached, when no sound of escaping

air can be heard, and a stable flow value is indicated (use the arrow keys to select the measuring point "Flow").• Adjust the determined filling time plus 20 seconds as parameter "Time P2" (see Section 5.3.6).

8. Switch the Solaris R3 control unit back to automatic operation either by simultaneously pressing both arrow keys or by switching the unit off/on. The system is now ready for operation.

The pumps are only switched on, if the collector temperature is higher than the minimum value for frost protection (see Section 5.2.10), and lower than the adjusted max. permissible temperature.

If there has been a longer pause between working steps 5 and 7, the collector temperature might be outside the permissible range. However, this can be overcome by switching over to manual operation for a few minutes (see Section 5.2.5).

Number of collectors Desired flow in l/min Desired flow in l/min

2 3.0 to 4.0 180 to 240

3 4.5 to 6.0 270 to 360

4 6.0 to 8.0 360 to 480

5 7.5 to 10.0 450 to 600

The final valve setting can only be determined on a sunny day during normal operation (only one pump) according to the temperature differences that are reached. With good solar radiation, the collector temperature should settle at a value that is about 10 to 15 °C above the return flow temperature.

If a calorimeter has been installed in the system, the flow can be adjusted according to the calorimeter display. During normal operation (circulation pump on/booster pump off) the value per collector should be about 90 to 120 l/h (1.5 to 2.0 l/min).

Within a few minutes, the filling level indicator in the Solaris Sanicube must show a filling level that is slightly lower than before. The reason for this is the small amount of water remaining in the lower pipes of the collectors. This amount of water represents no risk at sub-zero temperatures, as the empty collectors provide sufficient volume for expansion.

4 x Commissioning


9. Only if the RPS3 control unit is connected to two Solaris Sanicubes via a common return flow pipe (storage cylinder extension set CON SX):

– The measured joint flow in the Solaris inflow must be distributed evenly to both Solaris Sanicubes. For an even distribution, we recommend fitting a FlowGuard for each storage cylinder.

10. Instruct the user, fill out the acceptance report, and send it to the address indicated on the rear cover of this manual.

The final valve setting can only be determined on a sunny day during normal operation (only one pump) according to the temperature differences that are reached. With good solar radiation, the collector temperature should settle at a value that is about 10 to 15 °C above the return flow temperature.

If a calorimeter has been installed in the system, the flow can be adjusted according to the calorimeter display. During normal operation (circulation pump on/booster pump off) the value per collector should be about 90 to 120 l/h (1.5 to 2.0 l/min).

5 x Control unit operation


5 Control5.1 Operating and display elements

5.2 Controller operating principle

The Solaris system is operated throughout the year, without the need for manual intervention. Speed-controlled pump operation is regulated by the Solaris R3 temperature difference controller. The operating and display elements are shown in Figure 5-1.

5.2.1 Pump operation

Pump operation includes the following functions:– Continuous measurement of the temperature difference between collector and return flow temperatures, and a comparison

with the selected parameter "Delta T On".– Pump switch-on, if this parameter is exceeded (e.g. return flow temperature is 40 °C, and "Delta T On" is 15 K; collector

temperature > 55 °C).– Additional filling of the system with the upper booster pump (P2) as a function of the adjusted parameter value "Time P2"

in [s].– If the correctly adjusted FlowSensor measures a stable flow before this time has elapsed, the Solaris system is

completely filled with water.– Due to the siphon effect in the inflow pipe of the solar circuit, only with the circulation pump P1. Pump output is regulated

as a function of the temperature difference between Solaris inflow and return flow temperatures.

1 Main switch with indicator light2 Display for showing temperature and

parameters (energy saving function: Display illumination is switched off 10 minutes after the last key actuation)

3 Light for collector temperature display4 Light for Solaris inflow temperature

and flow measurement display (FLS)5 Light for storage cylinder temperature

display6 Light for solar return flow temperature

display7 Operating condition light for speed-

controlled circulation pump P1 (lights up when pump is operating)

8 Operating condition light for booster pump P2 (lights up when pump is operating; flashes when pump is throttled)

9 Up arrow for moving the temperature or parameter display up by one setting/increasing parameter settings

10 Down arrow for moving the temperature or parameter display down by one setting/decreasing parameter settings

11 Information key for accessing the information level (displays measured values, maximum values and calculated values) and OK key for confirming and storing settings in the setting menu

12 Controller housing13 Housing locking screws (device may only

be opened by an authorised specialist. Disconnect from mains supply before opening the housing).

Fig. 5-1 Operating and display elements



The pumps are switched off if:– The temperature difference of the adjusted parameter value "Delta T Off" is exceeded (e.g. return flow temperature is

45 °C, and "Delta T Off" is 2 K; Solaris inflow temperature < 47 °C).– The maximum storage cylinder temperature set via the "TS max" parameter is reached (TS light flashes). In this case,

the pumps can only be switched on again, if the storage cylinder temperature drops by more than 2 K.

5.2.2 Booster function for high collector temperatures

In addition to the standard circulation pump P1, the booster pump P2 is switched on automatically at a collector temperature of "TK max" = 70 °C (booster temperature).

– This increases the system pressure as well as the flow quantity, which enables more heat to be stored within a shorter time.A heating technician can change the booster temperature by means of the parameter "TK max". As soon as the collector temperature drops more than 5 K below "TK max", pump P2 is switched off automatically.

5.2.3 Switch-on inhibit function

This function (which can be disabled) prevents:

– System switch-on, if it has been switched off automatically because the adjusted max. storage cylinder temperature "TS max" has been reached.

– Pump operation, if the collector temperature exceeds the max. permissible value (the parameter "TK perm" is adjustable by a heating technician).

In case of continuous solar radiation, collector temperatures above 100 °C are possible after the pumps have been switched off. If, in such a situation, the storage cylinder temperature drops below the enable temperature ("TS max" – 2 K), for example because domestic hot water is consumed, the pumps are switched on again, provided that the collector temperature has also dropped 2 K below the max. permissible temperature "TK perm". When this happens, the TK light flashes.

With collector temperatures above 100 °C, the return flow water evaporates immediately as soon as it enters the collector. In a correctly installed Solaris system, the steam escapes into the storage cylinder, where most of it condenses again. It is possible that a reduction of the excess heating capacity in the collectors and the associated boiling noise will take several minutes. Similarly, a slightly increased consumption of cylinder water due to escaping steam is a normal operating condition.

5.2.4 Pump kick function

This is a protective function for the pumps in case of longer bad weather periods or after a standstill of more than 24 hours.

– Both pumps P1 and P2 are switched on for a short period to prevent them seizing.

5.2.5 Manual operation

Only for commissioning or for testing, the system can be switched to manual operation for a max. period of 30 minutes. Hereby, all control functions are disabled, and both pumps run continuously with the adjusted output, regardless of the system temperatures.

• Manual operation is toggled on/off by pressing both arrow keys simultaneously (>1 s).

Without an installed FlowSensor, or if it is defective, circulation pump P1 is operated constantly with the adjusted output (no speed control). The pumps are controlled exclusively via the difference between collector and Solaris return flow temperatures.

If pump P1 is operated without a FlowSensor, pump P2 is switched on every two hours for a period that is adjusted with parameter "Time P2".

CAUTION:

Uncontrolled manual operation can result in heat loss, excessively high storage cylinder temperatures, and even frost damage in extremely cold situations.



5.2.6 Solaris FlowSensor

The optional Solaris FlowSensor ( 16 41 05) is used to measure flow (V) and inflow temperature (TV). With the sensor connected and working:– The measurement values V and TV are displayed.– After the filling procedure, the control unit works with the actual system temperature difference between inflow and return

flow temperatures.When the system has detected the FlowSensor, and if a sensor fault develops, the display shows a corresponding error message (see Chapter 6.1). The system then works in the emergency mode without the FlowSensor.

No error message is displayed, if the FlowSensor is disabled by the heating technician. The control unit works without the measurement value V, and the inflow temperature (TV) is assumed to be the same as the collector temperature (TK).

5.2.7 Output calculation, maximum values, and yield count

With an installed FlowSensor, the system calculates and balances the system's operating data, e.g. instantaneous heat output, solar heat yield, etc. Maximum and calculated values can be displayed (see Chapter 5.3). Values greater than 0, which are not deleted, are still displayed even after disconnecting or disabling the FlowSensor (no updating).

5.2.8 Speed control of circulation pump P1

When all operational conditions have been fulfilled, the Solaris R3 control unit:– Switches on both pumps with full output up to the max. possible flow. – Switches off pump P2 when the adjusted minimum running time "Time P2" has elapsed (not in case of booster operation).– Reduces the output of pump P1 in steps until the difference between inflow temperature (TV) and return flow

temperature (TV) is within the set-value limits (see Figure 5-2) or until the flow falls below the minimum value V2 (Figure 5-3). – Switches the pump to the next output stage after a safety period t2 has elapsed (Figure 5-3).

If the pump output is too low, it is possible that the flow in the solar circuit is interrupted. If the flow drops below the value V2 (Figure 5-3) for at least 10 seconds, the control unit detects an interrupted flow, and the previously valid pump output stage is stored as the minimum limit. All lower pump output stages are disabled.

Subsequently, the temperature-dependent control of P1 remains between the determined minimum and maximum output stages. Hereby, the temperature difference between TV and TR is measured continuously, and compared with the set-value. If the temperature difference between TV and TR is too large, the output of pump P1 (max. 10 stages), and therefore the flow through the solar panel is increased until the set-value is reached. If the temperature difference is too small, pump output is reduced. While pump P1 is running, its instantaneous output "Flow" is displayed as a percentage next to the measured flow value. Figure 5-2 shows the typical operating curve of a Solaris system with modulated pump control.

The system's calculation and balancing functions (e.g. solar heat yield) are not substitutes for a calibrated calorimeter. These values may not be used for invoicing heating costs or similar legally valid accounting purposes.

TK Collector temperatureDT Temperature difference (difference between Solaris inflow and

return flow temperature)S1 Upper set temperature difference ("temperature difference 1")S1 Lower set temperature difference ("temperature difference 2")

T1 Frost protection temperature ("TR frost")T2 Booster temperature ("TK max")T3 Switch-on inhibit temperature ("TK perm")— Set value for temperature difference- - - Switching limits for pump modulation

Fig. 5-2 Pump output control as a function of temperature difference



Fig. 5-3 Example of modulated control with disabling of lower pump output stages after detection of a flow interruption

5.2.9 Overall reset function

The controller responds to an overall reset with a new start (self-test), whereby all parameters are set to their default (factory) values, and all disabled pump output stages are enabled. A reset is carried out by:

• Simultaneously pressing the OK and the arrow keys.

5.2.10 Frost protection function

In case of low outdoor temperatures, the Solaris system is started only if the operating conditions for a factory-defined frost protection temperature of 25 °C ("TR frost") for the return flow are fulfilled. If the measured return flow temperature is below the frost protection value ("TR frost"), the pumps are operated at least for the period defined in parameter "Time P2", even if the switch-off temperature condition has already occurred. This prevents the build-up of ice in the connecting pipe.

5.2.11 System leakage protection function

If no minimum flow V1 is detected by the Flow Sensor (according to Figure 5-3) after switch-on or after the max. starting period ("Time P2") for pumps P1 and P2 has elapsed, the reason can be: – A defect of the FlowSensor, or– A leak in the Solaris system.To prevent all the cylinder water being pumped out of the system in case of a leak, both pumps are switched of permanently, and the error message "F" appears in the left-hand column of the display.

• Replace the defective FlowSensor or repair the leak.• Restart the system in the manual operating mode.

t TimeV Solar circuit flowA Start phaseB Operating phase (modulation)C Interrupted flowD Low pump output stages are automatically disabled

when flow is interrupted

V1 Minimum flow in start phase ("VS min")V2 Minimum flow in operating phase ("S flow")t1 Maximum starting time of booster pump P2

("Time P2")t2 Stabilisation period ("S time")t3 Interruption detection period (10 s)



5.3 Adjustments and menu guidance

Table 5.1 gives an overview of the available measurement points and the associated display formats. Table 5.2 shows a summary of the displays for the calculated parameters.

Tab. 5-1 Overview of measurement points

Tab. 5-2 Maximum values and calculated values

5.3.1 Display during start-up

After switch-on, the Solaris R3 control unit goes through a self-testing routine, during which all the display elements and the adjustment parameters are shown separately. The following testing steps are carried out, and the results displayed for about 2 seconds (Figure 5-4): – Immediately after switch-on, the start-up display shows the installed software version and the controller's serial number. – During first commissioning, the display then shows the language selection page.– For safety reasons, the functions of the pumps and their operating condition lights can only be checked manually

(see section 5.2.5).

Measurement Name Measuring range

Resolution Sensor

DisplaytK Collector temperature –30 to 250 °C 1 K Pt 1000 temperature sensortR Return flow temperature 0 to 100 °C 1 K PTC temperature sensortS Storage cylinder temperature 0 to 100 °C 1 K PTC temperature sensortV Inflow temperature 0 to 100 °C 1 K FlowSensor with 0.5–3.5 V output signalV Flow 0.0 to 20.0 l/min 0.1 l/min FlowSensor with 0.5–3.5 V output signal

Parameter Name Value range Resolution Remark

TK maxMax. measured collector temperature

–30 to 250 °C 1 K none

TK minMin. measured collector temperature

–30 to 250 °C 1 K none

V max Maximum flow 0.0 to 20.0 l/min 0.1 l/min Maximum flow measured during filling

PS Peak output 0.0 and 99.9 kW 0.1 kWMaximum mean value determined during 5 minutes

PS (15h) Peak value of the day 0.0 and 99.9 kW 0.1 kWMaximum peak value during the last 15 hours

W (15h) Heat yield of the day 0.0 and 999.9 kW 0.1 kWhHeat yield calculated from instantaneous output during the last 15 hours

w Total heat yield0.0 to 9999.9 kWor 10,000 to 99,999 kW

0.1 kWh

0.0001 MWh

Total solar heat yield calculated from instantaneous output

P Instantaneous output 0.0 and 99.9 kW 0.1 kW Mean value during the last minute

DTSet-value for temperature difference

1 to 15 K 1 KSet-value for temperature difference TV–TR

during modulated operationP1 Present output stage of P1 0 to 100 1 % none

Min. stageSmallest enabled output stage of P1

0 to 100 to 100

1; 1 %Only accessible for an expert (see Figure 5-6)

Stage "On"Runtime of circulation pump P1

0 to 99999h 1hOnly accessible for an expert (see Figure 5-6)



5.3.2 Display during operation

During operation, the display shows the system temperatures, maximum values, and calculated values. After showing the start display, the Solaris R3 controller switches automatically to operation display mode, an operation value is displayed and the relevant light is illuminated. • Pressing the arrow keys permits navigating between the four measured temperature values and the measured flow value

(see Tab. 5-1 and Tab. 5-5). • Pressing the Info key displays the maximum values and the calculated values (see Tab. 5-2).

The left-hand column of the display shows the following status information :– "1" in the first line, circulation pump P1 running.– "2" in the 2nd line, booster pump P2 running.– "B" in the 3rd line, burner inhibit contact activated (see Section 5.3.7), or a fault status (see Chapter 6.1). – "H" in the 4th line, manual operating mode.

5.3.3 Setup menu

In the setup menu, the parameters of the Solaris R3 control unit are displayed and can be changed. • Pressing the OK key once (>2 s) either activates the setup menu or returns to the operating display. Briefly pressing the

key confirms a selection, opens the next menu item, or displays "Saved" for about 1 second after a value has been changed.• In the selected parameter display, pressing the OK key switches over to the parameter changing mode.The first line of the setup menu (Figure 5-6) shows the active menu item, whilst in the left-hand column a cursor (">") points to the next lower menu item or to a parameter. From here, you navigate to the respective menu tree by means of the arrow keys: up (+ key) or down (– key). The adjusted value can be changed accordingly with the arrow keys. Briefly pressing an arrow key changes the value by one step, and continuous pressing speeds up the change. After changing the required parameter, and moving down through the entire parameter list, then display returns to the selection menu ("Selection 2/2"), and from there to the operating display (see Figure 5-6). The control unit starts working with the changed parameter value(s) immediately. The display always returns to the operating display mode after 10 minutes, provided that no key is pressed during this time.

As long as no manual changes are made, or an event according to Tab. 6-2 triggers a different display format, the selected display of measurement or Info values remains active – also after a parameter change or if the system is switched off/on. If info values are displayed, no measuring point indicator lights are activated.

Fig. 5-4 Display during start-up Fig. 5-5 Display during operation



Fig. 5-6 Setup menu



5.3.4 Password protection

The Expert level of the setup menu is protected by a password, which must be entered at the beginning of the setup menu. Also the Operator level can be protected. The Operator and Expert levels are identified by different colours in the setup menu. Apart from the path described in Figure 5-6, the setup menu can also be called from the starting display by pressing the "Up" arrow key for a longer period.

As long as the system is being operated manually, no further password entry is required. Passwords remain valid for about 10 minutes after the last key has been pressed. After entering the password for the required level, the following display appears for about 2 seconds:

– "Operator OK"– "Expert OK" or– "Incorrect password"

Operator passwordWhen delivered, this password is not activated in the Solaris R3 control unit. By entering a 4-digit number code, all the parameters adjustable in Operator level are protected against unauthorised access (child protection or caretaker function). The parameters of the Operator level can only be changed with the correct Operator password or if password protection has been disabled.

Enabling and changing/reassigning the Operator password is done in the menu item: Selection 1/2 \Functions\"Passw. change" (see Figure 5-6).

• Enter the old password in the field "present 0000", and the new password in the field "new 0000". Hereby, every digit must be confirmed with the OK key.

• When assigning a new password, it must be entered in the field "present 0000" as well as in the field "new 0000".If the Operator password is enabled, the menu item "Selection 1/2" only shows "Password 0000". The Operator password is enabled only after 10 minutes or after a restart of the Solaris R3 control unit.

Expert passwordThe Expert password is entered in the menu item "Selection 1/2" under "Password 0000". It provides access to all the important system parameters required by the expert in the setup menu (see Figure 5-6).

Tab. 5-3 Overview of parameters

Parameter Name Access level Setting range Recommended setting

Factory setting

Step width

Delta T OnSwitch-on temperature difference

Operator

1...80(>"Delta Off"

10 to 15 K 15 K 1 K

Delta T OffSwitch-off temperature difference

1...20(<"Delta On"

2 to 5 K 2 K 1 K

TS maxMax. storage cylinder temperature

20 to 85 °C 75 to 85 °C 80 °C 1 K

Time P2 Max. filling time

Expert

10 to 999 KFilling time

+20 s150 s 1 s

TK maxBooster temperature (max. collector temperature)

20 to 110 °C — 80 °C 1 K

TK permSwitch-on inhibit temperature (max. permissible collector temp.)

90 to 50 °C — 95 °C 1 K

TR frost Frost protection temperature 10 to 60 °C — 25 °C 1 K

H/AAutomatic return from manual to automatic operation

1 to 900 l/min — 30 min 1 min

FLS enabled FlowSensor activation Yes/No Yes Yes —P min Min. output for burner stop 0.0 and 99.9 kW 99.9 kW 0.1 kW

TS minMin. temperature for burner stop

0 to 99 °C — 99 °C 1 K

CycleCycle for data output (serial interface RS 232)

0 to 300 K — 0 5 s

Bit rateTransmission speed of data output

2400, 4800, 9600, 19200

— 19200 —



5.3.5 Language selection

During first commissioning or after an overall reset, the starting display (Figure 5-4) is stopped, and a language selection is requested. • Use the arrow keys to select your language, and confirm it with the OK key. It is possible to select a different language later on via the menu item: Selection 1/2\Functions\"Change language" in the setup menu (Figure 5-6).

5.3.6 Adjusting and resetting parameters

Parameters are adjusted according to Figure 5-6. All adjustable parameters are displayed in Tab. 5-3 with access level, adjustment range, and factory setting. The menu item Selection 1/2\Parameter selection\Reset enables the max. values and calculated values (see Tab. 5-3) to be reset. Hereby, the selected max. value is set to zero immediately with the OK key. The arrow key "Down" cancels this operation, and the cursor goes back to the left. The OK key confirms the selection. Repeated pressing of the key "Down" takes you to the field "Selection 2/2". Confirming "Back" returns you to the operating display. Via the menu item: Selection 2/2\System\Reset, all system parameters can be reset to the default (factory) settings. Subsequently, the system is restarted (also see Section 5.2.9.)

5.3.7 Burner inhibit contact

This contact controls an external heat generator in such a way that under favourable weather conditions, the storage cylinder is not heated by the external source. For this purpose, the connecting cable ( 16 41 10) is required, which is available as an accessory. If the Solaris system reaches an instantaneous output value (adjustable by an expert via menu item Selection 1/2\Parameter selection\Operating parameter "P min") or if the storage cylinder is heated to a minimum temperature (adjustable by an expert via operating parameter "TS min" see Tab. 5-3), a contact disables e.g. the burner. Adjustment of the burner inhibit contact is described in Figure 5-6.

5.3.8 Manual adjustment of pump speed control

With some output stages of the speed-controlled pump P1 it is possible that noise problems arise. The present output of the selected stage is displayed as a percentage in the bottom line "Flow" of the operating display (see Figure 5-5). • Make a note of the problematic output stage. • Go to the menu item Selection 2/2\System\Modulation\"Stage" (see Figure 5-6).Here, up to 10 speed ranges can be disabled. Next to the reference number of the output stage (starting with 01 for the lowest output) and the operating status, the output of the relevant stage is displayed as a percentage under "Output".

• Disable the noisy stage by setting the parameter "Active" to "no".

From now on, this stage will be skipped during control of pump P1.

5.3.9 Correcting values for measurement points

If the measurement value of a sensor deviates from the true value, it can be compensated by means of a correcting value.

• Find the correcting parameter via the menu item Selection 2/2\System\Correcting values (see Figure 5-6), and change the values according to Tab. 5-4.

Tab. 5-4 Correcting values

Name Access level Measurement & adjusting range

Factory setting Step width

Collector temperature correction

Expert

–9 to +9 0 K 1 K

Return flow temperature correction –9 to +9 0 K 1 K

Storage cylinder temperature correction

–9 to +9 0 K 1 K

Inflow temperature correction –9 to +9 0 K 1 K

Flow correction –2 to +2 0 l/min 1 l/min



5.4 Recommended settings

5.4.1 Standard parameter values, recommended adjustment ranges

Tab. 5-3 summarises the default (factory) settings as well as possible and recommended adjustment ranges of the Solaris system parameters.

The following notes will help to determine the optimum settings, and guarantee an optimum heat yield with low power consumption:• Adjust the switch-on temperature difference "Delta T On" so that the system remains in operation under constant solar

radiation conditions, and does not switch off immediately when the collector temperature drops due to heat removal. The lower this value can be adjusted, the longer will be the operating periods with a correspondingly higher heat yield. If the adjusted switch-on temperature difference is too low, the collector will already cool down so far during filling, that the switch-off temperature difference is reached.

The pumps are switched off immediately, with resulting lower heat yield and higher power consumption.

• Adjust the switch-off temperature difference "Delta T Off" so that the heat yield obtainable at the switch-off point is higher than the electrical power required to drive the pump.

As the pump's power consumption is practically independent of the size of the connected solar panel, but the achievable heat yield is directly proportional to the number of collectors, this parameter value must be set higher with fewer collectors, and lower with more collectors.

• Adjust the operating period "Time P2" of the booster pump P2 so that the entire cross-section of the inflow pipe is filled with water under all operating conditions. Determine the time required between hearing escaping air when the pumps are switched on, and water entering the storage cylinder, and add a safety margin of 20 seconds. The filling period depends on the adjusted flowrate, the number of collectors, system height, and the length of the connecting pipe.

• The max. storage cylinder temperature "TS max" is adjusted according to individual requirements. The higher the parameter value, the higher the heat storage capacity available and, therefore, the potential performance of the Solaris system.

System switch-on involving steam generation can often be disconcerting for the operator. Therefore, the switch-on inhibit temperature "TK perm" has been factory-set to 95 °C, which prevents boiling noises and escaping steam. The Solaris control unit only switches the pumps on again, when the collector temperature has fallen 2 Kelvin below the adjusted parameter value. Consequently, the system starts gently, without evaporation in the collector. However, on a cloudless day, this can lead to a situation where the system only switches on again in the late afternoon, although the storage cylinder temperature permits additional heating.• For maximum heat yield, the switch-on inhibit temperature should be adjusted to a value above 100 °C, which disables the

inhibit function. In this case, the operator must be informed that there will be considerably more boiling noise and steam hammer during filling.

5.4.2 Other adjustments of your Solaris system

The following adjustment notes only apply for operation without a FlowSensor:

In this case, a FlowGuard (optional, 16 41 02) should be fitted to the inflow coupling of the Sanicube Solaris storage cylinder. Hereby, the water flow should be adjusted so that the throughput of every collector is 90 to 120 l/h. Adjust the flowrate either by selecting a speed range for pump P1 and/or by adjusting the FlowGuard regulating valve with flow indicator. Reference values for the correct valve/pump settings are given in Tab. 5-5.

During commissioning, the system parameters must be adjusted individually to suit the installed system, and might need fine tuning during subsequent operation. Usually, the system will operate with the default settings.

CAUTION:

With storage cylinder temperatures above 60 °C, a thermal mixer valve must be fitted to the storage cylinder's hot water coupling to prevent scalding.

When operating the Solaris system with a FlowSensor, the flow in the solar circuit is adapted continuously to the requirements by means of the temperature-difference dependent control of pump P1.



For indirect monitoring of the flowrate, it is important to observe the system temperatures during normal operation. Under optimum solar radiation conditions (cloudless sky, clear air, sun about vertical to the collector surface), the temperature increase in the collector should be about 10 to 15 Kelvin. During operation of pump P1, and with a return flow temperature of e.g. 50 °C, the collector temperature should be about 60 to 65 °C. If a calorimeter is installed, the flowrate can be adjusted by means of a direct measurement while operating a pump.

Tab. 5-5 Adjusting the flowrate of the FlowGuard (FLG)

5.4.3 Recommended settings for auxiliary heating via external heat sources or the electric heater, burner inhibit contact

For the highest performance potential:• Rarely with Sanicube Solaris, and only up to an adequate temperature, by means of an external heat source or the electric

heater. • Via a timer program for "normal use", with optimal times determined from observing regular consumption behaviour. • Supplementary charging, depending on the connected heat source, enabled one or two hours before the accustomed

consumption time.• The charging time should be limited so that the storage cylinder does not need to be directly heated after a normal

consumption cycle.The optimum charging temperature depends on personal needs; frequently a storage cylinder temperature of 50 °C is adequate. An average shower requires about 30 to 50 l of hot water with an outlet temperature of 40 °C. The cold water entering the storage cylinder during the shower must be heated in the Sanicube Solaris using the flow heater principle.

• With larger amounts of hot water and to ensure the required convenience also during unaccustomed consumption times, the temperature in the hot water section must be sufficiently high, or the heat source for charging must be enabled, e.g. by switching to a different timer program.

Heating by means of an external heat generator Depending heating requirements (related to the building's insulation standard, outdoor temperature, and desired room temperatures) and the installed collector surface, it might be expedient to disable the external heat generator by fitting a burner inhibit contact. For this purpose, also if the heater control demands additional heat:

• Adjust the operating parameters "P min" and "TS min" (see Section 5.3.7) so that the external generator does not supply heat, – if the collectors are supplying a minimum amount of heat, or – the storage cylinder has reached a sufficiently high temperature.

Number of collectors Desired flow in l/min Desired flow in l/min2 3.0 to 4.0 180 to 2403 4.5 to 6.0 270 to 3604 6.0 to 8.0 360 to 4805 7.5 to 10.0 450 to 600

To ensure fast and safe filling of the system, the booster pump P2 should always be operated in stage 3. If possible, the circulation pump P1 should be operated at a lower speed, it the system height H (height difference between mounting floor level of the Sanicube Solaris and the upper collector edge) is not more than 10 m (for stage 2) or 8 m (for stage 1), and the flowrate is still sufficient.

Even if the flowrate and the switch-on difference "Delta T On", have been adjusted correctly, and the weather conditions are ideal, the Solaris system sometimes switches off. With a rising or setting sun, and an increasing storage cylinder temperature, the collector temperature gradually falls after the pumps have been switched on, i.e. the switch-off conditions are met. Due to the continued solar radiation, the collector temperature increases again, the pumps are started, and the system cycles because the solar radiation is insufficient for continuous operation. The FlowSensor reduces this effect by regulating the pump speed.



5.4.4 Tips for optimised user behaviour

Hot water needs and user behaviour are highly individual. The higher the desired storage cylinder temperature is, and the longer the periods for non-solar charging heating have been adjusted, the more will the storage potential for solar heat generation be limited. Conscious user behaviour that is adapted to the special strengths of the Sanicube Solaris, will minimise the energy consumption of non-solar charging operations.

• Use modern and convenient shower heads with flowrates of 5–7 l/min.

The lower flowrate (hot water consumption per minute) results in a reduced need for supplementary heating, and therefore a larger amount of hot water at a higher temperature.

• Reduce the consumption times.

Lower energy consumption.

• Start filling the bathtub only with hot water.

After the 25 l of hot water stored in the Sanicube Solaris have been drawn, the hot water discharge temperature drops slightly, and the water is mixed in the bathtub. In this way, the storage capacity is used in an optimal manner with a minimum charging temperature; an adequate amount of hot water is available.

5.4.5 Domestic water hygiene

If no hot water is drawn during several days, and if the storage cylinder temperature is not maintained at a minimum of 60 °C by the Solaris system, a one-time temperature increase to above 60 °C or draining the stored hot water (25 l) is recommended for hygienic reasons (Legionella protection).

6 x Faults and disturbances


6 x Faults and disturbances6.1 Display of events

Via the menu item Selection 2/2\System\Events memory, and after entering the Expert password (see Section 5.3.4 and Figure 5-6), events occurring during operation can be displayed. For this purpose, the Solaris control unit contains a simple fault diagnosis system. The events memory stores nature and time of the event. The event is displayed in plain text and a code, the time since the event occurred is shown in hours. Starting with the most recent event, you can leaf through the individual events by means of the Info key. If the parameter "delete" is shown in the menu item: Selection 2/2\System\Events memory is set to "yes", all the events will be deleted. Deletion of individual events is not possible. An overview of the events memory is given in Tab. 6-1.

Tab. 6-1 Events memory

Sensor-specific error messages With a break or short circuit in a sensor or sensor cable, the Solaris control unit reacts as follows (see Tab. 6-2):– A blinking code letter in the status line indicates the fault, and an error message is generated.– The lamp associated to the sensor blinks. – In addition, the control unit automatically intervenes in system operation. All other sensor values remain accessible via the arrow keys.

Event code

Plain text display

Description Status display (blinks)

Lamp (blinks)

Consequence

0 Collector Collector sensor: Short-circuited or open K TK

Permanent switch-off of P1 and P21 Return flow Return flow sensor: Short-circuited or open R TR

2 Storage cylinder

Storage cylinder sensor: Short-circuited or open

S TS

3 Flow FlowSensor Short-circuited or open DOperation without FlowSensor

4 Inflow FlowSensor Short-circuited or open V

5 A/D Internal A/D converter fault G

Permanent switch-off of P1 and P26 Supply Internal supply voltage fault G

7 Reference Internal reference voltage fault G

8 Reset Overall reset was carried out G Parameters are set to default (factory) values, system restart

12 Start flow Minimum flowrate V1 (Fig. 4.2) was not reached during the starting phase after the time "Time P2" has elapsed – Description Item 4

F TV

Permanent switch-off of P1 and P2

13 TS > Tmax -Max. storage cylinder temp. ("TS max") exceeded – Description Item 1

TS

Temporary switch-off of P1 and P214 TR >> TS TR - TS > 10 K and TR > 40 °C –

Description Item 2TR

15 TK > TK perm

Max. permissible collector temperature ("TK perm") exceeded – Description Item 3

TK

16 Interrupt Interrupted flow detected during operating phase (V < "S-Flow")

Temporary switch-off of P1 and P2 (at least during stabilisation period), disabling of present and all lower pump output stages, refilling with P1 and P2 with "Time P2" with next switch-on condition.



Tab. 6-2 Table of sensor faults

6.2 Troubleshooting

Operational events that are similar to faultsThe storage cylinder temperature TS in the Solaris Sanicube does not reach the value adjusted with parameter "TS max":– Pumps are switched off, the system is drained. The TS lamp in the control unit blinks, the display shows the measured storage

cylinder temperature. As soon as the storage cylinder temperature falls more than 2 K, normal system operation is resumed.

The temperature in the collector is higher than the switch-on inhibit temperature "TK perm"– Pumps are switched off. The TK lamp in the Solaris control unit blinks. As soon as the adjusted switch-on inhibit temperature

falls more than 2 K, normal system operation is resumed.

DisturbancesReturn flow temperature R is greater than 40 °C and is 10 K above the storage cylinder temperature TS. The pumps are shut off and the TR light in the Solaris control unit flashes. The cause for this is a defective or incorrectly connected sensor, • Install the sensor correctly or replace it; normal system operation will be resumed.

Minimum flowrate V1 at the FlowSensor is not reached within the period defined with parameter "Time P2" after switch-on or after the pumps P1 and P2 are started (Figure 5-3). Pumps are switched off. The letter "F" blinks in the status line of the Solaris control unit.• Investigate for a possible leak in the Solaris system, rectify the problem, and finally restart the system by switching the

control unit off/on.

If the system cannot be filled (Status F), although the pumps have been started by the control unit, the following faults might be the cause:

1. Air, which has been drawn in during draining, has entered the pumps.

• Check the pumps for trapped air, and vent them. This is done by loosening (do not remove) the sealing cap of the automatic venting valve on the pump housing of booster pump P2. After venting, retighten the sealing cap of the automatic venting valve on circulation pump P1.

2. Checking for leaks

• Check the system for leaks, and rectify if necessary. Observe the notes in Chapter 4 "Start-up".

3. Or increase pump output with the selector switch (1, 2, 3) or increase the starting time "Time P2" (Chapter 5.4).

No display, and the main switch in the illuminated "On" position:• Replace the control unit (electronic fault).

The main switch is not illuminated in the "On" position, the control unit is not energised.• Check the connections of the mains plug and the voltage supply (fuses, switches).

Sensor Cause of the fault

Status (blinks) Display Lamp (blinks) Consequence

Collector temp.Interruption K uuuu TK

Permanent switch-off of P1 and P2

Short circuit –––– TK

Return flow temp.Interruption R uuuu TR

Short circuit –––– TR

Storage cylinder temp.

Interruption S uuuu TS

Short circuit –––– TS

Inflow temp. Voltage drop V –––– Without lampOperation without FlowSensor

FlowSensor Voltage drop D –––– Without lamp

Hereby, short-term evaporation in the collectors is possible. The pressureless steam escapes into the storage cylinder. On rare occasions, slight amounts of steam can escape from the Solaris Sanicube.



If steam escapes continuously from the Solaris Sanicube during solar radiation, the flow is too low. • In this case, the system settings must be checked.

Special notes on electric sensors

• Evaluate the display of the Solaris R3 control unit.• Open the housing of the Solaris control unit, and disconnect the affected sensor.• Examine the contact positions of the affected sensor, and measure the resistance (or the DC signals for inflow temperature

and flowrate) on the sensor end. When the fault has been rectified, the system automatically resumes normal operation and is in the operating mode.

The resistance and voltage values of the sensors are shown in Figure 8-13. Internal faults of the controller electronics that can be diagnosed, are shown in the display according to Tab. 6-1 (Status G). They also cause a safety switch-off of the pumps. Switching the system off and then on again after 2 minutes might remedy the internal fault; if not, the control unit must be replaced.

WARNING!

An electric shock can cause severe burns and life-threatening injuries. Therefore, before opening the control unit housing, the mains supply must be disconnected and secured against switch-on.

7 x Hydraulic system integration


7 Hydraulic system integration

1) The stainless steel corrugated pipe exchanger for heating support in the Sanicube Solaris can transfer approx. 0.2 kW per Kelvin of overtemperature compared with the average temperature in the solar area of the storage cylinder.

2) The second stainless steel corrugated pipe exchanger in the Sanicube Solaris can transfer approx. 1.0 kW per Kelvin of overtemperature compared with the average temperature in the hot water area of the storage cylinder.

WARNING!

High temperatures can arise in the storage cylinder. The hot water installation must be fitted with an adequate scalding protection (e.g. an automatic hot water mixer).

CAUTION:

The plastic anti-siphon valves fitted as standard in ROTEX equipment are designed for max. operating temperatures of 95 °C. If a heat exchanger is to be operated at more than 95 °C, the standard anti-siphon valve must be replaced with a suitable version.

Shown below is a selection of the most frequently installed system arrangements. The arrangements shown are only examples, and are no substitute for careful system planning. Additional arrangements are shown on the ROTEX website.

Fig. 7-1 Standard Solaris installation with SCS 538/16/0 1) 2)

SCS 38/16/0

M

A1-Inline

PK

tV

tR

MBAB

A

MiAMK1

PMi

tMi

tK

PS1

PS2

RPS2

tAU

700

1000

UV

2-5 Solaris V26

5

PZ

VS 2

2 8

77

77

6

FLS

3

4

1

7

tS,R

tWW

tS

tS,V

SV

010.

000

0302



1) The stainless steel corrugated pipe exchanger for heating support in the Sanicube Solaris can transfer approx. 0.2 kW per Kelvin of overtemperature compared with the average temperature in the solar area of the storage cylinder.

2) The second stainless steel corrugated pipe exchanger in the Sanicube Solaris can transfer approx. 1.0 kW per Kelvin of overtemperature compared with the average temperature in the bottom half of the storage cylinder.

Fig. 7-2 Wood-fired boiler combined with a standard Solaris system via a storage cylinder

Fig. 7-3 Wood-fired boiler combined with an SCS 58/16/16 1) 2)

010.

000

0352

SCS 38/16/0

M

A1-Inline

PK

tV

t1

M

BAB

A

MIAMK1

PMI

tMI

tK

PS1

PS2

RPS2

tAU

700

UV1

UV2

2-5 Solaris V26

5

PZ

VS

22

8

7

6

FLS

3

4

1

77 7

tS,R

tWW

tS

tS,V

1000

SV SC 38/0/0

7

M

AAB

B

WEx

T

TMV

PWEx

t2

tR

DTR

SCS 38/16/16

M

A1-Inline

PK

tV

MIAMK1

PMI

tMI

tK

PS1

PS2

RPS2

tAU

700

UV

UV

2-5 Solaris V26

5

PZ

VS2

2 8

7 7

6

FLS

3

4

1

7

7

7

tS,R

tWW

tS

tS,V

WEx

SCS-TR

tK,H

ÜV

PK,H

ggfs.Rück-lauftemp.-anhebung

1000

tR

MBAB

A

MBAB

A

SV

010.

000

0319



1) The swimming pool is heated almost exclusively by means of the solar heating system. Approx. 1.0 kW heat can be transferred per Kelvin in the solar section of the storage cylinder above the swimming pool circuit.

!) The heat exchanger is manufactured from high-grade stainless steel (1.4404). If the swimming pool water is to be heated directly in the exchanger, the corrosion resistance must be checked on site. In case of doubt, the systems must be separated.

1) The swimming pool is heated almost exclusively by means of the solar heating system. Approx. 1.0 kW heat can be transferred per Kelvin in the lower section of the storage cylinder above the swimming pool circuit.

! The heat exchanger is manufactured of high-grade stainless steel (1.4404). If the swimming pool water is to be heated directly in the exchanger, the corrosion resistance must be checked on site. In case of doubt, the systems must be separated.

Fig. 7-4 Swimming pool heating combined with an SCS 538/16/16 1)

Fig. 7-5 Wood-fired boiler combined with storage cylinder and swimming pool heating 1) with an SCS 538/16/16

SCS 38/16/16

M

A1-Inline

PK

tV

MIAMK1

PMI

tMI

tK

PS1

PS2

RPS2

tAU

700

UV

2-5 Solaris V26

5

PZ

VS22

8

10

7

7

6

FLS

3

4

1

7

77

7

tS,R

tWW

tS

tS,V

PB

SBR

tB

1000

tR

MBAB

A

SV

010.

000

0315

10

PB

SBR

tB

010.

000

0353

SCS 38/16/16

M

A1-Inline

PK

tV

t1

M

BAB

A

MIAMK1

PMI

tMI

tK

PS1

PS2

RPS2

tAU

700

UV1

UV2

2-5 Solaris V26

5

PZ

VS

22

8

7

6

FLS

3

4

1

77 7

tS,R

tWW

tS

tS,V

1000

SV SC 38/0/0

7

M

AAB

B

WEx

T

TMV

PWEx

t2

tR

DTR



* Disconnecting the standard connection: 3-way reversing valve UV1 must be removed and then reconnected outside the device.

Fig. 7-6 Gas Solar Unit Standard (GSU)

Fig. 7-7 Wood-fired boiler combined with a Gas Solar Unit (GSU)

010.

000

0305

tAG

tKtMI

PMI

PZPK

tV

tR

tAUtS,V

2-5 Solaris V26M

MI AMK1

5

2

2

3 4SV

SV

VS

6

7 77A

7A 7A

7A

7

BAB

AM

FLS

UV1

PS2

tWW

tS

PS1

tS,R

RPS2

GSU

1

700

1000

8

010.

000

0323

tAGPZ

PK

tV

tR

tAU

t1

t2

tS,V

2-5 Solaris V26M

MI AMK1

2

2

34

SV

SV

VS

6

7

77

7

FLS

PS2

tWW

PWEx

tS

PS1

tS,R

RPS2

GSU SC 38/0/0

1

700

1000

8

UV1

UV2BAB

AM

DTR

tKtMI

PMI

5

WExTMV

T

BAB

AM



* Disconnecting the standard connection: 3-way reversing valve UV1 must be removed and then reconnected outside the device.

Fig. 7-8 Parallel connection of a Solaris (SCS 538/16/0) and a Gas Solar Unit (GSU) with increased proportion of solar heating

Fig. 7-9 Series connection for pre-heating with a Solaris (SCS 538/0/0) and a Gas Compact Unit (GCU)

tAG

2-5 Solaris V26

PZ

VS

SV

SCS 38/16/0

PS2

RPS2

1000

tS

PS1

tS,R

PK

tV

tR

tAU

3

4

SV

7

7

tWW

GSU

700

UV1

1

FLGFLG

tS,V FLS

7

2

2

77

7 6

8

9

9

9

010.

000

0329

tK

tMI

PMI

M

MIAMK1

5

BAB

AM

tAG

PZ

VS

SV2

SCS 38/0/0

tK

PS2

RPS2

1000

2-5 SolarisV26

tSPS1

tS,R

tV

tR

tAU

3

4

SV

7A

7A 7A7A

tWW

GCU

700

UV1

1

tS,VFLS

7

2

2

7

7

7A7A

7A

7A

68

BAB

AM

tMI

PMI

M

MIAMK1

5

010.

000

0333

PK



Fig. 7-10 Pressurised solar system with a Gas Solar Unit (GSU)

Fig. 7-11 E-Solar Unit Standard (ESU 9)

tAG

tKtMI

PMI

PZ

PK

tV

tR

tAU

tS,V

M

MI AMK15

2

2

3 4

SV

SV

VS

6

7

7

7

AAB

BM

FLS

UV1

tWW

tS

PS1

tS,R

RPS2*

GSU

1

700

1000

PWT

SV2

PS2

Drucksystem

* Solaris Regelungs-und PumpeneinheitRPS2 muss umge-baut werden:P ausbauen.

P kann als Solar-

kreispumpe einge-setzt werden.Sie wird elektrischparallel zur P

angeschlossen.

S2

S2

S1

010.

000

0331

010.

000

0303

tKtMI

PMI

PZPK

tV

tR

tAUtS,V

2-5 Solaris V26M

MI AMK15

2

2

34

SV

VS

6

7 7

7

FLSUV1

PS2

tWW

tS

PS1

tS,R

RPS2

ESU

1

700

1000

8

A

AB

BM



Abbreviation Meaning Order no.

SCS 538/16/0 Solaris Sanicube INOX (1 charging heat exchanger) 16 45 16

SCS 538/16/16 Solaris Sanicube INOX (2 charging heat exchangers) 16 45 17

RPS3 Solaris control & pump unit 16 41 05

Solaris V26 Solaris high-performance flat collector 16 43 00

FLS Solaris FlowSensor (flowrate and inflow temperature measurement) 16 41 07

FLG Solaris FlowGuard regulating valve with flow indicator 16 41 02

A1-Inline A1 BO 20i 15 48 10

A1 BO 27i 15 48 11

A1 BO 35i 15 48 12

A1 BG 25i 15 58 00

A1 BG 40i 15 58 01

GSU Gas Solar Unit 320 15 70 25

Gas Solar Unit 320 F 15 70 26

Gas Solar Unit U 520S 15 71 10

Gas Solar Unit 520S F 15 71 20

Gas Solar Unit 530S 15 71 21

Gas Solar Unit 530S F 15 71 23

Gas Solar Unit U 535 15 71 40

Gas Solar Unit 535 F 15 71 45

ESU E-Solar Unit ESU 9 15 70 50

AMK1 Mixer group for all ROTEX heating boilers 15 60 44

HEM1 Heating circuit extension module 15 60 61

KW Cold water

WW Hot water

tK Solaris collector temperature sensor

tS Solaris cylinder temperature sensor

tS, V Solaris inflow temperature sensor

tS, R Solaris return temperature sensor

tWW Storage cylinder temperature sensor for boiler control 15 60 63

tAU Outdoor temperature sensor for boiler control

tV Boiler temperature sensor (inflow)

tR Boiler temperature sensor (return flow)

tMi Mixer circuit temperature sensor for boiler control 15 60 62

MI Three-way mixer valve

3W-UV, UV2 Three-way valve 15 60 34

ÜV Overflow valve

VS Scalding protection (e.g. thermal mixer valve), on site

PS1 Solaris circulation pump

PS2 Solaris booster pump

PK Boiler circuit pump

PMi Mixer circuit pump

PZ Circulation pump

SCS-TR Thermostat 16 41 30



Tab. 7-1 Explanation of the abbreviations in the hydraulic diagrams

Connection of a pressurised collector systemIf the building situation does not permit mounting the collectors above the storage cylinder, or if the connecting pipe cannot be installed with a continuous gradient between solar panel and storage cylinder, the non-pressurised Solaris system cannot be used. A conventional pressurised collector system operated with antifreeze can be integrated in a ROTEX heating system with a Solaris Sanicube or the Gas Solar Unit as follows:

• Integrate the pressurised collector system by means of an external plate heat exchanger (Fig. 7-10).• Connect to the primary circuit of the pressurised collector system. • Connect the secondary circuit via the control and pump unit, and operate it without pressure. • As no great heights are involved in this case, the booster pump P2 can be removed from the RPS3, and used as a solar

circulation pump. For this, the booster pump must be connected in parallel with the circulation pump P1. • Operate the solar system with the Solaris control unit. For this, a collector temperature sensor with a Pt 1000 element is

required (can be ordered optionally).

Series connectionAs an alternative to the purely parallel collector installation described in this manual (also see Fig. 2-1), the collectors can also be mounted above each other. With such an arrangement, the collectors or solar panels must be connected in series (Fig. 7-12). Per additional row of collectors for the selected solar system, one package of series connectors CON RV ( 16 42 17) is required.

Fig. 7-12 Alternative collector arrangement

WExExternal heat generator (e.g. wood pellet boiler, other solid matter boiler, heat pump)

SC 538/0/0 Sanicube as storage cylinder for external heat exchanger 16 45 15

PWEx Pump for external heat exchanger circuit

tK,H Wood-fired boiler temperature sensor for SCS-TR

PWT Plate heat exchanger, on site

MV Two-way solenoid valve

PB Swimming pool circuit pump

tB Swimming pool temperature sensor

1 Collector connector2 Mounting rail3 Collector securing clip4 Solaris flat collector5 Return flow connection collector6 Inflow connection collector7 Collector sealing cap8 Roof penetration boxes for inflow/

return flow9 VA 18 Solar return flow pipe10 VA 15 Solar inflow pipe11 Collector series connector CON RV12 Solaris solar panel (2 x 2 collectors)

Abbreviation Meaning Order no.

8 x Technical data


8 Technical data Basic data

Tab. 8-2 Technical data of Solaris V26 flat collector

Tab. 8-3 Technical data of control and pump unit

Solaris collector V26A H26A V21A

Dimensions L x B x H 2000 x 1300 x 95 cm 2000 x 1300 x 95 cm 2000 x 1006 x 95 cm

Net surface area 2.60 m2 2.60 m2 2.00 m2

Aperture surface area 2.35 m2 2.35 m2 1.75 m2

Absorbing surface area 2.33 m2 2.33 m2 1.78 m2

Absorber Harp-shaped aluminium tube register with welded-on highly selective aluminium sheet.

Coating MIRO-THERM (absorption max. 96%)

Glazing Single pane safety glass, transmission approx. 92 %

Heat insulation Rock wool (collector base 50 mm, side components 20 mm)

Weight 41 kg 44 kg 34 kg

Water content 1.63 l 2.05 l 1.23 l

Max. standstill temperature 195 °C

The collector is permanently standstill proof and thermo-shock tested. Minimum collector yield above 525 kWh/m2 per year with 40 % cloud coverage (location Würzburg)

Control and pump unit RPS3

Dimensions W x D x H 280 x 280 x 1000 cm

Operating voltage 230 V/50 Hz

Circulation pump Grundfos UPS 15-65 CIL2

Max. electric power consumption of the pump

20-90 W (modulated)

Booster pump Grundfos UPS 15-65 CACAO

Control Digital temperature difference controller with plain text display

Max. electric power consumption of the control unit

2 W

Collector temperature sensor Pt 1000

Storage cylinder and return flow temperature sensor

PTC

Feed temperature and flow sensor

VFS 1-20

Fig. 8-13 Resistance trends for the Solaris sensor Fig. 8-14 Characteristics of the FlowSensor

8 x Technical data


Temperature sensorSolaris sensor Sensor type Measured temperature in °C

–20 –10 0 10 20 30 40 50 60 70 80 90 100 110 120Sensor resistance in Ohm according to standard or manufacturer's indications

TR, TS PTC 1386 1495 1630 1772 1922 2080 2245 2418 2598 2786 2982 3185 3396TK Pt 1000 922 961 1000 1039 1077 1116 1155 1194 1232 1270 1308 1347 1385 1423 1461FlowSensor Sensor voltage in V acc. to manufacturerTV (0.5–3.5 V) 0.5 0.80 1.10 1.40 1.70 2.00 2.30 2.60 2.90 3.20 3.50FlowrateSolaris sensor Sensor type Measured flow in l/min

FlowSensor0.0 2.0 4.0 6.0 8.0 10.0 12.0 14.0 16.0 18.0 20.0Sensor resistance in Ohm according to standard or manufacturer's indications

V (0.36–3.5 V) 0.36 0.67 0.99 1.30 1.62 1.93 2.24 2.56 2.87 3.19 3.50

Tab. 8-4 Table of the Solaris sensors

Fig. 8-15 Terminal assignment

CONF Programming connector for controlunit update

FLS Flow sensorTS Storage cylinder temperature sensor

TR Return flow temperature sensorTK Collector temperature sensorBSK Burner inhibit contact

P1/P2 Operation and booster pumpF1 FusePower Mains supply

Technical data of the E-Solar Unit, Gas Solar Unit, and Sanicube series are given in the ROTEX price list and the corresponding technical documents of the products.

9 x List of keywords


9 List of keywordsBBurner inhibit contact . . . . . . . . . . . . 46

CCollector temperature sensor

Installation . . . . . . . . . . . . . . . . . 33Common return flow pipe . . . . . . . . . 20Connecting pipe . . . . . . . . . . . . . . . . . 19Control and pump unit . . . . . . . . . . 9, 13

DDesign . . . . . . . . . . . . . . . . . . . . . . . . . 7Drilling template . . . . . . . . . . . . . . . . 13Dual clip . . . . . . . . . . . . . . . . . . . . . . 28

EElectronic control . . . . . . . . . . . . . . . . 8Equipotential bonding terminal . . . . . . 30

FFlow controller . . . . . . . . . . . . . . . . . . 9FlowGuard . . . . . . . . . . . . . . . . . . . . . 9FlowSensor . . . . . . . . . . . . . . . . . . . . . 9

Without . . . . . . . . . . . . . . . . . . . . 35H

Hot water storage tankTechnical data . . . . . . . . . . . . . . . 61

Hot water storage tanksSeveral . . . . . . . . . . . . . . . . . . . . 20

LLanguage selection . . . . . . . . . . . . . . 46Lubricant . . . . . . . . . . . . . . . . . . . . . . 28

MMethod of operation . . . . . . . . . . . . . . 8Mounting rails

Installation . . . . . . . . . . . . . . . . . 25N

Noise problems . . . . . . . . . . . . . . . . . 46O

On-roof mounting . . . . . . . . . . . . . . . 23P

Password . . . . . . . . . . . . . . . . . . . . . 45Expert . . . . . . . . . . . . . . . . . . . . . 45Operator . . . . . . . . . . . . . . . . . . . 45

Product description . . . . . . . . . . . . . . . 7Pump speed control

Manual . . . . . . . . . . . . . . . . . . . . 46R

Roof penetration box . . . . . . . . . . . . . 31Roof space

Necessary . . . . . . . . . . . . . . . . . . 25Roof tie

Installation . . . . . . . . . . . . . . . . . 25ROTEX . . . . . . . . . . . . . . . . . . . . . . . . 1

SSealing plug . . . . . . . . . . . . . . . . . . . 28Sensor correcting value . . . . . . . . . . 46Setting ranges

Recommended . . . . . . . . . . . . . . . 47Speed control

Automatic . . . . . . . . . . . . . . . . . . 15Standard parameter values . . . . . . . . 47Storage cylinder . . . . . . . . . . . . . . . . . .8Storage cylinder temperature sensor . 18Supporting structure . . . . . . . . . . 23, 27System concepts . . . . . . . . . . . . . . . 12

TTool

Pump unit . . . . . . . . . . . . . . . . . . 14Roof mounting . . . . . . . . . . . . . . 25

FA ROTEX Solaris - 07/2007

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FA solaris panel solar

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Transcript of FA solaris panel solar