Anda di halaman 1dari 64

For specialist technical operation

ROTEX Solaris
Solar 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

GB
Issue 07/2007

Guarantee
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.

FA ROTEX Solaris - 07/2007

Contents
1

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1
1.2
1.3
1.4
1.5

Refer to the manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Warning signs and explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Danger prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instructions for working safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1
Design and components of the Solaris system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2
Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12
13
13
17
18
19
19
20
21
22
23
27
27
27
28
30
30
33
34
34

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.1
4.2

7
8
9
9
9
9

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1
System concepts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2
Installing the control and pump unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1
Mounting the pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2
Installing the sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.3
Installing the cylinder temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3
Installing the connecting pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.1
Fitting the connecting pipe to the collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.2
Connect several Sanicube hot water storage tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.3
Installing the common return flow pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4
Installing the collector components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.1
Installing the supporting structure for subsequent installation on the roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.2
Installing the supporting structure for subsequent installation on a flat roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.3
Installing the supporting structure for subsequent in-roof installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.4
Installing the first collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.5
Installing the other collectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.6
Installing the equipotential bonding terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.7
Running the connecting pipes and the collector temperature sensor cable through the roof . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.8
Installing the collector temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.9
Uninstalling the collectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.10 Additional notes about connecting pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5
5
6
6
6

Operating Solaris systems without a FlowSensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35


Operation of Solaris systems with a FlowSensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.1
Operating and display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2
Controller operating principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1
Pump operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2
Booster function for high collector temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3
Switch-on inhibit function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.4
Pump kick function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.5
Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.6
Solaris FlowSensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.7
Output calculation, maximum values, and yield count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.8
Speed control of circulation pump P1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.9
Overall reset function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.10 Frost protection function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.11 System leakage protection function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FA ROTEX Solaris - 07/2007

38
38
38
39
39
39
39
40
40
40
41
41
41

Contents
5.3
Adjustments and menu guidance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.3.1
Display during start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.3.2
Display during operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.3.3
Setup menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.3.4
Password protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.3.5
Language selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.3.6
Adjusting and resetting parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.3.7
Burner inhibit contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.3.8
Manual adjustment of pump speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.3.9
Correcting values for measurement points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.4
Recommended settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.4.1
Standard parameter values, recommended adjustment ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.4.2
Other adjustments of your Solaris system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.4.3
Recommended settings for auxiliary heating via external heat sources or the electric heater, burner inhibit contact . . . . . . . . . . 48
5.4.4
Tips for optimised user behaviour. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.4.5
Domestic water hygiene. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Faults and disturbances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50


6.1
6.2

Display of events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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

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

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

FA ROTEX Solaris - 07/2007

1 x Safety
11.1

Safety to the manual


Refer

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 documents
The 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 warnings
The warnings are classified in this manual according to their severity and probability of occurrence.
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.

Special warning signs


Some types of danger are indicated by special warning signs.
Risk of burning or scalding.

Electric power

Order number
Notes 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.

FA ROTEX Solaris - 07/2007

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

1.3

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

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.

FA ROTEX Solaris - 07/2007

2 x Product description
22.1

Product
Designdescription
and components

of the Solaris system

II gleichseitiger Anschluss - 2 oder maximal 3 Kollektoren


(nur bei Aufdach- und Flachdachmontage)

10

TK

11

I wechselseitiger Anschluss - 2 bis 5 Kollektoren

10

TK

0,5 %

>2%
9

11

11

12
2
12
M

FLS

12 m

6
FLS
TV

13
20

3
4
16

14
PS2

14

3
4
16

15

18
TR

RPS 2

PS2

19

PS1

TS

RPS 2

15

TV

20

5
A

13

19

PS1

TS

18
TR

17

17
SCS

GSU

Das gezeigte Anlagenschema erhebt keinen Anspruch auf Vollstndigkeit und ersetzt nicht die sorgfltige Anlagenplanung. nderung und Irrtum vorbehalten!

Fig. 2-1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Standard design of a ROTEX Solaris system (ROTEX recommends a two-way connection)

Cold water connection pipe


Drinking water (hot) distributor
Stainless steel corrugated pipe heat exchanger for drinking water (hot)
Stainless steel corrugated pipe heat exchanger for generating heat
(storage cylinder charging)
Well for storage cylinder temperature sensor
Fill level display
Filling and draining cock
Solaris R3 differential temperature control
Solar return flow pipe (at the bottom of the collector/VA 18 Solar)
Solaris solar panel
Solar inflow pipe (at the top of the collector/VA 15 Solar)
Thermal mixer valve (prevents scalding; installed by the customer)
Anti-siphon valve
Solaris inflow multilayer pipe
Stainless steel corrugated pipe heat exchanger for heating support
Insulating hose sleeve for stainless steel corrugated pipe heat exchanger for
heating support

FA ROTEX Solaris - 07/2007

17
18
19
20

Solaris return flow connection


Well for Solaris return flow temperature sensor
Equipotential bonding terminal cable connection (with valve attachment) for
storage cylinder extension
Safety overflow connection

A
Area with water for domestic use
B
Solar area
C
Heating support area
TR Solaris return flow temperature sensor
TS Solaris storage cylinder temperature sensor
TK Solaris collector temperature sensor
TV Solaris inflow temperature sensor
RPS3 Control and pump unit
FLS Solaris flow sensor (flow rate measurement) or Solaris FlowGuard
(flow rate setting)
PS1 Solaris circulation pump
PS2 Booster pump

2 x Product description
2.2

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

Method of operation
The 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 design
The system consists of several pre-assembled modules. Plug-in technology and a high degree of pre-assembly ensure fast and
simple system installation.

Storage cylinder
The 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.
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.

Electronic control
The 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.

FA ROTEX Solaris - 07/2007

2 x Product description
2.3

System components
2.3.1 Control and pump unit

Fig. 2-2
Scope of supply for pump and control unit (RPS3) (
16 41 06)
1
Cover
2
Connection pipe with circulation pump, booster pump, filling and draining cock
3
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

2.3.2 Optional FlowGuard flow controller and FlowSensor

Fig. 2-3
1
2

Flow controller and flow sensor (scope of supply)

FlowGuard (
16 427)
FlowGuard seal

3
4

FlowSensor (
16 41 07)
FlowSensor seal

2.3.3 Collector accessories


CON A and CON R

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) (
Red connection pipe (CON R) (

FA ROTEX Solaris - 07/2007

16 42 11)

16 42 12)

Fig. 2-4

CON A and CON R (optional)

2 x Product description
CON F

Solaris connection pipe (


flat roof installation

16 47 13) for
Fig. 2-5

CON F (optional)

Fig. 2-6

CON I (optional)

Fig. 2-7

CON SX (optional)

Fig. 2-8

Collector mounting rails

CON I

Solaris connection pipe (


in-roof installation

16 46 10) for

CON SX

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.

Collector mounting rails

FIX-100 (
16 42 24):
Two mounting rails for a V21A collector
FIX-130 (
16 42 25):
Two mounting rails for a V26A collector
FIX-200 (
16 42 26):
Two mounting rails for one H26A collector
or two V21A collectors
FIX-260 (
16 42 27):
Two mounting rails for two V26A collectors

10

FA ROTEX Solaris - 07/2007

2 x Product description
Rail connector FIX-VB

Profile connector (
mounting rails:

16 42 22) for connecting the

Splicing plate (2x)


Allen wrench
Fixing screws (4x)

Fig. 2-9

Rail connector FIX-VB

Solaris flat collectors V21A, V26A and H26A

V21A collector (
16 43 06):
H x B x T: 2000 x 1006 x 95 mm, weight: approx. 34 kg
V26A collector (
16 43 04):
H x B x T: 2000 x 1300 x 95 mm, weight: approx. 41 kg
H26A 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)

CON V

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

Fig. 2-12

On-roof mounting brackets FIX-AD

FIX-AD

Kit for installing a collector on a roof (


Roof ties (4x)
Wood screws ( 8 x 6 mm, 8x)

FA ROTEX Solaris - 07/2007

16 47 00)

11

3 x Installation
33.1

Installation concepts
System

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

12

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)

FA ROTEX Solaris - 07/2007

3 x Installation
3.2

Installing the control and pump unit


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 ( 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

3.2.1 Mounting the pump unit

Fig. 3-7

Working step 1

Fig. 3-8

Working step 2

Fig. 3-9

Working step 3

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.

FA ROTEX Solaris - 07/2007

13

3 x Installation

Fig. 3-10

Working step 6

Fig. 3-11

Working step 6

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.

Fig. 3-12

Working step 7

Fig. 3-13

Working step 8

Fig. 3-14

Working step 9

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 ( 22/ 18).

Fig. 3-15

Working step 10

Fig. 3-16

Working step 11

Fig. 3-17

Working step 12

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.

14

FA ROTEX Solaris - 07/2007

3 x Installation

Fig. 3-18

Working step 13

Fig. 3-19

Working step 14

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

Fig. 3-20 Terminal assignment


CONF Programming connector for control TR
unit update
TK
FLS
Flow sensor
BSK
TS
Storage cylinder temperature sensor

Return flow temperature sensor


Collector temperature sensor
Burner inhibit contact

P1/P2 Circulation and booster pump


F1
Fuse
Power Mains supply

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. 3-21

Working step 1

Fig. 3-22

Working step 2

Fig. 3-23

Working step 3

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 %.

FA ROTEX Solaris - 07/2007

15

3 x Installation

Fig. 3-24

Basic wiring: Sensors for storage cylinder,


return flow, and collector, pump supply, mains supply

Fig. 3-25

Additional cable of FlowSensor

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.

Fig. 3-26

Working step 4

Fig. 3-27

Working step 5

Fig. 3-28

Working step 6

Fig. 3-30

Working step 2

Fig. 3-31

Working step 3

Fitting the silencer hood

Fig. 3-29

16

Working step 1

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.

FA ROTEX Solaris - 07/2007

3 x Installation

Fig. 3-32

Completely installed RPS3

3.2.2 Installing the sensors


Note the direction of flow when installing the FlowSensor.

FlowSensor
The 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 pushin 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. 3-33

FA ROTEX Solaris - 07/2007

Working step 1

Fig. 3-34

Working step 2

Fig. 3-35

Optional FlowSensor is supplied


with 3 m long cable

17

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.

Fig. 3-36

Working steps 1 + 2

Fig. 3-37

Optional FlowGuard

3.2.3 Installing the cylinder temperature sensor


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

Fig. 3-39

Working steps 2 + 3

Fig. 3-40

Working steps 2 + 3

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. 3-41

18

Working step 1

Working step 4

FA ROTEX Solaris - 07/2007

3 x Installation
3.3

Installing the connecting pipes


3.3.1 Fitting the connecting pipe to the collector
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.
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).

Fig. 3-42

FA ROTEX Solaris - 07/2007

Mark the connecting pipe

Fig. 3-43

Shorten it to length

Fig. 3-44

Push the fitting onto the


coupling

19

3 x Installation
3.3.2 Connect several Sanicube hot water storage tanks
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.
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 (
and pump unit RPS3 (Figure 3-45).

16 01 07), 2 Solaris Sanicubes can be connected per control

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.

1
2
3
4
5
6
7
8

Sanicube Solaris
Non-pressurised area
Solar panel
Control and pump unit RPS3
Return flow connection pipe
(non-pressurised area)
Solaris inflow distributor
Solaris return flow pipe
Solaris inflow pipe

H Difference in level in non-pressurised

storage cylinder area


FLS Flow sensor
FLG FlowGuard
Fig. 3-45

20

Operating principle of the common return flow pipe

FA ROTEX Solaris - 07/2007

3 x Installation
3.3.3 Installing the common return flow pipe
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).
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.

13
10

12

11

Fig. 3-46

FA ROTEX Solaris - 07/2007

Installing the inflow distribution pipe (top)

21

3 x Installation

Fig. 3-47

3.4

Cylinder extension (lower connecting pipe)

Installing the collector components


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.

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.

22

FA ROTEX Solaris - 07/2007

3 x Installation
3.4.1 Installing the supporting structure for subsequent installation on the roof
Instead of the mounting kit FIX-AD, the roof fixtures FIX-WD (
and the fixtures FIX-BD (
16 47 04) for trapezoidal roofs.

16 47 03) are used for corrugated roofs,

Main dimensions of Solaris solar panel for on-roof mounting


Number of collectors
Measurement
Width of solar panel

1
Dim.
V21A
V26A
H26A

Distance from roof penetration box


Height of solar panel

H0
V21A
V26A
H26A

Distance from lower collector edge to lower mounting


rail
Spacing of the mounting rails

V21A
V26A
H26A

Distance from lower collector edge to lower edge of


the perforated plate of
roof mounting bracket
Max. distance from edge of solar panel to the first
roof mounting bracket
Spacing of the roof mounting brackets of a collector

V21A
V26A
H26A

Spacing of roof mounting brackets between two


collectors
Distance between solar panel and the first collector
securing clip
Spacing of the securing clips of a collector

V21A
V26A
H26A

Spacing of the securing clips between two collectors


Distance from collector edge to pipe coupling
Centre-to-centre distance of the collector couplings

FA ROTEX Solaris - 07/2007

h1

V21A
V26A
H26A

1100
1370
2150

Y0

230

Y1

1400 to 1600
1400 to 1600
800 to 1000

Y2

260 to 290

X0

450

X1

400 to 1000
400 to 1000

X2

300 to 900

A0

100 to 300

A1
A2
E0

Upper collector edge to collector sensor connection


Tab. 3-1

2
3
4
Dimensions in mm
2150
3250
4300
2740
4110
5480
4300
6450

300 to 700
2000
2000
1303

E1
F

5
5400
6850

800 to 1100
800 to 1100
120 to 1800
200 to 600
70
1884
1884
1187
175

Main dimensions of Solaris solar panel for on-roof mounting

23

3 x Installation

Fig. 3-48
1
2
3

Roof mounting bracket


Mounting rail
Collector securing clip

Fig. 3-49

24

Main dimensions of a Solaris solar panel for on-roof mounting (example shows V26A collectors)
4
5
6

Solaris V26 flat collector


Return flow connection pipe
Inflow connection pipe

7
8

Collector drain plug


Universal roof penetration boxes

Side view of Solaris collector mounted on a roof

FA ROTEX Solaris - 07/2007

3 x Installation
Installing the roof brackets and mounting rails
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.
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.
As the mounting rails will have to be separated again before final installation, only one splicing plate is required
for this step.

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.

geplante
Kollektorunterkante

Y2

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.
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).

FA ROTEX Solaris - 07/2007

25

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

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).

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

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).

Fig. 3-56

Mark the exit position of the


Fig. 3-57
mounting bracket on the roof tile

Remove the lower roof tile web

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.
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.

26

FA ROTEX Solaris - 07/2007

3 x Installation

Fig. 3-58

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

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.
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.

4.

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

Fig. 3-59

FA ROTEX Solaris - 07/2007

Inserting the collector


securing clips

Fig. 3-60

Positioning the collector


securing clips

Fig. 3-61

Lowering and aligning the


collector

27

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.

Fig. 3-62

Correct mounting position

Fig. 3-63

Securing the equipotential


bonding terminal

Fig. 3-64

Clip with equipotential bonding


connection

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).
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.

3.

Mount the fitting (Figure 3-67).

Fig. 3-65

28

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

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).

FA ROTEX Solaris - 07/2007

3 x Installation

Fig. 3-68

7.

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

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.
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.

8.

Tighten the dual clip (Figure 3-72).

9.

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

Fig. 3-71

FA ROTEX Solaris - 07/2007

Push collectors together

Fig. 3-72

Tightening the dual clip

29

3 x Installation
3.4.6 Installing the equipotential bonding terminal
WARNING!
The equipotential bonding terminal is not a substitute for a lightning rod. It is merely intended to protect the
collector temperature sensor.
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.
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

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

Number of collectors
2
3
4
5

Pipe extension kits CON X 25 (2.5 m), CON X 50 (5 m) and


CON X 100 (10 m) are available.
Tab. 3-2

30

Max. possible total length


of pipe
45 m
30 m
17 m
15 m

Lengthening options with CON X connection pipes

FA ROTEX Solaris - 07/2007

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).
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.

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).

Fig. 3-75

Shorten the plastic connecting


pipe to the required length

Fig. 3-76

Run the pipe and the cable


Fig. 3-77
through the roof penetration box

Install the roof penetration box

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).

FA ROTEX Solaris - 07/2007

31

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).
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.

8.

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

Fig. 3-78

9.

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

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).

Fig. 3-81

32

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

FA ROTEX Solaris - 07/2007

3 x Installation
3.4.8 Installing the collector temperature sensor
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.
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.
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 spiral drill.

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:
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

FA ROTEX Solaris - 07/2007

Cutting off the well cover

Fig. 3-85

Inserting the temperature sensor Fig. 3-86


up to the specified depth in the
well

Secure the sensor cable with


cable ties

33

3 x Installation
3.4.9 Uninstalling the collectors
CAUTION:
Danger of burns from hot collector couplings and hot collector frame.
Do not touch hot parts.
Wear protective gloves.
If the collectors are to be separated, the fittings or the end cap must be removed as follows:

Fig. 3-87

Clip the removal tool behind the fitting

Fig. 3-88

Pull the fitting off the collector

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.

34

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.

FA ROTEX Solaris - 07/2007

4 x Commissioning
4

Start-up

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

7.

Switch off the Solaris control unit.

8.

Check the filling level in the Solaris Sanicube.


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.

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.

FA ROTEX Solaris - 07/2007

35

4 x Commissioning
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).
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.
Number of collectors

Desired flow in l/min

Desired flow in l/min

3.0 to 4.0

180 to 240

4.5 to 6.0

270 to 360

6.0 to 8.0

360 to 480

7.5 to 10.0

450 to 600

Tab. 4-3

Reference values for adjusting the flow on systems without a FlowSensor

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).

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.


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.

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.

36

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.
FA ROTEX Solaris - 07/2007

4 x Commissioning
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).
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.

FA ROTEX Solaris - 07/2007

37

5 x Control unit operation


55.1

Control
Operating
and display elements

1
2

3
4
5
6
7

Main switch with indicator light


8
Display for showing temperature and
parameters (energy saving function:
Display illumination is switched
off 10 minutes after the last key
9
actuation)
Light for collector temperature display
Light for Solaris inflow temperature
and flow measurement display (FLS)
10
Light for storage cylinder temperature
display
Light for solar return flow temperature
display
Operating condition light for speedcontrolled circulation pump P1
(lights up when pump is operating)

Fig. 5-1

5.2

Operating condition light for booster


11
pump P2 (lights up when pump is
operating; flashes when pump is
throttled)
Up arrow for moving the temperature
or parameter display up by one
12
setting/increasing parameter
13
settings
Down arrow for moving the
temperature or parameter display down
by one setting/decreasing parameter
settings

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
Controller housing
Housing locking screws (device may only
be opened by an authorised specialist.
Disconnect from mains supply before
opening the housing).

Operating and display elements

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.

38

FA ROTEX Solaris - 07/2007

5 x Control unit operation


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.
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.

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.
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".

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

FA ROTEX Solaris - 07/2007

39

5 x Control unit operation


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


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.
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.

TK
DT
S1
S1

Collector temperature
Temperature difference (difference between Solaris inflow and
return flow temperature)
Upper set temperature difference ("temperature difference 1")
Lower set temperature difference ("temperature difference 2")

Fig. 5-2

40

T1
T2
T3

---

Frost protection temperature ("TR frost")


Booster temperature ("TK max")
Switch-on inhibit temperature ("TK perm")
Set value for temperature difference
Switching limits for pump modulation

Pump output control as a function of temperature difference

FA ROTEX Solaris - 07/2007

5 x Control unit operation

t
V
A
B
C
D

Time
Solar circuit flow
Start phase
Operating phase (modulation)
Interrupted flow
Low pump output stages are automatically disabled
when flow is interrupted

Fig. 5-3

V1
V2
t1
t2
t3

Minimum flow in start phase ("VS min")


Minimum flow in operating phase ("S flow")
Maximum starting time of booster pump P2
("Time P2")
Stabilisation period ("S time")
Interruption detection period (10 s)

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.

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41

5 x Control unit operation


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.
Measurement

Display
Collector temperature
Return flow temperature
Storage cylinder temperature
Inflow temperature
Flow

tK
tR
tS
tV
V
Tab. 5-1

Name

Measuring
range
30 to 250 C
0 to 100 C
0 to 100 C
0 to 100 C
0.0 to 20.0 l/min

Resolution

1K
1K
1K
1K
0.1 l/min

Pt 1000 temperature sensor


PTC temperature sensor
PTC temperature sensor
FlowSensor with 0.53.5 V output signal
FlowSensor with 0.53.5 V output signal

Overview of measurement points

Parameter

V max

Name
Max. measured collector
temperature
Min. measured collector
temperature
Maximum flow

PS

Peak output

0.0 and 99.9 kW

0.1 kW

PS (15h)

Peak value of the day

0.0 and 99.9 kW

0.1 kW

W (15h)

Heat yield of the day

0.0 and 999.9 kW

0.1 kWh

Total heat yield

Instantaneous output
Set-value for temperature
difference
Present output stage of P1
Smallest enabled output
stage of P1
Runtime of circulation
pump P1

0.0 to 9999.9 kW
or 10,000
to 99,999 kW
0.0 and 99.9 kW

0.1 kWh

TK max
TK min

DT
P1
Min. stage
Stage "On"
Tab. 5-2

Sensor

Value range

Resolution

Remark

30 to 250 C

1K

none

30 to 250 C

1K

none

0.0 to 20.0 l/min

0.1 l/min

Maximum flow measured during filling


Maximum mean value determined during
5 minutes
Maximum peak value during the last
15 hours
Heat yield calculated from instantaneous
output during the last 15 hours

1 to 15 K
0 to 100
0 to 10
0 to 100
0 to 99999h

Total solar heat yield calculated from


instantaneous output

0.0001 MWh
0.1 kW
Mean value during the last minute
Set-value for temperature difference TVTR
1K
during modulated operation
1%
none
Only accessible for an expert
1; 1 %
(see Figure 5-6)
Only accessible for an expert
1h
(see Figure 5-6)

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).

42

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5 x Control unit operation


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.
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

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.

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43

5 x Control unit operation

Fig. 5-6

44

Setup menu

FA ROTEX Solaris - 07/2007

5 x Control unit operation


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 password
When 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 password
The 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).
Parameter
Delta T On
Delta T Off
TS max
Time P2

TK perm
TR frost
H/A
FLS enabled
P min

Cycle
Bit rate
Tab. 5-3

FA ROTEX Solaris - 07/2007

Switch-on temperature
difference
Switch-off temperature
difference
Max. storage cylinder
temperature

Access level

Operator

Max. filling time

TK max

TS min

Name

Booster temperature
(max. collector temperature)
Switch-on inhibit temperature
(max. permissible collector
temp.)
Frost protection temperature
Automatic return from manual
to automatic operation
FlowSensor activation
Min. output for burner stop
Min. temperature for
burner stop
Cycle for data output (serial
interface RS 232)
Transmission speed of data
output

Expert

Setting range Recommended


setting
1...80
10 to 15 K
(>"Delta Off"
1...20
2 to 5 K
(<"Delta On"

Factory
setting

Step
width

15 K

1K

2K

1K

20 to 85 C

75 to 85 C

80 C

1K

10 to 999 K

Filling time
+20 s

150 s

1s

20 to 110 C

80 C

1K

90 to 50 C

95 C

1K

10 to 60 C

25 C

1K

1 to 900 l/min

30 min

1 min

Yes/No
0.0 and 99.9 kW

Yes

Yes
99.9 kW

0.1 kW

0 to 99 C

99 C

1K

0 to 300 K

5s

2400, 4800,
9600, 19200

19200

Overview of parameters

45

5 x Control unit operation


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.
Name

Measurement &
adjusting range

Factory setting

Step width

Collector temperature correction

9 to +9

0K

1K

Return flow temperature correction

9 to +9

0K

1K

9 to +9

0K

1K

Inflow temperature correction

9 to +9

0K

1K

Flow correction

2 to +2

0 l/min

1 l/min

Storage cylinder temperature


correction

Tab. 5-4

46

Access level

Expert

Correcting values

FA ROTEX Solaris - 07/2007

5 x Control unit operation


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.
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.
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.
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.
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


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.
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.

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47

5 x Control unit operation


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.
Number of collectors
2
3
4
5
Tab. 5-5

Desired flow in l/min


3.0 to 4.0
4.5 to 6.0
6.0 to 8.0
7.5 to 10.0

Desired flow in l/min


180 to 240
270 to 360
360 to 480
450 to 600

Adjusting the flowrate of the FlowGuard (FLG)

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.

5.4.3 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.

48

FA ROTEX Solaris - 07/2007

5 x Control unit operation


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 57 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).

FA ROTEX Solaris - 07/2007

49

6 x Faults and disturbances


66.1

x Faults andof
disturbances
Display
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.
Event
code

Plain text
display

Collector

Description

Status
display
(blinks)

Lamp
(blinks)

TK

TR

Storage cylinder sensor: Short-circuited or


open

TS

Collector sensor: Short-circuited or open

Return flow Return flow sensor: Short-circuited or open

Storage
cylinder

Flow

FlowSensor Short-circuited or open

Inflow

FlowSensor Short-circuited or open

A/D

Internal A/D converter fault

Supply

Internal supply voltage fault

7
8
12

Reference Internal reference voltage fault


Reset

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

Operation without FlowSensor

Permanent switch-off of P1 and P2


Parameters are set to default (factory) values,
system restart
TV
Permanent switch-off of P1 and P2

13

TS > Tmax -Max. storage cylinder temp. ("TS max")


exceeded Description Item 1

TS

14

TR >> TS TR - TS > 10 K and TR > 40 C


Description Item 2

TR

TK > TK Max. permissible collector temperature


perm
("TK perm") exceeded Description Item 3

16

Interrupt

Tab. 6-1

Interrupted flow detected during operating


phase (V < "S-Flow")

Permanent switch-off of P1 and P2

Overall reset was carried out

15

Consequence

Temporary switch-off of P1 and P2

TK
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.

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.

50

FA ROTEX Solaris - 07/2007

6 x Faults and disturbances


Sensor

Cause of the Status (blinks)


fault
Interruption

Collector temp.

Short circuit

Return flow temp.

Interruption

Short circuit
S

Lamp (blinks)

uuuu

TK

TK

uuuu

TR

TR

uuuu

TS

TS

Storage cylinder
temp.

Interruption

Inflow temp.

Voltage drop

Without lamp

FlowSensor

Voltage drop

Without lamp

Tab. 6-2

6.2

Display

Short circuit

Consequence

Permanent switch-off of P1 and P2

Operation without FlowSensor

Table of sensor faults

Troubleshooting
Operational events that are similar to faults
The 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.
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.
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.

Disturbances
Return 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).

FA ROTEX Solaris - 07/2007

51

6 x Faults and disturbances


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


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.
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.

52

FA ROTEX Solaris - 07/2007

7 x Hydraulic system integration


7

Hydraulic system integration

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.

tK

2-5

Sol

aris

tMi

Mi
M

PZ

PMi

AMK1

8
VS

4
tAU

V26

FLS
7

tS,V

1
tV
UV

RPS2

SV
PK

tR

tWW

PS2

tS

PS1

7
A1-Inline

Fig. 7-1
1)
2)

FA ROTEX Solaris - 07/2007

SCS 38/16/0

tS,R

010.000 0302

700

B
A

1000

AB

Standard Solaris installation with SCS 538/16/0 1) 2)

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.
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.

53

7 x Hydraulic system integration


tK

tMI

PMI
MI

aris

FLS

tS,V

RPS2

700

AB

tAU

UV1

1000

V26

VS

tV

Sol
8

AMK1

2-5

PZ

PK t
1

t2

tWW

PS2

TMV

AB
A

tR

PS1

UV2

SV

DTR

WEx

tS,R

SCS 38/16/0

PWEx

SC 38/0/0

010.000 0352

A1-Inline

tS

Fig. 7-2

Wood-fired boiler combined with a standard Solaris system via a storage cylinder

tK
5

2-5

Sol

aris

tMI
PMI

PZ

AMK1

VS

7
4

tAU

FLS
7

ggfs.Rcklauftemp.anhebung

tV
M

UV

SCS-TR
PK,H

PK

AB

tR

UV
B

54

tS

PS1

SV
SCS 38/16/16
7

2)

PS2

A1-Inline

1)

tWW

tK,H

WEx

Fig. 7-3

RPS2

700

B
A

1000

AB

tS,V

tS,R

010.000 0319

MI

V26

Wood-fired boiler combined with an SCS 58/16/16 1) 2)

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.
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.

FA ROTEX Solaris - 07/2007

7 x Hydraulic system integration


tK

2-5

tMI

Sol

aris

PMI
MI
M

PZ

AMK1

2
VS
FLS

tAU

V26

10

tS,V

AB

M
A

UV

RPS2

SV
PK

tWW

PS2

tS

PS1

tR

tB

SBR

A1-Inline

1)

010.000 0315

Fig. 7-4

PB

1000

700

tV

tS,R

SCS 38/16/16

Swimming pool heating combined with an SCS 538/16/16 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.

!)

tK

tMI

PMI

PZ

2-5

aris

VS

MI

AMK1

Sol
8

V26
PB

7
4
7

tAU

FLS
7

10

tS,V
tB

AB

RPS2

700

tV

UV1

SBR

1000

PK t
1

t2

tWW

PS2

TMV

AB
A

tR

PS1

UV2

SV

DTR

SCS 38/16/16

tS,R

WEx
SC 38/0/0

Fig. 7-5
1)

FA ROTEX Solaris - 07/2007

PWEx
010.000 0353

A1-Inline

tS

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

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.

55

7 x Hydraulic system integration


tK

tMI
5

PMI
MI

2-5

Sol

aris

AMK1

8
3
7A

tAG

SV

VS

UV1

tV
AB

PZ
2

M
A

7A

7A

PK

V26

7A

FLS
tS,V

tAU

tR

1000

700

SV

tWW
PS2
tS

RPS2

010.000 0305

PS1
7
tS,R
GSU

Fig. 7-6

Gas Solar Unit Standard (GSU)

tK

tMI

2-5

PMI
MI

AMK1

2
2

Sol

aris

V26

3
SV

PZ

VS

tAG

AB

tV

7
6

SV

1000

UV2

t1

M
A

B
A

UV1

FLS

PK

tS,V

tAU

DTR

tR
t2

700

AB

tWW

TMV
PS2

tS

WEx

RPS2

7
PWEx
GSU

Fig. 7-7

tS,R

SC 38/0/0

010.000 0323

PS1

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

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

56

FA ROTEX Solaris - 07/2007

7 x Hydraulic system integration


tK

5
tMI

olaris

2-5 S

PMI
M

FLS

9
7

tAG

tS,V

MI

AMK1

VS

SV
AB

M
A

tV

UV1

8
PZ
7

PK

V26

FLG
tR

tAU

6
7

FLG

700

1
SV

1000

tWW
PS2
RPS2

tS

7
010.000 0329

PS1

tS,R
SCS 38/16/0

GSU

Fig. 7-8

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

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

tK

PZ

tMI
PMI
MI

AMK1

ola

S
2-5

26
is V
7

VS

8
3
tAG

7A

M
A

PK

7A

7A

tV
AB

7A

SV

UV1
tS,V FLS
7A

tAU
tR

7A
7A

7A

1000

700

tWW

SV2

PS2
RPS2

7
tS,R
GCU

Fig. 7-9

FA ROTEX Solaris - 07/2007

SCS 38/0/0

010.000 0333

tS

PS1

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

57

7 x Hydraulic system integration


tK

tMI

Dru

cks

PMI
MI

yst

AMK1

em

PWT

SV2

tAU

SV

PZ
7

PS2

VS

tAG

UV1

tV
A

AB

FLS
tS,V

PK

tR

SV

700

1000

tWW
tS

* Solaris Regelungsund Pumpeneinheit


RPS2 muss umgebaut werden:
PS2 ausbauen.
PS2 kann als Solarkreispumpe eingesetzt werden.
Sie wird elektrisch
parallel zur PS1
RPS2* angeschlossen.
010.000 0331

PS1
tS,R

7
GSU

Fig. 7-10

Pressurised solar system with a Gas Solar Unit (GSU)

tMI

tK
2-5

PMI
MI

AMK1

aris

VS

PZ

V26

2
2

Sol

UV1

AB

tV

tR
PK

FLS
tS,V

tAU

SV

700

1000

tWW
PS2
tS

RPS2
tS,R

7
ESU

Fig. 7-11

58

010.000 0303

PS1

E-Solar Unit Standard (ESU 9)

FA ROTEX Solaris - 07/2007

7 x Hydraulic system integration


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

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

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

MI

Three-way mixer valve

3W-UV, UV2

Three-way valve

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

GSU

FA ROTEX Solaris - 07/2007

15 60 63

15 60 62
15 60 34

16 41 30
59

7 x Hydraulic system integration


Abbreviation

Meaning

WEx

External 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

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

Tab. 7-1

Order no.

16 45 15

Explanation of the abbreviations in the hydraulic diagrams

Connection of a pressurised collector system


If 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 connection
As 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.

1
2
3
4
5
6
7
8
9
10
11
12
Fig. 7-12

60

Collector connector
Mounting rail
Collector securing clip
Solaris flat collector
Return flow connection collector
Inflow connection collector
Collector sealing cap
Roof penetration boxes for inflow/
return flow
VA 18 Solar return flow pipe
VA 15 Solar inflow pipe
Collector series connector CON RV
Solaris solar panel (2 x 2 collectors)

Alternative collector arrangement

FA ROTEX Solaris - 07/2007

8 x Technical data
8

Technical data

Basic data
Solaris collector

V26A

H26A

V21A

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

Dimensions L x B x H

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 Wrzburg)
Tab. 8-2

Technical data of Solaris V26 flat collector

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
Control

Grundfos UPS 15-65 CACAO


Digital temperature difference controller with plain text display

Max. electric power


consumption of the control
unit
Collector temperature sensor

Pt 1000

Storage cylinder and return


flow temperature sensor

PTC

Feed temperature and flow


sensor

VFS 1-20

Tab. 8-3

Fig. 8-13

2W

Technical data of control and pump unit

Resistance trends for the Solaris sensor

FA ROTEX Solaris - 07/2007

Fig. 8-14

Characteristics of the FlowSensor

61

8 x Technical data
Temperature sensor
Solaris sensor Sensor type

TR, TS
TK
FlowSensor
TV
Flowrate
Solaris sensor
FlowSensor
V
Tab. 8-4

PTC
Pt 1000
(0.53.5 V)

Measured temperature in C
20 10 0
10
20
30
40
50
60
70
Sensor resistance in Ohm according to standard or manufacturer's indications
1386 1495 1630 1772 1922 2080 2245 2418 2598 2786
922 961 1000 1039 1077 1116 1155 1194 1232 1270
Sensor voltage in V acc. to manufacturer
0.5
0.80 1.10 1.40 1.70 2.00 2.30 2.60

80

90

100

110

120

2982 3185 3396


1308 1347 1385 1423 1461
2.90

3.20

Measured flow in l/min


0.0
2.0
4.0
6.0
8.0
10.0 12.0 14.0 16.0 18.0 20.0
Sensor resistance in Ohm according to standard or manufacturer's indications
(0.363.5 V)
0.36 0.67 0.99 1.30 1.62 1.93 2.24 2.56 2.87 3.19

3.50

3.50

Sensor type

Table of the Solaris sensors

Fig. 8-15
CONF
FLS
TS

Terminal assignment
Programming connector for control TR
unit update
TK
BSK
Flow sensor
Storage cylinder temperature sensor

Return flow temperature sensor


Collector temperature sensor
Burner inhibit contact

P1/P2 Operation and booster pump


F1
Fuse
Power 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.

62

FA ROTEX Solaris - 07/2007

9 x List of keywords
9B

List of keywords

Burner inhibit contact . . . . . . . . . . . . 46

Collector temperature sensor


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

E
F

Design . . . . . . . . . . . . . . . . . . . . . . . . . 7
Drilling template . . . . . . . . . . . . . . . . 13
Dual clip . . . . . . . . . . . . . . . . . . . . . . 28
Electronic control . . . . . . . . . . . . . . . . 8
Equipotential bonding terminal . . . . . . 30

S
Sealing plug . . . . . . . . . . . . . . . . . . . 28
Sensor correcting value . . . . . . . . . . 46
Setting ranges
Recommended . . . . . . . . . . . . . . . 47
Speed control
Automatic . . . . . . . . . . . . . . . . . . 15
Standard parameter values . . . . . . . . 47
Storage cylinder . . . . . . . . . . . . . . . . . .8
Storage cylinder temperature sensor . 18
Supporting structure . . . . . . . . . . 23, 27
System concepts . . . . . . . . . . . . . . . 12

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

Flow controller . . . . . . . . . . . . . . . . . . 9
FlowGuard . . . . . . . . . . . . . . . . . . . . . 9
FlowSensor . . . . . . . . . . . . . . . . . . . . . 9
Without . . . . . . . . . . . . . . . . . . . . 35

Hot water storage tank


Technical data . . . . . . . . . . . . . . . 61
Hot water storage tanks
Several . . . . . . . . . . . . . . . . . . . . 20
Language selection . . . . . . . . . . . . . . 46
Lubricant . . . . . . . . . . . . . . . . . . . . . . 28

Method of operation . . . . . . . . . . . . . . 8
Mounting rails
Installation . . . . . . . . . . . . . . . . . 25

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

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

Password . . . . . . . . . . . . . . . . . . . . . 45
Expert . . . . . . . . . . . . . . . . . . . . . 45
Operator . . . . . . . . . . . . . . . . . . . 45
Product description . . . . . . . . . . . . . . . 7
Pump speed control
Manual . . . . . . . . . . . . . . . . . . . . 46

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


Roof space
Necessary . . . . . . . . . . . . . . . . . . 25
Roof tie
Installation . . . . . . . . . . . . . . . . . 25
ROTEX . . . . . . . . . . . . . . . . . . . . . . . . 1

FA ROTEX Solaris - 07/2007

63

FA ROTEX Solaris - 07/2007

008.16 04144 Errors and technical modifications reserved Original manual 008.16 04149 07/2007 german