Rotex V26P Manuel technique

For certified companies

ROTEX Solaris

Planning and installation

instructions

DrainBack solar system

Valid for the following components

- Solaris V21P

- Solaris V26P

- Solaris H26P

- Solaris assembly packages

Edition 09/2016

(Drain Back)

Table of contents

2FA ROTEX Solaris DrainBack - 09/2016

1 General information. . . . . . . . . . . . . . . . . . . 3

1.1 Refer to the manual . . . . . . . . . . . . . . . . . . . . . . 3

1.2 Warranty conditions . . . . . . . . . . . . . . . . . . . . . . 3

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1 Warning signs and explanation of symbols . . . . 4

2.1.1 Meaning of the warnings . . . . . . . . . . . . . . . . . . . . .4

2.1.2 Order number . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2.1.3 Handling instructions. . . . . . . . . . . . . . . . . . . . . . . .4

2.2 Avoiding danger . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.3 Use as intended . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.4 Instructions for operating safety. . . . . . . . . . . . . 5

2.4.1 Working on the roof. . . . . . . . . . . . . . . . . . . . . . . . .5

2.4.2 Before working on the heating system . . . . . . . . . .5

2.4.3 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . .5

2.4.4 Installation room, water quality, heating and

sanitary connection . . . . . . . . . . . . . . . . . . . . . . . . .5

2.4.5 Instruct the owner . . . . . . . . . . . . . . . . . . . . . . . . . .5

2.4.6 Relevant national regulations . . . . . . . . . . . . . . . . .5

3 Product description. . . . . . . . . . . . . . . . . . . 6

3.1 Construction and components of the

Solaris system (unpressurised system) . . . . . . . 6

3.2 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.3 System components for pressure-less systems. 7

3.3.1 System components for all systems . . . . . . . . . . . .7

3.3.2 System components for roof-mounted systems

(ADM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

3.3.3 System components for in-roof systems (IDM) . . .11

3.3.4 System components for flat roof systems (FDM) .13

4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.1 Transport and storage . . . . . . . . . . . . . . . . . . . 16

4.1.1 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

4.1.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

4.2 System layouts. . . . . . . . . . . . . . . . . . . . . . . . . 17

4.2.1 Parallel connection . . . . . . . . . . . . . . . . . . . . . . . .17

4.2.2 Series connection . . . . . . . . . . . . . . . . . . . . . . . . .17

4.3 Laying the connecting pipe . . . . . . . . . . . . . . . 18

4.4 Mounting the flat solar panels . . . . . . . . . . . . . 20

4.5 Connecting the pressure-less Solaris system

hydraulically . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.6 Installing the equipotential bonding terminal . . 24

4.7 Installing the solar panel temperature sensor . 24

5 Start-up and taking out of service . . . . . . 25

5.1 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.2 Decommissioning. . . . . . . . . . . . . . . . . . . . . . . 25

5.2.1 Temporary shutdown . . . . . . . . . . . . . . . . . . . . . .25

5.2.2 Final shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . .25

6 Technical data . . . . . . . . . . . . . . . . . . . . . . 27

6.1 Product Fiche. . . . . . . . . . . . . . . . . . . . . . . . . . 27

6.2 General technical information . . . . . . . . . . . . . 27

6.3 Roof-mounted system – Max. permissible

snow load (roof-mounted)

as per EN 1991-1-3 . . . . . . . . . . . . . . . . . . . . . 28

6.4 Flat roof system – Required ballast weights

(flat roof mounting) as per EN 1991-1-4. . . . . . 29

6.5 Flat roof system – Shading . . . . . . . . . . . . . . . 30

7 List of keywords . . . . . . . . . . . . . . . . . . . . 31

1 xGeneral information

FA ROTEX Solaris DrainBack - 09/2016 3

1 General information

1.1 Refer to the manual

These instructions are a >> translation of the original

version << in your language.

All procedures required for installation, start-up, operation and

adjustment of the system are described in this instruction manual

and associated documents. Detailed information on the con-

nected components of your heating system is given in the rel-

evant manuals.

●Work on the ROTEX Solaris system (such as hydraulic and

electrical connection and initial start-up) is only to be carried

out by persons who are authorised and who have success-

fully completed qualifying technical or vocational training in

the respective activity and who have taken part in profes-

sional advanced training courses recognised by the

competent authority. This especially includes heating

specialists who have experience in the proper installation and

maintenance of heating and solar systems due to their

technical training and specialist knowledge.

●Please read this manual carefully and thoroughly before

proceeding with the installation and initial start-up or modifi-

cation of the system.

●Comply strictly with warning instructions.

Relevant documents

Documents listed below are part of the technical documentation

of the ROTEX solar system and therefore must be observed. The

documents are part of the scope of delivery of the respective

components.

– ROTEX Solaris RPS4: Operating and installation instructions

– ROTEX hot water storage tank (Sanicube Solaris / Hybrid-

Cube, GCU compact or HPSU compact): Operating and

installation instructions

– Quick instructions for solar panel assembly and the requisite

assembly materials, which accompany the respective con-

struction kits, for roof-mounted, in-roof and flat roof mounting

When connecting to an external heat generator or storage tank

which is not included in the scope of delivery, the individual asso-

ciated operating and installation instructions apply.

1.2 Warranty conditions

The legal guarantee conditions fundamentally apply. Our war-

ranty conditions beyond that can be found online on your sales

presentative's webpage.

4FA ROTEX Solaris DrainBack - 09/2016

2 xSafety

2 Safety

2.1 Warning signs and explanation of

symbols

2.1.1 Meaning of the warnings

Warnings in this manual are classified according

into their severity and probability of occurrence.

Special warning signs

Some types of danger are represented by

special warning symbols.

2.1.2 Order number

References to order numbers can be recognised

from the goods symbol .

2.1.3 Handling instructions

●Handling instructions are shown as a list.

Actions of which the sequential order must be

maintained are numbered.

Results of actions are identified with an

arrow.

2.2 Avoiding danger

ROTEX solar installations are state-of-the-art

and are built to meet all recognised technical

requirements. However, improper use may result

in serious physical injuries or death, as well as

property damage. To prevent such risks, install

and operate the ROTEX solar installations only:

– as stipulated and in perfect condition,

– with an awareness of safety and the hazards

involved.

This assumes knowledge and use of the con-

tents of this manual, of the relevant accident pre-

vention regulations as well as the recognised

safety-related and occupational health rules.

2.3 Use as intended

The ROTEX solar system may only be used for

solar-supported heating of hot water systems.

The ROTEX solar system must be installed, con-

nected and operated only according to the in-

structions in this manual.

Any other use outside the intended use is con-

sidered as improper. The operator alone shall

bear responsibility for any resulting damage.

Intended use also includes compliance with the

maintenance and service conditions. Re-

placement parts must at least satisfy the tech-

nical requirements defined by the manufacturer.

This is the case, for example, with original spare

parts.

DANGER!

Draws attention to imminent danger.

Disregarding this warning can lead to serious

injury or death.

WARNING!

Indicates a potentially dangerous situation.

Disregarding this warning may result in serious

physical injury or death.

CAUTION!

Indicates a situation which may cause possible

damage.

Disregarding this warning may cause damage

to property and the environment.

This symbol identifies user tips and par-

ticularly useful information, but not warn-

ings or hazards.

Electric current

Risk of burning or scalding

Danger of falling

Danger of falling parts

2 xSafety

FA ROTEX Solaris DrainBack - 09/2016 5

2.4 Instructions for operating safety

2.4.1 Working on the roof

●Installation work on the roof may only be

carried out by authorised and trained persons

(heating technicians, roofers, etc.) in

compliance with the relevant Accident

Prevention Regulations.

●Material and tools must be secured against

falling down.

●Barriers must be erected to prevent persons

from entering the area below the roof where

the work is being carried out.

2.4.2 Before working on the heating system

●All work on the heating system (such as instal-

lation, connection and start-up) may only be

carried out by authorised and trained heating

technicians.

●Switch off the main switch and secure it

against unintended switching on when

carrying out any work on the heating system.

2.4.3 Electrical installation

●Electrical installations must only be carried

out by electrical engineers and in compliance

with valid electrical guidelines as well as the

specifications of the energy supply company

(EVU).

●Connect the mains in accordance with

IEC 60335-1 via a separator device which

exhibits contact separation in all poles with a

contact opening distance that provides full

disconnection in accordance with the condi-

tions of overvoltage category III and a residual

current circuit breaker (RCD) with a reaction

time ≤0.2 s.

●Compare the mains voltage (230 V, 50 Hz)

indicated on the nameplate with the supply

voltage before connecting to the mains.

●Before beginning work on live parts,

disconnect them from the power supply

(switch off main switch, remove fuse) and

secure against unintentional restart.

●Equipment covers and service panels must be

replaced as soon as the work is completed.

2.4.4 Installationroom,waterquality,heating

and sanitary connection

The requirements on installing the hot water

storage tank (Sanicube Solaris, Hybridcube,

GCU compact or HPSU compact,), on the water

quality as well as the heating and sanitary con-

nection are described in detail in the instructions

for the hot water tank. It is essential they are

complied with.

2.4.5 Instruct the owner

●Before you hand over the heating system,

explain to the user/owner how to operate and

check the heating system.

●Document the handover by filling out the

installation and instruction forms together with

the owner and sign them.

2.4.6 Relevant national regulations

●DIN 1055-4: 2005/ EN 1991-1-4 Wind actions

●DIN 1055-5: 2005/ EN 1991-1-3 Snow loads

●DIN 18338 Roofing and Roof-Sealing Work

●DIN 18451 Scaffolding Work

●DGUV Information 208-016

●DGUV Information 201-054

●DGUV Regulation 112-198

The accident prevention regulations must be

heeded when working on the roof.

6FA ROTEX Solaris DrainBack - 09/2016

3 xProduct description

3 Product description

3.1 Construction and components of the Solaris system (unpressurised system)

1 Cold water connection pipe

2 Hot water distribution pipe

3 Filling and draining ball valve (accessory KFE BA,16 52 15)

4 Solaris R4 control unit

5 Solar return flow pipe (bottom on the solar panel)

6 Solar inflow pipe (top on the solar panel)

7 Solar panel array

8 Solar inflow layering pipe

9 Solar return flow connection

A Hot water zone

B Solar zone

FLS Solaris FlowSensor (flow rate measurement)

PSSolaris operating pump

RPS4Control and pump unit

TKSolaris solar panel temperature sensor

TRSolaris return flow temperature sensor

TSSolaris storage tank temperature sensor

TVSolaris inflow temperature sensor

GCU compact

Gas Combi Unit

HPSU compact

Solar tank with integrated interior heat pump unit

SCS/HYC

Sanicube energy storage tank Solaris / HybridCube

Fig. 3-1 Standard design of a ROTEX Solaris system (ROTEX recommends a two-way connection)

SCS/HYC

≤12 m

444

999

FLS

22 2

TKTK

>2%

≥0,5 %

666

555

GCU compact HPSU compact

333

FLS

RPS4 RPS4 RPS4

3 xProduct description

FA ROTEX Solaris DrainBack - 09/2016 7

3.2 Brief description

The ROTEX solar system is a thermal solar system for supplying

hot water for consumption and solar support.

Operating mode

The Solaris V21P, V26P and H26P high performance flat solar

panels convert solar radiation into heat with a high degree of ef-

ficiency. The heat carrying medium is water with which the

storage tanks are filled in accordance with the associated instal-

lation instructions.

As soon as the solar panels have reached a useful temperature

level, the buffer water in the storage tank (which is not under

pressure) is pumped directly through the panels. With insufficient

panel temperature, the circulation pump is switched off and the

system is drained automatically. This operating mode has

several advantages:

– High operating safety as there are no components (such as

expansion vessel, safety valve, vent valves) sensitive to dam-

age or interference

– Excellent heat transfer and heat storage capacity (system

works without antifreeze agents)

– Minimum maintenance requirements

– Frost proof

– No additional solar heat exchanger required

– No stagnation problems

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.

outer layer of storage tank

The following storage tanks can be used for the ROTEX solar

system:

– ROTEX Sanicube Solaris (SCS): Highly thermally insulated,

pressure-less solar stratified tank (with possibility to connect

to a ROTEX condensing boiler).

– ROTEX HybridCube (HYC): Highly thermally insulated, pres-

sure-less solar stratified tank (with possibility to connect to a

ROTEX air/water heating pump).

– ROTEX GCU compact: Solar stratified tank with integrated

gas condensing boiler.

– ROTEX HPSU compact: Solar stratified tank with integrated

indoor unit of an air/water heating pump.

Electronic control

The fully electronic ROTEX Solaris R4 control unit ensures op-

timum utilisation of the solar heat (hot water heating, heating

support) and the observance of all safety-relevant aspects. All

parameters needed for trouble-free operation have been preset

at the factory.

3.3 System components for pressure-less

systems

3.3.1 System components for all systems

High performance flat solar panels

V21P ( 16 20 12)

H x W x D: 2000 x 1006 x 85 mm, weight: approx. 35 kg

V26P ( 16 20 10)

H x W x D: 2000 x 1300 x 85 mm, weight: approx. 42 kg

H26P ( 16 20 11)

H x W x D: 1300 x 2000 x 85 mm, weight: approx. 42 kg

Solar panel mounting rails FIX-MP

FIX-MP100 ( 16 20 66) for a V21P flat solar panel

FIX-MP130 ( 16 20 67) for a V26P flat solar panel

FIX-MP200 ( 16 20 68) for an H26P flat solar panel

The pressure-less system (DrainBack) must only be

used with the RPS4 control and pump unit (RPS3 25M

for large systems).

Prerequisite for fault-free operation in the DrainBack system is

that the connecting pipes are laid with a consistent gradient (at

least 2 %) and, with two-way connection, the bottom edges of

the solar panel with constant gradient to the return flow con-

nection or with equilateral connection, mounted horizontally.

Design, functionality, start-up and operation of the stor-

age tanks and other components not mentioned in

chap. 3.3 Solaris are not described in these instruc-

tions. Detailed information on these components can be

found in the associated operating and installation instructions.

The handling instructions and descriptions mentioned in these

instructions basically apply to all ROTEX storage tanks that can

be used in this solar system, even if only one type (e.g. SCS) is

described for illustrative purposes. If there are variances to other

storage tanks, special reference is made.

1a High performance flat solar panel V21P / V26P

1b High performance flat solar panel H26P

Fig. 3-2 Flat solar panel

2a Mounting profile rail

2b Solar panel securing clips

Fig. 3-3 FIX-MP

V21P

V26P H26P

2a (2x)

2b (2x)

8FA ROTEX Solaris DrainBack - 09/2016

3 xProduct description

Solar panel connectionSolaris

FIX-VBP ( 16 20 16)

Connection pipes CON 15 and CON 20

CON 15 ( 16 47 32), L=15 m

and

CON 20 ( 16 47 33), L=20 m

Connecting pipes between solar panel array and RPS4 (heat-in-

sulated inflow pipe and return flow pipe (Al-PEX compound pipe)

with integrated sensor cable).

Extension kits for connection pipe CON X

CON X 25 ( 16 42 61), L=2.5 m

CON X 50 ( 16 42 62), L=5 m

CON X 100 ( 16 42 63), L=10 m

Heat insulated feed and return line with integrated sensor cable,

pipe clamps and connecting fittings.

Extension kit for feed line CON XV

CON XV 80 ( 16 42 64), L=8 m

UV-resistant thermally insulated feed line with integrated sensor

cable, pipe clamps, cable connection fitting and connecting

fitting.

Vessel holder set (TS) for CON 15 and CON 20

connecting pipes

TS ( 16 42 45), L=1.30 m

Vessel holders for supporting CON 15 and CON 20 connecting

pipes (avoidance of water sacks).

3a Double terminal block for solar panel fastening

3b Mounting profile connector

3c Compensator for solar panel connection with mounting support

Fig. 3-4 FIX-VBP

Fig. 3-5 CON 15 / CON 20

Fig. 3-6 CON X (optional)

3a (2x) 3b (2x) 3c (2x)

Fig. 3-7 CON XV (optional)

4a Vessel holders

4b Quick instructions

Fig. 3-8 TS (optional)

4a (5x)

3 xProduct description

FA ROTEX Solaris DrainBack - 09/2016 9

3.3.2 System components for roof-mounted systems (ADM)

Roof penetration packs, roof-mounted

RCAP ( 16 20 33) (anthracite)

RCRP ( 16 20 34) (brick-red)

Solar panel row connector

CON RVP ( 16 20 35)

For connecting two solar panel rows one above the other.

On-roof mounting packs

FIX-ADDP ( 16 20 85) for roof tiles/shingles

FIX-ADS ( 16 47 23) for flat roofing (e.g. slate)

5a Solar panel connecting elbow, return flow

5b Solar panel connecting elbow, inflow

5c Sealing plugs

5d Transition fitting

5e-g Pipe clamps with hangar bolts

5h Single terminal block with equipotential bonding terminal

5i Single terminal block

5j Cable tie

5k Solar panel temperature sensor

5l-n Extraction tool with inserts for Ø 15 mm and Ø 18 mm

5o Planning and installation instructions

5p Quick instructions

5q Cable connection fitting

5r Roof penetration box

5s Foam wedge

5v HT-Armaflex ø22x13 UV-resistant (2 m)

Fig. 3-9 RCAP, RCRP

(ø18)

5r (2x)

(2x)

5s (2x)

(12x) 5f

(8x)

(4x)

(5x)

(ø15)

(3x)

5i Single terminal block

5h Single terminal block with equipotential bonding terminal

5c Sealing plugs

5a Solar panel connecting elbow

5w 1 m heat-insulated Al-PEX compound pipe

Fig. 3-10 CON RVP

12a Roof mounting hook

12b Packing plate 2 mm

12c Packing plate 5 mm

12d Hexagon wood screws M8 x100

12e Quick instructions

Fig. 3-11 FIX-ADDP

12f Roof mounting hook

12g Quick instructions

Fig. 3-12 FIX-ADS

5h ( x)2

5i ( x)2

(2x)

12d (4x)

12b

(2x)

12a

(2x)

12c

(2x)

12e

12g

12f

(4x)

10 FA ROTEX Solaris DrainBack - 09/2016

3 xProduct description

FIX-WD ( 16 47 03) for corrugated roofing

FIX-BD ( 16 47 04) for folded sheet metal roofing

12h Mounting profile beam

12i Quick instructions

Fig. 3-13 FIX-WD

12j Mounting profile beam

12k Quick instructions

Fig. 3-14 FIX-BD

12h

4(x)

12i

12j

4(x)

12k

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