Daikin RHSX04P30D, RHSX04P50D, RHSXB04P30D, RHSXB04P50D, RHSX08P30D Installation manuals
...
Installation and
maintenance in-
structions
HPSU compact Ultra
RHSX(B)04P30D
RHSX(B)04P50D
06/2018
RHSX(B)08P30D
RHSX(B)08P50D
Installation and maintenance instructions
HPSU compact Ultra
English
List of contents
List of contents
1 General safety precautions 3
1.1 Particular safety instructions ..................................................... 3
1.1.1 Observing the instructions .......................................... 3
1.1.2 Meaning of warnings and symbols.............................. 4
1.2 Safety instructions for installation and operation....................... 4
1.2.1 General ....................................................................... 4
1.2.2 Intended use ............................................................... 5
1.2.3 Device installation room.............................................. 5
1.2.4 Electrical installation ................................................... 5
1.2.5 Requirements for the heating water............................ 5
1.2.6 Heating system and sanitary connection .................... 6
1.2.7 Operation .................................................................... 6
2 Handover to operator and warranty 7
2.1 Instruct the owner...................................................................... 7
2.2 Warranty conditions................................................................... 7
3 Product description 8
3.1 Design and components............................................................ 8
3.2 Function of the 3-way switch valves.......................................... 11
4 Set-up and installation 12
4.1 Dimensions and connection dimensions ................................... 12
4.2 Transport and delivery............................................................... 14
4.3 Installing the heat pump ............................................................ 14
4.3.1 Selecting the installation site....................................... 14
4.3.2 Installing the device .................................................... 15
4.4 Preparing the device for installation .......................................... 16
4.4.1 Remove the front screen............................................. 16
4.4.2 Remove the protective cover ...................................... 16
4.4.3 Moving the controller housing to the service position . 16
4.4.4 Open the controller housing........................................ 17
4.4.5 Removing the bottom thermal insulation..................... 17
4.4.6 Opening the vent valve ............................................... 18
4.4.7 Aligning the connections of the heating inflow and
return flow ................................................................... 18
4.4.8 Making the hood opening............................................ 19
4.4.9 Installing the rotary switch of the controller................. 20
4.5 Installing optional accessories................................................... 20
4.5.1 Installation of the electric backup heater..................... 20
4.5.2 Installation of the external heat generator connection
set ............................................................................... 20
4.5.3 Installation of the DB connection kit............................ 20
4.5.4 Installation of the P connection kit .............................. 21
4.6 Water connection ...................................................................... 21
4.6.1 Connecting hydraulic lines .......................................... 21
4.6.2 Connecting the drain................................................... 22
4.7 Electrical connection ................................................................. 23
4.7.1 Overall connection diagram ........................................ 24
4.7.2 Position of the printed circuit boards and terminal
strips ........................................................................... 25
4.7.3 Mains connection ........................................................ 25
4.7.4 General information on the electrical connection........ 25
4.7.5 Connecting the heat pump outdoor unit...................... 25
4.7.6 Connecting the outside temperature sensor
(optional) ..................................................................... 26
4.7.7 External switching contact .......................................... 26
4.7.8 EBA (external requirement request) ........................... 26
4.7.9 Connecting an external heat generator....................... 26
4.7.10 Connecting the room thermostat................................. 27
4.7.11 Connection of optional RoCon system components ... 28
4.7.12 Connecting the HP convector ..................................... 28
4.7.13 Connecting switching contacts (AUX outputs) ............ 29
4.7.14 Off-peak mains connection (HT/NT) ........................... 29
4.7.15 Connecting an intelligent controller (Smart Grid - SG) 30
4.8 Connection for refrigerant........................................................... 30
4.8.1 Laying refrigerant lines................................................. 30
4.8.2 Pressure test and filling the refrigerant circuit.............. 31
4.9 Filling the system........................................................................ 31
4.9.1 Checking the water quality and adjusting the
pressure gauge ............................................................ 31
4.9.2 Filling hot water heat exchangers ................................ 31
4.9.3 Filling the storage tank................................................. 31
4.9.4 Filling the heating system ............................................ 31
5 Start-up 32
5.1 Initial commissioning .................................................................. 32
5.1.1 Requirements............................................................... 32
5.1.2 Starting the unit and start-up........................................ 32
5.1.3 Bleeding the hydraulic system ..................................... 32
5.1.4 Checking the minimum flow ......................................... 33
5.1.5 Setting the screed program parameter (only as
required)....................................................................... 33
5.2 Re-commissioning...................................................................... 33
5.2.1 Requirements............................................................... 33
5.2.2 Start-up ........................................................................ 34
6 Hydraulic connection 35
6.1 Hydraulic system connection...................................................... 35
7 Inspection and maintenance 37
7.1 General overview of inspection and maintenance...................... 37
7.2 Inspection and maintenance tasks ............................................. 38
7.2.1 Filling, topping up the storage tank.............................. 38
7.2.2 Filling, topping up the heating system.......................... 39
8 Faults and malfunctions 41
8.1 Troubleshooting.......................................................................... 41
8.2 Overview of possible malfunctions ............................................. 41
8.3 Fault codes................................................................................. 44
8.4 Emergency operation ................................................................. 54
9 Taking out of operation 55
9.1 Temporary shutdown.................................................................. 55
9.1.1 Draining the storage tank............................................. 55
9.1.2 Draining the heating circuit and hot water circuit ......... 56
9.2 Final shutdown and disposal ...................................................... 56
10 Technical data 58
10.1 Basic data................................................................................... 58
10.2 Characteristic lines ..................................................................... 59
10.2.1 Sensor characteristic lines ........................................... 59
10.2.2 Characteristic curves for pumps .................................. 60
10.3 Tightening torque ....................................................................... 60
10.4 Minimum floor area and ventilation openings ............................. 60
10.5 Electrical connection diagram .................................................... 62
11 Notes 64
List of keywords 67
Installation and maintenance instructions
2
HPSU compact
HPSU compact Ultra
008.1444444_00 – 06/2018 – EN
1 General safety precautions
1.1 Particular safety instructions
1 General safety precautions
WARNING
Devices that have not been set up and
installed correctly can impair the function of the device and/or cause serious
or fatal injury to the user.
▪ Work on the HPSU compact (such
as set-up, inspection, connection
and initial commissioning) must only
be carried out by persons who are
authorised and who have successfully completed qualifying technical
or vocational training and who
have taken part in advanced training
sessions recognised by the relevant
authorities responsible for the specific activity. These include, in particular, certified heating engineers,
qualified electricians and HVAC
specialists who, because of their
professional training and expert
knowledge, have experience in the
professional installation and maintenance of heating, cooling and air
conditioning systems as well as hot
water storage tanks.
WARNING
Disregarding the following safety instructions may result in serious physical injury or death.
▪ This device must only be used by
children aged 8 and above and by
persons with restricted physical,
sensory or mental capabilities or with
a lack of experience and knowledge,
if they are under supervision or if
they have been instructed in the safe
use of the equipment and understand the dangers arising therefrom.
Children must not play with the
device. Cleaning and user mainten-
ance must not be carried out by
children without supervision.
▪ Make up the power supply in accord-
ance with IEC 60335-1, via a separator device which exhibits contact
separation in all poles with a contact
opening distance that provide full
disconnection in accordance with
overvoltage category III.
▪ All the electrical work must only be
carried out by electrically qualified
experts and with consideration of the
local and national regulations, and
the instructions in this manual.
Check that a suitable electrical circuit is being used.
Inadequate capacity of the power circuit or improperly executed connections can cause electrocution or fire.
▪ The customer must install a pressure
relief device with rated over-pressure
less than 0.6MPa (6bar). The connected drain line must have a continuous gradient and a free outlet in
a frost-free environment (seeChap.
4.3).
▪ Water may drip out of the drain line
of the pressure relief device. The
drain opening must be left free to atmosphere.
▪ The pressure relief device must be
operated regularly in order to remove scale deposits and to make
sure it is not blocked.
▪ The storage tank and hot water cir-
cuit can be drained. The instructions
in chap. must be observed.
1.1.1 Observing the instructions
▪ The original documentation is written in German. All other lan-
guages are translations.
▪ Please read this manual carefully and thoroughly before proceed-
ing with the installation or modification of the heating system.
▪ The precautionary measures described in this document cover
very important topics. Follow them meticulously.
▪ The installation of the system, and all activities described in this
manual and the applicable documents for the installer must be
carried out by an approved installer.
HPSU compact
HPSU compact Ultra
008.1444444_00 – 06/2018 – EN
Installation and maintenance instructions
3
1 General safety precautions
This manual provides all the necessary information for installation,
start-up and maintenance, as well as basic information on operation
and settings. Please see the attached documents for a detailed description of operation and control.
All heating parameters needed for smooth operation are already
factory-set. Please refer to other relevant documents for information
on setting the control.
Relevant documents
▪ HPSU compact:
▪ Installation instructions
▪ Start-up checklist
▪ Heat pump operating manual
▪ RoCon+ HP:
▪ Installation instructions
▪ Operating instructions
▪ Outdoor unit: Installation instructions
▪ Room station RoCon U1 and mixer module RoCon M1: Operating
instructions
▪ Other optional accessories and optional system components: As-
sociated installation and operating instructions
The guides are included in the scope of supply for the individual
devices.
1.1.2 Meaning of warnings and symbols
Warnings in this manual are classified according into their severity
and probability of occurrence.
DANGER
Indicates an immediate 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 can cause damage to property
and the environment, and result in minor injuries.
This symbol identifies user tips and particularly useful information, but not warnings or hazards
Special warning signs
Some types of danger are represented by special symbols:
Electric current
Danger of explosion
Risk of burning or scalding
Risk of poisoning
Validity
Some information in this manual has limited validity. The validity is
highlighted by a symbol.
Exterior heat pump unitRRGA
Heat pump indoor unitHPSU compact
HP convector
Comply with the stipulated tightening torque (see
chap.Chap. 10.3)
Only applies to devices with unpressurised solar system
connection (DrainBack).
Only applies to devices with a bivalent solar system connection (Biv).
Only valid for HPSU compact with cooling function
Handling instructions
1 Handling instructions are shown as a list. Actions for which the
sequential order must be maintained are numbered.
è
Results of actions are identified with an arrow.
1.2 Safety instructions for installation and operation
1.2.1 General
WARNING
Devices that have not been set up and installed correctly
can impair the function of the device and/or cause serious
or fatal injury to the user.
▪ Work on the HPSU compact (such as set-up, inspection,
connection and initial commissioning) must only be carried out by persons who are authorised and who have
successfully completed qualifying technical or voca-
tional training and who have taken part in advanced
training sessions recognised by the relevant authorities
responsible for the specific activity. These include, in
particular, certified heating engineers, qualified elec-
tricians and HVAC specialists who, because of their
professional training and expert knowledge, have ex-
perience in the professional installation and maintenance of heating, cooling and air conditioning systems as
well as hot water storage tanks.
▪ Switch off the external main switch before starting any
work on the HPSU compact and secure it against unintentional switch-on.
▪ Do not leave any tools or other objects below the hood
of the unit after finishing installation or maintenance
work.
Avoiding danger
HPSU compact conforms to the state-of-the-art and meets all recognised technical requirements. However, improper use may result in
serious physical injuries or death, as well as property damage. To
prevent such risks, only install and operate the devices:
▪ as stipulated and in perfect condition,
▪ with an awareness of safety and the hazards involved.
This assumes knowledge and use of the contents of this manual, of
the relevant accident prevention regulations as well as the recognised safety-related and occupational health rules.
Before working on the hydraulic system
▪ Work on the system (such as installation, connection and initial
commissioning, for example) must only be carried out by persons
who are authorised, who have successfully completed qualifying
technical or vocational training for the respective activity and who
have taken part in advanced training sessions recognised by the
relevant responsible authority.
Installation and maintenance instructions
4
HPSU compact
HPSU compact Ultra
008.1444444_00 – 06/2018 – EN
1 General safety precautions
▪ When carrying out any work on the system, switch off the main
switch and secure against being switched on inadvertently.
▪ Seals must not be damaged or removed.
▪ Make sure that the safety valves comply with the requirements of
EN12828 when connecting on the heating side, and with the requirements of EN12897 when connecting on the domestic water
side.
1.2.2 Intended use
The HPSU compact may only be used for the preparation of hot water, as a room heating system and, depending on its design, as a
room cooling system.
The HPSU compact must be installed, connected and operated only
according to the indications in this manual.
Only the use of a suitable outdoor unit approved by the manufacturer
is permitted.
HPSU compact
RHSX04P30D
RHSX04P50D
RHSXB04P30D
RHSXB04P50D
RRGA04DAV3 P -
RRGA06DAV3 - P
RRGA08DAV3 - P
Tab.1-3 Permissible combinations
Any other use outside the intended use is considered as improper.
The operator alone shall bear responsibility for any resulting damage.
Intended use also includes compliance with the maintenance and inspection conditions. Replacement parts must at least satisfy the
technical requirements defined by the manufacturer. This is the
case, for example, with original spare parts.
RHSX08P30D
RHSX08P50D
RHSXB08P30D
RHSXB08P50D
1.2.3 Device installation room
WARNING
The plastic wall of the storage tank of the HPSU compact
can melt under the effects of external heat (>80°C) and, in
the extreme case, can catch fire.
▪ Only install the HPSU compact at a minimum distance of
1m to other heat sources (>80°C) (e.g. electrical
heater, gas heater, chimney) and combustible materials.
CAUTION
▪ Only install the HPSU compact if sufficient load-carrying
capacity of the ground of 1050kg/m2 plus safety margin
is ensured. The ground must be flat, horizontal and
level.
▪ Outdoor installation is not permissible.
▪ Installation in an explosion-risk environment is not per-
missible.
▪ The electronic control system must not be exposed to
whether effects like rain and snow under any circumstances.
▪ The storage tank may not be exposed to continuous dir-
ect sunlight, as the UV radiation and the effects of the
weather will damage the plastic.
▪ The HPSU compact must be installed protected from
frost.
▪ Make sure that the supply company does not provide
corrosive domestic water. Suitable water treatment may
be required.
▪ Always ensure the minimum distances to walls and other objects
( Chap. 4.1).
▪ Observe the special installation requirements of the R32 refriger-
ant (see Chap. 4.3.1).
CAUTION
▪ If a DrainBack solar heating system is connected:
Install the HPSU compact far enough under the solar
panels to allow complete emptying of the solar heating
system. (Follow instructions in the DrainBack solar heating system manual). An insufficient height difference
may lead to the destruction of the DrainBack solar heating system.
▪ The HPSU compact must not be operated in rooms with
ambient temperatures above 40°C.
1.2.4 Electrical installation
▪ Electrical installations may only be carried out by electrical techni-
cians and in compliance with valid electrical guidelines as well as
the specifications of the responsible energy supply company.
▪ Compare the mains voltage (230V, 50Hz) indicated on the name-
plate 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.
▪ Device covers and service panels must be replaced as soon as
the work is completed.
HPSU compact
HPSU compact Ultra
008.1444444_00 – 06/2018 – EN
1.2.5 Requirements for the heating water
Avoid damage caused by deposits and corrosion: Comply with the
applicable engineering regulations on prevention of corrosion
products and deposits (VDI 2035, BDH/ZVSHK technical information
"Scale formation").
Minimum requirements regarding the quality of filling and supplementary water:
▪ Water hardness (calcium and magnesium, calculated as calcium
carbonate): ≤3mmol/l
▪ Conductivity: ≤1500 (ideal: ≤100) μS/cm
▪ Chloride: ≤250mg/l
▪ Sulphate: ≤250mg/l
▪ pH-values (heating water): 6.5 - 8.5
Installation and maintenance instructions
5
1 General safety precautions
Measures for desalination, softening or hardness stabilisation are
necessary if the filling and top-up water have a high total hardness
(>3mmol/l - total of the calcium and magnesium concentrations, calculated as calcium carbonate). We recommend the use of Fernox
KSK limescale and corrosion protector. For other properties deviating from the minimum requirements, suitable conditioning measures
are necessary to maintain the required water quality.
Using filling water and top-up water which does not meet the stated
quality requirements can cause a considerably reduced service life
of the device. The responsibility for this lies solely with the operator.
1.2.6 Heating system and sanitary connection
▪ Create a heating system according to the safety requirements of
EN12828.
▪ The plumbing connection must comply with the requirements of
EN12897. The requirements of the following must also be observed:
▪ EN1717 – Schutz des Trinkwassers vor Verunreinigungen in
Trinkwasser-Installationen und allgemeine Anforderungen an
Sicherheitseinrichtungen zur Verhütung von Trinkwasserverunreinigungen durch Rückfließen. Protection against pollution of
potable water installations and general requirements of devices
to prevent pollution by backflow. Protection contre la pollution
de l'eau potable dans les réseaux intérieurs et exigences
générales des dispositifs de protection contre la pollution par
retour
▪ EN61770 – Elektrische Geräte zum Anschluss an die
Wasserversorgungsanlage – Vermeidung von Rücksaugung
und des Versagens von Schlauchsätzen. Electric appliances
connected to the water mains – Avoidance of backsiphonage
and failure of hose-sets. Appareils électriques raccordés au
réseau d'alimentation en eau – Exigences pour éviter le retour
d'eau par siphonnage et la défaillance des ensembles de raccordement
▪ EN806 – Technische Regeln für Trinkwasserinstallationen
(TRWI). Specifications for installations inside buildings conveying water for human consumption. Spécifications techniques relatives aux installations pour l'eau destinée à la consummation
humaine à l'intérieur des bâtiments
▪ and, in addition, the country-specific legislation.
During operation of the HPSU compact with additional heat source,
the storage tank temperature may exceed 65°C, above all when
solar energy is used.
▪ For this reason, some form of scalding protection needs to be in-
cluded when you install the system (hot water mixing device, e.g.
VTA32).
If the HPSU compact is connected to a heating system with steel
pipes, radiators or non-diffusion-proof floor heating pipes, sludge
and chips can enter the hot water storage tank and cause blockages, local overheating or corrosion damage.
▪ To prevent possible damage, install a dirt filter or sludge separator
into the heating return flow of the system (SAS 1 or SAS 2).
▪ The dirt filter must be cleaned at regular intervals.
▪ only operate if the protective cover is installed.
The specified servicing intervals should be adhered to and inspection work must be carried out.
1.2.7 Operation
The HPSU compact:
▪ Do not operate until all installation and connection work is com-
pleted.
▪ Only operate with a completely full storage tank (Level indicator)
and heating circuit.
▪ Operate at a maximum pressure of 3bar.
▪ Only connect with a pressure reducer on the external water supply
(supply line).
▪ Only operate the with the specified quantity of coolant and the
type of coolant specified.
Installation and maintenance instructions
6
HPSU compact
HPSU compact Ultra
008.1444444_00 – 06/2018 – EN
2 Handover to operator and
warranty
2.1 Instruct the owner
▪ Before you hand over the heating system, explain to the owner
how he/she can operate and check the heating system.
▪ Hand over the technical documentation (at least the operating in-
structions and operating manual) to the operator and advise him
that these documents must be made available at all times and be
stored in the immediate vicinity of the device.
▪ Document the handover by filling out the installation and instruc-
tion forms together with the owner and sign them.
2.2 Warranty conditions
Germany: www.rotex.de > "Warranty conditions" (via search
function)
Austria: www.daikin.at > General commercial terms and con-
ditions (WARRANTY AND LIABILITY)
Switzerland: www.domotec.ch > Documents > Download > Cata-
logue brochures > Price list… (general terms and
conditions/warranty conditions)
There is only an entitlement to warranty services when it can be certified that the annual maintenance work according to Chap. 7 has
been regularly completed.
2 Handover to operator and warranty
HPSU compact
HPSU compact Ultra
008.1444444_00 – 06/2018 – EN
Installation and maintenance instructions
7
3 Product description
RoCon+ B1 33 26
24
10
25
A
A
6
30
5
(34)
4
(34)
3UV DHW 3UVB1
15
17
1 32 3UV DHWDS31 35 38
t
V,BH
7
39 37
3UV DHW
2
FLS
8
t
V,BHtR
3
t
V
3 Product description
3.1 Design and components
Outside of the device
Upper side of the device
Fig.3-1 Design and components - Outside of the device
Fig.3-2 Design and components - Top of the device
(1)
(1)
(1)
For legend, see Tab. 3-1
Installation and maintenance instructions
8
HPSU compact
HPSU compact Ultra
008.1444444_00 – 06/2018 – EN
3 Product description
Internal structure…04P30D/…08P30D
Internal structure …B04P30D / …B08P30D (Biv)
Fig.3-3 Design and components – Internal struc-
ture ...04P30D/...08P30D
(1)
For legend, see Tab. 3-1
HPSU compact
HPSU compact Ultra
008.1444444_00 – 06/2018 – EN
(1)
Fig.3-4 Design and components - Internal struc-
ture ...B04P30D / ...B08P30D (Biv)
Installation and maintenance instructions
(1)
9
3 Product description
Internal structure …04P50D / …08P50D
Internal structure …B04P50D / …B08P50D (Biv)
Fig.3-5 Design and components - Internal struc-
ture ...04P50D / ...08P50D
(1)
For legend, see Tab. 3-1
Installation and maintenance instructions
(1)
10
Fig.3-6 Design and components - Internal structure …
B04P50D / …B08P50D (Biv)
(1)
HPSU compact
HPSU compact Ultra
008.1444444_00 – 06/2018 – EN
3 Product description
Item Designation Item Designation
1 Solar inflow or connec-
25 Type plate
tion for another heat
source (BIV only)
2 Cold water connection 26 Protective cover
3 Domestic hot water 27 Solar - return flow
4 Heating inflow 28 Solar - inflow
5 Heating return flow 29 Solar - return flow
6 Circulation pump 30 Plate heat exchanger
7 Pressure relief valve 31 Connection for refrigerant
fluid line
7a Non-return valve (ac-
cessory)
32 Connection for refrigerant
gas line
8 Automatic vent valve 33 Status display
9 Storage tank (polypropyl-
ene double walled jacket
34 Ball valve (heating cir-
cuit)
with PUR hard foam heat
insulation)
10 Filling and draining con-
nection or solar return
flow connection
11 Mount for solar controller
or handle
12 Heat exchanger (stain-
less steel) for domestic
35 Combined filling and
draining valve (heating
circuit)
37
Storage tank temperature
sensor
t
,
DHW1
t
DHW2
38 Connection for dia-
phragm expansion vessel
hot water heating
13 Heat exchanger (stain-
39 Control system housing
less steel) for storage
tank charging or heating
support
14 Heat exchanger (stain-
less steel) for pressurised solar system storage
3UVB13-way switch valve (in-
ternal heat generator circuit)
charging
15 Connection for optional
electrical backup heater
3UV
3-way switch valve (hot
DHW
water/heating)
BUxx
16 Solar - inflow layering
DS Pressure sensor
pipe
17 Fill level indicator (tank
FLS FlowSensor
water)
18 Optional: electric backup
heater (BUxx)
19 Submersible sensor
sleeve for storage tank
temperature sensor t
and t
DHW2
20 Pressure-free storage
tank water
21 Solar zone RoCon
DHW1
t
Return flow temperature
R
sensor
t
Inflow temperature
V
sensor
t
Backup heater inflow
V, BH
temperature sensor
Controller control panel
+ B1
22 Hot water zone RPS4 Optional: Solar control
and pump unit
23 Safety overflow connec-
tion
MAG Diaphragm expansion
vessel
24 Mount for handle
Tab.3-1 Legend for Fig. 3-1 to Fig. 3-6
3.2 Function of the 3-way switch valves
Fig.3-7 3-way switch valve function
HPSU compact
HPSU compact Ultra
008.1444444_00 – 06/2018 – EN
Installation and maintenance instructions
11
4 Set-up and installation
0
B
45
161
0
183
334
490
1770
1380
1659
1565
642
0 0
1599
1905
4 Set-up and installation
WARNING
Cooling systems (heating pumps), climate control systems
and heating devices that have been set up and installed incorrectly can both endanger human life and health and be
impaired in their function.
▪ Work on the HPSU compact (such as installation, repair,
connection and initial commissioning, for example) must
only be carried out by persons who are authorised, who
have successfully completed qualifying technical or vocational training for the respective activity and who have
taken part in advanced training sessions recognised by
the relevant responsible authority. These include, in particular, certified heating engineers, qualified electricians
and HVAC specialists who, because of their professional
training and expert knowledge, have experience in the
professional installation and maintenance of heating,
cooling and air conditioning systems and heat pumps.
Incorrect set-up and installation would render the manufacturer's
guarantee void. If you have questions, please contact our Technical
Customer Service.
4.1 Dimensions and connection dimensions
Dimensions …04P30D/…08P30D
Fig.4-1 Dimensions, side view - …04P30D/…08P30D
Installation and maintenance instructions
12
HPSU compact
HPSU compact Ultra
008.1444444_00 – 06/2018 – EN
4 Set-up and installation
0
125
315
490
590
9
7
5
26
A
B
418
3
0
388
615
±5
95
97
184
205
259
0
280
432
588
1651
1591
1555
B
1380
642
0
0
1762
1905
45
7
6
Dimensions …04P50D/…08P50D
Fig.4-2 Dimensions, top of the device - Type …04P30D/…
08P30D
Fig.4-3 Dimensions, side view - Type …04P50D/…08P50D
HPSU compact
HPSU compact Ultra
008.1444444_00 – 06/2018 – EN
Installation and maintenance instructions
13
4 Set-up and installation
587,5
0
432
412,5
147,5
9 8
21
45
3
A
B
6 7
785
0
249
332,5
452,5
162,5
147,5
A (2x)
B (3x)
C (1x)
D (1x)
E (2x)
H (2x)
F (2x)
G (1x)
I (1x)
J (1x)
K (1x)
L (1x)
Fig.4-4 Dimensions, top of the device - Type …04P50D/…
Item Designation
1 Solar - inflow
2 Cold water
3 Domestic hot water
4 Heating inflow
5 Heating return flow
6 Connection for refrigerant gas line
7 Connection for refrigerant fluid line
8 Solar – inflow (…Biv type only)
9 Solar – return flow (…Biv type only)
A front
B rear
Tab.4-1
4.2 Transport and delivery
The HPSU compact is delivered on a pallet. All industrial trucks,
such as lifting trucks and forklift trucks, are suitable for transporting
it.
Scope of delivery
▪ HPSU compact (preassembled),
▪ Bag of accessories (see Fig. 4-5),
▪ Document pack.
08P50D
WARNING
The HPSU compact is top-heavy in the unfilled state and
could tip over during transport. That could put persons in
danger or damage the unit.
▪ Secure the HPSU compact well, transport carefully, use
the handles.
Installation and maintenance instructions
14
Fig.4-5 Contents of bag of accessories
Item Designation Item Designation
A Handles (only required
for transport)
B cover panel H Cable tie
C Hose connecting piece
for safety overflow
D Assembly wrench J Venting hose
E Ball valve K Drain hose cover
F Flat gasket L RoConPlus controller
Tab.4-2
For further accessories for the HPSU compact, see Price list.
G O-ring
I Plug bracket
rotary switch
4.3 Installing the heat pump
4.3.1 Selecting the installation site
CAUTION
If the total refrigerant charge in the system is ≥ 1.84kg, it is
essential to comply with additional requirements for minimum footprint and minimum ventilation openings. ObserveChap. 10.4.
Information on the total refrigerant charge can be found on
the type plate of the outdoor unit. Please follow the installation instructions.
HPSU compact
008.1444444_00 – 06/2018 – EN
HPSU compact Ultra
4 Set-up and installation
The installation site of the HPSU compact must meet the minimum
requirements below (see alsoChap. 1.2.3).
Installation area
▪ The base must be level and smooth and have a sufficient ground
load-bearing capacity of 1050kg/m² plus safety factor. Install a
pedestal if necessary.
▪ Observe the installation dimensions (see Chap. 4.1).
Minimum distance
DANGER: RISK OF BURNING
The plastic wall of the storage tank of the HPSU compact
can melt under the effects of external heat (>80°C) and, in
the extreme case, can catch fire.
▪ Only install the HPSU compact with a minimum distance
of 1m to other heat sources (>80°C) (e.g. electrical
heater, oil heater, chimney) and the material to be combusted.
CAUTION
If the HPSU compact is not installed a sufficient
distance below the flat solar panels (the top edge of the
storage tank is higher than the bottom edge of the solar
panels), the unpressurised solar system in the outdoor
area will not be able to drain completely.
▪ When a solar connection is used, install the HPSU com-
pact low enough at the flat solar panels (observe minimum gradient in the solar connection lines).
Recommended minimum distances:
To the wall: (back) ≥100mm, (sides) ≥500mm
To the ceiling: ≥1200mm, at least 480mm.
Installation
4.3.2 Installing the device
WARNING
The HPSU compact is top-heavy in the unfilled state and
could tip over during transport. That could put persons in
danger or damage the unit.
▪ Secure the HPSU compact well, transport carefully, use
handles.
Precondition
▪ The installation site complies with applicable country-specific reg-
ulations and meets the minimum requirements described in Chap.
4.3.1.
Fig.4-6 Installing the handles
Item Designation
A Handle
B cover panel
F Threaded piece
Tab.4-3
1 Remove packing and dispose of it in an environment-friendly
manner.
2 Pull off the cover screens from the storage tank (Fig. 4-6, itemB)
and unscrew the threaded fittings (Fig. 4-6, itemF) from the
openings at which the handles are to be fitted.
3 Screw the handles (Fig. 4-6, itemA) into the now uncovered
threaded holes.
4 Carefully transport the HPSU compact to the installation site,
use the handles.
HPSU compact
HPSU compact Ultra
008.1444444_00 – 06/2018 – EN
Installation and maintenance instructions
15
4 Set-up and installation
A
5 Installing the HPSU compact at the installation site.
▪ When setting up the unit in a cabinet, behind panels or in other
restricted conditions, ensure sufficient ventilation (e.g. using
ventilation gratings). If the total refrigerant charge in the system
is ≥ 1.84kg, further requirements of the ventilation openings
must be met (see Chap. 10.4).
4.4 Preparing the device for installation
4.4.1 Remove the front screen
1 Undo the screws (1.).
2 Press the lateral holding burls upwards with your fingers (2.),
stem from above with the thumbs.
3 Remove the front screen to the front (3.).
Fig.4-8 Remove the protective cover
Fig.4-7 Remove the front screen
4 After completing the installation: Place the front screen
straight directly above the rotary switch of the RoCon+ HP.
Press on the top and bottom until the front screen is securely engaged again.
4.4.2 Remove the protective cover
1 Undo the screws (1.).
2 Unhook the protective cover from the rearward facing holding
burls (2.), lift at the back (3.) and remove to the front (4.).
Installation and maintenance instructions
16
Fig.4-9 Without protective cover
4.4.3 Moving the controller housing to the service position
To facilitate work on the hydraulics of the HPSU compact, the control
box can be moved to the service position.
1 Loosen the screws (1) of the holder of the controller housing.
HPSU compact
HPSU compact Ultra
008.1444444_00 – 06/2018 – EN
1
1
Fig.4-10 Moving the controller housing to the service position
1
2
2 Remove the controller housing from the front and insert it into
the bracket with the hooks on the rear brackets.
4 Set-up and installation
Fig.4-12 Open the controller housing
3 Hook in the cover on the controller housing with the lateral
hooks.
Fig.4-11 Controller housing in the service position
4.4.4 Open the controller housing
To make the electrical connections, the controller housing itself must
be opened. This can be done in both the normal and the service position.
1 Loosen the front screw.
2 Push the cover upwards and pull it away to the front.
Fig.4-13 Hooking in the cover
4.4.5 Removing the bottom thermal insulation
CAUTION
The thermal insulation (Fig. 4-9, itemA) consists of pressure-sensitive EPP moulded parts that can be easily damaged if not handled correctly.
▪ Only remove the thermal insulation in the order stated
1 Remove the thermal insulation in the following order:
below and in the stated directions.
▪ Do not use force.
▪ Do not use tools.
▪ Pull the side insulating element off horizontally (itemA).
▪ Pull the rear insulating element off horizontally (itemB).
▪ Pull the front insulating element off horizontally (itemC).
HPSU compact
HPSU compact Ultra
008.1444444_00 – 06/2018 – EN
Installation and maintenance instructions
17
4 Set-up and installation
A
B
C
A
B
Fig.4-14 Removing the top thermal insulation
2 As required: Remove the bottom thermal insulation in the fol-
lowing order:
▪ Pull the side insulating element off vertically (itemA).
▪ Pull the rear insulating element off vertically (itemB).
Fig.4-16 Opening the vent valve
4.4.7 Aligning the connections of the heating inflow and return flow
CAUTION
When working on the hydraulics, pay attention to the installation position of the O-rings to avoid damaging them
and causing leaks.
▪ Always place O-rings on the part to be inserted after dis-
assembly or before assembly (see Fig. 4-18).
▪ The heating lines must be connected free of tension via
the plug connectors. Establish a suitable strain relief especially when connecting with flexible lines (not open to
diffusion!) (see ).
Fig.4-15 Removing the bottom thermal insulation
INFORMATION
The thermal insulation is installed in reverse order.
4.4.6 Opening the vent valve
1 Removing the thermal insulation (see Chap. 4.4.5).
2 Open the vent valve on the pump by one turn.
CAUTION
If the plug brackets cannot be put on properly, the couplings can be detached from their mountings to ensure a
very strong or continuous escape of liquid can occur.
▪ Before putting on a plug bracket, make sure that the stir-
rup engages in the coupling groove. To do so, insert the
coupling far enough into the mounting that the groove is
visible through the plug bracket mounting.
▪ Insert the plug bracket up to the end stop.
The connections of the heating inflow and return flow can be directed upwards or backwards in order to adapt it optimally to the structural conditions of the installation site.
The device is supplied with upwards aligned connections as standard. The following conversion steps are required in order to direct
the connections to the rear out of the device:
1 Remove the protective cover and top thermal insulation
(seeChap. 4.4.2).
Installation and maintenance instructions
18
HPSU compact
HPSU compact Ultra
008.1444444_00 – 06/2018 – EN
4 Set-up and installation
Fig.4-17 Aligning the heating inflow and return flow upwards
2 Pull the two plug brackets off the connection couplings (Fig.
4-17, itemC).
3 Pull off the two connection couplings (Fig. 4-17, itemB).
Fig.4-18 Hydraulic system plug connectors
4 Remove the retaining plate (Fig. 4-17, itemA).
5 Pull off the sealing plug bracket (Fig. 4-17, itemD).
6 Pull out the sealing plug (Fig. 4-17, itemE).
7 Turn the elbow (Fig. 4-17, itemH) 90° to the rear.
8 Pull the plug bracket off the manifold (Fig. 4-17, itemG).
9 Carefully pull the manifold (Fig. 4-17, itemF) so far backwards
out of its horizontal mounting that the retaining plate (Fig. 4-19,
itemA) can be pushed vertically in between.
Fig.4-19 Heating inflow and return flow connections aligned to the
rear
10 Slide the retaining plate between the manifold and its horizontal
mounting and insert the manifold (Fig. 4-19, itemF) back into its
mounting through the middle hole of the retaining plate.
11 Secure the manifold with plug bracket (Fig. 4-19, itemG) in its
mounting again.
12 Insert the two connection couplings (Fig. 4-19, itemB) into the
lateral mountings through the retaining plate.
13 Secure the two connection couplings with plug bracket (Fig.
4-19, itemC) in their mountings.
14 Insert the sealing plug (Fig. 4-19, itemE) into the upper mount-
ing.
15 Secure the sealing plug with plug bracket (Fig. 4-19, itemD).
16 Cut out side openings in the thermal insulation (Fig. 4-20,
itemA) using a suitable tool.
HPSU compact
HPSU compact Ultra
008.1444444_00 – 06/2018 – EN
Fig.4-20 Cut-out in thermal insulation
4.4.8 Making the hood opening
1 With the heating inflow and return flow directed upwards: Cut the
hood along the perforation with a suitable tool.
Installation and maintenance instructions
19
4 Set-up and installation
1 2
3
A B
3
A
D
B
C
Fig.4-21 Making the hood opening
3 Attach the connection set to the controller housing of the HPSU
compact. To do this, insert the hooks (1) of the connection set
into the slots of the controller housing (2); then press the connection set downwards.
4.4.9 Installing the rotary switch of the controller
1 Place the rotary switch on the rotary switch holder of the RoCon
+ HP and press it on.
Fig.4-22 Putting on the rotary switch
4.5 Installing optional accessories
4.5.1 Installation of the electric backup heater
(BUxx)
INFORMATION
If the ceiling height is low, the storage tank must be tilted to
install the backup heater when empty. This must be done
before any further installation steps.
The HPSU compact provides the option of installing an electrical
auxiliary heater (backup heater BUxx). For example, renewable energy can be used as an additional heat source.
Fig.4-23 Fitting the connection set
4 Attach the grommet (3) to the bushing between the connection
set (A) and the controller housing (B). Make sure that the grommet surrounds both plates.
Fig.4-24 Cable gland
5 Guide the cable of the Ultra EHS printed circuit board through
the cable grommet and connect it to the RoCon BM2C (see Fig.
4-38).
6 After the installation and the electrical connections (see Chap.
4.6or Chap. 4.7) have been completed, replace the cover and
close it with the screw.
4.5.3 Installation of the DB connection kit
The optional DB connection kit allows better access for connecting
the DrainBack pipe (solar inflow).
INFORMATION
A separate manual containing instructions about installation and operation is included with this component.
4.5.2 Installation of the external heat generator connection set
The connection set for external heat generators must be installed to
control an electrical backup heater or another external heat generator.
1 Open the housing by removing the screw.
2 Remove additional components from the housing (strain relief
clip, cable tie, grommet).
Installation and maintenance instructions
20
Fig.4-25 DB connection kit
HPSU compact
HPSU compact Ultra
008.1444444_00 – 06/2018 – EN
4 Set-up and installation
AB
Item Designation
A DB pipe connection (solar inflow)
B FlowSensor (not part of the DB connection kit, but in-
cluded with RPS4)
C Flow rate limiter (FlowGuard)
D
Tab.4-4
Solar - inflow connection on the storage tank
4.5.4 Installation of the P connection kit
The optional P connection kit for Biv device types allows better access for connecting the inflow and return flow lines of a pressurised
solar system or another external heat generator on the storage tank.
The kit contains two thermally insulated corrugated pipes that are
connected to the connections of the storage tank via a union nut. At
the other end of the corrugated pipes there is an adapter for different
connection sizes of the inflow and return flow lines.
CAUTION
If the HPSU compact is connected to a cold water line
where steel pipes are used, chips can get into the stainless
steel corrugated pipe heat exchanger and remain there.
This can lead to contact corrosion damage and subsequently to leakage.
▪ Flush the feed pipes before filling the heat exchanger.
▪ Install the dirt filter in the cold water supply (e.g. SAS 1
or SAS 2).
CAUTION:BIV ONLY
If the heat exchanger for pressurised solar system charging (see Chap. 4.1, items8+ 9) is connected to an ex-
ternal heater (e.g. wood-burning boiler), the HPSU compact can be damaged or destroyed due to an excessively
high inflow temperature at these connections.
▪ The inflow temperature of the external heating unit
should be limited to max. 95°C.
CAUTION
Corrosion may be caused by air entering the heating water
network and by a quality of the heating water that does not
comply with the requirements in accordance with Requirements for the heating water. Corrosion products (particles)
thus created may clog pumps and valves and cause malfunctions.
▪ Device may not be connected by permeable, flexible
lines.
▪ For potable water lines, observe the provisions of EN806,
DIN1988 and the additional applicable national regulations for
potable water installation.
▪ Install the HPSU compact close to the withdrawal point to dis-
pense with the need for a circulation line. If a circulation line is
mandatory, it must be installed according to the schematic diagrams in Chap. 6.1.
Fig.4-26 P connection kit for Biv device types
Item Designation
A Connection for inflow (red)
B Connection for return flow (blue)
4.6 Water connection
Important information
CAUTION
If the HPSU compact is connected to a heating system
with steel pipes, radiators or non-diffusion-proof floor
heating pipes, slurry and swarf could enter the hot water
storage tank and cause blockages, local overheating or
corrosion damage.
▪ Rinse supply lines before filling the device.
▪ Rinse out the heat distribution network (in the existing
heating system).
▪ Install a dirt filter or sludge separator in the heating re-
turn flow (see chap.).
4.6.1 Connecting hydraulic lines
DANGER: RISK OF BURNING
There is a danger of scalding at hot water temperatures
over 65°C. This is possible when using solar energy if an
external heater is connected, the Legionella protection is
activated, or the target hot water temperature is set to be
greater than 65°C.
▪ Install a scalding protection (hot water mixer device (e.g.
VTA32)).
INFORMATION
The HPSU compact is equipped with a pressure sensor.
The system pressure in monitored electronically and can
be displayed with the device switched on.
Nevertheless, we recommend installing a mechanical pressure gauge between the HPSU compact and the diaphragm expansion vessel, for example.
▪ Install the pressure gauge so that it is easy to see when
filling.
1 Check the cold water connection pressure (maximum 6bar).
▪ If a higher pressure is present in the domestic water pipe, a
pressure reducer will need to be installed.
2 Fix the hydraulic block in place with a screwdriver.
HPSU compact
HPSU compact Ultra
008.1444444_00 – 06/2018 – EN
Installation and maintenance instructions
21
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