Daikin RRGA04DAV3, RRGA06DAV3, RRGA08DAV3, RHBX04DA6V, RHBX04DA9W Installer reference guide

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Installer reference guide

ROTEX HPSU Bi-Bloc Ultra

RRGA04DAV3 RRGA06DAV3 RRGA08DAV3

RHBX04DA6V RHBX04DA9W RHBX08DA6V RHBX08DA9W

Installer reference guide

ROTEX HPSU Bi-Bloc Ultra

English

Table of contents

1 General safety precautions 3

1.1 About the documentation .......................................................... 3

1.1.1 Meaning of warnings and symbols.............................. 3

1.2 For the installer.......................................................................... 4

1.2.1 General ....................................................................... 4

1.2.2 Installation site ............................................................ 4

1.2.3 Refrigerant .................................................................. 4

1.2.4 Brine............................................................................ 5

1.2.5 Water .......................................................................... 5

1.2.6 Electrical ..................................................................... 6

2 About the documentation 6

2.1 About this document.................................................................. 6

2.2 Installer reference guide at a glance ......................................... 7

3 About the box 7

3.1 Overview: About the box ........................................................... 7

3.2 Outdoor unit............................................................................... 7

3.2.1 To unpack the outdoor unit ......................................... 7

3.2.2 To handle the outdoor unit.......................................... 7

3.2.3 To remove the accessories from the outdoor unit....... 8

3.3 Indoor unit ................................................................................. 8

3.3.1 To unpack the indoor unit ........................................... 8

3.3.2 To remove the accessories from the indoor unit......... 8

4 About the units and options 8

4.1 Overview: About the units and options...................................... 8

4.2 Identification .............................................................................. 8

4.2.1 Identification label: Outdoor unit ................................. 8

4.2.2 Identification label: Indoor unit .................................... 9

4.3 Combining units and options ..................................................... 9

4.3.1 Possible options for the outdoor unit........................... 9

4.3.2 Possible options for the indoor unit............................. 9

4.3.3 Possible combinations of indoor unit and outdoor

unit .............................................................................. 10

4.3.4 Possible combinations of indoor unit and domestic

hot water tank ............................................................. 10

5 Application guidelines 10

5.1 Overview: Application guidelines............................................... 10

5.2 Setting up the space heating/cooling system ............................ 10

5.2.1 Single room................................................................. 10

5.2.2 Multiple rooms – OneLWT zone ................................ 12

5.2.3 Multiple rooms – TwoLWT zones............................... 14

5.3 Setting up an auxiliary heat source for space heating............... 15

5.4 Setting up the domestic hot water tank ..................................... 16

5.4.1 System layout – Standalone DHW tank...................... 16

5.4.2 Selecting the volume and desired temperature for

the DHW tank.............................................................. 16

5.4.3 Setup and configuration – DHW tank.......................... 17

5.4.4 DHW pump for instant hot water................................. 17

5.4.5 DHW pump for disinfection ......................................... 17

5.4.6 DHW pump for tank preheating .................................. 18

5.5 Setting up the energy metering ................................................. 18

5.5.1 Produced heat............................................................. 18

5.5.2 Consumed energy....................................................... 18

5.5.3 Normal kWh rate power supply................................... 18

5.5.4 Preferential kWh rate power supply............................ 19

5.6 Setting up the power consumption control ................................ 19

5.6.1 Permanent power limitation ........................................ 19

5.6.2 Power limitation activated by digital inputs ................. 20

5.6.3 Power limitation process ............................................. 20

5.7 Setting up an external temperature sensor ............................... 20

6 Preparation 21

6.1 Overview: Preparation............................................................... 21

6.2 Preparing the installation site .................................................... 21

6.2.1 Installation site requirements of the outdoor unit ......... 21

6.2.2 Additional installation site requirements of the

outdoor unit in cold climates ........................................ 22

6.2.3 Installation site requirements of the indoor unit ........... 23

6.3 Preparing refrigerant piping........................................................ 25

6.3.1 Refrigerant piping requirements................................... 25

6.3.2 Refrigerant piping insulation ........................................ 25

6.4 Preparing water piping ............................................................... 25

6.4.1 Water circuit requirements ........................................... 25

6.4.2 Formula to calculate the expansion vessel pre-

pressure ....................................................................... 26

6.4.3 To check the water volume and flow rate .................... 26

6.4.4 Changing the pre-pressure of the expansion vessel.... 27

6.4.5 To check the water volume: Examples ........................ 28

6.5 Preparing electrical wiring .......................................................... 28

6.5.1 About preparing electrical wiring.................................. 28

6.5.2 About preferential kWh rate power supply ................... 28

6.5.3 Overview of electrical connections except external

actuators ...................................................................... 29

6.5.4 Overview of electrical connections for external and

internal actuators ......................................................... 29

7 Installation 29

7.1 Overview: Installation ................................................................. 29

7.2 Opening the units ....................................................................... 30

7.2.1 About opening the units ............................................... 30

7.2.2 To open the outdoor unit.............................................. 30

7.2.3 To open the indoor unit ................................................ 30

7.3 Mounting the outdoor unit........................................................... 31

7.3.1 About mounting the outdoor unit.................................. 31

7.3.2 Precautions when mounting the outdoor unit............... 31

7.3.3 To provide the installation structure ............................. 31

7.3.4 To install the outdoor unit............................................. 32

7.3.5 To provide drainage ..................................................... 33

7.3.6 To prevent the outdoor unit from falling over ............... 33

7.4 Mounting the indoor unit............................................................. 34

7.4.1 About mounting the indoor unit.................................... 34

7.4.2 Precautions when mounting the indoor unit................. 34

7.4.3 To install the indoor unit............................................... 34

7.4.4 To connect the drain hose to the drain ........................ 35

7.5 Connecting the refrigerant piping ............................................... 35

7.5.1 About connecting the refrigerant piping ....................... 35

7.5.2 Precautions when connecting the refrigerant piping.... 35

7.5.3 Guidelines when connecting the refrigerant piping...... 35

7.5.4 Pipe bending guidelines............................................... 36

7.5.5 To flare the pipe end .................................................... 36

7.5.6 To braze the pipe end .................................................. 36

7.5.7 Using the stop valve and service port .......................... 36

7.5.8 To connect the refrigerant piping to the outdoor unit ... 37

7.5.9 To connect the refrigerant piping to the indoor unit ..... 37

7.6 Checking the refrigerant piping .................................................. 37

7.6.1 About checking the refrigerant piping .......................... 37

7.6.2 Precautions when checking the refrigerant piping ....... 38

7.6.3 To check for leaks........................................................ 38

7.6.4 To perform vacuum drying ........................................... 38

7.7 Charging refrigerant ................................................................... 38

7.7.1 About charging refrigerant ........................................... 38

7.7.2 Precautions when charging refrigerant ........................ 39

7.7.3 To determine the additional refrigerant amount........... 39

7.7.4 To determine the complete recharge amount.............. 39

7.7.5 To charge additional refrigerant ................................... 39

7.7.6 To fix the fluorinated greenhouse gases label ............. 39

7.8 Connecting the water piping....................................................... 39

7.8.1 About connecting the water piping............................... 39

7.8.2 Precautions when connecting the water piping............ 40

7.8.3 To connect the water piping......................................... 40

7.8.4 To fill the water circuit .................................................. 40

7.8.5 To fill the domestic hot water tank ............................... 41

7.8.6 To insulate the water piping ......................................... 41

7.9 Connecting the electrical wiring.................................................. 41

Installer reference guide

RRGA04~08DAV3 + RHBX04+08DA

ROTEX HPSU Bi-Bloc Ultra

4P495262-1A – 2018.11

1 General safety precautions

7.9.1 About connecting the electrical wiring......................... 41

7.9.2 About electrical compliance ........................................ 41

7.9.3 Precautions when connecting the electrical wiring ..... 41

7.9.4 Guidelines when connecting the electrical wiring ....... 41

7.9.5 Specifications of standard wiring components............ 41

7.9.6 To connect the electrical wiring on the outdoor unit.... 42

7.9.7 To connect the electrical wiring on the indoor unit...... 42

7.9.8 To connect the main power supply ............................. 43

7.9.9 To connect the backup heater power supply .............. 43

7.9.10 To connect the shut-off valve ...................................... 45

7.9.11 To connect the electrical meters ................................. 45

7.9.12 To connect the domestic hot water pump ................... 45

7.9.13 To connect the alarm output ....................................... 45

7.9.14 To connect the space cooling/heating ON/OFF

output .......................................................................... 45

7.9.15 To connect the changeover to external heat source ... 45

7.9.16 To connect the power consumption digital inputs ....... 46

7.9.17 To connect the safety thermostat (normal closed

contact) ....................................................................... 46

7.10 Finishing the outdoor unit installation ........................................ 46

7.10.1 To finish the outdoor unit installation .......................... 46

7.11 Finishing the indoor unit installation .......................................... 46

7.11.1 To close the indoor unit............................................... 46

8 Configuration 46

8.1 Overview: Configuration ............................................................ 46

8.1.1 To access the most used commands ......................... 47

8.2 Configuration wizard.................................................................. 47

8.3 Possible screens ....................................................................... 48

8.3.1 Possible screens: Overview........................................ 48

8.3.2 Home screen............................................................... 48

8.3.3 Main menu screen ...................................................... 49

8.3.4 Menu screen ............................................................... 49

8.3.5 Setpoint screen........................................................... 49

8.3.6 Detailed screen with values ........................................ 50

8.3.7 Detailed screen with weather-dependent curve.......... 50

8.3.8 Schedule screen: Example ......................................... 50

8.4 Settings menu ........................................................................... 52

8.4.1 Malfunction.................................................................. 52

8.4.2 Room .......................................................................... 52

8.4.3 Main zone ................................................................... 53

8.4.4 Additional zone ........................................................... 57

8.4.5 Space heating/cooling................................................. 59

8.4.6 Tank ............................................................................ 62

8.4.7 User settings ............................................................... 65

8.4.8 Information .................................................................. 67

8.4.9 Installer settings .......................................................... 67

8.5 Menu structure: Overview user settings .................................... 76

8.6 Menu structure: Overview installer settings............................... 77

11.5.3 To install the water filter ............................................... 83

12 Troubleshooting 84

12.1 Overview: Troubleshooting......................................................... 84

12.2 Precautions when troubleshooting ............................................. 84

12.3 Solving problems based on symptoms....................................... 84

12.3.1 Symptom: The unit is NOT heating or cooling as

expected ...................................................................... 84

12.3.2 Symptom: The compressor does NOT start (space

heating or domestic water heating).............................. 85

12.3.3 Symptom: The system is making gurgling noises

after commissioning ..................................................... 85

12.3.4 Symptom: The pump is making noise (cavitation) ....... 85

12.3.5 Symptom: The pressure relief valve opens.................. 85

12.3.6 Symptom: The water pressure relief valve leaks ......... 86

12.3.7 Symptom: The space is NOT sufficiently heated at

low outdoor temperatures ............................................ 86

12.3.8 Symptom: The pressure at the tapping point is

temporarily unusually high ........................................... 86

12.3.9 Symptom: Decoration panels are pushed away due

to a swollen tank .......................................................... 86

12.3.10 Symptom: Tank disinfection function is NOT

completed correctly (AH-error)..................................... 86

12.4 Solving problems based on error codes ..................................... 87

12.4.1 To display the help text in case of a malfunction ......... 87

12.4.2 Error codes: Overview ................................................. 87

13 Disposal 88

13.1 Overview: Disposal..................................................................... 88

13.2 To pump down............................................................................ 88

13.3 To start and stop forced cooling ................................................. 89

14 Technical data 90

14.1 Piping diagram: Outdoor unit...................................................... 90

14.2 Piping diagram: Indoor unit ........................................................ 91

14.3 Wiring diagram: Outdoor unit ..................................................... 92

14.4 Wiring diagram: Indoor unit ........................................................ 93

14.5 Table 1 – Maximum refrigerant charge allowed in a room:

indoor unit................................................................................... 96

14.6 Table 2 – Minimum floor area: indoor unit .................................. 96

14.7 Table 3 – Minimum venting opening area for natural

ventilation: indoor unit ................................................................ 97

14.8 ESP curve: Indoor unit ............................................................... 98

15 Glossary 98

16 Field settings table 99

1 General safety precautions

9 Commissioning 78

9.1 Overview: Commissioning......................................................... 78

9.2 Precautions when commissioning ............................................. 78

9.3 Checklist before commissioning................................................ 78

9.4 Checklist during commissioning ................................................ 78

9.4.1 To check the minimum flow rate ................................. 79

9.4.2 Air purge function........................................................ 79

9.4.3 To perform an operation test run ................................ 79

9.4.4 To perform an actuator test run .................................. 80

9.4.5 Underfloor heating screed dryout................................ 80

10 Hand-over to the user 81

11 Maintenance and service 81

11.1 Overview: Maintenance and service ......................................... 81

11.2 Maintenance safety precautions................................................ 81

11.3 Checklist for yearly maintenance of the outdoor unit ................ 81

11.4 Checklist for yearly maintenance of the indoor unit................... 82

11.5 About cleaning the water filter in case of trouble....................... 83

11.5.1 To remove the water filter ........................................... 83

11.5.2 To clean the water filter in case of trouble .................. 83

RRGA04~08DAV3 + RHBX04+08DA ROTEX HPSU Bi-Bloc Ultra 4P495262-1A – 2018.11

1.1 About the documentation

▪ The original documentation is written in English. All other

languages are translations.

▪ The precautions described in this document cover very important

topics, follow them carefully.

▪ The installation of the system, and all activities described in the

installation manual and the installer reference guide MUST be performed by an authorised installer.

1.1.1 Meaning of warnings and symbols

DANGER

Indicates a situation that results in death or serious injury.

DANGER: RISK OF ELECTROCUTION

Indicates a situation that could result in electrocution.

Installer reference guide

1 General safety precautions

DANGER: RISK OF BURNING

Indicates a situation that could result in burning because of extreme hot or cold temperatures.

DANGER: RISK OF EXPLOSION

Indicates a situation that could result in explosion.

WARNING

Indicates a situation that could result in death or serious injury.

WARNING: FLAMMABLE MATERIAL

CAUTION

Indicates a situation that could result in minor or moderate injury.

NOTICE

Indicates a situation that could result in equipment or property damage.

INFORMATION

Indicates useful tips or additional information.

Symbol Explanation

Before installation, read the installation and operation manual, and the wiring instruction sheet.

Before performing maintenance and service tasks, read the service manual.

For more information, see the installer and user reference guide.

1.2 For the installer

1.2.1 General

If you are NOT sure how to install or operate the unit, contact your dealer.

NOTICE

Improper installation or attachment of equipment or accessories could result in electric shock, short-circuit, leaks, fire or other damage to the equipment. Only use accessories, optional equipment and spare parts made or approved by ROTEX.

WARNING

Make sure installation, testing and applied materials comply with applicable legislation (on top of the instructions described in the ROTEX documentation).

CAUTION

Wear adequate personal protective equipment (protective gloves, safety glasses,…) when installing, maintaining or servicing the system.

WARNING

Tear apart and throw away plastic packaging bags so that nobody, especially children, can play with them. Possible risk: suffocation.

DANGER: RISK OF BURNING

▪ Do NOT touch the refrigerant piping, water piping or

internal parts during and immediately after operation. It could be too hot or too cold. Give it time to return to normal temperature. If you must touch it, wear protective gloves.

▪ Do NOT touch any accidental leaking refrigerant.

WARNING

Provide adequate measures to prevent that the unit can be used as a shelter by small animals. Small animals that make contact with electrical parts can cause malfunctions, smoke or fire.

CAUTION

Do NOT touch the air inlet or aluminium fins of the unit.

NOTICE

▪ Do NOT place any objects or equipment on top of the

unit.

▪ Do NOT sit, climb or stand on the unit.

NOTICE

Works executed on the outdoor unit are best done under dry weather conditions to avoid water ingress.

In accordance with the applicable legislation, it might be necessary to provide a logbook with the product containing at least: information on maintenance, repair work, results of tests, stand-by periods,…

Also, at least, following information MUST be provided at an accessible place at the product:

▪ Instructions for shutting down the system in case of an emergency

▪ Name and address of fire department, police and hospital

▪ Name, address and day and night telephone numbers for

obtaining service

In Europe, EN378 provides the necessary guidance for this logbook.

1.2.2 Installation site

▪ Provide sufficient space around the unit for servicing and air

circulation.

▪ Make sure the installation site withstands the unit's weight and

vibration.

▪ Make sure the area is well ventilated. Do NOT block any

ventilation openings.

▪ Make sure the unit is level.

Do NOT install the unit in the following places:

▪ In potentially explosive atmospheres.

▪ In places where there is machinery that emits electromagnetic

waves. Electromagnetic waves may disturb the control system, and cause malfunction of the equipment.

▪ In places where there is a risk of fire due to the leakage of

flammable gases (example: thinner or gasoline), carbon fibre, ignitable dust.

▪ In places where corrosive gas (example: sulphurous acid gas) is

produced. Corrosion of copper pipes or soldered parts may cause the refrigerant to leak.

Installer reference guide

1.2.3 Refrigerant

If applicable. See the installation manual or installer reference guide of your application for more information.

RRGA04~08DAV3 + RHBX04+08DA

ROTEX HPSU Bi-Bloc Ultra

4P495262-1A – 2018.11

1 General safety precautions

NOTICE

Make sure refrigerant piping installation complies with applicable legislation. In Europe, EN378 is the applicable standard.

NOTICE

Make sure the field piping and connections are NOT subjected to stress.

WARNING

During tests, NEVER pressurize the product with a pressure higher than the maximum allowable pressure (as indicated on the nameplate of the unit).

WARNING

Take sufficient precautions in case of refrigerant leakage. If refrigerant gas leaks, ventilate the area immediately. Possible risks:

▪ Excessive refrigerant concentrations in a closed room

can lead to oxygen deficiency.

▪ Toxic gas may be produced if refrigerant gas comes

into contact with fire.

DANGER: RISK OF EXPLOSION

Pump down – Refrigerant leakage. If you want to pump

down the system, and there is a leak in the refrigerant circuit:

▪ Do NOT use the unit's automatic pump down function,

with which you can collect all refrigerant from the system into the outdoor unit. Possible consequence: Self-combustion and explosion of the compressor because of air going into the operating compressor.

▪ Use a separate recovery system so that the unit's

compressor does NOT have to operate.

WARNING

ALWAYS recover the refrigerant. Do NOT release them directly into the environment. Use a vacuum pump to evacuate the installation.

NOTICE

After all the piping has been connected, make sure there is no gas leak. Use nitrogen to perform a gas leak detection.

NOTICE

▪ To avoid compressor breakdown, do NOT charge more

than the specified amount of refrigerant.

▪ When the refrigerant system is to be opened,

refrigerant MUST be treated according to the applicable legislation.

WARNING

Make sure there is no oxygen in the system. Refrigerant may only be charged after performing the leak test and the vacuum drying.

▪ In case re-charge is required, refer to the nameplate of the unit. It

states the type of refrigerant and necessary amount.

▪ The unit is factory charged with refrigerant and depending on pipe

sizes and pipe lengths some systems require additional charging of refrigerant.

▪ Only use tools exclusively for the refrigerant type used in the

system, this to ensure pressure resistance and prevent foreign materials from entering into the system.

▪ Charge the liquid refrigerant as follows:

If Then

A siphon tube is present

(i.e., the cylinder is marked with "Liquid filling siphon attached")

A siphon tube is NOT present Charge with the cylinder upside

▪ Open refrigerant cylinders slowly.

▪ Charge the refrigerant in liquid form. Adding it in gas form may

prevent normal operation.

CAUTION

When the refrigerant charging procedure is done or when pausing, close the valve of the refrigerant tank immediately. If the valve is NOT closed immediately, remaining pressure might charge additional refrigerant. Possible consequence: Incorrect refrigerant amount.

Charge with the cylinder upright.

down.

1.2.4 Brine

If applicable. See the installation manual or installer reference guide of your application for more information.

WARNING

The selection of the brine MUST be in accordance with the applicable legislation.

WARNING

Take sufficient precautions in case of brine leakage. If brine leaks, ventilate the area immediately and contact your local dealer.

WARNING

The ambient temperature inside the unit can get much higher than that of the room, e.g. 70°C. In case of a brine leak, hot parts inside the unit can create a hazardous situation.

WARNING

The use and installation of the application MUST comply with the safety and environmental precautions specified in the applicable legislation.

1.2.5 Water

If applicable. See the installation manual or installer reference guide of your application for more information.

NOTICE

Make sure water quality complies with EU directive 98/83EC.

RRGA04~08DAV3 + RHBX04+08DA ROTEX HPSU Bi-Bloc Ultra 4P495262-1A – 2018.11

Installer reference guide

2 About the documentation

1.2.6 Electrical

DANGER: RISK OF ELECTROCUTION

▪ Turn OFF all power supply before removing the

switch box cover, connecting electrical wiring or touching electrical parts.

▪ Disconnect the power supply for more than 1 minute,

and measure the voltage at the terminals of main circuit capacitors or electrical components before servicing. The voltage MUST be less than 50 V DC before you can touch electrical components. For the location of the terminals, see the wiring diagram.

▪ Do NOT touch electrical components with wet hands.

▪ Do NOT leave the unit unattended when the service

cover is removed.

WARNING

If NOT factory installed, a main switch or other means for disconnection, having a contact separation in all poles providing full disconnection under overvoltage category III condition, MUST be installed in the fixed wiring.

WARNING

▪ ONLY use copper wires.

▪ Make sure the field wiring complies with the applicable

legislation.

▪ All field wiring MUST be performed in accordance with

the wiring diagram supplied with the product.

▪ NEVER squeeze bundled cables and make sure they

do NOT come in contact with the piping and sharp edges. Make sure no external pressure is applied to the terminal connections.

▪ Make sure to install earth wiring. Do NOT earth the unit

to a utility pipe, surge absorber, or telephone earth. Incomplete earth may cause electrical shock.

▪ Make sure to use a dedicated power circuit. NEVER

use a power supply shared by another appliance.

▪ Make sure to install the required fuses or circuit

breakers.

▪ Make sure to install an earth leakage protector. Failure

to do so may cause electric shock or fire.

▪ When installing the earth leakage protector, make sure

it is compatible with the inverter (resistant to high frequency electric noise) to avoid unnecessary opening of the earth leakage protector.

CAUTION

When connecting the power supply, the earth connection must be made before the current-carrying connections are established. When disconnecting the power supply, the current-carrying connections must be separated before the earth connection is. The length of the conductors between the power supply stress relief and the terminal block itself must be as such that the current-carrying wires are tautened before the earth wire is in case the power supply is pulled loose from the stress relief.

NOTICE

Precautions when laying power wiring:

▪ Do NOT connect wiring of different thicknesses to the

power terminal block (slack in the power wiring may cause abnormal heat).

▪ When connecting wiring which is the same thickness,

do as shown in the figure above.

▪ For wiring, use the designated power wire and connect

firmly, then secure to prevent outside pressure being exerted on the terminal board.

▪ Use an appropriate screwdriver for tightening the

terminal screws. A screwdriver with a small head will damage the head and make proper tightening impossible.

▪ Over-tightening the terminal screws may break them.

Install power cables at least 1 metre away from televisions or radios to prevent interference. Depending on the radio waves, a distance of 1metre may not be sufficient.

WARNING

▪ After finishing the electrical work, confirm that each

electrical component and terminal inside the electrical components box is connected securely.

▪ Make sure all covers are closed before starting up the

unit.

NOTICE

Only applicable if the power supply is three‑phase, and the compressor has an ON/OFF starting method.

If there exists the possibility of reversed phase after a momentary black out and the power goes on and off while the product is operating, attach a reversed phase protection circuit locally. Running the product in reversed phase can break the compressor and other parts.

2 About the documentation

2.1 About this document

Target audience

Authorised installers

Documentation set

This document is part of a documentation set. The complete set consists of:

▪ General safety precautions:

▪ Safety instructions that you must read before installing

▪ Format: Paper (in the box of the indoor unit)

▪ Indoor unit installation manual:

▪ Installation instructions

▪ Format: Paper (in the box of the indoor unit)

▪ Outdoor unit installation manual:

▪ Installation instructions

▪ Format: Paper (in the box of the outdoor unit)

Installer reference guide

RRGA04~08DAV3 + RHBX04+08DA

ROTEX HPSU Bi-Bloc Ultra

4P495262-1A – 2018.11

3 About the box

1 2

▪ Installer reference guide:

▪ Preparation of the installation, good practices, reference data,…

▪ Format: Digital files on the ROTEX homepage

▪ Addendum book for optional equipment:

▪ Additional info about how to install optional equipment

▪ Format: Paper (in the box of the indoor unit) + Digital files on

the ROTEX homepage

Latest revisions of the supplied documentation may be available on the regional ROTEX website or via your dealer.

The original documentation is written in English. All other languages are translations.

2.2 Installer reference guide at a glance

Chapter Description

General safety precautions

About the documentation What documentation exists for the

About the box How to unpack the units and remove

About the units and options

Application guidelines Various installation setups of the system

Preparation What to do and know before going

Installation What to do and know to install the

Configuration What to do and know to configure the

Commissioning What to do and know to commission the

Hand‑over to the user What to give and explain to the user

Maintenance and service How to maintain and service the units

Troubleshooting What to do in case of problems

Disposal How to dispose of the system

Technical data Specifications of the system

Glossary Definition of terms

Field settings table Table to be filled in by the installer, and

Safety instructions that you must read before installing

installer

their accessories

▪ How to identify the units

▪ Possible combinations of units and

options

on‑site

system

system after it is installed

system after it is configured

kept for future reference

Note: There is also an installer settings table in the user reference guide. This table has to be filled in by the installer and handed over to the user.

▪ Prepare the path along which you want to bring the unit inside in

advance.

3.2 Outdoor unit

3.2.1 To unpack the outdoor unit

3.2.2 To handle the outdoor unit

CAUTION

To avoid injury, do NOT touch the air inlet or aluminium fins of the unit.

1 Handle the unit using the sling to the left and the handle to the

right. Pull up both sides of the sling at the same time to prevent disconnection of the sling from the unit.

3 About the box

3.1 Overview: About the box

This chapter describes what you have to do after the boxes with the outdoor and indoor unit are delivered on-site.

Keep the following in mind:

▪ At delivery, the unit MUST be checked for damage. Any damage

MUST be reported immediately to the carrier's claims agent.

▪ Bring the packed unit as close as possible to its final installation

position to prevent damage during transport.

RRGA04~08DAV3 + RHBX04+08DA ROTEX HPSU Bi-Bloc Ultra 4P495262-1A – 2018.11

2 While handling the unit:

Installer reference guide

4 About the units and options

ENERG

IJAY IAIE

ENERG

IJAY IAIE

1×1× 1× 1× 2× 1×

da b c e f

1 2

1× 1× 1× 1×

a b c d

2×4× 1×

fe g

1×

▪ Keep both sides of the sling level. ▪ Keep your back straight.

3 After mounting the unit, remove the sling from the unit by pulling

1 side of the sling.

3.2.3 To remove the accessories from the outdoor unit

1 Lift the outdoor unit. See "3.2.2 To handle the outdoor unit"on

page7.

2 Remove the accessories at the bottom of the package.

3.3.2 To remove the accessories from the indoor unit

Some accessories are located inside the unit. To open the unit, see

"7.2.3To open the indoor unit"on page30.

a General safety precautions b Addendum book for optional equipment c Indoor unit installation manual d Operation manual e Sealing ring for shut-off valve

f Shut-off valve g Overpressure bypass valve h Wall bracket

a Outdoor unit installation manual b Fluorinated greenhouse gases label c Multilingual fluorinated greenhouse gases label d Energy label e Unit mounting plate

f Bolts, nuts, washers, spring washers and wire clamp

3.3 Indoor unit

3.3.1 To unpack the indoor unit

4 About the units and options

4.1 Overview: About the units and options

This chapter contains information about:

▪ Identifying the outdoor unit

▪ Identifying the indoor unit

▪ Combining the outdoor unit with options

▪ Combining the indoor unit with options

4.2 Identification

NOTICE

When installing or servicing several units at the same time, make sure NOT to switch the service panels between different models.

4.2.1 Identification label: Outdoor unit

Location

Installer reference guide

Model identification

Example: RRGA06DAV3

Code Explanation

RR Split outdoor pair heat pump

RRGA04~08DAV3 + RHBX04+08DA

ROTEX HPSU Bi-Bloc Ultra

4P495262-1A – 2018.11

4 About the units and options

Code Explanation

G Medium water temperature – ambient zone: −10~

−20°C

A Refrigerant R32

06 Capacity class

DA Model series

V3 Power supply

4.2.2 Identification label: Indoor unit

Location

Model identification

Example: RHBX04DA6V

Code Description

R ROTEX model

HB Wall-mounted indoor unit

X Heating/cooling

04 Capacity class

DA Model series

6V Backup heater model

4.3 Combining units and options

4.3.1 Possible options for the outdoor unit

Drain pan kit (EKDP008D)

The drain pan kit is required to gather the drain from the outdoor unit. The drain pan kit consists of:

▪ Drain pan

▪ Installation brackets

For installation instructions, see the installation manual of the drain pan.

Drain pan heater (EKDPH008CA)

The drain pan heater is required to avoid freezing-up of the drain pan.

It is recommended to install this option in colder regions with possible low ambient temperatures or heavy snowfall.

For installation instructions, see the installation manual of the drain pan heater.

U-beams (EKFT008D)

The U-beams are installation brackets on which the outdoor unit can be installed.

It is recommended to install this option in colder regions with possible low ambient temperatures or heavy snowfall.

For installation instructions, see the installation manual of the outdoor unit.

Low sound cover (EKLN08A1)

In sound sensitive areas (e.g. near a bedroom), you can install the low sound cover to decrease the operation noise of the outdoor unit.

You can install the low sound cover:

▪ On mounting feet to the ground. This must withstand 200kg.

▪ On brackets to the wall. This must withstand 200kg.

If you install the low sound cover, you also need to install one of the following options:

▪ Recommended: Drain pan kit (with or without drain pan heater)

▪ U-beams

For installation instructions, see the installation manual of the low sound cover.

4.3.2 Possible options for the indoor unit

Room thermostat (RKRTWA, RKRTR1)

You can connect an optional room thermostat to the indoor unit. This thermostat can either be wired (RKRTWA) or wireless (RKRTR1).

For installation instructions, see the installation manual of the room thermostat and addendum book for optional equipment.

Remote sensor for wireless thermostat (EKRTETS)

You can use a wireless indoor temperature sensor (EKRTETS) only in combination with the wireless thermostat (RKRTR1).

For installation intructions, see the installation manual of the room thermostat and addendum book for optional equipment.

Digital I/O PCB (EKRP1HB)

The digital I/O PCB is required to provide following signals:

▪ Alarm output

▪ Space heating/cooling On/OFF output

▪ Changeover to external heat source

For installation instructions, see the installation manual of the digital I/O PCB and addendum book for optional equipment.

Demand PCB (EKRP1AHTA)

To enable the power saving consumption control by digital inputs you must install the demand PCB.

For installation instructions, see the installation manual of the demand PCB and addendum book for optional equipment.

Remote outdoor sensor (EKRSCA1)

By default the sensor inside the outdoor unit will be used to measure the outdoor temperature.

As an option the remote outdoor sensor can be installed to measure the outdoor temperature on another location (e.g. to avoid direct sunlight) to have an improved system behaviour.

For installation instructions, see the installation manual of the remote outdoor sensor.

PC cable (EKPCCAB)

The PC cable makes a connection between the switch box of the indoor unit and a PC. It gives the possibility to update the software of the indoor unit.

For installation instructions, see the installation manual of the PC cable and "8Configuration"on page46.

Heat pump convector (RFWXV)

For providing space heating/cooling, it is possible to use heat pump convectors (RFWXV).

RRGA04~08DAV3 + RHBX04+08DA ROTEX HPSU Bi-Bloc Ultra 4P495262-1A – 2018.11

Installer reference guide

5 Application guidelines

For installation instructions, refer to the installation manual of the heat pump convectors, and the addendum book for optional equipment.

LAN adapter for smartphone control + Smart Grid applications (BRP069A61)

You can install this LAN adapter to:

▪ Control the system via a smartphone app.

▪ Use the system in various Smart Grid applications.

For installation instructions, see the installation manual of the LAN adapter.

LAN adapter for smartphone control (BRP069A62)

You can install this LAN adapter to control the system via a smartphone app.

For installation instructions, see the installation manual of the LAN adapter.

4.3.3 Possible combinations of indoor unit and outdoor unit

Indoor unit Outdoor unit

RRGA04 RRGA06 RRGA08

RHBX04 O — —

RHBX08 — O O

4.3.4 Possible combinations of indoor unit and domestic hot water tank

Indoor unit Domestic hot water tank

HYC

RHBX04 O

RHBX08 O

5 Application guidelines

5.2 Setting up the space heating/ cooling system

The heatpump system supplies leaving water to heat emitters in one or more rooms.

Because the system offers a wide flexibility to control the temperature in each room, you need to answer the following questions first:

▪ How many rooms are heated or cooled by the ROTEX heatpump

system?

▪ Which heat emitter types are used in each room and what is their

design leaving water temperature?

Once the space heating/cooling requirements are clear, ROTEX recommends to follow the setup guidelines below.

NOTICE

If an external room thermostat is used, the external room thermostat will control the room frost protection. However, the room frost protection is only possible if the leaving water temperature control on the unit's user interface is turned ON.

INFORMATION

In case an external room thermostat is used and room frost protection needs to be guaranteed in all conditions, then you have to set Emergency [9.5] to Automatic.

NOTICE

An overpressure bypass valve can be integrated in the system. Keep in mind that this valve might not be shown on the illustrations.

5.2.1 Single room

Underfloor heating or radiators – Wired room thermostat

Setup

5.1 Overview: Application guidelines

The purpose of the application guidelines is to give a glance of the possibilities of the ROTEX heatpump system.

NOTICE

▪ The illustrations in the application guidelines are meant

for reference only, and are NOT to be used as detailed hydraulic diagrams. The detailed hydraulic dimensioning and balancing are NOT shown, and are the responsibility of the installer.

▪ For more information about the configuration settings to

optimize heatpump operation, see "8Configuration"on

page46.

This chapter contains application guidelines for:

▪ Setting up the space heating/cooling system

▪ Setting up an auxiliary heat source for space heating

▪ Setting up the domestic hot water tank

▪ Setting up the energy metering

▪ Setting up the power consumption control

▪ Setting up an external temperature sensor

A Main leaving water temperature zone B One single room

a User interface used as room thermostat

▪ The under floor heating or radiators are directly connected to the

indoor unit.

▪ The room temperature of the main room is controlled by the user

interface used as a room thermostat (optional equipment EKRUDAS).

Configuration

Setting Value

Unit temperature control:

▪ #: [2.9]

▪ Code: [C-07]

2 (Room thermostat): Unit operation is decided based on the ambient temperature of the user interface.

Installer reference guide

RRGA04~08DAV3 + RHBX04+08DA

ROTEX HPSU Bi-Bloc Ultra

4P495262-1A – 2018.11

5 Application guidelines

Setting Value

Number of water temperature zones:

▪ #: [4.4]

▪ Code: [7-02]

Benefits

▪ Highest comfort and efficiency. The smart room thermostat

functionality can decrease or increase the desired leaving water temperature based on the actual room temperature (modulation). This results in:

▪ Stable room temperature matching the desired temperature

(higher comfort)

▪ Less ON/OFF cycles (more quiet, higher comfort and higher

efficiency)

▪ Lowest possible leaving water temperature (higher efficiency)

▪ Easy. You can easily set the desired room temperature via the

user interface:

▪ For your daily needs, you can use preset values and schedules.

▪ To deviate from your daily needs, you can temporarily overrule

the preset values and schedules, use the holiday mode…c

0 (Single zone): Main

Underfloor heating or radiators – Wireless room thermostat

Setup

Benefits

▪ Wireless. The ROTEX external room thermostat is available in a

wireless version.

▪ Efficiency. Although the external room thermostat only sends ON/

OFF signals, it is specifically designed for the heatpump system.

Heatpump convectors

Setup

A Main leaving water temperature zone B One single room

a Remote controller of the heatpump convectors

▪ The heat pump convectors are directly connected to the indoor

unit.

▪ The desired room temperature is set via the remote controller of

the heatpump convectors.

▪ The space heating/cooling demand signal is sent to one digital

input on the indoor unit (X2M/35 and X2M/30).

▪ The space operation mode is sent to the heatpump convectors by

one digital output on the indoor unit (X2M/4 and X2M/3).

A Main leaving water temperature zone B One single room

a Receiver for wireless external room thermostat

b Wireless external room thermostat

▪ The under floor heating or radiators are directly connected to the

indoor unit.

▪ The room temperature is controlled by the wireless external room

thermostat (optional equipment RKRTR1).

Configuration

Setting Value

Unit temperature control:

▪ #: [2.9]

▪ Code: [C-07]

Number of water temperature zones:

▪ #: [4.4]

▪ Code: [7-02]

External room thermostat for the main zone:

▪ #: [2.A]

▪ Code: [C-05]

1 (External room thermostat): Unit operation is decided by the external thermostat.

0 (Single zone): Main

1 (1 contact): When the used external room thermostat or heatpump convector can only send a thermo ON/OFF condition. No separation between heating or cooling demand.

INFORMATION

When using multiple heat pump convectors, make sure each one receives the infrared signal from the remote controller of the heatpump convectors.

Configuration

Setting Value

Unit temperature control:

▪ #: [2.9]

▪ Code: [C-07]

Number of water temperature zones:

▪ #: [4.4]

▪ Code: [7-02]

External room thermostat for the main zone:

▪ #: [2.A]

▪ Code: [C-05]

Benefits

▪ Cooling. The heat pump convector offers, besides heating

capacity, also excellent cooling capacity.

▪ Efficiency. Optimal energy efficiency because of the interlink

function.

▪ Stylish.

1 (External room thermostat): Unit operation is decided by the external thermostat.

0 (Single zone): Main

1 (1 contact): When the used external room thermostat or heatpump convector can only send a thermo ON/OFF condition. No separation between heating or cooling demand.

RRGA04~08DAV3 + RHBX04+08DA ROTEX HPSU Bi-Bloc Ultra 4P495262-1A – 2018.11

Installer reference guide

5 Application guidelines

B C

Combination: Underfloor heating + Heatpump convectors

▪ Space heating is provided by:

▪ The underfloor heating

▪ The heatpump convectors

▪ Space cooling is provided by the heatpump convectors only. The

underfloor heating is shut off by the shut-off valve.

Setup

A Main leaving water temperature zone B One single room

a Remote controller of the heatpump convectors

▪ The heat pump convectors are directly connected to the indoor

unit.

▪ A shut-off valve (field supply) is installed before the under floor

heating to prevent condensation on the floor during cooling operation.

▪ The desired room temperature is set via the remote controller of

the heatpump convectors.

▪ The space heating/cooling demand signal is sent to one digital

input on the indoor unit (X2M/35 and X2M/30).

▪ The space operation mode is sent by one digital output (X2M/4

and X2M/3) on the indoor unit to:

▪ The heatpump convectors

▪ The shut-off valve

Configuration

Setting Value

Unit temperature control:

▪ #: [2.9]

▪ Code: [C-07]

Number of water temperature zones:

▪ #: [4.4]

▪ Code: [7-02]

External room thermostat for the main zone:

▪ #: [2.A]

▪ Code: [C-05]

Benefits

▪ Cooling. Heat pump convectors provide, besides heating

capacity, also excellent cooling capacity.

▪ Efficiency. Under floor heating has the best performance with

ROTEX HPSU.

Installer reference guide

1 (External room thermostat): Unit operation is decided by the external thermostat.

0 (Single zone): Main

1 (1 contact): When the used external room thermostat or heatpump convector can only send a thermo ON/OFF condition. No separation between heating or cooling demand.

▪ Comfort. The combination of the two heat emitter types provides:

▪ The excellent heating comfort of the underfloor heating

▪ The excellent cooling comfort of the heatpump convectors

5.2.2 Multiple rooms – OneLWT zone

If only one leaving water temperature zone is needed because the design leaving water temperature of all heat emitters is the same, you do NOT need a mixing valve station (cost effective).

Example: If the heat pump system is used to heat up one floor where all the rooms have the same heat emitters.

Underfloor heating or radiators – Thermostatic valves

If you are heating up rooms with under floor heating or radiators, a very common way is to control the temperature of the main room by using a thermostat (this can either be the user interface or an external room thermostat), while the other rooms are controlled by so-called thermostatic valves, which open or close depending on the room temperature.

Setup

A Main leaving water temperature zone B Room 1 C Room 2

a User interface used as room thermostat

▪ The under floor heating of the main room is directly connected to

the indoor unit.

▪ The room temperature of the main room is controlled by the user

interface used as a room thermostat (optional equipment EKRUDAS).

▪ A thermostatic valve is installed before the under floor heating in

each of the other rooms.

INFORMATION

Mind situations where the main room can be heated by another heating source. Example: Fireplaces.

Configuration

Setting Value

Unit temperature control:

▪ #: [2.9]

▪ Code: [C-07]

Number of water temperature zones:

▪ #: [4.4]

▪ Code: [7-02]

Benefits

▪ Easy. Same installation as for one room, but with thermostatic

valves.

2 (Room thermostat): Unit operation is decided based on the ambient temperature of the user interface.

0 (Single zone): Main

RRGA04~08DAV3 + RHBX04+08DA

ROTEX HPSU Bi-Bloc Ultra

4P495262-1A – 2018.11

5 Application guidelines

M2M1

B C

a a

B C

Underfloor heating or radiators – Multiple external room thermostats

Setup

A Main leaving water temperature zone B Room 1 C Room 2

a External room thermostat

b Bypass valve

▪ For each room, a shut-off valve (field supplied) is installed to avoid

leaving water supply when there is no heating or cooling demand.

▪ A bypass valve must be installed to make water recirculation

possible when all shut-off valves are closed. To guarantee reliable operation, provide a minimum water flow as described in table "To check the water volume and flow rate" in "6.4 Preparing water

piping"on page25.

▪ The user interface connected on the indoor unit decides the space

operation mode. Mind that the operation mode on each room thermostat must be set to match the indoor unit.

▪ The room thermostats are connected to the shut-off valves, but do

NOT have to be connected to the indoor unit. The indoor unit will supply leaving water all the time, with the possibility to program a leaving water schedule.

Configuration

Setting Value

Unit temperature control:

▪ #: [2.9]

▪ Code: [C-07]

Number of water temperature zones:

▪ #: [4.4]

▪ Code: [7-02]

0 (Leaving water): Unit operation is decided based on the leaving water temperature.

0 (Single zone): Main

B Room 1 C Room 2

a Remote controller of the heatpump convectors

▪ The desired room temperature is set via the remote controller of

the heatpump convectors.

▪ The user interface connected on the indoor unit decides the space

operation mode.

▪ The heating or cooling demand signals of each heat pump

convector are connected in parallel to the digital input on the indoor unit (X2M/35 and X2M/30). The indoor unit will only supply leaving water temperature when there is an actual demand.

INFORMATION

To increase comfort and performance, ROTEX recommends to install the valve kit option EKVKHPC on each heatpump convector.

Configuration

Setting Value

Unit temperature control:

▪ #: [2.9]

1 (External room thermostat): Unit operation is decided by the external thermostat.

▪ Code: [C-07]

Number of water temperature

0 (Single zone): Main

zones:

▪ #: [4.4]

▪ Code: [7-02]

Benefits

Compared with heatpump convectors for one room:

▪ Comfort. You can set the desired room temperature, including

schedules, for each room via the remote controller of the heatpump convectors.

Combination: Underfloor heating + Heatpump convectors – Multiple rooms

Setup

Benefits

Compared with underfloor heating or radiators for one room:

▪ Comfort. You can set the desired room temperature, including

schedules, for each room via the room thermostats.

Heatpump convectors – Multiple rooms

Setup

A Main leaving water temperature zone

RRGA04~08DAV3 + RHBX04+08DA ROTEX HPSU Bi-Bloc Ultra 4P495262-1A – 2018.11

A Main leaving water temperature zone B Room 1 C Room 2

a External room thermostat b Remote controller of the heatpump convectors

▪ For each room with heat pump convectors: The heat pump

convectors are directly connected to the indoor unit.

▪ For each room with under floor heating: Two shut-off valves (field

supply) are installed before the underfloor heating:

▪ A shut-off valve to prevent hot water supply when the room has

no heating demand

▪ A shut-off valve to prevent condensation on the floor during

cooling operation of the rooms with heatpump convectors.

▪ For each room with heat pump convectors: The desired room

temperature is set via the remote controller of the heat pump convectors.

Installer reference guide

5 Application guidelines

a a

▪ For each room with under floor heating: The desired room

temperature is set via the external room thermostat (wired or wireless).

▪ The user interface connected to the indoor unit decides the space

operation mode. Mind that the operation mode on each external room thermostat and remote controller of the heat pump convectors must be set to match the indoor unit.

INFORMATION

To increase comfort and performance, ROTEX recommends to install the valve kit option EKVKHPC on each heatpump convector.

Configuration

Setting Value

Unit temperature control:

▪ #: [2.9]

0 (Leaving water): Unit operation is decided based on the leaving water temperature.

▪ Code: [C-07]

Number of water temperature

0 (Single zone): Main

zones:

▪ #: [4.4]

▪ Code: [7-02]

5.2.3 Multiple rooms – TwoLWT zones

If the heat emitters selected for each room are designed for different leaving water temperatures, you can use different leaving water temperature zones (maximum 2).

In this document:

▪ Main zone = Zone with the lowest design temperature in heating,

and the highest design temperature in cooling

▪ Additional zone = Zone with the highest design temperature in

heating, and the lowest design temperature in cooling.

CAUTION

When there is more than one leaving water zone, you must ALWAYS install a mixing valve station in the main zone to decrease (in heating)/increase (in cooling) the leaving water temperature when the additional zone has demand.

Typical example:

Room (zone) Heat emitters: Design

Living room (main zone) Underfloor heating:

▪ In heating: 35°C

▪ In cooling: 20°C (only

Bed rooms (additional zone) Heatpump convectors:

▪ In heating: 45°C

▪ In cooling: 12°C

temperature

refreshment, no real cooling allowed)

Setup

A Additional leaving water temperature zone B Room 1 C Room 2 D Main leaving water temperature zone E Room 3

a Remote controller of the heatpump convectors b User interface used as room thermostat c Mixing valve station d Pressure regulating valve

INFORMATION

A pressure regulating valve should be implemented before the mixing valve station. This is to guarantee the correct water flow balance between the main leaving water temperature zone and the additional leaving water temperature zone in relation to the required capacity of both water temperature zones.

▪ For the main zone:

▪ A mixing valve station is installed before the underfloor heating.

▪ The pump of the mixing valve station is controlled by the ON/

OFF signal on the indoor unit (X2M/29 and X2M/21; normal closed shut-off valve output).

▪ The room temperature is controlled by the user interface, which

is used as room thermostat (optional equipment EKRUDAS).

▪ For the additional zone:

▪ The heat pump convectors are directly connected to the indoor

unit.

▪ The desired room temperature is set via the remote controller of

the heatpump convectors for each room.

▪ The heating or cooling demand signals of each heat pump

convector are connected in parallel to the digital input on the indoor unit (X2M/35 and X2M/30). The indoor unit will only supply the desired additional leaving water temperature when there is an actual demand.

▪ The user interface connected to the indoor unit decides the space

operation mode. Mind that the operation mode on each remote controller of the heatpump convectors must be set to match the indoor unit.

Installer reference guide

RRGA04~08DAV3 + RHBX04+08DA

ROTEX HPSU Bi-Bloc Ultra

4P495262-1A – 2018.11

5 Application guidelines

a b c d e f g h j

FHL1

FHL2

FHL3

Configuration

Setting Value

Unit temperature control:

▪ #: [2.9]

▪ Code: [C-07]

2 (Room thermostat): Unit operation is decided based on the ambient temperature of the user interface.

Note:

▪ Main room = user interface

used as room thermostat functionality

▪ Other rooms = external room

thermostat functionality

Number of water temperature

1 (Dual zone): Main + additional

zones:

▪ #: [4.4]

▪ Code: [7-02]

In case of heatpump convectors:

External room thermostat for the additional zone:

▪ #: [3.A]

▪ Code: [C-06]

1 (1 contact): When the used external room thermostat or heatpump convector can only send a thermo ON/OFF condition. No separation between heating or cooling demand.

Shut-off valve output Set to follow the thermo demand

of the main zone.

Shut-off valve If the main zone must be shut off

during cooling mode to prevent condensation on the floor, set it accordingly.

At the mixing valve station Set the desired main leaving

water temperature for heating and/or cooling.

INFORMATION

▪ During heating operation of the heat pump, the

heat pump operates to achieve the desired temperature set via the user interface. When weatherdependent operation is active, the water temperature is determined automatically depending on the outdoor temperature.

▪ During heating operation of the auxiliary boiler, the

auxiliary boiler operates to achieve the desired water temperature set via the auxiliary boiler controller.

Setup

▪ Integrate the auxiliary boiler as follows:

Benefits

▪ Comfort.

▪ The smart room thermostat functionality can decrease or

increase the desired leaving water temperature based on the actual room temperature (modulation).

▪ The combination of the two heat emitter systems provides the

excellent heating comfort of the under floor heating, and the excellent cooling comfort of the heatpump convectors.

▪ Efficiency.

▪ Depending on the demand, the indoor unit supplies different

leaving water temperature matching the design temperature of the different heat emitters.

▪ Under floor heating has the best performance with ROTEX

HPSU.

5.3 Setting up an auxiliary heat source

▪ Space heating can be done by:

▪ The indoor unit

▪ An auxiliary boiler (field supply) connected to the system

▪ When the room thermostat requests heating, the indoor unit or the

auxiliary boiler starts operating depending on the outdoor temperature (status of the changeover to external heat source). When the permission is given to the auxiliary boiler, the space heating by the indoor unit is turned OFF.

▪ Bivalent operation is only possible for space heating, NOT for

domestic hot water production. Domestic hot water is always produced by the DHW tank connected to the indoor unit.

RRGA04~08DAV3 + RHBX04+08DA ROTEX HPSU Bi-Bloc Ultra 4P495262-1A – 2018.11

for space heating

a Outdoor unit b Indoor unit c Heat exchanger d Backup heater e Pump

f Shut-off valve g Motorised 3‑way valve (delivered with DHW tank) h Non-return valve (field supply)

i Shut-off valve (field supply)

j Collector (field supply) k Auxiliary boiler (field supply)

l Aquastat valve (field supply)

m DHW tank

n Heat exchanger coil

FHL1...3 Underfloor heating

NOTICE

▪ Make sure the auxiliary boiler and its integration in the

system complies with applicable legislation.

▪ ROTEX is NOT responsible for incorrect or unsafe

situations in the auxiliary boiler system.

▪ Make sure the return water to the heatpump does NOT exceed

55°C. To do so:

▪ Set the desired water temperature via the auxiliary boiler

controller to maximum 55°C.

▪ Install an aquastat valve in the return water flow of the

heatpump.

▪ Set the aquastat valve to close above 55°C and to open below

55°C.

▪ Install non-return valves.

▪ Make sure to only have one expansion vessel in the water circuit.

An expansion vessel is already pre-mounted in the indoor unit.

▪ Install the digital I/O PCB (option EKRP1HB).

Installer reference guide

5 Application guidelines

Com

K2AK1A

X2M

K2AK1A

Indoor/Auto/Boiler

3530 X Y

Indoor

FHL1

FHL2

FHL3

a b c d e hf g

i j

▪ Connect X1 and X2 (changeover to external heat source) on the

digital I/O PCB to the auxiliary boiler thermostat.

▪ To setup the heat emitters, see "5.2Setting up the space heating/

cooling system"on page10.

Configuration

Via the user interface (quick wizard):

▪ Set the use of a bivalent system as external heat source.

▪ Set the bivalent temperature and hysteresis.

NOTICE

▪ Make sure the bivalent hysteresis has enough

differential to prevent frequent changeover between indoor unit and auxiliary boiler.

▪ Because the outdoor temperature is measured by the

outdoor unit air thermistor, install the outdoor unit in the shadow so that it is NOT influenced or turned ON/OFF by direct sunlight.

▪ Frequent changeover may cause corrosion of the

auxiliary boiler. Contact the manufacturer of the auxiliary boiler for more information.

Changeover to external heat source decided by an auxiliary contact

▪ Only possible in external room thermostat control AND one

leaving water temperature zone (see "5.2 Setting up the space

heating/cooling system"on page10).

▪ The auxiliary contact can be:

▪ An outdoor temperature thermostat

▪ An electricity tariff contact

▪ A manually operated contact

▪ …

▪ Setup: Connect the following field wiring:

BTIBoiler thermostat input

A Auxiliary contact (normal closed)

H Heating demand room thermostat (optional) K1A Auxiliary relay for activation of indoor unit (field supply) K2A Auxiliary relay for activation of boiler (field supply)

Indoor Indoor unit

Auto Automatic

Boiler Boiler

NOTICE

▪ Make sure the auxiliary contact has enough differential

or time delay to prevent frequent changeover between indoor unit and auxiliary boiler.

▪ If the auxiliary contact is an outdoor temperature

thermostat, install the thermostat in the shadow so that it is NOT influenced or turned ON/OFF by direct sunlight.

▪ Frequent changeover may cause corrosion of the

auxiliary boiler. Contact the manufacturer of the auxiliary boiler for more information.

Installer reference guide

5.4 Setting up the domestic hot water tank

5.4.1 System layout – Standalone DHW tank

a Outdoor unit b Indoor unit c Heat exchanger d Backup heater e Pump

f Shut-off valve g Motorised 3‑way valve h Collector (field supply)

i DHW tank j Heat exchanger coil

FHL1...3 Underfloor heating

5.4.2 Selecting the volume and desired temperature for the DHW tank

People experience water as hot when its temperature is 40°C. Therefore, the DHW consumption is always expressed as equivalent hot water volume at 40°C. However, you can set the DHW tank temperature at a higher temperature (example: 53°C), which is then mixed with cold water (example: 15°C).

Selecting the volume and desired temperature for the DHW tank consists of:

1 Determining the DHW consumption (equivalent hot water

volume at 40°C).

2 Determining the volume and desired temperature for the DHW

tank.

Determining the DHW consumption

Answer the following questions and calculate the DHW consumption (equivalent hot water volume at 40°C) using typical water volumes:

Question Typical water volume

How many showers are needed per day?

How many baths are needed per day?

How much water is needed at the kitchen sink per day?

Are there any other domestic hot water needs?

Example: If the DHW consumption of a family (4 persons) per day is as follows:

▪ 3 showers

▪ 1 bath

▪ 3 sink volumes

1shower = 10min×10l/min = 100l

1bath = 150l

1sink = 2min×5l/min = 10l

—

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ROTEX HPSU Bi-Bloc Ultra

4P495262-1A – 2018.11

5 Application guidelines

c f

a b

c a b

d f

e g

Then the DHW consumption = (3×100l)+(1×150l)+(3×10l)=480l

Determining the volume and desired temperature for the DHW tank

Formula Example

V1=V2+V2×(T2−40)/(40−T1) If:

▪ V2=180l

▪ T2=54°C

▪ T1=15°C

Then V1=280l

V2=V1×(40−T1)/(T2−T1) If:

▪ V1=480l

▪ T2=54°C

▪ T1=15°C

Then V2=307l

V1DHW consumption (equivalent hot water volume at 40°C) V2Required DHW tank volume if only heated once T2DHW tank temperature T1Cold water temperature

Possible DHW tank volumes

Type Possible volumes

Standalone DHW tank ▪ 150l

▪ 180l

▪ 200l

▪ 250l

▪ 300 l (polypropylene tank is

compatible with solar kit)

▪ 500l (compatible with solar kit)

Energy saving tips

▪ If the DHW consumption differs from day to day, you can program

a weekly schedule with different desired DHW tank temperatures for each day.

▪ The lower the desired DHW tank temperature, the more cost

effective. By selecting a larger DHW tank, you can lower the desired DHW tank temperature.

▪ The heatpump itself can produce domestic hot water of maximum

55°C (50°C if outdoor temperature is low). The electrical resistance integrated in the heat pump can increase this temperature. However, this consumes more energy. ROTEX recommends to set the desired DHW tank temperature below 55°C to avoid using the electrical resistance.

▪ The higher the outdoor temperature, the better the performance of

the heatpump.

▪ If energy prices are the same during the day and the night,

ROTEX recommends to heat up the DHW tank during the day.

▪ If energy prices are lower during the night, ROTEX

recommends to heat up the DHW tank during the night.

▪ When the heatpump produces domestic hot water, it cannot heat

up a space. In case you need domestic hot water and space heating at the same, ROTEX recommends to produce the domestic hot water during the night when there is lower space heating demand.

5.4.3 Setup and configuration – DHW tank

▪ For large DHW consumptions, you can heat up the DHW tank

several times during the day.

▪ To heat up the DHW tank to the desired DHW tank temperature,

you can use the following energy sources:

▪ Thermodynamic cycle of the heatpump

▪ Electrical booster heater

▪ For more information about:

▪ Optimizing the energy consumption for producing domestic hot

water, see "8Configuration"on page46.

▪ Connecting the electrical wiring of the standalone DHW tank to

the indoor unit, see the installation manual of the DHW tank.

▪ Connecting the water piping of the standalone DHW tank to the

indoor unit, see the installation manual of the DHW tank.

5.4.4 DHW pump for instant hot water

Setup

a Indoor unit b DHW tank c DHW pump (field supply)

f Shower (field supply) g Cold water h Domestic hot water OUT

i Recirculation connection

▪ By connecting a DHW pump, instant hot water can be available at

the tap.

▪ The DHW pump and the installation are field supply and the

responsibility of the installer.

▪ For more information about connecting the recirculation

connection, see the installation manual of the domestic hot water tank.

Configuration

▪ For more information, see "8Configuration"on page46.

▪ You can program a schedule to control the DHW pump via the

user interface. For more information, see the user reference guide.

5.4.5 DHW pump for disinfection

Setup

a Indoor unit b DHW tank c DHW pump (field supply) d Heater element (field supply) e Non‑return valve (field supply)

f Shower (field supply) g Cold water h Domestic hot water OUT

i Recirculation connection

▪ The DHW pump is field-supplied and its installation is the

responsibility of the installer.

▪ If applicable legislation requires disinfection of the water piping

until the tapping point, you can connect a DHW pump and heater element (if needed) as shown above.

Configuration

The indoor unit can control DHW pump operation. For more information, see "8Configuration"on page46.

RRGA04~08DAV3 + RHBX04+08DA ROTEX HPSU Bi-Bloc Ultra 4P495262-1A – 2018.11

Installer reference guide

5 Application guidelines

c a b

5.4.6 DHW pump for tank preheating

Setup

a Indoor unit b DHW tank c DHW pump (field supply) d Non‑return valve (field supply) e Shower (field supply)

f Cold water g Domestic hot water OUT h Recirculation connection

▪ The DHW pump is field-supplied and its installation is the

responsibility of the installer.

▪ For the standalone DHW tank: If there is no electrical backup

heater in the space heating circuit, you must install a DHW pump for tank preheating.

Configuration

The indoor unit can control DHW pump operation. For more information, see "8Configuration"on page46.

5.5 Setting up the energy metering

▪ Via the user interface, you can read out the following energy data:

▪ Produced heat

▪ Consumed energy

▪ You can read out the energy data:

▪ For space heating

▪ For space cooling

▪ For domestic hot water production

▪ You can read out the energy data:

▪ Per month

▪ Per year

5.5.2 Consumed energy

You can use the following methods to determine the consumed energy:

▪ Calculating

▪ Measuring

INFORMATION

You cannot combine calculating the consumed energy (example: for backup heater) and measuring the consumed energy (example: for outdoor unit). If you do so, the energy data will be invalid.

Calculating the consumed energy

▪ The consumed energy is calculated internally based on:

▪ The actual power input of the outdoor unit

▪ The set capacity of the backup heater and booster heater (if

applicable)

▪ The voltage

▪ Setup and configuration: To get accurate energy data, measure

the capacity (resistance measurement) and set the capacity via the user interface for:

▪ The backup heater (step1 and step2) (if applicable)

▪ The booster heater

Measuring the consumed energy

▪ Applicable for all models.

▪ Preferred method because of higher accuracy.

▪ Requires external power meters.

▪ Setup and configuration: When using electrical power meters, set

the number of pulses/kWh for each power meter via the user interface.

INFORMATION

When measuring the electrical power consumption, make sure ALL power input of the system is covered by the electrical power meters.

INFORMATION

The calculated produced heat and consumed energy are an estimation, the accuracy cannot be guaranteed.

5.5.1 Produced heat

INFORMATION

The sensors used to calculate the produced heat are calibrated automatically.

▪ Applicable for all models.

▪ The produced heat is calculated internally based on:

▪ The leaving and entering water temperature

▪ The flow rate

▪ The power consumption of the booster heater (if applicable) in

the domestic hot water tank

▪ Setup and configuration:

▪ No additional equipment needed.

▪ Only in case a booster heater is present in the system, measure

its capacity (resistance measurement) and set the capacity via the user interface. Example: If you measure a booster heater resistance of 17.1Ω, the capacity of the heater at 230 V is 3100W.

5.5.3 Normal kWh rate power supply

General rule

One power meter that covers the entire system is sufficient.

Setup

Connect the power meter to X5M/5 and X5M/6.

Power meter type

In case of… Use a… power meter

▪ Single-phase outdoor unit

▪ Backup heater supplied from a

single-phase grid (i.e. the backup heater model is *6V connected to a single-phase grid)

▪ Three-phase outdoor unit

▪ Backup heater supplied from a

three-phase grid (i.e. the backup heater model is *9W or *6V connected to a threephase grid)

Single-phase

(*6V (6V): 1N~230V)

Three-phase

(*6V (6T1): 3~230V)

(*9W: 3N~400V)

Installer reference guide

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ROTEX HPSU Bi-Bloc Ultra

4P495262-1A – 2018.11

5 Application guidelines

c c

fed

A B C

gfe

A B C

c c d



e efe

ihg

A B C



0 1

Example

Single-phase power meter Three-phase power meter

A Outdoor unit

B Indoor unit

C DHW tank

a Electrical cabinet (L1/N)

b Power meter (L1/N)

c Fuse (L1/N)

d Outdoor unit (L1/N)

e Indoor unit (L1/N)

f Backup heater (L1/N)

g Booster heater (L1/N)

A Outdoor unit

B Indoor unit

C DHW tank

a Electrical cabinet (L1/L2/L3/N)

b Power meter (L1/L2/L3/N)

c Fuse (L1/L2/L3/N)

d Fuse (L1/N)

e Outdoor unit (L1/L2/L3/N)

f Indoor unit (L1/L2/L3/N)

g Backup heater (L1/L2/L3/N)

h Booster heater (L1/N)

Exception

▪ You can use a second power meter if:

▪ The power range of one meter is insufficient.

▪ The electrical meter cannot easily be installed in the electrical

cabinet.

▪ 230 V and 400 V three-phase grids are combined (very

uncommon), because of technical limitations of power meters.

▪ Connection and setup:

▪ Connect the second power meter to X5M/3 and X5M/4.

▪ In the software the power consumption data of both meters is

added so you do NOT have to set which meter covers which power consumption. You only need to set the number of pulses of each power meter.

▪ See "5.5.4 Preferential kWh rate power supply"on page 19 for

an example with two power meters.

5.5.4 Preferential kWh rate power supply

General rule

▪ Power meter1: Measures the outdoor unit.

▪ Power meter2: Measures the rest (i.e. indoor unit, backup heater

and optional booster heater).

Setup

▪ Connect power meter1 to X5M/5 and X5M/6.

▪ Connect power meter2 to X5M/3 and X5M/4.

Power meter types

▪ Power meter1: Single- or three-phase power meter according to

the power supply of the outdoor unit.

▪ Power meter2:

▪ In case of a single-phase backup heater configuration, use a

single-phase power meter.

▪ In other cases, use a three-phase power meter.

Example

Single-phase outdoor unit with a three-phase backup heater:

A Outdoor unit B Indoor unit C DHW tank

a Electrical cabinet (L1/N): Preferential kWh rate power

supply

b Electrical cabinet (L1/L2/L3/N): Normal kWh rate power

supply

c Power meter (L1/N) d Power meter (L1/L2/L3/N) e Fuse (L1/N)

f Fuse (L1/L2/L3/N) g Outdoor unit (L1/N) h Indoor unit (L1/N)

i Backup heater (L1/L2/L3/N)

j Booster heater (L1/N)

5.6 Setting up the power consumption control

▪ The power consumption control:

▪ Allows you to limit the power consumption of the entire system

(sum of outdoor unit, indoor unit, backup heater and optional booster heater).

▪ Configuration: Set the power limitation level and how it has to

be achieved via the user interface.

▪ The power limitation level can be expressed as:

▪ Maximum running current (inA)

▪ Maximum power input (inkW)

▪ The power limitation level can be activated:

▪ Permanently

▪ By digital inputs

5.6.1 Permanent power limitation

Permanent power limitation is useful to assure a maximum power or current input of the system. In some countries, legislation limits the maximum power consumption for space heating and DHW production.

RRGA04~08DAV3 + RHBX04+08DA ROTEX HPSU Bi-Bloc Ultra 4P495262-1A – 2018.11

PiPower input

Installer reference guide

5 Application guidelines

A B C

A8P

DI4

DI3

DI1

A B C

t Time

DI Digital input (power limitation level)

a Power limitation active b Actual power input

Setup and configuration

▪ No additional equipment needed.

▪ Set the power consumption control settings in [9.9] via the user

interface (for the description of all settings, see

"8Configuration"on page46):

▪ Select continuous limitation mode

▪ Select the type of limitation (power in kW or current in A)

▪ Set the desired power limitation level

5.6.2 Power limitation activated by digital inputs

Power limitation is also useful in combination with an energy management system.

The power or current of the entire ROTEX system is limited dynamically by digital inputs (maximum four steps). Each power limitation level is set via the user interface by limiting one of the following:

▪ Current (in A)

▪ Power input (in kW)

The energy management system (field supply) decides the activation of a certain power limitation level. Example: To limit the maximum power of the entire house (lighting, domestic appliances, space heating…).

Configuration

▪ Set the power consumption control settings in [9.9] via the user

interface (for the description of all settings, see

"8Configuration"on page46):

▪ Select limitation by digital inputs.

▪ Select the type of limitation (power in kW or current in A).

▪ Set the desired power limitation level corresponding to each

digital input.

INFORMATION

In case more than 1 digital input is closed (at the same time), the digital input priority is fixed: DI4 priority>…>DI1.

5.6.3 Power limitation process

The outdoor unit has better efficiency than the electrical heaters. Therefore, the electrical heaters are limited and turned OFF first. The system limits power consumption in the following order:

1 Limits certain electrical heaters.

If… has priority Then set the priority heater

via the user interface to…

Domestic hot water production Booster heater (if applicable)

Result: The backup heater will be turned OFF first.

Space heating Backup heater

Result: The booster heater (if applicable) will be turned OFF first.

Setup

▪ Demand PCB (option EKRP1AHTA) needed.

▪ Maximum four digital inputs are used to activate the

corresponding power limitation level:

▪ DI1 = weakest limitation (highest energy consumption)

▪ DI4 = strongest limitation (lowest energy consumption)

▪ For the specifications of the digital inputs, and for where to

connect them, refer to the wiring diagram.

Installer reference guide

A Outdoor unit B Indoor unit C DHW tank D Energy management system

a Power limitation activation (4 digital inputs) b Backup heater c Booster heater

PiPower input

t Time

DI Digital inputs (power limitation levels)

a Power limitation active b Actual power input

2 Turns OFF all electrical heaters.

3 Limits the outdoor unit.

4 Turns OFF the outdoor unit.

Example

If the configuration is as follows:

▪ Power limitation level does NOT allow operation of both booster

heater and backup heater (step1 and step2).

▪ Priority heater = Booster heater (if applicable).

Then power consumption is limited as follows:

PhProduced heat CeConsumed energy

A Outdoor unit B Booster heater C Backup heater

a Limited outdoor unit operation b Full outdoor unit operation c Booster heater turned ON d Backup heater step1 turned ON e Backup heater step2 turned ON

5.7 Setting up an external temperature sensor

You can connect one external temperature sensor. It can measure the outdoor ambient temperature. ROTEX recommends to use an external temperature sensor in the following cases:

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6 Preparation

≤1200

>250

>350

(mm)(mm)

>100

>350

(mm)

>100

Outdoor ambient temperature

▪ In the outdoor unit, the outdoor ambient temperature is measured.

Therefore, the outdoor unit must be installed on a location:

▪ At the north side of the house or at the side of the house where

the most heat emitters are located

▪ That is NOT exposed to direct sunlight

▪ If this is NOT possible, ROTEX recommends to connect a remote

outdoor sensor (option EKRSCA1).

▪ Setup: For installation instructions, see the installation manual of

the remote outdoor sensor.

▪ Configuration: Select outdoor sensor [9.B].

▪ When the power saving functionality of the outdoor unit is active

(see "8 Configuration" on page 46), the outdoor unit is turned down to reduce standby energy losses. As a result, the outdoor ambient temperature is NOT read out.

▪ If the desired leaving water temperature is weather dependent, the

full time outdoor temperature measurement is important. This is another reason to install the optional outdoor ambient temperature sensor.

INFORMATION

The external outdoor ambient sensor data (either averaged or instantaneous) is used in the weather-dependent control curves and in the automatic heating/cooling changeover logic. To protect the outdoor unit, the internal sensor of the outdoor unit is always used.

6.2.1 Installation site requirements of the outdoor unit

INFORMATION

6.1 Overview: Preparation

This chapter describes what you have to do and know before going on-site.

It contains information about:

▪ Preparing the installation site

▪ Preparing the refrigerant piping

▪ Preparing the water piping

▪ Preparing the electrical wiring

6.2 Preparing the installation site

Do NOT install the unit in places often used as work place. In case of construction works (e.g. grinding works) where a lot of dust is created, the unit MUST be covered.

Choose an installation location with sufficient space for carrying the unit in and out of the site.

WARNING

The appliance shall be stored in a room without continuously operating ignition sources (example: open flames, an operating gas appliance or an operating electric heater).

a Low sound cover

NOTICE

▪ Do NOT stack the units on each other.

▪ Do NOT hang the unit on a ceiling.

Strong winds (≥18 km/h) blowing against the outdoor unit’s air outlet causes short circuit (suction of discharge air). This may result in:

▪ deterioration of the operational capacity;

▪ frequent frost acceleration in heating operation;

▪ disruption of operation due to decrease of low pressure or

increase of high pressure;

▪ a broken fan (if a strong wind blows continuously on the fan, it

may start rotating very fast, until it breaks).

It is recommended to install a baffle plate when the air outlet is exposed to wind.

It is recommended to install the outdoor unit with the air inlet facing the wall and NOT directly exposed to the wind.

WARNING

DO NOT reuse refrigerant piping that has been used with any other refrigerant. Replace the refrigerant pipes or clean thoroughly.

RRGA04~08DAV3 + RHBX04+08DA ROTEX HPSU Bi-Bloc Ultra 4P495262-1A – 2018.11

Installer reference guide

6 Preparation

4×

b e

a Baffle plate b Prevailing wind direction c Air outlet

Do NOT install the unit in the following places:

▪ Sound sensitive areas (e.g. near a bedroom), so that the

operation noise will cause no trouble.

▪ In places where a mineral oil mist, spray or vapour may be

present in the atmosphere. Plastic parts may deteriorate and fall off or cause water leakage.

It is NOT recommended to install the unit in the following places because it may shorten the life of the unit:

▪ Where the voltage fluctuates a lot

▪ In vehicles or vessels

▪ Where acidic or alkaline vapour is present

Seaside installation. Make sure the outdoor unit is NOT directly exposed to sea winds. This is to prevent corrosion caused by high levels of salt in the air, which might shorten the life of the unit.

Cooling mode 10~43°C

Heating mode –25~25°C

6.2.2 Additional installation site requirements of the outdoor unit in cold climates

In areas with low ambient temperatures and high humidity, or in areas with heavy snowfall, remove the suction grille to ensure proper operation.

Non-exhaustive list of areas: Austria, Czech Republic, Denmark, Estonia, Finland, Germany, Hungary, Latvia, Lithuania, Norway, Poland, Romania, Serbia, Slovakia, Sweden, …

1 Remove the screws holding the suction grille.

2 Remove the suction grille, and dispose of it.

3 Reattach the screws to the unit.

Install the outdoor unit away from direct sea winds.

Example: Behind the building.

If the outdoor unit is exposed to direct sea winds, install a windbreaker.

▪ Height of windbreaker≥1.5×height of outdoor unit

▪ Mind the service space requirements when installing the

windbreaker.

a Sea wind b Building

The outdoor unit is designed for outdoor installation only, and for the following ambient temperatures:

Installer reference guide

c Outdoor unit d Windbreaker

a Suction grille

Protect the outdoor unit against direct snowfall and take care that the outdoor unit is NEVER snowed up.

a Snow cover or shed b Pedestal c Prevailing wind direction d Air outlet e EKFT008D option kit

In any case, provide at least 300mm of free space below the unit. Additionally, make sure the unit is positioned at least 100mm above the maximum expected level of snow. See "7.3 Mounting the

outdoor unit"on page31 for more details.

In heavy snowfall areas it is very important to select an installation site where the snow will NOT affect the unit. If lateral snowfall is possible, make sure that the heat exchanger coil is NOT affected by the snow. If necessary, install a snow cover or shed and a pedestal.

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6 Preparation

H≥1150

≥200

≥500

(mm)

≥450

6.2.3 Installation site requirements of the indoor unit

INFORMATION

Also read the precautions and requirements in the "General safety precautions" chapter.

▪ The indoor unit is designed for indoor installation only and for the

following ambient temperatures:

▪ Space heating operation: 5~30°C

▪ Space cooling operation: 5~35°C

▪ Domestic hot water production: 5~35°C

▪ Mind the measurement guidelines:

Maximum refrigerant piping length between indoor unit and outdoor unit

Minimum refrigerant piping length between indoor unit and outdoor unit

Maximum height difference between indoor unit and outdoor unit

Maximum distance between the 3‑way valve and the indoor unit (for installations with domestic hot water tank)

Maximum distance between the domestic hot water tank and the indoor unit (for installations with domestic hot water tank)

▪ Mind the following spacing installation guidelines:

30m

3m

20m

3m

10m

Special requirements for R32

WARNING

▪ Do NOT pierce or burn.

▪ Do NOT use means to accelerate the defrosting

process or to clean the equipment, other than those recommended by the manufacturer.

▪ Be aware that R32 refrigerant does NOT contain an

odour.

WARNING

The appliance shall be stored so as to prevent mechanical damage and in a well-ventilated room without continuously operating ignition sources (example: open flames, an operating gas appliance or an operating electric heater) and have a room size as specified below.

NOTICE

▪ Do NOT re-use joints which have been used already.

▪ Joints made in installation between parts of refrigerant

system shall be accessible for maintenance purposes.

WARNING

Make sure installation, servicing, maintenance and repair comply with instructions from ROTEX and with applicable legislation (for example national gas regulation) and are executed only by authorised persons.

NOTICE

▪ Pipework shall be protected from physical damage.

▪ Installation of pipework shall be kept to a minimum.

H Height measured from the bottom of the casing to the floor

Do NOT install the unit in places such as:

▪ In places where a mineral oil mist, spray or vapour may be

present in the atmosphere. Plastic parts may deteriorate and fall off or cause water leakage.

▪ Sound sensitive areas (e.g. near a bedroom), so that the

operation noise will cause no trouble.

▪ In places with high humidity (max. RH=85%), for example a

bathroom.

▪ In places where frost is possible. Ambient temperature around the

indoor unit must be >5°C.

RRGA04~08DAV3 + RHBX04+08DA ROTEX HPSU Bi-Bloc Ultra 4P495262-1A – 2018.11

Installer reference guide

6 Preparation

Input from installer:

▪ Total refrigerant charge (m

) (kg) ▪ Installation height (H) (m) ▪ Area of room A (A

room A

) (m2)

Start

Use table 1 in chapter "Technical data" to calculate the maximum refrigerant charge (m

max

) (kg) allowed for room A.

Contact your dealer.

Use table 3 in chapter "Technical data" and dm to calculate the minimum opening area for natural ventilation between room A and

room B (VA

min

) (cm2).

Unit can be installed at room A if: ▪ 2 ventilation openings (permanently open) are provided between room A and B, 1 at the top and 1 at the bottom. ▪ Bottom opening: The bottom opening must meet the minimum area requirements (VA

min

). It must be as close as possible to the floor and lower than H. If the ventilation opening starts from the floor, the height must be ≥20 mm. The bottom of the opening must be situated ≤100 mm from the floor. At least 50% of the required opening area must be situated <200 mm from the floor. The entire area of the opening must be situated <300 mm from the floor.

▪ Top opening: The area of the top opening must be larger than or equal to the bottom opening. The bottom of the top opening must be situated at least 1.5 m

above the top of the bottom opening.

▪ Ventilation openings to the outside are NOT considered suitable ventilation openings (the user can block them when it is cold).

The unit can be installed in room A at the specified installation height, and without further room size or ventilation requirements.

Determine the refrigerant amount that exceeds

max

(dm) (kg). (dm=mc–m

max

)

max≥mc

Yes

Use table 2 in chapter "Technical data" to calculate the total minimum floor area (A

min total

) (m2) required for the total refrigerant

charge (m

) at the selected installation height

(H).

a Indoor unit A Room where the indoor unit is installed. B Room adjacent to room A.

min total≤Aroom A+Aroom B

Yes

Input from installer:

▪ Area of adjacent room B (A

room B

) (m2)

≥1.5 m

If the total refrigerant charge in the system is ≥1.84kg (i.e. if the piping length is ≥27m), you need to comply with the minimum floor area requirements as described in the following flow chart. The flow chart uses the following tables: "14.5Table 1 – Maximum refrigerant charge

allowed in a room: indoor unit" on page 96, "14.6 Table 2 – Minimum floor area: indoor unit" on page96 and "14.7 Table 3 – Minimum venting opening area for natural ventilation: indoor unit"on page97.

INFORMATION

Systems with a total refrigerant charge (mc) <1.84kg (i.e. if the piping length is <27 m) are NOT subjected to any requirements to the installation room.

INFORMATION

Multiple indoor units. If two or more indoor units are

installed in a room, you must consider the maximum refrigerant charge that can be released in the room when a SINGLE leak occurs. Example: If two indoor units are installed in the room, each with its own outdoor unit, then you have to consider the refrigerant charge of the largest indoor-outdoor combination.

Installer reference guide

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ROTEX HPSU Bi-Bloc Ultra

4P495262-1A – 2018.11

6 Preparation

ØiØ

ØpØ

6.3 Preparing refrigerant piping

6.3.1 Refrigerant piping requirements

INFORMATION

Also read the precautions and requirements in the "General safety precautions" chapter.

▪ Piping material: Phosphoric acid deoxidised seamless copper.

▪ Piping diameter:

Liquid piping Ø6.4mm (1/4")

Gas piping Ø15.9mm (5/8")

▪ Piping temper grade and thickness:

Outer diameter

(Ø)

6.4mm (1/4") Annealed (O) ≥0.8mm

15.9mm (5/8") Annealed (O) ≥1.0mm

(a) Depending on the applicable legislation and the unit's

Temper grade Thickness (t)

maximum working pressure (see "PS High" on the unit name plate), larger piping thickness might be required.

(a)

6.3.2 Refrigerant piping insulation

▪ Use polyethylene foam as insulation material:

▪ with a heat transfer rate between 0.041 and 0.052W/mK (0.035

and 0.045kcal/mh°C)

▪ with a heat resistance of at least 120°C

▪ Insulation thickness

Pipe outer diameter

(Øp)

6.4mm (1/4") 8~10mm 10mm

15.9mm (5/8") 16~20mm 13mm

If the temperature is higher than 30°C and the humidity is higher than RH 80%, the thickness of the insulation materials should be at least 20 mm to prevent condensation on the surface of the insulation.

Insulation inner

diameter (Øi)

Insulation thickness

(t)

6.4 Preparing water piping

▪ Valve towards expansion vessel. The valve towards the

expansion vessel (if equipped) MUST be open.

▪ Connecting piping – Force. Do NOT use excessive force when

connecting the piping. Deformation of the piping can cause malfunctioning of the unit.

▪ Connecting piping – Tools. Only use appropriate tooling to

handle brass, which is a soft material. If NOT, pipes will get damaged.

▪ Connecting piping – Air, moisture, dust. If air, moisture or dust

gets into the circuit, problems may occur. To prevent this:

▪ Only use clean pipes

▪ Hold the pipe end downwards when removing burrs.

▪ Cover the pipe end when inserting it through a wall, to prevent

dust and/or particles entering the pipe.

▪ Use a decent thread sealant to seal connections.

▪ Closed circuit. Use the indoor unit ONLY in a closed water

system. Using the system in an open water system will lead to excessive corrosion.

▪ Glycol. For safety reasons, it is NOT allowed to add any kind of

glycol to the water circuit.

▪ Piping diameter. Select the water piping diameter in relation to

the required water flow and the available external static pressure of the pump. See "14 Technical data"on page90 for the external static pressure curves of the indoor unit.

▪ Water flow. You can find the minimum required water flow for

indoor unit operation in the following table. In all cases, this flow needs to be guaranteed. When the flow is lower, the indoor unit will stop operation and display error 7H.

Minimum required flow rate

12l/min

▪ Field supply components – Water. Only use materials that are

compatible with water used in the system and with the materials used in the indoor unit.

▪ Field supply components – Water pressure and temperature.

Check that all components in the field piping can withstand the water pressure and water temperature.

▪ Water pressure. The maximum water pressure is 4 bar. Provide

adequate safeguards in the water circuit to ensure that the maximum pressure is NOT exceeded.

▪ Water temperature. All installed piping and piping accessories

(valve, connections,…) MUST withstand the following temperatures:

INFORMATION

The following illustration is an example and might NOT match your system layout.

6.4.1 Water circuit requirements

INFORMATION

Also read the precautions and requirements in the "General safety precautions" chapter.

NOTICE

In case of plastic pipes, make sure they are fully oxygen diffusion tight according to DIN 4726. The diffusion of oxygen into the piping can lead to excessive corrosion.

▪ Connecting piping – Legislation. Make all piping connections in

accordance with the applicable legislation and the instructions in the "Installation" chapter, respecting the water inlet and outlet.

RRGA04~08DAV3 + RHBX04+08DA ROTEX HPSU Bi-Bloc Ultra 4P495262-1A – 2018.11

Installer reference guide

6 Preparation

FCU1

FCU2

FCU3

FHL1

FHL2

FHL3

l k

fd ecba

65°C

89°C

c d

a b

a Outdoor unit b Indoor unit c Heat exchanger d Backup heater e Pump

f Shut-off valve

g Motorised 3-way valve (supplied with the domestic hot

water tank)

h Motorised 2-way valve (field supply)

i Collector j Domestic hot water tank

k Heat exchanger coil

l Booster heater

FCU1...3 Fan coil unit (optional) (field supply)

FHL1...3 Floor heating loop (field supply)

T Room thermostat (optional) (field supply)

▪ Drainage – Low points. Provide drain taps at all low points of the

system in order to allow complete drainage of the water circuit.

▪ Drainage – Pressure relief valve. Connect the drain hose

properly to the drain to avoid water dripping out of the unit. See

"7.4.4To connect the drain hose to the drain"on page35.

▪ Air vents. Provide air vents at all high points of the system, which

must also be easily accessible for servicing. Two automatic air purges are provided in the indoor unit. Check that the air purges are NOT tightened too much, so that automatic release of air in the water circuit is possible.

▪ Zn-coated parts. Never use Zn-coated parts in the water circuit.

Because the unit's internal water circuit uses copper piping, excessive corrosion may occur.

▪ Non-brass metallic piping. When using non-brass metallic

piping, insulate the brass and non-brass properly so that they do NOT make contact with each other. This to prevent galvanic corrosion.

▪ Valve – Separating circuits. When using a 3-way valve in the

water circuit make sure that the domestic hot water circuit and the floor heating circuit is fully separated.

▪ Valve – Change‑over time. When using a 2-way valve or a 3-way

valve in the water circuit, the maximum change-over time of the valve must be 60seconds.

▪ Domestic hot water tank – Capacity. To avoid stagnation of

water, it is important that the storage capacity of the domestic hot water tank meets the daily consumption of domestic hot water.

▪ Domestic hot water tank – After installation. Immediately after

installation, the domestic hot water tank must be flushed with fresh water. This procedure must be repeated at least once a day the first 5 consecutive days after installation.

▪ Domestic hot water tank – Standstills. In cases where during

longer periods of time there is no consumption of hot water, the equipment MUST be flushed with fresh water before usage.

▪ Domestic hot water tank – Disinfection. For the disinfection

function of the domestic hot water tank, see "8.4.6 Tank" on

page62.

▪ Thermostatic mixing valves. In accordance with the applicable

legislation, it may be necessary to install thermostatic mixing valves.

▪ Hygienic measures. The installation must be in compliance with

the applicable legislation and may require additional hygienic installation measures.

▪ Recirculation pump. In accordance with the applicable

legislation, it may be required to connect a recirculation pump in between the hot water end point and the recirculation connection of the domestic hot water tank.

a Recirculation connection b Hot water connection c Shower d Recirculation pump

▪ Valve towards expansion vessel. The valve towards the

expansion vessel (if equipped) MUST be open.

6.4.2 Formula to calculate the expansion vessel pre-pressure

The pre-pressure (Pg) of the vessel depends on the installation height difference (H):

Pg=0.3+(H/10) (bar)

6.4.3 To check the water volume and flow rate

The indoor unit has an expansion vessel of 10litre with a factory-set pre-pressure of 1bar.

To make sure that the unit operates properly:

▪ You must check the minimum and maximum water volume.

▪ You might need to adjust the pre-pressure of the expansion

vessel.

Minimum water volume

Check that the total water volume in the installation is minimum 10litres, the internal water volume of the indoor unit NOT included.

INFORMATION

In critical processes, or in rooms with a high heat load, extra water might be required.

NOTICE

When circulation in each space heating/cooling loop is controlled by remotely controlled valves, it is important that the minimum water volume is guaranteed, even if all of the valves are closed.

Installer reference guide

RRGA04~08DAV3 + RHBX04+08DA

ROTEX HPSU Bi-Bloc Ultra

4P495262-1A – 2018.11

6 Preparation

FHL1

FHL2

FHL3

M2T2M3

fdcba

g h

0.3

0.5

1.5

2.4

5020 100 150 200 250 290

a Outdoor unit

b Indoor unit

c Heat exchanger

d Backup heater

e Pump

f Shut-off valve g Collector (field supply) h Overpressure bypass valve (delivered as accessory)

FHL1...3 Floor heating loop (field supply)

T1...3 Individual room thermostat (optional)

M1...3 Individual motorised valve to control loop FHL1...3 (field

supply)

Maximum water volume

Use the following graph to determine the maximum water volume for the calculated pre-pressure.

Installation

height

difference

(a)

≤200l >200l

>7m Do the following:

▪ Increase the pre-

pressure according to the required installation height difference. The prepressure should

Water volume

The expansion vessel of the indoor unit is too small for the installation. In this case, it is recommended to install an extra vessel outside the unit.

increase by 0.1 bar for each metre above 7 m.

▪ Check if the water

volume does NOT exceed the maximum allowed water volume.

(a) This is the height difference (m) between the highest point

of the water circuit and the indoor unit. If the indoor unit is at the highest point of the installation, the installation height is 0m.

Minimum flow rate

Check that the minimum flow rate in the installation is guaranteed in all conditions. This minimum flow rate is required during defrost/ backup heater operation. For this purpose, use the overpressure bypass valve delivered with the unit, and respect the minimum water volume.

NOTICE

When circulation in each or certain space heating loops is controlled by remotely controlled valves, it is important that the minimum flow rate is guaranteed, even if all valves are closed. In case the minimum flow rate cannot be reached, a flow error 7H will be generated (no heating or operation).

Minimum required flow rate

12l/min

See the recommended procedure as described in "9.4 Checklist

during commissioning"on page78.

6.4.4 Changing the pre-pressure of the

a Pre-pressure (bar)

b Maximum water volume (l)

Example: Maximum water volume and expansion vessel prepressure

Installation

height

difference

(a)

≤200l >200l

≤7m No pre-pressure

adjustment is required.

Water volume

Do the following:

▪ Decrease the pre-

pressure according to the required installation height difference. The pre-pressure should decrease by 0.1 bar for

When changing the default pre-pressure of the expansion vessel (1bar) is required, take following guidelines into account:

▪ Only use dry nitrogen to set the expansion vessel pre-pressure.

▪ Inappropriate setting of the expansion vessel pre-pressure will

lead to malfunction of the system.

Changing the pre-pressure of the expansion vessel should be done by releasing or increasing nitrogen pressure through the Schrader valve of the expansion vessel.

each metre below 7 m.

▪ Check if the water

volume does NOT exceed the maximum allowed water volume.

expansion vessel

NOTICE

Only a licensed installer may adjust the pre-pressure of the expansion vessel.

RRGA04~08DAV3 + RHBX04+08DA ROTEX HPSU Bi-Bloc Ultra 4P495262-1A – 2018.11

Installer reference guide

6 Preparation

WARNING

▪ If the power supply has a missing or wrong N-phase,

equipment might break down.

▪ Establish proper earthing. Do NOT earth the unit to a

utility pipe, surge absorber, or telephone earth. Incomplete earthing may cause electrical shock.

▪ Install the required fuses or circuit breakers.

▪ Secure the electrical wiring with cable ties so that the

cables do NOT come in contact with sharp edges or piping, particularly on the high-pressure side.

▪ Do NOT use taped wires, stranded conductor wires,

extension cords, or connections from a star system. They can cause overheating, electrical shock or fire.

▪ Do NOT install a phase advancing capacitor, because

this unit is equipped with an inverter. A phase advancing capacitor will reduce performance and may cause accidents.

a Schrader valve

6.4.5 To check the water volume: Examples

Example 1

The indoor unit is installed 5 m below the highest point in the water circuit. The total water volume in the water circuit is 100l.

No actions or adjustments are required.

Example 2

The indoor unit is installed at the highest point in the water circuit. The total water volume in the water circuit is 250l.

Actions:

▪ Because the total water volume (250l) is more than the default

water volume (200l), the pre-pressure must be decreased.

▪ The required pre-pressure is:

Pg = (0.3+(H/10))bar = (0.3+(0/10))bar=0.3bar.

▪ The corresponding maximum water volume at 0.3 bar is 290 l.

(See the graph in the chapter above).

▪ Because 250 l is lower than 290 l, the expansion vessel is

appropriate for the installation.

6.5 Preparing electrical wiring

6.5.1 About preparing electrical wiring

INFORMATION

Also read the precautions and requirements in the "General safety precautions" chapter.

WARNING

▪ All wiring MUST be performed by an authorised

electrician and MUST comply with the applicable legislation.

▪ Make electrical connections to the fixed wiring.

▪ All components procured on-site and all electrical

construction MUST comply with the applicable legislation.

WARNING

The backup heater MUST have a dedicated power supply and MUST be protected by the safety devices required by the applicable legislation.

WARNING

ALWAYS use multicore cable for power supply cables.

6.5.2 About preferential kWh rate power supply

Electricity companies throughout the world work hard to provide reliable electric service at competitive prices and are often authorized to bill clients at benefit rates. E.g. time-of-use rates, seasonal rates, Wärmepumpentarif in Germany and Austria, ...

This equipment allows for connection to such preferential kWh rate power supply delivery systems.

Consult with the electricity company acting as provider at the site where this equipment is to be installed to know whether it is appropriate to connect the equipment in one of the preferential kWh rate power supply delivery systems available, if any.

When the equipment is connected to such preferential kWh rate power supply, the electricity company is allowed to:

▪ interrupt power supply to the equipment for certain periods of time;

▪ demand that the equipment only consumes a limited amount of

electricity during certain periods of time.

The indoor unit is designed to receive an input signal by which the unit switches into forced off mode. At that moment, the outdoor unit compressor will not operate.

Whether the power supply is interrupted or not, the wiring to the unit is different.

Installer reference guide

RRGA04~08DAV3 + RHBX04+08DA

ROTEX HPSU Bi-Bloc Ultra

4P495262-1A – 2018.11

7 Installation

0 1

5 3

0 1

6.5.3 Overview of electrical connections except external actuators

Normal power

supply

Preferential kWh rate power supply

Power supply is NOT interrupted

Power supply is

interrupted

Item Description Wires Maximum

running

current

9 Domestic hot water

(d)

tank thermistor

10 User interface used as

(f)

room thermostat

11 Room thermostat 3 or 4 100mA

12 Outdoor ambient

(b)

temperature sensor

13 Indoor ambient

(b)

temperature sensor

14 Heat pump convector 2 100mA

(b)

Field supplied components

(b)

(e)

During preferential kWh rate power supply activation, power supply is NOT interrupted. The outdoor unit is turned off by the control.

Remark: The electricity company must always allow the power consumption of the indoor unit.

a Normal power supply

b Preferential kWh rate power supply

1 Power supply for outdoor unit 2 Power supply and interconnection cable to indoor unit 3 Power supply for backup heater 4 Preferential kWh rate power supply (voltage free contact) 5 Normal kWh rate power supply (to power the indoor unit

PCB in the event of power supply interruption of the preferential kWh rate power supply)

kWh rate power supply activation, power supply is interrupted immediately or after some time by the electricity company. In this case, the indoor unit must be powered by a separate normal power supply.

6.5.4 Overview of electrical connections for external and internal actuators

During preferential

Item Description Wires Maximum

Outdoor unit and indoor unit power supply

1 Power supply for

2+GND

outdoor unit

2 Power supply and

interconnection cable to

running

current

(a)

(g)

15 Shut-off valve 2 100mA

16 Electricity meter 2 (per meter)

17 Domestic hot water

pump

18 Alarm output 2

19 Changeover to external

heat source control

20 Space cool/heat

operation control

21 Power consumption

digital inputs

2 (per input signal)

22 Safety thermostat 2

(a) Refer to name plate on outdoor unit. (b) Minimum cable section 0.75mm². (c) Cable section 2.5mm². (d) The thermistor and connection wire (12m) are delivered

with the domestic hot water tank.

(e) Cable section 0.75mm² till 1.25mm²; maximum length:

50m. Voltage-free contact shall ensure the minimum applicable load of 15VDC, 10mA.

(f) Cable section 0.75mm² till 1.25mm²; maximum length:

500m. Applicable for both single user interface and dual user interface connection.

(g) Cable section 1.5mm².

NOTICE

More technical specifications of the different connections are indicated on the inside of the indoor unit.

Backup heater

type

Power supply Required number of

conductors

*6V 1N~ 230V (6V) 2+GND

3~ 230V (6T1) 3+GND

*9W 3N~ 400V 4+GND

indoor unit

3 Power supply for

backup heater

4 Preferential kWh rate

power supply (voltage free contact)

5 Normal kWh rate power

supply

See table below. —

(e)

2 6.3A

7 Installation

7.1 Overview: Installation

This chapter describes what you have to do and know on-site to install the system.

Optional equipment

6 3‑way valve 3 100mA

7 Power supply for

4+GND

(b)

(c)

booster heater and

8 Power supply for

thermal protection (from indoor unit)

2+GND 13A booster heater (to indoor unit)

RRGA04~08DAV3 + RHBX04+08DA ROTEX HPSU Bi-Bloc Ultra 4P495262-1A – 2018.11

Installer reference guide

7 Installation

4×

2×

Typical workflow

Installation typically consists of the following stages:

1 Mounting the outdoor unit.

2 Mounting the indoor unit.

3 Connecting the refrigerant piping.

4 Checking the refrigerant piping.

5 Charging refrigerant.

6 Connecting the water piping.

7 Connecting the electrical wiring.

8 Finishing the outdoor installation.

9 Finishing the indoor installation.

INFORMATION

Depending on the units and/or the installation conditions, it might be necessary to connect electrical wiring before you can charge refrigerant.

7.2 Opening the units

7.2.1 About opening the units

At certain times, you have to open the unit. Example:

▪ When connecting the refrigerant piping

▪ When connecting the electrical wiring

▪ When maintaining or servicing the unit

DANGER: RISK OF ELECTROCUTION

Do NOT leave the unit unattended when the service cover is removed.

7.2.2 To open the outdoor unit

DANGER: RISK OF ELECTROCUTION

DANGER: RISK OF BURNING

See "7.5.8To connect the refrigerant piping to the outdoor unit" on

page 37 and "7.9.6 To connect the electrical wiring on the outdoor unit"on page42.

7.2.3 To open the indoor unit

1 Remove the front panel.

3 If you have to do work behind the switch box, open the switch

box.

4 If you have to do work behind the user interface panel or upload

new software into the user interface, open the user interface panel.

2 If you have to connect electrical wiring, remove the switch box

cover.

Installer reference guide

5 Optional: Remove the user interface panel.

NOTICE

If you remove the user interface panel, also disconnect the cables from the back of the panel to prevent damage.

RRGA04~08DAV3 + RHBX04+08DA

ROTEX HPSU Bi-Bloc Ultra

4P495262-1A – 2018.11

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