For the installer / owner Start-up, maintenance and troubleshooting manual, notes for the operator Solar System and auroSTOR unvented solar cylinder Solar hot water systems GB
Contents Contents 1 Notes on the documentation .............................. 3 2 2.1 2.2 2.3 Overview of standards, safety instructions ..... 3 Overview of EU standards...........................................3 Regulations in Great Britain ...................................... 4 Safety instructions ....................................................... 4 3 3.1 3.2 System description .............................................. 5 Intended use .....................................................
Notes on the documentation 1 Overview of standards, safety instructions 2 1 Notes on the documentation Your solar system is a quality product from Vaillant. This manual describes the entire system, all of its components and the cylinder and provides you with information on start-up, maintenance and troubleshooting. It is a supplement to the operating, installation and assembly manuals of the individual components. Observe the manuals for each individual system component in conjunction with this manual.
2 Overview of standards, safety instructions Solar cylinder and cylinder installation 2.3 Pressure equipment directive 97/23/EC Directive of the European Parliament and Council from 29th May, 1997 for the approximation of the laws on pressure equipment of the Member States The entire solar system must always be installed and operated in accordance with recognised technical standards.
Overview of standards, safety instructions 2 System description 3 Use the automatic Vaillant air separator system (item no. 302 418). It works fully automatically and does not need to be subsequently blocked. It must be installed in an area however, in which no steam can enter, preferably in the return pipe nearby the solar cylinder.
3 System description 6 7 8 9 C D DHW 2 3 4 M 11 10 1 A 5 B M Fig. 3.
System description 3 The Vaillant auroTHERM exclusive tube collector (6) transforms solar energy into heat and transfers the heat energy to a frost-protected solar fluid. The solar pump of the solar pump unit (7) ensures the heat is transported from the collector to the bivalent solar cylinder (2) via a pipe system. The solar pump unit is controlled by the solar control.
4 Description of the components 4 4.1 Description of the components Collectors H Danger! Risk of burns! To avoid injuries due to hot parts of the collectors, all work on the collectors should be carried out on cloudy days. Alternatively work can be carried out in the morning or evening of sunny days or with the collector covered. 4.1.
Description of the components 4 Technical data of the tube collectors Appliance designation Units °C auroTHERM exclusive VTK 275 0.68 / 0.41 1695 440 100 10.3 1.6 3/4“ 10-6 6 94 ± 1 5±2 95 ± 1.0 6 0036 250 auroTHERM exclusive VTK 550 1.28 / 0.82 1695 790 100 20 3.56 3/4“ 10-6 6 94 ± 1 5±2 95 ± 1.
4 Description of the components 4.1.2 VFK 900 flat collector Equipment The Vaillant VFK 900 flat collector includes a seawaterresistant aluminium frame as well as a copper surface absorber with selective Cermet Vacuum coating. The Vaillant VFK 900 flat collector has a CFC-free, standstill temperature-resistant mineral wool insulation for long-life, excellent heat insulation. For easy assembly, all connections were designed as flat gasket.
Description of the components 4 4.1.3 Disposal All Vaillant solar collectors meet the requirements for the German “Blauer Engel” (Blue Angel) environmental mark. Therefore, we, as the manufacturer, will take back and recycle components when they have to be disposed of after years of reliable use.
4 Description of the components 1 0,5 3 2 6 5 4 1 0,5 3 2 L/min Flow rate meter 4 5 6 4.4 4.5 L/min 4.3 Solar pump The solar pump unit is equipped with a three-speed solar pump (Fig. 4.9, pos. 8) for the optimum adaptation of the required circulating volume and the pump capacity in the solar circuit. Select the pump capacity, depending on the solar system (e. g.
Description of the components 4 h Note! Do not use any other anti-freeze or inhibitors with Vaillant solar collectors. Only Vaillant solar fluid is approved. a Caution! Risk of damage! Vaillant solar fluid is ready mixed. You may not under any circumstances mix it with water or other fluids. Otherwise it will become ineffective as an antifreeze or anticorrosive, resulting in damage to collectors or other parts of the system.
4 Description of the components 4.6.4 1. 1.1 1.2 2. 2.1 Safety data sheet Substance/Formulation and company name Information on the product: Trade name of the Vaillant solar fluid (item no. 302 362) Information on the supplier: Vaillant GmbH, Berghauser Str. 40, 42859 Remscheid, Germany Telephone +49 (02191) 18 - 0, fax +49 (02191) 182810, Emergency information: your local poison information centre (see directory assistance or telephone directory).
Description of the components 4 9. 10. 10.1 10.2 10.3 11. 11.1 11.2 12. 12.1 12.2 Physical and chemical properties Form: fluid Colour: violet Odour: product-specific Solidification temperature: approx. -28 °C (DIN 51583) Boiling temperature: > 100 °C (ASTM D 1120) Flash point: none Lower explosion limit: 2.6 % by vol. (details for Upper explosion limit: 12.6 % by vol. 1.2 propylene glycol) Ignition temperature: omitted vapour pressure (20 °C): 20 mbar Density (20 °C): approx. 1.
4 Description of the components Control of the hot water temperature The hot water temperature in the top half of the cylinder can be controlled by the Vaillant auroMATIC VRS 560 solar control or by using a separate hot water programmer (refer to Section 5.8, Electrical installation). 4.7 auroSTOR solar cylinder The auroSTOR solar cylinder is described in detail in Section 5.1, Installation of the solar cylinder, of this manual. 4.
Description of the components 4 Installation 5 Control Center VR 65 The Control Center VR 65 provides a system solution which allows Vaillant low-voltage eBUS controllers to be used in the English market with valves and hot water cylinders with traditional 230 V cylinder thermostats. The information on the heat requirements of the solar cylinder is forwarded to the Vaillant ecoTEC boiler by the Control Center VR 65.
5 Installation Solar sets auroTHERM exclusive Mini Standard Medium Large Item no.
Installation 5 Solar sets auroTHERM exclusive Mini Standard Medium Large Item no.
5 Installation Solar set auroTHERM flat plate collector Item no. 0020036552 auroTHERM VFK 900 2 Roof bracket set for concrete tiles (qty 6) 1 On-roof kit for two panels 1 Stainless steel connection pipe DN12 2x1m 1 Single insulated tube, DN16, length 15m 2 Fittings pack for DN16 tube 1 Solar pump unit 1 Expansion vessel 18 litres 1 Protection vessel 1 Automatic air separator 1 Table 5.
Installation 5 auroTHERM flat plate collector solar set Item no. Thermostatic mixing valve 0020036552 1 Solar control auroMATIC 560 1 NTC sensor VR10 (solar gain) 1 Solar fluid (20 litre) 2 Table 5.
5 Installation auroSTOR solar cylinders VIH S GB 200 S VIH S GB 250 S VIH S GB 300 S Item no.
Installation 5 5.1 Installation of the solar cylinder 5.1.1 Description of the solar cylinder 1 19 L 20 C° N immersion heater 24 21 cylinder control C° 23 18 6 3 2 3 2 1 22 5 4 7 17 16 8 9 10 15 14 11 12 13 Fig. 5.
5 Installation auroSTOR solar cylinders are available in three sizes: 200, 250 and 300 litres. The containers are made of stainless steel and insulated with EPS.The cylinders are equipped with all necessary cold and hot water control devices and a motorised 2 port valve. The auroSTOR cylinders are operated at the pressure of the water supply pipe and do not need a cold water tank for their supply. They have hot and cold water connections of 22 mm diameter.
Installation 5 5.1.
45 30 40 VIH S GB 300 S VIH S GB 250 S 35 25 20 30 VIH S GB 200 S 25 15 10 20 12 15 20 25 30 35 Reheat time for 70 % of cylinder contents (minutes) Approximate cylinder heat up time 15 C to 45 C (minutes) 5 Installation 38 Heat input to cylinder (kW) 8 bar* 40 4 bar* 3 bar* 2 bar* 30 1 bar* 20 10 0 20 30 40 10 Flow available (litres/min) at entry to system Fig. 5.
Installation 5 5.1.3 Intended use The Vaillant solar cylinders auroSTOR VIH S GB 200 S, VIH S GB 250 S and VIH S GB 250 are unvented, indirectly heated hot water cylinders for solar systems designed for usage with boilers in hot water supply systems in accordance with the GB standard. They are used only to supply potable water heated up to 85 °C in solar systems with a collector array. They may only be used for this purpose.
5 Installation 5.1.9 Transport A cylinder carrier handle is supplied to make the transport to the installation site easier. 1 Fig. 5.7 Fastening the cylinder carrier handle • Fasten the carrier handle (1) to the hot water connection of the solar cylinder.
Installation 5 5.1.10 Dimensions 1 2 3 8 h f k a g b 7 598 554 e d c 4 5 6 45 Fig. 5.
5 Installation 5.2 Functional diagram 6 7 8 9 C D DHW 2 3 4 M 11 10 1 A 5 B M Fig. 5.
Installation 5 5.3 Installation of the solar circuit piping 5.3.1 General instructions The Vaillant solar system is a closed hydraulic system in which heat can be transferred to the cylinders only by means of heat exchangers due to the special heat transfer fluid of the solar system.Observe the following points to ensure perfect operation with maximum energy utilisation: • Bleed the system completely during start-up and maintenance since air in the system has a considerable effect on the efficiency.
5 Installation 5.3.5 Bleeding of the solar circuit Air in the system impairs the efficiency of the solar system considerably.Install therefore the automatic Vaillant air separator system (item no. 302 418) in the return of the solar circuit (see Fig. 5.12) between the solar circuit and solar pump unit. High temperature vapour is unlikely in this area. The Vaillant air separator system works fully automatically and does not need to be subsequently isolated. 5.
Installation 5 thermostat mixer warm water mixed water cold water Fig. 5.14 Hot water thermostatic mixing valve 2 4 Example: The available flow rate of mixed water of 40 °C is 25 l/ min (15 l/min hot water of 60 °C from the solar cylinder mixed with 10 l/min cold water of 10 °C) if the measured static cold mains water pressure is 2 bar and the available flow rate 30 l/min. The solar cylinder operates satisfactorily at a mains water pressure of below 2 bar, but at a reduced flow rate.
5 Installation a Danger! Risk of bursts for the solar cylinder due to overpressure! The outlet of the expansion relief valve may not be covered or closed. • Test the expansion relief valve (Fig. 5.16, pos. 2) regularly to avoid calcification. • Connect the solar cylinder to the cold water supply (Fig. 5.16, pos. B). To ensure an optimum performance of the solar cylinder, in particular in installations in which the pressurecontrolled cold water outlet (Fig. 5.16, pos.
Installation 5 Minimum diameter of the discharge pipe from the tundish Maximum permissible total resistance, expressed as straight pipe length (without elbows or bends) Resistance due to each elbow or bend 22 mm Up to 9 m 0.8 m 28 mm Up to 18 m 1.0 m 35 mm Up to 27 m 1.4 m H Danger! Risk of being scalded by escaping hot water! Make sure the discharge pipe ends at a safe point inside or outside the building (safe and visible), where there is no risk of anyone coming in contact with hot water.
5 Installation 5.8.1 Immersion heater The auroSTOR VIH S GB 200 - 300 S solar cylinders have been equipped with an immersion heater by the manufacturer. tundish 300 mm minimum discharge pipe 230 V AC 3 kW metal hopper head 5 L N 1 Fig. 5.18 High discharge connection 3 5.8 Electrical installation Wiring should be performed by a qualified specialist in accordance with the building regulations, Part P of the current IEE regulations and further applicable regulations and directives.
Installation 5 Caution! a Risk of damage! The immersion heater is equipped with a thermal cut out and may under no circumstance be replaced by a standard immersion heater. Caution! a Risk of damage! If the immersion heater is not connected, you must connect the earth wire to terminal E on the terminal strip of the immersion heater. You can find a wiring sheme on the inside of the cylinder cover. Only correct original Vaillant spare parts are allowed. 5.8.
5 Installation Boiler Wiring Solar circuit control Vaillant, eBUS-capable Control Center VR 65 VRS 560 Vaillant, eBUS-capable or not Standard wiring box eBUS-capable VRS 560 Device from a third-party manufacturer, not eBUS-capable Solar cylinder reheating Control of the he- Wiring schecontrol ating circuits me VRT 360 VRS 560 2, Fig. 5.28 Device from a third-party manufacturer (DHW timer) Programmer VRS 560 3, Fig. 5.
Installation 5 cylinder control C° • Undo the lock (2) of the cylinder thermostat (1) and take it out of the terminal box. • Remove the capillary tubes (3) of the cylinder thermostat and thermal cut out from the immersion sleeve of the solar cylinder. • Make sure the two capillary tubes of the controller for the immersion heater have not been removed. • Establish the eBUS connections from the boiler and VRT 360 to the Control Center VR 65.
Earth E E on L L cyl. 2 CH N 7 L Collector Pump E on black on cyl. VR 65 remove TCO and cyl. thermostat according to manual 2 1 VRS 560 solar control EP L 2 1 Earth Blue Brown Grey Orange Central Heating 2 Port Valve E VR 65 CH N E DHW N E Blue Brown Hot Water 2 Port Valve Earth E N 230 V~ 1 2 3 TCO and cyl. thermostat TCO collector pump boiler reheat auroSTOR cylinder black N D L A C B D A add. terminal strip E add.
Installation 5 Wiring plan 2 - Vaillant boiler - Wiring via standard wiring box - Solar circuit control via VRS 560 - Solar circuit reheating control via VRS 560 - Heating circuit control via programmer - Overview connection of the cylinder thermostat to the wiring box - Installation of two VR 10 temperature sensors in the solar cylinder (see Fig. 5.26) - Attachment of the the solar gain sensor to the solar circuit return (see Fig. 5.
L 230 V~ N E Kol 1-P N L Earth E 10 N E 3 4 Collector Pump L Blue Brown Grey Orange Hot Water 2 Port Valve N additional terminal strip A B C D additional terminal strip D B A 8 4 4 E 9 5 5 N 9 black 10 3 4 Earth Blue Brown Grey Orange Central Heating 2 Port Valve E E 7 N 230 V~ E 7 VRS 560 solar control EP L 2 1 L E not used LP/UV 1 N 6 Central Heating Programmer 230 V~ water heating on on L N E L 1 2 3 TCO and cyl. thermostat Note! Set temp. of cyl.
Installation 5 Wiring plan 3 - Vaillant boiler - Wiring via standard wiring box - Solar circuit control via VRS 560 - Solar cylinder reheating control via a separate hot water programmer from a third party manufacturer - Heating circuit control via a separate programmable timer from a third party manufacturer • Attach the temperature sensor for the gain (2) to the return pipe of the solar circuit nearby the solar cylinder.
5 Installation h Note! Programme the auroMATIC 560 solar control to provide hot water when required by the customer. The auroMATIC 560 control will only signal to the boiler if the cylinder is below target temperature, if the solar system is not operating and if the hot water programmer is on. h Note! Programme the separate hot water programmer to provide hot water when required by the customer.
L 230 V~ N E Manual - Solar hot water systems Kol 1-P N L Earth E 10 N E 3 4 Collector Pump L Blue Brown Grey Orange Hot Water 2 Port Valve N additional terminal strip A B C D additional terminal strip D B A 8 4 4 E 9 5 5 10 N 230 V~ 10 N 9 3 4 Earth Blue Brown Grey Orange Central Heating 2 Port Valve E E VRS 560 solar control EP L 2 1 L E 7 LP/UV 1 N 6 Central Heating Programmer 230 V~ hot central water heating L N E black E black 1 2 3 TCO collector pump TCO and c
5 Installation Wiring plan 4 - Boiler from third party manufacturer - Wiring via standard wiring box - Solar circuit control via VRS 560 - Solar circuit reheating control via VRS 560 - Heating circuit control via a separate central heating programmer from a third party manufacturer - Overview connection of the cylinder thermostat to the wiring box - Installation of two VR 10 temperature sensors in the solar cylinder (see Fig. 5.32) - Attachment of the solar gain sensor to the solar circuit return (see Fig.
L 230 V~ N E Manual - Solar hot water systems Kol 1-P N L Earth 4 Blue Brown Grey Orange Hot Water 2 Port Valve 10 N E L N L additional terminal strip D B A E E Collector Pump N additional terminal strip A B C D N E Heating Pump (if not in boiler) L 3 8 E 9 L not used 6 10 7 VRS 560 solar control EP L 2 1 E E * N 9 L 4 Earth Blue Brown Grey Orange Central Heating 2 Port Valve E N LP/UV 1 N L C1 C2 1 2 SP 1 SP 2 auroSTOR Coll.
5 Installation Wiring plan 5 - Boiler from third party manufacturer - Wiring via standard wiring box - Solar circuit control via VRS 560 - Solar cylinder reheating control via a separate hot water programmer from a third party manufacturer - Heating circuit control via a separate central heating programmer from a third party manufacturer • Attach the temperature sensor for the gain (2) to the return pipe of the solar circuit nearby the solar cylinder.
Installation 5 h Note! Programme the separate hot water programmer to provide hot water when required by the customer. Consider carefully when the solar system might be running and try to time to HW programmer to run when there is unlikely to be any solar gain. h Note! The auroMATIC 560 control will only control the solar system.
L 230 V~ N E Kol 1-P N L N E Earth E 10 N E L 4 Collector Pump L additional terminal strip D B A additional terminal strip A B C D Blue Brown Grey Orange Hot Water 2 Port Valve N N E Heating Pump (if not in boiler) L 3 8 E 9 L 7 10 N 9 L 4 Earth Blue Brown Grey Orange Central Heating 2 Port Valve E 6 VRS 560 solar control EP L 2 1 E V~ black E black 1 2 3 TCO collector pump TCO and cyl.
Installation 5 Start-up 6 Alternatively to the Vaillant VRT 30 room thermostat, you can also connect devices from third-party manufacturers. • Connect the room thermostat as illustrated in Fig. 5.38.
6 Start-up • Switch off the filling pump and switch on the solar pump (13) to allow air bubbles to escape via the bleeder. • Block the gravity brakes (8 and 14) (position 45°) to discharge the remaining air. • When bleeding is completed release the gravity brakes. Collector circuit filling pressure The filling pressure Pa should be approx. 0.5 bar over the static pressure Pstat. Pa = h x 0.1 + 0.5 bar 2 6a 6b 6.
Start-up 6 Tube collectors auroTHERM exclusive Number in series Flow rate Minimum cross-section of the copper pipe in the solar circuit at a total pipe length of: Net surface area l/min l/h 0.82 1.64 2.64 3.28 4.10 0.55 1.10 1.65 2.20 2.75 33 66 99 132 165 1 2 3 4 5 Pump speed: 20 m 15 15 15 15 15 Minimum (speed 1) 50 m 15 15 15 22 22 Maximum (speed 3) Table 6.
6 Start-up L cylinder control C° N 1 C° Close the pressure control valves in the water, solar and heating circuits in accordance with the Installation chapter. They may under no circumstances be covered or closed. immersion heater d Danger! Risk of bursts! 3 2 2 1 6.5 Setting the hot water thermostatic mixing valve The hot water from the solar cylinder can be set to a desired maximum temperature between 30 °C and 70 °C by mixing hot and cold water.
Start-up 6 6.8 Start-up protocol • Fill in the start-up protocol (see Section 9) of this manual • Fill in the start-up protocol (see Section 11) of this manual. Fig. 6.5 Benchmark logo 6.9 Handing over the system to the owner • Hand over the manuals intended for the owner as well as the documents of the auroSTOR. • Tell the owner to keep the manuals nearby the appliances. • Draw special attention to the safety instructions which the owner must follow.
7 Inspection and maintenance 7 Inspection and maintenance To ensure reliability and long service life regular inspections and maintenance work have to be performed on the solar system by a specialist. As the owner, never try to carry out maintenance work on your system yourself. Use an approved qualified servicing company for this work. We recommend making a maintenance agreement with an approved qualified servicing company.
Troubleshooting 8 8 Troubleshooting The following tables provide information on possible malfunctions during the operation of the solar system as well as their cause and remedy. All work on the Vaillant solar system (installation, maintenance, repairs etc.) may be performed only by approved specialists. d Danger! Risk of serious injury or death! Never try to correct faults in the solar system yourself. Bear in mind that you risk death or serious injury if the work is performed incorrectly.
8 Troubleshooting Malfunction Cause Pump starts up and goes off shortly afterwards.This is repeated several times until the system runs its course. The same occurs in the evening. The temperature difference of the controller Check whether the entire pipework is fully is too low or the pump speed is set too high. insulated.Increase the temperature The solar radiation is not yet sufficient to difference of the controller. heat up the entire pipework. The pump is making noises. Remedy 1.
Troubleshooting 8 Malfunction Cause Reheating is not working. The boiler runs 1. Air in the reheating heat exchanger for a short time, goes off and then back 2. Heat exchanger surface area too on again. This is repeated until the small cylinder is at its target temperature. Only cold or lukewarm water comes out of the taps. 1. Cold and hot water connections on the cylinder have been mixed up. 2. Hot water thermostat mixer set too low. 3. Solar heating insufficient; boiler does not reheat.
9 Notes for the owner 9 Notes for the owner • Please read this manual thoroughly to ensure optimum utilisation of your Vaillant hot water solar system. 9.1 General notes We recommend declaring the solar system as an increase in value to the insurance and insuring it explicitly against lightning. It may also make sense to take out an insurance against hailstorms in particularly prone areas.
Notes for the owner 9 Caution! a Risk of damage! Caution! a Risk of damage! In the unlikely event of a malfunction occurring of the auro STOR, such as hot water flowing out of the temperature and pressure relief valve, switch off the boiler and the immersion heater and contact Vaillant Ltd. or your installer. 9.6 Do not remove or modify any components of the solar cylinder.
9 Notes for the owner 10 Customer service and manufacturer's warrenty 9.7 What should be done if ... Malfunction Remedy … fluid drips out of the system? Collect it (in a bucket) if possible and notify a qualified servicing company. Notify a qualified servicing company. … the fluid level rises in the collecting container under the solar pump unit? … fluid or steam comes out of the expansion relief valve? Notify a qualified servicing company.
Start-up protocol 11 11 Start-up protocol The solar system of: has been started up, while taking the following points into consideration: 1.
11 Start-up protocol Information Unit Value/Detail Benchmark no. Registration no.
Start-up protocol 11 Information Unit Controller settings Installed controller(s)/timer(s) Manufacturer Reheating with boiler starts at (TSP1 min. see installation manual of solar control)? Switch-on temperature difference: Switch-off temperature difference: °C Value/Detail Kelvin Kelvin Other settings Important activated functions Name of the installer (in block letters) Corgi ID No. Date Signature Signature of the owner to confirm the receipt of all manuals of the system Table 11.
11 Start-up protocol 66 Manual - Solar hot water systems
Start-up protocol 11 Manual - Solar hot water systems 67
0020009607_01 GB 012007
