Vaillant auroTHERM VFK 900 Technical data

Vaillant auroTHERM VFK 900 Technical data
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 ...................................................................5
Design and function of the solar system ................5
5.6
5.6.1
5.6.2
5.6.3
5.7
5.7.1
5.7.2
5.8
5.8.1
5.8.2
Installation of the cold water supply pipework ... 33
Mains water supply pressure ................................... 33
Cold water piping ....................................................... 33
Drain valve ................................................................... 34
Discharge pipework ................................................... 34
Discharge pipework ................................................... 34
High level termination............................................... 35
Electrical installation ................................................. 36
Immersion heater ....................................................... 36
Electrical connection
to the cylinder control device ..................................37
5.8.3 Combination options
of the control components .......................................37
Description of the components .......................... 8
Collectors ....................................................................... 8
auroTHERM exclusive tube collector ...................... 8
VFK 900 flat collector ............................................... 10
Disposal .......................................................................... 11
Solar pump unit ............................................................ 11
Design ............................................................................. 11
Water control pack ....................................................... 11
Solar expansion vessel ................................................ 11
Protection vessel (item no. 302 405) ..................... 11
Solar pump.................................................................... 12
Thermal cut out of the solar pump ........................ 12
Flow rate meter ........................................................... 12
Solar fluid ...................................................................... 12
Properties of the solar fluid ..................................... 12
Protection of the solar circuit against frost
and corrosion ............................................................... 13
4.6.3 Frost protection of the bivalent solar cylinder .... 13
4.6.4 Safety data sheet ........................................................ 14
4.7
auroSTOR solar cylinder............................................ 16
4.8 Solar control ................................................................. 16
6
6.1
6.2
6.3
6.4
6.5
5
5.1
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5
5.1.6
5.1.7
5.1.8
5.1.9
5.1.10
5.2
5.3
5.3.1
5.3.2
5.3.3
5.3.4
9.3.2
9.4
9.4.1
9.4.2
9.5
9.5.1
9.5.2
9.6
9.6.1
9.6.2
9.7
4
4.1
4.1.1
4.1.2
4.1.3
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.3
4.4
4.5
4.6
4.6.1
4.6.2
Installation ...........................................................17
Installation of the solar cylinder ............................ 23
Description of the solar cylinder ............................ 23
Technical data of the auroSTOR solar cylinder .. 25
Intended use .................................................................27
Data badge ....................................................................27
Safety devices ..............................................................27
Safety instructions and regulations .......................27
Scope of delivery.........................................................27
Requirements of the installation site .....................27
Transport ...................................................................... 28
Dimensions .................................................................. 29
Functional diagram .................................................... 30
Installation of the solar circuit piping .................... 31
General instructions ................................................... 31
Material .......................................................................... 31
Laying of the solar circuit pipes .............................. 31
Connection of the collectors
to the solar pump unit ............................................... 31
5.3.5 Bleeding of the solar circuit .................................... 32
5.4
Installation of the reheating circuit piping .......... 32
5.5
Installation of the hot water pipework.................. 32
5.5.1 Hot water thermostatic mixing valve .................... 32
2
6.6
6.7
6.8
6.9
Start-up ................................................................51
Flushing and filling the solar circuit ....................... 51
Setting the flow rate and pump .............................. 52
Programming the flow rate on the controller ..... 53
Filling the hot water secondary circuit ................. 53
Setting the hot water
thermostatic mixing valve........................................ 54
Filling the reheating circuit...................................... 54
Starting up the boiler ................................................ 54
Start-up protocol ........................................................ 55
Handing over the system to the owner ................ 55
7
Inspection and maintenance ............................56
8
Troubleshooting ..................................................57
9
9.1
9.2
9.3
9.3.1
Notes for the owner ...........................................60
General notes ..............................................................60
Operation of the solar system ................................60
Operation of the solar cylinder...............................60
Setting the standby temperature
of the cylinder .............................................................60
Switching off the solar cylinder ............................... 61
Frost protection ........................................................... 61
Frost protection of the solar system ...................... 61
Frost protection of the solar cylinder .................... 61
Care ................................................................................ 61
Care of the collectors ................................................. 61
Care of the solar cylinder ......................................... 61
Maintenance ................................................................. 61
Maintenance of the solar system ............................ 61
Maintenance of the solar cylinder .......................... 61
What should be done if ............................................ 62
10
10.1
10.2
Customer service
and manufacturer's warranty ...........................62
Vaillant service............................................................ 62
Vaillant warranty ........................................................ 62
11
Start-up protocol ...............................................63
Manual - Solar hot water systems
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.
Look after this manual and pass it on to the next owner.
h
Note!
The “Start-up” and “Maintenance and
troubleshooting” chapters of this manual are
intended only for approved specialists.
Vaillant accepts no liability for any damage caused by
failure to observe this manual.
Other applicable documents
- Assembly manual of the collectors
- Operating and installation manual of the controller
- Operating and installation manual of the boiler (if
used)
- Assembly, operating and installation manuals of all
accessories used
- Warranty card
Symbols used
Please observe the safety instructions in this manual
when operating and installing the solar system and the
auroSTOR solar cylinder.
The symbols used in the manual are explained
below:
d Danger!
Immediate risk of serious injury or death!
e Danger!
Danger of death from electric shock!
e
Danger!
Risk of burns or scalding!
Caution!
a Potentially
dangerous situation for the product
and environment.
h Note!
Application recommendation.
• Symbol for a required task
Manual - Solar hot water systems
2
Overview of standards,
safety instructions
2.1
Overview of EU standards
Solar system in general
EN ISO 9488
Thermal solar system and components, terminology
(ISO/DIS 9488; 1995)
EN 12975-1
Thermal solar systems and components; Collectors, Part
1: General requirements
EN 12975-2
Thermal solar systems and components; Collectors; Part
2: Test methods
ENV 1991-2-3
Eurocode 1 – Basis of design and actions on structures,
Part 2–3: Actions on structures - Snow loads
EN 12976-1
Thermal solar systems and components;
Factory made systems - Part 1: General requirements
EN 12976-2
Thermal solar systems and components;
Factory made systems - Part 2: Testing methods
ENV 12977-1
Thermal solar systems and components;
Custom built systems,
Part 1: General requirements
ENV 12977-2
Thermal solar systems and components;
Factory made systems,
Part 2: Testing methods
ISO 9459-1: 1993
Solar heating – Domestic water heating systems – Part 1:
Performance rating procedure using indoor test
methods
ISO/TR 10217
Solar energy – Water heating systems – Guide to
material selection with regard to internal corrosion
Collectors and collector assembly
ENV 1991-2-4
Eurocode 1 – Basis of design and actions on structures Part 2–4: Actions on structures - Wind actions
3
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.
EN 12977-3
Thermal solar systems and components;
Custom built systems,
Part 3: Performance characterisation of stores for solar
heating systems
EN 12897
Water supply - specification for indirectly heated
unvented (closed) storage water heaters
EN 806-1
Specifications for installations inside buildings conveying
water for human consumption - Part 1: General
EN 1717
Protection against pollution of potable water
installations and general requirements of devices to
prevent pollution by backflow
EN 60335-2-21
Safety of household and similar electrical appliances;
Part 2: Particular requirements for storage water
heaters (hot water cylinders and hot water boilers)
(IEC 335-2-21: 1989 and supplements 1; 1990 and 2; 1990,
modified)
Lightning protection
ENV 61024-1
Protection of structures against lightning – Part 1:
General principles (IEC 1024-1: 1990; modified)
BS 6651 Code of practice for protection of structures
against lightning
2.2
Regulations in Great Britain
Building Regulation, dating from 1991 (England and
Wales)
Requirement G3, L1 and Regulation 7
BS 7671
Requirements for electrical installations
(IEE Wiring Regulations, 16th edition)
BS 6759-1
Directive for the usage of the safety assembly for hot
water cylinders
4
Safety instructions
d Danger!
Risk of falling!
Make sure you adhere to the valid work
protection regulations, in particular when
working on the roof. Make absolutely sure you
wear anti-fall devices whenever there is a risk
of falling. (We recommend Vaillant fall
protection systems, item no. 302 066.)
Observe the accident prevention regulations of
the trade associations.
H Danger!
Risk of being burned or scalded by hot
components! Install and replace collectors or
collector parts on very cloudy days. Perform
installation work on sunny days only in the
morning or evening or with the collector
covered.
Danger!
Risk of being burned or scalded by hot solar
fluid or components! Fill and flush the solar
system when the collectors are cold. Cover the
collectors while doing so.
Danger!
Risk of being burned or scalded by escaping hot
steam!
Steam can escape from the expansion relief
valve of the solar pump unit if the system is
shut down. To avoid injuries, you must connect
the expansion relief valve to a collecting
container with a hose line.
Danger!
Risk of being scalded by hot water! With the
Vaillant auroSTOR combi cylinder, the outlet
temperatures at the taps can be up to 85 °C. To
provide effective protection against scalding in
the event of secondary return, integrate a hot
water thermostat mixer in the system (refer
to Section 5.5.1 and 5.5.2).
Danger!
Risk of being burned or scalded by escaping hot
steam! Steam can escape from unblocked
automatic bleeders if the system is shut down.
Therefore block all automatic bleeders after
bleeding.
Manual - Solar hot water systems
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.
e Danger!
Danger of death by electric shock!
All live parts of the system may be installed,
serviced and repaired only by a qualified
servicing company!
Danger!
Risk of overvoltage!
Earth the solar circuit as potential equalisation
and protection against overvoltage! Attach
earthing pipe clips to the solar circuit pipes and
connect the clips to a potential rail with a
16 mm2 copper cable.
3
System description
3.1
Intended use
The Vaillant solar system is used for the solar-supported
supply of drinking water.
Any other use or extended use is considered to be
improper. The manufacturer / supplier is not liable for
any resulting damage. The user alone bears the risk.
Intended use includes the observance of the system
description and all other applicable documents, as well
as adherence to the maintenance and inspection
conditions.
a Caution!
We accept no liability for any damage or injuries
caused by failure to observe this manual.
At the end of this manual is a start-up protocol, which
should be filled in by the installer and/or start-up
engineer and handed over to the owner.
All CORGI-approved installers have a CORGI ID card and
a registration number. Both of them should be entered
on the start-up checklist. You can check the details of
your installer at CORGI under the telephone number
+49 (0)1256 372300.
3.2
Design and function of the solar system
The solar system consists of four main components:
– The collectors, which absorb the solar radiation and
utilise it (refer to Section 4.1, Collectors).
– The solar control, which monitors, displays and
controls all functions of the system (refer to Section
4.8, Solar control).
– The solar pump unit, which transports the solar heat
(refer to Section 4.2, Solar pump unit).
– The solar cylinder (refer to Section 5.1, Installation of
the solar cylinder).
On days on which the solar radiation is insufficient to
heat the drinking water in the cylinder, the stored water
must be reheated by a heating system. This can be done
with boilers or electrically with an immersion heater.
Manual - Solar hot water systems
5
3 System description
6
7
8
9
C
D
DHW
2
3
4
M
11
10
1
A
5
B
M
Fig. 3.1 System for solar heating of drinking water
Key
1 Boiler
2 auroSTOR solar cylinder
3 230 V∼motorised 2 port valve (supplied together with the solar
cylinder)
4 Immersion heater
5 230 V∼ motorised 2 port valve (supplied together with the
boiler)
6 auroTHERM collector
7 Solar pump unit
8 Protection vessel (optional)
6
9
10
11
A
B
C
D
Solar expansion vessel
Automatic air separator system
Drinking water expansion vessel
Boiler flow
Boiler return
Solar circuit flow
Solar circuit return
Manual - Solar hot water systems
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.
The solar control switches the solar pump on or off as
soon as the difference in temperature between the
collector and solar cylinder falls below or exceeds the
preset value. If the solar energy is insufficient, the
control system switches on the boiler (1) so that the
upper third of the cylinder is reheated to the set value
for the hot drinking water temperature. In addition the
solar cylinder can be reheated by the immersion heater
installed by the manufacturer.
The solar system is a closed system and must be bled
carefully. We recommend the automatic Vaillant air
separator system for this purpose (item no. 302 418). It
works fully automatically and does not need to be
subsequently blocked.
The automatic air separator system must be installed in
an area in which no steam can enter, preferably in the
return pipe between the solar pump unit and the solar
cylinder.
The solar expansion vessel (9) compensates pressure
fluctuations in the solar circuit.
The optional protection vessel (8) protects the
expansion vessel from increased temperatures in the
solar circuit. We recommend installing a protection
vessel.
The Vaillant solar system enables various system
configurations and control concepts:
Electrical wiring
The Vaillant Control Center VR 65 can be used to wire
up the system if an eBUS-capable Vaillant boiler is used.
A standard wiring box can be used if a Vaillant boiler
which is not eBUS-capable or an external boiler is used.
Control of the hot water temperature
The hot water temperature in the upper third of the
cylinder can be controlled by the VRS 560 or by a
separate hot water programmer.
d Danger!
Risk of being scalded by hot water to provide
effective protection against scalding, install a
thermostat mixer in the hot water pipe as
described in Section 5.5, Installation of the hot
drinking water pipework. Set the thermostat
mixer to below 60 °C and check the
temperature at a hot water tap.
Heating control
The heating can be regulated by means of a
programmable Vaillant VRT 360 room thermostat or
VRC 400 weather compensator if an eBUS-capable
Vaillant boiler is used.
The Vaillant VRT 30 room thermostat or a standard
room thermostat can be used if a non-eBUS Vaillant
boiler or an external boiler is used.
Manual - Solar hot water systems
7
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.
4.1.1
auroTHERM exclusive tube collector
Interior design
The Vaillant auroTHERM exclusive VTK 275 and 550
tube collectors consist of 8 or 16 collector tubes
connected in parallel. With its collector tubes with
internal mirror of pure silver and glass-glass connection
of sleeve and absorber pipe for lasting vacuum sealing,
the collector ensures constant high performance over its
entire service life. The high-performance absorber has a
Cermet Aluxid® vacuum coating. Extremely low heat
losses of k1 = 0.68 W/(m2K) thanks to a high vacuum of
< 10-6 bar ensure year-round use.
By deliberately interrupting heat transfer to the
downstream system, the auroTHERM exclusive provides
effective system protection against excess temperatures
above 180 °C if the system is shut down.
The collectors are connected in series.
1
2
6
5
3
4
Fig. 4.1 auroTHERM exclusive VTK 550 tube collector
Fig. 4.3 Cross-section through four tubes with direction of flow
Key
1 Outer collector tube
2 Inner collector tube
3 Guide tube
4 Absorber tube
5 Outlet
6 Inlet
Fig. 4.2 auroTHERM exclusive VTK 275 tube collector
8
Manual - Solar hot water systems
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 ± 1.0
6
0036
250
Surface area (gross, aperture/net)
Height
Width
Depth
Weight
Collector capacity
Copper pipe connection, flat-face
Insulation: high vacuum
Maximum operating pressure
Pure silver mirror, degree of reflection ρ
Absorber emission ε
Absorber absorption α
Solar sensor sleeve
CE label
Shutdown temperature (according to prEN 12975-2,
c < 1 m/s) in the glass tube
Shutdown temperature (according to prEN 12975-2,
c < 1 m/s) at the collector connection
Efficiency η0 (according to EN 12975)
Efficiency coefficient k1
Efficiency coefficient k2
m2
mm
mm
mm
kg
l
Thread
bar
bar
%
%
%
∅ mm
°C
180
180
%
W/(m2•K)
W/(m2•K2)
78 ± 3%
1.09 ± 0.2
0.01 ± 0.002
78 ± 3%
1.09 ± 0.2
0.01 ± 0.002
Table 4.1 Technical data tube collector auroTHERM exclusive
[%] 1,0
40
0,9
0,8
Pressure loss [mbar]
0,7
0,6
0,5
0,4
0,3
auroTHERM
exclusive
30
20
10
0,2
0,1
0
0
20
W/m2
40
60
1000
Insolation
800 W/m2 Insolation
2
300 W/m Insolation
80
100 120
140 160
180
200 220 240
Temperature difference (collektor/ambient) [K]
auroTHERM exclusive
Fig. 4.4 Efficiency of the auroTHERM exclusive according to
DIN 4757/4
Manual - Solar hot water systems
0
0
50
100
150
200
250
300
Volume flow [l/h]
Fig. 4.5 Pressure loss of the auroTHERM exclusive collector
9
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. The sensor sleeve integrated in the middle and
the symmetric interior structure means that the
collector array can be connected variably.
Fig. 4.6 View of the auroTHERM VFK 900, two modules
Technical data of the flat collector
Appliance designation
Unit.
auroTHERM VFK 900
Surface area (gross, aperture/net)
Height
Width
Depth
Weight
Absorber capacity
Copper pipe connection, flat-face
Insulation thickness
Max. operating pressure
Solar safety glass transmission τ (dew)
Absorber emission ε (epsilon)
Absorber absorption α (alpha)
Solar sensor sleeve
Qualification approval mark
Shutdown temperature (according to prEN 12975-2,
c < 1 m/s)
Efficiency η0
Efficiency coefficient k1
Efficiency coefficient k2
m2
mm
mm
mm
kg
l
Ø mm
mm
bar
%
%
%
Ø mm
2.24/2.02
1930
1160
110
43
1,1
G 1/2"
60
10
90 ± 2
5±2
95 ± 2
6
CE 0036
°C
227
%
W/(m2•K)
W/(m2•K2)
81,9
3,47
0,0101
Table 4.2 Technical data of the flat collector auroTHERM VFK 900
Solar fluid at 30˚C
140
120
Pressure loss [mbar]
3 x 900
100
80
2 x 900
60
40
1 x 900
20
Temperature difference (collector/ambient) [K] VKF 900
1000 W/m2 Insolation
800 W/m2 Insolation
300 W/m2 Insolation
Fig. 4.7 Efficiency of the auroTHERM VFK 900
acc. to DIN 4757/4
10
0
0
50
100
150
200
250
300
Volume flow [l/h]
Fig. 4.8 Pressure loss auroTHERM VFK 900
Manual - Solar hot water systems
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.
- Two fill/vent valves for filling and draining the solar
circuit (6 and 9)
- A three-speed solar pump (8)
- A flow rate meter to optimally adjust the required flow
rate (7)
- A solar expansion vessel (4) (separate accessory)
- A protection vessel (5) (separate accessory)
4.2
4.2.2 Water control pack
The solar pump unit is delivered with a water control
pack, consisting of an expansion relief valve (1) and a
pressure gauge (2) for visual inspections.
Solar pump unit
1
2
11
4.2.3 Solar expansion vessel
The solar expansion vessel (4), is used to equalise the
pressure while the pressure relief valve (1) blows off the
solar fluid into the collecting container via the pressure
release pipe (3) if the operating pressure of 6 bar is
exceeded.
9
8
10
7
6
Note!
h The
solar fluid container is of sufficient size
and intended as a collecting container. Lay a
pressure release pipe from the expansion relief
valve to the collecting container.
5
3
4
Fig. 4.9 Design of the solar pump unit
Key
1 Expansion relief valve
2 Pressure gauge
3 Pressure release pipe with collecting container
4 Solar expansion vessel
5 Protection vessel (optional)
6 Fill/vent valve (for filling and draining the solar circuit)
7 Flow rate meter
8 Three-speed solar pump
9 Fill/vent valve (for filling the solar circuit)
10 Group of pipes with insulation
11 Stop valves with gravity brakes
4.2.1 Design
The solar pump unit transports heat from the collector
to the consumer safely and efficiently.
The solar pump unit mainly consists of:
- The group of pipes of the solar pump unit with
insulation (10)
- Two stop valves with gravity brakes (11) to prevent
heat diversion. (The gravity brakes are ineffective if
the stop valves are in the 45° position.)
- The water control pack with an expansion relief valve
(1) with 6 bar blow-off pressure and a pressure gauge
(2) for visual inspection
Manual - Solar hot water systems
The size of the solar expansion vessel is based on the
collector volume and the expansion volume of the solar
system.
The expansion vessel not only accommodates the
expansion volume of the solar fluid, but also the entire
volume of the collectors in the event of a shutdown. The
total volume of the solar system is the total of the
individual values of the collector, heat exchanger volume
and the volume of the pipeline.
The admission pressure of the solar expansion vessel
can be set between 0.5 and 4.0 bar.
4.2.4 Protection vessel (item no. 302 405)
In the event of unfavourable system configurations (e. g.
very large collector surface, installation of the solar
pump unit under roof), the solar expansion vessel (4)
may be subjected to excessive temperatures by the solar
fluid if the system is shut down. In worst cases, this can
cause the membrane of the solar expansion vessel to be
overheated and to fail.
The installation of a protection vessel (5) is
recommended in all cases. The solar expansion vessel is
protected from excessive temperatures by 5 l of solar
fluid in front of it. Vaillant recommends the installation
of the protection vessel for all solar systems (item
no. 302 405).
11
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. collector surface, pipe diameter, length of the solar
circuit), so that the actual flow rate is slightly higher
than the nominal flow rate. The flow rate meter (Fig. 4.9,
pos. 7) is used for fine adjustment of the flow rate.
Observe the notes in Section 6.2, Setting the flow rate
and pump.
1
1,1 l/min
Thermal cut out of the solar pump
2
Fig. 4.11 Flow rate meter 0 - 6 l/min
3
1
3
A
B
C
D
A
B
C
D
3
The flow rate meter (pos. 7, Fig. 4.6) installed in the
return pipe is an essential component of the solar
system. To achieve optimum heat transfer, you must
achieve a certain flow rate, which is referred to as the
nominal flow rate (refer to Section 6.2, Setting the flow
rate and pump).
Upper deviations are not as serious as lower deviations.
Make the rough adjustments with the solar pump first.
You can make the fine adjustments with the adjustment
valve (1) of the flow rate meter. You can view the set
value on the display (2) of the flow rate meter.
The flow rate meter has a fill/vent valve for filling and
draining the solar circuit.
h Note
Do not under any circumstances set the flow
rate below the calculated flow rate. The
collector efficiency will be considerably reduced.
Fig. 4.10 Connection diagram of the solar pump TCO
The solar pump is secured by its own thermal cut out
(TCO) (1) which is mounted on the solar cylinder (preassembled at the factory for the VIH S GB 250 and
300 S). The power supply to the pump is interrupted at
cylinder temperatures higher than 90 °C.
4.6
Solar fluid
4.6.1 Properties of the solar fluid
This information applies to Vaillant solar fluid (20 l
canister: item no. 302 429).
Vaillant solar fluid is a ready-mixed antifreeze and
anticorrosive, consisting of approximately 45%
propylene glycol with anti-corrosion inhibitors and 55%
water. It is resistant to high temperatures and can be
used both with Vaillant tube collectors and Vaillant flat
plate collectors.
Furthermore the solar fluid has a high thermal capacity.
The inhibitors provide reliable corrosion prevention
when using different types of metal (mixed installations).
12
Manual - Solar hot water systems
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.
Proceed as follows to check the solar fluid; refer to the
operating manual of the solar fluid tester (item no.
002 002 0155):
• Suck in the amount of fluid for the float to freely float
without sticking at the top with the suction ball of the
solar fluid tester (item no. 00 2002 0645).
• View the density on the scale. The density must be
greater than 1.05 g/cm3. You must otherwise replace
the solar fluid.
• Measure the pH value with a pH value measuring strip.
You must replace the solar fluid if the pH value is
below 7.5.
Vaillant solar fluid is infinitely durable in hermetically
sealed containers.
Skin contact is normally not dangerous. Eye contact only
causes minor irritations, you should nevertheless
immediately wash your eyes.
Observe the safety data sheet (refer to Section 4.6.4).
Protection of the solar circuit against frost
and corrosion
To protect the solar system reliably against frost in
winter, the entire solar circuit must be filled 100 % with
solar fluid (item no. 302 429).
1
2
3
4
4.6.2
h Note!
You can achieve frost resistance of about
-28 °C by filling the solar system with Vaillant
solar fluid.
No damage is caused by frost even at outside
temperatures below -28 °C, since the expansive
effect of the water is reduced. Check the
antifreeze effect after filling the system and
then once a year.
Component
VIH S GB 200 S heat exchanger solar circuit
VIH S GB 250 S heat exchanger solar circuit
VIH S GB 300 S heat exchanger solar circuit
VIH S GB 200 S heat exchanger reheating circuit
VIH S GB 250 S heat exchanger reheating circuit
VIH S GB 300 S heat exchanger reheating circuit
Solar pump unit
auroTHERM exclusive VTK 550
auroTHERM exclusive VTK 275
auroTHERM VFK 900
Protection vessel
Volume (l)
4.12
4.12
4.4
3.7
3.7
3.7
0.9
3.56
1.6
1.1
5.0
6
5
Fig. 4.12 Solar fluid tester
Key
1 Transport case
2 Areometer
3 Thermometer
4 pH indicator rod
5 Standing cylinder
6 Operating manual
a Caution!
Risk of damage!
Use only the original Vaillant solar fluid tester
(item no. 00 2002 0645). Otherwise an
incorrect antifreeze value may be indicated.
4.6.3 Frost protection of the bivalent solar cylinder
You must drain the solar cylinder completely if it is to be
shut down in a room prone to frost. It is drained at the
cold water inlet with a T-piece with tap to be provided by
the installer.
• Also drain all heat exchangers which are not filled with
solar fluid.
Table 4.3 Volume of the individual components
Pipe diameter
15 mm
18 mm
22 mm
28 mm
Pipeline volume (l/m)
0.18
0.20
0.31
0.50
Table 4.4 Pipeline volume
Manual - Solar hot water systems
13
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: <NewLine/>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).
Composition/Information on components
Chemical properties
Watery solution of 1.2 propylene glycol with
corrosion inhibitors
3.
3.1
Possible risks
No particular risks known
4.
4.1
First-aid measures
General notes:
Remove dirty clothes.
After inhaling:
Discomfort after inhaling fumes/
aerosol: fresh air, help from a doctor.
After skin contact:
Wash off with water and soap.
After eye contact:
Wash thoroughly under running water with wide
open eyes for at least 15 minutes.
After swallowing:
Rinse your mouth and then drink plenty of water.
Notes for the doctor:
Treatment of symptoms (decontamination,
vital function), no specific antidote known.
6.
6.1
6.2
6.3
7.
7.1
7.2
4.2
4.3
4.4
4.5
4.6
5.
5.1
5.2
5.3
5.4
14
Firefighting measures
Appropriate extinguishing agents:
Spray, solid extinguishing agent, alcohol-fast
foam, carbon dioxide (CO2)
Particular hazards:
Fumes which are detrimental to health. Formation
of smoke/mist. The specified substances/
substance groups may be released in the event of
a fire.
Special protective equipment for fire fighting:
Wear a breathing apparatus which is independent
of the circulating air in the event of a fire.
Further details:
The hazard depends on the combustible
substances and the fire conditions. Polluted fire
water must be disposed of according to local
official regulations.
7.3
8.
8.1
8.2
8.3
Measures to be taken if substances are
released accidentally
Individual-related measures:
No particular measures required.
Environmental measures:
The product may not be discharged into waters
without pre-treatment (biological sewage plant).
Cleaning/Collection methods:
Pump out the product in the event of large
quantities.
Absorb small quantities with appropriate fluid
bonding material. Then dispose of them according
to regulations.
Rinse away splashes with plenty of water. Inform
the local water authority in the event of large
quantities which could flow into the drainage or
waters.
Handling and storage
Handling:
Good ventilation of the workplace, no other
particular measures required.
Fire and explosion protection:
No exceptional measures required.
Cool any endangered containers with water.
Storage:
Close containers tightly and store them at dry
places. Do not use any galvanised containers for
storage.
Limitation of exposure and personal protective
equipment
Personal protective gear:
Hand protection: chemical-resistant protective
gloves (EN 374). Suitable materials even in the
event of prolonged, direct contact (recommended:
protection index 6, corresponding to > 480
minutes permeation time according to EN 374):
flour elastomer (FKM) – 0.7 mm layer thickness.
Suitable materials for brief contact or splashes
(recommended: at least protection index 2,
corresponding to > 30 minutes permeation time
according to EN 374): nitrile rubber (NBR) – 0.4
mm layer thickness. Due to the large variety of
types, observe the instruction manuals of the
manufacturer.
Eye protection:
Safety glasses with lateral protection (framed
glasses) (EN 166)
General safety and hygiene measures:
Observe the usual protective measures for
dealing with chemicals.
Manual - Solar hot water systems
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. 1.030 g/cm3 (DIN 51757)
Water solubility: entirely soluble
Solubility (qualitative) solvent: polar solvents:
soluble
pH value (20 °C): 9.0 – 10.5 (ASTM D 1287)
Viscosity, kinematic (20 °C): approx. 5.0 mm2/s
(DIN 51562)
Stability and reactivity
Substances to be avoided: Strong oxidants
Dangerous reactions:
No dangerous reactions if the storage and
handling regulations/notes are observed
Dangerous decomposition products:
No dangerous decomposition products if the
storage and handling regulations/notes are
observed.
Toxicological information
Acute toxicity:
LD50/oral/rat: > 2000 mg/kg
Primary skin irritation/rabbit: not irritating.
(OECD guideline 404)
Primary irritation to the mucous membrane/
rabbit: not irritating.
(OECD guideline 405)
Additional notes:
The product has not been checked. The
statements have been taken from the individual
components.
Ecological information
Ecological toxicity:
Fish toxicity: LC50 leuciscus idus (96 h):
> 100 mg/l
Aquatic invertebrates: EC50 (48 h): > 100 mg/l
Water plants: EC50 (72 h): > 100 mg/l
Micro-organisms/effect on activated sludge:
DEV-L2 > 1000 mg/l. No disturbances to the
biodegrading activity of the activated sludge are
expected in adapted biological sewage plants if
discharged appropriately in low concentrations.
Assessment of aquamatic toxicity:
The product has not been checked. The
statements have been taken from the properties
of the individual components.
Manual - Solar hot water systems
12.3
Persistence and biodegradability/information on
elimination:
OECD 301 A test method (new version)
Analysis method: DOC acceptance
Degree of elimination > 70 % (28 d)
Assessment: easily biodegradable.
13.
13.1
Note on disposal
Disposal:
Vaillant solar fluid (item no. 302 363) must de
disposed of at an appropriate waste site or waste
incineration plant, for example, while observing
local regulations. Contact the local municipal
sanitation office or the mobile environmental
service for quantities under 100 l.
Uncleaned packings:
Uncontaminated packings can be reused. Dispose
of packings which are unable to be cleaned
together with the substance.
13.2
14.
Transport information:
VbF: not subject to the ordinance on combustible
fluids.
Mailing permitted. GGVE/RID: -, UN no.: -,
GGVS/ADR: -, IATA DGR: -, IMDG code: -, TA air: -.
No dangerous goods according to transport
regulations.
15.
15.1
Regulations
Labelling in accordance with EC directives/
national regulations:<NewLine/>No labelling
obligation
Other regulations: water hazard class (Germany,
Appendix 4 of the VwVwS (administrative
regulation on water-pollutant substances) from
17.05.1999): (1), slightly water-pollutant
15.2
16.
Other information
The safety data sheet is intended to provide
essential physical, safety-related, toxicological and
ecological data and give recommendations for
safe handling or safe storage, handling and safe
transport of chemical substances and
formulations. No liability is assumed for damage
in connection with the usage of this information
or the usage, application, adaptation or
processing of the products described here. This
does not apply as long as we, our statutory
agents or assistants are liable in the event of
intention or gross negligence. No liability is
assumed for indirect damage.
This information has been compiled to the best of
our knowledge and conscience according to our
current state of knowledge.
No guarantee can be made for product properties.
17.
Version
Compiled by Vaillant GmbH on 1/7/2003
15
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.
4.8
Solar control
Wiring
The Vaillant Control Center VR 65 can be used to wire
up the system if an eBUS-capable Vaillant boiler is used.
A standard wiring box can be used for all other boilers.
Kol 1
1
230 V~
2
6
3
5
A
4
Sp 1
B
Solar pump control
Temperature differences, not absolute temperature
values, are important for the operation of solar systems.
That is why solar systems are controlled by what is
referred to as temperature difference controllers.
Temperature sensors measure the difference between
the collector and solar cylinder.
The solar pump is switched on if the difference in
temperature (Kol 1 - Sp 2) is greater than 7 K. The solar
pump of the solar system is switched off if the difference
in temperature (Kol 1 - Sp 2) is lower than 3 K.
Furthermore the solar control constantly measures the
cylinder temperature. Reheating is switched on if the
value (Sp 1) falls below the set target value.
You can set the difference in temperature on the
controller between 2 and 15 K. The default setting of 7 K
is sufficient for most solar systems.
Do not set temperature differences too low. This would
result in a number of unnecessary and uneconomic
switch-on and switch-off procedures.
C
auroMATIC 560 controller
Sp 2
D
Solar gain
Fig. 4.13 Temperature difference control
Key
1
2
3
4
5
6
Kol 1
Sp 1
Solar control
Boiler
Solar cylinder
Thermal cut out of the solar pump
Solar pump
Solar pump unit
Collector temperature sensor
Upper stored water temperature sensor
(reheating circuit/standby part)
Sp 2 Lower stored water temperature sensor (solar circuit)
A
Boiler flow
B
Boiler return
C
Solar flow
D
Solar return
Type of solar control
The Vaillant solar system enables various system
configurations and control concepts.
16
Fig. 4.14 auroMATIC 560
The auroMATIC 560 solar control is a differential
temperature-controlled control set for solar-supported
hot water supply with a demand driven reheating
function for Vaillant boilers.
The control set is a fully-equipped system for solar
systems with a collector array and a solar cylinder.
It is possible to determine the solar gain by means of an
additional gain sensor (available as an accessory).
Manual - Solar hot water systems
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. The boiler decides whether
hot water requirements has to be met and sends the
signal to control the 230 V valves via the VR 65.
In this way, the boiler can store different target
temperatures for heating and hot water operation.
Standard 230 V components can be integrated in the
Vaillant eBUS system via the Control Center VR 65. For
wiring, refer to Section 5.8, Electrical installation, and
the installation manual of the Control Center VR 65
(item no. 00 2000 7476).
VRT 360 programmable room thermostat
The VRT 360 is a programmable room thermostat with a
week programme for heating, hot water and circulation
pump, which can be connected to Vaillant boilers with
With the VRT 360, you can preset the room temperature
with a heating programme.
The VRT 360 has additional functions including central
heating override and the time control function of an
additional circulation pump.
For wiring, refer to Section 5.8, Electrical installation,
and the operating and installation manual of the
VRT 360 (item no. 838 568).
5
Installation
• Use the following tables to check the scope of delivery
before beginning with the installation.
Installation sequence
Install the solar system in the following order:
- Solar collectors and solar pump unit
- Solar cylinder
- Solar circuit piping
- Reheating circuit piping
- Hot water piping and secondary return (if available)
- Cold water supply
- Discharge pipe
- Electrical installation
• Assemble the collectors according to the assembly
manual (item no. 835 254)
• Install the solar pump unit according to the installation
manual (item no. 00 2000 7485)
• Proceed with the installation as described in the
following sections.
h Note!
If the VRT 360 is used for central heating
control, the Control Center VR 65 is
additionally required to measure the solar
cylinder temperature and switch from cylinder
reheating to heating mode and vice versa as
required.
VRC 400 weather compensator
The VRC 400 weather compensator is an external
temperature compensator and can be used in
conjunction with a Vaillant eBus boiler to provide time
and temperature control of the central heating.
Manual - Solar hot water systems
17
5 Installation
Solar sets auroTHERM exclusive
Mini
Standard
Medium
Large
Item no.
0020025413 0020025414 0020025415 0020025416
auroTHERM exclusive 550
2
3
4
5
auroTHERM exclusive 275
1
-
-
-
Mounting bar (long) for 2 x VTK 550
1
1
2
2
Mounting bar (normal) for 1 x VTK 550
-
1
-
1
Mounting bar (short) for 1 x VTK 275
1
-
-
-
Roof bracket set for 2 x VTK 550
1
1
2
2
Roof bracket set for 1 x VTK 550 or 1 x VTK 275
1
1
-
1
Rafter plate
2
2
2
3
Connection set for collector area
1
1
1
1
Single insulated stainless steel tube, DN16, 15 m
2
2
2
2
Table 5.1 Scope of delivery of the auroTHERM exclusive solar sets
18
Manual - Solar hot water systems
Installation 5
Solar sets auroTHERM exclusive
Mini
Standard
Medium
Large
Item no.
0020025413 0020025414 0020025415 0020025416
Fittings pack for DN16 tube
1
1
1
1
Solar pump unit
1
1
1
1
Expansion vessel 25 l
1
1
-
-
Expansion vessel 35 l
-
-
1
1
Protection vessel for expansion vessel
1
1
1
1
Automatic air separator
1
1
1
1
Thermostat mixer
1
1
1
1
Solar control auroMATIC 560
1
1
1
1
Solar gain sensor (VR 10)
1
1
1
1
Solar fluid (20 litres)
2
2
3
3
Table 5.1 Scope of delivery of the auroTHERM exclusive solar
sets (continuation)
Manual - Solar hot water systems
19
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 5.2 Scope of delivery the auroTHERM flat plate collector
solar set
20
Manual - Solar hot water systems
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 5.2 Scope of delivery of the auroTHERM flat plate
collector solar set (continuation)
Manual - Solar hot water systems
21
5 Installation
auroSTOR solar cylinders
VIH S GB 200 S VIH S GB 250 S VIH S GB 300 S
Item no.
307 206
307 207
307 208
Cold water control pack with tundish
1
1
1
Motorised 2 port valve
1
1
1
DHW expansion vessel 18 l
1
-
-
DHW expansion vessel 25 l
-
1
1
Mounting bracket for expansion vessel
1
1
1
Carrier handle
1
1
1
Compression fittings
1
1
1
Drain valve
1
1
1
pre-assembled
pre-assembled
pre-assembled
A
Thermal cut out-box for solar pump (holder, cable, capillary
tube)
B
Table 5.3 Scope of delivery auroSTOR
22
Manual - Solar hot water systems
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. 5.1 auroSTOR function elements
Key
1 Hot water connection
2 Temperature and pressure relief valve (95 °C, 7 bar)
3 Expansion vessel
4 Connection for expansion vessel
5 Pressure-controlled cold water outlet
6 Connection for secondary return
7 Cold water supply
8 Pressure limiting valve (3.5 bar) with line strainer
9 Expansion relief valve (one port valve, 6.0 bar)
10 Tundish
11 Cylinder drain valve
12 Sp 2 temperature sensor immersion sleeve
13 Adjustable feet
14 Return (solar circuit)
15 Flow (solar circuit)
Manual - Solar hot water systems
16
17
18
19
Return (boiler)
Flow (boiler)
Immersion heater switch
Thermal cut out of solar pump, set to 90 °C, connected to the
solar pump in order to isolate this heat source in the event of
failure of the solar control.
20 Thermal cut out of immersion heater
21 Cylinder thermostat (20 °C - 65 °C)
22 Immersion heater
23 Thermal cut out of the cylinder thermostat, set to 90 °C,
connected to the motorised 2 port valve, in order to isolate the
primary heat source in the event of failure of the domestic hot
water thermostat.
24 Thermostat, immersion heater
23
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.A cold water supply of
appropriate pressure and flow rate is required to operate
the solar cylinder ideally (refer to Section 5.6.1, Cold
water supply pressure).
VIH S GB 250 S and VIH S GB 300 S
The thermal cut out and temperature sensor have been
pre-installed by the manufacturer.
Control of the hot water temperature
The hot water temperature in the top half of the cylinder
can be optionally regulated by the Vaillant auroMATIC
VRS 560 solar control by means of the programmable
Vaillant VRT 360 room thermostat or a timer.
The temperature settings for solar water heating and
the maximum cylinder temperature are made by means
of this solar control, e. g. auroMATIC VRS 560. The
auroSTOR must be wired properly in order to adhere to
the G3 building regulations.
1
The solar pump must be connected to the solar control
via a thermal cut out (TCO) (refer to Section 5.8,
Electrical installation). It ensures the solar pump is
switched off if the hot water temperature in the cylinder
rises above 90°C.
Fig. 5.3 NTC capillary tube guide
A VR 10 temperature sensor (1) must be used instead of
the installed thermostat if the auroMATIC VRS 560 is
used (refer to Section 5.8.2, Electrical connection to the
cylinder control device, for the removal of the
thermostat).
Immersion heater
The auroSTOR solar cylinders are equipped with an
additional immersion heater of 3 kW, including the
operating thermostat and energy cut-off device.The
immersion heater is situated behind the front plate. It is
designed for use in unvented cylinders and includes a
thermostat control and thermal cut out for over heat
protection.
Note:
In the event of a replacement, only the right
immersion heater equipped with a thermal cut
out fur overheating protection may be used.
Fig. 5.2 Attachment of the solar pump TCO
24
Secondary return
The water control pack has a connection for a secondary
return.
• Remove the 3/4“ dummy plug (BSP thread) from the
water control pack.
• Connect a WRAS-approved circulating pump, which
contains a non-return valve, to the water control pack
(see Fig. 5.1).
• Establish the connection to the secondary return.
Manual - Solar hot water systems
Installation 5
5.1.2
Technical data of the auroSTOR solar cylinder
Entry
Cylinder:
Size
Maximum water supply pressure
Operating pressure
Pressure limiting valve
Expansion relief valve
Hot water expansion vessel admission pressure
Temperature and pressure relief valve
Net weight
Weight (full)
Height
Cylinder connections:
Cold water supply
Hot water connection
Pressure-controlled cold water outlet
Secondary return
Flow (boiler/solar circuit)
Return (boiler/solar circuit)
Electrical connections:
3 kW immersion heater (according to ENBS 60335)
Length of the immersion heater
Motorised 2 port valve
Cylinder thermostat
Thermal cut out for solar pump
Heating coil:
Heat loss
Heat up time (boiler part)
Recovery (boiler part)
Unit
VIH S GB 200 S
VIH S GB 250 S
VIH S GB 300 S
l
bar
bar
bar
bar
bar
°C/bar
kg
kg
mm
200
250
300
10
3.5
3.5
6.0
4.0
95 / 7.0
39
245
1499
49
340
2109
22 mm pressure pipe
22 mm pressure pipe
22 mm pressure pipe
G 3/4
22 mm pressure pipe
22 mm pressure pipe
Inches
230/240 V, 50 Hz
430
230/240 V, 50 Hz
230/240 V, 50 Hz
230/240 V, 50 Hz
mm
kW/24 h
mins
mins
44
310
1789
1.9
21
13
2.1
26
16
2.4
30
21
Table 5.4 Technical data of the auroSTOR solar cylinder
h Note!
The heat-up time is based on a primary flow
rate of 9 l/min at 80 °C.
Temperature rise from 15 °C to 65 °C
Manual - Solar hot water systems
25
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. 5.5 auroSTOR hot water flow rates at 60 °C
Flow out (litres/min) of the system
Flow out (litres/min) of the system
Fig. 5.4 auroSTOR cylinder heat-up times (boiler part)
40
Mixed water of 40 °C, mixed from
60 % hot water of 60 °C and
40 % cold water of 10 °C
8 bar*
4 bar*
3 bar*
2 bar*
1 bar*
30
20
10
0
10
20
30
40
Flow available (litres/min) at entry to system
Fig. 5.6 auroSTOR mixed water flow rates
* Static operating pressure of the cold water supply
The displayed flow rates apply to installations in which
the cold water supply is of appropriate dynamic
pressure.
Please contact Vaillant Ltd if the static water pressure is
below 1 bar.
26
Manual - Solar hot water systems
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. The solar cylinders can be
used in combination with a downstream boiler for hot
water supply in accordance with the GB standard.
a Caution!
Risk of damage!
The appliances may only be used to heat up
potable water. Damage to the appliance due to
corrosion cannot be excluded if the water does
not correspond to the specifications of the
water ordinance.
Any other use or extended use is considered to be
improper. The manufacturer/supplier is not liable for any
resulting damage.The owner alone bears the risk.
Intended use includes the observance of the system
manual and the adherence to the inspection and
maintenance conditions.
a Caution!
Any improper use is forbidden.
Valliant solar cylinders are state-of-the-art appliances
which have been constructed in accordance with
recognised safety regulations. Nevertheless, there is still
a risk of injury or death to the user or others or of
damage to the equipment and other property in the
event of improper use or use for which they are not
intended.
5.1.4 Data badge
The data badge has been applied to the top of the solar
cylinder by the manufacturer.
5.1.5 Safety devices
The solar cylinder has been provided with all safety and
control devices for operation of the unvented domestic
hot water supply:
– Temperature and pressure relief valve (95 °C, 7 bar)
– Pressure limiting valve (3.5 bar) with line strainer
– Expansion relief valve (one port valve, 6.0 bar)
– Thermal cut out of the solar pump, set to 90 °C,
connected to the solar pump in order to isolate this
heat source in the event of failure of the solar control.
– Thermal cut out of the immersion heater
– Thermal cut out of the solar cylinder, set to 90 °C,
connected to the motorised 2 port valve, in order to
isolate the primary heat source in the event of failure
of the domestic water thermostat.
Manual - Solar hot water systems
5.1.6 Safety instructions and regulations
This product has been checked for adherence to the
building regulations for unvented hot water cylinder
systems. It may not be changed or modified in any way
whatsoever.
It should be installed by a qualified specialist, who
should observe the applicable regulations of the local
authorities, the building regulations, the building
regulations for Scotland, the building regulations for
Northern Ireland and the directives of the local water
supply companies.Building approval is required for the
installation.The local authority should be notified about
the intended installation.Only original spare parts from
Vaillant Ltd. may be used for the replacement of parts.
5.1.7 Scope of delivery
• Check the scope of delivery of the cylinder box.
- Water control pack (pressure limiting valve, expansion
relief valve; connections for: secondary return, hot
water expansion vessel)
- Motorised 2 port valve
- Tundish
- Cylinder drain valve
- System description
- Assembly set for hot water expansion vessel
- Hot water expansion vessel:
- 18 litres for VIH S GB 200 S
(max. storage volume at 3.5 bar = 255 l)
- 25 litres for VIH S GB 250 /300 S
(max. storage volume at 3.5 bar = 315 l)
- Thermal cut out for solar pump with holder
- Solar cylinder
Make sure the cylinder is stored in an upright position in
a dry environment prior to its installation.
5.1.8 Requirements of the installation site
Place the solar cylinder at an appropriate place in the
building, while observing the following:
– The discharge pipe from the tundish must be installed
at a minimum slope of 1:200 and end at a safe and
visible point (refer to Section 5.7, Installation of the
discharge pipe).
– The installation surface must be level and able to bear
the weight of the full cylinder (refer to Section 5.1.2,
Technical data of the auroSTOR solar cylinder).
– The installation site may not be prone to frost.A frost
protection thermostat must be installed if necessary.
– The controller of the installed cylinder thermostat
under the front plate must be accessible to the owner.
– There must be sufficient space to install, check and
repressurise the expansion vessel.
– Floor unevenness should not be greater than those
able to be compensated by the adjustable feet of the
solar cylinder.
27
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.
28
Manual - Solar hot water systems
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. 5.8 Dimensions of the auroSTOR solar cylinder
Key
1 Hot water connection
2 Temperature and pressure relief valve
3 Immersion heater
4 Solar circuit flow
5
6
7
8
Cold water supply connection
Solar circuit return
Return (boiler)
Boiler flow
Cylinder type
A
B
C
d
A
F
g
h
R
VIH S GB 200 S
1468
1499
454
384
314
589
1118
813
953
VIH S GB 250 S
1758
1789
454
384
314
589
1408
924
1064
VIH S GB 300 S
2078
2109
454
384
314
589
1648
1101
1241
Table 5.5 Dimensions
Manual - Solar hot water systems
29
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. 5.9 Functional diagram
Key
1 Boiler
2 auroSTOR solar cylinder
3 230 V∼ motorised 2 port valve (supplied with the solar cylinder)
4 Immersion heater
5 230 V∼ motorised 2 port valve (supplied with the boiler)
6 auroTHERM collector
7 Solar pump unit
8 Protection vessel (optional)
30
9
10
11
A
B
C
D
Solar expansion vessel
Automatic air separator system
Hot water expansion vessel
Boiler flow
Boiler return
Solar circuit flow
Solar circuit return
Manual - Solar hot water systems
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.
• The pipe diameters should not be too large, otherwise
the the flow in the solar system will slow down,
reducing the efficiency.
• Lay all system components in such a way to ensure an
even flow at the required nominal flow rate.
• Provide sufficient thermal insulation of the pipes to
prevent excessive heat loss. Select weather and UV
resistant insulation which is “bird peck proof“
especially for pipes laid outside.
• Use hard solder only.
• Do not use any plastic pipes.
• Do not use any Teflon tape in the solar circuit.
• Use press fittings only if temperatures of up to 200 °C
are allowed by the manufacturer.
5.3.3 Laying of the solar circuit pipes
The right selection of the pipe diameters plays a
significant role in terms of maximum efficiency of the
solar system.
To keep the pressure loss in the solar circuit to a
minimum, the flow velocity in the copper pipe should not
be higher than 1.5 m/s.
A nominal flow rate of 0.66 l/min per net m2 collector
surface is required by the collectors to achieve optimum
heat transfer.
Another decisive criteria for the optimum operation of
your solar system is the right layout of the solar pump.
The pump must be able to deliver more than the
nominal flow rate at the specified operating pressure.
The selection of the required pump speed depends on
the installed system.Reference value for the pump
selection can be found in Section 6.2, Setting the flow
rate and pump.
5.3.4
Connection of the collectors to the solar
pump unit
Vaillant provides various flexible hose systems for the
connection of the collectors to the solar pump unit:
309 644: Solar Flexpipe 2 in 1 DN 16 X 15 m
00 2002 3066: single flex pipe DN 16 X 15 m
a
Caution!
Earth the solar circuit!
The solar pipe work must be earthed in
accordance with the requirements of BS 7671
IEE Wiring Regulations. Wiring protection
should be provided if there is high risk of
lightning strikes. The electronics in the solar
system, heating system or in the house could
otherwise be destroyed if they were to be hit by
lightning. Connect the collectors to an existing
lightning protection on the house.
a Caution!
Risk of damage to the collectors due to
Instructions for the connection of these flexible hose
systems can be found in the corresponding installation
manual.
Fig. 5.10 Solar flex pipe
excessive pressure.
The installation of a motorised 2 port valve in
the pipes of the solar system is not allowed,
since the safety devices in the solar circuit
could be overridden by it.
5.3.2
Material
a Caution!
Risk of damage because of wrong piping
material!
Plastic pipes, such as PE pipes or similar, must
not be used because of the high temperatures
that solar fluid might reach.
• Use copper pipes preferably as solar circuit pipes.
Fig. 5.11 Installation of flex pipes at the solar pump unit
Manual - Solar hot water systems
31
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.
5.4
Installation of the reheating circuit piping
Copper pipes with a minimum diameter of 22 mm should
be used for the pipes in the reheating circuit between
the Vaillant boiler and the solar cylinder.
Larger pipe diameters may be necessary for relatively
large distances between the boiler and the cylinder.
Since all wall-mounted Vaillant boilers (except
ecoMAX pro with open ventilation) have an installed
circulating pump, it is not necessary to install them.
An appropriate pump must be installed in the reheating
circuit if the solar cylinder is used with a different boiler
in accordance with the GB standard.
1
A
´B´ Port
B
´A´ Port
Fig. 5.13 Motorised 2 port valve
To prevent the uniSTOR from overheating the 2 port
motorised valve supplied with the boiler must be fitted
to the primary flow to the indirect coil.
5.5
Installation of the hot water pipework
• Connect the hot water outlet to the 22 mm hot water
connection of the solar cylinder.
• Lay a further 22 mm pipe to the first T-piece.
A pipe of 15 mm diameter should then be sufficient.
If the pipe is very long or several outlets are supplied,
continue with another 22 mm pipe.
Fig. 5.12 Installation position of the automatic air separator
system
The system must be bled whenever it is filled or
subjected to maintenance.Bleeding is performed
constantly by means of the automatic Vaillant air
separator system as long as the solar pump is in
operation.
32
5.5.1 Hot water thermostatic mixing valve
A hot water thermostatic mixing valve ensures the hot
water from the cylinder is mixed with cold water to a
desired maximum temperature between 30 and 60° C.
• Set the thermostatic mixing valve to the desired
maximum temperature during the solar system
start-up.
This maximum temperature is maintained at the hot
water taps.
H Danger!
Risk of scalding
Set the thermostat mixer to below 60 °C and
check the temperature at a hot water tap to
ensure effective protection against scalding.
Manual - Solar hot water systems
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.The unvented solar cylinder should not be installed
if the mains water pressure is below 1 bar.You can obtain
information on alternative hot water supply systems
from Vaillant Ltd.
To keep the friction losses at a minimum, a minimum
diameter of 22 mm is recommended for the cold water
supply in the building, satisfactory performances can
also be achieved with 15 mm pipes however.
5.6.2
1
Cold water piping
3
5
4
1
2
5
6
3
Fig. 5.15 Installation of the hot water thermostatic mixing valve
(for systems without secondary return)
Key
1 Hot water pipe
2 Gravity brake
3 Cold mains water supply pipe
4 Hot water thermostatic mixing valve
5 Expansion relief valve
6 Bivalenter solar cylinder
5.6
Installation of the cold water supply pipework
5.6.1 Mains water supply pressure
The performance of unvented cylinders depends on the
available mains water pressure and the flow rate.
In order for the performance of the auroSTOR solar
cylinder to be ideal, an appropriate cold water supply
must be available, i. e. the measured static pressure
must be at least 2.0 bar. A corresponding flow rate of at
least 20 - 25 l/min should be available.
h Note!
The mains water pressure is reduced during
periods of high water consumption.Make sure
you take measurements during these periods of
time.
Manual - Solar hot water systems
A
B
2
Fig. 5.16 Water control pack
Key
A Cold water supply
B Cylinder connection
1 Secondary return connection
2 Expansion relief valve
3 Pressure limiting valve with line strainer
4 Hot water expansion vessel connection
5 Balanced pressure cold water connection
• Connect both parts of the water control pack as
illustrated in Fig. 5.16.
• When installing the valves, make sure they are aligned
in such a way that the 15 mm connection of the
expansion relief valve (Fig. 5.16, pos. 2) can be
connected to the tundish.
• Install the discharge pipe of the expansion relief valve
(Fig. 5.16, pos. 2) so that it has a constant outward
slope and ends at a safe, visible point where there is
no risk of freezing.
33
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. 5) is used,
copper pipes with a diameter of at least 22 mm should
be used for the pipe from the main stop valve of the
building to the solar cylinder.
• Install the drain valve in the cold water supply at the
lowest point between the solar cylinder and the water
control pack (see Fig. 5.9).
• Install the assembled water control pack in the cold
water supply at an appropriate place next to the solar
cylinder.Make sure there is sufficient space for
maintenance and the connection of the discharge pipe
from the expansion relief valve.
If the discharge pipes are all together, the expansion
relief valve may not be installed more than 500 mm
away from the temperature and pressure relief valve
(see 2 and 8, Fig. 5.1).
a Caution!
Risk of bursts for the solar cylinder!
No stop valve may be installed between the cold
water control pack and the cylinder.
The Vaillant solar cylinder is supplied with an external
hot water expansion vessel (DW EV).
Connect this expansion vessel to the installed water
control pack as follows:
• Screw the expansion vessel directly onto the water
control pack (Fig. 5.16, pos. 4) via the connection
intended for this purpose or
• Connect the expansion vessel to the water control
pack with a copper pipe or an appropriate hose. Make
sure the expansion vessel is supported sufficiently.
Use the supplied mounting bracket if the expansion
vessel is to be mounted on the wall.
• Establish (if necessary) the connection to the
pressure-controlled cold water connection of the water
control pack (see 5, Fig. 5.16).
34
h Note!
In areas with high water pressure (4 bar or
more), a bath or shower mixer valve can also be
connected to the pressure-controlled cold water
connection (4, Fig. 5.16) of the water control
pack to ensure the pressure of the hot and cold
water supply to the mixer valve is about the
same. The cold water supply for all other
connections should be installed in front of the
water control pack in the cold water supply to
the solar cylinder by means of a T-piece.
5.6.3 Drain valve
The drain valve supplied with the auroSTOR must be
installed as low as possible in the cold water supply
between the solar cylinder and the water control pack
(see Fig. 5.1).
We recommend applying a hose which reaches about 1 m
under the base of the cylinder to the outlet of the drain
valve.
Pipe for the outlet of the expansion relief valve
• Connect the temperature and pressure relief valve and
the expansion relief valve to the tundish with a 15 mm
pipe and lay the discharge pipe from the tundish as
described in Section 5.7.1, Discharge pipework.
5.7
Discharge pipework
5.7.1
Discharge pipework
The outlet connections of both the temperature and
pressure relief valve and expansion relief valve should
be connected in 15 mm copper tube to the tundish
supplied. The tundish should be installed vertically, as
close to the uniSTOR as possible and within 500 mm of
the temperature and pressure relief outlet. It must be
positioned away from any electrical components and
installed in the same space as the uniSTOR cylinder, so
that it is visible to the user. The D1 discharge pipe from
the T&P Valve/Expansion valve can be teed together
upstream of the tundish (see fig. 5.1).
The discharge pipework must be installed using
minimum 22 mm copper pipework from the 22 mm
connection on the tundish to a safe and visible discharge
point.
There must be a vertical section of pipe at least 300 mm
long, below the tundish before any bends or elbows in
the pipework. Increase the diameter of the pipework if
the total resistance of the discharge pipework exceeds
the figures shown in the table below. The installation of
the discharge pipework must be in accordance with G3
(refer to Section 2.2, Regulations in Great Britain).
Manual - Solar hot water systems
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.
Table 5.6 Air resistance
Examples:
22 mm discharge pipe with 4 elbows and of 7 m length
from the tundish to the discharge point:
Resistance for 4 elbows
per 0.8 m
Resistance for discharge pipe
Total resistance
=
=
=
3.2 m
7.0 m
10.2 m
The total resistance of the discharge pipe is higher
than the maximum permissible value for 22 mm
pipes (9 m). Base your calculations therefore on the
next largest pipe diameter.
28 mm discharge pipe with 4 elbows and of 7 m length
from the tundish to the discharge point:
Resistance for 4 elbows
per 1.0 m
Resistance for discharge pipe
Total resistance
=
=
=
4.0 m
7.0 m
11.0 m
The total resistance of the discharge pipe is lower
than the maximum permissible value for 28 mm
pipes (18 m),which means this pipe diameter can
be used.
safety device
(e. g. temperature
relief valve
ventil)
metal discharge pipe from
temperature relief valve to
tundish
500 mm
minimum
tundish
300 mm
minimum
metal discharge pipe
from tundish with
continuous fall
Water which is almost boiling may escape from the
discharge pipe in the event of an error.
discharge below
fixed grating
A suitable point is, for example, under a fixed grating
above the trap of a trapped gully. Low discharge pipes,
for example up to 100 mm above external surfaces, such
as parking spaces, grasslands etc., can be used, provided
they are secured by a wire fence or something similar to
prevent children from coming in contact with the waste
water, and the system is visible. No valves or taps may
be installed in the discharge pipe.
• Make sure the discharge pipe is at a constant slope of
at least 1:200 from the tundish to the discharge point.
The discharge pipe from the pressure relief valve of the
Vaillant boiler can be connected to the horizontal
discharge pipe of the solar cylinder behind the tundish
with a T-piece.
5.7.2 High level termination
Providing that the point of termination is such that
persons in or around the building will not be endangered
should discharge take place, the method of termination
shown in fig. 3.1 is satisfactory. Examples of points to
consider when deciding whether a location for the high
level of discharge is suitable are:
– The possibility, taking into account wind effect, that
someone may be in the path of the water being
discharged and if so, whether the temperature of the
discharge water will have been sufficiently reduced to
not be dangerous. Thermal conductivity of the
structure's surface, climatic conditions and location
and orientation of the discharge pipe may or may not
have an effect on reducing the temperature of the
discharge water.
– The location of windows and similar openings.
– The likelihood of a pram being left beneath the point
of discharge.
– The ability of structures surface to withstand near
boiling water.
– The possibility of ice formation if water is discharged
onto pedestrian walkways.
fixed grating
trapped gully
Fig. 5.17 Typical drainage installation
Manual - Solar hot water systems
35
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.
Commercial standard lines should be used for wiring.
- Minimum cross-section of the wires: 0.75 mm2
The following line lengths may not be exceeded:
- Bus wires: 300m
230 V connection lines and bus wires should be laid
separately if they are longer than 10 m.
The discharge pipes of the tundish, drain valves,
motorised valves etc. should be laid at a distance to
electrical components.
e
Danger!
Danger of death from electric shock!
You must earth the solar cylinder for potential
equalisation.
2
2
4
1
3
Fig. 5.19 Electrical connection of the immersion heater
Key
1 Immersion heater thermal cut out with reset button
2 Cylinder thermostat (adjustable)
3 Temperature sensors in immersion sleeves
4 Cylinder thermostat thermal cut out with reset button
5 Immersion heater thermostat (adjustable)
e Danger!
Danger of death from electric shock!
You must earth the immersion heater for
potential equalisation.
• Install a separate electrical power supply line for the
immersion heater in accordance with current IEE
regulations (BS 7671).
You must lay a heat-resistant line (3 x 2.5 mm2) from a
double pole isolating switch for the immersion heater.
The circuit must be protected by a 13 A fuse.
The connection of the immersion heater is illustrated in
detail in Fig. 5.19.
36
Manual - Solar hot water systems
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.
5.8.2
Electrical connection to the cylinder control
device
The Vaillant auroSTOR solar cylinder and an appropriate
Vaillant boiler can be controlled by various controllers
(refer to Section 4.8, Solar control). An overview of the
application options for controllers can be found in
Table 5.7 (refer to Section 5.8.3, Combination options of
the control components).
The auroSTOR solar cylinder is equipped with
appropriate thermal cut outs for the cylinder and solar
circuit and with a cylinder thermostat.
The entire inner wiring has been pre-assembled at the
factory.
The cylinder thermostat for the regulation of the hot
water temperature (1, Fig. 5.20) can be set between
20 °C and 65 °C. The installed thermal cut out is
activated at 90 °C. If the thermal cut out is triggered,
the motorised 2 port valve is actuated, which then
blocks the flow to the cylinder.
Caution!
a Risk
of damage!
Switch off the power supply before resetting the
thermal cut out or making any other changes to
the temperature setting of the cylinder
thermostat.
C°
N
Combination options of the control
components
Boiler used
eBUS-capable boiler, such as the Vaillant ecoTEC, or a
boiler which is not eBUS-capable, such as the Vaillant
turboMAX or ecoMAX, or appliances which are not
eBUS-capable from third-party manufacturers.
Wiring
Wiring via the Control Center VR 65 as system solution
which allows Vaillant low-voltage eBUS controllers to be
used in the English market with valves and hot water
cylinders of the traditional 230 V range. Alternatively via
a standard wiring box.
Solar circuit control
Control of the solar circuit by means of the temperature
difference controlled auroMATIC 560 control set for
solar supported hot water supply.
Hot water reheating control
Control of the hot water heating by means of the
temperature difference controlled auroMATIC 560
control set for solar-supported hot water supply with
demand driven reheating function for Vaillant boilers.
Alternatively by means of a timer (from a third-party
manufacturer).
Control of the heating circuits
Control of the heating circuits by means of the
programmable VRT 360 room thermostat with week
programme for heating for connection to eBUS-capable
Vaillant boilers. Alternatively by means of a device from
a third party manufacturer.
immersion
heater
L
5.8.3
cylinder
control
2
C°
1
3
2
1
An overview of the combination options of these control
components can be found in Table 5.7.
h Note!
The entire wiring must be performed in
accordance with BS 7671: Requirements for
Electrical Installations (IEE Wiring Regulations,
16th edition).
Fig. 5.20 Cylinder control device
• Actuate the reset button (2, Fig. 5.20), to reset the
thermal cut out and the motorised 2 port valve.
Manual - Solar hot water systems
An additional terminal strip is required to wire
the connections A, B, C, D for the connection of
the solar pump, solar control and solar pump
thermal cut out at the cylinder (see wiring
schemes 1 - 5).
37
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. 5.31
Device from a third-party
manufacturer
(DHW timer)
Standard wiring box
1, Fig. 5.25
4, Fig. 5.34
5, Fig. 5.37
Table 5.7 Combination options of the control components
• Select the correct wiring scheme for the installation,
depending on the boiler and control components used,
as specified in Table 5.7.
h Note!
You must set the controller of the cylinder
thermostat (1) to maximum temperature if you
use one of the wiring schemes 2 or 4.
• Fit the Control Center V 65 next to the cylinder for
easy electrical connection.
To wiring box
1
2
3
L
- Overview removal of the cylinder thermostat (see
Fig. 5.22)
- Installation of two VR 10 temperature sensors in the
solar cylinder (see Fig. 5.23)
- Attachment of the solar gain sensor to the solar
circuit return (see Fig. 5.23)
- Connection of the solar pump to the solar control via
its own thermal cut out (see Fig. 5.24)
7
10
Before the VR 10 temperature sensor can be installed,
the cylinder thermostat, the thermal cut out (TCO) and
the capillary tubes of the cylinder thermostat and thermal cut out must first be removed.
3
N
2
1
3
2
1
1
1
Fig. 5.21 Electrical connection of the cylinder thermostat
Wiring of the control components
Wiring scheme 1
- eBUS-capable Vaillant boiler
- Wiring via VR 65
- Solar circuit control via VRS 560
- Solar circuit reheating control via VRS 560
- Heating circuit control via VRT 360 or VRC 400
38
2
3
Fig. 5.22 Removal of the cylinder thermostat
Key
1 Cylinder thermostat
2 Lock
3 Capillary tube
Manual - Solar hot water systems
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.
The electrical connection of the VR 65 is described in
the VR 65 installation manual (item no. 00 2000 7476),
the connection of the VRT 360 in the operating and
installation manual of the VRT 360 (item no. 838 568).
3
2
1
1
3
1
3
2
A
B
C
D
A
B
C
D
3
3
Fig. 5.24 Connection diagram of the solar pump TCO
Fig. 5.23 Installation of the VR 10 temperature sensor
• Push one of the VR 10 temperature sensors (1)
supplied with the solar control in the now vacant
immersion sleeve, as illustrated in Fig. 5.23.
• Connect this temperature sensor to terminal “SP 1” in
the auroMATIC 560 solar control.
• Push a further VR 10 temperature sensor (3) in the
immersion sleeve for the bottom cylinder area.
• Connect this temperature sensor to terminal “SP 2” in
the auroMATIC 560 solar control.
• Attach the temperature sensor for the gain (2) to the
return pipe of the solar circuit nearby the solar
cylinder.
• Connect this temperature sensor to the terminal
“Ertrag” in the auroMATIC 560 solar control.
• Make sure the temperature sensors of the immersion
heater, solar cylinder and solar control fit properly in
the immersion sleeves.
• Connect the collector temperature sensor to terminal
“Kol 1” in the auroMATIC 560 solar control.
• Establish the connection between the terminal “EP” in
the auroMATIC 560 solar control and the terminal
“Cyl.” in the Control Center VR 65.
Manual - Solar hot water systems
• Connect the solar pump, the thermal cut out intended
for this purpose and terminal “Kol 1-P” of the solar
control to each other by means of an additionally
protected terminal strip.
• Establish the connections to the mains supply.
h Note!
Programme the hot water channel of the VRT
360 or VRC 400 to constant. Programme the
auroMATIC 560 solar control to provide hot
water when required by the customer.
h Note!
The auroMATIC 560 control will only signal to
the boiler if the cylinder is below target temperature, if solar system is not operating and if
the programmer is on.
39
40
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. terminal strip
additional terminal strip
A
B
C
D
Kol 2-P/ZP
E
N
L
L
LEG/BYP
N
VR 65 Control Center
DHW
on
off
on
do not use
Boiler terminal strip (Vaillant Ebus boiler)
24V
230 V~
8
9
L
N
E
3
Earth Blue Brown
Central Heating
2 Port Valve
E
A
B
C
additional terminal strip
E
Kol 1-P
N
2
EP
VRS 560
1
1
-
Bus + Bus Bus
Blue Brown Grey Orange
Hot Water 2 Port Valve
VR 65
DHW
N
N
230 V~
230 V~
N
L
L
L
+
BUS
E
4
BUS
-
LP/UV 1
N
BUS
L
BUS + BUS -
+
5
NTC
1 2
C1 C2
1 2
Bus + Bus Bus
VRT 360
BUS
+
-
Coll.
NTC
Kol 1
1 2
SP 2
1 2
SP 1
SP 2
auroSTOR
SP 1
1 2
SP 3
1 2
gain
sensor
Ertrag Kol 2
1 2
1 2
Wiring scheme 1
E
N
E
230 V~
E
N
230 V~
230 V~
N
E
3 amp fused supply
230 V~
E
N
L
5 Installation
- eBUS-capable Vaillant boiler
- Wiring via VR 65
- Solar circuit control via VRS 560
- Solar circuit reheating control via VRS 560
- Heating circuit control via VRT 360
Fig. 5.25 Wiring scheme 1
Manual - Solar hot water systems
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. 5.26)
- Connection of the solar pump to the solar control via
its own thermal cut out (see Fig. 5.27)
• Connect this temperature sensor to the terminal
“Ertrag” in the auroMATIC 560 solar control.
• Make sure the temperature sensors of the immersion
heater, solar cylinder and solar control fit properly in
the immersion sleeves.
h Note!
Set the controller of the cylinder thermostat to
maximum temperature (1, Fig. 5.20).
• Set the maximum temperature (MAXT 1) of the
auroMATIC 560 solar control to 70 ºC
(see auroMATIC 560 manual).
• Connect the collector temperature sensor to terminal
“Kol 1” in the auroMATIC 560 solar control.
cylinder
control
C°
• Fit a wiring box near to the cylinder for easy electrical
connection.
3
2
1
3
1
1
3
A
B
C
D
A
B
C
D
3
2
Fig. 5.27 Connection diagram of the solar pump TCO
3
Fig. 5.26 Installation of the VR 10 temperature sensor
• Push one of the VR 10 temperature sensors (1)
supplied with the solar control in an immersion sleeve
where there is still room, as illustrated in Fig. 5.26.
• Connect this temperature sensor to terminal “SP 1” in
the auroMATIC 560 solar control.
• Push a VR 10 temperature sensor (3) in the immersion
sleeve for the bottom cylinder area.
• Connect this temperature sensor to terminal “SP 2” in
the auroMATIC 560 solar control.
• Attach the temperature sensor for the gain (2) to the
return pipe of the solar circuit nearby the solar
cylinder.
Manual - Solar hot water systems
• Connect the solar pump, the thermal cut out intended
for this purpose and terminal “Kol 1-P” of the solar
control to each other by means of an additionally
protected terminal strip.
• Establish the connections to the mains supply.
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.
41
42
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. thermostat
boiler reheat
TCO collector pump
to max. temperature.
auroSTOR cylinder
black
10
LEG/BYP
N
additional terminal strip
C
A
D
Kol 2-P / ZP
E
N
L
7
3
10-way wiring box
4
5
6
N
L
A
B
C
additional terminal strip
230 V~
to 10-way wiring box.
NOT separate fused
spur
E
3
E
3
N
230 V~
N
E
L
L
any Vaillant boiler
230 V~
*
N
C1 C2
1 2
Coll.
NTC
Kol 1
1 2
SP 2
1 2
SP 1
SP 2
auroSTOR
SP 1
1 2
6
9
5
for other room thermostats see manual
L
Room thermostat
Vaillant VRT 30
SP 3
1 2
gain
sensor
Ertrag
1 2
Kol 2
1 2
Wiring scheme 2
E
L
N
E
L
N
230 V~
E
L
N
E
3 amp fused supply
230 V~
5 Installation
- eBUS-capable or eBUS-incapable 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
Fig. 5.28 Wiring scheme 2
Manual - Solar hot water systems
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.
• Connect this temperature sensor to the terminal
“Ertrag” in the auroMATIC 560 solar control.
• Make sure the temperature sensors of the immersion
heater, solar cylinder and solar control fit properly in
the immersion sleeves.
- Overview connection of the cylinder thermostat to the
wiring box
- Installation of two VR 10 temperature sensors in the
solar cylinder (see Fig. 5.29)
- Attachment of the solar gain sensor to the solar
circuit return (see Fig. 5.29)
- Connection of the solar pump to the solar control via
its own thermal cut out (see Fig. 5.30)
h Note!
Set the controller of the cylinder thermostat to
the target temperature (1, Fig. 5.20).
• Set the maximum temperature (MAXT 1) of the
auroMATIC 560 solar control to 70 ºC
(see auroMATIC 560 manual).
• Connect the collector temperature sensor to terminal
“Kol 1” in the auroMATIC 560 solar control.
cylinder
control
C°
• Fit a wiring box near to the cylinder for easy electrical
connection.
3
2
1
a wiring box next to the cylinder in order to establish
the electrical
connections.
1
3
1
3
2
A
B
C
D
A
B
C
D
3
Fig. 5.30 Connection diagram of the solar pump TCO
3
Fig. 5.29 Installation of the VR 10 temperature sensor
• Push one of the VR 10 temperature sensors (1)
supplied with the solar control in an immersion sleeve
where there is still room, as illustrated in Fig. 5.29.
• Connect this temperature sensor to terminal “SP 1” in
the auroMATIC 560 solar control.
• Push a VR 10 temperature sensor (3) in the immersion
sleeve for the bottom cylinder area.
• Connect this temperature sensor to terminal “SP 2” in
the auroMATIC 560 solar control.
Manual - Solar hot water systems
• Connect the solar pump, the thermal cut out intended
for this purpose and terminal “Kol 1-P” of the solar
control to each other by means of an additionally
protected terminal strip.
• Wire up the Vaillant boiler, the programmer and the
room thermostat.
• Establish the connections to the mains supply.
43
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. 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.
44
Manual - Solar hot water systems
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 cyl. thermostat
auroSTOR cylinder
7
LEG/BYP
N
additional terminal strip
C
A
D
Kol 2-P / ZP
E
N
L
7
3
10-way wiring box
4
5
6
N
L
A
B
C
additional terminal strip
230 V~
to 10-way wiring box.
NOT separate fused
spur
E
3
E
3
N
230 V~
N
E
L
L
any Vaillant boiler
230 V~
L
*
N
C1 C2
1 2
SP 1
1 2
SP 1
SP 2
auroSTOR
Kol 1
1 2
Coll.
NTC
SP 2
1 2
6
9
5
for other room thermostats see manual
L
Room thermostat
Vaillant VRT 30
SP 3
1 2
gain
sensor
Ertrag
1 2
Kol 2
1 2
Wiring scheme 3
E
L
N
E
L
N
230 V~
E
L
N
E
3 amp fused supply
230 V~
Installation 5
- eBUS-capable or eBUS-incapable Vaillant boiler
- Wiring via standard wiring box
- Solar circuit control via VRS 560
- Solar cylinder reheating control via a device
from a third-party manufacturer (DHW timer)
- Heating circuit control via programmer
Fig. 5.31 Wiring scheme 3
45
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. 5.32)
- Connection of the solar pump to the solar control via
its own thermal cut out (see Fig. 5.33)
• Connect this temperature sensor to the terminal
“Ertrag” in the auroMATIC 560 solar control.
• Make sure the temperature sensors of the immersion
heater, solar cylinder and solar control fit properly in
the immersion sleeves.
h Note!
Set the controller of the cylinder thermostat to
maximum temperature (1, Fig. 5.20).
• Set the maximum temperature (MAXT 1) of the
auroMATIC 560 solar control to 70 ºC
(see auroMATIC 560 manual).
• Connect the collector temperature sensor to terminal
“Kol 1” in the auroMATIC 560 solar control.
cylinder
control
C°
• Fit a wiring box near to the cylinder for easy electrical
connection.
3
2
1
• Attach a wiring box next to the cylinder in order to
establish the electrical connections.
3
1
1
3
A
B
C
D
A
B
C
D
3
2
Fig. 5.33 Connection diagram of the solar pump TCO
3
Fig. 5.32 Installation of the VR 10 temperature sensor
• Push one of the VR 10 temperature sensors (1)
supplied with the solar control in an immersion sleeve
where there is still room, as illustrated in Fig. 5.32.
• Connect this temperature sensor to terminal “SP 1” in
the auroMATIC 560 solar control.
• Push a VR 10 temperature sensor (3) in the immersion
sleeve for the bottom cylinder area.
• Connect this temperature sensor to terminal “SP 2” in
the auroMATIC 560 solar control.
• Attach the temperature sensor for the gain (2) to the
return pipe of the solar circuit nearby the solar
cylinder.
46
• Connect the solar pump, the thermal cut out intended
for this purpose and terminal “Kol 1-P” of the solar
control to each other by means of an additionally
protected terminal strip.
• Wire up the boiler of the third-party manufacturer, the
programmer and the room thermostat.
• Establish the connections to the mains supply.
h Note!
Programme the auroMATIC 560 solar control to
provide hot water when required by the
customer.
h Note!
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.
Manual - Solar hot water systems
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.
NTC
SP 2
1 2
SP 1
1 2
Kol 1
1 2
6
9
N
for other room thermostats see manual
L
Room thermostat
Vaillant VRT 30
Note!
black
E
black
1
2
3
TCO collector pump TCO and cyl. thermostat Set temp. of cyl. thermostat
to max. temperature.
auroSTOR cylinder
7
LEG/BYP
N
10
N
230 V~
Central Heating Programmer
230 V~
hot central
water heating
L
N
E
additional terminal strip
C
A
D
Kol 2-P / ZP
E
N
L
7
SL
10-way wiring box
4
5
6
N
L
A
B
C
230 V~
additional terminal strip
to 10-way wiring box.
NOT separate fused
spur
E
3
E
4
N
N
E
3
PL
Boiler Terminal Strip
230 V~
SP 3
1 2
gain
sensor
Ertrag
1 2
Kol 2
1 2
Wiring scheme 4
E
L
N
E
L
N
230 V~
E
L
N
E
3 amp fused supply
230 V~
Installation 5
- eBUS-incapable boiler, 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 programmer
Fig. 5.34 Wiring scheme 4
47
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.
• Connect this temperature sensor to the terminal
“Ertrag” in the auroMATIC 560 solar control.
• Make sure the temperature sensors of the immersion
heater, solar cylinder and solar control fit properly in
the immersion sleeves.
- Overview of the connection of the cylinder thermostat
to the wiring box.
- Installation of two VR 10 temperature sensors in the
solar cylinder (see Fig. 5.35)
- Attachment of the solar gain sensor to the solar
circuit return (see Fig. 5.35)
- Connection of the solar pump to the solar control via
its own thermal cut out (see Fig. 5.36)
h Note!
Set the controller of the cylinder thermostat to
target temperature (1, Fig. 5.20).
• Set the maximum temperature (MAXT 1) of the
auroMATIC 560 solar control to 70 ºC
(see auroMATIC 560 manual).
• Connect the collector temperature sensor to terminal
“Kol 1” in the auroMATIC 560 solar control.
cylinder
control
C°
• Fit a wiring box near to the cylinder for easy electrical
connection.
3
2
1
1
3
1
3
2
A
B
C
D
A
B
C
D
3
Fig. 5.36 Connection diagram of the solar pump TCO
3
Fig. 5.35 Installation of the VR 10 temperature sensor
• Push one of the VR 10 temperature sensors (1)
supplied with the solar control in an immersion sleeve
where there is still room, as illustrated in Fig. 5.36.
• Connect this temperature sensor to terminal “SP 1” in
the auroMATIC 560 solar control.
• Push a VR 10 temperature sensor (3) in the immersion
sleeve for the bottom cylinder area.
• Connect this temperature sensor to terminal “SP 2” in
the auroMATIC 560 solar control.
48
• Connect the solar pump, the thermal cut out intended
for this purpose and terminal “Kol 1-P” of the solar
control to each other by means of an additionally
protected terminal strip.
• Wire up the boiler of the third-party manufacturer, the
programmer and the room thermostat.
• Establish the connections to the mains supply.
Manual - Solar hot water systems
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.
Manual - Solar hot water systems
49
50
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. thermostat
auroSTOR cylinder
7
LEG/BYP
N
10
N
230
Central Heating Programmer
230 V~
hot
central
water heating
L
N
E
additional terminal strip
C
A
D
Kol 2-P / ZP
E
N
L
7
SL
10-way wiring box
4
5
6
N
L
A
B
C
230 V~
additional terminal strip
to 10-way wiring box.
NOT separate fused
spur
E
3
E
4
N
N
E
3
PL
Boiler Terminal Strip
230V~
E
*
N
LP/UV 1
N
L
C1 C2
1 2
SP 1
SP 2
auroSTOR
Coll.
NTC
SP 2
1 2
SP 1
1 2
Kol 1
1 2
6
9
N
for other room thermostats see manual
L
Room thermostat
Vaillant VRT 30
SP 3
1 2
gain
sensor
Ertrag
1 2
Kol 2
1 2
Wiring scheme 5
E
L
N
E
L
N
230 V~
E
L
N
E
3 amp fused supply
230 V~
5 Installation
- eBUS-incapable boiler, third-party manufacturer
- Wiring via standard wiring box
- Solar circuit control via VRS 560
- Solar cylinder reheating control via a device
from a third-party manufacturer (DHW timer)
- Heating circuit control via programmer
Fig. 5.37 Wiring scheme 5
Manual - Solar hot water systems
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.
Room thermostat
5
ACL Drayton Digistat 2, 3, 4
ACL Drayton RTS 1, 2
N
Danfoss Randall RX-1
9
6
3
1
3
L
3
2
L
N
C
B
E
Danfoss Randall RMT 230
4
2
1
Danfoss Randall RET 230
N
3
L
Tower SS
4
2
2
3
1
1
E
Honeywell T6360
Horstmann HRT 1
4
2
1
E
1
3
E
4
2
1
Siemens-Landys & Staefa RAD 1
Sunvic TLX 2000 series
E
Fig. 5.38 Connection of room thermostats from third-party
manufacturers if the external wiring box is used
6
Start-up
You must adhere to the following procedure for the
start-up of the total system:
• Flush and fill the solar circuit with solar fluid (refer to
Section 6.1).
• Set the flow rate and pump (refer to Section 6.2).
• Set the flow rate on the controller
(refer to Section 6.3).
• Fill the hot water secondary circuit
(refer to Section 6.4).
• Set the hot water thermostatic mixing valve (refer to
Section 6.5.)
• Fill the reheating circuit (refer to Section 6.6).
Use only Vaillant solar fluid (item no. 302 429) for
pressure tests and for flushing and filling the solar
circuit.
6.1
Flushing and filling the solar circuit
Vaillant recommends using the Vaillant filling pump to
flush and fill the solar circuit. Observe the operating
manual when using the Vaillant filling pump. It is not
permitted to use manual pumps for filling.
Expansion vessel admission pressure
During the start-up, the gas side admission pressure pv
of the expansion vessel must be adjusted to the
equipment height whilst disconnected. The static
pressure pstat corresponds, to a certain extent, to the
static height h between the collector array and the
expansion vessel.
10 m static height correspond to approx. 1 bar.
pv = pstat = h x 0.1
h Note!
A deviation from the optimum admission or
filling pressure always results in a reduction of
the expansion vessel's effective volume. This
can cause operational malfunctions.
Manual - Solar hot water systems
51
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
6.2
Setting the flow rate and pump
1
0,5
3
1
0,5
3
12
2
5
13
2
1
14
L/min
8
6
5
4
15
3
4
5
6
L/min
20
1
21
11
1,1 l/min
9
19
10
2
Fig. 6.2 Setting the flow rate
Fig. 6.1 Start-up of the total system
Flushing and filling the solar circuit and subjecting it to
a hydraulic pressure test
Flushing is performed from the solar pump unit to the
cylinder via the collector. This is how to do it:
• Open the fill/vent valve (1) and connect the filling
pump to the fill/vent valve (1).
• Place the three-way ball valve (15) into flush position.
• Connect the drain hose of the Vaillant filling pump or a
similar hose with filter (9) to the fill/drain valve (12).
Put the other end into the solar fluid container (10).
• Pump in solar fluid from the container by the filling
pump (19) via the fill/drain valve (1), so that the solar
fluid from fill/drain valve (12) is filtered and flows back
into the container.
• To flush and filter the solar circuit, pump circularly for
10 minutes. Monitor the filter and clean it if necessary.
A self-priming pump with a pressure of 2 to 3 bar is
required to fill the solar circuit. This is how to do it (see
Fig. 6.1):
• After flushing close the fill/drain valve (12) and pump
in solar fluid once a pressure of 1.7 bar is achieved.
• Close the fill/vent valve (1) too and place the threeway ball valve (15) into circulation position.
52
The 3-speed circulating pump can be fine-tuned to
adjust the flow rate to the collector's performance.
h Note!
We recommend a value of 0.66 l/min per m
2
collector surface area.
This is how to do it:
• Use Table 6.1 to calculate the flow rate to be set by
multiplying the installed collector surface area with
the value of 0.66 l/m2 • min.
• Set the pump speed to roughly set the flow rate.
• Use an Allen key to finely adjust the flow rate at the
adjustment valve (see Fig. 6.2 Pos. 1).
The adjusted flow rate can be viewed on the display (2).
Table 6.1 and 6.2 provide reference values for possible
pump speeds depending on the collector connection and
pipe length and cross-section.
If you use auroMATIC 560 solar control, the flow rate
can be used to calculate the gain. To make an accurate
calculation, the flow rate must be entered on the
controller. You can find further information in the
operating and installation manual of the control.
Manual - Solar hot water systems
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 6.1 Layout of the pipe cross-section and pump speed
depending on the collector connection for tube
collectors
Flat collectors VFK 900
Number
Flow rate
in series
l/min
Minimum cross-section of the copper pipe in
the solar circuit at a total pipe length of:
l/h
20 m
50 m
1
1
1.33
80
15
15
2
2
2.66
160
15
15
3
3
4.00
240
15
15
4
4
5.33
320
15
18
Pump speed:
Minimum (speed 1)
Maximum (speed 3)
Table 6.2 Layout of the pipe cross-section and pump speed
depending on the collector connection for flat
collectors
The pump speed is used to achieve a particular flow rate
in the collector array. The final flow rate should not be
significantly above or below the calculated value. An up
to 10 % lower solar gain or unnecessarily high power
consumption of the pump can otherwise be the
consequence.
6.3
Programming the flow rate on the controller
When programming the flow rate on the solar control,
refer to Section 6.1, Setting system parameters, of the
auroMATIC 560 operating and installation manual.
6.4
Make the pump setting as follows:
Let the pump run first at the lowest speed (minimum
power consumption).
Check whether the calculated value is achieved on the
flow rate meter.
Example:
The installed (net) collector surface area for 3 VTK550
is 2.64 m2. Multiplied with the value for the specific flow
rate of 0.66 l/m2 • min, it results in a calculated flow rate
of 1.6 l/min, which should be indicated by the flow rate
meter (see Fig. 6.2).
For the design and function of the flow rate meter, refer
to Section 4.5, Flow rate meter.
Select the next pump speed if the calculated flow rate is
not achieved on the flow rate meter. Switch to a lower
speed if it is exceeded. If the flow rate is unable to be
achieved even at the highest pump speed, check
whether it is possible to switch fewer collectors in series
and resort to a combination of series and parallel
connections.
Filling the hot water secondary circuit
a Caution!
Risk of damage!
Do not manually open the temperature/pressure
relief valve or the expansion vessel for venting
purposes. Any foreign matter in the pipework
may cause damage to the valve seats.
• Make sure the cylinder drain valve (11, Fig. 5.1) is
closed.
• Open all cold and hot water taps and the
corresponding outlets.
• Open the mains water supply to the auroSTOR and fill
it with water until it flows freely out of the outlets.
Make sure all air bubbles have been removed.
• Close the outlets and check the system for leaks.
Check in particular the immersion heater connection
for leaks.
The system must now be flushed thoroughly.
• Open the hot water taps at the opposite ends of the
systems and let the water flow out for at least 5
minutes.
• Close the hot water taps.
Also check other ways of reducing the pressure loss.
Observe here the Vaillant solar planning information.
Manual - Solar hot water systems
53
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.
• Set the hot water thermostatic mixing valve with the
adjusting knob to maintain your desired temperature
at the hot water taps.
H Danger!
Risk of being scalded by hot water!
Set the thermostat mixer to below 60 °C and
check the temperature at a hot water tap to
ensure effective protection against scalding.
6.6
Filling the reheating circuit
h Note!
Do not use the pressure relief valve of the
boiler for bleeding.
1
A
´B´ Anschluss
B
´A´ Anschluss
Fig. 6.3 Motorised 2 port valve
• Flush the entire primary central heating system with
cold and hot water. Fill and bleed the central heating
system according to the installation manual of the
boiler.
• Set the lever (1) on the motorised 2 port valve to
MANUAL and lock it in this position.
• Fill and bleed the central heating system after draining
it completely.
• Unlock the lever on the motorised 2 port valve by
setting it back to AUTO.
54
Fig. 6.4 Setting thermostats
• Set the knob of the hot water thermostat of the solar
cylinder (2, Fig. 6.4) and immersion heater (1, Fig. 6.4)
to the middle position (about 45 °C) for start-up and
to achieve maximum energy efficiency.
• Start up the boiler (refer to Section 6.7) until the solar
cylinder is at operating temperature and all radiators
in the system are warm. Then drain the entire central
heating system again to remove any residue from the
pipes. Fill and bleed it again afterwards as described
above.
6.7
Starting up the boiler
• Switch on the main switch of the boiler.
• Make sure the control device and the thermostats are
set in such a way that heating is necessary.
• Check whether the boiler starts up and the water in
the solar cylinder and radiators is heated up according
to the hot water and room thermostat settings.
• Perform the commissioning and testing procedures in
accordance with the installation manual for the boiler.
• After finished the starting-up set the hot water
temperature at the controller (e. g. solar control
auroMATIC 560) to 45 °C. This will achieve maximum
energy efficiency of the solar system.
If the hot water temperature is controlled via the
build-in cylinder thermostat, set the according knob
(2, Fig. 6.4) to 45 °C.
Set the thermostat of the immersion heater
(1, Fig. 6.4) to the desired temperature.
Manual - Solar hot water systems
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.
• Draw special attention to the safety instructions,
which the owner must follow.
• Instruct the owner on how to operate the boiler, solar
cylinder and control devices safely.
• Show the owner how to operate the solar control, hot
water control and heating control. Tell the owner that
the cylinder temperature should be limited to 45 °C to
achieve maximum solar gain.
a InNote!
areas with hard water the set hot water
temperature should not exceed 45 °C to avoid
calcification.
• Go through the operating manuals with the owner and
answer any questions.
• Point out the required safety precautions to the owner
to prevent damage to the system and building in the
event of frost if the system is not kept in operation.
• Also tell the owner that the immersion heater is
intended as standby device for water heating and
should not be used simultaneously with the boiler to
heat up the water in the solar cylinder.
• Tell the owner that the settings you have made on the
solar system are not allowed to be changed.
• Inform the owner that the boiler and solar cylinder
have to be subjected to maintenance by a qualified
specialist at least once a year.Recommend making a
maintenance agreement with a qualified servicing
company to ensure the boiler and solar cylinder are
subjected to regular maintenance.
Further information can be obtained from Vaillant
service
(+49 (0)870 - 6060777).
Manual - Solar hot water systems
55
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.
The operational reliability of the solar system may be
impaired, resulting in damge to property or personal
injury, if the inspections and maintenance work are not
carried out.
The main maintenance work on the solar system and the
corresponding maintenance intervals are specified in the
following table.
Maintenance
Maintenance interval
Solar circuit
Check the frost protection of the solar fluid (use the Vaillant 302 064 solar fluid tester)
Check the system pressure
Check the pH value of the solar fluid (with litmus paper, pH > 7.5)
Check the solar pump function
Bleed the system
Check the circulating volume in the solar circuit
Check the hot water thermostat mixer function
Refill with solar fluid if necessary
Check the quantity of blow-off liquid
Release the return flow preventer
Check the charge pressure of the expansion vessel
Collector
Visual inspection of the collector, collector fastenings and connections
Check whether the brackets and collector components are clean and fitted properly
Check the pipe insulation for damage
Solar control
Check the pump function (on/off, automatic)
Check the sensor temperature display
Secondary return/reheating
Check the circulation pump
Check the timer/time programme settings
Reheating: does it deliver the desired deactivation temperature?
Solar cylinder
Bleed the heat exchanger if necessary
Check the connections for leaks
Check the temperature and pressure relief valve
Checking the expansion relief valve
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Table 7.1 Maintenance checklist
Checking the temperature and pressure relief valve
and expansion relief valve
• Actuate each valve manually by turning the valve cap
and check whether the water flows unhindered to the
discharge point via the tundish. Make sure both valves
fit properly in idle position.
Checking the charge pressure of the expansion vessel
• Block the water supply and open the nearest hot water
tap to reduce the pressure from the secondary water
system.
• Check the pressure of the expansion vessel at the
measurement point with a pressure gauge. If the
pressure is below 3.0 bar, increase it with an
appropriate air pressure pump.
• Perform the maintenance part of the start-up protocol.
h Note!
Only use original spare parts from Vaillant Ltd.
for the replacement of parts.
56
Manual - Solar hot water systems
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.
Consult an approved qualified servicing company in the event of malfunctions.
h Note!
Only use original spare parts from Vaillant Ltd.
for the replacement of parts.
We recommend making a maintenance agreement.
Malfunction
Cause
Remedy
Solar pump
Pump is not running although the
collectoris warmer than the cylinder
(neither motor noises can be heard nor
vibrations felt).
1. No current available.
2.Temperature difference set too high or
controller is not switching.
Check the power cables and fuses.
• Check the controller.
• Check the temperature sensor.
• Reduce the temperature difference.
3. Maximum temperature reached.
4. Pump shaft jammed by deposits in the
bearings.
5. Pump dirty.
Pump is running, but no solar fluid is
coming from the collector (pump gets
hot).
Forward- and return flow temperatures
are the same or the storage tank
temperature not increasing at all or only
slowly.
6. Pump defective.
7. Flow rate set incorrectly
Air is in the pipework.
Switch temporarily to max. speed or unblock the
rotor, insert a screwdriver in the notch and turn
it by hand.
Dismantle the pump and clean it. Close the flow
rate meter and pump ball valve.
Replace the pump.
Check the setting and adjust it if necessary.
Check the system pressure. Operate the pump
intermittently at maximum power. Open the
bleeder at the pump and at the cylinder and
bleed. Bleed the back flow prohibition.
If there is no improvement, check whether there
is a “u pocket” anywhere in the piping (e. g. at
beam projections or at the bend of water pipes).
Change the pipework or install additional air
vents. If the system has already been started up
and is refilled again, check the automatic air
vent: Unscrew the protective cap and check the
floater for mobility with a blunt needle. If the
floater is jammed, replace the air vent.
Reduce the temperature difference.
Pump goes on too late and stops running 1. The temperature difference between the
early.
collector and cylinder has been set too high.
2. Collector connection pieces not insulated Insulate the collector connection pieces.
(tube collector).
Table 8.1 Troubleshooting
Manual - Solar hot water systems
57
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. Air in the pump
Bleed the pump.
2. Insufficient system pressure.
Increase the system pressure.
Clocking of the system.
Incorrect position of the collector sensor
Position the collector sensor in the flow.
Insulate the collector sensor.
The pressure gauge indicates a drop in
pressure.
A drop in pressure is normal shortly after
filling the system, since air still escapes from
the system.If a pressure drop occurs again
later on, the cause may be an air bubble,
which has been subsequently released.
Furthermore there are fluctuations to the
pressure in normal operation mode between
0.2 to 0.3 bar, depending on the system
temperature. If the pressure drops
continuously, there is a leak in the solar
circuit, in particular in the collector array.
Pressure in the main cold water supply too
low.
Line strainer in the pressure limiting valve
dirty.
Pressure limiting valve defective.
Blockage in the system.
First check all screw connections, stuffing
boxes at gate valves and threaded
connections, then the soldering points.
Check the collector array and replace a tube
or the collector if necessary.
Solar system
The water pressure and amount of
discharged water decreases at hot water
taps.
Inform the owner and notify the water
supply company.
Clean the line strainer in the pressure
limiting valve and replace it if necessary.
Replace the pressure limiting valve.
Unblock the blockage and replace any
blocked parts.
Check the system for water leaks at the
expansion relief valve and temperature/
pressure limiting valve.
The system is making noises. Normal in the
first few days after filling the system.
If it occurs later, there are two possible
causes:
1. The system pressure is too low. The pump
is drawing air via the bleeder.
Increase the system pressure.
2. Pump power set too high.
Switch to a lower speed.
The solar gain is unusually low.
The pipe insulation is too thin or incorrect.
The system may have been designed
incorrectly.
Check the insulation. Check the layout of the
system (collector size, shading, pipe lengths)
and modify the system if necessary.
Solar control
auroMATIC 560: display example “KOL 1 Err“ Defective sensor (short circuit or
or similar
interruption).
1. Check the cable connection.
2. Measure the resistance values of the
disconnected sensor at known
temperatures, and compare these with the
manufacturer's specifications.
3. Inspection of the piping for damage.
Solar cylinder
The cylinder cools down at night.
1. The gravity brake is blocked.
The flow and return temperatures vary after
switching off the pump. The collector
temperature is higher than the air
temperature at night.
2. One-pipe circulation in the event of short
pipe networks with low pressure loss.
1. Check the position of the blue handle.
2. Check the gravity brake for tightness
(jammed cuttings, particles of dirt in the
sealing face).
3. Do not connect the solar heat exchanger
directly, rather pull the supply pipes
downwards and then upwards to the
collector (syphon supports the gravity
brake) or install a 2-port valve, which is
switched on at the same time as the pump.
Install a gravity brake (as close as possible
to the cylinder).
Table 8.1 Troubleshooting (continuation)
58
Manual - Solar hot water systems
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.
External control device faulty.
Air in the reheating heat exchanger
Water flows out of the expansion relief
valve (only when heating up).
Remedy
Bleed the reheating heat exchanger.
Compare the specifications of the boiler
manufacturer with those of the cylinder
manufacturer. The problem may be able to be solved
by a higher setting of the flow temperature at the
boiler.
Turn off the cold water supply, then let water flow out
via the hot water connection. Only a few litres of
water flow out if the connection is laid correctly. The
inlet of the hot water draw-off pipe then rests in the
air space; no further emptying is possible. If the
entire solar cylinder runs empty via the hot water
connection, the connections have been laid
incorrectly. Change the connections!
Increase the setting.
Check whether the boiler is working.
Check whether the external control device is working.
Check whether the two port valve is in the hot water
position.
Replace the two port valve.
Bleed the reheating heat exchanger.
Cylinder temperature sensor
defective.
Dirt on the valve seat of the expansion
relief valve.
Check the thermal cut out and reset it.
Replace the cylinder thermostat.
Check the expansion relief valve and reset it
manually.
Pressure limiting valve defective.
Switch off the boiler and immersion heater and check
whether the pressure behind the pressure limiting
valve is lower than 3.0 bar if water flows out only
when heating up. If so, replace the pressure limiting
valve.
Check the pressure in the expansion vessel. If the
pressure is insufficient, re-establish the pressure and
check whether the equalisation tank maintains the
pressure.
If the pressure is normal, replace the expansion relief
valve.
Expansion vessel defective.
Expansion relief valve defective.
Water comes out of the temperature and Dirt on the valve seat of the
pressure relief valve (only when heating temperature and pressure relief valve.
up).
Temperature control of the boiler
defective.
Check the seat of the temperature and pressure relief
valve and reset it manually.
Check the temperature control of the boiler if water
only comes out when reheating with the boiler.
Check whether the two port valve switches to the
heating position after reaching the cylinder
temperature.
Cylinder temperature sensor defective. Check the cylinder temperature sensor and the
corresponding thermal cut outs and replace the
temperature sensor and reset the thermal cut outs if
necessary.
Two port valve defective.
Check whether the two port valve is working and
replace it if necessary.
Temperature and pressure relief valve Replace the temperature and pressure relief valve if
defective.
water only comes out when heating up with the
immersion heater.
Immersion heater defective.
Check the temperature sensor of the immersion
heater and the corresponding thermal cut out and
replace the immersion heater if necessary.
Table 8.1 Troubleshooting (continuation)
Manual - Solar hot water systems
59
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.
h Note!
In the event of leaks in the water pipework
close the cold water stop valve at the cylinder
immediately to limit any water damage.
The cold water stop valve can be found in the pipe joint
from your domestic water connection to the solar
cylinder (cold water connection) normally nearby the
cylinder.
H Danger!
Risk of scalding
The outlet temperature at the taps can be up to
85 °C with Vaillant VIH S GB 200 S,
VIH S GB 250 S and VIH S GB 300 S solar
cylinders.
9.2
Operation of the solar system
The solar system is set once during the start-up and
then works automatically. You do not even need to make
any adjustments when you go on holiday.
H
Danger!
Risk of burns!
The collectors and pipes can become very hot –
be careful when touching them!
H Danger!
Risk of scalding and bursts due to inappropriate
alterations!
You must not make any changes to the cylinder
or controller, to pipework or to electricity (if
available), to the pressure release pipe and to
the expansion relief valve for the stored water.
Otherwise steam can escape, pipes can burst or
the system may be damaged. The system
operates automatically after the initial
commissioning.
In order for your Vaillant solar system to work perfectly,
please observe the following instructions:
• Do not open or close any of the valves.
• Never switch off the solar system – even when you go
on holiday or assume an error has occurred.
Only exception:
The tube(s) of a Vaillant tube collector have been damaged, resulting in a pressure drop in the solar system or
solar fluid escaping. Observe the notes in Section 9.7,
What should be done if …
Do not take out the fuse or switch off the fuse box.
Do not under any circumstances fill the solar circuit
yourself.
9.3
Operation of the solar cylinder
Your boiler and the unvented auroSTOR solar cylinder
are provided with connections for a solar system as well
as a reheating system.
How to control the solar system is described in the
manuals for each controller.
60
a Caution!
Risk of frost!
The cylinder must be completely drained if its
is to be shut down for a long period of time in
an unheated room (e. g. winter holidays etc.).
Have the cylinder drained by a specialist.
9.3.1
Setting the standby temperature of the
cylinder
You can set the standby temperature of the cylinder, the
maximum cylinder temperature and also the minimum
temperature for reheating with the boiler on the
controller according to the design of your system.
If no controller is used, the standby cylinder
temperature is set on the hot water thermostat installed
in the solar cylinder.
The hot water thermostat for the boiler for reheating
the auroSTOR can be set between 20 and 65 °C. The
desired temperature is set by the installer during the
start-up of the auroSTOR solar cylinder.
Maximum energy efficiency can be achieved in the
45 °C setting.
• Make sure the boiler is ready for operation in
accordance with the operating manual supplied with
the appliance.
• Set the standby cylinder temperature on the controller
or on the hot water thermostat of the cylinder
according to the design of your system.
The setting options can be taken from the operating
manual of the corresponding controller.
h Note!
In areas with hard water the set hot water
temperature should not exceed 45 °C to avoid
calcification. The temperature for solar heating
can be set up to a maximum of 80 °C. It is
controlled by the auroMATIC 560 solar control.
Manual - Solar hot water systems
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.
h Note!
If the auroSTOR has been installed in a cup-
board for ventilation purposes, make sure no
items of clothing or other objects are placed on
the cylinder, control devices, lines or other
system components.
h Note!
Keep it accessible to allow the operation of the
hot water thermostat control and the mixer
valve.
9.3.2 Switching off the solar cylinder
To switch off the heating and hot water system
temporarily, simply switch off the boiler (refer to the
operating manual of the boiler).
9.4
Frost protection
9.4.1 Frost protection of the solar system
• Have the solar system checked for frost protection
once a year by a qualified servicing company. This
work is usually part of a maintenance agreement with
your approved specialist.
Do not refill the solar circuit with fluid. Do not mix the
solar fluid with other fluids.
Do not use any abrasives or solvents, since
they could damage the exterior or the
connections.
Maintenance
9.6.1 Maintenance of the solar system
The prerequisite for permanent operational readiness,
reliability and a long service life is that regular
inspections and maintenance work are performed on
your Vaillant solar system by the specialist. Never
attempt to perform maintenance work or repairs
yourself. Assign an approved qualified servicing
company with this work. We recommend making a
maintenance agreement. Observe our maintenance
checklist in Section 7, Inspection and maintenance, for
the contents of the maintenance agreement.
d Danger!
Risk of damage to the system or personal
injury!
The operational reliability of the system can be
impaired, resulting in damage to property or
personal injury, if the inspections and
maintenance work are not carried out.
The solar gain of the system may not meet expectations
as a result.
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. Consult an approved qualified
servicing company in the event of malfunctions.
9.4.2 Frost protection of the solar cylinder
Make sure the central heating remains switched on and
the temperature in all rooms and the installation room
of the auroSTOR solar cylinder are kept above freezing
point if you are absent for long periods.
9.6.2 Maintenance of the solar cylinder
Just like for the entire solar system, regular inspections
and maintenance by a specialist are the best way to
ensure reliability and a high service life also for the
Vaillant VIH S GB 200 S, VIH S GB 250 S and
VIH S GB 300 S cylinders.
9.5
It is important that your hot water cylinder is serviced
annually. To ensure regular servicing, it is strongly
recommended that arrangements are made for a
Maintenance Agreement. Please contact Vaillant Service
Solutions (0870 6060 777) for further details.
Care
9.5.1 Care of the collectors
The collectors do not have to be cleaned. Solar
collectors become dirty in the same way as roof
windows. They are cleaned sufficiently by rain however.
9.5.2 Care of the solar cylinder
You can clean the exterior of the solar cylinder with a
damp cloth and a little soap.
Manual - Solar hot water systems
61
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.
… “ Sensor defective” or “Broken cable” is displayed on the controller? Notify a qualified servicing company.
… the pressure on the pressure gauge falls below minimum
operating pressure?
… no temperature difference is visible between the flow and return
thermometer at the solar pump unit?
Notify a qualified servicing company.
… the pane of a flat plate collector has been damaged?
Do not touch the collector interior. Cover the collector with a
canvas as protection against rain. Notify a qualified servicing
company.
Shut down the solar system. To do so, change the operating mode
from “Auto” to “Off” on the auroMATIC 560 control. The necessary
steps are explained in the operating and installation manual for the
control.
Notify a qualified servicing company.
… the tube of a tube collector has been damaged?
... the cylinder does not deliver enough hot water?
Wait five to ten minutes. If the system is then still running, the
system may be defective.
Notify a qualified servicing company.
Check whether the standby cylinder temperature has been set
properly on the controller (approx. 60 °C recommended). Check the
hot water thermostat mixer setting (approx. 60 °C recommended).
If the settings are correct, the cylinder maybe calcified. In this case
notify a qualified servicing company.
Table 9.1 Troubleshooting instructions for the owner
10 Customer service and
manufacturer's warranty
10.1
Vaillant service
To ensure regular servicing, it is strongly recommended
that arrangements are made for a Maintenance
Agreement. Please contact Vaillant Service Solutions
(0870 6060 777) for further details.
10.2
Vaillant warranty
Vaillant provide a full parts and labour warranty for this
appliance.
The appliance must be installedby a suitably competent
person in accordance with the Gas Safety (Installation
and Use) Regulations 1998, and the manufacturer's
instructions. In the UK 'GORGI' registered installers
undertake the work in compliance with safe and
satisfactory standards.
All unvented domestic hot water cylinders must be
installed by a competent person to the prevailing
building regulations at the time of installation (G3).
Terms and conditions apply to the warranty, details of
which can be found on the warranty registration card
included with this appliance.
Failure to install and commission this appliance in
compliance with the manufacturer’s instructions may
invalidate the warranty (this does not affect the
customer’s statutory rights).
62
Manual - Solar hot water systems
Start-up protocol 11
11
Start-up protocol
The solar system of:
has been started up, while taking the following points
into consideration:
1. Assembly
Roof bracket fixed according to instructions?
Solar pipework connected to potential equalisation?
Roof covering refixed according to instructions after laying the roof bracket?
Roof membrane not damaged?
All connecting clips pushed in (with tube collectors)?
Pressure release pipe installed at the expansion relief valve of the solar circuit?
Catch vessel (empty canister) placed under pressure release pipe?
Pressure release pipe installed at expansion relief valve on hot water side and connected to
waste water?
Thermostat mixer installed, temperature set and checked?
O.K.
Remarks
2. Start-up
System filled with prescribed solar fluid?
Solar circuit flushed with solar fluid?
Line strainer cleaned after flushing the system?
System bled several times?
Solar circuit subjected to hydraulic pressure test, including leak inspection of screw
connections and soldering points?
Stuffing boxes at stop valve and fill/vent valve checked for leaks (retighten union nuts if
necessary)?
Temperature and pressure relief valve checked?
Stop valve for reheating source installed (normally motorised 2 port valve)?
Flow rate set according to system manual?
Pump, cylinder heat exchanger and collector bled (gravity brake blocked for bleeding)?
Gravity brake released?
Fill/vent valve caps screwed tight?
Cylinder bled?
Heating circuit bled?
Does the system installation meet the requirements of the building regulations?
Has the system been installed and started up in accordance with the installation manuals
of the manufacturer?
3. Control systems
Do the temperature sensors display plausible values?
Solar pump running and circulating (flow rate measuring meter)?
Solar circuit and cylinder become warm?
The temperature difference between the flow and return is a max. of 10 to 14 °C
at full sunshine?
Correct hydraulic plan set (auroMATIC 560 only)?
4. Instruction
The system owner has been instructed as follows:
– Basic functions and operation of the solar control?
– Functions and operation of the reheating system?
– Frost protection of the system?
– Maintenance intervals?
– Manuals/documents (possibly with special circuit plan) handed over to the owner?
Table 11.1 Start-up protocol
Manual - Solar hot water systems
63
11 Start-up protocol
Information
Unit
Value/Detail
Benchmark no.
Registration no.
Basic acceptances
Number of persons:
Additional hot water equipment:
Circulation
Circulation runtime
(please tick as appropriate)
Daily hot water consumption in
At a cylinder temperature of
Estimated solar coverage of the total hot water consumption
Collector array performance data
Installed effective collector surface area
Maximum power at full solar radiation
Solar cylinder
Appliance type
Appliance designation
Capacity
Serial number
Boiler
Appliance type
Appliance designation
Serial number
Boiler system type
Washing machine, dish
washer etc.
Available/Not available
h/d
l/d
°C
%
m2
kW (500–600 W/m2
collector)
Vented/Unvented
l
Open/Closed
Installation location of pressure limiting valve
System values
Hot water temperature at the nearest tap
Achievable maximum cylinder temperature
Maximum hot water temperature
Maximum hot water volume at maximum temperature
Boiler flow temperature
Operating pressure setting at pressure limiting valve
Charge pressure in DHW expansion vessel (check before filling)
Charge pressure in solar expansion vessel (check before filling)
Cold water system pressure at pressure limiting valve (cold)
Set flow rate
Temperature difference between flow and return at full solar radiation
Volume of solar expansion vessel
Operating pressure at solar pump unit pressure gauge in cold condition
Frost protection set to
°C
°C
°C
l/min.
°C
bar
bar
bar
bar
l/min
Kelvin
l
bar
Density of solar fluid
> 1.05 g/cm3
Table 11.2 Start-up data
64
Manual - Solar hot water systems
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 11.2 Start-up data (continuation)
Manual - Solar hot water systems
65
11 Start-up protocol
66
Manual - Solar hot water systems
Start-up protocol 11
Manual - Solar hot water systems
67
0020009607_01 GB 012007
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