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Installation manual For the competent person Installation manual auroTHERM, auroTHERM plus VFK 145 H/V, VFK 150 H/V, 155 H/V GB, IE Legal information Document type: Installation manual Product: Target group: auroTHERM, auroTHERM plus – VFK 145 H/V – VFK 150 H/V – VFK 155 H/V Authorised competent person Language: EN Document_number_version: 0020100571_00 Created on: 23.04.2012 Publisher/manufacturer Vaillant GmbH Berghauser Str. 40 D-42859 Remscheid Telefon +49 21 91 18‑0 Telefax +49 21 91 18‑28 10 [email protected] www.vaillant.de © Vaillant GmbH 2012 These instructions, or extracts thereof, may only be printed with the written consent of Vaillant GmbH. All designations of products in these instructions are brand names/trade marks of the companies in question. We reserve the right to make technical changes. Contents Contents 2.5 Regulations (directives, laws, standards) ............... 8 2.5.1 Installation regulations................................................ 8 1 Notes on the documentation .............................. 5 2.5.2 Regulations for the prevention of accidents ......... 8 1.1 Symbols used................................................................. 5 2.6 CE label............................................................................ 9 1.2 Observing other applicable documents .................. 5 3 Description of the unit ....................................... 10 1.3 Document storage ........................................................ 5 3.1 Type overview .............................................................. 10 1.4 Applicability of the instructions ................................ 5 3.2 Information on the identification plate .................. 10 1.5 Name................................................................................ 5 3.3 Purpose of the unit...................................................... 10 2 Safety .................................................................... 6 4 On-roof fitting and installation .......................... 11 2.1 Action-related warnings.............................................. 6 4.1 Preparing for fitting and installation ....................... 11 2.2 Required personnel qualifications............................ 6 2.2.1 Authorised competent person................................... 6 2.3 General safety information ........................................ 6 2.3.1 Danger due to improper use ...................................... 6 2.3.2 Risk of death due to improper fastening systems ........................................................................... 6 2.3.3 Risk of death due to inadequate load-bearing capacity of the roof...................................................... 6 2.3.4 Risk of death due to falling parts.............................. 6 2.3.5 Risk of injury and material damage due to incorrect maintenance and repairs .......................... 6 2.3.6 Risk of death due to inadequate fastening of the collectors ................................................................. 7 2.3.7 Risk of burns due to hot collector surfaces ........... 7 2.3.8 Risk of injury due to breaking glass ......................... 7 2.3.9 Material damage caused by a high-pressure cleaner............................................................................. 7 2.3.10 Material damage due to lightning............................. 7 2.3.11 Frost damage due to water in the solar circuit ..... 7 2.3.12 Material damage due to an unsuitable tool............ 7 2.3.13 Risk of death from electric shock ............................. 7 2.3.14 Material damage due to overvoltage....................... 7 2.3.15 4.1.1 Delivery, transport and positioning.......................... 11 4.1.2 Complying with clearances and installation clearances...................................................................... 14 4.1.3 Selecting suitable connection................................... 14 4.1.4 Preparing the roof duct.............................................. 14 4.1.5 Putting together components .................................. 16 4.1.6 Determining the number of required roof brackets.......................................................................... 18 4.1.7 Defining the edge clearances of the roof brackets.......................................................................... 18 4.1.8 Defining the roof bracket clearances ..................... 18 4.2 Carrying out the installation ................................... 20 4.2.1 Installing roof brackets ............................................ 20 4.2.2 Installing collectors .................................................... 24 4.2.3 Installing hydraulic connections ............................. 29 4.3 Completing and checking the installation ............. 31 4.3.1 Using the customer service card ............................. 31 4.3.2 Checking the installation .......................................... 32 4.3.3 Disposing of the packaging ...................................... 33 5 Flat roof fitting and installation ...................... 34 Risk of death and material damage due to contact corrosion.......................................................... 7 5.1 Preparing for fitting and installation ..................... 34 5.1.1 Delivery, transport and positioning........................ 34 2.3.16 Material damage due to snow falling from roofs................................................................................. 7 5.1.2 Complying with clearances and installation clearances..................................................................... 36 2.4 Intended use .................................................................. 8 5.1.3 Selecting suitable connection.................................. 36 2.4.1 Intended use .................................................................. 8 5.1.4 Preparing the roof duct............................................. 37 2.4.2 Suitability of the equipment....................................... 8 5.1.5 Selecting the installation variant............................ 37 2.4.3 Improper use.................................................................. 8 5.1.6 Putting together components ................................ 38 2.4.4 Other applicable documents ...................................... 8 5.1.7 Determining the ballast load (floating installation) ................................................................. 38 5.1.8 Defining the rack clearances .................................. 46 0020100571_00 auroTHERM, auroTHERM plus Installation manual 3 Contents 5.2 Carrying out the installation .................................... 47 5.2.1 Installing racks ............................................................ 47 5.2.2 Installing collectors ..................................................... 51 5.2.3 Installing hydraulic connections ............................ 54 5.3 Completing and checking the installation ........... 55 5.3.1 Using the customer service card ........................... 55 5.3.2 Checking installation................................................. 56 5.3.3 Disposing of the packaging ...................................... 57 6 Inspection and maintenance............................. 58 6.1 Maintenance plan....................................................... 58 6.1.1 Calendar-based maintenance intervals................ 58 6.2 Observing inspection and maintenance intervals ....................................................................... 58 6.3 General inspection and maintenance instructions ................................................................. 58 6.4 Preparing for inspection and maintenance......... 58 6.4.1 Spare parts for maintenance.................................. 58 6.4.2 Preparing for maintenance ..................................... 58 6.5 Checking collectors and connections for damage, dirt and lack of tightness ........................ 59 6.6 Cleaning collectors .................................................... 59 6.7 Checking brackets and collector components for firm seating........................................................... 59 6.8 Check the pipe insulations for damage ................ 59 6.9 Replacing damaged pipe insulations..................... 59 6.10 Disposing of damaged pipe insulations................ 59 7 Troubleshooting ................................................. 60 7.1 Spare parts for repair............................................... 60 7.2 Carrying out repairs.................................................. 60 7.2.1 Replace leaking collectors....................................... 60 7.2.2 Disposing of defective collectors........................... 60 7.2.3 Sealing leaking connections.................................... 60 7.2.4 Replacing defective pipe insulations .................... 60 7.2.5 Disposing of defective pipe insulations................ 60 4 8 Decommissioning ................................................ 61 8.1 Temporary decommissioning ................................... 61 8.2 Permanently decommissioning ................................ 61 8.2.1 Removing collectors ................................................... 61 8.2.2 Recycling and disposal ............................................... 61 9 Customer service............................................... 63 10 Technical data .................................................... 64 10.1 Technical data table.................................................. 64 10.2 Dimensions .................................................................. 65 Index .................................................................................... 67 Installation manual auroTHERM, auroTHERM plus 0020100571_00 Notes on the documentation 1 1 Notes on the documentation 1.1 Symbols used 1.3 Document handover ▶ Symbols The following symbols may appear: Document storage Pass this installation manual and all other applicable documents and, if necessary, any required tools to the system operator. Availability of documents Warning symbol (→ Page 6) The system operator is responsible for storing the documents so that they are available whenever required. Information symbol 1.4 Symbol for a required action Symbol for the result of an action Applicability of the instructions These instructions apply for the following only: Collector types and article numbers Symbol for the completion of records and checklists Symbol for a required qualification VFK 145 H 0010004457, 0010008899 VFK 145 V 0010004455, 0010008898 VFK 150 H 0010006285, 0010008902 VFK 150 V 0010006283, 0010008901 VFK 155 H 0010013174 VFK 155 V 0010013173 Table 1.1: Collector types and article numbers Symbol for a required tool 1.5 Name In this manual, flat collectors are referred to as collectors. Symbol for the specification of a technical value n u 1.2 ▶ Symbol for adjacent array configuration Symbol for array configuration on top of each other Observing other applicable documents All installation instructions for the component parts and components of the solar plant must be observed when installing the collectors. These installation instructions are enclosed with the various system parts and supplementary components. 0020100571_00 auroTHERM, auroTHERM plus Installation manual 5 2 Safety 2 2.1 Safety Action-related warnings Classification of action-related warnings The action-related warnings are classified in accordance with the severity of the possible danger using the following warning signs and signal words: Warning symbols and signal words Danger! Imminent danger to life or risk of severe personal injury Danger! Risk of death from electric shock Warning. Risk of minor personal injury Caution. Risk of material or environmental damage 2.2 Required personnel qualifications This manual is intended for persons with the following qualifications 2.2.1 Authorised competent person The installation, assembly and removal, start-up, maintenance, repair and decommissioning of Vaillant products and accessories must only be carried out by authorised competent persons. Note Each competent person is qualified for specific activities on the basis of their training. They must only work on units if they have the required qualification. When working on the units, the competent persons must observe all applicable directives, standards, laws and other regulations. 2.3 General safety information 2.3.1 Danger due to improper use Vaillant auroTHERM VFK flat collectors are constructed using state-of-the-art technology in accordance with the recognised safety rules and regulations. Nevertheless, there is still a risk of injury or death to the user or others or of damage to the unit and other property in the event of improper use or use for which it is not intended. 2.3.2 Risk of death due to improper fastening systems The collectors may fall due to improper fastening systems. Only the combination of Vailllant collectors and Vaillant fastening systems has been tested. This combination can withstand the forces caused by additional wind and snow loads. ▶ Only use the collector fastening systems that are approved by Vaillant. 2.3.3 Risk of death due to inadequate loadbearing capacity of the roof A roof with an insufficient load-bearing capacity may collapse due to the additional load of the collectors. Above all, additional wind and snow loads may result in higher forces which could cause the roof to collapse. ▶ ▶ Ensure that a structural engineer has confirmed the roof as suitable for collector installation. Only install the collectors on a roof that has adequate load-bearing capacity. 2.3.4 Risk of death due to falling parts Unsecured collectors can fall from the roof and present a danger to persons. ▶ ▶ Block off the areas in the fall area below the place of work to a sufficient extent so that persons cannot be injured by falling objects. Indicate the working area, e.g. with information signs, in accordance with the applicable regulations. 2.3.5 Risk of injury and material damage due to incorrect maintenance and repairs If maintenance or repair work is not carried out, or is carried out incorrectly, this may result in injuries or in damage to the solar plant. ▶ 6 Ensure that only an approved competent person carries out maintenance and repair work. Installation manual auroTHERM, auroTHERM plus 0020100571_00 Safety 2 2.3.6 Risk of death due to inadequate fastening of the collectors ▶ ▶ Collectors can fall from their anchors if they are not properly fastened on the roof. Collectors falling from the roof could cause life-threatening accidents. ▶ ▶ ▶ Perform all work steps as described in this manual. Observe all safety precautions described in this manual. In addition, comply with all safety regulations that specifically apply in your region. 2.3.7 Risk of burns due to hot collector surfaces In the event of solar radiation inside the units, collectors can reach 200 °C. If you touch the collectors without protection, you could burn yourself. ▶ ▶ ▶ ▶ ▶ If a sun protection film has been attached to the collectors in the factory, remove it only after the solar plant has been started up. Avoid performing installation and maintenance work under direct sunlight. Cover the collectors before starting work. You should preferably perform the work in the morning. Wear suitable safety gloves. 2.3.12 Material damage due to an unsuitable tool An unsuitable tool may damage the solar plant. ▶ ▶ The glass of the collectors may break due to mechanical destruction or torsion. ▶ ▶ Wear suitable safety gloves. Wear suitable protective goggles. 2.3.9 Material damage caused by a high-pressure cleaner High-pressure cleaners may damage the collectors due to the extremely high pressure. ▶ Never clean the collectors with a high-pressure cleaner. 2.3.10 Material damage due to lightning Lightning can damage the collector system. ▶ Connect the collector system to a lightning protection device in accordance with applicable regulations. Only use a suitable tool. In particular, only use the tool specified in the work steps of this manual. 2.3.13 Risk of death from electric shock Incorrect installation or a faulty power cable can result in a supply voltage on the pipes, which can cause life-threatening injuries. ▶ ▶ Secure earthing pipe clamps to the pipes. Connect the earthing pipe clamps to a busbar using 16 mm² copper cable. 2.3.14 Material damage due to overvoltage Overvoltage may damage the solar plant. ▶ 2.3.8 Risk of injury due to breaking glass Only fill and flush the collector with Vaillant ready-mixed solar fluid. Check the solar fluid regularly with an antifreeze tester. ▶ ▶ Earth the solar circuit to provide equipotential bonding and overvoltage protection. Secure earthing pipe clamps to the pipes. Bond the earthing pipe clamps to a busbar using 16 mm² copper cable. 2.3.15 Risk of death and material damage due to contact corrosion For roofs or façade sections made of metals more precious than aluminium (e.g. copper roof), contact corrosion may occur on the brackets. Collectors could fall and put persons at risk. ▶ Use suitable underlays to separate the metals. 2.3.16 Material damage due to snow falling from roofs If the collector field is installed below a sloping roof, then snow falling from the roof may damage the collectors. ▶ Install snow fences above the collectors as protection against falling snow. 2.3.11 Frost damage due to water in the solar circuit Water residue in the collector may freeze in frosty conditions and damage the collector. ▶ Never fill or flush the collector with water. 0020100571_00 auroTHERM, auroTHERM plus Installation manual 7 2 Safety 2.4 Intended use 2.5 Regulations (directives, laws, standards) 2.4.1 Intended use 2.5.1 Installation regulations Vaillant auroTHERM VFK flat collectors are used for solar heating support and for solar-supported hot water generation. Regulations Applies to: Great Britain Technical Guidance 2.4.2 Suitability of the equipment The collectors must only be operated with Vaillant readymixed solar fluid. Passing heating water or hot water directly through the collectors constitutes improper use. 2.4.3 Improper use Any use which is not explicitly mentioned in the chapter "Intended use" (→ Page 8) is deemed improper. Any other or additional use does not comply with the intended use. Any direct commercial or industrial use is also deemed to be improper. The manufacturer/supplier is not liable for any damage resulting from such use. The user alone bears the risk. 2.4.3.1 Combination with other components Vaillant auroTHERM VFK flat collectors must only be combined with components (fastenings, connections, etc.) and system parts that are supplied by Vaillant. The use of other components or system parts shall be considered as improper use. 2.4.3.2 Installation in or on vehicles Installation of the Vaillant auroTHERM VFK flat collector in or on a vehicle is not permissible and is considered improper use. Units that are not classed as vehicles are those that are installed in a fixed and permanent location (known as "fixed installation"). 2.4.4 Other applicable documents Intended use includes the following: – observance of accompanying operating, installation and servicing instructions for Vaillant products as well as for other parts and components of the system, – installing and fitting the unit in accordance with the boiler and system approval, – compliance with all inspection and maintenance conditions listed in the instructions. The system must be installed in accordance with all relevant and applicable national regulations, and must be installed to suit site conditions. Observe all national regulations, including: – – – – – – Working at Heights Regulations 2005 Health and Safety at Work Act 1974 Electricity at Work Regulations 1989 IEE Wiring Regulations BS 7671 Lightning protection requirements Equipotential bonding of electrical installations. Related documents The installation of the solar system must be in accordance with the relevant requirements of Health and Safety Document No. 635 (The Electricity at Work Regulations 1989), BS7671 (IEE Wiring Regulations) and the Water Supply (Water Fitting) Regulations 1999, or The Water Bylaws 2000 (Scotland). It should also be in accordance with the relevant requirements of the Local Authority, Building Regulations, The Building Regulations (Scotland), The Building Regulations (Northern Ireland) and the relevant recommendations of the following British Standards: – BS EN 806: Specification for installations inside buildings conveying water for human consumption – BS 6700: Services supplying water for domestic use within buildings and their curtilages – BS 5449 Forced circulation hot water central heating systems for domestic premises. Note: only up to 45 kW – BS. 6880 Low temperature hot water heating systems of output greater than 45 kW – Part 1 Fundamental and design considerations. – Part 2 Selection of equipment – Part 3 Installation, commissioning and maintenance – BS 6114: Expansion vessels using an internal diaphragm for unvented hot water supply systems – BS. 4814 Specification for: Expansion vessels using an internal diaphragm, for sealed hot water heating systems – Unvented hot water systems must comply with building regulation G section 3 2.5.2 Regulations for the prevention of accidents Applies to: Great Britain When carrying out works such as solar installation work it is necessary to do so in a safe and workman like manner, taking due care of any aspects of the works that could result in 8 Installation manual auroTHERM, auroTHERM plus 0020100571_00 Safety 2 injuries to person in or about the building as well as workers, passers by and the general public at large. To that end these works must conform, but not be limited to, the current regulations in force such as the following: – – – – Health and Safety at Work act 1974 Work at Height Regulations 2005 Electricity at Work Regulations 1989 All necessary Building Regulations Work should be preceded by a risk assessment covering all aspects of health and safety risks, or training requirements that can reasonably be foreseen to be associated with the work. All scaffolding in the UK, other than prefabricated (zip-up) scaffold towers, must be designed and constructed by a vetted contractor, and have suitable kick boards, hand rails and where appropriate netting. Areas around the scaffolding should be zoned off and marked with suitable warning signs to a suitable distance to protect persons from falling objects. Workers should have available and use personal protective equipment as necessary. This would include equipment such as fall protection systems, safety gloves, goggles, dust masks as well as any specialised equipment that may be in use such as lifting and handling equipment. The completed works shall comply with all necessary BS EN Standards and Codes of practice as well as Building control or planning requirements and be confirmed where necessary by notification to building control or the appropriate competence based notification body. 2.6 CE label The CE label documents that the appliances as described in the type overview satisfy the basic requirements of the following directives: – Directive 97/23/EC of the European Parliament and Council on the approximation of the laws of the member states regarding pressure equipment 0020100571_00 auroTHERM, auroTHERM plus Installation manual 9 3 Description of the unit 3 Description of the unit Information on the identification plate Meaning Type overview tstgf Stagnation temperature Horizontal collector position Pmax Max. permissible operating pressure 3.1 – VFK 145 H – VFK 150 H – VFK 155 H Serial-No. Vertical collector position Table 3.1: Information on the identification plate – VFK 145 V – VFK 150 V – VFK 155 V 3.2 3.3 Information on the identification plate Information on the identification plate Bar code with serial number, The 7th to 16th digits of the serial number form the article number Purpose of the unit The collectors are used for solar heating support as well as for solar-supported hot water generation. Meaning CE label: The collectors comply with the relevant product-specific European guidelines. Solar Keymark: The collectors have been successfully tested according to the rules and requirements for the Solar Keymark. CSTBat Only VFK 150 H, VFK 150 V, VFK 155 H and VFK 155 V: CSTBat: The collectors have been successfully tested according to the rules and requirements for the CSTBat. Read the installation manual. VFK 145 H VFK 145 V VFK 150 H VFK 150 V VFK 155 H VFK 155 V Type designation VFK Vaillant flat collector 145, (150, 155) Collector output /2 Unit generation H Horizontal design V Vertical design Flat plate collector Flat collector AG Gross area VF Liquid volume m Weight A Dimensions Qmax Max. output 10 Installation manual auroTHERM, auroTHERM plus 0020100571_00 On-roof fitting and installation 4 4 ▶ On-roof fitting and installation When fitting and installing the collectors, you must observe the chapter "Safety". 4.1 Preparing for fitting and installation 4.1.1 Delivery, transport and positioning 4.1.1.1 Storing collectors ▶ To prevent moisture from penetrating into the collector, always store the collectors dry and in a weatherproof area. 0020100571_00 auroTHERM, auroTHERM plus Installation manual 11 4 On-roof fitting and installation 4.1.1.2 Checking the scope of delivery 15 1 14 2 10 3 13 12 4 5 11 6 10 7 8 9 Fig. 4.1: Installation set for vertical and horizontal on-roof installation (here: vertical collector) List of materials for on-roof installation 1 Rail mounting set, vertical 2 pc. Rail mounting set, horizontal 2 pc. 2 Flow (outlet with opening for collector sensor) from set of hydraulic connections 1 pc. 3 Roof bracket type P (for pantile) (basic set) 4 pc. Roof bracket type P (for pantile) (extension set, on top of each other) 2 pc. 4 4 pc. 2 pc. 5 Roof bracket type S flat (for beaver tail, etc.) (basic set) 4 pc. Roof bracket type S flat (for beaver tail, etc.) (extension set, on top of each other) 2 pc. 12 6 7 8 9 10 11 12 Hanger bolt fastening set (basic set) 4 pc. Hanger bolt fastening set (extension set, on top of each other) 2 pc. Hydraulic connections from hydraulic extension set 2 pc. Clamp from hydraulic extension set 4 pc. Return (inlet) from hydraulic connections set 1 pc. Top and bottom plugs (with vent opening) from set of hydraulic connections 2 pc. Rail connector from hydraulic extension set 2 pc. Long base, hook type P 4 pc. Installation manual auroTHERM, auroTHERM plus 0020100571_00 On-roof fitting and installation 4 13 ▶ auroTHERM VFK 145 V collector 1 pc. auroTHERM VFK 145 H collector 1 pc. auroTHERM VFK 150 V collector 1 pc. auroTHERM VFK 150 H collector 1 pc. auroTHERM VFK 155 V collector 1 pc. auroTHERM VFK 155 H collector 1 pc. 14 15 Clamp from hydraulic connections set 4 pc. Pipe connector (only for horizontal collector) 1 pc. Use the illustration to check that the installation sets are complete. 0020100571_00 auroTHERM, auroTHERM plus Installation manual 13 4 On-roof fitting and installation 4.1.1.3 Transporting collectors Conditions: Number of collectors: 6 … 12 1. To protect the collectors against damage, always transport them horizontally. 2. Transport the collectors to the roof using suitable aids. 4.1.2 1 Complying with clearances and installation clearances 2 ... 11 12 In order to fit the collectors correctly, the specified clearances and installation clearances must be observed. ▶ For the necessary edge clearances, see chapter "Defining edge clearances of the roof brackets". Fig. 4.4: Series switching 6 - 12 collectors (shown here: vertical collector) ▶ 4.1.3 ▶ Selecting suitable connection Select the appropriate connection for the collectors. 1 2 3 To guarantee a complete flow through the collector field, arrange the hydraulic connections diagonally. Conditions: Number of collectors: ≥ 13 4 1 2 ... 6 7 8 9 ... 13 14 Fig. 4.2: Flow direction (illustrated here: vertical collector) ▶ ▶ For the hydraulic connection of the collectors, select one of the four variants shown in the illustration. Ensure that the solar fluid always flows through the collectors from the bottom to the top. Fig. 4.5: Parallel switching (shown here: vertical collector) Conditions: Number of collectors: 1 … 5 1 ... 4 5 ▶ ▶ ▶ ▶ ▶ Fig. 4.3: Series switching 1 - 5 collectors (shown here: vertical collector) ▶ Configure the hydraulic connections on top of each other on one side. Always connect as many collectors as possible in series. Set up several parallel connector rows. Connect the collector rows hydraulically in parallel. To avoid pressure losses in the sub-collector fields, only use parallel connection for collector rows with the same number of collectors. Ensure that each sub-collector field has the same total pipe length in the flow and return (Tichelmann system), in order to avoid pressure losses in the connection pipes. 4.1.4 Preparing the roof duct Caution. Building damage due to penetrating water. If the roof duct is not prepared properly, water may penetrate the building interior. ▶ Ensure that the roof duct is prepared properly. 14 Installation manual auroTHERM, auroTHERM plus 0020100571_00 On-roof fitting and installation 4 Fig. 4.6: Guiding the pipe through the roofing felt membrane 1. Make a v-shaped cut in the roofing felt membrane. 2. Fold the upper, wider flap onto the roof batten above, and fold the lower, narrower flap onto the roof batten below. 3. Fix the roofing felt membrane tight to the roof batten, so that any moisture runs off to the side. 0020100571_00 auroTHERM, auroTHERM plus Installation manual 15 4 On-roof fitting and installation 4.1.5 Putting together components Conditions: Array configuration: Adjacent ▶ Using the following table, put together the components for installation. Collector position Number of collectors: 1 2 3 Components 4 5 6 7 8 9 10 Required quantity Hydraulic installation set 1 Hydraulic connection set − 1 2 3 4 5 6 7 8 9 1 2 3 5 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 Bracket set 1 type P Horizontal Bracket set 2 type S Bracket set 2 type S flat Bracket set 3 hanger bolts Horizontal rail, anodised Hydraulic installation set 1 Hydraulic connection set − 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 Bracket set 1 type P Vertical Bracket set 2 type S Bracket set 2 type S flat Bracket set 3 hanger bolts Vertical rail, anodised Table 4.1: Components for on-roof installation, adjacent array configuration Conditions: Array configuration: On top of each other ▶ Use the following table to put together the components for installation. Collector position Number of collectors: Components Required quantity Hydraulic installation set 1 1 − − − − − − − − Hydraulic connection set − 1 − − − − − − − − 1 1 − − − − − − − − − 1 − − − − − − − − Horizontal rail, anodised 1 2 − − − − − − − − Hydraulic installation set 1 2 − − − − − − − − 1 1 − − − − − − − − − 1 − − − − − − − − Bracket set 1 type P Bracket set 2 type S Bracket set 2 type S flat Horizontal Bracket set 3 hanger bolts Bracket extension set 1 type P Bracket extension set 2 type S Bracket extension set 2 type S flat Bracket extension set 3 hangar screws Bracket set 1 type P Bracket set 2 type S Bracket set 2 type S flat Vertical Bracket set 3 hanger bolts Bracket extension set 1 type P Bracket extension set 2 type S Bracket extension set 2 type S flat Bracket extension set 3 hanger bolts 16 Installation manual auroTHERM, auroTHERM plus 0020100571_00 On-roof fitting and installation 4 Collector position Components Number of collectors: Vertical Vertical rail, anodised 1 2 3 1 2 − 4 5 6 7 8 9 10 − − − Required quantity − − − − Table 4.2: Components for on-roof installation, array configuration on top of each other 0020100571_00 auroTHERM, auroTHERM plus Installation manual 17 4 On-roof fitting and installation 4.1.6 Determining the number of required roof brackets ▶ ▶ 1. Ask the local building authority for the regional maximum snow load sk. b [m] Conditions: Maximum snow load: ≤ 3 kN/m² ▶ Install 4 roof brackets per collector. Conditions: Maximum snow load: 3 < × ≤ 4.5 kN/m² ▶ Calculate the building width w, building height h and building length l. The values for the edge clearances to be observed, eshort and elong can be found in the following tables. Install 6 roof brackets per collector. H [m] 5 6 7 8 9 10 8 1.0 9 1.0 10 1.0 11 12 11 1.0 Conditions: Maximum snow load: > 4.5 kN/m² 12 1.0 ▶ ▶ 13 1.0 1.2 1.3 14 1.0 1.2 1.4 15 1.0 1.2 1.4 1.5 16 1.0 1.2 1.4 1.6 17 1.0 1.2 1.4 1.6 1.7 18 1.0 1.2 1.4 1.6 1.8 Compile statistics for the individual case. Ensure that the maximum permissible snow load per collector is 5.4 kN/m². Note The maximum permissible load per roof bracket type S/type P is: Fmax = 1.875 kN. 13 14 15 13 14 15 1.1 1.2 Table 4.3: Edge clearances eshort [m] l [m] 2. If you are using extension sets, ensure that the roof bracket is positioned centrally with equal clearances. h [m] 5 6 7 8 9 Defining the edge clearances of the roof brackets Maximum lift points caused by wind loads can occur at the cut-away edges of wall and roof areas (e.g. verge and eaves). These maximum lift points result in high loads on the collectors and installation systems. 11 12 1.0 10 4.1.7 10 11 1.0 1.1 12 1.0 1.2 13 1.0 1.2 1.3 14 1.0 1.2 1.4 15 1.0 1.2 1.4 16 1.5 Areas in which lift points occur are called edge areas. Corner areas are zones in which edge areas overlap and especially high pull forces occur. 1.0 1.2 1.4 17 1.0 1.2 1.4 1.6 1.6 1.7 18 1.0 1.2 1.4 1.6 1.8 Edge and corner areas must not be used as installation areas. 19 1.0 1.2 1.4 1.6 1.8 1.9 20 1.0 1.2 1.4 1.6 1.8 2.0 Table 4.4: Edge clearances elong [m] ekurz ▶ elang h When installing the roof brackets, observe the calculated edge clearances. 4.1.8 Defining the roof bracket clearances The roof brackets have different clearances depending on the array configuration of the collectors (adjacent or on top of each other). b l Fig. 4.7: Edge clearances eshort and elong b Building width h Building height 18 l Building length Installation manual auroTHERM, auroTHERM plus 0020100571_00 On-roof fitting and installation 4 4.1.8.1 nAdjacent array configuration Conditions: Collector position: Vertical 1245 * / 1220 ** 2045 * / 2020 ** Conditions: Collector position: Horizontal 660 - 860 1460 - 1660 200 - 300 200 - 300 200 - 300 200 - 300 200 - 300 Fig. 4.8: Clearances for adjacent array configuration and horizontal collector position ▶ ▶ Define the clearances of the roof brackets. Ensure that the roof brackets have sufficient play. Specifications/technical data Pre-installation dimension (*) 200 - 300 200 - 300 200 - 300 Fig. 4.9: Clearances for adjacent array configuration and vertical collector position ▶ Define the clearances of the roof brackets. Specifications/technical data Pre-installation dimension (*) = Finished installation dimension (**) + 2025 mm = Finished installation dimension (**) + 2025 mm 0020100571_00 auroTHERM, auroTHERM plus Installation manual 19 4 On-roof fitting and installation 4.1.8.2 uArray configuration on top of each 4.2.1 other Installing roof brackets 4.2.1.1 Installing type P (for pantile) Conditions: Collector position: Horizontal SW 13 spanner 2500 * / 2480 ** 1245 * / 1220 ** 1 200 - 300 1460 - 1660 3 2 Fig. 4.11: Roof bracket type P 1 Lower roof bracket 3 Middle roof bracket 2 Top roof bracket 1. Use the top, middle and lower type P roof brackets shown. Fig. 4.10: Clearances for array configuration on top of each other and horizontal collector position ▶ Define the clearances of the roof brackets. Specifications/technical data Pre-installation dimension (*) = Finished installation dimension (**) + 2025 mm A 4.2 Carrying out the installation 5 mm The installation steps and notes in this manual apply to both collector positions and array configurations. Any different installation steps are clearly indicated in individual cases. B 2 1 Fig. 4.12: Turning the base 2. Secure the type P roof bracket either to the rafters (A) or to the roof batten (B). 3. To do this, loosen the bolt (1) on the base of the roof bracket with the enclosed bit and unscrew the bolt by approx. 5 mm. 4. If you wish to secure the roof bracket onto the rafters, turn the base (2) outwards (A). 20 Installation manual auroTHERM, auroTHERM plus 0020100571_00 On-roof fitting and installation 4 5. If you wish to secure the roof bracket onto the roof batten, turn the base (2) inwards (B). 5 Conditions: Fastening type: To rafters A 6 B 2 1 Fig. 4.15: Securing the type P roof bracket on the rafters ▶ Fig. 4.13: Exposing the rafters and fitting the type P roof bracket ▶ ▶ ▶ ▶ ▶ Define the clearances of the roof brackets. (→ Page 19) Expose the rafters at the corresponding position (1). Position the roof bracket (2). Ensure the correct position of the top, middle and lower roof brackets. Screw the roof bracket onto the rafters using the three bolts supplied (5). Slide the pantiles into their original position again (6). To ensure that the tiles lie tightly together, notch guttering onto the underside (A) or the top side (B) of the pantile using a hammer, if necessary. Note For some roof types, it may be necessary to offset the roof bracket laterally opposite the rafters. To do this, use the accessory "long base" article number 0020080177 (not available in all countries). 3 Conditions: Fastening type: To roof batten 4 2 Fig. 4.14: Positioning the type P roof bracket correctly on the rafters ▶ 3 1 Undo the top bolt until the height of the roof bracket can be adjusted (3). Working materials SW 13 spanner ▶ ▶ Adjust the roof bracket to the height of the pantiles, so that the top part of the roof bracket lies on the roofing (4). Tighten the top bolt. Working materials SW 13 spanner Fig. 4.16: Exposing the roof batten and fitting the type P roof bracket ▶ ▶ ▶ Define the clearances of the roof brackets. (→ Page 19) Slide one to two pantiles upwards at the corresponding position above the roof batten (1). Undo the top bolt until the height of the roof bracket can be adjusted (2). Working materials SW 13 spanner 0020100571_00 auroTHERM, auroTHERM plus Installation manual 21 4 On-roof fitting and installation ▶ Hang the roof bracket on the roof batten (3). Ensure that the top, middle and lower roof brackets are positioned correctly. 4.2.1.2 Installing type S (for slate) 1 2 4 Fig. 4.17: Positioning the type P roof bracket correctly on the roof batten ▶ ▶ Adjust the roof bracket to the height of the pantiles, so that the top part lies on the roofing and the bottom part is pushed tight against the roof batten from the bottom (4). Ensure that the roof bracket fits securely around the roof batten and pantile when it engages. Fig. 4.19: Remove slates and fit type S roof bracket (shown here: on the roof batten) 1. Define the clearances of the roof brackets. (→ Page 19) 2. At the appropriate position, expose the rafters or roof batten (1). 3. Position the roof bracket. Ensure the correct position of the top, middle and lower roof brackets (2). 3 4 5 A 6 Fig. 4.20: Screw on the type S roof bracket and lay the slates again (shown here: on the roof batten) Fig. 4.18: Securing the type P roof bracket on the roof batten ▶ Tighten the top bolt (5). Working materials 4. Screw the roof bracket onto the roof batten or rafters using the three screws supplied (3). 5. Slide the pantiles into their original position again (4). SW 13 spanner ▶ ▶ 22 Slide the pantiles into their original position again (6). To ensure that the tiles lie tightly together, notch guttering onto the underside of the pantiles (A) using a hammer, if necessary. Installation manual auroTHERM, auroTHERM plus 0020100571_00 On-roof fitting and installation 4 4.2.1.3 Installing type S flat (for slate) 4.2.1.4 Installing the hanger bolt type SW 17 spanner 1 2 1 2 Fig. 4.21: Remove slates and fit the type S flat roof bracket (shown here: on the roof batten) 1. Define the clearances of the roof brackets. (→ Page 19) 2. At the appropriate position, expose the rafters or roof batten (1). 3. Position the roof bracket. Ensure that the top, middle and lower roof brackets (2) are positioned correctly. 3 Fig. 4.23: Defining the position of the roof bracket on the rafters 1. Define the clearances of the roof brackets. (→ Page 19) 2. At the corresponding position, drill a hole in the pantile (1). 3. Tighten the hanger bolt onto the rafters through the pantile(2). 4 3 Fig. 4.22: Screw on the type S flat roof bracket and lay the slates again (shown here: on the roof batten) 4. Screw the roof bracket onto the roof batten or rafters using the three screws supplied (3). 5. Slide the pantiles into their original position again (4). Fig. 4.24: Tightening the nut, fitting the roof bracket 4. Position the central nut so that, after inserting the upper part of the roof bracket, the front contact area lies on the roofing (3). Ensure the correct positioning of the top, middle and lower roof brackets. 0020100571_00 auroTHERM, auroTHERM plus Installation manual 23 4 On-roof fitting and installation Installing mounting rails 1 6 5 4 2 Fig. 4.25: Adjusting the roof bracket; cutting off the threaded rod 5. Position the roof bracket on the central nut (4). 6. Screw the second nut on and tighten (5). Working materials SW 17 spanner 7. Disconnect the threaded rod directly above the nut (6). 8. Deburr the interface. 4.2.2 Installing collectors 4.2.2.1 nAdjacent array configuration Fig. 4.26: Installing mounting rails 2. Use the clamping elements to secure the top and lower mounting rail for the first collector to the roof brackets ((1) and (2)). 3. Position the lower rail as far as possible downwards on the roof brackets. 4. Position the top rail on the roof brackets with the preinstallation clearance dimension from the lower rail (→ chapter "Defining roof bracket clearances"). Taring mounting rails 1 SW 13 spanner 2 Danger! Personal injury and material damage due to a falling collector. Improper fastening may cause a collector to fall. ▶ Tighten the clamping elements. ▶ Check for proper tensioning by shaking the clamping blocks. ▶ If a clamping block is mobile, tighten the Fig. 4.27: Taring mounting rails 5. Secure the mounting rails horizontally. 6. Compensate for any height differences by moving the clamping elements. 7. To do this, pull the clamping element upwards (1), move it (2) and release it so that it engages. nut again. 1. Install the collectors on the roof as specified in the following sections. Note Mounting rails and clamping elements cannot be moved at the same time. 24 Installation manual auroTHERM, auroTHERM plus 0020100571_00 On-roof fitting and installation 4 Laying and hooking collectors 1 Fitting connectors A B Fig. 4.28: Laying and hooking collectors Fig. 4.29: Fitting connectors Danger! Risk of burns and scalding! Caution. Risk of damage to the collector. In the event of solar radiation inside the units, collectors can reach 200 °C. Improper installation of the pipe connectors may damage the collector. ▶ Avoid working in direct sunlight. ▶ Cover the collectors before starting ▶ Ensure that the clamps (A) slide into the ▶ ▶ work. You should preferably perform the work in the morning. Wear suitable safety gloves. 8. Lay the lower edge of the first collector in the lower mounting rail and hook it in at the clamping elements (1). 9. Ensure that the top clamping block of the clamping element is positioned above the edge of the collector. 10. Tighten the clamping elements of the lower mounting rail. grooves of the pipe connector (B). 11. Insert the hydraulic connectors into the provided mounting openings at the side of the previously installed collector until they reach the stop position. 12. Secure the connectors with the clamps, slide the clamp into the guide from the top for the top connection and from the bottom for the lower connection. Connecting mounting rails 1 Working materials SW 13 spanner Fig. 4.30: Connecting mounting rails 13. Insert the connecting elements laterally into the mounting rails until you feel them engage (1). 14. Slide the mounting rails of the next collector onto the mounting rails of the previously installed collector (1). 15. Secure the mounting rails for the next collector onto the roof brackets using the clamping elements. 16. Tare the mounting rails. (→ Page 24) 0020100571_00 auroTHERM, auroTHERM plus Installation manual 25 4 On-roof fitting and installation Installing additional collectors Positioning the top mounting rails 1 A B Fig. 4.31: Installing additional collectors Fig. 4.32: Positioning the top mounting rails 17. Lay the lower edge of the next collector in the lower mounting rail and hook it in at the clamping elements. 18. Ensure that the top clamping block of the clamping element is above the edge of the collector. 19. Slide the collector to the first collector, observing the hydraulic connectors. 22. Slide all the top mounting rails until they are flush with the lower collectors, one after the other (1). 23. Ensure that the edges of the mounting rails grip around the collectors. 24. Slide the clamping elements down to the lower collectors, one after the other (1). 25. Ensure that the clamping block of the clamping elements lies over the collector edges. 26. Tighten the clamping elements of the top mounting rails. Caution. Risk of damage to the collector. Improper installation of the pipe connectors may damage the collector. ▶ Ensure that the clamps (A) slide into the grooves of the pipe connector (B). Working materials SW 13 spanner Completing installation of the collectors 27. Tighten all remaining clamping elements. 20. Secure the hydraulic connectors with the clamps. 21. Tighten the clamping elements of the lower mounting rail. Working materials SW 13 spanner Working materials SW 13 spanner 28. Check for proper tensioning by shaking the clamping blocks. 29. If a clamping block can be moved, tighten the nut again. Completing collector rows Conditions: Not all collectors of a row have been installed yet. ▶ ▶ ▶ 26 Fit the connectors. (→ Page 25) Connect the mounting rails. (→ Page 25) Install an additional collector. (→ Page 26) Installation manual auroTHERM, auroTHERM plus 0020100571_00 On-roof fitting and installation 4 4.2.2.2 uArray configuration on top of each other 4. Position the top rail on the roof brackets with the preinstallation clearance dimension from the lower rail (→ chapter "Defining clearances of the roof brackets"). Taring mounting rails SW 13 spanner 1 2 Danger! Personal injury and material damage due to a falling collector. Improper fastening may cause a collector to fall. ▶ Tighten the clamping elements. ▶ Check for proper tensioning by shaking ▶ 1. the clamping blocks. If a clamping block is mobile, tighten the nut again. Install the collectors on the roof as specified in the following sections. Note Mounting rails and clamping elements cannot be moved at the same time. Fig. 4.34: Taring mounting rails 5. Secure the mounting rails horizontally. 6. Compensate for any height differences by moving the clamping elements. 7. To do this, pull the clamping element upwards (1), move it (2) and release it so that it engages. Laying and hooking collectors 1 Note With array configuration on top of each other and with a vertical collector position, the collectors must be hydraulically balanced (Tichelmann System). Installing mounting rails 2 Fig. 4.35: Laying and hooking collectors Danger! Risk of burns and scalding! 1 In the event of solar radiation inside the units, collectors can reach 200 °C. ▶ Avoid working in direct sunlight. ▶ Cover the collectors before starting work. ▶ You should preferably perform the work Fig. 4.33: Installing mounting rails 2. Use the clamping elements to secure the top and lower mounting rail for the first collector to the roof brackets ((1) and (2)). 3. Position the lower rail as far as possible downwards on the roof brackets. 0020100571_00 auroTHERM, auroTHERM plus Installation manual in the morning. ▶ Wear suitable safety gloves. 8. Lay the lower edge of the first collector in the lower mounting rail and hook it in at the clamping elements (1). 27 4 On-roof fitting and installation 9. Ensure that the top clamping block of the clamping element is positioned above the edge of the collector. 10. Tighten the clamping elements of the lower mounting rail. Installing the next collector Conditions: Not all collectors of a column have been installed yet. Working materials 2 SW 13 spanner Positioning the top mounting rail 1 Fig. 4.37: Mounting rails between two collectors ▶ ▶ Fig. 4.36: Positioning the top mounting rail 11. Slide the top mounting rail until it is flush with the collector. 12. Ensure that the edge of the mounting rail grips around the collector. ▶ Repeat all installation steps with the next higher collector. Ensure that both mounting rails are installed between the collectors as shown in the illustration ((1) and (2)). Ensure that the clamping blocks between the collectors grip around both mounting rails. Fitting connectors Conditions: The last installed collector is not the top collector of a column. ▶ ▶ Slide the appropriate clamping elements onto the mounting rail (I). Ensure that the clamping block of the clamping elements lies over the collector edge. A 1 Conditions: The last installed collector is the top collector of a column. ▶ ▶ Slide the appropriate clamping elements onto the mounting rail (II). Ensure that the clamping block of the clamping elements lies over the collector edge. B Fig. 4.38: Fitting connectors 13. Connect the collectors with the pipe connectors (1). Caution. Risk of damage to the collector. Improper installation of the pipe connectors may damage the collector. ▶ Ensure that the clamps (A) slide into the grooves of the pipe connector (B). 14. Secure the pipe connectors with the clamps. Completing installation of the collectors 15. Tighten all remaining clamping elements. Working materials SW 13 spanner 28 Installation manual auroTHERM, auroTHERM plus 0020100571_00 On-roof fitting and installation 4 16. Check for proper tensioning by shaking the clamping blocks. 17. If a clamping block can be moved, tighten the nut again. Conditions: Number of collectors: 1 … 5 1 4.2.3 Installing hydraulic connections Caution. Lack of tightness due to incorrect accessories. 2 Incorrect accessories may result in lack of tightness of the solar circuit and cause material damage. ▶ Only work in the solar circuit with hard soldered connections, flat seals, compression fittings or press fittings which have been approved by the manufacturer for use in solar circuits and at correspondingly high temperatures. The hydraulic connections must be installed differently according to the array configuration of the collectors (adjacent or on top of each other). 4.2.3.1 1. nAdjacent array configuration Fig. 4.39: Installing the flow/return and collector sensor ▶ ▶ ▶ ▶ ▶ ▶ ▶ Connect the flow (outlet with opening for collector sensor) at the top (1). Secure the flow with the clamp (1). Remove the red plug from the opening for the collector sensor. Insert the VR 11 collector sensor into the opening (1). Use a cable tie to secure the VR 11 collector sensor against slipping out. Connect the return (inlet) at the bottom (2). Secure the return with the clamp (2). 4 Install the hydraulic connections on the collectors, as specified in the following sections. Note If you connect six or more collectors one behind the other, you must arrange the hydraulic connections diagonally in order to force complete flow. If you connect six or more collectors one behind the other, you must arrange the hydraulic connections diagonally in order to force complete flow. (→ Page 14) 3 Fig. 4.40: Installing plugs with vent openings ▶ ▶ ▶ ▶ 0020100571_00 auroTHERM, auroTHERM plus Installation manual Install the two plugs with vent openings on the other side of the collector field at the top and bottom of the collector ((3) and (4)). Secure the two plugs with the clamps ((3) and (4)). Connect the collector flow and return to the system with the connection pipes. Check the connections for tightness. 29 4 On-roof fitting and installation Conditions: Number of collectors: ≥ 6 4.2.3.2 1 u Array configuration on top of each other 1 2 2 Fig. 4.41: Installing the return and the first plug ▶ ▶ ▶ ▶ Insert the return (inlet) on one side in the lower lateral opening (2). Secure the return with the clamp (2). Install the first plug with vent opening at the top lateral opening (1). Secure the first plug with the clamp (1). 4 Fig. 4.43: Installing the flow, return and collector sensor 1. Connect the flow (outlet) at the top collector (1). 2. Remove the red plug from the opening for the collector sensor. 3. Insert the VR 11 collector sensor into the opening (1). 4. Use a cable tie to secure the collector sensor VR 11 against slipping out. 5. Secure the flow with the clamp (1). 6. Connect the return (inlet) at the lower collector (2). 7. Secure the return with the clamp (2). 1 3 2 Fig. 4.42: Installing the flow, second plug and collector sensor ▶ ▶ ▶ ▶ ▶ ▶ ▶ ▶ ▶ 30 Insert the flow (outlet with opening for collector sensor) diagonally opposite into the top lateral opening (4). Secure the flow with the clamp (4). Remove the red plug from the opening for the collector sensor. Insert the VR 11 collector sensor into the opening (4). Use a cable tie to secure the VR 11 collector sensor against slipping out. Install the second plug with vent opening at the lower lateral opening (3). Secure the second plug with the clamp (3). Connect the collector flow and return to the system with the connection pipes. Check the connections for tightness. Fig. 4.44: Installing plugs with vent openings 8. At the opposite side of each collector, install the two plugs with the vent openings (1) and (2). 9. Secure all four plugs with the clamps (1) and (2). 10. Connect the collector flow and return to the system with the connection pipes. 11. Check the connections for tightness. Installation manual auroTHERM, auroTHERM plus 0020100571_00 On-roof fitting and installation 4 4.3 Completing and checking the installation 4.3.1 Using the customer service card 1. Remove the packaging with the serial number sticker from the transport packaging of the collector. 2. Remove the serial number sticker from the packaging. Fig. 4.45: Serial number sticker for customer service card 2. auroTHERM auroTHERM auroTHERM auroTHERM auroTHERM auroTHERM M M M auroTHER auroTHER M M auroTHER auroTHER 1. auroTHER M auroTHER 3. Remove the customer service card from the hydraulic installation set. 4. 3. 1 2 3 4 5 6 Fig. 4.46: Customer service card 4. Stick the sticker onto the first field in the customer service card. 5. Secure the customer service card in an easily visible place near the solar system cylinder. 0020100571_00 auroTHERM, auroTHERM plus Installation manual 31 4 On-roof fitting and installation 4.3.2 Checking the installation Use the following checklist to ensure that all work steps have been performed. Note After initial start-up, and in seasons with significant ambient temperature fluctuations, condensate may form in the collector. This is normal. Note Reflections caused by irregularities of the glass are typical of the material. Operations Yes No All hydraulic connections secured with clamps ☐ ☐ Hydraulic connections routed correctly ☐ ☐ Collector sensor VR 11 connected ☐ ☐ All clamping elements tightened ☐ ☐ Collectors connected to lightning protection device (Optionally for lightning protection device) ☐ ☐ Pressure testing performed (Ideally with compressed air) ☐ ☐ ☐ ☐ All connections tight Date All installation work has been performed correctly. 32 Comments Signature ˍˍ.ˍˍ.ˍˍˍˍ Installation manual auroTHERM, auroTHERM plus 0020100571_00 On-roof fitting and installation 4 4.3.3 Disposing of the packaging The transport packaging consists largely of recyclable materials. ▶ ▶ Observe the applicable regulations. Dispose of the transport packaging properly. 0020100571_00 auroTHERM, auroTHERM plus Installation manual 33 5 Flat roof fitting and installation 5 ▶ Flat roof fitting and installation When fitting and installing the collectors, you must observe the chapter "Safety". 5.1 Preparing for fitting and installation 5.1.1 Delivery, transport and positioning 5.1.1.1 Storing collectors ▶ To prevent moisture from penetrating into the collector, always store the collectors dry and in a weatherproof area. 34 Installation manual auroTHERM, auroTHERM plus 0020100571_00 Flat roof fitting and installation 5 5.1.1.2 Checking the scope of delivery 1 2 12 3 11 4 10 9 5 6 8 7 Fig. 5.1: Installation set for flat roof installation (here: vertical collector) List of materials for flat roof installation 1 Rail mounting set, vertical 2 pc. Rail mounting set, horizontal 2 pc. 2 Flow (outlet with opening for collector sensor) from set of hydraulic connections 1 pc. 3 Frame set, vertical base 1 pc. 4 Frame set, horizontal base 1 pc. 5 Load plates from load plate set 1 pc. 6 Clamp from hydraulic connections set 4 pc. 7 Hydraulic connections from hydraulic extension set 2 pc. 8 Return (inlet) from hydraulic connections set 1 pc. ▶ 9 10 11 12 Clamp from hydraulic connections set 4 pc. Top and bottom plugs (with vent opening) from set of hydraulic connections 2 pc. Rail connector from frame set auroTHERM VFK 145 V collector 1 pc. auroTHERM VFK 145 H collector 1 pc. auroTHERM VFK 150 V collector 1 pc. auroTHERM VFK 150 H collector 1 pc. auroTHERM VFK 155 V collector 1 pc. auroTHERM VFK 155 H collector 1 pc. Use the image to check that the installation sets are complete. 0020100571_00 auroTHERM, auroTHERM plus Installation manual 35 5 Flat roof fitting and installation 5.1.1.3 Transporting collectors Conditions: Number of collectors: 6 … 12 1. To protect the collectors against damage, always transport them horizontally. 2. Transport the collectors to the roof using suitable aids. 5.1.2 1 Complying with clearances and installation clearances 2 ... 11 12 During storms, strong wind forces occur along the edges of flat roofs. ▶ When defining the installation position, maintain an edge clearance of at least 1 m from the roof edge. Fig. 5.4: Series switching 6 - 12 collectors (shown here: vertical collector) ▶ 5.1.3 ▶ Selecting suitable connection Select the appropriate connection for the collectors. 1 2 3 To guarantee a complete flow through the collector field, arrange the hydraulic connections diagonally. Conditions: Number of collectors: ≥ 13 4 1 2 ... 6 7 8 9 ... 13 14 Fig. 5.2: Flow direction (illustrated here: vertical collector) ▶ ▶ For the hydraulic connection of the collectors, select one of the four variants shown in the illustration. Ensure that the solar fluid always flows through the collectors from the bottom to the top. Fig. 5.5: Parallel switching (shown here: vertical collector) Conditions: Number of collectors: 1 … 5 1 ... 4 5 ▶ ▶ ▶ ▶ ▶ Fig. 5.3: Series switching 1 - 5 collectors (shown here: vertical collector) ▶ Always connect as many collectors as possible in series. Set up several parallel collector rows. Connect the collector rows hydraulically in parallel. To avoid pressure losses in the sub-collector fields, only use parallel connection for collector rows with the same number of collectors. Ensure that each sub-collector field has the same total pipe length in the flow and return (Tichelmann system), in order to avoid pressure losses in the connection pipes. Configure the hydraulic connections on top of each other on one side. 36 Installation manual auroTHERM, auroTHERM plus 0020100571_00 Flat roof fitting and installation 5 5.1.4 Preparing the roof duct Caution. Lack of tightness due to destruction of the roof skin. In the event of destruction of the roof skin, water may penetrate the building. ▶ Ensure adequate protection of the roof ▶ ▶ ▶ skin during installation on roof sealing surfaces. Place large-area building protection mats underneath the installation system. After installation, check the tightness of the building shell where there are directly connected racks. Commission a roofer to prepare the roof duct. 5.1.5 Selecting the installation variant C B A Fig. 5.6: Flat roof installation variants ▶ Make a selection from the three available installation variants: Installation variants Meaning A Floating installation with load plates and load weights. B Floating installation without load plates. The rack must be screwed onto suitable load weights. C Rack screwed directly onto the roof. Table 5.1: Flat roof installation variants 0020100571_00 auroTHERM, auroTHERM plus Installation manual 37 5 Flat roof fitting and installation 5.1.6 ▶ Putting together components Use the following table to put together the components for installation. Collector position Number of collectors: 1 2 3 Components 4 5 2 3 4 5 6 Hydraulic installation set 8 9 10 7 8 9 10 11 5 6 7 8 9 1 Hydraulic connection set − 1 2 Horizontal rack 2 3 Horizontal rail, aluminium 1 2 Load plate set (optional) 2 Hydraulic connection set 3 4 4 5 6 7 8 9 10 11 3 4 5 6 7 8 9 10 3 4 5 6 7 8 9 10 11 − 1 2 3 4 5 6 7 8 9 Vertical rack 2 3 4 5 6 7 8 9 10 11 Vertical rail, aluminium 1 2 3 4 5 6 7 8 9 10 Hydraulic installation set Vertical 7 Required quantity Load plate set (optional) Horizontal 6 1 Table 5.2: Components for flat roof installation 5.1.7 Determining the ballast load (floating installation) Danger! Risk of death and material damage due to excessive basic wind speeds! The racks are designed for basic wind speeds of up to 108 km/h. If the basic wind speed at the site is greater than 108 km/h, then there can be no guarantee claim for the system. ▶ Only install the rack in locations where the basic wind speed is a maximum of 108 km/h. 1. Please note the following for floating installation: Installation variants Please note Weights that are firmly screwed onto the rack must consist of material capable of screw connections. B A and B All weights must be weatherproof. Table 5.3: Properties of the weights 2. For detailed determination of the basic wind speed at the site and the required weights for the rack, use the Vaillant tool for dimensioning the wind and snow loads. 3. For quick determination of the basic wind speed at the site, use the following map. 4. For quick dimensioning of the required weights, use the following tables. Note The map and tables are used for quick dimensioning of the ballast loads. Detailed dimensioning of the ballast loads is only possible using the Vaillant tool for dimensioning the wind and snow loads. If you have any questions on this subject, please contact your responsible Vaillant sales partner. 38 Installation manual auroTHERM, auroTHERM plus 0020100571_00 GR MK AL ME BA IT SI AT > 108 km/h < 108 km/h < 99 km/h < 90 km/h < 81 km/h < 72 km/h PT ES IE IS AD GB FR BE NL CH LU DE DK NO CZ HR SE HU SK PL RS LT RO BG LV FI EE BY MD UA RU TR Flat roof fitting and installation 5 Fig. 5.7: Basic wind speeds according to site 5. Use the map to determine the basic wind speed at the site. 0020100571_00 auroTHERM, auroTHERM plus Installation manual 39 5 Flat roof fitting and installation L2 L1 Fig. 5.8: Front (L1) and rear (L2) weights 6. Use the tables to determine the required weights. Horizontal collector position Installation angle 30° Weights/rack [kg] To secure against sliding and lifting To secure only against lifting (if secured/anchored against sliding) Building height Building height L2 L1 Basic wind speed [km/h] Position up to 10 m 10-18 m 18-25 m up to 10 m 10-18 m 18-25 m up to 72 Inland L₁ L₂ 286 184 359 235 407 269 30 184 38 235 45 269 up to 72 Coast and islands L₁ L₂ 392 259 461 307 505 345 43 259 53 307 59 338 up to 81 Inland L₁ L₂ 339 221 445 296 515 345 35 221 50 296 61 345 up to 81 Coast and islands L₁ L₂ 499 334 588 396 643 435 58 334 71 396 79 435 up to 90 Inland L₁ L₂ 445 296 550 370 621 419 50 296 66 370 76 419 up to 90 Coast and islands L₁ L₂ 586 395 691 469 762 518 71 395 86 469 96 518 up to 99 Inland L₁ L₂ 550 370 656 444 762 518 66 370 81 444 96 518 up to 99 Coast and islands L₁ L₂ 727 494 833 568 903 617 91 494 107 568 117 617 up to 108 Inland L₁ L₂ 656 444 797 543 903 617 81 444 101 543 117 617 up to 108 Coast and islands L₁ L₂ 868 593 974 667 1079 741 112 593 127 667 142 741 Table 5.4: Weights for horizontal collector position, installation angle 30° 40 Installation manual auroTHERM, auroTHERM plus 0020100571_00 Flat roof fitting and installation 5 Horizontal collector position Installation angle 45° Weights/rack [kg] To secure against sliding and lifting To secure only against lifting (if secured/anchored against sliding) Building height Building height L2 L1 Basic wind speed [km/h] Position up to 10 m 10-18 m 18-25 m up to 10 m 18-25 m 18-25 m up to 72 Inland L₁ L₂ 299 213 372 274 421 314 30 191 30 242 30 276 up to 72 Coast and islands L₁ L₂ 406 301 476 359 521 396 30 265 30 315 30 346 up to 81 Inland L₁ L₂ 352 257 495 345 531 404 30 228 30 303 30 352 up to 81 Coast and islands L₁ L₂ 515 391 604 464 661 510 30 341 30 404 30 443 up to 90 Inland L₁ L₂ 459 345 566 433 638 492 30 303 30 377 30 427 up to 90 Coast and islands L₁ L₂ 602 462 709 550 781 609 30 402 30 477 30 526 up to 99 Inland L₁ L₂ 566 433 673 521 781 609 30 377 30 452 30 526 up to 99 Coast and islands L₁ L₂ 745 579 852 667 923 726 30 502 30 576 30 626 up to 108 Inland L₁ L₂ 673 521 816 638 923 726 30 452 30 551 30 626 up to 108 Coast and islands L₁ L₂ 888 697 995 785 1102 873 30 601 30 675 30 750 Table 5.5: Weights for horizontal collector position, installation angle 45° 0020100571_00 auroTHERM, auroTHERM plus Installation manual 41 5 Flat roof fitting and installation Horizontal collector position Installation angle 60° Weights/rack [kg] To secure against sliding and lifting To secure only against lifting (if secured/anchored against sliding) Building height Building height L2 L1 Basic wind speed [km/h] Position up to 10 m 10-18 m 18-25 m up to 10 m 10-18 m 18-25 m up to 72 Inland L₁ L₂ 268 297 334 377 378 430 30 196 37 247 45 281 up to 72 Coast and islands L₁ L₂ 365 414 430 491 474 539 43 271 54 320 62 351 up to 81 Inland L₁ L₂ 316 355 413 472 484 550 33 233 52 308 64 357 up to 81 Coast and islands L₁ L₂ 468 532 557 630 613 691 61 346 76 408 85 448 up to 90 Inland L₁ L₂ 413 472 519 589 590 667 52 308 70 382 82 432 up to 90 Coast and islands L₁ L₂ 555 628 661 744 731 822 76 407 94 481 106 531 up to 99 Inland L₁ L₂ 519 589 625 705 731 822 70 382 88 456 106 531 up to 99 Coast and islands L₁ L₂ 696 783 802 900 873 978 100 506 118 580 130 630 up to 108 Inland L₁ L₂ 625 705 767 861 873 978 88 456 112 556 130 630 up to 108 Coast and islands L₁ L₂ 838 939 944 1056 1050 1172 124 605 142 680 160 754 Table 5.6: Weights for horizontal collector position, installation angle 60° 42 Installation manual auroTHERM, auroTHERM plus 0020100571_00 Flat roof fitting and installation 5 Vertical collector position Installation angle 30° Weights/rack [kg] To secure against sliding and lifting To secure only against lifting (if secured/anchored against sliding) Building height Building height L2 L1 Basic wind speed [km/h] Position up to 10 m 10-18 m 18-25 m up to 10 m 10-18 m 18-25 m up to 72 Inland L₁ L₂ 301 167 378 213 429 244 44 167 40 213 70 244 up to 72 Coast and islands L₁ L₂ 413 234 487 279 534 307 67 234 81 279 90 307 up to 81 Inland L₁ L₂ 357 201 469 268 544 313 56 201 78 268 92 313 up to 81 Coast and islands L₁ L₂ 527 303 621 359 680 395 89 303 108 359 119 395 up to 90 Inland L₁ L₂ 469 268 581 335 656 380 78 268 100 335 115 380 up to 90 Coast and islands L₁ L₂ 619 358 731 425 806 470 107 358 129 425 144 470 up to 99 Inland L₁ L₂ 581 335 694 403 806 470 100 335 122 403 144 470 up to 99 Coast and islands L₁ L₂ 768 448 881 515 955 560 137 448 159 515 174 560 up to 108 Inland L₁ L₂ 694 403 843 492 955 560 122 403 152 492 174 560 up to 108 Coast and islands L₁ L₂ 918 537 1030 605 1143 672 166 537 188 605 211 672 Table 5.7: Weights for vertical collector position, installation angle 30° 0020100571_00 auroTHERM, auroTHERM plus Installation manual 43 5 Flat roof fitting and installation Vertical collector position Installation angle 45° Weights/rack [kg] To secure against sliding and lifting To secure only against lifting (if secured/anchored against sliding) Building height Building height L2 L1 Basic wind speed [km/h] Position up to 10 m 10-18 m 18-25 m up to 10 m 10-18 m 18-25 m up to 72 Inland L₁ L₂ 321 191 401 245 454 281 30 173 30 220 30 251 up to 72 Coast and islands L₁ L₂ 437 270 513 321 562 354 30 241 30 286 30 314 up to 81 Inland L₁ L₂ 379 230 495 309 572 361 30 207 30 275 30 320 up to 81 Coast and islands L₁ L₂ 555 350 652 415 713 4547 30 310 30 366 30 402 up to 90 Inland L₁ L₂ 495 309 611 388 688 440 30 275 30 342 30 388 up to 90 Coast and islands L₁ L₂ 650 414 766 493 843 545 30 365 30 433 30 478 up to 99 Inland L₁ L₂ 611 388 727 466 843 545 30 342 30 410 30 478 up to 99 Coast and islands L₁ L₂ 804 519 920 598 998 650 30 455 30 523 30 568 up to 108 Inland L₁ L₂ 727 466 882 571 998 650 30 410 30 500 30 568 up to 108 Coast and islands L₁ L₂ 959 624 1075 703 1191 781 30 546 30 613 34 681 Table 5.8: Weights for vertical collector position, installation angle 45° 44 Installation manual auroTHERM, auroTHERM plus 0020100571_00 Flat roof fitting and installation 5 Vertical collector position Installation angle 60° Weights/rack [kg] To secure against sliding and lifting To secure only against lifting (if secured/anchored against sliding) Building height Building height L2 L1 Basic wind speed [km/h] Position up to 10 m 10-18 m 18-25 m up to 10 m 10-18 m 18-25 m up to 72 Inland L₁ L₂ 297 267 372 339 421 387 30 179 30 225 37 256 up to 72 Coast and islands L₁ L₂ 406 372 477 441 522 485 30 246 30 291 35 325 up to 81 Inland L₁ L₂ 352 319 460 424 532 494 30 212 30 280 37 325 up to 81 Coast and islands L₁ L₂ 516 479 607 566 664 621 35 315 45 372 52 407 up to 90 Inland L₁ L₂ 460 424 568 529 641 599 30 280 41 348 49 393 up to 90 Coast and islands L₁ L₂ 604 564 713 669 785 739 45 370 58 438 67 483 up to 99 Inland L₁ L₂ 568 529 677 634 785 739 41 348 54 415 67 483 up to 99 Coast and islands L₁ L₂ 749 704 857 809 930 879 62 461 75 528 84 573 up to 108 Inland L₁ L₂ 677 634 821 774 930 879 54 415 71 506 84 573 up to 108 Coast and islands L₁ L₂ 893 844 1002 949 1110 1054 80 551 92 619 105 686 Table 5.9: Weights for vertical collector position, installation angle 60° 0020100571_00 auroTHERM, auroTHERM plus Installation manual 45 5 Flat roof fitting and installation Defining the rack clearances B 5.1.8 C A F E C D Fig. 5.9: Rack clearances ▶ Define the rack clearances. 30° Number of collectors Vertical Horizontal 1) A 1 970 2 2200 3 3463 4 4726 5 5989 6 7252 7 8515 8 9778 9 11041 10 12304 1 1770 2 3800 3 5863 4 7926 5 9989 6 12052 7 14115 8 16178 9 18241 10 20304 B 45° F 1) B 60° F 1) B F 1) C D E − − − 1280 2927 1731 3666 2065 4019 2034 1100 − 1263 − − 881 1897 1165 2276 1373 2446 1304 1900 2063 Dimension applies to 20° position of the sun and must be checked according to the geographical location. Table 5.10: Rack clearances 46 Installation manual auroTHERM, auroTHERM plus 0020100571_00 Flat roof fitting and installation 5 5.2 Carrying out the installation Specifications/technical data 5.2.1 Installing racks Installation angle – 30° – 45° – 60° Danger! Risk of death due to falling collectors! Unsecured collectors may fall from the flat roof due to the wind and present a danger to persons. 1 ▶ Perform the following safety precau- tions according to the installation type. ▶ For direct connection, screw the rack ▶ ▶ 1. properly onto the base. Only use suitable load weights. Observe the required ballast load of the load weights. Determine the required number of racks. Specifications/technical data For the first collector Two racks For each additional collector One additional rack 2 Fig. 5.12: Setting the installation angle 4. Push the locking button (1) on the telescopic rail. 5. Pull the telescopic rail (2) into the desired installation angle and allow the locking button to engage again. 2 3 1 1 Fig. 5.13: Fixing crossbeams in the telescopic rail Fig. 5.10: Folding out the rack 2. Fold out the first rack. 60° 45° 30° 6. Position the crossbeams (1) such that their fastening holes lie between the corresponding threaded holes in the telescopic rail. 7. To secure the rack, insert the fixing screw (2) through all rails. 8. Secure the fixing screw (2) with the self-locking nuts (3). 9. Tighten the nuts. Fig. 5.11: Selecting the installation angle 3. Select the required installation angle. 0020100571_00 auroTHERM, auroTHERM plus Installation manual 47 5 Flat roof fitting and installation Conditions: Type of installation: Direct mounting Fig. 5.14: Rack for direct mounting Screwing on the rack Conditions: Type of installation: Floating installation (with load plates) Fig. 5.15: Rack for installation with load plates Preparing load plates Caution. Lack of tightness due to destruction of the roof skin. In the event of destruction of the roof skin, water can penetrate the building. ▶ Check the tightness of the roof skin after tightening screw connections. ▶ Restore the tightness of the roof skin if necessary. ▶ ▶ ▶ ▶ Define the required rack clearances as described in the chapter "Defining rack clearances". Drill the required holes at the defined positions. Secure the rack with fastenings appropriate to the base (diameter: at least 10 mm). Mount as many racks as you need to hold the collectors. Caution. Lack of tightness due to destruction of the roof skin. In the event of destruction of the roof skin, water may penetrate the building. ▶ Ensure adequate protection of the roof skin during installation on roof sealing surfaces. ▶ Place large-area, non-slip building protection mats underneath the installation system. ▶ If the roof is covered with gravel, remove the gravel at the places where you wish to position the load plates, and use non-slip building protection mats to protect the roof skin. Fig. 5.16: Connecting two load plates ▶ ▶ 48 Connect two load plates as shown in the illustration. Connect two additional load plates as shown in the illustration. Installation manual auroTHERM, auroTHERM plus 0020100571_00 Flat roof fitting and installation 5 Note For each rack, you will need four load plates: one pair each for the front and rear rack feet. ▶ Align the load plates approximately in their final position on the flat roof. Fig. 5.19: Rack installed on load plates ▶ ▶ Note For one collector, you will need two racks. For each additional adjacent collector, you will need an additional rack. Fig. 5.17: Inserting and fixing hammer-head bolt ▶ ▶ ▶ Insert the first hammer-head bolt centrally in the groove between the first two load plates. To secure the hammer-head bolt, turn it by 90° in a clockwise direction. Secure the second hammer-head bolt in the same way between the other two load plates. 3 Install the second rack on the load plates as described above. Mount as many racks and load plates as you need to hold the collectors. 1 Fig. 5.20: Three racks aligned to hold two collectors ▶ 2 Fig. 5.18: Screwing the rack onto load plates ▶ Align all racks with the load plates in their final position on the flat roof. The rack clearances can be found in the chapter "Defining rack clearances". Screwing the rack onto load plates and aligning ▶ ▶ ▶ ▶ ▶ Take hold of the first rack already secured in the installation angle. Position the front rack feet above the hammer-head bolt (1). When positioning the rack feet, ensure that the antirotation lock (2) engages. Secure the rack feet with the self-locking nut (3). Secure the rear rack feet in the same way on the other two load plates. ◁ The first rack is installed so that it is stable. 0020100571_00 auroTHERM, auroTHERM plus Installation manual 49 5 Flat roof fitting and installation Fig. 5.21: Load weights on load plates Placing load weights on load plates ▶ ▶ ▶ ▶ Transport the required number of loading weights to the flat roof. Place the load weights on the load plates as shown above. Ensure that the distance between the loading weights and the racks is as small as possible. Danger! Risk of death due to inadequate fastening of the load weights onto the load plates! If the load weights are inadequately secured on the load plates, collectors could fall from the roof and cause life-threatening accidents. ▶ Secure all load weights on the load plates adequately against slipping and tilting. ▶ Fig. 5.22: Rack for installation on weights Define the required rack clearances as described in the chapter "Defining rack clearances". Note For each rack, you need two equal weights. For the first collector, you therefore need four weights. For each additional collector, you will need an additional rack. ▶ ▶ Transport the required number of weights to the flat roof. Lay the weights in the final positions of the installation site. Note The four weights for holding two racks for a collector are very heavy. Therefore, it is advisable to determine the final position and orientation of the weights before screwing on the rack and laying the weights there. Distribute the load weights evenly over the load plates. Conditions: Type of installation: Floating installation (without load plates) Preparing weights ▶ ▶ Select a suitable fastening material for the weights used (diameter: at least 10 mm). Drill a hole into the centre of each weight. Caution. Lack of tightness due to destruction of the roof skin. In the event of destruction of the roof skin, water may penetrate the building. ▶ Ensure adequate protection of the roof skin during installation on roof sealing surfaces. ▶ Place large-area, non-slip building protection mats underneath the installation system. ▶ 50 If the roof is covered with gravel, remove the gravel at the places where you wish to position the weights, and use non-slip building protection mats to protect the roof skin. Installation manual auroTHERM, auroTHERM plus 0020100571_00 Flat roof fitting and installation 5 5.2.2 Installing collectors 5 mm Allen key Danger! Personal injury and material damage due to a falling collector. Improper fastening may cause a collector to fall. Fig. 5.23: Screwing the rack onto a weight ▶ Tighten the clamping elements. ▶ Check for proper tensioning by shaking Screwing the rack onto weights ▶ ▶ ▶ the clamping blocks. Take hold of the first rack that is already secured in the installation angle. Screw the front rack feet onto the first weight. Screw the rear rack feet onto the second weight. ◁ The first rack is installed so that it is stable. ▶ If a clamping block is mobile, tighten the nut again. 1. Install the collectors on the roof as specified in the following sections. Sliding on mounting rails 1 2 3 Fig. 5.24: Rack installed on weights ▶ ▶ Install the second rack on the next two weights as described above. Fit as many racks as you need to hold the collectors. 0020100571_00 auroTHERM, auroTHERM plus Installation manual Fig. 5.25: Sliding on mounting rails 2. Slide the two mounting rails (top and bottom) onto the brackets, as shown in the image. 3. Ensure that the open side of the bottom mounting rail is facing upwards and that the open side of the top mounting rail is facing downwards. 4. First slide the mounting rail onto one bracket (1). 5. Slide the mounting rail a little outwards (2). 6. Then slide the mounting rail back to the other bracket (3). 7. Perform these steps one after the other for all racks. 51 5 Flat roof fitting and installation Fitting mounting rails to several racks A Securing the mounting rails at the bottom B 2 50 -2 00 1 Fig. 5.26: Fitting mounting rails to several racks Fig. 5.28: Securing the mounting rails at the bottom 8. When installing several collectors next to each other, allow the mounting rails to end in the centre of the brackets (A). 9. Allow the mounting rails on the first and last rack to protrude 50-200 mm over the edge (B). 12. Screw the brackets tightly onto the lower mounting rails. Connecting mounting rails Hooking the collector in at the bottom Working materials 5 mm Allen key 1 1 Fig. 5.27: Connecting mounting rails 10. Clamp the rail connector (1) into the mounting rails. 11. Ensure that the rail connector (1) engages in the holes of the mounting rails. Note After installation, the rail connectors are no longer accessible. Fig. 5.29: Hooking the collector in at the bottom Danger! Risk of burns and scalding! In the event of solar radiation inside the units, collectors can reach 200 °C. ▶ Avoid working in direct sunlight. ▶ Cover the collectors before starting work. ▶ You should preferably perform the work in the morning. ▶ Wear suitable safety gloves. 13. Lay the collector with the lower edge in the profile of the mounting rail (1). Ensure that the mounting rail (1) surrounds the lower edge of the collector. 52 Installation manual auroTHERM, auroTHERM plus 0020100571_00 Flat roof fitting and installation 5 Securing the collector at the top Installing additional collectors 1 2 1 A 2 B Fig. 5.30: Securing the collector at the top Fig. 5.32: Installing additional collectors 14. Slide the left side of the top mounting rail (1) until it is flush with the collector. 15. Ensure that the mounting rail (1) surrounds the top edge of the collector. 16. Screw the bracket securely on the top left (2). 21. Position the next collector on the lower mounting rail. 22. Slide the collector to the first collector. Caution. Risk of damage to the collector. Working materials Improper installation of the pipe connectors may damage the collector. 5 mm Allen key 17. Ensure that the mounting rail does not slip while you are tightening the screw. ▶ Ensure that the clamps (A) slide into the grooves of the pipe connector (B). Installing hydraulic connectors 1 A 23. Secure the top and bottom hydraulic connectors with the clamps ((1) and (2)). 24. Slide the second top mounting rail until it is flush with the collector. 25. Screw the second top mounting rail tightly onto the mounting rail of the first collector using the corresponding bracket. 2 B Working materials 5 mm Allen key Completing collector rows Conditions: Not all collectors in a row have been installed yet. Fig. 5.31: Installing hydraulic connectors ▶ ▶ Install the hydraulic connectors. (→ Page 53) Install an additional collector. (→ Page 53) Caution. Risk of damage to the collector. Improper installation of the pipe connectors may damage the collector. ▶ Ensure that the clamps (A) slide into the grooves of the pipe connector (B). 18. Remove the delivery plugs from the mounting openings. 19. Insert the top (1) and bottom (2) pipe connectors into the mounting openings until the stop. 20. Slide the clamps into the rails of the mounting openings (2). 0020100571_00 auroTHERM, auroTHERM plus Installation manual 53 5 Flat roof fitting and installation 5.2.3 Installing hydraulic connections 1 Caution. Lack of tightness due to incorrect accessories. Incorrect accessories may result in lack of tightness of the solar circuit and cause material damage. 2 ▶ Only work in the solar circuit with hard soldered connections, flat seals, compression fittings or press fittings which have been approved by the manufacturer for use in solar circuits and at correspondingly high temperatures. Fig. 5.34: Installing plugs with vent openings ▶ 1. Install the hydraulic connections on the collectors, as specified in the following sections. Note If you connect six or more collectors one behind the other, you must arrange the hydraulic connections diagonally in order to force complete flow. (→ Page 14) ▶ ▶ ▶ Install the two plugs with vent openings on the other side of the collector field at the top and bottom of the collector ((1) and (2)). Secure the two plugs with the clamps ((1) and (2)). Connect the collector flow and return to the system with the connection pipes. Check the connections for tightness. Conditions: Number of collectors: ≥ 6 Conditions: Number of collectors: 1 … 5 1 1 2 2 Fig. 5.35: Installing the return and the first plug ▶ Fig. 5.33: Installing the flow/return and collector sensor ▶ ▶ ▶ ▶ ▶ ▶ ▶ 54 Connect the flow (outlet with opening for collector sensor) at the top (1). Secure the flow with the clamp (1). Remove the red plug from the opening for the collector sensor. Insert the VR 11 collector sensor into the opening (1). Use a cable tie to secure the VR 11 collector sensor against slipping out. Connect the return (inlet) at the bottom (2). Secure the return with the clamp (2). ▶ ▶ ▶ Insert the return (inlet) on one side into the lower lateral opening (2). Secure the return with the clamp (2). Install the first plug with vent opening at the top lateral opening (1). Secure the first plug with the clamp (1). Installation manual auroTHERM, auroTHERM plus 0020100571_00 auroTHERM auroTHERM auroTHERM auroTHERM auroTHERM auroTHERM M M auroTHER auroTHER 2. M M auroTHER auroTHER 1. auroTHER M auroTHER 1 M Flat roof fitting and installation 5 4. 3. 2 1 2 3 4 5 6 Fig. 5.36: Installing the flow, second plug and collector sensor ▶ ▶ ▶ ▶ ▶ ▶ ▶ ▶ ▶ Insert the flow (outlet with opening for collector sensor) diagonally opposite into the top lateral opening (1). Secure the flow with the clamp (1). Remove the red plug from the opening for the collector sensor. Insert the VR 11 collector sensor into the opening (1). Use a cable tie to secure the VR 11 collector sensor against slipping out. Install the second plug with vent opening at the lower lateral opening (2). Secure the second plug with the clamp (2). Connect the collector flow and return to the system with the connection pipes. Check the connections for tightness. Fig. 5.38: Customer service card 5.3 Completing and checking the installation 5.3.1 Using the customer service card 4. Stick the sticker onto the first field in the customer service card. 5. Secure the customer service card in an easily visible place near the solar system cylinder. 1. Remove the packaging with the serial number sticker from the transport packaging of the collector. 2. Remove the serial number sticker from the packaging. Fig. 5.37: Serial number sticker for customer service card 3. Remove the customer service card from the hydraulic installation set. 0020100571_00 auroTHERM, auroTHERM plus Installation manual 55 5 Flat roof fitting and installation 5.3.2 Checking installation Use the following checklist to ensure that all work steps have been performed. Note After initial start-up, and in seasons with significant ambient temperature fluctuations, condensate may form in the collector. This is normal. Note Reflections caused by irregularities of the glass are typical of the material. Operations Yes No Building statics taken into account during installation of the system ☐ ☐ Clearances from the roof edge complied with in accordance with the specifications ☐ ☐ Rack positioned in accordance with the dimensions specifications ☐ ☐ All bolts securely tightened (Installation and telescopic rail) ☐ ☐ Adequate ballast weights used (Only for floating installation) ☐ ☐ Load weights adequately secured against slipping and tilting (Only for floating installation) ☐ ☐ Rack anchored and bolts tightened (Only for direct connection) ☐ ☐ All hydraulic connections secured with clamps ☐ ☐ Hydraulic connections routed correctly ☐ ☐ VR 11 collector sensor connected ☐ ☐ Collectors connected to lightning protection device (Optionally for lightning protection device) ☐ ☐ Pressure testing performed (Ideally with compressed air) ☐ ☐ ☐ ☐ All connections tight Date All installation work has been performed correctly. 56 Comments Signature ˍˍ.ˍˍ.ˍˍˍˍ Installation manual auroTHERM, auroTHERM plus 0020100571_00 Flat roof fitting and installation 5 5.3.3 Disposing of the packaging The transport packaging consists largely of recyclable materials. ▶ ▶ Observe the applicable regulations. Dispose of the transport packaging properly. 0020100571_00 auroTHERM, auroTHERM plus Installation manual 57 6 Inspection and maintenance 6 6.1 Inspection and maintenance 6.3 Maintenance plan Danger! Risk of death, injury and material damage due to improper maintenance and repairs! The following table shows the inspection and maintenance work that must be carried out at specific intervals. 6.1.1 General inspection and maintenance instructions Improper maintenance work or repairs can impair the operating safety of the unit and result in material damage and personal injury. Calendar-based maintenance intervals Calendar-based maintenance intervals Interval Maintenance work Page Annually Checking collectors and connections for damage, dirt and lack of tightness 59 Cleaning collectors 59 ▶ Only perform maintenance work and repairs on the collectors if you are a qualified competent person. Checking brackets and collector components for firm seating 59 Check the pipe insulations for damage 59 6.4 Preparing for inspection and maintenance Replacing damaged pipe insulations 59 Disposing of damaged pipe insulations 6.4.1 Spare parts for maintenance 59 Procuring spare parts 6.2 Observing inspection and maintenance intervals Regular inspection/maintenance of the entire solar plant by a competent person is a prerequisite for ensuring that the system is constantly ready for operation, reliable and has a long service life. Vaillant recommends that you sign a maintenance contract. Danger! Risk of death, injury and material damage due to failure to perform maintenance and repairs work! Failure to perform maintenance or repair work, or failure to comply with the specified maintenance intervals, may impair the operating safety of the unit and cause material damage and personal injury. ▶ Instruct the operator to observe the ▶ 58 specified maintenance intervals strictly. Perform maintenance work on the collectors in accordance with the maintenance plan. If you require spare parts for servicing or repair work, use only Vaillant genuine spare parts. The original components of the unit were also certified as part of the CE declaration of conformity. If you do not use certified Vaillant genuine spare parts, this voids the CE conformity of the unit. We therefore strongly recommend that you fit Vaillant genuine spare parts. Replacement parts Applies to: Great Britain An overview of the available genuine Vaillant spare parts can be obtained: – From your parts wholesaler – Alternatively contact Spares Technical Enquiries on 01773 596615 or via email: [email protected] 6.4.2 Preparing for maintenance ▶ Put together all the tools and materials required for the maintenance work. Installation manual auroTHERM, auroTHERM plus 0020100571_00 Inspection and maintenance 6 6.5 Checking collectors and connections for damage, dirt and lack of tightness 1. Check the collectors for damage. If the collectors are damaged: ▶ Replace the collectors. 2. Check the collectors for dirt. If the collectors are dirty: ▶ Clean the collectors. (→ Page 59) 3. Check the connections for lack of tightness. If the connections are not tight: ▶ Seal the leaking connections. (→ Page 60) 6.6 6.7 ▶ Check the firm seating of all threaded connections. If threaded connections are loose: ▶ Tighten the threaded connections. 6.8 ▶ Checking brackets and collector components for firm seating Check the pipe insulations for damage Check the pipe insulations for damage. If the pipe insulations are damaged: ▶ To avoid heat losses, replace any damaged pipe insulations. (→ Page 59) Cleaning collectors Danger! Risk of burns and scalding! In the event of solar radiation inside the units, collectors can reach 200 °C. ▶ Avoid working in direct sunlight. ▶ You should preferably perform the work ▶ ▶ in the morning. Wear suitable safety gloves. Wear suitable protective goggles. Caution. Material damage due to high-pressure cleaner. 6.9 Replacing damaged pipe insulations 1. Put the solar plant temporarily out of operation (→ Page 61). 2. Replace the damaged pipe insulations. 3. Start the solar plant up again. 6.10 Disposing of damaged pipe insulations The pipe insulations consist largely of recyclable materials. The pipe insulations must not be disposed of with normal household waste. ▶ ▶ Observe the applicable regulations. Dispose of the damaged pipe insulations properly. High-pressure cleaners may damage the collectors due to the extremely high pressure. ▶ Never clean the collectors with a highpressure cleaner. Caution. Material damage due to cleaning agent. Cleaning agents may damage the surface structure of the collector and decrease its efficiency. ▶ Never clean the collector with cleaning agents. ▶ Clean the collectors with a sponge and water. 0020100571_00 auroTHERM, auroTHERM plus Installation manual 59 7 Troubleshooting 7 Troubleshooting 7.1 7.2.3 Sealing leaking connections Spare parts for repair Danger! Risk of burns and scalding! Procuring spare parts If you require spare parts for servicing or repair work, use only Vaillant genuine spare parts. In the event of solar radiation inside the units, collectors can reach 200 °C. The original components of the unit were also certified as part of the CE declaration of conformity. If you do not use certified Vaillant genuine spare parts, this voids the CE conformity of the unit. We therefore strongly recommend that you fit Vaillant genuine spare parts. ▶ Avoid working in direct sunlight. ▶ Cover the collectors before starting ▶ ▶ Replacement parts work. You should preferably perform the work in the morning. Wear suitable safety gloves. Applies to: Great Britain 1. An overview of the available genuine Vaillant spare parts can be obtained: – From your parts wholesaler – Alternatively contact Spares Technical Enquiries on 01773 596615 or via email: [email protected] 7.2 Carrying out repairs 7.2.1 Replace leaking collectors Danger! Risk of burns and scalding! In the event of solar radiation inside the units, collectors can reach 200 °C. Put the solar plant temporarily out of operation (→ Page 61). 2. Seal the leaking connections. 3. Start up the solar plant again as described in the operating system instructions. 7.2.4 Replacing defective pipe insulations 1. Put the solar plant temporarily out of operation (→ Page 61). 2. To avoid heat losses, replace any defective pipe insulations. 3. Start up the solar plant again as described in the operating system instructions. 7.2.5 Disposing of defective pipe insulations ▶ Avoid working in direct sunlight. ▶ Cover the collectors before starting The pipe insulations consist largely of recyclable materials. ▶ ▶ ▶ ▶ work. You should preferably perform the work in the morning. Wear suitable safety gloves. The pipe insulations must not be disposed of with normal household waste. Observe the applicable regulations. Dispose of the defective pipe insulations properly. 1. Put the solar plant temporarily out of operation (→ Page 61). 2. Replace the leaking collectors. 3. Start up the solar plant again as described in the operating system instructions. 7.2.2 Disposing of defective collectors Your Vaillant collector consists largely of recyclable materials. The Vaillant collector must not be disposed of with normal household waste. ▶ ▶ Observe the applicable regulations. Dispose of defective Vaillant collectors properly. 60 Installation manual auroTHERM, auroTHERM plus 0020100571_00 Decommissioning 8 8 Decommissioning 8.1 Temporary decommissioning 8.2 Permanently decommissioning 8.2.1 Removing collectors Caution. Damage to the collectors. Danger! Risk of burns and scalding! Collectors that are not in operation may age more rapidly due to long periods of high idle temperatures. In the event of solar radiation inside the units, collectors can reach 200 °C. ▶ Only put the solar plant out of operation ▶ Avoid working in direct sunlight. ▶ Cover the collectors before starting ▶ Do not decommission the collectors for ▶ You should preferably perform the work ▶ Cover any collectors that are not in use. ▶ Wear suitable safety gloves. ▶ Caution. Damage to the collector and the solar plant. if you are a competent person. work. more than four weeks. in the morning. Make sure that the cover is securely fastened. In the event of long periods of decommissioning of the solar plant, dismantle the collectors. Improper removal may cause damage to the collector and to the solar plant. Caution. Oxidation of the solar fluid. ▶ Before removing the collectors, ensure that a competent person or a Vaillant customer service engineer decommissions the solar plant. If the solar circuit is opened when out of service for a prolonged period of time, the solar fluid may age more rapidly due to the penetrating oxygen in the air. ▶ Only decommission the solar plant if you Caution. Environmental hazard due to solar fluid. ▶ After the solar plant is decommissioned, the collector is still filled with solar fluid which can leak out during removal. ▶ ▶ are a competent person. Do not decommission the collectors for more than four weeks. Before decommissioning the system for a prolonged period of time, drain the entire solar plant and dispose of the solar fluid properly. In the event of long periods of decommissioning of the solar plant, dismantle the collectors. For repair or maintenance work, you can temporarily decommission the solar plant. To do this, you must switch off the solar pump. ▶ Temporarily decommission the solar plant, as described in the operating system instructions. ▶ During transport from the roof, seal the pipe connections of the collector with the red plugs. 1. 2. 3. 4. 5. Undo the hydraulic connections. Undo the brackets. Remove the collectors from the roof. Remove the hydraulic connections. Drain the collector fully into a canister through two connections. 6. Close the collector connections. 7. Use adequate packing around the collectors. 8. Dispose of the collectors and the solar fluid. 8.2.2 Recycling and disposal Your Vaillant collector consists largely of recyclable materials. ▶ 0020100571_00 auroTHERM, auroTHERM plus Installation manual Observe the applicable regulations. 61 8 Decommissioning Disposing of collectors You must not dispose of your Vaillant collector or any of its accessories in normal domestic waste. ▶ Dispose of the old unit and any accessories properly. Disposing of solar fluid The solar fluid must not be disposed of with normal household waste. ▶ ▶ Dispose of the solar fluid in compliance with local regulations through an appropriate disposal company. Dispose of packaging that cannot be cleaned in the same way as solar fluid. Uncontaminated packaging can be reused. 62 Installation manual auroTHERM, auroTHERM plus 0020100571_00 Customer service 9 9 Customer service Vaillant Service Applies to: Great Britain To ensure regular servicing, it is strongly recommended that arrangements are made for a Maintenance Agreement. Please contact Vaillant Service Solutions for further details: +44 80 70 606 07 77 0020100571_00 auroTHERM, auroTHERM plus Installation manual 63 10 Technical data 10 Technical data 10.1 Technical data table Unit Absorber type − Dimensions of vertical collectors (L x W x H) mm Dimensions of horizontal collectors (L x W x H) mm Weight Liquid volume Max. permissible operating pressure VFK 145 H/V kg VFK 150 H/V Serpentine horiz./vert. 2033 x 1233 x 80 1233 x 2033 x 80 38 l bar VFK 155 H/V 2.16 (H) 1.85 (V) 10 Shutdown temperature °C Gross area m² 2.51 171 Aperture surface area m² 2.35 172 175 Absorber surface area m² 2.33 Absorber mm Aluminium (vacuum-coated) 0.5 x 1178 x 1978 Coating − High selective (blue) α = 95% ε = 5% Glass covering mm Glass type − Transmission % Back wall insulation mm W/m²K 3.2 Solar safety glass (prismatic structure) Solar safety glass (anti-reflective coating) τ = 91 τ = 96 40 λ = 0.035 Edge insulation − Efficiency η0 % Heat capacity Ws/m²K Heat loss factor (k1) W/m²K 3.32 (H) 2.41 (V) 3.82 (H) 2.33 (V) 3.288 (H) 3.297 (V) Heat loss factor (k2) W/m²K² 0.023 (H) 0.049 (V) 0.018 (H) 0.049 (V) 0.018 (H) 0.017 (V) None Available 80.1 (H) 79.1 (V) 84.2 (H) 83.3 (V) 9700 (H) 8200 (V) Max. wind load kN/m² 1.6 Max. standard snow load kN/m² 5.0 On-roof installation angle ° 15 - 75 Flat roof installation angle ° 30, 45, 60 82.7 (H) 83.2 (V) 7070 Table 10.1: Technical data table 64 Installation manual auroTHERM, auroTHERM plus 0020100571_00 Technical data 10 66,5 1233 1223 1178 80 2033 1100 66,5 Dimensions 5 10.2 1978 Fig. 10.1: Dimensions of horizontal collectors 0020100571_00 auroTHERM, auroTHERM plus Installation manual 65 10 Technical data 80 1223 1233 79 80 5 2033 1875 1978 79 1178 Fig. 10.2: Dimensions of vertical collectors 66 Installation manual auroTHERM, auroTHERM plus 0020100571_00 Index Index H A Hydraulic connections Installation ............................................................................... 29 Installing................................................................................... 54 Applicability Manual .........................................................................................5 Article number .................................................................................5 I Identification plate ........................................................................ 10 B Installation clearances Complying with ................................................................. 14, 36 Ballast load (floating installation) Determining............................................................................. 38 Brackets Checking................................................................................... 59 C CE label ..............................................................................................9 Checklist Installing............................................................................ 32, 56 Clearances Complying with ................................................................. 14, 36 Collector components Checking................................................................................... 59 Collectors Checking................................................................................... 59 Cleaning.................................................................................... 59 Disposal ....................................................................................60 Installing...................................................................... 24, 27, 51 Removing .................................................................................. 61 Replacing..................................................................................60 Storing ................................................................................. 11, 34 Transporting...................................................................... 14, 36 Components Putting together............................................................... 16, 38 Connection Selecting............................................................................. 14, 36 Connection rules..................................................................... 14, 36 Connection schemas.............................................................. 14, 36 Installing Checking............................................................................ 32, 56 Intended use .................................................................................... 8 L Leaking connections Sealing ......................................................................................60 M Maintenance Preparing ................................................................................. 58 Maintenance plan ......................................................................... 58 P Packaging Disposal ..............................................................................33, 57 Pipe insulations Checking................................................................................... 59 Disposal .............................................................................59–60 Replacing...........................................................................59–60 Purpose Unit ............................................................................................. 10 R Rack Defining clearances ............................................................... 46 Installing................................................................................... 47 Customer service.......................................................................... 63 Recycling Collectors .................................................................................. 61 Packaging...........................................................................33, 57 Solar fluid.................................................................................. 61 D Decommissioning........................................................................... 61 Roof bracket Defining edge clearances...................................................... 18 Determining the number....................................................... 18 Connections Checking................................................................................... 59 Sealing ......................................................................................60 Disposal Collectors .................................................................................. 61 Packaging...........................................................................33, 57 Solar fluid.................................................................................. 61 Roof duct Preparing ........................................................................... 14, 37 Documents, other applicable ........................................................5 Scope of delivery Checking..............................................................................12, 35 F Select installation variant, flat roof ......................................... 37 Service............................................................................................. 63 Final work Installing............................................................................ 32, 56 0020100571_00 auroTHERM, auroTHERM plus Installation manual S 67 Index Spare parts Maintenance............................................................................ 58 Troubleshooting .....................................................................60 T Technical data ............................................................................ 64 Dimensions .............................................................................. 65 Type overview ................................................................................ 10 U Unit Purpose ..................................................................................... 10 Use, intended................................................................................... 8 68 Installation manual auroTHERM, auroTHERM plus 0020100571_00 0020100571_00 Vaillant Ltd Trident Close Vaillant House RochesterKent Rochester ME2 4 EZ Telephone +44 16 34 29 23 00 Fax +44 16 34 29 01 66 Please contact Vaillant Service Solutions for further details +44 80 70 606 07 77 [email protected] www.vaillant.co.uk
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