Vaillant auroTHERM plus VFK 155 H Installation Manual Download

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For the competent person

Installation manual

auroTHERM, auroTHERM
plus

VFK 145/2 H/V, VFK 155 H/V

GB, IE

Installation manual

Publisher/manufacturer
Vaillant GmbH

Berghauser Str. 40

D-42859 Remscheid

Telefon 021

‑

Telefax 021

‑

28 10

[email protected]

www.vaillant.de

Summary of Contents for auroTHERM plus VFK 155 H

Page 1: ...on manual auroTHERM auroTHERM plus VFK 145 2 H V VFK 155 H V GB IE Installation manual Publisher manufacturer Vaillant GmbH Berghauser Str 40 D 42859 Remscheid Telefon 021 91 18 0 Telefax 021 91 18 28 10 info vaillant de www vaillant de ...

Page 2: ...reparing for fitting and installation 22 5 2 Carrying out the installation 35 5 3 Completing and checking the installation 41 6 Inspection and maintenance 43 6 1 Maintenance plan 43 6 2 Observing inspection and maintenance intervals 43 6 3 General inspection and maintenance instructions 43 6 4 Preparing for inspection and maintenance 43 6 5 Checking collectors and connections for damage dirt and l...

Page 3: ...y 1 2 3 Risk of death due to falling parts Unsecured collectors can fall from the roof and create a possible danger to people Block off the areas in the fall area below the place of work to a sufficient extent so that people cannot be injured by falling objects Indicate the working area e g with inform ation signs in accordance with the applic able regulations 1 2 4 Risk of injury and material dam...

Page 4: ...m copper cable 1 2 13 Material damage due to overvoltage Overvoltage may damage the solar plant Earth the solar circuit to provide equipoten tial bonding and overvoltage protection Secure earthing pipe clamps to the pipes Bond the earthing pipe clamps to a busbar using 16 mm copper cable 1 2 14 Risk of death and material damage due to contact corrosion For roofs or façade sections made of metals m...

Page 5: ...ance with the rel evant requirements of the Local Authority Building Regulations The Building Regula tions Scotland The Building Regulations Northern Ireland and the relevant recom mendations of the following British Stand ards BS EN 806 Specification for installations inside buildings conveying water for hu man consumption BS 6700 Services supplying water for domestic use within buildings and the...

Page 6: ...s 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 special ised 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 Build...

Page 7: ...specific European guidelines Solar Keymark The collectors have been successfully tested according to the rules and requirements for the Solar Keymark CSTBat CSTBat CSTBat VFK 155 H and VFK 155 V only CSTBat The collectors have been successfully tested according to the rules and requirements for the CSTBat Read the installation manual Information on the identific ation plate Meaning VFK 145 2 H VFK...

Page 8: ...ts Roof bracket type S flat for beaver tail etc from exten sion set on top of each other 2 units 6 Hanger bolt fastening set from the basic set 4 units Hanger bolt fastening set from extension set on top of each other 2 units 7 Hydraulic connections from hydraulic extension set 2 units 8 Clamp from hydraulic extension set 4 units 9 Return inlet from hydraulic connections set 1 unit 10 Top and bott...

Page 9: ...ide Conditions Number of collectors 6 12 1 12 11 2 To guarantee a complete flow through the collector field arrange the hydraulic connections diagonally Conditions Number of collectors 13 1 7 6 2 8 14 13 9 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 ...

Page 10: ...2 type S flat Bracket set 3 hanger bolts Vertical rail anodised 1 2 3 4 5 6 7 8 9 10 Conditions Array configuration On top of each other Use the following table to put together the components for installation Collector position Number of collectors 1 2 3 4 5 6 7 8 9 10 Components Required quantity Horizontal Hydraulic installation set 1 1 Hydraulic connection set 1 Bracket set 1 type P 1 1 Bracket...

Page 11: ...ectors and installation systems 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 Edge and corner areas must not be used as installation areas elang ekurz h b l b Building width h Building height l Building length Calculate the building width w building height h and building length l The values for the ed...

Page 12: ...clearances of the roof brackets Pre installation dimension Finished installation dimension 20 25 mm 4 1 8 2 Array configuration on top of each other Conditions Collector position Horizontal 1245 1220 2500 2480 200 300 1460 1660 Define the clearances of the roof brackets Pre installation dimension Finished installation dimension 20 25 mm 4 2 Carrying out the installation The installation steps and ...

Page 13: ...als 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 5 6 A B 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 gut tering onto the und...

Page 14: ...stalling type S for slate 2 1 1 Define the clearances of the roof brackets Page 12 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 4 3 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 ...

Page 15: ...rface 4 2 2 Installing collectors 4 2 2 1 nAdjacent array configuration 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 moves tighten the nut again 1 Install the collectors on the roof as specified in the fol lowing sect...

Page 16: ...tors into the provided mount ing openings at the side of the previously installed col lector 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 13 Insert the connecting elements laterally into the mount ing rails until you feel them en...

Page 17: ...y configuration on top of each other 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 moves tighten the nut again 1 Install the collectors on the roof as specified in the fol lowing sections Note Mounting rails and clampi...

Page 18: ...ing rail I Ensure that the clamping block of the clamping elements lies over the collector edge Conditions The last installed collector is the top collector of a column Slide the appropriate clamping elements onto the mount ing rail II Ensure that the clamping block of the clamping elements lies over the collector edge Installing the next collector Conditions Not all collectors of a column have be...

Page 19: ...onditions Number of collectors 1 5 1 2 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 ...

Page 20: ...e the return with the clamp 2 2 1 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 tubes 11 Check the connections for tightness 4 3 Completing and checking the installation 4 3 1 Using the customer service card 1 Remove the packagin...

Page 21: ...ctor This is normal Note Reflections caused by irregularities of the glass are typical of the material Operations Yes No Comments 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 performe...

Page 22: ... applicable regulations Dispose of the transport packaging properly 5 Flat roof fitting and installation When fitting and installing the collectors you must ob serve 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 weather...

Page 23: ...he sensor set 4 x clamp 10 Plug from the sensor set 2 x plug 11 Rail connector from the sensor set 2 x connector 12 auroTHERM VFK 145 2 V collector 1 x collector auroTHERM VFK 155 V collector 1 x collector List of materials for flat roof installation for horizontal collectors 1 Rail mounting set horizontal 1 x set 2 Hydraulic connections from the sensor set 2 x connection 4 Frame set horizontal ba...

Page 24: ... Conditions Number of collectors 6 12 1 12 11 2 To guarantee a complete flow through the collector field arrange the hydraulic connections diagonally Conditions Number of collectors 13 1 7 6 2 8 14 13 9 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 fie...

Page 25: ...the installation variant A B C 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 ...

Page 26: ...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 B Weights that are firmly screwed onto the rack must consist of material capable o...

Page 27: ...roTHERM plus Installation manual 27 IS IE SE FI GB BE DE PL CH AT CZ HU SK SI HR BA RS RO BG MK ME TR GR AL NL PT ES FR IT NO DK BY UA MD EE RU LV LT LU AD 72 km h 81 km h 90 km h 99 km h 108 km h 108 km h 5 Use the map to determine the basic wind speed at the site ...

Page 28: ...8 m 18 25 m up to 10 m 10 18 m 18 25 m up to 72 Inland L L 286 184 359 235 407 269 30 184 38 235 45 269 up to 72 Coast and islands L L 392 259 461 307 505 345 43 259 53 307 59 338 up to 81 Inland L L 339 221 445 296 515 345 35 221 50 296 61 345 up to 81 Coast and islands L L 499 334 588 396 643 435 58 334 71 396 79 435 up to 90 Inland L L 445 296 550 370 621 419 50 296 66 370 76 419 up to 90 Coast...

Page 29: ... 515 391 604 464 661 510 30 341 30 404 30 443 up to 90 Inland L L 459 345 566 433 638 492 30 303 30 377 30 427 up to 90 Coast and islands L L 602 462 709 550 781 609 30 402 30 477 30 526 up to 99 Inland L L 566 433 673 521 781 609 30 377 30 452 30 526 up to 99 Coast and islands L L 745 579 852 667 923 726 30 502 30 576 30 626 up to 108 Inland L L 673 521 816 638 923 726 30 452 30 551 30 626 up to ...

Page 30: ...19 589 590 667 52 308 70 382 82 432 up to 90 Coast and islands L L 555 628 661 744 731 822 76 407 94 481 106 531 up to 99 Inland L L 519 589 625 705 731 822 70 382 88 456 106 531 up to 99 Coast and islands L L 696 783 802 900 873 978 100 506 118 580 130 630 up to 108 Inland L L 625 705 767 861 873 978 88 456 112 556 130 630 up to 108 Coast and islands L L 838 939 944 1056 1050 1172 124 605 142 680...

Page 31: ...58 731 425 806 470 107 358 129 425 144 470 up to 99 Inland L L 581 335 694 403 806 470 100 335 122 403 144 470 up to 99 Coast and islands L L 768 448 881 515 955 560 137 448 159 515 174 560 up to 108 Inland L L 694 403 843 492 955 560 122 403 152 492 174 560 up to 108 Coast and islands L L 918 537 1030 605 1143 672 166 537 188 605 211 672 Vertical collector position Installation angle 45 Weights r...

Page 32: ...388 727 466 843 545 30 342 30 410 30 478 up to 99 Coast and islands L L 804 519 920 598 998 650 30 455 30 523 30 568 up to 108 Inland L L 727 466 882 571 998 650 30 410 30 500 30 568 up to 108 Coast and islands L L 959 624 1075 703 1191 781 30 546 30 613 34 681 Vertical collector position Installation angle 60 Weights rack kg L1 L2 To secure against sliding and lifting To secure only against lifti...

Page 33: ...0 280 41 348 49 393 up to 90 Coast and islands L L 604 564 713 669 785 739 45 370 58 438 67 483 up to 99 Inland L L 568 529 677 634 785 739 41 348 54 415 67 483 up to 99 Coast and islands L L 749 704 857 809 930 879 62 461 75 528 84 573 up to 108 Inland L L 677 634 821 774 930 879 54 415 71 506 84 573 up to 108 Coast and islands L L 893 844 1002 949 1110 1054 80 551 92 619 105 686 5 1 8 Defining t...

Page 34: ... B mm F 1 mm B mm F 1 mm B mm F 1 mm Vertical 8 9778 1280 2927 1731 3666 2065 4019 2034 1100 1263 9 11041 10 12304 Horizontal 1 1770 881 1897 1165 2276 1373 2446 1304 2 3800 1900 3 5863 2063 4 7926 5 9989 6 12052 7 14115 8 16178 9 18241 10 20304 1 Dimension applies to 20 position of the sun and must be checked according to the geographical location ...

Page 35: ...itional rack 2 Fold out the first rack 60 45 30 3 Select the required installation angle Installation angle 30 45 60 1 2 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 1 2 3 1 6 Position the crossbeams 1 such that their fastening holes lie between the corresponding threaded holes in th...

Page 36: ...ing installation on roof sealing surfaces Place large area non slip building pro tection 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 Connect two load plates as shown in the illustration Connect two additional load plates as sho...

Page 37: ...ights 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 acci dents Secure all load weights on the load plate...

Page 38: ...stallation 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 Install the second rack on the next two weights as de scribed above Fit as many racks as you need to hold the collectors 5 2 2 Installing collectors Danger Personal injury and material damage due to a falling collector Improper fastening ...

Page 39: ...e lower mounting rails Working materials 5 mm Allen key Hooking the collector in at the bottom 1 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 ...

Page 40: ...or using the correspond ing bracket Working materials 5 mm Allen key Completing collector rows Conditions Not all collectors in a row have been installed yet Install the hydraulic connectors Page 40 Install an additional collector Page 40 5 2 3 Installing hydraulic connections Caution Leak caused by incorrect accessories Incorrect accessories may result in a leak in the solar circuit and cause mat...

Page 41: ...m 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 tubes Check the connections for tightness 5 3 Com...

Page 42: ...mplied with in accord ance with the specifications Rack positioned in accordance with the dimensions spe cifications 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 hyd...

Page 43: ...th the maintenance plan 6 3 General inspection and maintenance instructions Danger Risk of death injury and material damage due to improper maintenance and repairs Improper maintenance work or repairs can impair the operating safety of the unit and result in material damage and personal injury Only perform maintenance work and re pairs on the collectors if you are a quali fied competent person 6 4...

Page 44: ...claration of conformity If you do not use certified Vaillant original spare parts for maintenance or re pair work this voids the CE conformity of the product We therefore strongly recommend that you fit Vaillant genuine spare parts You can find information about the available Vaillant original spare parts on the back page of these in structions below the contact address If you require spare parts ...

Page 45: ...solar plant and dispose of the solar fluid properly In the event of long periods of decommis sioning of the solar plant dismantle the collectors For repair or maintenance work you can temporarily decom mission 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 8 2 Permanently decommissioning 8 2 1...

Page 46: ...te Dispose of the solar fluid in compliance with local regula tions through an appropriate disposal company Dispose of packaging that cannot be cleaned in the same way as solar fluid Uncontaminated packaging can be reused 9 Customer service To ensure regular servicing it is strongly recommended that arrangements are made for a Maintenance Agreement Please contact Vaillant Service Solutions 0207 02...

Page 47: ...area m 2 35 Absorber surface area m 2 33 Absorber mm Aluminium vacuum coated 0 4 x 1178 x 1978 Aluminium vacuum coated 0 5 x 1178 x 1978 Coating High selective blue α 95 ε 5 Glass thickness mm 3 2 Glass type Solar safety glass prismatic structure Solar safety glass anti reflective coating Transmission τ 91 τ 95 Back wall insulation mm W m K kg m 40 λ 0 035 ρ 55 Edge insulation None Available Effic...

Page 48: ...10 Technical data 48 Installation manual auroTHERM auroTHERM plus 0020100571_03 10 2 Dimensions 80 2033 1178 1233 1978 66 5 66 5 1100 1223 5 1178 79 79 1875 80 80 5 1233 1223 2033 1978 ...

Page 49: ...tors 45 Packaging 22 43 Solar fluid 45 F Final work Installing 21 42 H Hydraulic connections Installation 19 Installing 40 I Identification plate 7 Installation clearances Complying with 9 24 Installing Checking 21 42 Intended use 4 L Leaking connections Sealing 44 M Maintenance Preparing 43 Maintenance plan 43 P Packaging Disposal 22 43 Pipe insulations Checking 44 Disposal 44 45 Replacing 44 45 ...

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Page 52: ...1 Vaillant Service Solutions 0330 100 3461 Spares Technical Enquiries 017 73 59 66 15 info vaillant co uk technicalspares groupservice co uk www vaillant co uk These instructions or parts thereof are protected by copyright and may be reproduced or distributed only with the manufacturer s written consent ...

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