Vaillant auroTHERM VFK 900 Start-Up, Maintenance And Troubleshooting Manual Download

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For the installer / owner

Start-up, maintenance and troubleshooting manual, notes for the operator

Solar System and auroSTOR unvented solar
cylinder

Solar hot water systems

Summary of Contents for auroTHERM VFK 900

Page 1: ...For the installer owner Start up maintenance and troubleshooting manual notes for the operator Solar System and auroSTOR unvented solar cylinder Solar hot water systems GB ...

Page 2: ... the solar circuit pipes 35 5 3 4 Connection of the collectors to the solar pump unit 35 5 3 5 Bleeding of the solar circuit 36 5 4 Installation of the reheating circuit piping 36 5 5 Installation of the hot water pipework 36 5 5 1 Hot water thermostatic mixing valve 36 5 6 Installation of the cold water supply pipework 37 5 6 1 Mains water supply pressure 37 5 6 2 Cold water piping 37 5 6 3 Drain...

Page 3: ...OR solar cylinder The symbols used in the manual are explained below d Danger Immediate risk of serious injury or death e Danger Danger of death from electric shock e Danger Risk of burns or scalding a Caution Potentially dangerous situation for the product and environment h Note Application recommendation Symbol for a required task 1 3 Validity of the manual This manual is valid exclusively for u...

Page 4: ... national regulations and must be in stalled 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 2 2 2 Related documents The installation of the solar system must...

Page 5: ... collector covered d Danger Risk of being burned or scalded by hot solar fluid or components Fill and flush the solar system when the collectors are cold Cover the collectors while doing so Danger Risk of being burned or scalded by escaping hot steam Steam can escape from the expansion relief valve of the solar pump unit if the system is shut down To avoid injuries you must connect the expansion r...

Page 6: ...erating and installation instructions as well as all other applica ble documents and also compliance with the inspection and maintenance requirements a Caution Improper use of any kind is prohibited You will find a start up report at the end of this manual This should be filled in by the installer and or start up engineer and handed over to the operator All CORGI approved installers have a CORGI I...

Page 7: ...otorised 2 port valve supplied together with the solar cylinder 4 Immersion heater 5 230 V motorised 2 port valve 6 auroTHERM collector 7 Solar pump unit 8 Protection vessel 9 Solar expansion vessel 10 Automatic air separator system 11 Drinking water expansion vessel 12 Thermostat mixing valve A Boiler flow B Boiler return C Solar circuit flow D Solar circuit return System description 3 ...

Page 8: ... third of the cylinder can be controlled by the VRS 560 or by a separate hot water programmer d Danger Risk of being scalded by hot water to provide effective protection against scalding install a thermostat mixer in the hot water pipe as described in Section 5 5 Installation of the hot drinking water pipework Set the thermostat mixer to below 60 C and check the temperature at a hot water tap Heat...

Page 9: ...lusive VTK 570 sho wing direction of flow Key 1 Thermal insulation 2 Receiving tank 3 Supply or return connection 4 Temperature sensor pocket 5 Vacuum tubes 6 Thermal baffle plate 7 CPC mirror 8 U tube 9 Supply or return connection 10 Energy collector tube or distributor pipe Description of the components 4 ...

Page 10: ...orption α 95 1 0 Solar sensor sleeve mm 6 CE label 0036 Shutdown temperature according to prEN 12975 2 c 1 m s in the glass tube C 250 Shutdown temperature according to prEN 12975 2 c 1 m s at the collector connection C 180 Efficiency η0 according to 12975 78 3 Efficiency coefficient k1 W m2 K 1 09 0 2 Efficiency coefficient k2 W m2 K2 0 01 0 002 Table 4 1 Technical data auroTHERM exclusive tube c...

Page 11: ...r K Efficiency η Fig 4 4 Efficiency of auroTHERM collector with radiation ener gy content of 800 W m2 Pressure loss mbar Flow rate l min VTK 1140 VTK 570 0 0 20 40 60 80 100 120 0 25 0 5 0 75 1 1 25 1 5 1 75 2 2 25 2 5 2 75 3 3 25 3 5 3 75 4 4 25 4 5 4 75 5 Fig 4 5 Pressure loss of the auroTHERM exclusive collector Description of the components 4 ...

Page 12: ...w off line between the expansion relief valve and collection tank The size of the solar expansion vessel is based on the collector volume and the expansion volume of the solar system The expansion vessel not only accommodates the expansion volume of the solar fluid but also the entire volume of the collectors in the event of a shutdown The total volume of the solar system is the total of the indiv...

Page 13: ...o the pump is interrupted at cylinder temperatures higher than 90 C 4 5 Flow rate meter 0 5 1 2 3 0 5 1 2 3 4 5 6 4 5 6 L min L min 1 1 l min 1 2 Fig 4 11 Flow rate meter 0 6 l min The flow rate meter pos 7 Fig 4 6 installed in the return pipe is an essential component of the solar system To achieve optimum heat transfer you must achieve a certain flow rate which is referred to as the nominal flow...

Page 14: ...eat exchanger reheating circuit 3 7 VIH S GB 250 S heat exchanger reheating circuit 3 7 VIH S GB 300 S heat exchanger reheating circuit 3 7 Solar pump unit 0 9 auroTHERM exclusive VTK 570 0 8 auroTHERM VFK 900 1 1 auroTHERM classic VFK 990 1 1 1 Protection vessel 5 12 or 18 l Table 4 3 Volume of the individual components Pipe diameter Pipeline volume l m 15 mm 0 18 18 mm 0 20 22 mm 0 31 28 mm 0 50...

Page 15: ...the fire conditions Polluted fire water must be disposed of according to local official regulations 6 Measures to be taken if substances are released accidentally 6 1 Individual related measures No particular measures required 6 2 Environmental measures The product may not be discharged into waters without pre treatment biological sewage plant 6 3 Cleaning Collection methods Pump out the product i...

Page 16: ...dividual components 12 3 Persistence and biodegradability information on elimination OECD 301 A test method new version Analysis method DOC acceptance Degree of elimination 70 28 d Assessment easily biodegradable 13 Note on disposal 13 1 Disposal Vaillant solar fluid item no 302 363 must de disposed of at an appropriate waste site or waste incineration plant for example while observing local regul...

Page 17: ...mperature differences not absolute temperature values are important for the operation of solar systems That is why solar systems are controlled by what is referred to as temperature difference controllers Temperature sensors measure the difference between the collector and solar cylinder The solar pump is switched on if the difference in temperature Kol 1 Sp 2 is greater than 7 K The solar pump of...

Page 18: ... central heating override and the time control function of an additional circulation pump For wiring refer to Section 5 8 Electrical installation and the operating and installation manual of the VRT 360 item no 838568 h Note If the VRT 360 is used for central heating control the Control Center VR 65 is additionally required to measure the solar cylinder temperature and switch from cylinder reheati...

Page 19: ...M VFK fixing sets auroSTOR solar cylinders VIH S GB 200 S VIH S GB 250 S VIH S GB 300 S Item no 307206 307207 307208 Safety group with tundish 1 1 1 Motorised 2 port valve for regulation of reheating circuit A B 1 1 1 Hot water expansion tank 18 l 1 Hot water expansion tank 25 l 1 1 Wall bracket for hot water expansion tank 1 1 1 Carrier handle 1 1 1 Crimp connections 1 1 1 Drain valve 1 1 1 Safet...

Page 20: ...1 Sp 2 temperature sensor immersion pocket 12 Adjustable feet 13 Return solar circuit 14 Supply solar circuit 15 Return gas fired wall hung boiler 16 Supply gas fired wall hung boiler 17 Immersion heater switch 18 Safety thermostat for solar pump set at 90 C connected to solar pump isolates this heat source if the solar control mal functions 19 Safety thermostat for immersion heater 20 Cylinder th...

Page 21: ... maximum solar gains from your system If other controls are utilised then the VRS 560 2 can be employed as a solar only controller and wired to work with your chosen hot water control The temperature settings for solar water heating and the maximum cylinder temperature are made by means of this solar control e g auroMATIC VRS 560 The auroSTOR must be wired properly in order to adhere to the G3 bui...

Page 22: ... relief valve C bar 95 7 0 Net weight kg 39 44 49 Weight full kg 245 310 340 Height mm 1499 1789 2109 Cylinder connections Cold water supply 22 mm pressure pipe Hot water connection 22 mm pressure pipe Pressure controlled cold water outlet 22 mm pressure pipe Secondary return Inches G 3 4 Flow boiler solar circuit 22 mm pressure pipe Return boiler solar circuit 22 mm pressure pipe Electrical conne...

Page 23: ...ntry to system Flow out litres min of the system 10 10 0 Fig 5 5 auroSTOR hot water flow rates at 60 C Static operating pressure of the cold water supply The displayed flow rates apply to installations in which the cold water supply is of appropriate dynamic pressure Please contact Vaillant Ltd if the static water pressure is below 1 bar 8 bar 4 bar 3 bar 2 bar 1 bar Flow available litres min at e...

Page 24: ...f failure of the domestic water thermostat 5 1 6 Safety instructions and regulations This product has been checked for adherence to the building regulations for unvented hot water cylinder systems It may not be changed or modified in any way whatsoever It should be installed by a qualified specialist who should observe the applicable regulations of the local authorities the building regulations th...

Page 25: ... 5 1 9 Transport A cylinder carrier handle is supplied to make the transport to the installation site easier 1 Fig 5 7 Fastening the cylinder carrier handle Fasten the carrier handle 1 to the hot water connection of the solar cylinder 5 Installation ...

Page 26: ...emperature and pressure relief valve 3 Immersion heater 4 Solar circuit flow Cylinder type A B C d A F g h R VIH S GB 200 S 1468 1499 454 384 314 589 1118 813 953 VIH S GB 250 S 1758 1789 454 384 314 589 1408 924 1064 VIH S GB 300 S 2078 2109 454 384 314 589 1648 1101 1241 Table 5 5 Dimensions 5 Cold water supply connection 6 Solar circuit return 7 Return boiler 8 Boiler flow Installation 5 ...

Page 27: ... 3 230 V motorised 2 port valve supplied with the solar cylinder 4 Immersion heater 5 230 V motorised 2 port valve 6 auroTHERM collector 7 Solar pump unit 8 Protection vessel 9 Solar expansion vessel 10 Automatic air separator system 11 Hot water expansion vessel 12 Thermostat mixing valve A Boiler flow B Boiler return C Solar circuit flow D Solar circuit return 5 Installation ...

Page 28: ...llation of a motorised 2 port valve in the pipes of the solar system is not allowed since the safety devices in the solar circuit could be overridden by it 5 3 2 Material a Caution Risk of damage because of wrong piping material Plastic pipes such as PE pipes or similar must not be used because of the high temperatures that solar fluid might reach Use copper pipes preferably as solar circuit pipes...

Page 29: ...ters may be necessary for relatively large distances between the boiler and the cylinder Since all wall mounted Vaillant boilers except ecoMAX pro with open ventilation have an installed circulating pump it is not necessary to install them An appropriate pump must be installed in the reheating circuit if the solar cylinder is used with a different boiler in accordance with the GB standard B Port A...

Page 30: ...ixed with 10 l min cold water of 10 C if the measured static cold mains water pressure is 2 bar and the available flow rate 30 l min The solar cylinder operates satisfactorily at a mains water pressure of below 2 bar but at a reduced flow rate The unvented solar cylinder should not be installed if the mains water pressure is below 1 bar You can obtain information on alternative hot water supply sy...

Page 31: ...ote In areas with high water pressure 4 bar or more a bath or shower mixer valve can also be connected to the pressure controlled cold water connection 4 Fig 5 16 of the water control pack to ensure the pressure of the hot and cold water supply to the mixer valve is about the same The cold water supply for all other connections should be installed in front of the water control pack in the cold wat...

Page 32: ... risk of anyone coming in contact with hot water A suitable point is for example under a fixed grating above the trap of a trapped gully Low discharge pipes for example up to 100 mm above external surfaces such as parking spaces grasslands etc can be used provided they are secured by a wire fence or something similar to prevent children from coming in contact with the waste water and the system is...

Page 33: ...earth the solar cylinder for potential equalisation 5 8 1 Immersion heater The auroSTOR VIH S GB 200 300 S solar cylinders have been equipped with an immersion heater by the manufacturer 1 2 4 5 3 230 V AC 3 kW 1 2 3 N L Fig 5 19 Electrical connection of the immersion heater Key 1 Immersion heater thermal cut out with reset button 2 Cylinder thermostat adjustable 3 Temperature sensors in immersion...

Page 34: ...ersion heater You can find a wiring sheme on the inside of the cylinder cover 5 8 3 Combination options of the control components Boiler used eBUS capable boiler such as the Vaillant ecoTEC or a boiler which is not eBUS capable such as the Vaillant turboMAX or ecoMAX or appliances which are not eBUS capable from third party manufacturers Wiring Wiring via the Control Center VR 65 as system solutio...

Page 35: ...imum temperature if you use one of the wiring schemes 2 or 4 1 2 3 N L 1 7 2 10 3 To wiring box 1 2 3 1 Fig 5 21 Electrical connection of the cylinder thermostat Wiring of the control components Wiring scheme 1 eBUS capable Vaillant boiler Wiring via VR 65 Solar circuit control via VRS 560 Solar circuit reheating control via VRS 560 Heating circuit control via Vaillant eBUS compatible controller O...

Page 36: ...in the immersion sleeve for the bottom cylinder area Connect this temperature sensor to terminal SP 2 in the auroMATIC 560 solar control Attach the temperature sensor for the gain 2 to the return pipe of the solar circuit nearby the solar cylinder Connect this temperature sensor to the terminal Ertrag in the auroMATIC 560 solar control Make sure the temperature sensors of the immersion heater sola...

Page 37: ...ns of an additionally protected terminal strip Establish the connections to the mains supply h Note Programme the hot water channel of the Vaillant eBUS controller to constant Program me the auroMATIC 560 solar control to provide hot water when required by the customer h Note The auroMATIC 560 control will only signal to the boiler if the cylinder is below target tempe rature if solar system is no...

Page 38: ...rth Blue Brown Grey Orange Earth Blue Brown Grey Orange Hot Water 2 Port Valve VR 65 DHW add terminal strip LEG BYP Central Heating 2 Port Valve VR 65 CH auroSTOR cylinder 3 amp fused supply Boiler terminal strip Vaillant Ebus boiler do not use 230 V 230 V 230 V additional terminal strip cyl 24V 230 V 230 V BUS VRS 560 230 V Bus add terminal strip auroSTOR remove TCO and cyl thermostat according t...

Page 39: ...o terminal SP 2 in the auroMATIC 560 solar control Attach the temperature sensor for the gain 2 to the return pipe of the solar circuit nearby the solar cylinder Connect this temperature sensor to the terminal Ertrag in the auroMATIC 560 solar control Make sure the temperature sensors of the immersion heater solar cylinder and solar control fit properly in the immersion sleeves h Note Set the cont...

Page 40: ... 2 Port Valve Central Heating Programmer 230 V 230 V 230 V LP UV 1 LEG BYP VRS 560 solar control 230 V EP Coll NTC auroSTOR additional terminal strip auroSTOR cylinder TCO collector pump additional terminal strip TCO and cyl thermostat boiler reheat Collector Pump additional terminal strip to 10 way wiring box NOT separate fused spur additional terminal strip Room thermostat Vaillant VRT 30 230 V ...

Page 41: ... in the auroMATIC 560 solar control Push a VR 10 temperature sensor 3 in the immersion sleeve for the bottom cylinder area Connect this temperature sensor to terminal SP 2 in the auroMATIC 560 solar control Attach the temperature sensor for the gain 2 to the return pipe of the solar circuit nearby the solar cylinder Connect this temperature sensor to the terminal Ertrag in the auroMATIC 560 solar ...

Page 42: ...programmer to provide hot water when required by the cus tomer Consider carefully when the solar system might be running and try to time to HW pro grammer to run when there is unlikely to be any solar gain h Note The auroMATIC 560 control will only control the solar system Installation 5 ...

Page 43: ...ector Pump Hot Water 2 Port Valve 3 amp fused supply 230 V any Vaillant boiler Central Heating 2 Port Valve Central Heating Programmer 230 V TCO collector pump VRS 560 solar control TCO and cyl thermostat auroSTOR 230 V Kol 1 P Kol 2 P ZP 230 V additional terminal strip EP to 10 way wiring box NOT separate fused spur additional terminal strip Room thermostat Vaillant VRT 30 additional terminal str...

Page 44: ...a Connect this temperature sensor to terminal SP 2 in the auroMATIC 560 solar control Attach the temperature sensor for the gain 2 to the return pipe of the solar circuit nearby the solar cylinder Connect this temperature sensor to the terminal Ertrag in the auroMATIC 560 solar control Make sure the temperature sensors of the immersion heater solar cylinder and solar control fit properly in the im...

Page 45: ...ammer Boiler Terminal Strip 230 V LP UV 1 additional terminal strip LEG BYP not used to 10 way wiring box NOT separate fused spur Central Heating 2 Port Valve 230 V Hot Water 2 Port Valve auroSTOR cylinder TCO collector pump TCO and cyl thermostat Collector Pump Heating Pump if not in boiler additional terminal strip Room thermostat Vaillant VRT 30 Coll NTC auroSTOR VRS 560 solar control 230 V 10 ...

Page 46: ...nal SP 1 in the auroMATIC 560 solar control Push a VR 10 temperature sensor 3 in the immersion sleeve for the bottom cylinder area Connect this temperature sensor to terminal SP 2 in the auroMATIC 560 solar control Attach the temperature sensor for the gain 2 to the return pipe of the solar circuit nearby the solar cylinder Connect this temperature sensor to the terminal Ertrag in the auroMATIC 56...

Page 47: ... programmer to provide hot water when required by the cus tomer Consider carefully when the solar system might be running and try to time to HW pro grammer to run when there is unlikely to be any solar gain h Note The auroMATIC 560 control will only control the solar system 5 Installation ...

Page 48: ...ogrammer Heating Pump if not in boiler 230 V Collector Pump additional terminal strip LEG BYP TCO collector pump EP additional terminal strip auroSTOR cylinder Coll NTC auroSTOR TCO and cyl thermostat VRS 560 solar control 230 V 10 way wiring box additional terminal strip Kol 1 P Kol 2 P ZP to 10 way wiring box NOT separate fused spur 230 V additional terminal strip LP UV 1 230 V Room thermostat V...

Page 49: ...l when using the Vaillant filling pump It is not permitted to use manual pumps for filling Expansion vessel admission pressure During the start up the gas side admission pressure pv of the expansion vessel must be adjusted to the equipment height whilst disconnected The static pressure pstat corresponds to a certain extent to the static height h between the collector array and the expansion vessel...

Page 50: ...ed on the display 2 Table 6 1 and 6 2 provide reference values for possible pump speeds depending on the collector connection and pipe length and cross section If you use auroMATIC 560 solar control the flow rate can be used to calculate the gain To make an accurate calculation the flow rate must be entered on the controller You can find further information in the operating and installation manual...

Page 51: ... programming the flow rate on the solar control refer to Section 6 1 Setting system parameters of the auroMATIC 560 operating and installation manual 6 4 Filling the hot water secondary circuit a Caution Risk of damage Do not manually open the temperature pressure relief valve or the expansion vessel for venting purposes Any foreign matter in the pipework may cause damage to the valve seats Make s...

Page 52: ...r cylinder 2 Fig 6 4 and immersion heater 1 Fig 6 4 to the middle position about 45 C for start up and to achieve maximum energy efficiency Start up the boiler refer to Section 6 7 until the solar cylinder is at operating temperature and all radiators in the system are warm Then drain the entire central heating system again to remove any residue from the pipes Fill and bleed it again afterwards as...

Page 53: ... owner that the immersion heater is intended as standby device for water heating and should not be used simultaneously with the boiler to heat up the water in the solar cylinder Tell the owner that the settings you have made on the solar system are not allowed to be changed Inform the owner that the boiler and solar cylinder have to be subjected to maintenance by a qualified specialist at least on...

Page 54: ...y Annually Secondary return reheating Check the circulation pump Annually Check the timer time programme settings Annually Reheating does it deliver the desired deactivation temperature Annually Solar cylinder Bleed the heat exchanger if necessary Annually Check the connections for leaks Annually Check the temperature and pressure relief valve Annually Checking the expansion relief valve Annually ...

Page 55: ...to max speed or unblock the rotor insert a screwdriver in the notch and turn it by hand 5 Pump dirty Dismantle the pump and clean it Close the flow rate meter and pump ball valve 6 Pump defective Replace the pump 7 Flow rate set incorrectly Check the setting and adjust it if necessary Pump is running but no solar fluid is coming from the collector pump gets hot Forward and return flow temperatures...

Page 56: ...limiting valve and replace it if necessary Pressure limiting valve defective Replace the pressure limiting valve Blockage in the system Unblock the blockage and replace any blocked parts Check the system for water leaks at the expansion relief valve and temperature pressure limiting valve The system is making noises Normal in the first few days after filling the system If it occurs later there are...

Page 57: ...ting up Dirt on the valve seat of the expansion relief valve Check the expansion relief valve and reset it manually Pressure limiting valve defective Switch off the boiler and immersion heater and check whether the pressure behind the pressure limiting valve is lower than 3 0 bar if water flows out only when heating up If so replace the pressure limiting valve Expansion vessel defective Check the ...

Page 58: ...eating system How to control the solar system is described in the manuals for each controller h Note In the event of leaks in the water pipework close the cold water stop valve at the cylinder immediately to limit any water damage The cold water stop valve can be found in the pipe joint from your domestic water connection to the solar cylinder cold water connection normally nearby the cylinder H D...

Page 59: ... You can clean the exterior of the solar cylinder with a damp cloth and a little soap a Caution Risk of damage Do not use any abrasives or solvents since they could damage the exterior or the connections 9 6 Maintenance 9 6 1 Maintenance of the solar system The prerequisite for permanent operational readiness reliability and a long service life is that regular inspections and maintenance work are ...

Page 60: ...n set properly on the controller approx 60 C recommended Check the hot water thermostat mixer setting approx 60 C recommended If the settings are correct the cylinder maybe calcified In this case notify a qualified servicing company Table 9 1 Troubleshooting instructions for the owner 10 Customer service and manufacturer s warranty 10 1 Vaillant service To ensure regular servicing it is strongly r...

Page 61: ...nts Stuffing boxes at stop valve and fill vent valve checked for leaks retighten union nuts if necessary Temperature and pressure relief valve checked Stop valve for reheating source installed normally motorised 2 port valve Flow rate set according to system manual Pump cylinder heat exchanger and collector bled gravity brake blocked for bleeding Gravity brake released Fill vent valve caps screwed...

Page 62: ...nce designation Serial number Boiler system type Open Closed Installation location of pressure limiting valve System values Hot water temperature at the nearest tap C Achievable maximum cylinder temperature C Maximum hot water temperature C Maximum hot water volume at maximum temperature l min Boiler flow temperature C Operating pressure setting at pressure limiting valve bar Charge pressure in DH...

Page 63: ...SP1 min see installation manual of solar control C Switch on temperature difference Kelvin Switch off temperature difference Kelvin Other settings Important activated functions Name of the installer in block letters Corgi ID No Date Signature Signature of the owner to confirm the receipt of all manuals of the system Table 11 2 Start up data continuation 11 Start up protocol ...

Page 64: ...71 Manual Solar hot water systems 0020009607_02 Start up protocol 11 ...

Page 65: ...Manual Solar hot water systems 0020009607_02 72 11 Start up protocol ...

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