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Instructions on commissioning, maintenance, and troubleshooting for auroSTOR 0020111119_02

Connection wiring diagram 6 (S plan or Y plan
hydraulics)

VRS 560

KOL 1-P

KOL 2-P / ZP

230 V grid

LEG / Byp

1
2

LP/UV 1

C1 C2

1
2

Kol 1

SP 1

1
2

SP 2

1
2

SP 3

1
2

Ertrag

1
2

Kol 2

1
2

O s

olar cir

cuit

olar pump

SP1

SP2

Standard cabling box

S-plan or Y-plan

ylinder

Solar yield

Yield

Kol 1

Cylinder thermostat

and TCO

2 1

Fig. 6.22 Connection wiring diagram 6

6 Installation

Содержание VIH S GB 210/2 S

Страница 1: ...tions for commissioning maintenance and troubleshooting For the competent person GB IE Instructions for commissioning maintenance and troubleshooting Solar heating system with auroSTOR Solar hot water...

Страница 2: ...Installation 24 6 1 Installation sequence 24 6 2 Installation of solar circuit piping 24 6 2 1 Piping material in the solar circuit 24 6 2 2 Layout of piping in the solar circuit 24 6 2 3 Realisation...

Страница 3: ...so that they are available when required 1 3 Symbols used The symbols used in the text are explained below i Symbol that denotes useful tips and information Symbol for a required action 1 4 Applicabil...

Страница 4: ...ing Regulations The Benchmark Checklist can be used to dem onstrate compliance with Building Regulations and should be provided to the customer for future reference Installers are required to carry ou...

Страница 5: ...ce condi tions listed in the instructions Improper use of any kind is prohibited At the end of these instructions there is a commission ing report which you must fill in and hand over to the operator...

Страница 6: ...le water Avoiding burns and scalds Install and replace collectors or collector parts on very cloudy days Only carry out installation work in the early morning or in the evening on sunny days or cover...

Страница 7: ...nst lightning 2 5 Regulations for Great Britain 2 5 1 Technical Guidance The system must be installed in accordance with all rele vant and applicable national regulations and must be installed to suit...

Страница 8: ...ing objects Workers should have available and use personal protec tive equipment as necessary This would include equip ment such as fall protection systems safety gloves goggles dust masks as well as...

Страница 9: ...linder 4 Electric immersion heater 5 Two port motorised valve 230 V 6 Collector tube collector with top connections example or flat collector with top and bottom connections 7 Solar pump unit 8 Solar...

Страница 10: ...der to the set hot water temperature value The water in the cylin der can also be reheated using the electric immersion heater installed at the factory A solar expansion vessel compensates for pressur...

Страница 11: ...Ertrag 13 Cold water inlet 14 Solar circuit thermal cut out TCO set to 80 C to be con nected with the solar pump in order to isolate this heat source if there is a fault in the solar control 15 Solar...

Страница 12: ...ar circuit thermal cut out set to 80 C to be connec ted with the solar pump in order to isolate this heat source if there is a fault in the solar control Thermal cut out for electric immersion heater...

Страница 13: ...eater The cylinder is equipped with an additional electric immersion heater 3 with a heating output of 3 kW The electric immersion heater is located behind the top front cladding The electric immersio...

Страница 14: ...t solar fluid is infinitely durable in hermetically sealed containers It is not dangerous if it comes into contact with the skin Eye contact only causes minor irritations you should nevertheless immed...

Страница 15: ...ammable Surrounding fire can be combated with sprayed water dry extinguishers alco hol resistant foam and carbon dioxide CO2 5b Special dangers Fumes which are detrimental to health Formation of smoke...

Страница 16: ...tion rabbits Non irritant OECD Directive 404 Primary mucous membrane irritation rabbits Non irritant OECD Directive 405 11a Additional information The product has not been checked The statements are d...

Страница 17: ...ed hot water production with demand controlled primary heat ing for Vaillant gas fired wall hung boilers The control set is a fully equipped system for solar heat ing systems with a collector array an...

Страница 18: ...8 2 connection wiring diagram 5 section 6 8 The lower cylinder sensor SP 2 and the solar yield temperature sensor are connected up to the VR 68 2 The solar pump is controlled via a VRC 1 230 V 3 A C D...

Страница 19: ...lant Control Centre and the recharging of the cylin der is triggered The primary heating device activates and the Vaillant Control Centre switches the zone valves into the correct position for the rec...

Страница 20: ...heat exchanger performance kW 16 7 16 5 16 0 Flow rate for primary heat exchanger performance l min 23 3 Primary heat exchanger pressure drop mbar 79 78 79 Primary heat exchanger volume Liter 2 37 Pri...

Страница 21: ...rmostat 230 240 V 50 Hz Thermal cut out solar 230 240 V 50 Hz Material data Cylinder body material Stainless steel 1 4521 Cylinder jacket material Polypropylene Insulation material EPS with infrared a...

Страница 22: ...Primary heater flow 5 Primary heating circuit cylinder dry pocket SP 1 Unit type a b c d e f g h i j k l VIH S GB 210 2 S 1625 1593 1341 1158 1052 912 822 802 534 506 259 51 VIH S GB 260 2 S 1875 184...

Страница 23: ...injuries Use a suitable transportation aid sack truck or similar Transport the packaged cylinder to the installation site Only remove the cylinder from its packaging once it reaches the installation...

Страница 24: ...eflon band You should preferably use copper pipes in the solar circuit Use brazing solder to solder the piping in the solar circuit Only use press fittings if the manufactu rer has stated that they ca...

Страница 25: ...ectors to an existing buil ding lightning protection system b Caution Risk of damage to the collectors due to excessive pressure The safety devices in the solar circuit can be knocked out of operation...

Страница 26: ...the solar circuit in the case of larger systems the flow rate in the collector array must be below 30 l m2 h Tab 6 1 Nominal flow rate in relation to collector quantity pipe diameter and pipe length...

Страница 27: ...e not shut off whilst the system is in stagnation The loss of solar fluid results in functional problems Close all automatic air vents once ven ting is complete b Caution Malfunction due to unsuitable...

Страница 28: ...i e during commissioning or maintenance For flat collectors install a plug with a vent opening at the highest point i Whilst the solar heating system is being oper ated the vent opening must be closed...

Страница 29: ...e valve with the valve head facing upwards fig 6 3 6 4 Installing hot water pipes Connect the hot water piping to the 22 mm hot water draw off of the cylinder Lay the 22 mm piping up to the first T pi...

Страница 30: ...on pump 7 Contact thermostat 8 Expansion relief valve 9 Cold mains inlet 10 Bivalent solar cylinder Where possible avoid installing a secondary circulation line since a secondary circulation line resu...

Страница 31: ...e cold water supply has a dynamic pressure and flow rate appropriate for the system If the static water pressure is less than 1 bar contact Vaillant Ltd 6 6 2 Mounting the safety assembly b Caution Ri...

Страница 32: ...safety assembly as follows Screw the expansion vessel directly to the safety assem bly via the provided connection 5 or Connect the expansion vessel with the safety assembly via a copper pipe or suita...

Страница 33: ...istance due to each elbow or bend 22 mm up to 9 m 0 8 m 28 mm up to 18 m 1 0 m 35 mm up to 27 m 1 4 m Tab 6 4 Sizing of copper discharge pipe D2 for G1 2 temperature and pressure relief valve outlet s...

Страница 34: ...the Health and Safety Exe cutive e Danger Risk of death from electric shock Without potential equalisation life threat ening voltage can reach the piping and water draw off points Earth the heating sy...

Страница 35: ...or solar aided hot water production with demand control led primary heating for Vaillant gas fired wall hung boil ers Alternatively via a Vaillant dual circuit eBUS con troller or a timer from a third...

Страница 36: ...9 and a cyl inder thermostat 13 i Before wiring the control components dismantle the casing 5 to facilitate work on the components When reinstalling the casing use the cutouts in the casings for routi...

Страница 37: ...BS 7671 Use heat resistant cables H05BN4 F 1 5 mm2 3 wire HOFR coated for the cabling of the electric immer sion heater Use the cable grip 2 to firmly secure the supply cable of the immersion heater...

Страница 38: ...d terminal strip 2 and 3 core cable provided by the cus tomer The solar pump and solar circuit thermal cut out must be earthed using a protective earth You must carry out a protective earth test Conne...

Страница 39: ...Instructions on commissioning maintenance and troubleshooting for auroSTOR 0020111119_02 39 Installation 6...

Страница 40: ...PE L off on N PE on DO NOT USE M PE Blue Brown DHW M PE Blue Brown CH VRS 560 KOL 1 P KOL 2 P ZP N PE L 230 V grid N PE L LEG Byp N PE L EP 1 2 LP UV 1 N PE L N PE L C1 C2 1 2 1 2 Kol 1 SP 1 1 2 SP 2...

Страница 41: ...ostat to Vaillant Control Centre Dismantle the cover of the cylinder thermostat 13 fig 6 11 Connect the terminals 1 cylinder thermostat 3 fig 6 12 and C primary heating circuit TCO 5 fig 6 12 to the t...

Страница 42: ...E on DO NOT USE M PE Blue Brown or white Grey Orange VRS 560 KOL 1 P KOL 2 P ZP N PE L 230 V grid N PE L LEG Byp N PE L EP 1 2 LP UV 1 N PE L N PE L C1 C2 1 2 1 2 Kol 1 SP 1 1 2 SP 2 1 2 SP 3 1 2 Ertr...

Страница 43: ...ostat to Vaillant Control Centre Dismantle the cover of the cylinder thermostat 13 fig 6 11 Connect the terminals 1 cylinder thermostat 3 fig 6 12 and C primary heating circuit TCO 5 fig 6 12 to the t...

Страница 44: ...USE M PE Blue Brown DHW M PE Blue Brown CH VRS 560 KOL 1 P KOL 2 P ZP N PE L 230 V grid N PE L LEG Byp N PE L EP 1 2 LP UV 1 N PE L N PE L C1 C2 1 2 1 2 Kol 1 SP 1 1 2 SP 2 1 2 SP 3 1 2 Ertrag 1 2 Kol...

Страница 45: ...r minal CYL of the Vaillant Control Centre i The terminals NTC and CYL of the Vaillant Con trol Centre may not be connected at the same time Mount the casing 5 fig 6 11 on the cylinder and use the cut...

Страница 46: ...USE M PE Blue Brown or white Grey Orange VRS 560 KOL 1 P KOL 2 P ZP N PE L 230 V grid N PE L LEG Byp N PE L EP 1 2 LP UV 1 N PE L N PE L C1 C2 1 2 1 2 Kol 1 SP 1 1 2 SP 2 1 2 SP 3 1 2 Ertrag 1 2 Kol...

Страница 47: ...r minal CYL of the Vaillant Control Centre i The terminals NTC and CYL of the Vaillant Con trol Centre may not be connected at the same time Mount the casing 5 fig 6 11 on the cylinder and use the cut...

Страница 48: ...f M PE Blue Brown HW M PE Blue Brown HZ1 M PE Blue Brown HZ2 VR 68 2 MA KOL 1 P N PE L 230 V grid N PE L LEG P N PE L N PE L BUS 1 2 1 2 Kol 1 SP 1 1 2 SP 2 1 2 Ertrag 1 2 TD 2 1 2 TD 1 1 2 PE TCO sol...

Страница 49: ...Connect the VR 11 collector sensor Kol 1 to the terminal Kol 1 of the VR 68 2 Mount the casing 5 fig 6 11 on the cylinder and use the cutouts in the casings for routing the cables Mount the front cla...

Страница 50: ...ZP N PE L 230 V grid N PE L LEG Byp N PE L EP 1 2 LP UV 1 N PE L N PE L C1 C2 1 2 1 2 Kol 1 SP 1 1 2 SP 2 1 2 SP 3 1 2 Ertrag 1 2 Kol 2 1 2 PE TCO solar circuit 2 1 L N PE Solar pump PE 3A N L 2 SP1 S...

Страница 51: ...tor and protective earth Connect the connection 1 of the terminal EP of the VRS 560 2 with the terminal 1 3 fig 6 12 of the cylinder thermostat Connect the protective earth connection of the VRS 560 w...

Страница 52: ...for pressure tests flushing and filling 7 1 Checking leak tightness For the pressure test first fill the solar circuit with Vaillant solar fluid ready mixed A self priming filling pump with a pressure...

Страница 53: ...ling and draining tap 16 of the solar circuit Completely open the combined filling and draining taps 1 and 16 on the solar pump unit to ensure a maximum flow rate Open the ball valve 8 on the solar p...

Страница 54: ...collec tor array must be lower than 0 50 l m2 min For a suitable nominal flow rate for the collectors pipe diameter and pipe length used see Tab 6 1 and 6 2 0 5 1 2 3 0 5 1 2 3 4 5 6 4 5 6 L min L min...

Страница 55: ...leaning agents for the system can be obtained from Sentinel Betz Dearborn Ltd Widnes Cheshire WA8 8UD Tel 0151 420 9595 or Fernox Alpha Fry Technologies Tandem House Marlow Way Croydon CR0 4XS Tel 087...

Страница 56: ...in case of exceeding the limit values given in this table softening desalination hardness stabilisation and desludging Table 7 3 Guidelines for the heating water Water hardness Heating water charac te...

Страница 57: ...o MAN OPEN and lock it into this position Flush the entire primary central heating system including the primary heating circuit with cold and hot water Flush fill and vent the central heating system i...

Страница 58: ...to maintain the required temperature on the hot water taps 7 11 Filling in the commissioning report Fill in the benchmark cylinder commissioning checklist located on the last few pages of these instru...

Страница 59: ...d in the following table Servicing After servicing the servicing engineer must complete the relevant Service Interval Record section of the Benchmark Checklist located on the inside back pages of this...

Страница 60: ...f the collector collector fastenings and connections Visual inspection only from suitable safe location Annually Check the pipe insulation for damage and arrange repair if necessary Annually Solar con...

Страница 61: ...to check the expansion vessel pressure at the measuring point If the pressure is below 3 0 bar increase it using a suitable air pump Fill in the maintenance section of the commissioning report 8 3 Dr...

Страница 62: ...driver in the notch and turn it by hand 5 The solar pump is dirty Dismantle and clean the solar pump Close the flow rate limiter and pump ball valve 6 Solar pump is faulty Replace the solar pump 7 The...

Страница 63: ...r in the pressure reduc ing valve and replace it if necessary Pressure reducing valve faulty Replace the pressure reducing valve Blockage in the system Unblock the blockage and replace any blocked par...

Страница 64: ...e pressure behind the pressure reducing valve is lower than 3 0 bar If so replace the pressure reducing valve Expansion vessel faulty Check the pressure in the expansion vessel If the pressure is insu...

Страница 65: ...wer supply Prevent the power supply from being switched on again Ensure that any electrical work is carried out by a qualified competent person Switch the boiler off Drain the cylinder section 8 3 Dis...

Страница 66: ...alled by suitably competent persons in accordance with all current and relevant safety building control and planning regulations and in full compliance with the manufacturer s instructions All unvente...

Страница 67: ...Commissioning checklist and service record...

Страница 68: ...pressure relief valve and expansion valve been WWHG and discharge tested Yes No The tundish and discharge pipework have been connected and terminated to Part G of the Building Regulations Yes Are all...

Страница 69: ...mments Signature SERVICE 3 Date Engineer Name Company Name Telephone Number Comments Signature SERVICE 4 Date Engineer Name Company Name Telephone Number Comments Signature SERVICE 5 Date Engineer Nam...

Страница 70: ...QG XVKHG Yes Filled and purged for air Yes System heDt trDnsIer uLd detDLls KDW W SH PDNH RI KHDW WUDQVIHU XLG XVHG 6 VWHP YROXPH OLWres KDW LV WKH XLG PL Water Glycol Frost protection prRYLGHG WR V W...

Страница 71: ...mments Signature SERVICE 3 Date Engineer Name Company Name Telephone Number Comments Signature SERVICE 4 Date Engineer Name Company Name Telephone Number Comments Signature SERVICE 5 Date Engineer Nam...

Страница 72: ...0020111119_02 GBIE 022012 Subject to change Manufacturer Supplier...

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