Vaillant auroTHERM VFK 125, auroTHERM VFK 135 D, auroTHERM VFK 150 H/V, auroTHERM VFK 140 D, auroTHERM VFK 145 H/V Installation Manual
auroTHERM
VFK 125
VFK 135 D
VFK 140 D
VFK 145 H/V
VFK 150 H/V
ES, GB, NL, PT
For the expert technician
Installation manual
auroTHERM
On-roof/flat roof installation
Contents
1 Notes on the documentation .........................2
1.1 Other applicable documents ................................2
1.2 Document storage ..................................................2
1.3 Symbols used ...........................................................2
1.4 Applicability of the manual ...................................2
2 Intended use ....................................................2
2.1 Combination with other components ................2
2.2 Operational conditions ..........................................3
2.3 CE mark .....................................................................3
3 Safety information ......................................... 3
3.1 Technical Guidance .................................................3
3.2 Related documents .................................................3
3.3 Regulations for the prevention of accidents ...4
3.4 Lightning protection ...............................................4
3.5 Frost protection.......................................................4
4 Before installation ..........................................5
4.1 Safety information ..................................................5
4.2 Scope of delivery ....................................................6
4.2.1 On-roof mounting ...................................................6
4.2.2 Flat roof installation ............................................... 7
4.3 Collector field packaging.......................................8
4.4 Interconnection diagram .......................................9
4.5 Hydraulic connection preparation .................... 10
4.5.1 On-roof mounting ................................................. 10
VFK 145 H/V
VFK 150 H/V
4.5.2 Flat roof installation ............................................. 10
4.6 Required tools ........................................................10
5 Flat roof installation .................................... 10
5.1 Collector position and field arrangement ....... 10
5.2 Weighting and arrangement of the frames ......11
5.3 Collector installation .............................................12
6 On-roof mounting ...........................................16
6.1 Collector position and field arrangement ....... 16
6.2 Roof anchor installation .......................................17
6.2.1 Roof anchor type P (pantile) .............................. 19
6.2.2 Roof anchor type S and roof anchor
type S flat (for beaver tail) ..................................21
6.2.3 Stair bolt mounting kit .........................................22
6.3 Collector installation ............................................22
7 Concluding work ............................................27
8 Recycling and disposal .................................27
8.1 Collectors ................................................................27
8.2 Packaging ................................................................27
8.3 Solar fluid ................................................................27
9 Vaillant Customer Service and warranty ..27
9.1 Vaillant warranty...................................................27
9.2 Vaillant Service ......................................................27
10 Technical data .............................................. 28
GB
1 Notes on the documentation
2 Intended use
1 Notes on the documentation
The instructions below are intended to help you
throughout the entire documentation.
1.1 Other applicable documents
All installation instructions of flat collectors and components of the installation must be observed when installing the solar system. These instructions are included
with the individual components of the system and the
additional components.
We accept no liability for any damage caused by failure to observe these instructions.
1.2 Document storage
Please pass on this installation manual and all other applicable documents and auxiliary equipment to the plant
operator, whose responsibility it is to ensure the manuals and auxiliary equipment are available whenever required.
1.3 Symbols used
Please observe the safety instructions in this installation
manual for the installation of the collector!
Danger!
d
Immediate risk of serious injury or death!
Danger!
e
Risk of death from electric shock!
Danger!
H
Danger of burning and scalding!
Caution!
a
Potentially dangerous situations for the product and the environment!
Note
h
Useful information and instructions.
• Symbol indicating the required action
1.4 Applicability of the manual
These installation manual applies exclusively to flat collectors with the following article numbers:
Vaillant flat collectors are available in different versions:
one for the horizontal position, one for the vertical position.
Besides, collectors in the collector field can be arranged
side by side and on top of each other.
Generally, the installation steps and the instructions
described in this manual are valid for both collector
positions and field arrangements.
Any different installation steps are clearly pointed out:
With horizontal collector position
w
With vertical collector position
s
With fields arranged side by side
n
With fields arranged on top of each other
u
2 Intended use
The Vaillant auroTHERM flat collectors are built and designed according to accepted safety rules and regulations.
Nevertheless, improper use may cause danger to life
and limb of the user or third parties and could impair
the operation of the unit and other objects.
The unit is not intended for use by persons (including
children) with reduced physical, sensory or mental capabilities, or lack of experience and/or knowledge, unless
they have been given supervision or instruction concerning use of the unit by a person responsible for their
safety.
Children must be watched to ensure that they do not
play with the unit.
Vaillant auroTHERM flat collectors are used for heating
support and for solar hot water generation.
Any other use or use exceeding the above-mentioned
applications shall be considered as improper use. The
manufacturer/supplier shall not be responsible for any
damages resulting from such improper use. The user
alone bears the risk.
Intended use includes observance of the operating and
installation manuals and all other applicable documents,
as well as adherence to the maintenance and inspection
conditions.
Collector type Article number
VFK 145 H 0010004457
VFK 145 V 0010004455
VFK 150 H 0010006285
VFK 150 V 0010006283
Table 1.1 Collector types and article numbers
For the flat collector article number please see the identification plate on the upper collector edge.
Caution!
a
Any improper use is forbidden!
2.1 Combination with other components
Vaillant flat collectors should be combined only with
Vaillant components (fixing, connections) and system
components.
The use of other components or system components
shall be considered as improper use. We accept no liability.
Installation manual auroTHERM 0020057143_042
Intended use 2
Safety information 3
2.2 Operational conditions
Caution!
a
The roof may collapse!
Mount the flat collectors only on roofs with a
sufficient load-carrying capacity.
If necessary, call a technician.
Caution!
Collector damage!
Flat collectors are suitable for a maximum
snow load of 5.0 kN/m
load of 1.6 kN/m
On-roof mounting:
The flat collectors can be mounted on roofs with inclinations from 15º to 75º.
Flat roof installation:
Flat collectors can be installed on flat roof frames in the
as-delivered condition with an angle of 30°, 45° or 60°.
2.3 CE mark
The CE mark certifies that the appliances, according to
the models available, satisfy the basic requirements of
the following directives:
– Directive 97/23/EWG of the European Parliament and
Council for approximation of the laws of the member
states regarding pressure equipment
auroTHERM flat collectors are built according to the state of the art and recognised
safety rules and regulations.
Conformity with the applicable standards
has been demonstrated.
auroTHERM flat collectors have been successfully tested according to the rules and
requirements for the Solar Keymark.
2
2
and a maximum wind
.
Danger!
H
Danger of burning and scalding!
In case of solar irradiation inside the units, collectors can reach 200 °C. Remove the sun protection film installed at the factory only after
the solar energy system has been started up.
Danger!
H
Danger of burning and scalding!
In case of solar irradiation inside the units, collectors can reach 200 °C.
Do not perform maintenance work under direct
sunlight.
Caution!
a
Risk of corrosion!
On roofs made of metals more noble than aluminium (e.g. copper roofs) galvanic corrosion
can occur at the anchor points, whereby the attachment of the collectors is no longer guaranteed. Ensure that the metals are separated by
suitable underlays.
Caution!
Collector damage!
In order to install flat collectors according to
the installation manual, a qualified engineer is
required.
The installation should be performed only by
qualified engineers.
3.1 Technical Guidance
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.
3 Safety information
The following safety instructions, technical rules and accident prevention regulations must be observed when
installing the flat collectors.
Danger!
d
Danger to life as a result of falling from the
roof!
Danger to life from parts falling from the roof!
Observe the applicable national regulations for
working at heights.
3.2 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), BS 7671 (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 build-
ings conveying water for human consumption.
GB
3Installation manual auroTHERM 0020057143_04
3 Safety information
— 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.
3.3 Regulations for the prevention of accidents
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 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.
3.4 Lightning protection
Caution!
a
Damage from lightning!
If the installation height is more than 20 m or
if the collectors are projected above the roof
ridge, electro-conductive components must be
connected to a lightning protection device!
3.5 Frost protection
Caution!
a
Damage due to frost!
Under no circumstances should water on its
own be in the collector if there is a danger of
frost!
After pressurisation and flushing, the collectors
may contain water residues.
Immediately fill the solar system with solar
fluid. Check the fluid concentration with a frost
protection tester. Water remaining in the solar
circuit may dilute the fluid.
Installation manual auroTHERM 0020057143_044
4 Before installation
4.1 Safety information
Please note the following instructions before and during
installation:
Danger!
d
Risk of death from falls and falling objects!
Observe the national regulations for working at
heights.
Wear the Vaillant safety belt
(article number 302066).
Danger!
H
Danger of burning and scalding!
In case of solar irradiation inside the units, collectors can reach 200 °C. Remove the sun protection film installed at the factory only after
the solar energy system has been started up.
Caution!
a
Collectors may be damaged by incorrect storage!
Always store the collectors in a dry place and
protected from the elements.
Before installation 4
Caution!
System error function due to air bubbles!
To fill the system, use the fill trolley
(article number 0020042548) to avoid air
bubbles.
Use the manual air vent installed on the collector field.
Alternatively, install the Vaillant Solar automatic air vent (article number 302019) in the
highest point of the system or the automatic
de-aerator (article number 302418) in the solar
circuit.
Observe the relevant installation and operating
manual.
Caution!
Danger of damaging internal components!
The interior of the collector is vented by the
opening integrated in the pipe penetration.
Keep the vent opening clear for trouble-free operation.
GB
5Installation manual auroTHERM 0020057143_04
6
g
p
g
4 Before installation
4.2 Scope of delivery
• Check the mounting kit for completeness based on the
illustrations and bills of materials.
4.2.1 On-roof mounting
5
14
4
1
2
7
8
9
10
11
12
13
3
Fig. 4.1 On-roof mounting kit (here: vertical collector)
Pos. Description Quantity Article number (kit)
1 Mounting rail 2
2 Supply (outlet with opening for collector sensor) 1
3 Return (inlet) 1
4 Lower plug 1
5 Upper plug (with vent) 1
6 Clam
7 Roof anchor type P (for pantile)
8 Long lower section type P (optional)
9 Roof anchor type S (for beaver tail, etc.)
10 Roof anchor type S flat (for beaver tail, etc.)
11 Stair bolt mounting kit
12 Hydraulic connections 2
13 Clamp 4
14 Collector 1
Table 4.1 On-roof mounting bill of materials
0020059899 (Vertical rail mounting kit)
0020059898 (Horizontal rail mountin
0020059891 (Hydraulic connection kit)
4
420020067273 (Basic kit)
0020067274 (Extension kit for stacked mounting)
1 0020080177
420020067275 (Basic kit)
0020067276 (Extension kit for stacked mounting)
420020080145 (Basic kit)
0020080147 (Extension kit for stacked mounting)
420020067277 (Basic kit)
0020087855 (Extension kit for stacked mountin
0020055181 (Hydraulic extension kit)
0010004455 (auroTHERM VFK 145 V)
0010004457 (auroTHERM VFK 145 H)
0010006283 (auroTHERM VFK 150 V)
0010006285 (auroTHERM VFK 150 H)
Installation manual auroTHERM 0020057143_046
kit)
)
4.2.2 Flat roof installation
g
Before installation 4
5
12
4
6
1
2
7
8
9
3
Fig. 4.2 Mounting kit for flat roof installation
(here: vertical collector)
Pos. Description Quantity Article number (kit)
1 Mounting rail 2
2 Supply (outlet with opening for collector sensor) 1
3 Return (inlet) 1
4 Lower plug 1
5 Upper plug (with vent) 1
6 Clamp 4
7 Frame with clamping element 1
8 Gravel tray (optional)
9 Safety clamps 2
10 Hydraulic connections 2
11 Clamp 4
12 Collector 1
Table 4.2 Flat roof installation bill of materials
10
11
0020059901 (Vertical rail mounting kit)
0020059900 (Horizontal rail mountin
0020059891 (Hydraulic connection kit)
0020055206 (Base vertical frame kit)
0020055207 (Base horizontal frame kit)
2
0020059904 (Gravel tray kit 2 pieces)
3
0020059905 (Gravel tray kit 3 pieces)
0020055181 (Hydraulic extension kit)
0010004455 (auroTHERM VFK 145 V)
0010004457 (auroTHERM VFK 145 H)
0010006283 (auroTHERM VFK 150 V)
0010006285 (auroTHERM VFK 150 H)
kit)
GB
7Installation manual auroTHERM 0020057143_04
4 Before installation
4.3 Collector field packaging
The following tables list the required components according to the type of installation.
On-roof mounting
Number of collectors: 1 2 3 4 5 6 7 8 9 10
Hyd. connection kit article number 0020059891
Hyd. connection kit article number 0020055181 - 1 2 3 4 5 6 7 8 9
Anchor set type P article number 0020067273
Anchor set type S article number 0020067275
position
Anchor set type S flat article number 0020080145
Anchor set stair bolt Article number 0020067277
Horizontal collector
Horizontal rail, anodized - Article No. 0020059898 1 2 3 4 5 6 7 8 9 10
Hyd. connection kit article number 0020059891 1
Hyd. connection kit article number 0020055181 - 1 2 3 4 5 6 7 8 9
Anchor set type P article number 0020067273
Anchor set type S article number 0020067275
sition
Field arrangement side by side
Field arrangement on top of each other
* Caution!
When the vertical collector arrays are arranged on top of one another, the collectors must be hydraulically balanced with respect to
one another (Tichelmann system).
Table 4.3 On-roof mounting components
Anchor set type S flat article number 0020080145
Anchor set stair bolt Article number 0020067277
Vertical collector po-
Vertical rail, anodized - Article No. 0020059899 1 2 3 4 5 6 7 8 9 10
Hyd. connection kit article number 0020059891 1 1 -------Hyd. connection kit article number 0020059894 - 1 -------Anchor set type P article number 0020055174
Anchor set type S article number 0020055184
Anchor set type S flat article number 0020080145
Anchor set stair bolt Article number 0020059897
Anchor extension kit type P article number 0020059896
position
Anchor extension kit type S article number 0020059895
Horizontal collector
Anchor extension kit type S flat article number 0020080147
Anchor extension kit hanger bolt
anodised Item no. 0020087854
Horizontal rail, anodized - Article No. 0020059898 1 2 --------
Hyd. connection kit article number 0020059891 1 2 3 4 5 6 7 8 9 10
Hyd. connection kit article number 0020059894
Anchor set type P article number 0020055174
Anchor set type S article number 0020055184
Anchor set type S flat article number 0020080145
Anchor set stair bolt Article number 0020059897
Anchor extension kit type P article number 0020059896
Vertical
Anchor extension kit type S article number 0020059895
collector position *
Anchor extension kit type S flat article number 0020080147
Anchor extension kit hanger bolt
anodised Item no. 0020087854
Vertical rail, anodized - Article No. 0020060379 1 2 --------
12345678910
12345678910
11--------
Required quantity
-1--------
1111111111
-123456789
12345678910
1
Installation manual auroTHERM 0020057143_048
Flat roof installation
Gravel tray article number 0020059905
Hyd. connection kit article number 0020059891 1
Hyd. connection kit article number 00 20055181 - 1 2 3 4 5 6 7 8 9
Horizontal frame article number 0020055207 2 3 4 5 6 7 8 9 10 11
Horizontal
Horizontal rail, aluminium article number 0020059900 1 2 3 4 5 6 7 8 9 10
collector position
Gravel tray (3 pieces) article number 0020059905 2 4 4 6 8 8 10 12 12 14
Gravel tray (2 pieces) article number 0020059904 1 0 2 1 0 2 1 0 2 1
Hyd. connection kit article number 0020059891 1
Hyd. connection kit article number 0020055181 - 1 2 3 4 5 6 7 8 9
Vertical
Field arrangement side by side
Table 4.4 Flat roof installation components
4.4 Interconnection diagram
Vertical frame article number 0020055206 2 3 4 5 6 7 8 9 10 11
collector position
Vertical rail, aluminium article number 0020059901 1 2 3 4 5 6 7 8 9 10
Before installation 4
Number of collectors: 1 2 3 4 5 6 7 8 9 10
2 3 4 5 6 7 8 9 10 11
Required quantity
Note
h
Observe the planning information when dimensioning the field volume flow.
Field arrangement side by side
n
Note
h
If you connect 1 to 5 collectors one after
another, the hydraulic connections can be laid
one below the other on one side.
145...
Fig. 4.3 Field arrangement side by side for 1 - 5 collectors
Note
h
If you connect 6 or more collectors one after
another, the hydraulic connections must be arranged diagonally, to force a complete flow.
max. 12
1
Fig. 4.4 Field arrangement side by side for 6 - 12 collectors
Field arrangement on top of each other
u
...
2
11
12
max. 2
Fig. 4.5 Field arrangement on top of each other
GB
9Installation manual auroTHERM 0020057143_04
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