Vaillant auroTHERM VFK 145 H/V, auroTHERM VFK 150 H/V, auroTHERM VFK 125 Installation Manual

auroTHERM

VFK 125
VFK 135 D
VFK 140 D
VFK 145 H/V
VFK 150 H/V

ES, GB, NL, PT

In roof

For the expert technician

Installation manual

auroTHERM

VFK 145 H/V
VFK 150 H/V

In-roof mounting

GB

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 a damage caused by failure
to observe these instructions.

1.2 Attachment and storage of documents

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!

d

Danger!

Immediate risk of serious injury or death!

e

Danger!

Risk of death from electric shock!

H

Danger!

Danger of burning and scalding!

a

Caution!

Potentially dangerous situations for the prod­uct and the environment!

h

Note

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:

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.

Contents

1 Notes on the documentation .............................. 2

1.1 Other applicable documents ...................................... 2

1.2 Attachment and storage of documents ..................2

1.3 Symbols used ................................................................. 2

1.4 Applicability of the manual ......................................... 2

2 Intended use ..........................................................3

2.1 Combination with other components ...................... 3

2.2 Operational conditions ................................................3

2.3 CE mark ........................................................................... 3

3 Safety instructions ............................................. 4

3.1 Technical Guidance .......................................................4

3.2 Related documents .......................................................4

3.3 Regulations for the prevention of accidents .........4

3.4 Lightning protection .....................................................5

3.5 Frost protection............................................................. 5

4 Installation ............................................................ 5

4.1 Before installation ........................................................ 5

4.2 Scope of delivery ..........................................................6

4.3 Collector field packaging........................................... 10

4.4 Interconnection diagram .............................................11

4.5 Installation dimensions ...............................................12

4.6 Hydraulic connection preparation ...........................14

4.7 Installation .....................................................................14

4.8 Concluding work ..........................................................25

5 Disposal ............................................................... 25

6 Vaillant Customer Service and warranty ....... 25

6.1 Vaillant warranty.........................................................25

6.2 Vaillant Service ............................................................25

7 Technical data ....................................................26

Installation manual auroTHERM 0020057148_032

Contents
1 Notes on the documentation

Vaillant auroTHERM 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:

w

With horizontal collector position

s

With vertical collector position

n

With fields arranged side by side

u

With fields arranged on top of each other

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.
Use includes observance of the operating and installa­tion manuals and all other applicable documents, as well
as adherence to the maintenance and inspection condi­tions.

a

Caution!

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.

2.2 Operational conditions

a

Caution!

Collector damage!
Flat collectors are suitable for a maximum
snow load of 5.0 kN/m

2

and a maximum wind

load of 1.6 kN/m

2

.

Caution!

The roof may collapse!
Mount the flat collectors only on roofs with a
sufficient load-carrying capacity.
If necessary, call a technician.

Caution!

Lack of tightness!
For in-roof mounting, the roof must have a
pitch of ≥ 22°.
With roof angles <22° rainwater can collect on
the cover plates and leaks can occur.
With roof angles of 15°-22° use the Vaillant
cover kit 0020059599 or 0020059879.

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.

3Installation manual auroTHERM 0020057148_03

Notes on the documentation 1

Intended use 2

GB

3 Safety instructions

The following safety instructions, technical rules and ac­cident prevention regulations must be observed when
installing the flat collectors.

d

Danger!

Risk of death from falls and falling objects!
Observe the national regulations for working at
heights.

H

Danger!

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.

H

Danger!

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.

a

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.

3.2 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), 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 build-

ings 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 dia-

phragm for unvented hot water supply systems

— BS 4814 Specification for: Expansion vessels using an

internal diaphragm, for sealed hot water heating sys-

tems.
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.

Installation manual auroTHERM 0020057148_034

3 Safety instructions

3.4 Lightning protection

a

Caution!

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

a

Caution!

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.

4 Installation

4.1 Before installation

Please note the following instructions before and during
installation:

d

Danger!

Risk of death from falls and falling objects!
Observe the national regulations for working at
heights.
Wear the Vaillant safety belt
(article number 302066).

d

Danger!

Risk of death from falls!
During installation never step on the cover
plate. It might break due to an excessive load.

H

Danger!

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.

a

Caution!

Collectors may be damaged by incorrect stor­age!
Always store the collectors in a dry place and
protected from the elements.

Caution!

Roof construction damage due to missing rear
roof ventilation!
There must be roof back ventilation in accord­ance with regulations.

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.

5Installation manual auroTHERM 0020057148_03

Safety instructions 3

Installation 4

GB

4.2 Scope of delivery

• Check the mounting kit for completeness based on the
illustrations and bills of materials.

9

12

20

22

23

17

27

29

19

24

11

21

13

10

18

26

15

16

28

25

14

Fig. 4.1 Vertical collector mounting kit

h

Note

The vertical collectors are arranged side by
side in the collector field.

1

2

4

5

6

3

7

8

Installation manual auroTHERM 0020057148_036

4 Installation

Roof angle 15-22° Roof angle 22-75°

Basic kit Basic kit Extension kit

Number of
collectors

23121

Pos.

Description

Number Kit

no.

Number Kit

no.

Number Kit

no.

Number Kit

no.

Number Kit

no.

1 Clamp 4

0020065267400200652674002006526740020065267

-

2 Upper supply (with probe) 1 1 1 1 -

3 Return (inlet) 1 1 1 1 -

4 Lower plug 1 1 1 1 -

5 Upper plug (with ventilation) 1 1 1 1 -

6 Pipe coupling 2

0020055181

4

2x

0020055181

2

00200551812002005518120020055181

7 Clamp 4 8 4 4 4

8 Collector 2 3 1 2 1

9 Tile bar 2

0020059599

3

0020059879

1

0020060175

2

0020055196

10 Ridge plate - - 1 - -

0020055198

11 Upper ridge plate coupling - - - 1 1

12 Right ridge plate - - - 1 -

13 Left ridge plate - - - 1 -

14 Ridge plate extension - - - - 1

15

Ridge plate 2 collectors roof angle
15-22°

1----

16

Ridge plate 3 collectors roof angle
15-22°

-1---

17 Right side section 1 1 1 1 -

18 Left side section 1 1 1 1 -

19 Profile end 3 4 2 3 1

20 Central front section - 1 1 - 1

21 Right front section 1 1 - 1 -

22 Left front section 1 1 - 1 -

23 Intermediate plate 1 2 - 1 1

24 Support board - - 1 1 1

25 Lower ridge plate coupling - - 2 3 1

26 Roof batten 3 3 2 3 3

27 Inner clamp 9 12 6 9 3

28 Bolt kits (no. 1-5)

(TX 25)

Bolts no. 1 28 40 16 28 12

Bolts no. 2 17 19 15 17 2

Bolts no. 3 10 13 7 10 3

Bolts no. 4 10 14 6 10 4

Bolts no. 5 3 5 - 3 2

29 External clamp 10 10 10 10 -

Table 4.1 Vertical collector mounting kit side by side

7Installation manual auroTHERM 0020057148_03

Installation 4

GB

h

Note

The horizontal collectors can be arranged in the
collector field both side by side and on top of
each other.

11

29

25

20

28

17

26

24

13

10

23

14

19

22

9

21

31

2712

30

18

16

15

Fig. 4.2 Horizontal collector mounting kit

7

4

6

3

2

5

1

8

Installation manual auroTHERM 0020057148_038

4 Installation