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Vaillant Solar System and auroSTOR unvented solar cylinder Start-Up, Maintenance And Troubleshooting Manual

Solar hot water systems
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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
GB

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Summary of Contents for Vaillant Solar System and auroSTOR unvented solar cylinder

  • 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...

  • Page 2: Table Of Contents

    Installation of the solar circuit piping ....35 manufacturer's warranty ........67 5.3.1 General instructions ..........35 10.1 Vaillant service ............67 5.3.2 Material ................. 35 10.2 Vaillant warranty ............67 5.3.3 Laying of the solar circuit pipes ......35 5.3.4 Connection of the collectors to the...

  • Page 3: Notes On The Documentation 1

    Overview of standards, safety instructions 2 Notes on the documentation Note! Application recommendation. Your solar system is a quality product from Vaillant. This manual describes the entire system, all of its • Symbol for a required task components and the cylinder and provides you with...

  • Page 4: Regulations In Great Britain

    2 Overview of standards, safety instructions ENV 12977-2 BS 6651 Code of practice for protection of structures Thermal solar systems and components; against lightning Factory made systems, Part 2: Testing methods Regulations in Great Britain ISO 9459-1: 1993 2.2.1 Technical Guidance Solar heating –...

  • Page 5: Safety Instructions

    Safety instructions For air removal from the solar system pipe work use the Vaillant The entire solar system must always be installed and Use the automatic Vaillant air separator system (item automatic air separator system (item no.

  • Page 6: System Description

    Children must be supervised to ensure they do not play with the unit. The purpose of the Vaillant solar system is to provide a solar-supported hot water supply. Any other use or extended use is considered to be im- proper.
  • Page 7 System description 3 Fig. 3.1 System for solar heating of drinking water 9 Solar expansion vessel Boiler 10 Automatic air separator system 2 auroSTOR solar cylinder 11 Drinking water expansion vessel 3 230 V motorised 2 port valve (supplied together with the solar 12 Thermostat mixing valve cylinder) A Boiler flow...

  • Page 8: Description Of The Components

    Electrical wiring The Vaillant Control Center VR 65 can be used to wire up the system if an eBUS-capable Vaillant boiler is used. A standard wiring box can be used if a Vaillant boiler which is not eBUS-capable or an external boiler is used.
  • Page 9 Description of the components 4 Fig. 4.2 Section through auroTHERM exclusive VTK 570 sho- wing direction of flow 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...
  • Page 10 4 Description of the components Technical data, tube collectors Appliance designation Units auroTHERM exclusive VTK 570 Surface area (gross, aperture/net) 1,28 / 0,82 Height 1695 Width Depth Weight Collector capacity 3,56 Copper pipe connection, flat-face Thread 3/4“ Insulation: high-vacuum Max. operating pressure Spiegel Reinsilber, Reflexionsgrad Absorber emission Absorber absorption...
  • Page 11 Description of the components 4 T = T Collector Ambient air Fig. 4.4 Efficiency of auroTHERM collector with radiation ener- gy content of 800 W/m VTK 1140 VTK 570 0,25 0,5 0,75 1 1,25 1,5 1,75 2 2,25 2,5 2,75 3,25 3,5 3,75 4 4,25 4,5 4,75 5 Flow rate [l/min] Fig.

  • Page 12: Disposal

    Design The installation of a protection vessel (5) is recommen- Fig 4.9 key) is recommended in all cases. In the case of Vaillant The solar pump unit transports heat from the collector ded in all cases. The solar expansion vessel is protected solar sets a combined expansion and protection vessel is supplied.

  • Page 13: Solar Pump

    The Vaillant auroSTOR cylinder has such as device facto- ry fitted, and this is wired in series with the power supp- Fig. 4.11 Flow rate meter 0 - 6 l/min ly to the solar pump.

  • Page 14: Protection Of The Solar Circuit Against Frost And Corrosion

    0.27 Risk of damage! flexible pipe DN 20 mm 0.36 Vaillant solar fluid is ready mixed. You may not under any circumstances mix it with water or Table 4.4 Pipeline volume other fluids. Otherwise it will become ineffective as an antifreeze or anticorrosive, Proceed as follows to check the solar fluid;...

  • Page 15: Safety Data Sheet

    Substance/Formulation and company name Individual-related measures: Information on the product: No particular measures required. Trade name of the Vaillant solar fluid Environmental measures: (item no. 302 362) The product may not be discharged into waters Information on the supplier: without pre-treatment (biological sewage plant).
  • Page 16 Lower explosion limit: 2.6 % by vol. (details for 13.1 Disposal: Upper explosion limit: 12.6 % by vol. 1.2 propylene Vaillant solar fluid (item no. 302 363) must de glycol) disposed of at an appropriate waste site or waste Ignition temperature: omitted incineration plant, for example, while observing vapour pressure (20 °C): 20 mbar...

  • Page 17: Aurostor Solar Cylinder

    (refer to Section 5.8, Electrical installation). Solar control Wiring The Vaillant Control Center VR 61 or VR 65 can be used to wire up the system if an eBUS-capable Vaillant boiler is used. Kol 1 A standard wiring box can be used for all other boilers.

  • Page 18: Installation 5

    - Hot water piping and secondary return (if available) Standard 230 V components can be integrated in the - Cold water supply Vaillant eBUS system via the Control Center VR 65. For - Discharge pipe wiring, refer to Section 5.8, Electrical installation, and...
  • Page 19 5 Installation auroTHERM VFK fixing sets In-roof kit for 2 collectors In-roof kit for 3 collectors Item no.: 0020057933 0020059990 In-roof basic kit (fixing material) 309633 309633 In-roof extra kit (metal sheets) 302389 302389 In roof extension set (for an additional collector) 302390 Table 5.4 Scope of delivery, auroTHERM VFK fixing sets auroSTOR solar cylinders...

  • Page 20: Installation Of The Solar Cylinder

    23 Thermostat, immersion heater 14 Supply (solar circuit) Note! The safety thermostat can be removed if the solar energy system is operated using a Vaillant auroMATIC VRS 560 in conjunction with a Vaillant eBUS compatible boiler. Manual - Solar hot water systems 0020009607_02...
  • Page 21 Control of the hot water temperature The hot water temperature in the top half of the cylinder can be optionally regulated by the Vaillant auroMATIC VRS 560 solar control by means of the programmable Vaillant VRT 360 room thermostat or a timer.

  • Page 22: Technical Data Of The Aurostor Solar Cylinder

    Installation 5 Immersion heater Note! The auroSTOR solar cylinders are equipped with an The heat-up time is based on a primary flow additional immersion heater of 3 kW, including the rate of 9 l/min at 80 °C. operating thermostat and energy cut-off device.The Temperature rise from 15 °C to 65 °C immersion heater is situated behind the front plate.
  • Page 23 * 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. Manual - Solar hot water systems 0020009607_02...

  • Page 24: Intended Use

    Intended use 5.1.6 Safety instructions and regulations The Vaillant solar cylinders auroSTOR VIH S GB 200 S, This product has been checked for adherence to the VIH S GB 250 S and VIH S GB 250 are unvented, building regulations for unvented hot water cylinder indirectly heated hot water cylinders for solar systems systems.

  • Page 25: Transport

    5 Installation 5.1.9 Transport A cylinder carrier handle is supplied to make the transport to the installation site easier. Fig. 5.7 Fastening the cylinder carrier handle • Fasten the carrier handle (1) to the hot water connection of the solar cylinder. Manual - Solar hot water systems 0020009607_02...

  • Page 26: Dimensions

    Installation 5 5.1.10 Dimensions Fig. 5.8 Dimensions of the auroSTOR solar cylinder 5 Cold water supply connection Hot water connection 6 Solar circuit return 2 Temperature and pressure relief valve 7 Return (boiler) 3 Immersion heater 8 Boiler flow 4 Solar circuit flow Cylinder type VIH S GB 200 S 1468...

  • Page 27: Functional Diagram

    5 Installation Functional diagram Fig. 5.9 Functional diagram 9 Solar expansion vessel Boiler 10 Automatic air separator system 2 auroSTOR solar cylinder 11 Hot water expansion vessel 3 230 V motorised 2 port valve (supplied with the solar cylinder) 12 Thermostat mixing valve 4 Immersion heater A Boiler flow 5 230 V motorised 2 port valve...

  • Page 28: Installation Of The Solar Circuit Piping

    5.3.1 General instructions significant role in terms of maximum efficiency of the The Vaillant solar system is a closed hydraulic system in solar system. which heat can be transferred to the cylinders only by To keep the pressure loss in the solar circuit to a...

  • Page 29: Bleeding Of The Solar Circuit

    Larger pipe diameters may be necessary for relatively system considerably.Install therefore the automatic large distances between the boiler and the cylinder. Vaillant air separator system (item no. 302 418) in the Since all wall-mounted Vaillant boilers (except return of the solar circuit (see Fig. 5.12) between the ecoMAX pro with open ventilation) have an installed solar circuit and solar pump unit.

  • Page 30: Installation Of The Cold Water Supply Pipework

    1 bar.You can obtain information on alternative hot water supply systems from Vaillant Ltd. cold water To keep the friction losses at a minimum, a minimum diameter of 22 mm is recommended for the cold water Fig.

  • Page 31: Drain Valve

    15 mm copper tube to the tundish supplied. The tundish should be installed vertically, as The Vaillant solar cylinder is supplied with an external close to the uniSTOR as possible and within 500 mm of hot water expansion vessel (DW EV).

  • Page 32: High Level Termination

    Total resistance 10.2 m The discharge pipe from the pressure relief valve of the Vaillant boiler can be connected to the horizontal The total resistance of the discharge pipe is higher discharge pipe of the solar cylinder behind the tundish than the maximum permissible value for 22 mm with a T-piece.

  • Page 33: Electrical Installation

    5 Installation 5.8.1 Immersion heater tundish The auroSTOR VIH S GB 200 - 300 S solar cylinders have been equipped with an immersion heater by the 300 mm manufacturer. minimum discharge pipe 230 V AC metal hopper 3 kW head Fig.

  • Page 34: Electrical Connection To The Cylinder Control Device

    Vaillant boiler can be controlled by various controllers Boiler used (refer to Section 4.8, Solar control). An overview of the eBUS-capable boiler, such as the Vaillant ecoTEC, or a application options for controllers can be found in boiler which is not eBUS-capable, such as the Vaillant Table 5.7 (refer to Section 5.8.3, Combination options of...
  • Page 35 - Overview removal of the cylinder thermostat, see depending on the boiler and control components used, Fig. 5.22 (if a Vaillant eBUS controller is used) as specified in Table 5.7. - Installation of two VR 10 temperature sensors in the solar cylinder (see Fig.
  • Page 36 Installation 5 Fig. 5.22 Removal of the cylinder thermostat Fig. 5.23 Installation of the VR 10 temperature sensor Cylinder thermostat 2 Lock • Push one of the VR 10 temperature sensors (1) 3 Capillary tube supplied with the solar control in the now vacant •...
  • Page 37 • Establish the connections to the mains supply. 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. Note!
  • Page 38 Installation 5 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 VRT 360 Fig. 5.25 Wiring scheme 1...
  • Page 39 5 Installation Wiring plan 2 • Connect this temperature sensor to the terminal - Vaillant boiler “Ertrag” in the auroMATIC 560 solar control. - Wiring via standard wiring box • Make sure the temperature sensors of the immersion - Solar circuit control via VRS 560...
  • Page 40 Installation 5 Wiring scheme 2 - eBUS-capable or eBUS-incapable Vaillant boiler - Wiring via standard wiring box - Solar circuit control via VRS 560 - Solar circuit reheating control via VRS 560 - Heating circuit control via programmer Fig. 5.28 Wiring scheme 2...
  • Page 41 Fig. 5.29 Installation of the VR 10 temperature sensor protected terminal strip. • Push one of the VR 10 temperature sensors (1) • Wire up the Vaillant boiler, the programmer and the supplied with the solar control in an immersion sleeve room thermostat.
  • Page 42 Installation 5 Note! Programme the separate hot water 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.
  • Page 43 5 Installation Wiring scheme 3 - eBUS-capable or eBUS-incapable Vaillant boiler - Wiring via standard wiring box - Solar circuit control via VRS 560 - Solar cylinder reheating control via a device from a third-party manufacturer (DHW timer) - Heating circuit control via programmer Fig.
  • Page 44 Installation 5 Wiring plan 4 • Connect this temperature sensor to the terminal - Boiler from third party manufacturer “Ertrag” in the auroMATIC 560 solar control. - Wiring via standard wiring box • Make sure the temperature sensors of the immersion - Solar circuit control via VRS 560 heater, solar cylinder and solar control fit properly in - Solar circuit reheating control via VRS 560...
  • Page 45 5 Installation Wiring scheme 4 - eBUS-incapable boiler, third-party manufacturer - Wiring via standard wiring box - Solar circuit control via VRS 560 - Solar circuit reheating control via VRS 560 - Heating circuit control via programmer Fig. 5.34 Wiring scheme 4 Manual - Solar hot water systems 0020009607_02...
  • Page 46 Installation 5 Wiring plan 5 • Attach the temperature sensor for the gain (2) to the - Boiler from third party manufacturer return pipe of the solar circuit nearby the solar - Wiring via standard wiring box cylinder. - Solar circuit control via VRS 560 •...
  • Page 47 5 Installation Note! Programme the separate hot water 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.
  • Page 48 Installation 5 Wiring scheme 5 - eBUS-incapable boiler, third-party manufacturer - Wiring via standard wiring box - Solar circuit control via VRS 560 - Solar cylinder reheating control via a device from a third-party manufacturer (DHW timer) - Heating circuit control via programmer Fig.

  • Page 49: Start-Up

    • Place the three-way ball valve (15) into flush position. permitted to use manual pumps for filling. • Connect the drain hose of the Vaillant filling pump or a similar hose with filter (9) to the fill/drain valve (12). Expansion vessel admission pressure Put the other end into the solar fluid container (10).

  • Page 50: Setting The Flow Rate And Pump

    Also check other ways of reducing the pressure loss. Observe here the Vaillant solar planning information. Manual - Solar hot water systems 0020009607_02...

  • Page 51: Programming The Flow Rate On The Controller

    6 Start-up Minimum cross-section of the copper pipe in the Number of auroTHERM Flow rate collector circuit with a total length of: exclusive VTK 570 tube collectors connected in l/min 20 m 50 m series 0,40 0,80 1,20 1,60 2,00 2,40 2,80 3,20...

  • Page 52: Filling The Reheating Circuit

    Start-up 6 • Set the hot water thermostatic mixing valve with the adjusting knob to maintain your desired temperature at the hot water taps. Danger! Risk of being scalded by hot water! Set the thermostat mixer to below 60 °C and check the temperature at a hot water tap to ensure effective protection against scalding.

  • Page 53: Start-Up Protocol

    Further information can be obtained from Vaillant service (+49 (0)870 - 6060777). Manual - Solar hot water systems 0020009607_02...
  • Page 54 Inspection and maintenance 7 Maintenance Maintenance interval Solar circuit Check the frost protection of the solar fluid (use the Vaillant 302 064 solar fluid tester) Annually Check the system pressure Annually Check the pH value of the solar fluid (with litmus paper, pH > 7.5)

  • Page 55: Troubleshooting

    The following tables provide information on possible malfunctions during the operation of the solar system as well as their cause and remedy. All work on the Vaillant solar system (installation, main- tenance, repairs etc.) may be performed only by appro- ved specialists.
  • Page 56 Troubleshooting 8 Malfunction Cause Remedy Pump starts up and goes off shortly The temperature difference of the controller Check whether the entire pipework is fully afterwards.This is repeated several times is too low or the pump speed is set too high. insulated.Increase the temperature until the system runs its course.
  • Page 57 8 Troubleshooting Malfunction Cause Remedy Reheating is not working. The boiler runs 1. Air in the reheating heat exchanger Bleed the reheating heat exchanger. for a short time, goes off and then back 2. Heat exchanger surface area too Compare the specifications of the boiler on again.

  • Page 58: Notes For The Owner 9

    The hot water thermostat for the boiler for reheating In order for your Vaillant solar system to work perfectly, the auroSTOR can be set between 20 and 65 °C. The please observe the following instructions: desired temperature is set by the installer during the •...

  • Page 59: Switching Off The Solar Cylinder

    Vaillant VIH S GB 200 S, VIH S GB 250 S and VIH S GB 300 S cylinders. Care It is important that your hot water cylinder is serviced 9.5.1...

  • Page 60: What Should Be Done If

    Agreement. Please contact Vaillant Service Solutions (0870 6060 777) for further details. 10.2 Vaillant warranty Vaillant provide a full parts and labour warranty for this appliance. The appliance must be installed by a suitably competent person in accordance with the Gas Safety (Installation and Use) Regulations 1998, and the manufacturer's instructions.

  • Page 61: Start-Up Protocol

    11 Start-up protocol Start-up protocol The solar system of: has been started up, while taking the following points into consideration: 1. Assembly O.K. Remarks Roof bracket fixed according to instructions? Solar pipework connected to potential equalisation? Roof covering refixed according to instructions after laying the roof bracket? Roof membrane not damaged? All connecting clips pushed in (with tube collectors)? Has the protective film been removed from the collectors?
  • Page 62 Start-up protocol 11 Information Unit Value/Detail Benchmark no. Registration no. Basic acceptances Number of persons: Additional hot water equipment: Washing machine, dish washer etc. Circulation Available/Not available Circulation runtime (please tick as appropriate) Daily hot water consumption in At a cylinder temperature of °C Estimated solar coverage of the total hot water consumption Collector array performance data...
  • Page 63 11 Start-up protocol Information Unit Value/Detail Controller settings Installed controller(s)/timer(s) Manufacturer Reheating with boiler starts at °C (TSP1 min. see installation manual of solar control)? 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.
  • Page 64 Start-up protocol 11 Manual - Solar hot water systems 0020009607_02...
  • Page 65 11 Start-up protocol Manual - Solar hot water systems 0020009607_02...

This manual is also suitable for:

Aurotherm exclusive vtk 570Aurotherm exclusive vfk 900Aurotherm exclusive vfk 900/1

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