Instructions for commissioning, maintenance and troubleshooting For the competent person Instructions for commissioning, maintenance and troubleshooting Solar heating system with auroSTOR Solar hot water system GB, IE
Table of contents Table of contents 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Notes on the documentation ................................ 3 Other applicable documents ................................... 3 Storing documents ..................................................... 3 Symbols used ............................................................... 3 Applicability of the instructions .............................. 3 Cylinder identification plate .....................................4 CE label ...................
Notes on the documentation 1 1 8 8.1 8.3 Inspection and maintenance ...............................59 Checking the temperature/pressure relief valve and expansion relief valve .................61 Checking the charge pressure of the expansion vessel ............................................61 Draining the cylinder ................................................61 9 Fault finding ..............................................................62 10 10.1 10.2 Taking the cylinder out of service .......
1 Notes on the documentation 2 Safety instructions and regulations 1.5 Cylinder identification plate The identification plate is attached to the cylinder at the factory. 1.6 2 Safety instructions and regulations 2.1 Safety and warning information When conducting installation and maintenance work, observe the general safety instructions and the warning notes which appear before each of the actions.
Safety instructions and regulations 2 2.2 Intended use The Vaillant solar heating system has been constructed using state-of-the-art technology in accordance with recognised safety regulations. Nevertheless, there is still a risk of injury or danger of death to the operator or others or of damage to the unit and other property in the event of improper use or use for which the unit is not intended.
2 Safety instructions and regulations Cylinder safety information Following an inspection, it was ascertained that this product complies with the building regulations for closed hot water cylinder systems and must not be changed or rebuilt in any way. > When replacing parts, only original replacement parts from Vaillant Ltd. may be used. The installation must be approved in accordance with the building regulations. > Installation plans must be disclosed to the relevant authorities.
Safety instructions and regulations 2 ENV 12977-1 Solar heating systems and components; Custom built systems, Part 1: General requirements ENV 12977-2 Solar heating systems and components; Factory made systems, Part 2: Testing methods ISO 9459-1: 1993 Solar heating – Domestic water heating systems – Part 1: System rating procedures using indoor test methods ISO/TR 10217 Solar energy; Water heating system; Guideline for material selection with reference to internal corrosion 2.4.
2 Safety instructions and regulations 3 System description 2.5.3 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.
System description 3 6 7 8 9 10 C D DHW 12 2 3 M 4 11 1 M M 5 A B 5 Fig. 3.
3 System description i i The collection canister for solar fluid collects escaping solar fluid. The solar fluid must not reach the drainage system. i If a cylinder is fitted very high up in the building, negative pressure may form in the cylinder. Under such circumstances, the competent person must decide whether an anti-vacuum valve is required in order to prevent damage to the cylinder.
Description of the components 4 4 4.1 Description of the components auroSTOR solar cylinder 1 26 2 3 25 21 22 24 4 23 7 20 6 5 9 19 3 4 2 5 8 1 3 18 17 16 15 14 13 10 12 11 Fig. 4.1 auroSTOR solar cylinder function elements Key 1 Hot water draw off 2 Expansion relief valve (6.0 bar) 3 Pressure reducing valve (3.
4 Description of the components The auroSTOR solar cylinder is available in three sizes: 210, 260, and 310 litres. The cylinder is made from stainless steel and is insulated with EPS with heat radiation absorbers. The cylinder is supplied along with all required cold and hot water control devices and a two port motorised valve. The cylinder works with the pressure of the water supply line and does not need a cold water tank for its supply.
Description of the components 4 1 Electric immersion heater 1 3 2 3 3 4 2 2 3 5 1 3 4 3 Fig. 4.4 Electric immersion heater operating elements Fig. 4.3 Connection diagram for solar pump Key 1 Solar controller or solar module 2 Terminal strip for series circuit to solar pump via TCO solar circuit 3 Solar pump 4 Solar circuit thermal cut-out i You must connect the solar pump to the solar controller via the solar circuit thermal cut-out (5) (¬ section 6.8).
4 Description of the components 4.2 Solar fluid 4.2.1 Properties of solar fluid 4.2.2 Solar circuit frost and corrosion protection system This information applies to Vaillant solar fluid (20 l canister: article number 302498 and 10 l canister: article number 302363). Vaillant solar fluid is a ready-mixed frost and corrosion protection agent, consisting of approximately 45% propylene glycol with anti-corrosion inhibitors and 55% water.
Description of the components 4 4.2.4 Safety data sheet for Vaillant solar fluid 1) 1a) 1b) 1c) 1d) 2) 2a) Name of substance/preparation and company details: Trade name: Vaillant ready-mixed solar fluid Use: Heat transfer fluid for solar heating systems Company: Vaillant GmbH Berghauser Str. 40 42859 Remscheid, Germany Tel. 0049 (0) 2191 18-0, Fax 0049 (0) 2191 18-2810 Emergency information: your local poison information centre (see directory assistance or telephone directory).
4 Description of the components 8) 8a) 8b) 9) Exposure prevention and personal protective equipment: Personal protective equipment: Breathing protection: Breathing protection if vapours/aerosols are released. Hand protection: chemical-resistant protective gloves (EN 374). Recommended: Nitrile rubber (NBR), protection class 6. Owing to the large variety of types, observe the manufacturers' operating instructions.
Description of the components 4 16) Other information Complete wording for hazard symbols and R phrases if stated in "Hazardous ingredients" in section 3: Xi: Irritant. R36: Irritates the eyes. All information which has been changed since the last edition is identified by means of a vertical slash on the left-hand side of the passage in question. In such cases, the information shown in older editions loses its validity.
4 Description of the components 4.3.2 Control functions Hot water temperature control The hot water temperature in the top half of the cylinder can be controlled in one of the following ways: Kol 1 – Vaillant auroMATIC VRS 560/2 solar controller or – using one of the Vaillant Control Centre‘s with the Vaillant dual-channel eBUS controller – Vaillant VRC weather compensator with VR 61/2 mixer module and VR 68/2 solar module or – using the cylinder thermostat in conjunction with a timer.
Description of the components 4 Primary heating circuit control system The primary heating circuit can be controlled in one of the following ways: Vaillant dual-channel eBUS controller with Vaillant Control Centre (connection wiring diagrams 1 and 2, ¬ section 6.8) Important: Terminals NTC and CYL. of the Vaillant Control Centre may not be connected at the same time. – Option 1: The upper cylinder sensor NTC is connected to terminal NTC of the Vaillant Control Centre.
4 Description of the components 4.3.
Description of the components 4 Unit Electrical connections Immersion heater (according to EN BS 60335) Length of immersion heater Two port motorised valve Cylinder thermostat Thermal cut-out solar Material data Cylinder body material Cylinder jacket material Insulation material Insulation thickness Corrosion protection Blowing agent for insulation material ODP inch mm VIH S GB 210/2 S VIH S GB 260/2 S VIH S GB 310/2 S 2.
4 Description of the components 4.3.4 Dimensions 1 2 3 4 5 6 7 9 b 10 c a 8 k 633 j i Ø 554,5 h g f e d 11 25° l 45° Fig. 4.
Assembly 5 5 Assembly 5.1 5.2 Transporting the cylinder Scope of delivery a 8 7 6 1 5 4 3 > Transport the packaged cylinder to the installation site. > Only remove the cylinder from its packaging once it reaches the installation site. 5.3 2 Danger! Risk of injury due to heavy load! Heavy load can cause injuries. > At least two people should lift the cylinder to prevent injuries. > Use a suitable transportation aid (sack truck or similar).
6 Installation 6 6.1 Installation Installation sequence Install the solar heating system in the following order: – – – – – Solar collectors and solar pump unit Cylinder Solar circuit piping Primary heating circuit piping Hot water piping, with secondary circulation line if required – Cold water piping – Discharge pipes – Electrical installation 6.2 Installation of solar circuit piping 6.2.
Installation 6 6.2.3 Realisation of solar circuit piping a Danger! Risk of death from electric shock! Incorrect installation or a faulty power cable can result in a supply voltage on the pipes, which can cause personal injury. > Attach earthing pipe clamps to the pipes and connect the earthing pipe clamps to a potential equalisation bar using 16 mm2 cable.
6 Installation Nominal flow rate and pipe diameter in the solar circuit Flat collectors auroTHERM plus VFK 150 H/V, auroTHERM VFK 145 H/V Quantity Qty.
Installation 6 6.2.4 Venting the solar circuit a Danger! Risk of burns and scalds resulting from escaping hot steam! Hot steam can discharge from automatic air vents which are not shut off if the system is in stagnation. > Use automatic air vents with a manufacturer's release to at least 150 ºC. > Shut off the automatic air vents when operating the system.
6 Installation Air in the system impairs the efficiency of the solar heating system considerably. For this reason, there must be sufficient venting points in every solar circuit. Automatic air separator system > Select one of the following venting methods in relation to the filling type of the solar circuit as per Tab. 6.3: – Only for flat collectors: Venting via the vent opening (¬ Fig. 6.1) – Venting via an air separator system (¬ Fig. 6.2) Vent opening (only for flat collectors) 1 2 Fig. 6.
Installation 6 6.3 Pipes for the primary heating circuit 6.4 Make sure that the pipes in the primary heating circuit between the gas-fired wall-hung boiler and cylinder are as short as possible. Use copper piping with a minimum diameter of 22 mm. A heating pump is installed in all Vaillant gas-fired wallhung boilers (apart from the ecoMAX pro with open ventilation).
6 Installation 6.5.1 Installing the hot water thermostat mixer (without secondary circulation line) 6.5.2 Installing the hot water thermostat mixer (with secondary circulation line) 3 2 2 3 4 230 1 1 7 5 6 5 8 4 6 1 10 Fig. 6.5 Installing the hot water thermostat mixer (system without secondary circulation line) Fig. 6.
Installation 6 6.6 Installation of cold mains inlet 6.6.1 Pressure in cold mains inlet 6.6.2 The efficiency of an unvented cylinder depends on the available pressure in the cold mains inlet and the flow rate. To obtain optimum cylinder output, there must be a suitable cold mains inlet, i.e. the measured static line pressure must be at least 2.0 bar. A corresponding flow rate of at least 20-25 l/min must be available.
6 Installation > Mount the discharge pipe of the expansion relief valve with a constant slope to the outside. The discharge pipe must finish at a safe and visible point where there is no danger of it freezing up and where it poses no risk of injury to persons. > Actuate the expansion relief valve regularly to prevent calcification. > Connect the cylinder to the cylinder connection (4).
Installation 6 Safety valve (e.g. Temperature and pressure relief valve) Metal discharge pipe (D1) from temperature and pressure relief valve to tundish Max. 600 m m Thundish At least 300 mm Discharge point beneath grille Fixed grille Metal discharge pipe (D2) from tundish with constant incline Gully with siphon Worked example The example below is for a G1/2 temperature relief valve with a discharge pipe (D2) having 4 No. 22 mm elbows and length of 7 m from the tundish to the point of discharge.
6 Installation 6.7.2 High drain 6.8 tundish At least 300 mm Electrical installation e Danger! Risk of death from electric shock! Improperly executed electrical connections can impair the operational safety of the unit. > The electrical installation may only be performed by a competent person approved at the time by the Health and Safety Executive. e Danger! Risk of death from electric shock! Without potential equalisation, life-threatening voltage can reach the piping and water draw-off points.
Installation 6 Solar circuit control system Solar circuit control via one of the following means: – The auroMATIC 560/2 differential temperature-controlled control set for solar-aided hot water production – The VRC weather compensator with VR 68/2. i The temperature sensors VR 10 (cylinder sensor) and VR 11 (collector sensor) are supplied with the VRS 560/2 solar controller or VR 68/2 solar module.
6 Installation 6.8.2 Electrical connection of control components 1 7 1 12 13 11 2 3 3 2 6 3 5 4 3 4 2 4 5 1 5 10 Fig. 6.
Installation 6 6.8.3 Connecting up the electric immersion heater The Vaillant auroSTOR VIH S GB 210/2 S, VIH S GB 260/2 S, and VIH S GB 310/2 S solar cylinders are fitted with an electric immersion heater at the factory. a 1 2 3 4 3 2 5 1 Caution! Corrosion and short circuits may occur due to incorrect earthing.
6 Installation 6.8.4 Connection of the solar pump Connection wiring diagrams 1, 2, 3, 4, and 6 (VRS 560/2): 1 > Connect the terminal strip with the terminal Kol 1-P of the VRS 560/2 (1). Connection wiring diagram 5 (VR 68/2): > Connect the terminal strip with the terminal Kol 1-P of the VR 68/2 (1). 3 6.8.5 3 2 Connecting up the solar yield temperature sensor 3 4 3 1 2 Fig. 6.
Installation 6 Instructions on commissioning, maintenance, and troubleshooting for auroSTOR 0020111119_02 39
6 Installation 6.8.6 Installing the control components in accordance with the connection wiring diagrams 2 Solar pump N PE 230 V grid L KOL 1-P PE 1 2 + BUS Vaillant dual-channel eBUS controller 2 BUS N L 230 V grid PE 3A CYL.
Installation 6 – – – – eBUS-compatible Vaillant gas-fired wall-hung boiler Wiring via Vaillant Control Centre Solar circuit control via VRS 560/2 solar controller Primary heating circuit control via Vaillant dual-channel eBUS controller – Room heating control via Vaillant dual-channel eBUS controller – S plan hydraulics > Next to the solar cylinder, install the Vaillant Control Centre. > Dismantle the cover of the Vaillant Control Centre.
6 Installation 2 Solar pump N PE 230 V grid L KOL 1-P PE 1 2 + BUS Vaillant dual-channel eBUS controller 2 + BUS N L 230 V grid PE 3A CYL.
Installation 6 – – – – eBUS-compatible Vaillant gas-fired wall-hung boiler Wiring via Vaillant Control Centre Solar circuit control via VRS 560/2 solar controller Primary heating circuit control via Vaillant dual-channel eBUS controller – Room heating control via Vaillant dual-channel eBUS controller – Y plan hydraulics > Next to the solar cylinder, install the Vaillant Control Centre. > Dismantle the cover of the Vaillant Control Centre.
6 Installation 2 1 2 Kol 1 2 N PE Solar pump 2 2 1 L PE 1 + BUS Vaillant dual-channel eBUS controller 2 + N L 230 V grid PE 3A CYL.
Installation 6 – – – – eBUS-compatible Vaillant gas-fired wall-hung boiler Wiring via Vaillant Control Centre Solar circuit control via VRS 560/2 solar controller Primary heating circuit control via VRS 560/2 solar controller – Room heating control via Vaillant dual-channel eBUS controller – S plan hydraulics > Next to the solar cylinder, install the Vaillant Control Centre. > Dismantle the cover of the Vaillant Control Centre.
6 Installation 2 1 2 Kol 1 2 N PE Solar pump 2 2 1 L PE 1 + BUS Vaillant dual-channel eBUS controller 2 + N L 230 V grid PE 3A CYL.
Installation 6 – – – – eBUS-compatible Vaillant gas-fired wall-hung boiler Wiring via Vaillant Control Centre Solar circuit control via VRS 560/2 solar controller Primary heating circuit control via VRS 560/2 solar controller – Room heating control via Vaillant dual-channel eBUS controller – Y plan hydraulics > Next to the solar cylinder, install the Vaillant Control Centre. > Dismantle the cover of the Vaillant Control Centre.
6 Installation L N PE 2 1 SP2 SP1 PE 1 2 + VR 81 BUS + BUS + BUS Vaillant dual-channel eBUS controller HZ2 M HZ1 M Brown Blue PE Vaillant ecoTEC 230 V grid 2 TCO solar circuit N L Cylinder VR 61/2 ZP / LP Brown Blue PE HW M HK1 / P N L HK2 Brown Blue PE PE 3A HK2 / P + - 2 1 BUS PE N L PE N L PE N L PE N on off PE N L VF2 Solar pump 2 2 230 V grid Kol 1 3A MA PE KOL 1-P PE N L PE N L PE N L PE N L LEG-P VR 68/2 2 2 1 Kol 1 BUS Solar yield Yield 2 SP 1 2 1
Installation 6 – eBUS-compatible Vaillant gas-fired wall-hung boiler – Wiring via VR 68/2 solar module and VR 61/2 mixer module – Control of the solar circuit via a VRC weather compensator and the VR 68/2 solar module – Control of the primary heating circuit via a VRC controller – Control of the room heating via a VRC controller – S plan hydraulics with VR 81 for 2nd zone > Next to the solar cylinder, install the VR 61/2 mixer module. > Install a VRC weather compensator next to the solar cylinder.
6 Installation 2 1 2 Kol 1 2 2 SP 1 KOL 1-P 2 1 SP1 SP2 PE 1 2 Cylinder TCO solar circuit PE N L 230 V grid Solar pump KOL 2-P / ZP N PE LEG / Byp L EP Kol 1 3A LP/UV 1 PE N L PE N L PE N L PE N L 2 1 PE N L C1 C2 VRS 560 Solar yield Yield 2 1 SP 2 2 1 SP 3 2 2 1 Ertrag 2 1 Kol 2 2 1 Connection wiring diagram 6 (S plan or Y plan hydraulics) PE C PE 2 1 Cylinder thermostat and TCO Standard cabling box S-plan or Y-plan Fig. 6.
Installation 6 – – – – Third-party boiler, non-eBUS-compatible Wiring via standard cabling box Solar circuit control via VRS 560/2 solar controller Primary heating circuit control via VRS 560/2 solar controller – Room heating control via programmable timer and room thermostat – S or Y plan hydraulics > Install a bridge between the protective earth terminal (2 ¬ fig. 6.12) of the cylinder thermostat and the protective earth terminal (4 ¬ fig. 6.12) of the primary heating circuit TCO.
7 Commissioning 7 Commissioning You must adhere to the following procedure for the commissioning of the total system: > > > > > > > 4 Check for leak-tightness. Flush the solar circuit with solar fluid. Fill the solar circuit with solar fluid. Set the solar pump. Set the flow rate limiter. Check the controller. Set the hot water thermostat mixer. i 6a 6b 2 7.1 5 For the pressure test, first fill the solar circuit with Vaillant solar fluid (ready mixed).
Commissioning 7 7.2 Flushing the solar circuit with solar fluid Flushing is performed from the solar pump unit to the cylinder via the collector. > Connect the pressure hose of the filling pump (19) to the upper combined filling and draining tap (1) of the solar circuit. > Connect the return hose (17) to the lower combined filling and draining tap (16) of the solar circuit. > Close the 3-way ball valve (15). > Open the air vent (4). > Switch the filling pump on.
7 Commissioning 7.4 Setting the flow rate in the solar circuit In addition to factors such as the temperature, pipe diameter, number of collectors and so on, the flow rate is important for ensuring optimum heat transfer. A flow rate above the nominal flow rate is not as unfavourable as a flow rate below the nominal flow rate. i Never allow the flow rate to fall below the nominal flow rate.
Commissioning 7 7.5 Flushing the primary heating circuit Detailed recommendations for the water circuit can be found in BS 6798 and BS 5449: Part 1 (for central heating systems with both small and the smallest pipe width). Pipes which do not form part of the usable heating surface must be insulated in order to prevent heat losses and possible freezing. Pipe insulation is particularly important if you are installing pipes under the roof or in open areas under the floor.
7 Commissioning > Inform the operator of the necessary measures if you have used these additives. > Inform the operator about the required measures for frost protection. > Observe all valid national and technical regulations when treating the filling and supplementary water. 7.7 Filling the cylinder b Caution! Risk of material damage due to unsuitable water! Unsuitable water can lead to deposits and corrosion damage in the cylinder and in the hot water circuit.
Commissioning 7 7.8 Filling the central heating system The system can be filled using the built-in filling loop (ecoTEC plus combi boiler only) or via a separate filling connection that is fitted at an easily accessible location in the heating circuit. The filling loop must be removed once filling is complete. If a temporary connection is not possible due to legal regulations, a closed system filling pump with a buffer tank must be used.
7 Commissioning 7.9 Commissioning the gas-fired wall-hung boiler > Make sure that the control device and thermostats are set so that heating is required. > Carry out the commissioning and testing measures for the gas-fired wall-hung boiler in accordance with the installation instructions. > Check whether the gas-fired wall-hung boiler starts operating and the water in the cylinder and radiators heats up in accordance with the hot water and room thermostat settings.
Inspection and maintenance 8 8 Inspection and maintenance Vaillant solar heating systems are designed for a long and stable working life. In order to guarantee this, the solar heating system should be maintained annually by a competent person approved at the time by the Health and Safety Executive. This can be performed at the same time as boiler and cylinder maintenance and consists primarily of visual inspections. Inspection access to the cylinder is available through the immersion heater boss.
8 Inspection and maintenance Maintenance work Maintenance interval Solar circuit Check the system pressure at the gauge on the solar pump station. Visually check pipe work and connections for solar fluid leaks. Check the solar fluid discharge pipe is secure and canister is empty. If necessary following above checks arrange for corrective work to be carried out. Ensure system cannot go into stagnation. Avoid middle of day (cover collectors if possible). Depressurise the system.
Inspection and maintenance 8 8.1 Checking the temperature/pressure relief valve and expansion relief valve > Open each valve manually by turning the valve cap and check whether water is able to flow to the drain via the tundish without obstruction. Make sure that both valves sit correctly in their idle position. 8.
9 Fault finding 9 Fault finding The tables below provide information on possible faults when the solar heating system is being operated, information on their causes and how to rectify them. All work on the Vaillant solar heating system (installation, maintenance, repairs etc.) may be performed only by approved competent persons. a Danger! Risk of death from electric shock! Improperly executed work on the solar heating system can result in risk to life and limb.
Fault finding 9 Fault Cause Remedy The solar pump starts up and switches off again shortly afterwards. This is repeated several times until the system runs its course. The same occurs in the evening. The controller temperature difference is too Check whether the entire pipework is fully small or the pump speed has been set too insulated. Increase the temperature differhigh. The solar radiation is not yet sufficient ence of the controller. to heat up the entire pipework.
9 Fault finding Fault Cause Remedy Primary heating is not working. The gasfired wall-hung boiler runs for a short time, goes off, and then comes back on again. This is repeated until the cylinder is at its target temperature. 1. Air in the primary heating heat exchanger. Vent the primary heating heat exchanger. 2. Heat exchanger surface area too small. Compare the specifications of the boiler manufacturer with those of the cylinder manufacturer.
Taking the cylinder out of service 10 Recycling and disposal 11 10 Taking the cylinder out of service 11 10.1 Both the cylinder and its transport packaging are made primarily of recyclable raw materials. Temporarily taking the cylinder out of service b Caution! Risk of damage as a result of the cylinder freezing! Frost protection and monitoring devices are only active while the boiler is connected up to the power supply. > Make sure that the cylinder cannot be damaged if there is a frost. 11.
12 Customer service and manufacturer’s guarantee 12 Customer service and manufacturer's guarantee 12.1 Vaillant service To ensure regular servicing, it is strongly recommended that arrangements are made for a Maintenance Agreement. Please contact Vaillant Service Solutions (0870 6060 777) for further details. 12.2 Vaillant guarantee Vaillant provides a full parts and labour guarantee for this appliance.
Commissioning checklist and service record
MAINS PRESSURE HOT WATER STORAGE SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the storage system as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. Failure to install and commission this equipment to the manufacturer’s instructions will invalidate the warranty but does not affect statutory rights.
SERVICE RECORD It is recommended that your hot water system is serviced regularly and that the appropriate Service Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.
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SERVICE RECORD It is recommended that your hot water system is serviced regularly and that the appropriate Service Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.
Manufacturer 0020111119_02 GBIE 022012 – Subject to change Supplier