elco AURON B 15 DF User manual

Operating manual
For professional installers
AURON
with EDF evacuated tubes
04/2013 Art.Nr.12 054 556

2
Table of contents ................................................................................................................... 2
Guidelines, Standards and Specifications ................................................................................................................... 3
Product description AURON solar heating system .................................................................... 4
EDF evacuated tube collectors................................................................... 5
Technical data............................................................................................7
Collector connections, accessories, heat transfer fluid...............................8
Mounting hardware and assembly.............................................................. 9
Design configuration and sizing Collectors and heat storage tank.............................................................. 10
Piping .......................................................................................................11
Expansion tank......................................................................................... 13
Hydraulics Solar circuit ..............................................................................................15
Collector panel .........................................................................................16
Bill of materials AURON DF collector components............................................................ 18
Mounting hardware...................................................................................19
Collector assembly Choosing a suitable mounting location..................................................... 21
Vertical mounting – brief description ........................................................22
Horizontal mounting – brief description .................................................... 24
Flat roof mounting rack.............................................................................26
Flat roof mounting rack – solar panel lying flat ......................................... 29
Assembly on a rack for tiled roofs, vertical ...............................................32
Assembly on a rack for tiled roofs, horizontal........................................... 36
Assembly on a building façade rack ........................................................40
Assembly on a non-standard roof rack..................................................... 43
Preparing the manifolds and the bottom rail ............................................ 44
Manifold assembly ................................................................................... 45
Installing the bottom rail ........................................................................... 46
Sensor installation and connecting the solar panel ..................................47
Installing the tubes ................................................................................... 48
Start-up .................................................................................................................49
Start-up report .................................................................................................................51
Operating the system .................................................................................................................53
Troubleshooting: problems and remedies .................................................................................................................54
Maintenance report .................................................................................................................55
Safety bulletin for Antifrogen SOL HT ................................................................................................................. 56
Installation
The proper sequence for installing a AURON solar heating system is as follows:
Planning the installation
Sizing the solar panel, heat storage tank, piping and expansion tank
Defining the installation location and pipe routing
Installing the solar circuit as specified in the operating instructions
Installing the heat storage tank; pump assembly and expansion tank
Routing the piping to the collector installation location
Installing the solar controller
Assembling the collectors
Installing the mounting rack on a building
Preparing the manifolds and the bottom rails
Assembling the manifolds and the bottom rails
Installing the tubes
Connecting the collectors
Pressure test
Start-up
Using the start-up report for start-up
Training the operator
Table of contents

3
• ÖNORM H 5195-1 Preventing dam-
age caused by corrosion and scaling
in closed hot water heating systems
with operating temperatures up to
100°C
• ÖNORM M 7700 Solar energy – ter-
minology and definitions
• ÖNORM M 7701 VORNORM
Solar energy systems – estimating
procedure for sizing flat collectors in
hot water heating systems
• ÖNORM M 7710 Flat collectors in
solar energy systems – technical re-
quirements and test specifications
• ÖNORM M 7826 Soldering copper
piping installations
• BGBI.Nr. 57/1965 Electrical engineer-
ing act - ETG; latest version
• ÖNORM B 4013 Design loads for
buildings - snow and ice loads
• ÖNORM B 4014 - 1 Design loads for
buildings - static wind loads
• ÖNORM M 7510-1 Guidelines for
assessing heating systems – basic
principles
• ÖNORM M 7580 Insulation of heating
systems - specifications, verification,
calculation procedure
Transportation/Storage
• Comply with markings on the packing
indicating proper orientation (up/
down) when transporting and storing
tubes.
• To avoid damaging collectors, keep
them in their packing containers until
they reach the final installation loca-
tion.
• Never allow evacuated tubes to come
into contact with copper tubes, as this
is a potential fire hazard. Do not re-
move protective cardboard until just
prior to installation.
• Keep evacuated tubes covered until
start-up.
Grounding and lightning protection
The solar circuit's copper tubes shall be
connected to the main ground loop us-
ing a green/yellow copper conductor
having a minimum diameter of 16 mm2
(H07 V-U or R). The collectors can be
connected to the lightning protection
system if it exists; otherwise, a ground
rod can be used. The ground conductor
shall be routed outside the house. The
ground rod shall also be connected to
the main ground loop via a conductor
having the same diameter.
Assembly and installation
Assembly, installation and initial start-up
shall only be carried out by professional
installers, who assume responsibility for
proper installation and start-up.
The support systems are tested to snow
load Zone III, 700 m above NN (Normal
Null) and wind load Zone II. In the event
of higher loads, the system shall be
reinforced if necessary on the basis of
site-specific calculations.
Operation
• Do not switch off the system when in
direct sunlight!
• Inspect the system on a regular basis.
Recycling
The collectors may be returned to EL-
CO / ELCOTHERM after they have
been used. All collector materials are
recyclable and the company will ensure
proper disposal. The costs of disassem-
bling and shipping the collectors are not
covered.
Details regarding warranty condi-
tions
The warranty does not cover damage
resulting from any of the following:
• improper use
• improper installation or start-up by the
purchaser or third parties, including
the use of third-party components
• start-up of the system or the collector
prior to filling
• leaving the system unfilled for several
days
• exceeding rated system pressure
during operation
• using an antifreeze solution other than
Antifrogen SOL HT
Adhering to the following will ensure
that the warranty applies:
• operating the system as it was de-
signed to be used
• operating the system in accordance
with factory specifications
Guidelines, Standards and Specifications
Specifications
Observe all standards, regulations and
guidelines to ensure the system will save
energy, operate safely and conform to
environmental requirements. The follow-
ing are particularly important:
• EN 12975 - 1 and 2 - General require-
ments and test procedures for collec-
tors
• EN 12976 - 1 and 2 - General require-
ments and test procedures for prefab-
ricated equipment
• EN 12977 1-3
Solar thermal systems and their com-
ponents - custom systems
• EN 1991-2-3-4 - Basic requirements
for support structure design and effects
of snow and wind loads on support
structures
• EN 516 - Equipment for working on a
roof
• EN 517 Roof safety hooks
• EN 62305-3
Lightning conductor
Supplementary standards for
Germany
• EnEV - Piping insulation
• DampfKV - Steam vessel
regulations
• DIN 1055 - Design loads for
buildings, Parts 1 – 5
• DIN 18338 - Roofing and roof
waterproofing
• DIN 18339 - Flashing and guttering
• DIN 18451 - Scaffolding
• DIN VDE 0185 – Lightning
protection
Supplementary standards for
Switzerland:
• Design calculations for wind loads on
roofs and anchoring (as per SIA
260+261)
• SVGW standards
• Local and cantonal fire department
regulations
• VKF fire safety standards
• SWKI 93-1 standards
Safety equipment for heating systems
Supplementary standards for
Austria
• ÖNORM B 3800-1 to 4
Combustion characteristics of con-
struction materials and components
• ÖNORM B 8131 Closed water heater
systems – safety, design and test
specifications
• ÖNORM H 5150-1 Design of central
heating systems – sizing

4
The AURON DF solar hot water
heating system is comprised of the
following components:
• solar panels
• mounting rack
• heat transfer fluid
• expansion tank
• solar storage tank
• solar pump with flow limiter
• solar controller including tempera-
ture sensors for collector and stor-
age tank
• air separation tank, vent, safety
valve and miscellaneous parts
The AURON solar energy system
may also be used to support a central
heating system if a suitable storage
tank and solar controller are selected.
The AURON DF solar collectors con-
vert direct and diffused sunlight into
heat. The energy radiating from the sun
is absorbed by the absorption surface
of the collector. An associated piping
system transfers the heat away. The
vacuum inside the tubes and the design
of the collector minimize heat loss to
the surrounding environment.
The Solar controller controls the entire
system. As soon as the collectors be-
come hotter than the lower part of the
storage tank due to the absorbed solar
energy, a circulating pump is switched
on and the heat is transferred to the
storage tank. The pump is shut off
when the collector temperature falls
below the temperature in the storage
tank. To prevent boiling in the storage
tank, the pump also shuts off when the
temperature in the storage tank has
reached its maximum rated level. Sys-
tem operation is fully automatic.
The air separation tank and manual
vent ensure that the solar heating cir-
cuit is free of air pockets that may inter-
fere with proper operation of the pump.
The hot water is stored in the heat
storage tank until it is ready to be
used. The size of the storage tank
should be selected so that it is able to
supply enough water to last through
short periods of bad weather . The up-
per part of the storage tank has provi-
sions to be heated by some other
source, if necessary, to ensure that hot
water will also be available during bad
weather conditions . Solar energy is the
sole source of heat for the lower part of
the tank.
The expansion tank is used to com-
pensate for the temperature-related
expansion and contraction of the heat
transfer fluid. The tank is sized to pre-
vent venting of the heat transfer fluid
via the safety valve, even if the fluid
vapourises. This can occur when not
enough heat is being removed from the
collector because the pump is off.
Amounting rack is used to facilitate
installation of the collectors. Various
suitably designed roof mounting sys-
tems are available for different types of
roofs.
The heat transfer fluid, which is
pumped through the solar circuit using
the solar pump, transfers the heat
from the collectors to the storage tank,
where it is transferred to the domestic
water system via a heat exchanger.
The heat transfer fluid has anti-freeze
in it so that the system does not freeze
and incur damage during the winter.
The non-toxic and physiologically harm-
less heat transfer fluid is designed to
accommodate the extreme temperature
swings from – 30°C to over 200°C .
Product description
AURON solar heating system

5
Attributes and role of the collector
The AURON DF solar energy system is
especially designed for the climate that
is prevalent in Central Europe. The
heart of the system is an evacuated
tube solar panel through which heat
transfer fluid is pumped directly. Its
hydraulic system is especially designed
to maximize absorption capacity and
heat transfer characteristics. These
properties enable it to convert even
very low radiation levels to useful ener-
gy in the form of heat.
When the system is shut down
When the system is shut down, the
evacuated tube and manifold contents
vaporize during periods of high solar
radiation. The displaced fluid is con-
tained in an appropriately sized expan-
sion tank. Excess heat should still be
removed from the collector hydraulically
to prevent evaporation.
Available models
AURON B 15 DF
Basic module consisting of 15 tubes
and temperature sensor connector.
AURON E 15 DF
Expansion module consisting of 15
tubes.
AURON B 20 DF
Basic module consisting of 20 tubes
and temperature sensor connector.
AURON E 20 DF
Expansion module consisting of 20
tubes.
Every collector panel needs one
basic module to allow a temperature
sensor to be connected and to pro-
vide the hydraulic connection fit-
tings required to interface to the so-
lar energy circuit.
The different modules can be com-
bined as required.
Product description
EDF evacuated tube collectors
Design and role of the EDF evacuat-
ed tubes
Radiant energy emitted by the sun is
converted to heat by means of an ab-
sorption surface inside an evacuated
glass tube. The design virtually elimi-
nates heat loss to the ambient air. The
absorber surface is made of aluminium
and has a highly selective coating. The
entire surface area conducts the heat to
a coaxial copper tubing system. The
absorbed heat is transferred directly
and almost entirely without any heat
loss to the solar energy circuit's glycol-
water mixture by this coaxial copper
tubing. The water-glycol mixture flows
directly through the evacuated tubes.
The evacuated tubes are connected to
a manifold using compression fittings
and a tube connector made of weather-
resistant plastic. The entire connecting
area of the tubes is permanently pro-
tected by this threaded connector.

6
Supply and return connections are
located at each end of the manifold.
The supply connection is labelled
HOT and the return connection is
labelled COLD.
The connecting plug for the collector
sensor is located on the left face of the
AURON B 15/20 DF basic modules.
Evacuated tube components and
dimensions
1 Coaxial tube system
2 Threaded compression fitting
3 Tube connector
4 Aluminium absorber with se-
lective coating
5 Spacer
6 Glass tube
7 Protective cap
HOTCOLD
1790
∅70
1
2
3
4
5
6
7
The collector consists of a manifold,
the evacuated tubes and a bottom rail.
Product description
EDF evacuated tube collectors

7
Model AURON 15 DF AURON 20 DF
Number of evacuated tubes 15 20
Effective absorber area m ² 1.5 2.0
Aperture area m ² 1.58 2.11
Collector dimensions mm 1380 x 1910 1840 x 1910
Total area m ² 2.63 3.51
Collector weight (empty) including tubes
-sloped roof
-flat roof, vertically mounted
(without ballast weight or storm proofing)
-flat roof, laid flat
(without ballast weight or storm proofing)
kg
kg
kg
kg
51
62
73
58
68
79
90
75
Manifold hydraulics brass-copper
Manifold enclosure Aluminium, black coating, insulated
Collector fluid volume including tubes l 4.3 5.7
Connectors (supply and return) on manifold 3/4“ internal thread flat sealing
Heat transfer circuit filled with premixed Antifrogen SOL HAT heat transfer fluid
Maximum operating pressure bar 6
Maximum mechanical load (distributed load) kg/ m² 350
Pressure loss (80 l/m²h) mbar ca. 30 ca.30
Performance characteristics per DIN 12975
(Refers to: absorber area / aperture area) η0 % 83.5 / 79.2 83.5 / 79.2
k
1W/m²K 2.79 / 2.65 2.79 / 2.65
k
2W/m²K 0,01 / 0,009 0,01 / 0,009
Thermal capacity (DIN 12975 from material specs) kJ/m²K 21,95
IAM 50 = IAML(40°) x IAMT(40°) 1.003
Minimum mounting angle 0°
Installation orientation
Evacuated tubes EDF
Temperature at shutdown °C 230 °
Minimum mounting angle 0°
Tube material borosilicate glass
Outer diameter mm 70
Length mm 1790
Thermal insulation high vacuum
Heat transfer direct flow
Absorber surface made of aluminium, selective coating
Net absorber surface area m² 0.1
Tubing material copper
Weight kg 2.5
vertical / horizontal
21,80
Product description
Technical data

8
Collector connections
The collector is connected to the solar
energy circuit using two 3/4" x 22 mm
threaded compression fittings.
The two collector connections that are
not required are fitted with dummy
plugs designed to be used as vent
valves.
Seals
The collector connections are sealed
using solar radiation-resistant gaskets.
The gaskets are pre-installed on the
collector ports.
Expansion fittings
The collectors are connected to each
other by means of two expansion fit-
tings. These expansion fittings compen-
sate for differences in length caused by
temperature changes and mitigate the
resulting mechanical forces.
Insulation
A matching insulation cover made of
high-temperature resistant EPDM seal-
ing material is available for the expan-
sion fittings.
Heat transfer fluid
The Antifrogen SOL HT heat transfer
fluid is non-toxic and physiologically
harmless.
The product is optimized for use in
high-performance collectors. It is ex-
tremely suitable for high temperature
use and has excellent freeze protec-
tion properties.
To ensure that it performs to specifi-
cations for extended periods , the
solar energy circuit should be well
flushed before filling it with the heat
transfer fluid (two hours).
Cleaning agent
The cleaning agent Antifrogen SOL
Clean is used for cleaning the solar
system pipework. See also the chap-
ter "Operating the system /
maintenance".
Antifrogen SOL HT glycol mixture
Freeze protection to – 28 °C
Composition Higher boiling temperature glycol
Viscosity at 20°C Approx. 7,4 mm²/s
Density at 20°C Approx. 1.082 g/cm³
Vapour pressure at 20°C 1 mbar
Observe instructions in safety bulletin!
Product description
Collector connections, accessories,
heat transfer fluid
Air separator / air trap
For problem-free operation, the solar
circuit must be completely free of air.
The small air bubbles that develop in
the de-aerated system at higher tem-
peratures are removed by the air sepa-
rator. The air separator can be mount-
ed at the system's highest point or at
the solar system inlet just ahead of the
storage tank in the basement. The air in
systems that have no air separator is
collected in an air trap installed at the
system's highest point, from where it is
manually vented.

9
Mounting alternatives
A very flexible and rugged assembly
system is available to mount the collec-
tors. This and the innovative hydraulic
design of the AURON DF collector en-
sure that there is provision for every
possible mounting alternative for the
equipment.
ASloped roof assembly, vertical
BSloped roof assembly, horizontal
(recommended for roofs sloped at
less than 30°)
CFlat roof, lying flat, mounting rack
with no adjustable angle of inclina-
tion (recommended in southern
latitudes, as well as when using the
system during summer months ).
DBuilding façade assembly
(recommended in northern latitudes
and when using the system in the
shoulder seasons and winter
months).
EOutdoor / flat roof assembly using
mounting rack with adjustable angle
of inclination.
Roof fasteners/Supports
• A universal roof hook is available for
tile roofs. It is extremely flexible and
can normally also be used for beaver
tail or special tiles. Since the roof
hook is bolted directly to the rafters,
the mounting method is particularly
robust.
• A flexible mounting rack is used for
outdoor or flat roof installation; the
angle of the frame can be adjusted to
suit local requirements. The standard
angle is 45°.
• Type C is a special rack that lies flat
on the roof. The rack is bolted to a
suitable substructure (e.g., concrete
paving stones). The substructure
shall be provided by others.
• Special mounting hardware such as
hanger bolts, metal seam clamps or
slate roof brackets is available for
façades, as well as metal and corru-
gated sheet roofs.
• For plain tile roofs and uneven roofs /
special tiles there is an suitable roof
hook for each.
A
B
C
D
E
Product description
Mounting hardware and assembly

10
Design table
The accompanying table can be used
to estimate the required collector area
and storage tank size if the installa-
tion involves a standard domestic
application.
Use accepted design and calculation
methods to size the system precisely.
Attach a calculation to the start-up
report if the design configuration devi-
ates from the recommendations in-
cluded here. The warranty and guar-
antee becomes null and void in the
event of major sizing errors.
* The number of collectors required depends on the amount of hot water consumed or the heating requirements, roof slope
and direction and the amount of available solar radiation.
** The volume of the storage tank depends on the desired solar contribution and
the amount of heat required.
Use the following table to roughly estimate the size of the collector and
storage tank:
Design configuration and sizing
Collectors and heat storage tank
Sizing the solar storage tank
The solar collectors may only be op-
erated in conjunction with a properly
sized solar storage tank. The collector
will continually be subjected to inter-
nal overtemperature if the storage
tank is too small, which potentially
shortens the life of the collector.
Sizing the collector area
It is very important to size the collec-
tor area properly so that users may
enjoy many years of trouble-free op-
eration of the solar heating system.
The required collector area shall be
individually calculated for each instal-
lation taking into consideration the
amount of heat required, the slope of
the roof and its direction, as well as
the available solar radiation at the
site.
Hot water heating
Hot water heating
and central heating system support
persons
Water require-
ment (45°C)
in l
Area of tubes
collectors in m²
(absorber)*
Number* of
tubes
Minimum storage
cylinder volume**
in l
Area of tubes
collectors in m²
(absorber)*
Number* of
tubes
Minimum storage
cylinder volume**
in l
~ 30 to 80 litres
per person
~ 1.1 m² per 50
litre hot water
requirement
~ 2 x min. hot water
requirement
~ 1.8 to 2.5 x
Area of hot water
plant
~ 50 to 70 litres stor-
age volume per m²
collector area
from to from to from to
from to from to
2 150 3,5 35 300 7,5 75 750
3 150 200 3,5 4,5 35 45 300 7,5 10,0 75 100 750
4 150 200 3,5 4,5 35 45 300 7,5 10,0 75 100 750
4 200 300 4,5 6,5 45 65 400 10,0 14,5 100 145 1000
5 150 200 3,5 4,5 35 45 300 7,5 10,0 75 100 750
5 200 300 4,5 6,5 45 65 400 10,0 14,5 100 145 750
5 250 350 5,5 7,5 55 75 500 12,0 16,5 120 165 1000
6 200 300 4,5 6,5 45 65 400 10,0 14,5 100 145 1000
6 250 350 5,5 7,5 55 75 500 12,0 16,5 120 165 1500
7 200 300 4,5 6,5 45 65 400 10,0 14,5 100 145 1000
7 250 350 5,5 7,5 55 75 500 12,0 16,5 120 165 1000
7 350 550 7,5 12,0 75 120 750 16,5 26,5 165 265 1500
8 250 350 5,5 7,5 55 75 500 12,0 16,5 120 165 1000
8 350 550 7,5 12,0 75 120 750 16,5 26,5 165 265 1500
9 350 550 7,5 12,0 75 120 750 16,5 26,5 165 265 1500
9 500 700 11,0 15,5 110 155 1000 24,0 34,0 240 340 2000
10 350 550 7,5 12,0 75 120 750 16,5 26,5 165 265 1500
10 500 700 11,0 15,5 110 155 1000 24,0 34,0 240 340 2000

11
Design configuration and sizing
Piping
Material
The piping material used for the solar
circuit shall be approved for use in solar
heating systems as per EN 12975. We
recommend using copper or stainless
steel piping with connectors that form a
metal-to-metal seal. All solder connec-
tions shall be hard soldered.
The materials and connections used
shall be guaranteed to withstand tem-
peratures of up to 270°C. They shall
also be rated for use with the heat
transfer fluid and be weather resistant.
The warranty becomes null and void if
collectors are damaged as a result of
using unsuitable piping.
Sizing
The required pipe diameter is shown in
the table on the left. The table is valid
for the solar pump group 65.
Pipe diameter and flow resistance shall
be individually calculated for large sys-
tems or for very long pipe runs and be
matched to the circulating pump design
specifications.
Pipe size shall be selected to ensure
that the heat transfer fluid flow rate
remains between 0.5 m/s and 1.0 m/s
per second.
When choosing the pump, keep in mind
that the heat transfer fluid pressure
drop is greater than the pressure drop
for water.
*The actual pressure drop across the collector panel depends strongly on the
flow velocity and temperature of the heat transfer fluid.
Rule of thumb:
Pressure drop (heat transfer fluid) = 1.5 x pressure drop (water)
Cop-
per
Stainless
steel
corrugated
tube
Number of collectors (AURON 20)
with pipe lengths 15 double metre
1 2345 678 910
DN 13 DN 16 x xxx
DN 16 DN 20 x xx
DN 20 DN 25 xx
Cop-
per
Stainless
steel
corrugated
tube
Number of collectors (AURON 20)
with pipe lengths 25 double metre
12345678910
DN 16 DN 20 xxx
DN 20 DN 25
xxx
DN 25
xx
x= design operating range
x = maximum limit

12
Diagonal connection One-side connection
Absorber-
surface
m2
No. of
tubes Minimum flow rate
l/h
Nominal
flow rate
l/h
Maximum
flow rate
l/h
Minimum
flow rate
l/h
Nominal
flow rate
l/h
Maximum
flow rate
l/h
1,5 15 45 90 120 68 90 120
2 20 60 120 160 90 120 160
3 30 90 180 240 135 180 240
3,5 35 105 210 280 158 210 280
4 40 120 240 320 180 240 320
4,5 45 135 270 360 203 270 360
5 50 150 300 400 225 300 400
5,5 55 165 330 440 248 330 440
6 60 180 360 480 270 360 480
6,5 65 195 390 520
maximum 6 m² = 60 tubes permitted
7 70 210 420 560
7,5 75 225 450 600
8 80 240 480 640
9 90 270 540 720
10 100 300 600 800
11 110 330 660 880
12 120 360 720 960
Minimum flow rate with diagonal connection 30 l/m2h
Minimum flow rate with one-side connection 45 l/m2h
Nominal flow rate for both connection types 60 l/m2h
Maximum flow rate for both connection types 80 l/m2h
max. 120 tubes max. 60 tubes
Design configuration and sizing
Expansion tank
related to water 20°C
-corresponds to
Antifrogen SOL HT 60°C

13
Design configuration and sizing
Expansion tank
Collector Capacity in litres
AURON 15 DF / AURON 20 DF 4,3 / 5,7
Expansion
volume in litres
3–10 m 11 m 12 m 13 m 14 m 15 m
5 14 14 14 15 15 16
6 15 16 16 16 17 17
7 17 17 18 18 19 19
8 19 19 20 20 21 21
9 20 21 21 22 22 23
10 22 22 23 24 24 25
11 23 24 25 25 26 27
12 25
26 26 27 28 29
13 27 27 28 29 30 31
14 28 29 30 31 32 32
15 30 31 32 32 33 34
16 32 32 33 34 35 36
17 33 34 35 36 37 38
18 35 36 37 38 39 40
19 37 38 39 40 41 42
20 38 39 40 41 43 44
21 40 41 42 43 44 46
22 42 43 44 45 46 48
23 43 44 45 47 48 49
24 45 46 47 48 50 51
25 46 48 49 50 52 53
26 48 49 51 52 54 55
27 50 51 52 54 55 57
28 51 53 54 56 57 59
29 53 54 56 57 59 61
30 55 56 58 59 61 63
31 56 58 59 61 63 64
32 58 59 61 63 64 66
33 60 61 63 64 66 68
34 61 63 64 66 68 70
35 63 64 66 68 70 72
36 64 66 68 70 72 74
37 66 68 70 72 74 76
38 68 70 71 73 75 78
39 69 71 73 75 77 80
40 71 73 75 77 79 81
41 73 75 77 79 81 83
42 74 76 78 80 83 85
43 76 78 80 82 85 87
44 78 80 82 84 86 89
45 79 81 84 86 88 91
46 81 83 85 88 90 93
47 83 85 87 89 92 95
48 84 86 89 91 94 96
49 86 88 90 93 96 98
50 87 90 92 95 97 100
System elevation in metres
VISTRON Cap.
litres
FS 300 9,6
FS 400 11,8
FS 500 15,2
FS 750 21,9
FS 1000 28,4
VISTRON Cap.
litres
FSX 300 9,2
FSX 500 13,7
FSX 750 22,7
BS 300 9,7
BS 500 12,3
BS 750 15,6
BS 1000 19,3
Description Inside-Ø mm Capacity (l/m)
Cu 10 x 1 80,05
Cu 12 x 1 10 0,079
Cu 15 x 1 13 0,133
Cu 18 x 1 16 0,201
Cu 22 x 1 20 0,314
Cu 28 x 1 26 0,531
Cu 28 x 1,5 25 0,491
VISTRON Cap.
litres
HS 500 10,4
HS 750 14,4
HS 1000 22,3
THS 800/300 17,5
THS 1000/300 20,0
Example:
3 m2Collector area with AURON DF
Vkoll (collector content): Vkoll = 8.6 l (4.3 l/module = 2 x 4.3 l)
Vr(connecting line): Vr= 0.266 l (both sides 1 m,
DN 15 = 2 x 0,314)
VA(system content): collector volume = 8.6 l
Pipeline volume = 3.99 l
(30 m pipeline DN 15 = 30 x 1.33)
Heat exchanger volume = 9,6 l
V
A= 22,19 l
VD= Vkoll + Vr + (e * Va)
VD= 8.6 l + 0.628 l + (0.085 * 22,19 l)
VD= 11,11 l (expansion volume)
A plant height of 10 m results in a size of the expansion tank
of at least VEXPmin = 23 l.Here an expansion tank of 25 l should
be used.
Intermediate container:
VZG = VEXP min. x 0.5 = 23 l * 0.5 = 11,5 l
Here an intermediate tank of 12 l should be used.
Basis for the table is a safety valve with a trip pressure of 6 bar, system
pressure of pstat + 0.5 bar and the expansion volume of the solar plant
installed. The expansion volume (Vd) is derived from the collector volume
(Vkoll), the volume of the connecting pipes (Vr) and the plant volume (Va)
multiplied by the coefficient of expansion (e) of the heat transfer medium.
Design of intermediate container
Intermediate tanks are to be used in all plants with very short pipe runs
and/or very small cross sections, or with large collector areas or collectors
with large volume (content of return pipework < 50% of a properly de-
signed expansion tank VEXP).
VZG = VEXP min. x 0.5
Vkoll =Collector volume
VA=Volume of plant
Vr=Volume of connecting pipework
VD=Volume of expansion
VV=liquid MAG (0.5 % of the volume of the plant,
but at least 3 l)
VZG =Volume of intermediate tank (initial tank - optional)
VEXPmin = Minimum volume of expansion tank
e =Coefficient of expansion of the heating transfer medium
(0.085 at filling temp.10° and maximum temperature of 130°)
pstat =Height of plant in m * 0.1 bar/m
pa=Filling pressure of plant (0.5 bar + pstat)
pe=Plant pressure (response pressure SV – 10 %)
In order to be able to use the following table, the expansion
volume VDmust be calculated: VD= Vkoll + Vr+ (e * VA)
Basis for the calculation of the table is:
VMAGmin = (VD+VV) * (pe+1) / (pe– pa)

14
Design configuration and sizing
Expansion tank
Adjusting the precharge pressure
The hydraulic back pressure in the ex-
pansion tank shall always be 3 litres.
The parameters that determine the tank
precharge setting are: total vertical
height, system pressure and the size of
the expansion tank. System pressure is
1.5 bar between 3 and 10 meters.
Vertical
height System
pressure
3 bis 10 1.5 1.3 1.3 1.4 1.4
11 1.6 1.3 1.4 1.5 1.5
12 1.7 1.4 1.5 1.6 1.6
13 1.8 1.5 1.6 1.6 1.7
14 1.9 1.6 1.7 1.7 1.8
15 2.0 1.7 1.8 1.8 1.9
Expansion tank volume in
l18 25 35 50 to 100
Expansion tank precharge pressure

15
Solar circuit hydraulics
B6 Collector sensor
B3 Top hot water cylinder sensor
B31 Bottom hot water cylinder sensor
Q5 Solar circuit pump
MAG Expansion vessel
VL Supply
RL Return
Z Circulation
WW Hot water
KW Cold water
TWM Thermal hot water mixer to prevent
risk of scalding (accessory)
DR Flow regulating valve
SV Safety valve
SuB Flush and fill provision
LA Air vent
B6
SV
SuB
Q5
DR
SuB
MAG
WW
TWM
VL
RL
Z
VL
RL
KW
KW
B31
B3
VISTRON
LOGON B
SOL

16
Collector panel hydraulics
max. 120 tubes Vertical installation
Diagonal connecting pipes:
A maximum of 120 tubes (12 m² ab-
sorber surface) can be connected to-
gether in a collector panel array.
The minimum flow shall not fall below
30 l/m²h (caution when using variable
speed pumps).
Installations with more than 120 tubes
(12 m² absorber surface) shall be con-
nected in parallel based on the Tichel-
mann principle. The minimum flow shall
not fall below 30 l/m²h per Tichelmann
circuit (caution when using variable
speed pumps).
Interconnecting pipe on one side
only
A maximum of 60 tubes (6 m² absorber
surface) can be interconnected in a
collector panel array when intercon-
nected on one side only.
The minimum flow shall not fall below
45 l/m²h (caution when using variable
speed pumps).
When interconnected on one side only,
installations with more than 60 tubes (6
m²) shall be connected in parallel
based on the Tichelmann principle.
The minimum flow shall not fall below
45 l/m²h per Tichelmann circuit (caution
when using variable speed pumps).
max. 120 tubes
max. 60 tubes
max. 60 tubes

17
Collector panel hydraulics
Horizontal installation
The collectors can be assembled with
either the right side or left side pointing
down. When the left side is pointing
down the collector sensor is at the bot-
tom, and it is at the top when the right
side is down. Installing the collectors
horizontally improves the vapourization
behaviour at zero flow. The vapour
generated completely forces the solar
fluid out of the collector panel, which
slows down the fluid aging process. To
retain this benefit when collector panels
are joined together from one side only,
they should be connected together at
the bottom.
Diagonal connecting pipes
A maximum of 120 tubes (12 m² ab-
sorber surface) can be interconnected
in a collector panel array when they are
connected diagonally.
The minimum flow shall not fall below
30 l/m²h (caution when using variable
speed pumps).
When interconnected diagonally, instal-
lations with more than 120 tubes (12
m²) shall be connected in parallel
based on the Tichelmann principle.
The minimum flow shall not fall below
30 l/m²h per Tichelmann circuit (caution
when using variable speed pumps).
Interconnecting pipe on one side
only (horizontal)
When interconnecting the collector pan-
els on one side only, the connecting
pipes should be located at the bottom
to improve vapourization behaviour.
A maximum of 60 tubes (6 m² absorber
surface) can be interconnected in a
collector panel array when intercon-
nected on one side only.
The minimum flow shall not fall below
45 l/m²h (caution when using variable
speed pumps).
When interconnected on one side only,
installations with more than 60 tubes (6
m²) shall be connected in parallel
based on the Tichelmann principle.
The minimum flow shall not fall below
45 l/m²h per Tichelmann circuit (caution
when using variable speed pumps).
max. 120 tubes max. 120 tubes
max. 60 tubes
max. 60 tubes

18
Bill of materials
AURON DF collector components
Tools required to assemble the tubes:
size 24 open-end wrench
Tools required to assemble the connec-
tion fittings and the expansion sets.
size 30 open-end wrench
size 32 open-end wrench
AURON models Basic module
(with sensor connector)
Item: Description B 15 DF B 20 DF E 15 DF E 20 DF
1 vacuum tube with threaded pipe fitting 15 20 15 20
2 basic manifold with sensor sleeve 1 1 - -
3 manifold extension without sensor sleeve - - 1 1
4 foot rail with tube fasteners 1 1 1 1
5 tube neck insulator 15 20 15 20
6 cover for manifold connector 2 2 - -
7 cover for manifold interconnector - - 1 1
8 end plug with vent 2 2 - -
9 connection fitting 2 2 - -
10 interconnecting plate for manifold - - 1 1
11 interconnecting plate for bottom rail - - 1 1
Accessories
12 expansion module interconnecting kit with
insulator
- - 1 1
Expansion module
(without sensor connector)
Item 1
Item 2
Item 3
Item 7
Item 4
Item 6 Item 10+11
Item 8 + Item 9
Item 12
Item 5

19
Bill of materials
Mounting hardware
Item Description Basic module Expansion module
Tile roof, vertical (A) B 15 DF B 20 DF E 15 DF E 20 DF
13 manifold fastener 2 2 1 2
14 universal solar fastener 2 2 1 2
15 mounting rail 2 2 1 2
16 roof hook 4 4 2 4
17 lag bolts for rafters 8 8 4 8
Tile roof, horizontal (B)
13 manifold fastener 4 4 1 2
14 universal solar fastener 2 2 1 2
15 mounting rail 2 2 1 2
16 roof hook 4 4 2 4
17 lag bolts for rafters 8 8 4 8
Flat roof, lying flat (C) (materials to attach the rack to the roof covering (concrete paving stones; bolts) shall be supplied at site)
13 manifold fastener 2 2 1 2
14 universal solar fastener 2 2 1 2
15 mounting rail 2 2 1 2
Building façade (D) (hanger bolts shall be used; details shall be coordinated with the contractor responsible for façade construction)
13 manifold fastener 4 4 1 2
14 universal solar fastener 2 2 1 2
15 mounting rail 2 2 1 2
21 hanger bolt (Walls with timber beams) 4 4 2 4
25 connecting bolt 4 4 2 4
Flat roof, inclined mounting (E) (materials to attach the rack to the roof covering shall be supplied at site)
13 manifold fastener 2 2 1 2
14 universal solar fastener 2 2 1 2
18 mounting frame, vertical (pre-assembled) 2 2 1 2
19 cross bracing 1 1 1 1
20 right-angle fastener 2 2 2 2
Non-standard roof configurations, vertical (A) (when clamps are used for mounting, three clamps per mounting rail shall be used)
13 manifold fastener 2 2 1 2
14 universal solar fastener 2 2 1 2
15 mounting rail 2 2 1 2
21 hanger bolts 4 4 2 4
22 roof hooks for slate 4 4 2 4
23 metal seam clamp 6 6 3 6
24 KalZip roof clamp 6 6 3 6
25 connecting bolt 6 6 3 6
Non-standard configurations, horizontal (B) (when clamps are used for mounting, three clamps per mounting rail shall be used)
13 manifold fastener 4 4 1 2
14 universal solar fastener 2 2 1 2
15 mounting rail 2 2 1 2
21 hanger bolts 4 4 2 4
22 roof hooks for slate 4 4 2 4
23 metal seam clamp 6 6 3 6
24 KalZip roof clamp 6 6 3 6
25 connecting bolt 6 6 3 6
26 Tiled roof hook flexible 2 2 1 2
27 Beavers tail roof hook 2 2 1 2
26 Tiled roof hook flexible 2 2 1 2
27 Beavers tail roof hook 2 2 1 2
Tools required to assemble the mounting rack:
size 17 socket wrench or socket
size 13 socket wrench or socket
Torx 50 Adapter
Measuring tape; cut-off angle grinder for roof tiles
Torx 50 Adapter

20
Bill of materials
Mounting hardware
Pos.13+14+15 Pos. 16+17
Pos.18
Pos.19+20
Pos.22 Pos.23
Pos.24 Pos.25
Pos.21
Pos. 26
Pos. 27