Vaillant aurotherm classic VFK 135/2 VD User manual

For the competent person
Installation manual
auroTHERM classic
VFK 135/2 VD, VFK 140/2 VD
GB, IE
Installation manual
Publisher/manufacturer
Vaillant GmbH
Berghauser Str. 40 D-42859 Remscheid
Telefon [phone]‑0 Telefax 021 91 18‑28 10
[email protected] www.vaillant.de

Contents
2Installation manual auroTHERM classic 0020159946_01
Contents
1 Safety .................................................................... 3
1.1 Action-related warnings ......................................... 3
1.2 General safety information .................................... 3
1.3 Intended use .......................................................... 4
1.4 Regulations (directives, laws, standards) .............. 5
1.5 CE label ................................................................. 6
2 Notes on the documentation .............................. 7
2.1 Observing other applicable documents ................. 7
2.2 Storing documents................................................. 7
2.3 Applicability of the instructions .............................. 7
2.4 Name ..................................................................... 7
3 Description of the unit......................................... 7
3.1 Type overview........................................................ 7
3.2 Information on the identification plate.................... 7
3.3 Purpose of the unit................................................. 7
4 On-roof fitting and installation ........................... 7
4.1 Preparing for fitting and installation ....................... 7
4.2 Carrying out the installation ................................. 10
4.3 Completing and checking the installation ............ 17
5 Flat roof fitting and installation........................ 18
5.1 Preparing for fitting and installation ..................... 18
5.2 Carrying out the installation ................................. 27
5.3 Completing and checking the installation ............ 34
6 Inspection and maintenance ............................ 35
6.1 Maintenance plan ................................................ 35
6.2 Observing inspection and maintenance
intervals ............................................................... 35
6.3 General inspection and maintenance
instructions........................................................... 35
6.4 Preparing for inspection and maintenance .......... 35
6.5 Checking collectors and connections for
damage, dirt and lack of tightness....................... 35
6.6 Cleaning collectors .............................................. 35
6.7 Checking brackets and collector components
for firm seating ..................................................... 36
6.8 Check the pipe insulations for damage ............... 36
6.9 Replacing damaged pipe insulations................... 36
6.10 Disposing of damaged pipe insulations ............... 36
7 Troubleshooting ................................................ 36
7.1 Procuring spare parts .......................................... 36
7.2 Carrying out repairs ............................................. 36
8 Decommissioning.............................................. 37
8.1 Temporary decommissioning .............................. 37
8.2 Permanently decommissioning............................ 37
9 Customer service............................................... 38
10 Technical data.................................................... 38
10.1 Technical data table............................................. 38
10.2 Dimensions .......................................................... 39
Index ................................................................................... 40

Safety 1
0020159946_01 auroTHERM classic Installation manual 3
1 Safety
1.1 Action-related warnings
Classification of action-related warnings
The action-related warnings are classified in
accordance with the severity of the possible
danger using the following warning signs and
signal words:
Warning symbols and signal words
Danger!
Imminent danger to life or risk of
severe personal injury
Danger!
Risk of death from electric shock
Warning.
Risk of minor personal injury
Caution.
Risk of material or environmental
damage
1.2 General safety information
1.2.1 Risk of death due to improper
fastening systems
The collectors may fall if fastening systems
are incorrectly fitted.
Only the combination of Vailllant collectors
and Vaillant fastening systems has been
tested. This combination can withstand the
forces caused by additional wind and snow
loads.
▶Only use the collector fastening systems
that are approved by Vaillant.
1.2.2 Risk of death due to inadequate
load-bearing capacity of the roof
A roof with an insufficient load-bearing capa-
city may collapse due to the additional load of
the collectors.
Above all, additional wind and snow loads
may result in higher forces which could cause
the roof to collapse.
▶Ensure that a structural engineer has con-
firmed the roof as suitable for collector in-
stallation.
▶Only install the collectors on a roof that
has adequate load-bearing capacity.
1.2.3 Risk of death due to falling parts
Unsecured collectors can fall from the roof
and create a possible danger to people.
▶Block off the areas in the fall area below
the place of work to a sufficient extent so
that people cannot be injured by falling
objects.
▶Indicate the working area, e.g. with inform-
ation signs, in accordance with the applic-
able regulations.
1.2.4 Risk of injury and material damage
due to incorrect maintenance and
repairs
If maintenance or repair work is not carried
out, or is carried out incorrectly, this may res-
ult in injuries or in damage to the solar plant.
▶Ensure that only an approved competent
person carries out maintenance and repair
work.
1.2.5 Risk of death due to inadequate
fastening of the collectors
Collectors can fall from their anchors if they
are not properly fastened on the roof. Col-
lectors falling from the roof could cause life-
threatening accidents.
▶Perform all work steps as described in this
manual.
▶Observe all safety precautions described
in this manual.
▶In addition, comply with all safety regula-
tions that specifically apply in your region.
1.2.6 Risk of burns due to hot collector
surfaces
In the event of solar radiation inside the units,
collectors can reach 200 °C. If you touch the
collectors without protection, you could burn
yourself.
▶If a sun protection film has been attached
to the collectors in the factory, remove it
only after the solar plant has been started
up.
▶Avoid performing installation and mainten-
ance work under direct sunlight.
▶Cover the collectors before starting work.
▶You should preferably perform the work in
the morning.

1 Safety
4Installation manual auroTHERM classic 0020159946_01
▶Wear suitable safety gloves.
1.2.7 Risk of injury due to breaking glass
The glass of the collectors may break due to
mechanical destruction or torsion.
▶Wear suitable safety gloves.
▶Wear suitable protective goggles.
1.2.8 Material damage caused by a high-
pressure cleaner
High-pressure cleaners may damage the
collectors due to the extremely high pressure.
▶Never clean the collectors with a high-
pressure cleaner.
1.2.9 Material damage due to lightning
Lightning can damage the collector system.
▶Connect the collector system to a lightning
protection device in accordance with ap-
plicable regulations.
1.2.10 Frost damage due to water in the
solar circuit
Water residue in the collector may freeze in
frosty conditions and damage the collector.
▶Never fill or flush the collector with water.
▶Only fill and flush the collector with Vaillant
ready-mixed solar fluid.
▶Check the solar fluid regularly with an anti-
freeze tester.
1.2.11 Material damage due to frost
Frost may damage the collectors.
▶Ensure that the system can be drained
completely.
The system can be drained completely if the
bottom edges of the collectors are aligned
precisely in a horizontal plane and the
pipeline has a steady downward gradient.
▶During the installation, ensure that the bot-
tom edges of the collectors are positioned
above the cylinder connection.
1.2.12 Material damage due to an
unsuitable tool
An unsuitable tool may damage the solar
plant.
▶Only use a suitable tool.
▶In particular, only use the tool specified in
the work steps of this manual.
1.2.13 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 life-threatening injuries.
▶Secure earthing pipe clamps to the pipes.
▶Connect the earthing pipe clamps to a
busbar using 16 mm²copper cable.
1.2.14 Material damage due to overvoltage
Overvoltage may damage the solar plant.
▶Earth the solar circuit to provide equipoten-
tial bonding and overvoltage protection.
▶Secure earthing pipe clamps to the pipes.
▶Bond the earthing pipe clamps to a busbar
using 16 mm²copper cable.
1.2.15 Risk of death and material damage
due to contact corrosion
For roofs or façade sections made of metals
more precious than aluminium (e.g. copper
roof), contact corrosion may occur on the
brackets. Collectors could fall and put per-
sons at risk.
▶Use suitable underlays to separate the
metals.
1.2.16 Material damage due to snow falling
from roofs
If the collector field is installed below a slop-
ing roof, then snow falling from the roof may
damage the collectors.
▶Install snow fences above the collectors as
protection against falling snow.
1.3 Intended use
There is a risk of injury or death to the user or
others, or of damage to the product and other
property in the event of improper use or use
for which it is not intended.
The Vaillant VFK VD flat collector is used for
solar heating support and for solar-supported
hot water generation.
The collectors must only be operated with
Vaillant ready-mixed solar fluid. Passing
heating water or hot water directly through
the collectors constitutes improper use.

Safety 1
0020159946_01 auroTHERM classic Installation manual 5
The Vaillant VFK VD flat collector must
only be combined with Vaillant components
(fastenings, connections, etc.) and parts of
the auroFLOW plus system from Vaillant.
The use of other components or system parts
shall be considered as improper use.
Intended use includes the following:
–observing the included operating, install-
ation and servicing instructions for the
Vaillant product and any other system
components
–compliance with all inspection and main-
tenance conditions listed in the instruc-
tions.
Installation of the collector in or on a vehicle
is not permissible and is considered im-
proper. Units that are not classed as vehicles
are those that are installed in a fixed and
permanent location (known as "fixed
installation").
Any other use that is not specified in these
instructions, or use beyond that specified in
this document shall be considered improper
use. Any direct commercial or industrial use
is also deemed to be improper.
Caution.
Improper use of any kind is prohibited.
1.4 Regulations (directives, laws,
standards)
1.4.1 Regulations (directives, laws,
standards)
Technical Guidance
The system must be installed in accordance
with all relevant and applicable national regu-
lations, and must be installed to suit site con-
ditions. Observe all national regulations, in-
cluding:
–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 installa-
tions.
Related documents
The installation of the solar system must
be in accordance with the relevant require-
ments 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 rel-
evant requirements of the Local Authority,
Building Regulations, The Building Regula-
tions (Scotland), The Building Regulations
(Northern Ireland) and the relevant recom-
mendations of the following British Stand-
ards:
–BS EN 806: Specification for installations
inside buildings conveying water for hu-
man consumption
–BS 6700: Services supplying water for
domestic use within buildings and their
curtilages
–BS 5449 Forced circulation hot water cent-
ral heating systems for domestic premises.
Note: only up to 45 kW
–BS. 6880 Low temperature hot water heat-
ing systems of output greater than 45 kW
–Part 1 Fundamental and design consid-
erations.
–Part 2 Selection of equipment
–Part 3 Installation, commissioning and
maintenance
–BS 6114: Expansion vessels using an in-
ternal diaphragm for unvented hot water
supply systems
–BS. 4814 Specification for: Expansion
vessels using an internal diaphragm, for
sealed hot water heating systems
–Unvented hot water systems must comply
with building regulation G section 3
1.4.2 Regulations for the prevention of
accidents
When carrying out works such as solar in-
stallation 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 fol-
lowing:
–Health and Safety at Work act 1974