Vaillant auroTHERM VFK 125 User manual

auroTHERM
VFK 125
VFK 135 D
VFK 140 D
VFK 145 H/V
VFK 150 H/V
ES, GB, NL, PT

For the expert technician
Installation manual
auroTHERM
VFK 145 H/V
VFK 150 H/V
On-roof/flat roof installation
Contents
1 Notes on the documentation.........................2
1.1 Other applicable documents ................................2
1.2 Document storage ..................................................2
1.3 Symbols used ...........................................................2
1.4 Applicability of the manual...................................2
2 Intended use....................................................2
2.1 Combination with other components ................2
2.2 Operational conditions ..........................................3
2.3 CE mark .....................................................................3
3 Safety information .........................................3
3.1 Technical Guidance.................................................3
3.2 Related documents.................................................3
3.3 Regulations for the prevention of accidents ...4
3.4 Lightning protection...............................................4
3.5 Frost protection.......................................................4
4 Before installation..........................................5
4.1 Safety information..................................................5
4.2 Scope of delivery ....................................................6
4.2.1 On-roof mounting ...................................................6
4.2.2 Flat roof installation...............................................7
4.3 Collector field packaging.......................................8
4.4 Interconnection diagram.......................................9
4.5 Hydraulic connection preparation.................... 10
4.5.1 On-roof mounting ................................................. 10
4.5.2 Flat roof installation............................................. 10
4.6 Required tools........................................................ 10
5 Flat roof installation .................................... 10
5.1 Collector position and field arrangement....... 10
5.2 Weighting and arrangement of the frames......11
5.3 Collector installation .............................................12
6 On-roof mounting...........................................16
6.1 Collector position and field arrangement....... 16
6.2 Roof anchor installation.......................................17
6.2.1 Roof anchor type P (pantile).............................. 19
6.2.2 Roof anchor type S and roof anchor
type S flat (for beaver tail)..................................21
6.2.3 Stair bolt mounting kit.........................................22
6.3 Collector installation ............................................22
7 Concluding work............................................27
8 Recycling and disposal.................................27
8.1 Collectors ................................................................27
8.2 Packaging................................................................27
8.3 Solar fluid................................................................27
9 Vaillant Customer Service and warranty..27
9.1 Vaillant warranty...................................................27
9.2 Vaillant Service......................................................27
10 Technical data.............................................. 28
GB

Installation manual auroTHERM 0020057143_042
1 Notes on the documentation
2 Intended use
1 Notes on the documentation
The instructions below are intended to help you
throughout the entire documentation.
1.1 Other applicable documents
All installation instructions of flat collectors and compo-
nents of the installation must be observed when install-
ing the solar system. These instructions are included
with the individual components of the system and the
additional components.
We accept no liability for any damage caused by fail-
ure to observe these instructions.
1.2 Document storage
Please pass on this installation manual and all other ap-
plicable documents and auxiliary equipment to the plant
operator, whose responsibility it is to ensure the manu-
als and auxiliary equipment are available whenever re-
quired.
1.3 Symbols used
Please observe the safety instructions in this installation
manual for the installation of the collector!
dDanger!
Immediate risk of serious injury or death!
eDanger!
Risk of death from electric shock!
HDanger!
Danger of burning and scalding!
aCaution!
Potentially dangerous situations for the prod-
uct and the environment!
hNote
Useful information and instructions.
• Symbol indicating the required action
1.4 Applicability of the manual
These installation manual applies exclusively to flat col-
lectors with the following article numbers:
Collector type Article number
VFK 145 H 0010004457
VFK 145 V 0010004455
VFK 150 H 0010006285
VFK 150 V 0010006283
Table 1.1 Collector types and article numbers
For the flat collector article number please see the iden-
tification plate on the upper collector edge.
Vaillant flat collectors are available in different versions:
one for the horizontal position, one for the vertical posi-
tion.
Besides, collectors in the collector field can be arranged
side by side and on top of each other.
Generally, the installation steps and the instructions
described in this manual are valid for both collector
positions and field arrangements.
Any different installation steps are clearly pointed out:
wWith horizontal collector position
sWith vertical collector position
nWith fields arranged side by side
uWith fields arranged on top of each other
2 Intended use
The Vaillant auroTHERM flat collectors are built and de-
signed according to accepted safety rules and regula-
tions.
Nevertheless, improper use may cause danger to life
and limb of the user or third parties and could impair
the operation of the unit and other objects.
The unit is not intended for use by persons (including
children) with reduced physical, sensory or mental capa-
bilities, or lack of experience and/or knowledge, unless
they have been given supervision or instruction con-
cerning use of the unit by a person responsible for their
safety.
Children must be watched to ensure that they do not
play with the unit.
Vaillant auroTHERM flat collectors are used for heating
support and for solar hot water generation.
Any other use or use exceeding the above-mentioned
applications shall be considered as improper use. The
manufacturer/supplier shall not be responsible for any
damages resulting from such improper use. The user
alone bears the risk.
Intended use includes observance of the operating and
installation manuals and all other applicable documents,
as well as adherence to the maintenance and inspection
conditions.
aCaution!
Any improper use is forbidden!
2.1 Combination with other components
Vaillant flat collectors should be combined only with
Vaillant components (fixing, connections) and system
components.
The use of other components or system components
shall be considered as improper use. We accept no liabil-
ity.

2.2 Operational conditions
aCaution!
The roof may collapse!
Mount the flat collectors only on roofs with a
sufficient load-carrying capacity.
If necessary, call a technician.
Caution!
Collector damage!
Flat collectors are suitable for a maximum
snow load of 5.0 kN/m2and a maximum wind
load of 1.6 kN/m2.
On-roof mounting:
The flat collectors can be mounted on roofs with inclina-
tions from 15º to 75º.
Flat roof installation:
Flat collectors can be installed on flat roof frames in the
as-delivered condition with an angle of 30°, 45° or 60°.
2.3 CE mark
The CE mark certifies that the appliances, according to
the models available, satisfy the basic requirements of
the following directives:
– Directive 97/23/EWG of the European Parliament and
Council for approximation of the laws of the member
states regarding pressure equipment
auroTHERM flat collectors are built accord-
ing to the state of the art and recognised
safety rules and regulations.
Conformity with the applicable standards
has been demonstrated.
auroTHERM flat collectors have been suc-
cessfully tested according to the rules and
requirements for the Solar Keymark.
3 Safety information
The following safety instructions, technical rules and ac-
cident prevention regulations must be observed when
installing the flat collectors.
dDanger!
Danger to life as a result of falling from the
roof!
Danger to life from parts falling from the roof!
Observe the applicable national regulations for
working at heights.
HDanger!
Danger of burning and scalding!
In case of solar irradiation inside the units, col-
lectors can reach 200 °C. Remove the sun pro-
tection film installed at the factory only after
the solar energy system has been started up.
HDanger!
Danger of burning and scalding!
In case of solar irradiation inside the units, col-
lectors can reach 200 °C.
Do not perform maintenance work under direct
sunlight.
aCaution!
Risk of corrosion!
On roofs made of metals more noble than alu-
minium (e.g. copper roofs) galvanic corrosion
can occur at the anchor points, whereby the at-
tachment of the collectors is no longer guaran-
teed. Ensure that the metals are separated by
suitable underlays.
Caution!
Collector damage!
In order to install flat collectors according to
the installation manual, a qualified engineer is
required.
The installation should be performed only by
qualified engineers.
3.1 Technical Guidance
The system must be installed in accordance with all rel-
evant and applicable national regulations, and must be
installed to suit site conditions.
Observe all national regulations, including:
— Working at Heights Regulations 2005
— Health and Safety at Work Act 1974
— Electricity at Work Regulations 1989
— IEE Wiring Regulations BS 7671
— Lightning protection requirements
— Equipotential bonding of electrical installations.
3.2 Related documents
The installation of the solar system must be in accord-
ance with the relevant requirements of Health and Safe-
ty Document No. 635 (The Electricity at Work Regula-
tions 1989), BS 7671 (IEE Wiring Regulations) and the
Water Supply (Water Fitting) Regulations 1999, or The
Water Bylaws 2000 (Scotland). It should also be in ac-
cordance with the relevant requirements of the Local
Authority, Building Regulations, The Building Regula-
tions (Scotland), The Building Regulations
(Northern Ireland) and the relevant recommendations of
the following British Standards:
— BS EN 806: Specification for installations inside build-
ings conveying water for human consumption.
3Installation manual auroTHERM 0020057143_04
Intended use 2
Safety information 3
GB

— BS 6700: Services supplying water for domestic use
within buildings and their curtilages.
— BS 5449 Forced circulation hot water central heating
systems for domestic premises.
Note: only up to 45 kW.
— BS 6880 Low temperature hot water heating systems
of output greater than 45 kW.
Part 1 Fundamental and design considerations.
Part 2 Selection of equipment.
Part 3 Installation, commissioning and maintenance.
- BS 6114: Expansion vessels using an internal dia-
phragm for unvented hot water supply systems
- BS 4814 Specification for: Expansion vessels using an
internal diaphragm, for sealed hot water heating sys-
tems.
Unvented hot water systems must comply with building
regulation G section 3.
3.3 Regulations for the prevention of accidents
When carrying out works such as solar installation work
it is necessary to do so in a safe and workman like man-
ner, taking due care of any aspects of the works that
could result in injuries to person in or about the building
as well as workers, passers by and the general public at
large. To that end these works must conform, but not be
limited to, the current regulations in force such as the
following
— Health and Safety at Work act 1974
— Work at Height Regulations 2005.
— Electricity at Work Regulations 1989
— All necessary Building Regulations.
Work should be preceded by a risk assessment covering
all aspects of health and safety risks, or training re-
quirements that can reasonably be foreseen to be asso-
ciated with the work. All scaffolding in the UK, other
than prefabricated (zip-up) scaffold towers, must be de-
signed and constructed by a vetted contractor, and
have suitable kick boards, hand rails and where appro-
priate netting. Areas around the scaffolding should be
zoned off and marked with suitable warning signs to a
suitable distance to protect persons from falling objects.
Workers should have available and use personal protec-
tive equipment as necessary. This would include equip-
ment such as fall protection systems, safety gloves,
goggles, dust masks as well as any specialised equip-
ment that may be in use such as lifting and handling
equipment.
The completed works shall comply with all necessary BS
EN Standards and Codes of practice as well as Building
control or planning requirements and be confirmed
where necessary by notification to building control or
the appropriate competence based notification body.
3.4 Lightning protection
aCaution!
Damage from lightning!
If the installation height is more than 20 m or
if the collectors are projected above the roof
ridge, electro-conductive components must be
connected to a lightning protection device!
3.5 Frost protection
aCaution!
Damage due to frost!
Under no circumstances should water on its
own be in the collector if there is a danger of
frost!
After pressurisation and flushing, the collectors
may contain water residues.
Immediately fill the solar system with solar
fluid. Check the fluid concentration with a frost
protection tester. Water remaining in the solar
circuit may dilute the fluid.
Installation manual auroTHERM 0020057143_044
3 Safety information

4 Before installation
4.1 Safety information
Please note the following instructions before and during
installation:
dDanger!
Risk of death from falls and falling objects!
Observe the national regulations for working at
heights.
Wear the Vaillant safety belt
(article number 302066).
HDanger!
Danger of burning and scalding!
In case of solar irradiation inside the units, col-
lectors can reach 200 °C. Remove the sun pro-
tection film installed at the factory only after
the solar energy system has been started up.
aCaution!
Collectors may be damaged by incorrect stor-
age!
Always store the collectors in a dry place and
protected from the elements.
Caution!
System error function due to air bubbles!
To fill the system, use the fill trolley
(article number 0020042548) to avoid air
bubbles.
Use the manual air vent installed on the collec-
tor field.
Alternatively, install the Vaillant Solar auto-
matic air vent (article number 302019) in the
highest point of the system or the automatic
de-aerator (article number 302418) in the solar
circuit.
Observe the relevant installation and operating
manual.
Caution!
Danger of damaging internal components!
The interior of the collector is vented by the
opening integrated in the pipe penetration.
Keep the vent opening clear for trouble-free op-
eration.
5Installation manual auroTHERM 0020057143_04
Before installation 4
GB

4.2 Scope of delivery
• Check the mounting kit for completeness based on the
illustrations and bills of materials.
4.2.1 On-roof mounting
1
3
12
10
2
4
14
5
11
7
13
6
9
8
Fig. 4.1 On-roof mounting kit (here: vertical collector)
Pos. Description Quantity Article number (kit)
1 Mounting rail 2 0020059899 (Vertical rail mounting kit)
0020059898 (Horizontal rail mountin
g
kit)
2 Supply (outlet with opening for collector sensor) 1
0020059891 (Hydraulic connection kit)
3 Return (inlet) 1
4 Lower plug 1
5 Upper plug (with vent) 1
6 Clam
p
4
7 Roof anchor type P (for pantile) 4
20020067273 (Basic kit) 0020067274 (Extension kit for stacked mounting)
8 Long lower section type P (optional) 10020080177
9 Roof anchor type S (for beaver tail, etc.) 4
20020067275 (Basic kit) 0020067276 (Extension kit for stacked mounting)
10 Roof anchor type S flat (for beaver tail, etc.) 4
20020080145 (Basic kit) 0020080147 (Extension kit for stacked mounting)
11 Stair bolt mounting kit 4
20020067277 (Basic kit) 0020087855 (Extension kit for stacked mountin
g
)
12 Hydraulic connections 2 0020055181 (Hydraulic extension kit)
13 Clamp 4
14 Collector 1
0010004455 (auroTHERM VFK 145 V)
0010004457 (auroTHERM VFK 145 H)
0010006283 (auroTHERM VFK 150 V)
0010006285 (auroTHERM VFK 150 H)
Table 4.1 On-roof mounting bill of materials
Installation manual auroTHERM 0020057143_046
4 Before installation

7Installation manual auroTHERM 0020057143_04
4.2.2 Flat roof installation
1
311
7
2
6
4
12
5
8
10
9
Fig. 4.2 Mounting kit for flat roof installation
(here: vertical collector)
Pos. Description Quantity Article number (kit)
1 Mounting rail 2 0020059901 (Vertical rail mounting kit)
0020059900 (Horizontal rail mountin
g
kit)
2 Supply (outlet with opening for collector sensor) 1
0020059891 (Hydraulic connection kit)
3 Return (inlet) 1
4 Lower plug 1
5 Upper plug (with vent) 1
6 Clamp 4
7 Frame with clamping element 1 0020055206 (Base vertical frame kit)
0020055207 (Base horizontal frame kit)
8 Gravel tray (optional) 2
30020059904 (Gravel tray kit 2 pieces)
0020059905 (Gravel tray kit 3 pieces)
9 Safety clamps 2
10 Hydraulic connections 2 0020055181 (Hydraulic extension kit)
11 Clamp 4
12 Collector 1
0010004455 (auroTHERM VFK 145 V)
0010004457 (auroTHERM VFK 145 H)
0010006283 (auroTHERM VFK 150 V)
0010006285 (auroTHERM VFK 150 H)
Table 4.2 Flat roof installation bill of materials
Before installation 4
GB

4.3 Collector field packaging
The following tables list the required components ac-
cording to the type of installation.
On-roof mounting
Number of collectors: 1 2 3 4 5 6 7 8 9 10
Field arrangement side by side
Horizontal collector
position
Hyd. connection kit article number 0020059891
Required quantity
1
Hyd. connection kit article number 0020055181 - 1 2 3 4 5 6 7 8 9
Anchor set type P article number 0020067273
12345678910
Anchor set type S article number 0020067275
Anchor set type S flat article number 0020080145
Anchor set stair bolt Article number 0020067277
Horizontal rail, anodized - Article No. 0020059898 1 2 3 4 5 6 7 8 9 10
Vertical collector po-
sition
Hyd. connection kit article number 0020059891 1
Hyd. connection kit article number 0020055181 - 1 2 3 4 5 6 7 8 9
Anchor set type P article number 0020067273
12345678910
Anchor set type S article number 0020067275
Anchor set type S flat article number 0020080145
Anchor set stair bolt Article number 0020067277
Vertical rail, anodized - Article No. 0020059899 1 2 3 4 5 6 7 8 9 10
Field arrangement on top of each other
Horizontal collector
position
Hyd. connection kit article number 0020059891 1 1 --------
Hyd. connection kit article number 0020059894 - 1 --------
Anchor set type P article number 0020055174
11--------
Anchor set type S article number 0020055184
Anchor set type S flat article number 0020080145
Anchor set stair bolt Article number 0020059897
Anchor extension kit type P article number 0020059896
-1--------
Anchor extension kit type S article number 0020059895
Anchor extension kit type S flat article number 0020080147
Anchor extension kit hanger bolt
anodised Item no. 0020087854
Horizontal rail, anodized - Article No. 0020059898 1 2 --------
Vertical
collector position *
Hyd. connection kit article number 0020059891 1 2 3 4 5 6 7 8 9 10
Hyd. connection kit article number 0020059894
1111111111
Anchor set type P article number 0020055174
Anchor set type S article number 0020055184
Anchor set type S flat article number 0020080145
Anchor set stair bolt Article number 0020059897
-123456789
Anchor extension kit type P article number 0020059896
Anchor extension kit type S article number 0020059895
Anchor extension kit type S flat article number 0020080147
Anchor extension kit hanger bolt
anodised Item no. 0020087854 12345678910
Vertical rail, anodized - Article No. 0020060379 1 2 --------
* Caution!
When the vertical collector arrays are arranged on top of one another, the collectors must be hydraulically balanced with respect to
one another (Tichelmann system).
Table 4.3 On-roof mounting components
Installation manual auroTHERM 0020057143_048
4 Before installation

Flat roof installation
Number of collectors: 1 2 3 4 5 6 7 8 9 10
Field arrangement side by side
Horizontal
collector position
Gravel tray article number 0020059905
Required quantity
2 3 4 5 6 7 8 9 10 11
Hyd. connection kit article number 0020059891 1
Hyd. connection kit article number 00 20055181 - 1 2 3 4 5 6 7 8 9
Horizontal frame article number 0020055207 2 3 4 5 6 7 8 9 10 11
Horizontal rail, aluminium article number 0020059900 1 2 3 4 5 6 7 8 9 10
Vertical
collector position
Gravel tray (3 pieces) article number 0020059905 2 4 4 6 8 8 10 12 12 14
Gravel tray (2 pieces) article number 0020059904 1 0 2 1 0 2 1 0 2 1
Hyd. connection kit article number 0020059891 1
Hyd. connection kit article number 0020055181 - 1 2 3 4 5 6 7 8 9
Vertical frame article number 0020055206 2 3 4 5 6 7 8 9 10 11
Vertical rail, aluminium article number 0020059901 1 2 3 4 5 6 7 8 9 10
Table 4.4 Flat roof installation components
4.4 Interconnection diagram
hNote
Observe the planning information when dimen-
sioning the field volume flow.
nField arrangement side by side
hNote
If you connect 1 to 5 collectors one after
another, the hydraulic connections can be laid
one below the other on one side.
145...
Fig. 4.3 Field arrangement side by side for 1 - 5 collectors
hNote
If you connect 6 or more collectors one after
another, the hydraulic connections must be ar-
ranged diagonally, to force a complete flow.
112
11
2...
max. 12
Fig. 4.4 Field arrangement side by side for 6 - 12 collectors
uField arrangement on top of each other
max. 2
Fig. 4.5 Field arrangement on top of each other
9Installation manual auroTHERM 0020057143_04
Before installation 4
GB

4.5 Hydraulic connection preparation
4.5.1 On-roof mounting
Fig. 4.7 Passing the pipe through the sarking membrane
If there is a sarking membrane, proceed as follows:
• Cut the sarking membrane vee-shaped.
• Fold the upper, larger tab on the roof batten above,
and the lower, smaller tab on the roof batten below.
• Fix the sarking membrane tight to the roof batten.
This ensure that the dampness flows away to the side.
• With the roofs activated, cut out a hole with the com-
pass saw.
• Work the roofing felt as described for the sarking
membrane.
4.5.2 Flat roof installation
aCaution!
The roof skin can break and cause lack of tight-
ness!
When installing the roof sealing surfaces, make
sure the roof skin is adequately protected.
• Place large protection mats under the system.
• If the frame is screwed directly, check the sealing of
the building shell.
4.6 Required tools
• For the installation of flat collectors, prepare the fol-
lowing tools.
Fig. 4.8 Assembly tools: water level, cordless screwdriver, Torx
bit (TX30, supplied), socket/combination wrench (SW
13), hammer, measuring tape / folding rule
5 Flat roof installation
With flat roof installation, flat collectors are fastened to
frames.
The flat roof frames allow for a flexible installation with
an angle of 30°, 45° or 60°.
Besides, the height of the mounting rails is variable, in
order to compensate for small floor irregularities.
5.1 Collector position and field arrangement
Vaillant flat collectors are available in different versions:
one for horizontal position, one for vertical position.
Generally, the installation steps and the instructions
described in this manual are valid for both collector
positions.
Any different installation steps are clearly pointed out:
wWith horizontal collector position
sWith vertical collector position
Installation manual auroTHERM 0020057143_0410
4 Before installation
5 Flat roof installation

11Installation manual auroTHERM 0020057143_04
5.2 Weighting and arrangement of the frames
First of all, define the necessary load of the frames
based on Tab. 5.1.
Load [kg/collector]
Height above ground
Angle of attack 0-10 m 10-18 m 18-25 m
30° 159 178 197
45° 225 252 279
60° 276 309 342
Table 5.1 Flat roof installation load
aCaution!
The roof may collapse!
Before installation, check the maximum roof
load!
If necessary, call a technician.
For the required space and the distances among frames
please see Tab. 5.2.
A
B
D
E
Number of
collectors A* 30° 45° 60° CD*A
BFBFBF
Vertical
1** 1136
1283
2800
1740
4060
2080
4810
2357
--
2 2300
1150
-
3 3563
1263
4 4826
5 6089
6 7352
7 8615
8 9878
9 11141
10 12404
C
CF
Horizontal
1 1650
883
1250
1173
2030
1387
2560
1812
--
2 3900
1950
-
3 5963
2063
4 8026
5 10089
6 12152
7 14215
8 16278
9 18341
10 20404
* Dimension A can vary by +/- 50 mm in connection with dimension D.
** Possible only with 4 offset gravel trays.
1) Angle of attack (30°, 45° or 60°)
Table 5.2 Distances among frames
aCaution!
Starting from an installation height of 25 m
above ground, a specific static calculation must
be made!
aCaution!
For determining the installation location, keep a
distance of 1 m from the roof edge! A different
distance causes high wind loads.
Flat roof installation 5
GB

5.3 Collector installation
1
23
Fig. 5.2 Preparing the frame
• Open the frames.
aCaution!
Observe Table 5.1 for determining the
required load!
With screwed connection on the roof
• Fix the lower telescopic section with bolt
and safety clip.
2
1
2
Fig. 5.3 Mounting the gravel trays
If gravel trays are used:
• Slide the gravel tray (1) on the floor sec-
tion.
Collector
position Number of gravel trays per frame
w3
s4
Table 5.3 Number of gravel trays
• Apply the safety clamps (2) from the top in
the floor sections (2 x frame) to fix the gra-
vel tray.
• Fix the lower telescopic section with bolt
and safety clip.
60°
45°
30°
1
2
Fig. 5.4 Frame assembly
• Insert the telescopic sections into each
other, until the holes of the desired angular
position are placed one above the other.
hNote
You can choose 30°, 45° or 60°
(standard: 45°).
• Insert the retaining pin into the correspon-
ding hole (1).
• Fix the retaining pin with the safety clip(2).
Installation manual auroTHERM 0020057143_0412
5 Flat roof installation

13Installation manual auroTHERM 0020057143_04
Fig. 5.5 Frames with gravel trays
If gravel trays are used:
• Place large protection mats under the sy-
stem.
• Assembly frames based on the number of
collectors to be installed.
aCaution!
Before mounting the collectors, fill
the gravel trays on the first frame
with gravel or other suitable
weighting material, to give the sy-
stem stability.
hNote
For load weights and distances,
please see Tab. 5.1 and 5.2.
Fig. 5.6 Direct screwed connection
With screwed connection to the flat roof:
• Assembly frames based on the number of
collectors to be installed.
hNote
For load weights and distances,
please see Tab. 5.1 and 5.2.
• Fix the frames on the roof.
aCaution!
The roof skin can break and cause
lack of tightness!
When installing the roof sealing sur-
faces, make sure the roof skin is ade-
quately protected.
Fig. 5.7 Fixing and blocking the mounting rail
• Fix the horizontal mounting rails to the
frame clamping elements.
• Compensate any difference in height by
moving the clamping elements.
• Pull the lower part of the clamping element
upward, now it can be moved and it enga-
ges again when released.
Flat roof installation 5
GB

Installation manual auroTHERM 0020057143_0414
20
AB
Fig. 5.8 Positioning the mounting rails
• If multiple collectors are mounted, the
mounting rails meet in the centre of the
clamping elements (A).
• On the first and last frame, the mounting
rails can be projected by 20 mm (B).
Fig. 5.9 Joining the mounting rails
• Insert the connecting elements into the
mounting rails by the side.
• Position another frame (see Fig. 5.2 to 5.4).
• Join the mounting rails and fix them to the
frame clamping elements.
• Compensate any difference in height by
moving the clamping elements.
1
Fig. 5.10 Hooking the collector
• Place the collector with the lower edge in
the section of the mounting rail.
• Make sure that the upper part (1) of the
clamping element is above the collector
edge.
Fig. 5.11 Positioning the upper mounting rail
• Slide the upper mounting rail until it flus-
hes with the collector.
• Make sure that the upper part of the clam-
ping element is above the collector edge.
• Tighten the lower clamping elements with
the socket/combination wrench (SW 13).
5 Flat roof installation

15Installation manual auroTHERM 0020057143_04
1
2
1
2
a
A
B
Fig. 5.12 Attaching the pipe coupling
• Remove the plugs from the openings.
• Insert the pipe couplings into the opening
up to the stop (1).
• Slide the clamp in the rail of the ope-
ning (2).
aCaution!
Danger of damage to the collector as
a result of incorrect assembly!
Make sure that the clamp (A) slides
into the slot on the pipe coupler (B).
1
2
1
2
a
A
B
Fig. 5.13 Mounting other collectors
• Place the next collector on the lower
mounting rail.
• Slide the collector on the first collector (1)
and fix the hydraulic connectors with the
clamps (2).
• Tighten both clamping elements of the first
collector.
aCaution!
Danger of damage to the collector as
a result of incorrect assembly!
Make sure that the clamp (A) slides
into the slot on the pipe coupler (B).
1
2
3
4
Fig. 5.14 Mounting the hydraulic connections (1 - 5 collectors)
• Connect the supply (outlet with opening for
collector sensor) (1) on top.
• Remove the red plug and plug the collector
sensor into the opening.
• Use a cable tie to prevent the collector
sensor from slipping out.
• Connect the return (inlet) (2) at the bot-
tom.
• Mount the plug without vent (3) in the
lower part of the collector.
• Mount the plug with vent (4) in the highest
position.
• Fix connections and plugs with the clamps.
• Connect the collector supply and return to
the system with the connection pipes.
• If necessary check the connections for
leaks.
Flat roof installation 5
GB

Installation manual auroTHERM 0020057143_0416
1
2
3
4
Fig. 5.15 Mounting the hydraulic connections (6 or more collectors)
hNote
If you connect 6 or more collectors
one after another, the hydraulic con-
nections must be arranged diagonal-
ly, to force a complete flow.
• Insert the return (inlet) (2) into the lower
side opening on one side and, diagonally
across it, the supply (outlet with opening
for collector sensor) (4) into the upper side
opening.
• Remove the red plug and plug the collector
sensor into the opening.
• Use a cable tie to prevent the collector
sensor from slipping out.
• Mount the plug without vent (3) in the
lower part of the collector.
• Mount the plug with vent (1) in the highest
position.
• Fix connections and plugs with the clamps.
• Connect the collector supply and return to
the system with the connection pipes.
• If necessary check the connections for
leaks.
6 On-roof mounting
With on-roof mounting, flat collectors are fastened to
horizontal mounting rails quickly and reliably with at-
tachment clips. To ensure a good adaptation to the dif-
ferent roofings, three different roof anchors are availa-
ble:
— Type P for standard tiles and bricks (e.g. pantile),
— Type S for flat shingles and tiles (e.g. beaver tail,
slate) and extremely high protruding tiles (e.g. Medi-
terranean clay tiles)
— Stair bolt mounting kit for universal fixing (e.g. corru-
gated slabs, sheet with trapezoidal corrugations, shin-
gles).
6.1 Collector position and field arrangement
Vaillant flat collectors are available in different versions:
one for horizontal position, one for vertical position.
Besides, they can be arranged in the collector field side
by side and on top of each other.
Generally, the installation steps and the instructions
described in this manual are valid for both collector
positions and field arrangements.
Any different installation steps are clearly pointed out:
wWith horizontal collector position
sWith vertical collector position
nWith fields arranged side by side
uWith fields arranged on top of each other
5 Flat roof installation
6 On-roof mounting

17Installation manual auroTHERM 0020057143_04
6.2 Roof anchor installation
aCaution!
Risk of corrosion!
On roofs made of metals more noble than alu-
minium (e.g. copper roofs) galvanic corrosion
can occur at the anchor points, whereby the at-
tachment of the collectors is no longer guaran-
teed. Ensure that the metals are separated by
suitable underlays.
• First of all, define the required number of roof an-
chors based on Table 6.1.
Number of
collectors Elevation [m] up to
Snow load zone
5432 1
Roof angle from:
10° 40° 10° 40° 10° 40° 10° 40° 10° 40°
1
700
Number of anchors
4444444444
900 4444446464
1200 4 4 4 4 6 4 8 6 8 6
2
700 8888888888
900 8 8 8 8 8 8 12 8 12 8
1200 8 8 8 8 12 8 16 12 16 12
3
700 12 12 12 12 12 12 12 12 12 12
900 12 12 12 12 12 12 18 12 18 12
1200 12 12 12 12 18 12 24 18 24 18
4
700 16 16 16 16 16 16 16 16 16 16
900 16 16 16 16 16 16 24 16 24 16
1200 16 16 16 16 24 16 32 24 32 24
5
700 20 20 20 20 20 20 20 20 20 20
900 20 20 20 20 20 20 30 20 30 20
1200 20 20 20 20 30 20 40 30 40 30
6
700 24 24 24 24 24 24 24 24 24 24
900 24 24 24 24 24 24 36 24 36 24
1200 24 24 24 24 36 24 48 36 48 36
7
700 28 28 28 28 28 28 28 28 28 28
900 28 28 28 28 28 28 42 28 42 28
1200 28 28 28 28 42 28 56 42 56 42
Field of application according to EN 1991 T 1-3
Anchor Fmax: type S / type P 1.875 kN
Wind load: based on the design loads according to EN 1991 T 1-3, the following minimum distances among collectors must be respected:
1. The smallest value of 1/10 of the building length (eaves length) or 1/5 of the building heigth with respect to eaves and ridge.
2. The smallest value of 1/10 of the building width (gable width) or 1/5 of the building height with respect to side edges.
If extension kits are used, make sure that the roof hooks are positioned in the middle at equal distances. With an elevation above
900 HH [m] and roof angles below 40°, starting from snow load zone 2 a specific static calculation must be made.
Table 6.1 Number of required roof anchors
On-roof mounting 6
GB

Installation manual auroTHERM 0020057143_0418
A
BBB B
C
Fig. 6.1 Distances with field arrangement side by side
nWith fields arranged side by side
• Mount the anchors for the mounting rails
at the following distances:
w s
A* 1245 / 1220 2045 / 2020
B 200 - 300
C 1460 - 1660 660 - 860
* Pre-assembly dimension / Finished dimension
During final fixing of the collectors, the pre-as-
sembly dimension is reduced by approx. 20 - 25
mm.
Table 6.2 Distances with fields arranged side by
side
hNote
During final fixing the pre-assembly
dimension is reduced by
approx. 20 - 25 mm. Take care that
there is adequate clearance on the
anchors, therefore.
A
B
C
D
Fig. 6.2 Distances with field arrangement on top of each other
uWith fields arranged on top of each
other
• Mount the anchors for the mounting rails
at the following distances:
Distance in mm
A* 1245 / 1220
B* 2500 / 2480
C 200 - 300
D 1460 - 1660
* Pre-assembly dimension / Finished dimension
During final fixing of the collectors, the pre-as-
sembly dimension is reduced by
approx. 20 - 25 mm.
Table 6.3 Distances with field arrangement on top
of each other
hNote
During final fixing the pre-assembly
dimension is reduced by
approx. 20 - 25 mm. Take care that
there is adequate clearance on the
anchors, therefore.
6 On-roof mounting