Vaillant Solar hot water systems User guide

For the installer / owner
Start-up, maintenance and troubleshooting manual, notes for the operator
Solar System and auroSTOR unvented solar
cylinder
Solar hot water systems
GB

Contents
Manual - Solar hot water systems2
Contents
1 Notes on the documentation.............................. 3
2 Overview of standards, safety instructions..... 3
2.1 Overview of EU standards...........................................3
2.2 Regulations in Great Britain ...................................... 4
2.3 Safety instructions....................................................... 4
3 System description.............................................. 5
3.1 Intended use...................................................................5
3.2 Design and function of the solar system ................5
4 Description of the components.......................... 8
4.1 Collectors ....................................................................... 8
4.1.1 auroTHERM exclusive tube collector ...................... 8
4.1.2 VFK 900 flat collector ............................................... 10
4.1.3 Disposal .......................................................................... 11
4.2 Solar pump unit............................................................ 11
4.2.1 Design ............................................................................. 11
4.2.2 Water control pack....................................................... 11
4.2.3 Solar expansion vessel................................................ 11
4.2.4 Protection vessel (item no. 302 405) ..................... 11
4.3 Solar pump.................................................................... 12
4.4 Thermal cut out of the solar pump ........................ 12
4.5 Flow rate meter ........................................................... 12
4.6 Solar fluid...................................................................... 12
4.6.1 Properties of the solar fluid ..................................... 12
4.6.2 Protection of the solar circuit against frost
and corrosion ............................................................... 13
4.6.3 Frost protection of the bivalent solar cylinder .... 13
4.6.4 Safety data sheet ........................................................ 14
4.7 auroSTOR solar cylinder............................................ 16
4.8 Solar control................................................................. 16
5 Installation...........................................................17
5.1 Installation of the solar cylinder ............................ 23
5.1.1 Description of the solar cylinder............................ 23
5.1.2 Technical data of the auroSTOR solar cylinder .. 25
5.1.3 Intended use.................................................................27
5.1.4 Data badge....................................................................27
5.1.5 Safety devices ..............................................................27
5.1.6 Safety instructions and regulations .......................27
5.1.7 Scope of delivery.........................................................27
5.1.8 Requirements of the installation site.....................27
5.1.9 Transport...................................................................... 28
5.1.10 Dimensions .................................................................. 29
5.2 Functional diagram .................................................... 30
5.3 Installation of the solar circuit piping.................... 31
5.3.1 General instructions ................................................... 31
5.3.2 Material.......................................................................... 31
5.3.3 Laying of the solar circuit pipes.............................. 31
5.3.4 Connection of the collectors
to the solar pump unit ............................................... 31
5.3.5 Bleeding of the solar circuit .................................... 32
5.4 Installation of the reheating circuit piping .......... 32
5.5 Installation of the hot water pipework.................. 32
5.5.1 Hot water thermostatic mixing valve.................... 32
5.6 Installation of the cold water supply pipework... 33
5.6.1 Mains water supply pressure................................... 33
5.6.2 Cold water piping ....................................................... 33
5.6.3 Drain valve ................................................................... 34
5.7 Discharge pipework ................................................... 34
5.7.1 Discharge pipework ................................................... 34
5.7.2 High level termination............................................... 35
5.8 Electrical installation................................................. 36
5.8.1 Immersion heater....................................................... 36
5.8.2 Electrical connection
to the cylinder control device ..................................37
5.8.3 Combination options
of the control components .......................................37
6 Start-up................................................................51
6.1 Flushing and filling the solar circuit ....................... 51
6.2 Setting the flow rate and pump.............................. 52
6.3 Programming the flow rate on the controller..... 53
6.4 Filling the hot water secondary circuit................. 53
6.5 Setting the hot water
thermostatic mixing valve........................................ 54
6.6 Filling the reheating circuit......................................54
6.7 Starting up the boiler................................................ 54
6.8 Start-up protocol ........................................................ 55
6.9 Handing over the system to the owner ................ 55
7 Inspection and maintenance ............................56
8 Troubleshooting..................................................57
9 Notes for the owner...........................................60
9.1 General notes ..............................................................60
9.2 Operation of the solar system ................................60
9.3 Operation of the solar cylinder...............................60
9.3.1 Setting the standby temperature
of the cylinder.............................................................60
9.3.2 Switching off the solar cylinder............................... 61
9.4 Frost protection ........................................................... 61
9.4.1 Frost protection of the solar system ...................... 61
9.4.2 Frost protection of the solar cylinder .................... 61
9.5 Care ................................................................................ 61
9.5.1 Care of the collectors................................................. 61
9.5.2 Care of the solar cylinder ......................................... 61
9.6 Maintenance ................................................................. 61
9.6.1 Maintenance of the solar system ............................ 61
9.6.2 Maintenance of the solar cylinder .......................... 61
9.7 What should be done if ............................................ 62
10 Customer service
and manufacturer's warranty...........................62
10.1 Vaillant service............................................................ 62
10.2 Vaillant warranty ........................................................ 62
11 Start-up protocol ...............................................63

3Manual - Solar hot water systems
1 Notes on the documentation
Your solar system is a quality product from Vaillant.
This manual describes the entire system, all of its
components and the cylinder and provides you with
information on start-up, maintenance and trouble-
shooting. It is a supplement to the operating, installation
and assembly manuals of the individual components.
Observe the manuals for each individual system
component in conjunction with this manual.
Look after this manual and pass it on to the next owner.
hNote!
The “Start-up” and “Maintenance and
troubleshooting” chapters of this manual are
intended only for approved specialists.
Vaillant accepts no liability for any damage caused by
failure to observe this manual.
Other applicable documents
- Assembly manual of the collectors
- Operating and installation manual of the controller
- Operating and installation manual of the boiler (if
used)
- Assembly, operating and installation manuals of all
accessories used
- Warranty card
Symbols used
Please observe the safety instructions in this manual
when operating and installing the solar system and the
auroSTOR solar cylinder.
The symbols used in the manual are explained
below:
dDanger!
Immediate risk of serious injury or death!
eDanger!
Danger of death from electric shock!
eDanger!
Risk of burns or scalding!
aCaution!
Potentially dangerous situation for the product
and environment.
hNote!
Application recommendation.
• Symbol for a required task
2 Overview of standards,
safety instructions
2.1 Overview of EU standards
Solar system in general
EN ISO 9488
Thermal solar system and components, terminology
(ISO/DIS 9488; 1995)
EN 12975-1
Thermal solar systems and components; Collectors, Part
1: General requirements
EN 12975-2
Thermal solar systems and components; Collectors; Part
2: Test methods
ENV 1991-2-3
Eurocode 1 – Basis of design and actions on structures,
Part 2–3: Actions on structures - Snow loads
EN 12976-1
Thermal solar systems and components;
Factory made systems - Part 1: General requirements
EN 12976-2
Thermal solar systems and components;
Factory made systems - Part 2: Testing methods
ENV 12977-1
Thermal solar systems and components;
Custom built systems,
Part 1: General requirements
ENV 12977-2
Thermal solar systems and components;
Factory made systems,
Part 2: Testing methods
ISO 9459-1: 1993
Solar heating – Domestic water heating systems – Part 1:
Performance rating procedure using indoor test
methods
ISO/TR 10217
Solar energy – Water heating systems – Guide to
material selection with regard to internal corrosion
Collectors and collector assembly
ENV 1991-2-4
Eurocode 1 – Basis of design and actions on structures -
Part 2–4: Actions on structures - Wind actions
Notes on the documentation 1
Overview of standards, safety instructions 2

Manual - Solar hot water systems4
Solar cylinder and cylinder installation
Pressure equipment directive 97/23/EC
Directive of the European Parliament and Council from
29th May, 1997 for the approximation of the laws on
pressure equipment of the Member States
EN 12977-3
Thermal solar systems and components;
Custom built systems,
Part 3: Performance characterisation of stores for solar
heating systems
EN 12897
Water supply - specification for indirectly heated
unvented (closed) storage water heaters
EN 806-1
Specifications for installations inside buildings conveying
water for human consumption - Part 1: General
EN 1717
Protection against pollution of potable water
installations and general requirements of devices to
prevent pollution by backflow
EN 60335-2-21
Safety of household and similar electrical appliances;
Part 2: Particular requirements for storage water
heaters (hot water cylinders and hot water boilers)
(IEC 335-2-21: 1989 and supplements 1; 1990 and 2; 1990,
modified)
Lightning protection
ENV 61024-1
Protection of structures against lightning – Part 1:
General principles (IEC 1024-1: 1990; modified)
BS 6651 Code of practice for protection of structures
against lightning
2.2 Regulations in Great Britain
Building Regulation, dating from 1991 (England and
Wales)
Requirement G3, L1 and Regulation 7
BS 7671
Requirements for electrical installations
(IEE Wiring Regulations, 16th edition)
BS 6759-1
Directive for the usage of the safety assembly for hot
water cylinders
2.3 Safety instructions
The entire solar system must always be installed and
operated in accordance with recognised technical
standards.
dDanger!
Risk of falling!
Make sure you adhere to the valid work
protection regulations, in particular when
working on the roof. Make absolutely sure you
wear anti-fall devices whenever there is a risk
of falling. (We recommend Vaillant fall
protection systems, item no. 302 066.)
Observe the accident prevention regulations of
the trade associations.
HDanger!
Risk of being burned or scalded by hot
components! Install and replace collectors or
collector parts on very cloudy days. Perform
installation work on sunny days only in the
morning or evening or with the collector
covered.
Danger!
Risk of being burned or scalded by hot solar
fluid or components! Fill and flush the solar
system when the collectors are cold. Cover the
collectors while doing so.
Danger!
Risk of being burned or scalded by escaping hot
steam!
Steam can escape from the expansion relief
valve of the solar pump unit if the system is
shut down. To avoid injuries, you must connect
the expansion relief valve to a collecting
container with a hose line.
Danger!
Risk of being scalded by hot water! With the
Vaillant auroSTOR combi cylinder, the outlet
temperatures at the taps can be up to 85 °C. To
provide effective protection against scalding in
the event of secondary return, integrate a hot
water thermostat mixer in the system (refer
to Section 5.5.1 and 5.5.2).
Danger!
Risk of being burned or scalded by escaping hot
steam! Steam can escape from unblocked
automatic bleeders if the system is shut down.
Therefore block all automatic bleeders after
bleeding.
2 Overview of standards, safety instructions

5Manual - Solar hot water systems
Use the automatic Vaillant air separator system (item
no. 302 418). It works fully automatically and does not
need to be subsequently blocked. It must be installed in
an area however, in which no steam can enter, preferably
in the return pipe nearby the solar cylinder.
eDanger!
Danger of death by electric shock!
All live parts of the system may be installed,
serviced and repaired only by a qualified
servicing company!
Danger!
Risk of overvoltage!
Earth the solar circuit as potential equalisation
and protection against overvoltage! Attach
earthing pipe clips to the solar circuit pipes and
connect the clips to a potential rail with a
16 mm2copper cable.
3 System description
3.1 Intended use
The Vaillant solar system is used for the solar-supported
supply of drinking water.
Any other use or extended use is considered to be
improper. The manufacturer / supplier is not liable for
any resulting damage. The user alone bears the risk.
Intended use includes the observance of the system
description and all other applicable documents, as well
as adherence to the maintenance and inspection
conditions.
aCaution!
We accept no liability for any damage or injuries
caused by failure to observe this manual.
At the end of this manual is a start-up protocol, which
should be filled in by the installer and/or start-up
engineer and handed over to the owner.
All CORGI-approved installers have a CORGI ID card and
a registration number. Both of them should be entered
on the start-up checklist. You can check the details of
your installer at CORGI under the telephone number
[phone].
3.2 Design and function of the solar system
The solar system consists of four main components:
– The collectors, which absorb the solar radiation and
utilise it (refer to Section 4.1, Collectors).
– The solar control, which monitors, displays and
controls all functions of the system (refer to Section
4.8, Solar control).
– The solar pump unit, which transports the solar heat
(refer to Section 4.2, Solar pump unit).
– The solar cylinder (refer to Section 5.1, Installation of
the solar cylinder).
On days on which the solar radiation is insufficient to
heat the drinking water in the cylinder, the stored water
must be reheated by a heating system. This can be done
with boilers or electrically with an immersion heater.
Overview of standards, safety instructions 2
System description 3

Manual - Solar hot water systems6
6
7
9
2
C
D
4
11
3
10
1
BA
5
M
DHW
M
8
Fig. 3.1 System for solar heating of drinking water
Key
1 Boiler
2 auroSTOR solar cylinder
3 230 V∼motorised 2 port valve (supplied together with the solar
cylinder)
4 Immersion heater
5 230 V∼ motorised 2 port valve (supplied together with the
boiler)
6 auroTHERM collector
7 Solar pump unit
8 Protection vessel (optional)
9 Solar expansion vessel
10 Automatic air separator system
11 Drinking water expansion vessel
A Boiler flow
B Boiler return
C Solar circuit flow
D Solar circuit return
3 System description

7Manual - Solar hot water systems
The Vaillant auroTHERM exclusive tube collector (6)
transforms solar energy into heat and transfers the heat
energy to a frost-protected solar fluid. The solar pump
of the solar pump unit (7) ensures the heat is
transported from the collector to the bivalent solar
cylinder (2) via a pipe system. The solar pump unit is
controlled by the solar control.
The solar control switches the solar pump on or off as
soon as the difference in temperature between the
collector and solar cylinder falls below or exceeds the
preset value. If the solar energy is insufficient, the
control system switches on the boiler (1) so that the
upper third of the cylinder is reheated to the set value
for the hot drinking water temperature. In addition the
solar cylinder can be reheated by the immersion heater
installed by the manufacturer.
The solar expansion vessel (9) compensates pressure
fluctuations in the solar circuit.
The optional protection vessel (8) protects the
expansion vessel from increased temperatures in the
solar circuit. We recommend installing a protection
vessel.
The Vaillant solar system enables various system
configurations and control concepts:
Electrical wiring
The Vaillant Control Center VR 65 can be used to wire
up the system if an eBUS-capable Vaillant boiler is used.
A standard wiring box can be used if a Vaillant boiler
which is not eBUS-capable or an external boiler is used.
Control of the hot water temperature
The hot water temperature in the upper third of the
cylinder can be controlled by the VRS 560 or by a
separate hot water programmer.
dDanger!
Risk of being scalded by hot water to provide
effective protection against scalding, install a
thermostat mixer in the hot water pipe as
described in Section 5.5, Installation of the hot
drinking water pipework. Set the thermostat
mixer to below 60 °C and check the
temperature at a hot water tap.
Heating control
The heating can be regulated by means of a
programmable Vaillant VRT 360 room thermostat or
VRC 400 weather compensator if an eBUS-capable
Vaillant boiler is used.
The Vaillant VRT 30 room thermostat or a standard
room thermostat can be used if a non-eBUS Vaillant
boiler or an external boiler is used.
The solar system is a closed system and must be bled
carefully. We recommend the automatic Vaillant air
separator system for this purpose (item no. 302 418). It
works fully automatically and does not need to be
subsequently blocked.
The automatic air separator system must be installed in
an area in which no steam can enter, preferably in the
return pipe between the solar pump unit and the solar
cylinder.
System description 3

Manual - Solar hot water systems8
4 Description of the components
4.1 Collectors
HDanger!
Risk of burns!
To avoid injuries due to hot parts of the
collectors, all work on the collectors should be
carried out on cloudy days. Alternatively work
can be carried out in the morning or evening of
sunny days or with the collector covered.
4.1.1 auroTHERM exclusive tube collector
Fig. 4.1 auroTHERM exclusive VTK 550 tube collector
Fig. 4.2 auroTHERM exclusive VTK 275 tube collector
Interior design
The Vaillant auroTHERM exclusive VTK 275 and 550
tube collectors consist of 8 or 16 collector tubes
connected in parallel. With its collector tubes with
internal mirror of pure silver and glass-glass connection
of sleeve and absorber pipe for lasting vacuum sealing,
the collector ensures constant high performance over its
entire service life. The high-performance absorber has a
Cermet Aluxid®vacuum coating. Extremely low heat
losses of k1= 0.68 W/(m2K) thanks to a high vacuum of
< 10-6 bar ensure year-round use.
By deliberately interrupting heat transfer to the
downstream system, the auroTHERM exclusive provides
effective system protection against excess temperatures
above 180 °C if the system is shut down.
The collectors are connected in series.
12
56
3
4
Fig. 4.3 Cross-section through four tubes with direction of flow
Key
1 Outer collector tube
2 Inner collector tube
3 Guide tube
4 Absorber tube
5 Outlet
6 Inlet
4 Description of the components

9Manual - Solar hot water systems
Technical data of the tube collectors
Appliance designation Units auroTHERM exclusive VTK
275
auroTHERM exclusive VTK
550
Surface area (gross, aperture/net) m20.68 / 0.41 1.28 / 0.82
Height mm 1695 1695
Width mm 440 790
Depth mm 100 100
Weight kg 10.3 20
Collector capacity l 1.6 3.56
Copper pipe connection, flat-face Thread 3/4“ 3/4“
Insulation: high vacuum bar 10-6 10-6
Maximum operating pressure bar 6 6
Pure silver mirror, degree of reflection ρ% 94 ±1 94 ±1
Absorber emission ε% 5 ±2 5 ±2
Absorber absorption α% 95 ±1.0 95 ±1.0
Solar sensor sleeve ∅mm 6 6
CE label 0036 0036
Shutdown temperature (according to prEN 12975-2,
c < 1 m/s) in the glass tube
°C 250 250
Shutdown temperature (according to prEN 12975-2,
c < 1 m/s) at the collector connection
°C 180 180
Efficiency η0(according to EN 12975) % 78 ± 3% 78 ± 3%
Efficiency coefficient k1W/(m2•K) 1.09 ±0.2 1.09 ±0.2
Efficiency coefficient k2W/(m2•K2) 0.01 ±0.002 0.01 ±0.002
Table 4.1 Technical data tube collector auroTHERM exclusive
1,0
0,9
0,8
0,7
0,6
0,5
0,4
0,3
0,2
0,1
00 20 40 60 80 100 120 140 160 180 200 220 240
[%]
1000 W/m
2 Insolation Temperature difference (collektor/ambient) [K]
auroTHERM exclusive
800 W/m
2 Insolation
300 W/m
2 Insolation
Fig. 4.4 Efficiency of the auroTHERM exclusive according to
DIN 4757/4
40
30
20
10
0
050
Pressure loss [mbar]
100 150 200 250 300
Volume flow [l/h]
auroTHERM
exclusive
Fig. 4.5 Pressure loss of the auroTHERM exclusive collector
Description of the components 4

Manual - Solar hot water systems10
4.1.2 VFK 900 flat collector
Fig. 4.6 View of the auroTHERM VFK 900, two modules
Equipment
The Vaillant VFK 900 flat collector includes a seawater-
resistant aluminium frame as well as a copper surface
absorber with selective Cermet Vacuum coating.
The Vaillant VFK 900 flat collector has a CFC-free,
standstill temperature-resistant mineral wool insulation
for long-life, excellent heat insulation.
For easy assembly, all connections were designed as flat
gasket. The sensor sleeve integrated in the middle and
the symmetric interior structure means that the
collector array can be connected variably.
4 Description of the components
Technical data of the flat collector
Appliance designation Unit. auroTHERM VFK 900
Surface area (gross, aperture/net) m22.24/2.02
Height mm 1930
Width mm 1160
Depth mm 110
Weight kg 43
Absorber capacity l 1,1
Copper pipe connection, flat-face Ø mm G 1/2"
Insulation thickness mm 60
Max. operating pressure bar 10
Solar safety glass transmission τ(dew) % 90 ±2
Absorber emission ε(epsilon) %5±2
Absorber absorption α(alpha) %95±2
Solar sensor sleeve Ø mm 6
Qualification approval mark CE 0036
Shutdown temperature (according to prEN 12975-2,
c < 1 m/s) °C 227
Efficiency η
0
% 81,9
Efficiency coefficient k1 W/(m2•K) 3,47
Efficiency coefficient k2 W/(m2•K2) 0,0101
Table 4.2 Technical data of the flat collector auroTHERM VFK 900
Fig. 4.7 Efficiency of the auroTHERM VFK 900
acc. to DIN 4757/4
1 x 900
2 x 900
3 x 900
140
120
100
80
60
40
20
0
025020015010050 300
Solar fluid at 30˚C
]rabm[
Volume flow [l/h]
Pressure loss
1000 W/m
2 Insolation
800 W/m
2 Insolation
300 W/m
2 Insolation
Temperature difference (collector/ambient) [K] VKF 900
Fig. 4.8 Pressure loss auroTHERM VFK 900

11Manual - Solar hot water systems
4.1.3 Disposal
All Vaillant solar collectors meet the requirements for
the German “Blauer Engel” (Blue Angel) environmental
mark.
Therefore, we, as the manufacturer, will take back and
recycle components when they have to be disposed of
after years of reliable use.
4.2 Solar pump unit
1
2
9
8
11
10
7
6
5
4
3
Fig. 4.9 Design of the solar pump unit
Key
1 Expansion relief valve
2 Pressure gauge
3 Pressure release pipe with collecting container
4 Solar expansion vessel
5 Protection vessel (optional)
6 Fill/vent valve (for filling and draining the solar circuit)
7 Flow rate meter
8 Three-speed solar pump
9 Fill/vent valve (for filling the solar circuit)
10 Group of pipes with insulation
11 Stop valves with gravity brakes
4.2.1 Design
The solar pump unit transports heat from the collector
to the consumer safely and efficiently.
The solar pump unit mainly consists of:
- The group of pipes of the solar pump unit with
insulation (10)
- Two stop valves with gravity brakes (11) to prevent
heat diversion. (The gravity brakes are ineffective if
the stop valves are in the 45° position.)
- The water control pack with an expansion relief valve
(1) with 6 bar blow-off pressure and a pressure gauge
(2) for visual inspection
- Two fill/vent valves for filling and draining the solar
circuit (6and 9)
- A three-speed solar pump (8)
- A flow rate meter to optimally adjust the required flow
rate (7)
- A solar expansion vessel (4) (separate accessory)
- A protection vessel (5) (separate accessory)
4.2.2 Water control pack
The solar pump unit is delivered with a water control
pack, consisting of an expansion relief valve (1) and a
pressure gauge (2) for visual inspections.
4.2.3 Solar expansion vessel
The solar expansion vessel (4), is used to equalise the
pressure while the pressure relief valve (1) blows off the
solar fluid into the collecting container via the pressure
release pipe (3) if the operating pressure of 6 bar is
exceeded.
hNote!
The solar fluid container is of sufficient size
and intended as a collecting container. Lay a
pressure release pipe from the expansion relief
valve to the collecting container.
The size of the solar expansion vessel is based on the
collector volume and the expansion volume of the solar
system.
The expansion vessel not only accommodates the
expansion volume of the solar fluid, but also the entire
volume of the collectors in the event of a shutdown. The
total volume of the solar system is the total of the
individual values of the collector, heat exchanger volume
and the volume of the pipeline.
The admission pressure of the solar expansion vessel
can be set between 0.5 and 4.0 bar.
4.2.4 Protection vessel (item no. 302 405)
In the event of unfavourable system configurations (e. g.
very large collector surface, installation of the solar
pump unit under roof), the solar expansion vessel (4)
may be subjected to excessive temperatures by the solar
fluid if the system is shut down. In worst cases, this can
cause the membrane of the solar expansion vessel to be
overheated and to fail.
The installation of a protection vessel (5) is
recommended in all cases. The solar expansion vessel is
protected from excessive temperatures by 5 l of solar
fluid in front of it. Vaillant recommends the installation
of the protection vessel for all solar systems (item
no. 302 405).
Description of the components 4

Manual - Solar hot water systems12
4.3 Solar pump
The solar pump unit is equipped with a three-speed solar
pump (Fig. 4.9, pos. 8) for the optimum adaptation of
the required circulating volume and the pump capacity
in the solar circuit.
Select the pump capacity, depending on the solar system
(e. g. collector surface, pipe diameter, length of the solar
circuit), so that the actual flow rate is slightly higher
than the nominal flow rate. The flow rate meter (Fig. 4.9,
pos. 7) is used for fine adjustment of the flow rate.
Observe the notes in Section 6.2, Setting the flow rate
and pump.
4.4 Thermal cut out of the solar pump
1
3
A
B
C
D
A
B
C
D
3
3
Fig. 4.10 Connection diagram of the solar pump TCO
The solar pump is secured by its own thermal cut out
(TCO) (1) which is mounted on the solar cylinder (pre-
assembled at the factory for the VIH S GB 250 and
300 S). The power supply to the pump is interrupted at
cylinder temperatures higher than 90 °C.
4.5 Flow rate meter
0,5
1
2
3
0,5
1
2
3
4
5
6
4
5
6
L/min
L/min
1,1 l/min
1
2
Fig. 4.11 Flow rate meter 0 - 6 l/min
The flow rate meter (pos. 7, Fig. 4.6) installed in the
return pipe is an essential component of the solar
system. To achieve optimum heat transfer, you must
achieve a certain flow rate, which is referred to as the
nominal flow rate (refer to Section 6.2, Setting the flow
rate and pump).
Upper deviations are not as serious as lower deviations.
Make the rough adjustments with the solar pump first.
You can make the fine adjustments with the adjustment
valve (1) of the flow rate meter. You can view the set
value on the display (2) of the flow rate meter.
The flow rate meter has a fill/vent valve for filling and
draining the solar circuit.
h
Note
Do not under any circumstances set the flow
rate below the calculated flow rate. The
collector efficiency will be considerably reduced.
4.6 Solar fluid
4.6.1 Properties of the solar fluid
This information applies to Vaillant solar fluid (20 l
canister: item no. 302 429).
Vaillant solar fluid is a ready-mixed antifreeze and
anticorrosive, consisting of approximately 45%
propylene glycol with anti-corrosion inhibitors and 55%
water. It is resistant to high temperatures and can be
used both with Vaillant tube collectors and Vaillant flat
plate collectors.
Furthermore the solar fluid has a high thermal capacity.
The inhibitors provide reliable corrosion prevention
when using different types of metal (mixed installations).
4 Description of the components

13Manual - Solar hot water systems
h
Note!
Do not use any other anti-freeze or inhibitors
with Vaillant solar collectors.
Only Vaillant solar fluid is approved.
a
Caution!
Risk of damage!
Vaillant solar fluid is ready mixed. You may not
under any circumstances mix it with water or
other fluids. Otherwise it will become
ineffective as an antifreeze or anticorrosive,
resulting in damage to collectors or other parts
of the system.
Vaillant solar fluid is infinitely durable in hermetically
sealed containers.
Skin contact is normally not dangerous. Eye contact only
causes minor irritations, you should nevertheless
immediately wash your eyes.
Observe the safety data sheet (refer to Section 4.6.4).
4.6.2 Protection of the solar circuit against frost
and corrosion
To protect the solar system reliably against frost in
winter, the entire solar circuit must be filled 100 % with
solar fluid (item no. 302 429).
h
Note!
You can achieve frost resistance of about
-28 °C by filling the solar system with Vaillant
solar fluid.
No damage is caused by frost even at outside
temperatures below -28 °C, since the expansive
effect of the water is reduced. Check the
antifreeze effect after filling the system and
then once a year.
Component Volume (l)
VIH S GB 200 S heat exchanger solar circuit 4.12
VIH S GB 250 S heat exchanger solar circuit 4.12
VIH S GB 300 S heat exchanger solar circuit 4.4
VIH S GB 200 S heat exchanger reheating circuit 3.7
VIH S GB 250 S heat exchanger reheating circuit 3.7
VIH S GB 300 S heat exchanger reheating circuit 3.7
Solar pump unit 0.9
auroTHERM exclusive VTK 550 3.56
auroTHERM exclusive VTK 275 1.6
auroTHERM VFK 900 1.1
Protection vessel 5.0
Table 4.3 Volume of the individual components
Pipe diameter Pipeline volume (l/m)
15 mm 0.18
18 mm 0.20
22 mm 0.31
28 mm 0.50
Table 4.4 Pipeline volume
Proceed as follows to check the solar fluid; refer to the
operating manual of the solar fluid tester (item no.
002 002 0155):
• Suck in the amount of fluid for the float to freely float
without sticking at the top with the suction ball of the
solar fluid tester (item no. 00 2002 0645).
• View the density on the scale. The density must be
greater than 1.05 g/cm3. You must otherwise replace
the solar fluid.
• Measure the pH value with a pH value measuring strip.
You must replace the solar fluid if the pH value is
below 7.5.
1
2
3
4
5
6
Fig. 4.12 Solar fluid tester
Key
1 Transport case
2 Areometer
3 Thermometer
4 pH indicator rod
5 Standing cylinder
6 Operating manual
a
Caution!
Risk of damage!
Use only the original Vaillant solar fluid tester
(item no. 00 2002 0645). Otherwise an
incorrect antifreeze value may be indicated.
4.6.3 Frost protection of the bivalent solar cylinder
You must drain the solar cylinder completely if it is to be
shut down in a room prone to frost. It is drained at the
cold water inlet with a T-piece with tap to be provided by
the installer.
• Also drain all heat exchangers which are not filled with
solar fluid.
Description of the components 4

Manual - Solar hot water systems14
4.6.4 Safety data sheet
1. Substance/Formulation and company name
1.1 Information on the product:
Trade name of the Vaillant solar fluid
(item no. 302 362)
1.2 Information on the supplier: <NewLine/>Vaillant
GmbH, Berghauser Str. 40,
42859 Remscheid, Germany
Telephone [phone] - 0,
fax [phone],
Emergency information: your local poison
information centre
(see directory assistance or telephone directory).
2. Composition/Information on components
2.1 Chemical properties
Watery solution of 1.2 propylene glycol with
corrosion inhibitors
3. Possible risks
3.1 No particular risks known
4. First-aid measures
4.1 General notes:
Remove dirty clothes.
4.2 After inhaling:
Discomfort after inhaling fumes/
aerosol: fresh air, help from a doctor.
4.3 After skin contact:
Wash off with water and soap.
4.4 After eye contact:
Wash thoroughly under running water with wide
open eyes for at least 15 minutes.
4.5 After swallowing:
Rinse your mouth and then drink plenty of water.
4.6 Notes for the doctor:
Treatment of symptoms (decontamination,
vital function), no specific antidote known.
5. Firefighting measures
5.1 Appropriate extinguishing agents:
Spray, solid extinguishing agent, alcohol-fast
foam, carbon dioxide (CO2)
5.2 Particular hazards:
Fumes which are detrimental to health. Formation
of smoke/mist. The specified substances/
substance groups may be released in the event of
a fire.
5.3 Special protective equipment for fire fighting:
Wear a breathing apparatus which is independent
of the circulating air in the event of a fire.
5.4 Further details:
The hazard depends on the combustible
substances and the fire conditions. Polluted fire
water must be disposed of according to local
official regulations.
6. Measures to be taken if substances are
released accidentally
6.1 Individual-related measures:
No particular measures required.
6.2 Environmental measures:
The product may not be discharged into waters
without pre-treatment (biological sewage plant).
6.3 Cleaning/Collection methods:
Pump out the product in the event of large
quantities.
Absorb small quantities with appropriate fluid
bonding material. Then dispose of them according
to regulations.
Rinse away splashes with plenty of water. Inform
the local water authority in the event of large
quantities which could flow into the drainage or
waters.
7. Handling and storage
7.1 Handling:
Good ventilation of the workplace, no other
particular measures required.
7.2 Fire and explosion protection:
No exceptional measures required.
Cool any endangered containers with water.
7.3 Storage:
Close containers tightly and store them at dry
places. Do not use any galvanised containers for
storage.
8. Limitation of exposure and personal protective
equipment
8.1 Personal protective gear:
Hand protection: chemical-resistant protective
gloves (EN 374). Suitable materials even in the
event of prolonged, direct contact (recommended:
protection index 6, corresponding to > 480
minutes permeation time according to EN 374):
flour elastomer (FKM) – 0.7 mm layer thickness.
Suitable materials for brief contact or splashes
(recommended: at least protection index 2,
corresponding to > 30 minutes permeation time
according to EN 374): nitrile rubber (NBR) – 0.4
mm layer thickness. Due to the large variety of
types, observe the instruction manuals of the
manufacturer.
8.2 Eye protection:
Safety glasses with lateral protection (framed
glasses) (EN 166)
8.3 General safety and hygiene measures:
Observe the usual protective measures for
dealing with chemicals.
4 Description of the components

15Manual - Solar hot water systems
9. Physical and chemical properties
Form: fluid
Colour: violet
Odour: product-specific
Solidification temperature: approx. -28 °C
(DIN 51583)
Boiling temperature: > 100 °C (ASTM D 1120)
Flash point: none
Lower explosion limit: 2.6 % by vol. (details for
Upper explosion limit: 12.6 % by vol. 1.2 propylene
glycol)
Ignition temperature: omitted
vapour pressure (20 °C): 20 mbar
Density (20 °C): approx. 1.030 g/cm3 (DIN 51757)
Water solubility: entirely soluble
Solubility (qualitative) solvent: polar solvents:
soluble
pH value (20 °C): 9.0 – 10.5 (ASTM D 1287)
Viscosity, kinematic (20 °C): approx. 5.0 mm2/s
(DIN 51562)
10. Stability and reactivity
10.1 Substances to be avoided: Strong oxidants
10.2 Dangerous reactions:
No dangerous reactions if the storage and
handling regulations/notes are observed
10.3 Dangerous decomposition products:
No dangerous decomposition products if the
storage and handling regulations/notes are
observed.
11. Toxicological information
11.1 Acute toxicity:
LD50/oral/rat: > 2000 mg/kg
Primary skin irritation/rabbit: not irritating.
(OECD guideline 404)
Primary irritation to the mucous membrane/
rabbit: not irritating.
(OECD guideline 405)
11.2 Additional notes:
The product has not been checked. The
statements have been taken from the individual
components.
12. Ecological information
12.1 Ecological toxicity:
Fish toxicity: LC50 leuciscus idus (96 h):
> 100 mg/l
Aquatic invertebrates: EC50 (48 h): > 100 mg/l
Water plants: EC50 (72 h): > 100 mg/l
Micro-organisms/effect on activated sludge:
DEV-L2 > 1000 mg/l. No disturbances to the
biodegrading activity of the activated sludge are
expected in adapted biological sewage plants if
discharged appropriately in low concentrations.
12.2 Assessment of aquamatic toxicity:
The product has not been checked. The
statements have been taken from the properties
of the individual components.
12.3 Persistence and biodegradability/information on
elimination:
OECD 301 A test method (new version)
Analysis method: DOC acceptance
Degree of elimination > 70 % (28 d)
Assessment: easily biodegradable.
13. Note on disposal
13.1 Disposal:
Vaillant solar fluid (item no. 302 363) must de
disposed of at an appropriate waste site or waste
incineration plant, for example, while observing
local regulations. Contact the local municipal
sanitation office or the mobile environmental
service for quantities under 100 l.
13.2 Uncleaned packings:
Uncontaminated packings can be reused. Dispose
of packings which are unable to be cleaned
together with the substance.
14. Transport information:
VbF: not subject to the ordinance on combustible
fluids.
Mailing permitted. GGVE/RID: -, UN no.: -,
GGVS/ADR: -, IATA DGR: -, IMDG code: -, TA air: -.
No dangerous goods according to transport
regulations.
15. Regulations
15.1 Labelling in accordance with EC directives/
national regulations:<NewLine/>No labelling
obligation
15.2 Other regulations: water hazard class (Germany,
Appendix 4 of the VwVwS (administrative
regulation on water-pollutant substances) from
17.05.1999): (1), slightly water-pollutant
16. Other information
The safety data sheet is intended to provide
essential physical, safety-related, toxicological and
ecological data and give recommendations for
safe handling or safe storage, handling and safe
transport of chemical substances and
formulations. No liability is assumed for damage
in connection with the usage of this information
or the usage, application, adaptation or
processing of the products described here. This
does not apply as long as we, our statutory
agents or assistants are liable in the event of
intention or gross negligence. No liability is
assumed for indirect damage.
This information has been compiled to the best of
our knowledge and conscience according to our
current state of knowledge.
No guarantee can be made for product properties.
17. Version
Compiled by Vaillant GmbH on 1/7/2003
Description of the components 4

Manual - Solar hot water systems16
4.7 auroSTOR solar cylinder
The auroSTOR solar cylinder is described in detail in
Section 5.1, Installation of the solar cylinder, of this
manual.
4.8 Solar control
1
230 V~
3A
C
D
B
4
2
5
Sp 1
Sp 2
Solar gain
6
Kol 1
Fig. 4.13 Temperature difference control
Key
1 Solar control
2 Boiler
3 Solar cylinder
4 Thermal cut out of the solar pump
5 Solar pump
6 Solar pump unit
Kol 1 Collector temperature sensor
Sp 1 Upper stored water temperature sensor
(reheating circuit/standby part)
Sp 2 Lower stored water temperature sensor (solar circuit)
A Boiler flow
B Boiler return
C Solar flow
D Solar return
Type of solar control
The Vaillant solar system enables various system
configurations and control concepts.
Control of the hot water temperature
The hot water temperature in the top half of the cylinder
can be controlled by the Vaillant auroMATIC VRS 560
solar control or by using a separate hot water
programmer (refer to Section 5.8, Electrical installation).
Wiring
The Vaillant Control Center VR 65 can be used to wire
up the system if an eBUS-capable Vaillant boiler is used.
A standard wiring box can be used for all other boilers.
Solar pump control
Temperature differences, not absolute temperature
values, are important for the operation of solar systems.
That is why solar systems are controlled by what is
referred to as temperature difference controllers.
Temperature sensors measure the difference between
the collector and solar cylinder.
The solar pump is switched on if the difference in
temperature (Kol 1 - Sp 2) is greater than 7 K. The solar
pump of the solar system is switched off if the difference
in temperature (Kol 1 - Sp 2) is lower than 3 K.
Furthermore the solar control constantly measures the
cylinder temperature. Reheating is switched on if the
value (Sp 1) falls below the set target value.
You can set the difference in temperature on the
controller between 2 and 15 K. The default setting of 7 K
is sufficient for most solar systems.
Do not set temperature differences too low. This would
result in a number of unnecessary and uneconomic
switch-on and switch-off procedures.
auroMATIC 560 controller
Fig. 4.14 auroMATIC 560
The auroMATIC 560 solar control is a differential
temperature-controlled control set for solar-supported
hot water supply with a demand driven reheating
function for Vaillant boilers.
The control set is a fully-equipped system for solar
systems with a collector array and a solar cylinder.
It is possible to determine the solar gain by means of an
additional gain sensor (available as an accessory).
4 Description of the components

17Manual - Solar hot water systems
Control Center VR 65
The Control Center VR 65 provides a system solution
which allows Vaillant low-voltage eBUS controllers to be
used in the English market with valves and hot water
cylinders with traditional 230 V cylinder thermostats.
The information on the heat requirements of the solar
cylinder is forwarded to the Vaillant ecoTEC boiler by
the Control Center VR 65. The boiler decides whether
hot water requirements has to be met and sends the
signal to control the 230 V valves via the VR 65.
In this way, the boiler can store different target
temperatures for heating and hot water operation.
Standard 230 V components can be integrated in the
Vaillant eBUS system via the Control Center VR 65. For
wiring, refer to Section 5.8, Electrical installation, and
the installation manual of the Control Center VR 65
(item no. 00 2000 7476).
VRT 360 programmable room thermostat
The VRT 360 is a programmable room thermostat with a
week programme for heating, hot water and circulation
pump, which can be connected to Vaillant boilers with
With the VRT 360, you can preset the room temperature
with a heating programme.
The VRT 360 has additional functions including central
heating override and the time control function of an
additional circulation pump.
For wiring, refer to Section 5.8, Electrical installation,
and the operating and installation manual of the
VRT 360 (item no. 838 568).
h
Note!
If the VRT 360 is used for central heating
control, the Control Center VR 65 is
additionally required to measure the solar
cylinder temperature and switch from cylinder
reheating to heating mode and vice versa as
required.
VRC 400 weather compensator
The VRC 400 weather compensator is an external
temperature compensator and can be used in
conjunction with a Vaillant eBus boiler to provide time
and temperature control of the central heating.
5 Installation
• Use the following tables to check the scope of delivery
before beginning with the installation.
Installation sequence
Install the solar system in the following order:
- Solar collectors and solar pump unit
- Solar cylinder
- Solar circuit piping
- Reheating circuit piping
- Hot water piping and secondary return (if available)
- Cold water supply
- Discharge pipe
- Electrical installation
• Assemble the collectors according to the assembly
manual (item no. 835 254)
• Install the solar pump unit according to the installation
manual (item no. 00 2000 7485)
• Proceed with the installation as described in the
following sections.
Description of the components 4
Installation 5

Manual - Solar hot water systems18
Solar sets auroTHERM exclusive Mini Standard Medium Large
Item no. 0020025413 0020025414 0020025415 0020025416
auroTHERM exclusive 550 2 3 4 5
auroTHERM exclusive 275 1 - - -
Mounting bar (long) for 2 x VTK 550 1 1 2 2
Mounting bar (normal) for 1 x VTK 550 -1-1
Mounting bar (short) for 1 x VTK 275 1 - - -
Roof bracket set for 2 x VTK 550 1 1 2 2
Roof bracket set for 1 x VTK 550 or 1 x VTK 275 1 1 - 1
Rafter plate 2 2 2 3
Connection set for collector area 1 1 1 1
Single insulated stainless steel tube, DN16, 15 m 2 2 2 2
Table 5.1 Scope of delivery of the auroTHERM exclusive solar sets
5 Installation

19Manual - Solar hot water systems
Solar sets auroTHERM exclusive Mini Standard Medium Large
Item no. 0020025413 0020025414 0020025415 0020025416
Fittings pack for DN16 tube 1111
Solar pump unit 1 1 1 1
Expansion vessel 25 l 1 1 - -
Expansion vessel 35 l - - 1 1
Protection vessel for expansion vessel 1 1 1 1
Automatic air separator 1 1 1 1
Thermostat mixer 1 1 1 1
Solar control auroMATIC 560 1 1 1 1
Solar gain sensor (VR 10) 1 1 1 1
Solar fluid (20 litres) 2 2 3 3
Table 5.1 Scope of delivery of the auroTHERM exclusive solar
sets (continuation)
Installation 5

Manual - Solar hot water systems20
Solar set auroTHERM flat plate collector
Item no. 0020036552
auroTHERM VFK 900 2
Roof bracket set for concrete tiles (qty 6) 1
On-roof kit for two panels 1
Stainless steel connection pipe DN12 2x1m 1
Single insulated tube, DN16, length 15m 2
Fittings pack for DN16 tube 1
Solar pump unit 1
Expansion vessel 18 litres 1
Protection vessel 1
Automatic air separator 1
Table 5.2 Scope of delivery the auroTHERM flat plate collector
solar set
5 Installation