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Provides technical guidance and relevant national regulations for solar system installation.
Lists applicable documents, British Standards, and building regulations for solar installations.
Details regulations for preventing accidents during solar installation work.
Defines proper application of collectors and warns against improper use to prevent danger.
Explains the meaning of warning symbols: Danger, Caution, and Note, for safe operation.
Specifies the collector types and article numbers for which this manual provides instructions.
Details the components and basic set for the in-roof covering frame installation module.
Lists all necessary accessories for the in-roof basic and extension mounting modules.
Provides measurements for the fitting field and guides on determining area and installing mounting laths.
Provides detailed instructions for safe and correct assembly of the in-roof mounting system.
This document provides an installation manual for the Vaillant auroTHERM VFK 900 flat solar collector panels, specifically for in-roof mounting. It is intended for heating engineers and covers various aspects of the installation process, safety instructions, and technical guidance.
The manual begins with notes on the documentation, emphasizing that it is designed to guide the user through the entire process. It also states that other documents may apply in combination with this manual and that the manufacturer accepts no liability for damage caused by failure to observe the instructions. The document highlights the importance of observing all installation manuals for structural parts and components of the solar heating system, which are included with the individual parts. Users are instructed to pass the installation manual on to the system owner for storage.
Safety instructions are a critical component of the manual, with various warning symbols used to indicate potential hazards. These include "Danger!" for immediate risk of serious injury or death, "Danger! Danger of death by electrocution!", "Danger! Danger of burning or scalding!", and "Caution!" for potentially dangerous situations for the product and environment. A "Note!" symbol is used for useful information and instructions. The manual specifies that it applies exclusively to flat collectors with particular article numbers, which can be found on the identification plate on the upper collector edge.
Technical guidance emphasizes that the system must be installed in accordance with all relevant national regulations and site conditions. It lists several key regulations to observe, including those related to working at heights, health and safety, electricity at work, IEE Wiring Regulations, lightning protection, and equipotential bonding. The installation of the solar system must also comply with various British Standards, such as those for water installations, hot water central heating systems, and expansion vessels. The manual stresses that all work must be preceded by a risk assessment and carried out in a safe and workmanlike manner, with workers using appropriate personal protective equipment. Scaffolding must be designed and constructed by a vetted contractor, with suitable safety measures in place.
The intended use of the Vaillant auroTHERM flat collectors is for heating support and solar hot water generation, built and designed according to accepted safety rules. Any other use is considered improper and the manufacturer will not be responsible for resulting damages. Proper use includes observing all operating and installation manuals, as well as adherence to maintenance and inspection conditions.
The in-roof mounting section provides a detailed overview of the installation module, including its components as a basic set and an extension kit. The basic set includes covering plates, collector support plates, wooden supports, side plates, corner plates, and a measuring template. The assembly set contains foam rubber seal strips, silicone T-profiles, lead curtains, roofing felt nails, tin screws, quick-assembly screws, cellular rubber support strips, collector connection hoses, seals, fixing holds, fixing straps, and collector in-roof holders. The extension module includes similar components but in different quantities.
The manual also includes fitting dimensions, specifying the mounting field width and height for various numbers of collectors. It provides a diagram illustrating the measurements for the fitting field and the location of fitting laths, emphasizing that the thickness of the lath should match existing laths. A crucial caution is given regarding the roof pitch: for in-roof mounting, the roof must have a pitch of ≥ 27°, as rainwater can collect on cover plates and leaks can occur at pitches below this.
The assembly instructions provide step-by-step guidance. Collectors must be stored correctly, not vertically or horizontally outside due to vent holes. Collector connections must be protected during tightening using two open-ended spanners to prevent damage. Proper roof back ventilation is required. To avoid frost damage, the solar heating installation should be immediately filled with solar fluid after pressurization and flushing, and the concentration should be checked with an anti-freeze tester. Water alone should not be permitted in the collector if there is a risk of frost.
The installation process involves determining the fitting area and fitting mounting laths, using a template to transfer dimensions and ensure proper sealing against tiles. Laths are fixed to the rafters, allowing collectors to slide onto the inclined edge. The manual details how to push pipes through the lower mounting track, make V-shaped cuts, and treat roofing felt. It also illustrates the tools required for installation, such as a folding rule, power drill, spanners, hammer, carpet knife, and silicone injection tube.
Further steps include marking and securing lath positions, using carrying handles to bolt collectors, and sliding collectors into the inclined lath B, maintaining a consistent gap for the silicone T-profile. The silicone T-profile is then inserted into the gap between collectors, and collectors are pushed together. Solar collectors are screwed to the laths using in-roof retainers. Collector connection pipes are connected to the free collector connections and Cu pipes of the solar circuit under the roof, with connections sealed if the underside of the roof is enclosed. A thin bead of silicone is applied between the profile flanks of the T-profile and the collector frame for sealing.
The solar sensor is inserted into its sleeve, the rubber plug is pushed onto the cable, and the cable is run into the roof. Wooden supports are placed on the collector and fixed with quick-assembly screws. The lead apron is slid onto the lower edge of the collector and nailed in position, allowing for an overlap at the side. The lead apron is bent up through 90° using a lath. Side plates are inserted into the deep groove on the collector and nailed to the roof laths. Sheet metal straps are fixed on the lead apron. The lead apron is folded over the side plates or neighboring tile. A thin cellular rubber strip is glued on the upper narrow side of the collector frame. Corner covers are placed in position, with silicone applied, and upper closing plates are slid into the collector fold.
Corners are connected to the upper closing plate with tin-plate screws and packing washers. Upper closing plates are fixed onto the roof lath with fixing nails. Silicone is applied between the overlap of the upper cover plates, and they are connected with tin-plate screws, maintaining a space to the plate edges. If necessary, additional laths are nailed to match the inclination of the tiles. A thick foam rubber strip is glued on the upper closing plate. If tiles are laid onto side plates, a suspension notch is knocked out, a hole is drilled in the tile, and it is screwed to the lath. Finally, the lead apron is cut to suit the tile, ensuring collectors are fixed into the roof correctly.
The disposal section states that all Vaillant GmbH solar collectors comply with the German environmental mark "Blue Angel." The manufacturer commits to receiving back structural components for re-use if disposal is needed after many years of operation.
The manual concludes with information on Vaillant Service, recommending regular servicing and maintenance agreements. It outlines the Vaillant warranty, stating that the appliance must be installed by a competent person in accordance with relevant regulations and manufacturer's instructions. Failure to comply may invalidate the warranty.
General| Type | Flat-plate collector |
|---|---|
| Absorber material | Copper |
| Maximum operating pressure | 10 bar |
| Max. operating temperature | 120 °C |
| Optical efficiency | 0.8 |
| Heat loss coefficient | 3.89 W/(m²K) |
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