DHW, Domestic Hot Water Cylinder BSS 2C-250-21-2 / BSS 2C-250-26-2 BSS 2C-340-21-2 / BSS 2C-340-26-2 BSS 2C-400-21-3 / BSS 2C-400-26-3 BSS 2C-250-2E / BSS 2C-340-2E BSS 2C-400-3E 6 720 618 429 (2011/01) AU/NZ Installation and maintenance instructions for contractors This solar hot water system must be installed in accordance with the manufacturer's installation instructions, AS5601, AS3500.4. AS3000 wiring regulations (in New Zealand NZBC G12) and all Local Building, Water and Gas fitting regulations.
| Table of Contents AU/NZ Table of Contents 1 1.1 1.2 Key to symbols and safety instructions Explanation of symbols Safety instructions 3 3 3 6.3 6.4 6.5 6.6 Adjusting the flow rate Fitting the casing shell After commissioning User information from the system installer 25 25 26 26 2 2.1 2.2 2.2.1 5 5 5 7 7.1 7.2 Shutting down Shutting down the DHW cylinder Shutting down the DHW cylinder if there is a risk of frost 27 27 2.3 2.4 2.5 2.
AU/NZ Key to symbols and safety instructions | 3 1 Key to symbols and safety instructions 1.1 Explanation of symbols Warnings 1.2 Safety instructions Installation, conversion Warnings in this document are framed and identified by a warning triangle printed against a grey background. If there is a danger due to electricity, the exclamation mark in the warning triangle is replaced by a lightning symbol.
| Key to symbols and safety instructions Using the electric heating element (BSS 2C-250-2E / BSS 2C-340-2E / BSS 2C-400-3E) B Ensure that any electrical work is only carried out by an approved electrician. B Before starting electrical work on the solar thermal system, isolate all poles of the system and secure against unintentional reconnection. B Ensure the system has been isolated from the supply.
AU/NZ Product information | 5 2 Product information 2.1 Standard delivery The DHW cylinder is delivered fully assembled with the solar circuit pump attached. The following parts of the standard delivery are packed separately: • SolaStat-Eco solar controller • Pressure-temperature relief (PTR) valve • Foot bolts • Technical documentation 2.2 Product description The BSS 2C-250/340-2E, BSS 2C-400-3E DHW cylinder is equipped with an electric heating element.
| Product information • Solar circuit pump assembly The solar circuit pump assembly supplies the solar circuit. • Casing shell AU/NZ 2.2.1 Main components of the solar circuit pump and safety assemblies The solar circuit pump and safety assemblies (Æ Fig. 3) are pre-assembled on the DHW cylinder. • Casing lid • Electric heating element (for SM250/340/400 E BO only) In addition to the collectors, the electric heating element is an additional heat source for DHW heating.
AU/NZ 2.3 Product information | 7 Correct use The DHW cylinder is designed for heating and storing domestic hot water. Please observe all DHW regulations, guidelines and standards for your country. Operate the DHW cylinder via the solar circuit using heat transfer medium only and in sealed unvented systems only. The solar pump station may only be used for the operation of solar thermal systems in conjunction with suitable controllers from the same manufacturer.
| Product information 2.5 Fig.
AU/NZ 2.
| Regulations 3 AU/NZ Regulations Different or supplementary regulations (e.g. mains connection requirements) may apply subject to the installation location (e.g. in different countries or regions). B Observe the country-specific or regional regulations, guidelines and standards (e.g. those of the power supply utility) when installing and operating the DHW cylinder and the electric heating element. All installations must be carried out in accordance with AS/NZS3500.
AU/NZ 4 Shipping | 11 Shipping WARNING: Risk of injury from carrying heavy loads and inadequately securing loads for transport. B Use suitable means of transportation, e.g. a hand trolley with strap. B Transport the DHW cylinder to the installation location. B Remove packaging. B Remove wood screws [1] from locking plate [2]. B Unscrew and remove locking plate. B Secure the DHW cylinder against slipping. Where possible, transport the DHW cylinder fully packed to the installation location.
| Installation 5 AU/NZ Installation The DHW cylinder is delivered as a fully assembled unit. B Check that the delivered package(s) are complete and in perfect condition (Æ Chapter 2.1, page 5). B Dispose of packaging in an environmentally responsible manner. 5.1 Location 5.1.1 Requirements for installation location The DHW cylinder may be installed either indoors or outdoors. NOTICE: System damage through inadequate load-bearing capacity of the supporting surface or unsuitable substrate.
AU/NZ Installation | 13 B It is a requirement of the National Plumbing Code AS/ NZS3500.4.2 that new water heaters be installed in a safe tray where in the event of a leak, property may be damaged (ie internal installations). Installation of such trays must comply with Clause 4.4 and SubClauses 1 to 5 of the above mentioned Code. Fig. 9 1 2 3 5.2 Removing the casing shell B Remove four push rivets [1] from the casing shell. B Lift the casing shell [2] up and off.
| Installation 5.3 Water connections DANGER: Risk of fire through soldering and welding! AU/NZ 5.3.1 Connection options Hydraulic connections on the DHW cylinder can be routed out either to the left [A] or the right [B] through the casing shell. B Take appropriate protective measures when soldering and welding as the thermal insulation is flammable, for example cover the thermal insulation. LEFT RIGHT B Check thermal insulation after completion for perfect condition.
AU/NZ Installation | 15 B To prevent air locks: route the pipes from the cylinder to the collector field on a rising incline. Connecting piping B Copper pipes for solar thermal systems should always be soldered with brazing or silver solder (i.e. not soft solder). B Compression fittings or push-fit fittings can be used instead of soldering if they are glycol and heatresistant (150 °C). We recommend carrying out a pipe network analysis to design the piping. Basic design estimates can be made using Tab. 5.
| Installation AU/NZ Laying pipes with an automatic air vent valve on the roof (available as accessory) 5.3.3 B Pipes to the air vent valve should follow a rising gradient. Any downward change of direction requires an additional automatic air vent valve (temperatureresistant to 150 °C. B Use only threaded fittings, with shut-off valves if required, to connect lines to the cylinder. Connect cylinder connections to piping on site.
AU/NZ Installation | 17 5.3.4 Electric Boosted System Fitting the PTR valve The PTR valve is included in the standard delivery and must be fitted. The drain line must be installed in accordance with AS3500.4. B Fit PTR valve [1] on DHW cylinder (Position Æ Fig. 4, page 8). Install connection for the blow-off line (1/2" female thread) facing down. B Cut blow-off line DN15 [2] to length and bend according to Fig. 16. B Fit blow-off line to PRT valve.
| Installation 5.4 Installing the temperature sensors Ensure that any electrical work is only carried out by an approved electrician. The temperature sensors are not polarity sensitive. 5.4.1 Installing the DHW temperature sensor B Fit a DHW temperature sensor [2] at test point M for measuring and monitoring the DHW temperature at the DHW cylinder (Æ Fig. 4, page 8). B Take the DHW temperature sensor from the standard delivery of the controller.
AU/NZ 5.5 Installation | 19 Electrical connections DANGER: Risk to life from electric shock! B Ensure that any electrical work is only carried out by an approved electrician. B Before opening the controller, isolate all poles of the solar thermal system. B Secure the solar thermal system against unintentional reconnection. B Observe all local regulations! 5.5.
| Installation 5.5.3 Gas Booster Installation Gas solar booster The Bosch solar booster is an external, electronically controlled gas boosted solar water heater. The Bosch YS2170RAH & YS2670RAH appliances are supplied set to operate without temperature selector pads and are factory set to deliver a constant 55 °C but must be reprogrammed to 75 °C.
AU/NZ 6 Commissioning the system | 21 Commissioning the system B Ensure that the installer of the solar thermal system or a qualified contractor commissions the cylinder. B For gas boost turn on isolation valves at booster. B Plug in three pin plug to power supply and turn on. B Commission booster (See separate Booster Installation Instructions for more detail). B Check and adjust temperature control valve. 6.2 Purging and filling 6.2.
| Commissioning the system AU/NZ B Open all shut-off fittings. B Close the ball valve [1] on the solar circuit pump assembly and the ball valve on the air vent valve (Æ Fig. 21, [3]). B Purge the pipework, making sure that the maximum operating pressure is not exceeded. B Shut off the water supply. B Close the DFVs [3] in the solar circuit pump assembly. Fig.
AU/NZ 6.2.3 Commissioning the system | 23 Replacing water with heat transfer medium The pipes must be completely emptied of water, otherwise the heat transfer medium can become diluted. B Using a pump, fill the solar thermal system with medium via one of the DFVs [1]. The solar thermal system must only be operated with heat transfer medium. The heat transfer medium is premixed and ready to use.
| Commissioning the system 6.2.4 Verifying that the solar thermal system is free of air AU/NZ 6.2.6 NOTICE: System damage due to low temperatures! If the black pointer on the pressure gauge [1] indicates pressure fluctuations when the solar pump is switched on and off, there is still air in the solar thermal system which must be removed. B Switch solar circuit pump [2] on and off manually via the solar controller (Æ documentation for the solar controller).
AU/NZ 6.3 Commissioning the system | 25 Adjusting the flow rate The flow rate is set to a fixed flow rate when the system is cold (30 – 40 °C). B Set the ball valve [4] to 0° (gravity brake is operational). B Fully open the flow limiter [2] using a size 4 Allen key. B Control solar circuit pump manually using the solar controller (Æ documentation for the solar controller). B Check the flow rate through the inspection window of the flow limiter [3].
| Commissioning the system 6.5 After commissioning The viscosity of the heat transfer medium makes air bubbles substantially more resilient than those in pure water. B After several hours of solar circuit pump operation, vent the solar thermal system via the air vent valve on the roof. 6.6 User information from the system installer Explain to the user how the solar thermal system and the DHW cylinder work and how to handle both.
AU/NZ 7 Shutting down | 27 Shutting down Never use the heating emergency switch to switch off the heating system when you are away on holiday as this will disable the solar thermal system. 7.1 Shutting down the DHW cylinder B Shut down the solar thermal system (Æ documentation for the controller, the heat source and the solar thermal system). B Disconnect the electric heating element (for Electric Boosted ONLY) and secure against unintentional reconnection. 7.
| Environmental protection/disposal 8 Environmental protection/disposal Environmental protection is one of the fundamental company policies of the Bosch Group. We regard quality of performance, economy and environmental protection as equal objectives. All legislation pertaining to the environment is strictly observed. To protect the environment, we use the best possible technology and materials whilst taking into account economical aspects.
AU/NZ 9 Maintenance | 29 Maintenance NOTICE: Cylinder damage through poor cleaning and maintenance! 9.1 DANGER: Risk to life from electric shock! B Carry out cleaning and maintenance at least every two years. B Do not operate electrically heated DHW cylinders without an anode. B Remedy all faults immediately. Generally, we recommend that the DHW cylinder is checked by a contractor at least every two years. Inform the system user accordingly.
| Maintenance Replacing anode rods B Remove the 2 hexagon bolts [1]. B Remove serrated washer [2], washer [3] and gasket [4]. B Replace magnesium anode [5] and screw onto flange. AU/NZ 9.2 Restarting the DHW cylinder after maintenance NOTICE: Cylinder damage through faulty gasket. B To prevent the DHW cylinder from leaking, put a new gasket on the flange after cleaning and maintenance. B Insert flange into DHW cylinder by hand using 8 hexagon bolts.
AU/NZ 10 Warranty details | 31 Warranty details Your Bosch Hot Water product is guaranteed as follows For appliances used in domestic applications, i.e. normal hot water drawn from household outlets, the warranty period is six (6) years part and one (1) year labour on the tank only, eight (8) years part and one (1) year labour on the solar collectors only, two (2) years part and one (1) year labour on all other components. Purchased spare parts are guaranteed for 12 months, replacement only.
Australia Robert Bosch (Australia) Pty Ltd 1555 Centre Rd Clayton, VIC 3168 Phone 1300 30 70 37 Fax 1300 30 70 38 www.bosch.com.au/hotwater 6720618429 0001 New Zealand Phone 0800 4 Bosch or 08 543 352 www.bosch.co.
