MODELS BSS250E-2 / BSS250-21-2 / BSS250-26-2 BSS300E-2 / BSS300-21-2 / BSS300-26-2 BSS400E-2 / BSS400-21-2 / BSS400-26-2 Australia & New Zealand INSTALLATION AND USER HANDBOOK System Installation Controller & Pump Solar Panels Gas solar booster Solar Tank 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.
INDEX Page Number Basic Solar Hot Water Layout 3-4 Introduction 5 Basic Installation steps 5-6 Contents 7 Solar Collectors 8- 14 Solar Tank and Components 15-21 Electric Boosting 22-23 Solar Tank Specifications 24 Gas Boosting 25-32 Controller & Pump 32-42 Commissioning 42 Home Owners Guide & Safety Instructions 43-50 Warranty Details 51-52 2
BASIC SOLAR TANK AND COMPONENT LAYOUT I 250L, 300L & 400L Gas boosted Solar Solar panel sensor Solar Booster Set to 75°c Solar return from panel Isolating valves Non-Return valve Flow to panels Solar storage tank Tank outlet PTR Hot water supply to fixtures (Temperature control valve Must be fitted) Gas piping Dual GPO Solar circulation pump and controller Tank sensor Power supply to solar pump & controller Cold water inlet valve train isolation valve, nonreturn valve PLV (600Kpa & cold water expa
BASIC PANEL LAYOUT 1,2 & 3 PANEL Auto Air vent Must be upright and ensure vent cap is open Custom fitting to suit top left of collector with inbuilt sensor socket and connection for Air Relief Valve *NOTE: All pipes and fittings must be lagged with pipe insulation to prevent heat loss.
INTRODUCTION The following instructions are for the installation of a Split solar hot water system/s, being the panels are mounted on the roof of the dwelling and the solar tank is located either internally or externally at ground level. Where a gas solar booster is to be used, it should be mounted adjacent (In an external location) to the solar tank.
Pump & Controller (See page 30 - 39 for more detail) Pump and controller is securely mounted on a wall to the side of the tank (within 500mm of the tank.) The power supply lead to the pump and controller is 1500mm in length. A continuous supply power point is within 1.5 metres of the controller.
Clean up site Hand the customer the operating instructions Explain the system operation Answer any customer queries. CONTENTS Your „Solar Wizard‟ Solar hot water system is supplied with the following components: Parts List Item No. Qty Description 1 1 storage tank 2 1 or 2 3 2 2610mm (L) x 38mm (W) x 25mm (H) x 1.
SOLAR COLLECTORS The solar panels absorber material is Black painted copper fins, the outer casing is constructed from corrosion resistant brown anodized aluminum and the glass is low-ironed prismatic glass. Width (mm) Length (mm) Weight empty (Kg) 1200 2040 42 Weight Full (Kg) 44 SOLAR COLLECTOR LOCATION The solar collectors must be installed in a shade free position. The solar collectors are to be installed facing toward the equator (i.e.
Conduct an inspection of the intendant installation position and ensure that the panels can be fitted in this position prior to commencing any work. 1. Position the lower bracket on the roof ensuring there is sufficient room to fit the panels. 2. Remove the row of tiles above the bracket position. 3. Loop bracket support strap through the bracket and fix bracket support to the roof rafters, Ensure the bracket is level. 4. Flatten out return of bracket strap 5. Bend all bracket straps to fit over tiles. 6.
16. Replace tiles 17. Make all water connections, fit all valves and components as per the solar layout diagram contained in these instructions. 18. Note: The panels should be covered fully to prevent the panels heating up to temperatures that have potential to cause damage or injury during system fill or commissioning.
8. Remove the panels, align the upper bracket with the marked line and fix the panel to the steel roof using roofing screws or rivets. 9. Weather proof screw heads and rivets with silicone sealant. 10. Refit the panels between the brackets. 11. Centre the panels onto the brackets and secure the panels onto the brackets 20mm above the bottom of the bracket using the hex screws supplied.
8. Position the mounting rail and insert the screws through the rail and into the roof batten, place a rubber washer as a seal between the roof surface and the mounting rail, then evenly tighten the screws. Do not over tighten and break a tile. NOTE: ensure a rubber sealing washer is placed between the rail and the roof surface for each screw hole, to provide adequate sealing of the screw hole from water ingress. Use adequate amounts of silicone sealant into the holes before placing the screws in the holes.
header pipe, diagonally opposite from the inlet and returns to the “Solar Return” on the tank. 18. Install the air bleed valve onto the outlet of the panels at the top Left hand corner of the panels. 19. NOTE: The air bleed valve needs to be commissioned and checked to ensure the valve top is opened and that when the pump operates the valve seals properly. This can be done by listening to the valve to ensure air is not entering the pipe work.
Upon completion of the water heater installation, check the panels and associated plumbing for leaks while the pump is operating. COLLECTOR INSTALLATION IN CYCLONE AREAS The solar panels are SUITABLE for installation in cyclonic locations when installed with an additional rail mounting and brackets to provide the required additional fixing to the roof frame. This ensures conformance with AS1170.2. Three mounting rails meet the requirement for a C3 rated area.
SOLAR TANK Important Note: Please ensure you remove plastic transit plugs from tank and replace with brass plugs supplied with panel fitting kit (These plastic plugs will not withstand solar water temperature and will melt causing leakage from tank). Solar tanks are available in 250 Litre, 300 & 400 Litres capacities. All three tanks have cold water inlet and hot water outlets on both the left and right hand sides of the tanks for convenience.
INSTALLATION – STORAGE TANK COMPLIANCE WITH STANDARDS The installation must be performed by an Authorised Persons and comply with the requirements of AS/NZS 3500.4, AS/NZS 3000 in New Zealand NZBC G12 and all local codes and regulatory authority requirements. It is recommended the solar storage tank be installed at ground or floor level. The water heater must stand vertically upright.
Adequate provision must be made to dispose of any water escaping from heater or adjacent plumbing that might result in damage to property. The water heater must be connected in such a way that: Electrical covers are accessible to a service agent. Space is allowed for the removal of the heating element. The pump is accessible for servicing. or complete removal of the unit if necessary. CONFINED SPACES If the thermostat fails the unit may produce excessive steam.
SAFE TRAY 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 Sub-Clauses 1 to 5 of the abovementioned Code. HOT WATER DELIVERY This heater supplies water at a temperature exceeding 50oC.
WATER PRESSURE Test incoming water pressure with a gauge. If the pressure exceeds 750kPa, an approved pressure limiting valve is required. Pressure limiting valves are not supplied with Water Heaters. PUMP LIMITS Head limit of 6 meters. A different model pump (available from Bosch) will be required to maintain water flow through the solar collectors for heads greater than 6 metres.
SOLAR PLUMBING CONNECTIONS To connect the solar cold pipe on the storage tank. Connect the “Solar Flow” pipe to the non-return valve that has to be fitted on nipple on the outlet side of the pump. This pipe will run to the bottom right of the collector array. The “Solar Flow” Pipe will carry water from the tank up to the panels for heating. It is very important that this pipe runs continuously upwards or horizontally from the outlet of the pump to the inlet of the panels.
INLET/OUTLET CONNECTIONS To allow for disconnection of the water heater a mechanical union must always be provided at the cold water inlet, solar hot water inlet and hot water outlet on the water heater to allow for disconnection of the water heater. The pipe work must be cleared of foreign matter before connection. All pipe fittings must be assembled using two spanners – do not exert excessive amounts of torque on the pipes or water heater fittings.
SAFETY WARNING: As the function of the PTR valve is to discharge high temperature water under certain conditions, it is strongly recommended the pipe work downstream of the relief valve be capable of carrying water exceeding 95ºC. Failure to observe this precaution may result in damage to pipe work and property. Should this pipe become obstructed (eg. squashed, kinked or blocked), then the water heater may be damaged due to internal pressure.
Other forms of Electrical connections for solar may result in unintended operation of the system. STANDARD WIRING CONFIGURATION Electrical installation of solar storage tank with circuit breaker only. For electric Solar boost applications only L1 For Gas Solar boost applications no electrical connection is made to the Solar tank.
SOLAR WIZARD TANK SPECIFICATIONS A B F H E G D C A B C D E F G H 250 1325 620 92 192 532 1100 372 782 OVERALL HEIGHT OVERALL DIAMETER COLD WATER INLET SOLAR OUTLET SOLAR RETURN HOT WATER OUTLET TANK SENSOR (LOWER) TANK SENSOR (UPPER) 300 1545 620 92 192 532 1322 372 892 400 1600 710 92 192 532 1375 372 912 Please Note: Connections for Cold water inlet, hot water outlet, solar outlet and solar return are both left and right hand connections.
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 as per procedure on page 31.
TECHNICAL DATA Nominal hourly gas consumption by proportional gas control: 21E 26E Natural Gas LP Gas 170 Mj/hr 200 Mj/hr 170 Mj/hr 200 Mj/hr Test Point Pressure (kPa): Model YS2170RAH YS2670RAH Natural Gas Max kPa Natural Gas Min kPa LP Gas Max kPa LP Gas Min kPa .69 .72 .21 .19 .91 .80 .23 .
Maximum Inlet Water Pressure (Booster) 1000 kPa Input voltage single phase 50Hz 240 Volt Maximum output current 1 Amp Inlet gas connection male thread 18mm Cold water connection male thread 18mm Hot water connection male thread 18mm Relief valve pressure setting 1600 kPa DATA PLATE Fitted inside of front cover GAS TYPE The gas type is nominated on a temporary label located on the front cover, and on the data plate located inside the front cover.
CLEARANCES FOR FLUE TERMINAL (front of heater) The location of the flue terminal must comply with the clearances shown on this page. If you are unsure about clearances not indicated here, in general refer to AS5601, or your local authority. In Western Australia refer to the WA Office of Energy Safety rules and regulations. Use as a guide only.
COMPONENT DETAILS YS2170RAH YS2670RAH 29
GAS CONNECTION Fit a union to the Bosch solar booster gas inlet for easy connection and removal. The thread diameter is 18 mm. THIS DOES NOT INDICATE THE SIZE OF THE GAS SUPPLY. (2) Fit an AGA approved isolating gas cock in the supply line adjacent to the water heater gas connection. (3) Ensure that the supply pipe and the gas pressure regulator (LPG or Natural Gas) has sufficient flow capacity for this and other appliances connected to the fitting line.
ELECTRICAL CONNECTION The booster is equipped with a three pinned earthed plug to be connected to a 240V, 50Hz continuous electrical supply. The electrical rating of the appliance is 0.4 Amps The appliance requires a 240V, 50Hz weatherproof plug installed in a protected position adjacent to the appliance. IMPORTANT: The appliance should always be disconnected from the power supply before any maintenance is carried out.
N.B. The combustion fan can continue to operate for up to approximately 7 minutes after the unit is turned off. This is normal, not a fault. USER SAFETY INSTRUCTIONS PLEASE CAREFULLY READ THIS USER INSTRUCTION BEFORE USE. You have selected the Bosch Electronic computer controlled solar booster unit. The following instructions will assist you to obtain the best performance from your Bosch solar booster. SAFETY Always check water temperature by hand before entering the shower or bath.
Your SolaStat-Eco is pre-programmed in the factory as per below: Pump ON 12 °c Pump OFF 6°c Top Out 75°c Frost 4°c Your SolaStat-Eco has a microcomputer at its core that intelligently and automatically controls your solar hot water system at greater efficiency. The SolaStat-Eco measures water temperatures at 2 different places in the system and turns on a water pump at the optimum time. The pump moves hot water from the solar collector into the hot water tank.
· Sensor diagnostics: The SolaStat-Eco constantly checks the sensors. If the roof sensor is above 140°C, the pump is disabled. If a sensor is outside the specified temperature range of 40°C to 150°C then the display flashes the „Topout‟ light for the Roof sensor and flashes the „Frost‟ light for the Inlet sensor and the controller enters Smart Shutdown mode.
Installation Precautions. 1. Power leads must be facing directly down, not sideways or upwards. 2. Must be in a safe environment for users to inspect. 3. Failure to mount sensors correctly can lead to a poorly controlled solar hot water system with safety issues like overheating and over pressure damage to the plumbing and hot water tank and freezing damage to the solar hot water collector. Electrical Precautions. 1. All mains voltage electrical work to be carried out by a qualified electrician. 2.
The sensors are the only way the SolaStat-Eco can efficiently control and protect the system. 1. The 10m ROOF Sensor. The „ROOF‟ sensor is best fitted into a metal immersion „pocket‟ just inside the solar collector in the hot water outlet pipe. Liberally apply heat transfer compound between the sensor and the lining of the „pocket‟. Sensor should be sealed with neutral cure sealant and externally lagged, also the cable should be insulated from the bare pipe.
2. Complete all the installation and that the Sola-Stat–Eco is securely mounted. 3. The system is full of water. 4. Power outlet socket to be installed by a qualified electrician. 5. There is no water, metal shavings or other electrical hazards to contaminate the plug, socket and surrounding environment. Only then; Plug it in and turn it on. What You Should See. The first thing you should see after power up is; 1. On the top left the „PWR‟ light should be on. 2.
1. Remove the mains power supply, preferably remove the plug from the wall socket. Make sure no other power source is feeding back through other connections. 2. Remove the 4 screw covers on each corner of the lid of the enclosure. This will require a fine tipped tool such as a screw driver. Be careful not to damage the lid. Always press the tool away from you to avoid injury if you slip. 3. Remove the 4 screws that hold the lid on. 4. Unscrew the damaged sensor from the terminal block. 5.
PWR light ON, pump not running and yet is sunny outside. PUMP light is OFF. TOPOUT light is OFF. a. Sensor not mounted properly. b. Water not hot enough yet. c. Roof sensor over 140C. a. Check sensor is thermally bonded to Solar Panel outlet. b. Check temperatures of Roof and Inlet, they need to be greater than the difference programmed for pump ON. Wait. c. Normal Operation, Pump disabled. Pump will not operate and yet is sunny outside. PUMP light is OFF. TOPOUT light is ON. a.
. SolaStat-Eco Trouble-shooting Guide. This is intended as an initial guide to minimise service calls. Introduction. Any solar hot water system involves professional level plumbing and water much hotter than would normally be seen in standard domestic hot water systems, any installation must be carried out by a registered and qualified plumber. All parts including the pump must be rated for the elevated temperatures found in solar hot water systems. Solar Hot Water Specifics. 1. Tempering valve.
SolaStat-Eco Plumbing Issues, Cont. 5. Cavitation. A pump is used to circulate the water between the tank and the collector. If the pressure at the inlet or impellor of the pump falls below the vapour pressure of the liquid being pumped, cavitation will occur. Cavitation in a pump is more likely to occur as the temperature of the water rises and/or the pressure of the water decreases.
To avoid cavitation noise and damage to the pump bearing at high temperatures, the following minimum pressure is required at the pump suction port: Liquid temperature Minimum inlet water pressure 65°c 2.8m head 0.27 bar CONNECTIONS 15mm female BSP. COMMISSIONING TO FILL AND TURN ON THE WATER SUPPLY TO THE SYSTEM The power supply to the solar storage tank and solar control unit MUST NOT be switched on until the water heater is filled with water. Turn on the water supply to the system.
HOME OWNER USER GUIDELINES IF THE HOT WATER SYSTEM IS NOT USED FOR TWO WEEKS OR MORE, A QUANTITY OF HIGHLY FLAMMABLE HYDROGEN GAS MAY ACCUMULATE IN THE WATER HEATER. TO DISSIPATE THIS GAS SAFELY, IT IS RECOMMENDED THAT A HOT TAP BE TURNED ON FOR SEVERAL MINUTES OR UNTIL DISCHARGE OF GAS CEASES. USE A SINK, BASIN, OR BATH OUTLET, BUT NOT A DISHWASHER, CLOTHES WASHER, OR OTHER APPLIANCE. DURING THIS PROCEDURE, THERE MUST BE NO SMOKING, OPEN FLAME, OR ANY ELECTRICAL APPLIANCE OPERATING NEARBY.
MAINS PRESSURE LIMITS The water heater is designed to operate at mains pressure by connecting directly to the mains water supply. If the mains supply pressure exceeds 750kPa, a pressure-limiting valve must be fitted before the inlet of the heater, rated at 600kPa. HOW HOT SHOULD THE WATER BE? When operated in a domestic situation the system‟s outlet temperature should be between 50oC and 80oC.
SAFTEY WARNING This water heater is not intended to be operated, adjusted or tampered with by young children or infirm persons. Young children should be supervised to ensure they do not play with the water heater. DOES THE WATER QUALITY AFFECT THE WATER HEATER? The water heater is not recommended for connection to a bore water supply.
Collectors shaded Ensure the glass on your solar collectors is free of dust, salt spray or any other matter, which may reduce the effectiveness of the solar collectors. Hose or wash the collector glass with water and a soft brush when the solar collectors are cool. Trim any trees which may shade the solar collectors. If trees or other objects shade the solar collectors or if the glass is dirty, the effectiveness of the solar collectors will be greatly reduced.
operating temperature. The tank may also leak small amounts of water in summer, when the hot weather will cause the tank to reach higher temperatures. Continuous dribble Try gently raising the easing lever on the relief valve for a few seconds this may dislodge any trapped particles of foreign matter and clear the fault. Release the lever gently. Steady flows for long period (often at night) This may indicate the mains water pressure sometimes rises above the designed pressure of the water heater.
COLLECTOR GLASS Solar Wizard WARRANTY DOES NOT cover breakage of solar collector glass. Check your household insurance policy to ensure that the policy covers collector glass breakage. In the event of the Collectors glass being broken a new collector will need to be installed. Onsite replacement of the glass is not possible. MAINTENANCE REQUIREMENTS SAFETY WARNING This water heater is supplied with a thermostat pressure relief and non-return valve. These devices must not be tampered with or removed.
Switch off the electrical supply at the isolating switch to the solar storage tank and at the power outlet for the solar control unit. Unscrew the water heater drain fitting, sliding the temperature probe out until water flows freely. If it is necessary to run the water away from the heater (eg. if the tank is indoors), the wires to the temperature probe can be unscrewed from the controller circuit, and reconnected later, allowed the probe to be removed from the drain fitting.
ELECTRIC BOOSTING Water stored in the storage tank is heated automatically by an electric booster heating unit. The booster element heats the water during very cloudy or rainy weather, during the winter months, or during periods of unusually high demand, such as when friends or relatives visit. The booster heating unit is controlled by an electric thermostat. The thermostat and heating element are mounted on the solar storage tank inside the two covers.
Robert Bosch (Australia) Pty Ltd (Bosch) Manufacturer’s Warranty (Applicable for purchases from 1 January 2012) All Bosch hot water units are carefully checked, tested and subject to stringent quality controls. 1. Warranty Bosch offers, at its option, to repair or exchange this Bosch hot water unit or the relevant part listed in clause 2 below at no charge, if it becomes faulty or defective in manufacture or materials during the warranty period also stated in clause 2.
(d) changes in the condition or operational qualities of the hot water unit due to incorrect storage or mounting or due to climatic, environmental or other influences. NOTE: Any service call costs incurred by the owner or user of the hot water unit for any matter not covered by the terms of this warranty will not be reimbursed by Bosch, even if those costs are incurred during the warranty period.
