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Bosch BSS250-21-2, Installation And User Manual

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Bosch BSS250-21-2 Installation And User Manual Download Page 2

2 

 

 

 

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 

 
 

 

 

 

 

 

 

 

 

 

Summary of Contents for BSS250-21-2

Page 1: ...l Building Water and Gas fitting regulations To be installed and serviced only by an authorised person This appliance is not suitable for use as a pool heater Please see important note regarding tank on Page 15 The authorised installing person is responsible for 1 Correct commissioning of this system 2 Ensure units perform to the specifications stated on the rating label 3 Demonstrate operation of...

Page 2: ...asic 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 ...

Page 3: ...Electric boosted solar PTR NOTE For ease of installation the tank has cold inlet and hot outlet ports on both the left and right hand sides Cold water inlet valve train isolation valve non return valve PLV 600Kpa cold water expansion Where required Hot water supply to fixtures Temperature control valve Must be fitted Power supply from switchboard to booster GPO Solar circulation pump and controlle...

Page 4: ...om fitting to suit top left of collector with inbuilt sensor socket and connection for Air Relief Valve Frost valve x nipple Cold water flow from pump Barrel union with pipe insulation NOTE All pipes and fittings must be lagged with pipe insulation to prevent heat loss Return to tank Custom fitting for inlet connection ...

Page 5: ...e 1200mm x 2040 plus pipe and fittings At and before installation cover panels to prevent excessive heat building up in the panels that may cause damage to the panels and personal injury Fix panels securely with brackets provided in Cyclonic areas cyclone kits are required Tank location See page 15 22 for more detail As close as possible to the most frequently used fixture As close as possible to ...

Page 6: ...is within 1 metre of the booster Booster is fitted in accordance with the manufacturer s installation instructions AS3500 4 AS3000 wiring regulations in New Zealand NZBC G12 AS 5601 NZS 5261 and all Local Building Water regulations Commissioning the system Once the installation is complete the system will need to be filled with water and commissioned First flush all piping of debris Turn the water...

Page 7: ...lation Kit See contents below 5 1 Pump station Controller Optional tank installation kit available as an accessory Please check to make sure all these components are included with the kit Solar PK1 Panel Installation Kit 20mm Barrel Unions MI x MI 2 Custom Connection for top left of collector include Sensor Pocket 1 Custom Connection for bottom right of collector 1 20mm x 15mm Hex Nipple 15mm Hex ...

Page 8: ...simplicity of installation and appearance but must never be flat If the roof angle varies by 15 from the correct angle efficiency will be reduced by 10 The installer must ensure the structural integrity of the building is not compromised by the solar water heater installation and the roof structure is suitable to carry the full weight of the solar collector s If in doubt the roof structure should ...

Page 9: ...e brass barrel unions supplied in the panel installation kit 10 Centre the panels onto the lower bracket and secure the panels onto the bracket 20mm above the bottom of the bracket using the hex screws supplied Warning Do not drill above 20mm from the bottom of the bracket as this may cause damage to the internal workings of the panel and this will void the warranty 11 Remove the row of tiles abov...

Page 10: ...tion prior to commencing any work 1 Position the lower bracket on the roof ensuring there is sufficient room to fit the panels 2 Level the panel bracket and fix to the steel roof using roofing screws or rivets one fastener per rib is recommended 3 Weather proof screw heads and rivets with silicone sealant 4 Unpack panels where fitted remove protective plastic from the panels 5 Place panels into po...

Page 11: ...ble place to install the lower mounting rail on the roof align panel location as high as possible on the roof 2 Locate lower rail and mark 4 bolt positions on the rail The bolts are positioned to line up with the peaks of the tin or tile profile DO NOT drill in the troughs of the roofing material Ensure the holes are a minimum of 120mm from the end of the rail 3 Drill the 4 bolt positons on the to...

Page 12: ... as per steps 3 thrhough to 9 12 After the three mounting rails have been fixed to the roof fix a set of side brackets on the lefthand edge of each of the rails Then lift the first panel into place and fix that panel to the rail bracket Once this has been done you can then lift the 2nd panel into place and using the two barrell unions supplied in the panel fixing kit join the 2nd panel to the firs...

Page 13: ...illed in the roof once this is done seal the hole with silicone 22 NOTE Do not use the same hole as the pipe work as movement of the pipes will case the cable to break or short circuit 23 Install the Solar Hot Pipe and Solar Cold Pipe to run between the storage tank and the collectors Both pipes should be DN15 1 2 copper pipe with 13mm or thicker synthetic rubber insulation Armaflex Bradflex All i...

Page 14: ...lar 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 Note Drawing for illustration purposes only connection points may vary from product to product ...

Page 15: ...gnesium anode rods which softens the water and lengthens the service life of inner vessel The inner vessel is insulated by a thickened high density environment friendly polyurethane thermal insulation layer The external casing is a high quality galvanized sheet shell with outdoor coating technology anticorrosive and rust resistant makes for a longer service life 250 Litre 300 Litre 400 Litre DIMEN...

Page 16: ... of known heavy frost or altitudes higher than 600 m above sea level are not suitable for this system The minimum temperature these systems are suitable for in no lower than 5 C NOTE THIS WATER HEATER IS NOT SUITABLE FOR POOL HEATING LOCATION Whether located outdoor or indoor the solar water storage tank should be installed close to the most frequently used hot water outlet typically the shower an...

Page 17: ...e heater should be installed in a well ventilated space to avoid condensation build up If installed in confined areas make provision for Service Access FOUNDATION To ensure adequate tank support position the unit on an approved support base such as a concrete slab See figure below Suitable Water Heater Foundation Alternative forms of water heater bases are acceptable providing they allow for adequ...

Page 18: ...maged 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 50o C A tempering valve must be fitted between the water heater and the outlets in bathrooms and ensuites to comply with the water temperature requirements of AS 3500 4 ...

Page 19: ...solar gain or high hot water use The recommended installation is for the electric element to be connected to a continuous electrical tariff Other configurations of wiring the booster element are not recommended and may affect overall system performance and will not be covered by the warranty SADDLING PIPE WORK To prevent damage to the cylinder when attaching pipe clips or saddles to the water heat...

Page 20: ...e panels to the tank the reason for this is given in the section above Fitting of a non return valve in the solar line after the pump We recommend the installation of a inch spring check valve supplied in panel installation kit in the solar pump line to prevent the backflow of air from the panels into the pump which can cause cavitation of the pump the next time it starts Dual spring check valves ...

Page 21: ...efer to the relevant plumbing regulations DO NOT USE PLASTIC PIPE WORK BETWEEN COLLECTORS AND TANK NOTE The Solar Flow and Solar Return pipes between the solar storage tank and the solar collectors must be of copper and fully insulated with Bradflex Armaflex insulation or similar minimum thickness 13 mm Plastic pipe must not be used as it will not withstand the temperature of the water generated b...

Page 22: ...her appliance During this procedure there must be no smoking open flame or any electrical appliance operating nearby If the hydrogen is discharged through the tap it will probably make an unusual sound as with escaping air CONNECTIONS ELECTRICAL electric boosting NOTE Power must not be turned on until the solar storage tank is filled with water and electrical circuits are found to be satisfactory ...

Page 23: ...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 Wiring diagram PE Element Thermostat L1 N ...

Page 24: ...r return are both left and right hand connections 250 300 400 A OVERALL HEIGHT 1325 1545 1600 B OVERALL DIAMETER 620 620 710 C COLD WATER INLET 92 92 92 D SOLAR OUTLET 192 192 192 E SOLAR RETURN 532 532 532 F HOT WATER OUTLET 1100 1322 1375 G TANK SENSOR LOWER 372 372 372 H TANK SENSOR UPPER 782 892 912 A F E D C G H B ...

Page 25: ...d 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 Before installing this appliance carefully check that all packing materials have been removed and that the appliance is correct for the gas supply to which it is to be connected DIMENSIONS YS2170RAH 21 YS2670RAH ...

Page 26: ...l Natural Gas LP Gas 21E 170 Mj hr 170 Mj hr 26E 200 Mj hr 200 Mj hr Test Point Pressure kPa Model Natural Gas Max kPa Natural Gas Min kPa LP Gas Max kPa LP Gas Min kPa YS2170RAH 69 21 91 23 YS2670RAH 72 19 80 22 Water heating capacity 21E 26E Litres a minute raised 25 C 21 26 ...

Page 27: ...e DO NOT OPERATE WITH ANY OTHER GAS TYPE WARNING LABELS Located on the front of the cabinet PLEASE READ THESE LABELS CAREFULLY POSITION FOR INSTALLATION The heater must be installed by using a fixing method sufficient to hold the 20Kg weight of unit see the technical sheet for dimensions of mounting brackets and positions N B On combustible surfaces e g weatherboards etc it is not required to inst...

Page 28: ... 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 Refer to AS5601 or local gas fitting rules for specific locations ...

Page 29: ...29 COMPONENT DETAILS YS2170RAH YS2670RAH ...

Page 30: ...moval of the water heater Pipe sizing from the solar storage tank should be sized according to local BY LAWS for water supply ISOLATING GATE VALVE A GATE VALVE OR BALL VALVE must be used on the inlet to the solar booster THIS REQUIREMENT IS AN AUSTRALIA WIDE REQUIREMENT UNDER THE NATIONAL PLUMBING CODE STOP TAPS OR COMBINATION STOP TAPS AND NON RETURN VALVES ARE NOT TO BE USED N B NO PRESSURE REDU...

Page 31: ...plastic bag 5 Located on the right hand side of the booster is the Printed Circuit Board PCB 6 At the top of the PCB Between the temperature controller connection points is provision for the insertion of a polarised plug 7 Carefully insert the bridge into the PCB 8 Refit the front cover of the unit Refit the earth wire 9 Fit three pin power plug to the power supply 10 Turn the power supply on The ...

Page 32: ...turn off and contact the local gas authority the manufacturer or an authorized service person IN CASE OF DIFFICULTIES If the Bosch solar booster ceases to operate please check that the electricity supply is available Also check that the gas supply is turned on If a fault develops there are no user adjustments or serviceable components contained in this appliance Please contact an authorized servic...

Page 33: ...is way There is a huge amount of energy in sunshine as high as 1000 watts per square metre This can lead to water temperatures present in the hot water tank beyond what it is designed to handle close to boiling This is especially true of ceramic lined tanks Also pressure can build which can cause other plumbing problems To protect the hot water tank and stop pressure problems a maximum temperature...

Page 34: ...least 2 C lower The FROST light comes on when the value stored for the onset of a frost condition has been detected on the solar collector To stop the collector freezing and bursting the pump will come on just enough to raise the temperature of the collector by 2 C Only a small amount of warm water is needed to protect the collector The PUMP button will turn the pump on as long as the button is he...

Page 35: ... 95 C which is adequate for electric element heating safety However in solar hot water systems this temperature can be exceeded and the over temperature cut out may activate turning the electric element off The cut out needs to be manually reset by a qualified electrician In these installations it may be necessary to modify the electrics in a manner approved by the hot water tank manufacturer or s...

Page 36: ...een the sensor and the lining of the pocket If a pocket is not available then bond the sensor against the metal wall of the tank not the outside cladding or insulation using thermal transfer compound between the tank and sensor Warning 1 Sensors must not be immersed in water 2 It is recommended that sensor leads be kept 300mm away from mains and comms cables 3 Ensure the correct sensors are mounte...

Page 37: ... Note 1 See User Guide for explanation of display and status lights Note 2 See Trouble shooting section if system not working correctly SolaStat Eco Sensor Maintenance Lengthening SolaStat Eco Sensor Wire The sensor wire can be lengthened within certain guidelines Poor connections or induced interference can cause false temperature readings 1 The sensor is not polarized it can be connected either ...

Page 38: ...here the old sensor came from and retighten the screws 9 Do not allow the sensor cables to come within 10mm of the high voltage connectors or components inside the enclosure Tighten the screws on the cable clamp 10 Replace the lid replace the 4 screws and tighten 11 Push in 4 new screw covers available from your distributor Note there are locating lugs to ensure correct orientation 12 Reconnect th...

Page 39: ...ns at night FROST light is ON a Frost outside Pump runs at night a Normal operation FROST light is OFF a System is reverse thermosiphoning a The non return valve is not fitted correctly or is faulty Hot Water drops significantly overnight yet little or no draw off of hot water by the user a System is reverse thermosiphoning b System is in an excessive frost area c Tank losing heat a The non return...

Page 40: ... and the water descends back down to the tank To stop this loss of hot water at night or during cloudy skies there has to be a one way or non return valve fitted The failure of this non return valve is a common problem with solar hot water systems The orientation of the valve as per manufacturer s instructions is critical Also the valve sometimes will not close when swarf or other debris gets caug...

Page 41: ...nutes it will turn off for one minute This cycle is repeated as long as the pump is required to run and will not affect normal operation in a standard hot water collector and cylinder installation The one minute turn off period helps any accumulated air to escape from the pump and has been effective as a backup in exceptional conditions This should not be considered a substitute for the afore ment...

Page 42: ... heater The solar panels must only be filled when they are cold so it is important to ensure that the panels are fully covered for a suitable time beforehand Filling hot panels may cause injury by scalding Loosen the fitting on top of the solar panel return pipe to the solar storage tank and then turn on the mains cold water supply Cover the loosened fitting with a cloth to prevent water spraying ...

Page 43: ... the sun heats the water in the solar collectors the increase in temperature activates the water circulator Pump The water pump switches on whenever the water in the solar collectors is hotter than the water in the tank Cooler water from the solar storage tank is circulated to the solar collectors to be heated by the sun s energy This process continues while solar energy is available and will stop...

Page 44: ...thermostat This requires a licensed tradesperson to make any temperature adjustments The thermostat is located inside the electrical cover The tank thermostat is factory set at 66 c for electric boost and the gas booster must be set to 75 c at the time of installation These temperatures are required to protect your family from the potential of leigonella SAFETY WARNING Ensure all sources of electr...

Page 45: ...ODE PROTECTION REQUIRED Vitreous Enamel lined displacement storage tank water heaters use an anode to provide protection from corrosion on the steel walls of the tank Notes Pipe work between the solar collectors and solar storage tank MUST be insulated with the specified material or better FAULTS SERVICE Check the items below before making a service call You will be charged for attending to any co...

Page 46: ...ge It is a good idea to restrict the amount of hot water used by simply fitting an inexpensive water saver shower rose Conventional shower roses can require up to 20L min of flow to spray properly but a large amount of this water is wasted We recommend showers roses that pass 8 9L min of shower flow Thermostat setting Ensure the thermostat setting is appropriate You may choose to have your electri...

Page 47: ...ul planning of hot water usage Should you at any time feel your electricity account is too high we suggest you check the following points Is the relief valve running excessively Are you using more hot water than you think Is there a leaking hot water pipe dripping hot water tap etc Even a small leak will waste a surprising quantity of hot water and energy Replace faulty tap washers and have your p...

Page 48: ... relief valve should be checked for correct operation at least once every six months Gently raise and lower the lever until a constant flow of water is released Bosch recommend that the anode and relief valve are replaced at interval of five years Please contact Bosch on 1300307037 for advice on the correct components SOLAR COLLECTOR GLASS Ensure the glass on your solar collectors is free of dust ...

Page 49: ... obtain information from your local water supply authority WARRANTY of this product is VOID where the product is installed in areas where corrosive water is present or has been present in the product in the time span of the warranty This product should only be connected to a potable water supply Water that is corrosive to copper is typically associated with some bore water supplies of water not tr...

Page 50: ...radesperson adjustable It has a minimum temperature setting of 60ºC and a recommended maximum temperature setting of 75ºC It can only be adjusted by an authorised person Automatic safety controls are fitted to the water heater to provide safe and efficient operation Bosch recommends that the thermostat be set at 75 ºC for the best efficiency GAS BOOSTING Where gas boosting in used the electric ele...

Page 51: ... components within the solar booster are covered by a Five 5 year parts and labour warranty All warranty periods commence on the date of purchase of the hot water unit by the end user However where the date of purchase by the end user is more than 24 months after the date of manufacture all warranty periods will automatically commence 24 months after the date of manufacture 3 Warranty exclusions T...

Page 52: ...be ready to provide the model and serial numbers date of installation purchase details and a full description of the problem Warranty claims must be made before the end of the warranty period b All warranty service calls must conducted by an authorised Bosch service agent c Invoices for attendance and repair of a hot water unit by third parties not authorised by Bosch will not be accepted for paym...

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