Bosch FCB 120-1V-NB User Manual & Installation Manuallines Download Page 1

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Thermosiphon systems

User manual & installation guidelines

C08002D : Version 2 : 20140910

6 720 803 996

Summary of Contents for FCB 120-1V-NB

Page 1: ...1 Thermosiphon systems User manual installation guidelines C08002D Version 2 20140910 6 720 803 996 ...

Page 2: ...ation Commissioning of 2 C Systems 16 9 1 Installation of tank and collector 16 9 2 Installation of makeup tank 16 9 3 Procedure for filling Secondary Circuit in 2 C Systems 16 9 4 Quantity of DM Water glycol mixture required for 2 C Systems 16 9 5 Recommended Properties of Glycol 17 9 6 Glycol Health hazard data 17 9 7 Preventive Measures 17 __________________________________________ 10 0 Install...

Page 3: ...o prevent accidents during all works on roof Take precautions against a possible fall of objects while working on roof Always wear personal protective clothing and safety equipment during entire installation activity After completing the installation check the mounting set the collectors and the tank are securely positioned Installation and maintenance Only have the appliance installed or modified...

Page 4: ...whether a lightning protection system is required Lightning protection is normally required for buildings higher than 20 m Have a qualified electrician to install the lightning protection If a lightning protection system is installed at the location check whether the solar thermal system is also included Consult a Civil Engineer Architect for further information if necessary on Recommendations on ...

Page 5: ...through riser tubes placed beneath the absorber As the water gets heated it becomes light and moves upwards towards the insulated solar tank The void thus created will be filled by the heavy cold water from the tank The cycle repeats and this process is called Thermosiphon Process This process continues until the temperature of the hot water in the storage tank and the absorber equalizes Since the...

Page 6: ...ollector Box Aluminium Extrusion German Design with Single piece screw less construction Collector Back Sheet Aluminium Alloy Back Insulation Rockwool 48 kg m 3 density with thermal resistance of 0 96 m 2 o C W Side Insulation Polyurethane Foam 28 32 kg m 3 density with thermal resistance of 0 48 m 2 o C W Reflective Sheet Aluminium Foil Glazing Textured Solar glass 3 2 mm thick with transmissivit...

Page 7: ... System Non Pressurized Stainless Tank Storage tank 100L 125L 200L 250L 500L Type l 1C Volume of tank l 100 125 200 250 500 Diameter mm 450 480 600 640 900 Length mm 1150 1190 1140 1190 1230 Approx Weight empty tank kg 18 3 21 26 29 52 Max operating pressure KPa 50 Non pressurized system Open vented Inner tank SS 304L Outer cover GI pre coated sheet Insulation 50 mm Polyurethane foam insulation CF...

Page 8: ...mm 970 990 Approx Weight empty tank kg 14 22 Max operating pressure KPa 0 Integrated with Float Tank Inner tank Food grade LMDPE 5 mm thick Outer cover LMDPE 3 mm thick Insulation Polyurethane Foam 28 32 kg m 3 density 5 0 Before installation Make yourself familiar with the on site conditions and local regulations before commencing the installation 5 1 General notes We recommend that you engage th...

Page 9: ...r radiation into account southerly orientation Avoid shade from high trees or similar structures The stability of the installation surface Remove gravel or similar material Only use original spare parts from the manufacturer and replace faulty parts immediately Have a professional roofer to carry out all difficult roof repairs particularly sealing the roof if there is any seepage of water through ...

Page 10: ... space requirements NOTICE System damage through wind eddies and wind pressure peaks at the flat roof perimeter Before commencing installation ensure that a clearance of at least one metre is allowed between the flat roof frame and the roof perimeter NOTE It is mandatory to install the system with collector facing south direction in a shadow free area Fig 5 Space requirement collector array The di...

Page 11: ... mounting structure and align it to the centre of the two supports Ensure that cold water pipe should be positioned down The tank will be held in its position by the virtue of its own weight Ensure that the EPE pads are pasted on the U bracket before placing the tank 6 3Collector Installation 6 3 1 Installation of collector on flat roofs Observe the following safety instructions and user informati...

Page 12: ... personnel below the working area during installation 6 4Positioning the first collector Fix the front end collector front supports using collector clamp and M8 screws as shown in picture 9 10 Fig 9 Fig 10 After fixing the front end supports lift the rear end of the collector and place it on the tank mounting support as shown in fig Position the collectors and clamp it to the mounting structure us...

Page 13: ...ollector Fig 15 Fig 16 Fig 17 Move the second collector towards the first collector and Insert the header pipe into the hose and clamp it rigidly Fig 18 First Collector Round off the ends of the header pipes to avoid possible damage of the hose during insertion Use silicon gel or edible oil for easy insertion of the hose pipe into header pipe EPDM Hose with hose clamps ...

Page 14: ...ect one end of EPDM hose to the bottom Header pipe of the second collector Fix the hose pipe support bracket to the second collector Connect other end of EPDM hose to the cold water outlet pipe of the tank using hose clamp Route the hose pipe through support bracket 7 3 Connecting hot water inlet pipe Fig 22 Remove the plastic cap from the header pipe Insert one end of the EPDM hose into the colle...

Page 15: ...ectric Backup HWI Hot Water Inlet B Bosch Scope CWI Cold Water Outlet C Customer Scope Electric Heater is not part of standard supplied system If Electric Heater is required for backup heating contact authorized dealer installer Always use ISI marked electric heater Air vent pipes must be securely tied with three guy ropes at 120 o apart ...

Page 16: ... top of the tank and start filling the DM water Water glycol mixture till the air inside the system is vented out and water flows over the disconnected hot water rising pipe Connect back the hot water rising pipe into the tank Continue filling till the water reaches the maximum level level of the makeup tank and close the lid of the tank Fig 24 Ensure the water level is between maximum minimum mar...

Page 17: ...C mm Hg 0 07 Odour Odourless Solubility in water Mixable Specific gravity water 1 1 035 1 037 Flammable material No Combustible material Yes Corrosive material No Oxidizer No 9 6 Glycol Health Hazard Data Description Remarks Routes of entry Inhalation Eye contact Skin absorption Ingestion Effects of exposure Symptoms Massive ingestion symptoms similar to alcohol intoxication inhalation of high vap...

Page 18: ...nd collector Similarly for 300 500L system the connector should be fixed to the last collector Insert the other end of the pressurized hose with L bend into the straight push fit connector and clamp it firmly 10 2 2 Hot Water Pipe Assembly Fix the hose nipple firmly into the hot water inlet pipe of the tank Insert the pressurized hose pipe and tighten it with hose clamp Insert the straight push fi...

Page 19: ...t filled into the solar tank by gravity from the overhead tank 12 Important Instructions 12 1 Instructions to Installers Check the performance of the system after 3 days Never attempt to service the system when the system is functioning Make sure there is no air trapped inside the secondary circuit If air is trapped in the secondary circuit system will not function When system is installed in high...

Page 20: ...d capacity of the system every day 13 Checks following commissioning and maintenance Only carry out the final insulation work when the points in the check list have been ticked off Checks Solar hose secured with hose clamps Mounting structure connection screws rigidly fixed No leakage of water through the connections Air vent correctly installed Mounting structure fixed on the roof with concrete S...

Page 21: ...ric Back up heater 14 4 1 Enamel Tank Systems Provision for fixing the backup electric heater is made in all tanks Remove the heater cap located on the hot water outlet side of the tank Using tubular spanner of 1 or 52 mm remove the plug Insert the heater coil and tighten it Ensure that there is no leakage through the joints 14 4 2 Stainless Steel Tank Systems Remove the 1 plug provided on the rig...

Page 22: ...g Remove the bend if the length of the hose is more cut to the required length Properly support the hosepipe on the provided L plate If problem is not solved contact local After sales person ASA 16 Environment and Disposal Bosch group is committed towards environmental protection The quality of our products their economy and environmental safety are all of equal importance to us and all environmen...

Page 23: ...Annexure 1 Schematic layout of Non Pressurized system Doc no 8 718 598 325 ii Annexure 2 Schematic layout of 1C Pressurized system Doc no 8 718 596 473 iii Annexure 3 Schematic layout of 2C system Doc no 8 718 598 324 ...

Page 24: ...__________ Checklist for before commissioning the system Check and confirm air vent at hot water out let is provided Check and confirm the cold water supply pipeline and hot water supply pipeline is duly supported Check and confirm the overall system installation is as per the instructions given in the manual Note to the Customer if the system is not commissioned as on the above date due to any re...

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Page 26: ... from the date of invoice In the event of replacement repair of parts the warranty will thereafter continue for the reminder period of original warranty All Products must be installed and used according to the installation manual and local legislations An incorrect installation from the consumer or an installation that does not fulfil the requirements of law will not be considered for Warranty In ...

Page 27: ...the opinion of the company are due to misuse or neglect or accident or due to force majeure Damages caused due to modifications alteration of the system by customer or unauthorized persons If the quality of water fed into system is not as per recommendations Refer Installation manual for permissible limits for a particular system If the inlet water pressure is more than the permissible limits Dama...

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