Bosch TSS Series Installation And Maintenance Instructions Manual Download Page 1

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6720887693 (2018/10) KEN

Installation and maintenance instructions for specialists

Thermosiphon system, on-roof installation

TSS

TSS150-2E/FCC-2, TSS200-2E/FCC-2, TSS300-2E/FCC-2

Summary of Contents for TSS Series

Page 1: ...6720887693 2018 10 KEN Installation and maintenance instructions for specialists Thermosiphon system on roof installation TSS TSS150 2E FCC 2 TSS200 2E FCC 2 TSS300 2E FCC 2 ...

Page 2: ...iles 14 6 5 Fitting special roof hooks for slate shingles 15 6 6 Installing the profile rails 15 7 Installing the storage tank 16 8 Installing the collectors 17 8 1 Preparing the collector installation 17 8 2 Installing the collector clamp on the right side 18 8 3 Place first collector on the profile rail 18 8 4 Inserting the double sided collector clamp 18 8 5 Placing the second collector on the ...

Page 3: ...ocument all work performed H Intended use The collectors are designed to produce heat in a thermal solar system thermosiphon system The installation set is exclusively designed for the safe installation of collectors and the storage tank Only operate collectors in hydraulically sealed unvented thermal solar systems no oxygen in the pipework Do not place other objects on the collectors H Risk of sc...

Page 4: ...e relief valves avoid standing in this area Point out that the valves on the cylindercanbecomeveryhotandthat these parts pose a risk of burning Babiesinparticularmustbekeptaway from the cylinder Point out that conversion or repair may be carried out only by a licensed contractor Also point out the need for inspection and preventative maintenance for safe and environmentally friendly operation Hand...

Page 5: ...2 11 10 2 9 3 4 6 7 8 0010015338 01 0010015338 01 5 No Component TSS150 TSS200 TSS300 1 Storage tank strap 2 3 2 Double sided collector clamp 2 3 Aluminium nut M8 6 9 4 Oval head screw M8 20 4 6 5 Oval head screw M8 16 8 12 6 Hexagon bolt M8 50 2 3 7 Washer 2 3 8 Storage tank protection adhesive strip 2 3 9 Profile rail long 2 2 10 Anti slip protection 2 4 11 Single sided collector clamp 4 4 12 Pr...

Page 6: ...00 2 9 Hose clip TSS150 200 4 Hose clip TSS300 8 10 Solar hose 55 mm with plug and hose clip 2 11 Solar pressure relief valve 2 5 bar 1 12 Potable water pressure relief valve 8 bar 1 13 Storage tank connection pipe bent 11 1 TSS200 2 14 Storage tank connection pipe straight 12 2 TSS200 0 0010014993 01 7 4 6 8 9 1 2 5 3 No Component 1 Connection G for solar pressure relief valve 2 Filler Solar G 3 ...

Page 7: ...te of sulphate ions unit m mol l System Daily water consumption litres day 110 l 140 l 170 l 200 l 250 l 300 l 400 l Qd kWh y annual heat demand 1270 1621 1962 2313 2891 3469 4625 QL kWh y annual system performance TSS150 1025 1218 1367 1454 1577 1621 TSS200 1226 1384 1516 1638 1726 1787 TSS300 1454 1717 1954 2295 2593 2935 fsol solar coverage TSS150 81 75 70 63 55 47 TSS200 76 71 66 57 50 39 TSS3...

Page 8: ... these between 15 00 and 18 00 PositionthethermosiphonsystemsothattheDHWpipeisasshortas possible Ensure the DHW pipe is very well insulated 2 8 Declaration of conformity collector This product in design and operation conforms to the European Directives and supplementary national requirements Compliance is demonstrated by the CE marking Youcanrequestthedeclarationofconformityoftheproduct Forthissee...

Page 9: ...working on the roof take all necessary precautions against a possible fall If there is not any independent anti fall safety device wear personal protective equipment CAUTION Risk of injury from carrying heavy weights Incorrect lifting and carrying of heavy loads can cause injuries Observe the transport instructions on the packaging Only lift the appliance at the points provided for this purpose Li...

Page 10: ...llation location Remove the DHW cylinder from the packaging only at the installation location Fig 12 Transporting the storage tank with hand truck 6 Installing the roof connection 6 1 Transferring the clearances of the roof connection to the roof NOTICE Roof leaks from incorrect positioning of the roof connection Roof tiles have a peak and a valley Always install double ended screws on the peak Al...

Page 11: ...bstructure Fig 15 Drilling through roof tile and timber NOTICE Roof leaks from damaged sealing washer Only screw the nut over the sealing washer hand tight onto the flat washer Turn the pre assembled double ended screw on the retaining block with a 19 mm spanner until dim Z tab is reached Tighten the nut 2 by hand until the sealing washer 4 makes full contact with the roof tile Retighten nut with ...

Page 12: ...n the lower part of the roof hook dimensions in mm Hooking the roof hooks into the roof batten Slide the roof tiles up around the roof hook positions Fig 18 Roof hook hooked into place Placetheroofhooksintothevalleyofthecorrugationandhookunder the batten Push the bottom part of the roof hook 1 up to the batten Tighten nut 3 when the serrated washer 2 grips the teeth of the bottom part of the roof ...

Page 13: ...bjected to loads Fig 22 Fitting rafter anchors on the board plank The roof hook needs a little room for movement at the top edge of the roof tile 1 If required trim the top of the roof tile It may be necessary to underlay the lower part of the roof hook with boards plankssothattheroofhookliesontopofthetiletothefront 4 When the serrated washer 2 grips the teeth of the bottom part of the roof hook T...

Page 14: ...e combined thickness of the roof tile and batten is more than 70 mm use the roof hook as a rafter anchor NOTICE Roof leaks from incorrectly positioned roof hooks Position the roof hook centrally on the roof tile The bottom part then lies on the rafter boards planks Where required secure boards planks with adequate load bearing capacitytotherafters Whererequired removecounterbattensfrom this area W...

Page 15: ...for the storage tank Place the the profile rails in the centre and screw in each retaining block with two short screws M8 16 Fig 30 Installing the upper and lower profile rails It is important for the subsequent collector installation that the profile rails are accurately aligned Use assembly aids e g a roof batten 1 Level the profile rails horizontally and with the stated clearance Use a spirit l...

Page 16: ...nd tighten Fig 33 Installing the storage tank strap The storage tank is heavy and awkward to handle Note the position of the storage tank on the installation set before carrying it Adhere the adhesive strips to the storage tank straps as tank protection 1 Place the storage tank in the middle of the storage tank straps and rotate it until the storage tank connections are vertical 2 Fig 34 Placing a...

Page 17: ... hose clip without locking ring NOTICE Leaks from the solar hose Tomakeinstallationeasier werecommendplacingthesolarhosesinhot water before installation Do not use lubricants containing mineral oil such as thread sealing compound 8 1 Preparing the collector installation CAUTION Riskofinjuryandleaksfromescapingsolarheattransfermediumas a result of unsecured solar hoses Secureeverysolarhosetothecoll...

Page 18: ... Fig 43 Tightening the screw of the collector clamp If only one collector is installed then install the collector clamp on the left 8 4 Inserting the double sided collector clamp If two collectors are installed Placethedouble sidedcollectorclampontheprofilerailandpushup to the collector Do not tighten yet Fig 44 Only insert a double sided collector clamp 8 5 Placing the second collector on the pro...

Page 19: ...mp on the left 9 Hydraulic connection NOTICE Leaks from using non approved thread sealing compound If pipe threads are caulked with hemp Use temperature resistant thread sealing compound e g Neo Fermit NOTICE No solar heated water from incorrectly installed flow and return pipes To enable the heat transfer medium to flow from the collector into the storage tank through different densities and for ...

Page 20: ...n nut 1 over the collector connection Place clamping washer 2 behind the bead on the collector connection and press together NOTICE Collector damage from twisted pipes Counterhold when tightening the fittings on the angled ferrule Push angled ferrule with O ring 3 against the collector connection and secure with union nut NOTICE Leak from the storage tank connection The gasket can be damaged by ov...

Page 21: ...water storage tank connection in such a way that the lever for venting can be set to the maintenance position 6 Connectthecoldandhotwaterpipesonsiteinaccordancewithlocal regulations Fig 55 Connecting potable water pipework 1 DHW storage tank connection 2 Cold water storage tank connection 3 Pressure relief valve 8 bar with non return valve lever in operating position 4 Water outlet opening 5 Expan...

Page 22: ...tionofthestoragetank Neverleavethesystembeforethefillingprocessofthepotablewater circuit has been completed Install a filter if required Turn on the DHW tap until the pipework is filled 10 3 Filling the solar circuit CAUTION Risk of injury from contact with heat transfer medium When handling heat transfer medium always wear protective gloves and goggles If heat transfer medium comes into contact w...

Page 23: ...f valve and cap 10 4 Carrying out checks After completing the checks carry out the thermal insulation to complete the work Table 15 Checks 10 5 Insulating the connection lines and pipework Thermallyinsulatetheon siteexternalpipeworkusingmaterialthatis resistant to UV rays weather influences and high temperatures 150 C Insulate internal pipework with high temperature resistant 150 C material Protec...

Page 24: ...alsareenvironmentallycompatibleandcanbe recycled Used appliances Used appliances contain valuable materials that can be recycled Thevariousassembliescanbeeasilydismantled Syntheticmaterialsare markedaccordingly Assembliescanthereforebesortedbycomposition and passed on for recycling or disposal 11 2 Shutdown WARNING Risk of scalding from hot water Let the DHW cylinder cool down sufficiently To empt...

Page 25: ...y all faults maintenance Fill out the report and tick off the tasks performed Table 16 Table 17 Commissioning inspection and maintenance tasks User System location Commissioning inspection and maintenance tasks Inspection maintenance Date Visual inspection of collectors storage tank and installation system carried out correct seating visual impression e g corrosion anode Visual inspection for leak...

Page 26: ...e tester is available as an accessory Follow the operating instructions for the anode tester Insulated installation of the magnesium anode is a prerequisite for using an anode tester to measure the protection current The protection current can be measured only with a filled DHW cylinder Ensure proper contact of the connecting terminals Connect terminals only to shiny metal surfaces Remove the stor...

Page 27: ...sium anode if the diameter is less than 15 mm Check the transfer resistance between the protective conductor connection and the magnesium anode Reseal the magnesium anode Hose down the inside of the DHW cylinder Fig 69 Hosing down the inside of the storage tank Use a wet dry vacuum to remove any residue If an immersion heater is installed When installing turn the handhole cover until the immersion...

Page 28: ...ector panel Clean collector panels with water when the sun is not shining Never use acetone or glass cleaner Collectors are in the shade Remove shading of collectors Fault potable water too hot risk of scalding Solar yields are too great which means that temperatures higher than 60 C are reached To avoid scalding install mixing device and set limit at 60 C Fault heat transfer medium discharged fre...

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Page 32: ...Bosch Thermotechnik GmbH Junkersstrasse 20 24 D 73249 Wernau www bosch thermotechnology com ...

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