Bosch BSS250E-2 User manual

19/07/2011 Version 19 Solar Wizard

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.

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 the system to the customer before leaving.

4. Hand these instructions to customer.

Failure to install this system in accordance with these installation instructions may void warranty

Note: These instructions are subject to change, due to continuous product improvement.

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

BASIC SOLAR TANK AND COMPONENT LAYOUT

250L, 300L & 400L Gas

boosted Solar

Solar Booster

Set to 75°c

Hot water supply to fixtures

(Temperature control valve Must be

fitted)

Gas

piping

Dual GPO

Power supply to

solar pump &

controller

Solar storage tank

Cold water inlet valve train isolation valve, non-

return valve PLV (600Kpa & cold water expansion

(Where required)

Solar circulation

pump and controller

Tank outlet

Tank sensor

Solar return

from panel

Solar panel sensor

Flow to panels

250L, 300L & 400L 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 controller

Flow to panels

Solar panel sensor

Solar return from

panel

PTR

Tank sensor

Solar storage tank

*NOTE For ease of installation, the tank has

cold inlet and hot outlet ports on both the left

and right hand sides

Continuous

supply

Continuous supply

Non-Return valve

Isolating

valves

BASIC PANEL LAYOUT 1,2 & 3 PANEL

Solar Panel

2040 x 1200

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

Frost valve

¾ x ½ nipple

Cold water flow

from pump

¾ Barrel union

with pipe insulation

*NOTE: All pipes and fittings must be

lagged with pipe insulation to prevent

heat loss.

Brass plug

Return to tank

Custom

fitting for

inlet

connection

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.

BASIC INSTALLATION STEPS

Check packaging and product for damage (If the product is damaged, do not install and

contact your supplier immediately)

Check and ensure that you have all components as listed on page 7

Panel installation (See page 7 –14 for more detail)

Select Panel location

Facing north (Not unduly shaded during the day and to the pitch requirements)

Roof structure can support filled weight of panels (44Kg each)

Panels can fit on available space on the roof (Panels are 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 the solar panels (Max 8m)

Ensure the tank is mounted on a solid base

Power, water is accessible to be connected to the tank and system

PTR drain is discharged in a safe manner and conforms to AS 3500.4

Note There are inlets and outlets on both sides of the tank, so ensure the unused

points are plugged with brass plugs prior to filling the tank.(Plastic plugs must be

discarded)

Tank is fitted in accordance with the manufacturer‟s installation instructions,

AS3500.4. AS3000 wiring regulations (in New Zealand NZBC G12) and all Local

Building, Water regulations.

The piping between the panels and tank is copper and is well insulated.

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.

Run sensor leads to the tank and panels (it is recommend that the sensor leads are

protected from the elements and mechanical damage)

Gas Booster (See page 23 - 29 for more detail)

Booster is mounted on either the left or right hand side of the tank

The 75c bridge is fitted to the booster. (See page 29 for more detail)

A continuous supply power point 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 isolation valve on at the tank.

Check pipework for leaks.

Open household taps individually and purge out any air.

Open vent on auto vent cap (At panels).

For electric boost turn power supply onto tank.

Turn power supply onto Controller/Pump station

For gas boost turn on isolation valves at booster.

Plug in three pin plug to power supply and turn on

Commission booster (See page 29 for more detail)

Check and adjust temperature control valve

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

storage tank

1 or 2

solar collector

2610mm (L) x 38mm (W) x 25mm (H) x 1.6mm (T) Upper mounting rail

–3 units required for Cyclone areas or Standard bracket kit

Solar PK1 –Panel Installation Kit (See contents below)

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)

Custom Connection for top left of collector include

Sensor Pocket

Custom Connection for bottom right of collector

20mm x 15mm Hex Nipple

15mm Hex Nipple

15mm MI x C Unions

20mm Brass Plugs

NVHT-15F-15C

15mm High Temperature Non-Return Valve

AEHT-10

Air Eliminator

FPV15

Anti-Frost Valve

PTR15/1000

15mm 1000kPa TPR Valve

Note

Insulation kits for most valves & Fittings

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)

Weight Full (Kg)

1200

2040

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. north facing in the

southern hemisphere and south facing in the northern hemisphere). Where this orientation is

not practical, a system facing up to 45° from the equator will have its efficiency reduced by

approximately 4%.

Inclination of the solar collectors should be approximately equal to 90% of the local latitude

angle.

Solar collectors may be installed at the roof angle for 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 be suitably strengthened.

Each solar collector and its fittings weighs approximately 44 kg when full of water.

INSTALLATION –SOLAR COLLECTORS

PREFACE:

Approximate roof area required:

2 Collectors are 2.8m wide x 2.4m high. (88kgs total, filled with water)

3 Collectors are 4m wide x 2.4m high. (132kgs total, filled with water)

NOTE: Ensure the mounting surface is strong enough to support the collectors. Most roofs can

support the panels, but if unsure consult a structural engineer.

ONLY QUALIFIED TRADESPERSONS SHOULD INSTALL THESE COLLECTORS.

GLAZING CANNOT BE REPLACED ONSITE.

FRAME INSTALLATION Tiled roof (Non Cyclone Area)

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. Replace tiles above the bracket

7. Unpack panels (where fitted remove protective plastic from the panels)

8. Place panels into position and fit against lower bracket

9. Join the panels together using the 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 above the panels to enable the upper bracket to be fitted.

12. Loop bracket support strap through the bracket, Flatten out return of bracket strap

13. Secure bracket to panels 20mm above the bottom of the bracket using hex self-drilling

screws. 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.

14. Fix bracket support strap to the roof rafters.

15. Bend all bracket straps to fit through and over tiles.

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.

FRAME INSTALLATION metal roof (Non Cyclone Area)

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. 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 position and fit against lower bracket

6. Join the panels together using the brass barrel unions supplied in the panel installation

kit.

7. Slide the upper panel support bracket under the top of the panels then press it flush

against the top of the panels. Mark its position on the roof.

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