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Summary of Contents for BSS Audio BOSS 100
- Page 1 Direct, Indirect & Solar Unvented Cylinder Installation & Maintenance Manual REGISTER THIS PRODUCT ONLINE WITHIN 28 DAYS OF COMMISSIONING IRELAND www.joule.ie/register-a-product UNITED KINGDOM www.jouleuk.co.uk/register-a-product BSS-DID-INS-006-10-2017 Boss Direct / Indirect Installation Guide...
- Page 2 Warranty Card MUST BE COMPLETED AND THEN REGISTERED ONLINE Please register your product online TO COMPLETE WARRANTY Homeowner Installer Name Name Address Address Contact Tel. Contact Tel. Contact Email Contact Email Product Product Serial Number Installation Installed Date Cylinder Located on cylinder badge I accept the terms and conditions in the installation manual www.bssindustrial.co.uk...
- Page 3 BSS Product Warranty Terms & Conditions BSS BOSS™ Warning To The User • Do not remove or adjust any part of this The BSS BOSS™ stainless steel vessel carries a unvented water heater. fully transferable 25-year guarantee against faulty • If the unvented water heater develop fault, such materials or manufacture provided that: as a flow of water from the discharge pipe...
- Page 4 www.bssindustrial.co.uk...
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Page 5: Table Of Contents
Table Of Contents Introduction General Requirements Unvented Kit Components Unvented Kit Checklist ErP Product Fiche Information Technical Data Indirect Technical Specification Direct Technical Specification Solar Technical Specification Plumbing G3 Unvented Kit Testing Smart Control Immersion Setup Immersion Installation Cylinder Schematic S-Plan Cylinder Schematic Y-Plan Electronic Controls Discharge Arrangement... -
Page 6: Introduction
Introduction The instructions are an integral part of the appliance and must be given to the end user on completion of the installation in order to comply with the current regulation. It is important to carefully read the manual to understand all the information to enable safe installation, use and servicing. - Page 7 Handling Care must be taken when transporting, storing and installing the equipment: • At least two people should lift the cylinder to prevent injuries. • The cylinder must be stored in a dry area and must never be dropped during handling. •...
- Page 8 Water Supply The performance of any unvented system is only as good as the mains water supply available. To this effect the maximum possible water demand should be assessed, with the knowledge that the mains supplies both hot and cold services simultaneously. The water heater itself operates at a pressure of 3bar, controlled by the inlet control set, and is capable of delivering over 50 litres per minute.
- Page 9 Water Chemistry Levels Affecting Warranty The BSS warranty of this water heater will not cover resultant faults on components including the storage cylinder where water stored in the storage cylinder exceeds at any time any of the following levels: Components Maximum Permitted Levels Total Dissolved Solids 600 mg/litre...
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Page 10: General Requirements
General Requirements Siting The Unit This unit can supply outlets above it or at some distance from it but any outlets above the unit will reduce the available outlet pressure by 0.1 bar for every 1m of height dfference. The maximum length of the “dead leg”... - Page 11 Balanced Cold Connection If there are to be showers, bidets or monobloc taps in the installation then a balanced cold supply is necessary. There is a 22mm balanced connection on the inlet control set. Fitting The Inlet Control Group Excess pressure can lead to the cylinder bursting. The inlet control set supplied has an expansion relief valve with a 15mm connection to allow it to be connected to the tundish.
- Page 12 Prior to connecting the expansion vessel to the system the pipework should be flushed and tested. When the vessel is connected the system should be pressurised when cold. If the initial system water pressure is too high, the diaphragm will be displaced too far into the vessel. This will leave the vessel unable to accommodate the volume of expansion water.
- Page 13 Dead Legs The length of hot water draw off to taps and other outlets should be kept to a minimum to reduce the amount of cold water drawn off before the hot water arrives. The maximum recommended dead leg lengths are shown in the table below. Where there is more than one size of pipe on a dead leg, the equivalent length and size should be estimated.
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Page 14: Unvented Kit Components
Unvented Kit Components 34331116 34331160 34330830 34331127 34330863 34330948 34330896 34330852 34330937 19711233 19711436 34330701 Smart 19711244 19711266 19711255 www.bssindustrial.co.uk... -
Page 15: Unvented Kit Checklist
Unvented Kit Checklist Capacity (ltr) Inlet Group 34330863 34330852 1971 1971 1971 Expansion Vessel 19711233 19711244 1255 1436 1266 T&P Valve 3433116 34331127 Tundish 34330948 34330937 Dual Stat 34330830 Prim. Coil 2-P Z.Valve 34330896 Direct Indirect Inlet Control Group Inlet Control Group Tundish Tundish T&P Valve (fitted) -
Page 16: Erp Product Fiche Information
ErP Product Fiche Information Nominal Capacity (ltr) Direct Vertical Storage volume V (ltr) Mixed water at 40°C (ltr) The declared load profile ErP Rating Energy Efficiency (%) Ann. el. consumption (kWh) 2650 2654 2715 2719 2723 2764 4508 Sound Power Level (dB) Thermostat Temp. -
Page 17: Technical Data
Technical Data Indirect models in conformance with BS EN 12897:2016 Maximum mains water supply pressure 2.5MPa (25 bar) Operating pressure/PRV 0.3MPa (3 bar) Expansion vessel pressure 1.0MPa (10 bar max) Expansion relief valve setting 0.6MPa (6 bar) Maximum design pressure 0.4MPa (4 bar) T&P relief valve setting 0.7MPa/90 °C (7 bar) -
Page 18: Indirect Technical Specification
Indirect Technical Specification 15º 30º 30º Boiler Return Cold Water Inlet Aquastat Pocket Boiler Flow Incoloy Immersion (fact. fitted) 10 Secondary Return 13 T&P Relief Valve 14 Hot Water Draw Off www.bssindustrial.co.uk... - Page 19 Connection Sizes & Safety Hot & Cold Conn. Ø (mm) Coil Connection Ø (mm) Secondary Return Ø BSP F (“) T&P Connection Ø BSP F (“) 0.75 0.75 T&P Press. Set. (bar) 3bar Exp. Relief Set. (bar) Dimensions Cylinder Height (A, mm) 1030 1190 1310...
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Page 20: Direct Technical Specification
Direct Technical Specification 30º 30º Cold Water Inlet Incoloy Immersion (fact. fitted) 10 Secondary Return 13 T&P Relief Valve 14 Hot Water Draw Off 15 Smart Immersion (fact. fitted) www.bssindustrial.co.uk... - Page 21 Connection Sizes & Safety Hot & Cold Conn. Ø (mm) Coil Connection Ø (mm) Secondary Return Ø BSP F (“) T&P Connection Ø BSP F (“) T&P Press. Set. (bar) 3bar Exp. Relief Set. (bar) Dimensions Cylinder Height (A, mm) 1030 1190 1310...
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Page 22: Solar Technical Specification
Solar Technical Specification 30º 30º Boiler Return Cold Water Inlet Aquastat Pocket Boiler Flow Incoloy Immersion (fact. fitted) 10 Secondary Return 13 T&P Relief Valve 14 Hot Water Draw Off 15 Solar Sensor 16 Solar / Boiler Flow 17 Solar / Boiler Return www.bssindustrial.co.uk... - Page 23 Connection Sizes & Safety Hot & Cold Conn. Ø (mm) Primary Coil Connection Ø (mm) Solar Coil Connection Ø (mm) Secondary Return Ø BSP F (“) T&P Connection Ø BSP F (“) 0.75 0.75 T&P Press. Set. (bar) 3bar Exp. Relief Set. (bar) Dimesions Cylinder Height (A, mm) 1310...
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Page 24: Plumbing G3 Unvented Kit
Plumbing G3 Unvented Kit All unvented cylinders must have full G3 kit as supplied with cylinder installed correctly Inlet Control Group Valve must be fitted on incoming cold feed within 3m of cylinder Potable Expansion Vessel must be fitted on cold feed between Inlet Valve and cylinder Tundish... -
Page 25: Testing
Testing Do not connect a 6kW Immersion without using a relay switch. 20 Amp Fused 2-pole Isolating Switch 230V AC ~50Hz Standard Immersion 20 Amp Fused 2-pole Isolating Switch 230V AC ~50Hz Smart Immersion Fitting The Immersion Heater Always check the immersion for signs of leakage before wiring commences. The immersion heater must be completely submerged in water with a minimum of 200mm of water above the top of the immersion. - Page 26 Smart Immersion Functions On the new Smart Immersion we have four setting options: • ECO – smart control: starts for 2 weeks at 70°C and then it will select automatically storage • temperatures through the day MANUAL – works as standard mechanical thermostat can be set up to 70°C •...
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Page 27: Immersion Installation
Immersion Installation Check your mains power voltage matches the voltage rating indicated on the label of the plastic terminal cover. The immersion heater must be fixed to the cylinder using the gasket provided. Please ensure that the unit is not over tightened into the tank boss. Silicon sealant on the gasket is recommended. This heater should only be installed in systems where the element is always below water level, such as a cistern fed tank. - Page 28 uce limestone deposit (Not lower tors (live and neutral) by a single Immersion Installation events excessive temperatures. In evice will act to limit the water tat. Knob setting position tly then we recommend to consult The Thermowatt TMEC-2 Electronic Thermostat has 5 operating modes, and is supplied set to rmostat may need to be replaced.
- Page 29 the most efficient use of electricity. In the event of any power loss the thermostat will lose all recorded Electrical Connections data, and will restart learning mode. Antibacterial mode will function. NOTE: Changing thermostat setting from the factory pre-set position may impact upon the efficiency rating of the cylinder in which it is fitted. This unit should be connected by a suitably qualified electrician in accordance with the latest I.E.E.
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Page 30: Cylinder Schematic S-Plan
Cylinder Schematic Mechanical Diagram S-Plan Cold Main Hot Water Outlet Balanced Cold Connection High Limit Stat Dual Stat Boiler Prim. Flow Boiler Prim. Return Secondary Return Bronze Pump (not supplied) Non Return Valve (not supplied) Inlet Control Group Temperature & Pressure Relief Valve Isolation Valve (not supplied) Exp. -
Page 31: Cylinder Schematic Y-Plan
Cylinder Schematic Electrical Diagram S-Plan Boss Direct / Indirect Installation Guide... - Page 32 Cylinder Schematic Mechanical Diagram Y-Plan Cold Main Hot Water Outlet Balanced Cold Connection High Limit Stat Dual Stat Boiler Prim. Flow Boiler Prim. Return Secondary Return Bronze Pump (not supplied) Non Return Valve (not supplied) Inlet Control Group Temperature & Pressure Relief Valve Isolation Valve (not supplied) Exp.
- Page 33 Cylinder Schematic Electrical Diagram Y-Plan Boss Direct / Indirect Installation Guide...
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Page 34: Electronic Controls
Electronic Controls Electrical Controls Suitable time and temperature controls should be installed to allow the cylinder to operate at it’s maximum efficiency. All electrical work carried out must comply with IEE Wiring Regulations (BS 3456). Products must also be installed as per the regulations in G3 of the Building Regulations. A boiler interlock should be in place and is a wiring arrangement where the boiler cannot fire unless there is a demand for hot water generation. -
Page 35: Discharge Arrangement
Discharge Arrangement Discharge Pipework The inlet control group should be positioned so that the discharge from both safety valves can be combined via a 15mm end feed tee. Connect the tundish and route the discharge pipe which must be routed in accordance with Building Regulations - Part G3 of schedule 1. When operating normally water will not be discharged. - Page 36 Discharge Arrangement Examples Of Acceptable Dischargement Arrangements Ideally below the fixed grating and above the water seal in a trapped gulley. Downward discharges at a low level; i.e. up to 100mm above external surfaces such as car parks, hard standings, grassed areas etc. are acceptable providing that where children play or otherwise come into contact with discharges, a wire cage or similar guard is positioned to prevent contact whilst maintaining visibility.
- Page 37 Safety Device (temperature relief valve) Metal discharge pipe (D2) from temperature relief valve to tundish Tundish Minimum 300mm Discharge below fixed grating (Building Regulation G3 section 3.61 gives alternative points to of discharge) Metal discharge pipe (D2) from tundish, with continuous fall. (See Building Regulation G3 section 3.56, Table 1 and Fixed Grating...
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Page 38: Commissioning
Commissioning Filling First you must ensure that the pressure in the expansion vessel is the same as the setting of the pressure reducing valve i.e. 3 bar (45PSI). The valve is of the Schrader car tyre type. Check all the connections for water tightness including any factory made connections such as the immersion heater and the temperature and pressure relief valve. -
Page 39: Maintenance
Maintenance General Servicing should only be carried out by competent installers and any spare parts used must be purchased from BSS. Never bypass any safety devices or operate the unit without them being fully operational Draining Switch the electrical power off (important to avoid damage to element). Isolate boiler from the unit. Turn off the cold water supply valve. - Page 40 Immersion Heater Replacement If the thermal cut out on the Immersion heater operates contact a competent installer. If the thermal cut out fault occurs again the immersion will need to be replaced. Prior to installing the replacement Immersion, ensure the o-ring is correctly positioned on the head of the Immersion and lubricate the threads before fitting.
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Page 41: Taking The Cylinder Out Of Use
Taking The Cylinder Out Of Use Shutting Down • Ensure the cold water supply is isolated and at least two hot water draw off points are open prior to draining the cylinder. • One of the hot water draw off points should be as close as possible to the height of cylinder in draw off terms. -
Page 42: Troubleshooting
Troubleshooting Your stainless system is automatic in normal use and requires only annual servicing. You should employ a competent installer to perform the annual servicing. Normally this is timed to coincide with the annual boiler service. If water is flowing from the safety valves through the tundish this indicates a fault condition and action is needed. - Page 43 Fault Possible Cause Solution Water escaping from the Compression fitting on hot - Check / remake joint sealing paste. case unit. draw off not sealing. Cold water at hot tops. Immersion heater not switched Check / reset. on or cutout has triggered. Indirect - Boiler not working.
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Page 44: Benchmark Checklist
Mains Pressure Direct & Indirect Benchmark Checklist www.bssindustrial.co.uk... - Page 45 Water Storage System Commisioning Boss Direct / Indirect Installation Guide...
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Page 46: Service Record
Service Record It is recommended that your hot water system is serviced regularly and that the apprepriate Service Record’s completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions. -
Page 47: Notes
Notes Boss Direct / Indirect Installation Guide... - Page 48 The BSS Group Ltd BOSS™ Court, 7 Barton Close, Enderby, Leicester LE19 1SJ BSS-DID-INS-006-10-2017 www.bssindustrial.co.uk...
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