Bosch AGS10-2, Installation And Servicing Instructions

Page 1: ...Installation and servicing instructions Solar pump station for solar thermal systems AGS10 2 AGS10E 2 AGS20 2 AGS50 2 6 720 811 270 2015 04 UK ...

Page 2: ...t NOTICE indicates a situation that could result in damage to property or equipment CAUTION indicates a situation that could result in minor to medium injury WARNING indicates a situation that could result in severe injury or death DANGERindicatesa situation that will result insevereinjury or death Important information Additional symbols 1 2 General safety instructions Mounting Installation and m...

Page 3: ...sulation part forwards Fig 1 Fig 2 Single and twin line solar pump stations without front insulation parts and without integral controllers and modules 1 Ball valve with thermometer red flow1 blue return and integrated check valve position 0 normal running 45 check valve bypassed 2 Compression fitting 3 Pressure relief valve 4 Pressure gauge 5 Connection for expansion vessel 6 Drain fill valve DFV...

Page 4: ...5x185x180 Flow and return connections compression fittings mm 15 22 15 22 Table 2 Specifications of AGS10 2 and AGS10E 2 AGS20 2 AGS50 2 Maximum possible temperature C Flow 130 return 110 pump Safety valve response pressure bar 6 6 Pressure relief valve DN 15 connection DN 20 1 connection Mains voltage 230V AC 50 60 Hz 230V AC 50 60 Hz Maximum current consumption per pump A 0 7 A EEI 0 2 1 0 A EEI...

Page 5: ...ble controllers Solar pump stations may only be installed vertically Fig 3 and indoors The AGS solar pump stations must only be operated with propylene glycol water mixtures heat transfer medium L or LS The use of any other heat transfer medium is not permitted 2 3 Components and technical documentation A solar thermal system is designed to heat domestic hot water DHW and can also provide central ...

Page 6: ...on to the usual tools a 13 mm socket with a 150 mm extension is required for the installation work 2 7 Air vent valve Alwaysprovide an automatic air ventvalveoneachrow ofcollectorsfor the following systems connected in parallel 1 System with more than two collector rows 2 System with AGS50 solar pump station Solar Lifestyle Solar Lito flat plate collectors The solar system is ventilated through on...

Page 7: ...or domestic use within buildings and their curtilages Installations should be made in accordance to the relevant MCS Solar standards if the homeowner is applying for RHI 4 Installing pipework 4 1 General information regarding pipework NOTICE System damage through faulty parts Only use materials which are resistant to glycol pressure and heat at least up to 150 C Do not use plastic pipes e g polyet...

Page 8: ...nstalled underneath the collectors e g in the case of attic installations Form a pipe trough with the flow in order to prevent overheating in such systems Firstly route the flow to the height of collector return connection 2 Then route it to the solar pump station Fig 10 Connecting pipework Copper pipes must only be soldered with brazing solder i e no low temperature soldering or Use glycol and he...

Page 9: ...der 2 Solar station 3 Expansion vessel 4 Drip pan 5 2 Mounting the solar pump station Use a socket 13 mm with a 150 mm extension to screw in the screws Withshorterextensions thehandlesandtemperaturegauges 3 canbe pulled forwards and removed for easier access to the screws Single line solar pump station Drill hole and fix solar pump station using rawl plug and screw supplied 1 2 Twin line solar pum...

Page 10: ...site Fig 15 Installing the pre cooling vessel 1 Flexible stainless steel hose from the connection set for the expansion vessel available as accessory 2 Safety assembly provided by installer 3 Pre cooling vessel 4 Pipe clip on site 5 Expansion vessel 5 5 2 Installing the solar expansion vessel available as an accessory Install the expansion vessel with the mounting materials provided Never turn off...

Page 11: ...intotheholdingcontainer 4 and secure it in place with a pipe clip 3 Maintain an air break Fig 17 Connection to solar pump station 1 Compression joints on all four outlets 2 Discharge pipe not supplied 3 Pipe clip on site 4 Empty solar fluid container holding container 5 Connection bracing points The pre charge pressure of the expansion vessel is calculated based on the static system head1 plus an ...

Page 12: ...g heat transfer medium available as an accessory 6 2 Purging and filling with a hand pump air vent on roof 7747006489 19 2ST 5 2 4 1 3 2 NOTICE Collector damage through evaporation in the solar circuit or frozen water Flushandfillthesolarsystemonlywhenthesunisnot shining on the collectors and if flushing with water no frost is expected When filling with heat transfer medium take the additional vol...

Page 13: ...he solar thermal system is vented by opening the plug screw 2 on the automatic air vent valve Open the ball valve 2 Unscrew the plug screw 1 one turn Fig 21 Opening the air vent valve 1 Shut off screw 2 Ball valve Set the ball valves 1 on the thermometers to 45 and open the flow limiter 2 and other shut off devices Carry out a tightness test observing the permissible pressures for all assemblies A...

Page 14: ...ystemintooperation theoperatingpressuremustbe 0 7 bar above the static pressure 1 metre difference in height equals 0 1 bar The system pressure must be at least 1 5 bar when cold 20 C If there is not enough pressure pump in more heat transfer medium Once ventilation is complete close the ball valve 2 of the air vent and the plug screw 1 Fig 25 Closing the air vent and ball valve The pipes must be ...

Page 15: ...th speed control or if speed control has been deactivated the flow rate must be set to a fixed flow rate If you wish to set the flow rate 1 Carry out the preparatory work Chapter 6 3 1 2 Check the flow rate Chapter 6 3 2 3 Set the flow rate Chapter 6 3 3 6 3 1 Carrying out the preparatory work Rotate ball valves 1 to 0 check valves ready for operation Completely open the flow limiter 2 On the cont...

Page 16: ... flow rate depending on the type 4 Ventilation at the air separator If the pre set flow rate is not reached at the pump s highest speed stage Check maximum permitted pipe lengths and sizing Chapter 4 1 If necessary install a more powerful solar pump Quantity Flat plate l min1 1 Nominal flow rate per collector 50 l h Evacuated tube l min2 2 Nominal flow rate per collector 30 l h 1 1 0 5 0 6 2 1 5 2...

Page 17: ...est possible technology and materials for protecting the environment taking into account of economic considerations Packaging Weparticipateintherecyclingprogrammesofthecountriesinwhichour products are sold to ensure optimum recycling All of our packaging materials are environmentally friendly and can be recycled Old appliance Old appliances contain materials that must be recycled The relevant asse...

Page 18: ...fill out log DANGER Risk to life by falling from roof Whilst working on the roof take all necessary precautions against a possible fall If there are no general anti fall safety devices available wear personal protective equipment DANGER Danger to life through electric shock Before carrying out work on electrical components isolatethemfromthepowersupply 230 VAC fuse circuit breaker and secure again...

Page 19: ...EHHQ WWHG RU KDV 7PD EHHQ OLPLWHG WR Û Yes No KDW W SH RI VFDOH UHGXFHU KDV EHHQ WWHG Air purged from solar primary circuit Yes 3ULPDU FLUFXLW YDOYHV DQG DLU YHQW V VHW WR QDO RSHUDWLQJ SRVLWLRQV Yes Pump speed setting recorded Speed setting 0D ÀRZ UDWH litres min Solar primary circuit pressure relief valves tested for correct operation Yes RFDWLRQ HYLFH IRU OLPLWLQJ KRW ZDWHU WHPSHUDWXUH RXWOHWV ...

Page 20: ...20 Commissioning inspection and maintenance reports AGS10 2 AGS10E 2 AGS20 2 AGS50 2 6 720 811 270 2015 04 ...

Page 21: ...k flow and return installed and earthed 8 2 Pipework flushed and tightness test carried out 13 3 Air vent closed 14 4 Charge pressure of the expansion vessel checked 11 ____ bar 5 Solar system verified to be free of air 14 6 pH level of heat transfer fluid checked Replace heat transfer fluid if value is 7 heat transfer fluid coloured brown strong odour 1 7 Frost protection to _______ C checked and...

Page 22: ...eactivation temperature difference of solar pump ΔT pump 2 checked and entered here _ K _ K _ K _ K _ K _ K _ K _ K _ K _ K 4 Temperature indicated by all temperature sensors resistances checked 5 Temperature sensors correctly positioned insulated and connected 6 Maximum cylinder temperature Tmax for solar storage cylinder 1 checked and entered here ____ C ____ C ____ C ___ C ___ C Maximum cylinde...

Page 23: ...structed in the applicable operating instructions maximum 60 C Check that backup heating is functioning properly Temperature differences in solar circuit are too high flow temperature is too high high collector temperature reached too quickly Solar yield too low or system damage Faulty temperature sensor or controller malfunction Check temperature sensor and settings of controller Air in the syste...

Page 24: ...in the case of ventilated collectors Clean ventilation openings System performance is falling Solar yield too low Collectors are under shade Remove shade Air in the system Bleed or purge the system Pump is running at decreased power Check the pump Heat exchanger dirty calcified Wash decalcify the heat exchanger Collector glazing is very dirty Clean the collector glazing with a glass cleaning agent...

Page 25: ... 25 6 720 811 270 2015 04 AGS10 2 AGS10E 2 AGS20 2 AGS50 2 Notes ...

Page 26: ...26 AGS10 2 AGS10E 2 AGS20 2 AGS50 2 6 720 811 270 2015 04 Notes ...

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