BOSCH WP 180 P1 Heat Pump Storage Installation Guide

BOSCH WP 180 P1 Heat Pump Storage

Product Information

• Product Name : Stora
• Model Numbers : WP 180 P1 / WP 300 KP1

Product Usage Instructions

Installation and Maintenance

• Refer to the installation and maintenance instructions provided in the user manual for qualified persons.
• Ensure that the installation is carried out by a qualified specialist.
• Follow the guidelines and recommendations for proper maintenance.

Notices for the Operator

• The operator should refer to the notices section in the user manual.
• Adhere to the instructions and warnings provided.
• Ensure proper understanding of the operation and safety precautions.

Water Parameters

• Measure and monitor the following water parameters
• pH: Maintain a range between 6.5 and 9.5
• ppm CaCO3: Ensure levels are above 36
• grain/US gallon : Maintain levels above 2.1
• S/cm : Maintain levels above 2

Other Instructions

• Refer to sections 6, 7, 8, and 9 in the user manual for additional instructions and guidelines.
• For specific scenarios or troubleshooting, refer to the relevant sections in the manual.

Please consult the complete user manual for detailed instructions and information.

Explanation of symbols and safety instructions

Explanation of symbols

Warnings
In warnings, signal words at the beginning of a warning are used to indicate the type and seriousness of the ensuing risk if measures for minimizing danger are not taken.
The following signal words are defined and can be used in this document

DANGER
DANGER indicates that severe or life-threatening personal injury will occur.

WARNING
WARNING indicates that severe to life-threatening personal injury may occur.

CAUTION
CAUTION indicates that minor to medium personal injury may occur.

NOTICE
NOTICE indicates that material damage may occur.

Important information
The info symbol indicates important information where there is no risk to people or property.

Additional symbols

General safety instructions

Installation, commissioning, maintenance

• Installation, commissioning and maintenance may be performed only by an approved contractor.
• Install and commission cylinders and their accessories according to the relevant installation instructions.
• To reduce oxygen permeation and therefore corrosion to a minimum, do not use vapour-permeable components! Never use open, vented expansion vessels.
• Never close the pressure relief valve.
• Use only original spare parts.

Notices for the target group
These installation instructions are intended for gas, plumbing, heating and electrical contractors. All instructions must be observed. Failure to comply with instructions may result in material damage and personal injury, including danger to life.

• Read the installation, service and commissioning instructions (heat source, heating controller, pumps, etc.) before installation.
• Observe the safety instructions and warnings.
• Follow national and regional regulations, technical regulations and guidelines.
• Record all work carried out.

Handover to the user
When handing over, instruct the user how to operate the heating system and inform the user about its operating conditions.

• Explain how to operate the heating system and draw the user’s attention to any safety relevant action.
• In particular, point out the following
  • Alterations and repairs must only be carried out by an approved contractor.
  • Safe and environmentally compatible operation requires inspection at least once a year and responsive cleaning and maintenance.
• Point out the possible consequences (personal injury, including danger to life or material damage) of non-existent or improper inspection, cleaning and maintenance.
• Point out the dangers of carbon monoxide (CO) and recommend the use of CO detectors.
• Leave the installation instructions and the operating instructions with the user for safekeeping.

Notices for the operator

About this chapter
This chapter and the chapter “Data Protection Notice” contains important information and notices for the operator of the system. All other chapters are intended exclusively for the qualified person for water installations, heating and electrical engineering.

Safety instructions
The following notices must be observed. Failure to comply may result in material damage and personal injury, including danger to life.

• The cylinder, the connection technology and the piping may be very hot. These parts can therefore inflict burns. Keep small children in particular away from these parts.
• Have the cylinder inspected by a contractor annually and maintained at regular intervals. We recommend concluding a maintenance and inspection contract with an approved contractor.
• Only have the assembly, maintenance, conversion or repairs carried out by an approved contractor.
• Operating instructions for the operator are enclosed with the heating system.
• Also observe the notices in these instructions!
• Keep installation instructions in a safe place.

Product information

Intended use

• Enamelled DHW cylinders (cylinders) are designed for heating and storing potable water. Please observe the applicable country-specific regulations, guidelines and standards for potable water.
• Only install the enamelled DHW cylinder (cylinder) in sealed unvented DHW heating systems.
• All other use is considered unsuitable. Any damage that results from such use is excluded from liability.

Scope of delivery

• Domestic hot water cylinder
• Technical documentation
• The cylinder is delivered fully assembled.
• Check that the cylinder is complete and undamaged.

Product description

Table 3 Product description (Fig. 1, page 65/Fig. 10, page 67)

Type plate

Table 4 Type plate

Technical data

| Unit| WP 180 P1 B| WP 300 KP1 B
---|---|---|---
Dimensions and specifications| –| à Fig. 2,

page 65

| à Fig. 2,

page 65

Pressure drop diagram| –| à Fig. 3/ 3, page 66| à Fig. 3/ 3, page 66
General information|
Tilt height| mm| 1343| 1951
Minimum room height for anode replacement| mm| 2100| 2100
Connection size, DHW| DN| R1″| R1″
Connection size, cold water| DN| R1″| R1″
Connection size, circulation| DN| R¾ “| R¾ “
Temperature sensor inner diameter| mm| 19.5| 19.5
Inside diameter of handhole| mm| 120| 120
Cylinder capacity|
Useful capacity (overall)| l| 173.5| 290.0
Cylinder capacity V40 according to EN16147| l| 286| 489
Standby heat loss in accordance with DIN 4753 part 81)| kWh/ 24 h| 1.15| 1.52
Maximum flow rate at cold water inlet| L/min| 14.5| 20.1
Maximum DHW temperature| °C| 95| 95
Maximum operating pressure, potable water| bar (posit ive)| 10| 10
Heat exchanger|
Content| l| 11.5| 11.5
Surface area| m2| 1.69| 1.69
Rating code NL according to DIN 47082)| NL| 1.6| 8
Continuous output (at 80 °C flow temperature, 45 °C DHW outlet temperature and 10 °C cold water temperature)| kW l/h| 46.4

1140

| 45.1

1108

Heating water volumetric flow rate| l/h| 2600| 2600
Heat-up time at 12 kW constant, temperature difference 5 K from 35 °C to 60 °C| min| 44| 63
Maximum heating water temperature| °C| 95| 95
Maximum heating water operating pressure| bar (posit ive)| 10| 10
Connection size, heating water| DN| R1″| R1″

1. Excluding distribution losses outside the cylinder.
2. Rating code NL =1 according to DIN 4708 for 3.5 persons, standard bath tub and kitchen sink.
   • ` Temperatures: cylinder 60 °C, DHW outlet temperature 45 °C and cold water 10 °C. Measured at max. heat output. If the heat output is reduced, NL becomes smaller.

Table 5 Technical data

Product data for energy consumption
The following product data satisfy the requirements of the EU Regulations No. 812/2013 and No. 814/2013 supplementing EU Ordinance 2017/1369.
Manufacturers who implement these guidelines and state the ErP values are permitted to use the “CE” mark.

Product number| Product type| Cylinder volume (V)| Heat retention loss (S)| Energy efficiency class for DHW

treatment

---|---|---|---|---
7735502481| WP 180 P1 B| 173,5 l| 48,1 W| B
7735502482| WP 300 KP1 B| 290,0 l| 63,5 W| B

Table 6 Product data for energy consumption

Regulations
Observe the following guidelines and standards

• Local regulations
• EnEG (Building Regulations) (in Germany)
• EnEV (Energy Savings Order) (in Germany)
• Installation of, and equipment for, heating and water heating systems
• DIN and EN standards
• DIN 4753-1 – Water heaters …; requirements, identification, equipment and testing
• DIN 4753-3 – Water heaters …; corrosion protection on the water side with glass lining; requirements and testing (product standard)
  • DIN 4753-7 – Water heaters, containers with a volume up to 1000 l, manufacturing, thermal insulation and corrosion protection requirements
  • DIN EN 12897 – Water supply – regulation for … DHW cylinders (product standard)
  • DIN 1988-100 – Technical rules for potable water installations
  • DIN EN 1717 – Protection of potable water against pollution …
  • DIN EN 806-5 – Technical rules for potable water installations
  • DIN 4708 – Central water heating systems
  • EN 12975 – Thermal solar systems and their components (collectors)
• DVGW
  • Code of Practise W 551 – Potable water heating systems and pipework; technical measures to inhibit the growth of legionella bacteria in new systems; …
  • Code of Practise W 553 – Sizing DHW circulation systems …

Product data for energy consumption

• EU Regulation and Directives
  • EU Regulation 2017/1369
  • EU Regulation 812/2013 and 814/2013 Standards and guidelines applicable for France
• Regulation for installation and maintenance in residential buildings
  • Health regulation of the department
  • Standard NF C 15-100 – Electrical low-voltage installation – Regulations
  • Standard NF EN 60-335/1 – Safety of electrical appliances for domestic use and similar purposes
  • Standard NF EN 41-221 – Copper pipes – Cold water and hot water distribution, disposal of waste water and rain water, HVAC technology (formerly DTU 60.5)
• Standard NF P 40-201 – Sanitary engineering for residential buildings (formerly DTU 60.1)
• Standard NF EN 1717 – Protection of internal potable water systems against pollution and general requirements for devices that prevent pollution of potable water due to flow-back
  • Ordinance of 23 June 1978, amended ordinance of 30 November 2005 on heating systems, DHW supply, regulations for installation and safety – In particular, it must be ensured that the maximum DHW temperature is adhered to.
  • Ordinance of the Ministry of Health on the protection of potable water – The filling system of the installation must be equipped with a separation system, approved materials and accessories must be used for potable water (ACS certification in France).

Transport

WARNING
Risk of injury from carrying heavy loads and inadequately securing loads for transport!

• Use suitable means of transport.
• Secure the cylinder to prevent it falling.
• Move packed cylinder with a sack truck and lashing strap (Fig. 5, page 66).
• Move unpacked cylinder with a transport net, during handling, protect connections against possible damage.

Mounting method

Installation location

NOTICE
Risk of damage from inadequate load-bearing capacity of the installation surface or unsuitable floor surface!

• Ensure that the installation surface is level and offers sufficient load-bearing capacity.
• Install the cylinder in a dry frost-free interior.
• If there is any danger of water accumulating on the floor of the installation location : place the cylinder on a plinth.
• Observe the minimum wall clearances inside the installation room ( Fig. 4, page 66).

Setting up the cylinder

• Remove packaging.
• Remove protective caps.
• Set up and align the cylinder ( Fig. 7/ 8 page 67).
• Apply Teflon tape or Teflon string. ( Fig. 9, page 67).

Hydraulic connections

WARNING
Risk of fire from soldering and welding!

• Take appropriate safety measures when soldering and welding as theca thermal insulation is combustible (e.g. cover thermal insulation).
• Check cylinder jacket for damage after completing work.

WARNING
Risk of injury from contaminated water!
Work carried out without due care for cleanliness pollutes the water.

• Install and equip the cylinder hygienically in accordance with national standards and guidelines.

Establishing the hydraulic connection to the cylinder System schematics with all recommended valves in the graphic part Fig. 10, page 67)

• Use installation material that is temperature-resistant up to 130°C (260°F).
• Never use open, vented expansion vessels.
• Use metal connection fittings in DHW heating systems with plastic lines.
• Size the drain line in accordance with the connection.
• To facilitate debris removal, never install elbows in the drain line.
• Keep primary line as short as possible and insulate it.
• If using a non-return valve in the cold water supply: Install a pressure relief valve between the non-return valve and cold water inlet.
• Install a pressure reducer in the cold water pipe if the static pressure in the system is in excess of 5 bar.
• Seal all unused connections.

Installing a pressure-relief valve

• Install a pressure-relief valve that is approved for potable water (≥ DN 20) in the cold water supply ( Fig. 10, page 67).
• Observe the pressure relief valve installation instructions.
• Terminate the discharge pipe where it will be easily visible in the frost-proof area via a dewatering point.
  • The discharge pipe must be at least equal to the outlet cross-section of the pressure relief valve.
  • The discharge pipe must be able to discharge at least the volumetric flow rate that could possibly arise at the cold water inlet ( Tab. 5).
• Attach a notice with the following text to the pressure relief valv e: “Never close the discharge pipe. During heating, water may be discharged for operational reasons.”

If the static system pressure exceeds 80 % of the pressure relief valve excess pressure

Install a pressure reducer upstream (Fig. 10, page 67).

Gas supply pressure

(static pressure)

| Pressure relief valve excess pressure| Pressure reducer
---|---|---
In the EU + CH| Outside the EU
< 4.8 bar| ≥ 6 bar| Not required| Not required
5 bar| 6 bar| ≤ 4.8 bar| ≤ 4.8 bar
5 bar| ≥ 8 bar| Not required| Not required
6 bar| ≥ 8 bar| ≤ 5 bar| Not required
7.8 bar| 10 bar| ≤ 5 bar| Not required

Table 7 Selection of a suitable pressure reducer

Temperature sensor
Mount a temperature sensor for measuring and monitoring the water temperature. Number and position of the temperature sensor (sensor pocket), see process description, Tab. 3.

Fit the temperature sensor (Fig. 11, page 68).
To ensure good thermal contact, ensure that the sensor surface has contact with the sensor pocket surface over its full length.

Commissioning

DANGER
Danger of cylinder damage through positive pressure!

Positive pressure can result in stress cracks in the glass lining.

• Never close the discharge pipe of the pressure relief valve.
• Before connecting the cylinder, carry out a tightness test on the water lines. Commission the wall mounted boiler, assemblies and accessories according to the manufacturer’s notices and the technical documentation.

Commissioning the cylinder

CAUTION
Health risk from contaminated potable water!

Before filling the cylinder

• Rinse any contamination out of the pipework and the cylinder.
• Fill the cylinder free of air whilst a DHW draw-off point is fully open, until clear water flows steadily from it.
• Carry out tightness test.

Only perform the tightness test of the cylinder using potable water. On the DHW side, the test pressure must not exceed 10 bar positive pressure.

Setting the cylinder temperature

• Set the required cylinder temperature in accordance with the operating instructions of the wall mounted boiler, taking the risk of scalding at the DHW draw-off points into consideration (Chapter 7.2).

Instructions for the user

WARNING
Risk of scalding at the DHW draw-off points!

• Depending on the system and operating conditions (thermal disinfection) there is a risk of scalding at the DHW draw-off points in DHW mode.
• Installation of a thermal mixer is prescribed when setting a DHW temperature above 60 °C.

Advise users that they should draw off only mixed water.

• Explain the operation and handling of the heating system and cylinder, making a particular point of safety-relevant features.
• Explain the function and how to check the pressure relief valve.
• Hand all enclosed documents over to the user.

Highlight the following for the user

• Setting the DHW temperature.
  • Water may be discharged from the pressure relief valve when heating-up.
  • Always keep discharge pipe for pressure-relief valve open.
  • Comply with maintenance intervals ( Chapter 10.3).
  • Where there is a risk of frost and when the operator is briefly away: Keep the heating system in operation and set the lowest possible DHW temperature.

Shutdown

• If an immersion heater has been installed (accessory), isolate the cylinder from the power supply.
• Switch off the temperature controller at the control unit.

WARNING

Risk of scalding from hot water!

Hot water can cause serious burns.

• Allow the cylinder to cool down sufficiently.
• Drain the cylinder ( Fig. 17 / 16, page 69).

Use the nearest water taps to the cylinder for this.

• Decommission all assemblies and accessories of the heating system according to the manufacturer’s notes in the technical documentation.
• Close the shut-off valves (Fig. 17, page 69).
• Depressurise the heat exchanger.
• Drain and blow out the heat exchanger (Fig. 18, page 69).

To prevent corrosion

• Leave the cover of the inspection aperture open to allow the interior to dry completely.

Environmental protection and disposal

• Environmental protection is a fundamental corporate strategy of the Bosch Group.
• The quality of our products, their economy and environmental safety are all of equal importance to us and all environmental protection legislation and regulations are strictly observed.
• We use the best possible technology and materials for protecting the environment taking account of economic considerations.

Packaging
Where packaging is concerned, we participate in country-specific recycling processes that ensure optimum recycling.
All of our packaging materials are environmentally compatible and can be recycled.

Used appliances
Used appliances contain valuable materials that can be recycled.
The various assemblies can be easily dismantled. Synthetic materials are marked accordingly. Assemblies can therefore be sorted by composition and passed on for recycling or disposal.

Inspection and maintenance

WARNING
Risk of scalding from hot water!

Hot water can cause serious burns.

• Allow the cylinder to cool down sufficiently.
• Allow the cylinder to cool down sufficiently before carrying out any maintenance.
• Carry out cleaning and maintenance procedures in the specified intervals.
• Remedy all faults immediately.
• Only use genuine spare parts!

Inspection
An inspection/check of the cylinders must be carried out every 2 months in accordance with DIN EN 806-5. During this the set temperature should be checked and compared with the actual temperature of the heated water.

Maintenance

• Annual maintenance should be carried out in accordance with
• DIN EN 806-5, Appendix A, tab. A1, line 42.

This includes the following work

• Function check of the pressure-relief valve
• Tightness test of all connections
• Cleaning of the cylinder
• Checking of the anode

Maintenance intervals

• The maintenance to be carried out depends on the flow rate, operating temperature and water hardness ( Tab. 8). We recommend the maintenance intervals specified in tab. 8 which are based on many years of experience.
• The use of chlorinated potable water or a water softener unit reduces the maintenance intervals.
• You can check the water quality with your water supply utility.
• Depending on the composition of the water, it can make sense to deviate from the reference values listed.

At a normal flow rate ( < cylinder content/24 h)
< 60 °C| 24| 21| 15
60…70 °C| 21| 18| 12

70 °C| 15| 12| 6
At an increased flow rate ( > cylinder content/24 h)
< 60 °C| 21| 18| 12
60…70 °C| 18| 15| 9
70 °C| 12| 9| 6

Table 8 Maintenance intervals in months

Maintenance work

Testing the pressure relief valve

Check the pressure relief valve annually.

Descaling and cleaning
In order to improve the cleaning effect, heat up the heat exchanger prior to cleaning it with a water jet. The thermal shock effect separates deposits (e.g. limescale) more readily.

• Isolate the cylinder from the piping on the domestic water side.
• Close the shut-off valves and isolate the immersion heater (if used) from the mains power supply. (Fig. 17, page 69).
• Drain the cylinder ( Fig. 16, page 69).
• Open the inspection aperture on the cylinder.
• Check the interior of the cylinder for pollution.

In the case of soft water
Check the container regularly and clean to remove limescale.

• In the case of hard water or severe pollution: Regularly descale the cylinder in line with the actual amount of limescale using chemical cleaning methods (e.g. with a suitable descaling agent based on citric acid).
• Hose down the inside of the cylinder ( Fig. 20, page 70).
• Use a wet & dry vacuum cleaner with plastic suction hose to remove the residues.
• Close the inspection aperture with a new gasket ( Fig. 21, page 70).

Checking the magnesium anode

• Failure to service the magnesium anode properly voids the warranty for the cylinder.
• Failure to service the magnesium anode properly voids the warranty for the cylinder.
• A non-insulated magnesium anode (Variant A, Fig. 25, page 71).
• An insulated magnesium anode ( Variant B, Fig. 25, page 71).

We recommend that insulated magnesium anodes are additionally checked regarding the protection current using an anode tester on an annual basis ( Fig. 25, page 71). The anode tester is available as an accessory.

NOTICE

Corrosion damage!
If the anode is neglected, this could lead to premature corrosion.

Inspect the anode every one or two years, depending on the on-site water quality, replace if required.

Never bring the magnesium anode surface into contact with oil or grease.

• Keep everything clean.
• Shut off the cold water inlet.
• Depressurise the cylinder ( Fig. 16, page 69).
• Remove and test the magnesium anode (Fig. 24 to Fig. 24, page 71).
• Replace the magnesium anode if its diameter has been reduced to less than 15 mm.
• If the magnesium anode is insulated: check the transfer resistance between the protective conductor connection and the magnesium anode. If the anode current is <0.3 mA, replace the magnesium anode ( Fig. 25, page 71).

Recommissioning

• Flush the cylinder thoroughly after cleaning or repair.
• Vent on the heating side and on the domestic water side.

Function check

NOTICE

Damage through positive pressure.
A pressure-relief valve malfunction can result in damage due to positive pressure.

• Check the pressure-relief valve function and flush through several times by venting.
• Never close the blow-off opening of the pressure-relief valve.

Checklist for maintenance
Fill out the report and note the tasks performed.

| Date| | | | | | |
---|---|---|---|---|---|---|---|---
1| Check the function of the pressure-relief valve| | | | | | |
2| Check tightness of connections| | | | | | |
3| Descale/clean the inside of the cylinder| | | | | | |
4| Signature Stamp| | | | | | |

Table 9 Checklist for inspection and maintenance

Data Protection Notice

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References

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