Bosch TSS Series User manual

6720887696 (2018/05) KE
Installation and maintenance instructions for specialists
Thermosiphon system, flat roof installation
TSS
TSS150-2E/FCC-2, TSS200-2E/FCC-2, TSS300-2E/FCC-2

Table of contents
TSS – 6720887696 (2018/05)
2
Table of contents
1 Explanation of symbols and safety instructions . . . . . . . . . . . 3
1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . 3
2 Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Supplied parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Product data for energy consumption. . . . . . . . . . . . . . . 8
2.3 Performance data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Selecting the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7 Recommendations for energy savings . . . . . . . . . . . . . . 9
2.8 Declaration of conformity (collector) . . . . . . . . . . . . . . . 9
3 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . .10
4.2 Determining the space required . . . . . . . . . . . . . . . . . .10
4.3 Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Fitting the WSF flat roof frame . . . . . . . . . . . . . . . . . . . . . . . . 12
6.1 Installing angle profiles . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.2 Fitting flat profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.3 Installing the profile rails . . . . . . . . . . . . . . . . . . . . . . . . 14
6.4 Installing accessories for higher loads . . . . . . . . . . . . . 15
6.5 Making the roof connection. . . . . . . . . . . . . . . . . . . . . .15
7 Installing the MTSS flat roof frame . . . . . . . . . . . . . . . . . . . . . 16
7.1 Installing the wind cross on the supports . . . . . . . . . . .16
7.2 Installing angle profiles with 2 collectors . . . . . . . . . . .16
7.3 Fitting upper clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.4 Fitting base bracket and lower clamps . . . . . . . . . . . . . 17
8 Installing the collectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8.1 Preparing the collector installation . . . . . . . . . . . . . . . .18
8.2 Installing collectors, WSF . . . . . . . . . . . . . . . . . . . . . . . 19
8.2.1 Installing the collector clamp on the right side. . . . . . . 19
8.2.2 Place first collector on the profile rail . . . . . . . . . . . . . . 19
8.2.3 Inserting the double-sided collector clamp . . . . . . . . . 19
8.2.4 Placing the second collector on the profile rails. . . . . .19
8.2.5 Installing the collector clamp on the left. . . . . . . . . . . . 20
8.3 Installing collectors, MTSS . . . . . . . . . . . . . . . . . . . . . . 20
8.3.1 Installing the collector . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.3.2 Installing the second collector. . . . . . . . . . . . . . . . . . . . 20
8.3.3 Making the roof connection. . . . . . . . . . . . . . . . . . . . . . 21
9 Installing the storage tank . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
10 Hydraulic connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10.1 Connecting the flow pipe. . . . . . . . . . . . . . . . . . . . . . . . 23
10.2 Connecting the return pipe . . . . . . . . . . . . . . . . . . . . . .23
10.3 Connecting potable water pipe . . . . . . . . . . . . . . . . . . . 24
11 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
11.1 Lightning protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
11.2 Filling the potable water circuit. . . . . . . . . . . . . . . . . . . 26
11.3 Filling the solar circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 26
11.4 Carrying out checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
11.5 Insulating the connection lines and pipework . . . . . . . 27
12 Environmental protection, shutdown, disposal . . . . . . . . . . 27
12.1 Environmental protection and disposal . . . . . . . . . . . . 27
12.2 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
13 Maintenance, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Explanation of symbols and safety instructions
3
TSS – 6720887696 (2018/05)
1 Explanation of symbols and safety instructions
1.1 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
minimising 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
Table 1
1.2 General safety instructions
HNotice for the target group
These installation instructions are intended for
competent persons who are skilled in dealing with
water installations, heating and electrical systems.
▶ Read the installation instructions before starting
the installation.
▶ Observe the safety and warning instructions.
▶ Observe national and regional regulations,
technical rules and guidelines.
▶ Document all work performed.
HIntended 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.
HRisk of scalding at the DHW draw-off points
▶ In order to avoid scalding a mixer must be installed
in the DHW system that restricts the DHW
temperature to 60 °C. If in doubt, ask the specialist.
HLoad bearing capacity of the roof
▶ Only install the product on roofs with sufficient load
bearing capacity.
▶ If in doubt, consult a structural engineer and/or
roofer.
HStoring the components
The supplied components may cause burns when
exposed to solar radiation.
▶ Protect the components from solar exposure. Wear
personal protective equipment.
▶ Store the collectors in dry conditions. If stored
outside, use a rain cover.
▶ Do not stand on the collectors.
HWorking on the roof
There is a danger of falling when working on the roof if
measures are not taken to prevent accidents.
▶ If there is no independent anti-fall safety device,
wear personal protective equipment or safety
equipment.
▶ Observe accident prevention regulations.
Symbol Meaning
▶ a step in an action sequence
a reference to a related part in the document
• a list entry
– a list entry (second level)

Product Information
TSS – 6720887696 (2018/05)
4
HImmersion heater (accessory)
If the storage tank is not filled with potable water and
an immersion heater is connected, it can be damaged
(due to superheating and a short circuit).
▶ Only connect an immersion heater when the
storage tank is filled with potable water.
HHandover to the user
When handing over the thermal solar system, explain
the operation and operating conditions to the user.
▶ Explain operation – with particular emphasis on all
safety-related actions.
▶ If an immersion heater is used, advise the user on
energy-saving operation.
▶ 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 over the installation and operating
instructions to the user for safekeeping.
2 Product Information
The heat transfer medium circulating through different densities heats
the potable water in the storage tank.
The thermosiphon systems differ in the following:
• Number of collectors
• Size of the storage tanks
• Installation system
Fig. 1 WSF installation system
Fig. 2 MTSS installation system
These instructions show only the WSF installation system. If the
installation varies for the MTSS system, this is indicated in the text.
0010015018-01
A
TSS150
TSS200
TSS300
TSS150
TSS200
0010016146-01
TSS300

Product Information
5
TSS – 6720887696 (2018/05)
2.1 Supplied parts
▶ Check that the delivery is complete and undamaged.
WSF installation set for flat roof frame
Fig. 3 WSF installation set for flat roof
Table 2 Installation set WSF2 (for 1 collector)
Table 3 Installation set WSF3 (expansion for the second collector)
0010014861-01
3
4
1
4
2
13 12 11
10
9
8
7
650 mm
40
2050 mm
1380 mm
670 mm
30
2215 mm
1 2
34
35°
5
6
5
No. Component Number
1 Angle profile 2050 mm 2
2 Flat profile 670 mm 2
3 Flat profile 650 mm 2
4 Angle profile 1380 mm 4
5 Angle profile 2215 mm 2
6 Storage tank protection adhesive strip 2
7 Flat profile (wind brace) 2
8 Nut M8 27
9 Oval head screw M8 × 20 27
10 Profile rail1)
1) The profile rail in the installation set is an expansion for system TSS300
2
11 Single-sided collector clamp 4
12 Anti-slip protection 2
No. Component Number
1 Angle profile 2050 mm 1
2 Flat profile 670 mm 1
3 Flat profile 650 mm 1
4 Angle profile 1380 mm 2
5 Angle profile 2215 mm 1
6 Storage tank protection adhesive strip 1
7 Flat profile (wind brace) 2
8 Nut M8 16
9 Oval head screw M8 × 20 16
10 Profile rail 2
12 Anti-slip protection 2
13 Double-sided collector clamp 2

Product Information
TSS – 6720887696 (2018/05)
6
MTSS installation set for flat roof frame
Fig. 4 MTSS installation set for flat roof
Table 4 Installation set MTSS1 (1 collector)
Table 5 Installation set MTSS2 (2 collectors)
0010016135-02
M8x20
M8x35
1
2
4
6
7
8
9
10
5
12
11
3
No. Component Number
1 Left storage tank brace 1
2 Flat profile for wind brace 4
3 Right storage tank brace 1
4 Right base support 1
5 Left base support 1
6 Storage tank protection adhesive strip 2
7 Nut M8 14
8 Clamp 4
9 Oval head screw M8 × 35 4
10 Flat washer 24
11 Hexagon bolt M8 × 20 10
No. Component Number
1 Left storage tank brace 1
2 Flat profile for wind brace 4
3 Right storage tank brace 1
4 Right base support 2
5 Left base support 2
6 Storage tank protection adhesive strip 2
7 Nut M8 22
8 Clamp 8
9 Oval head screw M8 × 35 8
10 Flat washer 36
11 Hexagon bolt M8 × 20 14
12 Angle profile 2

Product Information
7
TSS – 6720887696 (2018/05)
Connection set
Fig. 5 Connection set
Table 6 Connection set
Memory
Fig. 6 Storage tank for thermosiphon system
Table 7 Storage tank for thermosiphon system
14
13
11
2
10 8 7 6
5
1
3 4
1
0010015800-01
9
12
No. Component Numb
er
1 Solar hose (TSS150/300: 3.3 m / TSS200: 2.9 m) 1
2 Return pipe bracket 1
3 Cap ½" 1
4 Gasket 24 × 17 2
5 Angled ferrule G1xD21 1
6 Clamping washer 1
7 Nut G1 1
8 Solar hose, 97 mm (TSS300) 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
No. Component
1 Connection G½for solar pressure relief valve
2 Filler Solar G½
3 Integrated nuts for handle accessories
4 Data plate position
5 Handhole cover
6 Cold water connection G½
7 Solar return connection G¾
8 Domestic hot water connection G½
9 Solar flow connection G¾
0010014993-01
7
4
68
9
1 2
5
3

Product Information
TSS – 6720887696 (2018/05)
8
Collector
Fig. 7 Collector
Table 8 Collector
2.2 Product data for energy consumption
Detailed information about energy consumption can be found on our
website.
2.3 Performance data
Table 9 Calculated annual result, location: Athens
For an optimal cost/benefit ratio, we recommend solar coverage of
60-75 %.
2.4 Selecting the system
Fig. 8 Recommendation: selection of the thermosiphon system
according to daily DHW consumption
2.5 Specifications
Table 10 Collector
Table 11 Memory
Table 12 Entire thermosiphon system
No. Component
1 Flow connection
2 Return connection
3 Data plate position
System Daily water consumption (litres/day)
110 l 140 l 170 l 200 l 250 l 300 l 400 l
QdkWh/y annual heat demand
1270 1621 1962 2313 2891 3469 4625
QLkWh/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
TSS300 90 87 84 80 75 64
0010014994-01
1
2
2
1
3
0010015998-01
0010015998-01
TSS150
TSS200
TSS300
45°C
110 - 170 l/d
140 - 200 l/d
TSS...
200 - 350 l/d
+
FCC-2
Certificate: CE marking, Solar Keymark register
no. 011-7S2181 F
Length mm 2025
Width mm 1030
Height mm 67
Clearance between collectors mm 69
Collector connection (in the shape of a ferrule) mm 23
Absorber capacity (VF) l 0.8
Total collector area (gross area, AG) m22.09
Absorber surface area (net area, AA)m
21.92
Aperture area (area on which the usable sunlight
falls, Aa)
m21.94
Net weight excluding packaging (mc)kg30
Permissible collector operating pressure bar 6
150 l 200 l 300 l
Weight, empty (mTank)kg617596
Weight, filled kg 215 275 384
Primary circuit contents
(heat transfer medium VF)
l 4 5.2 7.5
Secondary circuit contents
(potable water VW)
l 145 195 280
Max. operating pressure, primary
circuit (pF)
bar 2.5
Max. operating pressure, secondary
circuit (pW)
bar 8
Max. temperature, primary circuit °C 110
Max. temperature, secondary circuit °C 95
Heat loss W/K 1.44 1.61 2.57
Insulation mm 50
Diameter mm 580
Width mm 1100 1350 1820
150 200 300
Certificate: Solar Keymark, register
no. 011-7S2816 A
Total weight, filled (approximate) kg 290 340 510

Product Information
9
TSS – 6720887696 (2018/05)
2.6 Intended use
The installation system is intended solely for the secure mounting of
collectors and the storage tank. The collector angle of inclination is 35°.
It can be used on a roof with a maximum slope of 15°.
▶ Never modify components.
▶ Do not damage the roof or building structure.
Mount the installation system parallel to the roof, as described in these
instructions.
▶ Do not raise the installation system on-site in order to increase the
solar yields. The additional solar yields are minimal.
Fig. 9 Pay attention to the permissible roof inclination and positioning
Permissible heat transfer medium
▶ To protect the collectors against damage through frost and corrosion,
operate them with solar heat transfer medium L (70 % water, 30 %
propylene glycol).
▶ If water is used as a heat transfer medium, the following prerequisites
must be fulfilled:
– Continuous ambient temperatures above 5 °C.
– Closed circuit. This prevents the introduction of oxygen. In the
event of a pressure drop, remedy the fault immediately.
– Have the water checked (table).
Table 13 Limits for water as a heat transfer medium:
1) c (HCO3–) = concentration of hydrogen carbonate ions (unit: m mol/l)
c (SO42–) = concentrate of sulphate ions (unit: m mol/l)
Permissible loads
▶ Only install collectors in locations with values lower than those shown
in the following. If required, consult a structural engineer.
The following loads refer to a system with a filled storage tank.
▶ Fill the storage tank immediately after installation!
Table 14 Maximum loads with reference to DIN EN 1991, parts 3 and 4,
roof slope 0 - 15 °
When determining the maximum wind speed, take the following factors
into account:
• Location of the thermal solar system
• Geographical height of the terrain
• Topography (terrain/buildings)
• Height of building
The maximum snow load is calculated using regional zones (snow load
zones) and the ground level elevation.
▶ Enquire about the locally applicable snow loads.
Corrosion protection
All supplied components are protected against corrosion through either
the material (e.g. aluminium, plastic) or coatings.
▶ Only use materials on site that can withstand local weather
conditions.
▶ Immediately repair any possible damage to the coating on site.
The potable water area in the storage tank is protected against corrosion
through enamel coating and a magnesium anode. To maintain this
protection:
▶ Observe the maintenance intervals and instructions in the
"Maintenance, inspection" section.
2.7 Recommendations for energy savings
▶ Install the DHW mixing valve as close as possible to the storage tank
(section "Hydraulic connection" for system examples).
▶ When using an immersion heater:
– Only connect the immersion heater to the mains power supply
when insufficient solar exposure is expected (e.g. during winter,
at night).
– Disconnect the immersion heater from the mains power supply
when solar exposure is sufficient or during absences
(e.g. holidays).
– Use a timer or similar to ensure appropriate use of the immersion
heater.
– Set the temperature as low as possible.
▶ To be able to use as much solar-heated water as possible, draw hot
water only after the sun has peaked (midday).
▶ Connect dishwashers and washing machines (if suitable) to the DHW
pipe and where possible use these between 15:00 and 18:00.
▶ Position the thermosiphon system so that the DHW pipe is as short as
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.
You can request the declaration of conformity of the product. For this see
the contact address on the back cover of these instructions.
Parameter Value
pH value 7.5 - 9
Electrical conductivity 100 - 1500 microS/cm
Carbonate hardness and
sulphate1)
Chloride content maximum 30 mg/l
0010015324-010010015324-01
35°
<15°
Installation
system
Maximumsnowload
on the ground1)
1) according to DIN EN 1991-1-3
Maximum wind speed
according to DIN EN 1991-1-4
WSF < 1 kN/m2< 129 km/h (corresponds to a
dynamic pressure of 0.8 kN/m2)
WSF2)
2) With accessories for higher loads
< 1 kN/m2< 151 km/h (corresponds to a
dynamic pressure of 1.1 kN/m2)
MTSS -- < 129 km/h (corresponds to a
dynamic pressure of 0.8 kN/m2)

Regulations
TSS – 6720887696 (2018/05)
10
3 Regulations
▶ Observe updated regulations or supplements. These regulations also
apply at the time of installation.
▶ Observe all standards and guidelines applicable to the installation
and operation of the system in your country and region.
Technical regulations applicable for the installation of collectors
• Rooftop installation:
– DIN EN 1991: Actions on structures
• Connection of thermal solar systems:
– EN 12976: Thermal solar systems and components
(factory-made systems)
– EN 12977: Thermal solar systems and components
(custom-built systems)
• Electrical connection:
– DIN EN 62305 Part 3 / VDE 0185-305-3: Protection against
lightning, physical damage to structures and life hazard
Technical rules for the installation of DHW cylinders
• DIN EN 12897: Water supply – specification for storage water
heaters (product standard)
• DIN EN 1717: Protection against pollution of potable water installations
• DIN EN 806: Technical rules for potable water installations
4 Before installation
4.1 General information
CAUTION:
Risk of burning from hot components!
The collector and installation materials can become very hot after being
exposed to solar radiation for prolonged periods of time.
▶ Wear personal protective equipment.
▶ Protect the collector and installation material from solar exposure.
We recommend that you engage the services of a roofing contractor, as
they are experienced in working on roofs and will be aware of the risk of
falling.
▶ Obtain information about on-site conditions and local regulations.
▶ Avoid potential shading.
▶ Align the collectors towards the south, where possible.
Fig. 10 Optimal alignment of the collectors and loss of solar yields in
case of deviations in % (location: Athens)
Height differentials in roofs
Where there are height differentials in the roof, snow loads must be
prevented from sliding down from a roof pitch of > 15°. The length of
the additional load through sliding snow loads results from the height
differential: ls= 2 × h
▶ Avoid installing collectors within the ls area below height differentials
In case of installation below a height differential:
▶ Fit a snow guard to the higher roof area.
Fig. 11 Collector arrangement with height differentials
[1] Additional loads through sliding snow
[2] Standard snow load
4.2 Determining the space required
WARNING:
Risk to life from incorrectly installed collectors!
Wind loads are especially high at the edges of the roof.
▶ Maintain the minimum clearance to the edge of the roof and roof
structures.
The clearances to be maintained to the edge of the roof and to the roof
structures can be found in DIN EN 1991-1-4 and the Code of Practice 61
of the BDH (Federal Association of the German Heating Industry).
Fig. 12 Observe the minimum clearances (a, b)
0010015520-02
N
S
W
0%
-5%
E
-20%
-17%
-3%
0010014998-01
0010014936-01
d1
d2
l1
l2
b
hA
<d2
d1
≤
d1
3 x h d13 x h
a = 0,15 x
a
d1
≤
1 m
ha = 0,45 x
a
≤
0,04 x d1
a
≤
1 m
2
b = 0,5 x l2
2
+
b = hA
l1
<

Transport
11
TSS – 6720887696 (2018/05)
▶ For the pipes on the right and left of the collector array, allow an extra
0.5 m on either side.
▶ Allow sufficient space for maintenance and repair work at a later date.
Fig. 13 WSF dimensions (value in brackets: TSS150/200)
Fig. 14 MTSS dimensions (value in brackets: TSS150/200)
4.3 Required tools
Installation set:
• Allen key, 5 mm, with rounding
• Spanner 13 mm
Connection set:
• Spanner 27, 30 and 37 mm
5 Transport
WARNING:
Risk to life from falling from roof!
▶ Never use a ladder to move components to the roof because the
installation material and collectors are heavy and difficult to handle.
▶ Whilst 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.
▶ Lift and carry the device with a sufficient number of persons.
- or -
▶ Use suitable means of transportation, (e. g. a pallet truck, hand truck
with strap).
▶ Secure the appliance to prevent it slipping, tilting and falling.
All packaging materials used are environmentally friendly and reusable.
▶ Dispose of shipping packaging by environmentally compatible means.
▶ To make it easier to transport the components, you can use the
following aids, which have sufficient load-bearing capacity:
– Lifting/transportation devices as used by professional roofers
– Handles for the storage tank (accessories)
– Lifting belt
– 3-point suction lift
– Roofing ladder or equipment for sweeping chimneys
Transporting the collector
DANGER:
Risk to life from falling load.
▶Never use the collector connections as lifting points!
▶ Collectors must always be carried by two people.
Fig. 15 Do not place any load on collector connections
Fig. 16 Only remove caps once on the roof
[1] Caps on the collector connection
0010014937-01
[mm]
1675
2365
2140 (1345)
0010016184-01
1690
2445
2140 (1345)
[mm]
0010015284-01
0010015285-01

Fitting the WSF flat roof frame
TSS – 6720887696 (2018/05)
12
Transporting the storage tank
If you want to place the storage tank on level ground:
▶ Lay the storage tank on the styrofoam panel [1] of the packaging.
Fig. 17 Lay the storage tank on the styrofoam panel
To protect the storage tank during transport:
▶ Do not remove the DHW cylinder from its packaging until it has
reached the installation location.
▶ Position the hand truck at the side of the DHW cylinder with the
styrofoam panel.
▶ Secure the DHW cylinder to the means of transportation with a strap.
▶ Transport the DHW cylinder to the installation location.
▶ Remove the DHW cylinder from the packaging only at the installation
location.
Fig. 18 Transporting the storage tank with hand truck
6 Fitting the WSF flat roof frame
WARNING:
Risk to life from falling from roof!
▶ Whilst 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.
NOTICE:
Damage to the roof from incorrect form of stabilisation!
▶ Consider the roof statics when selecting the form of stabilisation.
NOTICE:
Roof leaks from damaged roof membrane!
▶ Lay out standard protective building mats to protect the roof
membrane.
▶ Lay profiles and installation material only on these protective
building mats.
To facilitate installation, first tighten all screws by hand.
6.1 Installing angle profiles
For a system with a collector, the triangles A and B are required. The only
difference between the triangles is the mirror-image arrangement of the
profiles. For two collectors, a second triangle A is required.
Fig. 19 Three triangles for two collectors
Fig. 20 Arrangement of the triangles on the systems
0010015281-01
1
0010015282-01
0010014818-01
A
B
A
0010014819-01
A
B
A
BA
TSS150
TSS200
TSS300

Fitting the WSF flat roof frame
13
TSS – 6720887696 (2018/05)
To facilitate installation, first tighten all screws by hand.
1. Screw profiles 1380 mm to profile 2215 mm.
2. Screw profiles 1380 mm together in the centre.
Fig. 21 Fitting cross on profile 2215 mm (triangle A)
3. Screw profile 2050 mm to the top of the cross.
4. Screw profile 2050 mm at the bottom to profile 2215 mm.
Fig. 22 Fitting profile 2050
▶ Screw triangle B with the same profiles, in mirror-image to triangle A.
Fig. 23 Fitting triangle B
▶ TSS300: Fit another triangle A.
6.2 Fitting flat profiles
▶ Screw flat profile 650 mm to profiles 1380 mm and 2050 mm.
Fig. 24 Fitting flat profile 650 mm
0010014817-01
M8x20
2215
1380
1380
[mm]
A
1.
2.
0010014820-01
2050
A
[mm]
3.
4.
0010014821-01
B
0010014822-01
A
B
A
[mm]
650

Fitting the WSF flat roof frame
TSS – 6720887696 (2018/05)
14
▶ Screw flat profiles 1650/1570 mm together to form a wind cross.
Fig. 25 Screwing flat profiles together to form a wind cross
▶ Screw the top of the wind cross along with the storage tank support
(profile 670 mm) to the profile 1380 mm [1]. The screw head points
to where the storage tank will be installed later (arrow).
▶ Mount the bottom of the wind cross to profile 1380 mm [2].
Fig. 26 Installing the wind cross
Fig. 27 Fitting wind cross for the second collector (TSS300)
6.3 Installing the profile rails
▶ Align the angle profiles 2215 mm at the bottom so they are parallel to
each other.
▶ Place the profile rails in the centre and screw them together.
▶ Tighten all screw connections of the angle, flat and U profiles
(corresponds to approx. 15 Nm).
Fig. 28 Installing the upper and lower profile rails
The triangles above the elongated holes mark the position of the anti-slip
protectors.
▶ Push the anti-slip protector down over the profile rail and let it click
into the slot.
Fig. 29 Installing anti-slip brackets on the lower profile rails
[1] Lower profile rail for two collectors
[2] Lower profile rail for one collector
0010014823-01
x
x
x = 1650
x = 1570
0010014824-01
B
A
1
1
2
2
0010014825-01
A
A
B
1
1
2
2
0010014826-01
=
=
=
0010014827-01
1
2
click!

Fitting the WSF flat roof frame
15
TSS – 6720887696 (2018/05)
6.4 Installing accessories for higher loads
▶ Screw the angle profiles 680 mm [2] to the profiles 2050 mm
and 2215 mm.
▶ Place the profile rails [1] in the centre and screw them together.
Fig. 30 Installing accessories for higher loads
6.5 Making the roof connection
▶ Design the substructure and fastenings according to the table to
ensure that the system can withstand the wind forces that occur.
Table 15 Values for the required stabilisation of the system
A base anchor or ballast troughs (only TSS150/200) can be used to
create the roof connection for stabilisation of thermosiphon system.
Base anchor
The base anchor can be created through a substructure provided by the
customer (e.g. l-beam) or direct connection to the roof.
▶ Design the on-site substructure so that the collectors can withstand
the wind forces affecting them.
▶ Transfer the hole dimensions to the l-beams and drill the necessary
holes.
▶ Fasten each angle profile 2215 mm at the bottom with 3 screws,
washers and nuts, to be provided by the customer.
Fig. 31 Example: Installing angle profiles on l-beams
[1] Protective building mat
Ballast troughs
▶ Insert 4 ballast troughs into angle profiles.
▶ Place ballast (concrete slabs, gravel, etc) into the ballast troughs.
Weight "Values for the required stabilisation of the system" table.
Fig. 32 Inserting ballast troughs
[1] Angle profile
[2] Ballast trough
[3] Hook ballast troughs into each other
[4] Protective building mat
Wind speed Base anchor Weight in ballast troughs
(minimum weight)
102 km/h 3 x M8/8.8 (per
triangle)
100 kg per collector
129 km/h 150 kg per collector
151 km/h --
0010014828-01
2
1
0010014830-02
1272 330
950
1
0010014831-02
4

Installing the MTSS flat roof frame
TSS – 6720887696 (2018/05)
16
7 Installing the MTSS flat roof frame
WARNING:
Risk to life from falling from roof!
▶ Whilst 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.
NOTICE:
Damage to the roof from incorrect form of stabilisation!
▶ Consider the roof statics when selecting the form of stabilisation.
NOTICE:
Roof leaks from damaged roof membrane!
▶ Lay out standard protective building mats to protect the roof
membrane.
▶ Lay profiles and installation material only on these protective
building mats.
To facilitate installation, first tighten all screws by hand.
7.1 Installing the wind cross on the supports
▶ Screw flat profiles together to form a wind cross.
Fig. 33 Screwing flat profiles together
Two positions are possible for installing the wind cross on the assembly
stand.
Fig. 34 Lower wind cross fastening position
▶ Install wind cross with hexagon bolts and washers on the assembly
stand.
Fig. 35 Installing the wind cross (here: TSS200)
7.2 Installing angle profiles with 2 collectors
1. Slide the angle profiles into each other.
2. Screw the angle profiles together with hexagon bolts,
washers and nuts.
Fig. 36 Pre-assemble angle profiles
0010016137-01
M8x20
0010016136-01
TSS200
TSS150
TSS300
0010016138-01
0010016139-02
1.
2.

Installing the MTSS flat roof frame
17
TSS – 6720887696 (2018/05)
1. Slide up angle profiles.
2. Screw angle profiles to the assembly stand.
Fig. 37 Fastening connected angle profiles to the assembly stand
7.3 Fitting upper clamps
Only slightly tighten the screw connections, so that the collector can still
be installed.
▶ When there is one collector, screw clamps directly onto the assembly
stand using an oval head screw (arrow).
Fig. 38 MTSS1: Screw clamps directly onto the assembly stand
▶ When there are two collectors, fit clamps to the angle profile using an
oval head screw (arrow).
Fig. 39 MTSS2: Screwing clamps onto angle profiles
7.4 Fitting base bracket and lower clamps
▶ Fit the base bracket so that
– the collector sits at the bottom of the base bracket profile [1] and
– the clamp grips the side of the collector edge [2].
▶ Tighten all screw connections (corresponds to approx. 15 Nm).
Fig. 40 Fitting the base bracket
0010016140-01
1.
2.
0010016152-01
0010016141-01
0010016142-02
2 x 4 x
1
2

Installing the collectors
TSS – 6720887696 (2018/05)
18
8 Installing the collectors
WARNING:
Risk to life from falling from roof!
▶ Installation of the collectors on the roof must be performed by at least
2 people.
WARNING:
Risk of injury from falling parts!
▶ During transport, secure the collectors and installation material to
prevent them from falling.
▶ After completing installation, check that the installation set and
collectors are securely positioned.
Important information on handling solar hoses
CAUTION:
Risk of injury from tightened circlip prior to installation!
▶ Tighten the circlip only after the hose clip has been placed over the
solar hose.
The solar hoses [2] are secured with the hose clip [1] by tightening the
circlip [3].
Fig. 41 Securing solar hoses (here: with plugs)
NOTICE:
Leaks at the collector connection!
Subsequent loosening of the hose clip can impair its tensioning capacity.
▶ Push the hose clip immediately in front of the bead of the collector
connection. Only then should the circlip be tightened.
Fig. 42 Move hose clip without locking ring
NOTICE:
Leaks from the solar hose!
To make installation easier, we recommend placing the solar hoses in hot
water before installation.
▶ Do not use lubricants containing mineral oil (such as thread sealing
compound).
8.1 Preparing the collector installation
CAUTION:
Risk of injury and leaks from escaping solar heat transfer medium as
a result of unsecured solar hoses.
▶ Secure every solar hose to the collector connection using a hose clip.
▶ Rotate the collector so that the black sensor well [1] is always at the
top of the collector frame. The sensor well has no function.
Fitting the plug
▶ Push the solar hoses [2] with pre-assembled plugs onto the available
collector connections.
▶ Tighten the circlip when hose clip [3] is located directly in front
of the bead.
Fig. 43 Fitting the plug
0010014490-01
0010014055-001
0010015571-01
55
3
AB

Installing the collectors
19
TSS – 6720887696 (2018/05)
Installing connection set for 2 collectors
The first collector is installed on the right (A). Then the collector is
installed on the left (B).
▶ Push solar hose [2] with hose clips onto the collector connection of
the collector on the left side.
▶ Tighten the circlip when hose clip [1] is located directly in front of the
bead.
Fig. 44 Installing the connection set on the collector on the left side
8.2 Installing collectors, WSF
8.2.1 Installing the collector clamp on the right side
▶ Slide the one-sided collector clamp into the profile rail and let it click
into the slot (only on the right; the left side is done later).
Fig. 45 Installing the collector clamp on the right side
8.2.2 Place first collector on the profile rail
WARNING:
Risk of injury from falling collectors.
▶ Ensure that the collector profile engages in the anti-slip protector.
▶ Place the collector on the right onto the profile rails and allow it to
slide into the anti-slip protector.
Fig. 46 Let the collector on the right slide into the anti-slip protectors
▶ Carefully push the collector up against the collector clamp and level
horizontally.
▶ Tighten the screw of the collector clamp.
Fig. 47 Tightening the screw of the collector clamp
If only one collector is installed, then install the collector clamp on the left.
8.2.3 Inserting the double-sided collector clamp
If two collectors are installed:
▶ Place the double-sided collector clamp on the profile rail and push up
to the collector. Do not tighten yet.
Fig. 48 Only insert a double-sided collector clamp
8.2.4 Placing the second collector on the profile rails
▶ Place second collector along with the pre-assembled solar hoses
onto the profile rails and let it slide into the anti-slip protectors.
▶ Push the second hose clip [1] onto the solar hoses.
▶ Push the collector up to the first collector so that the solar hoses are
pushed onto the collector connections.
Fig. 49 Push the left collector to the right collector
0010014492-01
97
B
0010014493-01
0010014494-01
0010014495-01
A
0010014496-01
0010014497-01

Installing the collectors
TSS – 6720887696 (2018/05)
20
▶ Tighten the screw of the double-sided collector clamp [1].
Fig. 50 Double-sided collector clamp
CAUTION:
Risk of injury and leaks from escaping solar heat transfer medium as
a result of unsecured solar hoses.
▶ Secure every solar hose to the collector connection using a hose clip.
▶ Tighten the circlip when the hose clip is located directly in front of the
bead.
Fig. 51 Fully assembled connection hose
8.2.5 Installing the collector clamp on the left
▶ Push the collector clamp into the profile rail and let it click
into the slot.
▶ Tighten the screw of the collector clamp.
Fig. 52 Installing the collector clamp on the left
8.3 Installing collectors, MTSS
8.3.1 Installing the collector
▶ MTSS1: Lay the collector in the centre at the top and screw to the
assembly stand using both clamps [1].
▶ MTSS2: Put the first collector on the top right of the stand and slide it
to the end of the angle profile [2]. Then screw down using both
clamps [1].
Fig. 53 Securing the collector at the top
8.3.2 Installing the second collector
▶ Place the second collector on the assembly stand.
▶ Push the second hose clip [2] onto the solar hoses.
To push the second collector to the first:
▶ Hold the first collector in place [1].
▶ Push the collector up to the first collector so that the solar hoses are
pushed onto the collector connections [3].
Fig. 54 Collectors should be installed by two people
0010014498-01
0010014499-01
0010014500-01
0010016143-01
2 x 4 x
1
2
0 mm
0010016241-01
2
1
3