BSS Audio BOSS 100 Instruction Manual

Boss Direct / Indirect Installation Guide
1
Direct, Indirect & Solar
Unvented Cylinder
Installation & Maintenance Manual
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COMMISSIONING
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BSS-DID-INS-006-10-2017

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2
Warranty Card
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Homeowner
Name
Address
Contact Tel.
Contact Email
Installer
Name
Address
Contact Tel.
Contact Email
Product Product
Installed
Serial Number Installation
Date
Cylinder Located on
cylinder badge
I accept the terms and conditions in the installation manual
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TO COMPLETE WARRANTY

Boss Direct / Indirect Installation Guide
3
BSS Product Warranty Terms & Conditions
BSS BOSS™
The BSS BOSS™ stainless steel vessel carries a
fully transferable 25-year guarantee against faulty
materials or manufacture provided that:
• It has been installed in the United Kingdom
or the Republic of Ireland as per the
instructions provided in the installation
manual provided with the cylinder and in
accordance with all of the relevant standards,
regulations and codes of practice in force at
the time.
• It has not been modied in any way, other than
by BSS
• It has not been misused, tampered with or
subjected to neglect.
• The system is fed from the public mains water
supply.
• It has only been used for the storage of
portable water.
• It has not been subjected to frost damage.
• The unit has been serviced annually.
• The Service Log Book has been completed
after each annual service.
• The warranty card is lled in and a copy is
sent by email to [email protected]
Exclusions
The guarantee does not cover cylinders aected
by the following;
• The eects of scale build up on the cylinder.
•
Any consequential losses caused by the failure
or malfunction of the unit.
Please note that invoices for servicing may be
requested to prove that the unit has been serviced
annually.
Unvented Kit & Other Components
The BOSS™ 25-year warranty covers BOSS™
cylinders installed in domestic properties against
corrosion for a period of 25 years from the date of
purchase. All other components, including valves,
expansion vessels, immersion heaters, ttings and
controls are covered by a two year warranty from
the date of purchase of the BOSS™ product which
includes one year’s parts and labour and one year
parts only.
Warning To The User
• Do not remove or adjust any part of this
unvented water heater.
• If the unvented water heater develop fault, such
as a ow of water from the discharge pipe
switch the heater o.
• In all cases contact a competent installer.
• The Benchmark Log Book at the end of the
manual must be lled in at annual service.
Warning To The Installer
• Read the installation instructions before
commencing.
• Unvented water heaters are a controlled
service as dened in the latest edition of the
Building Regulations and should only be
tted by a competent installer.
• The installation is subject to approval.
• You must notify the local authority of intention
to install.
• After installation the instructions manual must
be completed and left with the householder.
• Use only manufacturer’s recommended
replacement parts.
Installed by
Installer
Name
Address
Contact Tel.
Completion
Date

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Boss Direct / Indirect Installation Guide
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Table Of Contents
6 Introduction
10 General Requirements
14 Unvented Kit Components
15 Unvented Kit Checklist
16 ErP Product Fiche Information
17 Technical Data
18 Indirect Technical Specication
20 Direct Technical Specication
22 Solar Technical Specication
24 Plumbing G3 Unvented Kit
25 Testing
26 Smart Control Immersion Setup
27 Immersion Installation
30 Cylinder Schematic S-Plan
32 Cylinder Schematic Y-Plan
34 Electronic Controls
35 Discharge Arrangement
38 Commissioning
39 Maintenance
41 Taking The Cylinder Out Of Use
42 Troubleshooting
44 Benchmark Checklist
46 Service Record
47 Notes
NEW

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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. These instructions consist of details for installation, servicing, fault nding and
replacement of parts for the cylinder purchased.
BSS will not accept any liability in the event of damage for not complying with the guidance in this
instruction manual.
The instructions for this installation manual apply to the range of BSS BOSS™ Unvented Cylinders.
Safety is paramount when installing unvented hot water systems and the following instructions must
be adhered to:
• Only certied competant installers can install, commission and service the equipment supplied.
• The cylinder must be used for potable hot water only. Any other applications will be considered
incorrect use and BSS will not be held liable for any losses resulting from such use.
• All installation and maintenance instructions must be observed to ensure the correct operation of
the equipment.
• The electric immersion must not be switched on unless the cylinder is completely full of water.
• Domestic hot water may be stored at temperatures exceeding 60°C. Preventative measures
should be put in place to negate the possibility of scalding.
• A maintenance schedule should be put in place with a competent person to service the equipment
annually to comply with the warranty conditions.
• When servicing the system the mains supply to the cylinder should be isolated.
•
Only genuine spare parts should be used. A full list of items with relevant codes can be found on page 14.
The installation must be carried out by a person competent to install unvented hot water systems.
The installation must be carried out in accordance with the following recommendations:
All current Building Regulations issued by the Department of the Environment, i.e. Building Regulation
G3 (England and Wales), Technical Standard P3 (Scotland) or Building Regulation P5 (Northern Ireland)
and the Water Fitting Regulations (England and Wales) or Water Byelaws (Scotland). The installation
should also be in accordance with the following British Standard Codes of Practice:
BS 5449:1990 Forced circulation hot water systems
BS 5546:2000 Installation of hot water supplies for domestic purposes
BS 5918:1989 Solar heating systems for domestic hot water
BS 6700:2006 Design, installation, testing and maintenance of services supplying water.
Failure to install this appliance correctly could lead to prosecution and will invalidate the guarantee.
It is in your own interest and that of safety to ensure that the law is complied with.

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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.
• Packaging should only be removed at the installation location.
• The cylinder must be installed on a level oor with the required load bearing capability. Installation,
servicing, maintenance and repair must be carried out by a competent person.
• All electrical wiring must be carried out by a qualied electrician and be installed in accordance
with current I.E.E Wiring Regulations.
• A lack of safety devices can lead to potentially fatal injuries, all necessary safety devices must
be installed correctly in the system. The use of an electric immersion may lead to the build up of
electrical potential in the water. This can in turn cause corrosion of the immersion. To prevent this,
ensure the immersion heater, and the hot and cold pipework are correctly bonded and connected
to the earth line.
•
If plastic pipes are used they must be approved temperature resistant to 95°C at a pressure of 10bar.
A thermostatic mixer should be installed in the system to prevent the risk of scalding. If there are leaks
found in the system, shut o the cold water stop valve from the main supply and contact a competent
person immediately. Also ensure to isolate the power going to any immersions tted to the cylinder
What Is Benchmark?
Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that
customers are provided with the correct equipment for their needs, that it is installed, commissioned
and serviced in accordance with the manufacturer’s instructions by competent persons and that it
meets the requirements of the appropriate Building Regulations.
The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and
should be provided to the customer for future reference. Installers are required to carry out installation,
commissioning and servicing work in accordance with the Benchmark Code of Practice which is
available from the Heating and Hot Water Industry Council who manage and promote the scheme.
Visit www.centralheating.co.uk

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Water Supply
The performance of any unvented system is only as good as the mains water supply available. To this
eect 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. The high
quality inlet control set has been designed to make the most of the low rates available.
The water supply should be checked to ensure it can meet these requirements. If necessary, consult
the local water authority regarding the likely pressure and ow rate availability.
Consideration should be given to upgrading existing 1⁄2” (15mm) cold mains pipework to a larger
size if the recommended minimum pressure / ow rate is not being achieved. BSS recommend that
primary pipework used has a minimum diameter of 22mm to ensure low pressure loss.
A high static (no ow) mains pressure is no guarantee of good ow availability. In a
domestic installation 1.5bar and 25ltr/min should be regarded as the minimum. The
maximum mains pressure that the inlet control set can cope with is 10bar.
Change Of Water Supply
The changing or alternating from one water supply to another can have a detrimental eect on the
operation and/or life expectation of the water heater storage cylinder, pressure temperature relief
valve and heating unit.
Where there is a changeover from one water supply to another, e.g. a rainwater tank supply, bore
water supply, desalinated water supply, public reticulated water supply or water brought in from
another supply, then water chemistry information should be sought from the supplier or it should
be tested to ensure the water supply meets the requirements given in these guidelines for the BSS
warranty to apply.
Water Chemistry
This water heater must be installed in accordance with this advice to be covered by the BSS warranty.
This water heater is manufactured to suit the water conditions of most public reticulated water supplies.
However, there are some known water chemistries which can have detrimental eects on the water
heater and its operation and/or life expectancy. If you are unsure of your water chemistry, you may be
able to obtain information from your local water supply authority.

Boss Direct / Indirect Installation Guide
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Water Chemistry Levels Aecting 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
Total Hardness 200 mg/litre
Chloride 300 mg/litre
Magnesium 10 mg/litre
Calcium 20 mg/litre
Soldium 150 mg/litre
Iron 1 mg/litre
Maximum pH 9.5
Minimum pH 6.5
Total Dissolved Solids (TDS)
Some water analysis reports may state the conductivity of the water rather than the level of total
dissolved solids. Conductivity, measured in microsiemens per centimetre (μS/cm), is directly proportional
to the TDS content of the water. TDS, in mg/L, is approximately 70% of the conductivity in μS/cm.
The BSS warranty will not cover resultant faults to the storage cylinder if this water heater is connected
at anytime to a water supply where the TDS content of the water exceeds 600 mg/L. 16 In locations
where TDS approaches 600 mg/L, e.g. due to sediment, we strongly recommend tting an appropriate
lter to ensure water entering or in the water heater does not exceed this level at any time i.e. due
to sediment build up.
Features Of The Unvented Cylinder
• Made from Duplex Stainless Steel for excellent corrosion resistance.
• Strong rust-proofed steel case.
• Insulation is by means of an approved CFC/HCFC free polyurethane foam with an ozone depletion
factor of zero.
• Available in a variety of sizes to suit - 100L, 125L, 150L, 170L, 200L, 250L, 300L, 400L and 500 litres.
• All models including Solar models are available in Twin versions supplied complete with all the
necessary safety and control devices needed to connect to cold water mains
• All safety and control devices are pre-set.
• High quality controls selected that combine high ow rate performance with minimum pressure
drop which gives fantastic performance in all areas, with great improvements in areas with poor
water pressure.

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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 derence. The maximum length
of the “dead leg” should be as stated in the Water Supply (Water Fittings) Regulations 1999 G18.7,
in particular to the area of most frequent use.
Particular attention is needed if siting in a garage or outbuilding as the unit should be protected from
frost. All exposed pipework must be insulated. The unit must be installed upright on a base capable
of supporting its weight when full (please see the technical specication section for weights).
Sucient access to allow maintenance of the valves should be considered. In addition the immersion
heaters are 400mm in length and this distance should be considered to allow withdrawal for servicing
if required. The discharge pipework from the safety valves should fall continuously and terminate safely.
Negative pressure may form in cylinders installed very high in a building. To counteract this, an anti-
vacuum valve can be installed to prevent damage to the cylinder. The anti-vacuum valve ensures
pressure compensation as a result of air owing into the cylinder.
Connecting To The Cylinder
All of the pipework connections on the cylinder are compression connection and female threaded. Upon lling
and commissioning, ensure all connections are completely watertight.
No control or isolation valve should be tted between the expansion relief valve and the
storage cylinder. The relief valve connections should not be used for any other purpose.
Cold Mains Pipework
Run the cold main through the building to the place where is to be installed. Take care not to run the
cold pipe near hot water or heating pipe work so that the heat pick-up is minimized. Identify the cold
water supply pipe and t an isolating valve (not supplied). A 22mm BS1010 stopcock can typically be
used but a 22mm quarter turn full bore valve would be better as it does not restrict the ow as much.
Do not use “screwdriver slot” or similar valves.
Make the connection to the cold feed of the cylinder and incorporate a drain valve. Position the
inlet control just above the Temperature & Pressure Relief Valve (TPRV) mounted on the side of the
cylinder. This ensures that the cylinder does not have to be drained down in order to service the inlet
control set. Ensure that the arrow points in the direction of the water ow. Select a suitable position
for the expansion vessel. Mount it to the wall using the bracket provided.

Boss Direct / Indirect Installation Guide
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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. Make sure that there is
sucient space for future maintenance and also for connection of the discharge pipe for the expansion
relief valve.
It is essential that this connection is not covered or closed. The hot water expansion vessel should be
hard xed into pipework and insulated.
Hot Water Pipework
Run the rst part of the hot water distribution pipework in 22mm. This can be reduced to 15mm and
10mm as appropriate for the type of tap etc. Your aim should be to reduce the volume of the hot
draw-o pipework to a practical minimum so that the time taken for the hot water is as quick as possible.
Do not use monobloc mixer tap or showers if the balanced cold connection is not provided. Outlets
of this type can back pressurise the unit and result in discharge.
Expansion Vessel
The expansion vessel receives the increased water volume when expansion takes place as the system
heats up and it maintains a positive pressure in the system. The expansion vessel contains a exible
diaphragm, which is initially charged on one side with nitrogen, but can be topped up with air when required.
Select a suitable position for the expansion vessel. Mount it to the wall using the bracket provided
(0-24L only, 35L and above are oor standing) and hard x into pipework and insulate. Ensure that the
top of the vessel is accessible for servicing. The pipe connecting the expansion vessel to the system
should have a diameter of not less than 15mm and must not contain any restrictions.

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Prior to connecting the expansion vessel to the system the pipework should be ushed 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. The result of this is an increase in system
pressure and the safety valve will lift.
Primary Coil Connections
Connect the primary connections (Indirect only). The primary circuit must be positively pumped. Either
primary connection may be used as the primary ow. Reheat times are identical either way. The primary
circuit can be open vented or sealed, with up to a maximum pressure of 3.5 bar. If you seal the primary
circuit an additional expansion vessel and safety valve is required.
The boiler may be Gas, Electric or Oil but must be under eective thermostatic control. Uncontrolled
heat sources such as some AGA’s, back boilers, solid fuel stoves, etc. are not suitable. Please contact
our Technical department for guidance. Connect the two port zone valve (indirect only) into the primary
ow pipework. The direction of ow arrow should be towards the primary ow connection.
Installing The Two Port Motorised Valve
The function of the Two Port Motorised Valve prevents the cylinder from overheating. It can be installed
on either horizontal or vertical pipework.
If it is mounted onto horizontal pipework the valve head must face upwards. The direction of ow is
marked on the body of the valve with arrows.
Thermostatic Mixer
When installing a solar system with an unvented BSS BOSS™ twin coil cylinder, a thermostatic mixing
valve should be installed. Its function is to act as an anti-scald protection. The thermostatic mixer is
to be set to a temperature of between 30°C and 60°C and is supplied by the installer.
Secondary Circulation
On larger installations long pipe runs to draw-o points can cause signicant volumes of water to be
drawn o before an acceptable temperature can be reached. Secondary pumped circulation using
a stainless steel or a bronze pump, and combined with eective time and temperature controls can
overcome this problem. Where secondary return circulation is required the pipework should be run in
15mm pipe. A suitable WRAS approved stainless steel or bronze circulation pump must be used. A
check valve must also be installed to prevent back ow.
On large secondary circulation systems it may be necessary to incorporate an extra expansion vessel
into the circuit to accommodate the increased system water volume. Secondary circulation should be
avoided on Direct electrically heated units being used on o-peak electricity taris. It should be noted
that the use of a secondary circulation circuit can increase running costs as there will be circulation pipe
losses. High levels of insulation on secondary pipework are required to keep energy losses to a minimum.

Boss Direct / Indirect Installation Guide
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Dead Legs
The length of hot water draw o to taps and other outlets should be kept to a minimum to reduce the
amount of cold water drawn o 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. Where the dead leg length exceeds the recommended
maximum, secondary circulation should be installed. It should be controlled by a time switch and
incorporate a motorized valve that can prevent gravity circulation in the circuit.
Pipe Size (mm) Maximum Length (m)
10, 12 20
15, 22 12
28 8
35 and above 3
System Noise
Noise in pipework may occur as a result of expansion of pipework over joists or where the pipe has
been left touching other pipes or a part of the building structure. Care must be taken to ensure that
the pipework is correctly bracketed, is not in tension or compression, and does not carry the weight
of components such as a circulation pump.
Setting The Hot Water Temperature
The hot water temperature is set on the dual thermostat by the competent person during the installation.
The dual thermostat should be set to 60°C. If you are heating water in the cylinder for the rst time,
or the time controls for the DHW zone have been o for a prolonged period of time, the cylinder may
take additional time to heat up.
Inappropriate adjustments can lead to the damages in the system. If any changes are
made to the cylinder, the controls, the water and power supply lines or the expansion
relief components there is a risk of steam escaping or rupture to the system.

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34331116
34331127
34331160 34330830
34330948
34330937
34330896
19711233
19711244
19711255
34330863
34330852
34330701
Unvented Kit Components
19711436
19711266 Smart

Boss Direct / Indirect Installation Guide
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Capacity (ltr) 100 125 150 170 200 250 300 400 500
Inlet Group 34330863 34330852
Expansion Vessel 19711233 19711244 1971
1255
1971
1436
1971
1266
T&P Valve 3433116 34331127
Tundish 34330948 34330937
Dual Stat 34330830
Prim. Coil 2-P Z.Valve 34330896
Unvented Kit Checklist
Direct Indirect
Inlet Control Group Inlet Control Group
Tundish Tundish
T&P Valve (tted) T&P Valve (tted)
3kW Immersion (tted) 3kW Immersion (tted)
Expansion Vessel Expansion Vessel
Dual Cylinder Stat
2-port Zone Valve

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ErP Product Fiche Information
Nominal Capacity (ltr) 100 125 150 170 200 250 300 400 500
Direct Vertical
Storage volume V (ltr) 99 127 150 169 200 250 294 - -
Mixed water at 40°C (ltr) 149 191 225 254 300 377 441 - -
The declared load prole L L L L L L XL - -
ErP Rating CCCCCCD - -
Energy Eciency (%) 39 39 38 38 38 37 37 - -
Ann. el. consumption (kWh)
2650 2654 2715 2719 2723 2764 4508 - -
Sound Power Level (dB) 16 16 16 16 16 16 16 - -
Thermostat Temp. Set. (°C) 60 60 60 60 60 60 60 - -
Daily En. Usage Qelec
(kWh/24h) 12.189 12.213 12.577 12.601 12.625 12.868 20.962 - -
Nominal Capacity (ltr) 100 125 150 170 200 250 300 400 500
Indirect & Solar Vertical
Storage Volume V (ltr) 96 124 147 168 194 247 290 390 495
Standing Loss (kW) 44 52 55 58 78 87 92 102 115
ErP Rating B B B B CCCCC

Boss Direct / Indirect Installation Guide
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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)
Primary coil operating pressure (max) 0.6MPa (6 bar)
Immersion heater rating (a.c. supply only) single phase 3kW 50/60Hz ~
Storage weights (empty and full) See Specication Tables
Indirect coil ratings See Specication Tables
Pressure drop across the indirect coils See Specication Tables
Coil surface area See Specication Tables
Technical Data
Indirect models in conformance with BS EN 12897:2016

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Indirect Technical Specication
2 Boiler Return
3 Cold Water Inlet
7 Aquastat Pocket
8 Boiler Flow
9 Incoloy Immersion (fact. tted)
10 Secondary Return
13 T&P Relief Valve
14 Hot Water Draw O
F
CC
D
A
B
13
10
9
8
7
3
2
E
G
H
14
15º
30º
93
30º

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Dimensions 100 125 150 170 200 250 300 400 500
Cylinder Height (A, mm) 950 1030 1190 1310 1490 1815 1600 1570 1900
Cylinder Diameter (B, mm) 500 540 540 540 540 540 600 710 710
Connection Height C (mm) 188 196 196 196 196 196 218 225 225
Connection Height D (mm) 333 211 341 341 341 361 383 405 455
Connection Height E (mm) 478 511 486 486 516 586 608 675 745
Connection Height F (mm) 543 651 651 651 581 651 673 740 810
Connection Height G (mm) 628 751 786 881 981 1271 1153 1180 1440
Connection Height H (mm) 743 800 911 1031 1211 1531 1333 1280 1640
Performance 100 125 150 170 200 250 300 400 500
Heat Up Time ΔT 50°C (min) 22 23 26 27 31 37 42 52 54
1º Re-Heat time (70% dr. o) 15L/m 12 14 17 18 21 25 29 37 38
Weight Empty (kg) 27 30 34 37 41 49 56 62 89
Weight Full (kg) 152 155 184 207 241 299 356 462 589
Prim. Coil Surf. Area (m2)0.58 0.58 0.58 0.58 0.67 0.77 0.77 1.16 1.25
Prim. Coil Rat. @15L/m (kW, 80±2ºC) 20 20 20 20 21 23 23 25 26
Pr. Coil Press. Drop @ 60L/hr (mbar) 45 45 45 45 65 76 76 88 90
Cont. Output @60ºC ΔT 50°C (L/hr) 382 382 382 382 401 440 440 478 497
Connection Sizes & Safety 100 125 150 170 200 250 300 400 500
Hot & Cold Conn. Ø (mm) 22 22 22 22 22 22 22 28 28
Coil Connection Ø (mm) 22 22 22 22 22 22 22 22 22
Secondary Return Ø BSP F (“) 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
T&P Connection Ø BSP F (“) 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.75 0.75
3bar T&P Press. Set. (bar) 777777777
Exp. Relief Set. (bar) 666666666

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Direct Technical Specication
DC
A
B
13
10
9
3
F
G
14
15
E
30º 30º
10 3
3 Cold Water Inlet
9 Incoloy Immersion (fact. tted)
10 Secondary Return
13 T&P Relief Valve
14 Hot Water Draw O
15 Smart Immersion (fact. tted)