Installation and Maintenance Manual 6 720 615 190 - 02/2008 US Logalux SM300/1 Logalux SM400/1 Solar and High Capacity Domestic Hot Water Documentation for the contractor Please read carefully prior to installation and maintenance When the anode rod is not professionally and annually maintained, the tank will lose its warranty. Annual service records must be maintained and shown in case of a warranty claim along with an original proof of purchase.
Index Index Index 2 1 1.1 1.2 Safety Precautions and symbol clarification Placement, remodeling Symbol Clarification 3 3 3 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 Product Description Applications Situation Applications Guidelines for Installations Product Disposal Product Packaging Dimensions and Connections Technical Specifications 4 4 4 4 4 5 7 9 3 3.1 3.1.1 3.1.2 3.2 Transportation Transportation Means Transportation with dolly Transportation with overhead crane Product Placement 10 10 10 11 11 4 4.
Safety Precautions and symbol clarification 1 Safety Precautions and symbol clarification 1.1 Placement, remodeling Placement, remodeling V Fire danger! Solder and welding operations can result in fire, as the insulation is combustible. V The solar tank can only be installed or renovated by technical specialists. Installation and Start-up Procedure V Carefully follow these installation instructions, to ensure long and trouble-free operation. V Do not assemble the equipment in a damp environment.
2 Product Description 2 Product Description 2.1 Applications The solar tanks SM300/1 and SM400/1 are designed for the heating and storage of domestic hot water. Applicable guidelines for domestic hot water must be followed. 2.2 Situation Applications The domestic hot water can be heating by a solar system with a boiler as a back-up system, or by a boiler in general for high output hot water heating. (Operate the 2 coils either in series or in parallel).
Product Description 2.5 2 Product Packaging Solar hot water tank consists of: – Tank shell with corrosion protection – The cathodic corrosion protection consists of hygienic Buderus Thermoglaze Duo-Clean and a magnesium anode protection system. – Tank insulation made from non FCKW insulation material. – SM300/1: direct attached to tank shell. – SM400/1: Insulation must separately be installed.
2 Product Description B-Kit Komponenten Fig. 2 1 2 3 4 5 6 Tank kit fittings Tee piece with P & T relief valve Bracket for mounting of aquastat Spacer set for securing DHW tank sensor Cover cap for DHW recirc connection (EZ) Tee piece with tank drain valve Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice.
Product Description 2.6 Dimensions and Connections Fig. 3 SM300/1 Dimensions and connections AW VS1 VS2 RS1 RS2 M1 M2 EK EL EZ 2 DHW outlet Solar coil supply Boiler coil supply Solar coil return Boiler coil return Temperature measuring point for DHW temperature sensor (FB) or aquastat Temperature measuring point for solar DHW sensor (FSS) Cold water feed Tank drain DHW recirc tapping Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice.
2 Product Description Fig.
Product Description 2.7 2 Technical Specifications Tank Model Tank volume Volume of solar heat exchanger Diameter Height H1) SM300/1 SM400/1 gal 77 103 Liter 290 390 gal 2 2.5 Liter 8 9.
3 Transportation 3 Transportation 3.1 Transportation Means One can move the solar water heater tank SM300/1 with a hand dolly and the SM400/1 also with a lifting crane or device. Danger: Potential danger due to falling over of tank. V Use only transport devices that are in safe operating condition V Place the lifting hook only in the designated location. Danger: Potential for injury due to carrying of heavy loads. V Also move and lift the tank with at least two people.
Transportation 3 3.1.2 Transportation with overhead crane V Place the two lifting hooks of the chain into the designated lifting rings on top of the tank [1]. V Hook the crane chain into the lifting chain. V Protect the tank from falling and lift the tank to its final installation location. V Lower the tank carefully to the floor; do not drop down onto the floor! One can move the tank inside the building also in a horizontal manner due to possible height restrictions.
4 Tank Assembly 4 Tank Assembly 4.1 SM300/1 Placement and Installation 4.1.1 Installation of tank feet V Place top foam material on the floor [1]. V Carefully place the solar tank on its side on top of the foam material. V Remove the tank support bolts M10x30 from the Styrofoam packaging and screw into the bottom of the tank [2]. V Put solar tank straight-up and level by adjusting the tank bolts [2]. Fig. 8 1 2 4.1.
Tank Assembly 4 Installation of tank temperature sensor (Supplied with R2107, 4000 series control or Stecca control) 1 Make sure to have the entire sensor surface come in good contact with the dry tank well. 2 3 4 V Identify and remove the DHW tank sensor from the control package. V Slide the sensor assembly (R2107 or 4000 controls) into the dry well [5] (item 12, page 5) along with quarter pie pieces and tension spring. The plastic wrap [3] will automatically slide from the assembly.
4 Tank Assembly Installation of aquastat V Remove cover from aquastat [2] ). Loosen hex head screw from cover. V Secure mounting bracket [3] with 2 sheet metal screws [1] to tank jacket. Fig. 11 Installation of aquastat bracket 1 2 3 Sheet metal screws Aquastat Mounting bracket V Slide capillary and tension spring together into the dry well. V Secure aquastat [2] with 2 screws [1] to the mounting bracket. V Install aquastat cover in its place. Fig.
Tank Assembly 4.2 4 SM400/1 Placement and Installation V Place tank shell in desired location. V Slide insulation disc under tank between the tank supports. 4.2.1 Installation of M2 - M5 temperature sensors Alternatively to the sensor dry wells the M2 - M5 sensor tension brackets can be used to install temperature sensor on the outside of the DHK tank shell. Make sure to sensing elements are fully inserted into the wells and that they make good surface contact.
4 4.2.2 Tank Assembly Installation of Tank Insulation for SM400/1 Tank We recommend to only installing the insulation after all piping and a water test has been successfully completed. The insulation is best installed at a room temperature of 59 °F/15 °C. Slight tapping on the insulation in the direction of the connection eases the installation of the insulation. V Route sensor wiring carefully along tank shell. V Connect both pieces of insulation [6] on the front of the tank shell.
Tank Assembly 4.3 4 Water side Piping Connections for both Tank Models Danger: Fire danger due to soldering and welding! V Take proper precautionary measures during soldering and welding, as the insulation material is combustible. V Check the insulation following work for irregularities. Warning: Scalding due to excessively hot water! During solar operation, the domestic hot water can reach 194 °F/90 °C temperature.
4 Tank Assembly Installation of tank kit components Danger: Personal and system damage due to incorrectly installed relief valve discharge line! V Pipe relief valve discharge piping full port to nearest floor drain. (Maximum length: 6 ft and maximum 290° elbows). V Attach a note to discharge piping saying: "Do not close off discharge. Water can discharge from piping during operation". V Size discharge piping to conform with relief valve discharge dimension (Tab. 2).
Tank Assembly 4.4 4 Connections for Solar station KS Warning: Potential system damage due to very high temperatures and pressures! V Use pressure and temperature resistant piping connections. V Use not any galvanized piping, connections and graphite or plastic gasket materials or PEX or plastic piping or connections of any such type. V When soldering piping connections, make sure to use high temperature rated lead free solder. (Melt temperature > 455 °F/ 235 °C).
4 4.5 Tank Assembly Connections for High Output Indirect Fired Tank Piping The SM300/1 and SM400/1 tanks can also be used for high capacity indirect fired hot water tanks. Two scenarios exist. 4.5.1 V V V V Serial Connections of the bottom and top coils Connect SM300/1 or SM400/1 coils in series by connecting the upper connection of the lower coil to the lower connection of the upper coil. Connect tank charging pump to the upper connection of the top coil.
Start-up and Shut-down of Tank 5 Start-up and Shut-down of Tank 5.1 Start-up Operations 5 The pressure testing of the domestic hot water system should only be conducted with fresh water. The maximum test pressure shall not exceed 145 psi (10bar). V Open the air vent at the highest point of the solar system. V To fill the hot water heater, open the shut-off valve location in the tank fill connection.
5 Start-up and Shut-down of Tank 5.1.2 System start-up The initial start-up must be performed by the installing contractor or service technician. V Install and follow operating instructions of controls and accessories furnished by other manufacturers. 5.2 Decommissioning of the system Danger: Danger of scalding! Hot water can cause serious injury. V Allow the solar hot water tank to cool down sufficiently. Caution: Tank damage. Corrosion formation due to residual moisture.
Maintenance 6 6 Maintenance We recommend an annual service and maintenance program for the solar hot water heater through a mechanical contractor and service company. Please inform the end user. V Use shorter service intervals in case of hard or extremely hard water conditions and high temperature operation. Caution: Possible tank damage due to incorrect cleaning and maintenance! V Clean and perform a maintenance program on an annual basis. V Correct any possible deficiencies. 6.
6 6.2 Maintenance Cleaning of solar hot water tank V Inspect tank interior for lime deposits. Caution: Tank damage due to damaging of the tank surface. V Do not use any hard or sharp objects to clean the tank interior. When solid lime deposits are observed in the tank, proceed as follows: V Rinse out inner surface with a strong cold water stream (58 - 72.5 psi / 4 to 5 bar) (Æ Fig. 20).
Maintenance 6.3 6 Checking of magnesium anode rod The magnesium anode rod is sacrificial anode rod which will be consumed during its operation. V Check the diameter and surface of the anode rod annually. When the anode rod is not professionally and annually maintained, the tank will loose its warranty. Annual service records must be maintained and shown in case of a warranty claim along with an original proof of purchase. Avoid contact between the anode rod and oil or grease. V Keep the anode rod clean.
6 Maintenance Replacing of bottom magnesium anode rod and SM400/1 top anode rod V Disassemble clean out cover (Æ Fig. 19, page 23) if not done already. V Remove M8 nut [8] to release the ground wire eyelet [10]. V Remove M8 nut [7]. V Remove the clean out cover [3] from the magnesium anode [1]. V Replace the magnesium anode. V Fit the new magnesium anode together with all small parts supplied with it, as shown in Fig. 22. Fig. 22 Replacement magnesium anode rod.
Maintenance 6.4 6 Placing solar tank back in operation after cleaning Caution: Tank damage due to a defective gasket! V To avoid leak sites, replace the clean-out gasket following removal of the clean-out cover. V Install new gasket with clean-out cover. V Tighten 6 bolts by hand. V Further tighten the bolts with a wrench. Tighten evenly. Torque bolts evenly to about 25 - 30 Nm (18 - 22 lb-ft). V Fill the solar water heater and start up the system. V Check all connections and clean-out cover for leaks.
7 Replacement Parts 7 Replacement Parts 7.1 Replacement parts for SM300/1 - 300/1W Position Part-Nr. Description Number 10 7747021398 Buderus Logalux SM300/1 blue 1 11 7747021398 Buderus Logalux SM300/1W white 1 Available components 20 63043454 120 x 152 x 10 gasket 1 30 63014368 Clean-out cover 1 40 x Washer 8 50 x M10 x 30 8.
Replacement Parts 7 90 60 100 110 10 120 20 40 50 60 50 70 30 80 7747102527.aa.RS-Solarspeicher SS300/SM300 USA Fig. 24 Solar Hot Water Heater SM300/1 - SM300/1 W Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice.
7 7.2 Replacement Parts Access cover and anode rod assembly for SM300/1 - 300/1W Position Part Nr.
Replacement Parts 7.3 Replacement parts for SM400/1 Position 10 7 Part-Nr. 7747022557 Description Number Buderus Logalux SM400/1 Available components 20 63043454 120 x 152 x 10 gasket 2 30 63014368 Tank access and clean-out cover 1 40 x Washer 8 50 x Access cover mounting bolts M10 x 30 8.8 8 60 63004276 1-½" Tank drain plug with gasket 1 70 5592176 Magnesium anode rode 33x400 1 Tab.
7 Replacement Parts 20 10 70 40 20 50 30 60 7747102531.aa.RS-Speicher-WE SM400 USA Fig. 25 SM400/1 Solar Hot Water Heater 32 Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice.
Replacement Parts 7.4 7 Tank access cover and anode rod assembly for SM400/1 Position Part Nr.
7 Replacement Parts 90 80 90 100 80 40 110 70 60 120 130 140 10 20 50 30 30 7747102529.aa.RS-Handlochdeckel und Anode SS300/SM300 USA Fig. 26 Tank access cover and anode rod assembly for SM400/1 tank 34 Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice.
Replacement Parts 7.5 7 Tank Jacket System for SM400/1 Tank Position Part Nr.
7 Replacement Parts 10 40 30 160 20 70 100 70 90 60 70 80 130 110 50 120 140 150 7747102530.aa.RS-Verkleidung SM400 USA Fig. 27 Complete tank jacket panel and insulation set for SM400/1 36 Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice.
7 Notes Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice.
7 Notes 38 Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice.
7 Notes Logalux SM300/1 - SM400/1 - Technical specifications are subject to change without prior notice.
Bosch Thermotechnology Corp. 50 Wentworth Avenue Londonderry, NH 03053 Tel. 603-552-1100 Fax 603-584-1681 www.buderus.net Products manufactured by Bosch Thermotechnik GmbH D-35573 Wetzlar www.buderus.de Bosch Thermotechnology Corp. reserves the right to make changes without notice due to continuing engineering and technological advances.
