Installing A Pressure Relief Valve (Provided By The Customer); Fitting The Hot Water Temperature Sensor; Immersion Heater (Accessory); Commissioning - Bosch W 500-5 Series Installation And Maintenance Instructions For The Contractor

5.3.2 Installing a pressure relief valve (provided by the
customer)
▶ Install a pressure relief valve that is approved for potable water
(DN 20) in the cold water pipe
( Fig. 27, page 51 and Fig. 26, page 51).
▶ Observe the installation instructions for the pressure relief valve.
▶ Terminate the discharge pipe of the pressure relief valve via a
dewatering point, which is located in a frost-proof area that is easily
visible.
– 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 flow
rate, which may possibly arise at the cold water inlet
( tab. 4, page 5).
▶ Attach a notice with the following text to the pressure relief valve:
"Never close the discharge pipe. During heating, water may be
discharged for operational reasons."
If the static pressure in the system exceeds 80 % of the response
pressure for the pressure relief valve:
▶ Install a pressure reducer upstream
( Fig. 27, page 51 and Fig. 26, page 51).
Mains
pressure Excess pressure for
(static pressure relief
pressure) valve
6 bar
< 4.8 bar
5 bar 6 bar
8 bar
5 bar
8 bar
6 bar
7.8 bar 10 bar
Table 8 Selection of a suitable pressure reducer
5.4

Fitting the hot water temperature sensor

For measuring and monitoring the DHW temperature at the cylinder:
▶ Fitting the DHW temperature sensor ( Fig. 28, page 52).
Positions of the sensor test points:
• WS 500-1000-5E and WS 400-500-5EL... ( Fig. 8, page 45):
Fit sensor for heat source at Position 3. Fit sensor for solar system at
Position 7.
• W 500-1000-5E... ( Fig. 7, page 45):
Fit sensor for heat source at Position 3.
Ensure that the sensor area has contact with the sensor
pocket area for the sensor's full length.
5.5

Immersion heater (accessory)

If an immersion heater is used:
▶ ( Fig. 25, page 50)
– ErP "C": cut round perforation to create recess.
– ErP "B": insert compass provided, turn to cut out circular piece.
▶ Install the immersion heater in accordance with the separate
installation instructions.
▶ When the cylinder installation is complete, inspect the earth
connection (including the metal connection fittings).
W 500-5 | W 750-5 | W 1000-5 | WS 500-5 E | WS 750-5 E | WS 1000-5 E | WS 400-5 EL | WS 500-5 EL
Pressure reducer
Within the EU Outside the EU
Not Not
required required
4.8 bar 4.8 bar
Not Not
required required
5.0 bar
Not required
5.0 bar
Not required
6

Commissioning

NOTICE: Risk of system damage from excessive
pressure.
Excessive pressure can result in tension cracks in the
enamel coating.
▶ Never close the blow-off line of the safety relief valve.
▶ Commission all assemblies and accessories as specified in the
manufacturer's technical documents.
Only carry out the leak test for the DHW cylinder with
potable water.
6.1

Commissioning the DHW cylinder

After the cylinder has been filled, it must be subjected to a pressure test.
On the DHW side, the test pressure must not exceed 10 bar (150 psi)
positive pressure.
▶ Carrying out the leak test ( Fig. 31, page 52).
▶ Flush the DHW cylinder and pipework thoroughly prior to
commissioning ( Fig. 32, page 53).
6.2

Instructing users

WARNING: Risk of scalding at the DHW draw-off points!
There is a risk of scalding at the DHW draw-off points
during thermal disinfection and if the DHW temperature
is set at 60 °C.
▶ Advise users that they should only draw off mixed
water.
▶ Explain the operation and handling of the heating system and DHW
cylinder, making a particular point of safety-relevant features.
▶ Explain the function and checking of the pressure relief valve.
▶ Hand all enclosed documents over to the owner/operator.
▶ Recommendation for the user: Sign a maintenance and inspection
contract with an approved contractor. Have the DHW cylinder
serviced and inspected annually at the specified service intervals
( tab. 9, page 10).
Highlight the following for the user:
▶ Setting the DHW temperature.
– When heating-up, water may be discharged from the pressure
relief valve.
– The discharge pipe for the pressure relief valve must always be
kept open.
– Service intervals must be observed ( tab. 9, page 10).
– Where there is a risk of frost and when the user is briefly
away: Keep the heating system in operation and set the lowest
possible DHW temperature.
Commissioning | 9
6 720 821 900 (2017/05)