Bosch 25/32kW Instruction Manual Download

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ELECTRICS

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)

X12

X11

X13

X10

gy gy

pk pk

y y

bk r

g gy w

1 2

3 4 5

r r

or pk y

w w

bk r

g gy w

1 2

3 4 5

g bk r gy w

230V

bl
br
w

N L

Mains
connection

Service
connection

M o d e
switch

ELECTRICS

Electrical components:

1 Printed circuit board

2 Thermostat - boiler high limit

3 Thermostat - DHW control

4 Thermostat - CH control

5 Indicator lamp - boiler mode

6 Indicator lamp - lock-out

7 Manual reset - overheat thermostat

8 Manual reset - flue overheat thermostat

9 Manual reset - burner lock-out

10 External programmer (not supplied)

11 Burner socket

12 Burner plug

13 Burner control box (12/18 & 18/25 shown)

14 Flow switch

15 Circulating pump

16 Diverter valve

17 Frost stat

18 Frost stat

Wire colour code:

br - Brown

bl - Blue

gy - Green/Yellow

- Red

w - White

- Yellow

g - Grey

bk - Black

or - Orange

pk - Pink

Summary of Contents for 25/32kW

Page 1: ...LER USING BALANCED FLUE SYSTEM FOR OPEN VENT AND SEALED CENTRAL HEATING SYSTEMS WITH DOMESTIC MAINS FED HOT WATER THE APPLIANCE IS FOR USE WITH KEROSENE 28 SECOND OIL ONLY INSTRUCTION MANUAL INSTALLATION COMMISSIONING SERVICING GB THE APPLIANCE IS FOR USE WITH KEROSENE 28 SECOND OIL ONLY INSTRUCTION MANUAL GB ...

Page 2: ...organisations operate self certification schemes e g NAPIT and BESCA Ltd and it may be possible for installers who are members of these organisations to self certify their work Alternatively you must submit a building control notice to the LABC before installing any boiler The LABC will then arrange regular inspection visits during the work to ensure that the installation complies with the regulat...

Page 3: ...WORK CONNECTIONS 23 24 OIL BURNER AND PUMP 25 REFITTING COMPONENTS 26 ELECTRICS 27 28 COMMISSIONING PRE COMMISSIONING CHECKS APPLIANCE 29 FILLING THE SYSTEM 30 STARTING THE APPLIANCE 31 34 WATER TREATMENT 35 FINISHING COMMISSIONING APPLIANCE 36 SERVICING SPARES INSPECTION AND SERVICE 37 40 SHORT PARTS LIST 12 18 41 SHORT PARTS LIST 18 25 42 SHORT PARTS LIST 25 32 43 FAULT FINDING DIAGNOSIS FAULT F...

Page 4: ...he appliance Failure to install appliances correctly could lead to prosecution The appliance should be installed by a competent person The person installing the appliance should be aware of the Health and Safety at Work Act and take appropriate action to ensure that the regulations are adhered to In order to give optimum efficiency and trouble free operation the appliance must be commissioned by a...

Page 5: ...N STANDARD PACKAGE A Floor standing oil fired condensing boiler for open vent and sealed domestic central heating and mains fed hot water B Literature pack C Condensate trap kit D 100mmØ services duct E Cabinet key Check List Item Qty Greenstar Heatslave External Installation Servicing Instructions 1 Users Instructions 1 100mm Ø Services Duct 1 Condensate Trap Kit 1 Warranty Return Envelope 1 Cabi...

Page 6: ...xpansion BSP Condensate polypropylene mm Electrical Electrical power supply voltage AC V Frequency Hz Max power consumption W Thermostats CH control thermostat range cut in cut out C DHW control thermostat range cut in cut out C CH DHW control thermostat differential C Boiler high limit thermostat set point C Boiler manual reset overheat thermostat set point C Flue reset overheat thermostat set po...

Page 7: ...IL ISOLATION VALVE 27 CONDENSATE TRAP 28 CONDENSATE TRAP BRACKET 29 COMBUSTION CHAMBER ACCESS DOOR 30 HEATSLAVE TANK DRAIN 31 HEATSLAVE TANK 32 MODE SWITCH 33 BOILER MODE INDICATOR 34 LOCKOUT INDICATOR 35 OVERHEAT RESET BUTTONS boiler flue temperature 36 LOCKOUT RESET BUTTON 37 SERVICE CONNECTION 38 CH TEMPERATURE CONTROL 39 DHW TEMPERATURE CONTROL 40 DATA LABEL 41 FROST THERMOSTAT SENSORS 42a BEN...

Page 8: ...the boiler is fired up Run the boiler and system at normal operating temperature in accordance with the manufacturer s instructions Drain and thoroughly flush the system to remove the flushing agent and any debris IMPORTANT All the following Pre Installation sections must be read and requirements met before starting boiler or flue installation CAUTION ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY...

Page 9: ...ater supply can cause a pressure build up which could damage the boiler and other household appliances Where the water main supply has a non return back flow prevention valve fitted a mini expansion vessel A must be connected to the mains water inlet pipe B between the non return valve C and the boiler D as shown opposite Use in hard water areas Normally there is no need for water treatment to pre...

Page 10: ...as possible Fit an oil strainer and water seperator C to the oil supply pipe near the oil storage tank Fit an additional oil filter N 16µm max filtration size close to the boiler but not inside the boiler casing Fit a fire valve in accordance with BS 5410 The fire valve D must be fitted externally at least 1 metre from the appliance with the fire valve sensor F located within the appliance case A ...

Page 11: ...all radiators except the radiator where the room thermostat is sited this must be fitted with lockshield valves and left open All installations should have TRVs fitted to radiators within the sleeping accommodation An automatic bypass valve must be connected between the heating flow and return where TRVs are used on all radiators fitted to give at least a 3m circuit when activated Drain cocks are ...

Page 12: ...HW system Taps and mixing valves must be capable of sustaining a pressure up to 10 bar in accordance with the Water Regulations as they will be operating at mains water pressure Hot water temperature and flow rate are affected by the size and insulation of pipework making up the distribution system and are controlled by the hot water tap and the water main inlet pressure A mixing valve can be fitt...

Page 13: ...k IMPORTANT Condensate pipework must not leak and the condensate trap must be filled with water before the boiler is started to prevent the possibility of potentially harmful flue products escaping via the condensate route A Condensate from the boiler condensate trap supplied which has a 75mm minimum water seal B Sink C 21 5mm Ø polypropylene condensate pipe D Gully E Internal soil and vent stack ...

Page 14: ...l surface to ensure that condensate does not enter the primary heat exchanger Tarmac and wood hardstandings are not recommended CLEARANCES Min service flue clearances Above 600mm Front 600mm RH LH flue outlet on opposite side 10mm RH flue outlet on rear 85mm LH flue outlet on rear 10mm Rear flue outlet on side 150mm Rear rear flue outlet 2500mm It is strongly recommended that the flue terminal fac...

Page 15: ...standing the dimensions above a terminal should be at least 300mm from combustible material e g a window frame 2 A way of providing protection of combustible material would be to fit a heat shield at least 750mm wide Flue terminals must be positioned to avoid combustion products entering into buildings The flue must be fitted and terminated in accordance with the recommendations of BS5410 The flue...

Page 16: ... less than 2m above the ground balcony flat roof or other place to which any person has access the terminal should be protected by a guard 6 Notwithstanding the dimensions given above a terminal should not be sited closer than 300mm to combustible material In the case of a thatched roof double this separation distance should be provided It is also advisable to treat the thatch with a fire retardan...

Page 17: ...D Flue bend 45 E Vertical Terminal Kit incl 90 elbow F Horizontal terminal kit incl 90 elbow Calculating the flue length Measure the total flue length required noting that the maximum straight flue length including the terminal is Horizontal 80 125mmØ 4000mm Vertical 80 125mmØ 100 150mmØ 25 32 only 7000mm Then reduce the total straight flue length for each extra flue bend excluding the vertical fl...

Page 18: ...fitted to the rear or either side of the cabinet IMPORTANT It is strongly recommended that the flue terminal faces away from walls to minimise the occurance of wetting A External horizontal flue kit Part No 7 716 190 052 B 90 inline elbow 80 125mm Part No 7 716 190 034 C Terminal guard Part No 7 716 190 050 FRONT FRONT FRONT Plan view Plan view Plan view REAR FLUE OUTLET A C LEFT HAND FLUE OUTLET ...

Page 19: ...carton up and away from the boiler Remove the plastic bag from the boiler and place safely aside UNPACKING THE BOILER LIFTING AND CARRYING PRECAUTIONS Lift only a manageable weight or ask for help When lifting or putting things down bend the knees and keep the back straight and feet apart Do not lift and twist at the same time Lift and carry objects close to the body Wear protective clothing and g...

Page 20: ...rvices duct 100mmØ Drain optional fill feed expansion 3 4 BSP Pressure relief pipe 15mmØ Condensate outlet 21 5mmØ NOTE For servicing purposes keep the condensate and pressure relief discharge pipes away from components and pipework connections CAUTION Ensure there are no pipes electric cables damp proof courses or other hazards before drilling PIPEWORK FLUE POSITIONS PIPEWORK FLUE POSITIONS INSTA...

Page 21: ...s D then withdraw the burner E from the boiler and store safely away from the installation point 8 Remove the screws securing the base panel to the transit pallet and lift the boiler off the pallet and into its installation position taking care not to scrape the base panel across the hard standing Do not attempt to lift and position the boiler on your own Do not use the copper pipes to move the bo...

Page 22: ...ree grease supplied 2 Carefully remove the blanking plate from the appropriate flue aperture if necessary and refit the blanking plate in the unused aperture 3 Carefully remove the insulation from the flue aperture in the cabinet that the flue is to pass through and fit to the unused aperture if necessary 4 Refer to the flue manual supplied with the flue kit for flue installation FLUE INSTALLATION...

Page 23: ...iler output as shown in the plan views opposite 3 Refit combustion chamber door A Secure with nuts and washers B and tighten until the door is firmly secured do not over tighten the nuts 4 Unscrew screws E and remove flue manifold access cover F 5 Check that all the baffles G and baffle retainer H or J are correctly fitted to the secondary heat exchanger COMBUSTION CHAMBER H F 2 E 4 G 5 A B 1 3 D ...

Page 24: ...sting Ensure all pipework is clean Align water pipework through the 100mm Ø duct and connect ensuring that the expansion tank and control box fit correctly before permanently connecting the pipework Check that all unused sockets have been capped OIL SUPPLY CONNECTIONS NOTE Oil filters and de aeration devices are not to be fitted within the casing and the fire valve body must be at least 1 metre fr...

Page 25: ...50mm min for every metre Carefully pour 500ml of water into the condensate collection R to fill condensate trap Check the water is running away and the condensate pipework joints are water tight Check the flue manifold seal is undamaged and seated correctly Refit flue manifold access cover Q and secure with screws P IMPORTANT The condensate trap must be correctly filled to prevent the possibility ...

Page 26: ...gle pipe operation with the flexible oil hose fitted Check connections before use Converting the oil pump for a double pipe system 1 Check the inlet hose connection a DANFOSS BFP 11 L3 Remove pump front cover A ensuring a suitable receptacle is used to catch any oil residue Remove changeover screw B Remove horseshoe washer C Refit changeover screw B Refit front cover A Remove oil pump return plug ...

Page 27: ...asket B correctly fitted Push firmly down to compress the gasket B Tighten burner retainers C sufficiently to ensure a good seal IMPORTANT Ensure the gasket is a good seal between the burner combustion head and the boiler housing to prevent flue gases escaping from the combustion chamber into the cabinet Attach the flexible air duct and tighten clamp D to secure to the burner air intake 2 Plug bur...

Page 28: ...l N Connect EARTH wire Green Yellow to the connector Route the power cable down the side panel and through the service duct to the internal property connection point avoiding any potentially hot surfaces Any external device connected to the boiler must take its power supply from the boiler supply only and must NOT have a separate supply External 230V programmer terminal block X4 4 Remove 4 pin plu...

Page 29: ...12 18 bl br w g 10 1 N L Mains connection Service connection Mode switch ELECTRICS Electrical components 1 Printed circuit board 2 Thermostat boiler high limit 3 Thermostat DHW control 4 Thermostat CH control 5 Indicator lamp boiler mode 6 Indicator lamp lock out 7 Manual reset overheat thermostat 8 Manual reset flue overheat thermostat 9 Manual reset burner lock out 10 External programmer not sup...

Page 30: ...ble oil hose Turn on the main oil supply valve at the tank check the oil supply pipework and connections Rectify any leaks 3 Check the flue is correctly fitted and the connections are secure 4 Check the condensate pipework is correctly fitted and connected Check the condensate trap is filled with water 5 Check the CH circulating pump is set to 3 NOTE The CH circulating pump is preset to number 3 a...

Page 31: ...the system feed and expansion cistern and allow the system to fill Sealed systems only fill the system to between 1 and 2 bar pressure via a WRAS approved filling link Monitor the pressure gauge during venting and repressurise if required Check air is being discharged from the automatic air vent Vent all radiators retighten when completed check the system and correct any leaks Bleed air from both ...

Page 32: ...sed the pipework will need to be primed before the oil will discharge under gravity When completed close the isolating valve reconnect the flexible oil hose Double pipe sub gravity feed systems and single pipe suction lift with de aerator To prime a de aerator disconnect the flexible oil inlet hose F from the isolation valve and place in a container of kerosene G Connect a spare flexible oil hose ...

Page 33: ...e until the smoke from burning organic binder in the access door insulation has ceased Check the CO2 levels and adjust the air shutter L setting according to the table opposite Check the flue gas temperature is close to the values shown in the table If the flue gas temperature is too high and the baffles are correctly fitted then reduce the oil pump pressure B 5 10p s i to compensate for nozzle va...

Page 34: ...ump ON 2 Close the hot water tap Set the DHW thermostat control C to minimum as shown Set the programmer to DHW ON The burner should be ON with the circulating pump to heat the water in the Heatslave external tank When minimum set temperature is reached the burner and circulating pump will switch off 3 Fully open a hot water tap The burner should be ON with the circulating pump Check the water flo...

Page 35: ...se Turn the CH thermostat control D to max The burner should be ON with the circulating pump The diverter valve E should open to port B for CH Ensure all radiators are heating up evenly and balance the system to the temperature difference required across the heating flow and return relevant to the heating load 2 Set the room thermostat to minimum The burner and circulating pump should be off The d...

Page 36: ...rain cocks C and manual air vents are closed and all radiator valves are open 5 Add a suitable inhibitor I or combined inhibitor anti freeze if the system is exposed to freezing conditions to the heating system in accordance with the manufacturers instructions The inhibitor or combined inhibitor anti freeze must not cause damage to the materials within the boiler mild steel stainless steel copper ...

Page 37: ...ssure at the edges of the panels when securing to avoid accidental damage Handover Complete the guarantee registration card combustion record page 49 and a CD11 or an equivalent commissioning form Set up the controls and show the user how to operate all the controls shown in the User Guide and all system controls Where applicable instruct the customer how to repressurise the system If the applianc...

Page 38: ...e mode at switch A 2 Depress locking ears and unplug burner lead B from control box C An adapter lead is available to allow mains voltage service aids to be operated from the service connection G Service lead Part No 8 716 113 483 0 3 Loosen clip D to detach air duct 4 Unscrew burner retainers E to release the burner combustion head F Lift burner away taking care not to over strain the flexible oi...

Page 39: ...or if the O ring is damaged and replace with a new one Refit the check valve 25 32 Check the nozzle holder is clear of any debris and clean if neccessary 12 18 18 25 25 32 Fit a new oil atomising nozzle E DO NOT dismantle the nozzle and DO NOT clean the nozzle tip Check the electrodes F and reset if necessary as shown opposite Refit the combustion head Check that the nozzle E lies centrally in the...

Page 40: ...sary Refit the flue manifold access cover F and secure with screws E Combustion chamber Release the M10 retaining nuts and washers B and remove combustion chamber access door A Check the fibreglass rope seal on the combustion chamber access door A and replace if necessary Remove and check the baffle retainer D Remove the baffles C clean and check the condition of the baffles and the acoustic insul...

Page 41: ...fit the top panel and press down to compress the seal when fitting the securing screws Push the front panel up behind the top panel and push in at the base to secure the screws with the tool provided After service handover Make a note of the date of any water treatment Set the controls back to the users requirements Complete the service interval record at the back of this manual and a CD11 or an e...

Page 42: ...ntrol thermostat Part Number 8 716 107 621 0 14 Auto reset High Limit thermostat Part Number 8 716 107 640 0 15 Manual reset High Limit thermostat Part Number 8 716 107 625 0 16 Manual reset flue thermostat Part Number 8 716 107 624 0 17 DHW control thermostat Part Number 8 716 107 637 0 18 Cleaning brush Part Number 8 716 109 428 0 19 Manifold access cover seal Part Number 8 716 107 536 0 20 Seco...

Page 43: ...ut off valve Part Number 8 716 156 658 0 11 Flexible oil line kit Part Number 8 716 106 346 0 12 Burner O ring gasket Part Number 8 716 109 158 0 13 Heating control thermostat Part Number 8 716 107 621 0 14 Auto reset High Limit thermostat Part Number 8 716 107 640 0 15 Manual reset High Limit thermostat Part Number 8 716 107 625 0 16 Manual reset flue thermostat Part Number 8 716 107 624 0 17 DHW...

Page 44: ...rner O ring gasket Part Number 8 716 109 158 0 10 Heating control thermostat Part Number 8 716 107 621 0 11 Auto reset High Limit thermostat Part Number 8 716 107 640 0 12 Manual reset High Limit thermostat Part Number 8 716 107 625 0 13 Manual reset flue thermostat Part Number 8 716 107 624 0 14 DHW control thermostat Part Number 8 716 107 637 0 15 Cleaning brush Part Number 8 716 109 428 0 16 Ma...

Page 45: ...gnition transformer Replace Open circuit ignition Check and replace electrodes or high tension leads if necessary Faulty control box or electrical connections not properly made Correct control box electrical connections or replace control box BURNER FAILS No power to boiler Check electrical control circuit TO START Faulty boiler thermostat Check by temporarily linking out high limit and control th...

Page 46: ...culating pump Short Cycling Burner rating incorrect Correct burner rating Boiler thermostat differential incorrect Replace boiler thermostat External controls not operating correctly Check and correct external controls OIL SMELLS Blocked flue fumes on startup Check seals gaskets Oil soaked boiler faulty burner operation numerous lockouts Rectify burner operation and lockouts Odour in cabinet oil l...

Page 47: ...Yes Yes No Yes Yes Yes Yes No No No Yes Yes Yes Yes No No No No No Yes Yes Yes Yes Yes No No No No Yes Yes Yes Yes Replace lead No Reset air setting No Reset combustion head No FAULT FINDING LOGIC FOR SATRONIC CONTROL BOX Note This chart assumes all wiring within the control box base is correct if in doubt check the wiring against the diagram on the base of the control box before replacing any com...

Page 48: ... Replace photo cell No Boiler or flue blocked No Reseal BF Yes Replace control box Yes Replace electrodes leads No Unblock or replace pipe No Reset air setting No Reset combustion head No FAULT FINDING LOGIC FOR 535 SE LD RDB CONTROL BOX All resistance measurements are actual measured values and some variation is to be expected therefore measured values should be similar to but not necessarily ide...

Page 49: ... X12 PIN 4 grey BURNER X13 PIN 1 yellow pink X13 PIN 3 X13 PIN 2 orange 2 4 C 2 4 C grey X13 PIN 5 red red PLUG IN CONNECTOR CENTRAL HEATING CONTROL THERMOSTAT AUTO RESET HIGH LIMIT THERMOSTAT MANUAL RESET BOILER OVERHEAT THERMOSTAT X3 PIN 3 X8 PIN 1 LIVE SUPPLY FOR ALTERNATIVE DIVERTER VALVE CH DHW 3 2 MANUAL RESET FLUE OVERHEAT THERMOSTAT red NC NO 3 NC orange NO 3 red 2 6 LOCKOUT RESET SWITCH X...

Page 50: ...Group specified spare parts when replacing all controls COMMISSIONING ENGINEER COMBUSTION CHECKS COMPANY NAME PUMP PRESSURE PSI ADDRESS CO2 SMOKE READING ENGINEERS NAME F G T C SIGNATURE FLUE PRESSURE DATE BURNER MODEL FOR ALL BOILERS CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS YES OIL TYPE USED IS KEROSENE YES THE SYSTEM HAS BEE...

Page 51: ... OFTEC REG No PUMP PRESSURE psi CO2 NOZZLE CHANGED YES NO F G T C FLUE PRESSURE COMMENTS SIGNATURE SERVICE 2 DATE ENGINEER NAME COMPANY NAME TEL No OFTEC REG No PUMP PRESSURE psi CO2 NOZZLE CHANGED YES NO F G T C FLUE PRESSURE COMMENTS SIGNATURE SERVICE 4 DATE ENGINEER NAME COMPANY NAME TEL No OFTEC REG No PUMP PRESSURE psi CO2 NOZZLE CHANGED YES NO F G T C FLUE PRESSURE COMMENTS SIGNATURE SERVICE...

Page 52: ...pipe oil supply is a being used has a non return valve been fitted to the inlet pipe Refer to the instructions for guidelines No domestic hot water external programmer 1 Is the mains water in connected to the 15mm isolation valve 2 Is there a domestic hot water demand from the programmer and has the tank reached temperature 3 Is there 230V on pin 2 of terminal block X4 4 Remove the external wiring...

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