Bosch WORCESTER Greenstar Heatslave II External 12/18 Installation, Commissioning And Servicing Instructions
Floor standing oil fired condensing combination boiler balanced flue
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Installation, Commissioning and Servicing instructions
Floor standing oil fired condensing combination boiler balanced flue
2022+
Greenstar Heatslave II External
12/18, 18/25 & 25/32
For fully pumped sealed central heating systems and mains pressure domestic hot water.
These appliances are for use with Kerosene (Class C2) only.
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Summary of Contents for Bosch WORCESTER Greenstar Heatslave II External 12/18
- Page 1 Installation, Commissioning and Servicing instructions Floor standing oil fired condensing combination boiler balanced flue 2022+ Greenstar Heatslave II External 12/18, 18/25 & 25/32 For fully pumped sealed central heating systems and mains pressure domestic hot water. These appliances are for use with Kerosene (Class C2) only.
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Page 2: Table Of Contents
Contents Contents Key to symbols and safety instructions ....3 Commissioning ........33 Key to symbols . -
Page 3: Key To Symbols And Safety Instructions
Key to symbols and safety instructions Key to symbols and safety instructions Key to symbols General safety instructions These installation instructions are intended for heating engineers, Warnings plumbers, and electricians. Warnings in this document are identified by a warning ▶ Read any installation instructions (boiler, heating controls, etc.) triangle printed against a grey background. -
Page 4: Installation Regulations
Installation regulations Installation, commissioning and servicing Installation Installation, commissioning and servicing must only be carried out by a Failure to install appliances correctly could lead to prosecution. competent registered engineer. The appliance should be installed by a competent person. The person ▶... -
Page 5: Appliance Information
Appliance information Appliance information General information Technical data Description Units 12/18 18/25 25/32 Standard package Central heating Primary water capacity (total) litres Available pump head (20°C metres difference) at max. output water Max. permissible system operating pressure in accordance with WRAS guidelines Flow restrictor colour Lime Beige Grey... -
Page 6: Energy Efficiency
Appliance information Energy efficiency The following product data satisfy the requirements of the EU Regulations No. 811/2013 and No. 812/2013 supplementing Directive 2010/30/EU. Product data Symbol Unit 7731600263 7731600264 7731600265 Product type – – Greenstar Heatslave II Greenstar Heatslave II Greenstar Heatslave II External 2022+... -
Page 7: Layout & Components
Appliance information Layout & components The diagram below excludes the top, front and RH side casing panels. 6720821722-01.1Wo Fig. 2 Boiler layout Greenstar Heatslave II External 2022+ - 6 721 843 980 (2022/01) -
Page 8: Pre-Installation
DWTA code of practice and inhibitor manufacturer‘s guidelines. WARNING: Sealing agents ▶ In cases where all attempts to find a system micro leak have failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer. Water treatment products... -
Page 9: Mains Supply
Pre-Installation Artificially softened water It is possible to have an ion exchange water softener fitted to the cold water system of the property. However, the boiler requires an untreated cold water connection taken from the mains supply, before the water softener, to the primary water filling point of the heating system. -
Page 10: Pipework
Pre-Installation Single pipe gravity feed system Maximum pipe run for double pipe sub-gravity fed system The oil storage tank [1] must be positioned so that the oil level does not Head [M] 10mmØ 12mmØ Head [M] 10mmØ 12mmØ exceed 4 metres above the level of the burner oil pump [9] and in addition the oil level must be at least 300mm above the oil pump [9]. -
Page 11: Boiler Isolation Valve
Pre-Installation ▶ Fit a fire valve in accordance with BS 5410. The fire valve [5] should • All other valves should conform to BS 1010. be fitted externally to the building and appliance with the fire valve • An automatic bypass valve must be connected between the heating sensor [8] located within the appliance case. -
Page 12: Condensate Pipework
Pre-Installation Condensate pipework Mini expansion vessel NOTICE: Rainwater or external drain disposal (0.75ltr capacity) Untreated condensate must not be allowed to flow into Hot water supply streams or rivers to property ▶ A rainwater down pipe or an external drain shall only Greenstar Heatslave II be used for condensate disposal if the down pipe or external oil fired... -
Page 13: Soak Away
Pre-Installation • The soak away must use a 100mm Ø plastic tube with two rows of three 12mm holes on 25mm centres and 50mm from the bottom of the tube. The holes must face away from the house. • The tube must be surrounded by at least 100mm of limestone chippings to a depth of 400mm. -
Page 14: Pressure Relief Pipework
Pre-Installation Pressure relief pipework 600mm • The pressure relief discharge pipe [2]should be at least 15mm diameter copper pipe and run downwards away from the boiler and discharge away from any electrical or other hazard, preferably to an external drain or soakaway. •... -
Page 15: Flue Gas System Considerations
Pre-Installation Flue gas system considerations • Avoid discharging flue gases into car ports or narrow passageways. CAUTION: Non accessible flue systems: ▶ Where a flue system is not going to be accessible, provision must be made for service and inspection. ▶... - Page 16 Pre-Installation 1500 RIDGE VENT RIDGE FLUE 1500 1500 1500 1500 2000 BOUNDARY LINE DORMA SKYLIGHT OPENING OPPOSITE 1500 1500 1000 1500 2000 2000 2500 1500 1500 1000 1200 1500 1000 1000 2500 1000 1500 2500 1000 1000 1000 1800 1200 BOUNDARY LINE 1000 1000...
- Page 17 Pre-Installation 13. 300mm adjacent to a boundary line unless it will cause a nuisance. NOTICE: BS 5410: Part 1 recommended that care is taken when siting ▶ All measurements are the minimum clearances terminal in relation to boundary lines. required. 14.
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Page 18: Flue Options
Pre-Installation Flue options 4.8.1 Cabinet mounted balanced horizontal flue options It is strongly recommended that the flue terminal faces away from walls to minimise the occurrence of wetting. • The horizontal flue is fitted to the rear or either side of the cabinet. REAR FLUE OUTLET 6720645523-50.1Wo Fig. -
Page 19: Plume Management Considerations
Pre-Installation 4.8.3 Plume management considerations FLUE TERMINAL GUARD ±45° 7 716 191 176 2500 2500 ≥140 ≥ 5 ≥ 5 0 0 5 0 0 ±80° EXCLUSION ZONE A EXCLUSION ZONE A EXCLUSION ZONE A 1000 2500 1000 2500 2500 1000 1800 1200... - Page 20 Pre-Installation 12. The distance between a boundary facing a terminal can be measured diagonally from the point of discharge with a minimum distance of 600mm which must be maintained. The exclusion zone ensures compliance with Approved Document J of the building regulations, 13.
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Page 21: Installation
Installation All dimensions in mm Installation Unpacking the boiler Flue All the previous Pre-Installation sections must be read and requirements met before starting boiler or flue Services installation Condensate LIFTING AND CARRYING PRECAUTIONS: ▶ Lift only a manageable weight, or ask for help. ▶... -
Page 22: Boiler Installation
Installation Boiler installation – Depress the two levers [H], one on either side beneath the slide rail, to release the control box and pull fully forward. WARNING: This appliance is serviced & repaired – Swivel the complete control box assembly upwards. externally. -
Page 23: Side Flue Options - Heatslave Ii
Installation ▶ Fit the air inlet telescopic sections [2 & 3] to the boiler flue cowl and secure the inner section with the clamp [1]. ▶ Push the air inlet outer section [3] (see figure 31) through the rear 3.3mmØ panel opening until the end of the tube is against the stops [4] on the clamp assembly [5]. -
Page 24: All Flue Options, Final Assembly
Installation 3.3mmØ & 6720807912-13.1Wo 6720807912-11.1Wo Fig. 33 Tab detail Fig. 31 5.4.4 All flue options, final assembly Flue clamp ▶ Lightly grease the flue pipe seal with the solvent free grease supplied. [2a & 2b] Flue section ▶ Remove the screw from the clamp bracket [1] and open the clamp. ▶... -
Page 25: Terminal Guard
Installation Model range Output (kW) Flue damper fitted 12/18 18/25 21,5 25/32 Yes 4m flue length No > 4m flue length Insert the flue damper into the inner tube of the straight extension or 90° elbow and fit the flue as shown in figure 37. Ensure that the rubber seal is fitted into the inner tube. -
Page 26: Pipework Connections
Installation That surplus water may be present due to factory testing. ▶ Align water pipework and connect ▶ Check that all unused sockets have been capped. Oil supply connections ▶ Route the oil supply pipe [W] along either side of the boiler as required and connect to the isolating valve [G] and ensure the valve is closed. -
Page 27: Oil Burner And Pump
Installation Fire valve Check that the oil supply pipe has a fire valve fitted externally to the building and appliance with the fire valve sensor located in the case. A fire valve sensor clip [1] is provided for this purpose on the support bar between the side panels. -
Page 28: Refitting Components
Installation Fig. 44 Converting to double pipe system Return plug By-pass screw Return pipe connection Refitting components 6720821683-12.1Wo WARNING: Flue gas leakage. Fig. 42 Nozzle access The seal between the burner and the mounting flange Refer to figure 43: must form a gas tight seal to prevent leakage of ▶... -
Page 29: Electrical
Installation 3. Plug burner lead [G] into connector [H]. Electrical 4. Swivel the expansion vessel [H] back into position taking care not to CAUTION: ISOLATE THE 230V ELECTRICITY SUPPLY kink the flexible hose or snag electric cables. ▶ Ensure that the electricity supply is safely Isolated 5. - Page 30 Installation Fig. 48 External 230 V Twin Channel Programmer and Room Mains voltage socket (provided) Shown here from top view, Thermostat wiring access is from other side. NOTE: on both plug & socket Earth is wired centrally. Frost Thermostat Pipe Thermostat Mains supply plug (pre-wired) Mains supply plug &...
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Page 31: Electrical Schematic
Installation 5.10 Electrical schematic 3 2 1 N 3 2 1 N Fig. 50 [14] Diverter valve [15] Tank overheat thermostat Fuse (slow blow) 5A [16] Circulation pump Worcester 24V controls point [17] Tank sensor Storage tank temperature control [18] Flow turbine EMS bus connections [19] Boiler earth Diagnostic port... -
Page 32: Weather Compensation
Installation 5.11 Weather compensation The sensor is wired directly into the control box via terminal 4 in the low voltage terminal strip ( page 30). The appliance will modulate the CH flow temperature based on the outside temperature when an outdoor sensor is connected to the The heating curve outdoor sensor connection on the control board and the weather The CH flow temperature has an upper limit of 82°C (this can be capped... -
Page 33: Commissioning
Commissioning Filling the system Commissioning 1. The diverter valve will sit in mid-position when the boiler has no demand and is powered up. Pre-commissioning checks-appliance CAUTION: Isolate the mains supplies before starting any work and observe relevant safety precautions. 1. Check that the service and water pipes are connected correctly. 2. -
Page 34: Starting The Appliance
Commissioning If an extra expansion vessel is fitted to the central heating return, adjust ▶ Turn on the main oil supply valve at the tank and draw off at least this to the same pressure as the appliance internal expansion vessel, 2.5 litres of oil until a steady flow of clear uncontaminated oil can be refer to separate instructions supplied with the extra expansion vessel. -
Page 35: Burner Head Setting
Commissioning 6.3.3 Burner head setting Adjustments to the burner head are made on the basis of the required output, refer to table 9 for the required setting for your boiler. Fig. 60 Priming the pump Fig. 62 Burner head adjustment thumbwheel Oil supply De-aerator One complete rotation clockwise (cw) from the minimum position... -
Page 36: Switching The Appliance On/Off
Commissioning ▶ Set the clock/programmer to continuously ON and the room thermostat to maximum temperature °C °F 6720805209-90.1Wo Fig. 64 ▶ Wait two minutes then press the lockout reset button [K] to initiate another start sequence. Fig. 67 ▶ Repeat procedure until a flame is established. 1. -
Page 37: Selecting Service Menus
Commissioning Centigrade symbol Displays next to the temperature reading. Confirmation symbol This symbol confirms a manual change. Alpha/Numerical display Displays a temperature or boiler status code. Text display Displays ECO or diagnostic code. Status code During normal operation various status codes can be displayed by pressing the service button. - Page 38 Commissioning Menu 2 parameter 2.7A Demand /fault 0 = The blue light will only operate as a flashing fault alert. indicator 1 = The blue light will operate as a boiler (blue light) activation demand light and fault alert. This is set to 1 by default. Reset to factory settings To reset any or all changes made in Menu 2 back to the factory default setting:...
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Page 39: Finish Commissioning Boiler Checks
Commissioning 6.3.7 Finish commissioning boiler checks ▶ Refit the sample point cap (hand tighten only, do not over tighten) and refit the burner cover. APPLIANCE MUST BE SET TO CO LEVELS. ▶ Complete the oil boiler commissioning checklist at the back of this manual. -
Page 40: Water Treatment
12 months or sooner if system content is lost. ▶ In cases where all attempts to find a micro leak have failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer. 6720805209-87.1Wo Water treatment products Fig. -
Page 41: Finishing Commissioning - Appliance
[E] using the key [F] provided. or repaired free of charge by Bosch Thermotechnology Ltd. • The householder may be asked to prove the date of installation, that... -
Page 42: Service And Spares
Service and spares See the following instructions for detail of some of the service Service and spares requirements listed below: ▶ Check and clean the burner. Inspection and service ▶ Replace burner nozzle and flexible oil hose/s. CAUTION: Isolate the water, electricity and oil mains ▶... - Page 43 Service and spares Pump filter ▶ Refer to figure 85 and remove the oil pump internal filter, clean in Kerosene and reassemble. The internal filter is accessed by removing screws [1] and the oil pump cover [2]. 6720821683-17.1Wo Fig. 85 Pump filter access ▶...
- Page 44 Service and spares ▶ Refit the flue manifold access cover [2] and secure with screws [1]. 6720821683-19.1Wo Fig. 86 Secondary heat exchanger and condensate trap detail Combustion chamber Refer to figure 87 ▶ Remove the retaining nuts and washers [A]. ▶...
- Page 45 Service and spares ▶ Check that the burner is seated correctly on its mounting flange and that the oil hose/s are routed correctly as shown in Fig. 40 on page 27 and not trapped in front of or underneath the burner. 1.
- Page 46 Service and spares 6 720 805 210-16.2Wo Fig. 91 Spares For Worcester Bosch spares refer to the the website at www.worcester- bosch.co.uk/spares Greenstar Heatslave II External 2022+ 6 721 843 980 (2022/01)
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Page 47: Fault Finding And Diagnosis
Fault finding and diagnosis Fault finding and diagnosis Status cause codes These cause codes are displayed during the normal operation of the boiler. They are not faults, they just give information on the current status of the boiler in real time. Cause code During normal operation various status codes can be displayed by pressing the service button. -
Page 48: Service Menus
Fault finding and diagnosis i13 Thermal This is the thermal store current temperature, store displayed in real time (rounded to 0.5°C units). current temperature i14 DCW inlet Current DCW inlet temperature displayed in real temperature time (rounded to 0.5°C units). i15 Out door This is the out door temperature displayed in real temperature... -
Page 49: Factory Reset And Fault Codes
Fault finding and diagnosis reset 2. Press the button and “reset” will be displayed with the tick symbol for 3 seconds. After 3 seconds the display will revert to the normal operation screen. 6 720 805 209-67.1TL Fig. 96 2.7A Demand/fault O = The blue light will only LED (blue light) activation operate as a flashing fault... -
Page 50: Cause And Fault Codes
Fault finding and diagnosis 8.4.3 Cause and fault codes Cause Fault Reset code code Description type Blocking Locking Possible cause Maximum temperature thermostat or air Reset Flue gas or tank thermostat overheat. Reset the overheat pressure switch activated thermostat or air pressure switch before resetting appliance. Safety or flow temperature rises too high Air lock or reduced water content. -
Page 51: Dhw Function Chart
Fault finding and diagnosis DHW function chart Fig. 99 Greenstar Heatslave II External 2022+ - 6 721 843 980 (2022/01) -
Page 52: Ch Function Chart
Fault finding and diagnosis CH function chart Flow temp peaks: Flow at more than Burner CH setpoint minus CH adaptive offset CH adaptive setpoint adjusted [200] [200] [200] 230V on CH LR AND fascia mounted Flow temp less than NO DEMAND Blue light ON Appliance Pump... -
Page 53: Solar Compatibility
Fault finding and diagnosis Power interruption during lockout Any CUS Mains F0 263 Normal Mains Press reset lockout - Blue power lockout - Blue operation power loss button light flashing restored light flashing IF the original lockout 9F 855 was due to a burner Press reset lockout - Blue lockout (9F, 855) then... -
Page 54: Burner Diagnostics Mode
Fault finding and diagnosis Burner diagnostics mode Service/installation engineers only. To access the Burner control box diagnostics or to use the burner reset button to reset the burner, the burner diagnostic mode must be activated as follows: Burner LOCKOUT Hold down the service mode Blue light flashing &... -
Page 55: 8.10.2 Fault Finding
Fault finding and diagnosis Last lockout memory feature ▶ Release the button. LED displaying the type of lockout memorised for 10 seconds The control box allows the last lockout that happened to be displayed. The time displaying the type of lockout can be extended by pressing the Access to this function is possible in both STANDBY and OPERATING reset button again during the display of the lockout (the lock out display status. -
Page 56: Flame Sensing Photocell
Fault finding and diagnosis Line Check Action Air set correctly? Go to line 10 Adjust combustion air settings Does the burner light? Go to line 11 Go to line 10a Is the nozzle atomising the fuel? Go to line 11 Go to line 10b Nozzle new? Go to line 10c... -
Page 57: Air Pressure Switch Connections
Fault finding and diagnosis ▶ Remove the screws securing the cover [1] 8.14 Air pressure switch connections ▶ Remove the cover [2] NOTICE: APS pressure sensing tubes ▶ Press the black reset button ▶ Ensure that the pressure sensing tubes are not ▶... - Page 58 Fault finding and diagnosis Is the system pressure constantly increasing even when the boiler is off for extended periods of time? PRV = Pressure Relief Valve EV = Expansion Vessel Does system pressure Can you confirm that the filling increase when the link is not stuck open/passing boiler is on? water in any way?
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Page 59: Oil Appliance Commissioning Checklist
Fault finding and diagnosis 8.16 Oil appliance commissioning checklist IMPORTANT This Commissioning checklist is to be completed in full by the competent ▶ Leave this manual with the Homeowner. person who commissioned the appliance as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. -
Page 60: Service Interval Record
Fault finding and diagnosis 8.17 Service interval record It is recommended that your appliance is serviced annually and that the Service Interval Record is completed and signed. Before completing the service Interval record below, ensure that you have carried out the service functions described in this manual. Always use the manufacturer’s recommended spare parts Service 1 Date:... - Page 61 Notes Greenstar Heatslave II External 2022+ - 6 721 843 980 (2022/01)
- Page 62 Notes Greenstar Heatslave II External 2022+ 6 721 843 980 (2022/01)
- Page 63 Notes Greenstar Heatslave II External 2022+ - 6 721 843 980 (2022/01)
- Page 64 SALES: 0330 123 9669 Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0330 123 9559 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. worcester-bosch.co.uk 6 721 843 980 (2022/01)