Related Manuals for Bosch Worcester Greenstar HIU E
Summary of Contents for Bosch Worcester Greenstar HIU E
- Page 1 Installation and maintenance instructions Heat Interface Unit Greenstar HIU, HIU E, HIU E Plus & HIU KE Plus For connection to a district heating system supplying heating and domestic hot water...
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Page 2: Table Of Contents
Contents Contents 5.3.4 Cable retainer clamps ......28 Key to symbols and safety instructions ....4 Frost protection . - Page 3 Contents Differential pressure control valve ....55 Circulating pump ......55 Heat meter .
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Page 4: Key To Symbols And Safety Instructions
Key to symbols and safety instructions List entries, first and second levels Key to symbols and safety instructions • A single component/item • A component/list, made up of multiple parts/items. Key to symbols – Sub component or sublist of main component/list. Warnings –... - Page 5 Key to symbols and safety instructions Packaging Danger of burns and scalds The following points should be observed during unpacking: ▶ Surfaces of individual components, connections and leaking water can be very hot and cause severe burns and scalds. • Check the delivery immediately upon receipt for completeness and ▶...
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Page 6: Appliance Information
Appliance information Appliance information General information Model matrix Model HIU KE Plus with heat meter Accessory Accessory 58.6 HIU KE Plus Accessory Accessory Accessory 58.6 HIU E Plus with heat meter Accessory Accessory 39.1 Pink HIU E Plus Accessory Accessory Accessory 39.1 Pink... -
Page 7: Intended Use
Appliance information Intended use Type plate The appliance provides domestic hot water and central heating to Refer to figure 1 properties that are serviced from district heating or central boiler plants. The type plate contains information on device performance, the The appliance consists of two heat exchangers, one for the domestic hot registration data and the serial number. -
Page 8: Standard Delivery
Appliance information Standard delivery 6720808928-07.1Wo Fig. 3 Standard package contents Heat Interface Unit Support bracket Mounting frame Filling link assembly Fittings and literature pack: - Installation and Maintenance Instructions - User Instructions - Wall mounting template - Sealing pack - Compression fittings - Pressure Relief Valve installer connection elbow Pre-payment scheme kit Appliance dimensions and hydraulic connections... -
Page 9: Internal Layout
Appliance information Internal layout Domestic Hot Water control valve Control unit Central heating control valve Manual air vent (district heating) Manual air vent (central heating) Return sensor NTC (district heating) Plate heat exchanger (central heating) Differential pressure control valve (if fitted, Table 2, Model matrix for standard component or accessory) Flow sensor NTC (central heating) [10] Heat meter (if fitted, ... -
Page 10: Electrical Schematic
Appliance information Electrical schematic 120/230 VAC Fig. 6 Electrical schematic Control unit [10] Mains 230V supply Low voltage connections (rear in service position) [11] Circulating pump 230V connections (rear in service position) [12] Flow sensor NTC (central heating) Low voltage connections (front in service position) [13] Return sensor NTC (district heating) 230V connections (front in service position) [14] Central heating control valve... - Page 11 Appliance information Control unit connections Component connections Installer connections Connections/ Connections/ Symbol Function Symbol Function Circulation pump Limiter thermostat (under-floor safety cut-off) • Live output [Brown] • Potential free • Neutral output [Blue] • Earth output [Green/Yellow] 230 V feed to external controls modules Flow turbine connection 230V •...
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Page 12: Designation Of Components
Appliance information 2.10 Designation of components 6720808928-02.2Wo Fig. 7 Designation of components 6 720 808 928 (2017/06) - Page 13 Appliance information Legend to Figure 7, Designation of components: Control unit Manual air vent (Domestic Hot Water) Manual air vent (district heating) Domestic Hot Water control valve Central heating control valve Return sensor NTC (district heating) Manual air vent (central heating) Plate heat exchanger (central heating) Flow sensor NTC (central heating) [10] Circulating pump...
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Page 14: Appliance Information
Appliance information 2.11 Appliance information Technical data HIU KE plus with heat HIU E Plus with Description Units HIU KE plus meter HIU E Plus heat meter General Height Width Depth Total unit weight (lift weight) Packaged unit weight Minimum inlet pressure to achieve nominal DHW flow rate Nominal output to domestic hot water 58.6 58.6... - Page 15 Appliance information HIU E with HIU with heat Description Units HIU E heat meter meter General Height Width Depth Total unit weight (lift weight) Packaged unit weight Minimum inlet pressure to achieve nominal DHW flow rate Nominal output to domestic hot water 39.1 39.1 39.1...
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Page 16: Function Schematic
Appliance information 2.12 Function Schematic The electronic control unit [1] provides fully modulated heating and hot water control between maximum and minimum heat output. There are two LEDs located on the top of the control unit [1] (visible through two viewing holes in the top of the case). -
Page 17: Regulations
Regulations System preparation Regulations Water system and pipe-work General • Any plastic pipe-work used on the central heating system must have a polymeric oxygen barrier coating and at least 1000mm length of The special rules must be followed for buildings where the appliance is copper or steel pipe connected to the appliance. -
Page 18: Domestic Water Supply
Pre-installation requirements Domestic water supply Use in hard water areas Normally there is no need for water treatment to prevent scale formation as the maximum temperature of the DHW heat exchanger is limited by the electronic control. In areas where temporary water hardness exceeds 200 ppm, consideration may need to be given to the fitting of a scale prevention device. -
Page 19: Cleaning Primary System
Pre-installation requirements Cleaning primary system NOTICE: Risk of damage to system or appliance! Debris from the system can damage the appliance and reduce efficiency. Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance guarantee. -
Page 20: Compartment Clearances
Pre-installation requirements 4.6.4 Compartment clearances Example layouts If the appliance is to be fitted in a compartment, the following minimum 4.7.1 Unmixed central heating with radiators clearances for the compartment dimensions apply. This is in addition to the normal installation and servicing clearances. •... -
Page 21: Unmixed Central Heating With Under-Floor
Pre-installation requirements 4.7.2 Unmixed central heating with under-floor Option 2: Control of under-floor with 230V programmable room thermostat example 120/230 VAC Fig. 16 Option 1: Control of under-floor with Sense II (EMS controller) Fig. 18 example Connections/ Symbol Function Limiter thermostat (under-floor safety cut-off) •... -
Page 22: Mounting Frame
Installation Mounting frame Installation Support bracket and mounting frame fitting NOTICE: Damage to property! Damage caused by drilling into pipes, electrical cables, damp proof course or other hazards. ▶ Before drilling ensure that there are no obstructions or other hazards. 5.1.1 Wall mounting template The wall mounting template has been sized to allow for... -
Page 23: Fitting Support Bracket And Mounting Rail
Installation 5.1.2 Fitting support bracket and mounting rail 5.1.4 Fitting the filling link assembly ▶ Secure the support bracket [4] to the wall, with appropriate fittings Fit the Integral filling link, supplied with the appliance, [5] for appliance weight and wall type. before hanging the appliance on the frame. -
Page 24: Fitting An External Filling Link (Not Supplied With Appliance)
Installation 5.1.5 Fitting an external filling link (not supplied with appliance) 5.1.6 Flushing valve accessory installation The cental heating sealed system must be filled using a WRAS approved A close-coupled flushing by-pass valve accessory is available and can be filling loop, example configurations shown in figures 24 and 25. fitted behind the mounting frame directly into the district heating supply and return connections. -
Page 25: Flow Regulating Valve (Not Supplied With Appliance)
Installation 5.1.7 Flow regulating valve (not supplied with appliance) NOTICE: The pressure differential across the primary circuit of the heat interface unit must not exceed 80kPa (800mbar) on units without a DPCV (differential pressure control valve) as standard. For units with internal DPCV (differential pressure control valve) fitted, the maximum differential pressure is 400kPa (4000mbar). -
Page 26: Electrical
Installation Electrical 0-30V 230V DANGER: Risk of electric shock! ▶ Before carrying out any work on electrical components, isolate them from the power supply (230 V AC) (fuse, circuit breaker) and secure against unintentional re-connection. ▶ Information on safe isolation can be found in the Health and Safety Executive Guidance HSG85. -
Page 27: Installer Connections
Installation 5.3.2 Installer connections 5.3.3 Access to electrical connections: Control box service position NOTICE: Risk of equipment damage ▶ The control box [1] incorporates a hook on the underside to support ▶ Only 230V room thermostats or 230V the control unit on the plate heat exchanger top bracket [2] whilst programmable room thermostats can be used with working in the control unit. -
Page 28: Cable Retainer Clamps
Installation 5.3.4 Cable retainer clamps Securing the cables Figure 36 Cable retainer clamps ▶ Unscrew the cable retaining screw [3]. ▶ Each cable entering the control box must be placed ▶ Feed the cable [4] through the cable clamp ensuring there is ample and secured under a cable retainer. -
Page 29: By-Pass Function
Installation By-pass function Limit return temperature The by-pass function, sometimes called summer by-pass function or The limit return function helps to ensure high system efficiency. Since a keep warm function, implements a feature to keep the supply side of the high return temperature results in a lower efficiency for the heating HIU hot. -
Page 30: Commissioning
Commissioning 6.3.1 Integral keyless filling link Commissioning ▶ When opening the isolation valves take care not to induce any water hammer. Cleaning the primary circuit ▶ Open the district heating supply isolation valve. Ensure the pipe-work systems connected to the heat distribution unit ▶... -
Page 31: External Filling Link (Not Supplied With Appliance)
Commissioning 6.3.2 External filling link (not supplied with appliance) Control unit The control units LED indicators can be seen from the top of the case External filling loop through two viewing holes. ▶ It is recommended that the external filling loop is fitted to the District primary side of the system, as this contains treated water. -
Page 32: Domestic Hot Water Rotary Switch
Commissioning The service function for both domestic hot water and central Left LED Right LED heating combines two functions whilst the rotary switch is set to (DHW) (CH) Description position. Yellow Yellow HIU starting up • Control valve calibration. flashing flashing •... -
Page 33: Control Valve Status Indication
Commissioning Control valve status indication Central heating circulation pump The control valves for Central Heating and Domestic Hot Water have The circulating pump has five LED indicators [1], this shows details of three indicators on the head of the actuator to denote operational states, operational status, current pump curve setting, adjusting pump curve see figure 7, items [4] and [5] to locate the valves. -
Page 34: Available Hydraulic Pressure
Commissioning Operational status indication 6.6.4 Central heating circulation pump Characteristics When the circulation pump is running, LED1 is green. The four yellow Modulating speed characteristics LEDs indicate the current power consumption (P1) as shown in table 13. When the operation mode is active, all active LEDs are constantly on in order to differentiate this mode. -
Page 35: Pump Curve Adjustment
Commissioning 6.6.5 Pump curve adjustment Sense II (EMS controller) configuration It is recommended that only proportional pressure curves be used on The EMS controller will need to be configured to optimise performance this appliance. This ensures the most efficient operation and maintains with the HIU. -
Page 36: Central Heating Settings - Outdoor Temperature Or Room Temperature Compensated Control
Commissioning Confirming or rejecting the change 6.7.3 Heat Interface Unit settings ▶ Enter the Service menu and navigate through the menus and select Rejecting the change the Heat Interface Unit settings menu. ▶ Press the selector to activate the marked entry or to ▶... -
Page 37: Floor Drying Function
– Wait time before start for screed drying. – Start phase duration Bosch cannot accept responsibility for mis-setting of – Start phase temperature temperatures. – Heat-up phase step range – Heat-up phase temp. diff. -
Page 38: Integral Heat Meter (If Fitted)
Commissioning Integral heat meter (if fitted) The heat meter is designed on the basis of the proven fluid oscillation principle. Due to the use of a static flow sensor, the heat meter does not The heat meter complies with the requirements of the European have any moving parts and thus no wear. - Page 39 Commissioning Integrator display ▶ To enter the category required press and hold the navigation button for approximately 2 seconds. ▶ To cycle through the displayed data pressing the navigation button repeatedly. Once all the data has been displayed for the category the display will move to the error display before returning to the default display screen of Energy [1], figure 53.
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Page 40: Water Quality
Commissioning Contact details for obtaining Prog7X9 software, DMS Metering Heat meter pulse output connection (only available on accessary) Solutions. Pulse meter accessory - the pulse outputs are made with SELV circuits • By post (Safety Extra Low Voltage) and must only be connected with other SELV circuits. -
Page 41: Domestic Hot Water For Copper Brazed Plate Heat Exchangers
Commissioning 6.9.2 Domestic hot water for copper brazed plate heat exchangers Concentration Water containing (mg/l or ppm) AISI 316 Copper Alkalinity (HCO <70 70-300 >300 Sulfate (SO <70 70-300 >300 >1 <1 Electrolytic conductivity <10 (μS/cm) 10-500 >500 <6.0 6.0-7.5 7.5-9.0 >9 Ammonia (NH... -
Page 42: Domestic Hot Water Performance Chart
Commissioning 6.10 Domestic hot water performance chart K v = 1.1 m³/hr K v = 1.3 m³/hr K v = 1.3 m³/hr K v = 1.7 m³/hr 50°C 45°C 6720808928-25.1Wo Fig. 55 Domestic hot water performance 6 720 808 928 (2017/06) - Page 43 Commissioning Key to Domestic hot water performance chart, Figure 55: Domestic hot water power output [kW]. Supply return temperature. Supply flow temperature. Supply volumetric flow rate [l/s] and [l/h]. Domestic hot water maximum volumetric flow rate [l/m]. Supply differential pressure [kPa] (Standard unit). Supply differential pressure [kPa] (Standard unit and heat meter).
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Page 44: Central Heating Performance Charts
Commissioning 6.11 Central heating performance charts 6.11.1 15kW & 7.5kW K v = 1.1 m³/hr K v = 1.3 m³/hr K v = 1.4 m³/hr K v = 1.7 m³/hr 6720808928-29.1Wo Fig. 56 Central heating performance 15kW & 7.5kW 6 720 808 928 (2017/06) - Page 45 Commissioning Key to Central heating performance chart, Figure 56: Supply volumetric flow rate [l/s] and [l/h]. Supply flow temperature [ °C]. Supply differential pressure [kPa] (Standard unit). Supply differential pressure [kPa] (Standard unit and heat meter). Supply differential pressure [kPa] (Standard unit and Differential pressure control valve).
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Page 46: 6.11.2 5Kw & 3.5Kw
Commissioning 6.11.2 5kW & 3.5kW K v = 1.1 m³/hr K v = 1.3 m³/hr K v = 1.4 m³/hr K v = 1.7 m³/hr 6720808928-59.1Wo Fig. 57 Central heating performance 5kW & 3.5kW 6 720 808 928 (2017/06) -
Page 47: Testing
Commissioning Key to Central heating performance chart, Figure 57: 6.12 Testing Supply volumetric flow rate [l/s] and [l/h]. Functional checking, heat outputs and balancing flow for a system Supply flow temperature [ °C]. containing multiple Heat Interface Units: Supply differential pressure [kPa] (Standard unit). ▶... -
Page 48: Commissioning Checklist
Commissioning 6.13 Commissioning checklist Customer name: Telephone number: Address: Installed by (print name): Installation date: Company name: Telephone number: Company address: Commissioned by (print name): Registered Operative ID number: Company name: Telephone number: Company address: Building Regulations Notification Number (if applicable): Appliance make and model: Appliance serial number: Commissioning... - Page 49 Commissioning Measure and record values: Central heating Central heating flow temperature (at Heat Interface unit) °C Central heating return temperature (at Heat Interface unit) °C Central heating flow rate l/min Central heating output Supply flow temperature °C Supply return temperature °C Supply volumetric flow rate Supply differential pressure...
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Page 50: Fitting The Cover
• During the period of this guarantee any components of the appliance which are proven to be faulty or defective in manufacture will be exchanged or repaired free of charge if repaired directly by Bosch Thermotechnology Ltd. • Invoices for attendance and repair of this appliance by third parties will not be accepted for payment by Bosch Thermotechnology Ltd. -
Page 51: Inspection And Maintenance
Inspection and maintenance 7.1.2 Draining the appliance Inspection and maintenance NOTICE: Risk of water damage to appliance or property! Due to HIUs being an inherently low maintenance space heating system, Damage from disconnecting water pathways which may the recommendation from BSRIA BG 62/2015 that a maintenance have retained some water. -
Page 52: Inspection Record
Inspection and maintenance Inspection record Inspection 01 Date: Inspection 04 Date: Engineer name: Engineer name: Company name: Company name: Telephone Number: Telephone Number: Supply return temperature central heating mode °C Supply return temperature central heating mode °C Secondary heating ΔT Secondary heating ΔT °C °C... - Page 53 Inspection and maintenance Inspection 07 Date: Inspection 09 Date: Engineer name: Engineer name: Company name: Company name: Telephone Number: Telephone Number: Supply return temperature central heating mode °C Supply return temperature central heating mode °C Secondary heating ΔT Secondary heating ΔT °C °C Supply flow temperature domestic hot water mode...
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Page 54: Replacement Of Parts
Replacement of parts Plate heat exchanger Replacement of parts Correct orientation ▶ When refitting the plate heat exchanger ensure it is CAUTION: Accessing internal components: correctly orientated, the label will have an arrow ▶ Isolate the district heating and the electrical mains below the heat exchanger usage . -
Page 55: Control Valves
Replacement of parts Control valves Refer to figure 66 ▶ Undo the connection pipes [5] and remove the differential pressure Refer to figure 64 control valve [4] from the upper and lower pipe work. ▶ Ensure the appliance is fully drained. ▶... -
Page 56: Heat Meter
Replacement of parts Heat meter Domestic hot water NTC sensor and safety valve Refer to figure 68 Hot water NTC sensor ▶ Ensure the appliance is fully drained. Refer to figure 70 ▶ Release the integrator assembly[4] via the locking buttons [3] on ▶... -
Page 57: Flow Turbine, Flow Regulator Assembly And Filter
Replacement of parts Flow turbine, flow regulator assembly and filter 8.10 Summer by-pass (if fitted) Refer to figure 71 Refer to figure 73 ▶ Ensure the domestic hot water circuit is fully drained. ▶ Ensure the appliance is fully drained. ▶... -
Page 58: Control Unit
Replacement of parts 8.12 Control unit When re-fitting the cables and associated strain reliefs: ▶ Ensure the power cables and signal cables are replaced in the Refer to figure 75 appropriate section of the control unit. ▶ Ensure the power supply to the appliance has been isolated and secure against unintentional reconnection. -
Page 59: Fault Finding And Diagnostics
Fault finding and diagnostics Fault finding and diagnostics Basic checks ▶ Ensure that there is 230Vac power supply and the polarity is correct to the appliance. ▶ Ensure that the appliance/controller settings and functionality are operating correctly. Central heating trouble shooting guide Problem Possible cause Possibly solution/check... -
Page 60: Domestic Hot Water Trouble Shooting Guide
Fault finding and diagnostics Problem Possible cause Possibly solution/check Central heating flow HiU Control unit incorrectly set or ▶ Adjust HIU control unit. Ensure that the flow temperature set-point is set correctly on the HIU controller. section 6.4 temperature too faulty high ▶... -
Page 61: Hiu Control Unit Led Indications
Fault finding and diagnostics Problem Possible cause Possibly solution/check Time taken to get Mechanical by-pass valve has dirt ▶ Clean valve if necessary. hot water at the tap inside valve body is too long Mechanical by-pass valve is set ▶ Adjust by-pass valve. incorrectly, or is faulty ▶... -
Page 62: Control Valve Fault Indication
Fault finding and diagnostics Control valve fault indication 9.4.2 Control valve calibration The control valve can be calibrated by: The modulating control valves for CH and DHW have three indicators on the head of the actuator to denote operational states, see figure 7, ▶... -
Page 63: Sense Ii (Ems Controller) Diagnosis Menu
Fault finding and diagnostics Sense II (EMS controller) Diagnosis menu Confirming or rejecting the change Rejecting the change 9.6.1 Operating the service menu ▶ Press the selector to activate the marked entry or to The first press of any Key or adjustment of the Selector confirm the change. -
Page 64: Heat Interface Unit Function Test Menu
Fault finding and diagnostics 9.6.4 Heat Interface Unit function test menu Component resistance characteristics ▶ Enter the Service menu and navigate through the menus and select 9.9.1 Flow/return temperature NTC sensors the Diagnosis menu. Resistance ( Ω) Temperature ( °C) ▶... - Page 65 Notes 6 720 808 928 (2017/06)
- Page 66 Notes 6 720 808 928 (2017/06)
- Page 67 Notes 6 720 808 928 (2017/06)
- Page 68 0330 123 9119 TRAINING: 0330 123 0166 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 6 720 808 928 (2017/06)