Bosch 12/18 Instruction Manual
Floor standing external oil fired condensing combination boiler using balanced flue system
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Also See for 12/18:
- User instructions & customer care manual (20 pages) ,
- Users instructions and customer care manual (16 pages) ,
- Instruction manual (56 pages)
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GREENSTAR HEATSLAVE EXTERNAL
12/18, 18/25, 25/32kW
FLOOR STANDING EXTERNAL OIL FIRED CONDENSING COMBINATION
BOILER 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
THE APPLIANCE IS FOR USE WITH KEROSENE ( 28 SECOND
OIL) ONLY
OIL) ONLY
INSTRUCTION MANUAL
INSTRUCTION MANUAL
INSTALLATION COMMISSIONING
& SERVICING
GB
GB
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Table of Contents
Related Manuals for Bosch 12/18
Summary of Contents for Bosch 12/18
- Page 1 GREENSTAR HEATSLAVE EXTERNAL 12/18, 18/25, 25/32kW FLOOR STANDING EXTERNAL OIL FIRED CONDENSING COMBINATION BOILER 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...
- Page 2 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 regulations.
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Page 3: Table Of Contents
FAULT FINDING LOGIC FOR SATRONIC CONTROL BOX FAULT FINDING LOGIC FOR 535 SE/LD RDB CONTROL BOX ELECTRICAL SCHEMATIC COMMISSIONING & SERVICE RECORDS COMBUSTION RECORD SERVICE INTERVAL RECORD INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 10-11 23-24 27-28 31-34... -
Page 4: Safety Precautions
OFTEC registered personnel) using approved spares, to help maintain the economy, safety and reliability of the appliance. SAFETY PRECAUTIONS & INSTALLATION REGULATIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 INSTALLATION REGULATIONS Failure to install appliances correctly could lead to prosecution. -
Page 5: General Information
100mm Ø Services Duct... 1 Condensate Trap Kit...1 Warranty Return Envelope ... 1 Cabinet Key... 1 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) GENERAL INFORMATION STANDARD PACKAGE: A - Floor standing oil fired condensing boiler for open vent and sealed domestic central heating and mains fed hot water. -
Page 6: Technical Data
°C kg/hr AC...V °C °C °C °C °C °C °C class mg/kW hr INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 TECHNICAL DATA 12/18 18/25 25/32 Lime — — 21.5 21.5 21.5 55/81 55/81 55/81 55/72... -
Page 7: Layout & Components
35/36 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) iii) LAYOUT & COMPONENTS The diagram opposite excludes the top, front and RH side casing panels. 1. CONTROL BOX ASSEMBLY 2. DIVERTER VALVE 3. -
Page 8: Cleaning Primary Systems
CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. CLEANING PRIMARY SYSTEMS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 CLEANING PRIMARY SYSTEMS IMPORTANT: Debris from the system can damage the boiler and reduce efficiency. -
Page 9: Mains Supplies
A - Mini expansion vessel, part No. 7 716 102 105 B - Mains water inlet C - Non-return valve D - Boiler INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) MAINS SUPPLIES ELECTRIC SUPPLY: •... -
Page 10: Oil Supply
2.5kg/h 5kg/h 10kg/h 8mmØ 8mmØ 8mmØ 10mmØ INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 OIL SUPPLY This appliance is suitable for kerosene (28 second oil) only, no other fuel must be used. OIL SUPPLY: • Plastic or steel tanks should be installed to BS 5410. -
Page 11: Water Systems & Pipework
L - Lockshield valve E - Feed & expansion cistern P - Pressure relief discharge TYPICAL SEALED SYSTEM INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) R - Radiators S - Static head... - Page 12 1000mm above the highest point of the system INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 WATER SYSTEMS & PIPEWORK FILLING PRIMARY SEALED SYSTEMS: • Filling the system must comply with one of the methods shown opposite.
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Page 13: Condensate & Pressure Relief Pipework
Invert (Unsuitable for clay soil types) 500mm min. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 75mm min. 25mm min. 400mm min. 200mm min. CONDENSATE & PRESSURE RELIEF PIPEWORK CONDENSATE PIPEWORK: • All national and, where appropriate, local... -
Page 14: Boiler Location & Clearances
Plan 85mm view FRONT 600mm 10mm 10mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 BOILER LOCATION & CLEARANCES WARNING: This appliance should not be installed where there is a potential for excessive ground water coverage. This boiler is only suitable for installing... -
Page 15: Cabinet Mounted Low Level Flue Terminal Positions
2 A way of providing protection of combustible material would be to fit a heat shield at least 750mm wide. boundary boundary INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) B(H) 600mm 600mm... -
Page 16: High Level Flue Terminal Positions
— 300mm — 1 000mm Pitched roof INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 HIGH LEVEL FLUE TERMINAL POSITIONS • 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 BS 5410. -
Page 17: External Oilfit Balanced Flue Options
125mmØ x4 Vertical terminal (rear outlet) L = 6000mm 125mmØ x4 Vertical terminal (side outlet) INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) BALANCED EXTERNAL OILFIT FLUE OPTIONS IMPORTANT: The weather seal (supplied) must be fitted to every flue joint to give the required level of weather protection. -
Page 18: Cabinet Mounted Horizontal Balanced Flue Options
Plan view FRONT Plan view FRONT INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 CABINET MOUNTED BALANCED HORIZONTAL FLUE OPTIONS • The horizontal flue is 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. -
Page 19: Unpacking The Boiler
IIMPORTANT: All the previous Pre-Installation sections must be read and requirements met before starting boiler or flue installation. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) UNPACKING THE BOILER LIFTING AND CARRYING PRECAUTIONS: •... -
Page 20: Pipework & Flue Positions
Fire valve capillary & drain access Flue Services LEFT HAND SIDE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 PIPEWORK & FLUE POSITIONS CAUTION: Ensure there are no pipes, electric cables, damp proof courses or other hazards before drilling. -
Page 21: Boiler Installation
THIS APPLIANCE IS INSTALLED AND SERVICED EXTERNALLY TO THE PROPERTY, BUT THE ENGINEER MUST HAVE ACCESS TO THE INSIDE OF THE PROPERTY WHEN INSTALLING OR SERVICING THE APPLIANCE. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) BOILER INSTALLATION... -
Page 22: Flue Installation
FLUE INSTALLATION INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 FLUE INSTALLATION INSTALLATION NOTES: Ensure all the seals are in good condition and seated properly. To ease assembly of flue components, grease seals lightly with the solvent free grease supplied. -
Page 23: Combustion Chamber
Plan sectional view Plan sectional view 12/18 & 18/25kW 25/32kW FRONT FRONT INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) COMBUSTION CHAMBER Combustion chamber: Release retaining nuts and washers (B). Remove combustion chamber access door (A). -
Page 24: Pipework Connections
CAUTION: ISOLATE THE OIL & WATER MAINS SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. PIPEWORK CONNECTIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 PIPEWORK CONNECTIONS CH flow 22mmØ copper (28mmØ on 25/32 models) DHW flow 22mmØ... - Page 25 IMPORTANT: Insulate all external condensate pipe work or run in 32mm pipe work to prevent freezing. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) PIPEWORK CONNECTIONS Flue manifold condensate outlet Condensate outlet (21.5mmØ) -...
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Page 26: Oil Burner And Pump
2.5 - 3.0mm 7.5mm Electrode gap 4mm b) SUNTEC AS47C OIL PUMP INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 OIL BURNER & PUMP CAUTION: ISOLATE THE OIL & WATER MAINS SUPPLY BEFORE STARTING ANY W OR K AN D OB S E RVE ALL R E LE VANT SAFETY PRECAUTIONS. -
Page 27: Refitting Components
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) REFITTING COMPONENTS Align burner combustion head (A) into boiler housing tube with gasket (B) correctly fitted. Push firmly down to compress the gasket (B). Tighten burner retainers (C) sufficiently to ensure a good seal. -
Page 28: Electrics
PROGRAMMER (EXTERNAL) CH channel clock HW channel FROST STAT(2) Fuse INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 ELECTRICS DANGER - 230V: ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. IMPORTANT: THIS APPLIANCE... - Page 29 M o d e switch Service connection gy gy INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) pk pk bk r g gy w 1 2 3 4 5 6 1 2 3 4 5 6...
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Page 30: Pre-Commissioning Checks - Appliance
1000 1200 1400 1600 1800 Litres per hour PRE-COMMISSIONING CHECKS - APPLIANCE 2000 2200 2400 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 PRE-COMMISSIONING CHECKS - APPLIANCE CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. -
Page 31: Filling The System
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) FILLING THE SYSTEM Pull lever (C) up and push to the left to move the diverter valve to the mid-position between ports A and B. -
Page 32: Starting The Appliance
SUNTEC AS47C OIL PUMP RDB OIL PUMP E - Lockout indicator TANK INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 STARTING THE APPLIANCE IMPORTANT: Never run the appliance when the appliance/system is unpressurised (sealed systems) or empty. 1 Check the oil supply is correctly fitted and in good working order before turning on the oil supply valves to the boiler. - Page 33 11.5 0.75 60°ES 0.75 60°ES 2.45 12.0 2.75 3.48 12.5 0.85 60°ES INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 25/32 (on top of burner control box) RIELLO RDB OIL PUMP APPROX. APPLIANCE...
- Page 34 GREENSTAR HEATSLAVE EXTERNAL INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 STARTING THE APPLIANCE Domestic hot water: 1 Set the CH/DHW programmer to OFF. Fully open a hot water tap. The burner should be OFF and the circulating pump ON.
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Page 35: Starting The Appliance
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) Central heating: The burner should be ON with the circulating service pump. The diverter valve (E) should open to lockout port B for CH. -
Page 36: Water Treatment
WATER TREATMENT 1 - 2 bar INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 WATER TREATMENT IMPORTANT: Debris from the system can damage the boiler and reduce efficiency. Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance warranty. -
Page 37: Finishing Commissioning - Appliance
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) FINISHING COMMISSIONING - APPLIANCE Refit the top panel and press down to compress the seal when fitting the securing screws (A). Push the front panel up behind the top panel and push in at the base to secure the screws (B) with the tool provided. -
Page 38: Inspection And Service
INSPECTION AND SERVICE service INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 INSPECTION AND SERVICE CAUTION: ISOLATE THE WATER, ELECTRICITY AND OIL MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. DO NOT USE PRESSURE WASHERS OR STEAM CLEANERS ON THIS APPLIANCE OR ITS CABINET. - Page 39 BFP 11 L3 OIL PUMP AS47C OIL PUMP A - Retaining screws - cover B - Cover - oil pump INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) INSPECTION AND SERVICE 1 Clean the Burner: Remove the air intake cover (H) and clear any debris from the air intake and air damper.
- Page 40 INSPECTION AND SERVICE Plan sectional view 25/32kW FRONT INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 INSPECTION AND SERVICE External oil filter: Remove the paper element from the external oil filter and replace it. If the filter contains a washable element, thoroughly clean in kerosene and reassemble into the filter.
- Page 41 25/32 - Riello RDB Burner: 2.15 2.72 11.5 0.75 60°ES 0.75 60°ES 2.45 12.0 2.75 3.48 12.5 0.85 60°ES INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) APPROX. APPLIANCE INPUT OUTPUT SETTING Btu/hr Btu/hr 12.4 42300 40900 15.5...
- Page 42 SHORT PARTS LIST 12/18 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 SHORT PARTS LIST 12/18 1 Burner - Sterling 40 Part Number: 8 716 112 507 0 2 Combustion head - burner Part Number: 8 716 112 604 0...
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Page 43: Short Parts List 18/25
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) SHORT PARTS LIST 18/25 1 Burner - Sterling 50 2 Combustion head - burner 3 Control box Satronic DKO 970 4 Photocell Satronic MZ770s 5 Control box base Satronic S98 12 pole... -
Page 44: Short Parts List 25/32
SHORT PARTS LIST 25/32 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 SHORT PARTS LIST 25/32 1 Burner - Riello RDB 2.2 25/32 HE Part Number: 8 716 112 512 0 2 Combustion head - burner Part Number: 8 716 112 521 0... -
Page 45: Fault Finding & Diagnosis
Incorrect combustion settings Oil pressure incorrect Incorrect components used on combustion head Faulty nozzle INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 106 252b (07/06 REMEDY FAULT FINDING BOILER LOCKOUT : Set up as in installation instructions... - Page 46 Correct burner rating Replace boiler thermostat Check and correct external controls Check seals/gaskets Rectify burner operation and lockouts Rectify oil leaks, replace components if necessary INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 FAULT FINDING 8 716 113 389b (09/07)
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Page 47: Fault Finding Logic For Satronic Control Box
Worcester, Bosch Group cannot be held responsible for costs incurred by persons not deemed to be competent. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 106 252b (07/06 FAULT FINDING LOGIC FOR... -
Page 48: Fault Finding Logic For 535 Se/Ld Rdb Control Box
Worcester, Bosch Group cannot be held responsible for costs incurred by persons not deemed to be competent. FAULT FINDING INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 FAULT FINDING LOGIC FOR 535 SE/LD RDB CONTROL BOX 8 716 113 389b (09/07) -
Page 49: Electrical Schematic
ELECTRICAL SCHEMATIC INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 ELECTRICAL SCHEMATIC 8 716 106 252b (07/06... -
Page 50: Combustion Record
Service Provider. Before completing the appropriate Service Interval Record overleaf, please ensure you have carried out the service as described in this manual. Always use Worcester, Bosch Group specified spare parts when replacing all controls. OIL BOILER COMBUSTION RECORD SERIAL No. - Page 51 SERVICE 1 DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: NOZZLE CHANGED? F.G.T. °C FLUE PRESSURE: COMMENTS SIGNATURE SERVICE 3 DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: NOZZLE CHANGED? F.G.T. °C FLUE PRESSURE: COMMENTS SIGNATURE...
- Page 52 General checks 1. Is the mode switch in boiler mode (indicator on)? 2. Is there 230V across the boiler live and neutral terminals? 3. Is the polarity correct? (230V across live and earth, 0V across neutral and earth) 4. Is the air bled from the primary system? 5.