Bosch GREENSTAR HEATSLAVE EXTERNAL 18/25 Instruction Manual
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Bosch GREENSTAR HEATSLAVE EXTERNAL 18/25 Instruction Manual

Bosch GREENSTAR HEATSLAVE EXTERNAL 18/25 Instruction Manual

Open vent & sealed central heating systems with mains fed domestic hot water
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8 716 113 389d
30/3/10
14:01
INSTRUCTION MANUAL
INSTALLATION, COMMISSIONING & SERVICING
FLOOR STANDING EXTERNAL OIL FIRED CONDENSING
COMBINATION BOILER USING BALANCED FLUE SYSTEM
GREENSTAR HEATSLAVE EXTERNAL
12/18, 18/25 & 25/32
FOR OPEN VENT & SEALED CENTRAL HEATING SYSTEMS WITH
MAINS FED DOMESTIC HOT WATER
All manuals and user guides at all-guides.com
Page 1
THE APPLIANCE IS FOR USE WITH KEROSENE
(28 SECOND OIL) ONLY
UK

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  • Page 1 All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 1 INSTRUCTION MANUAL INSTALLATION, COMMISSIONING & SERVICING FLOOR STANDING EXTERNAL OIL FIRED CONDENSING COMBINATION BOILER USING BALANCED FLUE SYSTEM GREENSTAR HEATSLAVE EXTERNAL 12/18, 18/25 & 25/32 FOR OPEN VENT &...

  • Page 2: Important Information And Symbols

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 2 INSTALLATION & SERVICING INSTRUCTIONS SYMBOLS USED IN THIS MANUAL: PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION. THESE INSTRUCTIONS ARE APPLICABLE TO THE WORCESTER APPLIANCE MODEL(S) Domestic hot water STATED ON THE FRONT COVER OF THIS MANUAL ONLY AND MUST NOT BE USED WITH ANY OTHER MAKE OR MODEL OF APPLIANCE.

  • Page 3: Table Of Contents

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 3 CONTENTS SAFETY & REGULATIONS IMPORTANT INFORMATION AND SYMBOLS SAFETY PRECAUTIONS AND INSTALLATION REGULATIONS APPLIANCE INFORMATION GENERAL INFORMATION TECHNICAL DATA LAYOUT & COMPONENTS PRE-INSTALLATION CLEANING PRIMARY SYSTEMS MAINS SUPPLIES OIL SUPPLY WATER SYSTEMS &...

  • Page 4: Safety Precautions And Installation Regulations

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 4 SAFETY PRECAUTIONS INSTALLATION REGULATIONS OIL FUMES OR LEAKS FROM THE APPLIANCE: Failure to install appliances correctly could lead to prosecution. Extinguish any naked flames. The appliance should be installed by a competent Isolate the electrical supply.

  • Page 5: General Information

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 5 GENERAL INFORMATION STANDARD PACKAGE: A - Floor standing oil fired condensing boiler for open vent and sealed domestic central heating 640mm 770mm and mains fed hot water. B - Literature pack.

  • Page 6: Technical Data

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 6 TECHNICAL DATA DESCRIPTION UNITS 12/18 18/25 25/32 Central Heating Primary water capacity (total) litres Maximum static head metres Minimum static head metres Available pump head (20°C difference) at max. output metres water Max.

  • Page 7: Layout & Components

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 7 LAYOUT & COMPONENTS The diagram opposite excludes the top, front and RH side casing panels. 1. CONTROL BOX ASSEMBLY 2. DIVERTER VALVE 3. PRESSURE GAUGE 4.

  • Page 8: Cleaning Primary Systems

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 8 CLEANING PRIMARY SYSTEMS IMPORTANT: All the following Pre-Installation sections must be read and requirements met before starting boiler or flue installation. IMPORTANT: Debris from the system can damage the boiler and reduce efficiency.

  • Page 9: Mains Supplies

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 9 IMPORTANT: The appliance provides a permanent external electrical supply MAINS SUPPLIES for servicing and must therefore be fed via a circuit breaker incorporating earth leakage protection. ELECTRIC SUPPLY: •...

  • Page 10: Oil Supply

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 10 OIL SUPPLY - Oil storage tank - Oil supply pipe - Isolating valve - Oil pump OIL SUPPLY: - Oil strainer & water separator - Full base (plastic tanks) This appliance is suitable for kerosene (28 - Fire valve to BS5410 - Non-return valve...

  • Page 11: Water Systems & Pipework

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 11 WATER SYSTEMS & PIPEWORK IMPORTANT: The boiler should not be allowed t o operat e wit h a ret urn temperature of less than 40°C when the system is up to operating temperature.

  • Page 12: Pressure Relief Pipework

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 12 WATER SYSTEMS & PIPEWORK Water main Heating return supply FILLING PRIMARY SEALED SYSTEMS: Non return Non return • Filling the system must comply with one of valve valve Hose...

  • Page 13: Condensate Pipework

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 13 CONDENSATE & PRESSURE RELIEF PIPEWORK CONDENSATE PIPEWORK: • All national and, where appropriate, local regulations for the discharge and neutralisation of condensate should be followed. •...

  • Page 14: Cabinet Mounted Low Level Flue Terminal Positions

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 14 CABINET MOUNTED LOW LEVEL Minimum dimensions of flue terminal positions for oil fired appliances: FLUE TERMINAL POSITIONS TERMINAL POSITION B(H) • Flue terminals must be positioned to avoid combustion products entering into buildings.

  • Page 15: High Level Flue Terminal Positions

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 15 HIGH LEVEL FLUE TERMINAL Minimum dimensions of flue terminal positions for oil fired appliances: TERMINAL POSITION B(H) B(V) POSITIONS Directly below an opening, air brick, opening window, etc 600mm •...

  • Page 16: Boiler Location & Clearances

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 16 BOILER LOCATION & CLEARANCES 600mm WARNING: This appliance should not be installed where there is a potential for excessive ground water coverage. This boiler is only suitable for installing externally at a suitable location onto a fixed permanent rigid surface c apable of supporting the boiler weight.

  • Page 17: Balanced External Oilfit Flue Options

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 17 BALANCED EXTERNAL OILFIT L = 2000mm FLUE OPTIONS IMPORTANT: The weather seal (supplied) must be fitted to every flue joint to give the required level of weather protection. The diagrams (opposite) show the components used and the maximum flue length (L) for 125mmØ...

  • Page 18: Cabinet Mounted Balanced Horizontal Flue Options

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 18 CABINET MOUNTED BALANCED HORIZONTAL FLUE OPTIONS • The horizontal flue is fitted to the rear or REAR FLUE OUTLET either side of the cabinet. A + C IMPORTANT: It is strongly recommended that the flue terminal faces away from walls to...

  • Page 19: Unpacking The Boiler

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 19 UNPACKING THE BOILER IMPORTANT: All the previous Pre-Installation sections must be read and requirements met before starting boiler or flue installation. LIFTING AND CARRYING PRECAUTIONS: •...

  • Page 20: Pipework & Flue Positions

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 20 All dimensions in mm PIPEWORK & FLUE POSITIONS Flue CAUTION: Ensure there are no pipes, electric cables, damp proof courses or other hazards before drilling. Services SAFETY: All relevant safety precautions must be undertaken.

  • Page 21: Boiler Installation

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 21 WARNING: THIS APPLIANCE IS SERVICED AND REPAIRED EXTERNALLY. BOILER INSTALLATION EXTERNAL EQUIPMENT OPERATED AT 230V SHOULD NOT BE INSTALLED, SERVICED OR REPAIRED UNDER ADVERSE WEATHER CONDITIONS. NOTE: The cabinet is not load bearing and only provides weather THIS APPLIANCE IS INSTALLED AND SERVICED EXTERNALLY TO THE PROPERTY, BUT...

  • Page 22: Flue Installation

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 22 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

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 23 COMBUSTION CHAMBER Combustion chamber: Release retaining nuts and washers (B). Remove combustion chamber access door (A). Ensure the baffles (C) and baffle retainer (D) are correctly fitted for the boiler output as shown in the plan views opposite.

  • Page 24: Pipework Connections

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 24 CAUTION: ISOLATE THE OIL & WATER MAINS SUPPLY BEFORE STARTING ANY PIPEWORK CONNECTIONS WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. CH flow 22mmØ copper (28mmØ on 25/32 models) DHW flow 22mmØ...

  • Page 25: Short Parts List Riello Rdb 2.2

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 25 PIPEWORK CONNECTIONS Flue manifold condensate outlet Condensate outlet (21.5mmØ) - supplied Condensate pipe - not supplied Internal condensate trap Pressure relief (15mmØ) CONDENSATE CONNECTION: Connect 21.5mm polypropylene pipe (K) (not supplied) to the condensate pipe flexible push fit connector (J) before terminating to waste.

  • Page 26: Oil Burner And Pump

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 26 OIL BURNER & PUMP BENTONE CAUTION: ISOLATE THE OIL & WATER 12/18 & 18/25kW MAINS SUPPLY BEFORE STARTING ANY W OR K AN D OB S E RVE ALL R E LE VANT Electrode gap SAFETY PRECAUTIONS.

  • Page 27: Refitting Components

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 27 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

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 28 ELECTRICS DANGER - 230V: ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. IMPORTANT: THIS APPLIANCE PROVIDES A PERMENANT EXTERNAL ELECTRICAL SUPPLY FOR SERVICING AND MUST THEREFORE BE FED VIA A CIRCUIT BREAKER INCORPORATING...
  • Page 29 All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 29 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...

  • Page 30: Pre-Commissioning Checks - Appliance

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 30 PRE-COMMISSIONING CHECKS - APPLIANCE CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. Check that the service and water pipes are connected correctly.

  • Page 31: Filling The System

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 31 FILLING THE SYSTEM 1 Pull lever (C) up and push to the left to move the diverter valve to the mid-position between ports A and B. Push and hold lever (C) down to lock.

  • Page 32: Starting The Appliance

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 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 All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 33 STARTING THE APPLIANCE SUNTEC RIELLO DANFOSS Remove plastic cover from the burner casing AS47C OIL PUMP RDB OIL PUMP BFP 11 L3 OIL PUMP (there is no plastic cover on the Riello burner). Fit a suitable pressure gauge to port (A) on the oil pump.
  • Page 34 All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 34 STARTING THE APPLIANCE RIELLO SUNTEC DANFOSS AS47C OIL PUMP RDB OIL PUMP BFP 11 L3 OIL PUMP Check the CO levels and adjust the air shutter (L) setting according to the table opposite.
  • Page 35 All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 35 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.
  • Page 36 All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 36 STARTING THE APPLIANCE Central heating: Open all radiator valves. Set room thermostat to maximum. Set programmer to ON for CH. Turn the DHW thermostat control (C) fully anti-clockwise.

  • Page 37: Water Treatment

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 37 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 38: Finishing Commissioning - Appliance

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 38 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 39: Inspection And Service

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 39 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 service STEAM CLEANERS ON THIS APPLIANCE OR ITS CABINET.
  • Page 40 All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 40 INSPECTION AND SERVICE 1 Clean the Burner: Remove the air intake cover (H) and clear BENTONE any debris from the air intake and air damper. STERLING 40 &...
  • Page 41 All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 41 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 42 All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 42 INSPECTION AND SERVICE Fire valve: Check that the oil supply pipe has a fire valve fitted at least 1m away from the appliance with the fire valve sensor located within the appliance case.
  • Page 43 All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 43 BENTONE Sterling 40 burner 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 3 Control box Satronic DKO 970 Part Number: 8 716 142 396 0...
  • Page 44 All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 44 BENTONE Sterling 50 burner SHORT PARTS LIST 18/25 1 Burner - Sterling 50 Part Number: 8 716 112 570 0 2 Combustion head - burner Part Number: 8 716 108 573 0 3 Control box Satronic DKO 970 Part Number: 8 716 142 396 0...

  • Page 45: Short Parts List Riello Rdb

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 45 RIELLO RDB 1 burner SHORT PARTS LIST 12/18 1 Burner - Riello RDB 1 12/18 Part Number: 8 718 685 873 0 2 Combustion head - LD2SX (Short) Part Number: 8 718 685 902 0 3 Control box MO535 Part Number: 8 718 682 250 0...
  • Page 46 All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 46 RIELLO RDB 2.2 burner SHORT PARTS LIST 18/25 1 Burner - Riello RDB 2.2 18/25 Part Number: 8 718 685 836 0 2 Combustion head - LD2SX (Short) Part Number: 8 718 685 872 0 3 Control box MO535 Part Number: 8 718 682 250 0...

  • Page 47: Short Parts List Riello Rdb 2.2

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 47 RIELLO RDB 2.2 burner 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 3 Control box MO535 Part Number: 8 718 682 250 0...

  • Page 48: Fault Finding & Diagnosis

    All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 48 PROBLEM CAUSE REMEDY FAULT FINDING LOCKOUT: BOILER LOCKOUT : Pulsation on start Combustion settings incorrect Set up as in installation instructions Indicated by the illumination of the 'Lockout' Faulty nozzle Replace nozzle indicator on the fascia.
  • Page 49 All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 49 PROBLEM CAUSE REMEDY FAULT FINDING FAULTY BOILER OPERATION: Noisy operation Pump noise from air in pump or Bleed air from pump or replace pump worn pump Worn motor bearings Replace motor Fan out of balance...

  • Page 50: Riello Controlbox Operation

    Whilst every effort has been taken to ensure the information given is CONTROL BOX OPERATION correct and complete we cannot guarantee that every eventuality has been covered. Worcester, Bosch Group cannot be held responsible for costs incurred by persons not deemed to be competent. STATUS...

  • Page 51: Fault Finding Logic For Satronic Control Box

    All manuals and user guides at all-guides.com Stray light Replace Replace Photo cell Replace coil Boiler not on photo control box lead lead OK? lead operating cell? with a heating / hot water demand 230V at Disconnect photo cell, Replace Coil lead Replace Replace...

  • Page 52: Fault Finding Logic For Riello Control Boxes

    All manuals and user guides at all-guides.com FAULT FINDING & DIAGRAMS MO535 IMPORTANT NOTE: The box has a built in delay of 11 seconds before activating the motor. The preheater link must be fitted at for the box to operate Replace Replace Boiler not...

  • Page 53: Electrical Schematic

    All manuals and user guides at all-guides.com MAINS CONNECTION X1 (PIN 5) MANUAL RESET TANK LOCKOUT OVERHEAT INDICATOR BOILER MODE THERMOSTAT INDICATOR X1 (PIN 6) X11 (PIN 2) X11 (PIN 3) X12 (PIN 3) brown X9 (PIN 1) X9 (PIN 2) X7 (PIN 1) X3 (PIN 3 (L)) white...

  • Page 54: Service Interval Record

    It is recommended that the heating system is serviced regularly and that you complete the appropriate Service Interval Record Overleaf. 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.
  • Page 55 All manuals and user guides at all-guides.com 8 716 113 389d 30/3/10 14:01 Page 55 SERVICE 2 SERVICE 1 DATE DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No. TEL No. OFTEC REG No. OFTEC REG No. PUMP PRESSURE: PUMP PRESSURE: NOZZLE CHANGED? NOZZLE CHANGED?
  • Page 56 TO OPERATE WITH ANY CONTROL LINKED OUT OR OVER RIDDEN. Dedicated to heating comfort Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0844 892 9900 Fax. 01905 754619 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. www.worcester-bosch.co.uk 8 716 113 389d (03/2010)

This manual is also suitable for:

Greenstar heatslave external 12/18Greenstar heatslave external 25/32

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