Bosch 12/18 Instruction Manual

[Page 1] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

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 ...

[Page 2] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

INSTALLATION & SERVICING INSTRUCTIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 1 Check List Hardware/Literature pack Item Qty Greenstar Heatslave External In...

[Page 3] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

SAFETY & REGULATIONS IMPORTANT INFORMATION AND SYMBOLS 1 SAFETY PRECAUTIONS AND INSTALLATION REGULATIONS 3 APPLIANCE INFORMATION GENERAL INFORMATION 4 TECHNICAL DATA 5 LAYOUT & COMPONENTS 6 PRE-INSTALLATION CLEANING PRIMARY SYSTEMS 7 MAINS ...

[Page 4] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

SAFETY PRECAUTIONS & INSTALLATION REGULATIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 3 SAFETY & REGULATIONS SAFETY PRECAUTIONS INSTALLATION REGULATIONS ...

[Page 5] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

GENERAL INFORMATION INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 4 APPLIANCE INFORMATION A B 770mm 950mm 640mm C D E GENERAL INFORMATION STANDARD PACKAGE: A - Floor s...

[Page 6] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

TECHNICAL DATA INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 5 TECHNICAL DATA Central Heating Primary water capacity (total) litres Maximum static head metres Minimum st...

[Page 7] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

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. AUTO AIR VENT 5. CH CONTROL AND MANUAL RESET OVERHEAT THERMOSTAT PHIAL 6. CASIN...

[Page 8] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

CLEANING PRIMARY SYSTEMS BEFORE CLEANING THE SYSTEM: ENSURE THE SYSTEM AND PIPEWORK IS IN GOOD WORKING ORDER. FLUSH THE EXISTING SYSTEM WITH A POWER FLUSHING MACHINE OR WITH A CHEMICAL CLEANER BEFORE INSTALLING NEW COMPONENTS. CLEANING THE PRIMARY SY...

[Page 9] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

MAINS SUPPLIES ELECTRIC SUPPLY: • Supply: 230V - 50Hz. • Cable: PVC insulated 0.75mm 2 (24 x 0.2mm) temperature rated to 90°C. • Protection IP45. • External 5A fuse to BS 1362. • The appliance must be earthed. • Please refer to IEE...

[Page 10] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

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. A steel tank should conform to BS 799: part 5 and have a slope of 1 in 24 a...

[Page 11] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

TYPICAL OPEN VENT SYSTEM D R R R R C T L T L T L L L E S 1000mm min. F G D TYPICAL SEALED SYSTEM D R R R R B P D C T L T L T L L L A U H G INSTALLATIONCOMMISSIONING A - Appliance expansion vessel B - Extra expansion vessel C - Automatic bypass valve...

[Page 12] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

WATER SYSTEMS & PIPEWORK FILLING PRIMARY SEALED SYSTEMS: • Filling the system must comply with one of the methods shown opposite. • The filling point must be at low level and must never be a permanent direct fixing to the mains water supply...

[Page 13] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

K J b E C Invert 450 min. A c D A C 75mm min. a A B C D 400mm min. 500mm min. d F I H G A C 25mm min. 200mm min. (Unsuitable for clay soil types) CONDENSATE & PRESSURE RELIEF PIPEWORK INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREE...

[Page 14] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

BOILER LOCATION & CLEARANCES INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 13 PRE - INSTALLATION BOILER LOCATION & CLEARANCES WARNING: This appliance should not...

[Page 15] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

CABINET MOUNTED LOW LEVEL FLUE TERMINAL POSITIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 14 PRE - INSTALLATION Minimum dimensions of flue terminal positions for o...

[Page 16] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

HIGH LEVEL FLUE TERMINAL POSITIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 8 716 106 252d (08/07) 15 PRE - INSTALLATION Minimum dimensions of flue terminal positions for oil fired appliances: TER...

[Page 17] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

BALANCED EXTERNAL OILFIT FLUE OPTIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 16 PRE - INSTALLATION IMPORTANT: The weather seal (supplied) must be fitted to every...

[Page 18] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

BALANCED FLUE OPTIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 17 PRE - INSTALLATION CABINET MOUNTED BALANCED HORIZONTAL FLUE OPTIONS • The horizontal flue is fi...

[Page 19] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

Unpacking: It is advised that two or more persons are involved in the transfer of the packaged boiler from the van to the point of delivery. 1  Once the packaged boiler has been delivered, the outer carton is removed first. Care should be taken w...

[Page 20] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

All dimensions in mm 256 650 58 802 258 81 105 171 374 161 650 787 670 518 105 94 55 269 658 669 705 715 650 794 670 518 158 124 89.5 55 658 679 698 718 528 230 INSTALLATIONCOMMISSIONING SAFETY: All relevant safety precautions must be undertake...

[Page 21] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

BOILER INSTALLATION Note: The cabinet is not load bearing it only provides weather protection for the boiler inside. 1Mark position of the 100mm services duct on the exterior wall and make a hole through. 2Remove the key for the door fastners...

[Page 22] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

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.  A terminal guard must be fitted if the terminal is 2m...

[Page 23] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

COMBUSTION CHAMBER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 22 INSTALLATION Combustion chamber: 1 Release retaining nuts and washers (B).  Remove combustion c...

[Page 24] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

PIPEWORK CONNECTIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 23 INSTALLATION PIPEWORK CONNECTIONS A - CH flow 22mmØ copper (28mmØ on 25/32 models) B - DHW flow ...

[Page 25] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

PIPEWORK CONNECTIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 24 INSTALLATION PIPEWORK CONNECTIONS H - Flue manifold condensate outlet J - Condensate outlet (21.5mm...

[Page 26] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

OIL BURNER & PUMP INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 25 INSTALLATION CAUTION: ISOLATE THE OIL & WATER MAINS SUPPLY BEFORE STARTING ANY WO...

[Page 27] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

REFITTING COMPONENTS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 26 INSTALLATION REFITTING COMPONENTS 1 Align burner combustion head (A) into boiler housing tube w...

[Page 28] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

ELECTRICS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 27 INSTALLATION F R L R Ns Fs F R Ls N L DHW CH ELECTRICS 1 DANGER - 230V: ISOLATE THE MAINS ELECTRICITY ...

[Page 29] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

ELECTRICS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 28 INSTALLATION X4 X3 X12 X11 X2 X13 X9 X1 X10 X8 X7 X6 gy gy bl br gy or bl br g gy bl br gy bl br g pk or y pk...

[Page 30] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

PRE-COMMISSIONING CHECKS - APPLIANCE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 29 1 2 3 5 200 0 0 Bar Litres per hour 0.6 0.5 0.4 0.3 0.2 0.1 400 600 800 1000 1200 ...

[Page 31] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

FILLING THE SYSTEM INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 30 COMMISSIONING 1 Pull lever (C) up and push to the left to move the diverter valve to the mid-posit...

[Page 32] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

STARTING THE APPLIANCE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 31 COMMISSIONING F H G Return Flow TAN K A B C A B C A - Bleed & pressure gauge port B - Pres...

[Page 33] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

STARTING THE APPLIANCE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 32 COMMISSIONING STARTING THE APPLIANCE 2Remove plastic cover from the burner casing (there is n...

[Page 34] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

STARTING THE APPLIANCE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 33 COMMISSIONING GREENSTAR HEATSLAVE EXTERNAL max flue reset boiler reset max lockout on service G...

[Page 35] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

STARTING THE APPLIANCE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 34 COMMISSIONING GREENSTAR HEATSLAVE EXTERNAL max flue reset boiler reset max lockout on service G...

[Page 36] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

WATER TREATMENT INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 35 COMMISSIONING WATER TREATMENT IMPORTANT: Debris from the system can damage the boiler and reduce efficie...

[Page 37] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

31 FINISHING COMMISSIONING - APPLIANCE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 36 COMMISSIONING FINISHING COMMISSIONING - APPLIANCE 1 Refit the top panel and ...

[Page 38] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

INSPECTION AND SERVICE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 37 INSPECTION AND SERVICE CAUTION: ISOLATE THE WATER, ELECTRICITY AND OIL MAINS SUPPLIES BEFORE STA...

[Page 39] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

INSPECTION AND SERVICE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 38 SERVICING & SPARES 1 Clean the Burner: Remove the air intake cover (H) and clear any debr...

[Page 40] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

INSPECTION AND SERVICE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 39 SERVICING & SPARES INSPECTION AND SERVICE External oil filter: Remove the paper element fr...

[Page 41] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

INSPECTION AND SERVICE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 40 SERVICING & SPARES INSPECTION AND SERVICE Re-commission the burner: 1Align burner combusti...

[Page 42] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

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 4 Photocell Satronic MZ770s Part Number: 8 716 156 692 0 5 ...

[Page 43] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

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) 42 SERVICING & SPARES SHORT PARTS LIST 18/25 1 Burner - Sterling 50 Part Number: 8 716 112 570 0...

[Page 44] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

SHORT PARTS LIST 25/32 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07) 43 SERVICING & SPARES SHORT PARTS LIST 25/32 1 Burner - Riello RDB 2.2 25/32 HE Part Number: 8...

[Page 45] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

PROBLEM CAUSE REMEDY LOCKOUT: Pulsation on start Combustion settings incorrect Set up as in installation instructions Faulty nozzle Replace nozzle Intermittent lockout Bad electrical connection Check control box/electrical connections Intermittent fl...

[Page 46] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

FAULT FINDING PROBLEM CAUSE REMEDY FAULTY BOILER OPERATION: Noisy operation Pump noise from air in pump or worn pump Bleed air from pump or replace pump Worn motor bearings Replace motor Fan out of balance Replace fan Boiling Faulty boiler thermosta...

[Page 47] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

Boiler not operating with a heating / hot water demand Burner motor runs? Burner lights immediately motor runs? 230V at solenoid coil in purge? Replace control box Replace pump 230V at motor? Motor or pump seized? Replace motor capacitor Motor 40Ω...

[Page 48] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

Boiler not operating with a heating / hot water demand Burner motor runs? Lockout within 1 second? Replace control box Replace motor/pump Check boiler controls & supply Replace motor L & N to control box? Motor or pump seized? Photo cell fun...

[Page 49] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

ELECTRICAL SCHEMATIC LN N C1 BOILER MODE INDICATOR X9 (PIN 2) N X1 (PIN 1) FROST THERMOSTATS PROGRAMMER FUSE F1 3.15A FAST CERAMIC X2 (FS) X2 (FR) X2 (FR) X4 (PIN 3) X4 (PIN 1) white brown grey X4 (PIN 2) X2 (LS) X2 (NS) N LINK (REMOVE) 4 1 2 3 X2 (...

[Page 50] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

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, p...

[Page 51] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

SERVICE 1 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 3 DATE ENGINEER NAME C...

[Page 52] Bosch GREENSTAR HEATSLAVE II EXTERNAL 12/18

CONTACT INFORMATION WORCESTER, BOSCH GROUP: TECHNICAL: 08705 266241 SERVICE: 08457 256206 SPARES: 01905 752571 LITERATURE: 01905 752556 TRAINING: 01905 752526 SALES: 01905 752640 WEBSITE: www.worcester-bosch.co.uk WATER TREATMENT: FERNOX 01799 550811...