Bosch Appliances 25/32kW manual

GREENS T A R HE A T SL A V E E X T ERN A L 1 2/ 1 8, 1 8/25, 25/32kW F L O O R S T A ND IN G EX T ERN A L O IL F IRED CO ND ENSIN G CO MBIN A T I O N BOI L E R US I NG BALANCE D F L U E S Y STE M FOR O P E N VE NT AN D SEALE D CE NTRAL H EA TI NG SY STEM S W ITH DO M ESTIC MAI NS F E D H O T W A TE R TH E APP LIANC E IS FO R US E WITH K E ROSEN E ([...]

I N ST ALLA TI O N & SER V ICIN G IN S TRU C TI ONS INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 1 Check List Hardware/Literature pack Item Qt y Greenstar Heatslave External Inst allation/Ser vicing Instructions ........ . 1 Users Instructions...........[...]

SAFET Y & R EG U LA TION S I M PO RT ANT I N F O R MA TI O N AN D S YM B OLS 1 SAFETY P R EC AUTION S AN D I N ST ALLA TI ON R E G U LA TI ON S 3 APPL I ANCE IN FORMA TI ON G E N E R AL I N FO R MA TIO N 4 TEC H N ICAL DA T A 5 LA YOUT & CO M P ON E NTS 6 PR E -I NST ALL A TIO N C LEAN I NG P R I MARY S YS TE MS 7 MA INS SUPPLIES 8 OIL SUPP[...]

SAFETY P R E CAUTIO N S & I N ST ALLA TI O N R E G U LA TIO N S INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 3 SAFET Y & REGUL A TIO NS SAFETY P R EC AUTIO N S I N ST ALLA TIO N R EG U LA TI O N S OIL SMELL S, L EAKS OR FUMES FROM T HE APPL IAN CE : [...]

GENERA L INFORM A TI ON INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 4 APPL IANC E INFO RMA T IO N A B 770mm 950mm 640mm C D E GENER A L INF ORM A T ION ST AN DARD P AC K AGE: A - Floor standing oil fired condensing boiler for open vent and sealed domestic c[...]

T ECHNIC AL D A T A INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 5 T ECHNI C A L D A T A Central Heat ing Primary water capacity ( total ) litres Maximum static head metres Minimum static head metres Available pump head (20°C difference) at max . output met[...]

LA Y O UT & C OM P ON E NTS The diagram opposite e xcludes the top, front and R H side casing panels. 1. CO NTRO L BOX ASSE M B L Y 2. DIVE RTE R VAL VE 3. PRESSUR E G AUGE 4. AUT O AI R VE NT 5. CH C ONTR OL AN D MAN U AL R ESET OVER H EA T TH E R M OST A T PH IAL 6. C ASING SIDE P ANEL 7 . CIRCULA TING PUM P 8. AUT O -R ES ET H IG H LIM IT TH[...]

C LE AN I N G PR I MARY S Y S TE M S BEFO RE CLE A NING THE S Y S T EM: E NS U R E TH E SY STEM AN D PI P EWOR K I S IN GOOD W O RKI NG ORDER. FLU SH TH E E XI STI NG SY STEM W ITH A PO WER FL USHIN G M A CHINE O R W ITH A CHEMIC AL CLE ANER B E F OR E I NST ALLI N G N EW CO M P ON E NTS. C LEAN I N G TH E P R I MARY S YS TE M:  Cleanse the syst[...]

MA I NS SUPPLIES EL EC TRIC SUPPL Y : • Supply: 230V - 50Hz. • Cable: PVC insulated 0.75mm 2 (24 x 0.2mm) temperature rated to 90° C. • Protection I P45. • External 5A fuse to B S 1 362. • The appliance must be earthed. • Please refer to I E E regulations for cross bonding requirements. • It must be possible to isolate the appliance [...]

OIL SUPPL Y This appliance is suitable for kerosene (28 second oil) only, no other fuel must be used. OIL SUPPL Y: • Plastic or steel tanks should be installed to B S 54 1 0. A steel tank should conform to B S 799: part 5 and have a slope of 1 in 24 away from the outlet valve with a sludge cock at its lower end. • Do not use galvanised steel t [...]

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 IN ST ALLA TION COMMISSIONING A - Appliance expansion vessel B - Extra expansion vessel C - Automatic bypass valve D - Drain cock E - Feed & expansion cistern W A TE R SY STEM S & P I PEWO R K INST ALLA [...]

W A TE R S Y STE M S & P I P EWOR K FIL LIN G P RIM AR Y SE A L ED S YS TEMS : • 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 . • Filling loops must be WRAS approved. SH OWE R S /B I DETS: • If a showe[...]

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) CO NDENS A TE & PRESSU RE RE LIE F PIPEW OR K INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 12 PR E - IN ST A[...]

B OI LE R L O CA TIO N & CLEARA NCES INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 13 PR E - IN ST ALLA TION B O I LE R L OC A TI ON & CLEARA NC ES WAR N I N G : This appliance should not be installed where there is a pot ential for excessive ground w[...]

CAB I N ET MO U NTE D L OW LEVEL FLU E TE R M I NAL P O SITI ON S INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 14 PR E - IN ST ALLA TION Minimum dimensions of flue terminal posit ions for oil fired appliances: TER M I NAL PO S ITION B( H) A 1 Directly below [...]

H I G H LEVE L F LU E TE R M I NAL PO SITI O NS INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE 12/18-18/25-25/32 8 716 106 252d (08/07) 15 PR E - IN ST ALLA TION Minimum dimensions of flue terminal posit ions for oil fired appliances: TER M I NAL PO S ITION B(H ) B(V) A 1 2 Directly below an opening, air brick,[...]

BALANC E D EX TE R NAL O I LF IT FLU E O PTI ON S INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 16 PR E - IN ST ALLA TION IM P ORT ANT: The weather seal (supplied ) must be fitt ed to every flue joint t o give the required level of weat her protect ion. The d[...]

BALANC E D FLU E OPTI ON S INST AL LA TION & SERVICING INS TRUCTIONS FOR WORCEST ER GRE ENST AR HEA TSLA VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 17 PR E - IN ST ALLA TION CAB I N ET MO U NTE D BALAN C E D HO R IZ O NT AL F LU E OPTI O N S • The horizontal flue is fitted to the rear or either side of the cabinet. IM P ORT ANT: I[...]

Unpacking: It is advised that two or more persons are involved in the transfer of the pac k aged 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 when releasing the straps. If a sharp implement is used make sure the outer carton is not pierced a[...]

All dimensions in mm 256 650 58 802 258 81 10 5 171 37 4 161 650 787 670 518 10 5 94 55 269 658 669 705 715 650 794 670 518 15 8 12 4 89.5 55 658 679 698 718 528 230 IN ST ALLA TION COMMISSIONING SAFET Y: All relevant safety precautions must be undertaken . Protective clothing, footwear, gloves and safety goggles must be worn as appropriate. PIPEWO[...]

B O I LE R I N ST ALLA TI ON Note: The cabinet is not load bearing it only provides weather prot ection for t he boiler inside. 1  Mark position of the 1 00mm ser vices duct on the exterior wall and make a hole through. 2  Remove the key for the door fastners from its transport position in the left hand side panel flue outlet aperture. Undo t[...]

IN ST ALLA TION NOTES:  Ensure all the seals are in good condition and seated properly .  T o 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 or less above a surface where people have access. All flue options: 1  Lightly grease the flue[...]

CO M B U STIO N C HAM B E R INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 22 IN ST ALLA TION Combustion chamber: 1  Release retaining nuts and washers (B ).  Remove combustion chamber access door (A ). 2  Ensure the baffles (C ) and baffle retainer ([...]

PIPEW ORK CONN ECT IONS INST ALL A TION & SERVICING INS TRUCT IONS FOR WORCES TER GRE ENST AR HEA T SLA VE EXT ER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 23 IN ST ALLA TION PIPEW OR K CONN ECT IONS A - C H flow 22mmØ copper (28mmØ on 25/32 models) B - DHW flow 22mmØ C - W ater main inlet 1 5mmØ D - C H return 22mmØ copper (28mmØ on 2[...]

PIPEW ORK CONN ECT IONS INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 24 IN ST ALLA TION PIPEW O RK CONN ECT IONS H - Flue manifold condensate outlet J - Condens ate outlet (2 1 .5mmØ) - supplied K - C ondensate pipe - not supplied L - Condens ate trap with [...]

OIL BURNER & P UMP INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 25 IN ST ALLA TION CAUTION: ISO LA TE TH E O IL & WA TER MAIN S S U PP L Y B E FOR E ST ARTI NG ANY WOR K AN D OB S ER VE ALL RE LEVANT SAFET Y PR ECAUTION S . OIL BURNER: 1  Check th[...]

R E F ITTI N G CO M P O N E NTS INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 26 IN ST ALLA TION REFI TT ING CO MPO NEN T S 1  Align burner combustion head (A ) into boiler housing tube with gasket (B ) correctly fitted.  Push firmly down to compress th[...]

E LE CTR IC S INST AL LA TION & SERVICING INSTRUC TIONS F OR WORCE ST E R GREE NST AR HEA TSLA VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 27 IN ST ALLA TION F R L R Ns Fs F R Ls N L DHW CH EL EC T RIC S 1 DANGE R - 230V: ISO LA TE TH E MAI N S E LECTRICIT Y SU P PL Y BE FOR E ST ARTI NG ANY WOR K AN D OB S ER VE ALL RE LEVANT SAFET [...]

E LE CTR IC S INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 28 IN ST ALLA TION X4 X3 X1 2 X1 1 X2 X1 3 X9 X1 X1 0 X8 X7 X6 gy gy bl br gy or bl br g gy bl br gy bl br g pk or y pk pk pk pk y y y y bk r g gy w 1234 56 r r r r r g or 4 3 2 3 2 w 2 3 4 or pk y w[...]

PRE-COM MI SSIONI NG C H E C KS - AP PLIAN C E INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 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 1400 1600 200 0 0 Bar Litres per hour 0.6 0.5 0.4 0.3 0.2 0.1 400 600 800 1000 12[...]

FI LLI NG TH E S YS TE M INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 30 CO MMISSIONIN G 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. 2  Loos[...]

ST ARTI N G TH E AP PLIAN C E INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 31 CO MMISSIONIN G F H G Return Flow TA N K A B C A B C A - Bleed & pressure gauge port B - Pressure adjustment C - Vacuum gauge port D - Retaining screws - cover D D DANFOSS BFP [...]

ST ARTI N G TH E AP PLIAN C E INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 32 CO MMISSIONIN G ST ARTI N G TH E AP P LIANC E 2  Remove plastic cover from the burner casing (there is no plastic cover on the Riello burner ).  Fit a suitable pressure gauge[...]

ST ARTI N G TH E AP PLIAN C E INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 33 CO MMISSIONIN G GREENS T AR H EATSLA VE E XTER NAL max flue reset boiler reset max lockout on service GREENS T AR H EATSLA VE E XTER NAL max flue reset boiler reset max lockout on [...]

ST ARTI N G TH E AP PLIAN C E INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 34 CO MMISSIONIN G GREENS T AR H EATSLA VE E XTER NAL max flue reset boiler reset max lockout on service GREENS T AR H EATSLA VE E XTER NAL max flue reset boiler reset max lockout on [...]

W A TE R TR E A TM E NT INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 35 CO MMISSIONIN G W A TE R TR E A TM E NT IM P ORT ANT: Debris from the syst em can damage the boiler and reduce efficiency. Failure to comply with t he guidelines for the use of water t r[...]

31 FINI SHING CO MMIS SIO NING - APP LIANC E INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 36 CO MMISSIONIN G FINI SHIN G CO MMISS IO NING - APPL IA NCE 1  Refit the top panel and press down to compress the seal when fitting the securing screws (A ). 2 [...]

I NS P ECTI O N AN D SE RVIC E I NST ALL A TION & SERVICING INS TRUCT IONS FOR WORCESTER GREENST AR HEA T SLA VE EXT ER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 37 I N S PE CTI O N AN D S E RVIC E CAUTION: ISO LA TE TH E WA TE R , ELECTR ICIT Y AN D OI L MAIN S S U PP LI ES BE FO RE ST ARTI NG ANY W OR K AND OBS E RVE ALL R E LEVANT SAFETY [...]

I NS P ECTI O N AN D SE RVIC E INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 38 SERV ICIN G & SP ARES 1 Clean the Burner:  Remove the air intake cover (H ) and clear any debris from the air intake and air damper.  Disassemble the burner to allow acc[...]

I NS P ECTI O N AN D SE RVIC E I NST ALL A TION & SERVICING INS TRUCT IONS FOR WORCESTER GREENST AR HEA T SLA VE EXT ER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 39 SERV ICIN G & SP ARES I N S PE CTI O N AN D S E RVIC E External oil filt er:  Remove the paper element from the external oil filter and replace it. If the filter contains [...]

I NS P ECTI O N AN D SE RVIC E INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 40 SERV ICIN G & SP ARES INSPECT ION A ND SERVICE Re-commission the burner: 1  Align burner combustion head (A ) into the boiler housing tube with gasket (B ) correctly fitted[...]

SH O RT P ARTS LIST 12/18 1 Burner - Sterling 40 Part Number: 8 7 1 6 1 1 2 507 0 2 Combustion head - burner Part Number: 8 7 1 6 1 1 2 604 0 3 Control box Sat ronic DKO 97 0 Part Number: 8 7 1 6 1 42 396 0 4 Photocell Sat ronic MZ77 0s Part Number: 8 7 1 6 1 56 692 0 5 Control box base Sat ronic S98 1 2 pole Part Number: 8 7 1 6 1 42 782 0 6 Ignit[...]

SH O RT P ARTS LIST 1 8/25 INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 42 SERV ICIN G & SP ARES SH O RT P ARTS LIST 18/25 1 Burner - Sterling 50 Part Number: 8 7 1 6 1 1 2 5 7 0 0 2 Combustion head - burner Part Number: 8 7 1 6 1 08 57 3 0 3 Control box[...]

SH O RT P ARTS LIST 25/32 INST ALLA TION & SERVICING INST RUCTIONS FOR W ORCESTER GREE NST AR HEA TSL A VE EX TER NAL 12/18-18/25-25/32 8 716 113 389b (09/07) 43 SERV ICIN G & SP ARES SH O RT P ARTS LIST 25/32 1 Burner - Riello RDB 2.2 25/32 H E Part Number: 8 7 1 6 1 1 2 5 1 2 0 2 Combustion head - burner Part Number: 8 7 1 6 1 1 2 52 1 0 [...]

PROBLEM CAUSE REMED Y L OCKOUT: 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 flame detection fault See flame detection fault Burner motor fails to operate Faulty motor or electr[...]

F A UL T FIND ING PROBLEM CAUSE REMED Y F A UL TY BO ILER OPER A TION: Noisy operation Pump noise from air in pump or worn pump Bleed air from pump or replace pump W orn motor bearings Replace motor Fan out of balance Replace fan Boiling Faulty boiler thermostat Replace if necessar y Short circuit boiler thermostat T ake out of circuit to chec k Th[...]

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 40 Ω across L& N ? L & N t o control box? Control box locks out? Check boiler controls & sup[...]

Boiler not operating with a heating / hot water demand Burner motor runs? Loc kout within 1 second? Replace control box Replace motor/pump Check boiler controls & supply Replace motor L & N t o control box? Motor or pump seized? Photo cell functional? Solenoid coil functional (100 Ω )? Replace photo cell Motor gives 50 V olts on white wir[...]

EL EC T RIC A L SCHEM A T IC LN N C1 BOI LER MODE IN DICA T OR X9 (PI N 2) N X1 (PI N 1 ) FROS T T H ER MOST A TS PR OGR A MMER FUSE F 1 3. 1 5A FA S T CERA MIC X2 (FS) X2 (FR) X2 (FR) X4 (PI N 3) X4 (PI N 1 ) white brown grey X4 (PI N 2) X2 (LS) X2 (NS) N LINK (REMO VE ) 4 1 2 3 X2 (LR) N R E LA Y 1 ROOM T HERMO S T A T DIVE RTE R END S WI T CH X8[...]

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[...]

SERVICE 1 DA TE ENGINEER NAME COMP ANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: psi CO 2 %: NOZZLE CHANGED? YES NO F .G.T . °C FLUE PRESSURE: COMMENTS SIGNA TURE SERVICE 3 DA TE ENGINEER NAME COMP ANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: psi CO 2 %: NOZZLE CHANGED? YES NO F .G.T . °C FLUE PRESSURE: COMMENTS SIGNA TURE SERVICE 5 DA TE ENGINE[...]

C ONT ACT I N F OR MA TION WORC E STE R, B OS CH G R OU P: TEC H N I CAL: 087 05 26624 1 SE RVI C E: 0845 7 256206 SP AR ES: 0 1 905 7525 7 1 LITE RA TU R E: 0 1 905 752556 TRAI N I N G: 0 1 905 752526 SALES: 0 1 905 752640 WE B S ITE: www.worcester-bosc h .co.uk W A TE R TR EA TM E NT: FE R N OX 0 1 799 5508 1 1 www .fernox.com SE NTI N E L 0 1 5 [...]