Bosch Greenstar 12i Service Manual

UK/IEINSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONSWALL HUNG RSF GAS FIRED CONDENSING BOILERGREENSTAR i SYSTEM6720643356-00 1WoFOR SEALED CENT

APPLIANCE INFORMATION6 720 644 743b (2011/08)10Fig. 3 Additional components1 Burner ON indicator light (green) 9 PRV pipe connection point2 Power ON/O

PRE-INSTALLATION6 720 644 743b (2011/08)113 PRE-INSTALLATION3.1 CLEANING PRIMARY SYSTEMSBEFORE CLEANING THE SYSTEM:B Ensure that the system and pipe w

PRE-INSTALLATION6 720 644 743b (2011/08)123.2 MAINS SUPPLY3.2.1 ELECTRICAL SUPPLY• Supply: 230V - 50 Hz, 140 Watts• Cable: PVC insulated 0.75 mm2 (24

PRE-INSTALLATION6 720 644 743b (2011/08)133.3 WATER SYSTEM AND PIPE WORKPLASTIC PIPE WORK:• Any plastic pipe work must have a polymeric barrier with 6

PRE-INSTALLATION6 720 644 743b (2011/08)14EXISTING BUILDS: S AND Y PLAN SYSTEMS:S PLAN LAYOUTFig. 6 Existing build - S PlanY PLAN LAYOUTWITH EXTERNAL

PRE-INSTALLATION6 720 644 743b (2011/08)153.4 CONDENSATE PIPE WORK3.4.1 INTERNAL CONNECTIONSIn order to minimise risk of freezing during prolonged col

PRE-INSTALLATION6 720 644 743b (2011/08)163.4.2 EXTERNAL CONNECTIONSIf no other discharge method is possible then the use of an externally run condens

PRE-INSTALLATION6 720 644 743b (2011/08)17CONDENSATE SOAK AWAY• The condensate drainage pipe may be run above or below the ground to the soak away. Th

PRE-INSTALLATION6 720 644 743b (2011/08)183.6 BOILER LOCATION AND CLEARANCES3.6.1 INSTALLATIONThis boiler is only suitable for installing internally w

PRE-INSTALLATION6 720 644 743b (2011/08)193.6.5 BOILER CLEARANCES - UNVENTILATED COMPARTMENTS3.6.6 INSTALLATION CLEARANCES - UNVENTILATED COMPARTMENTS

CONTENTS6 720 644 743b (2011/08)2CONTENTS1 KEY TO SYMBOLS AND SAFETY PRECAUTIONS 31.1 Explanation of symbols . . . . . . . . . . . . . . 31.2 Safety

PRE-INSTALLATION6 720 644 743b (2011/08)203.7 PLUMBING MANIFOLD3.7.1 CONNECTIONSUse the fittings supplied in the Hardware literature pack.• If the boi

PRE-INSTALLATION6 720 644 743b (2011/08)213.8 FLUE OPTIONS FLUE LENGTHSThe flue systems have different maximum flue lengthsThe Greenstar series has th

PRE-INSTALLATION6 720 644 743b (2011/08)22350 mm 570 mm130 mm MinFlat roof300 mm500 mmPitchedroof234561098716720643895-12.1Wo

PRE-INSTALLATION6 720 644 743b (2011/08)233.9 FLUE TERMINAL POSITIONSFig. 22 Flue terminal positionsKey to illustration1. Flue clearance must be at le

PRE-INSTALLATION6 720 644 743b (2011/08)243.10 PLUME MANAGEMENT TERMINAL POSITIONSFig. 23 Plume terminal positionsKey to illustration1. 600 mm distanc

INSTALLATION6 720 644 743b (2011/08)254INSTALLATION4.1 UNPACKING THE WALL FRAME AND ANCILLARY ITEMS1. Wall mounting frame2. Wall mounting template3. I

INSTALLATION6 720 644 743b (2011/08)264.2 WALL MOUNTING TEMPLATE & FLUE OPENINGSAFETY:All relevant safety precautions must be undertaken. Protecti

INSTALLATION6 720 644 743b (2011/08)274.3 UNPACKING THE APPLIANCE1. Outer carton2. Inner sleeve (unwrap from front)3. Packing base4. Protective wrappi

INSTALLATION6 720 644 743b (2011/08)284.4 BOILER CONNECTIONSGAS AND WATER CONNECTIONSB Remove wall mounting template and secure the wall mounting fram

INSTALLATION6 720 644 743b (2011/08)29HANGING THE BOILERB Hang the boiler on to the wall mounting frame by the two brackets positioned left and right

KEY TO SYMBOLS AND SAFETY PRECAUTIONS6 720 644 743b (2011/08)31 KEY TO SYMBOLS AND SAFETY PRECAUTIONS1.1 EXPLANATION OF SYMBOLSWARNING SYMBOLSSignal w

INSTALLATION6 720 644 743b (2011/08)304.5 FLUE INSTALLATIONHORIZONTAL FLUE (60/100mm diameter)For vertical flues and 80/125mm horizontal flues, please

INSTALLATION6 720 644 743b (2011/08)314.5.3 INSTALLING THE TELESCOPIC FLUE:Refer to figure 41.1. Set the flue length to the distance required, secure

INSTALLATION6 720 644 743b (2011/08)324.5.4 FLUE TERMINAL PLUME RE-DIRECTIONThe flue discharge can be re-directed allowing some plume redirection cont

INSTALLATION6 720 644 743b (2011/08)334.6 CONDENSATE CONNECTIONNever terminate or discharge into any open source, including; sink, bath, shower, bidet

INSTALLATION6 720 644 743b (2011/08)344.7 ELECTRICAL• The mains electrical supply to the boiler must be through either a fused double pole isolator or

INSTALLATION6 720 644 743b (2011/08)35NEW COMPLETE SYSTEM INSTALLATIONSIf a new complete heating system is installed in a new build property or it is

COMMISSIONING6 720 644 743b (2011/08)365 COMMISSIONING5.1 PRE-COMMISSIONING CHECKSCheck that the service and water pipes are connected to the correct

COMMISSIONING6 720 644 743b (2011/08)375.2 FILLING THE SYSTEM1. Turn on the water main and open the system valves.2. Open all radiator valves.3. Fill

COMMISSIONING6 720 644 743b (2011/08)385.4 STARTING THE APPLIANCEFig. 61 Control panelSwitching the appliance on/off:B Turn on mains power supply, the

COMMISSIONING6 720 644 743b (2011/08)395.5 COMMISSIONINGHaving checked:B That the boiler has been installed in accordance with the installation instru

KEY TO SYMBOLS AND SAFETY PRECAUTIONS6 720 644 743b (2011/08)41.2 SAFETY PRECAUTIONSIF YOU SMELL GAS:B CALL NATIONAL GAS EMERGENCY SERVICE ON 0800 11

COMMISSIONING6 720 644 743b (2011/08)405.5.2 CHECKING THE GAS RATEB The gas rate should be measured at the gas meter after 10 minutes operation at max

COMMISSIONING6 720 644 743b (2011/08)415.6 FINISHING COMMISSIONING5.6.1 REPLACE OUTER CASING:B Replace outer casing making sure that the securing poin

SERVICE AND SPARES6 720 644 743b (2011/08)426SERVICE AND SPARES6.1 INSPECTION AND SERVICE• To ensure the continued efficient operation of the applianc

SERVICE AND SPARES6 720 644 743b (2011/08)436.2 CHECK THE GAS INLET PRESSURERefer to section 5.5.1 for more informationB Check the gas supply working

SERVICE AND SPARES6 720 644 743b (2011/08)446.4 FAN PRESSURE TESTSETTING THE BOILER TO MAXIMUM1. Press and HOLD service button for more than 10 second

SERVICE AND SPARES6 720 644 743b (2011/08)456.5 FLUE GAS ANALYSISCOMBUSTION TEST:B Connect the flue gas analyser to the flue gas sampling point as sho

SERVICE AND SPARES6 720 644 743b (2011/08)466.6 SETTING THE AIR/GAS RATIO6.6.1 SETTING THE CO/CO2B Refer to section 5.6.1 and ensure that the gas inle

SERVICE AND SPARES6 720 644 743b (2011/08)476.7 CLEANING THE HEAT EXCHANGERB Isolate the power to the appliance and remove outer case and base panel.1

SERVICE AND SPARES6 720 644 743b (2011/08)48BURNER REMOVALRefer to figure 831. Remove clamping plate.2. Remove spark/flame electrode assembly and seal

SERVICE AND SPARES6 720 644 743b (2011/08)49ACCESS COVER REMOVALRefer to figure 85.1. Remove the two pozi-drive screws 2. Remove the access cover3. Re

KEY TO SYMBOLS AND SAFETY PRECAUTIONS6 720 644 743b (2011/08)5British Standards:Where no specific instruction is given, reference should be made to th

SERVICE AND SPARES6 720 644 743b (2011/08)506.8 REPLACEMENT OF PARTS6.8.1 REMOVING OUTER CASE1. Undo the two screws securing the top of the boiler cas

SERVICE AND SPARES6 720 644 743b (2011/08)516.8.4 FLUE OVERHEAT THERMOSTAT(WITH GROMMET)To remove and replace the thermostat either:B Using a small te

SERVICE AND SPARES6 720 644 743b (2011/08)526.8.6 GAS VALVERefer to figure 92B Isolate gas supply at boiler gas cock.1. Remove wire clip from the gas

SERVICE AND SPARES6 720 644 743b (2011/08)53B Rotate fan and air/gas manifold assembly (1.) around the top of the heat exchanger until the lug on the

SERVICE AND SPARES6 720 644 743b (2011/08)546.8.9 ELECTRODE ASSEMBLY AND BURNERRefer to figure 98.B Disconnect spark electrodes and flame sensor conne

SERVICE AND SPARES6 720 644 743b (2011/08)55Refer to figure 101.1. Release the clip.2. Move the lower exhaust connector upB Remove the complete exhaus

SERVICE AND SPARES6 720 644 743b (2011/08)566.8.11 ACCESS TO BOILER CONTROL COMPONENTS1. Remove three screws.2. Remove cover from control.Fig. 104 Rem

SERVICE AND SPARES6 720 644 743b (2011/08)576.8.14 REPLACING CONTROLSRefer to figure 108.1. Remove ALL electrical connections from the control PCB inc

SERVICE AND SPARES6 720 644 743b (2011/08)586.8.15 SYPHON REMOVALTo release the syphon from the sump:1. Disconnect the discharge hose from the condens

SERVICE AND SPARES6 720 644 743b (2011/08)596.8.18 AUTO AIR VENTB Ensure the appliance has been fully drained.B Use a screwdriver or similar to rotate

APPLIANCE INFORMATION6 720 644 743b (2011/08)62APPLIANCE INFORMATION2.1 APPLIANCE2435* 710mm to top of case front1700mm*400mm330mmDepth to wall (When

SERVICE AND SPARES6 720 644 743b (2011/08)606.8.21 PRESSURE GAUGEB Refer to figure 117B Ensure the appliance has been fully drained.3. Prise the lugs

SERVICE AND SPARES6 720 644 743b (2011/08)616.8.23 CH PRESSURE RELIEF VALVEB Remove the hydraulic block from the boiler (See Removing the Hydraulic Bl

SERVICE AND SPARES6 720 644 743b (2011/08)62Expansion vessel replacement (Removing the Boiler)B Isolate electrical supply.B Isolate system and gas con

SERVICE AND SPARES6 720 644 743b (2011/08)636.9 SHORT PARTS LISTFan8 716 116 067 0GC No. H26 536Burner8 718 120 619 0GC No. H26 538Gas Valve8 716 111

FAULT FINDING AND DIAGNOSIS6 720 644 743b (2011/08)647 FAULT FINDING AND DIAGNOSIS7.1 FAULT FINDINGThe electronic control system for this boiler incor

FAULT FINDING AND DIAGNOSIS6 720 644 743b (2011/08)65Slow flash (mostly off, flashes on)Flashing (reset required)Ignition lockout B Gas present and at

FAULT FINDING AND DIAGNOSIS6 720 644 743b (2011/08)667.1.1 CIRCUIT DIAGRAMFANFSFR NP LPLNSNLSLRST8ST9ST17ST18ST5 ST4ST10EarthMAINSSUPPLYPUMPSUPPLYSPAR

FAULT FINDING AND DIAGNOSIS6 720 644 743b (2011/08)677.2 BOILER FUNCTIONFig. 124 Boiler functionNOYESMAINSPOWERSUPPLYONBOILERDEMANDFan tostartspeed.Pu

FAULT FINDING AND DIAGNOSIS6 720 644 743b (2011/08)687.3 PROTECTION FUNCTIONFig. 125 Protection functionInternal boilertemperaturebetween8°C & 5°C

6 720 644 743b (2011/08)69NOTES

APPLIANCE INFORMATION6 720 644 743b (2011/08)72.2 TECHNICAL DATADESCRIPTION NATURAL GAS LPGUNIT 12i 15i 18i 24i 12i 15i 18i 24iGas flow rate - Max. 10

Service RecordIt is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.Service P

Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the

Worcester, Bosch GroupCotswold Way, Warndon, Worcester WR4 9SW.Tel. 0844 892 9900Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd.

APPLIANCE INFORMATION6 720 644 743b (2011/08)82.3 LAYOUTFig. 1 Main boiler components6720644743-02.1Wo123130292827261014121113151625232422212019181734

APPLIANCE INFORMATION6 720 644 743b (2011/08)9Fig. 2 Hydraulic block components1Expansion Vessel 23 Hydraulic block mounting plate2 Sensor - Boiler fl