Install Instructions

30 | Installation
Greenstar FS
6 720 810 590 (2015/05)
6 Installation
6.1 Installation and operation
When installing and operating the heating system observe the following:
• The elevation of the installation location above sea level must be
taken into account ( Chapter 12.2).
• Follow all local building regulations regarding the installation
conditions on site.
• The local building regulations regarding air supply and venting
systems and the chimney flue connection.
• Electrical code requirements for connection to the electrical power
supply.
• The technical regulations of the gas company regarding the
connection of the gas burner to the local gas main.
• The regulations and standards relating to the DHW heating system.
6.1.1 Notes on installation and operation
Fill and make-up water for the heating system
Unsuitable fill and make-up water can result in the heating system
scaling up or failing prematurely.
Recommended steps for commissioning a new or retrofit boiler
installation
▶ Flush the system with clean water.
▶ Isolate the boiler, fill the system with fresh water and a boiler cleaner,
run for 30 minutes to 1 hour. Under no circumstances may boiler
cleaner be pumped through the boiler.
▶ Thoroughly flush the system with fresh water. Ensure all zones and
loops are flushed.
▶ Empty out sediment traps.
▶ Systems containing antifreeze not approved by Bosch, must be
completely flushed to ensure no old fluid remains.
▶ Fill the system with fresh water and the proper amount of inhibitor.
▶ Verify the pH is within the proper range.
▶ Add additional inhibitor if pH is not within the proper range.
▶ Check pH annually.
▶ If using antifreeze, fill with approved antifreeze and fresh water.
▶ Always follow the cleaner, antifreeze, or additive manufacturer’s
instructions.
▶ Do not mix different manufacturer’s products
▶ Follow manufacturer’s data to determine the anti-freeze ratio for the
desired freeze protection temperature.
Recirculation pump/DHW recirculation lines
Electrical connection of the DHW recirculation pump ( page 46).
Connect the DHW recirculation line as close as possible to the cold water
inlet on the appliance.
Open vented heating systems
▶ Convert open vented heating systems into closed systems.
Gravity heating systems
▶ Connect the appliance to the existing piping system via an external
low-loss header with a sludge separator, refer to XXXX.
Galvanized radiators or pipes.
To prevent gas formation:
▶ Do not use galvanized radiators or pipes.
Plastic pipe work
If using plastic pipe work for the heating system (eg.underfloor/radiant
heating), the type of pipe that should be used must be oxygen tight.
Use of a room temperature control
▶ Do not install thermostatic valves on radiators in the primary room.
Primary-secondary piping or a Low Loss Header (LLH)
Typically all multi zone applications with any combination of emitters like
baseboard, panel radiator or radiant would require primary secondary
piping or a low loss header for hydraulic separation.
In addition to that some larger single zone applications exceeding a flow
rate of 4.0 gpm requires primary secondary piping or a low loss header
to achieve hydraulic balance.
A Low Loss Header is used to achieve hydraulic balance on either side of
the appliance, using the lowest pump speed that delivers heat to all the
radiators in the system.
Radiant floor, panel radiator, multi zone and application systems
exceeding 70' (21 m) of 3/4" baseboard at a 20°F delta T and a flow rate
of 4.0 gpm plus the necessary supply and return piping, require primary-
secondary piping or a low loss header for hydraulic separation of the
system from the boiler.
DANGER: Explosion!
▶ Close the gas cock prior to working on the gas train.
▶ Check for gas leaks after carrying out work on the gas
train.
Installation, power connection, connection on the gas
and flue gas side and commissioning must only be
carried out by a contractor certified for such work by the
state or local jurisdiction or the local gas or power utility.
Transportation blank plugs
▶ Remove the blanking plugs from the appliance water
connections. There may be some water present from
the appliance testing.
Total length DHW/recirculation line Flow rate
≤ 33 ft (10 m) 0.66 gpm (2.5 l/min)
33 - 66 ft (10 - 20 m) 0.92 gpm (3.5 l/min)
66 - 98 ft (20 - 30 m) 1.32 gpm (5 l/min)
Table 4 Recommended flow rates
Use service function 6.d, to determine the current flow
rate ( page 60).
Enable the integrated Low Loss Header if hydraulic
separation is required and not already provided by a
configuration external to the appliance.