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Bosch Worcester Greenstar HIU E User Manual

Bosch Worcester Greenstar HIU E
68 pages
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Installation and maintenance instructions
Heat Interface Unit
Greenstar HIU, HIU E, HIU E Plus & HIU KE Plus
6720808928-00.1Wo
For connection to a district heating system supplying heating and domestic hot water
6 720 808 928 (2017/06) UK & IE

Table of Contents

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Bosch Worcester Greenstar HIU E Specifications

General IconGeneral
BrandBosch
ModelWorcester Greenstar HIU E
CategoryRecording Equipment
LanguageEnglish

Summary

1 Key to Symbols and Safety Instructions

1.1 Key to Symbols

Explains warning symbols and their severity levels.

1.2 General Safety Instructions

Provides essential safety guidelines for installation and operation.

Key Safety and Handling Precautions

Packaging and Unpacking Guidelines

Key points to observe when handling the appliance packaging.

Siting and Installation Requirements

Fundamental requirements for safe and economical appliance operation.

Commissioning and Maintenance Requirements

Ensures proper commissioning and outlines maintenance needs.

Electrical Work Safety and Cable Routing

Procedures and precautions for electrical work and cable management.

Customer Instruction and Handover

Guidance for informing the customer about operation and safety.

2 Appliance Information

2.1 General Information

Overview of the appliance's features and models.

Model Matrix Comparison

Table comparing features of different HIU models.

Appliance Details and Compliance

2.2 Intended Use and Misuse

Defines correct usage and consequences of improper operation.

2.4 Declaration of Conformity

States compliance with European Directives and standards.

2.5 Type Plate Identification

Location and purpose of the appliance's type plate.

Appliance Specifications and Dimensions

2.6 Standard Delivery Contents

Lists all components included in the appliance package.

2.7 Dimensions and Hydraulic Connections

Technical drawings detailing physical size and pipe connection points.

2.8 Internal Appliance Layout

Internal Component Designation

Provides a labeled diagram of all internal parts for reference.

2.9 Electrical Schematic

Electrical Schematic Diagram

Visual representation of the appliance's electrical wiring.

Control Unit Connections

Component Connections

Details connections for internal components on the control unit.

Installer Connections

Specifies connections for external devices and power supply.

2.10 Designation of Components

Designation of Components Diagram

Provides a labeled diagram of all internal parts for reference.

Component Legend

Legend to Figure 7, Designation of components

Detailed list of all components identified in the diagrams.

2.11 Appliance Information

Technical Data

Comprehensive specifications for HIU models, including dimensions and performance.

2.12 Function Schematic

Function Schematic and System Description

Explains how the appliance operates and its system interactions.

3 Regulations

3.1 General

Rules for installation and maintenance.

3.2 Standards and Guidelines

Applicable country-specific rules.

3.3 Inspection and Maintenance

Reasons for regular inspection and maintenance.

4 Pre-installation Requirements

4.1 General

General pre-installation notices.

4.2 System Preparation

Requirements for water system and pipe-work.

4.3 Domestic Water Supply

Use in Hard Water Areas

Guidelines for water quality, pressure, and supply.

4.4 Pressure Relief Pipe Work

Proper routing and safety for pressure relief valve discharge pipes.

4.5 Cleaning Primary System

Cleaning Primary System

Steps for cleaning the central heating system before installation.

4.6 Appliance Locations and Clearances

4.6.1 Location

General requirements for appliance placement.

4.6.2 Rooms Containing a Bath or a Shower

Specific electrical safety rules for rooms with baths or showers.

4.6.3 Installation and Maintenance Clearances

Rules for placing the appliance and required surrounding space.

4.6.4 Compartment Clearances

Compartment Clearances

Minimum clearances required when fitting the HIU into a compartment.

4.7 Example Layouts

4.7.1 Unmixed Central Heating with Radiators

Illustrative diagrams for radiator heating systems.

4.7.2 Unmixed Central Heating with Under-floor

Unmixed Central Heating with Under-floor

Provides an example layout for central heating with under-floor systems.

4.8 Mounting Frame

Mounting Frame

Information and diagrams related to the appliance's mounting frame.

5 Installation

5.1 Support Bracket and Mounting Frame Fitting

Step-by-step guide for fitting the support bracket and mounting frame.

5.1.1 Wall Mounting Template

Instructions on how to use the template for accurate wall mounting.

5.1.2 Fitting Support Bracket and Mounting Rail

Fitting Support Bracket and Mounting Rail

Securing the bracket and frame to the wall.

5.1.3 Example Pipe-work Installation

Example Pipe-work Installation

Illustrative examples of pipe-work connections to the appliance.

5.1.4 Fitting the Filling Link Assembly

Fitting the Filling Link Assembly

Guide on how to install the integral filling link assembly.

5.1.5 Fitting an External Filling Link

Fitting an External Filling Link

Instructions for fitting an external filling link if required.

5.1.6 Flushing Valve Accessory Installation

Flushing Valve Accessory Installation

Guide on installing the flushing valve accessory.

5.1.7 Flow Regulating Valve

Flow Regulating Valve Installation

Information on installing a flow regulating valve if needed.

5.1.8 Hydraulic Connections on Mounting Frame

Hydraulic Connections

How to make hydraulic connections on the frame.

5.2 Hanging the Appliance

Installing the Main Unit

Step-by-step instructions for safely hanging the main appliance unit.

5.3 Electrical

Electrical Considerations

Essential rules and precautions for electrical work.

Cable Routing

Best practices for routing power and signal cables safely.

5.3.2 Installer Connections

Installer Connections

Details on connecting external controls and thermostats.

5.3.3 Access to Electrical Connections

Control Box Service Position

Steps to access and work with the appliance's electrical connections.

5.3.4 Cable Retainer Clamps

Cable Retainer Clamps

Instructions for securing electrical cables using retainer clamps.

5.4 Frost Protection

Frost Protection Functionality

How the appliance protects itself and the system from freezing.

5.5 By-pass Function

By-pass Function

Details the by-pass feature for maintaining heat.

5.6 Limit Return Temperature

Limit Return Temperature

Explains the function for limiting return temperature for efficiency.

6 Commissioning

6.1 Cleaning the Primary Circuit

Procedure for cleaning the primary heating circuit.

6.2 Flushing Kit Accessory

Instructions for using the flushing kit accessory.

6.3 Filling and Venting the Unit

Step-by-step guide for filling and venting the appliance.

6.3.1 Integral Keyless Filling Link

How to install the integral keyless filling link.

6.3.2 External Filling Link

External Filling Link

Guide for installing an external filling link.

6.4 Control Unit

6.4.1 Control Unit LED Indicators

Explains the status indicated by the LEDs on the control unit.

6.4.2 Domestic Hot Water Rotary Switch

Domestic Hot Water Rotary Switch

How to set the DHW temperature using the rotary switch.

6.4.3 Central Heating Rotary Switch

Central Heating Rotary Switch

How to set the central heating temperature using the rotary switch.

6.5 Control Valve Status Indication

Control Valve Status Indication

Interpreting the colored indicators on control valves.

6.6 Central Heating Circulation Pump

6.6.1 Pump Key Lock Function

How to activate or deactivate the pump settings lock.

6.6.2 Pump Operational Status and View Pump Curve Setting

Methods to check pump operational status and curve settings.

6.6.3 Available Hydraulic Pressure

Available Hydraulic Pressure

Diagram showing hydraulic head for different pump settings.

6.6.4 Central Heating Circulation Pump Characteristics

Modulating Speed Characteristics

Modulating speed characteristics and performance curves for the pump.

6.6.5 Pump Curve Adjustment

Pump Curve Adjustment

Steps for adjusting the pump's operating curve for efficiency.

6.7 Sense II (EMS Controller) Configuration

6.7.1 Operating the Service Menu

Guide to operating and navigating the Sense II controller's service menu.

6.7.3 Heat Interface Unit Settings

Heat Interface Unit Settings

Configuration parameters for the HIU, including temperature set points.

6.7.4 Electronic By-pass Function Setup

Electronic By-pass Function Setup

How to configure the electronic by-pass for keep-hot functionality.

Heat Interface Unit Settings for Electronic By-pass Function

By-pass Settings

Specific settings for the electronic by-pass function.

6.7.5 Floor Drying Function

Floor Drying Function Setup

Instructions for enabling and configuring the floor drying function.

6.8 Integral Heat Meter

Integral Heat Meter (if fitted)

Technical data and features of the integral heat meter.

Integrator Display

Integrator Display and Menu Structure

Explanation of the heat meter's display interface and navigation.

Heat Meter Connections and Water Quality

Heat Meter External Signal Connections

Details on connecting external signals to the heat meter.

Heat Meter M-Bus Connection

Guide for connecting the heat meter via M-Bus.

6.9 Water Quality

Typical water quality parameters and requirements for district heating systems.

6.9.1 Typical for District Heating Water

Typical water quality parameters and requirements for district heating systems.

6.9.2 Domestic Hot Water for Copper Brazed Plate Heat Exchangers

Domestic Hot Water for Copper Brazed Plate Heat Exchangers

Water quality parameters for DHW systems.

6.10 Domestic Hot Water Performance Chart

Domestic Hot Water Performance Chart

Graphical representation of DHW output and flow rate performance.

Interpreting DHW Performance Charts

Key to Domestic Hot Water Performance Chart, Figure 55

Explanation of the elements within the DHW performance chart.

Domestic Hot Water Example

A practical example demonstrating how to use the DHW performance chart.

6.11 Central Heating Performance Charts

6.11.1 15kW & 7.5kW

Performance data graphical representation for specific CH outputs.

Interpreting Central Heating Performance Charts

Key to Central Heating Performance Chart, Figure 56

Explanation of the elements within the central heating performance chart.

Central Heating Example

A practical example demonstrating how to use the CH performance chart.

6.11.2 5kW & 3.5kW

5kW & 3.5kW Central Heating Performance

Performance data graphical representation for specific CH outputs.

6.12 Testing

Functional Testing Procedures

Guidelines for testing system functionality and heat outputs.

6.13 Commissioning Checklist

Commissioning Checklist

A comprehensive checklist to ensure all commissioning steps are completed.

6.14 Fitting the Cover

Fitting the Cover

Instructions for securing the appliance's outer cover.

6.15 Hand Over

Hand Over Procedures

Procedures for customer handover, including documentation.

6.16 Appliance Guarantee

Appliance Guarantee Terms

Details regarding the appliance guarantee terms and registration.

7 Inspection and Maintenance

7.1 Cleaning the District Filter

Steps for removing and cleaning the district filter element.

7.1.2 Draining the Appliance

Instructions on how to safely drain the appliance for maintenance.

7.1.3 Filter Removal

Specific steps for removing and cleaning the filter.

7.2 Inspection Record

Inspection Record Forms

Templates for documenting inspection findings and measurements.

8 Replacement of Parts

8.1 Draining the Appliance

Essential step to drain the appliance before replacing parts.

8.2 Plate Heat Exchanger

Procedure for removing and replacing the plate heat exchanger.

Component Replacement Procedures

8.3 Control Valves

Steps for replacing the control valves.

8.4 Differential Pressure Control Valve

Procedure for replacing the differential pressure control valve.

8.5 Circulating Pump

Steps for removing and replacing the circulating pump.

Component Replacement: Sensors, Vessels, and Valves

8.6 Heat Meter

Procedure for replacing the heat meter component.

8.7 Expansion Vessel

Steps for replacing the expansion vessel.

8.8 Domestic Hot Water NTC Sensor and Safety Valve

Procedures for replacing DHW sensors and safety valves.

Component Replacement: Flow and NTC Sensors

8.9 Flow Turbine, Flow Regulator Assembly and Filter

Procedure for replacing the flow turbine, regulator, and filter.

8.10 Summer By-pass (if fitted)

Steps for replacing the summer by-pass valve.

8.11 District and Central Heating NTC Sensors

Procedures for replacing district and central heating NTC sensors.

8.12 Control Unit

Control Unit Replacement

Detailed steps for replacing the main control unit.

9 Fault Finding and Diagnostics

9.1 Central Heating Trouble Shooting Guide

Troubleshooting guide for scenarios with no heat output from the CH system.

9.2 Domestic Hot Water Trouble Shooting Guide

Domestic Hot Water Trouble Shooting Guide

Troubleshooting guide for low/no flow and temperature issues.

9.3 HIU Control Unit LED Indications

HIU Control Unit LED Indications

Explains the meaning of LED indicators for fault finding.

Troubleshooting Control Valves and Pumps

9.4 Control Valve Fault Indication

Identifies and explains faults indicated by control valves.

9.4.2 Control Valve Calibration

Steps for calibrating control valves if they fault.

9.5 Circulating Pump Fault Indication

Explains fault indications for the circulating pump.

Advanced Diagnostics: Sense II and HIU Menus

9.6 Sense II (EMS Controller) Diagnosis Menu

How to access and navigate the Sense II diagnosis menu.

9.6.2 Heat Interface Unit Diagnosis Menu

Lists the available diagnostic menus for the Heat Interface Unit.

9.6.3 Heat Interface Unit Diagnosis Functions

Details on accessing and interpreting HIU diagnostic functions.

Diagnostic Tests and Component Data

9.6.4 Heat Interface Unit Function Test Menu

Menu for performing function tests on the HIU.

9.7 Central Heating Pump Test

Procedure to test the central heating pump's operation.

9.9 Component Resistance Characteristics

Resistance values for NTC sensors used in diagnostics.

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