Install Instructions

32 | Installation
Greenstar6 720 806 992 (2013/09)
6 Installation
6.1 Notes on 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 48).
Connect the DHW recirculation line with the cold water inlet as close as
possible to the Hydraulics connection plate.
Open vented heating systems
▶ Convert open vented heating systems into closed systems.
Gravity heating systems
▶ Connect the appliance to the existing piping system via a low-loss
header with a sludge separator.
Galvanized radiators or pipes.
To prevent gas formation:
▶ Do not use galvanized radiators or pipes.
Plastic pipework
If using plastic pipework 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
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.
Water Chemistry Guidelines
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.
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 13 Recommended flow rates
Use service function 6.d, to determine the current flow
rate ( page 62).
NOTICE: Insufficient antifreeze can accelerate
corrosion.
▶ Follow manufacturer's instructions on antifreeze
concentration.
▶ Frost protection level has to be checked annually
during the regular scheduled maintenance of the
condensing boiler.
NOTICE: System damage!
▶ It is the installer's responsibility to ensure that the
heating system is compatible with the boiler type and
size installed.
▶ pH-value of the heating water to be kept between 7
and 8.5.