Bosch 25-32kW User Manual

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GREENSTAR HEATSLAVE EXTERNAL 12/18, 18/25, 25/32kW

FLOOR STANDING EXTERNAL OIL FIRED CONDENSING COMBINATION BOILER USING BALANCED FLUE SYSTEM

FOR OPEN VENT AND SEALED CENTRAL HEATING SYSTEMS WITH DOMESTIC MAINS FED HOT WATER

THE APPLIANCE IS FOR USE WITH KEROSENE ( 28 SECOND

OIL) ONLY

GB

INSTRUCTION MANUAL

INSTALLATION COMMISSIONING & SERVICING

INSTALLATION & SERVICING INSTRUCTIONS

SYMBOLS USED IN THIS MANUAL:

Domestic hot water

Central heating

Room thermostat

Frost thermostat

Wait time period

Programmer/timer OFF

Programmer ON CH only

Programmer ON DHW only

Programmer ON CH and DHW

Cold water main supply

Electricity supply

IMPORTANT HANDLING INSTRUCTIONS: It is advised that more than one person is involved in the transfer of the packaged appliance from the van to the point of installation.

It is advised that no attempt should be made to move the packaged appliance without the use of a suitable truck.

At all times the correct method for handling heavy objects should be strictly observed.

GENERAL HANDLING GUIDELINES:

Lift only a manageable weight, or ask for help.

When lifting, bend the knees, and keep the back straight and feet apart.

Do not lift and twist at the same time.

Lift and carry items close to the body.

Wear protective clothing and gloves to protect from any sharp edges.

1

PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.

THESE INSTRUCTIONS ARE APPLICABLE TO THE WORCESTER APPLIANCE MODEL(S) STATED ON THE FRONT COVER OF THIS MANUAL ONLY AND MUST NOT BE USED WITH ANY OTHER MAKE OR MODEL OF APPLIANCE.

THE INSTRUCTIONS APPLY IN THE UK ONLY AND MUST BE FOLLOWED EXCEPT FOR ANY STATUTORY OBLIGATION.

THIS APPLIANCE MUST BE INSTALLED BY A COMPETENT PERSON. FAILURE TO INSTALL CORRECTLY COULD LEAD TO PROSECUTION.

COMPLYING WITH THE BUILDING REGULATIONS:

This heating appliance forms part of the controlled services for the building. It is law that all controlled services for buildings must comply with building regulations. You must be able to satisfy your Local Authority Building Control Body (LABC) that the work carried out concerning the installation and commissioning of this heating appliance has been carried out to a satisfactory standard.

OFTEC operate a competent persons scheme and registered installers are able to certify that their work complies with building regulations. Under the scheme;

OFTEC must be informed about every installation.

OFTEC will issue a building regulations compliance certificate to the householder and will notify the LABC.

OFTEC provide controlled document forms CD10 and CD11 for use during installation and commissioning respectively.

Other organisations operate self-certificationschemes e.g. NAPIT and BESCA Ltd. and it may be possible for installers who are members of these organisations to self certify their work.

Alternatively you must submit a building control notice to the LABC before installing any boiler. The LABC will then arrange regular inspection visits during the work to ensure that the installation complies with the regulations.

IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER TECHNICAL HELPLINE.

DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER.

PLEASE LEAVE THESE INSTRUCTIONS WITH THE COMPLETED COMMISSIONING FORM AND THE USER MANUAL WITH THE OWNER OR WITH THE APPLIANCE AFTER INSTALLATION OR SERVICING. THE SERVICE INTERVAL RECORD CAN BE FOUND ON THE BACK PAGE OF THIS MANUAL.

ABBREVIATIONS USED IN THIS MANUAL:

ØDiameter

CH

Central Heating

 

 

DHW

Domestic Hot Water

 

 

TRV

Thermostatic Radiator Valve

 

 

IP

Ingress Protection

 

 

CF

Conventional flue

 

 

BF

Balanced flue

 

 

N/A

Not allowed

 

 

SEDBUK

Seasonal Efficiency of Domestic Boilers in the United Kingdom

 

OFTEC

Oil Firing Technical Association for the Petrolium Industry

 

IEE

Institute of Electrical Engineers

 

LABC

Local Authority Building Control Body

 

STORE THE APPLIANCE IN A DRY AREA PRIOR TO INSTALLATION.

 

Check List

Hardware/Literature pack

Item

 

 

Qty

Greenstar Heatslave External Installation/Servicing Instructions

.........1

Users Instructions............................................................................................

 

1

Hardware Pack.................................................................................................

 

1

100mm Ø Services Duct................................................................................

 

1

Condensate Trap Kit........................................................................................

 

1

Warranty Return Envelope.............................................................................

 

1

Cabinet Key.......................................................................................................

 

1

INSTALLATION & SERVICING INSTRUCTIONS

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/328 716 113 389b (09/07)

CONTENTS

SAFETY & REGULATIONS

 

 

IMPORTANT INFORMATION AND SYMBOLS

1

 

 

 

SAFETY PRECAUTIONS AND INSTALLATION REGULATIONS

3

 

APPLIANCE INFORMATION

 

 

 

 

 

 

 

 

 

GENERAL INFORMATION

4

 

 

 

 

 

 

 

 

TECHNICAL DATA

5

 

 

 

 

 

 

 

 

LAYOUT & COMPONENTS

6

 

PRE-INSTALLATION

 

 

 

 

 

 

 

 

 

CLEANING PRIMARY SYSTEMS

7

 

 

 

 

 

 

 

 

MAINS SUPPLIES

8

 

 

 

 

 

 

 

 

OIL SUPPLY

9

 

 

 

WATER SYSTEMS & PIPEWORK

10-11

 

 

 

CONDENSATE & PRESSURE RELIEF PIPEWORK

12

 

 

 

 

 

 

 

 

BOILER LOCATION & CLEARANCES

13

 

 

 

CABINET MOUNTED LOW LEVEL FLUE TERMINAL POSITIONS

14

 

 

 

HIGH LEVEL FLUE TERMINAL POSITIONS

15

 

 

 

 

 

 

 

 

EXTERNAL OILFIT BALANCED FLUE OPTIONS

16

 

 

 

 

 

 

 

 

CABINET MOUNTED HORIZONTAL BALANCED FLUE OPTIONS

17

 

 

 

 

 

 

INSTALLATION

 

 

 

 

UNPACKING THE BOILER

18

 

 

 

PIPEWORK & FLUE POSITIONS

19

 

 

 

BOILER INSTALLATION

20

 

 

 

FLUE INSTALLATION

21

 

 

 

COMBUSTION CHAMBER

22

 

 

 

PIPEWORK CONNECTIONS

23-24

 

 

 

 

 

 

 

 

OIL BURNER AND PUMP

25

 

 

 

 

 

 

 

 

REFITTING COMPONENTS

26

 

 

 

ELECTRICS

27-28

 

COMMISSIONING

 

 

 

 

PRE-COMMISSIONINGCHECKS - APPLIANCE

29

 

 

 

FILLING THE SYSTEM

30

 

 

 

STARTING THE APPLIANCE

31-34

 

 

 

 

 

 

 

 

WATER TREATMENT

35

 

 

 

FINISHING COMMISSIONING - APPLIANCE

36

 

SERVICING & SPARES

 

 

 

 

INSPECTION AND SERVICE

37-40

 

 

 

 

 

 

 

 

SHORT PARTS LIST 12/18

41

 

 

 

 

 

 

 

 

SHORT PARTS LIST 18/25

42

 

 

 

 

 

 

 

 

SHORT PARTS LIST 25/32

43

 

 

 

 

 

FAULT FINDING & DIAGNOSIS

 

 

 

 

 

 

 

 

 

FAULT FINDING

44-45

 

 

 

 

 

 

 

 

FAULT FINDING LOGIC FOR SATRONIC CONTROL BOX

46

 

 

 

 

 

 

 

 

FAULT FINDING LOGIC FOR 535 SE/LD RDB CONTROL BOX

47

 

 

 

 

 

 

 

 

ELECTRICAL SCHEMATIC

48

 

 

 

 

 

COMMISSIONING & SERVICE RECORDS

 

 

 

 

COMBUSTION RECORD

49

 

 

 

SERVICE INTERVAL RECORD

50

 

 

 

 

 

 

SAFETY &

REGULATIONS

APPLIANCE

INFORMATION

PRE -

INSTALLATION

INSTALLATION

 

COMMISSIONING

 

SERVICING

& SPARES

FAULT FINDING

& DIAGRAMS

2

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/328 716 113 389b (09/07)

CONTENTS

SAFETY &

REGULATIONS

SAFETY PRECAUTIONS

OIL SMELLS, LEAKS OR FUMES FROM THE APPLIANCE:

Extinguish any naked flames.Isolate the electrical supply.Isolate the fuel supply to the boiler.Rectify fault.

HEALTH & SAFETY:

The appliance contains no asbestos and no substances have been used in the construction process that contravene the COSHH Regulations (Control of Substances Hazardous to Health Regulations 1988). Where applicable, the CE mark indicates compliance with relative EU Directives.

COMBUSTIBLE AND CORROSIVE MATERIALS:

Do not store or use any combustible materials (paper, thinners, paints etc.) inside or within the vicinity of the appliance.

The combustion air must be kept clear of chemically aggressive substances which can corrode the appliance and invalidate any warranty.

FITTING & MODIFICATIONS:

Fitting the appliance and any controls to the appliance may only be carried out by a competent engineer in accordance with these instructions and the relevant Installation Regulations.

Flue systems must not be modified in any way other than as described in the fitting instructions. Any misuse or unauthorised modifications to the appliance, flue or associated components and systems could invalidate the warranty. The manufacturer accepts no liability arising from any such actions, excluding statutory rights.

SERVICING:

Advise the user to have the system regularly serviced by a competent, qualified engineer (such as OFTEC registered personnel) using approved spares, to help maintain the economy, safety and reliability of the appliance.

INSTALLATION REGULATIONS

Failure to install appliances correctly could lead to prosecution.

The appliance should be installed by a competent person. The person installing the appliance should be aware of the Health and Safety at Work Act and take appropriate action to ensure that the regulations are adhered to. In order to give optimum efficiency and trouble free operation the appliance must be commissioned by a qualified OFTEC engineer.

The compliance with a British Standard does not, in itself, confer immunity from legal obligations. In particular the installation of this appliance must be in accordance with the relevant requirements of the following British Standards and regulations in respect of the safe installation of equipment:

BS 5410: part 1: Code of practice for Oil Fired Boilers.

BS 799: part 5: Specification for Oil Storage Tanks.

BS 7593: Code of Practice for treatment of water in domestic hot water central heating systems.

B S 5449: part 1: Specification for forced circulation hot water central heating for domestic premises.

BS 5955: part 8: Specification for the installation of thermoplastic pipes and associated fittings for use in domestic hot and cold water services and heating systems.

BS 7291: Thermoplastic pipes and associated fittings for hot and cold water for domestic purposes and heating installations in buildings.

BS 7074: part 1: Application, selection and installation of expansion vessels and ancillary equipment for sealed water systems.

BS 7671: IEE Wiring Regulations, current edition. BS 1362: Specification for general purpose fuse links for domestic and similar purposes.

The Building Regulations Part J and L1 England and Wales; Part F and Part J Section III Scotland; Part L and Part F Northern Ireland.

Local water company bye-laws.

The Control of Pollution (Oil) Regulations. OFTEC Standards.

Where no specific instruction is given, reference should be made to the relevant codes of practice.

3

SAFETY PRECAUTIONS

& INSTALLATION REGULATIONS

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/328 716 113 389b (09/07)

GENERAL INFORMATION

 

 

 

 

 

 

 

 

 

 

STANDARD PACKAGE:

 

 

 

640mm

 

 

 

 

770mm

A - Floor standing oil fired condensing boiler for

 

 

 

 

 

 

 

 

 

 

 

A

open vent and sealed domestic central heating

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

and mains fed hot water.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

B - Literature pack.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C - Condensate trap kit.

 

 

 

 

 

 

 

 

 

 

D - 100mmØ services duct.

 

 

 

 

 

 

 

 

 

 

E - Cabinet key

 

 

 

 

 

 

 

 

 

 

 

950mm

B

C

D

E

APPLIANCE

INFORMATION

Check List

 

Item

Qty

Greenstar Heatslave External Installation/Servicing Instructions

........1

Users Instructions ..........................................................................................

1

100mm Ø Services Duct...............................................................................

1

Condensate Trap Kit.......................................................................................

1

Warranty Return Envelope ............................................................................

1

Cabinet Key.......................................................................................................

1

4

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/328 716 113 389b (09/07)

GENERAL INFORMATION

TECHNICAL DATA

APPLIANCE

INFORMATION

DESCRIPTION

UNITS

12/18

18/25

25/32

 

 

 

 

 

 

 

 

Central Heating

 

 

 

 

 

 

 

Primary water capacity (total)

litres

69

69

72

Maximum static head

metres

30

30

30

 

 

 

 

 

Minimum static head

metres

1

1

1

Available pump head (20°C difference) at max. output

metres water

4.7

4.0

4.2

 

 

 

 

 

Max. permissible sealed system operating pressure

bar

2.5

2.5

2.5

in accordance with WRAS guidelines

 

 

 

 

 

 

 

 

 

 

 

 

Flow restrictor

colour

Lime

 

 

 

 

 

 

 

 

Domestic Hot Water

 

 

 

 

 

 

 

 

 

 

 

 

Optimum flow rate (±15%)

litres/min

15

18

22

 

 

 

 

 

Minimum inlet pressure (dynamic) for optimum flow rate

bar

1.5

1.2

0.9

 

 

 

 

 

Maximum hot water rise for 90 litres draw off (@optimum flow rate)

°C

40

40

40

 

 

 

 

 

 

 

 

Flue

 

 

 

 

 

 

 

 

 

 

 

 

Exit flue gas mass flow

kg/hr

29

40

51

 

 

 

 

 

 

 

 

Pipework connections

 

 

 

 

 

 

 

 

 

 

 

 

Fuel line (compression)

mm

10

10

10

 

 

 

 

 

CH flow

mm

22

22

28

 

 

 

 

 

CH return

mm

22

22

28

 

 

 

 

 

Water main inlet

mm

15

15

15

DHW outlet

mm

22

22

22

Open vent (optional)

BSP

1

1

1

CH drain/optional feed and expansion

BSP

3/

4

3/

4

3/

4

Condensate (polypropylene)

mm

21.5

21.5

21.5

 

 

 

 

 

 

 

 

Electrical

 

 

 

 

 

 

 

 

 

 

 

 

Electrical power supply voltage

AC...V

230

230

230

 

 

 

 

 

Frequency

Hz

50

50

50

 

 

 

 

 

Max. power consumption

W

240

240

263

Thermostats

 

 

 

 

 

 

 

CH control thermostat range (cut in/cut out)

°C

55/81

55/81

55/81

DHW control thermostat range (cut in/cut out)

°C

55/72

55/72

55/72

 

 

 

 

 

CH & DHW control thermostat differential

°C

5

5

5

 

 

 

 

 

Boiler high limit thermostat set point

°C

92

92

92

 

 

 

 

 

Boiler manual reset overheat thermostat set point

°C

105

105

105

 

 

 

 

 

Flue reset overheat thermostat set point

°C

110

110

110

 

 

 

 

 

 

 

 

General Data

 

 

 

 

 

 

 

 

 

 

 

 

Maximum hearth temperature

°C

<100

<100

<100

 

 

 

 

 

SEDBUK (Band A)

%

90.2

90.1

90.3

 

 

 

 

 

Appliance protection rating

IP

45

45

45

 

 

 

 

 

Weight (excluding packaging)

kg

195

195

206

 

 

 

 

 

Emissions class for NOx and CO

class

3

3

3

 

 

 

 

 

Typical NOx emissions figure

mg/kW hr

75

70

75

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

TECHNICAL DATA

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/328 716 113 389b (09/07)

44

43

i)

iv)

44

ii)

43

i)

42b

ii)

iii)

iv)

v)

42a

12

10 11

8 9

7

6

5

4

3

2

1

40 41

39

38

37 35/36 34

33

32

31

30

29

LAYOUT & COMPONENTS

iii)

v)

14

15

16

 

25 24

23 22

26

 

 

 

27

28

The diagram opposite excludes the top, front and RH side casing panels.

1.CONTROL BOX ASSEMBLY

2.DIVERTER VALVE

3.PRESSURE GAUGE

4.AUTO AIR VENT

5. CH CONTROL AND MANUAL RESET OVERHEAT THERMOSTAT PHIAL

6.CASING SIDE PANEL

7.CIRCULATING PUMP

8.AUTO-RESETHIGH LIMIT THERMOSTAT PHIAL

9. DHW FLOW SWITCH

10.PRESSURE RELIEF VALVE

11.DHW HEAT EXCHANGER

12.FLUE GAS SAMPLING POINT

13 13. FLUE OVERHEAT THERMOSTAT PHIAL

14. CASING SUPPORT PANEL

15. FLUE MANIFOLD ACCESS COVER

16. AIR INLET PIPE AND CASING

17. SECONDARY HEAT EXCHANGER BLEED POINT (ONE ON EITHER SIDE)

18. SECONDARY HEAT EXCHANGER

18

19.SECONDARY HEAT EXCHANGER DRAIN

20.EXPANSION VESSEL

21.OPTIONAL OPEN VENT/AIR VENT

1722. DRAIN AND OPTIONAL FEED AND EXPANSION

1923. CONDENSATE OUTLET

24.PRIMARY HEAT EXCHANGER

25.TRAY

26.OIL ISOLATION VALVE

27.CONDENSATE TRAP

28.CONDENSATE TRAP BRACKET

29.COMBUSTION CHAMBER ACCESS DOOR

30.HEATSLAVE TANK DRAIN

31.HEATSLAVE TANK

32.MODE SWITCH

33.BOILER MODE INDICATOR

34.LOCKOUT INDICATOR

35.OVERHEAT RESET BUTTONS (boiler & flue temperature)

36.LOCKOUT RESET BUTTON

37.SERVICE CONNECTION

38.CH TEMPERATURE CONTROL

39.DHW TEMPERATURE CONTROL

40.DATA LABEL

41.FROST THERMOSTAT SENSORS

42a. BENTONE STERLING BURNER (12/18 & 18/25)

i) CONTROL BOX 20 ii) MOTOR

21iii) AIR INTAKE CASING

iv)OIL PUMP

v)COMBUSTION HEAD

42b. RIELLO RDB 2.2 BURNER (25/32)

i)CONTROL BOX

ii)MOTOR

iii)AIR INTAKE CASING

iv)OIL PUMP

v)COMBUSTION HEAD

43.CLIP - AIR INTAKE HOSE

44.AIR INTAKE HOSE

APPLIANCE

INFORMATION

6

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/328 716 113 389b (09/07)

LAYOUT & COMPONENTS

IMPORTANT: All the following Pre-Installationsections must be read and requirements met before starting boiler or flue installation.

CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.

INSTALLATION

PRE -

CLEANING PRIMARY SYSTEMS

IMPORTANT: Debris from the system can damage the boiler and reduce efficiency. Failure to comply with the guidelines for t he use of wat er treatment with the appliance will invalidate the appliance warranty.

BEFORE CLEANING THE SYSTEM:

ENSURE THE SYSTEM AND PIPEWORK IS IN GOOD WORKING ORDER.

FLUSH THE EXISTING SYSTEM WITH A POWER FLUSHING MACHINE OR WITH A CHEMICAL CLEANER BEFORE INSTALLING NEW COMPONENTS.

CLEANING THE PRIMARY SYSTEM:

Cleanse the system in accodance with BS 7593.

Fill the system with cold mains water to the recommended pressure and check for leaks.

Open all drain cocks and drain the system.

Close drain cocks and add a suitable flushing agent at the correct strength for the system condition in accordance with the manufacturer's instructions.

Circulate the flushing agent before the boiler is fired up.

Run the boiler and system at normal operating temperature in accordance with the manufacturer's instructions.

Drain and thoroughly flush the system to remove the flushing agent and any debris.

7

CLEANING PRIMARY SYSTEMS

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32

8 716 113 389b (09/07)

IMPORTANT: The appliance provides a permanent external electrical supply for servicing and must therefore be fed via a circuit breaker incorporating earth leakage protection.

MAINS WATER EXPANSION VESSEL:

A - Mini expansion vessel, part No. 7 716 102 105

B - Mains water inlet

 

 

 

C - Non-returnvalve

 

 

 

D - Boiler

 

 

D

 

 

 

 

A

B

C

 

 

 

 

 

 

 

 

 

 

 

 

MAINS SUPPLIES

ELECTRIC SUPPLY:

 

Supply: 230V - 50Hz.

 

• Cable: PVC insulated 0.75mm2 (24 x

 

 

0.2mm) temperature rated to 90°C.

 

Protection IP45.

 

External 5A fuse to BS 1362.

 

The appliance must be earthed.

 

Please refer to IEE regulations for cross

 

 

bonding requirements.

 

It must be possible to isolate the appliance

 

 

from the electric supply with at least a 3mm

 

 

contact separation in both poles supplying

 

 

the appliance.

 

Wiring between the appliance and the

INSTALLATION

 

-PRE

electrical supply must comply with IEE wiring regulations and any local regulations which may apply for fixed wiring to a stationary appliance.

• Any system connected to the boiler must not have a separate electrical supply.

WATER SUPPLY:

The following are general requirements and if necessary the advice of the local water company should be sought before fitting the appliance.

The appliance cold water supply should be the first connection off the water main where possible.

Water Mains Pressure:

Minimum dynamic mains water pressure for optimum performance.

12/18kW

18/25kW

25/32kW

 

 

 

1.5 bar

1.2 bar

0.9 bar

 

 

 

Maximum mains fed water pressure 10 bar. If necessary, fit a pressure reducing valve.

IMPORTANT: Non-return,back flow prevention devices (including those associated with water meters) fitted to the mains water supply can cause a pressure build up which could damage the boiler and other household appliances.

Where the water main supply has a nonreturn, back flow prevention valve fitted, a mini expansion vessel (A) must be connected to the mains water inlet pipe (B) between the non-returnvalve (C) and the boiler (D) as shown opposite.

Use in hard water areas:

Normally there is no need for water treatment to prevent scale formation as the maximum temperature of the heat exchanger is limited by the control circuit.

In areas where the temporary water hardness exceeds 200ppm, consideration may need to be given to the fitting of a scale prevention device. In such circumstances, the advice of the local water authority should be sought.

8

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/328 716 113 389b (09/07)

MAINS SUPPLIES

PRE - INSTALLATION

9

A

- Oil storage tank

H

- Oil supply pipe

B

- Isolating valve

J

- Oil pump

C

- Oil strainer & water seperator

K

- Full base (plastic tanks)

D

- Fire valve to BS5410

L

- Non-returnvalve

E

- External casing

M

- De-aerator

F

- Fire valve sensor

N

- Oil filter (16µm max filtration size)

G- Oil burner

NOTE: All dimensions are in metres unless stated otherwise.

The maximum pipe run figures are based on using copper pipe with an inside diameter of

2mm less than the Ø.

 

.

 

1m min

 

 

a)

 

 

 

A

 

 

 

 

 

 

 

F

 

300mm min.

max.(13ft)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

K

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4m

 

 

 

 

B

C

 

H

 

B D

B N

G

 

J

 

MAXIMUM PIPE RUN FOR SINGLE PIPE GRAVITY FEED SYSTEM

 

E

 

 

HEAD

10mmØ

12mmØ

 

 

HEAD

10mmØ

12mmØ

 

 

 

 

 

 

 

 

 

0.5

12

30

 

 

 

 

2.5

 

62

100

 

 

 

 

1.0

25

69

 

 

 

 

3.0

 

74

100

 

 

 

 

1.5

37

91

 

 

 

 

3.5

 

87

100

 

 

 

 

2.0

49

100

 

 

 

 

4.0

 

99

100

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1m min

.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

b)

 

 

 

 

 

 

 

B

D

 

 

F

G

 

 

 

 

 

 

 

L

 

 

 

 

 

 

 

 

 

A

 

 

 

 

 

 

 

 

 

max.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(11.5ft)

 

 

 

B

C

 

L

H

 

B

N

 

J

 

 

 

 

 

 

 

 

 

 

 

 

 

150mm

 

 

 

 

K

 

 

 

 

 

 

 

 

3.5m

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

E

 

 

MAXIMUM PIPE RUN FOR DOUBLE PIPE SUB-GRAVITYFEED SYSTEM

 

 

 

 

HEAD

10mmØ

12mmØ

 

 

HEAD

10mmØ

12mmØ

 

 

 

 

0

50

100

 

 

 

 

2.0

 

26

66

 

 

 

 

0.5

44

100

 

 

 

 

2.5

 

20

50

 

 

 

 

1.0

38

95

 

 

 

 

3.0

 

14

37

 

 

 

 

1.5

32

80

 

 

 

 

3.5

 

8

22

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

F

 

 

 

 

 

 

 

 

 

 

M

 

 

 

G

 

c)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

max.

 

 

 

A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(11.5ft)

 

 

 

B

C

H

 

B

 

D

 

J

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

K

 

 

 

 

1m min

.

E

 

3.5m

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MAXIMUM PIPE RUN FOR SINGLE PIPE SUCTION LIFT WITH DE-AERATOR

 

 

 

HEAD

FUEL FLOW RATE

10kg/h

 

HEAD

FUEL FLOW RATE

10kg/h

2.5kg/h

5kg/h

10kg/h

 

2.5kg/h

5kg/h

10kg/h

 

8mmØ

8mmØ

8mmØ

10mmØ

 

 

 

8mmØ

8mmØ

8mmØ 10mmØ

0

100

55

26

100

 

2.0

 

60

30

14

 

65

 

0.5

95

45

23

100

 

2.5

 

45

25

11

 

50

 

1.0

80

40

20

 

90

 

3.0

 

35

15

8

 

35

 

1.5

70

35

17

 

75

 

3.5

 

25

10

5

 

20

 

The table and illustration above is a guide only and does not in any way override the deaerator manufacturers instructions.

OIL SUPPLY

This appliance is suitable for kerosene (28 second oil) only, no other fuel must be used.

OIL SUPPLY:

Plastic or steel tanks should be installed to BS 5410. A steel tank should conform to BS 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 tanks or pipework for the oil supply system.

Do not use soldered joints on the oil supply pipework.

a) Single pipe gravity feed system:

The oil storage tank (A) must be positioned so that the oil level does not exceed 4 metres above the level of the burner oil pump (J) and in addition the oil level must be at least 300mm above the oil pump (J). Where the maximum oil level in the oil storage tank exceeds 4 metres, a head breaking device must be installed between the tank (A) and the burner oil pump (J).

b)Double pipe sub-gravityfeed system:

Maximum suction height 3.5 metres. Non-returnvalves must be fitted to the inlet and return oil line between the oil pump (J) and oil storage tank (A).

c)Single pipe suction lift with de-aerator

Maximum suction height 3.5 metres. The oil tank (A) must be positioned below the oil pump

(J). Create an inlet and return loop between the de-aerator(M) and oil pump (J).

A non-returnvalve must be incorporated within thede-aeratoror fitted to the oil line between the oil storage tank (A) and thede-aerator(M).

A top feed oil tank fitted with a de-aeratorusing an internalnon-returnvalve should have anynon-returnvalves fitted in the base of the tank to the suction line removed to assist purging air from the oil line.

Pipework

Use copper pipe of the correct diameter according to the information shown opposite. Use flexible hoses to connect to the oil pump (J).

Lay the oil supply pipe (H) as straight and level as possible to avoid air pockets and unnecessary friction losses. Route away from the boiler access door or other hot surfaces.

Install a manual isolating valve (B) to the oil supply pipe (H), as close to the oil storage tank (A) as possible.

Fit an oil strainer and water seperator (C) to the oil supply pipe, near the oil storage tank. Fit an additional oil filter (N, 16µm max filtration size) close to the boiler, but not inside the boiler casing.

Fit a fire valve in accordance with BS 5410. The fire valve (D) must be fitted externally at least 1 metre from the appliance with the fire valve sensor (F) located within the appliance case.

A capillary type valve provides a neat and simple installation. Alternatively, a fusible link or electrical system may be used.

Under no circumstances should a combination isolating/fire valve be used as the sole fire protection device.

OIL SUPPLY

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/328 716 113 389b (09/07)