Bosch 12-18, 25-32kW, 18-25 User Manual

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Page 1

GREENSTAR HEATSLAVE EXTERNAL

THE APPLIANCE IS FOR USE WITH KEROSENE ( 28 SECOND

OIL) ONLY

INSTRUCTION MANUAL

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

INSTRUCTION MANUAL

INSTALLATION COMMISSIONING & SERVICING

Page 2

INSTALLATION & SERVICING INSTRUCTIONS

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

8 716 113 389b (09/07)

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

SYMBOLS USED IN THIS MANUAL:

Domestic hot water

Central heating

Room thermostat

Frost thermostat

Wait time period

Programmer/timer OFF

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 R EGULATIONS:

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-certification schemes 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 HELPLIN E.

DISTANCE LEARNING AND TRAI NING 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: Ø Diameter 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.

INSTALLATION & SERVICING INSTRUCTIONS

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.

Programmer ON CH only

Programmer ON DHW only

Programmer ON CH and DHW

Cold water main supply

Electricity supply

Page 3

SAFETY & REGULATIONS

IMPORTANT INFORMATION AND SYMBOLS 1

SAFETY PRECAUTIONS AND I NSTALLATION 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-COMMISSIONING CHECKS - 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 SCH EMATIC 48

COMMISSIONING & SERVICE RECORDS

COMBUSTION RECORD 49

SERVICE INTERVAL RECORD 50

CONTENTS

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

SAFETY &

REGULATIONS

APPLIANCE

INFORMATION

PRE -

INSTALLATION

INSTALLATIONCOMMISSIONING

SERVICING

& SPARES

FAU LT FIND ING

& DIAGRAMS

Page 4

SAFETY PRECAUTIONS & INSTALLATION REGULATIONS

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

8 716 113 389b (09/07)

SAFETY &

REGULATIONS

SAFETY PRECAUTIONS INSTALLATION REGULATIONS

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.

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. BS 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.

Page 5

GENERAL INFORMATION

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

APPLIANCE

INFORMATION

GENERAL INFORMATION

STANDARD PACKAGE:

A - Floor standing oil fired condensing boiler for

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

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

770mm

640mm

950mm

Page 6

TECHNICAL DATA

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

8 716 113 389b (09/07)

TECHNICAL DATA

Central Heating

Primary water capacity (total) litres

Maximum static head metres

Minimum static head metres

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

Max. permissible sealed system operating pressure bar

in accordance with WRAS guidelines

Flow restrictor colour

Domestic Hot Water

Optimum flow rate (±15%) litres/min

Minimum inlet pressure (dynamic) for optimum flow rate bar

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

Flue

Exit flue gas mass flow kg/hr

Pipework connections

Fuel line (compression) mm

CH flow mm

CH return mm

Water main inlet mm

DHW outlet mm

Open vent (optional) BSP

CH drain/optional feed and expansion BSP

Condensate (polypropylene) mm

Electrical

Electrical power supply voltage AC...V

Frequency Hz

Max. power consumption W

Thermostats

CH control thermostat range (cut in/cut out) °C

DHW control thermostat range (cut in/cut out) °C

CH & DHW control thermostat differential °C

Boiler high limit thermostat set point °C

Boiler manual reset overheat thermostat set point °C

Flue reset overheat thermostat set point °C

General Data

Maximum hearth temperature °C

SEDBUK (Band A) %

Appliance protection rating IP

Weight (excluding packaging) kg

Emissions class for NOx and CO class

Typical NOx emissions figure mg/kW hr

DESCRIPTION UNITS 12/18 18/25 25/32

APPLIANCE

INFORMATION

4.7

2.5

Lime

1. 5

21. 5

230

240

55/81

55/72

105

110

<100

90.2

19 5

4.0

2.5

—

1. 2

21. 5

230

240

55/81

55/72

105

110

<100

90.1

19 5

4.2

2.5

—

0.9

21. 5

230

263

55/81

55/72

105

110

<100

90.3

206

Page 7

LAYOUT & COMPONENTS

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-RESET HIGH LIMIT THERMOSTAT PHIAL

9. DHW FLOW SWITCH

10. PRESSURE RELIEF VALVE

11. DHW HEAT EXCHANGER

12. FLUE GAS SAMPLING POINT

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

19. SECONDARY HEAT EXCHANGER DRAIN

20. EXPANSION VESSEL

21. OPTIONAL OPEN VENT/AIR VENT

22. DRAIN AND OPTIONAL FEED AND EXPANSION

23. 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 ii) MOTOR iii) 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

LAYOUT & COMPONENTS

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

APPLIANCE

INFORMATION

35/36

42a

42b

iv)

iii)

ii)

iii)

ii)

iv)

Page 8

CLEANING PRIMARY SYSTEMS

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 COM PONENTS.

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.

IMPORTANT: All the following Pre-Installation sections 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.

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

CLEANING PRIMARY SYSTEMS

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

8 716 113 389b (09/07)

PRE -

INSTALLATION

Page 9

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

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.

• 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-return valve (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.

MAINS WATER EXPANSION VESSEL:

A - Mini expansion vessel, part No. 7 716 102 105 B - Mains water inlet C - Non-return valve D - Boiler

MAINS SUPPLIES

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

PRE -

INSTALLATION

12/18kW

Water Mains Pressure:

Minimum dynamic mains water pressure for

optimum performance.

1.5 bar 1.2 bar

0.9 bar

18/25kW 25/32kW

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

Page 10

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-gravity feed system:

Maximum suction height 3.5 metres. Non-return valves 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-return valve must be incorporated within the de-aerator or fitted to the oil line between the oil storage tank (A) and the de-aerator (M).

A top feed oil tank fitted with a de-aerator using an internal non-return valve should have any non-return valves 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.

4m (13ft) max.

300mm

min.

B DB C

MAXIMUM PIPE RUN FOR SINGLE PIPE GRAVITY FEED SYSTEM

3.5m (11.5ft) max.

MAXIMUM PIPE RUN FOR DOUBLE PIPE SUB-GRAVITY FEED SYSTEM

3.5m (11.5ft) max.

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

FUEL FLOW RATE

min

OIL SUPPLY

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

8 716 113 389b (09/07)

PRE -

INSTALLATION

A - Oil storage tank B - Isolating valve C - Oil strainer & water seperator D - Fire valve to BS5410 E - External casing F - Fire valve sensor G - Oil burner

H - Oil supply pipe J - Oil pump K - Full base (plastic tanks) L - Non-return valve M - De-aerator N - Oil filter (16µm max filtration size)

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.

HEAD 10mmØ 12mmØ

0.5 12 30

1. 0 25 69

1. 5 37 91

2.0 49 100

HEAD 10mmØ 12mmØ

2.5 62 100

3.0 74 100

3.5 87 100

4.0 99 100

HEAD 10mmØ 12mmØ

050 100

0.5 44 100

1. 0 3 8 9 5

1. 5 3 2 80

HEAD 10mmØ 12mmØ

2.0 26 66

2.5 20 50

3.0 14 37

3.5 8 22

HEAD 2.5kg/h 5kg/h 10kg/h 10kg/h

8mmØ 8mmØ 8mmØ 10mmØ

0 100 55 26 100

0.5 95 45 23 100

1.0 80 40 20 90

1. 5 70 3 5 17 75

HEAD 2.5kg/h 5kg/h 10kg/h 10kg/h

8mmØ 8mmØ 8mmØ 10mmØ

2.0 60 30 14 65

2.5 45 25 11 50

3.0 35 15 8 35

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.

Page 11

TYPICAL OPEN VENT SYSTEM

INSTALLATIONCOMMISSIONING

A - Appliance expansion vessel B - Extra expansion vessel C - Automatic bypass valve D - Drain cock E - Feed & expansion cistern

WATER SYSTEMS & PIPEWORK

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

PRE -

INSTALLATION

F - Feed & expansion 15mmØ min G - Appliance H - Open vent 22mmØ min L - Lockshield valve P - Pressure relief discharge

R - Radiators S - Static head T - TRV U - To filling system

WATER SYSTEMS & PIPEWORK

PRIMARY SYSTEM PLASTIC PIPEWORK:

• Plastic pipework must not

be used for

the DHW system.

• Any plastic pipework used for the CH system must have a polymeric barrier, comply with BS 7921 and installed to BS 5955 with 1000mm (minimum) length of copper or steel pipe connected to the boiler.

• Plastic pipework used for underfloor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approx. 50°C with 1000mm (minimum) length of copper or steel pipe connected to the boiler.

PRIMARY SYSTEM/CONNECTIONS/VALVES:

• Do not use galvanised pipes or radiators.

• All system connections, taps and mixing valves must be capable of sustaining a pressure of 3 bar.

• Radiator valves should conform to BS 2767:10.

• All other valves should conform to BS 1010.

• On new installations TRVs must be used on all radiators except the radiator where the room thermostat is sited, this must be fitted with lockshield valves and left open. All installations should have TRVs fitted to radiators within the sleeping accommodation.

• An automatic bypass valve must be connected between the heating flow and return where TRVs are used on all radiators, fitted to give at least a 3m circuit when activated.

• Drain cocks are required at all the lowest points on the system.

• Air vents are required at all high points on the system.

OPEN VENT PRIMARY SYSTEM:

• In order to comply with BS 5449 the feed and expansion pipe and the open vent pipe, (or the combined feed and vent pipe), must be connected to the BSP outlet/s on the right hand side of the primary heat exchanger.

• The feed and expansion cistern (E) must be positioned to provide a static head (S) of at least 1 metre above the highest point in the heating system to the water level in the feed and expansion cistern (E).

• Ensure adequate space is left in the expansion cistern for expansion of the system water.

• No valve shall be fitted in the open vent pipe (H) or the feed and expansion pipe (F).

• The open vent pipe (H) must be at least 22mmØ.

SEALED PRIMARY SYSTEM:

• Where the system volume is more than 180 litres at 0.5 bar or exceeds 2.65bar at maximum heating temperature an extra expansion vessel (B) must be fitted as close as possible to the appliance in the central heating return.

• Pressurise the extra expansion vessel (B) to the same figure as the expansion vessel built into the appliance.

IMPORTANT: The boiler should not be allowed to operate with a return temperature of less than 40°C when the system is up to operating temperature.

TYPICAL SEALED SYSTEM

1000mm min.

R R

Page 12

WATER SYSTEMS & PIPEWORK

FILLING PRIMARY SEALED SYSTEMS:

• Filling the system must comply with one of the methods shown opposite.

• The filling point must be at low level and must never be a permanent direct fixing to the mains water supply.

• Filling loops must be WRAS approved.

SHOWERS/BIDETS:

• If a shower head can be immersed in water or comes closer than 25mm from the top edge of a bath or shower tray spill over level then an anti-siphon device must be fitted to the shower hose.

• Only thermostatically controlled showers are suitable for use with this appliance.

• Bidets with direct hot & cold mains water can be used (with the approval of the local water authority) and must be the over rim flushing type with shrouded outlets to prevent the fitting of hand held sprays.

DOMESTIC HOT WATER:

• Plastic pipework must not

be used for

the DHW system.

• Taps and mixing valves must be capable of sustaining a pressure up to 10 bar in accordance with the Water Regulations as they will be operating at mains water pressure.

• Hot water temperature and flow rate are affected by the size and insulation of pipework making up the distribution system and are controlled by the hot water tap and the water main inlet pressure. A mixing valve can be fitted if a more permanent setting is required.

• If using more than one outlet at once causes water flow starvation, fit flow balancing valves or Ball-O-Fix valves to the appropriate outlets.

Heating return

Hose

return

Non return

valve

Non return

valve

Test cock

Stop cock

Water main

supply

Stop cock

Temporary hose

Heating return

Auto air

vent

Non return

valve

Stop cock

Make up

vessel

1000mm above the highest point of the system

Fill Point

INSTALLATIONCOMMISSIONING

WATER SYSTEMS & PIPEWORK

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

8 716 113 389b (09/07)

PRE -

INSTALLATION

Page 13

CONDENSATE &

PRESSURE RELIEF PIPEWORK

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

PRE -

INSTALLATION

CONDENSATE &

PRESSURE RELIEF PIPEWORK

CONDENSATE PIPEWORK:

• All national and, where appropriate, local

regulations for the discharge and neutralisation of condensate should be followed.

• The condensate pipe must be a minimum of

21.5mmØ polypropylene pipe.

• The condensate pipework must fall at least

50mm per metre towards the outlet and should take the shortest practicable route and not exceed 3 metres outside the building. If a run greater than 3m is required, 32mmØ polypropylene pipe must be used.

• The pipework must follow one of the options

shown opposite:

a - Internal waste drainage system

b - Soil/vent stack

c - External drainage system

d - External condensate absorption point

• Condensate pipework must not be connected

to rainwater downpipes.

• Use waterproof pipe insulation in exposed

positions and for external pipework

IMPORTANT: Condensate pipework must not leak and the condensate trap must be filled with water before the boiler is started to prevent the possibility of potentially harmful flue products escaping via the condensate route.

A - Condensate from the boiler condensate

trap (supplied) which has a 75mm minimum water seal.

B - Sink.

C - 21.5mm Ø polypropylene condensate pipe.

D - Gully.

E - Internal soil and vent stack. F - 300mm x 100mm Ø sealed plastic tube.

G - Ground level.

H - Drainage holes 50mm from base of tube

(12mm Ø at 25mm centres) facing away from building.

I - Limestone chippings.

PRESSURE RELIEF PIPEWORK:

IMPORTANT: The pressure relief valve is a safety device for the boiler and if activated may discharge boiling water or steam through the relief valve drain pipe. Care should be taken when siting the outlet pipe so that it does not cause an obstruction or discharge above a window, entrance or other public access where it could cause a hazard.

• The pressure relief drain pipe (K) should be

at least 15mm diameter copper pipe and run downwards away from the boiler and discharge away from any electrics or other hazard, preferably to an external drain or soakaway.

• Pipe (K) should be finished with a partial

bend, near the outlet to face the external boiler casing (as shown) to help prevent freezing.

J - External boiler casing.

K - Pressure relief pipe.

75mm

min.

450 min.

Invert

(Unsuitable for clay soil types)

500mm min.

200mm min.

25mm

min.

400mm

min.

Page 14

BOILER LOCATION & CLEARANCES

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

8 716 113 389b (09/07)

PRE -

INSTALLATION

BOILER LOCATION &

CLEARANCES

WARN ING:

This appliance should not be installed where there is a potential for excessive ground water coverage.

This boiler is only suitable for installing externally at a suitable location onto a fixed permanent rigid surface capable of supporting the boiler weight.

There must be a sufficient hard standing around the appliance to allow for servicing.

The boiler must be installed on a flat level surface to ensure that condensate does not enter the primary heat exchanger.

Tarmac and wood hardstandings are not recommended.

CLEARANCES: Min service & flue clearances

Above 600mm Front 600mm

RH/LH flue outlet on opposite side 10mm RH flue outlet on rear 85mm LH flue outlet on rear 10mm

Rear = flue outlet on side 150mm** Rear = rear flue outlet 2500mm*

It is strongly recommended that the flue terminal faces away from walls to reduce the possibility of wetting occuring.

*This can be reduced to 1200mm if there is at least 2500mm clearance on both sides of the

flue.

** 200mm if a high level terminal is used exiting

through the rear panel.

600mm

2500mm*

600mm

BASE

FRONT

2500mm*

150mm**

85mm10mm

600mm

10mm

600mm

2500mm*

FRONT

2500mm*

10mm

600mm

150mm**

Plan view

600mm

(min)

Page 15

CABINET MOUNTED LOW LEVEL

FLUE TERMINAL POSITIONS

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

PRE -

INSTALLATION

Minimum dimensions of flue terminal positions for oil fired appliances:

TERMINAL POSITION B(H)

Directly below an opening, air brick, opening windows, etc 600mm

Horizontally to an opening, air brick, opening window, etc 600mm

C Below a plastic/painted gutter, drainage pipe or eaves if 75mm

combustible material protected

Below a plastic/painted gutter, drainage pipe or eaves without 600mm protection to combustible material

E From vertical sanitary pipework 300mm

F From an external or internal corner or from a surface or boundry 300mm

alongside the terminal

G Above ground or balcony level 300mm*

H 1From a surface or boundary facing the terminal with 2500mm 1200mm

clearance to both sides of the terminal

H 2From a surface or boundary facing the terminal with less than 2500mm

2500mm clearance to either side of the terminal

I 1From a terminal facing the terminal with 2500mm clearance to 1200mm

clearance to both sides of the terminal

I 2From a terminal facing the terminal with less than 2500mm 2500mm

clearance to either side of the terminal

K Horizontally from a terminal 750mm

B(H) Balanced Horizontal flue

1 An opening means an openable

element, such as an openable window, or a permanent opening such as a permanently open air vent.

Notwithstanding the dimensions above, a terminal should be at least 300mm from combustible material, e.g. a window frame.

2 A way of providing protection of

combustible material would be to fit a heat shield at least 750mm wide.

• Flue terminals must be positioned to avoid combustion products entering into buildings.

• The flue must be fitted and terminated in accordance with the recommendations of BS5410.

• The flue must not cause an obstruction.

• Discharge from the flue outlet must not be a nuisance.

• Flue gases have a tendency to plume and in certain weather conditions a white plume of condensation will be discharged from the flue outlet which could be regarded as a nuisance, for example, near security lighting.

• There should be no restriction preventing the clearance of combustion products from the terminal.

• The air inlet/outlet duct and the terminal of the boiler must not be closer than 25mm to any combustible material. Detailed recommendations on protection of combustible materials are given in BS 5410:1

• A protective terminal guard must be fitted if the terminal is 2m or less above a surface where people have access.

Stainless steel terminal guard. Part No: 7 716 190 050

• The following additional guidelines (from part L Exceptions Guidance Document) are recommended when determining the flue outlet position:

• Avoid discharging flue gases into car ports or narrow passageways.

• *Minimum distance of the flue terminal from above ground is 2100mm where directed to a public footpath, private access route or a frequently used area and 2500mm from a car parking area.

boundary

C, D

boundary

CABINET MOUNTED LOW LEVEL

FLUE TERMINAL POSITIONS

Page 16

HIGH LEVEL FLUE TERMINAL POSITIONS

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

8 716 106 252d (08/07)

PRE -

INSTALLATION

Minimum dimensions of flue terminal positions for oil fired appliances:

TERMINAL POSITION B(H) B(V)

1 2

Directly below an opening, air brick, opening window, etc 600mm N/A

1 2

Horizontally to an opening, air brick, opening window, etc 600mm N/A

C Below a plastic/painted gutter, drainage pipe or eaves if 75mm N/A

combustible material protected

D3Below a plastic/painted gutter, drainage pipe or eaves without 600mm N/A

protection to combustible material

E From vertical sanitary pipework 300mm N/A

F From an external or internal corner or from a surface or boundry 300mm N/A

alongside the terminal

G Above ground or balcony level 300mm* N/A

H From a surface or boundary facing the terminal 600mm** N /A

J From a terminal facing the terminal 1200**mm —

K Vertically from a terminal on the same wall 1500mm N/A

L Horizontally from a terminal on the same wall 750mm —

M Above the point of highest intersection with the roof — 600mm

N From a vertical structure on the side of the terminal — 750mm

O Above a vertical structure less than 750mm from the side of the terminal — 600mm

P From a ridge terminal to a vertical structure on the roof — —

Q Above or to the side of any opening on a flat or sloping roof — 300mm

R Below any opening on a sloping roof — 1000mm

Key: — Not applicable, N/A Not allowed, B(H) Balanced Horizontal flue, B(V) B alanced Vertical flue.

Notes:

1. Terminals should be positioned so as to avoid products of combustion accumulating in stagnant pockets around the building or entering into buildings.

2. Vertical structure in N, O and P includes tank or lift rooms, parapets, dormers etc.

3. Terminating positions should be at least 1.8m from an oil storage tank unless a wall with at least 30 min fire resistance and

extending 300mm higher and wider than the tank is provided between the tank and the terminating position.

4. Where a flue is terminated less than 600mm away from a projection above it and the projection consists of plastics or has a combustible or painted surface, then a heat shield of at least 750mm wide should be fitted.

5. If the lowest part of the terminal is less than 2m above the ground, balcony, flat roof or other place to which any person has access, the terminal should be protected by a guard.

6. Notwithstanding the dimensions given above, a terminal should not be sited closer than 300mm to combustible material. In the case of a thatched roof, double this separation distance should be provided. It is also advisable to treat the thatch with a fire retardant material and close wire in the vicinity of the flue.

7. It is essential that a flue or chimney does not pass through the roof within the shaded area delineated by dimensions Q and R.

8. Where protection is provided for plastic components, such as guttering, it is essential that this is to the standard specified by the

manufacturer of the plastic components.

• Flue terminals must be positioned to avoid combustion products entering into buildings.

• The flue must be fitted and terminated in accordance with the recommendations of BS 5410.

• The flue must not cause an obstruction.

• Discharge from the flue outlet must not be a nuisance.

• There should be no restriction preventing the clearance of combustion products from the terminal.

• A protective terminal guard must be fitted if the terminal is 2m or less above a surface where people have access. The guard must be spaced equally (minimum 50mm) around the flue and fixed to the wall with plated screws.

Stainless steel terminal guard. Part No: 7 716 190 050

The following additional guidelines (from part L Exceptions Guidance Document) are recommended when determining the flue outlet position:

• Avoid discharging flue gases into car ports or narrow passageways.

• *Minimum distance of the flue terminal from above ground is 2100mm where directed to a public footpath, private access route or a frequently used area and 2500mm from a car parking area.

• **Minimum distance of the flue terminal to a facing wall, fence, building or property boundary is 2500mm.

HIGH LEVEL FLUE TERMINAL

POSITIONS

boundary

Pitched roof

Flat roof

C, D

boundary

Page 17

BALANCED EXTERNAL OILFIT

FLUE OPTIONS

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

PRE -

INSTALLATION

IMPORTANT: The weather seal (supplied)

must be fitted to every flue joint to give the required level of weather protection.

The diagrams (opposite) show the components used and the maximum flue length (L) for each flue configuration.

In all cases L is measured from the outside of the boiler casing.

• To achieve the maximum flue length (L), a flue section will have to be reduced in length.

• Only the straight flue extensions can be

reduced in length by cutting.

IMPORTANT: All horizontal sections must rise away from the boiler by 52mm per metre (3°) to allow the condensate to drain back to the boiler.

A - Horizontal terminal B - Straight flue extension C - Flue bend 90° D - Flue bend 45° E - Vertical Terminal Kit (incl. 90° elbow) F - Horizontal terminal kit (incl. 90° elbow)

Calculating the flue length:

Measure the total flue length required, noting that the maximum straight flue length including the terminal is: Horizontal 80/125mmØ: 4000mm. Vertical 80/125mmØ / 100/150mmØ (25/32 only): 7000mm.

Then reduce the total straight flue length for each extra flue bend (excluding the vertical flue kit 90° elbow) by:

1000mm for 90°

500mm for 45°

Flue Extension lengths:

Horizontal & Vertical: 1000mm overall length.

Effective length when engaged into sockets within the flue run is 950mm.

Flue Terminal lengths:

Horizontal 80/125mmØ: 720mm

Vertical 80/125mmØ: 1080mm + cage

* Rear exit only. ** Horizontal flue runs should be kept as

short as possible.

L = 2000mm

BALANCED EXTERNAL OILFIT

FLUE OPTIONS

High level horizontal terminal (rear outlet)

Vertical terminal (rear outlet)

Vertical terminal (side outlet)

125mmØ x2

L = 7000mm

125mmØ x5

L = 6000mm

125mmØ x4

L = 6000mm

125mmØ x4

Page 18

BALANCED FLUE OPTIONS

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

8 716 113 389b (09/07)

PRE -

INSTALLATION

CABINET MOUNTED BALANCED

HORIZONTAL FLUE OPTIONS

• The horizontal flue is fitted to the rear or either side of the cabinet.

IMPORTANT:

It is strongly recommended that the flue terminal faces away from walls to minimise the occurance of wetting.

A - External horizontal flue kit

Part No. 7 716 190 052

B - 90° inline elbow 80/125mm

Part No. 7 716 190 034

C - Terminal guard

Part No. 7 716 190 050

FRONT

Plan view

REAR FLUE OUTLET

A + C

LEFT HAND FLUE OUTLET

A + B + C

RIGHT HAND FLUE OUTLET

A + B + C

Page 19

Unpacking:

It is advised that two or more persons are involved in the transfer of the packaged boiler from the van to the point of delivery.

1  Once the packaged boiler has been

delivered, the outer carton is removed first. Care should be taken when releasing the straps. If a sharp implement is used make sure the outer carton is not pierced and that the implement is used in such a way so that it may not cause personal injury. All sharp objects must be covered or the blade retracted after use and put away in a safe place.

2  Lift carton up and away from the boiler.

 Remove the plastic bag from the boiler and

place safely aside.

UNPACKING THE BOILER

LIFTING AND CARRYING PRECAUTIONS:

• Lift only a manageable weight, or ask for help.

• When lifting or putting things down, bend the knees, and keep the back straight and feet apart.

• Do not lift and twist at the same time.

• Lift and carry objects close to the body.

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

IIMPORTANT: All the previous Pre-Installation sections must be read

and requirements met before starting boiler or flue installation.

UNPACKING THE BOILER

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

INSTALLATION

Page 20

All dimensions in mm

256

650

802

258

10 5

171

374

161

650

787

670

518

10 5

269

658 669 705 715

650

794

670

518

15 8

12 4

89.5 55

658 679 698 718

528

230

INSTALLATIONCOMMISSIONING

SAFETY:

All relevant safety precautions must be undertaken. Protective clothing, footwear, gloves and safety goggles must be worn as appropriate.

PIPEWORK CONNECTIONS:

CH flow 22mmØ copper (28mmØ on 25/32kW model)

DHW flow 22mmØ copper Mains water inlet 15mmØ CH return 22mmØ copper (28mmØ on

25/32kW model) Optional open vent 1'' BSP Services duct 100mmØ Drain/optional fill/feed & expansion

'' BSP Pressure relief pipe 15mmØ Condensate outlet 21.5mmØ

NOTE: For servicing purposes, keep the condensate and pressure relief discharge pipes away from components and pipework connections.

CAUTION: Ensure there are no pipes, electric cables, damp proof courses or other hazards before drilling.

PIPEWORK & FLUE POSITIONS

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

8 716 113 389b (09/07)

Condensate

Flue

Services

PRV

Fire valve capillary & drain access

Flue

Services

Condensate

PRV Oil

Flue

Services

Condensate

Oil

PRV

LEFT HAND SIDE

RIGHT HAND SIDE

REAR

Fire valve capillary & drain access

Page 21

BOILER INSTALLATION

Note: The cabinet is not load bearing it only provides weather protection for the boiler inside.

1Mark position of the 100mm services

duct on the exterior wall and make a hole through.

2Remove the key for the door fastners

from its transport position in the left hand side panel flue outlet aperture. Undo the screws at the bottom of the front panel (using the key provided) and remove the screws from the rear panel pulling both panels out and down to remove. Store safely away from the installation point.

3Remove the screws from the top panel

and lift up to remove, store safely away from the installation point.

4Slide the pressure gauge up out of its

bracket and carefully rest on top of the heat exchanger taking care not to snag or kink the capillary.

5Remove the screws securing the control

box to the side panels and carefully rest the control box on top of the heat exchanger taking care not to snag or kink the capillaries.

6Remove the screws securing the side

panels to the base panel and lift the side panels off complete with the rear support bar (shaded grey) and carefully stand the panels away from the installation point.

7Loosen the flexable air duct clamp (A)

and remove the air duct from the burner.

Depress the locking ears to unplug the

burner lead (B) from the control box (C).

Unscrew the burner retainers (D), then

withdraw the burner (E) from the boiler and store safely away from the installation point.

8Remove the screws securing the base

panel to the transit pallet and lift the boiler off the pallet and into its installation position taking care not to scrape the base panel across the hard standing. Do

not attempt to lift and position the boiler on your own. Do not use the copper pipes to move the boiler.

Fasten the base to the hard standing

using the holes provided. Care should be taken to ensure that the base is level.

9Refit the side panels and rear support

bar and screw the side panels to the baseplate and boiler.

Refit the control box and pressure

gauge taking care not to kink the capillary tubes.

Measure the 100mmØ services duct to

give at least 10mm inside the casing and to finish flush with the interior wall surface, cut to size and fit the duct. Fit the 100mm sealing ring where the duct enters the casing and seal the joint to the exterior wall and inside the cabinet with a suitable sealant.

BOILER INSTALLATION

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

INSTALLATION

WARNING: THIS APPLIANCE IS SERVICED AND REPAIRED EXTERNALLY.

EXTERNAL EQUIPMENT OPERATED AT 230V SHOULD NOT BE INSTALLED, SERVICED OR REPAIRED UNDER ADVERSE WEATHER CONDITIONS.

THIS APPLIANCE IS INSTALLED AND SERVICED EXTERNALLY TO THE PROPERTY, BUT THE ENGINEER MUST HAVE ACCESS TO THE INSIDE OF THE PROPERTY WHEN INSTALLING OR SERVICING THE APPLIANCE.

Page 22

INSTALLATION NOTES:

 Ensure all the seals are in good condition

and seated properly.

 To ease assembly of flue components,

grease seals lightly with the solvent free grease supplied.

 A terminal guard must be fitted if the

terminal is 2m or less above a surface where people have access.

All flue options:

1 Lightly grease the flue cowl seal with the

solvent free grease supplied.

2 Carefully remove the blanking plate from

the appropriate flue aperture (if necessary) and refit the blanking plate in the unused aperture.

3 Carefully remove the insulation from the

flue aperture in the cabinet that the flue is to pass through, and fit to the unused aperture (if necessary).

4 Refer to the flue manual supplied with the

flue kit for flue installation.

FLUE INSTALLATION

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

8 716 113 389b (09/07)

INSTALLATION

Page 23

COMBUSTION CHAMBER

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

INSTALLATION

Combustion chamber:

1 Release retaining nuts and washers (B).

 Remove combustion chamber access

door (A).

2 Ensure the baffles (C) and baffle retainer

(D) are correctly fitted for the boiler output

as shown in the plan views opposite.

3 Refit combustion chamber door (A).

 Secure with nuts and washers (B) and

tighten until the door is firmly secured, do not over tighten the nuts.

4 Unscrew screws (E) and remove flue

manifold access cover (F).

5 Check that all the baffles (G) and baffle

retainer (H) or ( J ) are correctly fitted to the secondary heat exchanger.

COMBUSTION CHAMBER

12/18 & 18/25kW

Plan sectional view

25/32kW

Plan sectional view

Hook the retainer ( J ) over the end two baffles

FRONT FRONT

Page 24

PIPEWORK CONNECTIONS

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

8 716 113 389b (09/07)

INSTALLATION

PIPEWORK CONNECTIONS

A - CH flow 22mmØ copper (28mmØ on

25/32 models) B - DHW flow 22mmØ C - Water main inlet 15mmØ D - CH return 22mmØ copper (28mmØ on

25/32 models) E - 10mmØ oil supply pipe connection F - Oil isolating valve (10mmØ) G - Flexible oil hose N - Optional open vent/air vent O - Drain/optional feed and expansion P - Fixing point for optional return oil pipe

WATER CONNECTIONS:

All service pipes into the property must pass

through the services duct.

Insulate all the system/supply pipes where

the pipes pass through the duct with at least 22mm insulation around the pipes.

Remove the transit bungs from the pipework

connections on the boiler.

NOTE: that surplus water may be present due to factory testing.

Ensure all pipework is clean. Align water pipework through the 100mm Ø

duct and connect, ensuring that the expansion tank and control box fit correctly before permanently connecting the pipework.

Check that all unused sockets have been

capped.

OIL SUPPLY CONNECTIONS:

NOTE: Oil filters and de-aeration devices are not to be fitted within the casing and the fire valve body must be at least 1 metre from the external casing.

Route the oil supply pipe through the

appropriate casing hole as required and connect to the isolating valve (F) and ensure the valve is closed.

Connect the flexible oil hose (G) to the

isolating valve (F).

Pass the fire valve sensor through the most

appropriate casing hole and locate the capillary in the cut out at the bottom of the hole.

Clip the sensor into the clip provided at the

rear of the control box.

Rotate the cover plate and seal so it does not

cover the capillary, then secure with the screws provided.

CAUTION: ISOLATE THE OIL & WATER MAINS SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.

Page 25

PIPEWORK CONNECTIONS

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

INSTALLATION

PIPEWORK CONNECTIONS

H - Flue manifold condensate outlet J - Condensate outlet (21.5mmØ) - supplied K - Condensate pipe - not supplied L - Condensate trap with clamp - supplied M - Pressure relief (15mmØ)

CONDENSATE CONNECTION:

The condensate trap (L) must be installed

onto the bracket supplied.

Measure condensate pipe (J) mark and cut

square to length required.

Fit sealing washer inside condensate pipe

nut and connect to the flue manifold outlet (H).

Connect 21.5mm polypropylene pipe (K) (not

supplied) to the condensate pipe (J) and condensate trap (L) before terminating to waste.

Secure the condensate trap (L) with clamp

supplied.

Ensure that the condensate pipe runs away

from the boiler at a constant fall of 50mm

(min.) for every metre.

Carefully pour 500ml of water into the

condensate collection (R) to fill condensate trap.

Check the water is running away and the

condensate pipework joints are water tight.

Check the flue manifold seal is undamaged

and seated correctly.

Refit flue manifold access cover (Q) and

secure with screws (P).

IMPORTANT: The condensate trap must be correctly filled to prevent the possibility of potentially harmful flue products escaping via the condensate pipework.

PRESSURE RELIEF CONNECTION:

Connect the pressure relief pipe (M) to a

copper discharge pipe (15mmØ min.) and terminate externally to the appliance casing.

Blank all unused casing holes with the bungs

or cover plates and seals supplied. The drain/fire valve capillary hole covers should be rotated so that the unused capillary slot is covered by the cover plate and seal.

Refit rear panel. Seal all joints where pipes pass through the

casing, with suitable waterproof sealant.

IMPORTANT: Insulate all external condensate pipe work or run in 32mm pipe work to prevent freezing.

Page 26

OIL BURNER & PUMP

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

8 716 113 389b (09/07)

INSTALLATION

CAUTION: ISOLATE THE OIL & WATER MAINS SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.

OIL BURNER:

1 Check the nozzle (A) and electrode (B)

settings are correct for the relevant burner as shown opposite.

 Ensure nozzle (A) is aligned centrally within

the combustion head (C).

 Inspect for any visible defects.

IMPORTANT: Whenever replacing the combustion head, ensure that the photocell is lined up with the sight hole.

OIL PUMP:

Connecting the oil pump for a single pipe system:

The pump is factory set for single pipe operation with the flexible oil hose fitted. Check connections before use.

Converting the oil pump for a double pipe system:

1 Check the inlet hose connection.

a) DANFOSS BFP 11 L3:

 Remove pump front cover (A) ensuring a

suitable receptacle is used to catch any oil residue.

 Remove changeover screw (B).

 Remove horseshoe washer (C).

 Refit changeover screw (B).

 Refit front cover (A).

 Remove oil pump return plug (2).

b) SUNTEC AS47C:

 Remove return port plug (2) and insert

grub screw (B).

c) RIELLO RDB:

 Unscrew return plug (2).

 Screw in by-pass screw (3).

2 Connect the flexible oil return hose

(not supplied) between the oil pump and

the return line connection, and tighten to secure.

5mm

Electrode gap

2.5 - 3.0mm

7.5mm

5mm

a) DANFOSS BFP 11 L3 OIL PUMP

b) SUNTEC AS47C OIL PUMP

5mm

Electrode gap 4mm

5mm

c) RIELLO RDB OIL PUMP

25/32 kW

12/18 & 18/25 kW

OIL BURNER & PUMP

Page 27

REFITTING COMPONENTS

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

INSTALLATION

REFITTING COMPONENTS

1 Align burner combustion head (A) into boiler

housing tube with gasket (B) correctly fitted.

 Push firmly down to compress the gasket (B).

 Tighten burner retainers (C) sufficiently to

ensure a good seal.

IMPORTANT: Ensure the gasket is a good seal between the burner combustion head and the boiler housing to prevent flue gases escaping from the combustion chamber into the cabinet.

 Attach the flexible air duct and tighten

clamp(D) to secure to the burner air intake.

2 Plug burner lead (E) into control box (F).

Page 28

ELECTRICS

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

8 716 113 389b (09/07)

INSTALLATION

ELECTRICS

DANGER - 230V:

ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.

IMPORTANT: THIS APPLIANCE PROVIDES A PERMENANT EXTERNAL ELECTRICAL SUPPLY FOR SERVICING AND MUST THEREFORE BE FED VIA A CIRCUIT BREAKER INCORPORATING EARTH LEAKAGE PROTECTION.

IMPORTANT: OBSERVE ELECTRONIC

STATIC DISCHARGE PRECAUTIONS. DO NOT TOUCH THE PCB CIRCUITS.

WARNING: EXTERNAL EQUIPMENT OPERATED AT 230 VOLTS SHOULD NOT BE SERVICED OR REPAIRED UNDER ADVERSE WEATHER CONDITIONS.

Access to 230V connections:

1Release screws (B) and remove cover

panel (C) from control box (A).

2Release screws (D) from cable clamp (E).

Pull inner clamp part (F) outwards. Feed sufficient power cable (G) through the

cable clamp (E) and secure grip with screw (D).

Separate wires from cable end and strip to 6mm.

230V connections (terminal block X1):

3Connect LIVE wire (Brown) to terminal L.

Connect NEUTRAL wire (Blue) to

terminal N.

Connect EARTH wire (Green/Yellow) to

the connector . Route the power cable down the side panel and through the service duct to the internal property connection point avoiding any potentially hot surfaces.

Any external device connected to the boiler must take its power supply from the boiler supply only and must NOT have a separate supply.

External 230V programmer (terminal block X4):

4 Remove 4 pin plug (M) from X4.

Remove test links (P) from plug block (M). Connect wires to plug block (M) as shown. Fit plug into terminal block X4. Connect earth to terminal block X1connector

230V room thermostat (terminal block X2):

6 Remove link (K).

Connect LIVE supply to terminal L

Connect SWITCHED LIVE supply to

terminal LR.

NOTE: This is sometimes refered to as ‘call for heat’ or ‘heating load’.

Connect NEUTRAL to terminal Ns.

NOTE: Some devices do not require this.

Refit electric control panel cover:

Refit panel (C) and secure with screws (B).

NOTE: Both frost thermostats are fitted as standard to the external appliance to provide frost protection.

2/3

230V

MAINS

SUPPLY

Neutral (if required)

Switched Live

Live

FROST STAT(1)

FROST

STAT(2)

7 k 7

ROOMSTAT

Accelerator resistor (if fitted)

PROG RAMMER (EXTERNAL)

clock

CH channel

HW channel

N Supply

L Supply

HW Demand

CH Demand

Fuse

CONTROL BOARD

DHW

Page 29

ELECTRICS

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

INSTALLATION

X12

X11

X13

X10

gygy bl br

gy or bl br g

gy bl

pk or

pk pk

y y

bk r g gy w

123456

r r

gor

or pk y

w w

987654321

bk r g gy w

123456

g bk r gy w

gy bl

gy or bl br

230V

w g

Mains connection

Service connection

Mode switch

ELECTRICS

Electrical components:

1 Printed circuit board 2 Thermostat - boiler high limit 3 Thermostat - DHW control 4 Thermostat - CH control 5 Indicator lamp - boiler mode 6 Indicator lamp - lock-out 7 Manual reset - overheat thermostat 8 Manual reset - flue overheat thermostat 9 Manual reset - burner lock-out 10 External programmer (not supplied) 11 Burner socket 12 Burner plug 13 Burner control box (12/18 & 18/25 shown) 14 Flow switch 15 Circulating pump 16 Diverter valve 17 Frost stat 18 Frost stat

Wire colour code:

br - Brown bl - Blue gy - Green/Yellow r - Red w - White y - Yellow g - Grey bk - Black or - Orange pk - Pink

Page 30

PRE-COMMISSIONING CHECKS - APPLIANCE

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

8 716 113 389b (09/07)

PRE-COMMISSIONING CHECKS -

APPLIANCE

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

1 Check that the service and water pipes are

connected correctly.

 Check that all unused sockets are capped.

2 Check that the oil supply is kerosene and

that the pipework is connected correctly to the oil pump via the supplied flexible oil hose.

 Turn on the main oil supply valve at the

tank, check the oil supply pipework and connections. Rectify any leaks.

3 Check the flue is correctly fitted and the

connections are secure.

4 Check the condensate pipework is

correctly fitted and connected.

 Check the condensate trap is filled with

water.

5 Check the CH circulating pump is set to 3.

NOTE: The CH circulating pump is preset to number 3 and should not be altered. The diagrams opposite show the pump outputs.

NOTE: The cabinet is not load bearing, it only provides weather protection for the boiler inside.

IMPORTANT: If the boiler is not to be commissioned immediately then:

After successfully completing all of the checks and any rectification work, close the water valves, shut off the oil supply and electrically isolate the boiler.

Complete the installation part of the Guarantee Registration Card, and complete a CD10 or its equivalent, to inform the LABC of the installation.

COMMISSIONING

12/18 & 18/25

0.6

Bar

0.5

0.4

0.3

0.2

0.1

200

400 600 800 1000 1200 1400 1600

Litres per hour

25/32

0.7

0.6

0.5

0.4

0.3

0.2

0.1

200

400 600 800 1000 1200 1400 1600 1800 2000 2200 2400

Litres per hour

Page 31

FILLING THE SYSTEM

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

COMMISSIONING

1 Pull lever (C) up and push to the left to

move the diverter valve to the mid-position between ports A and B.

 Push and hold lever (C) down to lock.

2 Loosen the automatic air vent cover. 4 Sealed systems only; check and if required,

adjust the expansion vessel pressure using the Schraeder type valve (D).

The charge pressure of the built-in 12 Litre expansion vessel is 0.5 bar as dispatched, which is equivalent to a static head of 5 metres (16.7 ft).

If an extra expansion vessel is fitted to the central heating return, adjust this to the same pressure as the appliance internal expansion vessel, refer to separate instructions supplied with the extra expansion vessel.

4 Open all system and radiator valves (E).

 Turn on the water main stop cock.

 Open vented systems only; turn on the

water to the system feed and expansion cistern and allow the system to fill.

 Sealed systems only; fill the system to

between 1 and 2 bar pressure via a WRAS approved filling link. Monitor the pressure gauge during venting and repressurise if required.

 Check air is being discharged from the

automatic air vent.

 Vent all radiators, retighten when completed,

check the system and correct any leaks.

 Bleed air from both of the secondary heat

exchanger air vents (F).

 Bleed air from the pipework using the

pump bleed screw.

5 Sealed systems only; connect a suitable

hose to the Heatslave tank drain. Open the drain valve to reduce the system to the correct pressure, then close the drain valve.

Ensure safe disposal of the discharge. Rotate the adjustable pointer on the pressure gauge to record the set system

pressure.

6  Check system and rectify any leaks.

 Push lever (C) to the left and pull

upwards to allow the lever to return to position A.

 Leave the lever (C) unlocked at

position A.

FILLING THE SYSTEM

1 - 2 bar

Total system

volume (litres)

18 0 107 13 8

Initial system

pressure (bar)

0.5

1. 0

Initial charge

pressure (bar)

0.5

1. 0

Page 32

STARTING THE APPLIANCE

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

8 716 113 389b (09/07)

COMMISSIONING

Return

Flow

TANK

A - Bleed & pressure gauge port

B - Pressure adjustment

C - Vacuum gauge port

D - Retaining screws - cover

DANFOSS

BFP 11 L3 OIL PUMP

SUNTEC

AS47C OIL PUMP

BURNER LOCKOUT

RIELLO

RDB OIL PUMP

BURNER LOCKOUT RESET BUTTON (D) FOR

25/32 MODEL

GREENSTAR HEATSLAVE EXTERNAL

max

flue

reset

boiler reset

max

lockout

service

BURNER LOCKOUT RESET

BUTTON (D) FOR 12/18

& 18/25 MODELS

(Under control box)

(On top of burner control box)

E - Lockout indicator

STARTING THE APPLIANCE

IMPORTANT: Never run the appliance when the appliance/system is unpressurised (sealed systems) or empty.

1Check the oil supply is correctly fitted and

in good working order before turning on the oil supply valves to the boiler.

Turn on the main oil supply valve at the tank

and draw off at least 21/2litres of oil until a steady flow of clear uncontaminated oil can be seen as follows:

• The oil supply to the boiler should be

primed before the burner is operated to avoid unnecessary pump wear.

• The use of an oil suction pump will prime and flush through any oil supply set up simply and easily, alternatively the following procedures can be used.

Single pipe gravity feed systems:

Disconnect the flexible oil hose and open

the isolating valve to discharge the oil into a suitable container.

If a top entry tank has been used the

pipework will need to be primed before the oil will discharge under gravity.

When completed, close the isolating valve,

reconnect the flexible oil hose.

Double pipe sub-gravity feed systems

and single pipe suction lift with de-aerator:

To prime a de-aerator, disconnect the

flexible oil inlet hose (F) from the isolation valve and place in a container of kerosene (G). Connect a spare flexible oil hose (H), to discharge into container (G). Open the isolating valve, turn on the power to the boiler and set the programmer to ON. Prime the de-aerator until there is a steady flow of oil into container (G). Turn off the boiler then

reconnect the flexible oil inlet hose (F).

Turn on the boiler, the oil level in the

de-aerator will drop as the oil is used until the oil is drawn from the tank. If the de-aerator empties and the burner locks out before the oil is drawn from the tank, prime the de-aerator again.

Open the isolating valve and the oil pump

bleed valve (A) to discharge into a suitable container once the boiler is started up.

Switch on the electricity supply to the boiler.

Set the programmer to ON for CH and DHW.

Turn on the boiler CH control thermostat.

Allow the burner to run through to lockout

indicated by the illumination of the lockout

indicator (E).

Wait 2 minutes then press the lockout reset

button (D).

Repeat the procedure at least 3 times or until a

steady stream of oil, without air, runs from the bleed port, then relock the bleed port (A).

Switch off the boiler.

Remove the oil pump filter, clean with

kerosene and refit.

The internal filter is accessed by removing the oil pump cover on the Danfoss BFP 11

L3, Suntec AS47C and Riello RDB.

Safely dispose of the container/discharge.

Page 33

STARTING THE APPLIANCE

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

COMMISSIONING

STARTING THE APPLIANCE

2Remove plastic cover from the burner casing

(there is no plastic cover on the Riello burner).

 Fit a suitable pressure gauge to port (A) on

the oil pump.

 Adjust the air shutter (L) and pump pressure

(B) as shown in the table opposite. The burner should ignite following a pre-ignition period of approx. 15 seconds.

Boiler lockout indicator on:

If the burner fails to establish a normal firing pattern or flame failure occurs the flame monitoring photocell mounted in the burner body will alert the burner control box to shut the burner down and provide a safe lockout state indicated by the illumination of the lockout indicator (E).

Wait 2 minutes then press the lockout

reset button (D) to initiate another start sequence.

Repeat procedure until a flame is established.

3Start and run for 3 minutes then switch off.

Check for after-spurting from the nozzle,

indicated by oil saturation on the combustion

head (F).

If after-spurting occurs:

Release the burner retainers. Remove the burner, combustion head (F).

and electrodes, hold the burner vertical to unscrew the nozzle and fill the nozzle holder with oil.

Refit nozzle, electrodes, combustion

head (F) and the burner.

Restart and run for 3 minute intervals until

after-spurting stops.

4Start and run for 20 minutes.

Remove sampling point plug (K) to check

the smoke reading is between 0-1. If the smoke level is above 1, check the combustion settings are correct and the oil nozzle is in good condition.

Note; smoke readings may be inaccurate until the smoke from burning organic binder in the access door insulation has ceased.

Check the CO2levels and adjust the air

shutter (L) setting according to the table opposite.

Check the flue gas temperature is close to

the values shown in the table.

If the flue gas temperature is too high and the baffles are correctly fitted, then reduce the oil pump pressure (B) 5-10p.s.i. to compensate for nozzle variations.

Turn off the electrical supply. Isolate the oil supply to the burner. Remove the oil pressure gauge. Refit the blanking plug (A). Check and rectify any oil leaks.

5Switch on the oil supply.

Switch on the electrical supply. Restart the boiler and run for 5 minutes. Recheck the CO2levels and if required,

adjust the air shutter setting (L) to obtain the correct CO2level.

D 12/18 & 18/25

(under control box)

DANFOSS

BFP 11 L3 OIL PUMP

SUNTEC

AS47C OIL PUMP

A - Bleed & pressure gauge port

B - Pressure adjustment

C - Vacuum gauge port

NOMINAL BOILER RATING AT NORMAL OPERATING TEMPERATURE USING 28sec KEROSENE:

NOZZLE

OIL PUMP

PRESSURE

(p.s.i.)

12/18 - Bentone Sterling 40 Burner:

0.35 80°SR

0.45 80°S

0.50 80°ES

115

140

18/25 - Bentone Sterling 50 Burner:

0.50 80°EH

0.55 80°EH

0.65 80°EH

130

145

150

25/32 - Riello RDB Burner:

0.75 60°ES

0.85 60°ES

105

140

150

FUEL

FLOW RATE

Kg/h l/h

1.04

1.32

1.29

1.63

1.55

1.96

1.56

1.98

1.86

2.36

2.17

2.75

2.15

2.72

2.45

3.1

2.75

3.48

APPROX.

FLUE GAS

TEMP °C

%CO

11.5

12.0

12.5

11.5

12.0

12.5

11.5

12.0

12.5

APPROX.

AIR

SETTING

2.5

4.5

5.25

4.25

6.0

8.0

3.0

4.0

5.0

D 25/32

(on top of burner control box)

RIELLO

RDB OIL PUMP

APPLIANCE

INPUT OUTPUT

kW Btu/hr kW Btu/hr

42300

52900

63500

75750

88000

87000

99300

21.5

28.5

12.4

15.5

18.6

22.2

25.8

25.5

29.1

111600

32.7

40900

51200

61400

73400

85300

97200

109200

Page 34

STARTING THE APPLIANCE

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

8 716 113 389b (09/07)

COMMISSIONING

STARTING THE APPLIANCE

Domestic hot water:

1Set the CH/DHW programmer to OFF.

Fully open a hot water tap.

The burner should be OFF and the circulating pump ON.

2Close the hot water tap.

Set the DHW thermostat control (C) to

minimum as shown.

Set the programmer to DHW ON.

The burner should be ON with the circulating

pump to heat the water in the Heatslave

external tank.

When minimum set temperature is reached the burner and circulating pump will switch off.

3 Fully open a hot water tap.

The burner should be ON with the circulating

pump.

 Check the water flow rate using a suitable

measuring container; 12/18KW 15 litres/min 18/25kW 18 litres/min* 25/32kW 22 litres/min*

* Manually regulate using the water main

inlet isolating valve on the boiler.

4 Fully close the hot water tap.

 Check the burner and circulating pump**

switch off.

**The high limit thermostat may activate

pump overrun until the correct

temperature is restored.

max

flue

boiler

reset

lockout

GREENSTAR HEATSLAVE EXTERNAL

service

max

flue

boiler

reset

lockout

GREENSTAR HEATSLAVE EXTERNAL

service

max

flue

boiler

reset

lockout

GREENSTAR HEATSLAVE EXTERNAL

service

Page 35

STARTING THE APPLIANCE

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

COMMISSIONING

STARTING THE APPLIANCE

Central heating:

1 Open all radiator valves.

Set room thermostat to maximum.  Set programmer to ON for CH.  Turn the DHW thermostat control (C) fully

anti-clockwise.

Turn the CH thermostat control (D) to max.

The burner should be ON with the circulating pump. The diverter valve (E) should open to port B for CH.

Ensure all radiators are heating up evenly

and balance the system to the temperature difference required across the heating flow and return relevant to the heating load.

2Set the room thermostat to minimum.

The burner and circulating pump should be off. The diverter valve (E) should return to port A for DHW (default).

Domestic hot water & central heating:

3Set the room thermostat to maximum.

Set the programmer to ON for DHW & CH. Turn the DHW thermostat control (C) fully

anti-clockwise.

Set the CH thermostat control (D) to max.

The burner should be ON with the circulating pump. The diverter valve (E) should open to port B for CH.

4Set the DHW thermostat control (C) to max.

The diverter valve (E) should move to port A and divert the flow to the Heatslave tank.

max

flue

boiler

reset

lockout

GREENSTAR HEATSLAVE EXTERNAL

service

max

flue

boiler

reset

lockout

GREENSTAR HEATSLAVE EXTERNAL

service

max

flue

boiler

reset

lockout

GREENSTAR HEATSLAVE EXTERNAL

service

max

flue

boiler

reset

lockout

GREENSTAR HEATSLAVE EXTERNAL

service

Page 36

WATER TREATMENT

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

8 716 113 389b (09/07)

COMMISSIONING

WATER TREATMENT

FLUSHING (Central Heating):

1Switch off the boiler.

Open vented systems only: turn off the

water to the system header tank.

Open all radiator valves/drain cocks (C) and

drain the system while the appliance is hot.

Close drain cocks (C).

2Add a suitable flushing agent (F) and refill

the system at the correct strength for the system condition in accordance with the manufacturer's instructions.

 Vent the boiler (there are two vent points

(A) at the top of the secondary heat exchanger. Only one may be in use, the other may be obscured by side fluing. Always vent (A) and the vent screw (B) on the pump and all radiators.

Run the boiler/system at normal operating

temperature for the time stated by the flushing agent manufacturer.

3Drain and thoroughly flush the system and

boiler to remove the flushing agent and debris (C).

INHIBITOR (Central Heating):

4Check drain cocks (C) and manual air vents

are closed and all radiator valves are open.

5Add a suitable inhibitor (I), (or combined

inhibitor/anti-freeze if the system is exposed to freezing conditions) to the heating system in accordance with the manufacturers instructions.

The inhibitor or combined inhibitor/anti-freeze must not cause damage to the materials within the boiler (mild steel, stainless steel, copper and brass) and any other materials/components within the system.

Open vented systems only: turn on the

water to the system header tank and allow the system to fill.

Sealed systems only: fill the system to

between 1 and 2 bar via a WRAS approved filling loop. Check the system pressure during venting and repressurise if necessary.

6Vent the boiler (there are two vent points

(A) at the top of the secondary heat

exchanger. Only one may be in use, the other maybe obscured by side fluing. Always vent (A) and the vent screw (B) on the pump and all radiators; retighten vents when complete.

7Record the date when the inhibitor was

added to the system on the guarantee card.

NOTE: The concentration level of inhibitor

in the system should be checked every 12 months or sooner if system content is lost.

The addition of sealing agents to the system water is not advised as this can cause problems with deposits left in the heat exchanger and invalidate the appliance and heat exchanger warranty .

1 - 2 bar

Page 37

FINISHING COMMISSIONING -

APPLIANCE

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

COMMISSIONING

FINISHING COMMISSIONING -

APPLIANCE

1 Refit the top panel and press down to

compress the seal when fitting the securing screws (A).

2 Push the front panel up behind the top

panel and push in at the base to secure the screws (B) with the tool provided.

Always apply pressure at the edges of the panels when securing to avoid accidental damage.

Handover:

Complete the guarantee registration card,

combustion record (page 49) and a CD11 or an equivalent commissioning form.

Set up the controls and show the user how

to operate all the controls shown in the User Guide, and all system controls.

Where applicable, instruct the customer how

to repressurise the system.

If the appliance is unused and exposed to

freezing conditions, shut off all the mains supplies and drain the system and boiler to prevent damage to the system and boiler.

NOTE: Release drain point (K) to drain the secondary heat exchanger.

Page 38

INSPECTION AND SERVICE

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

8 716 113 389b (09/07)

INSPECTION AND SERVICE

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

DO NOT USE PRESSURE WASHERS OR STEAM CLEANERS ON THIS APPLIANCE OR ITS CABINET.

WARNING: EXTERNAL EQUIPMENT OPERATED AT 230 VOLTS SHOULD NOT BE SERVICED OR REPAIRED UNDER ADVERSE WEATHER CONDITIONS

Routine servicing:

To maintain efficient boiler operation, the following should be carried out at least once a year:

Carry out a pre-service check and note any

operational faults:

Pre-Service Check:

1Unndo the screws at the base of the

front panel using the tool provided and pull the panel down and out to remove. Store safely away from the working area.

Operate the appliance and system and note any faults which may need to be corrected during the service.

Switch into service mode at switch (A).

2Depress locking ears and unplug burner

lead (B) from control box (C).

• An adapter lead is available to allow mains voltage service aids to be operated from the service connection (G). (Service lead Part No. 8 716 113 483 0).

3Loosen clip (D) to detach air duct.

4Unscrew burner retainers (E) to release

the burner combustion head (F).

Lift burner away, taking care not to over

strain the flexible oil hose/s or connections.

See the following instructions for detail of some of the service requirements listed below:

Check and clean the burner. Replace burner nozzle and flexible oil

hose/s.

Check and clean the baffle retainers. Check and clean the baffles. Check and clean the heat exchangers

surfaces.

Check the combustion chamber access

door insulation board.

Check that the flue system is unobstructed

and clean as necessary.

Clean or replace all oil filters. Check that the condensate system is not

obstructed, clean and refill the condensate trap as necessary.

 Sealed systems only: The PRV is a safety

device and must be checked for correct operation. The expansion vessel pressure must be checked and adjusted as required.

SERVICING

& SPARES

service

Page 39

INSPECTION AND SERVICE

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

SERVICING

& SPARES

1 Clean the Burner:

Remove the air intake cover (H) and clear

any debris from the air intake and air damper.

Disassemble the burner to allow access to

the fan impeller.

Check the condition of the gaskets between

these parts and replace if necessary.

Note the position of the air damper

adjustment and check the air damper moves freely.

Clean both sides of the fan impeller and

remove any debris from the burner housing.

Check that the impeller rotates freely.  Reassemble the components. Remove the combustion head (K) and

thoroughly clean any deposits.

Remove the nozzle (E).

2 12/18 & 18/25 Inspection of Mechanical

Shut-off Valve:

 Fasten an M5 screw, with a minimum length

of 30mm, into the threaded hole (L) and pull the screw to withdraw the check valve (M).

Check that the nozzle holder (N) is clear of

any debris and clean if necessary.

Check that the three holes in the check valve

(M) are clear of any debris. Check the

condition of the 'O' ring (O). Discard the check valve if the holes cannot be cleared, if the unit is defective or if the 'O' ring is damaged and replace with a new one.

Refit the check valve.

25/32

Check the nozzle holder is clear of any debris

and clean if neccessary.

12/18, 18/25 & 25/32

Fit a new oil atomising nozzle (E).

DO NOT dismantle the nozzle and DO NOT clean the nozzle tip.

Check the electrodes (F) and reset if

necessary as shown opposite.

Refit the combustion head. Check that the

nozzle (E) lies centrally in the combustion head and the head settings are as shown. Ensure that the photocell is lined up with the sight hole.

 Withdraw the photocell (P) from its housing

and wipe clean.

 Remove the oil pump internal filter, clean in

kerosene and reassemble.

The internal filter is accessed by removing screws (A) and the oil pump cover (B) on the Danfoss BFP 11 L3, Suntec AS47C and Riello RDB.

Replace the standard flexible oil hose/s at

every annual service to prevent the possibility of leakage due to ageing.

Reassemble the burner components. Check the sponge O-ring seal located

around the combustion head and replace if necessary.

This seal must be in good condition since failure will cause flue gases to escape into the cabinet.

INSPECTION AND SERVICE

A - Retaining screws - cover

B - Cover - oil pump

HPD

5mm

Electrode gap

2.5 - 3.0mm

7.5mm

5mm

DANFOSS

BFP 11 L3 OIL PUMP

SUNTEC

AS47C OIL PUMP

RIELLO

RDB OIL PUMP

5mm

Electrode gap 4mm

5mm

HPD

25/32

12/18 & 18/25

Page 40

INSPECTION AND SERVICE

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

8 716 113 389b (09/07)

SERVICING

& SPARES

INSPECTION AND SERVICE

External oil filter:

Remove the paper element from the external

oil filter and replace it. If the filter contains a washable element, thoroughly clean in kerosene and reassemble into the filter.

Clean the boiler:

Manifold access:

Remove top cover by releasing the

screws at each corner and lift free.

Release screws (E) to remove the flue

manifold access cover (F) and clear any debris.

Check the condensate route (G) is clear and

clean the condensate trap and pipework.

Check the flue system and clean if necessary. Remove the baffle retainer (J) and baffles (H)

from the secondary heat exchanger.

Check and clean the secondary heat

exchanger surfaces.

NOTE: Do not use wire brushes and cleaning agents to clean the stainless steel secondary heat exchanger components.

Pour 500ml of water into drain (G) to refill the

condensate trap.

Clean the secondary heat exchanger baffles

(H) if necessary and refit correctly.

 Refit the baffle retainer (J). Check the seal on the manifold access cover

(F) and replace if necessary.

Refit the flue manifold access cover (F)

and secure with screws (E).

Combustion chamber:

Release the M10 retaining nuts and washers

(B) and remove combustion chamber access door (A).

Check the fibreglass rope seal on the

combustion chamber access door (A) and replace if necessary.

Remove and check the baffle retainer (D). Remove the baffles (C), clean and check the

condition of the baffles and the acoustic insulation. Replace any baffles or insulation pads considered to be badly corroded/degraded.

Thoroughly clean all of the heat exchanger

surfaces using a suitable brush and clear all loose debris from the combustion chamber.

Check the condition of the combustion

chamber access door insulation. If the insulation is damaged the door assembly must be replaced.

Refit the items in reverse order ensure the

baffles (C) and baffle retainers (D) are correctly fitted for the boiler output as shown in the plan view opposite.

Refit combustion access door (A). Secure with nuts and washers (B) and

tighten until the door is firmly secured, do not over tighten the nuts.

Fire valve:

Check that the oil supply pipe has a fire valve

fitted at least 1m away from the appliance with the fire valve sensor located within the appliance case. A fire valve sensor clip (K) is provided for this purpose.

FRONT FRONT

Plan sectional view

12/18kW & 18/25kW

Plan sectional view

25/32kW

Page 41

INSPECTION AND SERVICE

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

SERVICING

& SPARES

INSPECTION AND SERVICE

Re-commission the burner:

1Align burner combustion head (A) into the

boiler housing tube with gasket (B) correctly fitted.

Push firmly down to compress the gasket (B). Tighten burner retainers (C) sufficiently to

ensure a good seal.

IMPORTANT: Ensure the gasket is a good seal between the burner combustion head and the boiler housing to prevent flue gases escaping.

Refit flexible air duct and secure with clip (D).

2Plug burner lead (E) into control box (F).

Connect an oil pressure gauge to the oil

pump, run the burner and check the oil pressure is correct for the required boiler output. Check that the smoke reading is between 0 and 1, if the smoke reading is above 1 check the air setting. If the air setting is correct check that the burner has been reassembled correctly.

Allow the boiler to warm up then check the combustion settings are correct as indicated in the table below, adjust the CO

if necessary using the air shutter. When the combustion is correct turn off the boiler, remove the pressure gauge and refit the blanking plug and plastic cover.

Refit panels:

3Refit the top panel and press down to

compress the seal when fitting the securing screws.

 Push the front panel up behind the top

panel and push in at the base to secure the screws with the tool provided.

After service handover:

Make a note of the date of any water treatment. Set the controls back to the users

requirements.

Complete the service interval record at the

back of this manual and a CD11 or an equivalent form.

If the appliance is unused and exposed to

freezing conditions; shut off all the mains supplies, isolate the boiler and drain the system and boiler, including the secondary heat exchanger.

%CO

NOMINAL BOILER RATING AT NORMAL OPERATING TEMPERATURE USING 28sec KEROSENE:

NOZZLE

12/18 - Bentone Sterling 40 Burner:

OIL PUMP

PRESSURE

(p.s.i.)

FUEL

FLOW RATE

Kg/h l/h

APPROX.

FLUE GAS

TEMP °C

APPROX.

AIR

SETTING

APPLIANCE

INPUT OUTPUT

kW Btu/hr kW Btu/hr

0.35 80°SR

0.45 80°S

0.50 80°ES

115

140

1.04

1.29

1.55

1.32

1.63

1.96

11.5

12.0

12.5

2.5

4.5

5.25

42300

52900

63500

40900

51200

61400

12.4

15.5

18.6

25/32 - Riello RDB Burner:

0.75 60°ES

0.85 60°ES

105

140

150

2.15

2.45

2.75

2.72

3.1

3.48

11.5

12.0

12.5

3.0

4.0

5.0

87000

99300

111600

28.5

85300

97200

109200

25.5

29.1

32.7

18/25 - Bentone Sterling 50 Burner:

0.50 80°EH

0.55 80°EH

0.65 80°EH

130

145

150

1.56

1.86

2.17

1.98

2.36

2.75

11.5

12.0

12.5

4.25

6.0

8.0

63500

75750

88000

21.5

61400

73400

85300

18.6

22.2

25.8

Page 42

SHORT PARTS LIST 12/18

1 Burner - Sterling 40

Part Number: 8 716 112 507 0

2 Combustion head - burner

Part Number: 8 716 112 604 0

3 Control box Satronic DKO 970

Part Number: 8 716 142 396 0

4 Photocell Satronic MZ770s

Part Number: 8 716 156 692 0

5 Control box base Satronic S98 12 pole

Part Number: 8 716 142 782 0

6 Ignition electrode

Part Number: 8 716 156 683 0

7 Motor

Part Number: 8 716 156 645 0

8 Oil pump - Danfoss BFP 11 L3

Part Number: 8 716 142 736 0

8a Oil pump - Suntec AS47C

Part Number: 8 716 157 014 0

9 Transformer (Excludes cable)

Part Number: 8 716 156 696 0

10 Mechanical shut-off valve

Part Number: 8 716 156 658 0

11 Flexible oil line kit

Part Number: 8 716 106 346 0

12 Burner 'O' ring gasket

Part Number: 8 716 109 158 0

13 Heating control thermostat

Part Number: 8 716 107 621 0

14 Auto reset High Limit thermostat

Part Number: 8 716 107 640 0

15 Manual reset High Limit thermostat

Part Number: 8 716 107 625 0

16 Manual reset flue thermostat

Part Number: 8 716 107 624 0

17 DHW control thermostat

Part Number: 8 716 107 637 0

18 Cleaning brush

Part Number: 8 716 109 428 0

19 Manifold access cover seal

Part Number: 8 716 107 536 0

20 Secondary Heat Exchanger gasket

Part Number: 8 716 112 954 0

21 Frost thermostat

Part Number: 8 716 105 965 0

22 Service lead

Part Number: 8 716 113 483 0

23 Oil nozzle

0.35 80° SR (12kW output) Part Number: 8 716 112 628 0

0.45 80° S (15kW output) Part Number: 8 716 106 197 0

0.50 80° ES (18kW output) Part Number: 8 716 156 669 0

SHORT PARTS LIST 12/18

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

8 716 113 389b (09/07)

SERVICING

& SPARES

3456

15 16

19 20

Page 43

SHORT PARTS LIST 18/25

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

SERVICING

& SPARES

SHORT PARTS LIST 18/25

1 Burner - Sterling 50

Part Number: 8 716 112 570 0

2 Combustion head - burner

Part Number: 8 716 108 573 0

3 Control box Satronic DKO 970

Part Number: 8 716 142 396 0

4 Photocell Satronic MZ770s

Part Number: 8 716 156 692 0

5 Control box base Satronic S98 12 pole

Part Number: 8 716 142 782 0

6 Ignition electrode

Part Number: 8 716 156 683 0

7 Motor

Part Number: 8 716 156 645 0

8 Oil pump - Danfoss BFP 11 L3

Part Number: 8 716 142 736 0

8a Oil pump - Suntec AS47C

Part Number: 8 716 157 014 0

9 Transformer (Excludes cable)

Part Number: 8 716 156 696 0

10 Mechanical shut-off valve

Part Number: 8 716 156 658 0

11 Flexible oil line kit

Part Number: 8 716 106 346 0

12 Burner 'O' ring gasket

Part Number: 8 716 109 158 0

13 Heating control thermostat

Part Number: 8 716 107 621 0

14 Auto reset High Limit thermostat

Part Number: 8 716 107 640 0

15 Manual reset High Limit thermostat

Part Number: 8 716 107 625 0

16 Manual reset flue thermostat

Part Number: 8 716 107 624 0

17 DHW control thermostat

Part Number: 8 716 107 637 0

18 Cleaning brush

Part Number: 8 716 109 428 0

19 Manifold access cover seal

Part Number: 8 716 107 536 0

20 Secondary Heat Exchanger gasket

Part Number: 8 716 112 954 0

21 Frost thermostat

Part Number: 8 716 105 965 0

22 Service lead

Part Number: 8 716 113 483 0

21 Oil nozzle

0.50 80° EH (18kW output) Part Number: 8 716 156 672 0

0.55 80° EH (21.5kW output) Part Number: 8 716 156 671 0

0.65 80° EH (25kW output) Part Number: 8 716 110 362 0

3456

15 16

19 20

Page 44

SHORT PARTS LIST 25/32

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

8 716 113 389b (09/07)

SERVICING

& SPARES

SHORT PARTS LIST 25/32

1 Burner - Riello RDB 2.2 25/32 HE

Part Number: 8 716 112 512 0

2 Combustion head - burner

Part Number: 8 716 112 521 0

3 Control box 535 SE/LD

Part Number: 8 716 109 203 0

4 Photocell

Part Number: 8 716 109 193 0

5 Ignition electrode

Part Number: 8 716 109 183 0

6 Motor

Part Number: 8 716 109 186 0

7 Oil pump - Riello RDB

Part Number: 8 716 109 182 0

8 Flexible oil line kit

Part Number: 8 716 106 346 0

9 Burner 'O' ring gasket

Part Number: 8 716 109 158 0

10 Heating control thermostat

Part Number: 8 716 107 621 0

11 Auto reset High Limit thermostat

Part Number: 8 716 107 640 0

12 Manual reset High Limit thermostat

Part Number: 8 716 107 625 0

13 Manual reset flue thermostat

Part Number: 8 716 107 624 0

14 DHW control thermostat

Part Number: 8 716 107 637 0

15 Cleaning brush

Part Number: 8 716 109 428 0

16 Manifold access cover seal

Part Number: 8 716 107 536 0

17 Secondary Heat Exchanger gasket

Part Number: 8 716 112 954 0

18 Frost thermostat

Part Number: 8 716 105 965 0

19 Service lead

Part Number: 8 716 113 483 0

20 Oil nozzle

0.75 60° ES (25 & 28.5kW output) Part Number: 8 716 106 156 0

0.85 60° ES (32kW output) Part Number: 8 716 110 083 0

910

Page 45

PROBLEM CAUSE REMEDY

LOCKOUT:

Pulsation on start Combustion settings incorrect Set up as in installation instructions

Faulty nozzle Replace nozzle

Intermittent lockout Bad electrical connection Check control box/electrical connections

Intermittent flame detection fault See flame detection fault

Burner motor fails to operate

Faulty motor or electrical supply to motor

Check for 230v at motor plug during startup period

Control box fault Replace control box

Flame detection Photocell filmed over (dirty) Wipe clean

fault Photocell faulty Replace

Control box faulty Replace

Incorrect CO

Air adjustment fault Set up as in installation instructions

Oil pressure incorrect Set up as in installation instructions

No oil from nozzle No oil at pump Check and refill oil tank/bleed oil line

Check and clean filters & valves from oil tank to boiler

Air in pump Bleed pump

Nozzle blocked Replace nozzle

Faulty pump or drive Replace

Faulty mechanical shut off valve Clean or replace

(12/18 & 18/25 only)

Ignition failure Electrode settings incorrect Set up as in installation instructions

Faulty ignition transformer Replace

Open circuit ignition Check and replace electrodes or high

tension leads if necessary

Faulty control box or electrical connections not properly made

Correct control box electrical connections or replace control box

BURNER FAILS No power to boiler Check electrical / control circuit

TO START Faulty boiler thermostat Check by temporarily linking out high

limit and control thermostats

Programmer open circuit Check by temporarily linking 8 & 9 on

the connector

Faulty control box Replace

HIGH SMOKE Air intake/flue blocked Check & clear air intake/flue

NUMBER Incorrect combustion settings Set up as in installation instructions

Oil pressure incorrect Adjust to correct pressure

Incorrect components used on combustion head

Check with installation instructions

Faulty nozzle Replace nozzle

FAULT FINDING

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 106 252b (07/06

FAU LT FIND ING

& DIAGRAMS

FAULT FINDING

BOILER LOCKOUT :

Indicated by the illumination of the 'Lockout' indicator on the fascia. To reset, wait 2 minutes then press the lockout reset button.

Also refer to fault finding logic on pages 46 and 47.

UNDER NO CIRCUMSTANCES MUST AN APPLIANCE BE LEFT TO OPERATE WITH ANY CONTOL LINKED OUT OR OVERRIDDEN.

Page 46

FAULT FINDING

PROBLEM CAUSE REMEDY

FAULTY BOILER OPERATION:

Noisy operation Pump noise from air in pump or

worn pump

Bleed air from pump or replace pump

Worn motor bearings Replace motor

Fan out of balance Replace fan

Boiling Faulty boiler thermostat Replace if necessary

Short circuit boiler thermostat Take out of circuit to check

Thermostat bulb not fully home in pocket

Ensure bulb is pushed fully home

No primary water circulation Check system / circulating pump

Short Cycling Burner rating incorrect Correct burner rating

Boiler thermostat differential incorrect

Replace boiler thermostat

External controls not operating correctly

Check and correct external controls

OIL SMELLS: Blocked flue, fumes on startup Check seals/gaskets

Oil soaked boiler, faulty burner operation, numerous lockouts

Rectify burner operation and lockouts

Odour in cabinet, oil leaks from pipework, flexible hoses connections

Rectify oil leaks, replace components if necessary

FAULT FINDING

& DIAGRAMS

FAULT FINDING

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

8 716 113 389b (09/07)

Page 47

Boiler not

operating

with a

heating /

hot water

demand

Burner

motor runs?

Burner

lights

immediately

motor runs?

230V at

solenoid coil

in purge?

Replace

control box

Replace

pump

230V at

motor?

Motor or

pump

seized?

Replace

motor

capacitor

Motor 40Ω

across

L& N?

L & N to

control box?

Control box

locks out?

Check boiler

controls &

supply

Check

connections/

replace leads

Replace

motor/

pump

Replace

motor

Replace

control box

Lockout

within 1

second?

Replace oil

pump

Oil to

pump?

Drive

coupling

broken?

Pump

produces

pressure?

Replace

transformer

Electrodes

& leads

OK?

230V at

transformer?

Spark

produced?

Lockout

after purge

before oil

solenoid

opens?

Replace

control box

Transformer

lead OK?

Photo cell

lead OK?

Disconnect photo cell,

reset lockout, burner

lights then locks out?

Stray light

on photo

cell?

Combustion

head set

correctly?

Combustion

air setting

correct?

Flame off

and

re-lights?

Nozzle

atomising

fuel?

Replace

photo cell

Photo cell

functional?

If BF

remove

burner

snorkle tube

& retest.

Lights OK?

Replace

photo cell

Replace coil

lead

230V at

solenoid

coil?

Coil lead

OK?

Boiler or

flue blocked

Reseal BF

reposition

Replace

control box

Replace

control box

Solenoid

operating?

2.2kΩ

across

solenoid

coil?

Pipe to

nozzle

holder OK?

Oil check

valve OK?

(if fitted)

Replace

nozzle

Replace

solenoid coil

Replace

pump

Replace oil

check valve

(if fitted)

Yes

Replace

lead

Reset air

setting

Reset

combustion

head

FAULT FINDING LOGIC FOR

SATRONIC CONTROL BOX

Note: This chart assumes all wiring within the control box base is correct, if in doubt check the wiring against the diagram on

the base of the control box before replacing any components.

All resistance measurements are actual measured values and some variation is to be expected, therefore measured values

should be similar to but not necessarily identical to the given values.

The operation of the photo cell can be tested by measuring the resistance across the photo cell, it should be a high resistance

(greater than 10MΩ or open circuit) in the dark and low resistance (15kΩ or less) in light.

Burners on balanced flue systems can recirculate flue products resulting in the burner cycling, if this happens check the flue

system integrity and the terminal position.

These fault finding charts are provided to assist competent and suitably qualified engineers to locate and rectify faults. Whilst every effort has been taken to ensure the information given is correct and complete we cannot guarantee that every eventuality has been covered. Worcester, Bosch Group cannot be held responsible for costs incurred by persons not deemed to be competent.

Measure all 230V tests between

Neutral (N) and the pin, wire or

terminal specified.

FAULT FINDING

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 106 252b (07/06

FAU LT FIND ING

& DIAGRAMS

Page 48

Boiler not

operating

with a

heating /

hot water

demand

Burner

motor runs?

Lockout

within 1

second?

Replace

control box

Replace

motor/pump

Check boiler

controls &

supply

Replace

motor

L & N to

control box?

Motor or

pump

seized?

Photo cell

functional?

Solenoid coil

functional

(100Ω)?

Replace

photo cell

Motor gives

50 Volts on

white wire?

Lockout

after 12 sec

purge?

Replace

control box

Replace

solenoid coil

Replace

motor

Ignition

spark

proved?

Oil to pump?

Drive

coupling

broken?

Purge

pressure

1-2 bar?

Pump

produces

pressure?

Replace

pump stem

valve,

pressure

OK?

Replace

solenoid coil

Pipe to

nozzle

holder OK?

Replace

nozzle

Replace oil

pump

Replace

control box

Eectrodes &

leads OK?

Yes

Motor 40Ω

between blue &

black wires ?

Replace

control box

Yes

Nozzle

atomising

fuel?

Combustion

air setting

correct?

Yes

Combustion

head set

correctly?

Solenoid operating?

Increase the pump

pressure, pressure OK?

Solenoid coil

functional

(100Ω)?

Coil lead

OK?

Yes

Replace

control box

Remove

burner

snorkle tube

& retest.

Lights OK?

Flame off &

re-lights?

Yes

Photo cell

functional?

Yes

Replace

photo cell

Boiler or flue

blocked

Reseal BF

Yes

Replace

control box

Yes

Replace

electrodes/

leads

Unblock or

replace pipe

Reset air

setting

Reset

combustion

head

FAULT FINDING LOGIC FOR

535 SE/LD RDB CONTROL BOX

All resistance measurements are actual measured values and some variation is to be expected, therefore measured

values should be similar to but not necessarily identical to the given values.

The operation of the photo cell can be tested by measuring the resistance across the photo cell, it should be a high

resistance (greater than 10MΩ or open circuit) in the dark and low resistance (3kΩ or less) in light.

Burners on balanced flue systems can recirculate flue products resulting in the burner cycling, if this happens check the

flue system integrity and the terminal position.

FAULT FINDING

& DIAGRAMS

FAULT FINDING

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

8 716 113 389b (09/07)

Page 49

ELECTRICAL SCHEMATIC

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 106 252b (07/06

FAU LT FIND ING

& DIAGRAMS

MOTORISE D

X8 (PIN 3)

DIVERTER

brown

X8 (PIN 4)

VALVE

LOC KOUT

BURNER

RESET SWITCH

grey

white

grey

X12 (PIN 4)

PLUG IN

CONNECTOR

CENTRAL HEATING

CONTROL THERMOSTAT

AUTO RESET HIGH LIMIT

orange

THERMOSTAT

NCNO

red

(C)

red

(C)

yellow

X13 (PIN 1)

pink

X13 (PIN 3)

MANUAL RESET BOILER

MANUAL RESET FLUE

OVERHEAT THERMOSTAT

red

grey

X7 (PIN 4)

X8 (PIN 6)

PUMP

brown

X7 (PIN 3)

X7 (PIN 1)

white

X11 (PIN 3)

X12 (PIN 3)

LOC KOUT

INDICATOR

X11 (PIN 2)

X3 (PIN 3 (L))

X13 (PIN 2)

X13 (PIN 5)

RELAY

RELAY 2

431

grey

X8 (PIN 2)

DIVERTER

END SWITCH

orange

X8 (PIN 5)

X10 (PIN 3) X10 (PIN 1)

124

RELAY

whitewhite

THERMOSTAT

DHW CONTROL

bluebrown

SWITCH

WATER FLOW

X6 (PIN 2) X6 (PI N 4)

RELAY 1

(LR)

(NS)

LINK

(REMOVE)

(LS)

ROOM

THERMOSTAT

LIVE SUPPLY FOR ALTERNATIVE DIVERTER VALVE

X3 (PIN 3)

X8 (PIN 1)

grey

X2 (FR)

white

X4 (PIN 1)

X4 (PIN 2)

brown

X4 (PIN 3)

DHW

FUSE F1

3.15A

FAST

CERAMIC

SERVICE

CONNECTION

FROST THERMOSTATS

BOILER MODE

INDICATOR

X9 (PIN 2)

X1 (PIN 5)

X9 (PIN 1)

X1 (PIN 6)

MAINS

CONNECTION

(FS)

MODE

PROGRAMMER

X1 (PIN 1)

SWITCH

X1 (PIN 3)

Page 50

SERVICE INTERVAL RECORD It is recommended that the heating system is serviced regularly and

that you complete the appropriate Service Interval Record Overleaf.

Service Provider. Before completing the appropriate Service Interval Record overleaf, please ensure you have carried out the service as described in this manual. Always use Worcester, Bosch Group specified spare parts when replacing all controls.

COMMISSIONING ENGINEER COMBUSTION CHECKS

COMPANY NAME

PUMP PRESSURE

(PSI):

ADDRESS: CO2%:

SMOKE READING:

ENGINEERS NAME: F.G.T°C:

SIGNATURE: FLUE PRESSURE:

DATE: BURNER MODEL:

FOR ALL BOILERS CONFIRM THE FOLLOWING

THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS YES

OIL TYPE USED IS KEROSENE YES

THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE INSTRUCTIONS? YES

THE SYSTEM CLEANER USED:

THE INHIBITOR USED:

BOILER MODEL SERIAL No.

OIL BOILER COMBUSTION RECORD

Page 51

SERVICE 1

DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: psi CO2%: NOZZLE CHANGED? YES NO F.G.T. °C FLUE PRESSURE: COMMENTS

SIGNATURE

SERVICE 3

DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: psi CO2%: NOZZLE CHANGED? YES NO F.G.T. °C FLUE PRESSURE: COMMENTS

SIGNATURE

SERVICE 5

DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: psi CO2%: NOZZLE CHANGED? YES NO F.G.T. °C FLUE PRESSURE: COMMENTS

SIGNATURE

SERVICE 7

DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: psi CO2%: NOZZLE CHANGED? YES NO F.G.T. °C FLUE PRESSURE: COMMENTS

SIGNATURE

SERVICE 9

DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: psi CO2%: NOZZLE CHANGED? YES NO F.G.T. °C FLUE PRESSURE: COMMENTS

SIGNATURE

SERVICE 2

DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: psi CO2%: NOZZLE CHANGED? YES NO F.G.T. °C FLUE PRESSURE: COMMENTS

SIGNATURE

SERVICE 4

DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: psi CO2%: NOZZLE CHANGED? YES NO F.G.T. °C FLUE PRESSURE: COMMENTS

SIGNATURE

SERVICE 6

DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: psi CO2%: NOZZLE CHANGED? YES NO F.G.T. °C FLUE PRESSURE: COMMENTS

SIGNATURE

SERVICE 8

DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: psi CO2%: NOZZLE CHANGED? YES NO F.G.T. °C FLUE PRESSURE: COMMENTS

SIGNATURE

SERVICE 10

DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: psi CO2%: NOZZLE CHANGED? YES NO F.G.T. °C FLUE PRESSURE: COMMENTS

SIGNATURE

Page 52

CONTACT INFORMATION

WORCESTER, BOSCH GROUP:

TECHNICAL: 08705 266241 SERVICE: 08457 256206 SPARES: 01905 752571 LITERATURE: 01905 752556 TRAINING: 01905 752526 SALES: 01905 752640 WEBSITE: www.worcester-bosch.co.uk

WATER TREATMENT:

FERNOX 01799 550811 www.fernox.com

SENTINEL 0151 420 9595 www.betzdearborn.com/sentinel

FLUE TERMINAL GUARD:

PART No. 7 716 190 050

In the unlikely event the boiler does not give complete satisfaction, before calling for a service engineer, the installer should check the following:-

General checks

1. Is the mode switch in boiler mode (indicator on)?

2. Is there 230V across the boiler live and neutral terminals?

3. Is the polarity correct? (230V across live and earth, 0V across neutral and earth)

4. Is the air bled from the primary system?

5. Is the air bled from the oil supply?

6. Is the flue sized and routed correctly?

Boiler runs straight to lockout

1. Has the oil line been purged of air?

2. Where an air eliminator is used in conjunction with a top feed oil tank the non-return valve, (if fitted), should be removed from the oil dip pipe.

Boiler locks out at the start of a demand (Heating off overnight for example)

1. If an air eliminator is being used, check that there are no leaks that allow air to be pulled into the oil supply.

2. If a two pipe oil supply is a being used, has a non-return valve been fitted to the inlet pipe? Refer to the instructions for guidelines.

No domestic hot water (external programmer)

1. Is the mains water in connected to the 15mm isolation valve?

2. Is there a domestic hot water demand from the programmer and has the tank reached temperature?

3. Is there 230V on pin 2 of terminal block X4?

4. Remove the external wiring from terminal block X4 and fit a link across 1 and 2, if the domestic hot water now operates there is a problem with the external programmer and/or its wiring.

No central heating (external programmer)

1. Are both programmer and room thermostat on demand for central heating?

2. Is the room thermostat wired correctly?

3. Refit the link across pins L

S and LR on terminal X2, if the central heating

now operates correctly the room thermostat and/or its wiring are faulty.

4. Is there 230V on pin 1 of terminal block X4?

5. Remove the external wiring to terminal block X4 and fit a link across pins 1 and 3 on terminal X4, if the central heating now operates correctly the room programmer and/or its wiring are faulty.

EXCELLENCE COMES AS STANDARD

Worcester, Bosch Group

Cotswold Way, Warndon, Worcester WR4 9SW.

Tel. 01905 754624 Fax. 01905 754619

Worcester, Bosch Group is a trading name of BBT

Thermotechnology UK Ltd.

www.worcester-bosch.co.uk

8 716 113 389b (09/07)

UNDER NO CIRCUMSTANCES MUST AN APPLIANCE BE LEFT

TO OPERATE WITH ANY CONTROL LINKED OUT OR OVER RIDDEN.

Bosch 12-18, 25-32kW, 18-25 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual