GREENSTAR HEATSLAVE EXTERNAL
12/18, 18/25, 25/32kW
FLOOR STANDING EXTERNAL OIL FIRED CONDENSING COMBINATION
BOILER USING BALANCED FLUE SYSTEM
FOR OPEN VENT AND SEALED CENTRAL HEATING SYSTEMS WITH DOMESTIC MAINS FED HOT WATER
THE APPLIANCE IS FOR USE WITH KEROSENE ( 28 SECOND
OIL) ONLY
GB
INSTRUCTION MANUAL
INSTALLATION COMMISSIONING
& SERVICING
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CONTENTS
SAFETY & REGULATIONS
IMPORTANT INFORMATION AND SYMBOLS
SAFETY PRECAUTIONS AND INSTALLATION REGULATIONS
1
3
APPLIANCE INFORMATION
GENERAL INFORMATION
TECHNICAL DATA
4
5
6
LAYOUT & COMPONENTS
PRE-INSTALLATION
CLEANING PRIMARY SYSTEMS
7
8
MAINS SUPPLIES
OIL SUPPLY
9
WATER SYSTEMS & PIPEWORK
10-11
12
CONDENSATE & PRESSURE RELIEF PIPEWORK
BOILER LOCATION & CLEARANCES
CABINET MOUNTED LOW LEVEL FLUE TERMINAL POSITIONS
HIGH LEVEL FLUE TERMINAL POSITIONS
EXTERNAL OILFIT BALANCED FLUE OPTIONS
CABINET MOUNTED HORIZONTAL BALANCED FLUE OPTIONS
13
14
15
16
17
INSTALLATION
UNPACKING THE BOILER
PIPEWORK & FLUE POSITIONS
BOILER INSTALLATION
FLUE INSTALLATION
18
19
20
21
COMBUSTION CHAMBER
PIPEWORK CONNECTIONS
OIL BURNER AND PUMP
REFITTING COMPONENTS
ELECTRICS
22
23-24
25
26
27-28
COMMISSIONING
PRE-COMMISSIONING CHECKS - APPLIANCE
FILLING THE SYSTEM
29
30
STARTING THE APPLIANCE
WATER TREATMENT
31-34
35
FINISHING COMMISSIONING - APPLIANCE
36
SERVICING & SPARES
INSPECTION AND SERVICE
SHORT PARTS LIST 12/18
SHORT PARTS LIST 18/25
SHORT PARTS LIST 25/32
37-40
41
42
43
FAULT FINDING & DIAGNOSIS
FAULT FINDING
44-45
46
FAULT FINDING LOGIC FOR SATRONIC CONTROL BOX
FAULT FINDING LOGIC FOR 535 SE/LD RDB CONTROL BOX
ELECTRICAL SCHEMATIC
47
48
COMMISSIONING & SERVICE RECORDS
COMBUSTION RECORD
49
50
SERVICE INTERVAL RECORD
2
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
CONTENTS
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SAFETY PRECAUTIONS
INSTALLATION REGULATIONS
Failure to install appliances correctly could lead to
prosecution.
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.
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.
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.
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.
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.
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.
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.
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.
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.
BS 7671: IEE Wiring Regulations, current edition.
BS 1362: Specification for general purpose fuse
links for domestic and similar purposes.
The Building Regulations Part J and L1 England
and Wales; Part F and Part J Section III Scotland;
Part L and Part F Northern Ireland.
Local water company bye-laws.
The Control of Pollution (Oil) Regulations.
OFTEC Standards.
Where no specific instruction is given, reference
should be made to the relevant codes of practice.
3
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
SAFETY PRECAUTIONS
8 716 113 389b (09/07)
& INSTALLATION REGULATIONS
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GENERAL INFORMATION
STANDARD PACKAGE:
640mm
770mm
A - Floor standing oil fired condensing boiler for
open vent and sealed domestic central heating
and mains fed hot water.
A
B - Literature pack.
C -Condensate trap kit.
D -100mmØ services duct.
E - Cabinet key
950mm
B
C
D
E
Check List
Item
Qty
Greenstar Heatslave External Installation/Servicing Instructions........1
Users Instructions ..........................................................................................1
100mm Ø Services Duct...............................................................................1
Condensate Trap Kit.......................................................................................1
Warranty Return Envelope ............................................................................1
Cabinet Key.......................................................................................................1
4
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
GENERAL INFORMATION
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TECHNICAL DATA
DESCRIPTION
UNITS
12/18
18/25
25/32
Central Heating
Primary water capacity (total)
Maximum static head
litres
metres
69
30
1
69
30
1
72
30
1
Minimum static head
metres
Available pump head (20°C difference) at max. output
metres water
bar
4.7
2.5
4.0
2.5
4.2
2.5
Max. permissible sealed system operating pressure
in accordance with WRAS guidelines
Flow restrictor
colour
Lime
—
—
Domestic Hot Water
Optimum flow rate ( 15%)
Minimum inlet pressure (dynamic) for optimum flow rate
Maximum hot water rise for 90 litres draw off (@optimum flow rate)
Flue
litres/min
bar
15
1.5
40
18
1.2
40
22
0.9
40
°C
Exit flue gas mass flow
kg/hr
29
40
51
Pipework connections
Fuel line (compression)
mm
mm
10
22
22
15
22
1
10
22
22
15
22
1
10
28
28
15
22
1
CH flow
CH return
mm
Water main inlet
mm
DHW outlet
mm
Open vent (optional)
BSP
BSP
mm
3
/
3
/
3
/
CH drain/optional feed and expansion
Condensate (polypropylene)
Electrical
4
4
4
21.5
21.5
21.5
Electrical power supply voltage
Frequency
AC...V
Hz
230
50
230
50
230
50
Max. power consumption
Thermostats
W
240
240
263
CH control thermostat range (cut in/cut out)
DHW control thermostat range (cut in/cut out)
CH & DHW control thermostat differential
Boiler high limit thermostat set point
Boiler manual reset overheat thermostat set point
Flue reset overheat thermostat set point
General Data
°C
°C
°C
°C
°C
°C
55/81
55/72
5
55/81
55/72
5
55/81
55/72
5
92
92
92
105
110
105
110
105
110
Maximum hearth temperature
SEDBUK (Band A)
°C
%
<100
90.2
45
<100
90.1
45
<100
90.3
45
Appliance protection rating
Weight (excluding packaging)
Emissions class for NOx and CO
Typical NOx emissions figure
IP
kg
195
3
195
3
206
3
class
mg/kW hr
75
70
75
5
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
TECHNICAL DATA
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LAYOUT & COMPONENTS
The diagram opposite excludes the top, front
and RH side casing panels.
44
43
i)
1. CONTROL BOX ASSEMBLY
2. DIVERTER VALVE
3. PRESSURE GAUGE
4. AUTO AIR VENT
iv)
iii)
5. CH CONTROL AND MANUAL RESET
OVERHEAT THERMOSTAT PHIAL
6. CASING SIDE PANEL
7. CIRCULATING PUMP
8. AUTO-RESET HIGH LIMIT
THERMOSTAT PHIAL
44
ii)
43
i)
42b
v)
ii)
9. DHW FLOW SWITCH
10. PRESSURE RELIEF VALVE
11. DHW HEAT EXCHANGER
12. FLUE GAS SAMPLING POINT
13. FLUE OVERHEAT THERMOSTAT
PHIAL
iii)
iv)
13
v)
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
42a
18
14
12
15
11
10
16
9
17
8
7
6
5
19
23. CONDENSATE OUTLET
24. PRIMARY HEAT EXCHANGER
25. TRAY
4
3
26. OIL ISOLATION VALVE
27. CONDENSATE TRAP
28. CONDENSATE TRAP BRACKET
29. COMBUSTION CHAMBER ACCESS
DOOR
2
1
41
40
30. HEATSLAVE TANK DRAIN
31. HEATSLAVE TANK
32. MODE SWITCH
33. BOILER MODE INDICATOR
34. LOCKOUT INDICATOR
35. OVERHEAT RESET BUTTONS (boiler &
flue temperature)
39
38
37
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)
35/36
34
33
32
i) CONTROL BOX
ii) MOTOR
20
iii) AIR INTAKE CASING
iv) OIL PUMP
v) COMBUSTION HEAD
21
31
22
23
30
24
25
26
42b. RIELLO RDB 2.2 BURNER (25/32)
i) CONTROL BOX
27
29
28
ii) MOTOR
iii) AIR INTAKE CASING
iv) OIL PUMP
v) COMBUSTION HEAD
43. CLIP - AIR INTAKE HOSE
44. AIR INTAKE HOSE
6
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
LAYOUT & COMPONENTS
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CLEANING PRIMARY SYSTEMS
IMPORTANT: All the following Pre-Installation sections must be read and
requirements met before starting boiler or flue installation.
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.
CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND
OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.
BEFORE CLEANING THE SYSTEM:
ENSURE THE SYSTEM AND PIPEWORK IS
IN GOOD WORKING ORDER.
FLUSH THE EXISTING SYSTEM WITH A
POWER FLUSHING MACHINE OR WITH A
CHEMICAL CLEANER BEFORE
INSTALLING NEW COMPONENTS.
CLEANING THE PRIMARY SYSTEM:
ꢀ Cleanse the system in accodance with
BS 7593.
ꢀ Fill the system with cold mains water to the
recommended pressure and check for leaks.
ꢀ Open all drain cocks and drain the system.
ꢀ Close drain cocks and add a suitable flushing
agent at the correct strength for the system
condition in accordance with the manufacturer's
instructions.
ꢀ Circulate the flushing agent before the boiler
is fired up.
ꢀ Run the boiler and system at normal operating
temperature in accordance with the
manufacturer's instructions.
ꢀ Drain and thoroughly flush the system to
remove the flushing agent and any debris.
7
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
CLEANING PRIMARY SYSTEMS
8 716 113 389b (09/07)
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IMPORTANT: The appliance provides a permanent external electrical supply
for servicing and must therefore be fed via a circuit breaker incorporating
earth leakage protection.
MAINS 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.
Water Mains Pressure:
Minimum dynamic mains water pressure for
optimum performance.
12/18kW
18/25kW
25/32kW
1.5 bar
1.2 bar
0.9 bar
MAINS WATER EXPANSION VESSEL:
A - Mini expansion vessel, part No. 7 716 102 105
B - Mains water inlet
• Maximum mains fed water pressure 10 bar.
If necessary, fit a pressure reducing valve.
C - Non-return valve
D - Boiler
D
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.
A
C
B
• Where the water main supply has a non-
return, 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.
8
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
MAINS SUPPLIES
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OIL SUPPLY
A
B
C
D
E
- Oil storage tank
- Isolating valve
H
J
- Oil supply pipe
- Oil pump
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.
- Oil strainer & water seperator
- Fire valve to BS5410
- External casing
K
L
- Full base (plastic tanks)
- Non-return valve
- De-aerator
M
N
F
- Fire valve sensor
- Oil burner
- Oil filter (16µm max filtration size)
G
NOTE: All dimensions are in metres unless stated otherwise.
The maximum pipe run figures are based on using copper pipe with an inside diameter of
2mm less than the Ø.
.
1m min
a)
a) 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 addi-
tion 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).
A
F
K
B
C
H
B D
B N
G
J
MAXIMUM PIPE RUN FOR SINGLE PIPE GRAVITY FEED SYSTEM
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).
E
HEAD 10mmØ
12mmØ
30
69
91
100
HEAD 10mmØ
12mmØ
0.5
1.0
1.5
2.0
12
25
37
49
2.5
3.0
3.5
4.0
62
74
87
99
100
100
100
100
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).
.
1m min
G
F
b)
B
D
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).
L
L
A
B
C
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.
B
N
J
H
150mm
K
E
MAXIMUM PIPE RUN FOR DOUBLE PIPE SUB-GRAVITY FEED SYSTEM
Pipework
HEAD 10mmØ
12mmØ
100
100
95
HEAD 10mmØ
12mmØ
66
50
37
22
ꢀ Use copper pipe of the correct diameter
according to the information shown opposite.
Use flexible hoses to connect to the oil pump (J).
0
50
44
38
32
2.0
2.5
3.0
3.5
26
20
14
8
0.5
1.0
1.5
ꢀ 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.
80
F
G
M
ꢀ Install a manual isolating valve (B) to the oil
supply pipe (H), as close to the oil storage
tank (A) as possible.
c)
A
B
J
C
H
B
D
ꢀ 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.
.
E
1m min
K
MAXIMUM PIPE RUN FOR SINGLE PIPE SUCTION LIFT WITH DE-AERATOR
ꢀ 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.
FUEL FLOW RATE
FUEL FLOW RATE
HEAD 2.5kg/h 5kg/h 10kg/h 10kg/h
8mmØ 8mmØ 8mmØ 10mmØ
HEAD 2.5kg/h 5kg/h 10kg/h 10kg/h
8mmØ 8mmØ 8mmØ 10mmØ
2.0
2.5
3.0
3.5
60
45
35
25
30
25
15
10
14
11
8
65
50
35
20
0
100
95
80
70
55
45
40
35
26
23
20
17
100
100
90
0.5
1.0
1.5
A capillary type valve provides a neat and
simple installation. Alternatively, a fusible
link or electrical system may be used.
5
75
Under no circumstances should a
combination isolating/fire valve be used
as the sole fire protection device.
The table and illustration above is a guide only and does not in any way override the de-
aerator manufacturers instructions.
9
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
OIL SUPPLY
8 716 113 389b (09/07)
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WATER SYSTEMS & PIPEWORK
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.
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.
TYPICAL OPEN VENT SYSTEM
PRIMARY SYSTEM/CONNECTIONS/VALVES:
S
E
1000mm min.
• Do not use galvanised pipes or radiators.
• All system connections, taps and mixing
valves must be capable of sustaining a
pressure of 3 bar.
F
H
R
R
R
R
• Radiator valves should conform to
BS 2767:10.
T
L
T
T
L
L
L
L
• 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.
G
• 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.
C
D
D
A - Appliance expansion vessel
B - Extra expansion vessel
C - Automatic bypass valve
D - Drain cock
F - Feed & expansion 15mmØ min
G - Appliance
H - Open vent 22mmØ min
L - Lockshield valve
R - Radiators
S - Static head
T - TRV
• Drain cocks are required at all the lowest
points on the system.
• Air vents are required at all high points on the
system.
U - To filling system
E - Feed & expansion cistern
P - Pressure relief discharge
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.
R
R
• 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).
T
T
TYPICAL SEALED SYSTEM
A
L
L
• Ensure adequate space is left in the expansion
cistern for expansion of the system water.
R
R
G
B
• No valve shall be fitted in the open vent pipe
(H) or the feed and expansion pipe (F).
L
T
L
L
• The open vent pipe (H) must be at least 22mmØ.
U
P
C
SEALED PRIMARY SYSTEM:
D
D
• 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.
10
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
WATER SYSTEMS & PIPEWORK
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WATER SYSTEMS & PIPEWORK
Water main
supply
Heating return
FILLING PRIMARY SEALED SYSTEMS:
Non return Non return
valve valve
• Filling the system must comply with one of
the methods shown opposite.
Hose
return
• The filling point must be at low level and must
never be a permanent direct fixing to the
mains water supply.
Stop
cock
Stop
cock
Test cock
Temporary hose
• 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.
Make up
vessel
Heating return
Auto air
vent
Non return
valve
1000mm above
the highest point
of the system
• 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.
Stop
cock
Fill Point
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.
11
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
WATER SYSTEMS & PIPEWORK
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CONDENSATE &
PRESSURE RELIEF PIPEWORK
a
c
C
CONDENSATE PIPEWORK:
B
• 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.
A
75mm
min.
D
• 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.
b
d
C
E
C
A
A
• The pipework must follow one of the options
shown opposite:
D
a - Internal waste drainage system
b - Soil/vent stack
Invert
c - External drainage system
d - External condensate absorption point
(Unsuitable for clay soil types)
500mm min.
C
• Condensate pipework must not be connected
to rainwater downpipes.
F
A
• Use waterproof pipe insulation in exposed
positions and for external pipework
25mm
min.
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.
G
400mm
min.
I
H
A - Condensate from the boiler condensate
trap (supplied) which has a 75mm
minimum water seal.
200mm min.
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.
J
K
• 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 -
K -
External boiler casing.
Pressure relief pipe.
12
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
CONDENSATE &
PRESSURE RELIEF PIPEWORK
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BOILER LOCATION &
CLEARANCES
600mm
WARNING:
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.
2500mm*
600mm
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.
BASE
600mm
(min)
CLEARANCES: Min service & flue clearances
2500mm*
Above
Front
600mm
600mm
RH/LH flue outlet on opposite side
RH flue outlet on rear
LH flue outlet on rear
10mm
85mm
10mm
Rear = flue outlet on side
Rear = rear flue outlet
150mm**
2500mm*
It is strongly recommended that the flue
terminal faces away from walls to reduce
the possibility of wetting occuring.
Plan
view
10mm
85mm
*This can be reduced to 1200mm if there is at
least 2500mm clearance on both sides of the
flue.
FRONT
** 200mm if a high level terminal is used exiting
through the rear panel.
600mm
150mm**
150mm**
2500mm*
10mm
10mm
2500mm*
Plan
view
Plan
view
FRONT
600mm
FRONT
600mm
13
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
BOILER LOCATION &
CLEARANCES
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CABINET MOUNTED LOW LEVEL
FLUE TERMINAL POSITIONS
Minimum dimensions of flue terminal positions for oil fired appliances:
TERMINAL POSITION
B(H)
• Flue terminals must be positioned to avoid
combustion products entering into buildings.
A 1 Directly below an opening, air brick, opening windows, etc
B 1 Horizontally to an opening, air brick, opening window, etc
600mm
600mm
75mm
• The flue must be fitted and terminated in
accordance with the recommendations of
BS5410.
C
Below a plastic/painted gutter, drainage pipe or eaves if
combustible material protected
• The flue must not cause an obstruction.
• Discharge from the flue outlet must not be a
nuisance.
D 2 Below a plastic/painted gutter, drainage pipe or eaves without
protection to combustible material
600mm
• 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
E
F
From vertical sanitary pipework
300mm
300mm
From an external or internal corner or from a surface or boundry
alongside the terminal
nuisance, for example, near security lighting.
• There should be no restriction preventing the
clearance of combustion products from the
terminal.
G
Above ground or balcony level
300mm*
H 1 From a surface or boundary facing the terminal with 2500mm
clearance to both sides of the terminal
1200mm
• 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
H 2 From a surface or boundary facing the terminal with less than
2500mm clearance to either side of the terminal
I 1
2500mm
1200mm
From a terminal facing the terminal with 2500mm clearance to
clearance to both sides of the terminal
• A protective terminal guard must be fitted if
the terminal is 2m or less above a surface
where people have access.
I 2 From a terminal facing the terminal with less than 2500mm
clearance to either side of the terminal
2500mm
750mm
Stainless steel terminal guard.
Part No: 7 716 190 050
K
Horizontally from a terminal
• The following additional guidelines (from part
L Exceptions Guidance Document) are
recommended when determining the flue
outlet position:
B(H) Balanced Horizontal flue
• Avoid discharging flue gases into car ports
or narrow passageways.
1
An opening means an openable
element, such as an openable
• *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.
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.
boundary
C, D
F
I
B
A
H
J
F
E
F
K
G
boundary
14
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
CABINET MOUNTED LOW LEVEL
FLUE TERMINAL POSITIONS
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Minimum dimensions of flue terminal positions for oil fired appliances:
HIGH LEVEL FLUE TERMINAL
POSITIONS
TERMINAL POSITION
B(H)
B(V)
A1 2 Directly below an opening, air brick, opening window, etc
B1 2 Horizontally to an opening, air brick, opening window, etc
600mm N/A
600mm N/A
• Flue terminals must be positioned to avoid
combustion products entering into buildings.
C
Below a plastic/painted gutter, drainage pipe or eaves if
combustible material protected
75mm
N/A
• The flue must be fitted and terminated in
accordance with the recommendations of
BS 5410.
D3
Below a plastic/painted gutter, drainage pipe or eaves without
protection to combustible material
600mm N/A
• The flue must not cause an obstruction.
• Discharge from the flue outlet must not be a
nuisance.
E
F
From vertical sanitary pipework
300mm N/A
300mm N/A
From an external or internal corner or from a surface or boundry
alongside the terminal
• 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
G
H
J
Above ground or balcony level
300mm* N/A
600mm** N/A
nuisance, for example, near security lighting.
From a surface or boundary facing the terminal
From a terminal facing the terminal
• There should be no restriction preventing the
clearance of combustion products from the
terminal.
1200**mm
—
K
L
Vertically from a terminal on the same wall
1500mm N/A
• 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
Horizontally from a terminal on the same wall
Above the point of highest intersection with the roof
From a vertical structure on the side of the terminal
Above a vertical structure less than 750mm from the side of the terminal
From a ridge terminal to a vertical structure on the roof
Above or to the side of any opening on a flat or sloping roof
Below any opening on a sloping roof
750mm
—
M
N
O
—
—
—
—
—
—
600mm
750mm
600mm
—
• 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.
P
Q
300mm
1000mm
R
Stainless steel terminal guard.
Part No: 7 716 190 050
Key: — Not applicable, N/A Not allowed, B(H) Balanced Horizontal flue, B(V) Balanced 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.
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.
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.
• *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.
P
Q
Q
Q
Q
Q
Q
O
Q
M
Flat roof
boundary
N
R
Pitched roof
F
C, D
J
B
A
H
K
F
E
F
L
G
boundary
15
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32
8 716 106 252d (08/07)
HIGH LEVEL FLUE TERMINAL
POSITIONS
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BALANCED EXTERNAL OILFIT
FLUE OPTIONS
L = 2000mm
F
IMPORTANT: The weather seal (supplied)
must be fitted to every flue joint to give
the required level of weather protection.
L
B
*
The diagrams (opposite) show the components
used and the maximum flue length (L) for
each flue configuration.
125mmØ x2
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.
High level horizontal terminal (rear outlet)
• 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.
L = 7000mm
L
A
C
D
F
E
E
B
B
125mmØ x5
**
A - Horizontal terminal
B - Straight flue extension
C - Flue bend 90°
D - Flue bend 45°
E - Vertical Terminal Kit (incl. 90° elbow)
Vertical terminal (rear outlet)
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.
L = 6000mm
L
Then reduce the total straight flue length for
each extra flue bend (excluding the vertical flue
kit 90° elbow) by:
D
D
E
1000mm for 90°
500mm for 45°
B
Flue Extension lengths:
125mmØ x4
Horizontal & Vertical: 1000mm overall length.
Effective length when engaged into sockets
within the flue run is 950mm.
**
**
Vertical terminal (rear outlet)
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 = 6000mm
L
E
C
B
125mmØ x4
Vertical terminal (side outlet)
16
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
BALANCED EXTERNAL OILFIT
FLUE OPTIONS
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CABINET MOUNTED BALANCED
HORIZONTAL FLUE OPTIONS
• The horizontal flue is fitted to the rear or
either side of the cabinet.
REAR FLUE OUTLET
A + C
IMPORTANT:
It is strongly recommended that the flue
terminal faces away from walls to
minimise the occurance of wetting.
Plan
view
FRONT
A - External horizontal flue kit
Part No. 7 716 190 052
LEFT HAND FLUE OUTLET
A + B + C
B - 90° inline elbow 80/125mm
Part No. 7 716 190 034
Plan
view
C - Terminal guard
Part No. 7 716 190 050
FRONT
RIGHT HAND FLUE
OUTLET
A + B + C
Plan
view
FRONT
17
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
BALANCED FLUE OPTIONS
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UNPACKING THE BOILER
IIMPORTANT: All the previous Pre-Installation sections must be read
and requirements met before starting boiler or flue installation.
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.
1
•
•
•
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.
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.
2
18
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
UNPACKING THE BOILER
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All dimensions in mm
256
374
PIPEWORK & FLUE POSITIONS
Flue
CAUTION: Ensure there are no pipes,
electric cables, damp proof courses or
other hazards before drilling.
171
Services
SAFETY:
58
802
All relevant safety precautions must be undertaken.
Protective clothing, footwear, gloves and safety
goggles must be worn as appropriate.
Condensate
PRV
650
PIPEWORK CONNECTIONS:
258
CH flow 22mmØ copper (28mmØ on
25/32kW model)
105
DHW flow 22mmØ copper
Mains water inlet 15mmØ
81
REAR
161
Fire valve capillary
& drain access
CH return 22mmØ copper (28mmØ on
25/32kW model)
Optional open vent 1'' BSP
670
518
Services duct 100mmØ
3
Drain/optional fill/feed & expansion / '' BSP
4
Pressure relief pipe 15mmØ
Condensate outlet 21.5mmØ
Flue
NOTE: For servicing purposes, keep the
condensate and pressure relief discharge
pipes away from components and pipework
connections.
Services
Condensate
787
650
528
269
230
PRV
Oil
105
94
55
658
RIGHT HAND SIDE
669
705
715
Fire valve capillary
& drain access
670
518
Flue
Services
794
Condensate
650
PRV
Oil
158
124
89.5
55
LEFT HAND SIDE
658
679
698
718
19
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
PIPEWORK & FLUE POSITIONS
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WARNING: THIS APPLIANCE IS SERVICED AND REPAIRED EXTERNALLY.
BOILER INSTALLATION
EXTERNAL EQUIPMENT OPERATED AT 230V SHOULD NOT BE INSTALLED, SERVICED OR
REPAIRED UNDER ADVERSE WEATHER CONDITIONS.
Note: The cabinet is not load bearing it
only provides weather protection for the
boiler inside.
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.
1ꢀMark position of the 100mm services
duct on the exterior wall and make a hole
through.
2ꢀRemove 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.
7
3ꢀRemove the screws from the top panel
and lift up to remove, store safely away
from the installation point.
C
B
4ꢀSlide 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.
5ꢀRemove 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.
3
6ꢀRemove 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.
4
5
7ꢀLoosen 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).
2
ꢀUnscrew the burner retainers (D), then
withdraw the burner (E) from the boiler and
store safely away from the installation point.
6
8ꢀRemove 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.
8
9ꢀRefit the side panels and rear support
bar and screw the side panels to the
baseplate and boiler.
E
2
D
ꢀRefit the control box and pressure
gauge taking care not to kink the
capillary tubes.
7
ꢀ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.
A
20
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
BOILER INSTALLATION
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FLUE INSTALLATION
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.
21
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
FLUE INSTALLATION
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COMBUSTION CHAMBER
E
F
Combustion chamber:
1ꢀRelease retaining nuts and washers (B).
ꢀ Remove combustion chamber access
4
door (A).
2ꢀEnsure the baffles (C) and baffle retainer
(D) are correctly fitted for the boiler output
as shown in the plan views opposite.
3ꢀRefit combustion chamber door (A).
ꢀSecure with nuts and washers (B) and
tighten until the door is firmly secured, do
not over tighten the nuts.
A
4ꢀUnscrew screws (E) and remove flue
manifold access cover (F).
B
5ꢀCheck that all the baffles (G) and baffle
retainer (H) or ( J ) are correctly fitted to the
secondary heat exchanger.
2
3
1
5
G
or
H
J
Plan sectional view
Plan sectional view
12/18 & 18/25kW
25/32kW
C
C
Hook the
retainer ( J )
over the
end two
baffles
D
D
FRONT
FRONT
22
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
COMBUSTION CHAMBER
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CAUTION: ISOLATE THE OIL & WATER MAINS SUPPLY BEFORE STARTING ANY
WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.
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
F
-
-
10mmØ oil supply pipe connection
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.
23
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
PIPEWORK CONNECTIONS
8 716 113 389b (09/07)
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PIPEWORK CONNECTIONS
H - Flue manifold condensate outlet
J
K
L
-
-
-
Condensate outlet (21.5mmØ) - supplied
Condensate pipe - not supplied
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.
24
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
PIPEWORK CONNECTIONS
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OIL BURNER & PUMP
CAUTION: ISOLATE THE OIL & WATER
MAINS SUPPLY BEFORE STARTING ANY
WORK AND OBSERVE ALL RELEVANT
SAFETY PRECAUTIONS.
12/18 & 18/25 kW
1
Electrode gap
2.5 - 3.0mm
OIL BURNER:
B
1ꢀCheck the nozzle (A) and electrode (B)
settings are correct for the relevant burner
as shown opposite.
A
5mm
5mm
C
ꢀ Ensure nozzle (A) is aligned centrally within
the combustion head (C).
ꢀInspect for any visible defects.
7.5mm
1
25/32 kW
A
B
IMPORTANT: Whenever replacing the
combustion head, ensure that the photocell
is lined up with the sight hole.
5mm
5mm
C
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.
Electrode gap 4mm
Converting the oil pump for a double pipe
system:
1ꢀCheck the inlet hose connection.
b) SUNTEC AS47C OIL PUMP
a) DANFOSS BFP 11 L3 OIL PUMP
a) DANFOSS BFP 11 L3:
ꢀRemove pump front cover (A) ensuring a
suitable receptacle is used to catch any oil
residue.
A
B
ꢀRemove changeover screw (B).
ꢀRemove horseshoe washer (C).
ꢀRefit changeover screw (B).
ꢀRefit front cover (A).
2
1
2
1
ꢀRemove oil pump return plug (2).
b) SUNTEC AS47C:
C
B
ꢀRemove return port plug (2) and insert
grub screw (B).
c) RIELLO RDB OIL PUMP
c) RIELLO RDB:
ꢀUnscrew return plug (2).
ꢀScrew in by-pass screw (3).
2ꢀConnect the flexible oil return hose
(not supplied) between the oil pump and
the return line connection, and tighten to
secure.
1
3
2
25
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
OIL BURNER & PUMP
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REFITTING COMPONENTS
1ꢀAlign 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.
B
ꢀAttach the flexible air duct and tighten
A
clamp(D) to secure to the burner air intake.
C
2ꢀPlug burner lead (E) into control box (F).
D
F
E
26
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
REFITTING COMPONENTS
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ELECTRICS
B
1
DANGER - 230V:
ISOLATE THE MAINS ELECTRICITY
SUPPLY BEFORE STARTING ANY
WORK AND OBSERVE ALL RELEVANT
SAFETY PRECAUTIONS.
C
B
IMPORTANT: THIS APPLIANCE
PROVIDES A PERMENANT EXTERNAL
ELECTRICAL SUPPLY FOR SERVICING
AND MUST THEREFORE BE FED VIA A
CIRCUIT BREAKER INCORPORATING
EARTH LEAKAGE PROTECTION.
230V
IMPORTANT: OBSERVE ELECTRONIC
STATIC DISCHARGE PRECAUTIONS.
DO NOT TOUCH THE PCB CIRCUITS.
MAINS
SUPPLY
A
D
WARNING: EXTERNAL EQUIPMENT
OPERATED AT 230 VOLTS SHOULD NOT
BE SERVICED OR REPAIRED UNDER
ADVERSE WEATHER CONDITIONS.
2/3
G
4
F
E
Access to 230V connections:
1ꢀRelease screws (B) and remove cover
panel (C) from control box (A).
G
P
2ꢀRelease 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.
Accelerator
ROOMSTAT
resistor
230V connections (terminal block X1):
3ꢀConnect LIVE wire (Brown) to terminal L.
ꢀConnect NEUTRAL wire (Blue) to
terminal N.
M
(if fitted)
6
PROGRAMMER (EXTERNAL)
ꢀConnect EARTH wire (Green/Yellow) to
the connector
.
5
Route the power cable down the side panel and
through the service duct to the internal property
connection point avoiding any potentially hot
surfaces.
CH channel
HW channel
clock
Any external device connected to the
boiler must take its power supply from
the boiler supply only and must NOT
have a separate supply.
FROST
STAT(2)
FROST
STAT(1)
External 230V programmer
(terminal block X4):
7
k
7
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.
M
X2
N
L
ꢀConnect earth to terminal block X1connector
.
Ns Fs
FR
L
R
Ls
FR
230V room thermostat (terminal block X2):
6 ꢀRemove link (K).
ꢀConnect LIVE supply to terminal LS.
ꢀConnect SWITCHED LIVE supply to
terminal LR.
DHW
CH
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.
CONTROL
BOARD
Fuse
Refit electric control panel cover:
ꢀRefit panel (C) and secure with screws (B).
X4
NOTE: Both frost thermostats are fitted as
standard to the external appliance to provide
frost protection.
27
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
ELECTRICS
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ELECTRICS
Electrical components:
1
2
3
4
5
6
7
8
9
Printed circuit board
230V
Thermostat - boiler high limit
Thermostat - DHW control
Thermostat - CH control
Indicator lamp - boiler mode
Indicator lamp - lock-out
Manual reset - overheat thermostat
Manual reset - flue overheat thermostat
Manual reset - burner lock-out
1
N L
Mains
18
17
connection
10 External programmer (not supplied)
11 Burner socket
12 Burner plug
13 Burner control box (12/18 & 18/25 shown)
14 Flow switch
Mode
switch
15 Circulating pump
16 Diverter valve
17 Frost stat
18 Frost stat
Service
connection
Wire colour code:
br - Brown
bl - Blue
1
gygy
bl
br
X3
y
y
gy - Green/Yellow
X11
X12
gy
or
bl
br
g
X1
X2
gy
bl
r
- Red
gy
bl
pk
pk
g
w - White
br
br
bk
bl
br
w
g
y
g
- Yellow
- Grey
X9
X7
g
X6
X8
w
w
pk
or
y
bk - Black
or - Orange
pk - Pink
X4
X10
X13
2
2
3
4
r or
g
w
3
w
3
4
4
pk pk
y
y
5
6
3
2
2
or pk
y
r
r
r
r
w
w
bk
1
r
g
4
gy
5
w
8
7
9
10
2
3
3
6
11
1
2
r
4
g
5
6
bl
12
bk
gy
w
14
15
16
br
gy
bl
br
g
7
bk
r
gy
w
gy
or
bl
br
g
1
2
3
4
5
6
8
9
13
A
28
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
ELECTRICS
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PRE-COMMISSIONING CHECKS -
APPLIANCE
1
CAUTION: ISOLATE THE MAINS SUPPLIES
BEFORE STARTING ANY WORK AND
OBSERVE ALL RELEVANT SAFETY
PRECAUTIONS.
3
1ꢀ Check that the service and water pipes are
connected correctly.
ꢀ Check that all unused sockets are capped.
2
2ꢀ 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.
3ꢀ Check the flue is correctly fitted and the
connections are secure.
4ꢀ Check the condensate pipework is
correctly fitted and connected.
5
ꢀ Check the condensate trap is filled with
water.
5ꢀ 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.
4
NOTE: The cabinet is not load bearing, it only
provides weather protection for the boiler
inside.
12/18 & 18/25
0.6
0.5
0.4
0.3
0.2
Bar
0.1
0
0
200 400 600 800 1000 1200 1400 1600
IMPORTANT: If the boiler is not to be
commissioned immediately then:
Litres per hour
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.
25/32
0.7
0.6
Complete the installation part of the
Guarantee Registration Card, and complete
a CD10 or its equivalent, to inform the LABC
of the installation.
0.5
0.4
0.3
0.2
Bar
0.1
0
0
200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400
Litres per hour
29
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
PRE-COMMISSIONING
CHECKS - APPLIANCE
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FILLING THE SYSTEM
1
2
B
1ꢀPull lever (C) up and push to the left to
move the diverter valve to the mid-position
between ports A and B.
A
C
ꢀPush and hold lever (C) down to lock.
2ꢀLoosen the automatic air vent cover.
4ꢀSealed 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).
Total system Initial system Initial charge
volume (litres) pressure (bar) pressure (bar)
180
107
138
0.5
1.0
1.0
0.5
0.5
1.0
D
3
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.
4ꢀOpen all system and radiator valves (E).
ꢀTurn on the water main stop cock.
1 - 2 bar
ꢀOpen vented systems only; turn on the
water to the system feed and expansion
cistern and allow the system to fill.
4
ꢀ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.
E
E
ꢀCheck air is being discharged from the
automatic air vent.
F
ꢀ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.
5ꢀSealed 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.
5
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.
6
B
C
A
30
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
FILLING THE SYSTEM
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STARTING THE APPLIANCE
IMPORTANT: Never run the appliance when
the appliance/system is unpressurised
(sealed systems) or empty.
1
1ꢀCheck 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
on
1
and draw off at least 2 / litres of oil until a
2
steady flow of clear uncontaminated oil can
be seen as follows:
service
max
max
lockout
flue
boiler
reset
reset
• The oil supply to the boiler should be
primed before the burner is operated to
avoid unnecessary pump wear.
GREENSTAR HEATSLAVE EXTERNAL
RIELLO
SUNTEC
AS47C OIL PUMP
DANFOSS
• The use of an oil suction pump will prime
and flush through any oil supply set up
simply and easily, alternatively the
RDB OIL PUMP
BFP 11 L3 OIL PUMP
A
D
C
D
A
B
following procedures can be used.
D
B
A
ꢀSingle pipe gravity feed systems:
B
C
C
ꢀ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.
A - Bleed & pressure gauge port
B - Pressure adjustment
C - Vacuum gauge port
ꢀWhen completed, close the isolating valve,
reconnect the flexible oil hose.
D - Retaining screws - cover
ꢀDouble pipe sub-gravity feed systems
and single pipe suction lift with de-aerator:
E - Lockout indicator
BURNER LOCKOUT
ꢀ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).
BURNER LOCKOUT RESET
BUTTON (D) FOR 12/18
& 18/25 MODELS
(Under control box)
BURNER LOCKOUT RESET
BUTTON (D) FOR
ꢀ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.
25/32 MODEL
(On top of burner control box)
ꢀ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.
Return
Flow
ꢀ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
H
button (D).
TANK
ꢀ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).
F
G
ꢀ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.
31
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
STARTING THE APPLIANCE
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2
STARTING THE APPLIANCE
E
2ꢀRemove 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.
D
D
25/32
Boiler lockout indicator on:
12/18 & 18/25
(under control box)
(on top of burner
control box)
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).
4
3
F
K
G
ꢀWait 2 minutes then press the lockout
reset button (D) to initiate another start
sequence.
ꢀRepeat procedure until a flame is established.
3ꢀStart and run for 3 minutes then switch off.
ꢀCheck for after-spurting from the nozzle,
indicated by oil saturation on the combustion
head (F).
RIELLO
SUNTEC
DANFOSS
RDB OIL PUMP
AS47C OIL PUMP
BFP 11 L3 OIL PUMP
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.
A
C
A
B
C
B
A
B
C
ꢀRefit nozzle, electrodes, combustion
head (F) and the burner.
ꢀRestart and run for 3 minute intervals until
after-spurting stops.
A - Bleed & pressure gauge port
B - Pressure adjustment
4ꢀStart 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.
C - Vacuum gauge port
5
Note; smoke readings may be inaccurate until
the smoke from burning organic binder in the
access door insulation has ceased.
L
ꢀCheck the CO2 levels and adjust the air
shutter (L) setting according to the table
opposite.
L
ꢀCheck the flue gas temperature is close to
the values shown in the table.
NOMINAL BOILER RATING AT NORMAL OPERATING
TEMPERATURE USING 28sec KEROSENE:
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.
OIL PUMP
PRESSURE FLOW RATE FLUE GAS
(p.s.i.) TEMP °C
FUEL
APPROX.
APPROX.
AIR
APPLIANCE
OUTPUT
NOZZLE
%CO
INPUT
Btu/hr
2
ꢀTurn off the electrical supply.
ꢀIsolate the oil supply to the burner.
ꢀRemove the oil pressure gauge.
ꢀRefit the blanking plug (A).
SETTING
Kg/h l/h
kW
kW
Btu/hr
12/18 - Bentone Sterling 40 Burner:
115
115
140
1.04 1.32
1.29 1.63
1.55 1.96
66
70
73
11.5
12.0
12.5
2.5
4.5
12.4 42300 12
15.5 52900 15
18.6 63500 18
40900
51200
61400
0.35 80°SR
0.45 80°S
0.50 80°ES
ꢀCheck and rectify any oil leaks.
5ꢀSwitch on the oil supply.
5.25
ꢀSwitch on the electrical supply.
ꢀRestart the boiler and run for 5 minutes.
ꢀRecheck the CO2 levels and if required,
adjust the air shutter setting (L) to obtain
the correct CO2 level.
18/25 - Bentone Sterling 50 Burner:
130
145
150
1.56 1.98
1.86 2.36
2.17 2.75
72
79
82
11.5
12.0
12.5
4.25
6.0
18.6 63500 18
61400
0.50 80°EH
0.55 80°EH
0.65 80°EH
22.2 75750 21.5 73400
8.0
25.8 88000 25
85300
25/32 - Riello RDB Burner:
87000
99300
111600
105
140
150
2.15 2.72
2.45 3.1
2.75 3.48
78
80
83
11.5
12.0
12.5
3.0
4.0
5.0
25.5
29.1
32.7
25
85300
0.75 60°ES
0.75 60°ES
0.85 60°ES
28.5 97200
32 109200
32
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
STARTING THE APPLIANCE
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STARTING THE APPLIANCE
Domestic hot water:
1ꢀSet the CH/DHW programmer to OFF.
ꢀFully open a hot water tap.
1
The burner should be OFF and the circulating
pump ON.
2ꢀClose 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.
2
on
service
max
max
3ꢀFully open a hot water tap.
The burner should be ON with the circulating
pump.
lockout
flue
boiler
reset
reset
GREENSTAR HEATSLAVE EXTERNAL
ꢀCheck the water flow rate using a suitable
measuring container;
C
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.
4ꢀFully close the hot water tap.
ꢀCheck the burner and circulating pump**
switch off.
3
**The high limit thermostat may activate
pump overrun until the correct
temperature is restored.
on
service
max
max
lockout
flue
boiler
reset
reset
GREENSTAR HEATSLAVE EXTERNAL
4
on
service
max
max
lockout
flue
boiler
reset
reset
GREENSTAR HEATSLAVE EXTERNAL
33
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
STARTING THE APPLIANCE
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STARTING THE APPLIANCE
1
Central heating:
1ꢀOpen all radiator valves.
ꢀSet room thermostat to maximum.
ꢀSet programmer to ON for CH.
ꢀTurn the DHW thermostat control (C) fully
anti-clockwise.
on
ꢀ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.
service
max
max
lock
flue
boiler
reset
reset
SLAVE EXTERNAL
ꢀ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.
C
D
E
2
2ꢀSet 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:
3ꢀSet the room thermostat to maximum.
ꢀSet the programmer to ON for DHW & CH.
ꢀTurn the DHW thermostat control (C) fully
anti-clockwise.
on
service
max
max
locko
flue
boiler
reset
ꢀSet the CH thermostat control (D) to max.
reset
SLAVE EXTERNAL
The burner should be ON with the circulating
pump. The diverter valve (E) should open to
port B for CH.
E
4ꢀSet the DHW thermostat control (C) to max.
The diverter valve (E) should move to port A
and divert the flow to the Heatslave tank.
3
on
service
max
max
lock
flue
boiler
reset
reset
SLAVE EXTERNAL
D
C
E
4
on
service
max
max
lock
flue
boiler
reset
reset
LAVE EXTERNAL
C
D
E
34
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
STARTING THE APPLIANCE
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WATER TREATMENT
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.
1
C
FLUSHING (Central Heating):
1ꢀSwitch 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).
C
2
2ꢀAdd 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.
A
ꢀRun the boiler/system at normal operating
temperature for the time stated by the
flushing agent manufacturer.
3ꢀDrain and thoroughly flush the system and
boiler to remove the flushing agent and
debris (C).
3
B
INHIBITOR (Central Heating):
4ꢀCheck drain cocks (C) and manual air vents
are closed and all radiator valves are open.
C
5ꢀAdd 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.
C
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.
4
5
ꢀ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.
C
6ꢀVent 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.
1 - 2 bar
A
6
7ꢀRecord 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 .
B
35
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
WATER TREATMENT
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FINISHING COMMISSIONING -
APPLIANCE
1ꢀRefit the top panel and press down to
compress the seal when fitting the
securing screws (A).
A
2ꢀPush the front panel up behind the top
panel and push in at the base to secure
the screws (B) with the tool provided.
A
Always apply pressure at the edges of the
panels when securing to avoid accidental
damage.
1
2
C
B
B
Handover:
ꢀComplete the guarantee registration card,
combustion record (page 49) and a CD11 or
an equivalent commissioning form.
K
ꢀ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.
36
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
FINISHING COMMISSIONING -
APPLIANCE
31
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INSPECTION AND SERVICE
CAUTION: ISOLATE THE WATER,
ELECTRICITY AND OIL MAINS SUPPLIES
BEFORE STARTING ANY WORK AND
OBSERVE ALL RELEVANT SAFETY
PRECAUTIONS.
on
DO NOT USE PRESSURE WASHERS OR
STEAM CLEANERS ON THIS APPLIANCE
OR ITS CABINET.
A
service
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:
1
C
ꢀCarry out a pre-service check and note any
operational faults:
2
ꢀPre-Service Check:
B
G
1ꢀUnndo 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).
2ꢀDepress 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).
3ꢀLoosen clip (D) to detach air duct.
4ꢀUnscrew 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:
3
4
ꢀ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.
D
ꢀCheck the combustion chamber access
door insulation board.
ꢀCheck that the flue system is unobstructed
and clean as necessary.
F
ꢀClean or replace all oil filters.
ꢀCheck that the condensate system is not
obstructed, clean and refill the condensate
trap as necessary.
E
ꢀ 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.
37
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
INSPECTION AND SERVICE
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INSPECTION AND SERVICE
1 Clean the Burner:
12/18 & 18/25
ꢀ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.
P
H
D
ꢀ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.
N
Electrode gap
2.5 - 3.0mm
ꢀ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.
M
O
L
F
E
5mm
5mm
ꢀRemove the nozzle (E).
2 12/18 & 18/25 Inspection of Mechanical
Shut-off Valve:
K
ꢀ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.
7.5mm
ꢀ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
P
H
D
25/32
ꢀCheck the nozzle holder is clear of any debris
and clean if neccessary.
E
F
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.
5mm
5mm
K
ꢀ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.
Electrode gap 4mm
ꢀ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.
DANFOSS
SUNTEC
RIELLO
RDB OIL PUMP
BFP 11 L3 OIL PUMP
AS47C OIL PUMP
ꢀ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.
A
A
A
B
B
B
This seal must be in good condition since
failure will cause flue gases to escape into
the cabinet.
A - Retaining screws - cover
B - Cover - oil pump
38
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
INSPECTION AND SERVICE
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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).
E
F
J
H
K
G
or
J
H
ꢀ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).
G
A
B
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.
Plan sectional view
Plan sectional view
12/18kW & 18/25kW
25/32kW
ꢀ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.
C
C
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.
D
D
FRONT
FRONT
39
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
INSPECTION AND SERVICE
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INSPECTION AND SERVICE
B
A
Re-commission the burner:
1ꢀAlign burner combustion head (A) into the
boiler housing tube with gasket (B)
correctly fitted.
C
ꢀPush firmly down to compress the gasket (B).
ꢀTighten burner retainers (C) sufficiently to
ensure a good seal.
D
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).
2ꢀPlug 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.
F
Allow the boiler to warm up then check the
combustion settings are correct as
E
indicated in the table below, adjust the
CO2 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:
3ꢀRefit 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.
NOMINAL BOILER RATING AT NORMAL OPERATING
TEMPERATURE USING 28sec KEROSENE:
OIL PUMP
PRESSURE FLOW RATE FLUE GAS
(p.s.i.) TEMP °C
FUEL
APPROX.
APPROX.
AIR
APPLIANCE
OUTPUT
NOZZLE
%CO
INPUT
2
SETTING
Kg/h l/h
kW
Btu/hr
kW
Btu/hr
12/18 - Bentone Sterling 40 Burner:
115
115
140
1.04 1.32
1.29 1.63
1.55 1.96
66
70
73
11.5
12.0
12.5
2.5
4.5
12.4 42300 12
15.5 52900 15
18.6 63500 18
40900
51200
61400
0.35 80°SR
0.45 80°S
0.50 80°ES
5.25
18/25 - Bentone Sterling 50 Burner:
130
145
150
1.56 1.98
1.86 2.36
2.17 2.75
72
79
82
11.5
12.0
12.5
4.25
6.0
18.6 63500 18
61400
0.50 80°EH
0.55 80°EH
0.65 80°EH
22.2 75750 21.5 73400
8.0
25.8 88000 25
85300
25/32 - Riello RDB Burner:
87000
99300
111600
105
140
150
2.15 2.72
2.45 3.1
2.75 3.48
78
80
83
11.5
12.0
12.5
3.0
4.0
5.0
25.5
29.1
32.7
25
85300
0.75 60°ES
0.75 60°ES
0.85 60°ES
28.5 97200
32 109200
40
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
INSPECTION AND SERVICE
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SHORT PARTS LIST 12/18
1
2
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
3
7
4
8
5
6
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
9
8a
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
13
11
12
10
17
14
15
19
16
20
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
18
21
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)
23
22
Part Number: 8 716 156 669 0
41
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
SHORT PARTS LIST 12/18
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SHORT PARTS LIST 18/25
1
2
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
3
7
4
8
5
6
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
9
8a
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
13
11
12
10
17
14
15
19
16
20
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
18
21
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
23
22
42
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
SHORT PARTS LIST 18/25
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SHORT PARTS LIST 25/32
3
4
2
1
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
5
6
7
7a
11
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
9
10
8
13
17
15
19
14
18
12
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
16
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
20
43
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
SHORT PARTS LIST 25/32
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PROBLEM
CAUSE
REMEDY
FAULT FINDING
LOCKOUT:
BOILER LOCKOUT :
Indicated by the illumination of the 'Lockout'
indicator on the fascia.
Pulsation on start
Combustion settings incorrect
Faulty nozzle
Set up as in installation instructions
Replace nozzle
To reset, wait 2 minutes then press the lockout
reset button.
Intermittent lockout Bad electrical connection
Check control box/electrical connections
Intermittent flame detection fault See flame detection fault
Also refer to fault finding logic on pages
46 and 47.
Burner motor fails to Faulty motor or electrical supply Check for 230v at motor plug during
operate
to motor
startup period
Control box fault
Replace control box
Flame detection
fault
Photocell filmed over (dirty)
Photocell faulty
Wipe clean
Replace
Control box faulty
Replace
Incorrect CO2
Air adjustment fault
Set up as in installation instructions
Set up as in installation instructions
Oil pressure incorrect
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
Replace nozzle
Replace
Nozzle blocked
Faulty pump or drive
Faulty mechanical shut off valve
(12/18 & 18/25 only)
Clean or replace
Ignition failure
Electrode settings incorrect
Faulty ignition transformer
Open circuit ignition
Set up as in installation instructions
Replace
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
TO START
No power to boiler
Check electrical / control circuit
Faulty boiler thermostat
Check by temporarily linking out high
limit and control thermostats
Programmer open circuit
Faulty control box
Check by temporarily linking 8 & 9 on
the connector
Replace
HIGH SMOKE
NUMBER
Air intake/flue blocked
Check & clear air intake/flue
Incorrect combustion settings
Oil pressure incorrect
Set up as in installation instructions
Adjust to correct pressure
Incorrect components used on
combustion head
Check with installation instructions
Faulty nozzle
Replace nozzle
UNDER NO CIRCUMSTANCES MUST AN
APPLIANCE BE LEFT TO OPERATE WITH
ANY CONTOL LINKED OUT OR
OVERRIDDEN.
44
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 106 252b (07/06
FAULT FINDING
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PROBLEM
CAUSE
REMEDY
FAULT FINDING
FAULTY BOILER
OPERATION:
Noisy operation
Pump noise from air in pump or
worn pump
Bleed air from pump or replace pump
Worn motor bearings
Fan out of balance
Replace motor
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 Ensure bulb is pushed fully home
pocket
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
45
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 113 389b (09/07)
FAULT FINDING
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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.
FAULT FINDING LOGIC FOR
SATRONIC CONTROL BOX
46
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 106 252b (07/06
FAULT FINDING
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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.
FAULT FINDING LOGIC FOR
535 SE/LD RDB CONTROL BOX
Worcester, Bosch Group cannot be held responsible for costs incurred by persons not
deemed to be competent.
47
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
FAULT FINDING
8 716 113 389b (09/07)
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ELECTRICAL SCHEMATIC
48
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
8 716 106 252b (07/06
ELECTRICAL SCHEMATIC
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OIL BOILER COMBUSTION RECORD
BOILER MODEL
SERIAL No.
COMMISSIONING ENGINEER
COMBUSTION CHECKS
COMPANY NAME
:
PUMP PRESSURE (PSI):
CO2 %:
ADDRESS:
SMOKE READING:
F.G.T°C:
ENGINEERS NAME:
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
OIL TYPE USED IS KEROSENE
YES
YES
YES
THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE INSTRUCTIONS?
THE SYSTEM CLEANER USED:
THE INHIBITOR USED:
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.
49
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SERVICE 2 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
SERVICE 1 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
OFTEC REG No.
PUMP PRESSURE:
NOZZLE CHANGED?
F.G.T. °C
OFTEC REG No.
PUMP PRESSURE:
NOZZLE CHANGED?
F.G.T. °C
psi
YES
FLUE PRESSURE:
CO2%:
psi
YES
FLUE PRESSURE:
CO2%:
NO
NO
COMMENTS
COMMENTS
SIGNATURE
SIGNATURE
SERVICE 4 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
SERVICE 3 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
OFTEC REG No.
PUMP PRESSURE:
NOZZLE CHANGED?
F.G.T. °C
OFTEC REG No.
PUMP PRESSURE:
NOZZLE CHANGED?
F.G.T. °C
psi
YES
FLUE PRESSURE:
CO2%:
psi
YES
FLUE PRESSURE:
CO2%:
NO
NO
COMMENTS
COMMENTS
SIGNATURE
SIGNATURE
SERVICE 6 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
SERVICE 5 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
OFTEC REG No.
PUMP PRESSURE:
NOZZLE CHANGED?
F.G.T. °C
OFTEC REG No.
PUMP PRESSURE:
NOZZLE CHANGED?
F.G.T. °C
psi
YES
FLUE PRESSURE:
CO2%:
psi
YES
FLUE PRESSURE:
CO2%:
NO
NO
COMMENTS
COMMENTS
SIGNATURE
SIGNATURE
SERVICE 8 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
SERVICE 7 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
OFTEC REG No.
PUMP PRESSURE:
NOZZLE CHANGED?
F.G.T. °C
OFTEC REG No.
PUMP PRESSURE:
NOZZLE CHANGED?
F.G.T. °C
psi
YES
FLUE PRESSURE:
CO2%:
psi
YES
FLUE PRESSURE:
CO2%:
NO
NO
COMMENTS
COMMENTS
SIGNATURE
SIGNATURE
SERVICE 10 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
SERVICE 9 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
OFTEC REG No.
PUMP PRESSURE:
NOZZLE CHANGED?
F.G.T. °C
OFTEC REG No.
PUMP PRESSURE:
NOZZLE CHANGED?
F.G.T. °C
psi
YES
FLUE PRESSURE:
CO2%:
psi
YES
FLUE PRESSURE:
CO2%:
NO
NO
COMMENTS
COMMENTS
50
SIGNATURE
SIGNATURE
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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?
CONTACT INFORMATION
3. Is there 230V on pin 2 of terminal block X4?
WORCESTER, BOSCH GROUP:
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.
TECHNICAL:
SERVICE:
SPARES:
08705 266241
08457 256206
01905 752571
01905 752556
01905 752526
01905 752640
LITERATURE:
TRAINING:
SALES:
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 LS 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?
WATER TREATMENT:
FERNOX
01799 550811
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.
SENTINEL
0151 420 9595
FLUE TERMINAL GUARD:
PART No. 7 716 190 050
UNDER NO CIRCUMSTANCES MUST AN APPLIANCE BE LEFT
TO OPERATE WITH ANY CONTROL LINKED OUT OR OVER RIDDEN.
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.
8 716 113 389b (09/07)
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