Worcester Greenstar Heatslave 12/18 Instruction Manual
Floor standing oil fired condensing combination boiler
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8 716 106 252f
30/3/10
12:56
INSTRUCTION MANUAL
INSTALLATION, COMMISSIONING & SERVICING
FLOOR STANDING OIL FIRED CONDENSING COMBINATION BOILER
CONVENTIONAL FLUE & ROOM SEALED FLUE
GREENSTAR HEATSLAVE
12/18, 18/25 & 25/32
FOR OPEN VENT & SEALED CENTRAL HEATING SYSTEMS WITH
MAINS FED DOMESTIC HOT WATER
Page 1
THE APPLIANCE IS FOR USE WITH KEROSENE
(28 SECOND OIL) ONLY
UK
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Table of Contents
Related Manuals for Worcester Greenstar Heatslave 12/18
Summary of Contents for Worcester Greenstar Heatslave 12/18
- Page 1 8 716 106 252f 30/3/10 12:56 Page 1 INSTRUCTION MANUAL INSTALLATION, COMMISSIONING & SERVICING FLOOR STANDING OIL FIRED CONDENSING COMBINATION BOILER CONVENTIONAL FLUE & ROOM SEALED FLUE GREENSTAR HEATSLAVE 12/18, 18/25 & 25/32 FOR OPEN VENT & SEALED CENTRAL HEATING SYSTEMS WITH MAINS FED DOMESTIC HOT WATER THE APPLIANCE IS FOR USE WITH KEROSENE (28 SECOND OIL) ONLY...
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Page 2: Important Information And Symbols
LABC will then arrange regular inspection visits during the work to ensure that the installation complies with the regulations. Programmer ON CH only IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER TECHNICAL HELPLINE. DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER. Programmer ON DHW only... -
Page 3: Table Of Contents
RIELLO CONTROL BOX OPERATION FAULT FINDING LOGIC FOR SATRONIC CONTROL BOX FAULT FINDING LOGIC FOR RIELLO CONTROL BOX ELECTRICAL SCHEMATIC COMMISSIONING CHECKLIST SERVICE INTERVAL RECORD INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 CONTENTS 8 716 106 252f (03/2010) -
Page 4: Safety Precautions And Installation Regulations
Republic of Ireland ETCI rules for electrical installation For further guidance see: OFTEC Technical book three - Regional requirements: Republic of Ireland INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 SAFETY PRECAUTIONS 8 716 106 252f (03/2010) & INSTALLATION REGULATIONS... -
Page 5: General Information
Greenstar Heatslave Installation/Servicing Instructions......1 Users Instructions ..................1 Fascia Information Card.................1 Flue Trim ......................1 Top Panel Inset Plate..................1 Edge Clips .......................1 Warranty Return Envelope ................1 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 GENERAL INFORMATION 8 716 106 252f (03/2010) -
Page 6: Technical Data
SEDBUK (Band A) 90.2 90.1 90.3 Appliance protection rating (with programmer blanking plate fitted) Appliance protection rating (with fascia programmer fitted) Weight (excluding packaging) INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 TECHNICAL DATA 8 716 106 252f (03/2010) -
Page 7: Layout & Components
46 CLIP - AIR INTAKE HOSE 47 AIR INTAKE HOSE OPTIONAL ACCESSORIES (not supplied) 7 day TWIN CHANNEL DIGITAL PROGRAMMER Part No. 7 716 192 033 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 LAYOUT & COMPONENTS 8 716 106 252f (03/2010) -
Page 8: Cleaning Primary Systems
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. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 CLEANING PRIMARY SYSTEMS 8 716 106 252f (03/2010) -
Page 9: Mains Supply
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. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 MAINS SUPPLY 8 716 106 252f (03/2010) -
Page 10: Oil Supply
The table and illustration above is a guide only and does not in any way override the as the sole fire protection device. de-aerator manufacturers instructions. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 OIL SUPPLY 8 716 106 252f (03/2010) -
Page 11: Water Systems & Pipework
• Pressurise the extra expansion vessel (B) to the same figure as the expansion vessel (A) built into the appliance. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 WATER SYSTEMS & PIPEWORK 8 716 106 252f (03/2010) -
Page 12: Pressure Relief Pipework
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 WATER SYSTEMS & PIPEWORK 8 716 106 252f (03/2010) -
Page 13: Condensate Pipework
(as shown) to help or other public access where it could cause prevent freezing. a hazard. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 CONDENSATE & 8 716 106 252f (03/2010) PRESSURE RELIEF PIPEWORK... -
Page 14: Boiler Location & Clearances
75mm. ** Due to changes to BS 5410 and modern building design, these figures no longer incorporate the adventitious ventilation allowance. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 BOILER LOCATION & CLEARANCES 8 716 106 252f (03/2010) -
Page 15: Boiler Location
In all cases the IEE wiring regulations must be consulted. All pipework in bathrooms and shower rooms must be cross bonded. 2250mm 2250m 600mm radius INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 BOILER LOCATION & CLEARANCES 8 716 106 252f (03/2010) -
Page 16: Flue Terminal Positions
• **Minimum distance of the flue terminal to a facing wall, fence, building or property boundary is 2500mm. Flat roof boundary Pitched roof C, D boundary INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 FLUE TERMINAL POSITIONS 8 716 106 252f (03/2010) -
Page 17: Conventional Flue
A - Boiler B - Flue C - Max. 2 bends at 135° D - Anti down-draught terminal E - Chimney INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 CONVENTIONAL FLUE 8 716 106 252f (03/2010) -
Page 18: Room Sealed Flue Options
1" BSP tapping (T). 125mmØ x3 125mmØ x5 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 ROOM SEALED FLUE OPTIONS 8 716 106 252f (03/2010) -
Page 19: Unpacking The Boiler
At all times the correct method for handling heavy objects should be strictly observed. UNPACKING THE BOILER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 8 716 106 252f (03/2010) -
Page 20: Pipework Positions / Flue Opening
Wall thickness Flue hole size 150 - 240mm 155mmØ 240 - 330mm 160mmØ 330 - 420mm 165mmØ 420 - 500mm 170mmØ 752** INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 PIPEWORK POSITIONS & 8 716 106 252f (03/2010) FLUE OPENING... -
Page 21: Boiler Installation
Lift burner assembly up to release the combustion head (K) from heat exchanger and store safely away from the boiler. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 BOILER INSTALLATION 8 716 106 252f (03/2010) -
Page 22: Flue Installation
The expansion vessel must be fitted outside the boiler and connected to the right hand side 1" BSP tappings (T). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 FLUE INSTALLATION 8 716 106 252f (03/2010) -
Page 23: Combustion Chamber
Plan sectional view Plan sectional view 12/18 & 18/25kW 25/23kW Hook the retainer (H) over the end two baffles FRONT FRONT INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 COMBUSTION CHAMBER 8 716 106 252f (03/2010) -
Page 24: Pipework Connections
PRESSURE RELIEF CONNECTION: Connect the pressure relief pipe (M) to a copper discharge pipe (15mmØ min.). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 PIPEWORK CONNECTIONS 8 716 106 252f (03/2010) -
Page 25: Oil Burner And Pump
Screw in by-pass screw (3). Connect the flexible oil return hose (not supplied) between the oil pump and the return line connection, and tighten to secure. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 OIL BURNER & PUMP 8 716 106 252f (03/2010) -
Page 26: Refitting Components
Plug burner lead (G) into control box (H). Press in the lugs ( I ), pivot the control box (H) down and slide into the boiler casing. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 REFITTING COMPONENTS 8 716 106 252f (03/2010) -
Page 27: Electrics
Connect common LIVE supply to terminal Fs. Connect each SWITCHED LIVE to terminals F Refit electric control panel cover: Refit panel (C) and secure with screws (B). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 ELECTRICS 8 716 106 252f (03/2010) - Page 28 - Blue gy - Green/Yellow - Red w - White y - Yellow g - Grey bk - Black or - Orange pk - Pink White INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 ELECTRICS 8 716 106 252f (03/2010)
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Page 29: Pre-Commissioning Checks - Appliance
CD10 or equivalent to inform the LABC of the installation. 1000 1200 1400 1600 1800 2000 2200 2400 Litres per hour INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 PRE-COMMISSIONING CHECKS - 8 716 106 252f (03/2010) APPLIANCE... -
Page 30: Filling The System
Push lever (C) to the left and pull upwards to allow the lever to return position A. Leave the lever (C) unlocked at position A. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 FILLING THE SYSTEM 8 716 106 252f (03/2010) -
Page 31: Starting The Appliance
The internal filter is accessed by removing PUMP the oil pump cover on the Danfoss BFP 11 L3, Suntec AS47C and Riello RDB. SHOWN Safely dispose of the container/discharge. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 STARTING THE APPLIANCE 8 716 106 252f (03/2010) - Page 32 NOTE: Smoke readings may be inaccurate until the smoke from burning organic binder in the access door insulation has ceased. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 STARTING THE APPLIANCE 8 716 106 252f (03/2010)
- Page 33 2.15 2.72 11.5 25.5 87040 85300 0.75 60°ES 2.45 3.10 12.0 29.1 99200 28.5 97200 0.85 60°ES 2.75 3.48 12.5 32.7 111400 109200 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 STARTING THE APPLIANCE 8 716 106 252f (03/2010)
- Page 34 Check the burner and circulating pump** switch off. **The high limit thermostat may activate pump overrun until the correct boiler temperature is restored. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 STARTING THE APPLIANCE 8 716 106 252f (03/2010)
- Page 35 4 Set the DHW thermostat control (C) to max. The diverter valve (E) should move to port A and divert the flow to the Heatslave tank. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 STARTING THE APPLIANCE 8 716 106 252f (03/2010)
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Page 36: Water Treatment
. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 WATER TREATMENT 8 716 106 252f (03/2010) -
Page 37: Finishing Commissioning - Appliance
NOTE: Release drain point (K) to drain the secondary heat exchanger. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 FINISHING COMMISSIONING - 8 716 106 252f (03/2010) APPLIANCE... -
Page 38: Inspection And Service
Clean or replace all oil filters. Check that the condensate system is not obstructed, clean and refill the condensate trap as necessary. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 INSPECTION AND SERVICE 8 716 106 252f (03/2010) - Page 39 B - Cover - oil pump This seal must be in good condition since failure will cause flue gases to escape into the room. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 INSPECTION AND SERVICE 8 716 106 252f (03/2010)
- Page 40 Check the seal on the manifold access cover (K) and replace if necessary. Refit the flue manifold access cover (B) and secure with screws (A). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 INSPECTION AND SERVICE 8 716 106 252f (03/2010)
- Page 41 A fire valve sensor clip (E) is provided for this purpose. Plan sectional view Plan sectional view 12/18kW & 18/25kW 25/32kW FRONT FRONT INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 INSPECTION AND SERVICE 8 716 106 252f (03/2010)
- Page 42 2.15 2.72 11.5 25.5 87040 85300 0.75 60°ES 2.45 3.10 12.0 29.1 99200 28.5 97200 0.85 60°ES 2.75 3.48 12.5 32.7 111400 109200 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 INSPECTION AND SERVICE 8 716 106 252f (03/2010)
- Page 43 23 Circulation pump UPS 15-60 Part Number: 8 718 685 525 0 24 Control board Part Number: 8 718 685 261 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 SHORT PARTS LIST 8 716 106 252f (03/2010) BENTONE 40 - 12/18...
- Page 44 23 Circulation pump UPS 15-60 Part Number: 8 718 685 525 0 24 Control board Part Number: 8 718 685 261 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 SHORT PARTS LIST 8 716 106 252f (03/2010) BENTONE 50 - 18/25...
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Page 45: Short Parts List Riello Rdb
20 Circulation pump UPS 15-60 Part Number: 8 718 685 525 0 21 Control board Part Number: 8 718 685 261 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 SHORT PARTS LIST 8 716 106 252f (03/2010) RIELLO RDB 1 - 12/18... -
Page 46: Short Parts List Riello Rdb 2.2
20 Circulation pump UPS 15-60 Part Number: 8 718 685 525 0 21 Control board Part Number: 8 718 685 261 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 SHORT PARTS LIST 8 716 106 252f (03/2010) RIELLO RDB 2.2 - 18/25... -
Page 47: Short Parts List Riello Rdb 2.2 - 25/32
20 Circulation pump UPS 15-70 Part Number: 8 718 685 526 0 21 Control board Part Number: 8 718 685 261 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 SHORT PARTS LIST 8 716 106 252f (03/2010) RIELLO RDB 2.2 - 25/32... -
Page 48: Fault Finding & Diagnosis
Incorrect components used on Check with installation instructions APPLIANCE BE LEFT TO OPERATE WITH combustion head ANY CONTROL LINKED OUT OR OVERRIDDEN. Faulty nozzle Replace nozzle INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 FAULT FINDING 8 716 106 252f (03/2010) - Page 49 Rectify burner operation and lockouts operation, numerous lockouts Odour in boiler room, oil leaks Rectify oil leaks, replace components if from pipework, flexible hoses necessary connections INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 FAULT FINDING 8 716 106 252f (03/2010)
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Page 50: Riello Control Box Operation
Whilst every effort has been taken to ensure the information given is CONTROL BOX OPERATION 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. STATUS... -
Page 51: Fault Finding Logic For Satronic Control Box
Stray light Replace Replace Photo cell Replace coil Boiler not on photo control box lead lead OK? lead operating cell? with a heating / hot water demand 230V at Disconnect photo cell, Replace Replace Coil lead Replace solenoid coil reset lockout, burner pump control box photo cell... -
Page 52: Fault Finding Logic For Riello Control Box
FAULT FINDING & DIAGRAMS MO535 IMPORTANT NOTE: The box has a built in delay of 11 seconds before activating the motor. The preheater link must be fitted at for the box to operate Replace Replace Boiler not control box nozzle operating with a heating /... -
Page 53: Electrical Schematic
MANUAL RESET TANK OVERHEAT LOCKOUT THERMOSTAT INDICATOR POWER ON INDICATOR X11 (PIN 2) X11 (PIN 3) brown X12 (PIN 3) X9 (PIN 1) X9 (PIN 2) X7 (PIN 1) X3 (PIN 3 (L)) white brown X7 (PIN 4) PUMP X7 (PIN 3) FROST THERMOSTATS (if fitted) brown RELAY 1... -
Page 54: Commissioning Checklist
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. - Page 55 8 716 106 252f 30/3/10 12:56 Page 55 SERVICE 2 SERVICE 1 DATE DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No. TEL No. OFTEC REG No. OFTEC REG No. PUMP PRESSURE: PUMP PRESSURE: NOZZLE CHANGED? NOZZLE CHANGED? F.G.T.
- Page 56 WEBSITE (EIRE): worcester-bosch.ie- Dedicated to heating comfort Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0844 892 9900 Fax. 01905 754619 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. www.worcester-bosch.co.uk 8 716 106 252f (03/2010)