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Installation, Commisioning and Servicing instructions
Floor standing oil fired condensing combination boiler balanced flue
ErP
Greenstar Heatslave II External
12/18, 18/25 & 25/32
For fully pumped open vent or sealed central heating systems and domestic hot water cylinders.
These appliances are for use with Kerosene (Class C2) only.
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Table of Contents
Related Manuals for Worcester Greenstar Heatslave II 12/18
Summary of Contents for Worcester Greenstar Heatslave II 12/18
- Page 1 Installation, Commisioning and Servicing instructions Floor standing oil fired condensing combination boiler balanced flue Greenstar Heatslave II External 12/18, 18/25 & 25/32 For fully pumped open vent or sealed central heating systems and domestic hot water cylinders. These appliances are for use with Kerosene (Class C2) only.
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Page 2: Table Of Contents
Contents Contents Key to symbols and safety instructions ....3 Service and Spares ........32 Key to symbols . -
Page 3: Key To Symbols And Safety Instructions
Read these instructions before starting any installation Installation, commissioning and servicing These instructions are applicable to the Worcester appliance model(s) Installation, commissioning and servicing must only be carried out by a stated on the front cove of this manual only and must not be used with competent registered engineer. -
Page 4: Installation Regulations
Installation regulations Fitting and Modification operation the appliance must be commissioned by a qualified OFTEC engineer. Fitting the appliance and any controls to the appliance may only be carried out by a competent engineer in accordance with these The compliance with a British Standard does not, in itself, confer instructions and the relevant Installation Regulations. -
Page 5: Appliance Information
Appliance information Appliance information General information Technical data Description Units 12/18 18/25 25/32 Standard package Central heating Primary water capacity (total) litres Available pump head (20°C metres difference) at max. output water Max. permissible system operating pressure in accordance with WRAS guidelines Flow restrictor colour Lime Beige Grey... -
Page 6: Energy Efficiency
Appliance information Energy efficiency The following product data satisfy the requirements of the EU Regulations No. 811/2013 and No. 812/2013 supplementing Directive 2010/30/EU. Product data Symbol Unit 7731600050 7731600051 7731600052 Product type – – Greenstar Heatslave II Greenstar Heatslave II Greenstar Heatslave II External 12/18... -
Page 7: Layout & Components
Appliance information Layout & components The diagram below excludes the top, front and RH side casing panels. 10 11 7 8 9 Fig. 2 Greenstar Heatslave II External ErP - 6 720 813 345 (2014/09) -
Page 8: Pre-Installation
[16] CONDENSATE OUTLET ▶ It is recommended that a primary water cleanser is [17] CONDENSATE TRAP fitted to the system. Worcester offers a system filter [18] CONDENSATE DRAIN PIPE that helps remove both magnetite and non-magnetic [19] FLEXIBLE CONDENSATE DRAIN PIPE CONNECTION debris. -
Page 9: Mains Supply
Pre-Installation ARTIFICIALLY SOFTENED WATER It is possible to have an ion exchange water softener fitted to the cold water system of the property. However, the boiler requires an untreated cold water connection taken from the mains supply, before the water softener, to the primary water filling point of the heating system. -
Page 10: Pipework
Pre-Installation Single pipe gravity feed system Maximum pipe run for double pipe sub-gravity fed system The oil storage tank [1] must be positioned so that the oil level does not Head [M] 10mmØ 12mmØ Head [M] 10mmØ 12mmØ exceed 4 metres above the level of the burner oil pump [9] and in addition the oil level must be at least 300mm above the oil pump [9]. -
Page 11: Boiler Isolation Valve
Pre-Installation ▶ Fit a fire valve in accordance with BS 5410. The fire valve [5] should • Pressurise the extra expansion vessel (B) to the same figure as the be fitted externally to the building with the fire valve sensor [8] expansion vessel (A) built into the appliance. -
Page 12: Condensate Pipework
Pre-Installation Condensate pipework Mini expansion vessel ▶ The condensate pipe must be nominally (0.75ltr capacity) 21.5mm Ø Polypropylene pipe. Hot water supply ▶ The condensate pipe work must fall at least 52mm to property per metre towards the outlet and should take the Greenstar Heatslave II shortest practicable route. -
Page 13: Soak Away
Pre-Installation 400mm min. 25mm min. 500mm min. 21.5mm Ø 21.5mm Ø Fig. 12 Disposal into a rainwater down pipe Where the pipe terminates over an open drain or gully, the pipe should terminate below the grating level, but above water level, in order to minimise “wind chill”... -
Page 14: Pressure Relief Pipework
Pre-Installation Pressure relief pipework 600mm • The pressure relief discharge pipe [2]should be at least 15mm diameter copper pipe and run downwards away from the boiler and discharge away from any electrical or other hazard, preferably to an external drain or soakaway. •... -
Page 15: Flue Terminal Positions
Pre-Installation Flue terminal positions boundary C, D boundary 6720809437-30.1Wo Fig. 20 External boiler flue terminal positions Terminal position Balanced horizontal flue Directly below an opening, air brick, opening window etc. 600mm Horizontally to an opening, air brick, opening window, etc. 600mm Below a plastic/painted gutter, drainage pipe or eaves if combustible material is protected 75mm... -
Page 16: Flue Options
Pre-Installation Flue options 4.8.1 Cabinet mounted balanced horizontal flue options It is strongly recommended that the flue terminal faces away from walls to minimise the occurrence of wetting. • The horizontal flue is fitted to the rear or either side of the cabinet. REAR FLUE OUTLET 6720645523-50.1Wo Fig. -
Page 17: Installation
Installation All dimensions in mm Installation Unpacking the boiler Flue All the previous Pre-Installation sections must be read and requirements met before starting boiler or flue Services installation Condensate LIFTING AND CARRYING PRECAUTIONS: ▶ Lift only a manageable weight, or ask for help. ▶... -
Page 18: Boiler Installation
Installation 4. Remove the key [A] for the door fasteners from the literature pack. For servicing purposes, keep the condensate and Undo the screws at the bottom of the front panel [B] using the key pressure relief (PRV) discharge pipes away from provided and remove the screws from the rear panel [C] - (optional) components and pipe work connections. -
Page 19: Pipework Connections
Installation Pipework connections CAUTION: Isolate the oil & water mains supply before starting any work and observe all relevant safety precautions. 12/18 kW Baffle 18/25 & 25/32 kW Baffle 6720805209-86.1Wo Fig. 27 ▶ Ensure one piece baffle set [C] is in the right location [D], correctly resting on the baffle rests [F] on either side of the combustion chamber and pushed securely into place. -
Page 20: Oil Burner And Pump
Installation Water connections ▶ Ensure all pipework is clean. That surplus water may be present due to factory testing. ▶ Align water pipework and connect ▶ Check that all unused sockets have been capped. Oil supply connections ▶ Route the oil supply pipe [W] along either side of the boiler as required and connect to the isolating valve [G] and ensure the valve is closed. -
Page 21: Refitting Components
Installation 6720805460-39.1Wo Fig. 31 Inlet pipe connection Return plug By-pass screw Brass air defector washer (12/18 models only) Locating circlip Electrode fixing screw Refitting components 1. Align burner combustion head into the boiler collar. ▶ Locate the burner retainer [A] over the threaded lug on the collar [B], push the burner firmly into the flange and secure in place with the retaining nut [C]. - Page 22 DHW. All Worcester twin channel digital controls provide this functionality, but the link is required for them to function. Fig. 34 External 230 V Twin Channel Programmer and Room...
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Page 23: Electrical Schematic
Installation 5.10 Electrical schematic Fig. 36 Greenstar Heatslave II External ErP - 6 720 813 345 (2014/09) -
Page 24: Weather Compensation
Installation 5.11 Weather compensation The sensor is wired directly into the control box via terminal 4 in the low voltage terminal strip ( page 22). The appliance will modulate the CH flow temperature based on the outside temperature when an outdoor sensor is connected to the The heating curve outdoor sensor connection on the control board and the weather The CH flow temperature has an upper limit of 82°C (this can be capped... -
Page 25: Filling System
Commissioning NOTICE: Commissioning If the boiler is not to be commissioned immediately then: Pre-commissioning checks-appliance After successfully completing all of the checks and any rectification work, close the water valves, shut off the oil CAUTION: Isolate the mains supplies before starting supply and electrically isolate the boiler. -
Page 26: Starting The Appliance
Commissioning Starting the appliance Total system volume Initial system Initial charge (litres) pressure (bar) pressure (bar) NOTICE: Never run the appliance when the appliance/system is unpressurised or empty. 1. Check the oil supply is correctly fitted, pressure tested and in good Table 6 working order before turning on the oil supply valves to the boiler. - Page 27 Commissioning lockout state indicated on the control panel LCD display [J] by code A - Bleed & pressure gauge port 9F 855. B - Pressure adjustment C - Vacuum gauge port ▶ Wait two minutes then press the lockout reset button [K] to initiate D - Retaining screws - cover another start sequence.
- Page 28 Commissioning Smoke readings may be inaccurate until the smoke from burning organic binder in the access door insulation has ceased. Fig. 51 Control board: Spanner/return button Reset button ECO button Boiler LCD display Central heating temperature control Scroll up button OK - Select/confirmation button Scroll down button Operation and fault indicator (blue)
- Page 29 Commissioning Centigrade symbol Displays next to the temperature reading. Confirmation symbol This symbol confirms a manual change. Alpha/Numerical display Displays a temperature or boiler status code. Text display Displays ECO or diagnostic code. Status code During normal operation various status codes can be displayed by pressing the service button.
- Page 30 Oil pump pressure Fuel flow rate temperature air setting (appliance) (appliance) disk setting Burner head Nozzle Kg/h °C %CO2 Greenstar Heatslave II 12/18 model 0.35 x 80° SR 1.04 1.32 11.0 12.4 12.0 12/15 LD2X Short 0.45 x 60° ES 1.28 1.63 11.5...
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Page 31: Water Treatment
Commissioning Water treatment NOTICE: 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. Flushing (Central heating) 1. Switch off the boiler. ▶... -
Page 32: Finishing Commissioning - Appliance
Service and Spares Finishing commissioning - Appliance Do not use pressure washers or steam cleaners on this 1. Rotate the control box [A] towards you. appliance or its cabinet. Slide back into position [B]. 2. Refit the top panel [C] and press down to compress the seal when fitting the securing screws at each corner. - Page 33 Service and Spares ▶ Check and clean the baffle retainers. ▶ Check and clean the baffles. ▶ Check and clean the heat exchangers surfaces. ▶ Check the combustion chamber access door insulation board. ▶ Check that the flue system is unobstructed and clean as necessary. ▶...
- Page 34 Service and Spares ▶ Release the trap locking tab [I] and move the trap up and back to Combustion chamber remove from its mountings. ▶ Remove the retaining nuts and washers [A]. ▶ Clean the trap by flushing with water. ▶...
- Page 35 Service and Spares Refit control box 12/18kW Baffle 5. Rotate the box towards you [J]. ▶ Slide control box drawer back into position. Refit panels 6. Refit the top panel [K] and press down to compress the seal when 18/25 & 25/32 kW Baffle fitting the securing screws at each corner.
- Page 36 Oil pump pressure Fuel flow rate temperature air setting (appliance) (appliance) disk setting Burner head Nozzle Kg/h °C %CO2 Greenstar Heatslave II 12/18 model 0.35 x 80° SR 1.04 1.32 11.0 12.4 12.0 12/15 LD2X Short 0.45 x 60° ES 1.28 1.63 11.5...
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Page 37: Short Parts Lists 12/18
Service and Spares Short parts lists 12/18 Description Part No. Combustion head - LD2X SH12/18 8 716 112 731 0 Control box MO535 MRF 8 718 682 250 0 Photocell 8 716 109 193 0 Ignition electrode 8 716 109 211 0 Motor 8 716 110 522 0 Oil pump - Riello RDB... -
Page 38: Short Parts Lists 18/25
Service and Spares Short parts lists 18/25 Description Part number Combustion head - LD2SX 18/25 8 718 682 170 0 Control box MO535 MRF 8 718 682 250 0 Photocell 8 716 109 193 0 Ignition electrode 8 716 109 211 0 Motor 8 716 110 522 0 Oil pump - Riello RDB... -
Page 39: Short Parts Lists 25/32
Service and Spares Short parts lists 25/32 Description Part number Combustion head - T2 SH 25/32 8 716 112 780 0 Control box MO535 MRF 8 718 682 250 0 Photocell 8 716 109 193 0 Ignition electrode 8 716 109 211 0 Motor 8 716 110 522 0 Oil pump - Riello RDB... -
Page 40: Fault Finding And Diagnosis
Fault finding and diagnosis Fault finding and diagnosis Status cause codes These cause codes are displayed during the normal operation of the boiler. They are not faults, they just give information on the current status of the boiler in real time. Cause code During normal operation various status codes can be displayed by pressing the service button. -
Page 41: Service Menus
Fault finding and diagnosis i13 Thermal This is the thermal store current temperature, store displayed in real time (rounded to 0.5°C units). current temperature i14 DCW inlet Current DCW inlet temperature displayed in real temperature time (rounded to 0.5°C units). i15 Out door This is the out door temperature displayed in real temperature... -
Page 42: Factory Reset And Fault Codes
Fault finding and diagnosis reset 2. Press the button and “reset” will be displayed with the tick symbol for 3 seconds. After 3 seconds the display will revert to the normal operation screen. 6 720 805 209-67.1TL Fig. 81 2.7A Demand/fault O = The blue light will only LED (blue light) activation operate as a flashing fault... -
Page 43: Cause And Fault Codes
Fault finding and diagnosis 8.4.3 Cause and fault codes Cause Fault Reset code code Description type Blocking Locking Possible cause Max temperature thermostat activated Reset Flue gas or tank thermostat overheat. Reset the overheat thermostat before resetting the appliance. Safety or flow temperature rises too high Air lock or reduced water content. -
Page 44: Dhw Function Chart
Fault finding and diagnosis DHW function chart Fig. 84 Greenstar Heatslave II External ErP - 6 720 813 345 (2014/09) -
Page 45: Ch Function Chart
Fault finding and diagnosis CH function chart Flow at more than Flow temp peaks: Burner CH setpoint minus CH adaptive offset CH adaptive setpoint adjusted [200] [200] [200] 230V on CH LR AND fascia mounted NO DEMAND Blue light ON Flow temp less than Appliance programmer CH =... -
Page 46: Solar Compatibility
Fault finding and diagnosis Power interruption during lockout Any CUS Mains F0 263 Normal Mains Press reset lockout - Blue power lockout - Blue operation power loss button light flashing restored light flashing IF the original lockout 9F 855 was due to a burner Press reset lockout - Blue lockout (9F, 855) then... -
Page 47: Burner Diagnostics Mode
Fault finding and diagnosis Burner diagnostics mode Service/installation engineers only. To access the Burner control box diagnostics or to use the burner reset button to reset the burner, the burner diagnostic mode must be activated as follows: Burner LOCKOUT Hold down the The controls Release Blue light flashing &... -
Page 48: Riello Digital Control Boxes
Fault finding and diagnosis 8.10 Riello digital control boxes RIELLO MO535 MRF DIGITAL CONTROL BOX FAULT FINDING LOGIC PRE-HEATER LINK FITTED FIT PRE-HEATER LINK Fig. 90 Greenstar Heatslave II External ErP - 6 720 813 345 (2014/09) - Page 49 Fault finding and diagnosis 6 720 805 209-76.1TL Fig. 91 Greenstar Heatslave II External ErP - 6 720 813 345 (2014/09)
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Page 50: Oil Supply Vacuum Testing
Fault finding and diagnosis 8.11 Oil supply vacuum testing A vacuum gauge can be attached to the oil pump vacuum test port [1] and the boiler operated to check the vacuum readings. Oil pumps can operate if readings are between plus 0.4 bar and minus 0.35 bar. This means oil tanks can be 4 metres higher (to top of oil) or 3.5 metres lower (if fitted with a de-aerator or two-pipe oil delivery system) than the oil pump. - Page 51 Notes Greenstar Heatslave II External ErP - 6 720 813 345 (2014/09)
- Page 52 Notes Greenstar Heatslave II External ErP - 6 720 813 345 (2014/09)
- Page 53 Notes Greenstar Heatslave II External ErP - 6 720 813 345 (2014/09)
- Page 54 OIL BOILER COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. BOILER DETAILS Boiler Make and Model Boiler Serial Number...
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Page 55: Service Interval Record
SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the manufacturer’s instructions. - Page 56 Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0330 123 9559 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. worcester-bosch.co.uk 6 720 813 345 (2014/09)