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Worcester GREENSTAR II HE OIL 12/22 Installation And Servicing Instructions

Room sealed bf floor standing oil-fired, condensing pressure jet appliance
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GREENSTAR II HE OIL
12/22
ROOM SEALED BF FLOOR STANDING OIL-FIRED
CONDENSING PRESSURE JET APPLIANCE
INSTALLATION AND

SERVICING INSTRUCTIONS

POWER ON
TEMP
LOCK OUT
GREENSTAR
HE 12/22
BOILER OUTPUT
Hot Water and Central Heating
12/22 MINIMUM 12 kW (41,000 Btu/h)
MAXIMUM 22 kW (75,000 Btu/h)
THESE INSTRUCTIONS APPLY TO UK MODELS ONLY
THESE INSTRUCTIONS ARE TO BE LEFT WITH THE APPLIANCE

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Summary of Contents for Worcester GREENSTAR II HE OIL 12/22

  • Page 1: Servicing Instructions

    GREENSTAR II HE OIL 12/22 ROOM SEALED BF FLOOR STANDING OIL-FIRED CONDENSING PRESSURE JET APPLIANCE INSTALLATION AND SERVICING INSTRUCTIONS POWER ON TEMP LOCK OUT GREENSTAR HE 12/22 BOILER OUTPUT Hot Water and Central Heating 12/22 MINIMUM 12 kW (41,000 Btu/h) MAXIMUM 22 kW (75,000 Btu/h) THESE INSTRUCTIONS APPLY TO UK MODELS ONLY THESE INSTRUCTIONS ARE TO BE LEFT WITH THE APPLIANCE...

  • Page 2: Table Of Contents

    Contents 1. Installation Regulations ...........Page 2 9. Heating and Hot Water System.......Page 13 2. General Information ..........Page 2 10. Electrical ..............Page 14 11. Installation ..............Page 18 3. Technical Data............Page 2 12. Commissioning the Appliance ........Page 19 4. Siting the Appliance ..........Page 4 5.
  • Page 3 Fig. 1. Principal Dimensions (All Dimensions are millimetres) POWER ON TEMP LOCK OUT GREENSTAR HE 12/22 12/22 Table 2. Electro Oil Bentone Sterling 40 Burner (See Fig. 27) RS Balanced Flue Appliance NOMINAL BOILER RATING AT NORMAL OPERATING TEMPERATURE Appliance Pump Fuel Flow Flue Gas...

  • Page 4: Siting The Appliance

    4. Siting the Appliance 6. Air Supply 4.1 The appliance is not suitable for external installation unless 6.1 The appliance does not require a separate vent for a suitable enclosure is provided. combustion air. 4.2 The appliance should be positioned on a non-combustible 6.2 Installation in cupboards or compartments requires solid base as near to the flue termination point as possible.
  • Page 5 Fig. 2. Components Control panel 13) Auto air vent connection 14) Heating flow Condenser drain point Secondary heat exchanger 15) Heating return Combustion product test point 16) Combustion products flue exit Secondary heat exchanger inspection/cleaning port 17) Electrical cover plate Condensate drain Heat exchanger drain point Burner air inlet pipe...
  • Page 6 Fig. 3. Principle of Operation Heating circuit return Heating circuit output The Greenstar HE Oil 12/22 is a sealed exhaust cir- cuit condensation boiler. Air is drawn in by the burner's fan from outside the appliance through the hose connected to the air inlet and combustion product evacuation concentric tube.

  • Page 7: Flue System

    Fig. 5. Extended Horizontal Flue 7. Flue System A flue system provided by Worcester Bosch, must be fitted in accordance with BS5410:Part 1 and the Building Regulations. The appliance is supplied ready for installation to a balanced flue system by the simple addition of one of the flue terminal kit options shown in Figs.
  • Page 8 Fig. 8. Flue with one 90° and two 45° Bends Fig. 11. Vertical Flue 300mm Total straight length 1+2+3 Total straight length 1+2+3 minimum must not exceed 3000mm must not exceed 3000mm 125mm 125mm (5") (5") 125mm 125mm (5") (5") Diameter Diameter 1150 - 5000mm...
  • Page 9 Fig. 14. Flue terminating positions for oil-fired appliances NOTE: The dimensions given are for general guidance only. Other surrounding buildings or objects may affect the clearance of combustion products. An alternative flue terminal position should be sought when there is any possibility of a nuisance being caused by inadequate dispersal of flue products.

  • Page 10: Oil Supply

    8. Oil Supply Fig. 15. Oil Pump. A. Danfoss BFP 11 Oil Pump. (See Fig. 16). 8.1 Plastic or steel tanks should be installed to BS5410. A steel tank should also conform to BS799: part 5 and be arranged 1. Inlet with a slope of 1 in 24 away from the outlet valve with a sludge 2.
  • Page 11 TABLE 6 Single Pipe Suction Lift with De-aerator MAXIMUM ALLOWABLE PIPE RUN FROM TANK TO DE-AERATOR (metres) Fuel Flowrate 2.5 (kg/h) 5.0 (kg/h) 10.0 (kg/h) 10.0 (kg/h) HEAD 6 mm inside dia. pipe 8 mm inside dia. pipe (metres) (8 mm O.D. copper) (10 mm O.D.
  • Page 12 Fig. 17. Typical Open Vent Fully Pumped System (Honeywell ‘Y’ plan). Fig. 18. Typical fully pumped sealed system (Honeywell ‘Y’ plan). Automatic air vent Domestic hot water cylinder Diverting N.B. A drain cock should be valve installed at the lowest point of Pressure the heating circuit Safety valve...

  • Page 13: Heating And Hot Water System

    Fig. 19. System filling and make-up Make up vessel Auto air vent Non return Heating valve return 30mm (12in) min. above highest point of the system Stop cock Fill point. Heating return Method 1 Method 2 9. Heating and Hot Water System 9.1 The appliance is suitable for connection to all conventional indi- rect hot water systems utilising an indirect double feed cylinder.

  • Page 14: Electrical

    requirements of BS5449: Part 1. The boiler must be fitted with a If the system is fully pre-wired at a junction box remotely from spring loaded safety valve set to operate at 3 bar (45 psi) and the boiler it can be connected to the boiler. The diagram shows the pipe connections made throughout the system must be connection details of two proprietary systems (Honeywell and capable of sustaining a pressure of up to 3 bar.
  • Page 15 Fig. 20. Wiring Diagram (Standard). Mains supply 230V 50Hz E N L Brown Earth Stud Green/Yellow Blue Blue White Grey Green/Yellow Brown Flue Overheat Manual reset Time clock thermostat thermostat white 7 8 9 10 connector L N E E N 1 2 3 4 5 6 Brown Blue Green/Yellow...
  • Page 16 Fig. 22. Pre-wired Remote ‘Y’ Plan or ‘S’ Plan. NOTE: When using a WHS programmer set the switch on the rear of the programmer to ‘P’. Remove link 1 to 3 NOTE: If a frost thermostat is required it can be wired to the remote junction box. NOTE: The 10 way junction box must be a terminal block type and current rated Remote Pre-wired...
  • Page 17 Fig. 23. Honeywell ‘S’ Plan. NOTE: When using a WHS programmer set the switch on the rear of the programmer to ‘P’. Remove link 1 to 3 and link 2 to 4 and make link 3 to 4 Room thermostat Heating Valve.

  • Page 18: Installation

    (c) Single pipe system oil supply pipe. Fig. 25. Frost Protection. 1. Bend a piece of 10mm or 12mm copper tube (as selected) to the correct profile to allow the pipe to be fed down the side of the appliance. The pipe may be routed along either the right or left hand side of the boiler as required.

  • Page 19: Commissioning The Appliance

    port. Re-lock the bleed port. 12. Commissioning the Appliance Two Pipe System A two pipe system will automatically vent the air back to the oil tank. Turn on the boiler thermostat and allow the burner to run Ensure that no foreign matter is left in the system as this could through to lockout.

  • Page 20: Instructions To The User

    12.15 Remove the oil pressure gauge and manifold and check 14. Routine Cleaning and Inspection all oil system joints for any signs of leakage. 12.16 Allow the burner to run for a further five minutes and then recheck the CO level and adjust the air setting if required.
  • Page 21 2. Clean the fan impeller using the following procedure: 14.6 Clean the Boiler (See Fig. 29) 1. Remove the boiler top access plate (3) by releasing the bolts (a) Remove the air adjustment cover. (2) with a 6mm Allen key and check the fibreglass rope seal. (b) Separate the main body of the burner from the burner front Replace the seal if necessary.
  • Page 22 14.7 Secondary Heat Exchanger. (See Fig. 30) 14.9 Recommission the Burner. Clean the secondary heat exchanger. 1. Connect the flexible oil supply hose to the isolating valve and tighten sufficently to form a good seal. Where a double pipe Remove the wing nut (4) and heat exchanger cover (5). system is being used connect the oil return flexible hose to the Remove each baffle (8), clean and check condition.

  • Page 23: Short Parts List

    15. Short Parts List Item Part Manufacturer’s Reference Ref. Part No. BOILER Front Panel Equipped FCX Greenstar HE Oil 12/22 Y 72.31765 8 716 105 396 0 ELECTRICAL BOX Casing for Clock Housing W 72.31736 8 716 148 124 0 BOILER Right Panel Equipped FCX Greenstar HE Oil 12/22 Y 72.31770...

  • Page 25: Fault Finding

    16. Fault Finding...
  • Page 28 Worcester Heat Systems Limited, Cotswold Way, Warndon, Worcester WR4 9SW. Telephone: (01905) 754624. Fax: (01905) 754619. Technical Helpline: (0990) 266241. This booklet is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or appearances are changed in the interests of continued improvement.

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