Worcester GREENSTAR II HE OIL 12/22 Installation And Servicing Instructions page 21

2. Clean the fan impeller using the following procedure:
(a) Remove the air adjustment cover.
(b) Separate the main body of the burner from the burner front
by removing the M6 allen screw (located beneath the air
adjustment screw), using a 5mm allen key.
(c) Note the position of the air damper adjustment and check
the air damper moves freely.
(d) Check the air path to the burner head is clear.
(e) Clean both sides of the fan impeller and remove any debris
from the burner housing.
(f) Check the impeller rotates freely.
(g) Re-assemble the components.
Fig. 28. Mechanical Shut-off Valve.
4. Inspection of Mechanical Shut-off Valve. (See Fig. 28)
a) Remove the nozzle.
b) Fasten an M5 screw, with a minimum length of 30mm, into the
threaded hole (A) and pull the screw to withdraw the check valve.
c) Check that the nozzle holder is clear of any debris and clean if
necessary.
d) Check that the 3 holes in the check valve are clear of any
debris. Discard the check valve if the holes cannot be cleared or
if the unit is defective and replace with a new one.
e) Replace in the reverse order.
5. It is strongly recommended that the oil atomising nozzle is
replaced at each service.
6. Check and reset the electrodes, where necessary, as shown in
Fig. 27.
7. Replace the combustion head and check that the nozzle lies
central to the combustion head and the head settings are as
shown in Fig. 27.
8. Withdraw the photocell from its housing and clean.
9. Remove and clean the oil pump internal filter using kerosene
or white spirit. The internal filter is accessed by removing the oil
pump cover on the Danfoss BFP 11 and Suntec AS47C as
indicated in Fig. 15.
10. It is recommended that the standard flexible oil line is
replaced at each yearly service to prevent the possibility of a
leak due to ageing.
11. Re-assemble the burner components.
12. Check the sponge O-ring seal located around the
combustion head and replace if necessary. It is imperative that
this seal is in good condition since failure will cause the flue
gases to escape.
14.4 Remove the paper element from the external oil filter and
replace. If the filter contains a washable element then
thoroughly clean in Kerosene or white spirit and re-assemble
into the filter.
14.5 Clean the air duct tube.
1. Remove the air duct from the burner.
2. Shine a light down the air duct and inspect for any sign of
debris and clean where necessary using a flexible hose
connected to a vacuum cleaner. A short length of garden hose
would be suitable for this purpose.
3. Reconnect the air duct tube.
14.6 Clean the Boiler (See Fig. 29)
1. Remove the boiler top access plate (3) by releasing the bolts
(2) with a 6mm Allen key and check the fibreglass rope seal.
Replace the seal if necessary.
2. Remove the flue deflector (4).
3.Remove the main baffle assembly (5), clean and check its
condition. Replace if considered to be badly corroded.
4. Thoroughly clean all of the heat exchanger surfaces using a stiff
wire brush and vacuum clean all loose debris from the combustion
chamber. Take care not to damage the base insulation!
5. Check the heat shield.
6.Check the condition of the combustion chamber base
insulation and replace if there is any sign of significant damage.
7. Check and clean the flue.
8. Reassemble all parts and be sure:
not to reverse them
to position the flue deflector with its
locating screw towards the front of the
boiler.
to position the cast iron plate against marker
opposite the locating screw.
Fig. 29. Boiler shell and baffles.
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1
1. Heat exchanger
2. Cover screws
3. Cover
4. Flue deflector
5. Baffle assembly
6. Locator pin
Fig. 30. Secondary heat exchanger.
4
5
6
8
7
1. Secondary heat exchanger
2. Combustion products screw
3. Inspection port
4. Wing nut
5. Cover
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3
2
2
3
4
3
2
6
5
1 2
1
5
5
4
4
1
1
1
3
2
6. Seal
7. Stainless steel tubes
8. Baffles
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