Worcester GREENSTAR 12/18 Instruction Manual
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Worcester GREENSTAR 12/18 Instruction Manual

Danesmoor wall mounted oil fired condensing boiler conventional flue & room sealed flue
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See also: Instructions for Using , Instruction Manual
GREENSTAR DANESMOOR WALL MOUNTED
12/18 & 18/25
WALL MOUNTED OIL FIRED CONDENSING BOILER
CONVENTIONAL FLUE & ROOM SEALED FLUE
FOR FULLY PUMPED OPEN VENT OR SEALED CENTRAL HEATING SYSTEMS AND DOMESTIC
HOT WATER CYLINDERS
THE APPLIANCE IS FOR USE WITH KEROSENE (28 SECOND
THE APPLIANCE IS FOR USE WITH KEROSENE (28 SECOND
OIL) ONLY
OIL) ONLY
INSTRUCTION MANUAL
INSTRUCTION MANUAL
INSTALLATION COMMISSIONING
& SERVICING
GB
GB

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  • Page 1 GREENSTAR DANESMOOR WALL MOUNTED 12/18 & 18/25 WALL MOUNTED OIL FIRED CONDENSING BOILER CONVENTIONAL FLUE & ROOM SEALED FLUE FOR FULLY PUMPED OPEN VENT OR SEALED CENTRAL HEATING SYSTEMS AND DOMESTIC HOT WATER CYLINDERS THE APPLIANCE IS FOR USE WITH KEROSENE (28 SECOND THE APPLIANCE IS FOR USE WITH KEROSENE (28 SECOND OIL) ONLY OIL) ONLY...
  • Page 2 Wear protective clothing and gloves to Warranty Return Envelope.............................. 1 protect from any sharp edges. Guarantee Registration Card............................1 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 INSTALLATION & 8 718 681 134a (08.08) SERVICING INSTRUCTIONS...

  • Page 3: Table Of Contents

    FAULT FINDING - HEATING & HOT WATER FAULT FINDING - BOILER FUNCTION DIAGNOSTICS FOR MO535 RDB CONTROL BOX MO535 RDB CONTROL BOX OPERATION COMBUSTION RECORD SERVICE INTERVAL RECORD INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 CONTENTS 8 718 681 134a (08.08)

  • Page 4: Safety Precautions

    OFTEC Standards. Where no specific instruction is given, reference should be made to the relevant codes of practice. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 SAFETY PRECAUTIONS 8 718 681 134a (08.08) & INSTALLATION REGULATIONS...

  • Page 5: General Information

    Casing Bolts..................................6 Literature Pack: Greenstar Danesmoor Wall Mounted Installation/Servicing Instructions..........1 Users Instructions................................1 Warranty Return Envelope.............................. 1 Guarantee Registration Card............................1 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 GENERAL INFORMATION 8 718 681 134a (08.08)

  • Page 6: Technical Data

    Appliance protection rating (with programmer blanking plate) Appliance weight (dry) 108.5 108.5 Lift weight Emissions class for NOx and CO class Typical NOx emission figures mg/kWhr INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 TECHNICAL DATA 8 718 681 134a (08.08)

  • Page 7: Layout & Components

    (LOCATED UNDER HEAT EXCHANGER) 35. PRIMARY HEAT EXCHANGER 37. BURNER SERVICE SUPPORT 38. PRIMARY HEAT EXCHANGER BLEED POINT 39. BOILER LIFTING HANDLE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 LAYOUT & 8 718 681 134a (08.08) COMPONENTS...

  • Page 8: Cleaning Primary Systems

    Drain and thoroughly flush the system to remove the flushing agent and any debris. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 CLEANING 8 718 681 134a (08.08) PRIMARY SYSTEMS...

  • Page 9: Mains Supply

    • Any system connected to the boiler must not have a separate electrical supply. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 MAINS SUPPLY 8 718 681 134a (08.08)

  • Page 10: Oil Supply

    The table and illustration above is a guide only and does not in any way override the de- as the sole fire protection device. aerator manufacturers instructions. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 OIL SUPPLY 8 718 681 134a (08.08)

  • Page 11: Water Systems & Pipework

    • A pressure gauge (G), 3 bar minimum, must be fitted to the heating flow pipe. • An automatic air vent (N) must be fitted. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 WATER SYSTEMS & 8 718 681 134a (08.08)

  • Page 12: Water Systems & Pipework

    Heating return Auto air vent Non return 1000mm above valve the highest point of the system Stop cock Fill Point INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 WATER SYSTEMS & 8 718 681 134a (08.08) PIPEWORK...

  • Page 13: Condensate Pipework

    G - Ground level. H - Drainage holes 50mm from base of tube (12mm Ø at 25mm centres) facing away from building. Limestone chippings. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 CONDENSATE PIPEWORK 8 718 681 134a (08.08)

  • Page 14: Pressure Relief Pipework

    • Pipe (A) should be finished with a partial bend, near the outlet to face the external wall (as shown) to help prevent freezing. Drain pipe. Outside wall. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 PRESSURE RELIEF PIPEWORK 8 718 681 134a (08.08)

  • Page 15: Boiler Location & Clearances

    * Due to changes in BS 5410 and modern 18/25 building design, these figures no longer incorporate the adventitious ventilation allowance. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 BOILER LOCATION & 8 718 681 134a (08.08) CLEARANCES...

  • Page 16: Boiler Location & Clearances

    Please refer to IEE regulations for cross bonding requirements. 600mm radius A - Bath or shower cubicle (zone 0) INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 FBOILER LOCATION & 8 718 681 134a (08.08) CLEARANCES...

  • Page 17: Flue Terminal Positions

    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. Flat roof boundary Pitched roof C, D boundary INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 FLUE TERMINAL 8 718 681 134a (08.08) POSITIONS...

  • Page 18: 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 DANESMOOR WALL MOUNTED OIL 12/18-18/25 CONVENTIONAL FLUE 8 718 681 134a (08.08)

  • Page 19: Room Sealed Flue Options

    950mm. Flue Terminal lengths: Horizontal 80/125mm Ø: 720mm Vertical 80/125mm Ø: 1080mm + cage * to outside wall. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 ROOM SEALED FLUE 8 718 681 134a (08.08) OPTIONS...

  • Page 20: Unpacking The Boiler

    The unpacking of the appliance requires the removal of the board support at the base of the boiler. Instructions for this are on the following pages. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 UNPACKING THE BOILER 8 718 681 134a (08.08)
  • Page 21 Undo the nut (F) securing the burner and remove the burner (G) from the appliance. Make sure the burner lead is unpluged from the boiler conrol box. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 UNPACKING THE BOILER 8 718 681 134a (08.08)
  • Page 22 It is important to keep these nuts as they will be required to re-mount the boiler onto the frame. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 UNPACKING THE BOILER 8 718 681 134a (08.08)
  • Page 23 Note: If a rear exit flue is also used the pipes whilst in the upright position will have to be shortened to miss the flue. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 UNPACKING THE BOILER 8 718 681 134a (08.08)

  • Page 24: Pipework Positions & Flue Opening

    CAUTION: Ensure t here are no pipes , electrical cables, damp proof courses or other hazards before drilling. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 PIPEWORK POSITIONS & 8 718 681 134a (08.08) FLUE OPENING...

  • Page 25: Boiler Installation

    Fit the oil isolation valve (supplied in the accessories box), and return bulkhead fitting to the bracket. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 BOILER INSTALLATION 8 718 681 134a (08.08)

  • Page 26: Combustion Chamber

    18/25 Plan sectional view Plan sectional view IMPORTANT when refitting the combustion chamber access door Combustion chamber access door tightening sequence. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 COMBUSTION 8 718 681 134a (08.08) CHAMBER...

  • Page 27: Condensate Trap

    ( J ) and return (K) pipes on the wall bracket. These are push fit connections secured with spring clips (L). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 CONDENSATE TRAP 8 718 681 134a (08.08)

  • Page 28: Oil Burner & Pump

    Fit a return plug (4) (not supplied) to the oil pump and tighten to secure. (on 12/18 model only) Brass air deflector washer Locating circlip INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 OIL BURNER & PUMP 8 718 681 134a (08.08)

  • Page 29: Refitting Components

    2.25 22.4 21.7 21.5-25 LD 25X 4HBP must be fitted. *0.75 80°ES 2.16 2.73 11.5 26.0 25.2 21.5-25 LD 25X 4HBP INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 REFITTING 8 718 681 134a (08.08) COMPONENTS...
  • Page 30 (E) and locate in the correct pockets. Slide the drip tray (F) back into position. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 REFITTING 8 718 681 134a (08.08) COMPONENTS...

  • Page 31: Electrics

    External 230V Refit the rear cover to the electrical box programmer and secure with screws (A). 7 8 9 10 From programmer INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 ELECTRICS 8 718 681 134a (08.08)
  • Page 32 L - LOCKOUT RESET SWITCH. M- BURNER SOCKET. N - BURNER PLUG. N1 N2 1 2 3 4 5 6 7 8 9 10 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 ELECTRICS 8 718 681 134a (08.08)
  • Page 33 (G). Connect terminal 6 on the boiler terminal block (G) to the ‘HOT WATER OFF’ at the remote junction box (O). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 ELECTRICS 8 718 681 134a (08.08)
  • Page 34 Note: The power indicator on the boiler will function as a demand indicator when the OUTSIDE BOILER programmer is wired into the remote wiring centre. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 ELECTRICS 8 718 681 134a (08.08)
  • Page 35 Connect the plug from programmer (P) into connector (F). INSIDE BOILER OUTSIDE BOILER Brown Grey Blue Yellow/Green Orange Brown Blue Grey Blue Yellow / Green Orange Brown Blue INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 ELECTRICS 8 718 681 134a (08.08)
  • Page 36 Move the orange wire from terminal 9 to terminal 6. INSIDE BOILER OUTSIDE BOILER Brown Blue Yellow/Green Blue White Orange Grey Blue INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 ELECTRICS 8 718 681 134a (08.08)

  • Page 37: Pre-Commissioning Checks - Appliance

    Complete the installation part of the Guarantee Registration Card, and complete a CD10 or equivalent to inform the LABC of the installation. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 PRE-COMMISSIONING 8 718 681 134a (08.08) CHECKS - APPLIANCE...

  • Page 38: Filling The System

    The (A) in use and (B) must be bled. Bleed air from the primary heat exchanger air vent (B). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 FILLING THE SYSTEM 8 718 681 134a (08.08)

  • Page 39: Starting The Appliance

    BURNER LOCKOUT RESET BUTTON ( I ) kerosene and refit. The internal filter is accessed by removing the oil pump cover. Safely dispose of the container/discharge. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 STARTING THE 8 718 681 134a (08.08) APPLIANCE...
  • Page 40 2.35 11.5 2.25 22.4 21.7 21.5-25 LD 25X 4HBP *0.75 80°ES 2.16 2.73 11.5 26.0 25.2 21.5-25 LD 25X 4HBP INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 STARTING THE 8 718 681 134a (08.08) APPLIANCE...

  • Page 41: Starting The Appliance

    The burner and circulating pump should be off. 3 Check that any other controls that are fitted to the system are operating properly. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 STARTING THE 8 718 681 134a (08.08)

  • Page 42: Water Treatment

    . INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 WATER TREATMENT 8 718 681 134a (08.08)

  • Page 43: Finishing Commissioning - Appliance

    NOTE: Release drain point ( I ) to drain the primary heat exchanger. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 FINISHING 8 718 681 134a (08.08) COMMISSIONING - APPLIANCE...

  • Page 44: Inspection And Service

    The PRV is a safety device and must be checked for correct operation. The expansion vessel pressure must also be checked and adjusted if required. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 INSPECTION AND 8 718 681 134a (08.08) SERVICE...
  • Page 45 Brass air deflection washer Locating circlip G - Retaining screws - cover H - Cover - oil pump INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 INSPECTION AND 8 718 681 134a (08.08) SERVICE...
  • Page 46 A fire valve sensor clip is provided for this purpose. Combustion chamber access door tightening sequence. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 INSPECTION AND 8 718 681 134a (08.08) SERVICE...

  • Page 47: Baffle Arrangement

    2 for 12/18 models, fitted into tubes 2 & 3. Remove and fit through baffle access door. COMBUSTION CHAMBER ACCESS DOOR INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 INSPECTION AND 8 718 681 134a (08.08)
  • Page 48 RESTRICTOR PLATE 1 for 18/25 models, fitted into tube 2. Remove and fit through baffle access door. COMBUSTION CHAMBER ACCESS DOOR INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 INSPECTION AND 8 718 681 134a (08.08) SERVICE...
  • Page 49 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 INSPECTION AND 8 718 681 134a (08.08) SERVICE...

  • Page 50: Short Parts List 12/18

    Part Number: 8 716 114 545 0 0.50 60° ES (18kW output) Part Number: 8 716 156 671 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 SHORT PARTS LIST 12/18 8 718 681 134a (08.08)

  • Page 51: Short Parts List 18/25

    Part Number: 8 716 156 670 0 0.75 80° ES (25kW output) Part Number: 8 716 109 387 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 SHORT PARTS LIST 18/25 8 718 681 134a (08.08)
  • Page 52 FAULT FINDING & DIAGRAMS Start BOILER LOCKOUT: Burner not operating normally. Find symptom list below. Indicated by the illumination of the lockout indicator on the fascia. To reset, wait 2 minutes then press the lockout reset button. Are the combustion Are the electrical Check the photocell using the Intermittent...

  • Page 53: Fault Finding - Heating & Hot Water

    Start UNDER NO No heating/hot water CIRCUMSTANCES MUST AN APPLIANCE BE LEFT OPERATING WITH ANY CONTROL LINKED OUT OR OVER RIDDEN. Check the power switch and its wiring. Press in the power button Rectify the fault. Is there 230V on terminal Follow the control box Is the power light Is the burner lockout...

  • Page 54: Fault Finding - Boiler Function

    FAULT FINDING & DIAGRAMS Start UNDER NO Boiler not operating normally. CIRCUMSTANCES MUST Find symptom list below. AN APPLIANCE BE LEFT OPERATING WITH ANY CONTROL LINKED OUT OR OVER RIDDEN. Is there an automatic bypass fitted, Is the control thermostat Boiler Is the system water Is flow temperature...

  • Page 55: Diagnostics For Mo535 Rdb Control Box

    Replace Replace Boiler not control box nozzle operating with a MEASURE ALL 230V heating / TESTS BETWEEN hot water NEUTRAL (N) AND THE demand Replace Pipe to Reset Eectrodes & Replace Unblock or Reset air PIN, WIRE OR TERMINAL electrodes/ nozzle combustion leads OK?

  • Page 56: Fault Finding & Diagnosis

    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 57: Combustion Record

    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. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 OIL BOILER 8 718 681 134a (08.08)
  • Page 58 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. °C FLUE PRESSURE: F.G.T. °C FLUE PRESSURE: COMMENTS COMMENTS SIGNATURE...
  • Page 59 NOTES INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR WALL MOUNTED OIL 12/18-18/25 NOTES 8 718 681 134a (08.08)
  • Page 60 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 Bosch Thermotechnology Ltd. www.worcester-bosch.co.uk 8 718 681 134a (08.08)

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