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Installation, Commissioning and Servicing instruction manual
Floor Standing oil-fired Condensing Combination Boiler using Conventional and Room
Sealed Flue
ErP
Greenstar Heatslave II
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.
UK
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Table of Contents
Related Manuals for Worcester Greenstar Heatslave II ErP 12/18
Summary of Contents for Worcester Greenstar Heatslave II ErP 12/18
- Page 1 Installation, Commissioning and Servicing instruction manual Floor Standing oil-fired Condensing Combination Boiler using Conventional and Room Sealed Flue Greenstar Heatslave II 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 Commissioning ........31 Key to symbols . -
Page 3: Key To Symbols And Safety Instructions
DWTA Domestic Water Treatment Association Read these instructions before starting any installation Additional symbols These instructions are applicable to the Worcester appliance model(s) stated on the front cove of this manual only and must not be used with Symbol Meaning any other make or model of appliance. - Page 4 Key to symbols and safety instructions Combustible and corrosive materials Handover to the user Do not store or use any combustible materials (paper, thinners, paints When handing over, instruct the user how to operate the heating system etc.) inside or within the vicinity of the appliance. and inform him about its operating conditions.
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Page 5: Installation Regulations
Installation regulations Installation regulations Complying with the building regulations This heating appliance forms part of the controlled services for the The Building Regulations Part G, Part J and L1 England and Wales; Part building. It is law that all controlled services for buildings must comply F, Part G and Part J Section III Scotland;... -
Page 6: 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 restricter colour Lime Beige... -
Page 7: 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 7731600047 7731600048 7731600049 Product type – – Greenstar Heatslave II Greenstar Heatslave II Greenstar Heatslave II 12/18 18/25... -
Page 8: Layout & Components
Appliance information Layout & components The diagram below excludes the top, front and RH side casing panels. 45 46 32 33 Fig. 2 Greenstar Heatslave II ErP - 6 720 813 344 (2014/09) - Page 9 CH TEMPERATURE CONTROL KNOB LCD DISPLAY CASING SIDE PANEL FLUE "KNOCK-OUT" SECTION TANK TEMPERATURE CONTROL KNOB DIAGNOSIS PORT - WORCESTER ENGINEER SYSTEM PRESSURE GAUGE [10] FLUE GAS SAMPLING POINT [11] FLUE MANIFOLD COVER [12] FLUE OVERHEAT THERMOSTAT PHIAL [13] AIR INLET CASING FLEXIBLE AIR DUCT...
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Page 10: Pre-Installation
WARNING: Sealing agents appliance or flue installations. ▶ In cases where all attempts to find a system micro leak have failed, Worcester, Bosch Group supports NOTICE: Risk of damage to system or appliance! the use of Fernox F4 leak sealer. -
Page 11: Oil Supply
Pre-Installation Mains water pressure Key to Oil supply illustrations, figures 4, 5 & 6 NOTICE: Boiler damage OIl storage tank ▶ Non-return, back flow prevention devices (including Full base (plastic tank) those associated with water meters) fitted to the Isolating valve mains water supply can cause a pressure build up Oil strainer and water separator which could damage the boiler and other household... -
Page 12: Single Pipe Suction Lift With De-Aerator
Pre-Installation Maximum pipe run for double pipe sub-gravity fed system – The fire valve should be fitted externally to the building with the fire valve sensor located within the appliance case. Head (m) 10mmØ 12mmØ Head (m) 10mmØ 12mmØ – A fire valve with a shut off temperature of 85°C or higher must be fitted to avoid the possibility of nuisance shut offs. - Page 13 Pre-Installation expansion vessel (B) must be fitted as close as possible to the Mini expansion appliance in the central heating return. vessel • Pressurise the extra expansion vessel (B) to the same figure as the (0.75ltr capacity) expansion vessel (A) built into the appliance. Hot water supply to property Greenstar Heatslave II...
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Page 14: Condensate Pipework
Pre-Installation Condensate pipework proprietary condensate pump, of a specification recommended by the boiler or condensate pump manufacturer. NOTICE: The pump outlet pipe should discharge to a suitable internal foul water ▶ Where a new or replacement boiler is being installed, discharge point such as an internal soil and vent stack, internal kitchen access to an internal “gravity discharge”... -
Page 15: Soak Away
Pre-Installation 4.5.3 Soak away • The condensate drainage pipe may be run above or below the ground to the soak away. The examples shown on this page run above ground. • The soak away must use a 100mm Ø plastic tube with two rows of three 12mm holes on 25mm centres and 50mm from the bottom of the tube. -
Page 16: Pressure Relief Pipework
Pre-Installation Pressure relief pipework Room sealed flue (RS) The appliance does not require a separate vent for combustion air. • The pressure relief discharge pipe [1] should be at least 15 mm diameter copper pipe and run downwards away from the boiler and Installation in cupboards or compartments require permanent vents for discharge away from any electrical or other hazard, preferably to an cooling purposes, one at high level and one at low level, either direct to... -
Page 17: Flue Terminal Positions
Pre-Installation Showers/bathrooms 0 m m WARNING: Conventional flues 1 2 0 ▶ Conventional flued boilers must not be installed in a bathroom, bedroom, or bedsitting room. 6 0 0 3 0 0 WARNING: Electrical ▶ Any appliance using mains electricity must not be able to be touched by a person using the bath or shower. - Page 18 Pre-Installation Flat roof boundary Pitched roof C, D boundary 6720808218-19.1Wo Terminal position RS(H) RS(V) 1) 2) Directly below an opening, air brick, opening window etc. 600mm 1) 2) 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 Below a plastic/painted gutter, drainage pipe or eaves without protection to combustible material 600mm...
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Page 19: Flue Options
The flue can be increased in size from the boiler take off point providing the joint is correctly sealed. Never reduce the flue diameter from the boiler take off point. CF Sizing Boiler size Third party flue size Worcester Flexible Flue 12/18 100/103mm Ø 100mmØ 18/25 100/103mm Ø 100mmØ... -
Page 20: Room Sealed Flue Options
Pre-Installation 4.9.2 Room sealed flue options In all cases L is measured from the outside of the boiler casing. • To achieve the maximum flue length [L], a flue section will have to be reduced in length. L = 120 - 240mm •... -
Page 21: Installation
Installation Installation Unpacking the boiler Lifting and carrying precautions: ▶ Lift only a manageable weight, or ask for help. ▶ When lifting or putting things down, bend the knees, and keep the back straight and feet apart. ▶ Do not lift and twist at the same time. ▶... -
Page 22: Pipework Positions And Flue Opening
Installation Pipework positions and flue opening CAUTION: Ensure there are no pipes, electric cables, damp proof courses or other hazards before drilling. Safety All relevant safety precautions must be undertaken. Protective clothing, footwear, gloves and safety goggles must be worn as appropriate. 6 720 805 209-06.1TL Pipework positions Fig. -
Page 23: Boiler Installation
Installation Boiler installation Flue installation ▶ Lift the top panel [A] upwards to disengage the ball stud connections The flue can exit the boiler from outlets A, B, C or D allowing vertical (RS) [B] and remove. and horizontal (RS low or high level) flues to be fitted. (CF position 'A' only). -
Page 24: Combustion Chamber
Installation ▶ Ensure one piece baffle set [C] is in the right location [D], correctly The boiler is not designed to take the weight of the flue resting on the baffle rests [F] on either side of the combustion system, this must be supported externally to the boiler. chamber and pushed securely into place. -
Page 25: Pipework Connections
Installation Pipework connections CAUTION: Isolate the oil & water mains supply before starting any work and observe all relevant safety precautions. Water connections ▶ Ensure all pipework is clean. Water may be present, due to factory testing. ▶ Align water pipework and connect ▶... -
Page 26: Oil Burner And Pump
Installation Oil burner and pump CAUTION: MAINS SUPPLIES ▶ Isolate the oil & water mains supply before starting any work and observe all relevant safety precautions. Oil burner 1. Check that the nozzle (A) and the electrode (B) alignment settings are correct as shown in figure 35. -
Page 27: Electrical
Installation 7. Locate top panel [N] onto brackets at rear of the side panels [O]. Access to electrical connections Locate ball stud connections [P] and press down to secure. Access to all wiring connections are via the Installer access cover at the bottom front of the control board. - Page 28 Installation DANGER: 230 Volts Isolate the mains electricity supply before starting any work and observe all relevant safety precautions. Mounting optional Plug-In controls Removing the blanking plate The control panel must be pulled fully forward to gain access to the top cover panel (refer to page 23 for access to the control panel).
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Page 29: Electrical Schematic
Installation 5.10 Electrical schematic Fig. 44 Greenstar Heatslave II ErP - 6 720 813 344 (2014/09) -
Page 30: Weather Compensation
Installation 5.11 Weather compensation The heating curve The CH flow temperature has an upper limit of 82°C (this can be capped The appliance will modulate the CH flow temperature based on the via the CH control knob setting) and a lower limit of 50°C, (it is outside temperature when an outdoor sensor is connected to the recommended that the CH knob is set to 82°C for the weather outdoor sensor connection on the control board and the weather... -
Page 31: Commissioning
Commissioning Filling the system Commissioning 1. The diverter valve will sit in mid-position when the boiler has no demand and is powered up. Pre-commissioning checks-appliance CAUTION: Isolate the mains supplies before starting any work and observe relevant safety precautions. 1. Check that the service and water pipes are connected correctly. 2. -
Page 32: Starting The Appliance
Commissioning 4. Open all system and radiator valves. – The use of an oil suction pump will prime and flush through any oil supply set up simply and easily, alternatively the following ▶ Turn on the water main stop cock. procedures can be used. - Page 33 Commissioning ▶ Switch off the boiler. ▶ Repeat procedure until a flame is established. Clean the oil pump filter If debris is found, then the oil supply system must be checked for the source of debris before the boiler is commissioned.
- Page 34 Commissioning Fig. 59 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) [10] Position for optional programmer [11] Hot water temperature control [12] Diagnostic port [13] System pressure gauge Fig.
- Page 35 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 36 Commissioning Menu 2 parameter 2.7A Demand /fault 0 = The blue light will only operate as a flashing fault alert. indicator 1 = The blue light will operate as a boiler (blue light) activation demand light and fault alert. This is set to 1 by default. Reset to factory settings To reset any or all changes made in Menu 2 back to the factory default setting:...
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Page 37: Water Treatment
12 months or sooner if system content is lost. ▶ In cases where all attempts to find a micro leak have failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer. Water treatment products Suitable water treatment products can be obtain from the following manufacturers: 6720805209-88.1Wo... -
Page 38: Service And Spares
Service and Spares 2. Pull the control box [C] all the way forwards. ▶ Depress the two levers [D], one on either side, to release the control box and pull fully forward and swivel control box upwards. 3. Remove securing screws [E] from front panel [G]. ▶... - Page 39 Service and Spares ▶ Check that the condensate system is not obstructed, clean and refill the condensate trap. Clean the burner ▶ Loosen the 2 hex head screws and remove the air intake cover [A] and clear any debris from the air intake and air damper. ▶...
- Page 40 Service and Spares ▶ Check the O ring seals and replace if necessary, grease the seals with a solvent free grease. ▶ Refit the trap making sure that the locking tabs are locked in place. ▶ Pour 500 ml of water into drain [E] to refill the condensate trap and check that the condensate discharge pipe is discharging.
- Page 41 Service and Spares Re-commission the burner 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 42 Service and Spares 6 720 805 209-59.1TL Fig. 79 Nominal boiler rating at normal operating temperature using Kerosene (Class C2) Approximate flue gas Approximate Input Output Air damper Oil pump pressure Fuel flow rate temperature air setting (appliance) (appliance) disk setting Burner head Nozzle Kg/h...
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Page 43: Short Parts Lists
Service and Spares Short parts lists Short parts list 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... - Page 44 Service and Spares Short parts list 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 45 Service and Spares Short parts list 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...
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Page 46: 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. During normal operation various status codes can be displayed by pressing the service button. -
Page 47: Service Menu
Fault finding and diagnosis i15 Out door This is the out door temperature displayed in real time (rounded to 0.5°C units). Only available if a temperature Weather Compensation sensor has been fitted and Weather Compensation is active. i19 Time inputs This indicates the status of the optional fascia mounted controls: 0 = CH off, DHW off 1 = CH off, DHW on... -
Page 48: Factory Reset And Fault Codes
Fault finding and diagnosis 2. Press the button and “reset” will be displayed with the tick reset symbol for 3 seconds. After 3 seconds the display will revert to the normal operation screen. 6 720 805 209-67.1TL Fig. 87 2.7A Demand/fault O = The blue light will only LED (blue light) activation operate as a flashing fault... -
Page 49: 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/solution Maximum temperature thermostat Reset Flue gas or tank thermostat overheat. Reset the overheat activated thermostat before resetting the appliance. No code Safety or flow temperature too high Air lock or reduced water content. -
Page 50: Dhw Function Chart
Fault finding and diagnosis DHW function chart Fig. 90 Greenstar Heatslave II ErP - 6 720 813 344 (2014/09) -
Page 51: 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 52: Protection Functions
Fault finding and diagnosis Protection functions Frost Protection Appliance: PHE OR Flow PHE OR Flow Pump OFF Pump 3WV to Waiting period sensor below 3WV to CH sensor below after 5 of 25 ninutes 8°C 9°C minutes Appliance automatic frost protection ( monitors PHE, flow and internal PHE AND... -
Page 53: Solar Compatibility
Fault finding and diagnosis Solar compatibility DCW in less than Normal DHW 40°C operation Burner OFF for DCW in more than DHW 10 l/min & 40°C (but less above (burn than 3 below) allowed for tank (for 2 sec or more) reheat during demand) During a DHW demand... -
Page 54: 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. 94 Greenstar Heatslave II ErP - 6 720 813 344 (2014/09) - Page 55 Fault finding and diagnosis 6 720 805 209-76.1TL Fig. 95 Greenstar Heatslave II ErP - 6 720 813 344 (2014/09)
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Page 56: 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 57 Notes Greenstar Heatslave II ErP - 6 720 813 344 (2014/09)
- Page 58 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 59: 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 60 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 6 720 813 344 (2014/09)
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