Worcester Greenstar 12/18 Installation, Commissioning And Servicing Instruction Manual
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Worcester Greenstar 12/18 Installation, Commissioning And Servicing Instruction Manual

Floor standing oil-fired condensing boiler using room sealed flue, danesmoor external regular & external system
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Download this manual See also: Instructions for Using, Instruction Manual
Installation, Commissioning and Servicing instruction manual
Floor Standing oil-fired Condensing Boiler using Room Sealed Flue
Greenstar Danesmoor External Regular
ErP
& External System
12/18, 18/25 & 25/32
ErP
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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Summary of Contents for Worcester Greenstar 12/18

  • Page 1 Installation, Commissioning and Servicing instruction manual Floor Standing oil-fired Condensing Boiler using Room Sealed Flue Greenstar Danesmoor External Regular & External System 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.

  • Page 2: Table Of Contents

    Contents Contents Filling the system ......27 Key to symbols and safety instructions ....3 Water treatment .

  • 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) Symbol Meaning stated on the front cove of this manual only and must not be used with a numbered step in an action sequence any other make or model of appliance.

  • Page 4: Installation Regulations

    Installation regulations The combustion air must be kept clear of chemically aggressive Handover to the user substances which can corrode the appliance and invalidate any When handing over, instruct the user how to operate the heating system warranty. and inform him about its operating conditions. Handling instructions and guidelines ▶...
  • Page 5 Installation regulations BS 7291: Thermoplastic pipes and associated fittings for hot and cold water for domestic purposes and heating installations in buildings. BS 7074: part 1: Application, selection and installation of expansion vessels and ancillary equipment for sealed water systems. BS 1254-2: Copper and copper alloys plumbing fittings part 2: Fittings with compression ends for use with copper...

  • Page 6: Appliance Information

    Appliance information Technical data Appliance information Description Units 12/18 18/25 25/32 General information Central heating Central heat output (max) Standard package: Primary water capacity (total) litres A - Floor standing oil fired condensing boiler Max.static head (Regular only) metres B - Literature pack: Min.

  • 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 7731600059 7731600060 7731600061 7731600068 7731600069 7731600070 Product type – – Danesmoor Danesmoor Danesmoor Danesmoor Danesmoor Danesmoor...

  • Page 8: Layout And Components - 18/25 Regular Appliance Shown

    Appliance information Layout and components - 18/25 Regular appliance shown 26 25 Fig. 2 18/25 Appliance shown Figure 2 does not include the top, front, and right hand side panel. Control box assembly Primary heat exchanger Flue manifold access cover Oil isolating valve Flue gas sampling point Optional oil return position...

  • Page 9: Layout And Components - 12/18 System Appliance Shown

    Appliance information Layout and components - 12/18 System appliance shown Fig. 3 Exploded system appliance view Control box assembly Primary heat exchanger drain Demand indicator Burner air intake - connected to air inlet casing by flexible duct Mode switch Oil pump (behind plastic cover) Flue manifold access cover Riello RDB burner Flue gas sampling point...

  • Page 10: Pre-Installation

    ▶ In cases where all attempts to find a system micro Building Regulations. leak have failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer. ▶ It is a requirement of the Building Services...

  • Page 11: Mains Supply

    Pre-Installation Mains supply 4.3.1 Single pipe gravity feed system: The oil storage tank [1] must be positioned so that the oil level does not 4.2.1 Electrical supply exceed 4 metres above the level of the burner oil pump [9] and in •...

  • Page 12: Single Pipe Suction Lift With De-Aerator

    Pre-Installation 4.3.3 Single pipe suction lift with de-aerator: • Under no circumstances should a combination isolating/fire valve be used as the sole fire protection device. Maximum suction height 3.5 metres. The oil tank [1] must be positioned below the oil pump [9]. Create an inlet and return loop between the de- 4.3.5 Boiler isolation valve aerator [12] and oil pump [9].
  • Page 13 Pre-Installation Open vent primary system (regular only) Fully pumped sealed primary system: • The open vent pipe [F] and feed and expansion pipe [H must rise • A pressure relief valve [P], spring loaded safety valve set to operate continuously from the appliance. at 3bar, must be fitted to the heating flow pipe as close as possible to the boiler or onto one of the boiler top 1”...

  • Page 14: Condensate Pipework

    Pre-Installation Filling primary sealed systems Condensate pipework NOTICE: FILLING THE SYSTEM NOTICE: ▶ The system must not be filled with artificially ▶ Where a new or replacement boiler is being installed, softened water. access to an internal “gravity discharge” point should be one of the factors considered in determining •...

  • Page 15: Soak Away

    Pre-Installation Fitting an external air break 4.5.2 Soak away • Refer to figure 13 when a rain water down pipe is used to dispose of NOTICE: Condensate waste condensate. ▶ Care should be taken when siting a soak-away to • An air break must be installed in the 43mm pipe work, between the avoid obstructing existing services.

  • Page 16: Pressure Relief Pipework

    Pre-Installation Pressure relief pipework 600mm • The pressure relief discharge pipe [2]should be at least 15 mm 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 17: Flue Terminal Positions

    Pre-Installation Flue terminal positions boundary C, D boundary 6720809437-30.1Wo Fig. 21 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 18: Flue Options

    Pre-Installation Flue options 4.9.1 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 19: Installation

    Installation Pipework positions and flue opening Installation REAR Unpacking the boiler CAUTION: Lifting and carrying ▶ Lift only a manageable weight, or ask for help. ▶ When lifting or putting things down, bend your knees, keep your back straight, and feet apart. ▶...

  • Page 20: Boiler Installation

    Installation Safety ▶ Unplug burner lead [1]from control box. ▶ Unscrew to loosen the retaining ring [4] that secures the flexible air All relevant safety precautions must be undertaken. supply tube [3] to the burner and remove from the burner. Protective clothing, footwear, gloves and safety goggles must be worn as ▶...

  • Page 21: Combustion Chamber (18/25 Regular Shown)

    Installation Combustion chamber (18/25 Regular shown) Pipework connections ▶ Unscrew screws and remove flue manifold access cover [5]. CAUTION: MAINS SUPPLIES ▶ Check that all the baffles [2] and baffle retainer [3] are correctly ▶ Isolate the oil & water mains supply before starting fitted to the secondary heat exchanger.
  • Page 22 Installation Water connections Surplus water may be present due to factory testing. ▶ Remove the transit bungs from the pipework connections on e boiler. ▶ Ensure all of the pipework is clean. 500ml ▶ Align the water pipework and connect. ▶...

  • Page 23: Oil Burner And Pump

    Installation Oil burner and pump Oil pump Connecting the oil pump for a single pipe system: CAUTION: MAINS SUPPLIES ▶ The pump is factory set for single pipe operation with the flexible oil ▶ Isolate the oil & water mains supply before starting pipe fitted.
  • Page 24 Installation This appliance provides a permanent external electrical supply for servicing and must therefore be fed via a circuit breaker incorporating earth leakage protection Access to 230V connections ▶ Remove the four cover panel retaining screws [2] from the control box [1].
  • Page 25 Installation Regular appliance electrical connections. Junction Box/Wiring Centre Control Box Green/Yellow Brown Brown Orange Blue L3 N L2 L1 L3 N L2 L1 Green/Yellow Riello Burner Control Box Fig. 38 Regular wiring diagram Key to components: Remote junction box (10 way). High limit thermostat Frost thermostat Earth stud...
  • Page 26 Installation System appliance electrical connections. Junction Box/Wiring Centre Control Box Green/Yellow Brown Brown Orange Blue L3 N L2 L1 L3 N L2 L1 Green/Yellow Riello Burner Control Box Fig. 39 System wiring diagram Key to components: Remote junction box (10 way). High limit thermostat Frost thermostat Earth stud...

  • Page 27: Commissioning

    Commissioning Filling the system Commissioning ▶ Open all system and radiator valves. ▶ Turn on the water main stop cock. Pre-Commissioning checks - 18/25 Regular shown ▶ Open vented systems only: CAUTION: 230 Volts – Turn on the water to the system feed and expansion cistern and ▶...

  • Page 28: Appliance Drain Points

    ▶ In cases where all attempts to find a micro leak have 1. Check the oil supply is correctly fitted and in good working order failed, Worcester, Bosch Group supports the use of before turning on the oil supply valves to the boiler.
  • Page 29 Commissioning Double pipe sub-gravity feed system and single pipe suction lift with ▶ Allow the burner to run through to 'lock-out' indicated by the de-aerator: illumination of the lockout indicator on the lockout reset button [1], (note: some systems will not lock out). Refer to figure 44.
  • Page 30 Commissioning ▶ Adjust the air shutter [3] figure 48 and pump pressure [2] figure 47 ▶ Restart and run for 3 minute intervals until after-spurting stops. as shown in the table 8 on page 31. The burner should ignite ▶ Start and run for 20 minutes following a pre-ignition period of approximately 15 seconds.
  • Page 31 Commissioning ▶ Turn off the electrical supply. Central heating ▶ Isolate the oil supply to the burner. ▶ Open all radiator valves. ▶ Remove the oil pressure gauge. ▶ Set room thermostat to maximum. ▶ Refit the blanking plug [4] figure 51. ▶...

  • Page 32: Finishing Commissioning

    Fig. 53 – Please send your completed form to: 6.5.1 Hand over Worcester, Bosch Group, Cotswold Way, Warndon, Worcester, WR4 9SW. ▶ Complete the Boiler commissioning checklist at the back of this manual and CD11 or an equivalent commissioning form.

  • Page 33: Service And Spares

    Service and Spares ▶ Switch into service mode at switch [1]. Service and Spares Inspection and service - 18/25 Regular shown CAUTION: MAINS SUPPLIES ▶ Isolate the water, electricity, and oil mains supplies before starting any work and observe all relevant safety precautions.

  • Page 34: Clean The Appliance

    Service and Spares Clean the appliance Secondary heat exchanger baffles and retainer checks Refer to figure 58 7.2.1 Accessing the flue manifold and secondary heat exchanger ▶ Refit all the baffles [2] and baffle retainer [3] are correctly fitted to Flue manifold access and secondary heat exchanger: the secondary heat exchanger.

  • Page 35: Condensate System

    Service and Spares 7.2.4 Condensate system 7.2.5 Clean the burner ▶ Check the discharge pipe for leaks or damage. ▶ Remove plastic cover [1] from the burner. Condensate trap removal. ▶ Unscrew to loosen the retaining ring [4]that secures the flexible air ▶...
  • Page 36 Service and Spares ▶ Remove the oil pump internal filter [2], clean in fuel oil and NOTICE: reassemble. ▶ Before removing or fitting a nozzle [3], loosen and ▶ The internal filter is accessed by removing screws [3] and oil pump move the electrodes [1] forward.
  • Page 37 Service and Spares ▶ Plug burner lead [1] into control box. ▶ Refit the top panel [2] and press down to compress the seal when fitting the securing screws [1]. ▶ Slide the burner into position in the heat exchanger and secure with the retaining nut [2] on top of the burner.

  • Page 38: Short Parts List 12/18

    Service and Spares Short parts list 12/18 Short parts list 18/25 Cleaning tool Service lead Cleaning tool Service lead 8 716 109 428 0 7 716 192 760 8 716 109 428 0 7 716 192 760 Cabinet key Oil nozzle (12kW) Cabinet key Oil nozzle (18kW) 8 716 114 013 0...

  • Page 39: Short Parts List 25/32

    Service and Spares Short parts list 25/32 Cleaning tool Service lead 8 716 109 428 0 7 716 192 760 Cabinet key Oil nozzle 8 716 114 013 0 (25 & 28.5kW) 0.75 80° ES 8 716 109 387 0 Oil nozzle (32kW) Flexible oil hose kit 0.85 80°...

  • Page 40: Fault Finding And Diagnosis

    Whilst every effort has been taken to ensure the information given is correct and complete we cannot guarantee that every eventuality has been covered. Worcester, Bosch Group can- not be held responsible for costs incurred by persons not deemed to be competent.

  • Page 41: Heating And Hot Water

    Worcester, Bosch Group cannot be held responsible for costs incurred by persons not deemed to be competent. Measure all 230V tests between Neutral (N) and the pin, wire or terminal specified.

  • Page 42: Boiler Function

    Whilst every effort has been taken to ensure the information given is 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.

  • Page 43: Logic For The 535 Se/Ld Rdb Control Box

    Fault finding and diagnosis Logic for the 535 SE/LD RDB control box Greenstar Danesmoor External and External System ErP - 6 720 813 288 (2014/09)

  • Page 44: Oil Supply Vacuum Testing

    Fault finding and diagnosis 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 45 Notes Greenstar Danesmoor External and External System ErP - 6 720 813 288 (2014/09)
  • Page 46 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. Notes BOILER DETAILS Boiler Make and Model...

  • Page 47: 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 48 0330 123 9119 TRAINING: 0330 123 0166 SALES: 0330 123 9669 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 6 720 813 288 (2014/09)

This manual is also suitable for:

Greenstar 25/32Greenstar 18/25

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