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

Floor standing oil fired condensing combination boiler
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INSTRUCTION MANUAL
INSTALLATION, COMMISSIONING & SERVICING
FLOOR STANDING OIL FIRED CONDENSING COMBINATION BOILER
CONVENTIONAL FLUE & ROOM SEALED FLUE
GREENSTAR HEATSLAVE
12/18, 18/25 & 25/32
FOR SEALED CENTRAL HEATING SYSTEMS WITH MAINS FED DOMESTIC
HOT WATER
THE APPLIANCE IS FOR USE WITH KEROSENE
(28 SECOND OIL) ONLY
UK

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Summary of Contents for Worcester GREENSTAR HEATSLAVE 12/18

  • Page 1 INSTRUCTION MANUAL INSTALLATION, COMMISSIONING & SERVICING FLOOR STANDING OIL FIRED CONDENSING COMBINATION BOILER CONVENTIONAL FLUE & ROOM SEALED FLUE GREENSTAR HEATSLAVE 12/18, 18/25 & 25/32 FOR SEALED CENTRAL HEATING SYSTEMS WITH MAINS FED DOMESTIC HOT WATER THE APPLIANCE IS FOR USE WITH KEROSENE (28 SECOND OIL) ONLY...
  • Page 2 LABC will then arrange regular inspection visits during the work to ensure that the installation complies with the regulations. Programmer ON CH only IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER TECHNICAL HELPLINE ON: 0844 892 366. DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER.

  • Page 3: Table Of Contents

    SHORT PARTS LIST RIELLO RDB 2.2 - 25/32 FAULT FINDING & DIAGNOSIS ELECTRICAL SCHEMATIC FAULT FINDING FAULT FINDING LOGIC FOR RIELLO DIGITAL CONTROL BOX COMMISSIONING CHECKLIST SERVICE INTERVAL RECORD INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 CONTENTS 6 720 802 432 issue A 04/2012...

  • Page 4: Safety Precautions And Installation Regulations

    ETCI rules for electrical installation For further guidance see: OFTEC Technical book three - Regional requirements: Republic of Ireland INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 SAFETY PRECAUTIONS 6 720 802 432 issue A 04/2012 & INSTALLATION REGULATIONS...

  • Page 5: General Information

    Hardware/Literature pack Item Greenstar Heatslave Installation/Servicing Instructions......1 Users Instructions ..................1 Fascia Information Card.................1 Flue Trim ......................1 Top Panel Inset Plate..................1 Edge Clips .......................1 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 GENERAL INFORMATION 6 720 802 432 issue A 04/2012...

  • Page 6: Technical Data

    SEDBUK (Band A) 90.2 90.1 90.3 Appliance protection rating (with programmer blanking plate fitted) Appliance protection rating (with fascia programmer fitted) Weight (excluding packaging) INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 TECHNICAL DATA 6 720 802 432 issue A 04/2012...

  • Page 7: Layout & Components

    48 AIR INTAKE HOSE OPTIONAL ACCESSORIES (not supplied) 7 day TWIN CHANNEL DIGITAL PROGRAMMER Part No. 7 716 192 033 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 LAYOUT & COMPONENTS 6 720 802 432 issue A 04/2012...

  • Page 8: Cleaning Primary Systems

    4 Drain and thoroughly flush the system to remove the flushing agent and any debris. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 CLEANING PRIMARY SYSTEMS 6 720 802 432 issue A 04/2012...

  • Page 9: Mains Supply

    In such circumstances, the advice of the local water authority should be sought. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 MAINS SUPPLY 6 720 802 432 issue A 04/2012...

  • Page 10: Oil Supply

    (J) and oil storage tank (A). 150mm MAXIMUM PIPE RUN FOR DOUBLE PIPE SUB-GRAVITY FEED SYSTEM HEAD 10mmØ 12mmØ HEAD 10mmØ 12mmØ INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 OIL SUPPLY 6 720 802 432 issue A 04/2012...
  • Page 11 Under no circumstances should a combination isolating/fire valve be used as the sole fire protection device. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 OIL SUPPLY 6 720 802 432 issue A 04/2012...

  • Page 12: Water Systems & Pipework

    (A) built into the appliance. IMPORTANT: The Greenstar Heatslave boiler is for use with sealed central heating systems only. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 WATER SYSTEMS & PIPEWORK 6 720 802 432 issue A 04/2012...
  • Page 13 & regulations, including building regulations part G, BS 7291 - 1,2 & 3: 2006, BS 8000 - 15-15: 1990 and information. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 WATER SYSTEMS & PIPEWORK 6 720 802 432 issue A 04/2012...

  • Page 14: Condensate Pipework Internal Connection

    • A suitable permanent connection to the foul waste pipe should be used. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 CONDENSATE PIPEWORK 6 720 802 432 issue A 04/2012 INTERNAL CONNECTION...

  • Page 15: Condensate Pipework External Connection

    • Pipe drainage will be improved if the end is cut at 45° as opposed to a straight cut. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 CONDENSATE PIPEWORK 6 720 802 432 issue A 04/2012...

  • Page 16: Condensate To Soak Away & Pressure Relief Pipework

    Outside wall. external wall (as shown) to help prevent freezing. Drain pipe. External drain. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 CONDENSATE TO SOAK AWAY & 6 720 802 432 issue A 04/2012 PRESSURE RELIEF PIPEWORK...

  • Page 17: Boiler Location & Clearances

    ** Due to changes to BS 5410 and modern building design, these figures no longer incorporate the adventitious ventilation allowance. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 BOILER LOCATION & 6 720 802 432 issue A 04/2012 CLEARANCES...

  • Page 18: Boiler Location

    In all cases the IEE wiring regulations must be consulted. All pipework in bathrooms and shower 2250m m rooms must be cross bonded. 2250m 600mm radius INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 BOILER LOCATION & CLEARANCES 6 720 802 432 issue A 04/2012...

  • Page 19: Flue Terminal Positions

    • **Minimum distance of the flue terminal to a facing wall, fence, building or property boundary is 2500mm. Flat roof boundary Pitched roof C, D boundary INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 FLUE TERMINAL POSITIONS 6 720 802 432 issue A 04/2012...

  • Page 20: 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 HEATSLAVE 12/18-18/25-25/32 CONVENTIONAL FLUE 6 720 802 432 issue A 04/2012...

  • Page 21: Room Sealed Flue Options

    A plume management kit (80mm) is available, part no: 7 716 190 092. 125mmØ x5 Please refer to instructions supplied with the kit. ‡ 125mmØ x11 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 ROOM SEALED FLUE OPTIONS 6 720 802 432 issue A 04/2012...

  • Page 22: Unpacking The Boiler

    At all times the correct method for handling heavy objects should be strictly observed. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 UNPACKING THE BOILER 6 720 802 432 issue A 04/2012...

  • Page 23: Pipework Positions / Flue Opening

    Flue hole size 150 - 240mm 155mmØ 240 - 330mm 160mmØ 330 - 420mm 165mmØ 420 - 500mm 170mmØ 752** PIPEWORK POSITIONS & INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 6 720 802 432 issue A 04/2012 FLUE OPENING...

  • Page 24: Boiler Installation

    4 Lift burner assembly up to release the combustion head (R) from heat exchanger and store safely away from the boiler. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 BOILER INSTALLATION 6 720 802 432 issue A 04/2012...

  • Page 25: Flue Installation

    The expansion vessel must be fitted outside the boiler and connected to the right hand side 1" BSP tappings (T). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 FLUE INSTALLATION 6 720 802 432 issue A 04/2012...

  • Page 26: Combustion Chamber

    Plan sectional view Plan sectional view 12/18 & 18/25kW 25/23kW Hook the retainer (H) over the end two baffles FRONT FRONT INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 COMBUSTION CHAMBER 6 720 802 432 issue A 04/2012...

  • Page 27: Pipework Connections

    PRESSURE RELIEF CONNECTION: 4Connect the pressure relief pipe (N) to a copper discharge pipe (15mmØ min.). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 PIPEWORK CONNECTIONS 6 720 802 432 issue A 04/2012...

  • Page 28: Oil Burner And Pump

    24 Connect the flexible oil return hose (not supplied) between the oil pump and the return line connection, and tighten to secure. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 OIL BURNER & PUMP 6 720 802 432 issue A 04/2012...

  • Page 29: Refitting Components

    44 Lift the control box upwards ( J ). 4 Rotate the box towards you (K). 4 Slide back into position (L). 4 Secure in place with screws (M). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 REFITTING COMPONENTS 6 720 802 432 issue A 04/2012...

  • Page 30: Electrics

    7 4Connect common LIVE supply to terminal Fs. 4Connect each SWITCHED LIVE to terminals F Refit electric control panel cover: 4Refit panel (C) and secure with screws (B). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 ELECTRICS 6 720 802 432 issue A 04/2012...
  • Page 31 - Green/Yellow - Red w - White y - Yellow g - Grey bk - Black or - Orange pk - Pink White INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 ELECTRICS 6 720 802 432 issue A 04/2012...

  • Page 32: Pre-Commissioning Checks - Appliance

    CD10 or equivalent to inform the LABC of the installation. 1000 1200 1400 1600 1800 2000 2200 2400 Litres per hour INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 PRE-COMMISSIONING CHECKS - 6 720 802 432 issue A 04/2012 APPLIANCE...

  • Page 33: Filling The System

    4 Push lever (C) to the left and pull upwards to allow the lever to return position A. 4 Leave the lever (C) unlocked at position A. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 FILLING THE SYSTEM 6 720 802 432 issue A 04/2012...

  • Page 34: Starting The Appliance

    4Remove the oil pump filter, clean with kerosene and refit. The internal filter is accessed by removing the oil pump cover. 4Safely dispose of the container/discharge. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 STARTING THE APPLIANCE 6 720 802 432 issue A 04/2012...
  • Page 35 NOTE: Smoke readings may be inaccurate until the smoke from burning organic binder in the access door insulation has ceased. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 STARTING THE APPLIANCE 6 720 802 432 issue A 04/2012...
  • Page 36 11.5 25.5 87040 85300 0.75 60°ES 2.45 3.10 12.0 29.1 99200 28.5 97200 0.85 60°ES 2.75 3.48 12.5 32.7 111400 109200 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 STARTING THE APPLIANCE 6 720 802 432 issue A 04/2012...
  • Page 37 4 Check the burner and circulating pump** switch off. **The high limit thermostat may activate pump overrun until the correct boiler temperature is restored. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 STARTING THE APPLIANCE 6 720 802 432 issue A 04/2012...
  • Page 38 44Set the DHW thermostat control (C) to max. The diverter valve (E) should move to port A and divert the flow to the Heatslave tank. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 STARTING THE APPLIANCE 6 720 802 432 issue A 04/2012...

  • Page 39: Water Treatment

    . INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 WATER TREATMENT 6 720 802 432 issue A 04/2012...

  • Page 40: Finishing Commissioning - Appliance

    NOTE: Release drain point (N) to drain the secondary heat exchanger. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 FINISHING COMMISSIONING - 6 720 802 432 issue A 04/2012 APPLIANCE...

  • Page 41: Inspection And Service

    4Clean or replace all oil filters. 4Check that the condensate system is not obstructed, clean and refill the condensate trap as necessary. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 INSPECTION AND SERVICE 6 720 802 432 issue A 04/2012...
  • Page 42 This seal must be in good condition since failure will cause flue gases to escape into the room. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 INSPECTION AND SERVICE 6 720 802 432 issue A 04/2012...
  • Page 43 4Check the seal on the manifold access cover (K) and replace if necessary. 4Refit the flue manifold access cover (B) and secure with screws (A). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 INSPECTION AND SERVICE 6 720 802 432 issue A 04/2012...
  • Page 44 A fire valve sensor clip (E) is provided for this purpose. Plan sectional view Plan sectional view 12/18kW & 18/25kW 25/32kW INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 INSPECTION AND SERVICE 6 720 802 432 issue A 04/2012...
  • Page 45 44 Locate left hand side onto pivot point. 4 Push box & slider fully in and secure with screws. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 INSPECTION AND SERVICE 6 720 802 432 issue A 04/2012...

  • Page 46: Short Parts List Riello Rdb 1 - 12/18

    Part Number: 8 718 685 261 0 22 DHW Pipe thermostat Part Number: 8 718 689 263 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 SHORT PARTS LIST 6 720 802 432 issue A 04/2012 RIELLO RDB 1 - 12/18...

  • Page 47: Short Parts List Riello Rdb 2.2

    Part Number: 8 718 685 261 0 22 DHW Pipe thermostat Part Number: 8 718 689 263 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 SHORT PARTS LIST 6 720 802 432 issue A 04/2012 RIELLO RDB 2.2 - 18/25...

  • Page 48: Short Parts List Riello Rdb 2.2 - 25/32

    Part Number: 8 718 685 261 0 22 DHW Pipe thermostat Part Number: 8 718 689 263 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 SHORT PARTS LIST 6 720 802 432 issue A 04/2012 RIELLO RDB 2.2 - 25/32...
  • Page 49 MANUAL RESET TANK OVERHEAT LOCKOUT THERMOSTAT INDICATOR POWER ON INDICATOR X11 (PIN 2) X11 (PIN 3) brown X12 (PIN 3) X9 (PIN 1) X9 (PIN 2) X7 (PIN 1) X3 (PIN 3 (L)) white brown X7 (PIN 4) PUMP X7 (PIN 3) FROST THERMOSTATS (if fitted) brown X2 (FR)

  • Page 50: Fault Finding & Diagnosis

    Check with installation instructions APPLIANCE BE LEFT TO OPERATE WITH combustion head ANY CONTROL LINKED OUT OR OVERRIDDEN. Faulty nozzle Replace nozzle INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 FAULT FINDING 6 720 802 432 issue A 04/2012...
  • Page 51 Rectify burner operation and lockouts operation, numerous lockouts Odour in boiler room, oil leaks Rectify oil leaks, replace components if from pipework, flexible hoses necessary connections INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 FAULT FINDING 6 720 802 432 issue A 04/2012...

  • Page 52: Fault Finding Logic For Riello Digital Control Box

    GREEN 0.2s ON / RED 0.2s ON Anomaly for reset push-bu on or more than 60s. remote reset failure When anomaly appears burner doesn't stop INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 FAULT FINDING 6 720 802 432 issue A 04/2012...
  • Page 53 - 1 to 2 LED - RED good - 3 to 4 very good - 5 to steady on INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 ELECTRICAL SCHEMATIC 6 720 802 432 issue A 04/2012...

  • Page 54: Commissioning Checklist

    It is recommended that the heating system is serviced regularly and that you complete the appropriate Service Interval Record Overleaf. 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.
  • Page 55 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 56 NOTES INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 NOTES 6 720 802 432 issue A 04/2012...
  • Page 57 NOTES INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 NOTES 6 720 802 432 issue A 04/2012...
  • Page 58 NOTES INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 NOTES 6 720 802 432 issue A 04/2012...
  • Page 59 NOTES INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32 NOTES 6 720 802 432 issue A 04/2012...
  • Page 60 Dedicated to heating comfort Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0844 892 9900 Fax. 01905 754619 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. www.worcester-bosch.co.uk 6 720 802 432 issue A 04/2012...

This manual is also suitable for:

Greenstar heatslave 18/25Greenstar heatslave 25/32

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