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

For open vent & sealed central heating systems with mains fed domestic hot water greenstar heatslave external
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8 716 113 389d
30/3/10
14:01
INSTRUCTION MANUAL
INSTALLATION, COMMISSIONING & SERVICING
FLOOR STANDING EXTERNAL OIL FIRED CONDENSING
COMBINATION BOILER USING BALANCED FLUE SYSTEM
GREENSTAR HEATSLAVE EXTERNAL
12/18, 18/25 & 25/32
FOR OPEN VENT & SEALED CENTRAL HEATING SYSTEMS WITH
MAINS FED DOMESTIC HOT WATER
Page 1
THE APPLIANCE IS FOR USE WITH KEROSENE
(28 SECOND OIL) ONLY
UK

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  • Page 1 FLOOR STANDING EXTERNAL OIL FIRED CONDENSING COMBINATION BOILER USING BALANCED FLUE SYSTEM GREENSTAR HEATSLAVE EXTERNAL 12/18, 18/25 & 25/32 FOR OPEN VENT & SEALED CENTRAL HEATING SYSTEMS WITH MAINS FED DOMESTIC HOT WATER THE APPLIANCE IS FOR USE WITH KEROSENE...

  • Page 2: Important Information And Symbols

    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. DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER. Programmer ON DHW only...

  • Page 3: Table Of Contents

    FAULT FINDING LOGIC FOR SATRONIC CONTROL BOX FAULT FINDING LOGIC FOR RIELLO CONTROL BOXES ELECTRICAL SCHEMATIC COMMISSIONING & SERVICE RECORDS OIL BOILER COMMISSIONING CHECKLIST SERVICE INTERVAL RECORD INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 CONTENTS 8 716 113 389d (03/2010)

  • Page 4: Safety Precautions And Installation Regulations

    Part J Republic of Ireland 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 EXTERNAL 12/18-18/25-25/32 SAFETY PRECAUTIONS 8 716 113 389d (03/2010) & INSTALLATION REGULATIONS...

  • Page 5: General Information

    Check List Item Greenstar Heatslave External Installation/Servicing Instructions..1 Users Instructions ..................1 100mm Ø Services Duct................1 Warranty Return Envelope ................1 Cabinet Key....................... 1 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 GENERAL INFORMATION 8 716 113 389d (03/2010)

  • Page 6: Technical Data

    Flue reset overheat thermostat set point °C General Data Maximum hearth temperature °C <100 <100 <100 SEDBUK (Band A) 90.2 90.1 90.3 Appliance protection rating Weight (excluding packaging) INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 TECHNICAL DATA 8 716 113 389d (03/2010)

  • Page 7: Layout & Components

    MOTOR iii) AIR INTAKE CASING iv) OIL PUMP v) COMBUSTION HEAD 45. CLIP - AIR INTAKE HOSE 46. AIR INTAKE HOSE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 LAYOUT & COMPONENTS 8 716 113 389d (03/2010)

  • Page 8: Cleaning Primary Systems

    Run the boiler and system at normal operating temperature in accordance with the manufacturer's instructions. Drain and thoroughly flush the system to remove the flushing agent and any debris. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 CLEANING PRIMARY SYSTEMS 8 716 113 389d (03/2010)

  • Page 9: Mains Supplies

    In such circumstances, the advice of the local water authority should be sought. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 MAINS SUPPLIES 8 716 113 389d (03/2010)

  • Page 10: Oil Supply

    The table and illustration above is a guide only and does not in any way override the de- combination isolating/fire valve be used aerator manufacturers instructions. as the sole fire protection device. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 OIL SUPPLY 8 716 113 389d (03/2010)

  • Page 11: Water Systems & Pipework

    • Pressurise the extra expansion vessel (B) to the same figure as the expansion vessel (A) built into the appliance. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 WATER SYSTEMS & PIPEWORK 8 716 113 389d (03/2010)

  • Page 12: Pressure Relief Pipework

    • If using more than one outlet at once causes water flow starvation, fit flow balancing valves or Ball-O-Fix valves to the appropriate outlets. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 WATER SYSTEMS & PIPEWORK 8 716 113 389d (03/2010)

  • Page 13: Condensate Pipework

    • Pipe (K) should be finished with a partial bend, near the outlet to face the external wall (as shown) to help prevent freezing. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 CONDENSATE & 8 716 113 389d (03/2010)

  • Page 14: Cabinet Mounted Low Level Flue Terminal Positions

    2 A way of providing protection of combustible material would be to fit a heat shield at least 750mm wide. boundary C, D boundary INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 CABINET MOUNTED LOW LEVEL 8 716 106 389c (01/2009) FLUE TERMINAL POSITIONS...

  • Page 15: High Level Flue Terminal Positions

    2500mm. Flat roof boundary Pitched roof C, D boundary INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 HIGH LEVEL FLUE TERMINAL 8 716 113 389d (03/2010) POSITIONS...

  • Page 16: Boiler Location & Clearances

    ** 200mm if a high level terminal is used exiting through the rear panel. 600mm FRONT 150mm** 150mm** 10mm 2500mm* 2500mm* 10mm Plan Plan view view 600mm 600mm FRONT FRONT INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 BOILER LOCATION & 8 716 113 389d (03/2010) CLEARANCES...

  • Page 17: Balanced External Oilfit Flue Options

    L = 4000mm horizontally. 125mmØ x4 Vertical terminal (side outlet) INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 BALANCED EXTERNAL OILFIT 8 716 113 389d (03/2010) FLUE OPTIONS...

  • Page 18: Cabinet Mounted Balanced Horizontal Flue Options

    NOTE: The flue terminal and services duct must FRONT not exit through the same panel. RIGHT HAND FLUE OUTLET A + B + C Plan view FRONT INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 BALANCED FLUE OPTIONS 8 716 113 389d (03/2010)

  • Page 19: Unpacking The Boiler

    Lift carton up and away from the boiler. Remove the plastic bag from the boiler and place safely aside. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 UNPACKING THE BOILER 8 716 113 389d (03/2010)

  • Page 20: Pipework & Flue Positions

    Services and pipework connections. Condensate 105 94 RIGHT HAND SIDE Fire valve capillary Flue Services Condensate 124 89.5 LEFT HAND SIDE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 PIPEWORK & FLUE POSITIONS 8 716 113 389d (03/2010)

  • Page 21: Boiler Installation

    100mm sealing ring where the duct enters the casing and seal the joint to the exterior wall and inside the cabinet with a suitable sealant. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 BOILER INSTALLATION 8 716 113 389d (03/2010)

  • Page 22: Flue Installation

    52mm for each metre away from the boiler to ensure that the condensate flows back to the boiler for safe disposal via the condensate waste pipe. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 FLUE INSTALLATION 8 716 113 389d (03/2010)

  • Page 23: Combustion Chamber

    Plan sectional view Plan sectional view 12/18 & 18/25kW 25/32kW Hook the retainer ( J ) over the end two baffles FRONT FRONT INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 COMBUSTION CHAMBER 8 716 113 389d (03/2010)

  • Page 24: Pipework Connections

    Rotate the cover plate and seal so it does not cover the capillary, then secure with the screws provided. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 PIPEWORK CONNECTIONS 8 716 113 389d (03/2010)

  • Page 25: Short Parts List Riello Rdb 2.2

    Seal all joints where pipes pass through the casing, with suitable waterproof sealant. IMPORTANT: Insulate all external condensate pipe work or run in 32mm pipe work to prevent freezing. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 PIPEWORK CONNECTIONS 8 716 113 389d (03/2010)

  • Page 26: Oil Burner And Pump

    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 EXTERNAL 12/18-18/25-25/32 OIL BURNER & PUMP 8 716 113 389d (03/2010)

  • Page 27: Refitting Components

    Attach the flexible air duct and tighten clamp(D) to secure to the burner air intake. Plug burner lead (E) into control box (F). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 REFITTING COMPONENTS 8 716 113 389d (03/2010)

  • Page 28: Electrics

    Refit panel (C) and secure with screws (B). NOTE: Both frost thermostats are fitted as standard to the external appliance to provide frost protection. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 ELECTRICS 8 716 113 389d (03/2010)
  • Page 29 - Green/Yellow - Red w - White y - Yellow g - Grey bk - Black or - Orange pk - Pink White INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 ELECTRICS 8 716 113 389d (03/2010)

  • Page 30: Pre-Commissioning Checks - Appliance

    CD10 or its 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 EXTERNAL 12/18-18/25-25/32 PRE-COMMISSIONING 8 716 113 389d (03/2010) CHECKS - APPLIANCE...

  • Page 31: Filling The System

    Push lever (C) to the left and pull upwards to allow the lever to return to position A. Leave the lever (C) unlocked at position A. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 FILLING THE SYSTEM 8 716 113 389d (03/2010)

  • Page 32: Starting The Appliance

    The internal filter is accessed by removing the oil pump cover on the Danfoss BFP 11 L3, Suntec AS47C and Riello RDB. Safely dispose of the container/discharge. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 STARTING THE APPLIANCE 8 716 113 389d (03/2010)
  • Page 33 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 EXTERNAL 12/18-18/25-25/32 STARTING THE APPLIANCE 8 716 113 389d (03/2010)
  • Page 34 2.72 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 EXTERNAL 12/18-18/25-25/32 STARTING THE APPLIANCE 8 716 113 389d (03/2010)
  • Page 35 GREENSTAR HEATSLAVE EXTERNAL reset reset service lockout flue boiler reset reset GREENSTAR HEATSLAVE EXTERNAL INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 STARTING THE APPLIANCE 8 716 113 389d (03/2010)
  • Page 36 Heatslave tank. service lockout flue boiler GREENSTAR HEATSLAVE EXTERNAL reset reset service lockout flue boiler GREENSTAR HEATSLAVE EXTERNAL reset reset INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 STARTING THE APPLIANCE 8 716 113 389d (03/2010)

  • Page 37: Water Treatment

    . INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 WATER TREATMENT 8 716 113 389d (03/2010)

  • Page 38: Finishing Commissioning - Appliance

    NOTE: Release drain point (K) to drain the secondary heat exchanger. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 FINISHING COMMISSIONING - 8 716 113 389d (03/2010) APPLIANCE...

  • Page 39: Inspection And Service

    Sealed systems only: The PRV is a safety device and must be checked for correct operation. The expansion vessel pressure must be checked and adjusted as required. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 INSPECTION AND SERVICE 8 716 113 389d (03/2010)
  • Page 40 B - Cover - oil pump 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 EXTERNAL 12/18-18/25-25/32 INSPECTION AND SERVICE 8 716 113 389d (03/2010)
  • Page 41 ( L ) and tighten, using the sequence shown in figure, until the chamber door is firmly secured, do not over tighten the nuts. FRONT FRONT INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 INSPECTION AND SERVICE 8 716 113 389d (03/2010)
  • Page 42 2.72 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 EXTERNAL 12/18-18/25-25/32 INSPECTION AND SERVICE 8 716 113 389d (03/2010)
  • Page 43 Part Number: 8 716 106 197 0 0.50 80° ES (18kW output) Part Number: 8 716 156 669 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 SHORT PARTS LIST 8 716 113 389d (03/2010) BENTONE 40 - 12/18...
  • Page 44 0.55 80° EH (21.5kW output) Part Number: 8 716 156 671 0 0.65 80° EH (25kW output) Part Number: 8 716 110 362 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 SHORT PARTS LIST 18/25 8 716 113 389d (03/2010)

  • Page 45: Short Parts List Riello Rdb

    Part Number: 8 716 156 679 0 0.5 60° ES (18kW output) Part Number: 8 716 156 671 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 SHORT PARTS LIST 8 716 113 389d (03/2010) RIELLO RDB 1 - 12/18...

  • Page 46: Short Parts List Riello Rdb 2.2 - 18/25

    Part Number: 8 716 115 843 0 0.75 60° ES (25kW output) Part Number: 8 716 106 156 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 SHORT PARTS LIST 8 716 113 389d (03/2010) RIELLO RDB 2.2 - 18/25...
  • Page 47 Part Number: 8 716 106 156 0 0.85 60° ES (32kW output) Part Number: 8 716 110 083 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 SHORT PARTS LIST 8 716 113 389d (03/2010) RIELLO RDB 1 - 12/18...

  • Page 48: Fault Finding & Diagnosis

    Faulty nozzle Replace nozzle UNDER NO CIRCUMSTANCES MUST AN APPLIANCE BE LEFT TO OPERATE WITH ANY CONTROL LINKED OUT OR OVERRIDDEN. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 FAULT FINDING 8 716 113 389d (03/2010)
  • Page 49 Rectify burner operation and lockouts operation, numerous lockouts Odour in cabinet, oil leaks from Rectify oil leaks, replace components if pipework, flexible hoses necessary connections FAULT FINDING INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 106 389c (01/2009)

  • Page 50: Riello Controlbox Operation

    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 51: Fault Finding Logic For Satronic Control Box

    Stray light Replace Replace Photo cell Replace coil Boiler not on photo control box lead lead OK? lead operating cell? with a heating / hot water demand 230V at Disconnect photo cell, Replace Replace Coil lead Replace solenoid coil reset lockout, burner pump photo cell control box...

  • Page 52: Fault Finding Logic For Riello Control Boxes

    FAULT FINDING & DIAGRAMS MO535 IMPORTANT NOTE: The box has a built in delay of 11 seconds before activating the motor. The preheater link must be fitted at for the box to operate Replace Replace Boiler not control box nozzle operating with a heating /...

  • Page 53: Electrical Schematic

    MAINS CONNECTION X1 (PIN 5) MANUAL RESET TANK LOCKOUT OVERHEAT INDICATOR BOILER MODE THERMOSTAT INDICATOR X1 (PIN 6) X11 (PIN 2) X11 (PIN 3) X12 (PIN 3) brown X9 (PIN 1) X9 (PIN 2) X7 (PIN 1) X3 (PIN 3 (L)) white brown X7 (PIN 4)

  • Page 54: Oil Boiler 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 8 716 113 389d 30/3/10 14:01 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.
  • Page 56 TO OPERATE WITH ANY CONTROL LINKED OUT OR OVER RIDDEN. 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 8 716 113 389d (03/2010)

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