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  5. Instruction Manual

Worcester 12/18 Instruction Manual

Manual is about: GREENSTAR CAMRAY KITCHEN FLOOR STANDING OIL FIRED CONDENSING BOILER CONVENTIONAL FLUE & ROOM SEALED FLUE

Summary of 12/18

  • Page 1

    Instruction manual installation commissioning & servicing gb 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...

  • Page 2

    Installation & servicing instructions installation & servicing instructions for worcester greenstar danesmoor wall mounted oil 12/18-18/25 8 718 681 134a (08.08) 1 symbols used in this manual: domestic hot water central heating room thermostat frost thermostat wait time period programmer/timer off i...

  • Page 3

    Safety & regulations important information and symbols 1 safety precautions and installation regulations 3 appliance information general information 4 technical data 5 layout & components 6 cleaning primary systems 7 mains supply 8 oil supply 9 water systems & pipework 10-11 condensate pipework 12 p...

  • Page 4

    Safety precautions & installation regulations installation & servicing instructions for worcester greenstar danesmoor wall mounted oil 12/18-18/25 8 718 681 134a (08.08) 3 saf et y & re gul a t io n s safety precautions installation regulations oil smells, leaks or fumes from the appliance: extingui...

  • Page 5

    General information installation & servicing instructions for worcester greenstar danesmoor wall mounted oil 12/18-18/25 8 718 681 134a (08.08) 4 ap p l ian c e inf o rm a t io n general information standard package: a - wall mounted oil fired condensing boiler. B - accessories tray. C - flue adapto...

  • Page 6

    Technical data installation & servicing instructions for worcester greenstar danesmoor wall mounted oil 12/18-18/25 8 718 681 134a (08.08) 5 technical data central heating primary water capacity (total) litres maximum static head metres minimum static head metres water side resistance (20°c differen...

  • Page 7

    Layout & components installation & servicing instructions for worcester greenstar danesmoor wall mounted oil 12/18-18/25 8 718 681 134a (08.08) 6 ap p l ian c e inf o rm a t io n 1 2 3 4 5 6 8 9 10 11 12 13 14 16 18 15 19 20 21 17 24 25 27 28 29 30 31 26 32 33 34 37 36 38 39 22 4.1 4.2 35 7 23 layou...

  • Page 8

    Cleaning primary systems before cleaning the system: ensure the system and pipework is in good working order. Flush the existing system with a power flushing machine or with a chemical cleaner before installing new components. Cleaning the primary system: cleanse the system in accordance with bs 759...

  • Page 9

    Mains supply electric supply: • supply: 230v - 50hz. • cable: pvc insulated 0.75mm 2 (24 x 0.2mm) temperature rated to 90°c. • protection ip20. • external 5a fuse to bs1362. • the appliance must be earthed. • please refer to iee regulations for cross bonding requirements. • it must be possible to is...

  • Page 10

    Oil supply oil supply : • this appliance is suitable for kerosene (28 second oil) only, no other fuel must be used. • plastic or steel tanks should be installed to bs 5410. A steel tank should conform to bs 799: part 5 and have a slope of 1 in 24 away from the outlet valve with a sludge cock at its ...

  • Page 11

    R typical open vent system: a - appliance. B - expansion vessel. C - automatic bypass valve. D - drain cock. E - feed and expansion cistern. F - feed and expansion 15mmØ min. G - pressure gauge. H - open vent 22mmØ min. J - circulating pump. K - zone valve. L - lockshield valve. M - hot water cylind...

  • Page 12

    Water systems & pipework filling primary sealed systems: • filling the system must comply with one of the methods shown opposite. • the filling point must be at low level and must never be a permanent direct fixing to the mains water supply. • filling loops must be wras approved. Heating return hose...

  • Page 13

    Condensate pipework condensate pipework: • all national and, where appropriate, local regulations for the discharge and neutralisation of condensate should be followed. • the condensate pipe must be a minimum of 21.5mmØ polypropylene pipe. Routing the pipework: wherever possible, the condensate pipe...

  • Page 14

    Pressure relief pipework important: the pressure relief valve is a safety device for the boiler and if activated may discharge boiling water or steam through the relief valve drain pipe. Care should be taken when siting the outlet pipe so that it does not cause an obstruction or discharge above a wi...

  • Page 15

    • this boiler is only suitable for installing internally within a property at a suitable location onto a fixed rigid vertical non combustable surface of the same size as the boiler and capable of supporting the boiler weight. • the boiler is not suitable for external installation unless a suitable e...

  • Page 16

    600mm 2250mm 600mm 750mm 1 1 2 3 2 3 a 0 600mm 2250mm 600mm radius 750mm a a - bath or shower cubicle (zone 0) 1 1 2 2 3 0 3 boiler location & clearances compartments: follow the requirements of bs 5410 and note: • minimum clearances must be maintained. • an access door is required to install, servi...

  • Page 17

    Minimum dimensions of flue terminal positions for oil fired appliances: terminal position cf rs(h) rs(v) a 1 2 directly below an opening, air brick, opening window, etc n/a 600mm n/a b 1 2 horizontally to an opening, air brick, opening window, etc n/a 600mm n/a c below a plastic/painted gutter, drai...

  • Page 18

    Conventional flue c b a d e a - boiler b - flue c - max. 2 bends at 135° d - anti down-draught terminal e - chimney • open (conventional) flued appliances must not be installed in a bedroom, bathroom or bedsitting room. • the flue system must be in accordance with bs 5410 : part 1 and the current bu...

  • Page 19

    Room sealed flue options the diagrams (opposite) show the components used and the maximum flue length (l) for each flue configuration. 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. • only ...

  • Page 20

    Unpacking: it is advised that two or more persons are involved in the transfer of the packaged boiler from the van to the point of delivery. 1 once the packaged boiler has been delivered, the outer carton is opened first. Care should be taken when releasing the straps. If a sharp implement is used m...

  • Page 21

    All removed parts must be placed safely away from the working area until required in order to avoid a potential tripping or slipping hazard. At all times the correct method for handling heavy objects should be strictly observed. Removing the base support board: it is advised that two or more persons...

  • Page 22

    In st al la ti o n unpacking the boiler installation & servicing instructions for worcester greenstar danesmoor wall mounted oil 12/18-18/25 8 718 681 134a (08.08) 21 all removed parts must be placed safely away from the working area until required in order to avoid a potential tripping or slipping ...

  • Page 23

    All packaging must be placed safely away from the working area in order to avoid a potential tripping or slipping hazard. At all times the correct method for handling heavy objects should be strictly observed. Removing the base support board: it is advised that two or more persons are involved in th...

  • Page 24

    Safety: all relevant safety precautions must be undertaken. Protective clothing, footwear, gloves and safety goggles must be worn as appropriate. Pipework positions: a - flow 22mm Ø copper. B - return 22mm Ø copper. C - primary drain hose connection. D - condensate outlet 21.5mm Ø. E - flue outlet. ...

  • Page 25

    24 in st al la ti o n boiler installation drill the 6 mounting holes (the wall bolts require 10mmØ x 90mm hole depth), the pipe fitting bracket fixing hole (wall plug and 5mmØ screw not supplied) and flue exit (using the size chart on the previous page). Caution: the bolts supplied are designed to b...

  • Page 26

    Combustion chamber: 3 check all the baffles (a), baffle retainers (b) and restrictor plates (c) are correctly fitted, (they may have moved during transport or installation), then refit the baffle access door (d). Refit the combustion chamber door (e) using the nuts and washers (f), tighten until the...

  • Page 27

    Important: the boiler is not designed to take the weight of the flue system, this must be supported externally to the boiler. Grease the vertical adaptor seal with the solvent free grease supplied. Install the flue following the instructions supplied with the flue. 1 refit the condensate trap (a)to ...

  • Page 28

    Caution: isolate the oil, water & electrical mains supplies before starting any work and observe all relevant safety precautions. Oil burner: 1 check the nozzle (a) and electrode (b) settings are correct as shown opposite. Ensure nozzle (a) is aligned centrally within the combustion head (c). Inspec...

  • Page 29

    Adjust position of air damper discs to suit burner output (see chart below), located as above. Access by removing the two star screws (sc) to release the air inlet manifold. 12/18 18/25 %co 2 nominal boiler rating at normal operating temperature using 28sec kerosene: nozzle boiler 12/18 rdb 1 oil pu...

  • Page 30

    2 refitting components 2 lift electrical control box (a) back onto the supporting bracket (b). Locate the control box bracket at the rear a and secure at the base of the primary heat exchanger with the securing nut (c). Carefully feed the capilleries (d) back over the front of the boiler and through...

  • Page 31

    1 = earth = live = neutral a a a f d c 3 5 2 b c g h 7 8 9 10 5 6 7 8 9 10 n1 n2 1 2 3 4 5 6 230v 4 e ch dhw external 230v programmer j from programmer f electrics danger - 230v: isolate the mains electricity supply before starting any work and observe all relevant safety precautions. Access to 230v...

  • Page 32

    B c d = earth = live = neutral riello burner m n l 1 2 3 4 5 6 1 2 3 4 5 6 a (c) (1) i g n1 n2 1 2 3 4 5 6 7 8 9 10 f h m n e k l j electrics 230v standard wiring diagram: key to components: a - earth tag. B - high limit thermostat. C - flue manual reset overheat thermostat. D - boiler manual reset ...

  • Page 33

    Electrics = earth • = live • = neutral • = switched live 7 8 9 10 f h 2 port 3 port o hot water off hot water on heating on inside boiler outside boiler p g n1 n2 1 2 3 4 5 6 danger - 230v: isolate the mains electricity pre-wired remote 2 or 3 port valve control set using internal programmer: key to...

  • Page 34

    Electrics 7 8 9 10 f h o inside boiler outside boiler g n1 n2 1 2 3 4 5 6 = earth • = live • = neutral • = switched live danger - 230v: isolate the mains electricity pre-wired remote 2 or 3 port valve control set using external programmer: key to components: o - remote junction box (10-way) to conne...

  • Page 35

    Electrics = earth • = live • = neutral 7 8 9 10 f h 2 port inside boiler outside boiler p g n1 n2 1 2 3 4 5 6 u q t c 2 1 s blue brown r blue blue grey yellow / green orange brown blue grey yellow/green orange brown danger - 230v: isolate the mains electricity 2 port valve control set: key to compon...

  • Page 36

    Electrics danger - 230v: isolate the mains electricity 3 port valve control set: key to components: r - room thermostat. S - circulating pump. F - internal programmer connector. G-terminal connector block. H - link connector. T - hot water cylinder thermostat. U - mid-position valve. P - optional 23...

  • Page 37

    1 4 3 2 5 pre-commissioning checks - appliance caution: isolate the mains electrical supplies before starting any work and observe all relevant safety precautions. 1 check that the service and water pipes are connected correctly. 2 check that the oil supply is kerosene and that the pipework is conne...

  • Page 38

    1 open all system and radiator valves. Turn on the water main stop cock. Open vented systems only: turn on the water to the system feed and expansion cistern and allow the system to fill. 2 sealed systems only: check and if required, adjust the expansion vessel pressure using the schraeder type valv...

  • Page 39

    A - bleed & pressure gauge port b - pressure adjustment c - vacuum gauge port d - retaining screws - cover c b a d riello rdb oil pump burner lockout reset button ( i ) burner lockout f e g return flow 1 h i starting the appliance important: never run the appliance when the appliance/system is unpre...

  • Page 40

    %co 2 nozzle boiler 12/18 rdb 1 oil pump pressure (p.S.I.) fuel flow rate kg/h l/h approx. Flue gas temp °c approx. Air setting input output kw kw 0.40 60 °es 0.45 60 °es 0.50 6 0 °es 100 110 120 1.06 1.30 1.55 1.34 1.65 1.96 63 69 71 12.0 12.0 12.5 2.25 2.5 4.25 12.4 15.2 18.1 12 15-18 12.7 15.6 bo...

  • Page 41

    Starting the appliance installation & servicing instructions for worcester greenstar danesmoor wall mounted oil 12/18-18/25 8 718 681 134a (08.08) 40 c o m m iss io n in g 1 a b 2 c starting the appliance central heating: 1 open all radiator valves. Set room thermostat to maximum. Set programmer to ...

  • Page 42

    31 water treatment important: debris from the system can damage the boiler and reduce efficiency. Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance warranty. Flushing (central heating): 1 switch off the boiler. Open vented systems o...

  • Page 43

    Finishing commissioning - appliance 1 locate the top rear edges of panel (a ) onto the supporting tabs ( b ) and drop the front panel carefully into position over the appliance. Push gently into place taking care to apply any pressure at the edges of the panel to avoid accidental damage lift the bot...

  • Page 44

    Inspection and service 1 a e c d b g 2 inspection and service installation & servicing instructions for worcester greenstar danesmoor wall mounted oil 12/18-18/25 8 718 681 134a (08.08) 43 ser v ic in g & s p ar e s caution: isolate the water, electrical and oil mains supplies before starting any wo...

  • Page 45

    Inspection and service installation & servicing instructions for worcester greenstar danesmoor wall mounted oil 12/18-18/25 8 718 681 134a (08.08) 44 ser v ic in g & sp a res clean the burner: remove the air intake cover (a) and clear any debris from the air intake and air damper. Disassemble the bu...

  • Page 46

    Inspection and service installation & servicing instructions for worcester greenstar danesmoor wall mounted oil 12/18-18/25 8 718 681 134a (08.08) 45 ser v ic in g & s p ar e s inspection and service external oil filter: remove the paper element from the external oil filter and replace it. If the fi...

  • Page 47

    Inspection and service installation & servicing instructions for worcester greenstar danesmoor wall mounted oil 12/18-18/25 8 718 681 134a (08.08) 46 ser v ic in g & sp a res baffle arrangement 12/18 12/18 model shown baffle access door baffle retainer remove and fit through baffle access door. Baff...

  • Page 48

    Baffle arrangement 18/25 18/25 model shown baffle access door baffle retainer remove and fit through baffle access door. Baffle 3 for 18/25 models, fitted in tubes 1, 3 & 4. Lift baffle to remove the baffle retainer then pull down to remove the baffle through the combustion chamber. Restrictor plate...

  • Page 49

    Inspection and service installation & servicing instructions for worcester greenstar danesmoor wall mounted oil 12/18-18/25 8 718 681 134a (08.08) 48 ser v ic in g & sp a res inspection and service re-commission the burner: 1 align burner combustion head into the combustion chamber door. Locate the ...

  • Page 50

    Short parts list 12/18 7 8 11 15 16 17 13 12 14 2 3 4 5 6 9 10 1 7a 18 19 20 1 burner - riello rdb 1 12/18 he part number: 8 718 681 015 0 2 combustion head - ld2x sh12/18 part number: 8 716 112 731 0 3 control box mo535 part number: 8 718 682 250 0 4 photocell part number: 8 716 109 193 0 5 ignitio...

  • Page 51

    Short parts list 18/25 installation & servicing instructions for worcester greenstar danesmoor wall mounted oil 12/18-18/25 8 718 681 134a (08.08) 50 ser v ic in g & sp a res 7 8 11 15 16 17 13 12 14 2 3 4 5 6 9 10 1 7a short parts list 18/25 1 burner - riello rdb 2.2 18/25 he part number: 8 718 681...

  • Page 52

    Fault finding & diagrams fa ul t f ind in g in s ta l l a t ion & se r v ici ng i n s t r u c t ions f o r w orce s t e r g r e e n s ta r d a n e smoor w a l l mou n t e d oi l 12/18-18/25 8 7 18 6 81 134a (0 8.0 8) 51 start burner not operating normally. Find symptom list below. Intermittent locko...

  • Page 53

    Fa ul t f ind in g in s ta l l a t ion & se r v ici ng i n s t r u c t ions f o r w orce s t e r g r e e n s ta r d a n e smoor w a l l mou n t e d oi l 12/18-18/25 8 7 18 6 81 134a (0 8.0 8) 52 fault finding & diagrams start no heating/hot water press in the power button no is the power button on? ...

  • Page 54

    Fault finding & diagrams fa ul t f ind in g in s ta l l a t ion & se r v ici ng i n s t r u c t ions f o r w orce s t e r g r e e n s ta r d a n e smoor w a l l mou n t e d oi l 12/18-18/25 8 7 18 6 81 134a (0 8.0 8) 53 start boiler not operating normally. Find symptom list below. Boiler overheat th...

  • Page 55

    Boiler not operating with a heating / hot water demand burner motor runs? Lockout within 1 second? Replace control box replace motor/pump check boiler controls & supply replace motor 230v to control box? Motor or pump seized? Photo cell functional? Solenoid coil functional (100Ω)? Replace photo cell...

  • Page 56

    Mo535 rdb control box operation this operation instruction is provided to assist competent and suitably qualified engineers to locate and rectify faults. Whilst every effort has been taken to ensure the information given is correct and complete we cannot guarantee that every eventuality has been cov...

  • Page 57: Service Interval Record

    Service interval record 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 desc...

  • Page 58

    Service 1 date engineer name company name tel no. Oftec reg no. Pump pressure: psi co 2 %: nozzle changed? Yes no f.G.T. °c flue pressure: comments signature service 3 date engineer name company name tel no. Oftec reg no. Pump pressure: psi co 2 %: nozzle changed? Yes no f.G.T. °c flue pressure: com...

  • Page 59

    Notes notes installation & servicing instructions for worcester greenstar danesmoor wall mounted oil 12/18-18/25 8 718 681 134a (08.08) 58 no t e s.

  • Page 60

    In the unlikely event the boiler does not give complete satisfaction, before calling for a service engineer, the installer should check the following:- general checks 1. Is there 230v across the boiler live and neutral terminals? 2. Is the polarity correct? (230v across live and earth, 0v across neu...