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Worcester Greenstar Heatslave 12/18 Instruction Manual

Other manuals for Greenstar Heatslave 12/18: Technical Information
Manual is about: FLOOR STANDING OIL FIRED CONDENSING COMBINATION BOILER

Summary of 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 open vent & sealed central heating systems with mains fed domestic hot water uk the appliance is for use...

  • Page 2

    Installation & servicing instructions installation & servicing instructions for worcester greenstar heatslave 12/18-18/25-25/32 8 716 106 252f (03/2010) 2 symbols used in this manual: domestic hot water central heating room thermostat frost thermostat wait time period programmer/timer off installati...

  • Page 3

    Safety & regulations important information and symbols 2 safety precautions and installation regulations 4 appliance information general information 5 technical data 6 layout & components 7 pre-installation cleaning primary systems 8 mains supply 9 oil supply 10 water systems & pipework 11 pressure ...

  • Page 4

    Safety precautions & installation regulations installation & servicing instructions for worcester greenstar heatslave 12/18-18/25-25/32 8 716 106 252f (03/2010) 4 saf et y & re gul a t io n s safety precautions installation regulations oil fumes or leaks from the appliance: extinguish any naked flam...

  • Page 5

    General information installation & servicing instructions for worcester greenstar heatslave 12/18-18/25-25/32 8 716 106 252f (03/2010) 5 a ppl ia n c e inf o rm a t io n general information standard package: a - floor standing oil fired condensing boiler for open vent and sealed domestic central hea...

  • Page 6

    Technical data installation & servicing instructions for worcester greenstar heatslave 12/18-18/25-25/32 8 716 106 252f (03/2010) 6 technical data central heating primary water capacity (total) litres maximum static head metres minimum static head metres available pump head (20°c difference) at max....

  • Page 7

    15 6 7 8 9 11 12 13 4 2 16 42 38 44 36 21 43 37 41 14 i) 46 45a ii) iii) iv) v) 1 47 17 18 19 26 27 28 i) 46 47 45b iii) v) 20 ii) iv) a 3 5 10 29 30 31 40 39 22 23 24 25 32 34 35 33 layout & components the diagram opposite excludes the top, front and rh side casing panels. 1 control box assembly 2 ...

  • Page 8

    Cleaning primary systems important: all the following pre-installation sections must be read and requirements met before starting boiler or flue installation. Caution: isolate the mains supplies before starting any work and observe all relevant safety precautions. Cleaning primary systems installati...

  • 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. • refer to iee regulations for cross bonding requirements. • it must be possible to isolate t...

  • Page 10

    Oil supply installation & servicing instructions for worcester greenstar heatslave 12/18-18/25-25/32 8 716 106 252f (03/2010) 10 p r e - in st al la ti o n oil supply oil supply : • this appliance is suitable for kerosene (28 second oil) only, no other fuel must be used. • plastic or steel tanks sho...

  • Page 11

    Water systems & pipework installation & servicing instructions for worcester greenstar heatslave 12/18-18/25-25/32 8 716 106 252f (03/2010) 11 p r e - in st al la ti o n water systems & pipework primary system plastic pipework: • any plastic pipework used for the ch system must have a polymeric barr...

  • 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 links must be wras approved. Showers/bidets: • i...

  • Page 13

    Condensate & pressure relief pipework installation & servicing instructions for worcester greenstar heatslave 12/18-18/25-25/32 8 716 106 252f (03/2010) 13 p r e - in st al la ti o n condensate & pressure relief pipework condensate pipework: • all national and, where appropriate, local regulations f...

  • Page 14

    • this boiler is only suitable for installing internally within a property at a suitable location onto a fixed rigid surface of the same size as the boiler and capable of supporting the boiler weight. • the boiler must be installed on a flat level surface to ensure condensate does not enter the prim...

  • Page 15

    600mm 2250mm 600mm 2250mm 600mm 600mm radius 750mm 750mm 2250mm m 2250m boiler location & clearances installation & servicing instructions for worcester greenstar heatslave 12/18-18/25-25/32 8 716 106 252f (03/2010) 15 p r e - in st al la ti o n compartments: follow the requirements of bs 5410 and n...

  • Page 16

    Flue terminal positions installation & servicing instructions for worcester greenstar heatslave 12/18-18/25-25/32 8 716 106 252f (03/2010) 16 p r e - in st al la ti o n flue terminal positions • flue terminals must be positioned to avoid combustion products entering into buildings. • the flue must b...

  • Page 17

    P r e - in st al la ti o n conventional flue installation & servicing instructions for worcester greenstar heatslave 12/18-18/25-25/32 8 716 106 252f (03/2010) 17 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)...

  • Page 18

    Room sealed flue options installation & servicing instructions for worcester greenstar heatslave 12/18-18/25-25/32 8 716 106 252f (03/2010) 18 p r e - in st al la ti o n room sealed flue options the diagrams (opposite) show the components used and the maximum flue length (l) for each flue configurat...

  • Page 19

    Unpacking the boiler installation & servicing instructions for worcester greenstar heatslave 12/18-18/25-25/32 8 716 106 252f (03/2010) 19 in st al la ti o n 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...

  • Page 20

    Safety: all relevant safety precautions must be undertaken. Protective clothing, footwear, gloves and safety goggles must be worn as appropriate. Pipework positions: a to h (opposite) show the flue and pipe positions: a - ch flow 22mmØ copper (28mmØ on 25/32kw model) b - dhw flow 22mmØ copper c - dc...

  • Page 21

    Boiler installation 1 lift the top panel (a) upwards to disengage the ball stud connections (b) and remove. 2 remove the installation and literature packs. 3 remove securing screws (c) from each side. Slide control box (g) out fully. Pivot control box (g) up and secure in the position shown. 4 depre...

  • Page 22

    The flue can exit the boiler from outlets a, b, c or d allowing vertical (rs) and horizontal (rs low or high level) flues to be fitted. (cf position 'a' only). Refer to the separate flue installation instructions supplied with the flue kits available for this boiler: rs flue kits & components 80/125...

  • Page 23

    Combustion chamber: 1 remove the retaining nuts and washers (b). Remove combustion chamber access door (a). 2 ensure the baffles (c) and baffle retainer (d) are correctly fitted for the boiler output as shown in the plan views below. 3 refit combustion chamber door (a). Important: secure with nuts a...

  • Page 24

    1m 50mm (min.) g e h j k l k q s t 500ml n p f o pipework connections installation & servicing instructions for worcester greenstar heatslave 12/18-18/25-25/32 8 716 106 252f (03/2010) 24 in st al la ti o n pipework connections a - ch flow 22mmØ copper (28mmØ on 25/32 models) b - dhw flow 22mmØ c - ...

  • Page 25

    Caution: isolate the oil & water mains supply before starting any w o r k an d o b s e r ve all r e le vant safety precautions. Oil burner: 1 check the nozzle (a) and electrode (b) settings are correct for the relevant burner as shown opposite. Ensure nozzle (a) is aligned centrally within the combu...

  • Page 26

    B e 1 4 f e i 3 h g 2 1 c a b d refitting components 1 align burner combustion head (a) into boiler housing tube with gasket (b) correctly fitted. Push firmly down to compress the gasket (b). Tighten burner retainers (c) sufficiently to ensure a good seal. Important: ensure the gasket is a good seal...

  • Page 27

    Roomstat l n f r l r ns fs f r ls n l dhw ch electrics green/yellow 1 electrics installation & servicing instructions for worcester greenstar heatslave 12/18-18/25-25/32 8 716 106 252f (03/2010) 27 in st al la ti o n danger - 230v: isolate the mains electricity supply before starting any work and ob...

  • Page 28

    Rese t white electrics electrical components: 1 printed circuit board 2 thermostat - boiler high limit 3 thermostat - dhw control 4 thermostat - ch control 5 indicator lamp - power on 6 indicator lamp - lock-out 7 flue manual reset overheat thermostat 8 boiler manual reset overheat thermostat 9 tank...

  • Page 29

    1 2 3 4 5 200 0 0 bar litres per hour 0.6 0.5 0.4 0.3 0.2 0.1 400 600 800 1000 1200 1400 1600 200 0 0 bar litres per hour 0.6 0.5 0.4 0.3 0.2 0.1 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 0.7 12/18 & 18/25 25/32 pre-commissioning checks - appliance caution: isolate the mains supplies befor...

  • Page 30

    1 pull lever (c) up and push to the left to move the diverter valve to the mid-position between ports a and b. Push and hold lever (c) down to lock. 2 loosen the tank automatic air vent cover. The pump automatic air vent has a protective cover that must remain in place, this auto air vent needs no a...

  • Page 31

    E f a b c a b c a - bleed & pressure gauge port b - pressure adjustment c - vacuum gauge port d - retaining screws - cover d d danfoss bfp 11 l3 oil pump suntec as47c oil pump burner lockout 1 c b a d riello rdb oil pump e burner lockout reset button (e) alternative burner lockout reset button (e) s...

  • Page 32

    Starting the appliance 2 remove plastic cover from the burner casing (there is no plastic cover on the riello burner). Fit a suitable pressure gauge to port (a) on the oil pump. Important: riello burners. If changing the burner output, ensure the position of the air damper disk is correct for the de...

  • Page 33

    Starting the appliance check the co 2 levels and adjust the air shutter (l) setting according to the table opposite. Check the flue gas temperature is close to the values shown in the table. If the flue gas temperature is too high and the baffles are correctly fitted, then reduce the oil pump pressu...

  • Page 34

    1 2 3 4 c starting the appliance domestic hot water: 1 set the ch/dhw programmer to off. Fully open a hot water tap. The burner should be off and the circulating pump on. 2 close the hot water tap. Set the dhw thermostat control (c) to minimum as shown. Set the programmer to dhw on. The burner shoul...

  • Page 35

    2 1 3 4 e d c d c d c e e e starting the appliance central heating: 1 open all radiator valves. Set room thermostat to maximum. Set programmer to on for ch. Turn the dhw thermostat control (c) fully anti-clockwise. Turn the ch thermostat control (d) to max. The burner should be on with the circulati...

  • Page 36

    31 water treatment a b c c c c 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 vent...

  • Page 37

    Finishing commissioning - appliance 1 release support lugs (h) to pivot the control box (a) down and into the boiler. Secure with screws (b). 2 locate top edge of panel (c) onto the top supporting ledge (d) on the boiler. Locate the ball stud connections (e) at the base of the front panel (c) and pu...

  • Page 38

    Inspection and service caution: isolate the water, electricity and oil mains supplies before starting any work and observe all relevant safety precautions. Routine servicing: to maintain efficient boiler operation, the following should be carried out at least once a year: carry out a pre-service che...

  • Page 39

    1 clean the burner: remove the air intake cover (h) and clear any debris from the air intake and air damper. Disassemble the burner to allow access to the fan impeller. Check the condition of the gaskets between these parts and replace if necessary. Note the position of the air damper adjustment and...

  • Page 40

    Inspection and service external oil filter: remove the paper element from the external oil filter and replace it. If the filter contains a washable element, thoroughly clean in kerosene and reassemble into the filter. Clean the boiler: manifold access: release screws (a) to remove the flue manifold ...

  • Page 41

    Inspection and service combustion chamber: release the m10 retaining nuts and washers (b) and remove combustion chamber access door (a). Check the fibreglass rope seal on the combustion chamber access door (a) and replace if necessary. Remove and check the baffle retainer (d). Remove the baffles (c)...

  • Page 42

    Inspection and service installation & servicing instructions for worcester greenstar heatslave 12/18-18/25-25/32 8 716 106 252f (03/2010) 42 ser v ic in g & sp a res inspection and service re-commission the burner: 1 align burner combustion head (k) into the boiler housing tube with gasket (o) corre...

  • Page 43

    Bentone sterling 40 burner short parts list 12/18 1 burner - sterling 40 part number: 8 716 112 507 0 2 combustion head - burner part number: 8 716 112 604 0 3 control box satronic dko 970 part number: 8 716 142 396 0 4 photocell satronic mz770s part number: 8 716 156 692 0 5 control box base satron...

  • Page 44

    1 7 8 9 13 14 15 16 11 10 12 2 3 4 5 6 17 18 19 20 8a 21 22 23 24 short parts list bentone 50 - 18/25 installation & servicing instructions for worcester greenstar heatslave 12/18-18/25-25/32 8 716 106 252f (03/2010) 44 ser v ic in g & sp a res bentone sterling 50 burner short parts list 18/25 1 bur...

  • Page 45

    7 8 11 13 12 14 2 3 4 5 6 9 10 1b 15 16 17 18 19 20 21 riello rdb 1 burner short parts list 12/18 1 burner - riello rdb 1 12/18 part number: 8 718 685 873 0 2 combustion head - ld2sx (short) part number: 8 718 685 902 0 3 control box mo535 part number: 8 718 682 250 0 4 photocell part number: 8 716 ...

  • Page 46

    Short parts list riello rdb 2.2 - 18/25 installation & servicing instructions for worcester greenstar heatslave 12/18-18/25-25/32 8 716 106 252f (03/2010) 46 ser v ic in g & sp a res 7 8 11 13 12 14 2 3 4 5 6 9 10 1b 15 16 17 18 19 20 21 riello rdb 2.2 burner short parts list 18/25 1 burner - riello...

  • Page 47

    Short parts list riello rdb 2.2 - 25/32 installation & servicing instructions for worcester greenstar heatslave 12/18-18/25-25/32 8 716 106 252f (03/2010) 47 ser v ic in g & sp a res 7 8 11 13 12 14 2 3 4 5 6 9 10 1b 15 16 17 18 19 20 21 riello rdb 2.2 burner short parts list 25/32 1 burner - riello...

  • Page 48

    F a ul t f ind in g & d ia g r a m s fault finding installation & servicing instructions for worcester greenstar heatslave 12/18-18/25-25/32 8 716 106 252f (03/2010) 48 fault finding problem cause remedy lockout: pulsation on start cf - flue draught incorrect cf - check flue draught combustion setti...

  • Page 49

    Fault finding installation & servicing instructions for worcester greenstar heatslave 12/18-18/25-25/32 8 716 106 252f (03/2010) 49 f a ul t f ind in g & d ia g r a m s fault finding problem cause remedy faulty boiler operation: noisy operation pump noise from air in pump or worn pump bleed air from...

  • Page 50

    F a ul t f ind in g & d ia g r a m s fault finding installation & servicing instructions for worcester greenstar heatslave 12/18-18/25-25/32 8 716 106 252f (03/2010) 50 riello control box operation this operation instruction is provided to assist competent and suitably qualified engineers to locate ...

  • Page 51

    Boiler not operating with a heating / hot water demand burner motor runs? Burner lights immediately motor runs? 230v at solenoid coil in purge? Replace control box replace pump 230v at motor? Motor or pump seized? Replace motor capacitor motor 40 Ω across l & n? L & n to control box? Control box loc...

  • Page 52

    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 l & n to control box? Motor or pump seized? Photo cell functional? Solenoid coil functional (100 Ω)? Replace photo ce...

  • Page 53

    El e c t r ic a l s c hem a t ic n c1 power on indicator live supply l x9 (pin 2) n x1 (pin 1) frost thermostats (if fitted) programmer fuse f1 3.15a fast ceramic x2 (fs) x2 (fr) x2 (fr) x4 (pin 3) x4 (pin 1) white brown grey x4 (pin 2) x2 (ls) x2 (ns) n link (remove) 4 1 2 3 x2 (lr) n relay 1 room ...

  • Page 54: Service Interval Record

    Boiler model serial no. Commissioning engineer commissioning checks company name: pump pressure (psi): address: co 2 %: smoke reading: engineers name: f.G.T.°c: signature: flue pressure: date: burner model: controls to comply with the building regulations, each section must have a tick in one or oth...

  • Page 55

    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 2 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 56

    Contact information worcester, bosch group: technical: 0844 892 3366 service: 0844 892 3000 service (eire): 01494 0099 spares: 01905 752571 literature: 0844 892 9800 training: 01905 752526 sales: 01905 752640 website: worcester-bosch.Co.Uk website (eire): worcester-bosch.Ie- if the boiler does not g...