Worcester Greenstar Heatslave 12/18 Instruction Manual Download Page 1

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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

Summary of Contents for Greenstar Heatslave 12/18

Page 1: ...LOOR 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 UK T...

Page 2: ...your Local Authority Building Control Body LABC that the work carried out concerning the installation and commissioning of this heating appliance has been carried out to a satisfactory standard OFTEC...

Page 3: ...CHAMBER 26 PIPEWORK CONNECTIONS 27 OIL BURNER AND PUMP 28 REFITTING COMPONENTS 29 ELECTRICS 30 COMMISSIONING PRE COMMISSIONING CHECKS APPLIANCE 32 FILLING THE SYSTEM 33 STARTING THE APPLIANCE 34 WATER...

Page 4: ...alling the appliance should be aware of the Health and Safety at Work Act and take appropriate action to ensure that the regulations are adhered to In order to give optimum efficiency and trouble free...

Page 5: ...ION STANDARD PACKAGE A Floor standing oil fired condensing boiler for open vent and sealed domestic central heating and mains fed hot water B Literature pack 855mm 600mm A 520mm B Check List Hardware...

Page 6: ...C V Frequency Hz Max power consumption W Thermostats CH control thermostat range cut in cut out C DHW control thermostat range cut in cut out C CH DHW control thermostat differential C Boiler high lim...

Page 7: ...R 26 PRIMARY HEAT EXCHANGER 27 CONDENSATE TRAP 28 CONDENSATE DRAIN PIPE WITH PUSH FIT CONNECTOR 29 PRIMARY HEAT EXCHANGER DRAIN COCK 30 TRAY 31 COMBUSTION CHAMBER ACCESS DOOR 32 HEATSLAVE TANK DRAIN C...

Page 8: ...CLEANING THE PRIMARY SYSTEM 4 Cleanse the system in accordance with BS 7593 4 Fill the system with cold mains water to the recommended pressure and check for leaks 4 Open all drain cocks and drain the...

Page 9: ...on devices including those associated with water meters fitted to the mains water supply can cause a pressure build up which could damage the boiler and other household appliances Where the water main...

Page 10: ...must be installed between the tank A and the burner oil pump J b Double pipe sub gravity feed system Maximum suction height 3 5 metres Non return valves must be fitted to the inlet and return oil lin...

Page 11: ...nd tighten the nut P 4 Use flexible hoses to connect to the oil pump J 4 Lay the oil supply pipe H as straight and level as possible to avoid air pockets and unnecessary friction losses Route away fro...

Page 12: ...in the sleeping accommodation An automatic bypass valve must be connected between the heating flow and return pipes where TRVs are used on radiators This must be fitted to give at least a 3m circuit w...

Page 13: ...water flow starvation fit flow balancing valves or Ball O Fix valves to the appropriate outlets Plastic pipework Any plastic pipework used for the DHW system must have a polymeric barrier complying wi...

Page 14: ...olonged cold spells the following methods of installing a condensate drainage pipe should be adopted in order of priority Wherever possible the condensate drainage pipe should be routed and terminated...

Page 15: ...t exceed three metres 4 The pipe should be run internally as far as possible before going externally and the pipe diameter should be increased to 32mm before it passes through the wall to the exterior...

Page 16: ...sely followed NOTE Internal pipe runs in unheated areas such as lofts basements and garages should be treated as external runs Making it safe Condensate pipework must not leak freeze or block up Conde...

Page 17: ...r be on the same wall to the outside air The minimum air vent free area is given in the table opposite a INSTALLATION CLEARANCES Diagram a shows the minimum space recommended to install the boiler onl...

Page 18: ...landing corridor lobby shaft etc Air vents must allow access for clean free air and must be sited to comply with the flue terminal position requirements Air ducting runs must not exceed 3m Low level...

Page 19: ...d less than 600mm away from a projection above it and the projection consists of plastics or has a combustible or painted surface then a heat shield of at least 750mm wide should be fitted 5 If the lo...

Page 20: ...The flue can be increased in size from the boiler take off point providing the joint is correctly sealed Never reduce the flue diameter from the boiler take off point CF Sizing 12 18 and 18 25 100 103...

Page 21: ...nsion C Flue bend 90 D Flue bend 45 E Vertical Terminal Kit incl 90 elbow Calculating the flue length Measure the total flue length required noting that the maximum straight flue length including the...

Page 22: ...top supporting ledge and store safely away from the working area 44 Remove the bolts securing the boiler to the transport pallet 4 Two or more persons are required to remove the boiler from the palle...

Page 23: ...000mm of horizontal length that the flue opening is away from the boiler NOTE All horizontal flue sections must rise away from the boiler by 52mm per metre to ensure that condensate flows back into th...

Page 24: ...ocking ears to unplug burner lead L from control box F 54 Release the expansion vessel M from the support bracket N and remove taking care not to snag the thermostat capillaries 4 Stand the expansion...

Page 25: ...6 190 050 INSTALLATION NOTES 4 When connecting a flue elbow directly to the boiler flue outlet loosen the flue elbow retaining bracket screws N before fitting the flue elbow Insert the flue elbow with...

Page 26: ...plan views below 34 Refit combustion chamber door A IMPORTANT Secure with nuts and washers B and tighten using the sequence shown in figure 3a until the chamber door is firmly secured do not over tigh...

Page 27: ...isolating valve G and ensure the valve is closed NOTE Replace flexible hose at annual service to prevent possible oil leakage 4Connect the flexible oil hose H to the isolating valve G CONDENSATE CONN...

Page 28: ...pump for a single pipe system The pump is factory set for single pipe operation with the flexible oil hose fitted Check connections before use Converting the oil pump for a double pipe system 14 Check...

Page 29: ...ses escaping from the combustion chamber into the room 4 Attach air duct and tighten clip D to secure to the burner air intake 24 Refit the expansion vessel E onto the support bracket F taking care no...

Page 30: ...g plate J 4Set the pin on the rear of the programmer H to pumped 4Clip programmer H into fascia panel 4Remove 4 pin plug from X4 and discard 4Connect programmer plug into terminal X4 Optional external...

Page 31: ...k manual reset overheat thermostat 10 Manual reset lock out 11 Optional fascia mounted external programmer 12 Burner socket 13 Burner plug 14 Burner control box 15 Flow switch 16 Circulating pump 17 D...

Page 32: ...via the supplied flexible oil hose 4 Turn on the main oil supply valve at the tank check the oil supply pipework and connections Rectify any leaks NOTE Replace flexible hose at annual service to preve...

Page 33: ...em to between 1 and 2 bar pressure via a WRAS approved filling link Monitor the pressure gauge during venting and repressurise if required 4 Check air is being discharged from the automatic air vents...

Page 34: ...he isolation valve and place in a container of kerosene H Connect a spare flexible oil hose I to discharge into container H Open the isolating valve turn on the power to the boiler and set the program...

Page 35: ...e flame monitoring photocell mounted in the burner body will alert the burner control box to shut the burner down and provide a safe lockout state indicated by the illumination of the lockout indicato...

Page 36: ...OW RATE Kg h l h APPROX FLUE GAS TEMP C AIR DAMPER DISC APPROX AIR SETTING APPLIANCE INPUT OUTPUT kW Btu hr kW Btu hr 12 18 Riello RDB 1 Burner 0 35 80 SR 0 45 60 ES 0 50 60 ES 105 120 125 1 04 1 29 1...

Page 37: ...ot water tap The burner should be OFF and the circulating pump ON The burner will turn ON when the DHW thermostat calls for heat 4 Check the water flow rate using a suitable measuring container 12 18K...

Page 38: ...t the room thermostat to minimum The burner and circulating pump should be off The diverter valve E should return to port A for DHW default Domestic hot water central heating 34Set the room thermostat...

Page 39: ...r combined inhibitor anti freeze if the system is exposed to freezing conditions to the heating system in accordance with the manufacturers instructions The inhibitor or combined inhibitor anti freeze...

Page 40: ...ndover 4Complete the Guarantee Registration Card Combustion Record at the rear of this manual and CD11 or an equivalent commissioning form 4Set up the controls and show the user how to operate all the...

Page 41: ...rol box G 54Release the expansion vessel M from the support bracket N and remove taking care not to kink or strain the flexible hose or snag the thermostat capillaries 4Stand the expansion vessel M on...

Page 42: ...nts 4Remove the combustion head K and thoroughly clean any deposits 4Remove the nozzle E 4Check the nozzle holder is clear of any debris and clean if necessary 4Fit a new oil atomising nozzle E DO NOT...

Page 43: ...stainless steel secondary heat exchanger components 4Check the condensate route C is clear 4The condensate trap D should be removed and checked for debris 4Release the pipe locking tab E and disconnec...

Page 44: ...using a suitable brush and clear all loose debris from the combustion chamber 4Check the condition of the combustion chamber access door insulation If the insulation is damaged the door assembly must...

Page 45: ...e ball stud connections P at the base of the front panel N and push towards the boiler to secure 64Locate the top panel R onto the ball stud connections S and press down to secure After service handov...

Page 46: ...ng control thermostat Part Number 8 716 107 621 0 11 Auto reset High Limit thermostat Part Number 8 716 107 640 0 12 Manual reset High Limit thermostat Part Number 8 716 107 625 0 13 Manual reset flue...

Page 47: ...ng control thermostat Part Number 8 716 107 621 0 11 Auto reset High Limit thermostat Part Number 8 716 107 640 0 12 Manual reset High Limit thermostat Part Number 8 716 107 625 0 13 Manual reset flue...

Page 48: ...art Number 8 716 107 625 0 13 Manual reset flue thermostat Part Number 8 716 107 624 0 14 DHW control thermostat Part Number 8 718 689 060 0 15 Manual reset tank thermostat Part Number 8 718 688 624 0...

Page 49: ...blue brown DHW CONTROL THERMOSTAT WATER FLOW SWITCH LOCKOUT INDICATOR X11 PIN 2 PUMP X7 PIN 1 brown MOTORISED DIVERTER VALVE R1 X8 PIN 3 brown grey X12 PIN 4 grey BURNER X13 PIN 1 yellow pink X13 PIN...

Page 50: ...settings incorrect Set up as in installation instructions Faulty ignition transformer Replace Open circuit ignition Check and replace electrodes or high tension leads if necessary Faulty control box o...

Page 51: ...ating incorrect Correct burner rating Boiler thermostat differential incorrect Replace boiler thermostat External controls not operating correctly Check and correct external controls OIL SMELLS Blocke...

Page 52: ...T AFTER 25s Y N N Y Y N N N Y Y N N N Y Y Y N N Y Y N Y N SOLENOID COIL LEAD OK REPLACE SOLENOID COIL LEAD Y N Y N REPLACE FAN MOTOR PHOTOCELL RESISTANCE 10 M IN DARK AND 10 k IN LIGHT REPLACE PHOTOCE...

Page 53: ...Y Y Y N N N Y Y Y N N Y N Y Y REPLACE NOZZLE N N N C E F PUMP PRIMING FEATURE see instruc on manual Sequence for pump priming ac va on The func on can only be ac vated using the remote reset during lo...

Page 54: ...SCALE REDUCER BEEN FITTED YES NO WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE RECORD WATER FLOW RATE lts min CONFIRM THE FOLLOWING THE HEATING AND HOT WATER SYSTE...

Page 55: ...TELNo OFTECREGNo PUMPPRESSURE psi CO2 NOZZLECHANGED YES NO F G T C FLUEPRESSURE COMMENTS SIGNATURE SERVICE 6 DATE ENGINEERNAME COMPANYNAME TELNo OFTECREGNo PUMPPRESSURE psi CO2 NOZZLECHANGED YES NO F...

Page 56: ...NOTES INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12 18 18 25 25 32 6 720 802 432 issue A 04 2012 56 NOTES NOTES...

Page 57: ...NOTES NOTES INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12 18 18 25 25 32 6 720 802 432 issue A 04 2012 57 NOTES...

Page 58: ...NOTES INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12 18 18 25 25 32 6 720 802 432 issue A 04 2012 58 NOTES NOTES...

Page 59: ...NOTES NOTES INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12 18 18 25 25 32 6 720 802 432 issue A 04 2012 59 NOTES...

Page 60: ...t water demand from the programmer and has the tank reached temperature No domestic hot water external programmer 1 Is there 230V on pin 2 of terminal block X4 2 Remove the external wiring from termin...

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