Worcester Greenstar Heatslave II 12/18 Installation, Commissioning & Servicing Instructions Download Page 1

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Installation, Commisioning and Servicing instructions

Floor standing oil fired condensing combination boiler balanced flue

Greenstar Heatslave II External

ErP

12/18, 18/25 & 25/32

6 720 805 210-00.1TL

For fully pumped open vent or sealed central heating systems and domestic hot water cylinders.
These appliances are for use with Kerosene (Class C2) only.

6 72

0 813 345 (2014/09)

Summary of Contents for Greenstar Heatslave II 12/18

Page 1: ...ing combination boiler balanced flue Greenstar Heatslave II External ErP 12 18 18 25 25 32 6 720 805 210 00 1TL For fully pumped open vent or sealed central heating systems and domestic hot water cyli...

Page 2: ...stallation 17 5 1 Unpacking the boiler 17 5 2 Pipework and flue positions 17 5 3 Boiler installation 18 5 4 Flue installation 18 5 5 Combustion chamber 18 5 6 Pipework connections 19 5 7 Oil burner an...

Page 3: ...substances which can corrode the appliance and invalidate any warranty Handling instructions and guidelines It is advised that more than one person is involved in the transfer of the packaged applianc...

Page 4: ...for installers who are members of these organisations to self certify their work Alternatively you must submit a building control notice to the LABC before installing any boiler The LABC will then arr...

Page 5: ...estrictor colour Lime Beige Grey Domestic Hot Water Maximum flow rate 15 litres min 15 18 22 Minimum inlet pressure dynamic for maximum flow rate bar 1 5 1 2 1 6 Maximum hot water temperature rise for...

Page 6: ...mperature regime 2 2 Low temperature means for condensing boilers 30 C for low temperature boilers 37 C and for other heaters 50 C return temperature at heater inlet P1 kW 5 7 7 9 10 2 Useful efficien...

Page 7: ...5 2014 09 7 3 4 Layout components The diagram below excludes the top front and RH side casing panels Fig 2 10 11 12 13 14 18 15 16 19 20 21 22 23 24 25 26 27 29 28 a 36 37 38 40 39 42 44 43 45 45 46 4...

Page 8: ...CE OF BS7593 Treatment of water in domestic hot water central heating and also the flushing guidelines below FLUSHING THE SYSTEM Fill the system with cold water and check for leaks Open all drain cock...

Page 9: ...pressure Maximum mains fed water pressure 10 bar If necessary fit a pressure reducing valve Where the water main supply has a non return back flow prevention valve fitted a mini expansion vessel A mus...

Page 10: ...ction line removed to assist purging air from the oil line Fig 6 De aerator feed Maximum pipe run for single pipe suction lift with de aerator 4 2 4 Pipework Use flexible hoses to connect to the oil p...

Page 11: ...3 bar Radiator valves should conform to BS 2767 10 All other valves should conform to BS 1010 An automatic bypass valve must be connected between the heating flow and return where TRVs are used on all...

Page 12: ...priate outlets 4 4 Condensate pipework Externally run condensate drainage pipe should terminate at a suitable foul water discharge point or purpose designed soak away If this method is chosen then the...

Page 13: ...here there are likely to be extremes of temperature or exposure theuseofaproprietarytrace heatingsystemforexternalpipe work incorporating an external frostthermostat should beconsidered If such a syst...

Page 14: ...ar clearance flue outlet on rear 2500mm It is strongly recommended that the flue terminal faces away from walls to reduce the possibility of wetting occurring Fig 16 Above clearance Fig 17 Rear exit f...

Page 15: ...t be fitted and terminated in accordance with the recommendations of BS5410 The flue must not cause an obstruction Discharge from the flue outlet must not be a nuisance Flue gases have a tendency to p...

Page 16: ...into the 90 bend then withdraw the tube by approximately 10mm to allow for expansion 2 Once the plume management system is in place and secured to the wall secure the terminal bend with the screws rem...

Page 17: ...25 models 28mm copper on 25 32 model Return 22mm copper 12 18 18 25 models 28mm copper on 25 32 model DCW In 15mm copper DHW Out 22mm copper PRV 15mm copper Services duct 100mm Condensate outlet 21 5m...

Page 18: ...10mminside the casing and to finish flush with the interior wall surface cut to size and fit the duct Fit the 100mm sealing ring where the duct enters the casing and seal the joint to the exterior wal...

Page 19: ...dels F 10mm oil supply connection G Oil isolating valve 10mm H Flexible oil hose J Flue manifold condensate outlet K Condensate outlet and flexible push fit connect 21 5mm supplied L Condensate pipe n...

Page 20: ...30 Ensure that the nozzle A is aligned centrally within the combustion head C Inspect for any visible defects Fig 30 Nozzle and electrode alignment Oil pump Connecting the oil pump for a single pipe s...

Page 21: ...ovided Always apply pressure at the edges of the boiler panels when securing to avoid accidental damage Fig 32 5 9 Electrical The boiler is pre fitted with a mains supply cable and plug A The 230V sup...

Page 22: ...tilted over DHW LR switched live This input provides the live feed in from a connection for a proprietary twin channel control to time the tank reheat function on the DHW All Worcester twin channel di...

Page 23: ...Installation Greenstar Heatslave II External ErP 6 720 813 345 2014 09 23 5 10 Electrical schematic Fig 36 6 720 805 209 24 1TL...

Page 24: ...s gives a 80 C flow at 4 C outdoor temperature and a 50 C flow at 14 C outdoor temperature which should be suitable for typical systems Point A is the projected value for the flow temperature at 10 C...

Page 25: ...quired adjusttheexpansionvesselpressureusingthe Schraeder type valve A Fig 42 The charge pressure of the built in 12 litre expansion vessel is 0 7 bar as dispatched which is equivalent to a static hea...

Page 26: ...used Single pipe gravity feed systems Disconnect the flexible oil hose and open the isolating valve to discharge the oil into a suitable container Ifa top entrytank hasbeen used the pipework will need...

Page 27: ...LCD display J by code 9F 855 Wait two minutes then press the lockout reset button K to initiate another start sequence Repeat procedure until a flame is established Fig 48 3 Start and run for 3 minut...

Page 28: ...econds 2 The control will run an internal test 3 When the internal test has been successfully performed this screen is displayed The boiler is in stand by Theflowtemperaturesensorindicatestheprimaryte...

Page 29: ...Menu 2 via the and arrow buttons Press and hold OK button for 1 second to enter Menu 2 The menu lists the boiler parameters that can be adjusted in this menu Fig 56 To modify setting 4 Select the desi...

Page 30: ...inal boiler rating at normal operating temperature using Kerosene Class C2 2 7A Demand fault indicator blue light activation 0 The blue light will only operate as a flashing fault alert 1 The blue lig...

Page 31: ...g system in accordance with the manufacturers instructions The inhibitor or combined inhibitor anti freeze must not cause damage to the materials within the boiler mild steel stainless steel copper an...

Page 32: ...aseofthefrontpanelusingthetoolprovided and pull the panel out and down to remove Store safely away from the working area Operatetheapplianceandsystemandnoteanyfaultswhichmayneedto be corrected during...

Page 33: ...screws H and the oil pump cover J Replace the standard flexible oil line s at every annual service to prevent the possibility of leakage due to ageing Reassemble the burner components Check the O ring...

Page 34: ...and replace if necessary Remove the one piece baffle set C clean and check the condition of the baffles Replace baffle set if considered to be badly corroded degraded Thoroughly clean all of the heat...

Page 35: ...CO2 if necessary using the air shutter When the combustion is correct turn off the boiler remove the pressure gauge and refit the blanking plug and plastic cover Refit control box 5 Rotate the box tow...

Page 36: ...D2X Short 0 45 x 60 ES 7 5 110 1 28 1 63 77 11 5 5 0 15 4 15 12 15 LD2X Short 0 55 x 80 ES 7 8 115 1 54 1 96 80 12 0 5 0 18 5 18 0 18 LD2X Short Greenstar Heatslave II 18 25 model 0 50 x 80 ES 8 5 125...

Page 37: ...Heat Exchanger gasket 8 718 690 792 0 13 Nozzle holder 8 716 116 638 0 14 Flue sample point screw 8 718 682 081 0 15 Oil nozzle 0 35 80 SR 12kW output 8 716 156 679 0 0 45 60 ES 15kW output 8 716 114...

Page 38: ...dary Heat Exchanger gasket 8 747 009 725 0 13 Flue sample point screw 8 718 682 081 0 14 Oil nozzle 0 50 80 ES 18kW output 8 716 156 671 0 0 60 60 ES 21 5kW output 8 716 156 680 0 0 75 80 ES 25kW outp...

Page 39: ...dary Heat Exchanger gasket 8 718 688 799 0 12 Flue sample point screw 8 718 682 081 0 13 Oil nozzle 0 75 80 ES 25 28 5kW output 8 716 109 387 0 0 85 80 EH 32kW output 8 716 156 644 0 14 Flow turbine 8...

Page 40: ...ng heated tank is being heated 202 CH Anti rapid cycle mode Time delay to prevent rapid cycling of the boiler on the room thermostat 203 System stand by The boiler has no CH or DHW demands 270 Power u...

Page 41: ...toconfirmtheupdateofthenew value i13 Thermal store current temperature This is the thermal store current temperature displayed in real time rounded to 0 5 C units i14 DCW inlet temperature Current DCW...

Page 42: ...ntion is required following clearance of the fault Press the reset button on the boiler fascia Blocking condition The boiler will stop operating and no fault code will be displayed Analphanumericfault...

Page 43: ...d the safety sensor on the main heat exchanger should be within 15 C of each other 276 E9 Flow temperature exceeds 95 C X Primary overheat boiler waits for temperature to reduce approximately 30 minut...

Page 44: ...Fault finding and diagnosis Greenstar Heatslave II External ErP 6 720 813 345 2014 09 44 8 5 DHW function chart Fig 84...

Page 45: ...m the last CH demand end Applianceautomaticfrost protection monitors PHE flow and internal tank sensors PHE OR Flow sensor below 8 C T ank will scavenge heat after any burn to heat tank to 10 C 3WV to...

Page 46: ...ring lockout 6720805209 73 1Wo Normal operation Any CUS lockout Blue light flashing Mains power loss Mains power restored Press reset button Press reset button IF the original lockout was due to a bur...

Page 47: ...until the power has been interrupted to the burner Burner LOCKOUT Blue light flashing 9F 855 cause code on display there is no power to the burner when the controls are in lockout Hold down the servi...

Page 48: ...diagnosis Greenstar Heatslave II External ErP 6 720 813 345 2014 09 48 8 10 Riello digital control boxes Fig 90 RIELLO MO535 MRF DIGITAL CONTROL BOX FAULT FINDING LOGIC PRE HEATER LINK FITTED FIT PRE...

Page 49: ...Fault finding and diagnosis Greenstar Heatslave II External ErP 6 720 813 345 2014 09 49 Fig 91 6 720 805 209 76 1TL...

Page 50: ...o top of oil or 3 5 metres lower iffittedwithade aeratorortwo pipeoildeliverysystem thanthe oil pump If vacuum is greater than minus 0 35 bar then you must also check that the oil supply is not obstru...

Page 51: ...Greenstar Heatslave II External ErP 6 720 813 345 2014 09 51 Notes...

Page 52: ...Greenstar Heatslave II External ErP 6 720 813 345 2014 09 52 Notes...

Page 53: ...Greenstar Heatslave II External ErP 6 720 813 345 2014 09 53 Notes...

Page 54: ...the manufacturer s instructions No Yes The operation of the boiler and system controls have been demonstrated to and understood by the customer No Yes The condensate drain has been installed in accor...

Page 55: ...ster No Pump Pressure Comments Signature Service 7 Nozzle Changed Flue Pressure F G T psi Yes No ppm CO CO CO2 ratio CO2 C Date Engineer Name Company Name Telephone No OFTEC Register No Pump Pressure...

Page 56: ...ld be removed from the oil dip pipe Boiler locks out at the start of a demand Heating off over night for example 1 If an air eliminator is being used check that there are no leaks that allow air to be...

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