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INSPECTION AND SERVICE

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32

6 720 802 432 issue A 04/2012

SER

RES

INSPECTION AND SERVICE

Removal of control box:

NOTE:

The control box does not need to be
removed for servicing.

Pull the control box slider fully out.

Lift the box slightly to align the pivot point
with the keyhole.

Push the lefthand side of the box in slightly
to release.

Lift the lefthand side up.

Pull away from the righthand side pivot

point.

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 check the air damper moves
freely.

Clean both sides of the fan impeller and

remove any debris from the burner housing.

Check that the impeller rotates freely.

Reassemble the components.

Remove the combustion head (K) and

thoroughly clean any deposits.

Remove the nozzle (E).

Check the nozzle holder is clear of any debris

and clean if necessary.

Fit a new oil atomising nozzle (E).

DO NOT dismantle the nozzle and DO NOT
clean the nozzle tip.

Check the electrodes (F) and reset if

necessary as shown opposite.

Refit the combustion head. Check that the

nozzle (E) lies centrally in the combustion
head and the head settings are as shown.
Ensure that the photo cell is lined up with the
sight hole.

Withdraw the photocell (P) from its housing

and wipe clean.

Remove the oil pump internal filter, clean in

kerosene and reassemble.

The internal filter is accessed by removing
screws (A) and the oil pump cover (B).

IMPORTANT

Replace the standard flexible oil hose/s

at every annual service to prevent the
possibility of oil leakage.

Reassemble the burner components.

Check the sponge O-ring seal located

around the combustion head and replace if
necessary.

This seal must be in good condition since
failure will cause flue gases to escape into
the room.

A - Retaining screws - cover

B - Cover - oil pump

RIELLO
RDB OIL PUMP

2.5mm

Electrode gap 4mm

5mm

RIELLO

RDB 1 & 2.2

12/18
18/25
25/32

Содержание Greenstar Heatslave 12/18

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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