Worcester greenstar heatslave 18 User manual

GREENSTAR HEATSLAVE
18/25
FLOOR STANDING OIL-FIRED CONDENSING COMBINATION BOILER
CONVENTIONAL FLUE & ROOM SEALED FLUE
FOR OPEN VENT AND SEALED CENTRAL HEATING SYSTEMS WITH DOMESTIC MAINS FED HOT
WATER
THE APPLIANCE IS FOR USE WITH 28 SECOND KEROSENE
ONLY
8-716-106-2 2a (03.0 )
INSTRUCTION MANUAL
INSTALLATION COMMISSIONING
& SERVICING
GB
Patent pending:
Application number 032764 .8

INSTALLATION & SERVICING INSTRUCTIONS
CONTACT INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
INSTALLATION &
SERVICING INSTRUCTIONS
8-716-106-2 2a (03.0 )
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
THESE INSTRUCTIONS ARE APPLICABLE TO THE WORCESTER BOSCH APPLIANCE
MODEL(S) STATED ON THE FRONT COVER OF THIS MANUAL ONLY AND MUST NOT BE
USED WITH ANY OTHER MAKE OR MODEL OF APPLIANCE.
THE INSTRUCTIONS APPLY IN THE UK ONLY AND MUST BE FOLLOWED EXCEPT FOR
ANY STATUTORY OBLIGATION.
THIS APPLIANCE MUST BE INSTALLED BY A COMPETENT PERSON. FAILURE TO INSTALL
CORRECTLY COULD LEAD TO PROSECUTION.
IF YOU ARE IN ANY DOUBT CONTACT WORCESTER BOSCH TECHNICAL HELPLINE.
DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER
BOSCH.
PLEASE LEAVE THESE INSTRUCTIONS WITH THE USER OR WITH THE APPLIANCE
AFTER INSTALLATION OR SERVICING.
WORCESTER BOSCH:
MAIN RECEPTION: 0190 7 4624
MAIN FAX: [phone]
TECHNICAL: 0870 266241
SERVICE: 08 47 2 6206
SPARES: 0190 7 2 71
LITERATURE: 0190 7 2 6
TRAINING: 0190 7 2 26
SALES: 0190 7 2640
WEBSITE: www.worcester-bosch.co.uk
WATER TREATMENT:
FERNOX 01799 0811
www.fernox.com
SENTINEL 01 1 420 9 9
www.betzdearborn.com/sentinel
FLUE TERMINAL GUARDS:
WORCESTER BOSCH
Contact details as above
CONVENTIONAL FLUE MANUFACTURERS:
INTERACTIVE (Flue Systems) Ltd., 01908 69887
Selkirk Manufacturing Ltd. (SF Ltd.), 01271 326633
CONDENSATE PUMP MANUFACTURERS:
ASPEN 01323 848842
OIL FIRING TECHNICAL ASSOCIATION:
OFTEC 084 6 8 080
www.oftec.org
ABBREVIATIONS USED IN THIS MANUAL:
Ø Diameter
CH Central Heating
DHW Domestic Hot Water
TRV Thermostatic Radiator Valve
IP Ingress Protection
CF Conventional flue
RS Room sealed flue
N/A Not allowed
SEDBUK Seasonal Efficiency for Domestic Boilers in the United Kingdom
OFTEC Oil Firing Technical Association for the Petroleum Industry
Store the applia ce i a dry area prior to
i stallatio .
IMPORTANT HANDLING INSTRUCTIONS:
It is advised that more than one person is
involved in the transfer of the packaged
appliance from the van to the point of installation.
It is advised that no attempt should be made
to move the packaged appliance without the
use of a suitable truck.
At a times the correct method for hand ing
heavy objects shou d be strict y observed.
GENERAL HANDLING GUIDELINES:
 Lift only a manageable weight, or ask for
help.
 When lifting, bend the knees, and keep the
back straight and feet apart.
 Do not lift and twist at the same time.
 Lift and carry items close to the body.
 Wear protective clothing and gloves to
protect from any sharp edges.
SYMBOLS USED IN THIS MANUAL:
Domestic hot water
Central heating
Room thermostat
Frost thermostat
Wait time period
Programmer/timer OFF
Programmer ON CH only
Programmer ON DHW only
Programmer ON CH and DHW
Cold water main supply
Electricity supply

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH CONTENTS
SAFETY &
REGULATIONS
FAULT FINDING
& DIAGRAMS
APPLIANCE
INFORMATION
PRE-
IN STALLATION
IN STALLATIONCOMMISSIONING
SERVICING
& SPARES
CONVERSION
KITS
CONTENTS
1
SAFETY & REGULATIONS
SAFETY PRECAUTIONS 2
INSTALLATION REGULATIONS 2
APPLIANCE INFORMATION
GENERAL INFORMATION 3
TECHNICAL DATA 4
LAYOUT & COMPONENTS
PRE-INSTALLATION
CLEANING PRIMARY SYSTEMS 6
MAINS SUPPLIES 7-8
WATER SYSTEMS & PIPEWORK 9-10
CONDENSATE & PRESSURE RELIEF PIPEWORK 11
BOILER LOCATION & CLEARANCES 12-13
FLUE OUTLET POSITIONS 14
CONVENTIONAL FLUE 1
ROOM SEALED FLUE OPTIONS 16
INSTALLATION
UNPACKING THE BOILER 17
PIPEWORK POSITIONS & FLUE OPENING 18
BOILER INSTALLATION 19
FLUE INSTALLATION 20
COMBUSTION CHAMBER 21
PIPEWORK CONNECTIONS 22
OIL BURNER & PUMP 23
REFIT COMPONENTS 24
ELECTRICS 2 -26
COMMISSIONING
PRE-COMMISSIONING CHECKS 27
FILLING THE SYSTEM 28
STARTING THE APPLIANCE 29-32
WATER TREATMENT 33
FINISHING COMMISSIONING 34
SERVICING & SPARES
INSPECTION AND SERVICE 3 -38
SHORT PARTS LIST 39
CONVERSION KITS
N/A
FAULT FINDING & DIAGRAMS
FAULT FINDING 40-41
ELECTRICAL SCHEMATIC 42
8-716-106-2 2a (03.0 )

SAFETY &
REGULATIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
SAFETY PRECAUTIONS INSTALLATION REGULATIONS
2SAFETY PRECAUTIONS &
INSTALLATION REGULATIONS
8-716-106-2 2a (03.0 )
OIL SMELLS, LEAKS OR FUMES FROM THE APPLIANCE:
Extinguish any naked flames
Open windows and doors
Isolate the electrical supply
Isolate the fuel supply to the boiler
Rectify fault.
HEALTH & SAFETY:
The appliance contains no asbestos and no substances have been used in the construction
process that contravene the COSHH Regulations (Control of Substances Hazardous to Health
Regulations 1988). Where applicable, the CE mark indicates compliance with relative EU
Directives.
COMBUSTIBLE AND CORROSIVE MATERIALS:
Do not store or use any combustible materials (paper, thinners, paints etc.) inside or within
the vicinity of the appliance.
The combustion air must be kept clear of chemically aggressive substances which can corrode
the appliance and invalidate any warranty.
FITTING & MODIFICATIONS:
Fitting the appliance and any controls to the appliance may only be carried out by a competent
engineer in accordance with these instructions and the relevant Installation Regulations.
Flue systems must not be modified in any way other than as described in the fitting instructions.
Any misuse or unauthorised modifications to the appliance, flue or associated components
and systems could invalidate the warranty. The manufacturer accepts no liability arising from
any such actions, excluding statutory rights.
SERVICING:
Advise the user to have the system regularly serviced by a competent, qualified engineer (such
as OFTEC registered personnel) using approved spares, to help maintain the economy, safety
and reliability of the appliance.
Failure to install appliances correctly could lead
to prosecution.
The appliance should be installed by a competent
person. The person installing 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 operation the
appliance must be commissioned by a qualified
OFTEC engineer.
The compliance with a British Standard does
not, of itself, confer immunity from legal obligations.
In particular the installation of this appliance must
be in accordance with the relevant requirements
of the following British Standards and regulations
in respect of the safe installation of equipment.
BS 410: part 1: Code of practice for Oil Fired
Boilers.
BS 799: part : Specification for Oil Storage
Tanks.
BS 7 93: Code of Practice for treatment of water
in domestic hot water central heating systems.
BS 449: part 1: Specification for forced
circulation hot water central heating for domestic
premises.
BS 9 : part 8: Specification for the
installation of thermoplastic pipes and associated
fittings for use in domestic hot and cold water
services and heating systems.
BS 7291: Thermoplastic pipes and associated
fittings for hot and cold water for domestic
purposes and heating installations in buildings.
BS 7074: part 1: Application, selection and
installation of expansion vessels and ancillary
equipment for sealed water systems.
BS 7671: IEE Wiring Regulations, current edition.
The Building Regulations Part J and L1 England
and Wales; Part F and Part J Section III Scotland;
Part L and Part F Northern Ireland.
Local water company bye-laws.
The Control of Pollution (Oil) Regulations.
OFTEC Standards.
Where no specific instruction is given, reference
should be made to the relevant codes of practice.

APPLIANCE
INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH 3
GENERAL INFORMATION
GENERAL INFORMATION
8-716-106-2 2a (03.0 )
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.
C - Condensate trap kit.
A
B
600mm
8 mm
20mm
C

APPLIANCE
INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
18/25kW
69
30
1
4
2.6
-
18
1.2
40
40
10
22
22
1
22
1
1
21.
230
0
240
/81
/72
92
10
110
<100
90.1
20
20
177
4
TECHNICAL DATA
TECHNICAL DATA 8-716-106-2 2a (03.0 )
Centra Heating
Primary water capacity (total) litres
Maximum static head metres
Minimum static head metres
Available pump head (20°C difference) metres water
Max. permissible sealed system operating pressure bar
Flow restrictor colour
Domestic Hot Water
Maximum flow rate (±1 %) litres/min
Minimum inlet pressure (dynamic) for maximum flow rate bar
Maximum hot water temperature rise for 90 litres draw off (@18 litres per min) °C
F ue
Exit flue gas mass flow kg/hr
Pipework connections
Fuel line (compression) mm
CH flow mm
CH return mm
Water main inlet mm
DHW outlet mm
CH vent (optional) inch BSP
CH drain inch BSP
Condensate (polypropylene) mm
E ectrica
Electrical power supply voltage AC...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 limit thermostat set point °C
Boiler manual reset overheat thermostat set point °C
Flue reset overheat thermostat set point °C
Genera Data
Maximum hearth temperature °C
SEDBUK (Band A) %
Appliance protection rating (with programmer blanking plate fitted) IP
Appliance protection rating (with fascia programmer fitted) IP
Weight (excluding packaging) kg
DESCRIPTION UNITS

APPLIANCE
INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH 5
LAYOUT & COMPONENTS
LAYOUT & COMPONENTS
8-716-106-2 2a (03.0 )
The diagram opposite excludes the top,front and
RH side casing panels.
1 CONTROL BOX ASSEMBLY
2 CASING SIDE PANEL
3 DIVERTER VALVE
4 FLUE 'KNOCK-OUT' SECTION
AUTO AIR VENT
6 CH CONTROL & MANUAL RESET HIGH
LIMIT THERMOSTATS
7 CIRCULATING PUMP
8 OVERHEAT THERMOSTAT (AUTOMATIC
RESET)
9 PRESSURE RELIEF VALVE
10 EXPANSION VESSEL
11 DHW HEAT EXCHANGER
12 CASING SUPPORT PANEL
13 MANUAL RESET FLUE OVERHEAT
THERMOSTAT
14 FLUE MANIFOLD ACCESS COVER
1 FLUE GAS SAMPLING POINT
16 CLIP FOR FIRE VALVE SENSOR
17 CLIP FOR POWER CABLE
18 AIR INLET PIPE & CASING
19 SECONDARY HEAT EXCHANGER MANUAL
AIR VENT
20 SECONDARY HEAT EXCHANGER DRAIN
21 CONDENSATE OUTLET PIPE
22 SECONDARY HEAT EXCHANGER
23 PRIMARY HEAT EXCHANGER
24 TRAY
2 COMBUSTION CHAMBER ACCESS DOOR
26 DATA LABEL
27 HEATSLAVE TANK DRAIN COCK
28 HEATSLAVE TANK
29 PRESSURE GAUGE
30 QUICK REFERENCE GUIDE SLOT
31 LOCK-OUT INDICATOR
32 POWER ON INDICATOR
33 OVERHEAT RESET BUTTONS (water
temperature & flue temperature)
34 LOCK-OUT RESET BUTTON
3 CH TEMPERATURE CONTROL
36 DHW TEMPERATURE CONTROL
37 BENTONE STERLING 0 BURNER
i) Control box
ii) Motor
iii) Air intake casing
iv) Oil pump
v) Combustion head
38 CLIP - AIR INTAKE HOSE
39 AIR INTAKE HOSE
OPTIONAL ACCESSORIES ( ot supplied)
a - 7 day TWIN CHANNEL DIGITAL TIMER
Part No. 7 716 192 033 0
1
3
6
789
2
4
10
11 12 13
16
34
33
32
31
36
23
29
21
22
3
30
14
i)
38
37
ii)
iii)
iv)
v)
a
1
39
17 18 19 20
24
2
26
27
28

PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
6
CLEANING PRIMARY SYSTEMS
CLEANING PRIMARY SYSTEMS
IMPORTANT:
Debris from the system can damage the
boi er and reduce efficiency. Fai ure to comp y
with the guide ines for the use of water
treatment with the app iance wi inva idate
the app iance warranty.
BEFORE CLEANING THE SYSTEM:
ENSURE THE SYSTEM AND PIPEWORK IS IN
GOOD WORKING ORDER.
USE THE EXISTING BOILER/CIRCULATING
PUMP WHERE POSSIBLE OR USE A POWER
FLUSHING MACHINE TO AID THE CLEANSING
PROCEDURE BEFORE INSTALLING A NEW
BOILER.
CLEANING THE PRIMARY SYSTEM:
Cleanse the system in accodance with BS7 93.
Fill the system with cold mains water to the
recommended pressure and check for leaks.
Open all drain cocks and drain the system.
Close drain cocks and add a suitable flushing
agent at the correct strength for the system
condition in accordance with the manufacturer's
instructions.
Circulate the flushing agent before the boiler is
fired up.
Run the boiler and system at normal operating
temperature in accordance with the
manufacturer's instructions.
Drain and thoroughly flush the system to remove
the flushing agent and any debris.
CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK
AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.
IMPORTANT: A the fo owing pre-insta ation sections must be read and requirements
met before starting boi er or f ue insta ation.
8-716-106-2 2a (03.0 )

PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
8-716-106-2 2a (03.0 )
7
MAINS SUPPLIES
ELECTRIC SUPPLY:
 Supply: 230V - 0Hz
 Cable: PVC insulated 0.7 mm² (24 x 0.2mm)
temperature rated to 90°C
 Protection IP20
 External A fuse to BS1362
 The appliance must be earthed
 All pipes to the boiler must be cross-bonded
 It must be possible to isolate the appliance from
the electric supply with at least a 3mm contact
separation in all poles supplying the appliance
 Wiring between the appliance and the electrical
supply must comply with IEE wiring regulations
and any local regulations which may apply for
fixed wiring to a stationary appliance
 Any system connected to the boiler must not
have a separate electricity supply
WATER SUPPLY:
The following are general requirements and if
necessary the advice of the local water company
should be sought before fitting the appliance.
 The appliance cold water supply should be the
first connection off the water main where
possible.
Water Mai s Pressure:
 Minimum dynamic mains water pressure 1.2 bar
for maximum performance
 Maximum mains fed water pressure 10 bar. If
necessary, fit a pressure reducing valve
IMPORTANT: Non-return, back f ow
prevention devices (inc uding those
associated with water meters) fitted to the
mains water supp y can cause a pressure
bui d up which cou d damage the boi er and
other househo d app iances.
 Where the water main supply has a non-return,
back flow prevention valve fitted, a mini expansion
vessel (A) should be connected to the mains
water inlet pipe (B) between the non-return valve
(C) and the boiler (D) as shown opposite.
Use i hard water areas:
Normally there is no need for water treatment to
prevent scale formation as the maximum temperature
of the heat exchanger is limited by the electronic
control circuit.
In areas where the temporary water hardness
exceeds 200ppm, consideration may need to be
given to the fitting of a scale prevention device. In
such circumstances, the advice of the local water
authority should be sought.
MAINS SUPPLIES
D
C
A
B
MAINS WATER EXPANSION VESSEL:
A - Mini expansion vessel, part No. 7 716 192 10
B - Water Main supply pipe
C - Non-return valve
D - Boiler

PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
8-716-106-2 2a (03.0 )8-716-106-2 2a (03.0 )
8MAINS SUPPLIES
OIL SUPPLY:
 Plastic or steel tanks should be installed to
BS 410. A steel tank should conform to BS799:
part and have a slope of 1 in 24 away from
the outlet valve with a sludge cock at its lower
end.
 Do not use ga vanised stee tanks or pipework
for the oi supp y system.
 Do not use so dered joints on the oi supp y
pipework as this cou d cause a hazard in the
event of a fire.
a) Si gle pipe gravity feed system:
The oil storage tank (A) must be positioned so that
the oil level does not exceed 4 metres above the
level of the burner oil pump (J) and in addition the
oil level must be at least 300mm above the oil pump
(J). Where the maximum oil level in the oil storage
tank exceeds 4 metres, a head breaking device
must be installed between the tank (A) and the
burner oil pump (J).
b) Double pipe sub-gravity feed system:
Maximum suction height 3. metres. Non-return
valves must be fitted to the inlet and return oil line
between the oil pump (J) and oil storage tank (A).
c) Si gle pipe suctio lift with de-aerator
Maximum suction height 3. metres. The oil tank
(A) must be positioned below the oil pump (J).
Create an inlet and return loop between the de-
aerator (M) and oil pump (J).
A non-return valve must be incorporated within the
de-aerator or fitted to the oil line between the oil
storage tank (A) and the de-aerator (M).
A top feed oil tank fitted with a de-aerator using
an internal non-return valve should have any non-
return valve/s fitted in the base of the tank to the
suction line removed to assist purging air from the
oil line.
Pipework
Use copper pipe of the correct diameter
according to the information shown opposite.
Use flexible hoses to connect to the oil pump
(J).
Lay the oil supply pipe (H) as straight and level
as possible to avoid air pockets and unnecessary
friction losses. Route away from the boiler access
door or other hot surfaces.
Install a manual isolating valve (B) to the oil
supply pipe (H), as close to the oil storage tank
(A) as possible.
Fit an oil filter (C) to the oil supply pipe, near the
oil storage tank. If there is doubt about the
internal condition of the oil supply pipe, fit an
additional oil filter (recommended paper filter
element) close to the boiler, but not inside the
boiler casing.
Fit a fire valve in accordance with BS 410. The
fire valve (D) should be fitted externally to the
building with the fire valve sensor (F) located
within the appliance case.
A capillary type valve provides a neat and simple
installation. Alternatively, a fusible link or electrical
system may be used.
Under no circumstances shou d a combination
iso ating/fire va ve be used as the so e fire
protection device.
MAINS SUPPLIES
AF
BC
G J
4m (13ft) max.
K
E
A - Oil storage tank
B - Isolating valve
C - Oil filter
D - Fire valve to BS 410
E - External wall
F - Fire valve sensor
G - Oil burner
H - Oil supply pipe
J - Oil pump
K - Full base (plastic tanks)
L - Non-return valve
M - De-aerator
a)
N TE: All dimensions are in metres unless stated otherwise.
The maximum pipe run figures are based on using copper pipe with an inside diameter
of 2mm less than the Ø.
HB DB C
300mm min.
HEAD 10mmØ 12mmØ
0. 12 30
1.0 2 69
1. 37 91
2.0 49 100
HEAD 10mmØ 12mmØ
2. 62 100
3.0 74 100
3. 87 100
4.0 99 100
MAXIMUM PIPE RUN FOR SINGLE PIPE GRAVITY FEED SYSTEM
B
A
DB
CB
E
K
3. m (11. ft) max.
1 0mm
L
L
b)
H
F
C
G
J
HEAD 10mmØ 12mmØ
0 0 100
0. 44 100
1.0 38 9
1. 32 80
HEAD 10mmØ 12mmØ
2.0 26 66
2. 20 0
3.0 14 37
3. 8 22
MAXIMUM PIPE RUN FOR DOUBLE PIPE SUB-GRAVITY FEED SYSTEM
The table and illustration above is a guide only and does not in any way override the de-aerator
manufacturers instructions.
HEAD 2. kg/h kg/h 10kg/h 10kg/h
8mmØ 8mmØ 8mmØ 10mmØ
0 100 26 100
0. 9 4 23 100
1.0 80 40 20 90
1. 70 3 17 7
HEAD 2. kg/h kg/h 10kg/h 10kg/h
8mmØ 8mmØ 8mmØ 10mmØ
2.0 60 30 14 6
2. 4 2 11 0
3.0 3 1 8 3
3. 2 10 20
MAXIMUM PIPE RUN FOR SINGLE PIPE SUCTION LIFT WITH DE-AERATOR
FUEL FLOW RATE FUEL FLOW RATE
B
A
M
B
F
CJ
K
3. m (11. ft) max.
E
D
c)
H
G