Worcester 12/18 Instruction Manual

FLOOR STANDING EXTERNAL OIL FIRED CONDENSING COMBINATION BOILER USING BALANCED FLUE SYSTEM GREENSTAR HEATSLAVE EXTERNAL 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 WITH KEROSENE (28 SECOND OIL) ONLY 8 716 113 389d 30/3/10 14:01 Page 1

8 716 113 389d (03/2010) 2 SYMBOLS USED IN THIS MANUAL: Domestic hot water Central heating Room thermostat Frost thermostat Wait time period Programmer/timer OFF INSTALLATION & SERVICING INSTRUCTIONS 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 all times the correct method for handling heavy objects should be strictly 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. Programmer ON CH only Programmer ON DHW only Programmer ON CH and DHW Cold water main supply Electricity supply WATER TREATMENT: FERNOX 01799 550811 fernox.com SENTINEL 0800 389 4670 sentinel-solutions.net FLUE TERMINAL GUARD: Part No. 7 716 190 050 PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION. THESE INSTRUCTIONS ARE APPLICABLE TO THE WORCESTER 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 AND EIRE 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. COMPLYING WITH THE BUILDING REGULATIONS: This heating appliance forms part of the controlled services for the building. It is law that all controlled services for buildings must comply with building regulations. You must be able to satisfy 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 operate a competent persons scheme and registered installers are able to certify that their work complies with building regulations. Under the scheme; � OFTEC must be informed about every installation. � OFTEC will issue a building regulations compliance certificate to the householder and will notify the LABC. OFTEC provide controlled document forms CD10 and CD11 for use during installation and commissioning respectively. Other organisations operate self-certification schemes e.g. NAPIT and BESCA Ltd. and it may be possible 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 arrange regular inspection visits during the work to ensure that the installation complies with the regulations. IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER TECHNICAL HELPLINE. DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER. PLEASE LEAVE THESE INSTRUCTIONS WITH THE COMPLETED COMMISSIONING FORM AND THE USER MANUAL WITH THE OWNER OR WITH THE APPLIANCE AFTER INSTALLATION OR SERVICING. THE SERVICE INTERVAL RECORD CAN BE FOUND ON THE BACK PAGE OF THIS MANUAL. ABBREVIATIONS USED IN THIS MANUAL: Ø Diameter CH Central Heating DHW Domestic Hot Water DCW Domestic Cold Water TRV Thermostatic Radiator Valve IP Ingress Protection CF Conventional flue BF Balanced flue N/A Not allowed SEDBUK Seasonal Efficiency of Domestic Boilers in the United Kingdom OFTEC Oil Firing Technical Association for the Petroleum Industry IEE Institute of Electrical Engineers LABC Local Authority Building Control Body STORE THE APPLIANCE IN A DRY AREA PRIOR TO INSTALLATION. 8 716 113 389d 30/3/10 14:01 Page 2

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 SUPPLIES 9 OIL SUPPLY 10 WATER SYSTEMS & PIPEWORK 11 PRESSURE RELIEF PIPEWORK 12 CONDENSATE PIPEWORK 13 CABINET MOUNTED LOW LEVEL FLUE TERMINAL POSITIONS 14 HIGH LEVEL FLUE TERMINAL POSITIONS 15 BOILER LOCATION & CLEARANCES 16 BALANCED EXTERNAL OILFIT FLUE OPTIONS 17 CABINET MOUNTED BALANCED HORIZONTAL FLUE OPTIONS 18 INSTALLATION UNPACKING THE BOILER 19 PIPEWORK & FLUE POSITIONS 20 BOILER INSTALLATION 21 FLUE INSTALLATION 22 COMBUSTION CHAMBER 23 PIPEWORK CONNECTIONS 24 OIL BURNER AND PUMP 26 REFITTING COMPONENTS 27 ELECTRICS 28 COMMISSIONING PRE-COMMISSIONING CHECKS - APPLIANCE 30 FILLING THE SYSTEM 31 STARTING THE APPLIANCE 32 WATER TREATMENT 37 FINISHING COMMISSIONING - APPLIANCE 38 SERVICING & SPARES INSPECTION AND SERVICE 39 SHORT PARTS LIST BENTONE STERLING 40 - 12/18 43 SHORT PARTS LIST BENTONE STERLING 50 - 18/25 44 SHORT PARTS LIST RIELLO RDB 1 - 12/18 45 SHORT PARTS LIST RIELLO RDB 2.2 - 18/25 46 SHORT PARTS LIST RIELLO RDB 2.2 - 25/32 47 FAULT FINDING & DIAGNOSIS FAULT FINDING 48 RIELLO CONTROLBOX OPERATION 50 FAULT FINDING LOGIC FOR SATRONIC CONTROL BOX 51 FAULT FINDING LOGIC FOR RIELLO CONTROL BOXES 52 ELECTRICAL SCHEMATIC 53 COMMISSIONING & SERVICE RECORDS OIL BOILER COMMISSIONING CHECKLIST 54 SERVICE INTERVAL RECORD 55 CONTENTS CONTENTS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 3 SAFETY & REGULATIONS APPLIANCE INFORMATION PRE - INSTALLATION INSTALLATION COMMISSIONING SERVICING & SPARES FAULT FINDING & DIAGRAMS 8 716 113 389d 30/3/10 14:01 Page 3

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 4 SAFETY & REGULATIONS SAFETY PRECAUTIONS INSTALLATION REGULATIONS OIL FUMES OR LEAKS FROM THE APPLIANCE: �Extinguish any naked flames. �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 free from 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. IMPORTANT: This boiler must only be operated by a responsible adult who has been instructed in, understands and is aware of the boiler’s operating conditions and effects. 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, in 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 5410: part 1: Code of practice for Oil Fired Boilers. BS 799: part 5: Specification for Oil Storage Tanks. BS 7593: Code of Practice for treatment of water in domestic hot water central heating systems. BS 5449: part 1: Specification for forced circulation hot water central heating for domestic premises. BS 5955: 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. BS 1362: Specification for general purpose fuse links for domestic and similar purposes. The Building Regulations Part G, 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. Installations in Eire (Republic of Ireland) The Installation must be performed by a competent and suitably trained person in accordance with the following Eire regulations. Current building regulations - Part J Republic of Ireland ETCI rules for electrical installation For further guidance see: OFTEC Technical book three - Regional requirements: Republic of Ireland 8 716 113 389d 30/3/10 14:01 Page 4

8 716 113 389d (03/2010) 5 APPLIANCE INFORMATION A B 770mm 950mm 640mm C D GENERAL INFORMATION 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 -100mmØ services duct. D - Cabinet key Check List Item Qty Greenstar Heatslave External Installation/Servicing Instructions........1 Users Instructions ..........................................................................................1 100mm Ø Services Duct...............................................................................1 Warranty Return Envelope ............................................................................1 Cabinet Key.......................................................................................................1 8 716 113 389d 30/3/10 14:01 Page 5

8 716 113 389d (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. output metres water Max. permissible sealed system operating pressure bar in accordance with WRAS guidelines Flow restrictor colour Domestic Hot Water Optimum flow rate (±15%) litres/min Minimum inlet pressure (dynamic) for optimum flow rate bar Maximum hot water rise for 90 litres draw off (@optimum flow rate) °C Flue 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 Combined feed and expansion and open vent (optional) BSP Condensate (polypropylene) mm Electrical 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 Tank manual reset overheat thermostat set point °C Flue reset overheat thermostat set point °C General Data Maximum hearth temperature °C SEDBUK (Band A) % Appliance protection rating IP Weight (excluding packaging) kg DESCRIPTION UNITS 12/18 18/25 25/32 APPLIANCE INFORMATION 69 30 1 4.7 2.5 Lime 15 1.5 40 29 10 22 22 15 22 1 21.5 230 50 240 55/81 55/72 5 92 105 94 110 <100 90.2 45 195 69 30 1 4.0 2.5 — 18 1.2 40 40 10 22 22 15 22 1 21.5 230 50 240 55/81 55/72 5 92 105 94 110 <100 90.1 45 195 72 30 1 4.2 2.5 — 22 0.9 40 51 10 28 28 15 22 1 21.5 230 50 263 55/81 55/72 5 92 105 94 110 <100 90.3 45 206 8 716 113 389d 30/3/10 14:01 Page 6

The diagram opposite excludes the top, front and RH side casing panels. 1. CONTROL BOX ASSEMBLY 2. DIVERTER VALVE 3. PRESSURE GAUGE 4. AUTO AIR VENT 5. CH CONTROL AND MANUAL RESET OVERHEAT THERMOSTAT PHIAL 6. CASING SIDE PANEL 7. CIRCULATING PUMP 8. AUTO-RESET HIGH LIMIT THERMOSTAT PHIAL 9. PUMP AUTO AIR VENT (under protective cap) 10. DHW FLOW SWITCH 11. PRESSURE RELIEF VALVE 12. DHW HEAT EXCHANGER 13. FLUE GAS SAMPLING POINT 14. FLUE OVERHEAT THERMOSTAT PHIAL 15. CASING SUPPORT PANEL 16. FLUE MANIFOLD ACCESS COVER 17. AIR INLET DUCT AND CASING 18. SECONDARY HEAT EXCHANGER BLEED POINT (ONE ON EITHER SIDE) 19. SECONDARY HEAT EXCHANGER 20. SECONDARY HEAT EXCHANGER DRAIN 21. EXPANSION VESSEL 22. COMBINED FEED & EXPANSION & OPEN SAFETY VENT PIPE OUTLET 23. CONDENSATE OUTLET 24. PRIMARY HEAT EXCHANGER 25. TRAY 26. OIL ISOLATION VALVE 27. CONDENSATE TRAP 28. CONDENSATE TRAP BRACKET 29. PRIMARY HEAT EXCHANGER DRAIN COCK 30. COMBUSTION CHAMBER ACCESS DOOR 31. HEATSLAVE TANK DRAIN 32. HEATSLAVE TANK 33. DATA LABEL 34. MODE SWITCH 35. BOILER MODE INDICATOR 36. LOCKOUT INDICATOR 37. MANUAL RESET TANK OVERHEAT THERMOSTAT (behind plastic cover) 38. OVERHEAT RESET BUTTONS (boiler & flue temperature) 39. LOCKOUT RESET BUTTON 40. SERVICE CONNECTION 41. CH TEMPERATURE CONTROL 42. DHW TEMPERATURE CONTROL 43. FROST THERMOSTAT SENSORS 44a. BENTONE STERLING BURNER (12/18 & 18/25) i) CONTROL BOX ii) MOTOR iii) AIR INTAKE CASING iv) OIL PUMP v) COMBUSTION HEAD 44b. RIELLO RDB 1 (12/18) & RDB 2.2 (18/25 & 25/32) i) CONTROL BOX ii) MOTOR iii) AIR INTAKE CASING iv) OIL PUMP v) COMBUSTION HEAD 45. CLIP - AIR INTAKE HOSE 46. AIR INTAKE HOSE LAYOUT & COMPONENTS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 7 APPLIANCE INFORMATION 1 6 2 4 8 7 5 10 21 12 15 3 14 16 13 17 18 20 22 29 23 19 24 25 30 33 31 32 34 35 9 38/39 42 41 44a 44b 45 46 45 46 v) iv) iii) ii) i) v) iii) i) ii) iv) 43 26 27 28 40 37 11 36 8 716 113 389d 30/3/10 14:01 Page 7

BEFORE CLEANING THE SYSTEM: ENSURE THE SYSTEM AND PIPEWORK IS IN GOOD WORKING ORDER. FLUSH THE EXISTING SYSTEM WITH A POWER FLUSHING MACHINE OR WITH A CHEMICAL CLEANER BEFORE INSTALLING NEW COMPONENTS. CLEANING THE PRIMARY SYSTEM: � Cleanse the system in accordance with BS 7593. � 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. 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. 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. CLEANING PRIMARY SYSTEMS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 8 PRE - INSTALLATION 8 716 113 389d 30/3/10 14:01 Page 8

• Cable: PVC insulated 0.75mm 2 (24 x 0.2mm) temperature rated to 90°C. • Protection IP45. • External 5A fuse to BS 1362. • The appliance must be earthed. • Please refer to IEE regulations for cross bonding requirements. • It must be possible to isolate the appliance from the electrical supply with at least a 3mm contact separation in both 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 electrical 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. • Maximum mains fed water pressure 10 bar. If necessary, fit a pressure reducing valve. IMPORTANT: Non-return, back flow prevention 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 supply has a non- return, back flow prevention valve fitted, a mini expansion vessel (A) must be connected to the mains water inlet pipe (B) between the non-return valve (C) and the boiler (D) as shown opposite. Use in 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 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 WATER EXPANSION VESSEL: A - Mini expansion vessel, part No. 7 716 192 105 B - Mains water inlet C - Non-return valve D - Boiler A B C D MAINS SUPPLIES INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 9 PRE - INSTALLATION 12/18kW Water Mains Pressure: Minimum dynamic mains water pressure for optimum performance. 1.5 bar 1.2 bar 0.9 bar 18/25kW 25/32kW IMPORTANT: The appliance provides a permanent external electrical supply for servicing and must therefore be fed via a circuit breaker incorporating earth leakage protection. 8 716 113 389d 30/3/10 14:01 Page 9

second oil) only, no other fuel must be used. • Plastic or steel tanks should be installed to BS 5410. A steel tank should conform to BS 799: part 5 and have a slope of 1 in 24 away from the outlet valve with a sludge cock at its lower end. • Do not use galvanised steel tanks or pipework for the oil supply system. • Do not use soldered joints on the oil supply pipework. a) Single 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 addi- tion 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 3.5 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) Single pipe suction lift with de-aerator Maximum suction height 3.5 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 valves 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 strainer and water separator (C) to the oil supply pipe, near the oil storage tank. Fit an additional oil filter (N, 16µm max filtration size) close to the boiler, but not inside the boiler casing. � Fit a fire valve in accordance with BS 5410. The fire valve (D) must be fitted externally at least 1 metre from the appliance with the fire valve sensor (F) located within the appliance case. A fire valve with a shut-off temperature of 85oC or higher must be fitted to avoid nuisance shut offs. A capillary type valve provides a neat and simple installation. Alternatively, a fusible link or electrical system may be used. Under no circumstances should a combination isolating/fire valve be used as the sole fire protection device. A F B N G J 4m max . K a) H 300mm min. B D B C MAXIMUM PIPE RUN FOR SINGLE PIPE GRAVITY FEED SYSTEM B A D B C E K 3.5m max . L L b) H F G B 150mm MAXIMUM PIPE RUN FOR DOUBLE PIPE SUB-GRAVITY FEED SYSTEM N J B A M B F C G J 3.5m max . E D c) MAXIMUM PIPE RUN FOR SINGLE PIPE SUCTION LIFT WITH DE-AERATOR H FUEL FLOW RATE FUEL FLOW RATE K 1m min . 1m min . 1m min . E OIL SUPPLY INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 10 PRE - INSTALLATION A - Oil storage tank B - Isolating valve C - Oil strainer & water separator D - Fire valve to BS5410 E - External casing 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 N - Oil filter (16µm max filtration size) NOTE: 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. HEAD 10mmØ 12mmØ 0.5 12 30 1.0 25 69 1.5 37 91 2.0 49 100 HEAD 10mmØ 12mmØ 2.5 62 100 3.0 74 100 3.5 87 100 4.0 99 100 HEAD 10mmØ 12mmØ 0 50 100 0.5 44 100 1.0 38 95 1.5 32 80 HEAD 10mmØ 12mmØ 2.0 26 66 2.5 20 50 3.0 14 37 3.5 8 22 HEAD 2.5kg/h 5kg/h 10kg/h 10kg/h 8mmØ 8mmØ 8mmØ 10mmØ 0 100 55 26 100 0.5 95 45 23 100 1.0 80 40 20 90 1.5 70 35 17 75 HEAD 2.5kg/h 5kg/h 10kg/h 10kg/h 8mmØ 8mmØ 8mmØ 10mmØ 2.0 60 30 14 65 2.5 45 25 11 50 3.0 35 15 8 35 3.5 25 10 5 20 The table and illustration above is a guide only and does not in any way override the de- aerator manufacturers instructions. 8 716 113 389d 30/3/10 14:01 Page 10

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 11 PRE - INSTALLATION WATER SYSTEMS & PIPEWORK A - Appliance expansion vessel B - Extra expansion vessel C - Automatic bypass valve D - Drain cock E - Feed & expansion cistern F - Combined feed & expansion and open vent safety pipe. G - Appliance L - Lockshield valve P - Pressure relief discharge R - Radiators S - Static head T - TRV U - To filling system PRIMARY SYSTEM PLASTIC PIPEWORK: • Any plastic pipework used for the CH system must have a polymeric barrier, complying with BS 7921 and installed to BS 5955 with 1000mm (minimum) length of copper or steel pipe connected to the boiler. • Plastic pipework used for underfloor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approx. 50°C with 1000mm (minimum) length of copper or steel pipe connected to the boiler. PRIMARY SYSTEM/CONNECTIONS/VALVES: • Do not use galvanised pipes or radiators. • All system connections, taps and mixing valves must be capable of sustaining a pressure of 3 bar. • Radiator valves should conform to BS 2767:10. • All other valves should conform to BS 1010. • On new installations TRVs must be used on all radiators except the radiator where the room thermostat is sited, this must be fitted with lockshield valves and left open. All installations should have TRVs fitted to radiators within 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 when activated. • Drain cocks are required at all the lowest points on the system. • Air vents are required at all high points on the system. OPEN VENT PRIMARY SYSTEM: • In order to comply with BS 5449 the combined feed and vent pipe must be connected to the BSP outlet on the right hand side of the primary heat exchanger. • The feed and expansion cistern (E) must be positioned to provide a static head (S) of at least 1 metre above the highest point in the heating system to the water level in the feed and expansion cistern (E). • No valve shall be fitted in the combined feed and expansion and open vent pipe (F). • The combined feed and expansion and open vent pipe (F) must be at least 22mmØ. SEALED PRIMARY SYSTEM: • Where the system volume is more than 180 litres at 0.5 bar or exceeds 2.65 bar at maximum heating temperature an extra expansion vessel (B) must be fitted as close as possible to the appliance in the central heating return. • Pressurise the extra expansion vessel (B) to the same figure as the expansion vessel (A) built into the appliance. IMPORTANT: The boiler should not be allowed to operate with a return temperature of less than 40°C when the system is up to operating temperature. 8 716 113 389d 30/3/10 14:01 Page 11

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 loops must be WRAS approved. SHOWERS/BIDETS: • If a shower head can be immersed in water or comes closer than 25mm from the top edge of a bath or shower tray spill over level then an anti-siphon device must be fitted to the shower hose. • Only thermostatically controlled showers are suitable for use with this appliance. • Bidets with direct hot & cold mains water can be used (with the approval of the local water authority) and must be the over rim flushing type with shrouded outlets to prevent the fitting of hand held sprays. DOMESTIC HOT WATER: • Plastic pipework must not be used for the DHW system. • Taps and mixing valves must be capable of sustaining a pressure up to 10 bar in accordance with the Water Regulations as they will be operating at mains water pressure. • Hot water temperature and flow rate are affected by the size and insulation of pipework making up the distribution system and are controlled by the hot water tap and the water main inlet pressure. A mixing valve can be fitted if a more permanent setting is required. • If using more than one outlet at once causes water flow starvation, fit flow balancing valves or Ball-O-Fix valves to the appropriate outlets. Heating return Hose return Non return valve Non return valve Test cock Stop cock Water main supply Stop cock Temporary hose Heating return Auto air vent Non return valve Stop cock Make up vessel 1000mm above the highest point of the system Fill Point INSTALLATION COMMISSIONING WATER SYSTEMS & PIPEWORK INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 12 PRE - INSTALLATION 8 716 113 389d 30/3/10 14:01 Page 12

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 13 PRE - INSTALLATION K J b E C Invert 450 min. A c D A C 75mm min. a A B C D 400mm min. 500mm min. d F I H G A C 25mm min. 200mm min. (Unsuitable for clay soil types) CONDENSATE PIPEWORK: • All national and, where appropriate, local regulations for the discharge and neutralisation of condensate should be followed. • The condensate pipe must be a minimum of 21.5mmØ polypropylene pipe. • The condensate pipework must fall at least 50mm per metre towards the outlet and should take the shortest practicable route • Support the pipe at least every 0.5m for near horizontal runs and 1m for vertical runs. • When a boiler is to be installed in an unheated location, such as a garage, all condensate pipes should be considered as external. External pipework: • The 21.5mmØ pipe must not exceed 3 metres outside the building. If a run greater than 3m is required, 32mmØ pipe must be used. • Any pipe exposed to windchill or extreme cold must be 32mmØ. • Protect all external pipes with weather resistant insulation and box-in, if necessary to reduce the risk of freezing. • Terminate as close to the ground or drain as possible (below the grating and above the water level) while still allowing for safe dispersal of the condensate. This will help reduce windchill freezing. Connection of a condensate pipe to a drain may be subject to to local building regulations. Making it safe: • Condensate pipework must not leak, freeze or block up. • Condensate traps must be filled before starting up the boiler to prevent potentially harmful flue products escaping via the condensate route. • Do not dispose of condensate into water recovery systems. Condensate can be discharged into a rain water hopper which is part of a sewer system carrying both rain water and foul water. • The pipework must follow one of the options shown opposite: a - Internal waste drainage system b - Soil/vent stack c - External drainage system d - External condensate absorption point A - Condensate from the boiler internal condensate trap which has a 75mm minimum water seal. B - Sink. C - 21.5mm Ø polypropylene condensate pipe. D - Gully. E - Internal soil and vent stack. F - 300mm x 100mm Ø sealed plastic tube. G - Ground level. H - Drainage holes 50mm from base of tube (12mm Ø at 25mm centres) facing away from building. I - Limestone chippings. PRESSURE RELIEF PIPEWORK: • The pressure relief drain pipe (K) should be at least 15mm diameter copper pipe and run downwards away from the boiler and discharge away from any electrics or other hazard, preferably to an external drain or soakaway. • Pipe (K) should be finished with a partial bend, near the outlet to face the external wall (as shown) to help prevent freezing. CONDENSATE & PRESSURE RELIEF PIPEWORK IMPORTANT: The pressure relief valve is a safety device for the boiler and if activated may discharge boiling water or steam through the relief valve drain pipe. Care should be taken when siting the outlet pipe so that it does not cause an obstruc- tion or discharge into a public area where it could cause a hazard. 8 716 113 389d 30/3/10 14:01 Page 13

FLUE TERMINAL POSITIONS CABINET MOUNTED LOW LEVEL FLUE TERMINAL POSITIONS 14 PRE - INSTALLATION Minimum dimensions of flue terminal positions for oil fired appliances: TERMINAL POSITION B(H) A 1 Directly below an opening, air brick, opening windows, etc 600mm B 1 Horizontally to an opening, air brick, opening window, etc 600mm C Below a plastic/painted gutter, drainage pipe or eaves if 75mm combustible material protected D 2 Below a plastic/painted gutter, drainage pipe or eaves without 600mm protection to combustible material E From vertical sanitary pipework 300mm F From an external or internal corner or from a surface or boundary 300mm alongside the terminal G Above ground or balcony level 300mm* H A From a surface or boundary facing the terminal with 2500mm 1200mm clearance to both sides of the terminal H B From a surface or boundary facing the terminal with less than 2500mm 2500mm clearance to either side of the terminal I A From a terminal facing the terminal with 2500mm clearance to 1200mm clearance to both sides of the terminal I B From a terminal facing the terminal with less than 2500mm 2500mm clearance to either side of the terminal K Horizontally from a terminal 750mm B(H) Balanced Horizontal flue 1 An opening means an openable element, such as an openable window, or a permanent opening such as a permanently open air vent. Notwithstanding the dimensions above, a terminal should be at least 300mm from combustible material, e.g. a window frame. 2 A way of providing protection of combustible material would be to fit a heat shield at least 750mm wide. • Flue terminals must be positioned to avoid combustion products entering into buildings. • The flue must 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 plume and in certain weather conditions a white plume of condensation will be discharged from the flue outlet which could be regarded as a nuisance, for example, near security lighting. • There should be no restriction preventing the clearance of combustion products from the terminal. • The air inlet/outlet duct and the terminal of the boiler must not be closer than 25mm to any combustible material. Detailed recommendations on protection of combustible materials are given in BS 5410:1 • A protective terminal guard must be fitted if the terminal is 2m or less above a surface where people have access. Stainless steel terminal guard. Part No: 7 716 190 050 • The following additional guidelines (from part L Exceptions Guidance Document) are recommended when determining the flue outlet position: • Avoid discharging flue gases into car ports or narrow passageways. • *Minimum distance of the flue terminal from above ground is 2100mm where directed to a public footpath, private access route or a frequently used area and 2500mm from a car parking area. boundary F I H B A G E C, D F F J K boundary INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 106 389c (01/2009) 8 716 113 389d 30/3/10 14:01 Page 14

POSITIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 15 PRE - INSTALLATION HIGH LEVEL FLUE TERMINAL POSITIONS • Flue terminals must be positioned to avoid combustion products entering into buildings. • The flue must be fitted and terminated in accordance with the recommendations of BS 5410. • The flue must not cause an obstruction. • Discharge from the flue outlet must not be a nuisance. • Flue gases have a tendency to plume and in certain weather conditions a white plume of condensation will be discharged from the flue outlet which could be regarded as a nuisance, for example, near security lighting. • There should be no restriction preventing the clearance of combustion products from the terminal. • The air inlet/outlet duct and the terminal of the boiler must not be closer than 25mm to any combustible material. Detailed recommendations on protection of combustible materials are given in BS 5410:1 • A protective terminal guard must be fitted if the terminal is 2m or less above a surface where people have access. The guard must be spaced equally (minimum 50mm) around the flue and fixed to the wall with plated screws. Stainless steel terminal guard. Part No: 7 716 190 050 The following additional guidelines (from part L Exceptions Guidance Document) are recommended when determining the flue outlet position: • Avoid discharging flue gases into car ports or narrow passageways. • *Minimum distance of the flue terminal from above ground is 2100mm where directed to a public footpath, private access route or a frequently used area and 2500mm from a car parking area. • **Minimum distance of the flue terminal to a facing wall, fence, building or property boundary is 2500mm. boundary F J H B A G E M C, D N F F K L boundary Q Q Q R Q Q Q Q Pitched roof Flat roof P O Key: — Not applicable, N/A Not allowed, B(H) Balanced Horizontal flue, B(V) Balanced Vertical flue. Notes: 1. Terminals should be positioned so as to avoid products of combustion accumulating in stagnant pockets around the building or entering into buildings. 2. Vertical structure in N, O and P includes tank or lift rooms, parapets, dormers etc. 3. Terminating positions should be at least 1.8m from an oil storage tank unless a wall with at least 30 min fire resistance and extending 300mm higher and wider than the tank is provided between the tank and the terminating position. 4. Where a flue is terminated 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 lowest part of the terminal is less than 2m above the ground, balcony, flat roof or other place to which any person has access, the terminal should be protected by a guard. 6. Notwithstanding the dimensions given above, a terminal should not be sited closer than 300mm to combustible material. In the case of a thatched roof, double this separation distance should be provided. It is also advisable to treat the thatch with a fire retardant material and close wire in the vicinity of the flue. 7. It is essential that a flue or chimney does not pass through the roof within the shaded area delineated by dimensions Q and R. 8. Where protection is provided for plastic components, such as guttering, it is essential that this is to the standard specified by the manufacturer of the plastic components. TERMINAL POSITION B(H) B(V) A 1 4 Directly below an opening, air brick, opening window, etc 600mm N/A B 1 4 Horizontally to an opening, air brick, opening window, etc 600mm N/A C 8 Below a plastic/painted gutter, drainage pipe or eaves if combustible material protected 75mm N/A D 8 Below a plastic/painted gutter, drainage pipe or eaves with- out protection to combustible material 600mm N/A E From vertical sanitary pipework 300mm N/A F 3 From an external or internal corner or from a surface or boundary alongside the terminal 300mm N/A G 3 Above ground or balcony level 300mm* N/A H 3 From a surface or boundary facing the terminal 600mm** N/A J From a terminal facing the terminal 1200**mm — K Vertically from a terminal on the same wall 1500mm N/A L Horizontally from a terminal on the same wall 750mm — M Above the point of highest intersection with the roof 600mm N 2 From a vertical structure on the side of the terminal — 750mm O 2 Above a vertical structure less than 750mm from the side of the terminal — 600mm P 2 From a ridge terminal to a vertical structure on the roof — — Q Above or to the side of any opening on a flat or sloping roof — 300mm R Below any opening on a sloping roof — 1000mm Minimum dimensions of flue terminal positions for oil fired appliances: 8 716 113 389d 30/3/10 14:01 Page 15

CLEARANCES INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 16 PRE - INSTALLATION BOILER LOCATION & CLEARANCES WARNING: This appliance should not be installed where there is a potential for excessive ground water coverage. This boiler is only suitable for installing externally at a suitable location onto a fixed permanent rigid surface capable of supporting the boiler weight. There must be a sufficient hard standing around the appliance to allow for servicing. The boiler must be installed on a flat level surface to ensure that condensate does not enter the primary heat exchanger. Tarmac and wood hardstandings are not recommended. CLEARANCES: Min service & flue clearances Above 600mm Front 600mm RH/LH flue outlet on opposite side 10mm RH flue outlet on rear 85mm LH flue outlet on rear 10mm Rear = flue outlet on side 150mm** Rear = rear flue outlet 2500mm* It is strongly recommended that the flue terminal faces away from walls to reduce the possibility of wetting occurring. *This can be reduced to 1200mm if there is at least 2500mm clearance on both sides of the flue. ** 200mm if a high level terminal is used exiting through the rear panel. 600mm 2500mm* 600mm BASE FRONT FRONT 2500mm* 150mm** 85mm 10mm 600mm 10mm 600mm 2500mm* FRONT FRONT 2500mm* 10mm 600mm 150mm** Plan view Plan view Plan view 600mm (min) 8 716 113 389d 30/3/10 14:01 Page 16

125mmØ x4 L L = 2000mm 125mmØ x2 B D D B E E B C D L F F L = 5000mm 125mmØ x5 L E B L = 4000mm 125mmØ x4 B E L C BALANCED EXTERNAL OILFIT FLUE OPTIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 17 PRE - INSTALLATION IMPORTANT: The weather seal (supplied) must be fitted to every flue joint to give the required level of weather protection. The diagrams (opposite) show the components used and the maximum flue length (L) for each flue configuration. In all cases L is measured from the outside of the boiler casing. • To achieve the maximum flue length (L), a flue section will have to be reduced in length. • Only the straight flue extensions can be reduced in length by cutting. IMPORTANT: All horizontal sections must rise away from the boiler by 52mm per metre (3°) to allow the condensate to drain back to the boiler. B - Straight flue extension C - Flue bend 90° D - Flue bend 45° E - Vertical Terminal Kit (incl. 90° elbow) F - Horizontal terminal kit (incl. 90° elbow) Calculating the flue length: Measure the total flue length required, noting that the maximum straight flue length including the terminal is: Horizontal: 2000mm. Vertical 80/125mmØ: 5000mm. Then reduce the total straight flue length for each extra flue bend (excluding the vertical flue kit 90° elbow) by: 1000mm for 90° 500mm for 45° Flue Extension lengths: Horizontal & Vertical: 1000mm overall length. Effective length when engaged into sockets within the flue run is 950mm. Flue Terminal lengths: Horizontal oilfit external = 305mm Vertical oilfit external 80/125mmØ = 185mm + cage * Rear exit only. ** Horizontal flue runs should be kept as short as possible. For satisfactory flue performance we recommend that no more than two metres of the vertical flue is run horizontally. BALANCED EXTERNAL OILFIT FLUE OPTIONS High level horizontal terminal (rear outlet) * ** Vertical terminal (rear outlet) Vertical terminal (rear outlet) Vertical terminal (side outlet) ** ** ** 8 716 113 389d 30/3/10 14:01 Page 17

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 18 PRE - INSTALLATION CABINET MOUNTED BALANCED HORIZONTAL FLUE OPTIONS • The horizontal flue is fitted to the rear or either side of the cabinet. IMPORTANT: It is strongly recommended that the flue terminal faces away from walls to minimise the occurrence of wetting. A - External horizontal flue kit Part No. 7 716 190 084 B - 90° inline elbow 80/125mm Part No. 7 716 190 034 C - Stainless steel terminal guard Part No. 7 716 190 050 NOTE: The flue terminal and services duct must not exit through the same panel. FRONT FRONT FRONT Plan view Plan view Plan view REAR FLUE OUTLET A + C LEFT HAND FLUE OUTLET A + B + C RIGHT HAND FLUE OUTLET A + B + C 8 716 113 389d 30/3/10 14:01 Page 18

in the transfer of the packaged boiler from the van to the point of delivery. 1 � Once the packaged boiler has been delivered, the outer carton is removed first. Care should be taken when releasing the straps. If a sharp implement is used make sure the outer carton is not pierced and that the implement is used in such a way so that it may not cause personal injury. All sharp objects must be covered or the blade retracted after use and put away in a safe place. 2 � Lift carton up and away from the boiler. � Remove the plastic bag from the boiler and place safely aside. UNPACKING THE BOILER LIFTING AND CARRYING PRECAUTIONS: • Lift only a manageable weight, or ask for help. • When lifting or putting things down, bend the knees, and keep the back straight and feet apart. • Do not lift and twist at the same time. • Lift and carry objects close to the body. • Wear protective clothing and gloves to protect from any sharp edges. IMPORTANT: All the previous Pre-Installation sections must be read and requirements met before starting boiler or flue installation. 1 2 UNPACKING THE BOILER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 19 INSTALLATION 8 716 113 389d 30/3/10 14:01 Page 19

256 650 58 802 258 81 105 171 374 161 650 787 670 518 105 94 55 269 658 669 705 715 650 794 670 518 158 124 89.5 55 658 679 698 718 528 230 INSTALLATION COMMISSIONING SAFETY: All relevant safety precautions must be undertaken. Protective clothing, footwear, gloves and safety goggles must be worn as appropriate. PIPEWORK CONNECTIONS: CH flow 22mmØ copper (28mmØ on 25/32kW model) DHW flow 22mmØ copper Mains water inlet 15mmØ CH return 22mmØ copper (28mmØ on 25/32kW model) Optional combined feed and expansion and open vent pipe 1'' BSP Services duct 100mmØ Pressure relief pipe 15mmØ Condensate outlet 21.5mmØ NOTE: For servicing purposes, keep the condensate and pressure relief discharge pipes away from components and pipework connections. CAUTION: Ensure there are no pipes, electric cables, damp proof courses or other hazards before drilling. PIPEWORK & FLUE POSITIONS PIPEWORK & FLUE POSITIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 20 Condensate Flue Services PRV Fire valve capillary Flue Services Condensate PRV Oil Flue Services Condensate Oil PRV LEFT HAND SIDE RIGHT HAND SIDE REAR Fire valve capillary 8 716 113 389d 30/3/10 14:01 Page 20

and only provides weather protection for the boiler. 1�Mark position of the 100mm services duct on the exterior wall and make a hole through. 2�Remove the key for the door fasteners from its transport position in the left hand side panel flue outlet aperture. Undo the screws at the bottom of the front panel (using the key provided) and remove the screws from the rear panel pulling both panels out and down to remove. Store safely away from the installation point. 3�Remove the screws from the top panel and lift up to remove, store safely away from the installation point. 4�Loosen the flexible air duct clamp (A) and remove the air duct from the burner. �Depress the locking ears to unplug the burner lead (B) from the control box (C). �Unscrew the burner retainers (D), then withdraw the burner (E) from the boiler and store safely away from the installation point. 5�Remove the screws securing the base panel to the transit pallet and lift the boiler off the pallet and into its installation position taking care not to scrape the base panel across the hard standing. Do not attempt to lift and position the boiler on your own. Do not use the copper pipes to move the boiler. �Fasten the base to the hard standing using the holes provided. Care should be taken to ensure that the base is level. 6�Measure the 100mmØ services duct to give at least 10mm inside 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 wall and inside the cabinet with a suitable sealant. BOILER INSTALLATION INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 21 INSTALLATION 2 3 2 5 4 B C D E A WARNING: THIS APPLIANCE IS SERVICED AND REPAIRED EXTERNALLY. EXTERNAL EQUIPMENT OPERATED AT 230V SHOULD NOT BE INSTALLED, SERVICED OR REPAIRED UNDER ADVERSE WEATHER CONDITIONS. THIS APPLIANCE IS INSTALLED AND SERVICED EXTERNALLY TO THE PROPERTY, BUT THE ENGINEER MUST HAVE ACCESS TO THE INSIDE OF THE PROPERTY WHEN INSTALLING OR SERVICING THE APPLIANCE. 8 716 113 389d 30/3/10 14:01 Page 21

and seated properly. � To ease assembly of flue components, grease seals lightly with the solvent free grease supplied. � A terminal guard must be fitted if the terminal is 2m or less above a surface where people have access. Refer to separate flue installation manual supplied with the flue kits available for this boiler. NOTE: All horizontal flue sections must rise by 52mm for each metre away from the boiler to ensure that the condensate flows back to the boiler for safe disposal via the condensate waste pipe. FLUE INSTALLATION FLUE INSTALLATION INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 22 INSTALLATION Balanced external oilfit flue kits and components 80/125mm Ø (not supplied): External horizontal flue kit 7 716 190 084 In-line elbow 90° x 1 7 716 190 034 Stainless steel terminal guard 7 716 190 050 80/125mmØ High level horizontal external flue kit 7 716 190 057 80/125mmØ Vertical External flue kit 7 716 190 053 80/125mmØ Balanced external flue 1m extension kit 7 716 190 054 80/125mmØ Balanced external flue 90° swept elbow kit 7 716 190 055 80/125mmØ Balanced external flue 45° elbow (2 off) kit 7 716 190 056 8 716 113 389d 30/3/10 14:01 Page 22

8 716 113 389d (03/2010) 23 INSTALLATION Combustion chamber: 1� Release 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 opposite. 3� 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 tighten the nuts. 4� Unscrew screws (E) and remove flue manifold access cover (F). 5� Check that all the baffles (G) and baffle retainer (H) or ( J ) are correctly fitted to the secondary heat exchanger. COMBUSTION CHAMBER H F 2 E 4 G 5 A B 1 3 D C 12/18 & 18/25kW Plan sectional view D C 25/32kW Plan sectional view J Hook the retainer ( J ) over the end two baffles or 1 2 4 3 3a FRONT FRONT 8 716 113 389d 30/3/10 14:01 Page 23

8 716 113 389d (03/2010) 24 INSTALLATION Q O PIPEWORK CONNECTIONS A - CH flow 22mmØ copper (28mmØ on 25/32 models) B - DHW flow 22mmØ C - Water main inlet 15mmØ D - CH return 22mmØ copper (28mmØ on 25/32 models) E - 10mmØ oil supply pipe connection F - Oil isolating valve (10mmØ) G - Flexible oil hose N - Optional combined feed and expansion and open vent O - CH flow pipe 22mmØ P - Fixing point for optional return oil pipe Q - Drain WATER CONNECTIONS: �All service pipes into the property must pass through the services duct. �Insulate all the system/supply pipes where the pipes pass through the duct with at least 22mm insulation around the pipes. �Remove the transit bungs from the pipework connections on the boiler. NOTE: That surplus water may be present due to factory testing. �Ensure all pipework is clean. �Remove the central heating flow pipe (O) from its packaging. Grease the flat washer with the grease supplied and fit the pipe and washer onto the isolation valve as shown. �Align water pipework through the 100mm Ø duct and connect, ensuring that the expansion tank and control box fit correctly before permanently connecting the pipework. �Check that all unused sockets have been capped. OIL SUPPLY CONNECTIONS: NOTE: Oil filters and de-aeration devices are not to be fitted within the casing and the fire valve body must be at least 1 metre from the external casing. �Route the oil supply pipe through the appropriate casing hole as required and connect to the isolating valve (F) and ensure the valve is closed. �Connect the flexible oil hose (G) to the isolating valve (F). �Pass the fire valve sensor through the most appropriate casing hole and locate the capillary in the cut out at the bottom of the hole. �Clip the sensor into the clip provided at the rear of the control box. �Rotate the cover plate and seal so it does not cover the capillary, then secure with the screws provided. CAUTION: ISOLATE THE OIL & WATER MAINS SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. 8 716 113 389d 30/3/10 14:01 Page 24

8 716 113 389d (03/2010) 25 INSTALLATION s T U PIPEWORK CONNECTIONS H - Flue manifold condensate outlet J - Condensate outlet (21.5mmØ) - supplied K - Condensate pipe - not supplied L - Internal condensate trap M - Pressure relief (15mmØ) CONDENSATE CONNECTION: �Connect 21.5mm polypropylene pipe (K) (not supplied) to the condensate pipe flexible push fit connector (J) before terminating to waste. �Do not use any solvents, adhesives or lubricants when pushing the pipe into the rubber connector (J). �Ensure that the condensate pipe runs away from the boiler at a constant fall of 50mm (min.) for every metre. �Carefully pour 500ml of water into the condensate collection (S) to fill condensate trap. �Check the water is running away and the condensate pipework joints are water tight. �Check the flue manifold seal is undamaged and seated correctly. �Refit flue manifold access cover ( T ) and secure with screws (U). IMPORTANT: The condensate trap must be correctly filled to prevent the possibility of potentially harmful flue products escaping via the condensate pipework. PRESSURE RELIEF CONNECTION: �Connect the pressure relief pipe (M) to a copper discharge pipe (15mmØ min.) and terminate externally to the appliance casing. �Blank all unused casing holes with the bungs or cover plates and seals supplied. The drain/fire valve capillary hole covers should be rotated so that the unused capillary slot is covered by the cover plate and seal. �Refit rear panel. �Seal all joints where pipes pass through the casing, with suitable waterproof sealant. IMPORTANT: Insulate all external condensate pipe work or run in 32mm pipe work to prevent freezing. 8 716 113 389d 30/3/10 14:01 Page 25

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 26 INSTALLATION CAUTION: ISOLATE THE OIL & WATER MAINS SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT 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 combustion head (C). � Inspect for any visible defects. IMPORTANT: Whenever replacing the combustion head, ensure that the photocell is lined up with the sight hole. OIL PUMP: Connecting the oil 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: 1� Check the inlet hose connection. a) DANFOSS BFP 11 L3: � Remove pump front cover (A) ensuring a suitable receptacle is used to catch any oil residue. � Remove changeover screw (B). � Remove horseshoe washer (C). � Refit changeover screw (B). � Refit front cover (A). � Remove oil pump return plug (2). b) SUNTEC AS47C: � Remove return port plug (2) and insert grub screw (B). c) RIELLO RDB: � Unscrew return plug (2). � Screw in by-pass screw (3). 2� Connect the flexible oil return hose (not supplied) between the oil pump and the return line connection, and tighten to secure. OIL BURNER & PUMP 5mm Electrode gap 2.5 - 3.0mm 7.5mm B A 1 C 1 2 B 1 2 B C A 5mm a) DANFOSS BFP 11 L3 OIL PUMP b) SUNTEC AS47C OIL PUMP 2.5mm Electrode gap 4mm B A 1 C 5mm c) RIELLO RDB OIL PUMP 1 2 3 BENTONE 12/18 & 18/25kW RIELLO 12/18, 18/25 & 25/32kW 8 716 113 389d 30/3/10 14:01 Page 26

8 716 113 389d (03/2010) 27 INSTALLATION 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 between the burner combustion head and the boiler housing to prevent flue gases escaping from the combustion chamber into the cabinet. � Attach the flexible air duct and tighten clamp(D) to secure to the burner air intake. 2� Plug burner lead (E) into control box (F). F A B C D E 8 716 113 389d 30/3/10 14:01 Page 27

8 716 113 389d (03/2010) 28 INSTALLATION FR LR Ns Fs FR Ls N L DHW CH ELECTRICS 1 DANGER - 230V: ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. IMPORTANT: THIS APPLIANCE PROVIDES A PERMENANT EXTERNAL ELECTRICAL SUPPLY FOR SERVICING AND MUST THEREFORE BE FED VIA A CIRCUIT BREAKER INCORPORATING EARTH LEAKAGE PROTECTION. IMPORTANT: OBSERVE ELECTRONIC STATIC DISCHARGE PRECAUTIONS. DO NOT TOUCH THE PCB CIRCUITS. WARNING: EXTERNAL EQUIPMENT OPERATED AT 230 VOLTS SHOULD NOT BE SERVICED OR REPAIRED UNDER ADVERSE WEATHER CONDITIONS. Access to 230V connections: 1�Release screws (B) and remove cover panel (C) from control box (A). 2�Release screws (D) from cable clamp (E). �Pull inner clamp part (F) outwards. �Feed sufficient power cable (G) through the cable clamp (E) and secure grip with screw (D). �Separate wires from cable end and strip to 6mm. 230V connections (terminal block X1): 3�Connect LIVE wire (Brown) to terminal L. �Connect NEUTRAL wire (Blue) to terminal N. �Connect EARTH wire (Green/Yellow) to the connector . Route the power cable down the side panel and through the service duct to the internal property connection point avoiding any potentially hot surfaces. Any external device connected to the boiler must take its power supply from the boiler supply only and must NOT have a separate supply. Terminal block (M) is provided with links (P) to test fire the boiler with DHW and CH permenant demand. Links (P) must be removed and a suitable programmer connected before commissioning. External 230V programmer (terminal block X4): 4 �Remove 4 pin plug (M) from X4. �Remove test links (P) from plug block (M). �Connect wires to plug block (M) as shown. �Fit plug into terminal block X4. �Connect earth to terminal block X1connector 230V room thermostat (terminal block X2): 6 �Remove link (K). �Connect LIVE supply to terminal LS. �Connect SWITCHED LIVE supply to terminal LR. NOTE: This is sometimes referred to as ‘call for heat’ or ‘heating load’. �Connect NEUTRAL to terminal Ns. NOTE: Some devices do not require this. Refit electric control panel cover: �Refit panel (C) and secure with screws (B). NOTE: Both frost thermostats are fitted as standard to the external appliance to provide frost protection. C B A 4 P M G D E 2/3 230V MAINS SUPPLY X2 6 Neutral (if required) Switched Live Live FROST STAT(1) FROST STAT(2) 7 k 7 ROOMSTAT Accelerator resistor (if fitted) PROGRAMMER (EXTERNAL) 5 clock CH channel HW channel N Supply L Supply HW Demand CH Demand X4 Fuse CONTROL BOARD . M B G F 8 716 113 389d 30/3/10 14:01 Page 28

8 716 113 389d (03/2010) 29 INSTALLATION RESET White ELECTRICS Electrical components: 1 Printed circuit board 2 Thermostat - boiler high limit 3 Thermostat - DHW control 4 Thermostat - CH control 5 Indicator lamp - boiler mode 6 Indicator lamp - lock-out 7 Manual reset - overheat thermostat 8 Manual reset - flue overheat thermostat 9 Manual reset - burner lock-out 10 Manual reset - tank overheat thermostat 11 External programmer (not supplied) 12 Burner socket 13 Burner plug 14 Burner control box 15 Flow switch 16 Circulating pump 17 Diverter valve 18 Frost stat 19 Frost stat Wire colour code: br - Brown bl - Blue gy - Green/Yellow r - Red w - White y - Yellow g - Grey bk - Black or - Orange pk - Pink 8 716 113 389d 30/3/10 14:01 Page 29

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 30 1 2 3 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 4 PRE-COMMISSIONING CHECKS - APPLIANCE CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. 1� Check that the service and water pipes are connected correctly. � Check that all unused sockets are capped. 2� Check that the oil supply is kerosene and that the pipework is connected correctly to the oil pump via the supplied flexible oil hose. � Turn on the main oil supply valve at the tank, check the oil supply pipework and connections. Rectify any leaks. 3� Check the flue is correctly fitted and the connections are secure. 4� Check the condensate pipework is correctly fitted and connected. � Check the condensate trap is filled with water. 5� Check the CH circulating pump is set to 3. NOTE: The CH circulating pump is preset to number 3 and should not be altered. The diagrams opposite show the pump outputs. NOTE: The cabinet is not load bearing, it only provides weather protection for the boiler inside. IMPORTANT: If the boiler is not to be commissioned immediately then: After successfully completing all of the checks and any rectification work, close the water valves, shut off the oil supply and electrically isolate the boiler. Complete the installation part of the Guarantee Registration Card, and complete a CD10 or its equivalent, to inform the LABC of the installation. COMMISSIONING 8 716 113 389d 30/3/10 14:01 Page 30

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 31 COMMISSIONING 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 automatic tank air vent. � The pump automatic air vent has a protective cover that must remain in place, this auto air vent needs no adjustment before filling the boiler. � Refit the protective cover. 3�Sealed systems only; check and if required, adjust the expansion vessel pressure using the Schraeder type valve (D). The charge pressure of the built-in 12 Litre expansion vessel is 0.5 bar as dispatched, which is equivalent to a static head of 5m. If an extra expansion vessel is fitted to the central heating return, adjust this to the same pressure as the appliance internal expansion vessel, refer to separate instructions supplied with the extra expansion vessel. 4�Open all system and radiator valves (E). �Turn on the water main stop cock. �Open vented systems only; turn on the water to the system feed and expansion cistern and allow the system to fill. �Sealed systems only; fill the system to between 1 and 2 bar pressure via a WRAS approved filling link. Monitor the pressure gauge during venting and repressurise if required. �Check air is being discharged from the automatic air vents. �Vent all radiators, retighten when completed, check the system and correct any leaks. �Bleed air from both of the secondary heat exchanger air vents (F). �Bleed air from the pump using the pump bleed screw. 5�Sealed systems only; connect a suitable hose to the Heatslave tank drain. Open the drain valve to reduce the system to the correct pressure, then close the drain valve. Ensure safe disposal of the discharge. Rotate the adjustable pointer on the pressure gauge to record the set system pressure. 6 �Check system and rectify any leaks. �Push lever (C) to the left and pull upwards to allow the lever to return to position A. �Leave the lever (C) unlocked at position A. FILLING THE SYSTEM Total system volume (litres) 180 107 138 Initial system pressure (bar) 0.5 1.0 1.0 Initial charge pressure (bar) 0.5 0.5 1.0 8 716 113 389d 30/3/10 14:01 Page 31

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 32 COMMISSIONING F H G Return Flow TANK 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 C B A D RIELLO RDB OIL PUMP ALTERNATIVE BURNER LOCKOUT RESET BUTTON (D) GREENSTAR HEATSLAVE EXTERNAL max flue reset boiler reset max lockout on service 1 BURNER LOCKOUT RESET BUTTON (D) (Under control box) (On top of burner control box) E - Lockout indicator STARTING THE APPLIANCE IMPORTANT: Never run the appliance when the appliance/system is unpressurised (sealed systems) or empty. 1�Check the oil supply is correctly fitted and in good working order before turning on the oil supply valves to the boiler. �Turn on the main oil supply valve at the tank and draw off at least 21/2 litres of oil until a steady flow of clear uncontaminated oil can be seen as follows: • The oil supply to the boiler should be primed before the burner is operated to avoid unnecessary pump wear. • The use of an oil suction pump will prime and flush through any oil supply set up simply and easily, alternatively the following procedures can be used. �Single pipe gravity feed systems: �Disconnect the flexible oil hose and open the isolating valve to discharge the oil into a suitable container. �If a top entry tank has been used the pipework will need to be primed before the oil will discharge under gravity. �When completed, close the isolating valve, reconnect the flexible oil hose. �Double pipe sub-gravity feed systems and single pipe suction lift with de-aerator: �To prime a de-aerator, disconnect the flexible oil inlet hose (F) from the isolation valve and place in a container of kerosene (G). Connect a spare flexible oil hose (H), to discharge into container (G). Open the isolating valve, turn on the power to the boiler and set the programmer to ON. Prime the de-aerator until there is a steady flow of oil into container (G). Turn off the boiler then reconnect the flexible oil inlet hose (F). �Turn on the boiler, the oil level in the de-aerator will drop as the oil is used until the oil is drawn from the tank. If the de-aerator empties and the burner locks out before the oil is drawn from the tank, prime the de-aerator again. When the oil reaches the pump, bleed the air from the pump as follows: �Open the isolating valve and the oil pump bleed valve (A) to discharge into a suitable container once the boiler is started up. �Switch on the electricity supply to the boiler. �Set the programmer to ON for CH and DHW. �Turn on the boiler CH control thermostat. �Allow the burner to run through to lockout indicated by the illumination of the lockout indicator (E). If no oil comes out of the port valve A, then re-prime the oil line as detailed above. �Wait 2 minutes then press the lockout reset button (D). �Repeat the procedure until a steady stream of oil, without air, runs from the bleed port, then relock the bleed port (A). �Switch off the boiler. �Remove the oil pump filter, clean with kerosene and refit. The internal filter is accessed by removing the oil pump cover on the Danfoss BFP 11 L3, Suntec AS47C and Riello RDB. �Safely dispose of the container/discharge. DANFOSS PUMP SHOWN 8 716 113 389d 30/3/10 14:01 Page 32

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 33 COMMISSIONING 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 desired output. Refer to the table on the following page. � 12/18 - RIELLO RDB 1 Adjust position of the air damper disc to suit the burner output (see chart on the following page), located as shown in the diagram opposite. Access is by removing the two star screws (SC) to release the air inlet manifold. • 18/25 - RIELLO RDB 2.2 The damper disk should not be moved, as it is required for all three outputs, 18, 21.5 and 25kW. � Adjust the air shutter (L) and pump pressure (B) as shown in the table opposite. The burner should ignite following a pre-ignition period of approximately 15 seconds. NOTE: The RIELLO control box has an 11 second delay before the start of the pre-ignition. Boiler lockout indicator on: If the burner fails to establish a normal firing pattern or flame failure occurs the 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 indicator (E). �Wait 2 minutes then press the lockout reset button (D) to initiate another start sequence. �Repeat procedure until a flame is established. 3�Start and run for 3 minutes then switch off. �Check for after-spurting from the nozzle, indicated by oil saturation on the combustion head (F). If after-spurting occurs: �Release the burner retainers. �Remove the burner, combustion head (F). and electrodes, hold the burner vertical to unscrew the nozzle and fill the nozzle holder with oil. �Refit nozzle, electrodes, combustion head (F) and the burner. �Restart and run for 3 minute intervals until after-spurting stops. 4�Start and run for 20 minutes. �Remove sampling point plug (K) to check the smoke reading is between 0-1. If the smoke level is above 1, check the combustion settings are correct and the oil nozzle is in good condition. NOTE: Smoke readings may be inaccurate until the smoke from burning organic binder in the access door insulation has ceased. 2 4 3 A B C A - Bleed & pressure gauge port B - Pressure adjustment C - Vacuum gauge port DANFOSS BFP 11 L3 OIL PUMP A B C SUNTEC AS47C OIL PUMP RIELLO RDB OIL PUMP C B A D SC SC G F K D (under control box) D Alternative lockout reset button (on top of burner control box) E 15/18kW 12kW 8 716 113 389d 30/3/10 14:01 Page 33

�Check the CO2 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 pressure (B) 5-10 p.s.i. to compensate for nozzle variations. �Turn off the electrical supply. �Isolate the oil supply to the burner. �Remove the oil pressure gauge. �Refit the blanking plug (A). �Check and rectify any oil leaks. 5�Switch on the oil supply. �Switch on the electrical supply. �Restart the boiler and run for 5 minutes. �Recheck the CO2 levels and if required, adjust the air shutter setting (L) to obtain the correct CO2 level. A B C A - Bleed & pressure gauge port B - Pressure adjustment C - Vacuum gauge port DANFOSS BFP 11 L3 OIL PUMP A B C SUNTEC AS47C OIL PUMP %CO2 NOMINAL BOILER RATING AT NORMAL OPERATING TEMPERATURE USING 28sec KEROSENE: NOZZLE 12/18 - Bentone Sterling 40 Burner: OIL PUMP PRESSURE (p.s.i.) FUEL FLOW 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 0.35 80°SR 0.45 80°S 0.50 80°ES 115 115 140 1.04 1.29 1.55 1.32 1.63 1.96 66 70 73 11.5 12.0 12.5 2.5 4.5 5.25 42300 52900 63500 12 15 18 40900 51200 61400 12.4 15.5 18.6 RIELLO RDB OIL PUMP C B A 12/18 - Riello RDB 1 Burner : 0.35 80°SR 0.45 60°ES 0.50 60°ES 105 120 125 1. 0 4 1.29 1.55 1.32 1.63 1.96 64 67 72 12 .0 12.0 12.5 4.5 3.0 4.5 42300 52900 6 3500 12 15 18 40900 51200 61400 12.4 15.5 18.6 18/25 - Riello RDB 2.2 Burner : 0.50 60°ES 0.65 60°ES 0.75 60°ES 125 120 115 1.56 1.86 2.17 1.98 2.36 2.75 75 78 84 11.5 12.0 12.5 2.0 3.0 4.5 63300 75100 8 9700 18 21.5 25 61400 73400 85300 18.6 22.2 25.8 25/32 - Riello RDB 2.2 Burner : 0.75 60°ES 0.75 60°ES 0.85 60°ES 105 140 150 2.15 2.45 2.75 2.72 3.10 3.48 78 80 83 11.5 12.0 12.5 3.0 4.0 5.0 87040 99200 111400 25 28.5 32 85300 97200 109200 25.5 29.1 32.7 18/25 - Bentone Sterling 50 Burner: 0.50 80°EH 0.55 80°EH 0.65 80°EH 130 145 150 1.56 1.86 2.17 1.98 2.36 2.75 72 79 82 11.5 12.0 12.5 4.25 6.0 8.0 63300 75100 87900 18 21.5 25 61400 73400 85300 18.6 22.2 25.8 N/A N/A N/A N/A N/A N/A 15-18kW 15-18kW 12kW 18-25kW 18-25kW 18-25kW N/A N/A N/A 5 L L STARTING THE APPLIANCE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 34 COMMISSIONING 8 716 113 389d 30/3/10 14:01 Page 34

max flue reset boiler reset max lockout on service GREENSTAR HEATSLAVE EXTERNAL max flue reset boiler reset max lockout on service 1 2 3 4 C GREENSTAR HEATSLAVE EXTERNAL max flue reset boiler reset max lockout on service 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 should be ON with the circulating pump to heat the water in the Heatslave external tank. When minimum set temperature is reached the burner and circulating pump will switch off. 3� Fully open a hot water tap. The burner should be OFF and the circulating pump ON.The burner will turn ON when the DHW thermostat calls for heat. � Check the water flow rate using a suitable measuring container; 12/18KW 15 litres/min 18/25kW 18 litres/min* 25/32kW 22 litres/min* * Manually regulate using the water main inlet isolating valve on the boiler. 4� Fully close the hot water tap. � Check the burner and circulating pump** switch off. **The high limit thermostat may activate pump overrun until the correct temperature is restored. STARTING THE APPLIANCE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 35 COMMISSIONING 8 716 113 389d 30/3/10 14:01 Page 35

max flue reset boiler reset max lockout on service GREENSTAR HEATSLAVE EXTERNAL max flue reset boiler reset max lockout on service GREENSTAR HEATSLAVE EXTERNAL max flue reset boiler reset max lockout on service GREENSTAR HEATSLAVE EXTERNAL max flue reset boiler reset max lockout on service 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 circulating pump. The diverter valve (E) should open to port B for CH. �Ensure all radiators are heating up evenly and balance the system to the temperature difference required across the heating flow and return relevant to the heating load. 2�Set 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: 3�Set the room thermostat to maximum. �Set the programmer to ON for DHW & CH. �Turn the DHW thermostat control (C) fully anti-clockwise. �Set the CH thermostat control (D) to max. The burner should be ON with the circulating pump. The diverter valve (E) should open to port B for CH. 4�Set the DHW thermostat control (C) to max. The diverter valve (E) should move to port A and divert the flow to the Heatslave tank. STARTING THE APPLIANCE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 36 COMMISSIONING 8 716 113 389d 30/3/10 14:01 Page 36

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 vented systems only: turn off the water to the system header tank. �Open all radiator valves/drain cocks (C) and drain the system while the appliance is hot. �Close drain cocks (C). 2�Add a suitable flushing agent and refill the system at the correct strength for the system condition in accordance with the manufacturer's instructions. �Vent the boiler (there are two vent points (A) at the top of the secondary heat exchanger. Only one may be in use, the other may be obscured by side fluing. Always vent (A) and the vent screw (B) on the pump and all radiators. �Run the boiler/system at normal operating temperature for the time stated by the flushing agent manufacturer. 3�Drain and thoroughly flush the system and boiler (C) to remove the flushing agent and debris. INHIBITOR (Central Heating): 4�Check drain cocks and manual air vents are closed and all radiator valves are open. 5�Add a suitable inhibitor, (or 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 must not cause damage to the materials within the boiler (mild steel, stainless steel, copper and brass) and any other materials/components within the system. �Open vented systems only: turn on the water to the system header tank and allow the system to fill. �Sealed systems only: fill the system to between 1 and 2 bar via a WRAS approved filling loop. Check the system pressure during venting and repressurise if necessary. 6�Vent the boiler (there are two vent points (A) at the top of the secondary heat exchanger. Only one may be in use, the other maybe obscured by side fluing. Always vent (A) and the vent screw (B) on the pump and all radiators; retighten vents when complete. 7�Record the date on the guarantee card when the inhibitor was added to the system . NOTE: The concentration level of inhibitor in the system should be checked every 12 months or sooner if system content is lost. The addition of sealing agents to the system water is not advised as this can cause problems with deposits left in the heat exchanger and invalidate the appliance and heat exchanger warranty . A A B C C C C 1 2 & 6 3 WATER TREATMENT INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 37 COMMISSIONING 8 716 113 389d 30/3/10 14:01 Page 37

APPLIANCE 1� Refit the top panel and press down to compress the seal when fitting the securing screws (A). 2� Push the front panel up behind the top panel and push in at the base to secure the screws (B) with the tool provided. Always apply pressure at the edges of the panels when securing to avoid accidental damage. Handover: �Complete the guarantee registration card, commissioning checklist (at the rear of this manual) and a CD11 or an equivalent commissioning form. �Set up the controls and show the user how to operate all the controls shown in the User Guide, and all system controls. �Where applicable, instruct the customer how to repressurise the system. �If the appliance is unused and exposed to freezing conditions, shut off all the mains supplies and drain the system and boiler to prevent damage to the system and boiler. NOTE: Release drain point (K) to drain the secondary heat exchanger. A A B B C 2 1 K INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 38 COMMISSIONING FINISHING COMMISSIONING - APPLIANCE 8 716 113 389d 30/3/10 14:01 Page 38

CAUTION: ISOLATE THE WATER, ELECTRICITY AND OIL MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. DO NOT USE PRESSURE WASHERS OR STEAM CLEANERS ON THIS APPLIANCE OR ITS CABINET. WARNING: EXTERNAL EQUIPMENT OPERATED AT 230 VOLTS SHOULD NOT BE SERVICED OR REPAIRED UNDER ADVERSE WEATHER CONDITIONS Routine servicing: To maintain efficient boiler operation, the following should be carried out at least once a year: �Carry out a pre-service check and note any operational faults: �Pre-Service Check: 1�Undo the screws at the base of the front panel using the tool provided and pull the panel down and out to remove. Store safely away from the working area. Operate the appliance and system and note any faults which may need to be corrected during the service. �Switch into service mode at switch (A). 2�Depress locking ears and unplug burner lead (B) from control box (C). • An adaptor lead is available to allow mains voltage service aids to be operated from the service connection (G). (Service lead Part No. 8 716 113 483 0). 3�Loosen clip (D) to detach air duct. 4�Unscrew burner retainers (E) to release the burner combustion head (F). �Lift burner away, taking care not to over strain the flexible oil hose/s or connections. See the following instructions for detail of some of the service requirements listed below: �Check and clean the burner. �Replace burner nozzle and flexible oil hose/s. �Check and clean the baffle retainers. �Check and clean the baffles. �Check and clean the heat exchangers surfaces. �Check the combustion chamber access door insulation board. �Check that the flue system is unobstructed and clean as necessary. �Clean or replace all oil filters. �Check that the condensate system is not obstructed, clean and refill the condensate trap as necessary. � Sealed systems only: The PRV is a safety device and must be checked for correct operation. The expansion vessel pressure must be checked and adjusted as required. on service F D 3 E 4 1 A C B 2 G INSPECTION AND SERVICE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 39 SERVICING & SPARES 8 716 113 389d 30/3/10 14:01 Page 39

�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). 2 Bentone Sterling 40 & 50 12/18 & 18/25 Inspection of Mechanical Shut-off Valve: � Fasten an M5 screw, with a minimum length of 30mm, into the threaded hole (L) and pull the screw to withdraw the check valve (M). �Check that the nozzle holder (N) is clear of any debris and clean if necessary. �Check that the three holes in the check valve (M) are clear of any debris. Check the condition of the 'O' ring (O). Discard the check valve if the holes cannot be cleared, if the unit is defective or if the 'O' ring is damaged and replace with a new one. �Refit the check valve. Riello RDB 1 & 2.2 12/18, 18/25 & 25/32 �Check the nozzle holder is clear of any debris and clean if necessary. ALL MODELS �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) on the Danfoss BFP 11 L3, Suntec AS47C and Riello RDB. 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. INSPECTION AND SERVICE A B A - Retaining screws - cover B - Cover - oil pump H P D 5mm Electrode gap 2.5 - 3.0mm 7.5mm F E 5mm K L N M O DANFOSS BFP 11 L3 OIL PUMP SUNTEC AS47C OIL PUMP A RIELLO RDB OIL PUMP B 2.5mm Electrode gap 4mm F E K 5mm H P D A B RIELLO RDB 1 & 2.2 BENTONE STERLING 40 & 50 12/18 18/25 12/18 18/25 25/32 INSPECTION AND SERVICE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 40 SERVICING & SPARES 8 716 113 389d 30/3/10 14:01 Page 40

M L O M K Plan sectional view 12/18kW & 18/25kW 25/32kW Plan sectional view or 1 2 4 3 A B I C H K C I H E D F G E G O M FRONT FRONT INSPECTION AND SERVICE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 41 SERVICING & SPARES 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 access cover (B) and clear any debris. �Check the flue system and clean if necessary. �Remove the baffle retainer (H) and baffles ( I ) from the secondary heat exchanger. �Check and clean the secondary heat exchanger surfaces. NOTE: Do not use wire brushes and cleaning agents to clean the stainless steel secondary heat exchanger components. �Check the condensate route (C) is clear. �The condensate trap (D) should be removed and checked for debris. �Release the pipe locking tab (E) and disconnect the flexible pipe (F) from the top of the trap and move the flexible pipe up away from the trap. � Release the trap locking tab (G) and move the trap up and back to remove from it mountings. �Clean the trap by flushing with water. �Check the O ring seals and replace if necessary, grease the seals with a solvent free grease. �Refit the trap making sure that the locking tabs are locked in place. �Pour 500ml of water into drain ( C ) to refill the condensate trap. �Clean the secondary heat exchanger baffles ( I ) if necessary and refit correctly. � Refit the baffle retainer (H). �Check the seal on the manifold access cover (K) and replace if necessary. �Refit the flue manifold access cover (B) and secure with screws (A). Combustion chamber: �Release the M10 retaining nuts and washers ( L ) and remove combustion chamber access door (M). �Check the fibreglass rope seal on the combustion chamber access door (M) and replace if necessary. �Remove and check the baffle retainer (N). �Remove the baffles (O), clean and check the condition of the baffles and the acoustic insulation. Replace any baffles or insulation pads considered to be badly corroded/degraded. �Thoroughly clean all of the heat exchanger surfaces using a suitable brush and clear all loose debris from the combustion chamber. �Check the condition of the combustion chamber access door insulation. If the insulation is damaged the door assembly must be replaced. �Refit the items in reverse order ensure the baffles (O) and baffle retainers (N) are correctly fitted for the boiler output as shown in the plan view opposite. � Refit combustion chamber door (M). IMPORTANT: Secure with nuts and washers ( L ) and tighten, using the sequence shown in figure, until the chamber door is firmly secured, do not over tighten the nuts. 8 716 113 389d 30/3/10 14:01 Page 41

Fire valve: �Check that the oil supply pipe has a fire valve fitted at least 1m away from the appliance with the fire valve sensor located within the appliance case. A fire valve sensor clip (A) is provided for this purpose. Re-commission the burner: 1�Align burner combustion head (B) into the boiler housing tube with gasket (C) correctly fitted. �Push firmly down to compress the gasket (C). �Tighten burner retainers (D) sufficiently to ensure a good seal. IMPORTANT: Ensure the gasket is a good seal between the burner combustion head and the boiler housing to prevent flue gases escaping. �Refit flexible air duct and secure with clip (E ). 2�Plug burner lead (F ) into control box (G). �Connect an oil pressure gauge to the oil pump, run the burner and check the oil pressure is correct for the required boiler output. Check that the smoke reading is between 0 and 1, if the smoke reading is above 1 check the air setting. If the air setting is correct check that the burner has been reassembled correctly. Allow the boiler to warm up then check the combustion settings are correct as indicated in the table below, adjust the 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 panels: 3�Refit the top panel and press down to compress the seal when fitting the securing screws. � Push the front panel up behind the top panel and push in at the base to secure the screws with the tool provided. After service handover: �Make a note of the date of any water treatment. �Set the controls back to the users requirements. �Complete the service interval record at the back of this manual and a CD11 or an equivalent form. �If the appliance is unused and exposed to freezing conditions; shut off all the mains supplies, isolate the boiler and drain the system and boiler, including the secondary heat exchanger. %CO2 NOMINAL BOILER RATING AT NORMAL OPERATING TEMPERATURE USING 28sec KEROSENE: NOZZLE 12/18 - Bentone Sterling 40 Burner: OIL PUMP PRESSURE (p.s.i.) FUEL FLOW 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 0.35 80°SR 0.45 80°S 0.50 80°ES 115 115 140 1.04 1.29 1.55 1.32 1.63 1.96 66 70 73 11.5 12.0 12.5 2.5 4.5 5.25 42300 52900 63500 12 15 18 40900 51200 61400 12.4 15.5 18.6 12/18 - Riello RDB 1 Burner : 0.35 80°SR 0.45 60°ES 0.50 60°ES 105 120 125 1. 0 4 1.29 1.55 1.32 1.63 1.96 64 67 72 12 .0 12.0 12.5 4.5 3.0 4.5 42300 52900 6 3500 12 15 18 40900 51200 61400 12.4 15.5 18.6 18/25 - Riello RDB 2.2 Burner : 0.50 60°ES 0.65 60°ES 0.75 60°ES 125 120 115 1.56 1.86 2.17 1.98 2.36 2.75 75 78 84 11.5 12.0 12.5 2.0 3.0 4.5 63300 75100 8 9700 18 21.5 25 61400 73400 85300 18.6 22.2 25.8 25/32 - Riello RDB 2.2 Burner : 0.75 60°ES 0.75 60°ES 0.85 60°ES 105 140 150 2.15 2.45 2.75 2.72 3.10 3.48 78 80 83 11.5 12.0 12.5 3.0 4.0 5.0 87040 99200 111400 25 28.5 32 85300 97200 109200 25.5 29.1 32.7 18/25 - Bentone Sterling 50 Burner: 0.50 80°EH 0.55 80°EH 0.65 80°EH 130 145 150 1.56 1.86 2.17 1.98 2.36 2.75 72 79 82 11.5 12.0 12.5 4.25 6.0 8.0 63300 75100 87900 18 21.5 25 61400 73400 85300 18.6 22.2 25.8 N/A N/A N/A N/A N/A N/A 15-18kW 15-18kW 12kW 18-25kW 18-25kW 18-25kW N/A N/A N/A 3 1 2 3 F A C B D F INSPECTION AND SERVICE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 42 SERVICING & SPARES E G 8 716 113 389d 30/3/10 14:01 Page 42

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 Satronic S98 12 pole Part Number: 8 716 157 042 0 6 Ignition electrode Part Number: 8 716 142 752 0 7 Motor Part Number: 8 716 156 645 0 8 Oil pump - Danfoss BFP 11 L3 Part Number: 8 716 142 736 0 8a Oil pump - Suntec AS47C Part Number: 8 716 157 014 0 9 Transformer (Excludes cable) Part Number: 8 716 156 696 0 10 Mechanical shut-off valve Part Number: 8 716 156 658 0 11 Flexible oil line kit Part Number: 8 716 115 312 0 12 Burner 'O' ring gasket Part Number: 8 716 140 902 0 13 Heating control thermostat Part Number: 8 716 107 621 0 14 Auto reset High Limit thermostat Part Number: 8 716 107 640 0 15 Manual reset Boiler thermostat Part Number: 8 716 107 625 0 16 Manual reset flue thermostat Part Number: 8 716 107 624 0 17 DHW control thermostat Part Number: 8 718 685 283 0 18 Manual reset tank thermostat Part Number: 8 718 685 269 0 19 Circulation pump UPS 15-60 Part Number: 8 718 685 525 0 20 Control board Part Number: 8 718 685 261 0 21 Cleaning brush Part Number: 8 716 109 428 0 22 Manifold access cover seal Part Number: 8 716 107 536 0 23 Secondary Heat Exchanger gasket Part Number: 8 716 112 954 0 24 Frost thermostat Part Number: 8 716 142 393 0 25 Service lead Part Number: 8 716 113 483 0 26 Spare 1/4 turn cabinet key Part Number: 8 716 114 013 0 27 Oil nozzle 0.35 80° SR (12kW output) Part Number: 8 716 112 628 0 0.45 80° S (15kW output) Part Number: 8 716 106 197 0 0.50 80° ES (18kW output) Part Number: 8 716 156 669 0 SHORT PARTS LIST BENTONE 40 - 12/18 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 43 SERVICING & SPARES 8 716 113 389d 30/3/10 14:01 Page 43

SHORT PARTS LIST 18/25 1 Burner - Sterling 50 Part Number: 8 716 112 570 0 2 Combustion head - burner Part Number: 8 716 108 573 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 Satronic S98 12 pole Part Number: 8 716 157 042 0 6 Ignition electrode Part Number: 8 716 142 752 0 7 Motor Part Number: 8 716 156 645 0 8 Oil pump - Danfoss BFP 11 L3 Part Number: 8 716 142 736 0 8a Oil pump - Suntec AS47C Part Number: 8 716 157 014 0 9 Transformer (Excludes cable) Part Number: 8 716 156 696 0 10 Mechanical shut-off valve Part Number: 8 716 156 658 0 11 Flexible oil hose kit Part Number: 8 716 115 312 0 12 Burner 'O' ring gasket Part Number: 8 716 140 902 0 13 Heating control thermostat Part Number: 8 716 107 621 0 14 Auto reset High Limit thermostat Part Number: 8 716 107 640 0 15 Manual reset Boiler thermostat Part Number: 8 716 107 625 0 16 Manual reset flue thermostat Part Number: 8 716 107 624 0 17 DHW control thermostat Part Number: 8 718 685 283 0 18 Manual reset tank thermostat Part Number: 8 718 685 269 0 19 Circulation pump UPS 15-60 Part Number: 8 718 685 525 0 20 Control board Part Number: 8 718 685 261 0 21 Cleaning brush Part Number: 8 716 109 428 0 22 Manifold access cover seal Part Number: 8 716 107 536 0 23 Secondary Heat Exchanger gasket Part Number: 8 716 112 954 0 24 Frost thermostat Part Number: 8 716 142 393 0 25 Service lead Part Number: 8 716 113 483 0 26 Spare 1/4 turn cabinet key Part Number: 8 716 114 013 0 27 Oil nozzle 0.50 80° EH (18kW output) Part Number: 8 716 156 672 0 0.55 80° EH (21.5kW output) Part Number: 8 716 156 671 0 0.65 80° EH (25kW output) Part Number: 8 716 110 362 0 SHORT PARTS LIST 18/25 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 44 SERVICING & SPARES 8 716 113 389d 30/3/10 14:01 Page 44

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: 8 716 109 193 0 5 Ignition electrode Part Number: 8 716 109 183 0 6 Motor Part Number: 8 716 109 186 0 7 Oil pump - Riello RDB Part Number: 8 716 115 297 0 8 Flexible oil hose kit Part Number: 8 716 115 312 0 9 Burner 'O' ring gasket Part Number: 8 718 682 439 0 10 Heating 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 Boiler thermostat Part Number: 8 716 107 625 0 13 Manual reset flue thermostat Part Number: 8 716 107 624 0 14 DHW control thermostat Part Number: 8 718 685 283 0 15 Cleaning brush Part Number: 8 716 109 428 0 16 Manifold access cover seal Part Number: 8 716 107 536 0 17 Secondary Heat Exchanger gasket Part Number: 8 716 112 954 0 18 Frost thermostat Part Number: 8 716 142 393 0 19 Manual reset tank thermostat Part Number: 8 718 685 269 0 20 Circulation pump UPS 15-60 Part Number: 8 718 685 525 0 21 Control board Part Number: 8 718 685 261 0 22 Service lead Part Number: 8 716 113 483 0 23 Spare 1/4 turn cabinet key Part Number: 8 716 114 013 0 24 Oil nozzle 0.35 80° SR (12kW output) Part Number: 8 716 112 628 0 0.45 60° ES (15kW output) Part Number: 8 716 156 679 0 0.5 60° ES (18kW output) Part Number: 8 716 156 671 0 SHORT PARTS LIST RIELLO RDB 1 - 12/18 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 45 SERVICING & SPARES 8 716 113 389d 30/3/10 14:01 Page 45

SHORT PARTS LIST 18/25 1 Burner - Riello RDB 2.2 18/25 Part Number: 8 718 685 836 0 2 Combustion head - LD2SX (Short) Part Number: 8 718 685 872 0 3 Control box MO535 Part Number: 8 718 682 250 0 4 Photocell Part Number: 8 716 109 193 0 5 Ignition electrode Part Number: 8 716 109 183 0 6 Motor Part Number: 8 716 109 186 0 7 Oil pump - Riello RDB Part Number: 8 716 115 297 0 8 Flexible oil hose kit Part Number: 8 716 115 312 0 9 Burner 'O' ring gasket Part Number: 8 718 682 439 0 10 Heating 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 Boiler thermostat Part Number: 8 716 107 625 0 13 Manual reset flue thermostat Part Number: 8 716 107 624 0 14 DHW control thermostat Part Number: 8 718 685 283 0 15 Cleaning brush Part Number: 8 716 109 428 0 16 Manifold access cover seal Part Number: 8 716 107 536 0 17 Secondary Heat Exchanger gasket Part Number: 8 716 112 954 0 18 Frost thermostat Part Number: 8 716 142 393 0 19 Manual reset tank thermostat Part Number: 8 718 685 269 0 20 Circulation pump UPS 15-60 Part Number: 8 718 685 525 0 21 Control board Part Number: 8 718 685 261 0 22 Service lead Part Number: 8 716 113 483 0 23 Spare 1/4 turn cabinet key Part Number: 8 716 114 013 0 24 Oil nozzle 0.5 60° ES (18kW output) Part Number: 8 716 156 671 0 0.65 60° ES (21,5kW output) Part Number: 8 716 115 843 0 0.75 60° ES (25kW output) Part Number: 8 716 106 156 0 SHORT PARTS LIST RIELLO RDB 2.2 - 18/25 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 46 SERVICING & SPARES 8 716 113 389d 30/3/10 14:01 Page 46

RIELLO RDB 1 - 12/18 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 47 SERVICING & SPARES RIELLO RDB 2.2 burner SHORT PARTS LIST 25/32 1 Burner - Riello RDB 2.2 25/32 HE Part Number: 8 716 112 512 0 2 Combustion head - burner Part Number: 8 716 112 521 0 3 Control box MO535 Part Number: 8 718 682 250 0 4 Photocell Part Number: 8 716 109 193 0 5 Ignition electrode Part Number: 8 716 109 183 0 6 Motor Part Number: 8 716 109 186 0 7 Oil pump - Riello RDB Part Number: 8 716 115 297 0 8 Flexible oil hose kit Part Number: 8 716 115 312 0 9 Burner 'O' ring gasket Part Number: 8 718 682 439 0 10 Heating 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 Boiler thermostat Part Number: 8 716 107 625 0 13 Manual reset flue thermostat Part Number: 8 716 107 624 0 14 DHW control thermostat Part Number: 8 718 685 283 0 15 Cleaning brush Part Number: 8 716 109 428 0 16 Manifold access cover seal Part Number: 8 716 107 536 0 17 Secondary Heat Exchanger gasket Part Number: 8 716 112 954 0 18 Frost thermostat Part Number: 8 716 142 393 0 19 Manual reset tank thermostat Part Number: 8 718 685 269 0 20 Circulation pump UPS 15-70 Part Number: 8 718 685 526 0 21 Control board Part Number: 8 718 685 261 0 22 Service lead Part Number: 8 716 113 483 0 23 Spare 1/4 turn cabinet key Part Number: 8 716 114 013 0 24 Oil nozzle 0.75 60° ES (25 & 28.5kW output) Part Number: 8 716 106 156 0 0.85 60° ES (32kW output) Part Number: 8 716 110 083 0 8 716 113 389d 30/3/10 14:01 Page 47

Combustion settings incorrect Set up as in installation instructions Faulty nozzle Replace nozzle Intermittent lockout Bad electrical connection Check control box/electrical connections Intermittent flame detection fault See flame detection fault Burner motor fails to operate Faulty motor or electrical supply to motor Check for 230v at motor plug during startup period Control box fault Replace control box Flame detection Photocell filmed over (dirty) Wipe clean fault Photocell faulty Replace Control box faulty Replace Incorrect CO2 Air adjustment fault Set up as in installation instructions Oil pressure incorrect Set up as in installation instructions No oil from nozzle No oil at pump Check and refill oil tank/bleed oil line Check and clean filters & valves from oil tank to boiler Air in pump Bleed pump Nozzle blocked Replace nozzle Faulty pump or drive Replace Faulty mechanical shut off valve Clean or replace (12/18 & 18/25 only) Ignition failure Electrode 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 or electrical connections not properly made Correct control box electrical connections or replace control box BURNER FAILS No power to boiler Check electrical / control circuit TO START Faulty boiler thermostat Check by temporarily linking out high limit and control thermostats Programmer open circuit Check by temporarily linking 8 & 9 on the connector Faulty control box Replace HIGH SMOKE Air intake/flue blocked Check & clear air intake/flue NUMBER Incorrect combustion settings Set up as in installation instructions Oil pressure incorrect Adjust to correct pressure Incorrect components used on combustion head Check with installation instructions Faulty nozzle Replace nozzle FAULT FINDING BOILER LOCKOUT : Indicated by the illumination of the 'Lockout' indicator on the fascia. To reset, wait 2 minutes then press the lockout reset button. Also refer to fault finding logic on pages 51 and 52. UNDER NO CIRCUMSTANCES MUST AN APPLIANCE BE LEFT TO OPERATE WITH ANY CONTROL LINKED OUT OR OVERRIDDEN. FAULT FINDING & DIAGRAMS FAULT FINDING INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 48 8 716 113 389d 30/3/10 14:01 Page 48

worn pump Bleed air from pump or replace pump Worn motor bearings Replace motor Fan out of balance Replace fan Boiling Faulty boiler thermostat Replace if necessary Short circuit boiler thermostat Take out of circuit to check Thermostat bulb not fully home in pocket Ensure bulb is pushed fully home No primary water circulation Check system / circulating pump Short Cycling Burner rating incorrect Correct burner rating Boiler thermostat differential incorrect Replace boiler thermostat External controls not operating correctly Check and correct external controls OIL SMELLS: Blocked flue, fumes on startup Check seals/gaskets Oil soaked boiler, faulty burner operation, numerous lockouts Rectify burner operation and lockouts Odour in cabinet, oil leaks from pipework, flexible hoses connections Rectify oil leaks, replace components if necessary & tank overheat thermostat FAULT FINDING 49 FAULT FINDING & DIAGRAMS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 106 389c (01/2009) 8 716 113 389d 30/3/10 14:01 Page 49

This operation instruction is provided to assist competent and suitably qualified engineers to locate and rectify faults. Whilst every effort has been taken to ensure the information given is correct and complete we cannot guarantee that every eventuality has been covered. Worcester, Bosch Group cannot be held responsible for costs incurred by persons not deemed to be competent. In the lock-out condition, the oil pump can be primed for 30 seconds: 1. Press the remote reset button for more than 6 seconds and then release. The control box lock-out reset will blink quickly green, orange and red. 2. Press the burner reset button again and release within 3 seconds and pump priming starts. Operational Codes OFF OFF Initial check time (11 seconds) before pre-purge OFF Pre-purge (15 seconds) ORANGE Flashing Safety time (maximum 5 seconds) GREEN Flashing Running GREEN Lock-out/Error Codes False light before ignition GREEN, RED Under voltage or over voltage RED, ORANGE lock-out for no flame during safety time RED Lock-out for false flame signal / RED Flashing Lock-out for burner control error Lock-out for maximum number of restarts RED Fast flashing Pump Priming Cycle Pump priming cycle GREEN, ORANGE, RED STATUS CODE ADDITIONAL INFORMATION Only when the solenoid valve is energised with no flame signal. Lock-out and Reset The control box can be reset of 5 times, after which the power supply has to be reset; then the control box can be reset a further 5 times. Limit of Restarts If the flame is lost during operation; the burner will restart 3 times. On the 4th restart the burner will go to lock-out. By resetting the power supply the control box is reset and allows 3 restarts. Flame Detection Flame detection minimum current: 30µA Flame loss maximum current: 25µA False flame maximum current (without false light): 19µA FAULT FINDING & DIAGRAMS FAULT FINDING INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 50 8 716 113 389d 30/3/10 14:01 Page 50

L & N to control box? Control box locks out? Check boiler controls & supply Check connections/ replace leads Replace motor/ pump Replace motor Replace control box Lockout within 1 second? Replace oil pump Oil to pump? Drive coupling broken? Pump produces pressure? Replace transformer Electrodes & leads OK? 230V at transformer? Spark produced? Lockout after purge before oil solenoid opens? Replace control box Transformer lead OK? Photo cell lead OK? Disconnect photo cell, reset lockout, burner lights then locks out? Stray light on photo cell? Combustion head set correctly? Combustion air setting correct? Flame off and re-lights? Nozzle atomising fuel? Replace photo cell Photo cell functional? If BF remove burner snorkel tube & retest. Lights OK? Replace photo cell Replace coil lead 230V at solenoid coil? Coil lead OK? Boiler or flue blocked Reseal BF on reposition Replace control box Replace control box Solenoid operating? 2.2kΩ across solenoid coil? Pipe to nozzle holder OK? Oil check valve OK? (if fitted) Replace nozzle Replace solenoid coil Replace pump Replace oil check valve (if fitted) Yes Yes Yes No No Yes Yes No No No No No Yes Yes No No Yes No No Yes No Yes Yes Yes No Yes Yes Yes Yes No No No Yes Yes Yes Yes No No No No No Yes Yes Yes Yes Yes No No No No Yes Yes Yes Yes Replace lead No Reset air setting No Reset combustion head No FAULT FINDING LOGIC FOR SATRONIC CONTROL BOX Note: This chart assumes all wiring within the control box base is correct, if in doubt check the wiring against the diagram on the base of the control box before replacing any components. All resistance measurements are actual measured values and some variation is to be expected, therefore measured values should be similar to but not necessarily identical to the given values. The operation of the photo cell can be tested by measuring the resistance across the photo cell, it should be a high resistance (greater than 10MΩ or open circuit) in the dark and low resistance (15kΩ or less) in light. Burners on balanced flue systems can recirculate flue products resulting in the burner cycling, if this happens check the flue system integrity and the terminal position. These fault finding charts are provided to assist competent and suitably qualified engineers to locate and rectify faults. Whilst every effort has been taken to ensure the information given is correct and complete we cannot guarantee that every eventuality has been covered. Worcester, Bosch Group cannot be held responsible for costs incurred by persons not deemed to be competent. Measure all 230V tests between Neutral (N) and the pin, wire or terminal specified. FAULT FINDING 51 FAULT FINDING & DIAGRAMS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 106 389c (01/2009) 8 716 113 389d 30/3/10 14:01 Page 51

control box? Motor or pump seized? Photo cell functional? Solenoid coil functional (100Ω)? Replace photo cell Motor gives 50 Volts on white wire? Lockout after 12 sec purge? Replace control box Replace solenoid coil Replace motor Ignition spark proved? Oil to pump? Drive coupling broken? Purge pressure 1-2 bar? Pump produces pressure? Replace pump stem valve, pressure OK? Replace solenoid coil Pipe to nozzle holder OK? Replace nozzle Replace oil pump Replace control box Eectrodes & leads OK? Yes No NO Yes No Yes No Yes Yes No No Yes Yes No No Yes Yes No Yes Motor 40Ω between blue & black wires ? Replace control box Yes Yes No Yes No Yes No No No Yes No Nozzle atomising fuel? Combustion air setting correct? Yes Yes Combustion head set correctly? Solenoid operating? Increase the pump pressure, pressure OK? Solenoid coil functional (100Ω)? No Coil lead OK? Yes Yes Replace control box No If BF, remove burner snorkel tube & retest. Burner OK? Flame off & re-lights? Yes Photo cell functional? No Yes Replace photo cell No Boiler or flue blocked No Reseal BF or reposition terminal Yes Replace control box Yes Replace electrodes/ leads No Unblock or replace pipe No Reset air setting No Reset combustion head No Yes FAULT FINDING LOGIC FOR RIELLO CONTROL BOXES All resistance measurements are actual measured values and some variation is to be expected, therefore measured values should be similar to but not necessarily identical to the given values. The operation of the photo cell can be tested by measuring the resistance across the photo cell, it should be a high resistance (greater than 10MΩ or open circuit) in the dark and low resistance (3kΩ or less) in light. Burners on balanced flue systems can recirculate flue products resulting in the burner cycling, if this happens check the flue system integrity and the terminal position. These fault finding charts are provided to assist competent and suitably qualified engineers to locate and rectify faults. Whilst every effort has been taken to ensure the information given is correct and complete we cannot guarantee that every eventuality has been covered. Worcester, Bosch Group cannot be held responsible for costs incurred by persons not deemed to be competent. MO535 IMPORTANT NOTE: The box has a built in delay of 11 seconds before activating the motor. The preheater link must be fitted at A for the box to operate FAULT FINDING & DIAGRAMS FAULT FINDING INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389d (03/2010) 52 8 716 113 389d 30/3/10 14:01 Page 52

N X1 (PIN 1) FROST THERMOSTATS 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 THERMOSTAT DIVERTER END SWITCH X8 (PIN 5) orange X8 (PIN 2) grey 1 4 3 N RELAY 2 4 3 1 N RELAY 3 X10 (PIN 3) X10 (PIN 1) white white 1 2 4 N RELAY 4 X6 (PIN 2) X6 (PIN 4) blue brown DHW CONTROL THERMOSTAT WATER FLOW SWITCH LOCKOUT INDICATOR X11 (PIN 2) PUMP X7 (PIN 1) brown MOTORISED DIVERTER VALVE X8 (PIN 3) brown grey X12 (PIN 4) grey BURNER X13 (PIN 1) yellow pink X13 (PIN 3) X13 (PIN 2) orange 2 4 (C) 2 4 (C) grey X13 (PIN 5) red red PLUG IN CONNECTOR CENTRAL HEATING CONTROL THERMOSTAT AUTO RESET HIGH LIMIT THERMOSTAT MANUAL RESET BOILER OVERHEAT THERMOSTAT X3 (PIN 3) X8 (PIN 1) LIVE SUPPLY FOR ALTERNATIVE DIVERTER VALVE CH DHW 3 2 MANUAL RESET FLUE OVERHEAT THERMOSTAT red NC NO 3 NC orange NO 3 red 2 6 LOCKOUT RESET SWITCH X3 (PIN 3 (L)) white white X9 (PIN 1) X1 (PIN 3) N 4 X11 (PIN 3) X12 (PIN 3) X7 (PIN 3) brown N X7 (PIN 4) N X8 (PIN 4) X8 (PIN 6) X1 (PIN 5) X1 (PIN 6) MODE SWITCH SERVICE CONNECTION MAINS CONNECTION R1 R2 C2 MANUAL RESET TANK OVERHEAT THERMOSTAT brown ELECTRICAL SCHEMATIC 53 FAULT FINDING & DIAGRAMS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 106 389c (01/2009) 8 716 113 389d 30/3/10 14:01 Page 53

COMPANY NAME: PUMP PRESSURE (PSI): ADDRESS: CO2%: 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 other of the boxes TIME & TEMPERATURE CONTROL TO HEATING ROOM T/STAT & PROGRAMMER/TIMER PROGRAMMABLE ROOMSTAT TIME CONTROL TO HOT WATER PROGRAMMER/TIMER HEATING ZONE VALVES FITTED NOT REQUIRED THERMOSTATIC RADIATOR VALVES FITTED AUTOMATIC BYPASS TO SYSTEM FITTED NOT REQUIRED CONFIRM THE FOLLOWING: THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE INSTRUCTIONS YES OIL TYPE USED IS KEROSENE YES THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE INSTRUCTIONS? YES THE SYSTEM CLEANER USED: THE INHIBITOR USED: HAS A WATER 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 SYSTEM COMPLIES WITH CURRENT BUILDING REGULATIONS NO YES THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS NO YES HAVE YOU RECORDED A CO/CO2 RATIO READING? N/A YES CO/CO2 RATIO THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER NO YES IMPORTANT: LEAVE THIS MANUAL WITH THE HOMEOWNER SERVICE INTERVAL RECORD It is recommended that the heating system is serviced regularly and that you complete the appropriate Service Interval Record Overleaf. Service Provider. Before completing the appropriate Service Interval Record overleaf, please ensure you have carried out the service as described in this manual. Always use Worcester, Bosch Group specified spare parts. HEATSLAVE BOILER COMMISSIONING CHECKLIST 8 716 113 389d 30/3/10 14:01 Page 54

ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: psi CO2%: 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 CO2%: NOZZLE CHANGED? YES NO F.G.T. °C FLUE PRESSURE: COMMENTS SIGNATURE SERVICE 3 DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: psi CO2%: NOZZLE CHANGED? YES NO F.G.T. °C FLUE PRESSURE: COMMENTS SIGNATURE SERVICE 4 DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: psi CO2%: NOZZLE CHANGED? YES NO F.G.T. °C FLUE PRESSURE: COMMENTS SIGNATURE SERVICE 5 DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: psi CO2%: NOZZLE CHANGED? YES NO F.G.T. °C FLUE PRESSURE: COMMENTS SIGNATURE SERVICE 6 DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: psi CO2%: NOZZLE CHANGED? YES NO F.G.T. °C FLUE PRESSURE: COMMENTS SIGNATURE SERVICE 7 DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: psi CO2%: NOZZLE CHANGED? YES NO F.G.T. °C FLUE PRESSURE: COMMENTS SIGNATURE SERVICE 8 DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: psi CO2%: NOZZLE CHANGED? YES NO F.G.T. °C FLUE PRESSURE: COMMENTS SIGNATURE SERVICE 9 DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: psi CO2%: NOZZLE CHANGED? YES NO F.G.T. °C FLUE PRESSURE: COMMENTS SIGNATURE SERVICE 10 DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: psi CO2%: NOZZLE CHANGED? YES NO F.G.T. °C FLUE PRESSURE: COMMENTS SIGNATURE 8 716 113 389d 30/3/10 14:01 Page 55

complete satisfaction, before calling for a service engineer, the installer should check the following:- General checks 1. Is the mode switch in boiler mode (indicator on)? 2. Is there 230V across the boiler live and neutral terminals? 3. Is the polarity correct? (230V across live and earth, 0V across neutral and earth) 4. Is the air bled from the primary system? 5. Is the air bled from the oil supply? 6. Is the flue sized and routed correctly? Boiler runs straight to lockout 1. Has the oil line been purged of air? 2. Where an air eliminator is used in conjunction with a top feed oil tank the non-return valve, (if fitted), should be removed from the oil dip pipe. Boiler locks out at the start of a demand (Heating off overnight for example) 1. If an air eliminator is being used, check that there are no leaks that allow air to be pulled into the oil supply. 2. If a two pipe oil supply is a being used, has a non-return valve been fitted to the inlet pipe? Refer to the instructions for guidelines. No domestic hot water (external programmer) 1. Is the mains water in connected to the 15mm isolation valve? 2. Is there a domestic hot water demand from the programmer and has the tank reached temperature? 3. Is there 230V on pin 2 of terminal block X4? 4. Remove the external wiring from terminal block X4 and fit a link across 1 and 2, if the domestic hot water now operates there is a problem with the external programmer and/or its wiring. No central heating (external programmer) 1. Are both programmer and room thermostat on demand for central heating? 2. Is the room thermostat wired correctly? 3. Refit the link across pins LS and LR on terminal X2, if the central heating now operates correctly the room thermostat and/or its wiring are faulty. 4. Is there 230V on pin 1 of terminal block X4? If not remove the external wiring to terminal block X4 and fit a link across pins 1 and 3 on terminal X4, if the central heating now operates correctly the programmer and/or its wiring are faulty. Dedicated to heating comfort Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0844 892 9900 Fax. 01905 754619 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. www.worcester-bosch.co.uk 8 716 113 389d (03/2010) UNDER NO CIRCUMSTANCES MUST AN APPLIANCE BE LEFT TO OPERATE WITH ANY CONTROL LINKED OUT OR OVER RIDDEN. 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 8 716 113 389d 30/3/10 14:01 Page 56