GREENSTAR HE 011. 12/22
Bosch Group
Hot Water and Central Heating
12/22 MINIMUM 12 kW (41,000 Btu/h)
MAXIMUM 22 kW (75,000 Btu/h)
Contents =
1. Installation Regulations ....Page 2
2. General Information Page 2
3. Technical Data Page 2
4. Siting the Appliance …Page 4
5. Removal of the Cabinet Page 4
6. Air Supply Page 4
7. Flue System …Page 7
8. Oil Supply …Page 10
9. Heating and Hot Water System.......... Page 12
10. Electrical : ...Page 13
11. Installation ....Page 13
12. Commissioning the Appliance ..... …Page 16
13. Instructions to the User Page 17
14. Routine Cleaning and Inspection............................ Page 18
15. Short Parts List cons ...Page 20
16. Fault Finding ..Page 23
1. Installation Regulations | о |
1.1 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 should be commissioned
by a qualified engineer.
1.2 The manufacturers notes must not be taken, in any way, as
overriding statutory obligations.
1.3 The compliance with a British Standard does not, of itself,
confer immunity from legal obligations. In particular the
installation of this appliance must be in accordance with the
relevant requirements of the following British Standards and
regulations in respect of the safe installation of equipment.
BS 5410: part 1: 1997 Code of practice for Oil Fired Boilers.
BS 799: part 5: 1987 Specification for Oil Storage Tanks.
BS 7593: 1992 Code of Practice for treatment of water in
domestic hot water central heating systems.
BS 5449: part 1: 1990 Code of practice for forced circulation hot
water Central Heating for Domestic Premises.
BS 7074: part 1: 1989 Application, selection and installation of
expansion vessels and ancillary equipment for sealed water
BS 7671: IEE Wiring Regulations, current edition.
The Building Regulations Part | England and Wales; Part F
Section [II Scotland; Part L Northern Ireland.
Local water company bye-laws.
The Control of Pollution (Oil) Regulations.
1.4 To ensure that the installation will perform to the highest
standards, the system and components should conform to those
mentioned in the instructions.
2. General Info rmation :
2.1 These instructions cover room sealed balanced flue (RS) appli-
ances only.
2.2 The Worcester Greenstar HE Oil appliance covered in these
instructions has been designed to serve domestic central heating
and hot water requirements ranging from 12 kW to 22 kw.
2.3 This RS balanced flue appliance forms a fully room sealed
system causing the combustion air to be drawn through a duct
from outside. The sealed burner cover gives excellent acoustic
noise reduction and alleviates the need for an air brick to be
located in the boiler room.
Because the balanced flue system does not rely on the cabinet
panels to form the room seal, combustion readings can be taken
from the test point on the condenser heat exchanger and the cabi-
net panels can be easily removed during installation thereby pre-
venting any damage.
2.4 The boiler is factory set to the mid-range output and can be
altered, if necessary, by adjusting the burner as specified in Table
2. This appliance is only suitable for use with 28 second Kerosene
heating oil.
NOTE: It is a mandatory requirement of the building
regulations that only 28 second kerosene is used on low level
discharge flues.
Table 1
Model 12/22
POWER SUPPLY 230/240V 50 Hz
MINIMUM FLUE Balanced Flue Kit
MAXIMUM STATIC HEAD | 30m (98 ft. )
PRIMARY WATER CAPACITY | 20 litres (4.4 gal.)
WEIGHT 121 Kg (267 lbs)
BURNER Electro Oil
Sterling 40
MASS FLOW 40 kg/hr
RANGE cut in to 80°C
maximum cut out
Fig. 1. Principal Dimensions (All Dimensions are millimetres)
WE = Fa 2j"
O a MA
у [|
12/22 Table 2. Electro Oil Bentone Sterling 40 Burner (See Fig. 25)
58 152
zo 0000000000000 МООА 00000
- 450
RS Balanced Flue Appliance
Pump Fuel Flow | Flue Gas Approx. Appliance
Fuel Nozzle Pressure Rate Temp. % СО, Air Input Output
(2.5.1) | Kg/h | I/h °C Setting | kW | Btu/hr | kW | Btu/hr
28 Sec. Kerosene 0.40 80°EH 150 1:24 1 1.55 60 10.5-11.0 2 14.7 | 50,000 | 14.1 | 48,000
28 Sec. Kerosene 0.45 80%H 150 1.46 | 1.83 70 11.0-11.5 3 17.3 | 59,000 16.6 | 57,000
28 Sec. Kerosene 0.50 80°EH 150 1.68 | 2.10 80 11.5-12.0 22.0 | 75,000 | 21.1 | 72,000
Note: These figures are given for guidance only, it is essential therefore that the settings are adjusted to give the correct CO, value.
4. Siting the Appliance
4.1 The appliance is not suitable for external installation unless
a suitable enclosure is provided.
4.2 The appliance should be positioned on a non-combustible
solid base as near to the flue termination point as possible. Care
should be taken to ensure that the appliance is level: use
packing at the corners where necessary.
4.3 The rear of the appliance must be positioned so that the flue
terminal can safely discharge the flue gases as described in
Section 7.
4.4 The following clearances must be left to allow access for
installation and servicing:
(a) Above 600mm
(b) In front - 600mm
(c) Right and left hand side — sufficient for panel
removal and access to pipe connections where
5. Removal of the АЕ
Ре. 2
1. Cabinet top panel
2. Front panel
3. Plastic facia surround
4. Electrical cover plate
5. Electrical cover plate securing screws
For installation and servicing of the appliance the cabinet should
be removed as follows: (See Fig. 2.)
5.1 Remove the cabinet top panel (1) by lifting squarely
upwards to release the four stud connections.
5.2 Remove the front panel (2) by pulling the upper part of the
panel forwards to release the studs and lifting the panel
upwards to release it from its supporting ledge.
5.3 Remove the plastic facia surround (3) by liffting up and for-
ward to release the four ball studs.
5.4 Remove electrical cover plate (4) by unscrewing the two
screws (5) at the rear of the connector protecter plate and hinge
up and away.
6. Air Supply
6.1 The appliance does not require a separate vent for
combustion air.
6.2 Installation in cupboards or compartments requires
permanent vents for cooling purposes, one at high level and one
at low level, either direct to outside air or to a room. Both vents
must pass to the same room or be on the same wall to the
outside air. The minimum air vent free area is given in Table 3.
6.3 There must be sufficient clearance around the appliance to
allow proper circulation of ventilation air. The clearances
required for Installation and Servicing will normally be adequate
for ventilation. See Section 4.4.
Table 3. Minimum Air Vent Free Area for Room Sealed
appliances installed in a compartment.
Ventilation to room or
internal space Ventilation to outside
High Level | Low Level | High Level | Low Level
12722 242cm* 242ст? 121cm* 121ст°
Fig. 3. Components
Control panel
Plastic cover
Condenser drain point
Secondary heat exchanger
Combustion product test point
Secondary heat exchanger inspection/cleaning port
Condensate drain
Heat exchanger drain point
Bumer air inlet pipe
10) Oil Burner
11) Lock out reset button
12) Sight glass
13) Boiler shell
15 17) (16
06 oo]
14) Pockets for water high limit safety and thermostat bulbs
15) Auto air vent connection
16) Heating flow
17) Heating return
18) Combustion products flue exit
19) Electrical cover plate
Fig. 4. Principle of Operation
The Greenstar HE Oil 12/22 is a sealed exhaust cir-
cuit condensation boiler.
Air is drawn in by the burner's fan from outside the
appliance through the hose connected to the air inlet
and combustion product evacuation concentric tube.
The boiler shell equipped with a system of remov-
able baffles, is linked to a stainless steel secondary
heat exchanger located directly on the heating
7. Flue System
A flue system provided by Worcester Bosch, must be fitted in
accordance with BS5410:Part 1 and the Building Regulations.
The appliance is supplied ready for installation to a balanced
flue system by the simple addition of one of the flue terminal kit
options shown in Figs. 5 to 14.
Details of the installation procedure are included in the Flue
Terminal Instructions supplied with the terminal kit.
7.1 Siting the flue terminal
1. The flue terminal must be located in a suitable position, as
shown in Fig.15, such that the products of combustion can be
freely dispersed without the possibility of the gases entering the
dwelling or that of a neighbouring dwelling.
2. Discharge of flue gases into car ports or narrow passageways
is not recommended.
3. The terminal must not cause an obstruction nor the discharge
cause a nuisance as a result of either flue gases or terminal
4. If a terminal is fitted less than 2 metres above a surface to which
people have access, a suitable terminal guard must be fitted.
A suitable guard is available from Worcester Heat Systems, Part
Number 7 716 190 009, or alternatively a proprietary terminal
guard may be used provided it leaves 75mm clearance all
around the terminal.
The guard should have suitable corrosion resistance due to the
acidic content of the flue gases.
5. The terminal guard must be evenly spaced about the flue
terminal and secured using screws so that the terminal guard
can be removed for maintenance to the flue terminal.
6. In certain weather conditions. The terminal may steam and
siting where this could cause a nuisance should be avoided.
7. Take care to ensure that combustion products do not enter
ventilated roof voids.
Fig. 5. Standard Horizontal Flue
Fig. 6. Extended Horizontal Flue
1000 - 5000mm
| (39.09") - (195.45") |
Fig. 7. Horizontal Flue with one 90° Bend
500 - 4000mm
| (19.7") - (157.5") |
Fig. 8. Horizontal Flue with two 90° Bends
Total straight length 1+2
must not exceed 3000mm
Fig. 9. Flue with one 90° and two 45° Bends
Total straight length 1+2+3
must not exceed 3000mm
$ “1
Total straight length 1+2
must not exceed 3000mm
Total straight length 1+2+3
must not exceed 3000mm
Fig. 12. Vertical Flue
Fig. 13. Vertical Flue with
two extra 90° Bends
Total straight length 1+2+3
must not exceed 3000mm
125mm (5") Diameter
Fig. 14. Vertical Flue with
two extra 45° Bends
Total straight length 1+2
must not exced 4000mm
125mm (5") Diameter
| 300mm
| minimum
1150 - 5000mm
Ï | 300mm
1 300mm
J minimum
Fig. 15. Flue terminating positions for oil-fired appliances
NOTE: The dimensions given are for general guidance only. Other surrounding buildings or objects may affect the clearance of
combustion products. An alternative flue terminal position should be sought when there is any possibility of a nuisance being
caused by inadequate dispersal of flue products.
Terminals should be positioned so as to avoid products of combustion entering into buildings.
Lom po
e Н.Е > o
| ;
| Window | B 3
“iE E Flue K E
> Terminal
. G 0-— e
> F
Minimum Distance (mm)
Terminal Position
A Directly below an opening, air brick, window, etc. ............... 600
B Horizontally to an opening, air brick, window, etc. .............. 600
C Below a gutter or sanitary pipe 75
D Below eaves or a balcony 600
E From vertical sanitary pipework 75
F From an internal or external corner 300
G Above ground or balcony level 300
H From a surface facing the terminal 600
] From a terminal facing the terminal 1200
K Vertically from a terminal on the same wall ......................... 1500
L Horizontally from a terminal on the same wall ..................... 300
M Above intersection with roof 300
N From a vertical structure on the side of the terminal ........... 600
O Above a vertical structure on the side of the terminal ......... 600.
8. Oil Supply
8.1 The oil storage tank must be installed in accordance with
B5799 Part 5. A steel tank should be arranged with a slope of 1
in 24 away from the outlet valve with a sludge cock at its lower
end. A plastc tank should be sited on a firm, level fireproof base.
The base should extend out 300mm from all sides of the tank.
There is generally no need for the tank to be installed on an
angle away from the outlet valve.
8.2 Do not use galvanised steel tanks or pipework for the oil
supply system.
8.3 Do not use soldered joints on the oil supply pipework as this
could cause a hazard in the case of a fire.
8.4 The burners on all appliances are supplied so as to be
connected to a single pipe gravity feed system. Details of how to
convert the burner to a double-pipe sub-gravity feed system are
shown in Fig. 16.
8.5 If a single pipe system is employed then the tank must be
positioned such that the oil level does not exceed 4 metres
above the level of the burner oil pump and in addition the oil
level must be at least 0.3 metres above the level of the oil pump.
Should it prove impossible to site the tank below the 4 metres
maximum oil level a head breaking device must be installed
between the tank and the burner.
8.6 If a double pipe system is used then the maximum suction
height allowable is 3.5 metres.
8.7 The oil supply pipe diameter can be determined using Tables
13 and 14 depending on whether a single or double pipe system
is being installed. Selection of the correct pipe diameter will
depend on the position of the oil storage tank relative to the
burner and the length of the pipe run.
8.8 The oil supply pipe should be laid as level as possible to
avoid air pockets and unnecessary friction losses.
8.9 The following components should be fitted in the fuel line
between the storage tank and burner:
1. A manual isolating valve installed as close to the tank as
2. A fire valve in accordance with BS799: Part 2 as shown in Fig.
17. The fire valve should be fitted externally with a fire detection
element located within the appliance case. Use of a capillary
type valve will allow a neat and simple installation. A suitable
valve is the KBB manufactured by Teddington Controls Limited.
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.
3. A paper element filter complying with the requirements of
B5799, Parts 2, 3 and 4 should be fitted in the fuel line between
the fire valve and the isolating valve but not within the appliance
TABLE 4 Single Pipe Gravity Feed System
HEAD (metres) (metres)
8 mm inside dia. pipe |10 mm inside dia. pipe
(10mm O.D. copper) | (12 mm O.D. copper)
0.5 10 20
1.0 20 40
1.5 40 80
2.0 60 100
Fig. 16. Oil Pump.
A. Danfoss BFP 11 Oil Pump.
To convert to a double pipe system: Remove the pump front
cover, remove the changeover screw (A) nearest to ports 1 and 2,
and the horseshoe washer underneath. Replace the changeover
screw back into the threaded hole. Connect the flow and return
pipes to 1 and 2.
Note: When removing the pump front cover ensure that a suitable
receptacle is placed below the pump to catch the oil residue.
B. Suntec AS47C Oil Pump.
To convert to a double pipe system, remove the return port plug (2)
and insert the grub screw (A) provided into the threaded hole (B).
Connect flow and return pipes to (1) and (2). )
1. Inlet
2. Return
3. Bleed and pressure
gauge port
4. Vacuum gauge port
5. Pressure adjustment
6. Nozzle outlet
TABLE 5 Double Pipe Sub-Gravity Feed System
HEAD (metres) (metres)
8 mm inside dia. pipe |10 mm inside dia. pipe
(10 mm О.Р. copper) | (12mmO.D. copper)
0 35 100
0.5 30 100
1.0 25 100
1,5 20 85
2.0 15 70
2.5 11 50
3.0 8 30
35 6 20
i Fig. 17. Oil Supply.
Maximum oil level
(a) Single pipe system
y y
Fire valve to
BS 799 Part 2 \
Fire detection
Sludge cock Tank raised 1 in 24
(40 mm per metre)
element Burner
Pa Fa valve
oil filter
(b) Double pipe system.
N Fire detection
on return element
valve Wall
2 Isolating
A Non
Sludge cock Tank raised 1 in 24
(40 mm per metre)
retum Fire valve to
BS 799 Part 2
oil filter
Fa Isolating A
A Н = 4 т (13 ft) maximum =
0.3 m (1 ft) minimum
3.5 m (11.5 ft) maximum
Feed and
Vent Cistern Он "Ч i er my mm pm ms mp re: en A Fp A i
S.H, - Minimum static head 1m (3ft)
measured from the highest point in the
heating system (top surface of the appliance
or highest point in the heating system) to the
( Fig. 18. Typical fully pumped open vent system (Honeywell ‘Y’ plan).
water level in the feed and expansion tank
coldfeed — SH Domestic hot ь
(15mm min.) water cylinder
| |
Heating vent — на soci
(22mm min.) Qo Aa X
= mise ening |
a | FA ша к 220 ki ed Ms a a sd
Diverting ||
valve | | N.B. A drain cock.should be
|| installed at the lowest point of
Auto air vent y 1 the heating circuit
5 lee reo Ya |
— i о-*
Boiler alfa Pump | Radiator
150mm max
( Fig. 19. Typical fully pumped
sealed system
(Honeywell ‘Y’ plan).
air vent
9. Heating and Hot Water System
9.1 The appliance is suitable for connection to all conventional indi-
rect hot water systems utilising an indirect double feed cylinder.
9.2 The flow and return connections are located at the rear of
the appliance.
9.3 There is no requirement for a system bypass.
9.4 The pressure jet burner fitted to the appliance has full
automatic control and hence there is no requirement for heat
leak radiators.
9.5 The primary system should be flushed and treated in
accordance with the recommendations of BS 7593:1992 before
the system is handed over to the user.
9.6 The pump should be set in accordance with the heating load
requirements to give a flow and return differential temperature
of 11°C under full load conditions.
Open Vent Primary System.
(See Figs. 18 and 19).
The following points are for guidance only. The system connection
point should be carried out in accordance with BS 5449: Part 1.
1. Feed and Expansion System
The feed and expansion pipes must rise continuously from the
appliance and must be of the minimum diameter shown in Figs
18 and 19.
Domestic hot !
water = Y bado eme
cylinder A ES т
lee | FA = == — == =. =! == == == = = —= —
Diverting |
| valve || N.B. A drain cock should be
ra a installed at the lowest point of
Auto a vent X Safety valve 0 gauge A | the heating circuit
Pi a |
Boiler Pump | Radiator
Expansion |
Y 3
| Г
| To system filling device (see fig.19a) 4
( Fig. 19a. System filling and make-up |
к bil Make up
ter combi-
orcester combi-fill system A vase]
Heating Heating vent Non return Î
return return valve
Nonreturn Non return 30mm (12in) min.
valve valve above highest \
oint of the system
« « Hose union Stop E ?
| { cock
| Stop cock Fill point.
; Heating return
Testcock „с
N emporary
The cistern must be arranged to provide a minimum static head of
1 metre above the top of the highest point in the heating circuit.
2. Filling and Venting
Air in the appliance is expelled through the vent pipe or
dissipated into the system. Manual air vents should be fitted at
any high points in the system.
There is a connection on the appliance for connecting an auto
air vent.
Sealed Primary System
The appliance is supplied with a manual reset thermostat and is
suitable for use with a sealed primary system.
The system should be installed in compliance with the
requirements of BS5449: Part 1. The boiler must be fitted with a
spring loaded safety valve set to operate at 3 bar (45 psi) and
the pipe connections made throughout the system must be
capable of sustaining a pressure of up to 3 bar.
The following is a list of major items which must be fitted to the
1. Safety valve — 3 bar
Pressure gauge — O to 4 bar.
Expansion vessel
4. Automatic air vent.
10. Electrical |
(See Figs. 20 to 22):
10.1 The wiring between the appliance and the electrical supply
shall comply with current IEE Wiring Regulations and any local
regulations which apply.
10.2 To gain access to the electrical terminal strip.
1. Isolate the mains electrical supply.
2. Remove the cabinet top panel by pulling squarely
3. Release the two screws securing the terminal connector
protector plate and remove.
10.3 Mains Wiring .
Mains supply — 230/240 V AC ~ 50 Hz 5A External Fuse.
LIVE - Brown, NEUTRAL - Blue, EARTH - Green/ Yellow
Mains Cable: 0.75mm? (24 x 0.20 mm) to BS 6500 Table 16.
The method of connection to the appliance must allow complete
isolation of the appliance, preferably via a double pole isolator
with a contact separation of 3 mm in all poles supplying the
boiler and controls only.
The mains supply cable should be connected into the terminals
marked L (Live), N (Neutral) and E (Earth) on the appliance
terminal strip and securely held in the cable clamp located on
the right-hand side of the electrical box.
The appliance must be earthed.
If an external programmer is fitted to the boiler, the link across ter-
minals 1 and 2 of the terminal strip should be removed (see Fig. 21).
Connect the programmer permanent live to terminal 1, switched
live to terminal 2 and neutral to terminal N.
NOTE: Under no circumstances should the timer be connected
to a separate electrical supply. Safety is assured from a single
fused supply to the boiler.
The timer must be suitable for use with mains voltage.
10.5 Safety Check
In the event of an electrical fault after the installation of the
appliance, the electrical system shall be checked for short
circuits, fuse failure or incorrect polarity of connections.
10.6 Honeywell “S” Plan
The “S” plan provides complete control on installations having pumped
circulation to both the domestic hot water and radiator circuits.
The domestic hot water and radiator circuits are independently
controlled by two motorised valves via a cylinder thermostat
and a room thermostat. Both thermostats switch the water
circulator and the boiler on and off.
10.7 Honeywell “Y” Plan
(See Fig. 18 and 19).
The “Y” Plan provides complete control on installations having
pumped circulation to both the domestic hot water cylinder and
radiator circuits.
The domestic hot water and radiator circuits are controlled by a
3 port motorised valve via a cylinder thermostat and a room
thermostat. Water flow is diverted to either circuit or to both
circuits at the same time. Both thermostats switch the water
circulator and the boiler on and off.
Note: The “Y” plan requires a live feed from the hot water “off”
switch position.
10.8 Programmer
(See Fig. 21).
An external programmer can be fitted to the system.
10.9 Frost Protection
For full frost protection a single pole switch thermostat can be
fitted across terminal 1 and 2 (see Fig. 21) regardless of any
other device using these terminals.
NOTE: For the frost thermostat to be effective, the boiler control
thermostat must be set to ON.
11. Installation
11.1 After unpacking the appliance it is recommended that the
top and front cabinet panels are removed, as described in Section
5, and stored in a safe place to avoid damage during installation
and allow easy inspection for any leaks after the system has
been filled.
11.2 Remove the burner as described below and store in a safe
place until the appliance is ready for commissioning.
1. Remove the air tube from the burner by loosening the jubilee
clip and pulling the tube up and away.
2. Remove the 13mm nut at the top of the burner and pull the
burner out, taking care not to put any tension on the electrical
11.3 Flue system installation.
Install the appliance flue system as described in Section 7.
11.4 Heating system installation.
1. Plumb the boiler into the central heating system.
2. Fit the auto air vent.
3. Fill the system and vent all radiators and high points to
remove air from the system.
4. Check the boiler and all pipework connections for leaks.
5. The primary system should be flushed in accordance with the
recommendations of BS 7593:1992.
11.5 Oil supply installation.
(See Section 8 and Fig. 17).
Note: Never route the oil supply pipe/hose directly below the
combustion chamber base.
Never use soldered joints on oil supply pipes as this could cause
a hazard in the case of a fire.
(a) Double pipe system oil return pipe.
1. fit the oil return pipe, from the tank, down the left hand side
of the boiler along the base. Terminate the end approximately
200mm from the front of the base.
2. Connect a flexible hose, of the same type as the one supplied, to
the pipe using a suitable adaptor.
Ensure that the connections are properly sealed.
3. Fit the oil supply pipe as described in the following section.
(b) Single pipe system oil supply pipe.
1. Fit the oil supply pipe, from the tank, down the left hand side
of the boiler along the base. Terminate the end approximately
200mm from the front of the base.
2. Open the main oil supply valve at the tank and check for any
3. Draw off at least 2.5 litres of oil until a steady flow of clear
uncontaminated oil can be seen and turn off the isolating valve.
NOTE: This method may not be possible on some installations
where a sub-gravity system is used. Where this problem arises-
bleed the system using the oil pump as described in Section 12
and remove and clean the oil pump filter to remove any debris
collected as a result of installation.
Fig. 20. Wiring Diagram (Standard).
— — Room thermostat, time clock or
S0HZ | frost thermostat
/ +Earth
Boiler shell earth 0912121910
connection \
@= Green/yellow
- Red
3 Blue
$ Green/yellow >
© ©
$ т т 5
; A 3 | Г CC — 44
A 1 а © Сгеу E Orange | Brown 0
2 2 1 2 i С
1 В „JE Г
L :Live
N:Neutral it wh
M/A :On/Off switch > 470 Slack
TRC:Boiler temperature control thermostat Cr
TSE: Water overheating safety thermostat = LO
TSF:Combustion product overheating safety thermostat
V1:On light
V2:Burner lock-out light
C:Connector for burner T 30.30016.00
Fig. 21. Room thermostat, time clock or frost No:control
thermostat connections. 0
y ТН
& + Live —] | 2% Live | Г |
| |=-| №112 ^ | |=-| №112
TH1 = Room thermostat, clock or frost thermostat
Fig. 22. Principle schematic
Neutral |
Burner A
On/off switch WA
Boiler temperature control
Water overheating safety
Combustion product overheating
safety thermostat
Burner lock-out light
On light
1 Timer controls
2 Extermal thermostat controls
11.6 Condense drain connection (see Fig. 23)
When connecting the condensate drain to the waste water
drain, it is essential:
— to maintain a downwards slope towards the waste
— to connect an accessible u-trap, allowing 80mm
clearance below for cleaning.
Note: The maximum production of condensate is 1.5 L/h. This
flow rate does not require any specific treatment.
Fig. 23. Condensate drain connection
PST pi ce 5
Eme Ae.
1. Accesible siphon/u-trap
2. Pipe @ 40mm
3. Elbow @ 40mm
4. Waste water drain
11.7 Replace the electrical control panel and side panels in
reverse order to the removal procedure of Section 5 and connect
the electrical supply as described in Section 10.
12 Commissioning the Appliance
Ensure that no foreign matter is left in the system as this could
cause damage to the appliance.
12.1 Check that the electrical supply to the appliance is
switched off.
12.2 When commissioning the appliance after initial installation
follow the procedure from 12.3, otherwise remove the burner
first as described in Section 14.3.
12.3 Prepare the heating system
1. After initial installation and checking for leaks, as previously
described, drain down the system sufficiently to add a flushing
agent. Flush the system in accordance with BS 7593:1992.
2. Refill the system.
12.4 Check the Burner
1. Check that the nozzle and electrode settings are correct for
the relevant burner. (See Fig. 25).
2. Check that the nozzle lies central with the combustion head hole.
3. Check for any visible defects.
12.5 Replace the burner
1. Connect the flexible oil supply hose and tighten sufficiently to
form a good seal. Where a double pipe system is being used con-
nect the oil return flexible hose to the return pipe fitting.
2. Insert the burner into the burner mounting flange and tighten
the locking nut using a 13mm spanner.
Note: It is important that a good seal is made between the
burner and the boiler to prevent the escape of the flue gases
from the combustion chamber.
12.6 Check the installation \
1. Check that the appliance is correctly wired as described in
Section 10.
2. Check that the baffles are correctly located.
3. Check that the combustion product high limit thermostat
phial is correctly located in the thermostat pocket positioned in
the top front of the condensing heat exchanger.
4. Check that the water high limit thermostat is located in the
pocket on the main heat exchanger.
5. Check that all of the air-ways to the burner are clear of any
12.7 Fit a pressure gauge and manifold to the burner pump at
the point indicated in Fig. 25.
12.8 Turn on the electricity to the appliance.
12.9 Bleed the burner
Single pipe systems only
Release the fuel bleed port on the manifold and place a suitable
receptacle beneath. Turn on the boiler thermostat. Set the
programmer to heating and hot water and allow the burner to
run through to lockout. Wait two minutes and reset the burner
control box. Repeat the procedure at least three times or until a
steady stream of oil, without air, is exhausted from the bleed
port. Re-lock the bleed port.
Two Pipe System
A two pipe system will automatically vent the air back to the oil
tank. Turn on the boiler thermostat and allow the burner to run
through to lockout. Wait two minutes and reset the burner con-
trol box. Repeat the procedure untill the burner fires and runs in
a steady state. This may take several attempts depending on the
oil pipe length and height.
12.10 Adjust the air shutter and pump pressure to the settings
recommended in Table 2. After a pre-ignition period of approxi-
mately 15 seconds the burner should ignite. Flame sensing is
carried out by means of a photocell mounted in the burner
body. Should the boiler fail to establish a normal firing pattern
(or should flame failure occur during running), the absence of a
flame is sensed and the control box is monitored to a safe lock-
out condition and the boiler is shut down. The lockout indicator
light in the boiler control panel will illuminate indicating that the
burner has gone to lockout. In this instance wait two minutes
and press the red lockout reset button mounted in the burner
control box. Another start sequence is then initiated. Repeat the
procedure until a flame is established.
Note: Persistent lockout when running indicates a fault and a
Service Engineer should be consulted.
12.11 Run the boiler for approximately 3 minutes and switch
off checking that there is no after-spurting from the nozzle. This
can be detected by oil saturation on the blast tube. If after-
spurting occurs remove the burner from the boiler, unscrew the
nozzle, and while holding the burner in a vertical position, fill the
nozzle holder with oil. Refit the burner and continue to run the
boiler for three minute periods until after-spurting stops.
Note: Use of a “T” piece pressure gauge manifold will increase the
oil line volume and hence increase the degree of after-spurting.
12.12 Run the boiler for a further 15 minute period and then
finally fine tune the air shutter setting to give the CO, level
specified in Tables 2 to 9. During this period some smoke will be
emitted due to the burning of the organic binder in the base
insulation board. Smoke readings will therefore be inaccurate at
this point.
Note: A combustion product sampling point is located on the
front of the condensing heat exchanger (see Fig. 24).
12.13 Check that the smoke reading is in the range 0-1. If this
cannot be achieved then check that the burner head is set
correctly and the nozzle is in good condition.
12.14 Check that the flue temperature does not exceed the
value specified in Table 2. If this is the case then check that the
baffles are correctly located. If the baffles are correctly located
then reduce the pump pressure since nozzle variations of up to
+ or — 15% may occur.
12.15 Remove the oil pressure gauge and manifold and check
all oil system joints for any signs of leakage.
12.16 Allow the burner to run for a further five minutes and
then recheck the CO; level and adjust the air setting if required.
Check that the smoke number is in the range 0-1. Repeat the
fine tuning procedure if found necessary.
12.17 Refit the cabinet top and front panels in the reverse order
to that described in Section 5.
12.18 When the heating circuit has reached full operating
temperature check the whole system for any leaks.
12.19 Add a suitable proprietary corrosion inhibitor such as
Fernox or Sentinel. This will inhibit corrosion, protect the circu-
lating pump and valves reducing the possibility of "kettling"
noises resulting from deposits of scale and sludge in the boiler.
Refer to the product manufacturers instructions for further infor-
Fig. 24. Secondary heat exchanger inspection
1. Inspection/cleaning port
2, Combustion test point
3. Washer
4. Test point screw
13. Instructions to the User
13.1 Hand the users instructions to the user or purchaser for
retention and instruct them in the efficient and safe operation of
the appliance and the heating/hot water system.
13.2 Advise the user or purchaser of the precautions necessary
to prevent damage to the heating/hot water system and to the
building in the event of the heating system remaining
inoperative during frost conditions.
13.3 Finally advise the user or purchaser that for continued
efficient and safe operation of the appliance it is important that
adequate servicing is carried out by a qualified engineer at least
once per year.
Worcester Heat Systems Limited will be pleased to discuss and
offer a comprehensive maintenance contract.
13.4 Set the system controls to the users requirements.
14. Routine Cleaning and Inspection
14.1 The following should be carried out at least once per year
to ensure efficient, trouble free operation.
1. Carry out a pre-service check noting any operational faults.
2. Check and clean the burner.
3. Check and clean the air intake tube and the air intake grille at
the end of the terminal.
4. Check and clean the baffles.
5. Check and clean the heat exchanger surface.
6. Check the heat shield.
7. Check the combustion chamber base insulation board.
8. Check and clean the secondary heat exchanger and baffles.
9. Check that the flue system is unobstructed and clean as necessary.
10. If the appliance has been installed in a compartment check
that the ventilation areas are clear.
11. Clean all oil filters.
Some of the servicing points are covered more fully in the
following instructions:-
14.2 Pre-Service Check
1. Remove the cabinet front and top panels as described in
section 5 .
Fig. 25. Electro Oil Bentone Sterling Burner.
Combustion Head Lockout
4.7-5.7mm Spark gap
| 4 2.5-3.1mm
Draught tube Nozzle Nozzle block
reset button
2. Operate the appliance and system, noting any faults which
may need to be corrected during the service.
14.3 Cleaning the Burner
IMPORTANT: Disconnect the electrical supply at the mains
before commencing any servicing. Tum off the oil at the service cock.
1. Remove the burner.
(a) Isolate the oil supply.
(b) Remove the 13mm nut at the top of the burner and pull the
burner out, taking care not to put any tension on the electrical
cable. |
2. Clean the fan impeller using the following procedure:
(a) Remove the air adjustment cover.
(b) Separate the main body of the burner from the burner front
by removing the M6 allen screw (located beneath the air
adjustment screw), using a 5mm allen key.
(c) Note the position of the air damper adjustment and check
the air damper moves freely.
(d) Check the air path to the burner head is clear.
(e) Clean both sides of the fan impeller and remove any debris
from the burner housing.
(f) Check the impeller rotates freely.
(8) Re-assemble the components.
Combustion head
box Transformer
й 4 '
ag Ei
Photocell Air adjustment screw Air control Screw
(4mm hexagonal head) indicator
Fig. 26. Mechanical Shut-off Valve.
Nozzle Assembly
“Check Valve
4. Inspection of Mechanical Shut-off Valve. (See Fig. 27)
a) Remove the nozzle.
b) Fasten an M5 screw, with a minimum length of 30mm, into
the threaded hole (A) and pull the screw to withdraw the check
¢) Check that the nozzle holder is clear of any debris and clean if
d) Check that the 3 holes in the check valve are clear of any
debris. Discard the check valve if the holes cannot be cleared or
if the unit is defective and replace with a new one.
e) Replace in the reverse order.
5. It is strongly recommended that the oil atomising nozzle is
replaced at each service.
6. Check and reset the electrodes, where necessary, as shown in
Fig. 25.
7. Replace the combustion head and check that the nozzle lies
central to the combustion head and the head settings are as
shown in Fig. 25.
8. Withdraw the photocell from its housing and clean.
9. Remove and clean the oil pump internal filter using kerosene
or white spirit. The internal filter is accessed by removing the oil
pump cover on the Danfoss BFP 11 and Suntec AS47C as
indicated in Fig. 16.
10. It is recommended that the standard flexible oil line is
replaced at each yearly service to prevent the possibility of a
leak due to ageing.
11. Re-assemble the burner components.
12. Check the sponge O-ring seal located around the
combustion head and replace if necessary. It is imperative that
this seal is in good condition since failure will cause the flue
gases to escape.
14.4 Remove the paper element from the external oil filter and
replace. If the filter contains a washable element then
thoroughly clean in Kerosene or white spirit and re-assemble
into the filter.
14.5 Clean the air duct tube.
1. Remove the air duct from the burner.
2. Shine a light down the air duct and inspect for any sign of
debris and clean where necessary using a flexible hose
connected to a vacuum cleaner. A short length of garden hose
would be suitable for this purpose.
3. Reconnect the air duct tube.
14.6 Clean the Boiler (See Fig. 27)
1. Remove the boiler top access plate (3) by releasing the bolts
(2) with a 6mm Allen key and check the fibreglass rope seal.
Replace the seal if necessary.
2. Remove the flue deflector (4).
3.Remove the main baffle assembly (5), clean and check its
condition. Replace if considered to be badly corroded.
4. Thoroughly clean all of the heat exchanger surfaces using a stiff
wire brush and vacuum clean all loose debris from the combustion
chamber. Take care not to damage the base insulation!
5. Check the heat shield.
6.Check the condition of the combustion chamber base
insulation and replace if there is any sign of significant damage.
7. Check and clean the flue.
8. Reassemble all parts and be sure:
р not to reverse them
b to position the flue deflector with its
locating screw towards the front of the
> to position the cast iron plate against marker
opposite the locating screw.
Fig. 27. Boiler shell and baffles.
1. Heat exchanger a
2. Cover screws
3. Cover
4. Flue deflector
5. Baffle assembly
6. Locator pin
14.7 Secondary Heat Exchanger. (See Fig. 28)
Clean the secondary heat exchanger.
Remove the wing nut (4) and heat exchanger cover (5).
Remove each baffle (8), clean and check condition. Use the
brush provided to clean each tube in the heat exchanger (7).
Wash any debris away by flushing with water.
Remove inspection plug (3) at base and clean as necessary.
Replace plug.
Replace baffles and cover, securing with wing nut, ensuring a
good seal is made.
Fig. 28. Secondary heat exchanger.
1. Secondary heat exchanger 6. Seal
2. Combustion products screw 7. Stainless steel tubes
3. Inspection port 8. Baffles
4. Wing nut
5. Cover
2. Insert the bummer into the burner mounting flange. Push the
burner firmly forward to compress the gasket and tighten the
locking nut with a 13mm spanner.
Note: It is important that a good seal is made between the
burner and the boiler to prevent the escape of the gases from
14.8 Fire Valve.
Check that a fire valve is fitted to the incoming oil line with the
body located outside the premises and the detection element
located within the appliance case. Test the operation of the fire
valve to ensure that the mechanism operates and that the oil
supply is completely isolated.
14.9 Recommission the Burner.
1. Connect the flexible oil supply hose to the isolating valve and
tighten sufficently to form a good seal. Where a double pipe
system is being used connect the oil return flexible hose to the
return pipe fitting.
the combustion chamber.
3. Turn on the oil supply at the service cock.
4. Recommission the burner as described in Section 12.
15. Short Parts List
Key Item Part Manufacturer's Reference WHS
No. Ref. Part No.
16 BOILER Top Panel Y 72.26519 8 716 103 275 0
1 BOILER Front Panel Y 72.26518 8716 103 260 0
26 BOILER Left Hand Side Panel Y 72.26665 8716 103 285 0
3 BOILER Right Hand Side Panel Y 72.26664 8716 103 2620
17 BOILER Facia Cover H 20.26493 87161032760
18 BOILER Facia Surround H 20.26489 8716 103 277 0
9 BOILER Baffle Assembly V 72.08493 8 716 103 268 0
10 BOILER Flue Deflector V 72.08531 8716 103 2690
11 BOILER Flue Deflector Insulation F 30.11048 8 716 103 270 0
12 BOILER Insulation Retaining Bracket V 72.28378 87161032710
13 BOILER Cover Plate Insulation V 70.09239 8 716 103 272 0
14 BOILER Ceramic Fibre Insulation F 20.28379 8 716 103 273 0
15 BOILER Boiler Shell Cover Plate H 00.28364 8 716 103 274 0
20 ВОШЕЕ Secondary Heat Exchanger Cover Plate V 72.08509 8 716 103 279 0
21 BOILER Secondary Heat Exchanger Cover Seal V 72.09520 8716 103 2800
22 BOILER Secondary Heat Exchanger Cover Fixing Screw V 72.26826 8 716 103 281 0
23 BOILER . | Secondary Heat Exchanger Assembly V 72.30129 8716 103 282 0
24 BOILER Seal AMF34 D. 18,6 x 12 2mm Depth E 20.06892 8716 103 2830
25 BOILER Brass Cap M1/2 K 20.13910 8716 103 2840
28 BOILER Nitrile 'O' Ring D 50 x 4 E 00.08776 8716 103 2870
29 BOILER Secondary Heat Exchanger Cleaning cap Assembly V 72.28241 8 716 103 288 0
31 BOILER Fibre Washer AMF34D 30x21x3 E 20.03889 8 716 103 290 0
32 BOILER Heating Retum Pipe U72.26515 87161032910
33 BOILER Heating Flow Pipe U 72.26517 8716 103 2920
34 BOILER Secondary Heat Exchanger Flange Seal E 20.26827 87161032930
39 BOILER Flue Seal D. 162x85x4 Silicone E 20.28092 8716103 2980
40 BOILER Air Duct Tube я U 65.29493 8 716 103 299 0
41 BOILER Condensate Discharge Assembly V 72.26687 8716 103 300 0
42 BOILER Drain Valve with Cap М1/2 - 3/4 K 50.11590 87161033010
47 BOILER Flow /Return Elbow 22mm U 72.30208 8 716 103 306 0
49 BOILER Secondary Heat Exchanger Baffle V 72.12096 8716 103 308 0
* BOILER Flue Seal Viton D. 80 E 20.30012 8 716 103 309 0
* BOILER | Nylon Stud (Male) T 25.07874 8716 103 3100
* BOILER Nylon Stud (Female) T 25.07875 87161033110
2 |¡EECTRICALBOX | Cable Grommet C 91.03071 8716 103 3130
3 |ELECTRICALBOX | Cable Clamp С 91.12561 8 716 103 314 0
4 ¡ELECTRCALBOX | Terminal Block 1014H SP 2311 C19.24474 8716 103 3150
5 [ELECIRICALBOX | Control Box Cover Y 72.26696 87161033160
6 |ELECTRICALBOX | Thermometer 69x14 LG CAPIL. 1500mm L 60.01135 8 716 103 317 0
7 |ELECTRCALBCK | Control Thermostat JAEGER 20/80 CAP1, 5 M TUA 4C L 71.04202 8716 103 3180
8 |ELECTRICALBOX | Control Knob H 20.18800 87161033190
9 |BECTRICALBOX | Control Knob Stop Plate Ref: 108 774.02 JAEGER PL: T 40. T40.18871 8716 103 320 0
10 |ELECTRICALBOX | Neon Indicator Red 230V С 90.03244 8 716 103 321 0
11 [ELECTRICALBOX | Facia Panel + Label \\у 72.301 22 8 716 103 322 0
12 |ELECTRICALBOX | Flue Safety Thermostat - 110 CAP 1,5M TG400 L71.11583 8 716 103 323 0
13 |ELECTRICALBOX | High Limit Thermostat - 120 CAP 1,5M TG400 L71.11584 8 716 103 324 0
14 [ELECTRICALBOX | On/Off Switch and Green Light C 20.24904 8 716 103 325 0
1 BURNER Burner - Elecro Oil/Bentone Sterling 40A T108 (PL10-51 6-2) 8 716 103 406 0
BURNER Blast Tube - PL 10-5-16-8 x 80mm 8716 103 407 0
3 BURNER Nozzle - danfoss 0.45 80 DEG EH 87161034080
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Bosch Group
Worcester Heat Systems Limited, Cotswold Way, Warndon, Worcester WR4 9SW.
Telephone: (01905) 754624. Fax: (01905) 754619.
Technical Helpline: (0990) 266241.
This booklet is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or appearances are changed in the interests
; of continued improvement.
All goods sold are subject to our official Conditions of Sale, a copy of which may be obtained on application.
PUBLICATION TTGB: 8 716 103 070a 09/01
TTGX: T 30. 30275
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