Bosch Appliances 12/18, 18/25, 25/32kW Base of the control box before replacing any components

Page 47

Boiler not operating with a heating / hot water demand

Replace

control box

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

230V at

 

 

 

 

Replace

solenoid coil

 

 

 

 

 

No

 

 

 

 

 

pump

 

 

in purge?

 

 

 

 

 

 

 

 

 

Replace

lead

 

 

 

 

 

Photo cell

 

 

 

 

 

 

 

No

 

 

Yes

 

 

 

 

lead OK?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Disconnect photo cell,

 

 

 

 

 

reset lockout, burner

 

 

 

No

 

 

 

lights then locks out?

 

 

 

 

Stray light

on photo

cell?

No

Replace

photo cell

Replace coil

lead

No

Coil lead

OK?

 

 

Replace

Yes

 

 

control box

 

 

 

 

These fault finding charts locate and rectify faults. correct and complete we Worcester, Bosch Group to be competent.

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 106 252b (07/06

FAULT FINDING

 

 

Yes

 

 

 

 

 

 

 

Yes

 

 

 

No

 

 

 

 

Burner

Yes

Burner

No

Lockout

No

Pump

Yes

Spark

Yes

Lockout

No

Nozzle

No

230V at

Yes

2.2kΩ

No

Replace

within 1

produces

after purge

atomising

solenoid

motor runs?

lights

produced?

across

solenoid coil

 

 

second?

 

pressure?

 

 

before oil

 

fuel?

 

coil?

 

 

 

 

immediately

 

 

 

 

 

 

 

 

solenoid

 

 

 

 

motor runs?

 

 

 

 

 

 

 

solenoid

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

coil?

 

 

 

 

 

 

 

 

 

 

 

opens?

 

 

 

 

 

 

 

 

 

 

Yes

 

No

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

Combustion

 

Reset air

 

Yes

 

 

No

 

 

 

 

 

 

 

 

 

 

 

air setting

No

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

setting

 

 

 

 

 

 

 

 

 

Drive

 

 

 

 

 

correct?

 

 

 

 

 

 

 

 

 

Replace

 

 

 

 

 

 

 

 

 

Solenoid

 

Replace

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

coupling

 

 

 

 

 

Yes

 

 

 

No

 

 

 

 

control box

 

 

 

 

 

 

 

 

 

operating?

pump

 

 

 

 

 

broken?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

230V at

 

Transformer

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

No

 

Combustion

 

Reset

 

Yes

 

 

 

 

 

 

 

 

 

transformer?

lead OK?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

head set

No

combustion

 

 

 

 

Control box

 

Motor or

 

Replace

 

Oil to

 

Yes

 

Yes

 

correctly?

 

head

 

Pipe to

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Yes

pump

Yes

motor/

 

 

 

 

 

 

Yes

 

 

 

nozzle

 

 

locks out?

 

pump?

 

 

 

 

 

 

 

 

 

 

 

seized?

 

pump

 

 

Electrodes

 

 

 

 

 

 

 

holder OK?

 

 

 

 

 

 

 

 

 

Replace

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

No

 

 

 

Yes

 

& leads

 

 

Flame off

 

 

 

Yes

 

 

 

 

 

 

 

 

control box

 

 

Boiler or

 

 

 

 

 

 

 

 

 

 

 

OK?

 

 

and

No

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

flue blocked

 

 

 

 

 

 

 

 

Check

 

 

 

Yes

 

 

 

re-lights?

 

 

Oil check

 

Replace oil

L & N to

 

230V at

 

 

Replace oil

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

connections/

 

 

 

 

 

 

Yes

 

 

 

valve OK?

No

check valve

control box?

 

motor?

 

pump

 

 

 

 

 

 

 

 

 

 

replace leads

 

 

 

 

 

 

 

 

 

 

(if fitted)

 

(if fitted)

 

 

 

 

 

 

 

Replace

 

 

 

 

 

 

 

 

No

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

transformer

 

 

 

If BF

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

remove

 

 

 

 

 

 

Check boiler

 

Motor 40Ω

 

Replace

 

 

 

 

 

 

 

burner

 

Reseal BF

 

Replace

 

 

controls &

 

across

No

 

 

 

 

 

 

 

snorkle tube

Yes

on

 

 

 

 

motor

 

 

 

 

 

 

 

 

nozzle

 

 

supply

 

L & N?

 

 

 

 

 

 

 

 

& retest.

 

reposition

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

 

Lights OK?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

 

 

 

 

 

Replace

 

 

 

 

 

 

 

 

 

 

 

Replace

 

 

 

 

 

 

motor

 

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Photo cell

control box

 

 

 

 

 

 

capacitor

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

functional?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Note: This chart assumes all wiring within the control box base is correct, if in doubt check the wiring against the diagram on

No

 

 

 

 

 

 

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.

 

 

 

 

 

 

Replace

 

 

Measure all 230V tests between

The operation of the photo cell can be tested by measuring the resistance across the photo cell, it should be a high resistance

photo cell

 

 

Neutral (N) and the pin, wire or

(greater than 10MΩ or open circuit) in the dark and low resistance (15kΩ or less) in light.

 

 

 

 

 

 

terminal specified.

 

 

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.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Whilst every effort has been taken to ensure the information given is cannot guarantee that every eventuality has been covered. cannot be held responsible for costs incurred by persons not deemed

are provided to assist competent and suitably qualified engineers to

SATRONIC CONTROL BOX

 

 

FAULT FINDING LOGIC FOR

 

 

 

 

 

46

FAULT FINDING

& DIAGRAMS

Page 46 Page 48
Image 47
Page 46 Page 48
Contents Greenstar Heatslave External 12/18, 18/25, 25/32kW Installation & Servicing Instructions Installation & Servicing InstructionsContents OIL SMELLS, Leaks or Fumes from the Appliance Safety PrecautionsInstallation Regulations Safety Precautions Installation RegulationsStandard Package General InformationGeneral Information BSP Technical DataTechnical Data DescriptionLayout & Components Layout & ComponentsCleaning Primary Systems Cleaning Primary SystemsElectric Supply Mains SuppliesMains Supplies Mains Water Expansion VesselHead OIL SupplyOIL Supply G JWater Systems & Pipework Water Systems & PipeworkDomestic HOT Water Filling Primary Sealed SystemsSHOWERS/BIDETS Pressure Relief Pipework Condensate Pressure Relief PipeworkCondensate Pressure Relief Pipework Condensate PipeworkFront Boiler Location ClearancesBoiler Location ClearancesTerminal Position Cabinet Mounted LOW Level Flue Terminal PositionsCabinet Mounted LOW Level Flue Terminal Positions Positions High Level Flue TerminalPositions High Level Flue TerminalAC D Balanced External Oilfit Flue OptionsBalanced External Oilfit Flue OptionsBalanced Flue Options Cabinet Mounted BalancedHorizontal Flue Options Unpacking the Boiler Lifting and Carrying PrecautionsUnpacking the Boiler Pipework & Flue Positions SafetyPipework & Flue Positions Boiler Installation Boiler InstallationInstallation Notes Flue InstallationFlue Installation Hook the retainer J over the end two baffles Combustion ChamberCombustion Chamber Hor Plan sectional viewOIL Supply Connections Pipework ConnectionsPipework Connections Water ConnectionsPressure Relief Connection Condensate ConnectionOIL Pump OIL Burner & PumpOIL Burner & Pump OIL BurnerPlug burner lead E into control box F Refitting ComponentsRefitting Components Electrics MainsProgrammer External Electrics BoardWhite Br BrownBlue Green/Yellow RedChecks Appliance PRE-COMMISSIONING Checks AppliancePRE-COMMISSIONING Filling the System Filling the SystemSafely dispose of the container/discharge Starting the ApplianceStarting the Appliance Holder with oil Pressure adjustment Vacuum gauge port 25/32Boiler lockout indicator on Bleed & pressure gauge portBurner should be OFF and the circulating pump on Set the room thermostat to minimum Central heating Open all radiator valvesPump and all radiators Water TreatmentWater Treatment Appliance Finishing CommissioningFinishing Commissioning Loosen clip D to detach air duct Inspection and ServiceInspection and Service Routine servicingAny debris and clean if necessary Clean the Burner3.0mm Clean both sides of the fan impeller Thoroughly clean any depositsFront 12.0 22.2 50 80EH11.5 18.6 55 80EHBurner Sterling Short Parts List 12/18Short Parts List 12/18 Auto reset High Limit thermostat Part Number 8 716 107 640Manifold access cover seal Short Parts List 18/25Short Parts List 18/25 Short Parts List 25/32 Short Parts List 25/32Fault Finding Fault FindingOIL Smells Problem Cause RemedyFaulty Boiler Operation Noisy operation Pump noise from air in pump orMeasure all 230V tests between Neutral N and the pin, wire orBase of the control box before replacing any components Control BOX Logic for 535 SE/LD RDB Fault FindingElectrical SchematicOIL Boiler Combustion Record Service 1 Date Excellence Comes AS Standard General checks
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