Instruction manual

ManualsBrandsBosch ManualsBoilerDANESMOOR UTILITY 32-50

INSTRUCTION MANUAL

INSTALLATION, COMMISSIONING & SERVICING

FLOOR STANDING OIL-FIRED CONDENSING BOILER CONVENTIONAL

FLUE & ROOM SEALED FLUE

GREENSTAR UTILITY

32/50 & 50/70

FOR FULLY PUMPED OPEN VENT OR SEALED CENTRAL HEATING SYSTEMS

AND DOMESTIC HOT WATER CYLINDERS

THE APPLIANCE IS FOR USE WITH KEROSENE

(28 SECOND OIL) ONLY

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Summary of content (52 pages)

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8 716 109 711 b 07.10 14/7/10 09:59 Page 2 INSTALLATION & SERVICING INSTRUCTIONS SYMBOLS USED IN THIS MANUAL: Domestic hot water 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.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 4 SAFETY & REGULATIONS SAFETY PRECAUTIONS INSTALLATION REGULATIONS OIL FUMES OR LEAKS FROM THE APPLIANCE: Failure to install appliances correctly could lead to prosecution. Extinguish any naked flames. Open windows and doors. Isolate the electrical supply. Isolate the fuel supply to the boiler. Rectify fault. The appliance should be installed by a competent person.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 5 GENERAL INFORMATION STANDARD PACKAGE: A - Floor standing oil fired condensing boiler for open vent and sealed domestic central heating and mains fed hot water. 520mm B - Literature pack. C - Hardware pack. D - Return pipe kit. APPLIANCE INFORMATION 815mm 1012mm Check List Hardware/Literature pack Item Qty Greenstar Utility Installation/Servicing Instructions.................................1 Users Instructions .............................................
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716 109 711 b 07.10 14/7/10 09:59 Page 8 CLEANING PRIMARY SYSTEMS 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.
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14/7/10 09:59 Page 9 MAINS SUPPLY ELECTRIC SUPPLY: • Supply: 230V - 50Hz. • Cable: PVC insulated 0.75mm2 (24 x 0.2mm) temperature rated to 90°C. • Protection IP20. • External 5A fuse to BS1362. • The appliance must be earthed. • 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.
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8 716 109 711 b 07.10 A B C D E F G 14/7/10 09:59 Page 10 H J K L M N - Oil storage tank. - Isolating valve. - Oil strainer & water separator. - Fire valve to BS 5410. - External wall. - Fire valve sensor. - Oil burner. OIL SUPPLY - Oil supply pipe. - Oil pump. - Full base (plastic tanks). - Non-return valve. - De-aerator. - Oil filter (16μm max filtration size) OIL SUPPLY : • This appliance is suitable for kerosene (28 second oil) only, no other fuel must be used.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 11 WATER SYSTEMS & PIPEWORK IMPORTANT: The boiler should not be allowed t o operat e wit h a ret urn temperature of less than 40°C when the system is up to operating temperature. TYPICAL OPEN VENT SYSTEM: PRIMARY SYSTEM PLASTIC PIPEWORK: • Any plastic pipework used must have a polymeric barrier, comply with BS 7921and be installed to BS 5955 with 1000mm (minimum) length of copper or steel pipe connected to the boiler. E 150mm max.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 12 WATER SYSTEMS & PIPEWORK Water main supply Heating return Hose return Non return Non return valve valve Stop cock Temporary hose Test cock FILLING PRIMARY SEALED SYSTEMS: • Filling the system must comply with one of the methods shown opposite. Stop cock • The filling point must be at low level and must never be a permanent direct fixing to the mains water supply. • Filling links must be WRAS approved.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 13 CONDENSATE & PRESSURE RELIEF PIPEWORK CONDENSATE PIPEWORK: C B A D 75mm min. b c C E C A A 450 min . EXTERNAL PIPEWORK: D Invert d Unsuitable for clay soil types C 500mm min. F A 25mm min. G I 400mm min. H 200mm min. K J K L J KL- Outside wall. Drain pipe. External drain. • All national and, where appropriate, local regulations for the discharge and neutralisation of condensate should be followed.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 14 BOILER LOCATION & a: RECOMMENDED IN STALLATION C LEARANC E S CLEARANCES • This boiler is only suitable for installing internally within a property at a suitable location onto a fixed rigid surface of the same size as the boiler and capable of supporting the boiler weight. • The boiler must be installed on a flat level surface to ensure condensate does not enter the primary heat exchanger.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 15 BOILER LOCATION & CLEARANCES COMPARTMENTS: Follow the requirements of BS 5410 and note: • Minimum clearances must be maintained. • An access door is required to install, service and maintain the boiler and any ancillary equipment. • If fitting the boiler into an airing cupboard use a non-combustible material (if perforated, maximum hole sizes of 13mm) to separate the boiler from the airing space.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 17 CONVENTIONAL FLUE • Open (conventional) flued appliances must not be installed in a bedroom, bathroom or bedsitting room. • The flue system must be in accordance with BS 5410 : Part 1 and the current Building Regulations. • The flue must be constructed of materials suitable for use with condensing combustion products. E • External flue systems must be of the insulated type.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 18 ROOM SEALED FLUE OPTIONS The diagrams (opposite) show the components used and the maximum flue length (L) from the boiler outlet to the ouside wall*/roof of the building 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 flue terminal or straight flue extensions can be reduced in length by cutting.
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14/7/10 09:59 Page 19 IMPORTANT: All the previous Pre-Installation sections must be read and requirements met before starting boiler or flue installation. 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.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 20 PIPEWORK POSITIONS & FLUE OPENING CAUTION: Ensure there are no pipes, electric cables, damp proof courses or other hazards before drilling. SAFETY: All relevant safety precautions must be undertaken. Protective clothing, footwear, gloves and safety goggles must be worn as appropriate.
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14/7/10 09:59 Page 21 BOILER INSTALLATION 1 Lift the top panel (A) upwards to disengage the ball stud connections (B) and remove. 2 Pull the upper front panel squarely forwards to disengage the ball stud connectors and remove from the control box (G). Remove securing screws (C) from each side. Slide control box (G) outwards to its full extent. 3 Depress locking ears to unplug burner lead (F) from cntrol box (G). 4 Sterling burner: Release burner retainers (O).
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8 716 109 711 b 07.10 14/7/10 09:59 Page 22 FLUE INSTALLATION The flue can exit the boiler from outlets A, B, C or D allowing vertical (RS &CF) and horizontal (RS low or high level) flues to be fitted. (CF position 'A' only). Refer to the separate flue installation instructions supplied with the flue kits available for this boiler: RS FLUE KITS & COMPONENTS Greenstar Oilfit 100/150mmØ (not supplied): Horizontal flue kit: Part No. 7 716 190 043 Vertical flue kit: Part No.
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14/7/10 09:59 Page 23 COMBUSTION CHAMBER Secondary heat exchanger: 1 Unscrew screws (B) and remove flue manifold access cover (A). Check that all the baffles and retainer are correctly fitted to the secondary heat exchanger: 32/50kW* 50/70kW SLOTS DOUBLE BAFFLES 25 10 31 15 SINGLE BAFFLES N/A 1 *Five of the slots do not have baffles. Combustion chamber: 2 Remove the retaining nuts and washers (D). Remove combustion chamber access door (C).
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8 716 109 711 b 07.10 14/7/10 09:59 Page 24 CAUTION: ISOLATE THE OIL & WATER MAINS SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. PIPEWORK CONNECTIONS A B C D E F G H J K N - CH flow /heating vent 11/2” Ø Primary drain/cold feed/drain 11/2” Ø CH Return 22mmØ copper - male Oil supply pipe - not supplied Oil isolating valve - not supplied Flexible oil hose* Condensate outlet (21.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 25 OIL BURNER & PUMP RIELLO RDB 3.2 BURNER SETTINGS RIELLO RDB 4.2 BURNER SETTINGS Combustion head setting (B) Combustion head setting (B) Set at top of combustion head (E) Set at top of combustion head (E) 3 1 4 2 5 3 RIELLO RDB BURNERS CAUTION: ISOLATE THE OIL & WATER MAINS SUPPLY BEFORE STARTING ANY W OR K AN D OB S E RVE ALL R E LE VANT SAFETY PRECAUTIONS. OIL BURNER: 1. RIELLO RDB 3.2 2. RIELLO RDB 4.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 26 OIL BURNER & PUMP BENTONE STERLING BURNERS CAUTION: ISOLATE THE OIL & WATER MAINS SUPPLY BEFORE STARTING ANY W OR K AN D OB S E RVE ALL R E LE VANT SAFETY PRECAUTIONS. OIL BURNER: 1 Check the nozzle (E) settings are correct for the relevant burner as shown opposite. Ensure nozzle (E) is aligned centrally within the breakplate (G). Inspect for any visible defects.
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14/7/10 09:59 Page 27 REFITTING COMPONENTS 1 Slide side panels (R) and top support bracket (L) together with control box (G) along base rails and push to secure into the retaining lugs. Secure side panel (R) with retaining screws (S) on both sides. 2 Carefully replace the Manual Reset thermostat (U), Automatic High Limit (T) and CH Control thermostat (Q) phials into the heat exchanger thermostat pocket. Refit split pins (P) to secure.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 28 ELECTRICS DANGER - 230V: ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. IMPORTANT: OBSERVE ELECTRONIC STATIC DISCHARGE PRECAUTIONS. DO NOT TOUCH THE PCB CIRCUITS. Access to 230V connections: 1 Pull control knob (D) forwards to remove from control panel (A). 2 Release scews (B) and remove cover panel (C) from control box (A). 3 Release screw (E) from cable clamp (F).
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14/7/10 09:59 Page 29 ELECTRICS 230V STANDARD WIRING DIAGRAM: Key to components: A - TERMINAL CONNECTOR BLOCK. B - EARTH CONNECTOR. C - FLUE THERMOSTAT (MANUAL RESET) D - HEATING THERMOSTAT (AUTOMATIC RESET) E - HEATING THERMOSTAT (MANUAL RESET). F - CONTROL THERMOSTAT. G - BURNER SOCKET. H - BURNER PLUG. INSTALLATION J - BURNER CONTROL BOX. H RIELLO CONTROL BOX J RESET 8 716 109 711 b 07.10 29 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 109 711B 07.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 30 ELECTRICS DANGER - 230V: ISOLATE THE MAINS ELECTRICITY PRE-WIRED REMOTE 2 OR 3 PORT VALVE CONTROL SETS: Key to components: A - Double pole switched fused spur (positioned in the boiler room next to the appliance. B - REMOTE JUNCTION BOX (10 way) to connect the following: Mains wiring 230V 50Hz. Hot water tank thermostat. Room thermostat. System water valves. Circulating pump. External programmer.
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14/7/10 09:59 Page 31 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 28 sec kerosene and that the pipework is connected correctly to the oil pump via the supplied flexible oil hose.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 32 FILLING THE SYSTEM 1 Open all system and radiator valves. 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. 2 Sealed systems only: Check and if required, adjust the expansion vessel pressure using the Schraeder type valve. Fill the system to between 1 and 2 bar pressure via a WRAS approved filling link.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 33 STARTING THE APPLIANCE RIELLO RDB OIL PUMP C B A Return Flow I TANK G DANFOSS PUMP SHOWN H 1 Check the oil supply is correctly fitted and in good working order before turning on the oil supply valves to the boiler.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 34 STARTING THE APPLIANCE RIELLO RDB BURNERS RIELLO RDB OIL PUMP 2 Fit a suitable pressure gauge to port (A) on the oil pump. Adjust the air shutter (F) and pump pressure (B) as shown in the table below. The burner should ignite following a pre-ignition period of approx. 15 seconds. If changing the burner output, check the combustion head sttings as shown in the table below.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 35 STARTING THE APPLIANCE BENTONE STIRLING BURNERS 2 Fit a suitable pressure gauge to port (A) on the oil pump. Adjust the air shutter (F) and pump pressure (B) as shown in the table below. The burner should ignite following a pre-ignition period of approx. 15 seconds.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 36 STARTING THE APPLIANCE Central heating: 1 Open all radiator valves. Set room thermostat to maximum. Set programmer to ON for CH & DHW (if applicable). Turn the boiler control thermostat (A) to max. The burner should be ON with the circulating pump. Ensure all radiators are heating up evenly and balance the system to the temperature difference required for the heating flow and return according to the heating load. 2 Set the room thermostat to minimum.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 37 WATER TREATMENT 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. 1 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 (B) and drain the system while the appliance is hot.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 38 FINISHING COMMISSIONING APPLIANCE 1 Locate edge of front panel (A) onto the supporting ledge (B) on the baseplate. Refit securing screws (C) to secure. 2 Slide control box (D) into boiler. Secure with screws (E). Locate the ball stud connectors (F) and push-fit upper front panel (G) towards the boiler to secure. COMMISSIONING 3 Locate the top panel (H) onto the ball stud connections ( J ) and press down to secure.
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14/7/10 09:59 Page 39 INSPECTION AND SERVICE CAUTION: ISOLATE THE WATER, ELECTRICITY AND OIL MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. 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 Lift the top panel (A) upwards to disengage the ball stud connections (B) and remove.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 40 INSPECTION AND SERVICE RIELLO RDB 3.2 BURNER SETTINGS RIELLO RDB 4.2 BURNER SETTINGS Combustion head setting (F) Combustion head setting (F) Set at top of Combustion head ( I ) Set at top of Combustion head ( I ) 3 1 4 2 5 3 1 Clean the Burner: Undo the three screws (A) and remove cover (B) from the burner. Loosen clip to remove the flexible air inlet hose (C) from the burner (RS flue systems only).
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14/7/10 09:59 Page 41 INSPECTION AND SERVICE 1 Clean the Burner: Loosen clip to remove the flexible air inlet hose (D) from the burner (RS flue systems only). Remove the air intake cover (H) by releasing the M4 screws. Seperate the main body of the burner from the front by removing the M5 screw ( J ), located beneath the air adjustment screw (K), using a 4mm allen key. Check the condition of the gasket between these two parts and replace if necessary.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 42 INSPECTION AND SERVICE Clean the boiler: Manifold access: Release screws (E) to remove the flue manifold access cover (F) and clear any debris. Check the flue system and clean if necessary. Remove the baffle retainer and baffles (H) from the secondary heat exchanger. 32/50kW* 50/70kW SLOTS DOUBLE BAFFLES 25 10 31 15 SINGLE BAFFLES N/A 1 *Five of the slots do not have baffles. Check and clean the secondary heat exchanger surfaces.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 43 INSPECTION AND SERVICE Fire valve: Check that the oil supply pipe has a fire valve fitted externally to the building with the fire valve sensor located within the appliance case. A fire valve sensor clip is provided for this purpose on the casing support panel. Re-commission the burner: 1 Sterling burner: Align burner combustion head (N) into boiler housing tube with gasket (O) correctly fitted. Push firmly down to compress the gasket (O).
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8 716 109 711 b 07.10 14/7/10 09:59 Page 44 RIELLO RDB BURNERS SHORT PARTS LIST 3 4 5 7 8 9 11 SERVICING & SPARES 2a 2 1 15 12 16 13 17 6 10 14 1 Burner - Riello RDB 3.2 32/50 Part Number: 8 718 686 583 0 Burner - Riello RDB 4.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 45 BENTONE STERLING BURNERS 1 2 3 4 5 6 7 8 8a 9 10 11 12 13 14 15 16 17 18 19 20 1 Burner - Sterling 133 32/50 Part Number: 8 716 108 063 0 Burner - Sterling 146 50/70 Part Number: 8 716 108 065 0 2 Combustion head - Type S 32/50 Part Number: 8 716 108 079 0 Combustion head - Type S 50/70 Part Number: 8 716 108 079 0 3 Control box Satronic TF 832.
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FAULT FINDING Yes 48 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 109 711B 07.
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INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 109 711B 07.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 50 GREENSTAR UTILITY BOILER COMMISSIONING CHECKLIST BOILER MODEL SERIAL No. COMMISSIONING ENGINEER COMMISSIONING CHECKS COMPANY NAME: ADDRESS: ENGINEERS NAME: SIGNATURE: PUMP PRESSURE (PSI): CO2 %: SMOKE READING: F.G.T.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 51 SERVICE 1 DATE SERVICE 2 DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: NOZZLE CHANGED? F.G.T. °C COMMENTS ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: NOZZLE CHANGED? F.G.T. °C COMMENTS psi CO2%: YES NO FLUE PRESSURE: SIGNATURE SIGNATURE SERVICE 3 DATE SERVICE 4 DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: NOZZLE CHANGED? F.G.T. °C COMMENTS ENGINEER NAME COMPANY NAME TEL No.
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8 716 109 711 b 07.10 14/7/10 09:59 Page 52 WORCESTER, BOSCH GROUP: TECHNICAL SUPPORT: 0844 892 3366 APPOINTMENTS: 0844 892 3000 SPARES: 01905 752571 LITERATURE: 0844 892 9800 TRAINING: 01905 752526 SALES: 01905 752640 WEBSITE: www.worcester-bosch.co.uk Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0844 892 9900 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. 8 716 109 711B 07.