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8 716 106 256 C 03.10 30/3/10 14:24 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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8 716 106 256 C 03.10 30/3/10 14:24 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.
8 716 106 256 C 03.10 30/3/10 14:24 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. 370mm B - Literature pack. C - Hardware pack including: Condensate trap D - Return pipe kit. APPLIANCE INFORMATION 600mm 855mm Check List Hardware/Literature pack Item Qty Greenstar Danesmoor Utility Installation/Servicing Instructions..........1 Users Instructions .................................
8 716 106 256 C 03.10 30/3/10 14:24 Page 6 TECHNICAL DATA DESCRIPTION UNITS 18/25 litres 24.5 Maximum static head metres 30 Minimum static head metres 1 mbar 57 bar 2.65 kg/hr 40 Fuel line (compression) mm 10 Flow & optional open vent/air vent BSP 1 Return mm 22 Primary drain & optional feed and expansion/feed BSP 1 Condensate (polypropylene) mm 21.5 AC...V 230 Frequency Hz 50 Max.
30/3/10 14:24 Page 7 LAYOUT & COMPONENTS The diagram opposite excludes the top, front and RH side casing panels.
716 106 256 C 03.10 30/3/10 14:24 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.
30/3/10 14:24 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.
8 716 106 256 C 03.10 A B C D E F G 30/3/10 14:24 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.
8 716 106 256 C 03.10 30/3/10 14:24 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.
8 716 106 256 C 03.10 30/3/10 14:24 Page 12 WATER SYSTEMS & PIPEWORK Water main supply Heating return Hose return Non return Non return valve valve Stop cock Temporary hose Heating return Test cock • 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 links must be WRAS approved.
8 716 106 256 C 03.10 30/3/10 14:24 Page 13 CONDENSATE & PRESSURE RELIEF PIPEWORK CONDENSATE PIPEWORK: a C A D 75mm min. b • The condensate pipework must fall at least 50mm per metre towards the outlet and should take the shortest practicable route and not exceed 3 metres outside the building. If a run greater than 3m is required, 32mmØ polypropylene pipe must be used.
8 716 106 256 C 03.10 30/3/10 14:24 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.
8 716 106 256 C 03.10 30/3/10 14:24 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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8 716 106 256 C 03.10 30/3/10 14:24 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.
8 716 106 256 C 03.10 30/3/10 L = 140 - 390mm 14:24 Page 18 ROOM SEALED FLUE OPTIONS L L L = 2000mm A A The diagrams (opposite) show the components used and the maximum flue length (L) for each flue configuration. B 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. 125mmØ x2 • Only the flue terminal or straight flue extensions can be reduced in length by cutting.
30/3/10 14:24 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.
8 716 106 256 C 03.10 30/3/10 14:24 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.
30/3/10 14:24 Page 21 BOILER INSTALLATION 1 Lift the top panel (A) upwards to disengage the ball stud connections (B) and remove. 2 Remove the installation and literature packs (T). 3 Pull the top front panel (E) away from the boiler to disengage the ball stud connectors and remove. 4 Remove retaining screws (C) from each side of the control box (G). Slide control box (G) outwards to its full extent. Pivot control box (G) upwards and secure in the position shown.
8 716 106 256 C 03.10 30/3/10 14:24 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 80/125mmØ (not supplied): Horizontal flue kit: Short telescopic Part No. 7 716 190 062 Horizontal flue kit: Standard telescopic Part No.
8 716 106 256 C 03.10 30/3/10 14:24 Page 23 COMBUSTION CHAMBER Combustion chamber: 1 Remove the 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 below. 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.
8 716 106 256 C 03.10 30/3/10 14:24 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 L - Flow/optional open vent/air vent 1” BSP Primary drain/cold feed 1” BSP Return 22mmØ copper Oil supply pipe (10mmØ) - not supplied Oil isolating valve Flexible oil hose* Condensate outlet (21.
8 716 106 256 C 03.10 30/3/10 14:24 Page 25 OIL BURNER & PUMP BENTONE 1 Electrode gap 2.5 - 3.0mm B 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: A 5mm 1 Check the nozzle (A) and electrode (B) settings are correct for the relevant burner as shown opposite. 5mm Ensure nozzle (A) is aligned centrally within the combustion head (C). C Inspect for any visible defects. 7.5mm 1 RIELLO 2.
8 716 106 256 C 03.10 30/3/10 14:24 Page 26 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 on the baseplate and align with the lugs on the rear support panel (T). Release control box (G) if secured. 2 Carefully replace the control and High Limit manual reset thermostats (Q) into the front thermostat pocket and the auto reset overheat thermostat (U) into the rear thermostat pocket.
30/3/10 14:24 Page 27 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 Release scews (B) and remove cover panel (C) from control box (A). 2 Release screw (D) from cable clamp (E). Pull inner clamp part (F) outwards.
8 716 106 256 C 03.10 30/3/10 14:24 Page 28 ELECTRICS 230V STANDARD WIRING DIAGRAM: Key to components: A - EARTH STUD. B - HIGH LIMIT THERMOSTAT. C - BOILER MANUAL RESET OVERHEAT THERMOSTAT. D - FLUE MANUAL RESET OVERHEAT THERMOSTAT. E - TERMINAL CONNECTOR BLOCK. F - CONTROL THERMOSTAT. G - BURNER SOCKET. H - BURNER PLUG. INSTALLATION J - BURNER CONTROL BOX.
30/3/10 14:24 Page 29 ELECTRICS DANGER - 230V: ISOLATE THE MAINS ELECTRICITY PRE-WIRED REMOTE 2 OR 3 PORT VALVE CONTROL SET USING REMOTE PROGRAMMER: Key to components: K - 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. E - TERMINAL CONNECTOR BLOCK.
8 716 106 256 C 03.10 30/3/10 14:24 Page 30 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.
30/3/10 14:24 Page 31 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.
8 716 106 256 C 03.10 30/3/10 14:24 Page 32 STARTING THE APPLIANCE IMPORTANT: Never run the appliance when the appliance/system is unpressurised (sealed systems) or empty.
8 716 106 256 C 03.10 30/3/10 14:24 Page 33 STARTING THE APPLIANCE 2 Fit a suitable pressure gauge to port (A) on the oil pump. Adjust the air shutter (K) 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 position of the air damper disc is correct to the output as shown in the table below.
8 716 106 256 C 03.10 30/3/10 14:24 Page 34 STARTING THE APPLIANCE Central heating: 1 Open all radiator valves. Set room thermostat to maximum. Set programmer to ON for CH, OFF for DHW (if applicable). Turn the boiler control thermostat (B) 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.
8 716 106 256 C 03.10 30/3/10 14:24 Page 35 1 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. B B A 2 A B 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.
8 716 106 256 C 03.10 30/3/10 14:24 Page 36 FINISHING COMMISSIONING APPLIANCE 1 Slide control box (A) into the boiler. Secure with screws (B). 2 Align the top front panel (H) and push the ball studs into the connectors (J) to secure. 3 Locate top edge of panel (C) onto the top supporting ledge (D) on the boiler. Locate the ball stud connections (E) at the base of the front panel (C) and push towards the boiler to secure.
30/3/10 14:24 Page 37 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.
8 716 106 256 C 03.10 30/3/10 14:24 Page 38 INSPECTION AND SERVICE BENTONE STERLING 50 1 Clean the Burner: P H D 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.
8 716 106 256 C 03.10 30/3/10 14:24 Page 39 INSPECTION AND SERVICE 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.
8 716 106 256 C 03.10 30/3/10 14:24 Page 40 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 (P) is provided for this purpose. Re-commission the burner: 1 Align burner combustion head (N) into the boiler housing tube with gasket (O) correctly fitted. Push firmly down to compress the gasket (O).
8 716 106 256 C 03.10 30/3/10 14:24 Page 41 RIELLO RDB 2.2 burner SHORT PARTS LIST 18/25 3 4 5 7 8 9 11 15 12 16 13 6 10 14 17 1 Burner - Riello RDB 2.
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8 716 106 256 C 03.10 30/3/10 14:24 Page 45 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.
FAULT FINDING 46 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 8 716 106 256C (03/2010) Replace photo cell Replace control box Replace control box Replace solenoid coil Replace motor Yes Replace oil pump Yes Oil to pump? No Drive coupling broken? No Purge pressure 1-2 bar? No Pump produces pressure? Yes Yes No Yes Replace solenoid coil No (100Ω)? Solenoid coil Yes functional No Solenoid operating? Increase the pump pressure, pressure OK? Ye
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 8 716 106 256C (03/2010) 230V at motor? Yes Motor 40Ω L & N to control box? No Check boiler controls & supply Replace motor capacitor Replace motor Check connections/ replace leads Replace motor/ pump Replace control box Yes Lockout within 1 second? No Replace oil pump Yes Oil to pump? No Drive coupling broken? No Pump produces pressure? Yes Replace transformer Yes Electrodes & leads OK? Yes 230V a
8 716 106 256 C 03.10 30/3/10 14:24 Page 48 DANESMOOR 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.
8 716 106 256 C 03.10 30/3/10 14:24 Page 49 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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30/3/10 14:24 Page 51 NOTES NOTES 8 716 106 256 C 03.
8 716 106 256 C 03.10 30/3/10 14:24 Page 52 If in the unlikely event the boiler does not give complete satisfaction, before calling for a service engineer, the installer should check the following:General checks 1. Is there 230V across the boiler live and neutral terminals? 2. Is the polarity correct? (230V across live and earth, 0V across neutral and earth) 2. Is the air bled from the primary system? 3. Is the air bled from the oil supply? 4.
