Table of Contents
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Installation, Commissioning and Servicing instruction manual
Floor Standing oil-fired Condensing Boiler Conventional Flue & Room Sealed Flue
Greenstar Danesmoor Utility Regular
ErP
& Utility System
12/18, 18/25, & 25/32
ErP
For fully pumped open vent or sealed central heating systems and domestic hot water cylinders
These appliances are for use with Kerosene (Class C2) only.
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Table of Contents
Related Manuals for Worcester Greenstar Danesmoor Utility Regular ErP 12/18
Summary of Contents for Worcester Greenstar Danesmoor Utility Regular ErP 12/18
- Page 1 Installation, Commissioning and Servicing instruction manual Floor Standing oil-fired Condensing Boiler Conventional Flue & Room Sealed Flue Greenstar Danesmoor Utility Regular & Utility System 12/18, 18/25, & 25/32 For fully pumped open vent or sealed central heating systems and domestic hot water cylinders These appliances are for use with Kerosene (Class C2) only.
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Page 2: Table Of Contents
Contents Contents Key to symbols and safety instructions ....3 Commissioning ........35 Key to symbols . -
Page 3: Key To Symbols And Safety Instructions
DWTA Domestic Water Treatment Association Read these instructions before starting any installation Additional symbols These instructions are applicable to the Worcester appliance model(s) Symbol Meaning stated on the front cove of this manual only and must not be used with a numbered step in an action sequence any other make or model of appliance. - Page 4 Key to symbols and safety instructions The combustion air must be kept clear of chemically aggressive Handover to the user substances which can corrode the appliance and invalidate any When handing over, instruct the user how to operate the heating system warranty.
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Page 5: Installation Regulations
Installation regulations The Building Regulations Part G, Part J and L1 England and Wales; Part Installation regulations F, Part G and Part J Section III Scotland; Part L and Part F Northern Ireland. Complying with the building regulations Local water company bye-laws. This heating appliance forms part of the controlled services for the The Control of Pollution (Oil) Regulations. -
Page 6: Appliance Information
Appliance information Technical data Appliance information Description Units 12/18 18/25 25/32 General information Central heating Central heat output (max) Standard package: Primary water capacity (total) litres A - Floor standing oil fired condensing boiler Maximum static head metres B - Literature pack: Minimum static head metres •... -
Page 7: Energy Efficiency
Appliance information Energy efficiency The following product data satisfy the requirements of the EU Regulations No. 811/2013 and No. 812/2013 supplementing Directive 2010/30/EU. Product data Symbol Unit 7731600056 7731600057 7731600058 7731600065 7731600066 7731600067 Product type – – Danesmoor Danesmoor Danesmoor Danesmoor Danesmoor Danesmoor... -
Page 8: Layout And Components - 18/25 System Appliance Shown
Appliance information Layout and components - 18/25 System appliance shown Greenstar Danesmoor Utility and Utility System - 6 720 813 286 (2014/09) - Page 9 Appliance information Fig. 1 System appliance shown Figure 1 does not include the top, front, left, and right hand side panel Return connection Oil pump (behind plastic cover) Flow connection Burner control box (behind plastic cover) Pressure relief valve Riello RDB burner Air inlet casing Lock out reset button (on the front of the burner control box) Secondary heat exchanger flow pipe...
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Page 10: Layout And Components - 18/25 Regular Appliance Shown
Appliance information Layout and components - 18/25 Regular appliance shown 8 9 10 11 9 Fig. 4 18/25 Regular appliance shown Figure 4 does not include the top, front, and right hand side panel. Control box assembly Condensate drain pipe Flue manifold access cover Flexible condensate drain pipe connection Flue gas sampling point... -
Page 11: Pre-Installation
Building Regulations to flush and inhibit the primary water system in accordance with BS 7593. ▶ It is recommended that you fit a primary water cleanser to the system. Worcester recommends fitting a filter that will help remove both magnetite and non-magnetic debris. -
Page 12: Inhibitor
▶ In cases where all attempts to find a system micro 1:24 away from the outlet with a sludge cock at the lower end. leak have failed, Worcester, Bosch Group supports • Do not use galvanised steel tanks or pipework for the oil system. -
Page 13: Double Pipe Sub-Gravity Feed System
Pre-Installation Maximum pipe run for single pipe gravity fed system Maximum pipe run for single pipe suction lift with de-aerator Head (m) 10mmØ 12mmØ Head (m) 10mmØ 12mmØ FUEL FLOW RATE 2.5kg/h 5kg/h 10kg/h 10kg/h Head (m) 8mmØ 8mmØ 8mmØ 10mmØ... -
Page 14: Water Systems And Pipework
Pre-Installation ▶ Offer the pipe to the fitting [2] and tighten the nut [1]. Fig. 10 Isolation valve bracket removed for clarity 6720808218-07.1Wo ▶ Use flexible hoses to connect from the boiler isolation valve/s and the oil pump. Fig. 11 Regular boiler, open vent system layout Regular appliance Water systems and pipework [A1]... - Page 15 Pre-Installation 6720808218-109.1Wo Fig. 13 System boiler system layout Filling primary sealed systems NOTICE: FILLING THE SYSTEM ▶ The system must not be filled with artificially softened water. • Where the system volume is more than 180 litres at 0.5 bar or exceeds 2.65 bar at maximum heating temperature an extra expansion vessel (B) must be fitted as close as possible to the appliance in the central heating return.
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Page 16: Condensate Pipework
Pre-Installation Condensate pipework Condensate pump Where “gravity discharge” to an internal termination is not physically NOTICE: possible, or where very long internal runs would be required to reach a ▶ Where a new or replacement boiler is being installed, suitable discharge point, condensate should be removed using a access to an internal “gravity discharge”... -
Page 17: Soak Away
Pre-Installation Fitting an external air break Continued - Key to condensate illustrations • Refer to figure 17 when a rain water down pipe is used to dispose of 100mm Ø minimum plastic pipe condensate. Drainage holes • An air break must be installed in the 43mm pipe work, between the Limestone chippings (25kg min.) boiler condensate outlet and the drainpipe, outside the property, to avoid flooding during adverse weather conditions. -
Page 18: Boiler Locations And Clearances
Pre-Installation The minimum air vent free area is given in the table opposite. Installation clearances Figure 22 shows the minimum space recommended to install the boiler only. 570mm 1200mm 300mm 100mm 100mm 600mm 6720808218-16.1Wo Fig. 22 Installation clearances Service clearances 6720646608-123.1Wo Fig. -
Page 19: Flue Terminal Positions
Pre-Installation Maintenance clearances Showers/bathrooms Figure 24 shows the clearances required for maintenance. WARNING: Conventional flues ▶ Conventional flued boilers must not be installed in a 380mm 1200mm bathroom 300mm WARNING: Electrical ▶ Any appliance using mains electricity must not be able to be touched by a person using the bath or shower. - Page 20 Pre-Installation Flat roof boundary Pitched roof C, D boundary 6720808218-19.1Wo Terminal position RS(H) RS(V) 1, 2 Directly below an opening, air brick, opening window etc. 600mm 1, 2 Horizontally to an opening, air brick, opening window, etc. 600mm Below a plastic/painted gutter, drainage pipe or eaves if combustible material is protected 75mm Below a plastic/painted gutter, drainage pipe or eaves without protection to combustible material 600mm...
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Page 21: Flue Options
CF Sizing: ▶ 12/18 and 18/25 = 100/103mmØ ▶ 25/32 = 130mmØ * * Unless installing a Worcester Greenstar Oilfit Conventional Flexible flue. • Because the flue operates at a lower temperature on a condensing boiler compared to that of a conventional appliance, the flue draught will be lower. -
Page 22: Room Sealed Flue Options
Pre-Installation 4.9.2 Room sealed flue options Figure 27 shows the components used and the maximum flue length (L) for each flue configuration. In all cases L is measured from the outside of the boiler casing. L = 140 - 335mm •... -
Page 23: Installation
Installation Installation Unpacking the boiler CAUTION: Lifting and carrying ▶ Lift only a manageable weight, or ask for help. ▶ When lifting or putting things down, bend your knees, keep your back straight, and feet apart. ▶ Do not lift and twist at the same time. ▶... - Page 24 Installation Pipework connections - Regular Pipework connections - System A - Flow connections 12/18 & 18/25 - 22mm Ø , 25/32 - 28mm Ø A - Flow connections (optional combined feed and vent) 1” BSP B - Return connections 22mmØ copper on 12/18, 18/25 models and B - Return connections 22mmØ...
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Page 25: Boiler Installation
Installation Flue centres Boiler installation 1. Lift the front of the top panel (A) upwards to disengage the ball stud RS 155 CF 170 connections (B) and pull forwards to release from the brackets (C) at the back to remove. Pull front panel (D) forward from the bottom and near the top disengaging the ball studs from their connections (E) and lift off the ledge (F) that runs along the bottom of the fascia to remove. -
Page 26: Flue Installation
Installation 3. Unscrew to loosen the retaining ring (H) that secures the flexible air The boiler is not designed to take the weight of the flue supply tube to the burner (I) and pull the flexible air supply tube free system, this must be supported externally to the boiler. -
Page 27: Combustion Chamber (18/25 Regular Shown)
Installation Combustion chamber (18/25 Regular shown) 4. Ensure one piece baffle set (E) is in the right location (F), correctly resting on the baffle rests (G) on either side of the combustion 1. Remove the control box securing screws (A, bottom screw both chamber and pushed securely into place. -
Page 28: Pipework Connections
Installation Pipework connections Water connections Surplus water may be present due to factory testing. CAUTION: MAINS SUPPLIES ▶ Isolate the oil & water mains supply before starting any work and follow all relevant safety precautions. ▶ Remove the transit bungs from the pipework connections on e boiler. ▶... -
Page 29: Oil Burner And Pump
Installation Oil burner and pump CAUTION: MAINS SUPPLIES ▶ Isolate the oil & water mains supply before starting any work and observe all relevant safety precautions. Oil burner 1. Check that the nozzle (A) and the electrode (B) alignment settings are correct as shown in figure 49. -
Page 30: Electrical
Installation Electrical External 230V programmer 4. Remove link (G). CAUTION: 230 Volts ▶ Connect wires as shown. ▶ Isolate the mains electricity supply before starting any work and follow all relevant safety precautions. Access to 230V connections 1. Remove the four fascia retaining screws (A) and position the fascia assembly (B) on the two fascia location lugs (C) as shown. - Page 31 Installation Utility - 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.
- Page 32 Installation Utility System - 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.
- Page 33 Installation Utility - Remote 2 or 3 port valve control set using remote programmer Key to components: K - REMOTE JUNCTION BOX (10-way) to • = EARTH connect the following (refer to manufacturers instructions): >Mains wiring 230V 50Hz. • = LIVE >Hot water tank thermostat.
- Page 34 Installation Utility System - Remote 2 or 3 port valve control set using remote programmer Key to components: K - REMOTE JUNCTION BOX (10-way) to connect the following (refer to manufacturers instructions): • = EARTH > Mains wiring 230V 50Hz. •...
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Page 35: Commissioning
Commissioning Filling the system Commissioning ▶ Open all system and radiator valves. ▶ Turn on the water main stop cock. Pre-Commissioning checks - 18/25 Regular shown ▶ Open vented systems only: CAUTION: 230 Volts – Turn on the water to the system feed and expansion cistern and ▶... -
Page 36: Water Treatment
12 months or sooner if system Return content is lost. ▶ In cases where all attempts to find a micro leak have failed, Worcester, Bosch Group supports the use of Flow Fernox F4 leak sealer. TANK Water treatment products... - Page 37 Commissioning Boiler lock out indicator on: If the burner fails to establish a normal firing pattern or flame failure occurs the flame monitoring photocell mounted in the burner body will alert the burner control box to shut the burner down and provide a safe lockout state indicated by the illumination of the lockout indicator (D).
- Page 38 Commissioning ▶ Turn off the electrical supply. ▶ Isolate the oil supply to the burner. ▶ Remove the oil pressure gauge. ▶ Refit the blanking plug (A). ▶ Check and rectify any oil leaks. 3. Switch on the oil supply. ▶...
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Page 39: Finishing Commissioning
Commissioning Central heating Finishing commissioning 1. Open all radiator valves. ▶ Pivot the control box (A) figure 71 up and into the boiler. Secure with ▶ Set room thermostat to maximum. screws (B). ▶ Set programmer to ON for CH, OFF for DHW (if applicable). Utility system only: ▶... -
Page 40: Hand Over
– You can register by ringing 0330 123 2552 • By post Fig. 71 – Please send your completed form to: Worcester, Bosch Group, Cotswold Way, Warndon, Worcester, 6.5.1 Hand over WR4 9SW. ▶ Complete the Boiler commissioning checklist at the back of this To read the full Terms &... -
Page 41: Service And Spares
Service and Spares Service and Spares Inspection and service - 18/25 Regular shown CAUTION: MAINS SUPPLIES ▶ 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. - Page 42 Service and Spares Service requirements Plastic cover Air shutter scale See the following instructions for detail of some of the service Air damper Air shutter adjuster requirements listed below: Hose clamp Air shutter disk ▶ Check and clean the burner. Flexible air supply hose Black foam strip (12/18) ▶...
- Page 43 Service and Spares RIELLO (on 12/18 model only) RDB OIL PUMP Brass air deflection washer Locating circlip G - Retaining screws - cover 6720808218-104.1Wo H - Cover - oil pump Fig. 78 Pump detail Combustion chamber - 18/25 Regular shown ▶...
- Page 44 Service and Spares 12/18kW Baffle 18/25 & 25/32kW Baffle 6720808218-92.1Wo Fig. 80 Baffle detail 6720808218-82.1Wo Fig. 82 Condensate trap removal Condensate trap Pipe locking tab Flexible pipe Trap locking tab Trap retaining bracket ▶ Pour 500ml of water into drain (E) to refill the condensate trap. Ensure that the trap is discharging correctly and that all condensate pipework joints are water tight.
- Page 45 Service and Spares Re-commissioning the burner correct as indicated in table 8 on page 38, ensure CO levels are correct. Adjust the air shutter if necessary see page 38, figure 67 for 1. Align burner combustion head into burner collar. details.
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Page 46: Short Parts List 12/18
Service and Spares Short parts list 12/18 Short parts list 18/25 Cleaning tool Oil nozzle (12kW) Cleaning tool Oil nozzle (18kW) 8 716 109 428 0 0.35 80° SR 8 716 109 428 0 0.50 80° ES 8 716 112 628 0 8 716 156 669 0 Oil nozzle (15kW) Oil nozzle (18kW) -
Page 47: Short Parts List 25/32
Service and Spares Short parts list 25/32 Cleaning tool Oil nozzle 8 716 109 428 0 (25 & 28.5kW) 0.75 80° ES 8 716 109 387 0 Oil nozzle (32kW) Flexible oil hose kit 0.85 80° EH 8 716 115 310 0 8 716 156 644 0 Combustion head 0- Manifold access... -
Page 48: Fault Finding And Diagnosis
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 can- not be held responsible for costs incurred by persons not deemed to be competent. -
Page 49: Heating And Hot Water
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. Greenstar Danesmoor Utility... -
Page 50: Boiler Function
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. -
Page 51: Logic For The 535 Se/Ld Rdb Control Box
Fault finding and diagnosis Logic for the 535 SE/LD RDB control box Greenstar Danesmoor Utility and Utility System - 6 720 813 286 (2014/09) -
Page 52: Oil Supply Vacuum Testing
Fault finding and diagnosis Oil supply vacuum testing A vacuum gauge can be attached to the oil pump vacuum test port [1] and the boiler operated to check the vacuum readings. Oil pumps can operate if readings are between plus 0.4 bar and minus 0.35 bar. This means oil tanks can be 4 metres higher (to top of oil) or 3.5 metres lower (if fitted with a de-aerator or two-pipe oil delivery system) than the oil pump. - Page 53 Fault finding and diagnosis Greenstar Danesmoor Utility and Utility System - 6 720 813 286 (2014/09)
- Page 54 OIL BOILER COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. BOILER DETAILS Boiler Make and Model Boiler Serial Number...
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Page 55: Service Interval Record
SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the manufacturer’s instructions. - Page 56 APPLIANCE BE LEFT TO OPERATE WITH ANY CONTROL LINKED OUT OR OVER RIDDEN. Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0330 123 9559 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. worcester-bosch.co.uk 6 720 813 286 (2014/09)