Worcester GREENSTAR UTILITY 18/25 Instruction Manual
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Worcester GREENSTAR UTILITY 18/25 Instruction Manual

Floor standing oil fired condensing boiler conventional flue & room sealed flue
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8 716 106 256 C 03.10
30/3/10
INSTRUCTION MANUAL
INSTALLATION, COMMISSIONING & SERVICING
FLOOR STANDING OIL FIRED CONDENSING BOILER CONVENTIONAL
FLUE & ROOM SEALED FLUE
GREENSTAR UTILITY
18/25
FOR FULLY PUMPED OPEN VENT OR SEALED CENTRAL HEATING SYSTEMS
AND DOMESTIC HOT WATER CYLINDERS
14:24
Page 1
THE APPLIANCE IS FOR USE WITH KEROSENE
(28 SECOND OIL) ONLY
UK

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Summary of Contents for Worcester GREENSTAR UTILITY 18/25

  • Page 1 8 716 106 256 C 03.10 30/3/10 14:24 Page 1 INSTRUCTION MANUAL INSTALLATION, COMMISSIONING & SERVICING FLOOR STANDING OIL FIRED CONDENSING BOILER CONVENTIONAL FLUE & ROOM SEALED FLUE GREENSTAR UTILITY 18/25 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...

  • Page 2: Important Information And Symbols

    LABC will then arrange regular inspection visits during the work to ensure that the installation complies with the regulations. Programmer ON DHW only IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER TECHNICAL HELPLINE. DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER. PLEASE LEAVE THESE INSTRUCTIONS WITH THE COMPLETED COMMISSIONING FORM...

  • Page 3: Table Of Contents

    RIELLO CONTROL BOX OPERATION FAULT FINDING LOGIC FOR RIELLO CONTROL BOX FAULT FINDING LOGIC FOR SATRONIC CONTROL BOX COMMISSIONING CHECKLIST SERVICE INTERVAL RECORD NOTES INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 CONTENTS 8 716 106 256C (03/2010)

  • Page 4: Safety Precautions And Installation Regulations

    Republic of Ireland ETCI rules for electrical installation For further guidance see: OFTEC Technical book three - Regional requirements: Republic of Ireland INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 SAFETY PRECAUTIONS 8 716 106 256C (03/2010) & INSTALLATION REGULATIONS...

  • Page 5: General Information

    Greenstar Danesmoor Utility Installation/Servicing Instructions..1 Users Instructions ..................1 Top Panel Inset Plate..................1 Edge Clips .......................1 Warranty Return Envelope ................1 Condensate Trap Kit ..................1 Return Pipe Kit ....................1 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 GENERAL INFORMATION 8 716 106 256C (03/2010)

  • Page 6: Technical Data

    Flue manual reset overheat thermostat set point °C General Data Maximum hearth temperature °C <100 SEDBUK (Band A) 92.6 Appliance protection rating Weight (excluding packaging) INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 TECHNICAL DATA 8 716 106 256C (03/2010)

  • Page 7: Layout & Components

    Air intake casing Oil pump Combustion head 31 LOCKOUT INDICATOR/RESET BUTTON 32 CLIP - AIR INTAKE HOSE 33 AIR INTAKE HOSE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 LAYOUT & COMPONENTS 8 716 106 256C (03/2010)

  • Page 8: Cleaning Primary Systems

    Run the boiler and system at normal operating temperature in accordance with the manufacturer's instructions. Drain and thoroughly flush the system to remove the flushing agent and any debris. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 CLEANING PRIMARY SYSTEMS 8 716 106 256C (03/2010)

  • Page 9: Mains Supply

    • Any system connected to the boiler must not have a separate electrical supply. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 MAINS SUPPLY 8 716 106 256C (03/2010)

  • Page 10: Oil Supply

    The table and illustration above is a guide only and does not in any way override the as the sole fire protection device. de-aerator manufacturers instructions. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 OIL SUPPLY 8 716 106 256C (03/2010)

  • Page 11: Water Systems & Pipework

    1” BSP outlets. • An automatic air vent (N) must be fitted. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 WATER SYSTEMS & PIPEWORK 8 716 106 256C (03/2010)
  • Page 12 Heating return Auto air vent Non return 1000mm above valve the highest point of the system Stop cock Fill Point INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 WATER SYSTEMS & PIPEWORK 8 716 106 256C (03/2010)

  • Page 13: Pressure Relief Pipework

    • Pipe (K) should be finished with a partial bend, near the outlet to face the external wall (as shown) to help prevent freezing. Outside wall. Drain pipe. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 CONDENSATE & 8 716 106 256C (03/2010) PRESSURE RELIEF PIPEWORK...

  • Page 14: Boiler Location & Clearances

    ** Due to changes to BS 5410 and modern 18/25 18/25 building design, these figures no longer incorporate the adventitious ventilation allowance. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 BOILER LOCATION & CLEARANCES 8 716 106 256C (03/2010)

  • Page 15: Boiler Location

    In all cases the IEE wiring regulations must be 750mm consulted. All pipework in bathrooms and shower rooms must be cross bonded. 2250mm 2250m 600mm radius INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 BOILER LOCATION & CLEARANCES 8 716 106 256C (03/2010)

  • Page 16: Flue Terminal Positions

    • **Minimum distance of the flue terminal to a facing wall, fence, building or property boundary is 2500mm. Flat roof boundary Pitched roof C, D boundary INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 FLUE TERMINAL POSITIONS 8 716 106 256C (03/2010)

  • Page 17: Conventional Flue

    A - Boiler B - Flue C - Max. 2 bends at 135° D - Anti down-draught terminal E - Chimney INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 CONVENTIONAL FLUE 8 716 106 256C (03/2010)

  • Page 18: Room Sealed Flue Options

    Horizontal 80/125mmØ: 350-450/460-670 mm Vertical 80/125mmØ: 1080mm + cage * to outside wall. L = 3000mm L = 5000mm 125mmØ x3 125mmØ x5 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 ROOM SEALED FLUE OPTIONS 8 716 106 256C (03/2010)

  • Page 19: Unpacking The Boiler

    At all times the correct method for handling heavy objects should be strictly observed. UNPACKING THE BOILER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 8 716 106 256C (03/2010)

  • Page 20: Pipework Positions / Flue Opening

    Wall thickness Flue hole size 150 - 240mm 155mmØ 240 - 330mm 160mmØ 330 - 420mm 165mmØ 420 - 500mm 170mmØ INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 PIPEWORK POSITIONS & 8 716 106 256C (03/2010) FLUE OPENING...

  • Page 21: Boiler Installation

    Remove and store safely away from the boiler. NOTE: to enable the panels to stand upright, reposition and secure control box (G) to the side panels. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 BOILER INSTALLATION 8 716 106 256C (03/2010)

  • Page 22: Flue Installation

    The horizontal terminal must be installed at 3° to ensure that the condensate drains back to the boiler whilst also preventing rain ingress down the air duct. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 FLUE INSTALLATION 8 716 106 256C (03/2010)

  • Page 23: Combustion Chamber

    (F). Check that all the baffles (G) and baffle retainer (H) are correctly fitted to the secondary heat exchanger. FRONT INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 COMBUSTION CHAMBER 8 716 106 256C (03/2010)

  • Page 24: Pipework Connections

    (M). IMPORTANT: The condensate trap must be correctly filled to prevent the possibility of potentially harmful flue products escaping via the condensate pipework. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 PIPEWORK CONNECTIONS 8 716 106 256C (03/2010)

  • Page 25: Oil Burner And Pump

    Connect the flexible oil return hose (not supplied) between the oil pump and the return line connection, and tighten to secure. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 OIL BURNER & PUMP 8 716 106 256C (03/2010)

  • Page 26: Refitting Components

    Plug burner lead (F) into control box (G). Pivot control box (G) down and slide into the boiler casing. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 REFITTING COMPONENTS 8 716 106 256C (03/2010)

  • Page 27: Electrics

    Refit electric control panel cover: Refit cover panel (C) to control box (A) and secure with screws (B). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 ELECTRICS 8 716 106 256C (03/2010)
  • Page 28 THERMOSTAT. E - TERMINAL CONNECTOR BLOCK. F - CONTROL THERMOSTAT. G - BURNER SOCKET. H - BURNER PLUG. J - BURNER CONTROL BOX. White INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 ELECTRICS 8 716 106 256C (03/2010)
  • Page 29 The junction box (K) must be fitted externally to the boiler. A frost thermostat can also be connected to the remote junction box if required. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 ELECTRICS 8 716 106 256C (03/2010)

  • Page 30: Pre-Commissioning Checks - Appliance

    Complete the installation part of the Guarantee Registration Card, and complete a CD10 or equivalent to inform the LABC of the installation. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 PRE-COMMISSIONING CHECKS - 8 716 106 256C (03/2010) APPLIANCE...

  • Page 31: Filling The System

    There are two venting bosses (A) on the top of the secondary heat exchanger. Only one is used if fluing to the side. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 FILLING THE SYSTEM 8 716 106 256C (03/2010)

  • Page 32: Starting The Appliance

    The internal filter is accessed by removing the oil pump cover on the Danfoss BFP 11 L3, Suntec AS47C and Riello RDB. Safely dispose of the container/discharge. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 STARTING THE APPLIANCE 8 716 106 256C (03/2010)
  • Page 33 0.75 60°ES 2.17 2.75 12.5 18-25kW 25.8 8 9700 85300 Refit the sample point cap (J)(hand tighten only, do not over tighten). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 STARTING THE APPLIANCE 8 716 106 256C (03/2010)
  • Page 34 The burner and circulating pump should be off. 3 Check that any other controls that are fitted to the system are operating properly. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 STARTING THE APPLIANCE 8 716 106 256C (03/2010)

  • Page 35: Water Treatment

    . INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 WATER TREATMENT 8 716 106 256C (03/2010)

  • Page 36: Finishing Commissioning - Appliance

    NOTE: Release drain point (K) to drain the secondary heat exchanger. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 FINISH COMMISSIONING - 8 716 106 256C (03/2010) APPLIANCE...

  • Page 37: Inspection And Service

    Clean or replace all oil filters. Check that the condensate system is not obstructed, clean and refill the condensate trap as necessary. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 INSPECTION AND SERVICE 8 716 106 256C (03/2010)
  • Page 38 This seal must be in good condition since failure will cause flue gases to escape into the room. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 INSPECTION AND SERVICE 8 716 106 256C (03/2010)
  • Page 39 ( J ) and tighten, using the sequence shown, until the chamber door is firmly secured, do not over tighten the nuts. FRONT INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 INSPECTION AND SERVICE 8 716 106 256C (03/2010)
  • Page 40 63300 61400 0.65 60°ES 1.86 2.36 12.0 18-25kW 22.2 75100 21.5 73400 0.75 60°ES 2.17 2.75 12.5 18-25kW 25.8 8 9700 85300 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 INSPECTION AND SERVICE 8 716 106 256C (03/2010)

  • Page 41: Short Parts List Riello Rdb 2.2

    Part Number: 8 716 115 843 0 0.75 60° ES (25kW output) Part Number: 8 716 106 156 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 SHORT PARTS LIST 8 716 106 256C (03/2010) RIELLO RDB 2.2 - 18/25...
  • Page 42 Part Number: 8 716 156 671 0 0.65 80° EH (25kW output) Part Number: 8 716 110 362 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 SHORT PARTS LIST 8 716 106 256C (03/2010) BENTONE 50 - 18...

  • Page 43: Fault Finding & Diagnosis

    Adjust to correct pressure ANY CONTROL LINKED OUT OR Incorrect components used on Check with installation instructions OVERRIDDEN. combustion head Faulty nozzle Replace nozzle INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 FAULT FINDING 8 716 106 256C (03/2010)
  • Page 44 Rectify burner operation and lockouts operation, numerous lockouts Odour in boiler room, oil leaks Rectify oil leaks, replace components if from pipework, flexible hoses necessary connections INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 FAULT FINDING 8 716 106 256C (03/2010)

  • Page 45: Riello Control Box Operation

    Whilst every effort has been taken to ensure the information given is CONTROL BOX OPERATION 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. STATUS...

  • Page 46: Fault Finding Logic For Riello Control Box

    FAULT FINDING & DIAGRAMS MO535 IMPORTANT NOTE: The box has a built in delay of 11 seconds before activating the motor. The preheater link must be fitted at for the box to operate Replace Replace Boiler not control box nozzle operating with a heating /...

  • Page 47: Fault Finding Logic For Satronic Control Box

    Stray light Replace Replace Photo cell Replace coil Boiler not on photo control box lead lead OK? lead operating cell? with a heating / hot water demand 230V at Disconnect photo cell, Replace Replace Coil lead Replace solenoid coil reset lockout, burner pump photo cell control box...

  • Page 48: Commissioning Checklist

    It is recommended that the heating system is serviced regularly and that you complete the appropriate Service Interval Record Overleaf. Service Provider. Before completing the appropriate Service Interval Record overleaf, please ensure you have carried out the service as described in this manual. Always use Worcester, Bosch Group specified spare parts.
  • Page 49 8 716 106 256 C 03.10 30/3/10 14:24 Page 49 SERVICE 2 SERVICE 1 DATE DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No. TEL No. OFTEC REG No. OFTEC REG No. PUMP PRESSURE: PUMP PRESSURE: NOZZLE CHANGED? NOZZLE CHANGED? F.G.T.

  • Page 50: Notes

    8 716 106 256 C 03.10 30/3/10 14:24 Page 50 NOTES INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 NOTES 8 716 106 256C (03/2010)
  • Page 51 8 716 106 256 C 03.10 30/3/10 14:24 Page 51 NOTES INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 NOTES 8 716 106 256C (03/2010)

  • Page 52: 716 106 256C (03/2010)

    WEBSITE (EIRE): worcester-bosch.ie- Dedicated to heating comfort Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0844 892 9900 Fax. 01905 754619 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. www.worcester-bosch.co.uk 8 716 106 256C (03/2010)

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