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Bosch Worcester Danesmoor Utility Regular ErP+ 12/18 Installation, Commissioning And Servicing Instruction Manual

Floor standing oil-fired condensing boiler conventional flue & room sealed flue
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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.
UK

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  Summary of Contents for Bosch Worcester 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 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.
  • Page 2: Table Of Contents

    Contents Contents Electrical ........32 Key to symbols and safety instructions .
  • Page 3: Key To Symbols And Safety Instructions

    Key to symbols and safety instructions Key to symbols and safety instructions Key to symbols List entries, first and second levels • A single component/item Warnings • A component/list, made up of multiple parts/items. – Sub component or sublist of main component/list. Warnings in this document are identified by a warning triangle printed against a grey background.
  • Page 4 Key to symbols and safety instructions Combustible and corrosive materials Electrical work Do not store or use any combustible materials (paper, thinners, paints Electrical work must only be carried out by a qualified electrician. etc.) inside or within the vicinity of the appliance. ▶...
  • 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 7731600147 7731600151 7731600155 7731600148 7731600152 7731600156 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 6720821720-01.1Wo Fig. 1 System appliance shown Greenstar Danesmoor Utility ErP+ and Utility System ErP+ - 6 720 821 720 (2018/04)
  • Page 9 Appliance information 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 Expansion vessel...
  • Page 10: Layout And Components - 18/25 Regular Appliance Shown

    Appliance information Layout and components - 18/25 Regular appliance shown 6720821720-02.1Wo Fig. 4 18/25 Regular appliance shown Figure 4 does not include the top, front, and right hand side panel. Control box assembly Oil isolating valve Flue manifold access cover Optional oil return position Flue gas sampling point Burner mounting plate...
  • Page 11: Pre-Installation

    Pre-Installation Pre-Installation Cleaning primary systems ▶ Sealed systems only: – Fill the system to between 1 and 1.5 bar via a WRAS approved DANGER: Danger to life through electric shock! filling loop. ▶ Before carrying out any work on electrical ▶...
  • Page 12: Inhibitor

    ▶ In cases where all attempts to find a system micro • Do not use galvanised steel tanks or pipework for the oil system. leak have failed, Worcester, Bosch Group supports • Do not use soldered joints on the oil supply pipework.
  • Page 13: Double Pipe Sub-Gravity Feed System

    Pre-Installation 4.3.2 Double pipe sub-gravity feed system: 4.3.4 Pipework Maximum suction height 3.5 metres. Non-return valves must be fitted to ▶ Refer to the oil supply sections Single pipe gravity feed the inlet and return oil line between the oil pump [9] and oil storage tank system: 4.3.1, Double pipe sub-gravity feed system: 4.3.2 &...
  • Page 14: Water Systems And Pipework

    Pre-Installation Water systems and pipework Open vent primary system (Regular only) • The open vent pipe (F) and feed and expansion pipe (H) must rise NOTICE: continuously from the appliance. ▶ The boiler should not be allowed to operate with a •...
  • Page 15: Condensate Discharge

    Pre-Installation Fully pumped sealed primary system: Condensate discharge For correct installation and trouble free operation of the appliance the • A pressure relief valve (P), spring loaded safety valve set to operate following advice should be followed: at 3bar, must be fitted to the heating flow pipe as close as possible to the boiler or onto one of the boiler top 1”...
  • Page 16: Internal Connections

    Pre-Installation 4.5.2 Internal connections 4.5.3 External connections In order to minimise risk of freezing during prolonged cold spells, the NOTICE: Rainwater or external drain disposal following methods of installing condensate drainage pipe should be Untreated condensate must not be allowed to flow into adopted, in order of priority.
  • Page 17 Pre-Installation FITTING AN EXTERNAL AIR BREAK CONDENSATE SOAK AWAY • Refer to figure 18 when a rain water down pipe is used to dispose of • The condensate soak away must be sited at least 500mm away from condensate. building footings. •...
  • Page 18: Pressure Relief Pipework

    Pre-Installation Pressure relief pipework Room sealed balanced flue models (RS) The appliance does not require a separate vent for combustion air. • The pressure relief discharge pipe (1) should be at least 15 mm diameter copper pipe and run downwards away from the boiler and Installation in cupboards or compartments require permanent vents for discharge away from any electrical or other hazard, preferably to an cooling purposes, one at high level and one at low level, either direct to...
  • Page 19: Flue Terminal Positions

    Pre-Installation Maintenance clearances Rooms containing a bath or shower Figure 25 shows the clearances required for maintenance. WARNING: Conventional flues ▶ Conventional flue boilers must not be installed in a 380mm 1200mm bathroom 300mm WARNING: Electric shock ▶ Any switch or appliance using mains electricity must not within reach of a person using the bath or shower.
  • Page 20 Pre-Installation 1000 1500 2000 1000 RIDGE FLUE RIDGE VENT 1500 1000 1000 1500 1500 1000 1200 1500 1000 1000 1000 2500 1500 2500 1000 1000 1800 1200 BOUNDARIES 1000 1000 1500mm vertically between terminals and the same wall. 1000mm below a Velux window for a vertical flue (1000mm for horizontal 1000mm below eaves, gutters, pipes and drains.
  • Page 21: Flue Options

    Pre-Installation Flue options 4.9.1 Conventional flue (CF) • Open (conventional) flued appliances must not be installed in a bedroom, bathroom or bed-sitting room. • The flue system must be in accordance with BS 5410 : Part 1 and the current Building Regulations. •...
  • Page 22: Room Sealed Flue Options

    Pre-Installation 4.9.2 Room sealed flue options Figure 28 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. • To achieve the maximum flue length (L), a flue section will have to be L = 120 - 240mm reduced in length.
  • 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: Pipework Positions And Flue Opening

    Installation Pipework positions and flue opening CAUTION: Drilling ▶ Ensure there are no pipes, electrical 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.
  • Page 25 Installation Pipework connections - System Flue centres A - Flow connections 12/18 & 18/25 - 22mm Ø , 25/32 - 28mm Ø RS 155 CF 170 B - Return connections 22mmØ copper on 12/18, 18/25 models and 28mmØ copper on 25/32 models C - Condensate outlet 21.5mm Ø...
  • Page 26: Boiler Installation

    Installation Boiler installation 3. Unscrew to loosen the retaining ring (H) that secures the flexible air supply tube to the burner and pull the flexible air supply tube free 1. Lift the front of the top panel (A) upwards to disengage the ball stud from the burner (see figure 38).
  • Page 27: Flue Damper Installation

    Installation 5.4.1 Flue damper installation The boiler is not designed to take the weight of the flue system, this must be supported externally to the boiler. NOTICE: Fitting the flue damper Failure to fit the flue damper, when required will effect the performance of the boiler and may cause “Lockouts”...
  • Page 28: Combustion Chamber (18/25 Regular Shown)

    Installation Combustion chamber (18/25 Regular shown) 3. Release retaining nuts and washers (C). Remove baffle/combustion chamber access door (D). 1. Remove the control box securing screws (A, bottom screw both 4. Ensure one piece baffle set (E) is in the right location (F), correctly sides) and loosen the pivot screws (B, top screw both sides).
  • Page 29: 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 boiler pipework connections. ▶...
  • Page 30: Oil Burner And Pump

    Installation Fire valve Where required, 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 [1] is provided for this purpose on the support bar between the side panels.
  • Page 31: Refitting Components

    Installation Oil pump - two pipe connection Refer to figure 53 1. Align burner combustion head into the boiler collar. Converting the oil pump for a double pipe system: 1. Check the inlet pipe connection. ▶ Locate the burner retainer [A] over the threaded lug on the collar [B], ensure that the burner is level and push the burner firmly onto the ▶...
  • Page 32: Electrical

    Installation Electrical CAUTION: ISOLATE THE 230v ELECTRICITY SUPPLY ▶ Ensure that the electricity supply is safely Isolated and secured to prevent inadvertent re-connection. Information on safe isolation can be found in the Health and Safety Executive guidance HSG85. Using test equipment approved to GS38 confirm that the electricity supply is disconnected.
  • Page 33 Installation Utility - 230V Standard wiring diagram 1 2 3 = EARTH Green/Yellow = LIVE = NEUTRAL Grey Key to components: Grey A - EARTH STUD B - HIGH LIMIT THERMOSTAT C - AIR PRESSURE SWITCH D - BOILER MANUAL RESET OVERHEAT THERMOSTAT E - FLUE MANUAL RESET OVERHEAT THERMOSTAT...
  • Page 34 Installation Utility System - 230V Standard wiring diagram = EARTH = LIVE = NEUTRAL 1 2 3 Green/Yellow Grey Key to components: A - EARTH STUD B - HIGH LIMIT THERMOSTAT C - AIR PRESSURE SWITCH D - BOILER MANUAL RESET OVERHEAT THERMOSTAT E - FLUE MANUAL RESET OVERHEAT THERMOSTAT...
  • Page 35 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 36 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. •...
  • Page 37: 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 38: Water Treatment

    ▶ Repeat the procedure until a steady stream of oil without air, runs ▶ In cases where all attempts to find a micro leak have from the bleed port, then lock bleed port [A]. failed, Worcester, Bosch Group supports the use of ▶ Switch off the boiler. Fernox F4 leak sealer.
  • Page 39: Pump Adjustments

    Commissioning Fig. 64 Priming the pump Oil supply De-aerator Return Flow Spare flexible oil hose Container of oil Oil pump flexible inlet hose Bleed and pressure gauge port ▶ Switch off the boiler. ▶ Safely dispose of the container/discharge. 6.4.3 Pump adjustments ▶...
  • Page 40: Burner Head Setting

    Commissioning 6.4.4 Burner head setting 6.4.5 Boiler lockout indicator on: Adjustments to the burner head are made on the basis of the required If the burner fails to establish a normal firing pattern or flame failure output, refer to table 11 for the required setting for your boiler. 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 41: Combustion Checks

    Commissioning 6.4.6 Combustion checks ▶ Turn off the electrical supply. ▶ Isolate the oil supply to the burner. ▶ Start and run for 20 minutes ▶ Remove the oil pressure gauge. ▶ Remove sampling point plug (K) to check the smoke reading is ▶...
  • Page 42: Central Heating

    Commissioning 6.4.7 Central heating Finishing commissioning 1. Open all radiator valves. ▶ Pivot the control box (A) figure 75 up and into the boiler. Secure with screws (B). ▶ Set room thermostat to maximum. ▶ Set programmer to ON for CH, OFF for DHW (if applicable). Utility system only: ▶...
  • Page 43: Hand Over

    • During the period of this guarantee any components of the appliance which are proven to be faulty or defective in manufacture will be exchanged or repaired free of charge by Bosch Thermotechnology Ltd. Fig. 75 • The householder may be asked to prove the date of installation, that...
  • Page 44: Service And Spares

    – Please send your completed form to: To maintain efficient boiler operation, the following should be carried Worcester, Bosch Group, Cotswold Way, Warndon, Worcester, out at least once a year, carry out a pre-service check and note any WR4 9SW.
  • Page 45: Service Requirements

    Service and Spares Service requirements See the following instructions for detail of some of the service requirements listed below: ▶ Check and clean the burner. ▶ Replace the burner nozzle and flexible oil pipe/s. ▶ Check and clean the baffle retainers. ▶...
  • Page 46: Pump Filter

    Service and Spares ▶ Use a suitable spanner to stop the nozzle body turning ▶ Replace the standard flexible oil line/s at every annual service to prevent the possibility of leakage due to ageing. ▶ Remove the nozzle [8]and secure the new nozzle, hand tight ▶...
  • Page 47: Oil Supply System And Tank

    Service and Spares ▶ Pour 500 ml of water into drain [5] to refill the condensate trap and check that the condensate discharge pipe is discharging. 12/18kW ▶ Clean the secondary heat exchanger baffles [4] if necessary and refit Baffle correctly.
  • Page 48: After Service Hand Over

    6720808218-81.1Wo 7.14 Spares Fig. 90 Oil pump and hose detail For Worcester Bosch spares refer to the the website at www.worcester- Oil pump bosch.co.uk/spares Flexible oil hose route. Ensure that the rigid 90° connection at the pump points to right when the boiler is viewed from the front and the flexible hose follows the route as show in the figure above.
  • Page 49: 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 50: 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 51: 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 52: 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 ErP+ and Utility System ErP+ - 6 720 821 720 (2018/04)
  • Page 53: Riello Control Box 12/18 Model

    Fault finding and diagnosis Riello control box 12/18 model 8.5.1 Last lockout memory feature The control box allows the last lockout that happened to be displayed. ▶ Release the button. LED displaying the type of lockout memorised for 10 seconds Access to this function is possible in both STANDBY and OPERATING status.
  • Page 54 Fault finding and diagnosis Line Check Action Burner does not fire, burner locks out after 25 seconds from motor start? Go to line 5a Go to line 6 Burner fires when the photo cell is covered? Remove extraneous light Go to line 5b Photo cell voltage ≥...
  • Page 55: Flame Sensing Photocell 12/18 Models

    Fault finding and diagnosis 8.5.4 Flame sensing photocell 12/18 models Air pressure switch and flue overheat reset To check the correct functioning of the photocell, perform the following This is a blocking error that must be reset by pressing thermostat reset actions: button or air pressure switch reset button.
  • Page 56: Oil Appliance Commissioning Checklist

    Fault finding and diagnosis Oil appliance commissioning checklist IMPORTANT This Commissioning checklist is to be completed in full by the competent ▶ Leave this manual with the Homeowner. person who commissioned the appliance as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.
  • Page 57: Service Interval Record

    Fault finding and diagnosis 8.10 Service interval record It is recommended that your appliance is serviced annually and that the Service Interval Record is completed and signed. Before completing the service Interval record below, ensure that you have carried out the service functions described in this manual. Always use the manufacturer’s recommended spare parts Service 1 Date:...
  • Page 58 Notes Greenstar Danesmoor Utility ErP+ and Utility System ErP+ - 6 720 821 720 (2018/04)
  • Page 59 Greenstar Danesmoor Utility ErP+ and Utility System ErP+ - 6 720 821 720 (2018/04)
  • Page 60 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 6 720 821 720 (2018/04)

This manual is also suitable for:

Worcester danesmoor utility regular erp+ 18/25Worcester danesmoor utility regular erp+ 25/32Worcester danesmoor utility system erp+ 12/18Worcester danesmoor utility system erp+ 18/25Worcester danesmoor utility system erp+ 25/32