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

Floor standing oil-fired condensing boiler using room sealed flue for fully pumped open vent or sealed central heating systems and domestic hot water cylinders
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Installation, Commissioning and Servicing instruction manual
Floor Standing oil-fired Condensing Boiler using Room Sealed Flue
Greenstar Danesmoor External Regular
ErP+
& External 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 Greenstar Danesmoor External Regular ErP+ 12/18

  • Page 1 Installation, Commissioning and Servicing instruction manual Floor Standing oil-fired Condensing Boiler using Room Sealed Flue Greenstar Danesmoor External Regular ErP+ & External 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 Key to symbols and safety instructions ....3 Commissioning ........28 Key to symbols .

  • Page 3: Key To Symbols And Safety Instructions

    Key to symbols and safety instructions List entries, first and second levels Key to symbols and safety instructions • A single component/item • A component/list, made up of multiple parts/items. Key to symbols – Sub component or sublist of main component/list. –...

  • Page 4: Installation Regulations

    Installation regulations Handling instructions and guidelines Handover to the user It is advised that more than one person is involved in the transfer of the When handing over, instruct the user how to operate the heating system packaged appliance from the van to the point of installation. and inform him about its operating conditions.
  • Page 5 Installation regulations BS 7291: Thermoplastic pipes and associated fittings for hot and cold water for domestic purposes and heating installations in buildings. BS 7074: part 1: Application, selection and installation of expansion vessels and ancillary equipment for sealed water systems. BS 1254-2: Copper and copper alloys plumbing fittings part 2: Fittings with compression ends for use with copper...

  • 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 Max.static head (Regular only) metres B - Literature pack: Min.

  • 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 7731600149 7731600153 7731600157 7731600150 7731600154 7731600158 Product type – – Danesmoor Danesmoor Danesmoor Danesmoor Danesmoor Danesmoor...

  • Page 8: Layout And Components - 18/25 Regular Appliance Shown

    Appliance information Layout and components - 18/25 Regular appliance shown 26 25 Fig. 2 18/25 Appliance shown Figure 2 does not include the top, front, and right hand side panel. Control box assembly Primary heat exchanger Flue manifold access cover Oil isolating valve Flue gas sampling point Optional oil return position...

  • Page 9: Layout And Components - 12/18 System Appliance Shown

    Appliance information Layout and components - 12/18 System appliance shown Fig. 3 Exploded system appliance view Control box assembly Primary heat exchanger drain Demand indicator Burner air intake - connected to air inlet casing by flexible duct Mode switch Oil pump (behind plastic cover) Flue manifold access cover Riello RDB burner Flue gas sampling point...

  • Page 10: Pre-Installation

    ▶ In cases where all attempts to find a system micro Building Regulations. leak have failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer. ▶ It is a requirement of the Building Services...

  • Page 11: Mains Supply

    Pre-Installation Mains supply 4.3.1 Single pipe gravity feed system: The oil storage tank [1] must be positioned so that the oil level does not 4.2.1 Electrical supply exceed 4 metres above the level of the burner oil pump [9] and in •...

  • Page 12: Single Pipe Suction Lift With De-Aerator

    Pre-Installation 4.3.3 Single pipe suction lift with de-aerator: • Under no circumstances should a combination isolating/fire valve be used as the sole fire protection device. Maximum suction height 3.5 metres. The oil tank [1] must be positioned below the oil pump [9]. Create an inlet and return loop between the de- 4.3.5 Boiler isolation valve aerator [12] and oil pump [9].
  • Page 13 Pre-Installation Open vent primary system (regular only) Fully pumped sealed primary system: • The open vent pipe [F] and feed and expansion pipe [H must rise • A pressure relief valve [P], spring loaded safety valve set to operate continuously from the appliance. 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 14: Condensate Pipework

    Pre-Installation Filling primary sealed systems Externally run condensate drainage pipe should terminate at a suitable foul water discharge point, or purpose-designed soak away. If this NOTICE: FILLING THE SYSTEM method is chosen then the following measures should be adopted: ▶ The system must not be filled with salt based, ▶...

  • Page 15: Soak Away

    Pre-Installation Where the pipe terminates over an open drain or gully, the pipe should Key to condensate soakaway terminate below the grating level, but above water level, in order to Condensate discharge from boiler minimise “wind chill” at the open end. Universal connector The use of a drain cover (such as those used to prevent blockage by Pipe work transition...

  • Page 16: Boiler Locations And Clearances

    Pre-Installation Boiler locations and clearances 2500mm WARNING: This appliance should not be installed where there is a potential for excessive ground water coverage. This boiler is only suitable for installing externally at a suitable location onto a fixed permanent rigid surface FRONT capable of supporting the boiler weight.
  • Page 17 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 18: Flue Options

    Pre-Installation Flue options 4.9.1 Cabinet mounted balanced horizontal flue options It is strongly recommended that the flue terminal faces away from walls to minimise the occurrence of wetting. • The horizontal flue is fitted to the rear or either side of the cabinet. REAR FLUE OUTLET 6720645523-50.1Wo Plan...

  • Page 19: Installation

    Installation Pipework positions and flue opening Installation REAR 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. ▶...

  • Page 20: Boiler Installation

    Installation Safety ▶ Unplug burner lead [1]from control box. ▶ Unscrew to loosen the retaining ring [4] that secures the flexible air All relevant safety precautions must be undertaken. supply tube [3] to the burner and remove from the burner. Protective clothing, footwear, gloves and safety goggles must be worn as ▶...

  • Page 21: Flue Installation

    Installation Flue installation Combustion chamber (18/25 Regular shown) ▶ Release the screws and remove flue manifold access cover [4]. 5.4.1 Flue damper installation ▶ Check that all the baffles [2] and baffle retainer [3] are correctly fitted to the secondary heat exchanger. NOTICE: Fitting the flue damper Hook the retainer [1] over the end two baffles.

  • Page 22: 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 the boiler.

  • Page 23: 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. NOTICE: Nozzle orifice contamination 500ml ▶ to avoid contamination do not dismantle, clean or touch the nozzle tip Oil burner nozzle Before removing or fitting a new nozzle refer to figure 34:...

  • Page 24: Refitting Components

    Installation Refer to figure 35: Refitting components ▶ Check that the nozzle [1] and the electrode [2] alignment settings WARNING: Flue gas leakage are correct. The seal between the burner and the mounting flange ▶ Ensure that the nozzle [1] is aligned centrally within the combustion must form a gas tight seal to prevent leakage of head [3].

  • Page 25: Electrical

    Installation Fig. 39 Refitting the control panel 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 26 Installation Regular appliance electrical connections. Junction Box/Wiring Centre Control Box Green/Yellow Brown Blue L3 N L2 L1 L3 N L2 L1 Green/Yellow Riello Burner Control Box Fig. 41 Regular wiring diagram Key to components: Remote junction box (10 way). Air pressure switch High limit thermostat Frost thermostat Earth stud...
  • Page 27 Installation System appliance electrical connections. Junction Box/Wiring Centre Control Box Green/Yellow Brown Brown Blue L3 N L2 L1 L3 N L2 L1 Green/Yellow Riello Burner Control Box Fig. 42 System wiring diagram Key to components: Remote junction box (10 way). Air pressure switch High limit thermostat Frost thermostat...

  • Page 28: 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: DANGER: ISOLATE THE 230V ELECTRICITY SUPPLY – Turn on the water to the system feed and expansion cistern and ▶...

  • Page 29: Appliance Drain Points

    ▶ In cases where all attempts to find a micro leak have 2.5 litres of oil until a steady flow of clear uncontaminated oil can be failed, Worcester, Bosch Group supports the use of seen as follows: Fernox F4 leak sealer.

  • Page 30: Pump Adjustments

    Commissioning ▶ Turn on the boiler, set the programmer to ON and turn the room thermostat up to create a demand for heat. The oil level in the de-aerator will drop whilst the oil is being drawn from the tank. If the de-aerator empties and the burner locks out before the oil is drawn from the tank, you will have to prime the de- aerator again.

  • Page 31: Boiler Lock Out Indicator On

    Commissioning ▶ Restart and run for 3 minute intervals until after-spurting stops. 6.4.6 Combustion checks ▶ Start and run the boiler for 20 minutes ▶ Remove sampling point plug [1] to check the smoke reading is between 0-1. If the smoke level is above 1, check the combustion settings are correct and the oil nozzle is in good condition.

  • Page 32: Central Heating

    Commissioning 6.4.7 Central heating ▶ Open all radiator valves. ▶ Set room thermostat to maximum. ▶ Set programmer to ON for CH, OFF for DHW (if applicable). ▶ Turn the thermostat control [1] to max. The demand indicator [2] should illuminate and the burner should be ON with the circulating pump.

  • Page 33: Finishing Commissioning

    • 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. • The householder may be asked to prove the date of installation, that...

  • Page 34: 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 35: Clean The Appliance

    Service and Spares Clean the appliance 7.2.2 Combustion chamber baffle check Refer to figure 61 7.2.1 Cleaning the flue manifold and secondary heat exchanger ▶ Release retaining nuts and washers [3] and remove combustion Refer to figures 60. chamber access door [1]. ▶...

  • Page 36: Clean The Burner

    Service and Spares 7.2.3 Clean the burner ▶ Remove the two hex head screws [1] and remove the air intake cover [2] and clear any debris from the air intake and air damper. ▶ Remove the four screws [3] and remove the suction inlet [4] to gain access to the fan.

  • Page 37: Re-Commission The Burner

    Service and Spares 7.2.4 Re-commission the burner WARNING: Flue gas leakage The seal between the burner and the mounting flange must form a gas tight seal to prevent leakage of potentially dangerous gas from the combustion chamber. ▶ Unless the burner is level when pushing the burner into the flange the O-ring may not seat properly allowing flue gas to escape! ▶...
  • Page 38 ▶ If the appliance is unused and exposed to freezing conditions; shut off all the mains supplies, isolate the boiler and drain the system and boiler, including the secondary heat exchanger. Spares For Worcester Bosch spares refer to the the website at www.worcester- bosch.co.uk/spares 6720809437-29.2Wo Fig. 70...

  • Page 39: 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 40: Heating And Hot Water

    Worcester, Bosch Group cannot be held responsible for costs incurred by persons not deemed to be competent. Measure all 230V tests between Neutral (N) and the pin, wire or terminal specified.

  • Page 41: 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 42: Logic For The 535 Se/Ld Rdb Control Box

    Fault finding and diagnosis Logic for the 535 SE/LD RDB control box Greenstar Danesmoor External ErP+ and External System ErP+ 6720821725 (2018/04)

  • Page 43: Riello Control Box 12/18 Model

    Fault finding and diagnosis Riello control box 12/18 model 8.5.1 Control box LED codes Anomaly types (Burner in stand-by) Lockout types (burner in lockout) Green 0.5s ON / Refer to Fault finding chart, section 8.5.2, go to line number on chart Lock out after 25s RED 0.5s ON RED steady ON...
  • Page 44 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 45: Flame Sensing Photocell 12/18 Models

    Fault finding and diagnosis 8.5.3 Flame sensing photocell 12/18 models To check the correct functioning of the photocell, perform the following actions: ▶ Electrically isolate the burner ▶ Remove the photocell ▶ Connect a voltmeter across the blue and brown wires to the photocell ▶...

  • Page 46: 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 47: Service Interval Record

    Fault finding and diagnosis 8.10 Service interval record Before completing the service Interval record below, ensure that you have carried out the service functions described in this manual. It is recommended that your appliance is serviced annually and that the Always use the manufacturer’s recommended spare parts Service Interval Record is completed and signed.
  • Page 48 0330 123 9119 TRAINING: 0330 123 0166 SALES: 0330 123 9669 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 821725 (2018/04)

This manual is also suitable for:

Worcester greenstar danesmoor external system erp+ 12/18Worcester greenstar danesmoor external regular erp+ 18/25Worcester greenstar danesmoor external system erp+ 18/25Worcester greenstar danesmoor external system erp+ 25/32Worcester greenstar danesmoor external regular erp+ 25/32