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Installation, Commissioning and Servicing instruction manual
Floor Standing oil-fired Condensing Boiler using Conventional Flue & Room Sealed Flue
Greenstar Danesmoor Utility Regular
& Utility System
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.
2022+
12/18, 18/25, & 25/32
2022+
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Table of Contents
Related Manuals for Bosch WORCESTER Danesmoor Utility Regular 2022+ 12/18
Summary of Contents for Bosch WORCESTER Danesmoor Utility Regular 2022+ 12/18
- Page 1 Installation, Commissioning and Servicing instruction manual Floor Standing oil-fired Condensing Boiler using Conventional Flue & Room Sealed Flue 2022+ Greenstar Danesmoor Utility Regular 2022+ & 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 Refitting components ......34 Key to symbols and safety instructions ....3 Electrical . -
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. ▶...
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Page 5: Installation Regulations
Installation regulations BS EN 12828 Heating systems in buildings. Design for water- Installation regulations based heating systems. The Building Regulations Part G, Part J and L1 England and Wales; Part Complying with the building regulations F, Part G and Part J Section III Scotland; Part L and Part F Northern Ireland. -
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 7731600245 7731600246 7731600247 7731600254 7731600255 7731600256 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 6720821720-01.2Wo Fig. 1 System appliance shown Greenstar Danesmoor Utility 2022+ and Utility System 2022+ - 6 721 846 263 (2022/01) - 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 Riello RDB burner Pressure relief valve Burner control box (behind plastic cover) Air inlet casing Lock out reset button (on the front of the burner control box) Secondary heat exchanger baffles Expansion vessel...
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Page 10: Layout And Components - 18/25 Regular Appliance Shown
Appliance information Layout and components - 18/25 Regular appliance shown Utility Regular 6720821720-02.2Wo Fig. 4 18/25 Regular appliance shown Figure 4 does not include the top, front, and right hand side panel. Control box assembly Optional oil return position Flue manifold access cover Oil isolating valve Flue gas sampling point Burner mounting plate... -
Page 11: Pre-Installation
▶ In cases where all attempts to find a system micro Debris from the system can damage the appliance and leak have failed, Worcester, Bosch Group supports reduce efficiency. Failure to comply with the guidelines the use of Fernox F4 leak sealer. -
Page 12: Oil Supply
Pre-Installation Oil supply Maximum pipe run for single pipe gravity fed system Head (m) 10mmØ 12mmØ Head (m) 10mmØ 12mmØ NOTICE: Contaminated oil supplies can damage the appliance. Failure to ensure that the oil supply is clear of contaminants may invalidate the appliance warranty. ▶... -
Page 13: Pipework
Pre-Installation Water systems and pipework FUEL FLOW RATE 2.5kg/h 5kg/h 10kg/h 10kg/h NOTICE: Head (m) 8mmØ 8mmØ 8mmØ 10mmØ ▶ The boiler should not be allowed to operate with a return temperature of less than 30°C when the system is up to operating temperature. Oil burners cannot modulate to accommodate a reduction in heating loads. - Page 14 Pre-Installation Fully pumped sealed primary system: • A pressure relief valve (P), spring loaded safety valve set to operate 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” BSP outlets. •...
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Page 15: Condensate Discharge
Pre-Installation Condensate discharge 4.5.2 Internal connections In order to minimise risk of freezing during prolonged cold spells, the For correct installation and trouble free operation of the appliance the following methods of installing condensate drainage pipe should be following advice should be followed: adopted, in order of priority. -
Page 16: External Connections
Pre-Installation 4.5.3 External connections FITTING AN EXTERNAL AIR BREAK • Refer to figure 16 when a rain water down pipe is used to dispose of NOTICE: Rainwater or external drain disposal condensate. Untreated condensate must not be allowed to flow into •... -
Page 17: Pressure Relief Pipework
Pre-Installation CONDENSATE SOAK AWAY Pressure relief pipework • The condensate soak away must be sited at least 500mm away from • The pressure relief discharge pipe (1) should be at least 15 mm building footings. diameter copper pipe and run downwards away from the boiler and •... - Page 18 Pre-Installation The minimum free area of each vent is shown opposite and depends Maintenance clearances whether the air is taken from another room or from outside the building. Figure 23 shows the clearances required for maintenance. Where the air is taken from another room that room must contain an air 380mm 1200mm inlet as described above.
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Page 19: Flue Gas System Considerations
Pre-Installation Rooms containing a bath or shower Flue gas system considerations WARNING: Conventional flues CAUTION: Non accessible flue systems: ▶ Conventional flue boilers must not be installed in a ▶ Where a flue system is not going to be accessible, bathroom provision must be made for service and inspection. - Page 20 Pre-Installation • Avoid discharging flue gases into car ports or narrow passageways. 1500 RIDGE VENT RIDGE FLUE 1500 1500 1500 1500 2000 BOUNDARY LINE DORMA SKYLIGHT OPENING OPPOSITE 1500 1500 1000 1500 2000 2000 2500 1500 1500 1000 1200 1500 1000 1000 2500...
- Page 21 Pre-Installation 13. 300mm adjacent to a boundary line unless it will cause a nuisance. NOTICE: BS 5410: Part 1 recommended that care is taken when siting ▶ All measurements are the minimum clearances terminal in relation to boundary lines. required. 14.
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Page 22: Flue Options
Pre-Installation Flue options 4.9.1 Conventional flue (CF) • Open (conventional) flued appliances must not be installed in a bedroom, bathroom, bed-sitting room, or garage. • The flue system must be in accordance with BS 5410 : Part 1 and the current Building Regulations. -
Page 23: 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. • To achieve the maximum flue length (L), a flue section will have to be L = 120 - 240mm reduced in length. -
Page 24: 4.10 Plume Management
Pre-Installation 4.10 PLUME MANAGEMENT FLUE TERMINAL GUARD ±45° 7 716 191 176 2500 2500 ≥140 ≥ 5 ≥ 5 0 0 5 0 0 ±80° EXCLUSION ZONE A EXCLUSION ZONE A EXCLUSION ZONE A 1000 2500 1000 2500 2500 1000 1800 1200 BOUNDARY LINE... - Page 25 Pre-Installation 12. The distance between a boundary facing a terminal can be measured diagonally from the point of discharge with a minimum distance of 600mm which must be maintained. The exclusion zone ensures compliance with Approved Document J of the building regulations, 13.
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Page 26: 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 27: 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 28 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...
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Page 29: 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 30: 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 31: 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 32: 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 33: 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 34: 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 35: 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 36 Installation Utility - 230V Standard wiring diagram 1 2 3 = EARTH Green/Yellow = LIVE = NEUTRAL Grey Key to components: Brown A - EARTH STUD B - HIGH LIMIT THERMOSTAT C - AIR PRESSURE SWITCH D - BOILER MANUAL RESET OVERHEAT THERMOSTAT E - FLUE MANUAL RESET OVERHEAT THERMOSTAT...
- Page 37 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 38 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 39 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 • = EARTH (refer to manufacturers instructions): > Mains wiring 230V 50Hz. •...
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Page 40: 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 41: 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 [1]. failed, Worcester, Bosch Group supports the use of ▶ Switch off the boiler. Fernox F4 leak sealer. -
Page 42: Pump Adjustments
Commissioning Fig. 63 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 43: Boiler Lockout Indicator On
Commissioning 6720808218-59.1Wo Fig. 68 6.4.6 Combustion checks ▶ Start and run for 20 minutes ▶ Remove sampling point plug (K) 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. 6720808218-60.1Wo Fig. - Page 44 Commissioning 6720809437-34.2Wo Fig. 70 APPLIANCE MUST BE SET TO CO LEVELS. AIR SETTINGS GIVEN ARE APPROXIMATE ONLY, AS FLUE LENGTH AND NOZZLE VARIATIONS WILL AFFECT THIS. Nominal boiler rating at normal operating temperature using Kerosene (Class C2) Approx Oil pump Fuel flow flue gas Combustion...
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Page 45: Central Heating
Commissioning 6.4.7 Central heating Finishing commissioning 1. Open all radiator valves. ▶ Pivot the control box (A) figure 74 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 46: 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. • The householder may be asked to prove the date of installation, that... -
Page 47: 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 48: 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 49: Pump Filter
Service and Spares ▶ Use a suitable spanner to stop the nozzle body turning ▶ Remove the nozzle [8]and secure the new nozzle, hand tight 3 ± 0.3mm ▶ Tighten the nozzle utilising the two spanners used during removal, do not over-tighten 4 ±... -
Page 50: Oil Supply System And Tank
Service and Spares 7.10 Oil supply system and tank ▶ The oil pipeline, filters, fire valve and tank should be inspected and maintained in accordance with OFTEC regulations. 7.11 Clean the boiler - Manifold access Refer to figure 87. ▶ Release screws [1] to remove the flue manifold access cover [2] and clear any debris. -
Page 51: Re-Commissioning The Burner
Service and Spares 7.12 Re-commissioning 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 52: After Service Hand Over
7.14 Spares For Worcester Bosch spares refer to the the website at www.worcester- bosch.co.uk/spares Greenstar Danesmoor Utility 2022+ and Utility System... -
Page 53: 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 54: 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 55: 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 56: 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 2022+ and Utility System 2022+ - 6 721 846 263 (2022/01) -
Page 57: 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 58 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 ...
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Page 59: 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 60: 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 61: 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 62 Notes Greenstar Danesmoor Utility 2022+ and Utility System 2022+ - 6 721 846 263 (2022/01)
- Page 63 Greenstar Danesmoor Utility 2022+ and Utility System 2022+ - 6 721 846 263 (2022/01)
- Page 64 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 6 721 846 263 (2022/01)