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Bosch WORCESTER Greenstar Danesmoor 18/25 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
ErP+
Greenstar Danesmoor Kitchen Regular
ErP+
& Kitchen 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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Summary of Contents for Bosch WORCESTER Greenstar Danesmoor 18/25

  • Page 1 Installation, Commissioning and Servicing instruction manual Floor Standing oil-fired Condensing Boiler Conventional Flue & Room Sealed Flue ErP+ Greenstar Danesmoor Kitchen Regular ErP+ & Kitchen 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.

  • Page 2: Table Of Contents

    Contents Contents Key to symbols and safety instructions ....3 Commissioning ........40 Key to symbols .

  • 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 Installation regulations Complying with the building regulations This heating appliance forms part of the controlled services for the The Building Regulations Part G, Part J and L1 England and Wales; Part building. It is law that all controlled services for buildings must comply F, Part G and Part J Section III Scotland;...

  • Page 6: Appliance Information

    Appliance information Appliance information General information Technical data Standard package: Description Units 12/18 18/25 25/32 A - Floor standing oil fired condensing boiler Central heating B - Literature pack: Central heat output (max) Primary water capacity (total) litres • Greenstar Danesmoor Installation, Commissioning and Servicing instruction manual Max.static head (Regular only) 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 7731600159 7731600161 7731600163 7731600160 7731600162 7731600164 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 6720821686-01.1Wo Fig. 1 System appliance shown Greenstar Danesmoor Kitchen ErP+ and Kitchen System ErP+ -6 720 821 686 (2018/04)
  • Page 9 Appliance information Figure 1 does not include the top, front, and right hand side panel. Flue overheat thermostat phial Expansion vessel bracket Pressure relief valve Expansion vessel Air inlet casing Location of optional programmer Heat exchanger flow pipe Quick reference guide slot Secondary heat exchanger Lock out indicator Secondary heat exchanger baffles...

  • Page 10: Layout And Components - 18/25 Regular Appliance Shown

    Appliance information Layout and components - 18/25 Regular appliance shown 6720821686-04.1Wo Fig. 4 18/25 Regular appliance shown Greenstar Danesmoor Kitchen ErP+ and Kitchen System ErP+ -6 720 821 686 (2018/04)
  • Page 11 Appliance information Figure 4 does not include the top, front, and right hand side panel. Control box assembly One piece baffle arrangement Flue manifold access cover Base plate and oil drip tray Flue gas sampling point Primary heat exchanger drain Secondary heat exchanger Burner air intake - connected by flexible duct to air inlet casing Casing side panel...

  • Page 12: Pre-Installation

    ▶ In cases where all attempts to find a system micro ▶ Sealed systems only: leak have failed, Worcester, Bosch Group supports – Fill the system to between 1 and 1.5 bar via a WRAS approved the use of Fernox F4 leak sealer.

  • Page 13: Artificially Softened Water

    Pre-Installation Water treatment products Oil supply Suitable water treatment products can be obtain from the following NOTICE: Contaminated oil supplies can damage the manufacturers: appliance. ADEY 01242 546717 Failure to ensure that the oil supply is clear of www.adey.com contaminants may invalidate the appliance warranty. FERNOX 0870 601 5000 ▶...

  • Page 14: 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 15: 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 16: 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 17: 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 18 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 19: 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 15mm 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 20: 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 bathroom 0 m m 1 2 0 WARNING: Electric shock 6 0 0 ▶...
  • Page 21 Pre-Installation Key to illustration 22: 1500mm vertically between terminals and the same wall. 1000mm below eaves, gutters, pipes and drains. External flue joints must be sealed with suitable silicon sealant. 1,500mm measured horizontally between a vertical flue terminal and a window, dormer window or opening. 1,200mm between terminals facing each other.
  • Page 22 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 Fig. 27 Flue terminal positions Greenstar Danesmoor Kitchen ErP+ and Kitchen System ErP+ -6 720 821 686 (2018/04)

  • Page 23: 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 24: Room Sealed Flue Options

    Pre-Installation 4.9.2 Room sealed flue options Figure 29 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 25: 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 26 Installation Pipework connections - Regular Pipework connections - System A - Flow connections (optional combined feed and vent) 1” BSP A - Flow connections 12/18 & 18/25 - 22mm Ø , 25/32 - 28mm Ø B - Return connections 22mmØ copper on 12/18, 18/25 models and B - Return connections 22mmØ...

  • Page 27: 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 28: Flue Installation

    Installation 3. Unscrew to loosen the retaining ring (H) that secures the flexible air 5.4.1 Flue damper installation supply tube to the burner and pull the flexible air supply tube free NOTICE: Fitting the flue damper from the burner (see figure 39). Failure to fit the flue damper, when required will effect the performance of the boiler and may cause “Lockouts”...

  • Page 29: Installation Notes

    Installation 5.4.2 Installation notes Combustion chamber (18/25 Regular shown) ▶ If using an extension or horizontal terminal onto the boiler outlet, 1. Remove the control box securing screws (A, bottom screw both remove the flue elbow retaining bracket [6]. sides) and loosen the pivot screws (B, top screw both sides). 2.

  • Page 30: Pipework Connections

    Installation 3. Release retaining nuts and washers (C). Pipework connections Remove baffle/combustion chamber access door (D). CAUTION: MAINS SUPPLIES 4. Ensure one piece baffle set (E) is in the right location (F), correctly ▶ Isolate the oil & water mains supply before starting resting on the baffle rests (G) on either side of the combustion any work and follow all relevant safety precautions.
  • Page 31 Installation Water connections Fire valve Where required, check that the oil supply pipe has a fire valve fitted Surplus water may be present due to factory testing. 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 ▶...

  • Page 32: Oil Burner And Pump

    Installation Oil burner and pump Burner head adjustment The burner head adjustments are made to achieve the required output CAUTION: MAINS SUPPLIES from the burner. The adjustments are made via a thumb-wheel on the ▶ Isolate the oil & water mains supply before starting burner.

  • Page 33: Refitting Components

    Installation Refitting components 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 gases 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 34 Installation Optional Worcester 230V programmer 5. Remove blanking plate (H). ▶ Set the pin on the rear of the programmer to ‘pumped’. ▶ Remove link (G) from connection 8 and 9. ▶ Clip the programmer (I) in position and connect programmer plug J into terminals 7 to 10.
  • Page 35 Installation 230V Standard wiring diagram Brow N1 1 2 3 4 5 6 Green/Yellow White Green/Yellow Brow 7 8 9 10 Grey Grey PUMP SYSTEM BOILER ONLY Brow Brow Brow Brow Green/Yellow Black = EARTH = LIVE = NEUTRAL L3 N 6720808218-47.2Wo Fig.
  • Page 36 Installation Pre-wired remote 2 or 3 port valve control set using internal programmer • = EARTH Key to components: • = LIVE Remote junction box (10 way) • = NEUTRAL to connect the following: • = SWITCHED LIVE > Mains wiring 230V 50 Hz >...
  • Page 37 Installation Pre-wired remote 2 or 3 port valve control set using remote programmer • = EARTH • = NEUTRAL Key to components: • = SWITCHED LIVE Remote junction box (10 way) to connect the following: > Mains wiring 230V 50 Hz >...
  • Page 38 Installation 2 Port valve control set Terminator connector block (G): > Remove link 1 to 3. Brown > Remove link 2 to 4. Blue > Make link 3 to 4. Optional 230V Worcester programmer (P): > Set the pin on the rear of the programmer = EARTH to ‘pumped’.
  • Page 39 Installation 3 Port valve control set Terminal connector block (G): > Remove link 1 to 3. = EARTH > Remove link 2 to 4. = LIVE > Make link 3 to 5. = NEUTRAL Optional 230V Worcester programmer (P): Blue >...

  • 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

    ▶ Switch off the boiler. content is lost. ▶ In cases where all attempts to find a micro leak have failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer. Water treatment products Suitable water treatment products can be obtain from the following...

  • Page 42: 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 43: 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 10 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 [H].

  • Page 44: Combustion Checks

    Commissioning 6.4.6 Combustion checks ▶ Turn off the electrical supply. ▶ Isolate the oil supply to the burner. ▶ Start and run the boiler for 20 minutes. ▶ Remove the oil pressure gauge. ▶ Remove the sampling point plug [1] to check the smoke reading is ▶...

  • Page 45: Central Heating

    Commissioning 6.4.7 Central heating Finishing commissioning 1. Open all radiator valves. ▶ Pivot the control box [1] up and into the boiler and tighten the pivot screws [2] on both sides of the control box. ▶ Set room thermostat to maximum. ▶...

  • 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

    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 48: Service Requirements

    Service and Spares Service requirements Oil burner nozzle See the following instructions for detail of some of the service Before removing or fitting a new nozzle refer to figure 86: requirements listed below: ▶ Remove the screws [1] from the blast tube [2] and remove the blast ▶...

  • Page 49: Pump Filter

    Service and Spares Pump filter ▶ Refer to figure 88 and remove the oil pump internal filter, clean in Kerosene and reassemble. The internal filter is accessed by removing screws [1] and the oil pump cover [2]. 6720821683-17.1Wo Fig. 88 Pump filter access ▶...

  • Page 50: Oil Supply System And Tank

    Service and Spares 7.10 Oil supply system and tank 7.12 Re-commissioning the burner ▶ The oil pipeline, filters, fire valve and tank should be inspected and WARNING: Flue gas leakage maintained in accordance with OFTEC regulations. The seal between the burner and the mounting flange must form a gas tight seal to prevent leakage of 7.11 Clean the boiler - Manifold access...

  • Page 51: After Service Hand Over

    3. Locate the top edge of panel (G) onto the supporting ledge (H) and secure near the top and at the bottom by gently pushing home the For Worcester Bosch spares refer to the the website at www.worcester- ball studs into the retaining slots (I). Remember always to apply bosch.co.uk/spares...

  • Page 52: 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 53: 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 Kitchen...

  • Page 54: 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 55: Logic For The 535 Se/Ld Rdb Control Box

    Fault finding and diagnosis Logic for the 535 SE/LD RDB control box Greenstar Danesmoor Kitchen ErP+ and Kitchen System ErP+ - 6 720 821 686 (2018/04)

  • Page 56: 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 57 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 58: Flame Sensing Photocell 12/18 Models

    Fault finding and diagnosis 8.5.3 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 59: 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 60: 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 61 Notes Greenstar Danesmoor Kitchen ErP+ and Kitchen System ErP+ - 6 720 821 686 (2018/04)
  • Page 62 Notes Greenstar Danesmoor Kitchen ErP+ and Kitchen System ErP+ -6 720 821 686 (2018/04)
  • Page 63 Greenstar Danesmoor Kitchen ErP+ and Kitchen System ErP+ - 6 720 821 686 (2018/04)
  • 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 6 720 821 686 (2018/04)

This manual is also suitable for:

Worcester greenstar danesmoor 12/18Worcester greenstar danesmoor 25/32

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