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Worcester Greenstar utility 32-50kW Instruction Manual

Floor standing oil-fired condensing boiler conventional flue & room sealed flue installation commissioning & servicing
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Summary of Contents for Worcester Greenstar utility 32-50kW

  • Page 1 GB/IE GB/IE GB/IE GB/IE...
  • Page 2 WORCESTER BOSCH: WATER TREATMENT: ABBREVIATIONS USED IN THIS MANUAL: FLUE TERMINAL GUARDS: OIL FIRING TECHNICAL ASSOCIATION: CONVENTIONAL FLUE MANUFACTURERS: SYMBOLS USED IN THIS MANUAL: IMPORTANT HANDLING INSTRUCTIONS: GENERAL HANDLING GUIDELINES: Store the appliance in a dry area prior to installation.

  • Page 4: Health And Safety

    OIL SMELLS, LEAKS OR FUMES FROM THE APPLIANCE: HEALTH & SAFETY: COMBUSTIBLE AND CORROSIVE MATERIALS: FITTING & MODIFICATIONS: SERVICING:...

  • Page 5: Standard Package

    STANDARD PACKAGE:...
  • Page 8 CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. CLEANING THE PRIMARY SYSTEM:...

  • Page 9: Electric Supply

    ELECTRIC SUPPLY:...

  • Page 10: Oil Supply

    OIL SUPPLY: Note: All dimesions are in metres unless stated otherwise. The maximum pipe run figures are based on using copper pipe with an inside diameter of 2mm less than the Ø. a) Single pipe gravity feed system: b) Double pipe sub-gravity feed system: c) Single pipe suction lift with de-aerator: A top feed oil tank fitted with a de-aerator using an internal non-return valve should have any non-...

  • Page 11: Plastic Pipework

    PLASTIC PIPEWORK: TYPICAL OPEN VENT SYSTEM: PRIMARY SYSTEM/CONNECTIONS/VALVES: OPEN VENT PRIMARY SYSTEM: TYPICAL SEALED SYSTEM: FULLY PUMPED SEALED PRIMARY SYSTEM:...

  • Page 12: Filling Primary Systems

    FILLING PRIMARY SYSTEMS:...

  • Page 13: Condensate Pipework

    CONDENSATE PIPEWORK: A condensate trap is supplied with the boiler for external installation. PRESSURE RELIEF PIPEWORK:...
  • Page 14 a: INSTALLATION & SERVICE CLEARANCES a: INSTALLATION & SERVICE CLEARANCES: Air supply - CF (Conventional flue): b: COMPARTMENTS: Conventional flue appliances: Venting compartments: MINIMUM AIR VENT AREA (cm²) FOR APPLIANCES INSTALLED IN A COMPARTMENT: *Internal air to and from a space/room inside the building. **External air to and from directly outside the building Conventional flue: Room Sealed flue:...
  • Page 15 SHOWER / BATHROOMS:...
  • Page 16 See 'Contact Information' on the inside front cover Not applicable for flue guard information. N/A Not allowed CF Conventional flue RS(H) Room Sealed Horizontal flue RS(V) Room Sealed Vertical flue 1 An opening means an openable element, such as an openable window, or a permanent opening such as a permanently open air vent.
  • Page 17 NOTE: The flue can be increased in size from the boiler take off point providing the joint is correctly sealed. Never reduce the flue diameter from the boiler take off point Manuafacturers of conventional flue systems suitable for this appliance are listed under 'Contact Information' on the inside front cover.
  • Page 18 Calculating the flue length: Flue Extension lengths: Flue Terminal lengths:...

  • Page 19: General Handling Guidelines

    IMPORTANT: All the previous Pre-Installation sections must be read and requirements met before starting boiler or flue installation. Unpacking: GENERAL HANDLING GUIDELINES: THIS BOILER IS NOT SUITABLE FOR ROOF SPACE OR EXTERNAL INSTALLATION.

  • Page 20: Flue Opening

    CAUTION: Ensure there are no pipes, electric cables, damp proof course or other hazards before drilling. SAFETY: PIPEWORK POSITIONS: NOTE: For servicing purposes, keep the condensate and pressure relief discharge pipes away from components and pipework connections. FLUE OPENING: NOTE: all horizontal flue sections must rise away from the boiler by 52mm per metre to ensure that condensate flows back into the boiler for safe discharge via the condensate waste pipe.

  • Page 22: Installation Notes

    RS FLUE KITS & COMPONENTS: Greenstar Oilfit 100/150mmØ (not supplied): CF FLUE KITS & COMPONENTS: Greenstar Oilfit 130mmØ (not supplied): INSTALLATION NOTES:...
  • Page 23 Secondary heat exchanger: * Five of the slots do not have baffles. Combustion chamber: 32/50kW 50/70kW...

  • Page 24: Water Connections

    CAUTION: ISOLATE THE OIL & WATER MAINS SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. WATER CONNECTIONS: Note: that surplus water may be present due to factory testing. OIL SUPPLY CONNECTIONS: CONDENSATE CONNECTION:...

  • Page 25: Oil Pump

    32/50kW 50/70kW STERLING 133 BURNER SETTINGS: STERLING 146 BURNER SETTINGS: CAUTION: ISOLATE THE OIL MAINS SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.OIL BURNER: OIL PUMP: The burner is factory set for a single pipe system. Converting the oil pump to a double pipe system: 32/50kW 50/70kW...
  • Page 27 DANGER - 230v: ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. Access to 230v connections: 230v 230v connections: Route the power cable to the connection point avoiding any potentially hot surfaces. 230v Allow sufficient cable for the control panel (A) to be pulled forward for servicing.
  • Page 28 230v STANDARD WIRING DIAGRAM: Key to components: 1 2 3 3 5 1...
  • Page 29 PRE-WIRED REMOTE 3 or 2 PORT VALVE CONTROL SETS: Key to components: Remote junction box (A) requirements: A frost thermostat can also be connected to the remote juction box if required. 1 2 3...
  • Page 30 CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.
  • Page 32 32/50kW 50/70kW DANFOSS BFP 11 L3 OIL PUMP DANFOSS BFP 52E L3 OIL PUMP Air will be automatically vented when the boiler is started up. BURNER LOCKOUT/RESET...
  • Page 33 Boiler lockout indicator on: If the boiler fails to establish a normal firing pattern or flame failure 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 reset button (E).
  • Page 34 Central heating: The burner should be ON with the circulating pump. The burner and circulating pump should be off.
  • Page 35 FLUSHING (Central Heating): INHIBITOR (Central Heating): NOTE: The concentration level of inhibitor in the system should be checked every 12 months or sooner if system content is lost. The addition of sealing agents to the system water is not recommended as this can cause problems with deposits left in the heat exchanger.
  • Page 36 Handover: Note: Release drain point (K) to drain the secondary heat exchanger.
  • Page 37 CAUTION: ISOLATE THE WATER, ELECTRICITY AND OIL MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. Routine servicing: To assist efficient boiler operation, the following should be carried out at least once a year. Operate the appliance and system and note any faults which may need to be corrected during the service.
  • Page 38 32/50kW 50/70kW STERLING 133 BURNER SETTINGS: STERLING 146 BURNER SETTINGS: 1 Clean the Burner: 2 Inspection of Mechanical Shut-off Valve: 50/70kW 32/50kW DANFOSS BFP 52E L3 OIL PUMP DANFOSS BFP 11 L3 OIL PUMP External oil filter:...
  • Page 39 Clean the boiler: 32/50kW 50/70kW Fire valve:...
  • Page 40 Re-commission the burner: Refit panels: After service handover:...

  • Page 42: Boiler Lockout

    BOILER LOCKOUT:...
  • Page 44 Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW Worcester, Bosch Group is a trading name of BBT Thermotechnology UK Ltd.

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Greenstar utility50/70kw

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