Bosch Worcester Greenstar Utility 32/50, Installation, Commissioning And Servicing Instruction Manual

Page 1: ...ed condensing appliance conventional flue room sealed flue Greenstar Utility ErP 32 50 50 70 6720821751 00 1Wo 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 6 720 821 751 2018 04 UK ...

Page 2: ... Filling the system 28 6 3 Water treatment 28 6 4 Starting the appliance 28 6 4 1 Priming a single pipe gravity feed systems 28 6 4 2 Priming a double pipe sub gravity feed systems and single pipe suction lift with de aerator 29 6 4 3 Riello RDB burners 29 6 4 4 Appliance lockout indicator on 29 6 4 5 Burner commissioning check 29 6 4 6 Central heating 30 6 5 Combustion and burner settings 30 6 5 ...

Page 3: ...ces which can corrode the appliance and invalidate any warranty Handling instructions and guidelines It is advised that more than one person is involved in the transfer of the packaged appliance from the van to the point of installation It is advised that no attempt should be made to move the packaged appliance without the use of a suitable truck At all times the correct method for handling heavy ...

Page 4: ...nce flue or associated components and systems could invalidate the warranty The manufacturer accepts no liability arising from any such actions excluding statutory rights Electrical work Electrical work must only be carried out by a qualified electrician Before starting electrical work Isolate the mains electrical supply and secure against unintentional re connection Check for zero potential Also ...

Page 5: ...to give optimum efficiency and trouble free operation the appliance must be commissioned by a qualified OFTEC engineer The compliance with a British Standard does not in itself confer immunity from legal obligations In particular the installation of this appliance must be in accordance with the relevant requirements of the following British Standards and regulations in respect of the safe installa...

Page 6: ...Flue Exit flue gas mass flow kg hr 76 106 Conventional flue min diameter required mm 130 130 Room sealed flue diameter mm 100 150 100 150 Pipework connections Fuel line compression mm 10 10 CH flow inch BSP 1 1 CH return mm 28 28 CH vent inch BSP 1 1 Condensate polypropylene mm 21 5 21 5 Electrical Electrical power supply voltage AC V 230 230 Frequency Hz 50 50 Thermostats Appliance flow temperatu...

Page 7: ...me means 60 C return temperature at heater inlet and 80 C feed temperature at heater outlet P4 kW 50 1 71 8 At 30 of rated heat output and low temperature regime 2 2 Low temperature means for condensing boilers 30 C for low temperature boilers 37 C and for other heaters 50 C return temperature at heater inlet P1 kW 15 99 22 90 Useful efficiency At rated heat output and high temperature regime 1 η4...

Page 8: ...7 Condensate pipe connector 8 Condensate drain pipe 9 Condensate trap 10 Oil supply isolation valve 11 Burner mounting flange 12 Primary HE drain point 13 Burner 14 Burner fault indicator reset 15 Combustion chamber access door 16 Primary HE baffle 17 Flue overheat manual reset 18 Overheat manual reset 19 Control knob 20 Control panel 21 Flue manifold access cover 22 Flue gas sample point 23 Secon...

Page 9: ... benecessarytoprovideanuntreatedwaterby passtotheprimarywater filling point of the heat system DANGER Danger to life through electric shock Before carrying out any work on electrical components isolate them from the power supply 230VAC fuse circuitbreaker andsecureagainst unintentional re connection NOTICE Risk of damage to appliance or accessories All the following pre installation sections must ...

Page 10: ...stalled between the tank 1 and the burner oil pump 9 Fig 3 Single pipe feed Maximum pipe run for single pipe gravity feed system 4 3 2 Double pipe sub gravity feed system Maximumsuctionheight3 5metres Non returnvalvesmustbefittedto theinletandreturnoil line between theoil pump 9 andoil storage tank 1 Fig 4 Double pipe feed Maximum pipe run for double pipe sub gravity feed system NOTICE Contaminate...

Page 11: ...erpipeofthecorrectdiameteraccordingtotheinformation shown in oil supply sections 4 3 1 4 3 2 4 3 3 If using soft copper pipe R220 with a compression fitting an insert must be used to prevent the pipe from collapsing or distorting when the fitting is tightened Slide nut 1 and olive 5 onto the oil supply pipe 4 Slide insert 3 into the pipe Offer the pipe to the fitting 2 and tighten the nut 1 Fig 6 ...

Page 12: ...return pipe as close as possible to the appliance and pressurised for the system volume according to the instructions supplied with the vessel A pressure gauge G 3 bar minimum must be fitted to the heating flow pipe or one of the appliance 1 BSP outlets An automatic air vent N must be fitted Fig 8 Typical sealed system A Appliance B Expansion vessel C Automatic bypass valve D Drain cock E Feed and...

Page 13: ...te drain pipe is connected down stream of the waste trap Fig 11 Disposal to a waste pipe CONDENSATE PUMP Where gravity discharge to an internal termination is not physically possible or where very long internal runs would be required to reach a suitable discharge point condensate should be removed using a proprietary condensate pump of a specification recommended by the appliance or condensate pum...

Page 14: ... leaves may offer further protection from wind chill Pipe drainage will be improved if the end is cut at 45 as opposed to a straight cut Fig 14 External disposal Fig 15 External disposal with an air break NOTICE Rainwater or external drain disposal Untreated condensate must not be allowed to flow into streams or rivers A rainwater down pipe or an external drain shall only be used for condensate di...

Page 15: ...ld beconsidered If such a system is used the requirement to use 32mm pipe does not apply However all other guidance above and the instructions for the trace heating system should be closely followed Fig 17 Discharge to a soakaway 4 6 Pressure relief pipework The pressure relief drain pipe K should be at least 15mm diameter copper pipe and run downwards away from the appliance and discharge away fr...

Page 16: ... to a room Both vents must pass to the same room or be on the same wall to the outside air The minimum air vent free area is given in the table 9 4 7 1 Appliance clearances There are several clearances to be considered when either installing or servicing a appliance in an unventilated or ventilated compartment Fig 19 Appliance clearances 4 7 2 Compartments Follow the requirements of BS 5410 and no...

Page 17: ...ding External2 ventilation 2 External air to and from directly outside the building High level Low level High level Low level 32 50 550 825 275 550 50 70 770 1155 385 770 Table 8 Conventional flue Room sealed flue models Internal ventilation1 External ventilation2 High level Low level High level Low level 32 50 550 550 275 275 50 70 770 770 385 385 Table 9 Room Sealed flue 6720821751 02 1Wo 2 1 3 ...

Page 18: ...are the minimum clearances required Terminals must be positioned so to avoid combustion products entering the building Support the flue at approximately one metre intervals and at a change of direction use suitable brackets and fittings Inspiteofthedimensionsgivenhere theterminalmustnotbecloserthan300mmtocombustiblematerial inthecaseofathatched roof double this dimension Terminals must be position...

Page 19: ...nd extending 300mm wider and higher than the tank is between the tank and the terminal 19 For thepurpose of determining suitable flue terminal positionsfor the appliances the boundary can be considered to extend to the centrelineofanyadjacentroutesorwaterwayse g paths streets rights of way canals rivers or railways 4 9 Conventional flue Open conventional flued appliances must not be installed in a...

Page 20: ...lue length Measurethetotalfluelengthrequired noting thatthemaximumstraight flue length including the terminal is Horizontal 100 150mmØ 6400mm excluding 270mm of terminal extending outside the building Vertical 100 150mmØ 10000mm measured from the appliance top panel Then reduce the total straight flue length for each extra flue bend excluding the vertical flue kit 90 elbow by 1000 mm for 90 500 mm...

Page 21: ...urations 32 50 50 70 1 Horizontal flue assembly 630 630 2 Horizontal flue extension 6400 6400 3 Horizontal flue with 1 x 90 bend 6400 6400 4 Horizontal flue with 2 x 45 bends 6400 6400 5 Horizontal side exit flue 4400 5400 6 High level horizontal flue 6400 6400 7 Vertical flue 10000 10000 8 Vertical flue with 2 x 45 bends 10000 10000 9 Rear exit with vertical flue 12000 12000 Table 11 Maximum flue...

Page 22: ... and away from the supporting ledge on the appliance and store away from the working area remove the screws securing the appliance to the transport pallet Fig 26 5 2 Pipework positions and flue opening Safety All relevant safety precautions must be undertaken Protective clothing footwear gloves and safety goggles must be worn as appropriate Pipework positions Fig 27 Pipework position Key to figure...

Page 23: ...lhorizontalfluesectionsmustrisebyatleast52mmforeachmetre away from the appliance to ensure that condensate flows back into the appliance for safe discharge via the condensate waste pipe The horizontal terminal must be installed at 3 to ensure that the condensate drains back to the appliance whilst also preventing rain ingress down the air duct Aflueterminalguardmustbefittediftheflueoutletisbelow2m...

Page 24: ...k connections on the appliance Ensure all pipework is clean Align water pipework and connect to 1 and 2 Check that the unused socket have been capped Oil supply connections Route oil supply pipe 8 along theside of the appliance as required finishing close to the burner Avoid hot surfaces Connect the oil supply pipe 8 to the isolating valve 7 ensure the valve is closed Connect the flexible oil hose...

Page 25: ...on sump 10 Flue manifold access cover 11 Flue manifold access cover screws 12 Primary drain 5 6 Oil burner and pump Riello RDB burners Oil burner RIELLO RDB 3 2 BX 32 50 RIELLO RDB 3 2 BT 50 70 Oil pump Single pipe connection Connecting the oil pump for a single pipe system The pump is factory set for single pipe operation with the flexible oil pipe fitted Check connections before use Oil pump two...

Page 26: ... 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 AlwayscheckthattheO ringsealisingoodcondition before fitting the burner Replace the O ring seal if defective 6720821683 25 1Wo A 1 2 ...

Page 27: ...liance B Remote junction box 10 way to connect the following Mains wiring 230V 50Hz Hot water tank thermostat Room thermostat System water valves Circulating pump External programmer C Appliance control box terminal connector block Remote junction box A requirements This must be a terminal block type current rated to at least 5 amps A 5 amp fuse must be fitted to the mains supply The junction box ...

Page 28: ... the appliance commissioningchecklistand inthe guarantee registration Water treatment products Suitable water treatment products can be obtain from the following manufacturers 6 4 Starting the appliance 1 Check the oil supply is correctly fitted and in good working order before turning on the oil supply valves to the appliance Turn on the main oil supply valve at the tank and draw off at least 2 5...

Page 29: ...ablish 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 indicator reset button 4 Wait 2 minutes then press the lockout indicator reset button 4 to initiate another start sequence Repeat procedure until a fla...

Page 30: ...roperly 6 5 Combustion and burner settings 6 5 1 Burner settings 32 50 appliances burner settings information 50 70 appliances burner settings information 6 720 813 304 37 1TL APPLIANCE MUST BE SET TO CO2 LEVELS AIR SETTINGS GIVEN ARE APPROXIMATE ONLY AS FLUE LENGTH AND NOZZLE VARIATIONS WILL AFFECT THIS Description Unit Values Output appliance kW 32 41 50 Nozzle gph 0 85 1 10 1 25 Nozzle spray an...

Page 31: ...o set 17mm at the combustion head turn the adjustment screw until six notches are visible from the zero 0 notch and then back the adjustment screw off one turn 1mm to achieve 17mm One complete rotation of the adjustment screw A equals one millimetre of movement at the combustion head All distances are measured from the zero 0 notch to the adjustment assembly face X Fig 45 RDB 3 2 BX combustion hea...

Page 32: ...lves Set the programmer to ON for central heating Set the room thermostat to maximum The burner should be ON along with the circulating pump Ensure all radiators are heating up evenly Balance the system to the temperature difference required for the heating flow and return according to the heating load Set the room thermostat to minimum The burner and circulating pump should be OFF Check hot water...

Page 33: ...r To confirmtheguaranteeperiodapplicabletoyour product pleasevisit our website www worcester bosch co uk The guarantee must be registered within 30 days of installation The householder may be asked to prove the date of installation and that the appliance was correctly commissioned This should be documented as a part of the Commissioning Checklist The product must be correctly installed and commiss...

Page 34: ...t the front of the top panel up to disengage the ball stud connections 1 and pull the panel towards you to remove 2 Pull the upper front panel squarely forwards to disengage ball stud connections 2 lift from the bottom edge of the appliance and remove Operatetheapplianceandsystemandnoteanyfaultswhichmayneedto be corrected during the service Switch off and electrically isolate the appliance Loosent...

Page 35: ...quired and baffles and retainer checks are complete Fig 50 7 3 2 Replacing the flue manifold To gain access to the flue manifold Remove the manifold access cover Loosen the hose clip and detach the air duct Disconnect the electrical lead to the dip tube Remove the four bolts securing the manifold to the heat exchanger Discard the old seal fit the one supplied with the new manifold Fig 51 Cross sec...

Page 36: ...at exchanger Fig 56 Tighten bolts 7 3 3 Combustion chamber Remove the six retaining nuts and washers 1 Remove combustion chamber access door 2 Check that the combustion chamber seal 3 is in good condition replace if necessary Remove the baffle 4 check the condition of the baffle clean or replace as necessary Thoroughly clean all of the heat exchanger surfaces using a suitable brush and clear all l...

Page 37: ...iderations Clean fan and housing and check for damage Check and clean the combustion head Replace the oil nozzle Check the ignition electrodes readjust or replace as necessary Refit the combustion head Ensure that the electrode settings are correct Check the pump filter and clean if necessary Check and clean the oil filters replace if necessary Check the condition of the flexibleoil hoses and repl...

Page 38: ...onnect the electrode cables 6 loosen the screw 8 and disconnect the electrode cables Remove the electrode stabiliser unit 3 Secure the nozzle holder 7 in position with a spanner and with another spanner remove the nozzle 4 Still securing the nozzle holder 7 with the spanner fit a new nozzle and tighten with the other spanner Reconnect the electrode cables 6 and tighten screw 8 to secure Reassemble...

Page 39: ... minutes uninterrupted before re commissioning the burner Check Oil pressure is correct for the required appliance output Bacharach smoke reading is between 0 1 If the Bacharach smoke reading is above 1 Check the air settings If the air setting is correct Check that the burner has been reassembled correctly Allow the appliance to warm up then Ensure that the CO2 levels are correct as indicated in ...

Page 40: ...1 or an equivalent form If the appliance is unused and exposed to freezing conditions shut off all the mains supplies Isolate the appliance and drain the system and appliance including the secondary heat exchanger 7 6 Spare parts WARNING Mains supplies Isolate the appliance Turnofftheoilsupplyandisolatethemainselectrical supply before starting any work and observe all relevant safety precautions D...

Page 41: ...r high tension leads if necessary Faulty control box or electrical connections not properly made Correct electrical control box connections or replace control box BURNER FAILS TO START No power to appliance Check electrical control circuit Programmer open circuit Check programmer Faulty appliance thermostat Check by temporarily linking out high limit and control thermostats Faulty control box Repl...

Page 42: ...and eliminate any extraneous light Burner runs normally in the The photocell is dirty Red Clean it pre purge and ignition cycle and The photocell is faulty Steady ON Replace it looks out after about 5 seconds Flame moves away or fails Check pressure and output of the fuel Check air output Check oil nozzle Check the coil of solenoid valve Burner starts with an ignition delay The ignition electrodes...

Page 43: ...econds When anomaly appears the burner does not stop Anomaly types Burner in stand by Table 21 Line Check Action 1 Control box is supplied with heat demand Yes Go to line 2 No Check boiler and system controls 2 Is the pre heater fitted or if no pre heater is fitted is the link fitted Yes Go to line 3 No Fit the Pre Heater or link 3 Motor starts after initialization check time 3 5 seconds Yes Go to...

Page 44: ...5 seconds ON red 0 5 seconds ON before lockout Yes Go to line 5a No Go to line 8b 8b Contaminated fuel filters Yes Clean Replace filters No Go to line 8c 8c Coil lead OK Yes Go to line 8d No Replace solenoid coil lead 8d Solenoid coil resistance 90 to 110 Ω Yes Go to line 8e No Replace solenoid coil 8e After 15 seconds from motor start 25 to 30 Volts d c to solenoid coil coil connected Yes Replace...

Page 45: ...use the air pressure switch to trip bringing the appliance into a lockout state Clear the restriction or blockage Reset by pressing the protruding button 4 on the air pressure switch 1 Flue overheat reset button 2 If the flue gas temperature exceeds the cut off set point the appliance will lockout When the flue has cooled down reset by pressing the protruding cross button the button will click whe...

Page 46: ...d appliance manufacturer s instructions Yes What system cleaner was used What inhibitor was used Quantity litres Has a system filter been fitted Yes No The condensate drain has been installed in accordance with the manufacturer s instructions and or BS5410 Yes If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation fitted Yes Central Heating mo...

Page 47: ...ue pressure F G T C Flue pressure Comments Comments Signature Signature Service 5 Date Service 6 Date Engineer s name Engineer s name Company name Company name Telephone number Telephone number Registration number Registration number Fire valve inspected rated to 85 C Yes No Fire valve inspected rated to 85 C Yes No Nozzle changed Yes No Pump pressure bar psi Nozzle changed Yes No Pump pressure ba...

Page 48: ...l supply Is the flue sized and routed correctly Boiler runs straight to lockout Has the oil line been purged of air Where an air eliminator is used in conjunction with a top feed oil tank the non return valve if fitted should be removed from the oil dip pipe No domestic hot water Is there a domestic hot water demand from the programmer and has the tank reached temperature Is the circulating pump o...