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Bosch Worcester Danesmoor Utility Regular ErP+ 12/18, Installation, Commissioning And Servicing Instruction Manual, Page: 51 / 60

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Bosch Worcester Danesmoor Utility Regular ErP+ 12/18 Installation, Commissioning And Servicing Instruction Manual Download Page 51

Fault finding and diagnosis

 Greenstar Danesmoor Utility 

ErP+ 

and Utility System 

ErP+ 

- 6 720 821 720 (2018/04)

51

8.3

Boiler function

These fault finding charts are provided to assist com-
petent and suitably qualified engineers to locate and 
rectify faults. 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.

Summary of Contents for Worcester Danesmoor Utility Regular ErP+ 12/18

Page 1: ...er Conventional Flue Room Sealed Flue Greenstar Danesmoor Utility Regular ErP Utility System ErP 12 18 18 25 25 32 6720809436 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 6 720 821 720 2018 04 ...

Page 2: ...installation 27 5 4 2 Installation notes 27 5 5 Combustion chamber 18 25 Regular shown 28 5 6 Pipework connections 29 5 7 Oil burner and pump 30 5 8 Refitting components 31 5 9 Electrical 32 6 Commissioning 37 6 1 Pre Commissioning checks 18 25 Regular shown 37 6 2 Filling the system 37 6 3 Water treatment 38 6 4 Starting the appliance 38 6 4 1 Single pipe gravity feed system 38 6 4 2 Double pipe ...

Page 3: ...n failuretoinstall correctly could lead to prosecution 1 2 General safety instructions These installation instructions are intended for heating engineers plumbers and electricians Read any installation instructions boiler heating controls etc carefully before starting the installation Observe the safety instructions and warnings Observe national and regional regulations technical rules and guideli...

Page 4: ...aning and user maintenance shall not be made by children without supervision Installation commissioning and servicing Installation commissioning and servicing must only be carried out by a competent registered engineer Only use original spares Advise the user to have the system regularly serviced by a competent qualifiedengineer suchasOFTECregisteredpersonnel using approved spares to help maintain...

Page 5: ... 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 installation of equipment BS 5410 part 1 Code of practice for Oil Fired Boilers BS 799 part 5 Sp...

Page 6: ...um permissible sealed system operating pressure in accordance with WRAS guidelines bar 2 5 2 5 2 5 Flue Exit flue gas mass flow kg hr 29 40 51 Pipework connections Fuel line compression mm 10 10 10 Flow Utility BSP 1 1 1 Flow Utility System mm 22 22 28 Utility flow and optional vent air vent BSP 1 1 1 Return mm 22 22 28 Condensate Polypropylene mm 21 5 21 5 21 5 PRV outlet Utility System mm 15 15 ...

Page 7: ...at output At rated heat output and high temperature regime 1 1 High temperature regime means 60 C return temperature at heater inlet and 80 C feed temperature at heater outlet P4 kW 18 2 25 6 32 3 18 2 25 6 32 3 At 30 of rated heat output andlowtemperatureregime 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 h...

Page 8: ...ty ErP and Utility System ErP 6 720 821 720 2018 04 8 3 4 Layout and components 18 25 System appliance shown Fig 1 System appliance shown 27 26 28 30 29 31 1 2 3 4 6 5 7 8 9 10 11 12 13 14 16 17 18 19 20 21 22 23 24 15 25 32 34 33 6720821720 01 1Wo ...

Page 9: ...t 28 Flue manifold access cover 9 Condensate discharge 29 Combustion chamber access door primary baffle inside 10 Condensate trap 30 Flue gas sampling point 11 Optional oil return position 31 System pressure gauge 12 Oil isolating valve 32 Flue overheat thermostat phial 13 Primary heat exchanger 33 Flue manifold 14 Pump drain point 34 Air pressure switch 15 Burner mount plate 35 Burner lead connec...

Page 10: ...or clip 27 Oil pump behind plastic cover 9 Air inlet casing 28 Lockout reset button on front of burner control box 10 Flexible air duct connecting to air intake 25 on burner 29 Combustion chamber access door 11 Secondary heat exchanger bleed point one on either side 30 One piece baffle arrangement 12 Secondary heat exchanger 31 Combustion chamber 13 Heat exchanger flow pipe 32 Boiler overheat rese...

Page 11: ... See figure 6 for appliance manual vent points 4 1 3 Appliance drain points The appliance can be drained via the primary heat exchanger point 3 There is an additional drain point on the secondary heat exchanger 1 Fig 5 Appliance drain points 1 Secondary heat exchanger drain point 2 Secondary heat exchanger drain hose 3 Primary heat exchanger drain point 4 1 4 Appliance vent points There are two ve...

Page 12: ...pework for the oil system Do not use soldered joints on the oil supply pipework 4 3 1 Single pipe gravity feed system The oil storage tank 1 must be positioned so that the oil level does not exceed 4 metres above the level of the burner oil pump 9 and in addition the oil level must be at least 300mm above the oil pump 9 Where the maximum oil level in the oil storage tank exceeds 4 metres a head br...

Page 13: ... as close to the oil storage tank as possible Fit an oil strainer and water separator to the oil supply pipe near the oil storage tank Fit an additional oil filter 70 μm max filtration size close to the boiler but not inside the boiler casing Fit a fire valve in accordance with BS 5410 The fire valve should be fitted externally to the building with the fire valve sensor located within the applianc...

Page 14: ...d at all the lowest points on the system Air vents are required at all high points on the system Open vent primary system Regular only The open vent pipe F and feed and expansion pipe H must rise continuously from the appliance The feed and expansion cistern E must be positioned to provide a static head S of at least 1 metre above the highest point in the heating system to the water level in the f...

Page 15: ...m per metre to ensure adequate condensate flow 2 The pipework route must allow air to be supplied back to the appliance for correct operation of the condensate trap 3 Connection to a rainwater down pipe must include an air break Also Keepexternalpipeworkasshortaspossibleandnotexceed3metres length External pipework should be increased to a minimum diameter of 32mm and ideally be insulated Minimise ...

Page 16: ...rnally and the pipe diameter should be increased to 32mm before it passes through the wall to the exterior The pipe should be insulatedusingsuitablewaterproofandweatherresistantinsulation if not using a CondenseSure siphon Theexternalpipeshouldtaketheshortestandleastexposedrouteto the discharge point and should fall as steeply as possible away from the boiler with no horizontal runs in which conde...

Page 17: ...heground to the soak away The examples shown on this page run above ground The soak away must use a 100mm Ø plastic tube with two rows of three 12mm holes on 25mm centres and 50mm from the bottom of the tube The holes must face away from the house The tube must be surrounded by at least 100mm of limestone chippings to a depth of 400mm In situations where there are likely to be extremes of temperat...

Page 18: ...e an adequate supply of air Iftheapplianceistobeinstalledinaconfinedspaceorcompartmenttwo air vents are required one at high level and one at low level The minimum free area of each vent is shown opposite and depends whether the air is taken from another room or from outside the building Where the air is taken from another room that room must contain an air inlet as described above Room sealed bal...

Page 19: ...ion External ventilation High level Low level High level Low level 12 18 198 297 99 198 18 25 275 413 138 275 25 32 330 495 165 330 Table 7 Conventional flue Model Internal ventilation External ventilation High level Low level High level Low level 12 18 198 198 99 99 18 25 275 275 138 138 25 32 330 330 165 165 Table 8 Room sealed flue 600mm 300mm 5mm 5mm 380mm 1200mm 1155mm 6720808218 18 1Wo WARNI...

Page 20: ...alexhaust 300mmaboveortoeithersideoftheVeluxwindow The terminal must be at least 1000mm from the Velux when measured horizontally 13 The flue must extend at least 600 mm above the roof and 400mm horizontally from a pitched roof or 500mm in regions with heavy snow fall 14 1500mm clearance to any vertical structure on a roof or open flue or 1 000 to a room sealed flue 15 1000mm below eaves and gutte...

Page 21: ...2 18 and 18 25 100 103mmØ 25 32 130mmØ Unless installing a Worcester Greenstar Oilfit Conventional Flexible flue Because the flue operates at a lower temperature on a condensing boiler comparedtothatofaconventional appliance the fluedraught will be lower Typically the draught will be between 0 5mmwg and 4 4mmwg measured with the flue warm but the burner not firing The actual figure will vary depen...

Page 22: ...cluding the terminal is Horizontal 80 125mm Ø 6000mm excluding 120mm of terminal extending outside the building Vertical 80 125mm Ø 8000mm measured from the boiler top panel Then reduce the total straight flue length for each extra flue bend excluding the vertical flue kit 90 elbow by 1000mm for 90 500mm for 45 Flue extension lengths Horizontal Vertical 80 125mm Ø 1000mm overall length Effective l...

Page 23: ...2 Lift carton up and away from the boiler Remove the plastic bag and upper front protection cover from the boiler and place safely aside Two or more people are required to move the boiler taking care not to damage the boiler panels or the floor Fig 29 Unpacking CAUTION Lifting and carrying Lift only a manageable weight or ask for help When lifting or putting things down bend your knees keep your b...

Page 24: ... models C Condensate outlet 21 5mm Ø D Flue outlet E Oil pipe optional centres F Optional oil line return line connection Fig 30 Top view of Regular boiler pipe connections Fig 31 Front view of Regular boiler pipe connections CAUTION Drilling Ensure there are no pipes electrical cables damp proof courses or other hazards before drilling Forservicingpurposes keepcondensatedischargepipe away from co...

Page 25: ...wall thickness as shown below Fig 35 Flue opening For servicing purposes keep condensate and pressure relief discharge pipes away from components and pipework connections 35 69 48 19 67 48 B All dimensions in are millimetres 6720808218 98 1Wo 370 TOP VIEW PRV A 69 35 67 21 5 100 A C D B PRV FRONT VIEW 825 6720808218 99 1Wo All dimensions in are millimetres 412 E F 321 40 Allhorizontalfluesectionsm...

Page 26: ...t secures the flexible air supply tube to the burner and pull the flexible air supply tube free from the burner see figure 38 Fig 38 Undo and remove the retaining nut J on top of the burner The burner mounting K can now be eased off the lug L on the burner collar to remove the burner from the heat exchanger Store the burner and retaining nut safely away from the boiler Carefully move the boiler in...

Page 27: ...ith the solvent free grease supplied A clamp should be installed for every 1m and at every change of direction Fig 41 Allhorizontalfluesectionsmustrisebyatleast52mmforeachmetre 3 away from the boiler to ensure that condensate flows back into the boiler 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 bo...

Page 28: ...bustion chamber and pushed securely into place Baffle sets for the 18 25 and 25 32 boilers are identified with tabs on the front and rear edge Fig 43 Baffle arrangement 5 Secure baffle combustion chamber access door D with nuts and washers C Tighten until door is firmly secured Do not overtighten the nuts 6 Release the screws H and remove flue manifold access cover I 7 Check that all the baffles J...

Page 29: ...urethattheisolatingvalve H isclosedand routetheoilsupplypipealongtherightsideoftheboilerandconnect to the isolating valve H Condensate connection Connect the 21 5mm polypropylene pipe not supplied to the condensate waste pipe flexible push fit connector F and terminate to waste Do not use any solvents adhesives or lubricants when pushing the pipe into the flexible push fit connector F Ensure that ...

Page 30: ...le 5 are aligned and secure with the screw 3 into the seating provided 7 Reconnect the HT leads 4 Refit the blast tube 2 and secure with the screws 1 Fig 49 Nozzle access Refer to figure 50 Check that the nozzle 1 and the electrode 2 alignment settings are correct Ensure that the nozzle 1 is aligned centrally within the combustion head 3 Inspect for any visible defects Fig 50 Nozzle and electrode ...

Page 31: ... the retaining nut C Tighten sufficiently to hold the burner but do not over tighten Check that the burner is seated correctly on its mounting flange and that the oil hose s are routed correctly as shown in Fig 37 and not trapped in front of or underneath the burner 2 Attach air duct and tighten clip D to secure to the burner air intake Fig 53 Refitting the burner 3 Swing control box back up into ...

Page 32: ... electricity supply is disconnected The mains electrical supply to the boiler and system wiring centre must be common and through either a common fused double pole isolator or a fused three pin plug and unswitched socket The isolator shall be sited next to the boiler for new systemsand wherepracticable replacementboilers The isolator must have a contact separation of 3mm minimum between all poles ...

Page 33: ...2 3 A B D Green Yellow Green Yellow Green Yellow Brown Re 3 2 Grey Grey Brown Brown EARTH LIVE NEUTRAL Blue F 6720809436 21 2Wo 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 F TERMINAL CONNECTOR BLOCK G CONTROL THERMOSTAT H BURNER SOCKET L3 N L2 L1 C E H G ...

Page 34: ...y Grey E Brow Brown Blue F 6720809436 22 2Wo 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 F TERMINAL CONNECTOR BLOCK G CONTROL THERMOSTAT H BURNER SOCKET J BURNER PLUG K BURNER CONTROL BOX L CIRCULATING PUMP G H L3 N L2 L1 L N EARTH LIVE NEUTRAL Riello control box Black Red Gre Green Y...

Page 35: ... refer to manufacturers instructions Mains wiring 230V 50Hz Hot water tank thermostat Room thermostat System water valves Circulating pump External programmer E TERMINAL CONNECTOR BLOCK Remote 10 way junction box K requirements The junction box K 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 K must be fitted external...

Page 36: ...grammer E TERMINAL CONNECTOR BLOCK M PUMP LINK Remote 10 way junction box K requirements The junction box K 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 K must be fitted externally to the boiler A frost thermostat can also be connected to the remote junction box if required If the junction box has a pump overrun fea...

Page 37: ...n completed Monitor the pressure gauge during venting and repressurise if required Check the system and correct any leaks Bleed air from at least one of the secondary heat exchanger air vents a radiator key is ideal for this There are two venting bosses 1 on the top of the secondary heat exchanger Only one can used if fluing to the side Fig 62 Manual vent points 1 Manual vent points each side of t...

Page 38: ... under gravity When completed close the isolating valve reconnect the flexible oil hose When the oil reaches the pump bleed the air from the pump Opentheisolatingvalveandthe oilpumpbleed port 1 todischarge into a suitable container once the boiler is started up Switch on the electricity supply to the boiler Set the programmer to ON for CH and DHW Turn on the boiler CH control thermostat Allow the ...

Page 39: ...4 Return connection 5 Inlet connection 6 Auxiliary pressure gauge port Adjust the air shutter 3 figure 66 and pump pressure 2 figure 65 to the values shown in the table 11 on page 41 The burner should ignite following a pre ignition period of approximately 15 seconds If changing the burner output check the position of the air damper disk 5 is correct to the output values shown in table 11 Fig 66 1...

Page 40: ...4 5 Boiler lockout indicator on If the burner 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 indicator D Wait 2 minutes then press the lockout reset button D figure 71 to initiate anothe...

Page 41: ...high and the baffles are correctlyfitted thenreducetheoilpumppressure B 5 10p s i to compensate for nozzle variations 2 K 6720808218 60 1Wo RIELLO RDB OIL PUMP C B A G D L 6720808218 61 1Wo APPLIANCE MUST BE SET TO CO2 LEVELS AIR SETTINGS GIVEN ARE APPROXIMATE ONLY AS FLUE LENGTH AND NOZZLE VARIATIONS WILL AFFECT THIS Oil pump pressure Fuel flow rate Approx fluegas temp Combustion head settings Ap...

Page 42: ...oad Fig 72 2 Set the room thermostat to minimum Check that any other controls that are fitted to the system are operating properly Fig 73 6 5 Finishing commissioning Pivotthecontrolbox A figure 75upandintotheboiler Securewith screws B Utility system only Refer to figure 74 Slide the expansion vessel up and locate the top edge into the bracket 1 located under the control panel Push the expansion ve...

Page 43: ...e customer how to safely isolate the appliance Advise the customer where they can find information on the Worcester Bosch Group website www worcester bosch co uk Advise the customer that the varying external temperatures will affect the output of the appliance especially the DHW Ensure that the User Guide and Installation Commissioning and Service manual with the Boiler commissioning checklist and...

Page 44: ... service check and note any operational faults 7 2 Pre service checks 1 Pull front panel A forward from the bottom and near the top disengaging the ball studs from their connections B and lift off the ledge C that runs along the bottom of the fascia figure 78 to remove and store safely away from the working area Fig 76 Access to internal components Utility system only In the case of the Utility sy...

Page 45: ...e trap 7 4 Sealed system only The PRV is a safety device and must be checked for correct operation The expansion vessel pressure must also be checked and adjusted if required 7 5 Clean the burner Removethetwohexheadscrews 1 andremovetheairintakecover 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 Clean bot...

Page 46: ...scape into the room 7 8 External oil filter Remove the paper element from the external oil filter and replace it If the filter contains a washable element thoroughly clean in Kerosene and reassemble into the filter 7 9 Combustion chamber 18 25 Regular shown Release the M10 retaining nuts and washers A and remove baffle combustion chamber access door B Check the fibreglass rope seal on the baffle c...

Page 47: ...ked in place Pour 500 ml of water into drain 5 to refill the condensate trap and check that the condensate discharge pipe is discharging Cleanthesecondaryheatexchangerbaffles 4 ifnecessaryandrefit correctly Refit the baffle retainer 3 Check and clean the flue damper ensure that it is correctly fitted Check the seal on the manifold access cover 6 and replace if necessary Refit the flue manifold acc...

Page 48: ...fortherequiredboileroutput Check that the smoke reading is between 0 1 If above 1 check the air setting If the air setting is correct check that the burner has been reassembled correctly Allow the boiler to warm up then check the combustion settings are correct as indicated in table 11 on page 41 ensure CO2 levels are correct Adjust the air shutter if necessary see page 41 figure 71 for details Wh...

Page 49: ...lt finding charts are provided to assist competent and suitably qualified engineers to locate and rectify faults 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 50: ...g charts are provided to assist compe tentandsuitablyqualifiedengineerstolocateandrectify faults 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 51: ...rts are provided to assist com petent and suitably qualified engineers to locate and rectify faults 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 costsincurred bypersonsnot deemed to be competent ...

Page 52: ...Fault finding and diagnosis Greenstar Danesmoor Utility ErP and Utility System ErP 6 720 821 720 2018 04 52 8 4 Logic for the 535 SE LD RDB control box ...

Page 53: ... Table 12 Anomaly types Burner in stand by Green 0 5 s ON Green 2 5 s OFF Pre heating time Fit pre heat link Green 0 5s ON RED 0 5s ON Extraneous light Lock out after 25s Orange steady ON Abnormal frequency supply When an anomaly appears during pre purge the burner remains in pre purge after ignition burner remains in operation When anomalies disappear the burner re starts Orange 0 2s ON Green 0 2...

Page 54: ...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 oil pump No Replace control box 9 Air set correctly Yes Go to line 10 No ...

Page 55: ...you must also check that the oil supply is not obstructed and that the oil supply pipe is correctly sized Accessory 8 716 116 333 0 is available to assist in connecting a vacuum gauge to the vacuum test port Fig 92 Oil pump ports connections 1 Vacuum gauge port 2 Pressure adjuster 3 Bleed and pressure gauge port 4 Return connection 5 Inlet connection 6 Auxiliary pressure gauge port 8 7 Air pressur...

Page 56: ...S7593 and 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 BS5546 BS6789 Yes If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation fitted Yes Cen...

Page 57: ...CO2 ratio F G T C Flue 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 psi Nozzle changed Yes c N...

Page 58: ...Greenstar Danesmoor Utility ErP and Utility System ErP 6 720 821 720 2018 04 58 Notes ...

Page 59: ...Greenstar Danesmoor Utility ErP and Utility System ErP 6 720 821 720 2018 04 59 ...

Page 60: ...Boiler locks out at the start of a demand Heating off over night for example 1 If an air eliminator is being used check that there are no leaks that allow air to be pulled into the oil supply 2 If a two pipe oil supply is a being used has a non return valve beenfittedtotheinletpipe Refertotheinstructionsforguide lines No domestic hot water 1 Is there a domestic hot water demand from the programmer...

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