Worcester GREENSTAR UTILITY 18/25 Instruction Manual Download Page 1

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INSTRUCTION MANUAL

INSTALLATION, COMMISSIONING & SERVICING

FLOOR STANDING OIL FIRED CONDENSING BOILER CONVENTIONAL

FLUE & ROOM SEALED FLUE

GREENSTAR UTILITY
18/25

FOR FULLY PUMPED OPEN VENT OR SEALED CENTRAL HEATING SYSTEMS

AND DOMESTIC HOT WATER CYLINDERS

THE APPLIANCE IS FOR USE WITH KEROSENE

(28 SECOND OIL) ONLY

8 716 106 256 C 03.10 30/3/10 14:24 Page 1

Summary of Contents for GREENSTAR UTILITY 18/25

Page 1: ...ED CONDENSING BOILER CONVENTIONAL FLUE ROOM SEALED FLUE GREENSTAR UTILITY 18 25 FOR FULLY PUMPED OPEN VENT OR SEALED CENTRAL HEATING SYSTEMS AND DOMESTIC HOT WATER CYLINDERS UK THE APPLIANCE IS FOR US...

Page 2: ...nd registered installers are able to certify that their work complies with building regulations Under the scheme OFTEC must be informed about every installation OFTEC will issue a building regulations...

Page 3: ...6 CONVENTIONAL FLUE 17 ROOM SEALED FLUE OPTIONS 18 INSTALLATION UNPACKING THE BOILER 19 PIPEWORK POSITIONS FLUE OPENING 20 BOILER INSTALLATION 21 FLUE INSTALLATION 22 COMBUSTION CHAMBER 23 PIPEWORK CO...

Page 4: ...ompetent person The person installing the appliance should be aware of the Health and Safety at Work Act and take appropriate action to ensure that the regulations are adhered to In order to give opti...

Page 5: ...vent and sealed domestic central heating and mains fed hot water B Literature pack C Hardware pack including Condensate trap D Return pipe kit 855mm 600mm 370mm Check List Hardware Literature pack It...

Page 6: ...Return mm Primary drain optional feed and expansion feed BSP Condensate polypropylene mm Electrical Electrical power supply voltage AC V Frequency Hz Max power consumption W Thermostats Boiler flow t...

Page 7: ...8 REAR CABINET SUPPORT BRACKET 19 OIL ISOLATION VALVE 20 PRIMARY HEAT EXCHANGER 21 INTERNAL CONDENSATE TRAP 22 CONDENSATE OUTLET 23 BASE PLATE 24 COMBUSTION CHAMBER ACCESS DOOR 25 OVERHEAT RESET BUTTO...

Page 8: ...SYSTEM Cleanse the system in accordance with BS 7593 Fill the system with cold mains water to the recommended pressure and check for leaks Open all drain cocks and drain the system Close drain cocks...

Page 9: ...th at least a 3mm contact separation in both poles supplying the appliance Wiring between the appliance and the electrical supply must comply with IEE wiring regulations and any local regulations whic...

Page 10: ...es Install a manual isolating valve B to the oil supply pipe H as close to the oil storage tank A as possible Fit an oil strainer and water separator C to the oil supply pipe near the oil storage tank...

Page 11: ...s must be fitted with lockshield valves and left open All installations should have TRVs fitted to radiators within the sleeping accommodation An automatic bypass valve must be connected between the h...

Page 12: ...AS approved Heating return Hose return Non return valve Non return valve Test cock Stop cock Water main supply Stop cock Temporary hose Heating return Auto air vent Non return valve Stop cock Make up...

Page 13: ...of potentially harmful flue products escaping via the condensate route A Condensate from the boiler condensate trap supplied which has a 75mm minimum water seal B Sink C 21 5mm polypropylene condensa...

Page 14: ...evel either direct to outside air or 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 opposite a INSTALLAT...

Page 15: ...be taken from a room or internal space containing a bath or shower and must not communicate with a protected area such as a hall stairway landing corridor lobby shaft etc Air vents must allow access...

Page 16: ...d extending 300mm higher and wider than the tank is provided between the tank and the terminating position 4 Where a flue is terminated less than 600mm away from a projection above it and the projecti...

Page 17: ...ust be sealed to prevent the leakage of condensate and combustion products Ensure that joints are made so that the condensate runs away and is not collected within the joint NOTE The flue can be incre...

Page 18: ...e bend 45 E Vertical Terminal Kit incl 90 elbow Calculating the flue length Measure the total flue length required noting that the maximum straight flue length including the terminal is Horizontal 80...

Page 19: ...ection cover from the boiler and place safely aside 3 Pull base of front panel E away from the boiler to disengage ball stud connectors Lift front panel E upwards off the top supporting ledge and stor...

Page 20: ...y 52mm for every 1000mm of horizontal length that the flue opening is away from the boiler NOTE All horizontal flue sections must rise away from the boiler by 52mm per metre to ensure that condensate...

Page 21: ...y away from the boiler 7 Release split pin to remove the flue thermostat M from the flue hood 8 Release split pins P Carefully remove the overheat thermostat phial Q automatic reset from the rear heat...

Page 22: ...lbow Insert the flue elbow with its clamp loosely fitted then tighten the bracket screws N Clamp the elbow when adjusted to its required orientation If using an extension or horizontal terminal onto t...

Page 23: ...ighten using the sequence shown in figure 3a until the chamber door is firmly secured do not over tighten the nuts 4 Unscrew screws E and remove flue manifold access cover F 5 Check that all the baffl...

Page 24: ...ly pipe D along either side of the boiler as required and connect to the isolating valve E ensure the valve is closed NOTE Replace flexible hose at annual service to prevent possible oil leakage Conne...

Page 25: ...a DANFOSS BFP 11 L3 Remove pump front cover A ensuring a suitable receptacle is used to catch any oil residue Remove changeover screw B Remove horseshoe washer C Refit changeover screw B Refit front...

Page 26: ...split pin 4 Align burner combustion head N into boiler housing tube with gasket O correctly fitted Push firmly down to compress the gasket O Tighten burner retainers H sufficiently to ensure a good s...

Page 27: ...te wires from cable end and strip to 6mm 230V connections 3 Connect SWITCHED LIVE wire Brown to terminal L Connect NEUTRAL wire Blue to terminal N Connect EARTH wire Green Yellow to the terminal Route...

Page 28: ...INSTALLATION ELECTRICS 230V STANDARD WIRING DIAGRAM Key to components A EARTH STUD B HIGH LIMIT THERMOSTAT C BOILER MANUAL RESET OVERHEAT THERMOSTAT D FLUE MANUAL RESET OVERHEAT THERMOSTAT E TERMINAL...

Page 29: ...e following 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 O requiremen...

Page 30: ...y fitted and the connections are secure 4 Check the condensate pipework is correctly fitted and connected Check the condensate trap is filled with water IMPORTANT If the boiler is not to be commission...

Page 31: ...Monitor the pressure gauge during venting and repressurise if required 3 Vent all radiators retighten when completed Check the system and correct any leaks Bleed air from at least one of the secondary...

Page 32: ...ct a spare flexible oil hose I to discharge into container H Open the isolating valve turn on the power to the boiler and set the programmer to ON Prime the de aerator until there is a steady flow of...

Page 33: ...button E to initiate another start sequence Repeat procedure until a flame is established 3 Start and run for 3 minutes then switch off Check for after spurting from the nozzle indicated by oil satura...

Page 34: ...ly and balance the system to the temperature difference required for the heating flow and return according to the heating load 2 Set the room thermostat to minimum The burner and circulating pump shou...

Page 35: ...conditions to the heating system in accordance with the manufacturers instructions The inhibitor or combined inhibitor anti freeze must not cause damage to the materials within the boiler mild steel s...

Page 36: ...the Guarantee Registration Card Combustion Record at the rear of this manual and CD11 or an equivalent commissioning form Set up the controls and show the user how to operate all the controls shown in...

Page 37: ...em and note any faults which may need to be corrected during the service Switch off and electrically isolate the boiler 4 Depress locking ears and unplug burner lead F from control box G 5 RS flue onl...

Page 38: ...oil atomising nozzle E DO NOT dismantle the nozzle and DO NOT clean the nozzle tip Check the electrodes F and reset if necessary as shown opposite Refit the combustion head Check that the nozzle E lie...

Page 39: ...solvent free grease Refit the trap making sure that the locking tabs are locked in place Pour 500ml of water into drain E to refill the condensate trap Clean the secondary heat exchanger baffles D if...

Page 40: ...p edge of panel E onto the top supporting ledge D on the boiler Locate the ball stud connections K at the base of the front panel E and push towards the boiler to secure Align top front panel H and pu...

Page 41: ...rt Number 8 716 107 621 0 11 Auto reset High Limit thermostat Part Number 8 716 107 623 0 12 Manual reset High Limit thermostat Part Number 8 716 107 625 0 13 Manual reset flue thermostat Part Number...

Page 42: ...8 0 11 Flexible oil hose kit Part Number 8 716 115 312 0 12 Burner O ring gasket Part Number 8 716 140 902 0 13 Boiler control thermostat Part Number 8 716 107 621 0 14 Auto reset High Limit thermosta...

Page 43: ...e settings incorrect Set up as in installation instructions Faulty ignition transformer Replace Open circuit ignition Check and replace electrodes or high tension leads if necessary Faulty control box...

Page 44: ...g incorrect Correct burner rating Boiler thermostat differential incorrect Replace boiler thermostat External controls not operating correctly Check and correct external controls OIL SMELLS Blocked fl...

Page 45: ...ition GREEN RED Under voltage or over voltage RED ORANGE lock out for no flame during safety time RED Lock out for false flame signal RED Flashing Lock out for burner control error Lock out for maximu...

Page 46: ...or reposition terminal If BF Remove burner snorkel tube retest Lights OK FAULT FINDING LOGIC FOR RIELLO CONTROL BOXES All resistance measurements are actual measured values and some variation is to b...

Page 47: ...Yes Yes Yes No Yes Yes Yes Yes No No No Yes Yes Yes Yes No No No No No Yes Yes Yes Yes Yes No No No No Yes Yes Yes Yes Replace lead No FAULT FINDING LOGIC FOR SATRONIC CONTROL BOX Note This chart ass...

Page 48: ...YES NO WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE RECORD WATER FLOW RATE lts min CONFIRM THE FOLLOWING THE HEATING AND HOT WATER SYSTEM COMPLIES WITH CURRENT BU...

Page 49: ...PRESSURE psi CO2 NOZZLECHANGED YES NO F G T C FLUEPRESSURE COMMENTS SIGNATURE SERVICE 6 DATE ENGINEERNAME COMPANYNAME TELNo OFTECREGNo PUMPPRESSURE psi CO2 NOZZLECHANGED YES NO F G T C FLUEPRESSURE CO...

Page 50: ...NOTES NOTES NOTES INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18 25 8 716 106 256C 03 2010 50 8 716 106 256 C 03 10 30 3 10 14 24 Page 50...

Page 51: ...NOTES NOTES INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18 25 8 716 106 256C 03 2010 51 NOTES 8 716 106 256 C 03 10 30 3 10 14 24 Page 51...

Page 52: ...valve if fitted should be removed from the oil dip pipe Boiler locks out at the start of a demand Heating off overnight for example 1 If an air eliminator is being used check that there are no leaks...

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