Worcester Greenstar utility 32-50kW Instruction Manual Download Page 9 | Manualshive

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INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH

8-716-109-711a (04.05)

7

MAINS SUPPLIES

MAINS SUPPLIES

ELECTRIC SUPPLY:

Supply: 230V - 50Hz
Cable: PVC insulated 0.75mm² (24 x 0.2mm)

temperature rated to 90°C

Protection IP20
External 5A fuse to BS1362
The appliance must be earthed
All pipes to the boiler must be cross-bonded
It must be possible to isolate the appliance from

the electric supply with at least a 3mm contact

separation in all poles supplying the appliance

Wiring between the appliance and the electrical

supply must comply with IEE wiring regulations

and any local regulations which may apply for

fixed wiring to a stationary appliance

Any system connected to the boiler must not

have a separate electricity supply.

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Summary of Contents for Greenstar utility 32-50kW

Page 1: ...NE ONLY GB IE 8 716 109 711a 04 05 INSTRUCTION MANUAL INSTALLATION COMMISSIONING SERVICING GB IE FOR FULLY PUMPED OPEN VENT OR SEALED CENTRAL HEATING SYSTEMS AND HOT WATER CYLINDERS Patent pending Application number 0327645 8 THE APPLIANCE IS FOR USE WITH 28 SECOND KEROSENE THE APPLIANCE IS FOR USE WITH 28 SECOND KEROSENE ONLY GB IE INSTRUCTION MANUAL GB IE ...

Page 2: ...TOWER FLUE COMPONENTS VALE RISE TONBRIDGE TN9 1TB OIL FIRING TECHNICAL ASSOCIATION OFTEC 0845 6585080 www oftec org CONVENTIONAL FLUE MANUFACTURERS INTERACTIVE Flue Systems Ltd sales interactive uk com Selkirk Manufacturing Ltd www selkirk co uk SYMBOLS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL Ø Diameter CH Central Heating DHW Domestic Hot Water TRV Thermostatic Radiator Valve IP Ingr...

Page 3: ...K 9 10 CONDENSATE PRESSURE RELIEF PIPEWORK 11 BOILER LOCATION CLEARANCES 12 13 FLUE OUTLET POSITIONS 14 CONVENTIONAL FLUE 15 ROOM SEALED FLUE OPTIONS 16 INSTALLATION UNPACKING THE BOILER 17 PIPEWORK POSITIONS FLUE OPENING 18 BOILER PANEL REMOVAL 19 FLUE INSTALLATION 20 COMBUSTION CHAMBER 21 PIPEWORK CONNECTIONS 22 OIL BURNER PUMP 23 REFIT COMPONENTS 24 ELECTRICS 25 27 COMMISSIONING PRE COMMISSIONI...

Page 4: ...intain the economy safety and reliability of the appliance Failure to install appliances correctly could lead to prosecution The appliance should be installed by a competent 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 optimum efficiency and trouble free ope...

Page 5: ...TIONS FOR WORCESTER BOSCH 3 GENERAL INFORMATION GENERAL INFORMATION 8 716 109 711a 04 05 STANDARD PACKAGE A Floor standing oil fired condensing boiler B Literature pack C Hardware pack including Condensate trap Oil isolating valve A B 815mm 997mm 520mm C ...

Page 6: ...e mbar Waterside resistance 10 C difference mbar Flue Exit flue gas mass flow kg hr Conventional flue minimum diameter required mm Room sealed flue diameter mm Pipework connections Fuel line compression mm CH flow inch BSP CH return mm CH vent inch BSP CH make up inch BSP Condensate polypropylene mm Electrical Electrical power supply voltage AC V Frequency Hz Max power consumption W Thermostats Bo...

Page 7: ...RMOSTATS 8 CABLE CLAMP 9 FLUE MANIFOLD ACCESS COVER 10 CH RETURN PIPE 11 MANUAL RESET FLUE OVERHEAT THERMOSTAT 12 FLUE MANIFOLD 13 FLUE GAS SAMPLING POINT 14 SECONDARY HEAT EXCHANGER 15 CH FLOW CONNECTION LEFT RIGHT HAND SIDE 16 OPTIONAL COLD FEED DRAIN LEFT RIGHT HAND SIDE 17 CONDENSATE OUTLET 18 SECONDARY TO PRIMARY HEAT EXCHANGER RETURN PIPE 19 PRIMARY HEAT EXCHANGER 20 BASE PLATE 21 COMBUSTION...

Page 8: ...THE SYSTEM ENSURE THE SYSTEM AND PIPEWORK IS IN GOOD WORKING ORDER USE THE EXISTING BOILER CIRCULATING PUMP WHERE POSSIBLE OR USE A POWER FLUSHING MACHINE TO AID THE CLEANSING PROCEDURE BEFORE INSTALLING A NEW BOILER FOR GUIDANCE REFER TO BS 7593 CLEANING THE PRIMARY SYSTEM Fill the system with cold mains water to the recommended pressure and check for leaks Open all drain cocks and drain the syst...

Page 9: ...pliance must be earthed All pipes to the boiler must be cross bonded It must be possible to isolate the appliance from the electric supply with at least a 3mm contact separation in all poles supplying the appliance Wiring between the appliance and the electrical supply must comply with IEE wiring regulations and any local regulations which may apply for fixed wiring to a stationary appliance Any s...

Page 10: ...om the boiler access door or other hot surfaces 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 filter C to the oil supply pipe near the oil storage tank If there is doubt about the internal condition of the oil supply pipe fit an additional oil filter close to the boiler Fit a fire valve in accordance with BS5410 The fire valve...

Page 11: ...ed at all the high points on the system OPEN VENT PRIMARY SYSTEM The cold feed F and expansion tank 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 expansion tank E The heating vent H and cold feed F pipes must rise continuously from the appliance The heating vent pipe H must be at least 22mmØ and 350mm abo...

Page 12: ...g point must be at low level and must never be a permanent direct fixing to the mains water supply Filling loops must be WRAS approved 10 WATER SYSTEMS PIPEWORK WATER SYSTEMS PIPEWORK 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 vessel 1000mm above the high...

Page 13: ...Condensate from boiler B Sink C 21 5mmØ plastic polypropylene condensate pipe D Gulley E Internal soil and vent stack F Condensate trap 75mm min G 300mm x 100mmØ sealed plastic tube H Ground level J Drainage holes 50mm from base of tube 12mmØ at 25mm centres facing away from building K Limestone chippings PRESSURE RELIEF PIPEWORK IMPORTANT The pressure relief valve is a safety device for the boile...

Page 14: ...rovided for boilers fitted into compartments as described in BS 5410 A minimum of 2 air vents must be fitted one at low level and another at high level onto the same wall using the same air for circulation Free air must not 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 v...

Page 15: ... 0 SHOWER BATHROOMS The boiler must not be installed in zones 0 1 or 2 or in the shaded areas shown on the diagrams opposite IMPORTANT conventional flued boilers must not be fitted in a bathroom IMPORTANT any switch or appliance control using mains electricity must not be able to be touched by a person using the bath or shower Electrical switches fused spur and socket outlets must not be situated ...

Page 16: ...ic footpath private access route or a frequently used area and 2500mm from a car parking area 14 FLUE OUTLET POSITIONS FLUE OUTLET POSITIONS Minimum dimensions mm of flue terminal positions for oil fired appliances TERMINAL POSITION CF RS H RS V A Below an opening 1 2 N A 600 N A B Horizontally to an opening 1 2 N A 600 N A C Below a plastic painted gutter drainage pipe or eaves if combustible mat...

Page 17: ...aled 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 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 The flue should be vertical and contain as few bends as possibl...

Page 18: ... C Flue bend 90 D Flue bend 45 E Vertical Terminal F 90 inner elbow inner flue to boiler G Air intake box Calculating the flue length Measure the total flue length required noting that the maximum straight flue length including the terminal is Horizontal 100 150mmØ 3000mm excluding 220mm of terminal extending outside the building Vertical 100 150mmØ 6000mm Then reduce the total straight flue lengt...

Page 19: ...ancilliary items a b 5 Pull the upper front panel C forwards to disengage the ball stud connectors 6 Remove securing screws D from front panel E Pull front panel E up and away from the supporting ledge on the boiler and store away from the working area 7 Remove the bolts securing the boiler to the transport pallet At all times the correct method for handling heavy objects should be strictly observ...

Page 20: ...rom components and pipework connections FLUE OPENING Follow the diagram opposite to mark the centre of the flue 1 2 for rear opening 2 3 for side opening or 1 4 for top opening IMPORTANT for horizontal flues increase this height by 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 me...

Page 21: ...o release blast tube N from heat exchanger and store safely away from the boiler 5 Release split pin P to remove the flue thermostat M from the flue hood 6 Release split pins P Carefully remove the CH Control thermostat Q Automatic High Limit T and Manual Reset thermostat U phials from the heat exchanger thermostat pocket 7 Unscrew side panel R retaining screws S from both sides Slide both side pa...

Page 22: ... 716 190 049 INSTALLATION NOTES Ensure all flue seals are in good condition To ease assembly of flue components grease seals lightly with a solvent free grease Use flue clamps where supplied to support the flue system IMPORTANT The boiler is not designed to take the weight of the flue system this must be supported externally to the boiler All horizontal flue sections must rise by at least 52mm for...

Page 23: ...kW 31 15 1 Five of the slots do not have baffles Combustion chamber 3 Release retaining nuts and washers B Remove combustion chamber access door A 4 Remove the transit packaging and ensure the baffles C and baffle retainers D are correctly fitted for the boiler output as shown in the plan views 5 Refit combustion chamber door A Secure with nuts and washers B and tighten gradually in the sequence 1...

Page 24: ...the burner Avoid potentially hot surfaces Connect the oil supply pipe D to the islolating valve E and ensure the valve is closed Connect the flexible oil pipe F to the isolating valve E CONDENSATE CONNECTION Fit sealing washer to condensate waste pipe G and connect to the flue manifold outlet H Connect 21 5mm polypropylene plastic pipe J not supplied to the condensate waste pipe G and condensate t...

Page 25: ...ipe system a DANFOSS BFP 11 L3 Remove pump front cover A ensuring a suitable recepticle is used to catch any oil residue Remove changeover screw B Remove horseshoe washer C Refit changeover screw B Refit front cover A and secure Remove oil pump return plug D Connect the flexible oil hose to the pump return and tighten to secure b DANFOSS BFP 52E L3 Remove plug A and screw in grub screw B Refit plu...

Page 26: ...efit split pins P to secure 3 Carefully replace the flue thermostat M into the flue hood and refit split pin to secure 4 Align burner blast tube 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 seal IMPORTANT Ensure the gasket is a good seal between the burner blast tube and the boiler housi...

Page 27: ...rip to 6mm 230v connections 4 Connect LIVE wire Brown or Red to terminal L Connect NEUTRAL wire Blue or Black to terminal N Connect EARTH wire Green Yellow to the connector E 5 Secure the cable to the cable clamp K Route the power cable to the connection point avoiding any potentially hot surfaces Allow sufficient cable for the control panel A to be pulled forward for servicing Any external device...

Page 28: ...EARTH CONNECTOR C FLUE THERMOSTAT MANUAL RESET D HEATING THERMOSTAT AUTOMATIC RESET E HEATING THERMOSTAT MANUAL RESET F CONTROL THERMOSTAT G BURNER CONTROL PLUG IN CONNECTOR 26 ELECTRICS ELECTRICS 8 716 109 711a 04 05 1 2 3 A B C F G E EARTH L LIVE N NEUTRAL Blue 1 2 NC C 3 Green Yellow D E BURNER Brown Brown Brown Blue Green Yellow Brown Brown Brown ...

Page 29: ...ater tank thermostat Room thermostat System water valves Circulating pump External timer C BOILER 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 A must be fitted externally to the boiler A frost thermostat can also be connected to the remote ...

Page 30: ...sec Kerosene and that the pipework is connected correctly to the oil pump Turn on the main oil supply valve at the tank and check the oil supply pipework connections and rectify any leaks 3 Check the flue is correctly 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 ...

Page 31: ...eed and expansion tank and allow the system to fill 2 Sealed systems only Fill the system to between 1 and 2 bar pressure via a WRAS approved filling link Check the expansion vessel pressure and and adjust if necessary using the Schrader type valve Check the pressure relief valve operates by turning anti clockwise until water is expelled from the discharge pipe 3 Vent all radiators retighten when ...

Page 32: ...le oil inlet hose nearest to the de aerator and place in a container of the same oil fuel Place an empty container to collect oil from the oil inlet pipe connection of the de aerator Prime the de aerator and reconnect the flexible oil inlet hose Open the isolating valve and the oil pump bleed valve A to discharge into a suitable container once the boiler is started up It is recommended to connect ...

Page 33: ... run for 3 minutes then switch off Check for after spurting from the nozzle indicated by oil saturation on the blast tube E If after spurting occurs release the burner retainers F remove the burner hold vertical to unscrew the nozzle G and fill the nozzle holder H with oil refit nozzle G and burner restart and run for 3 minute intervals until after spurting stops 4 Start and run for 20 minutes Rem...

Page 34: ...m thermostat to maximum Set programmer to ON for CH DHW Turn the thermostat control A to max The burner should be ON with the circulating pump Ensure all radiators are heating up evenly 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 should be off A ...

Page 35: ...g agent manufacturer 3 Drain and thoroughly flush the system to remove the flushing agent and debris INHIBITOR Central Heating 4 Check drain cocks are closed and all radiator valves are open 5 Add a suitable inhibitor I or combined inhibitor anti freeze if the system is exposed to freezing conditions to the heating system in accordance with the manufacturers instructions Open vented systems only t...

Page 36: ...Locate the top panel H onto the ball stud connections J and press down to secure Handover Set up the controls and show the user how to operate all the controls shown in the User Guide Where applicable instruct the customer how to repressurise the system If the appliance is unused and exposed to freezing conditions advise the customer of the precautions necessary to prevent damage to the boiler sys...

Page 37: ...m the supporting ledge D on the boiler Operate the appliance and system 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 H from control box G 5 RS flue only loosen clip J to detach air duct pipe K from the air intake box 6 Unscrew burner retainers M to release the burner blast tube L L...

Page 38: ... and replace with a new one Refit the mechanical shut off valve Remove the combustion head and thoroughly clean any deposits Replace the 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 Replace the combustion head Check that the nozzle E lies central to the combustion head and the head settings are as...

Page 39: ...heck the fibreglass rope seal on the combustion chamber access door A and replace if necessary Remove and check the baffle retainer D where fitted Remove the baffles C clean and check their condition Replace any baffles considered to be badly corroded Thoroughly clean all of the heat exchanger surfaces using brush and clear all loose debris from the combustion chamber Check the condition of the co...

Page 40: ...G THE APPLIANCE under the Commissioning section Refit panels 3 Locate edge of front panel A onto the supporting ledge B on the baseplate Refit securing screws C to secure 4 Slide control box D into the boiler Secure with screws E Locate ball stud connectors F and push fit upper front panel G towards the boiler to secure If the data label plate has been removed ensure it is refitted to the applianc...

Page 41: ...8 716 109 767 0 11 Control Box Satronic TF 832 3 Part Number 8 716 156 648 0 12 Photocell Satronic MZ770 Part Number 8 716 156 692 0 13 Control box base Satronic S98 12 pole Part Number 8 716 142 782 0 14 Motor Sterling 133 and 146 FHP 125 W Part Number 8 716 109 768 0 15 Transformer Danfoss EBI 052F0037 excludes cable Part Number 8 716 156 696 0 16 Mechanical shut off valve Part Number 8 716 156 ...

Page 42: ...ace Control box faulty Replace Air adjustment fault Incorrect CO Set up as in installation instructions No oil from nozzle No oil at pump Check and refill oil tank Check andclean filters from oil tank to boiler Air in pump Bleed pump Nozzle blocked Replace nozzle Faulty pump or drive Replace Faulty mechanical shut off valve Clean or replace Ignition failure Electrode settings incorrect Set up as i...

Page 43: ...iler thermostat Take out of circuit to check Thermostat bulb not fully home in pocket Ensure bulb is pushed fully home Short Cycling Boiler rating incorrect Correct boiler rating Boiler thermostat differential incorrect Replace boiler thermostat External controls not operating correctly Check and correct external controls OIL SMELLS Blocked flue fumes on startup Check flue with gauge Oil soaked he...

Page 44: ...orcester Bosch Group Cotswold Way Warndon Worcester WR4 9SW INSTRUCTION MANUAL INSTALLATION COMMISSIONING SERVICING Part Number Worcester Bosch Group is a trading name of BBT Thermotechnology UK Ltd www worcester bosch co uk ...

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