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Installation, Commissioning and Servicing instruction manual
Floor Standing oil-fired condensing appliance conventional flue & room sealed flue
Greenstar Utility
32/50 & 50/70
ErP+
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.
UK
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Table of Contents
Related Manuals for Bosch Worcester Greenstar Utility 32/50
Summary of Contents for Bosch Worcester Greenstar Utility 32/50
- Page 1 Installation, Commissioning and Servicing instruction manual Floor Standing oil-fired condensing appliance conventional flue & room sealed flue Greenstar Utility 32/50 & 50/70 ErP+ 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.
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Page 2: Table Of Contents
Contents Contents Key to symbols and safety instructions ....3 Commissioning ........28 Key to symbols . -
Page 3: Key To Symbols And Safety Instructions
Key to symbols and safety instructions This appliance must be installed by a competent person, failure to install Key to symbols and safety instructions correctly could lead to prosecution. Key to symbols General safety instructions These installation instructions are intended for heating engineers, Warnings plumbers, and electricians. - Page 4 Key to symbols and safety instructions 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, qualified engineer (such as OFTEC registered personnel) using approved spares, to help maintain the economy, safety and reliability of the appliance.
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Page 5: Installation Regulations
Installation regulations Installation regulations Complying with the building regulations This heating appliance forms part of the controlled services for the The Building Regulations Part G, Part J and L1 England and Wales; Part building. It is law that all controlled services for buildings must comply F, Part G and Part J Section III Scotland;... -
Page 6: Appliance Information
Appliance information Technical data Appliance information Description Units 32/50 50/70 General information Central heating Primary water capacity (total) litres Standard package Maximum static head metres 1 - Floor standing oil fired condensing appliance Minimum static head metres 2 - Literature pack: Water side resistance (20°C difference) mbar •... -
Page 7: Energy Efficiency
Appliance information Energy efficiency The following product data satisfy the requirements of the EU Regulations No. 811/2013 and No. 812/2013 supplementing Directive 2010/30/EU. Product data Symbol Unit 7 731 600 171 7 731 600 172 Product type – – Greenstar Utility ErP+ 32/50 Greenstar Utility ErP+ 50/70 Condensing boiler –... -
Page 8: Layout & Components
Appliance information Layout & components Fig. 2 Appliance components (The diagram excludes the top, front and RH side casing panels.) CH flow connector (left and right) 2 Flue over heat thermostat Air pressure switch Air sample point Air supply duct to burner 6 Appliance overheat thermostat Condensate pipe connector Condensate drain pipe... -
Page 9: Pre-Installation
▶ In cases where all attempts to find a system micro and non-magnetic debris. leak have failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer. 4.1.1 Before cleaning the system: ▶... -
Page 10: Mains Supply
Pre-Installation Mains supply 4.3.1 Single pipe gravity feed system: The oil storage tank [1] must be positioned so that the oil level does not 4.2.1 Electrical supply exceed 4 metres above the level of the burner oil pump [9] and in •... -
Page 11: Single Pipe Suction Lift With De-Aerator
Pre-Installation 4.3.3 Single pipe suction lift with de-aerator: 4.3.5 Appliance oil isolation valve Maximum suction height 3.5 metres. The oil tank [1] must be positioned ▶ Use copper pipe of the correct diameter according to the information below the oil pump [9]. Create an inlet and return loop between the de- shown in oil supply sections 4.3.1, 4.3.2 &... - Page 12 Pre-Installation Open vent primary system Fully pumped sealed primary system: • The open vent pipe [F] and feed and expansion pipe [H] must rise • A pressure relief valve [P], spring loaded safety valve set to operate continuously from the appliance. at 3bar, must be fitted to the heating flow pipe as close as possible to the appliance or onto one of the appliance top 1¼...
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Page 13: Condensate Discharge
Pre-Installation Condensate discharge For correct installation and trouble free operation of the appliance the following advice should be followed: 1. To minimize the risk of freezing, wherever possible: the condensate drain should be installed internally. 2. All condensate pipework must ‘fall’ from the appliance by a minimum of 3 degrees (52mm per metre) to ensure adequate condensate 21.5mm Ø... -
Page 14: External Connections
Pre-Installation 4.5.3 External connections ▶ The use of fittings, elbows etc. should be kept to a minimum and any internal “burrs” on cut pipe work should be removed so that the NOTICE: Rainwater or external drain disposal internal pipe section is as smooth as possible. Untreated condensate must not be allowed to flow into FITTING AN EXTERNAL AIR BREAK streams or rivers... -
Page 15: Pressure Relief Pipework
Pre-Installation 400mm min. 25mm min. 500mm min. 25mm min. 6720644744-12.4Wo Fig. 16 Condensate pump to external disposal CONDENSATE SOAK-AWAY Condensate soak-away considerations Before deciding to use a soak-away, the ability of the surrounding area should be accessed for the ability to disperse the condensate. Areas prone to flooding and ground with a high clay content can result in a blocked condensate pipe in freezing conditions. -
Page 16: Appliance Locations And Clearances
Pre-Installation Appliance locations and clearances 4.7.1 Appliance clearances There are several clearances to be considered when either installing or ▶ This appliance is only suitable for installing internally within a servicing a appliance in an unventilated or ventilated compartment. property at a suitable location onto a fixed rigid, non-combustible surface of the same size as the appliance and capable of supporting the appliance weight. -
Page 17: Rooms Containing A Bath Or Shower
Pre-Installation 4.7.3 Rooms containing a bath or shower WARNING: Conventional flues ▶ Conventional flue appliances must not be installed in a bathroom WARNING: Electric shock ▶ Any switch or appliance using mains electricity must not within reach of a person using the bath or shower. The installation must be in accordance with the latest amendments in the latest edition of the IET wiring regulations (BS7671), in all cases. -
Page 18: Flue Terminal Positions
Pre-Installation FLUE TERMINAL POSITIONS 1000 1500 2000 1000 RIDGE FLUE RIDGE VENT 1500 1000 1000 1500 1500 1000 1200 1500 1000 1000 1000 2500 1500 2500 1000 1000 1800 1200 BOUNDARIES 1000 1000 Fig. 22 Flue terminal positions NOTICE: ▶ All measurements are the minimum clearances required. ▶... -
Page 19: Conventional Flue
Pre-Installation KEY TO ILLUSTRATION 1500mm vertically between terminals and the same wall. Conventional flue • Open (conventional) flued appliances must not be installed in a 1000mm below eaves, gutters, pipes and drains. External flue bedroom, bathroom or bed-sitting room. joints must be sealed with suitable silicon sealant. •... -
Page 20: Room Sealed Flue Options
Pre-Installation 4.9.3 Room sealed flue options Figure 25 shows the components used and table 11 gives maximum flue length [L] from the appliance outlet to the outside wall/roof of the building for each flue configuration. In all cases L is measured from the outside of the appliance casing. •... - Page 21 Pre-Installation Fig. 25 Room sealed flue options * to outside wall. 32/50 and 50/70 models Total flue length L(mm) Flue configurations 32/50 50/70 1 Horizontal flue assembly 2 Horizontal flue extension 6400 6400 3 Horizontal flue with 1 x 90° bend 6400 6400 4 Horizontal flue with 2 x 45°...
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Page 22: Installation
Installation Pipework positions and flue opening Installation CAUTION: Ensure there are no pipes, electric cables, damp proof courses or other hazards before drilling. Unpacking the appliance LIFTING AND CARRYING PRECAUTIONS: ▶ Lift only a manageable weight, or ask for help. Safety: ▶... -
Page 23: Flue Installation
Installation Flue installation For servicing purposes, keep the condensate and Refer to figure 29 pressure relief discharge pipes away from components The flue can exit the appliance from outlets A, B, C or D allowing vertical and pipework connections. (RS &CF) and horizontal (RS low or high level) flues to be fitted. Flue opening (CF position 'A' only). -
Page 24: Combustion Chamber
Installation Combustion chamber Secondary heat exchanger: Refer to figure 31 1. Remove the seven screws [1] securing the flue manifold access cover [2]. ▶ Check that all the baffles and retainer [3] are correctly fitted to the secondary heat exchanger: ▶... -
Page 25: Oil Burner And Pump - Riello Rdb Burners
Installation ▶ Fill the condensate trap [6] with 500ml of water via the Oil burner and pump - Riello RDB burners condensate collection sump [9]. CAUTION: ▶ Check the water is running away and the condensate pipework joints ▶ Isolate the oil and mains electrical supply before are water tight. -
Page 26: Refitting Components
Installation Refitting components Electrical DANGER: ISOLATE THE 230V ELECTRICITY SUPPLY WARNING: Flue gas leakage ▶ Ensure that the electricity supply is safely Isolated The seal between the burner and the mounting flange and secured to prevent inadvertent re-connection. must form a gas tight seal to prevent leakage of Information on safe isolation can be found in the potentially dangerous gas from the combustion Health and Safety Executive guidance HSG85. - Page 27 Installation PRE-WIRED REMOTE 2 OR 3 PORT VALVE CONTROL SETS: Fig. 38 Fig. 36 Key to components: 230V STANDARD WIRING DIAGRAM Double pole switched fused spur, positioned in the boiler room next to the appliance. Remote junction box (10 way) to connect the following: –...
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Page 28: Commissioning
▶ In cases where all attempts to find a micro leak have After successfully completing all of the checks and any failed, Worcester, Bosch Group supports the use of rectification work, close the water valves, shut off the oil Fernox F4 leak sealer. -
Page 29: Priming A Double Pipe Sub-Gravity Feed Systems And Single Pipe Suction Lift With De-Aerator
Commissioning ▶ Allow the burner to run through to lockout indicated by the 6.4.3 Riello RDB burners illumination of the lockout indicator/reset button [4]. 2. Fit a suitable pressure gauge to the port [1] on the oil pump. If no oil comes out of the port valve A, then re-prime the oil line. Refer to tables 13 &... -
Page 30: Central Heating
Commissioning ▶ Replace the bleed/oil pressure port blanking plug (refer to figure 39 Combustion and burner settings item [1]). APPLIANCE MUST BE SET TO CO LEVELS. ▶ Check and rectify any oil leaks. AIR SETTINGS GIVEN ARE APPROXIMATE ONLY, AS 5. -
Page 31: Electrode Settings
Commissioning 6.5.2 Electrode Settings Burner adjustment Riello RDB 3.2 BX (32/50) 6.6.1 Combustion head adjustment The burner head is shown without the recirculation tube Riello RDB 3.2 BX (32/50) for clarity. ▶ Turn the adjustment screw [A] and set the combustion head to the correct output required, refer to table 13. -
Page 32: Air Damper Adjustment
Commissioning 6.6.2 Air damper adjustment Finishing commissioning The air damper is factory set according to the values indicated in the Completion of commissioning burner settings table for the relevant burner (tables 13 and 14). The When the commissioning has been completed: adjustments are for guidance only. -
Page 33: Appliance Hand Over
▶ Advise the customer where they can find information on the exchanged or repaired free of charge if repaired directly by Bosch Worcester, Bosch Group website www.worcester-bosch.co.uk. Thermotechnology Ltd. -
Page 34: Inspection And Maintenance
Inspection and maintenance Preparing for inspection and maintenance Inspection and maintenance Pre-service checks 1. Lift the front of the top panel up to disengage the ball stud DANGER: Risk of electric shock! connections [1] and pull the panel towards you to remove. ▶... -
Page 35: Appliance Maintenance
Inspection and maintenance Appliance maintenance 7.3.2 Replacing the flue manifold DANGER: Risk to life 7.3.1 Secondary heat exchanger Escaping flue gas from an improperly fitted manifold Refer to figure 50. ▶ Remove the seven screws [1] securing the flue manifold access ▶... -
Page 36: Combustion Chamber
Inspection and maintenance ▶ Identify the protruding lower edge [3] of the heat exchanger ▶ Tighten the four bolts [6] gradually in a rotating sequence until the flue manifold is securely seated on the Heat exchanger. Fig. 53 Protruding edge ▶... -
Page 37: Condensate Trap
Inspection and maintenance 7.3.4 Condensate trap Burner maintenance ▶ Check the discharge pipe for leaks or damage. 7.4.1 Maintenance frequency Condensate trap removal: ▶ Release the pipe locking tab [2] and lift connector [1] and flexible Notes on safety for maintenance. pipe away from the trap [4]. -
Page 38: Fan And Housing Cleaning
Inspection and maintenance 7.4.3 Fan and housing cleaning Riello RDB 3.2 BX (32/50) ▶ To remove the blast tube [1], loosen the three screws [2] from the CAUTION: collar and remove the blast tube. ▶ Ensure that no dust has accumulated inside the fan ▶... -
Page 39: Oil Pump
Inspection and maintenance Riello RDB 3.2 BT (50/70) Re-commission the burner ▶ To remove the blast tube [1] loosen the fixing screws [2] and remove WARNING: Flue gas leakage the blast tube. The seal between the burner and the mounting flange ▶... -
Page 40: Spare Parts
▶ Drain the appliance/system where necessary and protect any electrical equipment from water ingress during component replacement. Only use Worcester, Bosch Group original spare parts with this appliance. Non Worcester, Bosch Group spare parts will invalidate the guarantee (if applicable) and any warranty. -
Page 41: Fault Finding And Diagrams
Fault finding and diagrams WARNING: Under no circumstances must an appliance Fault finding and diagrams be left to operate with any control linked out or Fault finding overridden. PROBLEM CAUSE REMEDY LOCKOUT Pulsation on start CF - Flue draught incorrect CF - Check flue draught Combustion settings incorrect Set up as in installation instructions... -
Page 42: Burner Fault Indicator Diagnostics
Fault finding and diagrams Burner fault indicator diagnostics When the lockout LED illuminates, the burner will attempt to restart only after pressing the reset button. After that, if the burner is working properly, the trip can be attributed to a temporary fault that is not dangerous. Otherwise, if the trip persists, the cause of the fault must be sought and the solutions indicated in Table must be implemented. -
Page 43: Fault Finding
Fault finding and diagrams Anomaly types (Burner in stand-by) Anomaly types (Burner in stand-by) Green 0.2s ON / Remote reset / pushbutton is activated for Red 0.2s ON more than 60 seconds. Green 0.5 s ON / Green 2.5 s OFF Reset pushbutton or When anomaly appears the burner does Fit pre-heat link... -
Page 44: Flame Sensing Photocell
Fault finding and diagrams Line Check Action Pump washing pressure 1 to 2 bar? Go to line 7 Go to line 6a Pump pressure more than 6 bar? Replace oil pump Go to line 6b Check oil supply to the pump, if oil supply is OK Go to line 6c Drive coupling broken? Replace drive coupling... -
Page 45: Oil Supply Vacuum Testing
Fault finding and diagrams Oil supply vacuum testing Appliance reset A vacuum gauge can be attached to the oil pump vacuum test port [1] 8.6.1 Appliance reset buttons and the appliance operated to check the vacuum readings. Oil pumps can operate if readings are between plus 0.4 bar and minus 0.35 bar. Air pressure switch reset [1] Flue system restriction or blockage will cause the air pressure switch to This means oil tanks can be 4 metres higher (to top of oil) or 3.5 metres... -
Page 46: Oil Appliance Commissioning Checklist
Fault finding and diagrams Oil appliance commissioning checklist IMPORTANT This Commissioning checklist is to be completed in full by the competent ▶ Leave this manual with the Homeowner or at the person who commissioned the appliance as a means of demonstrating appliance. -
Page 47: Service Interval Record
Fault finding and diagrams Service interval record It is recommended that your appliance is serviced annually and that the Service Interval Record is completed and signed. Before completing the service Interval record below, ensure that you have carried out the service functions described in this manual. Always use the manufacturer’s recommended spare parts Service 1 Date:... - Page 48 0330 123 9119 TRAINING: 0330 123 0166 SALES: 0330 123 9669 Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0330 123 9559 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. worcester-bosch.co.uk 6 720 821 751 (2018/04)