Bosch Worcester Greenstar Danesmoor 12/18 Installation, Commissioning And Servicing Instruction Manual
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Bosch Worcester Greenstar Danesmoor 12/18 Installation, Commissioning And Servicing Instruction Manual

Bosch Worcester Greenstar Danesmoor 12/18 Installation, Commissioning And Servicing Instruction Manual

Floor standing oil-fired condensing boiler conventional flue & room sealed flue
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Installation, Commissioning and Servicing instruction manual
Floor Standing oil-fired Condensing Boiler Conventional Flue & Room Sealed Flue
Greenstar Danesmoor Kitchen Regular
& Kitchen System 12/18, 18/25, & 25/32
For fully pumped open vent or sealed central heating systems and domestic hot water cylinders
UK
THESE APPLIANCES ARE FOR USE WITH
KEROSENE (28SECOND OIL) ONLY

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Summary of Contents for Bosch Worcester Greenstar Danesmoor 12/18

  • Page 1 Installation, Commissioning and Servicing instruction manual Floor Standing oil-fired Condensing Boiler Conventional Flue & Room Sealed Flue Greenstar Danesmoor Kitchen Regular & Kitchen System 12/18, 18/25, & 25/32 For fully pumped open vent or sealed central heating systems and domestic hot water cylinders THESE APPLIANCES ARE FOR USE WITH KEROSENE (28SECOND OIL) ONLY...

  • Page 2: Table Of Contents

    Contents Contents Key to symbols and safety instructions ....3 Service and Spares ........39 Key to symbols .

  • Page 3: Key To Symbols And Safety Instructions

    Key to symbols and safety instructions Key to symbols and safety instructions Key to symbols General safety instructions These installation instructions are intended for heating engineers, Warnings plumbers, and electricians. ▶ Read any installation instructions (boiler, heating controls, etc.) Warnings in this document are identified by a warning carefully before starting the installation.

  • Page 4: Installation Regulations

    Installation regulations Installation, commissioning and servicing Alternatively you must submit a building control notice to the LABC before installing any boiler. The LABC will then arrange regular Installation, commissioning and servicing must only be carried out by a inspection visits during the work to ensure that the installation complies competent registered engineer.

  • Page 5: Appliance Information

    Appliance information Technical data Appliance information Description Units 12/18 18/25 25/32 General information Central heating Central heat output (max) Standard package: Primary water capacity (total) litres A - Floor standing oil fired condensing boiler Max.static head (Regular only) metres B - Literature pack: Min.

  • Page 6: Layout And Components - 18/25 System Appliance Shown

    Appliance information Layout and components - 18/25 System appliance shown 6720808218-94.1Wo Fig. 1 System appliance shown 6 720 808218 (2013/10) Danesmoor Kitchen and Kitchen System...
  • Page 7 Appliance information Figure 1 does not include the top, front, and right hand side panel. Flue overheat thermostat phial Expansion vessel bracket Pressure relief valve Expansion vessel Air inlet casing Location of optional programmer Heat exchanger flow pipe Quick reference guide slot Secondary heat exchanger baffles Lock out indicator Secondary heat exchange drain point...

  • Page 8: Layout And Components - 18/25 Regular Appliance Shown

    Appliance information Layout and components - 18/25 Regular appliance shown 6720808218-02.1Wo Fig. 4 18/25 Regular appliance shown Figure 4 does not include the top, front, and right hand side panel. Control box assembly Primary heat exchanger Flue manifold access cover Oil isolating valve Flue gas sampling point Optional oil return position...

  • Page 9: Pre-Installation

    ▶ In cases where all attempts to find a system micro CAUTION: MAINS POWER leak have failed, Worcester, Bosch Group supports ▶ ISOLATE THE MAINS SUPPLIES BEFORE STARTING the use of Fernox F4 leak sealer. ANY WORK AND OBSERVE ALL RELEVANT SAFETY Water treatment PRECAUTIONS.

  • Page 10: Oil Supply

    Pre-Installation 4.2.2 Oil supply • This appliance is suitable for Kerosene (28 second oil) only, no other fuel must be used. • Plastic or steel tanks should be installed to BS 5410. A steel tank should conform to BS 799: part 5 and have a slope of 1:24 away from the outlet with a sludge cock at the lower end. •...

  • Page 11: Water Systems And Pipework

    Pre-Installation c) Single pipe suction lift with de-aerator Maximum suction height 3.5 metres. The oil tank (A) must be positioned below the oil pump (J). Create an inlet and return loop between the de-aerator (M) and oil pump (J). A non-return valve must be incorporated within the de-aerator or fitted to the oil line between the oil storage tank (A) and the de-aerator (M). A top feed oil tank fitted with a de-aerator using an internal non-return valve should have any non-return valves fitted in the base of the tank to the suction line removed to assist purging air from the oil line.
  • Page 12 Pre-Installation 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 feed and expansion cistern.

  • Page 13: Condensate Pipework

    Pre-Installation Condensate pipework Condensate pump Where “gravity discharge” to an internal termination is not physically NOTICE: possible, or where very long internal runs would be required to reach a ▶ Where a new or replacement boiler is being installed, suitable discharge point, condensate should be removed using a access to an internal “gravity discharge”...

  • Page 14: Soak Away

    Pre-Installation FITTING AN EXTERNAL AIR BREAK Continued - Key to condensate illustrations • Refer to figure 11 when a rain water down pipe is used to dispose of 100mm Ø minimum plastic pipe condensate. Drainage holes • An air break must be installed in the 43mm pipe work, between the Limestone chippings (25kg min.) boiler condensate outlet and the drainpipe, outside the property, to avoid flooding during adverse weather conditions.

  • Page 15: Pressure Relief Pipework

    Pre-Installation Pressure relief pipework Room sealed balanced flue models (RS) The appliance does not require a separate vent for combustion air. • The pressure relief discharge pipe (1) should be at least 15mm diameter copper pipe and run downwards away from the boiler and Installation in cupboards or compartments require permanent vents for discharge away from any electrical or other hazard, preferably to an cooling purposes, one at high level and one at low level, either direct to...

  • Page 16: Flue Terminal Positions

    Pre-Installation Maintenance clearances Showers/bathrooms Figure 18 shows the clearances required for maintenance. WARNING: Conventional flues ▶ Conventional flued boilers must not be installed in a 380mm 1200mm bathroom, bedroom, or bedsitting room. 300mm WARNING: Electrical ▶ Any appliance using mains electricity must not be able to be touched by a person using the bath or shower.
  • Page 17 Pre-Installation Terminal position RS(H) RS(V) 1, 2 Directly below an opening, air brick, opening window etc. 600mm 1, 2 Horizontally to an opening, air brick, opening window, etc. 600mm Below a plastic/painted gutter, drainage pipe or eaves if combustible material is protected 75mm Below a plastic/painted gutter, drainage pipe or eaves without protection to combustible material 600mm...

  • Page 18: Flue Options

    Pre-Installation Flue options 4.8.1 Conventional flue (CF) • Open (conventional) flued appliances must not be installed in a bedroom, bathroom or bed-sitting room. • The flue system must be in accordance with BS 5410 : Part 1 and the current Building Regulations. •...

  • Page 19: Room Sealed Flue Options

    Pre-Installation 4.8.2 Room sealed flue options Figure 21 shows the components used and the maximum flue length (L) for each flue configuration. L = 140 - 335mm In all cases L is measured from the outside of the boiler casing. •...

  • Page 20: Installation

    Installation Installation Unpacking the boiler CAUTION: Lifting and carrying ▶ Lift only a manageable weight, or ask for help. ▶ When lifting or putting things down, bend your knees, keep your back straight, and feet apart. ▶ Do not lift and twist at the same time. ▶...
  • Page 21 Installation Pipework connections - Regular Pipework connections - System A - Flow connections (optional combined feed and vent) 1” BSP A - Flow connections 12/18 & 18/25 - 22mm Ø , 25/32 - 28mm Ø B - Return connections 22mmØ copper on 12/18, 18/25 models and B - Return connections 22mmØ...

  • Page 22: Boiler Installation

    Installation Flue centres Boiler installation 1. Lift the front of the top panel (A) upwards to disengage the ball stud RS 155 CF 170 connections (B) and pull forwards to release from the brackets (C) at the back to remove. Pull front panel (D) forward from the bottom and near the top disengaging the ball studs from their connections (E) and lift off the ledge (F) that runs along the bottom of the fascia to remove.

  • Page 23: Flue Installation

    Installation 3. Unscrew to loosen the retaining ring (H) that secures the flexible air The boiler is not designed to take the weight of the flue supply tube to the burner (I) and pull the flexible air supply tube free system, this must be supported externally to the boiler.

  • Page 24: Combustion Chamber (18/25 Regular Shown)

    Installation Combustion chamber (18/25 Regular shown) 4. Ensure one piece baffle set (E) is in the right location (F), correctly resting on the baffle rests (G) on either side of the combustion 1. Remove the control box securing screws (A, bottom screw both chamber and pushed securely into place.

  • Page 25: Pipework Connections

    Installation Pipework connections Water connections Surplus water may be present due to factory testing. CAUTION: MAINS SUPPLIES ▶ Isolate the oil & water mains supply before starting any work and follow all relevant safety precautions. ▶ Remove the transit bungs from the pipework connections on e boiler. ▶...

  • Page 26: Oil Burner And Pump

    Installation Oil burner and pump CAUTION: MAINS SUPPLIES ▶ Isolate the oil & water mains supply before starting any work and observe all relevant safety precautions. Oil burner 1. Check that the nozzle (A) and the electrode (B) alignment settings are correct as shown in figure 43.

  • Page 27: Electrical

    Installation Electrical External 230V programmer 4. Remove link (G). CAUTION: 230 Volts ▶ Connect wires as shown. ▶ Isolate the mains electricity supply before starting any work and follow all relevant safety precautions. Access to 230V connections 1. Remove the four fascia retaining screws (A) and position the fascia assembly (B) on the two fascia location lugs (C) as shown.
  • Page 28 Installation 230V Standard wiring diagram Brown N1 1 2 3 4 5 6 6 a Green/Yellow Grey White Green/Yellow Blue Blue Brown 7 8 9 10 PUMP SYSTEM Orange BOILER ONLY Brown Brown Brown Brown Green/Yellow Black = EARTH = LIVE Blue = NEUTRAL Grey...
  • Page 29 Installation Pre-wired remote 2 or 3 port valve control set using internal programmer • = EARTH Key to components: • = LIVE Remote junction box (10 way) • = NEUTRAL to connect the following: • > Mains wiring 230V 50 Hz = SWITCHED LIVE >...
  • Page 30 Installation Pre-wired remote 2 or 3 port valve control set using remote programmer • = EARTH • = NEUTRAL Key to components: • Remote junction box (10 way) to connect the following: = SWITCHED LIVE > Mains wiring 230V 50 Hz >...
  • Page 31 Installation 2 Port valve control set Terminator connector block (G): > Remove link 1 to 3. Brown > Remove link 2 to 4. Blue > Make link 3 to 4. Optional 230V Worcester programmer (P): > Set the pin on the rear of the programmer = EARTH to ‘pumped’.
  • Page 32 Installation 3 Port valve control set Terminal connector block (G): > Remove link 1 to 3. = EARTH > Remove link 2 to 4. = LIVE > Make link 3 to 5. = NEUTRAL Optional 230V Worcester programmer (P): Blue >...

  • Page 33: Commissioning

    Commissioning Filling the system Commissioning 1. Open all system and radiator valves. ▶ Turn on the water main stop cock. Pre-Commissioning checks - 18/25 Regular shown ▶ Open vented systems only: CAUTION: 230 Volts ▶ Turn on the water to the system feed and expansion cistern and allow ▶...

  • Page 34: Starting The Appliance

    Commissioning Starting the appliance NOTICE: ▶ Never run the appliance when the appliance/system is unpressurised (sealed systems) or empty. Check the oil supply is correctly fitted and in good working order before turning on the oil supply valves to the boiler. ▶...
  • Page 35 Commissioning Boiler lock out indicator on: Smoke readings may be inaccurate until the smoke from If the burner fails to establish a normal firing pattern or flame failure burning organic binder in the access door insulation has occurs the flame monitoring photocell mounted in the burner body will ceased.
  • Page 36 Commissioning Nominal boiler rating at normal operating temperature using 28 second kerosene Oil pump Fuel flow rate Approx. Approx Input Output Air damper pressure flue gas disk Nozzle (bar/psi) kg/h temp. °C %CO setting setting Burner head Boiler 12/18 RDB 2.2 0.35x80°SR 9/132 1.04...

  • Page 37: Water Treatment

    Commissioning Water treatment Debris from the system can damage the boiler and reduce efficiency. Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance guarantee. The use of a magnetic system filter such as the Worcester Greenstar System Filter is recommended.

  • Page 38: Finishing Commissioning

    Commissioning Finishing commissioning 1. Pivot the control box (A) up and into the boiler. Secure with screws (B). Kitchen system only: ▶ Slide the expansion vessel up and locate the top edge into the bracket [1] located under the control panel. ▶...

  • Page 39: Service And Spares

    Service and Spares Service and Spares Inspection and service - 18/25 Regular shown CAUTION: MAINS SUPPLIES ▶ Isolate the water, electricity, and oil mains supplies before starting any work and observe all relevant safety precautions. Routine servicing To maintain efficient boiler operation, the following should be carried out at least once a year, carry out a pre-service check and note any operational faults.
  • Page 40 Service and Spares Service requirements DO NOT dismantle the nozzle and DO NOT clean the See the following instructions for detail of some of the service nozzle tip. requirements listed below: ▶ Check and clean the burner. ▶ Check the electrodes (E) and reset if necessary as shown opposite. ▶...
  • Page 41 Service and Spares This seal must be in good condition, seal failure will 12/18kW cause flue gases to escape into the room. Baffle RIELLO (on 12/18 model only) RDB OIL PUMP Brass air deflection washer 18/25 & 25/32kW Baffle Locating circlip 6720808218-92.1Wo Fig.
  • Page 42 Service and Spares Cleaning the boiler, manifold access: Do not use wire brushes and cleaning agents to clean the stainless steel secondary heat exchanger components. ▶ Release screws (A) to remove the flue manifold access cover (B) and clear any debris. ▶...
  • Page 43 Service and Spares Re-commissioning the burner correct as indicated in table 4 on page 36, ensure CO levels are correct. Adjust the air shutter if necessary see page 35, figure 64 for 1. Align burner combustion head into burner collar. details.

  • Page 44: Short Parts Lists 12/18

    Service and Spares Short parts lists 12/18 Fig. 84 Short parts list 12/18 Burner - Riello RDB 2.2 12/18 Part No.: 8 718 690 333 0 15 Cleaning brush Part No.: 8 716 109 428 0 Combustion head - LD2X SH12/18 Part No.: 8 716 112 731 0 16 Manifold access cover seal Part No.: 8 716 107 536 0 Control box 535 RSE/LD...

  • Page 45: Short Parts List 18/25

    Service and Spares Short parts list 18/25 Fig. 85 Short parts list 18/25 Burner - Riello RDB 2.2 18/25 Part No.: 8 718 690 334 0 14 Air damper disc 18 21.5-25 Part No.: 8 718 690 458 0 Combustion head - LD2X SH18/25 Part No.: 8 718 682 170 0 15 Cleaning brush Part No.: 8 716 109 428 0 Control box 535 RSE/LD...

  • Page 46: Short Parts List 25/32

    Service and Spares Short parts list 25/32 Fig. 86 Short parts list 25/32 Burner - Riello RDB 2.2 25/32 Part No.: 8 718 690 335 0 Manual reset flue thermostat Part No.: 8 716 107 624 0 Combustion head - T2 SH 25/32 Part No.: 8 716 112 780 0 Cleaning brush Part No.: 8 716 109 428 0...
  • Page 51 Notes Danesmoor Kitchen and Kitchen System 6 720 808218 (2013/10)
  • Page 52 Notes 6 720 808218 (2013/10) Danesmoor Kitchen and Kitchen System...
  • Page 53 Notes Danesmoor Kitchen and Kitchen System 6 720 808218 (2013/10)
  • Page 54 OIL BOILER COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. BOILER DETAILS Boiler Make and Model Boiler Serial Number...
  • Page 55 SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.
  • Page 56 APPLIANCE BE LEFT TO OPERATE WITH ANY CONTROL LINKED OUT OR OVER RIDDEN. 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 6 720 808 218 (2013/10)

This manual is also suitable for:

Worcester greenstar danesmoor 18/25Worcester greenstar danesmoor 25/32

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