Worcester GREENSTAR UTILITY 32/50 Instruction Manual
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Worcester GREENSTAR UTILITY 32/50 Instruction Manual

Installation, commissioning & servicing floor standing oil-fired condensing boiler conventional flue & room sealed flue
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8 716 109 711 b 07.10
14/7/10
INSTRUCTION MANUAL
INSTALLATION, COMMISSIONING & SERVICING
FLOOR STANDING OIL-FIRED CONDENSING BOILER CONVENTIONAL
FLUE & ROOM SEALED FLUE
GREENSTAR UTILITY
32/50 & 50/70
FOR FULLY PUMPED OPEN VENT OR SEALED CENTRAL HEATING SYSTEMS
AND DOMESTIC HOT WATER CYLINDERS
09:59
Page 1
THE APPLIANCE IS FOR USE WITH KEROSENE
(28 SECOND OIL) ONLY
UK

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Summary of Contents for Worcester GREENSTAR UTILITY 32/50

  • Page 1 8 716 109 711 b 07.10 14/7/10 09:59 Page 1 INSTRUCTION MANUAL INSTALLATION, COMMISSIONING & SERVICING FLOOR STANDING OIL-FIRED CONDENSING BOILER CONVENTIONAL FLUE & ROOM SEALED FLUE GREENSTAR UTILITY 32/50 & 50/70 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...
  • Page 2 LABC will then arrange regular inspection visits during the work to ensure that the installation complies with the regulations. Programmer ON DHW only IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER TECHNICAL HELPLINE. DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER. PLEASE LEAVE THESE INSTRUCTIONS WITH THE COMPLETED COMMISSIONING FORM...

  • Page 3: Table Of Contents

    FAULT FINDING & DIAGNOSIS FAULT FINDING FAULT FINDING LOGIC FOR RIELLO CONTROL BOX FAULT FINDING LOGIC FOR SATRONIC CONTROL BOX COMMISSIONING CHECKLIST SERVICE INTERVAL RECORD INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 CONTENTS 8 716 109 711B 07.2010...

  • Page 4: Safety Precautions And Installation Regulations

    Republic of Ireland ETCI rules for electrical installation For further guidance see: OFTEC Technical book three - Regional requirements: Republic of Ireland INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 SAFETY PRECAUTIONS 8 716 109 711B 07.2010 & INSTALLATION REGULATIONS...

  • Page 5: General Information

    Greenstar Utility Installation/Servicing Instructions......... 1 Users Instructions ..................1 Top Panel Inset Plate..................1 Edge Clips .......................1 Warranty Return Envelope ................1 Return Pipe Kit ....................1 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 GENERAL INFORMATION 8 716 109 711B 07.2010...

  • Page 6: Technical Data

    Flue manual reset overheat thermostat (+ 0.6°C) °C General Data Maximum hearth temperature °C SEDBUK (Band A) 93.0 92.5 Appliance protection rating Weight (excluding packaging) INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 TECHNICAL DATA 8 716 109 711B 07.2010...

  • Page 7: Layout & Components

    Air intake casing Oil pump Combustion head 31 LOCKOUT INDICATOR/RESET BUTTON 32 CLIP - AIR INTAKE HOSE 33 AIR INTAKE HOSE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 LAYOUT & COMPONENTS 8 716 109 711B 07.2010...

  • Page 8: Cleaning Primary Systems

    Run the boiler and system at normal operating temperature in accordance with the manufacturer's instructions. Drain and thoroughly flush the system to remove the flushing agent and any debris. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25 CLEANING PRIMARY SYSTEMS 8 716 109 711B 07.2010...

  • Page 9: Mains Supply

    • Any system connected to the boiler must not have a separate electrical supply. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/70 8 716 MAINS SUPPLY 109 711B 07.2010...

  • Page 10: Oil Supply

    The table and illustration above is a guide only and does not in any way override the as the sole fire protection device. de-aerator manufacturers instructions. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 OIL SUPPLY 109 711B 07.2010...

  • Page 11: Water Systems & Pipework

    1 ” BSP outlets. • An automatic air vent (N) must be fitted. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/70 8 716 WATER SYSTEMS & PIPEWORK 109 711B 07.2010...
  • Page 12 Heating return Auto air vent Non return 1000mm above valve the highest point of the system Stop cock Fill Point INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/70 WATER SYSTEMS & PIPEWORK 8 716 109 711B 07.2010...

  • Page 13: Pressure Relief Pipework

    (as shown) to help prevent freezing. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 CONDENSATE PIPEWORK 109 711B 07.2010...

  • Page 14: Boiler Location & Clearances

    * Due to changes to BS 5410 and modern 32/50 32/50 building design, these figures no longer 50/70 1073 50/70 incorporate the adventitious ventilation allowance. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 BOILER LOCATION & CLEARANCES 109 711B 07.2010...

  • Page 15: Boiler Location

    In all cases the IEE wiring regulations must be 7 50m m consulted. All pipework in bathrooms and shower rooms must be cross bonded. 2250m m 2250m 600mm radius INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 BOILER LOCATION & CLEARANCES 109 711B 07.2010...

  • Page 16: Flue Terminal Positions

    • **Minimum distance of the flue terminal to a facing wall, fence, building or property boundary is 2500mm. Flat roof boundary Pitched roof C, D boundary INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 FLUE TERMINAL POSITIONS 109 711B 07.2010...

  • Page 17: Conventional Flue

    A - Boiler B - Flue C - Max. 2 bends at 135° D - Anti down-draught terminal E - Chimney INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 CONVENTIONAL FLUE 109 711B 07.2010...

  • Page 18: Room Sealed Flue Options

    950mm. Flue Terminal lengths: Horizontal 100/150mmØ: 1000mm Vertical 100/150mmØ: 1290mm + cage * to outside wall. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 ROOM SEALED FLUE OPTIONS 109 711B 07.2010...

  • Page 19: Unpacking The Boiler

    Remove the bolts securing the boiler to the transport pallet. At all times the correct method for handling heavy objects should be strictly observed. UNPACKING THE BOILER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 109 711B 07.2010...

  • Page 20: Pipework Positions / Flue Opening

    Flue hole size 150 - 240mm 175mmØ 240 - 330mm 185mmØ 330 - 420mm 195mmØ 420 - 500mm 205mmØ INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/70 PIPEWORK POSITIONS & 8 716 109 711B 07.2010 FLUE OPENING...

  • Page 21: Boiler Installation

    Remove and store safely away from the boiler. NOTE: to enable the panels to stand upright, reposition and secure control box (G) to the side panels. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 BOILER INSTALLATION 109 711B 07.2010...

  • Page 22: Flue Installation

    A flue terminal guard must be fitted if the flue outlet is below 2 metres from the ground level. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 FLUE INSTALLATION 109 711B 07.2010...

  • Page 23: Combustion Chamber

    (D) and tighten gradually in the sequence (1-6) shown until the chamber door is firmly secured, do not over tighten the nuts. FRONT FRONT INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 COMBUSTION CHAMBER 109 711B 07.2010...

  • Page 24: Pipework Connections

    (L). IMPORTANT: The condensate trap must be correctly filled to prevent the possibility of potentially harmful flue products escaping via the condensate pipework. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 PIPEWORK CONNECTIONS 109 711B 07.2010...

  • Page 25: Oil Burner And Pump - Riello Rdb Burners

    (not supplied) between the oil pump and the return line connection, and tighten to secure. RIELLO RDB OIL PUMP INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 OIL BURNER & PUMP 109 711B 07.2010 RIELLO RDB BURNERS...

  • Page 26: Oil Burner And Pump - Bentone Sterling Burners

    (B). Refit plug (A). Remove oil pump return plug (D). Connect the flexible oil return hose to the INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 OIL BURNER & PUMP 109 711B 07.2010 BENTONE STERLING BURNERS...

  • Page 27: Refitting Components

    (J) to secure to the burner air intake box and the burner air intake. Plug burner lead (F) into control box (G). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 REFITTING COMPONENTS 109 711B 07.2010...

  • Page 28: Electrics

    Refit electric control panel cover: Refit cover panel (C) to control box (A) and secure with screws (B). Refit control knob (D). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 ELECTRICS 109 711B 07.2010...
  • Page 29 E - HEATING THERMOSTAT (MANUAL RESET). F - CONTROL THERMOSTAT. G - BURNER SOCKET. H - BURNER PLUG. J - BURNER CONTROL BOX. RIELLO CONTROL BOX INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 ELECTRICS 109 711B 07.2010...
  • Page 30 The junction box (A) must be fitted externally to the boiler. A frost thermostat can also be connected to the remote junction box if required. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 ELECTRICS 109 711B 07.2010...

  • Page 31: Pre-Commissioning Checks- Appliance

    Complete the installation part of the Guarantee Registration Card, and complete a CD10 or equivalent to inform the LABC of the installation. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 PRE-COMMISSIONING CHECKS- 109 711B 07.2010 APPLIANCE...

  • Page 32: Filling The System

    There are two venting bosses (A) on the top of the secondary heat exchanger. Only one is used if fluing to the side. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 FILLING THE SYSTEM 109 711B 07.2010...

  • Page 33: Starting The Appliance

    Danfoss BFP 11 L3, Danfoss BFP 52E L3 and Riello RDB. Safely dispose of the container/discharge. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 STARTING THE APPLIANCE 109 711B 07.2010...

  • Page 34: (Starting The Appliance - Riello Rdb Burners)

    Refit the sample point cap (L)(hand tighten only, do not over tighten). 249000 240000 2.00 45° S 6.05 7.66 12.0 72.9 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 STARTING THE APPLIANCE 109 711B 07.2010 RIELLO RDB BURNERS...

  • Page 35: Starting The Appliance Bentone Sterling Burners

    1.50 45° S 145/150 6.58 12.0 62.5 213000 205000 2.00 45° S 110/135 6.05 7.66 12.0 13.0 72.9 249000 240000 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 STARTING THE APPLIANCE 109 711B 07.2010 BENTONE STERLING BURNERS...
  • Page 36 The burner and circulating pump should be off. 3 Check that any other controls that are fitted to the system are operating properly. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 STARTING THE APPLIANCE 109 711B 07.2010...

  • Page 37: Water Treatment

    . INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 WATER TREATMENT 109 711B 07.2010...

  • Page 38: Finishing Commissioning - Appliance

    NOTE: Release drain point (K) to drain the secondary heat exchanger. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 FINISHING COMMISSIONING - 109 711B 07.2010 APPLIANCE...

  • Page 39: Inspection And Service

    Clean or replace all oil filters. Check that the condensate system is not obstructed, clean and refill the condensate trap as necessary. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 INSPECTION AND SERVICE 109 711B 07.2010...

  • Page 40: (Inspection And Service - Riello Rdb Burners)

    If the filter contains a washable element, thoroughly clean in kerosene and reassemble into the filter. RIELLO RDB OIL PUMP RIELLO RDB OIL PUMP INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 INSPECTION AND SERVICE 109 711B 07.2010...

  • Page 41: Inspection And Service - Bentone Sterling Burners)

    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. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 INSPECTION AND SERVICE 109 711B 07.2010...
  • Page 42 ( B ) and tighten, using the sequence shown, until the chamber door is firmly secured, do not over tighten the nuts. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 INSPECTION AND SERVICE 109 711B 07.2010...
  • Page 43 213000 205000 1.50 45° S 6.58 12.0 62.5 heat exchanger. 249000 2.00 45° S 6.05 7.66 12.0 72.9 240000 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 INSPECTION AND SERVICE 109 711B 07.2010...

  • Page 44: Short Parts List Riello Rdb Burners

    Part Number: 8 716 108 098 0 2.00 45° S (70kW output) Part Number: 8 716 110 047 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 SHORT PARTS LIST 109 711B 07.2010 REILLO RDB BURNERS...

  • Page 45: Short Parts List Bentone Sterling Burners

    Part Number: 8 716 108 098 0 2.00 45° S (70kW output) Part Number: 8 716 110 047 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 SHORT PARTS LIST 109 711B 07.2010 BENTONE STERLING BURNERS...

  • Page 46: Fault Finding & Diagnosis

    Set up as in installation instructions Oil pressure incorrect Adjust to correct pressure Incorrect components used on Check with installation instructions combustion head Faulty nozzle Replace nozzle INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 FAULT FINDING 109 711B 07.2010...
  • Page 47 Rectify burner operation and lockouts operation, numerous lockouts Odour in boiler room, oil leaks Rectify oil leaks, replace components i f from pipework, flexible hoses necessary connections INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 FAULT FINDING 109 711B 07.2010...

  • Page 48: Fault Finding Logic For Riello Control Box

    Worcester, B osch Group cannot be held responsible for costs incurred by persons not deemed to be competent. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 FAULT FINDING 109 711B 07.2010...

  • Page 49: Fault Finding Logic For Satronic Control Box

    SATRONIC CONTROL BOX 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. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716 FAULT FINDING 109 711B 07.2010...

  • Page 50: Commissioning Checklist

    It is recommended that the heating system is serviced regularly and that you complete the appropriate Service Interval Record Overleaf. Service Provider. Before completing the appropriate Service Interval Record overleaf, please ensure you have carried out the service as described in this manual. Always use Worcester, Bosch Group specified spare parts.
  • Page 51 8 716 109 711 b 07.10 14/7/10 09:59 Page 51 SERVICE 2 SERVICE 1 DATE DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No. TEL No. OFTEC REG No. OFTEC REG No. PUMP PRESSURE: PUMP PRESSURE: NOZZLE CHANGED? NOZZLE CHANGED? F.G.T.
  • Page 52 0844 892 9800 TRAINING: 01905 752526 SALES: 01905 752640 WEBSITE: www.worcester-bosch.co.uk Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0844 892 9900 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. 8 716 109 711B 07.2010...

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