Fault Finding And Diagrams; Fault Finding - Bosch Worcester Greenstar Utility 32/50 Installation, Commissioning And Servicing Instruction Manual

8

Fault finding and diagrams

8.1

Fault finding

PROBLEM CAUSE
LOCKOUT
Pulsation on start CF - Flue draught incorrect
Combustion settings incorrect
Faulty nozzle
Intermittent lockout Bad electrical connection
Combustion settings incorrect
Intermittent flame detection fault
Down draught
Burner motor fails to operate Faulty motor or electrical supply to motor
Control box fault
Flame detection fault Photocell filmed over (dirty)
Photocell faulty
Control box faulty
Incorrect CO2 Air adjustment fault
Oil pressure incorrect
No oil from nozzle No oil at pump
Air in pump
Nozzle blocked
Faulty pump or drive
Ignition failure Electrode settings incorrect
Faulty ignition transformer
Open circuit ignition
Faulty control box or electrical connections not properly
made
BURNER FAILS TO START: No power to appliance
Programmer open circuit
Faulty appliance thermostat
Faulty control box
HIGH SMOKE NUMBER: Air intake/flue blocked
Incorrect combustion settings
Oil pressure incorrect
Incorrect components used on combustion head
Faulty nozzle
FAULTY APPLIANCE OPERATION
Noisy operation Pump noise from air in pump or worn pump
Worn motor bearings
Fan out of balance
Boiling No primary water circulation
Short circuit appliance thermostat
Thermostat bulb not fully home in pocket
Faulty appliance thermostat
Short Cycling External controls not operating correctly
Appliance thermostat differential incorrect
Burner rating incorrect
OIL SMELLS: Blocked flue, fumes on startup
Oil soaked appliance, faulty burner operation, numerous
lockouts
Odour in appliance room, oil leaks from pipework,
flexible hoses connections
Greenstar Utility ErP - 6 720 821 751 (2018/04)
Fault finding and diagrams
WARNING: Under no circumstances must an appliance
be left to operate with any control linked out or
overridden.
REMEDY
CF - Check flue draught
Set up as in installation instructions
Replace nozzle
Check control box/electrical connections
Set up as in installation instructions
See flame detection fault
Extend flue or fit an anti-down draught cowl (CF only)
Check for 230V to motor during startup period
Replace control box
Wipe clean
Replace
Replace
Set up as in installation instructions
Set up as in installation instructions
Check and refill oil tank/bleed oil line
Check and clean filters & valves from oil tank to appliance
Bleed pump
Replace nozzle
Replace
Set up as in installation instructions
Replace
Check and replace electrodes or high tension leads if
necessary
Correct electrical control box connections or replace
control box
Check electrical / control circuit
Check programmer
Check by temporarily linking out high limit and control
thermostats
Replace
Check & clear air intake/flue
Set up as in installation instructions
Adjust to correct pressure
Check with installation instructions
Replace nozzle
Bleed air from pump or replace pump
Replace motor
Replace fan
Check system / circulating pump
Temporarily take out of circuit to check
Ensure bulb is pushed fully home
Replace if necessary
Check and correct external controls
Replace appliance thermostat
Correct burner rating
CF - Check flue with gauge and check seals/gaskets
RS - Check seals/gaskets
Rectify burner operation and lockouts
Rectify oil leaks, replace components if necessary
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