1. DL manuals
  2. Worcester
  3. Boiler
  4. Greenstar utility 32-50kW
  5. Instruction manual

Worcester Greenstar utility 32-50kW Instruction manual

Manual is about: floor standing oil-fired condensing boiler conventional flue & room sealed flue installation commissioning & servicing

Summary of Greenstar utility 32-50kW

  • Page 1

    Greenstar utility 32/50kw & 50/70kw floor standing oil-fired condensing boiler conventional flue & room sealed flue the appliance is for use with 28 second kerosene only gb/ie 8-716-109-711a (04.05) instruction manual installation commissioning & servicing gb/ie for fully pumped open vent or sealed ...

  • Page 2

    Installation & servicing instructions contact information installation & servicing instructions for worcester bosch installation & servicing instructions 8-716-109-711a (04.05) please read these instructions carefully before starting installation. These instructions are applicable to the worcester b...

  • Page 3

    Installation & servicing instructions for worcester bosch contents saf et y & re gul at io n s fa ul t find in g & d ia g r am s appl ia n c e in for m at ion pr e- in s ta ll at io n in s ta ll at io n c o mmi s s io nin g s e r vici ng & s pa r e s con ve r s ion k its contents 1 safety & regulati...

  • Page 4

    Saf et y & re gul at io n s installation & servicing instructions for worcester bosch safety precautions installation regulations 2 safety precautions & installation regulations 8-716-109-711a (04.05) oil smells, leaks or fumes from the appliance: extinguish any naked flames open windows and doors i...

  • Page 5

    Appl ia n c e in for m at ion installation & servicing instructions 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 val...

  • Page 6

    Appl ia n c e in for m at ion installation & servicing instructions for worcester bosch 32/50kw 50/70kw 28 28 50 51 30 30 1 1 26 40 52 104 76 106 130 130 100/150 100/150 10 10 1½ 1½ 28 28 1½ 1½ 1½ 1½ 21.5 21.5 230 230 50 50 190 220 60/82 60/82 5 5 100 100 110 110 120 120 100 100 93.0 (a) 92.5 (a) 20...

  • Page 7

    Appl ia n c e in for m at ion installation & servicing instructions for worcester bosch 5 layout & components layout & components 8-716-109-711a (04.05) the diagram opposite shows the controls in the servicing position and excludes the top,front and rh side casing panels. 1 ch thermostat control 2 r...

  • Page 8

    Pr e- in s ta ll at io n installation & servicing instructions for worcester bosch 6 cleaning primary systems cleaning primary systems caution: isolate the mains supplies before starting any work and observe all relevant safety precautions. Important: all the following pre-installation sections must...

  • Page 9

    Pr e- in s ta ll at io n 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 ...

  • Page 10

    Pr e- in s ta ll at io n installation & servicing instructions for worcester bosch 8-716-109-711a (04.05) 8 mains supplies mains supplies oil supply: • plastic or steel tanks should be installed to bs5410. A steel tank should conform to bs799: part 5 and arranged with a slope of 1 in 24 away from th...

  • Page 11

    Pr e- in s ta ll at io n installation & servicing instructions for worcester bosch 8-716-109-711a (04.05) plastic pipework: • any plastic pipework must have a polymeric barrier with 1000mm (minimum) length of copper or steel pipe connected to the boiler • plastic pipework used for underfloor heating...

  • Page 12

    Pr e- in s ta ll at io n installation & servicing instructions for worcester bosch 8-716-109-711a (04.05) filling primary systems: • filling the system must comply with one of the methods shown opposite diagram shown opposite • the filling point must be at low level and must never be a permanent dir...

  • Page 13

    Pr e- in s ta ll at io n installation & servicing instructions for worcester bosch 8-716-109-711a (04.05) 11 condensate & pressure relief pipework condensate & pressure relief pipework condensate pipework: a condensate trap is supplied with the boiler for external installation. The condensate pipe m...

  • Page 14

    Pr e- in s ta ll at io n installation & servicing instructions for worcester bosch 12 boiler location & clearances boiler location & clearances 8-716-109-711a (04.05) this boiler is only suitable for installing internally within a property at a suitable location onto a fixed rigid non-combustible su...

  • Page 15

    Pr e- in s ta ll at io n installation & servicing instructions for worcester bosch 8-716-109-711a (04.05) 13 boiler location & clearances boiler location & clearances 600mm 2250mm 600mm 2250mm 600mm 600mm radius 750mm 750mm a a a - bath or shower cubicle (zone 0) shower / bathrooms: the boiler must ...

  • Page 16

    Pr e- in s ta ll at io n installation & servicing instructions for worcester bosch 8-716-109-711a (04.05) • flue terminals must be positioned to avoid combustion products entering into buildings • the flue must be fitted and terminated in accordance with the recommendations of bs5410 • the flue must...

  • Page 17

    Pr e- in s ta ll at io n installation & servicing instructions for worcester bosch 8-716-109-711a (04.05) open (conventional) flued appliances must not be installed in a bedroom, bathroom or bedsitting room the flue system must be in accordance with bs5410 : parts 1 & 2 and the current building regu...

  • Page 18

    Pr e- in s ta ll at io n installation & servicing instructions for worcester bosch 16 room sealed flue options 8-716-109-711a (04.05) room sealed flue options the diagrams (opposite) show the components used and the maximum flue length (l) from the boiler outlet to the outside wall /roof of the buil...

  • Page 19

    In s ta ll at io n installation & servicing instructions for worcester bosch 17 unpacking the boiler unpacking the boiler 8-716-109-711a (04.05) important: all the previous pre-installation sections must be read and requirements met before starting boiler or flue installation. Unpacking: 1 cut the t...

  • Page 20

    In s ta ll at io n installation & servicing instructions for worcester bosch 18 pipework positions & flue opening pipework positions & flue opening 8-716-109-711a (04.05) caution: ensure there are no pipes, electric cables, damp proof course or other hazards before drilling. Safety: all relevant saf...

  • Page 21

    In s ta ll at io n installation & servicing instructions for worcester bosch 1 lift the top panel (a) upwards to disengage the ball stud connections (b) and remove 2 pull upper front panel squarely forwards to disengage the ball stud connections and remove from the control box (g) remove securing sc...

  • Page 22

    In s ta ll at io n installation & servicing instructions for worcester bosch the flue can exit the boiler from outlets a, b, c or d allowing vertical (rs & cf) and horizontal (rs low or high level) flues to be fitted. Refer to the separate flue installation instructions supplied with the flue kits a...

  • Page 23

    In s ta ll at io n installation & servicing instructions for worcester bosch 21 combustion chamber combustion chamber 8-716-109-711a (04.05) secondary heat exchanger: 1 check that all the baffles and retainer are correctly fitted to the secondary heat exchanger: slots double single baffles baffles 3...

  • Page 24

    In s ta ll at io n installation & servicing instructions for worcester bosch 22 pipework connections pipework connections 8-716-109-711a (04.05) caution: isolate the oil & water mains supply before starting any work and observe all relevant safety precautions. A - ch flow/heating vent 1½''Ø b - prim...

  • Page 25

    In s ta ll at io n installation & servicing instructions for worcester bosch 23 oil burner & pump oil burner & pump 8-716-109-711a (04.05) a - nozzle to front of break plate b - nozzle to front of blast tube c - front of break plate to front of blast tube caution: isolate the oil mains supply before...

  • Page 26

    In s ta ll at io n installation & servicing instructions for worcester bosch 24 refit components refit components 8-716-109-711a (04.05) 1 slide side panels (r) and top support bracket (l) together with control box (g) along base rails and push to secure into the retaining lugs secure side panel (r)...

  • Page 27

    In s ta ll at io n installation & servicing instructions for worcester bosch 25 electrics electrics 8-716-109-711a (04.05) danger - 230v: isolate the mains electricity supply before starting any work and observe all relevant safety precautions. Access to 230v connections: 1 pull control knob (d) for...

  • Page 28

    In s ta ll at io n installation & servicing instructions for worcester bosch 3 5 1 230v standard wiring diagram: key to components: a - terminal connector block b - earth connector c - flue thermostat (manual reset) d - heating thermostat (automatic reset) e - heating thermostat (manual reset) f - c...

  • Page 29

    In s ta ll at io n installation & servicing instructions for worcester bosch pre-wired remote 3 or 2 port valve control sets: key to components: a - double pole switched fused spur (positioned in the boiler room next to the appliance) b - remote junction box (10-way) to connect the following: mains ...

  • Page 30

    C o mmi s s io nin g installation & servicing instructions for worcester bosch 28 pre-commisioning checks pre-commisioning checks 8-716-109-711a (04.05) caution: isolate the mains supplies before starting any work and observe all relevant safety precautions. 1 check that the service and water pipes ...

  • Page 31

    C o mmi s s io nin g installation & servicing instructions for worcester bosch 29 filling the system filling the system 8-716-109-711a (04.05) 1 open all system and radiator valves turn on the water main stop cock open vented systems only; turn on the water to the system feed and expansion tank and ...

  • Page 32

    C o mmi s s io nin g installation & servicing instructions for worcester bosch 30 starting the appliance starting the appliance 8-716-109-711a (04.05) 1 important: never run the appliance when the appliance/system is unpressurised or empty. 1 check the oil supply is correctly fitted and in good work...

  • Page 33

    C o mmi s s io nin g installation & servicing instructions for worcester bosch 31 starting the appliance starting the appliance 8-716-109-711a (04.05) % co 2 nominal boiler rating at normal operating temperature using 28sec kerosene: nozzle bentone sterling 133 burner (32/50kw): oil pump 1st / 2nd s...

  • Page 34

    C o mmi s s io nin g installation & servicing instructions for worcester bosch 32 starting the appliance starting the appliance 8-716-109-711a (04.05) 1 central heating: 1 open all radiator valves set room thermostat to maximum set programmer to on for ch & dhw turn the thermostat control (a) to 'ma...

  • Page 35

    C o mmi s s io nin g installation & servicing instructions for worcester bosch 33 water treatment water treatment 8-716-109-711a (04.05) important: 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 applia...

  • Page 36

    C o mmi s s io nin g installation & servicing instructions for worcester bosch 34 finishing commissioning finishing commissioning 8-716-109-711a (04.05) 1 locate edge of front panel (a) onto the supporting ledge (b) on the baseplate refit securing screws (c) to secure 2 slide control box (d) into th...

  • Page 37

    S e r vici ng & s pa r e s installation & servicing instructions for worcester bosch 35 inspection and service inspection and service 8-716-109-711a (04.05) caution: isolate the water, electricity and oil mains supplies before starting any work and observe all relevant safety precautions. Routine se...

  • Page 38

    S e r vici ng & s pa r e s installation & servicing instructions for worcester bosch 36 inspection and service inspection and service 8-716-109-711a (04.05) a - nozzle to front of break plate b - nozzle to front of blast tube c - front of break plate to front of blast tube 1 clean the burner: loosen...

  • Page 39

    S e r vici ng & s pa r e s inspection and service installation & servicing instructions for worcester bosch heatslave 8-716-106-252a (03.05) inspection and service 37 clean the boiler: manifold access: release screws (e) to remove the manifold access cover (f) and clear any debris check the condensa...

  • Page 40

    S e r vici ng & s pa r e s installation & servicing instructions for worcester bosch 38 inspection and service inspection and service 8-716-109-711a (04.05) re-commission the burner: 1 align burner blast tube (n) into the boiler housing tube with the gasket (o) correctly fitted push firmly down to c...

  • Page 41

    S e r vici ng & s pa r e s installation & servicing instructions for worcester bosch 39 short parts list short parts list 8-716-109-711a (04.05) 1 burner for 32/50 bentone sterling 133 part number: 8 716 108 063 0 2 igition/electrode for 32/50 a 21 breakplate/electrodes part number: 8 716 108 082 0 ...

  • Page 42

    S e r vici ng & s pa r e s installation & servicing instructions for worcester bosch 40 fault finding fault finding 8-716-109-711a (04.05) boiler lockout: indicated by the illumination of the 'lockout' reset button on the burner control box. To reset, wait 2 minutes then press the lockout reset butt...

  • Page 43

    Fa ul t find in g & d ia g r am s installation & servicing instructions for worcester bosch 41 fault finding fault finding 8-716-109-711a (04.05) problem cause remedy faulty boiler operation: noisy operation pump noise from air in pump or worn pump bleed air from pump or replace pump worn motor bear...

  • Page 44: Instruction Manual

    8-716-109-711a (04.05) worcester, 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.