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Worcester GREENSTAR UTILITY 32/50 Instruction manual

Other manuals for GREENSTAR UTILITY 32/50: User Instructions, User Instructions & Customer Care Manual
Manual is about: INSTALLATION, COMMISSIONING & SERVICING FLOOR STANDING OIL-FIRED CONDENSING BOILER CONVENTIONAL FLUE & ROOM SEALED FLUE

Summary of GREENSTAR UTILITY 32/50

  • 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 uk the appliance is for use with ke...

  • Page 2

    Installation & servicing instructions installation & servicing instructions for worcester greenstar danesmoor utility 18/25 8 716 109 711b 07.2010 2 symbols used in this manual: installation & servicing instructions important handling instructions: it is advised that more than one person is involved...

  • Page 3

    Contents installation & servicing instructions for worcester greenstar danesmoor utility 18/25 8 716 109 711b 07.2010 3 saf et y & re gul a t io n s a ppl ia n c e inf o rm a t io n p r e - in st al la ti o n in st al la ti o n c o m m iss io n in g ser v ic in g & sp a res f a ul t f ind in g & d i...

  • Page 4

    Safety precautions & installation regulations installation & servicing instructions for worcester greenstar danesmoor utility 18/25 8 716 109 711b 07.2010 4 saf et y & re gul a t io n s safety precautions installation regulations oil fumes or leaks from the appliance: extinguish any naked flames. Op...

  • Page 5: Check List

    General information installation & servicing instructions for worcester greenstar danesmoor utility 18/25 8 716 109 711b 07.2010 5 a ppl ia n c e inf o rm a t io n general information standard package: a - floor standing oil fired condensing boiler for open vent and sealed domestic central heating a...

  • Page 6

    Technical data installation & servicing instructions for worcester greenstar danesmoor utility 18/25 8 716 109 711b 07.2010 6 technical data central heating primary water capacity (total) litres maximum static head metres minimum static head metres water side resistance (20°c difference) mbar water ...

  • Page 7

    Burner cover cut-away view layout & components the diagram opposite excludes the top, front and rh side casing panels. 1 ch thermostat control 2 reset button boiler overheat 3 reset button flue overheat 4 control box assembly 5 casing side panel 6 casing support panel 7 clip - fire sensor 8 control,...

  • Page 8

    Cleaning primary systems important: all the following pre-installation sections must be read and requirements met before starting boiler or flue installation. Caution: isolate the mains supplies before starting any work and observe all relevant safety precautions. Cleaning primary systems installati...

  • Page 9

    Mains supply electric supply: • supply: 230v - 50hz. • cable: pvc insulated 0.75mm 2 (24 x 0.2mm) temperature rated to 90°c. • protection ip20. • external 5a fuse to bs1362. • the appliance must be earthed. • refer to iee regulations for cross bonding requirements. • it must be possible to isolate t...

  • Page 10

    Oil supply installation & servicing instructions for worcester greenstar utility 32/50 & 50/708 716 109 711b 07.2010 10 p r e - in st al la ti o n oil supply oil supply : • this appliance is suitable for kerosene (28 second oil) only, no other fuel must be used. • plastic or steel tanks should be in...

  • Page 11

    Water systems & pipework installation & servicing instructions for worcester greenstar utility 32/50 & 50/70 8 716 109 711b 07.2010 11 p r e - in st al la ti o n r typical open vent system: a - appliance. B - expansion vessel. C - automatic bypass valve. D - drain cock. E - feed and expansion cister...

  • Page 12

    Water systems & pipework filling primary sealed systems: • filling the system must comply with one of the methods shown opposite. • the filling point must be at low level and must never be a permanent direct fixing to the mains water supply. • filling links must be wras approved. Heating return hose...

  • Page 13

    Condensate pipework installation & servicing instructions for worcester greenstar utility 32/50 & 50/708 716 109 711b 07.2010 13 p r e - in st al la ti o n condensate & pressure relief pipework condensate pipework: • all national and, where appropriate, local regulations for the discharge and neutra...

  • Page 14

    External2 ventilation high low level level 248 248 358 358 room sealed flue:* internal1ventilation high low model level level 32/50 495 495 50/70 715 715 external2 ventilation high low level level 248 495 358 715 conventional flue:* internal1ventilation high low model level level 32/50 495 743 50/70...

  • Page 15

    600m m 2250m m 600m m 2250m m 600mm 600mm radius 7 50m m 7 50m m 2250m m m 2250m boiler location & clearances installation & servicing instructions for worcester greenstar utility 32/50 & 50/708 716 109 711b 07.2010 15 p r e - in st al la ti o n compartments: follow the requirements of bs 5410 and n...

  • Page 16

    Flue terminal positions installation & servicing instructions for worcester greenstar utility 32/50 & 50/708 716 109 711b 07.2010 16 p r e - in st al la ti o n flue terminal positions • flue terminals must be positioned to avoid combustion products entering into buildings. • the flue must be fitted ...

  • Page 17

    P r e - in st al la ti o n conventional flue installation & servicing instructions for worcester greenstar utility 32/50 & 50/708 716 109 711b 07.2010 17 conventional flue c b a d e a - boiler b - flue c - max. 2 bends at 135° d - anti down-draught terminal e - chimney • open (conventional) flued ap...

  • Page 18

    Room sealed flue options installation & servicing instructions for worcester greenstar utility 32/50 & 50/708 716 109 711b 07.2010 18 p r e - in st al la ti o n room sealed flue options the diagrams (opposite) show the components used and the maximum flue length (l) from the boiler outlet to the ous...

  • Page 19

    Unpacking the boiler installation & servicing instructions for worcester greenstar utility 32/50 & 50/708 716 109 711b 07.2010 19 in st al la ti o n unpacking: it is advised that two or more persons are involved in the transfer of the packaged boiler from the van to the point of delivery. 1 once the...

  • Page 20

    Safety: all relevant safety precautions must be undertaken. Protective clothing, footwear, gloves and safety goggles must be worn as appropriate. Pipework positions: a to d (opposite) show the flue and pipe positions: a - ch flow /heating vent 1 1 / 2 ” Ø bsp b - primary drain/cold feed 1 1 / 2 ” Ø ...

  • Page 21

    Boiler installation 1 lift the top panel (a) upwards to disengage the ball stud connections (b) and remove. 2 pull the upper front panel squarely forwards to disengage the ball stud connectors and remove from the control box (g). Remove securing screws (c) from each side. Slide control box (g) outwa...

  • Page 22

    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. (cf position 'a' only). Refer to the separate flue installation instructions supplied with the flue kits available for this boiler: rs flue kits & components gr...

  • Page 23

    Secondary heat exchanger: 1 unscrew screws (b) and remove flue manifold access cover (a). Check that all the baffles and retainer are correctly fitted to the secondary heat exchanger: slots double single baffles baffles 32/50kw* 25 10 n/a 50/70kw 31 15 1 *five of the slots do not have baffles. Combu...

  • Page 24

    Pipework connections installation & servicing instructions for worcester greenstar utility 32/50 & 50/708 716 109 711b 07.2010 24 in st al la ti o n caution: isolate the oil & water mains supply before starting any work and observe all relevant safety precautions. Pipework connections a - ch flow /h...

  • Page 25

    Oil burner & pump riello rdb burners installation & servicing instructions for worcester greenstar utility 32/50 & 50/708 716 109 711b 07.2010 25 in st al la ti o n caution: isolate the oil & water mains supply before starting any w o r k an d o b s e r ve all r e le vant safety precautions. Oil bur...

  • Page 26

    Caution: isolate the oil & water mains supply before starting any w o r k an d o b s e r ve all r e le vant safety precautions. Oil burner: 1 check the nozzle (e) settings are correct for the relevant burner as shown opposite. Ensure nozzle (e) is aligned centrally within the breakplate (g). Inspect...

  • Page 27

    Refitting components 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) with retaining screws (s) on both sides. 2 carefully replace the manual reset thermostat (u), automatic high limit...

  • Page 28

    Electrics danger - 230v: isolate the mains electricity supply before starting any work and observe all relevant safety precautions. Important: observe electronic static discharge precautions. Do not touch the pcb circuits. Access to 230v connections: 1 pull control knob (d) forwards to remove from c...

  • Page 29

    H rese t j riello control box electrics 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 - control thermostat. G - burner socket. H ...

  • Page 30

    Electrics danger - 230v: isolate the mains electricity pre-wired remote 2 or 3 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 wiring 230v 50hz. Hot ...

  • Page 31

    Pre-commissioning checks - appliance caution: isolate the mains supplies before starting any work and observe all relevant safety precautions. 1 check that the service and water pipes are connected correctly. Check that all unused sockets are capped. 2 check that the oil supply is 28 sec kerosene an...

  • Page 32

    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 cistern and allow the system to fill. 2 sealed systems only: check and if required, adjust the expansion vessel pressure using the schraeder type valv...

  • Page 33

    C b a riello rdb oil pump starting the appliance important: never run the appliance when the appliance/system is unpressurised (sealed systems) or empty. 1 check the oil supply is correctly fitted and in good working order before turning on the oil supply valves to the boiler. Turn on the main oil s...

  • Page 34

    Starting the appliance riello rdb burners installation & servicing instructions for worcester greenstar utility 32/50 & 50/708 716 109 711b 07.2010 34 c o mmi s s io n in g %co 2 nominal boiler rating at normal operating temperature using 28sec kerosene: nozzle oil pump pressure (p.S.I.) fuel flow r...

  • Page 35

    %co 2 nominal boiler rating at normal operating temperature using 28sec kerosene: nozzle oil pump pressure (p.S.I.) fuel flow rate kg/h l/h combustion head setting approx. Air setting appliance input output kw btu/hr kw btu/hr bentone sterling 146 burner (50/70kw): 1.25 45 ° s 1.50 45 ° s 2.00 45 ° ...

  • Page 36

    Starting the appliance central heating: 1 open all radiator valves. Set room thermostat to maximum. Set programmer to on for ch & dhw (if applicable). Turn the boiler control thermostat (a) to max. The burner should be on with the circulating pump. Ensure all radiators are heating up evenly and bala...

  • Page 37

    Water treatment 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 appliance will invalidate the appliance warranty. Flushing (central heating): 1 switch off the boiler. Open vented systems only...

  • Page 38

    Finishing commissioning - appliance 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 boiler. Secure with screws (e). Locate the ball stud connectors (f) and push-fit upper front panel (g) towards the bo...

  • Page 39

    Inspection and service caution: 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 che...

  • Page 40

    1 clean the burner: undo the three screws (a) and remove cover (b) from the burner. Loosen clip to remove the flexible air inlet hose (c) from the burner (rs flue systems only). Remove the air intake cover (d) by releasing the m4 screws. Check the condition of the gasket between these two parts and ...

  • Page 41

    1 clean the burner: loosen clip to remove the flexible air inlet hose (d) from the burner (rs flue systems only). Remove the air intake cover (h) by releasing the m4 screws. Seperate the main body of the burner from the front by removing the m5 screw ( j ), located beneath the air adjustment screw (...

  • Page 42

    J i l i k l front inspection and service clean the boiler: manifold access: release screws (e) to remove the flue manifold access cover (f) and clear any debris. Check the flue system and clean if necessary. Remove the baffle retainer and baffles (h) from the secondary heat exchanger. Slots double s...

  • Page 43

    Inspection and service fire valve: check that the oil supply pipe has a fire valve fitted externally to the building with the fire valve sensor located within the appliance case. A fire valve sensor clip is provided for this purpose on the casing support panel. Re-commission the burner: 1 sterling b...

  • Page 44

    78 11 13 12 14 2 34 5 6 910 1 15 16 17 2a riello rdb burners short parts list 1 burner - riello rdb 3.2 32/50 part number: 8 718 686 583 0 burner - riello rdb 4.2 50/70 part number: 8 718 686 726 0 2 combustion head - elica g3 32/50 part number: 8 716 116 102 0 2a combustion head - elica g10 50/70 p...

  • Page 45

    1 78 9 13 14 15 16 11 10 12 2 34 5 6 17 18 19 20 8a bentone sterling burners short parts list 1 burner - sterling 133 32/50 part number: 8 716 108 063 0 burner - sterling 146 50/70 part number: 8 716 108 065 0 2 combustion head - type s 32/50 part number: 8 716 108 079 0 combustion head - type s 50/...

  • Page 46

    Fault finding problem cause remedy lockout: pulsation on start cf - flue draught incorrect cf - check flue draught combustion settings incorrect set up as in installation instructions faulty nozzle replace nozzle intermittent lockout bad electrical connection check control box/electrical connections...

  • Page 47

    Fault finding 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 bearings replace motor fan out of balance replace fan boiling faulty boiler thermostat replace if necessary short circuit boiler thermos...

  • Page 48

    Boiler not operating with a heating / hot water demand burner motor runs? L o ckout within 1 second? Replace control b o x replace motor/pump chec k b oiler controls & supply replace motor chec k l & n to control bo x motor or pump seized? Photo cell functional? S olenoid coil functional (100 Ω )? R...

  • Page 49

    Boiler not operating with a heating / hot water demand burner motor runs? Burner lights immediately motor runs? 23 0v at solenoid coil in purge? Replace control b o x replace pump 23 0v at motor? Motor or pump seized? Replace motor capacitor motor 4 0 Ω across l& n ? L & n to control b o x? Control ...

  • Page 50: Service Interval Record

    Boiler model serial no. Commissioning engineer commissioning checks company name: pump pressure (psi): address: co 2 %: smoke reading: engineers name: f.G.T.°c: signature: flue pressure: date: burner model: controls to comply with the building regulations, each section must have a tick in one or oth...

  • Page 51

    Service 1 date engineer name company name tel no. Oftec reg no. Pump pressure: psi co 2 %: nozzle changed? Yes no f.G.T. °c flue pressure: comments signature service 2 date engineer name company name tel no. Oftec reg no. Pump pressure: psi co 2 %: nozzle changed? Yes no f.G.T. °c flue pressure: com...

  • Page 52

    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 worcester, bosch group: technical support: 0844 892 3366 appointments: 0844 892 3000 spares: 01905 752571 literature: 0844 ...