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Worcester GREENSTAR UTILITY Instruction Manual

Manual is about: Floor Standing oi-fired condensing boiler conventional flue-room sealed flue 18/25kW

Summary of GREENSTAR UTILITY

  • Page 1

    Greenstar utility 18/25kw floor standing oil-fired condensing boiler conventional flue & room sealed flue for fully pumped open vent or sealed central heating systems and domestic hot water cylinders the appliance is for use with 28 second kerosene only gb/ie 8-716-106-256a (08.05) instruction manua...

  • Page 2

    Installation & servicing instructions contact information installation & servicing instructions for worcester bosch installation & servicing instructions 8-716-106-256a (08.05) 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 8-716-106-256a (08.05) 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 8-716-106-256a (08.05) standard package: a - floor standing oil fired condensing boiler. B - literature pack. C - hardware pack including: condensate trap. 600mm 855mm 37...

  • Page 6

    Appl ia n c e in for m at ion installation & servicing instructions for worcester bosch 18/25kw 24.5 30 1 57 2.65 40 10 1 22 1 1 21.5 230 50 155 55/81 5 95 105 110 92.9 20 120 4 technical data technical data 8-716-106-256a (08.05) description units central heating primary water capacity (total) litr...

  • Page 7

    Appl ia n c e in for m at ion installation & servicing instructions for worcester bosch 5 layout & components layout & components 8-716-106-256a (08.05) the diagram opposite excludes the top,front and rh side casing panels. 1 control box assembly 2 casing side panel 3 flue 'knock-out' panel 4 clip -...

  • Page 8

    Pr e- in s ta ll at io n installation & servicing instructions for worcester bosch 6 cleaning primary systems cleaning primary systems 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 applianc...

  • Page 9

    Pr e- in s ta ll at io n installation & servicing instructions for worcester bosch 8-716-106-256a (08.05) 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. • ...

  • Page 10

    Pr e- in s ta ll at io n installation & servicing instructions for worcester bosch 8-716-106-256a (08.05) the table and illustration above is a guide only and does not in any way override the de-aerators manufacturers instructions. A f b c g j 4m ( 13ft ) max . B a d b c b e k 3.5m ( 11 .5ft ) max ....

  • Page 11

    Pr e- in s ta ll at io n installation & servicing instructions for worcester bosch pr e- in s ta ll at io n installation & servicing instructions for worcester bosch 8-716-106-256a (08.05) 9 water systems & pipework water systems & pipework primary system plastic pipework: • any plastic pipework mus...

  • Page 12

    Pr e- in s ta ll at io n installation & servicing instructions for worcester bosch 8-716-106-256a (08.05) 10 water systems & pipework 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 l...

  • Page 13

    Pr e- in s ta ll at io n installation & servicing instructions for worcester bosch 8-716-106-256a (08.05) 11 condensate & pressure relief pipework invert 450 min . 75mm min. 75mm min. 75mm min. M n l m a b c d e a a c a b c d c f f f condensate & pressure relief pipework condensate pipework: the con...

  • Page 14

    Pr e- in s ta ll at io n installation & servicing instructions for worcester bosch 12 boiler location & clearances boiler location & clearances 8-716-106-256a (08.05) • this boiler is only suitable for installing internally within a property at a suitable location onto a fixed rigid non-combustible ...

  • Page 15

    Pr e- in s ta ll at io n installation & servicing instructions for worcester bosch 8-716-106-256a (08.05) 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) c: compartments: follow the requirem...

  • Page 16

    Pr e- in s ta ll at io n installation & servicing instructions for worcester bosch 8-716-106-256a (08.05) • 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 mu...

  • Page 17

    Pr e- in s ta ll at io n installation & servicing instructions for worcester bosch 8-716-106-256a (08.05) 15 conventional flue conventional flue a - boiler b - flue c - max. 2 bends at 135° d - anti down-draught terminal e - chimney c b a d e • open (conventional) flued appliances must not be instal...

  • Page 18

    Pr e- in s ta ll at io n installation & servicing instructions for worcester bosch 16 room sealed flue options 8-716-106-256a (08.05) room sealed flue options the diagrams (opposite) show the components used and the maximum flue length (l) for each flue configuration. • to achieve the maximum flue l...

  • Page 19

    In s ta ll at io n installation & servicing instructions for worcester bosch 17 unpacking the boiler unpacking the boiler 8-716-106-256a (08.05) unpacking: 1 cut the ties securing the carton taking care not to pierce the carton or cause personal injury. 2 open the top flaps of carton and lift carton...

  • Page 20

    In s ta ll at io n installation & servicing instructions for worcester bosch 18 pipework positions & flue opening pipework positions & flue opening 8-716-106-256a (08.05) 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 extract the installation and literature packs (t). 3 pull the top front panel (e) away from the boiler to disengage the ball stud con...

  • 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. (cf position 'a' only). Refer to the separate flue installation instructions suppl...

  • Page 23

    In s ta ll at io n installation & servicing instructions for worcester bosch 21 combustion chamber combustion chamber 8-716-106-256a (08.05) combustion chamber: 1 release retaining nuts and washers (b). Remove combustion chamber access door (a). 2 ensure the baffles (c) and baffle retainer (d) are c...

  • Page 24

    In s ta ll at io n installation & servicing instructions for worcester bosch 22 pipework connections pipework connections 8-716-106-256a (08.05) caution: isolate the oil & water mains supply before starting any work and observe all relevant safety precautions. A - ch flow/heating vent 1''Ø bsp b - p...

  • Page 25

    In s ta ll at io n installation & servicing instructions for worcester bosch 23 oil burner & pump oil burner & pump 8-716-106-256a (08.05) caution: isolate the oil mains supply before starting any work and observe all relevant safety precautions. Oil burner: 1 check the nozzle (a) and electrode (b) ...

  • Page 26

    In s ta ll at io n installation & servicing instructions for worcester bosch 24 refit components refit components 8-716-106-256a (08.05) 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 on the baseplate and ...

  • Page 27

    In s ta ll at io n installation & servicing instructions for worcester bosch 25 electrics electrics 8-716-106-256a (08.05) danger - 230v: isolate the mains electricity supply before starting any work and observe all relevant safety precautions. Important: observe electronic static discharge precauti...

  • Page 28

    In s ta ll at io n installation & servicing instructions for worcester bosch 230v standard wiring diagram: key to components: a - earth stud b - high limit thermostat c - boiler manual reset thermostat d - flue manual reset thermostat e - terminal connector block f - control thermostat g - burner co...

  • Page 29

    In s ta ll at io n installation & servicing instructions for worcester bosch pre-wired remote 2 or 3 port valve control set using remote programmer: key to components: k - remote junction box (10-way) to connect the following: mains wiring 230v 50hz hot water tank thermostat room thermostat system w...

  • Page 30

    C o mmi s s io nin g installation & servicing instructions for worcester bosch 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...

  • Page 31

    C o mmi s s io nin g installation & servicing instructions for worcester bosch 29 filling the system filling the system 8-716-106-256a (08.05) 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 header tank and allow the ...

  • Page 32

    C o mmi s s io nin g installation & servicing instructions for worcester bosch 30 starting the appliance starting the appliance 8-716-106-256a (08.05) important: never run the appliance when the appliance/system is unpressurised (sealed systems) or empty. 1 check the oil supply is correctly fitted a...

  • Page 33

    C o mmi s s io nin g installation & servicing instructions for worcester bosch starting the appliance 31 starting the appliance 8-716-106-256a (08.05) 2 fit a suitable pressure gauge to port (a) on the oil pump. Remove plastic cover from the burner casing. Adjust the air shutter (l) and pump pressur...

  • Page 34

    C o mmi s s io nin g installation & servicing instructions for worcester bosch 32 starting the appliance starting the appliance 8-716-106-256a (08.05) 1 open all radiator valves. Set room thermostat to maximum. Set programmer to on for ch. Turn the thermostat control (a) to 'max'. The burner should ...

  • Page 35

    C o mmi s s io nin g installation & servicing instructions for worcester bosch 33 water treatment 8-716-106-256a (08.05) 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 applia...

  • Page 36

    C o mmi s s io nin g installation & servicing instructions for worcester bosch 34 finishing commissioning 8-716-106-256a (08.05) finishing commissioning 1 slide control box (a) into the boiler. Secure with screws (b). 2 align the top front panel (h) and push the ball studs into the connectors (j) to...

  • 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 8-716-106-256a (08.05) 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 8-716-106-256a (08.05) 1 clean the burner: remove the air intake cover (h) by removing the m5 screws and clear any debris from the air intake and air damper. Separate...

  • Page 39

    S e r vici ng & s pa r e s installation & servicing instructions for worcester bosch 37 inspection and service inspection and service external oil filter: remove the paper element from the external oil filter and replace it. If the filter contains a washable element, thoroughly clean in kerosene and...

  • 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 8-716-106-256a (08.05) re-commission the burner: 1 align burner combustion head (n) into the boiler housing tube with the gasket (o) correctly fitted. Push firmly dow...

  • 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 8-716-106-256a (08.05) 1 burner - sterling 50 part number: 8-716-108-571-0 2 combustion head - burner part number: 8-716-108-573-0 3 control box satronic dko 970 part number: 8-7...

  • Page 42

    Fa ul t find in g & d ia g r am s installation & servicing instructions for worcester bosch 40 fault finding fault finding 8-716-106-256a (08.05) boiler lockout: indicated by the illumination of the 'lockout' indicator on the burner control box. To reset, wait 2 minutes then press the lockout indica...

  • 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 8-716-106-256a (08.05) 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

    8-716-106-256a (08.05) worcester, bosch group cotswold way, warndon, worcester wr4 9sw telephone: (01905) 754624 fax: (01905) 754619 instruction manual installation commissioning & servicing part number: worcester, bosch group is a trading name of bbt thermotechnology uk ltd. Www.Worcester-bosch.Co....

  • Page 45: User Instructions

    Gb/ie user instructions & customer care guide 8-716-106-257a (08.05) greenstar utility 18-25kw floor standing oil-fired condensing boiler conventional flue & room sealed flue for fully pumped open vent or sealed central heating systems and domestic hot water cylinders the appliance is for use with 2...

  • Page 46

    User instructions & customer care guide contact information user instructions & customer care guide 8-716-106-257a (08.05) please read these instructions carefully before operating your appliance. These instructions are applicable to the worcester bosch appliance model(s) stated on the front cover o...

  • Page 47

    User instructions & customer care guide 8-716-106-257a (08.05) mai nte nan c e ener g y sa vi n g u s in g y o u r appl ia n c e in tr oduc tion g u ar ante e 1 contents contents introduction safety precautions 2 excellence comes as standard 3 general information 4-6 using your appliance controls 7 ...

  • Page 48

    User instructions & customer care guide in tr oduc tion 8-716-106-257a (08.05) safety precautions safety precautions 2 oil smells, leaks or fumes from the appliance: extinguish any naked flames open windows and doors switch off the appliance electricity supply isolate the fuel supply to the boiler c...

  • Page 49

    User instructions & customer care guide in tr oduc tion 8-716-106-257a (08.05) thank you for purchasing a greenstar oil-fired condensing boiler from worcester bosch. The company prides itself on manufacturing boilers to the strictest quality control standards throughout every stage of production. Wo...

  • Page 50

    User instructions & customer care guide in tr oduc tion 8-716-106-257a (08.05) general information 4 general information read these instructions carefully to get the best from your appliance. Central heating systems: during the first few hours of operation of the central heating system, check that a...

  • Page 51

    User instructions & customer care guide in tr oduc tion 8-716-106-257a (08.05) boiler location: this boiler is only suitable for installing internally within a property at a suitable location onto a fixed rigid non-combustible surface at least the same size as the boiler and capable of supporting th...

  • Page 52

    User instructions & customer care guide in tr oduc tion 8-716-106-257a (08.05) if a cupboard or compartment which is to be used for storage or airing is built around the appliance after installation there must be a non-combustible partition around the boiler. Further information can be found in bs 5...

  • Page 53

    User instructions & customer care guide u s in g y o u r appl ia n c e 8-716-106-257a (08.05) controls 7 controls a temperature control (behind front top panel) b reset button - burner lock-outindicator/reset button (on burner control box, under top panel) c reset button - flue overheat thermostat (...

  • Page 54

    User instructions & customer care guide u s in g y o u r appl ia n c e 8 operating the appliance 8-716-106-257a (08.05) operating the appliance switching the boiler on/off: to switch on the boiler; turn on the water, oil and electricity supply to the boiler check the programmer/timer is correct and ...

  • Page 55

    User instructions & customer care guide u s in g y o u r appl ia n c e operating the appliance 8-716-106-257a (08.05) operating the appliance 9 frost protection: use a suitable anti-freeze/inhibitor at the correct strength to protect against freezing a frost thermostat should be fitted to the system...

  • Page 56

    User instructions & customer care guide u s in g y o u r appl ia n c e operating the appliance 8-716-106-257a (08.05) operating the appliance 10 fault conditions: the burner lockout indicator can indicate some basic fault conditions: lockout indicator: a) lockout indicator on, boiler not firing; 1 c...

  • Page 57

    User instructions & customer care guide ener g y sa vi n g 8-716-106-257a (08.05) tips on energy saving 11 heating economically: the boiler is designed to provide a high level of comfort while keeping oil consumption and the resulting environmental effect as low as possible. The central heating cont...

  • Page 58

    User instructions & customer care guide ener g y sa vi n g 12 tips on energy saving 8-716-106-257a (08.05) room thermostats: reducing the setting of the room thermostat by 1°c can reduce fuel consumption by up to 10%. New control systems: upgrade your heating control system with the latest equipment...

  • Page 59

    User instructions & customer care guide mai nte nan c e maintaining your appliance 8-716-106-257a (08.05) 13 maintaining your appliance your new appliance represents a long term investment in a reliable, high quality product. In order to realise its maximum working life and to ensure it continues to...

  • Page 60

    User instructions & customer care guide mai nte nan c e fault finding 8-716-106-257a (08.05) fault finding 14 desired room temperature is not reached thermostatic radiator valve(s) set too low increase thermostatic radiator valve setting(s) room thermostat set too low increase room thermostat settin...

  • Page 61

    User instructions & customer care guide mai nte nan c e 8-716-106-257a (08.05) fault or breakdown 15 fault or breakdown this appliance is supported in the uk by worcester bosch, part of bbt themotechnology uk ltd. Specialist factory trained service engineers are available to attend a breakdown occur...

  • Page 62

    User instructions & customer care guide g u ar ante e 8-716-106-257a (08.05) 16 guarantee guarantee this appliance is guaranteed against faulty materials or workmanship for a period of 24 calendar months from the date of installation subject to the following conditions: that during the period of thi...

  • Page 63

    User instructions & customer care guide g u ar ante e guarantee registration 8-716-106-257a (08.05) 17 guarantee registration you should complete and return the postpaid guarantee registration card within 30 days of purchase. Returning the card will register you as the owner of your new appliance an...

  • Page 64: User Instructions

    User instructions & customer care guide part number: worcester, bosch group cotswold way, warndon, worcester wr4 9sw worcester, bosch group is a trading name of bbt thermotechnology uk ltd. Www.Worcester-bosch.Co.Uk 8-716-106-257a (08.05).