Worcester Greenstar Danesmoor 25kW User manual

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 FULL PUMPED OPEN VENT OR SEALED CENTRAL HEATING S STEMS AND
DOMESTIC HOT WATER C LINDERS
THE APPLIANCE IS FOR USE WITH 28 SECOND
KEROSENE ONL
THE APPLIANCE IS FOR USE WITH 28 SECOND
KEROSENE ONL

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 OF
THIS MANUAL ONL AND MUST NOT BE USED
WITH AN OTHER MAKE OR MODEL OF
APPLIANCE.
IF OU ARE IN ANY DOUBT CONTACT THE
WORCESTER BOSCH TECHNICAL HELPLINE.
PLEASE KEEP THESE INSTRUCTIONS WITH
THE INSTALLATION AND SERVICING
INSTRUCTIONS IN A SAFE PLACE OR WITH
THE APPLIANCE AFTER INSTALLATION OR
SERVICING.
DO NOT INTERFERE WITH ANY SEALED
COMPONENTS.
WORCESTER BOSCH:
TEL: FAX:
Ser ice call centres:
UK: 08547 256206 757536
SCOTLAND ONL : 01506 - 441687
EIRE: 01494 0099
Other enquiries:
MAIN RECEPTION: 01905 754624 754619
TECHNICAL: 08705 266241
SPARES: 01905 752571
LITERATURE: 01905 752556
SALES: 01905 752640
WEBSITE: www.worcester-bosch.co.uk
WATER TREATMENT:
FERNOX 01799 550811
www.fernox.com
SENTINEL 0151 420 9595
www.betzdearborn.com/sentinel
FLUE TERMINAL GUARDS:
WORCESTER BOSCH
OIL FIRING TECHNICAL ASSOCIATION:
OFTEC 0845 6585080
www.oftec.org
ABBREVIATIONS:
Ø Diameter
CH Central Heating
DHW Domestic Hot Water
TRV Thermostatic Radiator Valve
IP Ingress Protection
CF Conventional flue
RS Room sealed flue
N/A Not allowed
PCB Electronic Printed Circuit Board
SEDBUK Seasonal Efficiency for Domestic Boilers
in the United Kingdom
OFTEC Oil Firing Technical Association for the
Petroleum Industry

USER INSTRUCTIONS & CUSTOMER CARE GUIDE
8-716-106-257a (08.05)
MAINTENANCE ENERGY
SAVING
USING YOUR
APPLIANCE INTRODUCTION
GUARANTEE
1
CONTENTS
CONTENTS
INTRODUCTION
SAFET PRECAUTIONS 2
EXCELLENCE COMES AS STANDARD 3
GENERAL INFORMATION 4-6
USING YOUR APPLIANCE
CONTROLS 7
OPERATING THE APPLIANCE
Switching the boiler on/off 8
Setting the heating temperature 8
Controlling central heating 8
Frost protection 9
Fault conditions 10
ENERGY SAVING
TIPS ON ENERG SAVING 11-12
MAINTENANCE
MAINTAINING OUR APPLIANCE 13
FAULT FINDING 14
FAULT OR BREAKDOWN 15
GUARANTEE
GUARANTEE 16
GUARANTEE REGISTRATION 17

USER INSTRUCTIONS & CUSTOMER CARE GUIDE
INTRODUCTION
8-716-106-257a (08.05)
SAFET PRECAUTIONS
SAFET 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
Contact boiler engineer
HEALTH & SAFETY:
The appliance contains no asbestos and no
substances have been used in the construction
process that contravene the COSHH Regulations
(Control of Substances Hazardous to Health
Regulations 1988). Where applicable, the CE
mark indicates compliance with relative EU
Directives.
COMBUSTIBLE AND CORROSIVE
MATERIALS:
Do not store or use any combustible materials
(paper, thinners, paints etc.) inside or within the
vicinity of the appliance.
The combustion air must be kept clear of
chemically aggressive substances which can
corrode the appliance and invalidate any warranty.
FITTING & MODIFICATIONS:
Fitting the appliance and any controls to the
appliance may only be carried out by a competent
engineer in accordance with the relevant
Installation Regulations.
Flue systems must not be modified in any way
other than as described in the fitting instructions.
Any misuse or unauthorised modifications to the
appliance, flue or associated components and
systems could invalidate the warranty. The
manufacturer accepts no liability arising from any
such actions, excluding statutory rights.
SERVICING:
The user must have the system regularly serviced
by a competent, qualified OFTEC registered
engineer using approved spares, to help maintain
the economy, safety and reliability of the
appliance.
The appliance should be serviced once each
year after installation unless the installation
conditions and usage demand more frequent
services.
DO NOT OPERATE THE APPLIANCE WHEN:
The appliance, flue or system is incorrectly fitted,
faulty or damaged
The flue terminal outlet fitted on the outside wall
or roof is obstructed or damaged
There are fumes, fuel leaks or fuel smells from
the fuel supply, appliance or flue system
The system is empty or frozen
The condensate pipe is blocked or restricted
The appliance clearances are inadequate
The air supply is restricted or vents damaged.

USER INSTRUCTIONS & CUSTOMER CARE GUIDE
INTRODUCTION
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.
Worcester Bosch has led the field in innovative
appliance design and performance for more than
40 years. This heritage means all products are of
exceptional quality and proven reliability.
The condensing range in particular, is extremely
energy efficient, converting more of the fuel
consumed into heat offering you economical running
costs and value for money. It sits in SEBUK band
A, at the top of the energy rated appliances available.
There is also the assurance of our no-nonsense
parts and labour guarantee - backed up by
'Worcester Total Cover', an optional complete
maintenance scheme to keep your boiler operating
at peak condition and efficiency.
To find out more about Worcester Bosch, use the
'Contact Information' shown on the inside front
cover.
EXCELLENCE COMES AS
STANDARD
EXCELLENCE COMES AS STANDARD
3

USER INSTRUCTIONS & CUSTOMER CARE GUIDE
INTRODUCTION
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 all radiators are being
heated at an even rate.
If the top of a radiator is at a lower temperature
than the bottom then it should be vented by releasing
air through the venting screw at the top of the
radiator. Ask your installer to show you how this is
done. Repeated venting will reduce the quantity of
water in the system and this must be replenished
for safe and satisfactory operation of the appliance.
When excessive venting or water leaks are found
in the system you must contact a service engineer
to inspect the installation and rectify any fault.
Only use additives compatible with the appliance
and system. Use of incompatible additives can cause
damage and will invalidate the appliance guarantee.
Sealed eating systems:
Where the appliance is fitted to a sealed heating
system your installer will inform you of the minimum
and maximum pressure which must be indicated
on the pressure gauge.
Regularly check the pressure is maintained and
contact your installer or maintenance engineer if
there is a noticeable, permanent drop in pressure.
If the system loses pressure it should be
repressurised and the cause of the fall investigated.
CONDENSATE:
This is a high efficiency appliance using condensing
technology which will under normal operation
produce a regular discharge of condensate to drain
and at times, give out a plume of water vapour from
the flue terminal.
ROOM THERMOSTAT:
A room temperature controller must be fitted to
control the central heating. Refer to the instructions
supplied with the thermostat for information on
siting and setting.
THERMOSTATIC RADIATOR VALVES:
It is recommended that this type of valve is fitted
to all but one of the radiators (or at least those in
the sleeping accommodation). The remaining
radiator, which must be where the room thermostat
is located, should be un-controlled and must be
left open.

USER INSTRUCTIONS & CUSTOMER CARE GUIDE
INTRODUCTION
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 the boiler
weight.
The boiler is not suitable for external installation
unless a suitable enclosure is provided.
Roof space installations must fully conform to
BS5410 part 1 section 4.6.9
VENTILATION:
Air vents must be functional at all times and the air
supply must not be restricted or contaminated.
The appliance clearances must meet the minimum
shown opposite for servicing and venting purposes.
* If this clearance is less than 75mm the flue 'knock-
out' panel sections must be removed to improve
air circulation and cooling.
Do not place clothes or objects to hinder the air
circulation required by the appliance.
Conventional flue appliances require an adequate
supply of fresh air which must be delivered to the
boiler for combustion purposes through a permanent
inlet, such as an air brick, into the area where the
boiler is situated.
600mm
300mm
5mm*
5mm*
380mm
1200mm
1155mm
Conventional flued appliances:
Minimum area of air inlet for combustion:
110cm² for 18/25kW appliances.
GENERAL INFORMATION
GENERAL INFORMATION
5

USER INSTRUCTIONS & CUSTOMER CARE GUIDE
INTRODUCTION
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 5410 which also describes venting
requirements.
Venting compartments:
 Ventilation must be provided for boilers fitted
into compartments as described in BS 5410
 A minimum of 2 air vents must be fitted, one at
low level and another at high level onto the same
wall using the same air for circulation.
Free air must not be taken from a room or internal
space containing a bath or shower and must not
communicate with a protected area such as a
hall, stairway, landing, corridor, lobby, shaft etc.
 Air vents must allow access for clean free air
and must be sited to comply with the flue terminal
position requirements.
 Air ducting runs must not exceed 3m.
 Low level air vents must be less than 450mm
from the floor.
A warning label must be added to the vents with
a statement to the effect: ''Do not block this vent.
Do not use for storage'.
Internal* ventilation
High
Level
Low
Level
kW
External** ventilation
High
Level
Low
Level
18/25 220 330 110 220
18/25 220 220 110 110
Internal* ventilation
High
Level
Low
Level
kW
External** ventilation
High
Level
Low
Level
GENERAL INFORMATION
6
GENERAL INFORMATION
*Internal air to and from a space/room inside the building.
**External air to and from directl outside the building.
Conventional flue:
Room Sealed flue:
MINIMUM AIR VENT AREA (cm²) FOR
APPLIANCES INSTALLED IN A COMPARTMENT:

USER INSTRUCTIONS & CUSTOMER CARE GUIDE
USING YOUR
APPLIANCE
8-716-106-257a (08.05) CONTROLS
7
CONTROLS
A Temperature control (behind front top panel)
B Reset button - burner lock-out indicator/reset
button (on burner control box, under top panel)
C Reset button - flue overheat thermostat (behind
front panel)
D Reset button - boiler overheat thermostat (behind
front panel)
E Front panel
F Top panel
G Front top panel
AF
G
E
C
D
B

USER INSTRUCTIONS & CUSTOMER CARE GUIDE
USING YOUR
APPLIANCE
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 it is
set to ON
Set the room thermostat to the desired setting
Open and set thermostatic radiator valves as
required
Turn the boiler water temperature control to the
required setting
To switch off the boiler; turn the programmer/timer
to OFF for heating and hot water. If the appliance
is left unused and exposed to freezing conditions;
shut off all the mains supplies, isolate the boiler
and drain the s stem and boiler.
SETTING TEMPERATURE:
Turn the control clockwise to increase the water
temperature
Turn the control anti-clockwise to reduce the
water temperature
The burner will run until the water reaches the set
temperature on the heating control. Once the water
temperature has been reached the burner turns off.
The minimum and maximum ranges of the heating
control positions are approx. 55°C to 82°C.
CONTROLLING CENTRAL HEATING:
Set the programmer/timer to the correct time
with the required ON/OFF periods
Turn the room thermostat to the temperature
required
Set thermostatic radiator valves to the required
temperature for each room
TEMPERATURE CONTROL:

USER INSTRUCTIONS & CUSTOMER CARE GUIDE
USING YOUR
APPLIANCE
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
where the system is most exposed and at risk of
freezing.

USER INSTRUCTIONS & CUSTOMER CARE GUIDE
USING YOUR
APPLIANCE
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 Check the oil level in the oil storage tank
2 Press lockout indicator/reset button (B). Boiler
should fire
3 If no response, wait 2 minutes - press lockout
indicator/reset button (B) again
4 If lockout light stays on, do not attempt further
resets. Contact your service engineer for advice.
b) Lockout indicator OFF, boiler not on, no
heating/hot water;
1 Ensure there is a power supply to the boiler
2 Check the programmer is set to on for heating
3 Press the reset buttons (C, D)
4 If the boiler remains off, contact your service
engineer for advice.
ACCESSING RESET BUTTONS:
Lockout indicator/reset button (B):
Pull top panel (A) squarely upwards to remove.
To refit, align the panel to the boiler and push
squarely down until secured, taking care not to
damage the panel.
Reset buttons (C,D):
Pull front panel (E) away at the base of the boiler
then lift upwards to remove.
To refit, position the top edge of the panel onto
the boiler ledge then align the base to the boiler
and push firmly towards the boiler until secured,
taking care not to damage the panel.
B
E
A
C
D

USER INSTRUCTIONS & CUSTOMER CARE GUIDE
ENERGY
SAVING
8-716-106-257a (08.05) TIPS ON ENERG 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 control on the boiler should be
set as low as possible while still maintaining a
comfortable room temperature.
The temperature of each room can be set individually
using the thermostatic radiator valves (except the
primary room with the room thermostat).
Roof insulation:
Around 30% of the heat loss from a property is
through the roof. Replace any old insulation with
new insulation, preferably to a minimum thickness
of 200mm.
Window frames:
Single glazed windows, particularly those with steel
frames, can lose a great deal of heat.
Consideration should be given to replacement with
PVCu or wooden framed double glazed units.
Curtains:
Lined curtains, or heavier full length curtains can
provide excellent insulation. However, always ensure
that the curtains do not drape over radiators.
Draug ts:
Try to ensure that draughts around doors, windows,
letterboxes and keyholes etc., are reduced by using
a suitable draught excluder.
Warning: do not block or seal any air ents that
are installed to ensure the central heating boiler
(or other appliance) operate safely.
TIPS ON ENERG SAVING

USER INSTRUCTIONS & CUSTOMER CARE GUIDE
ENERGY
SAVING
12
TIPS ON ENERG SAVING 8-716-106-257a (08.05)
Room t ermostats:
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 available. The minimum level of control
for a heating system is a programmer, interlocking
room thermostat and thermostatic radiator valves.
Radiators:
More often than not radiators will be sited underneath
a window, so the warm air from the radiator heats
the colder incoming air from the window.
The performance of the radiator will be affected if
the curtains are allowed to drape over the radiator
or shelves are fitted above it.
The positioning of furniture and tables in front of
the radiator should also be avoided.
It is advisable to manually adjust all radiator valves
every 2-3 months to prevent them from sticking. It
is also important that the plastic tops of all valves
are always in position and not cracked or damaged
to help prevent accidents. Care should be taken
when vacuum cleaning carpets to avoid damage to
valves and pipework.
The heating system and the outputs of the radiators
have been carefully selected by your installer. The
temperature obtainable in any given room is
dependent on all radiators being operated at the
same time. If you decide to turn off radiators in
unused rooms, spare bedrooms etc., you may
experience slightly lower room temperatures in
rooms adjacent to unheated rooms.
TIPS ON ENERG SAVING

USER INSTRUCTIONS & CUSTOMER CARE GUIDE
MAINTENANCE
MAINTAINING OUR APPLIANCE
8-716-106-257a (08.05)
13
MAINTAINING OUR APPLIANCE
our 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 operate at peak efficiency
and performance, it is essential that servicing and
maintenance checks are performed at least once a
year by a competent person beyond the initial
guarantee period.
If you would like to know more about a Worcester
Bosch service contract, please tick the appropriate
box on your warranty registration card.
If your appliance requires servicing please contact
a Worcester Bosch contact centre (see inside front
cover for details).

USER INSTRUCTIONS & CUSTOMER CARE GUIDE
MAINTENANCE
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 setting
Temperature control on
boiler set too low
Increase temperature control
setting
Air trapped in heating
system
Bleed radiators and recharge
heating system
Desired room temperature
exceeded by large amount
Radiators are too hot Turn down thermostatic radiator
valves / room thermostat / boiler
temperature control setting
Temperature rises instead
of falling
Clock is incorrectly set Check setting
Hot water temperature too
low
Hot water temperature set
too low
Check setting of cylinder
thermostat then boiler
temperature control setting
Tank cold Check programmer timings
PROBLEM CAUSE REMEDY

USER INSTRUCTIONS & CUSTOMER CARE GUIDE
MAINTENANCE
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 occurring on this
appliance.
No charge will be made for parts and/or labour
providing:
An appliance fault is found and the appliance
has been installed within the past 24 months
Reasonable evidence of this must be supplied
on request
A call-out charge will be made where:
The appliance has been installed for over 24
months OR
Our Field Service Engineer finds no fault
with the appliance (see Note). OR
The cause of breakdown is misuse or with
other parts of your plumbing/heating system,
or with equipment not supplied by BBT
Themotechnology UK Ltd.
Note: NO APPLIANCE FAULT IS FOUND ON
OVER 30% OF ALL SERVICE CALL OUTS.
Please read this guide carefully to gain a good
understanding of the operation of your appliance.
In the case of a suspected fault, refer to the fault
finding section of this guide.
If in doubt contact Worcester Bosch quoting the
boiler serial and model number. These numbers are
printed on a Data Label which is located as shown
opposite. ( ou can record this information on the
inside back cover of this manual.)
In the event of an appliance fault or breakdown
please contact a contact centre (see inside front
cover for details). our service administrator will
arrange for an Engineer to call with the minimum
of delay. Under normal circumstances this will be
from 1 to 3 working days (excluding weekends) for
priority breakdown situations (no hot water and/or
heating).
Invoices for attendance and repair work carried out
on this appliance by any third party will not be
accepted.
APPLIANCE
DATA LABEL

USER INSTRUCTIONS & CUSTOMER CARE GUIDE
GUARANTEE
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 this guarantee any
components of the unit which are proved to be
faulty or defective in manufacture will be
exchanged or repaired free of material charges
and free of labour charges if repaired directly by
BBT Thermotechnology UK Ltd. Invoices for
attendance and repair of this appliance by third
parties will not be accepted for payment by BBT
Thermotechnology UK Ltd.
That the householder may be asked to prove the
date of installation that the appliance was correctly
commissioned and, where appropriate, that the
12 month service inspection has been carried
out to the satisfaction of BBT Thermotechnology
UK Ltd, when requested. The guarantee card
must then be returned within 30 days of
installation.
That any product or part thereof returned for
servicing under the guarantee must be
accompanied by a claim stating the Model, Serial
Number and Date of Installation.
That BBT Thermotechnology UK Ltd will not
accept responsibility for damage caused by faulty
installation, neglect, misuse or accidental damage
the non-observance of the instructions contained
in the Installation and Users Instructions leaflets.
That the appliance has been used only for normal
domestic purposes, for which it was designed.
That this guarantee applies only to equipment
purchased and used in mainland Great Britain.
This guarantee is given in addition to all your normal
statutory rights.
Worcester, Bosch Group is a trading name of BBT
Thermotechnolog UK Ltd.

USER INSTRUCTIONS & CUSTOMER CARE GUIDE
GUARANTEE
GUARANTEE REGISTRATION
8-716-106-257a (08.05)
17
GUARANTEE REGISTRATION
ou 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 and will assist us in maintaining
an effective and efficient customer service by
establishing a reference and permanent record for
your boiler.
This does not affect your statutory rights.
MODEL:
SERIAL No.
(See identity label inside the appliance casing)
T PE / SIZE:
DATE OF INSTALLATION:
For our own record:

USER INSTRUCTIONS
& CUSTOMER CARE GUIDE
Part Number:
Worcester, Bosc Group
Cotswold Way, Warndon, Worcester WR4 9SW
Worcester, Bosch Group is a trading name of BBT Thermotechnolog UK Ltd.
www.worcester-bosc .co.uk
8-716-106-257a (08.05)