Worcester GREENSTAR UTILITY 32/50 User manual

GREENSTAR UTILITY
32/50 & 50/70
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 BOILER IS FOR USE WITH
KEROSENE (28 SECOND OIL) ONLY
UK
USER INSTRUCTIONS & CUSTOMER CARE GUIDE
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USER INSTRUCTIONS &
CUSTOMER CARE GUIDE
GREENSTAR UTILITY 32/50 - 50/70
8 716 109 712b (07.2010)
CONTACT INFORMATION
WORCESTER, BOSCH GROUP:
TECHNICAL: 0844 892 3366
SERVICE: 0844 892 3000
SERVICE (EIRE) 01494 0099
LITERATURE: 0844 892 9800
SALES: 01905 752640
WEBSITE: worcester-bosch.co.uk
USER INSTRUCTIONS &
CUSTOMER CARE GUIDE
PLEASE READ THESE
INSTRUCTIONS CAREFULLY BEFORE
OPERATING YOUR BOILER
THESE INSTRUCTIONS ARE
APPLICABLE TO THE WORCESTER
BOILER MODEL(S) STATED ON THE
FRONT COVER OF THIS MANUAL ONLY
AND MUST NOT BE USED WITH ANY
OTHER MAKE OR MODEL OF BOILER.
THE INSTRUCTIONS APPLY IN
MAINLAND UK ONLY AND SHOULD
BE FOLLOWED EXCEPT FOR ANY
STATUTORY OBLIGATION.
IF YOU ARE IN ANY DOUBT CONTACT
THE WORCESTER, BOSCH GROUP
TECHNICAL SUPPORT.
THIS BOILER MUST BE INSTALLED BY
A OFTEC REGISTERED, COMPETENT
PERSON. FAILURE TO INSTALL
CORRECTLY COULD LEAD TO
PROSECUTION.
PLEASE LEAVE THIS GUIDE, THE
INSTALLATION INSTRUCTIONS AND
THE COMPLETED CHECKLIST WITH
THE USER.
NOTE: A CHECKLIST AND SERVICE
INTERVAL RECORD CAN BE FOUND
AT THE REAR OF THE INSTALLATION,
COMMISSIONING AND SERVICE
INSTRUCTIONS.
ABBREVIATIONS:
SEDBUK Seasonal Efficiency for Domestic
Boilers in the United Kingdom.
OFTEC Oil Firing Technical Association for the
Petroleum Industry.
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CONTENTS
GREENSTAR UTILITY 32/50 - 50/70
8 716 109 712b (07.2010)
1
CONTENTS
INTRODUCTION
SAFETY PRECAUTIONS 2
USING YOUR BOILER
CONTROLS 3
OPERATING THE BOILER
Switching the boiler on/off 4
Setting the heating temperature 4
Controlling central heating 4
Frost protection 5
Fault conditions 6
Fault finding 7
MAINTENANCE
MAINTAINING YOUR BOILER 8
SERVICING 9
GENERAL INFORMATION
VENTILATION INFORMATION 10 - 11
GENERAL NOTES 12
ENERGY SAVING
TIPS ON ENERGY SAVING 13
GUARANTEE
FAULT OR BREAKDOWN 14
YOUR GUARANTEE AND REGISTRATION 15
INTRODUCTION
USING YOUR
BOILER
GENERAL
INFORMATION MAINTENANCE
ENERGY
SAVING
GUARANTEE
PLEASE READ THESE INSTRUCTIONS CAREFULLY
These instructions are applicable to the Worcester, Bosch Group model stated on the front cover only.
These instructions apply in the UK/IE only and must be followed except for any statutory obligation.
After installation please leave this User Manual along with the Installation, Commissioning and
Servicing Instructions and completed Benchmark Checklist with the user.
DEDICATED TO HEATING COMFORT
Thank you for purchasing a Greenstar oil fired condensing boiler from Worcester, Bosch Group. The
company prides itself on manufacturing boilers to the strictest quality control standards throughout
every stage of production.
Worcester, Bosch Group has led the field in innovative boiler design and performance for almost 50
years. This heritage means that all our products are of exceptional quality and proven reliability.
The condensing range in particular, is extremely energy efficient, offering you economical running
costs and value for money. It sits in SEDBUK Band A, and is therefore amongst the top energy rated
boilers available.
There is also the assurance of our no-nonsense 2 years 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.
NOTES
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SAFETY PRECAUTIONS GREENSTAR UTILITY 32/50 - 50/70
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2
INTRODUCTION
SAFETY PRECAUTIONS
OIL FUMES OR LEAKS FROM THE BOILER:
Extinguish any naked flames.
Open windows and doors.
Switch off the boiler electricity supply.
Isolate the fuel supply to the boiler.
Contact installer/service engineer.
IMPORTANT:
This boiler must only be operated by a responsible adult who has been instructed in,
understands and is aware of the boiler’s operating conditions and effects.
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 boiler.
The combustion air must be kept clear of chemically aggressive substances which can corrode
the boiler and invalidate any warranty.
FITTING & MODIFICATIONS:
Fitting the boiler and any controls to the boiler 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 boiler, flue or associated components and
systems could invalidate the warranty. The manufacturer accepts no liability arising from any such
actions, excluding statutory rights.
This boiler is suitable for use with kerosene only, no other fuel may be used.
DO NOT OPERATE THE APPLIANCE WHEN:
The appliance, flue or system is incorrectly fitted, faulty or damaged.
The flue terminal outlet is obstructed or damaged.
There are fumes, fuel leaks or fuel smells from the fuel supply, appliance or internal flue system.
The system is empty, frozen or unpressurised (sealed systems).
The condensate pipe is blocked or restricted.
The appliance clearances are inadequate.
The air supply is restricted or vents damaged.
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CONTROLS
GREENSTAR UTILITY 32/50 - 50/70
8 716 109 712b (07.2010)
A Temperature control (behind upper front panel)
B Reset button - boiler overheat thermostat (behind front panel)
C Reset button - flue overheat thermostat (behind front panel)
D Reset button - lockout (top of burner under top panel)
E Upper front panel (pull squarely away from the boiler to remove)
F Top panel (lift squarely up from boiler to remove)
CONTROLS
USING YOUR
BOILER
3
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OPERATING THE BOILER GREENSTAR UTILITY 32/50 - 50/70
8 716 109 712b (07.2010)
USING YOUR
BOILER
OPERATING THE BOILER
SWITCHING THE BOILER ON/OFF:
To switch on the boiler; turn on the oil and electricity supply to the boiler.
Check the programmer/timer is correct and 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 boiler is left unused and exposed to freezing conditions; shut off all the mains supplies,
isolate the boiler and drain the system and boiler.
SETTING TEMPERATURE:
Turn the control clockwise to increase the water temperature.
Turn the control anti-clockwise to reduce the water temperature.
The minimum and maximum ranges of the temperature control positions are approximately 60°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.
4
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OPERATING THE BOILER
GREENSTAR UTILITY 32/50 - 50/70
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5
OPERATING THE BOILER
FROST PROTECTION:
Frost thermostats can be wired into the boiler.
Frost protection should be fitted to the system where the system is most exposed and at risk
of freezing.
If there is no hot water or heating, check page 6 and 7 for fault condition guidance.
USING YOUR
BOILER
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OPERATING THE BOILER GREENSTAR UTILITY 32/50 - 50/70
8 716 109 712b (07.2010)
USING YOUR
BOILER
6
OPERATING THE BOILER
FAULT CONDITIONS:
If the boiler fails to operate.
Check the oil level in the oil storage tank.
Check there is not a power cut and the
power supply to the boiler is switched on.
Check the programmer is set to on.
Check the room thermostat and where fitted,
the radiator thermostats are set correctly.
Remove upper front panel and check the
thermostat control knob (A) is turned on.
If the above checks prove satisfactory and the
boiler remains off, then a safety device in the
boiler control system may have been activated to
prevent the boiler from operating.
Automatic reset:
An excessive boiler operating temperature
can activate a thermostat to switch off the
boiler. This thermostat automatically resets
when the boiler has cooled down sufficiently.
Do not attempt to repeatedly start the boiler
using the manual reset buttons as persistent
failure indicates a fault requiring the attention
of a service engineer.
Boiler overheat (manual reset):
Should the boiler temperature rise beyond
the automatic reset level, a high limit
thermostat will switch the boiler off,
indicated by button (B) standing proud.
When the boiler has cooled down, press
and release (B) to reset the thermostat.
Flue overheat (manual reset):
Excessive combustion gas temperatures can
activate a thermostat to switch off the boiler,
indicated by button (C) standing proud.
Press and release (C) to reset thermostat.
Burner lockout (manual reset):
Flame failure, for any reason, will cause the
burner to go safely to a lockout condition.
Remove the boiler top panel and check the
lockout button (D). If this is illuminated it
indicates a ‘lockout’ condition. To cancel
lockout, wait 2 minutes, then press and
release button (D).
ACCESSING RESET BUTTONS:
Reset buttons (A B & C):
To remove upper front panel pull panel
squarely away from the front of the boiler.
To replace, realign ball studs and push back
into place.
Burner lockout reset button (D):
Pull top panel squarely upwards to
remove.
To replace, realign ball studs and push
back into place.
Always keep pressure to the edges of the
panels to avoid accidental damage.
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FAULT FINDING
Problem Cause Remedy
Desired room temperature
is not reached
Thermostatic radiator
valve(s) set too low
Room thermostat set too Increase room thermostat
low setting
Temperature control on
boiler set too low
Air trapped in heating
system
Desired room temperature
exceeded by large amount
Temperature rises instead
of falling
Radiators are too hot
Clock is incorrectly set
Increase thermostatic
radiator valve setting(s)
Increase temperature
control setting
Bleed radiators and
recharge heating system
Turn down thermostatic
radiator valves / room
thermostat / boiler
temperature control setting
Check setting
FAULT FINDING
GREENSTAR UTILITY 32/50 - 50/70
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7
USING YOUR
BOILER
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8
MAINTAINING YOUR BOILER
Your new boiler 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 an OFTEC engineer or other suitably qualified person.
If you would like to know more about servicing options from Worcester, Bosch Group, please visit
worcester-bosch.co.uk. Please tick the appropriate box on your warranty registration card for
further details of the Worcester, Bosch Group Service Contract .
When your boiler requires servicing please contact a Worcester, Bosch Group contact centre
(see inside front cover for details).
In addition to the service contract we are pleased to offer a one-off annual service or breakdown
call out for your boiler.
Maintenance tips:
Regularly check the oil level in the tank.
Do not obstruct the flue outlet or the air inlet.
MAINTAINING YOUR BOILER GREENSTAR UTILITY 32/50 - 50/70
8 716 109 712b (07.2010)
MAINTENANCE
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SERVICING
GREENSTAR UTILITY 32/50 - 50/70
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9
SERVICING
SERVICING:
You must have the boiler regularly serviced by a competent, qualified OFTEC registered
engineer using approved spares, to help maintain the economy, safety and reliability of the
boiler.
The boiler should be serviced once each year after installation unless the installation
conditions and usage demand more frequent services.
IMPORTANT:- Ensure that the service engineer completes the Service Record in
the checklist after each service.
The completed checklist will be required in the event of any warranty work
and may be required by the local Building Control Inspector.
NOTE: The checklist and service interval record can be found at the rear of the
Installation, Commissioning and Servicing Instructions.
MAINTENANCE
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VENTILATION INFORMATION
VENTILATION INFORMATION
BOILER LOCATION:
**The boiler can be installed under a worktop as long as:
The worktop above the boiler is easily removable for maintenance.
There is at least 10mm clearance above the boiler.
The front of the boiler is not enclosed.
VENTILATION:
Air vents must be functional at all times and the air supply must not be restricted or contaminated.
The boiler clearances must meet the minimum shown below 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 boiler.
ANNUAL
SERVICE CLEARANCES
600mm
300mm
10mm
10mm
720mm
1415mm
1312mm
10 GREENSTAR UTILITY 32/50 - 50/70
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GENERAL
INFORMATION
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VENTILATION INFORMATION
VENTILATION INFORMATION
Conventional flue boilers 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.
If a cupboard or compartment which is to be used for storage or airing is built around the boiler 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.
Conventional flued boilers:
Minimum area of of air inlet for combustion:
248cm2 for 32/50kW appliances. 358cm2 for 50/70kW appliances.
MINIMUM AIR VENT AREA (cm2) FOR BOILERS INSTALLED IN A COMPARTMENT:
1Internal air to and from a space/room inside the building. 2External air to and from directly outside the building.
Venting compartments:
Ventilation must be provided for boilers fitted into compartments as described in BS 5410
A minimum of two air vents must be fitted, one at low level and another at high level onto the
same wall using the same air for circulation.
Combustion 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 attached to the vents with a statement to the effect:
''Do not block this vent.
Do not use for storage''.
Conventional flue
kW
Internal1ventilation External2ventilation
High
Level
Low
Level
High
Level
Low
Level
32/50 495 743 248 495
50/70 715 1073 358 715
Room Sealed flue:
kW
Internal1ventilation External2ventilation
High
Level
Low
Level
High
Level
Low
Level
32/50 495 495 248 248
50/70 715 715 358 358
GREENSTAR UTILITY 32/50 - 50/70
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11
GENERAL
INFORMATION
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GENERAL NOTES
GENERAL NOTES
To get the best from your boiler. please read these instructions carefully.
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 boiler.
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 boiler and system. Use of incompatible additives can cause
damage and will invalidate the boiler guarantee.
CONDENSATE DRAIN
This is a condensing boiler and the terminal will, at times give out a plume of water vapour. This is
quite normal.
The boiler also produces quantities of condensate which is discharged regularly via a pipe to drain.
This pipe must not be blocked or altered in any way.
CLEARANCES - SERVICE
Your installer will have provided adequate space around the boiler for safety and servicing access.
Do not restrict this space with the addition of cupboards, shelves etc. next to the boiler.
ROOM THERMOSTAT
A room temperature controller must be fitted to control the central heating. Refer to 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.
12 GREENSTAR UTILITY 32/50 - 50/70
8 716 109 712b (07.2010)
GENERAL
INFORMATION
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TIPS ON ENERGY SAVING
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 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.
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.
Draughts:
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 vents that are installed to ensure
the central heating boiler (or other appliance) operate safely.
TIPS ON ENERGY SAVING
ENERGY
SAVING
GREENSTAR UTILITY 32/50 - 50/70
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13
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FAULT OR BREAKDOWN GREENSTAR UTILITY 32/50 - 50/70
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14
BOILER DATA LABEL
The data label can be found on the inside of the
boiler on top of the control box.
To access:
Lift top panel to release lugs.
To replace top panel:
Replace the top panel and gently push down
(from the edges so as not to damage the
panel) until it clips back into place.
(You can record this information on the inside
back cover of this manual.)
FAULT OR BREAKDOWN
This boiler is supported in mainland UK by
Worcester, Bosch Group, part of Bosch
Thermotechnology Ltd.
Specialist trained, Worcester, Bosch Group
Service Engineers are available to attend in the
unlikely event that a breakdown occurs on this
boiler.
No charge will be made for parts and/or
labour providing:
A boiler fault is found and the boiler 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 boiler has been installed for over 24
months. OR
Our Field Service Engineer finds no fault
with the boiler (see Note). OR
Evidence cannot be provided that the first
year service inspection has been carried out.
(i.e. an entry in the service interval record
found at the rear of the boiler installation
and servicing manual). OR
The cause of breakdown is misuse or with
other parts of your plumbing/heating system,
or with equipment not supplied by Bosch
Thermotechnology Ltd.
NOTE: NO BOILER 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 boiler. In
the case of a suspected fault, refer to the fault
finding section of this guide.
If in doubt contact our Technical Support
In the event of an boiler fault or breakdown
please contact our Service Department. Your
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 boiler by any third party will not be
accepted.
GUARANTEE
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15
GUARANTEE REGISTRATION
Model
Serial No.
(See identity label inside boiler casing)
Type / size
Date of installation
Installer details
GUARANTEE REGISTRATION
You should complete and return the postpaid
Guarantee Registration Card within 30 days of
installation.
Returning your card will register you as the
owner of your new boiler 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.
For your own record:
YOUR GUARANTEE
This boiler is guaranteed against faulty materials
or workmanship for a period of 24 calendar
months (60 months for the primary heat
exchanger) 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
Bosch Thermotechnology
Ltd. Please be aware that invoices
for attendance and repair of this
boiler by third parties will not be
accepted for payment by Bosch
Thermotechnology Ltd.
That the householder may be asked to
prove, when requested, the date of
installation, that the boiler was correctly
commissioned and, where appropriate, that
the 12 month service inspection has been
carried out to the satisfaction of Bosch
Thermotechnology 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 Bosch Thermotechnology Ltd will not
accept responsibility for damage caused by
faulty installation, neglect, misuse or
accidental damage and non-observance of
the instructions contained in the Installation
and Users Instructions leaflets.
That the boiler has been used only for
normal domestic purposes, for which it was
designed.
This guarantee applies only to equipment
purchased and installed in mainland UK.
This guarantee is given in addition to all your
normal statutory rights.
Worcester, Bosch Group is a brand name of
Bosch Thermotechnology Ltd.
GREENSTAR UTILITY 32/50 - 50/70
8 716 109 712b (07.2010)
GUARANTEE
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NOTES GREENSTAR UTILITY 32/50 - 50/70
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16
NOTES
NOTES
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17
NOTES
NOTES
GREENSTAR UTILITY 32/50 - 50/70
8 716 109 712b (07.2010)
NOTES
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Worcester, Bosch Group
Cotswold Way, Warndon, Worcester WR4 9SW.
Tel. [phone]
Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd.
8 716 109 712b (07.2010)
WORCESTER, BOSCH GROUP:
TECHNICAL SUPPORT: 0844 892 3366
APPOINTMENTS: 0844 892 3000
SPARES: 01905 752571
LITERATURE: 0844 892 9800
TRAINING: 01905 752526
SALES: 01905 752640
WEBSITE: www.worcester-bosch.co.uk
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