Worcester GREENSTAR UTILITY 32/50 User manual

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 KEROSENE
(28 SECOND OIL) ONLY
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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 in the transfer of the packaged appli-
ance from the van to the point of installation.
It is advised that no attempt should be made to
move the packaged appliance without the use of
a suitable truck.
At all times the correct method for handling
heavy objects should be strictly observed.
GENERAL HANDLING GUIDELINES:
• Lift only a manageable weight, or ask for
help.
• When lifting, bend the knees, and keep the
back straight and feet apart.
• Do not lift and twist at the same time.
• Lift and carry items close to the body.
• Wear protective clothing and gloves to
protect from any sharp edges.
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
THESE INSTRUCTIONS ARE APPLICABLE TO THE WORCESTER APPLIANCE MODEL(S)
STATED ON THE FRONT COVER OF THIS MANUAL ONLY AND MUST NOT BE USED WITH
ANY OTHER MAKE OR MODEL OF APPLIANCE.
THE INSTRUCTIONS APPLY IN THE UK AND EIRE ONLY AND MUST BE FOLLOWED
EXCEPT FOR ANY STATUTORY OBLIGATION.
THIS APPLIANCE MUST BE INSTALLED BY A COMPETENT PERSON. FAILURE TO INSTALL
CORRECTLY COULD LEAD TO PROSECUTION.
COMPLYING WITH THE BUILDING REGULATIONS:
This heating appliance forms part of the controlled services for the building. It is law that all controlled
services for buildings must comply with building regulations. You must be able to satisfy your Local
Authority Building Control Body (LABC) that the work carried out concerning the installation and
commissioning of this heating appliance has been carried out to a satisfactory standard.
OFTEC operate a competent persons scheme and registered installers are able to certify that their
work complies with building regulations. Under the scheme;
OFTEC must be informed about every installation.
OFTEC will issue a building regulations compliance certificate to the householder and will
notify the LABC.
OFTEC provide controlled document forms CD10 and CD11 for use during installation and
commissioning respectively.
Other organisations operate self-certification schemes e.g. NAPIT and BESCA Ltd. and it may be
possible for installers who are members of these organisations to self certify their work.
Alternatively you must submit a building control notice to the LABC before installing any boiler. The
LABC will then arrange regular inspection visits during the work to ensure that the installation
complies with the regulations.
IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER TECHNICAL HELPLINE.
DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER.
PLEASE LEAVE THESE INSTRUCTIONS WITH THE COMPLETED COMMISSIONING FORM
AND THE USER MANUAL WITH THE OWNER OR WITH THE APPLIANCE AFTER
INSTALLATION OR SERVICING. THE SERVICE INTERVAL RECORD CAN BE FOUND ON
THE BACK PAGE OF THIS MANUAL.
ABBREVIATIONS USED IN THIS MANUAL:
Ø Diameter
CH Central Heating
DHW Domestic Hot Water
DCW Domestic Cold Water
TRV Thermostatic Radiator Valve
IP Ingress Protection
CF Conventional flue
BF Balanced flue
N/A Not allowed
SEDBUK Seasonal Efficiency of Domestic Boilers in the United Kingdom
OFTEC Oil Firing Technical Association for the Petroleum Industry
IEE Institute of Electrical Engineers
LABC Local Authority Building Control Body
STORE THE APPLIANCE IN A DRY AREA PRIOR TO INSTALLATION.
WATER TREATMENT:
FERNOX 01799 550811
fernox.com
SENTINEL 0800 389 4670
sentinel-solutions.net
FLUE TERMINAL GUARD: Part No. 7 716 190 050
Domestic hot water
Central heating
Room thermostat
Wait time period
Programmer/timer OFF
Programmer ON CH only
Programmer ON DHW only
Programmer ON CH and DHW
Electricity supply
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CONTENTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25
8 716 109 711B 07.2010
3
SAFETY &
REGULATIONS
APPLIANCE
INFORMATION
PRE -
INSTALLATION
INSTALLATIONCOMMISSIONING
SERVICING
& SPARES
FAULT FINDING
& DIAGRAMS
COMMISSIONING
CHECKLIST
SAFETY & REGULATIONS
IMPORTANT INFORMATION AND SYMBOLS 2
SAFETY PRECAUTIONS AND INSTALLATION REGULATIONS 4
APPLIANCE INFORMATION
GENERAL INFORMATION 5
TECHNICAL DATA 6
LAYOUT & COMPONENTS 7
PRE-INSTALLATION
CLEANING PRIMARY SYSTEMS 8
MAINS SUPPLY 9
OIL SUPPLY 10
WATER SYSTEMS & PIPEWORK 11
PRESSURE RELIEF PIPEWORK 13
CONDENSATE PIPEWORK 13
BOILER LOCATION & CLEARANCES 14
FLUE TERMINAL POSITIONS 16
CONVENTIONAL FLUE 17
ROOM SEALED FLUE OPTIONS 18
INSTALLATION
UNPACKING THE BOILER 19
PIPEWORK POSITIONS / FLUE OPENING 20
BOILER INSTALLATION 21
FLUE INSTALLATION 22
COMBUSTION CHAMBER 23
PIPEWORK CONNECTIONS 24
OIL BURNER AND PUMP - RIELLO RDB BURNERS 25
OIL BURNER AND PUMP - BENTONE STERLING BURNERS 26
REFITTING COMPONENTS 27
ELECTRICS 28
COMMISSIONING
PRE-COMMISSIONING CHECKS - APPLIANCE 31
FILLING THE SYSTEM 32
STARTING THE APPLIANCE 33
(STARTING THE APPLIANCE - RIELLO RDB BURNERS) 34
(STARTING THE APPLIANCE - BENTONE STERLING BURNERS) 35
WATER TREATMENT 37
FINISHING COMMISSIONING - APPLIANCE 38
SERVICING & SPARES
INSPECTION AND SERVICE 39
(INSPECTION AND SERVICE - RIELLO RDB BURNERS) 40
INSPECTION AND SERVICE - BENTONE STERLING BURNERS) 41
SHORT PARTS LIST RIELLO RDB BURNERS 44
SHORT PARTS LIST BENTONE STERLING BURNERS 45
FAULT FINDING & DIAGNOSIS
FAULT FINDING 46
FAULT FINDING LOGIC FOR RIELLO CONTROL BOX 48
FAULT FINDING LOGIC FOR SATRONIC CONTROL BOX 49
COMMISSIONING CHECKLIST 50
SERVICE INTERVAL RECORD 51
CONTENTS
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SAFETY PRECAUTIONS
& INSTALLATION REGULATIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25
8 716 109 711B 07.2010
4
SAFETY &
REGULATIONS
SAFETY PRECAUTIONS INSTALLATION REGULATIONS
OIL FUMES OR LEAKS FROM THE APPLIANCE:
 Extinguish any naked flames.
 Open windows and doors.
 Isolate the electrical supply.
 Isolate the fuel supply to the boiler.
 Rectify fault.
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 these instructions and 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:
Advise the user to have the system regularly serviced by a competent, qualified engineer (such
as OFTEC registered personnel) using approved spares, to help maintain the economy, safety
and reliability of the appliance.
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.
Failure to install appliances correctly could lead to
prosecution.
The appliance should be installed by a competent
person. The person installing the appliance should
be aware of the Health and Safety at Work Act and
take appropriate action to ensure that the
regulations are adhered to. In order to give
optimum efficiency and trouble free operation the
appliance must be commissioned by a qualified
OFTEC engineer.
The compliance with a British Standard does not,
in itself, confer immunity from legal obligations. In
particular the installation of this appliance must be
in accordance with the relevant requirements of the
following British Standards and regulations in
respect of the safe installation of equipment:
BS 5410: part 1: Code of practice for Oil Fired
Boilers.
BS 799: part 5: Specification for Oil Storage
Tanks.
BS 7593: Code of Practice for treatment of water
in domestic hot water central heating systems.
BS 5449: part 1: Specification for forced
circulation hot water central heating for domestic
premises.
BS 5955: part 8: Specification for the installation
of thermoplastic pipes and associated fittings for
use in domestic hot and cold water services and
heating systems.
BS 7291: Thermoplastic pipes and associated
fittings for hot and cold water for domestic
purposes and heating installations in buildings.
BS 7074: part 1: Application, selection and
installation of expansion vessels and ancillary
equipment for sealed water systems.
BS 7671: IEE Wiring Regulations, current edition.
BS 1362: Specification for general purpose fuse
links for domestic and similar purposes.
The Building Regulations Part G, Part J and L1
England and Wales; Part F, Part G and Part J
Section III Scotland; Part L and Part F Northern
Ireland.
Local water company bye-laws.
The Control of Pollution (Oil) Regulations.
OFTEC Standards.
Where no specific instruction is given, reference
should be made to the relevant codes of practice.
Installations in Eire (Republic of Ireland)
The Installation must be performed by a
competent and suitably trained person in
accordance with the following Eire regulations.
Current Building Regulations -
Republic of Ireland
ETCI rules for electrical installation
For further guidance see:
OFTEC Technical book three -
Regional requirements: Republic of Ireland
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GENERAL INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25
8 716 109 711B 07.2010
5
APPLIANCE
INFORMATION
GENERAL INFORMATION
STANDARD PACKAGE:
A - Floor standing oil fired condensing boiler for
open vent and sealed domestic central heating
and mains fed hot water.
B - Literature pack.
C -Hardware pack.
D - Return pipe kit.
1012mm
815mm 520mm
Check List
Hardware/Literature pack
Item Qty
Greenstar Utility Installation/Servicing Instructions.................................1
Users Instructions ..........................................................................................1
Top Panel Inset Plate......................................................................................1
Edge Clips .......................................................................................................1
Warranty Return Envelope ............................................................................1
Return Pipe Kit ................................................................................................1
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TECHNICAL DATA INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25
8 716 109 711B 07.2010
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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 side resistance (10°C difference) mbar
Flue
Exit flue gas mass flow kg/hr
Conventional flue (minimum diameter required) mm
Room sealed flue (diameter) mm
Pipework connections
Fuel line (compression) mm
CH flow inch BSP
CH return mm
CH vent inch BSP
CH make up inch BSP
Condensate (polypropylene) mm
Electrical
Electrical power supply voltage AC...V
Frequency Hz
Max. power consumption W
Thermostats
Boiler flow temperature range (cut out) °C
CH control thermostat differential °C
Boiler high limit thermostat set point (+ 0.6°C) °C
Boiler manual reset overheat thermostat (cut out) °C
Flue manual reset overheat thermostat (+ 0.6°C) °C
General Data
Maximum hearth temperature °C
SEDBUK (Band A) %
Appliance protection rating IP
Weight (excluding packaging) kg
DESCRIPTION UNITS 32/50 50/70
APPLIANCE
INFORMATION
51
30
1
40
104
106
130
100/150
10
11/2
28
11/2
11/2
21.5
230
50
220
60/82
5
100
110
120
100
92.5
20
280
50
30
1
26
52
76
130
100/150
10
11/2
28
11/2
11/2
21.5
230
50
190
60/82
5
100
110
120
100
93.0
20
20
270
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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, AUTOMATIC HIGH LIMIT &
MANUAL HIGH LIMIT THERMOSTATS
9 CLIP - POWER CABLE
10 FLUE MANIFOLD ACCESS COVER
11 CH RETURN PIPE
12 MANUAL RESET FLUE OVERHEAT
TH E R M OS TAT
13 FLUE MANIFOLD
14 FLUE GAS SAMPLING POINT
15 - 16 SECONDARY HEAT EXCHANGER
17 MANUAL AIR VENT - SECONDARY
HEAT EXCHANGER
18 MANUAL AIR VENT - SECONDARY TO
PRIMARY HEAT EXCHANGER
RETURN PIPE
19 SECONDARY TO PRIMARY HEAT
EXCHANGER RETURN PIPE
20 DRAIN-SECONDARY HEAT
EXCHANGER
21 CH FLOW CONNECTION LEFT &
RIGHT HAND SIDE
22 CONDENSATE OUTLET
23 INTERNAL CONDENSATE TRAP
24 CONDENSATE DRAIN
25 CONDENSTAE DRAIN PUSH-FIT
CONNECTOR
26 OPTIONAL COLD FEED/DRAIN LEFT
& RIGH HAND SIDE
27 PRIMARY HEAT EXCHANGER
28 BASE PLATE
29 COMBUSTION CHAMBER ACCESS
DOOR
30 OIL DRIP TRAY
31 TOP FRONT PANEL
30a RIELLO RDB 3.2 (32/50)
RIELLO RDB 4.2 (50/70)
i) Control box
ii) Motor
iii) Air intake casing
iv) Oil pump
v) Combustion head
30b BENTONE STERLING 133 (32/50)
BENTONE STERLING 146 (50/70)
i) Control box
ii) Motor
iii) Air intake casing
iv) Oil pump
v) Combustion head
31 LOCKOUT INDICATOR/RESET
BUTTON
32 CLIP - AIR INTAKE HOSE
33 AIR INTAKE HOSE
LAYOUT & COMPONENTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25
8 716 109 711B 07.2010
7
APPLIANCE
INFORMATION
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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 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/25
8 716 109 711B 07.2010
8
PRE -
INSTALLATION
BEFORE CLEANING THE SYSTEM:
ENSURE THE SYSTEM AND PIPEWORK IS
IN GOOD WORKING ORDER.
FLUSH THE EXISTING SYSTEM WITH A
POWER FLUSHING MACHINE OR WITH A
CHEMICAL CLEANER BEFORE
INSTALLING NEW COMPONENTS.
CLEANING THE PRIMARY SYSTEM:
Cleanse the system in accordance with
BS 7593.
Fill the system with cold mains water to the
recommended pressure and check for leaks.
Open all drain cocks and drain the system.
Close drain cocks and add a suitable flushing
agent at the correct strength for the system
condition in accordance with the manufacturer's
instructions.
Circulate the flushing agent before the boiler
is fired up.
Run the boiler and system at normal operating
temperature in accordance with the
manufacturer's instructions.
Drain and thoroughly flush the system to
remove the flushing agent and any debris.
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.
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MAINS SUPPLY
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 appliance must be earthed.
• Refer to IEE regulations for cross bonding
requirements.
• It must be possible to isolate the appliance
from the electrical supply with at least a 3mm
contact separation in both poles supplying
the appliance.
• Wiring between the appliance and the
electrical supply must comply with IEE wiring
regulations and any local regulations which
may apply for fixed wiring to a stationary
appliance.
• Any system connected to the boiler must not
have a separate electrical supply.
MAINS SUPPLY
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/70 8 716
109 711B 07.2010
9
PRE -
INSTALLATION
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OIL SUPPLY INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716
109 711B 07.2010
10
PRE -
INSTALLATION
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 installed to
BS 5410. A steel tank should conform to
BS 799: part 5 and have a slope of 1 in 24
away from the outlet valve with a sludge cock
at its lower end.
• Do not use galvanised steel tanks or
pipework for the oil supply system.
• Do not use soldered joints on the oil
supply pipework.
a) Single pipe gravity feed system:
The oil storage tank (A) must be positioned so
that the oil level does not exceed 4 metres above
the level of the burner oil pump (J) and in addi-
tion the oil level must be at least 300mm above
the oil pump (J). Where the maximum oil level in
the oil storage tank exceeds 4 metres, a head
breaking device must be installed between the
tank (A) and the burner oil pump (J).
b) Double pipe sub-gravity feed system:
Maximum suction height 3.5 metres. Non-return
valves must be fitted to the inlet and return oil line
between the oil pump (J) and oil storage tank (A).
c) Single pipe suction lift with de-aerator
Maximum suction height 3.5 metres. The oil
tank (A) must be positioned below the oil pump
(J). Create an inlet and return loop between the
de-aerator (M) and oil pump (J).
A non-return valve must be incorporated within
the de-aerator or fitted to the oil line between
the oil storage tank (A) and the de-aerator (M).
A top feed oil tank fitted with a de-aerator
using an internal non-return valve should have
any non-return valves fitted in the base of the
tank to the suction line removed to assist
purging air from the oil line.
Pipework
Use copper pipe of the correct diameter
according to the information shown opposite.
Use flexible hoses to connect to the oil pump (J).
Lay the oil supply pipe (H) as straight and
level as possible to avoid air pockets and
unnecessary friction losses. Route away
from the boiler access door or other hot
surfaces.
Install a manual isolating valve (B) to the oil
supply pipe (H), as close to the oil storage
tank (A) as possible.
Fit an oil strainer and water separator (C) to
the oil supply pipe, near the oil storage tank.
Fit an additional oil filter (N, 16μmmax
filtration size) close to the boiler, but not
inside the boiler casing.
Fit a fire valve in accordance with BS 5410.
The fire valve (D) should be fitted externally
to the building with the fire valve sensor (F)
located within the appliance case.
A fire valve with a shut off temperature of
85°C or higher must be fitted to avoid
the possibility of nuisance shut offs.
A capillary type valve provides a neat and
simple installation. Alternatively, a fusible
link or electrical system may be used.
Under no circumstances should a
combination isolating/fire valve be used
as the sole fire protection device.
AF
BN GJ
4m max.
K
a)
H
300mm min.
B DB C
MAXIMUM PIPE RUN FOR SINGLE PIPE GRAVITY FEED SYSTEM
B
A
DB
C
E
K
3.5m max.
L
L
b)
H
FG
B
150mm
MAXIMUM PIPE RUN FOR DOUBLE PIPE SUB-GRAVITY FEED SYSTEM
NJ
B
A
M
B
F
C
G
J
E
D
c)
MAXIMUM PIPE RUN FOR SINGLE PIPE SUCTION LIFT WITH DE-AERATOR
H
FUEL FLOW RATE FUEL FLOW RATE
K
E
3.5m max.
A - Oil storage tank.
B - Isolating valve.
C - Oil strainer & water separator.
D - Fire valve to BS 5410.
E - External wall.
F - Fire valve sensor.
G - Oil burner.
H - Oil supply pipe.
J - Oil pump.
K - Full base (plastic tanks).
L - Non-return valve.
M - De-aerator.
N - Oil filter (16μmmax filtration size)
NOTE: All dimensions are in metres unless stated otherwise.
The maximum pipe run figures are based on using copper pipe with an inside diameter of
2mm less than the Ø.
HEAD 10mmØ 12mmØ
0.5 12 30
1.0 25 69
1.5 37 91
2.0 49 100
HEAD 10mmØ 12mmØ
2.5 62 100
3.0 74 100
3.5 87 100
4.0 99 100
HEAD 10mmØ 12mmØ
050 100
0.5 44 100
1.0 38 95
1.5 32 80
HEAD 10mmØ 12mmØ
2.0 26 66
2.5 20 50
3.0 14 37
3.5 8 22
HEAD 2.5kg/h 5kg/h 10kg/h 10kg/h
8mmØ 8mmØ 8mmØ 10mmØ
0 100 55 26 100
0.5 95 45 23 100
1.0 80 40 20 90
1.5 70 3 5 17 75
HEAD 2.5kg/h 5kg/h 10kg/h 10kg/h
8mmØ 8mmØ 8mmØ 10mmØ
2.0 60 30 14 65
2.5 45 25 11 50
3.0 35 15 8 35
3.5 25 10 5 20
The table and illustration above is a guide only and does not in any way override the
de-aerator manufacturers instructions.
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