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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WATER SYSTEMS & PIPEWORK
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/70 8 716
109 711B 07.2010
11
PRE -
INSTALLATION
R
TYPICAL OPEN VENT SYSTEM:
A - Appliance.
B - Expansion vessel.
C - Automatic bypass valve.
D - Drain cock.
E - Feed and expansion cistern.
F - Feed and expansion
15mmØ min.
G - Pressure gauge.
H - Open vent 22mmØ min.
J - Circulating pump.
K - Zone valve.
L - Lockshield valve.
M - Hot water cylinder.
N - Automatic air vent.
P - Pressure relief
discharge.
R - Radiators.
S - Static head.
T - Thermostatic radiator
valve (TRV).
U - To filling system.
E
1000mm min.
FH
A
R R
R R
D
C
T L T L
T L L L
J K
M
150mm max.
K
TYPICAL SEALED SYSTEM:
A
D
R R
R
B
P
D
C
T L T L
T L L L
G
J K
M
N
D
U
S
WATER SYSTEMS & PIPEWORK
PRIMARY SYSTEM PLASTIC PIPEWORK:
• Any plastic pipework used must have a
polymeric barrier, comply with BS 7921and
be installed to BS 5955 with 1000mm
(minimum) length of copper or steel pipe
connected to the boiler.
• Plastic pipework used for underfloor heating
must be correctly controlled with a
thermostatic blending valve limiting the
temperature of the circuits to approx. 50°C
with 1000mm (minimum) length of copper or
steel pipe connected to the boiler.
PRIMARY SYSTEM/CONNECTIONS/VALVES:
•Do not use galvanised pipes or radiators.
• All system connections, taps and mixing
valves must be capable of sustaining a
pressure of 3 bar.
• Radiator valves should conform to
BS 2767:10.
• All other valves should conform to BS 1010.
• On new installations TRVs must be used on
all radiators except the radiator where the
room thermostat is sited, this must be fitted
with lockshield valves and left open. All
installations should have TRVs fitted to
radiators within the sleeping accommodation.
• An automatic bypass valve must be connected
between the heating flow and return where
TRVs are used on all radiators, fitted to give
at least a 3 metre circuit when activated.
• Drain cocks are required at all the lowest
points on the system.
• Air vents are required at all high points on the
system.
OPEN VENT PRIMARY SYSTEM:
• The open vent pipe (H) and feed and
expansion pipe (F) must rise continuously
from the appliance.
• The feed and expansion cistern (E) must be
positioned to provide a static head (S) of at
least 1 metre above the highest point in the
heating system to the water level in the feed
and expansion cistern (E).
• Ensure adequate space is left in the expansion
cistern for expansion of the system water.
• No valve shall be fitted in the open vent pipe
(H) or the feed and expansion pipe (F).
• The open vent pipe (H) must be at least
22mmØ.
FULLY PUMPED SEALED PRIMARY SYSTEM:
• A pressure relief valve (P), spring loaded
safety valve set to operate at 3bar, must be
fitted to the heating flow pipe as close as
possible to the boiler or onto one of the boiler
top 11/2” BSP outlets.
• An expansion vessel (B) must be fitted to the
heating return pipe as close as possible to
the boiler and pressurised for the system
volume according to the instructions supplied
with the vessel.
• A pressure gauge (G), 3 bar minimum, must
be fitted to the heating flow pipe or one of the
boiler 11/2” BSP outlets.
• An automatic air vent (N) must be fitted.
IMPORTANT: The boiler should not be
allowed to operate with a return
temperature of less than 40°C when the
system is up to operating temperature.
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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
return
Non return
valve Non return valve
Test cock
Stop
cock
Water main
supply
Stop
cock
Temporary hose
Heating return Auto air
vent Non return
valve
Stop
cock
Make up
vessel
1000mm above
the highest point
of the system
Fill Point
WATER SYSTEMS & PIPEWORK INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/70
8 716 109 711B 07.2010
12
PRE -
INSTALLATION
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CONDENSATE PIPEWORK
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716
109 711B 07.2010
13
PRE -
INSTALLATION
CONDENSATE &
PRESSURE RELIEF PIPEWORK
CONDENSATE PIPEWORK:
• All national and, where appropriate, local
regulations for the discharge and neutralisation
of condensate should be followed.
• The condensate pipe must be a minimum of
21.5mmØ polypropylene pipe.
• The condensate pipework must fall at least
50mm per metre towards the outlet and should
take the shortest practicable route.
• Support the pipe at least every 0.5m for near
horizontal runs .
• When a boiler is to be installed in an unheated
location, such as a garage, all condensate
pipes should be considered as external.
EXTERNAL PIPEWORK:
• The 21.5mmØ pipe mus not exceed 3 metres
outside the building. If a run greater than 3m is
required, 32mmØ pipe must be used.
• Any pipe exposed to windchill or extreme cold
must be 32mmØ.
• Protect all external pipes with weather resistant
insulation and box-in, if necessary to reduce the
risk of freezing.
• Terminate as close to the ground as possible
(below the grating and above the water level)
while still allowing for safe dispersal of conden-
sate. This will help reduce windchill freezing.
Connection of a condensate pipe to a drain may
be subject to local building regulations.
MAKING IT SAFE:
• Condensate pipework must not leak, freeze or
block up.
• Condensate traps must be filled before starting
up the boiler to prevent potentially harmful flue
products escaping via the condensate route.
• Do not dispose of condensate into water
recovery systems.
Condensate can be discharged into a rain water
hopper which is part of a sewer system carrying
both rain water and foul water.
• The pipework must follow one of the options
shown opposite:
a - Internal waste drainage system
b - Soil/vent stack
c - External drainage system
d - External condensate absorbtion point
A - Condensate from the boiler internal con-
densate trap which has a 75mm water seal.
B - Sink.
C - 21.5mmØ polypropylene condensate pipe.
D - Gully.
E - Internal soil and vent stack.
F - 300mm 100mm Ø sealed plastic tube .
G - Ground level.
H - Drainage holes 50mm from base of tube
(12mmØ at 25mm centres) facing away
from building.
I - Limestone chippings.
b
E
C
Invert
450 min.
A
c
D
A
C
75mm
min.
a
A
B C
D
400mm
min.
500mm min.
d
F
I
H
G
A
C
25mm
min.
200mm min.
Unsuitable for clay soil types
PRESSURE RELIEF PIPEWORK:
• The pressure relief drain pipe (K) should be at
least 15mm diameter copper pipe and run
downwards away from the boiler and discharge
away from any electrics or other hazard,
preferably to an external drain or soak away.
• Pipe (K) should be finished with a partial bend,
near the outlet to face the external wall
(as shown) to help prevent freezing.
IMPORTANT: The pressure relief valve is a
safety device for the boiler and if activated
may discharge boiling water or steam
through the relief valve drain pipe.
Care should be taken when siting the
outlet pipe so that it does not cause an
obstruction or discharge above a window,
entrance or other public access where it
could cause a hazard.
K
J
K
L
J - Outside wall.
K - Drain pipe.
L - External drain.
8 716 109 711 b 07.10 14/7/10 09:59 Page 13

External 2ventilation
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
External 2ventilation
High Low
Level Level
248 495
358 715
Conventional flue:*
Internal1ventilation
High Low
Model Level Level
32/50 495 743
50/70 715 1073
• This boiler is only suitable for installing
internally within a property at a suitable
location onto a fixed rigid surface of the same
size as the boiler and capable of supporting
the boiler weight.
• The boiler must be installed on a flat level
surface to ensure condensate does not enter
the primary heat exchanger.
• The boiler is not suitable for external
installation unless a suitable enclosure is
provided.
• The boiler is not suitable for roof space
installations.
Open flue model (CF):
• In order to ensure clean and efficient
combustion an adequate supply of air must
be delivered to the combustion chamber.
• To provide sufficient air a suitable inlet must
be provided into the room or space in which
the boiler is situated.
An air brick or other form of continuous air
supply may have to be built into the installation
in order to ensure an adequate supply of air.
• If the appliance is to be installed in a confined
space or compartment two air vents are
required, one at high level and one at low level.
The minimum free area of each vent is
shown opposite and depends whether the
air is taken from another room or from
outside the building.
• Where the air is taken from another room that
room must contain an air inlet as described
above.
Room sealed balanced flue model (RS):
The appliance does not require a separate vent
for combustion air.
• Installation in cupboards or compartments
require permanent vents for cooling purposes,
one at high level and one at low level, either
direct to outside air or to a room.
• Both vents must pass to the same room or be
on the same wall to the outside air.
The minimum air vent free area is given in the
table opposite.
a: INSTALLATION CLEARANCES:
Diagram (a) shows the minimum space
recommended to install the boiler only.
b: SERVICE CLEARANCES:
Diagram (b) shows the minimum space
required to carry out an annual service.
c: MAINTENANCE & REPAIR CLEARANCES:
The appliance is suitable for an under worktop
installation providing that the worktop above the
boiler (min 10mm clearance) is removable for
maintenance and repair and the front of the
boiler is not enclosed.
* Due to changes to BS 5410 and modern
building design, these figures no longer
incorporate the adventitious ventilation allowance.
BOILER LOCATION & CLEARANCES INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716
109 711B 07.2010
14
PRE -
INSTALLATION
BOILER LOCATION &
CLEARANCES
600mm
300mm
100mm
100mm
720mm
1415mm
13 12 m m
a: RECOMMENDED
INSTALLATION CLEARANCES
b: ANNUAL SERVICE CLEARANCES
600mm
300mm
10mm
10mm
720mm
1415mm
1312mm
c: MAINTENANCE & REPAIR
CLEARANCES
600mm
300mm
10mm
10mm
720mm
1415mm
1312mm
MINIMUM AIR VENT AREA (cm2) FOR APPLIANCES INSTALLED IN A COMPARTMENT:
1Internal air to and from a space/room inside the building. 2External air to and from directly outside the building.
32/50kW
CF minimum air inlet sizes*
248 358
50/70kW
Output
Size cm2
8 716 109 711 b 07.10 14/7/10 09:59 Page 14

600mm
2250mm
600mm
2250mm
600mm
600mm radius
750mm
750mm
2250mm
m
2250m
BOILER LOCATION & CLEARANCES
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716
109 711B 07.2010
15
PRE -
INSTALLATION
COMPARTMENTS:
Follow the requirements of BS 5410 and note:
• Minimum clearances must be maintained.
• An access door is required to install, service
and maintain the boiler and any ancillary
equipment.
• If fitting the boiler into an airing cupboard
use a non-combustible material (if perforated,
maximum hole sizes of 13mm) to separate
the boiler from the airing space.
Venting compartments:
There must be sufficient clearance around the
appliance to allow proper circulation of
ventilation air. The clearances required for
installation and servicing will normally be
adequate for ventilation.
• Ventilation must be provided for boilers
fitted into compartments as described in
BS 5410.
• 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 added to the vents
with a statement to the effect: ''Do not block
this vent. Do not use for storage.”
SHOWER / BATHROOMS:
The boiler must not be installed in zones 0, 1
or 2 (the shaded areas shown on the diagrams oppo-
site).
IMPORTANT: conventional flued boilers
must not be fitted in a bathroom.
IMPORTANT: any appliance control using
mains electricity must not be able to be
touched by a person using the bath or shower.
Electrical switches, fused spur and socket
outlets must not be fitted in the bathroom.
In all cases the IEE wiring regulations must be
consulted.
All pipework in bathrooms and shower rooms
must be cross bonded.
BOILER LOCATION &
CLEARANCES
1
212
0
1
212
0
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FLUE TERMINAL POSITIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716
109 711B 07.2010
16
PRE -
INSTALLATION
FLUE TERMINAL POSITIONS
• 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
BS 5410.
• The flue must not cause an obstruction.
• Discharge from the flue outlet must not be a
nuisance.
• Flue gases have a tendency to plume and in
certain weather conditions a white plume of
condensation will be discharged from the flue
outlet which could be regarded as a
nuisance, for example, near security lighting.
• There should be no restriction preventing the
clearance of combustion products from the
terminal.
• The air inlet/outlet duct and the terminal of
the boiler must not be closer than 25mm to
any combustible material. Detailed
recommendations on protection of
combustible materials are given in BS 5410:1
• A protective terminal guard must be fitted if
the terminal is 2m or less above a surface
where people have access.
The guard must be spaced equally (minimum
50mm) around the flue and fixed to the wall
with plated screws.
Stainless steel terminal guard.
Part No: 7 716 190 050
The following additional guidelines (from part
L Exceptions Guidance Document) are
recommended when determining the flue
outlet position:
• Avoid discharging flue gases into car ports
or narrow passageways.
• *Minimum distance of the flue terminal from
above ground is 2100mm where directed to a
public footpath, private access route or a
frequently used area and 2500mm from a
car parking area.
• **Minimum distance of the flue terminal to a
facing wall, fence, building or property
boundary is 2500mm.
O
P
boundary
F
J
H
B
A
G
E
M
C, D
N
F
F
K
L
boundary
Q
Q
Q
R
Q
Q
Q
Q
Pitched roof
Flat roof
Key: — Not applicable, N/A Not allowed, CF Conventional flue, RS(H) Room Sealed Horizontal flue,
RS(V) Room Sealed Vertical flue.
Notes:
1. Terminals should be positioned so as to avoid products of combustion accumulating in stagnant pockets around the building or
entering into buildings.
2. Vertical structure in N, O and P includes tank or lift rooms, parapets, dormers etc.
3. Terminating positions should be at least 1.8m from an oil storage tank unless a wall with at least 30 min fire resistance and
extending 300mm higher and wider than the tank is provided between the tank and the terminating position.
4. Where a flue is terminated less than 600mm away from a projection above it and the projection consists of plastics or has a
combustible or painted surface, then a heat shield of at least 750mm wide should be fitted.
5. If the lowest part of the terminal is less than 2m above the ground, balcony, flat roof or other place to which any person has
access, the terminal should be protected by a guard.
6. Notwithstanding the dimensions given above, a terminal should not be sited closer than 300mm to combustible material. In the
case of a thatched roof, double this separation distance should be provided. It is also advisable to treat the thatch with a fire
retardant material and close wire in the vicinity of the flue.
7. It is essential that a flue or chimney does not pass through the roof within the shaded area delineated by dimensions Q and R.
8. Where protection is provided for plastic components, such as guttering, it is essential that this is to the standard specified by the
manufacturer of the plastic components.
TERMINAL POSITION CF RS(H) RS(V)
A1 4 Directly below an opening, air brick, opening window, etc N/A 600mm N/A
B1 4 Horizontally to an opening, air brick, opening window, etc N/A 600mm N/A
C8Below a plastic/painted gutter, drainage pipe or eaves if
combustible material protected
N/A 75mm N/A
D8Below a plastic/painted gutter, drainage pipe or eaves
without protection to combustible material
N/A 600mm N/A
EFrom vertical sanitary pipework N/A 300mm N/A
F 3From an external or internal corner or from a surface or
boundary alongside the terminal
N/A 300mm N/A
G5Above ground or balcony level N/A 300mm* N/A
H3From a surface or boundary facing the terminal N/A 600mm** N/A
JFrom a terminal facing the terminal — 1200**mm —
KVertically from a terminal on the same wall N/A 1500mm N/A
LHorizontally from a terminal on the same wall — 750mm —
MAbove the point of highest intersection with the roof 600mm — 600mm
N2From a vertical structure on the side of the terminal 750mm —750mm
O2Above a vertical structure less than 750mm from the side of the
terminal
600mm —600mm
P2 From a ridge terminal to a vertical structure on the roof 1500mm —N/A
QAbove or to the side of any opening on a flat or sloping roof 300mm — 300mm
RBelow any opening on a sloping roof 1000mm —1000mm
Minimum dimension of the flue terminal position for oil fired appliances:
8 716 109 711 b 07.10 14/7/10 09:59 Page 16

PRE -
INSTALLATION
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 appliances must
not be installed in a bedroom, bathroom or
bedsitting room.
• The flue system must be in accordance with
BS 5410 : Part 1 and the current Building
Regulations.
• The flue must be constructed of materials
suitable for use with condensing combustion
products.
• External flue systems must be of the insulated
type.
• Brick and masonry chimneys must be lined
with a suitable non-combustible material and
properly jointed to withstand the effects of
the working temperature (minimum rating of
material 120°C) of the appliance and any
condensate which may form.
• All flue joints must be sealed to prevent the
leakage of condensate and combustion
products.
• Ensure that joints are made so that the
condensate runs away and is not collected
within the joint.
NOTE: The flue can be increased in size from
the boiler take off point providing the joint is
correctly sealed. Never reduce the flue diameter
from the boiler take off point.
CF Sizing:
• 32/50 & 50/70 = 150mmØ
• Because the flue operates at a lower
temperature on a condensing boiler
compared to that of a conventional
appliance, the flue draught will be lower.
Typically the draught will be between
0.5mmwg and 4.4mmwg, measured with the
flue warm but the burner not firing. The actual
figure will vary depending on weather
conditions, flue height and position.
• The flue should be vertical and contain as few
bends as possible, a maximum of two 135°
bends should be used.
• The flue outlet must be extended beyond the
eaves of the building and where possible,
above the apex.
• Fit a suitable anti down-draught terminal
where down draughts are experienced.
8 716 109 711 b 07.10 14/7/10 09:59 Page 17

ROOM SEALED FLUE OPTIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716
109 711B 07.2010
18
PRE -
INSTALLATION
ROOM SEALED FLUE OPTIONS
The diagrams (opposite) show the components
used and the maximum flue length (L) from
the boiler outlet to the ouside wall*/roof of the
building for each flue configuration.
In all cases L is measured from the outside of
the boiler casing.
• To achieve the maximum flue length (L), a flue
section will have to be reduced in length.
• Only the flue terminal or straight flue
extensions can be reduced in length by
cutting.
• The flue terminal end can be fitted from the
inside or outside of the building.
IMPORTANT: All horizontal sections must
rise away from the boiler by 52mm per
metre (3°) to allow the condensate to
drain back to the boiler.
A - Horizontal terminal
B - Straight flue extension
C - Flue bend 90°
D - Flue bend 45°
E - Vertical Terminal
F - 90° inner elbow - inner flue to boiler
G - Air intake box
Calculating the flue length:
Measure the total flue length required, noting
that the maximum straight flue length including
the terminal is:
Horizontal 100/150mmØ: 3000mm (excluding
220mm of terminal extending outside the building)
Vertical 100/150mmØ: 6000mm (measured
from the boiler top panel).
Then reduce the total straight flue length for
each extra flue bend (excluding the vertical flue
kit 90° elbow) by:
1000mm for 90°
500mm for 45°
Flue Extension lengths:
Horizontal & Vertical 100/150mmØ: 1000mm
overall length.
Effective length when engaged into sockets
within the flue run is 950mm.
Flue Terminal lengths:
Horizontal 100/150mmØ: 1000mm
Vertical 100/150mmØ: 1290mm + cage
* to outside wall.
E
E
E
E
8 716 109 711 b 07.10 14/7/10 09:59 Page 18

UNPACKING THE BOILER
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716
109 711B 07.2010
19
INSTALLATION
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 packaged boiler has been
delivered, the outer carton is removed first.
Care should be taken when releasing the
straps. If a sharp implement is used make
sure the outer carton is not pierced and that
the implement is used in such a way so that
it may not cause personal injury. All sharp
objects must be covered or the blade
retracted after use and put away in a safe
place.
2Lift carton up and away from the boiler.
Remove the plastic bag and upper front
protection cover from the boiler and place
safely aside.
3 Lift top panel (A) upwards to disengage ball
stud connectors (B) and remove.
4Extract the ancilliary items (a) & (b).
5Pull the upper front panel (C) forwards to
disengage the balll stud connectors.
6Remove securing screws (D) from front
panel (E).
Pull front panel (E) up and away from the
supporting ledge on the boiler and store
away from the working area.
7Remove the bolts securing the boiler to the
transport pallet.
At all times the correct method for handling
heavy objects should be strictly observed.
UNPACKING THE BOILER
LIFTING AND CARRYING PRECAUTIONS:
• Lift only a manageable weight, or ask for
help.
• When lifting or putting things down, bend
the knees, and keep the back straight
and feet apart.
• Do not lift and twist at the same time.
• Lift and carry objects close to the body.
• Wear protective clothing and gloves to
protect from any sharp edges.
IMPORTANT: All the previous Pre-Installation sections must be read
and requirements met before starting boiler or flue installation.
8 716 109 711 b 07.10 14/7/10 09:59 Page 19

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 11/2” Ø BSP
B - Primary drain/cold feed 11/2” Ø BSP
C - CH return 28mm Ø copper
D - Flue outlet
E - Condensate outlet 21.5mm Ø
NOTE: For servicing purposes, keep the
condensate and pressure relief
discharge pipes away from
components and pipework
connections.
FLUE OPENING:
Follow the diagram opposite to mark the
centre of the flue (1, & 2) for rear opening,
(2 & 3) for side opening or
(1 & 4) for top opening.
** IMPORTANT: for horizontal flues, increase
this height by 52mm for every 1000mm of
horizontal length that the flue opening is
away from the boiler.
NOTE: All horizontal flue sections must rise
away from the boiler by 52mm per metre
to ensure that condensate flows back into
the boiler for safe discharge via the
condensate waste pipe.
Make an opening (F, G or H) through the wall
using a core drill or similar at a size relative to
the wall thickness as shown below:
150mmØ flue:
Wall thickness Flue hole size
150 - 240mm 175mmØ
240 - 330mm 185mmØ
330 - 420mm 195mmØ
420 - 500mm 205mmØ
E
E
420
123
19
INSTALLATIONCOMMISSIONING
CAUTION: Ensure there are no pipes,
electric cables, damp proof courses or
other hazards before drilling.
PIPEWORK POSITIONS &
FLUE OPENING
PIPEWORK POSITIONS &
FLUE OPENING
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/70
8 716 109 711B 07.2010
20
FRONT VIEW SIDE VIEW
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