Bosch DANESMOOR UTILITY 32-50 Instruction Manual

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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
8 716 109 711 b 07.10 14/7/10 09:59 Page 1
Page view 0
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Summary of Contents

Page 1 - 32/50 & 50/70

INSTRUCTION MANUALINSTALLATION, COMMISSIONING & SERVICINGFLOOR STANDING OIL-FIRED CONDENSING BOILER CONVENTIONALFLUE & ROOM SEALED FLUEGREENST

Page 2 - SERVICING INSTRUCTIONS

OIL SUPPLYINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716109 711B 07.201010PRE -INSTALLATIONOIL SUPPL

Page 3 - CONTENTS

WATER SYSTEMS & PIPEWORKINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/70 8 716109 711B 07.201011PRE -IN

Page 4 - 8 716 109 711B 07.2010

WATER SYSTEMS & PIPEWORKFILLING PRIMARY SEALED SYSTEMS:• Filling the system must comply with one of themethods shown opposite.• The filling point

Page 5 - Check List

CONDENSATE PIPEWORKINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716109 711B 07.201013PRE -INSTALLATION

Page 6 - TECHNICAL DATA

External2ventilationHigh LowLevel Level248 248358 358Room Sealed flue:*Internal1ventilationHigh LowModel Level Level32/

Page 7 - LAYOUT & COMPONENTS

600m m 2250m m 600m m 2250m m 600mm 600mm radius 7 50m m 7 50m m 2250m m m 2250m BOILER LOCATION & CLEARANCESINSTALLATION & SERVICING INSTRUCT

Page 8 - CLEANING PRIMARY SYSTEMS

FLUE TERMINAL POSITIONSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716109 711B 07.201016PRE -INSTALLA

Page 9 - MAINS SUPPLY

PRE -INSTALLATIONCONVENTIONAL FLUEINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716109 711B 07.201017CO

Page 10 - OIL SUPPLY

ROOM SEALED FLUE OPTIONSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716109 711B 07.201018PRE -INSTALL

Page 11 - WATER SYSTEMS & PIPEWORK

UNPACKING THE BOILERINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716109 711B 07.201019INSTALLATIONUnpa

Page 12 - WATER SYSTEMS & PIPEWORK

INSTALLATION &SERVICING INSTRUCTIONSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/258 716 109 711B 07.201

Page 13 - PRESSURE RELIEF PIPEWORK

SAFETY:All relevant safety precautions must be undertaken.Protective clothing, footwear, gloves and safetygoggles must be worn as appropriate.PIPEWORK

Page 14 - CLEARANCES

BOILER INSTALLATION1 Lift the top panel (A) upwards todisengage the ball stud connections (B) and remove.2 Pull the upper front panel squarely forwa

Page 15

The flue can exit the boiler from outlets A, B, Cor D allowing vertical (RS &CF) and horizontal(RS low or high level) flues to be fitted. (CFposit

Page 16 - FLUE TERMINAL POSITIONS

Secondary heat exchanger:1 Unscrew screws (B) and remove flue manifold access cover (A). Check that all the baffles and retainer arecorrectly fitte

Page 17 - CONVENTIONAL FLUE

PIPEWORK CONNECTIONSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716109 711B 07.201024INSTALLATIONCAUT

Page 18 - ROOM SEALED FLUE OPTIONS

OIL BURNER & PUMPRIELLO RDB BURNERSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716109 711B 07.201

Page 19 - UNPACKING THE BOILER

CAUTION: ISOLATE THE OIL & WATER MAINS SUPPLY BEFORE STARTING ANYWORK AND OBSERVE ALL RELEVANTSAFETY PRECAUTIONS.OIL BURNER:1 Check t

Page 20 - FLUE OPENING

REFITTING COMPONENTS1 Slide side panels (R) and top support bracket (L) together with control box (G) along base rails and push to secure into the

Page 21 - BOILER INSTALLATION

ELECTRICSDANGER - 230V:ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALLRELEVANT SAFETY PRECAUTIONS.IMPORTANT: OBSERVE

Page 22 - FLUE INSTALLATION

HRESETJRIELLO CONTROL BOXELECTRICS230V STANDARD WIRING DIAGRAM:Key to components:A - TERMINAL CONNECTOR BLOCK.B - EARTH CONNECTOR.C - FLUE THERM

Page 23 - COMBUSTION CHAMBER

CONTENTSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/258 716 109 711B 07.20103SAFETY &REGULATIONSAPPLIAN

Page 24 - PIPEWORK CONNECTIONS

ELECTRICSDANGER - 230V:ISOLATE THE MAINS ELECTRICITY PRE-WIRED REMOTE 2 OR 3 PORT VALVECONTROL SETS: Key to components:A - Double pole switched fuse

Page 25 - RIELLO RDB BURNERS

PRE-COMMISSIONING CHECKS -APPLIANCECAUTION: ISOLATE THE MAINS SUPPLIESBEFORE STARTING ANY WORK ANDOBSERVE ALL RELEVANT SAFETYPRECAUTIONS.1Check that

Page 26 - BENTONE STERLING BURNERS

1 Open all system and radiator valves. Turn on the water main stop cock. Open vented systems only: Turn on the water to the system feed and expans

Page 27 - REFITTING COMPONENTS

CBARIELLORDB OIL PUMPSTARTING THE APPLIANCEIMPORTANT: Never run the appliance whenthe appliance/system is unpressurised(sealed systems) or empty.1Che

Page 28 - ELECTRICS

STARTING THE APPLIANCERIELLO RDB BURNERSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR UTILITY 32/50 & 50/708 716109 711B 07.20

Page 29 - RIELLO CONTROL BOX

%CO2NOMINAL BOILER RATING AT NORMAL OPERATING TEMPERATUREUSING 28sec KEROSENE:NOZZLEOILPUMPPRESSURE(p.s.i.)FUELFLOW RATEKg/h l/hCOMBUSTIONHEADSETTING

Page 30

STARTING THE APPLIANCECentral heating:1Open all radiator valves.Set room thermostat to maximum.Set programmer to ON for CH &DHW (if applicable)

Page 31 - APPLIANCE

WATER TREATMENTIMPORTANT: Debris from the system candamage the boiler and reduce efficiency. Failure to comply with the guidelines for the use of wate

Page 32 - FILLING THE SYSTEM

FINISHING COMMISSIONING - APPLIANCE1 Locate edge of front panel (A) onto the supporting ledge (B) on the baseplate. Refit securing screws (C) to sec

Page 33 - STARTING THE APPLIANCE

INSPECTION AND SERVICECAUTION: ISOLATE THE WATER,ELECTRICITY AND OIL MAINS SUPPLIES BEFORE STARTING ANY WORK ANDOBSERVE ALL RELEVANT SAFETYPRECAUTIONS

Page 34

SAFETY PRECAUTIONS& INSTALLATION REGULATIONSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/258 716 109 711

Page 35 - BENTONE STIRLING BURNERS

1 Clean the Burner: Undo the three screws (A) and remove cover(B) from the burner.Loosen clip to remove the flexible air inlet hose(C) from the burn

Page 36

1 Clean the Burner:Loosen clip to remove the flexible air inlet hose(D) from the burner (RS flue systems only). Remove the air intake cover (H) by r

Page 37 - WATER TREATMENT

JILIKLFRONT INSPECTION AND SERVICEClean the boiler:Manifold access:Release screws (E) to remove the flue manifoldaccess cover (F) and clear any debri

Page 38 - FINISHING COMMISSIONING

INSPECTION AND SERVICEFire valve:Check that the oil supply pipe has a fire valvefitted externally to the building with the firevalve sensor located w

Page 39 - INSPECTION AND SERVICE

78111312142345691011516 172aRIELLO RDB BURNERS SHORT PARTS LIST1 Burner - Riello RDB 3.2 32/50 Part Number: 8 718 686 583 0Burner - Riello RDB 4.2

Page 40

1789131415 1611101223456171819 208aBENTONE STERLING BURNERSSHORT PARTS LIST1 Burner - Sterling 133 32/50Part Number: 8 716 108 063 0Burner - Sterling

Page 41

FAULT FINDINGPROBLEM CAUSE REMEDYLOCKOUT:Pulsation on start CF - Flue draught incorrect CF - Check flue draughtCombustion settings incorrect Set up as

Page 42

FAULT FINDINGPROBLEM CAUSE REMEDYFAULTY BOILEROPERATION:Noisy operation Pump noise from air in pump orworn pumpBleed air from pump or replace pumpWorn

Page 43

Boiler notoperatingwith aheating /hot waterdemandBurnermotor runs?Lockoutwithin 1second?Replacecontrol boxReplacemotor/pumpCheck boilercontrols &s

Page 44 - SHORT PARTS LIST

Boiler notoperatingwith aheating /hot waterdemandBurnermotor runs?Burnerlights immediatelymotor runs?230V atsolenoid coilin purge?Replacecontrol boxRe

Page 45

GENERAL INFORMATIONINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/258 716 109 711B 07.20105APPLIANCEINFORMATIO

Page 46 - FAULT FINDING

BOILER MODEL SERIAL No.COMMISSIONING ENGINEER COMMISSIONING CHECKSCOMPANY NAME:PUMP PRESSURE(PSI):ADDRESS:

Page 47

SERVICE 1DATEENGINEER NAMECOMPANY NAMETEL No.OFTEC REG No.PUMP PRESSURE: psi CO2%:NOZZLE CHANGED? YES NOF.G.T. °C

Page 48 - 535 SE/LD RDB CONTROL BOX

Worcester, Bosch GroupCotswold Way, Warndon, Worcester WR4 9SW.Tel. 0844 892 9900 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd

Page 49 - SATRONIC CONTROL BOX

TECHNICAL DATAINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR DANESMOOR UTILITY 18/258 716 109 711B 07.20106TECHNICAL DATACentral He

Page 50 - SERVICE INTERVAL RECORD

Burner Covercut-awayviewLAYOUT & COMPONENTSThe diagram opposite excludes the top, frontand RH side casing panels.1 CH THERMOSTAT CONTROL 2

Page 51

CLEANING PRIMARY SYSTEMSIMPORTANT: All the following Pre-Installation sections must be read and requirements met before starting boiler or flue insta

Page 52

MAINS SUPPLYELECTRIC SUPPLY:• Supply: 230V - 50Hz.• Cable: PVC insulated 0.75mm2(24 x0.2mm) temperature rated to 90°C.• Protection IP20.• External

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