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Worcester-Bosch Greenstar Danesmoor Utility Regular - Utility System Manual

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Contents
Greenstar Danesmoor Utility 2022+ and Utility System 2022+ - 6 721 846 263 (2022/01)2
Contents
1 Key to symbols and safety instructions . . . . . . . . . . . . . . . . . . . 3
1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Installation regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Complying with the building regulations . . . . . . . . . . . . . 5
3 Appliance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Energy efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Layout and components
- 18/25 System appliance shown . . . . . . . . . . . . . . . . . . 8
3.5 Layout and components
- 18/25 Regular appliance shown . . . . . . . . . . . . . . . . . 10
4 Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1 Cleaning primary systems . . . . . . . . . . . . . . . . . . . . . . . 11
4.1.1 Before cleaning the system: . . . . . . . . . . . . . . . . . . . . . 11
4.1.2 Flushing the system . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1.3 Inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1.4 Artificially softened water . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Mains supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2.1 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3 Oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3.1 Single pipe gravity feed system: . . . . . . . . . . . . . . . . . . 12
4.3.2 Double pipe sub-gravity feed system: . . . . . . . . . . . . . 12
4.3.3 Single pipe suction lift with de-aerator: . . . . . . . . . . . . 12
4.3.4 Pipework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3.5 Boiler isolation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.4 Water systems and pipework . . . . . . . . . . . . . . . . . . . . 13
4.5 Condensate discharge . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.5.1 Condensate pipe work . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.5.2 Internal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.5.3 External connections . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.6 Pressure relief pipework . . . . . . . . . . . . . . . . . . . . . . . . 17
4.7 Boiler locations and clearances . . . . . . . . . . . . . . . . . . 17
4.8 Flue gas system considerations . . . . . . . . . . . . . . . . . . 19
4.8.1 Combustion air quality . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.8.2 Flue terminal positions . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.9 Flue options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.9.1 Conventional flue (CF) . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.9.2 Room sealed flue options . . . . . . . . . . . . . . . . . . . . . . . 23
4.10 Plume management . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.1 Unpacking the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2 Pipework positions and flue opening . . . . . . . . . . . . . . 27
5.3 Boiler installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.4 Flue installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.4.1 Flue damper installation . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4.2 Installation notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.5 Combustion chamber (18/25 Regular shown) . . . . . . 31
5.6 Pipework connections . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.7 Oil burner and pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.8 Refitting components . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.9 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.1 Pre-Commissioning checks - 18/25 Regular shown . . . 40
6.2 Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.3 Water treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.4 Starting the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.4.1 Single pipe gravity feed system: . . . . . . . . . . . . . . . . . . 41
6.4.2 Double pipe sub-gravity feed systems and single pipe
suction lift with de-aerator: . . . . . . . . . . . . . . . . . . . . . . 41
6.4.3 Pump adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.4.4 Burner head setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.4.5 Boiler lockout indicator on: . . . . . . . . . . . . . . . . . . . . . . 43
6.4.6 Combustion checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.4.7 Central heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.5 Finishing commissioning . . . . . . . . . . . . . . . . . . . . . . . . 45
6.5.1 Hand over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.5.2 Appliance guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7 Service and Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.1 Inspection and service - 18/25 Regular shown . . . . . . . 47
7.2 Pre-service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.3 Service requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.4 Sealed system only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.5 Clean the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.6 Oil burner nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.7 Pump filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.8 External oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.9 Combustion chamber - 18/25 Regular shown . . . . . . . 49
7.10 Oil supply system and tank . . . . . . . . . . . . . . . . . . . . . . . 50
7.11 Clean the boiler - Manifold access . . . . . . . . . . . . . . . . . 50
7.12 Re-commissioning the burner . . . . . . . . . . . . . . . . . . . . 51
7.13 After service hand over . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.14 Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8 Fault finding and diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.1 Burner functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.2 Heating and hot water . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.3 Boiler function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.4 Logic for the 535 SE/LD RDB control box . . . . . . . . . . . 56
8.5 Riello control box 12/18 model . . . . . . . . . . . . . . . . . . . 57
8.5.3 Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.5.4 Flame sensing photocell 12/18 models . . . . . . . . . . . . 59
8.5.5 Flame sensing photocell 18/25 and 25/32 models . . . 59
8.6 Oil supply vacuum testing . . . . . . . . . . . . . . . . . . . . . . . . 59
8.7 Air pressure switch and flue overheat reset . . . . . . . . . 59
8.8 Air pressure switch connections . . . . . . . . . . . . . . . . . . 59
8.9 Oil appliance commissioning checklist . . . . . . . . . . . . . 60
8.10 Service interval record . . . . . . . . . . . . . . . . . . . . . . . . . . 61
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