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INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS
WALL HUNG RSF GAS FIRED CONDENSING REGULAR BOILER
Greenstar Ri Compact
FOR OPEN VENTED AND SEALED CENTRAL HEATING SYSTEMS AND
INDIRECT MAINS FED DOMESTIC HOT WATER
These appliances are for use with:
Natural Gas or L.P.G.
(Cat. II 2H 3P type C13, C33 & C53)
Model
Natural Gas
27Ri Compact
30Ri Compact
L.P.G.
27Ri Compact
30Ri Compact
UK/IE
GC Number
41-406-17
41-406-19
41-406-18
41-406-20
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Table of Contents
Related Manuals for Worcester 27Ri Compact
Summary of Contents for Worcester 27Ri Compact
- Page 1 INDIRECT MAINS FED DOMESTIC HOT WATER These appliances are for use with: Natural Gas or L.P.G. (Cat. II 2H 3P type C13, C33 & C53) Model GC Number Natural Gas 27Ri Compact 41-406-17 30Ri Compact 41-406-19 L.P.G. 27Ri Compact 41-406-18...
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Page 2: Table Of Contents
CONTENTS CONTENTS 5.5.2 Checking the gas rate and pressure ....30 Key to symbols and safety instructions ....3 5.5.3 Gas rating test . -
Page 3: Key To Symbols And Safety Instructions
The following keywords are defined and can be used in this document: prosecution. • NOTICE indicates a situation that could result in damage to property If you are in any doubt, contact the Worcester Technical helpline or equipment. (0330 123 3366). - Page 4 Only use Worcester, Bosch approved flue systems, no other living area is more than 70% of the total usable floor area. Then this type manufacturer’s flue systems have been approved for use with Worcester of dwelling can be controlled as one zone.
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Page 5: Appliance Information
APPLIANCE INFORMATION APPLIANCE INFORMATION APPLIANCE 270mm 590mm* 390mm *600mm to top of case front Fig. 1 Ri Compact standard package STANDARD PACKAGE: CHECK LIST - Hardware literature pack Qty. Wall hung gas fired condensing regular boiler for central Greenstar Ri Compact Installation, Commissioning and heating and domestic hot water Servicing Instructions Tail pipes - water only... -
Page 6: Layout
APPLIANCE INFORMATION LAYOUT Fig. 2 Ri Compact main boiler components Greenstar Ri Compact 6 720 646 610 (2013/12) - Page 7 APPLIANCE INFORMATION Wall mounting frame Temperature control and reset Primary return pipe Primary flow pipe Flow temperature sensor (NTC) Flue connector Electrode assembly Flue overheat thermostat Maximum safety sensor (NTC) Primary return connection Auto air vent Primary flow connection Heat exchanger Gas inlet isolator Flueway Bottom panel...
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Page 8: Technical Data
90.0 90.0 Table 5 Ri Compact technical data ** All Worcester Greenstar boilers are tested in an acoustic chamber to sound level and there may some differences in situ dependant on installation site i.e. corners of rooms, fabric of property walls. -
Page 9: Pre-Installation
Regulations. 3.2.1 ELECTRICAL SUPPLY ▶ It is recommended that you fit a primary water cleanser to the system. Worcester offers a filter that helps • Supply: 230V - 50 Hz, 50 Watts plus pump remove both magnetite and non-magnetic debris. - Page 10 PRE-INSTALLATION SEALED PRIMARY SYSTEM: EXISTING INSTALLATIONS S PLAN LAYOUT NOTICE: ARTIFICALLY SOFTENED WATER MUST NOT BE USED TO FILL THE SYSTEM. • If the system is sealed then the system must be filled using a WRAS approved filling loop or comply with figure 3 for system fill. •...
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Page 11: Condensate Pipe Work
PRE-INSTALLATION NEW INSTALLATION SEALED SYSTEM LAYOUT 22mm Ø Fig. 4 Disposal to soil vent stack Alternatively if the first option is not possible an internal kitchen or bathroom waste pipe, washing machine waste pipe etc. can be used. CONDENSATE PIPE WORK Ensure that the condensate drain pipe is connected “down stream”... -
Page 12: External Connections
PRE-INSTALLATION ▶ The use of fittings, elbows etc. should be kept to a minimum and any internal “burrs” on cut pipe work should be removed so that the internal pipe section is as smooth as possible. FITTING AN EXTERNAL AIR BREAK •... -
Page 13: Boiler Location And Clearances
PRE-INSTALLATION 3.5.2 INSTALLATION AND SERVICING CLEARANCES Minimum hole size for the condensate soak away must be Figure 11 shows the minimum space required to install and service the 400mm deep by 300mmØ . boiler in a compartment. In situations where there are likely to be extremes of temperature or 870mm exposure, the use of a proprietary trace-heating system for external pipe 170/210mm***... -
Page 14: Plumbing Manifold
PRE-INSTALLATION PLUMBING MANIFOLD FLUE OPTIONS WARNING: Flue systems 3.6.1 CONNECTIONS ▶ Only use Worcester, Bosch approved flue systems, no Heating System 22mm compression fittings other manufacturer’s flue systems have been 22mm compression fitting approved for use with Worcester appliances. Use the fittings supplied in the Hardware literature pack. - Page 15 PRE-INSTALLATION 350 mm - 570 mm 130 mm Min 500 mm 300 mm Flat roof 6720643895-12.1Wo Greenstar Ri Compact 6 720 646 610 (2013/12)
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Page 16: Flue Terminal Positions
PRE-INSTALLATION FLUE TERMINAL POSITIONS All measurements in millimetres 52mm 104mm 1,500 1,500 300 300 300 300 1,200 Boundary Line Fig. 15 Flue terminal positions NOTICE: ▶ All measurements are the minimum clearances required. ▶ Terminals must be positioned so to avoid combustion products entering the building. ▶... -
Page 17: Plume Management Terminal Positions
PRE-INSTALLATION PLUME MANAGEMENT TERMINAL POSITIONS All measurements in millimetres Flue terminal guard 7 716 191 176 ±45° Plume re-direction: 180° Flue Exhaust Outlet 1,500 Air Intake ±80° 1,200 Boundary Line Fig. 16 Plume terminal positions NOTICE: ▶ All measurements are the minimum clearances required. ▶... -
Page 18: Determine The Plume Management System Length
PRE-INSTALLATION 3.9.1 DETERMINE THE PLUME MANAGEMENT SYSTEM LENGTH FLUE LENGTH VERSUS PLUME MANAGEMENT LENGTH Effective straight flue length with plume management Minimum plume length (M) Maximum plume length (M) 500mm 4,500mm Max flue length (L) 5,000mm Max flue length (L) 2,200mm Note: Measurement “M”... -
Page 19: Installation
INSTALLATION WALL MOUNTING TEMPLATE & FLUE OPENING INSTALLATION WARNING: BEFORE DRILLING, WARNING: All the previous “Pre-Installation” sections ENSURE THAT THERE ARE NO PIPES, ELECTRICAL must be read and the requirements met before starting CABLES, DAMP PROOF COURSES OR OTHER boiler or flue installation. HAZARDS. -
Page 20: Unpacking The Appliance
INSTALLATION Fig. 24 Remove packaging 1. Outer carton 2. Inner sleeve 3. Packing base 4. Protective wrapping 5. Primary flow and return water pipes REMOVING THE OUTER CASE Fig. 22 Marking the flue position ▶ Before the case can be remove the control panel must be moved into the service position, i.e. -
Page 21: Boiler Connection
INSTALLATION Fig. 26 Wall mounting plate 4.4.2 GAS AND WATER CONNECTIONS ▶ The flow and return pipes can be fitted to the boiler before hanging the boiler on the wall plate. ▶ If there is greater than 600mm clearance below the appliance it is possible to fit the flow and return pipes, supplied, with the boiler installed on the wall. -
Page 22: Hanging The Boiler
INSTALLATION 4.4.3 HANGING THE BOILER NOTICE: Before hanging the boiler. ▶ If pipes require reducing in length this is best done before they are fitted to the boiler. NOTICE: Lifting the boiler. ▶ Lift the boiler using the handling holes at either side of the frame. -
Page 23: Flue Installation
INSTALLATION ▶ When the condensate connections are complete, pour approximately 4.5.1 MEASURING THE FLUE (STANDARD FLUE): 200 to 250ml of clean water through the inner flue opening on top of ▶ Measure from the outside of the wall to the centre line of the flue turret the boiler to fill the siphon. -
Page 24: Installing The Telescopic Flue
INSTALLATION To reduce the flue length further: 265 mm 130 mm 6720643895-32.2Wo Fig. 36 Further reduction ▶ Mark the length required for the terminal as shown (min.130mm) and Fig. 38 Aligning the turret cut square, taking care not to damage the tubes. ▶... -
Page 25: Electrical
INSTALLATION 2. Refit to the terminal, ensuring that the clips (1 & 2) are engaged and Opening in building secure. Flue discharge 3. Loosen screws (3) and rotate the entire outlet assembly to redirect Plume deflector the plume. Tighten screws (3) to secure in the required position. Minimum 1500mm from an opening in the building The flue terminal outlet has built-in stops to limit rotation Table 8 Key to figure 42... -
Page 26: Mounting Optional Plug-In Controls
INSTALLATION REMOVING THE BLANKING PLATE The control panel must be released and swung forward slightly to gain access to the top cover panel, refer to section 6.4 for access to the control panel. 1. Release the captive screws securing the top cover panel. 2. - Page 27 ▶ External diverter valve(s) and all other 230V parts are not supplied with the boiler. ▶ Refer to manufacturer's instructions when connecting external parts to the wiring centre. ▶ Worcester, Bosch Group cannot be held responsible Wiring Centre/Junction Box for wiring errors. External Pump Fig.
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Page 28: Commissioning
COMMISSIONING FILLING THE SYSTEM COMMISSIONING Open vented systems: ▶ Ensure all system and boiler drain points are closed. PRE-COMMISSIONING CHECKS ▶ Open all radiator valves. ▶ Turn on the water supply to the system header tank and allow the WARNING: ELECTRIC SHOCK system to fill. -
Page 29: Starting The Appliance
COMMISSIONING STARTING THE APPLIANCE CAUTION: RUNNING THE APPLIANCE ▶ Never run the appliance when the appliance/system is empty or partially filled. reset Fig. 52 Control panel Switching the appliance ON/OFF: ▶ Turn on the mains power supply. ▶ Turn on any external controls ▶... -
Page 30: Commissioning
COMMISSIONING COMMISSIONING Meter Gas Control Natural Gas valve NOTICE: The combustion settings on this gas-fired boiler < 2.5mbar have been checked, adjusted and preset at the factory for difference operation on the gas type defined on the data plate. No measurement of the combustion values is necessary provided there is a meter installed allowing the gas rate to 19 - 23 mbar be checked. -
Page 31: Co And Combustion Checks
Check and zero the analyser in fresh air as specified by the manufacturer. ▶ The air/gas ratio valve is factory set and must not be adjusted during commissioning unless this action is recommended following contact with the Worcester, Bosch Group help line 0330 123 3366. Zero the analyser Set boiler to >... -
Page 32: Finishing Commissioning
COMMISSIONING FINISHING COMMISSIONING 5.7.1 REPLACING OUTER CASING: 1. Replace outer casing. 2. Ensure that the securing clips on top of the case are properly located. 3. Tighten bottom two screws (2). 4. Raise the control panel and engage the lugs on the top of the control panel with the chassis. -
Page 33: Handover
▶ Show the customer how to safely isolate the boiler personnel! ▶ Advise the customer where they can find information on the Worcester, Bosch Group website. NOTICE: CO/CO ANALYSER ▶ Advise the customer that the varying external temperatures will affect ▶... -
Page 34: Checking The Gas Inlet Pressure
SERVICE AND SPARES CHECKING THE GAS INLET PRESSURE COMPONENT ACCESS To remove the outer case, to gain access to the components: NOTICE: 1. Remove the bottom panel. ▶ Ensure that the gas pressure is satisfactory with all 2. Release the two screws securing the control panel. other gas appliances working. -
Page 35: Fan Pressure Test
▶ Re-check the fan pressure readings. If the boiler, after completing the above checks, fails the fan pressure test then contact Worcester, Bosch Group for advice. ▶ After the measurements are taken switch the boiler off. ▶ Remove the combustion air intake pipe. -
Page 36: Flue Gas Analysis
SERVICE AND SPARES FLUE GAS ANALYSIS NOTICE: Combustion testing ▶ Combustion testing must be carried out by a competent person. Testing must not be attempted unless the person carrying out the combustion check is equipped with a Combustion Analyser conforming to BS 7927 and is competent in its use. -
Page 37: Cleaning The Heat Exchanger
SERVICE AND SPARES CLEANING THE HEAT EXCHANGER NOTICE: Gaskets and seals ▶ Replace the burner and electrode assembly gaskets and the Flueway sump seal after cleaning the heat exchanger. Do not attempt the cleaning procedure unless new gaskets and seals are available. There is an optional tool available to assist in cleaning the heat exchanger, part number 7 746 901 479... -
Page 38: Replacement Of Parts
SERVICE AND SPARES REPLACEMENT OF PARTS CAUTION: Mains supplies: ▶ Turn off the gas supply and isolate the mains supplies before starting any work on the boiler and observe all relevant safety precautions. CAUTION: Component replacement: ▶ Replace the burner housing gasket and the Flueway sump seal when re-assembling the heat exchanger. -
Page 39: Draining The Boiler
SERVICE AND SPARES Fig. 77 Control panel removal 1. Disconnect the discharge hose from the siphon. 2. Rotate the siphon body clockwise to release the bayonet connection. 3. Pull the siphon body down and away from the boiler. Fig. 78 Siphon removal ▶... -
Page 40: Maximum Safety Sensor
SERVICE AND SPARES 6.8.5 “MAXIMUM SAFETY SENSOR” 6.8.7 AUTO AIR VENT ▶ Disconnect the electrical connectors to the “Maximum safety sensor”. Ensure that the boiler has been fully drained. 1. Remove the spring clip completely. 1. Remove the screw securing the sensor. 2. -
Page 41: Fan Assembly
SERVICE AND SPARES 6.8.9 FAN ASSEMBLY REMOVE THE USED SEAL 4. Discard the “tubular” seal [2] or the “moulded” seal [3], depending on CAUTION: Component replacement: which type is fitted and replace with the seal that is provided. ▶ After replacement of a gas related component, where a gasket or seal has been disturbed or replaced, check for gas tightness using a gas sniffer/analyser. -
Page 42: Air/Gas Flap Valve Assembly
SERVICE AND SPARES COMBUSTION AIR INLET AND GAS PIPE DISCONNECTION 1. Rotate the combustion air inlet pipe anti-clockwise to release from the fan assembly and pull away from the fan. 2. Undo the top gas pipe connector at the gas valve. Fig. -
Page 43: Electrode Assembly
SERVICE AND SPARES 6.8.12 ELECTRODE ASSEMBLY 3. Pull the burner housing up and forward to remove. To remove the burner and gasket. CAUTION: Component replacement: 1. Lift the gasket (1) and burner mesh (2) from the heat exchanger body. ▶ After replacement of a gas related component, where ▶... -
Page 44: Heat Exchanger
SERVICE AND SPARES 6.8.14 HEAT EXCHANGER Before removal: ▶ Isolate the electrical power to the boiler. ▶ Drain the boiler. HEAT EXCHANGER DISCONNECTION 1. Undo the flow and return connections. 2. Pull both the flow and return pipes away from the heat exchanger. ▶... -
Page 45: Access To Boiler Control Components
Fig. 100 Removing the control panel Low voltage connectors 1. Release the screws securing the access cover. Diagnostic port (for Worcester Bosch service engineers only) 2. Lift the cover. Mains voltage and earth connectors 3. Pull the cover forward to remove. -
Page 46: Short Parts List
SERVICE AND SPARES SHORT PARTS LIST Gas Valve 7 746 009 09A 0 8 718 600 04A 0 Burner 8 718 600 23B 0 Flue overheat thermostat Electrodes (grommet type) (including gasket) 8 717 206 213 0 8 718 600 28A 0 Control panel 8 718 682 010 0 Spark generator Flow NTC... -
Page 47: Fault Finding And Diagnosis
(a) EARTH CONTINUITY, This fault finding information is for guidance only. (b) SHORT CIRCUIT CHECK, Worcester cannot be held responsible for costs incurred (c) POLARITY and by persons not deemed to be competent. (d) RESISTANCE TO EARTH. -
Page 48: Group 1 Fault Codes
FAULT FINDING AND DIAGNOSIS 7.1.1 GROUP 1 FAULT CODES Flash sequence Type of fault Fault Possible solutions/check Light OFF No fault No boiler demand - boiler is OK Light ON Heating demand on boiler- boiler is OK Group 1 Flashing codes Locking No ionisation detection after ignition Failure of four ignition attempts, the boiler waits 30... -
Page 49: Group 2 Fault Codes
FAULT FINDING AND DIAGNOSIS 7.1.2 GROUP 2 FAULT CODES Flash sequence Type of fault Fault Possible solutions/check Light OFF No boiler demand - boiler is OK Light ON Heating demand on boiler- boiler is OK Group 2 Flashing codes Locking Sensor test failed On power up all safety sensors are checked, the check failed. -
Page 50: Group 3 Fault Codes
Mains voltage interrupted after locking error Reset the boiler by turning the control knob anti- clockwise to the reset position. Locking Internal control board faults Call Worcester, Bosch Group technical help-line 0330 123 3366 Locking All other faults Miscellaneous Reset the boiler by turning the control knob anti- clockwise to the reset position. -
Page 51: Wiring Diagram
JUNCTION BOX EXTERNAL PUMP Neutral Live Switched Live MAINS SUPPLY Service Mode Fuse, slow Switch F 5A H 230 V 230V 230V TEMPERATURE Worcester 24V CONTROL AND controls point RESET DIAGNOSTIC INPUT 6720646610-19.3Wo Greenstar Ri Compact 6 720 646 610 (2013/12) -
Page 52: Boiler Function
FAULT FINDING AND DIAGNOSIS BOILER FUNCTION Fig. 108 Greenstar Ri Compact 6 720 646 610 (2013/12) -
Page 53: Protection Function
FAULT FINDING AND DIAGNOSIS PROTECTION FUNCTION AUTOMATIC INTERNAL FROST FUNCTION Internal boiler Internal boiler Pump switches off temperature Pump runs temperature after a 3 minute between rises above 9°C overrun period 8°C & 5°C Boiler automatic frost function (monitors internal boiler primary temperature) Internal boiler Central heating... - Page 56 0330 123 9119 TRAINING: 0330 123 0166 SALES: 0330 123 9669 Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0330 123 9559 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. worcester-bosch.co.uk Document No.6 720 646 610 (2013/12)