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INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS
WALL HUNG RSF GAS FIRED CONDENSING COMBINATION BOILER
GREENSTAR 24/28/30
FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER
The appliance is for use with Natural Gas
(Cat I 2H type C
, C
& C
)
13
33
53
Model
Natural Gas
24 kW
28 kW
30 kW
GC Number
47-406-54
47-406-56
47-406-64
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Table of Contents
Related Manuals for Worcester GREENSTAR 24
Summary of Contents for Worcester GREENSTAR 24
- Page 1 INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS WALL HUNG RSF GAS FIRED CONDENSING COMBINATION BOILER GREENSTAR 24/28/30 FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER The appliance is for use with Natural Gas (Cat I 2H type C & C...
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Page 2: Table Of Contents
Contents CONTENTS Pre-commissioning checks ..... . . 28 Key to symbols and safety instructions ....3 Filling the system . -
Page 3: Key To Symbols And Safety Instructions
12.4.2 DHW temperature sensor ..... . . 49 If you are in any doubt, contact the Worcester Technical helpline 12.5 Code plug . -
Page 4: Safety Precautions
Key to symbols and safety instructions SAFETY PRECAUTIONS IMPORTANT The service engineer must complete the Service Record on the IF YOU SMELL GAS: Benchmark Checklist after each service. A gas leak could potentially cause an explosion. If you smell gas, observe the following rules. INSTALLATION REGULATIONS Current Gas Safety (Installation &... -
Page 5: Appliance Information
Artificially softened water must not be used to fill the central heating system. • Pump anti-seize protection • Compatible with all Worcester standard and intelligent controls • Mains electrical cable pre-wired to control board APPLIANCE INFORMATION • Built-in fault-finding diagnostics •... -
Page 6: Technical Data
Appliance information TECHNICAL DATA Greenstar 24, 28, and 30 UNIT Domestic Hot Water Minimum heat input Maximum rated heat output 29.6 Maximum rated heat input (net) 24.6 Maximum mains inlet pressure (standing pressure) Minimum mains inlet pressure (working) for max. flow Minimum mains inlet pressure (working) for operation Domestic hot water temp. -
Page 7: Appliance Layout
Appliance information APPLIANCE LAYOUT 6 720 811 922-01.1O Fig. 2 Main boiler components Control panel [22] Inlet pressure test point ON/OFF button [23] CH flow Burner ON indicator light (green) [24] Flow temperature sensor (NTC) Service button [25] Air pressure switch (30 kW only) Performance test button [26] Expansion vessel CH temperature control... -
Page 8: Pre-Installation
CAUTION: ▶ In cases where all attempts to find a micro leak have ▶ ISOLATE THE MAINS SUPPLIES BEFORE STARTING failed, Worcester, Bosch Group supports the use of ANY WORK AND OBSERVE ALL RELEVANT SAFETY Fernox F4 leak sealer. PRECAUTIONS. -
Page 9: Water Systems And Pipe Work
Pre-Installation SHOWERS/BIDETS: NOTICE: Non return, back flow prevention devices • If a shower head can be immersed in water or comes closer than (including those associated with water meters) fitted to 25mm from the top edge of a bath or shower tray spill over level then the mains water supply can cause a pressure build up an anti-syphon device must be fitted to the shower hose. -
Page 10: Condensate Pipe Work
Pre-Installation 3.4.1 INTERNAL CONNECTIONS In order to minimise risk of freezing during prolonged cold spells, the following methods of installing condensate drainage pipe should be adopted, in order of priority. Wherever possible, the condensate drainage pipe should be routed and terminated so that the condensate drains away from the boiler under gravity to a suitable internal foul water discharge point such as an internal soil and vent stack. -
Page 11: External Connections
Pre-Installation 75mm min. 22mm Ø 6720644744-08.2Wo Fig. 10 Disposal into a rainwater down pipe Fig. 9 Condensate pump disposal 3.4.2 EXTERNAL CONNECTIONS Condensate drainage pipe can be run above or below ground. NOTICE: Freezing conditions ▶ Pipe work length should be kept to a minimum and the route as vertical as possible. -
Page 12: Pressure Relief Pipe Work
Pre-Installation In situations where there are likely to be extremes of temperature or • The pressure relief drain pipe (1) should be finished with a partial exposure, the use of a proprietary trace-heating system for external pipe bend, near the outlet to face the external wall (as shown) to help work, incorporating an external frost thermostat, should be considered. -
Page 13: Boiler Location And Clearances
Pre-Installation BOILER LOCATION AND CLEARANCES 3.6.3 COMPARTMENTS Follow the requirements of BS6798 and BS5440 Part 2 and note: 3.6.1 INSTALLATION • Minimum clearances must be maintained. This boiler is only suitable for installing internally within a property at a • An access door is required to install, service and maintain the boiler suitable location onto a fixed, rigid surface at least the same size as the and any ancillary equipment. - Page 14 Part number 7 716 191 086. Refer to the manual supplied with the Plume Management kits for complete installation instructions Maximum total flue Greenstar 24/28/30 boilers length L (mm) FLUE TYPE 60/100 80/125 Telescopic horizontal flue assembly...
- Page 15 Pre-Installation 350 mm - 570 mm 130 mm Min 500 mm 300 mm Flat roof 6720643895-12.1Wo Fig. 17 6 720 811 922 (2014/07)
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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. 18 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. 19 Plume terminal positions The minimum plume management length for any length of flue is 500mm and the maximum length is 4.5 metres for the appliances detailed on the front of this manual. -
Page 18: Installation
Installation 2. Lift out the two accessory trays. INSTALLATION WARNING: All the previous “Pre- Installation” sections must be read and the requirements met before starting boiler or flue installation. DANGER: Risk of explosion ▶ Isolate the gas supply before working on gas related components. -
Page 19: Wall Mounting Template & Flue Opening
Installation WALL MOUNTING TEMPLATE & FLUE OPENING WARNING: BEFORE DRILLING ENSURE THAT THERE ARE NO PIPES, ELECTRICAL CABLES, DAMP PROOF COURSES OR OTHER HAZARDS. NOTICE: Never carry the appliance by the control box or rest the full weight of the appliance on it. SAFETY: All relevant safety precautions must be undertaken. -
Page 20: Pre-Plumbing The Boiler Connections
Installation Fig. 24 Isolation valves CH flow 22mm DHW Outlet (15mm) Gas inlet (22mm bonded washer) Domestic cold water inlet (15mm) CH return 22mm ▶ All pipe connections in the heating system must be suitable for a pressure of 3 bar and for 10 bar in a hot water DHW circuit. ▶... -
Page 21: Flue Installation
Installation Fig. 27 PRV Connection CONNECTING THE CONDENSATE TRAP ▶ Remove red blanking cap on condensate drain. ▶ Remove the grey condensate hose from the combustion chamber during unpacking. 6 720 614 156-03.1O ▶ Fit the grey condensate hose onto the condensate trap and route the Fig. -
Page 22: Measuring The Flue (Standard Flue)
Installation 4.5.1 MEASURING THE FLUE (STANDARD FLUE): ▶ Measure from the outside of the wall to the centre line of the flue 265 mm turret to determine length L. ▶ Subtract 50mm from the length L to give the correct dimension to the flue elbow connection. -
Page 23: Flue Terminal Plume Re-Direction
Installation 52mm 104mm 6720644842-10.1Wo Fig. 35 Slope for condensate disposal 4.5.4 FLUE TERMINAL PLUME RE-DIRECTION: The flue discharge can be re-directed allowing some plume redirection control, alternatively, a complete plume management system can be fitted to the flue terminal. RE-DIRECTING THE FLUE DISCHARGE Fig. -
Page 24: Electrical
Electrical ELECTRICAL GENERAL CAUTION: Risk of electric shock ▶ Isolate the mains electrical supply before starting any work and observe all relevant safety precautions. The boiler is pre-fitted with a mains supply cable. Route the cable through one of the holes adjacent to the flow and return valves on the isolating valve bracket, leaving some slack for movement of control panel. -
Page 25: Mounting Optional Plug-In Controls
Zone Valve 5.3.1 MOUNTING OPTIONAL PLUG-IN CONTROLS Worcester provides a range of optional plug-in controls with fitting instructions supplied with the accessories. CONNECTING A 230 VOLT ON/OFF CONTROLLER The controller must be suitable for mains voltage (from boiler) and must not have its own earth connection. -
Page 26: Existing Installations
PROGRAMMABLE THERMOSTAT The programmable thermostat may be a hard wired or RF type.This diagram is applicable for the hard wired unit and the receiver section of the RF pack. Plug in Worcester timer. (see timer operating Programmable 230V instructions for... -
Page 27: Electrical Wiring Diagram
Electrical ELECTRICAL WIRING DIAGRAM 19 20 PR PO NP LP Ls Ns 9V/25 V AC 230 V AC 230V 6 720 812 922-02.1O Fig. 46 Ignition transformer [16] Air pressure switch (30 kW only) Flow temperature control [17] Flue gas temperature limiter Terminal strip, 230 V AC [18] Temperature sensor, CH flow Fuse, 2.5 A slow (230 V AC) -
Page 28: Commissioning
Commissioning WATER TREATMENT COMMISSIONING NOTICE: Artificially softened water must not be used to PRE-COMMISSIONING CHECKS fill the central heating system. CAUTION: Isolate the mains electricity supply before starting any work and observe all relevant safety ENSURE THAT THE SYSTEM HAS BEEN CLEANED. precautions. -
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. Fig. 47 Performance test button NOTICE: RESET Service button ▶ Do not press the blue Mains ON/OFF indicator [15] Burner ON/OFF indicator light (green) to reset the boiler. -
Page 30: Switching The Appliance On/Off
Commissioning SWITCHING THE APPLIANCE ON/OFF Position CH flow temperature SWITCHING ON Approx. 35 °C ▶ Switch appliance on at the ON/OFF switch. Approx. 43 °C The display indicates the current heating water flow temperature. Approx. 50 °C The indicator for burner operation/faults is permanently on, as long Approx. -
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 >... -
Page 32: Setting The Dhw Temperature
Commissioning ▶ Record the settings in the Benchmark Commissioning checklist at the DHW thermostat DHW temperature back of this manual. Approx. 40 °C FITTING THE FASCIA FLAP Approx. 50 °C ▶ Check the orientation of dampers [1] ( Fig. 52). Approx. -
Page 33: Button Lock
Setting the control panel ▶ Leave appliance switched on, set CH flow temperature control position 1 at least. reset 6 720 615 065-14.1O Fig. 55 Frost protection ▶ Add a suitable inhibitor with anti-freeze to the central heating system water ( page 8) and drain the DHW system. 6 720 615 065-19.1O Additional instructions are contained in the operating instructions for Fig. -
Page 34: Service Functions Overview
Setting the control panel SERVICE FUNCTIONS OVERVIEW 7.2.2 SERVICE LEVEL 2: ACCESSED FROM SERVICE LEVEL 1; 7.2.1 SERVICE LEVEL 1 SERVICE KEY ILLUMINATES (PRESS SERVICE KEY UNTIL ILLUMINATED) (PRESS ECO KEY AND KEY LOCK SIMULTANEOUSLY UNTIL A CODE SUCH AS 8.A APPEARS) Display Service function Page... -
Page 35: Description Of Service Functions
Setting the control panel DESCRIPTION OF SERVICE FUNCTIONS The venting function can be activated after maintenance. 7.3.1 SERVICE LEVEL 1 SERVICE FUNCTION 1.A: HEATING OUTPUT The heating output in percent can be limited between the minimum and The following settings are possible: maximum rated output to suit the specific heat demand. - Page 36 Setting the control panel SERVICE FUNCTION 3.C: SWITCHING DIFFERENTIAL SERVICE FUNCTION 5.A: RESET INSPECTION Only if automatic cycle block (service function 3.A) has been switched This service function enables you to reset on the display after off will this service function be active. completing inspection/maintenance of the appliance.
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Page 37: Service Level 2
Setting the control panel • 00: Central heating disabled, DHW disabled. ▶ Hold down the service key until it illuminates. The display shows a code such as 1.A • 01: Central heating disabled, DHW enabled. ▶ Hold down eco key and key lock simultaneously until the displays a •... -
Page 38: Service
Service SERVICE FUNCTION B.F: START DELAY Meter Gas Control Natural Gas This service function allows you to set the time in seconds before the valve appliance starts DHW heating. Set the start delay in accordance with system conditions. If a start delay is set, the demand signal is no longer possible ... -
Page 39: Measuring Co Content Of Flue Gas
Service ▶ Insert a flue gas probe approx. 135 mm into the test port socket (1) With a type C or C flue system, the gas and seal the port. tightness of the flue system can be tested by ▶ Hold down the Central Heating boost button until it illuminates. -
Page 40: Fan Pressure Test
If the boiler, after completing the above checks, fails the fan pressure All safety, modulation and control components are monitored by the test then contact Worcester, Bosch Group for advice. Control unit. ▶ After the measurements are taken switch the boiler off. -
Page 41: Description Of Various Maintenance Operations
Inspection/Maintenance – Electronic flue gas emission meter for CO , CO and flue gas temperature – Pressure gauge for 0 - 30 bar (resolution at least 0.1 bar) • Special tools are not required ▶ Use 8 719 918 658 0 as heat conducting paste. ▶... - Page 42 Inspection/Maintenance ▶ Remove the top baffle. ▶ Remove the bottom baffle using the extractor. ▶ Clean both baffles as required. 6 720 611 626-82.1R Fig. 69 WARNING: Risk of burning. The heat exchanger baffles can still be very hot even after the appliance has not been used for some time.
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Page 43: 10.1.3 Filter In Cold Water Pipe
Inspection/Maintenance Clean the heat exchanger with the brush as follows: 10.1.3 FILTER IN COLD WATER PIPE 1. Move the brush up and down as far as possible ▶ Undo cold water pipe and check filter for debris. 2. Rotate the brush in both directions 1. -
Page 44: 10.1.5 Gas Valve
Inspection/Maintenance 10.1.5 GAS VALVE 10.1.7 REPLACING THE DIVERTER VALVE MOTOR 1. Remove the two screws securing the motor to the diverter valve NOTICE: Aluminium washers: body. ▶ Always re-assemble with a new aluminium washers, 2. Rock the motor in the direction of the arrow to disengage the motor do not re-use the old washers. -
Page 45: 10.1.9 Cleaning Condensate Trap
Inspection/Maintenance 10.1.9 CLEANING CONDENSATE TRAP 10.1.12 CHANGING THE EXPANSION VESSEL ▶ Undo screw and remove condensate trap. If there is 400 millimetres or more space above the boiler and the flue exits to the right or left, the expansion vessel can be removed without ▶... -
Page 46: 14Checking Wiring
Inspection/Maintenance Pressure gauge reading High limit stat 8 707 206 196 0 PRV 8 716 010 793 0 1 bar Minimum system pressure (when cold) 1 - 2 bar Optimum system pressure 3 bar Maximum system pressure at maximum central heating system temperature: must not be exceeded (safety valve opens). -
Page 47: Displays
Displays Flue sample plug Flue sample plug - air intake - vertical adapter 8 710 506 199 0 8 716 111 253 0 Flue sample plug - gas outlet Air pressure switch 8 716 111 252 0 8 716 106 633 0 Air pressure switch bracket Hose 8 716 010 113 0... -
Page 48: Fault Finding
Fault finding Special Special display Description display Description The display shows the flow temperature alternating with The display shows the flow temperature alternating with : the set inspection interval has elapsed, service . The appliance operates for 15 minutes at the minimum rated output. -
Page 49: Faults That Are Not Displayed
Fault finding 12.3 FAULTS THAT ARE NOT DISPLAYED Appliance faults Remedy Excessive combustion noise; rumbling noises ▶ Insert coding plug correctly. Replace if required. ▶ Check gas type. ▶ Check gas supply pressure. Adjust if required. ▶ Check flue system. Clean or repair if required. ▶... - Page 50 NOTES 6 720 811 922 (2014/07)
- Page 51 NOTES 6 720 811 922 (2014/07)
- Page 52 NOTES 6 720 811 922 (2014/07)
- Page 53 NOTES 6 720 811 922 (2014/07)
- Page 54 GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. CONTROLS Optimum start control Fitted...
- Page 55 SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider SERVICE 01 SERVICE 02 ² % ² % ² % ² % SERVICE 03 SERVICE 04 ² % ²...
- 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 6 720 811 922 (2014/07)