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Worcester GREENSTAR 24i junior Instruction Manual

Wall hung rsf gas fired condensing combination boiler, for sealed central heating systems and mains fed domestic hot water
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See also: Installation, Commissioning & Servicing Instructions , Instruction Manual
INSTRUCTION MANUAL
INSTALLATION, COMMISSIONING & SERVICING
WALL HUNG RSF GAS FIRED CONDENSING COMBINATION BOILER
GREENSTAR 24i
FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED

DOMESTIC HOT WATER

j j u u n n i i o o r r
/ 28i
THE APPLIANCE IS FOR USE WITH
NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13, C33 & C53)
NATURAL GAS:
LIQUID PETROLEUM GAS:
UK/IE
j j u u n n i i o o r r
24i junior GC NUMBER 47-311-86
28i junior GC NUMBER 47-311-87
24i junior GC NUMBER 47-311-90
28i junior GC NUMBER 47-311-91

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Summary of Contents for Worcester GREENSTAR 24i junior

  • Page 1: Domestic Hot Water

    INSTRUCTION MANUAL INSTALLATION, COMMISSIONING & SERVICING WALL HUNG RSF GAS FIRED CONDENSING COMBINATION BOILER GREENSTAR 24i j j u u n n i i o o r r / 28i j j u u n n i i o o r r FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER THE APPLIANCE IS FOR USE WITH...

  • Page 2: Servicing Instructions

    SENTINEL 0800 389 4670 www.sentinel-solutions.net FLUE TERMINAL GUARDS: TOWER FLUE COMPONENTS LTD. Vale Rise, Tonbridge TN9 1TB 01732 351555 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior INSTALLATION & 8 716 115 166b (03/2009) SERVICING INSTRUCTIONS...

  • Page 3: Table Of Contents

    L.P.G. CONVERSION FAULT FINDING & DIAGNOSIS FAULT FINDING CENTRAL HEATING FUNCTION PREHEAT AND DHW FUNCTION PROTECTION FUNCTION BENCHMARK CHECKLIST SERVICE INTERVAL RECORD SHEET INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior CONTENTS 8 716 115 166b (03/2009)

  • Page 4: Safety Precautions & Symbols

    INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior SAFETY PRECAUTIONS 8 716 115 166b (03/2009) & INSTALLATION REGULATIONS...

  • Page 5: General Information

    • Plate type DHW heat exchanger Syphon assembly.................... 1 Installation instructions.................. 1 Irish Guidelines Leaflet ................. 1 Warranty Return Envelope ................1 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior GENERAL INFORMATION 8 716 115 166b (03/2009)

  • Page 6: Technical Data

    Noise output level (Max central heating) dB(A) Total boiler weight 39.5 39.5 39.5 39.5 Lift weight 27.1 27.1 27.1 27.1 SEDBUK 90.1 90.1 91.8 91.8 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior TECHNICAL DATA 8 716 115 166b (03/2009)

  • Page 7: Layout & Components

    32 F LU E AI R P R ES S U R E SWITC H CONNECTION (BLANKED OFF ON THIS APPLIANCE) INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior LAYOUT & COMPONENTS 8 716 115 166b (03/2009)
  • Page 8 50 CH TEMPERATURE CONTROL 51 POSITION FOR OPTIONAL PROGRAMMER 52 SERVICE MODE BUTTON 53 BURNER ON INDICATOR LIGHT (GREEN) 54 MASTER SWITCH ON/OFF INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior LAYOUT & COMPONENTS 8 716 115 166b (03/2009)

  • Page 9: Cleaning Primary Systems

    • It may be necessary to use a power flushing machine to aid the cleansing procedure in some circumstances INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior CLEANING PRIMARY SYSTEMS 8 716 115 166b (03/2009)

  • Page 10: Mains Supply

    In such circumstances, the advice of the local water authority should be sought. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior MAINS SUPPLY 8 716 115 166b (03/2009)

  • Page 11: Water Systems & Pipework

    • Do not use galvanised pipes or radiators. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior WATER SYSTEMS & PIPEWORK 8 716 115 166b (03/2009)

  • Page 12: Condensate Pipework

    An air break must be installed in the 32/43 mm pipework, between the boiler condensate outlet and the drainpipe, outside the property, to avoid flooding during adverse weather conditions. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior CONDENSATE PIPEWORK 8 716 115 166b (03/2009)

  • Page 13: Pressure Relief Pipework

    (as shown) to help prevent freezing. L - Outside wall O,M - Drain pipe N - External drain INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior PRESSURE RELIEF PIPEWORK 8 716 115 166b (03/2009)

  • Page 14: Boiler Location & Clearances

    Minimum level area 122 cm free area 61 cm Minimum free Minimum level area 122 cm free area 61cm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior BOILER LOCATION & CLEARANCES 8 716 115 166b (03/2009)

  • Page 15: Boiler Location

    Additional RCD (Residual Current Device) pro- tection may be required. Refer to the latest IEE wiring regulations. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior BOILER LOCATION & CLEARANCES 8 716 115 166b (03/2009)

  • Page 16: Plumbing Manifold

    Further guidance on pipe routing can be found printed on the boiler template (supplied with the boiler). Mains Gas Mains Water Supply 22mm (DHW IN) 15mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior PLUMBING MANIFOLD 8 716 115 166b (03/2009)

  • Page 17: Flue Options

    Maximum total flue length 28 i jun. 2,400mm 11,000mm 100mmØ 125mmØ 24 i jun. 2,600mm 11,000mm 28 i jun. 2,600mm 11,000mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior FLUE OPTIONS 8 716 115 166b (03/2009)

  • Page 18: Flue Terminal Positions

    50 mm) around the flue and fixed to the wall with plated screws. See Contact Information (inside front cover). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior FLUE TERMINAL POSITIONS 8 716 115 166b (03/2009)
  • Page 19 FLUE TERMINAL POSITIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior FLUE TERMINAL POSITIONS 8 716 115 166b (03/2009)

  • Page 20: Installation

    2. Remove template (F) and wall mounting frame (E) from the packaging. 3. Remove boiler bottom panel (D) and installer pack (C). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior UNPACKING WALL FRAME AND 8 716 115 166b (03/2009) ANCILLARY ITEMS...

  • Page 21: Wall Mounting Template / Flue Opening

    This kit can be used in conjunction with the optional filling loop 7 716 192 281(not sup- plied with the boiler). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior WALL MOUNTING PLATE FLUE OPENING 8 716 115 166b (03/2009)

  • Page 22: Unpacking The Appliance

    6.2). Remove any packaging within the boiler and the packaging base (C). CAUTION: Caps fitted to pipes must be removed before hanging the boiler. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior UNPACKING THE APPLIANCE 8 716 115 166b (03/2009)

  • Page 23: Boiler Connections

    UP until the stop on the inside of the handle is over the shoulder of the metal bracket to secure in place. Stop in locked position INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior BOILER CONNECTIONS 8 716 115 166b (03/2009)
  • Page 24 15mm compression joint (J) using the compression nut and olive supplied in the hardware literature pack. 22mm 15mm 22mm 15mm 22mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior BOILER CONNECTIONS 8 716 115 166b (03/2009)

  • Page 25: Flue Installation

    After cutting, the end must be square and free from burrs to prevent damage to the 130mm flue seals. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior FLUE INSTALLATION 8 716 115 166b (03/2009)
  • Page 26 Do not attempt to force beyond the limit stops. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior FLUE INSTALLATION 8 716 115 166b (03/2009)
  • Page 27 • The flue is set at an angle of 3° or 52mm per 1m length. Flat at back This screw should be fitted last for rear exit INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior FLUE INSTALLATION 8 716 115 166b (03/2009)

  • Page 28: Condensate Connections

    Re-fit the drainage cap to bottom of the syphon. DRAINAGE CAP DISCHARGE HOSE WALL FRAME CONNECTOR INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior CONDENSATE CONNECTION 8 716 115 166b (03/2009)

  • Page 29: Electrics

    5 Optional external frost stat connection (ST6): Connect froststat cables to terminals (FS) and (FR). These are not polarity sensitive. 6 Refit panels. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior ELECTRICS 8 716 115 166b (03/2009)

  • Page 30: Position Of Wired Components

    POSITION OF WIRED COMPONENTS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior POSITION OF WIRED COMPONENTS 8 716 115 166b (03/2009)

  • Page 31: Pre-Commissioning Checks

    22mm 15mm 22mm 15mm 22mm Preplumbing manifold connector Condensate pipe INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior PRE-COMMISSIONING CHECKS 8 716 115 166b (03/2009)

  • Page 32: Filling The System

    This kit can be used in conjunction with the optional filling loop 7 716 192 281(not sup- plied with the boiler). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior FILLING THE SYSTEM 8 716 115 166b (03/2009)

  • Page 33: Starting The Appliance

    To reset press and hold the reset button (E) for 2 seconds. The boiler will be reset. CAUTION: DO NOT PRESS POWER INDICATOR (B) TO RESET BOILER. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior STARTING THE APPLIANCE 8 716 115 166b (03/2009)

  • Page 34: Water Treatment

    The addition of sealing agents to the system water is not recommended as this can cause problems with deposits left in the heat exchanger. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior WATER TREATMENT 8 716 115 166b (03/2009)

  • Page 35: Commissioning

    When the ECO button is illuminated the boiler will be in Economy mode with pre-heat no longer active. Inlet Test Nipple INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior COMMISSIONING 8 716 115 166b (03/2009)

  • Page 36: Finishing Commissioning

    If the appliance is unused and exposed to freezing conditions, shut off all the mains supplies and drain the system and boiler. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior FINISHING COMMISSIONING 8 716 115 166b (03/2009)

  • Page 37: Inspection And Service

    Commissioning. Operate the appliance and take note of any irregularities. Refer to Fault Finding for rectification procedures. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior INSPECTION AND SERVICE 8 716 115 166b (03/2009)
  • Page 38 2.1 Remove screw (C) securing control. 2.2 Gently pull the control forward until it is fully lowered into the service position. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior INSPECTION AND SERVICE 8 716 115 166b (03/2009)
  • Page 39 28i junior - 3.9 mbar 28i junior - 4.6mbar • Pressures measured below these figures will indicate that the heat exchanger will require cleaning. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior INSPECTION AND SERVICE 8 716 115 166b (03/2009)
  • Page 40 Catch the debris and condensate from the syphon into a suitable container. Re-fit the drainage cap (E) to bottom of the syphon. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior INSPECTION AND SERVICE 8 716 115 166b (03/2009)
  • Page 41 (K). Remove clamping plate (L). Remove spark/flame electrode assembly from boiler. Remove seal from the top of the heat exchanger. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior INSPECTION AND SERVICE 8 716 115 166b (03/2009)
  • Page 42 BETWEEN THE AIR/GAS MANIFOLD AN D TH E H EAT E XCHANG E R I S DISTURBED THE SEALING GASKET MUST BE REPLACED. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior INSPECTION AND SERVICE 8 716 115 166b (03/2009)

  • Page 43: Replacement Of Parts

    Undo the flue connection from the sump and push the flue tube up. Push the flue limit thermostat outwards from the sump. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166b (03/2009)
  • Page 44 Replace valve with new seals and check for gas soundness. Note: The valve will require setting; follow procedure “Setting the air/gas ratio” . INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166b (03/2009)
  • Page 45 Remove 5 screws (C) retaining the rear panel of the control and remove panel. Spare Fuse order T1.6L 250V F2 T2.5H 250V F1 T500L 250V F3 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166b (03/2009)
  • Page 46 IS RE-FITTED TO THE NEW CONTROL. IF THIS IS NOT DONE THE BOILER WILL INDICATE ERROR AND WILL NOT FUNCTION. 10.3 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166b (03/2009)
  • Page 47 Lift up assembly and remove from boiler. NOTE: After re-assembly, check the CO/CO levels as described in the setting of the air/gas ratio section. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166b (03/2009)
  • Page 48 IMPORTANT: IF THE JOINT BETWEEN THE AIR/GAS MANIFOLD AND THE HEAT EXCHANGER IS DISTURBED THE SEALING GASKET MUST BE REPLACED. 15.4 15.2 15.3 15.1 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166b (03/2009)
  • Page 49 19.1 Withdraw the spring clip. 19.2 Withdraw the sensor (D) from the housing. To refit, follow the above in reverse. 19.2 19.1 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166b (03/2009)
  • Page 50 23.2 Withdraw the drain tap from its housing To refit, follow the above in reverse. Ensure any seals that have been disturbed are renewed. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166b (03/2009)
  • Page 51 25.2 Withdraw the pressure release valve (A) from its housing. To refit, follow the above in reverse. Ensure any seals that have been disturbed are renewed. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166b (03/2009)
  • Page 52 27.2 Remove the heat exchanger To refit, follow the above in reverse. Ensure any seals that have been disturbed are renewed. 27.2 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166b (03/2009)
  • Page 53 Gently raise the boiler off the mounting frame. Replace expansion vessel and refit the boiler to the mounting frame. Follow the commissioning procedure in this manual. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166b (03/2009)
  • Page 54 Remove manometer and re-seal inlet pressure point on gas valve. Re-assemble and refit boiler case. ‘C’ INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166b (03/2009)

  • Page 55: Setting The Air/Gas Ratio

    Remove manometer and re-seal inlet pressure point on gas valve. Re-assemble and refit boiler case. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166b (03/2009)

  • Page 56: Short Parts List

    GC No. E27 305 Fuse 0.5 Amp F3 WORCESTER Part No. 1 904 522 730 0 GC No. E27 300 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166b (03/2009)

  • Page 57: L. P. G. Conversion

    S ET TI N G TH E AI R / GAS R ATI O 28kW NG SECTION OF THIS MANUAL. 28kW LPG INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior LPG CONVERSION 8 716 115 166b (03/2009)

  • Page 58: Fault Finding & Diagnosis

    FAULT FINDING NOTE : This fault finding information is for guidance only. Worcester cannot be held responsible for costs incurred by persons not deemed to be competent. The electronic control system for this boiler incorporates a blue central indicator. This normally confirms the permanent mains supply but, by flashing at different rates during a fault, provides a guide to the cause as listed.

  • Page 59: Central Heating Function

    CENTRAL HEATING FUNCTION INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior CENTRAL HEATING FUNCTION 8 716 115 166b (03/2009)

  • Page 60: Preheat And Dhw Function

    PREHEAT AND DHW FUNCTION INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior PREHEAT AND DHW FUNCTION 8 716 115 166b (03/2009)

  • Page 61: Protection Function

    PROTECTION FUNCTION Boiler temperature Run autofroststat below 8°C function Pump run 5 seconds Pump antiseize every 24hrs INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior PROTECTION FUNCTION 8 716 115 166b (03/2009)
  • Page 64 5. Is the incoming gas pressure at least 18mbar with the boiler at maximum output? Dedicated to heating comfort Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 01905 754624 Fax. 01905 754619 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. www.worcester-bosch.co.uk 8 716 115 166b (03/2009)

This manual is also suitable for:

Greenstar 28i junior

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