Worcester GREENSTAR 25Si Instruction Manual
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Worcester GREENSTAR 25Si Instruction Manual

Wall hung rsf gas fired condensing combination boiler
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See also: Installation, Commissioning & Servicing Instructions , Instructions for Installation and Servicing
INSTRUCTION MANUAL
INSTALLATION, COMMISSIONING & SERVICING
WALL HUNG RSF GAS FIRED CONDENSING COMBINATION BOILER
GREENSTAR 25Si/30Si
FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED

DOMESTIC HOT WATER

THE APPLIANCE IS FOR USE WITH
NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13, C33 & C53)
NATURAL GAS: 25Si GC NUMBER 47-311-84
LIQUID PETROLEUM GAS: 25Si GC NUMBER 47-311-88
UK/IE
30Si GC NUMBER 47-311-85
30Si GC NUMBER 47-311-89

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Summary of Contents for Worcester GREENSTAR 25Si

  • Page 1: Domestic Hot Water

    INSTRUCTION MANUAL INSTALLATION, COMMISSIONING & SERVICING WALL HUNG RSF GAS FIRED CONDENSING COMBINATION BOILER GREENSTAR 25Si/30Si FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER THE APPLIANCE IS FOR USE WITH NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13, C33 & C53)
  • Page 2 the nation’s favourite PLUMBING & HEATING SUPPLIES FREE SHIPPING SECURE PAYMENTS on all orders over £100 to mainland UK shop online with confidence FINANCE AVAILABLE PRICE MATCH spread the cost with low interest rates always get the best deals available we have H U G E R E D U C T I O N S...

  • Page 3: Important Information And Symbols Used In This Manual

    THIS APPLIANCE MUST BE INSTALLED BY A CORGI REGISTERED, COMPETENT PERSON. FAILURE TO INSTALL CORRECTLY COULD LEAD TO PROSECUTION. Hot water storage cylinder IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER TECHNICAL HELPLINE. DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER. Cold water main supply...

  • Page 4: Table Of Contents

    SHORT PARTS LIST CONVERSION KITS L.P.G. CONVERSION FAULT FINDING & DIAGNOSIS FAULT FINDING CENTRAL HEATING FUNCTION PREHEAT AND DHW FUNCTION PROTECTION FUNCTION BENCHMARK CHECKLIST SERVICE RECORD INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si CONTENTS 8 716 115 165a (06/2008)

  • Page 5: Safety Precautions

    EN:12828 : Central heating for domestic premises BS5440:1 : Flues and ventilation for gas appli- A Benchmark Checklist is provided by Worcester, Bosch Group, at the back of this manual, ances of rated heating not exceeding 70kW (net) : for the installer to complete. The checklist will include their CORGI registration number to...

  • Page 6: General Information

    Syphon assembly..................1 • DHW flow sensor & temperature control Installation instructions................1 • Plate type DHW heat exchanger Irish Guidelines Leaflet .................. 1 Warranty Return Envelope ................1 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si GENERAL INFORMATION 8 716 115 165a (06/2008)

  • Page 7: Technical Data

    Packaged boiler weight 44.4 44.4 44.4 44.4 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 25Si/30Si TECHNICAL DATA 8 716 115 165a (06/2008)

  • Page 8: Layout & Components

    31 FAN PRESSURE TEST POINT 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 25Si/30Si LAYOUT & COMPONENTS 8 716 115 165a (06/2008)
  • Page 9 DIAGNOSTIC LIGHT (BLUE) 51 CH TEMPERATURE CONTROL 52 POSITION FOR OPTIONAL PROGRAMMER 53 SERVICE MODE BUTTON 54 BURNER ON INDICATOR LIGHT (GREEN) 55 MASTER SWITCH ON/OFF INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si LAYOUT & COMPONENTS 8 716 115 165a (06/2008)

  • Page 10: 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 25Si/30Si CLEANING PRIMARY SYSTEMS 8 716 115 165a (06/2008)

  • Page 11: Mains Supply

    200ppm, consideration may need to be given to the fitting of a scale prevention device. In such circumstances, the advice of the local water authority should be sought. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si MAINS SUPPLY 8 716 115 165a (06/2008)

  • Page 12: Water Systems & Pipework

    • Pressurise the extra expansion vessel (B) to the same figure as the expansion vessel built into the appliance. • Do not use galvanised pipes or radiators. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si WATER SYSTEMS & PIPEWORK 8 716 115 165a (06/2008)

  • Page 13: 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 25Si/30Si CONDENSATE PIPEWORK 8 716 115 165a (06/2008)

  • Page 14: 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 25Si/30Si PRESSURE RELIEF PIPEWORK 8 716 115 165a (06/2008)

  • Page 15: Boiler Location & Clearances

    If front clearance (to Then overall height clearances removable door) is must be increased to (approx): increased to: reduced to: 50mm 511mm 505mm 25mm 596mm 569mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si BOILER LOCATION & CLEARANCES 8 716 115 165a (06/2008)

  • Page 16: 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 25Si/30Si BOILER LOCATION & CLEARANCES 8 716 115 165a (06/2008)

  • Page 17: 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 25Si/30Si PLUMBING MANIFOLD 8 716 115 165a (06/2008)

  • Page 18: Flue Options

    Maximum total flue length 100mmØ 125mmØ 25 Si 2,400mm 11,000mm Maximum total flue length 30 Si 2,400mm 11,000mm 100mmØ 125mmØ 25 Si 2,600mm 11,000mm 30 Si 2,600mm 11,000mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si FLUE OPTIONS 8 716 115 165a (06/2008)

  • Page 19: Flue Terminal Positions

    The guard must be spaced equally (mini- mum 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 25Si/30Si FLUE TERMINAL POSITIONS 8 716 115 165a (06/2008)

  • Page 20: Flue Terminal Positions

    FLUE TERMINAL POSITIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si FLUE TERMINAL POSITIONS 8 716 115 165a (06/2008)

  • Page 21: Installation

    2. Remove template (F) and wall mounting frame (E) from the packaging. 3. Remove boiler bottom panel (D), front fascia (H) and installer pack (C). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si UNPACKING WALL FRAME AND ANCILLARY ITEMS 8 716 115 165a (06/2008)

  • Page 22: 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). WALL MOUNTING PLATE FLUE OPENING INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si 8 716 115 165a (06/2008)

  • Page 23: 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 25Si/30Si UNPACKING THE APPLIANCE 8 716 115 165a (06/2008)

  • Page 24: 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 25Si/30Si BOILER CONNECTIONS 8 716 115 165a (06/2008)
  • Page 25 8. Connect the pressure relief drain pipe to 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 25Si/30Si BOILER CONNECTIONS 8 716 115 165a (06/2008)

  • Page 26: Flue Installation

    The aluminium tape is not required when reducing the terminal. 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 25Si/30Si FLUE INSTALLATION 8 716 115 165a (06/2008)
  • Page 27 Do not attempt to force beyond the limit stops. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si FLUE INSTALLATION 8 716 115 165a (06/2008)
  • Page 28 • 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 25Si/30Si FLUE INSTALLATION 8 716 115 165a (06/2008)

  • Page 29: Condensate Connection

    Empty the debris and condensate from the syphon into a suitable container. Re-fit the drainage cap to bottom of the syphon. DRAINAGE CAP DISCHARGE HOSE WALL FRAME CONNECTOR INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si CONDENSATE CONNECTION 8 716 115 165a (06/2008)

  • Page 30: Electrics

    NOTE: Some devices do not require this. 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 25Si/30Si ELECTRICS 8 716 115 165a (06/2008)

  • Page 31: Position Of Wired Components

    POSITION OF WIRED COMPONENTS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si POSITION OF WIRED COMPONENTS 8 716 115 165a (06/2008)

  • Page 32: Pre-Commissioning Checks

    22mm 15mm 22mm 15mm 22mm Pre-plumbing manifold connector Condensate pipe INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si PRE-COMMISSIONING CHECKS 8 716 115 165a (06/2008)

  • Page 33: 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 25Si/30Si FILLING THE SYSTEM 8 716 115 165a (06/2008)

  • Page 34: 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 25Si/30Si STARTING THE APPLIANCE 8 716 115 165a (06/2008)

  • Page 35: 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 25Si/30Si WATER TREATMENT 8 716 115 165a (06/2008)

  • Page 36: Commissioning

    When the ECO button is illuminated the boiler will be in Economy mode with pre-heat no Inlet Test Nipple longer active. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si COMMISSIONING 8 716 115 165a (06/2008)

  • Page 37: 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 25Si/30Si FINISHING COMMISSIONING 8 716 115 165a (06/2008)

  • Page 38: Inspection And Service

    Refill and re-pressurise if applicable as described in Commissioning. Operate the appliance and take note of any irregularities. Refer to Fault Finding for rectification procedures. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si INSPECTION AND SERVICE 8 716 115 165a (06/2008)
  • Page 39 2. Lowering boiler control to the service position 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 25Si/30Si INSPECTION AND SERVICE 8 716 115 165a (06/2008)
  • Page 40 25Si - 3.7 mbar 30Si - 4.5 mbar 30Si - 5.2 mbar • Pressures measured below these figures will indicate that the heat exchanger will require cleaning. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si INSPECTION AND SERVICE 8 716 115 165a (06/2008)
  • Page 41 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 25Si/30Si INSPECTION AND SERVICE 8 716 115 165a (06/2008)
  • Page 42 Disconnect spark electrode and flame sensor connections (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 25Si/30Si INSPECTION AND SERVICE 8 716 115 165a (06/2008)
  • Page 43 JOI NT 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 25Si/30Si INSPECTION AND SERVICE 8 716 115 165a (06/2008)

  • Page 44: Replacement Of Parts

    Remove electrical connections. 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 25Si/30Si REPLACEMENT OF PARTS 8 716 115 165a (06/2008)
  • Page 45 Disconnect electrical connections. 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 25Si/30Si REPLACEMENT OF PARTS 8 716 115 165a (06/2008)
  • Page 46 Remove 4 screws (D) 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 25Si/30Si REPLACEMENT OF PARTS 8 716 115 165a (06/2008)
  • Page 47 IMPORTANT: ENSURE CODE PLUG IS RE-FITTED TO THE NEW CONTROL. IF THIS IS NOT DONE THE BOILER WILL INDICATE ERROR AND WILL NOT FUNCTION. 12.3 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si REPLACEMENT OF PARTS 8 716 115 165a (06/2008)
  • Page 48 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 25Si/30Si REPLACEMENT OF PARTS 8 716 115 165a (06/2008)
  • Page 49 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 25Si/30Si REPLACEMENT OF PARTS 8 716 115 165a (06/2008)

  • Page 50: Diverter Valve Motor

    19.1 Withdraw the spring clip. 19.2 Withdraw the sensor (F) from the housing. To refit, follow the above in reverse. 19.1 19.2 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si REPLACEMENT OF PARTS 8 716 115 165a (06/2008)

  • Page 51: Pressure Gauge

    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 25Si/30Si REPLACEMENT OF PARTS 8 716 115 165a (06/2008)

  • Page 52: Ch Pressure Relief Valve

    25.2 Withdraw the pressure release valve (C) 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 25Si/30Si REPLACEMENT OF PARTS 8 716 115 165a (06/2008)

  • Page 53: Dhw Heat Exchanger

    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 25Si/30Si REPLACEMENT OF PARTS 8 716 115 165a (06/2008)

  • Page 54: Expansion Vessel

    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 25Si/30Si REPLACEMENT OF PARTS 8 716 115 165a (06/2008)

  • Page 55: Setting The Air/Gas Ratio

    Remove manometer and re-seal inlet pressure point on gas valve. Re-assemble and refit boiler case. ‘C’ INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si REPLACEMENT OF PARTS 8 716 115 165a (06/2008)
  • Page 56 Remove manometer and re-seal inlet pressure point on gas valve. Re-assemble and refit boiler case. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si REPLACEMENT OF PARTS 8 716 115 165a (06/2008)

  • Page 57: Short Parts List

    1 904 522 740 0 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 25Si/30Si REPLACEMENT OF PARTS 8 716 115 165a (06/2008)

  • Page 58: L. P. G. Conversion

    P R O C E D U R E C AN B E F O U N D I N 25kW LPG S ET TI N G TH E AI R / GAS R ATI O 30kW NG SECTION OF THIS MANUAL. 30kW LPG LPG CONVERSION INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si 8 716 115 165a (06/2008)

  • Page 59: 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 60: Central Heating Function

    Over temperature shut- Gas valve OFF. down if water tempera- 3 minute wait Fan overrun ture is 5°C above set 30 seconds value. Room thermostat and/or mains programmer ON Fan (& gas) (or link fitted at modulation GREEN 10 second END OF ST10) Fan to...

  • Page 61: Preheat And Dhw Function

    FAULT FINDING & DIAGRAMS Burner shut down if primary temperature 94°C (until 84°C) Over temperature Wait shut-down if water Gas valve OFF. 5 seconds temperature is 8°C above set value. DOMESTIC Tap open WATER (recognised DEMAND by flow (priority over Fan (&...

  • Page 62: 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 25Si/30Si PROTECTION FUNCTION 8 716 115 165a (06/2008)
  • Page 65 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 165a (06/2008)

This manual is also suitable for:

Greenstar 30si

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