Wall hung rsf gas fired condensing boiler for open vented and sealed central heating systems and indirect mains fed domestic hot water, this boiler is used with natural gas or lpg cat ii 2h3p type c13, c33 & c53 (56 pages)
Floor standing oil fired condensing boiler conventional flue and room sealed flue
for sealed central heating systems with mains fed domestic hot water (16 pages)
Wall hung rsf gas fired condensing system boiler for sealed central heating systems and indirectly fed domestic hot water (56 pages)
Summary of Contents for Worcester GREENSTAR Ri
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INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS WALL HUNG RSF GAS FIRED CONDENSING BOILER GREENSTAR Ri FOR OPEN VENTED AND SEALED CENTRAL HEATING SYSTEMS AND INDIRECT MAINS FED DOMESTIC HOT WATER The appliance is for use with Natural Gas or L.P.G. (Cat II 2H3P type C13, C33 & C53)
INSTALL CORRECTLY COULD LEAD TO PROSECUTION. instructions. • NOTICE indicates possible damage to property or IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER equipment, but where there is no risk of injury. TECHNICAL HELPLINE. • CAUTION indicates possible injury.
KEY TO SYMBOLS AND SAFETY PRECAUTIONS SAFETY PRECAUTIONS FITTING AND MODIFICATIONS Fitting the appliance and any controls to the appliance IF YOU SMELL GAS: may only be carried out by a competent engineer in B CALL NATIONAL GAS EMERGENCY SERVICE ON accordance with the current Gas Safety (Installation and 0800 111 999 Use) Regulations.
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CHECK LIST BS5440:2 Flues and ventilation for gas appliances of - HARDWARE LITERATURE PACK: Qty. rated heating not exceeding 70kW (net) : Air Greenstar Ri Installation, Commissioning and Supply Servicing Instructions BS7593 Treatment of water in domestic hot water Users Instructions...
APPLIANCE INFORMATION APPLIANCE INFORMATION APPLIANCE 270mm 590mm* 390mm *600mm to top of case front 6720644744-01.1Wo Fig. 1 Appliance STANDARD PACKAGE: Wall hung gas fired condensing regular boiler for central heating and domestic hot water Tail pipes - water Wall plate Hardware literature pack (see checklist) Bottom panel Tab.
APPLIANCE INFORMATION TECHNICAL DATA DESCRIPTION NATURAL GAS UNIT 12Ri 15Ri 18Ri 24Ri 12Ri 15Ri 18Ri 24Ri Gas flow rate - Max. 10 minutes from lighting Natural Gas G20 m³/h 1.63 1.96 Propane Gas (LPG) kg/h 0.96 1.20 1.44 1.91 Central Heating Max.
PRE-INSTALLATION PRE-INSTALLATION CLEANING PRIMARY SYSTEMS INHIBITOR NOTICE: Add a suitable inhibitor or combined inhibitor/anti- B All the following Pre-Installation sections freeze, if the system is exposed to freezing conditions, to must be read and requirements met the heating system in accordance with the DWTA code of before starting boiler or flue installations.
PRE-INSTALLATION MAINS SUPPLY 3.2.1 ELECTRICAL SUPPLY 3.2.3 GAS SUPPLY • Supply: 230V - 50 Hz, 140 Watts • Boilers using Natural Gas (NG) must be connected to a governed meter. • Cable: PVC insulated 0.75 mm (24 x 0.2 mm) temperature rated to 90 °C.
PRE-INSTALLATION WATER SYSTEMS AND PIPE WORK PLASTIC PIPE WORK: SYSTEM FILL • Any plastic pipe work must have a polymeric barrier SYSTEM FILL with 600mm (minimum) length of copper pipe Heating Mains connected to the boiler. return supply Hose union •...
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PRE-INSTALLATION S AND Y PLAN SYSTEMS: S PLAN LAYOUT NOTICE: Bypass S PLAN LAYOUT B Generally a bypass is not necessary on a Y plan system as one of the ports is open to flow. Static head - Minimum static head 250mm measured 150 mm from the highest point in the heating system (top surface of the appliance or the highest...
PRE-INSTALLATION CONDENSATE PIPE WORK Alternatively if the first option is not possible an internal NOTICE: kitchen or bathroom waste pipe, washing machine B Where a new or replacement boiler is waste pipe etc. can be used. being installed, access to an internal “gravity discharge”...
PRE-INSTALLATION 3.4.2 EXTERNAL CONNECTIONS FITTING AN EXTERNAL AIR BREAK NOTICE: Freezing conditions • Refer to figure 9 when a rain water down pipe, that B Pipe work length should be kept to a goes directly into a sewer that carries both rainwater minimum and the route as vertical as and foul water, is used to dispose of condensate.
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PRE-INSTALLATION CONDENSATE SOAK AWAY • The condensate drainage pipe may be run above or below the ground to the soak away. • The examples shown on this page run above ground. • The soak away must use a 100mm Ø plastic tube with two rows of three 12 mm holes on 25 mm centres and 50 mm from the bottom of the tube.
PRE-INSTALLATION PRESSURE RELIEF PIPE WORK NOTICE: B The pressure relief valve is a safety device for the boiler and if activated may discharge boiling water steam through the relief valve drain pipe. B Care should be taken when siting the outlet pipe so that it does not cause an obstruction or discharge above a window, entrance or other public access...
PRE-INSTALLATION BOILER LOCATION AND CLEARANCES 3.6.1 INSTALLATION 3.6.3 COMPARTMENTS: This boiler is only suitable for installing internally within Follow the requirements of BS6798 and BS5440 Part 2 a property at a suitable location onto a fixed, rigid and note: surface at least the same size as the boiler and capable •...
PRE-INSTALLATION 3.6.5 BOILER CLEARANCES- UNVENTILATED COMPARTMENTS The tables below show the options for the minimum space required to install and service the boiler inside an unventilated compartment. 3.6.6 INSTALLATION CLEARANCES - UNVENTILATED COMPARTMENTS CAUTION: CLEARANCES B Top and bottom clearances must not be reduced below the values shown in table 11 as they are the minimum clearances required for servicing.
PRE-INSTALLATION PLUMBING MANIFOLD 3.7.1 CONNECTIONS From left Diameter Heating System 22mm compression fittings Function case edge of pipe 22mm compression fittings 55 mm 22 mm Condensate 210 mm 22 mm Use the fittings supplied in the Hardware literature pack: Cylinder & CH Flow 285 mm 22 mm •...
PRE-INSTALLATION FLUE TERMINAL POSITIONS All measurements in millimetres Dormer Window 1,500 Velux Window Drainpipe 1,200 1,500 Boundary Window 6720643895-13.2Wo Fig. 18 Flue terminal positions NOTICE: B All measurements are the minimum clearances required. B Terminals must be positioned so to avoid combustion products entering the building. B Support the flue at approximately one metre intervals and at a change of direction, use suitable brackets and fittings (Flue bracket part numbers.: 100mm - 7 716 191 092, 125mm - 8 716 110 272).
PRE-INSTALLATION 3.10 PLUME TERMINAL POSITIONS All measurements in millimetres ±45° Plume management deflector: Flue Exhaust Outlet 180° Air Intake ±80° 1,200 Balcony Window Window Window Door Boundary Drainpipe 6720643895-14.1Wo Fig. 19 Plume terminal positions NOTICE: B All measurements are the minimum clearances required. B Refer to figure 18 for all concentric flue terminal positions unless the flue position is specified on the figure above “Plume terminal positions”.
INSTALLATION INSTALLATION WARNING: All the previous “Pre- Installation” sections must be read and the requirements met before starting boiler or flue installation. UNPACKING THE WALL FRAME AND ANCILLARY ITEMS CAUTION: LIFTING AND CARRYING B Only lift a manageable weight, or ask for help.
INSTALLATION WALL MOUNTING TEMPLATE & FLUE OPENING WARNING: BEFORE DRILLING: ENSURE THAT THERE ARE NO PIPES, ELECTRICAL CABLES, DAMP PROOF COURSES OR OTHER HAZARDS . SAFETY: All relevant safety precautions must be undertaken. Protective clothing, footwear, gloves and safety goggles must be worn as appropriate.
INSTALLATION OUTER CASE REMOVAL 1. Undo the two captive screws securing boiler casing at the bottom of the appliance. 2. Undo the two screws securing boiler casing at the top of the appliance. 3. Pull case upwards. 4. Remove cardboard packing piece from appliance. With the outer case removed the appliance is suitable for a one man lift (<25kg).
INSTALLATION BOILER CONNECTION CAUTION: Return Flow B ISOLATE THE MAINS GAS SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. WARNING: B Caps fitted to pipes must be removed before hanging the boiler GAS AND WATER CONNECTIONS: B Remove wall mounting template and secure the wall mounting frame to the wall with the appropriate fittings for the boiler weight and wall type.
INSTALLATION 4.4.1 CONDENSATE CONNECTION Never terminate or discharge into any open source, including; sink, bath, shower, bidet, toilet etc. NOTICE: Condensate disposal B Follow the recommendations given in section 3.4 “Condensate pipe work” for all condensate disposal installation. B Ensure that the condensate pipe work falls at least 50mm per metre towards the outlet.
INSTALLATION FLUE INSTALLATION HORIZONTAL FLUE (60/100mm diameter) 4.5.2 REDUCING THE TELESCOPIC FLUE LENGTH: For vertical flues and 80/125mm horizontal flues, please Ensure that the “TOP” label is facing up refer to separate instructions supplied with the flue kit. before securing the flue section to the turret.
INSTALLATION 4.5.3 INSTALLING THE TELESCOPIC FLUE: Refer to figure 32. B If fitting the outer seal from outside the building, slide the outer wall seal onto the terminal as shown. 1. Set the flue length to the distance required, secure with screws provided.
INSTALLATION 4.5.4 FLUE TERMINAL PLUME RE-DIRECTION: NOTICE: Outlet position The flue discharge can be re-directed allowing some B The flue terminal outlet position must plume redirection control, alternatively, a complete follow those stated in the relevant plume management system can be fitted to the flue appliance instruction manual.
INSTALLATION ELECTRICAL CONNECTIONS The mains supply to the boiler must be either: ACCESS TO ELECTRICAL CONTROL PANEL: B from a fused double pole isolator situated next to the B Remove boiler casing to access control panel. appliance. The isolator must have a minimum of 3mm 1.
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INSTALLATION EXTERNAL WIRING CENTRE System components wired into terminal strip in accordance with system manufacturers instructions. 230V MAINS SUPPLY External Pump 90W max Wiring Centre/Junction Box Fig. 41 External wiring centre Refit electric control panel covers: B Refit panel and secure with screws. 6 720 644 744a (2010/10)
COMMISSIONING COMMISSIONING PRE-COMMISSIONING CHECKS WARNING: ELECTRIC SHOCK NOTICE: Do not use solvents, adhesive or lubricant when pushing the pipe onto the B ISOLATE THE MAINS SUPPLIES BEFORE rubber connector. STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS B Check that the condensate pipe has been connected to the syphon.
COMMISSIONING FILLING THE SYSTEM WATER TREATMENT Open vented systems: NOTICE: B Ensure all system and boiler drain points are closed. B ARTIFICIALLY SOFTENED WATER MUST B Open all radiator valves. NOT BE USED TO FILL THE CENTRAL HEATING SYSTEM. B Turn on the water supply to the system header tank and allow the system to fill.
COMMISSIONING STARTING THE APPLIANCE B If the boiler fails to light and the boiler goes to flame CAUTION: RUNNING THE APPLIANCE lock-out, the BLUE power indicator (2) will flash. B Never run the appliance when the appliance/system is empty or partially NOTICE: RESET filled.
COMMISSIONING COMMISSIONING If the pressure drops are greater than shown below, NOTICE: The combustion settings on this then this would indicate a problem with the pipe work or gas-fired boiler have been checked, adjusted connections within the system. and preset at the factory for operation on the gas type defined on the data plate.
COMMISSIONING FINISHING COMMISSIONING 5.6.1 REPLACE THE OUTER CASE: 5.6.2 INSTALL THE BOTTOM PANEL Replace outer casing making sure that the securing The cut out in the bottom panel fits easily over the points are properly located. syphon elbow and outlet, however care should be taken not to disturb any sealed components.
SERVICE AND SPARES SERVICE AND SPARES INSPECTION AND SERVICE COMPONENT ACCESS Removing outer case CAUTION: TURN OFF THE GAS SUPPLY AND 1. Undo and remove two screws securing boiler casing ISOLATE THE MAINS SUPPLIES BEFORE at the top of the appliance. STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.
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SERVICE AND SPARES LOWERING THE BOILER CONTROLS TO THE SERVICE POSITION: 1. Remove two screws securing the control. 2. Pull the control forward. 3. Lower the control to align the slots at the top of the control with the lugs on the boiler framework. 4.
SERVICE AND SPARES CHECKING GAS INLET PRESSURE CHECKING FLUE INTEGRITY Refer to section 5.5.1 for more information The integrity of the flue system and performance of the boiler can be checked via the flue turret sample points. NOTICE: B Ensure that the gas inlet pressure is Flue gas sample point satisfactory with all other gas appliances Air inlet sample point...
SERVICE AND SPARES FAN PRESSURE TEST FAN PRESSURE TEST This test is to determine if the heat cell requires cleaning/attention. SETTING THE BOILER TO MAXIMUM 1. Remove the three screws retaining the control cover. 2. Remove the control cover. 3. Remove the plastic tool clipped inside the cover. 4.
SERVICE AND SPARES FLUE GAS ANALYSIS If the boiler fails the fan pressure test then before adjusting the air/gas ratio, try the following: COMBUSTION TEST: B Check the syphon is not blocked. 1. Remove the screws securing the sump cover. Ensure that the gas inlet pressure has been 2.
Fig. 61 Gas valve adjustment B Refer to section 6.4 for setting the boiler to maximum and minimum output. CO/CO settings for Greenstar Ri B Refer to table 20 and check the CO/CO at maximum and if required adjust for maximum using a 2.5mm CO/CO should be measured after 10 minutes.
SERVICE AND SPARES CLEANING THE HEAT EXCHANGER B Remove electrical connector and earth wire from fan. NOTICE: COMBUSTION TESTING B Combustion testing must be carried out To prevent damage to the electrodes when by a competent person. Testing must not removing the air/gas manifold, disconnect be attempted unless the person carrying the leads to the electrodes.
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SERVICE AND SPARES BURNER REMOVAL BAFFLE REMOVAL Refer to figure 65 Refer to figure 66. 1. Remove clamping plate. 1. Remove top baffle. 2. Remove spark/flame electrode assembly and seal 2. Remove lower baffle. from the top of the heat exchanger. If the lower baffle is stuck, it may be 3.
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SERVICE AND SPARES ACCESS COVER REMOVAL THE HEAT EXCHANGER DOES NOT HAVE TO BE REMOVED TO CLEAN. Refer to figure 67. The heat exchanger is shown removed from 1. Remove the two pozi-drive screws the boiler to illustrate cleaning more clearly. 2.
SERVICE AND SPARES 6.7.1 SYPHON REMOVAL AND CLEANING Remove the syphon assembly to clean. To release the syphon from the sump: 1. Undo the plastic nut on the bottom of the syphon and move the condensate pipe away from the syphon. 2.
SERVICE AND SPARES REPLACEMENT OF PARTS CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. NOTICE: REPLACEMENT OF COMPONENTS. B After replacement of any components always check for gas tightness where relevant and carry out functional checks as described in Commissioning.
SERVICE AND SPARES 6.8.2 PRIMARY SENSOR (CH NTC) 6.8.4 FLUE OVERHEAT THERMOSTAT (WITH GROMMET) To gain access to the following components To remove and replace the thermostat either: the outer case has to be removed: B Using a small terminal screwdriver, prise the B Primary sensor thermostat and grommet from the plastic housing.
SERVICE AND SPARES 6.8.5 LOWERING THE BOILER CONTROLS TO THE 6.8.6 GAS VALVE SERVICE POSITION: Refer to figure 76 1. Remove two screws securing control. B Isolate gas supply at boiler gas cock. 2. Pull the control forward. 1. Remove wire clip from the gas valve outlet. 3.
SERVICE AND SPARES 6.8.7 AIR/GAS MANIFOLD AND FAN ASSEMBLY B Rotate fan and air/gas manifold assembly (1.) around The following components require the the top of the heat exchanger until the lug on the air/ air/gas manifold and fan assembly to be gas manifold is visible.
SERVICE AND SPARES 6.8.8 AIR PRESSURE SWITCH 6.8.9 B Remove the air/gas manifold from the boiler as NOTICE: Pressure switch described in the previous section. B Ensure that the tube is reconnected to 1. Remove two screws retaining the fan to the air/gas the pressure switch manifold.
SERVICE AND SPARES FLAP VALVE ASSEMBLY 6.8.10 ELECTRODE ASSEMBLY AND BURNER 1. Twist the mounting flange clockwise to release. Refer to figure 84. B Disconnect spark electrodes and flame sensor 2. Pull mounting flange off the flap valve assembly. connection. 3.
SERVICE AND SPARES 6.8.11 HEAT EXCHANGER B Drain the system. Refer to figure 87. B Remove syphon. 1. Release the clip. B Remove the air/gas manifold and fan. 2. Move the lower exhaust connector up Refer to figure 85. B Remove the complete exhaust assembly. 1.
SERVICE AND SPARES Refer to figure 89. 6.8.12 ACCESS TO BOILER CONTROL COMPONENTS 1. Lift the heat exchanger up to clear. 1. Remove three screws. 2. Pull the heat exchanger forward from the case. 2. Remove cover from control. 6.8.13 PCB FUSE B Remove fuse holder with fuse F1 (1) from the control and replace with a new fuse.
SERVICE AND SPARES 6.8.15 TRANSFORMER/PCB To change either the PCB, F2 fuse or transformer: B Remove two screws securing the control. B Pull the control forward. B Lower the control to align the slots at the top of the control with the lugs on the boiler framework. B Hang control on two lugs on boiler framework.
SERVICE AND SPARES 6.8.16 SYPHON REMOVAL To release the syphon from the sump: 1. Undo the plastic nut on the bottom of the syphon and move the condensate pipe away from the syphon. 2. Remove the two screws retaining the syphon bracket. 3.
(i.e. not a first installation error). This fault finding information is for guidance only. Worcester cannot be held responsible PRELIMINARY CHECKS : Preliminary electrical system for costs incurred by persons not deemed to checks are the first electrical checks to be carried out be competent.
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...
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Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect the customer’s statutory rights. If yes, and if required by the manufacturer, has a water scale reducer been fitted? CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798 If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation fitted?
Service Record It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.
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LITERATURE: 0844 892 9800 TRAINING: 01905 752526 SALES: 01905 752640 Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0844 892 9900 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. worcester-bosch.co.uk 6 720 644 744a (2010/10)