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INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS
WALL HUNG RSF GAS FIRED CONDENSING SYSTEM BOILER
Greenstar i System Compact
FOR 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
27i System Compact 41-406-13
30i System Compact 41-406-15
L.P.G.
27i System Compact 41-406-14
30i System Compact 41-406-16
UK/IE
GC Number
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Table of Contents
Related Manuals for Worcester 27i System Compact
Summary of Contents for Worcester 27i System Compact
- Page 1 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 27i System Compact 41-406-13 30i System Compact 41-406-15 L.P.G. 27i System Compact 41-406-14 30i System Compact 41-406-16 UK/IE...
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Page 2: Table Of Contents
CONTENTS 5.7.3 Fitting the fascia flap ......36 CONTENTS 5.7.4 Installing the bottom panel ..... . . 36 5.7.5 Handover . -
Page 3: Key To Symbols And Safety Instructions
Keywords at the start of a warning indicate the type and prosecution. seriousness of the ensuing risk if measures to prevent If you are in any doubt, contact the Worcester Technical helpline the risk are not taken. (0844 892 3366). -
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 INSTALLATION REGULATIONS the following rules. -
Page 5: Appliance Information
APPLIANCE INFORMATION APPLIANCE INFORMATION APPLIANCE Depth to wall 280mm (When fitted to wall frame) 680mm* * 690mm to top of case front 390mm 6720646609-01.2Wo STANDARD PACKAGE 1. Wall hung gas-fired condensing system boiler for central heating and domestic hot water 2. -
Page 6: Technical Data
Table 3 Technical data i System Compact * used with the optional integral diverter valve kit. ** All Worcester Greenstar boilers are tested in an acoustic chamber to sound levels and there may be some differences in situ dependant on installation site i.e. -
Page 7: Layout
APPLIANCE INFORMATION LAYOUT 6720646609-02.3Wo 40 39 Fig. 1 Main boiler components Greenstar i System Compact - 6 720 807 726 (2013/05) - Page 8 The FR110 and FW100 assume control over the DHW set point temperature control, making the manual DHW temperature control inoperative. Worcester fascia mounted mechanical timers cannot be used with this appliance. Greenstar i System Compact - 6 720 807 726 (2013/05)
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Page 9: Pre-Installation
▶ In cases where all attempts to find a micro leak have An external automatic bypass should be used if the failed, Worcester, Bosch Group supports the use of system flow can be significantly adjusted or stopped by Fernox F4 leak sealer. -
Page 10: S And Y Plan Systems
PRE-INSTALLATION SEALED PRIMARY SYSTEM: NOTICE: Automatic bypass ▶ An automatic bypass valve is required when fitting an NOTICE: Artificially softened water must not be used to S-plan type system with two-port valves. fill the central heating system. NOTICE: Drain cock •... -
Page 11: Condensate Pipework
PRE-INSTALLATION CONDENSATE PIPEWORK NOTICE: ▶ Where a new or replacement boiler is being installed, access to an internal “gravity discharge” point should be one of the factors considered in determining boiler location. ▶ The condensate pipe must be nominally 100mm 22mm Ø... - Page 12 PRE-INSTALLATION The use of a drain cover (such as those used to prevent blockage by Continued - Key to condensate illustrations leaves) may offer further protection from wind chill. PVCu strap on fitting Pipe drainage will be improved if the end is cut at 45° as opposed to a 100mm Ø...
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Page 13: Pressure Relief Pipework
PRE-INSTALLATION BOILER LOCATION AND CLEARANCES 3.6.1 INSTALLATION This boiler is only suitable for installing internally within a property at a suitable location onto a fixed, rigid surface at least the same size as the boiler and capable of supporting the boiler weight. NOTICE: No surface protection is required against heat transfer 500mm min. -
Page 14: Bathrooms
Part number: 7 716 192 712. • To cover the pipework under the boiler, down to the counter top, an optional Worcester accessory “Below boiler pipe cover” can be used. Part number: 7 716 192 608 Fig. 15 Plumbing manifold... -
Page 15: 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. 16 Flue terminal positions NOTICE: ▶ All measurements are the minimum clearances required. ▶ Terminals must be positioned so to avoid combustion products entering the building. ▶... -
Page 16: Flue Options
PRE-INSTALLATION FLUE OPTIONS CAUTION: Non accessible flue systems: ▶ Where a flue system is not going to be accessible, provision must be made for service and inspection. ▶ Voids containing concealed flues must have at least one inspection hatch no less than 300mm square. ▶... - Page 17 PRE-INSTALLATION 350 mm - 570 mm 130 mm Min 500 mm 300 mm Flat roof 6720643895-12.1Wo Greenstar i System Compact - 6 720 807 726 (2013/05)
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Page 18: Plume Management Terminal Positions
PRE-INSTALLATION 3.10 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. 17 Plume terminal positions NOTICE: ▶ All measurements are the minimum clearances required. ▶... -
Page 19: Determine The Plume Management System Length
PRE-INSTALLATION 3.10.1 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 plume length ▶... -
Page 20: Installation
INSTALLATION Additional requirements for roof space installation: INSTALLATION • The boiler should be first unpacked before ascending a ladder to the loft space. WARNING: All the previous “Pre-Installation” sections • Two sets of steps should be used. must be read and the requirements met before starting •... -
Page 21: Unpacking The Appliance
INSTALLATION 6. Remove the inner packing (2) from the back of the boiler. 7. Lie the boiler on the floor ensuring that the V shaped cardboard insert (8) is in place. Fig. 24 Finish unpacking REMOVING THE OUTER CASE ▶ Before the case can be removed, the control panel must be moved into the service position, i.e. -
Page 22: Pre-Plumbing Boiler Connections
INSTALLATION Refer to Figure 26. The connector (1) in the wiring harness is for use on other appliances and does not provide a function on this Greenstar iSystem Compact 25mm Fig. 28 Condensate connection PRV PRE-PLUMBING CONNECTION Fig. 26 Unused connector 1. -
Page 23: Hanging The Boiler
INSTALLATION HANGING THE BOILER CAUTION: Lifting the boiler ▶ There are two handling holes incorporated into the inner casing left and right in the lower section of the appliance. ▶ Do not lift the boiler using the control panel as a hand hold. -
Page 24: Flue Installations
INSTALLATION CONNECTING THE EXPANSION VESSEL CONNECTING THE SIPHON OUTLET To connect the expansion vessel to the hydraulic pump manifold 1. Push the black rubber siphon discharge hose onto the wall frame situated to the left of the pump: connector until fully engaged. 1. -
Page 25: Measuring The Flue (Standard Flue)
INSTALLATION 4.6.1 MEASURING THE FLUE (STANDARD FLUE) To reduce the flue length further: ▶ Measure from the outside of the wall to the centre line of the flue turret 265 mm to determine length L. ▶ Subtract 50mm from the length L to give the correct dimension to the flue elbow connection. -
Page 26: Flue Terminal Plume Re-Direction
INSTALLATION 2. Refit to the terminal, ensuring that the clips (1 & 2) are engaged and secure. 3. Loosen screws (3) and rotate the entire outlet assembly to redirect the plume. Tighten screws (3) to secure in the required position. The flue terminal outlet has built-in stops to limit rotation for horizontal flues to allow condensate to run back into the boiler for safe disposal. -
Page 27: Electrical
INSTALLATION ELECTRICAL Low voltage connections CAUTION: Isolate the mains electrical supply before starting any work and observe all relevant safety precautions. Additional equipment requiring 230V must be connected to the boiler‘s electrical supply. Fig. 47 Low voltage connectors The boiler is pre-fitted with a mains supply cable. Low voltage terminal strip External fuse rating - 3 Amps Low voltage room thermostat input (Not used) -
Page 28: Mounting Optional Plug-In Controls
INSTALLATION 4.7.1 MOUNTING OPTIONAL PLUG-IN CONTROLS CAUTION: Isolate the mains electrical supply before starting any work and observe all relevant safety precautions. Refer the to Programmer/Timer manual for set up and operation of the unit. 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. - Page 29 INSTALLATION NEW COMPLETE SYSTEM INSTALLATIONS If a new complete heating system installation is in a new build property or is a first time installation in an existing property, heating systems must conform to current building regulations Part L1a. All new heating systems in dwellings must have at least two heating zones.
- Page 30 INSTALLATION EXTERNAL 230V PROGRAMMER AND TWO HEAT ZONES WITH UNVENTED CYLINDER (S-PLAN PLUS) SYSTEM BOILER CONNECTIONS 230V 230V FR FS LR LR 230V Mains Voltage Double Pole Fused Spur Room T/Stat Zone 1 Dual Thermostat Heating Zone 1 Valve Cylinder Zone Valve Heating Programmer...
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Page 31: Commissioning
▶ Close the gas valve ▶ Worcester, Bosch Group cannot be held responsible for wiring errors. ▶ Close the water shut off valve ▶ A fascia mounted digital programmer/timer cannot be ▶... -
Page 32: Starting The Appliance
(10) to reset the boiler. Hot water temperature control* To reset the boiler, press the reset button (4) , the tick symbol will be Diagnostic port (Worcester engineers only) displayed briefly for a successful reset. System pressure gauge Only operational when the optional integral diverter valve is fitted. -
Page 33: Boiler Start Up Screens
COMMISSIONING 5.4.1 BOILER START UP SCREENS SCREEN DISPLAY DESCRIPTION On initial start up, the following screens are displayed: All possible screen symbols This screen is displayed briefly 1. All the symbols are displayed for approximately two seconds. during boiler start up and shows 2. -
Page 34: Commissioning
COMMISSIONING COMMISSIONING ≈ ≈ NOTICE: The combustion settings on this gas-fired boiler have been checked, adjusted and preset at the factory for °C reset °F 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 be checked. -
Page 35: Checking The Gas Rate
COMMISSIONING ▶ Do not allow the product to come into contact with the electrical Regulator Gas Control L.P.G. wiring. valve < 4.0mbar DOMESTIC HOT WATER difference Controlling the hot water temperature: NOTICE: Domestic Hot Water ▶ The hot water temperature can only be controlled 32 - 45 mbar when the “Optional diverter valve”... -
Page 36: Securing The Control Panel
▶ Show the customer how to safely isolate the boiler ▶ Advise the customer where they can find information on the Worcester Bosch website. ▶ Advise the customer that the varying external temperatures will affect the output of the boiler. -
Page 37: Service And Spares
SERVICE AND SPARES SERVICE AND SPARES CHECKING THE GAS INLET PRESSURE CAUTION: Mains supplies ▶ Turn off the gas supply and isolate the electrical mains NOTICE: supply before starting any work on the appliance and ▶ Ensure that the gas pressure is satisfactory with all observe all relevant safety precautions. -
Page 38: Checking Flue Integrity
SERVICE AND SPARES CHECKING FLUE INTEGRITY COMPONENT ACCESS The integrity of the flue system and performance of the boiler can be To gain access to the components, remove the outer case: checked via the flue turret sample points. 1. Remove the two screws securing the control panel. 2. -
Page 39: 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 40: Flue Gas Analysis
SERVICE AND SPARES FLUE GAS ANALYSIS – The boiler will take 30 to 35 seconds to ramp down to minimum NOTICE: Combustion testing output. ▶ Combustion testing must be carried out by a – Allow the boiler to stabilise at minimum output for at least 10 competent person. -
Page 41: Cleaning The Siphon
SERVICE AND SPARES 6.7.1 CLEANING THE SIPHON 6.7.2 CLEANING THE PRIMARY HEAT EXCHANGER 1. Protect the controller from water ingress and disconnect the black SINGLE BLADED TOOL AND BRUSH discharge hose from the wall frame connector. Use a suitable blade to clean the heat exchanger channels. 2. -
Page 42: Replacement Of Parts
SERVICE AND SPARES ▶ Use the brush to dislodge the debris and pour water down the channels to flush out the debris. Fig. 81 Bottom panel 1. Locate and remove the two screws under the front of the boiler. 2. Pull the two catches, located under the front of the boiler, down to release the control panel 3. -
Page 43: Draining The Boiler
SERVICE AND SPARES 6.8.2 DRAINING THE BOILER Many of the tasks in this section require that the boiler be isolate and drained. 1. Connect a suitable hose firmly to the drain point and run the hose outside to a suitable point or container. 2. -
Page 44: Auto Air Vent
SERVICE AND SPARES 6.8.7 AUTO AIR VENT 6.8.9 FAN ASSEMBLY Ensure that the boiler has been fully drained. CAUTION: Component replacement: 1. Remove the spring clip completely. ▶ After replacement of a gas related component, where 2. Lift the air vent out of the housing and remove. a gasket or seal has been disturbed or replaced, check for gas tightness using a gas sniffer/analyser. - Page 45 SERVICE AND SPARES SUMP SEAL 1. Place seal on sump interface. 2. Be sure the ear lugs of the seal are mounted on the lugs of the sump. Before placing the flue pipe. ▶ Be sure the seal is clean and free of debris. Fig.
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Page 46: Air/Gas Flap Valve Assembly
SERVICE AND SPARES 6.8.10 AIR/GAS FLAP VALVE ASSEMBLY 1. Remove the single screw securing the air/gas flap valve assembly. 2. Pull the flap assembly away from the housing. Fig. 97 Electrode assembly 6.8.13 BURNER HOUSING, BURNER/ GASKET The front two bolts retaining the burner housing are NOT captive and will drop out when the nuts are removed. -
Page 47: Heat Exchanger
SERVICE AND SPARES 6.8.14 HEAT EXCHANGER Before removal: ▶ Isolate the electrical power to the boiler. ▶ Drain the system. HEAT EXCHANGER DISCONNECTION 1. Undo the flow and return connections. 2. Pull both the flow and return pipes away from the heat exchanger. ▶... -
Page 48: Diverter Valve Motor And Diverter Valve Removal
SERVICE AND SPARES 6.8.16 PUMP HEAD Before removal: ▶ Isolate the electrical power to the boiler. ▶ Drain the system. ▶ There may be water inside the pump. Protect any electrical items from water ingress. 1. Disconnect the main electrical connector from the bottom of the pump. -
Page 49: Boiler Return Sensor (Ntc)
SERVICE AND SPARES 6.8.18 BOILER RETURN SENSOR (NTC) ▶ Isolate the boiler and ensure that the system is fully drained. 1. Withdraw the spring clip to release the sensor. 2. Pull the sensor down to remove from the housing. ▶ To refit follow the above actions in reverse. Fig. -
Page 50: Bypass Valve
SERVICE AND SPARES 6.8.22 BYPASS VALVE PCB FUSE Remove the hydraulic block from the boiler, refer to section 6.8.21. The fuse is located next to the high voltage connectors and the spare fuse (1) is located on the back of the access cover. 1. -
Page 51: Expansion Vessel
SERVICE AND SPARES Fig. 114 Access to the cables Low voltage cable inlet Mains voltage cable inlet HCM - Heating Control Module Pressure gauge Low voltage connectors Mains voltage and earth connectors REMOVING THE CONTROL UNIT ▶ Support the control unit and detach the control unit support strap. Fig. - Page 52 SERVICE AND SPARES Fig. 116 EXPANSION VESSEL REPLACEMENT (REMOVE BOILER) ▶ Isolate the power from the boiler. ▶ Isolate the systems and gas connection using the service valves. ▶ Drain the boiler. ▶ Disconnect the electrical supply and any external controls. ▶...
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Page 53: Short Parts List
SERVICE AND SPARES SHORT PARTS LIST Burner Gas Valve 7 746 009 09A 0 8 718 600 23B 0 8 718 600 04A 0 Control panel Flue overheat thermostat Electrodes 8 737 909 (grommet type) (including gasket) 49A 0 8 717 206 213 0 8 718 600 28A 0 Spark generator Pump assembly... -
Page 54: Fault Finding And Diagnosis
PUMP SUPPLY VALVE PLUG (NOT USED) PUMP CONTROL Fuse, slow 230V 230V FR FS LR LR F 5A H 230 V Worcester 24V controls point CH TEMPERATURE DHW TEMPERATURE CONTROL EMS BUS point CONTROL DIAGNOSTIC LCD DISPLAY INPUT HCM (at rear of PCB) 6720646609-04.3Wo... -
Page 55: Heating Function
FAULT FINDING AND DIAGNOSIS HEATING FUNCTION Fig. 118 Heating function Greenstar i System Compact - 6 720 807 726 (2013/05) -
Page 56: Protection Functions
FAULT FINDING AND DIAGNOSIS PROTECTION FUNCTIONS Fig. 119 Protection function Greenstar i System Compact - 6 720 807 726 (2013/05) -
Page 57: Information And Service Menus
FAULT FINDING AND DIAGNOSIS INFORMATION AND SERVICE MENUS STATUS CODES Status Fault During normal boiler operation various Status codes can be displayed by codes codes pressing the button. First Safety timing error The first screen of the Information menu displays the current Status 262 &... -
Page 58: Selecting The Information Menu
FAULT FINDING AND DIAGNOSIS 7.4.1 SELECTING THE INFORMATION MENU Status Fault codes codes The Information Menu is a "read only" menu. Information about the boiler is displayed here, some of the values are updated in real time to give the No pressure variation detected after switching pump current status of the boiler. -
Page 59: Selecting Service Menus
FAULT FINDING AND DIAGNOSIS 7.4.2 SELECTING SERVICE MENUS Current status Every operation and mode of the 1. Press and hold buttons together for one second, the boiler has a related boiler status code. display will show Menu 1. The boiler status code is displayed on the screen as a three figure number. -
Page 60: Menu 1 - System Parameters
FAULT FINDING AND DIAGNOSIS 7.4.3 MENU 1 - SYSTEM PARAMETERS 2.1d Pump speed setting This function is only available when Initially Menu 1 will be displayed, but will contain no options. parameter 2.1C is set to 0. 1 = Min. and Max. speed can be Menu 1 options will appear on the display when the Intelligent Solar changed manually Module ISM1 is installed on the Greenstar i System Compact range only. -
Page 61: Reset To Factory Settings
FAULT FINDING AND DIAGNOSIS 7.4.5 RESET TO FACTORY SETTINGS To reset any or all changes made in menu 2 back to the factory defaults setting: °C reset °F Menu 1 NOTICE: Menu 3 ▶ Any changes made in Menu 3 are not reset via these actions. -
Page 62: Using The Test Menu
FAULT FINDING AND DIAGNOSIS 7.4.7 USING THE TEST MENU TESTING THE COMPONENT This menu enables the testing of the functionality of components in an ▶ Select a component to test. ON/OFF mode.The duration of each test is limited to 30 seconds. ▶... - Page 63 FAULT FINDING AND DIAGNOSIS RESETTING THE TEST COMPONENT After completing the test: Test ▶ Press the button, the value 1 will flash. Igniter test. The igniter will spark for a maximum ▶ Press the arrow button, the value will change to a flashing 0. Checking the igniter of 30 seconds.
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Page 64: Fault Codes
FAULT FINDING AND DIAGNOSIS FAULT CODES Should a fault develop with this boiler (or the system), the boiler will enter a locking or blocking condition, and fault code information will be generated as described in this section. Locking error The boiler display will flash a warning triangle and fault code. At the same time a (static) cause code will also be displayed. Manual intervention is required following clearance of the fault: ▶... -
Page 65: Blocking Errors
Fault codes codes Description Reset type Possible cause Internal error Call Worcester, Bosch Group Technical helpline 0844 892 3366 Gas valve error Reset button Leaking gas valve 242 - 256 Internal error Call Worcester, Bosch Group Technical helpline 0844 892 3366 Sensor test failed Reset button On power up all safety sensors are checked. - Page 66 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?
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Page 67: Service Record
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. - Page 68 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 Document No. 6 720 807 726 (2013/05)