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INSTRUCTION MANUAL INSTALLATION, COMMISSIONING & SERVICING WALL HUNG RSF GAS FIRED CONDENSING BOILER GREENSTAR 12i/24i System FOR SEALED CENTRAL HEATING SYSTEMS AND INDIRECT FED DOMESTIC HOT WATER THIS BOILER IS USED WITH NATURAL GAS OR LPG (Cat II 2H3P TYPE C13, C33 & C53)
BOILER FUNCTION PROTECTION FUNCTION ADDITIONAL INSTRUCTIONS FOR FITTING OPTIONAL DIVERTER VALVE CAN BE FOUND AT THE REAR OF THIS MANUAL BENCHMARK CHECKLIST SERVICE INTERVAL RECORD SHEET INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System CONTENTS 8 716 115 167b (03/2009)
Pre-wired and pre-plumbed Item Greenstar 12i/24i System Installation/Servicing Instructions ...1 Galvanised steel inner frame Users Instructions ..........1 Digital control system Consumer Guarantee Card .
20 FLOW 21 ACCESS COVER FOR TRANSFORMER & 22 PUMP 23 GAS VALVE 24 FAN 25 MANUAL VENT POINT 26 FAN PRESSURE TEST POINT INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System LAYOUT & COMPONENTS 8 716 115 167b (03/2009)
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42 CH TEMPERATURE CONTROL 43 POSITION FOR OPTIONAL PROGRAMMER 44 SERVICE MODE BUTTON 45 BURNER ON INDICATOR LIGHT (GREEN) 46 MASTER SWITCH ON/OFF INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System LAYOUT & COMPONENTS 8 716 115 167b (03/2009)
• It may be necessary to use a power flushing machine to aid the cleansing procedure in some circumstances INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System CLEANING PRIMARY SYSTEMS 8 716 115 167b (03/2009)
Generally the appliance would need to be within 3 to 4 metres of the gas meter. However, this will depend upon the distribution pipe size and route. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System MAINS SUPPLY 8 716 115 167b (03/2009)
• Pressurise the extra expansion vessel (B) to cylinder the same figure as the expansion vessel built into the appliance. • Do not use galvanised pipes or radiators. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System WATER SYSTEMS & PIPEWORK 8 716 115 167b (03/2009)
High Minimum free 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 12i/24i System BOILER LOCATION & CLEARANCES 8 716 115 167b (03/2009)
Additional RCD (Residual Current Device) pro- tection may be required. Refer to the latest IEE wiring regulations. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System BOILER LOCATION & CLEARANCES 8 716 115 167b (03/2009)
ADDITIONAL INFORMATION section at the back of this book. Flow 22mm Return 22mm Mains Gas Supply 22mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System PLUMBING MANIFOLD 8 716 115 167b (03/2009)
12 i system 2,400mm 11,000mm Maximum total flue length 24 i system 2,400mm 11,000mm 100mmØ 125mmØ 12 i system 2,600mm 11,000mm 24 i system 2,600mm 11,000mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System FLUE OPTIONS 8 716 115 167b (03/2009)
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 12i/24i System FLUE TERMINAL POSITIONS 8 716 115 167b (03/2009)
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INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System FLUE TERMINAL POSITIONS 8 716 115 167b (03/2009)
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 12i/24i System UNPACKING WALL FRAME AND 8 716 115 167b (03/2009) ANCILLARY ITEMS...
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 12i/24i System WALL MOUNTING PLATE FLUE OPENING 8 716 115 167b (03/2009)
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 12i/24i System UNPACKING THE APPLIANCE 8 716 115 167b (03/2009)
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 12i/24i System BOILER CONNECTIONS 8 716 115 167b (03/2009)
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8. Connect the pressure relief drain pipe to 15mm compression joint (H) using the nut and olive supplied in the hardware literature pack. 22mm 22mm 22mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System BOILER CONNECTIONS 8 716 115 167b (03/2009)
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 12i/24i System FLUE INSTALLATION 8 716 115 167b (03/2009)
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±80° allow condensate to run back into the boiler for safe disposal. Do not attempt to force beyond the limit stops. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System FLUE INSTALLATION 8 716 115 167b (03/2009)
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• The flue is set at an angle of 3° or 52mm per 1m length. Flat at back This screw should be fitted last for easier installation when rear exit INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System FLUE INSTALLATION 8 716 115 167b (03/2009)
FITTING THE WALL FRAME DIVE RTE R VALVE in the ADDITIONAL CONNECTOR INFORMATION section at the back of this book. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System CONDENSATE CONNECTION 8 716 115 167b (03/2009)
This option is also covered in the Fault Finding Guide on page 55 of these instructions. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System ELECTRICAL 8 716 115 167b (03/2009)
POSITION OF WIRED COMPONENTS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System POSITION OF WIRED COMPONENTS 8 716 115 167b (03/2009)
8 Rotate the adjustable pointer on the pressure gauge to record the set system pressure. 9 Isolate and remove filling loop connection to system. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System FILLING THE SYSTEM 8 716 115 167b (03/2009)
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 12i/24i System STARTING THE APPLIANCE 8 716 115 167b (03/2009)
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 12i/24i System WATER TREATMENT 8 716 115 167b (03/2009)
F - Service button G - Not used H - System pressure gauge I - Cover or optional programmer Inlet Test Nipple DUNGS VALVE Inlet Test Nipple INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System COMMISSIONING 8 716 115 167b (03/2009)
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 12i/24i System FINISHING COMMISSIONING 8 716 115 167b (03/2009)
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 12i/24i System INSPECTION AND SERVICE 8 716 115 167b (03/2009)
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2. Lowering boiler control to service position 2.1 Remove screw (C) securing control. 2.2 Gently pull forward until it comes to rest in service position. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System INSPECTION AND SERVICE 8 716 115 167b (03/2009)
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There is a special accessory kit available specifically designed for cleaning the heat exchanger. If required order 7 716 192 312. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System INSPECTION AND SERVICE 8 716 115 167b (03/2009)
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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 12i/24i System INSPECTION AND SERVICE 8 716 115 167b (03/2009)
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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 12i/24i System INSPECTION AND SERVICE 8 716 115 167b (03/2009)
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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 12i/24i System INSPECTION AND SERVICE 8 716 115 167b (03/2009)
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 12i/24i System REPLACEMENT OF PARTS 8 716 115 167b (03/2009)
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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 12i/24i System REPLACEMENT OF PARTS 8 716 115 167b (03/2009)
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Pull transformer upwards from PCB. Spare Fuse order T1.6L 250V F2 T2.5H 250V F1 T500L 250V F3 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System REPLACEMENT OF PARTS 8 716 115 167b (03/2009)
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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. 10.3 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System REPLACEMENT OF PARTS 8 716 115 167b (03/2009)
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Lift up assembly and remove from boiler. NOTE: After re-assembly, check CO/CO levels as described in the setting of the air/gas ratio section. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System REPLACEMENT OF PARTS 8 716 115 167b (03/2009)
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Check CO/CO 2 levels as described in the “setting the air/gas ratio” section. 15.4 15.2 15.3 15.1 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System REPLACEMENT OF PARTS 8 716 115 167b (03/2009)
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18.2 Lift the air vent (E) out of the housing and remove. To refit, follow the above in reverse. 18.1 18.2 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System REPLACEMENT OF PARTS 8 716 115 167b (03/2009)
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21.2 Withdraw the drain tap from its housing To refit, follow the above in reverse. Ensure any seals that have been disturbed are renewed. 21.1 21.2 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System REPLACEMENT OF PARTS 8 716 115 167b (03/2009)
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23.2 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. 23.1 23.2 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System REPLACEMENT OF PARTS 8 716 115 167b (03/2009)
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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 12i/24i System REPLACEMENT OF PARTS 8 716 115 167b (03/2009)
Re-assemble and refit boiler case. If fitted to an S or Y plan system, the system must only be run in central heating mode. ‘C’ INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System REPLACEMENT OF PARTS 8 716 115 167b (03/2009)
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Re-assemble and refit boiler case. hot water circuits. If fitted to an S or Y plan system, the system must only be run in central heating mode. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System REPLACEMENT OF PARTS 8 716 115 167b (03/2009)
24kW LPG with internal diverter valve - 1115 24kW LPG with external diverter valve - 1111 THE SETTING THE AIR/GAS RATIO SECTION OF THIS MANUAL. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System LPG CONVERSION 8 716 115 167b (03/2009)
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.
Disregard this page and refer to the correct versions for CENTRAL HEATING and DHW FUNCTIONS in the ADDITIONAL INFORMATION section at the back of this book. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System BOILER FUNCTION 8 716 115 167b (03/2009)
PROTECTION FUNCTION Boiler temperature Run autofroststat below 8°C function Pump run 5 seconds Pump antiseize every 24hrs INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System PROTECT FUNCTION 8 716 115 167b (03/2009)
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ADDITIONAL INSTRUCTIONS FOR GREENSTAR 12i/24i System WITH OPTIONAL INTEGRAL DIVERTER VALVE WALL HUNG RSF GAS-FIRED CONDENSING BOILER FOR SEALED CENTRAL HEATING SYSTEMS AND INDIRECTLY FED DOMESTIC HOT WATER DIVERTER KIT NUMBERS: 12kW 7 716 192 566 24KW 7 716 192 409...
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NOW R ETU R N TO TH E MAIN IN STR UCTION S PAG E 16 TO CONTINUE INSTALLATION. Flow 22mm CH Return 22mm Mains Gas Supply 22mm Cylinder Return 15mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System PLUMBING MANIFOLD 8 716 115 167b (03/2009)
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Re-tighten the clamping plate by re-tightening the two screws (B) as shown in fig: 2. • 4.1 On completion the pipe assembly should look as shown. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System BOILER CONNECTIONS 8 716 115 167b (03/2009)
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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 12i/24i System BOILER CONNECTIONS 8 716 115 167b (03/2009)
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NOW R ETU R N TO TH E MAIN INSTRUCTIONS PAGE 25 (FLUE INSTALLATION) TO CONTINUE INSTALLATION. 22mm 22mm 15mm 22mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System BOILER CONNECTIONS 8 716 115 167b (03/2009)
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(see ELECTRICAL on the following page). Code plug numbers 12kW i System KIT: NATURAL GAS 1118 1119 24kW i System KIT: NATURAL GAS 1114 1115 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System BOILER CONNECTIONS 8 716 115 167b (03/2009)
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ST17 (see following page). THE OPTIONAL INTEGRAL DIVERTER VALVE IS INCOMPATIBLE WITH A MAINS PRESSURE UNVENTED CYLINDER. IF INSTALLING AN UNVENTED CYLINDER USE AN EXTERNAL DIVERTER VALVE. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System ELECTRICAL 8 716 115 167b (03/2009)
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POSITION OF WIRED COMPONENTS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System POSITION OF WIRED COMPONENTS 8 716 115 167b (03/2009)
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PAG E ( F I LLI NG TH E SYSTE M ) TO CONTINUE INSTALLATION. 22mm 22mm 15mm 22mm Preplumbing manifold connector Condensate pipe INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System PRE- COMMISSIONING CHECKS 8 716 115 167b (03/2009)
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BOILER FUNCTION INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System BOILER FUNCTION 8 716 115 167b (03/2009)
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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 167b (03/2009)
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