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Summary of Contents for Worcester GREENSTAR 29
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Page 1: Installation And Servicing Instructions
Installation and Servicing Instructions GREENSTAR 29 HE Conventional Wall mounted condensing boiler 6 720 610 577-00.10 HE Conventional GC-Number Natural Gas: 41 311 56 GC-Number LPG: 41 311 57... -
Page 2: Table Of Contents
Contents Contents Safety precautions Individual settings Mechanical settings 6.1.1 Setting the boiler flow temperature Symbols Settings on the Bosch Heatronic 6.2.1 Operating the Bosch Heatronic 6.2.2 Setting the anti-cycle time Details of the appliance (Service Function 2.4) EC Declaration of Conformity 6.2.3 Setting the maximum flow temperature Standard package (Service Function 2.5) -
Page 3: Safety Precautions
Safety precautions Safety precautions Symbols Safety instructions in this document If you smell gas B Turn off gas service cock at the meter. are identified by a warning-triangle sym- B Open windows and doors. bol and are printed on a grey back- B Do not operate any electrical switches. -
Page 4: Details Of The Appliance
Details of the appliance Details of the appliance Description of appliance • Wall-mounted appliance, siting not dependent on room size EC Declaration of Conformity • Natural gas models are low-emission appliances This appliance is in accordance with the applicable • Multifunction display requirements of the Gas Appliance Directive, Boiler Efficiency Directive, Electromagnetic Compatibility •... -
Page 5: Accessories
Details of the appliance Accessories • Standard horizontal flue kit at 100 mm outside diameter for flues upto 4 m in length. • Flue duct kits for horizontal (125 mm outside diameter) for flue lengths upto 13 m and vertical flue systems for flue lengths upto 15 m. -
Page 6: Layout Of Appliance
Details of the appliance Layout of appliance 221.1 221.2 234.1 32.1 6 720 611 137-01.1 O Fig. 2 Heatronic control 221.1 Flue duct Y-S-module 221.2 Combustion air intake Heat exchanger safety temperature limiter Fan assembly Testing point for gas supply pressure Appliance type sticker Flue gas temperature limiter Testing point for combustion products... -
Page 7: Function
Details of the appliance Function 234.1 ϑ 29.1 52.1 6 720 611 137-02.1O Fig. 3 Bosch Heatronic control 234.1 Testing point for combustion air Y-S-module Display Temperature limiter, heat exchanger Condensate trap Testing point for gas supply pressure Drain valve Flue gas temperature limiter Siphon Manifold... -
Page 8: Electrical Wiring Diagram
Details of the appliance Electrical wiring diagram o - orange bl - black r - red 25 V 230 V 230V/AC 1 2 4 7 8 9 mains supply 52.1 6 720 611 137-03.1O Fig. 4 Ignition transformer Code plug Y-S-module Earth connection Temperature limiter, heat exchanger... -
Page 9: Technical Data
Details of the appliance Technical data Units Natural gas Propane Max. rated heat output net 40/30˚C central heating 29.3 29.3 Max. rated heat output net 50/30˚C central heating 29.0 29.0 Max. rated heat output net 80/60˚C central heating 27.4 27.4 Max. -
Page 10: Installation Regulations
Installation regulations Condensate analysis, mg/l Gas supply Ammonium 1.2 Nickel 0.15 Total length of gas supply pipe Pipe diameter ≤ 0.01 Mercury ≤ 0.0001 Lead (metres) (mm) ≤ 0.001 Sulphate Cadmium ≤ 0.005 Zinc ≤ 0.015 Chromium ≤ 0.01 Halogenated Gas discharge rate (m ≤... -
Page 11: Installation
"dry loft" can be realised. For more information con- i.e. 2-port valves, can result in the closure of the CH and tact Worcester Heat Systems Helpline 08705 266241. DHW circuits when the boiler is hot. If mechanically Note: Indirect coil type or a direct cylinders with an... - Page 12 Installation Typical system la yout if using Honeywell 'Y' plan Feed and Vent Cistern S.H. – Minimum static head 1.0m measured from the highest point in the S.H. heating system (top surface of the appliance S.H. or highest point in the heating system) to the Primary Domestic hot water level in the feed and expansion tank...
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Page 13: Siting The Appliance
Installation Fully pumped sealed system Note: INDIRECT A drain cock CYLINDER should be fitted at the lowest point of the heating circuit and beneath the appliance BOILER Pressure Gauge Bypass Expansion balancing valve or Vessel uncontrolled radiator with tw o lockshield valves Relief Radiator Valve - Flow RV... -
Page 14: Wall Mounting Frame Assembly
Installation B Screw the pre-plumbing manifold with two screws to Wall mounting frame assembly the wall mounting frame. B Take the wall mounting frame out of the package and screw together with 6 screws as shown in fig. 9. Use the inner lugs on the top and bottom horizontal sec- tions for the appliances that are 440 mm wide. -
Page 15: Fitting The Appliance
Installation Condensate Termination and Route External condensate pipework The condensate connection on the Greenstar appli- All Greenstar condensing boilers have within a ances is in 22 mm plastic. The pipe should be extended syphonic condensate trap. Rather than the condensate and run away from the appliance with a constant fall of constantly dripping into the discharge pipe, the con- 2.5 °... -
Page 16: Checking The Connections
The only flue systems that may be used are those sup- B Fit the washers onto the gas and water connections. plied by Worcester Heat Systems. B Lift the boiler onto the wall-mounting frame. The lugs The flue system must be installed in accordance with pass through the rectangular holes in the boiler back the requirements of BS5440:1. -
Page 17: Siting The Flue Terminal
Installation 3.8.1 Siting the Flue Terminal The flue must be installed in accordance with lighting, activated by passive infra-red sensing heads. BS 5440:1 and the Building Regulations. Flue termi- If the terminal is less than 2 m above a surface to which nals in carports and under balconies are to be avoided. -
Page 18: Installation Of The Flue
Installation 3.8.2 Installation of the flue The standard 100 mm diameter horizontal flue system is suitable for lengths upto 4 m. Flues upto 650 mm do not require an extension duct assembly. Flues between 600 mm and 4000 mm require exten- Terminal sion duct assemblies. - Page 19 Installation Terminal Assembly Flue Turret Maximum 1600mm Outer Wall Clamp Extension Clamp Duct 6 720 610 602 - 09.1O Fig. 20 Flue with one extension Terminal Assembly Flue Turret Outer Wall Clamp Clamp Extension Extension Clamp Duct Duct 6 720 610 602 - 10.1O Fig.
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Page 20: Flue Duct Preparation And Assembly
Installation 3.8.3 Flue duct preparation and assembly Measure the flue length L. Refer to fig. 23, 24. Outer Wall Flue Terminal Face Raised Ring locating the terminal relative to the outside wall face NOTE: THE FLUE MUST BE INCLINED T O THE 6 720 610 576 - 20.1O BOILER 6 720 610 602 - 12.1O... -
Page 21: Electrical Connections
Electrical connections Electrical connections B Remove screw and slide terminal cover forwards to B Always disconnect the power supply to remove. Refer to fig. 28. the appliance at the mains before carry- ing out any work on the electrical sys- tems and components. -
Page 22: Wiring To Your System
HEATRONIC CONNECTOR to the proprietary junction box according to the instruc- tions supplied with the box. Worcester Heat Systems cannot be held responsible for any incorrect wiring to these parts of the system. -
Page 23: Commissioning
Commissioning Commissioning 317 366 367 6 720 611 137-11.1O Fig. 32 Commissioning Safety valve Automatic vent Reset button Never run the appliance when empty or, Master switch with sealed systems, unpressurised. Temperature control for central heating Service cocks on flow and return Gas cock (shown in on position) Appliance type sticker The operational CO... -
Page 24: Switching The Appliance On/Off
Commissioning B Before commissioning, the gas supply pres- Switching off the appliance sure must be checked at the gas supply pres- B Set the master switch to (0). sure test point (see page 6, fig. 2, item 7). The green indicator lamp goes out. Natural gas appliances must not be operated if the gas supply pressure is below 18 mbar or B Always disconnect the appliance from... -
Page 25: Fault Condition
Commissioning Fault Condition A list of faults that may occur is given on page 40. In the unlikely event of a fault occuring while the appli- ance is in operation: The display then shows a fault code and the button may also flash. -
Page 26: Individual Settings
Individual settings Individual settings Mechanical settings 6.1.1 Setting the boiler flow temperature Settings on the Bosch Heatronic The central heating flow temperature can be set to 6.2.1 Operating the Bosch Heatronic between 50˚C and 88˚C. The Bosch Heatronic enables easy setting and check- Limited maximum setting for low-temperature ing of a large number of appliance functions. -
Page 27: Setting The Anti-Cycle Time (Service Function 2.4)
Individual settings Entering a setting 6.2.5 Setting the heating output (Service Function 5.0) B To enter the setting for a function, turn the function The heating output can be set to any level between min. control. rated heat output and max rated heat output to limit it to the specific heat requirements. -
Page 28: Setting The Gas/Air Ratio
Individual settings B Measure the gas flow rate and compare with the fig- Setting the gas/air ratio ures specified for the code number displayed. If fig- The appliance is set at the factory and adjustment is not ures do not match, adjust the code number! necessary. -
Page 29: Converting The Appliance To Different Gas Types
Converting the appliance to different gas types Converting the appliance to different gas types Setting the gas/air ratio The setting is factory sealed at maximum. Adjustment to the rated heat input and min. heat input is not neces- The gas/air ratio may only be adjusted on the sary. - Page 30 Converting the appliance to different gas types B Turn the function control until the display shows 2. B Remove the seal from the gas valve adjusting (= max. rated heat output). screw (64) and adjust the CO level to the figure The display and the button will flash.
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Page 31: Testing Combustion Air/Flue Gas At Set Heat Output
Converting the appliance to different gas types Testing combustion air/flue gas at set heat output 7.2.1 Testing the O or CO level in the combus- 7.2.2 Testing CO and CO tion air B Press and hold the button until the display By testing the O or CO level in the com-... -
Page 32: Maintenance
Maintenance Maintenance B Always disconnect the appliance from the electrical power supply (fuse, circuit breaker) before carrying out any work on the electrical systems or compo- nents. B Always turn off the gas cock before car- rying out any work on components which carry gas. -
Page 33: Pre-Service Check List
Maintenance Pre-Service Check List Date Call up the last fault stored by the Bosch Heatronic, Service Function .0, (see page 34). Check ionisation current, Service Function 3.3, (see page 34). Perform visual check of air/flue duct.Visual check of diaphragm for soiling and splits (see page 36). -
Page 34: Description Of Servicing Operations
Maintenance B Remove the fan and the burner as described in the Description of servicing operations text headed “Burner” (see page 35). The combustion performance must be checked before and after any servicing work on the combustion and burner components. Refer to section 7.2. Check “Last fault stored”: B Select Service Function .0 (see page 26 “Selecting Service Function”). - Page 35 Maintenance B Clean out the condensate collector and trap connec- tion (with other end of brush). 6 720 610 332-75.2R Fig. 52 B Refit the clean-out cover using a new seal and tighten screws to torque of approx. 5 Nm. Burner B Check that the gas cock is turned off and the master switch is in the OFF position.
- Page 36 Maintenance B Refit and prime the siphon. Diaphragm in mixer unit B Take care not to damage diaphragm (443) when removing and refitting it. B Open mixer unit (29). Condensate B Carefully withdraw diaphragm (443) from fan intake Drain tube and check for soiling and splits. Siphon 6 720 611 137 - 22.
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Page 37: Replacement Of Parts
Maintenance B Remove the pcb control board. Replacement of Parts Before changing any components check that the gas is turned off and that the appliance is electrically isolated. When necessary close the system valves and drain the appliance. Refitting is a reverse of the procedure for removal using new seals or o-rings as appropriate. -
Page 38: Fan Assembly
Maintenance 8.3.2 Fan Assembly Flue Temperature Limiter – Item 9, fig. 2, 57 B Pull-off the connectors. B Unscrew the sensor. 8.3.4 Gas Valve B Check that the gas cock is turned off. B Lower the control panel. Refer to fig. 60. 6 720 611 137- 25.1O Fig. -
Page 39: Electrode Assembly
Maintenance 8.3.8 Primary Heat Exchanger B Drain the appliance. B Check that the gas supply is turned off. B Check that the appliance is electrically isolated. B Remove the fan assembly complete with the gas/air tube and mixer assembly. Refer to section 8.3.2. B Remove the burner. -
Page 40: Appendix
Appendix Appendix Fault Codes More detailed fault finding procedures are described in the Service booklet for the Engineer number 7 181 465 346. Display code Description Remedy Break in communication Check connecting lead to programmer Module not detected. Check connecting lead between TA211E/ TR212E and Heatronic Keyed plug not detected. -
Page 41: Short Parts List
Appendix Short parts list Description Qty GC Spare part number Sensor - Flue gas temp. 8 729 000 144 0 Sensor - CH flow temp. 8 714 500 087 0 Control board 8 748 300 418 0 Gas valve 8 747 003 516 0 Fan assembly 8 717 204 373 0 Fan washer... - Page 42 Over temperature Gas valve e shuts. Burner remains OFF shut-down if water External Pump until flow temperature temperature is 5°C remains ON. is below set value. above set value. Room thermostat and/or mains Boiler programmer or operates to link ON External Pump ON Burner...
- Page 43 Appendix 6 720 611 137 GB (03.02)
- Page 44 EXCELLENCE COMES AS STANDARD Worcester Heat Systems Limited, Cotswold Way, Warndon, Worcester WR4 9SW. Telephone: (01905) 754624 Fax: (01905) 754619...
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