Worcester GREENSTAR 12Ri Instruction Manual
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
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Also See for GREENSTAR 12Ri:
- Technical information (44 pages) ,
- Installation and servicing instructions (68 pages) ,
- User manual (53 pages)
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INSTRUCTION MANUAL
INSTALLATION, COMMISSIONING & SERVICING
WALL HUNG RSF GAS FIRED CONDENSING BOILER
GREENSTAR 12Ri, 15Ri, 18Ri & 24Ri
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)
NATURAL GAS
12 Ri GC NUMBER: 41 311 63
15 Ri GC NUMBER: 41 311 75
18 Ri GC NUMBER: 41 311 77
24 Ri GC NUMBER: 41 311 65
LIQUID PETROLEUM GAS
12 Ri GC NUMBER: 41 311 64
15 Ri GC NUMBER: 41 311 76
18 Ri GC NUMBER: 41 311 78
24 Ri GC NUMBER: 41 311 66
UK/IE
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Table of Contents
Related Manuals for Worcester GREENSTAR 12Ri
Summary of Contents for Worcester GREENSTAR 12Ri
- Page 1 INSTRUCTION MANUAL INSTALLATION, COMMISSIONING & SERVICING WALL HUNG RSF GAS FIRED CONDENSING BOILER GREENSTAR 12Ri, 15Ri, 18Ri & 24Ri 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)
- Page 2 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...
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Page 3: Table Of Contents
GAS. CONVERSION FAULT FINDING & DIAGNOSIS ELECTRICAL WIRING DIAGRAM FAULT FINDING MAIN FUNCTION BENCHMARK CHECKLIST & SERVICE RECORD SHEET PRINTED AT THE REAR OF THE MANUAL INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri CONTENTS 8 716 115 168a (06/2008) -
Page 4: Safety Precautions & Symbols
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 5: General Information
Condensate trap & syphon Environment 2010 Art Leaflet ..................... 1 Irish Guidelines Leaflet ......................1 Consumer Guarantee Card ....................1 Warranty Return Envelope ....................1 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri GENERAL INFORMATION 8 716 115 168a (06/2008) -
Page 6: Technical Data
27.4 27.4 27.4 27.4 27.4 27.4 Lift weight 22.6 22.6 22.6 22.6 22.6 22.6 22.6 22.6 SEDBUK 90.1 90.1 90.1 90.2 91.4 91.4 91.4 92.0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri TECHNICAL DATA 8 716 115 168a (06/2008) -
Page 7: Layout & Components
27 DRAIN POINT 28 RETURN CONNECTION 22mm COMPRESSION 29 HEAT EXCHANGER 30 GAS COCK (ACCESS POINT) 31 SILICONE TUBE (USE TO VENT AIR FROM HEAT EXCHANGER) INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri LAYOUT & COMPONENTS 8 716 115 168a (06/2008) -
Page 8: Cleaning Primary Systems
• Drain and thoroughly flush the system to remove the flushing agent and debris. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri CLEANING PRIMARY SYSTEMS 8 716 115 168a (06/2008) -
Page 9: Mains Supply
Generally speaking, the appliance would need to be within 3 to 4 metres of the gas meter. However, this will depend on the dis- tribution pipe size and route. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri MAINS SUPPLY 8 716 115 168a (06/2008) -
Page 10: Water Systems & Pipework
L Stop Valve Fixed Cylinder Type or sealed systems approved connection NOTE: A drain cock should be fitted at the lowest point of the heating circuit and beneath the appliance. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri WATER SYSTEMS & PIPEWORK 8 716 115 168a (06/2008) -
Page 11: Condensate Pipework
43 mm 90° pipework, between the boiler condensate outlet M & F bend and the drainpipe, outside the property, to avoid flooding during adverse weather conditions. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri CONDENSATE PIPEWORK 8 716 115 168a (06/2008) -
Page 12: 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 Ri BOILER LOCATION & CLEARANCES 8 716 115 168a (06/2008) - Page 13 Additional RCD (Residual Current Device) pro- tection may be required. Refer to the latest IEE wiring regulations. (See Technical Data for IP ratings.) INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri BOILER LOCATION & CLEARANCES 8 716 115 168a (06/2008)
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Page 14: Plumbing Manifold
• If the flow and return pipes are to be run behind the appliance it maybe an advantage to connect the pipes before hanging on the wall especially if space is limited. Return Flow INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri PLUMBING MANIFOLD 8 716 115 168a (06/2008) -
Page 15: Flue Options
125mmØ 18 Ri 2,400mm 11,000mm 12 Ri 2,600mm 11,000mm 24 Ri 2,400mm 11,000mm 15 Ri 2,600mm 11,000mm 18 Ri 2,600mm 11,000mm 24 Ri 2,600mm 11,000mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri FLUE OPTIONS 8 716 115 168a (06/2008) -
Page 16: 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 Ri FLUE TERMINAL POSITIONS 8 716 115 168a (06/2008) - Page 17 FLUE TERMINAL POSITIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri FLUE TERMINAL POSITIONS 8 716 115 168a (06/2008)
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Page 18: Installation
Before installing appliance ensure system has been cleaned as explained on page 6. NOTE: Carefully cut along perforated line to release wall template. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri UNPACKING THE BOILER 8 716 115 168a (06/2008) -
Page 19: Wall Mounting Plate Flue Opening
Allow for a rise of 52mm per metre length of flue, to give a 3° angle. Clear any debris from the site. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri WALL MOUNTING PLATE FLUE OPENING 8 716 115 168a (06/2008) -
Page 20: Outer Case Removal
3. Pull case upwards. 4. Remove cardboard packing piece from appliance. With the outer case removed the appliance is suitable for a 1 man lift (<25kg). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri OUTER CASE REMOVAL 8 716 115 168a (06/2008) -
Page 21: Boiler Connections (Gas/Water)
22mm compression fitting (pipe not supplied). 22mm Ø 22mm Ø (Not supplied) 22mm Ø Pipes in alternative position Condensate outlet 112mm A, B and C 18mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri BOILER CONNECTIONS 8 716 115 168a (06/2008) -
Page 22: Flue Installation
The aluminium tape is not required when reducing the terminal. 130mm After cutting, the end must be square and free from burrs to prevent damage to the flue seals. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri FLUE INSTALLATION 8 716 115 168a (06/2008) - Page 23 ±80° 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 Ri FLUE INSTALLATION 8 716 115 168a (06/2008)
- Page 24 • The flue is set at an angle of 3° or 52mm per 1m length. Apply silicone grease to seal Flat at back This screw should be fitted last for easier installation INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri FLUE INSTALLATION 8 716 115 168a (06/2008)
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Page 25: Condensate Connections
• A 22mm adaptor (A) and sealing washer (B) is supplied in the fitting pack Mains cable Inlet INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri CONDENSATE, GAS & WATER 8 716 115 168a (06/2008) CONNECTIONS... -
Page 26: Electrics
CENTRE Refit electric control panel covers: Refit panel (B) and secure with screws. Locate lugs at top edge of panel (A) and clip in at base. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri ELECTRICS 8 716 115 168a (06/2008) -
Page 27: Position Of Wired Components
POSITION OF WIRED COMPONENTS DIAGNOSTIC INTERFACE green 2 red 2 blue 2 violet 2 orange INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri POSITION OF WIRED COMPONENTS 8 716 115 168a (06/2008) -
Page 28: Pre-Commissioning Checks
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri PRE-COMMISSIONING CHECKS 8 716 115 168a (06/2008) -
Page 29: Filling The System
Open gas cock on the boiler and purge the gas supply to the boiler ensuring that the room is well ventilated. Test for gas supply for soundness as described in BS 6891. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri FILLING THE SYSTEM 8 716 115 168a (06/2008) -
Page 30: Starting The Appliance
5 seconds then turn to maximum. The boiler will be reset. CAUTION: DO NOT PRESS POWER INDICATOR (B) TO RESET BOILER. RESET INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri STARTING THE APPLIANCE 8 716 115 168a (06/2008) -
Page 31: 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 Ri WATER TREATMENT 8 716 115 168a (06/2008) -
Page 32: Commissioning
Re-seal the screw in the gas inlet pressure test point. Replace controls cover. DUNGS VALVE Note: This boiler is designed with differential of 20°C across the heating system. Inlet Test Nipple INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri COMMISSIONING 8 716 115 168a (06/2008) -
Page 33: Finishing Commissioning
User Guide. 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 Ri FINISHING COMMISSIONING 8 716 115 168a (06/2008) -
Page 34: 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 Ri INSPECTION AND SERVICE 8 716 115 168a (06/2008) - Page 35 2. Adjusting boiler control to service position 2.1 Remove two screws (D) securing control. 2.2 Hang control on two lugs (E) on boiler framework. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri INSPECTION AND SERVICE 8 716 115 168a (06/2008)
- Page 36 Pressure will read negative and be greater than: After measurement replace test point cover and return mode switch to normal. Replace controls cover. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri INSPECTION AND SERVICE 8 716 115 168a (06/2008)
- Page 37 Syphon The syphon body is opaque so that contents can be examined Empty the contents and flush with clean water INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri INSPECTION AND SERVICE 8 716 115 168a (06/2008)
- Page 38 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 Ri INSPECTION AND SERVICE 8 716 115 168a (06/2008)
- Page 39 IN DAMAGE TO THE BOILER 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 Ri INSPECTION AND SERVICE 8 716 115 168a (06/2008)
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Page 40: Setting The Air/Gas Ratio
The power indicator will flash and the boiler will stay in this mode for 15 minutes if no further change is made to the switch. NORM INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri SETTING THE AIR/GAS RATIO 8 716 115 168a (06/2008) - Page 41 Remove manometer and re-seal inlet pressure point on gas valve. Re-assemble and refit boiler case. ‘D’ INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri SETTING THE AIR/GAS RATIO 8 716 115 168a (06/2008) FOR THE SIT 848.093 SIGMA...
- Page 42 Remove manometer and re-seal inlet pressure point on gas valve. Re-assemble and refit boiler case. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri SETTING THE AIR/GAS RATIO 8 716 115 168a (06/2008) FOR THE DUNGS GB-ND 055 D01 S20...
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Page 43: 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 Ri REPLACEMENT OF PARTS 8 716 115 168a (06/2008) - Page 44 Drop condensate tube away from syphon. 7.2 Remove two screws (E) retaining the bracket. 7.3 Pull the syphon towards you to release from the connection and remove. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri REPLACEMENT OF PARTS 8 716 115 168a (06/2008)
- Page 45 THE APPLIANCE WILL INDICATE ERROR AND WILL NOT FUNCTION. 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 Ri REPLACEMENT OF PARTS 8 716 115 168a (06/2008)
- Page 46 Refit new pressure switch to bracket. 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 Ri REPLACEMENT OF PARTS 8 716 115 168a (06/2008)
- Page 47 NOTE: After re-assembly, check CO/CO levels as described in the setting of the air/gas ratio section. 17.1b 17.2 17.3 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri REPLACEMENT OF PARTS 8 716 115 168a (06/2008)
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Page 48: Short Parts List
Worcester Part No. 8 716 106 635 0 GC No. H26-546 13 Fuse (F2) Worcester Part No. 8 716 156 001 0 GC No. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri SHORT PARTS LIST 8 716 115 168a (06/2008) -
Page 49: Gas Conversion
Code plugs 12kW NG 1034 12kW LPG 1035 15kW NG 1036 15kW LPG 1037 18kW NG 1038 18kW LPG 1039 24kW NG 1041 24kW LPG 1040 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri GAS CONVERSION 8 716 115 168a (06/2008) -
Page 50: Electrical Wiring Diagram
23. Fuse F2 (T1.25A, H250V). 13. ST8, No connection. 14. Temperature control and lockout reset. 15. ST9 connector 16. Flame sense electrode, Pin 1 = green. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri ELECTRICAL WIRING DIAGRAM 8 716 115 168a (06/2008) -
Page 51: Fault Finding
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 52: Main Function
MAIN FUNCTION INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR Ri MAIN FUNCTION 8 716 115 168a (06/2008) - Page 56 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 168a (06/2008)