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INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS
WALL HUNG RSF GAS FIRED CONDENSING SYSTEM BOILER
GREENSTAR i SYSTEM
FOR SEALED CENTRAL HEATING SYSTEMS AND INDIRECTLY FED DOMESTIC HOT WATER
The appliance is for use with Natural Gas or
L.P.G. (Cat II 2H3P type C13, C33 & C53)
Natural Gas
Liquid Petroleum Gas
UK/IE
Model
GC Number
12i System
41-311-67
15i System
41-311-84
18i System
41-311-86
24i System
41-311-68
12i System
41-311-69
15i System
41-311-85
18i System
41-311-87
24i System
41-311-70
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Summary of Contents for Worcester Greenstar i Series
- Page 1 INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS WALL HUNG RSF GAS FIRED CONDENSING SYSTEM BOILER GREENSTAR i SYSTEM FOR SEALED CENTRAL HEATING SYSTEMS AND INDIRECTLY FED DOMESTIC HOT WATER The appliance is for use with Natural Gas or L.P.G. (Cat II 2H3P type C13, C33 & C53) Model GC Number Natural Gas...
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Page 2: Table Of Contents
CONTENTS CONTENTS 5.5.2 Checking the gas rate ......32 KEY TO SYMBOLS AND SAFETY PRECAUTIONS ... . 3 5.5.3 Domestic hot water: . -
Page 3: Key To Symbols And Safety Precautions
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 KEY TO SYMBOLS AND SAFETY PRECAUTIONS The purpose is to ensure that customers are provided with the correct BS7593Treatment of water in domestic hot water central heating equipment for their needs, that it is installed, commissioned and systems serviced in accordance with the manufacturer's instructions by BS6798Installation of gas fired boilers of rated input up to 70kW (net) competent persons and that it meets the requirements of the Irish Standards...
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Page 5: Appliance Information
APPLIANCE INFORMATION APPLIANCE INFORMATION APPLIANCE Depth to wall 330mm (When fitted to wall frame) 700mm* 400mm * 710mm to top of case front 6720644743-01.3Wo STANDARD PACKAGE: Wall hung gas fired condensing system boiler for central heating and hot water Wall mounting frame Hardware literature pack (see checklist) Bottom Panel Fascia panel... -
Page 6: Technical Data
APPLIANCE INFORMATION TECHNICAL DATA DESCRIPTION NATURAL GAS UNIT Gas flow rate - Max. 10 minutes from lighting Natural Gas G20 m³/h 1.33 1.63 1.96 2.67 Propane Gas (LPG) kg/h 0.96 1.20 1.44 1.91 Central Heating Maximum rated heat input (net) 12.32 15.40 18.48... -
Page 7: Layout
APPLIANCE INFORMATION LAYOUT Fig. 1 Main boiler components 6 720 804 532 (2012/09) - Page 8 APPLIANCE INFORMATION Expansion Vessel Hydraulic block mounting plate Sensor - Boiler flow Left side hand-hold for lifting boiler Removable panel - for servicing Gas valve Electrode assembly Flue air pressure switch connection (not used) Overheat thermostat Securing nut - Air/Gas manifold clamp Manual vent point Silicon tube - heat exchanger air vent Fan pressure test point...
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Page 9: Pre-Installation
PRE-INSTALLATION Fig. 3 Additional components Burner ON indicator light (green) PRV pipe connection point Power ON/OFF indicator/fault diagnostic light (blue) CH return isolator Position for optional programmer Gas inlet connection 22mm & isolator Reset button CH flow isolator System pressure gauge Condensate connection ECO button (not used) CH temperature control... -
Page 10: Mains Supply
▶ In cases where all attempts to find a micro leak have • All system connections, taps and mixing valves must be capable of failed, Worcester, Bosch Group supports the use of sustaining a pressure up to 3 bar. Fernox F4 leak sealer. -
Page 11: Condensate Pipe Work
PRE-INSTALLATION OPTIONAL DIVERTER VALVE This boiler is designed to operate on a sealed system only. The boiler will require a second return pipe from the water cylinder to the wall mounting frame and terminate in 15mm copper pipe. EXISTING BUILD - SYSTEM LAYOUT WITH OPTIONAL INTERNAL DIVERTER VALVE (NOT SUPPLIED WITH BOILER) Fig. -
Page 12: Internal Connections
PRE-INSTALLATION 3.4.1 INTERNAL CONNECTIONS In order to minimise risk of freezing during prolonged cold spells, the following methods of installing condensate drainage pipe should be adopted, in order of priority. Wherever possible, the condensate drainage pipe should be routed and terminated so that the condensate drains away from the boiler under gravity to a suitable internal foul water discharge point such as an 75mm... - Page 13 PRE-INSTALLATION ▶ The external pipe should take the shortest and least exposed route to • The soak away must use a 100mm Ø plastic tube with two rows of the discharge point, and should "fall" as steeply as possible away from three 12mm holes on 25mm centres and 50mm from the bottom of the boiler, with no horizontal runs in which condensate might stand.
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Page 14: Pressure Relief Pipe Work
PRE-INSTALLATION PRESSURE RELIEF PIPE WORK To room or internal Vent position space Direct to outside NOTICE: High level Minimum free area Minimum free area 61 ▶ The pressure relief valve is a safety device for the 122 cm boiler and if activated may discharge boiling water or Low level Minimum free area Minimum free area 61... -
Page 15: Bathrooms
PRE-INSTALLATION PLUMBING MANIFOLD Unventilated Compartment Installation Clearances (millimetres) The suggested total unventilated compartment minimum clearances 3.7.1 CONNECTIONS are: Side Above Below Front WARNING: IF FITTING AN OPTIONAL INTERNAL (to removable door) DIVERTER VALVE ▶ Refer to the “Greenstar Optional Integral Diverter 170 approx. -
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 6 720 804 532 (2012/09)
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Page 18: 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. 22 Flue terminal positions NOTICE: ▶ All measurements are the minimum clearances required. ▶ Terminals must be positioned so to avoid combustion products entering the building. ▶... -
Page 19: 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. 23 Plume terminal positions Maximum and minimum plume management lengths: ▶... -
Page 20: Installation
INSTALLATION proper technique for safe lifting of any heavy object should be strictly INSTALLATION observed. Additional requirements for roof space installation: WARNING: All the previous “Pre-Installation” sections • The boiler should be first unpacked before ascending ladder to loft must be read and the requirements met before starting space. -
Page 21: Unpacking The Appliance
INSTALLATION SIDE OUTLET: 4. Mark from the centre line of the wall template to the wall which the flue will pass through (4). ▶ Allow for a rise of 52mm per metre length of flue, to give a 3° angle. ▶... -
Page 22: Boiler Connections
INSTALLATION 25mm Fig. 30 Condensate drain pipe work detail PREPARING THE WALL FRAME ▶ Fit sealing washers to service valves before hanging boiler. Fig. 29 Outer case screw removal BOILER CONNECTIONS CAUTION: ISOLATE THE MAINS GAS SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. - Page 23 INSTALLATION ▶ Remove the screw from the control panel retaining bracket and lower CAUTION: Caps or plastic strip fitted to pipes must be the control panel into the service position. removed before hanging the boiler. ▶ Make connections to the heating system. Connect the gas supply to the boiler gas cock 22mm compression.
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Page 24: Flue Installation
INSTALLATION FLUE INSTALLATION 4.5.2 REDUCING THE TELESCOPIC FLUE LENGTH: HORIZONTAL FLUE (60/100mm diameter) Ensure that the “TOP” label is facing up before securing For vertical flues and 80/125mm horizontal flues, please refer to the flue section to the turret. separate instructions supplied with the flue kit. To ease assembly of flue components, apply silicone The flue terminal MUST be fitted with the 'TOP' label uppermost to allow lubricant to sealing surfaces. -
Page 25: Installing The Telescopic Flue
INSTALLATION 4.5.3 INSTALLING THE TELESCOPIC FLUE: 1. Refer to figure 41 and set the flue length to the distance required, secure with screws provided. 2. Seal the joint with the aluminium tape provided. 3. Slide the inner wall seal onto the terminal. 4. -
Page 26: Condensate Connection
INSTALLATION CONDENSATE CONNECTION Never terminate or discharge into any open source, including; sink, bath, shower, bidet, toilet etc. NOTICE: Any external condensate pipe work must be protected with weather resistant insulation to help prevent freezing. • Ensure that the condensate drain is a 22mm diameter plastic pipe. The pipe must fall at least 50mm per metre towards the outlet. -
Page 27: Electrical
INSTALLATION ACCESS TO ELECTRICAL CONNECTIONS: ▶ Remove boiler casing to access control panel. 1. Refer to figure 51 and remove the screw securing the control panel. 2. Lower the control panel into the horizontal service position. 6720644743-18.1Wo Fig. 51 Moving control panel into the service position When stripping wires always ensure copper strands do 6720644743-13.2Wo not fall into the control box. -
Page 28: Mounting Optional Plug-In Controls
INSTALLATION 4.7.1 MOUNTING OPTIONAL PLUG-IN CONTROLS Refer to the Programmer/Timer manual for set up and operation of the unit. PLUG-IN PROGRAMMER/TIMERS The programmers/timers listed can be used with the boilers stated on the front of this manual. Part number Description 7 716 192 038 DT20 twin channel digital timer 7 716 192 054 DT20RF digital RF thermostat with twin channel programmer... -
Page 29: Commissioning
▶ Refer to manufacturers‘ instructions when connecting external parts to the wiring centre. Fig. 59 Pipe fittings ▶ Worcester, Bosch Group cannot be held responsible Ensure that the washers have been fitted to the water connections and for wiring errors. -
Page 30: Filling The System
COMMISSIONING 6720804530-12.1Wo Fig. 63 Venting 5. Vent all radiators, tighten when completed and check the system and correct any leaks. ▶ The boiler integral expansion vessel is pre-charged to 0.75 bar (equal to a static head of 7.5m (22ft). A Schraeder type valve is fitted to the expansion vessel to allow for pressure adjustment if required. -
Page 31: Starting The Appliance
▶ In cases where all attempts to find a micro leak have COMMISSIONING failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer. NOTICE: The combustion settings on this gas-fired boiler... -
Page 32: Checking The Gas Rate
COMMISSIONING ▶ If pressure and gas rate are satisfactory press the service button again Ensure inlet pressure is satisfactory with all other gas and the boiler will return to normal operation. appliances working. – If left in the service mode the control will return to normal operation after 15 minutes. -
Page 33: Fitting Fascia Flap
SERVICE AND SPARES 5.6.2 FITTING FASCIA FLAP NOTICE: COMPONENTS. ▶ Present the flap up to the appliance with the hinge pins facing the ▶ After replacement of any components always check appliance. for gas tightness where relevant and carry out ▶... -
Page 34: Check The Gas Inlet Pressure
SERVICE AND SPARES Flue gas sample point Air inlet sample point Table 19 Key to figure 72 6720643895-67.1Wo Fig. 72 Flue test points ▶ With the boiler case on and the boiler running at maximum. ▶ Insert the analyser probe into the air intake test point. ▶... -
Page 35: Flue Gas Analysis
SERVICE AND SPARES ▶ Check the syphon is not blocked. 1. Remove the screws securing the sump cover. 2. Remove the sump cover. 3. Clean the sump and heat exchanger with a suitable brush ▶ Check the exhaust path and flue for restriction. ▶... -
Page 36: Setting The Air/Gas Ratio
SERVICE AND SPARES SETTING THE AIR/GAS RATIO NOTICE: THE SETTING OF THE GAS RATIO MUST BE CARRIED OUT BY A COMPETENT PERSON. SETTING OF THE GAS RATIO MUST NOT BE ATTEMPTED UNLESS 2.5 mm THE PERSON CARRYING OUT THE TEST IS EQUIPPED WITH A COMBUSTION ANALYSER CONFORMING TO BS 7927 AND IS COMPETENT IN ITS USE. - Page 37 SERVICE AND SPARES BURNER REMOVAL Refer to figure 84 1. Remove clamping plate. 2. Remove spark/flame electrode assembly and seal from the top of the heat exchanger. 3. Remove burner. 6720643895-72.1Wo Fig. 81 Gas valve connection ▶ Remove electrical connector and earth wire from fan. To prevent damage to the electrodes when removing the air/gas manifold, disconnect the leads to the electrodes.
- Page 38 SERVICE AND SPARES ▶ Using a suitable container to collect water from syphon connection at the base of the boiler flush heat exchanger with water. ▶ Re-assemble ensuring that the lower baffle (2) and the top baffle (1) are refitted correctly. ▶...
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Page 39: Replacement Of Parts
SERVICE AND SPARES REPLACEMENT OF PARTS 6.8.3 OVERHEAT THERMOSTAT Refer to figure 89 for removal. CAUTION: Turn off the gas supply and isolate the mains ▶ Remove two electrical connectors from thermostat. supplies before starting any work and observe all 3. -
Page 40: Moving Controls To Service Position
SERVICE AND SPARES 6720643895-72.1Wo Fig. 93 Gas valve upper connection Fig. 91 Remove thermostat 1. Refer to figure 94 and undo bottom gas connection to gas valve. To replace, push the thermostat and grommet gently back into the 2. Undo two securing screws on the underside of casing. opening until contact with the locating ridge is felt. -
Page 41: Fan
SERVICE AND SPARES Fig. 95 ▶ Undo the securing nut at the top of the heat exchanger and remove the retaining plate assembly (1). Disconnect spark electrodes and flame sensor connection. This will prevent damage to the electrodes and sensor when the air/gas manifold is rotated. -
Page 42: Heat Exchanger
SERVICE AND SPARES ▶ Ensure that burner tabs, as shown in figure 99, fit correctly their 1. Refer to figure 101 and remove the three screws securing the turret respective locations. to the top of the boiler. 2. Turn the upper exhaust connector clockwise to release from the hook. NOTICE: Heat exchanger seal 3. -
Page 43: Access To Boiler Control Components
SERVICE AND SPARES 1. Refer to figure 104 and lift the heat exchanger up to clear. 6.8.12 PCB FUSE 2. Pull the heat exchanger forward from the case. ▶ Remove fuse holder with the fuse F1 (1) from the PCB, change the fuse and replace in the PCB. -
Page 44: Replacing Controls
SERVICE AND SPARES 6.8.14 REPLACING CONTROLS NOTICE: ▶ Do not replace the control unit if a CO/CO analyser is NOT available. The control box is supplied within its plastic housing. The complete unit must be replaced. Refer to figure 109. 1. -
Page 45: Siphon Removal
SERVICE AND SPARES 6.8.15 SIPHON REMOVAL ▶ Remove the diverter valve cover, if fitted. 2. Undo the two screws holding the valve to the plastic housing. Removal of the siphon assembly will give access to the 3. Withdraw the valve and clean the valve chamber if necessary. Auto Air Vent. -
Page 46: Pump Head
SERVICE AND SPARES 6.8.19 PUMP HEAD 6. Remove the pressure sensing head and pressure gauge capillary from the housing. ▶ Ensure the boiler is fully drained). ▶ Disconnect the electrical connection from the bottom of the pump. NOTICE: Heat damage ▶... -
Page 47: Ch Pressure Relief Valve
SERVICE AND SPARES ▶ Undo the screw securing the left hand plastic housing to the heat exchanger. ▶ Move the housing to the left to free up the one end of the pipe. ▶ Remove the pipe from the right hand housing to reveal the bypass valve. - Page 48 SERVICE AND SPARES ▶ Undo connection to boiler at the service valves. Fig. 124 Removing expansion vessel from wall frame ▶ Release the clip from expansion vessel connection to the pump manifold. ▶ Carefully lift the boiler off the mounting frame. 1.
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Page 49: Short Parts List
SERVICE AND SPARES SHORT PARTS LIST Burner Gas Valve 8 716 116 067 0 8 718 120 619 0 8 716 111 325 0 GC No. H26 536 GC No. H26 538 GC No. H26 540 Control board Flue overheat Electrodes (including HT3 BUS enabled thermostat... -
Page 50: Fault Finding And Diagnosis
On completion of the Service/Fault-Finding task which has required the This fault finding information is for guidance only. Worcester cannot be breaking and remaking of electrical connections, check: held responsible for costs incurred by persons not deemed to be (a) EARTH CONTINUITY, competent. -
Page 51: Circuit Diagram
Blue ST17 Yellow Green Black Blue EMS BUS contacts Blue Purple (for FX controls) Purple Orange WORCESTER 24V CONTROLS Orange OPTION, PLUG IN POINT Green (under blanking cover on fascia) Black 230V~ Yellow Yellow Yellow PRE WIRED LINK ST18 DIAGNOSTIC 6720804530-09.2Wo... -
Page 52: Boiler Function
FAULT FINDING AND DIAGNOSIS BOILER FUNCTION Fig. 125 Boiler function 6 720 804 532 (2012/09) -
Page 53: Protection Function
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... - Page 54 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?
- Page 55 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 56 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 6 720 804 532 (2012/09)
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