Related Manuals for Bosch Worcester Greenstar 8000 Series
Summary of Contents for Bosch Worcester Greenstar 8000 Series
- Page 1 Installation and Maintenance Instructions Gas fired condensing system boiler Greenstar 8000 Style GR8700iW 30 S | GR8700iW 35 S | GR8700iW 30 SB | GR8700iW 35 SB...
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Page 2: Table Of Contents
Table of contents Electrical connection ......36 Table of contents 5.5.1 Installer connections ......36 5.5.2 Cable preparations . -
Page 3: Table Of Contents
Table of contents 8.10.1 Checking and, if required, adjusting the gas/air Explanation of symbols and safety instructions ratio ........63 Explanation of symbols Replacement parts . -
Page 4: General Safety Instructions
Information on safe isolation can be found in the ▶ Worcester Bosch offer flue gas systems which are Health and Safety Executive guidance HSG85. suitable for use with the appliance. It is the – Using test equipment approved to GS38 to... - Page 5 Explanation of symbols and safety instructions H Handover to the user (Control of Substances Hazardous to Health Regulations 1988). When handing over, instruct the user how to operate the heating system and inform the user about its H Combustion and corrosive materials operating conditions.
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Page 6: Regulations
Regulations Irish Standards Regulations The current relevant Irish standards should be followed, including: • ECTI Installation regulations – National rules for electrical installations Current Gas Safety (Installation and Use) Regulations: • IS 813 All gas appliances must be installed by a competent, registered gas –... -
Page 7: Scope Of Delivery
Product Information Scope of delivery Appliance type overview This appliance are for use with: • Natural Gas or L.P.G. (Cat.II 2H3P type C13, C33 & C53) This document refers to the following appliance types: Appliance type Part number Gas Council number GR8700iW 30 S NG 7 738 100 805 41-406-87... -
Page 8: Pipe Work Positions And Flue Outlet
Product Information Pipe work positions and flue outlet Function From left Diameter of pipe case edge 1 Condensate Outlet 58mm 22mm • Rubber push fit connection 2 CH Flow 90mm 22mm • Compression fitting 3 Cylinder Return 155mm 15mm • Compression fitting 4 Gas inlet 220mm 22mm... -
Page 9: Designation Of Components
Product Information Designation of components 0010023657-001 Fig. 3 Product overview System boilers, combustion cover removed KEY accessory housing slot (wireless Gateway) Schrader Valve Condensate trap Data plate 1 Expansion vessel Pressure sensor [10] Heating flow Pressure gauge [11] Air-gas manifold with non-return valve Venturi (sealed) [12] Ignition transformer Greenstar 8000 Style –... -
Page 10: Product Data For Energy Consumption
Product Information [13] Flue [14] Ignition electrodes [15] Flame sensing electrode [16] Flow temperature sensor at flow pipe [17] Heating block temperature limiter [18] Flow temperature sensor at heating block [19] Inspection cover [20] Condensate sump [21] Gas valve [22] Automatic air vent valve (pump) [23] Data plate 2 [24] Diverter valve (accessory) [25] Heating pump... -
Page 11: Pre-Installation
Pre-Installation Hot water: Pre-Installation • Taps and mixing valves must be capable of sustaining a pressure up to 10 bar. NOTICE: • Hot water temperature and flow rate are affected by the size and Risk of damage to system or appliance! insulation of pipe work making up the distribution system and are Before installation controlled by the hot water tap and the water main inlet pressure. -
Page 12: System Layouts Examples
Pre-Installation Checking the size of the expansion vessel Sealed primary system - Cylinder and 2 x central heating zones: To determine whether an additional expansion vessel is required: Follow Typical S-Plan Plus example the steps below: • The cylinder return must be the last connection on the common ▶... -
Page 13: System Fill
Pre-Installation 4.1.4 System fill Filling primary sealed systems NOTICE: Filling the primary sealed system The system must not be filled with salt based softened water. ▶ Ensure the primary water filling point uses an untreated cold water connection from the mains supply, before a water softener. •... -
Page 14: Mains Supply
Pre-Installation Mains supply 4.2.1 Electrical supply Natural Gas: • Supply: 230V AC - 50 Hz ▶ When using this table to estimate the gas flow rate in pipe work of a • This appliance must not be connected to a three phase supply. known length, the effective length will be increased by 0.5m for each •... -
Page 15: Rooms Containing A Bath Or Shower
Pre-Installation 4.3.2 Rooms containing a bath or shower NOTICE: CAUTION: Damage to appliance: Risk of electric shock Contaminated combustion air. ▶ Any switch or appliance control using mains electricity must not be ▶ Do not use any cleaners containing chlorine or hydrogen halide (i.e. within reach of a person using the bath or shower. -
Page 16: Flue Systems Considerations
▶ If this is not possible, bends should be viewable from both directions. Description Dimensions (mm) Appliance width Appliance height Refer to the manual supplied with the Worcester, Bosch Group flue kit for Appliance depth complete installation instructions. Installation/Maintenance Overall clearance height... -
Page 17: Flue Options
Pre-Installation Vertical maximum flue lengths Horizontal fixed length flue assembly Flue length [L] Flue length [L] 1050 mm Output 60/100 80/125 35kW 14,000mm 29,000mm 30kW 21,000mm 25,000mm 330 mm Min Table 10 Maximum flue lengths - Vertical flues Flue system bends NOTICE: Fig. - Page 18 Pre-Installation High level horizontal flue Vertical balanced flue assembly A = 300 mm B = 500 mm Fig. 21 Horizontal flue option • Flue length [L] (initial bend included in length calculation) Fig. 24 Vertical flue option – Maximum flue length as stated in "Horizontal maximum flue •...
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Page 19: Plume Management System
Pre-Installation 4.4.3 Plume management system For every extra 1000mm of plume management after the first 500mm, the internal 60/100 flue length must be reduced by 700mm, up to a maximum of 4500mm of plume management. 2,800 2,100 1,400 [mm] 1,500 2,500 3,500 4,500... - Page 20 Pre-Installation Vertical flue terminal positions RIDGE VENT RIDGE FLUE 1500 1500 1500 1500 2000 1500 1200 1500 BOUNDARY LINE BOUNDARIES Fig. 29 Vertical flue terminal positions Key to figure 29: 400mm measured diagonally from a pitched roof or 500mm in regions with heavy snow fall.
- Page 21 Pre-Installation Horizontal flue terminal positions BOUNDARY LINE DORMA SKYLIGHT OPENING OPPOSITE 2000 1500 1200 1500 1200 1000 BOUNDARY LINE BELOW GROUND OPEN LIGHT WELL <1000 BOUNDARIES 25 100 25 100 0010021442-001 Fig. 30 Horizontal flue terminal positions Key to figure 30: The terminal must be at least 1500mm from the opening or vent when sited below the window or 600mm when sited to either side 200mm below eaves and 75mm below gutters, pipe and drains.
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Page 22: Plume Re-Direct And Plume Management Terminal
Pre-Installation [11] 300mm above, below and either side of an opening door, air vent or opening window. [12] Below ground level in an open lightwell. The flue must be at least 600mm from the opposing surface and have at least 300mm clearance either side and below. - Page 23 Pre-Installation ±45° 180° ≥140 1,500 ≥ 5 ≥ 5 0 0 5 0 0 ±80° ±80° EXCLUSION ZONE EXCLUSION ZONE EXCLUSION ZONE 1500 1200 BOUNDARY LINE OPENING FLUE TERMINAL GUARD OPPOSITE 7 716 191 176 2000 BOUNDARY LINE Fig. 31 Plume re-direct and plume management terminal positions Key to figure 31 - Plume re-direct terminal positions: 300mm adjacent to a boundary line, unless it will cause a nuisance.
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Page 24: Condensate Discharge
Pre-Installation exhaust terminal must be positioned at least 1200mm away from Condensate discharge any opening into the building which is sited within the footprint of the carport. If the exhaust terminal is extended at least 300mm beyond the Full details on condensate discharge. footprint of the carport then the distance from the terminal to an ▶... -
Page 25: Internal Connections
Pre-Installation Condensate pipe work - Unheated internal areas Condensate pump Figure 34 NOTICE: Where direct connection to a “gravity discharge” pipe work is not Unheated internal areas. physically possible, or where very long internal runs would be required to reach a suitable discharge point, condensate should be removed using a Although the large volume siphon will reduce the risk of freezing, proprietary condensate pump, of a specification recommended by the... - Page 26 Pre-Installation NOTICE: Condensate waste disposal ▶ Care should be taken when siting a soak-away to avoid causing damage to existing services If no other discharge method is possible then the use of an externally run condensate drainage pipe terminating at a suitable foul water discharge point, or purpose-designed soak away, may be considered.
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Page 27: Pressure Relief Discharge
Pre-Installation Open drain or gully with external air break 400mm min. Figure 37 25mm min. Where the pipe terminates over an open drain or gully and there is a risk 500mm min. of ground flooding, then the additional requirement below is recommended: •... -
Page 28: Alternative Prv Connections - Combined Prv
▶ The Building Services Compliance Guide recommends that a primary water cleanser is fitted to the system. ▶ Worcester Bosch recommend fitting a filter that will help remove both magnetite and non-magnetic debris. Worcester offers two filters that helps remove both magnetite and non-magnetic debris;... -
Page 29: Flushing The System
▶ In cases where all attempts to find a micro leak have failed, Risk of damage to appliance or accessories. Worcester, Bosch Group supports the use of Fernox F4 leak sealer. ▶ All the previous pre-installation sections must be read and requirements met before starting the appliance or flue installations. - Page 30 Installation Unpacking 0010023424-001 Fig. 40 Unpacking Additional requirements for roof space installations appliance installation point. This will allow access for installation, normal use and servicing. • The unpacked appliance can now be moved into the loft space • Two sets of steps should be used. •...
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Page 31: Position The Appliance
Installation Position the appliance WARNING: Flue turret ▶ Ensure the mains gas supply is isolated before starting any work ▶ The flue turret has an in-built 3° angle giving the flue assembly the rise and follow all relevant safety precautions. from the appliance to ensure the condensate flows back to the appliance. -
Page 32: Appliance Connections
Installation 0010023273-001 Fig. 42 Transport, lifting and handling Preparing the appliance installation NOTICE: Incorrect mounting can cause material damage. If the appliance is mounted incorrectly, it may fall off the wall. ▶ Only install the appliance on a rigid, solid wall. This wall must be able to carry the weight of the appliance and must at least be as large as the bearing surface of the appliance. -
Page 33: Hanging The Appliance
Installation ▶ Apply a smear of silicone lubricant to the seal to ease connection later. 0010023669-001 Fig. 44 Connections on the gas and the water side Heating flow valve Gas isolator Heating return valve Preparing the wallframe ▶ Fit sealing washers to service valves before hanging appliance. 0010023674-001 0010023277-001 Fig. - Page 34 Installation Hanging the appliance Fitting the condensate pipework ▶ Ensure that top and side panels are removed. ▶ Secure the pipe to the wall at the last joint. ▶ Fit the sealing washers to service valves. ▶ Ensure the pipe protrudes through the wall frame by 25mm. ▶...
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Page 35: Flue Turret/Adaptor Installation
Installation Flue turret/adaptor installation ▶ Check the appliance flue seal [2] is correctly seated and apply silicone grease. NOTICE: Flue installation ▶ Refer to the Flue Kit Installation instructions provided with your flue kit to correctly install the flue with this appliance. ▶... -
Page 36: Electrical Connection
Installation Electrical connection 5.5.1 Installer connections Connect external accessories DANGER: ▶ Flip down the control appliance ( Fig. 54). Risk of electric shock! ▶ Open the cover. ▶ Isolate electrical components from the power supply (230 V AC) (fuse, circuit breaker) and secure against unintentional re- connection before carrying out any work. - Page 37 Installation ▶ For splash water protection (IP): cut the strain relief to match the Symbol Function diameter of the cable. Without function Without function Without function Ø Table 13 Power supply (power cables) terminal strip for external Ø 8-9 accessories Ø...
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Page 38: Cable Preparations
Installation 5.5.2 Cable preparations NOTICE: 230V AC Damage to control unit! Small pieces of wire can cause shorts and damage to electronics. ▶ When stripping wires always ensure copper strands do not fall into the control box. Mains voltage (power cables), example figure 58 ▶... -
Page 39: Commissioning
▶ In cases where all attempts to find a system micro leak have failed, ▶ Check the gas type specified on the identification plate matches that Worcester, Bosch Group supports the use of Fernox F4 leak sealer. of the gas supply. -
Page 40: System
Commissioning ▶ Manually vent all radiators, tighten when completed and check the 6.3.1 Control panel overview system for any leaks and correct if required. ▶ Top up the system pressure if the pressure drops below 1 bar. ▶ Isolate and remove filling loop connections to the system. 6.2.2 Adjusting the operating pressure of the heating system Display on the pressure gauge... -
Page 41: Chimney Sweep Mode
Commissioning The next time there is a heat requirement for heating, the appliance is Parameters when optional integral diverter valve kit held at low thermal output for 15 minutes. The siphon filling mode is fitted remains active until the appliance has completed 15 minutes of operation with increased min. -
Page 42: Checking Gas Inlet Pressure
Commissioning Checking gas inlet pressure ▶ Exit the chimney sweep mode. ▶ Switch off the appliance, close the gas isolator, remove the pressure 6.6.1 Checking the gas supply pressure gauge and tighten the screw. ▶ Switch off the appliance and close the gas isolator. ▶... -
Page 43: Checking The Gas Rate
▶ Check and zero the analyser in fresh air as specified by the manufacturer. ▶ The air/gas ratio valve is factory set and must not be adjusted during commissioning unless this action is recommended following contact with the Worcester, Bosch Group help line 0330 123 3366. Greenstar 8000 Style – 6720883855 (2019/01) -
Page 44: Checking Flue Integrity
Check CO and combustion Set boiler to ratio at minimum rate minimum rate. Turn off boiler and Boiler is operating call Worcester, Bosch CO < 350ppm satisfactorily. Group help line. CO/CO ratio No further action 0330 123 3366 <... -
Page 45: Flue Gas Analysis
Commissioning 6.11 Flue gas analysis 6.12 Finishing commissioning NOTICE: 6.12.1 Fitting the combustion casing Combustion testing ▶ Combustion testing must be carried out by a competent qualified person. Testing must not be attempted unless the person carrying out the combustion check is equipped with a calibrated Flue Gas Analyser conforming to BS 7967 and is competent in its use. -
Page 46: Fitting The Appliance Casing
▶ Show the customer how to safely isolate the appliance. ▶ Advise the customer where they can find information on the Worcester, Bosch Group website, www.worcester-bosch.co.uk. ▶ Advise the customer that outside temperatures will affect the output of the appliance, especially the DHW. -
Page 47: 6.12.3 Appliance/Product Guarantee
▶ Press the Hot water key or the Heating key. that are proven to be faulty or defective in manufacture will be -or- exchanged or repaired free of charge if repaired directly by Bosch ▶ Press the d key. Thermotechnology Ltd. -
Page 48: Service Menu
Settings in the service menu Service menu 7.2.1 Overview of the service menu – Standby time Benchmark – Clock inh. T. off – Clock inh. T. on – Actual temp. – Hot water – DHW flow rate – Max. DHW output –... - Page 49 Settings in the service menu – Solar pump type – Start solar system Function check – Activate test – Burner – Ignition – Fan – Pump – Cyl. prim. pump – 3-way valve – HC1 pump – DHW circ. pump –...
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Page 50: Benchmark And Info Menu
Settings in the service menu 7.2.2 Benchmark and Info menu Menu item Comment/restriction Actual temp. Flow temperature in °C DHW flow rate Hot water flow rate in l/min Hot water temp.Outlet temperature in °C Table 17 Benchmark menu Menu item Comment/restriction ... -
Page 51: Settings Menu
Settings in the service menu 7.2.3 Settings menu The menu is adapted to your system automatically. Some menu items are only available if the system has been set up accordingly. The menu items The factory settings are highlighted in the following table. are only displayed in systems in which the corresponding system components are installed, e.g. - Page 52 Settings in the service menu Menu item Settings/adjustment range Comment/restriction Pump Pump range map • Output dependent 0: pump rate proportional ▶ Set low pump curve to save energy and avoid possible to thermal output flow noise ( Chapter 12.5, page 71). •...
- Page 53 Settings in the service menu Menu item Settings/adjustment range Comment/restriction Maintenance Maintenance type • Without Landlord: • Burner run time This menu item allows a date to be set for annual service/ • Boiler run time maintenance (End date). The service display appears as a •...
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Page 54: Function Check Menu
Settings in the service menu 7.2.4 Function check menu Menu item Settings/adjustment range Comment/restriction Activate test Burner • Off...100 % This service function enables testing of the burner. Ignition • On Permanent ignition. • Off Test the ignition with permanent ignition without gas supply. -
Page 55: Inspection And Maintenance
Inspection and maintenance Inspection and maintenance considerations Inspection and maintenance • To ensure continued efficient operation the appliance must be checked at regular interval. DANGER: • The frequency of servicing will depend upon the particular Risk of electric shock! installation conditions and usage, however, normally an annual service is recommended. -
Page 56: Component Access
Inspection and maintenance Component access Removing bottom panel 1. Push in the clip securing the bottom panel. 2. Pull bottom panel sidewards to release from service position and remove. 0010019013-001 Fig. 73 Removing outer case Fan pressure test NOTICE: Fan pressure test ▶... -
Page 57: Check Working Gas Inlet Pressure
If the boiler, after completing the above checks, fails the fan pressure causes have been checked, please contact the Worcester Bosch Group test then contact Worcester, Bosch Group for advice. -
Page 58: Checking The Burner
Inspection and maintenance 8.9.1 Checking the burner 8.9.2 Checking the non-return valve in the air-gas manifold 1. Remove the combustion cover Fig. 62. 1. Unscrew the screws at the air-gas manifold. 2. Unscrew the screws on the burner cover. 2. -
Page 59: Fan Removal
Inspection and maintenance 8.9.3 Fan removal 8.9.4 Cleaning the heat exchanger 1. Undo connection of venturi. Access to the heat exchanger 2. Remove venturi and move pipe to the far right. The following items will have to be removed to gain access to the heat exchanger for cleaning: ▶... - Page 60 Inspection and maintenance ▶ Using the cleaning blade, working from the bottom to the top, to loosen any deposits in the heat exchanger. It is possible to rinse any remaining debris from the heat exchanger either through the access point or alternatively through the top of the heat exchanger when the burner is removed.
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Page 61: Checking Electrodes
Inspection and maintenance ▶ Refit the cleaning access cover assembly in reverse order the new ▶ Check tightness of electrode set. seal [2], and the access cover [1]. ▶ Hand tighten the bolts and then use a spanner to tighten the bolts a further half turn. -
Page 62: Setting The Air/Gas Ratio
▶ The gas valve and venturi are factory set and should not need to be and is flush with the top edge of the gasket. adjusted if found to be out of tolerance and when all other possible causes have been checked, please contact the Worcester Bosch Group Helpline 0330 123 3366. NOTICE: Combustion testing ▶... -
Page 63: Checking And, If Required, Adjusting The Gas/Air
Inspection and maintenance 8.10.1 Checking and, if required, adjusting the gas/air ratio ▶ Switch on the appliance. ▶ Switch off the appliance. ▶ Remove the plug from the flue gas test port. ▶ Remove the front cover. ▶ Push the flue gas probe centrally into the flue gas test port. ▶... -
Page 64: Replacement Parts
▶ Also after re-assembly, carry out the following checks: Fan pressure. Flue gas analysis. Only use Worcester, Bosch Group original spare parts with this appliance. Non Worcester, Bosch Group original spare parts will invalidate the guarantee (if applicable) and any warranty. -
Page 65: Overheat Thermostat Removal
Replacement parts Overheat thermostat removal Pressure relief valve removal ▶ Remove two electrical connectors from thermostat. ▶ Unscrew [1] the sensor [2]. 0010023622-001 ▶ Open the cover Fig. 54. ▶ Remove the condensate trap Fig. 90. ▶ Pull the spring up [1]. ▶... -
Page 66: Checking/Replacing The Motor Of The 3-Way Valve
Replacement parts 1. Unplug the plug. Checking/replacing the motor of the 3-way valve 2. Unscrew the union nut. ▶ Check the motor in the Menu > Function check > Activate test > 3-way valve. ▶ Check/replace the motor of the 3-way valve in the Service menu > Special function >... -
Page 67: Fault Finding And Diagnosis
Fault finding and diagnosis • Ensure the room thermostat is functioning. Fault finding and diagnosis • Ensure the cylinder thermostat (if fitted) is functioning. • Ensure the cold water mains is turned on? • Ensure the primary system has adequate pressure/system content This fault finding information is for guidance only. - Page 68 Fault finding and diagnosis Fault text on the display, description Remedy 306 V Flame signal after closing the fuel supply 1. Replace the air/gas ratio control valve. 2. Replace the ionisation cable. 3. Replace the control unit/burner control unit. 815 B Low loss header temp.
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Page 69: 10.1.3 Faults That Are Not Displayed
Environmental protection and disposal Environmental protection is a fundamental corporate strategy of the Used appliances Bosch Group. Used appliances contain valuable materials that can be recycled. The quality of our products, their economy and environmental safety are The various assemblies can be easily dismantled. Synthetic materials are all of equal importance to us and all environmental protection legislation marked accordingly. -
Page 70: Technical Specifications/Logs
Technical Specifications/Logs To dispose of old electrical or electronic devices, you should use the Batteries must not be disposed together with your household waste. return and collection systems put in place in the country concerned. Used batteries must be disposed of in local collection systems. Technical Specifications/Logs 12.1 Technical data... -
Page 71: Ionisation Current
Technical Specifications/Logs 12.2 Ionisation current When the burner is running at a minimum rated heat Type Gas type Faulty ≥ 3 A < 3 A GR8700iW 30 S Natural gas ≥ 3 A < 3 A ≥ 7 A < 7 A GR8700iW 35 S Natural gas ≥... -
Page 72: Setting Values For Central Heating/Dhw Output
Technical Specifications/Logs 12.6 Setting values for central heating/DHW output (20 mbar) (20 mbar) Gross [kWh/m 11.2 Gross [kWh/m 11.2 S(0 °C) S(0 °C) calorific calorific value value Net calorific [kWh/m Net calorific [kWh/m i(15 °C) i(15 °C) value value Performance Load [kW] Display [%] Gas volume... -
Page 73: Electrical Wiring
Technical Specifications/Logs 12.7 Electrical wiring 230V 230V 11 8 10 16 0010023666-001 Fig. 105 Electrical wiring Pressure sensor Ignition transformer Air/gas ratio control valve Flow temperature sensor at flow pipe [10] Control cable of the heating pump Flow temperature sensor at heating block [11] Heating pump 230 V Flame sensing electrode [12] Connecting lead for KEY slot... - Page 74 Technical Specifications/Logs [15] Terminal strip for external accessories ( terminal assignment Tab. 13) [16] 3-way valve (Accessory) [17] Connecting lead [18] Earth (PE) [19] Earth bar [20] Not used Greenstar 8000 Style – 6720883855 (2019/01)
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Page 75: Gas Boiler System Commissioning Checklist
Technical Specifications/Logs 12.8 Gas boiler system commissioning checklist This Commissioning checklist is to be completed in full by the competent person who commissioned the appliance as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. -
Page 76: Inspection And Maintenance Checklist
Technical Specifications/Logs 12.9 Inspection and maintenance checklist ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ Table 33 Inspection and maintenance checklist Greenstar 8000 Style –... -
Page 77: 12.10 Service Record
Technical Specifications/Logs 12.10 Service record It is recommended that your heating system is serviced annually and that the Service record is completed. Service Provider Before completing the Service record below, please ensure that you have carried out the service as described in the manufacturer’s instructions. Always use the manufacturer’s recommended spare parts. - Page 80 CONTROLS AND CONNECTIVITY TEAM: 0330 123 3641 APPOINTMENTS: 0330 123 9339 SPARES: 0330 123 9779 LITERATURE: 0330 123 9119 TRAINING: 0330 123 0166 SALES: 0330 123 9669 Bosch Thermotechnology Ltd. Cotswold Way, Warndon Worcester WR4 9SW United Kingdom Tel. 0330 123 9559 worcester-bosch.co.uk...