Summary of Contents for Worcester Greenstar 8000 Life
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Installation and Maintenance Instructions Gas fired condensing combi boiler Greenstar 8000 Life GR8300iW 30 C | GR8300iW 35 C | GR8300iW 40 C | GR8300iW 45 C | GR8300iW 50 C...
Explanation of symbols and safety instructions Explanation of symbols and safety instructions • If you are in any doubt, contact the Worcester, Explanation of symbols Bosch Group help line Warnings (0330 123 3366). In warnings, signal words at the beginning of a warning are used to indicate the type and seriousness of the ensuing risk if measures for •...
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– Advise the user to have the appliance and system substances have been used in the construction serviced annually to help ensure economy, safety process that contravene the COSHH Regulations and reliability. (Control of Substances Hazardous to Health Regulations 1988). Greenstar 8000 Life – 6720883865 (2021/11)
▶ When handling appliances, secure them against a fall. ▶ Let only trained personnel undertake the handling. ▶ The correct method for handling heavy objects should be strictly observed, at all times. Greenstar 8000 Life – 6720883865 (2021/11)
WRAS. The installation must also comply with the requirements of Part G of the Building Regulations. CH Water Salt based artificially softened water must not be used to fill the central heating system. Greenstar 8000 Life – 6720883865 (2021/11)
CE marking. You can ask for a copy of the declaration of conformity for this product. For this see the contact address on the back cover of these instructions. Greenstar 8000 Life – 6720883865 (2021/11)
[28] Drain point [29] Pressure relief valve (heating circuit) [30] Filling Link [31] Control unit Product data for energy consumption The product data on energy consumption can be found in the operating instructions for the user. Greenstar 8000 Life – 6720883865 (2021/11)
However; any appliance fitted with a modulating pump may not require a system bypass. • Drain cocks are required at all the lowest points on the system. • Air vents are required at all high points on the system. Greenstar 8000 Life – 6720883865 (2021/11)
Integral filling link Typical primary system example • An optional filling link accessory is available to fill the system ( section "Integral keyless filling link", page 45). Fig. 6 Single central heating circuit example Appliance Greenstar 8000 Life – 6720883865 (2021/11)
90° elbow or tee and by 0.3m for each 45° bend or straight coupler. and the inlet to each appliance does not exceed 1mbar (NG) 2.5mbar (LPG) ( table 16 ”Allowed mbar pressure drop”). Greenstar 8000 Life – 6720883865 (2021/11)
We recommend that the frost thermostat is sited in the coldest unheated area in which pipework is located and that it is set to call for heat at 5 °C. The Pipe stat should be located on whichever pipe is Greenstar 8000 Life – 6720883865 (2021/11)
• The bottom of the appliance case must be between 1000mm and [2*] Without the end wall, zone 2 must extend 600mm from the bath 1500mm from the floor. 600mm radius from the bath or shower Greenstar 8000 Life – 6720883865 (2021/11)
Below appliance - 200mm Flue systems Possible flue gas escape ▶ Use Worcester, Bosch Group approved Condensfit II flue systems only, no other manufacturer’s flue have been tested or approved for use with Worcester, Bosch Group appliances. Greenstar 8000 Life – 6720883865 (2021/11)
Table 11 Effective length of bends 4.4.2 Flue options Refer to the manual supplied with the Worcester, Bosch Group flue kit for The systems have different maximum flue lengths, refer to the following complete installation instructions. example flue options for those maximum flue lengths.
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• Flue length [L] (adaptor bend included in length calculation) – Maximum flue length as stated in "Horizontal maximum flue lengths" minus 2 x 90° bends equivalent straight flue length as stated in Table 11 "Effective length of bends". Greenstar 8000 Life – 6720883865 (2021/11)
Fig. 25 Vertical flue option • Flue length [L] – Maximum flue length as stated in "Vertical maximum flue lengths" minus 2 x 45° bends equivalent straight flue length as stated in Table 11 "Effective length of bends". Greenstar 8000 Life – 6720883865 (2021/11)
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Pre-Installation 5 0 0 ±80° 0010013548-001 Fig. 27 Terminal exclusion zone NOTICE Cutting the 500mm pipe ▶ The Plume management extension kit contains the components required for such a configuration. Greenstar 8000 Life – 6720883865 (2021/11)
▶ Terminals must be positioned so to avoid combustion products entering the building. Vertical flue terminal positions RIDGE VENT RIDGE FLUE 1500 1500 1500 1500 2000 1500 1200 1500 BOUNDARY LINE BOUNDARIES Fig. 28 Vertical flue terminal positions Greenstar 8000 Life – 6720883865 (2021/11)
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▶ Where a vertical flue terminates in an area that is enclosed on 3 sides, the flue must be no more than 1,000mm below the lowest roof line. You must ensure that all clearances are maintained and that products of combustion disperse safely from the area. Greenstar 8000 Life – 6720883865 (2021/11)
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Horizontal flue terminal positions BOUNDARY LINE DORMER SKYLIGHT OPENING OPPOSITE 2000 1500 1200 1500 1200 1000 BOUNDARY LINE BELOW GROUND OPEN LIGHT WELL <1000 BOUNDARIES 25 100 25 100 0010021442-004 Fig. 29 Horizontal flue terminal positions Greenstar 8000 Life – 6720883865 (2021/11)
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▶ A flue terminal guard shall be fitted whenever a terminal or air inlet is fitted less than 2,000mm above ground, above a balcony or above a flat roof to which people have access. Greenstar 8000 Life – 6720883865 (2021/11)
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. 30 Plume re-direct and plume management terminal positions Greenstar 8000 Life – 6720883865 (2021/11)
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600mm. 1) 600mm in case two plume management kits are used on opposing terminals. Each terminal should use a minimum length of 500mm plume management. Greenstar 8000 Life – 6720883865 (2021/11)
▶ Internal pipe runs in unheated areas such as lofts, basements and garages should be treated as external runs. For additional information refer to “External Connections” section 4.5.4. Greenstar 8000 Life – 6720883865 (2021/11)
▶ Ensure minimum and maximum pump lifting heights are followed as pipe section is as smooth as possible. per condensate pump manufacturers instructions. ▶ All external pipe drainage will be improved if the end is cut at 45° as opposed to a straight cut. Greenstar 8000 Life – 6720883865 (2021/11)
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Insulation recessed into the wall [20] Rain water hopper Condensate discharge pipe [21] Increase pipe size Good Practice ▶ The following guidance indicates the good practices that must be maintained for the Installation and Maintenance of a product. Greenstar 8000 Life – 6720883865 (2021/11)
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Trace heating fitted: • Check with trace heating manufactures instructions for additional Minimum hole size for the condensate soak away must be 400mm deep requirements. by Ø 300mm. Greenstar 8000 Life – 6720883865 (2021/11)
The tundish should be sited in a position where damage to the property or injury to occupants cannot occur from any spillage or discharge. Greenstar 8000 Life – 6720883865 (2021/11)
Flushing the system water cleanser is fitted to the system. Flushing the system using existing appliance/circulating pump or new ▶ Worcester Bosch recommend fitting a filter that will help remove both appliance. magnetite and non-magnetic debris. Worcester offers three filters that help remove both magnetite and non-magnetic debris;...
• All sharp objects must be covered or the blade retracted after use and put away in a safe place. Care should be taken when lifting the appliance from the base and the proper technique for safe lifting of any heavy object should be strictly observed. Greenstar 8000 Life – 6720883865 (2021/11)
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• Ensure that the roof space has permanent fixed lighting, a permanent fixed retractable ladder and a fixed floor area, from the hatch to the appliance installation point. This will allow access for installation, normal use and servicing. Greenstar 8000 Life – 6720883865 (2021/11)
Fig. 41 Wall mounting template – Additional fixing points for the appliance will be indicated on the Side exit flue example wall mounting template. Rear exit flue example Wall mounting template Primary fixing points 87mm Greenstar 8000 Life – 6720883865 (2021/11)
Surplus water may be present inside the appliance due to factory testing. External condensate pipework or internal pipe runs in unheated areas such as lofts, basements and garages exposed to prolonged cold temperatures should be protected ( chapter 4.5). Greenstar 8000 Life – 6720883865 (2021/11)
Do not lift by the top case panel. There are two handling holes incorporated into the inner casing left and right in the lower section of the appliance ( Fig. 42). Greenstar 8000 Life – 6720883865 (2021/11)
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▶ Connect the installation side plastic pipe work to the end of the condensate hose. 0010023577-003 ▶ Push the plastic pipe work inside the condensate hose at least Fig. 48 Fitting the pipe on the (heating) pressure relief valve 25mm. Greenstar 8000 Life – 6720883865 (2021/11)
▶ Cutting the flue to an exact measurement is not required as the flat facing [3] to the rear of the appliance. telescopic flue terminal can allow for some adjustment. The flue turret/adaptor should be pushed straight down, on to the appliance. Greenstar 8000 Life – 6720883865 (2021/11)
DC modulating pump according to IET wiring regulations. ▶ External fuse 3A Amps. ▶ When stripping the wires, ensure copper strands do not fall into the control box. Greenstar 8000 Life – 6720883865 (2021/11)
Table 14 Low voltage (signal cables) terminal strip for external accessories Fig. 62 Low voltage (signal cables) preparation Connecting the automatic filling (accessory) ▶ Flip down the control unit( Fig. 56). ▶ Plug cables to solenoid valve. Cables are not polarity sensitive. Greenstar 8000 Life – 6720883865 (2021/11)
▶ In cases where all attempts to find a system micro leak have failed, Checks before commissioning: Worcester, Bosch Group supports the use of Fernox F4 leak sealer. ▶ Check that the service and water pipes are connected correctly. ▶ Check the gas type specified on the identification plate matches that of the gas supply and that the gas supply is properly purged.
If the display reads more than 1.5 bar as a result of over filling: ▶ Bleed one radiator until the pressure, shown on the display, returns to between 1 and 1.5 bar. Greenstar 8000 Life – 6720883865 (2021/11)
The siphon filling mode is interrupted when the chimney sweep mode is function): press 5 seconds for chimney sweeper mode started. eco key: Hot water preheat selection Hot water key: Adjusting the hot water temperature Heating key: Heating mode on, set the maximum flow temperature Greenstar 8000 Life – 6720883865 (2021/11)
▶ If this is not possible: isolate the appliance on the gas side and notify the gas supplier. ▶ Exit the chimney sweep mode. ▶ Switch off the appliance, close the gas isolator, remove the pressure 0010020558-002 gauge and tighten the screw. Fig. 68 Removing the combustion cover Greenstar 8000 Life – 6720883865 (2021/11)
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29.5–42.5 mbar 0010023572-002 Fig. 72 LPG pressures ≤ 40 kW > 40 kW GR8300iW 30 C GR8300iW 40 C GR8300iW 35 C GR8300iW 45 C GR8300iW 50 C Table 18 Pressure drop LPG Greenstar 8000 Life – 6720883865 (2021/11)
▶ 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 Life – 6720883865 (2021/11)
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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 < 0.004 is required. 0010023581-002 Fig. 73 Commissioning checks flow chart Greenstar 8000 Life – 6720883865 (2021/11)
( chapter 7.2.1, Menu 3 (L.3) Basic settings, Service function 3-b1, ▶ Ensure that the gas inlet pressure has been checked and is page 54). satisfactory. ▶ Refit the test point plugs after the test has been completed. Greenstar 8000 Life – 6720883865 (2021/11)
Registered Gas Installer (RGII). – Present, where relevant, maintenance aids and reminders within the appliance menus. – Arrange an inspection/maintenance contract with an approved 0010023240-002 heating contractor. Fig. 76 Fitting the appliance casing side covers front bottom Greenstar 8000 Life – 6720883865 (2021/11)
▶ To select the desired value, press the or the key. The new value will be saved after 5 s or after pressing the ok key. Exiting the menu item without saving values ▶ Press the d key. The value is not saved. Greenstar 8000 Life – 6720883865 (2021/11)
Coding plug number. 1-E4 Code plug version Coding plug version. 1-EA Software version of the equipment electronics (main version) – 1-Eb Software version of the equipment electronics (ancillary version) – Table 20 Menu 1: Info menus Greenstar 8000 Life – 6720883865 (2021/11)
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70 °C for the duration of • ON 10 minutes, when domestic hot water is extracted. Thermal Disinfection will be completed after 10 minutes or after a domestic hot water extraction of 3 minutes. Greenstar 8000 Life – 6720883865 (2021/11)
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4-A3 3-way valve middle position • OFF The function ensures that the system is fully drained and that the motor can be easily removed. • ON The 3-way valve remains at the centre position for approx. 15 minutes. Greenstar 8000 Life – 6720883865 (2021/11)
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Only available if the solar module is activated. • 1: PWM • 2: 0-10 V 4-C3 Solar module active • OFF Only available if the solar module is detected. • ON 4-d0 Motorised filling valve present • YES/NO Greenstar 8000 Life – 6720883865 (2021/11)
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• 35 ... 60 °C Limits the adjustment range for the hot water temperature. 5-A3 Minimum boiler output (heating and • 10 ... 50% Minimum heat output. DHW) Table 24 Menu 5: Limit values Greenstar 8000 Life – 6720883865 (2021/11)
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Set the desired heating flow temperature. • ON 0-A2 Set temperature for manual mode • 30 …70 °C This service function will only be available, if service function 0-A1 is activated. Table 26 Menu 0: Manual mode Greenstar 8000 Life – 6720883865 (2021/11)
(PRV) and the heating system should be checked for leaks. has been disturbed or replaced, check for gas tightness using a gas sniffer/analyser. ▶ Also after re-assembly, carry out the following checks: Fan pressure. Flue gas analysis. Greenstar 8000 Life – 6720883865 (2021/11)
3. Pull bottom of front cover forwards and upwards to release the clip on 2. Pull bottom panel sidewards to release from service position and top of the boiler and remove outer case. remove. 0010019013-001 Fig. 78 Removing outer case 0010023671-003 Fig. 77 Removing bottom panel Greenstar 8000 Life – 6720883865 (2021/11)
▶ Re-check the fan pressure readings. If the boiler, after completing the above checks, fails the fan pressure test then contact Worcester, Bosch Group for advice. ▶ Replace test point cover after completing pressure check. Check working gas inlet pressure...
▶ Remove the combustion cover ( Fig. 68). causes have been checked, please contact the Worcester Bosch Group ▶ Remove the burner cover. Helpline 0330 123 3366.
Checking the non-return valve in the air-gas manifold 1. Unplug the transformer. 2. Unscrew the screws at the air-gas manifold. 3. Remove the air-gas manifold. 0010023759-001 Fig. 86 Venturi removal 0010017096-003 Fig. 84 Removing the air-gas manifold Greenstar 8000 Life – 6720883865 (2021/11)
▶ Protect the controller from water ingress. 0010023693-001 The heat exchanger does not have to be removed in order to clean. Fig. 89 Cleaning blade The heat exchanger is shown removed from the appliance to illustrate cleaning more clearly. Greenstar 8000 Life – 6720883865 (2021/11)
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▶ Ensure seal is replaced with new seal and is correctly fitted. Fig. 91 Pour water into the heat exchanger ▶ Check the siphon unit is clean before refitting to appliance. On completion of the heat exchanger cleaning and reassembly, perform the fan pressure test. Greenstar 8000 Life – 6720883865 (2021/11)
▶ Clean the condensate trap, and check that the aperture towards the heat exchanger is clear. ▶ Remove the gasket on the top of the condensate trap. ▶ Check the gasket for cracks, deformation or breakage and replace if required. Greenstar 8000 Life – 6720883865 (2021/11)
When the gasket is correctly inserted, the pin is visible in the recess adjusted if found to be out of tolerance and when all other possible and is flush with the top edge of the gasket. causes have been checked, please contact the Worcester Bosch Group Helpline 0330 123 3366. NOTICE Combustion testing ▶...
Fig. 101 Setting the adjustable venturi Security Seal Adjustable venturi ▶ Switch on the appliance. ▶ Remove the plug from the flue gas test port. ▶ Push the flue gas probe centrally into the flue gas test port. Greenstar 8000 Life – 6720883865 (2021/11)
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▶ Exit the chimney sweep mode. ▶ Enter the CO contents in the servicing record ( chapter 12.8, page 92). ▶ Remove the flue gas probe from the flue gas test port and refit the plug. Greenstar 8000 Life – 6720883865 (2021/11)
▶ 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 0010019116-001 invalidate the guarantee (if applicable) and any warranty.
3. Remove the gas pipe. 0010007251-001 Fig. 109 Removing the gas control valve ▶ Install the air/gas ratio control valve in reverse order, and check the gas/air ratio. 0010017782-001 Fig. 107 Removing the gas pipe Greenstar 8000 Life – 6720883865 (2021/11)
▶ Select the service menu 1-b2, current turbine flow rate. ▶ Blow in the flow direction of the turbine. ▶ If nothing appears on the display, replace the turbine. Fig. 113 Removing the 3-way valve Greenstar 8000 Life – 6720883865 (2021/11)
▶ Check the strainer in the cold water pipe for contamination ( Chapter 9.6, page 73). -or- This fault finding information is for guidance only. Worcester cannot be ▶ Remove the plate heat exchanger and replace. held responsible for costs incurred by persons not deemed to be 1.
1. Check the gas supply to the property and check the working pressure on the gas valve inlet. 2. Check the gas-air ratio. 3. Check the ionisation electrode and the harness for damage or contamination. 4. LPG: Sufficient gas in the tank or recently refilled? Greenstar 8000 Life – 6720883865 (2021/11)
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4. Replace the code plug if required. 5. Replace the control unit (PCB). Heat demand lower than energy supplied Not applicable, operating message, is not a fault. Relay test was activated Not applicable, status message. Greenstar 8000 Life – 6720883865 (2021/11)
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1019 Incorrect pump type detected 1. Pump communication failure or wrong pump is fitted (non-ErP). 2. Check the pump communication wire is connected and has continuity. 3. Replace the pump for correct modulating pump. Greenstar 8000 Life – 6720883865 (2021/11)
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1. Restart the appliance to see if the problem re-occurs. 2915 2. If the fault remains after resetting: the burner controller (PCB) is defective. 2916 2920 Fault in flame monitoring Possible PCB fault, no checks available. Greenstar 8000 Life – 6720883865 (2021/11)
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4. CH hydraulic = 1/ON 2957 Boiler electr. system fault 1. Restart the appliance to see if the problem re-occurs. 2. If the fault remains after resetting: the burner controller (PCB) is defective and must be replaced. Greenstar 8000 Life – 6720883865 (2021/11)
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1. Check the continuity down harness for the pressure sensor and replace if required. 2. Check the voltage at the pressure sensor and replace if required. 2972 Mains voltage too low Check the mains voltage on the appliance (L and N). Table 30 Indicators and fault displays Greenstar 8000 Life – 6720883865 (2021/11)
▶ If the system is to be drained, the boiler must be electrically isolated. ▶ Failure to properly maintain the heating system may result in damage to the system and appliance, and may affect the boiler warranty. Greenstar 8000 Life – 6720883865 (2021/11)
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Further gassing. investigation The system should required be cleaned and treated to comply with BS 7593 0010036323-001 Fig. 115 System gassing flow chart Greenstar 8000 Life – 6720883865 (2021/11)
You can find more information here: www.weee.bosch-thermotechnology.com/ Batteries Batteries must not be disposed together with your household waste. Used batteries must be disposed of in local collection systems. Greenstar 8000 Life – 6720883865 (2021/11)
V Frequency Maximum power consumption (running) Maximum power consumption (stand-by) Energy efficiency index (EEI) heating pump ‒ ≤ 0.2 ≤ 0.2 ≤ 0.2 ≤ 0.2 General data Expansion vessel capacity 10.0 10.0 10.0 10.0 Greenstar 8000 Life – 6720883865 (2021/11)
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≤ 40 ≤ 40 ≤ 40 Condensate Maximum condensate rate pH value, approx. ‒ 4.5 – 5.0 4.5 – 5.0 4.5 – 5.0 4.5 – 5.0 Electrical Electrical power supply voltage a.c. V Frequency Greenstar 8000 Life – 6720883865 (2021/11)
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(after 10 min) 10.8 level at min. rated heat output (after 10 min) 10.2 class at range rated output ‒ rating (EN 15502-1) at range rated output mg/kWh ≤ 40 ≤ 40 Greenstar 8000 Life – 6720883865 (2021/11)
(*) in order to achieve the NO values GR8300iW 40 LPG Liquid Petroleum Gas 20038 quoted on page 84. GR8300iW 45 LPG Liquid Petroleum Gas 20039 GR8300iW 50 LPG Liquid Petroleum Gas 20040 Table 38 Code plug Greenstar 8000 Life – 6720883865 (2021/11)
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(*) in order to achieve the NO values be capped at values marked (*) in order to achieve the NO values quoted on page 84. quoted on page 84. Greenstar 8000 Life – 6720883865 (2021/11)
GAS BOILER SYSTEM COMMISSIONING CHECKLIST & WARRANTY VALIDATION RECORD Address: Boiler make and model: Boiler serial number: Commissioned by (PRINT NAME): Gas Safe registration number: Company name: Telephone number: Company email: Company address: Commissioning date: Heating and hot water system complies with the appropriate Building Regulations? Time, temperature control and boiler interlock provided for central heating and hot water Boiler Plus requirements (tick the appropriate box(s)) Weather compensation...
SERVICE & INTERIM BOILER WORK RECORD It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed. Service provider When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the manufacturers’...
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SERVICE & INTERIM BOILER WORK RECORD It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed. Service provider When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the manufacturers’...
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Questions and answers
what gas pressure is required for greenstar 40kw combi
For the Worcester Greenstar 8000 Life 40kW combi:
- Natural Gas:
- Supply pressure: 19–23 mbar
- Appliance inlet pressure: 16.5–20.5 mbar
- LPG:
- Supply pressure: 32–45 mbar
- Appliance inlet pressure: 28–41 mbar
This answer is automatically generated