Failure to install correctly could lead to CAUTION prosecution. CAUTION indicates that minor to medium personal injury may occur. • If you are in any doubt, contact the Worcester, Bosch Group help line (0330 123 3366). NOTICE • Distance learning and training courses are available NOTICE indicates that material damage may occur.
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In the Republic of Ireland servicing work must be carried out by a Registered Gas Installer (RGII). Approved spares must be used to help maintain the efficiency, safety and reliability of the appliance. Greenstar 2000 – 6 721 820 552 (2021/02)
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Any misuse or unauthorised modifications to the appliance, flue or associated components and systems could invalidate the warranty. The manufacturer accepts no liability arising from any such actions, excluding statutory rights. Greenstar 2000 – 6 721 820 552 (2021/02)
WRC and hold approval by a notified body, e.g. WRAS. The installation must also comply with the requirements of Part G of the Building Regulations. Greenstar 2000 – 6 721 820 552 (2021/02)
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 2000 – 6 721 820 552 (2021/02)
Comfort+ II RF. Weather compensation is available with the EasyControl without the need for a physical outdoor sensor, however, it can improve control accuracy for installations in isolated micro-climates or highly sheltered locations such as valleys. Greenstar 2000 – 6 721 820 552 (2021/02)
3 metre circuit when activated. • Drain cocks are required at all the lowest points on the system. • Air vents are required at all high points on the system. Greenstar 2000 – 6 721 820 552 (2021/02)
Operational capacity of the expansion vessel (left of the relevant curve) Additional expansion vessel required (right of the relevant curve) Maximum operating temperature [ °C] Total System Volume [l] The default pre-charge pressure for the expansion vessel is 0.75 bar Greenstar 2000 – 6 721 820 552 (2021/02)
Basic pipe sizing calculation Basic pipe sizing calculation. ▶ This method is only a guide - for more complex design please refer to latest version of BS6891 and training given in ACS. Greenstar 2000 – 6 721 820 552 (2021/02)
90° elbow or tee used and by 0.3m for each 45° bend or straight known length, the effective length will be increased by 0.5m for each coupler used. 90° elbow and tee fitted and by 0.3m for each 45° bend. Greenstar 2000 – 6 721 820 552 (2021/02)
• In all cases the installation must be in accordance with the latest appliance. amendments to the latest edition of the IET Wiring Regulations ▶ System frost protection can be achieved when using either Worcester (BS7671). weather-compensating controls or via a hard-wired thermostat when •...
Above appliance - Same clearance required as for standard clearances of 60/100 flue or 80/125mm flue. In front of appliance - Minimum 450mm. Bottom of appliance to the floor - 1,000 - 1,500mm. Below appliance - 200mm Greenstar 2000 – 6 721 820 552 (2021/02)
▶ Inspection hatches should be located at changes of direction. ▶ If this is not possible, bends should be viewable from both directions. Refer to the manual supplied with the Worcester, Bosch Group flue kit for Fig. 13 Reduced front maintenance clearances - Front view complete installation instructions.
• 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 16 "Effective length of bends". Greenstar 2000 – 6 721 820 552 (2021/02)
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• 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 16 "Effective length of bends". Greenstar 2000 – 6 721 820 552 (2021/02)
▶ Terminals must be positioned so to avoid combustion products entering the building. ±80° 0010013548-003 Fig. 26 Terminal exclusion zone NOTICE Cutting the 500mm pipe ▶ The Plume management extension kit contains the components required for such a configuration. Greenstar 2000 – 6 721 820 552 (2021/02)
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400mm measured diagonally from a pitched roof or 500mm in regions with heavy snow fall. 300mm measured vertically from the air intake to the closest intersection with the roof. 1,200mm separation measured between a vertical flue and a horizontal flue terminal. Greenstar 2000 – 6 721 820 552 (2021/02)
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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 2000 – 6 721 820 552 (2021/02)
±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 2000 – 6 721 820 552 (2021/02)
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[14] Clearances no less than 200mm from the lowest point of the balcony or overhang. 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 2000 – 6 721 820 552 (2021/02)
The condensate discharge may freeze in areas during prolonged cold temperatures. ▶ Internal pipe runs in unheated areas such as lofts, basements and garages should be treated as external runs and consideration should be given to using a CondenseSure siphon. Greenstar 2000 – 6 721 820 552 (2021/02)
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Fig. 33 Condensate pump example Condensate discharge from appliance Condensate pump Pipework transition Gravity discharge pipework Proprietary condensate pump ▶ Ensure minimum and maximum pump lifting heights are followed as per condensate pump manufacturers instructions. Greenstar 2000 – 6 721 820 552 (2021/02)
▶ The hole through the wall for the condensate pipe should be sleeved and be sealed to the building fabric on the internal and external face using a suitable building material. Greenstar 2000 – 6 721 820 552 (2021/02)
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• An air break must be installed in the external pipework as shown to avoid an airlock during ground flooding/adverse weather conditions which could prevent the condensate from discharging. Minimum hole size for the condensate soak away must be 400mm deep by Ø 300mm. Greenstar 2000 – 6 721 820 552 (2021/02)
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[21] Increase pipe size Insulation External face sealed Condensate discharge pipe Minimum Standard ▶ The following guidance indicates the minimum standards that must be maintained for the Installation and Maintenance of a product. Greenstar 2000 – 6 721 820 552 (2021/02)
Table 18 water cleanser is fitted to the system. 4.7.1 Flushing the system ▶ Worcester Bosch recommend fitting a filter that will help remove both Flushing the system using existing appliance/circulating pump or new magnetite and non-magnetic debris. appliance. Worcester offers varies filters that helps remove both magnetite and non-magnetic debris;...
Before installing the appliance, ensure that the system has been cleaned. Now remove the front casing and set safely aside. This is to protect the casing from damage during installation. Greenstar 2000 – 6 721 820 552 (2021/02)
▶ Mark centre line of flue to be used; the external diameter of the hole can also be marked if required. ▶ If extensions are to be added then the complete flue must rise at an angle of 3° from the appliance. Greenstar 2000 – 6 721 820 552 (2021/02)
▶ OPTIONAL: Fit the supplied copper CH tails [1]to the CH flow and return 22mm compression connections. – These tails are designed to allow all hydraulic and gas connections to be 30mm from the wall. Fig. 43 CH pipe tails fitting Greenstar 2000 – 6 721 820 552 (2021/02)
90 °C. – Wiring must comply with the latest edition of BS 7671 (IET wiring regulations). ▶ Connect the cable so that the protective conductor is longer than the other wires. Greenstar 2000 – 6 721 820 552 (2021/02)
▶ Guide the cable through the strain relief. ▶ Connect the cable to the terminal block for external accessories. 0010033609-001 ▶ Secure the cable to the strain relief. Fig. 51 Moving control panel into service position Greenstar 2000 – 6 721 820 552 (2021/02)
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Not to be used with 3rd party controls, separated extra low voltage cannot be guaranteed. Communication BUS connection for hard-wired Worcester/Bosch EMS controls. Low voltage power supply for hard-wired Worcester mechanical controls. Greenstar 2000 – 6 721 820 552 (2021/02)
230V mains supply to the appliance. 230V supply from the appliance to the external controls. Heating (()/ zone Switch Live (Demand) from the external controls. External frost protection Live supply and Switch Live (Demand). Greenstar 2000 – 6 721 820 552 (2021/02)
▶ Close the water shut-off valves to the appliance. exchanger. ▶ Label appropriately. ▶ In cases where all attempts to find a system micro leak have failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer. Greenstar 2000 – 6 721 820 552 (2021/02)
If the indicator is below 1 bar when the system is cold: ▶ Top up the water until the indicator is between 1 bar and 1.5 bar again. If pressure is not being maintained: ▶ Check tightness of expansion vessel and heating system. Greenstar 2000 – 6 721 820 552 (2021/02)
Automatic siphon fill mode will begin when the appliance is first powered-up. When the flow temperature and the symbol appear alternately on the display, the siphon filling program is active. 0010016015-004 Fig. 61 Screen display Greenstar 2000 – 6 721 820 552 (2021/02)
▶ To return to comfort mode: press the * key until eco vanishes from the display. ▶ To disable Manual Mode press and hold the ( key for 5 seconds. Greenstar 2000 – 6 721 820 552 (2021/02)
▶ If this is not possible: isolate the device on the gas side and notify the gas supplier. ▶ Exit the chimney sweep mode. ▶ Switch off the device, close the gas isolator, remove the pressure gauge and tighten the screw. ▶ Refit the casing. Greenstar 2000 – 6 721 820 552 (2021/02)
▶ Use an approved gas sniffer or leak detection fluid to check all connections for possible leaks. Leak detection fluid must be certified as a gas leak testing agent. ▶ Do not allow leak detection fluid to come into contact with the electrical components. Greenstar 2000 – 6 721 820 552 (2021/02)
▶ 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. Zero the analyser ≥ 20.6% START...
– Ensure that the probe reaches the centre of the flue gas exhaust, adjust the cone on the probe so that it seals the sample point and correctly positions the end of the probe. ▶ Check the CO and combustion readings. Greenstar 2000 – 6 721 820 552 (2021/02)
▶ Set up the appliance controls and show the customer how to operate all the control unit/s for central heating and DHW operation. – Also show where in the appliance/controls documentation where this information can be found. Greenstar 2000 – 6 721 820 552 (2021/02)
-or- If you want to leave the appliance switched off: The current setting starts to flash. ▶ Mix Worcester-approved anti-freeze into the heating water ( ▶ To change the setting: press arrow key or . "Water treatment products", page 34) and drain the DHW circuit.
This setting defines where the sensor of the low loss header is connected. • 1: (not available) • 2: low loss header connected to the module Table 26 Menu 2: hydraulic settings Greenstar 2000 – 6 721 820 552 (2021/02)
• 1 … 3 … 60 minutes The pump overrun begins at the end of the heat heating mode demand by the heating controller. • 61: 24 hours Table 27 Menu 3: factory settings Greenstar 2000 – 6 721 820 552 (2021/02)
• 20 ... 90 °C This service function is only available if service weather-compensated control function 4-b1 is activated. Set flow temperature for an outside temperature of + 20 °C ( heating curve, page 90). Greenstar 2000 – 6 721 820 552 (2021/02)
Service function Settings/adjustment range Remark/restriction 0-A1 Manual operation • OFF: switched off • ON: switched on 0-A2 Set temperature in manual operation • 30 … 60 ... 82 °C Table 31 Menu 0 Greenstar 2000 – 6 721 820 552 (2021/02)
▶ After replacement of a gas related component, where a gasket or seal 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 2000 – 6 721 820 552 (2021/02)
▶ Re-check the fan pressure readings. If the appliance, after completing the above checks, fails the fan pressure test then contact Worcester, Bosch Group for advice. ▶ Switch the appliance off after completing pressure check. This test is to determine if the heat exchanger requires cleaning or ▶...
After all checks have been completed and the CO is still out of tolerance ▶ Do not attempt the cleaning procedure unless new gaskets and seals then contact Worcester, Bosch Group helpline 0330 123 3366 before are available. making any adjustment to the gas valve.
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▶ Remove M8 nut [3]. ▶ Remove the burner cover [4]. On re-assembly, to ensure a full gas tight seal, tighten the M8 nut down firmly, without over tightening. Fig. 76 Removing the burner Greenstar 2000 – 6 721 820 552 (2021/02)
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▶ Check and adjust if required the gas/air ratio. On completion of the heat exchanger cleaning and reassembly, perform the fan pressure test. Fig. 78 Cleaning the heat exchanger ▶ Clean out residue and re-fit the inspection aperture again. Greenstar 2000 – 6 721 820 552 (2021/02)
▶ Remove and check the gasket for cracks, deformation or breakage and replace if required. 0010021752-001 Fig. 81 Removing the condensate trap 0010017274-001 Fig. 83 Removing the gasket on the top of the condensate trap Greenstar 2000 – 6 721 820 552 (2021/02)
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▶ Fill the condensate trap with approximately 150 ml water. 0010019159-001 Fig. 85 Pressing on the gasket ▶ Replace the condensate trap and check for tightness. ▶ Check the condensate hose and clean if required. Greenstar 2000 – 6 721 820 552 (2021/02)
▶ Enter the CO contents in the servicing record. found to be out of tolerance and when all other possible causes have been checked, please contact the Worcester Bosch Group helpline Adjusting the maximum rated output settings(LPG appliances) 0330 123 3366.
Fan pressure. collect any water. 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. ▶ A comprehensive list of appliance spares can be found on the website www.worcester-bosch.co.uk/spares...
▶ Top up the water until the indicator is between 1 bar and 1.5 bar again. If pressure is not being maintained: ▶ Check tightness of expansion vessel and heating system. 0010006636-002 Fig. 92 Checking the strainer in the cold water pipe Greenstar 2000 – 6 721 820 552 (2021/02)
2. Pull out the automatic air vent valve. 0010015949-001 0010006638-003 Fig. 95 Removing the gas valve Fig. 97 Removing the automatic air vent valve ▶ Install the gas valve in reverse order, and check the gas/air ratio. Greenstar 2000 – 6 721 820 552 (2021/02)
Fig. 103 Replacing the Control box housing with PCB Fig. 101 Replacing the control unit ▶ Open the cover [1] on the enclosure of the appliance electronics. ▶ Insert the code plug [2]. 0010033726-001 Fig. 102 Inserting the code plug Greenstar 2000 – 6 721 820 552 (2021/02)
▶ Align the side panel so that the underside can be guided along the flange. ▶ Push the side panel towards the rear. ▶ Tighten the fixing screws. 0010019239-001 Fig. 104 Attaching the side panel Greenstar 2000 – 6 721 820 552 (2021/02)
Blocking faults result in the heating system being shut down temporarily. The heating system restarts automatically as soon as the blocking fault is This fault finding information is for guidance only. Worcester cannot be removed. held responsible for costs incurred by persons not deemed to be competent.
▶ Check the gas supply to the property and check the working pressure on the gas valve inlet. ▶ Check the gas-air ratio. ▶ Check the ionisation electrode and the harness for damage or contamination. ▶ LPG: Sufficient gas in the tank or recently refilled? Greenstar 2000 – 6 721 820 552 (2021/02)
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▶ Replace the control unit (PCB). – System fault boiler electronics / basic ▶ Reset burner control - factory reset. controller ▶ Check electrical connections of burner control. ▶ Replace burner control. Greenstar 2000 – 6 721 820 552 (2021/02)
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▶ Check the electrical connections on board (check for loose wires etc.). ▶ Check the code plug, if present, is not damaged. ▶ Replace the code plug, if present and required. ▶ Replace the control unit (PCB). Greenstar 2000 – 6 721 820 552 (2021/02)
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Device may not start temporarily, never been off for 20 min for 24 h. – Test volatile lockout Overpressure setting is detected. 356 B Power supply for the boiler is too low ▶ Establish supply voltage of at least 196 VAC. Greenstar 2000 – 6 721 820 552 (2021/02)
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▶ Replace the control unit and/or burner control unit. 1018 W Maintenance interval expired ▶ Check the maintenance date set in the menu. ▶ Reset the maintenance code via the reset menu. Greenstar 2000 – 6 721 820 552 (2021/02)
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Fault in flue system ▶ Check the flue for obstructions and remove any found. ▶ Check the flue integrity test. ▶ Check for water in the sump and check the siphon operation. Greenstar 2000 – 6 721 820 552 (2021/02)
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▶ Check the resistance of the gas valve coils. ▶ Check the continuity of harness and replace if required. ▶ The gas valve or the PCB may have a fault. Greenstar 2000 – 6 721 820 552 (2021/02)
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▶ Check the CO settings and adjust. ▶ Check the burner and the heat exchanger gaskets and the inner flue gaskets. ▶ Check the gas pressure during burning at full load (working pressure, dropping low). Greenstar 2000 – 6 721 820 552 (2021/02)
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▶ Check the heat exchanger sensor (primary thermistor) and the plug connected to the temperature sensor. ▶ Check the resistance of the temperature sensor and replace if required. ▶ Check the continuity of the harness and replace if required. Greenstar 2000 – 6 721 820 552 (2021/02)
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▶ Check the EMS connection cable for the remote control for damage. The BUS voltage on the remote control must be between 12 and 15 V DC. ▶ The remote control is defective. Table 36 Indicators and fault displays Greenstar 2000 – 6 721 820 552 (2021/02)
• Pump is not connected to mains ▶ Check cable connection and supply supply to pump. • Faulty LED ▶ Check if pump is running. • Faulty electronics ▶ Replace pump. Table 37 Pump operation and diagnosis Greenstar 2000 – 6 721 820 552 (2021/02)
No function, the display remains dark. ▶ Check the electrical wiring for damage. ▶ Replace defective cables. ▶ Check the fuse, replace if required. Table 38 Faults that are not shown on the display Greenstar 2000 – 6 721 820 552 (2021/02)
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 2000 – 6 721 820 552 (2021/02)
Electrical Electrical power supply voltage a.c. V Frequency Maximum power consumption (running) 90/110 Maximum power consumption (stand-by) Energy efficiency index (EEI) heating pump ≤ 0.2 ≤ 0.2 ≤ 0.2 Greenstar 2000 – 6 721 820 552 (2021/02)
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3) Appliances are fitted with a flow regulator set to achieve a 35°C temperature rise. A 40°C temperature rise is possible at lower flow rates. 4) Protection rating may change depending on the control unit/s used on this appliance. Table 39 Technical data Greenstar 2000 NG Greenstar 2000 – 6 721 820 552 (2021/02)
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Maximum condensate rate pH value, approx. Electrical Electrical power supply voltage a.c. V Frequency Maximum power consumption (running) Maximum power consumption (stand-by) Energy efficiency index (EEI) heating pump ≤ 0.2 ≤ 0.2 Greenstar 2000 – 6 721 820 552 (2021/02)
Base point (at the outside temperature + 20 °C) max Maximum flow temperature Flow temperature at the end point of the heating curve Flow temperature at the foot point of the heating curve Automatic heating switch-off (summer mode) Supply temperature Greenstar 2000 – 6 721 820 552 (2021/02)
[19] Low voltage I/Os for controls Diverter valve [20] Code plug interface - Not used Exhaust gas temperature limiter [21] 230V external controls interface Gas valve [10] Flow temperature sensor [11] Fan Greenstar 2000 – 6 721 820 552 (2021/02)
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’...
6 (1) sentence 1 (f) GDPR. To exercise your rights, please contact us via privacy.ttgb@bosch.com To find further information, please follow the QR-Code. Greenstar 2000 – 6 721 820 552 (2021/02)