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INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS
WALL HUNG RSF GAS FIRED CONDENSING BOILER
Greenstar Ri
FOR OPEN VENTED & SEALED CENTRAL HEATING SYSTEMS & INDIRECT MAINS FED DOMESTIC HOT WATER
ErP
UK/IE
These appliances are for use with:
Natural Gas or L.P.G.
(Cat. II 2H 3P type C13, C33 & C53)
Model
Natural Gas
12Ri
ErP
15Ri
ErP
18Ri
ErP
24Ri
ErP
LPG
12Ri
ErP
15Ri
ErP
18Ri
ErP
24Ri
ErP
If you smell gas:
▶ Well away from the building: call the National Gas Emergency
Service on 0800 111 999.
▶ L.P.G. boilers: Call the supplier's number on the side of the gas tank.
GC Number
41-406-41
41-406-43
41-406-45
41-406-47
41-406-42
41-406-44
41-406-46
41-406-48
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Related Manuals for Bosch WORCESTER GREENSTAR Ri ErP Series
Summary of Contents for Bosch WORCESTER GREENSTAR Ri ErP Series
- Page 1 INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS WALL HUNG RSF GAS FIRED CONDENSING BOILER Greenstar Ri FOR OPEN VENTED & SEALED CENTRAL HEATING SYSTEMS & INDIRECT MAINS FED DOMESTIC HOT WATER These appliances are for use with: Natural Gas or L.P.G. (Cat. II 2H 3P type C13, C33 & C53) Model GC Number Natural Gas...
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Page 2: Table Of Contents
CONTENTS CONTENTS KEY TO SYMBOLS AND SAFETY PRECAUTIONS ... . 3 COMMISSIONING ........30 Key to symbols . -
Page 3: Key To Symbols And Safety Precautions
KEY TO SYMBOLS AND SAFETY PRECAUTIONS List entries, first and second levels KEY TO SYMBOLS AND SAFETY • A single component/item PRECAUTIONS • A component/list, made up of multiple parts/items. – Sub component or sublist of main component/list. KEY TO SYMBOLS –... -
Page 4: Safety Precautions
KEY TO SYMBOLS AND SAFETY PRECAUTIONS SAFETY PRECAUTIONS appliance, flue or associated components and systems could invalidate the warranty. The manufacturer accepts no liability arising from any IF YOU SMELL GAS such actions, excluding statutory rights. A gas leak could potentially cause an explosion. If you smell gas, observe Servicing the following rules. -
Page 5: Regulations
REGULATIONS Regulations Installation regulations Current Gas Safety (Installation & Use) Regulations: All gas appliances must be installed by a competent person in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution. The appliance must be installed in accordance with, and comply to, the current: Gas Safety Regulations, IET Regulations, Building Regulations, Building Standards (Scotland) (Consolidation), Building Regulations (Northern Ireland), local water by-laws, Health &... -
Page 6: Appliance Information
APPLIANCE INFORMATION APPLIANCE INFORMATION APPLIANCE 270mm 590mm* 390mm *600mm to top of case front 6720813283-02.1Wo Fig. 1 Appliance CHECK LIST Do not use the pre-formed copper pipes supplied with the boiler for the gas supply. - HARDWARE LITERATURE PACK: Qty. These copper pipes are for water only. -
Page 7: Technical Data
APPLIANCE INFORMATION TECHNICAL DATA DESCRIPTION NATURAL GAS UNIT 12Ri 15Ri 18Ri 24Ri 12Ri 15Ri 18Ri 24Ri Gas flow rate - Max. 10 minutes from lighting Natural Gas G20 m³/h 1.63 1.96 Propane Gas (LPG) kg/h 0.96 1.20 1.44 1.91 Central Heating Max. -
Page 8: Energy Efficiency
APPLIANCE INFORMATION Energy efficiency NATURAL GAS APPLIANCES The following product data satisfy the requirements of the EU Regulations No. 811/2013 and No. 812/2013 supplementing Directive 2010/30/EU. Product data Symbol Unit 7733600074 7733600072 7733600070 7733600068 Product type – – 12Ri ErP NG 15Ri ErP NG 18Ri ErP NG 24Ri ErP NG... - Page 9 APPLIANCE INFORMATION LPG appliances The following product data satisfy the requirements of the EU Regulations No. 811/2013 and No. 812/2013 supplementing Directive 2010/30/EU. Product data Symbol Unit 7733600075 7733600073 7733600071 7733600069 Product type – – 12Ri LPG 15Ri LPG 18Ri LPG 24Ri LPG Condensing boiler –...
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Page 10: Boiler Main Components
APPLIANCE INFORMATION BOILER MAIN COMPONENTS Air/Gas Manifold Power and fault indicator (blue) Sensor - Boiler flow Wiring connections cover Flow pipe Burner indicator (green) Return pipe Boiler ON/OFF switch Removable servicing panel Condensate connection Electrode assembly Syphon / Trap Overheat thermostat Gas inlet connection Silicon tube - Heat Exchanger air vent Mains cable inlet... -
Page 11: Pre-Installation
▶ In cases where all attempts to find a micro leak have The radiator where the room thermostat is sited must be fitted with failed, Worcester, Bosch Group supports the use of lock-shield valves and left open. Fernox F4 leak sealer. - Page 12 PRE-INSTALLATION SEALED PRIMARY SYSTEM: FULLY PUMPED SEALED SYSTEM: The central heating sealed system must be filled using a WRAS approved NOTICE: Artificially softened water must not be used to filling loop or comply with figure 2 for System fill. fill the central heating system. S PLAN LAYOUT •...
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Page 13: Condensate Discharge
PRE-INSTALLATION NEW BUILD SYSTEM LAYOUTS 4.4.1 Appliance siphonic condensate trap The appliance has a large capacity condensate trap reducing the risk of The latest Part L1a regulation for new installations require separate zone condensate discharge freezing up in prolonged cold temperatures. controls for the central heating. -
Page 14: External Connection Considerations
PRE-INSTALLATION Alternatively if the first option is not possible an internal kitchen, NOTICE: Condensate waste bathroom or washing machine waste pipe etc. can be used. ▶ Care should be taken when siting a soak-away to avoid Ensure that the condensate drain pipe is connected “down stream” of obstructing existing services. -
Page 15: Pressure Relief Pipe Work
PRE-INSTALLATION The use of a drain cover (such as those used to prevent blockage by 400mm min. leaves) may offer further protection from wind chill. 25mm min. Pipe drainage will be improved if the end is cut at 45° as opposed to a 500mm min. -
Page 16: Boiler Location And Clearances
PRE-INSTALLATION 930 mm 410 mm + 30 mm above elbow Using 100 mm flue kit 5 mm 1080 mm Using 125 mm flue kit 5 mm 1100 mm 20 mm* 600 mm** 200 mm Fig. 16 Ventilated compartment 6720646608-123.1Wo Fig. 15 Pressure relief pipe work Minimum clearance to removable door Outside wall Minimum clearance required for servicing... -
Page 17: Boiler Clearances- Unventilated Compartments
PRE-INSTALLATION 4.6.4 BOILER CLEARANCES- UNVENTILATED COMPARTMENTS 4.6.6 ROOMS CONTAINING A BATH OR SHOWER NOTICE: Any switch or appliance control using mains The tables below show the options for the minimum space required to electricity must not be within reach of a person using the install and service the boiler inside an unventilated compartment. -
Page 18: Plumbing Manifold
PRE-INSTALLATION PLUMBING MANIFOLD 4.7.1 CONNECTIONS Heating System 22mm compression fittings From left Diameter of Function case edge pipe 22mm compression fittings 55mm 22mm Use the fittings supplied in the Hardware literature pack: Condensate 210mm 22mm Cylinder & CH Flow 285mm 22mm Do not use the pre-formed copper pipes supplied with Cylinder &... -
Page 19: Flue Options
FLUE OPTIONS TELESCOPIC HORIZONTAL FLUE ASSEMBLY WARNING: Flue systems 60/100 mm ▶ Only use Worcester, Bosch approved flue systems, no 350 mm - 570 mm other manufacturer’s flue systems have been approved for use with Worcester appliances. CAUTION: Non accessible flue systems: 130 mm Min ▶... - Page 20 PRE-INSTALLATION High level horizontal flue Vertical balanced flue assembly A = 300 mm B = 500 mm Maximum flue length Maximum flue length (mm) (mm) 60/100 80/125 60/100 80/125 Vertical balanced flue assembly 6,400 15,000 High level horizontal flue 4,600 13,000 Table 26 Table 23...
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Page 21: Flue Terminal Positions
PRE-INSTALLATION Flue terminal positions 1500 VELUX WINDOW 1500 RIDGE FLUE RIDGE VENT 1500 1500 2000 1500 1200 1500 1500 1000 1200 BOUNDARY LINE <1000 BELOW GROUND <1000 OPEN LIGHT WELL EXIT BOUNDARIES BOUNDARY LINE OPPOSITE 2000 OPENING 1000 FIXED OPEN 2000 6720813276-20.1Wo Fig. - Page 22 PRE-INSTALLATION NOTICE: ▶ All measurements are the minimum clearances required. ▶ Terminals must be positioned so to avoid combustion products entering the building. ▶ Support the flue at approximately one metre intervals and at a change of direction, use suitable brackets and fittings: - flue bracket 100mm x 1 - part number: 7 716 191 177 - flue bracket 100mm x 6 - part number: 7 716 191 178 - flue bracket 125mm x 1 - part number: 7 716 191 179...
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Page 23: Plume Management Terminal Positions
PRE-INSTALLATION 4.10 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. 21 Plume terminal positions Maximum and minimum plume management lengths: ▶... -
Page 24: Determine The Plume Management System Length
INSTALLATION 4.10.1 Determine the plume management system length INSTALLATION Note: Measurement M plume length ▶ M must be a minimum of 500mm and must not exceed WARNING: All the previous “Pre-Installation” sections 4,500mm for a 60mm plume management system must be read and the requirements met before starting used with the horizontal Ø... -
Page 25: Wall Mounting Template & Flue Opening
INSTALLATION ▶ Flatten the outer cardboard sleeve and place on the floor behind the 4. Mark from the centre line of the wall template to the wall which the flue boiler. will pass through (4). ▶ Lay the boiler on its back on the cardboard. ▶... -
Page 26: Outer Case Removal
INSTALLATION OUTER CASE REMOVAL BOILER CONNECTION 1. Undo the two captive screws securing boiler casing at the bottom of CAUTION: the appliance. ▶ ISOLATE THE MAINS GAS SUPPLY BEFORE 2. Undo the two screws securing boiler casing at the top of the STARTING ANY WORK AND OBSERVE ALL RELEVANT appliance. -
Page 27: Condensate Connection
INSTALLATION 5.4.1 CONDENSATE CONNECTION Return Flow Never terminate or discharge into any open source, including; sink, bath, shower, bidet, toilet etc. NOTICE: Condensate disposal ▶ Follow the recommendations given in section 4.4 “Condensate pipe work” for all condensate disposal installation. ▶... -
Page 28: Flue Turret/Adaptor Installation
INSTALLATION 6720806944-84.1Wo Fig. 32 Flue turret centre 127mm [W] 195mm ▶ Align the flue turret/vertical adaptor to the appliance flue outlet with flat facing [3] to the rear of the appliance. WALL The flue turret/adaptor should be pushed straight down, on to the appliance. -
Page 29: Electrical Connections
INSTALLATION ELECTRICAL CONNECTIONS CAUTION: Isolate the mains electrical supply before starting any work and observe all relevant safety precautions. The boiler is already wired with a mains supply cable. A spare strain relief block is supplied in case the pre- wired cable is replaced.1 ▶... -
Page 30: Commissioning
COMMISSIONING EXTERNAL WIRING CENTRE System components wired into terminal strip in accordance with system manufacturers instructions. 230V MAINS SUPPLY External Pump 90W max Wiring Centre/Junction Box Fig. 36 External wiring centre Refit electric control panel covers: Fig. 38 Data plate location ▶... -
Page 31: Filling The System
▶ In cases where all attempts to find a micro leak have failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer. WATER TREATMENT PRODUCTS... -
Page 32: Commissioning
COMMISSIONING Switching the appliance ON/OFF: GAS PRESSURE WITHIN THE SYSTEM ▶ Turn on mains power, the power ON indicator (2) illuminates BLUE. Refer to the figures below for natural gas or L.P.G gas pressures. ▶ Turn on any external controls The pressure at the boiler must not be less than the pressure read at the ▶... -
Page 33: Checking The Gas Rate
April 2014 and these values must be recorded on the Benchmark check during commissioning if found to be out of tolerance, list, at the back of this manual. please contact the Worcester, Bosch Group help line 0330 123 3366. Zero the analyser Set boiler to ≥... -
Page 34: Finishing Commissioning
• During the period of this guarantee any components of the appliance which are proven to be faulty or defective in manufacture will be exchanged or repaired free of charge by Bosch Thermotechnology Ltd. • The householder may be asked to prove the date of installation, that Fig. -
Page 35: Service And Spares
SERVICE AND SPARES SERVICE AND SPARES INSPECTION AND SERVICE CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. NOTICE: COMPONENTS. ▶ After replacement of any components always check for gas tightness where relevant and carry out functional checks as described in Commissioning. -
Page 36: Checking Gas Inlet Pressure
SERVICE AND SPARES CHECKING GAS INLET PRESSURE FAN PRESSURE TEST Refer to section 6.5.1 for checking the gas inlet pressure This test is to determine if the heat cell requires NOTICE: cleaning/attention. ▶ Do not continue with the other checks if the correct gas inlet pressure can not be achieved. -
Page 37: Flue Gas Analysis
SERVICE AND SPARES FAN PRESSURE TEST 6720644744-40.1Wo Fig. 55 Sump access Fig. 53 Fan pressure test FLUE GAS ANALYSIS ▶ Remove the cover and connect a digital manometer to the fan pressure test point. COMBUSTION TEST: ▶ The pressure will read negative, refer to the chart in figure 54. Ensure that the gas inlet pressure has been checked and ▶... -
Page 38: Setting The Air/Gas Ratio
SERVICE AND SPARES SETTING THE AIR/GAS RATIO CLEANING THE HEAT EXCHANGER NOTICE: THE SETTING OF THE GAS RATIO MUST BE NOTICE: COMBUSTION TESTING CARRIED OUT BY A COMPETENT PERSON. SETTING OF ▶ Combustion testing must be carried out by a THE GAS RATIO MUST NOT BE ATTEMPTED UNLESS competent person. - Page 39 SERVICE AND SPARES 1. Refer to figure 60 and rotate fan and air/gas manifold assembly 1. Refer to figure 62and remove top baffle. around the top of the heat exchanger until it stops at the lug. 2. Remove lower baffle. ▶...
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Page 40: Syphon Removal And Cleaning
SERVICE AND SPARES CLEANING THE PRIMARY HEAT EXCHANGER 7.7.1 SYPHON REMOVAL AND CLEANING ▶ Refer to figure 64 and access the heat exchanger flue ways by Remove the syphon assembly to clean. inserting the cleaning brush (7 716 192 312) through the top access hole in the casing, removal of panel shown in figure 60. -
Page 41: Replacement Of Parts
SERVICE AND SPARES REPLACEMENT OF PARTS 7.8.2 PRIMARY SENSOR (CH NTC) CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE To gain access to the following components the outer THE MAINS SUPPLIES BEFORE STARTING ANY WORK case has to be removed: AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. -
Page 42: Flue Overheat Thermostat (With Grommet)
SERVICE AND SPARES 7.8.4 FLUE OVERHEAT THERMOSTAT 7.8.5 LOWERING THE BOILER CONTROLS TO THE SERVICE (WITH GROMMET) POSITION: To remove and replace the thermostat either: 1. Remove two screws securing control. ▶ Using a small terminal screwdriver, prise the thermostat and grommet 2. -
Page 43: Gas Valve
SERVICE AND SPARES 7.8.6 GAS VALVE ▶ Remove electrical connector and earth wire the from fan. ▶ Remove wire clip from gas valve outlet then pull gas pipe free from the ▶ Isolate gas supply at boiler gas cock. gas valve (see figure 72). 1. -
Page 44: Air Pressure Switch
SERVICE AND SPARES 7.8.8 AIR PRESSURE SWITCH 7.8.9 FAN ▶ Remove the air/gas manifold from the boiler as described in the NOTICE: Pressure switch previous section. ▶ Ensure that the tube is reconnected to the pressure 1. Remove two screws retaining the fan to the air/gas manifold. switch 2. -
Page 45: Electrode Assembly And Burner
SERVICE AND SPARES 7.8.10 ELECTRODE ASSEMBLY AND BURNER ▶ Locate the edge of the clamping plate [7] under the bracket [4] and fit the retaining plate[1] hand tight ▶ Refer to figure 80 and disconnect spark electrodes and flame sensor ▶... -
Page 46: Heat Exchanger
SERVICE AND SPARES 6720802047-05.1Wo Fig. 82 Clamping plate detail Fig. 85 Upper exhaust assembly 1. Refer to figure 86 and release the clip. 2. Move the lower exhaust connector up ▶ Remove the complete exhaust assembly. Fig. 83 Clamping plate secured 7.8.12 HEAT EXCHANGER ▶... -
Page 47: Syphon Removal
SERVICE AND SPARES 7.8.15 PCB FUSE ▶ Remove fuse holder with fuse F1 (1) from the control and replace with a new fuse. A spare 2A fuse for F1 clipped onto the inside of the cover. Fig. 88 Heat exchanger removal ▶... - Page 48 SERVICE AND SPARES F2, 1.25A fuse 6720813283-04.1Wo Fig. 91 Transformer/PCB/Fuse access ▶ Remove the code plug from the old control board. ▶ Fit the code plug into the new control board. ▶ Re-assemble in reverse order. NOTICE: CODE PLUG ▶ Ensure that the code plug is fitted to the new control. ▶...
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Page 49: Short Parts List
SERVICE AND SPARES SHORT PARTS LIST 8 716 116 067 0 Burner 12 & 15Ri: Gas Valve GC No. H26 536 8 716 116 379 0 12/15/18 & 24Ri GC No. H26 537 8 716 111 325 0 18 & 24Ri: GC No. -
Page 50: Fault Finding And Diagnosis
FAULT FINDING AND DIAGNOSIS FAULT FINDING AND DIAGNOSIS FAULT FINDING This fault finding information is for guidance only. Worcester cannot be held responsible for costs incurred by persons not deemed to be competent. The electronic control system for this boiler incorporates a blue central indicator. This normally confirms the permanent mains supply but, by flashing at different rates during a fault, provides a guide to the cause as listed.This fault finding system assumes that the appliance has been operating normally until the time of failure (i.e. -
Page 51: Internal Wiring Diagram
FAULT FINDING AND DIAGNOSIS 8.1.1 INTERNAL WIRING DIAGRAM FLAME SENSE ELECTRODE OVERHEAT PRESSURE STAT † Fan wiring: SPARK SWITCH ELECTRODES Live = purple FLOW TEMP. Neutral = brown SENSOR (NTC) FLUE OVERHEAT STAT VALVE SAFETY SOLENOID SAFETY SOLENOID Slow T1.25 A fuse SPARK TRANSFORMER ON/OFF... -
Page 52: Boiler Function
FAULT FINDING AND DIAGNOSIS BOILER FUNCTION Fig. 92 Boiler function Greenstar Ri - 6 720 813 283 (2016/07) -
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 56 0330 123 9119 TRAINING: 0330 123 0166 SALES: 0330 123 9669 Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0330 123 9559 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. worcester-bosch.co.uk 6 720 813 283 (2016/07)