Related Manuals for Worcester Greenstar 1000 GR1000W 24 C NG
Summary of Contents for Worcester Greenstar 1000 GR1000W 24 C NG
- Page 1 Installation and Maintenance Instructions Gas-fired condensing combi appliance Greenstar 1000 GR1000W 24 C NG | GR1000W 30 C NG...
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Page 2: Table Of Contents
Table of contents Table of contents Installation ......... 32 Explanation of symbols and safety instructions . - Page 3 Table of contents Inspection and maintenance......53 11 Fault finding and diagnosis......86 Inspection and maintenance considerations .
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Page 4: Explanation Of Symbols And Safety Instructions
Gas Safe registered engineer including a British occur. Gas engineer. Failure to install correctly could lead to prosecution. • If you are in any doubt, contact the Worcester, Bosch Group help line (0330 123 3366). WARNING •... - Page 5 ▶ Refer to the manufacturer’s information when installing non Fitting the appliance and any controls to the appliance may only be Worcester components and systems to the Worcester appliance. carried out by a competent engineer in accordance with the current Gas HHandover to the user Safety (Installation and Use) Regulations.
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Page 6: Regulations
Regulations Regulations Installation regulations British Standards Current Gas Safety (Installation and Use) Regulations: Where no specific instruction is given, reference should be made to the relevant British Standard codes of Practice. All gas appliances must be installed by a competent, registered gas •... -
Page 7: Product Information
Product Information Product Information Scope of delivery Appliance features • Stainless steel heat exchanger. • NOx emissions 35mg/kWh. • Direct burner ignition. • Zero pressure governor gas valve with fully modulating fan. • Display for appliance status and access to diagnostics, system and commissioning parameters. -
Page 8: Product Identification
Product Information Product identification Function From left Diameter of pipe case edge Data plate 1 Condensate Outlet 27mm 22mm The data plate contains performance data, approval data and the serial number of the product. • Rubber push fit connection The position of the data plate can be found in the product overview in this 2 CH Flow 72mm 22mm... -
Page 9: Product Overview
Product Information Product overview 0010042668-002 Fig. 3 Product overview Greenstar 1000 – 6721835943 (2023/08) -
Page 10: Product Data For Energy Consumption
Greenstar System filter (28mm) [18] Air vent adaptor 7 733 600 476 Greenstar System filter brass (22mm) [19] Pipe pool 7 716 192 746 Worcester CondenseSure [20] Pump 7 736 902 627 Accessory Pipe Kit [21] Diverter valve [22] Pressure gauge housing... -
Page 11: Pre-Installation
Pre-Installation Pre-Installation • Drain cocks are required at all the lowest points on the system. NOTICE • Air vents are required at all high points on the system. Risk of damage to system or appliance! Showers/Bidets: Before installation • If a shower head can be immersed in water or comes closer than ▶... -
Page 12: System Layouts Examples
Pre-Installation ▶ Determine the pre-charge in the expansion vessel based on static 4.1.3 System layouts examples head, 1 metre = 0.1 bar. Sealed primary system - Single central heating circuit: – Static head should be measured between the expansion vessel Typical primary system example and the highest point on the system (top of the highest radiator). -
Page 13: Mains Supply
Pre-Installation Basic pipe sizing calculation The pressure shown on the gauge may differ from that shown on the digital display. Final system pressure adjustments must be made whilst Basic pipe sizing calculation. referencing the digital display. ▶ This method is only a guide - for more complex design please refer to latest version of BS6891 and training given in ACS. -
Page 14: Appliance Location And Clearances
Mini expansion vessel location appliance. Mains water inlet pipe ▶ System frost protection can be achieved when using either Worcester Non-return valve weather-compensating controls or via a hard-wired thermostat when Mini expansion vessel - part no. 7 716 192 105 using external 230 V controls (refer to figure 62, page 41). -
Page 15: Rooms Containing A Bath Or Shower
Pre-Installation 4.3.2 Rooms containing a bath or shower CAUTION Risk of electric shock ▶ Any switch or appliance control using mains electricity must not be within reach of a person using the bath or shower. • In all cases the installation must be in accordance with the latest amendments to the latest edition of the IET Wiring Regulations (BS7671). - Page 16 Pre-Installation • There must be at least 300mm clear space to either the left hand or right hand side of the appliance. This clear space must be from the required clear height above the appliance to floor level. – This clearance will not apply if the appliance is sited within 300mm of a door way and the door frame is the only obstruction.
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Page 17: Flue Systems Considerations
Effective flue length 60/100 80/125 Table 15 Effective length of SimpleSwitch flue adaptor Refer to the manual supplied with the Worcester, Bosch Group flue kit for complete installation instructions. 4.4.2 Flue options The systems have different maximum flue lengths, refer to the following Flue kit part numbers example flue options for those maximum flue lengths. - Page 18 Pre-Installation Telescopic horizontal flue assembly [A] Horizontal flue with two additional 90° elbows • Flue length [L] (adaptor bend included in length calculation) – 60/100 = 350 - 570mm – 80/125 = 405 - 600mm Extended telescopic horizontal flue assembly [B] •...
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Page 19: Plume Management System
Pre-Installation High level horizontal flue with two additional 90° elbows Vertical balanced flue with 90° elbow offset 0010043004-001 Fig. 22 Horizontal flue option A = 300 mm B = 500 mm • Flue length [L] (initial bend included in length calculation) –... -
Page 20: Flue Terminal Positions
Pre-Installation Plume management bends WARNING NOTICE Minimum plume management length: Effective plume management lengths of bends: The minimum distance of 500mm must be maintained between air inlet and exhaust outlet. Each bend used has an equivalent straight plume management length. ▶... - Page 21 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 22 Pre-Installation 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. 30 Horizontal flue terminal positions Greenstar 1000 – 6721835943 (2023/08)
- Page 23 Pre-Installation Key to figure 30: 200mm below eaves and 75mm below gutters, pipe and drains. The dimension below eaves, gutters, pipes and drains can be reduced to 25mm, as long as the flue terminal is extended by 100mm past any overhang. The telescopic flue joint must be sealed with suitable silicone sealant if it is external to the building.
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Page 24: Plume Re-Direct And Plume Management Terminal Positions
Pre-Installation 4.4.5 Plume re-direct and plume management terminal positions NOTICE ▶ All measurements are the minimum clearances required. Maximum and minimum plume management lengths: ▶ Refer to “Horizontal flue terminal positions” for all concentric flue ▶ A minimum distance of 500mm must be maintained between the terminal positions unless the flue position is specified in plume management outlet and the flue air intake. -
Page 25: Condensate Discharge
Pre-Installation Key to figure 31 footprint of the carport then the distance from the terminal to an opening within the carport can be reduced to 600mm. - Plume re-direct terminal positions: The exhaust terminal can also be routed though the roof of the carport providing 25mm clearance is provided around the flue This feature allows some basic plume re-direction options on a pipe to any flammable material and that it extends at least 300mm... -
Page 26: Condensate Pipework
Pre-Installation Also: 4.5.3 Internal connections • Assessment of the risk of the condensate pipe freezing must be carried out and appropriate precautions taken where necessary. This must take into account the specific site conditions. Good Practice • The condensate pipe work connected to the condensate drain outlet ▶... -
Page 27: External Connections
Pre-Installation Condensate pump NOTICE Figure 34 Grey water recovery system Where direct connection to “gravity discharge” pipework is not physically possible, or where very long internal runs would be required to Contamination of recovered water reach a suitable discharge point, condensate should be removed using a ▶... - Page 28 Pre-Installation Additional protection for transition through a wall. Rain water down pipe with external air break Figure 36 The external pipework can be insulated to help prevent freezing during prolonged cold periods. • Refer to following example to dispose of condensate to a rain water •...
- Page 29 Pre-Installation Open drain or gully with external air break Figure 37 Where the pipe terminates over an open drain or gully and there is a risk of ground flooding, then the additional requirement below is 400mm min. recommended: 25mm min. •...
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Page 30: Pressure Relief Discharge
Pre-Installation Condensate pump or CondenseSure fitted to the appliance: • Installations with increased risk of freezing due to environmental factors: – Insulating the condensate pipework through the external wall [2] must be carried out. – The hole through the wall must be sealed to the building fabric on the internal [1] and external [3] face using a suitable building material. -
Page 31: Cleaning Primary Systems
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 varies filters that helps remove both magnetite and non-magnetic debris;... -
Page 32: Installation
Installation Installation NOTICE Risk of damage to appliance or accessories. ▶ All the previous pre-installation sections must be read and requirements met before starting the appliance or flue installations. CAUTION Risk of injury through incorrect lifting and carrying! ▶ Only lift a manageable weight, or ask for help. ▶... -
Page 33: Position The Appliance
Installation Position the appliance HRisk of explosion from escaping gas! Product clearances: Escaping gas can cause an explosion. ▶ Minimum clearances must be maintained around the product. ▶ Ensure the mains gas supply is isolated before starting any work and follow all relevant safety precautions. -
Page 34: Appliance Connections
Installation Rear flue outlet [2]. ▶ 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°... -
Page 35: Hanging The Appliance
Installation Connection sets fitting Installing pipework Installing the connection sets DANGER Contaminated heating water can damage the appliance! Residue in the pipe work can damage the appliance. Connection set fitting ▶ Flush the pipe work before installing the appliance. ▶ For ease of installation the connection sets can be connected before the appliance is mounted on the wall bracket. -
Page 36: Flue Turret/Adaptor Installation
Installation Connect PRV discharge pipe Flue turret/adaptor installation NOTICE It is recommended to fit the PRV pipework after isolation valves are Flue installation fitted; to provide more tool access for compression fittings ▶ Refer to the Flue Kit Installation instructions provided with your flue (... -
Page 37: Electrical Connection
Installation Vertical adaptor [B] fitting ▶ Align the vertical adaptor [B] to the appliance flue outlet with flat facing [3] to the rear of the appliance. Electrical considerations: – This should be pushed straight down, on to the appliance. ▶ All electrical work must be carried out by a competent and authorised ▶... - Page 38 Installation Mains cable routing ▶ Mains supply cable must be routed through either of the rubber grommets in the frame assembly at the left-hand rear of the appliance Figure 50. 0010042680-001 Fig. 52 Cable gland parts Locking nut Body Sealing grommet Sealing nut NOTICE...
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Page 39: Installer Connections
Installation Connect external accessories Low Voltage (signal cable) accessories connections. ▶ Release the latches (1) by using fingers. Arrows on the service cover indicate the position where the fingers must be inserted to release the latches. ▶ Open the service cover by rotating lifting upwards (2). 0010042682-001 Fig. -
Page 40: Cable Preparations
Symbol Function ▶ Release the latches [1] and remove cover. Outside temperature sensor. Communication BUS connection for hard-wired Worcester/Bosch EMS controls. Control unit 230V power supply connection Fuse Fuse 0010042683-001 Table 20 Terminal strip for external accessories (Control unit) Fig. -
Page 41: External Controls - Domestic Installations
Worcester weather-compensating controls have built-in external regulations and guidelines (e.g. UK standards advice found in BS frost protection functionality ( Worcester controller Instructions 6891). manual). ▶ Check the gas type specified on the identification plate matches that of the gas supply and that the gas supply is properly purged. -
Page 42: Filling The Appliance And Adding Inhibitor
Commissioning system pressure [bar] CH Flow Temperature [ °C] The inhibitor or combined inhibitor/anti-freeze must not cause damage to the materials within the appliance (plastic, rubbers, mild steel, stainless steel, copper and brass) and any other materials/components within the system. ▶... -
Page 43: Screen Display
Commissioning 6.3.2 Screen display 6.3.4 Setting the flow temperature The maximum flow temperature can be adjusted between 30 °C and 82 °C. The current flow temperature is shown on the display. ▶ Press the ( key. The set maximum flow temperature is displayed. ▶... -
Page 44: Setting Summer Mode
Commissioning 6.3.7 Setting summer mode 6.4.1 Setting the appliance to maximum ▶ Press C for at least 5 seconds. The pump and consequently the heating are switched off in summer mode. The DHW supply and also the power supply for heating controls –... -
Page 45: Checking The Gas Rate
▶ The air/gas ratio valve is factory set and must not be adjusted during Pressure loss across the appliance commissioning unless this action is recommended following contact Pressure reading at inlet test point with the Worcester, Bosch Group help line 0330 123 3366. Greenstar 1000 – 6721835943 (2023/08) -
Page 46: 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 47: Finishing Commissioning
▶ 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. ▶ Ensure that all documentation, is left with the appliance or homeowner. -
Page 48: Appliance/Product Guarantee
-or- If you want to leave the appliance switched off: Handover tool ▶ Mix Worcester-approved anti-freeze into the heating water ( "Water treatment products", page 31) and drain the DHW circuit. To assist your customer with the handover of the boiler, including how to use its key features, please scan this QR code. -
Page 49: Settings In The Service Menu
Settings in the service menu Settings in the service menu Many appliance functions can be set and checked in the service menu. It -or- includes: ▶ Press the d key. • Info: viewing information Navigating through the menu • Settings: general and appliance-specific settings ▶... -
Page 50: Menu 3
Settings in the service menu 8.2.2 Menu 3 ▶ Press ( and * at the same time until L.1 appears. ▶ Press until L.3 is displayed. ▶ To confirm the selection: press OK key. The basic settings are depicted as highlighted in the following table. Service function Settings/adjustment range Remark/restriction... -
Page 51: Menu 4
Settings in the service menu 8.2.3 Menu 4 ▶ Press ( and * at the same time until L.1 appears. ▶ Press until L.4 is displayed. The factory settings are highlighted in the following table. ▶ To confirm the selection: press ok. Service function Settings/adjustment range Remark/restriction... -
Page 52: Menu 5
Settings in the service menu Service function Settings/adjustment range Remark/restriction 4-b5 Device frost protection • OFF: switched off This service function is only available if service function 4-b1 is activated. • ON: switched on The device frost protection function switches the burner and heating pump on when the outside temperature falls below 5 °C. -
Page 53: Inspection And Maintenance
Inspection and maintenance Inspection and maintenance Inspection and maintenance considerations DANGER • To ensure continued efficient operation the appliance must be Risk of electric shock! checked at regular intervals. • The frequency of servicing will depend upon the particular ▶ Isolate electrical components from the power supply (230 V AC) installation conditions and usage, however, at least an annual service (fuse, circuit breaker) and secure against unintentional re- is recommended. -
Page 54: Check Working Gas Inlet Pressure
After all checks have been completed and the CO is still out of tolerance NOTICE then contact Worcester, Bosch Group helpline 0330 123 3366 before Gas inlet pressure making any adjustment to the gas valve. ▶ Do not continue with the other checks if the correct gas inlet pressure can not be achieved at maximum output. -
Page 55: Checking The Electrodes And Cleaning The Heat Exchanger
Inspection and maintenance 9.7.1 Checking the electrodes and cleaning the heat exchanger Refer to figure 74. ▶ Disconnect the ignition cable [1] from the electrode set. CAUTION ▶ Disconnect the gas hose [2] from the Venturi. Risk of burns due to hot surfaces! Individual components of the appliance can become very hot even after being shut down for a long time. - Page 56 Inspection and maintenance Refer to figure 76. Refer to figure 78. ▶ Take out the burner door assembly and subcomponents together. During the following cleaning operations, precautions should be taken in order not to damage the insulation, ▶ An optional kit with protective plate and a soft brush is available. Part number: 7736702369 ▶...
- Page 57 Inspection and maintenance Refer to figure 79. Refer to figure 79. ▶ Vacuum [1] the combustion residues. ▶ Vacuum [1] the remaining residues. Refer to figure 81. ▶ Rinse the heat exchanger bottom with mains water [1]. ▶ Do not use chemicals for cleaning. 0010045711-001 Fig.
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Page 58: Cleaning/Checking The Burner
Inspection and maintenance ▶ Check the heat exchanger insulation [2] for cracks, defects on heat Cleaning the condensate trap exchanger and replace if necessary according to Chapter 10.6, WARNING page 10.6. Danger to life due to poisoning! If the condensate trap is not filled, poisonous flue gas can escape. ▶... -
Page 59: Checking The Ionization And Ignition Electrode
▶ The air/gas ratio is factory set and should not need to be adjusted. If found to be out of tolerance and when all other possible causes have been checked, please contact the Worcester Bosch Group helpline 0010043106-001 0330 123 3366. -
Page 60: Cleaning The Rainguard
Inspection and maintenance Adjusting the minimum rated output settings ▶ Remove the water drain hose [1] from the rainguard. With the appliance in minimum rated output. ▶ Remove the seal from the adjusting screw of the gas valve and set the content for minimum rated output. -
Page 61: Checking The Expansion Vessel
Inspection and maintenance Cleaning the rainguard ▶ Tighten three screws [1] but do not over-tighten them. 0010046068-001 0010046069-001 Fig. 92 Cleaning the rainguard Fig. 94 Assembly of the water drain hose Inner surface Water drain hose Sheet metal nuts ▶ Assemble the water drain hose [1] into the outlet of the rainguard. Drain hole 9.14 Checking the expansion vessel... -
Page 62: Replacement Parts
▶ Also after re-assembly, carry out the following check: 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 63: Disassembly Of The Ignition Electrode On The Burner Door
Replacement parts 10.4 Disassembly of the ignition electrode on the burner door Removing the ignition electrode 0010045749-001 Fig. 98 Add silicone adhesive and place the new insulation ▶ Make sure the burner is in good condition. If necessary, replace according to Chapter 10.19, page 10.19. 0010045762-001 ▶... -
Page 64: Replace Insulation Disk On The Heat Exchanger
Replacement parts ▶ Replace a new lip seal in its groove. ▶ Make a square cuttıng around the stainless steel central insert so that the quarters come lose. ▶ Respect the mounting direction. ▶ Reassemble the burner door (Chapter 10.30, page 84). ▶... -
Page 65: Replace The Burner Door Seal
Replacement parts Mount the new insulation disk 0010045838-001 A-B=<30ºC Fig. 106 Front and back side of insulation Front side of insulation Back side of insulation The insulation disk is delivered ready to mount packed in a shrink wrap. Don’t remove this wrap! 0010051825-001 Fig. - Page 66 Replacement parts 0010045874-001 0010045876-001 Fig. 110 Disassembly of the screws Fig. 112 Remove the seal Screws Burner door seal ▶ Take out two screws [1] by the screw driver (Torx T20) and support ▶ Remove old burner door seal [1] and replace it with a new one. the fan-gas air pipe by hand.
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Page 67: Replace The Back Flow Prevention Valve
Replacement parts 10.8 Replace the back flow prevention valve When replacing the back flow prevention valve, the correct assembly of the burner door seal must be checked. ▶ Replace the burner door seal (Chapter 10.7, page 65). 0010045893-001 Fig. 116 Position of the back flow prevention valve on the fan Back flow prevention valve ▶... -
Page 68: Replace The Gas Hose
Replacement parts Assemble the gas air pipe to the burner door 0010045909-001 0010045877-001 Fig. 120 Assembly of the gas hose Fig. 118 Assembly of the gas air pipe to the burner door ▶ Push the new gas hose to the venturi and align the guide feature. Screws ▶... -
Page 69: Replace The Gas Valve
Replacement parts 0010045915-001 0010045917-001 Fig. 122 Assembly of the Fan Fig. 124 Disassembly of the gas valve Fan seal Inlet connection nut Screws ▶ Place the fan seal [1] into the fan. ▶ Push the venturi towards the fan. ▶ Rotate the inlet connection nut [1] counter-clockwise to remove the gas connection. -
Page 70: Replace The Temperature Limiter
Replacement parts 10.12 Replace the temperature limiter 0010045922-001 0010045927-002 Fig. 126 Assembly of the screws and nut Fig. 128 Disassembly of the temperature limiter ▶ Tighten two screws on the gas valve to fix it. Cable sockets ▶ Tighten the gas valve nut. Temperature limiter ▶... -
Page 71: Replace The Heat Exchanger
Replacement parts 10.13 Replace the heat exchanger ▶ Remove the clip [1] and the auto air vent [2]. Disassemble the heat exchanger Before starting this work: ▶ Shut down the appliance power. NOTICE Remaining water in the heat exchanger! The heat exchanger will retain water when the appliance is drained. ▶... - Page 72 Replacement parts ▶ Loosen three screws (Torx T25) in counter-clockwise direction and support the bottom of the heat exchanger by hand. 0010045939-001 Fig. 134 Disassembly of the NTCs and pipes 0010045998-001 Fig. 136 Disassembly of the heat exchanger ▶ Remove the two NTCs [1] from the pipes. ▶...
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Page 73: Replace The Ignition Transformer
Replacement parts ▶ Disconnect the ignition cable and all cables from the ignition transformer. ▶ Loosen the screw (Torx T20) counter-clockwise. ▶ Remove the ignition transformer. Assemble the ignition transformer 0010046000-001 0010046003-001 Fig. 138 Replacement of the new lip seal Fig. -
Page 74: Replace The Venturi
Replacement parts Assemble the new air intake pipe ▶ Pull off the condensate hose [2] from the condensate trap. 0010046014-002 0010046016-001 Fig. 142 Assemble the new air intake pipe Fig. 144 Disassembly of the venturi ▶ Push the new air intake pipe to the right. Snap fit ▶... -
Page 75: Replace The Gas Air Pipe
Replacement parts 10.17 Replace the gas air pipe ▶ Pull off the condensate hose [2] from the condensate trap. Disassemble the gas air pipe 0010045874-001 Fig. 148 Disassembly of the screws Screws ▶ Take out two screws between the burner door and the gas air pipe (... -
Page 76: Replace The Restrictor
Replacement parts Assemble the gas air pipe and the fan 10.18 Replace the restrictor Disassemble the restrictor Ensure that the back flow prevention valve sits properly between the gas air pipe and the fan. 0010046036-001 Fig. 152 Disassembly of the gas hose and nut ▶... -
Page 77: Replace The Burner Door Assembly
Replacement parts Assemble the restrictor 10.19 Replace the burner door assembly Disassemble the burner door assembly ▶ Remove the cable connections and the burner door assembly ( Chapter 9.7.1, page 55). 0010046038-002 Fig. 154 Place the o-ring on the restrictor Restrictor O-ring ▶... -
Page 78: Replace The Ignition Cable
Replacement parts Assemble the burner door assembly 10.20 Replace the ignition cable Disassemble the ignition cable 0010046040-002 Fig. 161 Replace the ignition cable Ignition electrode 0010046048-002 Ignition cable Fig. 159 Assembly of the burner door assembly Ignition transformer ▶ Assemble the gas hose to the venturi. ▶... -
Page 79: Replace The Lip Seal On The Flue Outlet
Replacement parts Assemble the NTC on the return pipe Disassemble the NTC from the flow pipe 0010046044-001 0010046046-001 Fig. 163 Assemble the new NTC on the return pipe Fig. 165 Replace the NTC at the flow pipe Ignition transformer Gas hose Auto air vent ▶... -
Page 80: Replace The Expansion Vessel
Replacement parts Assemble the lip seal Expansion vessel bracket Screw (pozi) Expansion vessel Ensure that the new lip seal sits properly around the groove. There should be no clearance on the outer diameter of the lip seal to the flue ▶... -
Page 81: Replace The Control Unit
Replacement parts 10.24 Replace the control unit 10.25 Replace the auto air vent The devices are delivered without code plug. Check that the red cap on the auto air vent is half open. ▶ When replacing the control unit, ensure the code plug supplied is ▶... -
Page 82: Replace The Plate Heat Exchanger
Replacement parts 10.27 Replace the plate heat exchanger ▶ Remove the PRV pipe. ▶ Before disassembly the plate heat exchanger, remove the condensate trap and the condensate trap inlet and outlet pipes. 1. Remove the screw. 2. Remove the plate heat exchanger. 0010046025-001 Fig. -
Page 83: Replace The Rainguard
Replacement parts 10.29 Replace the rainguard ▶ Remove the flue adaptor. ▶ Pull off the rain guard drain hose. 0010042749-001 0010042747-001 Fig. 180 Removing the flue kit Fig. 178 Removing the rainguard Flue kit Flue adaptor ▶ Take out the three screws by using suitable tool. ▶... -
Page 84: Reassemble The Burner Door
Replacement parts ▶ Pull off the rainguard from the front side by tilting. Installing the motor. ▶ Install the motor in the sequence shown. – Insert the motor and align above the ball head. Push down to engage. – Pull gently on the motor to ensure it has properly engaged onto the ball. -
Page 85: Replace The Pump
Replacement parts ▶ Install the motor in the sequence shown. 10.33 Adjusting the operating pressure of the heating – Insert the motor and align above the ball head. Push down to system engage. Display on the pressure gauge – Pull gently on the motor to ensure it has properly engaged onto the 1 bar Minimum charge pressure (when system is cold) ball. -
Page 86: Fault Finding And Diagnosis
11.1 General information Indicators (fault category O) This fault finding information is for guidance only. Worcester cannot be Indicators signal operating conditions during normal operation. held responsible for costs incurred by persons not deemed to be Indicators can be read out with the service function 1-A1. -
Page 87: Fault Code Table
Fault finding and diagnosis 11.2 Fault code table Description Remedy 200 O Boiler in heating mode Operating message, is not a fault. 201 O Boiler in hot water mode Operating message, is not a fault. 202 O Boiler in anti-cycle mode Operating message, is not a fault. - Page 88 Fault finding and diagnosis Description Remedy 229 B Flame failed during burner operation Tip: Check the ceramic insulator is not damaged, this can cause the spark to earth, twist and pull the ceramic insulator to ensure it is not broken. ▶...
- Page 89 Fault finding and diagnosis Description Remedy 249 V Internal software error ▶ Restart the appliance to see if the problem re-occurs. ▶ Check the electrical connections on the board (check for loose wires etc.). ▶ Check the code plug, if present, is not damaged. ▶...
- Page 90 Fault finding and diagnosis Description Remedy 275 O Boiler electronics in test mode Operating message, is not a fault. 283 O Burner starting Operating message, is not a fault. 284 O Opening air/gas ratio control valve/oil Operating message, is not a fault. solenoid valves 285 B Return temperature is too hot...
- Page 91 Fault finding and diagnosis Description Remedy 1010 O No BUS communication ▶ Check the HMI for display and remove the HMI and the test voltage to the HMI. ▶ Check the HMI plug on far right of the control unit (low voltage connection). ▶...
- Page 92 Fault finding and diagnosis Description Remedy 2924 V No feedback from the gas valve ▶ Check the voltage to the gas valve. ▶ Check the resistance of the gas valve coils. ▶ Check the continuity of harness and replace if required. ▶...
- Page 93 Fault finding and diagnosis Description Remedy 2951 V Loss of flame too many times Note: Front cover sealing issues can cause this fault. ▶ Refer to blocking errors(s) that lead to this locking error. Check the fault history on the appliance.
- Page 94 Fault finding and diagnosis Description Remedy 2967 B Flow/heat exchanger temperature sensor ▶ Check the flow through the appliance and the system is filled. differential too great ▶ Check for air locks in the system and purge if required. ▶ Check the isolation valves. ▶...
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Page 95: Faults That Are Not Displayed
Fault finding and diagnosis 11.3 Faults that are not displayed Appliance faults Remedy Combustion noises too loud; rumbling noises ▶ Check O setting. ▶ Check pollution Hex. ▶ Check flue integrity. ▶ Check the gas type. ▶ Check the gas supply pressure. ▶... -
Page 96: Environmental Protection And Disposal
Environmental protection is a fundamental corporate strategy of the We, Bosch Thermotechnology Ltd., Cotswold Way, Bosch Group. Warndon, Worcester WR4 9SW, United Kingdom The quality of our products, their economy and environmental safety are process product and installation information, all of equal importance to us and all environmental protection legislation technical and connection data, communication data, and regulations are strictly observed. -
Page 97: Technical Specifications/Logs
Technical Specifications/Logs Technical Specifications/Logs 14.1 Technical data Technical data table Greenstar 1000 Description Unit 24kW NG 30kW NG Gas flow maximum rate - 10 minutes from lighting Gas inlet pressure (nominal) mbar 20.0 20.0 Natural gas 2.47 3.02 Central Heating (CH) Maximum rated heat input (net) (Q 24.6 24.6... -
Page 98: Component Resistance Characteristics
Technical Specifications/Logs 14.2 Component resistance characteristics 14.3 Heating curve Temperature [°C] Resistance [] VT/°C 33 404 25 902 20 247 15 950 12 657 10 115 6 586 3 624 2 500 1 759 AT/°C 1 260 0 010 005 905-001 Fig. -
Page 99: Internal Wiring Of The Appliance
Technical Specifications/Logs 14.4 Internal wiring of the appliance 14.4.1 Electrical wiring 11 12 0010042983-002 Fig. 191 Electrical wiring Greenstar 1000 – 6721835943 (2023/08) -
Page 100: Setting Values For Output
Technical Specifications/Logs Legend to figure 191: 14.5 Setting values for output Fuse The maximum rated heat output can be reduced to up to 50 % of the Earth connections output range (service function 3-b1). Mains cable The minimum rated heat output can be increased to up to 50 % of the Earth connections on bottom plate output range (service function 5-A3). -
Page 101: Gas Boiler System Commissioning Checklist And Warranty Validation Record
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... -
Page 102: Inspection And Maintenance Checklist
Technical Specifications/Logs 14.7 Inspection and maintenance checklist ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ ________________________ ___________________ Table 42 Inspection and maintenance checklist Greenstar 1000 –... -
Page 103: Service And Interim Boiler Work Record
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’... - Page 104 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’...
- Page 105 Technical Specifications/Logs System gassing WARNING If you suspect the heating system is gassing, you must exercise caution when carrying out testing or remedial work as the gasses produced can be flammable. Do not vent air from radiators whilst the central heating is switched on.
- Page 106 Technical Specifications/Logs Is your system pressure constantly increasing even when the boiler is off for extended periods of time? PRV = Pressure Relief Valve EV = Expansion Vessel Does system pressure Have you confirmed that the increase when the filling link is not stuck boiler is on? open/passing water in any way? Does system pressure increase...
- Page 108 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...