Worcester Greenstar 1000 GR1000W 24 C NG Installation And Maintenance Instructions Manual page 3

9 Inspection and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . .53
9.1 Inspection and maintenance considerations . . . . . . . .53
9.2 Service functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
9.3 Component access. . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
9.4 Check working gas inlet pressure . . . . . . . . . . . . . . . . .54
9.5 Flue gas analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
9.6 Checking the flue integrity . . . . . . . . . . . . . . . . . . . . . . .54
9.7 Cleaning the heat exchanger . . . . . . . . . . . . . . . . . . . . .54
9.7.1 Checking the electrodes and cleaning the heat
exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
9.8 Cleaning/Checking the burner. . . . . . . . . . . . . . . . . . . .58
9.9 Cleaning the condensate trap . . . . . . . . . . . . . . . . . . . .58
9.10 Checking the ionization and ignition electrode. . . . . . .59
9.11 Checking the NTC position on the flow and return
pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
9.12 Setting the air/gas ratio . . . . . . . . . . . . . . . . . . . . . . . . .59
9.13 Cleaning the rainguard . . . . . . . . . . . . . . . . . . . . . . . . . .60
9.14 Checking the expansion vessel . . . . . . . . . . . . . . . . . . .61
10 Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
10.1 Component access. . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
10.2 Draining the appliance . . . . . . . . . . . . . . . . . . . . . . . . . .62
10.3 Replace the insulation on the burner door . . . . . . . . . .62
10.4 Disassembly of the ignition electrode on the
burner door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
10.5 Replace the lip seal on the burner door. . . . . . . . . . . . .63
10.6 Replace insulation disk on the heat exchanger. . . . . . .64
10.7 Replace the burner door seal. . . . . . . . . . . . . . . . . . . . .65
10.8 Replace the back flow prevention valve . . . . . . . . . . . .67
10.9 Replace the gas hose . . . . . . . . . . . . . . . . . . . . . . . . . . .68
10.10 Replace the fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
10.11 Replace the gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . .69
10.12 Replace the temperature limiter . . . . . . . . . . . . . . . . . .70
10.13 Replace the heat exchanger. . . . . . . . . . . . . . . . . . . . . .71
10.14 Replace the ignition transformer . . . . . . . . . . . . . . . . . .73
10.15 Replace the air intake pipe. . . . . . . . . . . . . . . . . . . . . . .73
10.16 Replace the venturi. . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
10.17 Replace the gas air pipe . . . . . . . . . . . . . . . . . . . . . . . . .75
10.18 Replace the restrictor. . . . . . . . . . . . . . . . . . . . . . . . . . .76
10.19 Replace the burner door assembly . . . . . . . . . . . . . . . .77
10.20 Replace the ignition cable . . . . . . . . . . . . . . . . . . . . . . .78
10.21 Replace the NTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
10.22 Replace the lip seal on the flue outlet . . . . . . . . . . . . . .79
10.23 Replace the expansion vessel . . . . . . . . . . . . . . . . . . . .80
10.24 Replace the control unit . . . . . . . . . . . . . . . . . . . . . . . . .81
10.25 Replace the auto air vent . . . . . . . . . . . . . . . . . . . . . . . .81
10.26 Replace the silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
10.27 Replace the plate heat exchanger . . . . . . . . . . . . . . . . .82
10.28 Replace the pressure relief valve (PRV) . . . . . . . . . . . .82
10.29 Replace the rainguard . . . . . . . . . . . . . . . . . . . . . . . . . .83
10.30 Reassemble the burner door . . . . . . . . . . . . . . . . . . . . .84
10.31 Checking/replacing the motor of the 3-way valve. . . . .84
10.32 Replace the pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
10.33 Adjusting the operating pressure of the heating
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
10.34 Tightening the flue adaptor . . . . . . . . . . . . . . . . . . . . . .85
Greenstar 1000 - 6721835943 (2023/08)
11 Fault finding and diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
11.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
11.2 Fault code table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
11.3 Faults that are not displayed . . . . . . . . . . . . . . . . . . . . . 95
12 Environmental protection and disposal . . . . . . . . . . . . . . . . . 96
13 Data Protection Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
14 Technical Specifications/Logs . . . . . . . . . . . . . . . . . . . . . . . . . 97
14.1 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
14.2 Component resistance characteristics . . . . . . . . . . . . . 98
14.3 Heating curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
14.4 Internal wiring of the appliance . . . . . . . . . . . . . . . . . . . 99
14.4.1 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
14.5 Setting values for output . . . . . . . . . . . . . . . . . . . . . . .100
14.5.1 Gas setting values (Natural Gas) . . . . . . . . . . . . . . . . .100
14.6 Gas Boiler System Commissioning Checklist and
Warranty Validation Record. . . . . . . . . . . . . . . . . . . . .101
14.7 Inspection and maintenance checklist . . . . . . . . . . . .102
14.8 Service and Interim Boiler Work Record. . . . . . . . . . .103
Table of contents
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