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Installation commissioning and servicing instructions
Wall hung RSF gas fired condensing system boiler
Greenstar i System
For sealed central heating systems and indirect mains fed domestic hot water
ErP
These appliances are for use with:
Natural Gas or L.P.G.
(Cat. II 2H 3P type C13, C33 & C53)
Natural Gas
L.P.G.
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.
UK/IE
Model
GC Number
Greenstar 9i System
41-406-21
ErP
Greenstar12i System
ErP
41-406-23
Greenstar 15i System
ErP
41-406-25
Greenstar 18i System
ErP
41-406-27
Greenstar 21i System
41-406-29
ErP
Greenstar 24i System
ErP
41-406-31
Greenstar 9i System
ErP
41-406-22
Greenstar12i System
ErP
41-406-24
Greenstar 15i System
41-406-26
ErP
Greenstar 18i System
41-406-28
ErP
Greenstar 21i System
ErP
41-406-30
Greenstar 24i System
ErP
41-406-32
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Table of Contents
Related Manuals for Worcester Greenstar12i System ErP
Summarization of Contents
Key to symbols and safety instructions
Key to symbols
Symbols used in the manual to indicate warnings, important information, and steps in instructions.
Safety precautions
General safety rules, precautions for gas leaks, appliance operation, and health/safety.
Regulations
Installation regulations
Compliance with Gas Safety, IET, Building Regulations, and other relevant standards.
British standards
Reference to relevant British Standard codes of Practice for installation and systems.
Appliance information
Appliance
Overview of the wall-hung gas-fired condensing system appliance and its standard package.
Technical data
Detailed technical specifications for Natural Gas appliances, including performance, electrical, and general data.
Energy efficiency
Product data for energy efficiency of Natural Gas appliances, per EU regulations.
Layout
Diagram showing the main appliance components with numbered labels for identification.
Electrical diagram
Schematic diagram illustrating the internal electrical connections of the appliance.
Pre-installation
Cleaning primary systems
Instructions for flushing and cleaning the heating system before installation, including water treatment advice.
Mains supply
Requirements for electrical and gas supply connections, including safety and regulations.
Water systems and pipe work
Guidelines for plastic pipework, primary system connections, and sealed primary system fills.
Appliance location and clearances
General requirements for appliance location, including surface suitability and access.
Installation and servicing clearances
Required clearances around the appliance for installation and servicing, illustrated with diagrams.
Pressure relief pipe work
Instructions and safety warnings for routing the pressure relief valve discharge pipe.
Condensate discharge
Explanation of the appliance's condensate trap design and benefits for freezing prevention.
Condensate pipe work
Requirements for condensate pipe material, fall, and route, including notes on unheated areas.
Internal connections
Methods for connecting the condensate drain pipe to internal waste systems.
External connections
Guidance on fitting condensate drainage pipes externally, including soak-away and rainwater downpipe disposal.
Condensate pump
Instructions for using condensate pumps when gravity discharge is not possible.
Condensate soak away
Details for creating a condensate soak away, including dimensions and materials.
Standard accessories
List of available accessory part numbers and their descriptions.
Plumbing manifold
Guidance on pipe routing and connections, including optional vertical pre-piping assembly.
Flue options
Overview of available flue systems and their compatibility.
Flue lengths
Tables and diagrams showing maximum flue lengths for various horizontal and vertical flue assemblies.
Determine the plume management system length
Guidelines for calculating minimum and maximum plume management lengths and terminal positions.
Flue terminal positions
Detailed diagrams and measurements for correct flue terminal positioning relative to building features and boundaries.
Plume management terminal positions
Specific clearances and positioning requirements for plume management terminals, including diagrams.
Installation
Important handling instructions
Advice on safe lifting, carrying, and unpacking of the appliance.
Wall mounting template & flue openings
Instructions for using the wall mounting template and drilling flue openings, with safety notices.
Appliance connections
General precautions for appliance connections, including gas, water, and condensate.
Front panel removal
Step-by-step guide on how to remove the appliance's front panel.
Hanging the appliance
Instructions and tips for safely hanging the appliance onto the wall mounting frame.
Siphon removal
Instructions on how to access and remove the appliance siphon.
Reconnecting the siphon
Step-by-step guide for refitting the appliance siphon.
Filling the siphon
Instructions for filling the siphon with water before appliance start-up.
Flue turret/adaptor installation
Instructions for fitting the flue turret or adaptor, including notes on replacement scenarios and materials.
Electrical
Important safety warnings regarding electrical connections and mains supply.
Access to electrical connections
Steps to access the appliance's electrical connection points.
External controls (wiring centre) - domestic installations
Wiring instructions for external controls and the integral diverter valve kit.
Commissioning
Pre-Commissioning checks
Essential checks to perform before starting the commissioning process, including safety.
Filling the system
Procedure for filling the central heating system with water and venting radiators.
Water treatment
Guidelines for flushing the system, adding inhibitor, and maintaining water quality.
Starting the appliance
Safety precautions and steps for initial start-up of the appliance.
Appliance start up screens
Description of the display sequence and internal test during initial appliance start-up.
Info menu and operational status codes
How to access and interpret information and status codes via the appliance menu.
Checking the gas inlet pressure
Procedure for checking the gas pressure at the appliance inlet.
Gas pressure within the system
Guidance on acceptable gas pressures for Natural Gas and LPG systems.
Checking the gas rate
How to measure the gas rate of the appliance at maximum output.
Gas rate testing
Procedure for setting the appliance to maximum output for gas rate testing.
Checking for leaks during operation
Method for checking for gas leaks while the appliance is operating.
Domestic hot water
How to control hot water temperature and pre-heat settings.
CO and combustion checks
Mandatory checks for CO levels, combustion ratios, and flue integrity, with a flow chart.
Checking flue integrity
Procedure for checking the integrity of the flue system using sample points.
Flue gas analysis
Instructions for performing flue gas analysis, including required equipment and competencies.
Service reminder function
How to set and manage the appliance's service reminder.
Benchmark menu
Explanation of the Benchmark menu function for completing the commissioning checklist.
Weather sensor settings menu
How to configure weather sensor settings for basic weather compensation.
Boiler settings menu
Overview of the boiler settings menu options for appliance functionality.
Master settings menu
Setting adjustment boundaries for boiler settings.
Finishing commissioning
Steps to complete the final stages of appliance commissioning.
Replace front panel
Step-by-step instructions for refitting the appliance's front panel.
Fitting facia flap
How to attach and close the facia flap on the appliance.
Installing bottom panel
Instructions for fitting the appliance's bottom panel.
Setting the central heating temperature
How to adjust the central heating flow temperature settings.
Setting the cylinder hot water temperature
How to set the hot water cylinder temperature when using the diverter valve kit.
Eco/Preheat mode activation
How to activate and switch between Eco and Preheat modes for hot water.
Toggle basic adjust mode
How to enable/disable basic adjust mode for limiting appliance functions.
Hand over
Steps for handing over the commissioned appliance to the customer, including documentation and user guidance.
Service and spares
Appliance guarantee
Details of the appliance guarantee, terms, conditions, and registration.
Basic adjust mode
Note that basic adjust mode disables service functions and needs to be disabled.
CAUTION: Mains supplies
Safety warning to turn off mains supplies before any work.
CAUTION: Component replacement
Precautions for component replacement, including gas tightness and checks.
Inspection and service
General guidance on inspecting the appliance and system during service.
History menu
How to access and interpret the appliance's history menu for errors and operational data.
Test menu
How to use the test menu to check individual component operations.
Checking flue integrity
Procedure to check flue joints, terminals, and guards for security and condition.
Check the gas inlet pressure
Warning not to proceed with other checks if gas inlet pressure is incorrect.
Fan pressure test
Procedure to test fan pressure to determine if the heat cell requires cleaning.
Flue gas analysis
Instructions for performing flue gas analysis, including required readings and checks.
Cleaning the siphon and heat exchanger
Steps for cleaning the siphon and heat exchanger components.
Cleaning the siphon
Steps to access and clean the appliance siphon.
Refitting the siphon after cleaning
Instructions for refitting the siphon after it has been cleaned.
Remove access cover panel
How to remove the access cover panel to gain further access.
Cleaning the primary heat exchanger
Procedure for cleaning the primary heat exchanger using a cleaning brush.
Replacement of parts
General precautions and steps for replacing appliance components.
Component access
Steps to remove the outer casing for component access.
Siphon removal replacement of parts
Instructions for accessing and removing the siphon for replacement.
Draining the appliance
Procedure for draining water from the appliance before working on components.
Fan assembly removal
Steps to remove the fan assembly for replacement or maintenance.
Air/gas manifold clamping plate removal
Instructions for removing the air/gas manifold clamping plate.
Burner and electrode removal
Steps to remove the burner and electrode assembly.
Baffle removal
Instructions for removing the top and lower baffles.
Flow pipe removal
Steps to remove the flow pipe from the heat exchanger.
Exhaust assembly removal
Instructions for removing the upper and lower exhaust assemblies.
Heat exchanger removal
Procedure for removing the heat exchanger, including necessary prior steps.
Primary sensor (CH NTC)
Instructions for removing and replacing the primary sensor.
Overheat thermostat
Steps for removing and replacing the overheat thermostat.
Spark generator
Instructions for removing and replacing the spark generator.
Flue overheat thermostat (with grommet)
Procedure for removing and replacing the flue overheat thermostat.
Fan
Instructions for removing the fan assembly.
Gas valve
Steps for removing and replacing the gas valve.
Expansion vessel removal
Procedure for removing and replacing the expansion vessel.
PCB fuse
Instructions for locating and replacing the PCB fuse.
Replacing control unit
Guide for replacing the appliance's control unit, including HCM transfer.
Hydraulic block components removal
General safety and preparatory steps for removing hydraulic block components.
Auto air vent
How to remove and refit the auto air vent.
Diverter valve motor (If optional integral diverter valve kit fitted)
Procedure for removing and refitting the diverter valve motor.
Diverter valve
Steps for removing and refitting the diverter valve.
Drain tap
How to remove and refit the drain tap.
Pump head
Instructions for removing and refitting the pump head.
Pressure gauge
Procedure for removing and refitting the pressure gauge.
Hydraulic block removal
Detailed instructions for removing the entire hydraulic block assembly.
CH pressure relief valve
Steps for removing and refitting the central heating pressure relief valve.
Bypass valve
Procedure for removing and refitting the bypass valve.
Fault finding and diagnosis
Short parts list
A list of common spare parts with their part numbers.
Fault finding
Introduction to fault finding, including locking/blocking errors and cause codes.
Locking error
Explanation of locking errors and how to reset the appliance.
Blocking error
Explanation of blocking errors and how they clear.
Cause code
Description of cause codes and how they are displayed.
Maintenance codes
Explanation of maintenance messages and their meanings.
Maintenance Menu
List of maintenance messages, their cause codes, descriptions, and possible checks.
Error codes
Table of error codes, their descriptions, and possible solutions/checks.
Factory Reset
Procedure for resetting all settings back to factory defaults.
Removing the optional integral diverter valve kit
Instructions for removing the diverter valve kit and performing a factory reset.
Component resistance characteristics
Tables of resistance values for various sensors and components used for diagnostics.
Flow temperature NTC sensor
Table of resistance values for the flow temperature NTC sensor at different temperatures.
DHW NTC sensor
Table of resistance values for the DHW NTC sensor at different temperatures.
Flue overheat thermostat
Resistance and temperature characteristics for the flue overheat thermostat.
Overheat thermostat
Resistance and temperature characteristics for the overheat thermostat.
Outdoor weather compensation sensor
Table of resistance values for the outdoor weather sensor.
Cylinder temperature sensor
Table of resistance values for the cylinder temperature sensor.
Gas valve resistances
Resistance values for the gas valve terminals.
Heating function
Flowchart illustrating the central heating operational sequence.
Hot water cylinder function (optional integral diverter valve kit fitted)
Flowchart illustrating the hot water cylinder operation with the diverter valve kit.
Protection function
Flowcharts illustrating automatic frost protection, pump overrun, and pump antisize functions.
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