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Installation And Maintenance Instructions
Gas-fired condensing system appliance
Greenstar 4000
GR4700iW S
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Table of Contents
Related Manuals for Worcester GR4700iW 21 S NG
Summarization of Contents
Explanation of Symbols and Safety Instructions
1.1 Explanation of Symbols
Explains signal words and symbols used in warnings to indicate risk severity.
1.2 General Safety Instructions
Provides crucial safety advice for installation, compliance with regulations, and competent engineer requirements.
Warnings
Defines signal words like DANGER, WARNING, CAUTION, NOTICE for risk communication.
If You Smell Gas
Risk to Life from Carbon Monoxide Poisoning
Details risks of flue gases, CO dangers, and necessary precautions like regular servicing.
Installation and Maintenance
Emphasizes that installation and maintenance must be done by qualified gas engineers.
Electrical Work
States electrical work must be done by a qualified electrician following safe isolation procedures.
Handover to the User
Instructions for the installer on how to hand over the appliance to the user, including safety and maintenance advice.
Servicing
Benchmark Service Record
Explains the importance of the Benchmark Service Record for ensuring correct installation, commissioning, and servicing.
Fitting and Modification
States that fitting and modification must be done by a competent engineer as per gas safety regulations.
2 Regulations
Installation Regulations
Outlines requirements for installation, including gas safety, IET, and building regulations.
British Standards
Lists relevant British Standards for installation and hot water systems.
Irish Standards
Mentions following current Irish standards for electrical and gas installations.
LPG Installations
Specifies safety requirements for LPG installations, particularly regarding room location.
3 Product Information
Appliance Features
Lists key features of the appliance, such as aluminium heat exchanger, low NOx, and digital display.
3.1 Scope of Delivery
Illustrates and lists the components included in the appliance packaging.
3.2 Declaration of Conformity
States compliance with European directives and national requirements, indicated by CE marking.
3.3 Appliance Type Overview
Lists appliance types, part numbers, and gas council numbers for Natural Gas and LPG.
3.4 Product Identification
Data Plate
Explains the data plate contains performance, approval, and serial number information.
Additional Type Plate
Mentions an additional plate with product name and data, located on the underside.
3.7 Standard Accessories
3.7.1 Appliance Accessories
Lists part numbers and descriptions for various appliance accessories like flue adaptors and filters.
3.7.2 Programmer/Timer Accessories
Lists compatible programmers, timers, and smart controls for the appliance.
Bosch EasyControl Smart Control System
Lists EasyControl accessories including smart thermostats and TRVs.
4 Pre-Installation
4.1 System Preparation
Covers essential system preparation steps before appliance installation.
4.1.1 Artificially Softened Water
Warns against using salt-based softened water and provides guidance on pH levels.
4.1.2 Water Systems and Pipework
Discusses requirements for plastic pipework, connections, and valve types.
4.1.3 System Layouts Examples
Checking the Size of the Expansion Vessel
Guides on determining the need for an additional expansion vessel using a chart and calculations.
Sealed Primary System - 3-Way Valve, Cylinder and Central Heating Zone
Optional Integral Diverter Valve Kit
Explains the diverter valve kit for sealed systems and its connection requirements.
Sealed Primary System - Internal Diverter Valve Kit
Details the internal diverter valve kit for sealed systems and its pipe configuration.
Unvented Cylinders
Advises contacting the cylinder manufacturer for compatibility with installation layouts.
4.1.4 System Fill
Filling Primary Sealed Systems
Provides instructions for filling primary sealed systems, including using untreated water and air breaks.
External Filling Loop
Illustrates an external filling loop system for filling the appliance.
4.2 Mains Supply
4.2.1 Electrical Supply
Specifies electrical supply requirements, RCD types, and cable specifications.
4.2.2 Gas Supply
Details requirements for Natural Gas and LPG connections, including pipe sizing.
4.3 Appliance Location and Clearances
4.3.1 Appliance Location
Gives guidance on selecting a suitable internal location, protecting from dust/moisture, and avoiding flammable materials.
Danger from Explosive and Flammable Materials
Warns about storing flammable materials near the appliance due to explosion risk.
Danger to Life from Explosion!
Details risks associated with ammonia and potential gas leaks leading to explosion.
4.3.2 Rooms Containing a Bath or Shower
Risk of Electric Shock
Warns about placing electrical switches or controls out of reach in bathrooms.
4.3.3 Appliance Clearances
Risk of Damage to Appliance or Property
Emphasizes maintaining clearances to prevent overheating and avoiding combustible materials.
4.4 Flue Systems Considerations
WARNING Flue Systems
Warns about possible flue gas escape and specifies using approved flue systems only.
CAUTION Concealed Flue Systems
Advises on provision for service and inspection of concealed flue systems.
4.4.1 Flue Length
Provides tables of maximum horizontal and vertical flue lengths for different appliance models.
4.4.2 Flue Options
Explains different flue systems and their maximum lengths, with examples.
4.4.3 Plume Management System
Plume Management Terminal
Provides installation guidelines for the plume management terminal, including clearances.
Plume Management Bends
Lists effective lengths of bends used in plume management systems.
4.4.4 Flue Terminal Positions
CAUTION Flue Terminal Positions
Warns about positioning terminals to avoid combustion products entering the building.
Key to Figure 33
Note:
Provides additional notes on flue installations, car ports, and light wells.
Key to Figure 34
Note:
Offers notes on car port installations, light wells, and condensate disposal.
4.5 Condensate Discharge
Condensate Pipework - Unheated Internal Areas
Advises on treating unheated internal pipe runs as external due to freezing risk.
4.5.3 Internal Connections
Provides guidance on good practices for installing condensate discharge points.
Soil Stack Connection
Details connecting condensate drainage to a soil stack, including pipe routing and materials.
4.5.4 External Connections
Waste Pipe Connection
Explains connecting condensate drain to waste pipes using a swept tee.
NOTICE Septic Tanks
Warns against connecting to septic tanks due to potential anaerobic bacteria impact.
NOTICE Rainwater Down Pipe or External Drain Disposal
Advises against discharging untreated condensate into streams or rivers.
NOTICE Grey Water Recovery System
Prohibits discharging condensate into grey water recovery systems for reuse.
External Disposal Considerations
NOTICE Freezing Conditions
Warns that frozen condensate will block the drain and stop the appliance.
NOTICE Condensate Waste Disposal
Advises on siting soak-aways carefully to avoid damage and using appropriate discharge methods.
4.6 Pressure Relief Discharge
4.6.1 Pressure Relief Pipework
Details requirements for PRV pipework, materials, and safe discharge points.
CAUTION Scalding Risk from Hot Water or Steam!
Warns about scalding risk from discharging unmixed hot water during disinfection.
4.6.2 Alternative PRV Connections - Combined PRV/Condensate
Explains connecting PRV or combined discharges to waste systems using tundishes or Hotuns.
4.7 Cleaning Primary Systems
NOTICE Risk of Damage to System or Appliance!
Warns that system debris can damage the appliance and affect efficiency.
NOTICE Sealing Agents
Recommends against sealing agents unless necessary, and supports specific products.
Inhibitor
Details the use of suitable inhibitors and their compatibility with appliance materials.
5 Installation
NOTICE Risk of Damage to Appliance or Accessories.
Reminds to read all pre-installation sections before starting appliance or flue installations.
CAUTION Risk of Injury Through Incorrect Lifting and Carrying!
Provides instructions for safe lifting and carrying of the appliance to prevent injury.
Appliance on Site
Advises checking delivery contents and unpacking the appliance for installation.
Important Handling Instructions
Recommends using two people for carrying and handling the appliance safely.
5.1 Position the Appliance
WARNING Ensure the Mains Gas Supply is Isolated...
Warns to isolate the gas supply before starting work and follow safety precautions.
Appliance Positioning
Guides on mounting the appliance on a flat, rigid surface, considering flue and discharge routes.
WARNING Damage to Property!
Warns about the risk of damage from drilling into pipes or cables.
NOTICE Damage to Appliance!
Advises flushing the system pipework to remove residue before connecting the appliance.
5.2 Appliance Connections
WARNING Appliance - Gas Connection
Warns to isolate the gas supply before working on connections.
NOTICE Appliance - Hydraulic Connections
Advises isolating water pipework and taking precautions with plastic components.
Plumbing Manifold
Refers to appliance template for pipe routing guidance and optional pre-piping kits.
Hanging the Appliance
WARNING Bonded Washer (Plumbing Manifold Gas Connection)
Stresses using the bonded washer for the gas pipe isolating valve connection.
Fitting the Siphon
Warns that an unfilled condensate trap can cause poisonous flue gas escape.
5.4 Flue Turret/Adaptor Installation
NOTICE Flue Installation
Refers to flue kit instructions and warns against exceeding maximum flue lengths.
Telescopic Flue
Notes that telescopic flue terminals allow for some adjustment in length.
Vertical Adaptor [B] Fitting
Guides on aligning and fitting the vertical adaptor to the appliance flue outlet.
Flue Turret [A] Fitting
Explains how to align and fit the flue turret to the appliance flue outlet.
5.5 Electrical Connection
DANGER Risk of Electric Shock!
Emphasizes isolating electrical components and securing against reconnection before work.
Electrical Considerations
States electrical work must be by a competent person, complying with IET regulations.
NOTICE Risk of Damage from Hot Appliance Components.
Warns to keep electrical cables away from hot components to prevent damage.
Cable Routing
Advises routing cables separately and maintaining separation between power and signal cables.
5.5.1 Cable Preparations
NOTICE Damage to Control Unit!
Warns about small wire pieces causing shorts and damaging electronics.
5.5.2 Installer Wiring Connections
Access to Electrical Connections
Guides on accessing electrical connections by releasing catches and opening the cover.
Stepped Cable Grommets
Explains how to cut cable grommets to match cable diameter for splash-water protection.
Earth Rail Location
Details the location of the earth rail and securing the protective conductor.
5.5.3 External Controls - Domestic Installations
External Equipment or Integral Diverter Valve Kit
Notes that external equipment is not supplied and details the optional diverter valve kit.
Appliance External Control Connections Example
Shows an example of appliance external control connections, including frost thermostat.
6 Commissioning
6.1 Pre-Commissioning Checks
Lists essential checks before commissioning, including electrical isolation and gas/water connections.
DANGER Risk of Electric Shock!
Emphasizes isolating electrical components before any work.
Checks Before Commissioning
Details checks for pipe connections, gas supply, water pressure, electrical connections, and flue integrity.
NOTICE If the Appliance is Not to be Commissioned Immediately Then...
Provides instructions for safely isolating the appliance if commissioning is delayed.
6.2 Water Treatment
Primary System Flushing (Central Heating)
Guides on system flushing, inhibitor use, and pH value requirements.
Inhibitor (Central Heating)
Advises on using suitable inhibitors and their compatibility with appliance materials.
NOTICE Sealing Agents
Recommends against sealing agents unless necessary, and supports specific products.
6.2.1 Filling the Appliance and Adding Inhibitor
Details filling the system with water, adding inhibitor, and setting expansion vessel pressure.
6.3 Starting the Appliance
NOTICE Damage to Appliance or System!
Warns against running the appliance when empty or partially filled.
6.3.1 Control Panel Overview
Explains the functions of the control panel buttons and display elements.
6.3.2 Turning On the Appliance
Instructs to turn on the appliance using the power supply isolator.
6.3.3 Operation
Refers to user instructions for setting CH flow and DHW temperatures.
6.5 Checking Gas Inlet Pressure
Measuring the Inlet Pressure
Details how to measure gas inlet pressure using a pressure gauge.
6.8 CO and Combustion Check
NOTICE Before CO and Combustion Checks
Lists pre-checks for CO/combustion analysis, including gas type, pressure, and flue integrity.
6.10 Flue Gas Analysis
NOTICE Combustion Testing
States combustion testing requires a competent person and calibrated analyser.
Flue Gas Analysis
Guides on performing flue gas analysis after checking gas inlet pressure.
CO/CO2 Settings
Provides tables for CO2 readings for Natural Gas and LPG appliances at different outputs.
6.11 Finishing Commissioning
Fitting the Front Casing
Details fitting the front casing and securing it with screws.
Benchmark Menu
Instructions on how to enter the Benchmark menu for setup and checks.
Appliance Handover
Guides on demonstrating features, controls, and providing documentation to the customer.
User Recommendation
Advises users on annual servicing and arranging maintenance contracts.
7 Settings in the Service Menu
7.1 Operating the Service Menu
Instructions on how to open, close, navigate, and change values in the service menu.
7.2 Service Menu
7.2.1 Overview of the Service Menu
Lists the main categories within the service menu: Benchmark, Info, Settings, Function check, Reset, Demo mode.
8 Inspection and Maintenance
7.3 Thermal Disinfection
Recommends thermal disinfection after long downtimes to prevent legionella.
CAUTION Risk of Scalding
Warns about scalding risk from discharging unmixed hot water during disinfection.
8.1 Inspection and Maintenance Considerations
Emphasizes regular checks for efficient operation, including gas joints and flue systems.
8.2 Component Access
Removing the Front Casing
Details how to remove the front casing for access to components.
8.5 Flue Gas Analysis
NOTICE Combustion Testing
Reiterates that combustion testing requires a competent person and calibrated analyser.
Flue Gas Analysis
Guides on performing flue gas analysis after checking gas inlet pressure.
CO/CO2 Settings
Provides tables for CO2 readings for Natural Gas and LPG appliances at different outputs.
8.7.2 Cleaning the Condensate Trap
WARNING Danger to Life Due to Poisoning!
Warns that an unfilled condensate trap can cause poisonous flue gas escape.
Damage Resulting from an Insufficiently Cleaned Trap is Excluded from the Warranty.
States warranty exclusion for damage caused by an unclean trap.
Removing the Siphon
Details removing the condensate siphon, including emptying and releasing it.
Replacing Siphon Gasket
Guides on removing, checking, and replacing the siphon gasket.
Refitting the Siphon
Explains how to refit the siphon, including checking the discharge elbow and filling with water.
8.8 Setting the Air/Gas Ratio
NOTICE Setting the Air/Gas Ratio
States the air/gas ratio is factory set and should not be adjusted unless advised.
NOTICE Combustion Testing
Reiterates that air/gas ratio checking requires a competent engineer and analyser.
Adjusting the Minimum Rated Output Settings
Guides on adjusting the CO2 content for minimum rated output.
Adjusting the Maximum Rated Output Settings (LPG Appliances)
Explains how to adjust CO2 content for maximum rated output on LPG appliances.
9 Replacement Parts
WARNING Mains Supplies - Isolate the Appliance
Emphasizes isolating gas and electrical supplies before replacement work.
WARNING Component Replacement
Advises checking gas tightness after replacing components and inspecting seals.
Only Use Worcester, Bosch Group Original Spare Parts...
States that using non-original parts invalidates the guarantee.
9.1 Component Access
Removing the Front Casing
Details how to remove the front casing for access to components.
9.2 Draining the Appliance
NOTICE Risk of Water Damage to Appliance or Property!
Warns about water damage from disconnecting water pathways.
9.3 Removing the Heat Exchanger Assembly
Separating Components from the Heat Exchanger Assembly
Guides on separating components from the heat exchanger assembly.
Removing the Heat Exchanger Assembly
Explains how to release the flue pipe clip and remove the assembly.
9.4 Checking/Replacing the Motor of the 3-Way Valve (Appliances Fitted with Diverter Valve Accessory)
Variant Without Screws
Explains how to check and detach the 3-way valve motor.
9.11 Replacing the Control Unit
Replacement Control Unit
Notes that replacement control units do not include code plugs or display covers.
Preparation Before Control Unit Removal
Details loosening screws, opening the cover, and removing connectors.
Control Unit Removal
Guides on releasing latches, pulling out the control unit, and removing the display cover panel.
10 Fault Finding and Diagnosis
Basic Checks
Lists initial checks for power supply, settings, programmer, thermostats, and water/gas availability.
NOTICE On Completion of the Service/Fault-Finding Task...
Reminds to check electrical connections after re-making them.
10.1 Operating and Fault Displays
Explains fault codes and categories (O, B, V, W) indicating operating status and faults.
Fault Code
10.1.3 Faults That Are Not Displayed
Lists common faults that may not trigger error codes, such as combustion noises and ignition issues.
11 Environmental Protection and Disposal
Packaging
Discusses participation in recycling processes and the use of compostable packaging.
Compostable Packaging
Explains how to dispose of compostable packaging.
Used Appliances
Advises on recycling used appliances and sorting materials.
Old Electrical and Electronic Appliances
Explains disposal of WEEE according to regulations and environmental responsibility.
13 Technical Specifications/Logs
13.1 Technical Data
Presents detailed technical data for Greenstar 4000 models in tables.
13.2 Energy Consumption
13.2.1 Product Data on Energy Consumption
Details product data on energy consumption for Natural Gas appliances, including efficiency classes.
13.3 Component Resistance Characteristics
13.3.1 Sensor Values - Flow Temperature Sensor
Provides resistance values for flow temperature sensors at different temperatures.
13.3.2 Sensor Values - Cylinder Temperature Sensor
Lists resistance values for cylinder temperature sensors at various temperatures.
13.3.3 Sensor Values - Flue Overheat Thermostat
Gives temperature and resistance values for the flue overheat thermostat.
13.3.4 Sensor Values - Heat Exchanger Assembly Temperate Limiter
Shows temperature and resistance values for the heat exchanger limiter.
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