Bosch WORCESTER GREENSTAR 24i junior Instruction Manual

Wall hung rsf gas fired condensing combination boiler for sealed central heating systems and mains fed domestic hot water

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INSTRUCTION

INSTALLATION, COMMISSIONING

WALL

HUNG

RSF

GREENSTAR

FOR SEALED

CENTRAL

DOMESTIC

HOT WATER

MANUAL

& SERVICING

GAS

FIRED

CONDENSING

24i

HEATING

SYSTEMS

COMBINATION

JunMor

/ 28i

AND MAINS

THE APPLIANCE

IS FOR USE WITH

NATURAL GAS OR L.P.G. (Cat

NATURAL

GAS;

LIQUID

PETROLEUM

GAS,

UK/IE

WORCESTER

Bosch

BOILER

FED

TYPE ctg. caa &

241junior GC NUMBER 47-311-86

28i

GC NUMBER

47-81187

24i junior GC NUMBER 47-311

28i junior GC NUM3ER 47,311+1

enchmar

Group

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Summary of Contents for Bosch WORCESTER GREENSTAR 24i junior

Page 1 IS FOR USE WITH NATURAL GAS OR L.P.G. (Cat TYPE ctg. caa & NATURAL GAS; 241junior GC NUMBER 47-311-86 GC NUMBER 47-81187 LIQUID PETROLEUM GAS, 24i junior GC NUMBER 47-311 28i junior GC NUM3ER 47,311+1 enchmar UK/IE WORCESTER Bosch Group...
Page 2 INSTALLATION & SERVICING INSTRUCTIONS SYMBOLS USED IN THIS MANUAL: PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION. THESE INSTRUCTIONS ARE APPLICABLE THE WORCESTER APPLIANCE MODEL(S) Domestic hot water STATEO ON THE FRONT COVER OF THIS MANUAL ONLY MUST USEO WITH ANY OTHER MAKE OR MODEL OF APPLIANCE, THE INSTRUCTIONS APPLY...
Page 3 )ONTENTS *AFETY & REGULATIONS INSTALLATION SERVICING INSTRUCTIONS SAFETY PRECAUTIONS & SYMBOLS INSTALLATION REGULATIONS \PPUANCE INFORMATION GENERAL INFORMATION TECHNICAL DATA LAYOUT COMPONENTS 'RE-INSTALLATION CLEANING PRIMARY SYSTEMS MAINS SUPPLY WATER SYSTEMS & PIPEWORK CONDENSATE PIPEWORK PRESSURE RELIEF BOILER LOCATION & CLEARANCES PLUMBING MANIFOLD FLUE OPTIONS...
Page 4 SAFETY PRECAUTIONS INSTALLATION REGULATIONS IF YOU SMELL GAS: Current Gas Safety {Installation & Use) All gas %Fliances must by a compete-yt X DON'T SMOKE OR STRIKE MATCHES personin accordar,ce with theaboverequatöns X DONTTURN ELECTRICAL swrrCHES ON OR OFF Faduto to install a pg%nce.g could toadto DO PUT OUT NAKED FLAMES The appianco rncjstbo "stalled...
Page 5 18.6 x 13.5 x 1.5 Condensate trap & Fibre Washer 23.9 17.2 • DHW flow sensor & temperaturecontrol Bonded Washer 3/4 Plate type D HW heatexchanger ;yphon nstallation instructions, rish Guidelines Leaflet Narranty Return Envelope VQORCESTER GENERAL INFORMATION Bosch Group...
Page 6 TECHNICAL DATA DESCRIPTION NATURAL L.P.G. UNIT 24 iJu nior 28 iJunior 24 iJunior 28 iJunior Domestic Hot Water Min, heat input 7.38 9.64 7.38 9.64 Max. rated heat output Max. rated heat input 24.49 28.57 24.49 28.57 Gas flow rate • Max. 10 minutes from lighting Natural my h 2.59...
Page 7 CONNECTION PLASTIC PIPE) PLATE TO PLATE OHW HEAT EXCHANGER 27 ACCESS POINT FOR CLEMING HEAT EXCHANGER/SUMP GAS VALVE MANUAL VENT POINT FAN PRESSURE TEST POINT FLUE PRESSURE SWITCH CONNECTION (BLANKED OFF ON THIS APPLIANCE) hORCESTE LAYOUT & COMPONENTS Bosch Group...
Page 8 LAYOUT & COMPONENTS SYSTEM PUMP I e SYSTEM PRESSURE GAUGE PLATE TO PLATE HEAT EXCHANGER FLOW TURBINE COMPACT HYDRAU LIC MOUNTI NG SCREW (2) TO BOILER PRESSURE REUEFVALVE DIVERTER VALVE CH RETURN CONNECTION TO SERVICE VALVE COLD WATER CONNECTION INTERNAL BYPASS WITHIN PLASTIC...
Page 9 • Drain and thoroughly flush lhe system to removethe flushing agent and debris. rnaybe necessary to use a power flushing machine to aid the cleansing procedure in some circumstances hORCESTE CLEANING PRIMARY SYSTEMS Bosch Group...
Page 10 MAINS SUPPLY ELECTRIC SUPPLY: Supply: 230V - 140 watts • Cabbe;PVC insulated0.75mm2{24 * 0.2mm) temperature rated to • External GA fuse to 35362. • The appaiance must be earthed, • This appliance not be connected to a three phasesupply. NOTE: is reduced to IP20 if following mechanicaltimers are fitted: 7 716 192...
Page 11 Close as possible to tho appliancein the central heatingreturn. • Pressurisethe extraexpansionvessel (B} to the same figure as the expansion vessel built into the appliance. • DO galvanised pipes or radiators, hORCESTE WATER SYSTEMS & PIPEWORK Bosch Group...
Page 12 VONDENSAI E PIPEWORK Condensing 30ilet IMPORTANT; Visible air break • Ensure there are no at plug hole blockages in the pipe tun Sink with • Care Should be taken when siting a soak-away to avoid tOOmm obstructing existing services 22 mmØ Insulation increase pipe size plastic pipe...
Page 13 • should be finished a partial bend, near the outlet to face tho external wall (as shown) to help preventfreezing, L • Outside O.M Drain pipe External drain hORCESTE PRESSURE RELIEF PIPEWORK Bosch Group...
Page 14 SERVICING CLEARANCES BOILER LOCATION & VENTED COMPARTMENT CLEARANCES 41 Omm 930m m This boiler is only suitable for installing internally within a property at a sunable location onto a + 30mrn above elbow fixed. nqid sudace at least the same size as the boiler and capable of supporting the boiler COMPARTMENTS Fod/ow...
Page 15 Additional {Residual Current Device) pr0• may be requjre.d. to the latest IEE wiring regulations. 600rnm 750mm 22bOmm 600mm radius hORCESTE BOILER LOCATION & CLEARANCES Bosch Group...
Page 16 PLUMBING MANIFOLD A Gas Supply(alternative fromaboveapphartce} 2 2mm 15mm CONNECTIONS: Heating System: 22mm compression fittings OHW IN (alternative from CH Return 22mm compression fittings aboveappaiance) 22mm compression fittings t5nm use the fittings suppliéd in the LitjHardware CH Flow 22mm • If the boiler pipes are to ho run appliance ensure that the pipes pass through the Slot in the White cardboard gude is fitted to the boiler frame,...
Page 17 I IONS The Greenstar series has the option Oftwo horizontal RSF (60/100 telescopic and 80/125) flue systems and two vertical RSF {60ft00 or 80/125) flue systems: The systemshave different maximumfluo lengths This page Shows various fluing options with the Straight flue lengths required to achieve the maximumflue length.
Page 18 Deduct ooe netro off the botalnaelength for every tend used g" the total ".•e e:katanc• 04 3• matoria) that flows for sale waite socaic•nø m uq nso by 3' 52mm •jeh away bode.' enswe boikm YWORCESTEI FLUE TERMINAL POSITIONS Bosch Group...
Page 19 FLUE TERMINAL POSITIONS NOTES: Plume management kits ore available 100mm hOTizOntalIy terminated flues. Please refer to the installation instructions supplied with the plume management kits, If plume redirection is utilised. the clearance from any opening must be increased in the direction Ot the plurne to t500mm.
Page 20 9; _Removestraps (A) and O pen the top Ofthe boiler packaging, 2. Removetemplate IF) and wall mounting frame {E) from the packaging, 3. Removeboiler bottom panel (D) and instalber p ack YWORCESTEI UNPACKING WALL FRAME Bosch Group ANCILLARY ITEMS...
Page 21 WALL MOUNTING TEMPLATE FLUE OPENING CAUTION; Ensure there are no pipes. electric cables damp proof courses or other hazards before drilling. SAFETY: All relevantsafetyE*ecautjcns mustbe Widertaken, Protectivoclothing, footwear,gbovesand safety USE APPROPRIATE goggles must be worn as appropriate; FIXINGS FIXING MOUNTING FRAME: WEIGHT WALL...
Page 22 UNPACKING THE APPLIANCE UNPACKING THE APPLIANCE A - Outer carton B Innersleeve (unwrapsfran front) C Packaging base D Protective wrappir»g E • Appliance Wter caw 4. Removeouter carton (A) and place safelyaway from the working 5. With the outer packag removedand the inner sleeve{Bj Slill in place gently lay the boiler on its back.
Page 23 oy Ine BOILER CONNECTIONS air gas manifold, CAUTION: ISOLATE MAINS SUPPLY BEFORE STARTING ANY WORK OBSERVE A1 i RELEVANT SAFETY PRECAUTIONS WATER CONNECTIONS; Remove template and secure the wall mounting frameto the wall with the fixings suppdled, Systempipes maybe run verticallyupwards behind the boiler or below it.
Page 24 BOILER CON NECTIONS CAUTION: ISOLATE MAINS SUPPLY BEFORE STARTING ANY WORK AND OOSERVE A1 1 RELEVANT SAFETY PRECAUTIONS GAS AN o WATER CONNECTIONS A • CH flow B • CH return (22mm)i C - Gas inlet (22mm). D • Mains water inlet (15mm), E •...
Page 25 Rentove any burrs charnfer outer edge Of the tubes to assist ease of corv»eetian and required reducingthetermirval. After cutting. tho end must be square and free from burrs to prevent to the seals. hORCESTE FLUE INSTALLATION Bosch Group...
Page 26 FLUE INSTALLATION Installing the standard flue: Set the flue iOng1h to the dislance required, secure With screw and seal joint With th' aluminiumtape supplied. Slide inner wall onto the terminal as shown. If fitting from inside the building; slide the outer wall sea/ {C) onto tho terminal (3) as shown.
Page 27 • Tho nue,when assembled,is fully sealed and components are pushed home. • The flue is set at an angle Of30or 52mrn per m length. Fiat at back T'iis screw should be fitted last for rear exit hORCESTE FLUE INSTALLATION Bosch Group...
Page 28 SUMP CONDENSATE CONNECTION CONNECTION CON OENSATE CONN ECTION: Never terminate or discharge into any open source, including; Sink, bath, shower, bidet, toilet etc: Note; Any external condensate pipework should be protected with weather resistant insulation to help prevent freezing. SUMP BLANKING •...
Page 29 LIVE return terminal (LR) NOTE: This is sometimes referred to as heat Ot STIO Connect external contto's NEUTRAL terminal {Ns) NOTE.Somedevicesdo notrequirethis Optionalexternal f rostStatconnection{ST3)t Connect tioststat cables to terrninals (FS) and Theseare polÜity Refit panels, hORCESTE ELECTRICS Bosch Group...
Page 30 POSITION OF WIRED COMPONENTS SPARK FLAMESENSE ELECTRODES ELECTRODE OVERHEAT FLOW S TAT VALVE OVERHEAT vnve PUMP SENSOR EXTERNAL MAINS FROST STAT SUPPLY {OPTIONAL) Earth PUMP aso V ROOM STAT/ PROGRAMMER 03 NtROt STIO Fiu•e Ft. S PARK TRANSFORMER ST17 ST18 DIAGNOSTIC COOE INtEfiFAce...
Page 31 22mm 15nnrn 22mm 15mm Preplumbing manifold Condensate pipe hORCESTE PRE-COMMISSIONING CHECKS Bosch Group...
Page 32 FILLING THE SYSTEM Turn on the water main and open the system valves. Open all radiator valves. Fill the system via a WRAS approved filling bop to t bar then turn the valve anti•clock• Wise to Close, Vent(A)anyairfromtho boilerheat using a suitable container to collect any water.
Page 33 BLUE power indicator CA)and reset button will Toregot press and hold the reset button tor 2 seconds. The will be CAUTION: DO NOT PRESS POWER INDICATOR (B) TO RESET BOILER. hORCESTE STARTING THE APPLIANCE Bosch Group...
Page 34 WATER TREATMENT IMPORTANT: ARTIFICIALLY SOFTENED WATER IMPORTANT± Debris from the system MUST NOT BE USED TO FILL THE CENTRAL damage the boiler and reduce efficiency. HEATING SYSTEM. Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance warranty.
Page 35 COMMISSIONING THE COMBUSTION FOR THE APPLIANCE NOTE: When running in the service mode, the boiler will operate both IS FACTORY SET. the central heating and the domestic NO ADJUSTMENT IS REQUIRED IFTHE water circuits. This is to allow GAS INLET PRESSURE IS CORRECT.
Page 36 Shownin the user Guide. Ptace the user guide into the tray (E) on the inside of the fascia cover, the appliance is unused and exposed to freezing conditions. shutoffallthe mains_vpplies anddrain thf System and boiler. YWORCESTEI FINISHING COMMISSIONING Bosch Group...
Page 37 INSPECTION AND SERVICE CAUTION: TURN SUPPLY ISOLATE MAINS SUPPLIES BEFORE STARTING WORK OBSERVE RELEVANT SAFETY PRECAUTIONS IMPORTANT: service work must be carried out by competent IMPORTANT: AFTER REPLACEMENT OF ANY COMPONENTS ALWAYS registered engineers such CHECK SOUNDNESS WHERE RELEVANT CARRY British Gas or Gas Safe registered FUNCTIONAL CHECKS...
Page 38 INSPECTION AND SERVICE Component Access 1. Removing outer case Remove bottom by pullingit forward and off. Undoandremove2 screws(A) securing boiler casing at the top Of the appliance- undo but do nat remove the 2 screws (B) securingboilercasing thebottom of the appliance, Pull case forward and remove.
Page 39 INSPECTION AND SERVICE Setting Boiler to Maximum, NOTE: running in the service mode. the boiler will operate both the Contrat Heating and OHW circuits, This is to allow sufficient time for the setting It will be necessary to 'un water through the ciicuit to ensure that...
Page 40 Assembly to clean, TOdrain debris from the syphon, the clips awd removethe drainagecap (E) from the bottom Of the syphon. Catch the debrig and condensate syphon into a suitablecontainer, Re•fitthe drainagecap (E) bottom Of the syphon. YWORCESTEI INSPECTION SERVICE Bosch Group...
Page 41 Rotate fanandait/gasmanifold assembly ( J) around thetopof thebeatexchanger untilit stops at the iug. Lift up assembly and rernove from bailer. Disconnectsparkelectrodeandflamesensor connections Remove plate Removespark/flarneelectrodeassernbiy from boiler, Remove seal f romthetopOftheheat hORCESTE INSPECTION AND SERVICE Bosch Gmup...
Page 42 : INSPECTION AND SERVICE Remove burner Remove top baffle Remove baffle (O), Remove the pozi-dtive screws(P) retainingthe accesscover(O) on sump. Access theheatexchanger fue waysby brush (7 716 192 312) Small throughme top accesshole in tt'± casing(RI Clean heatexchanger flue•ways ( S)usingthe ejeaningbrush(7 716 192 31 removing anydebrisfrom the accesspointin the sump.
Page 43 REPLACEMENT PARTS CAUTION: TURN SUPPLY ISOLATE MAINS SUPPLIES BEFORE STARTING WORK OBSERVE 1. Removing outer case RELEVANT SAFETY PRECAUTIONS. 1.1 Undo 4 screws (A) securing boiler casing i .2 poll case forward and remover IMPORTANT: AFTER REPLACEMENT OF ANY COMPONENTS ALWAYS To remove bottom tray.
Page 44 REPLACEMENT OF PARTS SIT AND DUNGS VALVES The following components require control moved jn to service position: valve Syphon fuse Transformer REMOVAL OF THE VALVE IS THE SAME FOR BOTH SIT AND DUNGS VALVES. SIT VALVE IS SHOWN IN THE DIAGRAM, REPLACEMENT VALVE...
Page 45 REPLACEMENT OF PARTS 7.Access to boiler control components Remove screws and remove cover 8. PCB fuse Remove fuse Fl (B) from the PCB and Thereis a sparefuse clippedinto tho underside of the electrical cover, 9.Transformer / PCB Disconnect all eleebical cortneedig.ns from the control- Remove 5 screws(C)retajningtheteat...
Page 46 REPLACEMENT OF PARTS to. Replacing control IMPORTANT: Do not replacethe control onit if a CO/CO?analyser i s NOTavailable. The control is supplied within its plastic housing. The complete unit must be replaced Remove ALL electrical connections from the control PCB including where cab'es rur through restraints.Thesecan be unclipped from plastic mouldingnoting their...
Page 47 REPLACEMENI PARIS 11.1 The following components require air / gas manifold assembly to be removed: Pressure switch Electrode assembly Burner Heat exchanger IMPORTANT: JOINT BETWEEN AIR/GAS MANIFOLD HEAT EXCHANGER DISTURBED SEALING GASKET M UST BE REPLACED. IMPORTANT: AFTER REASSEMBLY COMBUSTION MUST CHECKED USING...
Page 48 REPLACEMENT OF PARTS t 2.1 12. Fan 12.1Remove3 screws(A) retainingmixing chamber. 122 Remove 2 screws(B) retaining the fanto the air/gas manifold 12.3Removescrew (C) retainingplate and Re-assernble Withnew fan ensuringseals are ec«ectly fitted. CheckCO/C02 levelsasdescribed in the •setting Ot the ar/gas section.
Page 49 REPLACEMENT OF PARTS NOTE: Removal Of the syphon assembly will give access to Auto air vent, the syphon(A) the Sump connection, disengage the retaining clip on top OfIhe syphon and pull the syphon towards you. Disconnecttho dge:hargehose plumbingmanifold. RemoveIha completesyphon assembly; Diverter valve motor...
Page 50 20.1 REPLACEMENT OF PARTS 20.2 20. Pump head Ensure the boiler is drained (see drainingthe appliance}. Disconnect the electrical connection from the bottom of the puml) 20.' Remove t he{aurAllenballs(A) securing lhe pumpat eachcomet; •i 20.2Gentiypull the pumptowardsyouand remove TOrefit, fallow the reverse- 20.3 Pressure gauge 20.3...
Page 51 REPLACEMENT OF PARTS NOTE: Removethesyphonassembly. TOrelease the Syphon from the gurnp connection,disengagetho retainingclip on top ot the syphon and pull the syphon towards you. Disconnectthc dischargehoso (B) at the Plugnbng manifold„ Remove the complete syphon 24. Hydraulic Block Ensuretheapplvanee h asbeenfollydrajned {seed'ainihg theappliance}, Disconnect the electrical...
Page 52 REPLACEMENT OF PARTS NOTE: Remove the Hydraulicblockfrom the boiler(See removingthe Hydraulic on page51 26. Plastic protection device 26.2 Ensurethe systemis fully drained drainingtheappliance) Disconnectall pipesconnectedto the pump housing. Remove the electrical connection to the purrU% Withdrawihe metalclip tothe right of the pumpheadto releasethe pumphousing Sbde the deuce to the left and then wathd;ra it from the appliance...
Page 53 REPLACEMENT PARTS 28.1 Remove the Hydraulicbhck from the NOTE: boiler(Refer to page51). 28. Bypass valve Removethetwo spring clipsat eitherend of the copperbypzsspipe Undothe screwsecuringthe left hard 28.2 plastichousingto the heatexchanger Movethe housingto the left to free upthe oneend o/ the pipe. Removethe pipefrom theright handhousing to revealthe bypassvalve 782 Usinga par of pliers.pull out the bypass...
Page 54 SETTING / AIR RATIO THIS PAGE SHOWS SETTING PROCEDURE SIT VALVE ALTERNATIVE VALVES PAGE 55 FOR DUNGS. FOR THE SIT 848.093 SIGMA SETTING RATIO MUST CARRIED BY A COMPETENT PERSON. SETTING OF THE GAS RATIO MUST NOT BE ATTEMPTED UNLESS PERSON 30.1 CARRYING...
Page 55 THIS PAGE SHOWS SETTING PROCEDURE DUNGS SETTING / AIR RATIO VALVE FOR ALTERNATIVE VALVES PAGE 54 FOR SIT. FOR DUNGS GB-ND 055 DOI SETTING RATIO CARRIZO BY A COMPETENT PERSON. SETTING OF THE GAS RATIO MUST NOT ATTEMPTED UNLESS PERSON 30.1 CARRYING CONVERSION...
Page 56 SHORT PARTS LIST WORCESTER 204 453 0 GCN« H26 536 Burner WORCESTER Part 8716 120 619 0 H49 526 Gas valve NG & LPG WORCESTER Part No 8716 3250 Controa board WORCESTER Part 8 748 a006340 tumos,tat g 710 506 267 0 H44 419 Electrodes (includes gasket) 8 718 107 007 0...
Page 57 Not a fault code made selected rna,X, service button to Flow Sensor Tegi "Replace control board if: 5V is across the red and black cab*es, 1.$V-3.5Vis across the yellowand black cables (with water flowing}. Otherwise replace sensor. /ÜORCESTER FAULT FINDING Bosch...
Page 58 FUNGI ./QORCESTEI CENTRAL HEATING FUNCTION...
Page 59 PREHEATAND DHW FUNCTION PREHEATAND DHW FUNCTION VQORCESTER Bwch Group...
Page 60 PROTECTION FUNCTION Boiler temperature function Pumprun 5 seconds pump antiseize every94hrs YÜORCESTEI PROTECTION FUNCTION...
Page 61 BOILER COMMISSIONING CHECKLIST This Commissioning Checklist iS to be completed in full b} the competent person Who commiSSi0Gd the b0itec as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future referenee- Failure to install and commission this equipment to the instructions may invalidate the warranty but does not affect Statutory rights, Cusoornor...
Page 62 SERVICE RECOR D is recomtnended that yout heating system is serviced regularly and that the appropriate Service Record is completed, Service Provider Before completing the appropriate Sevice Record below. ensure you have carried out the service as described in the manufacturer's instructions.
Page 63 5, Is the incoming gas pressure at least with the boiler at maximum output? Dedicated to heating comfort 'Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 SW. Tot. otgos 754624 Fax. 01905 784619 Worcester,Bosch Group is a brand name01BoschThermotechnology Ltd. www.worcester•bosch.co.uk 8 "6 "5 662b 60/2009)

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Worcester greenstar 28i junior