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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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See also: Installation, Commissioning & Servicing Instructions , Instructions for Installation and Servicing
INSTRUCTION MANUAL
INSTALLATION, COMMISSIONING & SERVICING
WALL HUNG RSF GAS FIRED CONDENSING COMBINATION BOILER
GREENSTAR 24i
FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED
DOMESTIC HOT WATER
j
j
u
u
n
n
i
i
o
o
r / 28i
r
THE APPLIANCE IS FOR USE WITH
NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13, C33 & C53)
NATURAL GAS:
LIQUID PETROLEUM GAS:
UK/IE
j
j
u
u
n
n
i
i
o
o
r
r
24i junior GC NUMBER 47-311-86
28i junior GC NUMBER 47-311-87
24i junior GC NUMBER 47-311-90
28i junior GC NUMBER 47-311-91

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Summary of Contents for Worcester GREENSTAR 24i junior

  • Page 1 DOMESTIC HOT WATER THE APPLIANCE IS FOR USE WITH NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13, C33 & C53) NATURAL GAS: 24i junior GC NUMBER 47-311-86 28i junior GC NUMBER 47-311-87 LIQUID PETROLEUM GAS: 24i junior GC NUMBER 47-311-90...
  • Page 2 the nation’s favourite PLUMBING & HEATING SUPPLIES FREE SHIPPING SECURE PAYMENTS on all orders over £100 to mainland UK shop online with confidence FINANCE AVAILABLE PRICE MATCH spread the cost with low interest rates always get the best deals available we have H U G E R E D U C T I O N S...
  • Page 3 SENTINEL 0800 389 4670 www.sentinel-solutions.net FLUE TERMINAL GUARDS: TOWER FLUE COMPONENTS LTD. Vale Rise, Tonbridge TN9 1TB 01732 351555 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior INSTALLATION & 8 716 115 166a (06/2008) SERVICING INSTRUCTIONS...

  • Page 4: Table Of Contents

    L.P.G. CONVERSION FAULT FINDING & DIAGNOSIS FAULT FINDING CENTRAL HEATING FUNCTION PREHEAT AND DHW FUNCTION PROTECTION FUNCTION BENCHMARK CHECKLIST SERVICE INTERVAL RECORD SHEET INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior CONTENTS 8 716 115 166a (06/2008)

  • Page 5: Safety Precautions & Symbols

    IMPORTANT - The service engineer must complete the Service Record on the Benchmark Checklist after each service. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior SAFETY PRECAUTIONS 8 716 115 166a (06/2008)

  • Page 6: General Information

    • Plate type DHW heat exchanger Syphon assembly.................... 1 Installation instructions.................. 1 Irish Guidelines Leaflet ................. 1 Warranty Return Envelope ................1 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior GENERAL INFORMATION 8 716 115 166a (06/2008)

  • Page 7: Technical Data

    Noise output level (Max central heating) dB(A) Total boiler weight 39.5 39.5 39.5 39.5 Lift weight 27.1 27.1 27.1 27.1 SEDBUK 90.1 90.1 91.8 91.8 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior TECHNICAL DATA 8 716 115 166a (06/2008)

  • Page 8: Layout & Components

    32 F LU E AI R P R ES S U R E SWITC H CONNECTION (BLANKED OFF ON THIS APPLIANCE) INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior LAYOUT & COMPONENTS 8 716 115 166a (06/2008)
  • Page 9 50 CH TEMPERATURE CONTROL 51 POSITION FOR OPTIONAL PROGRAMMER 52 SERVICE MODE BUTTON 53 BURNER ON INDICATOR LIGHT (GREEN) 54 MASTER SWITCH ON/OFF INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior LAYOUT & COMPONENTS 8 716 115 166a (06/2008)

  • Page 10: Cleaning Primary Systems

    • It may be necessary to use a power flushing machine to aid the cleansing procedure in some circumstances INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior CLEANING PRIMARY SYSTEMS 8 716 115 166a (06/2008)

  • Page 11: Mains Supply

    In such circumstances, the advice of the local water authority should be sought. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior MAINS SUPPLY 8 716 115 166a (06/2008)

  • Page 12: Water Systems & Pipework

    • Do not use galvanised pipes or radiators. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior WATER SYSTEMS & PIPEWORK 8 716 115 166a (06/2008)

  • Page 13: Condensate Pipework

    An air break must be installed in the 32/43 mm pipework, between the boiler condensate outlet and the drainpipe, outside the property, to avoid flooding during adverse weather conditions. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior CONDENSATE PIPEWORK 8 716 115 166a (06/2008)

  • Page 14: Pressure Relief Pipework

    (as shown) to help prevent freezing. L - Outside wall O,M - Drain pipe N - External drain INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior PRESSURE RELIEF PIPEWORK 8 716 115 166a (06/2008)

  • Page 15: Boiler Location & Clearances

    Total side clearance must be removable door) is must be increased to (approx): increased to: reduced to: 50mm 511mm 505mm 25mm 596mm 569mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior BOILER LOCATION & CLEARANCES 8 716 115 166a (06/2008)

  • Page 16: Boiler Location

    Additional RCD (Residual Current Device) pro- tection may be required. Refer to the latest IEE wiring regulations. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior BOILER LOCATION & CLEARANCES 8 716 115 166a (06/2008)

  • Page 17: Plumbing Manifold

    Further guidance on pipe routing can be found printed on the boiler template (supplied with the boiler). Mains Gas Mains Water Supply 22mm (DHW IN) 15mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior PLUMBING MANIFOLD 8 716 115 166a (06/2008)

  • Page 18: Flue Options

    High level horizontal flue with 2x90° bends FLUE OPTIONS The Greenstar series has the option of two horizontal RSF (60/100 telescopic and 80/125) flue systems and two vertical RSF (60/100 or 80/125) flue systems: The systems have different maximum flue lengths This page shows various fluing options with the straight flue lengths required to achieve the maximum flue length.

  • Page 19: Flue Terminal Positions

    50 mm) around the flue and fixed to the wall with plated screws. See Contact Information (inside front cover). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior FLUE TERMINAL POSITIONS 8 716 115 166a (06/2008)
  • Page 20 FLUE TERMINAL POSITIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior FLUE TERMINAL POSITIONS 8 716 115 166a (06/2008)

  • Page 21: Installation

    2. Remove template (F) and wall mounting frame (E) from the packaging. 3. Remove boiler bottom panel (D) and installer pack (C). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior UNPACKING WALL FRAME AND 8 716 115 166a (06/2008) ANCILLARY ITEMS...

  • Page 22: Wall Mounting Template / Flue Opening

    This kit can be used in conjunction with the optional filling loop 7 716 192 281(not sup- plied with the boiler). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior WALL MOUNTING PLATE FLUE OPENING 8 716 115 166a (06/2008)

  • Page 23: Unpacking The Appliance

    6.2). Remove any packaging within the boiler and the packaging base (C). CAUTION: Caps fitted to pipes must be removed before hanging the boiler. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior UNPACKING THE APPLIANCE 8 716 115 166a (06/2008)

  • Page 24: Boiler Connections

    UP until the stop on the inside of the handle is over the shoulder of the metal bracket to secure in place. Stop in locked position INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior BOILER CONNECTIONS 8 716 115 166a (06/2008)
  • Page 25 15mm compression joint (J) using the compression nut and olive supplied in the hardware literature pack. 22mm 15mm 22mm 15mm 22mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior BOILER CONNECTIONS 8 716 115 166a (06/2008)

  • Page 26: Flue Installation

    After cutting, the end must be square and free from burrs to prevent damage to the 130mm flue seals. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior FLUE INSTALLATION 8 716 115 166a (06/2008)
  • Page 27 Do not attempt to force beyond the limit stops. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior FLUE INSTALLATION 8 716 115 166a (06/2008)
  • Page 28 • The flue is set at an angle of 3° or 52mm per 1m length. Flat at back This screw should be fitted last for rear exit INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior FLUE INSTALLATION 8 716 115 166a (06/2008)

  • Page 29: Condensate Connections

    Re-fit the drainage cap to bottom of the syphon. DRAINAGE CAP DISCHARGE HOSE WALL FRAME CONNECTOR INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior CONDENSATE CONNECTION 8 716 115 166a (06/2008)

  • Page 30: Electrics

    5 Optional external frost stat connection (ST6): Connect froststat cables to terminals (FS) and (FR). These are not polarity sensitive. 6 Refit panels. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior ELECTRICS 8 716 115 166a (06/2008)

  • Page 31: Position Of Wired Components

    POSITION OF WIRED COMPONENTS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior POSITION OF WIRED COMPONENTS 8 716 115 166a (06/2008)

  • Page 32: Pre-Commissioning Checks

    22mm 15mm 22mm 15mm 22mm Preplumbing manifold connector Condensate pipe INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior PRE-COMMISSIONING CHECKS 8 716 115 166a (06/2008)

  • Page 33: Filling The System

    This kit can be used in conjunction with the optional filling loop 7 716 192 281(not sup- plied with the boiler). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior FILLING THE SYSTEM 8 716 115 166a (06/2008)

  • Page 34: Starting The Appliance

    To reset press and hold the reset button (E) for 2 seconds. The boiler will be reset. CAUTION: DO NOT PRESS POWER INDICATOR (B) TO RESET BOILER. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior STARTING THE APPLIANCE 8 716 115 166a (06/2008)

  • Page 35: Water Treatment

    The addition of sealing agents to the system water is not recommended as this can cause problems with deposits left in the heat exchanger. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior WATER TREATMENT 8 716 115 166a (06/2008)

  • Page 36: Commissioning

    When the ECO button is illuminated the boiler will be in Economy mode with pre-heat no longer active. Inlet Test Nipple INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior COMMISSIONING 8 716 115 166a (06/2008)

  • Page 37: Finishing Commissioning

    If the appliance is unused and exposed to freezing conditions, shut off all the mains supplies and drain the system and boiler. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior FINISHING COMMISSIONING 8 716 115 166a (06/2008)

  • Page 38: Inspection And Service

    Commissioning. Operate the appliance and take note of any irregularities. Refer to Fault Finding for rectification procedures. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior INSPECTION AND SERVICE 8 716 115 166a (06/2008)
  • Page 39 2.1 Remove screw (C) securing control. 2.2 Gently pull the control forward until it is fully lowered into the service position. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior INSPECTION AND SERVICE 8 716 115 166a (06/2008)
  • Page 40 28i junior - 3.9 mbar 28i junior - 4.6mbar • Pressures measured below these figures will indicate that the heat exchanger will require cleaning. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior INSPECTION AND SERVICE 8 716 115 166a (06/2008)
  • Page 41 Catch the debris and condensate from the syphon into a suitable container. Re-fit the drainage cap (E) to bottom of the syphon. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior INSPECTION AND SERVICE 8 716 115 166a (06/2008)
  • Page 42 (K). Remove clamping plate (L). Remove spark/flame electrode assembly from boiler. Remove seal from the top of the heat exchanger. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior INSPECTION AND SERVICE 8 716 115 166a (06/2008)
  • Page 43 BETWEEN THE AIR/GAS MANIFOLD AN D TH E H EAT E XCHANG E R I S DISTURBED THE SEALING GASKET MUST BE REPLACED. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior INSPECTION AND SERVICE 8 716 115 166a (06/2008)

  • Page 44: Replacement Of Parts

    Undo the flue connection from the sump and push the flue tube up. Push the flue limit thermostat outwards from the sump. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166a (06/2008)
  • Page 45 Replace valve with new seals and check for gas soundness. Note: The valve will require setting; follow procedure “Setting the air/gas ratio” . INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166a (06/2008)
  • Page 46 Remove 5 screws (C) retaining the rear panel of the control and remove panel. Spare Fuse order T1.6L 250V F2 T2.5H 250V F1 T500L 250V F3 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166a (06/2008)
  • Page 47 IS RE-FITTED TO THE NEW CONTROL. IF THIS IS NOT DONE THE BOILER WILL INDICATE ERROR AND WILL NOT FUNCTION. 10.3 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166a (06/2008)
  • Page 48 Lift up assembly and remove from boiler. NOTE: After re-assembly, check the CO/CO levels as described in the setting of the air/gas ratio section. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166a (06/2008)

  • Page 49: Electrode Assembly

    IMPORTANT: IF THE JOINT BETWEEN THE AIR/GAS MANIFOLD AND THE HEAT EXCHANGER IS DISTURBED THE SEALING GASKET MUST BE REPLACED. 15.4 15.2 15.3 15.1 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166a (06/2008)

  • Page 50: Diverter Valve Motor

    19.1 Withdraw the spring clip. 19.2 Withdraw the sensor (D) from the housing. To refit, follow the above in reverse. 19.2 19.1 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166a (06/2008)

  • Page 51: Pressure Gauge

    23.2 Withdraw the drain tap from its housing To refit, follow the above in reverse. Ensure any seals that have been disturbed are renewed. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166a (06/2008)

  • Page 52: Ch Pressure Relief Valve

    25.2 Withdraw the pressure release valve (A) from its housing. To refit, follow the above in reverse. Ensure any seals that have been disturbed are renewed. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166a (06/2008)

  • Page 53: Dhw Heat Exchanger

    27.2 Remove the heat exchanger To refit, follow the above in reverse. Ensure any seals that have been disturbed are renewed. 27.2 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166a (06/2008)

  • Page 54: Expansion Vessel

    Gently raise the boiler off the mounting frame. Replace expansion vessel and refit the boiler to the mounting frame. Follow the commissioning procedure in this manual. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166a (06/2008)
  • Page 55 Remove manometer and re-seal inlet pressure point on gas valve. Re-assemble and refit boiler case. ‘C’ INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166a (06/2008)

  • Page 56: Setting The Air/Gas Ratio

    Remove manometer and re-seal inlet pressure point on gas valve. Re-assemble and refit boiler case. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166a (06/2008)

  • Page 57: Short Parts List

    GC No. E27 305 Fuse 0.5 Amp F3 WORCESTER Part No. 1 904 522 730 0 GC No. E27 300 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 8 716 115 166a (06/2008)

  • Page 58: L. P. G. Conversion

    S ET TI N G TH E AI R / GAS R ATI O 28kW NG SECTION OF THIS MANUAL. 28kW LPG INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior LPG CONVERSION 8 716 115 166a (06/2008)

  • Page 59: Fault Finding & Diagnosis

    :Replace control board if: 5V is not across the red and black cables. :1.5V-3.5V is across the yellow and black cables (with water flowing). Otherwise replace flow sensor. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior FAULT FINDING 8 716 115 166a (06/2008)

  • Page 60: Central Heating Function

    Over temperature shut- Gas valve OFF. down if water tempera- 3 minute wait Fan overrun ture is 5°C above set 30 seconds value. Room thermostat and/or mains programmer ON Fan (& gas) (or link fitted at modulation GREEN 10 second END OF ST10) Fan to...

  • Page 61: Preheat And Dhw Function

    FAULT FINDING Burner shut down if & DIAGRAMS primary temperature 94°C (until 84°C) Over temperature shut- Wait down if water tempera- Gas valve OFF. 5 seconds ture is 8°C above set value. DOMESTIC Tap open WATER (recognised DEMAND by flow (priority over Fan (&...

  • Page 62: Protection Function

    PROTECTION FUNCTION Boiler temperature Run autofroststat below 8°C function Pump run 5 seconds Pump antiseize every 24hrs INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior PROTECTION FUNCTION 8 716 115 166a (06/2008)
  • Page 65 If in the unlikely event the boiler does not give complete satisfaction, before calling for a service engineer, the installer should check the following:- No Central Heating Is the room stat correctly wired up at the boiler and the Pack Number room thermostat? Refit the link between Ls and L on terminal block ST 10.

This manual is also suitable for:

Greenstar 28i junior

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