Worcester GreenStart 25Si Instruction Manual
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Worcester GreenStart 25Si Instruction Manual

Worcester GreenStart 25Si Instruction Manual

Wall hung rsf gas-fires condensing combination boiler for sealed central heating systems and mains fed domestic hot water
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THE APPLIANCE IS FOR USE WITH
NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13 & C33)
NATURAL GAS: WORCESTER GREENSTAR 25Si GC NUMBER 47-311-84
WORCESTER GREENSTAR 30Si GC NUMBER 47-311-85
LIQUID PETROLEUM GAS: WORCESTER GREENSTAR 25Si GC NUMBER 47-311-88
WORCESTER GREENSTAR 30Si GC NUMBER 47-311-89
interval record, printed within this
manual
GB/IE
CHECKLIST & service

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Summary of Contents for Worcester GreenStart 25Si

  • Page 1 NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13 & C33) NATURAL GAS: WORCESTER GREENSTAR 25Si GC NUMBER 47-311-84 WORCESTER GREENSTAR 30Si GC NUMBER 47-311-85 LIQUID PETROLEUM GAS: WORCESTER GREENSTAR 25Si GC NUMBER 47-311-88 WORCESTER GREENSTAR 30Si GC NUMBER 47-311-89 GB/IE CHECKLIST &...
  • Page 2 THIS APPLIANCE MUST BE INSTALLED BY A COMPETENT PERSON. FAILURE TO INSTALL CORRECTLY COULD LEAD TO PROSECUTION. IF YOU ARE IN ANY DOUBT CONTACT WORCESTER TECHNICAL HELPLINE. WATER TREATMENT: DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER. FERNOX 01799 550811 www.fernox.com...

  • Page 3: Table Of Contents

    SETTING THE GAS/AIR RATIO SHORT PARTS LIST CONVERSION KITS L.P.G. CONVERSION FAULT FINDING & DIAGNOSIS FAULT FINDING CH FUNCTION DHW FUNCTION PROTECTION FUNCTION BENCHMARK CHECKLIST SERVICE INTERVAL RECORD SHEET INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si CONTENTS 8 716 107 337b (11/05)

  • Page 4: Safety Precautions And Installation Regulations

    IMPORTANT - The service engineer must complete the Service Record on the Benchmark Checklist after each service. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si SAFETY PRECAUTIONS 8 716 107 337b (11/05)

  • Page 5: General Information

    CH temperature sensor & control Pump anti-seizure protection Flue gas temperature limiter Condensate trap & syphon DHW flow sensor & temperature control Plate type DHW heat exchanger INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si GENERAL INFORMATION 8 716 107 337b (11/05)

  • Page 6: Technical Data

    Packaged boiler weight 44.4 44.4 44.4 44.4 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 25Si/30Si TECHNICAL DATA 8 716 107 337b (11/05)

  • Page 7: Layout & Components

    FROM HEAT EXCHANGER) 32 PUMP 33 SYSTEM PRESSURE GAUGE 34 CONTROL PANEL IN SERVICE POSITION 35 HEAT EXCHANGER 36 ACCESS COVER FOR TRANSFORMER & INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si LAYOUT & COMPONENTS 8 716 107 337b (11/05)
  • Page 8 53 MASTER SWITCH ON/OFF 54 ECO BUTTON 55 FAULT RESET BUTTON 56 SYSTEM PRESSURE GAUGE 57 POSITION FOR OPTIONAL PROGRAMMER 58 INTERNAL BYPASS WITHIN PLASTIC MOULDING INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si LAYOUT & COMPONENTS 8 716 107 337b (11/05)

  • Page 9: Cleaning Primary Systems

    5 Drain and thoroughly flush the system to remove the flushing agent and debris. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si CLEANING PRIMARY SYSTEMS 8 716 107 337b (11/05)

  • Page 10: Mains Supply

    200ppm, consideration may need to be given to the fitting of a scale prevention device. In such circumstances, the advice of the local water authority should be sought. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si MAINS SUPPLY 8 716 107 337b (11/05)

  • Page 11: Water Systems & Pipework

    • Pressurise the extra expansion vessel (B) to the same figure as the expansion vessel built into the appliance. • Do not use galvanised pipes or radiators. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si WATER SYSTEMS & PIPEWORK 8 716 107 337b (11/05)

  • Page 12: Condensate Pipework

    H - Ground level J - Drainage holes 50mm from base of tube (12mmØ at 25mm centres) facing away from building K - Limestone chippings INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si CONDENSATE PIPEWORK 8 716 107 337b (11/05)

  • Page 13: 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 25Si/30Si PRESSURE RELIEF PIPEWORK 8 716 107 337b (11/05)

  • Page 14: 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 25Si/30Si BOILER LOCATION & CLEARANCES 8 716 107 337b (11/05)
  • Page 15 Electrical switches, fused spur and socket out let s must not be sit uat ed in t he bathroom. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si BOILER LOCATION & CLEARANCES 8 716 107 337b (11/05)

  • Page 16: Plumbing Manifold

    Further guidance on pipe routing can be found printed on the boiler template (supplied with the boiler). Mains Gas Supply 22mm Mains Water (DHW IN) 15mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si PLUMBING MANIFOLD 8 716 107 337b (11/05)

  • Page 17: Flue Terminal Positions

    The flue should not penetrate the shaded area. Care should be taken to ensure terminal siting does not cause a nuisance to adjacent properties. 600mm 600mm 2000mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si FLUE TERMINAL POSITIONS 8 716 107 337b (11/05)

  • Page 18: Flue Options

    B x 4 + C x 2 + E x 1 Vertical 80/125mm: 1365mm to top of terminal Ø125 - 11000mm (including terminal) B x 13 + C x 2 + E x 1 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si FLUE OPTIONS 8 716 107 337b (11/05)

  • Page 19: Installation

    2. Remove template (F) and wall mounting frame (E) from the packaging. 3. Remove boiler bottom panel (D) and installer pack (C). UNPACKING WALL FRAME AND INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si 8 716 107 337b (11/05) ANCILLARY ITEMS...

  • Page 20: 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 25Si/30Si WALL MOUNTING PLATE FLUE OPENING 8 716 107 337b (11/05)

  • Page 21: Unpacking The Appliance

    7. Stand boiler upright and remove the protective inner packaging (F) at the rear of the boiler. CAUTION: Caps fitted to pipes must be removed before hanging the boiler. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si UNPACKING THE APPLIANCE 8 716 107 337b (11/05)

  • Page 22: 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 25Si/30Si BOILER CONNECTIONS 8 716 107 337b (11/05)

  • Page 23: Boiler Connections

    8. Connect the pressure relief drain pipe to 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 25Si/30Si BOILER CONNECTIONS 8 716 107 337b (11/05)

  • Page 24: Flue Installation

    250mm. After cutting, the end must be square and free from burrs to prevent damage to the flue seals. (250mm min) Turret Clamp Flue INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si FLUE INSTALLATION 8 716 107 337b (11/05)
  • Page 25 98mm per bend must be allowed from the centre line of the bend. In the example shown using a flue extension with 2 bends will achieve a total length of 1148mm. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si FLUE INSTALLATION 8 716 107 337b (11/05)

  • Page 26: Flue Installation

    • 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 25Si/30Si FLUE INSTALLATION 8 716 107 337b (11/05)

  • Page 27: Condensate Connection

    It must fall at least 50mm per metre towards the outlet. • An adaptor in 22mm pipe is contained in the fitting pack (A) along with sealing washer (B). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si CONDENSATE CONNECTION 8 716 107 337b (11/05)

  • Page 28: Electrics

    NOTE: Some devices do not require this. 8 Optional external frost stat connection (ST6): Connect froststat cables to terminals (FS) and (FR). These are not polarity sensitive. 9 Refit panels. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si ELECTRICS 8 716 107 337b (11/05)

  • Page 29: Position Of Wired Components

    POSITION OF WIRED COMPONENTS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si POSITION OF WIRED COMPONENTS 8 716 107 337b (11/05)

  • Page 30: Pre-Commissioning Checks

    22mm 15mm 22mm 15mm 22mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si PRE-COMMISSIONING CHECKS 8 716 107 337b (11/05)

  • Page 31: 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 25Si/30Si FILLING THE SYSTEM 8 716 107 337b (11/05)

  • Page 32: 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 25Si/30Si STARTING THE APPLIANCE 8 716 107 337b (11/05)

  • Page 33: Water Treatment

    * compatible with aluminium. The pH Agent value of the system water must be less than 8 or the appliance guarantee will be invalidated. Inhibitor INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si WATER TREATMENT 8 716 107 337b (11/05)

  • Page 34: Commissioning

    I - System pressure gauge J - Cover or optional programmer When the ECO button is illuminated the boiler will be in Economy mode with pre-heat no longer active. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si COMMISSIONING 8 716 107 337b (11/05)

  • Page 35: 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 25Si/30Si FINISHING COMMISSIONING 8 716 107 337b (11/05)
  • Page 36 Refill and re-pressurise if applicable as described in Commissioning. Operate the appliance and take note of any irregularities. Refer to Fault Finding for rectification procedures. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si INSPECTION AND SERVICE 8 716 107 337b (11/05)
  • Page 37 25Si - 3.7 mbar 30Si - 4.5 mbar 30Si - 5.2 mbar Pressures measured below these figures will indicate that the heat exchanger will require cleaning INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si INSPECTION AND SERVICE 8 716 107 337b (11/05)

  • Page 38: Inspection And Service

    There is a special accessory kit available specifically designed for cleaning the heat exchanger. If required order 7 716 192 312. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si INSPECTION AND SERVICE 8 716 107 337b (11/05)
  • Page 39 3.2 Remove hose (F). 3.3 Remove siphon Siphon The siphon body is transparent so contents can be examined for any blockage. If necessary flush with clean water. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si INSPECTION AND SERVICE 8 716 107 337b (11/05)
  • Page 40 Disconnect spark electrode and flame sensor connections (J). Remove clamping plate (K). Remove spark/flame electrode assembly from boiler. Remove seal from the top of the heat exchanger INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si INSPECTION AND SERVICE 8 716 107 337b (11/05)
  • Page 41 JOI NT 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 25Si/30Si INSPECTION AND SERVICE 8 716 107 337b (11/05)

  • Page 42: Replacement Of Parts

    NOTE: It is essential that the mating surface of the thermostat is coated with heat conductive paste. 4. Flue overheat thermostat Remove electrical connections. Unscrew thermostat from flue. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si REPLACEMENT OF PARTS 8 716 107 337b (11/05)
  • Page 43 8. Siphon 8.1 Undo plastic nut (E) on the siphon outlet. Drop condensate tube away from siphon. 8.2 Remove hose (F). 8.3 Remove siphon. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si REPLACEMENT OF PARTS 8 716 107 337b (11/05)

  • Page 44: Replacement Of Parts

    Remove 5 screws (D) 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 25Si/30Si REPLACEMENT OF PARTS 8 716 107 337b (11/05)
  • Page 45 IMPORTANT: ENSURE CODE PLUG IS RE-FITTED TO THE NEW CONTROL. IF THIS IS NOT DONE 12.2 THE BOILER WLL INDICATE ERROR AND WILL NOT FUNCTION. 12.3 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si REPLACEMENT OF PARTS 8 716 107 337b (11/05)
  • Page 46 Refit new pressure switch to bracket. I M PORTANT: E N S U R E TU B E I S REFITTED TO PRESSURE SWITCH 14.1 14.2 14.3 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si REPLACEMENT OF PARTS 8 716 107 337b (11/05)
  • Page 47 BETWEEN THE AIR/GAS MANIFOLD AN D TH E H EAT E XCHANG E R I S DISTURBED THE SEALING GASKET MUST BE REPLACED. 18.4 18.2 18.3 18.1 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si REPLACEMENT OF PARTS 8 716 107 337b (11/05)
  • Page 48 22.1 Withdraw the spring clip. 21.1 21.2 22.2 Withdraw the sensor (D) from the housing. To refit, follow the above in reverse. 22.1 22.2 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si REPLACEMENT OF PARTS 8 716 107 337b (11/05)
  • Page 49 26.2 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 25Si/30Si REPLACEMENT OF PARTS 8 716 107 337b (11/05)
  • Page 50 28.2 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. 28.1 28.2 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si REPLACEMENT OF PARTS 8 716 107 337b (11/05)
  • Page 51 30.2 Remove the heat exchanger 30.1 To refit, follow the above in reverse. Ensure any seals that have been disturbed are renewed. 30.2 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si REPLACEMENT OF PARTS 8 716 107 337b (11/05)
  • Page 52 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 25Si/30Si REPLACEMENT OF PARTS 8 716 107 337b (11/05)

  • Page 53: Setting The Gas/Air Ratio

    Re-connect mains electrical supply and check boiler operation as stated in the commissioning section. Fit new label from kit over existing label on the appliance bottom panel. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si SETTING THE GAS/AIR RATIO 8 716 107 337b (11/05)

  • Page 54: Short Parts List

    8 716 105 545 0 H05 206 GC No. Pressure relief valve 8 716 106 431 0 WORCESTER Part No. GC No. H09 750 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si SHORT PARTS LIST 8 716 107 337b (11/05)

  • Page 55: Conversion

    P R O C E D U R E C AN B E F O U N D I N 30kW NG THE REPLACEMENT PARTS SECTION 30kW LPG OF THIS MANUAL. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si L.P.G. CONVERSION 8 716 107 337b (11/05)

  • Page 56: Fault Finding & Diagnosis

    FAULT FINDING NOTE : This fault finding information is for guidance only. Worcester cannot be held responsible for costs incurred by persons not deemed to be competent. The electronic control system for this boiler incorporates a blue central indicator. This normally confirms the permanent mains supply but, by flashing at different rates during a fault, provides a guide to the cause as listed.

  • Page 57: Ch Function

    CENTRAL HEATING FUNCTION INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si CENTRAL HEATING FUNCTION 8 716 107 337b (11/05)

  • Page 58: Dhw Function

    PREHEAT AND DHW FUNCTION INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si PREHEAT AND DHW FUNCTION 8 716 107 337b (11/05)

  • Page 59: 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 25Si/30Si PROTECTION FUNCTION 8 716 107 337b (11/05)
  • Page 60 BENCHMARK No. GAS BOILER COMMISSIONING CHECKLIST C O L L E C T I V E M A R K BOILER SERIAL No. NOTIFICATION No. CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes TIME &...

  • Page 61: Service Interval Record

    SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below. Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions.

  • Page 62: Check List

    INSTALLATION, COMMISSIONING & SERVICING EXCELLENCE COMES AS STANDARD Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 01905 754624 Fax. 01905 754619 Worcester, Bosch Group is a trading name of BBT Thermotechnology UK Ltd. www.worcester-bosch.co.uk 8 716 107 337b (11.05)

This manual is also suitable for:

Greenstart 30si

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