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INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS WALL HUNG RSF GAS FIRED CONDENSING BOILER GREENSTAR Ri FOR OPEN VENTED & SEALED CENTRAL HEATING SYSTEMS & INDIRECT MAINS FED DOMESTIC HOT WATER The appliance is used with Natural Gas or L.P.G (Cat II 2H3P type C13, C33 & C53) Natural Gas 6720644744-00.1Wo Liquid Petroleum Gas 6 720 804 541 (2012/12) UK/IE Model GC Number 12Ri 41-311-63 15Ri 41-311-75 18Ri 41-311-77 24Ri 41-311-65 12Ri 41-311-64 15Ri 41-311-76 18Ri 41-311-78 24Ri 41-311-66 CONTENTS CONTENTS 1 KEY TO SYMBOLS AND SAFETY PRECAUTIONS . . . . . . . . . . . . 3 1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2 APPLIANCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.1 Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.3 Boiler main components . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3 PRE-INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3.1 Cleaning primary systems . . . . . . . . . . . . . . . . . . . . . . . . . 8 3.2 Mains supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3.2.1 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3.2.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3.3 Water systems and pipe work . . . . . . . . . . . . . . . . . . . . . . 8 3.4 Condensate pipe work . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.4.1 Internal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.4.2 External connections . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3.5 Pressure relief pipe work. . . . . . . . . . . . . . . . . . . . . . . . 12 3.6 Boiler location and clearances . . . . . . . . . . . . . . . . . . . 12 3.6.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.6.2 Servicing clearances Ventilated compartment . . . . . . . . . . . . . . . . . . . . . . . . 12 3.6.3 Compartments: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3.6.4 Boiler clearances- Unventilated compartments . . . . . 13 3.6.5 Installation clearances - unventilated compartments . 13 3.6.6 Bathrooms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3.7 Plumbing manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 3.7.1 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 3.8 Flue options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.9 Flue terminal positions . . . . . . . . . . . . . . . . . . . . . . . . . 17 3.10 Plume management terminal positions . . . . . . . . . . . . 18 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Unpacking the wall frame & ancillary items . . . . . . . . . 4.2 Wall mounting template & flue opening . . . . . . . . . . . . 4.3 Outer case removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 Boiler connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.1 Condensate connection . . . . . . . . . . . . . . . . . . . . . . . . 4.5 Flue installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.1 Measuring the flue (Standard flue): . . . . . . . . . . . . . . . 4.5.2 Reducing the telescopic flue length . . . . . . . . . . . . . . . 4.5.3 Installing the telescopic flue . . . . . . . . . . . . . . . . . . . . . 4.5.4 Flue terminal plume re-direction . . . . . . . . . . . . . . . . . 4.6 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . 19 19 20 20 21 22 23 23 23 23 24 25 5 COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 Pre-Commissioning checks . . . . . . . . . . . . . . . . . . . . . 5.2 Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Water treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 Starting the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.1 Checking the gas inlet pressure . . . . . . . . . . . . . . . . . . 5.5.2 Checking the gas rate . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 Finishing commissioning . . . . . . . . . . . . . . . . . . . . . . . 26 26 27 27 27 28 28 29 29 2 5.6.1 Replace the outer case: . . . . . . . . . . . . . . . . . . . . . . . . . 29 5.6.2 Install the bottom panel . . . . . . . . . . . . . . . . . . . . . . . . . 29 5.6.3 Hand over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 6 SERVICE AND SPARES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 6.1 Inspection and service . . . . . . . . . . . . . . . . . . . . . . . . . . 29 6.2 Checking gas inlet pressure . . . . . . . . . . . . . . . . . . . . . . 30 6.3 Checking flue integrity . . . . . . . . . . . . . . . . . . . . . . . . . . 30 6.4 Fan pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 6.5 Flue gas analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 6.6 Setting the air/gas ratio . . . . . . . . . . . . . . . . . . . . . . . . . 32 6.6.1 Setting the CO/CO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 6.7 Cleaning the heat exchanger . . . . . . . . . . . . . . . . . . . . . 33 6.7.1 Syphon removal and cleaning . . . . . . . . . . . . . . . . . . . . 35 6.8 Replacement of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 6.8.1 Removing the outer casing . . . . . . . . . . . . . . . . . . . . . . . 35 6.8.2 Primary sensor (CH NTC) . . . . . . . . . . . . . . . . . . . . . . . . 36 6.8.3 Overheat thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6.8.4 Flue overheat thermostat (with grommet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6.8.5 Lowering the boiler controls to the service position: . . 37 6.8.6 Gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 6.8.7 Air/gas manifold and fan assembly . . . . . . . . . . . . . . . . 37 6.8.8 Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 6.8.9 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 6.8.10 Electrode assembly and burner . . . . . . . . . . . . . . . . . . . 39 6.8.11 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 6.8.12 Syphon removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 6.8.13 Access to boiler control components . . . . . . . . . . . . . . 41 6.8.14 PCB Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 6.8.15 Code plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 6.8.16 Transformer/PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 6.9 Short parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 7 FAULT FINDING AND DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 43 7.1 Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 7.1.1 Internal wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 45 7.2 Boiler function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 7.3 Protection function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 6 720 804541 (2012/12) KEY TO SYMBOLS AND SAFETY PRECAUTIONS 1 1.1 KEY TO SYMBOLS AND SAFETY PRECAUTIONS KEY TO SYMBOLS WARNINGS Warnings in this document are identified by a warning triangle printed against a grey background. Keywords at the start of a warning indicate the type and seriousness of the ensuing risk if measures to prevent the risk are not taken. The following keywords are defined and can be used in this document: • NOTE indicates a situation that could result in damage to property or equipment. • CAUTION indicates a situation that could result in minor to medium injury. • WARNING indicates a situation that could result in severe injury or death. • DANGER indicates a situation that will result in severe injury or death. IMPORTANT INFORMATION This symbol indicates important information where there is no risk to people or property. ADDITIONAL SYMBOLS Symbol ▶ • – Explanation Step in an action sequence Cross-reference to another part of the document List entry List entry (second level) SYMBOLS USED IN THIS MANUAL PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION. These instructions are applicable to the Worcester appliance model(s) stated on the front cover of this manual only and must not be used with any other make or model of appliance. These instructions apply in the UK and Ireland only and must be followed except for any statutory obligations. This appliance must be installed by a GAS SAFE registered, competent person. Failure to install correctly could lead to prosecution. If you are in any doubt, contact the Worcester Technical helpline (0844 892 3366). Please leave these instructions with the completed BENCHMARK CHECKLIST, (or a certificate confirming compliance with IS 813, Eire only) and the user manual with the owner or at the gas meter after installation or servicing. Distance learning and training courses are available from Worcester. The BENCHMARK CHECKLIST can be found in the back of this Installation manual. Ø NG LPG CH DHW DCW PRV NTC IP RCD TRV ECV WRAS SEDBUK Diameter Natural Gas Liquid Petroleum Gas Central Heating Domestic Hot Water Domestic Cold Water Pressure Relief Valve Negative Temperature Coefficient (sensor) Ingress Protection Residual Current Device Thermostatic Radiator Valve Emergency Control Valve Water Regulations Advisory Scheme Seasonal Efficiency of Domestic Boilers in the UK Table 2 Abbreviations use in this manual Domestic Hot Water Central Heating 1.2 SAFETY PRECAUTIONS IF YOU SMELL GAS Hot Water Storage Cylinder Domestic Cold Water Supply Electrical Supply Gas Supply Table 1 Commonly used symbols A gas leak could potentially cause an explosion. If you smell gas, observe the following rules. ▶ Prevent flames or sparks: – Do not smoke, use a lighter or strike matches. – Do not operate any electrical switches or unplug any equipment. – Do not use the telephone or ring doorbells. ▶ Turn off the gas at the meter. ▶ Open windows and doors. ▶ Warn your neighbours and leave the building. ▶ Prevent anyone from entering the building. ▶ 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. BOILER OPERATION: This boiler must only be operated by a responsible adult who has been instructed in, understands, and is aware of the boiler's operating conditions and effects. 6 720 804 541 (2012/12) 3 KEY TO SYMBOLS AND SAFETY PRECAUTIONS EN12828 Central heating for domestic premises Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer's instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference. Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the scheme. Visit centralheating.co.uk for more information. BS5440:1 Flues and ventilation for gas appliances of rated heating not exceeding 70kW (net): Flues BS5440:2 Flues and ventilation for gas appliances of rated heating not exceeding 70kW (net): Air Supply BS7593 Treatment of water in domestic hot water central heating systems BS6798 Installation of gas fired boilers of rated input up to 70kW (net) Irish Standards The relevant Irish standards should be followed, including: • ECTI National rules for electrical installations • IS 813:2002 for Domestic Gas Installations. LPG Installations An appliance using L.P.G. must not be installed in a room or internal space below ground level unless one side of the building is open to the ground. HEALTH AND SAFETY Timber framed building: The appliance contains no asbestos and no substances have been used in the construction process that contravene the COSHH Regulations (Control of Substances Hazardous to Health Regulations 1988). Where the boiler is to be fitted to a timber framed building the guidelines laid down in BS5440: Part 1 and IGE "Gas Installations in Timber Frame Buildings” should be adhered to. COMBUSTION AND CORROSIVE MATERIALS Potable water: Do not store or use any combustible materials (paper, thinners, paints etc.) inside or within the vicinity of the appliance. All seals, joints and compounds (including flux and solder) and components used as part of the secondary domestic water system must be approved by WRAS. Chemically aggressive substances can corrode the appliance and invalidate any warranty. FITTING AND MODIFICATIONS Fitting the appliance and any controls to the appliance may only be carried out by a competent engineer in accordance with the current Gas Safety (Installation and Use) Regulations. CH Water: Artificially softened water must not be used to fill the central heating system. The service engineer must complete the Service Record on the Benchmark Checklist after each service. BOILER FEATURES AND CHECKLIST • Pre-wired and pre-plumbed • Galvanised steel inner frame • Digital control system • Automatic ignition • Direct burner ignition electrodes • Built-in frost protection • Built-in fault finding diagnostics • Modulating automatic gas valve • Combustion air fan with speed regulator • CH temperature sensor & control • External pump anti-seizure protection • Flue gas temperature limiter • Condensate siphonic trap INSTALLATION REGULATIONS CHECK LIST Current Gas Safety (Installation & Use) Regulations: - HARDWARE LITERATURE PACK: Greenstar Ri Installation, Commissioning and Servicing Instructions Users Instructions Consumer Guarantee Card Sealing Pack: - Compression Nut 22mm - Compression Ring 22mm Elbow assembly pack - Elbow Assembly - Fibre Washer Flue systems must not be modified in any way other than as described in the fitting instructions. Any misuse or unauthorised modifications to the appliance, flue or associated components and systems could invalidate the warranty. The manufacturer accepts no liability arising from any such actions, excluding statutory rights. SERVICING Advise the user to have the system serviced annually by a competent, qualified Gas Safe registered engineer. Approved spares must be used to help maintain the economy, safety and reliability of the appliance. IMPORTANT All gas appliances must be installed by a competent person in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution. The appliance must be installed in accordance with, and comply to, the current: Gas Safety Regulations, IEE Regulations, Building Regulations, Building Standards (Scotland) (Consolidation), Building Regulations (Northern Ireland), local water by-laws, Health & Safety Document 635 (The Electricity at Work Regulations 1989) and any other local requirements. British Standards: Where no specific instruction is given, reference should be made to the relevant British Standard codes of Practice. Qty. 1 1 1 1 3 3 1 1 1 Table 3 Hardware lit pack - checklist BS7074:1 Code of practice for domestic and hot water supply BS6891 Installation of low pressure gas pipe work up to 28mm (R1) BS5546 Installation of gas hot water supplies for domestic purposes 4 6 720 804541 (2012/12) APPLIANCE INFORMATION 2 APPLIANCE INFORMATION 2.1 APPLIANCE 2 270mm 1 3 590mm* 4 5 390mm *600mm to top of case front 6720644744-01.1Wo Fig. 1 Appliance Do not use the pre-formed copper pipes supplied with the boiler for the gas supply. These copper pipes are for water only. STANDARD PACKAGE: 1 Wall hung gas fired condensing regular boiler for central heating and domestic hot water 2 Tail pipes - water only 3 Wall plate 4 Hardware literature pack (see checklist) 5 Bottom panel and wall mounting template 6 720 804 541 (2012/12) 5 APPLIANCE INFORMATION 2.2 TECHNICAL DATA DESCRIPTION Gas flow rate - Max. 10 minutes from lighting Natural Gas G20 Propane Gas (LPG) Central Heating Max. rated heat input (net) Min. heat input Max. rated heat output 40/30 °C Max. rated heat output 50/30 °C Max. rated heat output 80/60 °C Max. flow temperature Max. permissible operating pressure Available pump head at 21 °C system temp. rise Flue Flue gas temp. 80/60 °C, rated/min. load Flue gas temp. 40/30 °C, rated/min. load CO2 level at max. rated heat output (after 30 min) CO2 level at min. rated heat output (after 30 min) NOx class NOx rating Condensate Maximum condensate rate pH value, approx. Electrical Electrical power supply voltage Frequency Maximum power consumption General data Appliance protection rating Permissible ambient temperatures Nominal capacity of appliance Noise output level (Max central heating) Packaged boiler weight Total boiler weight Lift weight SEDBUK SEDBUK 2005 NATURAL GAS UNIT 12Ri 15Ri 18Ri 24Ri LPG 12Ri 15Ri 18Ri 24Ri m³/h kg/h 1.3 - 1.63 - 1.96 - 2.6 - 0.96 1.20 1.44 1.91 kW kW kW kW kW °C bar m 12.32 3.45 12.85 12.74 12 82 2.5 2.0 15.40 4.62 16.06 15.92 15 82 2.5 2.0 18.48 5.54 19.28 19.11 18 82 2.5 2.0 24.62 7.38 25.67 25.45 24 82 2.5 2.0 12.32 5.95 12.85 12.74 12 82 2.5 2.0 15.40 5.95 16.06 15.92 15 82 2.5 2.0 18.48 9.64 19.28 19.11 18 82 2.5 2.0 24.62 9.64 25.67 25.45 24 82 2.5 2.0 62/56 41/33 9.65 8.65 5 mg/kWh 39 66/58 44/33 9.8 9.2 5 60 70/60 48/34 9.8 9.2 4 84 78/63 54/35 9.8 9.2 5 66 62/57 43/35 11.0 10.5 5 44 66/59 46/36 11.0 10.5 5 60 71/61 49/37 11.0 10.5 4 84 79/64 55/38 11.0 10.5 5 66 l/h 0.93 4.8 1.2 4.8 1.5 4.8 2.0 4.8 0.7 4.8 0.9 4.8 1.2 4.8 1.5 4.8 A.C. V Hz W 230 50 50 230 50 50 230 50 50 230 50 50 230 50 50 230 50 50 230 50 50 230 50 50 IP °C litre dBA kg kg kg band % 20 0 - 50 1.1 39 31 27.4 22.6 A 90.1 20 0 - 50 1.1 42.7 31 27.4 22.6 A 90.1 20 0 - 50 1.1 43.7 31 27.4 22.6 A 90.1 20 0 - 50 1.1 41 31 27.4 22.6 A 90.2 20 0 - 50 1.1 39 31 27.4 22.6 A 91.4 20 0 - 50 1.1 42.7 31 27.4 22.6 A 91.4 20 0 - 50 1.1 43.7 31 27.4 22.6 A 91.4 20 0 - 50 1.1 41 31 27.4 22.6 A 92.0 °C °C % % Table 4 Technical data Ri 6 6 720 804541 (2012/12) APPLIANCE INFORMATION 2.3 BOILER MAIN COMPONENTS 1 2 3 4 5 6 28 7 27 8 26 9 25 10 24 11 23 12 22 21 13 6720804541-01.1Wo 20 19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 18 Air/Gas Manifold Sensor - Boiler flow Flow pipe Return pipe Removable servicing panel Electrode assembly Overheat thermostat Silicon tube - Heat Exchanger air vent Heat Exchanger Flue overheat thermostat Access panel - Heat Exchanger/Sump cleaning Return connector with drain point Flow connector Boiler Temperature control and Reset knob 6 720 804 541 (2012/12) 17 16 15 16 17 18 19 20 21 22 23 24 25 26 27 28 15 14 Power and fault indicator (blue) Wiring connections cover Burner indicator (green) Boiler ON/OFF switch Condensate connection Syphon / Trap Gas inlet connection Mains cable inlet Gas Valve Flue air pressure switch connection Fan Manual vent point Fan pressure test point Air pressure switch 7 PRE-INSTALLATION 3 PRE-INSTALLATION FERNOX SENTINEL 3.1 CLEANING PRIMARY SYSTEMS ARTIFICIALLY SOFTENED WATER NOTICE: All the following Pre-Installation sections must be read and requirements met before starting boiler or flue installations. CAUTION: Isolate the mains supplies before starting any work and observe all relevant safety precautions. NOTICE: Debris from the system can damage the boiler and reduce efficiency. Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance warranty. BEFORE CLEANING THE SYSTEM: ▶ Ensure that the system and pipe work is in good working order. ▶ Where possible keep the existing boiler/circulating pump in place when flushing the system. FOLLOW THE GUIDANCE OF BS7593: Treatment of water in domestic hot water central heating and also the flushing guidelines below. NOTICE: Artificially softened water must not be used to fill the central heating system. FLUSHING THE SYSTEM ▶ Fill the system with cold water and check for leaks. ▶ Open all drain cocks and drain the system. ▶ Close drain cocks and add a suitable flushing agent compatible with aluminium at the correct strength for the system conditions in accordance with the manufacturer‘s instructions. The pH value of the system water must be less than 8 or the appliance guarantee will be invalidated. ▶ Circulate the flushing agent before the boiler is started. ▶ Run the boiler/system at normal operating temperature as directed by the manufacturer of the flushing agent. ▶ Drain and thoroughly flush the system to remove the flushing agent and debris. ▶ It may be necessary to use a power flushing machine to aid the cleansing procedure in some circumstances. ▶ Close the drain cocks and refill with fresh water and a suitable inhibitor. ▶ Vent any air from the boiler and system. INHIBITOR Add a suitable inhibitor or combined inhibitor/anti-freeze, if the system is exposed to freezing conditions, to the heating system in accordance with the DWTA code of practice and manufacturer‘s guidelines. WARNING: Sealing agents ▶ Normally the addition of sealing agents to the system water is not permitted as this can cause problems with deposits left in the heat exchanger. ▶ In cases where all attempts to find a micro leak have failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer. WATER TREATMENT PRODUCTS Suitable water treatment products can be obtain from the following manufacturers: 8 0870 601 5000 or www.fernox.com 0800 389 4670 or www.sentinel-solutions.net It is possible to have an Ion exchange water softener fitted to the cold water system of the property. However, the boiler requires an untreated cold water connection taken from the mains supply, before the water softener, to the primary water filling point of the heating system. Alternatively there are water softening/treatment devices that do not adjust or alter the pH levels of the water. With these devices it may not be necessary to provide an untreated water by-pass to the primary water filling point of the heat system. 3.2 MAINS SUPPLY 3.2.1 ELECTRICAL SUPPLY • • • • • • • Supply: 230V - 50 Hz, 140 Watts Cable: PVC insulated 0.75 mm2 (24 x 0.2 mm) temp. rated to 90 °C. External 3A fuse to BS1362. The appliance must be earthed. Do not connected the appliance to a 3 phase supply. IP20. Wiring must comply with the latest edition of BS 7671 (IEE wiring regulations). 3.2.2 GAS SUPPLY • Boilers using Natural Gas (NG) must be connected to a governed meter. • Liquid Petroleum Gas (LPG) must be connected to a regulator. • Installation and connection of the gas supply to the boiler must be in accordance with BS6891. • The meter or regulator and pipe work to the meter must be checked, preferably by the gas supplier. This is to ensure that the equipment is in good working order and can meet the gas flow and pressure requirements, in addition to the demand from any other appliance being served. NOTICE: 12Ri , 15Ri, 18Ri and 24Ri models ▶ Provided that the correct gas supply working pressure and gas rate can be achieved (see technical data on page 6, Check gas inlet pressure on page 28, also refer to B.S. 6891) ▶ Then it may be possible to reduce the gas supply pipe diameter to 15mm. 3.3 WATER SYSTEMS AND PIPE WORK PLASTIC PIPE WORK: • Any plastic pipe work must have a polymeric barrier with 600mm (minimum) length of copper pipe connected to the boiler. • Plastic pipe work used for underfloor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approximately 50 °C. PRIMARY SYSTEMS CONNECTIONS/VALVES: • All system connections, taps and mixing valves must be capable of sustaining a pressure up to 3 bar. • Radiator valves should conform to BS2767:10. • All other valves should conform to BS1010. • Thermostatic radiator valves (TRV) must be used on all radiators within the sleeping accommodation. The radiator where the room thermostat is sited must be fitted with lock-shield valves and left open. • A drain cock is required at the lowest point in the system. • An air vent is required at all high points in the system. 6 720 804541 (2012/12) PRE-INSTALLATION SEALED PRIMARY SYSTEM: FULLY PUMPED SEALED SYSTEM: NOTICE: Artificially softened water must not be used to fill the central heating system. The central heating sealed system must be filled using a WRAS approved filling loop or comply with figure 2 for System fill. S PLAN LAYOUT • The CH sealed system must be filled using a WRAS approved filling loop or comply with figure 2 for system fill. • An expansion vessel, of a size suitable for the system, must be fitted as close as possible to the appliance in the central heating return. • Also fit a pressure gauge, a 3 bar pressure relief valve and stop cock (fixed cylinder type or sealed system approved connection). • Do not use galvanised pipes or radiators. 1 3 8 2 7 150 mm max 4 M SYSTEM FILL SYSTEM FILL M 5 Mains supply Heating return Hose union CV SV CV reset max SV 6 6720644744-03.1Wo Test point Fig. 3 Y PLAN LAYOUT Temporary hose AA = Auto Air vent CV = Check Valve CV = Check Valve SV = Stop Valve Make up vessel AA CV SV 1000 mm (39 in) above the highest point of the system. 6720644743-08.1Wo 1 SYSTEM MAKE UP Heating return S plan 3 8 2 7 150 mm max 4 Fill point Fig. 2 M 5 System fill/System make-up reset max S AND Y PLAN SYSTEMS: NOTICE: Bypass ▶ Generally a bypass is not necessary on a Y plan system as one of the ports is open to flow. 6720644744-04.1Wo Fig. 4 Y plan SEALED SYSTEM Y PLAN LAYOUT 1 2 3 4 5 6 7 8 9 10 11 12 Static head Minimum static head 250mm measured from the highest point in the heating system (top surface of the appliance or the highest point in the heating system) to the water level in the feed and expansion tank Heating vent (22mm minimum) Primary cold feed (15mm minimum) Diverter/Zone valve Pump, maximum power 90 Watts Automatic bypass Radiator valve (Flow) Lock shield valve (Return) Expansion vessel Pressure gauge 3 bar pressure relief valve Stop cock 8 7 4 M 5 reset MCW max 12 10 Fig. 5 11 9 6720644744-05.1Wo Sealed system Table 5 Key to figures 3, 4 & 5 NOTICE: A drain cock should be fitted at the lowest point of the heating circuit and beneath the appliance. 6 720 804 541 (2012/12) 9 PRE-INSTALLATION NEW BUILD SYSTEM LAYOUTS 3.4.1 INTERNAL CONNECTIONS The latest Part L1a regulation for new installations require separate zone controls for the central heating. In order to minimise risk of freezing during prolonged cold spells, the following methods of installing condensate drainage pipe should be adopted, in order of priority. Open vent with two heat zones OPEN VENT LAYOUT 1 3 Wherever possible, the condensate drainage pipe should be routed and terminated so that the condensate drains away from the boiler under gravity to a suitable internal foul water discharge point such as an internal soil and vent stack. A suitable permanent connection to the foul waste pipe should be used. 8 2 7 150 mm max M M * 2 5 1 max M reset 4 6 6720644744-61.1Wo Sealed system with two heat zones 22mm Ø 3 SEALED SYSTEM LAYOUT Fig. 8 8 7 6720644744-06.2Wo Fig. 6 Disposal to soil vent stack M M Alternatively if the first option is not possible an internal kitchen or bathroom waste pipe, washing machine waste pipe etc. can be used. Ensure that the condensate drain pipe is connected “down stream” of the waste trap. 5 max M reset 10 * 4 6 11 9 Fig. 7 3.4 100mm 5 CONDENSATE PIPE WORK NOTICE: ▶ Where a new or replacement boiler is being installed, access to an internal “gravity discharge” point should be one of the factors considered in determining boiler location. ▶ The condensate pipe must be nominally 22mm Ø plastic pipe. ▶ The condensate pipe work must fall at least 52mm per metre towards the outlet and should take the shortest practicable route. ▶ Ensure there are no blockages in the pipe run. Key to condensate illustrations 1 Condensate discharge from boiler 2 Soil and vent stack 3 Minimum 450mm and up to three storeys 4 Visible air break at plug hole 5 Sink or basin with integrated overflow 6 75mm sink waste trap 7 Condensate pump * Condensate trap of 75mm already incorporated into the boiler 10 4 1 6720644744-62.1Wo 22mm Ø 75mm min. 6 Fig. 9 6720644744-07.2Wo MCW 12 Disposal to a waste pipe CONDENSATE PUMP Where “gravity discharge” to an internal termination is not physically possible, or where very long internal runs would be required to reach a suitable discharge point, condensate should be removed using a proprietary condensate pump, of a specification recommended by the boiler or condensate pump manufacturer. The pump outlet pipe should discharge to a suitable internal foul water discharge point such as an internal soil and vent stack, internal kitchen or bathroom waste pipe, washing machine waste pipe etc. A suitable permanent connection to the foul waste pipe should be used. 6 720 804541 (2012/12) PRE-INSTALLATION 4 5 * 75mm min. 1 22mm Ø 6 ▶ The external pipe should take the shortest and least exposed route to the discharge point, and should "fall" as steeply as possible away from the boiler, with no horizontal runs in which condensate might stand. ▶ The use of fittings, elbows etc. should be kept to a minimum and any internal “burrs” on cut pipe work should be removed so that the internal pipe section is as smooth as possible. FITTING AN EXTERNAL AIR BREAK • Refer to figure 11 when a rain water down pipe is used to dispose of condensate. • An air break must be installed in the 43mm pipe work, between the boiler condensate outlet and the drainpipe, outside the property, to avoid flooding during adverse weather conditions. 7 * 6720644744-08.2Wo 17 Fig. 10 Condensate pump disposal 1 13 3.4.2 EXTERNAL CONNECTIONS NOTICE: Condensate waste ▶ Care should be taken when siting a soak-away to avoid obstructing existing services. Continued - Key to condensate illustrations 8 PVCu strap on fitting 9 100mm Ø minimum plastic pipe 10 Drainage holes 11 Limestone chippings 12 Bottom of sealed tube 13 Insulate and increase pipe size 14 Pipe work transition 15 External air break 16 Air gap 17 External rain water pipe into foul water 18 43mm 90° male/female bend * Condensate trap of 75mm already incorporated into the boiler If no other discharge method is possible then the use of an externally run condensate drainage pipe terminating at a suitable foul water discharge point, or purpose-designed soak away, may be considered. If this method is chosen then the following measures should be adopted: 15 14 18 Fig. 11 Disposal into a rainwater down pipe Condensate drainage pipe can be run above or below ground. Where the pipe terminates over an open drain or gully, the pipe should terminate below the grating level, but above water level, in order to minimise “wind chill” at the open end. The use of a drain cover (such as those used to prevent blockage by leaves) may offer further protection from wind chill. Pipe drainage will be improved if the end is cut at 45° as opposed to a straight cut. * 1 6 720 804 541 (2012/12) 13 14 25mm min. Use of the CondenseSure siphon will prevent condensate freezing on a 3 metre straight, 32mm Ø , uninsulated pipe at a temperature of -15 °C for 48 hours. ▶ The external run be kept as short as possible and not exceed 3 metres. ▶ The pipe should be run internally as far as possible before going externally and the pipe diameter should be increased to 32mm before it passes through the wall to the exterior. The pipe should be insulated using suitable waterproof and weather resistant insulation, if not using a CondenseSure siphon. 8 6720644744-09.2Wo 16 6720644744-10.2Wo NOTICE: Freezing conditions ▶ When the position of the boiler prevents internal routing, we recommend installing a CondenseSure siphon to significantly reduce the risk of freezing. ▶ Pipe work length should be kept to a minimum and the route as vertical as possible. ▶ Weather proof insulation must be used, if not using a CondenseSure siphon. Fig. 12 External disposal CONDENSATE SOAK AWAY • The condensate drainage pipe may be run above or below the ground to the soak away. The examples shown on this page run above ground. • The soak away must use a 100mm Ø plastic tube with two rows of three 12mm holes on 25mm centres and 50mm from the bottom of the tube. The holes must face away from the house. 11 PRE-INSTALLATION • The tube must be surrounded by at least 100mm of limestone chippings to a depth of 400mm. • The pressure relief drain pipe (1) from the boiler should be at least 15mm diameter copper pipe and run downwards, away from any electrical equipment or other hazard, preferably to an external drain or soak away. • Pipe (1) should be finished with a partial bend, near the outlet to face the external wall (as shown) to help prevent freezing. Minimum hole size for the condensate soak away must be 400mm deep by 300mmØ . In situations where there are likely to be extremes of temperature or exposure, the use of a proprietary trace-heating system for external pipe work, incorporating an external frost thermostat, should be considered. If such a system is used, the requirement to use 32mm pipe does not apply. However, all other guidance above and the instructions for the trace heating system, should be closely followed. 1 1 NOTICE: Unheated internal areas. ▶ Internal pipe runs in unheated areas such as lofts, basements and garages should be treated as external runs and consideration should be given to using a CondenseSure siphon. 2 2 2 3 3 9 4 10 * 4 1 500mm min. 13 6720646608-123.1Wo Fig. 15 Pressure relief pipe work 14 9 11 10 400mm min. 12 6720644744-11.2Wo 25mm min. Fig. 13 Soak away 13 * Table 6 Key to fig 15 3.6 BOILER LOCATION AND CLEARANCES This boiler is only suitable for installing internally within a property at a suitable location onto a fixed, rigid surface at least the same size as the boiler and capable of supporting the boiler weight. NOTICE: No surface protection is required against heat transfer from the boiler 1 25mm min. 7 6720644744-12.2Wo Fig. 14 Condensate pump to external disposal PRESSURE RELIEF PIPE WORK NOTICE: ▶ The pressure relief valve is a safety device for the boiler and if activated may discharge boiling water or steam through the relief valve drain pipe. ▶ Care should be taken when siting the outlet pipe so that it does not cause an obstruction or discharge above a window, entrance or other public access where it could cause a hazard. 12 Outside wall Drain pipe External drain 3.6.1 INSTALLATION 14 3.5 2 1,3 4 3.6.2 SERVICING CLEARANCES VENTILATED COMPARTMENT Figure 16 shows the minimum space required to install and service the boiler in a ventilated compartment. • If a boiler is installed in a compartment with clearances less than shown in the tables 9, 10, or 11 ventilation is required. Refer to table 7 for ventilation requirements. To room or internal Vent position space High level Min. free area 122 cm2 Low level Min. free area 122 cm2 Direct to outside Minimum free area 61 cm2 Minimum free area 61 cm2 Table 7 Compartment ventilation 6 720 804541 (2012/12) PRE-INSTALLATION 410 mm + 30 mm above elbow Using 100 mm flue kit 5 mm 1080 mm Using 125 mm flue kit 1100 mm 6720643895-121.2Wo 5 mm 20 mm* 600 mm** 200 mm Fig. 16 Ventilated compartment * ** Minimum clearance to removable door Minimum clearance required for servicing Table 8 Minimum clearances 3.6.3 COMPARTMENTS: Follow the requirements of BS6798 and BS5440 Part 2 and note: • Minimum clearances must be maintained. • An access door is required to install, service and maintain the boiler and any ancillary equipment. • If the boiler is installed in an unventilated airing/storage cupboard, there is no requirement to make a partition between the boiler and the storage space as long as the minimum clearances around the boiler are maintained. If Side Clearances are Reduced (millimetres) If total side clearance is Increase height O Front clearance reduced to: (Combined clearances to (approx.): R (to removable left and right door) must be (Combined top & clearances excluding bottom clearances increased to: the boiler) excluding the appliance) 350 441 129 300 523 161 250 617 200 200 717 243 150 856 295 100 1012 358 50 1202 434 Table 10 Reduced side clearances If Front Clearance is Reduced (millimetres) If front clearance Increase overall height O (to removable clearances to R door) is reduced (approx.): to: (Combined top and bottom clearances excluding the appliance) 50 mm 511 mm 25 mm 596 mm 3.6.6 BATHROOMS The boiler may only be installed outside the shaded area. Additional RCD (Residual Current Device) protection may be required. Refer to the latest IEE wiring regulations. 2* Without the end wall, zone 2 must extend 600mm from the bath 600m The tables below show the options for the minimum space required to install and service the boiler inside an unventilated compartment. Unventilated Compartment Installation Clearances (millimetres) The suggested total unventilated compartment minimum clearances are: Side Above Below Front (to removable door) 400 170 mm approx. (30 mm 200 mm 100 mm mm above the elbow) m 600m 3.6.4 BOILER CLEARANCES- UNVENTILATED COMPARTMENTS CAUTION: CLEARANCES ▶ Top and bottom clearances must not be reduced below the values shown in table 9 as they are the minimum clearances required for servicing. 505 mm 569 mm Table 11 Reduced front clearances • Ideally, storage should be below the boiler, where the boiler is mounted in the upper part of the cupboard, whilst maintaining the clearances given in tables 9, 10, or 11. 1 2250mm 3.6.5 INSTALLATION CLEARANCES - UNVENTILATED COMPARTMENTS Increase total side clearance to: (Combined left and right clearances excluding the appliance) m 600m m 1 2* 2 * 2 2 1 2 2250mm 930 mm Radius 600mm 6720646608-124.3Wo Fig. 17 Bathroom installations Table 9 Minimum unventilated compartment clearances 6 720 804 541 (2012/12) 13 PRE-INSTALLATION 3.7 PLUMBING MANIFOLD 3.7.1 CONNECTIONS Heating System Gas 22mm compression fittings 22mm compression fittings Use the fittings supplied in the Hardware literature pack: Do not use the pre-formed copper pipes supplied with the boiler for the gas supply. These copper pipes are for water only. # 1 2 3 4 From left case edge 55 mm 210 mm 285 mm 350 mm Function Gas Condensate Cylinder & CH Flow Cylinder & CH Return Diameter of pipe 22 mm 22 mm 22 mm 22 mm Table 12 Key to figures 18 & 19 • Use the 22mm copper pipes (1 & 2) provided with the appliance, as shown in the diagram opposite. • If the flow and return pipes are to be run behind the appliance it maybe an advantage to connect the pipes before hanging on the wall especially if space is limited. Further guidance on pipe routing can be found printed on the boiler template (supplied with the boiler). Return Flow 4 3 reset 2 max 3 4 6720644744-17.1Wo 1 6720644744-13.1Wo Fig. 19 Pipe work dimensions 2 4 3 1 Pipes in alternative position Fig. 18 Plumbing manifold 14 6 720 804541 (2012/12) PRE-INSTALLATION 3.8 FLUE OPTIONS CAUTION: Non accessible flue systems: ▶ Where a flue system is not going to be accessible, provision must be made for service and inspection. ▶ Voids containing concealed flues must have at least one inspection hatch no less than 300mm square. ▶ Flue joints within the void must not be more than 1.5 metres from the edge of the inspection hatch. ▶ Inspection hatches should be located at changes of direction. ▶ If this is not possible, bends should be viewable from both directions. NOTICE: Effective flue lengths: ▶ each 90° bend used is equivalent to 2 metres of straight flue ▶ each 45° bend used is equivalent to 1 metre of straight flue Plume management kits are available for the 60/100 horizontal flue system. Refer to the manual supplied with the plume management kits for complete installation instructions FLUE LENGTHS The flue systems have different maximum flue lengths The Greenstar series has the option of two horizontal 60/100 RSF (telescopic and longer telescopic) and one horizontal 80/125 RSF (telescopic) flue system and two vertical RSF (60/100 or 80/125) flue systems: The next page shows various fluing options. Refer to the Flue options in table 13 for the straight flue lengths required to achieve the maximum flue length. Ri boilers FLUE TYPE 1 Telescopic horizontal flue assembly Longer telescopic horizontal flue assembly 2 Horizontal flue extension 3 Horizontal flue with 1 x 90° bend 4 Horizontal flue with 2 x 90° bends 5 High level horizontal flue 6 High level horizontal flue with 2 x 90° bends 7 High level horizontal flue with 3 x 90° bends 8 Vertical balanced flue assembly 9 Vertical balanced flue with 2 x 90° bends 10 Vertical balanced flue with 2 x 45° bends Maximum total flue length (mm) 60/100 80/125 570 1,070 790 N/A 4,600 13,000 2,600 11,000 N/A 9,000 4,600 13,000 2,600 11,000 N/A 9,000 6,400 15,000 2,400 11,000 4,400 13,000 Table 13 Flue options Part number 7 716 191 082 7 716 191 171 7 719 003 702 7 719 002 430 7 719 002 431 Flue 60/100 60/100 80/125 60/100 80/125 Description Telescopic horizontal flue assembly Longer telescopic horizontal flue assy. Telescopic horizontal flue assembly Vertical flue assembly Vertical flue assembly Table 14 Flue option part numbers 6 720 804 541 (2012/12) 15 PRE-INSTALLATION 350 mm - 570 mm 1 130 mm Min 7 2 Pitc h roo ed 500 mm f 300 mm Flat roof 8 3 4 9 5 10 6 16 6720643895-12.1Wo 6 720 804541 (2012/12) PRE-INSTALLATION 3.9 FLUE TERMINAL POSITIONS All measurements in millimetres 2m 1m 2 25 25 104mm 52mm 16 3 1,500 600 13 400 300 500 12 14 2 200 300 1 5 300 300 1,500 4 7 8 600 500 300 600 300 300 6 9 1,200 15 600 18 600 10 16 11 300 300 300 17 300 300 25 300 Boundary Line 06 672 438 95-1 o 3.3W Fig. 20 Flue terminal positions NOTICE: ▶ All measurements are the minimum clearances required. ▶ Terminals must be positioned so to avoid combustion products entering the building. ▶ Support the flue at approximately one metre intervals and at a change of direction, use suitable brackets and fittings. (flue bracket 100mm part number: 7 716 191 177, flue brackets 100mm x 6 part number: 7 716 191 178, flue bracket 125mm part number: 7 716 191 179). Key to illustration 1. 300mm adjacent to a boundary line. 2. The dimension below eaves, balconies and car ports can be reduced to 25mm, as long as the flue terminal is extended to clear any overhang. External flue joints must be sealed with suitable silicon sealant. 3. 1,500mm between a vertical flue terminal and a window or dormer window. 4. 1,200mm between terminals facing each other. 5. Vertical flue clearance, 300mm adjacent to a boundary line, unless it will cause a nuisance. BS 5440:Part 1 recommends that care is taken when siting terminal in relation to boundary lines. 6. 600mm distance to a boundary line, unless it will cause a nuisance. BS 5440:Part 1 recommends that care is taken when siting terminal in relation to boundary lines. 7. 600mm minimum clearance from a skylight to a vertical flue. 8. Vertical flue clearance, 500mm to non-combustible building material, and 1,500mm clearance to combustible building material. 9. 300mm above, below and either side of an opening door, air vent or opening window. 10.600mm diagonally to an opening door, air vent or opening window. 11.300mm to an internal or external corner. 12.2,000mm below a Velux window, 600mm above or to either side of the Velux window. 13.400mm from a pitched roof or 500mm in regions with heavy snow fall. 14.500mm clearance to any vertical structure on a roof, 600mm to room sealed flue or 1,500 to an open flue. 15.200mm below eaves and 75mm below gutters, pipe and drains. 6 720 804 541 (2012/12) 16.The dimension below eaves, balconies and car ports can be reduced to 25mm, as long as the flue terminal is extended to clear any overhang. External flue joints must be sealed with suitable silicon sealant. 17.Flue clearance must be at least 300mm from the ground. Terminal guards must be fitted if the flue is less than 2 metres from the ground or if a person could come into contact with the flue terminal. 18.600mm distance to a surface facing a terminal, unless it will cause a nuisance. BS 5440: Part 1 recommends that care is taken when siting terminals in relation to surfaces facing a terminal. Note: ▶ Installations in car ports are not recommended. ▶ The flue cannot be lower than 1,000mm from the top of a light well due to the build up of combustion products. ▶ Dimensions from a flue terminal to a fanned air inlet to be determined by the ventilation equipment manufacturer. 17 PRE-INSTALLATION 3.10 PLUME MANAGEMENT TERMINAL POSITIONS All measurements in millimetres Flue terminal guard 7 716 191 176 ±45° Plume re-direction: 100 600 1 180° Flue Exhaust Outlet 10 1,500 Air Intake ±80° 6 200 300 2 200 5 600 300 300 3 150 300 300 300 25 200 300 150 1,200 300 8 150 200 7 150 25 600 9 10 150 4 Boundary Line 672 064 389 5-14 o .2W Fig. 21 Plume terminal positions Maximum and minimum plume management lengths: ▶ A minimum distance of 500mm must be maintained between the plume management outlet and the flue air intake. ▶ The maximum plume management length is 4.5 metres for the appliances detailed on the front of this manual. ▶ The 45° bend is equivalent to 0.75 metres of straight plume management and the 90° bend is equivalent to 1.5 metres. NOTICE: ▶ All measurements are the minimum clearances required. ▶ Refer to previous page for all concentric flue terminal positions unless the flue position is specified on the figure above “Plume terminal positions”. ▶ Terminals must be positioned so to avoid combustion products entering the building. ▶ Support the flue at approximately one metre intervals and at a change of direction, use suitable brackets and fittings. Key to illustration 1. This feature allows some basic plume re-direction options on a standard telescopic horizontal flue terminal. 300mm minimum clearances to a opening e.g. window. However the minimum clearances to an opening in the direction that the plume management is facing, must be increased to 1,500mm. Where the flue is less than 150mm to a drainpipe and plume redirection is used the deflector should not be directed towards the drainpipe. 2. 300mm adjacent to a boundary line. 3. Plume Management kit air intake can be reduced to 150mm providing the flue exhaust outlet is no less than 300mm adjacent to a boundary line. 4. 1,200mm between terminals facing each other. 5. 600mm distance to a boundary line, unless it will cause a nuisance. BS 5440:Part 1 recommends that care is taken when siting terminal in relation to boundary lines. 6. Using a Plume Management kit the air intake measurement can be reduced to 150mm providing the flue exhaust outlet has a 300mm clearance. Plume kits running horizontally must have a 10° fall back to the boiler for proper disposal of condensate. For details on specific lengths see relevant boiler Technical & Specification information. 7. Internal/external corners. The air intake clearance can be reduced to 18 150mm providing the flue exhaust outlet has a 300mm clearance. 8. Clearances no less than 200mm from the lowest point of the balcony or overhang. 9. 1,200mm from an opening in a car port on the same wall e.g. door or window leading into the dwelling. 10.600mm distance to a surface facing a terminal, unless it will cause a nuisance. BS 5440: Part 1 recommends that care is taken when siting terminals in relation to surfaces facing a terminal. Note: ▶ Installations in car ports are not recommended. ▶ The flue cannot be lower than 1,000 mm from the top of a light well due to the build up of combustion products. ▶ Dimensions from a flue terminal to a fanned air inlet to be determined by the ventilation equipment manufacturer. 6 720 804541 (2012/12) INSTALLATION 4 ▶ Flatten the outer cardboard sleeve and place on the floor behind the boiler. ▶ Lay the boiler on its back on the cardboard. ▶ Remove the bottom tray. INSTALLATION WARNING: All the previous “Pre-Installation” sections must be read and the requirements met before starting boiler or flue installation. 4.1 IMPORTANT HANDLING INSTRUCTIONS: UNPACKING THE WALL FRAME & ANCILLARY ITEMS CAUTION: LIFTING AND CARRYING ▶ Only lift a manageable weight, or ask for help. ▶ Bend the knee and keep the back straight with feet apart, when lifting or putting down heavy objects. ▶ DO NOT lift and twist at the same time. ▶ Lift and carry object close to the body. Do not use the pre-formed water pipes on the gas supply, they must only be used for water. Additional requirements for roof space installation: • The boiler must be unpacked before ascending the steps to loft space. • Two sets of steps should be used. • Two people should share the lifting of the boiler up to the loft hatch, where the boiler is entered into the loft space, tilted, and slid on its back into the loft. • Once the appliance is removed from its packaging check the contents against the packing list. Remove the straps and open the top of the boiler packaging. 1. Remove the two 22 mm water pipes (1) 2. Remove the following items: – Wall mounting plate (2). – Wall mounting template and bottom panel (3). – Literature pack and pipe connectors and olives (4). 1 1. • It is advised that two people are used to carry the carton from the van to the point of delivery. • Once the carton has been delivered, remove the outer carton. Care should be taken when releasing the straps. If a sharp implement is used, ensure the outer carton is not pierced and that the implement is used in such a way that it will not cause personal injury. • All sharp objects must be covered or the blade retracted after use and put away in a safe place. The wall mounting frame, Installer pack, template and bottom panel can now be removed. Care should be taken when lifting the boiler from the base and the proper technique for safe lifting of any heavy object must be strictly observed. Before installing the appliance, ensure that the system has been cleaned as explained on page 8. 2 3 2. 6720644744-14.2Wo 4 Fig. 22 Unpacking 1 3. Remove the top carton (5). 4. Remove the outer cardboard sleeve (6). 5. Remove the plastic cover (7). 4. 5 5. 7 6 6720644744-15.2Wo 3. Fig. 23 Unpacking 2 6 720 804 541 (2012/12) 19 INSTALLATION 4.2 WALL MOUNTING TEMPLATE & FLUE OPENING 4.3 WARNING: BEFORE DRILLING, ENSURE THAT THERE ARE NO PIPES, ELECTRICAL CABLES, DAMP PROOF COURSES OR OTHER HAZARDS. SAFETY: All relevant safety precautions must be undertaken. Protective clothing, footwear, gloves and safety goggles must be worn as appropriate. FIXING THE MOUNTING FRAME: OUTER CASE REMOVAL 1. Undo the two captive screws securing boiler casing at the bottom of the appliance. 2. Undo the two screws securing boiler casing at the top of the appliance. 3. Pull case upwards. 4. Remove cardboard packing piece from appliance. With the outer case removed the appliance is suitable for a one man lift (<25kg). ▶ The boiler template shows the relative positions of the flue and the top and bottom fixing of the mounting frame. 1. Fix the template to the wall in the desired position. 2. Drill four holes for the wall mounting frame through the template. Drill two holes for the bottom fixing screws. 1. The template has been sized to allow for minimum clearances of 5mm sides, 200mm base and 30mm above a 100mm diameter flue elbow. REAR FLUE OUTLET ▶ The drawing opposite shows the boiler template with the flue centre lines of both the 100 mm and 125 mm flue systems. 3. Mark centre line of flue to be used (3); the external diameter of the hole can also be marked if required. ▶ If a 100 mm diameter flue is to be used, a 125 mm diameter hole is required. However, if using the weather sealing collar by pushing it through from inside the property, then a 150 mm diameter hole is required to accommodate this. ▶ The flue turret of the 100 mm flue has an in-built 3° angle. ▶ If extensions are to be added then the complete flue must rise at an angle of 3°. ▶ The 125 mm diameter flue system will require the flue to rise at an angle of 3°. ▶ Drill hole using a core drill or similar. 3. SIDE OUTLET: 2. 4. Mark from the centre line of the wall template to the wall which the flue will pass through (4). ▶ Allow for a rise of 52mm per metre length of flue, to give a 3° angle. ▶ Clear any debris from the site. 4. 3. 4. 1. 127 mm 6720804514-02.1Wo Fig. 25 Case removal 6720644744-16.2Wo 2. Fig. 24 Marking the flue position 20 6 720 804541 (2012/12) INSTALLATION 4.4 BOILER CONNECTION CAUTION: ▶ ISOLATE THE MAINS GAS SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. Return Flow 4 3 WARNING: ▶ Caps fitted to pipes must be removed before hanging the boiler GAS AND WATER CONNECTIONS: ▶ Remove wall mounting template and secure the wall mounting frame to the wall with the appropriate fittings for the boiler weight and wall type. ▶ If there is greater than 600mm clearance below the appliance it is possible to fit the flow and return pipes, supplied, with the boiler installed on the wall. ▶ If clearance is less than 600mm below the appliance it may be necessary to fit the flow and return pipes before hanging the appliance. 6720644744-13.1Wo The copper pipes supplied with the boiler are not to used for the gas supply. These copper pipes are for water only. 2 1. Gas inlet (22mm) 2. Condensate 3. Flow (22mm) 4. Return (22mm) NOTICE: ▶ Lift the boiler using the handling holes at either side of the frame. Do not lift the boiler by the air gas manifold or control box. System pipes may be run vertically up behind the boiler or below it. NOTICE: ▶ If pipes require reducing in length this is best done before they are fitted to the boiler. 4 3 1 Pipes in alternative position Fig. 26 Plumbing manifold ▶ Lift the boiler onto the wall plate. ▶ Level vertically using the feet (1) at the bottom rear of the boiler casing. ▶ Fit retaining screws through the holes (2) in the boiler frame to secure the boiler. ▶ Make connections to the heating system pipes. 2 1 6720644744-56.1Wo Fig. 27 Levelling and securing detail 6 720 804 541 (2012/12) 21 INSTALLATION 4.4.1 CONDENSATE CONNECTION Never terminate or discharge into any open source, including; sink, bath, shower, bidet, toilet etc. 5mm NOTICE: Condensate disposal ▶ Follow the recommendations given in section 3.4 “Condensate pipe work” for all condensate disposal installation. ▶ Ensure that the condensate pipe work falls at least 50mm per metre towards the outlet. ▶ * Do not use solvents, adhesive or lubricant when pushing the pipe onto the rubber connector. Figure 29 gives the pipe work dimensions with respect to the mounting surface. When using the pre-formed water pipes provided with the boiler, offset the water pipes connecting to them by 5mm to enable pipe clamps to be fitted. A sealing washer (1) and 22mm adaptor (2) are supplied in the fitting pack 1. 18mm 1 25mm 2 * 2. 6720644744-22.1Wo 6720644744-19.1Wo WALL 1. Fit washer (1) inside the plastic nut and attach firmly to the connection on the syphon. 2. Connect the condensate disposal pipe work to the elbow (2), refer to figure 29 and insert the condensate pipe 25mm into the elbow. 125mm Fig. 29 Pipe work dimensions Fig. 28 Condensate connections 22 6 720 804541 (2012/12) INSTALLATION 4.5 FLUE INSTALLATION 4.5.2 REDUCING THE TELESCOPIC FLUE LENGTH HORIZONTAL FLUE (60/100mm diameter) Ensure that the “TOP” label is facing up before securing the flue section to the turret. For vertical flues and 80/125mm horizontal flues, please refer to separate instructions supplied with the flue kit. To ease assembly of flue components, apply silicone lubricant to sealing surfaces. The flue terminal MUST be fitted with the 'TOP' label uppermost to allow the correct fit and use of the plume management system. 3 Basic instructions for the 60/100mm diameter flue are shown below. WALL 189 mm 1 2 Edge of case 200 mm 6720643895-29.1Wo Fig. 30 Flue turret centre 265 mm 1 4.5.1 MEASURING THE FLUE (STANDARD FLUE): ▶ Measure from the outside of the wall to the centre line of the flue turret to determine length L. ▶ Subtract 50mm from the length L to give the correct dimension to the flue elbow connection. ▶ If the length L falls within the telescopic range of 350 to 570mm or 570 to 790mm using the longer telescopic flue, then no cutting will be required. ▶ If the required length is less than 350mm the standard telescopic flue can be modified, refer to fig. 32. ▶ If the required length is greater than 570mm, then the longer telescopic flue, giving a range of 570 - 790mm, can be used ▶ If the required length is greater than 790mm, then flue extensions will have to be used. Refer to the 60/100 Horizontal Flue Instruction manual provided in the telescopic flue kit. ▶ Refer to section 3.8 for flue options. 6720643895-31.1Wo Fig. 32 Reducing the standard terminal ▶ Remove the screws (3) to detach the terminal assembly from the turret. ▶ Slide terminal section (2) from the terminal assembly and discard. ▶ To use terminal (1) without cutting remove the location lug (4) on the inner flue tube (5) and remove any burrs. To reduce the flue length further: 130 mm MIN 4 6 5 6720643895-32.2Wo ▶ Mark the length required for the terminal as shown (min. 130mm) and cut square, taking care not to damage the tubes. ▶ Remove any burrs and chamfer the outer edge of the tubes to assist ease of connection and prevent seal damage. The aluminium tape is not required when reducing the terminal. 4.5.3 INSTALLING THE TELESCOPIC FLUE Adjusting the telescopic flue length: 1. Refer to figure 33 and set the flue length to the distance required, secure with the screws provided. 2. Seal the joint with the aluminium tape provided. 3. Slide the inner wall seal onto the terminal. 4. If fitting from inside the building; slide the outer wall seal onto the terminal. L 570 mm 350 mm 3. 2. 2 1 TOP 1. 6720643895-30.1Wo Fig. 31 Standard telescopic flue 1. Extend tube (1) by withdrawing from tube (2) to achieve the flue length required, between 350 - 570mm. Secure with screw provided and seal joint with the aluminium tape supplied. 4. 6720644842-08.1Wo Fig. 33 Telescopic flue 6 720 804 541 (2012/12) 23 INSTALLATION The turret securing screws are from the boiler and are not in flue kit. Refer to figures 34 & 35. 1. Remove the three inner flue tube retaining screws (2). The inner tube will be held in place in the appliance. 2. Check the boiler flue seal is correctly seated and apply silicone grease. 3. Position terminal through the flue opening in the wall to the outside of the building by the distance shown. 4. Align the flue turret to the boiler flue outlet with flat facing (1) to the rear of the boiler. The flue turret should be pushed straight down, on to the boiler. 2m 1m 104mm 52mm 6720644842-10.1Wo Fig. 36 Slope for condensate disposal 4.5.4 FLUE TERMINAL PLUME RE-DIRECTION The flue discharge can be re-directed allowing some plume redirection control, alternatively, a complete plume management system can be fitted to the flue terminal. RE-DIRECTING THE FLUE DISCHARGE 1. Using a suitable tool, unclip (1 & 2) the terminal end and rotate through 180°. 1 NOTICE: DO NOT rotate the complete terminal assembly. 2 1. Refit to the terminal, ensuring that the clips (1 & 2) are engaged and secure. 2. Loosen screws (3) and rotate the entire outlet assembly to redirect the plume. Tighten screws (3) to secure in the required position. The flue terminal outlet has built-in stops to limit rotation for horizontal fluing to allow condensate to run back into the boiler for safe disposal. Do not attempt to force beyond the limit stops. 6720643895-35.1Wo Fig. 34 ▶ Fit the screws removed in step 1 to secure flue turret. ▶ If fitting the outer seal from outside the building, slide the outer wall seal onto the terminal as shown. 1. 1. 1. 1. 4. 1 3. 2. 2 2. 110 180° ±80° 6720643895-33.1Wo Fig. 35 Telescopic flue installation For more information refer to the 60/100 Horizontal Flue kit Instruction Manual 3. 3 1 ADDITIONAL NOTES AND REMINDERS: • Ensure that all cut lengths are square and free from burrs. • The flue is sealed when assembled correctly and the components are pushed fully home. • The flue is set at an angle of 3° or 52mm per metre length. • Support the flue at approximately one metre intervals and at a change of direction, use suitable brackets and fittings (flue bracket 100mm part number: 7 716 191 177, flue brackets 100mm x 6 part number: 7 716 191 178, flue bracket 125mm part number: 7 716 191 179) 24 6720643895-34.1Wo Fig. 37 Plume redirection NOTICE: Outlet position ▶ The flue terminal outlet position must follow those stated in the relevant appliance instruction manual. When redirecting the flue discharge the outlet terminal must be at least 1500mm from any opening in the direction of the discharge to prevent combustion products from entering the building. 6 720 804541 (2012/12) INSTALLATION ▶ Turn cable clamping screw clockwise to secure cable and replace clamp into control panel. 1 3. Mains power 230v connection (ST1): – Separate wires from cable end and strip to 6mm – Connect LIVE wire to terminal (L) – Connect NEUTRAL wire to the terminal (N) – Connect EARTH wire to earth bracket 4. External Pump (ST2): Max power 90 W – Connect NEUTRAL wire to terminal (Np) – Connect LIVE wire to terminal (Lp) – Connect EARTH wire to earth bracket 5. Boiler Demand (from external wiring centre) (ST2): – Connect SWITCHED LIVE wire to terminal (LR). 4 NOTICE: SYSTEM PUMP ▶ THE SYSTEM PUMP MUST BE CONNECTED TO THE APPLIANCE FOR THE PUMP OVER-RUN FUNCTION. 2 3 Fig. 38 Plume distance to opening 1 2 3 4 Opening in building Flue discharge Plume deflector Minimum 1500mm from an opening in the building 2. Table 15 Key to figure 38 4.6 ELECTRICAL CONNECTIONS 1. CAUTION: Isolate the mains electrical supply before starting any work and observe all relevant safety precautions. ST7 ST2 The boiler is already wired with a mains supply cable. A spare strain relief block is supplied in case the prewired cable is replaced.1 ▶ The mains supply to the boiler and system wiring centre must be common, and through either a fused double pole isolator or a fused three pin plug and unswitched socket. ▶ The isolator/socket, where practicable, should be situated next to the boiler. ▶ The isolator must have a contact separation of 3mm minimum in both poles. ▶ Any system connected to the boiler must not have a separate electrical supply. ▶ External fuse rating 3A. ACCESS TO ELECTRICAL CONTROL PANEL: ▶ Remove boiler casing to access control panel. 1. Unscrew the three screws in the control panel. 2. Remove the connections cover. ▶ Unclip cable clamp. ▶ Cut off the tapered cable entry to fit cable diameter required. ▶ Turn cable retaining screw anti-clockwise ▶ Run cable through the hole in the main crossbar marked “mains cable” and through the cable clamp, ensure there is ample cable to reach the connectors. 6 720 804 541 (2012/12) 3. 4. 5. 6720644744-25.1Wo ST1 Fig. 39 Wiring detail NEW COMPLETE SYSTEM INSTALLATIONS If a new complete heating system is installed in a new build property or it is a first time installation in an existing property, the heating systems must conform to current building regulations Part L1a or L1b. All new heating systems in dwellings must have at least two heating zones. Each of these zones will be controlled by a thermostat and zone valve. The exception to this are single storey, open plan dwellings where the living area is more than 70% of the total useable floor area. Then this type of dwelling can be controlled as one zone. An alternative would be individual electronically controlled TRVs. Hot water supplied would require separate time and temperature control. For dwellings with a floor area over 150m2, separate time and temperature control for each zone is required. All radiators must have TRVs fitted in all rooms except bathrooms and rooms with thermostats. 25 COMMISSIONING EXISTING INSTALLATIONS For boiler replacements on an existing system, it is not necessary to zone the upstairs and downstairs differently, compliance with the zone requirements can be achieved by a single room thermostat or programmable room thermostat. While the system is drained down, TRVs must be fitted to all rooms except the bathrooms and the room with the thermostat. 1 EXTERNAL WIRING CENTRE System components wired into terminal strip in accordance with system manufacturers instructions. ST2 LP NP LR N 6720804530-11.1Wo blue ST1 L green/yellow brown 230V MAINS SUPPLY L N E Fig. 42 Data plate location L N E SW Wiring Centre/Junction Box 6720644744-26.1Wo L N E Pump * External 90W max ▶ Turn on the main gas supply, check the gas pipe work, connections and rectify any leaks. NOTICE: Do not use solvents, adhesive or lubricant when pushing the pipe onto the rubber connector. Fig. 40 External wiring centre Refit electric control panel covers: ▶ Refit panel and secure with screws. 5 COMMISSIONING 5.1 PRE-COMMISSIONING CHECKS ▶ Check that the condensate pipe has been connected to the syphon. ▶ Ensure that the condensate pipe has been inserted at least 25mm into the elbow WARNING: ELECTRIC SHOCK ▶ ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS ▶ Check that the gas service pipe and water pipes are connected to the correct position on the manifold. 1. Gas inlet (22mm) 2. Flow (22mm) 3. Return (22mm) 25mm 6720644744-29.1Wo Fig. 43 Condensate connection If the boiler is not to be commissioned immediately then, after successfully completing all of the checks and any rectification work, shut off the gas and water supply and electrically isolate the boiler. 2 3 1 Fig. 41 ▶ Check the gas type specified on the identification plate (1) matches that of the gas supply. 26 6 720 804541 (2012/12) COMMISSIONING 5.2 FILLING THE SYSTEM INHIBITOR (Central Heating): Open vented systems: ▶ Ensure all system and boiler drain points are closed. ▶ Open all radiator valves. ▶ Turn on the water supply to the system header tank and allow the system to fill. ▶ Check drain cocks are closed and all radiator valves are open before adding a suitable inhibitor compatible with aluminium (or combined inhibitor/anti-freeze if the system is exposed to freezing conditions) to the heating system water in accordance with the manufacturers instructions. Sealed systems: ▶ Fill the system via a WRAS approved filling loop to 1 bar then turn the valve anti-clockwise to close. Opened vented and sealed systems: ▶ Vent (1) any air from the boiler heat exchanger using a suitable container to collect any water. Ensure tube outlet (2) is directed away from the fan or any other electrical component to prevent any water damage. Also place a suitable cover over the fan to prevent any spillage of water on to electrical connections. Ensure the cover is removed after venting. The pH value of the system water must be less than 8 or the appliance warrantee will be invalidated. ▶ Fill system as described in section 5.2 opposite. ▶ Set all controls to maximum. ▶ Record the date when the inhibitor was added to the system on the warrantee card. NOTICE: ▶ The concentration of inhibitor in the system should be checked every 12 months or sooner if system content is lost. ▶ Normally the addition of sealing agents to the system water is not permitted as this can cause problems with deposits left in the heat exchanger. ▶ In cases where all attempts to find a micro leak have failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer. 1 2 WATER TREATMENT PRODUCTS Suitable water treatment products can be obtain from the following manufacturers: 6720804530-12.1Wo Fig. 44 Venting ▶ Vent all radiators and the primary side of the hot water cylinder, tighten when completed and check the system and correct any leaks. Sealed systems only: ▶ If required increase system pressure back to 1 bar. ▶ Isolate and remove filling loop connection to system. 5.3 FERNOX SENTINEL 5.4 0870 601 5000 or www.fernox.com 0800 389 4670 or www.sentinel-solutions.net STARTING THE APPLIANCE CAUTION: RUNNING THE APPLIANCE ▶ Never run the appliance when the appliance/system is empty or partially filled. WATER TREATMENT 0 NOTICE: ▶ ARTIFICIALLY SOFTENED WATER MUST NOT BE USED TO FILL THE CENTRAL HEATING SYSTEM. 1 0 1 1. It is possible to have an ion exchange water softener fitted to the cold water system of the property. However, the boiler requires an untreated cold water connection taken from the mains supply, before the water softener, to the primary water filling point of the heating system. ENSURE THAT THE SYSTEM HAS BEEN CLEANED AS ON PAGE 8 OF THESE INSTRUCTIONS. 3 2 1 Alternatively there are water softening/treatment devices that do not adjust or alter the pH levels of the water. With these devices it may not be necessary to provide an untreated water by-pass to the primary water filling point of the heat system. 4 FLUSHING (Central Heating): min MIN RESET MAX 2. max 3. MIN RESET reset MAX 6720644744-30.1Wo ▶ Switch off the boiler. ▶ Open all drain cocks and drain the system while the appliance is hot. ▶ Close drain cocks and add a suitable flushing agent at the correct strength for the system condition in accordance with the manufacturer's instructions. ▶ Run the boiler/system at normal operating temperature for the time stated by the manufacturer of the flushing agent. ▶ Drain and thoroughly flush the system to remove the flushing agent and debris. Fig. 45 Boiler controls 6 720 804 541 (2012/12) 27 COMMISSIONING Switching the appliance ON/OFF: ▶ Turn on mains power, the power ON indicator (2) illuminates BLUE. ▶ Turn on any external controls ▶ Set the thermostatic radiator controls to maximum temperature ▶ Set the clock/programmer to continuously ON and the room thermostat to maximum temperature 1. Turn Power ON/OFF knob (1) from 0 (OFF position) to I (ON position), after two seconds the Power ON indicator (2) illuminates. 1 2 3 4 Power ON/OFF knob Power ON and fault indicator (Blue) Central heating temperature control Burner indicator (Green) ▶ Check the gas supply working pressure at the gas valve conforms to values shown in Fig. 47 or Fig. 48 . Ensure inlet pressure is satisfactory with all other gas appliances working. GAS PRESSURE WITHIN THE SYSTEM Refer to the figures below for natural gas or L.P.G gas pressures. Table 16 Control panel legend 2. Turn the boiler CH temperature control (3) to maximum. The burner on indicator (4) illuminates GREEN when the burner has lit. ▶ If the boiler fails to light and the boiler goes to flame lock-out, the BLUE power indicator (2) will flash. NOTICE: RESET ▶ Do not press the blue power indicator to reset the boiler. 3. To reset the lockout turn the boiler thermostat control to minimum, then passed minimum where the control knob will click at reset position, wait 5 seconds then turn to maximum. The boiler will be reset. 5.5 ▶ Open gas isolation valve. ▶ Measure the pressure with the boiler running at maximum. – Refer to section 6.4 to set the boiler to maximum output. – The boiler will stay at maximum for 15 minutes. – Return the boiler to normal after the checks. The pressure at the boiler must not be less than the pressure read at the meter minus: • 1 mbar for Natural Gas • 2.5 mbar for L.P.G. The pressure drop from the meter to the gas valve must not be more than: • 2.5 mbar for Natural Gas • 4 mbar for L.P.G. If the pressure drops are greater than shown below, then this would indicate a problem with the pipe work or connections within the system. Meter COMMISSIONING NOTICE: The combustion settings on this gas-fired boiler have been checked, adjusted and preset at the factory for operation on the gas type defined on the data plate. No measurement of the combustion values is necessary provided there is a meter installed allowing the gas rate to be checked. DO NOT ADJUST THE AIR/GAS RATIO VALVE. Having checked: ▶ That the boiler has been installed in accordance with the installation instructions. ▶ The integrity of the flue system and flue seals, as described in section 6.3 of this manual. ▶ The integrity of the boiler combustion circuit and relevant seals. 5.5.1 CHECKING THE GAS INLET PRESSURE Natural Gas < 2.5mbar difference Gas Control valve 19 - 23 mbar 16.5 - 20.5 mbar Boiler inlet 1 mbar drop 1.5 mbar drop 18 - 22 mbar Fig. 47 Natural gas pressures 6720644744-44.2Wo Equal to or less than ..... Regulator The inlet pressure to the appliance must be checked using the following procedure: MEASURING THE INLET PRESSURE L.P.G. < 4.0mbar difference Gas Control valve 32 - 45 mbar 28 - 41 mbar 1 Boiler inlet 2.5 mbar drop 1.5 mbar drop 6720643895-53.1Wo Fig. 46 Inlet pressure test point ▶ Close gas isolation valve. ▶ Slacken the screw in the inlet pressure test point (1) and connect a manometer. 28 29.5 - 42.5 mbar 6720644744-45.2Wo Fig. 48 L.P.G. pressures 6 720 804541 (2012/12) SERVICE AND SPARES NOTICE: Do not continue commissioning until the correct gas pressure is achieved. 5.5.2 CHECKING THE GAS RATE ▶ The gas rate should be measured at the gas meter after 10 minutes operation at maximum. See technical data section at the front of this manual. ▶ Where a gas meter is not available (e.g. L.P.G.) the CO/CO2 must be checked to the units shown in the setting of the air/gas ratio, refer to section 6.6. 5.6.2 INSTALL THE BOTTOM PANEL The cut out in the bottom panel fits easily over the syphon elbow and outlet, however care should be taken not to disturb any sealed components. 1. Hook the lip at the back of the bottom panel over the angled edge at the base of the connections manifold. 2. Push up into position. 3. Secure in position the screw provided. ▶ If pressure and gas rate are satisfactory press the service button and the boiler will return to normal operation. – If left in the service mode the control will return to normal operation after 15 minutes. 3. ▶ Close the gas isolation valve. ▶ Remove the manometer. ▶ Re-seal the screw in the gas inlet pressure test point. ▶ Open the gas isolation valve. ▶ Ensure that there are no gas leaks. ▶ Replace the outer case. 1. 2. FINISHING COMMISSIONING 6720644744-34.2Wo 5.6 1. Fig. 50 Bottom panel 5.6.1 REPLACE THE OUTER CASE: Replace outer casing making sure that the securing points are properly located. 5.6.3 HAND OVER ▶ Complete the Benchmark Gas Boiler Commissioning Checklist. 1. Replace top two screws. 2. Re-tighten bottom two screws. The Benchmark Checklist can be found at the rear of these instructions. ▶ Set up the controls and show the user how to operate all the controls shown in the User Guide. ▶ Ensure that the User guide is left with the boiler or homeowner. ▶ If the appliance is unused and exposed to freezing conditions, shut off all the mains supplies and drain the system and boiler. 1. 6 SERVICE AND SPARES 6.1 INSPECTION AND SERVICE CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. 2. 6720644744-33.1Wo NOTICE: COMPONENTS. ▶ After replacement of any components always check for gas tightness where relevant and carry out functional checks as described in Commissioning. Damaged O-rings or gaskets must be replaced. NOTICE: Service work must be carried out by a competent registered engineer, such as British Gas or Gas Safe registered personnel! NOTICE: SERVICE MUST NOT BE ATTEMPTED IF A CO/ CO2 ANALYSER IS NOT AVAILABLE. Fig. 49 Replacing outer case • To ensure the continued efficient operation of the appliance it must be checked at regular intervals. 6 720 804 541 (2012/12) 29 SERVICE AND SPARES • The frequency of servicing will depend upon the particular installation conditions and usage however, an annual service is recommended. • The extent of the service required by the appliance is determined by the operating condition of the appliance when tested by fully qualified engineers. • The service interval record sheet at the rear of these instructions must be completed after each service. 2. INSPECTION 1. 1. Check that the terminal and the terminal guard, if fitted, are clear and undamaged. 2. If the appliance is in a compartment or cupboard check that the specified service space around the appliance is clear. 3. Check all the joints and connections in the system and remake any that show signs of leakage. Refill and re-pressurise if applicable as described in Commissioning, section 5.2. 4. Operate the appliance and take note of any irregularities. Refer to Fault Finding on page 43 for rectification procedures. 1. 3. COMPONENT ACCESS 4. Removing outer case 1. Undo and remove two screws securing boiler casing at the top of the appliance. 2. Undo but do not remove the two screws securing boiler casing at the bottom of the appliance. 4. ▶ Pull case forward and remove. 6720644744-36.1Wo Fig. 52 Control panel into service position 6.2 CHECKING GAS INLET PRESSURE Refer to section 5.5.1 for checking the gas inlet pressure 1. NOTICE: ▶ Ensure that the gas inlet pressure is satisfactory with all other gas appliances working. ▶ Do not continue with the other checks if the correct gas inlet pressure can not be achieved. 6.3 CHECKING FLUE INTEGRITY The integrity of the flue system and performance of the boiler can be checked via the flue turret sample points. Flue gas sample point Air inlet sample point 1 2 2. 6720644744-35.1Wo Table 17 Key to figure 53 Fig. 51 Remove outer case LOWERING THE BOILER CONTROLS TO THE SERVICE POSITION: 1 2 1 1. Remove two screws securing the control. 2. Pull the control forward. 3. Lower the control to align the slots at the top of the control with the lugs on the boiler framework. 4. Hang control on two lugs on boiler framework. 2 1 2 6720643895-67.1Wo Fig. 53 Flue test points 30 6 720 804541 (2012/12) SERVICE AND SPARES ▶ With the boiler case on and the boiler running at maximum. ▶ Insert the analyser probe into the air intake test point. ▶ Allow the readings to stabilise and check that: – O2 is equal to, or greater than 20.6% – CO2 is less than 0.2% ▶ If the readings are outside these limits then this indicates that there is a problem with the flue system or combustion circuit, e.g. missing or dislodged seals. 3. 2. 6720644744-37.1Wo 1. MAX NORM MIN MAX NORM MIN Fig. 54 Flue integrity test 6.4 FAN PRESSURE TEST 4. This test is to determine if the heat cell requires cleaning/attention. 5. 6720644744-31.1Wo Fig. 55 Setting the boiler to maximum SETTING THE BOILER TO MAXIMUM FAN PRESSURE TEST 1. Remove the three screws retaining the control cover. 2. Remove the control cover. 3. Remove the plastic tool clipped inside the cover. 4. Insert the tool into the switch. 5. Using the tool set the mode switch to maximum output. Ensure the boiler is powered up and there is a demand from the external controls. 6720804530-13.1Wo The power indicator will flash and the boiler will stay in this mode for 15 minutes if no further change is made to the switch. Fig. 56 Fan pressure test ▶ Remove the cover and connect a digital manometer to the fan pressure test point. ▶ The pressure will read negative, refer to the chart in figure 57. ▶ After measurement replace test point cover and return mode switch to normal. ▶ Replace the control cover. ▶ Replace outer case. 6 720 804 541 (2012/12) 31 SERVICE AND SPARES ▶ Check the CO/CO2 readings against the information in table 18 CO/ CO2 settings on page 32. NOTICE: The boiler must be run at maximum output for Fan Pressure test and the Flue Gas analysis. FAN PRESSURE TEST Clean the Heat Ex. Heat Ex. ok NG Boilers - 3.1 24 Ri: - 7.4 18 Ri: - 5.5 15 Ri: - 3.6 12 Ri: 0 -1 -2 -3 -5 -4 mbar -6 -7 -8 LPG Boilers - 5.8 - 3.9 12 Ri: 0 -1 -2 -3 -5 -4 mbar -6 -7 -8 Fig. 57 Fan pressure readings If the boiler fails the fan pressure test then before adjusting the air/gas ratio, try the following: ▶ Check the syphon is not blocked. 1. Remove the screws securing the sump cover. 2. Remove the sump cover. 3. Clean the sump with a suitable brush. 6720804530-14.1Wo - 8.0 18 Ri: 15 Ri: 6720644744-39.1Wo - 4.1 24 Ri: Fig. 59 If the boiler fails the combustion test, check: 1. Air intake for restriction 2. Diaphragm in the fan, for correct operation 3. Cleanliness of the heat cell, plus blockages in the condensate disposal. 6.6 SETTING THE AIR/GAS RATIO NOTICE: THE SETTING OF THE GAS RATIO MUST BE CARRIED OUT BY A COMPETENT PERSON. SETTING OF THE GAS RATIO MUST NOT BE ATTEMPTED UNLESS THE PERSON CARRYING OUT THE TEST IS EQUIPPED WITH A COMBUSTION ANALYSER CONFORMING TO BS 7927 AND IS COMPETENT IN ITS USE. ▶ Check the exhaust path and flue for restriction. ▶ Re-check the Fan Pressure readings 6.6.1 SETTING THE CO/CO2 ▶ Refer to section 6.2 and ensure that the gas inlet pressure is correct before continuing. ▶ To adjust the CO/CO2 it will be necessary to first operate the boiler at maximum output. ▶ Refer to section 6.4 for setting the boiler to maximum and minimum output. 3. 2. 1. 1. ▶ Check CO is less than 200ppm. ▶ Set the control to minimum. 6720644744-40.1Wo Fig. 58 Sump access 6.5 FLUE GAS ANALYSIS COMBUSTION TEST: Ensure that the gas inlet pressure has been checked and is satisfactory, refer to section 5.5.1 ▶ Connect the flue gas analyser to the flue gas sampling point as shown in the figure below. ▶ Run the boiler at maximum output for at least 10 minutes. 32 ▶ Refer to table 18 and check the CO/CO2 at maximum. If required set the maximum CO/CO2 via adjuster (1) on the gas valve using a 2.5mm Allen key. ▶ The boiler will go to minimum power. ▶ Measure the CO/CO2 and check against table 18. If required set the minimum CO/CO2 via adjuster (2) on the gas valve until the correct measurement is set: – Remove dust cap with flat bladed screw driver. – Using a 4mm Allen key adjust CO2. – Replace the dust cap. ▶ Check that the CO is less than 200ppm. ▶ Return the boiler control to maximum and re-check the CO/CO2. If correct, set the boiler control to normal “NORM”. ▶ Re-fit the control cover ▶ Re-fit boiler outer case. 6 720 804541 (2012/12) SERVICE AND SPARES MAX 1 2.5 mm MIN 2 2. 1. 4 mm 6720643895-72.1Wo Fig. 61 Gas valve connection 6720643895-66.1Wo Fig. 60 Gas valve adjustment CO/CO2 settings for Greenstar Ri CO/CO2 should be measured after 10 minutes. Gas type CO2 max. CO2 min. Natural gas 12 Ri 9.65% 0.5 8.65% 0.5 Natural gas 15/18/24 Ri 9.8% 0.5 9.2% 0.5 L.P.G. 11.0% 0.5 10.5% 0.5 NOTE: When checking an existing appliance the tolerance is 0.5. ▶ Remove electrical connector and earth wire from fan. To prevent damage to the electrodes when removing the air/gas manifold, disconnect the leads to the electrodes. ▶ Disconnect spark electrode and flame sensor connections. 1. Refer to figure 62 and undo the securing nut on the top of the heat exchanger and remove the retaining plate assembly. If checking after cleaning or component replacement or for adjustment when the reading obtained is outside the tolerances given above, then the tolerance is 0.2. CO - less than 200 ppm (0.002 ratio) 1. Table 18 CO/CO2 settings CLEANING THE HEAT EXCHANGER NOTICE: COMBUSTION TESTING ▶ Combustion testing must be carried out by a competent person. Testing must not be attempted unless the person carrying out the combustion check is equipped with a Combustion Analyser conforming to BS 7927 and is competent in its use. NOTICE: CO/CO2 CHECKS ▶ If the joint between the Air/Gas manifold and heat exchanger is disturbed the sealing gasket must be replaced. ▶ After completing the service of the appliance, the CO/ CO2 must be checked and set to the limits shown in “Setting the air/gas ratio” on page 32. 6720643895-60.1Wo 6.7 Fig. 62 Securing nut 1. Refer to figure 63 and rotate fan and air/gas manifold assembly around the top of the heat exchanger until it stops at the lug. ▶ Lift up assembly and remove from boiler. 2. Remove the cover panel by removing retaining screw. 2. There is a special accessory kit available specifically designed for cleaning the heat exchanger. If required order 7 716 192 312. ▶ Isolate the power to the appliance and remove outer case and base panel. 1. 1. Refer to figure 61 and remove the clip from gas valve outlet. If the plastic elbow can not be easily removed, undo the nut to push the plastic elbow out of the fitting. 2. Pull the gas outlet elbow free from the gas valve. 6 720 804 541 (2012/12) Fig. 63 Rotate air/gas manifold 6720804530-16.1Wo 33 SERVICE AND SPARES BURNER REMOVAL Refer to figure 64 1. Remove clamping plate. 2. Remove spark/flame electrode assembly and seal from the top of the heat exchanger. 3. Remove burner. 1. 1. 2. 6720643895-61.1Wo 3. 6720643895-64.1Wo 2. Fig. 64 Burner removal Checking and cleaning the electrode assembly: NOTICE: Cleaning ▶ Do not use wire wool to clean the electrodes Fig. 65 Baffle removal ACCESS COVER REMOVAL ▶ Inspect the condition of the electrodes and ceramics, replace if necessary. ▶ Use a plastic scouring pad to clean the electrodes. BAFFLE REMOVAL Refer to figure 66. 1. Remove the two pozi-drive screws 2. Remove the access cover 3. Remove the gasket. 1. Refer to figure 65and remove top baffle. 2. Remove lower baffle. If the lower baffle is stuck, it may be necessary to use the “Baffle removal tool” from the heat exchanger cleaning kit - 7 716 192 312, as shown in figure 65. 3. 2. 1. 1. 6720644744-40.1Wo Fig. 66 Access cover removal 34 6 720 804541 (2012/12) SERVICE AND SPARES CLEANING THE PRIMARY HEAT EXCHANGER NOTICE: CO/CO2 CHECKS ▶ If the joint between the Air/Gas manifold and heat exchanger is disturbed then the sealing gasket must be replaced. ▶ After completing the service of the appliance, the CO/ CO2 must be checked and set to the limits shown in “Setting the air/gas ratio” on page 32. ▶ When replacing the burner gasket ensure that the clamping plate is fully tightened down to the heat exchanger. ▶ Refer to figure 67 and access the heat exchanger flue ways by inserting the cleaning brush (7 716 192 312) through the top access hole in the casing, removal of panel shown in figure 63. ▶ Clean heat exchanger flue ways using the cleaning brush removing any debris from the access point in the sump. ▶ Clean around the sealing surface on the sump. ▶ Replace the access cover. ▶ Using a suitable container to collect water from syphon connection at the base of the boiler flush heat exchanger with water. ▶ Re-assemble ensuring that the lower baffle (2) and the top baffle (1) are refitted correctly. ▶ Refer to figure 64 when re-fitting the burner to ensure that it fits centrally within the heat exchanger and location tabs are situated in location holes. ▶ Ensure that the seal is replaced with a new seal and ensure that the seal is correctly fitted. ▶ Check the syphon unit is clean before refitting to boiler. ▶ Reassemble and check combustion as stated in “SETTING THE AIR/ GAS RATIO” section on page 32. THE HEAT EXCHANGER DOES NOT HAVE TO BE REMOVED TO CLEAN. The heat exchanger is shown removed from the boiler to illustrate cleaning more clearly. 6.7.1 SYPHON REMOVAL AND CLEANING Remove the syphon assembly to clean. To release the syphon from the sump: 1. Undo the plastic nut on the bottom of the syphon and move the condensate pipe away from the syphon. 2. Remove the two screws retaining the syphon bracket. 3. Remove the bracket. 4. Remove the screw and release the syphon retaining clamp 5. Swing the clamp completely to the left away from the syphon 6. Pull the syphon towards you and remove from the sump connection. ▶ Empty the contents of the syphon into a suitable container. ▶ Flush the syphon through with clean water 4. 5. 6. 2. 3. 1. 6720643895-65.1Wo 6720644744-42.1Wo Fig. 67 Cleaning heat exchanger NOTICE: Heat exchanger baffles. The baffles (1) and (2) must be refitted into the heat exchanger in the order shown in figure 65. Failure to do so may result in damage to the boiler. Fig. 68 Syphon removal 6.8 REPLACEMENT OF PARTS CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. NOTICE: REPLACEMENT OF COMPONENTS. ▶ After replacement of any components always check for gas tightness where relevant and carry out functional checks as described in Commissioning. Damaged O-rings or gaskets must be replaced. 6.8.1 REMOVING THE OUTER CASING ▶ Remove bottom tray by pressing the tabs (2) in, at the front underside of the boiler. ▶ Lower the panel. 6 720 804 541 (2012/12) 35 SERVICE AND SPARES ▶ Pull the panel forward, off the retaining ledge (1) at the back of the boiler. ▶ Coat new sensor with heat conductive paste and replace. 6.8.3 OVERHEAT THERMOSTAT Refer to figure 71 for removal. ▶ Remove two electrical connectors from thermostat. 3. Slacken and remove fixing screw and thermostat (3). ▶ When replacing ensure thermostat sits correctly on surface of the casting with the left hand side of thermostat sitting up against the shoulder. 1. It is essential that the mating surface of the thermostat is coated with heat conductive paste. 1. 2. 2. 6720644744-34.1Wo Fig. 69 Remove bottom panel 1. Undo the two screws securing the top of the boiler casing. 2. Undo the two screws securing the bottom of the boiler casing. ▶ Pull case forward and remove. 3. 2. 6720804530-15.1Wo 1. 1. Fig. 71 Primary sensor and overheat thermostat 6.8.4 FLUE OVERHEAT THERMOSTAT (WITH GROMMET) To remove and replace the thermostat either: ▶ Using a small terminal screwdriver, prise the thermostat and grommet from the plastic housing. Take care not to damage the plastic housing. -or- 2. 6720644744-35.1Wo 1. Release the flue connection from the sump. 2. Push the flue tube up. Fig. 70 Remove outer case 1. To gain access to the following components the outer case has to be removed: ▶ Primary sensor ▶ Overheat thermostat ▶ Flue limit thermostat Refer to figure 71 for removal. 1. Remove electrical connection by pulling upwards. Squeeze retaining clip on plastic moulding of sensor and pull back and up until clear of pocket in heat exchanger. 2. Pull forward to remove completely. 36 2. 6720644744-47.1Wo 6.8.2 PRIMARY SENSOR (CH NTC) Fig. 72 Lower exhaust section ▶ Remove electrical connections. 1. Push the flue limit thermostat in from the sump. ▶ Retrieve the thermostat from the sump well. 6 720 804541 (2012/12) SERVICE AND SPARES 6.8.6 GAS VALVE ▶ Isolate gas supply at boiler gas cock. 1. Refer to figure 75 and re move the wire clip from the gas valve outlet. 2. Pull the gas pipe free from the gas valve. If the pipe will not pull out, unscrew the nut to aid removal. 1. 6720643895-70.1Wo Fig. 73 Remove thermostat 2. 1. To replace, push the thermostat and new grommet gently back into the opening until contact with the locating ridge is felt. 6.8.5 LOWERING THE BOILER CONTROLS TO THE SERVICE POSITION: 1. Remove two screws securing control. 2. Pull the control forward. 3. Lower the control to align the slots at the top of the control with the lugs on the boiler framework. 4. Hang control on two lugs on boiler framework. 6720643895-72.1Wo Fig. 75 Gas valve upper connection 1. Refer to figure 76 and undo bottom gas connection to gas valve. 2. Undo two securing screws on the underside of casing. ▶ Disconnect electrical connections. ▶ Pull valve up and forward out of boiler. ▶ Replace valve with new seals and check for gas tightness. 2. 3. 1. 1. 2. 6720643895-73.1Wo 1. Fig. 76 Gas valve lower connection NOTICE: The valve will require setting; follow procedure “Setting the air/gas ratio”. 4. 6.8.7 AIR/GAS MANIFOLD AND FAN ASSEMBLY 4. 6720644744-36.1Wo Fig. 74 Control panel into service position 6 720 804 541 (2012/12) The following components require the air/gas manifold and fan assembly to be removed: ▶ Fan electrode assembly ▶ Burner ▶ Heat exchanger NOTICE: ▶ If the joint between the Air/Gas manifold and heat exchanger is disturbed sealing gasket must be replaced. ▶ After re-assembly the combustion must be checked using the procedure in the section “Setting the Air/ Gas ratio”. Measurement and setting (if necessary) of the gas ratio must not be attempted unless the person is equipped with a combustion analyser conforming to BS 7927 and is competent in its use. 37 SERVICE AND SPARES ▶ Remove electrical connector and earth wire the from fan. ▶ Remove wire clip from gas valve outlet then pull gas pipe free from the gas valve (see figure 75). 1. 2. 3. 2. 1. Fig. 77 ▶ Undo the securing nut at the top of the heat exchanger and remove the retaining plate assembly (1). 6720644744-48.1Wo 6720804530-15.1Wo 4. 3. Fig. 79 Air pressure switch 1. Remove the two screws retaining the pressure switch to the bracket. 2. Refit the new Air pressure switch to the bracket. Disconnect spark electrodes and flame sensor connection. This will prevent damage to the electrodes and sensor when the air/gas manifold is rotated. 1. Rotate fan and air/gas manifold assembly (1.) around the top of the heat exchanger until the lug on the air/gas manifold is visible. ▶ Lift up assembly and remove from boiler. 1. 6720644744-49.1Wo 2. Fig. 80 Air pressure switch bracket NOTICE: After re-assembly, check the CO/CO2 levels as described in section 6.6 Setting the air/gas ratio. 1. 6.8.9 FAN ▶ Remove the air/gas manifold from the boiler as described in the previous section. 6720804530-16.1Wo Fig. 78 Rotate the air/gas manifold assembly NOTICE: After re-assembly, check the CO/CO2 levels as described in section 6.6 Setting the air/gas ratio. 1. Remove two screws retaining the fan to the air/gas manifold. 2. Remove the air/gas manifold. 3. Remove the screw holding the retaining plate. 4. Remove the retaining plate. 5. Remove three screws and the mixing chamber. Re-assemble with new fan ensuring seals are correctly fitted. 6.8.8 AIR PRESSURE SWITCH NOTICE: Pressure switch ▶ Ensure that the tube is reconnected to the pressure switch 1. Remove the electrical connections. 2. Slacken the top retaining screw and remove the bottom screw. 3. Disconnect the tube. 4. Remove the Air pressure switch assembly 38 6 720 804541 (2012/12) SERVICE AND SPARES ▶ Ensure that burner tabs, as shown in figure 83, fit correctly their respective locations. 2. 1. 1. 4. NOTICE: Heat exchanger seal ▶ If the joint between the Air/Gas manifold and heat exchanger is disturbed sealing gasket must be replaced. ▶ After re-assembly the combustion must be checked using the procedure in the section 6.6 “Setting the Air/Gas ratio”. ▶ Ensure that the seal is fitted. CAUTION: Clamping plate ▶ Ensure that the clamping plate is firmly tightened down on top of the heat exchanger. 3. 5. ▶ Replace the clamping plate. 5. 6. 1. 5. 6720643895-81.1Wo 2. Fig. 81 Dismantling the air/gas manifold assembly FLAP VALVE ASSEMBLY 3. 1. Twist the mounting flange clockwise to release. 2. Pull mounting flange off the flap valve assembly. 3. Pull rubber flap off flap valve assembly. 6720643895-61.1Wo ▶ To replace the flap valve: – Press the two lugs on the back of the flap into the two slots in the flap valve assembly. 3. Fig. 83 Electrode assembly and burner 6.8.11 HEAT EXCHANGER ▶ Drain the system. ▶ Remove syphon. ▶ Remove the air/gas manifold and fan. 1. Refer to figure 84, remove the clip from the elbow on the flow pipe. 2. Pull flow pipe away from heat exchanger. 2. 1. 6720643895-117.1Wo Fig. 82 Flap valve assembly 6.8.10 ELECTRODE ASSEMBLY AND BURNER 1. Remove spark/flame electrode assembly from heat exchanger. 2. Remove the seal from the top of the heat exchanger. 3. Remove the burner. ▶ Replace new burner in correct position. 6 720 804 541 (2012/12) 2. 1. 4744-51.1Wo ▶ Refer to figure 83 and disconnect spark electrodes and flame sensor connection. ▶ Remove clamping plate. Fig. 84 Flow pipe removal 39 SERVICE AND SPARES 1. Refer to figure 85 and re move the three screws securing the turret to the top of the boiler. 2. Turn the upper exhaust connector anti-clockwise to release from the hook. 3. Pull the upper exhaust connector down. 1. 2. 3. 6720644744-52.1Wo 1. 2. Fig. 87 Sump connections 6720643895-114.1Wo 3. Refer to figure 88. 1. Lift the heat exchanger up to clear. 2. Pull the heat exchanger forward from the case. Fig. 85 Upper exhaust assembly Refer to figure 86. 1. Release the clip. 2. Move the lower exhaust connector up ▶ Remove the complete exhaust assembly. 2. 2. Fig. 86 Release lower exhaust connection Refer to figure 87. 1. Unscrew the plastic nut. 2. Remove the nut from the bottom of the boiler. 3. Rotate lever to release the return pipe. 40 6720643895-115.1Wo 1. 6720644744-47.1Wo 1. Fig. 88 Heat exchanger removal ▶ Reassemble and check combustion as stated in the air/gas ratio section. 6.6. NOTICE: CO/CO2 CHECKS ▶ If the joint between the Air/Gas manifold and heat exchanger is disturbed sealing gasket must be replaced. ▶ After completing the service of the appliance, the CO/ CO2 must be checked and set to the limits shown in “Setting the air/gas ratio” in section 6.6. 6 720 804541 (2012/12) SERVICE AND SPARES 6.8.12 SYPHON REMOVAL To release the syphon from the sump: 1. Undo the plastic nut on the bottom of the syphon and move the condensate pipe away from the syphon. 2. Remove the two screws retaining the syphon bracket. 3. Remove the bracket. 4. Remove the screw and release the syphon retaining clamp 5. Swing the clamp completely to the left away from the syphon 6. Pull the syphon towards you and remove from the sump connection. 4. 5. 2. 1. 1 6. 2. 3. 1. 2 6720644744-53.1Wo 6720644744-42.1Wo Fig. 89 Syphon removal 6.8.13 ACCESS TO BOILER CONTROL COMPONENTS 1. Remove three screws. 2. Remove cover from control. Fig. 90 Removing the connection cover 6.8.15 CODE PLUG Refer to figure 90 for code plug replacement: ▶ Gently pull the code plug from the socket (2). ▶ The code plug should be left attached to the frame of the boiler by its plastic safety thread. 6.8.14 PCB FUSE ▶ Remove fuse holder with fuse F1 (1) from the control and replace with a new fuse. A spare 2A fuse for F1 clipped onto the inside of the cover. 6.8.16 TRANSFORMER/PCB To change either the PCB, F2 fuse or transformer: ▶ Remove two screws securing the control. ▶ Pull the control forward. ▶ Lower the control to align the slots at the top of the control with the lugs on the boiler framework. ▶ Hang control on two lugs on boiler framework. 1. Unscrew the three screws in the control panel. 2. Remove the connections cover and disconnect all electrical connections from the control. 3. Remove the control from the boiler. 4. Remove the four screws retaining the rear panel of the control. 5. Remove the rear panel. 6. Remove the transformer cover. 6 720 804 541 (2012/12) 41 SERVICE AND SPARES 3. 3. 2. 2. 1. 1. 7. 6. 5. 5. 4. 6. 6720644744-54.1Wo 4. Fig. 91 Transformer/PCB access 7. Remove the printed circuit board. F2, 1.25A fuse ▶ Remove the code plug from the old control board. ▶ Fit the code plug into the new control board. ▶ Re-assemble in reverse order. 6720644744-55.1Wo Fig. 92 Change PCB/Fuse location NOTICE: CODE PLUG ▶ Ensure that the code plug is fitted to the new control. ▶ The appliance will indicate an error and will not function correctly. NOTICE: CO/CO2 ▶ After completing the service of the control, the CO/ CO2 must be checked and set to the limits shown in “Setting the air/gas ratio” in section 6.6. 42 6 720 804541 (2012/12) FAULT FINDING AND DIAGNOSIS 6.9 SHORT PARTS LIST Fan 8 716 116 067 0 GC No. H26 536 Burner 12 & 15Ri: 8 716 116 379 0 GC No. H26 537 18 & 24Ri: 8 716 120 619 0 GC No. H26-538 Flue overheat thermostat (grommet type) 8 710 506 267 0 Control board 8 718 687 164 0 H26-541 Gasket - burner WB6 8 716 110 534 0 Sump gasket 8 716 113 829 0 Fuse F1 8 716 156 000 0 GC No. E27-716 7 FAULT FINDING AND DIAGNOSIS 7.1 FAULT FINDING Electrodes (including gasket) 8 718 107 087 0 Seal - Inner case/mantel 8 716 106 635 0 H26-545 Flow temperature sensor (NTC) 8 716 106 688 0 GC No. H26 542 High limit stat 8 707 206 196 0 GC No. H26 584 Seals kit 8 716 107 224 0 GC No. H10 876 Air pressure switch 8 716 106 633 0 G.C. No. H26 543 Flue sample plug - vertical adapter 8 710 506 199 0 Gas Valve 12/15/18 & 24Ri 8 716 111 325 0 GC No. H26 540 Flue sample plug - air intake 8 716 111 253 0 Flue sample plug - gas outlet 8 716 111 252 0 O ring - Syphon 8 716 113 851 0 Terminal end 8 718 681 828 0 Fuse F2 8 716 156 001 0 This fault finding information is for guidance only. Worcester cannot be held responsible for costs incurred by persons not deemed to be competent. Wall mounting template:- 8 718 689 070 0 (a) EARTH CONTINUITY, (b) SHORT CIRCUIT CHECK, (c) POLARITY and (d) RESISTANCE TO EARTH. 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.This fault finding system assumes that the appliance has been operating normally until the time of failure (i.e. not a first installation error).PRELIMINARY CHECKS: Preliminary electrical system checks are the first electrical checks to be carried out during a fault-finding procedure. On completion of the Service/Fault-Finding task which has required the breaking and remaking of electrical connections, check: 6 720 804 541 (2012/12) 43 FAULT FINDING AND DIAGNOSIS Blue light indication No light Fault No power at control board Possible solution/check Permanent mains supply to boiler. Boiler mains switch ON. Fuse F1 - 2A Slow blow. Fuse F2 - 1.25A Anti-surge. Transformer (both coils below 100 . Light ON Boiler ON but not operating during demand Slow flash (mostly off, flashes on) Ignition lockout Slow flash (mostly on, flashes off) Flue overheat Fast flash 2 pulses 5 pulses Otherwise replace control board. Live demand at ST2 terminal LR - is there a demand? Manual bypass is open. If CH is working check HW controls If HW is working check CH controls (i.e. external diverter valve, frost stat, room stat/ programmer. Otherwise replace board. ▶ Gas present and at correct pressure? ▶ Gas valve – Check that there is 35V d.c. to each solenoid – Check the resistance of each solenoid: Top solenoid = 380 10% (342 - 418 ) Bottom solenoid = 190 10% (171 - 209 ) ▶ Combustion CO2 level. ▶ Flue condition. – Blocked flue? ▶ Blocked condensate pipe or frozen condensate. ▶ Gas valve adjustment. ▶ Ignition electrodes/harness/connections. – Check for condition and resistance of leads (approximately 2100 ) ▶ Otherwise replace control board Flue temperature too high. ▶ Heat exchanger baffles removed and not refitted. Heat exchanger overheat ▶ Heat exchanger blocked ▶ Water pressure ▶ All air vented ▶ Pump/harness/connections. ▶ Water leaks/blockage ▶ Safety thermostats/low voltage wiring harness/connections ▶ Otherwise replace control board Flue pressure switch Blockage in the flue system. Volatile lockout (sensor, ▶ Temperature sensors fan or code plug) – Check condition and continuity of leads – Check resistance of sensor (8k - 20k ) ▶ Fan – 230V A.C. across the live (purple) and neutral (brown) ▶ Fan lead – Check continuity ▶ Code plug – Is code plug missing or not inserted properly. Service mode switch in min. position Service mode switch in max. position Table 19 Fault finding 44 6 720 804541 (2012/12) FAULT FINDING AND DIAGNOSIS 7.1.1 INTERNAL WIRING DIAGRAM FLAME SENSE ELECTRODE PRESSURE SWITCH † Fan wiring: Live = purple Neutral = brown SPARK ELECTRODES OVERHEAT STAT FLOW TEMP. SENSOR (NTC) Colour sequence † FAN FLUE OVERHEAT STAT GAS VALVE SAFETY SOLENOID SAFETY SOLENOID F2 Slow T1.25 A fuse SPARK TRANSFORMER 25V ON/OFF SWITCH CH TEMPERATURE CONTROL 230V/AC Slow 2 A fuse, AC 230 V DIAGNOSTIC INTERFACE ST2 ST6 CODE PLUG Max Min ST5 ST1 L N LP NP LR MODE SWITCH ST9 Green Red Colour sequence † Blue Violet Orange Live Earth Switched Live LP NP LR Pump Live N Pump Neutral L Norm Neutral F1 SL MAINS SUPPLY N L 230V WIRING CENTER/ JUNCTION BOX 6 720 804 541 (2012/12) EXTERNAL PUMP 6720644744-27.2Wo 45 MAINS POWER SUPPLY ON BLUE LIGHT ON Room thermostat and/or mains programmer ON (or link fitted at ST10) AND Facia mounted programmer (if fitted) ON AND Temperature control knob ON 46 LOCKOUT YES Pump ON. Fan to start speed. 5th attempt? NO Spark ignition and gas 4 seconds Wait 10 seconds Stop spark and gas. NO BURNER LIT? IGNITION SEQUENCE IGNITION SEQUENCE (see detail) GREEN FLAME LIGHT ON Gas valve OFF. Fan overrun 30 seconds YES 45 second stabilisation period. Fan modulation to achieve set temperature (40-82°C) Gas valve OFF Pump run 3 minutes Fan run 30 seconds END OF BOILER DEMAND 6720644744-60.1Wo Over temperature shutdown if water temperature is 5°C above set value. 7.2 BOILER DEMAND 3 minute pump over run FAULT FINDING AND DIAGNOSIS BOILER FUNCTION Fig. 93 Boiler function 6 720 804541 (2012/12) FAULT FINDING AND DIAGNOSIS 7.3 PROTECTION FUNCTION AUTOMATIC INTERNAL FROST FUNCTION Internal boiler temperature between 8°C & 5°C Pump runs Internal boiler temperature rises above 9°C Pump switches off after a 3 minute overrun period Boiler automatic frost function (monitors internal boiler primary temperature) Internal boiler temperature below 5°C Central heating demand is activated Internal boiler temperature rises above 12°C Central heating demand switches off Pump switches off after a 3 minute overrun period PUMP OVERRUN FUNCTION End of boiler demand (central heating or domestic hot water) Pump runs for 3 minutes to dissipate heat from the boiler into the system PUMP ANTISEIZE FUNCTION No central heating demand after a 24hr period Pump runs 5 seconds every 24hrs from last time pump ran A central heating demand activated, pump runs normally 6720643895-111.1Wo Fig. 94 Protection function 6 720 804 541 (2012/12) 47 NOTES 48 6 720 804541 (2012/12) NOTES 6 720 804 541 (2012/12) 49 Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect the customer’s statutory rights. If yes, and if required by the manufacturer, has a water scale reducer been fitted? CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798 Yes If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation fitted? Yes Service Record It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions. Always use the manufacturer’s specified spare part when replacing controls. Service 1 Date: Service 2 Date: Engineer Name: Engineer Name: Company Name: Company Name: Telephone No. Telephone No. Gas Safe Register No. Gas Safe Register No. Comments: Comments: Signature: Signature: Service 3 Date: Service 4 Date: Engineer Name: Engineer Name: Company Name: Company Name: Telephone No. Telephone No. Gas Safe Register No. Gas Safe Register No. Comments: Comments: Signature: Signature: Service 5 Date: Service 6 Date: Engineer Name: Engineer Name: Company Name: Company Name: Telephone No. Telephone No. Gas Safe Register No. Operative ID No. Comments: Comments: Signature: Signature: Service 7 Date: Service 8 Date: Engineer Name: Engineer Name: Company Name: Company Name: Telephone No. Telephone No. Gas Safe Register No. Gas Safe Register No. Comments: Comments: Signature: Signature: Service 9 Date: Service 10 Date: Engineer Name: Engineer Name: Company Name: Company Name: Telephone No. Telephone No. Gas Safe Register No. Gas Safe Register No. Comments: Comments: Signature: Signature: WORCESTER, BOSCH GROUP: Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0844 892 9900 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. worcester-bosch.co.uk 6 720 804 541 (2012/12) TECHNICAL SUPPORT: 0844 892 3366 APPOINTMENTS: 0844 892 3000 SPARES: 01905 752571 LITERATURE: 0844 892 9800 TRAINING: 01905 752526 SALES: 01905 752640
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