Installation manual for Greenstar Ri

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Installation manual for Greenstar Ri | Manualzz
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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