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THE APPLIANCE IS FOR USE WITH
NATURAL GAS OR LPG. (Cat II 2H3P TYPE C13 & C33)
NATURAL GAS:
WORCESTER GREENSTAR 12i System GC NUMBER 41-311-67
WORCESTER GREENSTAR 24i System GC NUMBER 41-311-68
LIQUID PETROLEUM GAS:
WORCESTER GREENSTAR 121 System GC NUMBER 41-311-69
WORCESTER GREENSTAR 24i System GC NUMBER 41-311-70
INSTRUCTION MANUAL
INSTALLATION,COMMISSIONING
A & SERVICING
7 WORCESTER (Benchmark) CHECKLIST & service
Sosch Group interval record, printed within this
manual
INSTALLATION & SERVICING INSTRUCTIONS
SYMBOLS USED IN THIS MANUAL: PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
Domestic hot water 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.
Central heating THE INSTRUCTIONS APPLY IN THE UK ONLY AND MUST BE FOLLOWED EXCEPT FOR ANY
STATUTORY OBLIGATION,
THIS APPLIANCE MUST BE INSTALLED BY A COMPETENT PERSON. FAILURE TO INSTALL
Hot water storage cylinder CORRECTLY COULD LEAD TO PROSECUTION.
IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER TECHNICAL HELPLIME.
Ñ Cold water main supply DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER.
PLEASE LEAVE THESE INSTRUCTIONS WITH THE COMPLETED BENCHMARK CHECKLIST,
{OR A CERTIFICATE CONFIRMING COMPLIANCE WITH IS 813, EIRE ONLY) AND THE USER
Electricity supply MANUAL WITH THE OWNER OR AT THE GAS METER AFTER INSTALLATION OR SERVIC-
ING. THE BENCHMARK CHECKLIST CAN BE FOUND IN THE BACK TWO PAGES OF THE
INSTALLATION MANUAL.
A Gas supply ABBREVIATIONS USED IN THIS MANUAL:
© Diameter
NG Natural Gas
LIFTING AND CARRYING PRECAUTIONS: LPG Liquid Petroleum Gas
« Lift only a manageable weight, or ask for CH Cantral Heating
help. CH Domestic Hot Water
* When lifting the boiler, bend the knees, IP Ingress Protection
and keep the back straight and feet apart, SEDBUK Seasonal Efficiency of Domestic Boilers in the United Kingdom
« Deo not ft and twist at the same time.
= Lift and camry the boiler close to the body
* Wear protective clothing and gloves to C h k | i 1
protect from any sharp edges ec S
Hardware/Literature pack
Item Qty
Greenstar 121 System241 System Installation/Servicing Instructions........ 1
UÜ[email protected] INSÉPUCTIONS L..nrensrorrenenmancenan nan seumaemenaranannenmantennenennsenen enenaseraneenmancennnnenmnn=nnns D
Benchmark Соб ВоюК, mses sss sssssssssss sons |
Benchmark Addendum Sheet... ce ee eee creme senna 1
Consumer Guarantee Card ......... e. eee re... eees reee enero crearan en ]
Compression Nut 22m ie... ee. eeeeeeea reina enana ena erre rence sacen conne sauna rennes À
Compression Ring 22m .....e. ee. ene essere ses sess veses reee reassess eme 3
Compression Nut 15M... mimes sss mess sss ass sss
Compression Ring 15/Mmm cece css eens sees sms sess sesmes sansa essa semen 1
Fibre Washer 23.9 x 17.2 X 1.5....... scenes ns rns sens eas 2
Bonded Washer Ys FOr Gas PIPE... ]
Environment 2010 Installer Leaflet ........... e... e... me nee reee ee recen reee 1
Environment 2010 Art Leaflet ........ ——.. eee... .e-.eceezaa rene rene renaa commas senss ss sss ss sess somes somes 1
Insh Guidelines Leaflet ........ e. ==... eee. ere. EEE ena een eee rrena asses sr ssss анна semes sense 1
Warranty Return Envelope ces ppeoosppeesppeess RNA ENERO ERUUA EURO PUNAA aaa EFENA bronas ]
INSTALLATION & INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i Syston 24i Syste WORCESTER
SERVICING INSTRUCTIONS Bosch Group
CONTENTS
SAFETY & REGULATIONS
SAFETY PRECAUTIONS & SYMBOLS
INSTALLATION REGULATIONS
APPLIANCE INFORMATION
GENERAL INFORMATION 4
TECHNICAL DATA 6
LAYOUT & COMPONENTS 6-7
PRE-INSTALLATION
CLEANING PRIMARY SYSTEMS
MAINS SUPPLY
WATER SYSTEMS 4 PIPEWORK 10
CONDENSATE PIPEWORK 11
PRESSURE RELIEF PIPEWORK 12
BOILER LOCATION & CLEARANCES 13-14
PLUMBING MANIFOLD 15
FLUE TERMINAL POSITIONS 18
FLUE OPTIONS 17
INSTALLATION
UNPACKING THE WALL FRAME 18
WALL MOUNTING TEMPLATE / FLUE OPENING 19
UNPACKING THE APPLIANCE 20
BOILER CONNECTIONS 91-29
FLUE INSTALLATION 23-25
CONDENSATE CONNECTION 26
ELECTRICAL 27
POSITION OF WIRED COMPONENTS 26
COMMISSIONING
PRE-COMMISSIONING CHECKS 29
FILLING THE SYSTEM 30
STARTING THE APPLIANCE 31
WATER TREATMENT 32
COMMISSIONING 33
FINISHING COMMISSIONING +4
SERVICING & SPARES
INSPECTION AND SERVICE 35-40
REPLACEMENT OF PARTS 41-51
SETTING THE GAS /AIR RATIO 52-54
ORT PARIS ich E
CONVERSION KITS
LEG. CONVERSION 56
FAULT FINDING & DIAGNOSIS
FAULT FINDING 57
CH FUNGTION 58
PROTECTION FUNCTION 59
ADDITIONAL INSTRUCTIONS FOR FITTING OPTIONAL DIVERTER VALVE CAN BE
FOUND AT THE REAR OF THIS MANUAL
BENCHMARK CHECKLIST
SERVICE INTERVAL RECORD SHEET
LAMORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 19 Sazter 24] Sester
E TIE 117 0556 (0405)
Bosch Group
CONTENTS
SAFETY &
REGULATIONS
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SAFETY PRECAUTIONS
IF YOU SMELL GAS:
X DONT SMOKE OR STRIKE MATCHES
X DONT TURN ELECTRICAL SWITCHES ON OR OFF
v DO PUT OUT NAKED FLAMES
v DO OPEN DOORS AND WINDOWS
+ DO KEEP PEOPLE AWAY FROM THE AREA AFFECTED
v DO TURN OFF THE CONTROL VALVE AT THE METER
v DO CALL YOUR GAS COMPANY
(benchmark)
A Benchmark Checklist is provided by the manufacturer for the installer to complete
including their CORGI registration number to confirm that the boiler has been installed,
commissioned and serviced according to the manufacturer's instructions,
IMPORTANT: The completed Benchmark Checklist will be required in the event of any
warranty work and may be required by the local Building Control Inspector.
HEALTH & SAFETY
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).
COMBUSTIBLE AND CORROSIVE MATERIALS
De not store or use any combustible materials (paper, thinners, paints etc.) inside or
within the vicinity of the appliance.
Chemically aggressive substances, such as halogenated hydrocarbons containing
chionne or fluonne compounds can corrode the appliance and invalidate any warranty.
FITTING & MODIFICATIONS
Fitting the appliance and amy controls to the appliance may only be camed out by a
competent engineer in accordance with the current Gas Safety (Installation and Use)
Regulations.
Fue systems must not be modified in any way other than as described in the fitting
instructions. Amy misuse or unauthorised modifications to the apphance, flue or
associated components and systems could invalidate the warranty, The manufacturer
accepts no lability ansing from any such actions, excluding statutory rights.
SERVICING
Advise the user to have the system serviced annually by a competent, qualified
angineer (such as British Gas or CORGI registered personnel) using approved spares,
to help maintain the economy, safety and reliability of the appliance.
IMPORTANT - The service engineer must complete the Service Record on the
Benchmark Checklist after each service.
INSTALLATION REGULATIONS
Curent Gas Safety (Installation & Use)
Regulations:
All gas appliances must be installed by a com -
petent parson in accordance with tha above regula-
tons. 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 (Morthem Ireland), local water by-laws,
Health & Safety Document 635 (The Electricity at
Work Regulations 1999) and any other local
requirements.
British Standards:
The relevant British Standards should be followed,
including:
B57074:1 : Code of practice for domestic and hot
water supply
BS56891 : Installaton of low pressure gas pipework
up to 28mm (R1)
855546 : Installation of gas hot water supplies for
domestic purposes
EN:12828 : Central heating for domestic premises
BS5440:1 : Pues and ventilation for gas appli-
ances of rated heating not exceeding 70kYY (net) :
Flues
BS5440:2 : Flués and ventilation for gas appli
ances of rated heating not exceeding TOKW (net) :
Air Supply
857593 ; Treatment of water In domestic hot water
central heating systeme
ES 6798 : Installation of gas fired boilers of rated
input up to 70kVV (net)
Whare no specific instruction is given, reference
should be made to the relevant British Standard
codes of Practica.
LEG. Installation:
An appliance using LEG. must not be installed in a
room or intemal space below ground level unless
one side of the building is open to the ground.
Timber framed buildings:
Whare tha bailar is to be fitted © a timber framed
building the guidelines laid down in BS6440: Part
1 and IGE "Gas Installations in Timber Frame
Buildings" should be adhered to.
Potable water:
All seals, joints and compounds (including flux and
solder) and components used as part of the sec-
ondary domestic walter system must be approved
by WRAS.
CH water:
Artificially softened water must not be used to fill the
central heating system.
SAFETY PRECAUTIONS
& INSTALLATION REGULATIONS
IMETALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREEMSTAR 11 Bye Zi Sparen
BE TI16 112 055 DATE) ZANORCESTER
Bosch Group
STANDARD PACKAGE:
(When fitted to wall frame) A - Wall hung gas fired condensing boiler for
cantral heating and indirect domestic hot water
B - Boiler support framed pre-plumbing jig
C - Hardware literature pack
D - Bottom Panel
B
heck Li
Check List sPEOAICATIONS
Pre-wired and pre-plumbed
Hardware/Literature pack Galvarised steel inner frame
Item Qty Digital control system
Greenstar 12i System/24i System Installation/Servicing Instructions.........1 Automatic ignition
Users INStUCHIONS L..…ucererterensrensonsensenssensenssensensiensasneensansennnsssensaseneonesenennmenmennmenmens Direct burner ignition electrodes
Benchmark LOG DOOK...….…ucirreenernmnmmnrsenmneennnennnnnnnnnnnnnnnnnnnnenmnnnennnnmennnmn 1 Built-in frost thermostat
Benchmark Addendum SHeet......... .. e... sr. e... recen rece ere reee EEG Built-in fault finding diagnostics
Consumer Guarantee Card .........e e eremita cn nece Modulating automatic gas valve
Sealing Pack 2... — | Combustion air fan with speed regulator
Compression Nut 22m .....e. ees es ess ere e rene eneenaseeman ares 3 CH temperature sensor & control
Compression Ring 22MM eee cca cece sernmen senannan rame sacrnma secs 3 | |
Compression Nut 1651 ....... e. ee. eeneeees enormes creeme. ree eres een rrmnens 1 Dump ant sets protection
Compression Ring 15MM e... .ee.-eecesse reee eeeecaa cena canne rennes avrana races 1 ue gas temperature limiter
Fibre Washer 23.9 x 17.2 X 1.5 .uucreraeeenenereca ensima ene a nana nana gp ~~ Condensale trap & syphon
Bonded Washer % For Gas Pipe erences sevens cress sesmsssssssssssenses 1
Irish Guidelines [email protected] ….……………errersmeennenenennsnmennnennnnennnnnnnnnnnnnnennnnnen |
\Varranty Return EnvVElOQE ………………scernsmsserans e... aunaman conan rnennn ernmenea rames senacan commen seen 1
LAMORCESTER TIA 119 Gage (De INSTRUCTIONS FOR WORCESTER GAEENSTAR 135 System System GENERAL IN FORMATION
Bosch Group
TECHNICAL DATA
NATURAL GAS LPG,
UNITS 121 Syatem 241 System 121 System 241 System
DESCRIFTION
A
=
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|=
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Gas flow rate - Max. 10 minutes from lighting
Natural Gas G20 mah 1.353 267 = -
Propane Gas (LPG) kgíh 0.46 1.91
Central Heating
Max. rated heat input KW 12.32 24.62 12.32 24.62
Min. heat input KAM 3.70 738 5.95 9.54
Max. rated heat output 40/30%C KW 12.85 25.67 25.67 25.67
Max. rated heat output 50/30%C KW 12.74 25.45 12.74 25.45
Max. rated heat output B0/60°C KAM 12 24 12 24
Max fowtemperawee Ñ 7 e e 2 e 82
Min. output °C 4.0 7.90 6.37 10.3
Max. flow temperature to cylinder when used with integral optional diverter valve) °C 76 75 75 75
Max. permissible operating pressure bar 2.5 2.5 2.5 2.5
Available pump head at 21°C system temperature rise m 2.0 2.0 2.0 2.0
Flue
Flue Gas Temp. B0/60°C, rated/min. load °С 62/56 78/63 62/57 79/64
Flue Gas Temp. 40/30°C, rated min. load °С 41/33 54/36 43/35 55/38
CO» level at max. rated heat output {after 30 mins) % 9.8 9.8 11.0 11.0
CO level at min. rated heat output (after 30 mins) % 9.2 9.2 10.5 10.5
NOx - class 5 5 5 5
Condensate
Max. condensation rate Ih 0.93 2.0 0.93 2.0
pH value, approx. 4,8 4.8 4.8 4.8
Electrical
Electrical power supply voltage АСМ 230 230 230 230
Frequency Hz 50 50 a0 50
Max. power consumption vu 140 140 140 140
General Data
SEDBUK band A A A A
Appliance protection rating IP x40 ха x40 x4D
Permissable ambient temperatures °С 0-50 0-50 0-50 0-50
Nominal capacity of appliance itr 3.9 3.9 3.9 3.9
Moise output level (Max central heating) dB(A) 42 42 42 42
_Packaged boller weight ___ Vo 444 444 444 —_ Ma
Total boiler weight Ко 39.5 39.5 39.5 39.5
Lift weight Kg 271 27.1 271 27
SEDBUK % 90.1 90.7 01.4 92.0
TECHNICAL DATA INSTALLATION & SERVICING INSTRUCTIONS POR WORCESTER GREENSTAR 121 Syriem/24) System AMORCESTER
Bosch Group
.” Tree Во 17 LAYOUT & COMPONENTS
a Ad | —— = e The diagram opposite shows the controls in the
senicing position and excludes the outer casa,
AIR J GAS MANIFOLD
FAN
AIR / GÂS ADJUSTMENT SCREW
: GAS VALVE (PRETTL CE427 SHOWN, AN
ALTERNATIVE VALVE MAY BE USED ON
LATER APPLIANCES)
INLET PRESSURE TEST POINT
EXPANSION VESSEL
WALL MOUNTING FEAME
COVER FOR EXTERMAL WIRING
RS CONNECTIONS
, | - 9 CONDENSATE CONNECTION FROM
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18 O es e HEAT EXCHANGER
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FAN PRESSURE TEST POINT
MANLAL VENT POINT
IGNITION AND FLAME SENSE ELECTRODES
OVERHEAT THERMOSTAT
FLAME VIEWING MIRROR REPLACED
BY RETAINING BRACKET ON LATER
APPLIANCES
SECURING NUT, AIR /
GAS MANIFOLD CLAMP
SENSOR - BOILER FLOW
FLUE AIR PRESSURE SWITCH
CONNECTION
FLUE OVERHEAT THERMOSTAT
ACCESS POINT FOR CLEANING HEAT
EXCHANGER/SUMP
REMOVABLE TOP CASE PAMEL FOR
SERVICING
GAS INLET CONNECTION 22mm
COMPRESSIÓN
TRAP / SYFHON
TRAP / SYPHON OUTLET
CONNECTION ( 22mm PLASTIC PIPE)
FLOW
В | | RETURN
a AA > de FIA DRAIN POINT
| ——] 3 4 SILICONE TUBE (USE TO VENT AIR
FROM HEAT EXCHANGER)
PUMP
SYSTEM PRESSURE GAUGE
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ACCESS COVER FOR TRANSFORMER &
PCB
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENMSTAR 13 Systems 2d System
SIE 117 0556 (0405)
LAYOUT & COMPONENTS
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LAYOUT & COMPONENTS
34 SYSTEM PUMP
35 UNUSED PORT
36 AUTO AIR VENT
37 FLOW CONNECTION FROM BOILER
HEAT EXCHANGER
38 FLOW CONNECTION TO
SERVICE VALYE
30 DRAIN POINT
40 RETURN CONNECTION TO
SERVICE VALVE
41 OPTIONAL INTEGRAL DIVERTER VALVE
POSITION
42 PRESSURE RELIEF VALVE
43 COMPACT HYDRAULIC MOUNTING
SCREW (2) TO BOILER
CH TEMPERATURE CONTROL
45 MAINS ON/OFF INDICATORS
DIAGNOSTIC LIGHT (BLUE)
dé SERVICE MODE BUTTON
47 BURNER ON INDICATOR LIGHT (GREEN)
48 MASTER SWITCH ON/OFF
49 NOT USED
50 FALILT RESET BUTTON
51 SYSTEM PRESSURE GAUGE
52 POSITION FOR OPTIONAL
FROGRAMMER
23 INTERNAL BYPASS WITHIN
FLASTIC MOULDING
LAYOUT & COMPONENTS
IMNETALLATION E SERVICING INSTRUCTIONS FOR WORCESTER GREEMSTAR 15 Bye di System
BE T16 112 055 DATE) AMORCESTER
Bosch Group
CLEANING PRIMARY SYSTEMS
IMPORTANT: All the following Pre-Installation sections must be read and
requirements met before starting boiler or flue installation. IMPORTANT: Debris from the system can
damage the boiler and reduce efficiency.
Failure to comply with the guidelines for
CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND the use of water treatment with the
EE mae appliance will invalidate the appliance
OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. warranty.
BEFORE CLEANING THE SYSTEM:
ENSURE THE SYSTEM ANDO PIPEWORK 15
IN GOOD WORKING ORDER
KEEP THE EXISTING BOILER!/
CIRCULATING PUMP WHERE POSSIBLE
OR USE A POWER FLUSHING MACHINE
TO AID THE CLEANSING PROCEDURE
BEFORE INSTALUNG À NEW BOILER.
CLEANING THE PRIMARY SYSTEM:
1 Fil the system with cold water and
check for leaks.
2 Open all drain cocks and drain the
system.
à Close drain cocks and add a suitable
flushing agent compatible with
aluminium at the correct strength for
the system condition 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 i= fired up.
4 Run the boiler/system at normal operating
temperature as directed by the manufacturer
of the flushing agent.
5 Drain and thoroughly flush the system to
remove the flushing agent and debris.
LAMORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 15 Systemd 24 System CLEANING PRIMARY SYSTEMS
Bosch Group
MAINS SUPPLY
ELECTRIC SUPPLY:
« Supply: 230V - 50Hz, 50 watts not including
pump.
« Cable: PVC insulated 0.75mm° (24 x 0.2mm)
temperature rated to 90°C,
« Extarnal 3A fusa to BS1362.
* The appliance must be earthed.
« \PX4D,
* All pipes to the boiler must be cross-bonded.
* Mans supply to the boiler and system wiring
centre must be through one common fused
double pole isolator situated adjacent to the
appliance,
* Wiring must comply with ¡EE winng regulations
and any local regulations which may apply to
fixed wiring to a stationary apphance.
* Any system connected to the boiler must not
have a separate electrical supply.
GAS SUPPLY:
* Balers using NG must be connected to a
a govemed meter.
Г 3 « LPG boilers must be connected to a
regulator,
* Installation and connection of the gas supply
to the boiler must be in accordance with
В 56891,
* Under no circumstances should the size of
thé gas supply pipe ba lass than that of tha
appliance inlet connection.
* Tha metar or regulator and pipework to the
meter must be checked, preferably by the gas
supplier, to ensure it 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,
IRSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 17 ma Ano
MAINS SUPPLY py eT RCESTER
Bosch Group
WATER SYSTEMS & PIPEWORK
IMPORTANT: The optional internal diverter valve should not be used with an
unvented cylinder unless a zone valve is fitted in the flow or return to the
cylinder to comply with unvented cylinder regulations.
PLASTIC PIPEWORK & UNDER FLOOR
HEATING:
« Any plastic pipework must have a polymenc
barrier with 800mm (minimum) length of
copper or steel pipe connected to the boiler.
S PLAN LAYOUT * Plastic pipawork used for underfloor heating
must ba correctly controlled with a
thermostatic blending valve limiting the
Ny ТТТ ТТ temperature of the circuits to approx. 50°C.
: 1
« All system connections, taps and mixing
valves must be capable of sustaining a
pressure up to 3 bar.
* Radiator valves should conform to
TT 8S2767:10.
- * All other valves should conform to BS 1010.
* Cn new installations TRV 5s must be used on
all radiators except where a room thermostat
is sited. On all installations they should at
least be fitted in the sleeping areas, See note
Y PLAN LAYOUT below on open radiator’ bypass
WITH EXTERNAL DIVERTER VALVE * À drain cock Is required at the lowest point
on the system,
* An air vant is required at the highest point on
the system.
NIE, ID, errores
A + NB The boiler is fitted with its own internal
bypass.
— | A Diverter Valve
B Radiator Valve (Flow)
Ae, CUT
C Lockshield Valve (Return)
* NB A drain cock should be fitted at the
lowest point of the heating circuit and
beneath the appliance.
SYSTEM LAYOUT OPTIONAL INTERNAL DIVERTER VALVE:
WITH OPTIONAL INTERNAL DIVERTER VALVE FITTED This bailer is designed to operate on a sealed
(НОТ SUPPLIED WITH BOILER) system only. The boiler will require a second
return pipe from the water cylinder to the wall
B mounting frame and terminate in 15mm Copper
a pipe.
HN 1 || bec * The CH sealed system must be filled using a
WRAS approved filling loop or comply with
the diagram opposite for system fill.
* Where the systam volume is more than 100
litres or exceeds 2.65 bar at maximum
|| heating temperature, an extra expansion
1 vessel (B) must be fitted as close as possible
É Ё to the appliance in the central heating return,
A —; ] A * Pressurise the extra expansion vessel (B) to
A Return from the same figure as the expansion vessel built
Return from central heating into the appliance.
cylinder + Do not use galvanised pipes or radiators.
Boiler flow
REE
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SYSTEM FILL SYSTEM MAKE UP Ни A
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Hear return Heabre
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LAMORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 13 System 24 System WATER SYSTEMS & PIPEWORK
Bosch Group
Internal sink/washing machine drain.
FAY
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E mir. A
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:
A -Condensate from boiler siphonirap.
B -Smk with integral overflow.
C - Plastic condensate pipe.
D -External drain or gulhy.
E -Intamal soil and vent stack.
F - Servicable condensate trap (75mm min).
E
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G -300mm x 100mm día. sealed plastic tube,
H -Ground level.
) - Drainage holes facing away from building.
K -Limestone chippings.
L - Weather resistant insulation.
CONDENSATE PIPEWORK
CONDEMSATE PIPEWORK:
« The condensate pipe must be a minimum of
22mm © plastic pipe.
« Pipe work length should be kept to a mini-
mum and the route as vertical as possible,
* Where pipe work could be subjected to
extreme cold or wind chill a weatharproaof
msulation should be used. Alternatively the
condensate pipawork could be increased in
size to 8 minimum 32mm © without the
requirement 10 insulate.
« The pipework must follow one of the options
shown opposite, Either into an mtémail
serviceable trap (min. 75mm) such as a
sink/washing machine waste, discharge
direct into à vent stack (E) 460mm min.
above pipe invert, or nto a gulley (D) below
ground but above the water level,
IMPORTANT: Ensure there are no
blockages in the pipe run.
1 Internal sink/washing machine drain
à Internal waste drainage system
3 Soil/vent stack
4 External drainage system
5 External condensate absorption point
CONDENSATE PIPEWORK
INSTALLATION E SERVICING INSTRUCTIONS FOR WORCESTER GREEMSTAR 14 Serie di aim
ETIB 117 077 DATE) AMORCESTER
Bosch Group
PRESSURE RELIEF PIPEWORK
PRESSURE RELIEF PIPEWORK:
IMPORTANT: The pressure relief valve
is a safety device for the boiler and if
activated may discharge boiling water
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.
* The pressure relief drain pipe (M} from the
boiler should be at least 16mm diameter
copper pipe and run downwards away from
any electrics or other hazard, preferably to an
external drain or soakaway,
« Pipe (M} should be finished with à partial
bend, near the outlet to face the external wall
(as shown) to help prevent hazard.
Mo. |
| L - Outside wall
+
OM - Drain pipe
М - External drain
BEE] ESE ape.
; :
O
N
LAMORCESTER INSTALLATION & SERWIEING INSTRUCTIONS FOR WORCESTER GREENSTAR 1% System 24 System PRESSURE RELIEF PIPEWORK
Bosch Group
SERVICING CLEARANCES
VENTED COMPARTMENT
7 80m Ta
hmm
Using 100mm flue kit
1080mm |
Using 125mm flue kit
- 1110mm
i ZOmm
lo removable door
| 600
front clearance
Ÿ for service
7 ' A00mm =
VENTILATION FREE COMPARTMENTS
INSTALLATION CLEARANCES
Ventilation Free Compartment Installation Clearances
The suggested total unventilated compartment minimum clearances are:
Side Above Below Front (to removable door)
400mm 170mm approx. 200mm 100mm
(30mm above
the elbow)
(Note: Top and bottom clearances must not be reduced below these values as they are the
minimum required for saracing).
Front clearance (to removable
reduced to: must be increased to (approx): OR | door) must be increased to:
+
350mm 441mm 129mm
300mm 523mm 161mm
250mm 617mm 200mm
200mm mm 243mm
150mm 856mm 295mm
100mm 1012mm 358mm
50mm 1202mm 434mm
If Front Clearance is Reduced
Н front clearance (to Then overall height clearances Total side clearance must be
BOILER LOCATION &
This boiler is only suitable for mstalling internally
within a properly at a suitable location onto a
fixed, rigid surface at least the same size as the
boiler and capable of supporting the boiler
weight.
COMPARTMENTS:
Follow the requirements of B56798 and
BS5440 Part 2 and note;
* Minimum clearances must be maintaned
= An access door is required to install, sermce
and maintain the bolder and any ancilliary
equipment.
« [If fitting the boiler into an airing cupboard
uza a non-combustible perforated material
(maximum hole sizes of 13mm) to separate
the boiler from the amng space.
BOILER CLEARANCES:
The diagram opposite shows the minimum
space required to install and service the boiler.
la boiler is installed in a compartment with
clearances less than shown in the tables oppo-
site, ventilation is required. Refer to tables
below for ventilation requirements.
12 & 24 kW
Vent To room or Direct to
position Internal space outside
High Minimum free Minimum
level area 122 em” free area
61 em’
Lew Minetmurn frèe Mineur
level area 122 em’ free area
81cm’
BOILER CLEARANCES - UNVENTILATED
COMPARTMENTS:
The tables opposite show the options for the
minimum space required to install and service
the boiler inside an urwentilated compartment.
"NOTE: These are the combined top & bottom
clearances excluding ihe appliance.
"NOTE: These are the combined left & right
clearances excluding the appliance.
removable door) is must be increased to (approx): increased to:
reduced Lo: + жж
0mm 511mm Ss0Smm
25mm 596mm 569mm
BOILER LOCATION & CLEARANCES НЕТАССАЛОМ #0 SIERMIEHNES WSTISOETICHE FOR WORGESTER EREENSTE 16 Eten AMORCESTER
Bosch Group
BOILER LOCATION &
CLEARANCES
750mm BATHROOMS:
The boiler can be installed in zones (2) or (3),
See [EE wiring regulations,
| #=50mm IMPORTANT: any switch or appliance |
control using mains electricity must not be |
able to be touched by à person using the |
bath or shower. |
Electrical switches, fused spur and socket |
outlets must not be situated In the |
bathroom. |
m
§00mm,
750mm
1 1
2260mm
2
—
600mm radius
LAMORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREEMSTAR 12 Esstemvzd] Sevien
2 TIE 112 06% {04.05}
Bosch Group
BOILER LOCATION & CLEARANCES
FLUMBING MANIFOLD
A (Gas Supply (alternative from above appliance) 22mm
Flow 22mm
CONNECTIONS:
Heating System: 22mm compression fittings
Return 22mm Gas: 2 2mm compression fittings
Use the fittings supplied m the Lit? Hardware
pack.
* |f the boiler pipes are to be run behind the
appliance ensure that the pipes pass through
the slot in the yellow plastic guide (A). This is
fitted to the boiler frame.
Further guidanca on pipe routing can be
found printed on the boiler template
(supplied with the boller).
IMPORTANT: IF FITTING OPTIONAL
INTEGRAL DIVERTER VALVE
Disregard this page and refer to the
correct version for installing the integral
diverter valve In the ADDITIONAL
INFORMATION section at the back of this
book.
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—
Flaw 22mm |
A
Mains Gas Supply 22mm
PLUMBING MANIFOLD INETALLATION & EERVICIMG INSTRUCTIONS FOR WORCESTER EE TI T1 Dee (DUT AORCESTER
Bosch Group
FLUE TERMINAL POSITIONS
Minimum dimensions of flue terminal positions for balanced room sealed flues with
fanned draught:
* The flua must ba fitted and terminated in
DRWG. | TERMINAL POSITION DISTANCE accordance with the recommendations of
REF: 555440 : Part 1.
| | , a , « The flue must not cause an obstruction.
A Directly below an opening, air brick, opening windows, atc. 300mm
* Discharge and any noise from the flue outlet
a Above an opening, air bnck, opening window, etc. 300mm must not cause à nuisance,
* Flue gases have a tendency to plume and in
С Honzontally to an opening, air brick, opening window, ete. 300mm certain weather conditions a white plume of
D Below gutters, soil pipes or drain pipes 75mm condensation will be discharged from the flue
outlet. This could be a nuisance, for example,
E Below eaves 200mm near security lighting.
F Below balconies or car port roof {lowest point) 200mm * The air inlet/outlet duct and the terminal of
a На the boiler must not be closer than 25mm to
G From à vertical drain pipe or soil pipe 150mm any combustible material.
H From internal or external comer or to a boundary alongside the terminal 300m * Detailed recommendations on protection of
; a _ combustible materials are given mn
! Above ground, roof or balcony 200 mm ES 5440:1.
J From a surface or boundary facing the terminal 00m ” * A protective terminal guard must be fitted if
tha terminal is 2m or less above a surface
K From a terminal facing the terminal 1200mm
to which people have access.
| From an opening in the car part (e.g. door, window) into the dweling | 1200mm The guard must be spaced equally {minimum
50mm} around the flue and fixed to the wall
M Vertically from a terminal on the same wall 1500mm with plated screws.
N Horizontally from a terminal on the same wall 300mm See Contact Information (back cover).
O From a non combustible vertical structure on the roof x
Р Above intersection with the roof x
Q Adjacent to windows and openings on pitched or flat roofs 800mm
- an ro = openings on piches m ere oom —
1 In addition, the terminal showld not be nearer than 150mm (fanned dracwght)
to an nimg in the building fabric formed for the purpose of accommodatin
N PET a POP 7 | Terminals adjacent to windows or openings on pitched
a buritr element such as a window frame, and flat f
2 Nof recommended.
* See instructions supplied with vertical flue kits. The flue should not penetrate
the shaded area.
* Y Care should be taken to ensure terminal siting
does not cause a nuisance fo adjacent properties.
boundary
|
NC
y Te,
-
ı: —FP N
7 M
E
+
E
LAMORCESTER RTE 112 apne an at INSTRUCTIONS FOR WORCESTER GREEHSTAR 135 Sestems 2d Systeme FLUE TERMINAL POSITIONS
Bosch Group
STANDARD FLUE HORIZONTAL MAXIMUM FLUE VERTICAL |»
START + 2 BENDS
A
SPECTRE A re à OF
В | т
©100 Hi co
RE
MAX BBG A x N a 21100 - 2600mm
MIN 250 Ax 1 a Ax1+Cx2+ Bxd
Fa
2125 ОР” + Ful
MAX 1070 Axl 2125 - 11000mm
MIN 250 Ax Ax1+Cx2+ Bx13
Requires cutting + Fui
MAXIMUM FLUE HORIZONTAL MAXIMUM FLUE VERTICAL
START + 3 BENDS
T À
Pomme A, FF & Tw
a LL ной = a 3
| 1 В — J
dl — có
Ax1+ Bx5 a 2125 - 5000mm
IRA + 1
£195 - 12000mm | ee NE Cx3+ Bxi
Ax1+ Bx13 e
MAXIMUM FLUE VERTICAL START + 1 BEND MAXIMUM FLUE VERTICAL
WITH 2 x 45° BENDS = т
Fi ELE А CA 5 =
| 1 E а
! 1
с Pa Г >
100 - 4600mm )
2100 - 4400mm
(including terminal)
Bx5+ Dx2 + Ex1
Ax1+Cx1 + Вх 5 +
F«1
E125 - 13000mm
Ax1+Cx1+ Bx13
+ Fx1
3125 - 13000mm
(including terminal}
Bx13+ DX2 +Ex1
MAXIMUM FLUE HORIZONTAL + 1 BEND VERTICAL FLUE WITH
2 x 90° BENDS
A ECCT т
А» e A
c @ == ;
a B | 3
Fe C
2100 - 2500mm e a,
Axi+ Bxÿ+Cx1 B100 - 2400mm
Ea
a
Te pe
2126 - 11000mm En. (including terminal)
Ax1+Bxi1+Cx1 | pass Bx4+Cx2+Ex1
5125 - 11000mm
{including terminal)
Ex13+ Cx2+Ex1
FLUE OPTIONS
+ The diagrams {opposite} show the
components used and the maximum flue
length for each configuration of 100mm and
125mm flues.
« Shaded flue components indicate the
standard 100mm horizontal flue.
« Only straight flue sections can be reduced in
length and cut.
* The flue terminal end can be fitted from the
inside or outside of the building.
* Fring kits ara supplied with the flue extension
kits.
* Horizontal 125mm and Vertical 100mm and
125mm flue kits are available with separate
instructions. Contact your supplier or
Worcester,
с D
CE 2 ©
1 , ff a
- Standard honzontal flue (100mm diameter
shown)
>
- Straight flue extension
- Flue bend 90°
- Flua band, 45°
т со
- Vertical terminal (vertical adaptor supplied
with terminal)
F - Vertical adaptor {used with horizontal
terminal)
Calculating the flue length:
Measure the total flue length required, noting
that the maximum straight flue length including
the terminal is:
Horizontal 601 00mm: 4600mm
Horizontal 80/125mm: 13000mm
vertical 60/100mm: 6400mm
Vertical 60/12 5mm: 15000mr
Then reduce the total straight five length for
each extra fue bend (excluding the flue elbow)
Бу:
2000mm for 90°
1000mm for 45°
Flue Extension lengths:
Horizontal & Vertical 60/100mm: S60mm
Horizontal & Vertical BOA25mm: 1000mm
Flue Terminal lengths:
Horizontal 504 00mm: 800mm nduding terminal
Horizontal BOA 25mm: 1200mm
Vertical 60100mm: 1140mm to top of terminal
Vertical 801 25mm: 1365mm to top of terminal
FLUE OPTIONS
IMNETALLATION £ SERVICING INSTRUCTIONS FOR WORCESTER GREEMSTAR 13 Syrie Hdi System
ZANORCESTER
Bosch Group
ET716 112 055 [DATE]
IMPORTANT: All the previous Pre-Installation sections must be read UNPACKING WALL FRAME AND
and requirements met before starting boiler or flue installation.
ANCILLARY ITEMS
LIFTING AND CARRYING PRECAUTIONS:
« Lift only a manageable weight, or ask for
help.
* When lifting or putting things down, bend |
the knees, and keep the back straight |
and feet apart. |
* Do not lt and twist at the same time.
« Lift and carry objects close to the body
A - Straps
B - Outer carton
G - Installer pack
D - Bottom panel
E - Wall mounting frame
F - Wall template
G - Inner packaging
IMPORTANT HANDLING INSTRUCTIONS
« 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, the outer
carton is removed first. Care should be taken
when releasing the straps. if a sharp implement
Is used make sure the outer carton is not
pierced and that the implement is used in such
a way so that it may not cause personal injury.
All sharp objects must be covered or the blade
retracted after use and put away in a safe
G place. The wall mounting frame, Installer
pack, template and bottom panel are now
removed. Care should be taken when lifting the
boiler from tha base and the proper technique
for safe lifting of any heavy object should be
strictly observed.
Additional reguirements for roof space
installation:
* The boiler should be first unpacked before
ascanding ladder 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.
Before installing appliance ensure system has
o_ been cleaned as explained on page &
>» 1, Remove straps (A) and open the top of the
boiler packaging.
+» 2. Remove template (F) and wall mounting
frame (E) from the packaging.
>» 3, Remove boiler bottom panel (D) and
installer pack (C).
LAMORCESTER TIA 12 One De IHETRLUACTIONS FOR WORCESTER GREEHETAR 13 Easter" Sem UNPACKI NG VALL FRAME AN D
Bosch Group ANCILLARY ITEMS
id > A WALL MOUNTING TEMPLATE
5 ана ON
No m= TR FLUE OPENING
Г < —+ N NN
E он ———— CAUTION: Ensure there are no pipes
m — == elecinc cables, damp proof courses or
9 — other hazards before drilling
п |
| Te os
{> = — SAFETY:
DE оо 4 | All relevant safety precautions must be undertaken.
ЭТА чи доу Te Protective clothing, footwear, gloves and safety
A ATE > | SYSTEM goggles must be wom as appropriate.
WEIGHT AND — == FIXING THE MOUNTING FRAME:
WALL TYPE |p === В * The boiler template shows the relative
TT | pasitions of tha flue and the top and bottom
| fixing of the mounting frame.
F Fix the template to the wall in the desired
position (A).
» Drll 4 holes for the wall mounting frame
through the template (2).
NOTE: The template has been sized to allow for
minimum clearances of Smm sides, 200mm
base and 30mm above a @ 100mm flue albow.
REAR FLUE OUTLET
« The drawing (B) opposite shows the boiler
template with the flue centre lines of both the
100mm and 125mm flue systems.
+» Mark centreline of flue to be used (1) the
external diameter of the hole can also be
marked if required.
« fa @100mm diameter flue is to be used,
al25mm diameter hale is required. However, if
using the weather sealing collar by pushing it
through from inside the property, then a
150mm diameter hole is required to
accommodate this.
* The terminal section of the 100mm flue has an
inbuilt 3° angle.
If extensions are to be added then the complete
flue must rise at an angle of 3°.
* The 125mm © flue system will require the flue
to rise at an angle of 3°,
» Dell hole using a core drill or similer.
SIDE OUTLET:
+ Mark from the centre hina of the wall template
to the wall which the flue will pass through (3),
+» Allow for a rise of 52mm per metre length of
flue, to give a 3° angle.
+» Clear any debris from the site.
* À pre-filing kit 7 716 192 262 is available for
mstallations where the boiler will not be fitted
immediately to the heating system. Thes allows
the heating system and mans water connec-
tions to be filled and checked prior to boiler
mstallation.
This kit can be used in conjunction with the
optional filling loop 7 716 192 281 (not sup-
plied with the boiler.
WALL MOUNTING PLATE FLUE OPENING INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 121 Erie! Cto ANORCESTER
Bosch Group
UNPACKING THE APPLIANCE
UNPACKING THE APPLIANCE
À - Outer carton
B - Inner sleeve {unwraps from front)
С + Packaging base
D - Protective wrapping
E - Apphance outer case
+ 4. Remove outer carton (A) and place
safely away from the working area.
» 5. With the outer packaging removed and
the mner sleeve (B) still in place gently
lay the boiler on its back.
» 6, The boiler will lie at an angle to the
floor to allow the boiler outer casing (E)
to be removed. The inner sleeve (B)
opens as shown. Remove the protective
wrapping (D) and undo the four screws,
two at the bottom of the boiler (H) and
two at the top (H] (see diagrams 6.1 and
6.2). Remove amy packaging within the
boiler and the packaging base (6),
WORCESTER ME Co paa e INSTRUCTIONS MOR WORCESTER GREENSTAR 12 Sterna! iste UNPACKING THE APPLIANCE
Bosch Group
Do not lift by the
air gas manifold.
И \
fo \
22mm 22mm bonded washer 2mm
„=...“ PEA,
"im
=
E
=
"a
- 254
a LIT
т
| Handling
: | Hole
[|
—
o
BOILER CONNECTIONS
IMPORTANT: IF FITTING OPTIONAL
INTEGRAL DIVERTER VALVE
Disregard this and the following page and
refer to the correct version for installing
the integral diverter valve in the
ADDITIONAL INFORMATION section at the
back of this book.
CAUTION: ISOLATE THE MAINS GAS
SUPPLY BEFORE STARTING ANY WORK
AND OBSERVE ALL RELEVANT SAFETY
PRECAUTIONS
GAS AND WATER CONNECTIONS:
Remove template and secure the wall mounting
frame to the wal with the frings supplied.
» System pipes may be run vertically upwards
behind the boiler or below it. See Plumbing
Manifold Section on page 15.
А - Flow (22mm), B - Return (22mm),
C - Gas inlet (22mm)
+ 1. Fit sealing washers to service valves
before hanging boiler,
IMPORTANT:
Before hanging the boiler onto the wall
mounting frame ensure that the pressure relief
valve connection is in the DOWN position. This
is located on the right hand side of the wall
frame at the rear.
к 2. Full the axtendad tab/laver forward and
down until there is no further travel.
2
» 3. Hang the boiler on to the wall mounting
frame by the two brackets positioned left
and right at the top rear of the appliance.
Ос по! И the appliance by the ar gas
manifold. There are two handling holes
incorporated nto the inner casing left and
right in the lower section of the appliance,
IMPORTANT:
The pressure relief connector must be
repositoned after the boiler has been correctly
mounted to the wall mounting frame.
к 4, Push the lever on the pressure relief
connector UP until the stop on the inside of
the handle is over the shoulder of the metal
bracket to secure in place.
BOILER CONNECTIONS
IMETALLATION E SERVICING INSTRUCTIONS FOR WORCESTER GREEMSTAR 13 Вузе di System
WORCESTER
Bosch Group
ETIA 117 CPP DATE)
BOILER CONNECTIONS
CALTTION: 150LATE THE MAINS GAS
SUPRELY BEFORE STARTING ANY WORK
AND OBSERVE ALL RELEVANT SAFETY
FRECALITICNS
GAS AND WATER CONNECTIONS:
A - Flow (22mm), B - Return (22mm),
С - Gas inlet (22mm).
k 5. Lower the control panel into the service
position by removing the screw (D) from the
retaming bracket.
» 6 Make connections to the heating system.
» Connect the gas supply to the boiler gas
cock 22mm compression.
7. Connect the expansion vessel flexible
|
|
Ne
| E pipe to the hydraulic manifold situated left of
| Tt the pump. It is necessary to remove and
TR discard the orange plastic blanking plug (E)
= from the connection at the hydraulic
‘ Em manifald before securng the expansion
fi vessel flexible pipe (F) in place with the wire
Be retaining clip (G).
Lal
к 8. Connect the pressure relief drain pipe to
15mm compression joint {(H) using the nut
and olive supplied in the hardware literature
F pack.
A
ET dE AA |
4 A Mba
LAMORCESTER RTE 113 onsen INSTRUCTIONS FOR WORCESTER GREENSTAR 13 Systems ad System BOI LER CONNECTIONS
FLUE INSTALLATION
rE] Horzomae
_ we | (60/100mm diameter)
For vertical flues and 80/125mm honzonial ues,
please refer fo separate instructions supplied wtf
188mm fag foie Mit
| ен о NOTE: to ease the assembly of fue components,
ZZ | NT apply silicone lubricant fo sealing surfaces.
| | — Ce The instructions for the GO/100mm diameter flue
are shawn below:
|
г
| MEASURING THE FLUE (Standard Flue):
| | | E + Measure from the outside wall to the centre
| | TRA с „ IM | line of the flue turret.
el co € | Za + Subtract 93mm from the length L to give
e | + the correct dimension to the flue elbow
connection.
+ The terminal section should be cut to this
dimension, however it must not be cut
shorter than 250mm,
+» After cutting, the end must be square and
free from burrs to prevent damage to the
flue seals.
| | №
co! |
Turret Cl
FLUE INSTALLATION IMETALLATION & SERVICING INSTRUCTS FOS WORCESTER eg 119 Oña (DATE) LNORCESTER
Bosch Group
FLUE INSTALLATION
MEASURING THE FLUE (Extension Flue Kits):
ONLY CUT EXTENDED FLUE LENGTHS
| As with the Standard Flue measure from the
: outside wall to the centre lina of the Aus
JT
— y » Subtract the length of the Standard Flue
and turret (725mm) from length L
Fb Subtract the full length 1m extension(s)
Clamp Clamp from the figure.
ke Cut one of the 1m extensions to the remainder.
+» Cut both tubes square taking care not to distort
the tubes.
+ Remove any burrs.
EXAMPLE:
Length L = 2380mm
Subtract Standard Flue+Tumet — 86m m
2380mm | Subtract Ful Extension — 960mm
| Cut Length = 734mm
| | | | | 1 NOTE: The minimum length a fue extension
| — can be cut to is 100mm
| 734mm Standard Flue
Extension Cut Length
Required Length
- Ч at >
A L |
| I
=== == == === ===. ===) NOTE: Where extensions are reduced, cut
| | length which DOES NOT contain the seal
|
| Seal
| 94mm
|
ADDITION OF FLUE BENDS:
When flue bends are being used an allowance
of 98mm per bend must be allowed from the
centre line of the bend. In the example shown
using a flue extension with 2 bends wall
achieve a total length of 1148mm,
HHSETALL ATIC & SERVICING INSTRUCTIONS FOR WORCESTER GREENMETAR 18 Seztemd Sd Syst
WORCESTER INSTALLATION & SER 5 SAA en FLUE INSTALLATION
Bosch Group
A - Standard Flue FLUE INSTALLATION
B - Internal Wall Saal
C - External Wall Seal
D - Clamp
ASSEMBLING THE FLUE
1 Slide inner collar (B) onto terminal (A)
2 Additional extensions or bands:
Push fit all extensionsbendarterminal
together and sécure connections with
clamps (D). Tha slope of the terminal outlet
must face downwards,
E - Extension Duct
FITTING THE FLUE
3 Fit the terminal (A) through the flue opening
in the wall, exposing the plastic outlet
} D section to the outside and fit the outer
E flue collar { C } over the notches to secura.
1 ! 4 Assemble elbow to boiler using the three
k screws (see below).
\ Note: Screws are m boiler not in fue kit,
|- FITTING THE ELBOW:
Apply silicone > This should * Flue elbow should push directly down and
grease to seal i = | be fitted last for not be twisted into correct position.
} easier installation » Remove the 3 inner flue tube retaining
% screws. The inner tube will be held in place
X in the appliance,
pa ' + Fit turret onto appliance and retain with the
0 three removed screws.
a a NOTE: The clamping plate flat should be at
я о the rear of the appliance.
0 |
| ADDITIONAL NOTES AMD REMINDERS:
ke ol * Ensure that all cut lengths are square and
0 free from burrs.
* The flue, when assembled, is fully sealed and
components are pushed home.
a " The flue is set at an angle of 3% or 52mm per
Im length.
ни
Hat at back
This screw should
be fitted last for
easier installation
when rear exit
FLUE INSTALLATION INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER SREENSTAR 15 Syste i Epvirn AMORCESTER
Bosch Group
CONDENSATE CONNECTION
CONDENSATE CONNECTION:
Never terminate or discharge into any open
source, including; sink, bath, shower, bidet,
tollet etc.
Nale: any external condensate pipework
should be protected with weather resistant
insulation to help prevent freazing.
+ Ensure that the condensate drain is 22mm
diameter plastic pipe, It must fall at least
50mm per metre towards the outlet.
* The adapter (4) and sealing washer (B) are
fitted to the appliance and can be removed
for easy fitting of the condensate pipe
{not supplied).
J
ni == =
-
a? rc
* Access to the condensate trapftube can be
improved with the removal of screw (C) on
lower cross support. This must be replaced
an completion of work.
A IMPORTANT: IF FITTING OPTIONAL
; INTEGRAL DIVERTER VALVE
Mow fit the diverter valve. For installa-
tion refer to FITTING THE DIVERTER
VALVE in the ADDITIONAL INFORMATION
section at the back of the book. You must
then disregard the following 3 pages con-
ceming ELECTRICAL and PRE-COMMIS-
SIONING CHECKS and refer to the cor-
rect versions that follow FITTING THE
DIVERTER VALVE in the ADDITIONAL
INFORMATION section at the back of this
book.
ANORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 13 System 24 System CONDENSATE CONNECTION
Bosch Group
2 ELECTRICAL
CAUTION: ISOLATE THE MAINS
ELECTRICITY SUPPLY BEFORE STARTING
AMY WORK AMD OBSERVE ALL
RELEVANT SAFETY PRECAUTIONS
Note: Mains supply fo the boiler and system
wiring centre must be through a common
fused double pole isolator situated adjacent
fo the appliance. The isolator must have a
contact separation of 3mm minimum in all
С = 3 poles, The system is supplied from the boifer.
\ Extarnal fuse 3A.
= A When stripping wires always ensure copper
2 ® д strands do nof fa into {he control box.
ar da E
= a Access to electrical connections:
or " Remove boiler casing to access contro panel.
1 Unscrew screw (A) and lower the control
box into the horizontal position.
2 Unscrew the three screws (B) in the contral
panel and pull off the connections cover.
3 Unclip cable clamp (C3).
4 Cut off the tapered cable entry to fit cable
diameter required.
5 Tum cable retaining screw (D) anti-clock-wise,
Run cable over the main crossbar and
through the cable clamp (C), ensuring there
is ample cable to reach the connectors.
Tum cable clamping screw (D) clockwise to
secure cable and replace clamp (C) into
i “— — WATER VALVE(S)
| FROSTSTAT
er
LL
=
=
| |
SY STEM Ea Е о LN ATA
WIRING
CENTRE
control pañel.
230V 6 Mains power 230v connection (ST10);
5 MAINS 6 » Separate wires from cable end and strip to
= SUPPLY &mm,
Е £ N E L » Connect LIVE wire to terminal (L)
§ E 5 8 к Соппес! NEUTRAL wire to the terminal (MN)
F Connect CARTA wire to the connector =
Note: Earth cable to be longer so that it pulls out
+ OF last if mains cable is snagged.
= = 7 System wiring centre connection (ST10):
y) » Remove link
+ Connect UVE wire to terminal (Ls).
» Connect NEUTRAL wire to terminal (Ms).
+» Connect SWVITCHED UVE wire to terminal (LI.
Note: A pump Is fitted in the boiter. There should
be no other pump fitted.
8 Refit panels,
NOTES:
» External diverter valvels) and all other 230
parts are not supplied with the boiler.
« A facia mounted programmer/timer should
not be fitted unless optional integral diverter
valve is used (see instructions at the rear of
this manual).
« Rafer to manufacturers instructions when
connecting external parts to the winng centre.
Worcester, Bosch cannot be held responsible
for wiring errors.
« There is an option to fit an internal diverter
valve, This also requires fitting an extra
harness and à code plug change. See
“Optional Diverter Valve” Section in these
mstructions or the instructions supplied with
the integral diverter valve kit.
This option is also covered in the Fault
Finding Guide on page 55 of these instructions.
green’ yellow
blue
brown
INSTALLATION & SERVICING INSTRUCTHERS FOR WORCESTER GREEMSTAR 15 Sri Буа A
ELECTRICAL rly plopped WORCESTER
Bosch Group
POSITION OF WIRED
HR
COMPONENTS
SPARK
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LAMORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 13 Systems 2d System
ET7IE 117 0556 (0405)
Bosch Group
POSITION OF WIRED COMPONENTS
PRE-COMMISSIONING
CHECKS
CAUTION: ISOLATE THE MAINS
SUPPLIES BEFORE olARTIMNG AMY
WORK AND OBSERVE AL
RELEVANT SAFETY PRECAUTIONS
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1 Check that the service and water pipes are
connected to the correct position on the
manifold.
À - Flow (22mm)
В - Return (22mm)
C - Gas inlet (22mm)
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à Check tha gas typa specified on the
identification plate (F) matches that of the
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gas supply. Turn on the main gas supply,
check the gas pipework connections and
rectify any leaks.
3 Check that the condensate pipe has been
connected to the syphon.
4 Check pressure relief drain pipe (H) is
comecth fitted and securely tightened.
IMPORTANT: If the boiler is not to be
commissioned immediately then:
after sucessfully completing all of the
checks and any rectification work,
close the gas and water valves, shut off
the gas supply, electrically isolate the
boiler and label appropriately.
COMMISSIONING
PRE-COMMISSIONING CHECKS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 121 Spriem/24i System ANORCESTER
Bosch Group
SYSTEM FILL
Heahng return
Sto
сос
Non retum Mon return
Haze valve valve
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Stop ek
Temporary hose Test cock
FILLING THE SYSTEM
1 Tum on the water main and open the
system valves,
2 Open all radiator valves.
3 Fill the system via a WRAS approved filling
loop.
4 Vent (A) any air from the boiler heat
exchanger using a suitable contamer to
collect any water. Ensura tube outlet (В) 15
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 ls removed after venting.
5 Мет! а! radiators, re-lighten when completed
and check the system and correct any leaks.
* The boiler integral expansion vessel is pre-
charged to 0.75 bar (equal to a static head
of 7.5m (22ft). A Schraeder type valve is
fitted to the expansion vessel to allow for
pressure adjustment r required,
If an extra expansion vessel is fitted to the
central heating return, aciust this to the
same pressure as he appliance internal
expansion vessel, refer fo separate instruc-
trans wrth the extra expansion vessel,
Erefly open the pressure relief vale to test
its operation.
If required increase system pressure back to
1 bar,
Rotate the adjustable pointer on the
pressure gauge to record the sat system
pressure.
Isolate and remove filling loop connection to
system.
WORCESTER
Bosch Group
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR | 3 Sysbems 24 System
SIE 117 055617410)
FILLING THE SYSTEM
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STARTING THE APPLIANCE
IMPORTANT: Never run the appliance
when the apphance/system is empty or
partially filled.
Switching the appliance on/off:
1» Turn on Mains power supply
+ Turn on any external controls
Set tha thermostatic radiator controls to
maximum temperature
Set the clockprogrammer to continuously
OM and the room thermostat to maximum
temperature
2 À - Onfoff button
B - On/off and fault indicator (BLUE)
C - Central heating temperature control
D - Burner indicator (GREEN)
Е - Reset button
F - Service button
G - Mot used
H - System pressure gauge
|- Cover or optional programmer
+ Press power button (A) and the power
on indicator (B) illuminates BLUE.
3 » Tum the boiler thermostat control (C) to
maximum. The burner on indicator (0)
illuminates GREEN when the bummer
has lit.
IT the boiler fails to light the BLUE power
indicator (B) and reset button (E) will
flash alternately.
To reset press and hold the reset button
(E) for 2 seconds. The boiler will be
rasat.
CAUTION: DO NOT PRESS POWER
INDICATOR (B) TO RESET BOILER
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INSTALLATION & SERVICING INSTRUCTERS FOR WORCESTER GREEMSTAR 15 pslem Tdi Sem A
STARTING THE APPLIANCE gly: pd peel WORCESTER
Bosch Group
WATER TREATMENT
IMPORTANT: 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.
ENSURE THAT THE SYSTEM HAS BEEN
CLEANED AS ON PAGE 8 OF THESE
INSTRUCTIONS.
FLUSHING {Central Heating):
1 Switch off the boiler (A).
» Open all drain cocks (B) and drain the
system (C) while the appliance is hot.
2 Close drain cocks (D) and add a suitable
flushing agent (E) at the correct strength for
the system condition in accordance with the
manufacturar's instructions.
3 Run the boiler/system at normal operating
temperature (F) for the time stated by the
manufacturer of the flushing agent (G),
4 Drain {H) and thoroughly flush the system to
remove the flushing agent and debris (1).
INHIBITOR (Central Heating):
6 Check drain cocks are closed { J } and all
radiator valves are open (K) before adding a
surtable"inhibitor (or combined inhibitor/anti-
freeze if the system is exposed to freezing
conditions) to the heating system water (L) in
accordance with the manufacturers instruchons.
6 Fill system via a WRAS approved filling loop
to batwaen | and 2 bar.
7 Yent all radiators; retighten vents when
complete (M. Vent any air from the boiler
heat exchanger using à suitable container to
collect any water (MN).
» Ensure tube outlet (0) is directed away
from the fan or any other electrical
component to prevent damage. Also
place a suitable cover over the fan to
prevent any spillage of water onto
electrical connections. Ensure the cover
is removed after venting.
8 Went all radiators (P) and primary side of the
hot water cylinder.
» Re-pressurise if necessary to 1Tbar (CI).
+ Set all controls to maximum (R).
» Record the date when the inhibitor was
| added to the system on the guarantee card.
| NOTE: The concentration level of infvbytor in
| the system should be checked every 12
| months, or sooner if system content is lost.
| The addition of sealing agents to the system
| water 15 nof recommended as this can cause
| problems with deposits left in the heat
| exchanger.
* compatible with aluminium. The pH
value of the system water must be
less than 8 or the appliance guarantee
0} = | | will be invalidated.
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Valve
Flushing
Agent
HESTALLATICA 4 SERVEING INSTELACTION:S FOR WORCESTER GAEEMSTAR 15 Cate 24 ler
WORCESTER INSTALLATION & SERVX Apna уно WATER TREATMENT
Bosch Group
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WHEN RUNNING IN SERVICE MODE
MOTE: When fitted with the optional
diverter valve {not supplied) and
running in service mode, the boiler
will operate both central heating and
hot water circuits.
If fitted to an S or Y plan system, the
system must only be run in central
heating mode.
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en A - Onvoff button
B - Onvaff and fault indicator (BLUE)
C - Central heating temperature control
D - Burner indicator (GREEM)
E - Reset button
F - Service button
G - Not used
H- System pressure gauge
|- Cover or optional programmer
DUNGS VALVE
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COMMISSIONING
THE COMBUSTION FOR THE APPLIANCE
IS FACTORY SET.
NO ADJUSTMENT IS REQUIRED IF THE
GAS INLET PRESSURE IS CORRECT.
CHECKING GAS INLET PRESSURE:
The inlet pressure to the appliance must be
checked using the following procedure:
SETTING THE BOILER ТО MAXIMUM:
1 Press service button (F) for 10 seconds and
set temperature to maximum.
" The service button will illuminate continually
and the blue power indicator will flash quickly.
MEASURING THE INLET PRESSURE:
2 Slacken the screw In the inlet pressure test
point and connect a manometer.
» Measure the pressure with the boiler
running at maximum.
+» Check the gas supply working pressure at
the gas valve inlet point:
M.G. 18.6 mbar (minimum)
LPG. 37 mbar (minimum)
» 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.
E Ensure Inlet pressure Is satisfactory with all
other gas appliances working.
» Replace controls cover. NOTE: This boiler is
designed with a differential of 20°C across
tha heating system.
IMPORTANT: Do not continue
commissioning until the correct
gas pressure is achieved.
k If pressure is satisfactory press the
service button (F) again and the boiler
will return to normal operation.
* Tf left in the service mode the control wall
return to normal operation after 15 minutes.
› Re-seal the screw mn the gas inlet pressure
teat point.
Inlet Test Nipple Inlet Test Nipple
IMETALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREEMSTAR 15 Spslemu di System
E TIO 117 O DD)
AMORCESTER
Bosch Group
COMMISSIONING
FINISHING COMMISSIONING
The boiler has been factory set, so there
should be no need to adjust any controls.
REFLACE OUTER CASING:
1 Replace outer casing making sure that the
securing points are properly located.
» Replace top two screws (A).
» Retighten bottom two screws (B).
INSTALLING BOTTOM PANEL:
2 The bottom panel sides onto two ledges
(C) either side of the boiler frame,
+» Hold the panel up against the underside of
the boiler and slide towards the rear until it
15 fully engaged.
HANDOVER:
+» Complete the Benchmark checklist.
NOTE: The Benchmark Checklist can be
found at the rear of these instructions.
+» Open the facia cover by gently pressing the
centre top of the cover (D).
+» Sat up the controls and show the usar how
to operate all the controls shown in the User
Guide,
» Place the user quide into the tray (E) on the
inside of the facia cover,
+ If the appliance is unused and exposed to
freezing conditions, shut off all the mains
supplies and drain the system and boiler.
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WORCESTER oe pf E INSTRUCTIONS FOR WESCESTER GRESNSTAR 13) Symiemve4l Systos FINISHING COMMISSIONING
Bosch Group
CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS
SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL
RELEVANT SAFETY PRECAUTIONS.
IMPORTANT: AFTER REPLACEMENT OF ANY COMPONENTS ALWAYS
CHECK FOR GAS SOUNDNESS WHERE RELEVANT AND CARRY OUT
FUNCTIONAL CHECKS AS DESCRIBED IN COMMISSIONING.
ANY O-RING OR GASKET THAT APPEARS DAMAGED MUST BE
REPLACED.
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INSPECTION AND SERVICE
IMPORTANT: Any service work
must be carried out by competent
registered engineers such as
British Gas or Corgi registered
personnel.
« To ensure the continued efficient operation
af the appliance it must be checked at
regular internals,
«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 tasted by
fully qualified engineers.
* The service interval record sheet at the rear
of these instructions must be completed
after each service.
Inspection
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 army that show signe of
leskage. Refill and re-pressurise if
\
applicable as described in Commissioning.
“ if 1 I I I 1 I
4
» Operate the appliance and take note of any
irregularities.
=e Ta. -— a" Refer to Fault Finding for rectification
| procedures.
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INSTALLATION & CERSICINS HET RLET OS AOE WORCESTER SREESMETAR 124 fom TH A
INSPECTION AND SERVICE aia Tie E e WORCESTER
Bosch Group
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Component Access
1. Removing outer case
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Remove bottom panel by pulling it forward
and off.
1.1 Undo and remove 2 screws (A) sacuring
boiler casing af the top of the appliance.
1.2 Undo but do not remove the ? screws
(B) securing boiler casing at the bottom of
the appliance.
1.3 Pull case forward and remove,
2. Adjusting boiler control to
service position
2.1 Remove screw (CC) securing control.
2.2 Gently pull forward until it comes to
rest In service position.
Primary Heat Exchanger
There ls a special accessory kil available
specifically designed for cleaning the
heat exchanger. If required order
7 716 192 312,
3 Check fan pressure al the test paint next to
the tan using an electronic manometer,
k» The boiler must be run at maximum output.
Pressure will read negative and be greater
than:
Natural gas LPG
12i System - 3.1 mbar 12i System - 4.9 mbar
24) System - ЭЛ баг 2440 System - 4.1 mbar
h Pressures measured below these figures
will indicate that the heat exchanger will
require cleaning.
WORCESTER
Bosch Group
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 13 Sysbems 24 System
2 TIE 112 0556 (04-06)
INSPECTION AND SERVICE
INSPECTION AND SERVICE
| Setting Boller to Maximum.
NOTE: When running in the service mode, the
boiler will operate both the Central Heating and
DHW circuits. This is to allow sufficient time for
the setting procedure.
WHEN RUNNING IN SERVICE MODE
NOTE: When fitted with the optional
diverter valve (not supplied) and
running in service mode, the boiler
will operate both central heating and
hot water circuits.
If fitted to an S or Y plan system, the
system must only be run in central
heating mode.
it will be necessary to run water through the
DHW circuit to ensure that the boiler will not
cycle an low heating demands.
A - Onfoff button
B - On/off and fault indicator (BLUE)
C - Central heating temperature control
D - Burner indicator (GREEN)
E - Reset button
F - Service button
G - Not used
Н- System pressure gauges
|- Cover or optional programmer
o:
= =
Press and HOLD service button (F) for 10
saconds and sat temperature to maximum.
Tha service buttan will illuminate continually
== == E E E ES ES ES НН НН ES EE ES E ES БН ES EZ ES ES EX НН ES ES ES ES НН БН ES НЫ НН ES ES ES ES EX ES E = ES EZ == = == =),
: —e6 ) and the blue power ndicator will flash quickly.
The boiler will stay in this mode for 15
D tte
minutes unless the service button is pressed
F —— = ] again,
wR ae
Full the cover off and connect a manometer
! to the fan pressure test point.
r » Áfter measurement replace test point cover.
Pressure will read negative and be greater
% 7 than:
3 — | < , Natural gas LPG
121 System - 3.1 mbar Tal system - 4.9 mbar
„” 24i System - 31 mbar — 24i System - 41mbar
„== === ==
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„” * Pressures measured below these figures
- will indicate that the heat exchanger will
require cleaning.
There is a special accessory kit available
specifically designed for cleaning the
heat exchanger, i required order
T 16 192 312.
INSPECTION AND SERVICE INSTALLATION EEN TA GTCAS FR TAG SATA ARENA aL Grad do AMORCESTER
Bcsch Group
Remove control refaining INSPECTION AND SERVICE
ECrew
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“=” ” “= =” IMPORTANT: IF THE JOINT
BETWEEN THE AIR/GAS MANIFOLD
AND THE HEAT EXCHANGER 15
DISTURBED THE SEALING GASKET
MUST BE REPLACED.
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To Clean the Heat Exchanger
1 With cuter case and base panel removed and
the power isolated from the appliance,
remove the cover panel (A) by removing the
retaining screw (B),
2 Remove dip (C) from gas valve outlet
| Pull gas adjustment assembly (D) or outlet
elbow (E} free from the plastic connection on
the qas valve
» Pull gas adjustment assembly (D} or outlet
elbow (E) forward to clear case
Removing Siphon
3.1 Undo plastic nut (F) on the siphon outlet
Crop condensate tube away from siphon.
3.2 Remove hose (GE)
43 Remove siphon
= ar
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Siphon
® [he siphon body is transparent 30 contents
can be axaminged for ary blockage,
к If necessary flush with clean water,
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AMORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 15 System 24] System INSPECTION AND SERVICE
Bosch Group
INSPECTION AND SERVICE
4 Remove electrical connector from far
5 Undo and remove securing nut (H) from the
top of the heat exchanger.
6 “Remove retaining plate (IL
7 Rotate fan and air/gas manifold assembly (J)
around the top of the heat exchanger until it
stops at the lug,
к Lift up assembly and remove from boiler,
8 [Disconnect spark electrode and flame sensor
G connections (FC)
» Remove clamping plate (L).
+ Remove spark”flame electrode assembly
from boiler,
, Remove seal from the top of the heat
exchanger,
== Бо == БШ =
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mirror which includes the retaining plate.
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INSPECTION AND SERVICE INSTALLATION BT TE RE EE LA Gir ed er AMORCESTER
Bosch Group
R INSPECTION AND SERVICE
Remove Burner (M.
Remove юр Бай (MJ).
Remove baffle (0).
Remove the two hexagon headed screws (F)
retaining the access cover (0) on the sump.
ко Access the heat exchanger flue ways by
inserting the cleaning brush (7 716 192 312)
through the top access hole in the casing (R).
» Clean heat exchanger flue ways (5) using the
cleaning brush (Y 16 194 317) removing
any debris from the access point in the sump.
vw = = ©
Clean around sealing surface on sump and
replace access cover (0) Using à suitable
container to collect water from syphon
connection at the base of the boier flush
heat exchanger with water,
» Re-assemble ensuring that the lower baffle
(O) and the top baffle (M) are refitted
correctly.
h When resfitting the bumer ensure that it fits
centrally within the heal exchanger and
location tabs are situated in location holes.
|» Ensure seal is replaced with new seal
and is correctly fitted.
к Check the syphon unit for blockage before
refitting to boder,
|» Reassemble and check combustion аз
stated in the gas conversion section.
NOTE: To show the heat exchanger more
clearly it has been shown external fo the
appliance
THE BAFFLES (QO) AND (N) MUST
BE REFITTED INTO THE HEAT
EXCHANGER AS SHOWN IN 9.
FAILURE TO DO 50 MAY RESULT
=-===== === === === == === ======4 | М ОАМАСЕ ТО ТНЕ ВОНЕВ
IMPORTANT: IF THE JOINT
BETWEEN THE AIR/GAS MANIFOLD
AND THE HEAT EXCHANGER I5
DISTURBED THE SEALING GASKET
MUST BE REPLACED.
AMORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 13 System] System INSPECTION AND SERVICE
Bosch Group
REPLACEMENT OF PARTS
CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS
SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL
RELEVANT SAFETY PRECAUTIONS. 1. Removing outer case
1.1 Undo 4 screws (A) securing boiler casing.
IMPORTANT: AFTER REPLACEMENT OF ANY COMPONENTS ALWAYS 12 Full case forward and remove,
CHECK FOR GAS SOUNDNESS WHERE RELEVANT AND CARRY OUT » To remove bottom tray, pull forward on the
FUNCTIONAL CHECKS AS DESCRIBED IN COMMISSIONING. tag on the underside of the tray.
ANY O-RING OR GASKET THAT APPEARS DAMAGED MUST BE
REPLACED. The following components can be
replaced with the outer case
removed:
Primary sensor
Overheat thermostat
Flue limit thermostat
2. Primary sensor
h Remove electrical connection (B) by pulling
upwards, Squeeze retaining clip on plastic
moulding (C} and pull sensor (D) upwards
until clear of pocket in heat exchanger.
+ Coat new sensor with heat conductive
paste and replace,
3. Overheat thermostat
+ Remove two electrical connectors from
thermostat.
Pb Slacken and remove fixing screw and
thermostat.
kb When replacing ensure thermostat sits
correctly on surface of the casting with the
left hand side of thermostat siting up
against the shoulder.
NOTE: It is essential that the mating surface of
the thermostat is coated with heat conductive paste.
4. Flue overheat thermostat
4.1 Type A (screw in type)
» Remove electrical connections.
» Unscrew thermostat from flue,
4.2 Type B (with grommet)
|» Remove electrical connections.
+ Undo the flue connection from the sump
and push the flue tube up.
Push the flue limit thermostat outwards
from the sump.
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RE PLACE MENT OF PARTS INSTALLATION E SEMACIAS MNSTRUCTIOAS FOR WORCESTER E aia gag Lier AMORCESTER
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REPLACEMENT OF PARTS
PRETTLE VALVE CE427
Access to the following compo-
nents require the control to be
moved in to the service position:
Gas valve
Siphon
PCE fuse
Transformer
9. Moving boller control to service
position
5.1 Remove screw (A) securing control,
5.2 Gently pull forward,
6. Gas valve"
№ Isolate gas supply at boiler gas cock.
61 Remove wire clip from gas valve outlet then
pull gas adjustment assembly free from
plastic connector and pull forward clear of
Case,
6.2 Undo bottom gas connection to gas valve
6.3 Undo two securing screws (C) on the
underside of casing.
» Pull valve up and forward out of boiler,
+» Disconnect electrical connections,
» Replace valve with new seals and check for
gas soundness,
Note: The valve will require setting; follow
procedure "Setting the gas/air ratio" in the gas
corversion section.
7, Gas adjuster
» Isolate gas supply at boiler gas cock.
+ Repeat step 6.1 above.
| Twist retaining clip (D) to release then
remove clip and tube,
Refit new adjuster and secure with clip.
8. Siphon
8.1 Undo plastic nut (E) on the siphon outlet.
Drop condensate tube away from siphon,
8.2 Remove hose (F).
8.3 Remove siphon,
CING
и
SERVI
“Refer also to page 43 as on later
appliances the valve and adjuster
have been changed.
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 13 Sysbems 24 System
STE 117 9556 174,095)
REPLACEMENT OF PARTS
REPLACEMENT OF PARTS
SIT AND DUNGS VALVES
The following components require
the control to be moved in to the
service position:
Gas valve
Siphon
PCE fuse
Transformer
==
„== —
за”
REMOVAL OF THE ADJUSTER AND
a VALVES 15 THE SAME FOR BOTH SIT
AND DUNGS VALVES. THE SIT VALVE 15
SHOWN IN THE DIAGRAM.
ON SOME EARLIER APPLIANCES A
DIFFERENT GAS VALVE IS USED. REFER
TO PAGE 42 FOR THIS INFORMATION.
"E
=
чая НП с „= 5 ПЕ о =”
2. Moving boiler control to service
position
5.1 Remove screw (A) securing control.
5.2 Gently pull forward.
„= шир == БЫ но
== == о == И
6. Gas valve"
| |solate gas supply at boiler gas cock
6.1 Remove wire clip from gas valve outlet then
pull gas adjustment assembly free from
plastic connector and pull forward clear of
CASE,
6.2 Lindo bottom gas connection fo gas valve,
6.3 Lindo two securing screws (C) on the
underside of casing.
» Pull valve up and forward nutof boiler
» Disconnect electrical connections
» Replace valve with new seals and check for
gas soundness,
Note: The valve will require setting; follow
procedure “Setting the gas/air ratio” in the gas
conversion section,
7, Valve outlet elbow
» láolate gas supply al boiler gas cock and
repeat step 6,1 above,
b Twist retaining clip (D) to release then
remove clip and tube,
> Refit new valve outlet elbow and secure
with clip.
8. Siphon
8.1 Undo plastic nut (E) on the siphon outlet,
Drop condensate tube away from siphon
B.2 Remove hose (FL
8.3 Remove siphon.
„я
RE PLACE MENT OF PARTS INSTALLATION £& SERACIHG IMETRULCTIONS ADE WORCESTER Dr i ope Ler AMORCESTER
Bosch Group
REPLACEMENT OF PARTS
9. Access to boiler control components
|» Remove 3 screws (A)and remove cover
from control,
10, PCE fuse
» Remove fuse F1 (Blfrom the PCB and
[= == == т т mm т wm mm mm em wn mm em ож он Em Em em mm mm жк кн == == == replace.
+ There is a spare fuse clipped into the
underside of tha electrical cover.
"Ч вы
= = = =
11.Transformer
+ Disconnect all electrical connections
from the control.
» Remove 5 screws (C) retaining the rear
panel of the control and remove panel.
ho Pull transformer upwards from PCB.
"E
Ts i == шо а "Я
y Spare Fuse order
Jo TEL 250V F2
0 T25H Z60V F1
i T500L 250V F3
ING
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rm pour PT
HHESTALLATICA & SERVICING IMSTRINCTHING FOR WORLDESTER GREEN ETAR | 3 Stem 24 i
WORCESTER INSTALLATION & SEF) 5 STAR 13 SystemV24i System REPLACEMENT OF PARTS
G
mm
REPLACEMENT OF PARTS
12. Replacing control
The control is supplied within its plastic
housing. The complete unit must be replaced.
» Remove ALL electrical connections from
the control PCB including where cables run
through restraints, These can be unclipped
trom the plastic moulding noting their
position.
» Remove the code plug (BE). The code plug
should be left attached to the frame of the
boiler by its plastic safety thread.
121 Remove the 3 screws (C) retaining the
front facia making sure to support the facia
when removing the last screw,
122 Using à suitable tool (D), press the button
(E) upwards and slide the control support
bracket (F) to the left
123 Support the control and unclip control
support cable (G) from the boiler frame.
| Remove the support cable and fit to the
new control
» Remove appropriate cable restraints from
the new control box
kb Fit control to the boiler
» Re-connect support cable to the boiler and
all electrical connections to the new control.
E
- ==
= = оны a
IMPORTANT: ENSURE CODE PLUG
15 RE-FITTED TO THE NEW
CONTROL. IF THIS IS NOT DONE
THE BOILER WLL INDICATE
ERROR AND WILL NOT FUNCTION.
REPLACEMENT OF PARTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREEMSTAR 24 | junior 8 junior A
a TIE 107 3385 111.705) WORCESTER
Bosch Group
REPLACEMENT OF PARTS
The following components require
the air / gas manifold and fan
assembly to be removed:
Pressure switch
Fan
Electrode assembly
Burner
Heat exchanger
IMPORTANT: IF THE JOINT |
BETWEEN THE AIR/GAS MANIFOLD |
AND THE HEAT EXCHANGER IS |
DISTURBED THE SEALING GASKET |
=
a =
|
| | 3
de
SRR mn
rer DOT
ATF
IMPORTANT: AFTER REASSEMBLY
THE COMBUSTION MUST BE
CHECKED USING THE PROCE-
DURE IN THE SECTION “SETTING
THE GAS AIR RATIO". MEASURE-
MENT AND SETTING (IF NECES-
SARY) OF THE GAS RATIO MUST
NOT BE ATTEMPTED UNLESS THE
PERSON IS EQUIPPED WITH A
COMBUSTION ANALYSER CON-
FORMING TO BS 7927 AND IS COM-
PETENT IN ITS USE
13. Air / gas manifold and fan
assembly
>» Remove electrical connector from fan
+ Remove wire clip from gas valve outlet then
pull gas adjustment assembly free from plastic
connector and pull clear of case, See 6.1.
13.1 Undo and remove securing nut (A) from the
top of the heat exchanger.
13.2 "Remove retaining plate (B).
13.3 Rotate fan and air/gas manifold assembly
{shaded) around the top of the heat
exchanger until the lug on the airgas
manifold is visible,
HO LIT up assembly and remove from boiler,
14. Pressure switch
141 Remove electrical connections (С).
14.2 Slacken top retaining screw and remove
bottom screw. (OD).
14.3 Remove tube (EJ.
144 Remove 2 screws (F) retaining pressure
switch to bracket
| Refit new pressure switch to bracket,
IMPORTANT: ENSURE TUBE IS |
REFITTED TO PRESSURE SWITCH
Var es 14.1 = +7 143
"NOTE: some earlier appliances have a viewing
mirror which includes the retaining plate.
INESTALLATICA & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 13 Systems Sys
2 TIE 112 O55 104.05] - - Ш vraie RE PLACEMENT OF PARTS
REPLACEMENT OF PARTS
15. Fan
15,1 Remove 3 screws (A) retaining mixing
chamber.
15,2 Remove 2 screws (B) retaining the fan to
the air/gas manifold,
15.3 Remove screw {C) retaining plate and
remove.
h Re-assemble with new fan ensuring seals
are correctly fitted
16. Electrode assembly
vy Disconnect spark electrodes and flame
sensor connection,
| Remove clamping plate (D).
» Remove spark/flame electrode assembly (E)
fram heat exchanger.
17. Burner
» Remove seal (F) from the top of the heat
exchanger.
' » Remove Богпег (6).
| Par i » Replace new burner in correct position,
. оли r » Ensura that bumer tab fits comecthy into hole.
E— 7” e ; v Ensure that the seal is replaced with à new one
= !
18. Heat Exchanger
¥ Isolate flow and return valves then drain the
boiler,
» Remove siphon,
18,1 Remove clip from plastic elbow on the flow
pipe and pull flow pipe away from heat
exchanger.
18.2 Remove plastic nut from the bottom of
the boiler.
18.3 Rotate lever to release retum pipe
184 Undo flue connection from sump.
y Pull heat exchanger assembly up to clear.
» Reassemble and check combustion as
stated in the gas conversion section.
-
„=
RE PLACE MENT OF PARTS INSTALLATION E SERACINS INSTRUCTIONS FOE WORCESTER (PRISE ET CEE DE AMORCESTER
Bosch Group
1
EEE 1
=
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==:
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REPLACEMENT OF PARTS
19. Diverter valve motor (if fitted)
» Ensure the appliance is in service mode
(there is no need to drain the appliance),
¥ Disconnect the electrical connactor from the
diverter valve motor,
18.1 Pull the motor assembly (A) towards you. The
assembly will slide free from the valve.
+» To refit, follow the above in reverse,
20. Diverter valve
+ Ensure the appliance has bean fully drained .
+ [Disconnect the electrical connector from the
divarter valve molor,
+ Undo the two screws holding the valve to the
plastic housing.
20.1 Withdraw the valve (B) and clean the valve
chamber if necessary,
+ To refit, follow the above in reverse. Ensure
any seals that have been disturbed are
renewed
21. Auto air vent
» Ensure the appliance has bean fully drained .
21.1 Use a screwdriver or similar to rotate the air
vent anticlockwise,
21.2 Lift the air vent (C) out of the housing and
remove,
+ To refit, follow the above in reverse.
WORCESTER
Bosch Group
INSTALLATICA & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 13 Syshems 24 System
2 TIE 112 O55 04.05]
REPLACEMENT OF PARTS
NG
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A
Led
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== E da AA
REPLACEMENT OF PARTS
22. Pump head
4
>
Ensure the boiler is fully drained.
Disconnect the electrical connection from
the bottom of the pump.
221 Remove the four Allen bolts (A) securing the
pump at éach corner.
222 Gently pull the pump towards you and
¥
remove,
To refit, follow the above m reverse
23. Pressure gauge
Li
h
Ensure the appliance has been fully drained.
Withdraw the spring clip from the pressure
sensing head housing.
Undo the nut on the rear of the pressure
auge,
Remove the pressure sensing head and
pressure gauge capillary fram the housing.
To redit, follow the above in reverse DO NOT
omit the washer from the capillary when
fitting a replacement gauge.
24. Drain tap
Ensure the appliance has been fully drained.
24.1 Rotate the drain tap fully anticlockwise.
242 Withdraw the drain tap from its housing
To refit, follow the above m reverse Ensure
any seals that have been disturbed are
renewed,
RE PLACE MENT OF PARTS INSTALLATION E SEMACINES INETRULCTIONS FOR WORCESTER GREEMNETAR 155 Булат МИ Буса AMORCESTER
В 719 112 бб, (СН)
Bosch Group
= = = = = що
=
-
==
вы
=
„тя == = = =
=
Lu
== ия: == e ="
pl
REPLACEMENT OF PARTS
25. Hydraulic Block
Fb Ensure the appliance has been fully drained.
» Disconnect the electrical connections to the
pump:
¥ Undo the nuts securing the copper water
pipes to the manifold (there is no need to
remove the gas pipe).
» Release the spring clips secunng these
water pipes to the plastic housing and
remove the pipes,
» Release the spring clip securing the
expansion vessel pipe to the plastic housing
and remove the pipe.
» Undo the nut securing the pressure gauge to
its bracket and remove the gauge.
» Release the locking devices that secure the
two copper water pipes leading to the
combustion chamber by squeezing the two
tabs together and rotating anticlockwise
{viewed from above).
» Remove the rubber pipe connecting the
sump and remove the syphon, NOTE: this is
not essential but makes the removal of the
block easier,
251 Undo the two screws securing the hydraukic
block to the chassis (located top left / top
right of the housing)
25.2 Lift the left hand side of the block slightly,
then manoeuvre the block out, starting with
the right hand side.
» Take care not to snag the harness or
prassura gauge bracket,
NOTE: the block will still contain a small amount
of water, which will spill if the block is tilted.
+» To refit, follow the above in reverse. Ensure
any seals that have been disturbed are
renewed.
26. CH pressure relief valve
h Remove the hydraulic block from the boiler
{See Removing the Hydraulic Block).
26.1 Remove the spring clip from the pressure
redief valve housing, =
26.2 Withdraw the pressure release valve (A) from ges
ts housing. =
Fb To refit, follow the above in reverse. Ensure Hi
any seals that have been disturbed are un
renewed,
LAMORCESTER EP TE IMSTRUCTIONS FOR (WORCESTER GREENSTAA 34 § gun" ZB y pro RE PLACEMENT OF PARTS
Bosch Group
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REPLACEMENT OF PARTS
27. Bypass valve
ho Remove the Hydraulic block from the boiler
(See Removing the Hydraulic Black).
271 Remove the two spring clips at either end of
the copper bypass pipe.
» Undo the screw securing the left hand
plastic housing to the heal exchanger
+ Move the housing to the left to free up
ana end of the pipe.
+ Remove the pipe from the right hand housing
to reveal the bypass valve,
272 Using a pair of pliers, pull out the bypass
valve (A) from the housing.
+» To refit, follow the above in reverse. Ensure
any seals that have been disturbed are
renewed.
28. Expansion vessel
The expansion vessel can be replaced with the
boiler in position if there is a side exit flue fitted
and there is a minimum clearance of 340mm
above the boiler casing. If vertical flue is fitted
then a similar clearance to one side and the flue
IS required,
If clearance is not available, the boiler will need to
be removed from the mounting frame to gain
access to the expansion vessel
Alternatively a second vessel of at least the
capacity of 7s can be fitted to the retum from
the heating system as close as possible to the
boikar.
Expansión vessel replacement
(Boller in place)
ко Isolate mains power from the boiler.
ко Place the controls in service position,
ho Isolate the boiler from the heating system
(and cylinder return if intemal diverter valve is
fitted) using service valves.
ho Drain boiler
28.1 Remove clip from expansion vessel
connection.
28.2 Remove screw relainng the vessel to the top
of the boiler casing,
28.3 Full the vessel up and out over the flue
system or to one side if fitted with a vertical
flue,
F Remove the flexible hose from the expansion
vessel and fit to the replacement vessel
using a new seal. Ensure that the connection
to he boiler will be pointing to the nght hand
side of the appliance when fitted.
Fb Reassemble expansion vessel into boiler and
connect flexible pipe fo boiler.
Removing boiler
+ Isolate electrical supply.
Isolate system and gas connections at the
service valves,
Crain boiler.
Disconnect electrical supply and any external
controls.
Disconnect flue connection from ihe boiler
Unda connection to boiler at the service valves,
Remove clip from expansion vessel
connection to the boiler,
» Gently raise the bosler off the mounting frame.
Replace expansion vessel and refit the boiler
ta the mounting frame.
» Follow the commissioning procadura in this
manual
REPLACEMENT OF PARTS
INSTALLATION E SEMACINS MSETRUCTICAS FOR WORCESTER GREENSTAR 155 Srriemai Siam
6716 112 0650 (DADE) ZANORCESTER
Bosch Group
SETTING THE GAS / AIR RATIO
THIS PAGE SHOWS THE SETTING PROCEDURE FOR THE PRETTLE
CE427 VALVE (WITH SEPERATE ADJUSTER) FOR ALTERNATIVE
VALVES SEE PAGE 53 FOR SIT AND 54 FOR DUNGS.
FOR THE PRETTL CE427
> MUST BE
Y A COMPETENT PERSO!
29. Setting the CO,
Note: When running in the service mode, the
boiler will operate both the central heating &
DA circuits. This is to allow sufficient time for
the setting procedure, It will be necessary to run
water through the DHW circuit to ensure that
the boiler will not cycle on low heating demands,
291 Connect manometer to inlet pressure pont
on the gas valve,
к To adjust the COs it will be necessary to first
operate the boiler at maximum output.
Press and hold down the service bution (A) for
10 seconds until illuminated, The blue power
indicator will flash,
29.2 Tumthe temperature control to maximum; the
boiler will then go to maximum output
Note: The control will resume normal operation
after 15 minutes ar if the service button is pressed
for over a second.
23.3 Using a flat blade screwdriver set the CO,
via adjuster (B} using table below.
CO» settings for Greenstar | System
Note. CO, should be measured after 10 minutes
4 - - = = = = = = = = = = = = =
Gas type
CO» setting
maximum
CO» setting
minimum
Natural gas
9.8% + 0.2%
9.2% x 0.2%
LPG
11.0% + 0.2%
10.6% + 0.2%
CO - less than 200ppm (0.002 ratio)
JET OEE и EN OER EN ЧН EF EF EF WF EN BN BN НО NW CER CES EN ER BF BF OES BN EN OE BN OBEY EN OER OEE =
¡Please note: The flue gas test point can be
{accessed on the appliance flue elbow by
"removing cap D
Check CO is less than 200ppm,
Measure the Intet pressure: it should be
no less than 1B.5mb NG or 37 mb for LPG,
234 Set the temperature control to minimum,
This will make the boiler go to minimum power,
23.5 Measure the Cl; it should now be at the
figure for minimum output, № not adjust (C)
on the gas valve until correct
+ Retumto maximum and re-check the СО, И
comect press and hold down the service
button for 2 seconds; the button will cease to
be illurninated and the blue power indicator will
be permanently illuminated.
>» Remove manometer and re-seal inet pressure
=== EEE
— — — paint an gas valve,
WHEN RUNNING IN SERVICE MODE + Fit mew plastic sealing cover on to outlet
adjuster (B),
NOTE: When fitted with the optional + Fit white cover aver valve adjuster (C) and
diverter valve {not supplied) and secure with black security tag.
| Remove red arrow from data plate and fit new
one in correct position for gas type.
Resassembie and refit boller case,
Re-connect mains electrical supply and
If fitted to an 5 or Y plan system, the check boiler operation as stated in the
system must only be run in central commissioning section.
heating mode. ho Fit new label from kit over existing label on the
appliance bottom panel,
running in service mode, the boiler
will operate both central heating and
hot water circuits.
AMORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENMSTAR 15 Cssbem"24i Speer
2 TIE 112 O55 104.05]
Bosch Group
REPLACEMENT OF PARTS
THIS PAGE SHOWS THE SETTI
FOR ALTERNATIVE VALVES SE
DUNGS,
cl EE EE EE EE EE e Ee Ee EE EEE ns e un us EE o EEE EEE EE CEE GEE GEE CEE SEEN ME Same БЕ: БЫ Es
TARA!
|
[== ^ a
NG PROCEDURE FOR THE SIT VALVE
E PAGE 52 FOR PRETTL AND 54 FOR
Max
Min ЧЁ
‘cr a |
ъ
%
= = =
ma m =
Inlet Test Nipple
om == =
HE EN BN EN BE TEE OTE OEE TEE ET EET ET EE EE = = = = ое = = = =]
/ WHEN RUNNING IN SERVICE MODE
| NOTE: When fitted with the optional
diverter valve (not supplied) and
running in service mode, the boiler
will operate both central heating and
| hot water circuits.
If fitted to an S or Ÿ plan system, the
system must only be run in central
| heating mode.
SETTING THE GAS / AIR RATIO
FOR THE SIT 848.093 SIGMA
THE SETTING €
CARRIED OUT BY A СОМРЕ
SETTING OF THE GAS RATIC
ATTEMPTED Ub
33. Setting the CO,
Note: When running in the service mode, the
boiler will operate both the central heating &
DAY circuits. This is to allow sufficient time for
the setting procedure, It will be necessary to run
sufficient water through the DHW circuit to
ensure that the boiler will not cycle on low
heating demands.
33.1 Connect manometer to inlet pressure point
on the gas valve.
FE To adjust the CO it will be necessary to first
operate the baller al maximum output
к Press and hold down the service button (A) for
10 seconds until illuminated. The blue power
indicator will flash.
33.2 Turn central heating control to maximum;
the boiler will then go to maximum output,
NOTE: The control will resume normal operation
after 15 minutes orif the service button is pressed
for over a second,
33.3 Using a 2.5mm allen key set the СО via
adjuster (B) using the table below,
C02 settings for Greenstar | System
Note. CO, should be measured after 10 minutes
Gas type CO» setting | CO» setting
maximum minimum
Natural gas 9.8% + 0.206 | 9.9% + 0.2%
LPG 11.0% E 0,2% | 10.6% T 0,206
CO - less than 200ppm (0.002 ratio)
Check CU is lass than 200ppm,
Measure the inlet pressure; It should bé no
less fran 18.5mb NG or 37mb for LPG,
334 Set the central heating control to minimum.
The boiler will go to minimum power.
335 Measure tha CO. and check against the
table above. If required adjust (C) on the gas
valve until the correct measurement is set.
Remove brass dust cap with flat bladed
screw driver, Then using a 4mm allen key
adjust CO, Replace dust cap.
+ Retum to maximum and re-check the CO. If
comect press and hold down the service
button for 2 seconds; the button will cease to
be illuminated and the blue power indicator will
be permanently illuminated,
» Remove manometer and re-seal inlet pressure
point on gas valve,
» Rerassemble and refit boiler case,
REPLACEMENT OF PARTS
INSTALLATION E SEMACINS METRUCTICAS FOR WORCESTER SREEMSTAR 15 SyrlemyT Syarlam
LANORCESTER
Bosch Group
В 719 112 бб (СИТ)
THIS PAGE SHOWS THE SETTING PROCEDURE FOR THE DUNGS SETTING THE GAS / AIR RATIO
23 POR SM ALTERNATIVE VALVES SEE PAGE 52 FOR PRETTL AND FOR DUNGS GB-ND 055 DO1 S20
ING OF THE GAS RATIO MUST BE
OD QUT BY A COMPETENT PERSON
Mia OF THE GAS RATIO MIEST
WING OUT THE COMVERSIC
=H Ll = Ls
33. Setting the CO,
Mote: When running in the service mode, the
boiler will operate both the central heating &
DHW circuits. This is to allow sufficient time for
the setting procedure. it will be necessary to run
sufficient water through the DHW circuit to
ensure that the boiler will not cycle on low
heating demands,
33.1 nect manometer to inlet pressure point
on the gas valve,
bo adjust the CO, m will be necessary to first
operate the boiler at maximum output.
» Press and hold down the service button (A) for
10 seconds until illuminated. The blue power
indicator will flash.
33.2 Tum central heating control to maximum
the bodler wil then go to maximum output.
NOTE: The control will resume normal operation
after 16 minutes or if the service button is pressed
for over à second.
33.3 Using a 2mm hexagonal ball driver set the
CO via adjuster {B) using table below.
COz settings for Greenstar i System
Note. CO, should be measured after 10 minutes
Gas type CO- setting | CO» setting
maximum minimum
Natural gas | 9.8% + 0.2% | 9.2% + 0.20
LPG 11.0% E 0.2% | 10,5% + 0.2%
CO - less than 200ppm (0.002 ratio)
» Check CO is less than 200pprr.
» Measure the inlet pressure it should be no
less than 18.5mb MG or 37mb for LPG,
33.4 Set the central heating control to minimum.
The boiler will go to minimum power.
33.5 Measure the CO, and check against the
table above, If required adjust {C) on the gas
valve, using a Zmm hexagonal ball driver,
LNtil the comect measurement is sat
+ Retum to maximum and re-check the CO. If
comect press and hold down the service
button for 2 seconds; the button will cease to
be illuminated and the blue power indicator will
be permanently illuminated.
> Remove manometer and re-seal inlet pressure
paint on gas vale,
kh Re-assemble and refit boiler case.
WHEN RUNNING IN SERVICE MODE
NOTE: When fitted with the optional
diverter valve (not supplied) and
running in service mode, the boller
will operate both central heating and
hot water circuits.
If fitted to an S or Ÿ plan system, the
system must only be run in central
heating mode.
LAMORCESTER BIE Ioan HCE FOR WHRCESTER GREENSIAR 18 Systems fysioe REPLACEMENT OF PARTS
Bosch Group
SHORT PARTS LIST
4
10
11
12
13
14
15
16
17
18
19
Fan
WORCESTER Part Ho 8717 204 4530
GC No, H26 536
Burner
WORCESTER Part Mo. 8 718 120 609 0
GC No, H26 538
Gas valve
NG WORCESTER Part No. 8 716 107 052 0
NG GC Nao H?6 540
LPGWORCESTER Part No. 8 716 107 0530
LPGGC No, H26 539
Altemative gas valve for SIT/Dungs
WHS Fart Ма. 8 716 111 325 0
Control box
WORCESTER Part Mo, 8 716 109 539 0
GC No, H28 966
Air pressure switch
WORCESTER Part No. 8 716 106 653 0
GC Ma. H26 543
Type a Flue overheat thermostat (Screw type)
WORCESTER Part No 8 722 963 858 0
GC No, HOB 291
Type b Flue overheat thermostat (Grommet type)
WORCESTER Part Mo. 8 717 206 213 0
Fuse
WORCESTER Part Mo. 8 T16 156 000 0
GC No, Е26-716
Electrodes
WORCESTER Part No. 8 718 107 087 0
GC Ma, H26 544
Gasket - burner/electrodes
WORCESTER Part Mo. 8 T16 106 506 0
GC No. H26 545
Seal - Inner case/mantel
WORCESTER Part No. 8 716 106 635 0
GC Mo, H26 546
Pump assembly 3 speed
WORCESTER Part Mo. 8 716 106 355 0
GC No. HO? 537
Pressure gauge
WORCESTER Part No. 8 717 208 107 0
GC Mo, HOZ 578
By-pass valve
WORCESTER Part Mo. 8 716 106 434 ©
GC Ma, HO? 532
Diverter valve assembly
WORCESTER Part No. 8 716 106 845 0
GC Ha, HOZ 533
Diverter valve motor
WORCESTER Fart Me. 8 Te 106 847 0
GC No HOZ 534
Control sensor - primary
WORCESTER Part No. 8 716 106 6880
GC No, H26 542
High limit stat
WORCESTER Part No. 8 707 206 196 0
tal No. H26 584
Valve - pressure relief
WORCESTER Part Ho 8 716 106 431 0
GC No, HOS 750
Expansion vessel
WORCESTER Part Mo. 8 716 105 545 0
GC No, HOS 206
RE PLACE MENT OF PARTS INSTALLATION & SERACIMG INSTRUCTIONS FOR WORCESTER Da ogg Lees AMORCESTER
Bosch Group
L. E G. CONVERSIÓN
| ISOLATE MAINS ELECTRICAL
| SUPPLY AND REMOVE OUTER CASE
| AS SHOWN IN THE INSTALLATION,
| COMMISSIONING & SERVICING
| INSTRUCTIONS
Important: The appliance shall not be installed
into a room or internal space below ground
level when it is intended for use with LPG
(propane - G31). This does not preclude the
installation into a room or space which is a
basement on one side of the building but open
to ground on the opposite side.
Installation Regulations
In addition to those specified in the main
booklet the following standard applies when
converting to an LPG applance: BS 5842
Domestic Propane Gas Burning
Installations.
All conversions will require tha air gas ratio to
be set corractly for the gas used. The
procedure for setting the air gas ratio is at
the rear of these instructions.
“= = ==
1. Moving boiler control to service
position
F Remove boiler case, as described on page 36,
1.1 Remove screw (A) from retaining bracket
1.2 Lower control panel into service position,
2. Gas valve
>» Isolate gas supply at boiler gas cock
21 Remove wire clip from gas vale outlet then
pull valve outlet elbow free from gas valve,
22 Undo bottom gas connection to gas valve.
23 Undo two securing screws (B) on the
underside of casing.
Pull valve up and forward out of boiler.
Disconnect electrical connections,
FF Fit plastic retaining nut to the outlet of the
gas valve from the kit and hand tighten,
>» Replace valve with new seals,
» Check for gas soundness.
3. Valve outlet elbow
b Twist retaining clip (D) to release then
remove clip and tube,
» Refit new valve outlet elbow and secure
with clip,
4, Code plug
41 Remove 3 screws (D) retaining plastic
cover at rear of control box and remove.
4.2 Replace code plug (E) with new one
supplied with conversion kit
Replace plastic cover,
› Face control in normal position and secure
with screw,
Code plugs [THE GAS / AIR RATIO MUST BE
12KW NG with internal diverter valve - 112 12kW NG with external diverter valve - 108 | RESET AFTER CONVERSION. THE
12kW LPG with internal diverter valve - 113 12kW LPG with external diverter valve - 109 | PROCEDURE CAN BE FOUND IN
24kW NG with internal diverter valve - 114 24kW NG with extemal diverter valve - 110 | THE REPLACEMENT PARTS SECTION
24kW LPG with internal diverter valve - 115 24kW LPG with external diverter valve - 111 | OF THIS MANUAL.
LAMORCESTER INSTALL ATICO & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 15 Sustem"24i Eystera LPG CONVERSION
Bosch Group
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FAULT FINDING
NOTE : This fault finding information is for quidance only. Worcester cannot be held responsible for costs incurred by persons not deemed
to be competent.
The electronic control system for this boiler incorporates a blue central indicator. This normally confirms the permanent mains supply but, by
flashing at different rates during a fault, provides a guide to the cause as listed.
This fault finding system assumes that the appliance has been operating normally until the time of failure (Le, 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. Un completion of the Service Fault-Finding task which has required the breaking and remaking of electrical connections, check
(a) EARTH CONTINUITY, (5) SHORT CIRCUIT CHECK, (c) POLARITY and (d) RESISTANCE TO EARTH.
Blue light |
Off
‘Esckoutresst FE es
Td e dee e ABU Possible solutlon/check 0000500055
-mdicatión: FDULION oon AN A ELA E
Off
| No power at control board
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FLTC
Permanent mains supply to boiler.
Bader mains switch.
Fuse F1, 2.5A or Fuse F3, 0.54
Transformer {both coils below 100631.
Otherwise replace control board.
On
Off
| Boiler not operating during
| central heating demand
| (HW ok)
External diverter valve,
External timer or room stat
OR
If optional diverter valve is fitted:
Temperature control in frost protection position,
Live demand at ST10-Lr {extemal CH demand).
Facia mounted timer (if fitted).
Diverter valve,
Control board.
| Boiler operating
| without live demand at
| ST10-LR {from external
| roomstat timer).
Soma older thermostats (containing capacitors) may give a low
voltage return at ST10-Lr when the thermostat contacts are open.
Check that there is not a permanent Ive at STIO-LR from another
source.
| Goiler not operating during
| hot water demand (CH ok).
External diverter valve.
External timer or cylinder stat
OR
If optional diverter valve is fitted:
Short circuit across STE from cylinder stattimer.
Facia mounted tirer (if fitted).
Diverter valve.
Control board.
| Boiler not operating during
| any demand,
Temperature contral in frost protection position.
Live demand at ST10-Lr (from external system).
Control board.
OR
If optional diverter valve is fitted:
Timer.
Control board.
Slow flash
(normally off,
flashes on)
Flashing (reset required)
| Ignitton lockout
Gas present and at correct pressure.
Combustion CO, level,
Flue condition.
lgnition ejectrodes / hamess / connections.
Gas valve (coils 140-1808) / low voltage hamess connection.
Otherwise replace control board.
Slow flash
(normally on,
flashes off)
aRAMS
Flashing (reset required)
| Flue overheat
Heat exchanger blocked.
Heat exchanger baffles removed and not refitted.
| Heat exchanger overheat
Water pressure,
All air vented.
Pump / harness / connections.
Water leaks / blockages.
Safety thermostats / low voltage wiring harness / connections.
Otherwise replace control board.
Flue blockage
Blockage in flue system.
Fast flash
=D
Off
| Volatile lockout
Temperature sensor (8000-20 0006).
Low voltage wiring harness / connections to sensor
Fan / fan hamess / connections to fan.
Code plug fitted,
Fast flash
Flashing
| Internal fault
Replace control board
2 pulses
No light
| Not a fault code
Service mode selected to min, press service button to retum to normal,
5 pulses
No light
| Not a fault code
Service mode selected to max, press service button to retum fo normal,
FAULT FINDING
IHSTALLATION £& EERCIHG INETRULCTIONS FOS WORCESTER GREEMNETAR 155 Spriemai Syaiem
<ZANORCESTER
Bosch Group
BTI6 117 CES MD
BOILER FUNCTION
IMPORTANT: IF THE OPTIONAL
INTEGRAL DIVERTER VALVE HAS
BEEN FITTED
correct versions for CENTRAL HEATING
and DHW FUNCTIONS in the ADDITIONAL
INFORMATION section at the back of this
Disregard this page and refer to the
book.
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PROTECTION FUNCTION
Boiler temperature Run autofroststat
below 8°C function
Fump antiseize —
Pump run 5 seconds
every Z4hrs
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PROTECT FUNCTION INSTALLATION & CERACING INSTRUCTIONS ADE WORCESTER aia 110 em Ie] AMORCESTER
Bosch Group
DIVERTER KIT NUMBERS:
12kY 7 716 192 408
24 7 716 192 409
KIT CONTENTS:
1 COPPER RETURN PIPE
1 BRASS SERVICE VALVE
1 15mm COMPRESSION NUT
1 15mm OLIVE
1 DIVERTER VALYE MOTOR
1 DIVERTER MOTOR HARNESS
2 SCREWS
2 CODE PLUGS
1 CODE PLUG CABLE
FOR 12kW0 | System KIT:
121 System NATURAL GAS 112
12i System LPG 113
FOR 24kW | System KIT:
24) System NATURAL GAS 114
THE APPLIANCE IS FOR USE WITH
NATURAL GAS OR LP.G. (Cat ll 2H3P TYPE C13 & C33)
NATURAL GAS:
WORCESTER GREENSTAR 12i System GC NUMBER 41-311-67
WORCESTER GREENSTAR 24i System GC NUMBER 41-311-68
LIQUID PETROLEUM GAS:
WORCESTER GREENSTAR 12i System GC NUMBER 41-311-69
WORCESTER GREENSTAR 24i System GC NUMBER 41-311-70
THESE ADDITIONAL
INSTRUCTIONS
MUST BE USED IN
CONJUNCTION WITH
THE MAIN
INSTRUCTION MANUAL
INSTALLATION,COMMISSIONING
& SERVICING
(Benchmark)
te
Bosch Group
FLUMBING MANIFOLD
CONNECTIONS:
Heating System: 22mm compression fittings
; | | Gas: 22mm compression fittings
A Gas Supply (alternative from above appliance) 22mm Cylinder Return 15mm compression fittings
Usa the fittings supplied in the Lit! Hardware
pack and the Optional Diverter Valve Kit,
« Before the wall mounting frame is fitted to the
wall you must first assemble the service valve
(A) included in the Optional Diverter Valve Kit
and secure to the wall mounting frame as
shown with the two screws (B) supplied.
* [f the boiler pipes are to be run behind the
appliance ensure that the pipes pass through
the slot in the yellow plastic guide (C). This is
fitted to the bodler frame.
NOTE: If the optional diverter valve is used with
an unvented cylinder then a zone valve must be
fitted in the flow or return to the cylinder to
comply with unvented cylinder regulations.
Further guidance on pipe routing can be
found printed on the boiler template
(supplied with the boiler).
NOW RETURN TO THE MAIN
INSTRUCTIONS PAGE 16 TO
CONTINUE INSTALLATION.
B 7 | | 1
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DU Pi]
5 Y 3 1
Flow 22mm | Te
Mains Gas A 3
Supply 22mm Cylinder
Return 15mm
PLUMBING MANIFOLD IMETALLATION E SERVICING STRUCTIERES FOR YWORT ESTER ARE ER EE er (re AORCESTER
Bosch Group
BOILER CONNECTIONS
+
MPORTANT: THE FOLLOWING MUST BE
COMPLETED BEFORE THE BOILER 15
MOUNTED ON THE WALL MOUNTING
ma
ASSEMBLY OF THE INTERMAL HOT WATER
RETURN PIPE TO THE BOILER
Using the boiler packaging as protection
turn the boller on its left hand side to
facilitate assembly of the hot water return
pipe.
+» 1, Move the control panel into the service
position by removing the screw (A) from the
retaining bracket.
› 2. Loosen the two retaining screws (B) to fres
the back clamping plate on the hydraulic block
(C) shown in 3.
» 3, Remove the brass bung assembly (D) from
the hydraulic block by removing the screw and
shiding it free from the flange on the clamping
plate (C). Make sure that the other brass
bung assembly (E) is retained in place.
¥ 4, Remove the copper pipe (F) from the
Optional Integral Diverter Valve Kit and feed the
flat end of the pipe through the rear of the boiler
as shown. Before fitting the pipe, check that the
seal is in postion on the plastic moulding. Side
the flat end of the pipe (G) under the flange (H)
on the hydraulic block clamping plate (C)
making sure that it is located comectiy,
» Re-tighten the clamping plate by re-tightening
the two screws (B) as shown in fig: 2
« 4.1 On completion the pipe assembly
should look as shown.
LAMORCESTER INSTALL ) TON 8 SERVICINE INSTRUCTIONS FOR WORCESTER GREENSTAR 13 Systeme 2d System BOILER CONNECTIONS
Bosch Group
BOILER CONNECTIONS
pa Ba Do not lift by the
CAUTION: ISOLATE THE MAINS GAS
SUPPLY BEFORE STARTING ANY WW
AND OBSERVE ALL RELEVANT
la РТ.) ОНОГО ИК
GAS AND WATER CONNECTIONS:
к Remove template and secure the wall mounting
frame to the wall with the fxings supplied.
к System pipes may be run vertically upwards
behind the boiler or below it. See Plumbing
Mantold Section on page 15.
A - Flow (22mm)
B - CH retum (22mm)
C - Gas mlet (22mm)
D - Cylinder return (15mm)
N
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NT
к 5, Fit sealing washers to service valves
before hanging boiler.
IMPORTANT:
Before hanging the boiler onto the wall
mounting frame ensure that the pressure relief
valve connection is in the DOWN position, This
is located on thé right hand side of the wall
frame at the rear.
» E, Pull the extended tab/lever forward and
down until there is no further travel.
Pi
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к 7 Hang the boler on to the wall mounting
frame by the two brackets positioned left
and right at the top rear of the appliance.
Ою not lift the appliance by the air gas
manifold. There are two handling holes
incorporated into tha inner casing left and
22mm Ë All — =
bonded = 4
22mm washer 15mm 22mm В
Ew
mi @ =
Handling right in the lower section of the appliance.
Hole IMPORTANT:
The pressure relief connector must be
repositionad after the boiler has been correctly
mounted to the wall mounting frame.
к B. Push tha lever on the pressure ralef
connector UP until the stop on the inside of
Эй
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я the handle is over the shoulder of the metal
a * J bracket to secure im place,
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BOI LER CONNECTIONS METAL LATIN EE SERVICING INSTRUCTS FOS WORCESTER ВЕНЕ а Эа ии (DATE LNORCESTER
Bosch Group
Remove control retaining 9
Screw
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BOILER CONNECTIONS
CAUTION: ISOLATE THE
SUPPLY BEFORE STARTING ANY WORK
ES E Tobe
AMD OBSERVE ALL RELEVANT SAFETY
FRECAUTIONES
GAS AND WATER CONNECTIONS:
À - Flow (22mm),
В - СН retum (22mm),
C - Gas inlet (22mm),
D - Cylinder returm (15mm).
к 9. Lower the control panel into the service
position by removing the screw from the
retaming bracket,
к 10. Make connections to the heating system.
» Connect the gas supply to the boiler gas
COCK 22mm compression.
Fb 11. Connect the expansion vessel flexible
pipe to the hydraulic manifold situated left of
the pump. It is necessary to remove and
discard the gray plastic blanking plug (E}
from the pressure vessel connection at the
hydraulic manifold before secunng the
expansion vessel flexible pipe (F) in place
with the wire retaining clip (5).
+ 12. Connect the pressure relief drain pipe to
15mm compression joint (H) using the nut
and olive supplied in the hardware literatura
pack,
NOW RETURN TO THE MAIN
INSTRUCTIONS PAGE 23 (FLUE |
INSTALLATION) TO CONTINUE
INSTALLATION. |
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENMSTAR 13 Systems 2d System
2 TIE 112 90556 (04:05)
BOILER CONNECTIONS
oe ows „=“
FITTING THE DIVERTER VALVE
CAUTION: ISOLATE THE MAIMS GAS
SUPPLY BEFORE STARTING ANY WORK
AND OBSERVE
sb RE Г В L = = L = LT А EE E A = ETY
FRECTAUTIONS
FITTING THE DIVERTER VALVE MOTOR:
к 1. Remove the diverter blanking plate (A) by
pulling It forwards to free it from its location,
+ 2. Replace with the diverter valve motor (B) by
pushing it in until it clicks securely into place,
к 3. After removing the cover at the rear of the
control box (see ELECTRICAL and POSMON
OF WIRED COMPONENTS on the following
pages) connect the electrical hamess from the
kit to the control (ST17) see ELECTRICAL and
POSITION OF WIRED COMPOMENTS on
the folowing pages.
k 4 Remove the code plug from the control and
cut he te to the boiler chassis so that it can be
completely discarded and replace with the one
from the kit making sure that it is secured to the
boiler chassis (see ELECTRICAL on the
following page).
Code plug numbers
12kVY ¡ System Kit:
12i System NATURAL GAS 112
12i System LPG 113
24kW i System Kit:
24) System NATURAL GAS 114
24) System LPG 115
/
/
1
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1
1
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BOILER CONNECTIONS OR CN AS NAT PT OPA PSE MONET POSE TT 12 CE (DATE) LNORCESTER
Bosch Group
ROOMSTAT E „”
230V
MAINS
SUPPLY © FROSTSTAT 9 TANKSTAT $
calling
10
® ®
ELECTRICAL
CAUTION: ISOLATE THE MAINS
ELECTRICITY SUPPLY BEFORE STARTING
ANY WORK AND OBSERVE ALI
RELEVANT SAFETY PRECAUTIONS
Note: Mains supply to the boiler must be
through a fused double pole isolator situated
adjacent to the appliance. The isolator must
have a contact separation of 3mm minimum
in all poles. External fuse rating 3A.
When stripping wires always ensure copper
strands do not fall into the control box.
There should be no external wiring centre.
A facia mounted twin channel! programmer
must be used,
Timers available: DT20 Twin Channel
Programmer (7 716 192 038), DTIORF
Digistat (7 716 192 039), DT20RF (7 716 192
047).
Access to electrical connections:
Remove boiler casing to access control panel.
1 Unscrew screw (A) and lower the control
box into the horizontal position.
2 Unscrew the three screws (B) in the control
panel and pull off the connections cover.
3 Unclip cable clamp (C).
4 Cut off the tapered cable entry to fit cable
diameter required.
5 Tum cable retaining screw (D) anti-clockwise.
Run cable over the main crossbar and
through the cable clamp (C), ensuring there
is ample cable to reach the connectors,
Tum cable clamping screw (D) clockwise to
secure cable and replace clamp (C) into
control pañel.
6 Mains power 230v connection (ST10):
>» Separate wires from cable end and strip
to Gr mi,
» Connect LIVE wire to terminal (L)
+» Connect NEUTRAL wire to the terminal (MN)
» Connect EARTH wire to the connector =
Note: Earth cable to be longer so that it
pulls out last if mains cable is snagged.
7 Central heating channel
230V room stat if required with timer
7 716 192 038 (ST10);
Remove link
Connect room stat LIVE supply to terminal (Ls)
Connect room stat LIVE retum to terminal (LR)
Connect room stat NEUTRAL to terminal (Ns)
Note: IF timer 7 716 1972 039 or 7 716 192
041 is used, the roomsiat is incorporated in
the transmitter. Therefore keep link fitted.
8 Hot water channel
Vaolt-free cylinder stat (STB):
+» Cylinder Stat wires to terminals 7 and 9,
NOTE: The cylinder stat must be volt-free,
Le not connected to any voltage source.
9 Optional external frost stat connection (STE):
+» Connect frost stat wires to teminal (Fs) and (Fe)
10 Diverter valve motor
(ST17):
+» Connect electrical hamess from diverter valve
motor to 5T17 (see following page).
ww Vv WW
LAMORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTIAR 15 Csbemv”Z2di Sysien
STE 117 0556 10409)
Bosch Group
ELECTRICAL
POSITION OF WIRED
COMPONENTS
eons | FLAME SENSE
PRESSURE SWITCH ELECTRODE
I OVERHEAT
fal |] STAT CM
Colour sequence
LILI
GAS
VALVE PUE
OVERHEAT
STAT J
SOLENOID
| DIVERTER
| SAFETY С VALVE
SOLENOID AL
i 3 ;
EXTERMAL
MAINS FROST STAT CYLINDER
SUPPLY (OPTIONAL) STAT
и оо a
Earth y
730 Y ROOM STAT
| I Хо | DH
—- —№- — — —— | TEMPERATURE
Ny CONTROL
Lit La des Ly STS
= 5710 | Fuse F1, alow
Г | pass À STS > STE
2.6 À, #0 290 VŸ
ST17
ST9
Fuss F3, do TS À
ee
Fuse F2, slow T1.6 A
+
ST18
DIAGNOSTIC
ST1 DN INTERFACE A]
POSITION OF WIRED COMPONENTS INSTALLATION & SERVICINS INSTRUCTIONS FOR WORGESTER GREENSTAR 13 Spalem/adi Spaem AMORCESTER
Bosch Group
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PRE-COMMISSIONING
CHECKS
CAUTION: ISOLATE THE MAINS
SUPPLIES BEFORE olARTIMNG AMY
WORK AND OBSERVE ALI
RELEVAKRT SAFETY FRECAUTIONS
1 Check that the service and water pipes are
connected to the correct position on the
manifold.
À - Flow (22mm)
В - СН Return (22mm)
C - Gas inlet (22mm)
D - Cylinder Return (15mm)
2 Check tha gas type specihed on the
identification plate (F) matches that of the
gas supply. Turn on the main gas supply,
check the gas pipework, connections and
rectify any leaks.
3 Check that the condensate pipe has been
connected to the syphon,
IMPORTANT: If the boiler is not to be
commissioned immediately then:
after sucessfully completing all of the
checks and any rectification work,
close the gas and water valves, shut off
the gas supply, electrically isolate the
boiler and label appropriately.
4 Check pressure relief drain pipe (H) is
correctly fitted and securaly tightenad.
NOW RETURN TO THE MAIN
INSTRUCTIONS PAGE 30
(FILLING THE SYSTEM) TO
CONTINUE INSTALLATION,
LAMORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GAEENSTAR 13 Systems 2d System
2 TIE 112 O55 104.05]
Bosch Group
FRE- COMMISSIONING CHECKS
CENTRAL HEATING FUNCTION
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CENTRAL HEATING FUNCTION
SHYHDYIO ®
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DHW FUNCTION
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INSTRUCTIONS PAGE 57 FOR
RETURN TO THE MAIN
PROTECTION FUNCTION.
NO
HILIMS
Y3MOd
DHW FUNCTION
IMSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 13 Sysbems 24 System
2 TIE 1132 OS
WORCESTER
Bosch Group
BENCHMARK No. | | | | | | |
—
(benchmar: GAS BOILER COMMISSIONING CHECKLIST
BOILER SERIAL No. NOTIFICATION No.
CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes
TIME & TEMPERATURE CONTROL TOHEATING | ROOM T/STAT & PROGRAMMER/TIMER | | PROGRAMMABLE ROOMSTAT | |
TIME & TEMPERATURE CONTROL TO HOT WATER | CYLINDER T/STAT & PROGRAMMERTIMER. | | COMBIBOILER | |
HEATING ZONE VALVES FITTED | | NOT REQUIRED | |
HOT WATER ZONE VALVES FITTED [| NOT REQUIRED [|
THERMOSTATIC RADIATOR VALVES FITTED | |
AUTOMATIC BYPASS TO SYSTEM I FITTED || NOTREQUIRED | |
FOR ALL BOILERS CONFIRM THE FOLLOWING
THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER'S INSTRUCTIONS?
THE SYSTEM CLEANER USED
THE INHIBITOR USED
FOR THE CENTRAL HEATING MODE, MEASURE & RECORD
CAS RATE e mm
BURNER OPERATING PRESSURE (IF APPLICABLE) || МА | mbar
CENTRAL HEATING FLOW TEMPERATURE || °С
CENTRAL HEATING RETURN TEMPERATURE | | °С
FOR COMBINATION BOILERS ONLY
HAS A WATER SCALE REDUCER BEEN FITTED? YES NO
WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED?
FOR THE DOMESTIC HOT WATER MODE, MEASURE & RECORD
GAS RATE | | métae fer
MAXIMUM BURNER OPERATING PRESSURE (IF APPLICABLE) LI NA | mbar
COLD WATER INLET TEMPERATURE | | °С
HOT WATER OUTLET TEMPERATURE | | °C
WATER FLOW RATE || нити
FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING
THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH
THE MANUFACTURER'S INSTRUCTIONS? YES
FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING
THE HEATING AND HOT WATER SYSTEM COMPLIES
WITH CURRENT BUILDING REGULATIONS
THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED
IN ACCORDANCE WITH THE MANUFACTURER'S INSTRUCTIONS
IF REQUIRED BY THE MANUFACTURER, HAVE YOU RECORDED A CO/COz RATIO READING? WA || YES | | СОЮСОгНАТО
THE OPERATION OF THE APPLIANCE AND SYSTEM
CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER
THE MANUFACTURER'S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER
COMMISSIONING ENG'S NAME PRINT CORGI ID No.
SIGN DATE
SERVICE INTERVAL RECORD
It is recommended that your heating system is serviced regularly
and that you complete the appropriate Service Interval Record Below.
Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service
as described in the boiler manufacturer's instructions. Always use the manufacturer's specified spare part when replacing all controls
SERVICE 1 DATE
ENGINEER NAME ENGINEER NAME
COMPANY NAME COMPANY NAME aa aaa
TEL No. TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SERVICE 3 DATE
SERVICE 2 DATE
COMMENTS
SIGNATURE
SERVICE 4 DATE
ENGINEER NAME ENGINEER NAME
COMPANY NAME COMPANY NAME
TEL No. TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SERVICE 5 DATE
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SERVICE 6 DATE
ENGINEER NAME ENGINEER NAME
COMPANY NAME COMPANY NAME
TEL No. TEL No. —
CORGI ID CARD SERIAL No. CORGI ID CARD SERIAL No.
COMMENTS COMMENTS
SIGNATURE SIGNATURE
SERVICE 7 DATE
SERVICE 8 DATE
ENGINEER NAME. — ENGINEER NAME
COMPANY NAME COMPANY NAME
TEL No. TEL No,
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SERVICE 9 DATE
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SERVICE 10 DATE
ENGINEER NAME ENGINEER NAME
COMPANY NAME COMPANY NAME
TEL No. TEL No.
CORGI ID CARD SERIAL No. CORGI ID CARD SERIAL No.
COMMENTS COMMENTS
SIGNATURE SIGNATURE
If in the unlikely event the boiler does not give
complete satisfaction, before calling for a service
engineer, the installer should check the following:-
No Central Heating but Hot Water OK
Unlikely to be a boiler fault, please ask your electrician to check the external
controls,
No Hot W ntral Heating OK
Unlikely to be a boiler fault, please ask your electrician to check the external
controls.
No HW or CH demand
ls there a demand from external controls? To eliminate the boiler as a fault,
remove the switched live from the wiring centre to Lr on ST10, then fit a link
between the Ls and Lr If the boiler and pump run normally then it is likely
there is a fault with the external controls. Please contact your electncian.
For boilers with internal diverter valve and controls
No Central Heating but Hot Water OK
Remove the room stat wiring from Ls, Lr and N on terminal block ST10. Fit a
link between Ls and LR, if the CH now works there Is likely to be a problem
with the room stat or wiring to it.
No Hot Water but Central Heating OK
Remove the cylinder stat wiring from 8 and 10 on the terminal block STB. Fit
link across 8 and 10.
For all boilers with internal or external controls
Burner lights then goes out in DHW or CH mode
Does the boiler run normally with the front cover off and then fail
when the cover is put back on?
If yes there is likely to be a flue problem - either the air inlet is blocked or the
inner flue is leaking flue gases into the air inlet.
Boiler noisy or going to overheat
1. Was the system flushed?
2. Has the pump been bled and the dust cap released.
General checks
1. Is all the air bled from the gas supply?
2. Is all the air bled from the primary water system?
3. Is there 230v ac across the boiler live and neutral terminals?
(L & N on ST10)
4. Is the polarity correct?
5. Is the incoming gas pressure at least 18mbar with the baller at maxmum
output?
EXCELLENCE COMES AS STANDARD
Worcester, Bosch Group
Cotswold Way, Warndon, Worcester WR4 95W.
Tel. 01905 754624 Fax, 01905 754619
Worcester, Bosch Group is a trading name of BET
Thermotechnology UK Lid.
www.worcester-bosch.co.uk
8 T16 112 055 (04/06)
Te
8716107332
Ш
8716112055
CONTACT INFORMATION
WORCESTER, BOSCH GROUP:
TECHNICAL: 08705 266241
SERVICE: 08457 256206
TN] Ta TY
LITERATURE 01905 752556
TRAINING: 01905 752526
SALES: 01805 752640
WEBSITE: vos womnmcesterbosch.co uk
WATER TREATMENT:
FERNOX 01799 550811
vw fernmox.com
SENTINEL 0151 420 9595
AT ег СО!
FLUE TERMINAL GUARD:
TOWER FLUE COMPONENTS
VALE RISE
TONBRIDGE
TN9 17B
TEL: 01737 351680
www.tic-group.co.uk
ea Тат
Bosch Group
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