Greenstar Ri Compact ErP
INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS
WALL HUNG RSF GAS FIRED CONDENSING REGULAR BOILER
Greenstar Ri Compact ErP
FOR OPEN VENTED AND SEALED CENTRAL HEATING SYSTEMS AND
INDIRECT MAINS FED DOMESTIC HOT WATER
These appliances are for use with:
Natural Gas or L.P.G.
(Cat. II 2H 3P type C13, C33 & C53)
Model
Natural Gas
27Ri Compact ErP
30Ri Compact ErP
L.P.G.
27Ri Compact ErP
30Ri Compact ErP
GC Number
41-406-54
41-406-56
41-406-55
41-406-57
6 720 813 282 (2015/07)
6720646610-00.1Wo
If you smell gas:
▶ Well away from the building: call the National Gas Emergency
Service on 0800 111 999.
▶ L.P.G. boilers: Call the supplier’s number on the side of the
gas tank.
Contents
Contents
1
Key to symbols and safety instructions . . . . . . . . . . . . . . . . . . . 4
1.1
Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2
Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3
Appliance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1
Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4
Energy efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4
Pre-installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1
Cleaning primary systems . . . . . . . . . . . . . . . . . . . . . . .
4.2
Mains supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3
Water systems and pipe work . . . . . . . . . . . . . . . . . . . .
4.4
Condensate pipe work . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1 Internal connections . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.2 External connections . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5
Boiler location and clearances . . . . . . . . . . . . . . . . . . .
4.5.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.2 Installation and servicing clearances . . . . . . . . . . . . . .
4.5.3 Compartments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.4 Bathrooms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6
Plumbing manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.1 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7
Flue options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.1 Flue lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8
Flue terminal positions . . . . . . . . . . . . . . . . . . . . . . . . .
4.9
Plume management terminal positions . . . . . . . . . . . .
4.9.1 Determine the plume management system length . . .
12
12
12
12
12
12
15
15
16
17
17
17
17
17
18
18
19
19
21
22
23
5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1
Unpacking the wall frame & ancillary items . . . . . . . . .
5.2
Wall mounting template & flue opening . . . . . . . . . . . .
5.3
Unpacking the appliance . . . . . . . . . . . . . . . . . . . . . . .
5.4
Boiler connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.1 Wall mounting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.2 Gas and water connections . . . . . . . . . . . . . . . . . . . . .
5.4.3 Hanging the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.4 Condensate connection . . . . . . . . . . . . . . . . . . . . . . . .
5.5
Flue turret/adaptor installation . . . . . . . . . . . . . . . . . .
5.6
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.1 Mounting optional plug-in controls only with Greenstar wiring centre (optional accessory
24
24
24
25
26
26
26
27
27
28
29
6
2
COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1
Pre-commissioning checks . . . . . . . . . . . . . . . . . . . . . .
6.2
Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3
Water treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4
Starting the appliance . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.1 Setting the appliance to service mode . . . . . . . . . . . . .
6.5
6.5.1
6.5.2
6.5.3
6.5.4
6.6
6.7
6.7.1
6.7.2
6.7.3
6.7.4
6.7.5
6.7.6
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Checking the gas inlet pressure . . . . . . . . . . . . . . . . . . . 33
Checking the gas rate and pressure . . . . . . . . . . . . . . . . 34
Gas rating test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Checking for leaks during operation . . . . . . . . . . . . . . . 34
CO and Combustion checks . . . . . . . . . . . . . . . . . . . . . . 34
Finishing commissioning . . . . . . . . . . . . . . . . . . . . . . . . 36
Replacing the outer case . . . . . . . . . . . . . . . . . . . . . . . . 36
Securing the control panel . . . . . . . . . . . . . . . . . . . . . . . 36
Fitting the fascia flap . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installing the bottom panel . . . . . . . . . . . . . . . . . . . . . . . 36
Handover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Boiler guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7
Service and spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.1
Inspection and service . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.1.1 Draining the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.2
Checking the gas inlet pressure . . . . . . . . . . . . . . . . . . . 38
7.3
Checking flue integrity . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.4
Component access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.5
Fan pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.5.1 Setting the boiler to maximum . . . . . . . . . . . . . . . . . . . . 39
7.5.2 Fan pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.6
Flue gas analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.7
Cleaning the heat exchanger . . . . . . . . . . . . . . . . . . . . . 41
7.7.1 Cleaning the siphon . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.7.2 Cleaning the primary heat exchanger . . . . . . . . . . . . . . 41
7.8
Replacement of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.8.1 Removing the outer case . . . . . . . . . . . . . . . . . . . . . . . . 43
7.8.2 Draining the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.8.3 Siphon removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.8.4 Primary sensor (CH NTC) . . . . . . . . . . . . . . . . . . . . . . . . 44
7.8.5 “Maximum safety sensor” . . . . . . . . . . . . . . . . . . . . . . . . 44
7.8.6 Flue overheat thermostat . . . . . . . . . . . . . . . . . . . . . . . . 45
7.8.7 Air Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.8.8 Auto air vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.8.9 Gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.8.10 Fan assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.8.11 Air/gas flap valve assembly . . . . . . . . . . . . . . . . . . . . . . 48
7.8.12 Ignition transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.8.13 Electrode assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.8.14 Burner housing, burner/ gasket . . . . . . . . . . . . . . . . . . . 48
7.8.15 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.8.16 Boiler return sensor (NTC) . . . . . . . . . . . . . . . . . . . . . . . 50
7.8.17 Access to boiler control components . . . . . . . . . . . . . . 50
7.8.18 Replacing the Heating Control Module (HCM) . . . . . . . 51
7.8.19 Replacing the control unit . . . . . . . . . . . . . . . . . . . . . . . . 51
7.9
Short parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8
Fault finding and diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.1
Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.1.1 Group 1 fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.1.2 Group 2 fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.1.3 Group 3 fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.2
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.3
Boiler function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.4
Protection function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
29
31
31
32
32
32
32
Greenstar Ri Compact ErP 6720813282 (2015/07)
Key to symbols and safety instructions
1
Key to symbols and safety instructions
1.1
Key to symbols
Warnings
Warnings in this document are identified by a warning
triangle printed against a grey background.
Keywords at the start of a warning indicate the type and
seriousness of the ensuing risk if measures to prevent
the risk are not taken.
The following keywords are defined and can be used in this document:
• NOTICE indicates a situation that could result in damage to property
or equipment.
• CAUTION indicates a situation that could result in minor to medium
injury.
• WARNING indicates a situation that could result in severe injury or
death.
• DANGER indicates a situation that will result in severe injury or
death.
Important information
This symbol indicates important information where
there is no risk to people or property.
List entries, first and second levels
• A single component/item
• A component/list, made up of multiple parts/items.
– Sub component or sublist of main component/list.
– etc.
SYMBOLS USED IN THIS MANUAL
Domestic Hot Water
Central Heating
Hot Water Storage Cylinder
Domestic Cold Water Supply
Electrical Supply
Gas Supply
Table 2 Commonly used symbols
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE
STARTING INSTALLATION.
Additional symbols
Symbol
Meaning
a numbered step in an action sequence
a step in an action sequence
Æ
1
a reference to a related part in the document or to other
related documents
a reference number to identify or refer to a part or item
a list entry
a list entry (second level)
Table 1 Symbols
Examples of additional symbols used
A numbered step in an action sequence
A sequence of numbered steps or actions carried out in a specific order
to complete a task.
1. First action
2. Second action
3. Third action
etc.
A step in an action sequence
A sequence of defined actions or steps carried out in order to complete
a task.
▶ Action
▶ Next action
▶ etc
These instructions are applicable to the Worcester appliance model(s)
stated on the front cover of this manual only and must not be used with
any other make or model of appliance.
These instructions apply in the UK and Ireland only and must be
followed except for any statutory obligations.
This appliance must be installed and serviced by a GAS SAFE
registered, competent person. Failure to install correctly could lead to
prosecution.
If you are in any doubt, contact the Worcester Technical helpline
(0330 123 3366).
Please leave these instructions with the completed BENCHMARK
CHECKLIST, (or a certificate confirming compliance with IS 813, Eire
only) and the user manual with the owner or at the gas meter after
installation or servicing.
Distance learning and training courses are available from Worcester.
The BENCHMARK CHECKLIST can be found in the back of this
Installation manual.
A reference to a related part in the document or to other related
documents.
To refer the reader to a specific figure/table/section within the manual.
Æ e.g. figure 1.
A reference number to identify or refer to a part or item.
In a related figure, items or parts identified by a sequential number.
Greenstar Ri Compact ErP 6720813282 (2015/07)
3
Key to symbols and safety instructions
Ø
NG
LPG
CH
DHW
DCW
DWTA
PRV
NTC
IP
RCD
TRV
ECV
WRAS
SEDBUK
Diameter
Natural Gas
Liquid Petroleum Gas
Central Heating
Domestic Hot Water
Domestic Cold Water
Domestic Water Treatment Association
Pressure Relief Valve
Negative Temperature Coefficient (sensor)
Ingress Protection
Residual Current Device
Thermostatic Radiator Valve
Emergency Control Valve
Water Regulations Advisory Scheme
Seasonal Efficiency of Domestic Boilers in the United
Kingdom
Table 3 Abbreviations use in this manual
1.2
Safety precautions
If you smell gas
A gas leak could potentially cause an explosion. If you smell gas, observe
the following rules.
▶ Prevent flames or sparks:
– Do not smoke, use a lighter or strike matches.
– Do not operate any electrical switches or unplug any equipment.
– Do not use the telephone or ring doorbells.
▶ Turn off the gas at the meter or regulator.
▶ Open windows and doors.
▶ Warn your neighbours and leave the building.
▶ Prevent anyone from entering the building.
▶ Well away from the building: call the National Gas Emergency Service
on 0800 111 999.
▶ L.P.G. boilers: Call the supplier’s number on the side of the gas tank.
Appliance operation:
This appliance can be used by children aged from 8 years and above and
persons with reduced physical, sensory or mental capabilities or lack of
experience and knowledge, if they have been given supervision or
instruction concerning the use of the appliance, in a safe way, and
understand the hazards involved.
Children shall not play with the appliance.
Cleaning and user maintenance shall not be made by children without
supervision.
Health and 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).
Combustion and corrosive materials
Do not store or use any combustible materials (paper, thinners, paints
etc.) inside or within the vicinity of the appliance.
Chemically aggressive substances can corrode the appliance and
invalidate any warranty.
Fittings and modifications
Fitting the appliance and any controls to the appliance may only be
carried out by a competent engineer in accordance with the current Gas
Safety (Installation and Use) Regulations.
Flue systems must not be modified in any way other than as described in
the fitting instructions. Any misuse or unauthorised modifications to the
appliance, flue or associated components and systems could invalidate
the warranty. The manufacturer accepts no liability arising from any
such actions, excluding statutory rights.
Servicing
Advise the user to have the system serviced annually by a competent,
qualified Gas Safe registered engineer. Approved spares must be used
to help maintain the economy, safety and reliability of the appliance.
Important
The service engineer must complete the Service Record on the
Benchmark Checklist after each service.
Flue System
Only use the approved Worcester Condensfit II flue system with this
appliance.
Worcester original spare parts
Only use Worcester original spare parts with this appliance.
Non Worcester original spare parts will invalidate the guarantee (if
applicable) and any warranty.
Benchmark places
responsibilities on both
manufacturers and
installers.
The purpose is to ensure
that customers are provided with the correct equipment for their needs,
that it is installed, commissioned and serviced in accordance with the
manufacturer's instructions by competent persons and that it meets the
requirements of the appropriate Building Regulations. The Benchmark
Checklist can be used to demonstrate compliance with Building
Regulations and should be provided to the customer for future
reference.
Installers are required to carry out installation, commissioning and
servicing work in accordance with the Benchmark Code of Practice
which is available from the Heating and Hotwater Industry Council who
manage and promote the scheme.
Visit centralheating.co.uk for more information.
4
Greenstar Ri Compact ErP 6720813282 (2015/07)
Regulations
2
Regulations
Installation regulations
Current Gas Safety (Installation & Use) Regulations:
All gas appliances must be installed by a competent person in
accordance with the above regulations.
Failure to install appliances correctly could lead to prosecution.
The appliance must be installed in accordance with, and comply to, the
current: Gas Safety Regulations, IET Regulations, Building Regulations,
Building Standards (Scotland) (Consolidation), Building Regulations
(Northern Ireland), local water by-laws, Health & Safety Document 635
(The Electricity at Work Regulations 1989), EU Regulations No. 811/
2013 - Energy Labelling and any other local requirements.
British standards
Where no specific instruction is given, reference should be made to the
relevant British Standard codes of Practice.
BS7074:1 Code of practice for domestic and hot water supply
BS6891 Installation of low pressure gas pipe work up to 28mm (R1)
BS5546 Installation of gas hot water supplies for domestic purposes
EN12828 Central heating for domestic premises
BS5440:1 Flues and ventilation for gas appliances of rated heating not
exceeding 70kW (net): Flues
BS5440:2 Flues and ventilation for gas appliances of rated heating not
exceeding 70kW (net): Air Supply
BS7593 Treatment of water in domestic hot water central heating
systems
BS6798 Installation of gas fired boilers of rated input up to 70kW (net)
L.P.G. Installations
An appliance using L.P.G. must not be installed in a room or internal
space below ground level unless one side of the building is open to the
ground.
Irish Standards
The relevant Irish standards should be followed, including:
• ECTI National rules for electrical installations
• IS 813:2002 for Domestic Gas Installations.
Timber Framed Buildings
Where the boiler is to be fitted to a timber framed building the guidelines
laid down in BS5440: Part 1 and IGE "Gas Installations in Timber Frame
Buildings” should be adhered to.
Potable Water
All seals, joints and compounds (including flux and solder) and
components used as part of the secondary domestic water system must
be approved by WRAS.
CH Water
Artificially softened water must not be used to fill the central heating
system.
Greenstar Ri Compact ErP 6720813282 (2015/07)
5
Appliance Information
3
Appliance Information
3.1
Appliance
1
3
270mm
2
4
590mm*
5
67206813282-2.1Wo
6
390mm
*600mm to top of case front
Fig. 1
Ri Compact ErP standard package
STANDARD PACKAGE:
1
Wall hung gas fired condensing regular boiler for central
heating and domestic hot water
2
Tail pipes - water only
3
Wall plate
4
Hardware literature pack (see checklist)
5
ErP Label
6
Bottom panel
7
Fascia panel
BOILER FEATURES AND CHECKLIST
• Pre-wired and pre-plumbed
• Aluminium coated steel inner frame
• Digital control system
• Memory retention after power cut
• Automatic ignition
• Direct burner ignition electrodes
• Built-in frost protection
• Built-in fault finding diagnostics
• Fixed gas valve settings
• Combustion air fan with speed regulator
• CH temperature sensor & control
• Pump anti-seizure protection
• Flue gas temperature sensor
• Condensate siphonic trap
6
7
CHECK LIST - Hardware literature pack
Greenstar Ri Compact ErP Installation, Commissioning and
Servicing Instructions
Users Instructions
Pipe condensate, elbow
Wall mounting template
Sealing Pack:
- Compression Nut 22mm
- Compression Ring 22mm
Screws (flap fixings)
Strain relief grommet
Qty.
1
1
1
1
1
3
3
2
1
Greenstar Ri Compact ErP 6720813282 (2015/07)
Appliance Information
3.2
Layout
1
4
3
2
5
11
6
12
7
8
9
10
13
15
16
14
20
19
21
22
23
18
24
17
32
25
31
30
26
29
Fig. 2
28
6720813282-03.1Wo
27
Ri Compact ErP main boiler components
Greenstar Ri Compact ErP 6720813282 (2015/07)
7
Appliance Information
Key to figure 2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Wall mounting frame
Primary return pipe
Primary flow pipe
Flue connector
Air Pressure switch
Flue overheat thermostat
Primary return connection
Primary flow connection
Gas inlet isolator
Bottom panel
Case retaining clips
Case
Case fixing screws
Control panel
Operation/fault indicator (blue)
Blanking panel (for optional programmer)
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Control panel flap
Temperature control and reset
Fan
Flow temperature sensor (NTC)
Electrode assembly
Maximum safety sensor (NTC)
Auto air vent
Heat exchanger
Flueway
Sump assembly
Return temperature sensor (NTC)
Condensate siphon
Gas connection
Gas valve
Air inlet
Ignition transformer
Table 4 Main boiler components
8
Greenstar Ri Compact ErP 6720813282 (2015/07)
Appliance Information
3.3
Technical data
Natural Gas
27kW
30kW
DESCRIPTION Ri Compact ErP
UNIT
Gas flow rate - Max. 10 minutes from lighting
Natural Gas G20
Gas flow L.P.G.
Central Heating
Minimum heat input
Maximum rated heat input (net)
Maximum rated heat output 40/30 °C
Maximum rated heat output 50/30 °C
Maximum rated heat output 80/60 °C
Maximum flow temperature
Maximum possible flow temperature
Maximum permissible operating pressure
Flue
Flue gas temperature 80/60 °C, rated/min. load
Flue gas temperature 40/30 °C, rated/min. load
CO2 level at max. rated heat output (after 30 minutes)
CO2 level at min. rated heat output (after 30 minutes)
NOx class
NOx rating
Condensate
Maximum condensate rate
pH value, approx.
Electrical
Electrical power supply voltage
Frequency
Maximum power consumption (without pump)
Maximum power consumption at standby
General data
Appliance protection rating
Permissible ambient temperatures
Nominal capacity of appliance
Total packaged weight
Lift weight
SEDBUK 2005
SEDBUK 2009
m³/h
kg/h
2.92
kW
kW
kW
kW
kW
°C
°C
bar
7.15
27.58
28.55
28.4
27.0
82
86
2.5
°C
°C
%
%
L.P.G.
27kW
30kW
3.24
2.1
2.33
7.15
30.65
31.70
31.57
30.0
82
86
2.5
7.15
27.58
28.55
28.4
27.0
82
86
2.5
7.15
30.65
31.70
31.57
30.0
82
86
2.5
67/64
48/36
9.1
8.5
5
35
70/64
50/36
9.1
8.5
5
35
69/66
50/37
10.6
9.6
5
40
72/66
52/37
10.6
9.6
5
42
l/h
2.5
4.8
2.5
4.8
2.5
4.8
2.5
4.8
a.c. V
Hz
W
W
230
50
34
1
230
50
40
1
230
50
33
1
230
50
39
1
IP
°C
litre
kg
kg
band
%
X4D
0 - 50
1.83
31.0
22.7
A
89.0
X4D
0 - 50
1.83
31.0
22.7
A
89.0
X4D
0 - -50
1.83
31.0
22.7
A
90.0
X4D
0 - -50
1.83
31.0
22.7
A
90.0
mg/kWh
Table 5 Ri Compact ErP technical data
Greenstar Ri Compact ErP 6720813282 (2015/07)
9
Appliance Information
3.4
Energy efficiency
The following product data satisfy the requirements of the EU Regulations No. 811/2013 and No. 812/2013 supplementing Directive 2010/30/EU.
Product data
Product type
Condensing boiler
Low temperature boiler
B1 boiler
Cogeneration space heater (CHP)
Combination heater
Rated heat output
Seasonal space heating energy efficiency
Energy efficiency class
Useful heat output
At rated heat output and high temperature
regime 1)
At 30% of rated heat output and low
temperature regime 2)
Useful efficiency
At rated heat output and high temperature
regime 1)
At 30% of rated heat output and low
temperature regime 2)
Auxiliary electricity consumption
At full load
At part load
In standby mode
Other items
Standby heat loss
Ignition burner power consumption
Emissions of nitrogen oxides
Annual energy consumption
Sound power level, indoors
Symbol
–
Unit
–
Prated
Ks
–
–
–
–
–
–
kW
%
–
7733600064
27Ri Compact ErP
NG
Yes
No
No
No
No
27
92
A
7733600066
30Ri Compact ErP
NG
Yes
No
No
No
No
30
93
A
7733600065
27Ri Compact ErP
LPG
Yes
No
No
No
No
27
93
A
7733600067
30Ri Compact ErP
LPG
Yes
No
No
No
No
30
93
A
–
–
–
–
–
P4
kW
27
30
27
30
P1
kW
8.9
9.9
8.9
9.9
K4
%
88.2
88.2
88.2
88.2
K1
%
97.3
97.3
97.3
97.3
elmax
elmin
PSB
kW
kW
kW
0.034
0.014
0.001
0.04
0.014
0.001
0.033
0.013
0.001
0.039
0.013
0.001
Pstby
Pign
NOx
QHE
LWA
kW
kW
mg/kWh
kWh
dB(A)
0.038
0
32
51
0.038
0
32
52
0.038
0
32
51
0.038
0
32
52
Table 6 Product data for energy consumption according to the EU regulations no. 811/2013 and no. 813/2013
1) High-temperature regime means 60 °C return temperature at heater inlet and 80 °C feed temperature at heater outlet.
2) Low temperature means for condensing boilers 30 °C, for low-temperature boilers 37 °C and for other heaters 50 °C return temperature (at heater inlet).
10
Greenstar Ri Compact ErP 6720813282 (2015/07)
Pre-installation
4
PRE-INSTALLATION
4.1
Cleaning primary systems
Inhibitor
Add a suitable inhibitor or combined inhibitor/anti-freeze, if the system
is exposed to freezing conditions, to the heating system in accordance
with the DWTA code of practice and manufacturer‘s guidelines.
NOTICE:
▶ All the following pre-installation sections must be
read and requirements met before starting boiler or
flue installations.
WARNING: Sealing agents
▶ The addition of sealing agents to the system water is
not permitted as this can cause problems with
deposits left in the heat exchanger.
▶ In cases where all attempts to find a micro leak have
failed, Worcester, Bosch Group supports the use of
Fernox F4 leak sealer.
CAUTION:
▶ Isolate the mains electrical supply before starting any
work and observe all relevant safety precautions.
NOTICE:
▶ Debris from the system can damage the boiler and
reduce efficiency.
Failure to comply with the guidelines for the use of
water treatment with the appliance will invalidate the
appliance warranty and contravene the Building
Regulations.
▶ It is recommended that you fit a primary water
cleanser to the system. Worcester offers a filter that
helps remove both magnetite and non-magnetic
debris.
Part number 7 716 192 609
Before cleaning the system:
▶ Ensure that the system and pipe work is in good working order.
▶ Where possible keep the existing boiler/circulating pump in
place when flushing the system.
Follow the guidance ofBS7593:
Treatment of water in domestic hot water central heating and also the
flushing guidelines below.
Artificially softened water
NOTICE: ARTIFICALLY SOFTENED WATER MUST NOT
BE USED TO FILL THE CENTRAL HEATING SYSTEM.
It is possible to have an ion exchange water softener fitted to the cold
water system of the property. However, the boiler requires an untreated
cold water connection taken from the mains supply, before the water
softener, to the primary water filling point of the heating system.
Alternatively there are water softening/treatment devices that do not
adjust or alter the pH level of the water. With these devices it may not be
necessary to provide an untreated water bypass to the primary water
filling point of the heating system.
Flushing the system
▶ Fill the system with cold water and check for leaks.
▶ Open all drain cocks and drain the system.
▶ Close drain cocks and add a suitable flushing agent compatible with
aluminium at the correct strength for the system conditions in
accordance with the manufacturer‘s instructions.
The pH value of the system water must be less than 8 or the
appliance guarantee will be invalidated.
▶ Circulate the flushing agent before the boiler is fired up.
▶ Run the boiler/system at normal operating temperature as directed
by the manufacturer of the flushing agent.
▶ Drain and thoroughly flush the system to remove the flushing agent
and debris.
▶ It may be necessary to use a power flushing machine to aid the
cleansing procedure in some circumstances.
▶ Close the drain cocks and refill with fresh water and a suitable
inhibitor.
▶ Vent any air from the boiler and system.
Greenstar Ri Compact ErP 6720813282 (2015/07)
Water treatment
Suitable water treatment products can be obtained from the following
manufacturers:
FERNOX
SENTINEL
4.2
0870 601 5000 - www.fernox.com
0800 389 4670 - www.sentinel-solutions.net
Mains supply
4.2.1 Electrical supply
• Supply: 230V - 50 Hz, 50 Watts plus pump
• Cable: PVC insulated 0.75mm2 (24 x 0.2mm) temperature rated to
90 °C.
• External 3A fuse to BS1362.
• The appliance must be earthed.
• This appliance must NOT be connected to a three phase supply.
• IPX4D.
• Wiring must comply with the latest edition of BS 7671 (IET wiring
regulations).
4.2.2 Gas supply
To ensure that the equipment is in good working order and can meet the
gas flow and pressure requirements, in addition to the demand from any
other appliance being served, the following applies:
• Boilers using Natural Gas (NG) must be connected to a governed
meter.
• Liquid Petroleum Gas (LPG) must be connected to a regulator.
• Installation and connection of the gas supply to the boiler must be in
accordance with BS6891.
• Gas pipe sizing should be calculated to ensure no more than the
permitted mbar drop between the meter/governor to the appliance
inlet. (Æ Commissioning section).
• The meter or regulator and pipe work to the meter must be checked,
preferably by the gas supplier.
4.3
Water systems and pipe work
Plastic pipework:
• Any plastic pipe work must have a polymeric barrier with 600mm
(minimum) length of copper pipe connected to the boiler.
• Plastic pipe work used for under-floor heating must be correctly
controlled with a thermostatic blending valve limiting the
temperature of the circuits to approximately 50 °C.
Primary systems connections/valves:
• All system connections, taps and mixing valves must be capable of
sustaining a pressure up to 3 bar.
• Radiator valves should conform to BS2767:10.
• All other valves should conform to BS1010.
• Thermostatic radiator valves (TRV) must be used on all radiators
within the sleeping accommodation but not the radiator where the
room thermostat is sited. This must be fitted with lock-shield valves
and left open.
• A drain cock is required at the lowest point in the system.
• An air vent is required at all the high points in the system.
11
Pre-installation
Existing installations
Sealed primary systems:
S PLAN LAYOUT
NOTICE: ARTIFICALLY SOFTENED WATER MUST NOT
BE USED TO FILL THE SYSTEM.
1
3
8
2
7
150 mm
max
4
M
M
5
SYSTEM FILL
6720646610-24.1Wo
• If the system is sealed then the system must be filled using a WRAS
approved filling loop or comply with figure 3 for system fill.
• The expansion vessel (2) must be fitted as close as possible to the
appliance in the central heating return.
• Do not use galvanised pipes or radiators.
Mains
supply
Heating
return
Hose union
CV
SV
CV
SV
6
Y PLAN LAYOUT
Test point
1
Temporary hose
AA = Auto Air vent
CV = Check Valve
Make up
vessel
AA
CV
SV
Fig. 3
1000 mm (39 in)
above the highest
point of the system.
7
150 mm
max
4
M
5
6720646610-25.1Wo
SYSTEM MAKE UP
8
2
6720644743-08.2Wo
CV = Check Valve
SV = Stop Valve
Heating
return
3
System Fill
SEALED SYSTEM LAYOUT
S and Y plan systems:
2
3
4
5
6
7
8
9
10
11
12
Static head Minimum static head 250mm measured from the highest point
in the heating system (top surface of the appliance or the
highest point in the heating system) to the water level in the feed
and expansion tank
Heating vent (22mm minimum)
Primary cold feed (15mm minimum)
Diverter valve and zone valve
Pump, maximum power 90 Watts
Automatic bypass
Radiator valve (Flow)
Lock shield valve (Return)
Expansion vessel
Pressure gauge
3 bar pressure relief valve
Stop cock
Table 7 Key to figures
4
M
5
MCW
12
11
10
9
OPEN VENT LAYOUT
1
3
8
2
7
150 mm
max
Fully pumped sealed system:
The central heating sealed system must be filled using a WRAS approved
filling loop or comply with figure 3 for System fill.
12
M
5
6
4
6720646610-27.1Wo
M
M
NOTICE: A drain cock should be fitted at the lowest
point of the heating circuit and beneath the appliance.
8
7
6720646610-26.1Wo
1
Greenstar Ri Compact ErP 6720813282 (2015/07)
Pre-installation
New Installation
SEALED SYSTEM LAYOUT
8
7
M
M
MCW
12
6720646610-28.1Wo
M
5
4
6
11
10
9
Boiler resistance
Greenstar Ri Compact Water Pressure Loss
3.50
Water Pressure loss (m/Wg)
3.00
2.50
2.00
1.50
1.00
0.50
0.00
0
200
400
600
800
Flow rate (l/hr)
Greenstar Ri Compact ErP 6720813282 (2015/07)
1000
1200
1400
1600
6720813282-07.1Wo
13
Pre-installation
Condensate pipe work
NOTICE:
▶ Where a new or replacement boiler is being installed,
access to an internal “gravity discharge” point should
be one of the factors considered in determining
boiler location.
▶ The condensate pipe must be nominally
22mm Ø plastic pipe.
▶ The condensate pipe work must fall at least 52mm
per metre towards the outlet and should take the
shortest practicable route.
▶ Ensure there are no blockages in the pipe run.
Key to condensate illustrations
1
Condensate discharge from boiler
2
Soil and vent stack
3
Minimum 450mm and up to three storeys
4
Visible air break at plug hole
5
Sink or basin with integrated overflow
6
75mm sink waste trap
7
Condensate pump
*
Condensate trap of 75mm already incorporated into the boiler
4
1
100mm
5
22mm Ø
6720644744-07.3Wo
4.4
75mm
min.
6
Fig. 5
Disposal to a waste pipe
Condensate pump
Where “gravity discharge” to an internal termination is not physically
possible, or where very long internal runs would be required to reach a
suitable discharge point, condensate should be removed using a
proprietary condensate pump, of a specification recommended by the
boiler or condensate pump manufacturer.
The pump outlet pipe should discharge to a suitable internal foul water
discharge point such as an internal soil and vent stack, internal kitchen
or bathroom waste pipe, washing machine waste pipe etc. A suitable
permanent connection to the foul waste pipe should be used.
4.4.1 Internal connections
In order to minimise risk of freezing during prolonged cold spells, the
following methods of installing condensate drainage pipe should be
adopted, in order of priority.
4
5
Wherever possible, the condensate drainage pipe should be routed and
terminated so that the condensate drains away from the boiler under
gravity to a suitable internal foul water discharge point such as an
internal soil and vent stack. A suitable permanent connection to the foul
waste pipe should be used.
75mm
min.
1
6
22mm Ø
7
2
1
6720644744-08.3Wo
22mm Ø
Fig. 4
3
Condensate pump disposal
6720644744-06.3Wo
Fig. 6
Disposal to soil vent stack
Alternatively if the first option is not possible an internal kitchen or
bathroom waste pipe, washing machine waste pipe etc. can be used.
Ensure that the condensate drain pipe is connected “down stream” of
the waste trap.
14
Greenstar Ri Compact ErP 6720813282 (2015/07)
Pre-installation
External connections
NOTICE: Freezing conditions
▶ When the position of the boiler prevents internal
routing, we recommend installing a CondenseSure
siphon to significantly reduce the risk of freezing.
▶ Pipe work length should be kept to a minimum and
the route as vertical as possible.
▶ Weather proof insulation must be used, if not using a
CondenseSure siphon.
NOTICE: Condensate waste
▶ Care should be taken when siting a soak-away to
avoid obstructing existing services.
Continued - Key to condensate illustrations
8
PVCu strap-on fitting
9
100mm Ø minimum plastic pipe
10
Drainage holes
11
Limestone chippings
12
Bottom of sealed tube
13
Insulate and increase pipe size
14
Pipe work transition
15
External air break
16
Air gap
17
External rain water pipe into foul water
18
43mm 90° male/female bend
*
Condensate trap of 75mm already incorporated into the boiler
17
1
13
15
14
16
18
Fig. 7
8
6720644744-09.3Wo
4.4.2
Disposal into a rainwater down pipe
Condensate drainage pipe can be run above or below
ground.
Where the pipe terminates over an open drain or gully, the pipe should
terminate below the grating level, but above water level, in order to
minimise “wind chill” at the open end.
The use of a drain cover (such as those used to prevent blockage by
leaves) may offer further protection from wind chill.
Pipe drainage will be improved if the end is cut at 45° as opposed to a
straight cut.
If no other discharge method is possible then the use of an externally run
condensate drainage pipe terminating at a suitable foul water discharge
point, or purpose-designed soak away, may be considered. If this
method is chosen then the following measures should be adopted:
Fitting an external air break
• Refer to figure 7 when a rain water down pipe is used to dispose of
condensate.
• An air break must be installed in the 43mm pipe work, between the
boiler condensate outlet and the drainpipe, outside the property, to
avoid flooding during adverse weather conditions.
1
25mm min.
14
Fig. 8
13
6720644744-10.3Wo
▶ Use a CondenseSure siphon to help prevent the condensate freezing.
▶ The external run be kept as short as possible and not exceed 3
metres.
▶ The pipe should be run internally as far as possible before going
externally and the pipe diameter should be increased to 32mm
before it passes through the wall to the exterior. The pipe should be
insulated using suitable waterproof and weather resistant insulation,
if not using a CondenseSure siphon.
▶ The external pipe should take the shortest and least exposed route to
the discharge point, and should "fall" as steeply as possible away
from the boiler, with no horizontal runs in which condensate might
stand.
▶ The use of fittings, elbows etc. should be kept to a minimum and any
internal “burrs” on cut pipe work should be removed so that the
internal pipe section is as smooth as possible.
External disposal
Condensate soak away
• The condensate drainage pipe may be run above or below the ground
to the soak away. The examples shown on this page run above
ground.
• The soak away must use a 100mm Ø plastic tube with two rows of
three 12mm holes on 25mm centres and 50mm from the bottom of
the tube. The holes must face away from the house.
• The tube must be surrounded by at least 100mm of limestone
chippings to a depth of 400mm.
Minimum hole size for the condensate soak away must be
400mm deep by 300mmØ .
In situations where there are likely to be extremes of temperature or
exposure, the use of a proprietary trace-heating system for external pipe
work, incorporating an external frost thermostat, should be considered.
If such a system is used, the requirement to use 32mm pipe does not
apply. However, all other guidance above and the instructions for the
trace heating system, should be closely followed.
Greenstar Ri Compact ErP 6720813282 (2015/07)
15
Pre-installation
4.5.2 Installation and servicing clearances
Figure 11 shows the minimum space required to install and service the
boiler in a compartment.
NOTICE: Unheated internal areas.
▶ Internal pipe runs in unheated areas such as lofts,
basements and garages should be treated as external
runs and consideration should be given to using a
CondenseSure siphon.
870mm
170/210mm***
20mm*
14
960/1000mm
13
1
25mm min.
7
600mm**
5mm
5mm
6720644744-12.3Wo
200mm
9
1
Fig. 11 Unventilated compartment
[*]
Minimum clearance to removable door
[**] Minimum clearance required for servicing
[***] Height for either 60/100 flue or 80/125 flue
500mm min.
13
4.5.3 Compartments
Follow the requirements of BS6798 and BS5440 Part 2 and note:
14
9
11
10
400mm
min.
12
6720644744-11.2Wo
25mm min.
Fig. 10 Soak away
4.5
290mm
400mm
10
*
Boiler location and clearances
• Minimum clearances must be maintained.
• An access door is required to install, service and maintain the boiler
and any ancillary equipment.
• If fitting the boiler into an airing cupboard use a non-combustible
material to separate the boiler from the airing space.
The material can be perforated up to a maximum hole size of 13mm.
4.5.4 Bathrooms
The appliance may be installed outside the shaded area, and in zone 2.
Additional RCD (Residual Current Device) protection may be required.
Refer to the latest IET wiring regulations.
4.5.1 Installation
This appliance is only suitable for installing internally within a property at
a suitable location onto a fixed, rigid surface at least the same size as the
appliance and capable of supporting the appliance weight.
600m
1
2250mm
The appliance must be installed where:
• An engineer can gain clear and safe access to work on the product or
component, including making adequate provision for visual
inspection of flues in voids.
• The homeowner can gain clear and safe access to the controls,
check, top up or reset the appliance.
• Products in loft cavities must have permanent fixed lighting, a
permanent fixed retractable ladder and a fixed floor area sufficient to
allow access for normal use and servicing directly under and around
the product and between and the access hatch.
m
600m
No surface protection is required against heat transfer
from the appliance.
16
6720646610-62.1Wo
Condensate pump to external disposal
m
600m
m
1
2
2* 2 *
2
1
2
2250mm
Fig. 9
Radius 600mm
6720646608-124.3Wo
Fig. 12 Bathroom installations
Greenstar Ri Compact ErP 6720813282 (2015/07)
Pre-installation
4.6
Plumbing manifold
4.6.1
Connections
Heating System
Gas
22mm compression fittings
22mm compression fitting
Use the fittings supplied in the Hardware literature pack.
3
4
6720646610-04.1Wo
1 2
Fig. 13 Pipe dimensions
3
4
3
1
2
6720646610-03.2Wo
4
Fig. 14 Plumbing manifold
Key to figures 13 & 14:
[1] Condensate 22mmØ - Distance to left edge of case = 33mm
[2] Gas 22mmØ - Distance to left edge of case = 65mm
[3] Primary flow 22mmØ - Distance to left edge of case = 247mm
[4] Primary return 22mmØ - Distance to left edge of case = 312mm
Greenstar Ri Compact ErP 6720813282 (2015/07)
17
Pre-installation
4.7
Flue options
WARNING: Flue systems
▶ Only use Worcester, Bosch approved flue systems,
no other manufacturer’s flue systems have been
approved for use with Worcester appliances.
Horizontal high level telescopic flue assembly
Flue length (mm)
60/100 80/125
202 - 603
N/A
Table 9
Telescopic horizontal flue assembly
CAUTION: Non accessible flue systems:
▶ Where a flue system is not going to be accessible,
provision must be made for service and inspection.
▶ Voids containing concealed flues must have at least
one inspection hatch no less than 300mm square.
▶ Flue joints within the void must not be more than 1.5
metres from the edge of the inspection hatch.
▶ Inspection hatches should be located at changes of
direction.
▶ If this is not possible, bends should be viewable from
both directions.
60/100 mm
130 mm Min
NOTICE: Effective flue lengths:
▶ each 90° bend is equivalent to 2 metres of straight
flue
▶ each 45° bend is equivalent to 1 metre of straight flue
Telescopic horizontal flue assembly
Longer telescopic horizontal flue assembly
Extended horizontal flue
7 733 600 048
60/100
7 719 003 702
7 719 002 430
7 719 002 431
80/125
60/100
80/125
Description
Telescopic horizontal flue assembly
Longer telescopic horizontal flue
assembly
Horizontal high level telescopic flue
kit
Telescopic horizontal flue assembly
Vertical flue assembly
Vertical flue assembly
6720806945-19.1Wo
Flue
60/100
60/100
Flue length (mm)
60/100
80/125
180 - 570 405 - 600
570 - 790
N/A
Table 10
Plume management kits are available for the 60/100
horizontal flue system.
Refer to the manual supplied with the Plume
Management kits for complete installation instructions
Part number
7 716 191 082
7 716 191 171
6720806945-18.1Wo
350 mm - 570 mm
Maximum flue length
(mm)
60/100
80/125
6,000
15,000
Extended horizontal flue
Table 11
Horizontal flue with additional elbow (1 x 90 ° bend)
Table 8 Flue kit part numbers
4.7.1 Flue lengths
The flue systems have different maximum flue lengths
6720806945-20.1Wo
The Greenstar series has the option of two horizontal 60/100 RSF
(telescopic and longer telescopic) and one horizontal 80/125 RSF
(telescopic) flue system and two vertical RSF (60/100 or 80/125) flue
systems:
Refer to the following example Flue options for the maximum flue
lengths.
Horizontal flue with 1 x 90° bend
Horizontal high level flue assembly
Table 12
60/100 mm
18
6720806945-29.1Wo
6720806945-21.1Wo
Horizontal flue with additional elbows (2 x 90 ° bends)
383 mm - 603 mm
130 mm Min
Maximum flue length
(mm)
60/100
80/125
4,000
13,000
Greenstar Ri Compact ErP 6720813282 (2015/07)
Pre-installation
Horizontal flue with 2 x 90° bends
Maximum flue length
(mm)
60/100
80/125
2,000
11,000
Vertical balanced flue assembly
High level horizontal flue
A = 300 mm
6720806945-22.1Wo
B = 500 mm
High level horizontal flue
Vertical balanced flue assembly
6720806945-25.1Wo
Table 13
Maximum flue length
(mm)
60/100
80/125
6,000
15,000
Table 17
Vertical balanced flue with elbow offset (2 x 90 ° bends)
Maximum flue length
(mm)
60/100
80/125
6,000
15,000
Table 14
6720806945-23.1Wo
6720806945-26.1Wo
High level horizontal flue with additional elbows
Maximum flue length
(mm)
60/100
80/125
High level horizontal flue with 2 x 90° bends 4,000
13,000
Vertical balanced flue with 2 x 90° bends
Maximum flue length
(mm)
60/100
80/125
2,000
11,000
Table 18
Vertical balanced flue with elbow offset (2 x 45 ° bends)
Table 15
6720806945-24.1Wo
6720806945-27.1Wo
High level horizontal flue with additional elbows
Vertical balanced flue with 2 x 45° bends
Maximum flue length
(mm)
60/100
80/125
4,000
13,000
Table 19
Maximum flue length
(mm)
60/100
80/125
High level horizontal flue with 3 x 90° bends 2,000
11,000
Table 16
Greenstar Ri Compact ErP 6720813282 (2015/07)
19
Pre-installation
4.8
Flue terminal positions
All measurements in millimetres
2m
1m
2
25
25
104mm
52mm
16
3
1,500
600
13
400
300
500
12
14
2
200
300
1
5
300
300
1,500
4
7
8
600
500
300
600
300 300
6
9
1,200
15
600
18
600
10
16
11
300 300
300
17
300 300
25
300
Boundary Line
06
672
438
95-1
o
3.3W
Fig. 15 Flue terminal positions
NOTICE:
▶ All measurements are the minimum clearances required.
▶ Terminals must be positioned so to avoid combustion products entering the building.
▶ Support the flue at approximately one metre intervals and at a change of direction, use suitable brackets and fittings.
(flue bracket 100mm part number: 7 716 191 177,
flue brackets 100mm x 6 part number: 7 716 191 178,
flue bracket 125mm part number: 7 716 191 179).
Key to illustration
1. 300mm adjacent to a boundary line.
2. The dimension below eaves, gutters, pipes and drains can be
reduced to 25mm, as long as the flue terminal is extended to clear
any overhang. External flue joints must be sealed with suitable silicon
sealant.
3. 1,500mm between a vertical flue terminal and a window or dormer
window.
4. 1,200mm between terminals facing each other.
5. Vertical flue clearance, 300mm adjacent to a boundary line unless it
will cause a nuisance. BS 5440:Part 1 recommends that care is taken
when siting terminal in relation to boundary lines
6. 600m distance to a boundary line, unless it will cause a nuisance. BS
5440:Part 1 recommends that care is taken when siting terminal in
relation to boundary lines.
7. 600mm minimum clearance from a skylight to a vertical flue.
8. Vertical flue clearance, 500mm to non-combustible building
material, and 1,500mm clearance to combustible building material.
9. 300mm above, below and either side of an opening door, air vent or
opening window.
10.600mm diagonally to an opening door, air vent or opening window.
11.300mm to an internal or external corner. This does not apply to
building protrusions less than 450mm.
12.2,000mm below a Velux window, 600mm above or to either side of
the Velux window.
13.400mm from a pitched roof or 500mm in regions with heavy snow
fall.
14.500mm clearance to any vertical structure on a roof, 600mm to
room sealed flue or 1,500 to an open flue.
15.200mm below eaves and 75mm below gutters, pipe and drains.
20
16.The dimension below eaves, balconies and car ports can be reduced
to 25mm, as long as the flue terminal is extended to clear any
overhang. External flue joints must be sealed with suitable silicon
sealant.
17.Flue clearance must be at least 300mm from the ground. Terminal
guards must be fitted if the flue is less than 2 metres from the ground
or if a person could come into contact with the flue terminal.
18.600mm distance to a surface facing a terminal, unless it will cause a
nuisance. BS 5440: Part 1 recommends that care is taken when
siting terminals in relation to surfaces facing a terminal.
Note:
▶ Installations in car ports are not recommended.
▶ The flue cannot be lower than 1,000mm from the top
of a light well due to the build up of combustion
products.
▶ Dimensions from a flue terminal to a fanned air inlet
to be determined by the ventilation equipment
manufacturer.
▶ A flue terminal guard should be fitted over a terminal,
if persons could come into contact with the terminal,
or it could be subject to damage and where the
terminal is less than 2,000mm from the finished floor
level.
Greenstar Ri Compact ErP 6720813282 (2015/07)
Pre-installation
4.9
Plume management terminal positions
All measurements in millimetres
Flue terminal guard 7 716 191 176
±45°
Plume re-direction:
100
600
1
180°
Flue Exhaust
Outlet
10
1,500
Air Intake
±80°
6
200
300
2
200
5
600
300
300
3
150
300
300 300
25
200
300
150
1,200
300
8
150
200
7
150
25
600
9
10
150
4
Boundary Line
672
064
389
5-14
o
.2W
Fig. 16 Plume terminal positions
Maximum and minimum plume management lengths:
▶ A minimum distance of 500mm must be maintained between the plume management outlet and the flue air intake.
▶ The maximum plume management length is 4.5 metres for the appliances detailed on the front of this manual.
▶ The 45° bend is equivalent to 0.75 metres of straight plume management and the 90° bend is equivalent to 1.5 metres.
NOTICE:
▶ All measurements are the minimum clearances required.
▶ Refer to previous page for all concentric flue terminal positions unless the flue position is specified on the figure above “Plume
terminal positions”.
▶ Terminals must be positioned so to avoid combustion products entering the building.
▶ Support the flue at approximately one metre intervals and at a change of direction, use suitable brackets and fittings.
Key to illustration
1. This feature allows some basic plume re-direction options on a
standard telescopic horizontal flue terminal.
300mm minimum clearances to a opening e.g. window.
However the minimum clearances to an opening in the direction that
the plume management is facing, must be increased to 1,500mm.
Where the flue is less than 150mm to a drainpipe and plume redirection is used the deflector should not be directed towards the
drainpipe.
2. 300mm adjacent to a boundary line.
3. Plume Management kit air intake can be reduced to 150mm
providing the flue exhaust outlet is no less than 300mm adjacent to a
boundary line.
4. 1,200mm between terminals facing each other.
5. 600mm distance to a boundary line, unless it will cause a nuisance.
BS 5440:Part 1 recommends that care is taken when siting terminal
in relation to boundary lines.
6. Using a Plume Management kit the air intake measurement can be
reduced to 150mm providing the flue exhaust outlet has a 300mm
clearance. The initial horizontal run from the terminal elbow must
have a minimum 10° fall back, (stop tabs in the elbow prevent less
than 10°) to the appliance for proper disposal of condensate. Any
further horizontal runs can be 3°.
Greenstar Ri Compact ErP 6720813282 (2015/07)
– For details on specific lengths see relevant appliance Technical &
Specification information.
7. Internal/external corners. The air intake clearance can be reduced to
150mm providing the flue exhaust outlet has a 300mm clearance.
8. Clearances no less than 200mm from the lowest point of the balcony
or overhang.
9. 1,200mm from an opening in a car port on the same wall e.g. door or
window leading into the dwelling.
10.600mm distance to a surface facing a terminal, unless it will cause a
nuisance. BS 5440: Part 1 recommends that care is taken when
siting terminals in relation to surfaces facing a terminal.
Note:
▶ Installations in car ports are not recommended.
▶ The flue cannot be lower than 1,000mm from the top
of a light well due to the build up of combustion
products.
▶ Dimensions from a flue terminal to a fanned air inlet
to be determined by the ventilation equipment
manufacturer.
21
Pre-installation
4.9.1
Determine the plume management system length
Flue length versus plume management length
Effective straight flue length with plume management
Minimum plume length (M)
Maximum plume length (M)
500mm
4,500mm
Max flue length (L) 5,000mm
Max flue length (L) 2,200mm
M
L
Note: Measurement “M” plume length
▶ “M” must be a minimum of 500mm and must not
exceed 4,500mm for a 60mm plume management
system used with the horizontal Ø 60/100mm flue.
Minimum plume management length
The minimum plume length should be calculated to ensure that the air
inlet and exhaust have a minimum distance of 500mm between them
(Æ figure 17).
The plume management can be in any configuration, within the
parameters of the plume management installation instructions, as long
as it does not terminate inside the shaded area.
6720803800-09.1Wo
Fig. 18 Effective lengths L and M
2
1
4,500
WARNING: Minimum plume management length.
The minimum distance of 500mm must be maintained
between air inlet and exhaust.
3,500
▶ Do not terminate the plume management inside the
shaded area shown in figure 17
2,500
M
1,500
m
0m
50
50
0m
m
500
500
m
Min
m
0
1,000 2,000 3,000 4,000 5,000 6,000
±80°
L
6720803800-08.1Wo
Fig. 19 Effective flue lengths versus plume management lengths
67206646610-75.1Wo
Fig. 17 Terminal exclusion zone
NOTICE: Cutting the 500mm pipe
If the 500mm plume management pipe kit is cut, an
additional elbow will be required to join the pipework.
▶ The Plume management extension kit contains the
components required for such a configuration.
[Min]
[M]
[L]
[1]
[2]
Minimum plume kit length 500mm
Plume management length allowed (mm)
Effective flue length (mm)
27 & 30 i System Compact ErP data line
Maximum plume length for all boilers
Refer to figure 19 to determine the appropriate plume length (M) versus
the flue length (L).
The lengths for both plume and flue are the effective lengths, which
includes the effective length of any bends plus the straight lengths.
The graph can be used to calculate:
• Effective flue length if a specific effective plume length is required.
• Effective plume length if a specific effective flue length is required.
22
Greenstar Ri Compact ErP 6720813282 (2015/07)
INSTALLATION
5
Before installing the appliance, ensure that the system has been
cleaned as explained on page 11.
INSTALLATION
WARNING: All the previous “Pre-Installation” sections
must be read and the requirements met before starting
boiler or flue installation.
5.1
5.2
WARNING: BEFORE DRILLING,
ENSURE THAT THERE ARE NO PIPES, ELECTRICAL
CABLES, DAMP PROOF COURSES OR OTHER
HAZARDS.
Unpacking the wall frame & ancillary items
CAUTION: LIFTING AND CARRYING
▶ Only lift a manageable weight, or ask for help.
▶ Bend the knee and keep the back straight with feet
apart, when lifting or putting down heavy objects.
▶ DO NOT lift and twist at the same time.
▶ Lift and carry object close to the body.
Safety:
All relevant safety precautions must be undertaken. Protective clothing,
footwear, gloves and safety goggles must be worn as appropriate.
Fixing the mounting plate:
1. Open the top of the carton and remove the water pipes (1) and the
wall mounting frame (2).
2. Remove all the other items to enable the boiler to be unpacked.
1
3
Wall mounting template & flue opening
1.
▶ The boiler template shows the relative positions of the flue and the
top and bottom fixing of the mounting frame.
1. Fix the template to the wall in the desired position.
2. Drill four holes for the wall mounting plate through the template,
utilising shaded mounting holes.
Drill two holes for the bottom fixing screws.
Additional holes may be used if required.
2
2.
4
5
6720646610-63.1Wo
6
6720813282-05.1Wo
Fig. 21 Mounting holes
Fig. 20 Unpacking
[1]
[2]
[3]
[4]
[5]
[6]
Wall mounting plate
Installer pack
ErP Label
Literature pack
Front fascia flap
Bottom panel
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, remove the outer carton. Care
should be taken when releasing the straps. If a sharp implement is
used, ensure the outer carton is not pierced and that the implement
is used in such a way so that it will not cause personal injury.
• All sharp objects must be covered or the blade retracted after use
and put away in a safe place. The wall mounting frame, Installer pack,
template and bottom panel can now be removed. Care should be
taken when lifting the boiler from the base and the proper technique
for safe lifting of any heavy object must be strictly observed.
Additional requirements for roof space installation:
The template has been sized to allow for minimum
clearances of 5mm sides, 200mm base and 30mm
above a 100mm diameter flue elbow.
Rear flue outlet
▶ The drawing opposite shows the boiler template with the flue centre
lines of both the 100mm and 125mm flue systems.
3. Mark centre line of flue to be used (3); the external diameter of the
hole can also be marked if required.
▶ If a 100mm diameter flue is to be used, a 125mm diameter hole 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 flue turret of the 100mm flue has an in-built 3° angle.
▶ If extensions are to be added then the complete flue must rise at an
angle of 3°.
▶ The 125mm diameter flue system will require the flue to rise at an
angle of 3°.
▶ Drill the hole, preferably using a core drill.
Side outlet:
4. Mark from the centre line of the wall template to the wall which the
flue will pass through (4).
▶ Allow for a rise of 52mm per metre length of flue, to give a 3° angle.
▶ Clear any debris from the site.
• The boiler must be unpacked before ascending 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,
insert the boiler into the loft space tilted and slid in on its back.
• Once the appliance is removed from its packaging check the contents
against the packing list.
Greenstar Ri Compact ErP 6720813282 (2015/07)
23
INSTALLATION
4.
1.
3.
3.
4.
4
5
170 mm
5.
6720646610-56.2Wo
2.
3
Fig. 24 Remove packaging
6720813282-01.2Wo
1.
2.
3.
4.
5.
Removing the outer case
▶ Before the case can be remove the control panel must be moved into
the service position, i.e. swivelled down.
Fig. 22 Marking the flue position
5.3
Outer carton
Inner sleeve
Packing base
Protective wrapping
Primary flow and return water pipes
Unpacking the appliance
1. Remove outer carton (1) and place safely away from the working
area.
2. With the outer packaging removed and the inner sleeve (2) can be
removed.
3. Remove the protective wrapping (4) from the boiler.
4. Lie the boiler on the floor and discard the packing base (3).
CAUTION: Hanging the boiler
▶ Remove the plastic bungs fitted to pipes before
hanging the boiler.
1. Unscrew the retained catches securing the fascia.
2. Pull the catches towards you to release the panel.
3. Pull the fascia towards you slightly and then lift and pull forward to
swivel down into the service position.
4. Ensure that the control panel is in the service position i.e. swivelled
down.
5. Release the two screws securing the lower part of the case.
6. Release the spring clips at the top of the boiler.
7. Slide the case off the frame and place safely away from the working
area.
1.
1
2.
3
6720646610-55.1Wo
2
Fig. 23 Remove outer carton
24
Greenstar Ri Compact ErP 6720813282 (2015/07)
INSTALLATION
3.
1.
2.
Wo
4.1
20
67
6
64
0-6
61
5.
4.
Fig. 26 Wall mounting plate
7.
6.
6720646610-05.2Wo
5.4.2 Gas and water connections
▶ The flow and return pipes can be fitted to the boiler before hanging
the boiler on the wall plate.
▶ If there is greater than 600mm clearance below the appliance it is
possible to fit the flow and return pipes, supplied, with the boiler
installed on the wall.
Fig. 25 Releasing the control panel
▶ Remove any packaging within the boiler and the packaging base (3).
5.4
1. Condensate (22mmØ )
2. Gas inlet (22mmØ )
3. Flow (22mmØ which is flared to 28mmØ at one end and can be
removed if required)
4. Return (22mmØ which is flared to 28mmØ at one end and can be
removed if required)
4
3
Boiler connection
CAUTION: Mains supply
▶ Isolate the mains electrical supply before starting any
work and observe all relevant safety precautions.
WARNING: Pipe caps
▶ Caps fitted to pipes must be removed before hanging
the boiler
5.4.1 Wall mounting plate
▶ Remove wall mounting template.
▶ Mount the wall plate to the wall utilising at least one mounting hole in
each of the shaded areas.
Use fittings appropriate for the boiler weight and wall type.
▶ Other mounting holes may be utilised if required.
3
1
2
6720646610-03.2Wo
4
Fig. 27 Plumbing connections
Greenstar Ri Compact ErP 6720813282 (2015/07)
25
INSTALLATION
5.4.3
Hanging the boiler
NOTICE: Lifting the boiler.
▶ Lift the boiler using the handling holes at either side
of the frame.
Do not lift the boiler by the air gas manifold or control
box.
6720646610-07.2Wo
NOTICE: Before hanging the boiler.
▶ If pipes require reducing in length this is best done
before they are fitted to the boiler.
2
System pipes may be run vertically up behind the boiler or below it.
1
The boiler mounting points on the wall frame are indicated in figure 28.
Ensure the wall frame sides are not slightly splayed out after mounting;
move the sides in to allow the boiler to slide on to frame.
Fig. 30 Levelling and securing detail
5.4.4 Condensate connection
Never terminate or discharge into any open source, including; sink, bath,
shower, bidet, toilet etc.
Fig. 28 Wall frame boiler mounting points
2
6720646610-61.1Wo
▶ Lift the boiler onto the wall plate.
▶ Ensure that the boiler is presented slightly higher than the wall frame
so that the slots in the boiler frame slide over the mounting points on
the wall frame.
▶ Lower the boiler onto the wall frame mounting point, ensure that the
wall frame mounting points are fully engaged with the slots in the
boiler frame.
Figure 32 gives the pipe work dimensions with respect to the mounting
surface.
▶ Fit the condensate discharge pipe as far back as possible to the wall
to ensure easy fitting of the boiler bottom panel.
▶ Route the condensate pipe to an appropriate discharge point, refer
to section 4.4.
▶ Plumb up to the wall frame with 22mm pipe.
▶ Ensure that there is enough pipe to insert 25mm into the rubber hose
connector. Attach the discharge hose from the siphon to the
condensate drain pipe.
25mm
Fig. 29 Hanging the boiler on the wall frame
▶ Level vertically using the feet (1) at the bottom rear of the boiler
casing.
▶ Fit retaining screws through the holes (2) in the boiler frame to
secure the boiler.
▶ Make connections to the heating system pipes.
26
6720646610-59.2Wo
6720646610-60.1Wo
NOTICE: Condensate disposal
▶ Follow the recommendations given in section 4.4
“Condensate pipe work” for all condensate disposal
installation.
▶ Ensure that the condensate pipe work falls at least
50mm per metre towards the outlet.
▶ * Do not use solvents, adhesive or lubricant when
pushing the pipe onto the rubber connector.
Fig. 31 Connecting and filling the siphon
Greenstar Ri Compact ErP 6720813282 (2015/07)
INSTALLATION
▶ When the condensate connections are complete, pour
approximately 200 to 250ml of clean water through the inner flue
opening on top of the boiler to fill the siphon.
D
1
23mm
ll
Wa
2
W
6720806944-84.1Wo
Fig. 33 Flue turret centre
WALL
[D]
[W]
170mm
195mm
23mm
149mm
6720646610-09.1Wo
▶ Align the flue turret/vertical adaptor to the appliance flue outlet with
flat facing [3] to the rear of the appliance.
The flue turret/adaptor should be pushed straight down, on to the
appliance.
▶ The three inner flue tube retaining screws [1] are, re-used for the flue
turret and replacement retaining screws [4] supplied with the
adaptor kit are used to secure turret/adaptor to the appliance.
Fig. 32 Pipe work dimensions
5.5
3
3
1
4
Flue turret/adaptor installation
To ease assembly of flue components, apply silicone
lubricant to sealing surfaces.
Refer to the manual supplied with the flue kit for
complete installation instructions.
For plume management effective lengths and the
effective flue lengths, refer to details in section 4.7.
Refer to figures 33 & 34.
▶ Remove the three inner flue tube retaining screws [1].
The inner tube will be held in place in the appliance.
▶ Check the appliance flue seal [2] is correctly seated and apply
silicone grease.
6720806944-85.1Wo
The flue turret/adaptor for the appliance is secured using three retaining
screws (figure 33, item [1]) which come in position on the appliance.
Fig. 34 Flue turret/adaptor connection
Additional notes and reminders:
• Ensure that all cut lengths are square and free from burrs.
• Ensure that the flue and seals are not damaged.
• The flue is sealed when assembled correctly, the components are
pushed fully home and secured.
• The flue is set at an angle of 3° or 52mm per metre length.
• Support the flue at approximately one metre intervals and at a
change of direction, use suitable brackets and fittings
(flue bracket 100mm part number: 7 716 191 177,
flue brackets 100mm x 6 part number: 7 716 191 178,
flue bracket 125mm part number: 7 716 191 179)
2m
1m
52mm
104mm
6720644842-10.1Wo
Fig. 35 Slope for condensate disposal
Greenstar Ri Compact ErP 6720813282 (2015/07)
27
INSTALLATION
NOTICE: The boiler is fitted with a mains power cable.
▶ Should this not be required it can be removed and
replaced with a cable suitable to the installation.
The electrical connector from the PCB must be
re-used. A replacement grommet is provided in the
hardware/literature pack but must be cut to suit the
cable diameter when fitting.
1.
3.
NOTICE: System pump
▶ The system pump must be connected to the
appliance for the pump over-run function.
4.
5.
6.
Fig. 36 Removing the installer access cover
4. Mains in connections
5. Pump connections
6. Mains out connections
230V and 24V Connectors
230V
Electrical - Greenstar wiring (optional accessory)
The additional following information applies:
▶ The mains electrical supply to the boiler and system wiring centre
should where practicable be common, and through either a fused
double pole isolator or a fused three pin plug and unswitched socket.
▶ If separate isolators are used refer to the Greenstar Wiring Centre
Installation Commissioning & Servicing Instructions for further
information
N L
▶ Route the 230 V mains power cable, from the control box, to the
mains isolator next to the boiler.
5A Fuse
230V
OUT
N L
230V
IN
L
N
1
24V
N L
Electrical - standard 230V wiring centre installations
▶ The mains electrical supply to the boiler and system wiring centre
must be common, and through either a fused double pole isolator or
a fused three pin plug and unswitched socket.
▶ The isolator/socket, where practicable, should be situated next to
the boiler.
▶ The isolator must have a minimum of 3mm contact separation in both
poles.
▶ Any system connected to the boiler must not have a separate
electrical supply.
▶ External fuse rating 3A.
2.
6720646610-14.2Wo
CAUTION: Mains electrical supply
▶ Isolate the mains electrical supply before starting
any work and observe all relevant safety precautions.
Access to electrical connections
1. Refer to fig. 36 and remove the screws in the installer access cover.
2. Lift the “Installer access cover”.
3. Remove the cover.
LR
Electrical
1 2
5.6
L
N
2
L
EMS
LR
N
4
5
6
3
6720646610-06.1Wo
Fig. 37 230V and 24V connections
1
2
3
4
5
6
5.6.1
230V mains input
Pump connection
230V output to external controls
Outdoor compensation sensor (not used)
External cut off switch (not used)
EMS BUS connection
Mounting optional plug-in controls only with Greenstar wiring centre (optional accessory
CAUTION: Mains electrical supply
▶ Isolate the mains electrical supply before starting
any work and observe all relevant safety precautions.
NOTICE: Link required
▶ L and LR must be linked when using the Greenstar
wiring centre
Refer the to Programmer/Timer manual for set up and operation of the
unit.
28
Greenstar Ri Compact ErP 6720813282 (2015/07)
INSTALLATION
Removing the blanking plate
The control panel must be released and swung forward slightly to gain
access to the top cover panel, refer to section 7.4 for access to the
control panel.
10.
9.
7.
8.
6720646610-73.2Wo
1. Release the captive screws securing the top cover panel.
2. Remove the cover panel to enable the blanking plate [1] to be
removed.
3. Press your thumbs on the bottom edge of the blanking plate to
release the clips from the slots in the control panel and push up.
4. Pull the blanking plate forward to remove.
1.
Fig. 40 Fitting the Programmer/Timer
2.
3.
Part number
7 733 600 003
7 733 600 001
7 733 600 002
6720646610-71.1Wo
1
4.
Fig. 38 Removing the blanking plate
Fitting the programmer/timer
5. Connect the ribbon cable connector [2] to the socket (3), ensuring
that the cable will fit into the recess (4).
6. Align the clips on the back of the Programmer/Timer with the slots.
Description
Greenstar Comfort
Greenstar Comfort I RF
Greenstar Comfort II RF
Table 20 Controls accessories
New installations
If a new complete heating system is installed in a new build property or it
is a first time installation in an existing property, the heating systems
must conform to current building regulations Part L1a.
The exception to this are single storey, open plan dwellings where the
living area is more than 70% of the total usable floor area. Then this type
of dwelling can be controlled as one zone.
An alternative would be individual electronically controlled TRVs.
For dwellings with a floor area over 150m2, separate time and
temperature control for each zone is required. All radiators must have
TRVs fitted in all rooms except bathrooms and rooms with thermostats.
4
6.
3
6.
While the system is drained down, TRVs must be fitted to all rooms
except the bathrooms and the room with the room thermostat.
5.
6720646610-72.2Wo
2
Existing installations
For boiler replacements on an existing system, it is not necessary to zone
the upstairs and downstairs separately, compliance with the zone
requirements can be achieved by a single room thermostat or
programmable room thermostat.
Fig. 39 Connecting the Programmer/Timer
7. Push the Programmer/Timer in to engage with the slots.
8. Pull the Programmer/Timer down to secure with the clips.
9. Replace the top cover panel.
10.Secure in position with the captive screws.
System wiring centre connection
▶ Connect external controls LIVE supply to terminal L at the 230V OUT
terminal block connection.
▶ Connect external controls LIVE return to terminal LR
▶ Connect external controls NEUTRAL to terminal N at the 230V OUT
terminal block connection.
▶ Refit the control panels.
230V
OUT
EMS
1 2
▶ Re-secure the control panel.
230V
IN
L
LR
N
LR
N L
E
N
L
L
N L
N
L
N L
230V
MAINS
SUPPLY
L NE
Wiring Centre/Junction Box
L N E
SW
6720646610-15.1Wo
External
Pump
N
Fig. 41 System wiring centre
Greenstar Ri Compact ErP 6720813282 (2015/07)
29
COMMISSIONING
Greenstar wiring centre connection
This method is particularly suited to replacing existing boilers where
additional wiring would otherwise be required to a standard system
wiring centre, existing wiring can be used to make the BUS connection.
6
COMMISSIONING
6.1
Pre-commissioning checks
The BUS is a low voltage communication cable and must not be run
alongside 230V cables in order to avoid interference.
The connection to the mains power, pump and valves may differ
depending on the system installed. The following description is a
suggestion on how to carry out the electrical connection of the module.
DANGER: Risk of electric shock
If the heating system is wired in such a way that the
Greenstar wiring centre and the boiler have separate
points of isolation, then:
WARNING: ELECTRIC SHOCK
▶ ISOLATE THE MAINS SUPPLIES BEFORE STARTING
ANY WORK AND OBSERVE ALL RELEVANT SAFETY
PRECAUTIONS
▶ Check that the gas service pipe and water pipes are connected to the
correct position on the manifold.
▶ Attach a warning label to each point of isolation. This
label has to advise that this is not the sole point of
isolation and also has to identify the location of the
other point of isolation.
▶ Electrically isolate the boiler and system
components. Secure against unintentional reconnection and ensure that the power supply is
disconnected.
4
1
25
10
30
3
▶ Check the gas type specified on the identification plate matches that
of the gas supply.
▶ Turn on the main gas supply, check the gas pipe work, connections
and rectify any leaks.
3
M
1
1
5
NOTICE: Do not use solvents, adhesive or lubricant
when pushing the pipe onto the rubber connector.
2
BUS
.....
1 2
BUS
1 2
120/230VAC
.....
N L
6720646610-77.1Wo
120/230VAC
N L
2
Fig. 43
20
15
6720646610-16.2Wo
1. Gas inlet (22mm)
2. Flow (22mm)
3. Return (22mm)
▶ Check that the condensate pipe has been connected to the siphon.
▶ Ensure that the condensate pipe has been inserted at least 25mm
into the elbow
Fig. 42 Example Greenstar wiring centre
Fused spurs
Greenstar wiring centre
Greenstar boiler
External controls
External devices
NOTICE: External devices
▶ External diverter valve(s) and all other 230V parts
are not supplied with the boiler.
▶ Refer to manufacturer's instructions when
connecting external parts to the wiring centre.
▶ Worcester, Bosch Group cannot be held responsible
for wiring errors.
30
25mm
6720646610-17.2Wo
[1]
[2]
[3]
[4]
[5]
Fig. 44 Condensate connection
If the boiler is not to be commissioned immediately then,
after successfully completing all of the checks and any
rectification work, shut off the gas and water supply and
electrically isolate the boiler.
Greenstar Ri Compact ErP 6720813282 (2015/07)
COMMISSIONING
6.2
Filling the system
6.4
Open vented systems:
▶ Ensure all system and boiler drain points are closed.
▶ Open all radiator valves.
▶ Turn on the water supply to the system header tank and allow the
system to fill.
Starting the appliance
CAUTION: RUNNING THE APPLIANCE
▶ Never run the appliance when the appliance/system
is empty or partially filled.
Sealed systems:
▶ Fill the system via a WRAS approved filling loop to 1 bar then turn the
valve anti-clockwise to close.
1
2
Opened vented and sealed systems:
▶ Air will be removed from the boiler heat exchanger via the Auto Air
Vent mounted on top of the heat exchanger.
Sealed systems only:
▶ If required increase system pressure back to 1 bar.
▶ Isolate and remove filling loop connection to system.
6.3
Water treatment
NOTICE: SOFTENED WATER
▶ ARTIFICIALLY SOFTENED WATER MUST NOT BE
USED TO FILL THE CENTRAL HEATING SYSTEM.
ENSURE THAT THE SYSTEM HAS BEEN CLEANED AS ON PAGE 11 OF
THESE INSTRUCTIONS.
3
Inhibitor (Central Heating):
Switching the appliance ON/OFF:
▶
▶
▶
▶
▶ Fill system as described in section 6.2.
▶ Set all controls to maximum.
▶ Record the date when the inhibitor was added to the system.
NOTICE:
▶ The concentration of inhibitor 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 is
not recommended as this can cause problems with
deposits left in the heat exchanger.
Turn on the mains power supply.
Turn on any external controls
Set the thermostatic radiator controls to maximum temperature
Set the clock/programmer to continuously ON and the room
thermostat to maximum temperature
1. The operation and fault Indicator (2) illuminates blue.
1
2
3
Burner ON indicator (Green)
Boiler operation and fault indicator (Blue)
Temperature control
Table 21 Control panel legend
2. Turn the boiler CH temperature control (3) to maximum. The burner
on indicator (4) illuminates GREEN when the burner has lit.
▶ If the boiler fails to light and the boiler goes to flame lock-out, the
BLUE indicator (2) will flash.
▶ Check drain cocks are closed and all radiator valves are open before
adding a suitable inhibitor compatible with aluminium (or combined
inhibitor/anti-freeze if the system is exposed to freezing conditions)
to the heating system water in accordance with the manufacturers
instructions.
The pH value of the system water must be less than 8 or
the appliance guarantee will be invalidated.
max
Fig. 45 Control panel
Flushing (Central Heating):
▶ Switch off the boiler.
▶ Open all drain cocks and drain the system while the appliance is hot.
▶ Close drain cocks and add a suitable flushing agent at the correct
strength for the system condition in accordance with the
manufacturer's instructions.
▶ Run the boiler/system at normal operating temperature for the time
stated by the manufacturer of the flushing agent.
▶ Drain and thoroughly flush the system to remove the flushing agent
and debris.
reset
6720646610-18.1Wo
min
▶ Vent all radiators and the primary side of the hot water cylinder,
tighten when completed and check the system and correct any leaks.
NOTICE: RESET
▶ Do not press the blue Operation/Fault indicator to
reset the boiler.
3. To reset the lockout; turn the boiler thermostat control to minimum,
then past minimum where the control knob will click at reset position.
Wait five seconds then turn to maximum. The boiler will be reset.
6.4.1 Setting the appliance to service mode
For checking the air/gas ratio, inlet pressure and gas rate, the boiler will
have to be switched into maximum and minimum output. The service
mode can be accessed as follows:
1.
2.
3.
4.
5.
6.
Undo the two screw catches.
Pull the catches down to release the control panel.
Pull the bottom of the panel forward.
Lower the control panel to the service position.
Release the two screws securing the Installer access cover.
Remove the installer access cover.
Water treatment
Suitable water treatment products can be obtained from the following
manufacturers:
FERNOX
SENTINEL
0870 601 5000 - www.fernox.com
0800 389 4670 - www.sentinel-solutions.net
Greenstar Ri Compact ErP 6720813282 (2015/07)
31
COMMISSIONING
6.5
Commissioning
Check the following points, and then continue with the commissioning:
▶ That the boiler has been installed in accordance with the installation
instructions.
▶ The integrity of the flue system and flue seals.
▶ The integrity of the boiler combustion circuit and relevant seals.
4.
3.
6.5.1 Checking the gas inlet pressure
The inlet pressure to the appliance must be checked using the following
procedure:
1.
measuring the inlet pressure
2.
5.
1
6720646608-41.1Wo
6.
6720646610-32.2Wo
7.
Fig. 46 Control panel to service position
1. Press the service button for more than five seconds and the boiler will
go into service mode.
2. The red LED will flash when the boiler is in the service mode.
▶ Turn the control knob to “max.” or “min.” for the desired output, the
red LED will flash a five flash sequence for maximum output and a two
flash sequence for minimum output.
The blue light on the fascia will also flash at the same rate
as the red LED
▶ Press the service button again briefly to switch out of service mode
and the LED will stop flashing.
Fig. 48 Inlet pressure test point
▶ Close gas isolation valve.
▶ Slacken the screw in the inlet pressure test point (1) and connect a
manometer.
▶ Open gas isolation valve.
▶ Measure the pressure with the boiler running at maximum, refer to
section 6.4.1.
▶ Check the gas supply working pressure at the gas valve conforms to
values shown in Fig. 49 or Fig. 50 .
1
≈5 s
min
max
6720646610-23.1Wo
2
Fig. 47 Service mode
▶ When the checks have been completed and the boiler is returned to
normal operation, replace the installer access cover and secure with
the screws.
▶ Return the control panel to normal operating position.
32
Greenstar Ri Compact ErP 6720813282 (2015/07)
COMMISSIONING
Gas pressure within the system
Refer to the figures below for natural gas or L.P.G gas pressures.
The pressure at the boiler must not be less than the pressure read at the
meter less 1 mbar for natural gas and less 2.5mbar for L.P.G.
The pressure drop from the meter to the gas valve must not be more than
2.5 mbar for natural gas or more than 4 mbar for L.P.G.
If the pressure drops are greater than shown below, then this would
indicate a problem with the pipe work or connections within the system.
Meter
Natural Gas
< 2.5mbar
difference
Gas Control
valve
19 - 23 mbar
16.5 - 20.5 mbar
Boiler inlet
1 mbar
drop
6.5.2 Checking the gas rate and pressure
▶ The gas rate should be measured at the gas meter after 10 minutes
operation at maximum output.
See Technical data section on page 9 of this manual.
▶ Set the boiler to maximum output (refer to section 6.4.1)
▶ Where a gas meter is not available (e.g. L.P.G.) the CO/CO2 must be
checked to the units shown in the setting of the air/gas ratio.
6.5.3 Gas rating test
▶ Isolate all other appliances.
▶ Set the boiler to maximum output (refer to section 6.4.1).
▶ Ensure that there is no modulating of the fan/gas valve.
▶ Carry out Gas rating procedures as described in “Essential Gas
Safety” third edition on pages 169 to 176.
6.5.4 Checking for leaks during operation
▶ Use an approved leak detector to check all connections for possible
leaks. The product must be certified as a gas leak testing agent.
▶ Do not allow the product to come into contact with electrical wiring.
1.5 mbar
drop
18 - 22 mbar
6720644744-44.2Wo
Fig. 49 Natural gas pressures
Regulator
L.P.G.
< 4.0mbar
difference
Gas Control
valve
32 - 45 mbar
28 - 41 mbar
Boiler inlet
2.5 mbar
drop
1.5 mbar
drop
29.5 - 42.5 mbar
6720644744-45.2Wo
Fig. 50 L.P.G. pressures
NOTICE:
Do not continue commissioning until the correct gas
pressure is achieved.
Greenstar Ri Compact ErP 6720813282 (2015/07)
33
COMMISSIONING
6.6
CO and Combustion checks
The following combustion and flue integrity checks are mandatory from
April 2014 and these values must be recorded on the Benchmark check
list, at the back of this manual.
Once the gas rate and pressure have been confirmed as acceptable then
the CO and combustion checks can be undertaken.
The flow chart is given for guidance, the details of the checks are given in
the following sections:
• Checking flue integrity, refer to section 7.3, page 37
• Flue gas analysis, refer to section 7.6, page 39
START
HERE
Set boiler to
maximum rate.
Zero the analyser
in fresh air.
See notice above
O2 ≥ 20.6%
CO2 < 0.2%
No
< = less than
≥ = greater than
NOTICE: BEFORE CO AND COMBUSTION CHECKS:
▶ Refer to section 6.5.1 and 6.5.2 to verify gas type,
gas inlet pressure, and gas rate.
Visually check the integrity of the whole flue system
and confirm that all the components are correctly
assembled, fixed and supported.
▶ The flue gas analyser must be the correct type as
specified in BS 7967.
Before use the analyser must have been calibrated as
specified by the manufacturer.
The installer must be competent in the use of the
analyser.
Check and zero the analyser in fresh air as specified
by the manufacturer.
▶ The gas valve is factory set and must not be adjusted
during commissioning if found to be out of tolerance,
please contact the Worcester, Bosch Group help line
0330 123 3366.
O2 ≥ 20.6%
CO2 < 0.2%
Flue integrity test
using analyser
Verify flue integrity
No
Check CO and
combustion ratio
at maximum rate
Yes
or equal to
No
CO < 350ppm
CO/CO2 ratio
< 0.004
Yes
Check all seals around the
burner, internal flue seals,
and case seals.
Rectify where necessary.
No
CO < 350ppm
CO/CO2 ratio
< 0.004
Yes
Record values.
Do not adjust
the gas valve.
Turn off boiler and
call Worcester, Bosch
Group help line.
0330 123 3366
Yes
Check CO and combustion
ratio at minimum rate
No
CO < 350ppm
CO/CO2 ratio
< 0.004
Set boiler to
minimum rate.
Yes
Boiler is operating
satisfactorily.
No further action
is required.
6720809056-01.2Wo
Fig. 51 Combustion check flow chart
34
Greenstar Ri Compact ErP 6720813282 (2015/07)
COMMISSIONING
6.7
Finishing commissioning
6.7.1 Replacing the outer case
1. Replace outer casing.
2. Ensure that the securing clips on top of the case are properly located.
3. Tighten bottom two screws (2).
4. Raise the control panel and engage the lugs on the top of the control
panel with the chassis.
6.7.3 Fitting the fascia flap
1. Rotate the hinge to be in-line with the flap and present the flap
assembly up to the fascia.
2. Push the pegs on the hinge into the slots in the front of the fascia and
close the flap.
3. Secure flap to the fascia with the two screws provided.
2.
2.
1.
3.
3.
6720646610-40.1Wo
1.
Fig. 53 Fitting fascia flap
6.7.4 Installing the bottom panel
1. The bottom panel slides onto two ledges either side of the boiler
frame.
2. Hold the panel up against the underside of the boiler, align the tabs
with the slots and slide towards the rear, until there is no more
movement.
3. Ensure that the two catches are fully engaged.
4.
Fig. 52 Fitting case
6.7.2 Securing the control panel
5. Push the control panel in to engage the catches at the bottom of the
panel.
6. Hand-tighten the two screws to secure the panel.
Greenstar Ri Compact ErP 6720813282 (2015/07)
1.
2.
3.
6720646610-22.1Wo
6.
6720646610-20.2Wo
5.
Fig. 54 Bottom panel installation
35
Service and spares
6.7.5 Handover
▶ Complete the Benchmark Gas Boiler Commissioning Checklist.
7
The Benchmark Checklist can be found at the rear of
these instructions.
▶ Open the fascia flap by hinging the flap downwards using the curved
hand hold in the centre of the flap.
▶ Set up the controls and show the customer how to operate all the
controls shown in the User Guide plus any external controls.
▶ Instruct the customer on:
– how to use the TRVs.
– how to reset the boiler.
▶ Show the customer the fault finding information in the User guide.
▶ Show the customer where the serial number/boiler information is
when they call in with a problem (Benchmark checklist at the rear of
the manual).
▶ Give the customer details of how to contact the installer/gas
emergency numbers.
▶ Show the customer how to safely isolate the boiler
▶ Advise the customer where they can find information on the
Worcester, Bosch Group website.
▶ Advise the customer that the varying external temperatures will
affect the output of the boiler.
▶ Ensure that the User Guide and Installation, Commissioning and
Service manual, with the Benchmark checklist and service record, is
left with the boiler or homeowner.
▶ If the appliance is unused and exposed to freezing conditions, shut
off all the mains supplies and drain the system and boiler, label
accordingly.
6.7.6 Boiler guarantee
This boiler has a guarantee against faulty materials or workmanship for a
period from the date of installation subject to the following terms and
conditions:
• During the period of this guarantee any components of the boiler
which are proven to be faulty or defective in manufacture will be
exchanged or repaired free of charge by Bosch Thermotechnology
Ltd.
• The householder may be asked to prove the date of installation, that
the boiler was correctly commissioned and, where appropriate, the
first year's service has been carried out to the satisfaction of Bosch
Thermotechnology Ltd., when requested. These should be
documented as a part of the Benchmark Checklist.
• The boiler has been used only for the normal domestic purposes for
which it was designed.
This guarantee does not affect your statutory rights.
Guarantee registration
Your Greenstar appliance carries a guarantee against faulty material or
manufacture subject to Terms and Conditions.
Guarantee Registration can be completed:
• On-line
– You can register on our website:
www.worcester-bosch.co.uk/guarantee
• By phone
– You can register by ringing 0330 123 2552
• By post
– Please send your completed form to:
Worcester, Bosch Group, Cotswold Way, Warndon, Worcester,
WR4 9SW.
Service and spares
CAUTION: Mains supplies
▶ Turn off the gas supply and isolate the electrical
mains supply before starting any work on the
appliance and observe all relevant safety
precautions.
CAUTION: Component replacement:
▶ After replacement of a gas related component,
where a gasket or seal has been disturbed or
replaced, check for gas tightness using a gas sniffer/
analyser.
▶ Also after re-assembly, carry out the following
checks:
Fan pressure in section 7.5,
Flue gas analysis in section 7.6.
NOTICE: Service work
▶ Service work must be carried out by a competent
engineer, such as Gas Safe registered personnel!
NOTICE: FLUE GAS ANALYSER
▶ Service work must not be attempted if a flue gas
analyser is not available.
• To ensure continued efficient operation the appliance must be
checked at regular interval.
• The frequency of servicing will depend upon the particular
installation conditions and usage, however normally an annual
service is recommended.
• The extent of the service work required by the appliance is
determined by the operating condition of the appliance when tested
by qualified engineers.
• After each service, the service interval record sheet at the rear of this
manual, must be completed.
7.1
Inspection and service
1. Check that the terminal and terminal guard, if fitted, are
unobstructed 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 joints and connections in the system and remake any that
show signs of leakage.
Refill and re-pressurise if applicable as described in the
commissioning section.
4. Operate the appliance and take note of any irregularities.
Refer to the fault finding pages for rectification procedure.
7.1.1 Draining the boiler
Many of the tasks in this section require that the boiler be isolated and
drained.
1. Connect a suitable hose firmly to the drain point and run the hose
outside to a suitable point or container.
2. Turn the drain valve a quarter turn anti-clockwise to open the drain.
Turn the valve firmly clockwise to close.
To read the full Terms & Conditions please visit us on-line at
www.worcester-bosch.co.uk/guarantee.
Your statutory rights are not affected by the manufacturer’s guarantee.
36
Greenstar Ri Compact ErP 6720813282 (2015/07)
Service and spares
7.2
Checking the gas inlet pressure
7.4
NOTICE:
▶ Do not continue with the other checks if the correct
gas pressure can not be achieved.
▶ Check that the gas working pressures in the system conform to the
figures shown in section 6.5.1:
7.3
Checking flue integrity
The integrity of the flue system and performance of the boiler can be
checked via the flue turret sample points.
Flue gas sample point
Air inlet sample point
Component access
To remove the outer case, to gain access to the components:
1.
2.
3.
4.
5.
6.
7.
8.
Remove the bottom panel.
Release the two screws securing the control panel.
Pull down to release the two catches.
Pull the bottom of the control panel forward and down.
Lower the control panel into the service position
Undo and remove the two bottom retaining screws.
Lift the spring clips on top of the case.
Pull the case towards you to remove.
1
2
Table 22 Key to figure 55
3.
1
2
2
1
1.
2.
1
2
6720643895-67.1Wo
Fig. 55 Flue turret test points
With the boiler case on and the boiler running at maximum output (refer
to section 7.5.1 “Setting the boiler to maximum”).
▶ Ensure that the probe reaches the centre of the air intake, adjust the
cone on the probe so that it seals the sample point and correctly
positions the end of the probe.
▶ Insert the analyser probe into the air intake sample point.
▶ Allow the readings to stabilise and check that:
– O2 is equal to, or greater than 20.6%.
– CO2 is less than 0.2%
▶ If the readings are outside these limits then this indicates that there
is a problem with the flue system or combustion circuit, e.g. missing
or dislodged seals.
6.
7.
1
4.
6720646610-43.2Wo
5.
6720646610-33.1Wo
Fig. 57 Component access
Fig. 56 Flue integrity test
Greenstar Ri Compact ErP 6720813282 (2015/07)
37
Service and spares
7.5
Fan pressure test
7.5.2
This test is to determine if the heat cell requires cleaning
or attention.
Fan pressure
1
Before setting the boiler to maximum output for the fan pressure test,
refer to figure 59:
▶
▶
▶
▶
Switch the boiler off.
Remove the combustion air intake pipe (1).
Remove the fan pressure test point cover (2).
Connect the digital manometer pipe (3) to the fan pressure test point
(4).
▶ Replace the combustion air intake pipe.
▶ Switch the boiler on.
▶ Set the boiler to maximum output.
6720646610-34.2Wo
7.5.1 Setting the boiler to maximum
To set the boiler to maximum output:
▶ With the Control panel in the service position, press the Service
mode button (1) for more than five seconds.
– The red L.E.D. (2) will flash.
– Turn the control knob to “max” and boiler will go to maximum
output, the red L.E.D. will give a five flash sequence.
▶ Turn the central heating control to maximum to ensure that the fan/
gas valve do not modulate.
4
3
2
Fig. 59 Fan pressure test point
NOTICE: Fan pressure test
▶ The boiler must be run at maximum output for the
fan pressure test and flue gas analysis.
With the combustion air intake pipe fitted and the boiler running at
maximum output, measure the fan pressure:
1
▶ The pressure will read negative, refer to the chart in figure 60 below.
FAN PRESSURE TEST
≈5 s
Clean the Heat Ex.
2
Heat Ex. ok
NG Boilers
27Ri:
-3.3
30Ri:
0
-1
-2
-3
-5
-4
mbar
-6
-7
-8
-3
-5
-4
mbar
-6
-7
-8
LPG Boilers
27Ri:
-3.3
30Ri:
-3.8
min
Fig. 58 Setting boiler to maximum
max
6720646610-23.1Wo
0
-1
-2
6720646610-65.2Wo
-3.8
Fig. 60 Fan pressure readings
▶ If the manometer reading is in the white area of the chart the heat
exchanger/exhaust path/siphon does not require attention.
▶ If the manometer reading is in the black area of the chart then carry
out the following checks:
– Check that the siphon is not blocked.
– Check the exhaust paths for restrictions.
– Clean the heat exchanger with a suitable cleaning tool, refer to
section 7.7 - Cleaning the heat exchanger.
▶ Re-check the fan pressure readings.
If the boiler, after completing the above checks, fails the fan pressure
test then contact Worcester, Bosch Group for advice.
▶
▶
▶
▶
38
After the measurements are taken switch the boiler off.
Remove the combustion air intake pipe.
Disconnect the manometer and replace the test point cover.
Replace the combustion air intake pipe.
Greenstar Ri Compact ErP 6720813282 (2015/07)
Service and spares
7.6
Flue gas analysis
NOTICE: Combustion testing
▶ Combustion testing must be carried out by a
competent person. Testing must not be attempted
unless the person carrying out the combustion check
is equipped with a Combustion Analyser conforming
to BS 7927 and is competent in its use.
1
Combustion test
▶ Connect the flue gas analyser to the flue gas sampling point (1) as
shown in the figure below.
▶ Ensure that the probe reaches the centre of the flue gas exhaust,
adjust the cone on the probe so that it seals the sample point and
correctly positions the end of the probe.
▶ With the Control panel in the service position, press the Service
mode button (1) for more than five seconds.
– The red L.E.D. (2) will flash.
– Turn the control knob to “max” and the boiler will go to maximum
output and the L.E.D. will flash in a five flash sequence.
1
≈5 s
2
6720646610-35.1Wo
NOTICE: Gas inlet pressure
▶ Ensure that the gas inlet pressure has been checked
and is satisfactory, refer to section 6.5.1
Fig. 62 Combustion test
▶ Check CO is less than 200ppm.
▶ Turn the control knob to “min” and the boiler will go to minimum
output.
– The LED will flash in a two flash sequence.
▶ Check that the CO is less than 200ppm.
▶ Return the boiler to maximum output, by turning the control knob to
“max”, and re-check the CO/CO2.
– The LED will flash in a five flash sequence.
▶ If correct, press the Service mode button once and the boiler will
return to normal operation, the LED will not be illuminated.
▶ Re-assemble and refit boiler case.
min
max
6720646610-23.1Wo
NOTICE: Minimum CO2
▶ The minimum CO2 reading must be at least 0.2 lower
that the maximum CO2 reading.
Fig. 61 Setting boiler to maximum
▶ Run the boiler at maximum output for at least 10 minutes.
▶ Check the CO/CO2 readings against the information in table 23 & 24.
NG Appliances
Output
Maximum setting
(measured after
10 minutes
Minimum setting
(measured after
10 minutes
CO2 Reading
Between 8.5 and 10.1.
CO Reading
Less than 200ppm
A minimum 0.2 lower than the Less than 50ppm
maximum reading taken but
above 7.5%
Table 23 NG CO/CO2 settings
LPG Appliances
Output
Maximum setting
(measured after
10 minutes
Minimum setting
(measured after
10 minutes
CO2 Reading
Between 9.8 and 11.1.
CO Reading
Less than 200ppm
A minimum 0.2 lower than the Less than 50ppm
maximum reading taken but
above 8.5%
Table 24 LPG CO/CO2 settings
Example of a Natural Gas appliance reading:
• Maximum CO2 reading taken = 9.5%
• The minimum CO2 reading must be between 8.0% and 9.3%
(a minimum 0.2 lower than the maximum reading of 9.5%)
If the boiler fails the combustion test, check:
1. Air intake for restriction
2. Cleanliness of the heat cell, condition of the burner, plus blockages in
the condensate disposal.
Greenstar Ri Compact ErP 6720813282 (2015/07)
39
Service and spares
Cleaning the heat exchanger
Refitting the siphon
▶ Fill siphon with 200 to 250 millilitres of water.
NOTICE: Gaskets and seals
▶ Replace the burner and electrode assembly gaskets
and the Flueway sump seal after cleaning the heat
exchanger.
Do not attempt the cleaning procedure unless new
gaskets and seals are available.
1. Push the siphon up onto the sump assembly until it fully engages with
the sump connection.
NOTICE: Do not use solvents, adhesive or lubricant
when pushing the pipe onto the rubber connector.
There is an optional tool available to assist in cleaning the
heat exchanger,
part number 7 746 901 479
2. Twist the siphon to the left to secure the bayonet connection.
3. Push the discharge hose, onto condensate pipe so that at least
25mm of the condensate pipe is inserted into the discharge hose.
The following items will have to be removed to gain access to the heat
exchanger for cleaning:
▶ Lower the control panel into the service position.
▶ Remove the case.
▶ Disconnect electrical wires to the fan, ignition transformer, spark
electrodes, flue overheat thermostat, main heat exchanger
temperature sensor and flow pipe temperature sensor.
▶ Flueway
▶ Fan assembly
▶ Ignition transformer
▶ Spark electrode assembly
▶ Burner housing, burner and gasket
Refer to sections 7.8.10 to 7.8.14 for instructions on how to remove
the items to gain access to the heat exchanger channels so that the heat
exchanger can be cleaned
2.
1.
3.
Fig. 64 Fitting siphon
CAUTION: Component replacement:
▶ After replacement of a gas related component,
where a gasket or seal has been disturbed or
replaced, check for gas tightness using a gas sniffer/
analyser.
▶ Also after re-assembly, carry out the following
checks:
Fan pressure in section 7.5,
Flue gas analysis in section 7.6,
7.7.1 Cleaning the siphon
▶ The Control panel will have to be removed to gain access to the
siphon for removal and cleaning, refer to section 7.8.3
1. Disconnect the discharge hose from the condensate pipe.
2. Rotate the siphon body clockwise to release the bayonet connection.
3. Pull the siphon body down and away from the boiler.
▶ Empty the water and debris into a suitable container.
▶ Visually inspect the siphon to ensure that it is clean and free from
debris.
▶ Fill the siphon with 200 to 250ml of clean water before refitting.
6720646610-69.1Wo
7.7
7.7.2
Cleaning the primary heat exchanger
Single bladed tool and brush
Use a suitable blade to clean the heat exchanger channels.
There is an optional tool available to clean the heat exchanger, part
number 7 746 901 479.
2.
3.
1.
6720646610-48.1Wo
1
2
Fig. 63 Cleaning the siphon
6720803800-02.1Wo
Fig. 65 Single-bladed cleaning tool and brush
▶ Visually inspect the inside of the heat exchanger by shining a torch
from the top down into the sump area.
▶ When there is little or no light visible this would suggest that those
channel(s) are restricted.
▶ It is recommended that all channels are cleaned.
▶ Remove the siphon and place a suitable container under the outlet to
catch the water and debris.
▶ Protect the controller from water ingress.
40
Greenstar Ri Compact ErP 6720813282 (2015/07)
Service and spares
To clean the rear and middle channel of the heat exchanger
1. Orient the cleaning tool (2) as shown in figure 66 and insert the tool
into the rear or middle channels for cleaning.
2. Move the cleaning tool handle in an up and down motion, using the
front edge of the heat exchanger as a pivot, to clean the channel.
On completion of the heat exchanger cleaning and reassembly, perform the fan pressure test as described in
section 7.5.2
1
2.
1.
6720803800-03.1Wo
Fig. 66 Heat exchanger cleaning tool
To clean the front channel of the heat exchanger
3. Orient the cleaning tool (2) as shown in figure 67 and insert the tool
into the front channel for cleaning.
4. Move the cleaning tool handle in an up and down motion, using the
front edge of the heat exchanger as a pivot, to clean the channel.
▶ Use the brush to dislodge the debris and pour water down the
channels to flush out the debris.
1
4.
6720803800-04.1Wo
3.
Fig. 67 Cleaning the front channels
Greenstar Ri Compact ErP 6720813282 (2015/07)
41
Service and spares
7.8
Replacement of parts
CAUTION: Mains supplies:
▶ Turn off the gas supply and isolate the mains supplies
before starting any work on the boiler and observe all
relevant safety precautions.
3.
CAUTION: Component replacement:
▶ Replace the burner housing gasket and the Flueway
sump seal when re-assembling the heat exchanger.
Do not reassembly the heat exchanger and Flueway
until new gaskets and seals are available.
▶ After replacement of a gas related component,
where a gasket or seal has been disturbed or
replaced, check for gas tightness using a gas sniffer/
analyser.
▶ On re-assembly check all affected seals for cracks,
hardness and deterioration.
If damaged or in any doubt the seal must be replaced.
▶ Also after re-assembly, carry out the following
checks:
Fan pressure in section 7.5,
Flue gas analysis in section 7.6.
1.
2.
6.
7.8.1 Removing the outer case
Remove the bottom panel:
1. Push in the two catches to release.
2. Lower the bottom panel slightly.
3. Slide forward to remove.
7.
5.
4.
Fig. 68 Bottom panel
To remove the outer case, to gain access to the components:
1.
2.
3.
4.
5.
6.
7.
42
Release the two screws securing the control panel.
Pull down to release the two catches.
Pull the bottom of the control panel forward and down.
Lower the control panel into the service position
Undo and remove the two bottom retaining screws.
Lift the spring clips on top of the case.
Pull the case towards you to remove.
6720646610-43.2Wo
1.
6720646610-49.2Wo
3.
2.
Fig. 69 Removing outer case
7.8.2 Draining the boiler
Many of the tasks in this section require that the boiler be isolated and
drained.
1. Connect a suitable hose firmly to the drain point and run the hose
outside to a suitable point or container.
2. Turn the drain valve a quarter turn anti-clockwise to open the drain.
Turn the valve firmly clockwise to close.
Greenstar Ri Compact ErP 6720813282 (2015/07)
Service and spares
7.8.3 Siphon removal
The Control panel will have to be removed to gain access to the siphon
for cleaning or removal.
Access to the siphon
The Control panel must be removed from the hinges to give enough
access to fit the siphon.
1. Swivel the control panel down to an angle of approximately 60° from
the horizontal.
2. Pull the Control panel up to release the panel from the hinges.
1.
2.
6720646610-10.1Wo
▶ Allow the Control panel to hang on the cables and support strap.
7.8.4 Primary sensor (CH NTC)
▶ Remove the combustion air inlet pipe from the pre-mix unit, rotate
anti-clockwise and pull away from the fan assembly.
▶ Ease the gas pipe to the left.
▶ Disconnect the electrical connectors to the sensor.
▶ Remove the sensor by pulling forward.
▶ Replace the sensor onto the flow pipe, ensure that the sensor
element is in contact with the pipe and that the clip is secure.
▶ Connect the lead to the sensor.
▶ Re-fit the combustion air inlet pipe to the pre-mix unit.
Fig. 70 Control panel removal
6720646608-96.1Wo
1. Disconnect the discharge hose from the siphon.
2. Rotate the siphon body clockwise to release the bayonet connection.
3. Pull the siphon body down and away from the boiler.
2.
1.
Fig. 71 Siphon removal
7.8.5 “Maximum safety sensor”
▶ Disconnect the electrical connectors to the “Maximum safety
sensor”.
1. Remove the screw securing the sensor.
2. Remove the sensor from the heat exchanger.
▶ When replacing the sensor, ensure that the assembly is properly
located on the orientation pin.
▶ The control panel can be refitted by holding the panel at
approximately 60° to the horizontal and engaging the panel into the
hinge slots.
2.
1.
6720646608-97.2Wo
3.
6720646610-48.1Wo
Fig. 72 Primary sensor
Fig. 73 Overheat sensor
Greenstar Ri Compact ErP 6720813282 (2015/07)
43
Service and spares
7.8.6 Flue overheat thermostat
▶ Disconnect the lead to the thermostat.
To remove and replace the Air pressure switch:
▶ Remove the two screws [5] retaining the switch to the bracket [4].
▶ Disconnect the tube [3] from the switch.
▶ Fit the new switch to the bracket and secure with the two screws [5].
▶ Re-connect the tube [3] to the switch, ensuring routing is looped as
in figure 75.
▶ Re-connect the connectors to the terminals [2].
▶ Align the Air pressure switch bracket [4] over the two screws [1] and
slide the assembly to the right, tighten the screws to secure.
Take care not to damage the housing when removing the
thermostat.
6720646608-98.1Wo
▶ Using a small screwdriver, gently prise the thermostat from the
housing taking care not to damage the housing or grommet.
Fig. 74 Flue overheat thermostat
▶ To replace, push the thermostat and new grommet gently back into
the opening until contact with the locating ridge is felt.
▶ The Flueway will have to be removed if the thermostat falls into the
housing, refer to section 7.8.10.
7.8.7
Air Pressure Switch
5
6720813276-07.1Wo
Fig. 76
7.8.8 Auto air vent
Ensure that the boiler has been fully drained.
1. Remove the spring clip completely.
2. Lift the air vent out of the housing and remove.
NOTICE: Air Pressure Switch
▶ Ensure that the tube is reconnected to the Air
Pressure Switch
To remove the Air pressure switch assembly:
▶ Slacken the two screws [1] but do not remove
▶ Remove the connector from the terminals [2]
▶ Disconnect the tube from the flue pipe
▶ Slide the assemble to left to release the retaining bracket
▶ Remove the assembly
2.
1.
4
6720646608-99.1Wo
1
Fig. 77 Auto air vent
When re-assembling ensure that the “O” ring is fitted to the Auto air vent
and NOT the heat exchanger, otherwise the Air vent will be difficult to fit.
2
Apply silicone grease to the “O” ring to ease assembly.
6720813276-06.1Wo
3
Fig. 75
44
Greenstar Ri Compact ErP 6720813282 (2015/07)
Service and spares
7.8.9 Gas valve
▶ Isolate the mains electrical supply and the gas supply at the boiler gas
cock.
▶ Remove the combustion air inlet pipe.
▶ Disconnect the electrical connector from the valve
1.
2.
3.
4.
5.
2. Using a screwdriver under the tabs (1) next to the screws, lever the
Flueway up to clear the seal and pull the Flueway forward.
3. Rotate the exhaust pipe to the left and pull the Flueway down to
separate from the exhaust pipe.
Remove the gas pipe from the top of the valve.
Undo the bottom gas pipe connection.
Remove the screw securing the gas valve.
Lift the gas valve to clear the bottom gas connection.
Pull the gas valve forward out of the boiler.
1.
3.
5.
2.
1
2.
1
6720646608-83.3Wo
4.
6720813267-04.1Wo
3.
1.
Fig. 78 Gas valve
Fig. 79 Flueway removal
▶ When fitting the new valve, start with the bottom gas connection and
tighten by hand before making any other connections to the valve.
▶ Secure the valve with the screw.
▶ Tighten the bottom connection firmly with a suitable spanner.
▶ Connect the top gas pipe.
▶ Reconnect the electrical connector.
▶ Open the boiler gas isolator.
▶ Check all the gas connections for gas tightness.
Remove the used seal
4. Discard the “tubular” seal [2] or the “moulded” seal [3], depending
on which type is fitted and replace with the seal that is provided.
7.8.10 Fan assembly
CAUTION: Component replacement:
▶ After replacement of a gas related component,
where a gasket or seal has been disturbed or
replaced, check for gas tightness using a gas sniffer/
analyser.
▶ On re-assembly check all affected seals for cracks,
hardness and deterioration.
If damaged or in any doubt the seal must be replaced.
▶ Also after re-assembly, carry out the following
checks:
Fan pressure in section 7.5,
Flue gas analysis in section 7.6.
2
4.
3
To remove the fan the following components will have to be removed
first:
• Flueway
• Combustion air inlet pipe and gas pipe
Flueway removal
CAUTION: Flueway sump seal.
▶ Replace the sump seal every time that the Flueway to
sump connection is disturbed.
6720803800-12.1Wo
Fig. 80 Remove the existing seal
Fitting the “moulded” sump seal
1. Place the seal [3] on the sump interface.
2. Ensure that the lug flaps are mounted onto the sump lugs.
Before fitting the Flueway:
▶ Ensure that the seal is clean and free from debris.
1. Release the two screws securing the Flueway to the sump.
Greenstar Ri Compact ErP 6720813282 (2015/07)
45
Service and spares
Fan removal
3. Rotate the exhaust pipe anti-clockwise to gain access to the fan
assembly securing screws.
4. Support the weight of the fan and remove the two screw securing the
fan.
6720803800-07.1Wo
1.
2.
4.
Fitting the “tubular” sump seal
3. Fit the Flueway sump seal [2] into the Flueway.
Ensure the seal is fitted fully into the recess in the underside of the
Flueway.
Before fitting the Flueaway:
▶ Ensure that the seal is clean and free of debris.
6720646608-85.1Wo
Fig. 81 Moulded style seal
3.
Fig. 84 Fan removal 1
5. Rotate the exhaust pipe clockwise.
6. Pull the fan assembly away from the mount, lift and rotate the fan
towards you. Ensure that the front of the fan clears the left hand front
castellated nut securing the burner housing.
7. Pull the gas pipe off the fan body connection, the pipe is secured by
the interference fit between the pipe and connector.
8. Remove the electrical connector and earth from the fan.
5.
6720803800-13.1Wo
6.
Fig. 82 Tubular style sump seal
Combustion air inlet and gas pipe disconnection
1. Rotate the combustion air inlet pipe anti-clockwise to release from
the fan assembly and pull away from the fan.
2. Undo the top gas pipe connector at the gas valve.
7.
1.
Fig. 85 Fan removal 2
6720646608-84.1Wo
2.
6720646608-86.1Wo
5.
Fig. 83 Combustion air inlet pipe removal
46
Greenstar Ri Compact ErP 6720813282 (2015/07)
Service and spares
2.
▶ If necessary, clean the spark electrodes and ionisation probe with a
plastic scouring pad.
▶ Re-assemble with a new electrode gasket (1),
1
2.
1.
2
1.
6720646608-87.1Wo
3
6720646608-89.1Wo
7.8.11 Air/gas flap valve assembly
1. Remove the single screw securing the air/gas flap valve assembly.
2. Pull the flap assembly away from the housing.
Fig. 88 Electrode assembly
Fig. 86 Air/gas flap valve
7.8.14 Burner housing, burner/ gasket
7.8.12 Ignition transformer
To remove the ignition transformer
▶ Isolate the boiler electrically.
▶ Remove the combustion air inlet pipe.
▶ Ensure that the harness wires are disconnected from the
transformer.
▶ Remove the electrode cables.
▶ Lift the transformer from the retaining clip.
The front two bolts retaining the burner housing are NOT
captive and will drop out when the nuts are removed.
To remove the burner housing.
1. Release and remove the four spring pins from the castellated nuts.
2. Undo the front two castellated nuts/springs and remove and retain
along with the front two bolts (1).
Slacken the two rear castellated nuts/springs, but do not remove.
2.
1.
1
6720813276-08.1Wo
6720646608-90.1Wo
3.
Fig. 87 Ignition transformer
7.8.13 Electrode assembly
CAUTION: Component replacement:
▶ After replacement of a gas related component, where
a gasket or seal has been disturbed or replaced,
check for gas tightness using a gas sniffer/analyser.
▶ Also after re-assembly, carry out the following
checks:
Fan pressure in section 7.5,
Flue gas analysis in section 7.6.
Fig. 89 Burner housing
3. Pull the burner housing up and forward to remove.
To remove the burner and gasket.
1. Lift the gasket (1) and burner mesh (2) from the heat exchanger
body.
▶ When fitting the burner, ensure that the convex side of the burner
faces down into the heat exchanger.
▶ Always fit a new gasket (1) when re-assembling the heat exchanger.
To remove the spark electrode assembly:
1. Undo and remove the two nuts securing the electrode assembly
2. Rotate the electrode assembly down and forward to remove from the
Heat exchanger.
▶ Inspect the spark electrodes (2), ionisation probe (3) and ceramics
for signs of contamination or damage, replace as necessary.
Greenstar Ri Compact ErP 6720813282 (2015/07)
47
Service and spares
7.8.15 Heat exchanger
1
Before removal:
▶ Isolate the electrical power to the boiler.
▶ Drain the boiler.
Heat exchanger disconnection
1. Undo the flow and return connections.
2. Pull both the flow and return pipes away from the heat exchanger.
6720646608-91.1Wo
▶ Replace the fibre washers (1) when replacing the heat exchanger.
2
2.
1.
Fig. 90 Burner and gasket
Tightening down the burner housing
1. Tighten the burner housing castellated nuts [1] down gradually and
evenly and in a rotating sequence.
2. Tighten the castellated nuts down until they “bottom out” on the heat
cell, as indicated by the arrow on the figure below.
1
1.
1
5
6720646608-93.1Wo
▶ Fit the spring clip [2] to secure the castellated nuts, if the hole does
not line up with a space, back the nut off slightly until the hole does
align with the slot.
2
3
Fig. 92 Heat exchanger disconnection
4
1.
6720646610-74.1Wo
2.
Fig. 91 Castellated nuts
[1]
[2]
[3]
[4]
[5]
48
Castellated nut
Spring clip
Washer
Burner housing bolts
Tension springs
Heat exchanger removal
▶ Ensure any electrical wires or connectors are removed.
▶ Remove the Auto air vent (refer to section 7.8.8) to ease removal of
the heat exchanger
1.
2.
3.
4.
Unscrew the heat exchanger retaining nut.
Remove the heat exchanger retaining nut.
Remove the two screws securing the heat exchanger to the air box.
Lift the heat exchanger until the lower connection clears the hole in
the air box.
5. Pull the heat exchanger towards you to remove.
CAUTION: Component replacement:
▶ After replacement of a gas related component,
where a gasket or seal has been disturbed or
replaced, check for gas tightness using a gas sniffer/
analyser.
▶ Also after re-assembly, carry out the following
checks:
Fan pressure in section 7.5,
Flue gas analysis in section 7.6.
▶ Re-assemble in the reverse order.
Greenstar Ri Compact ErP 6720813282 (2015/07)
Service and spares
4.
3.
3.
1.
2.
5.
4.
1.
Fig. 95 Removing the control panel
6720646610-36.2Wo
2.
6720646610-45.1Wo
5.
1. Release the screws securing the access cover.
2. Lift the cover.
3. Pull the cover forward to remove.
1.
Fig. 93 Heat exchanger removal
7.8.16 Boiler return sensor (NTC)
▶ Disconnect the electrical connectors from the sensor.
▶ Unclip the sensor from the pipe.
3.
6720646610-31.2Wo
2.
6720646610-44.1Wo
Fig. 96 Removing the installer access cover
1. Unplug the cables.
2. Pinch in the sides of the connector block to release.
3. Lift the complete connector block out.
3.
Fig. 94 Boiler return sensor
2.
7.8.17 Access to boiler control components
▶ Push in the catches and remove the bottom panel.
1.
Release the two screws securing the control panel.
Pull down to release the two catches.
Pull the bottom of the control panel forward.
Swivel the control panel down.
6720646610-46.2Wo
1.
2.
3.
4.
2.
Fig. 97 Cable removal
1. Release the screws retaining the cover.
2. Lift the cover to remove.
Greenstar Ri Compact ErP 6720813282 (2015/07)
49
Service and spares
1.
2.
2
1
4
3
8
7
6
6720646610-47.1Wo
5
Fig. 98 Control panel detail
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
Mains voltage cable outlet
Fuse holder
HCM - Heating Control Module
Spare fuse
Low voltage cable outlet
Low voltage connectors
Diagnostic port (for Worcester Bosch service engineers only)
Mains voltage and earth connectors
PCB fuse
The fuse and holder (2) are located next to the high voltage connectors
and the spare fuse (7) is located on the back of the installer access
cover.
To remove the fuse:
▶ Pull the fuse holder (2) up.
▶ Replace the fuse and re-insert the fuse holder.
7.8.18 Replacing the Heating Control Module (HCM)
▶ Press down on the retaining clip on the module and slide out from the
cover.
▶ Disconnect the HCM from the connector.
▶ Connect the new HCM and slide back into the retainer until the
module is secure.
7.8.19 Replacing the control unit
The control unit is supplied complete in the plastic
housing. The complete unit must be replaced.
▶ Reconnect the boiler cable edge connectors to the board.
▶ Reconnect the cables removed earlier in to the 230V connector
block.
▶ Replace the covers removed earlier.
▶ Hold the control panel at approximately 60° to the horizontal and reengage the panel with the hinges.
▶ Re-attach the support strap to the new control unit.
50
Greenstar Ri Compact ErP 6720813282 (2015/07)
Service and spares
7.9
Short parts list
Fan 8 716 117 417
Gas Valve
8 718 600 04A 0
Burner 8 718 600 23B 0
Flue overheat thermostat
(grommet type)
8 717 206 213 0
Electrodes
(including gasket)
8 718 600 28A 0
Control panel 8 718 682 010 0
Spark generator
8 716 117 077
Flow NTC
8 718 688 801 0
Burner seal 8 718 600 24A 0
Auto Air Vent
T 005 000 87A 0
Maximum safety sensor NTC
8 718 685 483 0
Air Pressure Switch
8 716 106 633 0
Table 25 Short parts list
Greenstar Ri Compact ErP 6720813282 (2015/07)
51
Fault finding and diagnosis
8
Fault finding and diagnosis
boiler will restart automatically. This may mean waiting for the boiler to
cool down or waiting for a pre-defined time period.
8.1
Fault finding
Locking faults require manual intervention, for example pressing the
Reset button on the boiler fascia.
This fault finding information is for guidance only.
Worcester cannot be held responsible for costs incurred
by persons not deemed to be competent.
The electronic control system for this boiler incorporates a blue light on
the front fascia. This light indicates normal operation, but by flashing at
different rates during a fault, provides a guide to the cause as listed.
Faults that might develop with this boiler are either Blocking or Locking
faults:
Blocking faults will stop the boiler operating, once the fault is cleared the
Flashing fault codes
The flashing sequences will be split into three groups:
1. A five second “off” period (A), followed by a count of either 1,2,3,4
or 5 flashes (B), at a rate of 1 second on and 1 second off.
2. A five second “off” period (A), followed by 4 fast flashes (C), lasting
2 seconds, followed by a count of either 1,2,3,4 or 5 flashes (B), at
a rate of 1 second on and 1 second off.
A
B
This fault finding system assumes that the appliance has been operating
normally until the time of failure (i.e. not a first installation error).
PRELIMINARY CHECKS: Preliminary electrical system checks are the
first electrical checks to be carried out during a fault-finding procedure.
On completion of the Service/Fault-Finding task which has required the
breaking and remaking of electrical connections, check:
(a) EARTH CONTINUITY,
(b) SHORT CIRCUIT CHECK,
(c) POLARITY and
(d) RESISTANCE TO EARTH.
3. A five second “off” period (A), followed by a count of either 1,2,3,4
or 5 flashes (B), at a rate of 1 second on and 1 second off followed by
4 fast flashes (C), lasting 2 seconds.
In all cases the sequences will be continually repeated after the 5 second
“off” period.
A
Group 1
A
C
B
A
Group 2
A
B
C
A
Group 3
6720646610-70.1Wo
Fig. 99 Fault flash timing
[A]
[B]
[C]
52
5 second off period
period with 1 to 5 flashes
2 second period with 4 fast flashes
Greenstar Ri Compact ErP 6720813282 (2015/07)
Fault finding and diagnosis
8.1.1
Group 1 fault codes
Flash
sequence
Type of fault
Light OFF
Light ON
Group 1
Flashing codes
1
Locking
Fault
No fault
Possible solutions/check
No boiler demand - boiler is OK
Heating demand on boiler- boiler is OK
No ionisation detection after ignition
Failure of four ignition attempts, the boiler waits 30
seconds before another attempt is made.
Reset the boiler by turning the control knob anticlockwise to the reset position.
An established flame has been extinguished.
Reset the boiler by turning the control knob anticlockwise to the reset position.
Gas valve coil disconnected. Check gas valve.
Reset the boiler by turning the control knob anticlockwise to the reset position.
The flame was not established during the first four
seconds of the ignition period.
Reset the boiler by turning the control knob anticlockwise to the reset position.
Gas valve leaking.
False flame detected.
Reset the boiler by turning the control knob anticlockwise to the reset position.
2
Locking
Loss of ionisation signal during operation
3
Locking
Gas valve error
4
Locking
First safety timing error/ignition timing error
5
Locking
Ionisation detected after burner stopped
Gas valve EV2 leak test failed
Gas valve EV1 leak test failed
Ionisation current detected before burner-start
Gas valve error
Ionisation sensor shorted
Fault code group 1
1 to 5 flashes
1 5 seconds off
5 seconds off
2 5 seconds off
3 5 seconds off
4 5 seconds off
5 5 seconds off
5 seconds off
5 seconds off
5 seconds off
5 seconds off
6720646610-66.2Wo
Fig. 100 Group 1 flash sequences
Greenstar Ri Compact ErP 6720813282 (2015/07)
53
Fault finding and diagnosis
8.1.2
Group 2 fault codes
Flash
sequence
Type of fault
Light OFF
Light ON
Group 2 Flashing codes
6
Locking
Fault
Possible solutions/check
No boiler demand - boiler is OK
Heating demand on boiler- boiler is OK
Sensor test failed
On power up all safety sensors are checked, the
check failed.
Reset the boiler by turning the control knob anticlockwise to the reset position.
The main heat exchanger has overheated.
Maximum temperature 105°C.
Reset the boiler by turning the control knob anticlockwise to the reset position.
Flue gas thermostat overheat or APS activated
Boiler overheat.
Reset the boiler by turning the control knob anticlockwise to the reset position.
Primary flow sensor overheated.
Reset the boiler by turning the control knob anticlockwise to the reset position.
7
Locking
Safety temperature too high
8
9
Blocking
Locking
MAX safety thermostat activated
Return temperature too high
10
Locking
Flow temperature too high Supply sensor exceeded 110°C
Fault code group 2
1 to 5 flashes preceeded by 4 fast flashes
6
5 seconds off
7
5 seconds off
8
5 seconds off
9
5 seconds off
10 5 seconds off
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
5 seconds off
1
2
3
4
5 seconds off
1
2
3
4
5 seconds off
1
2
3
4
5 seconds off
1
2
3
4
5 seconds off
1
2
3
4
6720646610-67.2Wo
Fig. 101 Group 2 flash sequences
54
Greenstar Ri Compact ErP 6720813282 (2015/07)
Fault finding and diagnosis
8.1.3
Group 3 fault codes
Flash
sequence
Type of fault
Light OFF
Light ON
Group 3 Flashing codes
11
Locking
12
Locking
Fault
Possible solutions/check
No boiler demand - boiler is OK
Heating demand on boiler- boiler is OK
HCM (Heat Control Module) Defective
Incorrect, faulty, or missing HCM.
Replace HCM with correct item
Reset the boiler by turning the control knob anticlockwise to the reset position.
Defective fan or blocked air way.
Reset the boiler by turning the control knob anticlockwise to the reset position.
Fan running too fast
Fan running too slow
No airflow after defined period of time
13
Locking
Fan not running
Mains voltage interrupted after locking error
14
Locking
Internal control board faults
15
Locking
All other faults
Reset the boiler by turning the control knob anticlockwise to the reset position.
Call Worcester, Bosch Group technical help-line
0330 123 3366
Miscellaneous
Reset the boiler by turning the control knob anticlockwise to the reset position.
Fault code group 3
1 to 5 flashes followed by 4 fast flashes
11 5 seconds off
1
2
3
4
5 seconds off
12 5 seconds off
13 5 seconds off
14 5 seconds off
15 5 seconds off
1
2
3
4
1
2
3
4
5 seconds off
1
2
3
4
1
2
3
4
5 seconds off
1
2
3
4
5 seconds off
1
2
3
4
1
2
3
4
1
2
3
4
5 seconds off
1
2
3
4
6720646610-68.3Wo
Fig. 102 Group 3 flash sequences
Greenstar Ri Compact ErP 6720813282 (2015/07)
55
Fault finding and diagnosis
8.2
Wiring diagram
AIR PRESSURE
SWITCH
Fan wiring:
Live = brown
Neutral = blue
FAN
FLUE
STAT
SPARK
ELECTRODES
FLAME SENSE
ELECTRODE
FLOW
NTC
SPARK
GENERATOR
MAX SAFETY NTC
FLAME SENSE
GROUND
NL
GAS
VALVE
SAFETY
SOLENOID
Red
G/Y
Blue
Orange
SAFETY
SOLENOID
RETURN
NTC
230V WIRING CENTER/
JUNCTION BOX
L
N
Live
Neutral
EXTERNAL
PUMP
SL
Neutral
Live
Switched Live
Pump Live
Pump Neutral
Pump Earth
WC/JB Live (LS)
WC/JB Neutral
WC/JB Earth
Switched Live (LR)
N L
N L
N L
N
LR
L
L
N
L
N
LR
DIAGNOSTIC
INPUT
1
Red
13
4
1
Red
Green
Blue
Black
Orange
White
White
White
Black
Red
Green
Yellow
4
White
Brown
Red
Blue
Orange
Blue
Blue
6
X3
1
X10
1
Worcester 24V
controls point
HCM
Orange
X11
3
G/Y
G/Y
G/Y
1
X12
EMS
X7
X7
X8
230V
OUT
230V
IN
TEMPERATURE
CONTROL AND
RESET
Service Mode
Switch
1 2
Fuse, slow
F 5A H 230 V
Mains Live
Mains Neutral
Mains Earth
MAINS
SUPPLY
6720813282-06.1Wo
56
Greenstar Ri Compact ErP 6720813282 (2015/07)
Greenstar Ri Compact ErP 6720813282 (2015/07)
6720813282-04.1Wo
MAINS
POWER
SUPPLY
ON
External
switched
live
demand
LOCKOUT
Fan to
start
speed.
YES
Pump ON.
BOILER
DEMAND
4th
attempt?
NO
Spark
ignition
and gas
4 seconds
Purge
30 seconds
Stop spark
and gas.
NO
BURNER
LIT?
IGNITION SEQUENCE
IGNITION
SEQUENCE
(see detail)
GREEN
FLAME
LIGHT
ON
Gas valve OFF.
Fan overrun
30 seconds
YES
90 second
stabilisation
period.
Fan
modulation
to achieve
set
temperature
(30-82°C)
Over temperature shutdown if water temperature is 4°C above set
value.
Gas valve
OFF
Pump run 3
minutes
Fan run 30
seconds
END OF
BOILER
DEMAND
BLUE
LIGHT
OFF
8.3
BLUE
LIGHT
ON
3 minute pump
over run
Fault finding and diagnosis
Boiler function
Fig. 103
57
Fault finding and diagnosis
8.4
Protection function
AUTOMATIC INTERNAL FROST FUNCTION
Internal boiler
temperature
between
8°C & 5°C
Pump runs
Internal boiler
temperature
rises above 9°C
Pump switches off
after a 3 minute
overrun period
Boiler automatic
frost function
(monitors internal boiler
primary temperature)
Internal boiler
temperature
below 5°C
Central heating
demand is activated
Internal boiler
temperature
rises above 12°C
Central heating
demand switches
off
Pump switches off
after a 3 minute
overrun period
End of boiler demand
(central heating or
domestic hot water)
Pump runs for 3 minutes
to dissipate heat from
the boiler into the system
6720646610-53.1Wo
PUMP OVERRUN FUNCTION
PUMP ANTISEIZE FUNCTION
No central heating
demand after
a 24hr period
Pump runs 5 seconds
every 24hrs from
last time pump ran
A central heating demand
activated, pump runs
normally
Fig. 104
58
Greenstar Ri Compact ErP 6720813282 (2015/07)
Notes
Greenstar Ri Compact ErP 6720813282 (2015/07)
59
Notes
60
Greenstar Ri Compact ErP 6720813282 (2015/07)
Notes
Greenstar Ri Compact ErP 6720813282 (2015/07)
61
GAS BOILER SYSTEM COMMISSIONING CHECKLIST
This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating
compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.
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ALL SYSTEMS
7KHV\VWHPKDVEHHQÀXVKHGDQGFOHDQHGLQDFFRUGDQFHZLWK%6DQGERLOHUPDQXIDFWXUHU¶VLQVWUXFWLRQV
Yes
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CENTRAL HEATING MODE PHDVXUHDQGUHFRUG
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COMBINATION BOILERS ONLY
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Yes
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CONDENSING BOILERS ONLY
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Yes
ALL INSTALLATIONS
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ZZZFHQWUDOKHDWLQJFRXN
SERVICE RECORD
It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.
Service Provider
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WORCESTER, BOSCH GROUP:
Worcester, Bosch Group
Cotswold Way, Warndon, Worcester WR4 9SW.
Tel. 0330 123 9559
Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd.
worcester-bosch.co.uk
6720813282 (2015/07)
TECHNICAL SUPPORT:
0330 123 3366
APPOINTMENTS:
0330 123 9339
SPARES:
0330 123 9779
LITERATURE:
0330 123 9119
TRAINING:
0330 123 0166
SALES:
0330 123 9669
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