THE APPLIANCE IS FOR USE WITH NATURAL GAS OR L.P.G.
CONTACT INFORMATION INSTALLATION & SERVICING INSTRUCTIONS WORCESTER: PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION. TECHNICAL: 08705 266241 SERVICE: 08457 256206 SPARES: 01905 752571 LITERATURE: 01905 752556 TRAINING: 01905 752526 SALES: 01905 752640 WEBSITE: www.worcester-bosch.co.uk 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.
SAFETY & REGULATIONS CONTENTS SAFETY PRECAUTIONS & SYMBOLS 3 INSTALLATION REGULATIONS 3 APPLIANCE INFORMATION SAFETY & REGULATIONS APPLIANCE INFORMATION GENERAL INFORMATION 4 TECHNICAL DATA 5 LAYOUT & COMPONENTS 6-7 PRE-INSTALLATION 9 WATER SYSTEMS & PIPEWORK 10 CONDENSATE PIPEWORK 11 PRESSURE RELIEF PIPEWORK BOILER LOCATION & CLEARANCES PLUMBING MANIFOLD 12 13-14 15 FLUE TERMINAL POSITIONS 16 FLUE OPTIONS 17 INSTALLATION MAINS SUPPLY 8 PRE INSTALLATION CLEANING PRIMARY SYSTEMS
SAFETY & REGULATIONS SAFETY PRECAUTIONS INSTALLATION REGULATIONS IF YOU SMELL GAS: ✗ DON’T SMOKE OR STRIKE MATCHES ✗ DON’T TURN ELECTRICAL SWITCHES ON OR OFF ✓ DO PUT OUT NAKED FLAMES ✓ DO OPEN DOORS AND WINDOWS ✓ DO KEEP PEOPLE AWAY FROM THE AREA AFFECTED ✓ DO TURN OFF THE CONTROL VALVE AT THE METER ✓ DO CALL YOUR GAS COMPANY A Benchmark Checklist is provided by the manufacturer for the installer to complete including their CORGI registration number to confirm that the boiler has been installed, commis
GENERAL INFORMATION STANDARD PACKAGE: A - Wall hung gas fired condensing boiler for central heating and indirect domestic hot water B - Boiler support frame/pre-plumbing jig C - Hardware literature pack (When fitted to wall frame) Depth to wall 330mm B A APPLIANCE INFORMATION D - Bottom Panel 700mm D C SPECIFICATIONS: 400mm Pre-wired and pre-plumbed Galvanised steel inner frame Digital control system Automatic ignition Direct burner ignition electrodes D Built-in frost thermostat Built-in fault
TECHNICAL DATA DESCRIPTION UNITS NATURAL GAS 12i System 24i System L.P.G. 12i System 24i System Gas flow rate - Max. 10 minutes from lighting Natural Gas G20 m3/h 1.33 2.67 - - Propane Gas (LPG) kg/h - - 0.46 1.91 Max. rated heat input KW 12.32 24.62 12.32 24.62 Min. heat input KW 3.70 7.38 5.95 9.64 Max. rated heat output 40/30°C KW 12.85 25.67 25.67 25.67 Max. rated heat output 50/30°C KW 12.74 25.45 12.74 25.45 Max.
LAYOUT & COMPONENTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 AIR / GAS MANIFOLD FAN AIR / GAS ADJUSTMENT SCREW GAS VALVE INLET PRESSURE TEST POINT EXPANSION VESSEL WALL MOUNTING FRAME COVER FOR EXTERNAL WIRING CONNECTIONS CONDENSATE CONNECTION FROM HEAT EXCHANGER FLUE PRESSURE SWITCH FAN PRESSURE TEST POINT MANUAL VENT POINT IGNITION AND FLAME SENSE ELECTRODES OVERHEAT THERMOSTAT FLAME VIEWING MIRROR SECURING NUT, AIR / GAS MANIFOLD CLAMP SENSOR - BOILER FL
LAYOUT & COMPONENTS 34 35 36 37 38 39 40 41 APPLIANCE INFORMATION 42 43 SYSTEM PUMP UNUSED PORT AUTO AIR VENT FLOW CONNECTION FROM BOILER HEAT EXCHANGER FLOW CONNECTION TO SERVICE VALVE DRAIN POINT RETURN CONNECTION TO SERVICE VALVE OPTIONAL INTEGRAL DIVERTER VALVE POSITION PRESSURE RELIEF VALVE COMPACT HYDRAULIC MOUNTING SCREW (2) TO BOILER 44 CH TEMPERATURE CONTROL 45 MAINS ON/OFF INDICATOR/ DIAGNOSTIC LIGHT (BLUE) 46 SERVICE MODE BUTTON 47 BURNER ON INDICATOR LIGHT (GREEN) 48 MASTER SWITCH ON/OFF 49
CLEANING PRIMARY SYSTEMS IMPORTANT: All the following Pre-Installation sections must be read and requirements met before starting boiler or flue installation. CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. IMPORTANT: Debris from the system can damage the boiler and reduce efficiency. Failure to comply with the guidelines for t he use of wat er treatment with the appliance will invalidate the appliance warranty.
MAINS SUPPLY PRE INSTALLATION ELECTRIC SUPPLY: • Supply: 230V - 50Hz, 50 watts not including 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. • IPX4D. • All pipes to the boiler must be cross-bonded. • Mains supply to the boiler and system wiring centre must be through one common fused double pole isolator situated adjacent to the appliance.
WATER SYSTEMS & PIPEWORK INSTALLATION WITH EXTERNAL DIVERTER VALVE 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. • On new installations TRV’s must be used on all radiators except where a room thermostat is sited. On all installations they should at least be fitted in the sleeping areas.
CONDENSATE PIPEWORK PRE INSTALLATION CONDENSATE PIPEWORK: • The condensate pipe must be a minimum of 22mmØ plastic pipe. • The condensate pipework must fall at least 50mm per metre towards the outlet and should take the shortest practicable route. • The pipework must follow one of the options shown opposite into an internal serviceable trap (min. 75mm) such as a sink/washing machine waste or discharge direct into a vent stack (E) 450mm min.
PRESSURE RELIEF PIPEWORK PRESSURE RELIEF PIPEWORK: IMPORTANT: The pressure relief valve is a safety device for the boiler and if activated may discharge boiling water steam through the relief valve drain pipe. • The pressure relief drain pipe (M) from the boiler should be at least 15mm diameter copper pipe and run downwards away from any electrics or other hazard, preferably to an external drain or soakaway.
SERVICING CLEARANCES VENTED COMPARTMENT BOILER LOCATION & CLEARANCES This boiler is only suitable for installing internally within a property at a suitable location onto a fixed, rigid non-combustible surface at least the same size as the boiler and capable of supporting the boiler weight. COMPARTMENTS: Follow the requirements of B S6798 and BS5440 Part 2 and note: • Minimum clearances must be maintained • An access door is required to install, service and maintain the boiler and any ancilliary equipment.
BOILER LOCATION & CLEARANCES 1 1 2 2 3 I M PORTANT: any switch or appliance control using mains electricity must not be able to be touched by a person using the bath or shower. Electrical switches, fused spur and socket out let s must not be sit uat ed in t he bathroom. PRE INSTALLATION 3 BATHROOMS: The boiler can be installed in zones 2 or 3 . See IEE wiring regulations.
PLUMBING MANIFOLD Flow 22mm Gas Supply (alternative from above appliance) 22mm Return 22mm CONNECTIONS: Heating System: 22mm compression fittings Gas: 22mm compression fittings Use the fittings supplied in the Lit/Hardware pack. • If the boiler pipes are to be run behind the appliance ensure that the pipes pass through the slot in the yellow plastic guide (A). This is fitted to the boiler frame.
Minimum dimensions of flue terminal positions for balanced room sealed flues with fanned draught: DRWG. REF: TERMINAL POSITION DISTANCE A1 Directly below an opening, air brick, opening windows, etc. 300mm B1 Above an opening, air brick, opening window, etc. 300 mm Horizontally to an opening, air brick, opening window, etc.
FLUE OPTIONS STANDARD FLUE HORIZONTAL MAXIMUM FLUE VERTICAL START + 2 BENDS A A F B C Ø100 MAX 686 A x 1 MIN 250 A x 1* Ø100 - 2600mm Ax1+Cx2+ Bx4 + Fx1 Ø125 MAX 1070 A x 1 MIN 250 A x 1* * Requires cutting Ø125 - 11000mm A x 1 + C x 2 + B x 13 + Fx1 PRE INSTALLATION MAXIMUM FLUE HORIZONTAL MAXIMUM FLUE VERTICAL START + 3 BENDS • The diagrams (opposite) show the components used and the maximum flue length for each configuration of 100mm and 125mm flues.
UNPACKING WALL FRAME AND IIMPORTANT: All the previous Pre-Installation sections must be read and requirements met before starting boiler or flue installation. ANCILLARY ITEMS LIFTING AND CARRYING PRECAUTIONS: • Lift only a manageable weight, or ask for help. • When lifting or putting things down, bend the knees, and keep the back straight and feet apart. • Do not lift and twist at the same time.
A WALL MOUNTING TEMPLATE FLUE OPENING X4 CAUTION: Ensure there are no pipes, electric cables, damp proof courses or other hazards before drilling. X4 SAFETY: All relevant safety precautions must be undertaken. Protective clothing, footwear, gloves and safety goggles must be worn as appropriate. USE APPROPRIATE FIXINGS FOR WEIGHT AND WALL TYPE FIXING THE MOUNTING FRAME: • The boiler template shows the relative positions of the flue and the top and bottom fixing of the mounting frame.
UNPACKING THE APPLIANCE UNPACKING THE APPLIANCE 4 A - Outer carton B - Inner sleeve (unwraps from front) 5 C - Packaging base D - Protective wrapping A E - Appliance outer case F B B C F C 6.1 E 6 6.2 H 4. Remove outer carton (A) and place safely away from the working area. 5. With the outer packaging removed and the inner sleeve (B) still in place gently lay the boiler on its back. 6. The boiler will lie at an angle to the floor to allow the boiler outer casing (E) to be removed.
Do not lift by the air gas manifold. 3 BOILER CONNECTIONS IMPORTANT: IF FITTING OPTIONAL INTEGRAL DIVERTER VALVE Disregard this and the following page and refer to the correct version for installing t he int egral divert er valve in t he ADDITIONAL INFORMATION section at the back of this book. CAUTION: ISOLATE TH E MAI NS GAS SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.
BOILER CONNECTIONS 5 D CAUTION: ISOLATE TH E MAI NS GAS SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. GAS AND WATER CONNECTIONS: A - Flow (22mm), B - Return (22mm), A B F 5. Lower the control panel into the service position by removing the screw (D) from the retaining bracket. 6. Make connections to the heating system. Connect the gas supply to the boiler gas cock 22mm compression. 7.
FLUE INSTALLATION WALL 189mm 93mm HORIZONTAL FLUE (60/100mm diameter) For vertical flues and 80/125mm horizontal flues, please refer to separate instructions supplied with the flue kit. NOTE: to ease the assembly of flue components, apply silicone lubricant to sealing surfaces. The instructions for the 60/100mm diameter flue are shown below. MEASURING THE FLUE (Standard Flue): Measure from the outside wall to the centre line of the flue turret.
FLUE INSTALLATION Clamp MEASURING THE FLUE (Extension Flue Kits): ONLY CUT EXTENDED FLUE LENGTHS As with the Standard Flue measure from the outside wall to the centre line of the flue turret. Subtract the length of the Standard Flue and turret (725mm) from length L . Subtract the full length 1m extension(s) from the figure. Cut one of the 1m extensions to the remainder. Cut both tubes square taking care not to distort the tubes. Remove any burrs.
FLUE INSTALLATION A - Standard Flue B - Internal Wall Seal ASSEMBLING THE FLUE 1 Slide inner collar (B) onto terminal (A) 2 Additional extensions or bends: Push fit all extensions/bends/terminal together and secure connections with clamps (D). The slope of the terminal outlet must face downwards.
CONDENSATE CONNECTION CONDENSATE CONNECTION: Never terminate or discharge into any open source, including; sink, bath, shower, bidet, toilet etc. Note: any external condensate pipework should be protected with weather resistant insulation to help prevent freezing. • Ensure that the condensate drain is 22mm diameter plastic pipe. It must fall at least 50mm per metre towards the outlet. INSTALLATION • An adapter in 22mm pipe is contained in the fitting pack (A) along with sealing washer (B).
ELECTRICAL 2 1 A CAUTION: ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS 3 C FROSTSTAT WATER VALVE(S) TANKSTAT TIMER ROOMSTAT B 4 7 D SYSTEM WIRING CENTRE 5 6 brown blue green/yellow neutral 230V MAINS SUPPLY live earth switched live INSTALLATION boiler demand ST10 F1 F3 F2 Note: Mains supply to the boiler and system wiring centre must be through a common fused double pole isolator situated adjacent to the appliance.
POSITION OF WIRED COMMISSIONING INSTALLATION COMPONENTS 28 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i System/24i System 8 716 107 375b (11/05) POSITION OF WIRED COMPONENTS
1 PRE-COMMISSIONING A B CHECKS CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS 1 Check that the service and water pipes are connected to the correct position on the manifold. A - Flow (22mm) B - Return (22mm) C - Gas inlet (22mm) 2 Check the gas type specified on the identification plate (F) matches that of the gas supply. Turn on the main gas supply, check the gas pipework connections and rectify any leaks.
FILLING THE SYSTEM 2 3 4 5 • A • B Turn on the water main and open the system valves. Open all radiator valves. Fill the system via a WRAS approved filling loop. Vent (A) any air from the boiler heat exchanger using a suitable container to collect any water. Ensure tube outlet (B) is directed away from the fan or any other electrical component to prevent any water damage. Also place a suitable cover over the fan to prevent any spillage of water on to electrical connections.
STARTING THE APPLIANCE IMPORTANT: Never run the appliance when the appliance/system is empty or partially filled.
1 A WATER TREATMENT 5 IMPORTANT: Debris from the system can damage the boiler and reduce efficiency. Failure to comply with the guidelines for t he use of wat er treatment with the appliance will invalidate the appliance warranty. J B K ENSURE THAT THE SYSTEM HAS BEEN CLE AN E D AS ON PAG E 8 OF TH E S E INSTRUCTIONS.
COMMISSIONING WHEN RUNNING IN SERVICE MODE NOTE: When fitted with the optional diverter valve (not supplied) and running in service mode, the boiler will operate both central heating and hot water circuits. If fitted to an S or Y plan system, the system must only be run in central heating mode. I COMMISSIONING A H D E F G THE COMBUSTION FOR THE APPLIANCE IS FACTORY SET. NO ADJUSTMENT IS REQUIRED IF THE GAS INLET PRESSURE IS CORRECT.
FINISHING COMMISSIONING The boiler has been factory set, so there should be no need to adjust any controls. REPLACE OUTER CASING: 1 Replace outer casing making sure that the securing points are properly located. Replace top two screws (A). Retighten bottom two screws (B). A INSTALLING BOTTOM PANEL: 2 The bottom panel slides onto two ledges (C) either side of the boiler frame. Hold the panel up against the underside of the boiler and slide towards the rear until it is fully engaged.
INSPECTION AND SERVICE CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS S U P P LI E S B E FOR E STARTI NG ANY WOR K AN D OB S E RVE ALL RELEVANT SAFETY PRECAUTIONS. I M P ORTANT: Any service work must be carried out by competent registered engineers such as British Gas or Corgi registered personnel. IMPORTANT: AFTER REPLACEMENT OF ANY COMPONENTS ALWAYS CHECK FOR GAS SOUNDNESS WHERE RELEVANT AND CARRY OUT FUNCTIONAL CHECKS AS DESCRIBED IN COMMISSIONING.
1. 1.2 INSPECTION AND SERVICE 1.1 Component Access 1. Removing outer case A 1. B 1.3 Remove bottom panel by pulling it forward and off. 1.1 Undo and remove 2 screws (A) securing boiler casing at the top of the appliance. 1.2 Undo but do not remove the 2 screws (B) securing boiler casing at the bottom of the appliance. 1.3 Pull case forward and remove. 2. Adjusting boiler control to service position 2.1 2.1 Remove screw (C) securing control. 2.
INSPECTION AND SERVICE Setting Boiler to Maximum. NOTE: When running in the service mode, the boiler will operate both the Central Heating and DHW circuits. This is to allow sufficient time for the setting procedure. WHEN RUNNING IN SERVICE MODE NOTE: When fitted with the optional diverter valve (not supplied) and running in service mode, the boiler will operate both central heating and hot water circuits. If fitted to an S or Y plan system, the system must only be run in central heating mode.
INSPECTION AND SERVICE Remove control retaining screw COMBUSTION TESTING MUST BE CARRIED OUT BY A COM PETE NT PE R SON. IT M UST NOT BE ATTEMPTED UNLESS THE PERSON CARRYING OUT THE COMBUSTION CHECK I S E Q U I P P E D W ITH A C O M B U STI O N ANALYSER CONFORMING TO BS 7927 AND IS COMPETENT IN IT’S USE. I M P ORTANT: I F TH E JOI NT BETWEEN THE AIR/GAS MANIFOLD AN D TH E H EAT E XCHANG E R I S DISTURBED THE SEALING GASKET MUST BE REPLACED.
5 INSPECTION AND SERVICE E 4 5 6 7 8 6 F Remove electrical connector from fan. Undo and remove securing nut (E) from the top of the heat exchanger. Remove stainless steel viewing mirror (F). Rotate fan and air/gas manifold assembly (G) around the top of the heat exchanger until it stops at the lug. Lift up assembly and remove from boiler. Disconnect spark electrode and flame sensor connections (J). Remove clamping plate (K). Remove spark/flame electrode assembly from boiler.
INSPECTION AND SERVICE Q 9 Small tab 9 Remove burner (L). Remove top baffle (M). Remove baffle (N). Remove the two hexagon headed screws (O) retaining the access cover (P) on the sump. Access the heat exchanger flue ways by inserting the cleaning brush (7 716 192 312) through the top access hole in the casing (Q). Clean heat exchanger flue ways (R) using the cleaning brush (7 716 192 312) removing any debris from the access point in the sump.
REPLACEMENT OF PARTS CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS S U P P LI E S B E FOR E STARTI NG ANY WOR K AN D OB S E RVE ALL RELEVANT SAFETY PRECAUTIONS. 1. Removing outer case 1.1 Undo 4 screws (A) securing boiler casing. 1.2 Pull case forward and remove. To remove bottom tray, pull forward on the tag on the underside of the tray. IMPORTANT: AFTER REPLACEMENT OF ANY COMPONENTS ALWAYS CHECK FOR GAS SOUNDNESS WHERE RELEVANT AND CARRY OUT FUNCTIONAL CHECKS AS DESCRIBED IN COMMISSIONING.
5.1 REPLACEMENT OF PARTS 5.2 Access to the following components require the control to be moved in to the service position: Gas valve Siphon PCB fuse Transformer A 5. Moving boiler control to service position 5.1 Remove screw (A) securing control. 5.2 Gently pull forward. 6. Gas valve 6.1 7 Isolate gas supply at boiler gas cock. 6.1 Remove wire clip from gas valve outlet then pull gas adjustment assembly free from plastic connector and pull forward clear of case. 6.
REPLACEMENT OF PARTS 9 9. Access to boiler control components Remove 3 screws (A) and remove cover from control. A 10. PCB fuse Remove fuse F1 (B) from the PCB and replace. There is a spare fuse clipped into the underside of the electrical cover. 11.Transformer Disconnect all electrical connections from the control. Remove 5 screws (C) retaining the rear panel of the control and remove panel. Pull transformer upwards from PCB. 10 B SERVICING & SPARES Spare Fuse order T1.6L 250V F2 T2.
REPLACEMENT OF PARTS 12 A 12. Replacing control B 12.1 C C C 12.2 The control is supplied within its plastic housing. The complete unit must be replaced. Remove ALL electrical connections from the control PCB including where cables run through restraints. These can be unclipped from the plastic moulding noting their position. Remove the code plug (B). The code plug should be left attached to the frame of the boiler by its plastic safety thread. 12.
13.1 A REPLACEMENT OF PARTS The following components require the air / gas manifold and fan assembly to be removed: Pressure switch Fan Electrode assembly Burner Heat exchanger 13.2 B 13.3 I M P ORTANT: I F TH E JOI NT BETWEEN THE AIR/GAS MANIFOLD AN D TH E H EAT E XCHANG E R I S DISTURBED THE SEALING GASKET MUST BE REPLACED. IMPORTANT: AFTER REASSEMBLY TH E C OM B USTION M UST B E CH ECK E D US I NG TH E P RO CEDURE IN THE SECTION “SETTING THE GAS AIR RATIO”.
REPLACEMENT OF PARTS 15.1 15.2 15. Fan 15.1 Remove 3 screws (A) retaining mixing chamber. 15.2 Remove 2 screws (B) retaining the fan to the air/gas manifold. 15.3 Remove screw (C) retaining plate and remove. Re-assemble with new fan ensuring seals are correctly fitted. B A 16. Electrode assembly 15.3 16 C Disconnect spark electrodes and flame sensor connection. Remove clamping plate (D). Remove spark/flame electrode assembly (E) from heat exchanger. 17.
REPLACEMENT OF PARTS 19.1 A 19. Diverter valve motor (if fitted) Ensure the appliance is in service mode (there is no need to drain the appliance). Disconnect the electrical connector from the diverter valve motor. 19.1 Pull the motor assembly (A) towards you. The assembly will slide free from the valve. To refit, follow the above in reverse. 20. Diverter valve 20.1 B Ensure the appliance has been fully drained . Disconnect the electrical connector from the diverter valve motor.
A 22.1 REPLACEMENT OF PARTS 22.2 22. Pump head Ensure the boiler is fully drained. Disconnect the electrical connection from the bottom of the pump. 22.1 Remove the four Allen bolts (A) securing the pump at each corner. 22.2 Gently pull the pump towards you and remove. To refit, follow the above in reverse. A 23. Pressure gauge Ensure the appliance has been fully drained. Withdraw the spring clip from the pressure sensing head housing. Undo the nut on the rear of the pressure gauge.
25.1 REPLACEMENT OF PARTS 25. Hydraulic Block 25.2 Ensure the appliance has been fully drained. Disconnect the electrical connections to the pump. Undo the nuts securing the copper water pipes to the manifold (there is no need to remove the gas pipe). Release the spring clips securing these water pipes to the plastic housing and remove the pipes. Release the spring clip securing the expansion vessel pipe to the plastic housing and remove the pipe.
REPLACEMENT OF PARTS 27.1 27. Bypass valve 27.2 Remove the Hydraulic block from the boiler (See Removing the Hydraulic Block). 27.1 Remove the two spring clips at either end of the copper bypass pipe. Undo the screw securing the left hand plastic housing to the heat exchanger Move the housing to the left to free up one end of the pipe. Remove the pipe from the right hand housing to reveal the bypass valve. 27.2 Using a pair of pliers, pull out the bypass valve (A) from the housing.
SETTING THE GAS / AIR RATIO 29.1 C THE SETTING OF THE GAS RATIO MUST BE CARRIED OUT BY A COMPETENT PERSON. SETTING OF THE GAS RATIO MUST NOT BE AT T E M P T E D U N L E S S T H E P E R S O N C AR RYI N G O UT TH E C O NVE R S I O N I S EQUIPPED WITH A COMBUSTION ANALYSER C O N F O R M I N G TO B S 79 2 7 A N D I S COMPETENT IN ITS USE. 29. Setting the CO2 Inlet Test Nipple 29.2 29.3 + CO2 settings – Note. CO2 should be measured after 10 minutes A B SERVICING & SPARES 29.
1 2 3 SHORT PARTS LIST Fan WORCESTER Part No. 8 717 204 453 0 GC No. H26 536 2 Burner WORCESTER Part No. 8 718 120 609 0 GC No. H26 538 3 Gas valve NG WORCESTER Part No. 8 716 107 052 0 NG GC No. H26 540 LPGWORCESTER Part No. 8 716 107 053 0 LPGGC No. H26 539 4 Control box WORCESTER Part No. 8 716 109 539 0 GC No. H28 966 5 Air pressure switch WORCESTER Part No. 8 716 106 633 0 GC No. H26 543 6 Temperature limit sensor WORCESTER Part No. 8 722 963 858 0 GC No. H08 291 7 Electrodes WORCESTER Part No.
GAS CONVERSION. 12kW ONLY I S O LATE MAI N S E LE CTR I C AL SUPPLY AND REMOVE OUTER CASE AS SHOWN ON PAGE 41. THE CONVERSION MUST BE CARRIED OUT BY A COM PETE NT PE R SON. IT M UST NOT B E AT T E M P T E D U N L E S S T H E P E R S O N C AR RYI N G O UT TH E C O NVE R S I O N I S EQUIPPED WITH A COMBUSTION ANALYSER C O N F O R M I N G TO B S 79 2 7 A N D I S COMPETENT IN ITS USE. 1.
GAS CONVERSION. 24kW ONLY 1.1 1.2 I S O LATE MAI N S E LE CTR I C AL SUPPLY AND REMOVE OUTER CASE AS SHOWN ON PAGE 41. THE CONVERSION MUST BE CARRIED OUT BY A COM PETE NT PE R SON. IT M UST NOT B E AT T E M P T E D U N L E S S T H E P E R S O N C AR RYI N G O UT TH E C O NVE R S I O N I S EQUIPPED WITH A COMBUSTION ANALYSER C O N F O R M I N G TO B S 79 2 7 A N D I S COMPETENT IN ITS USE. A 2.1 2.
FAULT FINDING NOTE : This fault finding information is for guidance only. Worcester cannot be held responsible for costs incurred by persons not deemed to be competent. The electronic control system for this boiler incorporates a blue central indicator. This normally confirms the permanent mains supply but, by flashing at different rates during a fault, provides a guide to the cause as listed. This fault finding system assumes that the appliance has been operating normally until the time of failure (i.e.
POWER SWITCH ON BLUE LIGHT ON FAULT FINDING & DIAGRAMS System demand at ST10 AND temperature control knob ON BOILER FUNCTION Fan to start speed. LOCKOUT YES Diverter valve in CH position Pump ON. BOILER DEMAND 3 minute wait 5th attempt? NO Spark ignition 4 seconds Stop spark. Wait 10 seconds NO BURNER LIT? IGNITION SEQUENCE IGNITION SEQUENCE (see detail) GREEN FLAME LIGHT ON Gas valve OFF. Fan overrun 30 seconds YES 10 second stabilisation period.
PROTECTION FUNCTION Run autofroststat function Pump antiseize Pump run 5 seconds every 24hrs FAULT FINDING & DIAGRAMS Boiler temperature below 8°C 57 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i System/24i System 8 716 107 375b (11/05) PROTECTION FUNCTION
DIVERTER KIT NUMBERS: 12kW 7 716 192 408 24kW 7 716 192 409 KIT CONTENTS: 1 COPPER RETURN PIPE 1 BRASS SERVICE VALVE 1 15mm COMPRESSION NUT 1 15mm OLIVE 1 DIVERTER VALVE MOTOR 1 DIVERTER MOTOR HARNESS 2 SCREWS 2 CODE PLUGS FOR 12kW i System KIT: 12i System NATURAL GAS 112 12i System LPG 113 FOR 24kW i System KIT: 24i System NATURAL GAS 114 24i System LPG 115 THE APPLIANCE IS FOR USE WITH NATURAL GAS OR L.P.G.
PLUMBING MANIFOLD CONNECTIONS: Heating System: 22mm compression fittings Gas: 22mm compression fittings Cylinder Return 15mm compression fittings Gas Supply (alternative from above appliance) 22mm Flow 22mm Cylinder Return 15mm Use the fittings supplied in the Lit/Hardware pack and the Optional Diverter Valve Kit.
A 1 BOILER CONNECTIONS IMPORTANT: THE FOLLOWING MUST BE COMPLETED BEFORE THE BOILER IS MOUNTED ON THE WALL MOUNTING FRAME 3. Remove the brass bung assembly (D) from the hydraulic block by removing the screw and sliding it free from the flange on the clamping plate (C). Make sure that the other brass bung assembly (E) is retained in place. 4. Remove the copper pipe (F) from the Optional Integral Diverter Valve Kit and feed the flat end of the pipe through the rear of the boiler as shown.
Do not lift by the air gas manifold. 7 BOILER CONNECTIONS CAUTION: ISOLATE TH E MAI NS GAS SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. GAS AND WATER CONNECTIONS: Remove template and secure the wall mounting frame to the wall with the fixings supplied. System pipes may be run vertically upwards behind the boiler or below it. See Plumbing Manifold Section on page 15. A D A - Flow (22mm) B - CH return (22mm) C - Gas inlet (22mm) D - Cylinder return (15mm) B 5.
BOILER CONNECTIONS 9 Remove control retaining screw CAUTION: ISOLATE TH E MAI NS GAS SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. GAS AND WATER CONNECTIONS: A - Flow (22mm), B - CH return (22mm), C - Gas inlet (22mm), A D B F 9. Lower the control panel into the service position by removing the screw from the retaining bracket. 10. Make connections to the heating system. Connect the gas supply to the boiler gas cock 22mm compression. 11.
FITTING THE DIVERTER VALVE CAUTION: ISOLATE TH E MAI NS GAS SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. INSTALLATION 1 A FITTING THE DIVERTER VALVE MOTOR: 1. Remove the diverter blanking plate (A) by pulling it forwards to free it from its location. 2. Replace with the diverter valve motor (B) by pushing it in until it clicks securely into place. 3.
ELECTRICAL 2 1 A CAUTION: ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS B 3 C 4 D ROOMSTAT 5 6 FROSTSTAT 9 TANKSTAT 8 brown blue green/yellow neutral 230V MAINS SUPPLY live switched live 7 calling ST6 ST10 10 F1 F3 F2 Access to electrical connections: Remove boiler casing to access control panel. 1 Unscrew screw (A) and lower the control box into the horizontal position.
POSITION OF WIRED COMMISSIONING INSTALLATION COMPONENTS 28 POSITION OF WIRED COMPONENTS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i System/24i System 8 716 107 375b (11/05)
1 PRE-COMMISSIONING A D B CHECKS CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS 1 Check that the service and water pipes are connected to the correct position on the manifold. A - Flow (22mm) B - CH Return (22mm) C - Gas inlet (22mm) D - Cylinder Return (15mm) 2 Check the gas type specified on the identification plate (F) matches that of the gas supply. Turn on the main gas supply, check the gas pipework, connections and rectify any leaks.
POWER SWITCH ON BLUE LIGHT ON FAULT FINDING & DIAGRAMS Room thermostat ON (and/or link fitted at ST10) AND Facia mounted programmer ON AND Temperature control ON CENTRAL HEATING FUNCTION Fan to start speed. LOCKOUT YES Diverter valve in CH position Pump ON. CENTRAL HEATING DEMAND 3 minute wait 5th attempt? NO Spark ignition 4 seconds Stop spark. Wait 10 seconds NO BURNER LIT? IGNITION SEQUENCE IGNITION SEQUENCE (see detail) GREEN FLAME LIGHT ON Gas valve OFF.
POWER SWITCH ON INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i System/24i System 8 716 107 375b (11/05) R ETU R N TO TH E MAI N INSTRUCTIONS PAGE 57 FOR PROTECTION FUNCTION. DHW FUNCTION FAULT FINDING & DIAGRAMS BLUE LIGHT ON Cylinder stat calling AND Facia mounted programmer ON DOMESTIC HOT WATER DEMAND LOCKOUT Diverter valve in DHW position Pump ON. Wait 5 seconds YES IGNITION SEQUENCE (see detail) 5th attempt? NO Spark ignition 4 seconds Stop spark.
BENCHMARK No. COLLECTIVE MARK GAS BOILER COMMISSIONING CHECKLIST BOILER SERIAL No. NOTIFICATION No.
SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below. Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions. Always use the manufacturer’s specified spare part when replacing all controls SERVICE 1 DATE SERVICE 2 DATE ENGINEER NAME COMPANY NAME TEL No.
Pack Number Check List Greenstar 12i System/24i System Hardware/Literature Pack Item Qty Greenstar 12i System/24i System Installation/Servicing Instructions.....1 Users Instructions ..........................................................................................1 Consumer Guarantee Card .........................................................................1 Sealing Pack...................................................................................................1 Compression Nut 22mm ....
