INSTRUCTION MANUAL INSTALLATION, COMMISSIONING & SERVICING WALL HUNG RSF GAS FIRED CONDENSING BOILER GREENSTAR 12i/24i System FOR SEALED CENTRAL HEATING SYSTEMS AND INDIRECT FED DOMESTIC HOT WATER THIS BOILER IS USED WITH NATURAL GAS OR LPG (Cat II 2H3P TYPE C13, C33 & C53) NATURAL GAS 12i System GC NUMBER: 41 311 67 24i System GC NUMBER: 41 311 68 LIQUID PETROLEUM GAS 12i System GC NUMBER: 41 311 69 24i System GC NUMBER: 41 311 70 UK/IE
WATER TREATMENT: FERNOX 01799 550811 www.fernox.com SENTINEL 0800 389 4670 www.sentinel-solutions.net FLUE TERMINAL GUARDS: TOWER FLUE COMPONENTS LTD.
SAFETY & REGULATIONS CONTENTS INSTALLATION & SERVICING INSTRUCTIONS 2 SAFETY PRECAUTIONS & SYMBOLS 4 INSTALLATION REGULATIONS 4 APPLIANCE INFORMATION SAFETY & REGULATIONS APPLIANCE INFORMATION GENERAL INFORMATION 5 TECHNICAL DATA 6 LAYOUT & COMPONENTS 7 PRE-INSTALLATION MAINS SUPPLY 10 WATER SYSTEMS & PIPEWORK 11 CONDENSATE PIPEWORK 12 PRESSURE RELIEF PIPEWORK 13 BOILER LOCATION & CLEARANCES 14 PLUMBING MANIFOLD 16 FLUE OPTIONS 17 FLUE TERMINAL POSITIONS 18 PRE INSTALLATION 9
SAFETY & REGULATIONS 4 SAFETY PRECAUTIONS & INSTALLATION REGULATIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System 8 716 115 167b (03/2009)
(When fitted to wall frame) Depth to wall 330mm GENERAL INFORMATION APPLIANCE INFORMATION A 700mm* B 400mm C D STANDARD PACKAGE: E A - Wall hung gas fired condensing boiler for central heating and indirect domestic hot water *710mm to top of case front F Check List Hardware/Literature pack Item Qty Greenstar 12i/24i System Installation/Servicing Instructions . . . . . . . . . . .1 Users Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA DESCRIPTION NATURAL L.P.G. UNITS 12i 24i 12i 24i Natural Gas G20 m3/h 1.33 2.67 - - Propane Gas (LPG) kg/h - - 0.96 1.91 Gas flow rate - Maximum 10 minutes from lighting APPLIANCE INFORMATION Central Heating Max. rated heat input kW 12.32 24.62 12.32 24.62 Min. heat input kW 3.70 Max. rated heat output 40/30°C kW 12.85 25.67 12.85 25.67 Max. rated heat output 50/30°C kW 12.74 25.45 12.74 25.45 Max. rated heat output 80/60°C kW 12 24 12 24 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 AIR / GAS MANIFOLD SENSOR - BOILER FLOW IGNITION AND FLAME SENSE ELECTRODES OVERHEAT THERMOSTAT RETAINING BRACKET EXPANSION VESSEL REMOVABLE TOP CASE PANEL FOR SERVICING SECURING NUT, AIR / GAS MANIFOLD CLAMP HEAT EXCHANGER WALL MOUNTING FRAME FLUE AIR PRESSURE SWITCH CONNECTION (BLANKED OFF ON THIS APPLIANCE) FLUE OVERHEAT THERMOSTAT ACCESS POINT FOR CLEANING HEAT EXCHANGER/SUMP SYSTEM PRESSURE GAUGE DRAIN POINT RET
LAYOUT & COMPONENTS APPLIANCE INFORMATION 27 AUTO AIR VENT 28 UNUSED PORT 29 COMPACT HYDRAULIC MOUNTING SCREW (2) TO BOILER 30 PRESSURE RELIEF VALVE 31 OPTIONAL INTEGRAL DIVERTER VALVE POSITION 32 RETURN CONNECTION TO SERVICE VALVE 33 DRAIN POINT 34 SYSTEM PUMP 35 FLOW CONNECTION TO SERVICE VALVE 36 FLOW CONNECTION FROM BOILER HEAT EXCHANGER 37 EXPANSION TANK CONNECTION 38 SYSTEM PRESSURE GAUGE 39 FAULT RESET BUTTON 40 NOT USED 41 MAINS ON/OFF INDICATOR/ DIAGNOSTIC LIGHT (BLUE) 42 CH TEMPERATURE CONTROL 4
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, 140 watts • 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. NOTE: this is reduced to IP20 if the following mechanical timers are fitted: 7 716 192 036 or 7 716 192 037. • Wiring must comply with latest IEE wiring regulations.
WATER SYSTEMS & PIPEWORK S PLAN LAYOUT Y PLAN LAYOUT WITH EXTERNAL DIVERTER VALVE PLASTIC PI PEWOR K & U N DE R FLOOR HEATING: • Any plastic pipework must have a polymeric barrier with 600mm (minimum) length of copper pipe connected to the boiler. • Plastic pipework used for underfloor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approx. 50°C.
PRE INSTALLATION 12 CONDENSATE PIPEWORK INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System 8 716 115 167b (03/2009)
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.
PRE INSTALLATION Vent position 12 & 24 kW To room or internal space High level Minimum free area 122 cm2 Minimum free area 61 cm2 Low level Minimum free area 122 cm2 Minimum free area 61cm2 14 BOILER LOCATION & CLEARANCES INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System 8 716 115 167b (03/2009) Direct to outside
BOILER LOCATION & CLEARANCES BATHROOMS: 1 A boiler fitted with a non-mechanical timer or with no timer can be installed in zone 2 or outside the shaded area . 1 2 2 A boiler with a mechanical timer, or RF mechanical timer with room thermostat must only be installed outside the shaded area. Additional RCD (Residual Current Device) protection may be required. PRE INSTALLATION Refer to the latest 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. CAUTION: The side rails of the wall mounting frame are manufactured from a plastic material! Do not apply excessive heat in these areas. There exists the possibility of damage to the plastic side rail when soldering copper pipe connections.
High level horizontal flue with 2x90° bends FLUE OPTIONS The Greenstar series has the option of two horizontal RSF (60/100 telescopic and 80/125) flue systems and two vertical RSF (60/100 or 80/125) flue systems: The systems have different maximum flue lengths This page shows various fluing options with the straight flue lengths required to achieve the maximum flue length.
• • • • PRE INSTALLATION • • The flue must be fitted and terminated in accordance with the recommendations of BS5440 : Part 1. The flue must not cause an obstruction. Discharge and any noise from the flue outlet must not cause a nuisance. Flue gases have a tendency to plume and in certain weather conditions a white plume of condensation will be discharged from the flue outlet. Where this could be a nuisance, for example, near security lighting, an alternate position should be found.
PRE INSTALLATION 19 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System 8 716 115 167b (03/2009) FLUE TERMINAL POSITIONS
UNPACKING WALL FRAME AND IMPORTANT: 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 5 B - Inner sleeve (unwraps from front) C - Packaging base D - Protective wrapping A E - Appliance outer case B B C C 6.1 E 6.2 INSTALLATION 6 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.
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), C - Gas inlet (22mm). A INSTALLATION B 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 HORIZONTAL FLUE (60/100mm diameter) For vertical flues and 80/125mm horizontal flues, please refer to separate instructions supplied with the flue kit. 93mm Edge of case NOTE: to ease assembly of flue components, apply silicone lubricant to sealing surfaces. Basic 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.
B A FLUE INSTALLATION C Installing the standard flue: D H E D B 1 Set the flue length to the distance required, secure with screw and seal joint with the aluminium tape supplied. Slide the inner wall seal (A) onto the terminal (B) as shown. If fitting from inside the building; slide the outer wall seal (C) onto the terminal (B) as shown. TOP 2 Remove the three screws (D, H) around the flue outlet (F) on the boiler. Check the boiler flue seal is correctly seated.
FLUE INSTALLATION ASSEMBLING THE FLUE Apply silicone grease to seal FITTING THE ELBOW: • Flue elbow should push directly down and not be twisted into correct position. Remove the 3 inner flue tube retaining screws. The inner tube will be held in place in the appliance. Fit turret onto appliance and retain with the three removed screws. NOTE: The clamping plate flat should be at the rear of the appliance. ADDITIONAL NOTES AND REMINDERS: • Ensure that all cut lengths are square and free from burrs.
CONDENSATE CONNECTION SUMP CONNECTION 1 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. SUMP BLANKING CAP Note: Do not use lubricants or sealing compounds.
2 1 A ELECTRICAL CAUTION: ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS B The mains supply to the boiler must be either: • from a fused double pole isolator situated next to the appliance. The isolator must have a minimum of 3mm contact separation in both poles. or • from a plug and non-switched socket FROSTSTAT WATER VALVE(S) TANKSTAT ROOMSTAT TIMER The boiler is pre-wired with a two metre mains supply cable.
POSITION OF WIRED COMMISSIONING INSTALLATION COMPONENTS 30 POSITION OF WIRED COMPONENTS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System 8 716 115 167b (03/2009)
1 A PRE-COMMISSIONING 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 1 Turn on the water main and open the system valves. 2 Open all radiator valves. 3 Fill the system via a WRAS approved filling loop. 4 Vent (A) any air from the boiler heat exchanger using a suitable 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.
WATER TREATMENT IMPORTANT: ARTIFICIALLY SOFTENED WATER MUST NOT BE USED TO FILL THE CENTRAL HEATING SYSTEM. IMPORTANT: Debris from the system can damage the boiler and reduce efficiency. Failure t o comply wit h t he guidelines for the use of water treatment with the appliance will invalidate the appliance warranty. ENSURE THAT THE SYSTEM HAS BEEN CLE AN E D AS ON PAG E 6 OF TH E S E INSTRUCTIONS. FLUSHING (Central Heating): Switch off the boiler.
COMMISSIONING 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 H A E D F G C 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). Re-tighten bottom two screws (B). A A 2. FITTING FASCIA FLAP: Present the flap up to the appliance with the hinge pins facing the appliance. Engage the left hand pin into the grey pivot.
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. 1.1 1.2 INSPECTION AND SERVICE 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. Lowering 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 O UT BY A C O M P ETE NT P E R S O N . IT M U ST 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. IMPORTANT: IF THE JOINT BETWEEN THE AIR/GAS MANIFOLD AND THE HEAT EXCHANGER IS DISTURBED THE SEALING GASKET MUST BE REPLACED.
5 INSPECTION AND SERVICE H 4 5 6 I Remove electrical connector from fan. Undo and remove securing nut (H) from the top of the heat exchanger. 6 Remove retaining plate (I). 7 Rotate fan and air/gas manifold assembly (J) around the top of the heat exchanger until it stops at the lug. Lift up assembly and remove from boiler. 8 Disconnect spark electrode and flame sensor connections (K). Remove clamping plate (L). Remove spark/flame electrode assembly from boiler.
INSPECTION AND SERVICE R 9 Small tab 9 Remove burner (M). Remove top baffle (N). Remove lower baffle (0). Remove the two pozi-drive screws (P) retaining the access cover (Q) 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 (R). Clean heat exchanger flue ways (S) 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 SIT AND DUNGS VALVES 5.2 The following components require the control to be moved in to the service position: Gas valve Siphon PCB fuse Transformer A REMOVAL OF THE VALVE IS THE SAME FOR BOTH SIT AND DUNGS VALVES. THE SIT VALVE IS SHOWN IN THE DIAGRAM. 6.1 R E P LAC E M E NT OF TH E GAS VALVE M U ST NOT B E C AR R I E D OUT I F A CO/CO2 ANALYSER IS NOT AVAILABLE. 5. Moving boiler control to service position 5.1 Remove screw (A) securing control. 5.2 Gently pull forward. 6.
REPLACEMENT OF PARTS A 7 7. Access to boiler control components Remove 3 screws (A) and remove cover from control. 8. PCB fuse Remove fuse F1 (B) from the PCB and replace. There is a spare fuse clipped into the underside of the electrical cover. 8.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. 8 B SERVICING & SPARES Spare Fuse order T1.6L 250V F2 T2.
A REPLACEMENT OF PARTS 10 10. Replacing control IMPORTANT: Do not replace the control unit if a CO/CO2 analyser is NOT available. B 10.1 C C C 10.2 NOTE: After re-assembly, check the CO/CO2 levels as described in the setting of the air/gas ratio section. F E IMPORTANT: ENSURE CODE PLUG IS RE-FITTED TO THE NEW CONTROL. IF THIS IS NOT DONE THE BOILER WILL INDICATE ERROR AND WILL NOT FUNCTION. F SERVICING & SPARES D The control is supplied within its plastic housing.
11.1 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 11.2 B 11.3 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 12.1 12.2 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. Check CO/CO 2 levels as described in the “setting the air/gas ratio” section. B A 12.3 13 12. Fan 13. Electrode assembly Disconnect spark electrodes and flame sensor connection. Remove clamping plate (D).
REPLACEMENT OF PARTS 16.1 NOTE: Removal of the syphon assembly will give access to Auto air vent. To release the syphon from the sump connection, pull towards you (A). Disconnect the discharge hose (B) at the plumbing manifold. Remove the complete syphon assembly. C 16. 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. Remove diverter valve cover if fitted. A 17.
19.1 REPLACEMENT OF PARTS 19.2 A 19. Pump head Ensure the boiler is fully drained. Release the screw securing the pump electrical cover. Disconnect the electrical harness from the terminal block, make a note of the L, N and earth connections and wire colours. 19.1 Remove the four Allen bolts (A) securing the pump at each corner. 19.2 Gently pull the pump towards you and remove. To refit, follow the above in reverse, ensuring that the L, N and Earth connections are correctly made. A 20.
REPLACEMENT OF PARTS 22.1 22. Hydraulic Block Ensure the appliance has been fully drained. Disconnect the electrical connections at the pump. Remove the syphon assembly (see page 49). 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 24.1 24. Bypass valve 24.2 Remove the Hydraulic block from the boiler (See Removing the Hydraulic Block). 24.1 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. 24.2 Using a pair of pliers, pull out the bypass valve (A) from the housing.
THIS PAGE SHOWS THE SETTING PROCEDURE FOR THE SIT VALVE FOR ALTERNATIVE VALVES SEE PAGE 54 FOR DUNGS VALVE. Max ‘B’ Min ‘C’ 26.1 SETTING THE AIR / GAS RATIO FOR THE SIT 848.093 SIGMA 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. 26.
THIS PAGE SHOWS THE SETTING PROCEDURE FOR THE DUNGS VALVE FOR ALTERNATIVE VALVES SEE PAGE 53 FOR SIT VALVE. 26.1 C SETTING THE AIR / GAS RATIO FOR DUNGS GB-ND 055 DO1 S20 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. 26.
1 2 3 SHORT PARTS LIST SIT 1 2 3 6 5 4 4 5 7 8 6 Expansion vessel WORCESTER Part No. 8 716 105 545 0 GC No. H05 206 7 Electrodes WORCESTER Part No. 8 718 107 087 0 GC No. H26 544 Gasket - burner/electrodes WORCESTER Part No. 8 716 106 506 0 GC No. H26 545 Seal - inner case/mantel WORCESTER Part No. 8 716 106 635 0 GC No. H26 546 9 8 9 10 11 12 Fan WORCESTER Part No. 8 717 204 453 0 GC No. H26 536 Burner WORCESTER Part No. 8 718 120 619 0 GC No.
1.1 1.2 L. P. G. CONVERSION I S O LATE MAI N S E LE CTR I C AL SUPPLY AND REMOVE OUTER CASE AS SHOWN IN THE INSTALLATION, C O M M I S S I O N I N G & S E RVI C I N G INSTRUCTIONS A 2.1 2.2 2.3 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.
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.
BOILER FUNCTION INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System 8 716 115 167b (03/2009) BLUE LIGHT ON FAULT FINDING & DIAGRAMS POWER SWITCH ON System demand at ST10 AND temperature control knob ON Fan to start speed. LOCKOUT YES Diverter valve in CH position Pump ON when optional integral valve is used. BOILER DEMAND 3 minute wait 5th attempt? NO Spark ignition 4 seconds Stop spark.
PROTECTION FUNCTION Run autofroststat function Pump antiseize Pump run 5 seconds every 24hrs FAULT FINDING & DIAGRAMS Boiler temperature below 8°C 59 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System 8 716 115 167b (03/2009) PROTECT FUNCTION
ADDITIONAL INSTRUCTIONS FOR GREENSTAR 12i/24i System WITH OPTIONAL INTEGRAL DIVERTER VALVE WALL HUNG RSF GAS-FIRED CONDENSING BOILER FOR SEALED CENTRAL HEATING SYSTEMS AND INDIRECTLY FED DOMESTIC HOT WATER DIVERTER KIT NUMBERS: 12kW 7 716 192 566 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 1 CODE PLUG CABLE FOR 12kW i System KIT: NATURAL GAS 1118 LPG 1119 FOR 24kW i Sys
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 CH Return 22mm Use the fittings supplied in the Lit/Hardware pack and the Optional Diverter Valve Kit.
1 BOILER CONNECTIONS A 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.
7 BOILER CONNECTIONS Do not lift by the air gas manifold. 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 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. 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 INTERNAL DIVERTER VALVE WITH A VENTED CYLINDER CAUTION: ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS 2 A Note: Mains supply to the boiler must be through a fused double pole isolator situated adjacent to the appliance. The isolator must have a contact separation of 3mm minimum in all poles. External fuse rating 3A. When stripping wires always ensure copper strands do not fall into the control box.
POSITION OF WIRED INSTALLATION COMPONENTS 30 POSITION OF WIRED COMPONENTS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System 8 716 115 167b (03/2009)
PRE-COMMISSIONING 1 A B CHECKS D 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 BOILER FUNCTION Fan to start speed. 58 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System 8 716 115 167b (03/2009) LOCKOUT YES Diverter valve in CH position Pump ON. CENTRAL HEATING DEMAND 3 minute wait 5th attempt? NO Spark ignition 4 seconds Stop spark.
If in the unlikely event the boiler does not give complete satisfaction, before calling for a service engineer, the installer should check the following:For boilers with external diverter valves and controls No Central Heating but Hot Water OK Unlikely to be a boiler fault, please ask your electrician to check the external controls. Pack Number No Hot Water but Central Heating OK Unlikely to be a boiler fault, please ask your electrician to check the external controls.
