THE APPLIANCE IS FOR USE WITH NATURAL GAS OR L.P.G.
CONTACT INFORMATION INSTALLATION & SERVICING INSTRUCTIONS WORCESTER BOSCH: 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 BOSCH 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 CLEANING PRIMARY SYSTEMS 7 MAINS SUPPLY 8 CONDENSATE PIPEWORK BOILER LOCATION & CLEARANCES 9 10 11-12 PLUMBING MANIFOLD 13 FLUE TERMINAL POSITIONS 14 FLUE OPTIONS 15 INSTALLATION WATER SYSTEMS & PIPEWORK PRE INSTALLATION PRE-INSTALLATION INSTALLATION UNPACKING THE BOI
SAFETY & REGULATIONS SAFETY PRECAUTIONS INSTALLATION REGULATIONS IF YOU SMELL GAS: 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.
GENERAL INFORMATION STANDARD PACKAGE: A - Wall hung gas fired condensing boiler for central heating and indirect domestic hot water B - Wall plate C - Hardware literature pack D - Tail pipes - water APPLIANCE INFORMATION E - Bottom Panel 270mm A B 600mm C D E 390mm SPECIFICATIONS: Pre-wired and pre-plumbed Galvanised steel inner frame Digital control system Automatic ignition Direct burner ignition electrodes Built-in frost thermostat Built-in fault finding diagnostics Modulating automatic gas valve
TECHNICAL DATA DESCRIPTION NATURAL GAS 15Ri 18Ri UNITS 12Ri Max. rated heat output net 40/30°C KW 12.85 16.06 Max. rated heat output net 50/30°C KW 12.74 Max. rated heat output net 80/60°C KW Max. rated heat input net L.P.G. 18Ri 24Ri 12Ri 15Ri 24Ri 19.28 25.67 12.85 16.06 19.28 25.67 15.92 19.11 25.45 24.74 15.92 19.11 25.45 12.0 15.0 18.0 24.0 12.0 15.0 18.0 24.0 KW 12.32 15.40 18.48 24.62 12.32 15.40 18.48 24.62 Max.
The diagram opposite shows the controls in the servicing position and excludes the outer case, inner covers and fascia panel.
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.
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. • 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 PLASTIC PI PEWOR K & U N DE R FLOOR HEATING: • Any plastic pipework must have a polymeric barrier with 600mm (minimum) length of copper or steel 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.
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. above pipe invert, or into a gulley (D) below ground but above the water level.
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 outside the shaded areas shown opposite. (Zone 3 according to IEE Wiring Regulations). (See Technical Data for IP ratings.
PLUMBING MANIFOLD Return Flow CONNECTIONS: Heating System: 22mm compression fittings* Gas: 22mm * Use the 22mm copper pipes provided with the appliance. Use the fittings supplied in the Lit/Hardware pack. PRE INSTALLATION • If the flow and return pipes are to be run behind the appliance it maybe an advantage to connect the pipes before hanging on the wall especially if space is limited.
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 THE BOILER IIMPORTANT: All the previous Pre-Installation sections must be read and requirements met before starting boiler or flue installation. 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 X6 WALL MOUNTING PLATE FLUE OPENING 10mm Ø CAUTION: Ensure there are no pipes, electric cables, damp proof courses or other hazards before drilling. X6 SAFETY: All relevant safety precautions must be undertaken. Protective clothing, footwear, gloves and safety goggles must be worn as appropriate. INSTALLATION FIXING THE MOUNTING FRAME: • The boiler template shows the relative positions of the flue and pipes to the boiler. Also clearances around the appliance.
OUTER CASE REMOVAL 1 REMOVING OUTER CASE 1. Undo and remove 2 screws (A) securing boiler casing at the top of the appliance. 2. Undo the 2 captive screws (B) securing boiler casing at the bottom of the appliance. 3. Pull case upwards. 4. Remove cardboard packing piece from appliance. With the outer case removed the appliance is suitable for a 1 man lift (<25kg).
A B 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 plate to the wall with the fixings supplied. • 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.
FLUE INSTALLATION WALL 127mm 93mm MEASURING THE FLUE (Standard Flue): Measure from the outside wall to the centre line of the flue turret. Subtract 93mm from the length L to give the correct dimension to the flue elbow connection. The terminal section should be cut to this dimension, however it must not be shorter than 250mm. After cutting the end must be square and free from burrs to prevent damage to the flue seals.
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, GAS & WATER CONNECTIONS 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).
ELECTRICS CAUTION: ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS Access to electric control panel: 1 Remove boiler casing to access control panel. 2 Unscrew the three screws (A) in the control panel and pull off the connections cover (B). 3 Unclip cable clamp (C). 4 Cut off the tapered cable entry to fit cable diameter required.
POSITION OF WIRED COMMISSIONING INSTALLATION COMPONENTS 25 POSITION OF WIRED COMPONENTS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri 8 716 109 699a (05/05)
PRE-COMMISSIONING 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 matches that of the gas supply. Turn on the main gas supply, check the gas pipework, connections and rectify any leaks.
FILLING THE SYSTEM A 4 B 1 Ensure all system and boiler drain points are closed. 2 If connected to an open vented system turn on the water supply to system header tank and allow to fill the system. 3 For sealed systems fill the system using a WRAS approved filling loop to a pressure of 1 bar. 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.
STARTING THE APPLIANCE IMPORTANT: Never run the appliance when the appliance/system is empty or partially filled. Switching the appliance on/off: 1 Turn on 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 2 Turn control (A) from 0 (off position) to I (on position) the power on indicator (B) illuminates BLUE.
1 WATER TREATMENT 5 A J B K ENSURE THAT THE SYSTEM HAS BEEN CLE AN E D AS ON PAG E 7 OF TH E S E INSTRUCTIONS. C 2 FLUSHING (Central Heating): 1 Switch off the boiler (A). If connected to an open vented system turn OFF the water supply to the system header tank Open all drain cocks (B) and drain the system (C) while the appliance is hot.
COMMISSIONING 1 THE COMBUSTION FOR THE APPLIANCE IS FACTORY SET. NO ADJUSTMENT IS REQUIRED IF THE GAS INLET PRESSURE IS CORRECT. CHECKING GAS INLET PRESSURE: The inlet pressure to the appliance must be checked using the following proceedure: A B 2 MAX MIN B NORM 3 MEASURING THE INLET PRESSURE: 3 Slacken the screw in the inlet pressure test point and connect a manometer. Measure the pressure with the boiler running at maximum.
FINISHING COMMISSIONING 1 The boiler has been factory set, so there should be no need to adjust any controls. 1 Install bottom panel. A The cut out in the bottom panel fits easily over the syphon elbow and outlet, however care should be taken not to disturb any sealed components. B Hook the lip at the back of the bottom panel over the angled edge at the base of the connections manifold. C Gently push up into position. Secure in place with the two screws supplied (D). C A 2 Replace outer casing.
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.
1.1a 1.1b 1.2 INSPECTION AND SERVICE Component Access B 1. Removing outer case 1.1a Undo and remove 2 screws (A) securing boiler casing at the top of the appliance. 1.1b Undo but do not remove the 2 screws (B) securing boiler casing at the bottom of the appliance. 1.2 Pull case forward and remove. It is necessary to remove bottom tray if action 2 to 2.2 is done, this is retained by two screws at the front and hooks over the bottom frame work of the boiler. A 2.
INSPECTION AND SERVICE 1 Primary Heat Exchanger There is a special accessory kit availble specifically designed for cleaning the heat exchanger. If required order 7 716 192 312. 3 Check fan pressure at the test point next to the fan using an electronic manometer The boiler must be run at maximum output. Pressure will read negative and be greater than: A NG B LPG 12kW - 3.6 mbar - 3.9 mbar 15kW - 5.5 mbar - 5.8 mbar 18kW - 7.4 mbar - 8.0 mbar 24kW - 3.1 mbar - 4.
INSPECTION AND SERVICE 1 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. B A 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.
4 E 5 F INSPECTION AND SERVICE Remove electrical connector from fan. Remove electrical connector from fan. 4 Undo and remove securing nut (E) from the top of the heat exchanger. 5 Remove stainless steel viewing mirror (F). 6 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. 7 Disconnect spark electrode and flame sensor connections (J). Remove clamping plate (K).
Q INSPECTION AND SERVICE 8 Small tab 8 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.
SETTING THE GAS / AIR RATIO I SOLATE MAI N S E LEC TR IC AL S U P P LY AN D R E MOVE OUTE R C AS E AS S HOWN I N TH E INSTALLATION, COMMISSIONING & SERVICING INSTRUCTIONS THE BOILER IS FACTORY SET. ADJUSTMENT OF AIR / GAS RATIO IS ONLY REQUIRED IF STATED IN THE SERVICING OR REPLACEMENT PARTS SECTION OF THE MAIN INSTRUCTIONS 1.1 A 1.1 Remove 3 screws (A) and cover (B) from control box. Clipped inside the cover is a plastic tool used to change the mode switch setting.
SETTING THE GAS / AIR RATIO 1.4 Inlet Test Nipple 1.5 – + A 1.6 MAX NORM SERVICING & SPARES MIN 1.7 – Please note: The flue gas test point can be accessed on the appliance flue elbow by removing cap C THE SETTING OF THE GAS RATIO MUST BE CARRIED OUT BY A COMPETENT PERSON.
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. If it is necessary to remove bottom tray, this is retained by two screws (B) at the front and hooks over the bottom frame work of the boiler.
5.1 REPLACEMENT OF PARTS 5.2 The following components require the control to be moved in to the service position and the bottom tray removed: Gas valve Syphon PCB fuse Transformer A 5. Moving boiler control to service position B 5.1 Remove two screws (A) securing control. 5.2 Hang control on two lugs (B) on boiler framework. 6.1 6. Gas valve Isolate gas supply at boiler gas cock. 6.
REPLACEMENT OF PARTS 9 9. Access to boiler control components Move control to the service position. Remove 3 screws (A) and remove cover from control. 10. PCB fuse Remove fuse in plastic housing (B) from the PCB and replace. There is a spare fuse clipped into the cover. A 11.Transformer / PCB Disconnect all electrical connections from the control. Remove 4 screws (C) retaining the rear panel of the control and remove panel. IMPORTANT: ENSURE CODE PLUG IS RE-FITTED TO THE NEW CONTROL.
12.1 REPLACEMENT OF PARTS A The following components require the air / gas manifold and fan assembly to be removed: Pressure switch Fan Electrode assembly Burner Heat exchanger 12.2 B 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. 12. Air / gas manifold and fan assembly 12.3 Remove electrical connector from fan.
REPLACEMENT OF PARTS 14.1 14.2 14. Fan 14.1 Remove 3 screws (A) retaining mixing chamber. 14.2 Remove 2 screws (B) retaining the fan to the air/gas manifold. 14.3 Remove screw (C) retaining plate and remove. Re-assemble with new fan ensuring seals are correctly fitted. B A 15. Electrode assembly 14.3 15 C Disconnect spark electrodes and flame sensor connection. Remove clamping plate (D). Remove spark/flame electrode assembly (E) from heat exchanger. 16.
SHORT PARTS LIST 1 2 3 1 4 5 7 8 10 11 6 9 Fan WHS Part No. GC No. 8 717 204 453 0 H26-536 2 Burner 12Ri WHS Part No. 12Ri GC No. 15Ri WHS Part No. 15Ri GC No. 18Ri WHS Part No. 18Ri GC No. 24Ri WHS Part No. 24Ri GC No. 8 718 120 616 0 H26-537 8 718 120 616 0 H26-537 8 718 120 619 0 H26-538 8 718 120 619 0 H26-538 3 Gas valve 12Ri WHS Part No. 12Ri GC No. 15Ri WHS Part No. 15Ri GC No. 18Ri WHS Part No. 18Ri GC No. 24Ri WHS Part No. 24Ri GC No.
GAS CONVERSION 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. 9 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 EQUPPED 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.
ELECTRICAL WIRING DIAGRAM 4 14 10 7 3 9 2 11 12 8 13 1a Mains Supply BOILER SWITCHED LIVE PUMP L 5 PUMP N 1 6 15 22 21 20 17 FAULT FINDING & DIAGRAMS 19 1. ST1, Terminal block, 230VAC mains supply. 1a. Control box earth connection. 2. Fuse F1 (T2A, H250V). 3. Boiler mains supply on/off switch. 4. Spark transformer. 5. Flame indicator. 6. ST2, Terminal block for pump & switched live. 7. Transformer connectors. 8. ST5, Fan 230VAC. 9. ST6, Diagnostic interface. 10.
FAULT FINDING NOTE : This fault finding information is for guidance only. Worcester, Bosch 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.
MAIN FUNCTION BLUE LIGHT ON Run autofroststat function Pump run 5 seconds every 24hrs Pump antiseize Fan to start speed. LOCKOUT Pump ON.
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.
INSTRUCTION MANUAL INSTALLATION, COMMISSIONING & SERVICING EXCELLENCE COMES AS STANDARD Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 01905 754624 Fax. 01905 754619 Worcester, Bosch Group is a trading name of BBT Thermotechnology UK Ltd. www.worcester-bosch.co.
