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Bosch Worcester GREENSTAR 12i System, Instruction Manual

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Bosch Worcester GREENSTAR 12i System Instruction Manual Download Page 53

SHORT PARTS LIST

1

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

LPG

WORCESTER Part No.

8 716 107 053 0

LPG

GC No.

H26 539

4

Control box

WORCESTER Part No.

8 717 207 667 0

GC No.

H02 525

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.

8 718 107 087 0

GC No.

H26 544

8

Gasket - burner/electrodes

WORCESTER Part No.

8 716 106 506 0

GC No.

H26 545

9

Seal - inner case/mantel

WORCESTER Part No.

8 716 106 635 0

GC No.

H26 546

10

Pump assembly 3 speed

WORCESTER Part No.

8 716 106 355 0

GC No.

H02 527

11

Pressure gauge

WORCESTER Part No.

8 717 208 107 0

GC No.

H02 528

12

By-pass valve

WORCESTER Part No.

8 716 106 434 0

GC No.

H02 532

13

Diverter valve assembly

WORCESTER Part No.

8 716 106 845 0

GC No.

H02 533

14

Diverter valve motor

WORCESTER Part No.

8 716 106 847 0

GC No.

H02 534

15

Control sensor - primary

WORCESTER Part No.

8 716 106 688 0

GC No.

H26 542

16

High limit stat

WORCESTER Part No.

8 707 206 196 0

GC No.

H26 584

17

Valve - pressure relief

WORCESTER Part No.  

8 716 106 431 0

GC No.

H09 750

18

Expansion vessel

WORCESTER Part No.

8 716 105 545 0

GC No.

H05 206

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REPLACEMENT OF PARTS

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System
8 716 107 375a (02/05)

52

SER

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IN

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Summary of Contents for Worcester GREENSTAR 12i System

Page 1: ...2H3P TYPE C13 C33 NATURAL GAS WORCESTER GREENSTAR 12i System GC NUMBER 41 311 67 WORCESTER GREENSTAR 24i System GC NUMBER 41 311 68 LIQUID PETROLEUM GAS WORCESTER GREENSTAR 12i System GC NUMBER 41 311 69 WORCESTER GREENSTAR 24i System GC NUMBER 41 311 70 GB IE ...

Page 2: ... LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER BOSCH PLEASE LEAVE THESE INSTRUCTIONS THE USER GUIDE AND THE COMPLETED BENCHMARK CHECKLIST OR A CERTIFICATE CONFIRMING COMPLIANCE WITH IS 813 EIRE ONLY WITH THE USER OR AT THE GAS METER AFTER INSTALLATION OR SERVICING ABBREVIATIONS USED IN THIS MANUAL Ø Diameter NG Natural Gas LPG Liquid Petroleum Gas CH Central Heating DHW Domestic Hot W...

Page 3: ...ITION OF WIRED COMPONENTS 28 COMMISSIONING PRE COMMISSIONING CHECKS 29 FILLING THE SYSTEM 30 STARTING THE APPLIANCE 31 WATER TREATMENT 32 COMMISSIONING 33 FINISHING COMMISSIONING 34 SERVICING SPARES INSPECTION AND SERVICE 35 40 REPLACEMENT OF PARTS 41 50 SETTING THE GAS AIR RATIO 51 SHORT PARTS LIST 52 CONVERSION KITS L P G CONVERSION 53 54 FAULT FINDING DIAGNOSIS FAULT FINDING 55 CH FUNCTION 56 P...

Page 4: ...y of the appliance IMPORTANT The service engineer must complete the Service Record on the Benchmark Checklist after each service Gas Safety Installation Use Regulations 1998 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 compl...

Page 5: ...atic ignition Direct burner ignition electrodes Built in frost thermostat Built in fault finding diagnostics Modulating automatic gas valve Combustion air fan with speed regulator CH temperature sensor control Pump anti seizure protection Flue gas temperature limiter Condensate trap syphon 700mm 400mm A D 330mm GENERAL INFORMATION INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 1...

Page 6: ...em temperature rise m 2 0 2 0 2 0 2 0 Flue Flue Gas Temp 80 60 C rated min load C 62 56 78 63 62 57 79 64 Flue Gas Temp 40 30 C rated min load C 41 33 54 35 43 35 55 38 CO2 level at max rated heat output 9 8 9 8 11 0 11 0 CO2 level at min rated heat output 9 2 9 2 10 5 10 5 NOx class 5 5 5 5 Condensate Max condensation rate l h 0 93 2 0 0 93 2 0 pH value approx 4 8 4 8 4 8 4 8 Electrical Electrica...

Page 7: ... 16 SECURING NUT AIR GAS MANIFOLD CLAMP 17 SENSOR BOILER FLOW 18 FLUE AIR PRESSURE SWITCH CONNECTION 19 FLUE OVERHEAT THERMOSTAT 20 ACCESS POINT FOR CLEANING HEAT EXCHANGER SUMP 21 REMOVABLE TOP CASE PANEL FOR SERVICING 22 GAS INLET CONNECTION 22mm COMPRESSION 23 TRAP SYPHON 24 TRAP SYPHON OUTLET CONNECTION 22mm PLASTIC PIPE 25 FLOW 26 RETURN 27 DRAIN POINT 28 SILICONE TUBE USE TO VENT AIR FROM HE...

Page 8: ... 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 NOT USED 50 FAULT RESET BUTTON 51 SYSTEM PRESSURE GAUGE 52 POSITION FOR OPTIONAL PROGRAMMER 53 INTERNAL BYPASS WITHIN PLASTIC MOULDING LAYOUT COMPONENTS INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER ...

Page 9: ... boiler system at normal operating temperature as directed by the manufacturer of the flushing agent 5 Drain and thoroughly flush the system to remove the flushing agent and debris 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 SA...

Page 10: ...r must not have a separate electrical supply GAS SUPPLY Boilers using NG must be connected to a governed meter LPG boilers must be connected to a regulator Installation and connection of the gas supply to the boiler must be in accordance with BS6891 Under no circumstances should the size of the gas supply pipe be less than that of the appliance inlet connection The meter or regulator and pipework ...

Page 11: ...stem An air vent is required at the highest point on the system S and Y PLAN SYSTEM NB The boiler is fitted with its own internal bypass A Diverter Valve B Radiator Valve Flow C Lockshield Valve Return NB A drain cock should be fitted at the lowest point of the heating circuit and beneath the appliance OPTIONAL INTERNAL DIVERTER VALVE This boiler is designed to operate on a sealed system only The ...

Page 12: ...ulation in exposed positions and for external pipework 1 Internal sink washing machine drain 2 Internal waste drainage system 3 Soil vent stack 4 External drainage system 5 External condensate absorption point A Condensate from boiler B Sink C 22mmØ plastic condensate pipe D Gulley E Internal soil and vent stack F Serviceable waste trap 75mm min G 300mm x 100mmØ sealed plastic tube H Ground level ...

Page 13: ...ent hazard L Outside wall O M Drain pipe N External drain IMPORTANT The pressure relief valve is a safety device for the boiler and if activated may discharge boiling water steam through the relief valve drain pipe Care should be taken when siting the outlet pipe so that it does not cause an obstruction or discharge above a window entrance or other public access where it could cause a hazard PRESS...

Page 14: ...th clearances less than shown in the diagrams A and B ventilation is required Refer to tables below for ventilation requirements BOILER CLEARANCES UNVENTILATED COMPARTMENTS The diagrams A and B opposite show two options for the minimum space required to install and service the boiler inside an unventi lated compartment This space can be reduced to 50mm for one side only as long as both the side cl...

Page 15: ...VICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System 24i System 8 716 107 375a 02 05 14 PRE INSTALLATION IMPORTANT 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 outlets must not be situated in the bathroom 1 1 2 3 2 3 1 1 2 3 ...

Page 16: ... MANIFOLD INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System 24i System 8 716 107 375a 02 05 15 PRE INSTALLATION Gas Supply alternative from above appliance 22mm Mains Gas Supply 22mm A Further guidance on pipe routing can be found printed on the boiler template supplied with the boiler IMPORTANT IF FITTING OPTIONAL INTEGRAL DIVERTER VALVE Disregard this page and refer to...

Page 17: ... 02 05 16 PRE INSTALLATION Minimum dimensions of flue terminal positions for balanced room sealed flues with fanned draught DRWG TERMINAL POSITION DISTANCE REF A1 Directly below an opening air brick opening windows etc 300mm B1 Above an opening air brick opening window etc 300 mm C1 Horizontally to an opening air brick opening window etc 300 mm D Below gutters soil pipes or drain pipes 75mm E Belo...

Page 18: ...5 Flue Extension lengths Horizontal Vertical 60 100mm 960mm Horizontal Vertical 80 125mm 1000mm Flue Terminal lengths Horizontal 60 100mm 800mm including terminal Horizontal 80 125mm 1200mm Vertical 60 100mm 1140mm to top of terminal Vertical 80 125mm 1365mm to top of terminal STANDARD FLUE HORIZONTAL Ø100 MAX 686 A x 1 MIN 250 A x 1 Ø125 MAX 1070 A x 1 MIN 250 A x 1 Requires cutting MAXIMUM FLUE ...

Page 19: ...g ladder to loft space Two sets of steps should be used Two people should share the lifting of the boiler up to the loft hatch where the boiler is entered into the loft space tilted and slid on its back into the loft Once the appliance is removed from its packaging check the contents against the packing list Before installing appliance ensure system has been cleaned as explained on page 8 1 Remove...

Page 20: ... to be used a125mm 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 terminal section of the 100mm flue has an inbuilt 3 angle If extensions are to be added then the complete flue must rise at an angle of 3 The 125mm Ø flue system will require the flue to rise at an ang...

Page 21: ...g D and undo the four screws two at the bottom of the boiler H and two at the top H see diagrams 6 1 and 6 2 Remove any packaging within the boiler and the packaging base C 7 Stand boiler upright and remove the protective inner packaging F at the rear of the boiler UNPACKING THE APPLIANCE INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System 24i System 8 716 107 375a 02 05 2...

Page 22: ...s in the DOWN position This is located on the right hand side of the wall frame at the rear 2 Pull the extended tab lever forward and down until there is no further travel 3 Hang the boiler on to the wall mounting frame by the two brackets positioned left and right at the top rear of the appliance Do not lift the appliance by the air gas manifold There are two handling holes incorporated into the ...

Page 23: ...y 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 Connect the expansion vessel flexible pipe to the hydraulic manifold situated left of the pump It is necessary to remove and discard the grey plastic blanking plug E from the connection at the hydraulic manifold before securing the expansion ve...

Page 24: ...easure 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 cut shorter than 250mm After cutting the end must be square and free from burrs to prevent damage to the flue seals Edge of case 200mm WALL 189mm 93mm 250mm min Flue ...

Page 25: ...ard Flue Turret 686mm Subtract Full Extension 960mm Cut Length 734mm NOTE The minimum length a flue extension can be cut to is 100mm NOTE Where extensions are reduced cut length which DOES NOT contain the seal ADDITION OF FLUE BENDS When flue bends are being used an allowance of 98mm per bend must be allowed from the centre line of the bend In the example shown using a flue extension with 2 bends ...

Page 26: ...in flue kit 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 length...

Page 27: ... sealing washer B CONDENSATE CONNECTION A B CONDENSATE CONNECTION INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System 24i System 8 716 107 375a 02 05 26 INSTALLATION IMPORTANT IF FITTING OPTIONAL INTEGRAL DIVERTER VALVE Now fit the diverter valve For installa tion refer to FITTING THE DIVERTER VALVE in the ADDITIONAL INFORMATION section at the back of the book You must the...

Page 28: ...g screw D clockwise to secure cable and replace clamp C into control panel 6 Mains power 230v connection ST10 Separate wires from cable end and strip to 6mm Connect LIVE wire to terminal L Connect NEUTRAL wire to the terminal N Connect EARTH wire to the connector NOTE Earth cable to be longer so that it pulls out last if mains cable is snagged 7 Boiler demand live from external wiring centre ST10 ...

Page 29: ...POSITION OF WIRED COMPONENTS COMMISSIONING POSITION OF WIRED COMPONENTS INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System 24i System 8 716 107 375a 02 05 28 INSTALLATION ...

Page 30: ...ks 3 Check that the condensate pipe has been connected to the syphon 4 Check pressure relief drain pipe H is correctly fitted and securely tightened IMPORTANT If the boiler is not to be commissioned immediately then after sucessfully completing all of the checks and any rectification work close the gas and water valves shut off the gas supply electrically isolate the boiler and label appropriately...

Page 31: ...ntegral expansion vessel is pre charged to 0 75 bar equal to a static head of 7 5m 22ft A Schraeder type valve is fitted to the expansion vessel to allow for pressure adjustment if required If an extra expansion vessel is fitted to the central heating return adjust this to the same pressure as the appliance internal expansion vessel refer to separate instruc tions with the extra expansion vessel 6...

Page 32: ...ss power button A and the power on indicator B illuminates BLUE 3 Turn the boiler thermostat control C to maximum The burner on indicator D illuminates GREEN when the burner has lit 4 If the boiler fails to light the BLUE power indicator B and reset button E will flash alternately To reset press and hold the reset button E for 2 seconds The boiler will be reset STARTING THE APPLIANCE IMPORTANT Nev...

Page 33: ... N Ensure tube outlet 0 is directed away from the fan or any other electrical component to prevent damage Also place a suitable cover over the fan to prevent any spillage of water onto electrical connections Ensure the cover is removed after venting 8 Vent all radiators P and primary side of the hot water cylinder Re pressurise if necessary to 1bar Q Set all controls to maximum R Record the date w...

Page 34: ...appliances working Replace controls cover NOTE This boiler is designed with a differential of 20 C across the heating system If pressure is satisfactory press the service button F again and the boiler will return to normal operation If left in the service mode the control will return to normal operation after 15 minutes Re seal the screw in the gas inlet pressure test point IMPORTANT Do not contin...

Page 35: ...slide towards the rear until it is fully engaged HANDOVER Complete the Benchmark checklist Open the facia cover by gently pressing the centre top of the cover D Set up the controls and show the user how to operate all the controls shown in the User Guide Place the user guide into the tray E on the inside of the facia cover If the appliance is unused and exposed to freezing conditions shut off all ...

Page 36: ... the system and remake any that show signs of leakage Refill and re pressurise if applicable as described in Commissioning Operate the appliance and take note of any irregularities Refer to Fault Finding for rectification procedures IMPORTANT Any service work must be carried out by competent registered engineers such as British Gas or Corgi registered personnel CAUTION TURN OFF THE GAS SUPPLY AND ...

Page 37: ...t Exchanger There is a special accessory kit available 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 Natural gas LPG 12i System 3 1 mbar 12i System 4 9 mbar 24i System 3 1mbar 24i System...

Page 38: ...s the service button is pressed again 2 Pull the cover off and connect a manometer to the fan pressure test point After measurement replace test point cover Pressure will read negative and be greater than Natural gas LPG 12i System 3 1 mbar 12i System 4 9 mbar 24i System 3 1 mbar 24i System 4 1mbar Pressures measured below these figures will indicate that the heat exchanger will require cleaning T...

Page 39: ...siphon Siphon The siphon body is transparent so contents can be examined for any blockage If necessary flush with clean water 1 A B 2 C D Remove control retaining screw 3 3 3 2 3 1 F E INSPECTION AND SERVICE INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System 24i System 8 716 107 375a 02 05 38 SERVICING SPARES COMBUSTION TESTING MUST BE CARRIED OUT BY A COMPETENT PERSON IT...

Page 40: ...the heat exchanger until it stops at the lug Lift up assembly and remove from boiler 8 Disconnect spark electrode and flame sensor connections J Remove clamping plate K Remove spark flame electrode assembly from boiler Remove seal from the top of the heat exchanger 5 6 E F 7 G 8 K J INSPECTION AND SERVICE INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System 24i System 8 716...

Page 41: ...tted correctly When re fitting the burner ensure that it fits centrally within the heat exchanger and location tabs are situated in location holes Ensure seal is replaced with new seal and is correctly fitted Check the siphon unit for blockage before refitting to boiler Reassemble and check combustion as stated in the gas conversion section NOTE To show the heat exchanger more clearly it has been ...

Page 42: ...l sensor D upwards until clear of pocket in heat exchanger Coat new sensor with heat conductive paste and replace 3 Overheat thermostat Remove two electrical connectors from thermostat Slacken and remove fixing screw and thermostat When replacing ensure thermostat sits correctly on surface of the casting with the left hand side of thermostat siting up against the shoulder Note It is essential that...

Page 43: ...ess Note The valve will require setting follow procedure Setting the gas air ratio in the gas conversion section 7 Gas adjuster Isolate gas supply at boiler gas cock Repeat step 6 1 above Twist retaining clip D to release then remove clip and tube Refit new adjuster and secure with clip 8 Siphon 8 1 Undo plastic nut E on the siphon outlet Drop condensate tube away from siphon 8 2 Remove hose F 8 3...

Page 44: ...e fuse clipped into the 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 9 10 11 A B C C REPLACEMENT OF PARTS INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System 24i System 8 716 107 375a 02 05 43 SERVICING SPARES ...

Page 45: ... 2 Using a suitable tool D press the button E upwards and slide the control support bracket F to the left 12 3 Support the control and unclip control support cable G from the boiler frame Remove the support cable and fit to the new control Remove appropriate cable restraints from the new control box Fit control to the boiler Re connect support cable to the boiler and all electrical connections to ...

Page 46: ...pressure switch to bracket Refit new pressure switch to bracket The following components require the air gas manifold and fan assembly to be removed Pressure switch Fan Electrode assembly Burner Heat exchanger 13 1 13 2 14 4 14 3 14 2 14 1 A B C D E F 13 3 IMPORTANT IF THE JOINT BETWEEN THE AIR GAS MANIFOLD AND THE HEAT EXCHANGER IS DISTURBED THE SEALING GASKET MUST BE REPLACED IMPORTANT ENSURE TU...

Page 47: ...nsure that burner tab fits correctly into hole Ensure that the seal is replaced with a new one 18 Heat Exchanger Isolate flow and return valves then drain the boiler Remove siphon 18 1 Remove clip from plastic elbow on the flow pipe and pull flow pipe away from heat exchanger 18 2 Remove plastic nut from the bottom of the boiler 18 3 Rotate lever to release return pipe 18 4 Undo flue connection fr...

Page 48: ...erter valve motor Undo the two screws holding the valve to the plastic housing 20 1 Withdraw the valve B and clean the valve chamber if necessary To refit follow the above in reverse Ensure any seals that have been disturbed are renewed 21 Auto air vent Ensure the appliance has been fully drained see draining the appliance 21 1 Use a screwdriver or similar to rotate the air vent anticlockwise 21 2...

Page 49: ... the nut on the rear of the pressure gauge Remove the pressure sensing head and pressure gauge capillary from the housing To refit follow the above in reverse DO NOT omit the washer from the capillary when fitting a replacement gauge 24 Drain tap Ensure the appliance has been fully drained see draining the appliance 24 1 Rotate the drain tap fully anticlockwise 24 2 Withdraw the drain tap from its...

Page 50: ... but makes the removal of the block easier 25 1 Undo the two screws securing the hydraulic block to the chassis located top left top right of the housing 25 2 Lift the left hand side of the block slightly then manoeuvre the block out starting with the right hand side Take care not to snag the harness or pressure gauge bracket NOTE the block will still contain a small amount of water which will spi...

Page 51: ...ains power from the boiler Place the controls in service position Isolate the boiler from the heating system and cylinder return if internal diverter valve is fitted using service valves Drain boiler 28 1 Remove clip from expansion vessel connection 28 2 Remove screw retaining the vessel to the top of the boiler casing 28 3 Pull the vessel up and out over the flue system or to one side if fitted w...

Page 52: ...r will be permanently illuminated Remove manometer and re seal inlet pressure point on gas valve Fit new plastic sealing cover on to outlet adjuster B Fit white cover over valve adjuster C and secure with black security tag Remove red arrow from data plate and fit new one in correct position for gas type Re assemble and refit boiler case Re connect mains electrical supply and check boiler operatio...

Page 53: ...35 0 GC No H26 546 10 Pump assembly 3 speed WORCESTER Part No 8 716 106 355 0 GC No H02 527 11 Pressure gauge WORCESTER Part No 8 717 208 107 0 GC No H02 528 12 By pass valve WORCESTER Part No 8 716 106 434 0 GC No H02 532 13 Diverter valve assembly WORCESTER Part No 8 716 106 845 0 GC No H02 533 14 Diverter valve motor WORCESTER Part No 8 716 106 847 0 GC No H02 534 15 Control sensor primary WORC...

Page 54: ... panel into service position 2 Code plug Code plugs With internal diverter valve 12kW NG 112 12kW LPG 113 With external diverter valve 12kW NG 108 12kW LPG 109 2 1 Remove 3 screws B retaining plastic cover at rear of control box and remove 2 2 Replace code plug C with new one supplied with conversion kit Replace plastic cover Place control in normal position and secure with screw 1 1 1 2 A ISOLATE...

Page 55: ...orward out of boiler Disconnect electrical connections Fit plastic retaining nut to the outlet of the gas valve from the kit and hand tighten Replace valve with new seals Check for gas soundness 3 Gas adjuster Twist retaining clip C to release then remove clip and tube Refit new adjuster and secure with clip Coloured red for LPG or black for NG 4 Code plug 4 1 Remove 3 screws D retaining plastic c...

Page 56: ...ltage wiring harness connections to sensor Fan fan harness connections to fan Code plug fitted Replace control board Service mode selected to min press service button to return to normal Service mode selected to max press service button to return to normal NOTE This fault finding information is for guidance only Worcester Bosch cannot be held responsible for costs incurred by persons not deemed to...

Page 57: ...ture shut down if water tempera ture is 5 C above set value Gas valve OFF Fan overrun 30 seconds 3 minute wait Spark ignition 4 seconds NO YES BOILER FUNCTION INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System 24i System 8 716 107 375a 02 05 56 FAULT FINDING DIAGRAMS System demand at ST10 AND temperature control knob ON IGNITION SEQUENCE IMPORTANT IF THE OPTIONAL INTEGRAL...

Page 58: ...ON INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System 24i System 8 716 107 375a 02 05 57 FAULT FINDING DIAGRAMS Boiler temperature below 8 C Run autofroststat function Pump antiseize Pump run 5 seconds every 24hrs ...

Page 59: ...stem GC NUMBER 41 311 69 WORCESTER GREENSTAR 24i System GC NUMBER 41 311 70 GB IE 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 Sys...

Page 60: ...If the boiler pipes are to be run behind the appliance ensure that the pipes pass through the slot in the yellow plastic guide C This is fitted to the boiler frame CH Return 22mm Flow 22mm PLUMBING MANIFOLD INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System 24i System 8 716 107 375a 02 05 15 PRE INSTALLATION Gas Supply alternative from above appliance 22mm Mains Gas Suppl...

Page 61: ...ree the back clamping plate on the hydraulic block C shown in 3 3 Remove the brass bung assembly D from the hydraulic block by removing the screw and 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...

Page 62: ...ion is in the DOWN position This is located on the right hand side of the wall frame at the rear 6 Pull the extended tab lever forward and down until there is no further travel 7 Hang the boiler on to the wall mounting frame by the two brackets positioned left and right at the top rear of the appliance Do not lift the appliance by the air gas manifold There are two handling holes incorporated into...

Page 63: ...nections to the heating system Connect the gas supply to the boiler gas cock 22mm compression 11 Connect the expansion vessel flexible pipe to the hydraulic manifold situated left of the pump It is necessary to remove and discard the gray plastic blanking plug E from the pressure vessel connection at the hydraulic manifold before securing the expansion vessel flexible pipe F in place with the wire...

Page 64: ...es 4 Remove the code plug from the control and cut the tie to the boiler chassis so that it can be completely discarded and replace with the one from the kit making sure that it is secured to the boiler chassis see ELECTRICAL on the following page Code plug numbers 12kW i System Kit 12i System NATURAL GAS 112 12i System LPG 113 24kW i System Kit 24i System NATURAL GAS 114 24i System LPG 115 FITTIN...

Page 65: ...e and replace clamp C into control panel 6 Mains power 230v connection ST10 Separate wires from cable end and strip to 6mm Connect LIVE wire to terminal L Connect NEUTRAL wire to the terminal N Connect EARTH wire to the connector NOTE Earth cable to be longer so that it pulls out last if mains cable is snagged 7 Optional external frost stat connection ST6 Connect frost stat wires to terminal Fs an...

Page 66: ...POSITION OF WIRED COMPONENTS COMMISSIONING POSITION OF WIRED COMPONENTS INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System 24i System 8 716 107 375a 02 05 28 INSTALLATION ...

Page 67: ...as been connected to the syphon 4 Check pressure relief drain pipe H is correctly fitted and securely tightened IMPORTANT If the boiler is not to be commissioned immediately then after sucessfully completing all of the checks and any rectification work close the gas and water valves shut off the gas supply electrically isolate the boiler and label appropriately C 2 3 F H PRE COMMISSIONING CHECKS A...

Page 68: ...LIGHT ON BURNER LIT GREEN FLAME LIGHT ON Stop spark Wait 10 seconds 5th attempt LOCKOUT 10 second stabilisation period Fan gas modulation to achieve set temperature 40 82 C END OF BOILER DEMAND Gas valve OFF Pump run 3 minutes Fan run 30 seconds Over temperature shut down if water tempera ture is 5 C above set value Gas valve OFF Fan overrun 30 seconds 3 minute wait Spark ignition 4 seconds NO YES...

Page 69: ...op spark Wait 10 seconds 5th attempt LOCKOUT Fan gas modulation to achieve set temperature 75 C DEMAND END Gas valve OFF Pump run 3 minutes Fan run 30 seconds Over temperature shut down if water tempera ture is 8 C above set value Gas valve OFF Spark ignition 4 seconds NO YES Cylinder stat calling AND Facia mounted programmer ON DOMESTIC HOT WATER DEMAND GREEN FLAME LIGHT ON Burner shut down if pr...

Page 70: ...up 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 uk 8 716 107 375a 02 05 INSTRUCTION MANUAL INSTALLATION COMMISSIONING SERVICING ...

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