Bosch Worcester GREENSTAR 12Ri ErP + Installation And Maintenance Instructions Manual Download | Manualshive

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Regulations

6 720 821 670 (2018/06)

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Regulations

Installation regulations

Current Gas Safety (Installation & Use) Regulations:

All gas appliances must be installed by a competent person in
accordance with the above regulations.
Failure to install appliances correctly could lead to prosecution.

The appliance must be installed in accordance with, and comply to, the
current: Gas Safety Regulations, IET Regulations, Building Regulations,
Building Standards (Scotland) (Consolidation), Building Regulations
(Northern Ireland), local water by-laws, Health & Safety Document 635
(The Electricity at Work Regulations 1989), EU Regulations No. 811/
2013 - Energy Labelling and any other local requirements.

British standards

Where no specific instruction is given, reference should be made to the
relevant British Standard codes of Practice.
BS7074:1

Code of practice for domestic and hot water supply

BS6891

Installation of low pressure gas pipe work up to 28mm

(R1)

BS5546

Installation of gas hot water supplies for domestic

purposes

EN12828

Central heating for domestic premises

BS5440:1

Flues and ventilation for gas appliances of rated heating

not exceeding 70kW (net): Flues

BS5440:2

Flues and ventilation for gas appliances of rated heating

not exceeding 70kW (net): Air Supply

BS7593

Treatment of water in domestic hot water central heating

systems

BS6798 Installation

of

gas fired boilers of rated input up to 70kW

(net)

LPG Installations

An appliance using LPG must not be installed in a room or internal space
below ground level unless one side of the building is open to the ground.

Irish Standards

The relevant Irish standards should be followed, including:

• ECTI National rules for electrical installations
• IS 813:2002 for Domestic Gas Installations.

Timber Framed Buildings

Where the boiler is to be fitted to a timber framed building the guidelines
laid down in BS5440: Part 1 and IGE "Gas Installations in Timber Frame
Buildings” should be adhered to.

Potable Water

All seals, joints and compounds (including flux and solder) and
components used as part of the secondary domestic water system must
be approved by WRAS.

CH Water

Artificially softened water must not be used to fill the central heating
system.

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Summary of Contents for Worcester GREENSTAR 12Ri ErP +

Page 1: ...rom the building call the National Gas Emergency Service on 0800 111 999 LPG appliances Call the supplier s number on the side of the gas tank These appliances are for use with Natural Gas or LPG Cat II 2H 3P type C13 C33 C53 Model GC Number Natural Gas 9Ri ErP 41 406 74 12Ri ErP 41 406 75 15Ri ErP 41 406 76 18Ri ErP 41 406 77 21Ri ErP 41 406 78 24Ri ErP 41 406 79 LPG 9Ri ErP 41 406 68 12Ri ErP 41...

Page 2: ...ms 31 5 2 Position the appliance 32 5 3 Wall mounting template flue opening 32 5 4 Outer case removal 33 5 5 appliance connection 33 5 5 1 Condensate connection 34 5 6 Flue turret adaptor installation 35 5 7 Electrical connections 36 6 COMMISSIONING 37 6 1 Pre Commissioning checks 37 6 2 Filling the system 38 6 3 Water treatment 38 6 4 Starting the appliance 39 6 4 1 Appliance controls 39 6 5 Comm...

Page 3: ... 9 OPERATIONAL FUNCTIONS 60 9 1 Appliance function 60 9 2 Protection function 61 9 3 Component Characteristics 62 9 3 1 Flow temperature NTC Sensor resistances 62 9 3 2 Flue overheat thermostat 62 9 3 3 Overheat thermostat 62 9 3 4 Gas valve coil resistances 62 9 3 5 Code plug numbers 62 ...

Page 4: ... not taken This symbol indicates important information where there is no risk to people or property Symbol Meaning a numbered step in an action sequence a step in an action sequence a reference to a related part in the document or to other related documents a reference number to identify or refer to a part or item a list entry a list entry second level Table 1 Symbols 1 Domestic Hot Water Central ...

Page 5: ...heating co uk for more information Health and safety The appliance contains no asbestos and no substances have been used in the construction process that contravene the COSHH Regulations Control of Substances Hazardous to Health Regulations 1988 Combustion and corrosive materials Do not store or use any combustible materials paper thinners paints etc inside or within the vicinity of the appliance ...

Page 6: ...for domestic purposes EN12828 Central heating for domestic premises BS5440 1 Flues and ventilation for gas appliances of rated heating not exceeding 70kW net Flues BS5440 2 Flues and ventilation for gas appliances of rated heating not exceeding 70kW net Air Supply BS7593 Treatment of water in domestic hot water central heating systems BS6798 Installation of gas fired boilers of rated input up to 7...

Page 7: ... hung gas fired condensing regular appliance for central heating and domestic hot water 2 Tail pipes water only 3 Wall plate 4 Hardware literature pack see checklist 5 ErP Label 6 Bottom panel and wall mounting template CHECK LIST HARDWARE LITERATURE PACK Qty Appliance Installation Commissioning and Servicing Instructions 1 Users Instructions 1 Consumer Guarantee Card 1 Sealing Pack 1 Compression ...

Page 8: ... C rated min load C 38 33 41 33 44 33 48 34 51 35 54 35 CO2 level at max rated heat output after 30 min 9 6 9 6 9 6 9 6 9 6 9 55 CO2 level at min rated heat output after 30 min 8 6 8 6 8 6 8 6 8 6 8 55 NOx class 6 6 6 6 6 6 NOx rating mg kWh 36 0 38 6 44 3 48 7 55 5 56 0 Condensate Maximum condensate rate l h 0 60 0 93 1 20 1 50 1 80 2 00 pH value approx 4 8 4 8 4 8 4 8 4 8 4 8 Electrical Electric...

Page 9: ...min load C 40 35 43 35 46 36 49 37 52 37 55 38 CO2 level at max rated heat output after 30 min 10 5 10 5 10 5 10 5 10 5 10 5 CO2 level at min rated heat output after 30 min 10 10 10 10 10 10 NOx class 6 6 6 6 6 6 NOx rating mg kWh 36 0 38 6 44 3 48 7 55 5 56 0 Condensate Maximum condensate rate l h 0 5 0 7 0 9 1 2 1 4 1 5 pH value approx 4 8 4 8 4 8 4 8 4 8 4 8 Electrical Electrical power supply v...

Page 10: ...eans 60 C return temperature at heater inlet and 80 C feed temperature at heater outlet P4 kW 9 12 15 18 21 24 At30 ofratedheatoutput and low temperature regime 2 2 Low temperature means for condensing boilers 30 C for low temperature boilers 37 C and for other heaters 50 C return temperature at heater inlet P1 kW 4 4 5 6 8 8 Useful efficiency At rated heat output and high temperature regime 1 η4 ...

Page 11: ...turn temperature at heater inlet and 80 C feed temperature at heater outlet P4 kW 9 12 15 18 21 24 At30 ofratedheatoutput and low temperature regime 2 2 Low temperature means for condensing boilers 30 C for low temperature boilers 37 C and for other heaters 50 C return temperature at heater inlet P1 kW 6 6 6 10 10 10 Useful efficiency At rated heat output and high temperature regime 1 η4 87 2 87 2...

Page 12: ...nger air vent 9 Heat Exchanger 10 Flue overheat thermostat 11 Access panel Heat Exchanger Sump cleaning 12 Return connector with drain point 13 Flow connector 14 Appliance Temperature control and Reset knob 15 Power and fault indicator blue 16 Wiring connections cover 17 Burner indicator green 18 Appliance ON OFF switch 19 Condensate connection 20 Syphon Trap 21 Gas inlet connection 22 Mains cable...

Page 13: ...ODE SWITCH Slow 2 A fuse AC 230 V EMS BUS CH TEMPERATURE CONTROL ON OFF SWITCH ST9 ST6 ST5 ST2 ST1 F1 230V Min Max Norm L N LPNPLR Earth 11 COMMON 230V MAINS SUPPLY SL L N 6720644744 27 3Wo 4 10 8 9 1 2 12 3 5 6 7 Colour sequence Colour sequence Green Live Neutral Red Blue Violet Orange Pump Live Pump Neutral Switched Live L N LP LR NP Installer connections Connection Function ST1 230V supply to t...

Page 14: ...should be installed to give at least a 3 metre circuit when activated However any appliance fitted with a modulating pump may not require a system bypass A drain cock is required at the lowest point in the system An air vent is required at all high points in the system OPEN VENT PRIMARY SYSTEM CONSIDERATIONS The open vent pipe and feed and expansion pipe must rise continuously from the appliance C...

Page 15: ... cold feed 15mm minimum 4 Diverter Zone valve 5 Pump maximum power 90 Watts 6 Automatic bypass 7 Radiator valve Flow 8 Lock shield valve Return 9 Expansion vessel 10 Pressure gauge 11 3 bar pressure relief valve 12 Stop cock Table 9 Key to figures 4 5 6 7 8 NOTICE A drain cock should be fitted at the lowest point of the heating circuit and beneath the appliance SYSTEM FILL CV Check Valve SV Stop V...

Page 16: ... the interior of the pipe 4 3 1 CONDENSATE PIPE WORK SEALED SYSTEM LAYOUT MCW 8 7 4 10 12 11 9 5 reset max M 6720644744 05 1Wo 6720644744 61 1Wo 8 7 1 3 2 4 6 5 150 mm max M reset max M M OPEN VENT LAYOUT 6720644744 62 1Wo 8 7 4 6 5 M reset max M M SEALED SYSTEM LAYOUT MCW 12 10 11 9 Full details on condensate discharge Follow the latest version of BS6798 and HHIC guidance NOTICE Where a new or re...

Page 17: ... be used Ensure that the condensate drain pipe is connected down stream of the waste trap Fig 10 Disposal to a waste pipe CONDENSATE PUMP Where gravity discharge to an internal termination is not physically possible or where very long internal runs would be required to reach a suitable discharge point condensate should be removed using a proprietary condensate pump of a specification recommended b...

Page 18: ...e use of a drain cover such as those used to prevent blockage by leaves may offer further protection from wind chill Pipe drainage will be improved if the end is cut at 45 as opposed to a straight cut Fig 13 External disposal Fig 14 Condensate pump to external disposal NOTICE Rainwater or external drain disposal Untreated condensate must not be allowed to flow into streams or rivers A rainwater do...

Page 19: ...external drain or soak away Pipe 1 or 3 should be finished with a partial bend near the outlet to face the external wall as shown to help prevent freezing Fig 16 Pressure relief pipe work 1 Discharge pipe turned back onto external wall example 2 Outside wall 1 Discharge pipe into drain or gully example 4 External drain 4 4 1 Alternative PRV connections Combined PRV condensate The PRV or a combined...

Page 20: ...in tables 14 15 or 16 4 5 4 APPLIANCE CLEARANCES UNVENTILATED COMPARTMENTS 4 5 5 INSTALLATION CLEARANCES UNVENTILATED COMPARTMENTS No surface protection is required against heat transfer from the appliance Vent position To room or internal space Direct to outside High level Min free area 122cm2 Minimum free area 61cm2 Low level Min free area 122cm2 Minimum free area 61cm2 Table 12 Compartment vent...

Page 21: ... the regulations The diagram is for guidance only The appliance must only be installed outside zone 2 Fig 18 Bathroom installations 1 Zone 1 2 Zone 2 2 Without the end wall zone 2 must extend 600mm from the bath A 600mm radius from bath or shower NOTICE Any switch or appliance control using mains electricity must not be withinreach of aperson using the bath or shower 6720646608 124 6Wo 2 1 2 1 2 2...

Page 22: ...tem 22mm compression fittings Gas 22mm compression fittings Do not use the pre formed copper pipes supplied with the appliance for the gas supply These copper pipes are for water only Further guidance on pipe routing can be found printed onthe appliancetemplate suppliedwiththeappliance Ensure that the pipes are adequately supported and room between the pipes to avoid noise 1 2 4 3 3 4 6720644744 1...

Page 23: ...e viewable from both directions NOTICE Effective flue lengths each90 bendisequivalentto2metresofstraightflue each 45 bend is equivalent to 1 metre of straight flue Plume management kits are available for the 60 100 horizontal flue system Refer to the manual supplied with the plume management kits for complete installation instructions Part number Flue Description 7 716 191 082 60 100 Telescopic ho...

Page 24: ... length mm 60 100 80 125 High level horizontal flue with 2 x 90 bends 2 600 11 000 Table 25 Maximum flue length mm 60 100 80 125 High level horizontal flue with 3 x 90 bends N A 9 000 Table 26 6720806945 22 1Wo 6720806945 23 1Wo 6720806945 24 1Wo Maximum flue length mm 60 100 80 125 Vertical balanced flue assembly 6 400 15 000 Table 27 Maximum flue length mm 60 100 80 125 Vertical balanced flue wi...

Page 25: ... penetrate the roof in the shaded area The terminal must be at least 1500mm from the opening or vent whensitedbelowthewindowor600mmwhensitedtoeitherside or above 7 400mm from a pitched roof or 500mm in regions with heavy snow fall 8 1 200mm separation between a vertical flue measured horizontally and a horizontal flue terminal Not required if the horizontal flue is 1 200mm above 9 Forthepurposeofd...

Page 26: ...LIGHT DORMA 1000 600 300 300 300 BELOW GROUND OPEN LIGHT WELL 15 2 2 1 1 1 200 25 100 16 25 100 10 300 600 BOUNDARIES 1 2 1 2 9 100 25 25 100 25 25 100 25 600 600 2000 OPENING OPPOSITE TOP BOUNDARY LINE 3 4 5 11 11 11 7 10 10 10 5 1 200 25 75 25 75 8 600 600 1000 1200 600 300 300 300 300 300 300 300 300 200 200 300 300 300 25 300 1500 1200 13 6720821670 08 1Wo 5 300 150 300 TOP ...

Page 27: ... or external corner 300mm above a surface such as the ground floor level or roof surface If the terminal section is less than 150mm and has two screws securing it to the elbow the terminal section will not require a supporting bracket 11 300mmabove belowandeithersideofanopeningdoor airvent or opening window 12 Below ground level in an open lightwell The flue must be at least 600mm from the opposin...

Page 28: ...orizontal flue terminal positions for all concentric flue terminal positions unless the flue position is specified in figure 23 for Plume re direct and plume management terminal positions Terminals must be positioned so to avoid combustion products entering the building Support the flue at approximately one metre intervals and at a change of direction use suitable brackets and fittings BOUNDARY LI...

Page 29: ...side of an opening door air vent or opening window UsingaPlumeManagementkittheairintakemeasurementcanbe reduced to 150mm providing the flue exhaust outlet has a 300mm clearance 11 Below balcony or overhange The air intake clearance can be reduced to 150mm providing the flue exhaust outlet has a 200mm clearance 12 1 200mm between terminals facing each other 13 Internal external corners The air inta...

Page 30: ...the system through the PRV of new appliances It may be necessary to use a power flushing machine to aid the cleansing procedure in some circumstances Close the drain cocks and manual air vents Existing appliance circulating pump if continuing to use before new appliance is installed Add a suitable inhibitor to the system in accordance with the manufacturers instructions Open vented systems only Tu...

Page 31: ...ce The wall mounting frame Installer pack template and bottom panel can now be removed Care should be taken when lifting the appliance from the base and the proper technique for safe lifting of any heavy object must be strictly observed Additional requirements for roof space installation The appliance must be unpacked before ascending the steps to loft space Two sets of steps should be used Two pe...

Page 32: ... core drill or similar SIDE OUTLET 4 Markfromthecentrelineofthewalltemplatetothewallwhichtheflue will pass through 4 Allow for a rise of 52mm per metre length of flue to give a 3 angle Clear any debris from the site Fig 26 Marking the flue position WARNING Ensure the mains gas supply is isolated before starting any work and follow all relevant safety precautions Appliance positioning Ensure the ap...

Page 33: ... is possible to fit the flow and return pipes supplied with the appliance installed on the wall If clearance is less than 600mm below the appliance it may be necessary to fit the flow and return pipes before hanging the appliance System pipes may be run vertically up behind the appliance or below it 6720804514 02 1Wo 2 3 1 4 CAUTION ISOLATE THE MAINS GAS SUPPLY BEFORE STARTING ANYWORKAND OBSERVE A...

Page 34: ... the fitting pack 1 Fit washer 1 inside the plastic nut and attach firmly to the connection on the syphon 2 Connect the condensate disposal pipe work to the elbow 2 refer to figure 31 and insert the condensate pipe 25mm into the elbow Fig 30 Condensate connections 1 2 4 3 3 4 6720644744 13 1Wo Pipes in alternative position Return Flow 1 2 6720644744 56 1Wo NOTICE Condensate disposal Follow the rec...

Page 35: ...tor to the appliance Fig 33 Flue turret adaptor connection Additional notes and reminders Ensure that all cut lengths are square and free from burrs Ensure that the flue and seals are not damaged The flue is sealed when assembled correctly the components are pushed fully home and secured The flue is set at an angle of 3 or 52mm per metre length Support the flue at approximately one metre intervals...

Page 36: ... first time installation in an existing property the heating systems must conform to current building regulations Part L1a The exception to this are single storey open plan dwellings where the living areaismore than70 of the total usable floor area Then this type of dwelling can be controlled as one zone An alternative would be individual electronically controlled TRVs For dwellings with a floor a...

Page 37: ...rth connection on the wiring centre junction box SL Demand Switched Live output to the appliance to fire for heating hot water Refit electric control panel covers Refit panel and secure with screws 6 COMMISSIONING 6 1 PRE COMMISSIONING CHECKS Check that the gas service pipe and water pipes are connected to the correct position on the manifold 1 Gas inlet 22mm 2 Flow 22mm 3 Return 22mm Fig 37 Check...

Page 38: ...em ENSURETHATTHESYSTEMHASBEENCLEANEDASONPAGE 30OF THESE INSTRUCTIONS FLUSHING Central Heating Switch off the appliance Open all drain cocks and drain the system while the appliance is hot Close drain cocks and add a suitable flushing agent at the correct strength for the system condition in accordance with the manufacturer s instructions Run the appliance system at normal operating temperature for...

Page 39: ...tallation instructions The integrity of the flue system and flue seals as described in section 7 3 of this manual The integrity of the appliance combustion circuit and relevant seals 6 5 1 CHECKING THE GAS INLET PRESSURE The inlet pressure to the appliance must be checked using the following procedure MEASURING THE INLET PRESSURE Fig 42 Inlet pressure test point Close gas isolation valve Slacken t...

Page 40: ... checks are mandatory from April 2014 and these values must be recorded on theBenchmark check list at the back of this manual Oncethegasrateand pressurehavebeenconfirmed asacceptable then the CO and combustion checks can be undertaken Theflowchartisgivenforguidance thedetailsofthechecksaregivenin the following sections Checking flue integrity refer to section 7 3 page 45 Flue gas analysis refer to...

Page 41: ...isfactorily No further action is required No No Verify flue integrity O2 20 6 CO2 0 2 O2 20 6 CO2 0 2 No Yes Check CO and combustion ratio at maximum rate Check CO and combustion ratio at minimum rate CO 350ppm CO CO2 ratio 0 004 CO 350ppm CO CO2 ratio 0 004 CO 350ppm CO CO2 ratio 0 004 Flue integrity test using analyser Yes Set boiler to maximum rate START HERE 6720809056 01 2Wo Zero the analyser...

Page 42: ...he customer the fault finding information in the User instructions Show the customer where the serial number appliance information islocated theywillneedthisinformationiftheycallinwithaproblem BenchmarkCommissioningchecklistcontainsallrelevantappliance information Give the customer details of how to contact the installer gas emergency numbers Show the customer how to safely isolate the appliance A...

Page 43: ... Ireland the Isle of Man or the Channel Islands For full terms and conditions please visit www worcester bosch co uk guarantee terms and conditions Guarantee registration Your Greenstar appliance carries a guarantee against faulty material or manufacture subject to Terms and Conditions Guarantee Registration can be completed On line You can register on our website www worcester bosch co uk guarant...

Page 44: ...ONTROLS TO THE SERVICE POSITION 1 Remove two screws securing the control 2 Pull the control forward 3 Lower the control to align the slots at the top of the control with the lugs on the appliance framework 4 Hang control on two lugs on appliance framework Fig 49 Control panel into service position 7 2 CHECKING GAS INLET PRESSURE Refer to section 6 5 1 for checking the gas inlet pressure 6720644744...

Page 45: ...Flue integrity test 7 4 FAN PRESSURE TEST SETTING THE APPLIANCE TO MAXIMUM 1 Remove the three screws retaining the control cover 2 Remove the control cover 3 Remove the plastic tool clipped inside the cover 4 Insert the tool into the switch 5 Using the tool set the mode switch to maximum output MAX Ensure the appliance is powered up and there is a demand from the external controls The powerindicat...

Page 46: ...MBUSTION TEST Connect the flue gas analyser to the flue gas sampling point as shown in the figure below Run the appliance at maximum output for at least 10 minutes Check the CO CO2 readings against the information in table 34 CO CO2 settings on page 47 Fig 56 If the appliance fails the combustion test check 1 Air intake for restriction 2 Diaphragm in the fan for correct operation 3 Cleanliness of ...

Page 47: ...move the retaining plate assembly Fig 59 Securing nut NOTICE THE SETTING OF THE GAS RATIO MUST BE CARRIED OUT BY A COMPETENT PERSON SETTING OF THE GAS RATIO MUST NOT BE ATTEMPTED UNLESS THE PERSON CARRYING OUT THE TEST IS EQUIPPED WITH A COMBUSTION ANALYSER CONFORMING TO BS 7927 AND IS COMPETENT IN ITS USE CO CO2 values CO CO2 should be measured after 10 minutes Gas type CO2 max CO2 min Natural ga...

Page 48: ...ning the electrode assembly Inspect the condition of the electrodes and ceramics replace if necessary Use a plastic scouring pad to clean the electrodes BAFFLE REMOVAL 1 Refer to figure 62and remove top baffle 2 Remove lower baffle Fig 62 Baffle removal ACCESS COVER REMOVAL Refer to figure 63 1 Remove the two pozi drive screws 2 Remove the access cover 3 Remove the gasket Fig 63 Access cover remov...

Page 49: ... page 47 Fig 64 Cleaning heat exchanger 7 7 1 SYPHON REMOVAL AND CLEANING To release the syphon from the sump 1 Undo the plastic nut on the bottom of the syphon and move the condensate pipe away from the syphon 2 Remove the two screws retaining the syphon bracket 3 Remove the bracket 4 Remove the screw and release the syphon retaining clamp 5 Swing the clamp completely to the left away from the sy...

Page 50: ...at exchanger 2 Pull forward to remove completely Coat new sensor with heat conductive paste and replace CAUTION TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS NOTICE REPLACEMENT OF COMPONENTS After replacement of any components always check for gas tightness where relevant and carry out functional checks as described in C...

Page 51: ...ermostat either Usingasmallterminalscrewdriver prisethethermostatandgrommet from the plastic housing Take care not to damage the plastic housing or 1 Release the flue connection from the sump 2 Push the flue tube up Fig 69 Lower exhaust section Remove electrical connections 1 Push the flue limit thermostat in from the sump Retrieve the thermostat from the sump well Fig 70 Remove thermostat To repl...

Page 52: ...orward out of appliance Replace valve with new seals and check for gas tightness Fig 73 Gas valve lower connection 7 8 7 AIR GAS MANIFOLD AND FAN ASSEMBLY Remove electrical connector and earth wire the from fan Removewireclipfromgasvalveoutletthenpullgaspipefreefromthe gas valve see figure 72 Fig 74 6720644744 36 1Wo 1 1 2 3 4 4 1 2 6720643895 72 1Wo NOTICE The valve will require setting follow pr...

Page 53: ...e air gas manifold from the appliance as described in the previous section 1 Remove two screws retaining the fan to the air gas manifold 2 Remove the air gas manifold 3 Remove the screw holding the retaining plate 4 Remove the retaining plate 5 Remove three screws and the mixing chamber Re assemble with new fan ensuring seals are correctly fitted Fig 78 Dismantling the air gas manifold assembly Di...

Page 54: ...etaining plate 1 hand tight Ensurethattheretainingplate 1 isinthepositionshowninfigure 81 At this point the Air Gas Manifold Fan assembly 8 should be fitted engage the lugs in the slots in the clamping plate and rotate clockwise to the stop position Rotate the retaining plate assembly 1 in the slot on the clamping plate 2 this will prevent the Air Gas manifold 8 rotating back Initially there will ...

Page 55: ... the two arrows in figure 83 Refer to figure 82 for detail of the clamping and mating surface 6 Itisimportanttoclamptheplatedownfirmly withoutovertightening to the heat exchanger to ensure a gas tight seal Fig 82 Clamping plate detail Fig 83 Clamping plate secured 7 8 12 HEAT EXCHANGER Drain the system Remove syphon Remove the air gas manifold and fan 1 Refer to figure 84 remove the clip from the ...

Page 56: ...Heat exchanger removal Reassemble and check combustion as stated in the air gas ratio section 7 6 7 8 13 SYPHON REMOVAL To release the syphon from the sump 1 Undo the plastic nut on the bottom of the syphon and move the condensate pipe away from the syphon 2 Remove the two screws retaining the syphon bracket 3 Remove the bracket 4 Remove the screw and release the syphon retaining clamp 5 Swing the...

Page 57: ...screws in the control panel Remove the connections cover and disconnect all electrical connections from the control Gently pull the code plug from the socket 2 Figure 91 Thecodeplugshouldbeleftattachedtotheframeoftheapplianceby its plastic safety thread Remove the control from the appliance Remove the four screws 3 retaining the rear panel 1 of the control Remove the rear panel 1 Remove the printe...

Page 58: ...sure system content for the system type Ensure there is gas to the appliance Are other gas appliances working gas cooker hob for example Has the credit run out on the gas pre payment meter This fault finding information is for guidance only Worcester cannot be held responsible for costsincurred by persons not deemed to be competent Thisfault finding system assumes that the appliance has been opera...

Page 59: ...ectrodes harness connections Condition and resistance of the leads approximately 2 100 Ω Replace control board Slow flash mostly on flashes off Flue overheat Flue temperature too high Check heat exchanger baffles are correctly fitted or removed and not refitted Heat exchanger overheat Check Water pressure All air is vented Pump harness connections Water leaks blockage Safety thermostats low voltag...

Page 60: ...t LOCKOUT 45 second stabilisation period Fan 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 pump over run Spark ignition and gas 4 seconds NO YES Room thermostat and or mains programmer ON or link fitted at ST1...

Page 61: ... minute overrun period Internal boiler temperature rises above 25 C Central heating demand switches off Pump switches off after a 3 minute overrun period Central heating demand is activated Pump runs for 3 minutes to dissipate heat from the boiler into the system End of boiler demand central heating or domestic hot water AUTOMATIC INTERNAL FROST FUNCTION PUMP OVERRUN FUNCTION A central heating dem...

Page 62: ...Normally closed thermostat Temperature C Resistance Ω Opening temperature 112 3 500 Close temperature 111 6 500 Table 37 Flue overheat thermostat Normally closed thermostat Temperature C Resistance Ω Opening temperature 120 50M Close temperature 119 5 000 Table 38 Overheat thermostat Position Resistance Ω 10 1 Top coil 380 342 418 2 Bottom coil 190 171 209 Table 39 Gas valve coil resistances 67208...

Page 63: ...6 720 821 670 2018 06 63 Notes ...

Page 64: ...6 720 821 670 2018 06 64 Notes ...

Page 65: ...6 720 821 670 2018 06 65 Notes ...

Page 66: ...LQWHUORFN 3URYLGHG ALL SYSTEMS 7KH V VWHP KDV EHHQ ÀXVKHG DQG FOHDQHG LQ DFFRUGDQFH ZLWK 6 DQG ERLOHU PDQXIDFWXUHU V LQVWUXFWLRQV Yes KDW V VWHP FOHDQHU ZDV XVHG KDW LQKLELWRU ZDV XVHG 4XDQWLW OLWUHV DV D SULPDU ZDWHU V VWHP OWHU EHHQ LQVWDOOHG Yes 1R CENTRAL HEATING MODE PHDVXUH DQG UHFRUG DV UDWH Pñ KU OR IWñ KU XUQHU RSHUDWLQJ SUHVVXUH LI DSSOLFDEOH mbar OR DV LQOHW SUHVVXUH mbar HQWUDO KHDWLQJ...

Page 67: ...HSKRQH 1R DV VDIH UHJLVWHU 1R 5HFRUG W PD UDWH 2 SSP AND 2 W PLQ UDWH KHUH 3RVVLEOH 2 SSP AND 2 RPPHQWV 6LJQDWXUH SERVICE 04 DWH QJLQHHU QDPH RPSDQ QDPH 7HOHSKRQH 1R DV VDIH UHJLVWHU 1R 5HFRUG W PD UDWH 2 SSP AND 2 W PLQ UDWH KHUH 3RVVLEOH 2 SSP AND 2 RPPHQWV 6LJQDWXUH SERVICE 05 DWH QJLQHHU QDPH RPSDQ QDPH 7HOHSKRQH 1R DV VDIH UHJLVWHU 1R 5HFRUG W PD UDWH 2 SSP AND 2 W PLQ UDWH KHUH 3RVVLEOH 2 SS...

Page 68: ...Worcester Bosch Group is a brand name of Bosch Thermotechnology Ltd worcester bosch co uk 6 720 821 670 2018 06 WORCESTER BOSCH GROUP TECHNICAL SUPPORT 0330 123 3366 APPOINTMENTS 0330 123 9339 SPARES 0330 123 9779 LITERATURE 0330 123 9119 TRAINING 0330 123 0166 SALES 0330 123 9669 ...

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