Page 1: ...C13 C33 NATURAL GAS WORCESTER GREENSTAR 25Si GC NUMBER 47 31t 84 WORCESTER GREENSTAR 30Si GC NUMBER 47 311 65 LIUUIU PETROLEUM GAS WORCESTER GREENSTAR 25Si GC NUMBER 47 311 88 WORCESTER GREENSTAR 30Si...
Page 2: ...PROSECUTION IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER TECHNICAL HELPLINE DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER PLEASELEAVE THESEINSTRUcnONS WITH THE COMPLETEDBENCHMAR...
Page 3: ...FLUE INSTALLATION CONDENSATE CONNECnON ELECTRICS POSinON OF WIRED COMPONENTS COMMISSIONING PRE COMMISSIONING CHECKS FILILING THE SYSTEM STARnNGTHEAPPUANCE WATER TREATMENT COMMISSIONING FINISHING COMM...
Page 4: ...ngineer must complete the Service Record on the Benchmark Checklist after each service INSTALLATION REGULATIONS Current Gas Safety Installation Use Re lations All gas appliances mUSIbe installed bya c...
Page 5: ...STER G p GENERAL INFORMATION STANDARD PACKAGE A Wall t ng gas fred condensng oombi booloriO centraJ heatingand domestichot water B Boiler support frame C Hardware literature pack seechecklisl D Bonom...
Page 6: ...5 2 5 2 5 Available pump head at 21 C system temperature rise m 2 0 2 0 2 0 2 0 Flue Rue Gas Temp 8016 C rated min load c 78 65 78166 79 66 79 67 Rue Gas Temp 40 30 C rated mm load c 54 37 54 38 55 40...
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Page 8: ...ION TO SERVICE VALVE 45 DIVERTER VALVE 46 PRESSUREREUEF VALVE 47 COMPACT HYDRAUUC MOUNnNG SCREW 2 TO BOILER t 36 32 45 48 CH TEMPERATURE CONTROL 49 MAINSON OFF INDICATOR DIAGNOSnC LIGHT BWE 50 DHW TEM...
Page 9: ...LATING PUMP WHERE POSSIBLE OR USE A POWER FLUSHING MACHINE TO AID THE CLEANSING PROCEDURE BEFOREINSTAI UNG A NEW BOILER CL ANING THEPRIMARY SYSTEM 1 Fil the ayotem wi1h cold woter ond chedt lor leal o...
Page 10: ...king order and can meet the gas flow and pressure requirements in addition to the demand from any other appliance being served WATER SUPPLY Water mains pressure Minimum mains water pressure 1 3 bar 25...
Page 11: ...tat is sited This must be fitted with lockshield valves and left open A drain cock is required at the lowest point in the system An air voot is requited a l all the high poinlt in the system NOTE The...
Page 12: ...h sholHd be kept to a mini mum and the route as vertical as possible o Where pipe work could be subjected to extreme coJd or wind chill a weatherproof insulation should be used A1temativety the conden...
Page 13: ...n siiing the outlet pipe so that jt does not c ause an obstruction or discharge above a window entrance or other public access where It could cause a hazard The pressure rel f drain pipe M from the bo...
Page 14: ...a suitable aHon onto a fixed rigid surface at least the same size as the boiler and capable of supporting the txmer waight COMPARTMENTS Follow the requirements of B 6798 and B 5440 Part 2 and note Min...
Page 15: ...ted in conjunction with a mechanical or RF mechanical timer the appliance can only be fitted in zone Oth rwise the appliance can be filted in both zones and See lEE wiring regulations IMPORTANT any sw...
Page 16: ...5mm compression fittings Gas 22mm Use the fittings supplied in the lit Hardware pack Hthe boiler pipes are to be run behind the appliance ensure that the pfpes pas through the slot in the yellow plast...
Page 17: ...n 85 5440 1 J From a su ac e or boundary toeing tl o terminal 600 A protec6ve t O al g anl mull bo lilted il tM termil al is 2m or leu above a aurface to whidl peoplo have acceso K From a terrnill81 f...
Page 18: ...ight flue sections can be reduced in length and cut The flue terminal end can be fitted from the in ide or outside of the building Faing kits ara supplied with the flue extension lOis Horizontal125mm...
Page 19: ...injury All sharp objects must beCO iered or the blade retracted alter use and put away in a a afo G place The waiJ mounting frame lnstaler c LJi 1 pack template and bottom panel are now removed Care...
Page 20: ...can also be marked arequired Ha 0 100mm diameter flue is to be used a125mm diameter hole is required However if using the weather sealing colfar by pushing it through from inside the property then a...
Page 21: ...carton A and place safely W Nay from the wosking area 5 W1th the outer packaging removed and the inner sleeve B still in place gently lay the boiler on its back 6 The boiler wi11 1 ie at an angle to t...
Page 22: ...PORTANT Before hanging the boiler onto the wall mounting frame ensure that the pressure relief valve oonnection is in the OOWNpositjon This is located on the right hand side of the wall frame at the r...
Page 23: ...ock 22mm oompression Connect mains watet in and OHW out 7 Connect the expansion vessel flexfble pipe to the hydraulic manifold situated left of the pump lt is necessary to remove and discard the orang...
Page 24: ...The instruction fOf the 601 00mm ditJmeter flue ate shown below MEASURING THE FLUE Standard Flue M Jasure from tho outside wall to the entre tine of the flue turret Subtract 93mm from the length l to...
Page 25: ...tandard Flue and turret 725mm from length L Subtracc the full length 1m extension s from the figure Cut one of the 1m cxtens ions to the remrundor Cutboth tubes squate taking carenot todistort tM rubo...
Page 26: ...Assemble elbow to boi ler using the three screws see below Note Screws are in boiler not in flue k t FITTING THE ELBOW Flue elbow should push directly down and not be twisted into correct position Re...
Page 27: ...should be protected with weather resistant insulation to help prevent freezing EI Sur that the oondensate drain i s 22mm diameter plastic pipe tt must fall at least 5 0mm per metre towards the outlet...
Page 28: ...the main crossbarand through the cable cl mp C ensuring there is ample cabl to rGach the connectors Tum cabte clamping screw D clockwise to secure cabte Mer wiring to conno tOta tt complete snap cabl...
Page 29: ...SFORMER ST10 mFu tF1 1ow ttl 2 5 A AC 230 V ST1 FWE n STAT 1 P J _MP 0 I _ P JMP SUPPLY c XT RNAL FROST STAT OVERHEAT STAT y oiVERTER VALVE rr4 ST6 ST8 ST17J ST9 r 3 _Fl ow 0 FU tt f 3 1f w l 0 S A t...
Page 30: ...kthe gas type specirted on the identificatKln plate F matches that of the gas supply Turn on the main gas supply cheok thegas pipework connections and rectify anyleaks 3 Check that the condensate pipe...
Page 31: ...to the expansion vessel to allow for pressure adjustment if required I I Ifan extra expansion vesselis fitted to the central heating retvm adjust this to the same pressure as the appliance internal ex...
Page 32: ...ing temperature control 0 Bumer indicator GREEN E Reset button F Servicebutton G OHW temperature control H ECO bult l I Syt tM I pressure gauge J Cover or optional programmer Press power button A and...
Page 33: ...e systemisexpcx ad to freezing condrtions to the heating system water L in accordance with themarv rfacturersinstructions 6 Fill system via a WRAS approved filling loop to belween 1 and 2 bar 7 Vent a...
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Page 35: ...side of the boiler frame Hold the panel up against the underside of the boiler and slide towards the reru until it is fully engaged HANDOVER Complete tho Benchmoll checklist NOTE The Benchmark Checkli...
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Page 37: ...cjjusting boiler control to service position 2 1 RemoYe screw C sec uring control 2 2 Gently pull forward until it oomes to rest in serviGe position Primary Heat Exchanger Then isa special accessory k...
Page 38: ...nal programmer 1 Press and HOLD service button F for 10 and setCentral Heating temperatt we to maxfmum The service button will illuminate continua lly and the blue powerindicator will flash quickly Th...
Page 39: ...l r mcwed and thB powef isolated ft om the appliance romove tho panel A byremoving IM mtaining SCfew B 2 Remove dip C f Omgas voJ e ovtlet P 111 gas adjustment ossembly D oroutlet elbow E free from th...
Page 40: ...he heatexchanger untilit stops at thelug Uft f assembly ard remO e from boiler a Disconnect spa1 k electrode and flame sei Sor conooctions K Remove clamping plala L Remove spatklflame electrode assemb...
Page 41: ...he sump Clean around sealing surfaceon Sll11p and replace access cmer 0 us ng a stitable c011taine r tocollod water from syphon conooction at the base of the boiler flush heatexchanger with water R as...
Page 42: ...lliog upwards Squeeze retaining clip on plastic moulding C ai CI pull sensor D upwatds until cl at of pocket in heat exchanger Coat new sensor vlith heat conductive paste aoo replace 3 Overheat thermo...
Page 43: ...d pull forward clear of case 6 2 Undo bottom gas conooction to gas valve 6 3 Undo two securing screws C on the undersid of casing Pvll valveup and forwardovt of boiler Disconnectelectrical connections...
Page 44: ...adjustment as sembly fi M ftom plastic connect01 and pull forward clear of case 6 2 Undo bottom gas connection to gas vaJve 6 3 Undo two securing screws C on the underside ot casing Pull valve up and...
Page 45: ...0 REPLACEMENT OF PARTS 9 Access to boilercontrol components Remove 3 screws A and remove cover from control 10 PCB fuse Remove fuse Fl B f om the PCB and r pla There is a spare fuse clipped into the u...
Page 46: ...thread 12 1 Remove the 3 screws C retaining the front facia making Su e to support the facia when removing the last screw 12 2 Using a suitable tool 0 press the button E upwardsMel slide the conlr ol...
Page 47: ...ectric connector from tal Remove wire clip from gas valveoullet then pullgas adjustment assembly free from ptastic connectorand pull clear of ease see6 1 13 1 Undo and remove secorlns nut A from the t...
Page 48: ...nc orr ect positiol Ensure that burner tab fits correctly into hole Ensure that the seaJ is replaced with anewone 18 Heat Exchanger Isolate flow and return valves then drain the boiler Re move siphon...
Page 49: ...he dlverter vaiW motor Undo the two screws holding the valve to the plastic housing 20 1 Wlthdraw the valve B and dean the valva chamber if necessary T o refi follow the above in reverse Ensure any se...
Page 50: ...dJlljned Disconnect the electrical connection to the turbina Remove the spring clip from the housing and move the bmss pipe to ooo side 2 4 1 v Athdraw the flow sensorMd filter from the housing Using...
Page 51: ...gether and rotating anticlockwise viewed from above Remove the rubber pipe connecting the sump and remcwe 1he syphon NOTE this is not ssentiaJ butmakes the removalof the blockeasier 27 1 Undo the two...
Page 52: ...ce to the left and then withdraw it from thQ appliance 29 1 Remove the spring dip from the pressure relief vatve housing 29 2 Wrthdraw the pressure relief vatve A To refit follow the above in reverse...
Page 53: ...can be frtted to the return from the heating system as close as possi lle to the boiler Expansion vessel replacement Boiler in place l solate mainspower from the boile1 Place the controls in service p...
Page 54: ...wddvar set the CO via adjus ter B using table below C02 settings for Greenstar Si NoTE CO shoukl be measured after 10 minutes Gas type C02 setting C02 setting maximum minimum Natural gas 9 8 0 2 9 2 0...
Page 55: ...2 5mm allen key set the C02via adjus ter B using the table below C02settings for Greenstar Si NOT CO should be measured after 10 minutes Gas type C02 setting C02 setting ma imum minimum Natural gas 9...
Page 56: ...to maximum the boiJef wll then go to maximum output NOTE The oontrol will resume normal operation after 16 mirvJtes orIf the servicebvHonI proosoct fOf o er a second 33 3 Using a 2mm hexagonal ball dr...
Page 57: ...o H26 546 10 Rowreg Type E Slit WORCESTERPari No 8 716 141 143 0 GC No 379 215 Rowreg Type e10 litre WORCESTER Part No 8 716 107 044 0 GCNo 394 291 12 Pressure relief valve OHW WORCESTER Part No 8 717...
Page 58: ...r case as describedon page 36 1 1 Remove screw A from retaining bracket 1 2 Lower contfol panel into seNice position 2 Gas valve Isolate gas supply at boilergas cock 2 1 RemO fe wire clip from gasvalv...
Page 59: ...No tigllt Not a fault oode Flow Sei SOf Test Replace oontrol board if SV is 021 across the red and black cables 1 5V 3 5V ii cross the yellow and black cables with water flowing Otherwise replace flo...
Page 60: ...N in CHposition PUmp ON YES LOCKOUT Gas valve OFF Fan overrun 30 seconds IGN nON GREEN SEQUENCE FLAME UGHT see detail ON IGNITION SEQUENCE Spark ignition 4 seconds t NO 5th aHempt BURN ER U T I NO Sto...
Page 61: ...er all other domands Oiverter valve inOHW f position PumpON f PREHEAT DEMAND YES LOCKOUT Gas vatve OFF Fan to IGNinON start f SEQUENCE 1 speed see detaiO IGNITION SEQUENCE Sperk ignition 4 seconds NO...
Page 62: ...PROTECTION FUNCTION Boiler temperature Run autofroststat bolow SOC fuoction Pump antiseiz Pump run 5 seconds evety 24hts PROTECTION FUNCTION...
Page 63: ...ILER 0 NOT REQUIRED NOT REQUIRED 0 NOT REQUIRED 0 Ift3 Jhr Imbar I c I c HAS AWAlER SCALE REDUCER BEEN FITTED YES 0 WHAT TYPEOF SCALE REDUCER H AS BEEN FillED OR THE DOMESnCHOTWATER MODE MEASURE RECOR...
Page 64: ...MMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 3 DATE SERVICE 4 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGIIDCARD SERIALNo CORGI ID CARD SERIALNo COMMENTS COMMENTS SIGN...
Page 65: ...boiler 1 Close the 15mm cold inlet bulkhead valve with a screwdriver 2 Open a hot tap no water should flow from the open tap 3 Connect flexible hose across filling link 4 Open valve to fill system If...
