Worcester 27Ri Compact Installation, Commissioning And Servicing Instructions Download

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Worcester, Bosch Group

Cotswold Way, Warndon, Worcester WR4 9SW.

Tel. 0330 123 9559

Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd.
worcester-bosch.co.uk

Document No.6 720 646 610 (2013/12)

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

Summary of Contents for 27Ri Compact

Page 1: ...46610 00 1Wo FOR OPEN VENTED AND SEALED CENTRAL HEATING SYSTEMS AND INDIRECT MAINS FED DOMESTIC HOT WATER 6 720 646 610 2013 12 These appliances are for use with Natural Gas or L P G Cat II 2H 3P type C13 C33 C53 Model GC Number Natural Gas 27Ri Compact 41 406 17 30Ri Compact 41 406 19 L P G 27Ri Compact 41 406 18 30Ri Compact 41 406 20 ...

Page 2: ...etting the appliance to service mode 29 5 5 Commissioning 30 5 5 1 Checking the gas inlet pressure 30 5 5 2 Checking the gas rate and pressure 30 5 5 3 Gas rating test 30 5 5 4 Checking for leaks during operation 30 5 6 CO and Combustion checks 31 5 7 Finishing commissioning 32 5 7 1 Replacing outer casing 32 5 7 2 Securing the control panel 32 5 7 3 Fitting fascia flap 32 5 7 4 Installing bottom ...

Page 3: ...ate the type and seriousness of the ensuing risk if measures to prevent the risk are not taken This symbol indicates important information where there is no risk to people or property Symbol Explanation Step in an action sequence Æ Cross reference to another part of the document List entry List entry second level Table 1 Domestic Hot Water Central Heating Hot Water Storage Cylinder Domestic Cold W...

Page 4: ...ng Regulations Building Standards Scotland Consolidation Building Regulations Northern Ireland local water by laws Health Safety Document 635 The Electricity at Work Regulations 1989 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 wate...

Page 5: ...sensor control Pump anti seizure protection Flue gas temperature sensor Condensate siphonic trap 600mm to top of case front 390mm 270mm 590mm 1 2 3 5 6 6720646610 01 2Wo 4 STANDARD PACKAGE 1 Wall hung gas fired condensing regular boiler for central heating and domestic hot water 2 Tail pipes water only 3 Wall plate 4 Hardware literature pack see checklist 5 Bottom panel 6 Fascia panel CHECK LIST H...

Page 6: ... INFORMATION Greenstar Ri Compact 6 720 646 610 2013 12 6 2 2 LAYOUT Fig 2 Ri Compact main boiler components 1 3 2 18 31 30 29 4 5 11 12 10 21 20 19 22 23 25 27 28 26 9 8 7 6 13 14 15 17 16 6720646610 02 2Wo 24 ...

Page 7: ... sensor NTC 6 Primary return connection 22 Auto air vent 7 Primary flow connection 23 Heat exchanger 8 Gas inlet isolator 24 Flueway 9 Bottom panel 25 Sump assembly 10 Case retaining clips 26 Return temperature sensor NTC 11 Case 27 Condensate siphon 12 Case fixing screws 28 Gas connection 13 Control panel 29 Gas valve 14 Operation fault indicator blue 30 Air inlet 15 Blanking panel for optional p...

Page 8: ...fter 30 minutes 9 1 9 1 10 6 10 6 CO2 level at min rated heat output after 30 minutes 8 5 8 5 9 6 9 6 NOx class 5 5 5 5 NOx rating mg kWh 35 35 40 42 Condensate Maximum condensate rate l h 2 5 2 5 2 5 2 5 pH value approx 4 8 4 8 4 8 4 8 Electrical Electrical power supply voltage a c V 230 230 230 230 Frequency Hz 50 50 50 50 Maximum power consumption without pump W 35 41 35 41 Maximum power consum...

Page 9: ...ition of BS 7671 IEE wiring regulations 3 2 2 GAS SUPPLY To ensure that the equipment is in good working order and can meet the gasflowandpressurerequirements inadditiontothedemandfromany other appliance being served the following applies Boilers using Natural Gas NG must be connected to a governed meter Liquid Petroleum Gas LPG must be connected to a regulator Installation and connection of the g...

Page 10: ...ting system to the water level in the feed and expansion tank 2 Heating vent 22mm minimum 3 Primary cold feed 15mm minimum 4 Diverter valve and 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 6 Key to figures NOTICE A drain cock should be fitted at the...

Page 11: ...oint condensate should be removed using a proprietary condensate pump of a specification recommended by the boiler or condensate pump manufacturer The pump outlet pipe should discharge to a suitable internal foul water discharge point such as an internal soil and vent stack internal kitchen or bathroom waste pipe washing machine waste pipe etc A suitable permanent connection to the foul waste pipe...

Page 12: ...lly the pipe should terminate below the grating level but above water level in order to minimise wind chill at the open end The 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 8 External disposal CONDENSATE SOAK AWAY The condensate drainage pipe...

Page 13: ... flue 3 5 3 COMPARTMENTS Follow the requirements of BS6798 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 ancillary equipment If fitting the boiler into an airing cupboard use a non combustible material to separate the boiler from the airing space The material can be perforated up to a maximum hole size...

Page 14: ...st one inspection hatch no less than 300mm square Flue joints within the void must not be more than 1 5 metres from the edge of the inspection hatch Inspection hatches should be located at changes of direction If this is not possible bends should be viewable from both directions NOTICE Effective flue lengths each90 bendisequivalentto2metresofstraightflue each 45 bend is equivalent to 1 metre of st...

Page 15: ...PRE INSTALLATION Greenstar Ri Compact 6 720 646 610 2013 12 15 350 mm 570 mm 130 mm Min Flat roof 300 mm 500 mm Pitched roof 2 3 4 5 6 10 9 8 7 1 6720643895 12 1Wo ...

Page 16: ...600mm to room sealed flue or 1 500 to an open flue 15 200mm below eaves and 75mm below gutters pipe and drains 16 The dimension below eaves balconies and car ports can be reduced to 25mm as long as the flue terminal is extended to clear any overhang Any external flue joints must be sealed with suitable silicon sealant 17 Flue clearance must be at least 300mm from the ground Terminal guards must be...

Page 17: ...9 1 200mm from an opening in a car port on the same wall e g door or window leading into the dwelling 10 600mm distance to a surface facing a terminal unless it will cause a nuisance BS 5440 Part 1 recommends that care is taken when siting terminals in relation to surfaces facing a terminal 200 300 150 200 8 4 5 3 2 9 200 600 All measurements in millimetres 300 300 150 150 300 300 25 25 150 1 200 ...

Page 18: ...e effective length of any bends plus the straight lengths The graph can be used to calculate Effective flue length if a specific effective plume length is required Effective plume length if a specific effective flue length is required Effective straight flue length with plume management Minimum plume length M 500mm Maximum plume length M 4 500mm Max flue length L 5 000mm Max flue length L 2 200mm ...

Page 19: ...NTING PLATE Theboilertemplateshowstherelativepositionsoftheflueandthetop and bottom fixing of the mounting frame 1 Fix the template to the wall in the desired position 2 Drill four holes for the wall mounting plate through the template utilising shaded mounting holes Drill two holes for the bottom fixing screws Additional holes may be used if required Fig 21 Mounting holes REAR FLUE OUTLET The dra...

Page 20: ...se can be remove the control panel must be moved into the service position i e swivelled down 1 Unscrew the retained catches securing the fascia 2 Pull the catches towards you to release the panel 3 Pull the fascia towards you slightly and then lift and pull forward to swivel down into the service position 4 Ensure that the control panel is in the service position i e swivelled down 5 Release the ...

Page 21: ...efittedtotheboilerbeforehangingthe boiler on the wall plate 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 1 Condensate 22mmØ 2 Gas inlet 22mmØ 3 Flow 22mmØ which is flared to 28mmØ at one end and can be removed if required 4 Return 22mmØ which is flared to 28mmØ at one end and can be remov...

Page 22: ...verterminateordischargeintoanyopensource including sink bath shower bidet toilet etc Figure 32 gives the pipe work dimensions with respect to the mounting surface Fitthecondensatedischargepipeasfarbackaspossibletothewallto ensure easy fitting of the boiler bottom panel Routethecondensatepipetoanappropriate dischargepoint refer to section 3 4 Plumb up to the wall frame with 22mm pipe Ensure that th...

Page 23: ...mm thenflueextensionswill have to be used Refer to the 60 100 Horizontal Flue Instruction manual provided in the telescopic flue kit Refer to section 3 7 for flue options Adjusting the telescopic flue length Fig 34 Standard telescopic flue Extend tube 1 by withdrawing from tube 2 to achieve the flue length required between 350 570mm or 570 to 790mm if using the longer telescopic flue Secure with s...

Page 24: ...n the flue turret to the boiler flue outlet with flat facing 1 to the rear of the boiler The flue turret should be pushed straight down on to the boiler Fig 38 Aligning the turret Fit the screws removed in step 1 to secure flue turret If fitting the outer seal from outside the building slide the outer wall seal onto the terminal as shown Makegood thegapbetweentheflueandinnerwallandifpossibleon the...

Page 25: ...isolators are used refer to the Greenstar Wiring Centre Installation Commissioning Servicing Instructions for further information ACCESS TO ELECTRICAL CONNECTIONS 1 Refer to fig 43 and remove the screws in the installer access cover 2 Lift the Installer access cover 3 Remove the cover Theflueterminaloutlethasbuilt instopstolimitrotation for horizontal flues to allow condensate to run back into the...

Page 26: ... THE PROGRAMMER TIMER 5 Connect the ribbon cable connector 2 to the socket 3 ensuring that the cable will fit into the recess 4 6 Align the clips on the back of the Programmer Timer with the slots Fig 46 Connecting the Programmer Timer 7 Push the Programmer Timer in to engage with the slots 8 Pull the Programmer Timer down to secure with the clips 9 Replace the top cover panel 10 Secure in positio...

Page 27: ...NECTION This method is particularly suited to replacing existing boilers where additional wiring would otherwise be required to a standard system wiring centre existing wiring can be used to make the BUS connection The BUS is a low voltage communication cable and must not be run alongside 230V cables in order to avoid interference The connection to the mains power pump and valves may differ depend...

Page 28: ...th for the system condition in accordance with the manufacturer s instructions Run the boiler system at normal operating temperature for the time stated by the manufacturer of the flushing agent Drain and thoroughly flush the system to remove the flushing agent and debris INHIBITOR Central Heating Check drain cocks are closed and all radiator valves are open before adding a suitable inhibitor comp...

Page 29: ...l the bottom of the panel forward 4 Lower the control panel to the service position 5 Release the two screws securing the Installer access cover 6 Remove the installer access cover Fig 53 Control panel to service position 1 Press the servicebutton for morethanfivesecondsandtheboiler will go into service mode 2 The red LED will flash when the boiler is in the service mode Turn the control knob to m...

Page 30: ...be measured at the gas meter after 10 minutes operation at maximum output See Technical data section on page 8 of this manual Set the boiler to maximum output refer to section 5 4 1 Where a gas meter is not available e g L P G the CO CO2 must be checked to the units shown in the setting of the air gas ratio 5 5 3 GAS RATING TEST Isolate all other appliances Set the boiler to maximum output refer t...

Page 31: ...e the analyser must have been calibrated as specified by the manufacturer The installer must be competent in the use of the analyser Checkandzerotheanalyserinfreshairasspecifiedby the manufacturer The air gas ratio valve is factory set and must not be adjusted during commissioning unless this action is recommended following contact with the Worcester Bosch Group help line 0330 123 3366 Yes No Yes ...

Page 32: ...he panel 5 7 3 FITTING FASCIA FLAP 1 Rotate the hinge to be in line with the flap and present the flap assembly up to the fascia 2 Push the pegs on the hinge into the slots in the front of the fascia and close the flap 3 Secure flap to the fascia with the two screws provided Fig 60 Fitting fascia flap 5 7 4 INSTALLING BOTTOM PANEL 1 The bottom panel slides onto two ledges either side of the boiler...

Page 33: ...ester bosch co uk guarantee The Guarantee Registration form is available on the website Register your guarantee in one of three ways The on line form can be completed and submitted electronically or Telephone one of our Guarantee Registration advisors on 0844 892 2552 or Complete the enclosed guarantee card and return by post Your statutory rights are not affected by the manufacturer s guarantee 6...

Page 34: ...CO2 is less than 0 2 Ifthe readings are outside these limits then this indicates that there is a problem with the flue system or combustion circuit e g missing or dislodged seals Fig 63 Flue integrity test 6 4 COMPONENT ACCESS To remove the outer case to gain access to the components 1 Remove the bottom panel 2 Release the two screws securing the control panel 3 Pull down to release the two catche...

Page 35: ...ill read negative refer to the chart in figure 67 below Fig 67 Fan pressure readings If the manometer reading is in the white area of the chart the heat exchanger exhaust path siphon does not require attention If the manometer reading is in the black area of the chart then carry out the following checks Check that the siphon is not blocked Check the exhaust paths for restrictions Clean the heat ex...

Page 36: ... re check the CO CO2 The LED will flash in a five flash sequence If correct press the Service mode button once and the boiler will return to normal operation the LED will not be illuminated Re assemble and refit boiler case If the boiler fails the combustion test check 1 Air intake for restriction 2 Cleanliness of the heat cell condition of the burner plus blockages in the condensate disposal NOTI...

Page 37: ...discharge hose Fig 71 Fitting siphon 6 7 2 CLEANING THE PRIMARY HEAT EXCHANGER SINGLE BLADED TOOL AND BRUSH Use a suitable blade to clean the heat exchanger channels There is an optional tool available to clean the heat exchanger part number 7 746 901 479 Fig 72 Single bladed cleaning tool and brush Visually inspect the inside of the heat exchanger by shining a torch from the top down into the sum...

Page 38: ...control panel into the service position 5 Undo and remove the two bottom retaining screws 6 Lift the spring clips on top of the case 7 Pull the case towards you to remove On completion of the heat exchanger cleaning and re assembly perform the fan pressure test as described in section 6 5 2 6720803800 03 1Wo 1 2 1 6720803800 04 1Wo 4 3 1 CAUTION Mains supplies Turn off the gas supply and isolate t...

Page 39: ...ow the Control panel to hang on the cables and support strap Fig 77 Control panel removal 1 Disconnect the discharge hose from the siphon 2 Rotate the siphon body clockwise to release the bayonet connection 3 Pull the siphon body down and away from the boiler Fig 78 Siphon removal The control panel can be refitted by holding the panel at approximately 60 to the horizontal and engaging the panel in...

Page 40: ...and remove Fig 82 Auto air vent When re assembling ensure that the O ring is fitted to the Auto air vent and NOTthe heat exchanger otherwisethe Air ventwill be difficult to fit Apply silicone grease to the O ring to ease assembly 6 8 8 GAS VALVE Isolate the gas supply at the boiler gas cock Remove the combustion air inlet pipe Disconnect the electrical connector from the valve 1 Remove the gas pip...

Page 41: ...ed onto the sump lugs Before fitting the Flueway Ensure that the seal is clean and free from debris Fig 86 Moulded style seal FITTING THE TUBULAR SUMP SEAL 3 Fit the Flueway sump seal 2 into the Flueway Ensure the seal is fitted fully into the recess in the underside of the Flueway Before fitting the Flueaway Ensure that the seal is clean and free of debris Fig 87 Tubular style sump seal CAUTION C...

Page 42: ...ars the left hand front castellated nut securing the burner housing 7 Pull the gas pipe off the fan body connection the pipe is secured by the interference fit between the pipe and connector 8 Remove the electrical connector and earth from the fan Fig 90 Fan removal 2 6 8 10 AIR GAS FLAP VALVE ASSEMBLY 1 Remove the single screw securing the air gas flap valve assembly 2 Pull the flap assembly away...

Page 43: ...y When fitting the burner ensure that the convex side of the burner faces down into the heat exchanger Always fit a new gasket 1 when re assembling the heat exchanger Fig 95 Burner and gasket TIGHTENING DOWN THE BURNER HOUSING 1 Tighten the burner housing castellated nuts 1 down gradually and evenly and in a rotating sequence 2 Tighten the castellated nuts down until they bottom out on the heat ce...

Page 44: ...e heat exchanger to the air box 4 Lift the heat exchanger until the lower connection clears the hole in the air box 5 Pull the heat exchanger towards you to remove Re assemble in the reverse order Fig 98 Heat exchanger removal 6 8 15 BOILER RETURN SENSOR NTC Disconnect the electrical connectors from the sensor Unclip the sensor from the pipe Fig 99 Boiler return sensor Before removal Isolate the e...

Page 45: ...Worcester Bosch service engineers only 8 Mains voltage and earth connectors PCB FUSE The fuse and holder 2 are located next to the high voltage connectors and the spare fuse 7 is located on the back of the installer access cover To remove the fuse Pull the fuse holder 2 up Replace the fuse and re insert the fuse holder 6 8 17 REPLACING THE HEATING CONTROL MODULE HCM Press down on the retaining cli...

Page 46: ... type 8 717 206 213 0 Electrodes including gasket 8 718 600 28A 0 Burner seal 8 718 600 24A 0 Spark generator 8 718 688 015 0 Flow NTC 8 718 688 801 0 Auto Air Vent T 005 000 87A 0 Maximum safety sensor NTC 8 718 685 483 0 Flue terminal end 8 718 681 828 0 Flue sample plug vertical adapter 8 710 506 199 0 Flue sample plug air intake 8 716 11 253 0 Flue sample plug gas outlet 8 716 111 252 0 Table ...

Page 47: ... out during a fault finding procedure On completion of the Service Fault Finding task which has required the breaking and remaking of electrical connections check a EARTH CONTINUITY b SHORT CIRCUIT CHECK c POLARITY and d RESISTANCE TO EARTH FLASHING FAULT CODES The flashing sequences will be split into three groups 1 Afivesecond off period A followedbyacountofeither1 2 3 4or 5 flashes B at a rate ...

Page 48: ...sition 3 Locking Gas valve error Gas valve coil disconnected Check gas valve Reset the boiler by turning the control knob anti clockwise to the reset position 4 Locking First safety timing error ignition timing error The flame was not established during the first four seconds of the ignition period Reset the boiler by turning the control knob anti clockwise to the reset position 5 Locking Ionisati...

Page 49: ...eset the boiler by turning the control knob anti clockwise to the reset position 8 Blocking MAX safety thermostat activated Flue gas thermostat overheat 9 Locking Return temperature too high Boiler overheat Reset the boiler by turning the control knob anti clockwise to the reset position 10 Locking Flow temperature too high Supply sensor exceeded 110 C Primary flow sensor overheated Reset the boil...

Page 50: ...ing Defective fan or blocked air way Reset the boiler by turning the control knob anti clockwise to the reset position 13 Locking Mains voltage interrupted after locking error Reset the boiler by turning the control knob anti clockwise to the reset position 14 Locking Internal control board faults Call Worcester Bosch Group technical help line 0330 123 3366 15 Locking All other faults Miscellaneou...

Page 51: ...E SENSE GROUND GAS VALVE SAFETY SOLENOID SAFETY SOLENOID Fan wiring Live brown Neutral blue G Y 6720646610 19 3Wo Red Blue Orange RETURN NTC G Y Black Black Blue Green Red Blue Blue Blue Red Orange Green Brown Yellow Red Red White White White White Orange Orange EXTERNAL PUMP MAINS SUPPLY Neutral Live Pump Live Pump Neutral Pump Earth Mains Live Mains Neutral Mains Earth SL L N 230V WIRING CENTER ...

Page 52: ...rge 30 seconds 4th attempt LOCKOUT 90 second stabilisation period Fan modulation to achieve set temperature 30 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 6 C above set value Gas valve OFF Fan overrun 30 seconds 3 minute pump over run Spark ignition and gas 4 seconds NO YES IGNITION SEQUENCE 6720646610 52 1Wo BLU...

Page 53: ...elow 5 C Internal boiler temperature rises above 12 C Central heating demand switches off Pump switches off after a 3 minute overrun period Central heating demand is activated AUTOMATIC INTERNAL FROST FUNCTION 6720646610 53 1Wo Pump runs for 3 minutes to dissipate heat from the boiler into the system End of boiler demand central heating or domestic hot water PUMP OVERRUN FUNCTION A central heating...

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Page 56: ...ter Bosch Group is a brand name of Bosch Thermotechnology Ltd worcester bosch co uk Document No 6 720 646 610 2013 12 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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