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Worcester Greenstar 12i System ErP, Installation, Commissioning And Servicing Instructions, Page: 1 / 56

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Worcester Greenstar 12i System ErP Installation, Commissioning And Servicing Instructions Download Page 1

UK/IE

INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS

WALL HUNG RSF GAS FIRED CONDENSING SYSTEM BOILER

GREENSTAR i SYSTEM

6720643895-00.1W

o

FOR SEALED CENTRAL HEATING SYSTEMS AND INDIRECTLY FED DOMESTIC HOT WATER

6 72

0 804 532 (2012/09)

The appliance is for use with Natural Gas or
L.P.G. (Cat II 2H3P type C13, C33 & C53)

Model

GC Number

Natural Gas

12i System

41-311-67

15i System

41-311-84

18i System

41-311-86

24i System

41-311-68

Liquid Petroleum Gas

12i System

41-311-69

15i System

41-311-85

18i System

41-311-87

24i System

41-311-70

Summary of Contents for Greenstar 12i System ErP

Page 1: ...L HEATING SYSTEMS AND INDIRECTLY FED DOMESTIC HOT WATER 6 720 804 532 2012 09 The appliance is for use with Natural Gas or L P G Cat II 2H3P type C13 C33 C53 Model GC Number Natural Gas 12i System 41...

Page 2: ...OMMISSIONING 29 5 1 Pre Commissioning checks 29 5 2 Filling the system 30 5 3 Water treatment 30 5 4 Starting the appliance 31 5 5 Commissioning 31 5 5 1 Checking the gas inlet pressure 31 5 5 2 Check...

Page 3: ...he start of a warning indicate 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 o...

Page 4: ...lding 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...

Page 5: ...of case front 1 700mm 400mm 330mm Depth to wall When fitted to wall frame 6 6720644743 01 3Wo STANDARD PACKAGE 1 Wall hung gas fired condensing system boiler for central heating and hot water 2 Wall...

Page 6: ...37 55 38 CO2 level at max rated heat output after 30 min 9 65 9 8 9 8 9 8 11 0 11 0 11 0 11 0 CO2 level at min rated heat output after 30 min 8 65 9 2 9 2 9 2 10 5 10 5 10 5 10 5 NOx class 5 5 4 5 5 5...

Page 7: ...APPLIANCE INFORMATION 6 720 804 532 2012 09 7 2 3 LAYOUT Fig 1 Main boiler components 6720804532 03 1Wo 1 2 30 29 28 27 26 10 14 12 11 13 15 16 25 23 24 22 21 20 19 18 17 3 4 5 6 7 8 9...

Page 8: ...m heat exchanger 11 Right side hand hold for lifting boiler 33 Expansion vessel hose connection point 12 Diverter valve assembly body 34 Auto air vent 13 Diverter valve actuator stepper motor blank 35...

Page 9: ...hine to aid the cleansing procedure in some circumstances Close the drain cocks and refill with fresh water and a suitable inhibitor Vent any air from the boiler and system 1 Burner ON indicator light...

Page 10: ...re up to 3 bar Radiator valves should conform to BS2767 10 All other valves should conform to BS1010 Thermostatic radiator valves TRV s must be used on all radiators within the sleeping accommodation...

Page 11: ...boiler is fitted with its own internal bypass 1 Diverter Zone valve 2 Radiator valve flow 3 Lock shield valve return 4 Bypass NOTICE A drain cock should be fitted at the lowest point of the heating ci...

Page 12: ...ate pump disposal 3 4 2 EXTERNAL CONNECTIONS Ifnootherdischargemethodispossiblethentheuseofanexternallyrun condensate drainage pipe terminating at a suitable foul water discharge point or purpose desi...

Page 13: ...NDENSATE SOAK AWAY The condensate drainage pipe may be run above or below the ground tothesoakaway Theexamplesshownonthispagerunaboveground The soak away must use a 100mm plastic tube with two rows of...

Page 14: ...long as the minimum clearances around the boiler are maintained Ideally storage should be below the boiler where the boiler is mounted in the upper part of the cupboard whilst maintaining the clearan...

Page 15: ...ent minimum clearances are Side Above Below Front to removable door 400 170 approx 30 above the elbow 200 100 Table 11 Minimum unventilated compartment clearances If Side Clearances are Reduced millim...

Page 16: ...e bends should be viewable from both directions NOTICE Effective flue lengths each 90 bend used is equivalent to 2 metres of straight flue each 45 bend used is equivalent to 1 metre of straight flue P...

Page 17: ...PRE INSTALLATION 6 720 804 532 2012 09 17 350 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 18: ...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 th...

Page 19: ...t point of the balcony or overhang 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...

Page 20: ...rotective clothing footwear gloves and safety goggles must be worn as appropriate FIXING THE WALL MOUNTING FRAME Theboilertemplateshowstherelativepositionsoftheflueandthetop and bottom fixing of the m...

Page 21: ...inner sleeve 2 still in place gently lay the boiler on its back Theboilerwilllieatanangletothefloortoallowtheboileroutercasing 5 to be removed The inner sleeve 2 opens as shown in figure 28 Remove th...

Page 22: ...mm insulated pipe Fig 30 Condensate drain pipe work detail PREPARING THE WALL FRAME Fit sealing washers to service valves before hanging boiler Fig 31 Sealing washers 1 Pull the extended tab lever for...

Page 23: ...ON To connect the expansion vessel flexible pipe to the hydraulic manifold situated to the left of the pump Removeanddiscardtheplasticcapfromtheexpansionvesselflexible pipe 1 Refer to figure 35 releas...

Page 24: ...Fig 38 Standard telescopic flue Extend tube 1 by withdrawing from tube 2 to achieve the flue length required between 350 570mm Secure with screw provided and seal joint with the aluminium tape suppli...

Page 25: ...y and the components are pushed fully home The flue is set at an angle of 3 or 52mm per metre length Support theflueatapproximatelyonemetreintervals andatachange of direction use suitable brackets and...

Page 26: ...on NOTICE Outlet position The flue terminal outlet position must follow those stated in the relevant appliance instruction manual When redirecting the flue discharge the outlet terminal must be at lea...

Page 27: ...screw securing the control panel 2 Lower the control panel into the horizontal service position Fig 51 Moving control panel into the service position 1 Refer to figure 52 and unscrew the three screws...

Page 28: ...the living area is more than 70 of the total useable floor area Then this type of dwelling can be controlled as one zone An alternative would be individual electronically controlled TRVs Hot water sup...

Page 29: ...discharge pipe 1 has been connected to the syphon and condensate outlet pipe NOTICE Externaldivertervalve s andallother230Vpartsare not supplied with the boiler A fascia mounted programmer timer cann...

Page 30: ...THAT THE SYSTEM HAS BEEN CLEANED AS ON PAGE 9 OF THESE INSTRUCTIONS FLUSHING Central Heating Switch off the boiler Open all drain cocks and drain the system while the appliance is hot Close drain coc...

Page 31: ...l Heating temperature to maximum The service button will illuminate continually and the blue power indicator will pulse five times Check the gas supply working pressure at the gas valve conforms to va...

Page 32: ...urntonormaloperation after 15 minutes Close the gas isolation valve Remove the manometer Re seal the screw in the gas inlet pressure test point Open the gas isolation valve Ensure that there are no ga...

Page 33: ...ditionoftheappliancewhentestedbyfullyqualified engineers The service interval record sheet at the rear of these instructions must be completed after each service INSPECTION 1 Check that the terminal a...

Page 34: ...n 0 2 If the readingsare outside these limits thenthis indicates that there is a problem with the flue system or combustion circuit Fig 73 Flue integrity test 6 4 FAN PRESSURE TEST SETTING THE BOILER...

Page 35: ...5 FLUE GAS ANALYSIS COMBUSTION TEST Connect the flue gas analyser to the flue gas sampling point as shown in the figure below Run the boiler at maximum output for at least 10 minutes Check the CO CO2...

Page 36: ...ve 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 AN...

Page 37: ...figure 84 1 Remove clamping plate 2 Remove spark flame electrode assembly and seal from the top of the heat exchanger 3 Remove burner Fig 84 Burner removal Checking and cleaning the electrode assembl...

Page 38: ...d ensure that the seal is correctly fitted Check the syphon unit is clean before refitting to boiler Reassemble and check combustion as stated in SETTING THE AIR GAS RATIO section on page 36 Fig 87 Cl...

Page 39: ...he shoulder Fig 89 Primary sensor and overheat thermostat 6 8 4 FLUE OVERHEAT THERMOSTAT WITH GROMMET To remove and replace the thermostat either Usingasmallterminalscrewdriver prisethethermostatandgr...

Page 40: ...on 6 8 7 AIR GAS MANIFOLD AND FAN ASSEMBLY Remove electrical connector and earth wire the from fan Removewireclipfromgasvalveoutletthenpullgaspipefreefromthe gas valve see figure 93 Toremove thefollow...

Page 41: ...AP VALVE ASSEMBLY 1 Twist the mounting flange clockwise to release 2 Pull mounting flange off the flap valve assembly 3 Pull rubber flap off flap valve assembly To replace the flap valve Press the two...

Page 42: ...ust connector down Fig 101 Upper exhaust assembly 1 Refer to figure 102 and release the clip 2 Move the lower exhaust connector up Remove the complete exhaust assembly Fig 102 Release lower exhaust co...

Page 43: ...trical connections from the control 1 Remove five screws retaining the rear panel of the control 2 Remove the rear panel Fig 108 PCB access REFITTING THE CONTROL BOARD COVER Ensure that all wires are...

Page 44: ...on upwards 2 Slide the control support bracket to the left Fig 111 Control unit release Remove appropriate cable restraints from the new control unit Fit control unit to the boiler Ensuring the contro...

Page 45: ...ilable Fig 114 Diverter valve and motor 6 8 17 DIVERTER VALVE IF FITTED Ensure the appliance has been fully drained Disconnect the electrical connector from the diverter valve motor Remove the diverte...

Page 46: ...e and pump Undo the nuts securing the copper water pipes to the manifold there is no need to remove the gas pipe 1 Release the spring clips securing these water pipes to the plastic housing and remove...

Page 47: ...of the flue is required If this clearance is not available then the boiler will need to be removed from the mounting frame to gain access to the expansion vessel Alternatively a second vessel of at le...

Page 48: ...connection to the pump manifold Carefully lift the boiler off the mounting frame 1 Remove the expansion vessel retaining screw 2 Lift the expansion off the cross beam 3 Pull the expansion vessel towa...

Page 49: ...y pass valve 8 716 106 434 0 GC No H02 532 Pressure gauge 8 718 224 344 0 Flow temperature sensor NTC 8 716 106 688 0 GC No H26 542 High limit stat 8 707 206 196 0 GC No H26 584 Fusing element set 8 7...

Page 50: ...that there is no permanent live at ST10 LR from another source Boiler not operating duringhotwaterdemand CH ok Ensure cold inlet DHW outlet are correctly piped i e are not crossed piped If the optiona...

Page 51: ...PERATURE CONTROL Red Neutral Supply 230V EXTERNAL CONTROLS OPTION WORCESTER 24V CONTROLS OPTION PLUG IN POINT under blanking cover on fascia Live Supply Live Return Neutral Live Orange Blue Yellow Gre...

Page 52: ...T 10 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...

Page 53: ...period 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 Pump runs for 3 minutes to...

Page 54: ...ffect the customer s statutory rights If yes and if required by the manufacturer has a water scale reducer been tted CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with...

Page 55: ...er Name Company Name Telephone No Gas Safe Register No Comments Signature Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature Date Engineer Name Company Name Telephone...

Page 56: ...Worcester Bosch Group is a brand name of Bosch Thermotechnology Ltd worcester bosch co uk 6 720 804 532 2012 09 WORCESTER BOSCH GROUP TECHNICAL SUPPORT 0844 892 3366 APPOINTMENTS 0844 892 3000 SPARES...

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