Worcester Greenstar 15i System ErP Installation, Commissioning And Servicing Instructions Download Page 1

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UK/IE

Installation commissioning and servicing instructions

Wall hung RSF gas fired condensing system boiler

Greenstar i System

ErP

6720806944-00.1W

For sealed central heating systems and indirect mains fed domestic hot water

6 72

0 806 945 (2015/07)

If you smell gas:
▶ Well away from the building: call the National Gas Emergency

Service on 0800 111 999.

▶ L.P.G. boilers: Call the supplier’s number on the side of the gas

tank.

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

Greenstar 9i System

ErP

41-406-21

Greenstar12i System

ErP

41-406-23

Greenstar 15i System

ErP

41-406-25

Greenstar 18i System

ErP

41-406-27

Greenstar 21i System

ErP

41-406-29

Greenstar 24i System

ErP

41-406-31

L.P.G.

Greenstar 9i System

ErP

41-406-22

Greenstar12i System

ErP

41-406-24

Greenstar 15i System

ErP

41-406-26

Greenstar 18i System

ErP

41-406-28

Greenstar 21i System

ErP

41-406-30

Greenstar 24i System

ErP

41-406-32

Summary of Contents for Greenstar 15i System ErP

Page 1: ...pplier snumberon thesideofthegas tank 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 Greenstar 9i System ErP 41 406 21 Greenstar12i Sy...

Page 2: ...the system 36 6 3 Water treatment 36 6 4 Starting the appliance 37 6 4 1 Appliance start up screens 37 6 4 2 Info menu and operational status codes 38 6 5 Commissioning 40 6 5 1 Checking the gas inlet...

Page 3: ...Diverter valve 62 7 7 25 Drain tap 62 7 7 26 Pump head 62 7 7 27 Pressure gauge 62 7 7 28 Hydraulic block removal 63 7 7 29 CH pressure relief valve 63 7 7 30 Bypass valve 63 7 8 Short parts list 64...

Page 4: ...BEFORE STARTING INSTALLATION Warnings in this document are identified by a warning triangle printed against a grey background Keywords at the start of a warning indicate the type and seriousness of th...

Page 5: ...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 Hazar...

Page 6: ...upplies 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 ventilati...

Page 7: ...domestic hot water 2 Wall mounting frame 2 1 Condensate pipe routing 2 2 CH Flow 2 3 Gas 2 4 CH Return 2 5 Pressure Relief Valve outlet 3 Hardware literature pack Installation Commissioning and Servi...

Page 8: ...8 9 8 9 8 9 8 CO2 level at min rated heat output after 10 minutes 9 1 9 1 9 1 9 1 9 1 9 1 NOx class NOx rating mg kWh 36 42 42 50 49 49 Condensate Maximum condensate rate l h 0 6 0 9 1 2 1 5 1 8 2 0 p...

Page 9: ...evel at min rated heat output after 10 minutes 10 5 10 5 10 5 10 5 10 5 10 5 NOx class NOx rating mg kWh 36 42 42 50 49 49 Condensate Maximum condensate rate l h 0 6 0 9 1 2 1 5 1 8 2 0 pH value appro...

Page 10: ...emperature regime means 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...

Page 11: ...egime means 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 co...

Page 12: ...nstar i SystemErP 6 720 806 945 2015 07 12 3 4 Layout Fig 2 Main appliance components 1 42 36 37 27 26 21 22 20 19 43 2 4 3 5 6 9 11 12 41 39 40 13 14 16 17 35 38 34 32 31 33 30 28 29 15 8 7 10 672080...

Page 13: ...s for service 1 Main superstructure 23 DHW settings increase button Increase button menu edit mode 2 Hanging bracket 24 DHW settings decrease button Decrease button menu edit mode 3 Removable panel fo...

Page 14: ...ck Violet 10 9 8 7 6 5 3 2 11 12 13 14 15 1 Red Blue Green Red Blue Blue Brown White Orange Yellow Blue Orange Orange Blue Brown Black Green Red White Red Orange Black Black Violet White Black 1 9 1 6...

Page 15: ...k found under installer connections cover 230V supply to the appliance Earth input Neutral input Live input 230V feed to external controls Live output Neutral output Switch live Live Return to applian...

Page 16: ...supply Appliances 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 gas supply to the appliance mu...

Page 17: ...pliance Do not use galvanised pipes or radiators System fill Fig 4 System fill Example installation S Plan Fig 5 Sealed system S Plan Example installation Y Plan Fig 6 Sealed system Y Plan Optional in...

Page 18: ...d safe access to work on the product or component including making adequate provision for visual inspection of flues in voids The homeowner can gain clear and safe access to the controls check top up...

Page 19: ...ownwardstoasafe point of discharge away from any electrical equipment or other hazard preferably to an external drain or soak away Pipe 1 shouldbefinishedwithapartialbend neartheoutlettoface the exter...

Page 20: ...romtheapplianceunder gravity to a suitable internal foul water discharge point such as an internal soil and vent stack A suitable permanent connection to the foul waste pipe should be used Fig 11 Disp...

Page 21: ...ings elbows etc should be kept to a minimum and any internal burrs on cut pipe work should be removed so that the internal pipe section is as smooth as possible Fitting an external air break Refer to...

Page 22: ...rd accessories Appliance accessories Integral diveter valve option The appliance has the option to fit an integral diverter valve kit which has multiple controls options for the use with vented and un...

Page 23: ...e systems Where a flue system is not going to be accessible provision must be made for service and inspection Voids containing concealed flues must have at least one inspection hatch no less than 300m...

Page 24: ...bends High level horizontal flue Flue length mm 60 100 80 125 Horizontal high level telescopic flue assembly 202 603 N A Table 16 Flue length mm 60 100 80 125 Telescopic horizontal flue assembly 180 5...

Page 25: ...rizontal flue with 2 x 90 bends 2 600 11 000 Table 22 Maximum flue length mm 60 100 80 125 High level horizontal flue with 3 x 90 bends N A 9 000 Table 23 Maximum flue length mm 60 100 80 125 Vertical...

Page 26: ...ength The Greenstar i range appliances can use up to 4 500mm of plume management regardless of flue length Note Measurement M plume length M must be a minimum of 500mm and must not exceed 4 500mm for...

Page 27: ...mm 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 External flue joints must be...

Page 28: ...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 600mmdistancetoasurfacefacingaterminal unlessitwillcausea nu...

Page 29: ...t 3 angle If extensions are to be added then the complete flue must rise at an angle of 3 from the appliance Drill hole using a core drill or similar Side outlet Mark from the centre line of the wall...

Page 30: ...densate drain pipe work detail Preparing the wallframe Fit sealing washers to service valves before hanging appliance Fig 26 Sealing washers 1 CH flow 22mm 2 Gas inlet 22mm bonded washer 3 CH return 2...

Page 31: ...anel 1 Hinge open the control panel 2 into service position Fig 31 Access for removing siphon Before Hanging the appliance If fitting the optional integral diverter valve kit the following needs to be...

Page 32: ...siphon Refer to figure 33 Slide the siphon 2 in over the control box assembly 3 with the sump tilted behind the control box Liftingthecontrolbox assembly 3 upalittlemayeasethefitting of the siphon Pus...

Page 33: ...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 ap...

Page 34: ...ler connections Passthe230Vmainspowercable fromthecontrolbox throughthe grommet at the right hand side of the pre plumbing manifold and route to the mains isolator next to the appliance Mains voltage...

Page 35: ...nnections 3 Live Neutral feed to wiring centre connections 4 CH DHW Switch Live from wiring centre connections 5 External frost protection connections Low voltage terminal connections 9 Cylinder tempe...

Page 36: ...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 the time stated by the manufactu...

Page 37: ...sequence Ifallcontrolsareworkingcorrectlytheradiatorsymbolwillappearonthe display confirming a central heating demand has been received If no radiator symbol is shown then check all controls as no dem...

Page 38: ...ode Hot water Displays this symbol during a DHW cylinder use only available when optional integral diverter valve kit fitted Central Heating Displays this symbol during a CH use Chimney sweep mode Dis...

Page 39: ...r system is being heated only available when using the optional integral diverter valve kit 202 Anti rapid cycle mode Theboiler hascommencedanti cycle period forCH Can be adjusted in boiler settings 2...

Page 40: ...the pipe work or connections within the system Fig 46 Natural gas pressures Fig 47 L P G pressures NOTICE Factory preset combustion settings The combustion settings on thisgas fired boiler have been c...

Page 41: ...rn to normal operation If left in the service mode the control will return to normal operation after 15 minutes 6 5 5 Checking for leaks during operation Use an approved leak detector to check all con...

Page 42: ...pe as specified in BS 7967 Beforeusetheanalysermusthavebeencalibratedas specified by the manufacturer The installer must be competent in the use of the analyser Check and zero the analyser in fresh ai...

Page 43: ...ion test 1 Flue gas sample point 2 Flue turret flue gas blank plug 3 Flue adaptor flue gas blank plug Setting the appliance to minimum Whilst the appliance is in Chimney sweep mode the chimney sweep s...

Page 44: ...t weather compensation controller with outdoor sensor provides this If a Worcester Intelligent weather compensation controller with outdoor sensor is installed the following procedure must be observed...

Page 45: ...n Enabled 5 W2 WDM Max temperature Set maximum supply temperature when outdoor sensor temperature is equal to or less than 10 C Range from 20 90 C 5 W3 WDM Min temperature Set minimum supply temperatu...

Page 46: ...usted settings in the Master settings menu following a power interruption The Master settings menu cannot be factory reset 6 6 Finishing commissioning 6 6 1 Replace front panel Replacefrontpanelmaking...

Page 47: ...urn to main screen or Wait 4 seconds for auto confirm and the display will return main screen Fig 56 Setting economic central heating temperature 6 6 5 Optional integral diver valve kit fitted Setting...

Page 48: ...menu button Reset button To enable disable the basic adjust mode operation of the appliance domestic hot water adjustment only when basic mode active Press and hold for 5 seconds the central heating...

Page 49: ...d are unobstructed and undamaged If the appliance is in a compartment or cupboard check that the specified service space around the appliance is clear Check all joints and connections in the system an...

Page 50: ...Check the gas inlet pressure Checkthegassupplyworkingpressuresinthesystemconformtothe readings shown in the table shown in section 6 5 1 Component access Remove the bottom panel Pull the catch down Sl...

Page 51: ...sure test then contact Worcester Bosch Group for advice After the measurements are taken switch the appliance off Disconnect the manometer and replace the test point cover Replace the combustion air i...

Page 52: ...ems to gain access to the heat exchanger channels so that the heat exchanger can be cleaned 7 6 1 Cleaning the siphon Access to the siphon Loosen the captive screw securing the control panel 1 Hinge o...

Page 53: ...lly inspect the siphon to ensure that it is clean and free from debris 7 6 2 Refitting the siphon after cleaning Fill siphon with 200 to 250 millilitres of water Slide the siphon in over the control b...

Page 54: ...ring that the lower baffle and the top baffle are refitted correctly Refer to figure 75 when re fitting the burner to ensure that it fits centrally within the heat exchanger and location tabs are situ...

Page 55: ...2 level and to the right as far as possible to release from the bayonet connection Pull the siphon 2 straight down to clear the connection Tilt the siphon 2 to the front and remove over the control bo...

Page 56: ...ode assembly 7 7 6 Burner and electrode removal Remove electrical connections from the primary sensor and remove the primary sensor 7 7 12 Primary sensor CH NTC Remove electrical connections from the...

Page 57: ...e spring clip to release the flow pipe elbow 1 from the heat exchanger Pull the flow pipe with elbow 1 away from the heat exchanger Fig 77 Flow pipe removal NOTICE Gasket The burner assembly gasket mu...

Page 58: ...s valve will need to be removed section 7 7 17 Refer to figure 80 Ensure the appliance is isolated and fully drained Loosen the left heat exchanger retaining screw 1 Remove the right heat exchanger re...

Page 59: ...om thermostat Slacken and remove fixing screw and thermostat 3 When replacing ensure thermostat sits correctly on surface of the casting with the left hand side of thermostat sitting up against the sh...

Page 60: ...ion from the valve Remove wire clip 2 from gas valve outlet Pull the gas pipe 1 free from the gas valve Undo the bottom gas pipe connection 3 Remove the two screws securing the bracket and remove gas...

Page 61: ...new control unit Hinge the electrical cover flaps 1 and 2 to allow access to electrical connections Lift the latches 3 over the catches 4 Thiswillneedtobedonefortheinstallerconnectionsside 1 and the...

Page 62: ...follow the above in reverse 7 7 25 Drain tap Refer to figure 93 Rotate the drain tap 10 fully anti clockwise and push in Withdraw the drain tap from its housing 7 7 26 Pump head Refer to figure 93 Dis...

Page 63: ...he above in reverse Ensure any seals that have been disturbed are renewed Fig 94 Hydraulic block removal 7 7 29 CH pressure relief valve Refer to figure 95 Remove the hydraulic block from the applianc...

Page 64: ...intervention is required following clearance of the fault Press the reset button briefly once on the appliance facia The last eight locking errors can be found in the History menu section 7 1 1 page...

Page 65: ...vice and reset the service reminder Service date set h08 Confirmation of service date This message will only be available if burner hours service option has been enabled in intelligent controller Rese...

Page 66: ...harness and connector 230 Vac across brown and blue wires Fan operation replace if necessary Connections of the control box Replace control box if necessary Fan Airflow fault C1 264 Fan stopped durin...

Page 67: ...s Wiring and connection of flame probe Replace flame probe necessary Ignition Ionisation fault EA 261 HCM potentially defective Reset the appliance If continues to go to this error Check HCM is insert...

Page 68: ...ternal error F0 290 Control box is defective Analogue Digital converter reference error Check HCM is inserted properly Connections of the burner control Replace burner control if necessary Internal er...

Page 69: ...This resets the appliance controls configuration it will not detect the cylinder sensor and Worcester controls are still connected Pump error A1 281 Pump stuck or running dry Check Primary system wat...

Page 70: ...mperature C Measurement tolerance 10 36 005 0 28 540 5 22 782 10 18 294 15 14 785 20 11 991 25 9 794 30 8 054 35 6 658 40 5 527 45 4 612 50 3 859 55 3 246 60 2 747 65 2 334 70 1 991 75 1 705 80 1 465...

Page 71: ...esistances Resistance Temperature C 36 005 0 28 540 5 22 782 10 18 294 15 14 785 20 11 991 25 9 794 30 8 054 35 6 658 40 5 527 45 4 611 50 3 859 55 3 246 60 2 747 65 2 334 70 1 991 75 1 705 80 1 465 8...

Page 72: ...e set value Gas valve OFF Fan overrun 30 seconds Wait until temperature is below set value LOCKOUT Stop spark and gas Purge 30 seconds 5th attempt BURNER LIT YES YES NO NO FLAME SYMBOL ON END OF APPLI...

Page 73: ...gas 4 seconds 90 second soft start Fan modulation to achieve set temperature 30 82 C Gas valve OFF Pump overrun 3 minutes Fan overrun 30 seconds Diverter valve returns to DHW position up for DHW prio...

Page 74: ...Central heating demand switches off End of appliance demand central heating Diverter valve returns to DHW position up for DHW priority Diverter valve returns to DHW position up for DHW priority Once...

Page 75: ...Greenstar i SystemErP 6 720 806 945 2015 07 75 Notes...

Page 76: ...Greenstar i SystemErP 6 720 806 945 2015 07 76 Notes...

Page 77: ...Greenstar i SystemErP 6 720 806 945 2015 07 77 Notes...

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Page 79: ...SKRQH 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 UDW...

Page 80: ...orcester Bosch Group is a brand name of Bosch Thermotechnology Ltd worcester bosch co uk 6 720 806 945 2015 07 WORCESTER BOSCH GROUP TECHNICAL SUPPORT 0330 123 3366 APPOINTMENTS 0330 123 9339 SPARES 0...

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