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Worcester GREENSTAR 29, Installation And Servicing Instructions

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Worcester GREENSTAR 29 Installation And Servicing Instructions Download Page 13

6 720 611 137 GB (03.02)

Installation

13

Fig. 7

 

Fig. 8

 

3.3

Siting the appliance

Regulations concerning the Installation Site

B

Relevant national regulations must be complied with 
section 3.8.1.

B

Consult the installation instructions for details of min-
imum clearances required.

Combustion air
In order to prevent corrosion, the combustion air must 
not contain any corrosive substances.
Substances classed as corrosion-promoting include 
halogenated hydrocarbons which contain chlorine and 
fluorine compounds and are contained in some sol-
vents, paints, adhesives, aerosol propellants and 
household cleaners, for example.

Surface temperature
The max. surface temperature of the casing and the flue 
is less than 85 °C. 
This means that, no special safety precautions are 
required with regard to flammable building materials 
and fitted furniture. The specified clearences must be 
maintained.

Cupboard/Compartment 
The appliance can be installed in a cupboard/compart-
ment need for airing clothes providing that the require-
ments of BS6798 and BS5440:2 are followed. The low 
casing losses from the appliance eliminate the need for 
ventilation openings in the compartment. Refer to Fig. 1 
for the required clearences around the appliance.

Note:
A drain cock
should be fitted
at the lowest 
point of the
heating circuit
and beneath
the appliance

 Fully pumped sealed system

RV

LV

LV

RV

RV

RV

LV

LV

INDIRECT
CYLINDER

BOILER

Heating R

eturn

Heating Flow

Cylinder R

eturn

Hot W

a

ter Flow

BS

Stop Valve Fixed Cylinder Type or sealed systems - Approved connection

Mains Cold Water

Radiator Valve - Flow RV
Lockshield Valve - Return   LV

Expansion

Vessel

Bypass 

balancing valve or

uncontrolled

radiator with tw o

lockshield valves

Pressure

Gauge

Relief
Valve

6 720 611 137 - 28.2O

Heating return

Non return

valve

Non return

valve

Hose union

Test cock

Temporary hose

Stop cock

Auto

air vent

Heating return

Stop

cock

Fill point

Non return
valve

Make up

vessel

1000mm (39 in)
above the highest
point of the system.

 Sealed system filling and make up

 

6 720 611 137 - 29.1O

Summary of Contents for GREENSTAR 29

Page 1: ...ion and Servicing Instructions GREENSTAR 29 HE Conventional Wall mounted condensing boiler 6 720 610 577 00 10 HE Conventional GC Number Natural Gas 41 311 56 GC Number LPG 41 311 57 6 720 611 137 GB...

Page 2: ...on 25 6 Individual settings 26 6 1 Mechanical settings 26 6 1 1 Setting the boiler flow temperature 26 6 2 Settings on the Bosch Heatronic 26 6 2 1 Operating the Bosch Heatronic 26 6 2 2 Setting the a...

Page 3: ...etc in the vicinity of the appliance Health and safety B This appliance contains no asbestos products B There is no potential hazard due to the appliance being electrically unsafe B There are no subst...

Page 4: ...ed appliance siting not dependent on room size Natural gas models are low emission appliances Multifunction display Bosch Heatronic control system Automatic ignition Modulating control Full safety sys...

Page 5: ...ty kit 1 5 Casing dimensions Fig 1 13 Wall mounting frame and Manifold assembly 101 Outer case 103 Facia cover X Standard Concentric Horizontal Flue System 100 mm min 310 mm Alternative Concentric Flu...

Page 6: ...64 Adjusting screw for min gas flow volume 102 Inspection window 120 Fixing points 221 1 Flue duct 221 2 Combustion air intake 226 Fan assembly 295 Appliance type sticker 234 Testing point for combust...

Page 7: ...ensor in boiler flow 43 Boiler flow 45 Gas inlet 47 Return 52 Solenoid valve 1 52 1 Solenoid valve 2 55 Filter 56 Gas valve CE 427 57 Main valve disc 61 Reset button 63 Adjustable gas flow restrictor...

Page 8: ...ler flow 151 Fuse slow 2 5 A AC 230 V 153 Transformer 161 Link 226 Fan 300 Code plug 302 Earth connection 310 Function control Service only 312 Fuse slow T 1 6 A 313 Fuse slow T 0 5 A 317 Digital disp...

Page 9: ...min load C 67 55 67 55 Flue gas temp 40 30 C rated min load C 43 32 43 32 Residual delivery pressure inc pressure drop in air intake duct Pa 80 80 CO2 level at max rated heat output CO2 level at min...

Page 10: ...546 Installation of gas hot water supplies for domestic purposes BS 5440 1 Flues and ventilation for gas appliances of rated input not exceeding 70 kW net Flues BS 5440 2 Flues and ventilation for gas...

Page 11: ...are available as proprietary kits The expan sion vessel and fittings must be connected at the neu tral point of the system on the entry to the pump A pump and diverter valves are also required as appr...

Page 12: ...hot water cylinder S H S H 150mm max Bypass or uncontrolled radiator if required 6 720 611 137 26 1O Refer to system notes Typical Bypass or uncontrolled radiator Primary cold feed 15mm min Heating ve...

Page 13: ...an be installed in a cupboard compart ment need for airing clothes providing that the require ments of BS6798 and BS5440 2 are followed The low casing losses from the appliance eliminate the need for...

Page 14: ...Refer to fig 1 and 18 B Mark the holes for the wall mounting frame onto the wall drill and plug the holes and screw the wall mounting frame to the wall with the screws provided Fig 10 B Screw the pre...

Page 15: ...pe of at least 2 5 3 6 Fitting the appliance B Remove packing taking care to observe the instruc tions on the packing B Lie the boiler on its back Removing the outer case B Turn the clips with a screw...

Page 16: ...m excessive pressure B Check gas supply pipe B Release the pressure on the gas supply pipe 3 8 Flue Systems The only flue systems that may be used are those sup plied by Worcester Heat Systems The flu...

Page 17: ...inal Position kW input expressed in net Balanced flues room sealed Fanned draught A1 Directly below an opening air brick opening windows etc 300 mm B1 Above an opening air brick opening window etc 300...

Page 18: ...plates Extension kit comprises Air duct Flue duct Duct clamp Refer to fig 22 Instructions for fitting other flue systems are packed with the relevant flue kit Check that the position chosen for the a...

Page 19: ...1600mm Flue Turret No Clamp Terminal Assembly Outer Wall Extension Duct 6 720 610 602 09 1O Clamp Flue Turret No Clamp Clamp Extension Duct Clamp Extension Duct Terminal Assembly Outer Wall 6 720 610...

Page 20: ...An inner wall sealing plate is provided which should be fitted to the ducts before assem bly Push the assembly through the wall and fix the turret to the appliance with the clamp Refer to fig 26 Fig 2...

Page 21: ...to the mains connection remove the drop down facia cover The drop down cover is removed by lowering it to the horizontal position and pushing firmly upwards at the rear of the supports to release the...

Page 22: ...valve s pump programmer etc to the proprietary junction box according to the instruc tions supplied with the box Worcester Heat Systems cannot be held responsible for any incorrect wiring to these par...

Page 23: ...given in BS7593 1992 Treatment of water in domestic hot water systems Full instruc tions are supplied with proprietary cleansers sold for this purpose If an inhibitor is to be used after flushing it...

Page 24: ...mains at minimum heating output for 15 minutes Switching off the appliance B Set the master switch to 0 The green indicator lamp goes out 5 3 Switching on the System The boiler flow temperature is adj...

Page 25: ...button flashes B Press and hold the button until the display shows The appliance will then start up again and the display will show the central heating flow temperature If the button does not flash B...

Page 26: ...full description of all available functions please refer to the Service booklet for the Engineer order no 7 181 465 346 Fig 36 Appliance controls 1 Service button 2 Chimney sweep button 3 Temperature...

Page 27: ...ow temperature is 30 C 6 2 5 Setting the heating output Service Function 5 0 The heating output can be set to any level between min rated heat output and max rated heat output to limit it to the speci...

Page 28: ...de number B Press and hold the and buttons simultane ously until the display shows The heating output is now stored Fig 39 B Return the temperature control and the function con trol to their original...

Page 29: ...he outer case see page 16 refer to fig 15 B Switch on the appliance at the master switch I B Set room thermostat to maximum temperature B Open thermostatic radiator valves B Unscrew sealing plug from...

Page 30: ...levels at min and max rated heat output and re adjust if necessary B Turn the function control anti clockwise as far as the stop so that the display shows 0 Normal operating mode The display and the b...

Page 31: ...The button will light up and the display shows the CH flow temperature B Remove sealing plug from flue gas testing point 234 fig 47 B Insert testing probe about 135 mm into the testing point and seal...

Page 32: ...ppliance shut the system valves and open the drain valve B Upon completion of any electrical work check for earth continuity correct polarisation and resistance to earth B Always disconnect the applia...

Page 33: ...r soiling and splits see page 36 4 Check gas supply pressure see page 29 mbar 5 Test combustion air flue gas see page 31 6 Check CO2 setting for min max gas air ratio see page 29 min max 7 Check gas a...

Page 34: ...bly 32 1 page 6 must be cleaned or replaced Primary Heat exchanger There is a special accessory kit no 840 for cleaning the heat exchanger order no 7 719 001 996 B Check control pressure on the air ga...

Page 35: ...in reverse order using a new seal B Adjust gas air ratio Refer to section 7 2 Condensation trap In order to prevent spillage of condensate the conden sation trap should be completely removed see page...

Page 36: ...disconnect the pipe to the siphon B Remove the yellow plug to drain the siphon B Unscrew the securing nut from beneath the side facia and remove the siphon Refer to figure below B Refit and prime the...

Page 37: ...ve screw holding power connector earth lead and remove earth lead B Remove two top fixing screws from the control box Refer to fig 57 Fig 57 B Lower the control box B Unscrew earth lead B Unscrew four...

Page 38: ...cement sensor Safety Temperature Limiter Item 6 fig 2 57 B Pull off the connectors B Unscrew the sensor Flue Temperature Limiter Item 9 fig 2 57 B Pull off the connectors B Unscrew the sensor 8 3 4 Ga...

Page 39: ...the fan assembly complete with the gas air tube and mixer assembly Refer to section 8 3 2 B Remove the burner Refer to section 8 2 B Disconnect the sensors Refer to section 8 3 3 B Undo the central he...

Page 40: ...connecting lead E9 Safety temp limiter in CH flow has tripped Check system pressure check safety temp lim iters check external pump operation check fuse on pcb bleed appliance EA Flame not detected I...

Page 41: ...999 0 10 Burner skin seal 1 8 711 004 168 0 11 Transformer facia 1 8 747 201 358 0 12 Heat exchanger washer 1 8 710 103 153 0 13 Washer set Condensation Trap 1 8 710 103 154 0 14 Fuse set 1 8 744 503...

Page 42: ...0 secs Fan speed reduces over 15 secs Gas valve closes Red light OFF Minimum heat input for 15min Boiler operates to match system load and temperature control setting Boiler unused for long period Ove...

Page 43: ...6 720 611 137 GB 03 02 Appendix 43...

Page 44: ...EXCELLENCE COMES AS STANDARD Worcester Heat Systems Limited Cotswold Way Warndon Worcester WR4 9SW Telephone 01905 754624 Fax 01905 754619...

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