Worcester Greenstar 8000 Style GR8700iW 30 C Installation And Maintenance Instructions Manual Download Page 1

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6720883864 (2019/02) UK/IE

Installation and Maintenance Instructions

Gas fired condensing combi boiler

Greenstar 8000 Style

Summary of Contents for Greenstar 8000 Style GR8700iW 30 C

Page 1: ...tion and Maintenance Instructions Gas fired condensing combi boiler Greenstar 8000 Style GR8700iW 30 C GR8700iW 35 C GR8700iW 40 C GR8700iW 45 C GR8700iW 50 C GR8700iW 30 CB GR8700iW 35 CB GR8700iW 40...

Page 2: ...tor installation 35 5 5 Electrical connection 36 5 5 1 Installer connections 36 5 5 2 Cable preparations 38 5 5 3 External controls domestic installations 38 6 Commissioning 39 6 1 Pre Commissioning c...

Page 3: ...oval 64 9 4 Pressure relief valve removal 64 9 5 Replacing the gas valve 64 9 6 Checking the strainer in the cold water pipe and the flow turbine 65 9 7 Checking replacing the motor of the 3 way valve...

Page 4: ...ibility of the designer installer of the flue to ensure this flue gas system operates correctly and in a safe manner H If you smell gas A gas leak could potentially cause an explosion If you smell gas...

Page 5: ...manage and promote the scheme Visit centralheating co uk for more information H Health and safety The appliance contains no asbestos and no substances have been used in the construction process that c...

Page 6: ...tice for domestic and hot water supply BS6891 Installation of low pressure gas pipe work up to 28mm R1 BS5546 Installation of gas hot water supplies for domestic purposes EN12828 Central heating for d...

Page 7: ...um Gas 3 6 Product identification Data plate The data plate includes the product performance information approval data and serial number The data plate location can be found in the product overview Ad...

Page 8: ...ns mm X Appliance width 440 Y Appliance height 780 Z Appliance depth 365 W Flue centre from appliance left side 220 D Flue centre from rear of appliance 87 0010023464 001 1 2 3 4 5 6 7 Function From l...

Page 9: ...Plate heat exchanger 2 KEY accessory housing slot wireless Gateway 3 Condensate trap 4 Data plate 1 5 Hot water temperature sensor 6 Pressure sensor 7 Pressure gauge 8 Venturi sealed 9 Schrader Valve...

Page 10: ...block temperature limiter 20 Flow temperature sensor at heating block 21 Inspection cover 22 Condensate sump 23 Gas valve 24 Automatic air vent valve 25 Flow Turbine 26 Data plate 2 27 Diverter valve...

Page 11: ...e required at all the lowest points on the system Air vents are required at all high points on the system Showers Bidets If a shower head can be immersed in water or comes closer than 25mmfromthetoped...

Page 12: ...ust not be filled with salt based softened water Ensure the primary water filling point uses an untreated cold water connection from the mains supply before a water softener Filling the system must co...

Page 13: ...knownlength theeffectivelengthwillbeincreasedby0 5mforeach 90 elbowandteefittedandby0 3mforeach90 bend Thismethod is only a estimate for more complex design please refer to BS6891 2015 and training gi...

Page 14: ...store or use these substances in the appliance room Avoid the build up of dust NOTICE Damage to appliance Extreme temperatures may cause damage to the heating system Ensure the ambient temperature is...

Page 15: ...sspacewiththeadditionofcupboards shelvesetc next to or around the appliance Do not store any combustible materials on or next to the appliance such as clothes towels paper or plastic bags Fig 11 Appli...

Page 16: ...bends NOTICE Effective flue lengths of bends Each bend used has an equivalent straight flue length Refer to the table below Table 11 Effective length of bends 4 4 2 Flue options The systems have diife...

Page 17: ...Horizontal maximum flue lengths minus the 90 bend equivalent straight flue length as stated in Table 11 Effective length of bends Horizontal flue with additional 90 elbows Fig 17 Horizontal flue opti...

Page 18: ...alent straight flue length as stated in Table 11 Effective length of bends 4 4 3 Plume management system For every extra 1000mm of plume management after the first 500mm the internal 60 100 flue lengt...

Page 19: ...Fig 25 Terminal exclusion zone NOTICE Cutting the 500mm pipe Ifthe500mmplumemanagementpipekitiscut anadditionalelbowwill be required to join the pipe work The Plume management extension kit contains...

Page 20: ...re 6 The flue must not penetrate the roof in the shaded area The terminal must be at least 1500mm from the opening or vent whensitedbelowthewindowor600mmwhensitedtoeitherside or above 7 400mm measured...

Page 21: ...l in relation to surfaces or boundary lines 6 The terminal must be at least 1500mm from the opening or vent whensitedbelowthewindowor600mmwhensitedtoeitherside or above 7 600mm diagonally to an openin...

Page 22: ...d with suitable silicon sealant if it is external to the building Note Installations in car ports are not recommended The flue cannot be lower than 1 000mm from the top of a light well due to the buil...

Page 23: ...ting a terminal in relation to surfaces or boundary lines 6 Proximity of flue duct outlet to boundaries 2000mm distance to an opening in adjacent building facing a terminal BS 5440 Part 1 recommends t...

Page 24: ...n condensate discharge Follow the latest version of BS6798 and HHIC guidance For correct installation and trouble free operation of the appliance the following advice should be followed 1 To minimize...

Page 25: ...pump Figure 31 Where direct connection to a gravity discharge pipe work is not physicallypossible orwhereverylonginternalrunswouldberequiredto reach a suitable discharge point condensate should be rem...

Page 26: ...y followed As well as trace heating other methods of protecting pipe work that is run externally should be considered to prevent freezing in prolonged periods Insulation materials can be used these sh...

Page 27: ...0mmfromthe bottom of the tube The holes must face away from the house The tube must be surrounded by at least 100mm of limestone chippings to a depth of 400mm An air break must be installed in the ext...

Page 28: ...e Building Regulations to flush and inhibit the primary water system in accordance with BS 7593 TheBuildingServicesComplianceGuiderecommendsthataprimary water cleanser is fitted to the system Worceste...

Page 29: ...n 1 and 1 5 bar via a WRAS approved filling loop Vent any air from the appliance and system New appliance Once the new appliance has been installed follow the guidance in Filling the appliance and add...

Page 30: ...ld share the lifting of the appliance up to the loft hatch tilt and slid on its back into the loft space Ensurethattheroofspacehaspermanentfixedlighting apermanent fixed retractable ladder and a fixed...

Page 31: ...ue and the top and bottom fixings of the wall mounting frame Fix the wall mounting template 3 to the wall in the desired position Drill the holes 4 through the template for the primary fixing points a...

Page 32: ...the wall Checkwhetherthescrewsandwallplugssuppliedwiththeappliance can be used Remove installation template from wall Drill suitable holes for the selected wall plugs and screws Fastenthemountingbrac...

Page 33: ...to protect the floor from residual water It is not necessary to lay the appliance on its back 2 After soldering connecting pipes ensure that the appliance internal plastic PRV pipe 1 is then connecte...

Page 34: ...ections Fitting the drain pipe on the heating pressure relief valve Fig 45 Fitting the pipe on the heating pressure relief valve Fitting the condensate pipework Secure the pipe to the wall at the last...

Page 35: ...are pushed fully home and secured Thefluerisesfromtheapplianceatanangleof3 or52mmpermetre length Support the flue at each flue extension joint and at each change of direction use suitable brackets an...

Page 36: ...re connected to the appliance that require 230 Volts must be connected to the same supply as the appliance Type A RCDs must be employed where additional protection is required External fuse 3A Amps Wh...

Page 37: ...rmostat return Without function 0010019570 001 5 7 8 9 10 12 13 14 0010023703 001 PE PC0 N L PW2 N L FS FR LR LR PW1 N L N IN 230V OUT 230V L L N TW1 1 2 T1 1 2 T0 1 2 LF0 1 2 I3 1 2 I1 1 2 BUS 1 2 TW...

Page 38: ...onnections example External 230V single channel timers Leave DHW pre wired link in place Theelectricalpowersupplytotheexternalequipment 2 issupplied from 230V OUT L Live N Neutral and earth terminals...

Page 39: ...amage to the materials within the appliance aluminium mild steel stainless steel copperandbrass andanyothermaterials componentswithinthe system Record the date when the inhibitor was added to the syst...

Page 40: ...the operating pressure of the heating system Table 15 If the indicator is below 1 bar when the system is cold Top up the water until the indicator is between 1 bar and 1 5 bar again If pressure is not...

Page 41: ...nutes of operation with increased min capacity During the siphon filling program Siphon fill prog appears on the display The siphon filling mode is interrupted when the chimney sweep mode is started 6...

Page 42: ...t possible isolate the appliance on the gas side and notify the gas supplier Exit the chimney sweep mode Switch off the appliance close the gas isolator remove the pressure gauge and tighten the screw...

Page 43: ...he following combustion and flue integrity checks are mandatory and these values must be recorded on the Benchmark check list at the end of these instructions Once the gas rate and pressure have been...

Page 44: ...point 1 Allow the readings to stabilise and check that O2 is equal to or greater than 20 6 CO2 is less than 0 2 If the readings are outside these limits then this indicates that there is a problem wi...

Page 45: ...pressure has been checked and is satisfactory Refit the test point plugs after the test has been completed The flue gas analysis performance of the appliance can be checked via the flue turret adaptor...

Page 46: ...serialnumber applianceinformationis located they will need this information if they call in with a problem Benchmark Commissioning checklist on page 77 contains all relevant appliance information Give...

Page 47: ...lation neglect misuse or accidental damage or the nonobservance of the instructions contained in the Installation and Users Instructions leaflets The appliance has been used only for the normal domest...

Page 48: ...p Solar fault Settings Hydraulics Low loss header DHW configuration HC1 configuration Pump config Heating Mx heat outp Standby time Clock inh T off Clock inh T on Hot water Turbine signal del DHW star...

Page 49: ...e service menu 49 Greenstar 8000 Style 6720883864 2019 02 Burner Ignition Fan Pump 3 way valve HC1 pump Ionisat oscill Solar pump Reset Default setting Fault history Hidden menu Reset Maintenance Land...

Page 50: ...on in Outside temp Current outside temperature in C HC1 pump Current status on off Burner starts Number of burner starts since commissioning Hours run Elapsed time of the system since commissioning Sy...

Page 51: ...r heated DHW cylinder is connected to the cold water inlet of a combi boiler DHW heating by the combi boiler will be suppressed expecting that solar thermal DHW will reach the hot water temperature se...

Page 52: ...Max refill time 5 30 240 seconds Blocking time 1 12 52 weeks Max refills 1 5 20 Reset refilling The automatic filling function ensures that the operating pressure is maintained If the operating pressu...

Page 53: ...hold at which outside temperature the heating system is to switch to summer mode Frost prot Off On Frost temp limit 0 5 10 C Temperature value for the system frost protection This service function is...

Page 54: ...detail of some of the service requirements Check that the safety and regulation appliances 3 bar pressure release valve air bleed etc are operating properly Check all joints and connections in the sys...

Page 55: ...securing both sides the outer case 3 Pullbottomoffrontcoverforwardsandupwardstoreleasetheclipon top of the boiler and remove outer case Fig 73 Removing outer case 8 5 Fan pressure test NOTICE Fan pres...

Page 56: ...s chapter 6 4 Check that the readings conform to those given in the following tables In addition to CO and CO CO2 ratio checks also check the maximum and minimum CO2 percentage reading Table 22 CO2 an...

Page 57: ...rt number 7 719 001 996 8 9 1 Checking the burner 1 Remove the combustion cover Fig 62 2 Unscrew the screws on the burner cover 3 Remove the burner cover Fig 76 Removing the burner cover Remove the bu...

Page 58: ...o be removed to gain access to the heat exchanger for cleaning Remove the combustion casing Lower the control panel into the service position Disconnect electrical wires to the fan ignition transforme...

Page 59: ...op to bottom Fig 84 Cleaning brush Use the handle of the brush to remove debris from the condensate tray It is possible to rinse any remaining debris from the heat exchanger either through the access...

Page 60: ...an pressure test 8 9 5 Checking electrodes Remove the electrode set with gasket Check electrodes for contamination Clean or replace electrodes if required Install electrode set with new gaskets Fig 88...

Page 61: ...e trap Check the gasket for cracks deformation or breakage and replace if required Align the new gasket correctly with the condensate trap Fig 91 Aligning the new gasket with the condensate trap Press...

Page 62: ...s after firing the appliance 8 10 1 Checking and if required adjusting the gas air ratio Switch off the appliance Remove the front cover Remove the combustion cover Fig 94 Removing the combustion cove...

Page 63: ...rreplacementofagasrelatedcomponent whereagasketorseal has been disturbed or replaced check for gas tightness using a gas sniffer analyser On re assembly check all affected seals for cracks hardness an...

Page 64: ...g 90 Pull the spring forward 1 Remove the pressure sensor 2 9 4 Pressure relief valve removal Open the cover Fig 51 Remove the condensate trap Fig 90 Pull the spring up 1 Press the PRV Pipe down light...

Page 65: ...r contamination Fig 102 Removing the strainer from the cold water pipe 1 Pull out the flow turbine Fig 103 Removing the flow turbine at the cold water pipe Select in the Service menu Info DHW flow rat...

Page 66: ...pliance Ensure that the appliance settings and functionality is correct Ensure the CH DHW programmer timer is functioning Ensure the room thermostat is functioning Ensure the cylinder thermostat if fi...

Page 67: ...k the sensor port 2 Check the differential sensor for incorrect installation position or breakage 1017 W Water pressure too low 1 Top up water and vent the system 2 Replace the pressure sensor 1021 B...

Page 68: ...burner starts automatically after cleaning 1 Set the correct gas air ratio correctly 2963 B Signal from flow and heat exchanger temperaturesensoroutsidethepermissible range Connect the connecting lead...

Page 69: ...must be disposed of in local collection systems 12 Technical Specifications Logs 12 1 Technical data 12 1 1 Specifications Combi Greenstar 8000 Style Violent ignition poor ignition Check the ignition...

Page 70: ...class 6 6 6 6 NOx rating EN 15502 1 mg kWh 40 40 40 40 Condensate Maximum condensate rate l h 3 5 3 5 4 1 4 1 pH value approx 4 5 5 0 4 5 5 0 4 5 5 0 4 5 5 0 Electrical Electrical power supply voltage...

Page 71: ...56 77 56 69 56 69 56 Flue gas temperature 80 60 C max min load C 77 56 77 56 69 56 69 56 Flue gas temperature 40 30 C max min load C 56 31 56 31 52 30 52 30 CO2 level at max rated heat output after 1...

Page 72: ...ressure working for max flow bar 2 5 2 5 Minimum mains inlet pressure working for operation bar 0 2 0 2 Minimum required flow to activate DHW demand l min 1 9 1 9 DHW temperature range C 35 60 35 60 M...

Page 73: ...ided assuumes the accepted NG average calorific value of 34 9 MJ m3 net 3 Appliances are fitted with a flow regulator set to achieve a 40 C temperature rise This ensures comfortable bathing during the...

Page 74: ...9 6 65 34 19 0 20 8 69 36 20 0 21 9 73 38 21 0 23 1 77 41 22 0 24 3 80 43 23 0 25 5 84 45 24 0 26 7 88 47 25 0 27 9 92 49 26 0 29 1 96 51 26 9 30 2 100 53 G20 20 mbar Gross calorific value HS 0 C kWh...

Page 75: ...heating block 6 Flame sensing electrode 7 Ignition electrode 8 Heating block temperature limiter 9 Ignition transformer 10 Flow Turbine 11 Fan 12 Control cable of the heating pump 13 Heating pump 230...

Page 76: ...Logs Greenstar 8000 Style 6720883864 2019 02 76 15 Display 16 Code plug 17 Terminal strip for external accessories terminal assignment Tab 5 5 1 page 36 18 3 way valve 19 Connecting lead 20 Earth PE...

Page 77: ...imary water system filter been installed Yes No The condensate drain has been installed in accordance with the manufacturer s instructions and or BS5546 BS6798 Yes CENTRAL HEATING MODE measure and rec...

Page 78: ...Yes Yes Yes No Yes Yes Yes Yes Yes Year 3 ________________________ ___________________ Yes Yes Yes Yes Yes Yes Yes Yes Yes No Yes Yes Yes Yes Yes Year 4 ________________________ ___________________ Y...

Page 79: ...gnature SERVICE 05 Date SERVICE 06 Date Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No Record At max rate CO ppm AND CO2 Reco...

Page 80: ...Kingdom Tel 0330 123 9559 worcester bosch co uk TECHNICAL SUPPORT 0330 123 3366 RENEWABLE SUPPORT 0330 123 9229 CONTROLS AND CONNECTIVITY TEAM 0330 123 3641 APPOINTMENTS 0330 123 9339 SPARES 0330 123...

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