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FAULT FINDING AND DIAGNOSIS

Greenstar Ri

ErP

- 6 720 813 283 (2015/07)

8.3

PROTECTION FUNCTION

Fig. 93 Protection function

Internal boiler

temperature

between

8°C & 5°C

Boiler automatic

frost function

(monitors internal boiler

primary temperature)

Internal boiler

temperature

below 5°C

Internal boiler

temperature

rises above 9°C

Pump runs

Pump switches off

after a 3 minute

overrun 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 dissipate heat from

the boiler into the system

End of boiler demand

(central heating or

domestic hot water)

AUTOMATIC INTERNAL FROST FUNCTION

PUMP OVERRUN FUNCTION

A central heating demand

activated, pump runs

normally

Pump runs 5 seconds

every 24hrs from

last time pump ran

No central heating

demand after
a 24hr period

PUMP ANTISEIZE FUNCTION

6720643895-111.1Wo

Содержание 12Ri ErP

Страница 1: ...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 w...

Страница 2: ...lectrical connections 27 6 COMMISSIONING 28 6 1 Pre Commissioning checks 28 6 2 Filling the system 29 6 3 Water treatment 29 6 4 Starting the appliance 29 6 5 Commissioning 30 6 5 1 Checking the gas i...

Страница 3: ...RTING 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 the ensuing...

Страница 4: ...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 Haza...

Страница 5: ...lies 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 ventilation...

Страница 6: ...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 ErP Label 6 Bottom panel and...

Страница 7: ...66 59 71 61 79 64 Flue gas temp 40 30 C rated min load C 41 33 44 33 48 34 54 35 43 35 46 36 49 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...

Страница 8: ...regime means 60 C return temperature at heater inlet and 80 C feed temperature at heater outlet P4 kW 12 15 18 24 At 30 of rated heat output and low temperature regime 2 2 Low temperature means for c...

Страница 9: ...urn temperature at heater inlet and 80 C feed temperature at heater outlet P4 kW 12 15 18 24 At 30 of rated heat output and low temperature regime 2 2 Low temperature means for condensing boilers 30 C...

Страница 10: ...mbly 20 Syphon Trap 7 Overheat thermostat 21 Gas inlet connection 8 Silicon tube Heat Exchanger air vent 22 Mains cable inlet 9 Heat Exchanger 23 Gas Valve 10 Flue overheat thermostat 24 Flue air pres...

Страница 11: ...3 phase supply IP20 Wiring must comply with the latest edition of BS 7671 IET wiring regulations 4 2 2 GAS SUPPLY To ensure that the equipment is in good working order and can meet the gasflowandpres...

Страница 12: ...assisnotnecessaryonaYplansystem as one of the ports is open to flow 1 Static head Minimum static head 250mm measured from the highest point in the heating system top surface of the appliance or the hi...

Страница 13: ...would be required to reach a suitable discharge point condensate should be removed using a proprietary condensate pump of a specification recommended by the boiler or condensate pump manufacturer The...

Страница 14: ...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 o...

Страница 15: ...ner can gain clear and safe access to the controls check top up or reset the appliance Products in loft cavities must have permanent fixed lighting a permanentfixedretractableladderandafixedfloorareas...

Страница 16: ...space required to install and service the boiler inside an unventilated compartment CAUTION CLEARANCES Top and bottom clearances must not be reduced below the values shown in table 12 as they are the...

Страница 17: ...mbing manifold Fig 19 Pipe work dimensions Heating System 22mm compression fittings Gas 22mm compression fittings Do not use the pre formed copper pipes supplied with the boiler for the gas supply The...

Страница 18: ...hould be viewable from both directions NOTICE Effective flue lengths each90 bendisequivalentto2metresofstraightflue each 45 bend is equivalent to 1 metre of straight flue Plume management kits are ava...

Страница 19: ...um flue length mm 60 100 80 125 High level horizontal flue with 2 x 90 bends 2 600 11 000 Table 23 Maximum flue length mm 60 100 80 125 High level horizontal flue with 3 x 90 bends N A 9 000 Table 24...

Страница 20: ...tters 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 sealed wit...

Страница 21: ...00mm clearance 8 Clearances no less than 200mm from the lowest 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...

Страница 22: ...d sleeve 6 5 Remove the plastic cover 7 Fig 25 Unpacking 2 Note Measurement M plume length Mmustbeaminimumof500mmandmustnotexceed 4 500mm for a 60mm plume management system used with the horizontal 60...

Страница 23: ...levant safety precautions must be undertaken Protective clothing footwear gloves and safety goggles must be worn as appropriate FIXING THE MOUNTING FRAME Theboilertemplateshowstherelativepositionsofth...

Страница 24: ...he appliance it is possible to fit the flow and return pipes supplied with the boiler installed on the wall If clearance is less than 600mm below the appliance it may be necessary to fit the flow and...

Страница 25: ...n the fitting pack 1 Fit washer 1 inside the plastic nut and attach firmly to the connection on the syphon 2 Connect the condensate disposal pipe work to the elbow 2 refer to figure 31 and insert the...

Страница 26: ...ptor kit are used to secure turret adaptor to the appliance Fig 33 Flue turret adaptor connection Additional notes and reminders Ensure that all cut lengths are square and free from burrs Ensure that...

Страница 27: ...iler Demand from external wiring centre ST2 Connect SWITCHED LIVE wire to terminal LR Fig 35 Wiring detail NEW COMPLETE SYSTEM INSTALLATIONS Ifanewcomplete heatingsystemisinstalled inanewbuild propert...

Страница 28: ...gas pipe work connections and rectify any leaks Check that the condensate pipe has been connected to the syphon Ensurethatthecondensatepipehasbeeninsertedatleast25mminto the elbow Fig 39 Condensate c...

Страница 29: ...s and drain the system while the appliance is hot Close drain cocks and add a suitable flushing agent at the correct strength for the system condition in accordance with the manufacturer s instruction...

Страница 30: ...en the screw in the inlet pressure test point 1 and connect a manometer Open gas isolation valve Measure the pressure with the boiler running at maximum Refer to section 7 4 to set the boiler to maxim...

Страница 31: ...heck flow chart NOTICE BEFORE CO AND COMBUSTION CHECKS Refer to section 6 5 1 and 6 5 2 to verify gas type gas inlet pressure and gas rate Visually check the integrity of the whole flue system and con...

Страница 32: ...n Commissioning and Service manual with the Benchmark checklist and service record is left with the boiler or homeowner Iftheapplianceisunusedandexposedtofreezingconditions shutoff all the mains suppl...

Страница 33: ...t Finding on page 48 for rectification procedures COMPONENT ACCESS Removing outer case 1 Undo and remove two screws securing boiler casing at the top of the appliance 2 Undo but do not remove the two...

Страница 34: ...Fig 51 Flue integrity test 7 4 FAN PRESSURE TEST SETTING THE BOILER TO MAXIMUM 1 Remove the three screws retaining the control cover 2 Remove the control cover 3 Remove the plastic tool clipped inside...

Страница 35: ...7 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 CO...

Страница 36: ...taining plate assembly Fig 59 Securing nut 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 T...

Страница 37: ...d cleaning the electrode assembly Inspect the condition of the electrodes and ceramics replace if necessary Use a plastic scouring pad to clean the electrodes BAFFLE REMOVAL 1 Refer to figure 62and re...

Страница 38: ...AND CLEANING To release the syphon from the sump 1 Undo the plastic nut on the bottom of the syphon and move the condensate pipe away from the syphon 2 Remove the two screws retaining the syphon brac...

Страница 39: ...lace 7 8 3 OVERHEAT THERMOSTAT Refer to figure 68 for removal Remove two electrical connectors from thermostat 3 Slacken and remove fixing screw and thermostat 3 When replacing ensure thermostat sits...

Страница 40: ...flue limit thermostat in from the sump Retrieve the thermostat from the sump well Fig 70 Remove thermostat To replace push the thermostat and new grommet gently back into the opening until contact wi...

Страница 41: ...sembly 1 around the top of the heat exchanger until the lug on the air gas manifold is visible Lift up assembly and remove from boiler Fig 75 Rotate the air gas manifold assembly NOTICE The valve will...

Страница 42: ...the screw holding the retaining plate 4 Remove the retaining plate 5 Remove three screws and the mixing chamber Re assemble with new fan ensuring seals are correctly fitted Fig 78 Dismantling the air...

Страница 43: ...lamping plate and the top of the heat exchanger refer to figure 81 Fig 81 Initial location of the clamping plate 1 Retaining plate assembly 2 Clamping plate 3 Gasket 4 Bracket 5 Underside view of the...

Страница 44: ...anti clockwise to release from the hook 3 Pull the upper exhaust connector down Fig 85 Upper exhaust assembly 1 Refer to figure 86 and release the clip 2 Move the lower exhaust connector up Remove the...

Страница 45: ...ket 2 The code plug should be left attached to the frame of the boiler by its plastic safety thread 7 8 17 TRANSFORMER PCB To change either the PCB F2 fuse or transformer Remove two screws securing th...

Страница 46: ...board Re assemble in reverse order NOTICE CODE PLUG Ensure that the code plug is fitted to the new control The appliance will indicate an error and will not function correctly NOTICE CO CO2 After com...

Страница 47: ...burner WB6 8 716 110 534 0 Seal Inner case mantel 8 716 106 635 0 H26 545 Flow temperature sensor NTC 8 716 106 688 0 GC No H26 542 Air pressure switch 8 716 106 633 0 G C No H26 543 Seals kit 8 716...

Страница 48: ...t ST2 terminal LR is there a demand Manual bypass is open If CH is working check HW controls If HW is working check CH controls i e external diverter valve frost stat room stat programmer Otherwise re...

Страница 49: ...fuse AC 230 V Slow T1 25 A fuse CH TEMPERATURE CONTROL PRESSURE SWITCH 230V WIRING CENTER JUNCTION BOX FAN Colour sequence SL L N Min Max Norm ON OFF SWITCH 230V AC 25V Red Blue Violet Orange Live Ne...

Страница 50: ...CKOUT 45 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 temp...

Страница 51: ...overrun 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 mi...

Страница 52: ...Greenstar Ri ErP 6 720 813 283 2015 07 52 NOTES...

Страница 53: ...Greenstar Ri ErP 6 720 813 283 2015 07 53 NOTES...

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Страница 56: ...orcester Bosch Group is a brand name of Bosch Thermotechnology Ltd worcester bosch co uk 6 720 813 283 2015 07 WORCESTER BOSCH GROUP TECHNICAL SUPPORT 0330 123 3366 APPOINTMENTS 0330 123 9339 SPARES 0...

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