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SHORT PARTS LIST

Fan

WORCESTER Part No.

8 717 204 453 0

GC No.

H26 536

Burner

WORCESTER Part No.

8 718 120 609 0

GC No.

H26 538

Gas valve

WORCESTER Part No.

8 716 107 052 0

GC No.

H26 540

LPG

WORCESTER Part No.

8 716 107 053 0

LPG

GC No.

H26 539

Control board

WORCESTER Part No.

8 716 109 540 0

GC No.

H31 408

Air pressure switch

WORCESTER Part No.

8 716 106 633 0

GC No.

H26 543

Temperature limit sensor

WORCESTER Part No.

8 722 963 858 0

GC No.

H08 291

Electrodes

WORCESTER Part No.

8 718 107 087 0

GC No.

H26 544

Gasket - burner/electrodes

WORCESTER Part No.

8 716 106 506 0

GC No.

H26 545

Seal - inner case/mantel

WORCESTER Part No.

8 716 106 635 0

GC No.

H26 546

Flow reg. Type E 9litre orange

WORCESTER Part No.

8 716 141 143 0

GC No.

324 823

Flow reg. Type E 11litre brown

WORCESTER Part No.

8 716 107 044 0

GC No.

H22 460

Pressure relief valve DHW

WORCESTER Part No.

8 717 401 029 0

GC No.

H02 526

Pump assembly 3 speed

WORCESTER Part No.

8 716 106 355 0

GC No.

H02 527

Pressure gauge

WORCESTER Part No.

8 717 208 107 0

GC No.

H02 528

Flow sensor

WORCESTER Part No.

8 716 107 223 0

GC No.

H02 529

DHW temperature sensor

WORCESTER Part No.

8 714 500 081 0

GC No.

H02 538

Heat exchanger 12 plate

WORCESTER Part No.

8 716 106 686 0

GC No.

H02 538

Heat exchanger 16 plate

WORCESTER Part No.

8 716 106 685 0

GC No.

H02 531

By-pass valve

WORCESTER Part No.

8 716 106 434 0

GC No.

H02 532

Diverter valve assembly

WORCESTER Part No.

8 716 106 845 0

GC No.

H02 533

Diverter valve motor

WORCESTER Part No.

8 716 106 847 0

GC No.

H02 534

Control sensor - primary

WORCESTER Part No.

8 716 106 688 0

GC No.

H26 542

High limit stat

WORCESTER Part No.

8 707 206 196 0

GC No.

H26 584

Expansion vessel

WORCESTER Part No.

8 716 105 545 0

GC No.

H05 206

25 Pressure relief valve

WORCESTER Part No.

8 716 106 431 0

GC No.

H09 750

SHORT PARTS LIST

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si

8 716 107 337b (11/05)

SER

RES

Содержание GreenStart 25Si

Страница 1: ...TURAL GAS WORCESTER GREENSTAR 25Si GC NUMBER 47 311 84 WORCESTER GREENSTAR 30Si GC NUMBER 47 311 85 LIQUID PETROLEUM GAS WORCESTER GREENSTAR 25Si GC NUMBER 47 311 88 WORCESTER GREENSTAR 30Si GC NUMBER...

Страница 2: ...LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER PLEASE LEAVE THESE INSTRUCTIONS WITH THE COMPLETED BENCHMARK CHECKLIST OR A CERTIFICATE CONFIRMING COMPLIANCE WITH IS 813 EIRE ONLY AND THE U...

Страница 3: ...23 25 CONDENSATE CONNECTION 26 ELECTRICS 27 POSITION OF WIRED COMPONENTS 28 COMMISSIONING PRE COMMISSIONING CHECKS 29 FILLING THE SYSTEM 30 STARTING THE APPLIANCE 31 WATER TREATMENT 32 COMMISSIONING 3...

Страница 4: ...uch as British Gas or CORGI registered personnel using approved spares to help maintain the economy safety and reliability of the appliance IMPORTANT The service engineer must complete the Service Rec...

Страница 5: ...n electrodes Built in frost thermostat Built in fault finding diagnostics Modulating automatic gas valve Combustion air fan with speed regulator CH temperature sensor control Pump anti seizure protect...

Страница 6: ...Max permissible operating pressure bar 2 5 2 5 2 5 2 5 Available pump head at 21 C system temperature rise m 2 0 2 0 2 0 2 0 Flue Flue Gas Temp 80 60 C rated min load C 78 65 78 66 79 66 79 67 Flue Ga...

Страница 7: ...MIRROR 17 SECURING NUT AIR GAS MANIFOLD CLAMP 18 SENSOR BOILER FLOW 19 FLUE AIR PRESSURE SWITCH CONNECTION 20 FLUE OVERHEAT THERMOSTAT 21 ACCESS POINT FOR CLEANING HEAT EXCHANGER SUMP 22 REMOVABLE TO...

Страница 8: ...6 PRESSURE RELIEF VALVE 47 COMPACT HYDRAULIC MOUNTING SCREW 2 TO BOILER 48 CH TEMPERATURE CONTROL 49 MAINS ON OFF INDICATOR DIAGNOSTIC LIGHT BLUE 50 DHW TEMPERATURE CONTROL 51 SERVICE MODE BUTTON 52 B...

Страница 9: ...will be invalidated Circulate the flushing agent before the boiler is fired up 4 Run the boiler system at normal operating temperature as directed by the manufacturer of the flushing agent 5 Drain an...

Страница 10: ...Si 2 0 bar 30Si for maximum performance Maximum mains fed water pressure 10 bar If necessary fit a pressure reducing valve Where the mains water supply has a non return back flow prevention valve fitt...

Страница 11: ...S If a shower head can be immersed in water or comes closer than 25mm from the top edge of a bath or shower tray spill over level then an anti siphon device must be fitted to the shower hose Bidets wi...

Страница 12: ...ipe insulation in exposed positions and for external pipework 1 Internal sink washing machine drain 2 Internal waste drainage system 3 Soil vent stack 4 External drainage system 5 External condensate...

Страница 13: ...lp prevent freezing L Outside wall O M Drain pipe N External drain IMPORTANT The pressure relief valve is a safety device for the boiler and if activated may discharge boiling water steam through the...

Страница 14: ...ptions for the minimum space required to install and service the boiler inside an unventilated compartment 25 30 kW Vent To room or Direct to position internal space outside High Minimum free Minimum...

Страница 15: ...ulations BOILER LOCATION CLEARANCES BOILER LOCATION CLEARANCES INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si 30Si 8 716 107 337b 11 05 14 PRE INSTALLATION IMPORTANT any switch or ap...

Страница 16: ...llow plastic guide A This is fitted to the boiler frame CH Return 22mm CH Flow 22mm PLUMBING MANIFOLD INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si 30Si 8 716 107 337b 11 05 15 PRE...

Страница 17: ...ow etc 300 mm C1 Horizontally to an opening air brick opening window etc 300 mm D Below gutters soil pipes or drain pipes 75mm E Below eaves 200mm F2 Below balconies or car port roof lowest point 200m...

Страница 18: ...00mm Then reduce the total straight flue length for each extra flue bend excluding the flue elbow by 2000mm for 90 1000mm for 45 Flue Extension lengths Horizontal Vertical 60 100mm 960mm Horizontal Ve...

Страница 19: ...lifting of any heavy object should be strictly observed Additional requirements for roof space installation The boiler should be first unpacked before ascending ladder to loft space Two sets of steps...

Страница 20: ...quired However if using the weather sealing collar by pushing it through from inside the property then a 150mm diameter hole is required to accommodate this The terminal section of the 100mm flue has...

Страница 21: ...allow the boiler outer casing E to be removed The inner sleeve B opens as shown Remove the protective wrapping D and undo the four screws two at the bottom of the boiler H and two at the top H see di...

Страница 22: ...ll frame 1A Fit sealing washers to service valves before hanging boiler NOTE The bonded washer supplied is for the Gas connection only IMPORTANT Before hanging the boiler onto the wall mounting frame...

Страница 23: ...the screw F from the retaining bracket 6 Make connections to the heating system Connect the gas supply to the boiler gas cock 22mm compression Connect mains water in and DHW out 7 Connect the expansi...

Страница 24: ...cone lubricant to sealing surfaces The instructions for the 60 100mm diameter flue are shown below MEASURING THE FLUE Standard Flue Measure from the outside wall to the centre line of the flue turret...

Страница 25: ...s to the remainder Cut both tubes square taking care not to distort the tubes Remove any burrs EXAMPLE Length L 2380mm Subtract Standard Flue Turret 686mm Subtract Full Extension 960mm Cut Length 734m...

Страница 26: ...r not in flue kit FITTING THE ELBOW Flue elbow should push directly down and not be twisted into correct position Remove the 3 inner flue tube retaining screws The inner tube will be held in place in...

Страница 27: ...insulation to help prevent freezing Ensure that the condensate drain is 22mm diameter plastic pipe It must fall at least 50mm per metre towards the outlet An adaptor in 22mm pipe is contained in the f...

Страница 28: ...wise to secure cable After wiring to connectors is complete snap cable clamp C into control box 6 Mains power 230v connection ST10 Separate wires from cable end and strip to 6mm Connect LIVE wire to t...

Страница 29: ...POSITION OF WIRED COMPONENTS COMMISSIONING POSITION OF WIRED COMPONENTS INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si 30Si 8 716 107 337b 11 05 28 INSTALLATION...

Страница 30: ...pipework connections and rectify any leaks 3 Check that the condensate pipe has been connected to the syphon 4 Check pressure relief drain pipe J is correctly fitted and securely tightened IMPORTANT I...

Страница 31: ...o the central heating return adjust this to the same pressure as the appliance internal expansion vessel refer to separate instruc tions with the extra expansion vessel 6 Briefly open the pressure rel...

Страница 32: ...Press power button A and the power on indicator B illuminates BLUE 3 Turn the boiler thermostat control C to maximum The burner on indicator D illuminates GREEN when the burner has lit 4 If the boiler...

Страница 33: ...ontainer to collect any water N Ensure tube outlet 0 is directed away from the fan or any other electrical component to prevent damage Also place a suitable cover over the fan to prevent any spillage...

Страница 34: ...screw in the gas inlet pressure test point DOMESTIC HOT WATER Controlling the hot water temperature The hot water temperature can be set to between approximately 40 C and 60 C using the temperature c...

Страница 35: ...t is fully engaged HANDOVER Complete the Benchmark checklist NOTE The Benchmark Checklist can be found at the rear of these instructions Open the facia cover by gently pressing the centre top of the c...

Страница 36: ...appliance is clear 3 Check all the joints and connections in the system and remake any that show signs of leakage Refill and re pressurise if applicable as described in Commissioning Operate the appli...

Страница 37: ...sition Primary Heat Exchanger There is a special accessory kit available specifically designed for cleaning the heat exchanger If required order 7 716 192 312 3 Check fan pressure at the test point ne...

Страница 38: ...l Heating temperature to maximum The service button will illuminate continually and the blue power indicator will flash quickly The boiler will stay in this mode for 15 minutes unless the service butt...

Страница 39: ...Remove siphon Siphon The siphon body is transparent so contents can be examined for any blockage If necessary flush with clean water 1 A B 2 C D 3 3 3 2 3 1 F E INSPECTION AND SERVICE INSTALLATION SE...

Страница 40: ...top of the heat exchanger until it stops at the lug Lift up assembly and remove from boiler 8 Disconnect spark electrode and flame sensor connections J Remove clamping plate K Remove spark flame elec...

Страница 41: ...ect water from syphon connection at the base of the boiler flush heat exchanger with water Re assemble ensuring that the lower baffle N and the top baffle M are refitted correctly When re fitting the...

Страница 42: ...nderside of the tray 2 Primary sensor Remove electrical connection B by pulling upwards Squeeze retaining clip on plastic moulding C and pull sensor D upwards until clear of pocket in heat exchanger C...

Страница 43: ...for gas soundness NOTE The valve will require setting follow procedure Setting the gas air ratio in the gas conversion section 7 Gas adjuster Isolate gas supply at boiler gas cock Repeat step 6 1 abov...

Страница 44: ...the underside of the electrical cover 11 Transformer PCB Disconnect all electrical connections from the control Remove 5 screws D retaining the rear panel of the control and remove panel 9 10 11 A B...

Страница 45: ...screw 12 2 Using a suitable tool D press the button E upwards and slide the control support bracket F to the left 12 3 Support the control and unclip control support cable G from the boiler frame Remo...

Страница 46: ...taining pressure switch to bracket Refit new pressure switch to bracket The following components require the air gas manifold and fan assembly to be removed Pressure switch Fan Electrode assembly Burn...

Страница 47: ...that the seal is replaced with a new one 18 Heat Exchanger Isolate flow and return valves then drain the boiler Remove siphon 18 1 Remove clip from plastic elbow on the flow pipe and pull flow pipe aw...

Страница 48: ...chamber if necessary To refit follow the above in reverse Ensure any seals that have been disturbed are renewed 21 Auto air vent Ensure the appliance has been fully drained 21 1 Use a screwdriver or s...

Страница 49: ...ove the brass pipe to one side 24 1 Withdraw the flow sensor and filter from the housing Using the cartridge tag withdraw the flow restrictor housing If the regulator housing has become stuck a pair o...

Страница 50: ...ial but makes the removal of the block easier 27 1 Undo the two screws securing the hydraulic block to the chassis located top left top right of the housing 27 2 Lift the left hand side of the block s...

Страница 51: ...lief valve housing 29 2 Withdraw the pressure relief valve A To refit follow the above in reverse Ensure any seals that have been disturbed are renewed 30 DHW Heat exchanger Remove the Hydraulic block...

Страница 52: ...Isolate mains power from the boiler Place the controls in service position Isolate the boiler from the heating system and cylinder return if internal diverter valve is fitted using service valves Dra...

Страница 53: ...If correct press and hold down the service button for 2 seconds the button will cease to be illuminated and the blue power indicator will be permanently illuminated Remove manometer and re seal inlet...

Страница 54: ...Pump assembly 3 speed WORCESTER Part No 8 716 106 355 0 GC No H02 527 14 Pressure gauge WORCESTER Part No 8 717 208 107 0 GC No H02 528 15 Flow sensor WORCESTER Part No 8 716 107 223 0 GC No H02 529 1...

Страница 55: ...ion 2 Gas valve Isolate gas supply at boiler gas cock 2 1 Remove wire clip from gas valve outlet then pull gas adjustment assembly free from plastic connector and pull forward clear of case 2 2 Undo b...

Страница 56: ...itted Replace control board Service mode selected to min press service button to return to normal Service mode selected to max press service button to return to normal NOTE This fault finding informat...

Страница 57: ...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 ture is 5 C above set value Gas valve OFF Fan overrun 30 seconds 3 minute w...

Страница 58: ...ition 4 seconds NO YES ECO button not illuminated ie preheat requested AND 20 minutes since last pre heat demand AND temperature at least 10 below set point PREHEAT DEMAND DOMESTIC HOT WATER DEMAND pr...

Страница 59: ...mperature below 8 C Run autofroststat function Pump antiseize Pump run 5 seconds every 24hrs PROTECTION FUNCTION INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si 30Si 8 716 107 337b 11...

Страница 60: ...HAT TYPE OF SCALE REDUCER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE RECORD GAS RATE ft3 hr MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE mbar COLD WATER INLET TEMPERATURE C HOT WATER O...

Страница 61: ...ARD SERIAL No COMMENTS SIGNATURE SERVICE 3 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 4 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No CO...

Страница 62: ...Pack Item Qty Greenstar 25Si 30Si Installation Servicing Instructions 1 Users Instructions 1 Consumer Guarantee Card 1 Sealing Pack 1 Compression Nut 22mm 3 Compression Ring 22mm 3 Compression Nut 15m...

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