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Installation manual for Greenstar Ri

1. Rea 9 Tt A 1 500 LO 300 200 ex 1 200 o LL 9 D Fig 20 Flue terminal positions NOTICE A gt All measurements are the minimum clearances required flue bracket 100mm part number 7 716 191 177 flue brackets 100mm x 6 part number 7 716 191 178 flue bracket 125mm part number 7 716 191 179 gt Terminals must be positioned so to avoid combustion products entering the building gt Support the flue at approximately one metre intervals and at a change of direction use suitable brackets and fittings Key to illustration 1 300mm adjacent to a boundary line 2 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 with suitable silicon sealant 3 1 500mm between a vertical flue terminal and a window or dormer window 4 1 200mm between terminals facing each other 5 Vertical flue clearance 300mm adjacent to a boundary line unless it will cause a nuisance BS 5440 Part 1 recommends that care is taken when siting terminal in relation to boundary lines 6 600mm distance to a boundary line unless it will cause a nuisance BS 5440 Part 1 recommends that care is taken when siting terminal in relation to boundary lines 7 600mm minimum clearance from a s
2. w I 6720646608 123 1Wt Fig 15 Pressure relief pipe work 2 Outside wall 1 3 Drain pipe 4 External drain Table 6 Key to fig 15 3 6 BOILER LOCATION AND CLEARANCES 3 6 1 INSTALLATION This boiler is only suitable for installing internally within a property at a suitable location onto a fixed rigid surface at least the same size as the boiler and capable of supporting the boiler weight NOTICE No surface protection is required against heat transfer from the boiler 3 6 2 SERVICING CLEARANCES VENTILATED COMPARTMENT Figure 16 shows the minimum space required to install and service the boiler in a ventilated compartment Ifaboiler is installed in a compartment with clearances less than shown in the tables 9 10 or 11 ventilation is required Refer to table 7 for ventilation requirements To room or internal Vent position space High level Min free area 122 cm2 Low level Min free area 122 cm Direct to outside Minimum free area 61 cm Minimum free area 61 cm2 Table 7 Compartment ventilation 12 6 720 804541 2012 12 WORCESTER Bosch Group PRE INSTALLATION S Using 100 mm flue kit 1080 mm Using 125 mm flue kit 1100 mm 6720643895 121 2Wo 200 mm If Side Clearances are Reduced millimetres Fig 16 Ventilated compartment Minimum cleara
3. the boiler WARNING Lg gt Caps fitted to pipes must be removed before hanging GAS AND WATER CONNECTIONS gt Remove wall mounting template and secure the wall mounting frame to the wall with the appropriate fittings for the boiler weight and wall type gt If there is greater than 600mm clearance below the appliance it is possible to fit the flow and return pipes supplied with the boiler installed on the wall gt If clearance is less than 600mm below the appliance it may be necessary to fit the flow and return pipes before hanging the appliance for the gas supply il The copper pipes supplied with the boiler are not to used These copper pipes are for water only 1 Gas inlet 22mm 2 Condensate 3 Flow 22mm 4 Return 22mm the frame Do not lift the boiler by the air gas manifold or control box NOTICE Lg gt Lift the boiler using the handling holes at either side of System pipes may be run vertically up behind the boiler or below it NOTICE gt If pipes require reducing in length this is best done before they are fitted to the boiler 6720644744 13 1Wo Pipes in alternative position Fig 26 Plumbing manifold gt Lift the boiler onto the wall plate gt Level vertically using the feet 1 at the bottom rear of the boiler casing gt Fit retaining screws through the holes 2 in the boiler frame to secure
4. Condensate trap of 75mm already incorporated into the boiler 3 4 1 INTERNAL CONNECTIONS In order to minimise risk of freezing during prolonged cold spells the following methods of installing condensate drainage pipe should be adopted in order of priority Wherever possible the condensate drainage pipe should be routed and terminated so that the condensate drains away from the boiler under 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 Deeg 22mm m Ia 6720644744 06 2Wo Fig 8 Disposal to soil vent stack Alternatively if the first option is not possible an internal kitchen or bathroom waste pipe washing machine waste pipe etc can be used Ensure that the condensate drain pipe is connected down stream of the waste trap c 22mm EN LS 6 6720644744 07 2Wo Fig 9 Disposal to a waste pipe CONDENSATE PUMP Where gravity discharge to an internal termination is not physically possible or where very long internal runs 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 pump outlet pipe should discharge to a suitable internal foul water discharge point such as an internal s
5. WALL z gt j 18mm 5 gt S 125mm Fig 29 Pipe work dimensions 6720644744 22 1Wo Fig 28 Condensate connections 22 6 720 804541 2012 12 WORCESTER Bosch Group INSTALLATION 4 5 FLUE INSTALLATION HORIZONTAL FLUE 60 100mm diameter For vertical flues and 80 125mm horizontal flues please refer to separate instructions supplied with the flue kit To ease assembly of flue components apply silicone lubricant to sealing surfaces Basic instructions for the 60 100mm diameter flue are shown below WALL ILZ 189 mm Edge j of lt 200 mm e case 6720643895 29 1Wo Fig 30 Flue turret centre 4 5 1 MEASURING THE FLUE STANDARD FLUE gt Measure from the outside of the wall to the centre line of the flue turret to determine length L gt Subtract 50mm from the length L to give the correct dimension to the flue elbow connection gt If the length L falls within the telescopic range of 350 to 570mm or 570to 790mm using the longer telescopic flue then no cutting will be required gt If the required length is less than 350mm the standard telescopic flue can be modified refer to fig 32 gt If the required length is greater than 570mm then the longer telescopic flue giving a range of 570 790mm can be used gt
6. 6720643895 33 1Wo Fig 35 Telescopic flue installation For more information refer to the 60 100 Horizontal Flue kit Instruction Manual ADDITIONAL NOTES AND REMINDERS Ensure that all cut lengths are square and free from burrs The flue is sealed when assembled correctly and the components are pushed fully home The flue is set at an angle of 3 or 52mm per metre length Support the flue at approximately one metre intervals and at a change of direction use suitable brackets and fittings flue bracket 100mm part number 7 716 191 177 flue brackets 100mm x 6 part number 7 716 191 178 flue bracket 125mm part number 7 716 191 179 Fig 36 Slope for condensate disposal 4 5 4 FLUE TERMINAL PLUME RE DIRECTION The flue discharge can be re directed allowing some plume redirection control alternatively a complete plume management system can be fitted to the flue terminal RE DIRECTING THE FLUE DISCHARGE 1 Using a suitable tool unclip 1 amp 2 the terminal end and rotate through 180 NOTICE DO NOT rotate the complete terminal N assembly 1 Refit to the terminal ensuring that the clips 1 amp 2 are engaged and secure 2 Loosen screws 3 and rotate the entire outlet assembly to redirect the plume Tighten screws 3 to secure in the required position The flue terminal outlet has built in stops to limit rotation D for horizontal fluing to allow condensate to run back into the boiler for safe
7. Greenstar Ri Installation Commissioning and Servicing 1 Instructions Users Instructions Consumer Guarantee Card Sealing Pack Compression Nut 22mm Compression Ring 22mm Elbow assembly pack Elbow Assembly Fibre Washer Table 3 Hardware lit pack checklist le kal ow wlej tal ta 6 720 804541 2012 12 WORCESTER Bosch Group APPLIANCE INFORMATION 2 APPLIANCE INFORMATION 2 1 APPLIANCE GE SE KM 6 H Cas Aore Ls 590mm Penn 390mm 600mm to top of case front 6720644744 01 1Wo Fig 1 Appliance Do not use the pre formed copper pipes supplied with il the boiler for the gas supply These copper pipes are for water only STANDARD PACKAGE 1 Wall hung gas fired condensing regular boiler for central heating and domestic hot water Tail pipes water only Wall plate Hardware literature pack see checklist Bottom panel and wall mounting template OO AJ wm 6 720 804 541 2012 12 5 APPLIANCE INFORMATION S WORCESTER Bosch Group 2 2 TECHNICAL DATA DESCRIPTION NATURAL GAS LPG UNIT DR 15Ri 18Ri 24Ri 12Ri 15Ri 18Ri 24Ri Gas flow rate Max 10 minutes from lighting Natural Gas G20 m h 1 3 1 63 1 96 2 6 Propane Gas LPG kg h 0 96 1 20 144 1 91 Central He
8. PLASTIC PIPE WORK Any plastic pipe work must have a polymeric barrier with 600mm minimum length of copper pipe connected to the boiler Plastic pipe work used for underfloor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approximately 50 C PRIMARY SYSTEMS CONNECTIONS VALVES All system connections taps and mixing valves must be capable of sustaining a pressure up to 3 bar Radiator valves should conform to BS2767 10 All other valves should conform to BS1010 Thermostatic radiator valves TRV must be used on all radiators within the sleeping accommodation The radiator where the room thermostat is sited must be fitted with lock shield valves and left open e Adrain cock is required at the lowest point in the system e An air vent is required at all high points in the system 6 720 804541 2012 12 WORCESTER Bosch Group PRE INSTALLATION SEALED PRIMARY SYSTEM NOTICE Artificially softened water must not be used to bg fill the central heating system The CH sealed system must be filled using a WRAS approved filling loop or comply with figure 2 for system fill An expansion vessel of a size suitable for the system must be fitted as close as possible to the appliance in the central heating return Also fit a pressure gauge a 3 bar pressure relief valve and stop cock fixed cylinder type or sealed system approved
9. 1 Gas 55mm 22mm Use the fittings supplied in the Hardware literature pack 7 Condensate OA 77 mm Do not use the pre formed copper pipes supplied with 3 Cylinder amp CH Flow 285 mm 22 mm the boiler for the gas supply 4 Cylinder amp CH Return 350 mm 22 mm These copper pipes are for water only Table 12 Keytofigures 18 amp 19 Use the 22mm copper pipes 1 amp 2 provided with the appliance as shown in the diagram opposite If the flow and return pipes are to be run behind the appliance it maybe an advantage to connect the pipes before hanging on the wall especially if space is limited Further guidance on pipe routing can be found printed il on the boiler template supplied with the boiler 1 P sel I I gt L Fig 19 Pipe work dimensions 6720644744 17 1Wo 6720644744 13 1Wo Pipes in alternative position Fig 18 Plumbing manifold 14 6 720 804541 2012 12 WORCESTER Bosch Group PRE INSTALLATION 3 8 FLUE OPTIONS CAUTION Non accessible flue systems gt Where a flue system is not going to be accessible Lg provision must be made for service and inspection gt Voids containing concealed flues must have at least one inspection hatch no less than 300mm square gt Flue joints within the void must not be more than 1 5 metres from the edge of the inspection hatch gt Inspection hatches should be located at cha
10. NA III ive al Pump Li Pump Neutr MAINS SUPPLY EXTERNAL 230V WIRING CENTER one JUNCTION BOX 6720644744 27 2Wo 6 720 804 541 2012 12 45 WORCESTER Bosch Group FAULT FINDING AND DIAGNOSIS BOILER FUNCTION 7 2 OML 09F727P90229 SPU099S OT PEM eg pue INOMIOT y eds doe SpU0oI9S O uns UE Samu ZU ses pue g uns dung Y3NYN4 vous 440 weds onen SED SPUO99S y NO NO dung qouy 014U09 s nressdwa GNV NO pany J 19wwe gold GNVW3qG ponad Ie p aas en pajunow ee NO 431108 Rena uonesigejs lt JONANOAS ya1loa aNv 1H91 40 ON EE puovas ep NOLLINSI OTLS ama ae ye Dan ul 10 ued NO Jewweisoid surew Jo pue jejsouuay wooy AONANOAS NOILINDI anjen S anoge I 5 SI ain und Jang spuovas DE unJaao ue e1adtua Jayem J UMOp ee ee nys aunyesadwd Jon duuind aynuiw NO AlddNS 43MOd SNIVIN Fig 93 Boiler function 6 720 804541 2012 12 46 CAWORCESTER Bosch Group FAULT FINDING AND DIAGNOSIS 7 3 PROTECTION FUNCTION AUTOMATIC INTERNAL FROST FUNCTION Internal boiler temperature between 8 C amp 5 C Internal boiler Pump switches off Pump runs temperature after a 3 minute rises above 9 C overrun period Boiler automatic frost function monitors internal boiler primary temperature Internal boiler Internal boiler Central heating Central heati
11. Record the date when the inhibitor was added to the system on the warrantee card NOTICE N gt The concentration of inhibitor in the system should be checked every 12 months or sooner if system content is lost gt Normally the addition of sealing agents to the system water is not permitted as this can cause problems with deposits left in the heat exchanger gt In cases where all attempts to find a micro leak have failed Worcester Bosch Group supports the use of Fernox F4 leak sealer WATER TREATMENT PRODUCTS Suitable water treatment products can be obtain from the following manufacturers FERNOX SENTINEL 0870 601 5000 or www fernox com 0800 389 4670 or www sentinel solutions net 5 4 STARTING THE APPLIANCE CAUTION RUNNING THE APPLIANCE N gt Never run the appliance when the appliance system is empty or partially filled 6720644744 30 1Wo Fig 45 Boiler controls 6 720 804 541 2012 12 27 COMMISSIONING WORCESTER Bosch Group Switching the appliance ON OFF gt Turnon mains power the power ON indicator 2 illuminates BLUE gt Turn on any external controls gt Set the thermostatic radiator controls to maximum temperature gt Set the clock programmer to continuously ON and the room thermostat to maximum temperature 1 Turn Power ON OFF knob 1 from 0 OFF position to O
12. SERVICE AND SPARES 6720643895 66 1Wo Fig 60 Gas valve adjustment CO CO settings for Greenstar Ri CO CO should be measured after 10 minutes Gas type CO max CO min Natural gas 12 Ri 9 65 0 5 8 65 0 5 Natural gas 15 18 24 Ri 9 8 0 5 9 2 0 5 L P G 11 0 0 5 10 5 0 5 NOTE When checking an existing appliance the tolerance is 0 5 If checking after cleaning or component replacement or for adjustment when the reading obtained is outside the tolerances given above then the tolerance is 0 2 CO less than 200 ppm 0 002 ratio Table 18 CO CO settings 6 7 CLEANING THE HEAT EXCHANGER NOTICE COMBUSTION TESTING gt Combustion testing must be carried out by a competent person Testing must not be attempted unless the person carrying out the combustion check is equipped with a Combustion Analyser conforming to BS 7927 and is competent in its use NOTICE CO CO CHECKS gt If the joint between the Air Gas manifold and heat exchanger is disturbed the sealing gasket must be replaced gt After completing the service of the appliance the CO CO must be checked and set to the limits shown in Setting the air gas ratio on page 32 There is a special accessory kit available specifically designed for cleaning the heat exchanger If required order 7 716 192 312 cei be gt I
13. Disposal into a rainwater down pipe 6720644744 09 2Wo Condensate drainage pipe can be run above or below il ground Where the pipe terminates over an open drain or gully the pipe should terminate below the grating level but above water level in order to minimise wind 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 opposed to a straight cut ee RN We AN Fig 12 External disposal CONDENSATE SOAK AWAY The condensate drainage pipe may be run above or below the ground to the soak away The examples shown on this page run above ground The soak away must use a 100mm plastic tube with two rows of three 12mm holes on 25mm centres and 50mm from the bottom of the tube The holes must face away from the house 6720644744 10 2Wo el 6 720 804 541 2012 12 11 PRE INSTALLATION WORCESTER Bosch Group The tube must be surrounded by at least 100mm of limestone chippings to a depth of 400mm Minimum hole size for the condensate soak away must be il 400mm deep by 300mm In situations where there are likely to be extremes of temperature or exposure the use of a proprietary trace heating system for external pipe work incorporating an external frost thermostat should be considered If such a
14. GAS Agas leak could potentially cause an explosion If you smell gas observe the following rules gt Prevent flames or sparks Donot smoke use a lighter or strike matches Do not operate any electrical switches or unplug any equipment Donot use the telephone or ring doorbells gt Turn off the gas at the meter gt Open windows and doors gt Warn your neighbours and leave the building gt Prevent anyone from entering the building gt Well away from the building call the National Gas Emergency Service on 0800 111 999 gt L P G boilers Call the supplier s number on the side of the gas tank BOILER OPERATION This boiler must only be operated by a responsible adult who has been instructed in understands and is aware of the boiler s operating conditions and effects 6 720 804 541 2012 12 KEY TO SYMBOLS AND SAFETY PRECAUTIONS WORCESTER Bosch Group Benchmark places J enchmar responsibilities on both COLLECTIE MARK manufacturers and THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING instal lers AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS The purpose is to ensure that customers are provided with the correct equipment for their needs that it is installed commissioned and serviced in accordance with the manufacturer s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations The Benchmark Checklist can be used to demonstra
15. If the required length is greater than 790mm then flue extensions will have to be used Refer to the 60 100 Horizontal Flue Instruction manual provided in the telescopic flue kit gt Refer to section 3 8 for flue options Adjusting the telescopic flue length 6720643895 30 1Wo Fig 31 Standard telescopic flue Extend tube 1 by withdrawing from tube 2 to achieve the flue length required between 350 570mm Secure with screw provided and seal joint with the aluminium tape supplied 4 5 2 REDUCING THE TELESCOPIC FLUE LENGTH Ensure that the TOP label is facing up before securing il the flue section to the turret The flue terminal MUST be fitted with the TOP label uppermost to allow the correct fit and use of the plume management system 6720643895 31 1Wo Fig 32 Reducing the standard terminal gt Remove the screws 3 to detach the terminal assembly from the turret gt Slide terminal section 2 from the terminal assembly and discard gt To use terminal 1 without cutting remove the location lug 4 on the inner flue tube 5 and remove any burrs To reduce the flue length further lt 265 mm p 1 bh 130 mm MIN 4 6 5 6720643895 32 2Wo gt Mark the length required for the terminal as shown min 130mm and cut square taking care not to damage the tubes gt Remove any burrs and chamfer the outer edge of the tubes to assist ease of connection and pr
16. disposal Do not attempt to force beyond the limit stops Fig 37 Plume redirection NOTICE Outlet position Lg gt The flue terminal outlet position must follow those stated in the relevant appliance instruction manual When redirecting the flue discharge the outlet terminal must be at least 1500mm from any opening in the direction of the discharge to prevent combustion products from entering the building 24 6 720 804541 2012 12 WORCESTER Bosch Group INSTALLATION ca Fig 38 Plume distance to opening Opening in building Flue discharge Plume deflector BY Ow NM m Minimum 1500mm from an opening in the building Table 15 Key to figure 38 4 6 ELECTRICAL CONNECTIONS The boiler is already wired with a mains supply cable Aspare strain relief block is supplied in case the pre wired cable is replaced 1 CAUTION Isolate the mains electrical supply before starting any work and observe all relevant safety precautions The mains supply to the boiler and system wiring centre must be common and through either a fused double pole isolator or a fused three pin plug and unswitched socket gt The isolator socket where practicable should be situated next to the boiler gt The isolator must have a contact separation of 3mm minimum in both poles gt Any system connected to the boiler must not have a sep
17. from the top of the heat exchanger 3 Remove burner 6720643895 61 1Wo Fig 64 Burner removal Checking and cleaning the electrode assembly NOTICE Cleaning Lg Do not use wire wool to clean the electrodes gt Inspect the condition of the electrodes and ceramics replace if necessary gt Use aplastic scouring pad to clean the electrodes BAFFLE REMOVAL 1 Refer to figure 65and remove top baffle 2 Remove lower baffle If the lower baffle is stuck it may be necessary to use the Baffle removal tool from the heat exchanger cleaning kit 7 716 192 312 as shown in figure 65 Fig 65 Baffle removal ACCESS COVER REMOVAL Refer to figure 66 1 Remove the two pozi drive screws 2 Remove the access cover 3 Remove the gasket Fig 66 Access cover removal 6720643895 64 1Wo 6720644744 40 1Wo 34 6 720 804541 2012 12 WORCESTER Bosch Group SERVICE AND SPARES CLEANING THE PRIMARY HEAT EXCHANGER gt Refer to figure 67 and access the heat exchanger flue ways by inserting the cleaning brush 7 716 192 312 through the top access hole in the casing removal of panel shown in figure 63 gt Clean heat exchanger flue ways using the cleaning brush removing any debris from the access point in the sump gt Clean around the sealing surface on the sump gt Replace the access cover gt Usinga suitable container to collec
18. g ele Q elle External Pump 90W max 6720644744 26 1Wo Wiring Centre Junction Box Fig 40 External wiring centre Refit electric control panel covers gt Refit panel and secure with screws 5 COMMISSIONING 5 1 PRE COMMISSIONING CHECKS ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK Lg gt ISOLATE THE MAINS SUPPLIES BEFORE STARTING Check that the gas service pipe and water pipes are connected to the correct position on the manifold 1 Gas inlet 22mm 2 Flow 22mm 3 Return 22mm Fig 41 gt Check the gas type specified on the identification plate 1 matches that of the gas supply 6720804530 11 1Wo Fig 42 Data plate location gt Turn on the main gas supply check the gas pipe work connections and rectify any leaks NOTICE Do not use solvents adhesive or lubricant A when pushing the pipe onto the rubber connector Check that the condensate pipe has been connected to the syphon gt Ensure that the condensate pipe has been inserted at least 25mm into the elbow 6720644744 29 1Wo Fig 43 Condensate connection If the boiler is not to be commissioned immediately then il after successfully completing all of the checks and any rectification work shut off the gas and water supply and electrically isolate the boiler 26 6 720 804541 2012 1
19. inlet pressure 28 5 5 2 Checkingthe gasrate 0 cece eee eee 29 5 6 Finishing commissioning 29 2 6 720 804541 2012 12 WORCESTER Bosch Group KEY TO SYMBOLS AND SAFETY PRECAUTIONS 1 KEY TO SYMBOLS AND SAFETY PRECAUTIONS 1 1 KEY TO SYMBOLS WARNINGS 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 risk if measures to prevent the risk are not taken The following keywords are defined and can be used in this document e NOTE indicates a situation that could result in damage to property or equipment CAUTION indicates a situation that could result in minor to medium injury e WARNING indicates a situation that could result in severe injury or death PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION These instructions are applicable to the Worcester appliance model s stated on the front cover of this manual only and must not be used with any other make or model of appliance These instructions apply in the UK and Ireland only and must be followed except for any statutory obligations This appliance must be installed by a GAS SAFE registered competent person Failure to install correctly could lead to prosecution If you are in any doubt contact the Worcester Technical helpline 0844 892 3366 Please l
20. of the boiler up to the loft hatch where the boiler is entered into the loft space tilted and slid on its back into the loft Once the appliance is removed from its packaging check the contents against the packing list Before installing the appliance ensure that the system has been cleaned as explained on page 8 6 720 804 541 2012 12 19 INSTALLATION WORCESTER Bosch Group 4 2 WALL MOUNTING TEMPLATE amp FLUE OPENING ARE NO PIPES ELECTRICAL CABLES DAMP PROOF WARNING BEFORE DRILLING ENSURE THAT THERE A COURSES OR OTHER HAZARDS SAFETY All relevant safety precautions must be undertaken Protective clothing footwear gloves and safety goggles must be worn as appropriate FIXING THE MOUNTING FRAME gt The boiler template shows the relative positions of the flue and the top and bottom fixing of the mounting frame 1 Fix the template to the wall in the desired position 2 Drill four holes for the wall mounting frame through the template Drill two holes for the bottom fixing screws The template has been sized to allow for minimum il clearances of 5mm sides 200mm base and 30mm above a 100mm diameter flue elbow REAR FLUE OUTLET gt The drawing opposite shows the boiler template with the flue centre lines of both the 100 mm and 125 mm flue systems 3 Mark centre line of flue to be used 3 the external diameter of the hole can also be marked if required gt Ifa 100 mm di
21. system is used the requirement to use 32mm pipe does not apply However all other guidance above and the instructions for the trace heating system should be closely followed basements and garages should be treated as external runs and consideration should be given to using a CondenseSure siphon NOTICE Unheated internal areas A gt Internal pipe runs in unheated areas such as lofts 500mm min 6720644744 11 2Wo Fig 13 Soak away SS 14 4 a 6720644744 12 2Wo Fig 14 Condensate pump to external disposal 3 5 PRESSURE RELIEF PIPE WORK NOTICE N gt The pressure relief valve is a safety device for the boiler and if activated may discharge boiling water or steam through the relief valve drain pipe Care should be taken when siting the outlet pipe so that it does not cause an obstruction or discharge above a window entrance or other public access where it could cause a hazard The pressure relief drain pipe 1 from the boiler should be at least 15mm diameter copper pipe and run downwards away from any electrical equipment or other hazard preferably to an external drain or soak away Pipe 1 should be finished with a partial bend near the outlet to face the external wall as shown to help prevent freezing
22. 000 9 Vertical balanced flue with 2 x 90 bends 2 400 11 000 10 Vertical balanced flue with 2 x 45 bends 4 400 13 000 Table 13 Flue options Partnumber Flue Description 7716191082 60 100 Telescopic horizontal flue assembly 7716191171 60 100 Longer telescopic horizontal flue assy 7719003702 80 125 Telescopic horizontal flue assembly 7719002430 60 100 Vertical flue assembly 7719002431 80 125 Vertical flue assembly Table 14 Flue option part numbers 6 720 804 541 2012 12 15 WORCESTER PRE INSTALLATION Bosch Group Im er ee 350 mm 570 mm i un Pit i Ss hoop ed 500mm amp 300 mm 5 5 6720643895 12 1Wo 16 6 720 804541 2012 12 WORCESTER Bosch Group PRE INSTALLATION 3 9 FLUE TERMINAL POSITIONS All measurements in millimetres
23. 1 1 ile 1 1 1 1 1 1 1 1 1 1 Noise output level Max central heating dBA 39 42 7 43 7 41 39 42 7 437 4 Packaged boiler weight kg 31 31 31 31 31 31 31 31 Total boiler weight kg 274 274 274 274 274 274 274 27 4 Lift weight kg 26 226 226 226 226 226 226 22 6 SEDBUK band A A A A A A A A SEDBUK 2005 90 1 901 901 9 2 914 91 4 914 92 0 Table 4 Technical data Ri 6 720 804541 2012 12 WORCESTER APPLIANCE INFORMATION Bosch Group 2 3 BOILER MAIN COMPONENTS 19 14 il Air Gas Manifold 15 Power and fault indicator blue 2 Sensor Boiler flow 16 Wiring connections cover 3 Flow pipe 17 Burner indicator green 4 Return pipe 18 Boiler ON OFF switch 5 Removable servicing panel 19 Condensate connection 6 Electrode assembly 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 pressure switch connection 11 Access panel Heat Exchanger Sump cleaning 25 Fan 12 Return connector with drain point 26 Manual vent point 13 Flow connector 27 Fan pressure test point 14 Boiler Temperature control and Reset knob 28 Air pressure switch 6 720 804 541 2012 12 PRE INSTALLATION WORCESTER Bosch Group 3 _ PRE INSTALLATION 3 1 CLEANING
24. 2 WORCESTER Bosch Group COMMISSIONING 5 2 FILLING THE SYSTEM Open vented systems gt Ensure all system and boiler drain points are closed gt Open all radiator valves gt Turn on the water supply to the system header tank and allow the system to fill Sealed systems gt Fill the system via a WRAS approved filling loop to 1 bar then turn the valve anti clockwise to close Opened vented and sealed systems gt Vent 1 any air from the boiler heat exchanger using a suitable container to collect any water Ensure tube outlet 2 is directed away from the fan or any other electrical component to prevent any water damage Also place a suitable cover over the fan to prevent any spillage of water on to electrical connections Ensure the cover is removed after venting 6720804530 12 1Wo Fig 44 Venting gt Vent all radiators and the primary side of the hot water cylinder tighten when completed and check the system and correct any leaks Sealed systems only gt If required increase system pressure back to 1 bar gt Isolate and remove filling loop connection to system 5 3 WATER TREATMENT NOTICE AN gt ARTIFICIALLY SOFTENED WATER MUST NOT BE USED TO FILL THE CENTRAL HEATING SYSTEM It is possible to have an ion exchange water softener fitted to the cold water system of the property However the boiler requires an untreated cold water co
25. 20644744 52 1Wo Fig 87 Sump connections Refer to figure 88 1 Lift the heat exchanger up to clear 3 2 Pull the heat exchanger forward from the case Wis Fig 85 Upper exhaust assembly Refer to figure 86 1 Release the clip 2 Move the lower exhaust connector up gt Remove the complete exhaust assembly H NS lt oa amp A ki Leem S St N 46 3 a l T r S Fig 88 Heat exchanger removal Fig 86 Release lower exhaust connection gt Reassemble and check combustion as stated in the air gas ratio Refer to figure 87 section 6 6 1 Unscrew the plastic nut 2 Remove the nut from the bottom of the boiler NOTICE CO CO CHECKS i 3 Rotate lever to release the return pipe gt If the joint between the Air Gas manifold and heat exchanger is disturbed sealing gasket must be replaced gt After completing the service of the appliance the CO CO must be checked and set to the limits shown in Setting the air gas ratio in section 6 6 40 6 720 804541 2012 12 WORCESTER Bosch Group SERVICE AND SPARES 6 8 12 SYPHON REMOVAL 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 sy
26. 7593 Treatment of water in domestic hot water central heating systems BS6798 Installation of gas fired boilers of rated input up to 70kW net Irish Standards The relevant Irish standards should be followed including ECTI National rules for electrical installations 1S 813 2002 for Domestic Gas Installations LPG Installations An appliance using L P G must not be installed in a room or internal space below ground level unless one side of the building is open to the ground Timber framed building Where the boiler is to be fitted to a timber framed building the guidelines laid down in BS5440 Part 1 and IGE Gas Installations in Timber Frame Buildings should be adhered to Potable water All seals joints and compounds including flux and solder and components used as part of the secondary domestic water system must be approved by WRAS CH Water Artificially softened water must not be used to fill the central heating system BOILER FEATURES AND CHECKLIST Pre wired and pre plumbed Galvanised steel inner frame Digital control system e Automatic ignition Direct burner ignition electrodes Built in frost protection Built in fault finding diagnostics Modulating automatic gas valve e Combustion air fan with speed regulator e CH temperature sensor amp control External pump anti seizure protection Flue gas temperature limiter e Condensate siphonic trap CHECK LIST HARDWARE LITERATURE PACK Qty
27. CKING THE GAS INLET PRESSURE The inlet pressure to the appliance must be checked using the following procedure MEASURING THE INLET PRESSURE 6720643895 53 1Wo Fig 46 Inlet pressure test point gt Close gas isolation valve gt Slacken the screw in the inlet pressure test point 1 and connect a manometer gt Open gas isolation valve gt Measure the pressure with the boiler running at maximum Refer to section 6 4 to set the boiler to maximum output The boiler will stay at maximum for 15 minutes Return the boiler to normal after the checks gt Check the gas supply working pressure at the gas valve conforms to values shown in Fig 47 or Fig 48 Ensure inlet pressure is satisfactory with all other gas appliances working GAS PRESSURE WITHIN THE SYSTEM Refer to the figures below for natural gas or L P G gas pressures The pressure at the boiler must not be less than the pressure read at the meter minus 1 mbar for Natural Gas 2 5 mbar for L P G The pressure drop from the meter to the gas valve must not be more than 2 5 mbar for Natural Gas AmbarforL P G If the pressure drops are greater than shown below then this would indicate a problem with the pipe work or connections within the system Natural Gas Beie lt 2 5mbar difference ho KO z 0 19 23 mba
28. H26 542 Seals kit High limit stat O0000000 Air pressure switch 99000000 87161072240 87072061960 87161066330 Os PA Im GC No H10 876 GC No H26 584 G C No H26543 ON A sl Ral SUD Flue sample plug Flue sample plug Flue sample plug AY vertical adapter air intake gas outlet oy 8710 506 1990 8716 111 2530 87161112520 gt Sump gasket O ring Syphon Terminal end 8716 113 8290 87161138510 87186818280 es Fuse F1 nr Fuse F2 Wall mounting template 8 718 689 0700 8716 156 0000 lt lt 2 87161560010 D GC No E27 716 Oza 7 FAULT FINDING AND DIAGNOSIS 7 1 FAULT FINDING SS i a EARTH CONTINUITY This fault finding information is for guidance only b SHORT CIRCUIT CHECK il Worcester cannot be held responsible for costs incurred c POLARITY and by persons not deemed to be competent d RESISTANCE TO EARTH The electronic control system for this boiler incorporates a blue central indicator This normally confirms the permanent mains supply but by flashing at different rates during a fault provides a guide to the cause as listed This fault finding system assumes that the appliance has been operating normally until the time of failure i e nota first installation error PRELIMINARY CHECKS Preliminary electrical system checks are the first electrical checks to be carried out during a fault finding procedure On completion of the Service Fault Finding task which has required the breaking and rema
29. INSTALLATION COMMISSIONING AND SERVICING INSTRUCTIONS WALL HUNG RSF GAS FIRED CONDENSING BOILER GREENSTAR Ri TING SYSTEMS amp INDIRECT MAINS FED DOMESTIC HOT WATER Natural Gas 12Ri 41 311 63 15Ri 41 311 75 18Ri 41 311 77 24Ri 41 311 65 Liquid Petroleum Gas 12Ri 41 311 64 15Ri 41 311 76 18Ri 41 311 78 24Ri 41 311 66 6720644744 00 1Wo DEN CHING THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS WORCESTER Bosch Group 6 720 804 541 2012 12 WORCESTER CONTENTS Bosch Group CONTENTS 5 6 1 Replace the outer case cece cece eee 29 1 KEY TO SYMBOLS AND SAFETY PRECAUTIONS 3 5 6 2 Install the bottom pang 29 1 1 Keytosymbols 0 0 ss eeeee cece eee ees 3 5 63 Handover eg Sdt ed A 29 1 2 Safety precautions 3 SERVICE AND SPARES NN 29 2 APPLIANCE INFORMATION SREB ESS Sia ARRATERA RA eae 5 6 1 Inspectionand service 29 2 1 Appliance se peda Peed wes dows kde reu he Hous Sates 5 6 2 Checking gas inlet presse 30 2 2 Technieald ta s see 6 63 Checking flue integrity cceeeeeeeees 30 2 3 Boilermain components en 7 GA Fanpressuretest eh 0EEENNEEE EE REENE d 31 6 5 Fluegasanalysis 00 rakinn ekpekis 32 3 PREINSTAULATON 8 GO ee eM all oe ale seen Reine 6 6 1 Settingthe CO CO2 nennen 32 3 1 Cleaning pr
30. N position after two seconds the Power ON indicator 2 illuminates Power ON OFF knob Power ON and fault indicator Blue Central heating temperature control BY oO mM re Burner indicator Green Table 16 Control panel legend 2 Turn the boiler CH temperature control 3 to maximum The burner on indicator 4 illuminates GREEN when the burner has lit gt If the boiler fails to light and the boiler goes to flame lock out the BLUE power indicator 2 will flash NOTICE RESET bg gt Do not press the blue power indicator to reset the boiler 3 To reset the lockout turn the boiler thermostat control to minimum then passed minimum where the control knob will click at reset position wait 5 seconds then turn to maximum The boiler will be reset 5 5 COMMISSIONING for operation on the gas type defined on the data plate No measurement of the combustion values is necessary provided there is ameter installed allowing the gas rate to be checked DO NOT ADJUST THE AIR GAS RATIO VALVE NOTICE The combustion settings on this gas fired boiler A have been checked adjusted and preset at the factory Having checked gt That the boiler has been installed in accordance with the installation instructions gt The integrity of the flue system and flue seals as described in section 6 3 of this manual gt The integrity of the boiler combustion circuit and relevant seals 5 5 1 CHE
31. O levels as Lg described in section 6 6 Setting the air gas ratio 6 8 8 AIRPRESSURE SWITCH switch NOTICE Pressure switch A gt Ensure that the tube is reconnected to the pressure 1 Remove the electrical connections 2 Slacken the top retaining screw and remove the bottom screw 3 Disconnect the tube 4 Remove the Air pressure switch assembly 6 8 9 FAN gt Remove the air gas manifold from the boiler as described in the previous section 1 Remove two screws retaining the fan to the air gas manifold 2 Remove the air gas manifold 3 Remove 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 38 6 720 804541 2012 12 WORCESTER Bosch Group SERVICE AND SPARES 6720643895 81 1Wo Fig 81 Dismantling the air gas manifold assembly FLAP VALVE ASSEMBLY 1 Twist the mounting flange clockwise to release 2 Pull mounting flange off the flap valve assembly 3 Pull rubber flap off flap valve assembly gt To replace the flap valve Press the two lugs on the back of the flap into the two slots in the flap valve assembly 6720643895 117 1Wo Fig 82 Flap valve assembly 6 8 10 ELECTRODE ASSEMBLY AND BURNER gt Refer to figure 83 and disconnect spark electrodes and flame sensor connection gt Remove clamping plate 1 Remove spark f
32. ON ANALYSER CONFORMING TO BS 7927 AND IS COMPETENT IN ITS USE Ensure thatthe gas inlet pressure has been checked and is satisfactory refer to section 5 5 1 gt Connect the flue gas analyser to the flue gas sampling point as shown in the figure below gt Run the boiler at maximum output for at least 10 minutes 6 6 1 SETTING THECO CO gt Refer to section 6 2 and ensure that the gas inlet pressure is correct before continuing gt To adjust the CO CO it will be necessary to first operate the boiler at maximum output gt Refer to section 6 4 for setting the boiler to maximum and minimum output gt Refer to table 18 and check the CO CO at maximum If required set the maximum CO CO via adjuster 1 on the gas valve using a 2 5mm Allen key Check CO is less than 200ppm gt Set the control to minimum gt The boiler will go to minimum power gt Measure the CO CO and check against table 18 If required set the minimum CO CO via adjuster 2 on the gas valve until the correct measurement is set Remove dust cap with flat bladed screw driver Using a 4mm Allen key adjust CO3 Replace the dust cap Check that the CO is less than 200ppm gt Return the boiler control to maximum and re check the CO CO gt If correct set the boiler control to normal NORM gt Re fit the control cover gt Re fit boiler outer case 32 6 720 804541 2012 12 WORCESTER Bosch Group
33. OUT Fig 3 S plan Y PLAN LAYOUT 6720644744 04 1Wo Fig 4 Yplan SEALED SYSTEM Y PLANLAYOUT 8 1 H H 1 x 9 6720644744 05 1Wo 10 g Fig 5 Sealed system 6 720 804 541 2012 12 PRE INSTALLATION WORCESTER Bosch Group NEW BUILD SYSTEM LAYOUTS The latest Part L1a regulation for new installations require separate zone controls for the central heating Open vent with two heat zones OPEN VENT LAYOUT 6720644744 61 1Wo Fig 6 SEALED SYSTEM LAYOUT di pl 6720644744 62 1Wo reg Fig 7 3 4 CONDENSATE PIPE WORK NOTICE gt Where anew or replacement boiler is being installed access to an internal gravity discharge point should be one of the factors considered in determining boiler location The condensate pipe must be nominally 22mm plastic pipe gt The condensate pipe work must fall at least 52mm per metre towards the outlet and should take the shortest practicable route gt Ensure there are no blockages in the pipe run Key to condensate illustrations Condensate discharge from boiler Soil and vent stack Minimum 450mm and up to three storeys Visible air break at plug hole Sink or basin with integrated overflow 75mm sink waste trap NI OO BY GC NM rm Condensate pump
34. PRIMARY SYSTEMS NOTICE All the following Pre Installation sections must N be read and requirements met before starting boiler or flue installations CAUTION Isolate the mains supplies before starting any N work and observe all relevant safety precautions NOTICE Debris from the system can damage the boiler and reduce efficiency Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance warranty BEFORE CLEANING THE SYSTEM gt Ensure that the system and pipe work is in good working order gt Where possible keep the existing boiler circulating pump in place when flushing the system FOLLOW THE GUIDANCE OF BS7593 Treatment of water in domestic hot water central heating and also the flushing guidelines below NOTICE Artificially softened water must not be used to bg fill the central heating system FLUSHING THE SYSTEM gt Fill the system with cold water and check for leaks gt Open all drain cocks and drain the system gt Close drain cocks and add a suitable flushing agent compatible with aluminium at the correct strength for the system conditions in accordance with the manufacturer s instructions The pH value of the system water must be less than 8 or the appliance guarantee will be invalidated gt Circulate the flushing agent before the boiler is started gt Run the boiler system at normal operating temperature as dire
35. Warndon Worcester WR4 9SW Tel 0844 892 9900 Worcester Bosch Group is a brand name of Bosch Thermotechnology Ltd worcester bosch co uk 6 720 804 541 2012 12 WORCESTER BOSCH GROUP TECHNICAL SUPPORT 0844 892 3366 APPOINTMENTS 0844 892 3000 SPARES 01905 752571 LITERATURE 0844 892 9800 TRAINING 01905 752526 SALES 01905 752640 WORCESTER Bosch Group
36. alve If the pipe will not pull out unscrew the nut to aid removal 6720643895 72 1Wo l DAN ai Fig 75 Gas valve upper connection 1 Refer to figure 76 and undo bottom gas connection to gas valve 2 Undo two securing screws on the underside of casing gt Disconnect electrical connections gt Pull valve up and forward out of boiler gt Replace valve with new seals and check for gas tightness 11 6720643895 73 1Wo L 2 h Fig 76 Gas valve lower connection NOTICE The valve will require setting follow N procedure Setting the air gas ratio 6 8 7 AIR GAS MANIFOLD AND FAN ASSEMBLY The following components require the il air gas manifold and fan assembly to be removed gt Fan electrode assembly gt Burner gt Heat exchanger NOTICE gt If the joint between the Air Gas manifold and heat exchanger is disturbed sealing gasket must be replaced gt After re assembly the combustion must be checked using the procedure in the section Setting the Air Gas ratio Measurement and setting if necessary of the gas ratio must not be attempted unless the person is equipped with acombustion analyser conforming to BS 7927 and is competent in its use 6 720 804 541 2012 12 37 SERVICE AND SPARES WORCESTER Bosch Group gt Remove electrical connector and earth wire the from fan gt Remove wi
37. ameter flue is to be used a 125 mm diameter hole is required However if using the weather sealing collar by pushing it through from inside the property then a 150 mm diameter hole is required to accommodate this gt The flue turret of the 100 mm flue has an in built 3 angle gt If extensions are to be added then the complete flue must rise at an angle of 3 gt The 125 mm diameter flue system will require the flue to rise at an angle of 3 gt Drill hole using a core drill or similar SIDE OUTLET 4 Mark from the centre line of the wall template to the wall which the flue will pass through 4 gt Allow for a rise of 52mm per metre length of flue to give a 3 angle gt Clear any debris from the site wm KH aron 6720644744 16 2Wo Fig 24 Marking the flue position 4 3 OUTER CASE REMOVAL 1 Undo the two captive screws securing boiler casing at the bottom of the appliance 2 Undo the two screws securing boiler casing at the top of the appliance 3 Pull case upwards 4 Remove cardboard packing piece from appliance With the outer case removed the appliance is suitable for a one man lift lt 25kg 6720804514 02 1Wo Fig 25 Case removal 20 6 720 804541 2012 12 WORCESTER Bosch Group INSTALLATION 4 4 BOILER CONNECTION CAUTION gt ISOLATE THE MAINS GAS SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS
38. anifold and heat 6 7 1 SYPHON REMOVAL AND CLEANING il Remove the syphon assembly to clean 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 bracket 3 Remove the bracket 4 Remove the screw and release the syphon retaining clamp 5 Swing the clamp completely to the left away from the syphon 6 Pull the syphon towards you and remove from the sump connection gt Empty the contents of the syphon into a suitable container gt Flush the syphon through with clean water 6720644744 42 1Wo Fig 68 Syphon removal 6 8 REPLACEMENT OF PARTS CAUTION TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS NOTICE REPLACEMENT OF COMPONENTS gt After replacement of any components always check for gas tightness where relevant and carry out functional checks as described in Commissioning Damaged O rings or gaskets must be replaced Gil 6 8 1 REMOVING THE OUTER CASING gt Remove bottom tray by pressing the tabs 2 in at the front underside of the boiler gt Lower the panel 6 720 804 541 2012 12 35 SERVICE AND SPARES WORCESTER Bosch Group gt Pull the panel forward off the retaining ledge 1 at the back of the gt Coat new sensor with heat cond
39. arate electrical supply gt External fuse rating 3A ACCESS TO ELECTRICAL CONTROL PANEL gt Remove boiler casing to access control panel 1 Unscrew the three screws in the control panel 2 Remove the connections cover gt Unclip cable clamp gt Cut off the tapered cable entry to fit cable diameter required gt Turn cable retaining screw anti clockwise gt Runcable through the hole in the main crossbar marked mains cable and through the cable clamp ensure there is ample cable to reach the connectors gt Turn cable clamping screw clockwise to secure cable and replace clamp into control panel 3 Mains power 230v connection ST1 Separate wires from cable end and strip to 6mm Connect LIVE wire to terminal L Connect NEUTRAL wire to the terminal N Connect EARTH wire to earth bracket 4 External Pump ST2 Max power 90 W Connect NEUTRAL wire to terminal Np Connect LIVE wire to terminal Lp Connect EARTH wire to earth bracket 5 Boiler Demand from external wiring centre ST2 Connect SWITCHED LIVE wire to terminal LR NOTICE SYSTEM PUMP A gt THE SYSTEM PUMP MUST BE CONNECTED TO THE APPLIANCE FOR THE PUMP OVER RUN FUNCTION 6720644744 25 1Wo Fig 39 Wiring detail NEW COMPLETE SYSTEM INSTALLATIONS Ifa new complete heating system is installed in a new build property or it is a first time installation in an existing property the heating systems must c
40. ating Max rated heat input net kW 12 32 15 40 1848 2462 12 32 15 40 1848 24 62 Min heat input kW 3 45 462 554 7 38 595 595 964 9 64 Max rated heat output 40 30 C kW 12 85 16 06 19 28 25 67 12 85 16 06 19 28 25 67 Max rated heat output 50 30 C kW 12 74 15 92 19 11 25 45 12 74 15 92 19 11 25 45 Max rated heat output 80 60 C kW 12 15 18 24 12 15 18 24 Max flow temperature C 82 82 82 82 82 82 82 82 Max permissible operating pressure bar 25 2 5 215 2 5 25 2 5 2 8 2 5 Available pump head at 21 C system temp rise m 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 Flue Flue gas temp 80 60 C rated min load C 62 56 66 58 70 60 78 63 62 57 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 CO level at max rated heat output after 30 min 965 9 8 9 8 9 8 11 0 110 110 11 0 CO level at min rated heat output after 30 min 8 65 92 9 2 9 2 105 105 105 105 NOx class 5 5 4 5 5 5 4 5 NOx rating mg kWh 39 60 84 66 44 60 84 66 Condensate Maximum condensate rate Wh 0 93 1 2 1 5 2 0 0 7 0 9 12 1 5 pH value approx 4 8 4 8 4 8 4 8 4 8 4 8 4 8 4 8 Electrical Electrical power supply voltage AC V 230 230 230 230 230 230 230 230 Frequency Hz 50 50 50 50 50 50 50 50 Maximum power consumption W 50 50 50 50 50 50 50 50 General data Appliance protection rating IP 20 20 20 20 20 20 20 20 Permissible ambient temperatures C 0 50 0 50 0 50 0 50 0 50 0 50 0 50 0 50 Nominal capacity of appliance litre Iil
41. ces Iftotalside clearanceis Increase height O Frontclearance reduced to Combined clearances to approx R to removable leftand right Combined top amp door must be clearances excluding bottom clearances increased to the boiler excluding the appliance 350 441 129 300 523 161 250 617 200 200 717 243 150 856 295 100 1012 358 50 1202 434 Table 10 Reduced side clearances If Front Clearance is Reduced millimetres Iffrontclearance Increase overallheight O Increase total side to removable clearances to R clearance to door is reduced approx Combined left and to Combined top and right clearances bottom clearances excluding the excluding the appliance appliance 50 mm 511mm 505 mm 25mm 596 mm 569 mm Table 11 Reduced front clearances 3 6 6 BATHROOMS The boiler may only be installed outside the shaded area Additional RCD Residual Current Device protection may be required Refer to the latest IEE wiring regulations 2 Without the end wall zone 2 must extend 600mm from the bath 800mm 2250mm 2250mm y Radius 600mm 6720646608 124 3Wo Fig 17 Bathroom installations 6 720 804 541 2012 12 13 WORCESTER PRE INSTALLATION Bosch Group 3 7 PLUMBING MANIFOLD 3 7 1 CONNECTIONS Heating System 22mm compression fittings From left Diameter of Gas 22mm compression fittings Function case edge pipe re Gei
42. connection Do not use galvanised pipes or radiators SYSTEM FILL SYSTEM FILL Heating Mains return supply Hose union CV cv SV SV Test point Temporary hose CV Check Valve AA Auto Air vent SV Stop Valve CV Check Valve SYSTEM MAKE UP Heating return Make up AA vessel 1000 mm 39 in above the highest point of the system 6720644743 08 1Wo Fig 2 System fill System make up S AND Y PLAN SYSTEMS NOTICE Bypass Lg gt Generally a bypass is not necessary ona Y plan system 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 highest point in the heating system to the water level in the feed and expansion tank 2 Heating vent 22mm minimum 3 Primary cold feed 15mm minimum 4 Diverter Zone valve 5 Pump maximum power 90 Watts 6 Automatic bypass T Radiator valve Flow 8 Lock shield valve Return 9 Expansion vessel 10 Pressure gauge 11 3 bar pressure relief valve 12 Stop cock Table 5 Key to figures 3 4 amp 5 NOTICE A drain cock should be fitted at the lowest Lg point of the heating circuit and beneath the appliance FULLY PUMPED SEALED SYSTEM The central heating sealed system must be filled using a WRAS approved filling loop or comply with figure 2 for System fill S PLAN LAY
43. cted by the manufacturer of the flushing agent gt Drain and thoroughly flush the system to remove the flushing agent and debris gt It may be necessary to use a power flushing machine to aid the cleansing procedure in some circumstances gt Close the drain cocks and refill with fresh water and a suitable inhibitor gt Vent any air from the boiler and system INHIBITOR Add asuitable inhibitor or combined inhibitor anti freeze if the system is exposed to freezing conditions to the heating system in accordance with the DWTA code of practice and manufacturer s guidelines WARNING Sealing agents gt Normally the addition of sealing agents to the system water is not permitted as this can cause problems with deposits left in the heat exchanger gt In cases where all attempts to find a micro leak have failed Worcester Bosch Group supports the use of Fernox F4 leak sealer WATER TREATMENT PRODUCTS Suitable water treatment products can be obtain from the following manufacturers FERNOX SENTINEL ARTIFICIALLY SOFTENED WATER It is possible to have an lon exchange water softener fitted to the cold water system of the property However the boiler requires an untreated cold water connection taken from the mains supply before the water softener to the primary water filling point of the heating system Alternatively there are water softening treatment devices that do not adjust or alter the pH levels of the wate
44. ducts gt Dimensions from a flue terminal to a fanned air inlet to be determined by the ventilation equipment manufacturer 6 720 804 541 2012 12 17 PRE INSTALLATION WORCESTER Bosch Group 3 10 PLUME MANAGEMENT TERMINAL POSITIONS All measurements in millimetres _ Plume re direction Flue terminal guard 7 716 191 176 t300 Y Fig 21 Plume terminal positions Maximum and minimum plume management lengths il gt Aminimum distance of 500mm must be maintained between the plume management outlet and the flue air intake gt The maximum plume management length is 4 5 metres for the appliances detailed on the front of this manual gt The 45 bend is equivalent to 0 75 metres of straight plume management and the 90 bend is equivalent to 1 5 metres terminal positions NOTICE gt All measurements are the minimum clearances required gt Refer to previous page for all concentric flue terminal positions unless the flue position is specified on the figure above Plume gt Terminals must be positioned so to avoid combustion products entering the building gt Support the flue at approximately one m
45. eave these instructions with the completed BENCHMARK CHECKLIST or a certificate confirming compliance with IS 813 Eire only and the user manual with the owner or at the gas meter after installation or servicing Distance learning and training courses are available from Worcester The BENCHMARK CHECKLIST can be found in the back of this Installation manual e DANGER indicates a situation that will result in severe injury or death Diameter IMPORTANT INFORMATION NG Natural Gas LPG Liquid Petroleum Gas This symbol indicates important information where CH Central Heating il there is no risk to people or property DHW Domestic Hot Water DCW Domestic Cold Water PRV Pressure Relief Valve ADDITIONAL SYMBOLS NTC Negative Temperature Coefficient sensor Symbol Explanation IP Ingress Protection gt Step in an action sequence RCD Residual Current Device E Cross reference to another part of the document TRV Thermostatic Radiator Valve List entry ECV Emergency Control Valve List entry second level WRAS Water Regulations Advisory Scheme SYMBOLS USED IN THIS MANUAL SEDBUK Seasonal Efficiency of Domestic Boilers in the UK Domestic Hot Water Central Heating Hot Water Storage Cylinder Domestic Cold Water Supply Electrical Supply Gas Supply Ne Ww BJ Table 1 Commonly used symbols Table 2 Abbreviations use in this manual 1 2 SAFETY PRECAUTIONS IF YOU SMELL
46. ed 1 Replace top two screws 2 Re tighten bottom two screws 2 i gt e ie Fig 49 Replacing outer case 5 6 2 INSTALL THE BOTTOM PANEL The cut out in the bottom panel fits easily over the syphon elbow and outlet however care should be taken not to disturb any sealed components 1 Hook the lip at the back of the bottom panel over the angled edge at the base of the connections manifold 2 Push up into position 3 Secure in position the screw provided 6720644744 34 2W0 Fig 50 Bottom panel 5 6 3 HAND OVER Complete the Benchmark Gas Boiler Commissioning Checklist The Benchmark Checklist can be found at the rear of il these instructions gt Set up the controls and show the user how to operate all the controls shown in the User Guide gt Ensure that the User guide is left with the boiler or homeowner gt If the appliance is unused and exposed to freezing conditions shut off all the mains supplies and drain the system and boiler 6 SERVICE AND SPARES 6 1 INSPECTION AND SERVICE CAUTION TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS NOTICE COMPONENTS gt After replacement of any components always check for gas tightness where relevant and carry out functional checks as described in Commissioning Damaged O rings or gaskets must be replaced NOTICE Service work mus
47. es Temperature C Water Flow Rate l min CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer s instructions and or BS5546 BS6798 If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation fitted ALL INSTALLATIONS If required by the manufacturer record the following CO OR CO Es OR CO CO Ratio The heating and hot water system complies with the appropriate Building Regulations Yes The boiler and associated products have been installed and commissioned in accordance with the manufacturer s instructions Yes The operation of the boiler and system controls have been demonstrated to and understood by the customer Yes The manufacturer s literature including Benchmark Checklist and Service Record has been explained and left with the customer Yes Commissioning Engineer s Signature Customer s Signature To confirm satisfactory demonstration and receipt of manufacturer s literature Service Record It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed Service Provider Before completing the appropriate Service Record below please ensure you have carried out the service as described in the manufacturer s instructions Always use the manufacturer s specified spare part when replacing controls Serv
48. etre intervals and at a change of direction use suitable brackets and fittings Key to illustration 1 This feature allows some basic plume re direction options ona standard telescopic horizontal flue terminal 300mm minimum clearances to a opening e g window However the minimum clearances to an opening in the direction that the plume management is facing must be increased to 1 500mm Where the flue is less than 150mm to a drainpipe and plume re direction is used the deflector should not be directed towards the drainpipe 2 300mm adjacent to a boundary line 3 Plume Management kit air intake can be reduced to 150mm providing the flue exhaust outlet is no less than 300mm adjacent to a boundary line 4 1 200mm between terminals facing each other 5 600mm distance to a boundary line unless it will cause a nuisance BS 5440 Part 1 recommends that care is taken when siting terminal in relation to boundary lines 6 Using a Plume Management kit the air intake measurement can be reduced to 150mm providing the flue exhaust outlet has a 300mm clearance Plume kits running horizontally must have a 10 fall back to the boiler for proper disposal of condensate For details on specific lengths see relevant boiler Technical amp Specification information 7 Internal external corners The air intake clearance can be reduced to 150mm providing the flue exhaust outlet has a 300mm clearance 8 Clearances no less than 200mm from the l
49. event seal damage The aluminium tape is not required when reducing the terminal 4 5 3 INSTALLING THE TELESCOPIC FLUE 1 Refer to figure 33 and set the flue length to the distance required secure with the screws provided 2 Seal the joint with the aluminium tape provided 3 Slide the inner wall seal onto the terminal 4 If fitting from inside the building slide the outer wall seal onto the terminal 6720644842 08 1Wo Fig 33 Telescopic flue 6 720 804 541 2012 12 23 WORCESTER INSTALLATION Bosch Group The turret securing screws are from the boiler and are a 2m il not in flue kit 4m Refer to figures 34 amp 35 a 1 Remove the three inner flue tube retaining screws 2 oe nA wen The inner tube will be held in place in the appliance 2 Check the boiler flue seal is correctly seated and apply silicone grease 3 Position terminal through the flue opening in the wall to the outside of the building by the distance shown 4 Align the flue turret to the boiler flue outlet with flat facing 1 to the rear of the boiler The flue turret should be pushed straight down on to the boiler 6720643895 35 1Wo Fig 34 gt Fit the screws removed in step 1 to secure flue turret gt If fitting the outer seal from outside the building slide the outer wall seal onto the terminal as shown T
50. f the control 5 Remove the rear panel 6 Remove the transformer cover 6 720 804 541 2012 12 41 CAWORCESTER SERVICE AND SPARES Bosch Group 4 Fig 91 Transformer PCB access 7 Remove the printed circuit board gt Remove the code plug from the old control board gt Fit the code plug into the new control board gt Re assemble in reverse order 6720644744 54 1Wo 6720644744 55 1Wo Fig 92 Change PCB Fuse location NOTICE CODE PLUG A gt Ensure that the code plug is fitted to the new control gt The appliance will indicate an error and will not function correctly NOTICE CO CO A gt After completing the service of the control the CO CO must be checked and set to the limits shown in Setting the air gas ratio in section 6 6 42 6 720 804541 2012 12 WORCESTER Sacchi Group FAULT FINDING AND DIAGNOSIS 6 9 SHORT PARTS LIST Fan 8716 1160670 Burner 12 amp 15Ri Gas Valve GC No H26 536 8716 116 3790 12 15 18 amp 24Ri GC No H26 537 8716 1113250 18 amp 24Ri GC No H26 540 87161206190 GC No H26 538 Flue overheat Electrodes including Control board thermostat grommet gasket 8718687 1640 type 8718 107 087 0 H26 541 8 710 506 2670 ee Gasket burner WB6 Seal Inner case mantel Flow temperature sensor s N A 87161105340 8716 106 6350 NTC C Zi H26 545 8716 106 688 0 Le gu GC No
51. ge point or purpose designed soak away may be considered If this method is chosen then the following measures should be adopted Use of the CondenseSure siphon will prevent il condensate freezing on a 3 metre straight 32mm uninsulated pipe atatemperature of 15 C for 48 hours gt The external run be keptas short as possible and not exceed 3 metres gt The pipe should be run internally as far as possible before going externally and the pipe diameter should be increased to 32mm before it passes through the wall to the exterior The pipe should be insulated using suitable waterproof and weather resistant insulation if not using a CondenseSure siphon gt The external pipe should take the shortest and least exposed route to the discharge point and should fall as steeply as possible away from the boiler with no horizontal runs in which condensate might stand gt The use of fittings 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 figure 11 when a rain water down pipe is used to dispose of condensate e An air break must be installed in the 43mm pipe work between the boiler condensate outlet and the drainpipe outside the property to avoid flooding during adverse weather conditions ee 17 ZH IN ae 18 8 Fig 11
52. ice 1 Date Engineer Name Service 2 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Gas Safe Register No Comments Comments Signature Signature Service 3 Date Engineer Name Service 4 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Gas Safe Register No Comments Comments Signature Signature Service 5 Date Engineer Name Service 6 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Operative ID No Comments Comments Signature Signature Service 7 Date Engineer Name Service 8 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Gas Safe Register No Comments Comments Signature Signature Service 9 Date Engineer Name Service 10 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Gas Safe Register No Comments Comments Signature Signature Worcester Bosch Group Cotswold Way
53. imary systems c0cc eens 8 39 Mains supply 8 6 7 Cleaning the heat exchanger 00 33 ES ee 6 7 1 Syphon removal and cleaning 35 3 2 1 Electricalsupply 8 6 8 Replacement of parts 35 3 2 2 lt GaS SUDPIV s u a 8 P 6 8 1 Removing the outer casing e 35 3 3 Water systems and pipe work 8 6 8 2 Primary sensor CH NIC 36 3 4 Condensate pipework 10 6 8 3 Overheat thermostat 36 3 4 1 Internalconnections 10 6 8 4 Flue overheat thermostat 3 4 2 Externalconnections 11 ER with grommet 36 3 5 Pressure relief pipe work 12 g 6 8 5 Lowering the boiler controls to the service position 37 3 6 Boiler location and clearances 12 i 68 6 Gas VaWe ee ANEN NEE ASSEN 37 3 6 1 Installation 0 cece cece eee ees 12 5 Ss 6 8 7 Air gas manifold and fan assembly 37 3 6 2 Servicing clearances i j 6 8 8 Airpressureswitch 00 cee eee eee ee 38 Ventilated compartment 12 689 FE 38 3 6 3 Compartments 13 6 8 10 Ge ne 8 U db Beg en 39 3 6 4 Boiler clearances Unventilated compartments 13 ne ee ee eee eae heen re g 6 8 11 Heatexchanger 0 c cece seen 39 3 6 5 Installation clearances unventilated compartments 13 6 8 12 Syphon removal cece cece eee eens 41 3 6 6 Bathrooms 0 ccc cece eee eee aes 13 6813 A to boil tio i 4 3 7 Plu
54. king of electrical connections check 6 720 804 541 2012 12 43 WORCESTER FAULT FINDING AND DIAGNOSIS Bosch Group Blue light indication Fault Possible solution check No light No power at control Permanent mains supply to boiler board Boiler mains switch ON Fuse F1 2A Slow blow Fuse F2 1 25A Anti surge Transformer both coils below 100 Q Otherwise replace control board Light ON Boiler ON but not Live demand at ST2 terminal Lp is there a demand operating during 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 replace board Slow flash mostly off flashes on Ignition lockout gt Gas present and at correct pressure gt Gas valve Check that there is 35V d c to each solenoid Check the resistance of each solenoid Top solenoid 380 Q 10 342 418 Q Bottom solenoid 190 Q 10 171 209 Q gt Combustion CO level gt Flue condition Blocked flue gt Blocked condensate pipe or frozen condensate gt Gas valve adjustment gt Ignition electrodes harness connections Check for condition and resistance of leads approximately 2100 Q gt Otherwise replace control board Slow flash mostly on flashes off Flue overheat Flue temperature too high gt Heat exchanger baffles removed and not refitted Heat exchanger ove
55. kylight to a vertical flue 8 Vertical flue clearance 500mm to non combustible building material and 1 500mm clearance to combustible building material 9 300mm above below and either side of an opening door air vent or opening window 10 600mm diagonally to an opening door air vent or opening window 11 300mm to an internal or external corner 12 2 000mm below a Velux window 600mm above or to either side of the Velux window 13 400mm from a pitched roof or 500mm in regions with heavy snow fall 14 500mm clearance to any vertical structure on a roof 600mm to room sealed flue or 1 500 to an open flue 15 200mm below eaves and 75mm 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 sealed with suitable silicon sealant 17 Flue clearance must be at least 300mm from the ground Terminal guards must be fitted if the flue is less than 2 metres from the ground or if a person could come into contact with the flue terminal 18 600mm distance to a surface facing a terminal unless it will cause a nuisance BS 5440 Part 1 recommends that care is taken when siting terminals in relation to surfaces facing a terminal Note il gt Installations in car ports are not recommended gt The flue cannot be lower than 1 000mm from the top of alight well due to the build up of combustion pro
56. lame electrode assembly from heat exchanger 2 Remove the seal from the top of the heat exchanger 3 Remove the burner gt Replace new burner in correct position gt Ensure that burner tabs as shown in figure 83 fit correctly their respective locations NOTICE Heat exchanger seal gt If the joint between the Air Gas manifold and heat exchanger is disturbed sealing gasket must be replaced gt After re assembly the combustion must be checked using the procedure in the section 6 6 Setting the Air Gas ratio gt Ensure that the seal is fitted CAUTION Clamping plate A gt Ensure that the clamping plate is firmly tightened down on top of the heat exchanger gt Replace the clamping plate 6720643895 61 1Wo Fig 83 Electrode assembly and burner 6 8 11 HEAT EXCHANGER gt Drain the system gt Remove syphon gt Remove the air gas manifold and fan 1 Refer to figure 84 remove the clip from the elbow on the flow pipe 2 Pull flow pipe away from heat exchanger 4744 51 1Wo Fig 84 Flow pipe removal 6 720 804 541 2012 12 39 CAWORCESTER SERVICE AND SPARES Bosch Group 1 Refer to figure 85 and re move the three screws securing the turret to the top of the boiler 2 Turn the upper exhaust connector anti clockwise to release from the hook 3 Pull the upper exhaust connector down 67
57. mbing manifold 14 Du ree nee 6 8 14 PCB Eege EENS EE 41 SCT GonnectiOns 24 49 KENE Ee ieren vestes 14 6815 Coden 41 3 8 Elei ege ege rent 15 i EE a Se 6 8 16 Transformer PCB c cece cece eee 41 3 9 Flue terminal positions 00 00 ee 17 69 ns 43 3 10 Plume management terminal positions 18 SE ees 4 INSTALLATION enee ege NEEN EE EEN ER 19 Sc nn nn ia a 4 1 Unpacking the wall frame amp ancillary items 19 anne ing See te Re i 7 1 1 Internal wiring diagram 0 0 cece eee eee 45 4 2 Wall mounting template amp flue opening 20 7 2 _Boilerfunction 0 cece cece eee ee ees 46 4 3 Outer case removal 0c cece eee ees 20 73 Protettion fin ti 47 4 4 Boiler connection 21 i ee 4 4 1 Condensate connection 0000 eee 22 4 5 Flue installation 0 c cece cee eee es 23 4 5 1 Measuring the flue Standard flue 23 4 5 2 Reducing the telescopic flue length 23 4 5 3 Installing the telescopic flue 23 4 5 4 Flue terminal plume re direction 24 4 6 Electrical connections 0 0cee cease 25 5 COMMISSIONING 26 5 1 Pre Commissioning checks e0008 26 5 2 Filling the system 27 5 3 Water treatment oeenn 27 5 4 Startingthe appliance 000 ee 27 5 5 Commissioning 28 5 5 1 Checking the gas
58. n 20 6 COvis less than 0 2 gt Ifthe readings are outside these limits then this indicates that there is a problem with the flue system or combustion circuit e g missing or dislodged seals 6720644744 37 1Wo Fig 54 Flue integrity test 6 4 FAN PRESSURE TEST This test is to determine if the heat cell requires cleaning attention 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 the cover 4 Insert the tool into the switch 5 Using the tool set the mode switch to maximum output Ensure the boiler is powered up and there is a demand from the external controls The power indicator will flash and the boiler will stay in this mode for 15 minutes if no further change is made to the switch 6720644744 31 1Wo Fig 55 Setting the boiler to maximum FAN PRESSURE TEST 6720804530 13 1Wo Lo Fig 56 Fan pressure test gt Remove the cover and connect a digital manometer to the fan pressure test point gt The pressure will read negative refer to the chart in figure 57 gt After measurement replace test point cover and return mode switch to normal gt Replace the control cover gt Replace outer case 6 720 804 541 2012 12 31 SERVICE AND SPARES WORCESTER Bosch Group NOTICE The boiler must be run at maximum outp
59. nce to removable door Minimum clearance required for servicing Table 8 Minimum clearances 3 6 3 COMPARTMENTS Follow the requirements of BS6798 and BS5440 Part 2 and note e Minimum clearances must be maintained An access door is required to install service and maintain the boiler and any ancillary equipment If the boiler is installed in an unventilated airing storage cupboard there is no requirement to make a partition between the boiler and the storage space as long as the minimum clearances around the boiler are maintained Ideally storage should be below the boiler where the boiler is mounted in the upper part of the cupboard whilst maintaining the clearances given in tables 9 10 or 11 3 6 4 BOILER CLEARANCES UNVENTILATED COMPARTMENTS The tables below show the options for the minimum space required to install and service the boiler inside an unventilated compartment 3 6 5 INSTALLATION CLEARANCES UNVENTILATED COMPARTMENTS CAUTION CLEARANCES gt Top and bottom clearances must not be reduced below the values shown in table 9 as they are the minimum clearances required for servicing Unventilated Compartment Installation Clearances millimetres The suggested total unventilated compartment minimum clearances are Side Above Below Front to removable door 400 170 mm approx 30mm 200mm 100 mm mm above the elbow Table 9 Minimum unventilated compartment clearan
60. ng temperature demand is activated temperature demand switches below 5 C rises above 12 C off Pump switches off after a 3 minute overrun period PUMP OVERRUN FUNCTION End of boiler demand Pump runs for 3 minutes central heating or to dissipate heat from domestic hot water the boiler into the system PUMP ANTISEIZE FUNCTION No central heating Pump runs 5 seconds A central heating demand demand after every 24hrs from activated pump runs a 24hr period last time pump ran normally 6720643895 111 1Wo Fig 94 Protection function 6 720 804 541 2012 12 47 WORCESTER Bosch Group NOTES 48 6 720 804541 2012 12 WORCESTER Bosch Group NOTES 6 720 804 541 2012 12 49 This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference Failure to install and commission according to the manufacturer s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty This does not affect the customer s statutory rights Customer Name Telephone Number Address Boiler Make and Model Boiler Serial Number Commissioned by print name __ Gas Safe Register Number Company Name Telephone Number Company Address Commissioning Date To be completed by the cust
61. nges of direction gt If this is not possible bends should be viewable from both directions NOTICE Effective flue lengths each 90 bend used is equivalent to 2 metres of straight flue each 45 bend used is equivalent to 1 metre of straight flue Plume management kits are available for the 60 100 horizontal flue system Refer to the manual supplied with the plume management kits for complete installation instructions FLUE LENGTHS The flue systems have different maximum flue lengths The Greenstar series has the option of two horizontal 60 100 RSF telescopic and longer telescopic and one horizontal 80 125 RSF telescopic flue system and two vertical RSF 60 100 or 80 125 flue systems The next page shows various fluing options Refer to the Flue options in table 13 for the straight flue lengths required to achieve the maximum flue length ondensfit II Maximum total Ri boilers flue length mm FLUE TYPE 60 100 80 125 1 Telescopic horizontal flue assembly 570 1 070 Longer telescopic horizontal flue assembly 790 N A 2 Horizontal flue extension 4 600 13 000 3 Horizontal flue with 1 x 90 bend 2 600 11 000 4 Horizontal flue with 2 x 90 bends N A 9 000 5 High level horizontal flue 4 600 13 000 6 High level horizontal flue with 2x 90 bends 2 600 11 000 7 High level horizontal flue with 3x 90 bends N A 9 000 8 Vertical balanced flue assembly 6 400 15
62. nnection taken from the mains supply before the water softener to the primary water filling point of the heating system Alternatively there are water softening treatment devices that do not adjust or alter the pH levels of the water With these devices it may not be necessary to provide an untreated water by pass to the primary water filling point of the heat system ENSURE THAT THE SYSTEM HAS BEEN CLEANED AS ON PAGE 8 OF THESE INSTRUCTIONS FLUSHING Central Heating gt Switch off the boiler gt Open all drain cocks and drain the system while the appliance is hot gt Close drain cocks and add a suitable flushing agent at the correct strength for the system condition in accordance with the manufacturer s instructions gt Run the boiler system at normal operating temperature for the time stated by the manufacturer of the flushing agent gt Drain and thoroughly flush the system to remove the flushing agent and debris INHIBITOR Central Heating Check drain cocks are closed and all radiator valves are open before adding a suitable inhibitor compatible with aluminium or combined inhibitor anti freeze if the system is exposed to freezing conditions to the heating system water in accordance with the manufacturers instructions The pH value of the system water must be less than 8 or the appliance warrantee will be invalidated gt Fill system as described in section 5 2 opposite gt Set al controls to maximum gt
63. not remove the two screws securing boiler casing at the bottom of the appliance gt Pull case forward and remove 6720644744 36 1Wo Fig 52 Control panel into service position 6 2 CHECKING GAS INLET PRESSURE Refer to section 5 5 1 for checking the gas inlet pressure NOTICE gt Ensure that the gas inlet pressure is satisfactory with Lg all other gas appliances working gt Do not continue with the other checks if the correct gas inlet pressure can not be achieved 6 3 CHECKING FLUE INTEGRITY The integrity of the flue system and performance of the boiler can be checked via the flue turret sample points IT SZ Flue gas sample point 1 DI Air inlet sample point Table 17 Key to figure 53 6720644744 35 1Wo Fig 51 Remove outer case LOWERING THE BOILER CONTROLS TO THE SERVICE POSITION 1 Remove two screws securing the control 2 Pull the control forward 3 Lower the control to align the slots at the top of the control with the lugs on the boiler framework 4 Hang control on two lugs on boiler framework 6720643895 67 1Wo Fig 53 Flue test points 30 6 720 804541 2012 12 WORCESTER Bosch Group SERVICE AND SPARES Withthe boiler case on and the boiler running at maximum gt Insert the analyser probe into the air intake test point gt Allow the readings to stabilise and check that Ov is equal to or greater tha
64. o be removed A gt Primary sensor Fig 72 Lower exhaust section gt Overheat thermostat gt Flue limit thermostat 6720644744 47 1Wo Refer to figure 71 for removal 1 Remove electrical connection by pulling upwards Squeeze retaining clip on plastic moulding of sensor and pull back and up until clear of pocket in heat exchanger 2 Pull forward to remove completely gt Remove electrical connections 1 Push the flue limit thermostat in from the sump gt Retrieve the thermostat from the sump well 36 6 720 804541 2012 12 WORCESTER Bosch Group SERVICE AND SPARES OX 6720643895 70 1Wo Fig 73 Remove thermostat To replace push the thermostat and new grommet gently back into the opening until contact with the locating ridge is felt 6 8 5 LOWERING THE BOILER CONTROLS TO THE SERVICE POSITION 1 Remove two screws securing control 2 Pull the control forward 3 Lower the control to align the slots at the top of the control with the lugs on the boiler framework 4 Hang control on two lugs on boiler framework 6720644744 36 1Wo Fig 74 Control panel into service position 6 8 6 GAS VALVE gt Isolate gas supply at boiler gas cock 1 Refer to figure 75 and re move the wire clip from the gas valve outlet 2 Pull the gas pipe free from the gas v
65. oil and vent stack internal kitchen or bathroom waste pipe washing machine waste pipe etc A suitable permanent connection to the foul waste pipe should be used 10 6 720 804541 2012 12 WORCESTER Bosch Group PRE INSTALLATION 6720644744 08 2Wo Fig 10 Condensate pump disposal 3 4 2 EXTERNAL CONNECTIONS routing we recommend installing a CondenseSure siphon to significantly reduce the risk of freezing gt Pipe work length should be kept toa minimum and the route as vertical as possible gt Weather proof insulation must be used if not using a CondenseSure siphon NOTICE Freezing conditions Lg gt When the position of the boiler prevents internal NOTICE Condensate waste Lg gt Care should be taken when siting a soak away to avoid obstructing existing services Continued Key to condensate illustrations 8 PVCu strap on fitting 9 100mm minimum plastic pipe 10 Drainage holes 11 Limestone chippings 12 Bottom of sealed tube 13 Insulate and increase pipe size 14 Pipe work transition 15 External air break 16 Air gap 17 External rain water pipe into foul water 18 43mm 90 male female bend Condensate trap of 75mm already incorporated into the boiler If no other discharge method is possible then the use of an externally run condensate drainage pipe terminating at a suitable foul water dischar
66. ollowing items Wall mounting plate 2 Wall mounting template and bottom panel 3 Literature pack and pipe connectors and olives 4 6720644744 14 2Wo nn Fig 22 Unpacking 1 3 Remove the top carton 5 4 Remove the outer cardboard sleeve 6 5 Remove the plastic cover 7 Fig 23 Unpacking 2 E 6720644744 15 2Wo gt Flatten the outer cardboard sleeve and place on the floor behind the boiler gt Lay the boiler on its back on the cardboard gt Remove the bottom tray IMPORTANT HANDLING INSTRUCTIONS Itis advised that two people are used to carry the carton from the van to the point of delivery Once the carton has been delivered remove the outer carton Care should be taken when releasing the straps If a sharp implement is used ensure the outer carton is not pierced and that the implement is used in such a way that it will not cause personal injury All sharp objects must be covered or the blade retracted after use and put away ina safe place The wall mounting frame Installer pack template and bottom panel can now be removed Care should be taken when lifting the boiler from the base and the proper technique for safe lifting of any heavy object must be strictly observed Additional requirements for roof space installation The boiler must be unpacked before ascending the steps to loft space Two sets of steps should be used Two people should share the lifting
67. omer on receipt of a Building Regulations Compliance Certificate Building Regulations Notification Number if applicable CONTROLS Tick the appropriate boxes Time and Temperature Control to Heating Room Thermostat and Programmable Load Weather Optimum Start Programmer Timer C Room Thermostat Compensation Control Time and Temperature Control to Hot Water Cylinder Thermostat and Programmer Timer Combination Boiler Heating Zone Valves Fitted Not Required Hot Water Zone Valves Fitted Not Required Thermostatic Radiator Valves Fitted Not Required Automatic Bypass to System Fitted Not Required Boiler Interlock Provided ALL SYSTEMS The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer s instructions ooog What system cleaner was used What inhibitor was used Quantity litres CENTRAL HEATING MODE Measure and Record Gas Rate Burner Operating Pressure if applicable Gas Inlet Pressure Central Heating Flow Temperature Central Heating Return Temperature COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm If yes and if required by the manufacturer has a water scale reducer been fitted What type of scale reducer has been fitted DOMESTIC HOT WATER MODE Measure and Record Gas Rate id m hr OR Burner Operating Pressure at maximum rate mbar OR Gas Inlet Pressure at maximum rate Cold Water Inlet Temperature Hot water has been checked at all outlets Y
68. onform to current building regulations Part Lia or L1b All new heating systems in dwellings must have at least two heating zones Each of these zones will be controlled by a thermostat and zone valve The exception to this are single storey open plan dwellings where the living area is more than 70 of the total useable floor area Then this type of dwelling can be controlled as one zone Analternative would be individual electronically controlled TRVs Hot water supplied would require separate time and temperature control For dwellings with a floor area over 150m2 separate time and temperature control for each zone is required All radiators must have TRVs fitted in all rooms except bathrooms and rooms with thermostats 6 720 804 541 2012 12 25 COMMISSIONING WORCESTER Bosch Group EXISTING INSTALLATIONS For boiler replacements on an existing system itis not necessary to zone the upstairs and downstairs differently compliance with the zone requirements can be achieved by a single room thermostat or programmable room thermostat While the system is drained down TRVs must be fitted to all rooms except the bathrooms and the room with the thermostat EXTERNAL WIRING CENTRE System components wired into terminal strip in accordance with system manufacturers instructions 230V MAINS SUPPLY er r z m brown green yellow Reeg o on DP Ki ole H o o o
69. owest point of the balcony or overhang 9 1 200mm from an opening ina car port on the same wall e g door or window leading into the dwelling 10 600mm distance to a surface facing a terminal unless it will cause a nuisance BS 5440 Part 1 recommends that care is taken when siting terminals in relation to surfaces facing a terminal Note il gt Installations in car ports are not recommended gt The flue cannot be lower than 1 000 mm from the top of a light well due to the build up of combustion products gt Dimensions froma flue terminal to a fanned air inlet to be determined by the ventilation equipment manufacturer 18 6 720 804541 2012 12 WORCESTER Bosch Group INSTALLATION 4 INSTALLATION WARNING All the previous Pre Installation sections must be read and the requirements met before starting boiler or flue installation 4 1 UNPACKING THE WALL FRAME amp ANCILLARY ITEMS apart when lifting or putting down heavy objects gt DO NOT lift and twist at the same time gt Lift and carry object close to the body Do not use the pre formed water pipes on the gas CAUTION LIFTING AND CARRYING gt Only lift a manageable weight or ask for help gt Bend the knee and keep the back straight with feet il supply they must only be used for water Remove the straps and open the top of the boiler packaging 1 Remove the two 22 mm water pipes 1 2 Remove the f
70. phon 2 Remove the two screws retaining the syphon bracket 3 Remove the bracket 4 Remove the screw and release the syphon retaining clamp 5 Swing the clamp completely to the left away from the syphon 6 Pull the syphon towards you and remove from the sump connection 6720644744 42 1Wo Fig 89 Syphon removal 6 8 13 ACCESS TO BOILER CONTROL COMPONENTS 1 Remove three screws 2 Remove cover from control 6 8 14 PCB FUSE gt Remove fuse holder with fuse F1 1 from the control and replace with anew fuse Aspare 2A fuse for F1 clipped onto the inside of the cover I Fig 90 Removing the connection cover 6720644744 53 1Wo 6 8 15 CODE PLUG Refer to figure 90 for code plug replacement gt Gently pull the code plug from the socket 2 gt The code plug should be left attached to the frame of the boiler by its plastic safety thread 6 8 16 TRANSFORMER PCB To change either the PCB F2 fuse or transformer gt Remove two screws securing the control gt Pull the control forward gt Lower the control to align the slots at the top of the control with the lugs on the boiler framework gt Hang control on two lugs on boiler framework 1 Unscrew the three screws in the control panel 2 Remove the connections cover and disconnect all electrical connections from the control 3 Remove the control from the boiler 4 Remove the four screws retaining the rear panel o
71. r 16 5 20 5 mbar Boiler inlet daneas 1 mbar 1 5 mbar drop drop 1 8 22m b ar 6720644744 44 2Wo Fig 47 Natural gas pressures lt Equal to or less han Regulator Gas Control L P G yalye lt 4 0mbar difference 28 41 mbar Boiler inlet 2 5 mbar D 1 5 mbar drop drop a 4 6720644744 45 2Wo 29 5 42 5 mbar Fig 48 L P G pressures 28 6 720 804541 2012 12 WORCESTER Bosch Group SERVICE AND SPARES NOTICE Do not continue commissioning until the correct gas pressure is achieved 5 5 2 CHECKING THE GAS RATE gt The gas rate should be measured at the gas meter after 10 minutes operation at maximum See technical data section at the front of this manual gt Where a gas meter is not available e g L P G the CO CO must be checked to the units shown in the setting of the air gas ratio refer to section 6 6 gt If pressure and gas rate are satisfactory press the service button and the boiler will return to normal operation If leftin the service mode the control will return to normal operation after 15 minutes gt Close the gas isolation valve gt Remove the manometer gt Re seal the screw in the gas inlet pressure test point gt Open the gas isolation valve gt Ensure that there are no gas leaks gt Replace the outer case 5 6 FINISHING COMMISSIONING 5 6 1 REPLACE THE OUTER CASE Replace outer casing making sure that the securing points are properly locat
72. r With these devices it may not be necessary to provide an untreated water by pass to the primary water filling point of the heat system 0870 601 5000 or www fernox com 0800 389 4670 or www sentinel solutions net 3 2 MAINS SUPPLY 3 2 1 ELECTRICAL SUPPLY Supply 230V 50 Hz 140 Watts Cable PVC insulated 0 75 mm 24 x 0 2 mm temp rated to 90 C External 3A fuse to BS1362 The appliance must be earthed Do not connected the appliance to a 3 phase supply IP20 Wiring must comply with the latest edition of BS 7671 IEE wiring regulations 3 2 2 GAS SUPPLY Boilers 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 boiler must be in accordance with BS6891 The meter or regulator and pipe work to the meter must be checked preferably by the gas supplier This is to ensure that the equipment is in good working order and can meet the gas flow and pressure requirements in addition to the demand from any other appliance being served NOTICE 12Ri 15Ri 18Ri and 24Ri models gt Provided that the correct gas supply working pressure and gas rate can be achieved see technical data on page 6 Check gas inlet pressure on page 28 also refer to B S 6891 gt Then it may be possible to reduce the gas supply pipe diameter to 15mm 3 3 WATER SYSTEMS AND PIPE WORK
73. re clip from gas valve outlet then pull gas pipe free from the gas valve see figure 75 br CD 6720804530 15 1Wo Fig 77 gt Undo the securing nut at the top of the heat exchanger and remove the retaining plate assembly 1 Disconnect spark electrodes and flame sensor connection This will prevent damage to the electrodes and sensor when the air gas manifold is rotated 1 Rotate fan and air gas manifold assembly 1 around the top of the heat exchanger until the lug on the air gas manifold is visible gt Lift up assembly and remove from boiler A vn EN PA 6720804530 16 1Wo Fig 78 Rotate the air gas manifold assembly 6720644744 48 1Wo m Fig 79 Air pressure switch 1 Remove the two screws retaining the pressure switch to the bracket 2 Refit the new Air pressure switch to the bracket 6720644744 49 1Wo Fig 80 Air pressure switch bracket NOTICE After re assembly check the CO CO levels as Lg described in section 6 6 Setting the air gas ratio NOTICE After re assembly check the CO C
74. rheat gt Heat exchanger blocked gt Water pressure gt Allair vented gt Pump harness connections gt Water leaks blockage gt Safety thermostats low voltage wiring harness connections gt Otherwise replace control board Flue pressure switch Blockage in the flue system Fast flash Volatile lockout sensor fan or code plug gt Temperature sensors Check condition and continuity of leads Check resistance of sensor 8k 20k Q gt Fan 230V A C across the live purple and neutral brown gt Fan lead Check continuity Code plug Is code plug missing or not inserted properly 2 pulses Service mode switch in min position 5 pulses Service mode switch in max position Table 19 Fault finding 44 6 720 804541 2012 12 WORCESTER Bosch Group FAULT FINDING AND DIAGNOSIS 7 1 1 INTERNAL WIRING DIAGRAM FLAME SENSE ELECTRODE OVERHEAT Fan wiring SPARK GC Live purple ELECTRODES FLOW TEMP Neutral brown SENSOR NTC FAN Colour sequence t FLUE OVERHEAT STAT SAFETY SOLENOID 1 L ER ER zu SAFETY LLS SOLENOID I J Slow T1 25 A fuse SPARK TRANSFORMER EM CH TEMPERATURE 230V AC CONTROL DIAGNOSTIC copE INTERFACE PLUG ST6 di Colour sequence t _ gt Min LL Norm MODE SWITCH
75. solate the power to the appliance and remove outer case and base panel 1 Refer to figure 61 and remove the clip from gas valve outlet If the plastic elbow can not be easily removed undo the nut to push the plastic elbow out of the fitting E 2 Pull the gas outlet elbow free from the gas valve 6720643895 72 1Wo gt Remove electrical connector and earth wire from fan To prevent damage to the electrodes when removing the air gas manifold disconnect the leads to the electrodes il gt Disconnect spark electrode and flame sensor connections 1 Refer to figure 62 and undo the securing nut on the top of the heat exchanger and remove the retaining plate assembly 6720643895 60 1Wo Fig 62 Securing nut 1 Refer to figure 63 and rotate fan and air gas manifold assembly around the top of the heat exchanger until it stops at the lug gt Lift up assembly and remove from boiler 2 Remove the cover panel by removing retaining screw Zielt A 6720804530 16 1Wo Fig 63 Rotate air gas manifold 6 720 804 541 2012 12 33 SERVICE AND SPARES WORCESTER Bosch Group BURNER REMOVAL Refer to figure 64 1 Remove clamping plate 2 Remove spark flame electrode assembly and seal
76. t be carried out by a competent registered engineer such as British Gas or Gas Safe registered personnel NOTICE SERVICE MUST NOT BE ATTEMPTED IF A CO CO ANALYSER IS NOT AVAILABLE Toensure the continued efficient operation of the appliance it must be checked at regular intervals 6 720 804 541 2012 12 29 WORCESTER Bosch Group SERVICE AND SPARES The frequency of servicing will depend upon the particular installation conditions and usage however an annual service is recommended The extent of the service required by the appliance is determined by the operating condition of the appliance when tested by fully qualified engineers The service interval record sheet at the rear of these instructions must be completed after each service INSPECTION 1 Check that the terminal and the terminal guard if fitted are clear and undamaged 2 If the appliance is in a compartment or cupboard check that the specified service space around the 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 section 5 2 4 Operate the appliance and take note of any irregularities Refer to Fault Finding on page 43 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
77. t water from syphon connection at the base of the boiler flush heat exchanger with water gt Re assemble ensuring that the lower baffle 2 and the top baffle 1 are refitted correctly gt Refer to figure 64 when re fitting the burner to ensure that it fits centrally within the heat exchanger and location tabs are situated in location holes gt Ensure that the seal is replaced with a new seal and ensure that the seal is correctly fitted Check the syphon unit is clean before refitting to boiler gt Reassemble and check combustion as stated in SETTING THE AIR GAS RATIO section on page 32 REMOVED TO CLEAN The heat exchanger is shown removed from the boiler to illustrate cleaning more clearly il THE HEAT EXCHANGER DOES NOT HAVE TO BE 6720643895 65 1Wo Fig 67 Cleaning heat exchanger NOTICE Heat exchanger baffles The baffles 1 and 2 must be refitted into the heat exchanger in the order shown in figure 65 Failure to do so may result in damage to the boiler exchanger is disturbed then the sealing gasket must be replaced gt After completing the service of the appliance the CO CO must be checked and set to the limits shown in Setting the air gas ratio on page 32 gt When replacing the burner gasket ensure that the clamping plate is fully tightened down to the heat exchanger NOTICE CO CO CHECKS N gt If the joint between the Air Gas m
78. te compliance with Building Regulations and should be provided to the customer for future reference Installers are required to carry out installation commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the scheme Visit centralheating co uk 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 Hazardous to Health Regulations 1988 COMBUSTION AND CORROSIVE MATERIALS Do not store or use any combustible materials paper thinners paints etc inside or within the vicinity of the appliance Chemically aggressive substances can corrode the appliance and invalidate any warranty FITTING AND MODIFICATIONS Fitting the appliance and any controls to the appliance may only be carried out by a competent engineer in accordance with the current Gas Safety Installation and Use Regulations Flue systems must not be modified in any way other than as described in the fitting instructions Any misuse or unauthorised modifications to the appliance flue or associated components and systems could invalidate the warranty The manufacturer accepts no liability arising from any such actions excluding statutory rights SERVICING Advise the user to have the system serviced annually by a compe
79. tent qualified Gas Safe registered engineer Approved spares must be used to help maintain the economy safety and reliability of the appliance IMPORTANT The service engineer must complete the Service Record on the Benchmark Checklist after each service INSTALLATION REGULATIONS Current Gas Safety Installation amp Use Regulations All gas appliances must be installed by a competent person in accordance with the above regulations Failure to install appliances correctly could lead to prosecution The appliance must be installed in accordance with and comply to the current Gas Safety Regulations IEE Regulations Building Regulations Building Standards Scotland Consolidation Building Regulations Northern Ireland local water by laws Health amp Safety Document 635 The Electricity at Work Regulations 1989 and any other local requirements British Standards Where no specific instruction is given reference should be made to the relevant British Standard codes of Practice BS7074 1 Code of practice 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 domestic premises BS5440 1 Flues and ventilation for gas appliances of rated heating not exceeding 7 OkW net Flues BS5440 2 Flues and ventilation for gas appliances of rated heating not exceeding 70kW net Air Supply BS
80. the boiler gt Make connections to the heating system pipes 6720644744 56 1Wo Fig 27 Levelling and securing detail 6 720 804 541 2012 12 21 INSTALLATION ZWWORCESTER Bosch Group 4 4 1 CONDENSATE CONNECTION Never terminate or discharge into any open source including sink bath shower bidet toilet etc NOTICE Condensate disposal gt Follow the recommendations given in section 3 4 Condensate pipe work for all condensate disposal installation gt Ensure that the condensate pipe work falls at least 50mm per metre towards the outlet gt Donot use solvents adhesive or lubricant when pushing the pipe onto the rubber connector Figure 29 gives the pipe work dimensions with respect to the mounting surface When using the pre formed water pipes provided with il the boiler offset the water pipes connecting to them by 5mm to enable pipe clamps to be fitted A sealing washer 1 and 22mm adaptor 2 are supplied in 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 29 and insert the condensate pipe 25mm into the elbow 5mm gt Le ZK ye A No lt T N
81. uctive paste and replace boiler 6 8 3 OVERHEAT THERMOSTAT Refer to figure 71 for removal gt Remove two electrical connectors from thermostat 3 Slacken and remove fixing screw and thermostat 3 gt When replacing ensure thermostat sits correctly on surface of the casting with the left hand side of thermostat sitting up against the shoulder It is essential that the mating surface of the thermostat is coated with heat conductive paste 6720644744 34 1Wo Fig 69 Remove bottom panel 1 Undo the two screws securing the top of the boiler casing 2 Undo the two screws securing the bottom of the boiler casing gt Pull case forward and remove 6720804530 15 1Wo Fig 71 Primary sensor and overheat thermostat 6 8 4 FLUE OVERHEAT THERMOSTAT WITH GROMMET To remove and replace the thermostat either gt Usingasmall terminal screwdriver prise the thermostat and grommet from the plastic housing d Take care not to damage the plastic housing or 1 Release the flue connection from the sump Ge 2 Push the flue tube up 6720644744 35 1Wo Fig 70 Remove outer case E T RICH CT 6 8 2 PRIMARY SENSOR CH NTC I f m HERE 2 w To gain access to the following components the outer case has t
82. ut for Fan Pressure test and the Flue Gas analysis FAN PRESSURE TEST Clean the Heat Ex HeatEx ok gt NG Boilers 24 Ri kr 18 Ri gt 15 Ri a gt 17 mt ET mbar i LPG Boilers zum C 5 cr Ty gt I5RE ET gt 2 ey gt Lustunelhaulondluclunlnutuellunvlaunclustualuuuoeluncluuslun D 1 2 38 4 6 6 7 3 6720644744 39 1Wo Fig 57 Fan pressure readings If the boiler fails the fan pressure test then before adjusting the air gas ratio try the following Check the syphon is not blocked 1 Remove the screws securing the sump cover 2 Remove the sump cover 3 Clean the sump with a suitable brush gt Check the exhaust path and flue for restriction gt Re check the Fan Pressure readings 6720644744 40 1Wo Fig 58 Sump access 6 5 FLUE GAS ANALYSIS COMBUSTION TEST gt Check the CO CO readings against the information in table 18 CO CO settings on page 32 a es 6720804530 14 1Wo Fig 59 If the boiler fails the combustion test check 1 Air intake for restriction 2 Diaphragm in the fan for correct operation 3 Cleanliness of the heat cell plus blockages in the condensate disposal 6 6 SETTING THE AIR GAS RATIO 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 THE TEST IS EQUIPPED WITH A COMBUSTI

Installation manual for Greenstar Ri

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