Documente Academic
Documente Profesional
Documente Cultură
UK/IE
WATER TREATMENT:
FERNOX 01799 550811
www.fernox.com
SENTINEL 0800 389 4670
www.sentinel-solutions.net
2
INSTALLATION &
SERVICING INSTRUCTIONS
SAFETY &
REGULATIONS
CONTENTS
INSTALLATION REGULATIONS
4
APPLIANCE
INFORMATION
APPLIANCE INFORMATION
GENERAL INFORMATION
TECHNICAL DATA
PRE-INSTALLATION
MAINS SUPPLY
10
11
CONDENSATE PIPEWORK
12
13
14
PLUMBING MANIFOLD
16
FLUE OPTIONS
17
18
PRE INSTALLATION
INSTALLATION
INSTALLATION
20
21
22
BOILER CONNECTIONS
23
FLUE INSTALLATION
25
CONDENSATE CONNECTIONS
28
ELECTRICS
29
30
COMMISSIONING
PRE-COMMISSIONING CHECKS
31
32
33
WATER TREATMENT
34
COMMISSIONING
35
FINISHING COMMISSIONING
36
SERVICING
& SPARES
COMMISSIONING
CONVERSION
KITS
REPLACEMENT OF PARTS
43
55
56
CONVERSION KITS
57
FAULT FINDING
& DIAGRAMS
L.P.G. CONVERSION
FAULT FINDING & DIAGNOSIS
FAULT FINDING
58
59
60
PROTECTION FUNCTION
BENCHMARK CHECKLIST
61
CONTENTS
SAFETY &
REGULATIONS
4
SAFETY PRECAUTIONS
& INSTALLATION REGULATIONS
GENERAL INFORMATION
APPLIANCE
INFORMATION
330mm
700mm*
B
400mm
D
C
E
STANDARD PACKAGE:
A - Wall hung gas fired condensing combi boiler
for central heating and domestic hot water
B - Boiler support frame
C - Hardware literature pack (see checklist)
D - Bottom Panel
F
*710mm to top case front
Check List
Hardware/Literature pack
Item
Qty.
Greenstar 24i Junior/28i Junior Installation/Servicing Instructions.....1
Users Instructions ..........................................................................................1
Consumer Guarantee Card .........................................................................1
Syphon assembly............................................................................................1
Installation instructions...........................................................................1
Sealing Pack...................................................................................................1
Compression Nut 22mm ....................................................................... 3
Compression Ring 22mm ..................................................................... 3
Compression Nut 15mm ....................................................................... 3
Compression Ring 15mm ..................................................................... 3
Fibre Washer 18.6 x 13.5 x 1.5 ............................................................ 2
Fibre Washer 23.9 x 17.2 x 1.5............................................................. 2
Bonded Washer 3/4 ...............................................................................1
Syphon assembly............................................................................................1
Installation instructions..................................................................................1
Irish Guidelines Leaflet .................................................................................1
Warranty Return Envelope ...........................................................................1
E - Fascia panel
F - Syphon assembly
SPECIFICATIONS:
5
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
GENERAL INFORMATION
TECHNICAL DATA
DESCRIPTION
NATURAL GAS
L.P.G.
UNIT
24 iJunior
28 iJunior
24 iJunior
28 iJunior
KW
7.38
7.38
9.64
9.64
KW
24
28
24
28
KW
24.49
28.57
24.49
28.57
m3/h
2.59
3.02
kg/h
1.9
2.22
bar
10
10
10
10
bar
1.3
1.3
1.3
1.3
bar
0.2
0.2
0.2
0.2
55
55
55
55
l/min
11.5
13.4
11.5
13.4
l/min
8.6
10
8.6
10
KW
24.62
24.62
24.62
24.62
KW
25.67
25.67
25.67
25.67
KW
25.45
25.45
25.45
25.45
KW
24
24
24
24
82
82
82
82
APPLIANCE
INFORMATION
Central Heating
bar
2.5
2.5
2.5
2.5
2.0
2.0
2.0
2.0
Flue
Flue Gas Temp. 80/60C, rated/min. load
78/63
78/64
79/64
79/65
54/35
54/36
55/38
55/39
9.8
9.8
11.0
11.0
9.2
9.2
10.5
10.5
2.0
2.0
2.0
2.0
4.8
4.8
4.8
4.8
NOx - class
Condensate
Max. condensation rate
l/h
pH value, approx.
Electrical
Electrical power supply voltage
AC...V
230
230
230
230
Frequency
Hz
50
50
50
50
140
140
140
140
band
IP
X4D
X4D
X4D
X4D
IP
20
20
20
20
0-50
0-50
0-50
0-50
General Data
SEDBUK
Itr
3.9
3.9
3.9
3.9
dB(A)
42
42
42
42
kg
39.5
39.5
39.5
39.5
Lift weight
kg
27.1
27.1
27.1
27.1
SEDBUK
90.1
90.1
91.8
91.8
6
TECHNICAL DATA
OVERHEAT THERMOSTAT
RETAINING BRACKET
EXPANSION VESSEL
APPLIANCE
INFORMATION
AIR VENT)
9
AI R
P R ES S U R E
SWITC H
7
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
38 DRAIN TAP
39 COLD WATER IN CONNECTION
40 INTERNAL BYPASS WITHIN PLASTIC
MOULDING
41 DHW OUT CONNECTION
42 CH FLOW CONNECTION TO SERVICE
VALVE
43 DHW SENSOR
44 FLOW CONNECTION FROM BOILER
HEAT EXCHANGER
45 AUTO AIR VENT
46 UNUSED PORT
47 FAULT RESET BUTTON
48 ECO BUTTON
49 MAINS ON/OFF INDICATOR/
DIAGNOSTIC LIGHT (BLUE)
50 CH TEMPERATURE CONTROL
51 POSITION FOR OPTIONAL
PROGRAMMER
52 SERVICE MODE BUTTON
53 BURNER ON INDICATOR LIGHT (GREEN)
54 MASTER SWITCH ON/OFF
8
LAYOUT & COMPONENTS
CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND
OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.
PRE INSTALLATION
9
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
MAINS SUPPLY
PRE INSTALLATION
ELECTRIC SUPPLY:
Supply: 230V - 50Hz, 140 watts
Cable: PVC insulated 0.75mm2 (24 x 0.2mm)
temperature rated to 90C.
External 3A fuse to BS1362.
The appliance must be earthed.
This appliance must not be connected to a
three phase supply.
IPX4D.
NOTE: this is reduced to IP20 if the
following mechanical timers are fitted:
7 716 192 036 or 7 716 192 037.
Wiring must comply with latest IEE wiring
regulations.
GAS SUPPLY:
Boilers using NG must be connected to a
governed meter.
LPG boilers must be connected to a
regulator.
Installation and connection of the gas supply
to the boiler must be in accordance with
BS6891.
Under no circumstances should the size of
the gas supply pipe be less than that of the
appliance inlet connection.
The meter or regulator and pipework to the
meter must be checked, preferably by the gas
supplier, to ensure it 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.
WATER SUPPLY:
Water mains pressure:
Minimum mains water pressure 1.3 bar for
maximum performance.
Maximum mains fed water pressure 10 bar.
If necessary, fit a pressure reducing valve.
IMPORTANT: Non-return, back flow prevention devices (including those associated with water meters) fitted to the
mains water supply can cause a pressure build up which could damage the
boiler and other household appliances.
Where the mains water supply has a nonreturn, back flow prevention valve fitted, a
mini expansion vessel (A) should be connected to the mains water inlet pipe (B) between
the non-return valve (C) and the boiler (D) as
shown opposite.
Use in hard water areas:
Normally there is no need for water treatment to
prevent scale formation as the maximum temperature of the DHW heat exchanger is limited
in the electronic circuit.
In areas where temporary water hardness
exceeds 200ppm, consideration may need to
be given to the fitting of a scale prevention
device. In such circumstances, the advice of
the local water authority should be sought.
10
MAINS SUPPLY
PRE INSTALLATION
PLASTIC PIPEWORK:
Any plastic pipework must have a polymeric
barrier with 600mm (minimum) length of
copper pipe connected to the boiler.
Plastic pipework used for underfloor heating
must be correctly controlled with a
thermostatic blending valve limiting the
temperature of the circuits to approx. 50C.
SHOWERS/BIDETS:
If a shower head can be immersed in water or
comes closer than 25mm from the top edge
of a bath or shower tray spill over level then
an anti-syphon device must be fitted to the
shower hose.
Bidets with direct hot and cold mains water
can be used (with the approval of the local
water authority) and must be the over rim
flushing type with shrouded outlets to prevent
the fitting of hand held sprays.
A
B
C
P
11
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
CONDENSATE PIPEWORK
IMPORTANT:
PRE INSTALLATION
CONDENSATE PIPEWORK:
The condensate pipe must be a minimum of
22 mm plastic pipe.
The condensate pipework must fall at
least 50 mm per metre towards the outlet
and should take the shortest practicable
route.
The pipework must follow one of the options
shown opposite or discharge directly into a
vent stack min. 450 mm above pipe invert or
into a gully below ground but above the water
level.
Wherever possible the condensate
discharge pipe work should be routed and
terminated internally. Should this not be
possible, and the only available route is
external, the following conditions should be
observed:
External pipe work
-
Condensate soakaway
The condensate drainage pipe may be run
above or below the ground to the soakaway.
The example shown opposite runs above
ground level.
The soakaway must use a 100mm diameter
plastic tube with two rows of three 12 mm
holes on 25 mm centres and 50 mm from
the bottom of the tube. The holes must face
away from the house.
The tube must be surrounded by at least
100 mm of limestone chippings to a depth
of 400mm.
12
CONDENSATE PIPEWORK
PRE INSTALLATION
M
L - Outside wall
O,M - Drain pipe
N - External drain
L
O
N
13
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
PRE INSTALLATION
Vent
position
24 & 28 kW
To room or
internal space
High
level
Minimum free
area 122 cm2
Minimum
free area
61 cm2
Low
level
Minimum free
area 122 cm2
Minimum
free area
61cm2
14
BOILER LOCATION & CLEARANCES
Direct to
outside
1
2
1
2
PRE INSTALLATION
1
2
15
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
PLUMBING MANIFOLD
Gas Supply (alternative from above appliance) 22mm
DHW OUT 15mm
DHW IN (alternative from
above appliance)
15mm
CH Return 22mm
CONNECTIONS:
Heating System: 22mm compression fittings
DHW:
15mm compression fittings
Gas:
22mm compression fittings
Use the fittings supplied in the Lit/Hardware
pack.
CH Flow 22mm
PRE INSTALLATION
*
A
Mains Gas
Supply 22mm
Mains Water
(DHW IN) 15mm
16
PLUMBING MANIFOLD
FLUE OPTIONS
The Greenstar series has the option of two horizontal RSF (60/100 telescopic and
80/125) flue systems and two vertical RSF (60/100 or 80/125) flue systems:
The systems have different maximum flue lengths
This page shows various fluing options with the straight flue lengths required to achieve
the maximum flue length. Note that:
each 90 bend used is equivalent to 2 metres of straight flue
each 45 bend used is equivalent to 1 metre of straight flue
NOTE: Plume management kits are available for the 60/100 horizontal flue option.
Refer to the manual supplied with the Plume management kits for complete
installation instructions
125mm
24 i jun.
2,600mm
11,000mm
28 i jun.
2,600mm
11,000mm
100mm
125mm
24 i jun.
570mm
1,070mm
28 i jun.
570mm
1,070mm
Maximum total flue length
100mm
125mm
24 i jun.
N/A
9,000mm
28 i jun.
N/A
9,000mm
PRE INSTALLATION
125mm
24 i jun.
4,600mm 13,000mm
24 i jun.
28 i jun.
4,600mm 13,000mm
28 i jun.
125mm
6,400mm 15,000mm
6,400mm 15,000mm
125mm
24 i jun.
4,400mm 13,000mm
100mm
28 i jun.
4,400mm 13,000mm
125mm
24 i jun.
4,600mm 13,000mm
28 i jun.
4,600mm 13,000mm
Vertical balanced flue with 2x90 bends
125mm
24 i jun.
2,400mm
11,000mm
28 i jun.
2,400mm
11,000mm
100mm
125mm
24 i jun.
2,600mm
11,000mm
28 i jun.
2,600mm
11,000mm
17
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
FLUE OPTIONS
PRE INSTALLATION
18
FLUE TERMINAL POSITIONS
PRE INSTALLATION
19
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
ANCILLARY ITEMS
LIFTING AND CARRYING PRECAUTIONS:
Lift only a manageable weight, or ask for
help.
When lifting or putting things down, bend
the knees, and keep the back straight
and feet apart.
Do not lift and twist at the same time.
Lift and carry objects close to the body
A - Straps
A
B - Outer carton
C - Installer pack
D - Bottom panel
G - Inner packaging
H - Front fascia
E
INSTALLATION
J - Syphon assembly
IMPORTANT HANDLING INSTRUCTIONS
3
C
D
F
20
UNPACKING WALL FRAME AND
ANCILLARY ITEMS
X4
X4
SAFETY:
All relevant safety precautions must be undertaken.
Protective clothing, footwear, gloves and safety
goggles must be worn as appropriate.
USE APPROPRIATE
FIXINGS FOR
WEIGHT AND
WALL TYPE
COMMISSIONING
189mm
INSTALLATION
21
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
A - Outer carton
5
B
B
C
6.1
INSTALLATION
E
6
6.2
H
22
UNPACKING THE APPLIANCE
BOILER CONNECTIONS
CAUTION: ISOLATE TH E MAI NS GAS
SUPPLY BEFORE STARTING ANY WORK
AND OBSERVE ALL RELEVANT SAFETY
PRECAUTIONS.
IMPORTANT:
Before hanging the boiler onto the wall
mounting frame ensure that the pressure
relief valve connection is in the DOWN
position. This is located on the right hand
side of the wall frame at the rear.
2. Pull the extended tab/lever forward
and down until there is no further travel.
INSTALLATION
Handling
Hole
2&4
22mm
15mm
22mm
bonded
washer
15mm
22mm
1A
C
IMPORTANT:
The pressure relief connector must be
repositioned after the boiler has been correctly
mounted to the wall mounting frame.
4. Push the lever on the pressure relief
connector UP until the stop on the inside of
the handle is over the shoulder of the metal
bracket to secure in place.
4
Stop in
locked
position
23
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
BOILER CONNECTIONS
BOILER CONNECTIONS
INSTALLATION
6
C
A
22mm
E
15mm
C
22mm
D
15mm
B
22mm
24
BOILER CONNECTIONS
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.
189mm
93mm
Edge of
case
200mm
570mm
350mm
INSTALLATION
WALL
D
E
130mm
MIN
25
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
FLUE INSTALLATION
FLUE INSTALLATION
TOP
INSTALLATION
4 Align the flue turret (E) to the boiler flue outlet (F)
with flat (G) facing to the rear of the boiler.
Push the flue turret (E) straight down into the
boiler flue outlet (F).
For ease of assembly, locate screw (H) first and
then fit screws (D) to secure flue turret (E).
If fitting from the outside of the building; slide the
outer wall seal (C) onto the terminal (B) as
shown.
110mm
TOP
VIEW
H
NOTE:
For more information refer to the
60/100 Horizontal Flue kit Instruction Manual
B
C
180
80
26
FLUE INSTALLATION
FLUE INSTALLATION
INSTALLATION
Flat at back
27
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
FLUE INSTALLATION
SUMP
CONNECTION
CONDENSATE CONNECTION
CONDENSATE CONNECTION:
Never terminate or discharge into any open
source, including; sink, bath, shower, bidet,
toilet etc.
Note: Any external condensate pipework
should be protected with weather
resistant insulation to help prevent
freezing.
SUMP
BLANKING CAP
INSTALLATION
DISCHARGE
HOSE
SYPHON
4 Push the discharge hose, onto the
wall frame connector, until fully engaged.
4
Maintenance
There is no need to remove the Syphon
Assembly for cleaning.
To drain debris from the syphon, during the
annual service, release the clips and remove
the drainage cap from the bottom of the
syphon.
Empty the debris and condensate from the
syphon into a suitable container.
Re-fit the drainage cap to bottom of the
syphon.
DRAINAGE CAP
DISCHARGE
HOSE
WALL FRAME
CONNECTOR
28
CONDENSATE CONNECTION
ELECTRICS
A
CAUTION: ISOLATE THE MAINS
ELECTRICITY SUPPLY BEFORE STARTING
ANY WORK AND OBSERVE ALL
RELEVANT SAFETY PRECAUTIONS
ROOMSTAT
ONLY
4
ROOMSTAT
ROOMSTAT
AND
PROGRAMMER
3
Access to electrical connections:
PROGRAMMER
INSTALLATION
brown
blue
green/yellow
230V
MAINS
SUPPLY
neutral
live
earth
switched live
FROSTSTAT
ST6
ST10
Remove link.
Connect room stat LIVE supply to terminal (LS)
Connect room stat LIVE return to terminal (LR)
NOTE:This is sometimes referred to as call for
heat or heating load.
Connect room stat NEUTRAL to terminal (NS)
NOTE: Some devices do not require this.
5 Optional external frost stat connection (ST6):
F1
29
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
ELECTRICS
POSITION OF WIRED
COMMISSIONING
INSTALLATION
COMPONENTS
30
POSITION OF WIRED COMPONENTS
PRE-COMMISSIONING
1
A
CHECKS
A
22mm
D
15mm
C
22mm
E
15mm
B
22mm
COMMISSIONING
Condensate pipe
Preplumbing manifold
connector
31
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
PRE-COMMISSIONING CHECKS
1
2
3
4
E
C
D
5
COMMISSIONING
32
FILLING THE SYSTEM
A - On/off button
B - On/off and fault indicator (BLUE)
C - Central heating temperature control
D - Burner indicator (GREEN)
E - Reset button
F - Service button
G - ECO button
H - System pressure gauge
I - Cover or optional programmer
COMMISSIONING
33
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
WATER TREATMENT
IMPORTANT: ARTIFICIALLY SOFTENED WATER
MUST NOT BE USED TO FILL THE CENTRAL
HEATING SYSTEM.
COMMISSIONING
34
WATER TREATMENT
COMMISSIONING
D
F
SIT VALVE
A - On/off button
B - On/off and fault indicator (BLUE)
C - Central heating temperature control
D - Burner indicator (GREEN)
E - Reset button
F - Service button
G - ECO button
H - System pressure gauge
I - Cover or optional programmer
Inlet Test Nipple
DUNGS VALVE
COMMISSIONING
35
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
COMMISSIONING
FINISHING COMMISSIONING
The boiler has been factory set, so there should be no
need to adjust any controls.
1. REPLACE OUTER CASING:
Replace outer casing making sure that the securing
points are properly located.
Replace top two screws (A).
Retighten bottom two screws (B).
COMMISSIONING
HANDOVER:
Complete the Benchmark Gas Boiler Commissioning
Checklist.
NOTE: The Benchmark Checklist can be found at the
rear of these instructions.
C
D
C
E
36
FINISHING COMMISSIONING
CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS
S U P P LI E S B E FOR E STARTI NG ANY WOR K AN D OB S E RVE ALL
RELEVANT SAFETY PRECAUTIONS.
Inspection
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.
Operate the appliance and take note of any
irregularities.
Refer to Fault Finding for rectification
procedures.
SERVICING
& SPARES
37
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
1.
1.1
1.2
1.
B
1.3
2.1
SERVICING
& SPARES
2.2
31
38
INSPECTION AND SERVICE
A - On/off button
B - On/off and fault indicator (BLUE)
C - Central heating temperature control
D - Burner indicator (GREEN)
E - Reset button
F - Service button
G - ECO button
H - System pressure gauge
I - Cover or optional programmer
1 Press and HOLD service button (F) for 10
seconds and set Central Heating temperature
to maximum.
The service button will illuminate continually
and the blue power indicator will flash quickly.
The boiler will stay in this mode for 15
minutes unless the service button is pressed
again.
SERVICING
& SPARES
2
B
39
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
IMPORTANT:
IF THE JOINT BETWEEN THE
AIR/GAS MANIFOLD AND THE HEAT
EXCHANGER IS DISTURBED THE
SEALING GASKET MUST BE
REPLACED.
AFTER COMPLETING THE
SERVICE OF THE APPLIANCE, THE
CO/CO2 MUST BE CHECKED AND
SET TO THE LIMITS SHOWN IN THE
SETTING THE AIR/GAS RATIO
B
A
SERVICING
& SPARES
Cleaning Syphon
3 There is no need to remove the Syphon
Assembly to clean.
To drain debris from the syphon, release
the clips and remove the drainage cap (E)
from the bottom of the syphon.
Catch the debris and condensate from the
syphon into a suitable container.
Re-fit the drainage cap (E) to bottom of
the syphon.
3
2
40
INSPECTION AND SERVICE
H
4
5
6
7
8
6
I
SERVICING
& SPARES
41
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
R
9
Small
tab
9
SERVICING
& SPARES
I M P ORTANT: I F TH E JOI NT
BETWEEN THE AIR/GAS MANIFOLD
AN D TH E H EAT E XCHANG E R I S
DISTURBED THE SEALING GASKET
MUST BE REPLACED.
42
INSPECTION AND SERVICE
REPLACEMENT OF PARTS
CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS
S U P P LI E S B E FOR E STARTI NG ANY WOR K AN D OB S E RVE ALL
RELEVANT SAFETY PRECAUTIONS.
1.1
1.2
2. Primary sensor
Remove electrical connection (B) by pulling
upwards. Squeeze retaining clip on plastic
moulding (C) and pull sensor (D) upwards
until clear of pocket in heat exchanger.
Coat new sensor with heat conductive
paste and replace.
3. Overheat thermostat
2
B
C
SERVICING
& SPARES
4.1
43
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
REPLACEMENT OF PARTS
5.1
REPLACEMENT OF PARTS
SIT AND DUNGS VALVES
5.2
6.1
6. Gas valve
SERVICING
& SPARES
6.2
6.3
44
REPLACEMENT OF PARTS
REPLACEMENT OF PARTS
7
8. PCB fuse
Remove fuse F1(B) from the PCB and
replace.
There is a spare fuse clipped into the
underside of the electrical cover.
9.Transformer / PCB
Disconnect all electrical connections from
the control.
Remove 5 screws (C) retaining the rear
panel of the control and remove panel.
SERVICING
& SPARES
45
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
REPLACEMENT OF PARTS
REPLACEMENT OF PARTS
11
B
10.1
C
C
10.2
F
E
SERVICING
& SPARES
10.3
46
REPLACEMENT OF PARTS
11.1
A
11.2
B
11.3
REPLACEMENT OF PARTS
I M P ORTANT: I F TH E JOI NT
BETWEEN THE AIR/GAS MANIFOLD
AN D TH E H EAT E XCHANG E R I S
DISTURBED THE SEALING GASKET
MUST BE REPLACED.
IMPORTANT: AFTER REASSEMBLY
TH E C OM B USTION M UST B E
CH ECK E D US I NG TH E P RO CEDURE IN THE SECTION SETTING
THE AIR/GAS RATIO. MEASUREMENT AND SETTING (IF NECESSARY) OF THE GAS RATIO MUST
NOT BE ATTEMPTED UNLESS THE
P E R SON I S EQU I P P E D W ITH A
C OM B USTION ANALYS E R C ONFORMING TO BS 7927 AND IS COMPETENT IN ITS USE.
SERVICING
& SPARES
47
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
REPLACEMENT OF PARTS
REPLACEMENT OF PARTS
12.1
12.2
12.3
13
12. Fan
14. Burner
E
14
SERVICING
& SPARES
15.1
15.2
15.3
48
REPLACEMENT OF PARTS
16.1
REPLACEMENT OF PARTS
NOTE:
18.2
18.1
SERVICING
& SPARES
19.2
19.1
49
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
REPLACEMENT OF PARTS
20.1
REPLACEMENT OF PARTS
20.2
Pressure gauge
21.1
22.1
SERVICING
& SPARES
23.1
23.2
50
REPLACEMENT OF PARTS
24.1
REPLACEMENT OF PARTS
NOTE:
Remove the syphon assembly.
To release the syphon from the sump connection,
pull towards you (A).
Disconnect the discharge hose (B) at the
plumbing manifold.
Remove the complete syphon assembly.
24.2
SERVICING
& SPARES
25.2
51
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
REPLACEMENT OF PARTS
REPLACEMENT OF PARTS
26.1
26.2
SERVICING
& SPARES
27.2
52
REPLACEMENT OF PARTS
REPLACEMENT OF PARTS
28.1
NOTE: Remove the Hydraulic block from the
boiler (Refer to page 51).
28.2
29.1
29.2
29.3
SERVICING
& SPARES
Removing boiler
Isolate electrical supply.
Isolate system and gas connections at the
service valves.
Drain boiler.
Disconnect electrical supply and any external
controls.
Disconnect flue connection from the boiler.
Undo connection to boiler at the service valves.
Remove clip from expansion vessel
connection to the boiler.
Gently raise the boiler off the mounting frame.
Replace expansion vessel and refit the boiler
to the mounting frame.
Follow the commissioning procedure in this
manual.
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
REPLACEMENT OF PARTS
53
THIS PAGE SHOWS THE SETTING PROCEDURE FOR THE SIT VALVE
FOR ALTERNATIVE VALVES SEE PAGE 55 FOR DUNGS.
Max
B
Min
C
30.1
30.2
30.3
Max
B
Gas type
CO2 setting
maximum
CO2 setting
minimum
Natural gas
9.8% 0.5%
9.2% 0.5%
LPG
SERVICING
& SPARES
30.5
Min
C
54
REPLACEMENT OF PARTS
30.1
30.2
30.3
Natural gas
LPG
30.4
30.5
9.8% 0.5%
9.2% 0.5%
SERVICING
& SPARES
A
B
55
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
REPLACEMENT OF PARTS
8
4
11
10
12
7
14
13
15
16
10
11
12
13
18
17
19
20
14
15
16
21
23
22
24
SERVICING
& SPARES
17
18
19
25
26
27
20
21
22
F1
F2
F3
23
24
25
26
27
Fan
WORCESTER Part No.
GC No.
Burner
WORCESTER Part No.
GC No.
Gas valve NG & LPG
WORCESTER Part No.
GC No.
Control board
WORCESTER Part No.
GC No.
56
REPLACEMENT OF PARTS
1.1
1.2
L. P. G. CONVERSION
I S O LATE
MAI N S
E LE CTR I C AL
SUPPLY AND REMOVE OUTER CASE
AS SHOWN IN THE INSTALLATION,
C O M M I S S I O N I N G & S E RVI C I N G
INSTRUCTIONS
2.1
2.2
2.3
2. Gas valve
3.1
3.2
CONVERSION
KITS
3. Code plug
Code plugs
24kW NG
24kW LPG
100
101
28kW NG
28kW LPG
102
103
TH E AI R / GAS R ATI O M U ST B E
R ESET AFTE R CONVE R SION. TH E
P R O C E D U R E C AN B E F O U N D I N
S ET TI N G TH E AI R / GAS R ATI O
SECTION OF THIS MANUAL.
57
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
LPG CONVERSION
FAULT FINDING
NOTE : This fault finding information is for guidance only. Worcester cannot be held responsible for costs incurred by persons not deemed
to be competent.
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. not a 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 remaking of electrical connections, check
(a) EARTH CONTINUITY, (b) SHORT CIRCUIT CHECK, (c) POLARITY and (d) RESISTANCE TO EARTH.
Blue light
indication
Lockout reset
button
Fault
Possible solution/check
Off
Off
On
Off
Boiler operating
without live demand at
ST10-LR (from external
roomstat timer).
Fan.
Control board.
Ignition lockout
Flue overheat
Water pressure.
All air vented.
Pump / harness / connections.
Water leaks / blockages.
Safety thermostats / low voltage wiring harness / connections.
Otherwise replace control board.
Flue blockage
Slow flash
(normally off,
flashes on)
Slow flash
(normally on,
FAULT FINDING
& DIAGRAMS
flashes off)
Fast flash
Off
Volatile lockout
Fast flash
2 pulses
5 pulses
Flashing
No light
No light
Internal fault
Not a fault code
58
FAULT FINDING
BLUE
LIGHT
ON
FAULT FINDING
& DIAGRAMS
POWER
SWITCH
ON
Room
thermostat and/or
mains
programmer ON
(or link fitted at
ST10)
AND
Facia mounted
programmer (if fitted) ON
AND
CH control knob
ON
Fan to
start
speed.
LOCKOUT
YES
Diverter valve
in CH position
Pump ON.
CENTRAL
HEATING
DEMAND
3 minute wait
5th
attempt?
NO
Spark
ignition
4 seconds
Stop spark.
Wait
10 seconds
NO
BURNER
LIT?
IGNITION SEQUENCE
IGNITION
SEQUENCE
(see detail)
GREEN
FLAME
LIGHT
ON
YES
10 second
stabilisation
period.
Gas valve
OFF
Pump run 3
minutes
Fan run 30
seconds
END OF
BOILER
DEMAND
59
BLUE
LIGHT
ON
POWER
SWITCH
ON
FAULT FINDING
& DIAGRAMS
ECO button
not
illuminated *
(ie preheat
requested)
AND
20 minutes
since last preheat demand
AND
temperature
at least 10
below set
point.
Tap open
(recognised
by flow
turbine)
Diverter valve
in DHW
position
Pump ON.
LOCKOUT
PREHEAT
DEMAND
DOMESTIC
HOT
WATER
DEMAND
(priority over
all other
demands)
Wait
5 seconds
YES
IGNITION
SEQUENCE
(see detail)
60
5th
attempt?
NO
Spark
ignition
4 seconds
Stop spark.
Wait
10 seconds
NO
BURNER
LIT?
IGNITION SEQUENCE
Fan to
start
speed.
YES
GREEN
FLAME
LIGHT
ON
Gas valve
OFF
Stop pump
Stop fan
DEMAND
END
Gas valve
OFF
Pump run 3
minutes
Fan run 30
seconds
DEMAND
END
PROTECTION FUNCTION
Run autofroststat
function
Pump antiseize
FAULT FINDING
& DIAGRAMS
Boiler temperature
below 8C
61
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior
8 716 115 166b (03/2009)
PROTECTION FUNCTION
Pack Number
Refit the link between Ls and LR on terminal block ST 10. If the boiler functions correctly, the problem may be with the external thermostat or the
wiring of it.
No Hot water
Are the domestic hot and cold pipes crossed?
Check 1: If the boiler has a built in filling loop.
1. Close the 15mm cold inlet bulkhead valve with a screwdriver.
2. Open a hot tap (no water should flow from the open tap).
3. Insert filling key into filling link.
4. Open valve to fill system.
If it is still possible to re-pressurise the sealed system, the domestic
hot and cold pipes are crossed.
General checks
1. Is all the air bled from the gas supply?
2. Is all the air bled from the primary water system?
3. Is there 230v ac across the boiler live and neutral terminals?
(L & N on ST10)
4. Is the polarity correct?
5. Is the incoming gas pressure at least 18mbar with the boiler at maximum
output?
www.worcester-bosch.co.uk
8 716 115 166b (03/2009)
CONTACT INFORMATION
WORCESTER, BOSCH GROUP:
TECHNICAL:
08705 266241
SERVICE:
08457 256206
SPARES:
01905 752571
LITERATURE:
01905 752556
TRAINING:
01905 752526
SALES:
01905 752640
WEBSITE: www.worcester-bosch.co.uk