Beruflich Dokumente
Kultur Dokumente
GREENSTAR 25Si/30Si
FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED
DOMESTIC HOT WATER
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
SAFETY PRECAUTIONS
INSTALLATION REGULATIONS
4
APPLIANCE
INFORMATION
APPLIANCE INFORMATION
GENERAL INFORMATION
TECHNICAL DATA
PRE-INSTALLATION
9
10
11
CONDENSATE PIPEWORK
12
13
14
PLUMBING MANIFOLD
16
FLUE OPTIONS
17
18
INSTALLATION
MAINS SUPPLY
PRE INSTALLATION
INSTALLATION
20
21
22
BOILER CONNECTIONS
23
FLUE INSTALLATION
25
CONDENSATE CONNECTION
28
ELECTRICS
29
30
COMMISSIONING
PRE-COMMISSIONING CHECKS
31
32
33
WATER TREATMENT
34
COMMISSIONING
35
FINISHING COMMISSIONING
36
SERVICING
& SPARES
COMMISSIONING
37
REPLACEMENT OF PARTS
43
54
56
CONVERSION
KITS
L.P.G. CONVERSION
FAULT FINDING
& DIAGRAMS
CONVERSION KITS
57
58
59
60
PROTECTION FUNCTION
61
BENCHMARK CHECKLIST
SERVICE RECORD
3
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si
8 716 115 165b (03/2009)
CONTENTS
SAFETY &
REGULATIONS
4
SAFETY PRECAUTIONS
& INSTALLATION REGULATIONS
Depth to wall
(When fitted to wall frame)
GENERAL INFORMATION
APPLIANCE
INFORMATION
330mm
700mm*
400mm
C
STANDARD PACKAGE:
F - Syphon assembly
Check List
Hardware/Literature pack
Item
Qty.
Greenstar 25Si / 30Si Installation/Servicing Instructions.....................1
Users Instructions ..........................................................................................1
Consumer Guarantee Card .........................................................................1
Sealing Pack...................................................................................................1
Compression Nut 22mm ....................................................................... 3
Compression Ring 22mm ..................................................................... 3
Compression Nut 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
SPECIFICATIONS:
5
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si
8 716 115 165b (03/2009)
GENERAL INFORMATION
TECHNICAL DATA
DESCRIPTION
L.P.G.
UNIT
KW
25Si
7.38
30Si
7.38
25Si
9.64
30SI
9.64
KW
25
30
25
30
KW
25.51
30.61
25.51
30.61
m3/h
2.7
3.24
kg/h
1.98
2.38
bar
10
10
10
10
bar
1.3
1.3
bar
0.2
0.2
0.2
0.2
40-60
40-60
40-60
40-60
l/min
12
14.3
12
14.3
l/min
10.8
10.8
Central Heating
Max. rated heat input
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
APPLIANCE
INFORMATION
NATURAL GAS
82
82
82
82
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
78/65
78/66
79/66
79/67
54/37
54/38
55/40
55/41
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
Itr
3.9
3.9
3.9
3.9
dB(A)
42
42
42
42
kg
44.4
44.4
44.4
44.4
kg
kg
39.5
27.1
39.5
27.1
39.5
27.1
39.5
27.1
SEDBUK
90.1
90.1
91.8
91.8
General Data
SEDBUK
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 25Si/30Si
8 716 115 165b (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 DHW TEMPERATURE CONTROL
50 MAINS ON/OFF INDICATOR/
DIAGNOSTIC LIGHT (BLUE)
51 CH TEMPERATURE CONTROL
52 POSITION FOR OPTIONAL
PROGRAMMER
53 SERVICE MODE BUTTON
54 BURNER ON INDICATOR LIGHT (GREEN)
55 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 25Si/30Si
8 716 115 165b (03/2009)
MAINS SUPPLY
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.
PRE INSTALLATION
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 22mm.
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 25Si,
2.0 bar 30Si, 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 25Si/30Si
8 716 115 165b (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
L - Outside wall
O,M - Drain pipe
N - External drain
O
N
13
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si
8 716 115 165b (03/2009)
PRE INSTALLATION
Vent
position
25 & 30 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
A boiler with a mechanical timer or RF mechanical timer with room thermostat must only be
installed outside the shaded area.
1
2
PRE INSTALLATION
1
2
15
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si
8 716 115 165b (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
Use the fittings supplied in the Lit/Hardware
pack.
CH Flow 22mm
PRE INSTALLATION
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
25 Si
2,600mm
11,000mm
30 Si
2,600mm
11,000mm
100mm
125mm
25 Si
570mm
1,070mm
30 Si
570mm
1,070mm
Maximum total flue length
100mm
125mm
25 Si
N/A
9,000mm
30 Si
N/A
9,000mm
PRE INSTALLATION
125mm
25 Si
4,600mm 13,000mm
25 Si
30 Si
4,600mm 13,000mm
30 Si
125mm
6,400mm 15,000mm
6,400mm 15,000mm
125mm
25 Si
4,400mm 13,000mm
100mm
30 Si
4,400mm 13,000mm
125mm
25 Si
4,600mm 13,000mm
30 Si
4,600mm 13,000mm
125mm
25 Si
2,400mm
11,000mm
30 Si
2,400mm
11,000mm
100mm
125mm
25 Si
2,600mm
11,000mm
30 Si
2,600mm
11,000mm
17
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si
8 716 115 165b (03/2009)
FLUE OPTIONS
PRE INSTALLATION
18
FLUE TERMINAL POSITIONS
PRE INSTALLATION
19
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si
8 716 115 165b (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
B - Outer carton
A
C - Installer pack
D - Bottom panel
E - Wall mounting frame
F - Wall template
G - Inner packaging
H - Front fascia
J - Syphon assembly
INSTALLATION
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 25Si/30Si
8 716 115 165b (03/2009)
A - Outer carton
5
B
B
C
6.1
E
INSTALLATION
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.
E
B
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.
2
INSTALLATION
2&4
1A
15mm
22mm
bonded
washer
15mm
22mm
23
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si
8 716 115 165b (03/2009)
BOILER CONNECTIONS
BOILER CONNECTIONS
INSTALLATION
J
G
A
22mm
15mm
22mm
15mm
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 25Si/30Si
8 716 115 165b (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 25Si/30Si
8 716 115 165b (03/2009)
FLUE INSTALLATION
SUMP
CONNECTION
CONDENSATE CONNECTION
1
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
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
neutral
live
230V
MAINS
SUPPLY
brown
blue
5
green/yellow
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)
F1
6 Refit panels.
29
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si
8 716 115 165b (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
Pre-plumbing manifold
connector
31
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si
8 716 115 165b (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 - DHW temperature control
H - ECO button
I - System pressure gauge
J - Cover or optional programmer
COMMISSIONING
33
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si
8 716 115 165b (03/2009)
WATER TREATMENT
IMPORTANT: ARTIFICIALLY SOFTENED WATER
MUST NOT BE USED TO FILL THE CENTRAL
HEATING SYSTEM.
COMMISSIONING
34
WATER TREATMENT
COMMISSIONING
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 - DHW and pre-heat temperature control
H - ECO button
I - System pressure gauge
J - Cover or optional programmer
DUNGS VALVE
COMMISSIONING
COMMISSIONING
35
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).
2. FITTING FASCIA FLAP:
Present the flap up to the appliance with the hinge pins
facing the appliance.
Engage the left hand pin into the grey pivot. The hinge
pin and pivot hole are both square, rotate the flap to
ensure that the pin is located in the pivot.
Support the flap in your left hand and with your right
hand, bend the right side down. This should enable
you to engage the right hand pin in the pivot. Rotate
the flap to ensure that the pins and pivots are located
securely.
Close the flap.
A
A
COMMISSIONING
HANDOVER:
Complete the Benchmark Gas Boiler Commissioning
Checklist.
NOTE: The Benchmark Checklist can be found at the
rear of these instructions.
C
A
D
C
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 25Si/30Si
8 716 115 165b (03/2009)
1.
1.1
1.2
1.
B
1.3
2.1
SERVICING
& SPARES
2.2
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 - DHW and pre-heat temperature
control
H - ECO button
I - System pressure gauge
J - 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.
1
J
SERVICING
& SPARES
2
B
39
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si
8 716 115 165b (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
1
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.
2
E
3
40
INSPECTION AND SERVICE
H
4
5
6
7
8
6
SERVICING
& SPARES
41
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si
8 716 115 165b (03/2009)
R
9
Small
tab
8
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
43
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si
8 716 115 165b (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
A
7
8. PCB fuse
Remove fuseholder with fuse F1 (B)
from the PCB and replace a new fuse.
There is a spare fuse clipped into the
underside of the electrical cover.
9.Transformer / PCB
Disconnect all electrical connections from
the control.
Remove 4 screws (D) retaining the rear
panel of the control and remove panel.
SERVICING
& SPARES
45
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si
8 716 115 165b (03/2009)
REPLACEMENT OF PARTS
REPLACEMENT OF PARTS
10
B
10.1
C
C
C
10.2
F
E
SERVICING
& SPARES
12.3
46
REPLACEMENT OF PARTS
REPLACEMENT OF PARTS
11.1
A
11.2
B
11.3
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 25Si/30Si
8 716 115 165b (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
REPLACEMENT OF PARTS
16.1
NOTE:
Removal of the syphon assembly will give access
to Auto air vent.
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.
17.1
18.1
18.2
19.1
SERVICING
& SPARES
19.2
49
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si
8 716 115 165b (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
25.1
25.2
51
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si
8 716 115 165b (03/2009)
REPLACEMENT OF PARTS
REPLACEMENT OF PARTS
26.1
NOTE: Remove the Hydraulic block from the
boiler (See removing the Hydraulic
Block on page 51).
26.2
27.1
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.
53
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si
8 716 115 165b (03/2009)
REPLACEMENT OF PARTS
THIS PAGE SHOWS THE SETTING PROCEDURE FOR THE SIT VALVE
FOR ALTERNATIVE VALVE SEE PAGE 55 DUNGS.
Max
B
Min
C
30.1
30.2
30.3
Max
B
CO2 setting
maximum
CO2 setting
minimum
Natural gas
9.8% 0.5%
9.2% 0.5%
A
LPG
SERVICING
& SPARES
30.5
Min
C
54
REPLACEMENT OF PARTS
30.1
30.2
30.3
CO2 setting
minimum
9.2% 0.5%
CO2 setting
maximum
30.5
SERVICING
& SPARES
LPG
55
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si
8 716 115 165b (03/2009)
REPLACEMENT OF PARTS
10
11
10
11
12
17
18
19
20
13
14
15
16
21
23
22
24
SERVICING
& SPARES
17
18
19
25
26
27
20
21
F1
F2
F3
22
23
24
25
26
27
56
REPLACEMENT OF PARTS
Electrodes
WORCESTER Part No.
8 718 107 087 0
GC No.
H26 544
Gasket - burner/electrodes
WORCESTER Part No.
8 716 110 534 0
GC No.
799 403
Seal - inner case/mantel
WORCESTER Part No.
8 716 106 635 0
GC No.
H26 546
Flow reg. Type E 9 litre
WORCESTER Part No.
8 716 141 143 0
GC No.
324 823
Flow reg. Type E 11 litre
WORCESTER Part No.
8 716 107 044 0
GC No.
H22 460
Pressure relief valve DHW
WORCESTER Part No.
8 717 401 029 0
GC No.
H02 526
Pump assembly 3 speed
WORCESTER Part No.
8 716 106 355 0
GC No.
H02 527
Pressure gauge
WORCESTER Part No.
8 717 208 107 0
GC No.
H02 528
Flow sensor
WORCESTER Part No.
8 716 107 223 0
GC No.
H02 529
16
12
15
14
Control board
WORCESTER Part No.
GC No.
13
Fan
WORCESTER Part No.
GC No.
Burner
WORCESTER Part No.
GC No.
Gas valve NG & LPG
WORCESTER Part No.
GC No.
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
3.1
3.2
3. Code plug
A
CONVERSION
KITS
2. Gas valve
Code plugs
25kW NG
25kW LPG
104
105
30kW NG
30kW LPG
106
107
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.
LPG CONVERSION
57
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
POWER
SWITCH
ON
BLUE
LIGHT
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
CENTRAL
HEATING
DEMAND
Fan to
start
speed.
Diverter valve
in CH position
Pump ON.
IGNITION
SEQUENCE
(see detail)
GREEN
FLAME
LIGHT
ON
BURNER
LIT?
NO
59
FAULT FINDING
& DIAGRAMS
END OF
BOILER
DEMAND
5th
attempt?
Stop spark.
Wait
10 seconds
YES
Gas valve
OFF
Pump run 3
minutes
Fan run 30
seconds
NO
YES
10 second
stabilisation
period.
IGNITION SEQUENCE
Spark
ignition
4 seconds
LOCKOUT
3 minute wait
60
FAULT FINDING
& DIAGRAMS
Wait
5 seconds
Tap open
(recognised
by flow
turbine)
BLUE
LIGHT
ON
ECO button
not
illuminated *
(ie preheat
requested)
AND
20 minutes
since last preheat demand
AND
temperature
at least 10
below set
point.
DOMESTIC
HOT
WATER
DEMAND
(priority over
all other
demands)
Diverter valve
in DHW
position
Pump ON.
IGNITION SEQUENCE
PREHEAT
DEMAND
Spark
ignition
4 seconds
NO
YES
LOCKOUT
5th
attempt?
Gas valve
OFF
Pump run 3
minutes
Fan run 30
seconds
GREEN
FLAME
LIGHT
ON
IGNITION
SEQUENCE
(see detail)
Fan to
start
speed.
BURNER
LIT?
NO
Stop spark.
Wait
10 seconds
DEMAND
END
DEMAND
END
YES
Gas valve
OFF
Stop pump
Stop fan
POWER
SWITCH
ON
Over temperature
shut-down if water
temperature is 8C
above set value.
PROTECTION FUNCTION
Run autofroststat
function
Pump antiseize
FAULT FINDING
& DIAGRAMS
Boiler temperature
below 8C
61
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 25Si/30Si
8 716 115 165b (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 165b (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