Bosch Worcester GREENSTAR 12i System User manual

THE APPLIANCE IS FOR USE WITH
NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13 & C33)
NATURAL GAS:
WORCESTER GREENSTAR 12i System GC NUMBER 41-311-67
WORCESTER GREENSTAR 24i System GC NUMBER 41-311-68
LIQUID PETROLEUM GAS:
WORCESTER GREENSTAR 12i System GC NUMBER 41-311-69
WORCESTER GREENSTAR 24i System GC NUMBER 41-311-70
GB/IE

WORCESTER BOSCH:
TECHNICAL: 08705 266241
SERVICE: 08457 256206
SPARES: 01905 752571
LITERATURE: 01905 752556
TRAINING: 01905 752526
SALES: 01905 752640
WEBSITE: www.worcester-bosch.co.uk
WATER TREATMENT:
FERNOX 01799 550811
www.fernox.com
SENTINEL 0151 420 9595
www.betzdearborn.com/sentinel
FLUE TERMINAL GUARD:
TOWER FLUE COMPONENTS
VALE RISE
TONBRIDGE
TN9 1TB
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
THESE INSTRUCTIONS ARE APPLICABLE TO THE WORCESTER BOSCH 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.
THE INSTRUCTIONS APPLY IN THE UK ONLY AND MUST BE FOLLOWED EXCEPT FOR ANY
STATUTORY OBLIGATION.
THIS APPLIANCE MUST BE INSTALLED BY A COMPETENT PERSON. FAILURE TO INSTALL
CORRECTLY COULD LEAD TO PROSECUTION.
IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER BOSCH TECHNICAL HELPLINE.
DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER
BOSCH.
PLEASE LEAVE THESE INSTRUCTIONS, THE USER GUIDE AND THE COMPLETED
BENCHMARK CHECKLIST OR A CERTIFICATE CONFIRMING COMPLIANCE WITH IS 813
(EIRE ONLY) WITH THE USER OR AT THE GAS METER AFTER INSTALLATION OR
SERVICING.
ABBREVIATIONS USED IN THIS MANUAL:
Ø Diameter
NG Natural Gas
LPG Liquid Petroleum Gas
CH Central Heating
DHW Domestic Hot Water
IP Ingress Protection
SEDBUK Seasonal Efficiency of Domestic Boilers in the United Kingdom
CONTACT INFORMATION INSTALLATION & SERVICING INSTRUCTIONS
SYMBOLS USED IN THIS MANUAL:
LIFTING AND CARRYING PRECAUTIONS:
• Lift only a manageable weight, or ask for
help.
• When lifting the boiler, bend the knees,
and keep the back straight and feet apart.
• Do not lift and twist at the same time.
• Lift and carry the boiler close to the body
• Wear protective clothing and gloves to
protect from any sharp edges
INSTALLATION &
SERVICING INSTRUCTIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System
8 716 107 375a (02/05)
1
STORE THE APPLIANCE IN A DRY
AREA PRIOR TO INSTALLATION.

SAFETY & REGULATIONS
SAFETY PRECAUTIONS & SYMBOLS 3
INSTALLATION REGULATIONS 3
APPLIANCE INFORMATION
GENERAL INFORMATION 4
TECHNICAL DATA 5
LAYOUT & COMPONENTS 6-7
PRE-INSTALLATION
CLEANING PRIMARY SYSTEMS 8
MAINS SUPPLY 9
WATER SYSTEMS & PIPEWORK 10
CONDENSATE PIPEWORK 11
PRESSURE RELIEF PIPEWORK 12
BOILER LOCATION & CLEARANCES 13-14
PLUMBING MANIFOLD 15
FLUE TERMINAL POSITIONS 16
FLUE OPTIONS 17
INSTALLATION
UNPACKING THE WALL FRAME 18
WALL MOUNTING TEMPLATE / FLUE OPENING 19
UNPACKING THE APPLIANCE 20
BOILER CONNECTIONS 21-22
FLUE INSTALLATION 23-25
CONDENSATE CONNECTION 26
ELECTRICAL 27
POSITION OF WIRED COMPONENTS 28
COMMISSIONING
PRE-COMMISSIONING CHECKS 29
FILLING THE SYSTEM 30
STARTING THE APPLIANCE 31
WATER TREATMENT 32
COMMISSIONING 33
FINISHING COMMISSIONING 34
SERVICING & SPARES
INSPECTION AND SERVICE 35-40
REPLACEMENT OF PARTS 41-50
SETTING THE GAS /AIR RATIO 51
SHORT PARTS LIST 52
CONVERSION KITS
L.P.G. CONVERSION 53-54
FAULT FINDING & DIAGNOSIS
FAULT FINDING 55
CH FUNCTION 56
PROTECTION FUNCTION 57
ADDITIONAL INSTRUCTIONS FOR FITTING OPTIONAL DIVERTER VALVE CAN BE
FOUND AT THE REAR OF THIS MANUAL
CONTENTS
CONTENTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System
8 716 107 375a (02/05)
2
SAFETY &
REGULATIONS
APPLIANCE
INFORMATION
PRE -
INSTALLATION
INSTALLATIONCOMMISSIONING
SERVICING
& SPARES
CONVERSION
KITS
FAULT FINDING
& DIAGRAMS

SAFETY PRECAUTIONS INSTALLATION REGULATIONS
IF YOU SMELL GAS:
✗DON’T SMOKE OR STRIKE MATCHES
✗DON’T TURN ELECTRICAL SWITCHES ON OR OFF
✓DO PUT OUT NAKED FLAMES
✓DO OPEN DOORS AND WINDOWS
✓DO KEEP PEOPLE AWAY FROM THE AREA AFFECTED
✓DO TURN OFF THE CONTROL VALVE AT THE METER
✓DO CALL YOUR GAS COMPANY
A Benchmark Checklist is provided by the manufacturer for the installer to complete
including their CORGI registration number to confirm that the boiler has been installed,
commissioned and serviced according to the manufacturer’s instructions.
IMPORTANT: The completed Benchmark Checklist will be required in the event of any
warranty work and may be required by the local Building Control Inspector.
HEALTH & 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).
COMBUSTIBLE 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, such as halogenated hydrocarbons containing
chlorine or fluorine compounds can corrode the appliance and invalidate any warranty.
FITTING & MODIFICATIONS
Fitting the appliance and any controls to the appliance may only be carried out by a
competent engineer in accordance with the Gas Safety (Installation and Use)
Regulations 1998.
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 competent, qualified
engineer (such as British Gas or CORGI registered personnel) using approved spares,
to help maintain the economy, safety and reliability of the appliance.
IMPORTANT - The service engineer must complete the Service Record on the
Benchmark Checklist after each service.
Gas Safety (Installation & Use) Regulations 1998:
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 & Safety
Document 635 (The Electricity at Work
Regulations 1989) and any other local
requirements.
British Standards:
The relevant British Standards should be followed,
including:
BS7074:1 : Code of practice for domestic and hot
water supply
BS6891 : Installation of low pressure gas
pipework up to 28mm (R1)
BS5546 : Installation of gas hot water supplies for
domestic purposes
EN:12828 : Central heating for domestic premises
BS5440:1 : Flues and ventilation for gas appli-
ances of rated heating not exceeding 70kW (net) :
Flues
BS5440:2 : Flues and ventilation for gas appli-
ances of rated heating not exceeding 70kW (net) :
Air Supply
BS7593 : Treatment of water in domestic hot
water central heating systems
BS 6798 : Installation of gas fired boilers of rated
input up to 70kW (net)
Where no specific instruction is given, reference
should be made to the relevant British Standard
codes of Practice.
L.P.G. Installation:
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 buildings:
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.
SAFETY PRECAUTIONS
& INSTALLATION REGULATIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System
8 716 107 375a (02/05)
3
SAFETY &
REGULATIONS

GENERAL INFORMATION
STANDARD PACKAGE:
A - Wall hung gas fired condensing boiler for
central heating and indirect domestic hot water
B - Boiler support frame/pre-plumbing jig
C -Hardware literature pack
D - Bottom Panel
SPECIFICATIONS:
Pre-wired and pre-plumbed
Galvanised steel inner frame
Digital control system
Automatic ignition
Direct burner ignition electrodes
Built-in frost thermostat
Built-in fault finding diagnostics
Modulating automatic gas valve
Combustion air fan with speed regulator
CH temperature sensor & control
Pump anti-seizure protection
Flue gas temperature limiter
Condensate trap & syphon
700mm
400mm
A
D
330mm
GENERAL INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System
8 716 107 375a (02/05)
4
APPLIANCE
INFORMATION
B
C
D
(When fitted to wall frame)
Depth to wall