Worcester Greenstar 12i System ErP User manual

UK/IE
THIS BOILER IS USED WITH
NATURAL GAS OR LPG (Cat II 2H3P TYPE C13, C33 & C53)
NATURAL GAS 12i System GC NUMBER: 41 311 67
24i System GC NUMBER: 41 311 68
LIQUID PETROLEUM GAS 12i System GC NUMBER: 41 311 69
24i System GC NUMBER: 41 311 70
INSTRUCTION MANUAL
INSTALLATION, COMMISSIONING & SERVICING
WALL HUNG RSF GAS FIRED CONDENSING BOILER
FOR SEALED CENTRAL HEATING SYSTEMS AND INDIRECT FED
DOMESTIC HOT WATER
GREENSTAR 12i/24i System

INSTALLATION &
SERVICING INSTRUCTIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System
8 716 115 167b (03/2009)
2
WATER TREATMENT:
FERNOX 01799 550811
www.fernox.com
SENTINEL 0800 389 4670
www.sentinel-solutions.net
FLUE TERMINAL GUARDS:
TOWER FLUE COMPONENTS LTD.
Vale Rise, Tonbridge TN9 1TB
01732 351555

SAFETY & REGULATIONS
INSTALLATION & SERVICING INSTRUCTIONS 2
SAFETY PRECAUTIONS & SYMBOLS 4
INSTALLATION REGULATIONS 4
APPLIANCE INFORMATION
GENERAL INFORMATION 5
TECHNICAL DATA 6
LAYOUT & COMPONENTS 7
PRE-INSTALLATION
CLEANING PRIMARY SYSTEMS 9
MAINS SUPPLY 10
WATER SYSTEMS & PIPEWORK 11
CONDENSATE PIPEWORK 12
PRESSURE RELIEF PIPEWORK 13
BOILER LOCATION & CLEARANCES 14
PLUMBING MANIFOLD 16
FLUE OPTIONS 17
FLUE TERMINAL POSITIONS 18
INSTALLATION
UNPACKING THE WALL FRAME & ANCILLARY ITEMS 20
WALL MOUNTING TEMPLATE / FLUE OPENING 21
UNPACKING THE APPLIANCE 22
BOILER CONNECTIONS 23
FLUE INSTALLATION 25
CONDENSATE CONNECTION 28
ELECTRICAL 29
POSITION OF WIRED COMPONENTS 30
COMMISSIONING
PRE-COMMISSIONING CHECKS 31
FILLING THE SYSTEM 32
STARTING THE APPLIANCE 33
WATER TREATMENT 34
COMMISSIONING 35
FINISHING COMMISSIONING 36
SERVICING & SPARES
INSPECTION AND SERVICE 37
REPLACEMENT OF PARTS 43
SETTING THE AIR/GAS RATIO 53
SHORT PARTS LIST 55
CONVERSION KITS
L.P.G. CONVERSION 56
FAULT FINDING & DIAGNOSIS
FAULT FINDING 57
BOILER FUNCTION 58
PROTECTION FUNCTION 59
ADDITIONAL INSTRUCTIONS FOR FITTING OPTIONAL DIVERTER VALVE CAN BE
FOUND AT THE REAR OF THIS MANUAL
BENCHMARK CHECKLIST
SERVICE INTERVAL RECORD SHEET
CONTENTS
CONTENTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System
8 716 115 167b (03/2009)
3
SAFETY &
REGULATIONS
APPLIANCE
INFORMATION
PRE -
INSTALLATION
INSTALLATIONCOMMISSIONING
SERVICING
& SPARES
CONVERSION
KITS
FAULT FINDING
& DIAGRAMS

SAFETY PRECAUTIONS
& INSTALLATION REGULATIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System
8 716 115 167b (03/2009)
4
SAFETY &
REGULATIONS
SAFETYPRECAUTIONS
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~ORCESTER
BoschGroup

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
E - Fascia panel
F - Syphon assembly
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
GENERAL INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System
8 716 115 167b (03/2009)
5
APPLIANCE
INFORMATION
700mm*
400mm
A
330mm
B
C
D
(When fitted to wall frame)
Depth to wall
Check List
Hardware/Literature pack
Item Qty
Greenstar 12i/24i System 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Compression Ring 15mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fibre Washer 23.9 x 17.2 x 1.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Bonded Washer 3/4For Gas Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Syphon assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Installation instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Irish Guidelines Leaflet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Warranty Return Envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
E
F
*710mm to top of case front

TECHNICAL DATA INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System
8 716 115 167b (03/2009)
6
TECHNICAL DATA
APPLIANCE
INFORMATION
DESCRIPTION NATURAL L.P.G.
UNITS 12i 24i 12i 24i
Gas flow rate - Maximum 10 minutes from lighting
Natural Gas G20 m3/h 1.33 2.67 - -
Propane Gas (LPG) kg/h - - 0.96 1.91
Central Heating
Max. rated heat input kW 12.32 24.62 12.32 24.62
Min. heat input kW 3.70 7.38 5.95 9.64
Max. rated heat output 40/30°C kW 12.85 25.67 12.85 25.67
Max. rated heat output 50/30°C kW 12.74 25.45 12.74 25.45
Max. rated heat output 80/60°C kW 12 24 12 24
Max. flow temperature °C 82 82 82 82
Max. flow temperature to cylinder (with integral optional diverter valve) °C 75 75 75 75
Max. permissible operating pressure bar 2.5 2.5 2.5 2.5
Available pump head at 21°C system temperature rise m 2.0 2.0 2.0 2.0
Flue
Flue Gas Temp. 80/60°C, rated/min. load °C 62/56 78/63 62/57 79/64
Flue Gas Temp. 40/30°C, rated min. load °C 41/33 54/35 43/35 55/38
CO2level at max. rated heat output (after 30 mins) % 9.8 9.8 11.0 11.0
CO2level at min. rated heat output (after 30 mins) % 9.2 9.2 10.5 10.5
NOx - class 5 5 5 5
Condensate
Max. condensation rate l/h 0.93 2.0 0.7 1.5
pH value, approx. 4.8 4.8 4.8 4.8
Electrical
Electrical power supply voltage AC...V 230 230 230 230
Frequency Hz 50 50 50 50
Max. power consumption W 140 140 140 140
General Data
SEDBUK band A A A A
Appliance protection rating IP X4D X4D X4D X4D
Appliance protection rating with mechanical or
RF mechanical timer fitted
IP 20 20 20 20
Permissible ambient temperatures °C 0-50 0-50 0-50 0-50
Nominal capacity of appliance Iitres 3.9 3.9 3.9 3.9
Noise output level (Max central heating) dB(A) 42 42 42 42
Packaged boiler weight kg 44.4 44.4 44.4 44.4
Total boiler weight kg 39.5 39.5 39.5 39.5
Lift weight kg 27.1 27.1 27.1 27.1
SEDBUK % 90.1 90.2 91.4 92.0

LAYOUT & COMPONENTS
The diagram opposite shows the controls in the
servicing position and excludes the outer case.
1 AIR / GAS MANIFOLD
2 SENSOR - BOILER FLOW
3 IGNITION AND FLAME SENSE ELECTRODES
4 OVERHEAT THERMOSTAT
5 RETAINING BRACKET
6 EXPANSION VESSEL
7 REMOVABLE TOP CASE PANEL FOR
SERVICING
8 SECURING NUT, AIR / GAS
MANIFOLD CLAMP
9 HEAT EXCHANGER
10 WALL MOUNTING FRAME
11 FLUE AIR PRESSURE SWITCH
CONNECTION (BLANKED OFF ON THIS
APPLIANCE)
12 FLUE OVERHEAT THERMOSTAT
13 ACCESS POINT FOR CLEANING HEAT
EXCHANGER/SUMP
14 SYSTEM PRESSURE GAUGE
15 DRAIN POINT
16 RETURN
17 CONTROL PANEL IN SERVICE POSITION
18 COVER FOR EXTERNAL WIRING
CONNECTIONS
19 GAS INLET CONNECTION 22mm
COMPRESSION
20 FLOW
21 ACCESS COVER FOR TRANSFORMER &
PCB
22 PUMP
23 GAS VALVE
24 FAN
25 MANUAL VENT POINT
26 FAN PRESSURE TEST POINT
LAYOUT & COMPONENTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System
8 716 115 167b (03/2009)
7
APPLIANCE
INFORMATION

LAYOUT & COMPONENTS
27 AUTO AIR VENT
28 UNUSED PORT
29 COMPACT HYDRAULIC MOUNTING
SCREW (2) TO BOILER
30 PRESSURE RELIEF VALVE
31 OPTIONAL INTEGRAL DIVERTER VALVE
POSITION
32 RETURN CONNECTION TO
SERVICE VALVE
33 DRAIN POINT
34 SYSTEM PUMP
35 FLOW CONNECTION TO
SERVICE VALVE
36 FLOW CONNECTION FROM BOILER
HEAT EXCHANGER
37 EXPANSION TANK CONNECTION
38 SYSTEM PRESSURE GAUGE
39 FAULT RESET BUTTON
40 NOT USED
41 MAINS ON/OFF INDICATOR/
DIAGNOSTIC LIGHT (BLUE)
42 CH TEMPERATURE CONTROL
43 POSITION FOR OPTIONAL
PROGRAMMER
44 SERVICE MODE BUTTON
45 BURNER ON INDICATOR LIGHT (GREEN)
46 MASTER SWITCH ON/OFF
LAYOUT & COMPONENTS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System
8 716 115 167b (03/2009)
8
APPLIANCE
INFORMATION

CLEANING PRIMARY SYSTEMS
IMPORTANT: All the following Pre-Installation sections must be read and
requirements met before starting boiler or flue installation.
CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND
OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.
CLEANING PRIMARY SYSTEMS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System
8 716 115 167b (03/2009)
9
PRE -
INSTALLATION
BEFORE CLEANING THE SYSTEM:
ENSURE THE SYSTEM AND PIPEWORK
IS IN GOOD WORKING ORDER
WHERE POSSIBLE KEEP THE EXISTING
BOILER/CIRCULATING PUMP IN PLACE
WHEN FLUSHING THE SYSTEM.
FOLLOW GUIDANCE OF BS7593:
TREATMENT OF WATER IN DOMESTIC
HOT WATER CENTRAL HEATING AND
ALSO FLUSHING GUIDELINES SET OUT
BELOW.
CLEANING THE PRIMARY SYSTEM:
IMPORTANT: ARTIFICIALLY SOFTENED
WATER MUST NOT BE USED TO FILL THE
CENTRAL HEATING SYSTEM
• Fill the system with cold water and
check for leaks.
• Open all drain cocks and drain the
system.
• Close drain cocks and add a suitable
flushing agent compatible with
aluminium at the correct strength for
the system condition 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.
• Circulate the flushing agent before the
boiler is fired up.
• Run the boiler/system at normal operating
temperature as directed by the manufacturer
of the flushing agent.
• Drain and thoroughly flush the system to
remove the flushing agent and debris.
• It may be necessary to use a power flushing
machine to aid the cleansing procedure in
some circumstances
IMPORTANT: 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.

MAINS SUPPLY
ELECTRIC SUPPLY:
• Supply: 230V - 50Hz, 140 watts
• Cable: PVC insulated 0.75mm2(24 x 0.2mm)
temperature rated to 90°C.
• 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.
• 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.
24 iSystem
• Under no circumstances should the size of
the gas supply pipe be less than 22mm.
GAS SUPPLY PIPE SIZING
12 iSystem models
Provided that the correct gas supply working
pressure and gas rate can be achieved (see
technical data on page 6, commissioning sec-
tion page 35, also refer to B.S. 6891)
Then it may be possible to reduce the gas
supply pipe diameter to 15mm.
Generally the appliance would need to be within
3 to 4 metres of the gas meter. However, this
will depend upon the distribution pipe size and
route.
MAINS SUPPLY INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System
8 716 115 167b (03/2009)
10
PRE -
INSTALLATION