Worcester Greenstar Ri User manual

Greenstar Ri
WALL HUNG GAS-FIRED BOILER
FOR OPEN VENT & SEALED CENTRAL HEATING SYSTEMS & INDIRECT FED DOMESTIC HOT WATER
USER INSTRUCTIONS &
CUSTOMER CARE GUIDE
THIS BOILER IS USED WITH
NATURAL GAS OR LPG (Cat II 2H3P TYPE C13, C33 & C53)
NATURAL GAS 12 Ri GC NUMBER: 41 311 63
15 Ri GC NUMBER: 41 311 75
18 Ri GC NUMBER: 41 311 77
24 Ri GC NUMBER: 41 311 65
LIQUID PETROLEUM GAS 12 Ri GC NUMBER: 41 311 64
15 Ri GC N U M B E R: 41 311 76
18 Ri GC N U M B E R: 41 311 78
24 Ri GC NUMBER: 41 311 66

CONTACT INFORMATION
WORCESTER BOSCH:
TECHNICAL: 08705 266241
SERVICE: 08457 256206
LITERATURE: 01905 752556
SALES: 01905 752640
WEBSITE: www.worcester-bosch.co.uk
USER INSTRUCTIONS & CUSTOMER
CARE GUIDE
PLEASE READ THESE INSTRUCTIONS
CAREFULLY BEFORE OPERATING
YOUR BOILER
THESE INSTRUCTIONS ARE
APPLICABLE TO THE WORCESTER,
BOSCH GROUP BOILER MODEL(S)
STATED ON THE FRONT COVER OF THIS
MANUAL ONLY AND MUST NOT BE
USED WITH ANY OTHER MAKE OR
MODEL OF BOILER.
THE INSTRUCTIONS APPLY IN THE UK
ONLY AND SHOULD BE FOLLOWED
EXCEPT FOR ANY STATUTORY
OBLIGATION.
IF YOU ARE IN ANY DOUBT CONTACT
THE WORCESTER, BOSCH GROUP
TECHNICAL SUPPORT.
DISTANCE LEARNING AND TRAINING
COURSES ARE AVAILABLE FROM
WORCESTER, BOSCH GROUP.
THIS BOILER MUST BE INSTALLED BY A
CORGI REGISTERED, COMPETENT
PERSON. FAILURE TO INSTALL
CORRECTLY COULD LEAD TO
PROSECUTION.
PLEASE LEAVE THIS GUIDE, THE
INSTALLATION INSTRUCTIONS AND
THE COMPLETED BENCHMARK
CHECKLIST WITH THE USER.
NOTE: THE BENCHMARK CHECKLIST
AND SERVICE INTERVAL RECORD CAN
BE FOUND AT THE REAR OF THE
INSTALLATION, COMMISSIONING AND
SERVICE INSTRUCTIONS.
ABBREVIATIONS USED IN THIS BOOK:
NG - Natural Gas
LPG - Liquid Petroleum Gas
CH - Central Heating
SEDBUK - Seasonal Efficiency of Domestic
Boilers in the United Kingdom
USER INSTRUCTIONS &
CUSTOMER CARE GUIDE
GREENSTAR Ri
8 716 115 172a (06/2008)

CONTENTS
GREENSTAR Ri
8 716 115 172a (06/2008) 1
CONTENTS
INTRODUCTION
DEDICATED TO HEATING COMFORT 1
SAFETY PRECAUTIONS 2
GENERAL NOTES 3
USING YOUR BOILER
CONTROLS 6
OPERATING THE BOILER 7
Switching the boiler on/off 7
Setting the central heating temperature 7
Controlling central heating 7
Frost protection 7
Fault condition 8
MAINTENANCE
MAINTAINING YOUR BOILER 9
FAULT FINDING 9
FAULT OR BREAKDOWN 10
GENERAL OPERATING NOTES 11
ENERGY SAVING
TIPS ON ENERGY SAVING 13
GUARANTEE
YOUR GUARANTEE 14
GUARANTEE REGISTRATION 15
INTRODUCTION
USING YOUR
BOILER
GUARANTEE
Dedicated to heating comfort
Thank you for purchasing a Greenstar gas-fired condensing boiler manufactured by
Worcester, Bosch Group. The company prides itself on manufacturing boilers to the strictest
quality control standards throughout every stage of production. Worcester, Bosch Group has
led the field in innovative boiler design and performance for more than 40 years. This
heritage means all products are of exceptional quality and proven reliability.
The Greenstar range in particular, is extremely energy efficient, offering low running costs
and value for money. It sits in SEDBUK band A, and is therefore amongst the top energy
rated boilers available.
There is also the reassurance of our no-nonsense 2 years parts and labour guarantee - backed
up by Worcester Total Cover, an optional complete maintenance scheme, to keep your boiler
operating at peak condition and efficiency.
To f i n d o u t m o r e a b o u t Wo r c e s t e r , B o s ch G r o u p l o g o n t o w w w. w o r c e s t e r - b o s c h . c o . u k .
ENERGY
SAVING MAINTENANCE

SAFETY PRECAUTIONS GREENSTAR Ri
8 716 115 172a (06/2008)
IF YOU SMELL GAS!
!DO NOT SMOKE OR STRIKE MATCHES
!DO NOT TURN ELECTRICAL SWITCHES ON OR OFF
"PUT OUT NAKED FLAMES
"OPEN DOORS AND WINDOWS
"KEEP PEOPLE AWAY FROM THE AREA AFFECTED
"TURN OFF THE CONTROL VALVE AT THE METER
"CALL YOUR GAS COMPANY
COMBUSTIBLE AND CORROSIVE MATERIALS
Do not store or use any combustible materials (paper, thinners, paints etc.) inside or within
the vicinity of the boiler.
Chemically aggressive substances can corrode the boiler and invalidate any warranty.
FITTING & MODIFICATIONS
Fitting the boiler and any controls to the boiler or removal of the outer casing may only be
carried out by a competent engineer in accordance with the 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 boiler, flue or associated components and
systems could invalidate the warranty.
The manufacturer accepts no liability arising from any such actions. This does not affect your
statutory rights.
SAFETY PRECAUTIONS
2
INTRODUCTION

GENERAL NOTES
GREENSTAR Ri
8 716 115 172a (06/2008)
GENERAL NOTES
3
INTRODUCTION
SERVICING
The boiler must be serviced regularly by a competent, qualified person, such as a Worcester
service engineer or alternatively a British Gas or other CORGI registered person.
Always use original spares, to help maintain the economy, safety and reliability of the boiler and
to have the Service Record completed in the Benchmark checklist.
IMPORTANT: - Ensure that the service engineer completes the Service Record in the
Benchmark checklist after each service.
The completed Benchmark checklist will be required in the event of any
warranty work and may be required by the local Building Control Inspector.
NOTE: The Benchmark checklist and service interval record can be found at the
rear of the Installation, Commissioning and Servicing Instructions.
BENCHMARK STANDARD
‘Benchmark’ is a code of practice for correctly installing, commissioning and servicing of
domestic water heating boilers.
A Benchmark checklist is provided by the manufacturer for the installer to complete ALL details
together with their CORGI registration number and sign to confirm that the boiler has been
installed and commissioned according to the manufacturer’s instructions.
HEALTH & SAFETY
No asbestos or other hazardous substances are used in the construction process that
contravene the COSHH Regulations (Control of Substances Hazardous To Health Regulations
1988).

+ 30mm
above elbow
5mm
5mm
600mm**
200mm
20mm*
GENERAL NOTES
4
To get the best from your boiler please
read these instructions carefully.
SEALED HEATING SYSTEMS
If this boiler is fitted to a sealed heating
system which is pre-pressurised. Your
installer will advise you of the minimum
and maximum pressure which should be
indicated on the system pressure gauge.
Check regularly that the pressure is
maintained and contact your installer or
maintenance engineer if a permanent
significant drop in pressure is indicated
on the pressure gauge. If the system
loses pressure it should be re-pressurised
and the cause of the fall investigated.
CENTRAL HEATING SYSTEMS
During the first few hours of operation of
the central heating system, check that all
radiators are being heated evenly. If the
top of a radiator is at a lower temperature
than the bottom then it should be vented
by releasing air through the venting screw
at the top of the radiator. Ask your
installer to show you how this is done.
This boiler is fitted to a sealed system;
repeated venting will reduce the quantity
of water in the system and this must be
replenished for safe and satisfactory
operation of the boiler.
Should water leaks be found in the
system or if excessive venting is required,
then a service engineer must be
contacted to inspect the installation and
rectify any fault.
Only additives that are compatible with
aluminium may be used in the system. Any
incompatible additive used will invalidate
the guarantee.
CONDENSATE DRAIN
This is a condensing boiler and the
terminal will, at times give out a plume of
water vapour. This is quite normal.
The boiler also produces quantities of
condensate which is discharged regularly
by a syphon within the boiler via a pipe to
drain. This pipe must not be blocked or
altered in any way.
CLEARANCES - VENTILATED
COMPARTMENT
Your installer will have provided adequate
space around the boiler for safety and
servicing access. Do not restrict this
space with the addition of cupboards,
shelves etc. next to the boiler.
GENERAL NOTES
ROOM THERMOSTAT
A room temperature controller and
programmer should be fitted to control the
central heating. Refer to the instructions
supplied with the thermostat for
information on siting and setting.
THERMOSTATIC RADIATOR VALVES
It is recommended that this type of valve is
fitted to all but one of the radiators (or at
least those in the sleeping
accommodation). The remaining radiator,
which must be where the room thermostat
is located, should be un-controlled and
must be left open. The thermostatic
radiator valves should conform to the
requirements of BS2767:10.
INTRODUCTION
*600mm service clearance required to a fixed surface
(**20mm from removable door or panel)
GREENSTAR Ri
8 716 115 172a (04/2008)

SAFETY PRECAUTIONS 5
BOILER CLEARANCES -
UNVENTILATED COMPARTMENT
The diagram opposite shows the
minimum space required to install and
service the boiler inside an unventilated
compartment.
** Space required for unventilated areas
with a removable door or panel.
*** 600mm clearance required to a fixed
surface for servicing.
* The boiler must have more clearance in
the unventilated compartment compared
to the ventilated compartment.
Two examples are shown opposite, refer
to the “Installation, commissioning and
servicing instruction manual” for further
information.
Do not add cupboards, shelves etc. to
restrict the space around the boiler.
VENTILATION
This is a room sealed boiler and does not
require any air for combustion from inside
the property. If the boiler is fitted into a
cupboard or a compartment is built
around the boiler after installation, then
the compartment must be separated from
the boiler space by a perforated non-
combustible partition as described in BS
6798.
Notwithstanding the requirements of BS
6798 and BS 5440 there is no need for
ventilation openings to be provided in the
compartment because of the low heat
loss from the boiler casing, if the
clearances shown are maintained.
Do not operate the boiler if the flue
terminal fitted on the outside wall or roof
is obstructed or damaged.
PUMP ANTI-SEIZURE
If there has been no heating demand for
24 hours the boiler will run the system
pump for a few seconds to reduce the
possibility of pump seizure during long
periods of inactivity, which is usually more
frequent during the summer months.
GENERAL NOTES
INTRODUCTION
+ 30mm
above elbow
200mm*
200mm*
100mm**
600mm***
200mm
**
***
GREENSTAR Ri
8 716 115 172a (06/2008)

CONTROLS GREENSTAR Ri
8 716 115 172a (06/2008)
CONTROLS
1. MAIN POWER “OFF/ON” KNOB
2. CENTRAL HEATING
TEMPERATURE CONTROL KNOB
3. INDICATOR/DIAGNOSTICS LIGHT
“MAINS ON/OFF” (BLUE)
4. BURNER “ON” INDICATOR LIGHT
(GREEN)
1
3
4
2
IMPORTANT: DO NOT PRESS THE
INDICATOR
LIGHT TO
RESET THE BOILER
6
USING YOUR
BOILER

OPERATING THE BOILER
GREENSTAR Ri
8 716 115 172a (06/2008)
SWITCHING THE BOILER ON/OFF
Switching on
! Switch on ( I ) the boiler at the main
power knob.
The indicator light shows blue.
Switching off
! Switch off ( O )the boiler at the main
power knob.
The blue indicator light goes out.
SETTING THE CENTRAL HEATING
TEMPERATURE
! Turn the central heating temperature
control to the desired level, the
range is between approximately
35°C and 82°C.
When the burner is lit, the green
indicator light underneath the on/off
knob is illuminated.
CONTROLLING CENTRAL HEATING
! Set the timer to the correct time.
! Set room thermostat to the desired
room temperature.
! Set the thermostatic radiator valves
to the desired settings.
FROST PROTECTION
! Leave main power knob on.
If the temperature falls to below 5°C
within the boiler the boiler will fire
periodically to avoid the possibility of
freezing.
! If remote pipework is exposed to
low temperatures, ensure that the
installer has added a frost
thermostat.
OPERATING THE BOILER
35°C 82°C
7
USING YOUR
BOILER

OPERATING THE BOILER GREENSTAR Ri
8 716 115 172a (06/2008)
FAU LT CONDITION
In the unlikely event of a fault occurring
while the boiler is in operation:
The mains indicator will flash at different
speeds dependant on fault.
! To r e s e t f a u l t t u r n t h e t h e r m o s t a t /
reset knob fully anticlockwise to
“reset” and then return the knob to
the desired temperature setting.
! The indicator will stop flashing and
the boiler will function normally,
dependant on programmer and
room thermostat settings.
If the electrical power to the boiler has
been interrupted a “reset fault”
condition will exist. Reset the boiler as
described above.
If the fault remains and cannot be
cleared:
! Call Worcester, Bosch Group for
assistance, giving a description of
the fault and, if possible the fault
flashing sequence from the mains
indicator.
OPERATING THE BOILER
8
USING YOUR
BOILER

MAINTAINING YOUR BOILER
/ FAULT FINDING
GREENSTAR Ri
8 716 115 172a (06/2008)
Yo u r n e w G r e e n s t a r g a s - f i r e d b o i l e r r e p r e s e n t s a l o n g t e r m i n v e s t m e n t i n a r e l i a b l e , h i g h q u a l i t y
product.
In order to realise its maximum working life, and to ensure it continues to operate at peak
efficiency and performance, it is essential that your boiler receives regular servicing and
maintenance checks from a competent person beyond the initial two year guarantee period.
If you would like to know more about a Worcester, Bosch Group service contract, please tick
the appropriate box on your warranty registration card.
If your Greenstar gas-fired boiler should fail to operate correctly or requires servicing please
contact the Worcester, Bosch Group Service Department, (see inside front cover for details).
MAINTAINING YOUR BOILER
9
MAINTENANCE
FAULT FINDING
Problem Cause Remedy
Switch off boiler at mains
power button, wait a few
seconds then switch on
again
Check setting
Desired room
temperature is not
reached
Thermostatic radiator
valve(s) set too low
Tempe r ature co n trol fo r
CH flow on boiler set too
low
Air trapped in heating
system
Desired room
temperature exceeded by
large amount
Tempe r ature ri s es
instead of falling
No on/off indicator
Hot water temperature
too low
Radiators are too hot
Clock is incorrectly set
Momentary power failure
Cylinder thermostat
temperature set too low
Programmer setting
Diverter valve
Increase thermostatic
radiator valve setting(s)
Increase CH flow
temperature control
setting
Bleed radiators and, if
fitted to a sealed system,
recharge heating system
Turn down thermostatic
radiator valves / room stat
Check setting
Adjust cylinder thermostat
Hot water temperature
too high
Cylinder thermostat set too
high
Diverter valve

GREENSTAR Ri
8 716 115 172a (06/2008)
10
MAINTENANCE
This boiler is supported in the UK and Ireland by Worcester, Bosch Group, part of
Bosch Thermotechnology Ltd.
Specially trained, Worcester, Bosch Group Service Engineers are available to attend a
breakdown occurring on this boiler.
No charge will be made for parts and/or labour providing:
! A boiler fault is found and the boiler has been installed within the past 24 months.
Reasonable evidence of this must be supplied on request. i.e. the Benchmark Checklist and the
warranty card has been returned.
A call-out charge will be made where:
! The boiler has been installed for over 24 months
OR
! Our Worcester Service Engineer finds no fault with the boiler (see Note).
OR
! The cause of breakdown is misuse or with other parts of your plumbing/heating system, or
with equipment not supplied by Worcester Bosch.
NOTE. NO BOILER FAULT IS FOUND ON OVER 30% OF ALL SERVICE CALL OUTS.
Please read this guide carefully to gain a good understanding of the operation of your boiler. In
the case of a suspected fault, refer to the fault finding section of this guide.
If in doubt contact our Technical Support
In the event of a boiler fault or breakdown please contact our Service Department. Your service
administrator will arrange for an engineer to call with the minimum of delay; under normal
circumstances this will be from one to three working days (excluding weekends) for priority
breakdown situations (no hot water and/or heating).
Invoices for attendance and repair work carried out on this boiler by any third party will not be
accepted.
FAULT OR BREAKDOWN
FAULT OR BREAKDOWN

11
GREENSTAR Ri
8 716 115 172a (06/2008)
Heating economically
The boiler is designed to provide a high level of comfort while keeping gas consumption and
the resulting environmental effect as low as possible. The gas supply to the burner is controlled
according to the level of demand for heat. The boiler continues to operate with a low flame if
the demand for heat reduces. The technical term for this process is modulating control.
Modulating control reduces temperature fluctuations and provides even distribution of heat
throughout the home. This means that the boiler may stay on for relatively long periods but will
use less gas than a boiler that continually switches on and off.
Central heating systems with room thermostats/thermostatic radiator valves
The central heating control on the boiler should be set to the maximum rated design
temperature of the central heating system.
The temperature of each room can be set individually (except primary room with the room
thermostat) using the thermostatic radiator valves.
Roof insulation
Around 30% of the heat loss from a property is through the roof. Replace any old insulation
with new insulation, preferably of around 200mm thickness or more.
Window frames
Single glazed windows, particularly those with steel frames, can lose a great deal of heat.
Consideration should be given to replacement with PVCu or wooden framed double glazed
units.
Curtains
Lined curtains, or heavier full length curtains can provide excellent insulation. However, always
ensure that the curtains do not drape over radiators.
Draughts
Tr y to ensure that draughts around doors , windows , letter box es and key holes etc . are reduced
by using a suitable draught excluder.
WARNING - Do not block or seal any air vents that are installed to ensure the central heating
boiler operates safely.
Room thermostats
Reducing the setting of the room thermostat by 1°C can reduce fuel consumption by up to 10%.
New control systems
Upgrade your heating control system if necessary with the latest equipment available. The
minimum level of control is a programmer, interlocking room thermostat and thermostatic
radiator valves.
Radiators
Radiators will normally be sited underneath a window, so the warm air from the radiator heats
the colder incoming air from the window. The performance of the radiator will be affected if
curtains are allowed to drape over the radiator or shelves are fitted above. Positioning of
furniture in front of the radiator should be avoided.
Manually adjust all radiator valves every two to three months to prevent them sticking. Ensure
that the plastic tops of all valves are always in position and not damaged. Care should be taken
when vacuum cleaning carpets to avoid damage to valves and pipework.
The heating system and the outputs of the radiators have been carefully selected by your
installer. The temperature obtainable in any given room is dependent on all radiators being
operated at the same time. If you decide to turn off radiators in unused rooms, spare bedrooms
etc., you may experience slightly lower room temperatures in rooms next to unheated rooms.
TIPS ON ENERGY SAVING
TIPS ON ENERGY SAVING
ENERGY
SAVING

12 GREENSTAR Ri
8 716 115 172a (06/2008)
YOUR GUARANTEE
This boiler is guaranteed against faulty material or workmanship for a period of 2 years from the
date of installation subject to the following terms and conditions:
! Yo u r G u a r a n t e e R e i s t r a t i o n C a r d m u s t b e r e t u r n e d w i t h i n 3 0 d a y s f o r t h e s e c o n d y e a r o f
your guarantee to become valid.
! During the period of this guarantee any components of the unit which are proven to be
faulty or defective in manufacture will be exchanged or repaired free of charge by Bosch
Thermotechnology Ltd.
! The householder may be asked to prove the date of installation, that the boiler was
correctly commissioned and, where appropriate, the first years service has been carried
out to the satisfaction of Bosch Thermotechnology Ltd. when requested. These should
be part of the Benchmark checklist.
! Any product or part returned for servicing under the guarantee must be accompanied by
a claim stating the model, serial number, date of installation.
! Bosch Thermotechnology Ltd will not accept responsibility for damage caused by faulty
installation, neglect, misuse or accidental damage or the non observance of the instructions
contained in the Installation, Commissioning and Servicing Instructions and Users
Instructions and Customer Care Guide.
! The boiler has been used only for normal domestic purposes for which it was designed.
This guarantee applies only to equipment purchased and used in the United Kingdom and
Eire.
This guarantee does not affect your statutory rights.
YOUR GUARANTEE
GUARANTEE

13
GREENSTAR Ri
8 716 115 172a (06/2008)
GUARANTEE
Yo u s h o u l d c o m p l e t e a n d r e t u r n t h e p o s t p a i d G u a r a n t e e
Registration Card within 30 days of purchase.
Returning the card will register you as the owner of your
new Greenstar Ri boiler and will assist us in maintaining
an effective and efficient customer service by establishing
a reference and permanent record for your boiler.
This does not affect your statutory rights.
For your own record:
Ensure that the Benchmark “checklist” has been
completed by your installer or service engineer.
NOTE: The Benchmark checklist and service interval
record can be found at the rear of the Installation,
Commissioning and Servicing Instructions.
GUARANTEE REGISTRATION
Model
Serial No.
(See identity label inside boiler casing)
Typ e / size
Date of installation
Name of Installer
Telephone number of Installer
GUARANTEE REGISTRATION

USER INSTRUCTIONS &
CUSTOMER CARE GUIDE
Dedicated to heating comfort
Worcester, Bosch Group
Cotswold Way, Warndon, Worcester WR4 9SW.
Tel. [phone] Fax. [phone]
www.worcester-bosch.co.uk
Worcester Bosch Group is a brand name of Bosch Thermotechnology Ltd.
8 716 115 172a (06/2008)