Worcester GREENSTAR i SYSTEM Bedienerhandbuch

UK/IETHIS BOILER IS USED WITHNATURAL GAS OR LPG (Cat II 2H3P TYPE C13, C33 & C53)NATURAL GAS 12i System GC NUMBER: 41 311 6724i System GC NUMBER:

MAINS SUPPLYELECTRIC SUPPLY:• Supply: 230V - 50Hz, 140 watts • Cable: PVC insulated 0.75mm2(24 x 0.2mm) temperature rated to 90°C.• External 3A fuse t

WATER SYSTEMS & PIPEWORKINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System8 716 115 167b (03/2009)11PRE -INSTALLATI

CONDENSATE PIPEWORKINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System8 716 115 167b (03/2009)12PRE -INSTALLATION

PRESSURE RELIEF PIPEWORKPRESSURE RELIEF PIPEWORK:• The pressure relief drain pipe (M) from the boiler should be at least 15mm diameter copper pipe and

12 & 24 kW Vent To room or Direct toposition internal space outsideHigh Minimum free Minimum level area 122 cm2free area61

BATHROOMS:A boiler fitted with a non-mechanical timer orwith no timer can be installed in zone 2 or out-side the shaded area . A boiler with a mechani

PLUMBING MANIFOLDCONNECTIONS:Heating System: 22mm compression fittingsGas: 22mm compression fittingsUse the fittings supplied in the Lit/Hardwar

PRE -INSTALLATIONFLUE OPTIONSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System8 716 115 167b (03/2009)17The Greenstar

FLUE TERMINAL POSITIONSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System8 716 115 167b (03/2009)18PRE -INSTALLATION• T

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System8 716 115 167b (03/2009)19FLUE TERMINAL POSITIONSPRE -INSTALLATION

INSTALLATION &SERVICING INSTRUCTIONSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System8 716 115 167b (03/2009)2WATE

A - StrapsB - Outer cartonC - Installer packD - Bottom panel E - Wall mounting frameF - Wall template G - Inner packagingH - Front fascia panelJ - Syp

SAFETY:All relevant safety precautions must be undertaken.Protective clothing, footwear, gloves and safetygoggles must be worn as appropriate.FIXING T

46UNPACKING THE APPLIANCEUNPACKING THE APPLIANCEA - Outer cartonB - Inner sleeve (unwraps from front)C - Packaging baseD - Protective wrappingE - Appl

BOILER CONNECTIONSCAUTION: ISOLATE THE MAINS GASSUPPLY BEFORE STARTING ANY WORKAND OBSERVE ALL RELEVANT SAFETYPRECAUTIONS.ABHandling HoleDo not lift b

BOILER CONNECTIONSCAUTION: ISOLATE THE MAINS GASSUPPLY BEFORE STARTING ANY WORKAND OBSERVE ALL RELEVANT SAFETYPRECAUTIONS.ABC22mm 22mm

FLUE INSTALLATIONHORIZONTAL FLUE(60/100mm diameter)For vertical flues and 80/125mm horizontal flues, pleaserefer to separate instructions supplied wit

FLUE INSTALLATIONInstalling the standard flue:1 Set the flue length to the distance required, secure with screw and seal joint with thealuminium tape

Flat at backFLUE INSTALLATIONASSEMBLING THE FLUE4 Assemble elbow to boiler using the three screws (see below).NOTE: Screws are in boiler not in flue k

IMPORTANT: IF FITTING OPTIONALINTEGRAL DIVERTER VALVENow fit the diverter valve. For installa-tion refer to FITTING THE DIVERTERVALVE in the ADDITIONA

ELECTRICALCAUTION: ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTINGANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONSThe boiler is pre-wired wit

SAFETY & REGULATIONSINSTALLATION & SERVICING INSTRUCTIONS 2SAFETY PRECAUTIONS & SYMBOLS 4INSTALLATION REGULATIONS 4APPLIANCE INFORMATIONGE

POSITION OF WIRED COMPONENTSCOMMISSIONINGINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System8 716 115 167b (03/2009)30PO

CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANYWORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS1 Check that the service and water pipes are

FILLING THE SYSTEM1 Turn on the water main and open the system valves.2 Open all radiator valves.3 Fill the system via a WRAS approved fillingloop.4 V

ADFCBGEHISwitching the appliance on/off:1  Turn on mains power supply Turn on any external controlsSet the thermostatic radiator controls to maximum

WATER TREATMENTINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System8 716 115 167b (03/2009)34WATER TREATMENTCOMMISSIONING

ADFCBGEHIA - On/off buttonB - On/off and fault indicator (BLUE)C - Central heating temperature controlD - Burner indicator (GREEN)E - Reset buttonF -

FINISHING COMMISSIONINGThe boiler has been factory set, so there shouldbe no need to adjust any controls.REPLACE OUTER CASING:1 Replace outer casing m

INSPECTION AND SERVICENOTE: A service must NOT beattempted if a CO/CO2analyser is NOT available.• To ensure the continued efficient operation of t

INSPECTION AND SERVICEComponent Access1. Removing outer case1. Remove bottom panel by pulling it forward and off.1.1 Undo and remove 2 screws (A) secu

INSPECTION AND SERVICESetting Boiler to Maximum.NOTE: When running in the service mode, theboiler will operate both the Central Heating andDHW circuit

SAFETY PRECAUTIONS& INSTALLATION REGULATIONSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System8 716 115 167b (03/20

INSPECTION AND SERVICEThere is a special accessory kit availablespecifically designed for cleaning the heatexchanger. If required order 7 716 192 312.

4 Remove electrical connector from fan.5 Undo and remove securing nut (H) from the top of the heat exchanger.6 Remove retaining plate (I).7 Rotate f

RINSPECTION AND SERVICE9MNOPQS9 Remove burner (M). Remove top baffle (N). Remove lower baffle (0). Remove the two pozi-drive screws (P) retaining t

CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINSSUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALLRELEVANT SAFETY PRECAUTIONS.IMPORTANT: AFTER R

5.1 5.2AREPLACEMENT OF PARTSSIT AND DUNGS VALVESREMOVAL OF THE VALVE IS THE SAMEFOR BOTH SIT AND DUNGS VALVES. THESIT VALVE IS SHOWN IN THE DIAGRAM.RE

REPLACEMENT OF PARTS7. Access to boiler control components Remove 3 screws (A) and remove cover from control.8. PCB fuse Remove fuse F1 (B) from the

REPLACEMENT OF PARTS10. Replacing control IMPORTANT:Do not replace the control unit if aCO/CO2analyser is NOT available.The control is supplied within

REPLACEMENT OF PARTS11. Air / gas manifold and fanassembly Remove electrical connector from fan. Remove wire clip from gas valve outlet then pull ga

REPLACEMENT OF PARTS12. Fan15.1Remove 3 screws (A) retaining mixing chamber.15.2Remove 2 screws (B) retaining the fan to the air/gas manifold.15.3Remo

REPLACEMENT OF PARTSNOTE:Removal of the syphon assembly will give accessto Auto air vent.To release the syphon from the sump connection,pull towards y

GENERAL INFORMATIONSTANDARD PACKAGE:A - Wall hung gas fired condensing boiler forcentral heating and indirect domestic hot waterB - Boiler support fra

REPLACEMENT OF PARTS19. Pump headEnsure the boiler is fully drained. Release the screw securing the pumpelectrical cover.Disconnect the electrical h

REPLACEMENT OF PARTS22. Hydraulic BlockEnsure the appliance has been fully drained.Disconnect the electrical connections at the pump.Remove the syp

REPLACEMENT OF PARTS24. Bypass valveRemove the Hydraulic block from the boiler (See Removing the Hydraulic Block).24.1Remove the two spring clips at

SETTING THE AIR / GAS RATIOFOR THE SIT 848.093 SIGMATHE SETTING OF THE GAS RATIO MUST BECARRIED OUT BY A COMPETENT PERSON.SETTING OF THE GAS RATIO MUS

SETTING THE AIR / GAS RATIOFOR DUNGS GB-ND 055 DO1 S20THE SETTING OF THE GAS RATIO MUST BECARRIED OUT BY A COMPETENT PERSON.SETTING OF THE GAS RATIO M

SHORT PARTS LIST1 FanWORCESTER Part No. 8 717 204 453 0GC No. H26 5362 BurnerWORCESTER Part No. 8 718 120 619 0GC No. H49 3263 Gas valve NG & LPGW

CONVERSION KITSA1.11.22.1THE AIR / GAS RATIO MUST BERESET AFTER CONVERSION. THEPROCEDURE CAN BE FOUND INTHE SETTING THE AIR/GAS RATIOSECTION OF THIS M

OffOnSlow flash(normally off,flashes on)Slow flash(normally on,flashes off)Fast flashFast flash2 pulses5 pulsesOffOffFlashing (reset required)Flashing

BOILER FUNCTIONNOYESPOWERSWITCH ONBOILERDEMANDFan tostartspeed.Diverter valvein CH positionPump ONwhen optionalintegral valveis used.IGNITIONSEQUENCE(

PROTECTION FUNCTIONBoiler temperaturebelow 8°CRun autofroststatfunctionPump antiseizePump run 5 secondsevery 24hrsFAULT FINDING& DIAGRAMSINSTALLAT

TECHNICAL DATAINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System8 716 115 167b (03/2009)6TECHNICAL DATAAPPLIANCEINFORMA

UK/IEDIVERTER KIT NUMBERS:12kW 7 716 192 56624KW 7 716 192 409KIT CONTENTS:1 COPPER RETURN PIPE1 BRASS SERVICE VALVE1 15mm COMPRESSION NUT1 15mm OLIV

PLUMBING MANIFOLDCONNECTIONS:Heating System: 22mm compression fittingsGas: 22mm compression fittingsCylinder Return 15mm compression fittings

BOILER CONNECTIONSIMPORTANT: THE FOLLOWING MUST BECOMPLETED BEFORE THE BOILER ISMOUNTED ON THE WALL MOUNTINGFRAMEBOILER CONNECTIONSINSTALLATION &

BOILER CONNECTIONSCAUTION: ISOLATE THE MAINS GASSUPPLY BEFORE STARTING ANY WORKAND OBSERVE ALL RELEVANT SAFETYPRECAUTIONS.ABHandling HoleDo not lift b

BOILER CONNECTIONSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System8 716 115 167b (03/2009)24INSTALLATIONBOILER CONNEC

FITTING THE DIVERTER VALVE MOTOR: 1. Remove the diverter blanking plate (A) by pulling it forwards to free it from its location. 2. Replace with the

ELECTRICALCAUTION: ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTINGANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONSNote: Mains supply to the b

POSITION OF WIRED COMPONENTSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System8 716 115 167b (03/2009)30POSITION OF WIR

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System8 716 115 167b (03/2009)31PRE- COMMISSIONING CHECKSCAUTION: ISOLATE T

LAYOUT & COMPONENTSThe diagram opposite shows the controls in theservicing position and excludes the outer case. 1 AIR / GAS MANIFOLD2 SENSOR - BO

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 12i/24i System8 716 115 167b (03/2009)58BOILER FUNCTIONNOYESPOWERSWITCH ONCENTRALHE

Pack NumberCONTACT INFORMATIONWORCESTER, BOSCH GROUP:TECHNICAL: 08705 266241SERVICE: 08457 256206SPARES: 01905 752571LITERATURE: 01905 752556TRAINING:

LAYOUT & COMPONENTS27 AUTO AIR VENT28 UNUSED PORT29 COMPACT HYDRAULIC MOUNTING SCREW (2) TO BOILER30 PRESSURE RELIEF VALVE31 OPTIONAL INTEGRAL DIV

CLEANING PRIMARY SYSTEMSIMPORTANT: All the following Pre-Installation sections must be read and requirements met before starting boiler or flue insta