Page 2 - CONTACT INFORMATION
SYMBOLS USED IN THIS MANUAL: WORCESTER: 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.betzdearbor...
Page 3 - CONTENTS
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 R...
Page 4 - SAFETY PRECAUTIONS; CORGI; FITTING & MODIFICATIONS
SAFETY PRECAUTIONS& INSTALLATION REGULATIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05) 3 SAF ET Y & RE GUL A T IO N S SAFETY PRECAUTIONS INSTALLATION REGULATIONS IF YOU SMELL GAS: ✗ DON’T SMOKE OR STRIKE MATCHES ✗ DON’T T...
Page 5 - GENERAL INFORMATION; Depth to wall
GENERAL INFORMATION STANDARD PACKAGE: A - Wall hung gas fired condensing combi boiler for central heating and domestic hot water B - Boiler support frame C - Hardware literature pack D - Bottom Panel SPECIFICATIONS: Pre-wired and pre-plumbed Galvanised steel inner frame Digital control system Automa...
Page 6 - TECHNICAL DATA
TECHNICAL DATA INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05) 5 TECHNICAL DATA A PPL IA N C E INF O RM A T IO N Domestic Hot Water Min. heat input KW 7.38 7.38 9.64 9.64 Max. rated heat output KW 24 28 24 28 Max. rated heat input KW 2...
Page 9 - compatible with; CLEANING PRIMARY SYSTEMS
CLEANING PRIMARY SYSTEMS BEFORE CLEANING THE SYSTEM: ENSURE THE SYSTEM AND PIPEWORK ISIN GOOD WORKING ORDER KEEP THE EXISTING BOILER/CIRCULATING PUMP WHERE POSSIBLEOR USE A POWER FLUSHING MACHINETO AID THE CLEANSING PROCEDUREBEFORE INSTALLING A NEW BOILER. CLEANING THE PRIMARY SYSTEM:1 Fill the syst...
Page 10 - MAINS SUPPLY
MAINS SUPPLY ELECTRIC SUPPLY:• Supply: 230V - 50Hz, 140 watts • Cable: PVC insulated 0.75mm 2 (24 x 0.2mm) temperature rated to 90°C. • External 3A fuse to BS1362.• The appliance must be earthed.• IPX4D. NOTE: this is reduced to IP20 if the following mechanical timers are fitted:7 716 192 036 or 7 7...
Page 11 - WATER SYSTEMS & PIPEWORK
WATER SYSTEMS & PIPEWORK PLASTIC PIPEWORK:• Any plastic pipework must have a polymeric barrier with 600mm (minimum) length of copper or steel pipe connected to the boiler. • Plastic pipework used for underfloor heating must be correctly controlled with a thermostatic blending valve limiting the ...
Page 12 - CONDENSATE PIPEWORK
CONDENSATE PIPEWORK CONDENSATE PIPEWORK:• The condensate pipe must be a minimum of 22mmØ plastic pipe. • The condensate pipework must fall at least 50mm per metre towards the outlet and should take the shortest practicable route. • The pipework must follow one of the options shown opposite into an i...
Page 13 - PRESSURE RELIEF PIPEWORK
PRESSURE RELIEF PIPEWORK PRESSURE RELIEF PIPEWORK: • The pressure relief drain pipe (M) from the boiler should be at least 15mm diameter copper pipe and run downwards away from any electrics or other hazard, preferably to an external drain or soakaway. • Pipe (M) should be finished with a partial be...
Page 14 - BOILER LOCATION & CLEARANCES; CLEARANCES; Side; If Side Clearances are Reduced; If Front Clearance is Reduced
BOILER LOCATION & CLEARANCES INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05) 13 P R E - IN ST AL LA TI O N BOILER LOCATION & CLEARANCES This boiler is only suitable for installing internallywithin a property at a suitable locat...
Page 16 - PLUMBING MANIFOLD
PLUMBING MANIFOLD CONNECTIONS:Heating System: 22mm compression fittingsDHW: 15mm compression fittings Gas: 22mm compression fittings Use the fittings supplied in the Lit/Hardware pack. • If the boiler pipes are to be run behind the appliance ensure that the pipes pass throughthe slot in the yellow p...
Page 17 - FLUE TERMINAL POSITIONS; See instructions supplied with vertical flue kits.
P R E - IN ST AL LA TI O N FLUE TERMINAL POSITIONS • The flue must be fitted and terminated in accordance with the recommendations of BS5440 : Part 1. • The flue must not cause an obstruction.• Discharge and any noise from the flue outlet must not cause a nuisance. • Flue gases have a tendency to pl...
Page 18 - FLUE OPTIONS
FLUE OPTIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05) 17 P R E - IN ST AL LA TI O N FLUE OPTIONS • The diagrams (opposite) show the components used and the maximum flue length for each configuration of 100mm and 125mm flues. • S...
Page 19 - UNPACKING WALL FRAME AND
I IMPORTANT: All the previous Pre-Installation sections must be read and requirements met before starting boiler or flue installation. E F A B C C D G UNPACKING WALL FRAME AND ANCILLARY ITEMS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/...
Page 20 - WALL MOUNTING PLATE FLUE OPENING; WALL MOUNTING TEMPLATE
WALL MOUNTING PLATE FLUE OPENING INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05) 19 IN ST AL LA TI O N C O MMI S S IO N IN G SAFETY:All relevant safety precautions must be undertaken.Protective clothing, footwear, gloves and safetygogg...
Page 21 - UNPACKING THE APPLIANCE; UNPACKING THE APPLIANCE
4 7 6 UNPACKING THE APPLIANCE UNPACKING THE APPLIANCE A - Outer carton B - Inner sleeve (unwraps from front) C - Packaging base D - Protective wrapping E - Appliance outer case F - Protective inner packaging 4 . Remove outer carton (A) and place safely away from the working area. 5 . With the outer ...
Page 22 - BOILER CONNECTIONS
A E D B BOILER CONNECTIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05) 21 IN ST AL LA TI O N Handling Hole Do not lift by theair gas manifold. 3 C 1A 22mm 15mm 22mm 15mm 22mm 2 & 4 H 1 BOILER CONNECTIONS C AU T I O N : I S O L ...
Page 23 - A E C D B
BOILER CONNECTIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/05) 22 IN ST AL LA TI O N BOILER CONNECTIONS C AU T I O N : I S O L AT E T H E M A I N S G A SSUPPLY BEFORE STARTING ANY WORKAN D OB SE RVE ALL R E LEVANT SAFETYPRECAUTIONS....
Page 24 - FLUE INSTALLATION; WALL
FLUE INSTALLATION INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05) 23 IN ST AL LA TI O N FLUE INSTALLATION HORIZONTAL FLUE (60/100mm diameter) For vertical flues and 80/125mm horizontal flues,please refer to separate instructions suppli...
Page 25 - ONLY CUT EXTENDED FLUE LENGTHS
FLUE INSTALLATION INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/05) 24 IN ST AL LA TI O N FLUE INSTALLATION MEASURING THE FLUE (Extension Flue Kits): ONLY CUT EXTENDED FLUE LENGTHS As with the Standard Flue measure from theoutside wall to...
Page 27 - CONDENSATE CONNECTION
CONDENSATE CONNECTION: Never terminate or discharge into any opensource, including; sink, bath, shower, bidet,toilet etc . N o t e : a n y e x t e r n a l c o n d e n s a t e p i p e w o r kshould be protected with weather resist antinsulation to help prevent freezing. • Ensure that the condensate d...
Page 28 - ELECTRICS
ELECTRICS A 1 2 B ELECTRICS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05) 27 IN ST AL LA TI O N CAUTION: ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS Mains supply to the bo...
Page 29 - POSITION OF WIRED COMPONENTS
POSITION OF WIRED COMPONENTS C O MMI S S IO N IN G POSITION OF WIRED COMPONENTS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/05) 28 IN ST AL LA TI O N
Page 30 - PRE-COMMISSIONING CHECKS; CHECKS; A D C E B
PRE-COMMISSIONING CHECKS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05) 29 C O M M ISS IO N IN G A E B C D 22mm 15mm 22mm 15mm 22mm 1 2 3 F J PRE-COMMISSIONING CHECKS CAUTION: ISOLATE THE MAINS S U P P LI E S B E F O R E STARTI N G AN...
Page 31 - FILLING THE SYSTEM; not supplied with the
FILLING THE SYSTEM INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/05) 30 C O MMI S S IO N IN G FILLING THE SYSTEM 1 Turn on the water main and open the system valves. 2 Open all radiator valves. 3 Fill the system via a WRAS approved fillin...
Page 32 - STARTING THE APPLIANCE
A D F C B G E H I Switching the appliance on/off:1 Turn on mains power supply Turn on any external controlsSet the thermostatic radiator controls to maximum temperatureSet the clock/programmer to continuouslyON and the room thermostat to maximumtemperature 2 A - On/off button B - On/off and fault in...
Page 33 - KEY; WATER TREATMENT
WATER TREATMENT E N S U R E THAT TH E SYSTE M HAS B E E NC L E A N E D A S O N PA G E 8 O F T H E S EINSTRUCTIONS. FLUSHING (Central Heating) : 1 Switch off the boiler (A). Open all drain cocks (B) and drain the system (C) while the appliance is hot. 2 Close drain cocks (D) and add a suitable flushi...
Page 34 - COMMISSIONING
COMMISSIONING THE COMBUSTION FOR THE APPLIANCEIS FACTORY SET. NO ADJ USTM E NT IS R EQU IR E D IF TH EGAS INLET PRESSURE IS CORRECT. CHECKING GAS INLET PRESSURE: The inlet pressure to the appliance must be checked using the following procedure: SETTING THE BOILER TO MAXIMUM:1 Press service button (F...
Page 35 - FINISHING COMMISSIONING
FINISHING COMMISSIONING INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/05) 34 C O MMI S S IO N IN G FINISHING COMMISSIONING The boiler has been fact ory set , so t hereshould be no need to adjust any controls. REPLACE OUTER CASING:1 Replac...
Page 36 - fully qualified engineers.; Inspection; TU R N OF F TH E GAS S U P P LY AN D I SOLATE TH E MAI N S; INSPECTION AND SERVICE
INSPECTION AND SERVICE To ensure the continued efficient operation of the appliance it must be checked at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage. However, an annual service is recommended . The extent of the service required by...
Page 37 - Component Access; Adjusting boiler control to
INSPECTION AND SERVICE Component Access 1. Removing outer case 1. Remove bottom panel by pulling it forward and off. 1.1 Undo and remove 2 screws (A) securing boiler casing at the top of the appliance. 1.2 Undo but do not remove the 2 screws (B) securing boiler casing at the bottom of the appliance....
Page 38 - Setting Boiler to Maximum.; negative
INSPECTION AND SERVICE Setting Boiler to Maximum. NOTE: When running in the service mode, theboiler will operate both the Central Heating andDHW circuits. This is to allow sufficient time forthe setting procedure.It will be necessary to run water through theDHW circuit to ensure that the boiler will...
Page 39 - To Clean the Heat Exchanger; Removing Siphon; Siphon; I F T H E J O I N T
INSPECTION AND SERVICE To Clean the Heat Exchanger 1 With outer case and base panel removed and the power isolated from the appliance, remove the cover panel (A) by removing the retaining screw (B). 2 Remove clip (C) from gas valve outlet. Pull gas adjustment assembly (D) free from the plastic conne...
Page 41 - Small
Q INSPECTION AND SERVICE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/05) 40 SER V IC IN G & SP A RES INSPECTION AND SERVICE 9 L M N 0 P R 9 Remove burner (L). Remove top baffle (M). Remove baffle (N). Remove the two hexagon headed s...
Page 42 - Removing outer case; REPLACEMENT OF PARTS
CAUTI ON: TU R N OF F TH E GAS S U P P LY AN D I SOLATE TH E MAI N S S U P P L I E S B E F O R E S TA R T I N G A N Y W O R K A N D O B S E R V E A L LRELEVANT SAFETY PRECAUTIONS. I M PORTANT: AFTE R R E PLACE M E NT OF ANY COM PON E NTS ALWAYS CH ECK FOR GAS SOU N DN E SS WH E R E R E LEVANT AN D C...
Page 44 - Access to boiler control components
REPLACEMENT OF PARTS 9. Access to boiler control components Remove 3 screws (A) and remove cover from control. 10. PCB fuse Remove fuse F1(B) from the PCB and replace. There is a spare fuse clipped into the underside of the electrical cover. 11.Transformer / PCB Disconnect all electrical connections...
Page 45 - Replacing control
12.3 REPLACEMENT OF PARTS 12. Replacing control Th e c o n t ro l i s s u p p l i e d w i t h i n i t s p l a s t i chousing. The complete unit must be replaced. Remove ALL electrical connections from the control PCB including where cables runthrough restraints. These can be unclipped from the plast...
Page 47 - Electrode assembly
REPLACEMENT OF PARTS 15. Fan 15.1 Remove 3 screws (A) retaining mixing chamber. 15.2 Remove 2 screws (B) retaining the fan to the air/gas manifold. 15.3 Remove screw (C) retaining plate and remove. Re-assemble with new fan ensuring seals are correctly fitted. 16. Electrode assembly Disconnect spark ...
Page 48 - Diverter valve motor; DHW temperature sensor
REPLACEMENT OF PARTS 19. Diverter valve motor Insure the appliance is in service mode (there is no need to drain the appliance). Disconnect the electrical connector from the diverter valve motor. 18.1 Pull the motor assembly (A) towards you. Theassembly will slide free from the valve. To refit, foll...
Page 49 - Pressure gauge
REPLACEMENT OF PARTS 23. Pump head Ensure the boiler is fully drained (see draining the appliance). Disconnect the electrical connection from the bottom of the pump. 23.1 Remove the four Allen bolts (A) securing the pump at each corner. 23.2 Gently pull the pump towards you and remove. To refit, fol...
Page 50 - CH pressure relief valve
REPLACEMENT OF PARTS 27. Hydraulic Block Ensure the appliance has been fully drained (see draining the appliance). Disconnect the electrical connections to the NTC, Turbine and pump. Undo the nuts securing the copper water pipes to the manifold (there is no need to remove the gas pipe) Release the s...
Page 51 - Plastic protection device
REPLACEMENT OF PARTS 29. Plastic protection device Ensure the system is fully drained (see draining the appliance). Disconnect all pipes connected to the pump housing. Remove the electrical connection to the pump. Withdraw the metal clip to the right of the pump head to release the pump housing. Sli...
Page 52 - Removing boiler
REPLACEMENT OF PARTS 31. Bypass valve Remove the Hydraulic block from the boiler (See Removing the Hydraulic Block). 31.1 Remove the two spring clips at either end of the copper bypass pipe. Undo the screw securing the left hand plastic housing to the heat exchanger Move the housing to the left to f...
Page 53 - CO2 settings; SETTING THE GAS / AIR RATIO
33. Setting the CO 2 Note: When running in the service mode, the boiler will operate both the central heating &DHW circuits. This is to allow sufficient time forthe setting procedure. It will be necessary to runwater through the DHW circuit to ensure thatthe boiler will not cycle on low heating ...
Page 54 - SHORT PARTS LIST
SHORT PARTS LIST 1 Fan WORCESTER Part No. 8 717 204 453 0 GC No. H26 536 2 Burner WORCESTER Part No. 8 718 120 609 0 GC No. H26 538 3 Gas valve NG WORCESTER Part No. 8 716 107 052 0 NG GC No. H26 540 LPG WORCESTER Part No. 8 716 107 053 0 LPG GC No. H26 539 4 Control board WORCESTER Part No. 8 716 1...
Page 55 - Code plugs
1.1 1.2 A 2.2 2.3 2.1 3 C B T H E G A S / A I R R AT I O M U S T B ER E S E T A F T E R C O N V E R S I O N . T H EP R O C E D U R E C A N B E F O U N D I NTHE REPLACEMENT PARTS SECTIONOF THIS MANUAL. 4.1 4.2 D E A L. P. G. CONVERSION L.P.G. CONVERSION INSTALLATION & SERVICING INSTRUCTIONS FOR W...
Page 56 - NOTE; FAULT FINDING
FAULT FINDING INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05) 55 FA U LT F IN D IN G & D IA G R A M S Off On Slow flash (normally off, flashes on) Slow flash (normally on, flashes off) Fast flash Fast flash 2 pulses 5 pulses Off Of...
Page 57 - YE; IG; CENTRAL HEATING FUNCTION
CENTRAL HEATING FUNCTION NO YE S PO WE R SW IT CH ON CE NTRAL HE A T IN G DE MAN D F an to start speed. Diverter valve in C H position P ump O N . IG N ITI O N SE QU E N CE (see detail) BL UE LI G H T ON BURNER L IT? GREEN F LAM E LI G H T ON Stop spark. W ait 10 seconds 5th attempt? L O CK OUT 10 s...
Page 58 - PREHEAT AND DHW FUNCTION
W ait 5 seconds IG N ITI O N SE QU E N CE (see detail) PREHEAT AND DHW FUNCTION NO YE S PO WE R SW IT CH ON Tap open (recognised by flow turbine) Diverter valve in D H W position P ump O N . BL UE LI G H T ON BURNER L IT? F an to start speed. Stop spark. W ait 10 seconds 5th attempt? L O CK OUT F an...
Page 59 - PROTECTION FUNCTION
PROTECTION FUNCTION Boiler temperature below 8°C Run autofroststat function Pump antiseize Pump run 5 seconds every 24hrs PROTECTION FUNCTION INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/05) 58 F A UL T F IND IN G & D IA G R A M S
Page 60 - GAS BOILER COMMISSIONING CHECKLIST
CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes TIME & TEMPERATURE CONTROL TO HEATING ROOM T/STAT & PROGRAMMER/TIMER PROGRAMMABLE ROOMSTAT TIME & TEMPERATURE CONTROL TO HOT WATER CYLINDER T/STAT & PROGRAMMER/TIMER COMBI BOI...
Page 61 - SERVICE INTERVAL RECORD; It is recommended that your heating system is serviced regularly
SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below. Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described...
Page 62 - EXCELLENCE COMES AS STANDARD; INSTRUCTION MANUAL; Check List; Pack Number
EXCELLENCE COMES AS STANDARD Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 01905 754624 Fax. 01905 754619 Worcester, Bosch Group is a trading name of BBT Thermotechnology UK Ltd. www.worcester-bosch.co.uk 8 716 107 336b (11.05) INSTRUCTION MANUAL INSTALLATION, COMMISSIONING&a...
