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Worcester 27i System Compact Installation, Commissioning And Servicing Instructions

Manual is about: Greenstar i System Compact

Summary of 27i System Compact

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    Uk/ie installation, commissioning and servicing instructions wall hung rsf gas fired condensing system boiler greenstar i system compact 6720646608-00.1w o for sealed central heating systems and indirect mains fed domestic hot water 6 72 0 807 726 (2013/05) these appliances are for use with: natural...

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    Contents greenstar i system compact - 6 720 807 726 (2013/05) 2 contents 1 key to symbols and safety instructions . . . . . . . . . . . . . . . . . . . 3 1.1 key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.2 safety precautions . . . . . . . . . . . . . . . . . . ...

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    Key to symbols and safety instructions greenstar i system compact - 6 720 807 726 (2013/05) 3 1 key to symbols and safety instructions 1.1 key to symbols warnings the following keywords are defined and can be used in this document: • notice indicates a situation that could result in damage to proper...

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    Key to symbols and safety instructions greenstar i system compact - 6 720 807 726 (2013/05) 4 1.2 safety precautions if you smell gas a gas leak could potentially cause an explosion. If you smell gas, observe the following rules. ▶ prevent flames or sparks: – do not smoke, use a lighter or strike ma...

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    Appliance information greenstar i system compact - 6 720 807 726 (2013/05) 5 2 appliance information 2.1 appliance standard package 1. Wall hung gas-fired condensing system boiler for central heating and domestic hot water 2. Wall mounting frame 3. Hardware literature pack: – greenstar i system comp...

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    Appliance information greenstar i system compact - 6 720 807 726 (2013/05) 6 2.2 technical data description i system compact natural gas l.P.G. Unit 27kw 30kw 27kw 30kw gas flow rate - max. 10 minutes from lighting natural gas g20 m³/h 2.92 3.24 l.P.G. Kg/h 2.1 2.33 heating minimum heat input kw 7.1...

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    Appliance information greenstar i system compact - 6 720 807 726 (2013/05) 7 2.3 layout fig. 1 main boiler components 6720646609-02.3wo 43 42 41 40 39 38 37 36 35 34 26 49 48 47 46 44 45 29 28 27 30 7 31 33 8 32 13 9 10 11 12 1 2 3 4 5 6 15 16 17 18 19 22 23 21 24 25 14 20

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    Appliance information greenstar i system compact - 6 720 807 726 (2013/05) 8 1 wall mounting frame 26 fan 2 expansion vessel 27 flow temperature sensor (ntc) 3 ch return isolator 28 electrode assembly 4 gas inlet isolator 29 maximum safety sensor ntc 5 ch flow isolator 30 auto air vent 6 condensate ...

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    Pre-installation greenstar i system compact - 6 720 807 726 (2013/05) 9 3 pre-installation 3.1 cleaning primary systems before cleaning the system: ▶ ensure that the system and pipework is in good working order. ▶ where possible keep the existing boiler/circulating pump in place when flushing the sy...

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    Pre-installation greenstar i system compact - 6 720 807 726 (2013/05) 10 sealed primary system: • the ch sealed system must be filled using a wras approved filling loop or comply with figure 2 for system fill. • where the system volume is more than 100 litres or exceeds 2.65 bar at maximum heating t...

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    Pre-installation greenstar i system compact - 6 720 807 726 (2013/05) 11 3.4 condensate pipework 3.4.1 internal connections in order to minimise risk of freezing during prolonged cold spells, the following methods of installing condensate drainage pipe should be adopted, in order of priority. Wherev...

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    Pre-installation greenstar i system compact - 6 720 807 726 (2013/05) 12 if no other discharge method is possible then the use of an externally run condensate drainage pipe terminating at a suitable foul water discharge point, or purpose-designed soak away, may be considered. If this method is chose...

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    Pre-installation greenstar i system compact - 6 720 807 726 (2013/05) 13 fig. 10 soak away 3.5 pressure relief pipework • the pressure relief drain pipe (1) from the boiler should be at least 15mm diameter copper pipe and run downwards, away from any electrical equipment or other hazard, preferably ...

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    Pre-installation greenstar i system compact - 6 720 807 726 (2013/05) 14 3.6.4 bathrooms a boiler fitted with an fw100 controller may only be installed outside the shaded area. A boiler with any other timer fitted (or blanking panel) can also be installed in zone 2. Additional rcd (residual current ...

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    Pre-installation greenstar i system compact - 6 720 807 726 (2013/05) 15 3.8 flue terminal positions fig. 16 flue terminal positions key to illustration 1. 300mm adjacent to a boundary line. 2. The dimension below eaves, balconies and car ports can be reduced to 25mm, as long as the flue terminal is...

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    Pre-installation greenstar i system compact - 6 720 807 726 (2013/05) 16 3.9 flue options the flue systems have different maximum flue lengths: the greenstar series has the option of two horizontal 60/100 rsf (telescopic and longer telescopic) and one horizontal 80/125 rsf (telescopic) flue system a...

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    Pre-installation greenstar i system compact - 6 720 807 726 (2013/05) 17 350 mm - 570 mm 130 mm min flat roof 300 mm 500 mm pitched roof 2 3 4 5 6 10 9 8 7 1 6720643895-12.1wo.

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    Pre-installation greenstar i system compact - 6 720 807 726 (2013/05) 18 3.10 plume management terminal positions fig. 17 plume terminal positions key to illustration 1. This feature allows some basic plume re-direction options on a standard telescopic horizontal flue terminal. 300mm minimum clearan...

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    Pre-installation greenstar i system compact - 6 720 807 726 (2013/05) 19 3.10.1 determine the plume management system length minimum plume management length the minimum plume length is 500mm to ensure that the air inlet and exhaust have a minimum distance of 500mm between them. The plume management ...

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    Installation greenstar i system compact - 6 720 807 726 (2013/05) 20 4 installation 4.1 unpacking wall frame & ancillary items ▶ remove the retaining straps from the carton. ▶ open the four carton flaps and unpack as follows: 1. Remove items 2, 3, 4 and 5 from the cardboard tray. 2. Remove the wall ...

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    Installation greenstar i system compact - 6 720 807 726 (2013/05) 21 fig. 22 marking the flue position ▶ remove the wall mounting template. ▶ secure the wall mounting frame to the wall with the appropriate fittings for the boiler weight and wall type. ▶ remove and discard the red plastic dust cap fr...

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    Installation greenstar i system compact - 6 720 807 726 (2013/05) 22 fig. 26 unused connector ▶ remove any packaging within the boiler and the packaging base (3). ▶ leave the v shaped support (5) in place until the boiler is ready to be hung on the wall frame, then remove. 4.4 pre-plumbing boiler co...

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    Installation greenstar i system compact - 6 720 807 726 (2013/05) 23 4.5 hanging the boiler ▶ stand the boiler upright to gain access to the rear of the hydraulic manifold. ▶ release the wire retaining clip securing the orange plastic blanking plug. 1. Remove the blanking plug from the expansion ves...

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    Installation greenstar i system compact - 6 720 807 726 (2013/05) 24 connecting the expansion vessel to connect the expansion vessel to the hydraulic pump manifold situated to the left of the pump: 1. Release the expansion vessel from the retaining bracket, see fig 34. 2. Ensure that the wire retain...

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    Installation greenstar i system compact - 6 720 807 726 (2013/05) 25 4.6.1 measuring the flue (standard flue) ▶ measure from the outside of the wall to the centre line of the flue turret to determine length l. ▶ subtract 50mm from the length l to give the correct dimension to the flue elbow connecti...

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    Installation greenstar i system compact - 6 720 807 726 (2013/05) 26 fig. 41 aligning the turret ▶ fit the screws removed in step 1 to secure flue turret. ▶ if fitting the outer seal from outside the building, slide the outer wall seal onto the terminal as shown. ▶ “make good” the gap between the fl...

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    Installation greenstar i system compact - 6 720 807 726 (2013/05) 27 4.7 electrical • the mains electrical supply to the boiler must be through either a fused double pole isolator or a fused three pin plug and unswitched socket, situated, where practicable, adjacent to the boiler. • the isolator mus...

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    Installation greenstar i system compact - 6 720 807 726 (2013/05) 28 4.7.1 mounting optional plug-in controls refer the to programmer/timer manual for set up and operation of the unit. Removing the blanking plate the control panel must be released and swung forward slightly to gain access to the top...

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    Installation greenstar i system compact - 6 720 807 726 (2013/05) 29 new complete system installations if a new complete heating system installation is in a new build property or is a first time installation in an existing property, heating systems must conform to current building regulations part l...

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    Installation greenstar i system compact - 6 720 807 726 (2013/05) 30 external 230v programmer and two heat zones with unvented cylinder (s-plan plus) fig. 53 external controls with unvented cylinder existing installations for boiler replacements on an existing system, it is not necessary to zone the...

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    Commissioning greenstar i system compact - 6 720 807 726 (2013/05) 31 optional external frost stat connection for protection of system pipework in unheated air space fig. 55 frost thermostat ▶ connect frost thermostat cables to terminals f s & f r . ▶ these connections are not polarity sensitive. ▶ ...

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    Commissioning greenstar i system compact - 6 720 807 726 (2013/05) 32 water treatment suitable water treatment products can be obtained from the following manufacturers: 5.4 starting the appliance fig. 56 control panel switching the appliance on/off: ▶ turn on the mains power supply, initially the “...

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    Commissioning greenstar i system compact - 6 720 807 726 (2013/05) 33 5.4.1 boiler start up screens on initial start up, the following screens are displayed: 1. All the symbols are displayed for approximately two seconds. 2. The control will run an internal test. 3. When the internal test has been s...

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    Commissioning greenstar i system compact - 6 720 807 726 (2013/05) 34 5.5 commissioning 5.5.1 checking the gas inlet pressure the inlet pressure to the appliance must be checked using the following procedure: measuring the inlet pressure fig. 59 inlet pressure test point ▶ close gas isolation valve....

  • Page 35

    Commissioning greenstar i system compact - 6 720 807 726 (2013/05) 35 fig. 62 l.P.G. Pressures 5.5.2 checking the gas rate ▶ the gas rate should be measured at the gas meter after the boiler has been operating for a minimum of 10 minutes at maximum output. ▶ see technical data section on page 6 of t...

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    Commissioning greenstar i system compact - 6 720 807 726 (2013/05) 36 5.7.2 securing the control panel 4. Raise the control panel. 5. Push the control panel up to engage the top edge under the case. 6. Lift the catches with your fingers. 7. Press the bottom of the control panel back to engage with t...

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    Service and spares greenstar i system compact - 6 720 807 726 (2013/05) 37 6 service and spares • to ensure continued efficient operation the appliance must be checked at regular intervals. • the frequency of servicing will depend upon the particular installation conditions and usage, however normal...

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    Service and spares greenstar i system compact - 6 720 807 726 (2013/05) 38 6.3 checking flue integrity the integrity of the flue system and performance of the boiler can be checked via the flue turret sample points. Fig. 69 flue turret test points with the boiler case on and the boiler running at ma...

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    Service and spares greenstar i system compact - 6 720 807 726 (2013/05) 39 6.5 fan pressure test before setting the boiler to maximum output for the fan pressure test, refer to figure 73: ▶ switch the boiler off. ▶ remove the combustion air intake pipe (1). ▶ remove the fan pressure test point cover...

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    Service and spares greenstar i system compact - 6 720 807 726 (2013/05) 40 6.6 flue gas analysis combustion test ▶ connect the flue gas analyser to the flue gas sampling point (1) as shown in the figure below. ▶ ensure that the probe reaches the centre of the flue gas exhaust, adjust the cone on the...

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    Service and spares greenstar i system compact - 6 720 807 726 (2013/05) 41 6.7.1 cleaning the siphon 1. Protect the controller from water ingress and disconnect the black discharge hose from the wall frame connector. 2. Rotate the siphon body clockwise to release the bayonet connection. 3. Pull the ...

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    Service and spares greenstar i system compact - 6 720 807 726 (2013/05) 42 ▶ use the brush to dislodge the debris and pour water down the channels to flush out the debris. Fig. 80 cleaning the front channels 6.8 replacement of parts 6.8.1 removing the outer case remove the bottom panel: 1. Pull the ...

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    Service and spares greenstar i system compact - 6 720 807 726 (2013/05) 43 6.8.2 draining the boiler many of the tasks in this section require that the boiler be isolate and drained. 1. Connect a suitable hose firmly to the drain point and run the hose outside to a suitable point or container. 2. Tu...

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    Service and spares greenstar i system compact - 6 720 807 726 (2013/05) 44 6.8.7 auto air vent ensure that the boiler has been fully drained. 1. Remove the spring clip completely. 2. Lift the air vent out of the housing and remove. Fig. 88 auto air vent when re-assembling ensure that the “o” ring is...

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    Service and spares greenstar i system compact - 6 720 807 726 (2013/05) 45 sump seal 1. Place seal on sump interface. 2. Be sure the ear lugs of the seal are mounted on the lugs of the sump. Before placing the flue pipe. ▶ be sure the seal is clean and free of debris. Fig. 91 sump seal combustion ai...

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    Service and spares greenstar i system compact - 6 720 807 726 (2013/05) 46 6.8.10 air/gas flap valve assembly 1. Remove the single screw securing the air/gas flap valve assembly. 2. Pull the flap assembly away from the housing. Fig. 95 air/gas flap valve 6.8.11 ignition transformer to remove the ign...

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    Service and spares greenstar i system compact - 6 720 807 726 (2013/05) 47 fig. 99 burner and gasket tightening down the burner housing 1. Tighten the burner housing castellated nuts [1] down gradually and evenly and in a rotating sequence. 2. Tighten the castellated nuts down until they “bottom out...

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    Service and spares greenstar i system compact - 6 720 807 726 (2013/05) 48 fig. 102 heat exchanger removal 6.8.15 diverter valve motor and diverter valve removal ▶ disconnect the lead from the diverter valve motor. 1. Pull the diverter valve motor from the housing. 2. Undo and remove the two screws ...

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    Service and spares greenstar i system compact - 6 720 807 726 (2013/05) 49 6.8.18 boiler return sensor (ntc) ▶ isolate the boiler and ensure that the system is fully drained. 1. Withdraw the spring clip to release the sensor. 2. Pull the sensor down to remove from the housing. ▶ to refit follow the ...

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    Service and spares greenstar i system compact - 6 720 807 726 (2013/05) 50 6.8.22 bypass valve remove the hydraulic block from the boiler, refer to section 6.8.21. 1. Remove the clip on the return connection. 2. Remove the clip on the pump connection. 3. Remove the spring clip retaining the copper b...

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    Service and spares greenstar i system compact - 6 720 807 726 (2013/05) 51 fig. 114 access to the cables [1] low voltage cable inlet [2] mains voltage cable inlet [3] hcm - heating control module [4] pressure gauge [5] low voltage connectors [6] mains voltage and earth connectors removing the contro...

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    Service and spares greenstar i system compact - 6 720 807 726 (2013/05) 52 fig. 116 expansion vessel replacement (remove boiler) ▶ isolate the power from the boiler. ▶ isolate the systems and gas connection using the service valves. ▶ drain the boiler. ▶ disconnect the electrical supply and any exte...

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    Service and spares greenstar i system compact - 6 720 807 726 (2013/05) 53 6.9 short parts list fan 7 746 009 09a 0 burner 8 718 600 23b 0 gas valve 8 718 600 04a 0 control panel 8 737 909 49a 0 flue overheat thermostat (grommet type) 8 717 206 213 0 electrodes (including gasket) 8 718 600 28a 0 bur...

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    Fault finding and diagnosis greenstar i system compact - 6 720 807 726 (2013/05) 54 7 fault finding and diagnosis 7.1 internal wiring diagram 1 13 1 13 1 13 ems 230v in 230v out fr fs lr lr l n l n l n l n l n pump supply flame sense electrode spark electrodes flow ntc max safety ntc flue stat diver...

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    Fault finding and diagnosis greenstar i system compact - 6 720 807 726 (2013/05) 55 7.2 heating function fig. 118 heating function.

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    Fault finding and diagnosis greenstar i system compact - 6 720 807 726 (2013/05) 56 7.3 protection functions fig. 119 protection function.

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    Fault finding and diagnosis greenstar i system compact - 6 720 807 726 (2013/05) 57 7.4 information and service menus status codes during normal boiler operation various status codes can be displayed by pressing the button. The first screen of the information menu displays the current status code, t...

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    Fault finding and diagnosis greenstar i system compact - 6 720 807 726 (2013/05) 58 7.4.1 selecting the information menu the information menu is a "read only" menu. Information about the boiler is displayed here, some of the values are updated in real time to give the current status of the boiler. A...

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    Fault finding and diagnosis greenstar i system compact - 6 720 807 726 (2013/05) 59 7.4.2 selecting service menus 1. Press and hold and buttons together for one second, the display will show menu 1. Double up or down arrows indicate that the menu can only be scrolled up or down, an up and down arrow...

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    Fault finding and diagnosis greenstar i system compact - 6 720 807 726 (2013/05) 60 7.4.3 menu 1 - system parameters initially menu 1 will be displayed, but will contain no options. Menu 1 options will appear on the display when the intelligent solar module ism1 is installed on the greenstar i syste...

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    Fault finding and diagnosis greenstar i system compact - 6 720 807 726 (2013/05) 61 7.4.5 reset to factory settings to reset any or all changes made in menu 2 back to the factory defaults setting: 1. Press and hold the , and arrow button for at lest five seconds. The screen will then display code 8e...

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    Fault finding and diagnosis greenstar i system compact - 6 720 807 726 (2013/05) 62 7.4.7 using the test menu this menu enables the testing of the functionality of components in an on/off mode.The duration of each test is limited to 30 seconds. 1. Select menu test via the and scroll buttons. 2. Pres...

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    Fault finding and diagnosis greenstar i system compact - 6 720 807 726 (2013/05) 63 resetting the test component after completing the test: ▶ press the button, the value 1 will flash. ▶ press the arrow button, the value will change to a flashing 0. ▶ press to confirm the change, a will displayed for...

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    Fault finding and diagnosis greenstar i system compact - 6 720 807 726 (2013/05) 64 7.5 fault codes should a fault develop with this boiler (or the system), the boiler will enter a locking or blocking condition, and fault code information will be generated as described in this section. Locking error...

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    Fault finding and diagnosis greenstar i system compact - 6 720 807 726 (2013/05) 65 blocking errors f0 237 internal error call worcester, bosch group technical helpline 0844 892 3366 238 gas valve error reset button leaking gas valve 239 242 - 256 258 259 262 263 267 272 279 290 internal error call ...

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    Failure to install and commission according to the manufacturer’s instructions and complete this benchmark commissioning checklist will invalidate the warranty. This does not affect the customer’s statutory rights. If yes, and if required by the manufacturer, has a water scale reducer been fitted? Co...

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    Service record it is recommended that your heating system is serviced regularly and that the appropriate service interval record is completed. Service provider before completing the appropriate service record below, please ensure you have carried out the service as described in the manufacturer’s in...

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    Worcester, bosch group cotswold way, warndon, worcester wr4 9sw. Tel. 0844 892 9900 worcester, bosch group is a brand name of bosch thermotechnology ltd. Worcester-bosch.Co.Uk document no. 6 720 807 726 (2013/05) worcester, bosch group: technical support: 0844 892 3366 appointments: 0844 892 3000 sp...