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  4. GREENSTAR 24i junior
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Worcester GREENSTAR 24i junior Instruction Manual

Manual is about: WALL HUNG RSF GAS-FIRED CONDENSING COMBINATION BOILER

Summary of GREENSTAR 24i junior

  • Page 1

    The appliance is for use with natural gas or l.P.G. (cat ii 2h3p type c13 & c33) natural gas: worcester greenstar 24i junior gc number 47-311-86 worcester greenstar 28i junior gc number 47-311-87 liquid petroleum gas: worcester greenstar 24i junior gc number 47-311-90 worcester greenstar 28i junior ...

  • Page 2

    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

    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 relief pipework 1...

  • Page 4

    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 turn electri...

  • Page 5

    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 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 24.49...

  • Page 7

    Layout & components the diagram opposite shows the controls in the servicing position and excludes the outer case. 1 air / gas manifold 2 fan 3 air / gas adjustment screw 4 gas valve 5 inlet pressure test point 6 expansion vessel 7 wall mounting frame 8 cover for external wiring connections 9 conden...

  • Page 8

    Layout & components 10 plate to plate dhw heat exchanger 32 system pump 36 flow turbine 37 unused port 38 auto air vent 39 flow connection from boiler heat exchanger 40 dhw sensor 41 ch flow connection to service valve 42 dhw out connection 43 cold water in connection 44 ch return connection to serv...

  • Page 9

    Cleaning primary systems before cleaning the system: ensure the system and pipework is in good working order keep the existing boiler/ circulating pump where possible or use a power flushing machine to aid the cleansing procedure before installing a new boiler. Cleaning the primary system: 1 fill th...

  • Page 10

    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...

  • Page 11

    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 tem...

  • Page 12

    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 ...

  • Page 13

    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 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 internally within a property at a suitable location onto a ...

  • Page 15

    Boiler location & clearances installation & servicing instructions for worcester greenstar 24 i junior/28 i junior 8 716 107 336b (11/05) 14 p r e - in st al la ti o n 1 1 2 3 2 3 1 1 2 3 bathrooms: if the appliance is fitted in conjunction with a mechanical or r f mechanical timer, the appliance ca...

  • Page 16

    Plumbing manifold connections: heating system: 22mm compression fittings dhw: 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 through the slot in the yello...

  • Page 17

    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 p...

  • Page 18

    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. • shade...

  • Page 19

    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 junior 8 716 107 336b (11/05)...

  • Page 20

    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 safety goggl...

  • Page 21

    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 pa...

  • Page 22

    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 the air gas manifold. 3 c 1a 22mm 15mm 22mm 15mm 22mm 2 & 4 h 1 boiler connections caution: isolate th e mai ns g...

  • Page 23

    Boiler connections installation & servicing instructions for worcester greenstar 24 i junior/28 i junior 8 716 107 336b (11/05) 22 in st al la ti o n boiler connections caution: isolate th e mai ns gas supply before starting any work and observe all relevant safety precautions. A e d b c 22mm 15mm 2...

  • Page 24

    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 supplied ...

  • Page 25

    Flue installation installation & servicing instructions for worcester greenstar 24 i junior/28 i junior 8 716 107 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 the outside wall to t...

  • Page 26

    Flue installation installation & servicing instructions for worcester greenstar 24 i junior/28 i junior 8 716 107 336b (11/05) 25 in st al la ti o n a b c d e a - standard flue b - internal wall seal c - external wall seal d - clamp e - extension duct flat at back flue installation assembling the fl...

  • Page 27

    Condensate connection: never terminate or discharge into any open source, including; sink, bath, shower, bidet, toilet etc. Note: any external condensate pipework should be protected with weather resistant insulation to help prevent freezing. • ensure that the condensate drain is 22mm diameter plast...

  • Page 28

    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 boiler...

  • Page 29

    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 junior 8 716 107 336b (11/05) 28 in st al la ti o n.

  • Page 30

    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 supplies before starting any work and observ...

  • Page 31

    Filling the system installation & servicing instructions for worcester greenstar 24 i junior/28 i junior 8 716 107 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 filling l...

  • Page 32

    A d f c b g e h i switching the appliance on/off: 1 turn on mains power supply turn on any external controls set the thermostatic radiator controls to maximum temperature set the clock/programmer to continuously on and the room thermostat to maximum temperature 2 a - on/off button b - on/off and fau...

  • Page 33

    Water treatment ensure that the system has been cle an e d as on pag e 8 of th e s e instructions. 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 flushing agent (e) at t...

  • Page 34

    Commissioning the combustion for the appliance is factory set. No adjustment is required if the gas 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) for...

  • Page 35

    Finishing commissioning installation & servicing instructions for worcester greenstar 24 i junior/28 i junior 8 716 107 336b (11/05) 34 c o mmi s s io n in g finishing commissioning the boiler has been factory set, so there should be no need to adjust any controls. Replace outer casing: 1 replace ou...

  • Page 36

    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

    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

    Inspection and service setting boiler to maximum. Note: when running in the service mode, the boiler will operate both the central heating and dhw circuits. This is to allow sufficient time for the setting procedure. It will be necessary to run water through the dhw circuit to ensure that the boiler...

  • Page 39

    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 40

    Inspection and service 4 remove electrical connector from fan. 5 undo and remove securing nut (e) from the top of the heat exchanger. 6 remove stainless steel viewing mirror (f). 7 rotate fan and air/gas manifold assembly (g) around the top of the heat exchanger until it stops at the lug. Lift up as...

  • Page 41

    Q inspection and service installation & servicing instructions for worcester greenstar 24 i junior/28 i junior 8 716 107 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 screws (...

  • Page 42

    Caution: turn off the gas supply and isolate the mains s u p p li e s b e for e starti ng any wor k an d ob s e rve all relevant safety precautions. Important: after replacement of any components always check for gas soundness where relevant and carry out functional checks as described in commission...

  • Page 43

    Replacement of parts 5. Moving boiler control to service position 5.1 remove screw (a) securing control. 5.2 gently pull forward. 6. Gas valve isolate gas supply at boiler gas cock. 6.1 remove wire clip from gas valve outlet then pull gas adjustment assembly free from plastic connector and pull forw...

  • Page 44

    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

    12.3 replacement of parts 12. Replacing control the control is supplied within its plastic housing. The complete unit must be replaced. Remove all electrical connections from the control pcb including where cables run through restraints. These can be unclipped from the plastic moulding noting their ...

  • Page 46

    Replacement of parts 13. Air / gas manifold and fan assembly remove electrical connector from fan. Remove wire clip from gas valve outlet then pull gas adjustment assembly free from plastic connector and pull clear of case (see 6.1). 13.1 undo and remove securing nut (a) from the top of the heat exc...

  • Page 47

    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

    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. The assembly will slide free from the valve. To refit, fol...

  • Page 49

    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

    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

    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

    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

    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 for the setting procedure. It will be necessary to run water through the dhw circuit to ensure that the boiler will not cycle on low heating ...

  • Page 54

    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

    1.1 1.2 a 2.2 2.3 2.1 3 c b th e gas / ai r r ati o m u st b e r eset afte r conve r sion. Th e p r o c e d u r e c an b e f o u n d i n the replacement parts section of this manual. 4.1 4.2 d e a l. P. G. Conversion l.P.G. Conversion installation & servicing instructions for worcester greenstar 24 ...

  • Page 56

    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 off flashi...

  • Page 57

    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

    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 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 junior 8 716 107 336b (11/05) 58 f a ul t f ind in g & d ia g r a m s.

  • Page 60

    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 boiler heating zone...

  • Page 61: Service Interval Record

    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: Check List

    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 &...