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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 & c53) natural gas: 24i junior gc number 47-311-86 28i junior gc number 47-311-87 liquid petroleum gas: 24i junior gc number 47-311-90 28i junior gc number 47-311-91 uk/ie instruction manual installation, commissioning & ...

  • Page 2

    Installation & servicing instructions installation & servicing instructions for worcester greenstar 24 i junior/28 i junior 8 716 115 166b (03/2009) 2 water treatment: fernox 01799 550811 www.Fernox.Com sentinel 0800 389 4670 www.Sentinel-solutions.Net flue terminal guards: tower flue components ltd...

  • Page 3

    Safety & regulations installation and servicing instructions 2 safety precautions & symbols 4 installation regulations 4 appliance information general information 5 technical data 6 layout & components 7 pre-installation cleaning primary systems 9 mains supply 10 water systems & pipework 11 condensa...

  • Page 4

    Safety precautions & installation regulations installation & servicing instructions for worcester greenstar 24 i junior/28 i junior 8 716 115 166b (03/2009) 4 s a fe ty & r e g u l a t ion s.

  • Page 5: Check List

    General information 700mm* 400mm a 330mm general information installation & servicing instructions for worcester greenstar 24 i junior/28 i junior 8 716 115 166b (03/2009) 5 ap p l ian c e in f o r m a t ion b c d (when fitted to wall frame) depth to wall check list hardware/literature pack item qty...

  • Page 6

    Technical data installation & servicing instructions for worcester greenstar 24 i junior/28 i junior 8 716 115 166b (03/2009) 6 technical data ap p l ian c e inf o rm a t io n description natural gas l.P.G. Unit 24 ijunior 28 ijunior 24 ijunior 28 ijunior domestic hot water min. Heat input kw 7.38 7...

  • Page 7

    Layout & components layout & components installation & servicing instructions for worcester greenstar 24 i junior/28 i junior 8 716 115 166b (03/2009) 7 ap p l ian c e in f o r m a t ion the diagram opposite shows the controls in the servicing position and excludes the outer case. 1 air / gas manifo...

  • Page 8

    Layout & components layout & components installation & servicing instructions for worcester greenstar 24 i junior/28 i junior 8 716 115 166b (03/2009) 8 ap p l ian c e inf o rm a t io n 14 system pressure gauge 15 system pump 26 plate to plate dhw heat exchanger 33 flow turbine 34 compact hydraulic ...

  • Page 9

    Cleaning primary systems installation & servicing instructions for worcester greenstar 24 i junior/28 i junior 8 716 115 166b (03/2009) 9 p r e - in st al la ti o n cleaning primary systems before cleaning the system: ensure the system and pipework is in good working order where possible keep the ex...

  • Page 10

    Mains supply installation & servicing instructions for worcester greenstar 24 i junior/28 i junior 8 716 115 166b (03/2009) 10 p r e - in st al la ti o n mains water expansion vessel: a - mini expansion vessel, part no. 7 716 102 105 b - mains water inlet c - non-return valve d - boiler a b c d elec...

  • Page 11

    Water systems & pipework plastic pipework: • any plastic pipework must have a polymeric barrier with 600mm (minimum) length of copper pipe connected to the boiler. • plastic pipework used for underfloor heating must be correctly controlled with a thermostatic blending valve limiting the temperature ...

  • Page 12

    Condensate pipework fitting an external air break use the situation opposite when a rain water down pipe is used to dispose of condensate and the down pipe goes directly into an existing sewer that carries both rainwater and foul water. An air break must be installed in the 32/43 mm pipework, betwee...

  • 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 8 716 115 166b (03/2009) 14 p r e - in st al la ti o n 24 & 28 kw vent to room or direct to position internal space outside high minimum free minimum level area 122 cm 2 free area 61 cm...

  • Page 15

    Boiler location & clearances installation & servicing instructions for worcester greenstar 24 i junior/28 i junior 8 716 115 166b (03/2009) 15 p r e - ins t a l l a t io n 1 1 2 2 1 1 2 bathrooms: a boiler fitted with a non-mechanical timer or with no timer can be installed in zone 2 or out- side th...

  • 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 - ins t a l l a t io n flue options installation & servicing instructions for worcester greenstar 24 i junior/28 i junior 8 716 115 166b (03/2009) 17 maximum telescopic flue length 100mmØ 125mmØ 24 i jun. 570mm 1,070mm 28 i jun. 570mm 1,070mm maximum total flue length 100mmØ 125mmØ 24 i jun. 4...

  • Page 18

    Flue terminal positions installation & servicing instructions for worcester greenstar 24 i junior/28 i junior 8 716 115 166b (03/2009) 18 p r e - in st al la ti o n • the flue must be fitted and terminated in accordance with the recommendations of bs5440 : part 1. • the flue must not cause an obstru...

  • Page 19

    Installation & servicing instructions for worcester greenstar 24 i junior/28 i junior 8 716 115 166b (03/2009) 19 flue terminal positions flue terminal positions p r e - ins t a l l a t io n.

  • Page 20

    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 1 2 3 a - straps b - outer carton c - installer pack d - bottom panel e - wall mounting frame f - wall template g - inner packaging h - front fascia j ...

  • Page 21

    C o mmi s s io nin g safety: all relevant safety precautions must be undertaken. Protective clothing, footwear, gloves and safety goggles must be worn as appropriate. Fixing the mounting frame: • the boiler template shows the relative positions of the flue and the top and bottom fixing of the mounti...

  • Page 22

    4 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 4. Remove outer carton (a) and place safely away from the working area. 5. With the outer packaging removed and the inner sle...

  • Page 23

    A e d b handling hole do not lift by the air gas manifold. 3 c 1a 22mm 15mm washer 15mm 22mm 2 & 4 h 1 boiler connections caution: isolate th e mai ns gas supply before starting any work and observe all relevant safety precautions. 4 2 stop in locked position gas and water connections: remove templa...

  • Page 24

    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 22mm 15mm 22mm a e c d b 5 f gas and water connections: a - ch flow (22mm), b - ch return (22mm), c - gas inlet (22mm), d - mains water inlet (15mm), e...

  • Page 25

    Flue installation horizontal flue (60/100mm diameter) for vertical flues and 80/125mm horizontal flues, please refer to separate instructions supplied with the flue kit. Note: to ease assembly of flue components, apply silicone lubricant to sealing surfaces. Basic instructions for the 60/100mm diame...

  • Page 26

    Top d e f d c b g a b 110mm c h g b a e top view h d a b b a 180° b c ±80° c flue installation installing the standard flue: 1 set the flue length to the distance required, secure with screw and seal joint with the aluminium tape supplied. Slide the inner wall seal (a) onto the terminal (b) as shown...

  • Page 27

    Flue installation 4 assemble elbow to boiler using the three screws (see below). Note: screws are in boiler not in flue kit. Fitting the elbow: • flue elbow should push directly down and not be twisted into correct position. Remove the 3 inner flue tube retaining screws. The inner tube will be held ...

  • Page 28

    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 29

    Electrics a 1 2 caution: isolate the mains electricity supply before starting any work and observe all relevant safety precautions the boiler is pre-wired with a two metre mains supply cable a spare strain relief block is supplied in case the pre-wired cable is not used. The mains supply to the boil...

  • Page 30

    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 8 716 115 166b (03/2009) 30 ins t a l l a t io n.

  • Page 31

    22mm 15mm 22mm 15mm 22mm a d c e b 2 3 f pre-commissioning checks caution: isolate the mains supplies before starting any work and observe all relevant safety precautions important: if the boiler is not to be commissioned immediately then: after successfully completing all of the checks and any rect...

  • Page 32

    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 loop to 1 bar then turn the valve anti-clock- wise to close. 4 vent (a) any air from the boiler heat exchanger using a suitable container to collect any w...

  • Page 33

    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 34

    Ensure that the system has been cleaned as on page 8 of these instructions. Flushing (central heating): switch off the boiler. Open all drain cocks and drain the system while the appliance is hot. Close drain cocks and add a suitable flushing agent at the correct strength for the system condition in...

  • Page 35

    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 36

    Finishing commissioning a a b b c c c c d e the boiler has been factory set, so there should be no need to adjust any controls. 1. Replace outer casing: replace outer casing making sure that the securing points are properly located. Replace top two screws (a). Retighten bottom two screws (b). 2. Fit...

  • Page 37

    Inspection and service note: a service must not be attempted if a co/co2 analyser is not available. • 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. ...

  • Page 38

    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 39

    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 40

    E 3 inspection and service to clean the heat exchanger there is a special accessory kit available specifically designed for cleaning the heat exchanger. If required order 7 716 192 312. 1 with outer case and base panel removed and the power isolated from the appliance, remove the cover panel (a) by ...

  • Page 41

    Inspection and service 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 fan and air/gas manifold assembly (j) around the top of the heat exchanger until it stops at the lug. Lift up assembly and remov...

  • Page 42

    R inspection and service 9 m n o p q s 9 remove burner (m). Remove top baffle (n). Remove lower baffle (o). Remove the two pozi-drive screws (p) retaining the access cover (q) on the sump. Access the heat exchanger flue ways by inserting the cleaning brush (7 716 192 312) through the top access hole...

  • Page 43

    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 44

    Replacement of parts sit and dungs valves removal of the valve is the same for both sit and dungs valves. The sit valve is shown in the diagram. R e p l ac e m e nt o f th e g as valve m u st n ot b e c ar r i e d o ut i f a co/co2 analyser is not available. 5. Moving boiler control to service posit...

  • Page 45

    8 b replacement of parts 7. Access to boiler control components remove 3 screws (a) and remove cover from control. 8. Pcb fuse remove fuse f1(b) from the pcb and replace. There is a spare fuse clipped into the underside of the electrical cover. 9.Transformer / pcb disconnect all electrical connectio...

  • Page 46

    10.3 replacement of parts 10. Replacing control important: do not replace the control unit if a co/co 2 analyser is not available. 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...

  • Page 47

    Replacement of parts 11. 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). 11.1 undo and remove securing nut (a) from the top of the heat exc...

  • Page 48

    Replacement of parts 12. Fan 12.1 remove 3 screws (a) retaining mixing chamber. 12.2 remove 2 screws (b) retaining the fan to the air/gas manifold. 12.3 remove screw (c) retaining plate and remove. Re-assemble with new fan ensuring seals are correctly fitted. Check co/co2 levels as described in the ...

  • Page 49

    Replacement of parts note: removal of the syphon assembly will give access to auto air vent. To release the syphon from the sump connection, pull towards you (a). Disconnect the discharge hose (b) at the plumbing manifold. Remove the complete syphon assembly. 16. Diverter valve motor insure the appl...

  • Page 50

    Replacement of parts 20. Pump head ensure the boiler is fully drained (see draining the appliance). Disconnect the electrical connection from the bottom of the pump. 20.1 remove the four allen bolts (a) securing the pump at each corner. 20.2 gently pull the pump towards you and remove. To refit, fol...

  • Page 51

    A b replacement of parts note: remove the syphon assembly. To release the syphon from the sump connection, pull towards you (a). Disconnect the discharge hose (b) at the plumbing manifold. Remove the complete syphon assembly. 24. Hydraulic block ensure the appliance has been fully drained (see drain...

  • Page 52

    Replacement of parts note: remove the hydraulic block from the boiler (see removing the hydraulic block on page 51). 26. 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 ...

  • Page 53

    Replacement of parts note: remove the hydraulic block from the boiler (refer to page 51). 28. Bypass valve 28.1 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 free up the...

  • Page 54

    Setting the gas / air ratio for the sit 848.093 sigma the setting of the gas ratio must be carried out by a competent person. Setting of the gas ratio must not be at t e m p t e d u n l e s s t h e p e r s o n c a r r y i n g o u t t h e c o n v e r s i o n i s equipped with a combustion analyser c ...

  • Page 55

    Setting the gas / air ratio for dungs gb-nd 055 do1 s20 the setting of the gas ratio must be carried out by a competent person. Setting of the gas ratio must not be at t e m p t e d u n l e s s t h e p e r s o n c a r r y i n g o u t t h e c o n v e r s i o n i s equipped with a combustion analyser ...

  • Page 56

    Short parts list 1 fan worcester part no. 8 717 204 453 0 gc no. H26 536 2 burner worcester part no. 8 718 120 619 0 gc no. H49 326 3 gas valve ng & lpg worcester part no. 8 716 111 325 0 gc no. 796 269 4 control board worcester part no. 8 716 109 540 0 gc no. H31 408 5 flue overheat thermostat (gro...

  • Page 57

    A 1.1 1.2 2.1 t h e a i r / g as r at i 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 s e t t i n g t h e a i r / g as r at i o section of this manual. 3.1 3.2 c d a l. P. G. Conversion important: the appliance shall not be installed into a room or internal s...

  • Page 58

    Off on slow flash (normally off, flashes on) slow flash (normally on, flashes off) fast flash fast flash 2 pulses 5 pulses off off flashing (reset required) flashing (reset required) off flashing no light no light permanent mains supply to boiler. Boiler mains switch. Fuse f1, 2.5a or fuse f3, 0.5a ...

  • Page 59

    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 pu m p o n . Ig n it ion se qu e n ce (see detail) bl ue li g h t on burner li t ? Green f lam e li g h t on stop spark. W a it 10 seconds 5th attempt? L o ck out 10...

  • Page 60

    Wa it 5 seconds ig n it ion 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 pu m p o n . Bl ue li g h t on burner li t ? F an to start speed. Stop spark. W a it 10 seconds 5th attempt? L o ck out f ...

  • Page 61

    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 8 716 115 166b (03/2009) 61 f a ul t f ind in g & d ia g r a m s.

  • Page 64

    Pack number contact information worcester, bosch group: technical: 08705 266241 service: 08457 256206 spares: 01905 752571 literature: 01905 752556 training: 01905 752526 sales: 01905 752640 website: www.Worcester-bosch.Co.Uk if in the unlikely event the boiler does not give complete satisfaction, b...