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Worcester GREENSTAR 25Si Instruction Manual

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

Summary of GREENSTAR 25Si

  • Page 1

    Uk/ie instruction manual installation, commissioning & servicing wall hung rsf gas fired condensing combination boiler greenstar 25si/30si for sealed central heating systems and mains fed domestic hot water the appliance is for use with natural gas or l.P.G. (cat ii 2h3p type c13, c33 & c53) natural...

  • Page 2: Plumbnation.Co.Uk

    The nation’s favourite for plumbing & heating supplies secure payments shop online with confidence free shipping on all orders over £100 to mainland uk finance available spread the cost with low interest rates price match always get the best deals available boilers radiators heating controls pipes &...

  • Page 3

    Symbols used in this manual: central heating domestic hot water cold water main supply electricity supply gas supply hot water storage cylinder please read these instructions carefully before starting installation. These instructions are applicable to the worcester appliance model(s) stated on the f...

  • Page 4

    Safety & regulations important information and symbols used in this manual 2 installation and servicing instructions 2 safety precautions 4 installation regulations 4 appliance information general information 5 technical data 6 layout & components 7 pre-installation cleaning primary systems 9 mains ...

  • Page 5

    Safety precautions installation regulations if you smell gas: don’t smoke or strike matches don’t turn electrical switches on or off ✓ do put out naked flames ✓ do open doors and windows ✓ do keep people away from the area affected ✓ do turn off the control valve at the meter ✓ do call your gas comp...

  • Page 6: Check List

    General information installation & servicing instructions for worcester greenstar 25si/30si 8 716 115 165a (06/2008) 5 ap p l ian c e in f o r m a t ion general information standard package: a - wall hung gas fired condensing combi boiler for central heating and domestic hot water b - boiler support...

  • Page 7

    Technical data installation & servicing instructions for worcester greenstar 25si/30si 8 716 115 165a (06/2008) 6 technical data ap p l ian c e inf o rm a t io n description natural gas l.P.G. Unit 25si 30si 25si 30si min. Heat input kw 7.38 7.38 9.64 9.64 max. Rated heat output kw 25 30 25 30 max. ...

  • Page 8

    Layout & components the diagram opposite shows the controls in the servicing position and excludes the outer case. 1 air / gas manifold 2 sensor - boiler flow 3 ignition and flame sense electrodes 4 overheat thermostat 5 retaining bracket 6 expansion vessel 7 removable panel for servicing 8 silicone...

  • Page 9

    Layout & components 14 system pressure gauge 15 system pump 26 plate to plate dhw heat exchanger 33 flow turbine 34 compact hydraulic mounting screw (2) to boiler 35 pressure relief valve 36 diverter valve 37 ch return connection to service valve 38 drain tap 39 cold water in connection 40 internal ...

  • Page 10

    Cleaning primary systems before cleaning the system: ensure the system and pipework is in good working order where possible keep the existing boiler/circulating pump in place when flushing the system. Follow guidance of bs7593: treatment of water in domestic hot water central heating and also flushi...

  • Page 11

    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. • this appliance must not be connected to a three phase supply. • ipx4d. Note: this is reduced to ip20...

  • Page 12

    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 13

    Condensate pipework installation & servicing instructions for worcester greenstar 25si/30si 8 716 115 165a (06/2008) 12 p r e - in st al la ti o n 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 pi...

  • Page 14

    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 b...

  • Page 15

    1450mm 930mm 410mm + 30mm above elbow 5mm 5mm 25mm to removable door 200mm 600mm front clearance for service this boiler is only suitable for installing internally within a property at a suitable location onto a fixed, rigid surface at least the same size as the boiler and capable of supporting the ...

  • Page 16

    Bathrooms: a boiler fitted with a non-mechanical timer or with no timer can be installed in zone 2 or out- side the shaded area . A boiler with a mechanical timer or rf mechani- cal timer with room thermostat must only be installed outside the shaded area. Additional rcd (residual current device) pr...

  • Page 17

    Plumbing manifold connections: heating system: 22mm compression fittings dhw: 15mm compression fittings gas: 22mm 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 yellow plastic guide (a). ...

  • Page 18

    P r e - ins ta l l a t io n flue options installation & servicing instructions for worcester greenstar 25si/30si 8 716 115 165a (06/2008) 17 maximum telescopic flue length 100mmØ 125mmØ 25 si 570mm 1,070mm 30 si 570mm 1,070mm maximum total flue length 100mmØ 125mmØ 25 si 4,600mm 13,000mm 30 si 4,600...

  • Page 19

    Flue terminal positions installation & servicing instructions for worcester greenstar 25si/30si 8 716 115 165a (06/2008) 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 obstruction. • disch...

  • Page 20

    P r e - ins ta l l a t io n flue terminal positions installation & servicing instructions for worcester greenstar 25si/30si 8 716 115 165a (06/2008) 19 flue terminal positions.

  • Page 21

    E f a b c d 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 - syphon assembly important handling instructions • it is advised that two people are used to carry the carton from the van to the point ...

  • Page 22

    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 23

    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 24

    Gas and water connections: remove template and secure the wall mounting frame to the wall with the fixings supplied. System pipes may be run vertically upwards behind the boiler or below it. See plumbing manifold section on page 16. A - ch flow (22mm), b - ch return (22mm), c - gas inlet (22mm), d -...

  • Page 25

    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 26

    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 27

    1 top d e f d 110mm c b g 4 a 3 2 b 110mm c h g b a e top view h d 1 a b b a 2 180° b 3 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 ...

  • Page 28

    Flat at back 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 ...

  • Page 29

    Condensate connection 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 ...

  • Page 30

    Electrics caution: isolate the mains electricity supply before starting any work and observe all relevant safety precautions a 1 2 b 4 f1 f3 f2 roomstat only programmer roomstat and programmer roomstat 230v mains supply st6 st10 eart h swit ched live live neut ral blue green/yellow brown froststat e...

  • Page 31

    Position of wired components c o mmi s s io n in g position of wired components installation & servicing instructions for worcester greenstar 25si/30si 8 716 115 165a (06/2008) 30 ins ta l l a t io n.

  • Page 32

    Pre-commissioning checks caution: isolate the mains supplies before starting any work and observe all relevant safety precautions 1 check that the service and water pipes are connected to the correct position on the manifold. A - ch flow (22mm) b - ch return (22mm) c - gas inlet (22mm) d - dhw (15mm...

  • Page 33

    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 34

    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 fault indicator (blue...

  • Page 35

    Water treatment 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 sys...

  • Page 36

    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 37

    Finishing commissioning 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. Fitting fascia flap: pr...

  • Page 38

    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 h...

  • Page 39

    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 40

    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 setting procedure. It will be necessary to run water through the dhw circuit to ensure that the boiler wil...

  • Page 41

    1 a b 2 c e inspection and service remove control retaining screw 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 isolate the power to the appliance and remove outer case and base panel. ...

  • Page 42

    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 remove from boiler. 8 disco...

  • Page 43

    R inspection and service 9 m n o p q s 8 remove burner (m). Remove top baffle (n). Remove lower baffle (0). 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 44

    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 45

    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 46

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

  • Page 47

    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 thro...

  • Page 48

    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 49

    Replacement of parts 12. 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. Check co/co2 levels as described in the ...

  • Page 50

    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 ensure the app...

  • Page 51

    Replacement of parts 20. Pump head ensure the boiler is fully drained). 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, follow the above in reverse. Pr...

  • Page 52

    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 . Disconnect t...

  • Page 53

    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 54

    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 55

    Setting the air / gas ratio for the sit 848.093 sigma this page shows the setting procedure for the sit valve for alternative valve see page 55 dungs. 30. Setting the co/co 2 note: when running in the service mode, the boiler will operate both the central heating & dhw circuits. This is to allow suf...

  • Page 56

    Setting the air / gas ratio for dungs gb-nd 055 do1 s20 this page shows the setting procedure for the dungs valve for alternative valve see page 54. 30. Setting the co/co 2 note: when running in the service mode, the boiler will operate both the central heating & dhw circuits. This is to allow suffi...

  • Page 57

    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 58

    Con v e r s ion ki t s lpg conversion installation & servicing instructions for worcester greenstar 25si/30si 8 716 115 165a (06/2008) 1.1 1.2 a 2.1 th e ai r / gas 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 s et ti n g th e ai r / gas r ati o sectio...

  • Page 59

    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 60

    C e ntr al h e a t in g f u n cti o n no yes power switch on central heating demand fan to start speed. Diverter valve in ch position pump on. Ignition sequence (see detail) blue light on burner lit? Green flame light on stop spark. Wait 10 seconds 5th attempt? Lockout 10 second stabilisation period...

  • Page 61

    Wait 5 seconds ignition sequence (see detail) p r e h e a t an d d hw f u n cti o n no yes power switch on tap open (recognised by flow turbine) diverter valve in dhw position pump on. Blue light on burner lit? Fan to start speed. Stop spark. Wait 10 seconds 5th attempt? Lockout fan (& gas) modulati...

  • Page 62

    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 25si/30si 8 716 115 165a (06/2008) 61 f a ul t f ind in g & d ia g r a m s.

  • Page 65

    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...