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- Worcester
- Boiler
- GREENSTAR 29
- Installation And Servicing Instructions
Worcester GREENSTAR 29 Installation And Servicing Instructions
Summary of GREENSTAR 29
Page 1
Installation and servicing instructions greenstar 29 he conventional wall mounted condensing boiler 6 720 610 577-00.10 he conventional gc-number natural gas: 41 311 56 gc-number lpg: 41 311 57 6 720 611 137 gb (03.02) osw.
Page 2: Contents
6 720 611 137 gb (03.02) 2 contents contents safety precautions 3 symbols 3 1 details of the appliance 4 1.1 ec declaration of conformity 4 1.2 standard package 4 1.3 description of appliance 4 1.4 accessories 5 1.5 casing dimensions 5 1.6 layout of appliance 6 1.7 function 7 1.8 electrical wiring d...
Page 3: Safety Precautions
6 720 611 137 gb (03.02) safety precautions 3 safety precautions if you smell gas b turn off gas service cock at the meter. B open windows and doors. B do not operate any electrical switches. B extinguish any naked flames. B telephone your gas company. If you smell fumes from the appliance b switch ...
Page 4: Details of The Appliance
6 720 611 137 gb (03.02) 4 details of the appliance 1 details of the appliance 1.1 ec declaration of conformity this appliance is in accordance with the applicable requirements of the gas appliance directive, boiler efficiency directive, electromagnetic compatibility directive and the low voltage di...
Page 5
6 720 611 137 gb (03.02) details of the appliance 5 1.4 accessories • standard horizontal flue kit at 100 mm outside diameter for flues upto 4 m in length. • flue duct kits for horizontal (125 mm outside diameter) for flue lengths upto 13 m and vertical flue systems for flue lengths upto 15 m. Fitti...
Page 6
6 720 611 137 gb (03.02) 6 details of the appliance 1.6 layout of appliance fig. 2 4 heatronic control 4.4 y-s-module 6 heat exchanger safety temperature limiter 7 testing point for gas supply pressure 9 flue gas temperature limiter 15 safety valve 27 automatic air vent 29 air gas mixer unit 32.1 el...
Page 7
6 720 611 137 gb (03.02) details of the appliance 7 1.7 function fig. 3 4 bosch heatronic control 4.4 y-s-module 6 temperature limiter, heat exchanger 7 testing point for gas supply pressure 9 flue gas temperature limiter 13 manifold 15 safety valve 27 automatic air vent 29 mixer unit 29.1 bi-metall...
Page 8
6 720 611 137 gb (03.02) 8 details of the appliance 1.8 electrical wiring diagram fig. 4 4.1 ignition transformer 4.4 y-s-module 6 temperature limiter, heat exchanger 9 flue gas temperature limiter 32 flame sensing electrode 33 ignition electrode 36 temperature sensor in primary flow 52 solenoid val...
Page 9
6 720 611 137 gb (03.02) details of the appliance 9 1.9 technical data units natural gas propane max. Rated heat output net 40/30˚c central heating max. Rated heat output net 50/30˚c central heating max. Rated heat output net 80/60˚c central heating kw kw kw 29.3 29.0 27.4 29.3 29.0 27.4 max. Rated ...
Page 10: Installation Regulations
6 720 611 137 gb (03.02) 10 installation regulations condensate analysis, mg/l flue system elbow - 90 ° equivalent length 2 m bend - 45 ° equivalent length 1m gas supply 2 installation regulations gas safety (installation & use) regulations: all gas appliances must be installed by a competent person...
Page 11: Installation
6 720 611 137 gb (03.02) installation 11 3 installation 3.1 important remarks b appliance is prepared to be installed in fully pumped sealed and open vent central heating systems. B to avoid gas formation in the system, galvanised radiators or pipes must not be used. B if a room thermostat is used: ...
Page 12
6 720 611 137 gb (03.02) 12 installation fig. 5 fig. 6 system layout if using honeywell 'y' plan primary cold feed (15mm min.) heating vent (22mm min.) feed and vent cistern diverting valve boiler pump radiator s.H. – minimum static head 1.0m measured from the highest point in the heating system (to...
Page 13
6 720 611 137 gb (03.02) installation 13 fig. 7 fig. 8 3.3 siting the appliance regulations concerning the installation site b relevant national regulations must be complied with section 3.8.1. B consult the installation instructions for details of min- imum clearances required. Combustion air in or...
Page 14
6 720 611 137 gb (03.02) 14 installation 3.4 wall mounting frame assembly b take the wall mounting frame out of the package and screw together with 6 screws as shown in fig. 9. Use the inner lugs on the top and bottom horizontal sec- tions for the appliances that are 440 mm wide. Fig. 9 b hold the w...
Page 15
6 720 611 137 gb (03.02) installation 15 condensate termination and route the condensate connection on the greenstar appli- ances is in 22 mm plastic. The pipe should be extended and run away from the appliance with a constant fall of 2.5 ° or 40 mm in every metre. The condensate pipe can terminate ...
Page 16: 1 .
6 720 611 137 gb (03.02) 16 installation b remove the plastic caps from the boiler connec- tions. Fig. 15 fixing the appliance b fit the washers onto the gas and water connections. B lift the boiler onto the wall-mounting frame. The lugs pass through the rectangular holes in the boiler back panel. B...
Page 17
6 720 611 137 gb (03.02) installation 17 3.8.1 siting the flue terminal the flue must be installed in accordance with bs 5440:1 and the building regulations. Flue termi- nals in carports and under balconies are to be avoided. The terminal must be positioned so that it does not cause an obstruction n...
Page 18
6 720 611 137 gb (03.02) 18 installation 3.8.2 installation of the flue the standard 100 mm diameter horizontal flue system is suitable for lengths upto 4 m. Flues upto 650 mm do not require an extension duct assembly. Flues between 600 mm and 4000 mm require exten- sion duct assemblies. Note: flue ...
Page 19
6 720 611 137 gb (03.02) installation 19 fig. 20 flue with one extension fig. 21 flue with extensions fig. 22 flue components maximum 1600mm flue turret no clamp terminal assembly outer wall extension duct 6 720 610 602 - 09.1o clamp flue turret no clamp clamp extension duct clamp extension duct ter...
Page 20
6 720 611 137 gb (03.02) 20 installation 3.8.3 flue duct preparation and assembly measure the flue length l. Refer to fig. 23, 24. Fig. 23 flue length - rear fig. 24 flue length - side mark off the lengths shown onto the ducts and cut to length. The cuts must be square and free from burrs. Terminal ...
Page 21: Electrical Connections
6 720 611 137 gb (03.02) electrical connections 21 4 electrical connections all control and safety systems are built into the appli- ance. B allow mains cable to protrude at least 50 cm from wall. B to make splash-water proof (ip): cut the cable grom- met hole size to match diameter of cable, see fi...
Page 22
6 720 611 137 gb (03.02) 22 electrical connections 4.2 wiring to your system mains electrical supply: the boiler should be connected to the permanent mains supply as described in section 4.1. This also provides the electrical supply to the system. Note: this must be the only electrical supply to the...
Page 23: Commissioning
6 720 611 137 gb (03.02) commissioning 23 5 commissioning fig. 32 15 safety valve 27 automatic vent 61 reset button 135 master switch 136 temperature control for central heating 170 service cocks on flow and return 172 gas cock (shown in on position) 295 appliance type sticker 310 function control (...
Page 24
6 720 611 137 gb (03.02) 24 commissioning b before commissioning, the gas supply pres- sure must be checked at the gas supply pres- sure test point (see page 6, fig. 2, item 7). Natural gas appliances must not be operated if the gas supply pressure is below 18 mbar or above 24 mbar. Lpg appliances m...
Page 25
6 720 611 137 gb (03.02) commissioning 25 5.6 fault condition in the unlikely event of a fault occuring while the appli- ance is in operation: the display then shows a fault code and the button may also flash. If the button flashes: b press and hold the button until the display shows “– –”. The appl...
Page 26: Individual Settings
6 720 611 137 gb (03.02) 26 individual settings 6 individual settings 6.1 mechanical settings 6.1.1 setting the boiler flow temperature the central heating flow temperature can be set to between 50˚c and 88˚c. Limited maximum setting for low-temperature operation the temperature control is factory l...
Page 27
6 720 611 137 gb (03.02) individual settings 27 entering a setting b to enter the setting for a function, turn the function control. Storing a setting b level 1: press and hold the button until the dis- play shows [ ]. B level 2: press and hold the and buttons simul- taneously until the display show...
Page 28
6 720 611 137 gb (03.02) 28 individual settings b measure the gas flow rate and compare with the fig- ures specified for the code number displayed. If fig- ures do not match, adjust the code number! B press and hold the and buttons simultane- ously until the display shows [ ]. The heating output is ...
Page 29
6 720 611 137 gb (03.02) converting the appliance to different gas types 29 7 converting the appliance to different gas types the setting is factory sealed at maximum. Adjustment to the rated heat input and min. Heat input is not neces- sary. Checking the gas supply pressure b check the gas supply p...
Page 30
6 720 611 137 gb (03.02) 30 converting the appliance to different gas types b turn the function control until the display shows 2. (= max. Rated heat output). The display and the button will flash. Fig. 43 b measure the co 2 level. B prise off the seal on the gas flow restrictor. B adjust the gas fl...
Page 31
6 720 611 137 gb (03.02) converting the appliance to different gas types 31 7.2 testing combustion air/flue gas at set heat output 7.2.1 testing the o 2 or co 2 level in the combus- tion air b press and hold the button until the display shows – –. “chimney sweep” mode is now active. The button will ...
Page 32: Maintenance
6 720 611 137 gb (03.02) 32 maintenance 8 maintenance b the user should be recommended to have the appli- ance serviced regularly by a competent person (see maintenance contract). B use only genuine spare parts b refer to the spare parts list when ordering spare parts. B always renew seals and o-rin...
Page 33
6 720 611 137 gb (03.02) maintenance 33 8.1 pre-service check list date 1 call up the last fault stored by the bosch heatronic, service function .0, (see page 34). 2 check ionisation current, service function 3.3, (see page 34). 3 perform visual check of air/flue duct.Visual check of diaphragm for s...
Page 34
6 720 611 137 gb (03.02) 34 maintenance 8.2 description of servicing operations the combustion performance must be checked before and after any servicing work on the combustion and burner components. Refer to section 7.2. Check “last fault stored”: b select service function .0 (see page 26 “selectin...
Page 35
6 720 611 137 gb (03.02) maintenance 35 b clean out the condensate collector and trap connec- tion (with other end of brush). Fig. 52 b refit the clean-out cover using a new seal and tighten screws to torque of approx. 5 nm. Burner b check that the gas cock is turned off and the master switch is in ...
Page 36
6 720 611 137 gb (03.02) 36 maintenance diaphragm in mixer unit b open mixer unit (29). B carefully withdraw diaphragm (443) from fan intake tube and check for soiling and splits. Fig. 55 b carefully refit diaphragm (443) the correct way round into the fan intake tube. B seal the mixer unit (29). Si...
Page 37
6 720 611 137 gb (03.02) maintenance 37 8.3 replacement of parts before changing any components check that the gas is turned off and that the appliance is electrically isolated. When necessary close the system valves and drain the appliance. Refitting is a reverse of the procedure for removal using ...
Page 38
6 720 611 137 gb (03.02) 38 maintenance 8.3.2 fan assembly fig. 59 b switch off the appliance. B disconnect the appliance from the power supply. B undo lower pipe union on gas pipe (1.). Refer to fig. 59. B remove fan lead and earth connector (2.). The earth connector has a positive clip fixing. B r...
Page 39
6 720 611 137 gb (03.02) maintenance 39 fig. 61 8.3.5 electrode assembly b refer to section 8.2. B use a new seal if the existing seal is damaged. 8.3.6 pressure relief valve b drain the appliance. B disconnect the drain pipe from the valve. Refer to fig. 32. B pull-out the clip securing the valve. ...
Page 40: Appendix
6 720 611 137 gb (03.02) 40 appendix 9 appendix 9.1 fault codes more detailed fault finding procedures are described in the service booklet for the engineer number 7 181 465 346. Display code description remedy a8 break in communication check connecting lead to programmer ac module not detected. Che...
Page 41
6 720 611 137 gb (03.02) appendix 41 9.2 short parts list 9.3 heating settings (n.G) 9.4 heating settings (l.P.G) key description qty gc spare part number 1 sensor - flue gas temp. 1 8 729 000 144 0 2 sensor - ch flow temp. 1 8 714 500 087 0 3 control board 1 8 748 300 418 0 4 gas valve 1 8 747 003 ...
Page 42
6 720 611 137 gb (03.02) 42 appendix 9.5 operational flow diagram fig. 63 mains switch on. Fan min. Speed for 90 secs. Green light on. Burner lights. Red light on. Ignition spark for 5 seconds. Fan runs to purge gas from burner. Repeats 5 times before lock-out. Room thermostat and/or mains programme...
Page 43
6 720 611 137 gb (03.02) appendix 43.
Page 44
Excellence comes as standard worcester heat systems limited, cotswold way, warndon, worcester wr4 9sw. Telephone: (01905) 754624 fax: (01905) 754619.