Worcester GREENSTAR 30 HE Service Manual download pdf (Page 2)

6 720 611 400 GB (03.11)

Contents

Safety precautions 3

Symbols 3

1Details of the appliance 4

1.1EC Declaration of Conformity 4

1.2 Standard package 4

1.3Description of appliance 4

1.4Accessories 5

1.5 Casing dimensions 5

1.6Layout of appliance 6

1.7Function 7

1.8Electrical wiring diagram 8

1.9Technical data 9

2Installation regulations 10

3Installation 11

3.1 Important remarks 11

3.2 Domestic hot water 11

3.3 Sealed systems 11

3.4Siting the appliance 12

3.5Wall mounting frame assembly 13

3.6 Pre-piping the system 13

3.7 Fitting the appliance 14

3.8Checking the connections 15

3.9Flue Systems 15

3.9.1Siting the Flue Terminal 16

3.9.2 Installation of the flue 17

3.9.3Flue duct preparation and assembly 19

4Electrical connections 20

4.1Connecting the appliance 20

4.2Connecting TR2 Room thermostat 21

4.3Mains Voltage external controls connections 21

5Commissioning 22

5.1Commissioning 22

5.2Switching the appliance on/off 23

5.3Switching on the central heating 23

5.4 System controls 23

5.5Setting the domestic hot water temperature and flow

rate 24

5.5.1 Domestic hot water temperature 24

5.5.2 Hot water flow rate 24

5.6 Summer mode (hot water only) 24

5.7 Frost protection 24

5.8 Pump anti-seize function 24

5.9Fault Condition 25

6Text Display 26

6.1 General Description 26

6.2 Programming 26

6.2.1 Deleting a setting 27

6.2.2Resetting all parameters to their original settings 27

6.3Menu structure 27

6.4 Setting the time/day 28

6.4.1 Setting the time and day 28

6.4.2 Holidays 28

6.5 Heating 28

6.5.1 Heating programme 28

6.5.2Setting Economy temperature (TR2 connected) 28

6.5.3Manual operating mode (TR2 not connected) 29

6.6 Hot water 29

6.6.1 Hot water programme 29

6.6.2 Hot water immediately 29

6.7 i Info 29

6.8 Settings 30

6.8.1Heating (if TR 2 is connected) 30

6.8.2 Hot Water (Storage Tank, system models only) 30

6.8.3 Service 30

6.9 Individual timer programmes 30

7Individual settings 31

7.1Mechanical settings 31

7.1.1Checking the size of the expansion vessel 31

7.1.2Setting the central heating flow temperature 31

7.2 Settings on the Bosch Heatronic 31

7.2.1 General description 31

7.2.2 Setting the anti-cycle time

(Service Function 2.4) 32

7.2.3Setting the maximum CH flow temperature (Service

Function 2.5) 32

7.2.4 Setting the heating output

(Service Function 5.0) 32

7.2.5 Constant hot water cycle time

(Service Function 6.8) 32

7.2.6 Variable pump settings

(Service Function 7.0) 32

7.3 Setting the gas/air ratio 32

8Converting the appliance to different

gas types 33

8.1 Setting the gas/air ratio 33

8.2 Testing combustion air/flue gas at set heat output 35

8.2.1 Testing the O2 or CO2 level in the combustion air 35

8.2.2 Testing CO and CO2 35

9Maintenance 36

9.1Pre-Service Check List 37

9.2Description of servicing operations 38

9.3 Replacement of Parts 41

9.3.1 PCB control board and transformer 41

9.3.2 Fan Assembly 42

9.3.3 Pump 42

9.3.4 3-way diverter valve 43

9.3.5 3-way diverter valve motor 43

9.3.6 Sensors 43

9.3.7 Gas Valve 44

9.3.8 Domestic Hot Water Heat Exchanger 44

9.3.9 Electrode assembly 44

9.3.10 Pressure gauge 44

9.3.11 Expansion vessel 44

9.3.12 Pressure Relief Valve 44

9.3.13 Burner 44

9.3.14 Flow switch 45

9.3.15 Primary Heat Exchanger 45

10 Appendix 46

10.1 Fault Codes 46

10.2 Short parts list 47

10.3 Heating/hot water output settings R 30 HE N.G. 48

10.4 Heating/hot water output settings R 30 HE L.P.G 48

10.5 Heating/hot water output settings R 35 HE N.G. 48

10.6 Heating/hot water output settings R 35 HE L.P.G 48

10.7 Operational Flow diagrams 49

10.7.1 Domestic hot water function 49

10.7.2 Central heating function 50

10.7.2Central heating

function 50

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Worcester GREENSTAR 30 HE Service Manual Page 2

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