Worcester Greenstar Ri Service Manual

THE APPLIANCE IS FOR USE WITHNATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13 & C33)NATURAL GAS: 24Ri GC NUMBER 41-311-6518Ri GC NUMBER 41-311-7715Ri

WATER SYSTEMS & PIPEWORKPLASTIC PIPEWORK & UNDER FLOORHEATING:• Any plastic pipework must have a polymeric barrier with 600mm (minimum) length

CONDENSATE PIPEWORKINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri8 716 109 699a (05/05)10PRE -INSTALLATIONCONDENSATE PIPEW

BOILER LOCATION & CLEARANCESINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri8 716 109 699a (05/05)11PRE -INSTALLATIONBOI

BOILER LOCATION & CLEARANCESINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri8 716 109 699a (05/05)12PRE -INSTALLATIONBAT

PLUMBING MANIFOLDCONNECTIONS:Heating System: 22mm compression fittings*Gas: 22mm * Use the 22mm copper pipes provided withthe appliance. Use the

FLUE TERMINAL POSITIONSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri8 716 109 699a (05/05)14PRE -INSTALLATIONFLUE TERMINA

PRE -INSTALLATIONFLUE OPTIONS• The diagrams (opposite) show the components used and the maximum flue length for each configuration of 100mm and 125mm

A - StrapsB - Outer cartonC - Base trayD - Inner wrap and wall templateE - Wall mounting plateF - Installer packG - Base PanelH - 22mm pipes (2) (syst

SAFETY:All relevant safety precautions must be undertaken.Protective clothing, footwear, gloves and safetygoggles must be worn as appropriate.FIXING T

1234BAOUTER CASE REMOVALREMOVING OUTER CASE1. Undo and remove 2 screws (A) securing boiler casing at the top of the appliance.2. Undo the 2 captive sc

INSTALLATION &SERVICING INSTRUCTIONSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri8 716 109 699a (05/05)1WORCESTER BOS

GAS AND WATER CONNECTIONS: Remove template and secure the wall mounting plate to the wall with the fixings supplied.• If there is greater than 600mm

FLUE INSTALLATIONHORIZONTAL FLUE(60/100mm diameter)For vertical flues and 80/125mm horizontal flues,please refer to separate instructions supplie with

FLUE INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri8 716 109 699a (05/05)21INSTALLATIONFLUE INSTALLATIONMEASUR

ABCDEA - Standard FlueB - Internal Wall SealC - External Wall SealD - Clamping PlateE - Extension DuctFlat at backFLUE INSTALLATIONASSEMBLING THE FLUE

CONDENSATE CONNECTION:Never terminate or discharge into any opensource, including; sink, bath, shower, bidet,toilet etc.Note: any external condensate

ELECTRICSCAUTION: ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTINGANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONSNote: Mains supply to the bo

POSITION OF WIRED COMPONENTSPOSITION OF WIRED COMPONENTSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri8 716 109 699a (05/0

PRE-COMMISSIONING CHECKSCAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANYWORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS1 Check that the serv

FILLING THE SYSTEM1 Ensure all system and boiler drain points areclosed.2 If connected to an open vented system turn on the water supply to system hea

Switching the appliance on/off:1  Turn on mains power supply Turn on any external controlsSet the thermostatic radiator controls to maximum temperat

SAFETY & REGULATIONSSAFETY PRECAUTIONS & SYMBOLS 3INSTALLATION REGULATIONS 3APPLIANCE INFORMATIONGENERAL INFORMATION 4TECHNICAL DATA 5LAYOUT &

WATER TREATMENTENSURE THAT THE SYSTEM HAS BEENCLEANED AS ON PAGE 7 OF THESEINSTRUCTIONS.FLUSHING (Central Heating):1 Switch off the boiler (A). If con

COMMISSIONINGTHE COMBUSTION FOR THE APPLIANCEIS FACTORY SET. NO ADJUSTMENT IS REQUIRED IF THEGAS INLET PRESSURE IS CORRECT.CHECKING GAS INLET PRESSURE

FINISHING COMMISSIONINGThe boiler has been factory set, so thereshould be no need to adjust any controls.1 Install bottom panel.A The cut out in the b

INSPECTION AND SERVICE To ensure the continued efficient operationof the appliance it must be checked atregular intervals.  The frequency of servici

INSPECTION AND SERVICEComponent Access1. Removing outer case1.1a Undo and remove 2 screws (A) securing boiler casing at the top of the appliance.1.1b

INSPECTION AND SERVICEPrimary Heat ExchangerThere is a special accessory kit availble specifically designed for cleaning the heat exchanger. If requir

INSPECTION AND SERVICE1AB32CDINSPECTION AND SERVICEINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri8 716 109 699a (05/05)35S

INSPECTION AND SERVICERemove electrical connector from fan. Remove electrical connector from fan.4 Undo and remove securing nut (E) from the top of t

INSPECTION AND SERVICE8LMN0PQRINSPECTION AND SERVICEINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri8 716 109 699a (05/05)37

1.11.2AB1.1 Remove 3 screws (A) and cover (B) from control box. Clipped inside the cover is a plastic tool used to change the mode switch setting. R

SAFETY PRECAUTIONS& INSTALLATION REGULATIONSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri8 716 109 699a (05/05)3SAFET

1.4 Remove covers from the air/gas outlet adjuster and gas valve adjuster. Connect manometer to inlet pressure point on the gas valve. The boiler sho

CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINSSUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALLRELEVANT SAFETY PRECAUTIONS.IMPORTANT: AFTER RE

REPLACEMENT OF PARTS5. Moving boiler control to serviceposition5.1 Remove two screws (A)securing control.5.2 Hang control on two lugs (B) on boiler fr

REPLACEMENT OF PARTS9. Access to boiler control components Move control to the service position. Remove 3 screws (A)and remove cover from control.10

REPLACEMENT OF PARTS12. Air / gas manifold and fanassembly Remove electrical connector from fan. Remove wire clip from gas valve outlet then pull ga

REPLACEMENT OF PARTS14. Fan14.1Remove 3 screws (A) retaining mixing chamber.14.2Remove 2 screws (B) retaining the fan to the air/gas manifold.14.3Remo

SHORT PARTS LIST1 FanWHS Part No. 8 717 204 453 0GC No. H26-5362 Burner12Ri WHS Part No. 8 718 120 616 012Ri GC No. H26-53715Ri WHS Part No. 8 718 120

GAS CONVERSION12kW & 15kW conversion Remove outer casing as described in Servicing & Spares section.1Remove 3 screws (A) retaining cover.2Rem

ELECTRICAL WIRING DIAGRAM1. ST1, Terminal block, 230VAC mains supply.1a. Control box earth connection.2. Fuse F1 (T2A, H250V).3. Boiler mains supply o

No lightLight on butboiler notoperating duringdemand*Slow flash(normally off,flashes on)*Slow flash(normally on,flashes off)Fast flash2 pulses5 pulses

GENERAL INFORMATIONSTANDARD PACKAGE:A - Wall hung gas fired condensing boiler forcentral heating and indirect domestic hot waterB - Wall plateC -Hardw

MAIN FUNCTIONNOYESPERMANENTMAIN SUPPLYTO BOILERBOILERDEMANDFROMSYSTEMFan tostartspeed.Pump ON.Prepurgethen ignitionspark 4 secondsBLUELIGHTONBURNERLI

CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxesTIME & TEMPERATURE CONTROL TO HEATING

SERVICE INTERVAL RECORDIt is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record

INSTRUCTION MANUALINSTALLATION, COMMISSIONING& SERVICINGEXCELLENCE COMES AS STANDARDWorcester, Bosch GroupCotswold Way, Warndon, Worcester WR4 9SW

TECHNICAL DATACentral HeatingMax. rated heat output net 40/30°C KW 12.85 16.06 19.28 25.67 12.85 16.06 19.28 25.67Max. rated heat ou

LAYOUT & COMPONENTSThe diagram opposite shows the controls in theservicing position and excludes the outer case,inner covers and fascia panel.1 AI

CLEANING PRIMARY SYSTEMSBEFORE CLEANING THE SYSTEM:ENSURE THE SYSTEM AND PIPEWORK ISIN GOOD WORKING ORDERKEEP THE EXISTING BOILER/CIRCULATING PUMP WHE

MAINS SUPPLYELECTRIC SUPPLY:• Supply: 230V - 50Hz, 50 watts not including pump.• Cable: PVC insulated 0.75mm2(24 x 0.2mm)temperature rated to 90°C.• E