THE APPLIANCE IS FOR USE WITH
NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13 & C33)
NATURAL GAS:
WORCESTER GREENSTAR 24i junior GC NUMBER 47-311-86 WORCESTER GREENSTAR 28i junior GC NUMBER 47-311-87
LIQUID PETROLEUM GAS:
WORCESTER GREENSTAR 24i junior GC NUMBER 47-311-90 WORCESTER GREENSTAR 28i junior GC NUMBER 47-311-91
GB/IE
CHECKLIST & service interval record, printed within this manual
CONTACT INFORMATION |
INSTALLATION & SERVICING INSTRUCTIONS |
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WORCESTER: |
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TECHNICAL: |
08705 266241 |
SERVICE: |
08457 256206 |
SPARES: |
01905 752571 |
LITERATURE: |
01905 752556 |
TRAINING: |
01905 752526 |
SALES: |
01905 752640 |
WEBSITE: www.worcester-bosch.co.uk
WATER TREATMENT:
FERNOX 01799 550811
www.fernox.com
SENTINEL 0151 420 9595
www.betzdearborn.com/sentinel
FLUE TERMINAL GUARD:
TOWER FLUE COMPONENTS
VALE RISE
TONBRIDGE
TN9 1TB
TEL: 01732 351680
FAX: 01732 354445
STORE THE APPLIANCE IN A DRY AREA PRIOR TO INSTALLATION.
LIFTING AND CARRYING PRECAUTIONS:
•Lift only a manageable weight, or ask for help.
•When lifting the boiler, bend the knees, and keep the back straight and feet apart.
•Do not lift and twist at the same time.
•Lift and carry the boiler close to the body
•Wear protective clothing and gloves to protect from any sharp edges
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
THESE INSTRUCTIONS ARE APPLICABLE TO THE WORCESTER APPLIANCE MODEL(S) STATED ON THE FRONT COVER OF THIS MANUAL ONLY AND MUST NOT BE USED WITH ANY OTHER MAKE OR MODEL OF APPLIANCE.
THE INSTRUCTIONS APPLY IN THE UK ONLY AND MUST BE FOLLOWED EXCEPT FOR ANY STATUTORY OBLIGATION.
THIS APPLIANCE MUST BE INSTALLED BY A COMPETENT PERSON. FAILURE TO INSTALL CORRECTLY COULD LEAD TO PROSECUTION.
IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER TECHNICAL HELPLINE.
DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER.
PLEASE LEAVE THESE INSTRUCTIONS WITH THE COMPLETED BENCHMARK CHECKLIST, (OR A CERTIFICATE CONFIRMING COMPLIANCE WITH IS 813, EIRE ONLY) AND THE USER MANUAL WITH THE OWNER OR AT THE GAS METER AFTER INSTALLATION OR SERVICING. THE BENCHMARK CHECKLIST CAN BE FOUND IN THE BACK TWO PAGES OF THE INSTALLATION MANUAL.
ABBREVIATIONS USED IN THIS MANUAL:
ØDiameter
NG |
Natural Gas |
LPG |
Liquid Petroleum Gas |
CH |
Central Heating |
DHW |
Domestic Hot Water |
IP |
Ingress Protection |
SEDBUK Seasonal Efficiency of Domestic Boilers in the United Kingdom
SYMBOLS USED IN THIS MANUAL:
1
INSTALLATION & SERVICING INSTRUCTIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05)
CONTENTS
SAFETY & REGULATIONS
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SAFETY PRECAUTIONS & SYMBOLS |
3 |
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INSTALLATION REGULATIONS |
3 |
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APPLIANCE INFORMATION |
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GENERAL INFORMATION |
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TECHNICAL DATA |
5 |
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LAYOUT & COMPONENTS |
6-7 |
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PRE-INSTALLATION |
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CLEANING PRIMARY SYSTEMS |
8 |
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MAINS SUPPLY |
9 |
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WATER SYSTEMS & PIPEWORK |
10 |
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CONDENSATE PIPEWORK |
11 |
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PRESSURE RELIEF PIPEWORK |
12 |
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BOILER LOCATION & CLEARANCES |
13-14 |
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PLUMBING MANIFOLD |
15 |
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FLUE TERMINAL POSITIONS |
16 |
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FLUE OPTIONS |
17 |
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INSTALLATION |
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UNPACKING THE WALL FRAME |
18 |
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WALL MOUNTING TEMPLATE / FLUE OPENING |
19 |
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UNPACKING THE APPLIANCE |
20 |
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BOILER CONNECTIONS |
21-22 |
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FLUE INSTALLATION |
23-25 |
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CONDENSATE CONNECTIONS |
26 |
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ELECTRICS |
27 |
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POSITION OF WIRED COMPONENTS |
28 |
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COMMISSIONING |
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PRE-COMMISSIONING CHECKS |
29 |
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FILLING THE SYSTEM |
30 |
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STARTING THE APPLIANCE |
31 |
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WATER TREATMENT |
32 |
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COMMISSIONING |
33 |
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FINISHING COMMISSIONING |
34 |
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SERVICING & SPARES |
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INSPECTION AND SERVICE |
35-40 |
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REPLACEMENT OF PARTS |
41-50 |
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SETTING THE GAS/AIR RATIO |
51 |
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SHORT PARTS LIST |
52 |
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CONVERSION KITS |
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L.P.G. CONVERSION |
53 |
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FAULT FINDING & DIAGNOSIS |
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FAULT FINDING |
54 |
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CH FUNCTION |
55 |
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DHW FUNCTION |
56 |
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PROTECTION FUNCTION |
57-58 |
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BENCHMARK CHECKLIST |
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SERVICE INTERVAL RECORD SHEET |
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SAFETY & |
REGULATIONS |
APPLIANCE |
INFORMATION |
PRE - |
INSTALLATION |
INSTALLATION |
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COMMISSIONING |
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SERVICING |
& SPARES |
CONVERSION |
KITS |
FAULT FINDING |
& DIAGRAMS |
2
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05)
CONTENTS
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SAFETY PRECAUTIONS |
SAFETY& REGULATIONS |
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DON’T TURN ELECTRICAL SWITCHES ON OR OFF |
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IF YOU SMELL GAS: |
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DON’T SMOKE OR STRIKE MATCHES |
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 COMPANY
A Benchmark Checklist is provided by the manufacturer for the installer to complete including their CORGI registration number to confirm that the boiler has been installed, commissioned and serviced according to the manufacturer’s instructions.
IMPORTANT: The completed Benchmark Checklist will be required in the event of any warranty work and may be required by the local Building Control Inspector.
HEALTH & SAFETY
The appliance contains no asbestos and no substances have been used in the construction process that contravene the COSHH Regulations (Control of Substances Hazardous to Health Regulations 1988).
COMBUSTIBLE AND CORROSIVE MATERIALS
Do not store or use any combustible materials (paper, thinners, paints etc.) inside or within the vicinity of the appliance.
Chemically aggressive substances, such as halogenated hydrocarbons containing chlorine or fluorine compounds can corrode the appliance and invalidate any warranty.
FITTING & MODIFICATIONS
Fitting the appliance and any controls to the appliance may only be carried out by a competent engineer in accordance with the current Gas Safety (Installation and Use) Regulations.
Flue systems must not be modified in any way other than as described in the fitting instructions. Any misuse or unauthorised modifications to the appliance, flue or associated components and systems could invalidate the warranty. The manufacturer accepts no liability arising from any such actions, excluding statutory rights.
SERVICING
Advise the user to have the system serviced annually by a competent, qualified engineer (such as British Gas or CORGI registered personnel) using approved spares, to help maintain the economy, safety and reliability of the appliance.
IMPORTANT - The service engineer must complete the Service Record on the
Benchmark Checklist after each service.
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INSTALLATION REGULATIONS
Gas Safety (Installation & Use) Regulations 1998: All gas appliances must be installed by a competent person in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution.
The appliance must be installed in accordance with, and comply to, the current: Gas Safety Regulations, I E E Regulations, Building Regulations, Building Standards (Scotland) (Consolidation), Building Regulations (Northern Ireland), local water by-laws, Health & Safety Document 635 (The Electricity at Work Regulations 1989) and any other local requirements.
British Standards:
The relevant British Standards should be followed, including:
BS7074:1 : Code of practice for domestic and hot water supply
B S6891 : Installation of low pressure gas pipework up to 28mm (R1)
BS5546 : Installation of gas hot water supplies for domestic purposes
EN:12828 : Central heating for domestic premises BS5440:1 : Flues and ventilation for gas appliances of rated heating not exceeding 70kW (net) : Flues
BS5440:2 : Flues and ventilation for gas appliances of rated heating not exceeding 70kW (net) : Air Supply
BS7593 : Treatment of water in domestic hot water central heating systems
BS 6798 : Installation of gas fired boilers of rated input up to 70kW (net)
Where no specific instruction is given, reference should be made to the relevant British Standard codes of Practice.
L.P.G. Installation:
An appliance using L.P.G. must not be installed in a room or internal space below ground level unless one side of the building is open to the ground.
Timber framed buildings:
Where the boiler is to be fitted to a timber framed building the guidelines laid down in BS5440: Part 1 and IGE "Gas Installations in Timber Frame Buildings” should be adhered to.
Potable water:
All seals, joints and compounds (including flux and solder) and components used as part of the secondary domestic water system must be approved by WRAS.
CH water:
Artificially softened water must not be used to fill the central heating system.
SAFETY PRECAUTIONS
& INSTALLATION REGULATIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05)
GENERAL INFORMATION
(When fitted to wall frame) Depth to wall
A
330mm
700mm
D
STANDARD PACKAGE:
A - Wall hung gas fired condensing combi boiler for central heating and domestic hot water
B - Boiler support frame
C - Hardware literature pack
D - Bottom Panel
B
C
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SPECIFICATIONS: |
400mm |
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Pre-wired and pre-plumbed |
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Galvanised steel inner frame |
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Digital control system |
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Automatic ignition |
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Direct burner ignition electrodes |
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D |
Built-in frost thermostat |
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Built-in fault finding diagnostics |
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Modulating automatic gas valve |
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Combustion air fan with speed regulator |
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CH temperature sensor & control |
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Pump anti-seizure protection |
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Flue gas temperature limiter |
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Condensate trap & syphon |
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DHW flow sensor |
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Plate type DHW heat exchanger |
APPLIANCE |
INFORMATION |
4
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05)
GENERAL INFORMATION
APPLIANCE |
INFORMATION |
5
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TECHNICAL DATA |
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DESCRIPTION |
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NATURAL GAS |
L.P.G. |
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Domestic Hot Water |
UNITS |
24i junior |
28i junior |
24i junior |
28i junior |
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Min. heat input |
KW |
7.38 |
7.38 |
9.64 |
9.64 |
Max. rated heat output |
KW |
24 |
28 |
24 |
28 |
Max. rated heat input |
KW |
24.49 |
28.57 |
24.49 |
28.57 |
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Gas flow rate - Max. 10 minutes from lighting |
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Natural Gas G20 |
m3/h |
2.59 |
3.02 |
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Propane Gas (LPG) |
kg/h |
- |
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1.9 |
2.22 |
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Max. mains inlet pressure |
bar |
10 |
10 |
10 |
10 |
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Min. mains inlet pressure (working) for max flow |
bar |
1.3 |
1.3 |
1.3 |
1.3 |
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Min. mains inlet pressure (working) for operation |
bar |
0.2 |
0.2 |
0.2 |
0.2 |
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Domestic Hot Water temperature setting |
°C |
55 |
55 |
55 |
55 |
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Domestic Hot Water specific rate - 30°C rise |
l/min |
11.5 |
13.4 |
11.5 |
13.4 |
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Max. Domestic Hot Water flow rate - 40°C rise +/— 15% |
l/min |
8.6 |
10 |
8.6 |
10 |
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Central Heating |
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Max. rated heat input |
KW |
24.62 |
24.62 |
24.62 |
24.62 |
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Max. rated heat output 40/30°C |
KW |
25.67 |
25.67 |
25.67 |
25.67 |
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Max. rated heat output 50/30°C |
KW |
25.45 |
25.45 |
25.45 |
25.45 |
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Max. rated heat output 80/60°C |
KW |
24 |
24 |
24 |
24 |
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Max. flow temperature |
°C |
82 |
82 |
82 |
82 |
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Max. permissible operating pressure |
bar |
2.5 |
2.5 |
2.5 |
2.5 |
Available pump head at 21°C system temperature rise |
m |
2.0 |
2.0 |
2.0 |
2.0 |
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Flue |
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Flue Gas Temp. 80/60°C, rated/min. load |
°C |
78/63 |
78/64 |
79/64 |
79/65 |
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Flue Gas Temp. 40/30°C, rated min. load |
°C |
54/35 |
54/36 |
55/38 |
55/39 |
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CO2 level at max. rated heat output |
% |
9.8 |
9.8 |
11.0 |
11.0 |
CO2 level at min. rated heat output |
% |
9.2 |
9.2 |
10.5 |
10.5 |
NOx - class |
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5 |
5 |
5 |
5 |
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Condensate |
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Max. condensation rate |
l/h |
2.0 |
2.0 |
2.0 |
2.0 |
pH value, approx. |
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4.8 |
4.8 |
4.8 |
4.8 |
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Electrical |
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Electrical power supply voltage |
AC...V |
230 |
230 |
230 |
230 |
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Frequency |
Hz |
50 |
50 |
50 |
50 |
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Max. power consumption |
W |
140 |
140 |
140 |
140 |
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General Data |
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SEDBUK |
band |
A |
A |
A |
A |
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Appliance protection rating |
IP |
X4D |
X4D |
X4D |
X4D |
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Appliance protection rating with mechanical or RF mechanical timer fitted IP |
20 |
20 |
20 |
20 |
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Permissible ambient temperatures |
°C |
0-50 |
0-50 |
0-50 |
0-50 |
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Nominal capacity of appliance |
Itr |
3.9 |
3.9 |
3.9 |
3.9 |
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Noise output level (Max central heating) |
dB(A) |
42 |
42 |
42 |
42 |
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Packaged boiler weight |
kg |
44.4 |
44.4 |
44.4 |
44.4 |
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Total boiler weight |
kg |
39.5 |
39.5 |
39.5 |
39.5 |
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Lift weight |
kg |
27.1 |
27.1 |
27.1 |
27.1 |
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SEDBUK |
% |
90.1 |
90.1 |
91.8 |
91.8 |
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TECHNICAL DATA
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05)
LAYOUT & COMPONENTS
The diagram opposite shows the controls in the servicing position and excludes the outer case.
1AIR / GAS MANIFOLD
2FAN
3AIR / GAS ADJUSTMENT SCREW
4GAS VALVE
5INLET PRESSURE TEST POINT
6EXPANSION VESSEL
7WALL MOUNTING FRAME
8COVER FOR EXTERNAL WIRING CONNECTIONS
9CONDENSATE CONNECTION FROM HEAT EXCHANGER
10PLATE TO PLATE
DHW HEAT EXCHANGER
11FLUE PRESSURE SWITCH
12FAN PRESSURE TEST POINT
13MANUAL VENT POINT
14IGNITION AND FLAME SENSE ELECTRODES
15OVERHEAT THERMOSTAT
16FLAME VIEWING MIRROR
17SECURING NUT, AIR / GAS MANIFOLD CLAMP
18SENSOR - BOILER FLOW
19FLUE AIR PRESSURE SWITCH CONNECTION
20FLUE OVERHEAT THERMOSTAT
21ACCESS POINT FOR CLEANING HEAT EXCHANGER/SUMP
22REMOVABLE TOP CASE PANEL FOR SERVICING
23GAS INLET CONNECTION 22mm COMPRESSION
24TRAP / SYPHON
25TRAP / SYPHON OUTLET CONNECTION ( 22mm PLASTIC PIPE)
26MAINS COLD WATER IN
27CH FLOW
28DHW OUT
29CH RETURN
30DRAIN POINT
31SILICONE TUBE (USE TO VENT AIR FROM HEAT EXCHANGER)
32PUMP
33SYSTEM PRESSURE GAUGE
34CONTROL PANEL IN SERVICE POSITION
35HEAT EXCHANGER
36ACCESS COVER FOR TRANSFORMER & PCB
APPLIANCE |
INFORMATION |
6
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05)
LAYOUT & COMPONENTS
APPLIANCE |
INFORMATION |
7
LAYOUT & COMPONENTS
10PLATE TO PLATE DHW HEAT EXCHANGER
32 SYSTEM PUMP
36FLOW TURBINE
37UNUSED PORT
38AUTO AIR VENT
39FLOW CONNECTION FROM BOILER HEAT EXCHANGER
40DHW SENSOR
41CH FLOW CONNECTION TO SERVICE VALVE
42DHW OUT CONNECTION
43COLD WATER IN CONNECTION
44CH RETURN CONNECTION TO SERVICE VALVE
45DIVERTER VALVE
46PRESSURE RELIEF VALVE
47COMPACT HYDRAULIC MOUNTING SCREW (2) TO BOILER
48CH TEMPERATURE CONTROL
49MAINS ON/OFF INDICATOR/ DIAGNOSTIC LIGHT (BLUE)
50SERVICE MODE BUTTON
51BURNER ON INDICATOR LIGHT (GREEN)
52MASTER SWITCH ON/OFF
53ECO BUTTON
54FAULT RESET BUTTON
55SYSTEM PRESSURE GAUGE
56POSITION FOR OPTIONAL PROGRAMMER
57INTERNAL BY-PASS WITHIN PLASTIC MOULDING
LAYOUT & COMPONENTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05)
IMPORTANT: All the following Pre-Installation sections must be read and requirements met before starting boiler or flue installation.
CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.
CLEANING PRIMARY SYSTEMS
IMPORTANT: Debris from the system can damage the boiler and reduce efficiency. Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance warranty.
BEFORE CLEANING THE SYSTEM:
ENSURE THE SYSTEM AND PIPEWORK IS IN GOOD WORKING ORDER
KEEP THE EXISTING BOILER/ CIRCULATING PUMP WHERE POSSIBLE OR USE A POWER FLUSHING MACHINE TO AID THE CLEANSING PROCEDURE BEFORE INSTALLING A NEW BOILER.
2 |
Open all drain cocks and drain the |
PREINSTALLATION |
CLEANING THE PRIMARY SYSTEM: |
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Fill the system with cold water and |
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check for leaks. |
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system.
3Close drain cocks and add a suitable flushing agent compatible with aluminium at the correct strength for
the system condition in accordance with the manufacturer's instructions.
The PH value of the system water must be less than 8 or the appliance guarantee will be invalidated.
Circulate the flushing agent before the boiler is fired up.
4Run the boiler/system at normal operating temperature as directed by the manufacturer of the flushing agent.
5Drain and thoroughly flush the system to remove the flushing agent and debris.
8
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05)
CLEANING PRIMARY SYSTEMS
INSTALLATION
PRE -
MAINS WATER EXPANSION VESSEL:
A - Mini expansion vessel, part No. 7 716 102 105
B - Mains water inlet |
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C - Non-return valve |
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D - Boiler |
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B |
C |
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9
MAINS SUPPLY
ELECTRIC SUPPLY:
•Supply: 230V - 50Hz, 140 watts
•Cable: PVC insulated 0.75mm2 (24 x 0.2mm) temperature rated to 90°C.
•External 3A fuse to BS1362.
•The appliance must be earthed.
•IPX4D. NOTE: this is reduced to IP20 if the following mechanical timers are fitted:
7 716 192 036 or 7 716 192 037.
•All pipes to the boiler must be cross-bonded.
•Wiring must comply with IEE wiring regulations.
GAS SUPPLY:
•Boilers using NG must be connected to a governed meter.
•LPG boilers must be connected to a regulator.
•Installation and connection of the gas supply to the boiler must be in accordance with BS6891.
•Under no circumstances should the size of the gas supply pipe be less than that of the appliance inlet connection.
•The meter or regulator and pipework to the meter must be checked, preferably by the gas supplier, to ensure it is in good working order and can meet the gas flow and pressure requirements in addition to the demand from any other appliance being served.
WATER SUPPLY:
Water mains pressure:
•Minimum mains water pressure 1.3 bar for maximum performance.
•Maximum mains fed water pressure 10 bar. If necessary, fit a pressure reducing valve.
IMPORTANT: Non-return, back flow prevention devices (including those associated with water meters) fitted to the mains water supply can cause a pressure build up which could damage the boiler and other household appliances.
•Where the mains water supply has a nonreturn, back flow prevention valve fitted, a mini expansion vessel (A) should be connected to the mains water inlet pipe (B) between the non-return valve (C) and the boiler (D) as shown opposite.
Use in hard water areas:
Normally there is no need for water treatment to prevent scale formation as the maximum temperature of the DHW heat exchanger is limited in the electronic circuit.
In areas where temporary water hardness exceeds 200ppm, consideration may need to be given to the fitting of a scale prevention device. In such circumstances, the advice of the local water authority should be sought.
MAINS SUPPLY
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05)
COMMISSIONING INSTALLATION
SYSTEM FILL
TYPICAL SEALED SYSTEM
A - Appliance expansion vessel - central heating
B - Extra expansion vessel - central heating return
C - Drain cock
P - Pressure relief discharge R - Radiators
A
B
P C
WATER SYSTEMS & PIPEWORK
PLASTIC PIPEWORK:
• Any plastic pipework must have a polymeric barrier with 600mm (minimum) length of copper or steel pipe connected to the boiler.
• Plastic pipework used for underfloor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approx. 50°C. The pipework from the boiler to the blending valve must be in copper or steel (protected from corrosion).
PRIMARY SYSTEMS CONNECTIONS/VALVES: |
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All system connections, taps and mixing |
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valves must be capable of sustaining a |
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pressure up to 3 bar. |
-PRE |
INSTALLATION |
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Radiator valves should conform to |
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BS2767:10. |
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All other valves should conform to BS1010. |
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Thermostatic radiator valves (TRV’s) must be |
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used on all radiators within the sleeping |
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accommodation but not the radiator where |
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the room thermostat is sited. This must be |
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fitted with lockshield valves and left open. |
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• A drain cock is required at the lowest point |
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in the system. |
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An air vent is required at all the high points in |
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the system. |
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NOTE: The boiler is equipped with an automatic |
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internal by-pass. |
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SHOWERS/BIDETS:
• If a shower head can be immersed in water or comes closer than 25mm from the top edge of a bath or shower tray spill over level then an anti-siphon device must be fitted to the shower hose.
• Bidets with direct hot and cold mains water can be used (with the approval of the local water authority) and must be the over rim flushing type with shrouded outlets to prevent the fitting of hand held sprays.
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SEALED PRIMARY SYSTEM: |
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The CH sealed system must be filled using a |
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WRAS approved filling loop or comply with |
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the diagram opposite for system fill. |
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Where the system volume is more than 100 |
R |
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litres or exceeds 2.65 bar at maximum |
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heating temperature, an extra expansion |
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vessel (B) must be fitted as close as possible |
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to the appliance in the central heating return. |
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Pressurise the extra expansion vessel (B) to |
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the same figure as the expansion vessel built |
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into the appliance. |
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Do not use galvanised pipes or radiators. |
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C
10
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05)
WATER SYSTEMS & PIPEWORK
PRE - INSTALLATION
11
CONDENSATE PIPEWORK
CONDENSATE PIPEWORK:
•The condensate pipe must be a minimum of 22mmØ plastic pipe.
•The condensate pipework must fall at least 50mm per metre towards the outlet and should take the shortest practicable route.
•The pipework must follow one of the options shown opposite into an internal serviceable trap (min. 75mm) such as a sink/washing machine) or discharge direct into a vent stack (E) 450mm min. above pipe invert or into a gulley (D) below ground but above the water level.
•Use waterproof pipe insulation in exposed positions and for external pipework.
IMPORTANT: Ensure there are no blockages in the pipe run.
1 Internal sink/washing machine drain
2 Internal waste drainage system
3 Soil/vent stack
4 External drainage system
5 External condensate absorption point
A - Condensate from boiler
B - Sink
C - 22mmØ plastic condensate pipe D - Gulley
E - Internal soil and vent stack
F - Serviceable waste trap (75mm min)
G - 300mm x 100mmØ sealed plastic tube H - Ground level
J - Drainage holes 50mm from base of tube (12mmØ at 25mm centres) facing away from building
K - Limestone chippings
CONDENSATE PIPEWORK
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05)
PRESSURE RELIEF PIPEWORK
PRESSURE RELIEF PIPEWORK:
IMPORTANT: The pressure relief valve is a safety device for the boiler and if activated may discharge boiling water steam through the relief valve drain pipe.
Care should be taken when siting the outlet pipe so that it does not cause an obstruction or discharge above a window, entrance or other public access where it could cause a hazard.
• 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 bend, near the outlet to face the external wall (as shown) to help prevent freezing.
M
L - Outside wall
O,M - Drain pipe
N - External drain
L
O
N
PRE - INSTALLATION
12
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05)
PRESSURE RELIEF PIPEWORK
SERVICING CLEARANCES
VENTED COMPARTMENT
Using 100mm flue kit 1080mm Using 125mm flue kit - 1110mm
INSTALLATION
PRE -
VENTILATION FREE COMPARTMENTS
INSTALLATION CLEARANCES
Ventilation Free Compartments Installation Clearances
The suggested total unventilated compartment minimum clearances are:
Side |
Above |
Below |
Front (to removable door) |
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400mm |
170mm approx. |
200mm |
100mm |
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(30mm above |
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the elbow) |
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(Note: Top and bottom clearances must not be reduced below these values as they are the minimum required for servicing).
If Side Clearances are Reduced
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If total side clearance is |
Then overall height clearances |
OR |
Front clearance (to removable |
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reduced to: |
must be increased to (approx): |
door) must be increased to: |
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350mm |
441mm |
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129mm |
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300mm |
523mm |
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161mm |
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250mm |
617mm |
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200mm |
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200mm |
727mm |
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243mm |
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150mm |
856mm |
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295mm |
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100mm |
1012mm |
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358mm |
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50mm |
1202mm |
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434mm |
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If Front Clearance is Reduced
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If front clearance (to |
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Then overall height clearances |
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Total side clearance must be |
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OR |
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removable door) is |
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must be increased to (approx): |
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increased to: |
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reduced to: |
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50mm |
511mm |
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505mm |
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25mm |
596mm |
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569mm |
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BOILER LOCATION &
CLEARANCES
This boiler is only suitable for installing internally within a property at a suitable location onto a fixed, rigid non-combustible surface at least the same size as the boiler and capable of supporting the boiler weight.
COMPARTMENTS:
Follow the requirements of B S6798 and BS5440 Part 2 and note:
•Minimum clearances must be maintained
•An access door is required to install, service and maintain the boiler and any ancilliary equipment.
•If fitting the boiler into an airing cupboard use a non-combustible perforated material (maximum hole sizes of 13mm) to separate the boiler from the airing space.
BOILER CLEARANCES:
The diagram opposite shows the minimum space required to install and service the boiler.
If a boiler is installed in a compartment with clearances less than shown in the tables opposite, ventilation is required. Refer to tables below for ventilation requirements.
24 & 28 kW
Vent |
To room or |
Direct to |
position |
internal space |
outside |
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High |
Minimum free |
Minimum |
level |
area 122 cm2 |
free area |
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61 cm2 |
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Low |
Minimum free |
Minimum |
level |
area 122 cm2 |
free area |
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61cm2 |
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BOILER CLEARANCES - UNVENTILATED COMPARTMENTS:
The tables opposite show the options for the minimum space required to install and service the boiler inside an unventilated compartment.
13
BOILER LOCATION & CLEARANCES
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05)
11
3
1 1
2 3
BOILER LOCATION &
CLEARANCES
BATHROOMS:
If the appliance is fitted in conjunction with a mechanical or R F mechanical timer, the
appliance can only be fitted in zone 3 .
Otherwise the appliance can be fitted in both
zones 2 and 3 .
See IEE wiring regulations.
IMPORTANT: any switch or appliance control using mains electricity must not be able to be touched by a person using the bath or shower.
Electrical switches, fused spur and socket outlets must not be situated in the bathroom.
PRE - INSTALLATION
14
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05)
BOILER LOCATION & CLEARANCES
Gas Supply (alternative from above appliance) 22mm
CH Flow 22mm |
DHW OUT 15mm |
DHW IN (alternative from CH Return 22mm above appliance)
15mm
INSTALLATION
PRE -
*
A
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 yellow plastic guide (A). This is fitted to the boiler frame.
Further guidance on pipe routing can be found printed on the boiler template (supplied with the boiler).
Mains Gas Supply 22mm |
Mains Water (DHW IN) 15mm |
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15
PLUMBING MANIFOLD
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05)
FLUE TERMINAL POSITIONS
Minimum dimensions of flue terminal positions for balanced room sealed flues with fanned draught:
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DRWG. |
TERMINAL POSITION |
DISTANCE |
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REF: |
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A1 |
Directly below an opening, air brick, opening windows, etc. |
300mm |
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B1 |
Above an opening, air brick, opening window, etc. |
300 mm |
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C1 |
Horizontally to an opening, air brick, opening window, etc. |
300 mm |
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D |
Below gutters, soil pipes or drain pipes |
75mm |
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E |
Below eaves |
200mm |
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F2 |
Below balconies or car port roof (lowest point) |
200mm |
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G |
From a vertical drain pipe or soil pipe |
150mm |
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H |
From internal or external corner or to a boundary alongside the terminal |
300mm** |
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I |
Above ground, roof or balcony |
300mm |
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J |
From a surface or boundary facing the terminal |
600mm** |
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K |
From a terminal facing the terminal |
1200mm |
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L2 |
From an opening in the car port (e.g. door, window) into the dwelling |
1200mm |
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M |
Vertically from a terminal on the same wall |
1500mm |
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N |
Horizontally from a terminal on the same wall |
300mm |
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O |
From a non combustible vertical structure on the roof |
* |
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P |
Above intersection with the roof |
* |
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•The flue must be fitted and terminated in accordance with the recommendations of BS5440 : Part 1.
•The flue must not cause an obstruction.
•Discharge and any noise from the flue outlet must not cause a nuisance.
•Flue gases have a tendency to plume and in certain weather conditions a white plume of condensation will be discharged from the flue outlet. This could be a nuisance, for example, near security lighting.
•The air inlet/outlet duct and the terminal of the boiler must not be closer than 25mm to any combustible material.
Detailed recommendations on protection of combustible materials are given in
BS 5440:1.
•A protective terminal guard must be fitted if the terminal is 2m or less above a surface to which people have access.
The guard must be spaced equally (minimum 50mm) around the flue and fixed to the wall with plated screws.
See Contact Information (inside front cover).
PRE - INSTALLATION
1 In addition, the terminal should not be nearer than 150mm (fanned draught) to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window frame.
2 Not recommended.
*
**Care should be taken to ensure terminal siting does not cause a nuisance to adjacent properties.
Terminals adjacent to windows or openings on pitched and flat roofs.
The flue should not penetrate the shaded area.
600mm
600mm
2000mm
16
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05)
FLUE TERMINAL POSITIONS
PRE - INSTALLATION
STANDARD FLUE HORIZONTAL
A
Ø100
MAX 686 A x 1 MIN 250 A x 1*
Ø125
MAX 1070 A x 1 MIN 250 A x 1* * Requires cutting
MAXIMUM FLUE HORIZONTAL
A
B
Ø100 - 4600mm A x 1 + B x 5
Ø125 - 13000mm A x 1 + B x 13
MAXIMUM FLUE VERTICAL START + 2 BENDS
A
F
B
C
Ø100 - 2600mm
A x 1 + C x 2 + B x 4 + F x 1
Ø125 - 11000mm
A x 1 + C x 2 + B x 13 + F x 1
MAXIMUM FLUE VERTICAL START + 3 BENDS
A
F
B
C
Ø100 - N/A
Ø125 - 9000mm
A x 1 + C x 3 + B x 11 + F x 1
MAXIMUM FLUE VERTICAL START + 1 BEND
F |
A |
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B |
C |
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Ø100 - 4600mm
A x 1 + C x 1 + B x 5 + F x 1
Ø125 - 13000mm
A x 1 + C x 1 + B x 13 + F x 1
MAXIMUM FLUE HORIZONTAL + 1 BEND
A
B
C
Ø100 - 2600mm
A x 1 + B x 3 + C x 1
Ø125 - 11000mm
A x 1 + B x 11 + C x 1
17
MAXIMUM FLUE VERTICAL WITH 2 x 45° BENDS
E
B
D
Ø100 - 4400mm (including terminal)
B x 5 + D x 2 + E x 1
Ø125 - 13000mm (including terminal)
B x 13 + D X 2 + E x 1
VERTICAL FLUE WITH 2 x 90° BENDS
E
B
C
Ø100 - 2400mm (including terminal) B x 4 + C x 2 + E x 1
Ø125 - 11000mm (including terminal) B x 13 + C x 2 + E x 1
FLUE OPTIONS
•The diagrams (opposite) show the components used and the maximum flue length for each configuration of 100mm and 125mm flues.
•Shaded flue components indicate the standard 100mm horizontal flue.
•Only straight flue sections can be reduced in length and cut.
•The flue terminal end can be fitted from the inside or outside of the building.
•Fixing kits are supplied with the flue extension kits.
•Horizontal 125mm and Vertical 100mm and 125mm flue kits are available with separate instructions. Contact your supplier or Worcester.
A - Standard horizontal flue (100mm diameter shown)
B - Straight flue extension
C - Flue bend 90°
D - Flue bend 45°
E - Vertical terminal (vertical adaptor supplied with terminal)
F - Vertical adaptor (used with horizontal terminal)
Calculating the flue length:
Measure the total flue length required, noting that the maximum straight flue length including the terminal is:
Horizontal 60/100mm: 4600mm Horizontal 80/125mm: 13000mm Vertical 60/100mm: 6400mm Vertical 80/125mm: 15000mm
Then reduce the total straight flue length for each extra flue bend (excluding the flue elbow) by:
2000mm for 90° 1000mm for 45°
Flue Extension lengths:
Horizontal & Vertical 60/100mm: 960mm Horizontal & Vertical 80/125mm: 1000mm
Flue Terminal lengths:
Horizontal 60/100mm: 800mm including terminal Horizontal 80/125mm: 1200mm including terminal Vertical 60/100mm: 1140mm to top of terminal Vertical 80/125mm: 1365mm to top of terminal
FLUE OPTIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05)
IIMPORTANT: All the previous Pre-Installation sections must be read |
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UNPACKING WALL FRAME AND |
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and requirements met before starting boiler or flue installation. |
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ANCILLARY ITEMS |
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LIFTING AND CARRYING PRECAUTIONS: |
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• Lift only a manageable weight, or ask for |
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help. |
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• When lifting or putting things down, bend |
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the knees, and keep the back straight |
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1 |
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and feet apart. |
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• Do not lift and twist at the same time. |
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• Lift and carry objects close to the body |
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B - Outer carton |
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C - Installer pack |
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D - Bottom panel |
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E - Wall mounting frame |
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F - Wall template |
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G - Inner packaging |
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IMPORTANT HANDLING INSTRUCTIONS |
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It is advised that two people are used to carry |
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the carton from the van to the point of delivery. |
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Once the carton has been delivered, the outer |
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carton is removed first. Care should be taken |
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when releasing the straps. If a sharp implement |
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is used make sure the outer carton is not |
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pierced and that the implement is used in such |
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a way so that it may not cause personal injury. |
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All sharp objects must be covered or the blade |
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3 |
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retracted after use and put away in a safe |
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C |
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place. The wall mounting frame, Installer |
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G |
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pack, template and bottom panel are now |
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removed. Care should be taken when lifting the |
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boiler from the base and the proper technique |
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for safe lifting of any heavy object should be |
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strictly observed. |
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F |
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Additional requirements for roof space |
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installation: |
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• The boiler should be first unpacked before |
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ascending ladder to loft space. |
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Two sets of steps should be used. |
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Two people should share the lifting of the |
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boiler up to the loft hatch, where the boiler is |
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entered into the loft space tilted and slid on its |
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back into the loft. |
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Once the appliance is removed from its |
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pack aging check the contents against the |
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packing list. |
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Before installing appliance ensure system has |
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been cleaned as explained on page 8. |
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1. Remove straps (A) and open the top of the |
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boiler packaging. |
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2. Remove template (F) and wall mounting |
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frame (E) from the packaging. |
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3. Remove boiler bottom panel (D) and |
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installer pack (C). |
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INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior |
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UNPACKING WALL FRAME AND |
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8 716 107 336b (11/05) |
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INSTALLATION
18
ANCILLARY ITEMS
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