Bosch Worcester GR8700iW 30 S NG, Worcester GR8700iW 35 S LPG, Worcester GR8700iW 35 SB NG, Worcester GR8700iW 30 S LPG, Worcester GR8700iW 30 SB LPG Installation And Maintenance Instructions Manual

...

Download

Installation and Maintenance Instructions

Gas fired condensing system boiler

Greenstar 8000 Style

GR8700iW 30 S | GR8700iW 35 S | GR8700iW 30 SB | GR8700iW 35 SB

6720883855 (2019/01) UK/IE

Table of contents

1 Explanation of symbols and safety instructions . . . . . . . . . . . 3

1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . 4

2 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.1 About the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.2 Misuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.3 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.4 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . 7

3.5 Appliance type overview . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.6 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.7 Pipe work positions and flue outlet. . . . . . . . . . . . . . . . . 8

3.8 Designation of components. . . . . . . . . . . . . . . . . . . . . . . 9

3.9 Product data for energy consumption. . . . . . . . . . . . . . 10

3.10 Standard accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4 Pre-Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

4.1 System preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

4.1.1 Artificially softened water . . . . . . . . . . . . . . . . . . . . . . . 11

4.1.2 Water systems and pipe work . . . . . . . . . . . . . . . . . . . .11

4.1.3 System layouts examples. . . . . . . . . . . . . . . . . . . . . . . . 12

4.1.4 System fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.2 Mains supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

4.2.1 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.2.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

4.3 Appliance location and clearances . . . . . . . . . . . . . . . . 14

4.3.1 Appliance location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.3.2 Rooms containing a bath or shower . . . . . . . . . . . . . . . 15

4.3.3 Appliance clearances. . . . . . . . . . . . . . . . . . . . . . . . . . .15

4.4 Flue systems considerations . . . . . . . . . . . . . . . . . . . . . 16

4.4.1 Flue length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.4.2 Flue options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.4.3 Plume management system. . . . . . . . . . . . . . . . . . . . . . 19

4.4.4 Flue terminal positions . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.4.5 Plume re-direct and plume management terminal

positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.5 Condensate discharge . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.5.1 Appliance siphonic condensate trap. . . . . . . . . . . . . . . 24

4.5.2 Condensate pipe work. . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.5.3 Internal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.5.4 External connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.6 Pressure relief discharge. . . . . . . . . . . . . . . . . . . . . . . . 27

4.6.1 Pressure relief pipe work. . . . . . . . . . . . . . . . . . . . . . . . 27

4.6.2 Alternative PRV connections - Combined PRV/

condensate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.7 Cleaning primary systems . . . . . . . . . . . . . . . . . . . . . . . 28

4.7.1 Flushing the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.1 Position the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.1.1 Mounting frame fixing . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.2 Appliance connections . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.3 Hanging the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.4 Flue turret/adaptor installation . . . . . . . . . . . . . . . . . . . 35

5.5 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5.5.1 Installer connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5.5.2 Cable preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

5.5.3 External controls - domestic installations. . . . . . . . . . . 38

6 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6.1 Pre-Commissioning checks . . . . . . . . . . . . . . . . . . . . . . 39

6.2 Water treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6.2.1 Filling the appliance and adding Inhibitor. . . . . . . . . . . 39

6.2.2 Adjusting the operating pressure of the heating

system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.3 Starting the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.3.1 Control panel overview . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.3.2 Turn on the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.3.3 Siphon filling mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.4 Chimney sweep mode . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6.5 Parameters when optional integral diverter valve

kit is fitted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6.6 Checking gas inlet pressure. . . . . . . . . . . . . . . . . . . . . . 42

6.6.1 Checking the gas supply pressure. . . . . . . . . . . . . . . . . 42

6.7 Checking the gas rate. . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6.8 Checking for gas leaks during operation. . . . . . . . . . . . 43

6.9 CO and combustion check. . . . . . . . . . . . . . . . . . . . . . . 43

6.10 Checking flue integrity. . . . . . . . . . . . . . . . . . . . . . . . . . 44

6.11 Flue gas analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

6.12 Finishing commissioning . . . . . . . . . . . . . . . . . . . . . . . . 45

6.12.1 Fitting the combustion casing . . . . . . . . . . . . . . . . . . . . 45

6.12.2 Fitting the appliance casing. . . . . . . . . . . . . . . . . . . . . . 46

6.12.3 Appliance/product guarantee . . . . . . . . . . . . . . . . . . . . 47

7 Settings in the service menu . . . . . . . . . . . . . . . . . . . . . . . . . . 47

7.1 Operating the service menu . . . . . . . . . . . . . . . . . . . . . 47

7.2 Service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

7.2.1 Overview of the service menu . . . . . . . . . . . . . . . . . . . . 48

7.2.2 Benchmark and Info menu. . . . . . . . . . . . . . . . . . . . . . . 50

7.2.3 Settings menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

7.2.4 Function check menu. . . . . . . . . . . . . . . . . . . . . . . . . . . 54

7.2.5 Reset menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

7.3 Thermal disinfection . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

8 Inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 55

8.1 Inspection and maintenance considerations . . . . . . . . 55

8.2 Resources for inspection and maintenance . . . . . . . . . 55

8.3 Inspection and maintenance steps . . . . . . . . . . . . . . . . 55

8.4 Component access . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

8.5 Fan pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

8.6 Check working gas inlet pressure . . . . . . . . . . . . . . . . . 57

8.7 Flue gas analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

8.8 Checking the flue integrity. . . . . . . . . . . . . . . . . . . . . . . 57

8.9 Cleaning the siphon and heat exchanger . . . . . . . . . . . 57

8.9.1 Checking the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

8.9.2 Checking the non-return valve in the air-gas

manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

8.9.3 Fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

8.9.4 Cleaning the heat exchanger . . . . . . . . . . . . . . . . . . . . . 59

8.9.5 Checking electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

8.9.6 Cleaning the siphon . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

8.10 Setting the air/gas ratio . . . . . . . . . . . . . . . . . . . . . . . . . 62

Greenstar 8000 Style – 6720883855 (2019/01)

Table of contents

8.10.1 Checking and, if required, adjusting the gas/air

ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

9 Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

9.1 Draining the appliance . . . . . . . . . . . . . . . . . . . . . . . . . .64

9.2 Overheat thermostat removal . . . . . . . . . . . . . . . . . . . .65

9.3 Pressure sensor removal . . . . . . . . . . . . . . . . . . . . . . . .65

9.4 Pressure relief valve removal . . . . . . . . . . . . . . . . . . . . . 65

9.5 Replacing the gas valve . . . . . . . . . . . . . . . . . . . . . . . . .65

9.6 Checking/replacing the motor of the 3-way valve. . . . .66

9.7 Replacing the optional 3-way valve . . . . . . . . . . . . . . . .66

9.8 Following inspection/maintenance . . . . . . . . . . . . . . . .66

10 Fault finding and diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

10.1 Operating and fault displays . . . . . . . . . . . . . . . . . . . . .67

10.1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

10.1.2 Fault code table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

10.1.3 Faults that are not displayed . . . . . . . . . . . . . . . . . . . . . 69

11 Environmental protection and disposal . . . . . . . . . . . . . . . . .69

12 Technical Specifications/Logs . . . . . . . . . . . . . . . . . . . . . . . . .70

12.1 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

12.1.1 Specifications System . . . . . . . . . . . . . . . . . . . . . . . . . .70

12.2 Ionisation current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

12.3 Component resistance characteristics . . . . . . . . . . . . .71

12.3.1 Sensor values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

12.4 Code plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

12.5 Pump characteristic map of the heating pump. . . . . . .71

12.6 Setting values for central heating/DHW output . . . . . .72

12.7 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

12.8 Gas boiler system commissioning checklist . . . . . . . . .75

12.9 Inspection and maintenance checklist . . . . . . . . . . . . .76

12.10 Service record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

1 Explanation of symbols and safety instructions

1.1 Explanation of symbols

Warnings

In warnings, signal words at the beginning of a warning are used to indicate the type and seriousness of the ensuing risk if measures for minimising danger are not taken.

The following signal words are defined and can be used in this document:

DANGER:

DANGER indicates that severe or life-threatening personal injury will

occur.

WARNING:

WARNING indicates that severe to life-threatening personal injury may

occur.

CAUTION:

CAUTION indicates that minor to medium personal injury may occur.

NOTICE:

NOTICE indicates that material damage may occur.

Important information

The info symbol indicates important information where there is no risk to people or property.

Additional symbols

Symbol Meaning

▶ a step in an action sequence  a reference to a related part in the document

• a list entry – a list entry (second level)

Table 1

Greenstar 8000 Style – 6720883855 (2019/01)

Explanation of symbols and safety instructions

1.2 General safety instructions

H 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.

• These instructions apply in the UK and Ireland only and must be followed except for any statutory obligations.

• This appliance must be installed by a competent registered gas engineer, such as a Gas Safe registered engineer including a British Gas engineer. Failure to install correctly could lead to prosecution.

• If you are in any doubt, contact the Worcester Technical help-line (0330 123 3366).

• Distance learning and training courses are available from Worcester.

• The BENCHMARK Commissioning Checklist can be found on page 75 of this Installation manual.

H Notes for the target group

These installation instructions are intended for gas, plumbing, heating and electrical contractors. All instructions must be observed. Failure to comply with instructions may result in material damage and personal injury, including danger to life.

▶ Read the installation instructions (heat source,

heating controller, etc.) before installation.

▶ Observe the safety instructions and warnings. ▶ Observe national and regional regulations,

technical rules and guidelines.

▶ Record all work carried out.

H Intended use

The appliance may only be used for heating water or domestic hot water in domestic properties.

▶ Observe the details on the data plate and the

specifications (installation manual) to ensure correct use of this appliance.

▶ Worcester Bosch offer flue gas systems which are

suitable for use with the appliance. It is the responsibility of the designer/installer of the flue to ensure this flue gas system operates correctly and in a safe manner.

H If you smell gas

A gas leak could potentially cause an explosion. If you smell gas, observe the following rules:

▶ Prevent flames or sparks:

– Do not smoke, use a lighter or strike matches. – Do not operate any electrical switches or unplug

any equipment.

– Do not use the telephone or ring doorbells. ▶ Turn off the gas at the meter or regulator. ▶ Open windows and doors. ▶ Warn your neighbours and leave the building. ▶ Prevent anyone from entering the building. ▶ Move well away from the building: call the National

Gas Emergency Service on 0800 111 999. ▶ L.P.G. boilers: Call the supplier’s number on the

side of the gas tank.

H Risk to life from carbon monoxide poisoning There is a risk to life from escaping flue gases

▶ Do not modify the flue gas system. ▶ Ensure that flue pipes and gaskets are undamaged.

If flue pipes are damaged or leaking:

▶ Turn off and isolate the appliance. ▶ Open windows and doors. ▶ If necessary, leave the building and warn your

neighbours. ▶ Prevent anyone from entering the building. ▶ Rectify any damage to the flue system immediately.

H Installation and maintenance

Installation and maintenance must only be carried out by a competent registered gas engineer, such as Gas Safe registered engineer or British Gas engineer.

▶ Carry out a gas tightness test after completing work

on gas-carrying components. ▶ Only use original spares.

H Electrical work

Electrical work must only be carried out by a qualified electrician:

▶ Before starting electrical work;

– Ensure that the electricity supply is safely

Isolated and secured to prevent inadvertent reconnection. Information on safe isolation can be found in the Health and Safety Executive guidance HSG85.

– Using test equipment approved to GS38 to

confirm that the electricity supply is disconnected.

▶ Refer to the manufacturer’s information when

installing non Worcester components and systems

to the Worcester appliance.

Greenstar 8000 Style – 6720883855 (2019/01)

Explanation of symbols and safety instructions

H Handover to the user

When handing over, instruct the user how to operate the heating system and inform the user about its operating conditions.

▶ Explain how to operate the heating system and draw

the user's attention to any safety relevant action.

▶ Explain that modifications and repairs must only be

performed by a competent, registered gas engineer, such as a Gas Safe registered engineer or British Gas engineer.

▶ Leave the installation instructions with the

completed Benchmark Checklist (or a certificate confirming compliance with IS 813, Eire only) and the operating instructions with the user or at the gas meter.

H Servicing

Advise the user to have the system serviced annually by a competent, registered gas engineer, such as a Gas Safe registered engineer or British Gas engineer. Approved spares must be used to help maintain the efficiency, safety and reliability of the appliance.

H Benchmark Service Record

The service engineer must complete the Benchmark Service Record at the back of this manual after each service.

Benchmark places responsibilities on both manufacturers and installers.

The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer's instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference.

Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hot water Industry Council who manage and promote the scheme. Visit centralheating.co.uk for more information.

H Health and 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).

H Combustion 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 can corrode the

appliance and invalidate any warranty.

H Fitting and modification

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.

H General manual handling guidelines

▶ Only remove packaging at the time of the final

installation.

▶ Always use Health and Safety guidance for manual

handling of an appliance. – Never lift or carry more than the safe guidance

limit on your own.

– Always use appropriate methods and equipment

when lifting/carrying an appliance. ▶ Never lift or carry packages by the shipping straps. ▶ During handling and unpacking, wear safety gloves

to prevent injuries to your hands through sharpedged appliance components.

▶ Dispose of packing materials appropriately.

H Important handling instructions

Care should be taken when transporting, lifting and carrying the appliance.

▶ Use a means of transport suitable for handling

appliances (e.g. sack truck with strap, stair climbing or step trolley).

▶ When handling appliances, secure them against a

fall. ▶ Let only trained personnel undertake the handling. ▶ The correct method for handling heavy objects

should be strictly observed, at all times.

Greenstar 8000 Style – 6720883855 (2019/01)

Regulations

2 Regulations

Installation regulations

Current Gas Safety (Installation and Use) Regulations:

All gas appliances must be installed by a competent, registered gas engineer, such as a Gas Safe registered engineer or British Gas engineer in accordance with the current 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, IET Regulations, Building Regulations, Building Standards (Scotland) (Consolidation),

Building Regulations (Northern Ireland), local water by-laws,

Health and Safety Document 635 (The Electricity at Work Regulations

1989) and any other local requirements.

EU Regulations No. 811/2013 - Energy Labelling.

Building Regulations Part L1A 2013 - new dwellings

If the installation is in a new build property or it is a first time installation in an existing property, the heating systems must conform to current building regulations Part L1A.

The exception to this are single storey, open plan dwellings where the living area is more than 70% of the total usable floor area. Then this type of dwelling can be controlled as one zone.

An alternative would be individual electronically controlled TRVs.

For dwellings with a floor area over 150m temperature control for each zone is required. It is best practice to fit Thermostatic Radiator Valves (TRV's) to all radiators except the area where the room thermostat is sited.

Building Regulations Part L1B 2010 - existing dwellings

For appliance replacements on an existing system, it is not necessary to zone the upstairs and downstairs separately, compliance with the zone requirements can be achieved by a single room thermostat or programmable room thermostat.

While the system is drained down, it is best practice to fit Thermostatic Radiator Valves (TRV's) to all radiators except the area where the room thermostat is sited.

British Standards

Where no specific instruction is given, reference should be made to the relevant British Standard codes of Practice.

• BS7074:1 – Code of practice for domestic and hot water supply

• BS6891 – Installation of low pressure gas pipe work up to 28mm (R1)

• BS5546 – Installation of gas hot water supplies for domestic purposes

• EN12828 – 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

• BS6798 – Installation of gas fired boilers of rated input up to 70kW (net)

• BS7671 – IET Wiring Regulations

, separate time and

Irish Standards

The current relevant Irish standards should be followed, including:

• ECTI – National rules for electrical installations

• IS 813 – Domestic Gas Installations

LPG Installations

An appliance using LPG 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 appliance 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

Salt based artificially softened water must not be used to fill the central heating system.

3 Product Information

3.1 About the appliance

The boiler has the following features:

• Pre-wired and pre-plumbed

• Galvanised steel inner frame

• Digital control system

• Automatic ignition

• Direct burner ignition electrodes

• Built-in frost protection

• Built-in fault finding diagnostics

• Automatic gas valve

• Modulating combustion air fan with speed regulator

• CH temperature sensor & control

• Pump anti-seizure protection

• Flue gas temperature sensor

• Condensate siphonic trap

• Plate type DHW heat exchanger

• Low Energy Modulating pump

3.2 Misuse

Appliance must be used as per the intended use statement. Operation outside the parameters of the intended use is considered misuse and could cause harm to people and damage to property.

Accessories should be as per accessories list. Minimum operational parameters are included in this document.

Using the appliance outside of its intended use may also invalidate the manufacturer's guarantee.

Greenstar 8000 Style – 6720883855 (2019/01)

Product Information

3.3 Scope of delivery

3.5 Appliance type overview

This appliance are for use with:

• Natural Gas or L.P.G. (Cat.II 2H3P type C13, C33 & C53)

This document refers to the following appliance types:

Appliance type Part number Gas Council number

GR8700iW 30 S NG 7 738 100 805 41-406-87 GR8700iW 35 S NG 7 738 100 806 41-406-86 GR8700iW 30 SB NG 7 738 100 837 41-406-83 GR8700iW 35 SB NG 7 738 100 838 41-406-82 GR8700iW 30 S LPG 7 738 100 854 41-406-89 GR8700iW 35 S LPG 7 738 100 855 41-406-88 GR8700iW 30 SB LPG 7 738 100 856 41-406-85 GR8700iW 35 SB LPG 7 738 100 857 41-406-84

Table 2 Type overview

The name of the appliance consists of the following parts:

• GR8700iW: Type name

• 30 or 35: Heat output in kW

• S: System appliance

• B: Black font panel

• NG: Gas type (Natural Gas)

• LPG: Gas type (Liquid Petroleum Gas)

3.6 Product identification

Fig. 1 Scope of delivery

[1] Wall mounted gas condensing boiler [2] Mounting bracket [3] Mounting plate [4] PRV Discharge pipe (including securing clips) [5] Guarantee card [6] Set of printed documents for product documentation [7] Fixing materials (screws with accessories) [8] Lower cover

3.4 Declaration of Conformity

The design and operation of this product comply with European Directives and the supplementary national requirements. Conformity has been demonstrated by the CE marking.

You can ask for a copy of the declaration of conformity for this product. For this see the contact address on the back cover of these instructions.

0010023673-001

Data plate

The data plate includes the product performance information, approval data and serial number. The data plate location can be found in the product overview.

Additional type plate

The product name and the most important product data are shown on the additional data plate. The additional type plate can be found on the outside of the product in an easily accessible location.

Greenstar 8000 Style – 6720883855 (2019/01)

Product Information

3.7 Pipe work positions and flue outlet

# Function From left

case edge

1 Condensate Outlet 58mm 22mm

2 CH Flow 90mm 22mm

3 Cylinder Return 1)155mm 15mm

4 Gas inlet 220mm 22mm

5 Cylinder Flow

6 CH Return 350mm 22mm

7 PRV Discharge 384mm 15mm

1) Only available if optional integral diverter valve kit is fitted.

Table 4 Pipe dimensions

For servicing purposes, keep condensate and pressure release valve discharge pipes away from other hydraulic components.

285mm 15mm

Diameter of pipe

• Rubber push fit connection

• Compression fitting

Fig. 2 Pipe and flue outlet dimensions

Description Dimensions (mm)

X Appliance width 440 Y Appliance height 780 Z Appliance depth 365 W Flue centre from appliance left side 220 D Flue centre from rear of appliance 87

Table 3 Appliance and flue outlet dimensions

0010023464-001

Greenstar 8000 Style – 6720883855 (2019/01)

3.8 Designation of components

9 8 7

Product Information

23 24

25 26

Fig. 3 Product overview System boilers, combustion cover removed

[1] KEY accessory housing slot (wireless Gateway) [2] Condensate trap [3] Data plate 1 [4] Pressure sensor [5] Pressure gauge [6] Venturi (sealed)

Greenstar 8000 Style – 6720883855 (2019/01)

0010023657-001

[7] Schrader Valve [8] Fan [9] Expansion vessel [10] Heating flow [11] Air-gas manifold with non-return valve [12] Ignition transformer

Product Information

[13] Flue [14] Ignition electrodes [15] Flame sensing electrode [16] Flow temperature sensor at flow pipe [17] Heating block temperature limiter [18] Flow temperature sensor at heating block [19] Inspection cover [20] Condensate sump [21] Gas valve [22] Automatic air vent valve (pump) [23] Data plate 2 [24] Diverter valve (accessory) [25] Heating pump [26] Drain point [27] Pressure relief valve (heating circuit) [28] Central heating return [29] Control unit

3.9 Product data for energy consumption

The product data on energy consumption can be found in the operating instructions for the user.

3.10 Standard accessories

The appliance has the option to fit an integral diverter valve kit, whichhas multiple controls options for the use with vented and unvented hotwater cylinders. The details can be found in the Installation Instructionsfor the diverter valve kit.

Greenstar 8000 Style – 6720883855 (2019/01)

4 Pre-Installation

NOTICE:

Risk of damage to system or appliance!

Before installation

▶ All the following Pre-Installation sections must be read and

requirements met before starting appliance or flue installations.

4.1 System preparation

4.1.1 Artificially softened water

It is possible to have an ion exchange water softener fitted to the cold water system of the property. However, the appliance requires an untreated cold water connection taken from the mains supply, before the water softener, to the primary water filling point of the heating system.

Alternatively there are water softening/treatment appliances that do not adjust or alter the pH levels of the water. With these appliances it may not be necessary to provide an untreated water by-pass to the primary water filling point of the heat system.

NOTICE:

▶ Salt based softened water must not be used to fill the central heating

system.

4.1.2 Water systems and pipe work

Pre-Installation

Hot water:

• Taps and mixing valves must be capable of sustaining a pressure up to

10 bar.

• Hot water temperature and flow rate are affected by the size and

insulation of pipe work making up the distribution system and are controlled by the hot water tap and the water main inlet pressure. A mixing valve can be fitted if a more permanent temperature setting is required.

• If using more than one outlet at once causes water flow starvation, fit

flow balancing valves or Ball-O-Fix valves to the appropriate outlets.

Primary system considerations - Combi & System appliances

Sealed system

• The CH sealed system must be filled using a WRAS approved filling

loop or comply with examples in 4.1.4 "System fill" section.

• Where the system volume is more than 100 litres or exceeds 2.5 bar

at maximum heating temperature an additional expansion vessel [2] must be fitted as close as possible to the appliance in the central heating return.

• Pressurise the extra expansion vessel [2] to the same value as the

built-in expansion vessel - refer to the Technical data page.

Primary system plastic pipework:

• Any plastic pipe work must have a polymeric barrier, complying with BS 7921 and installed to BS 5955 with 600mm (minimum) length of copper connected to the appliance.

• Plastic pipe work used for under-floor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approximately 50°C with 1000mm (minimum) length of copper or steel pipe connected to the appliance.

Primary system/connections/valves:

• Do not use galvanised pipes or radiators.

• All system connections, taps and mixing valves must be capable of sustaining a pressure of 3 bar.

• Radiator valves should conform to BS 2767:10.

• All other valves should conform to BS 1010.

• It is best practice to fit Thermostatic Radiator Valves (TRV's) to all radiators, except the area where the room thermostat is sited which must be fitted with lockshield valves that are left open.

• If the circulating pump speed is fixed and system circulation can be significantly adjusted or stopped by TRV's or zone valves, a system bypass should be installed to give at least a 3 metre circuit when activated. However; any appliance fitted with a modulating pump may not require a system bypass.

• Drain cocks are required at all the lowest points on the system.

• Air vents are required at all high points on the system.

Fig. 4 Additional expansion vessel

[1] Appliance expansion vessel [2] Additional expansion vessel [3] Pressure relief discharge [4] Heating return [5] Heating flow

0010021117-001

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 appliance 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.

Greenstar 8000 Style – 6720883855 (2019/01)

Pre-Installation

Checking the size of the expansion vessel

To determine whether an additional expansion vessel is required: Follow the steps below:

▶ Calculate the total system volume (litres). Plotting a line vertically on

the chart ( Fig. 5).

▶ Determine the central heating maximum operating flow temprature

(73 °C for condensing). Plot a line horizontally on the chart ( Fig.

5).

▶ Determine the pre charge in the expansion vessel based on static

head, 1 meter = 0.1 bar. (default = 10 metres).

▶ Select a curve from the key below (1-5).

If the dissected lines are in area A then no additional expansion is required.

If the dissected line is in are B then an additional expansion vessel must be installed ( Fig. 4).

T[°C]

Sealed primary system - Cylinder and 2 x central heating zones:

Typical S-Plan Plus example

• The cylinder return must be the last connection on the common return pipe to prevent reverse circulation.

Fig. 7 Cylinder and 2 x heating zones

[1] Appliance [2] Zone valves [3] Hot water cylinder

Sealed primary system - 3-way valve, cylinder and central heating zone:

Typical Y-Plan example

• The cylinder return must be the last connection on the common return pipe to prevent reverse circulation.

0010021230-001

0 100 200 300 400 500 600 700

V[l]

0010016558-002

Fig. 5 Curves for the expansion vessel

1 Pre-charge pressure 0.5 bar (minimum) 2 Pre-charge pressure 0.75 bar 3 Pre-charge pressure 1.0 bar (default setting) 4 Pre-charge pressure 1.2 bar 5 Pre-charge pressure 1.3 bar T Maximum operating temperature [ °C] V Total System Volume [l]

4.1.3 System layouts examples

Sealed primary system - Cylinder and central heating zone:

Typical S-Plan example

• The cylinder return must be the last connection on the common return pipe to prevent reverse circulation.

Fig. 8 3-way valve, cylinder and heating zone

[1] Appliance [2] 3-Way zone valve [3] Hot water cylinder

Optional integral diverter valve kit

This appliance is designed to operate on a sealed system only. The appliance will require to fit a separate flow and return pipe from the water cylinder to the wall mounting frame and terminate in 15mm copper pipe.

Details for the connection of the integral diverter valve kit components are found within the Installation Instructions for the kit.

0010021231-001

Fig. 6 Cylinder and heating zone

[1] Appliance [2] Zone valves [3] Hot water cylinder

0010021229-001

Sealed primary system - Internal diverter valve kit:

• This appliance is designed to operate on a sealed system only. The appliance will require a second flow and return pipe from the hot water cylinder to the wall mounting frame and terminate in 15mm copper pipe. The following system layouts show a simplified example of the pipe configuration to the appliance.

Greenstar 8000 Style – 6720883855 (2019/01)

4.1.4 System fill

Filling primary sealed systems

Pre-Installation

0010021286-001

Fig. 9 Example layout - Internal diverter valve kit

[1] Appliance with internal diverter valve kit [3] Unvented hot water cylinder

Unvented cylinders

In all cases the cylinder manufacturer must be contacted for confirmation their product is suitable for the installation layout shown in figure 9.

Although the accepted common practice of a 2-port motorised valve installed in the primary flow pipe to the cylinder and wired to the dualthermostat supplied with the cylinder. It is possible to use the integral diverter valve kit and not need the 2-port motorised valve to cut the flow of heat to the cylinder to comply with Building Regulation Part G3.

• The integral diverter valve kit cylinder sensor must be used.

• The general layout (figure 9) can be used for unvented cylinder by utilising the high limit thermal cut out of the cylinder dual-thermostat to interrupt the permanent live to the appliance, preventing any heat being produced from the appliance.

Example layout with unvented cylinder & cylinder safety valve.

If required by the cylinder manufacture to fit/use the cylinder safety valve then this can also be carried out (figure 10) with the integral diverter valve kit.

• The cylinder safety valve and dual-thermostat (control thermostat and high limit thermal cut out) are wired to interrupt the permanent live to the appliance, preventing any heat being produced from the appliance.

NOTICE:

Filling the primary sealed system

The system must not be filled with salt based softened water.

▶ Ensure the primary water filling point uses an untreated cold water

connection from the mains supply, before a water softener.

• Filling the system must comply with one of the following methods shown.

• The filling point must be at low level and must never be a permanent connection to the mains water supply.

• Filling loops must be WRAS approved.

• If the external filling link is sited away from the appliance, then a pressure gauge should be installed at the filling point.

External filling loop

3 3

0010012942-001

Fig. 11 External filling loop system fill example

[1] Cold mains inlet pipe [2] Stop valve [3] Check valve [4] Test point [5] Hose union [6] Central heating flow pipe

Top-up tank system fill

In situations where the cold mains pressure is not sufficient to pressurise the system to between 1 and 1.5bar an alternative can be to use a top-up tank.

2 3

Fig. 10 Example layout - Internal diverter valve kit with unvented

cylinder and cylinder safety valve

[1] Appliance with internal diverter valve kit [2] Cylinder safety valve (unvented cylinder) [3] Unvented hot water cylinder

Greenstar 8000 Style – 6720883855 (2019/01)

0010021233-001

0010012943-001

Fig. 12 Top-up tank system fill example

[2] Stop valve [3] Check valve [6] Central heating flow pipe [7] Top-up tank [8] Automatic air vent [9] Minimum height above the highest point of the system - 1000mm

(39 in)

Pre-Installation

4.2 Mains supply

4.2.1 Electrical supply

• Supply: 230V AC - 50 Hz

• This appliance must not be connected to a three phase supply.

• The wiring between the appliance and the electrical supply must comply with the latest IET wiring regulations that apply to wiring a fixed appliance.

• Type A RCDs must be employed where additional protection is required.

• External 3fuse to BS1362.

• The appliance must be earthed.

• Cable: PVC insulated 0.75mm

(24 x 0.2mm) temperature rated to

90 °C, to BS EN50525.

• Any additional components that are connected to the appliance with mains electrical supply must not have a separate supply.

• Additional equipment wired to the appliance must comply with the latest IET wiring regulations.

• Appliance IP rating - IPX4D

4.2.2 Gas supply

• Appliances using Natural Gas (NG) must be connected to a governed meter.

• Appliances using Liquid Petroleum Gas (LPG) must be connected to a regulator.

• Installation and connection of the gas supply to the appliance must be in accordance with BS6891.

• Gas pipe sizing should be calculated to ensure no more than the permitted mbar drop between the meter/governor to the appliance inlet. ( chapter 12.8).

• The meter or regulator and pipe work to the meter or regulator must be checked, preferably by the gas supplier. This is to ensure that the equipment 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.

Pipe sizing (NG & LPG)

Natural Gas:

▶ When using this table to estimate the gas flow rate in pipe work of a

known length, the effective length will be increased by 0.5m for each 90° elbow and tee fitted and by 0.3m for each 90° bend. This method is only a estimate - for more complex design please refer to BS6891 2015 and training given in ACS.

Liquid Petroleum Gas (LPG):

Discharge rates for copper tube with 2.5mbar differential pressure between the ends for LPG.

Discharge rates for LPG (m3/hr & kW)

with straight horizontal copper tube

Tubing Outside diameter

Length (m) 15mm 22mm 28mm

kW m3/hr kW m3/hr kW m3/hr 3 38.4 1.49 207 8.01 412 15.92 6 26.1 1.01 135 5.21 230 8.86 9 20.5 0.79 108 4.19 215 8.33

12 17.9 0.70 94 3.62 187 7.25 15 15.5 0.60 82 3.20 168 6.51 18 13.5 0.53 74 2.86 145 5.61 21 12.9 0.50 67 2.58 135 5.24 24 12.0 0.47 61 2.58 126 4.87

Table 6 Liquid Petroleum Gas (LPG)

Liquid Petroleum Gas (LPG):

▶ When using this table to estimate the Gas flow rate in pipe work of a

known length, the effective length will be increased by 0.6m for each 90° elbow or tee and by 0.3m for each 90° bend or straight coupler. This method is only a estimate - for more complex design please refer to BS6891 2015 and training given in ACS.

Gas pipe work:

▶ Gas installation pipe work must be designed to ensure the pressure

loss between the meter outlet (NG) or storage and regulator (LPG) and the inlet to each appliance does not exceed 1mbar (NG) 2.5mbar (LPG)  table ”Allowed mbar pressure drop”.

Natural Gas (NG):

Discharge rates for copper tube with 1mbar differential pressure between the ends for Natural Gas.

Discharge rates for Natural Gas (m3/hr)

with straight horizontal copper tube

Pipe Pipe Size (mm)

Length (m) 15 22 28 35

2.9 8.7 18 32 6 1.9 5.8 12 22 9

1.5 4.6 9.4 17

12 Discharge 1.3 3.9 8 15 15

m3/hr 1.1 3.4 7 13 20 0.95 2.9 5.9 11 25

0.92 2.5 5.2 9.5

30 0.88 2.3 4.7 8.5

Table 5 Natural Gas

4.3 Appliance location and clearances

4.3.1 Appliance location

• Follow local regulations for the location within the property that the appliance is to be installed.

• This appliance is only suitable for installing internally within a property at a suitable location onto a flat, fixed rigid surface capable of supporting the appliance weight.

• The appliance is not suitable for external installation.

No surface protection is required againat heat transfer from the appliance

DANGER:

Danger from explosive and flammable materials:

Storage of explosive and flammable materials.

▶ Do not store flammable materials (paper, curtains, clothing, primer,

paint, …) in proximity to the appliance.

Greenstar 8000 Style – 6720883855 (2019/01)

Pre-Installation

NOTICE:

Damage to appliance:

Contaminated combustion air.

▶ Do not use any cleaners containing chlorine or hydrogen halide (i.e.

spray cans, primers, cleaners, paint and glue). ▶ Do not store or use these substances in the appliance, room. ▶ Avoid the build up of dust.

NOTICE:

Damage to appliance:

Extreme temperatures may cause damage to the heating system.

▶ Ensure the ambient temperature is above 0 °C and below 35 °C.

NOTICE:

Damage to system:

The heating system pipe work can be damaged by frost if installed in an internal unheated area, such as a loft, basement or garage. The appliance internal frost protection only monitors the system water temperature within the appliance to provide protection for the appliance.

▶ Install a frost thermostat and pipe thermostat connected in series, to

protect the system pipe work.

We recommend that the frost thermostat is sited in the coldest

unheated area in which pipe work is located and that it is set to call for

heat at 5 °C. The Pipe stat should be located on whichever pipe is

furthest from the heated area where warmer water will be drawn from

considering the direction of flow, and set to end the demand at 15 °C. ▶ The system pipe work in the internal unheated area should be

insulated. ▶ If the appliance is to be shut down for an extended period, drain the

central heating system.

4.3.2 Rooms containing a bath or shower

CAUTION:

Risk of electric shock

▶ Any switch or appliance control using mains electricity must not be

within reach of a person using the bath or shower.

• In all cases the installation must be in accordance with the latest

amendments to the latest edition of the IET Wiring Regulations (BS7671).

• Check the IP rating of any control units to be used on this appliance.

• Circuit breaking appliances should be used in accordance with the regulations.

• Figure 13 is for guidance only.

600mm

2250mm

0010017086-001

Fig. 13 Bathroom installations

[1] Zone 1 [2] Zone 2 [2*] Without the end wall, zone 2 must extend 600mm from the bath [A] 600mm radius from the bath or shower

2250mm

The appliance must be installed where:

▶ The area is well lit, allowing to clearly see the appliance to carry out

any work or checks.

▶ An engineer can gain clear and safe access to work on the product or

component, including making adequate provision for visual inspection of flues in voids.

▶ The homeowner can gain clear and safe access to the controls, check,

top up or reset the appliance.

▶ Roof space installations must fully conform to BS 5410 part 1: roof

space installations.

▶ Products in roof spaces must have permanent fixed lighting, a

permanent fixed retractable ladder and a fixed floor area sufficient to allow access for normal use and servicing around the product and between and the access hatch. We would also recommend that a remote pressure gauge and filling loop are sited where the customer can gain easy access for checking and topping up.

4.3.3 Appliance clearances

Appliance clearances

• The following details covering the installation, service and maintenance clearances for the appliance.

CAUTION:

Risk of damage to appliance or property

The appliance will overheat if the clearance space around the appliance is restricted by objects.

▶ Do not restrict this space with the addition of cupboards, shelves etc.

next to or around the appliance.

▶ Do not store any combustible materials on or next to the appliance,

such as clothes, towels, paper or plastic bags.

Greenstar 8000 Style – 6720883855 (2019/01)

Pre-Installation

0010012940-001

Fig. 14 Appliance minimum clearances

Minimum clearances

Description Dimensions (mm)

X Appliance width 440 Y Appliance height 780 Z Appliance depth 365

Installation/Maintenance

1 Overall clearance height 1,150/1,190 * 2 Overall clearance depth 965 3 In front of appliance 600 4 Overall clearance width 450 5 Above the appliance 170/210 * 6 Either side of appliance 5 7 Below the appliance 200 8 Compartment depth 385 9 Appliance to removable door 20

Table 7

[*] Height for either 60/100 flue or 80/125 flue

Appliances in compartments

Follow the latest requirements of BS6798 and BS5440 and note:

• Minimum clearances must be maintained.

• An access door is required to install, service and maintain the appliance and any ancillary equipment.

• If the appliance is installed in an unventilated airing/storage cupboard, there is no requirement to make a partition between the appliance and the storage space as long as the minimum clearances around the appliance are maintained.

4.4 Flue systems considerations

WARNING:

Flue systems

Possible flue gas escape

▶ Use Worcester, Bosch Group approved Condensfit II flue systems

only, no other manufacturer’s flue have been tested or approved for use with Worcester, Bosch Group appliances.

CAUTION:

Concealed flue systems:

▶ Where a flue system is going to be concealed, provision must be

made for service and inspection.

▶ Voids containing concealed flues must have at least one inspection

hatch no less than 300mm square.

▶ Flue joints within the void must not be more than 1.5 metres from the

edge of the inspection hatch. ▶ Inspection hatches should be located at changes of direction. ▶ If this is not possible, bends should be viewable from both directions.

Refer to the manual supplied with the Worcester, Bosch Group flue kit for complete installation instructions.

Flue kit part numbers

Part number Flue Ø Description

7 738 112 869 60/100 Telescopic horizontal flue kit (Silver) 7 716 191 082 60/100 Telescopic horizontal flue kit 7 716 191 171 60/100 Extended telescopic horizontal flue kit 7 733 600 048 60/100 Horizontal high level telescopic flue kit 7 719 003 702 80/125 Telescopic horizontal flue kit 7 719 002 430 60/100 Vertical balanced flue kit 7 719 002 431 80/125 Vertical balance flue kit

Table 8 Flue kit assembly part numbers

4.4.1 Flue length

The maximum flue length will depend on the following factors:

• 60/100mm flue system

– Vertical/horizontal flue type

– Appliance output

– Plume management length

• 80/125mm flue system

– Vertical/horizontal flue type

– Appliance output

Horizontal maximum flue lengths

Maximum horizontal flue lengths (L) Output 60/100 80/125

No Plume management

+ 500mm of plume management

+4500mm of plume management

No plume management

available 35kW 10,000mm 10,000mm 7,200mm 29,000mm 30kW 17,000mm 17,000mm 14,200mm 25,000mm

Table 9 Maximum flue lengths - Horizontal flues

Greenstar 8000 Style – 6720883855 (2019/01)

Pre-Installation

Vertical maximum flue lengths

Flue length [L] Flue length [L]

Output 60/100 80/125

35kW 14,000mm 29,000mm 30kW 21,000mm 25,000mm

Table 10 Maximum flue lengths - Vertical flues

Flue system bends

NOTICE:

Effective flue lengths of bends:

Each bend used has an equivalent straight flue length.

▶ Refer to the table below.

Effective flue length

Bend 60/100 80/125

45° 0.5m 0.5m 90° 1.5m 1.5m

Table 11 Effective length of bends

4.4.2 Flue options

The systems have diiferent maximum flue lengths, refer to the following example flue options for those maximum flue lengths.

Horizontal high level flue assembly

60/100 mm

383 mm - 603 mm

Horizontal fixed length flue assembly

1050 mm

330 mm Min

0010015192-001

Fig. 17 Horizontal flue option

• Flue length [L] (adaptor bend included in length calculation) – 60/100 = 330 - 1,050mm – 80/125 = N/A

Extended horizontal flue

0010015193-001

Fig. 18 Horizontal flue option

• Flue length [L] (adaptor bend included in length calculation) – Maximum flue length as stated in "Horizontal maximum flue

lengths".

Horizontal flue with additional 90° elbow

130 mm Min

Fig. 15 Horizontal flue option

• Flue length [L] (initial bend included in length calculation) – 60/100 = 202 - 603mm – 80/125 = N/A

Telescopic horizontal flue assembly

60/100 mm

[A] 350 mm - 570 mm [B] 570 mm - 790 mm

130 mm Min

Fig. 16 Horizontal flue option

Telescopic horizontal flue assembly [A]

• Flue length [L] (adaptor bend included in length calculation) – 60/100 = 180 - 570mm – 80/125 = 405 - 600mm

Extended telescopic horizontal flue assembly [B]

• Flue length [L] (adaptor bend included in length calculation) – 60/100 = 570 - 790mm – 80/125 = N/A

0010015190-001

0010015194-001

Fig. 19 Horizontal flue option

• Flue length [L] (adaptor bend included in length calculation) – Maximum flue length as stated in "Horizontal maximum flue

lengths" minus the 90° bend equivalent straight flue length as stated in Table 11 "Effective length of bends".

Horizontal flue with additional 90° elbows

0010015191-001

0010015195-001

Fig. 20 Horizontal flue option

• Flue length [L] (adaptor bend included in length calculation) – Maximum flue length as stated in "Horizontal maximum flue

lengths" minus 2 x 90° bends equivalent straight flue length as stated in Table 11 "Effective length of bends".

Greenstar 8000 Style – 6720883855 (2019/01)

Pre-Installation

High level horizontal flue

Fig. 21 Horizontal flue option

• Flue length [L] (initial bend included in length calculation) – Maximum flue length as stated in "Horizontal maximum flue

lengths".

High level horizontal flue with additional 90° elbow

0010015196-001

0010015197-001

Vertical balanced flue assembly

= 300 mm

B = 500 mm

0010015199-001

Fig. 24 Vertical flue option

• Flue length [L] – Maximum flue length as stated in "Vertical maximum flue

lengths".

Vertical balanced flue with 90° elbow offset

Fig. 22 Horizontal flue option

• Flue length [L] (initial bend included in length calculation) – Maximum flue length as stated in "Horizontal maximum flue

lengths" minus the 90° bend equivalent straight flue length as stated in Table 11 "Effective length of bends".

High level horizontal flue with additional 90° elbows

Fig. 23 Horizontal flue option

• Flue length [L] (initial bend included in length calculation) – Maximum flue length as stated in "Horizontal maximum flue

lengths" minus 2 x 90° bends equivalent straight flue length as stated in Table 11 "Effective length of bends".

= 300 mm

B = 500 mm

0010015200-001

Fig. 25 Vertical flue option

• Flue length [L] – Maximum flue length as stated in "Vertical maximum flue lengths"

minus 2 x 90° bends equivalent straight flue length as stated in Table 11 "Effective length of bends".

Vertical balanced flue with 45° elbow offset

0010015198-001

= 300 mm

B = 500 mm

0010015201-001

Fig. 26 Vertical flue option

• Flue length [L] – Maximum flue length as stated in "Vertical maximum flue lengths"

minus 2 x 45° bends equivalent straight flue length as stated in Table 11 "Effective length of bends".

Greenstar 8000 Style – 6720883855 (2019/01)

4.4.3 Plume management system

For every extra 1000mm of plume management after the first 500mm, the internal 60/100 flue length must be reduced by 700mm, up to a maximum of 4500mm of plume management.

2,800

2,100

1,400

Pre-Installation

[mm]

700

500 1,500 2,500 3,500 4,500

[mm]

0010023114-001

Fig. 27 Reduction to flue length as plume length increases graph

[1] Reduction to flue length [mm] (maximum reduction 2,800mm) [2] Plume length [mm] (maximum plume length 4,500mm)

NOTICE:

Plume management length:

▶ The plume management length must be a minimum of 500mm and

must not exceed the maximum straight length for a horizontal Ø 60/ 100mm flue with a 60mm plume management system as stated previously.

Horizontal plume management runs

▶ The initial horizontal run from the terminal elbow must have a

minimum 10° fall back, (stop tabs in the elbow prevent less than 10°) to the appliance for proper disposal of condensate.

▶ Any further horizontal runs after an elbow can be 3°.

WARNING:

Minimum plume management length:

The minimum distance of 500mm must be maintained between air inlet and exhaust.

▶ Do not terminate the plume management inside the terminal

exclusion zone (shaded area) shown in figure 28.

±80°

0010013548-001

Fig. 28 Terminal exclusion zone

NOTICE:

Cutting the 500mm pipe

If the 500mm plume management pipe kit is cut, an additional elbow will be required to join the pipe work.

▶ The Plume management extension kit contains the components

required for such a configuration.

4.4.4 Flue terminal positions

CAUTION:

Flue terminal positions

▶ All measurements are the minimum clearances required. ▶ Terminals must be positioned so to avoid combustion products

entering the building.

Greenstar 8000 Style – 6720883855 (2019/01)

Pre-Installation

Vertical flue terminal positions

1/2

1500

RIDGE FLUERIDGE VENT

600

BOUNDARY LINE

BOUNDARIES

1500

300

1200

300

1500

600

300

1500

500

600

400

300

400

600

500

2000

600

1500

Fig. 29 Vertical flue terminal positions

Key to figure 29:

[1] 1,500mm measured horizontally between a vertical flue terminal

and an opening or vented window. 500mm measured horizontally between a vertical flue terminal and an opening or vented window providing the flue terminal is at least 300mm above the opening.

[2] Minimum clearance to an additional flue, 600mm to a room

sealed flue or 1,500mm to an open flue.

[3] 300mm clearance from a vertical flue terminal adjacent to a

boundary line, unless it will cause a nuisance. BS 5440: Part 1 recommends that care is taken when siting a terminal in relation to boundary lines.

[4] 600mm minimum clearance measured from an opening or vented

skylight to a vertical flue terminal. If the terminal is within 1,500mm of the opening or vented skylight then it must be at least 300mm above the opening.

[5] 500mm clearance measured horizontally from a vertical flue to a

vertical structure.

[6] The flue must not penetrate the roof in the shaded area.

The terminal must be at least 1500mm from the opening or vent when sited below the window or 600mm when sited to either side or above.

0010021441-001

[7] 400mm measured diagonally from a pitched roof or 500mm in

regions with heavy snow fall. 300mm measured vertically from the air intake to the closest intersection with the roof.

[8] 1,200mm separation between a vertical flue measured

horizontally and a horizontal flue terminal. Not required if the horizontal flue is 1,200mm above.

[9] For the purpose of determining suitable flue terminal positions for

gas appliances, the boundary can be considered to extend to the centre line of any adjacent routes or waterways e.g. paths, streets, rights of way, canals, rivers or railways.

Note:

▶ Where a vertical flue terminates in an area that is enclosed on 3 sides,

the flue must be no more than 1,000mm below the lowest roof line. You must ensure that all clearances are maintained and that products of combustion disperse safely from the area.

Greenstar 8000 Style – 6720883855 (2019/01)

Horizontal flue terminal positions

Pre-Installation

300

1500

300

BOUNDARY LINE

OPENING

OPPOSITE

2000

300

600

TOP

600

SKYLIGHTDORMA

600

1500

600

200

300

200

300

600

300

600

1200

300

1000

300

1200

BOUNDARY LINE

200

1/2

100

BOUNDARIES

200

100

Fig. 30 Horizontal flue terminal positions

Key to figure 30:

[1] 200mm below eaves and 75mm below gutters, pipe and drains. [2] The dimension below eaves, gutters, pipes and drains can be

reduced to 25mm, as long as the flue terminal is extended by 100mm past any overhang. The telescopic flue joint must be sealed with suitable silicone sealant if it is external to the building.

[3] 300mm adjacent to a boundary line, unless it will cause a

nuisance. BS 5440: Part 1 recommends that care is taken when siting terminal in relation to surfaces or boundary lines.

[4] 1,200mm separation measured between terminals facing each

other.

[5] 600m distance to a surface or boundary line facing a terminal,

unless it will cause a nuisance. BS 5440: Part 1 recommends that care is taken when siting terminal in relation to surfaces or boundary lines.

BELOW GROUND OPEN LIGHT WELL

<1000

300

600

300150

[6] The terminal must be at least 1500mm from the opening or vent

when sited below the window or 600mm when sited to either side or above.

[7] 600mm diagonally to an opening door, air vent or opening

window.

[8] 1,200mm separation between a vertical flue measured

horizontally and a horizontal flue terminal. Not required if the horizontal flue is 1,200mm above.

[9] For the purpose of determining suitable flue terminal positions for

gas appliances, the boundary can be considered to extend to the centre line of any adjacent routes or waterways e.g. paths, streets, rights of way, canals, rivers or railways.

[10] 300mm to an internal or external corner. 300mm above a

surface, such as the ground/ floor level or roof surface. * If the terminal section is less than 150mm and has two screws securing it to the elbow, the terminal section will not require a supporting bracket.

100

300

0010021442-001

Greenstar 8000 Style – 6720883855 (2019/01)

Pre-Installation

[11] 300mm above, below and either side of an opening door, air vent

or opening window.

[12] Below ground level in an open lightwell. The flue must be at least

600mm from the opposing surface and have at least 300mm clearance either side and below. The flue terminal must be no more than 1000mm from the top of the lightwell.

[13] Flues should clear any LPG storage by 1,000mm horizontally and

300mm above.

[14] Proximity of flue duct outlet to boundaries, 2000mm distance to

an opening in adjacent building facing a terminal. BS 5440: Part 1 recommends that care is taken when siting terminal in relation to boundary lines.

[15] 300mm from an opening or vented window, 150mm to a fixed

unvented window.

[16] The dimension below eaves, balconies and car ports can be

reduced to 25mm, as long as the flue terminal is extended to clear any overhang. The telescopic flue joint of the terminal must be sealed with suitable silicon sealant if it is external to the building.

Note:

▶ Installations in car ports are not recommended. ▶ The flue cannot be lower than 1,000mm from the top of a light well

due to the build up of combustion products.

▶ Dimensions from a flue terminal to a fanned air inlet to be determined

by the ventilation equipment manufacturer.

▶ A flue terminal guard shall be fitted whenever a terminal or air inlet is

fitted less than 2,000mm above ground, above a balcony or above a flat roof to which people have access.

4.4.5 Plume re-direct and plume management terminal positions

Maximum and minimum plume management lengths:

▶ A minimum distance of 500mm must be maintained between the

plume management outlet and the flue air intake.

▶ The maximum plume management length is 4.5 metres for the

appliances detailed on the front of this manual.

▶ The 45° bend is equivalent to 0.5 metres of straight plume

management and the 90° bend is equivalent to 1.0 metres.

NOTICE:

▶ All measurements are the minimum clearances required. ▶ Refer to “Horizontal flue terminal positions” for all concentric flue

terminal positions unless the flue position is specified in figure 31 “Plume re-direct and plume management terminal positions”.

▶ Terminals must be positioned so to avoid combustion products

entering the building.

▶ Support the flue at approximately one metre intervals and at a change

of direction, use suitable brackets and fittings.

Greenstar 8000 Style – 6720883855 (2019/01)

Pre-Installation

180°

200

300

200

300

150

300

600

BOUNDARY LINE

300

±80°

200

150

1200

BOUNDARY LINE

TOP

±45°

2000

600

EXCLUSION ZONE

OPENING

OPPOSITE

300

TOP

±80°

600

300

BOUNDARY LINE

600

300

150

1,500

150

300

1500

300

≥140

≥5

EXCLUSION ZONE

150

100

200

600

300

100

≥5

EXCLUSION ZONE

300

150

TOP

300

150

FLUE TERMINAL GUARD

7 716 191 176

0010021676-001

Fig. 31 Plume re-direct and plume management terminal positions

Key to figure 31 - Plume re-direct terminal positions:

[1] This feature allows some basic plume re-direction options on a

standard telescopic horizontal flue terminal. 300mm minimum clearances to a opening e.g. window. However the minimum clearances to an opening in the direction that the plume management is facing, must be increased to 1,500mm. Where the flue is less than 150mm to a drainpipe and plume redirection is used the deflector should not be directed towards the drainpipe.

[2] 300mm adjacent to a boundary line, unless it will cause a

nuisance. BS 5440: Part 1 recommends that care is taken when siting terminal in relation to surfaces or boundary lines.

[3] Where the flow of products of combustion is not at right angles to

the boundary, the 600mm dimension may be measured in the direction of flow as long as the terminal is not less than 300mm from the boundary.

[4] When redirecting the flue discharge the terminal end must be at

least 1,500mm from any opening in the direction of the discharge to prevent combustion products from entering the building.

Key to figure 31 - Plume management terminal positions:

[5] 600mm distance facing a surface or a boundary line, unless it will

cause a nuisance. BS 5440:Part 1 recommends that care is taken when siting a terminal in relation to surfaces or boundary lines.

[6] Proximity of flue duct outlet to boundaries, 2000mm distance to

an opening in adjacent building facing a terminal. BS 5440: Part 1 recommends that care is taken when siting terminal in relation to boundary lines.

[7] 300mm adjacent to a boundary line, unless it will cause a

nuisance. BS 5440: Part 1 recommends that care is taken when siting terminal in relation to surfaces or boundary lines.

[8] 300mm distance from a boundary line to the air intake as long as

the exhaust terminal faces away from the boundary line. The exhaust terminal must have a minimum 300mm clearance to a surface below and there must be at least 600mm clearance when measured horizontally in a straight line from the exhaust terminal to any other surface.

[9] Plume Management kit air intake can be reduced to 150mm

providing the flue exhaust outlet is no less than 300mm adjacent to a boundary line.

[10] Above, below and either side of an opening door, air vent or

opening window. Using a Plume Management kit the air intake measurement can be reduced to 150mm providing the flue exhaust outlet has a 300mm clearance.

[11] Below balcony or overhange. The air intake clearance can be

reduced to 150mm providing the flue exhaust outlet has a 200mm clearance.

[12] 1,200mm between terminals facing each other

[13] Internal/external corners. The air intake clearance can be reduced

to 150mm providing the flue exhaust outlet has a 300mm clearance.

[14] Clearances no less than 200mm from the lowest point of the

balcony or overhang.

[15] If a plume management kit is installed within the confines of a

carport or other covered, partially enclosed extension, then the

1) 600mm in case two plume management kits are used on opposing terminals.

Each terminal should use a minimum length of 500mm plume management.

Greenstar 8000 Style – 6720883855 (2019/01)

Pre-Installation

exhaust terminal must be positioned at least 1200mm away from any opening into the building which is sited within the footprint of the carport. If the exhaust terminal is extended at least 300mm beyond the footprint of the carport then the distance from the terminal to an opening within the carport can be reduced to 600mm. The exhaust terminal can also be routed though the roof of the carport providing 25mm clearance is provided around the flue pipe to any flammable material and that it extends at least 300mm above the roof. The air intake must have a minimum 150mm clearance to any opening in the building in order to ensure the integrity of the structure is maintained. If the exhaust terminates within the footprint of the carport then the carport must have at least 2 sides completely open. If the exhaust terminates at least 300mm beyond the footprint of the carport then the carport must have at least one completely open side. The exhaust terminal must be positioned to ensure that plume will not cause nuisance or damage to vehicles and that minimum clear distances in front of the terminal will not be impeded by vehicles.

Note:

▶ Installations in car ports are not recommended. ▶ The flue cannot be lower than 1,000mm from the top of a light well

due to the build up of combustion products.

▶ Dimensions from a flue terminal to a fanned air inlet to be determined

by the ventilation equipment manufacturer.

▶ Plume kits running horizontally must have at least a 3° fall back to the

appliance for proper disposal of condensate, except or the initial horizontal run from the terminal. The initial plume kit horizontal run will have at least a 10° fall back to the appliance, due to the terminal elbow design, for proper disposal of the condensate.

4.5 Condensate discharge

Full details on condensate discharge.

▶ Follow the latest version of BS6798 and HHIC guidance.

For correct installation and trouble free operation of the appliance the following advice should be followed:

1. To minimize the risk of freezing, wherever possible: the

condensate drain should be installed internally.

2. All condensate pipe work must ‘fall’ from the appliance by a minimum of 3° (52mm per metre) to ensure adequate condensate flow.

3. The pipe work route must allow air to be supplied back to the appliance for correct operation.

4. Connection to a rainwater down pipe must include an air break.

Also:

• The condensate pipe work connected to the condensate drain outlet on the appliance should have a minimum internal diameter (ID) of 19mm.

• Keep external pipe work as short as possible and do not exceed 3 metres length. Unless there is no means of routing the pipe internally. Further precautions against freezing must be taken if external pipe runs exceed 3m.

• External pipe work should have a minimum internal diameter (ID) of 30mm.

• Minimise the number of bends and connectors.

• Remove burrs after cutting pipe.

• Remove surplus solvent from the interior of the pipe.

• The condensate pipe work shall be run in standard drainpipe material, e.g. poly(vinyl chloride) (PVC), unplasticized (vinyl chloride) (PVC-U), acrylonitrilebutadiene.styrene (ABS), polypropylene (PP) or chlorinated poly(vinyl chloride) (PVC.C).

4.5.1 Appliance siphonic condensate trap

The appliance has a large capacity condensate trap reducing the risk of condensate discharge pipe work freezing up in prolonged cold temperatures.

The expanded siphonic operation discharges every 10 to 20 minutes. Resulting in:

• Increased velocity and flow rate.

• With less frequent siphonic actions per hour, the condensate pipe work is empty for longer.

• Significantly reducing freezing potential for a 48 hour period at 15 °C, provided the installation parameters listed below are followed.

4.5.2 Condensate pipe work

NOTICE:

General consideration

▶ Where a new or replacement appliance is being installed, access to

an internal “gravity discharge” point should be one of the factors considered in determining appliance location.

▶ Condensate pipe connection at the appliance:

The condensate pipe must have a nominally outside diameter of 22mm plastic pipe.

▶ Ensure there are no blockages in the pipe run. ▶ Ensure that the discharge method for the installation can effectively

handle the condensate waste from the appliance.

Greenstar 8000 Style – 6720883855 (2019/01)

Pre-Installation

Condensate pipe work - Unheated internal areas

NOTICE:

Unheated internal areas.

Although the large volume siphon will reduce the risk of freezing, condensate discharge may freeze in areas during prolonged cold temperatures.

▶ Internal pipe runs in unheated areas such as lofts, basements and

garages should be treated as external runs. For additional information refer to “External Connections” section.

4.5.3 Internal connections

Soil stack connection

 Figure 32

In order to minimise risk of freezing during prolonged cold spells, the following methods of installing condensate drainage pipe should be adopted.

Wherever possible, the condensate drainage pipe should be routed and terminated so that the condensate drains away from the appliance under gravity to a suitable internal foul water discharge point such as an internal soil and vent stack. A suitable permanent connection to the foul waste pipe should be used.

Condensate pump

 Figure 34

Where direct connection to a “gravity discharge” pipe work is not physically possible, or where very long internal runs would be required to reach a suitable discharge point, condensate should be removed using a proprietary condensate pump, of a specification recommended by the condensate pump manufacturer.

• The pump outlet should discharge to a suitable “gravity discharge”

outlet. – The condensate then flows, by gravity, through the 22mm plastic

pipe to the condensate discharge point.

Max.

Fig. 34 Condensate pump example

[1] Condensate discharge from appliance [7] Condensate pump [8] Pipe work transition [C] Gravity discharge pipe work

Min.

0010023656-001

0010012746-001

Fig. 32 Disposal to soil vent stack

[1] Condensate discharge from appliance [2] Soil and vent stack [3] Minimum 450mm and up to 3 storeys

Waste pipe connection

 Figure 33

Alternatively if the first option is not possible an internal kitchen, bathroom or washing machine waste pipe etc. can be used. Ensure that the condensate drain pipe is connected “down stream” of the waste trap.

Fig. 33 Waste pipe disposal

[1] Condensate discharge from appliance [5] Visible air break at plug hole [6] 75mm sink waste trap

75mm

min.

75mm

min.

0010012767-001

Proprietary condensate pump

▶ Ensure minimum and maximum pump lifting heights are followed as

per condensate pump manufacturers instructions.

4.5.4 External connections

NOTICE:

Rainwater down pipe or external drain disposal

Untreated condensate must not be allowed to flow into streams or rivers

▶ A rainwater down pipe or an external drain shall only be used for

condensate disposal if the down pipe or external drain is connected to a combined foul and rainwater drainage system

▶ Refer to BS 6798 for more information on condensate disposal

NOTICE:

Grey water recover system

Contamination of recovered water

▶ Condensate disposal shall not be allowed into a grey water recovery

system that is intended for re-use

External disposal considerations

NOTICE:

Freezing conditions

Frozen condensate will block the condensate drain pipe and stop the appliance from running

▶ Pipe lengths should be kept to a minimum and the route as vertically

as possible.

Greenstar 8000 Style – 6720883855 (2019/01)

Pre-Installation

NOTICE:

Condensate waste disposal

▶ Care should be taken when siting a soak-away to avoid causing

damage to existing services

If no other discharge method is possible then the use of an externally run condensate drainage pipe terminating at a suitable foul water discharge point, or purpose-designed soak away, may be considered. If this method is chosen then the following measures should be adopted:

▶ The external run be kept as short as possible and should not exceed

three metres. Additional precaution against freezing must be taken if the external pipe run exceeds 3m.

▶ The pipe should be run internally as far as possible before going

externally and the pipe diameter should be increased to a minimum diameter of 32mm before it passes through the wall to the exterior. The pipe should be insulated using suitable waterproof and weather resistant insulation.

▶ The external pipe should take the shortest and least exposed route to

the discharge point, and should "fall" as steeply as possible away from the appliance, with no horizontal runs in which condensate might stand.

▶ The use of fittings, elbows etc. should be kept to a minimum and any

internal burrs on cut pipe work should be removed so that the internal pipe section is as smooth as possible.

▶ All external pipe drainage will be improved if the end is cut at 45° as

opposed to a straight cut.

▶ In situations where there are likely to be extremes of temperature or

exposure, the use of a proprietary trace-heating system for external pipe work, incorporating an external frost thermostat, should be considered. All other guidance above and the instructions for the trace heating system, should be closely followed.

▶ As well as trace heating, other methods of protecting pipe work that

is run externally should be considered to prevent freezing in prolonged periods.

– Insulation materials can be used, these should be of class “O”

grade with an outer coating that is weather proof, bird/animal proof, and have a UV resistant finish. A minimum of 19mm thick insulation is recommended for 32mm external pipes.

– The use of a drain cover (such as those to prevent blockage by

leaves) may offer further protection from wind chill.

– An air break on the external pipe work can reduce the risk of the

appliance being inoperable due to the blocking and backing up of condense.

0010012784-001

Fig. 35 Disposal into rain water down pipe

[1] Condensate discharge from appliance [8] Pipe work transition [9] Insulate and increase pipe size [10] External rain water pipe to foul water [11] External air break [12] Air gap [13] Strap-on fitting [14] 43mm 90° male/female bend [20] Rain water hopper

Open drain or gully

 Figure 36

Where the pipe terminates over an open drain or gully:

• Refer to following example to dispose of condensate to an open drain or gully.

• The pipe should terminate below the grating level, but above water level, in order to minimise “wind chill” at the open end.

• The use of a drain cover (such as those used to prevent blockage by leaves) may offer further protection from wind chill.

Rain water down pipe with external air break

 Figure 35

• Refer to following example to dispose of condensate to a rain water down pipe.

• An air break or rain water hopper must be utilised, between the appliance condensate outlet and the drainpipe, outside the property, to avoid flooding of the appliance should the downpipe become obstructed.

Fig. 36 Disposal to open drain or gully

[1] Condensate discharge from appliance [8] Pipe work transition [9] Insulate and increase pipe size

Greenstar 8000 Style – 6720883855 (2019/01)

25mm min.

0010023655-001

Open drain or gully with external air break

 Figure 37

Where the pipe terminates over an open drain or gully and there is a risk of ground flooding, then the additional requirement below is recommended:

• An air break should be installed in the external pipe work as shown to

avoid an airlock during ground flooding/adverse weather conditions which could prevent the condensate from discharging.

Pre-Installation

400mm min.

25mm min.

500mm min.

10mm min.

25mm min.

Fig. 37 Disposal to open drain or gully with air break

[1] Condensate discharge from appliance [8] Pipe work transition [9] Insulate and increase pipe size [11] External air break [12] Air gap (minimum 10mm)

Condensate soak away considerations

Before deciding to use a purpose-made soak away the history of the locality and the ability of the surrounding area to disperse the condensate should be taken into account, e.g. areas prone to flooding and ground with a high clay content can result in an increased risk of freezing causing the condensate pipe to become blocked with ice and the boiler to shut down,

Although it is possible to increase the size of the soak away and the area with limestone chippings in clay soil areas, if the clay content is high and prevents effective dispersal of the condensate then a soak away may not be a suitable means of condensate disposal and an alternative method should be used.

0010012786-001

Fig. 38 Disposal to soak-away

[1] Condensate discharge from appliance [8] Pipe work transition [9] Insulate and increase pipe size [11] External air break [12] Air gap (minimum 10mm) [15] 100mm minimum Ø plastic pipe [16] Drainage holes [17] Limestone chippings [18] Bottom of sealed tube [19] Increase size of soak away size and the area with limestone

chippings if in clay soil area. Not recommended for high clay soil areas.

0010012788-001

4.6 Pressure relief discharge

4.6.1 Pressure relief pipe work

Condensate soak away with external air break

 Figure 38

• Refer to following example to dispose of condensate to a soak away.

• The condensate soak away must be sited at least 500mm away from

building footings.

• The condensate drainage pipe may be run above or below the ground

to the soak away. The following example shows drainage pipe run above ground.

• The soak away must use a minimum of a 100mm Ø plastic tube with

two rows of three 12mm holes on 25mm centres and 50mm from the bottom of the tube. The holes must face away from the house.

• The tube must be surrounded by at least 100mm of limestone

chippings to a depth of 400mm.

• An air break must be installed in the external pipe work as shown to

avoid an airlock during ground flooding/adverse weather conditions which could prevent the condensate from discharging.

Minimum hole size for the condensate soak away must be 400mm deep by Ø 300mm.

Greenstar 8000 Style – 6720883855 (2019/01)

CAUTION:

Scalding risk from hot water or steam!

▶ The pressure relief valve (PRV) is an appliance safety device and may

discharge hot water or steam when activated.

▶ The outlet pipe should be sited in such a way that it does not cause a

hazard or an obstruction when discharging, for example above a window, entrance door or other public access way.

• The pressure relief discharge pipe [1 or 3] should be run in at least 15mm diameter copper pipe or pipe made of a material that will withstand PRV discharge temperatures and pressures and which complies with BS 5254 or BS EN 1451.

• Plastic pipe work must be properly supported with a maximum of 300mm between supports to prevent sagging and run downwards away from the appliance.

• The pressure relief should discharge away from any electrical or other hazard, preferably to an external drain or soak-away.

• The pipe [1 or 3] should be finished with a partial bend, near the outlet to face the external wall (as shown) to help prevent freezing.

Pre-Installation

• In all normal circumstances a PRV discharge pipe installation as described above is suffice to meet all but the most exceptional circumstances.

– Where the PRV discharge pipe could be susceptible to damage,

vandalism, freezing etc that could cause either a blockage or restriction in the ability to discharge safely then a tundish should be considered. The tundish should be sited in a position where damage to the property or occupants cannot occur from any spillage or discharge.

6720818077-38.1Wo

Fig. 39 Pressure relief pipe work

[1] Discharge pipe (turned back onto external wall example) [2] Outside wall [3] Discharge pipe (into drain or gully example) [4] External drain

4.6.2 Alternative PRV connections - Combined PRV/condensate

The PRV or a combined PRV/ condensate discharge can be connected into a suitable internal waste system, the installer must ensure that all the pipe work, including the waste pipe, is capable of withstanding PRV temperatures and pressures.

Connection to a waste water pipe is possible by using either:

• A shielded tundish with non-return valve can be used to discharge upstream of a trap (there must not be a trap directly in the PRV discharge pipe without a tundish.

• A PRV can discharge directly into a suitable waste pipe downstream of a trap. Connections must be on top of the pipe to ensure they do not block. A Hotun (or similar) can be fitted for visual indication if desired but is not necessary.

The guidance of BS 6798 sections 6.3.5 and 6.4.3.2a must be followed.

4.7 Cleaning primary systems

NOTICE:

Risk of damage to system or appliance!

Debris from the system can damage the appliance and reduce efficiency. Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance guarantee and contravene the Building Regulations.

▶ It is a requirement of the Building Services Compliance Guide which

is a second tier document to the Building Regulations to flush and inhibit the primary water system in accordance with BS 7593.

▶ The Building Services Compliance Guide recommends that a primary

water cleanser is fitted to the system.

▶ Worcester Bosch recommend fitting a filter that will help remove both

magnetite and non-magnetic debris. Worcester offers two filters that helps remove both magnetite and non-magnetic debris; 22mm version, part number 7 733 600 236 and a 28mm version, part number 7 733 600 237.

NOTICE:

Risk of damage to system or appliance!

Artificially softened water must not be used to fill the central heating system.

▶ Salt based, artificially softened water MUST NOT be used to fill the

system

NOTICE:

Sealing agents

Normally the addition of sealing agents to the system water is not permitted as this can cause problems with deposits left in the heat exchanger.

▶ Heating systems may lose small amounts of water over time. In cases

where all attempts to find a system micro leak have failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer.

Before cleaning the system:

▶ Ensure that the system and pipe work is in good working order. ▶ Where possible keep the existing appliance/circulating pump in

place when flushing the system before installing the new appliance. Alternatively use an after market power flushing system or similar to remove magnetite and other debris from the central heating system.

– Even new central heating systems contain contaminants that

need to be removed before treating the system with inhibitor/antifreeze.

– When an appliance is installed onto a new system then it is

possible to use the appliance whilst cleaning the system. A system filter must be fitted to the return to reduce the risk of contaminants entering the appliance.

▶ Follow the guidance of BS7593.

Inhibitor

Add a suitable inhibitor or combined inhibitor/anti-freeze, if the system is exposed to freezing conditions, to the heating system in accordance with the DWTA code of practice and manufacturer‘s guidelines.

Products approved to the BuildCert standard are deemed as compatible with the components and equipment within the appliance and system.

Greenstar 8000 Style – 6720883855 (2019/01)

Installation

WARNING:

Sealing agents

▶ In cases where all attempts to find a micro leak have failed,

Worcester, Bosch Group supports the use of Fernox F4 leak sealer.

Water treatment products

Suitable water treatment products can be obtained from the following manufacturers:

ADEY 01242 546717

www.adey.com

FERNOX 0870 601 5000

www.fernox.com

SENTINEL 0800 389 4670

www.sentinel-solutions.net

Table 12

4.7.1 Flushing the system

Flushing the system using existing appliance/circulating pump or new appliance.

▶ Fill the system with cold water and check for leaks. ▶ Open all drain cocks and drain the system. ▶ Close drain cocks and add a suitable flushing agent compatible with

aluminium at the correct strength for the system conditions in

accordance with the manufacturer‘s instructions. ▶ Mark the position of the lockshield valves and open them fully. ▶ Fully open all TRVs. ▶ Circulate the flushing agent before the appliance is fired up. ▶ Run the appliance/system at normal operating temperature as

directed by the manufacturer of the flushing agent. ▶ Drain and thoroughly flush the system to remove the flushing agent

and debris. Do not drain the system through the PRV of new

appliances. ▶ It may be necessary to use a power flushing machine to aid the

cleansing procedure in some circumstances. ▶ Close the drain cocks and manual air vents. ▶ Existing appliance/circulating pump if continuing to use before

new appliance is installed.

– Add a suitable inhibitor to the system in accordance with the

manufacturers instructions.

– Fill the system to between 1 and 1.5 bar via a WRAS approved

filling loop.

– Vent any air from the appliance and system. ▶ New appliance.

– Once the new appliance has been installed follow the guidance in

Filling the appliance and adding inhibitor section.

5 Installation

NOTICE:

Risk of damage to appliance or accessories.

▶ All the previous pre-installation sections must be read and

requirements met before starting the appliance or flue installations.

CAUTION:

Risk of injury through incorrect lifting and carrying!

▶ Only lift a manageable weight, or ask for help. ▶ Bend the knees and keep the back straight with feet apart, when

lifting or putting down heavy objects. ▶ DO NOT lift and twist at the same time. ▶ Lift and carry object close to the body.

Appliance on site

▶ Check contents of delivery are undamaged. ▶ Remove the appliance from its packaging check the contents against

the scope of delivery. ▶ Once the appliance is unpacked the installation can commence.

Important handling instructions

• It is advised that two people are used to carry the carton from the van

to the point of delivery.

• Once the car ton has been delivered, the outer carton is removed first.

Care should be taken when releasing the straps. If a sharp implement

is used make sure the outer carton is not pierced and that the

implement is used in such a way so that it may not cause personal

injury.

• All sharp objects must be covered or the blade retracted after use and

put away in a safe place. Care should be taken when lifting the

appliance from the base and the proper technique for safe lifting of

any heavy object should be strictly observed.

Greenstar 8000 Style – 6720883855 (2019/01)

Installation

Unpacking

6a 6

Fig. 40 Unpacking

Additional requirements for roof space installations

• The unpacked appliance can now be moved into the loft space

• Two sets of steps should be used.

• Two people should share the lifting of the appliance up to the loft hatch, tilt and slid on its back into the loft space.

• Ensure that the roof space has permanent fixed lighting, a permanent fixed retractable ladder and a fixed floor area, from the hatch to the

0010023424-001

appliance installation point. This will allow access for installation, normal use and servicing.

Before installing the appliance, ensure that the system has been cleaned

Greenstar 8000 Style – 6720883855 (2019/01)

5.1 Position the appliance

Installation

WARNING:

▶ Ensure the mains gas supply is isolated before starting any work

and follow all relevant safety precautions.

Appliance positioning

▶ Ensure the appliance is mounted onto a flat, fixed rigid surface

capable of supporting the appliance weight.

▶ Ensure all aspects of the installation are considered when positioning

the appliance, flue run and discharge, condensate disposal, PRV discharge etc.

WARNING:

Damage to property!

Damage caused by drilling into pipes, electrical cables, damp proof course or other hazards.

▶ Before drilling ensure that there are no obstructions or other hazards.

NOTICE:

Damage to appliance!

Residue, metal shavings, and contaminants in the system pipe work can damage the appliance.

▶ Flush the system pipe work thoroughly to remove all residue. ▶ Follow the instructions with respect to cleaning primary systems.

Running pipes behind the appliance.

• Do not cross a pipe over another.

• The area around a rear flue outlet must be avoided.

5.1.1 Mounting frame fixing

Flue turret

▶ The flue turret has an in-built 3° angle giving the flue assembly the rise

from the appliance to ensure the condensate flows back to the appliance.

Rear flue outlet [2].

▶ Mark centre line of flue to be used; the external diameter of the hole

can also be marked if required.

▶ If extensions are to be added then the complete flue must rise at an

angle of 3° from the appliance.

Side flue outlet [1].

▶ Mark from the centre line of the wall mounting template to the wall

which the flue will pass through.

▶ Allow for a rise of 52mm per metre length of flue, to give a 3° angle.

Example hole size.

• If a 60/100mm diameter flue is to be used, a 125mm diameter hole is required.

• If using the weather sealing collar by pushing it through from inside the property, then a 150mm diameter hole is required to accommodate this.

Flue outlet position marked and ready to drill hole.

▶ Drill hole using a core drill or similar. ▶ Clear any debris from the site.

Appliance fixings and flue outlet drilled and ready.

▶ Remove the wall mounting template.

Existing wall fixings positions (CDi Classic)

ALL MOUNTING

▶The existing wall fixings can be used only if they are still

deemed by a competent person able to support the new appliance.

Wall mounting template

▶ The wall mounting template has been sized to allow for the minimum

clearances around the appliance, ( section "Appliance clearances").

 figure 41

The appliance wall mounting template shows the relative positions of the flue and the top and bottom fixings of the wall mounting frame.

▶ Fix the wall mounting template [3] to the wall in the desired position. ▶ Drill the holes [4] through the template for the primary fixing points

as indicated on the template. – Additional fixing points for the appliance will be indicated on the

wall mounting template.

Fig. 41 Wall mounting template

1 Side exit flue example 2 Rear exit flue example 3 Wall mounting template 4 Primary fixing points D 87mm

0010019928-001

Flue outlet position.

The appliance wall mounting template has the flue centre lines for the following flue systems:

• 60/100mm

• 80/125mm

Carry handles For transportation of the appliance always use the carry handles [1] and

[2] (with the control unit in the closed position).

Greenstar 8000 Style – 6720883855 (2019/01)

Installation

0010023273-001

Fig. 42 Transport, lifting and handling

Preparing the appliance installation

NOTICE:

Incorrect mounting can cause material damage.

If the appliance is mounted incorrectly, it may fall off the wall.

▶ Only install the appliance on a rigid, solid wall. This wall must be able

to carry the weight of the appliance and must at least be as large as the bearing surface of the appliance.

▶ Only use screws and wall plugs that are suitable for the wall type and

weight of the appliance.

0010023676-001

Fig. 43 Fitting the mounting bracket and the mounting plate

To make it easier to install the pipework, we recommend using a mounting plate. More information about this accessory can be found in our main catalogue.

▶ Remove the packaging, observing all notices in the packaging. ▶ Make sure that the gas type specified on the data plate is the same as

the gas type supplied.

▶ Make sure that the installation location is in the country of destination

specified on the data plate. ▶ Affix an installation template (if available) to the wall. ▶ Check whether the screws and wall plugs supplied with the appliance

can be used. ▶ Remove installation template from wall. ▶ Drill suitable holes for the selected wall plugs and screws. ▶ Fasten the mounting bracket to the wall using 4 screws and wall plugs

(scope of delivery). ▶ Attach the mounting plate to the lower screws and tighten.

5.2 Appliance connections

WARNING:

Appliance gas connection

▶ Ensure the mains gas supply is isolated before starting any work

and follow all relevant safety precautions.

NOTICE:

Appliance hydraulic connections

▶ Ensure all water pipe work, to be connected, is isolated/drained and

observe all relevant safety precautions.

▶ Be aware of plastic components when using a naked flame on pipe

work.

Surplus water may be present inside the appliance due to factory testing.

External condensate pipe work or internal pipe runs in unheated areas such as lofts, basements and garages exposed to prolonged cold temperatures should be protected  chapter 4.5.

NOTICE:

Commissioning without water damages the appliance!

▶ Operate this appliance only when filled with water

Greenstar 8000 Style – 6720883855 (2019/01)

Installation

▶ Apply a smear of silicone lubricant to the seal to ease connection

later.

Fig. 44 Connections on the gas and the water side

[1] Heating flow valve

[2] Gas isolator

[3] Heating return valve

Preparing the wallframe

▶ Fit sealing washers to service valves before hanging appliance.

0010023669-001

Fig. 45 Fitting the sealing washers

[1] CH flow (22 mm)

[2] Gas inlet (22 mm bonded washer)

[3] CH return (22 mm)

Before hanging the appliance onto the wall mounting frame ensure that

the pressure relief Drain Pipe is connected securely.

0010023674-001

0010023277-001

Fig. 46 Connect PRV discharge pipe

5.3 Hanging the appliance

Before hanging the appliance

1. Remove the orange plastic protective cover strip fitted to the appliance internal pipes by tilting the appliance forward, taking care to protect the floor from residual water. It is not necessary to lay the appliance on its back.

2. After soldering/connecting pipes, ensure that the appliance internal plastic PRV pipe [1] is then connected to the Pre-plumbing manifold (the printing on the pipe must be facing towards you).

3. Ensure that 3 black plastic ratchet clips are securely fixed and tightened. Ratchet clip number 4 must be fitted but left loose until the boiler is hung and connection to the PRV is made ( Fig. 45 and Fig.

48).

4. The appliance is a 2 person lift. Ensure that the control panel is in its closed position and the top and side panels are removed before lifting the appliance.

Greenstar 8000 Style – 6720883855 (2019/01)

Before hanging the appliance. If fitting the optional integral diverter valve kit, the following needs to be completed ( Optional integral diverter valve instructions for fitting details):

▶ The internal cylinder service connections need fitting. ▶ The internal cylinder pipe work need fitting.

Installation

Hanging the appliance

▶ Ensure that top and side panels are removed. ▶ Fit the sealing washers to service valves. ▶ Hang the appliance on to the wall mounting frame by the centre hook. ▶ Unlock the condensate trap and pull it forwards ( Fig. 90). ▶ Check the positioning of the sealing washers on the pipe

connections.

▶ Tighten the union nuts on the pipe connections starting with the CH

return on the right.

It is recommended the lifting operation is carried out by 2 people, observing all precautions for safe lifting of heavy objects

Do not lift by the top case panel. There are two handling holes incorporated into the inner casing left and right in the lower section of the appliance.

Fitting the condensate pipework

▶ Secure the pipe to the wall at the last joint. ▶ Ensure the pipe protrudes through the wall frame by 25mm. ▶ If exiting through the wall, to run externally, the pipe must have a 3°

fall and be increased to a 32mm insulated pipe.

25mm

6720806944-04.1Wo

Fig. 49 Fitting the condensate pipes to the mounting plate

Condensate connection

Never terminate or discharge into any open source, including; sink, bath, shower, bidet, toilet etc.

0010023675-001

Fig. 47 Hanging the boiler

5. Make connections between the boiler and the pre-plumbing manifold and the pre-plumbing manifold and the system pipes.

▶ Connect the gas supply to the boiler gas cock 22mm compression. ▶ Connect cold water in and DHW out to the boiler‘s 15mm

compression connectors.

▶ Connect the CH flow and CH return pipes to the boiler‘s 22mm

compression connections.

▶ Connect the condensate discharge pipe work to the boiler‘s

condensate outlet connections.

Fitting the drain pipe on the heating pressure relief valve

1. 2.

Any external condensate pipe work of an excessive run should be protected with weather resistant insulation to help prevent freezing.

▶ Ensure that the condensate drain is 22mm diameter plastic pipe. It

must fall at least 52mm per metre towards the outlet. ▶ Refer to Fig. 50, condensate connection: ▶ Align the installation side plastic pipe work through the pre-plumbing

manifold. ▶ Connect the installation side plastic pipe work to the end of the

condensate hose. ▶ Push the plastic pipe work inside the condensate hose at least

25mm.

0010023577-001

Fig. 48 Fitting the pipe on the (heating) pressure relief valve

0010023670-001

Fig. 50 Condensate connection

Greenstar 8000 Style – 6720883855 (2019/01)

Installation

5.4 Flue turret/adaptor installation

NOTICE:

Flue installation

▶ Refer to the Flue Kit Installation instructions provided with your flue

kit to correctly install the flue with this appliance.

▶ Do not exceed the maximum straight length for a horizontal or vertical

flue or a 60mm plume management system (if used) as stated in the relevant Installation and Maintenance Instructions manual or addendum.

Telescopic flue

▶ Cutting the flue to an exact measurement is not required as the

telescopic flue terminal can allow for some adjustment.

Apply silicone lubricant to sealing surfaces, to ease assembly of flue components. Refer to the manual supplied with the flue kit for complete installation instructions.

▶ For plume management effective lengths and the effective flue

lengths,  chapter 4.4.

Additional notes and reminders:

• Ensure that all cut lengths are square and free from burrs.

• Ensure that the flue and seals are not damaged.

• The flue is sealed when assembled correctly, the components are pushed fully home and secured.

• The flue rises from the appliance at an angle of 3° or 52mm per metre length.

• Support the flue at each flue extension joint and at each change of direction, use suitable brackets and fittings:

– Flue bracket (silver) 100mm part number: 7 738 112 876. – Support Bracket Kit (silver) 7 738 112 876. – Flue bracket 100mm part number: 7 716 191 177. – Flue brackets 100mm x 6 part number: 7 716 191 178. – Flue bracket 125mm part number: 7 716 191 179.

▶ Check the appliance flue seal [2] is correctly seated and apply

silicone grease.

6720806944-84.1Wo

Fig. 52 Flue turret centre

[D] 87mm [W] 220mm

▶ Align the flue turret/vertical adaptor to the appliance flue outlet with

flat facing [3] to the rear of the appliance. The flue turret/adaptor should be pushed straight down, on to the appliance.

▶ The three inner flue tube retaining screws [1] are, re-used for the flue

turret and replacement retaining screws [4] supplied with the adaptor kit are used to secure turret/adaptor to the appliance.

2,000mm

1,000mm

104mm52mm

Fig. 51 Slope for condensate disposal

▶ Remove the three inner flue tube retaining screws [1].

– The inner tube will be held in place in the appliance.

Greenstar 8000 Style – 6720883855 (2019/01)

6720806944-85.1Wo

Fig. 53 Flue turret/adaptor connection

0010013472-001

Installation

5.5 Electrical connection

DANGER:

Risk of electric shock!

▶ Isolate electrical components from the power supply (230 V AC)

(fuse, circuit breaker) and secure against unintentional reconnection before carrying out any work. Information on safe isolation can be found in the Health and Safety Executive guidance HSG85.

▶ Check for zero potential before proceeding with work, using test

equipment approved to GS38 to confirm that the electricity supply is disconnected.

Electrical considerations:

▶ All electrical work must be carried out by a competent and authorised

person. ▶ All work must comply with the current IET Wiring Regulations. ▶ The isolator shall be situated next to the appliance for new systems

and, where practicable, replacement appliances. ▶ The mains electrical supply to the appliance must be through either,

a fused double pole isolator or a fused three pin plug and unswitched

socket. ▶ The isolator must have contact separation of 3mm minimum between

poles. Any system connected to the appliance must not have a

separate electrical supply. ▶ Any additional components that are connected to the appliance that

require 230 Volts must be connected to the same supply as the

appliance. ▶ Type A RCDs must be employed where additional protection is

required. ▶ External fuse 3 Amps. ▶ When stripping the wires, ensure copper strands do not fall into the

control box.

5.5.1 Installer connections

Connect external accessories

▶ Flip down the control appliance ( Fig. 54). ▶ Open the cover.

NOTICE:

Risk of damage from hot appliance components.

Hot appliance components can damage electrical cables.

▶ Ensure all electrical cables are in the correct cable guides and away

from hot appliance components.

Cable routing

▶ Route cables through support guides and retaining clips. ▶ Run power cables separately from signal cables. Interference from

power cables can induce spurious faults on signal cables, ensure that

there is at least 100mm separation from each other. ▶ Ensure the cables are of sufficient length to allow the control box to

be moved to the service position.

If the power cable is of insufficient length, accessing the connection terminal  Fig.

▶ Replace with the following cable types:

– H05V2V2F x 0.75 mm ▶ Connect the cable so that the protective conductor is longer than the

other wires.

0010023672-001

Fig. 54 Opening the cover

Access to the electrical connections once the cover is opened.

Greenstar 8000 Style – 6720883855 (2019/01)

Installation

01LF0

BUS

NPWN

▶ For splash water protection (IP): cut the strain relief to match the

diameter of the cable.

5-7Ø

Ø 8-9

Ø 10-12

13-14Ø

0010019570-001

Fig. 55 Adapting the strain relief to the cable diameter

▶ Guide the cable through the strain relief.

▶ Connect the cable to the terminal strip for external accessories.

▶ Secure the cable on the strain relief.

Power supply (power cables) terminal strip

Symbol Function

Without function

PC0

Without function

PW2

Without function

PW1

Table 13 Power supply (power cables) terminal strip for external

accessories

Low voltage (signal cables) terminal strip

230

230V

TW1

230V

OUT

PC0

PW2

FSFRLR

FLRL

TW1

LF0

PW1

LF0

BUS

0010023776-001

Fig. 57 Low voltage (signal cables) terminal strip

Low voltage (signal cables) connections

230V

OUT

230V

OUT

TW1

PC0

LF0

PW2

PC0 N

FSFRLR

PW2

PW1

Fig. 56 Power supply (power cables) terminal strip

Power supply (power cables) connections

Symbol Function

Protective earth bar

▶ Connect the protective earth for power supply.

Power supply (power cable)

Pre-wired cable (Live and Neutral)

230V mains output to external controls/wiring centre

▶ If required: connect power supply for external

controls.

230V

OUT

Switch live (Live Return) to appliance

• k CH demand input

• j DHW demand input (active when optional integral diverter valve is fitted)

External frost thermostat

• FS output (frost thermostat supply)

• FR input (frost thermostat return)

Symbol Function

Without function.

TW1

Cylinder temperature sensor

▶ Connect cylinder with cylinder temperature sensor

directly.

BUS

-or-

▶ Connect cylinder temperature sensor.

PW1

Outdoor weather compensation sensor (used when

0010023703-001

LF0

accessory outdoor sensor is connected)

▶ Connect the outside temperature sensor. Without function.

Without function.

Low voltage external room thermostat contact.

▶ Remove link and connect the on/off temperature

controller.

External control system with EMS bus control,

BUS

1) Only available if optional integral diverter valve kit is fitted.

Worcester intelligent wall mounted controls, Boiler IQ.

▶ Connect 2 core cable.

Table 14 Low voltage (signal cables) terminal strip for external

accessories

Greenstar 8000 Style – 6720883855 (2019/01)

Installation

LPW2NL

1NL

5.5.2 Cable preparations

NOTICE:

Damage to control unit!

Small pieces of wire can cause shorts and damage to electronics.

▶ When stripping wires always ensure copper strands do not fall into

the control box.

Mains voltage (power cables), example  figure 58 ▶ Ensure the conductors (C) can reach the appropriate terminal

connection and that the protective (earth) conductor is longer than the other wires.

– Power cables connected to the appliance my have different

conductor lengths depending on the termination point.

230V

6-8mm

> C

Fig. 58 Mains voltage (power cables) preparation

Low voltage (signal cables), example  figure 59

0010023711-001

230V AC

230V

OUT

FSFRLR

FS FR

230V OUT

0010022788-001

Fig. 60 External controls connections example

[1] 230V mains supply to the appliance. [2] 230V supply from the appliance to the wiring centre. [3] CH & DHW Switch Live (Demand) from the external controls. [4] External frost protection Live supply and Switch Live (Demand).

6-8mm

0-30V

26-30mm

0010012956-001

Fig. 59 Low voltage (signal cables) preparation

5.5.3 External controls - domestic installations

External equipment or Integral diverter valve kit:

▶ External diverter valve(s) and all other 230V parts are not supplied

with the appliance.

▶ There is an optional integral diverter valve kit, this requires fitting a

diverter valve, internal pipe -work, cylinder sensor & connection. See optional diverter valve kit instructions for full details. This kit also allows for the Worcester controls options to be used, which details can be found in the diver valve kit instructions.

▶ The power supply to external controls must be taken from the

appliance; an alternative power supply must not be used.

Appliance external control connections example

▶ The electrical power supply to the external equipment [2] is supplied

from 230V OUT - L (Live), N (Neutral) and PE - \ (earth) terminals.

▶ The Switch Live from the wiring centre [3]:

– Both pre-wired links are removed, the CH & DHW demands are

combined and wired to the (LR terminal.

– Control for appliance Pre-heat function, optional.

The flow temperature must be set on the central heating control to a level at least 10 °C above the required cylinder temperature set on the cylinder control thermostat.

▶ External frost thermostat connections [4]:

– The Live supply is terminal FS – The Switch Live is terminal FR

Greenstar 8000 Style – 6720883855 (2019/01)

6 Commissioning

6.1 Pre-Commissioning checks

DANGER:

Risk of electric shock!

▶ Isolate electrical components from the power supply (230 V AC)

(fuse, circuit breaker) and secure against unintentional reconnection before carrying out any work. Information on safe isolation can be found in the Health and Safety Executive guidance HSG85.

▶ Check for zero potential before proceeding with work, using test

equipment approved to GS38 to confirm that the electricity supply is disconnected.

Checks before commissioning: ▶ Check that the service and water pipes are connected correctly. ▶ Check the gas type specified on the identification plate matches that

of the gas supply.

▶ Check that the appliance is filled with water and under pressure (1.5

bar) and that there are no leaks.

▶ Check that the electrical connections of the appliance are correct:

– Mains electrical supply - 230V, 50Hz – Compliant earth connection – Correct polarities. – External equipment and controls are wired in correctly.

▶ Check that the flue is correctly fitted, airtight, free from any

obstruction and the connections are secure.

▶ Check that the condensate pipe work is connected properly and that

there are no leaks.

NOTICE:

If the appliance is not to be commissioned immediately then, after successfully completing all of the checks and any rectification work:

▶ Isolate the electricity supply. ▶ Isolate the gas supply. ▶ Close the shut-off valve for the cold water inlet. ▶ Close the water shut-off valves to the appliance. ▶ Label appropriately.

6.2 Water treatment

Primary system flushing (Central Heating)

Ensure that the system has been cleaned:

• Following the guidance of BS 7593: – Code of Practice for treatment of water in hot water central

heating systems.

• Overview available in Pre-installation, Cleaning primary systems section.

Inhibitor (Central Heating):

Add a suitable inhibitor that is compatible with aluminium (or combined inhibitor/anti-freeze, if the system is exposed to freezing conditions), to the heating system in accordance with the DWTA code of practice and manufacturer‘s guidelines.

The pH value of the system water must be between 6.5 and 8 or the appliance warranty will be invalidated.

Commissioning

The inhibitor or combined inhibitor/anti-freeze must not cause damage to the materials within the appliance (aluminium, mild steel, stainless steel, copper and brass) and any other materials/components within the system.

▶ Record the date when the inhibitor was added to the system on the

guarantee card.

▶ The concentration level of inhibitor in the system should be checked

every 12 months or sooner if system content is lost.

NOTICE:

Sealing agents

Normally the addition of sealing agents to the system water is not permitted as this can cause problems with deposits left in the heat exchanger.

▶ In cases where all attempts to find a system micro leak have failed,

Worcester, Bosch Group supports the use of Fernox F4 leak sealer.

6.2.1 Filling the appliance and adding Inhibitor

Before pressurising the system.

Additional expansion vessel fitted to the system. The appliance integral expansion vessel is pre-charged to 1.0bar (equal to a static head of 10.0m (32.8ft)). A Schrader type valve is fitted to the expansion vessel to allow for pressure adjustment if required.

▶ If an extra expansion vessel is fitted to the central heating system,

ensure that it is set to the same pressure as the appliance internal expansion vessel, refer to separate instructions supplied with the extra expansion vessel.

Filling the system - Open Vent systems

NOTICE:

▶ Salt based softened water must not be used to fill the central heating

system.

▶ Check drain cocks and manual air vents are closed and all radiator

valves are open. Add a suitable inhibitor or combined inhibitor/antifreeze, if the system is exposed to freezing conditions, to the heating

system water in accordance with the manufacturers instructions. ▶ Turn on the water main to the system header and allow the system fill. ▶ The Automatic Air Vent will release any air trapped in the appliance. ▶ Vent all radiators and the primary side of the hot water cylinder,

tighten when completed and check the system for any leaks and

correct if required.

Filling the system - Sealed systems

NOTICE:

▶ Salt based softened water must not be used to fill the central heating

system.

▶ Check drain cocks and manual air vents are closed and all radiator

valves are open. Add a suitable inhibitor or combined inhibitor/anti-

freeze, if the system is exposed to freezing conditions, to the heating

system water in accordance with the manufacturers instructions. ▶ Turn on the water main and open the system valves. ▶ Fill the system to between 1 and 1.5 bar via a WRAS approved filling

loop. ▶ The Automatic Air Vent will release any air trapped in the appliance.

Greenstar 8000 Style – 6720883855 (2019/01)

Commissioning

▶ Manually vent all radiators, tighten when completed and check the

system for any leaks and correct if required. ▶ Top up the system pressure if the pressure drops below 1 bar. ▶ Isolate and remove filling loop connections to the system.

6.2.2 Adjusting the operating pressure of the heating system

Display on the pressure gauge

1 bar Minimum charge pressure (when system is cold) 1 - 1.5 bar Optimal charge pressure 3 bar Maximum charge pressure at maximum heating

water temperature must not be exceeded (pressure relief valve opens).

Table 15

If the indicator is below 1 bar when the system is cold: ▶ Top up the water until the indicator is between 1 bar and 1.5 bar

again.

If pressure is not being maintained: ▶ Check tightness of expansion vessel and heating system.

6.3 Starting the appliance

NOTICE:

Damage to appliance or system!

Running the appliance:

▶ Never run the appliance when the appliance/system is empty or

partially filled.

6.3.1 Control panel overview

Fig. 61 Control panel

[1] Display [2] and keys: To navigate through menus and increase/decrease

settings [3] d key: Return/back [4] OK key: Save settings, Chimney sweeper key: press 5 seconds for

chimney sweeper mode [5] Menu key [6] Hot water key: Hot water mode on/off, adjusting the hot water

temperature (only available if the optional integral diverter valve

kit fitted) [7] Heating key: Heating mode on/off, set the maximum flow

temperature [8] Burner display: Illuminates when the burner is alight.

0010018565-001

See the operating instructions for a description of the user menus.

6.3.2 Turn on the appliance

Set the language the first time the appliance is turned on. ▶ To scroll through the languages, press the  or the  key. ▶ To select the desired language, press the OK key.

When the display shows Siphon fill. prog., the siphon filling program is active. The condensate siphon in the appliance is filled ( Chapter 6.3.3).

6.3.3 Siphon filling mode

The siphon filling mode is activated automatically or manually by the installer on the appliance in the menu settings. The siphon filling mode is activated in the service menu under > Settings > Special function > Siphon fill mode.

While the siphon filling mode is active, access to the Hot water menu, the Heating menu and the service menu is possible.

The siphon filling mode is activated automatically in the following cases:

• The appliance is switched on using the On/Off switch.

• The burner was not in use for at least 28 days.

• After conversion from summer to winter mode.

Greenstar 8000 Style – 6720883855 (2019/01)

Commissioning

The next time there is a heat requirement for heating, the appliance is held at low thermal output for 15 minutes. The siphon filling mode remains active until the appliance has completed 15 minutes of operation with increased min. capacity.

During the siphon filling program, Siphon fill. prog. appears on the display.

The siphon filling mode is interrupted when the chimney sweep mode is started.

6.4 Chimney sweep mode

You have 30 minutes to take your measurements or to make your settings. After this time the appliance returns to normal operation.When running in the chimney sweep mode, the appliance will operate both the central heating and the domestic hot water circuits. This is to allow sufficient time for this part of the commissioning procedure. It will be necessary to run water through the domestic hot water circuit to ensure that the appliance will not overheat whilst in chimney sweep mode.

In chimney sweep mode the rated output of the appliance can be selected.

▶ Press the OK key when the countdown is completed and Chimney

sweep is displayed. ▶ Confirm the query with Yes. ▶ Set the desired rated output using the  or the  keys.

The value is accepted after 2 seconds and marked with a tick. ▶ To exit the chimney sweep mode, press the OK key or the d key.

6.5 Parameters when optional integral diverter valve kit is fitted

Some menu items/functions will only be available/active if the option integral diverter valve kit is fitted.

▶  chapter 7

Combustion casing removal

▶ Remove the combustion cover.

Adjustment with casing removed in chimney sweep mode

1. Set the chimney sweep mode and start up the appliance at maximum rated output.

2. Set the chimney sweep mode and set the appliance at minimum rated output.

Fig. 62 Removing the combustion cover

0 010 007 441-001

Greenstar 8000 Style – 6720883855 (2019/01)

Commissioning

6.6 Checking gas inlet pressure

6.6.1 Checking the gas supply pressure

▶ Switch off the appliance and close the gas isolator. ▶ Unscrew the screw on the test point for the gas supply pressure and

connect a pressure gauge.

▶ Exit the chimney sweep mode. ▶ Switch off the appliance, close the gas isolator, remove the pressure

gauge and tighten the screw.

▶ Check for gas tightness.

T10

0010024761-001

Fig. 63 Gas valve test points (above: SIT valve, below: Honeywell valve)

▶ Open the gas isolator and switch on the appliance. ▶ Ensure that there is heat transfer by opening the radiator valves and

by running a hot tap.

▶ Set the chimney sweep mode and start up the appliance at maximum

rated output.

▶ Check the required gas supply pressure according to table .

Commissioning must not take place outside of the permissible pressure range.

▶ Identify the cause and rectify the fault. ▶ If this is not possible: isolate the appliance on the gas side and notify

the gas supplier.

0010023566-001

Fig. 64 Refit combustion casing

▶ Refit the combustion casing. ▶ Ensure this cover is engaged onto top bracket [1] before securing

screw [3].

Gas pressure within the system

The appliance must be running at maximum output rate when performing the gas rate check, ( chapter 6.4).

Refer to the figures below for natural gas or L.P.G gas pressures.

The pressure drop from the meter or at the L.P.G. gas supply to the gas valve inlet test point must not be more than:

• 2.5 mbar for Natural Gas

• 4 mbar for L.P.G.

Allowed mbar pressure drop

Meter/ LPG supply

Natural gas

19 - 23 1 18 - 22 1.5 16.5 - 20.5

L.P.G.

32 - 45 2.5 29.5 -

mbar range

Table 16

If the pressure drops are greater than shown below, then this would indicate a problem with the pipe work or connections within the system.

Across pipe work

Appliance inlet

42.5

Across appliance

1.5 28 - 41

Gas valve

Greenstar 8000 Style – 6720883855 (2019/01)

Commissioning

NOTICE:

Do not continue commissioning until the correct gas pressure is achieved.

Gas supply pressure drop

Meter

Natural Gas

≤ 2.5 mbar

Gas Control

valve

difference

19 - 23 mbar

1 mbar

drop

Appliance inlet

18 - 22 mbar

16.5-20.5 mbar

1.5 mbar drop

0010023810-001

Fig. 65 Natural Gas pressures

LPG Storage

32 - 45 mbar

L.P.G.

≤ 4.0 mbar

Gas Control

valve

difference

0.5 mbar drop

Regulator

2.0 mbar drop

Appliance inlet

29.5 - 42.5 mbar

28-41 mbar

1.5 mbar drop

0010023811-001

Fig. 66 L.P.G. pressures

[≤ ] Less than or equal to

6.7 Checking the gas rate

▶ The gas rate should be measured at the gas meter after the appliance

has been operating for a minimum of 10 minutes at maximum output.

▶ Refer to Technical data section of this manual for the appliance gas

rates and CO/CO

▶ Where a gas meter is not available (e.g. L.P.G.) the CO/CO

ratios.

must be

checked.

▶ Gas rate must be checked with the appliance in service, maximum

output test mode.

▶ Carry out Gas rating procedures as described in current edition of the

“Essential Gas Safety”.

▶ Ensure all other gas appliances are isolated when carrying out the gas

rate check on the appliance.

▶ Set the chimney sweep mode and start up the appliance at maximum

rated output.

▶ Where a gas meter is not available (e.g. L.P.G.) the CO/CO

must be

checked to the units shown in the setting of the air/gas ratio.

▶ If pressure and gas rate are satisfactory press the OK key or the d key

and the boiler will return to normal operation.

▶ Close the gas isolation valve. ▶ Remove the manometer. ▶ Re-seal the screw in the gas inlet pressure test point. ▶ Open the gas isolation valve. ▶ Ensure that there are no gas leaks. ▶ Replace the outer case.

6.8 Checking for gas leaks during operation

▶ Use an approved gas leak detector to check all connections for

possible leaks. The product must be certified as a gas leak testing agent.

▶ Do not allow the product to come into contact with the electrical

wiring.

6.9 CO and combustion check

The following combustion and flue integrity checks are mandatory and these values must be recorded on the Benchmark check list, at the end of these instructions.

Once the gas rate and pressure have been confirmed as acceptable then the CO and combustion checks can be undertaken.

The flow chart is given for guidance, the details of the checks are given in the following sections:

• Checking flue integrity, ( chapter 6.10)

• Flue gas analysis, ( chapter 6.11)

Greenstar 8000 Style – 6720883855 (2019/01)

NOTICE:

Before CO and combustion checks:

▶ Verify the appliance is connected to the correct gas type. ▶ Ensure the appliance is supplied with the correct gas inlet pressure

and gas rate as specified previously in the Commissioning section.

▶ Visually check the integrity of the whole flue system and confirm that

all the components are correctly assembled, fixed and supported.

▶ The flue gas analyser must be the correct type as specified in BS

7967. Before use the analyser must have been calibrated as specified by the manufacturer. The installer must be competent in the use of the analyser.

▶ Check and zero the analyser in fresh air as specified by the

manufacturer.

▶ The air/gas ratio valve is factory set and must not be adjusted during

commissioning unless this action is recommended following contact with the Worcester, Bosch Group help line 0330 123 3366.

Commissioning

START

HERE

Record values.

Do not adjust the gas valve.

Set boiler to

maximum rate.

< =

less than

≥ =

greater than or equal to

CO < 350ppm

CO/CO2 ratio

< 0.004

Yes

Zero the analyser

in fresh air.

See notice above

O2 ≥ 20.6%

< 0.2%

Yes

Check all seals around the burner, internal flue seals,

Check CO and combustion

Flue integrity test

using analyser

Verify flue integrity

and case seals.

Rectify where necessary.

ratio at minimum rate

O2 ≥ 20.6%

< 0.2%

Yes

Check CO and combustion ratio at maximum rate

CO < 350ppm

CO/CO2 ratio

< 0.004

Yes

Set boiler to

minimum rate.

Turn off boiler and

call Worcester, Bosch

Group help line.

0330 123 3366

Fig. 67 Commissioning checks flow chart

6.10 Checking flue integrity

Flue integrity check

▶ The combustion casing must be fitted whilst this test is carried out. ▶ Refit the test point plugs after the test has been completed.

The integrity of the flue system and performance of the appliance can be checked via the flue turret/adaptor sample points.

Air inlet sample point location on flue turret/adaptor.

CO < 350ppm

CO/CO2 ratio

< 0.004

Yes

satisfactorily.

No further action

is required.

0010023581-002

Boiler is operating

0010015568-001

Fig. 68 Flue integrity check test point

[1] Air inlet sample point [2] Flue turret air inlet blank plug (with retaining ring) [3] Flue adaptor air inlet blank plug

▶ With the appliance casing on and the appliance running at maximum

output in chimney sweep mode, remove the blanking plug [2 or 3] for

the air inlet sample point [1]. ▶ Insert the analyser probe into the air inlet sample point [1]. ▶ Allow the readings to stabilise and check that:

–O

is equal to, or greater than 20.6%

–CO

is less than 0.2%

▶ If the readings are outside these limits then this indicates that there

is a problem with the flue system or combustion circuit.

Greenstar 8000 Style – 6720883855 (2019/01)

Commissioning

6.11 Flue gas analysis

NOTICE:

Combustion testing

▶ Combustion testing must be carried out by a competent qualified

person. Testing must not be attempted unless the person carrying out the combustion check is equipped with a calibrated Flue Gas Analyser conforming to BS 7967 and is competent in its use.

Flue gas analysis

▶ Ensure that the gas inlet pressure has been checked and is

satisfactory.

▶ Refit the test point plugs after the test has been completed.

The flue gas analysis performance of the appliance can be checked via the flue turret/adaptor sample points.

Flue gas sample point location on flue turret/adaptor.

6.12 Finishing commissioning

6.12.1 Fitting the combustion casing

Fig. 69 Combustion test

[1] Flue gas sample point [2] Flue turret flue gas blank plug [3] Flue adaptor flue gas blank plug

6.12.2 Fitting the appliance casing

0010015569-001

0010023566-001

Fig. 70 Fitting the combustion casing

▶ Ensure this cover is engaged onto top bracket [1] before securing

screw [3].

Greenstar 8000 Style – 6720883855 (2019/01)

Commissioning

3a. 4.

3b.

Fig. 71 Fitting the appliance casing

[1] side covers [2] top [3] front [4] bottom

0010023240-001

Appliance handover:

▶ Complete the Benchmark Gas Boiler Commissioning Checklist. ▶ Set up the appliance controls and show the customer how to operate

all the control unit/s for central heating operation.

– Also show where in the appliance/controls documentation where

this information can be found.

▶ Where applicable, instruct the customer on:

– the need to occasionally re-pressurise the appliance and the

pressure expected on the pressure menu. – location of the keyless filling link and system pressure menu. – the use of the keyless filling link and how to re-pressurise the

system. – how to set the TRVs. – how to reset the appliance.

▶ Show the customer where the serial number/appliance information is

located, they will need this information if they call in with a problem (Benchmark Commissioning checklist on page 75 contains all relevant appliance information).

▶ Give the customer details of how to contact the installer/ gas

emergency numbers.

▶ Show the customer how to safely isolate the appliance. ▶ Advise the customer where they can find information on the

Worcester, Bosch Group website, www.worcester-bosch.co.uk.

▶ Advise the customer that outside temperatures will affect the output

of the appliance, especially the DHW.

▶ Ensure that all documentation, is left with the appliance or

homeowner. – Appliance documentation. – Controls documentation. – Any other equipment documentation that is connected to the

appliance or system.

▶ Appliance not in use

– If the appliance is not going to be used immediately and may be

exposed to freezing conditions, advise the customer of the

precautions necessary to prevent damage to the appliance,

system and building. – If the appliance is unused and exposed to freezing conditions,

shut off all the mains supplies and drain the system and

appliance, label accordingly.

▶ Show the customer the location of the condensate pipe run in

unheated or external areas that my be at risk of freezing during prolonged cold spells.

▶ User recommendation: Arrange an inspection/maintenance

contract with an approved heating contractor.

The front casing is to be secured at the bottom with one screw (as supplied) against unauthorised removal (electrical safety).

▶ Always secure the casing with this screw.

▶ Remove the protective films from the boiler display and front cover

before handing over to the user.

At the time of commissioning, complete all relevant sections of the Benchmark Checklist located at the end of this chapter.

Greenstar 8000 Style – 6720883855 (2019/01)

6.12.3 Appliance/product guarantee

This appliance/product has a guarantee against faulty materials or workmanship for a period from the date of installation subject to the following terms and conditions.

• The guarantee period for your product/component will vary depending on its type and the accreditation of your installer. To confirm the guarantee period applicable to your product, speak to your installer or call 0330 123 2552.

• The guarantee must be registered within 30 days of installation.

• The householder may be asked to prove the date of installation and that the appliance was correctly commissioned. This should be documented as a part of the Commissioning Checklist.

• The product must be correctly installed and commissioned in accordance with the Installation instruction for your product and meet the requirements of the Benchmark initiative if applicable.

• The product must be maintained, inspected/serviced in accordance with the manufacturer’s product instructions by a Bosch Thermotechnology Ltd or other competent Engineer. Proof of inspection/servicing may be required to validate a guarantee.

• During the period of this guarantee any components of the appliance that are proven to be faulty or defective in manufacture will be exchanged or repaired free of charge if repaired directly by Bosch Thermotechnology Ltd.

• Invoices for attendance and repair of this appliance by third parties will not be accepted for payment by Bosch Thermotechnology Ltd.

• That any product or part thereof returned for servicing under the guarantee must be accompanied by a claim stating the Model, Serial Number, Date of Installation.

• That Bosch Thermotechnology Ltd will not accept responsibility for damage caused by faulty installation, neglect, misuse or accidental damage or the nonobservance of the instructions contained in the Installation and Users Instructions leaflets.

• The appliance has been used only for the normal domestic purposes for which it was designed.

• That this guarantee applies only to equipment purchased and used in the United Kingdom of Great Britain and Northern Ireland, the Republic of Ireland, the Isle of Man or the Channel Islands.

For full terms and conditions, please visit:

www.worcester-bosch.co.uk/guarantee-terms-and-conditions

Guarantee registration

Your appliance/product carries a guarantee against faulty material or manufacture subject to Terms and Conditions.

To read the full Terms & Conditions please visit us on-line at www.worcester-bosch.co.uk/guarantee.

Your statutory rights are not affected by the manufacturer’s guarantee

Settings in the service menu

7 Settings in the service menu

Many appliance functions can be set and checked in the service menu. It includes:

• Info: viewing information

• Settings: general and appliance-specific settings

• Function check: settings for function checks and start of function checks

• Reset: restoring the factory settings, resetting the maintenance intervals

• Demo mode: mode for testing and demonstrating the functions. Power off appliance for exit.

7.1 Operating the service menu

Opening the service menu

▶ Press the Hot water key and the Heating key simultaneously until the

service menu appears.

Closing the service menu

▶ Press the Hot water key or the Heating key.

-or-

▶ Press the d key.

Navigating through the menu

▶ To highlight a menu or a menu item, press the  key or the  key. ▶ Press the OK key.

The menu or the menu item is displayed.

▶ To return to the next higher menu level, press the d key.

Changing the setting values

▶ Select the menu item with the OK key. ▶ To select the desired value, press the  or the  key. ▶ Press the OK key.

The new value is saved.

Exiting the menu item without saving values

▶ Press the d key.

The value is not saved.

▶ Enter modified settings. ▶ Affix label to the appliance in a visible location.

Greenstar 8000 Style – 6720883855 (2019/01)

Settings in the service menu

7.2 Service menu

7.2.1 Overview of the service menu

Benchmark

– Actual temp. – DHW flow rate – Hot water temp.

Info

– Current status – Current fault – Fault history – Boiler

– Mx.heat.outp % – Mx.heat.outp kW – Actual temp. – Set flow temp. – Low-loss hdr.tmp – Heating mod. – Act. burner mod. – Burner output – Ionisation current – Pump mod. – Outside temp. – HC1 pump – Burner starts – Hours run – System pressure

–Hot water

– Max. outp.(%) – Max. outp.(kW) – Hot water temp. – DHW act. temp. – Hot water temp. – Act.DHWtmp.cyl. – DHW set temp.

–System

– Contr.device ver. – Progr. unit ver. – SW sub-ver. – Code plug no. – Code plug ver. – Time prog. ver.

– Solar

– Collector temp. – Cyl.temp.bottom – Collector pump – Solar fault

Settings

– Hydraulics

– Low-loss header – DHW configuration – HC1 configuration – Pump config.

– Heating

– Mx.heat.outp %

– Standby time – Clock inh. T. off – Clock inh. T. on

–Hot water

– Max. DHW output – DHW circ. pump – Cycle circ. pump – Turbine signal del. – DHW start del. – Preheat – Man. TD line – TD-Temperature – Max. TD duration – Start TD – Stop TD

– Pump

– Pump range map – Pump ctr. mode – Min. output – Max. output – Pump overrun – Min.syst.pressure – Target pressure

– Special function

– Ventilation func. – Siphon fill. prog. – 3-WV mid. pos. – Autom. filling Available for system?

– Autom. filling – Max. refill time – Blocking time – Max. refills – Reset refilling

– Maintenance

– Maintenance type

– Without – Boiler run time – Burner run time – Service date – Landlord

– End date – Maint. reminder – Installer tel. no.

– Limit values

– Max. flow temp. – Max. DHW temp. – Min. boiler outp.

– Heating curve

– Req. odr. temp. – Htg. curve base – Htg. curve end – Summer mode – Frost prot. – Frost temp. limit

– Solar

– Max. solar temp.

1) Only available if the optional integral diverter valve kit is fitted. 2) Only available with installed Key (accessories)

Greenstar 8000 Style – 6720883855 (2019/01)

– Solar pump type – Start solar system

Function check

– Activate test

– Burner – Ignition –Fan – Pump – Cyl. prim. pump – 3-way valve – HC1 pump – DHW circ. pump – Ionisat.oscill. – Solar pump

Reset

– Default setting – Fault history – Hidden menu: Reset Maintenance Landlord

Demo mode

Settings in the service menu

Greenstar 8000 Style – 6720883855 (2019/01)

Settings in the service menu

7.2.2 Benchmark and Info menu

Menu item Comment/restriction

Actual temp. Flow temperature in °C DHW flow rate Hot water flow rate in l/min Hot water temp.Outlet temperature in °C

Table 17 Benchmark menu

Menu item Comment/restriction

Current status  Tab. 24, page 67 Current fault  Tab. 24, page 67 Fault history Boiler

Mx.heat.outp % Max. heating output in %, Setting value in > Settings > Heating > Mx.heat.outp % Mx.heat.outp kW Max. heating output in kW Actual temp. Flow temperature in °C Set flow temp. Setting value of the flow temperature Low-loss hdr.tmp Only if installed. Momentary flow temperature in low loss header in °C Heating mod. Burner modulation (heating) in % Act. burner mod. Burner output Current burner output in kW Ionisation current Current ionisation current in μA Pump mod. Actual system pump modulation in % Outside temp. Current outside temperature in °C HC1 pump Current status on/off Burner starts Number of burner starts since commissioning Hours run Elapsed time of the system since commissioning System pressure Current system pressure in bar

Hot water

Max. outp.(%) Max. hot water output in % Max. outp.(kW) Max. hot water output in kW DHW flow rate Current hot water flow rate in l/min DHW act. temp. Actual hot water temperature in °C Hot water temp. Current water temperature in °C Act.DHWtmp.cyl. Current storage temperature in °C DHW set temp. Setting value of the hot water temperature

Refilling settings

System pressure Current system pressure in bar

System

Contr.device ver. Software version of the control device Progr. unit ver. Software version of the control unit Code plug no. Coding plug number Code plug ver. Coding plug version Time prog. ver. Version of installed key

Solar

Collector temp. Collector temperature Cyl.temp.bottom Cylinder temperature at bottom Collector pump Collector pump Solar fault Current faults

Table 18 Info menu

Greenstar 8000 Style – 6720883855 (2019/01)

Settings in the service menu

7.2.3 Settings menu

The menu is adapted to your system automatically. Some menu items are only available if the system has been set up accordingly. The menu items

The factory settings are highlighted in the following table.

are only displayed in systems in which the corresponding system components are installed, e.g. Key Timer.

Menu item Settings/adjustment range Comment/restriction

Hydraulics

Low-loss header • Low loss header not installed in the system

Position of the low loss header temperature sensor

• Low loss header installed, temperature sensor connected to the wall mounted boiler

• Low loss header installed, temperature sensor connected to the heating circuit module

• Low loss header installed, but no temperature sensor is connected

DHW configuration • Not installed

• 3-way valve installed

• System?: Cyl. prim. pump inst. after low loss hdr.

• System?: Cyl. primary pump installed

HC1 configuration • No heating circuit 1 (HK1) on the appliance

(HK1 not available or not connected via the heating circuit module)

• No own pump (flow rate for HK1 is realised by the heating pump)

• Own HC1 pump downstream the low loss header

• Dedicated pump installed

Pump config. • None

• Heating pump

Heating

Max. heat output Maximum released thermal output [%].

On natural gas applainces: ▶ Measure the gas rate. ▶ Compare the measurement with the setting tables

( Chapter 12.6, page 72).

▶ Correct deviations.

Standby time • 3…10…60 minutes The time interval determines the minimum delay between

starting and restarting the burner.

Clock inh. T. off

Clock inh. T. on

•2 … 6 … 15 Kelvin

• -15... -6...-2 Kelvin

Temperature standby period.

The difference between the current flow temperature and the set flow temperature until the burner is switched on or off.

Hot water

Max. DHW output • 10...100 % Maximum power on hot water DHW circ. pump • Off

Activation of hot water circulation pump

•On

Cycle circ. pump • 1 x 3 minutes/h

• 2 x 3 minutes/h

Number and duration of starts of hot water circulation pump per hour

• 3 x 3 minutes/h

• 4 x 3 minutes/h

• 5 x 3 minutes/h

• 6 x 3 minutes/h

• Permanent

TD-Temperature • 60...70…80 °C Max. TD duration • 10…30 minutes Max. duration of legionella protection cycle in minutes Start TD Start now? Start legionella protection cycle Stop TD Cancel now? Stop legionella protection cycle

Greenstar 8000 Style – 6720883855 (2019/01)

Settings in the service menu

Menu item Settings/adjustment range Comment/restriction

Pump

Pump range map • Output dependent 0: pump rate proportional

to thermal output

▶ Set low pump curve to save energy and avoid possible

flow noise ( Chapter 12.5, page 71).

• Delta-P dependent 1: constant pressure 150 mbar

• Delta-P dependent 2: constant pressure 200 mbar

• Delta-P dependent 3: constant pressure

250 mbar

• Delta-P dependent 4: constant pressure 300 mbar

• Delta-P dependent 5: constant pressure 350 mbar

• Delta-P dependent 6: constant pressure 400 mbar

Pump ctr. mode • Energy saving

• Heat demand

• Saving energy: intelligent heating pump stop in heating systems with weather-compensated controller. The heating pump is only switched on when needed.

• In case of a heat requirement: the flow temperature controller switches the heating pump. When there is a heat energy demand, the heating pump starts up with the burner.

Min. output • 10...100 % Pump rate at minimum thermal output. Only available

with pump characteristic map 0.

Max. output • 10...100 % Pump rate at maximum thermal output. Only available

with pump characteristic map 0.

Pump overrun • 1...2...60 minutes

• 24 h: 24 hours

Run-on time of the heating pump: pump run-on time begins at the end of the heat requirement.

Min.syst.pressure • 1...2...3 bar Target pressure • 0.8...1.3...1.8 bar

Special function

Ventilation func. • Off

• Auto

•On

The ventilation function can be activated after maintenance.

During ventilation, the following appears in the info area of the standard display Ventilation func.

Siphon fill. prog. • Off (only permissible during maintenance)

• On, boiler min.

• On, heating min.

The trap filling program is activated in the following cases:

• On, boiler min.: the appliance is switched on using the On/Off switch.

• On, heating min.: The burner was not in use for at least 28 days.

• The operating mode is switched from summer to winter mode.

The next time there is a heat requirement for heating, the appliance is held at low output for 15 minutes. The trap filling program remains active until the appliance has completed 15 minutes of operation at low output.

During the trap filling program the following appears in the info area of the standard display Siphon fill. prog.

3-WV mid. pos. • No

• Yes

The function ensures that the system is fully drained and that the motor can be easily removed. The 3-way valve remains at the centre position for approx. 15 minutes.

Greenstar 8000 Style – 6720883855 (2019/01)

Settings in the service menu

Menu item Settings/adjustment range Comment/restriction

Maintenance

Maintenance type • Without

• Burner run time

• Boiler run time

• Service date

• Landlord

Landlord:

This menu item allows a date to be set for annual service/ maintenance (End date). The service display appears as a reminder 30 days before the scheduled date. A contact telephone number (Installer tel. no.) is shown together with service display. The tenant should call this number to arrange a suitable maintenance date. A second reminder appears at the scheduled date. If the service display is not reset by the service engineer, the control unit limits the functions 14 days after the scheduled date.

Reduced functions are set at Maint. reminder:

• DHW reduced: reduced comfort (max. 35 °C flow

temperature)

• Boiler off: central heating and hot water1) functions

are set off.

Limit values

Max. flow temp. • 30...88 °C Limits the adjustment range for the flow temperature. Max. DHW temp. • 30...80 °C Limits the adjustment range for the hot water

temperature.

Min. boiler outp. • "Minimum rated output"…"maximum rated

output"

Minimum heat output depending on code plug Max output = 50 %

Heating curve

Req. odr. temp. • Off

•On

When connecting a weather-compensated control unit, no adjustment to the appliance is required. The system control unit optimises this setting. This service function activates a simple, weather-compensated controller with a linear heating curve. Depending on the on/off input, the heating is switched on or off.

Htg. curve base • 20…90 °C This is only displayed if the controller was activated. This

can be used to set the base point of the heating curve, which corresponds to a outside temperature of +20 °C.

Htg. curve end • 20...90 °C This is only displayed if the controller was activated. This

can be used to set the end point of the heating curve, which corresponds to a outside temperature of -10 °C.

Summer mode • 0...16...30 °C This is only displayed if the controller was activated. This

can be used to set the temperature threshold at which outside temperature the heating system is to switch to summer mode.

Frost prot. • Off

•On

Frost temp. limit • 0...5…10 °C Temperature value for the system frost protection.

This service function is only available if the frost protection function was activated. If the outside temperature does not exceed the frost threshold temperature, then the heating pump in the heating circuit switches on.

1) Only available if optional integral diverter valve kit is fitted.

Table 19 Settings menu

Greenstar 8000 Style – 6720883855 (2019/01)

Settings in the service menu

7.2.4 Function check menu

Menu item Settings/adjustment range Comment/restriction

Activate test

Burner • Off...100 % This service function enables testing of the burner. Ignition • On

• Off

Permanent ignition.

Test the ignition with permanent ignition without gas supply.

▶ To prevent damages to the ignition transformer, never

leave this function on for longer than 2 minutes.

Fan •On

• Off

Pump • On

Permanent fan operation.

Fan operation without gas supply or ignition. Permanent pump run (internal or external pumps).

• Off

Cyl. prim. pump •On

• Off

3-way valve • Hot water

Permanent pump run (hot water charge pump); only if cylinder primary pump is installed.

Permanent position of the 3-way valve.

• Heating

HC1 pump •On

• Off

DHW circ. pump • On

• Off

Ionisat.oscill. •On

Permanent HK1 pump run (downstream the low loss header).

Permanent hot water circulating pump run; only if hot water circulation pump is installed.

Check the ionisation measurement function at the flame.

• Off

Solar pump • On

Permanent pump run (solar pump).

• Off

Table 20 Function check menu

7.2.5 Reset menu

Menu item Settings/adjustment range Comment/restriction

Default setting Restore? All settings of the heat source are reset to the respective

default setting. The system needs to be re-commissioned following this reset.

Fault history Reset? Reset the maintenance first. The fault history of the heat

source is deleted. If currently a fault is present, it is immediately entered again.

Table 21 Reset menu

7.3 Thermal disinfection

To prevent hot water from becoming contaminated by bacteria such as legionella, we recommend thermal disinfection after long downtimes.

▶ Open all DHW draw-off points, from the nearest to the one furthest

away, and draw off hot water until hot water at a minimum of 70 °C has flown from all draw-off points for at least 3 minutes.

▶ Restore the original settings.

CAUTION:

Risk of scalding.

During thermal disinfection, discharging unmixed hot water can cause serious scalding.

▶ Only use the maximum adjustable hot water temperature for thermal

disinfection. ▶ Inform occupants of the premises of the risk of scalding. ▶ Perform thermal disinfection outside of the normal operating times. ▶ Do not discharge DHW unmixed.

Proper thermal disinfection involves the DHW system including the draw-off points.

▶ Set the thermal disinfection in the hot water program of the heating

controller ( heating controller operating instructions). ▶ Close DHW draw-off points. ▶ Set any DHW circulation pump to continuous operation. ▶ Wait until the maximum temperature is reached.

Greenstar 8000 Style – 6720883855 (2019/01)

Inspection and maintenance

8 Inspection and maintenance

DANGER:

Risk of electric shock!

▶ Isolate electrical components from the power supply (230 V AC)

(fuse, circuit breaker) and secure against unintentional reconnection before carrying out any work. Information on safe isolation can be found in the Health and Safety Executive guidance HSG85.

▶ Check for zero potential before proceeding with work, using test

equipment approved to GS38 to confirm that the electricity supply is disconnected.

CAUTION:

Mains supplies:

▶ Turn off the gas supply and isolate the electrical mains supply before

starting any work on the appliance and observe all relevant safety precautions.

NOTICE:

Personnel and equipment

▶ Any service work must carried out by competent registered

engineers.

▶ Service work must not be attempted if a calibrated CO/CO

and manometer are not available.

WARNING:

Hot surfaces!

If the appliance has been operating components may be hot.

▶ Ensure precautions are taken when working on the appliance.

CAUTION:

Component replacement:

▶ After replacement of a gas related component, where a gasket or seal

has been disturbed or replaced, check for gas tightness using a gas sniffer/analyser.

▶ Also after re-assembly, carry out the following checks:

 Fan pressure.  Flue gas analysis.

analyser

8.1 Inspection and maintenance considerations

• To ensure continued efficient operation the appliance must be checked at regular interval.

• The frequency of servicing will depend upon the particular installation conditions and usage, however, normally an annual service is recommended.

• The extent of the service work required by the appliance is determined by the operating condition of the appliance when tested by qualified engineers.

• After each service, the ser vice interval record sheet at the rear of this manual, must be completed.

See the following instructions for detail of some of the service requirements:

▶ Check that the safety and regulation appliances (3 bar pressure

release valve, air bleed, etc.) are operating properly.

▶ Check all joints and connections in the system and remake any that

show signs of leakage. Refill and re-pressurise if applicable as described in the commissioning section.

▶ When it is frequently necessary to add water to maintain pressure in

the installation, even though no leaks have been discovered, perform an expansion vessel check.

▶ Check that the condensate system is not obstructed, clean and refill

the condensate siphon.

▶ If the appliance is in a compartment or cupboard check that the

specified clearances around the appliance is clear.

▶ Check that the flue system is unobstructed and undamaged, clean/

replace as necessary. – If fitted ensure the flue terminal guard is also unobstructed and

undamaged.

▶ Operate the appliance and take note of any irregularities.

– Refer to the fault finding pages for rectification procedure.

8.2 Resources for inspection and maintenance

• The following measuring devices are required: – Electronic flue gas analyser for CO

temperature

– Pressure gauge 0 - 30 mbar (minimum resolution 0.1 mbar)

▶ Use heat conducting paste 8 719 918 658 0. ▶ Use approved greases.

, O2, CO and flue gas

8.3 Inspection and maintenance steps

 chapter 12.9 “Inspection and maintenance checklist”.

Maximum system pressure

▶ 2.5 bar must not be exceeded when the heating system water is at

maximum temperature. If this pressure is exceeded then an additional expansion vessel must be fitted into the system return as close as possible to the appliance.

▶ If the system does not retain the pressure, the pressure relief valve

(PRV) and the heating system should be checked for leaks.

Greenstar 8000 Style – 6720883855 (2019/01)

Inspection and maintenance

8.4 Component access

Removing bottom panel

1. Push in the clip securing the bottom panel.

2. Pull bottom panel sidewards to release from service position and remove.

0010023671-001

Fig. 72 Removing bottom panel

Removing front cover

1. Remove screw from bottom of front panel

2. Push in the green clips securing both sides the outer case.

3. Pull bottom of front cover forwards and upwards to release the clip on top of the boiler and remove outer case.

1. 1.

0010019013-001

Fig. 73 Removing outer case

8.5 Fan pressure test

NOTICE:

Fan pressure test

▶ The appliance must be running at maximum output in test mode for

the fan pressure test, ( chapter 6.4).

0 010 007 177-001

Fig. 74 Fan pressure test point

This test is to determine if the heat exchanger requires cleaning or attention.

Fan pressure test reading.

▶ The pressure reading will be in negative values.

Greenstar 8000 Style – 6720883855 (2019/01)

Inspection and maintenance

FAN PRESSURE TEST

Clean the Heat Ex. Heat Ex. ok

Appliances

GR8700iW 30:

GR8700iW 35:

- 3.5

-4

- 4.8

-5

mbar

-6

-3

-2-1

-7

- 10.0

-8

-9

0010025222-001

-10

Fig. 75 Fan pressure test values

If the manometer reading is within tolerance, between the appliance output value [P] mbar and -9.0 mbar.

▶ The heat exchanger/exhaust path/siphon does not require attention.

If the manometer reading is out of tolerance, between 0 mbar and the appliance output value [P] mbar then carry out the following checks.

▶ Check that the siphon is not restricted or blocked. ▶ Check the exhaust paths for restrictions. ▶ Clean the heat exchanger with a suitable cleaning tool, refer to

cleaning section.

▶ Re-check the fan pressure readings.

If the boiler, after completing the above checks, fails the fan pressure test then contact Worcester, Bosch Group for advice.

▶ Replace test point cover after completing pressure check.

8.6 Check working gas inlet pressure

NOTICE:

Gas inlet pressure

▶ Do not continue with the other checks if the correct gas inlet pressure

can not be achieved.

▶ Check the gas supply working pressures in the system conform to the

readings shown in the table shown in section 6.6 "Checking gas inlet pressure".

Maximum rated output Minimum rated output

Gas type CO2O

Natural gas 9.5 %

± 0.4

Liquid propane (LPG)

Table 22 CO

If the CO

10.8 % ± 0.4

and O2 contents

is out of tolerance then please check:

CO CO2O

4.0 % <250ppm 8.6 % ± 0.4

4.6 % <250ppm 10.2 % ± 0.4

5.5 % <75ppm

▶ The gas inlet pressure. ▶ The gas rate. ▶ The fan test pressure. ▶ The flue and air intake, plus any possible blockages in the condensate

disposal. ▶ The condition of burner. ▶ For leaks or obstructions in the exhaust paths. ▶CO

is correctly adjusted.

The gas valve and venturi are factory set and should not need to be adjusted, if found to be out of tolerance and when all other possible causes have been checked, please contact the Worcester Bosch Group Helpline 0330 123 3366.

8.8 Checking the flue integrity

NOTICE:

▶ Check flue joints are secure, the terminal and the terminal guard, if

fitted are clear and undamaged. ▶ Combustion testing must be carried out by a competent person.

Testing must not be attempted unless the person carrying out the

combustion check is equipped with a calibrated Flue Gas Analyser

conforming to BS 7967 and is competent in its use.

8.7 Flue gas analysis

NOTICE:

Combustion testing

▶ Combustion testing must be carried out by a competent person.

Testing must not be attempted unless the person carrying out the combustion check is equipped with a calibrated flue gas analyser conforming to BS 7967 and is competent in its use.

Flue gas analysis

▶ Ensure that the gas inlet pressure has been checked and is

satisfactory.

▶ Refit the test point plugs after the test has been completed.

▶ Set the appliance to maximum and minimum output in chimney

sweep mode for the flue gas analysis checks ( chapter 6.4).

▶ Check that the readings conform to those given in the following

tables. In addition to CO and CO/CO maximum and minimum CO

ratio checks also check the

percentage reading.

Flue gas analysis

▶ Ensure that the gas inlet pressure has been checked and is

satisfactory. ▶ Refit the test point plugs after the test has been completed.

▶ Refer to section 6.10 "Checking flue integrity" and check that the

readings conform to those given, confirming flue system and

combustion circuit are ok.

8.9 Cleaning the siphon and heat exchanger

WARNING:

Gaskets and seals - gas related components

▶ Replace gaskets and seals when disturbing gas related components

(e.g. burner, electrode assembly etc.), after cleaning the heat

exchanger. ▶ Do not attempt the cleaning procedure unless new gaskets and seals

are available.

There is an optional tool available to assist in cleaning the heat exchanger, part number 7 719 001 996.

Greenstar 8000 Style – 6720883855 (2019/01)

Inspection and maintenance

8.9.1 Checking the burner

1. Remove the combustion cover  Fig. 62.

2. Unscrew the screws on the burner cover.

3. Remove the burner cover.

Fig. 76 Removing the burner cover

▶ Remove the burner and clean its components.

0010023602-001

8.9.2 Checking the non-return valve in the air-gas manifold

1. Unscrew the screws at the air-gas manifold.

2. Remove the air-gas manifold.

0010017096-001

Fig. 78 Removing the air-gas manifold

1. Remove the non-return valve.

2. Check the non-return valve for contamination and cracks.

0010023603-001

Fig. 77 Burner

▶ Reinstall the burner in reverse order, including a new gasket. ▶ Install the burner and the burner cover. ▶ Check the gas/air ratio.

0010007068-001

Fig. 79 Non-return valve in the air-gas manifold

▶ Install the non-return valve. ▶ Install the air-gas manifold.

Greenstar 8000 Style – 6720883855 (2019/01)

Inspection and maintenance

8.9.3 Fan removal

1. Undo connection of venturi.

2. Remove venturi and move pipe to the far right.

8.9.4 Cleaning the heat exchanger

Access to the heat exchanger

The following items will have to be removed to gain access to the heat exchanger for cleaning:

▶ Remove the combustion casing. ▶ Lower the control panel into the service position. ▶ Disconnect electrical wires to the fan, ignition transformer, spark

electrodes, flue overheat thermostat, main heat exchanger

temperature sensor and flow pipe temperature sensor. ▶ Flueway ▶ Fan assembly ▶ Ignition transformer ▶ Spark electrode assembly ▶ Burner housing, burner and gasket

Cleaning the heat exchanger

▶ Remove the siphon and place a suitable container under the outlet to

catch the water and debris. ▶ Protect the controller from water ingress.

The heat exchanger does not have to be removed in order to clean.

The heat exchanger is shown removed from the appliance to illustrate cleaning more clearly.

Fig. 80 Venturi removal

3. Remove expansion foam (pull towards you).

4. Undo fan connection and remove screw and seal.

5. Remove fan.

▶ Remove the cleaning access cover [1] and seal [2].

0010023759-001

0010023710-001

Fig. 82 Access cover removal

Fig. 81 Fan removal

Greenstar 8000 Style – 6720883855 (2019/01)

0010023760-001

Inspection and maintenance

▶ Using the cleaning blade, working from the bottom to the top, to

loosen any deposits in the heat exchanger.

It is possible to rinse any remaining debris from the heat exchanger either through the access point or alternatively through the top of the heat exchanger when the burner is removed.

▶ Pour water into the heat exchanger to rinse the debris through to the

suitable container below the outlet to the siphon.

0010023693-001

Fig. 83 Cleaning blade

▶ Using the brush, clean the heat exchanger from top to bottom.

0 010 007 128-001

Fig. 84 Cleaning brush

▶ Use the handle of the brush to remove debris from the condensate

tray.

0010023695-001

Fig. 85 Pour water into the heat exchanger

0 010 007 129-001

Fig. 86 Cleaning debris

Greenstar 8000 Style – 6720883855 (2019/01)

Inspection and maintenance

▶ Refit the cleaning access cover assembly in reverse order the new

seal [2], and the access cover [1].

▶ Hand tighten the bolts and then use a spanner to tighten the bolts a

further half turn.

0010023584-001

Fig. 87 Re-fitting the access cover

▶ Ensure that the convex side of the burner faces down into the heat

exchanger when re-fitting the burner. ▶ Ensure seal is replaced with new seal and is correctly fitted. ▶ Check the siphon unit is clean before refitting to appliance.

On completion of the heat exchanger cleaning and reassembly, perform the fan pressure test.

8.9.5 Checking electrodes

▶ Remove the electrode set with gasket. ▶ Check electrodes for contamination. ▶ Clean or replace electrodes if required. ▶ Install electrode set with new gaskets.

▶ Check tightness of electrode set.

Gas/Gaz?

0010 007 499-002

Fig. 89 Checking for leaks

8.9.6 Cleaning the siphon

Cleaning the condensate trap

WARNING:

Danger to life due to poisoning!

If the condensate trap is not filled, poisonous flue gas can escape.

▶ Only turn off the siphon filling program during maintenance, and turn

it back on at the end of maintenance.

▶ Make sure that the condensate drains off properly.

Damages resulting from an insufficiently cleaned condensate trap are excluded from the warranty.

▶ Clean the condensate trap regularly.

1. Unlock the condensate trap.

2. Pull the condensate trap forwards and tilt to the left for draining.

3. Once empty pull the hose from the condensate trap.

Fig. 88 Installing electrode set

Greenstar 8000 Style – 6720883855 (2019/01)

3 - 4 Nm

0010017101-001

0010023585-001

Fig. 90 Removing the condensate trap

▶ Removing the condensate trap ▶ Clean the condensate trap, and check that the aperture towards the

heat exchanger is clear. ▶ Remove the gasket on the top of the condensate trap. ▶ Check the gasket for cracks, deformation or breakage and replace if

required.

Inspection and maintenance

▶ Align the new gasket correctly with the condensate trap.

0010019151-001

Fig. 91 Aligning the new gasket with the condensate trap

▶ Press on the gasket in the required order.

When the gasket is correctly inserted, the pin is visible in the recess and is flush with the top edge of the gasket.

▶ Check the condensate hose and clean if required. ▶ Fill the condensate trap with approx. 250 ml water. ▶ Replace the condensate trap and check for tightness.

0010020541-001

Fig. 93

8.10 Setting the air/gas ratio

NOTICE:

Setting the air/gas ratio

▶ The gas valve and venturi are factory set and should not need to be

adjusted if found to be out of tolerance and when all other possible causes have been checked, please contact the Worcester Bosch Group Helpline 0330 123 3366.

Fig. 92 Pressing on the gasket

0010019159-001

NOTICE:

Combustion testing

▶ The setting of the air/gas ratio must be carried out by a competent

registered gas engineer, such as a Gas Safe registered engineer or British Gas engineer.

▶ Setting of the air/gas ratio must not be attempted unless the person

carrying out the test is equipped with a flue gas analyser conforming to BS7927 and is competent in its use.

All CO/CO2 readings must be taken with the combustion chamber cover ON. Adjustments can only be made with the cover off.

CO2 should be measured 10 minutes after firing the appliance.

Greenstar 8000 Style – 6720883855 (2019/01)

Inspection and maintenance

8.10.1 Checking and, if required, adjusting the gas/air ratio

▶ Switch off the appliance. ▶ Remove the front cover. ▶ Remove the combustion cover.

▶ Switch on the appliance. ▶ Remove the plug from the flue gas test port. ▶ Push the flue gas probe centrally into the flue gas test port. ▶ Seal the test point.

0010023633-001

Fig. 96 Flue gas test port

▶ To ensure heat transfer: open the radiator valves. ▶ Set the chimney sweep mode and start up the appliance at maximum

rated output.

▶ Measure the CO ▶ Check the CO

or O2 content.

or O2 content at maximum rated output according to

Tab. 23 and adjust if required.

Fig. 94 Removing the combustion cover

Fig. 95 Setting the adjustable venturi

[1] Security Seal [2] Adjustable venturi

0 010 007 441-001

0 010 020 540-002

Security Seal [1] ( Fig. 95) must be removed before adjusting the Max CO

setting. Once adjustment has been made the seal must be replaced

with part number 8737708988.

▶ To increase the CO2 content, remove seal [1] and turn the adjustable

venturi to the left. ▶ To reduce the CO

content, remove seal [1] and turn the adjustable

venturi to the right.

Maximum rated output Minimum rated output

Gas type CO2O

Natural gas 9.5 %

± 0.4

Liquid propane (LPG)

Table 23 CO

10.8 % ± 0.4

and O2 contents

CO CO2O

4.0 % <250ppm 8.6 % ± 0.4

4.6 % <250ppm 10.2 % ± 0.4

5.5 % <75ppm

Greenstar 8000 Style – 6720883855 (2019/01)

Replacement parts

▶ Measure the CO content.

The CO content must be < 250 ppm. ▶ Set the minimum rated output. ▶ Measure the CO

or O2 content.

▶ Remove the seal from the adjusting screw of the air/gas ratio control

valve (only air/gas ratio control valve is shown in the below Fig. 97)

and set the CO

or O2 content for minimum rated output.

4 mm

9 Replacement parts

WARNING:

Mains supplies - Isolate the appliance

▶ Turn off the gas supply and isolate the mains electrical supply before

starting any work and observe all relevant safety precautions.

▶ Drain the appliance/system where necessary and protect any

electrical equipment from water ingress during component replacement.

WARNING:

Component replacement:

▶ Replace the burner housing gasket and the Flueway sump seal when

re-assembling the heat exchanger. Do not reassembly the heat exchanger and Flueway until new gaskets and seals are available.

▶ After replacement of a gas related component, where a gasket or seal

has been disturbed or replaced, check for gas tightness using a gas sniffer/analyser.

▶ On re-assembly check all affected seals for cracks, hardness and

deterioration.  If damaged or in any doubt the seal must be replaced.

▶ Also after re-assembly, carry out the following checks:

 Fan pressure.  Flue gas analysis.

T40

0010024762-001

Fig. 97 Setting the CO

Honeywell valve)

▶ Re-check settings at maximum and minimum rated output and re-

adjust if required.

▶ Seal the air/gas ratio control valve. ▶ Seal the adjustable venturi. ▶ Exit the chimney sweep mode. ▶ Enter the CO

page 75). ▶ Remove the flue gas probe from the flue gas test port and refit the

plug.

or O2 content (above: SIT valve, below:

contents in the servicing record (Chapter 12.8,

Only use Worcester, Bosch Group original spare parts with this appliance. Non Worcester, Bosch Group original spare parts will invalidate the guarantee (if applicable) and any warranty.

▶ A comprehensive list of appliance spares can be found on the website

www.worcester-bosch.co.uk/spares

9.1 Draining the appliance

NOTICE:

Risk of water damage to appliance or property!

Damage from disconnecting water pathways which may have retained some water.

▶ Take care after draining the appliance to protect equipment/property

from residual water content within components.

Many of the tasks in this section require that the appliance be isolated and drained. This will be indicated in the manual if required.

▶ The boiler drain is already connected to the condensate trap for ease

of draining.

-or-

▶ Connect a suitable hose firmly to the drain point and run the hose

outside to a suitable point or container.

▶ Turn the drain valve a ¼ turn anti-clockwise to open the drain. Turn

the valve firmly clockwise to close.

Greenstar 8000 Style – 6720883855 (2019/01)

Replacement parts

9.2 Overheat thermostat removal

▶ Remove two electrical connectors from thermostat.

▶ Unscrew [1] the sensor [2].

Fig. 98 Removing overheat thermostat

0010019116-001

9.4 Pressure relief valve removal

0010023622-001

▶ Open the cover  Fig. 54. ▶ Remove the condensate trap  Fig. 90. ▶ Pull the spring up [1]. ▶ Press the PRV Pipe down lightly [2]. ▶ Remove the Pressure relief valve [3].

9.5 Replacing the gas valve

▶ Close the gas isolator.

1. Unscrew the bayonet connection.

2. Unscrew the union nut.

3. Remove the gas pipe.

9.3 Pressure sensor removal

▶ Open the cover  Fig. 54.

▶ Remove the condensate trap  Fig. 90.

▶ Pull the spring forward [1].

▶ Remove the pressure sensor[2].

0010023621-001

0010017782-001

Fig. 99 Removing the gas pipe

Greenstar 8000 Style – 6720883855 (2019/01)

Replacement parts

1. Unplug the plug.

2. Unscrew the union nut.

Fig. 100 Unplugging the plug and unscrewing the union nut

1. Remove the 2 screws.

2. Remove the air/gas ratio control valve.

0010017781-001

9.6 Checking/replacing the motor of the 3-way valve

▶ Check the motor in the Menu > Function check > Activate test > 3-way

valve.

▶ Check/replace the motor of the 3-way valve in the Service menu >

Special function > 3-WV mid. pos. > Yes.

1. Pull out the motor.

2. Press the cable retaining clip.

3. Unplug the plug.

Fig. 102 Removing the motor of the 3-way valve

9.7 Replacing the optional 3-way valve

▶ Remove the screws. ▶ Pull out the 3-way valve. ▶ Press the cable retaining clip. ▶ Unplug the plug.

001001

7784-

001

0010007251-001

Fig. 101 Removing the gas control valve

▶ Install the air/gas ratio control valve in reverse order, and check the

gas/air ratio.

Fig. 103 Removing the 3-way valve

9.8 Following inspection/maintenance

▶ Re-tighten all the threaded connections that have been released. ▶ Restart the appliance. ▶ Check tightness of all joints. ▶ Check the gas/air ratio. ▶ Fit the combustion casing, side-, top panels and front cover.

0010017783-001

Greenstar 8000 Style – 6720883855 (2019/01)

10 Fault finding and diagnosis

This fault finding information is for guidance only. Worcester cannot be

held responsible for costs incurred by persons not deemed to be

competent.

This fault finding system assumes that the appliance has been operating

normally until the time of failure (i.e. not a first time installation error).

Basic checks

• Ensure that there is 230V power supply and the polarity is correct to the appliance.

• Ensure that the appliance settings and functionality is correct.

• Ensure the CH/DHW programmer/timer is functioning.

10.1 Operating and fault displays

Fault finding and diagnosis

• Ensure the room thermostat is functioning.

• Ensure the cylinder thermostat (if fitted) is functioning.

• Ensure the cold water mains is turned on?

• Ensure the primary system has adequate pressure/system content for the system type.

• Ensure there is gas to the appliance? – Are other gas appliances working, gas cooker/hob for example? – Has the credit run out on the gas pre-payment meter?

NOTICE:

On completion of the Service/Fault-Finding task which has required the breaking and remaking of electrical connections, check:

▶ Earth continuity, ▶ Short circuit check, ▶ Polarity ▶ Resistance to earth.

10.1.1 General information

• Fault code: indicates the fault.

• Fault category: indicates the fault and its effects.

Fault category O (operating code)

Operating codes indicate the operating conditions in normal operation.

Fault category B (blocking faults)

Blocking faults result in the heating system being shut down temporarily. The heating system restarts automatically as soon as the blocking fault is removed.

10.1.2 Fault code table

Fault text on the display, description Remedy

Fault

code

Fault

Bosch Worcester GR8700iW 30 S NG, Worcester GR8700iW 35 S LPG, Worcester GR8700iW 35 SB NG, Worcester GR8700iW 30 S LPG, Worcester GR8700iW 30 SB LPG Installation And Maintenance Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual