Bosch Worcester Greenstar 21Ri ErP +, Worcester Greenstar 9Ri ErP +, Worcester Greenstar 24Ri ErP +, Worcester Greenstar 18Ri ErP +, Worcester Greenstar 12Ri ErP + Installation And Maintenance Instructions Manual

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UK/IE

Installation and Maintenance Instructions

6720644744-00.1Wo

Wall hung rsf gas fired condensing appliance

Greenstar Ri

ErP +

For open vented & sealed system central heating systems & indirect mains fed domestic hot water

These appliances are for use with: Natural Gas or LPG (Cat. II 2H 3P type C13, C33 & C53)

Model GC Number

12Ri 15Ri 18Ri 21Ri 24Ri

ErP +

Natural Gas 9Ri

LPG 9Ri

41-406-74 41-406-75 41-406-76 41-406-77 41-406-78 41-406-79 41-406-68 41-406-69 41-406-70 41-406-71 41-406-72 41-406-73

If you smell gas: ▶ Keep well away from the building: call the National Gas Emergency

Service on 0800 111 999.

▶ LPG appliances: Call the supplier’s number on the side of the gas

tank.

6 720 821 670 (2018/06) UK/IE

CONTENTS

1 KEY TO SYMBOLS AND SAFETY PRECAUTIONS . . . . . . . . . . . . 4

1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

3 APPLIANCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.1 Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.3 Energy efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.4 appliance main components . . . . . . . . . . . . . . . . . . . . . 12

3.5 Internal wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . 13

4 PRE-INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.1 Mains supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.1.1 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.1.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.2 Water systems and pipe work . . . . . . . . . . . . . . . . . . . . 14

4.3 Condensate discharge . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.3.1 Condensate pipe work . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.3.2 Internal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.3.3 External connection considerations . . . . . . . . . . . . . . . 18

4.4 Pressure relief pipe work . . . . . . . . . . . . . . . . . . . . . . . 19

4.4.1 Alternative PRV connections - Combined

PRV/condensate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.5 appliance location and clearances . . . . . . . . . . . . . . . . 20

4.5.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.5.2 Servicing clearances -

Ventilated compartment . . . . . . . . . . . . . . . . . . . . . . . . 20

4.5.3 Compartments: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.5.4 appliance clearances- Unventilated

compartments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.5.5 Installation clearances - unventilated

compartments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.5.6 Rooms containing a bath or shower . . . . . . . . . . . . . . . 21

4.6 Plumbing manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.6.1 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.7 Flue options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.7.1 Flue lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.8 Flue terminal positions . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.8.1 Vertical flue terminal positions . . . . . . . . . . . . . . . . . . . 25

4.8.2 Horizontal flue terminal positions . . . . . . . . . . . . . . . . 26

4.8.3 Plume re-direct and plume management terminal

positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.9 Cleaning primary systems . . . . . . . . . . . . . . . . . . . . . . . 30

4.9.1 Flushing the system . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.1 Unpacking the wall frame & ancillary items . . . . . . . . . . 31

5.2 Position the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.3 Wall mounting template & flue opening . . . . . . . . . . . . . 32

5.4 Outer case removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.5 appliance connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.5.1 Condensate connection . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.6 Flue turret/adaptor installation . . . . . . . . . . . . . . . . . . . 35

5.7 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6 COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6.1 Pre-Commissioning checks . . . . . . . . . . . . . . . . . . . . . . 37

6.2 Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6.3 Water treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6.4 Starting the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6.4.1 Appliance controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6.5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6.5.1 Checking the gas inlet pressure . . . . . . . . . . . . . . . . . . . 39

6.5.2 Checking the gas rate . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.6 CO and Combustion checks . . . . . . . . . . . . . . . . . . . . . . 40

6.7 Finishing commissioning . . . . . . . . . . . . . . . . . . . . . . . . 42

6.7.1 Replace the outer case: . . . . . . . . . . . . . . . . . . . . . . . . . 42

6.7.2 Install the bottom panel . . . . . . . . . . . . . . . . . . . . . . . . . 42

6.7.3 Hand over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

6.7.4 Appliance guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

7 SERVICE AND SPARES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

7.1 Inspection and service . . . . . . . . . . . . . . . . . . . . . . . . . . 43

7.2 Checking gas inlet pressure . . . . . . . . . . . . . . . . . . . . . . 44

7.3 Checking flue integrity . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.4 Fan pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.5 Flue gas analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

7.6 Setting the air/gas ratio . . . . . . . . . . . . . . . . . . . . . . . . . 47

7.6.1 Setting the CO/CO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

7.7 Cleaning the heat exchanger . . . . . . . . . . . . . . . . . . . . . 47

7.7.1 Syphon removal and cleaning . . . . . . . . . . . . . . . . . . . . 49

7.8 Replacement of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

7.8.1 Removing the outer casing . . . . . . . . . . . . . . . . . . . . . . . 50

7.8.2 Primary sensor (CH NTC) . . . . . . . . . . . . . . . . . . . . . . . . 50

7.8.3 Overheat thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

7.8.4 Flue overheat thermostat

(with grommet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

7.8.5 Lowering the appliance controls to the service

position: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

7.8.6 Gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

7.8.7 Air/gas manifold and fan assembly . . . . . . . . . . . . . . . . 52

7.8.8 Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

7.8.9 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

7.8.10 Electrode assembly and burner . . . . . . . . . . . . . . . . . . . 54

7.8.11 Re-assembly of the burner clamping plate . . . . . . . . . . 54

7.8.12 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

7.8.13 Syphon removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

7.8.14 Access to electrical control panel . . . . . . . . . . . . . . . . . 57

7.8.15 PCB Fuse and code plug . . . . . . . . . . . . . . . . . . . . . . . . . 57

7.8.16 PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6 720 821 670 (2018/06)2

8 FAULT FINDING AND DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 58

8.1 Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

9 OPERATIONAL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

9.1 Appliance function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

9.2 Protection function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

9.3 Component Characteristics . . . . . . . . . . . . . . . . . . . . . 62

9.3.1 Flow temperature (NTC) Sensor resistances . . . . . . . . 62

9.3.2 Flue overheat thermostat . . . . . . . . . . . . . . . . . . . . . . . 62

9.3.3 Overheat thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

9.3.4 Gas valve coil resistances . . . . . . . . . . . . . . . . . . . . . . . 62

9.3.5 Code plug numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Contents

6 720 821 670 (2018/06) 3

KEY TO SYMBOLS AND SAFETY PRECAUTIONS

1 KEY TO SYMBOLS AND SAFETY

PRECAUTIONS

1.1 KEY TO SYMBOLS

WARNINGS

Warnings in this document are identified by a warning triangle printed against a grey background. Keywords at the start of a warning indicate the type and seriousness of the ensuing risk if measures to prevent the risk are not taken.

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

• NOTICE indicates a situation that could result in damage to property or equipment.

• CAUTION indicates a situation that could result in minor to medium injury.

• WARNING indicates a situation that could result in severe injury or death.

• DANGER indicates a situation that will result in severe injury or death.

IMPORTANT INFORMATION

List entries, first and second levels

• A single component/item

• A component/list, made up of multiple parts/items. – Sub component or sublist of main component/list. –etc.

SYMBOLS USED IN THIS MANUAL

Domestic Hot Water

Central Heating

Hot Water Storage Cylinder

Domestic Cold Water Supply

Gas Supply

Table 2 Commonly used symbols

PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.

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

ADDITIONAL SYMBOLS

Symbol Meaning

a numbered step in an action sequence

a step in an action sequence

 a reference to a related part in the document or to other

related documents a reference number to identify or refer to a part or item

a list entry

a list entry (second level)

Table 1 Symbols

Examples of additional symbols used

A numbered step in an action sequence

A sequence of numbered steps or actions carried out in a specific order to complete a task.

1. First action

2. Second action

3. Third action etc.

A step in an action sequence

A sequence of defined actions or steps carried out in order to complete a task.

▶Action ▶ Next action ▶etc

A reference to a related part in the document or to other related documents.

To refer the reader to a specific figure/table/section within the manual.  e.g. figure 1.

A reference number to identify or refer to a part or item.

In a related figure, items or parts identified by a sequential number.

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 and serviced by a GAS SAFE registered, competent person. Failure to install correctly could lead to prosecution.

If you are in any doubt, contact the Worcester Technical helpline (0330 123 3366).

Please leave these instructions with the completed BENCHMARK CHECKLIST, (or a certificate confirming compliance with IS 813, Eire only) and the user manual with the owner or at the gas meter after installation or servicing.

Distance learning and training courses are available from Worcester. The BENCHMARK CHECKLIST can be found in the back of this

Installation manual.

ØDiameter NG Natural Gas LPG Liquid Petroleum Gas CH Central Heating DHW Domestic Hot Water DCW Domestic Cold Water DWTA Domestic Water Treatment Association PRV Pressure Relief Valve NTC Negative Temperature Coefficient (sensor) IP Ingress Protection RCD Residual Current Device TRV Thermostatic Radiator Valve ECV Emergency Control Valve WRAS Water Regulations Advisory Scheme SEDBUK Seasonal Efficiency of Domestic Boilers in the United

Kingdom

Table 3 Abbreviations use in this manual

6 720 821 670 (2018/06)4

KEY TO SYMBOLS AND SAFETY PRECAUTIONS

1.2 SAFETY PRECAUTIONS

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. ▶ Well away from the building: call the National Gas Emergency Service

on 0800 111 999. ▶ LPG appliances: Call the supplier’s number on the side of the gas tank.

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 Hotwater Industry Council who manage and promote the scheme. Visit centralheating.co.uk for more information.

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).

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.

Fittings and modifications

Fitting the appliance and any controls to the appliance may only be carried out by a competent engineer in accordance with the current Gas Safety (Installation and Use) Regulations. Flue systems must not be modified in any way other than as described in the fitting instructions. Any misuse or unauthorised modifications to the appliance, flue or associated components and systems could invalidate the warranty. The manufacturer accepts no liability arising from any such actions, excluding statutory rights.

Servicing

Advise the user to have the system serviced annually by a competent, qualified Gas Safe registered engineer. Approved spares must be used to help maintain the economy, safety and reliability of the appliance.

Important The service engineer must complete the Service Record on the

Benchmark Checklist after each service.

FLUE SYSTEM

Only use the approved Worcester Condensfit II flue system with this appliance.

WORCESTER ORIGINAL SPARE PARTS

Only use Worcester original spare parts with this appliance. Non Worcester original spare parts will invalidate the guarantee (if applicable) and any warranty.

6 720 821 670 (2018/06) 5

Regulations

2Regulations

Installation regulations

Current Gas Safety (Installation & Use) Regulations: All gas appliances must be installed by a competent person in

accordance with the above regulations. Failure to install appliances correctly could lead to prosecution.

The appliance must be installed in accordance with, and comply to, the current: Gas Safety Regulations, IET Regulations, Building Regulations, Building Standards (Scotland) (Consolidation), Building Regulations (Northern Ireland), local water by-laws, Health & Safety Document 635 (The Electricity at Work Regulations 1989), EU Regulations No. 811/ 2013 - Energy Labelling and any other local requirements.

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)

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.

Irish Standards

The relevant Irish standards should be followed, including:

• ECTI National rules for electrical installations

• IS 813:2002 for Domestic Gas Installations.

Timber Framed Buildings

Where the boiler is to be fitted to a timber framed building the guidelines laid down in BS5440: Part 1 and IGE "Gas Installations in Timber Frame Buildings” should be adhered to.

Potable Water

All seals, joints and compounds (including flux and solder) and components used as part of the secondary domestic water system must be approved by WRAS.

CH Water

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

6 720 821 670 (2018/06)6

3 APPLIANCE INFORMATION

6720813283-02.1Wo

390mm

270mm

*600mm to top of case front

590mm*

3.1 APPLIANCE

APPLIANCE INFORMATION

Fig. 1 Appliance

Do not use the pre-formed copper pipes supplied with the appliance for the gas supply. These copper pipes are for water only.

STANDARD PACKAGE:

1 Wall hung gas fired condensing regular appliance for central

heating and domestic hot water 2 Tail pipes - water only 3 Wall plate 4 Hardware literature pack (see checklist) 5ErP Label 6 Bottom panel and wall mounting template

CHECK LIST

- HARDWARE LITERATURE PACK:

Appliance Installation, Commissioning and Servicing Instructions

Users Instructions 1 Consumer Guarantee Card 1 Sealing Pack: 1

- Compression Nut 22mm 3

- Compression Ring 22mm 3

Elbow assembly pack 1

- Elbow Assembly 1

- Fibre Washer 1

Table 4 Hardware lit pack - checklist

Qty.

6 720 821 670 (2018/06) 7

APPLIANCE INFORMATION

3.2 TECHNICAL DATA

Natural Gas Appliances

DESCRIPTION NATURAL GAS

UNIT 9kW 12kW 15kW 18kW 21kW 24kW

Gas flow rate - Max. 10 minutes from lighting

Natural Gas G20 m³/h 0.95 1.30 1.63 1.96 2.26 2.60

Central Heating

Max. rated heat input (net) kW 9.24 12.32 15.40 18.48 21.54 24.62 Min. heat input kW 3.45 3.45 4.62 5.54 7.38 7.38 Maximum rated heat output 40/30 °C kW 9.64 12.85 16.06 19.28 22.47 25.67 Maximum rated heat output 50/30 °C kW 9.55 12.74 15.92 19.11 22.27 25.45 Maximum rated heat output 80/60 °C kW 91215 18 21 24 Maximum flow temperature °C 82 82 82 82 82 82 Maximum possible flow temperature °C 87 87 87 87 87 87 Maximum permissible operating pressure bar 2.5 2.5 2.5 2.5 2.5 2.5

Flue

Flue gas temp. 80/60 °C, rated/min. load °C 60/56 62/56 66/58 70/60 74/63 78/63 Flue gas temp. 40/30 °C, rated/min. load °C 38/33 41/33 44/33 48/34 51/35 54/35 CO2 level at max. rated heat output (after 30 min) % 9.6 9.6 9.6 9.6 9.6 9.55 CO2 level at min. rated heat output (after 30 min) % 8.6 8.6 8.6 8.6 8.6 8.55 NOx class 666666 NOx rating mg/kWh 36.0 38.6 44.3 48.7 55.5 56.0

Condensate

Maximum condensate rate l/h 0.60 0.93 1.20 1.50 1.80 2.00 pH value, approx. 4.8 4.8 4.8 4.8 4.8 4.8

Electrical

Electrical power supply voltage A.C. V 230 230 230 230 230 230 Frequency Hz 50 50 50 50 50 50 Maximum power consumption W 25 33 44 49 42 51

General data

Appliance protection rating IP 20 20 20 20 20 20 Permissible ambient temperatures °C 0 - 50 0 - 50 0 - 50 0 - 50 0 - 50 0 - 50 Nominal capacity of appliance litre 1.1 1.1 1.1 1.1 1.1 1.1 Packaged appliance weight kg 31 31 31 31 31 31 Total appliance weight kg 27.4 27.4 27.4 27.4 27.4 27.4 Lift weight kg 22.6 22.6 22.6 22.6 22.6 22.6 SEDBUK 2005 % 89.8 89.8 89.7 89.7 89.6 89.6 SEDBUK 2009 % 89.1 89.1 88.9 88.9 88.7 88.7 Flue system Category II 2H 3P type C13, C33 & C53

Table 5 Technical data Natural Gas

6 720 821 670 (2018/06)8

APPLIANCE INFORMATION

LPG Appliances

DESCRIPTION LPG

UNIT 9kW 12kW 15kW 18kW 21kW 24kW

Gas flow rate - Max. 10 minutes from lighting

Propane Gas (LPG) kg/h 0.71 0.96 1.20 1.44 1.77 1.91

Central Heating

Max. rated heat input (net) kW 9.24 12.32 15.40 18.48 21.54 24.62 Min. heat input kW 5.95 5.95 5.95 9.64 9.64 9.64 Maximum rated heat output 40/30 °C kW 9.64 12.85 16.06 19.28 22.47 25.67 Maximum rated heat output 50/30 °C kW 9.55 12.74 15.92 19.11 22.27 25.45 Maximum rated heat output 80/60 °C kW 91215 18 21 24 Maximum flow temperature °C 82 82 82 82 82 82 Maximum possible flow temperature °C 87 87 87 87 87 87 Maximum permissible operating pressure bar 2.5 2.5 2.5 2.5 2.5 2.5

Flue

Flue gas temp. 80/60 °C, rated/min. load °C 59/57 62/57 66/59 71/61 75/64 79/64 Flue gas temp. 40/30 °C, rated/min. load °C 40/35 43/35 46/36 49/37 52/37 55/38 CO2 level at max. rated heat output (after 30 min) % 10.5 10.5 10.5 10.5 10.5 10.5 CO2 level at min. rated heat output (after 30 min) % 10 10 10 10 10 10 NOx class 666666 NOx rating mg/kWh 36.0 38.6 44.3 48.7 55.5 56.0

Condensate

Maximum condensate rate l/h 0.5 0.7 0.9 1.2 1.4 1.5 pH value, approx. 4.8 4.8 4.8 4.8 4.8 4.8

Electrical

Electrical power supply voltage A.C. V 230 230 230 230 230 230 Frequency Hz 50 50 50 50 50 50 Maximum power consumption W 26 36 52 55 44 54

General data

Appliance protection rating IP 20 20 20 20 20 20 Permissible ambient temperatures °C 0 - 50 0 - 50 0 - 50 0 - 50 0 - 50 0 - 50 Nominal capacity of appliance litre 1.1 1.1 1.1 1.1 1.1 1.1 Packaged appliance weight kg 31 31 31 31 31 31 Total appliance weight kg 27.4 27.4 27.4 27.4 27.4 27.4 Lift weight kg 22.6 22.6 22.6 22.6 22.6 22.6 SEDBUK 2005 % 90.1 90.1 90.5 90.4 90.0 90.0 SEDBUK 2009 % 89.0 89.0 89.1 89.2 88.9 88.9 Flue system Category II 2H 3P type C13, C33 & C53

Table 6 Technical data LPG

6 720 821 670 (2018/06) 9

APPLIANCE INFORMATION

3.3 Energy efficiency

Natural Gas appliances

The following product data satisfy the requirements of the EU Regulations No. 811/2013 and No. 812/2013 supplementing Directive 2010/30/EU.

Product data Symbol Unit 7733600306 7733600307 7733600308 7733600309 7733600310 7733600311

Product type – – 9Ri

ErP +

NG 12Ri Condensing boiler – – Yes Yes Yes Yes Yes Yes Low temperature boiler – – No No No No No No B1 boiler – – No No No No No No Cogeneration space heater

– – No No No No No No

(CHP) Combination heater – – No No No No No No Rated heat output P Seasonal space heating

rated

kW9 1215182124

%929292929292

energy efficiency Energy efficiency class––AAAAAA

Useful heat output

At rated heat output and high temperature regime

At 30 % of rated heat output and low temperature

regime

kW9 1215182124

kW445688

Useful efficiency

At rated heat output and

% 87.2 87.2 86.9 86.9 86.7 86.7

high temperature regime 1) At 30 % of rated heat output

% 98.1 98.1 97.6 97.6 97.2 97.2 and low temperature regime 2)

Auxiliary electricity consumption

At full load el At part load el In standby mode P

max

min

kW 0.025 0.033 0.044 0.049 0.042 0.051 kW 0.016 0.016 0.018 0.018 0.017 0.017 kW 0.003 0.003 0.003 0.003 0.003 0.003

Other items

Standby heat loss P Ignition burner power

stby

ign

kW 0.059 0.059 0.059 0.059 0.059 0.059 kW000000

consumption Emissions of nitrogen

NOx mg/kWh 32 35 40 44 50 51

oxides Annual energy

kWh------

consumption Sound power level, indoors L

dB(A)454548505050

Table 7 Product data for energy consumption

1) High-temperature regime means 60 °C return temperature at heater inlet and 80 °C feed temperature at heater outlet.

2) Low temperature means for condensing boilers 30 °C, for low-temperature boilers 37 °C and for other heaters 50 °C return temperature (at heater inlet).

ErP +

NG 15Ri

ErP +

NG 18Ri

ErP +

NG 21Ri

ErP +

NG 24Ri

ErP +

6 720 821 670 (2018/06)10

APPLIANCE INFORMATION

LPG appliances

The following product data satisfy the requirements of the EU Regulations No. 811/2013 and No. 812/2013 supplementing Directive 2010/30/EU.

Product data Symbol Unit 7733600300 7733600301 7733600302 7733600303 7733600304 7733600305

Product type – – 9Ri

ErP +

LPG 12Ri

ErP +

LPG 15Ri

ErP +

LPG 18Ri

ErP +

LPG 21Ri

ErP +

LPG 24Ri

ErP +

LPG Condensing boiler – – Yes Yes Yes Yes Yes Yes Low temperature boiler – – No No No No No No B1 boiler – – No No No No No No Cogeneration space heater

– – No No No No No No

(CHP) Combination heater – – No No No No No No Rated heat output P Seasonal space heating

rated

kW9 1215182124

%929292929292

energy efficiency Energy efficiency class––AAAAAA

Useful heat output

At rated heat output and high temperature regime

At 30 % of rated heat output and low temperature

regime

kW9 1215182124

kW 6 6 6 10 10 10

Useful efficiency

At rated heat output and high temperature regime

At 30 % of rated heat output and low temperature

regime

% 87.2 87.2 86.9 86.9 86.7 86.7

% 98.1 98.1 97.6 97.6 97.2 97.2

Auxiliary electricity consumption

At full load el At part load el In standby mode P

max

min

kW 0.026 0.036 0.052 0.055 0.044 0.054 kW 0.019 0.019 0.018 0.023 0.019 0.019 kW 0.003 0.003 0.003 0.003 0.003 0.003

Other items

Standby heat loss P Ignition burner power

stby

ign

kW 0.059 0.059 0.059 0.059 0.059 0.059 kW000000

consumption Emissions of nitrogen

NOx mg/kWh 32 35 40 44 50 51

oxides Annual energy consumption Q Sound power level, indoors L

kWh------

dB(A)454548505050

Table 8 Product data for energy consumption

1) High-temperature regime means 60 °C return temperature at heater inlet and 80 °C feed temperature at heater outlet.

2) Low temperature means for condensing boilers 30 °C, for low-temperature boilers 37 °C and for other heaters 50 °C return temperature (at heater inlet).

6 720 821 670 (2018/06) 11

APPLIANCE INFORMATION

6720804541-01.1Wo

3.4 APPLIANCE MAIN COMPONENTS

1 Air/Gas Manifold 2 Sensor - appliance flow 3 Flow pipe 4 Return pipe 5 Removable servicing panel 6 Electrode assembly 7 Overheat thermostat 8 Silicon tube - Heat Exchanger air vent 9Heat Exchanger 10 Flue overheat thermostat 11 Access panel - Heat Exchanger/Sump cleaning 12 Return connector with drain point 13 Flow connector 14 Appliance Temperature control and Reset knob

15 Power and fault indicator (blue) 16 Wiring connections cover 17 Burner indicator (green) 18 Appliance ON/OFF switch 19 Condensate connection 20 Syphon / Trap 21 Gas inlet connection 22 Mains cable inlet 23 Gas Valve 24 Flue air pressure switch connection 25 Fan 26 Manual vent point 27 Fan pressure test point 28 Air pressure switch

6 720 821 670 (2018/06)12

3.5 Internal wiring diagram

SPARK TRANSFORMER

DIAGNOSTIC INTERFACE

CODE PLUG

MODE SWITCH

Slow 2 A fuse,

AC 230 V

EMS BUS

CH TEMPERATURE CONTROL

ON/OFF SWITCH

ST9

ST6

ST5

ST2

ST1

230V~

Min

Max

Norm

LN LP NPLR

Earth

COMMON

230V MAINS

SUPPLY

6720644744-27.3Wo

Colour sequence 

Green

Live

Neutral

Red

Blue

Violet

Orange

Pump Live

Pump Neutral

Switched Live

LRNP

APPLIANCE INFORMATION

Fig. 2 Electrical diagram

[1] Air pressure switch [2] Fan (fan wiring: Live = purple wire, Neutral = brown wire [3] Flue overheat thermostat [4] Flow temperature sensor (NTC) [5] Flame sense electrode [6] Spark electrodes [7] Overheat thermostat [8] External pump [9] PCB [10] External wiring center/junction box [11] Earth bar connection [12] Gas valve

6 720 821 670 (2018/06) 13

Installer connections Connection Function

ST1 230V supply to the appliance

ST2 External pump supply connections and Switched live

• Live input (L)

• Neutral input (N)

(Live Return) to the appliance

•Pump Live (LP)

• Pump Neutral (NP)

• Demand input (LR)

• Earth connection, external pump supply

Earth • Earth connection, appliance 230V supply

PRE-INSTALLATION

4 PRE-INSTALLATION

NOTICE: All the following Pre-Installation sections must

be read and requirements met before starting appliance or flue installations.

CAUTION: Isolate the mains supplies before starting a ny work and observe all relevant safety precautions.

4.1 MAINS SUPPLY

4.1.1 ELECTRICAL SUPPLY

• Supply: 230V - 50 Hz, 140 Watts

• Cable: PVC insulated 0.75mm

• External 3A fuse to BS1362.

• The appliance must be earthed.

• Do not connected the appliance to a 3 phase supply.

• IP20.

• Wiring must comply with the latest edition of BS 7671 (IET wiring regulations).

4.1.2 GAS SUPPLY

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, the following applies:

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

• 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. ( Commissioning section).

• The meter or regulator and pipe work to the meter must be checked, preferably by the gas supplier.

(24 x 0.2mm) temp. rated to 90 °C.

4.2 WATER SYSTEMS AND PIPE WORK

PLASTIC PIPE WORK:

• Any plastic pipe work must have a polymeric barrier with 600mm (minimum) length of copper pipe connected to the appliance.

• Plastic pipe work used for underfloor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approximately 50 °C.

PRIMARY SYSTEMS CONNECTIONS/VALVES:

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

• Radiator valves should conform to BS2767:10.

• All other valves should conform to BS1010.

• 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.

• A drain cock is required at the lowest point in the system.

• An air vent is required at all high points in the system.

NOTICE: To prevent reverse circulation ▶ The cylinder return must be the last connection on the

common return pipe.

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

Pump speed characteristics ▶ In order to save as much energy as possible and the

minimise the possibility of water circulation noise. The circulating pump should be selected and adjusted to suit the system resistance.

OPEN VENT PRIMARY SYSTEM CONSIDERATIONS:

• The open vent pipe and feed and expansion pipe must rise continuously from the appliance.

• Close coupled feed and expansion pipe maximum separation of

150mm.

• The feed and expansion cistern must be positioned to provide a

minimum static head of 250mm above the highest point in the heating system to the water level in the feed and expansion cistern.

• Ensure adequate space is left in the expansion cistern for expansion

of the system water.

• No valve shall be fitted in the open vent pipe or the feed and

expansion pipe.

• The open vent pipe must be at least 22mmØ.

• Do not use galvanised pipes or radiators.

SEALED PRIMARY SYSTEM CONSIDERATIONS:

• The CH sealed system must be filled using a WRAS approved filling loop or comply with figure 3 for system fill.

• An expansion vessel, of a size suitable for the system, must be fitted as close as possible to the appliance in the central heating return.

• Also fit a pressure gauge, a 3 bar pressure relief valve and stop cock (fixed cylinder type or sealed system approved connection).

• No valve shall be fitted that can isolate the appliance from the

expansion vessel or pressure relief valve.

• An automatic air vent must be fitted.

• Do not use galvanised pipes or radiators.

6 720 821 670 (2018/06)14

PRE-INSTALLATION

Y PLAN LAYOUT

150 mm

max

reset max

6720644744-04.1Wo

SYSTEM FILL

Heating

return

SV SV

Hose union

Temporary hose

CV = Check Valve SV = Stop Valve

SYSTEM MAKE UP

Heating

return

Fig. 3 System fill/System make-up

S AND Y PLAN SYSTEMS:

NOTICE: Bypass considerations

▶ Appliances fitted with a modulating pump may not

require a system bypass.

Test point

AA = Auto Air vent CV = Check Valve

Make up

vessel

1000 mm (39 in) above the highest point of the system.

Mains

supply

SYSTEM LAYOUTS EXAMPLES:

S PLAN LAYOUT - OPEN VENT

S PLAN LAYOUT

150 mm

max

reset max

6720644743-08.2Wo

6720644744-03.1Wo

Fig. 4 S plan open vent

Y PLAN LAYOUT - OPEN VENT

1 Static head -

Minimum static head 250mm measured from the highest point in the heating system (top surface of the appliance or the highest point in the heating system) to the water level in

the feed and expansion tank 2 Heating vent (22mm minimum) 3 Primary cold feed (15mm minimum) 4 Diverter/Zone valve 5 Pump, maximum power 90 Watts 6 Automatic bypass 7 Radiator valve (Flow) 8 Lock shield valve (Return) 9 Expansion vessel

10 Pressure gauge 11 3 bar pressure relief valve 12 Stop cock

Table 9 Key to figures 4, 5, 6, 7 & 8

NOTICE: A drain cock should be fitted at the lowest point of the heating circuit and beneath the appliance.

Fig. 5 Y plan open vent

6 720 821 670 (2018/06) 15

PRE-INSTALLATION

SEALED SYSTEM LAYOUT

MCW

reset max

6720644744-05.1Wo

6720644744-61.1Wo

150 mm

max

reset max

OPEN VENT LAYOUT

6720644744-62.1Wo

reset max

SEALED SYSTEM LAYOUT

MCW

SEALED SYSTEM Y PLAN LAYOUT

The central heating sealed system must be filled using a WRAS approved filling loop or comply with figure 3 for System fill.

Fig. 6 Y plan sealed system

NEW BUILD SYSTEM LAYOUTS

The latest Part L1a regulation for new installations require separate zone controls for the central heating.

Open vent with two heat zones

4.3 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. All condensate pipework must ‘fall’ from the appliance by a minimum of 3 degrees (52mm per metre) to ensure adequate Condensate flow.

2. The pipework route must allow air to be supplied back to the appliance for correct operation of the siphon.

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

Also:

• Keep external pipework as short as possible and not exceed 3 metres length.

• External pipework should be increased to a minimum diameter of 32mm and ideally be insulated.

• Minimise the number of bends and connectors.

• Remove burrs after cutting pipe.

• Remove surplus solvent from the interior of the pipe.

4.3.1 CONDENSATE PIPE WORK

NOTICE:

▶ 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.

▶ The condensate pipe must be nominally

22mm Ø plastic pipe.

▶ The condensate pipe work must fall at least 52mm

per metre towards the outlet and should take the shortest practicable route.

▶ Ensure there are no blockages in the pipe run.

Fig. 7 Two heating zones open vent

Sealed system with two heat zones

Fig. 8 Two heating zones sealed system

NOTICE: Unheated internal areas. Although the large volume siphon will reduce the risk of

freezing, condensate discharge may freeze in areas of prolonged cold temperatures.

▶ Internal pipe runs in unheated areas such as lofts,

basements and garages should be treated as external runs.

Key to condensate illustrations, figures 9, 10, & 11 1 Condensate discharge from appliance 2 Soil and vent stack 3 Minimum 450mm and up to three storeys 4 Visible air break at plug hole 5 Sink or basin with integrated overflow 6 75mm sink waste trap 7 Condensate pump

Table 10 Key to Internal condensate disposal methods

6 720 821 670 (2018/06)16

PRE-INSTALLATION

4.3.2 INTERNAL CONNECTIONS

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

22mm Ø

6720644744-06.4Wo

Fig. 9 Disposal to soil vent stack

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.

CONDENSATE PUMP

Where “gravity discharge” to an internal termination 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 appliance or condensate pump manufacturer. The pump outlet pipe should discharge to a suitable internal foul water discharge point such as an internal soil and vent stack or if not possible to internal kitchen, bathroom or washing machine waste pipe etc. A suitable permanent connection to the foul waste pipe should be used.

Fig. 11 Condensate pump disposal

22mm Ø

6720819188-12.2Wo

Fig. 10 Disposal to a waste pipe

22mm Ø

75mm

min.

75mm

min.

6720819188-03.3Wo

6 720 821 670 (2018/06) 17

PRE-INSTALLATION

6720644744-12.4Wo

25mm min.

4.3.3 External connection considerations

NOTICE: Rainwater 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 it the down pipe or external drain is connected to a combined foul and rainwater system

▶ Refer to BS 6798 for more information

NOTICE: Grey water systems Contamination of recovered water ▶ Condensate disposal shall not be allowed into a grey

water recovery system that is intended for re-use

NOTICE: Freezing conditions ▶ Pipe work length should be kept to a minimum and the

route as vertical as possible.

▶ When required, use only weather proof insulation.

NOTICE: Condensate waste ▶ Care should be taken when siting a soak-away to avoid

causing damage to existing services.

Continued - Key to condensate illustrations, figures 12, 13, 14 &

15 1 Condensate discharge from appliance 7Condensate pump 8 Pipe work transition 9 Insulate and increase pipe size 10 External rain water pipe into foul water 11 External air break 12 Air gap 13 Strap-on fitting 14 43mm 90 ° male/female bend 15 100mm Ø minimum plastic pipe 16 Drainage holes 17 Limestone chippings 18 Bottom of sealed tube 19 Increase size of soak away with limestones chippings if in clay

soil area

Table 11 Key to external condensate disposal methods

▶ 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.

FITTING AN EXTERNAL AIR BREAK

• Refer to figure 12 when a rain water down pipe is used to dispose of condensate.

• An air break must be installed in the 43mm pipe work, between the appliance condensate outlet and the drainpipe, outside the property, to avoid flooding during adverse weather conditions.

22mm Ø

Fig. 12 Disposal into a rainwater down pipe

Where the pipe terminates over 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. Pipe drainage will be improved if the end is cut at 45° as opposed to a straight cut.

6720810188-05.5

Fig. 13 External disposal

25mm min.

6720644744-10.4Wo

Condensate drainage pipe can be run above or below ground. If the pipe work is run under ground, care must be taken to ensure that the pipe work “fall” towards the disposal point is maintained

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: ▶ Use a CondenseSure siphon to help prevent the condensate freezing. ▶ The external run be kept as short as possible and not exceed 3

metres.

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

externally and the pipe diameter should be increased to 32mm before it passes through the wall to the exterior. The pipe should be insulated using suitable waterproof and weather resistant insulation, if not using a CondenseSure siphon.

▶ 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.

Fig. 14 Condensate pump to external disposal

6 720 821 670 (2018/06)18

PRE-INSTALLATION

6720819188-06.6Wo

500mm min.

25mm min.

400mm min.

6720646608-123.1Wo

CONDENSATE 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 examples shown on this page run above ground.

• The soak away must use 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.

Minimum hole size for the condensate soak away m ust be 400mm deep by 300mmØ .

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. If such a system is used, the requirement to use 32mm pipe does not apply. However, all other guidance above and the instructions for the trace heating system, should be closely followed.

NOTICE: Unheated internal areas. ▶ Internal pipe runs in unheated areas such as lofts,

basements and garages should be treated as external runs and consideration should be given to using a CondenseSure siphon.

4.4 PRESSURE RELIEF PIPE WORK

NOTICE:

▶ The pressure relief valve is a safety device for the

appliance and if activated may discharge boiling water or steam through the relief valve drain pipe.

▶ Care should be taken when siting the outlet pipe so

that it does not cause an obstruction or discharge above a window, entrance or other public access where it could cause a hazard.

• The pressure relief 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 to BS 5252 or BS EN 1451.

• The connection to the PRV must be made in copper pipe. 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.

• 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.

Fig. 16 Pressure relief pipe work

[1] Discharge pipe (turned back onto external wall example)

Fig. 15 To a soakaway

[2] Outside wall [1] Discharge pipe (into drain or gully example) [4] External drain

4.4.1 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.

Worcester, Bosch Group endorses a PRV or a combined PRV/ Condensate internal discharge system, provided that a Hotun hiflo tundish is employed. The tundish is manufactured by RA Tech UK and is WRAS approved, information on the tundish can be found at www.hotun.co.uk.

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

6 720 821 670 (2018/06) 19

PRE-INSTALLATION

6720643895-121.2Wo

+ 30 mm

above elbow

930 mm 410 mm

20 mm* 600 mm**

5 mm

Using 100 mm ue kit 1080 mm

Using 125 mm ue kit 1100 mm

200 mm

5 mm

4.5 APPLIANCE LOCATION AND CLEARANCES

4.5.1 Installation

This appliance is only suitable for installing internally within a property at a suitable location onto a fixed, rigid surface at least the same size as the appliance and capable of supporting the appliance weight.

The appliance must be installed where:

• 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.

• Products in loft cavities must have permanent fixed lighting, a permanent fixed retractable ladder and a fixed floor area sufficient to allow access for normal use and servicing directly under and around the product and between and the access hatch.

4.5.2 SERVICING CLEARANCES -

Figure 17 shows the minimum space required to install and service the appliance in a ventilated compartment.

• If a appliance is installed in a compartment with clearances less than

shown in the tables 14, 15, or 16 ventilation is required. Refer to table 12 for ventilation requirements.

Vent position To room or internal

High level Min. free area 122cm2Minimum free area 61cm Low level Min. free area 122cm2Minimum free area 61cm

Table 12 Compartment ventilation

Fig. 17 Ventilated compartment

* Minimum clearance to removable door ** Minimum clearance required for servicing

Table 13 Minimum clearances

No surface protection is required against heat transfer from the appliance.

VENTILATED COMPARTMENT

Direct to outside

space

4.5.3 COMPARTMENTS:

Follow the requirements of BS6798 and BS5440 Part 2 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.

• Ideally, storage should be below the appliance, where the appliance is mounted in the upper part of the cupboard, whilst maintaining the clearances given in tables 14, 15, or 16.

4.5.4 APPLIANCE CLEARANCES- UNVENTILATED

COMPARTMENTS

The tables below show the options for the minimum space required to install and service the appliance inside an unventilated compartment.

4.5.5 INSTALLATION CLEARANCES - UNVENTILATED

COMPARTMENTS

CAUTION: CLEARANCES

▶ Top and bottom clearances must not be reduced

below the values shown in table 14 as they are the minimum clearances required for servicing.

Unventilated Compartment Installation Clearances (millimetres)

Suggested total unventilated compartment minimum clearances are: Side Above Below Front (to removable door) 400mm 170mm approx.

Table 14 Minimum unventilated compartment clearances

If Side Clearances are Reduced (millimetres)

If total side clearance is reduced to: (Combined left and right clearances excluding the appliance)

Table 15 Reduced side clearances

If Front Clearance is Reduced (millimetres)

If front clearance (to removable door) is reduced to:

Table 16 Reduced front clearances

(30mm above elbow)

Increase height clearances to (approx.): (Combined top & bottom clearances excluding the

appliance) 350 441 129 300 523 161 250 617 200 200 717 243 150 856 295 100 1012 358

50 1202 434

Increase overall height clearances to (approx.): (Combined top and bottom clearances excluding the

appliance) 50mm 511mm 505mm 25mm 596mm 569mm

200mm 100mm

OR Front clearance

(to removable door) must be

increased to:

OR Increase total side

clearance to: (Combined left and right clearances excluding the appliance)

6 720 821 670 (2018/06)20

4.5.6 ROOMS CONTAINING A BATH OR SHOWER

NOTICE: Any switch or appliance control using mains

electricity must not be within reach of a person using the bath or shower.

• The installation must be in accordance with the latest edition of the IET Wiring Regulations BS7671.

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

• The diagram is for guidance only.

The appliance must only be installed outside zone 2.

600mm

2250mm

PRE-INSTALLATION

6720646608-124.6Wo

Fig. 18 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 bath or shower

2250mm

6 720 821 670 (2018/06) 21

PRE-INSTALLATION

6720644744-13.1Wo

Pipes in alternative position

Return Flow

4.6 PLUMBING MANIFOLD

4.6.1 CONNECTIONS

Heating System 22mm compression fittings Gas 22mm compression fittings

Use the fittings supplied in the Hardware literature pack:

Do not use the pre-formed copper pipes supplied with the appliance for the gas supply. These copper pipes are for water only.

• Use the 22mm copper pipes (1 & 2) provided with the appliance, as shown in the diagram opposite.

• If the flow and return pipes are to be run behind the appliance it maybe an advantage to connect the pipes before hanging on the wall especially if space is limited.

Further guidance on pipe routing can be found printed on the appliance template (supplied with the appliance).

▶ Ensure that the pipes are adequately supported and

room between the pipes to avoid noise.

# Function From left case

edge

1Gas 55mm 22mm 2Condensate 210mm 22mm 3Cylinder & CH Flow 285mm 22mm 4 Cylinder & CH Return 350mm 22mm

Table 17 Key to figures 19 & 20

Diameter of

pipe

reset max

1 2 3 4

6720644744-17.1Wo

Fig. 20 Pipe work dimensions

Fig. 19 Plumbing manifold

6 720 821 670 (2018/06)22

PRE-INSTALLATION

6720806945-19.1Wo

6720806945-21.1Wo

4.7 FLUE OPTIONS

WARNING: Flue systems

▶ Only use Worcester, Bosch approved flue systems, no

other manufacturer’s flue systems have been approved for use with Worcester appliances.

CAUTION: Non accessible flue systems: ▶ Where a flue system is not going to be accessible,

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.

NOTICE: Effective flue lengths: ▶ each 90° bend is equivalent to 2 metres of straight flue ▶ each 45° bend is equivalent to 1 metre of straight flue

Plume management kits are available for the 60/100 horizontal flue system. Refer to the manual supplied with the plume management kits for complete installation instructions

TELESCOPIC HORIZONTAL FLUE ASSEMBLY

60/100 mm

350 mm - 570 mm

130 mm Min

6720806945-18.1Wo

Flue length (mm)

60/100 80/125

Telescopic horizontal flue assembly 180 - 570 405 - 600 Longer telescopic horizontal flue assembly 570 - 790 N/A

Table 20

Extended horizontal flue

Part number Flue Description

7 716 191 082 60/100 Telescopic horizontal flue assembly 7 716 191 171 60/100 Longer telescopic horizontal flue

assembly

7 733 600 048 60/100 Horizontal high level telescopic flue

kit 7 719 003 702 80/125 Telescopic horizontal flue assembly 7 719 002 430 60/100 Vertical flue assembly 7 719 002 431 80/125 Vertical flue assembly

Table 18 Flue kit part numbers

4.7.1 Flue lengths

The flue systems have different maximum flue lengths The Greenstar series has the option of two horizontal 60/100 RSF

(telescopic and longer telescopic) and one horizontal 80/125 RSF (telescopic) flue system and two vertical RSF (60/100 or 80/125) flue systems:

Refer to the following example Flue options for the maximum flue lengths.

Horizontal high level flue assembly

60/100 mm

383 mm - 603 mm

Maximum flue length

(mm)

60/100 80/125

Extended horizontal flue 4,600 13,000

Table 21

Horizontal flue with additional elbow (1 x 90 ° bend)

6720806945-20.1Wo

Maximum flue length

(mm)

60/100 80/125

Horizontal flue with 1 x 90° bend 2,600 11,000

Table 22

Horizontal flue with additional elbows (2 x 90 ° bends)

130 mm Min

6720806945-29.1Wo

Flue length (mm)

60/100 80/125

Horizontal high level telescopic flue assembly 202 - 603 N/A

Table 19

6 720 821 670 (2018/06) 23

Horizontal flue with 2 x 90° bends N/A 9,000

Table 23

Maximum flue length

(mm)

60/100 80/125

PRE-INSTALLATION

6720806945-23.1Wo

6720806945-25.1Wo

A = 300 mm

B = 500 mm

High level horizontal flue

6720806945-22.1Wo

Maximum flue length

(mm)

60/100 80/125

High level horizontal flue 4,600 13,000

Table 24

High level horizontal flue with additional elbows

Vertical balanced flue assembly

Maximum flue length

(mm)

60/100 80/125

Vertical balanced flue assembly 6,400 15,000

Table 27

Vertical balanced flue with elbow offset (2 x 90 ° bends)

Maximum flue length

(mm)

60/100 80/125

High level horizontal flue with 2 x 90° bends 2,600 11,000

Table 25

High level horizontal flue with additional elbows

Maximum flue length

(mm)

60/100 80/125

High level horizontal flue with 3 x 90 ° bends N/A 9,000

Table 26

6720806945-26.1Wo

Maximum flue length

(mm)

60/100 80/125

Vertical balanced flue with 2 x 90° bends 2,400 11,000

Table 28

Vertical balanced flue with elbow offset (2 x 45 ° bends)

6720806945-24.1Wo

6720806945-27.1Wo

Maximum flue length

(mm)

60/100 80/125

Vertical balanced flue with 2 x 45° bends 4,400 13,000

Table 29

6 720 821 670 (2018/06)24

4.8 Flue terminal positions

6720821670-07.1Wo

BOUNDARY LINE

300

600

500

1500

1200

300

1500

500

400

600

2000

1500

RIDGE FLUERIDGE VENT

1500

300

400

600

300

1500

BOUNDARIES

1/2

CAUTION: Flue terminal positions

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

4.8.1 Vertical flue terminal positions

PRE-INSTALLATION

Fig. 21 Vertical flue terminal positions

Key to figure 21:

[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.

[7] 400mm from a pitched roof or 500mm in regions with heavy

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

snow fall.

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.

6 720 821 670 (2018/06) 25

PRE-INSTALLATION

600

1500

300

BOUNDARY LINE

SKYLIGHTDORMA

<1000

600

300

BELOW GROUND OPEN LIGHT WELL

200

100

300

600

BOUNDARIES

1/2

100

600

2000

OPENING

OPPOSITE

TOP

BOUNDARY LINE

200

600

1000

1200

600

300

200

300

1500

1200

6720821670-08.1Wo

300150

300

TOP

4.8.2 Horizontal flue terminal positions

Fig. 22 Horizontal flue terminal positions

6 720 821 670 (2018/06)26

Key to Figure 22:

[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.

[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.

[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

re duc ed t o 25 mm, as l ong 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.

PRE-INSTALLATION

Note:

▶ Installations in car ports are not recommended. ▶ T he fl ue c anno t be lowe r 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.

6 720 821 670 (2018/06) 27

PRE-INSTALLATION

4.8.3 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 0.75 metres of straight plume management and the 90° bend is equivalent to 1.5 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 23

for “ 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.

180°

±80°

200

300

200

300

150

300

600

BOUNDARY LINE

300

150

BOUNDARY LINE

TOP

200

1200

±45°

2000

600

EXCLUSION ZONE

OPENING

OPPOSITE

300

TOP

±80°

600

300

BOUNDARY LINE

600

1,500

100

≥140

≥5

EXCLUSION ZONE

600

100

≥5

EXCLUSION ZONE

300

1500

300

150

200

300

600

300

150

300

150

300

150

TOP

300

150

FLUE TERMINAL GUARD

7 716 191 176

6720821670-09.1Wo

Fig. 23 Plume re-direct and plume management terminal positions

6 720 821 670 (2018/06)28

PRE-INSTALLATION

Key to Figure 23 - 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 23 - Plume management terminal positions:

[5] 600mm distance to 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 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.

6 720 821 670 (2018/06) 29

PRE-INSTALLATION

4.9 CLEANING PRIMARY SYSTEMS

NOTICE: 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

When an appliance is installed onto a new system. ▶ 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. There is a risk that debris could damage the appliance and reduce efficiency. 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.

WARNING: Sealing agents

▶ 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 micro leak have

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

Water treatment products

Suitable water treatment products can be obtain 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 30

4.9.1 Flushing the system

▶ Fill the system with cold water and check for leaks. ▶ Open vented systems only:

– Turn off the water to the system header tank. ▶ 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.

The pH value of the system water must be between 6.5 and 8 or

the appliance guarantee will be invalidated.

▶ 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.

– Open vented systems only:

Turn on the water to the system header tank and allow the system to fill.

– Sealed systems only:

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.

6 720 821 670 (2018/06)30

5 INSTALLATION

6720813283-03.1Wo

WARNING: All the previous “Pre-Installation” sections must be read and the requirements met before starting appliance or flue installation.

5.1 UNPACKING THE WALL FRAME & ANCILLARY ITEMS

CAUTION: LIFTING AND CARRYING

▶ Only lift a manageable weight, or ask for help. ▶ Bend the knee 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.

Do not use the pre-formed water pipes on the gas supply, they must only be used for water.

Remove the straps and open the top of the appliance packaging.

1. Remove the two 22mm water pipes (1)

2. Remove the following items: – Wall mounting plate (2). – Wall mounting template and bottom panel (3). – Literature pack and pipe connectors and olives (4).

– ErP label (5)

Fig. 24 Unpacking 1

INSTALLATION

3. Remove the top carton (5).

4. Remove the outer cardboard sleeve (6).

5. Remove the plastic cover (7).

Fig. 25 Unpacking 2

▶ Flatten the outer cardboard sleeve and place on the floor behind the

appliance. ▶ Lay the appliance on its back on the cardboard. ▶ Remove the bottom tray.

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 carton has been delivered, remove the outer carton. Care

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

used, ensure the outer carton is not pierced and that the implement is

used in such a way that it will not cause personal injury.

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

put away in a safe place. The wall mounting frame, Installer pack,

template and bottom panel can now be removed. Care should be

taken when lifting the appliance from the base and the proper

technique for safe lifting of any heavy object must be strictly

observed.

Additional requirements for roof space installation:

• The appliance must be unpacked before ascending the steps to loft

space.

• Two sets of steps should be used.

• Two people should share the lifting of the appliance up to the loft

hatch, where the appliance is entered into the loft space, tilted, and

slid on its back into the loft.

• Once the appliance is removed from its packaging check the contents

against the packing list.

Before installing the appliance, ensure that the system has been cleaned as explained on page 30.

6720644744-15.2Wo

6 720 821 670 (2018/06) 31

INSTALLATION

5.2 POSITION THE APPLIANCE 5.3 Wall mounting template & flue opening

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 level, 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. ▶ Flushing the system pipe work thoroughly and

completely to remove all residue.

▶ Follow the instructions with respect to cleaning

primary systems.

Flue outlet position ▶ Ensure all horizontal flue sections rise away from the

appliance by 52mm per metre to ensure that condensate flows back into the appliance for safe discharge via the condensate waste pipe.

SAFETY:

All relevant safety precautions must be undertaken. Protective clothing, footwear, gloves and safety goggles must be worn as appropriate.

FIXING THE MOUNTING FRAME:

▶ The appliance template shows the relative positions of the flue and

the top and bottom fixing of the mounting frame.

1. Fix the template to the wall in the desired position.

2. Drill four holes for the wall mounting frame through the template. Drill two holes for the bottom fixing screws.

The template has been sized to allow for minimum clearances of 5mm sides, 200mm base and 30mm above a 100mm diameter flue elbow.

REAR FLUE OUTLET

▶ The drawing opposite shows the appliance template with the flue

centre lines of both the 100mm and 125mm flue systems.

3. Mark centre line of flue to be used (3); the external diameter of the hole can also be marked if required.

▶ If a 100mm diameter flue is to be used, a 125mm diameter hole is

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

▶ The flue turret of the 100mm flue has an in-built 3° angle. ▶ If extensions are to be added then the complete flue must rise at an

angle of 3°.

▶ The 125mm diameter flue system will require the flue to rise at an

angle of 3°.

▶ Drill hole using a core drill or similar.

SIDE OUTLET:

4. Mark from the centre line of th e wall template to the wall which the flue will pass through (4).

▶ Allow for a rise of 52mm per metre length of flue, to give a 3° angle. ▶ Clear any debris from the site.

127 mm

Fig. 26 Marking the flue position

6720813283-01.1Wo

6 720 821 670 (2018/06)32

INSTALLATION

5.4 OUTER CASE REMOVAL

1. Undo the two captive screws securing appliance casing at the bottom of the appliance.

2. Undo the two screws securing appliance casing at the top of the appliance.

3. Pull case upwards.

4. Remove the transit packing piece from appliance and discard.

With the outer case removed the appliance is suitable for a one man lift (<25kg).

5.5 APPLIANCE CONNECTION

CAUTION:

▶ ISOLATE THE MAINS GAS SUPPLY BEFORE

STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.

WARNING:

▶ Caps fitted to pipes must be removed before hanging

the appliance

GAS AND WATER CONNECTIONS:

▶ Remove wall mounting template and secure the wall mounting frame

to the wall with the appropriate fittings for the appliance weight and wall type.

▶ If there is greater than 600mm clearance below the appliance it is

possible to fit the flow and return pipes, supplied, with the appliance installed on the wall.

▶ If clearance is less than 600mm below the appliance it may be

necessary to fit the flow and return pipes before hanging the appliance.

The copper pipes supplied with the appliance are not to used for the gas supply. These copper pipes are for water only.

Fig. 27 Case removal

6720804514-02.1Wo

NOTICE:

▶ Lift the appliance using the handling holes at either

side of the frame. Do not lift the appliance by the air gas manifold or control box.

System pipes may be run vertically up behind the appliance or below it.

NOTICE:

▶ If pipes require reducing in length this is best done

before they are fitted to the appliance.

6 720 821 670 (2018/06) 33

INSTALLATION

Return Flow

5.5.1 CONDENSATE CONNECTION

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

Figure 31 gives the pipe work dimensions with respect to the mounting surface.

A sealing washer (1) and 22mm adaptor (2) are supplied in the fitting pack

1. Fit washer (1) inside the plastic nut and attach firmly to the

2. Connect the condensate disposal pipe work to the elbow (2), refer to

6720644744-13.1Wo

NOTICE: Condensate disposal ▶ Follow the recommendations given in section 4.3

“Condensate pipe work” for all condensate disposal installation.

▶ Ensure that the condensate pipe work falls

continuously at least 50mm per metre towards the outlet.

▶ * Do not use solvents, adhesive or lubricant when

pushing the pipe onto the rubber connector.

When using the pre-formed water pipes provided with the appliance, offset the water pipes connecting to them by 5mm to enable pipe clamps to be fitted.

connection on the syphon.

figure 31 and insert the condensate pipe 25mm into the elbow.

Pipes in alternative position

Fig. 28 Plumbing manifold

[1] Gas inlet (22mm) [2] Condensate [3] Flow (22mm) [4] Return (22mm)

▶ Lift the appliance onto the wall plate. ▶ Level vertically using the feet (1) at the bottom rear of the appliance

casing.

▶ Fit retaining screws through the holes (2) in the appliance frame to

secure the appliance.

▶ Make connections to the heating system pipes.

Fig. 30 Condensate connections

6720644744-22.1Wo

Fig. 29 Levelling and securing detail

6720644744-56.1Wo

6 720 821 670 (2018/06)34

5mm

6720806944-84.1Wo

6720644842-10.1Wo

52mm

104mm

WALL

INSTALLATION

Fig. 32 Flue turret centre

[D] 127mm [W] 195mm

▶ 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.

18mm

25mm

Fig. 31 Pipe work dimensions

125mm

6720644744-19.2Wo

5.6 Flue turret/adaptor installation

The flue turret/adaptor for the appliance is secured using three retaining screws (figure 32, item [1]) which come in position on the appliance.

To ease assembly of flue components, apply silicone lubricant to sealing surfaces. Refer to the manual supplied with the flue kit for complete installation instructions. For plume management effective lengths and the effective flue lengths, refer to details in section 4.7.

Refer to figures 32 & 33. ▶ Remove the three inner flue tube retaining screws [1].

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

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

silicone grease.

Fig. 33 Flue turret/adaptor connection

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 is set at an angle of 3° or 52mm per metre length.

• Support the flue at approximately one metre intervals and at a change of direction, use suitable brackets and fittings (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)

6720806944-85.1Wo

6 720 821 670 (2018/06) 35

Fig. 34 Slope for condensate disposal

INSTALLATION

6720644744-25.1Wo

ST1 ST2

3. 4. 5.

ST7

5.7 ELECTRICAL CONNECTIONS

CAUTION: Isolate the mains electrical supply before

starting any work and observe all relevant safety precautions.

The appliance is already wired with a mains supply cable. A spare strain relief block is supplied in case the prewired cable is replaced.1

▶ The mains supply to the appliance and system wiring centre must be

common, and through either a fused double pole isolator or a fused three pin plug and unswitched socket.

▶ The isolator/socket, where practicable, should be situated next to the

appliance.

▶ The isolator must have a contact separation of 3mm minimum in both

poles.

▶ Any system connected to the appliance must not have a separate

electrical supply.

▶ External fuse rating 3A.

ACCESS TO ELECTRICAL CONTROL PANEL:

▶ Remove appliance casing to access control panel.

1. Unscrew the three screws in the control panel.

2. Remove the connections cover. ▶ Unclip cable clamp.

▶ Cut off the tapered cable entry to fit cable diameter required. ▶ Turn cable retaining screw anti-clockwise ▶ Run cable through the hole in the main crossbar marked “mains

cable” and through the cable clamp, ensure there is ample cable to reach the connectors.

▶ Turn cable clamping screw clockwise to secure cable and replace

clamp into control panel.

3. Mains power 230v connection (ST1): – Separate wires from cable end and strip to 6mm – Connect LIVE wire to terminal (L) – Connect NEUTRAL wire to the terminal (N) – Connect EARTH wire to earth bracket

4. External Pump (ST2): Max power 90 W – Connect NEUTRAL wire to terminal (Np) – Connect LIVE wire to terminal (Lp) – Connect EARTH wire to earth bracket

5. Appliance Demand (from external wiring centre) (ST2): – Connect SWITCHED LIVE wire to terminal (LR).

NOTICE: Mains supply and system pump ▶ The appliance must have a permanent 230V power

supply to the PCB connections L, N & E.

▶ The system pump must be powered from the pump

connections on the PCB Lp, Np and the earth bracket.

Fig. 35 Wiring detail

Installer connections Connection Function

ST1 230V supply to the appliance

• Live input (L)

• Neutral input (N)

ST2 External pump supply connections and Switched live

(Live Return) to the appliance

•Pump Live (LP)

• Pump Neutral (NP)

• Demand input (LR)

Earth • Earth connection, appliance 230V supply

• Earth connection, external pump supply

NEW COMPLETE SYSTEM INSTALLATIONS

If a new complete heating system is installed 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

, separate time and temperature control for each zone is required. All radiators must have TRVs fitted in all rooms except bathrooms and rooms with thermostats.

EXISTING INSTALLATIONS

For appliance replacements on an existing system, it is not necessary to zone the upstairs and downstairs differently, compliance with the zone requirements can be achieved by a single room thermostat or programmable room thermostat. While the system is drained down, TRVs must be fitted to all rooms except the bathrooms and the room with the thermostat.

6 720 821 670 (2018/06)36

EXTERNAL WIRING CENTRE

NE SLL

Wiring Centre/Junction Box

230V

MAINS SUPPLY

blue

brown

green/yellow

NP LRLP

ST1 ST2

6720644744-26.2Wo

External Pump

90W max

6720804530-11.1Wo

System components wired into terminal strip in accordance with system manufacturers instructions.

Fig. 36 External wiring centre

[\] Earth connection

Appliance connection - ST1:

[L] Permanent Live feed to the appliance [N] Permanent Neutral feed to the appliance

Appliance connection - ST2:

[LP] External pump Live feed from the appliance [NP] External pump Neutral feed from the appliance [LR] Demand (Live Return), input from wiring centre/junction box to

call the appliance to fire for heating/hot water

Wiring centre/junction box connection :

[L] Permanent Live feed to the wiring centre/junction box [N] Permanent Neutral feed to the wiring centre/junction box [E] Earth connection on the wiring centre/junction box [SL] Demand (Switched Live), output to the appliance to fire for

heating/hot water

Refit electric control panel covers: ▶ Refit panel and secure with screws.

COMMISSIONING

6 COMMISSIONING

6.1 PRE-COMMISSIONING CHECKS

WARNING: ELECTRIC SHOCK

▶ ISOLATE THE MAINS SUPPLIES BEFORE STARTING

ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS

▶ Check that the gas service pipe and water pipes are connected to the

correct position on the manifold.

1. Gas inlet (22mm)

2. Flow (22mm)

3. Return (22mm)

Fig. 37

▶ Check the gas type specified on the identification plate (1) matches

that of the gas supply.

6 720 821 670 (2018/06) 37

Fig. 38 Data plate location

▶ Turn on the main gas supply, check the gas pipe work, connections

and rectify any leaks.

COMMISSIONING

6720644744-29.1Wo

25mm

6720804530-12.1Wo

NOTICE: Do not use solvents, adhesive or lubricant when pushing the pipe onto the rubber connector.

▶ Check that the condensate pipe has been connected to the syphon. ▶ Ensure that the condensate pipe has been inserted at least 25mm into

the elbow

Fig. 39 Condensate connection

If the appliance is not to be commissioned immediately then, after successfully completing all of the checks and any rectification work, shut off the gas and water supply and electrically isolate the appliance.

6.2 FILLING THE SYSTEM

Open vented systems: ▶ Ensure all system and appliance drain points are closed. ▶ Open all radiator valves. ▶ Turn on the water supply to the system header tank and allow the

system to fill.

Sealed systems: ▶ Fill the system via a WRAS approved filling loop to 1 bar then turn the

valve anti-clockwise to close.

Opened vented and sealed systems: ▶ Vent (1) any air from the appliance heat exchanger using a suitable

container to collect any water. Ensure tube outlet (2) is directed away from the fan or any other electrical component to prevent any water damage. Also place a suitable cover over the fan to prevent any spillage of water on to electrical connections. Ensure the cover is removed after venting.

▶ Vent all radiators and the primary side of the hot water cylinder,

tighten when completed and check the system and correct any leaks.

Sealed systems only: ▶ If required increase system pressure back to 1 bar. ▶ Isolate and remove filling loop connection to system.

6.3 WATER TREATMENT

NOTICE:

▶ ARTIFICIALLY SOFTENED WATER MUST NOT BE

USED TO FILL THE CENTRAL HEATING SYSTEM.

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 devices that do not adjust or alter the pH levels of the water. With these devices it may not be necessary to provide an untreated water by-pass to the primary water filling point of the heat system.

ENSURE THAT THE SYSTEM HAS BEEN CLEANED AS ON PAGE 30 OF THESE INSTRUCTIONS.

FLUSHING (Central Heating):

▶ Switch off the appliance. ▶ Open all drain cocks and drain the system while the appliance is hot. ▶ Close drain cocks and add a suitable flushing agent at the correct

strength for the system condition in accordance with the manufacturer's instructions.

▶ Run the appliance/system at normal operating temperature for the

time stated by the manufacturer of the flushing agent.

▶ Drain and thoroughly flush the system to remove the flushing agent

and debris.

INHIBITOR (Central Heating):

▶ Check drain cocks are closed and all radiator valves are open before

adding a suitable inhibitor compatible with aluminium (or combined inhibitor/anti-freeze if the system is exposed to freezing conditions) to the heating system water in accordance with the manufacturers instructions.

The pH value of the system water must be less than 8 or the appliance guarantee will be invalidated.

▶ Fill system as described in section 6.2. ▶ Set all controls to maximum. ▶ Record the date when the inhibitor was added to the system on the

guarantee card.

Fig. 40 Venting

NOTICE:

▶ The concentration of inhibitor in the system should be

checked every 12 months or sooner if system content is lost.

▶ 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 micro leak have

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

6 720 821 670 (2018/06)38

COMMISSIONING

MIN

RESET

MAX

max

min

MIN

RESET

MAX

reset

6720644744-30.1Wo

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 31

6.4 STARTING THE APPLIANCE

CAUTION: RUNNING THE APPLIANCE

▶ Never run the appliance when the appliance/system is

empty or partially filled.

6.4.1 APPLIANCE CONTROLS

NOTICE: RESET

▶ Do not press the blue power indicator to reset the

appliance.

3. To reset the lockout turn the appliance thermostat control to minimum, then passed minimum where the control knob will click at reset position, wait 5 seconds then turn to maximum. The appliance will be reset.

6.5 COMMISSIONING

Having checked: ▶ That the appliance has been installed in accordance with the

installation instructions.

▶ The integrity of the flue system and flue seals, as described in

section 7.3 of this manual.

▶ The integrity of the appliance combustion circuit and relevant seals.

6.5.1 CHECKING THE GAS INLET PRESSURE

The inlet pressure to the appliance must be checked using the following procedure:

MEASURING THE INLET PRESSURE

6720643895-53.1Wo

Fig. 42 Inlet pressure test point

▶ Close gas isolation valve. ▶ Slacken the screw in the inlet pressure test point (1) and connect a

manometer.

Fig. 41 Appliance controls

Switching the appliance ON/OFF: ▶ Turn on mains power, the power ON indicator (2) illuminates BLUE.

▶ Turn on any external controls ▶ Set the thermostatic radiator controls to maximum temperature ▶ Set the clock/programmer to continuously ON and the room

thermostat to maximum temperature

1. Turn Power ON/OFF knob (1) from 0 (OFF position) to I (ON position), after two seconds the Power ON indicator (2) illuminates.

1Power ON/OFF knob 2 Power ON and fault indicator (Blue) 3 Central heating temperature control 4 Burner indicator (Green)

Table 32 Control panel legend

▶ Open gas isolation valve. ▶ Measure the pressure with the appliance running at maximum.

– Refer to section 7.4 to set the appliance to maximum output. – The appliance will stay at maximum for 15 minutes. – Return the appliance to normal after the checks.

▶ Check the gas supply working pressure at the gas valve conforms to

values shown in Fig. 43 or Fig. 44 .

2. Turn the appliance CH temperature control (3) to maximum. The burner on indicator (4) illuminates GREEN when the burner has lit.

▶ If the appliance fails to light and the appliance goes to flame lock-out,

the BLUE power indicator (2) will flash.

6 720 821 670 (2018/06) 39

COMMISSIONING

Meter

Boiler inlet

Gas Control

valve

19 - 23 mbar

18 - 22 mbar

16.5 - 20.5 mbar

1 mbar

drop

1.5 mbar drop

Natural Gas

< 2.5mbar difference

6720644744-44.2Wo

GAS PRESSURE WITHIN THE SYSTEM

Refer to the figures below for natural gas or L.P.G gas pressures. The pressure at the appliance must not be less than the pressure read at

the meter minus:

•1mbar for Natural Gas

•2.5mbar for LPG The pressure drop from the meter to the gas valve must not be more

than:

• 2.5mbar for Natural Gas

•4mbar for LPG If the pressure drops are greater than shown below, then this would

indicate a problem with the pipe work or connections within the system.

6.5.2 Checking the gas rate

▶ The gas rate should be measured at the gas meter after 10 minutes

operation at maximum. See technical data section at the front of this manual.

▶ Where a gas meter is not available (e.g. LPG) the CO/CO

checked to the units shown in the setting of the air/gas ratio, refer to section 7.6.

▶ If pressure and gas rate are satisfactory press the service button and

the appliance will return to normal operation. – If left in the service mode the control will return to normal operation

after 15 minutes. ▶ 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.

must be

6.6 CO AND COMBUSTION CHECKS

The following combustion and flue integrity checks are mandatory from April 2014 and these values must be recorded on the Benchmark check list, at the back of this manual.

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, refer to section 7.3, page 45

• Flue gas analysis, refer to section 7.5, page 46

Fig. 43 Natural gas pressures

≤ Equal to or less than .....

Regulator

L.P.G. < 4.0mbar difference

32 - 45 mbar

Boiler inlet

2.5 mbar drop

29.5 - 42.5 mbar

Fig. 44 LPG pressures

NOTICE:

Do not continue commissioning until the correct gas pressure is achieved.

1.5 mbar drop

Gas Control

valve

28 - 41 mbar

6720644744-45.2Wo

NOTICE: BEFORE CO AND COMBUSTION CHECKS: ▶ Refer to section 6.5.1 and 6.5.2 to verify gas type,

gas inlet pressure, and gas rate. 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 gas valve is factory set and must not be adjusted

during commissioning if found to be out of tolerance, please contact the Worcester, Bosch Group help line 0330 123 3366.

6 720 821 670 (2018/06)40

COMMISSIONING

Yes

Set boiler to

minimum rate.

Check all seals around the burner, internal flue seals,

and case seals.

Rectify where necessary.

Turn off boiler and

call Worcester, Bosch

Group help line.

0330 123 3366

Boiler is operating

satisfactorily.

No further action

is required.

Verify flue integrity

O2 ≥ 20.6%

< 0.2%

O2 ≥ 20.6%

< 0.2%

Yes

Check CO and combustion ratio at maximum rate

Check CO and combustion

ratio at minimum rate

CO < 350ppm

CO/CO

ratio

< 0.004

CO < 350ppm

CO/CO

ratio

< 0.004

CO < 350ppm

CO/CO

ratio

< 0.004

Flue integrity test

using analyser

Yes

Set boiler to

maximum rate.

START

HERE

6720809056-01.2Wo

Zero the analyser

in fresh air.

See notice above

Record values.

Do not adjust the gas valve.

≥ =

greater than or equal to

< =

less than

Fig. 45 Combustion check flow chart

6 720 821 670 (2018/06) 41

COMMISSIONING

6.7 FINISHING COMMISSIONING

6.7.1 REPLACE THE OUTER CASE:

Replace outer casing making sure that the securing points are properly located.

1. Replace top two screws.

2. Re-tighten bottom two screws.

6720644744-33.1Wo

Fig. 46 Replacing outer case

6.7.2 INSTALL THE BOTTOM PANEL

The cut out in the bottom panel fits easily over the syphon elbow and outlet, however care should be taken not to disturb any sealed components.

1. Hook the lip at the back of the bottom panel over the angled edge at the base of the connections manifold.

2. Push up into position.

3. Secure in position the screw provided.

6.7.3 HAND OVER

▶ 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 at the pressure gauge.

– location of the filling loop and system pressure gauge. – the use of the filling loop and how to re-pressurise the system. – where to find and store the filling loop key, if necessary. – how to set the TRVs. – how to reset the appliance.

▶ Show the customer the fault finding information in the User

instructions.

▶ 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 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.

Fig. 47 Bottom panel

6720644744-34.2Wo

6 720 821 670 (2018/06)42

6.7.4 Appliance guarantee

This appliance 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, please visit our website www.worcester-bosch.co.uk.

• 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 Greenstar appliance carries a guarantee against faulty material or manufacture subject to Terms and Conditions. Guarantee Registration can be completed:

• On-line – You can register on our website:

www.worcester-bosch.co.uk/guarantee

•By phone

– You can register by ringing 0330 123 2552

•By post – Please send your completed form to:

Worcester, Bosch Group, Cotswold Way, Warndon, Worcester, WR4 9SW.

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.

SERVICE AND SPARES

7 SERVICE AND SPARES

7.1 INSPECTION AND SERVICE

CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE

THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.

NOTICE: COMPONENTS. ▶ After replacement of any components always check

for gas tightness where relevant and carry out functional checks as described in Commissioning. Damaged O-rings or gaskets must be replaced.

NOTICE: Service work ▶ Service work must be carried out by a competent

engineer, such as Gas Safe registered personnel!

NOTICE: FLUE GAS ANALYSER ▶ Service work must not be attempted if a flue gas

analyser is not available.

• To ensure the continued efficient operation of the appliance it must be checked at regular intervals.

• The frequency of servicing will depend upon the par ticular installation conditions and usage however, an annual service is recommended.

• The extent of the service required by the appliance is determined by the operating condition of the appliance when tested by fully qualified engineers.

• The service interval record sheet at the rear of these instructions must be completed after each service.

INSPECTION

1. Check that the terminal and the terminal guard, if fitted, are clear and undamaged.

2. If the appliance is in a compartment or cupboard check that the specified service space around the appliance is clear.

3. Check all the joints and connections in the system and remake any that show signs of leakage. Refill and re-pressurise if applicable as described in Commissioning, section 6.2.

4. Operate the appliance and take note of any irregularities. Refer to Fault Finding on page 58 for rectification procedures.

6 720 821 670 (2018/06) 43

SERVICE AND SPARES

COMPONENT ACCESS

Removing outer case

1. Undo and remove two screws securing appliance casing at the top of the appliance.

2. Undo but do not remove the two screws securing appliance casing at the bottom of the appliance.

▶ Pull case forward and remove.

LOWERING THE APPLIANCE CONTROLS TO THE SERVICE POSITION:

1. Remove two screws securing the control.

2. Pull the control forward.

3. Lower the control to align the slots at the top of the control with the lugs on the appliance framework.

4. Hang control on two lugs on appliance framework.

Fig. 48 Remove outer case

6720644744-35.1Wo

6720644744-36.1Wo

Fig. 49 Control panel into service position

7.2 CHECKING GAS INLET PRESSURE

Refer to section 6.5.1 for checking the gas inlet pressure

NOTICE:

▶ Do not continue with the other checks if the correct

gas inlet pressure can not be achieved.

6 720 821 670 (2018/06)44

SERVICE AND SPARES

6720643895-67.1Wo

6720644744-37.1Wo

6720644744-31.1Wo

MAX

MIN

NORM

MAX

MIN

NORM

7.3 CHECKING FLUE INTEGRITY

The integrity of the flue system and performance of the appliance can be checked via the flue turret sample points.

Flue gas sample point 1 Air inlet sample point 2

Table 33 Key to figure 50

Fig. 50 Flue test points

▶ With the appliance case on and the appliance running at maximum. ▶ Insert the analyser probe into the air intake test point. ▶ 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, e.g. missing or dislodged seals.

7.4 FAN PRESSURE TEST

This test is to determine if the heat cell requires

cleaning/attention.

SETTING THE APPLIANCE TO MAXIMUM

1. Remove the three screws retaining the control cover.

2. Remove the control cover.

3. Remove the plastic tool clipped inside the cover.

4. Insert the tool into the switch.

5. Using the tool set the mode switch to maximum output (MAX). Ensure the appliance is powered up and there is a demand from the

external controls. The power indicator will flash and the appliance will stay in this mode f or

15 minutes if no further change is made to the switch.

Fig. 52 Setting the appliance to maximum

Fig. 51 Flue integrity test

6 720 821 670 (2018/06) 45

SERVICE AND SPARES

6720804530-13.1Wo

NG Boilers

LPG Boilers

-6

-5

-4

-3

-2-1

-8

-7

mbar

FAN PRESSURE TEST

Clean the Heat Ex.

Heat Ex. ok

-3.921kW:

-8.218kW:

-4.924kW:

9kW:

-2.2

12kW:

-3.7

15kW:

-5.9

6720644744-39.2Wo

-6

-5

-4

-3

-2-1

-8

-7

mbar

-3.421kW:

-7.518kW:

-4.324kW:

9kW:

-2.1

12kW:

-3.4

15kW:

-5.4

6720644744-40.1Wo

6720804530-14.1Wo

FAN PRESSURE TEST

Fig. 53 Fan pressure test

▶ Remove the cover and connect a digital manometer to the fan

pressure test point. ▶ The pressure will read negative, refer to the chart in figure 54. ▶ After measurement replace test point cover and return mode switch

to normal. ▶ Replace the control cover. ▶Replace outer case.

NOTICE:

The appliance must be run at maximum output for Fan Pressure test and the Flue Gas analysis.

3. Clean the sump with a suitable brush. ▶ Check the exhaust path and flue for restriction.

▶ Re-check the Fan Pressure readings

Fig. 55 Sump access

7.5 FLUE GAS ANALYSIS

COMBUSTION TEST:

Ensure that the gas inlet pressure has been checked and is satisfactory, refer to section 6.5.1

▶ Connect the flue gas analyser to the flue gas sampling point as shown

in the figure below. ▶ Run the appliance at maximum output for at least 10 minutes. ▶Check the CO/CO

CO2 settings on page 47.

readings against the information in table 34 CO/

Fig. 54 Fan pressure readings

If the appliance fails the fan pressure test then before adjusting the air/ gas ratio, try the following: ▶ Check the syphon is not blocked.

1. Remove the screws securing the sump cover.

2. Remove the sump cover.

Fig. 56

If the appliance fails the combustion test, check:

1. Air intake for restriction

2. Diaphragm in the fan, for correct operation

3. Cleanliness of the heat cell, plus blockages in the condensate

disposal.

6 720 821 670 (2018/06)46

SERVICE AND SPARES

6720643895-66.1Wo

MAX

MIN

2.5 mm

4 mm

6720643895-72.1Wo

6720643895-60.1Wo

7.6 SETTING THE AIR/GAS RATIO

NOTICE: THE SETTING OF THE GAS RATIO MUST BE

CARRIED OUT BY A COMPETENT PERSON. SETTING OF THE GAS RATIO MUST NOT BE ATTEMPTED UNLESS THE PERSON CARRYING OUT THE TEST IS EQUIPPED WITH A COMBUSTION ANALYSER CONFORMING TO BS 7927 AND IS COMPETENT IN ITS USE.

7.6.1 Setting the CO/CO

▶ Refer to section 7.2 and ensure that the gas inlet pressure is correct

before continuing.

▶To adjust the CO/CO

appliance at maximum output.

▶ Refer to section 7.4 for setting the appliance to maximum and

minimum output.

▶ Refer to table 34 and check the CO/CO

the maximum CO/CO

2.5mm Allen key.

▶ Check CO is less than 200ppm. ▶Set the control to minimum (MIN). ▶ The appliance will go to minimum power. ▶ Measure the CO/CO

If required set the minimum CO/CO2 via adjuster (2) on the gas valve until the correct measurement is set:

– Remove dust cap with flat bladed screw driver.

– Using a 4mm Allen key adjust CO

– Replace the dust cap. ▶ Check that the CO is less than 200ppm. ▶ Return the appliance control to maximum and re-check the CO/CO

If correct, set the appliance control to normal “NORM”. ▶ Re-fit the control cover ▶ Re-fit appliance outer case.

it will be necessary to first operate the

at maximum. If required set

via adjuster (1) on the gas valve using a

and check against table 34.

7.7 CLEANING THE HEAT EXCHANGER

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 Combustion Analyser conforming to BS 7927 and is competent in its use.

NOTICE: CO/CO2 CHECKS ▶ If the joint between the Air/Gas manifold and heat

exchanger is disturbed, replace the sealing gasket.

▶ After completing the service of the appliance, the

CO/CO

must be checked and set to the limits shown

in “Setting the air/gas ratio” on page 47.

There is a special accessory kit available specifically designed for cleaning the heat exchanger. If required order 7 716 192 312.

▶ Isolate the power to the appliance and remove outer case and base

panel.

1. Refer to figure 58 and remove the clip from gas valve outlet.

If the plastic elbow can not be easily removed, undo the nut to push the plastic elbow out of the fitting.

2. Pull the gas outlet elbow free from the gas valve.

Fig. 57 Gas valve adjustment

CO/CO2 values CO/CO2 should be measured after 10 minutes.

Gas type CO2 max. CO2 min. Natural gas: 9 - 21kW outputs 9.6% ± 0.5 8.6% ± 0.5 Natural gas: 24kW output 9.55% ± 0.5 8.55% ± 0.5 LPG: All outputs 10.5% ± 0.5 10% ± 0.5 NOTE: When checking an existing appliance the tolerance is ± 0.5. If checking after cleaning or component replacement or for adjustment

when the reading obtained is outside the tolerances given above, then the tolerance is ± 0.2.

CO - less than 200 ppm (0.002 ratio)

Table 34 CO/CO

settings

Fig. 58 Gas valve connection

▶ Remove electrical connector and earth wire from fan.

To prevent damage to the electrodes when removing the air/gas manifold, disconnect the leads to the electrodes.

▶ Disconnect spark electrode and flame sensor connections.

1. Refer to figure 59 and undo the securing nut on the top of the heat exchanger and remove the retaining plate assembly.

Fig. 59 Securing nut

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6720643895-61.1Wo

6720643895-64.1Wo

6720644744-40.1Wo

1. Refer to figure 60 and rotate fan and air/gas manifold assembly around the top of the heat exchanger until it stops at the lug.

▶ Lift up assembly and remove from appliance.

2. Remove the cover panel by removing retaining screw.

Fig. 60 Rotate air/gas manifold

BURNER REMOVAL

Refer to figure 61

1. Remove clamping plate.

2. Remove spark/flame electrode assembly and seal from the top of the heat exchanger.

3. Remove burner.

BAFFLE REMOVAL

1. Refer to figure 62and remove top baffle.

2. Remove lower baffle.

If the lower baffle is stuck, it may be necessary to use the “Baffle removal tool” from the heat exchanger cleaning kit - 7 716 192 312, as shown in figure 62.

Fig. 61 Burner removal

Checking and cleaning the electrode assembly:

NOTICE: Cleaning

▶ Inspect the condition of the electrodes and ceramics, replace if

necessary.

▶ Use a plastic scouring pad to clean the electrodes.

▶ Do not use wire wool to clean the electrodes

Fig. 62 Baffle removal

ACCESS COVER REMOVAL

Refer to figure 63.

1. Remove the two pozi-drive screws

2. Remove the access cover

3. Remove the gasket.

Fig. 63 Access cover removal

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6720644744-42.1Wo

CLEANING THE PRIMARY HEAT EXCHANGER

▶ Refer to figure 64 and access the heat exchanger flue ways by

inserting the cleaning brush (7 716 192 312) through the top access hole in the casing, removal of panel shown in figure 60.

▶ Clean heat exchanger flue ways using the cleaning brush removing any

debris from the access point in the sump. ▶ Clean around the sealing surface on the sump. ▶ Replace the access cover. ▶ Using a suitable container to collect water from syphon connection at

the base of the appliance flush heat exchanger with water. ▶ Re-assemble ensuring that the lower baffle (2) and the top baffle (1)

are refitted correctly. ▶ Refer to figure 61 when re-fitting the burner to ensure that it fits

centrally within the heat exchanger and location tabs are situated in

location holes. ▶ Ensure that the seal is replaced with a new seal and ensure that the

seal is correctly fitted.

– For full details on refitting the seal and clamping plate assembly

see section 7.8.11, Re-assembly of the burner clamping plate. ▶ Check the syphon unit is clean before refitting to appliance. ▶ Reassemble and check combustion as stated in “SETTING THE AIR/

GAS RATIO” section on page 47.

The heat exchanger does not need to be removed to clean. The heat exchanger is shown removed from the

appliance to illustrate cleaning more clearly.

NOTICE: CO/CO2 CHECKS ▶ If the joint between the Air/Gas manifold and heat

exchanger is disturbed, replace the sealing gasket.

▶ After completing the service of the appliance, the

CO/CO

must be checked and set to the limits shown

in “Setting the air/gas ratio” on page 47.

▶ When replacing the burner gasket ensure that the

clamping plate is fully tightened down to the heat exchanger.

7.7.1 SYPHON REMOVAL AND CLEANING

Remove the syphon assembly to clean.

To release the syphon from the sump:

1. Undo the plastic nut on the bottom of the syphon and move the condensate pipe away from the syphon.

2. Remove the two screws retaining the syphon bracket.

3. Remove the bracket.

4. Remove the screw and release the syphon retaining clamp

5. Swing the clamp completely to the left away from the syphon

6. Pull the syphon towards you and remove from the sump connection.

▶ Empty the contents of the syphon into a suitable container. ▶ Flush the syphon through with clean water

Fig. 65 Syphon removal

Fig. 64 Cleaning heat exchanger

NOTICE: Heat exchanger baffles. The baffles (1) and (2) must be refitted into the heat exchanger in the order shown in figure 62. Failure to do

so may result in damage to the appliance.

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6720644744-34.1Wo

6720644744-35.1Wo

7.8 REPLACEMENT OF PARTS

CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE

THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.

NOTICE: REPLACEMENT OF COMPONENTS. ▶ After replacement of any components always check

for gas tightness where relevant and carry out functional checks as described in Commissioning. Damaged O-rings or gaskets must be replaced.

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 in the Spares Booklet.

7.8.1 REMOVING THE OUTER CASING

▶ Remove bottom tray by pressing the tabs (2) in, at the front underside

of the appliance. ▶ Lower the panel. ▶ Pull the panel forward, off the retaining ledge (1) at the back of the

appliance.

1. Undo the two screws securing the top of the appliance casing.

2. Undo the two screws securing the bottom of the appliance casing. ▶ Pull case forward and remove.

Fig. 66 Remove bottom panel

Fig. 67 Remove outer case

7.8.2 PRIMARY SENSOR (CH NTC)

To gain access to the following components the outer case has to be removed:

▶ Primary sensor ▶ Overheat thermostat ▶ Flue limit thermostat

Refer to figure 68 for removal.

1. Remove electrical connection by pulling upwards. Squeeze retaining clip on plastic moulding of sensor and pull back and up until clear of pocket in heat exchanger.

2. Pull forward to remove completely.

▶ Coat new sensor with heat conductive paste and replace.

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6720644744-47.1Wo

6720643895-70.1Wo

7.8.3 OVERHEAT THERMOSTAT

Refer to figure 68 for removal. ▶ Remove two electrical connectors from thermostat.

3. Slacken and remove fixing screw and thermostat (3). ▶ When replacing ensure thermostat sits correctly on surface of the

casting with the left hand side of thermostat sitting up against the shoulder.

It is essential that the mating surface of the thermostat is coated with heat conductive paste.

7.8.4 FLUE OVERHEAT THERMOSTAT (WITH GROMMET)

To remove and replace the thermostat either: ▶ Using a small terminal screwdriver, prise the thermostat and grommet

from the plastic housing. Take care not to damage the plastic housing.

-or-

1. Release the flue connection from the sump.

2. Push the flue tube up.

Fig. 68 Primary sensor and overheat thermostat

Fig. 69 Lower exhaust section

▶ Remove electrical connections.

1. Push the flue limit thermostat in from the sump.

▶ Retrieve the thermostat from the sump well.

Fig. 70 Remove thermostat

To replace, push the thermostat and new grommet gently back into the opening until contact with the locating ridge is felt.

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6720644744-36.1Wo

6720643895-73.1Wo

6720804530-15.1Wo

7.8.5 LOWERING THE APPLIANCE CONTROLS TO THE SERVICE POSITION:

1. Remove two screws securing control.

2. Pull the control forward.

3. Lower the control to align the slots at the top of the control with the

lugs on the appliance framework.

4. Hang control on two lugs on appliance framework.

1. Refer to figure 73 and undo bottom gas connection to gas valve.

2. Undo two securing screws on the underside of casing. ▶ Disconnect electrical connections.

▶ Pull valve up and forward out of appliance. ▶ Replace valve with new seals and check for gas tightness.

Fig. 73 Gas valve lower connection

NOTICE: The valve will require setting; follow procedure “Setting the air/gas ratio”.

7.8.7 AIR/GAS MANIFOLD AND FAN ASSEMBLY

Fig. 71 Control panel into service position

7.8.6 GAS VALVE

▶ Isolate gas supply at appliance gas cock.

1. Refer to figure 72 and remove the wire clip from the gas valve outlet.

2. Pull the gas pipe free from the gas valve.

If the pipe will not pull out, unscrew the nut to aid removal.

The following components require the air/gas manifold and fan assembly to be removed:

▶ Fan electrode assembly ▶Burner ▶ Heat exchanger

NOTICE:

▶ If the joint between the Air/Gas manifold and heat

exchanger is disturbed sealing gasket must be replaced.

▶ After re-assembly the combustion must be checked

using the procedure in the section “Setting the Air/ Gas ratio”. Measurement and setting (if necessary) of the gas ratio must not be attempted unless the person is equipped with a combustion analyser conforming to BS 7927 and is competent in its use.

▶ Remove electrical connector and earth wire the from fan. ▶ Remove wire clip from gas valve outlet then pull gas pipe free from the

gas valve (see figure 72).

Fig. 72 Gas valve upper connection

6720643895-72.1Wo

Fig. 74

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6720643895-81.1Wo

▶ Undo the securing nut at the top of the heat exchanger and remove the

retaining plate assembly (1).

Disconnect spark electrodes and flame sensor connection. This will prevent damage to the electrodes and sensor when the air/gas manifold is rotated.

1. Rotate fan and air/gas manifold assembly (1.) around the top of the heat exchanger until the lug on the air/gas manifold is visible.

▶ Lift up assembly and remove from appliance.

Fig. 75 Rotate the air/gas manifold assembly

NOTICE: After re-assembly, check the CO/CO2 levels as described in section 7.6 Setting the air/gas ratio.

7.8.8 AIR PRESSURE SWITCH

1. Remove the two screws retaining the pressure switch to the bracket.

2. Refit the new Air pressure switch to the bracket.

Fig. 77 Air pressure switch bracket

NOTICE: After re-assembly, check the CO/CO2 levels as described in section 7.6 Setting the air/gas ratio.

7.8.9 FAN

▶ Remove the air/gas manifold from the appliance as described in the

previous section.

1. Remove two screws retaining the fan to the air/gas manifold.

2. Remove the air/gas manifold.

3. Remove the screw holding the retaining plate.

4. Remove the retaining plate.

5. Remove three screws and the mixing chamber. Re-assemble with new fan ensuring seals are correctly fitted.

NOTICE: Pressure switch ▶ Ensure that the tube is reconnected to the pressure

switch

1. Remove the electrical connections.

2. Slacken the top retaining screw and remove the bottom screw.

3. Disconnect the tube.

4. Remove the Air pressure switch assembly

Fig. 78 Dismantling the air/gas manifold assembly

Fig. 76 Air pressure switch

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6720643895-117.1Wo

6720643895-61.1Wo

FLAP VALVE ASSEMBLY

1. Twist the mounting flange clockwise to release.

2. Pull mounting flange off the flap valve assembly.

3. Pull rubber flap off flap valve assembly. ▶ To replace the flap valve:

– Press the two lugs on the back of the flap into the two slots in the

flap valve assembly.

Fig. 80 Electrode assembly and burner

7.8.11 RE-ASSEMBLY OF THE BURNER CLAMPING PLATE

Fig. 79 Flap valve assembly

7.8.10 ELECTRODE ASSEMBLY AND BURNER

▶ Refer to figure 80 and disconnect spark electrodes and flame sensor

connection.

▶ Remove clamping plate.

1. Remove spark/flame electrode assembly from heat exchanger.

2. Remove the seal from the top of the heat exchanger.

3. Remove the burner. ▶ Replace new burner in correct position.

▶ Ensure that burner tabs, as shown in figure 80, fit correctly their

respective locations.

NOTICE: Heat exchanger seal ▶ If the joint between the Air/Gas manifold and heat

exchanger is disturbed sealing gasket must be replaced.

▶ After re-assembly the combustion must be checked

using the procedure in the section 7.6 “Setting the Air/Gas ratio”.

▶ Ensure that the seal is fitted.

CAUTION: Clamping plate ▶ Ensure that the clamping plate is firmly tightened

▶ Replace the clamping plate.

down on top of the heat exchanger.

NOTICE: Heat exchanger seal ▶ If the joint between the Air/Gas manifold and heat

exchanger is disturbed the sealing gasket must be replaced.

▶ After re-assembly the combustion must be checked

using the procedure in the section 7.6 “Setting the Air/Gas ratio”.

▶ Ensure that the new gasket is fitted, with the electrode assembly and

gasket heat shield

CAUTION: Clamping plate ▶ Ensure that the clamping plate is firmly tightened

down on top of the heat exchanger.

▶ Locate the edge of the clamping plate [7] under the bracket [4] and

fit the retaining plate [1] hand tight ▶ Ensure that the retaining plate [1] is in the position shown in figure 81 ▶ At this point the Air/Gas Manifold/Fan assembly [8] should be fitted,

engage the lugs in the slots in the clamping plate and rotate clockwise

to the stop position. ▶ Rotate the retaining plate assembly [1] in the slot on the clamping

plate [2], this will prevent the Air/Gas manifold [8] rotating back ▶ Initially there will be a gap between the clamping plate and the top of

the heat exchanger, refer to figure 81

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Fig. 82 Clamping plate detail

6720802047-05.1Wo

6720802047-03.1Wo

Fig. 81 Initial location of the clamping plate

[1] Retaining plate assembly [2] Clamping plate [3] Gasket [4] Bracket [5] Underside view of the clamping plate [6] Mating surface [7] Location edge [8] Air/Gas manifold assembly

▶ Tighten the nut on the retaining plate assembly [1] until the underside

face of the clamping plate mates with the top of the heat exchanger as indicated by the two arrows in figure 83 Refer to figure 82 for detail of the clamping and mating surface [6]

▶ It is important to clamp the plate down firmly, without over tightening,

to the heat exchanger to ensure a gas tight seal

Fig. 83 Clamping plate secured

7.8.12 HEAT EXCHANGER

▶ Drain the system. ▶ Remove syphon. ▶ Remove the air/gas manifold and fan.

1. Refer to figure 84, remove the clip from the elbow on the flow pipe.

2. Pull flow pipe away from heat exchanger.

Fig. 84 Flow pipe removal

6 720 821 670 (2018/06) 55

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1. Refer to figure 85 and re move the three screws securing the turret to the top of the appliance.

2. Turn the upper exhaust connector anti-clockwise to release from the hook.

3. Pull the upper exhaust connector down.

Fig. 85 Upper exhaust assembly

1. Refer to figure 86 and release the clip.

2. Move the lower exhaust connector up

▶ Remove the complete exhaust assembly.

1. Refer to figure 88 and lift the heat exchanger up to clear.

2. Pull the heat exchanger forward from the case.

Fig. 88 Heat exchanger removal

▶ Reassemble and check combustion as stated in the air/gas ratio

section. 7.6.

NOTICE: CO/CO2 CHECKS ▶ If the joint between the Air/Gas manifold and heat

exchanger is disturbed sealing gasket must be replaced.

▶ After completing the service of the appliance, the

CO/CO2 must be checked and set to the limits shown in “Setting the air/gas ratio” in section 7.6.

Fig. 86 Release lower exhaust connection

1. Refer to figure 87 and unscrew the plastic nut.

2. Remove the nut from the bottom of the appliance.

3. Rotate lever to release the return pipe.

7.8.13 SYPHON REMOVAL

To release the syphon from the sump:

1. Undo the plastic nut on the bottom of the syphon and move the condensate pipe away from the syphon.

2. Remove the two screws retaining the syphon bracket.

3. Remove the bracket.

4. Remove the screw and release the syphon retaining clamp

5. Swing the clamp completely to the left away from the syphon

6. Pull the syphon towards you and remove from the sump connection.

Fig. 87 Sump connections

Fig. 89 Syphon removal

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7.8.14 ACCESS TO ELECTRICAL CONTROL PANEL

▶ Remove three screws retaining the control cover (1). ▶ Remove the control cover[1].

Fig. 90 Electrical control panel access

7.8.15 PCB FUSE AND CODE PLUG

PCB fuse and spare fuse ▶ Remove fuse holder with fuse F1 (1) from the control and replace

with a new fuse.

A spare 2A fuse (3) for F1 is clipped onto the inside of the cover.

7.8.16 PCB

▶ Remove two screws securing the control. ▶ Pull the control forward. ▶ Lower the control to align the slots at the top of the control with the

lugs on the appliance framework.

▶ Hang control on two lugs on appliance framework. ▶ Unscrew the three screws in the control panel.

▶ Remove the connections cover and disconnect all electrical

connections from the control. ▶ Gently pull the code plug from the socket (2), Figure 91. ▶ The code plug shoul d be left attached to the frame of the appliance by

its plastic safety thread.

▶ Remove the control from the appliance. ▶ Remove the four screws (3) retaining the rear panel (1) of the

control. ▶ Remove the rear panel (1). ▶ Remove the printed circuit board.

Code plug ▶ Gently pull the code plug from the socket (2).

▶ The code plug should be left attached to the frame of the appliance by

its plastic safety thread.

6720821670-02.1Wo

Fig. 91 PCB fuse and code plug location

Fig. 92 PCB

▶ Refit the code plug [4] into the new control board. ▶ Re-assemble in reverse order.

NOTICE: CODE PLUG ▶ Ensure that the code plug is fitted to the new control. ▶ The appliance will indicate an error and will not

function correctly if the code plug is not fitted.

NOTICE: CO/CO ▶ After completing the service of the control, the CO/

must be checked and set to the limits shown in

“Setting the air/gas ratio” in section 7.6.

6720821670-03.1Wo

6 720 821 670 (2018/06) 57

FAULT FINDING AND DIAGNOSIS

8 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.

• 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.

6 720 821 670 (2018/06)58

8.1 Fault finding

Blue light indication

No light No power at control

Light ON Appliance ON but not

Slow flash (mostly off, flashes on)

Slow flash (mostly on, flashes off)

Fast flash Volatile lockout (sensor,

2 pulses ▶Check

5 pulses ▶Check

Table 35 Fault finding

Fault Possible solution/check

▶Check

board

– Mains supply voltage to the appliance. – Appliance mains switch is ON.

– Fuse F1 - 2A Slow blow. ▶ Replace control board. ▶Check

operating during demand

– Live demand at ST2 terminal (L

– Manual bypass is open.

– If Central Heating is working, check Hot Water controls.

– If Hot Water is working, check Central Heating controls (i.e. external diverter valve, room

thermostat/programmer, frost thermostat).

▶ Replace control board.

Ignition lockout ▶Check

– Gas present and at the correct pressure?

– Gas valve:

• Is there 29V d.c. to each solenoid?

• The resistance of each solenoid ( 9.3.4). – Combustion CO2 level. – Blockage or restriction in the flue. – Gas valve adjustment. – Ignition electrodes/harness/connections.

• Condition and resistance of the leads (approximately 2,100 Ω).

▶ Replace control board.

Flue overheat Flue temperature too high.

▶ Check heat exchanger baffles are correctly fitted or removed and not refitted

Heat exchanger overheat ▶Check

– Water pressure. – All air is vented. – Pump/harness/connections. –Water leaks/blockage. – Safety thermostats/low voltage wiring harness/connections. – Blocked heat exchanger.

▶ Replace control board.

Flue pressure switch ▶ Check for blockage in the flue system.

▶Check

fan or code plug)

– Temperature sensors:

• Condition and resistance of the leads.

• Resistance of sensor ( 9.3.1). –Fan.

• 230V A.C. across the live (purple) and neutral (brown) – Fan lead continuity. –Code plug.

• Is code plug missing or not inserted properly?

– Service mode switch is in “MIN” position?

▶ Return mode switch to “NORM” position if minimum test mode not required.

– Service mode switch is in “MAX” position?

▶ Return mode switch to “NORM” position if maximum test mode not required.

) - is there a demand?

FAULT FINDING AND DIAGNOSIS

6 720 821 670 (2018/06) 59

OPERATIONAL FUNCTIONS

YES

MAINS

POWER

SUPPLY

BOILER

DEMAND

Fan to

start

speed.

Pump ON.

IGNITION

SEQUENCE

(see detail)

BLUE

LIGHT

BURNER

LIT?

GREEN

FLAME

LIGHT

Stop spark

and gas.

Wait

10 seconds

5th

attempt?

LOCKOUT

45 second

stabilisation

period.

Fan

modulation

to achieve

set

temperature

(40-82°C)

END OF

BOILER

DEMAND

Gas valve

OFF

Pump run 3

minutes

Fan run 30

seconds

Over temperature shut-

down if water tempera-

ture is 5°C above set

value.

Gas valve OFF.

Fan overrun

30 seconds

3 minute pump

over run

Spark

ignition

and gas

4 seconds

YES

Room

thermostat and/or

mains

programmer ON

(or link fitted at

ST10)

AND

Facia mounted

programmer (if

fitted) ON

AND

Temperature

control knob

IGNITION SEQUENCE

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9 OPERATIONAL FUNCTIONS

9.1 Appliance function

Fig. 93 appliance function

6 720 821 670 (2018/06)60

9.2 Protection function

AUTOMATIC INTERNAL FROST FUNCTION

OPERATIONAL FUNCTIONS

Boiler automatic

frost function

(monitors internal boiler

primary temperature)

PUMP OVERRUN FUNCTION

End of boiler demand

(central heating or

domestic hot water)

Pump runs for 3 minutes

to dissipate heat from

the boiler into the system

Internal boiler

temperature

between

8°C & 5°C

Internal boiler

temperature

below 5°C

Pump runs

Central heating

demand is activated

Internal boiler

temperature

rises above 9°C

Internal boiler

temperature

rises above 25°C

Pump switches off

after a 3 minute

overrun period

Central heating

demand switches

off

Pump switches off

after a 3 minute

overrun period

PUMP ANTISEIZE FUNCTION

No central heating

demand after a 24hr period

Fig. 94 Protection function

Pump runs 5 seconds

every 24hrs from

last time pump ran

A central heating demand

activated, pump runs

normally

6720821670-06.1Wo

6 720 821 670 (2018/06) 61

OPERATIONAL FUNCTIONS

9.3 Component Characteristics

9.3.1 Flow temperature (NTC) Sensor resistances

Temperature [ °C ± 10%] Resistance [ Ω]

0 35,975

5 28,516 10 22,763 15 18,279 20 14,772 25 11,981 30 9,786 35 8,047 40 6,653 45 5,523 50 4,608 55 3,856 60 3,243 65 2,744 70 2,332 75 1,990 80 1,704 85 1,464 90 1,262 95 1,093

100 950

Table 36 Flow temperature sensor

9.3.2 Flue overheat thermostat

Normally closed thermostat Temperature [ °C] Resistance [ Ω]

Opening temperature ≥ 112 3,500 Close temperature ≤ 111 6,500

Table 37 Flue overheat thermostat

9.3.3 Overheat thermostat

Normally closed thermostat Temperature [ °C] Resistance [ Ω]

Opening temperature ≥ 120 ≤ 50M Close temperature ≤ 119 5,000

Table 38 Overheat thermostat

9.3.4 Gas valve coil resistances

9.3.5 Code plug numbers

Gas type Appliance Code plug number

Natural Gas 9Ri ErP + 050

12Ri ErP + 051 15Ri ErP + 052 18Ri ErP + 053 21Ri ErP + 054 24Ri ErP + 055

Table 40 Natural Gas code plug numbers

Gas type Appliance Code plug number

LPG 9Ri ErP + 056

12Ri ErP + 057 15Ri ErP + 058 18Ri ErP + 059 21Ri ErP + 060 24Ri ErP + 061

Table 41 LPG code plug numbers

6720821670-04.1Wo

Fig. 95 Gas valve coil resistances

Position Resistance [ Ω ± 10%]

1 Top coil 380 (342 - 418) 2 Bottom coil 190 (171 - 209)

Table 39 Gas valve coil resistances

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Notes

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Notes

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Notes

6 720 821 670 (2018/06) 65

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This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.

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GAS BOILER SYSTEM COMMISSIONING CHECKLIST

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ALL SYSTEMS

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CENTRAL HEATING MODE PHDVXUHDQGUHFRUG

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ALL INSTALLATIONS

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Ratio

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It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.

Service Provider

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SERVICE RECORD

SERVICE 01

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SERVICE 02

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SERVICE 03

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SERVICE 04

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$WPLQUDWH

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SERVICE 05

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$WPLQUDWH

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SERVICE 06

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SERVICE 07

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SERVICE 08

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SERVICE 09

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SERVICE 10

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Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0330 123 9559 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. worcester-bosch.co.uk

6 720 821 670 (2018/06)

WORCESTER, BOSCH GROUP:

TECHNICAL SUPPORT: 0330 123 3366 APPOINTMENTS: 0330 123 9339 SPARES: 0330 123 9779 LITERATURE: 0330 123 9119 TRAINING: 0330 123 0166 SALES: 0330 123 9669

Bosch Worcester Greenstar 21Ri ErP +, Worcester Greenstar 9Ri ErP +, Worcester Greenstar 24Ri ErP +, Worcester Greenstar 18Ri ErP +, Worcester Greenstar 12Ri ErP + Installation And Maintenance Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

KEY TO SYMBOLS AND SAFETY PRECAUTIONS

1.1 KEY TO SYMBOLS

WARNINGS

IMPORTANT INFORMATION

SYMBOLS USED IN THIS MANUAL

PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.

ADDITIONAL SYMBOLS

1.2 SAFETY PRECAUTIONS

2Regulations

Installation regulations

British standards

LPG Installations

Irish Standards

Timber Framed Buildings

Potable Water

CH Water

3 APPLIANCE INFORMATION

3.1 APPLIANCE

3.2 TECHNICAL DATA

3.3 Energy efficiency

Natural Gas appliances

LPG appliances

3.4 APPLIANCE MAIN COMPONENTS

3.5 Internal wiring diagram

4 PRE-INSTALLATION

4.1 MAINS SUPPLY

4.1.1 ELECTRICAL SUPPLY

4.1.2 GAS SUPPLY

4.2 WATER SYSTEMS AND PIPE WORK

PLASTIC PIPE WORK:

PRIMARY SYSTEMS CONNECTIONS/VALVES:

OPEN VENT PRIMARY SYSTEM CONSIDERATIONS:

SEALED PRIMARY SYSTEM CONSIDERATIONS:

SYSTEM FILL

S AND Y PLAN SYSTEMS:

SYSTEM LAYOUTS EXAMPLES:

S PLAN LAYOUT - OPEN VENT

Y PLAN LAYOUT - OPEN VENT

SEALED SYSTEM Y PLAN LAYOUT

NEW BUILD SYSTEM LAYOUTS

4.3 Condensate discharge

4.3.1 CONDENSATE PIPE WORK

4.3.2 INTERNAL CONNECTIONS

4.3.3 External connection considerations

4.4 PRESSURE RELIEF PIPE WORK

4.4.1 Alternative PRV connections - Combined PRV/condensate

4.5 APPLIANCE LOCATION AND CLEARANCES

4.5.1 Installation

4.5.3 COMPARTMENTS:

4.5.6 ROOMS CONTAINING A BATH OR SHOWER

4.6 PLUMBING MANIFOLD

4.6.1 CONNECTIONS

4.7 FLUE OPTIONS

TELESCOPIC HORIZONTAL FLUE ASSEMBLY

Extended horizontal flue

4.7.1 Flue lengths

Horizontal high level flue assembly

Horizontal flue with additional elbow (1 x 90 ° bend)

Horizontal flue with additional elbows (2 x 90 ° bends)

High level horizontal flue

High level horizontal flue with additional elbows

Vertical balanced flue assembly

Vertical balanced flue with elbow offset (2 x 90 ° bends)

High level horizontal flue with additional elbows

Vertical balanced flue with elbow offset (2 x 45 ° bends)

4.8 Flue terminal positions

4.8.1 Vertical flue terminal positions

4.8.2 Horizontal flue terminal positions

4.8.3 Plume re-direct and plume management terminal positions

4.9 CLEANING PRIMARY SYSTEMS

Inhibitor

Water treatment products

4.9.1 Flushing the system

5 INSTALLATION

5.1 UNPACKING THE WALL FRAME & ANCILLARY ITEMS