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Worcester Greenstar 18Ri User Manual

Worcester Greenstar 18Ri
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UK/IE
INSTRUCTION MANUAL
INSTALLATION, COMMISSIONING & SERVICING
WALL HUNG RSF GAS FIRED CONDENSING BOILER
FOR OPEN VENTED AND SEALED CENTRAL HEATING SYSTEMS AND
INDIRECT MAINS FED DOMESTIC HOT WATER
THIS BOILER IS USED WITH
NATURAL GAS OR LPG (Cat II 2H3P TYPE C13, C33 & C53)
NATURAL GAS 12 Ri GC NUMBER: 41 311 63
15 Ri GC NUMBER: 41 311 75
18 Ri GC NUMBER: 41 311 77
24 Ri GC NUMBER: 41 311 65
LIQUID PETROLEUM GAS 12 Ri GC NUMBER: 41 311 64
15 Ri GC NUMBER: 41 311 76
18 Ri GC NUMBER: 41 311 78
24 Ri GC NUMBER: 41 311 66
GREENSTAR 12Ri, 15Ri, 18Ri & 24Ri

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Worcester Greenstar 18Ri Specifications

General IconGeneral
ModelGreenstar 18Ri
CategoryBoiler
Output18 kW
Efficiency89.1%
Fuel TypeNatural Gas
TypeRegular
Warranty5 years
Efficiency RatingA
ERP RatingA
MountingWall-mounted
Gas TypeNatural Gas

Summary

SAFETY & REGULATIONS

SAFETY PRECAUTIONS

Essential safety advice, including actions to take if gas is detected.

INSTALLATION REGULATIONS

Guidelines and standards for appliance installation, including Gas Safety and British Standards.

APPLIANCE INFORMATION

GENERAL INFORMATION

Overview of the boiler's standard package contents and key specifications.

TECHNICAL DATA

LAYOUT & COMPONENTS

CLEANING PRIMARY SYSTEMS

CLEANING THE PRIMARY SYSTEM

Procedure for flushing and cleaning the central heating system before boiler installation.

MAINS SUPPLY

ELECTRIC SUPPLY

Requirements for connecting the boiler to the mains electricity supply.

GAS SUPPLY

Regulations and considerations for connecting the gas supply to the boiler.

GAS SUPPLY PIPE SIZING

Guidance on appropriate pipe sizing for gas supply to different boiler models.

WATER SYSTEMS & PIPEWORK

PLASTIC PIPEWORK & UNDER FLOOR HEATING

Requirements for plastic pipework and specific considerations for underfloor heating systems.

CONNECTIONS/VALVES

Details on system connections, valves, and radiator valve conformity.

S and Y PLAN SYSTEM

Diagrammatic explanations of S and Y plan system layouts and components.

FULLY PUMPED SEALED SYSTEM

Information on filling and components for a fully pumped sealed central heating system.

CONDENSATE PIPEWORK

External pipe work

Guidelines for routing and installing condensate pipework externally, including insulation.

Condensate soakaway

Requirements for creating a condensate soakaway using specific materials and dimensions.

Fitting an external air break

Instructions for fitting an external air break when condensate drains into a rainwater downpipe.

BOILER LOCATION & CLEARANCES

SERVICING CLEARANCES (VENTED COMPARTMENT)

Minimum clearances required for servicing a boiler installed in a vented compartment.

VENTILATION FREE COMPARTMENTS INSTALLATION CLEARANCES

Clearances needed for installation within unventilated compartments, requiring ventilation.

BOILER CLEARANCES

Minimum space requirements for installing and servicing the boiler.

BOILER CLEARANCES - UNVENTILATED COMPARTMENTS

Minimum space requirements for installing and servicing within unventilated compartments.

BATHROOMS

Specific installation location requirements for boilers installed in bathrooms.

PLUMBING MANIFOLD

CONNECTIONS

Details regarding 22mm compression fittings for heating system and gas connections.

FLUE OPTIONS

FLUE OPTIONS

Overview of different horizontal and vertical flue systems and their maximum lengths.

FLUE TERMINAL POSITIONS

FLUE TERMINAL POSITIONS

Recommendations for flue terminal placement to avoid obstructions and nuisances.

UNPACKING THE BOILER

LIFTING AND CARRYING PRECAUTIONS

Safe practices for lifting and carrying the boiler unit during installation.

IMPORTANT HANDLING INSTRUCTIONS

Key advice for safely unpacking and handling the boiler carton and its contents.

WALL MOUNTING PLATE FLUE OPENING

SAFETY

General safety precautions to be observed before drilling or fixing.

FIXING THE MOUNTING FRAME

Step-by-step guide for fixing the wall mounting frame and template.

REAR FLUE OUTLET

Instructions for setting out and drilling the hole for a rear flue outlet.

SIDE OUTLET

Procedure for marking and drilling the hole for a side flue outlet.

OUTER CASE REMOVAL

REMOVING OUTER CASE

Detailed steps for safely removing the outer casing of the boiler.

BOILER CONNECTIONS

GAS AND WATER CONNECTIONS

Guide to connecting the gas and water pipes to the boiler.

FLUE INSTALLATION

HORIZONTAL FLUE (60/100mm diameter)

Instructions specific to the installation of horizontal 60/100mm diameter flues.

MEASURING THE FLUE (Standard Flue)

Method for measuring the flue length required for the standard flue kit.

Adjusting the standard terminal length

Steps to adjust the length of the standard flue terminal.

Reducing the standard terminal length

Procedure for shortening the standard flue terminal length.

Installing the standard flue

Detailed steps for installing the standard flue component.

FLUE TERMINAL PLUME RE-DIRECTION

Method for redirecting the flue discharge to manage plume visibility.

FITTING THE ELBOW

Instructions on how to correctly fit the flue elbow assembly to the boiler.

ADDITIONAL NOTES AND REMINDERS

Important reminders regarding flue cutting, sealing, and angles.

CONDENSATE CONNECTIONS

CONDENSATE CONNECTION

Guidelines for correctly connecting the condensate drain pipe.

ELECTRICS

Access to electric control panel

Steps to access the boiler's electric control panel for wiring.

POSITION OF WIRED COMPONENTS

PRE-COMMISSIONING CHECKS

PRE-COMMISSIONING CHECKS

Essential checks to perform before commencing the full commissioning process.

FILLING THE SYSTEM

FILLLING THE SYSTEM

Procedures for filling the central heating system and venting air.

GAS SUPPLY

Steps for purging the gas supply and testing for soundness.

STARTING THE APPLIANCE

Switching the appliance on/off

Instructions for safely powering up and switching the boiler on and off.

WATER TREATMENT

FLUSHING (Central Heating)

Detailed procedure for flushing the central heating system with a cleaning agent.

INHIBITOR (Central Heating)

Guidelines for adding inhibitor to the central heating system water.

COMMISSIONING

CHECKING GAS INLET PRESSURE

Procedure for verifying the gas inlet pressure to the boiler.

SETTING THE BOILER TO MAXIMUM

Steps to set the boiler to operate at its maximum output for testing.

MEASURING THE INLET PRESSURE

Method for measuring the gas inlet pressure using a manometer.

FINISHING COMMISSIONING

HANDOVER

Steps for completing the handover process, including checklists and user demonstration.

INSPECTION AND SERVICE

Inspection

Checks to perform during a routine inspection of the boiler and flue terminal.

Component Access

Instructions on how to access internal components for servicing.

1. Removing outer case

Detailed steps for removing the boiler's outer casing.

2. Adjusting boiler control to service position

Procedure to move the boiler control panel to a service-friendly position.

Primary Heat Exchanger

Information regarding cleaning and checking the primary heat exchanger.

Setting Boiler to Maximum

Steps to set the boiler to maximum output for testing purposes.

To Clean the Heat Exchanger

Detailed instructions for cleaning the boiler's heat exchanger.

Removing Syphon

Procedure for removing the condensate syphon for cleaning or inspection.

Syphon

Details on examining and flushing the condensate syphon.

SETTING THE AIR/GAS RATIO

SETTING THE AIR/GAS RATIO

Procedure for adjusting the air-to-gas ratio for optimal combustion.

SETTING THE AIR/GAS RATIO FOR THE SIT 848.093 SIGMA

1. Setting the CO/CO2

Steps to measure and adjust CO/CO2 levels for the SIT 848.093 Sigma gas valve.

SETTING THE AIR/GAS RATIO FOR THE DUNGS GB-ND 055 D01 S20

1. Setting the CO/CO2

Steps to measure and adjust CO/CO2 levels for the Dungs GB-ND 055 D01 S20 gas valve.

REPLACEMENT OF PARTS

8. Access to boiler control components

Guide to accessing the boiler's control components for replacement.

9. PCB fuse

Instructions for replacing the PCB fuse.

10. Transformer / PCB

Procedure for replacing the transformer or printed circuit board.

SIT AND DUNGS VALVE

Information on replacing SIT and Dungs gas valves.

5. Moving boiler control to service position

Steps to move the boiler control to a service position.

6. Gas valve

Procedure for replacing the gas valve, including checks.

7. Syphon

Instructions for removing and replacing the condensate syphon.

2. Primary sensor

How to replace the primary temperature sensor.

3. Overheat thermostat

Procedure for replacing the overheat thermostat.

4. Flue limit thermostat

Instructions for replacing the flue limit thermostat.

4.1 Type B (with grommet)

Specifics for replacing the Type B flue limit thermostat with a grommet.

12. Air / gas manifold and fan assembly

Steps for removing and replacing the air/gas manifold and fan assembly.

13. Pressure switch

Guide for replacing the boiler's pressure switch.

14. Fan

Instructions for replacing the boiler fan.

15. Electrode assembly

Procedure for replacing the ignition and flame sensor electrodes.

16. Burner

Steps for removing and replacing the boiler burner.

17. Heat Exchanger

Instructions for removing and replacing the heat exchanger.

SHORT PARTS LIST

SHORT PARTS LIST

A list of common replacement parts with part numbers and GC numbers.

GAS CONVERSION

Installation Regulations

Additional regulations specific to LPG appliance conversions.

All appliances

General steps for converting the appliance, including casing removal and CO2 reset.

The CO2 level must be reset

Instructions on resetting the CO2 level after conversion.

4. Code plug

Guidance on replacing the code plug for gas conversion.

ELECTRICAL WIRING DIAGRAM

FAULT FINDING

FAULT FINDING

Information to help diagnose and resolve common boiler faults based on operational indicators.

MAIN FUNCTION

MAIN FUNCTION

A flowchart illustrating the boiler's operational sequence and protection systems.

GAS BOILER COMMISSIONING CHECKLIST

CONTROLS Tick the appropriate boxes

Checklist for verifying installation of various system controls.

ALL SYSTEMS

Confirmation of system cleaning and compliance with regulations.

CENTRAL HEATING MODE Measure and Record

Section for recording central heating mode measurements like gas rate and temperatures.

COMBINATION BOILERS ONLY

Specific checks for combination boilers, including water scale reduction.

DOMESTIC HOT WATER MODE Measure and Record

Section for recording domestic hot water mode measurements.

CONDENSING BOILERS ONLY

Confirmation of correct installation for condensing boiler features.

ALL INSTALLATIONS

General confirmations for installation and commissioning compliance.

SERVICE RECORD

Service Provider

Fields for service engineer details and service history records.

CONTACT INFORMATION

CONTACT INFORMATION

Contact details for Worcester, Bosch Group for technical, service, and sales support.

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