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Worcester Greenstar 25Si Compact User Manual

Worcester Greenstar 25Si Compact
76 pages
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UK/IE
INSTALLATION COMMISSIONING AND SERVICING INSTRUCTIONS
WALL HUNG RSF GAS FIRED CONDENSING COMBINATION BOILER
Greenstar Si Compact
ErP
6720646608-00.1Wo
FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER
6 720 813 278 (2015/07)
If you smell gas:
Well away from the building: call the National Gas Emergency
Service on 0800 111 999.
L.P.G. boilers: Call the supplier’s number on the side of the gas tank.
These appliances are for use with:
Natural Gas or L.P.G.
(Cat. II 2H 3P type C13, C33 & C53)
Model GC Number
Natural Gas 25Si Compact
ErP
47-406-73
30Si Compact
ErP
47-406-75
L.P.G. 25Si Compact
ErP
47-406-74
30Si Compact
ErP
47-406-76

Table of Contents

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Worcester Greenstar 25Si Compact Specifications

General IconGeneral
ModelGreenstar 25Si Compact
CategoryBoiler
Output25kW
ERP RatingA
Dimensions690 x 390 x 280 mm
Fuel TypeNatural Gas
Flow Rate10.2 l/min
Warranty5 years
Boiler TypeCombi
MountingWall Mounted
Max Working Pressure3 bar
Central Heating Flow Temperature Range30°C to 80°C

Summary

Key to Symbols and Safety Instructions

1.1 Key to Symbols

Explains symbols used for warnings and instructions.

1.2 Safety Precautions

Outlines critical safety measures to prevent hazards.

Regulations

Installation Regulations

Details installation compliance with current gas, IET, and building regulations.

British Standards

Lists relevant British Standard codes of practice for installations.

Appliance Information

3.1 Appliance

Provides an overview of the appliance and its standard package contents.

3.2 Layout

Illustrates the main boiler components with numbered references.

3.3 Technical Data

Presents detailed technical specifications for the boiler models.

3.4 Energy Efficiency

Details the energy efficiency data according to EU regulations.

Pre-Installation

4.1 Cleaning Primary Systems

Instructions for cleaning the heating system before installation.

4.2 Mains Supply

Covers electrical and gas supply requirements and safety.

4.2.3 Water Supply

Guidance on water supply, pressure, and hard water areas.

4.3 Water Systems and Pipe Work

Details requirements for plastic pipework and primary system connections.

Pre-Installation (Continued)

4.4 Condensate Pipe Work

Guidance on installing condensate drainage pipes.

4.4.1 Internal Connections

Methods for connecting condensate drainage internally to prevent freezing.

4.4.2 External Connections

Guidance for external condensate drainage, including freeze prevention.

Pre-Installation (Continued)

4.5 Pressure Relief Pipe Work

Instructions for routing and fitting the pressure relief pipe.

4.6 Boiler Location and Clearances

Specifies requirements for boiler placement and surrounding clearances.

Pre-Installation (Continued)

4.7 Plumbing Manifold

Details the plumbing manifold connections and pipe dimensions.

Pre-Installation (Continued)

4.8 Flue Terminal Positions

Provides minimum clearances for flue terminal installations.

Pre-Installation (Continued)

4.9 Flue Options

Outlines approved flue systems and their specifications.

4.9.1 Flue Lengths

Details maximum flue lengths for different flue system configurations.

Pre-Installation (Continued)

4.10 Plume Management Terminal Positions

Specifies positions and clearances for plume management terminals.

Pre-Installation (Continued)

4.10.1 Determine the Plume Management System Length

Guidance on calculating plume management system lengths.

Installation

5.1 Unpacking Wall Frame & Ancillary Items

Instructions for unpacking the wall frame and associated items.

5.2 Wall Mounting Template & Flue Opening

Guides on using the template for drilling flue openings and fixing the frame.

Installation (Continued)

5.3 Unpacking the Appliance

Steps for safely unpacking the boiler unit.

Removing the Outer Case

Procedure for removing the boiler's outer casing.

Installation (Continued)

5.4 Pre-Plumbing Boiler Connections

Details pre-plumbing steps for condensate drain, PRV, gas, and water connections.

Installation (Continued)

5.5 Hanging the Boiler

Instructions for safely lifting and hanging the boiler onto the wall frame.

Installation (Continued)

Connecting the Expansion Vessel

Steps for connecting the expansion vessel to the pump manifold.

5.6 Flue Turret/Adaptor Installation

Guides on fitting the flue turret or adaptor securely.

Installation (Continued)

5.7 Electrical

Details electrical supply requirements and connections.

Installation (Continued)

5.7.1 Mounting Optional Plug-in Controls

Instructions for mounting optional controls like programmers/timers.

Installation (Continued)

5.7.2 New Complete System Installations

Requirements for new system installations and zoning.

Installation (Continued)

5.7.3 Existing Installations

Options for room thermostats and programmers in existing systems.

Commissioning

6.1 Pre-Commissioning Checks

Essential checks before starting the commissioning process.

6.2 Filling the System

Detailed steps for filling and venting the central heating system.

6.3 Water Treatment

Guidelines for system cleaning, flushing, and inhibitor addition.

Commissioning (Continued)

6.4 Starting the Appliance

Procedures for safely starting the boiler and setting controls.

Commissioning (Continued)

6.4.1 Boiler Start Up Screens

Explains the boiler's start-up display sequences and symbols.

Commissioning (Continued)

6.5 Commissioning

Overview of the commissioning process and service mode operation.

6.5.1 Checking the Gas Inlet Pressure

Procedure for measuring and verifying gas inlet pressure.

Commissioning (Continued)

6.5.2 Checking the Gas Rate

How to measure the gas rate at the meter and check CO/CO2 ratios.

6.5.3 Gas Rating Test

Steps for performing the gas rating test at maximum output.

6.6 Domestic Hot Water

Information on controlling hot water temperature and modes.

Commissioning (Continued)

6.7 CO and Combustion Checks

Mandatory checks for combustion performance and flue integrity.

Commissioning (Continued)

6.8 Finishing Commissioning

Steps to complete the commissioning process.

6.8.1 Replacing the Boiler Case

Instructions for refitting the boiler's outer case.

6.8.2 Securing the Control Panel

How to secure the control panel after access.

Service and Spares

7.1 Inspection and Service

Steps for initial inspection and routine service of the appliance.

7.2 Checking Flue Integrity

How to check the integrity of the flue system using sample points.

Service and Spares (Continued)

7.3 Component Access

Instructions for accessing internal boiler components by removing the case.

Service and Spares (Continued)

7.4 Checking the Gas Inlet Pressure

Verifying gas inlet pressure against system requirements.

7.5 Fan Pressure Test

Procedure for testing fan pressure to assess heat exchanger condition.

Service and Spares (Continued)

7.6 Flue Gas Analysis

Detailed procedure for performing flue gas analysis checks.

Service and Spares (Continued)

7.7 Cleaning the Heat Exchanger

Instructions for cleaning the heat exchanger.

7.7.1 Cleaning the Siphon

Steps for removing and cleaning the condensate siphon.

Service and Spares (Continued)

7.8 Replacement of Parts

General precautions for replacing boiler parts.

7.8.1 Removing the Outer Case

Steps for removing the boiler's outer case.

Service and Spares (Continued)

7.8.2 Draining the Boiler

Instructions for safely draining the boiler.

7.8.3 Siphon Removal

Procedure for removing the condensate siphon.

7.8.4 Primary Sensor (CH NTC)

Steps for removing and replacing the primary sensor.

Service and Spares (Continued)

7.8.5 Maximum Safety Sensor (NTC)

How to remove and replace the maximum safety sensor.

7.8.6 Flue Overheat Thermostat

Procedure for replacing the flue overheat thermostat.

7.8.7 Air Pressure Switch

Steps for removing and replacing the air pressure switch.

Service and Spares (Continued)

7.8.8 Auto Air Vent

Instructions for removing and refitting the auto air vent.

7.8.9 Gas Valve

Procedure for removing and replacing the gas valve.

7.8.10 Fan Assembly

Instructions for removing the fan assembly and related components.

Service and Spares (Continued)

7.8.11 Air/Gas Flap Valve Assembly

Procedure for removing the air/gas flap valve assembly.

Combustion Air Inlet and Gas Pipe Disconnection

How to disconnect combustion air inlet and gas pipes.

Service and Spares (Continued)

7.8.12 Ignition Transformer

Steps for removing and replacing the ignition transformer.

7.8.13 Electrode Assembly

How to remove and replace the electrode assembly.

Service and Spares (Continued)

7.8.14 Burner Housing, Burner/Gasket

Instructions for removing the burner housing, burner, and gasket.

7.8.15 Heat Exchanger

Procedure for removing the heat exchanger.

Service and Spares (Continued)

7.8.16 Diverter Valve Motor and Diverter Valve Removal

Instructions for removing the diverter valve motor and assembly.

7.8.17 DHW Temperature Sensor (NTC)

How to remove and replace the DHW temperature sensor.

7.8.18 Pump Head

Procedure for removing and replacing the pump head.

Service and Spares (Continued)

7.8.19 Flow Sensor, Flow Restrictor and Filter Removal

Steps for removing the flow sensor, restrictor, and filter.

7.8.21 Pressure Gauge

Procedure for removing the pressure gauge.

7.8.22 Boiler Return Sensor (NTC)

Steps for removing and replacing the boiler return sensor.

Service and Spares (Continued)

7.8.23 Drain Tap

Procedure for removing and refitting the drain tap.

7.8.24 CH Pressure Relief Valve

How to remove and replace the central heating pressure relief valve.

7.8.25 DHW Pressure Relief Valve

Steps for removing and replacing the DHW pressure relief valve.

7.8.26 DHW Plate Heat Exchanger

Procedure for removing and replacing the DHW plate heat exchanger.

Service and Spares (Continued)

7.8.27 Hydraulic Block Removal

Instructions for removing the hydraulic block assembly.

7.8.28 Bypass Valve

Procedure for removing and replacing the bypass valve.

7.8.29 Access to Boiler Control Components

How to access boiler control components.

Service and Spares (Continued)

7.8.30 Replacing the Control Unit

Detailed steps for replacing the boiler's control unit.

Service and Spares (Continued)

Expansion Vessel Replacement (Boiler Fitted)

Steps for replacing the expansion vessel with the boiler fitted.

Expansion Vessel Replacement (Boiler Removed)

Steps for replacing the expansion vessel with the boiler removed.

Service and Spares (Continued)

7.9 Short Parts List

A list of common spare parts with their part numbers.

Fault Finding and Diagnosis

8.1 Internal Wiring Diagram

Illustrates the internal wiring layout of the boiler for troubleshooting.

Fault Finding and Diagnosis (Continued)

8.2 Central Heating Function

Flowchart detailing the central heating operation sequence.

Fault Finding and Diagnosis (Continued)

8.3 Preheat and DHW Function

Flowchart explaining the preheat and domestic hot water operation.

Fault Finding and Diagnosis (Continued)

8.4 Protection Function

Explains the boiler's protection functions like frost and pump overrun.

Fault Finding and Diagnosis (Continued)

8.5 Information and Service Menus

Guide to accessing and interpreting boiler status and service codes.

Status Codes

Lists and explains boiler status codes for fault finding.

Fault Finding and Diagnosis (Continued)

8.5.1 Selecting the Information Menu

How to navigate and view information within the Information menu.

Fault Finding and Diagnosis (Continued)

8.5.2 Selecting Service Menus

Instructions for navigating and selecting options within the service menus.

Fault Finding and Diagnosis (Continued)

8.5.3 Menu 1 - System Parameters

Notes that Menu 1 has no adjustable parameters for this model.

8.5.4 Menu 2 - Boiler Parameters

Details adjustable boiler parameters and their settings.

Fault Finding and Diagnosis (Continued)

8.5.5 Reset to Factory Settings

Procedure to reset boiler parameters to factory defaults.

8.5.6 Menu 3 - Boiler Maximum & Minimum Limits

How to adjust boiler maximum and minimum output limits.

Fault Finding and Diagnosis (Continued)

8.5.7 Using the Test Menu

Guide to using the test menu for component functionality checks.

Fault Finding and Diagnosis (Continued)

8.6 Fault Codes

Lists and explains various locking faults and their possible causes.

Fault Finding and Diagnosis (Continued)

Blocking Errors

Lists and explains blocking errors and their possible causes.

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