Worcester Greenstar 4000 - Installation And Maintenance Instructions Manual

96 pages

Save Page as PDF

To Next Page

6 720 891 162 (2020/09) UK/IE

Installation and Maintenance Instructions

Gas-fired condensing system appliance

Greenstar 4000

GR4700iW S

Main Page

Table of Contents2
Explanation of Symbols and Safety Instructions4
Warnings4
Intended Use4
Misuse4
If You Smell Gas5
Electrical Work5
Installation and Maintenance5
Danger to Life from Carbon Monoxide5
Servicing6
Important Handling Instructions6
Health and Safety6
Installation Regulations7
Water Supply7
Scope of Delivery8
Appliance Type Overview8
Product Identification9
Pipework Positions and Flue Outlet9
Additional Type Plate9
Pipe and Flue Outlet Dimensions9
Product Overview10
Standard Accessories11
Appliance Accessories11
Programmer/Timer Accessories11
Bosch Easycontrol Smart Control System11
Pre-Installation12
System Preparation12
Water Systems and Pipework12
Primary System/Connections/Valves12
System Layouts Examples13
Checking the Size of the Expansion Vessel13
Curves for the Expansion Vessel13
Cylinder and Heating Zone13
Optional Integral Diverter Valve Kit14
3-Way Valve, Cylinder and Heating Zone14
Example Layout - Internal Diverter Valve Kit14
System Fill15
Gas Supply15
Pipe Sizing15
Mains Supply15
Liquid Petroleum Gas (LPG)16
Appliance Location and Clearances16
Rooms Containing a Bath or Shower17
Appliance Minimum Clearances17
Bathroom Installations17
Appliance Clearances17
Reduced Front Maintenance Minimum Clearances18
Appliances in Compartments18
Reduced Front Maintenance Clearances - Side View18
Flue Systems Considerations19
Flue System Bends19
Flue Length19
Flue Kit Part Numbers19
Telescopic Horizontal Flue Assembly20
Horizontal Flue Option20
Horizontal Fixed Length Flue Assembly20
Extended Horizontal Flue20
Vertical Flue Option21
Simpleswitch Flue Adaptor21
Plume Management System22
Terminal Exclusion Zone22
Plume Management Bends22
Horizontal Plume Management Runs22
Vertical Flue Terminal Positions23
Horizontal Flue Terminal Positions24
Plume Re-Direct and Plume Management Terminal Positions26
Condensate Discharge28
Condensate Pipework - Unheated Internal Areas28
Internal Connections28
Soil Stack Connection28
External Connections29
Waste Pipe Connection29
External Disposal Considerations29
Additional Protection for Transition through a Wall30
Disposal into Rain Water down Pipe30
Disposal to Open Drain or Gully with Air Break30
Condensate Soak Away Considerations31
Condensate Soak Away with External Air Break31
Disposal to Soak-Away31
Cavity Wall Considerations31
Pressure Relief Discharge32
Pressure Relief Pipework32
Through the Wall Lagging Example32
Alternative PRV Connections - Combined Prv/Condensate32
Cleaning Primary Systems33
Flushing the System33
Before Cleaning the System33
Inhibitor33
Installation34
Additional Requirements for Roof Space Installations34
Position the Appliance34
Appliance Positioning34
Mounting Frame Fixing35
Wall Mounting Template35
Appliance Connections36
Connections on the Gas and Water Side36
Condensate Discharge Connection Preparation36
Plumbing Manifold36
PRV Pre-Plumbing Connection Preparation37
Preparing the Service Valves37
Fitting the Sealing Washers37
Hanging the Appliance37
Preparing the Wall Frame38
Fitting the Siphon38
Wall Frame Preparation38
Flue Turret/Adaptor Installation39
Flue Turret/Adaptor Connection39
Slope for Condensate Disposal39
Electrical Connection40
Cable Preparations40
Installer Wiring Connections41
Power Supply (Power Cables) Terminal Strip41
Earth Rail Location41
Stepped Cable Grommets41
Power Supply (Power Cables) Connections42
External Controls - Domestic Installations42
Low Voltage (Signal Cables) Terminal Strip42
Low Voltage (Signal Cables) Connections42
Commissioning43
Pre-Commissioning Checks43
Filling the System - Sealed Systems43
Filling the Appliance and Adding Inhibitor43
Starting the Appliance44
Control Panel Overview44
Turning on the Appliance44
Chimney Sweep Mode44
Setting the Appliance to Maximum45
Setting the Appliance to Minimum45
Exiting Chimney Sweep Mode45
Checking Gas Inlet Pressure45
Checking the Gas Rate46
Checking for Gas Leaks During Operation46
Gas Supply Pressure Drop46
Allowed Mbar Pressure Drop46
CO and Combustion Check47
Before CO and Combustion Checks47
Commissioning Checks Flow Chart47
Checking Flue Integrity48
Flue Integrity Check Test Point48
Flue Gas Analysis48
Finishing Commissioning49
Fitting the Front Casing49
Benchmark Menu49
Appliance Handover49
Settings in the Service Menu50
Operating the Service Menu50
Changing the Setting Values50
Exiting the Menu Item Without Saving Values50
Service Menu51
Overview of the Service Menu51
Benchmark and Info Menu53
Settings Menu54
Menu Function Check57
Thermal Disinfection58
Inspection and Maintenance58
Mains Supplies58
Inspection and Maintenance Considerations58
Maintenance Reminder Options59
Checking Heat Exchanger Assembly59
Maximum System Pressure59
Natural Gas Appliances59
Check Working Gas Inlet Pressure60
Checking the Flue Integrity60
Cleaning the Siphon and Heat Exchanger60
Checking the Electrodes and Cleaning the Heat Exchanger60
Removing the Fan with Mixing Unit61
Non-Return Valve (Bearing Plate) in the Mixing Unit61
Removing the Burner61
Cleaning the Condensate Trap63
Replacing the Gasket63
Removing the Siphon63
Setting the Air/Gas Ratio64
Adjusting the Minimum Rated Output Settings64
Adjusting the Maximum Rated Output Settings (LPG Appliances)64
Replacement Parts65
Draining the Appliance65
Component Access65
Removing the Front Casing65
Removing the Heat Exchanger Assembly66
Separating Components from the Heat Exchanger Assembly66
Checking/Replacing the Motor of the 3-Way Valve67
Removing the Pump67
Replacing the Gas Valve68
Replacing the PRV68
Replacing the Expansion Vessel68
Replacing the Pressure Sensor68
Pressure Gauge Removal69
Replacing the Control Unit69
Control Unit Removal Preparations69
Fault Finding and Diagnosis70
Operating and Fault Displays70
10.1.2 Operating/Fault Code Table71
System Gassing79
Environmental Protection and Disposal81
Compostable Packaging81
Data Protection Notice81
Technical Specifications/Logs82
Technical Data82
Energy Consumption84
Product Data on Energy Consumption84
Component Resistance Characteristics88
Sensor Values - Flue Overheat Thermostat88
Sensor Values - Flow Temperature Sensor88
Sensor Values - Cylinder Temperature Sensor88
Pump Characteristic Map of the Heating Pump89
Constant Pressure89
Internal Wiring of the Appliance90
Inspection and Maintenance Checklist93

Worcester Greenstar 4000 - Installation And Maintenance Instructions Manual

Table of Contents

Other manuals for Worcester Greenstar 4000

Related product manuals