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Worcester Greenstar i System ErP Series

Worcester Greenstar i System ErP Series
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UK/IE
Installation commissioning and servicing instructions
Wall hung RSF gas fired condensing system boiler
Greenstar i System
ErP
6720806944-00.1Wo
For sealed central heating systems and indirect mains fed domestic hot water
6 720 806 945 (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 Greenstar 9i System
ErP
41-406-21
Greenstar12i System
ErP
41-406-23
Greenstar 15i System
ErP
41-406-25
Greenstar 18i System
ErP
41-406-27
Greenstar 21i System
ErP
41-406-29
Greenstar 24i System
ErP
41-406-31
L.P.G. Greenstar 9i System
ErP
41-406-22
Greenstar12i System
ErP
41-406-24
Greenstar 15i System
ErP
41-406-26
Greenstar 18i System
ErP
41-406-28
Greenstar 21i System
ErP
41-406-30
Greenstar 24i System
ErP
41-406-32

Table of Contents

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Worcester Greenstar i System ErP Series Specifications

General IconGeneral
BrandWorcester
ModelGreenstar i System ErP Series
CategoryBoiler
LanguageEnglish

Summary

Key to Symbols and Safety Instructions

Key to Symbols

Explains symbols for actions, references, and list entries used in the manual.

Safety Precautions

Details critical safety warnings (danger, warning, caution, notice) and general safety advice.

Regulations

Installation Regulations

Outlines compliance for gas safety, electrical, building regulations, and British standards.

Appliance Information

Appliance Overview

Provides a general description of the appliance and its standard package components with diagrams.

Technical Data

Lists detailed specifications, performance data, and electrical information for Natural Gas models.

Energy Efficiency

Presents product data for energy efficiency in accordance with EU regulations for Natural Gas.

Appliance Layout

Illustrates the main appliance components and provides a key for identification.

Electrical Diagram

Shows the wiring connections for the appliance's electrical system with component labels.

Pre-installation

Cleaning Primary Systems

Details procedures for flushing and cleaning the heating system before installation, including water treatment.

Mains Supply Requirements

Specifies electrical and gas supply requirements, IP ratings, and wiring regulations for safe installation.

Water Systems and Pipe Work

Covers requirements for plastic pipework, primary system connections, and sealed system filling procedures.

Appliance Location and Clearances

Defines necessary clearances for installation, servicing, access, and compartment requirements for safe operation.

Pressure Relief Pipe Work

Guides on the correct installation and routing of the pressure relief valve discharge pipe to prevent hazards.

Condensate Discharge

Explains the appliance's siphonic trap and methods for condensate pipe work and disposal to prevent freezing.

Standard Accessories

Lists available optional accessories for the appliance, such as filters and kits.

Plumbing Manifold

Details pipe dimensions and connections for external diverter valves and controls, including optional kits.

Flue Options

Describes flue system types, effective lengths, and installation considerations for horizontal and vertical flue options.

Flue Terminal Positions

Specifies minimum clearances for flue terminal positions to avoid combustion product entry and nuisance.

Plume Management Terminal Positions

Details clearances and requirements for plume management system installation to control exhaust discharge.

Installation

Important Handling Instructions

Provides guidance on safe lifting, carrying, unpacking, and general handling of the appliance.

Wall Mounting Template & Flue Openings

Covers fixing the wall mounting frame and preparing flue openings for correct appliance installation.

Appliance Connections

Details the process of making gas, water, and condensate pipework connections, including sealing.

Front Panel Removal

Explains how to remove the appliance's front panel for access to internal components.

Hanging the Appliance

Guides on safely hanging the appliance onto the wall mounting frame by the centre hook.

Pressure Relief Connections

Describes how to reposition the pressure relief connector after mounting for correct operation.

Siphon Removal

Details how to access and remove the appliance's siphon for cleaning or replacement.

Reconnecting the Siphon

Explains the procedure for re-fitting the siphon after removal, ensuring correct engagement.

Filling the Siphon

Instructs on how to fill the siphon with water before appliance operation to ensure it functions correctly.

Flue TurretAdaptor Installation

Covers the installation of the flue turret or adaptor for different flue configurations and pipework.

Electrical Connections

Details mains voltage and low voltage connections for appliance controls, timers, and sensors.

External Controls (Wiring Centre) - Domestic Installations

Explains wiring for external controls and the appliance's wiring centre, including power supply.

Commissioning

Pre-Commissioning Checks

Lists essential checks to be performed before starting the commissioning process, including pipework and gas connections.

Filling the System

Outlines the procedure for filling and pressurising the heating system, including venting radiators.

Water Treatment

Covers requirements for system flushing, inhibitor addition, and water treatment products to protect the system.

Starting the Appliance

Guides on the initial start-up procedure, button functions, and what to expect on the appliance display.

Appliance Start Up Screens

Details the sequence of displays shown during the appliance's initial start-up, including internal tests.

Info Menu and Operational Status Codes

Explains how to access and interpret appliance status codes and information menus for operational data.

Checking the Gas Inlet Pressure

Provides instructions for checking and verifying gas inlet pressure at the appliance using a manometer.

Gas Rate Testing

Details the procedure for setting the appliance to maximum output and testing the gas rate for correct operation.

Checking for Leaks during Operation

Advises on using leak detection agents to check for gas leaks during operation and electrical wiring safety.

Domestic Hot Water

Explains controls for hot water temperature and pre-heat function with optional diverter valve kit for user comfort.

CO and Combustion Checks

Outlines mandatory checks for combustion and flue integrity, including a flow chart for guidance.

Checking Flue Integrity

Details how to check the flue system's integrity using analyser sample points for safe exhaust discharge.

Flue Gas Analysis

Explains the procedure and requirements for performing flue gas analysis and checks for optimal combustion.

Service Reminder Function

Describes how to set and manage the appliance's service reminder function for scheduled maintenance.

Benchmark Menu

Provides information required for completing the Benchmark Commissioning Checklist for compliance.

Weather Sensor Settings Menu

Explains configuration settings for weather sensor accessories and basic weather compensation.

Boiler Settings Menu

Details the functionality and settings available within the boiler settings menu for appliance configuration.

Master Settings Menu

Allows adjustment of boundaries for values set in the Boiler settings menu, defining operational limits.

Finishing Commissioning

Covers final steps after commissioning, including panel replacement and fitting.

Replace Front Panel

Instructions for replacing the appliance's front panel after servicing, ensuring proper seating.

Fitting Facia Flap

Guides on how to fit the appliance's facia flap, aligning hinges and slots.

Installing Bottom Panel

Details how to install the appliance's bottom panel, ensuring secure engagement.

Setting the Central Heating Temperature

Explains how to adjust the central heating flow and economic temperatures via the control panel.

Economic Central Heating Temperature

Describes setting the economic flow temperature for optimal energy efficiency.

Setting the Cylinder Hot Water Temperature

Guides on setting cylinder hot water temperature with the optional diverter valve kit for domestic hot water.

Mid Point Domestic Hot Water Temperature

Sets the maximum temperature for the hot water cylinder to 50°C for domestic hot water supply.

EcoPreheat Mode Activation

Explains how to activate Eco and Preheat modes for hot water cylinder management based on demand.

Toggle Basic Adjust Mode

Details how to enable or disable basic adjust mode to lock functions and prevent accidental adjustments.

Hand Over

Covers final procedures for handing over the appliance to the customer, including operation and safety.

Service and Spares

Appliance Guarantee

Outlines the terms and conditions of the appliance's guarantee against faulty materials or workmanship.

Basic Adjust Mode

Explains how basic adjust mode affects service functions and the need to disable it for servicing.

Inspection and Service

Provides general guidance for carrying out routine inspection and servicing of the appliance, including checks and records.

History Menu

Describes how to access and interpret stored information on errors, service requests, and operating times via the History menu.

Test Menu

Details how to access and perform component tests for checking the operation of various parts.

Checking Flue Integrity

Guides on checking flue joints, terminal, and guard for damage and obstructions to ensure safe exhaust.

Check the Gas Inlet Pressure

Instructs on verifying gas inlet pressure against specified readings for correct appliance operation.

Fan Pressure Test

Explains how to perform a fan pressure test to assess the heat cell's condition and identify issues.

Flue Gas Analysis

Details the procedure and requirements for performing flue gas analysis and checks for optimal combustion.

Cleaning the Siphon and Heat Exchanger

Covers the process of cleaning the appliance's siphon and heat exchanger for efficient operation.

Cleaning the Siphon

Provides steps for accessing and cleaning the siphon, ensuring it is free from debris.

Component Access

Details how to remove outer panels to access appliance components for maintenance or replacement.

Siphon Removal Replacement of Parts

Explains how to remove and replace parts related to the siphon, including careful handling.

Access to the Siphon

Guides on how to gain access to the appliance's siphon by removing covers.

Draining the Appliance

Details the procedure for safely draining the appliance before component removal to prevent water damage.

Fan Assembly Removal

Explains how to remove the fan assembly from the appliance, including electrical and pipework disconnections.

AirGas Manifold Clamping Plate Removal

Guides on removing the air/gas manifold clamping plate, including electrical and sensor disconnections.

Burner and Electrode Removal

Details the process for removing the burner and electrode assembly for cleaning or replacement.

Flow Pipe Removal

Explains how to remove the flow pipe from the heat exchanger, including releasing clips.

Baffle Removal

Guides on removing the top and lower baffles from the heat exchanger, noting the use of special tools.

Exhaust Assembly Removal

Details how to remove the upper and lower exhaust assemblies, including support rings.

Heat Exchanger Removal

Explains the procedure for removing the heat exchanger, including gas valve and pipework disconnection.

Re-assembly of the AirGas Manifold Clamping Plate

Covers the re-assembly of the air/gas manifold clamping plate and associated checks for sealing and tightness.

Primary Sensor (CH NTC)

Guides on removing and replacing the primary sensor, including paste application.

Overheat Thermostat

Explains how to remove and replace the overheat thermostat, ensuring correct positioning.

Spark Generator

Details the process for removing and replacing the spark generator, including bracket alignment.

Flue Overheat Thermostat (with Grommet)

Guides on removing and replacing the flue overheat thermostat, noting housing care.

Fan

Details the removal and re-assembly of the fan assembly, including mixing unit and seals.

Gas Valve

Explains how to remove and replace the gas valve, including electrical and pipework connections.

Expansion Vessel Removal

Guides on how to remove and replace the expansion vessel, ensuring correct alignment and tightness.

PCB Fuse

Explains how to replace the PCB fuse, noting the location of spare fuses.

Replacing Control Unit

Details the procedure for replacing the appliance's control unit, including HCM transfer.

HCM (Heating Control Module) Removal

Guides on removing the HCM from the control unit for transfer to a new unit.

Control Box Removal

Explains how to remove the control box, including cable strain relief and retainers.

Pressure Gauge Indicator and Electrical Connections Removal

Covers the removal of the pressure gauge indicator and electrical connections, noting care for the capillary.

Hydraulic Block Components Removal

Details the removal of various components from the hydraulic block, including sensors, valves, and pump.

Auto Air Vent

Guides on removing and refitting the auto air vent, noting 'O' ring placement.

Diverter Valve Motor (If optional integral diverter valve kit fitted)

Explains how to remove and replace the diverter valve motor, ensuring it's in mid position.

Diverter Valve

Guides on removing and refitting the diverter valve, including cleaning the valve chamber.

Drain Tap

Explains how to remove the drain tap from its housing.

Pump Head

Details how to remove the pump head, including electrical and screw disconnections.

Pressure Gauge

Guides on removing the pressure gauge, noting care for the capillary and head.

CH Pressure Relief Valve

Explains how to remove the CH pressure relief valve from the hydraulic block.

Bypass Valve

Guides on removing the bypass valve from the hydraulic block housing.

Fault finding and diagnosis

Short Parts List

Lists common spare parts for the main appliance and integral diverter valve kit with part numbers.

Fault Finding Overview

Introduces locking/blocking errors, cause codes, and maintenance codes for effective fault diagnosis.

Locking Error

Describes how locking errors are indicated on the display and the initial reset procedure.

Blocking Error

Explains blocking errors, their automatic clearing, and how conditions change to locking.

Cause Code

Details the meaning of cause codes indicated by 'H' followed by a number for fault identification.

Maintenance Codes

Lists examples of maintenance messages found in the History menu for proactive checks.

Maintenance Menu

Lists maintenance messages, their cause codes, descriptions, and possible causes/checks for troubleshooting.

Error Codes

Provides a table of error codes, their descriptions, and possible solutions or checks for appliance faults.

Component Resistance Characteristics

Lists resistance values for various sensors and components at different temperatures for diagnostic checks.

Flow Temperature NTC Sensor

Provides resistance data for the flow temperature NTC sensor at various temperatures.

DHW NTC Sensor

Lists resistance data for the DHW NTC sensor at various temperatures.

Flue Overheat Thermostat

Provides resistance data for the flue overheat thermostat at different temperature states.

Overheat Thermostat

Lists resistance data for the overheat thermostat at different temperature states.

Outdoor Weather Compensation Sensor

Provides resistance data for the outdoor weather compensation sensor at various temperatures.

Cylinder Temperature Sensor

Lists resistance data for the cylinder temperature sensor at various temperatures.

Gas Valve Resistances

Provides resistance values for the gas valve connections for testing.

Heating Function

Illustrates the central heating operational sequence, including ignition and fault conditions.

Hot Water Cylinder Function (Optional Integral Diverter Valve Kit Fitted)

Shows the operational sequence for hot water cylinder function with the diverter valve kit for DHW priority.

Protection Function

Details the appliance's frost protection, pump overrun, and antiseize functions for system protection.

Automatic Internal Frost Protection

Explains how the appliance's internal frost protection operates by monitoring primary temperature.

Pump Overrun Function CH

Describes the pump overrun function for central heating to dissipate residual heat.

Pump Overrun Locking Error

Explains the pump overrun function in case of a locking error to prevent pump damage.

Pump Antiseize Function

Details the pump's antiseize function to prevent seizure by running periodically.

Factory Reset

Guides on how to reset all appliance settings to factory defaults via the menu.

Removing the Optional Integral Diverter Valve Kit

Explains the process of removing the integral diverter valve kit and performing a factory reset.

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