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Worcester Greenstar Ri User Manual

Worcester Greenstar Ri
53 pages
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THE APPLIANCE IS FOR USE WITH
NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13 & C33)
NATURAL GAS: 24Ri GC NUMBER 41-311-65
18Ri GC NUMBER 41-311-77
15Ri GC NUMBER 41-311-75
12Ri GC NUMBER 41-311-63
LIQUID PETROLEUM GAS: 24Ri GC NUMBER 41-311-66
18Ri GC NUMBER 41-311-78
15Ri GC NUMBER 41-311-76
12Ri GC NUMBER 41-311-64
GB/IE
CHECKLIST & service
interval record is printed at the rear of
this manual

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Worcester Greenstar Ri Specifications

General IconGeneral
TypeRegular
Fuel TypeNatural Gas
MountingWall-mounted
ERP RatingA
Central Heating Flow Temperature Range30°C to 80°C
Standard Warranty5 Years
Dimensions600 x 390 x 270 mm

Summary

Contact Information and Manual References

Worcester Bosch Contact Details

Provides phone numbers for technical, service, spares, literature, training, and sales support.

Water Treatment Suppliers

Lists contact information for Fernox and Sentinel water treatment products.

Flue Terminal Guard Supplier

Provides contact details for TFC Group for flue terminal guards.

Manual Abbreviations

Lists common abbreviations used in the manual, e.g., NG, LPG, CH, DHW.

Manual Symbols

Explains symbols used in diagrams for heating, water, and electrical components.

Safety Precautions and Installation Regulations

Health and Safety Aspects

Covers appliance materials, COSHH regulations, and general safety guidelines.

Fitting and Modification Rules

Guidelines for installation by competent engineers and prohibiting unauthorized modifications.

Servicing Recommendations

Importance of annual servicing by qualified engineers using approved spares.

Regulatory Compliance

Adherence to Gas Safety, IEE, Building Regulations, and British Standards.

Specific Installation Types

Requirements for LPG, timber-framed buildings, and potable water systems.

General Information

Standard Package Contents

Lists all items included in the boiler's standard packaging.

Key Boiler Specifications

Details main features like pre-wiring, digital control, and frost thermostat.

Technical Data

Central Heating Performance Data

Output and pressure data for central heating modes.

Gas and Flue System Specifications

Details gas consumption rates and flue gas temperatures.

Electrical and Condensate Data

Information on electrical requirements and condensate rates.

General Appliance Performance Metrics

Data on SEDBUK rating, IP rating, and noise levels.

Layout and Components

Boiler Component Identification

Lists and labels all internal and external parts of the boiler.

Plumbing Connection Points

Details connections for gas, water, and condensate systems.

Cleaning Primary Systems

System Preparation and Checks

Ensures the system is in good working order before cleaning.

Primary System Flushing Procedure

Step-by-step guide for flushing the heating system.

Mains Supply

Electrical Supply Requirements

Specifies voltage, frequency, cable type, and earthing for the mains supply.

Gas Supply Requirements

Details connection to meters/regulators and compliance with BS6891 for gas supply.

Water Systems and Pipework

Pipework for Plastic and Underfloor Heating

Guidelines for plastic pipework and underfloor heating systems.

System Connections and Valves

Details standard connections, valves, and system requirements.

Sealed Central Heating System Pipework

Specific requirements for fully pumped sealed central heating systems.

Condensate Pipework

Condensate Pipe Installation Requirements

Specifies pipe material, fall, route, and insulation for condensate.

Condensate Discharge Methods

Illustrates various methods for discharging condensate safely.

Boiler Location and Clearances

Compartment and General Clearances

Specifies clearances and access for compartments and general installation.

Ventilation Requirements for Compartments

Details ventilation needs based on clearances in compartments.

Bathroom Installation Safety Zones

Defines safety zones and restricts electrical controls in bathrooms.

Plumbing Manifold

Heating System and Gas Connections

Details 22mm compression fittings for heating and gas connections.

Flue Terminal Positions

Minimum Terminal Clearance Dimensions

Table detailing minimum distances for flue terminals according to BS5440.

Flue Terminal Siting Recommendations

Guidance on flue terminal placement to avoid obstructions and nuisances.

Flue Options

Standard and Extended Flue Configurations

Shows components and maximum lengths for 100mm and 125mm flue systems.

Calculating Flue Lengths and Bends

Instructions on how to calculate total flue length considering bends and extensions.

Unpacking the Boiler

Lifting and Carrying Precautions

Safety advice for handling and lifting the boiler during unpacking.

Handling and Storage Instructions

Guidance on removing packaging, handling the appliance, and checking contents.

Wall Mounting Plate and Flue Opening

Fixing the Mounting Frame and Flue Hole

Instructions for attaching the wall plate and drilling the flue opening.

Rear and Side Flue Outlet Installation

Procedures for installing rear and side flue outlets, including angles.

Outer Case Removal

Steps for Outer Case Removal

Detailed procedure for removing the boiler's outer casing.

Boiler Connections

Securing the Wall Plate and Pipework

Instructions for fixing the wall plate and connecting heating/gas pipes.

Boiler Lifting and Pipe Fitting

Guidance on lifting the boiler and fitting pipes before or after wall mounting.

Flue Installation

Measuring and Cutting Standard Flue

How to measure and cut the standard 60/100mm diameter flue.

Measuring and Cutting Extension Flue Kits

Instructions for measuring and cutting flue extensions and bend allowances.

Assembling and Fitting the Flue

Procedures for assembling flue components, fitting the terminal, and elbow.

Condensate, Gas & Water Connections

Condensate Pipe Connection

Details on connecting the condensate pipe and adapter.

Electrics

Mains Supply and Wiring Centre Connection

Requirements for mains supply, isolator, and wiring centre connection.

Control Panel Wiring

Steps for accessing the control panel and connecting wires.

Position of Wired Components

Electrical Diagram of Components

Illustrates the layout and connections of internal electrical components.

Pre-Commissioning Checks

System and Pipework Verification

Checks for pipe connections, gas type, and condensate pipe.

Temporary Isolation Procedure

Instructions for isolating the boiler if commissioning is delayed.

Filling the System

System Filling and Venting

Steps for filling the system, venting air from the boiler and radiators.

Gas Supply and Testing

Procedure for purging the gas supply and testing for soundness.

Starting the Appliance

Appliance On/Off Procedure

Steps for switching the appliance on and setting controls.

Lockout Reset Procedure

How to reset the boiler if it enters flame lock-out.

Water Treatment

System Cleaning and Flushing

Instructions for cleaning the system and adding flushing agent.

Inhibitor Addition and System Pressurisation

Guide for adding inhibitor and pressurising sealed systems.

Commissioning

Checking Gas Inlet Pressure

Procedure to check and set the gas inlet pressure.

Measuring Gas Rate and Pressure

How to measure gas rate and working pressure.

Finishing Commissioning

Re-assembling Bottom Panel and Casing

Steps for refitting the bottom panel, outer casing, and screws.

Benchmark Checklist and User Demonstration

Completing the checklist and demonstrating controls to the user.

Inspection and Service

Service Requirements and Frequency

Importance of regular servicing by qualified engineers and frequency.

Initial Inspection of Flue and System Joints

Checking flue terminal, service space, and system joints for leaks.

Component Access for Servicing

Procedures for removing the outer case and accessing controls.

Adjusting Boiler Control to Service Position

How to move the boiler control to a service-friendly position.

Primary Heat Exchanger Cleaning

Information on cleaning the heat exchanger and checking fan pressure.

Setting Boiler to Maximum Output

Procedure to set the boiler to maximum for testing.

Combustion Testing Procedure

Emphasizes competent person requirement and analyser use for combustion testing.

Heat Exchanger and Syphon Cleaning

Steps for cleaning the heat exchanger and removing/cleaning the syphon.

Fan and Manifold Assembly Removal

Steps to remove the fan and air/gas manifold assembly.

Electrode and Burner Assembly Removal

Procedures for disconnecting electrodes and removing the burner.

Burner and Heat Exchanger Servicing

Instructions for removing the burner, baffles, and cleaning the heat exchanger.

Setting the Gas / Air Ratio

Preparing for Gas Ratio Adjustment

Isolating supply, removing case and cover to access control box.

Setting Mode Switch to Maximum

Using the tool to set the mode switch to maximum for testing.

Connecting Manometer and CO2 Measurement

Connecting manometer and measuring CO2 at air/gas outlet adjuster.

Adjusting Gas Valve for Correct CO2

Setting the mode switch and adjusting the gas valve for minimum output CO2.

Replacement of Parts

Removing Outer Case and Accessing Components

Steps for removing the outer case and accessing primary sensor, thermostats.

Replacing Primary Sensor and Thermostats

Procedures for replacing the primary sensor and overheat/flue thermostats.

Moving Control to Service Position

How to reposition the boiler control for servicing.

Replacing Gas Valve and Syphon

Procedures for replacing the gas valve and syphon.

Replacing PCB Fuse and Transformer

Instructions for replacing the PCB fuse and transformer.

Accessing Boiler Control Components

Steps to access and replace PCB fuse, transformer, and code plug.

Removing Air/Gas Manifold and Fan Assembly

Steps to remove the fan, air/gas manifold, and associated parts.

Replacing Pressure Switch

Procedure for replacing the pressure switch.

Fan Replacement

Steps to remove and replace the fan.

Electrode Assembly and Burner Replacement

Procedures for replacing electrodes and the burner.

Heat Exchanger Replacement

Instructions for removing and replacing the heat exchanger.

Short Parts List

Fan, Burner, and Gas Valve Parts

Lists part numbers and GC numbers for fan, burner, and gas valve.

Control Board and Sensor Parts

Lists part numbers and GC numbers for control board, sensors, and thermostats.

Other Component Part Numbers

Lists part numbers and GC numbers for fuses, electrodes, seals, etc.

Gas Conversion

12kW & 15kW Gas Conversion Procedure

Steps for converting 12/15kW models to LPG, including code plug.

18kW & 24kW Gas Conversion Procedure

Steps for converting 18/24kW models to LPG, including code plug and adjuster.

Electrical Wiring Diagram

Terminal Block and Fuse Identification

Details on terminal blocks, fuses, and mains supply connections.

Component Wiring and Sensor Connections

Identifies wiring for spark transformer, pump, NTC sensor, and overheat sensors.

Fault Finding

Preliminary Electrical Checks

Initial electrical checks for earth continuity, short circuits, polarity, and resistance.

Fault Indications and Solutions

Table of fault indications (lights, flashes) and possible solutions.

Main Function

Boiler Operation Sequence

Flowchart illustrating the boiler's operating sequence and logic.

Protection System Functions

Details on safety features like over-temperature and pump anti-seize.

Benchmark Gas Boiler Commissioning Checklist

Control Compliance Confirmation

Checklists for time/temperature controls, zone valves, and bypass.

System Flush and Cleaner Confirmation

Confirmation of system flushing and cleaner usage.

Mode Measurement and Recording

Recording gas rate, pressures, temperatures, and CO/CO2 ratios.

Installation and Demonstration Confirmation

Confirmation of installation compliance, demonstration, and literature handover.

Service Interval Record

Service Log Entries

Template for recording service details by engineers.

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