Worcester Greenstar Ri Manuel de service Page 1

UK/IEINSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONSWALL HUNG RSF GAS FIRED CONDENSING BOILERGREENSTAR Ri6720644744-00.1WoFOR OPEN VENTED AND S

PRE-INSTALLATION6 720 644 744b (2011/08)103.3 WATER SYSTEMS AND PIPE WORKPLASTIC PIPE WORK:• Any plastic pipe work must have a polymeric barrier with

PRE-INSTALLATION6 720 644 744b (2011/08)11S PLAN LAYOUTFig. 3 S planY PLAN LAYOUTFig. 4 Y planSEALED SYSTEM Y PLAN LAYOUTFig. 5 Sealed systemNEW BUILD

PRE-INSTALLATION6 720 644 744b (2011/08)123.4 CONDENSATE PIPE WORK3.4.1 INTERNAL CONNECTIONSIn order to minimise risk of freezing during prolonged col

PRE-INSTALLATION6 720 644 744b (2011/08)133.4.2 EXTERNAL CONNECTIONSIf no other discharge method is possible then the use of an externally run condens

PRE-INSTALLATION6 720 644 744b (2011/08)14CONDENSATE SOAK AWAY• The condensate drainage pipe may be run above or below the ground to the soak away. Th

PRE-INSTALLATION6 720 644 744b (2011/08)153.6 BOILER LOCATION AND CLEARANCES3.6.1 INSTALLATIONThis boiler is only suitable for installing internally w

PRE-INSTALLATION6 720 644 744b (2011/08)163.6.5 BOILER CLEARANCES- UNVENTILATED COMPARTMENTS3.6.6 INSTALLATION CLEARANCES - UNVENTILATED COMPARTMENTST

PRE-INSTALLATION6 720 644 744b (2011/08)173.7 PLUMBING MANIFOLD3.7.1 CONNECTIONSUse the fittings supplied in the Hardware literature pack:• Use the 22

PRE-INSTALLATION6 720 644 744b (2011/08)183.8 FLUE OPTIONS FLUE LENGTHSThe flue systems have different maximum flue lengthsThe Greenstar series has th

PRE-INSTALLATION6 720 644 744b (2011/08)19350 mm 570 mm130 mm MinFlat roof300 mm500 mmPitchedroof234561098716720643895-12.1Wo

CONTENTS6 720 644 744b (2011/08)2CONTENTS1 KEY TO SYMBOLS AND SAFETY PRECAUTIONS 31.1 Explanation of symbols . . . . . . . . . . . . . . 31.2 Safety

PRE-INSTALLATION6 720 644 744b (2011/08)203.9 FLUE TERMINAL POSITIONSFig. 20 Flue terminal positionsKey to illustration1. Flue clearance must be at le

PRE-INSTALLATION6 720 644 744b (2011/08)213.10 PLUME TERMINAL POSITIONSFig. 21 Plume terminal positionsKey to illustration1. 600 mm distance to a boun

INSTALLATION6 720 644 744b (2011/08)224INSTALLATION4.1 UNPACKING THE WALL FRAME AND ANCILLARY ITEMS1. System flow and return pipes - 22mm x 22. Wall m

INSTALLATION6 720 644 744b (2011/08)234.2 WALL MOUNTING TEMPLATE & FLUE OPENINGSAFETY:All relevant safety precautions must be undertaken. Protecti

INSTALLATION6 720 644 744b (2011/08)244.3 OUTER CASE REMOVAL1. Undo the two captive screws securing boiler casing at the bottom of the appliance.2. Un

INSTALLATION6 720 644 744b (2011/08)254.4 BOILER CONNECTIONGAS AND WATER CONNECTIONS:B Remove wall mounting template and secure the wall mounting fram

INSTALLATION6 720 644 744b (2011/08)264.4.1 CONDENSATE CONNECTIONNever terminate or discharge into any open source, including; sink, bath, shower, bid

INSTALLATION6 720 644 744b (2011/08)274.5 FLUE INSTALLATIONHORIZONTAL FLUE (60/100mm diameter)For vertical flues and 80/125mm horizontal flues, please

INSTALLATION6 720 644 744b (2011/08)284.5.3 INSTALLING THE TELESCOPIC FLUE:Refer to figure 34.1. Set the flue length to the distance required, secure

INSTALLATION6 720 644 744b (2011/08)294.5.4 FLUE TERMINAL PLUME RE-DIRECTION:The flue discharge can be re-directed allowing some plume redirection con

KEY TO SYMBOLS AND SAFETY PRECAUTIONS6 720 644 744b (2011/08)31 KEY TO SYMBOLS AND SAFETY PRECAUTIONS1.1 EXPLANATION OF SYMBOLSWARNING SYMBOLSSignal w

INSTALLATION6 720 644 744b (2011/08)304.6 ELECTRICAL CONNECTIONSB The mains supply to the boiler and system wiring centre must be common, and through

INSTALLATION6 720 644 744b (2011/08)31NEW COMPLETE SYSTEM INSTALLATIONSIf a new complete heating system is installed in a new build property or it is

COMMISSIONING6 720 644 744b (2011/08)325 COMMISSIONING5.1 PRE-COMMISSIONING CHECKSB Check that the gas service pipe and water pipes are connected to t

COMMISSIONING6 720 644 744b (2011/08)335.2 FILLING THE SYSTEMOpen vented systems:B Ensure all system and boiler drain points are closed.B Open all rad

COMMISSIONING6 720 644 744b (2011/08)345.4 STARTING THE APPLIANCEFig. 46 Boiler controlsSwitching the appliance ON/OFF:B Turn on mains power supply, t

COMMISSIONING6 720 644 744b (2011/08)355.5 COMMISSIONINGHaving checked:B That the boiler has been installed in accordance with the installation instru

COMMISSIONING6 720 644 744b (2011/08)365.6 FINISHING COMMISSIONING5.6.1 REPLACE THE OUTER CASE:Replace outer casing making sure that the securing poin

SERVICE AND SPARES6 720 644 744b (2011/08)376SERVICE AND SPARES6.1 INSPECTION AND SERVICE• To ensure the continued efficient operation of the applianc

SERVICE AND SPARES6 720 644 744b (2011/08)38LOWERING THE BOILER CONTROLS TO THE SERVICE POSITION:1. Remove two screws securing the control.2. Pull the

SERVICE AND SPARES6 720 644 744b (2011/08)396.2 CHECKING GAS INLET PRESSURERefer to section 5.5.1 for more informationB Check the gas supply working

KEY TO SYMBOLS AND SAFETY PRECAUTIONS6 720 644 744b (2011/08)41.2 SAFETY PRECAUTIONSIF YOU SMELL GAS:B CALL NATIONAL GAS EMERGENCY SERVICE ON 0800 11

SERVICE AND SPARES6 720 644 744b (2011/08)406.4 FAN PRESSURE TESTSETTING THE BOILER TO MAXIMUM1. Remove the three screws retaining the control cover.2

SERVICE AND SPARES6 720 644 744b (2011/08)41If the boiler fails the fan pressure test then before adjusting the air/gas ratio, try the following: B Ch

SERVICE AND SPARES6 720 644 744b (2011/08)426.6 SETTING THE AIR/GAS RATIO6.6.1 SETTING THE CO/CO2B Refer to section 6.2 and ensure that the gas inlet

SERVICE AND SPARES6 720 644 744b (2011/08)436.7 CLEANING THE HEAT EXCHANGERB Isolate the power to the appliance and remove outer case and base panel.1

SERVICE AND SPARES6 720 644 744b (2011/08)44BURNER REMOVALRefer to figure 671. Remove clamping plate.2. Remove spark/flame electrode assembly and seal

SERVICE AND SPARES6 720 644 744b (2011/08)45ACCESS COVER REMOVALRefer to figure 69.1. Remove the two pozi-drive screws 2. Remove the access cover3. Re

SERVICE AND SPARES6 720 644 744b (2011/08)466.7.1 SYPHON REMOVAL AND CLEANINGTo release the syphon from the sump:1. Undo the plastic nut on the bottom

SERVICE AND SPARES6 720 644 744b (2011/08)476.8 REPLACEMENT OF PARTS6.8.1 REMOVING THE OUTER CASINGB Remove bottom tray by pressing the tabs (2) in, a

SERVICE AND SPARES6 720 644 744b (2011/08)486.8.2 PRIMARY SENSOR (CH NTC)Refer to figure 74 for removal.1. Remove electrical connection by pulling upw

SERVICE AND SPARES6 720 644 744b (2011/08)496.8.5 LOWERING THE BOILER CONTROLS TO THE SERVICE POSITION:1. Remove two screws securing control.2. Pull t

KEY TO SYMBOLS AND SAFETY PRECAUTIONS6 720 644 744b (2011/08)5British Standards:Where no specific instruction is given, reference should be made to th

SERVICE AND SPARES6 720 644 744b (2011/08)506.8.7 AIR/GAS MANIFOLD AND FAN ASSEMBLYB Remove electrical connector and earth wire the from fan.B Remove

SERVICE AND SPARES6 720 644 744b (2011/08)516.8.8 AIR PRESSURE SWITCH1. Remove the electrical connections.2. Slacken the top retaining screw and remov

SERVICE AND SPARES6 720 644 744b (2011/08)52FLAP VALVE ASSEMBLY1. Twist the mounting flange clockwise to release.2. Pull mounting flange off the flap

SERVICE AND SPARES6 720 644 744b (2011/08)536.8.11 HEAT EXCHANGERB Drain the system.B Remove syphon.B Remove the air/gas manifold and fan.Refer to fig

SERVICE AND SPARES6 720 644 744b (2011/08)54Refer to figure 91.1. Lift the heat exchanger up to clear.2. Pull the heat exchanger forward from the case

SERVICE AND SPARES6 720 644 744b (2011/08)556.8.15 TRANSFORMER/PCBTo change either the PCB, F2 fuse or transformer:B Remove two screws securing the co

SERVICE AND SPARES6 720 644 744b (2011/08)566.8.16 SYPHON REMOVALTo release the syphon from the sump:1. Undo the plastic nut on the bottom of the syph

SERVICE AND SPARES6 720 644 744b (2011/08)576.9 SHORT PARTS LISTFan8 716 116 067 0GC No. H26 536Burner12 & 15Ri:8 718 120 616 0GC No. H26 53718 &a

FAULT FINDING AND DIAGNOSIS6 720 644 744b (2011/08)587 FAULT FINDING AND DIAGNOSIS7.1 FAULT FINDINGThe electronic control system for this boiler incor

FAULT FINDING AND DIAGNOSIS6 720 644 744b (2011/08)59Slow flash (mostly on, flashes off)Flue overheat Flue temperature too high.B Heat exchanger baffl

APPLIANCE INFORMATION6 720 644 744b (2011/08)62APPLIANCE INFORMATION2.1 APPLIANCEFig. 1 Appliance123456720644744-01.1Wo390mm270mm*600mm to top of case

FAULT FINDING AND DIAGNOSIS6 720 644 744b (2011/08)607.1.1 INTERNAL WIRING DIAGRAMEXTERNALPUMPFLUEOVERHEATSTATLNLP NP LREarthMAINSSUPPLYSPARKTRANSFORM

FAULT FINDING AND DIAGNOSIS6 720 644 744b (2011/08)617.2 BOILER FUNCTIONFig. 96 Boiler functionNOYESMAINSPOWERSUPPLYONBOILERDEMANDFan tostartspeed.Pum

FAULT FINDING AND DIAGNOSIS6 720 644 744b (2011/08)627.3 PROTECTION FUNCTIONFig. 97 Protection functionInternal boilertemperaturebetween8°C & 5°CB

6 720 644 744b (2011/08)63NOTES

6 720 644 744b (2011/08)64NOTES

6 720 644 744b (2011/08)65

Service RecordIt is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.Service P

Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the

Worcester, Bosch GroupCotswold Way, Warndon, Worcester WR4 9SW.Tel. 0844 892 9900Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd.

APPLIANCE INFORMATION6 720 644 744b (2011/08)72.2 TECHNICAL DATADESCRIPTION NATURAL GAS LPGUNIT 12Ri 15Ri 18Ri 24Ri 12Ri 15Ri 18Ri 24RiGas flow rate -

APPLIANCE INFORMATION6 720 644 744b (2011/08)82.3 BOILER MAIN COMPONENTS1Air/Gas Manifold 16 Wiring connections cover2 Sensor - Boiler flow 17 Burner

PRE-INSTALLATION6 720 644 744b (2011/08)93 PRE-INSTALLATION3.1 CLEANING PRIMARY SYSTEMSBEFORE CLEANING THE SYSTEM:B Ensure that the system and pipe wo