Wall hung rsf gas fired condensing combination boiler (76 pages)
Summary of Contents for Bosch Worcester GREENSTAR 12i System
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THE APPLIANCE IS FOR USE WITH NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13 & C33) NATURAL GAS: WORCESTER GREENSTAR 12i System GC NUMBER 41-311-67 WORCESTER GREENSTAR 24i System GC NUMBER 41-311-68 LIQUID PETROLEUM GAS: WORCESTER GREENSTAR 12i System GC NUMBER 41-311-69...
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THIS APPLIANCE MUST BE INSTALLED BY A COMPETENT PERSON. FAILURE TO INSTALL CORRECTLY COULD LEAD TO PROSECUTION. IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER BOSCH TECHNICAL HELPLINE. WATER TREATMENT: DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER...
FAULT FINDING & DIAGNOSIS FAULT FINDING CH FUNCTION PROTECTION FUNCTION ADDITIONAL INSTRUCTIONS FOR FITTING OPTIONAL DIVERTER VALVE CAN BE FOUND AT THE REAR OF THIS MANUAL INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System CONTENTS 8 716 107 375a (02/05)
IMPORTANT - The service engineer must complete the Service Record on the Benchmark Checklist after each service. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System SAFETY PRECAUTIONS 8 716 107 375a (02/05)
Combustion air fan with speed regulator CH temperature sensor & control Pump anti-seizure protection Flue gas temperature limiter Condensate trap & syphon INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System GENERAL INFORMATION 8 716 107 375a (02/05)
29 PUMP 30 SYSTEM PRESSURE GAUGE 31 CONTROL PANEL IN SERVICE POSITION 32 HEAT EXCHANGER 33 ACCESS COVER FOR TRANSFORMER & INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System LAYOUT & COMPONENTS 8 716 107 375a (02/05)
5 Drain and thoroughly flush the system to remove the flushing agent and debris. Valve Flushing Agent INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System CLEANING PRIMARY SYSTEMS 8 716 107 375a (02/05)
• Do not use galvanised pipes or radiators. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System WATER SYSTEMS & PIPEWORK 8 716 107 375a (02/05)
H - Ground level J - Drainage holes 50mm from base of tube (12mmØ at 25mm centres) facing away from building K - Limestone chippings INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System CONDENSATE PIPEWORK 8 716 107 375a (02/05)
Electrical switches, fused spur and socket out let s must not be sit uat ed in t he bathroom. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System BOILER LOCATION & CLEARANCES 8 716 107 375a (02/05)
ADDITIONAL INFORMATION section at the back of this book. Flow 22mm Return 22mm Mains Gas Supply 22mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System PLUMBING MANIFOLD 8 716 107 375a (02/05)
Vertical 80/125mm: 1365mm to top of terminal Ø125 - 11000mm (including terminal) B x 13 + C x 2 + E x 1 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System FLUE OPTIONS 8 716 107 375a (02/05)
Allow for a rise of 52mm per metre length of flue, to give a 3° angle. Clear any debris from the site. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System WALL MOUNTING PLATE FLUE OPENING 8 716 107 375a (02/05)
See “OPTIONAL DIVE RTE R VALVE” Sect ion in t hese inst ruct ions or t he instructions supplied with the optional diverter valve kit. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System UNPACKING THE APPLIANCE 8 716 107 375a (02/05)
UP until the stop on the inside of the handle is over the shoulder of the metal bracket to secure in place. Stop in locked position INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System BOILER CONNECTIONS 8 716 107 375a (02/05)
8. Connect the pressure relief drain pipe to 15mm compression joint (H) using the nut and olive supplied in the hardware literature pack. 22mm 22mm 22mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System BOILER CONNECTIONS 8 716 107 375a (02/05)
After cutting, the end must be square and free from burrs to prevent damage to the flue seals. (250mm min) Turret Clamp Flue INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System FLUE INSTALLATION 8 716 107 375a (02/05)
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In the example shown using a flue extension with 2 bends will achieve a total length of 1148mm. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System FLUE INSTALLATION 8 716 107 375a (02/05)
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• The flue is set at an angle of 3° or 52mm per 1m length. Flat at back This screw should be fitted last for easier installation when rear exit INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System FLUE INSTALLATION 8 716 107 375a (02/05)
SIONING CHECKS and refer to the cor- rect versions that follow FITTING THE DIVE RTE R VALVE in the ADDITIONAL INFORMATION section at the back of this book. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System CONDENSATE CONNECTION 8 716 107 375a (02/05)
This option is also covered in the Fault Finding Guide on page 54 of these instructions. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System ELECTRICAL 8 716 107 375a (02/05)
POSITION OF WIRED COMPONENTS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System POSITION OF WIRED COMPONENTS 8 716 107 375a (02/05)
8 Rotate the adjustable pointer on the pressure gauge to record the set system pressure. 9 Isolate and remove filling loop connection to system. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System FILLING THE SYSTEM 8 716 107 375a (02/05)
To reset press and hold the reset button (E) for 2 seconds. The boiler will be reset. CAUTION: DO NOT PRESS POWER INDICATOR (B) TO RESET BOILER. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System STARTING THE APPLIANCE 8 716 107 375a (02/05)
* compatible with aluminium. The pH Agent value of the system water must be less than 8 or the appliance guarantee will be invalidated. Inhibitor INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System WATER TREATMENT 8 716 107 375a (02/05)
E - Reset button F - Service button G - Not used Inlet Test Nipple H - System pressure gauge I - Cover or optional programmer INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System COMMISSIONING 8 716 107 375a (02/05)
If the appliance is unused and exposed to freezing conditions, shut off all the mains supplies and drain the system and boiler. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System FINISHING COMMISSIONING 8 716 107 375a (02/05)
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Commissioning. Operate the appliance and take note of any irregularities. Refer to Fault Finding for rectification procedures. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System INSPECTION AND SERVICE 8 716 107 375a (02/05)
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24i System - 3. 1 mbar 24i System - 4. 1 mbar Pressures measured below these figures will indicate that the heat exchanger will require cleaning. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System INSPECTION AND SERVICE 8 716 107 375a (02/05)
There is a special accessory kit available specifically designed for cleaning the heat exchanger. If required order 7 716 192 312. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System INSPECTION AND SERVICE 8 716 107 375a (02/05)
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3.3 Remove siphon Siphon The siphon body is transparent so contents can be examined for any blockage. If necessary flush with clean water. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System INSPECTION AND SERVICE 8 716 107 375a (02/05)
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(J). Remove clamping plate (K). Remove spark/flame electrode assembly from boiler. Remove seal from the top of the heat exchanger INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System INSPECTION AND SERVICE 8 716 107 375a (02/05)
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BETWEEN THE AIR/GAS MANIFOLD AN D TH E H EAT E XCHANG E R I S DISTURBED THE SEALING GASKET MUST BE REPLACED. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System INSPECTION AND SERVICE 8 716 107 375a (02/05)
Note: It is essential that the mating surface of the thermostat is coated with heat conductive paste. 4. Flue overheat thermostat Remove electrical connections. Unscrew thermostat from flue. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System REPLACEMENT OF PARTS 8 716 107 375a (02/05)
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8.1 Undo plastic nut (E) on the siphon outlet. Drop condensate tube away from siphon. 8.2 Remove hose (F). 8.3 Remove siphon. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System REPLACEMENT OF PARTS 8 716 107 375a (02/05)
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Remove 5 screws (C) retaining the rear panel of the control and remove panel. Pull transformer upwards from PCB. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System REPLACEMENT OF PARTS 8 716 107 375a (02/05)
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IS RE-FITTED TO THE NEW CONTROL. IF THIS IS NOT DONE 12.2 THE BOILER WLL INDICATE ERROR AND WILL NOT FUNCTION. 12.3 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System REPLACEMENT OF PARTS 8 716 107 375a (02/05)
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I M PORTANT: E N S U R E TU B E I S REFITTED TO PRESSURE SWITCH 14.1 14.2 14.3 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System REPLACEMENT OF PARTS 8 716 107 375a (02/05)
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Pull heat exchanger assembly up to clear. Reassemble and check combustion as stated in the gas conversion section. 18.4 18.2 18.3 18.1 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System REPLACEMENT OF PARTS 8 716 107 375a (02/05)
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21.2 Lift the air vent (C) out of the housing and remove. To refit, follow the above in reverse. 21.1 21.2 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System REPLACEMENT OF PARTS 8 716 107 375a (02/05)
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24.2 Withdraw the drain tap from its housing To refit, follow the above in reverse. Ensure any seals that have been disturbed are renewed. 24.1 24.2 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System REPLACEMENT OF PARTS 8 716 107 375a (02/05)
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26.2 Withdraw the pressure release valve (A) from its housing. To refit, follow the above in reverse. Ensure any seals that have been disturbed are renewed. 26.1 26.2 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System REPLACEMENT OF PARTS 8 716 107 375a (02/05)
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Gently raise the boiler off the mounting frame. Replace expansion vessel and refit the boiler to the mounting frame. Follow the commissioning procedure in this manual. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System REPLACEMENT OF PARTS 8 716 107 375a (02/05)
Fit new label from kit over existing label on the system must only be run in central appliance bottom panel. heating mode. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System REPLACEMENT OF PARTS 8 716 107 375a (02/05)
P R O C E D U R E C AN B E F O U N D I N THE REPLACEMENT PARTS SECTION OF THIS MANUAL. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System L.P.G CONVERSION 8 716 107 375a (02/05)
P R O C E D U R E C AN B E F O U N D I N 24kW NG THE REPLACEMENT PARTS SECTION 24kW LPG OF THIS MANUAL. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System L.P.G CONVERSION 8 716 107 375a (02/05)
FAULT FINDING NOTE : This fault finding information is for guidance only. Worcester Bosch cannot be held responsible for costs incurred by persons not deemed to be competent. The electronic control system for this boiler incorporates a blue central indicator. This normally confirms the permanent mains supply but, by flashing at different rates during a fault, provides a guide to the cause as listed.
CENTRAL HEATING and DHW FUNCTIONS in the ADDITIONAL INFORMATION section at the back of this book. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System BOILER FUNCTION 8 716 107 375a (02/05)
PROTECTION FUNCTION Boiler temperature Run autofroststat below 8°C function Pump run 5 seconds Pump antiseize every 24hrs INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System PROTECTION FUNCTION 8 716 107 375a (02/05)
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THE APPLIANCE IS FOR USE WITH NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13 & C33) NATURAL GAS: WORCESTER GREENSTAR 12i System GC NUMBER 41-311-67 WORCESTER GREENSTAR 24i System GC NUMBER 41-311-68 LIQUID PETROLEUM GAS: WORCESTER GREENSTAR 12i System GC NUMBER 41-311-69...
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IN STR UCTION S PAG E 16 TO CONTINUE INSTALLATION. Flow 22mm Mains Gas CH Return 22mm Supply 22mm Cylinder Return 15mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System PLUMBING MANIFOLD 8 716 107 375a (02/05)
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Re-tighten the clamping plate by re-tightening the two screws (B) as shown in fig: 2. • 4.1 On completion the pipe assembly should look as shown. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System BOILER CONNECTIONS 8 716 107 375a (02/05)
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UP until the stop on the inside of the handle is over the shoulder of the metal bracket to secure in place. Stop in locked position INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System BOILER CONNECTIONS 8 716 107 375a (02/05)
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NOW R ETU R N TO TH E MAIN INSTRUCTIONS PAGE 23 (FLUE INSTALLATION) TO CONTINUE INSTALLATION. 22mm 22mm 15mm 22mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System BOILER CONNECTIONS 8 716 107 375a (02/05)
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12kW i System Kit: 12i System NATURAL GAS 112 12i System LPG 24kW i System Kit: 24i System NATURAL GAS 114 24i System LPG INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System BOILER CONNECTIONS 8 716 107 375a (02/05)
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10 Diverter valve motor (ST17): Connect electrical harness from diverter valve motor to ST17 (see following page). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System ELECTRICAL 8 716 107 375a (02/05)
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POSITION OF WIRED COMPONENTS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System POSITION OF WIRED COMPONENTS 8 716 107 375a (02/05)
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I N STR UC TION S PAG E ( F I LLI NG TH E SYSTE M ) TO CONTINUE INSTALLATION. 22mm 22mm 15mm 22mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System PRE- COMMISSIONING CHECKS 8 716 107 375a (02/05)
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CENTRAL HEATING FUNCTION INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System CENTRAL HEATING FUNCTION 8 716 107 375a (02/05)
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DHW FUNCTION R ETU R N TH E MAI N INSTRUCTIONS PAGE 57 FOR PROTECTION FUNCTION. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 12i System/24i System DHW FUNCTION 8 716 107 375a (02/05)
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INSTALLATION, COMMISSIONING & SERVICING EXCELLENCE COMES AS STANDARD Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 01905 754624 Fax. 01905 754619 Worcester, Bosch Group is a trading name of BBT Thermotechnology UK Ltd. www.worcester-bosch.co.uk 8 716 107 375a (02.05)