Worcester Greenstar 25Si Compact Installation, Commissioning And Servicing Instructions
Wall hung rsf gas fired condensing combination boiler
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INSTALLATION COMMISSIONING AND SERVICING INSTRUCTIONS
WALL HUNG RSF GAS FIRED CONDENSING COMBINATION BOILER
Greenstar Si Compact
FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER
ErP
These appliances are for use with:
Natural Gas or L.P.G.
(Cat. II 2H 3P type C13, C33 & C53)
Model
Natural Gas
25Si Compact
30Si Compact
L.P.G.
25Si Compact
30Si Compact
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.
UK/IE
GC Number
ErP
47-406-73
ErP
47-406-75
ErP
47-406-74
ErP
47-406-76
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Table of Contents
Related Manuals for Worcester Greenstar 25Si Compact
Summary of Contents for Worcester Greenstar 25Si Compact
- Page 1 INSTALLATION COMMISSIONING AND SERVICING INSTRUCTIONS WALL HUNG RSF GAS FIRED CONDENSING COMBINATION BOILER Greenstar Si Compact FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER 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...
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Page 2: Table Of Contents
CONTENTS CONTENTS Commissioning ....... . 36 Key to symbols and safety instructions ....4 6.5.1 Checking the gas inlet pressure . - Page 3 CONTENTS 7.8.30 Replacing the control unit ..... . . 56 7.8.31 Expansion vessel ......56 Short parts list .
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Page 4: Key To Symbols And Safety Instructions
If you are in any doubt, contact the Worcester Technical helpline (0330 123 3366). a list entry Please leave these instructions with the completed BENCHMARK... -
Page 5: Safety Precautions
▶ Turn off the gas at the meter or regulator. ▶ Open windows and doors. ▶ Warn your neighbours and leave the building. Only use the approved Worcester Condensfit II flue system with this ▶ Prevent anyone from entering the building. appliance. -
Page 6: Regulations
REGULATIONS Regulations Installation regulations Current Gas Safety (Installation & Use) Regulations: All gas appliances must be installed by a competent person in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution. The appliance must be installed in accordance with, and comply to, the current: Gas Safety Regulations, IET Regulations, Building Regulations, Building Standards (Scotland) (Consolidation), Building Regulations (Northern Ireland), local water by-laws, Health &... -
Page 7: Appliance Information
APPLIANCE INFORMATION APPLIANCE INFORMATION APPLIANCE Depth to wall 280mm (When fitted to wall frame) 680mm* * 690mm to top of case front 390mm 6720813278-01.1Wo STANDARD PACKAGE 1. Wall hung gas-fired condensing combi boiler for central heating and 5. PRV installer connection elbow domestic hot water 6. -
Page 8: Layout
APPLIANCE INFORMATION LAYOUT 6720813276-02.1Wo 48 47 46 45 44 43 42 Fig. 1 Main boiler components Greenstar Si Compact - 6 720 813 278 (2015/07) - Page 9 • Galvanised steel wall mounting frame • Standard wall frame provides vertical pipe route behind the boiler • Compatible with all Worcester standard and intelligent controls • Condensfit II flue systems 60/100 and 80/125mm allows plume re-direction as standard and ability to attach plume management kits...
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Page 10: Technical Data
APPLIANCE INFORMATION Technical data Natural gas L.P.G. DESCRIPTION Si Compact ErP UNIT 25kW 30kW 25kW 30kW Domestic Hot Water Minimum heat input 7.15 7.15 7.15 7.15 Maximum rated heat output Maximum rated heat input 25.5 30.61 25.5 30.61 Maximum mains inlet pressure (standing pressure) Minimum mains inlet pressure (working) for max. -
Page 11: Energy Efficiency
APPLIANCE INFORMATION Energy efficiency The following product data satisfy the requirements of the EU Regulations No. 811/2013 and No. 812/2013 supplementing Directive 2010/30/EU. Product data Symbol Unit 7733600050 7733600052 7733600051 7733600054 Product type – – 25Si Compact 30Si Compact 25Si Compact 30Si Compact Condensing boiler –... -
Page 12: Pre-Installation
▶ In cases where all attempts to find a micro leak have failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer. Greenstar Si Compact... -
Page 13: Water Supply
PRE-INSTALLATION 4.2.3 Water supply The boiler is equipped with an internal by-pass. Use in hard water areas: The internal bypass is not intended to be a substitute for an external system bypass. Normally there is no need for water treatment to prevent scale formation An external automatic bypass should be used if the as the maximum temperature of the DHW heat exchanger is limited by system flow can be significantly adjusted or stopped by... -
Page 14: Condensate Pipe Work
PRE-INSTALLATION SEALED PRIMARY SYSTEM: AVAILABLE PUMP HEAD NOTICE: Artificially softened water must not be used to In order to save as much energy as possible and the fill the central heating system. minimise the possibility of water circulation noise, a low characteristic should be chosen. -
Page 15: Internal Connections
PRE-INSTALLATION 4.4.1 Internal connections In order to minimise risk of freezing during prolonged cold spells, the following methods of installing condensate drainage pipe should be adopted, in order of priority. Wherever possible, the condensate drainage pipe should be routed and terminated so that the condensate drains away from the boiler under 75mm gravity to a suitable internal foul water discharge point such as an... - Page 16 PRE-INSTALLATION ▶ The use of fittings, elbows etc. should be kept to a minimum and any internal “burrs” on cut pipe work should be removed so that the internal pipe section is as smooth as possible. FITTING AN EXTERNAL AIR BREAK •...
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Page 17: Pressure Relief Pipe Work
PRE-INSTALLATION Pressure relief pipe work Boiler location and clearances 4.6.1 Installation NOTICE: This appliance is only suitable for installing internally within a property at ▶ The pressure relief valve is a safety device for the a suitable location onto a fixed, rigid surface at least the same size as the boiler and if activated may discharge boiling water or appliance and capable of supporting the appliance weight. -
Page 18: Bathrooms
PRE-INSTALLATION 4.6.4 Bathrooms Please check the IP rating of any control to be used on this appliance. Only certain controls can be fitted when the appliance is inside of the shaded area. An appliance with blanking panel or controls that do not change the IP rating can be installed in zone 2. -
Page 19: Flue Terminal Positions
PRE-INSTALLATION FLUE TERMINAL POSITIONS All measurements in millimetres 52mm 104mm 1,500 1,500 300 300 300 300 1,200 Boundary Line Fig. 17 Flue terminal positions NOTICE: ▶ All measurements are the minimum clearances required. ▶ Terminals must be positioned so to avoid combustion products entering the building. ▶... -
Page 20: Flue Options
FLUE OPTIONS TELESCOPIC HORIZONTAL FLUE ASSEMBLY WARNING: Flue systems 60/100 mm ▶ Only use Worcester, Bosch approved flue systems, no 350 mm - 570 mm other manufacturer’s flue systems have been approved for use with Worcester appliances. CAUTION: Non accessible flue systems: 130 mm Min ▶... - Page 21 PRE-INSTALLATION High level horizontal flue Vertical balanced flue assembly A = 300 mm B = 500 mm Maximum flue length Maximum flue length (mm) (mm) 60/100 80/125 60/100 80/125 Vertical balanced flue assembly 6,000 15,000 High level horizontal flue 6,000 15,000 Table 18 Table 15...
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Page 22: Plume Management Terminal Positions
PRE-INSTALLATION 4.10 PLUME MANAGEMENT TERMINAL POSITIONS All measurements in millimetres Flue terminal guard 7 716 191 176 ±45° Plume re-direction: 180° Flue Exhaust Outlet 1,500 Air Intake ±80° 1,200 Boundary Line Fig. 18 Plume terminal positions Maximum and minimum plume management lengths: ▶... -
Page 23: Determine The Plume Management System Length
PRE-INSTALLATION 4.10.1 DETERMINE THE PLUME MANAGEMENT SYSTEM LENGTH FLUE LENGTH VERSUS PLUME MANAGEMENT LENGTH Effective straight flue length with plume management Minimum plume length (M) Maximum plume length (M) 500mm 4,500mm Max flue length (L) 5,000mm Max flue length (L) 2,200mm Note: Measurement M plume length ▶... -
Page 24: Installation
INSTALLATION INSTALLATION Additional requirements for roof space installation: WARNING: All the previous “Pre-Installation” sections • The boiler should be first unpacked before ascending ladder to a loft must be read and the requirements met before starting space. boiler or flue installation. •... -
Page 25: Unpacking The Appliance
INSTALLATION 4. Remove the protective cardboard (5) from over the isolating valves. 5. Remove the protective cardboard (6) from around the expansion vessel. 6. Remove the inner packing (2) from the back of the boiler. 7. Lie the boiler on the floor ensuring that the V shaped cardboard insert (8) is in place. -
Page 26: Pre-Plumbing Boiler Connections
INSTALLATION Refer to Figure 27. The connector (1) in the wiring harness is for use on other appliances and does not provide a function on this Greenstar Si Compact 6720646608-111.2Wo Fig. 29 PRV pipe connection Once the wall frame has been mounted the PRV discharge pipe can be Fig. -
Page 27: Hanging The Boiler
INSTALLATION HANGING THE BOILER ▶ Replace the two screws (1) removed earlier and tighten firmly. ▶ The boiler is mounted on the wall frame utilising the two mounting CAUTION: Lifting the boiler points, indicated on figure 33, left and right at the top of the wall ▶... -
Page 28: Flue Turret/Adaptor Installation
INSTALLATION CONNECTING THE EXPANSION VESSEL To connect the expansion vessel to the hydraulic pump manifold situated to the left of the pump: 1. Release the expansion tank from the retaining bracket, see fig 35. 2. Ensure that the wire retaining clip on the pump manifold is fully withdrawn, but not removed, before inserting the expansion vessel pipe into pump manifold, see fig. -
Page 29: Electrical
INSTALLATION ▶ Align the flue turret/vertical adaptor to the appliance flue outlet with ACCESS TO ELECTRICAL CONNECTIONS: flat facing [3] to the rear of the appliance. ▶ Access to all wiring connections are via the Installer access cover at The flue turret/adaptor should be pushed straight down, on to the the bottom front of the control panel. -
Page 30: Mounting Optional Plug-In Controls
Refer the to Programmer/Timer manual for set up and operation of the unit. ▶ When connecting Worcester plug-in or EMS intelligent controls, the links ( items 8 & 9 in figure 42) must be left in the connection points. -
Page 31: New Complete System Installations
7 733 600 039 Comfort wall plate kit 7 738 110 058 Sense I intelligent room thermostat 7 738 111 064 Sense II weather compensation controller (preheat time control available) 7 716 192 072 Worcester Wave (thermostat) Table 23 Control accessories 230V 5.7.2 NEW COMPLETE SYSTEM INSTALLATIONS... -
Page 32: Existing Installations
Some devices do not require connection of a neutral i.e. battery powered devices. OPTIONAL EXTERNAL FROST STAT CONNECTION FOR PROTECTION Plug in OF SYSTEM PIPEWORK IN UNHEATED AIR SPACE Worcester timer. (see timer operating ▶ Connect frost thermostat cables to terminals F & F 230V... -
Page 33: Commissioning
▶ The concentration of inhibitor in the system should be 3. Fill the system via a WRAS approved filling loop or the optional checked every 12 months or sooner if system content Worcester Integral Filling Link accessory to 1 bar then close the filling loop valve(s). is lost. -
Page 34: Starting The Appliance
Operation and fault indicator (blue) Position for optional programmer Hot water temperature control Diagnostic port (for Worcester engineers use only) System pressure gauge Switching the appliance on/off: ▶ Turn on the mains power supply, initially the “Boiler start up screens”... -
Page 35: Boiler Start Up Screens
COMMISSIONING 6.4.1 BOILER START UP SCREENS SCREEN DISPLAY DESCRIPTION On initial start up, the following screens are displayed: All possible screen symbols This screen is displayed briefly 1. All the symbols are displayed for approximately two seconds. during boiler start up and shows 2. -
Page 36: Commissioning
COMMISSIONING COMMISSIONING ▶ The boiler will run for 15 minutes in service mode and return to normal if no other inputs are made. When running in the service mode, the boiler will operate After the tests are completed: both the central heating and the domestic hot water ▶... -
Page 37: Checking The Gas Rate
COMMISSIONING 6.5.2 CHECKING THE GAS RATE ▶ The gas rate should be measured at the gas meter after the boiler has been operating for a minimum of 10 minutes at maximum output. ▶ See Technical data section on page 10 of this manual for gas rates and CO/CO ratios. -
Page 38: Co And Combustion Checks
▶ The gas valve is factory set and must not be adjusted during commissioning if found to be out of tolerance, please contact the Worcester, Bosch Group help line 0330 123 3366. Zero the analyser Set boiler to ≥... -
Page 39: Finishing Commissioning
COMMISSIONING FINISHING COMMISSIONING 6.8.2 SECURING THE CONTROL PANEL 4. Raise the control panel. 6.8.1 Replacing the boiler case 5. Push the control panel up to engage the top edge under the case. 1. Replace the boiler case. 6. Lift the catches with your fingers. 2. -
Page 40: Hand Over
• By phone – You can register by ringing 0330 123 2552 • By post – Please send your completed form to: Worcester, Bosch Group, Cotswold Way, Warndon, Worcester, WR4 9SW. Greenstar Si Compact - 6 720 813 278 (2015/07) -
Page 41: Checking Flue Integrity
SERVICE AND SPARES CHECKING FLUE INTEGRITY COMPONENT ACCESS The integrity of the flue system and performance of the boiler can be To gain access to the components, remove the outer case: checked via the flue turret sample points. ▶ Remove the bottom, pulling down the catch and sliding the panel towards you. -
Page 42: Checking The Gas Inlet Pressure
SERVICE AND SPARES CHECKING THE GAS INLET PRESSURE When running at maximum output, and the water temperature is 65°C or less, the boiler will operate both NOTICE: Gas inlet pressure the central heating and DHW circuits with the diverter ▶ Do not continue with the other checks if the correct valve in the mid position. -
Page 43: Flue Gas Analysis
– “Min” will flash at the bottom left of the screen. If the boiler, after completing the above checks, fails the fan pressure test then contact Worcester, Bosch Group for advice. – The boiler will take 30 to 35 seconds to ramp down to minimum output. -
Page 44: Cleaning The Heat Exchanger
SERVICE AND SPARES CLEANING THE HEAT EXCHANGER 3. Push the black discharge hose, onto the wall frame connector, until fully engaged. NOTICE: Gaskets and seals ▶ Replace the burner and electrode assembly gaskets and the Flueway sump seal after cleaning the heat exchanger. -
Page 45: Replacement Of Parts
SERVICE AND SPARES REPLACEMENT OF PARTS CAUTION: Mains supplies: ▶ Turn off the gas supply and isolate the mains supplies before starting any work on the boiler and observe all relevant safety precautions. CAUTION: Component replacement: ▶ Replace the burner housing gasket and the Flueway sump seal when re-assembling the heat exchanger. -
Page 46: Draining The Boiler
SERVICE AND SPARES 7.8.3 SIPHON REMOVAL 1. Disconnect the discharge hose from the wall frame connector. 2. Rotate the siphon body clockwise to release the bayonet connection. 3. Pull the siphon body down and away from the boiler. Fig. 78 Siphon removal 7.8.4 PRIMARY SENSOR (CH NTC) ▶... -
Page 47: Maximum Safety Sensor (Ntc)
SERVICE AND SPARES 7.8.5 MAXIMUM SAFETY SENSOR (NTC) 7.8.7 AIR PRESSURE SWITCH ▶ Disconnect the lead to the Maximum safety sensor. NOTICE: Air Pressure Switch 1. Remove the screw securing the sensor. ▶ Ensure that the tube is reconnected to the Air 2. -
Page 48: Auto Air Vent
SERVICE AND SPARES 7.8.8 AUTO AIR VENT 7.8.10 FAN ASSEMBLY Ensure that the boiler has been fully drained. CAUTION: Component replacement: 1. Remove the spring clip completely. ▶ After replacement of a gas related component, where 2. Lift the air vent out of the housing and remove. a gasket or seal has been disturbed or replaced, check for gas tightness using a gas sniffer/analyser. - Page 49 SERVICE AND SPARES REMOVE THE USED SEAL COMBUSTION AIR INLET AND GAS PIPE DISCONNECTION 4. Discard the “tubular” seal [2] or the “moulded” seal [3], depending on 1. Rotate the combustion air inlet pipe anti-clockwise to release from the which type is fitted and replace with the seal that is provided. fan assembly and pull away from the fan.
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Page 50: Air/Gas Flap Valve Assembly
SERVICE AND SPARES When refitting the rubber gas pipe, ensure that the pipe is correctly oriented by aligning the notch in the pipe with the lug on the fan connector. Do not kink the pipe. There is a raised arrow on the pipe indicating the location of the notch. -
Page 51: Heat Exchanger
SERVICE AND SPARES 2. Undo the front two castellated nuts/springs and remove and retain along with the front two bolts (1). Slacken the two rear castellated nuts/springs, but do not remove. 6720646610-74.1Wo Fig. 98 Castellated nuts Castellated nut Fig. 96 Burner housing Spring clip 3. -
Page 52: Diverter Valve Motor And Diverter Valve Removal
SERVICE AND SPARES HEAT EXCHANGER REMOVAL 7.8.16 DIVERTER VALVE MOTOR AND DIVERTER VALVE REMOVAL ▶ Ensure any electrical wires or connectors are removed. ▶ Disconnect the lead from the diverter valve motor. ▶ Remove the Auto air vent (refer to section 7.8.8) to ease removal of 1. -
Page 53: Flow Sensor, Flow Restrictor And Filter Removal
SERVICE AND SPARES Fig. 105 Flow regulator assembly 7.8.21 PRESSURE GAUGE ▶ Ensure that the boiler is fully drained. 1. Carefully prise the lugs apart. 2. Remove the pressure gauge. 3. Withdraw the spring clip from the pressure sensing head housing. 4. -
Page 54: Drain Tap
SERVICE AND SPARES 7.8.23 DRAIN TAP 7.8.25 DHW PRESSURE RELIEF VALVE ▶ Ensure that the boiler is full drained down. Before removal: ▶ The drain tap rotates anti-clockwise for a ¼ turn to open. ▶ Isolate the electrical power to the boiler. 1. -
Page 55: Hydraulic Block Removal
SERVICE AND SPARES 7.8.27 HYDRAULIC BLOCK REMOVAL 7.8.29 ACCESS TO BOILER CONTROL COMPONENTS 1. Release the three captive screws retaining the installer access cover. Do not remove the hydraulic block assembly unless 2. The access cover can now be removed with the flap. absolutely necessary. -
Page 56: Replacing The Control Unit
SERVICE AND SPARES 7.8.30 REPLACING THE CONTROL UNIT REMOVING THE CONTROL UNIT ▶ Support the control unit and detach the control unit support strap. The control unit is supplied in a plastic housing. The 1. Release the two catches underneath the panel. complete unit must be replaced. - Page 57 SERVICE AND SPARES ▶ Lower the control panel into the service position. 5. Pull the expansion vessel down to remove. ▶ Isolate the boiler from the heating system using the service valves. ▶ Drain the boiler. ▶ At the pump manifold, release the clip and disconnect the expansion vessel.
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Page 58: Short Parts List
SERVICE AND SPARES SHORT PARTS LIST Fan 8 716 117 417 By pass valve 8 716 106 434 0 Gas Valve 8 718 600 04A 0 Control panel 8 737 909 49A 0 Flue overheat thermostat 8 717 206 213 0 Electrodes (including gasket) 8 718 600 28A 0 Burner seal 8 718 600 24A 0 Spark generator... -
Page 59: Fault Finding And Diagnosis
TURBINE DHW INLET NTC PRE WIRED LINK (PREHEAT OPTION) Fuse, slow 230V 230V FR FS LR LR F 5A H 230 V Worcester 24V controls point CH TEMPERATURE DHW TEMPERATURE CONTROL EMS BUS point CONTROL DIAGNOSTIC LCD DISPLAY INPUT HCM (at rear of PCB) 6720813276-14.1Wo... -
Page 60: Central Heating Function
FAULT FINDING AND DIAGNOSIS CENTRAL HEATING FUNCTION Fig. 121 Central Heating function Greenstar Si Compact - 6 720 813 278 (2015/07) -
Page 61: Preheat And Dhw Function
FAULT FINDING AND DIAGNOSIS PREHEAT AND DHW FUNCTION Fig. 122 PreHeat and DHW function Greenstar Si Compact - 6 720 813 278 (2015/07) -
Page 62: Protection Function
FAULT FINDING AND DIAGNOSIS PROTECTION FUNCTION Fig. 123 Protection function Greenstar Si Compact - 6 720 813 278 (2015/07) -
Page 63: Information And Service Menus
FAULT FINDING AND DIAGNOSIS INFORMATION AND SERVICE MENUS STATUS CODES Status Fault During normal boiler operation various Status codes can be displayed by codes codes pressing the button. First Safety timing error The first screen of the Information menu displays the current Status 262 &... -
Page 64: Selecting The Information Menu
FAULT FINDING AND DIAGNOSIS ▶ Press the button again to exit the Information menu. Status Fault codes codes No pressure variation detected after switching pump Supply sensor exceeded 110°C °C reset °F Start temporarily not allowed due to flow error on CH Too many short burner starts without confirmation of water flow CH: supply and/or return temperatures rising too fast... -
Page 65: Selecting Service Menus
FAULT FINDING AND DIAGNOSIS Maximum temperature This is the current temperature from the “Maximum safety sensor”. This sensor is mounted on the front of the °C reset heat exchanger. °F DHW flow temperature The current DHW flow temperature. DHW temperature This is the temperature selected via setpoint the Hot Water control knob on the... -
Page 66: Menu 1 - System Parameters
FAULT FINDING AND DIAGNOSIS 8.5.3 MENU 1 - SYSTEM PARAMETERS Para Parameter Description Updated Not applicable for Greenstar Si Compact value 2.1C Pump head Select the right pump map Initially Menu 1 will be displayed, but will contain no options. selection (load and modulation 8.5.4 MENU 2 - BOILER PARAMETERS... -
Page 67: Reset To Factory Settings
FAULT FINDING AND DIAGNOSIS 8.5.5 RESET TO FACTORY SETTINGS To reset any or all changes made in menu 2 back to the factory defaults setting: °C reset °F Menu 1 NOTICE: Menu 3 ▶ Any changes made in Menu 3 are not reset via these actions. -
Page 68: Using The Test Menu
FAULT FINDING AND DIAGNOSIS 8.5.7 USING THE TEST MENU TESTING THE COMPONENT This menu enables the testing of the functionality of components in an ▶ Select a component to test. ON/OFF mode.The duration of each test is up to 60 seconds. ▶... - Page 69 FAULT FINDING AND DIAGNOSIS °C reset °F °C °F reset °F °C °F °C reset °F Test 1 °C °F Fig. 132 Resetting test Note that it could be up to 10 seconds after the button is Test pressed before the selected component responds. Igniter test.
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Page 70: Fault Codes
FAULT FINDING AND DIAGNOSIS FAULT CODES Should a fault develop with this boiler (or the system), the boiler will enter a locking or blocking condition, and fault code information will be generated as described in this section. Locking error The boiler display will flash a warning triangle and fault code. At the same time a (static) cause code will also be displayed. Manual intervention is required following clearance of the fault: ▶... - Page 71 Description Reset type Possible cause 237 - 242 - Internal error Call Worcester, Bosch Group Technical helpline 0330 123 3366 Sensor test failed Reset button On power up all safety sensors are checked. Check has failed. Recycle time error Reset button After the burner has stopped, the recycle mode purges gas from the heat exchanger before attempting to burn again.
- Page 72 NOTES Greenstar Si Compact - 6 720 813 278 (2015/07)
- Page 73 NOTES Greenstar Si Compact - 6 720 813 278 (2015/07)
- Page 76 0330 123 9119 TRAINING: 0330 123 0166 SALES: 0330 123 9669 Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0330 123 9559 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. worcester-bosch.co.uk 6 720 813 278 (2015/07)
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