H Risk to life from carbon monoxide poisoning prosecution. There is a risk to life from escaping flue gases • If you are in any doubt, contact the Worcester ▶ Do not modify the flue gas system. Technical help-line ▶ Ensure that flue pipes and gaskets are undamaged.
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Explanation of symbols and safety instructions H Handover to the user (Control of Substances Hazardous to Health Regulations 1988). When handing over, instruct the user how to operate the heating system and inform the user about its H Combustion and corrosive materials operating conditions.
Regulations Irish Standards Regulations The current relevant Irish standards should be followed, including: • ECTI Installation regulations – National rules for electrical installations Current Gas Safety (Installation and Use) Regulations: • IS 813 All gas appliances must be installed by a competent, registered gas –...
This document refers to the following appliance types: Appliance type Part number Gas Council number GR8700iW 30 C NG 7 738 100 795 47-800-03 GR8700iW 35 C NG 7 738 100 796 47-800-02 GR8700iW 40 C NG 7 738 100 797 47-800-01 GR8700iW 45 C NG...
Product Information Pipe work positions and flue outlet Function From left Diameter of pipe case edge 1 Condensate Outlet 58mm 22mm • Rubber push fit connection 2 CH Flow 90mm 22mm • Compression fitting 3 DHW Outlet 155mm 15mm • Compression fitting 4 Gas Inlet 220mm 22mm...
Pre-Installation Hot water: Pre-Installation • Taps and mixing valves must be capable of sustaining a pressure up to 10 bar. NOTICE: • Hot water temperature and flow rate are affected by the size and Risk of damage to system or appliance! insulation of pipe work making up the distribution system and are Before installation controlled by the hot water tap and the water main inlet pressure.
Pre-Installation T[°C] Fig. 7 Separated heating zones 600 700 Appliance V[l] Zone valves 0010016558-002 4.1.4 System fill Fig. 5 Curves for the expansion vessel Filling primary sealed systems Pre-charge pressure 0.5 bar (minimum) Pre-charge pressure 0.75 bar NOTICE: Pre-charge pressure 1.0 bar (default setting) Pre-charge pressure 1.2 bar Filling the primary sealed system Pre-charge pressure 1.3 bar...
Pre-Installation Mains supply 4.2.1 Electrical supply Natural Gas: • Supply: 230V AC - 50 Hz ▶ When using this table to estimate the gas flow rate in pipe work of a • This appliance must not be connected to a three phase supply. known length, the effective length will be increased by 0.5m for each •...
Pre-Installation NOTICE: NOTICE: Non return valves in the cold water feed system. Damage to appliance: If a non return valve is fitted on the mains inlet, then pressure can Extreme temperatures may cause damage to the heating system. increase significantly over normal standing pressure when the appliance ▶...
Pre-Installation 4.3.2 Rooms containing a bath or shower CAUTION: Risk of electric shock ▶ Any switch or appliance control using mains electricity must not be within reach of a person using the bath or shower. • In all cases the installation must be in accordance with the latest amendments to the latest edition of the IET Wiring Regulations (BS7671).
29,000mm 30 kW 21,000mm 25,000mm Table 10 Maximum flue lengths - Vertical flues Refer to the manual supplied with the Worcester, Bosch Group flue kit for complete installation instructions. Flue system bends NOTICE: Flue kit part numbers Effective flue lengths of bends: Part number Flue Ø...
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Pre-Installation Telescopic horizontal flue assembly Horizontal flue with additional 90° elbow 60/100 mm [A] 350 mm - 570 mm [B] 570 mm - 790 mm 130 mm Min Fig. 16 Horizontal flue option • Flue length [L] (adaptor bend included in length calculation) Fig.
Pre-Installation High level horizontal flue with additional 90° elbows Vertical balanced flue with 45° elbow offset A = 300 mm B = 500 mm Fig. 20 Horizontal flue option • Flue length [L] (initial bend included in length calculation) Fig. 23 Vertical flue option –...
Pre-Installation WARNING: Minimum plume management length: The minimum distance of 500mm must be maintained between air inlet and exhaust. ▶ Do not terminate the plume management inside the terminal exclusion zone (shaded area) shown in figure 25. 5 0 0 ±80°...
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Pre-Installation Vertical flue terminal positions RIDGE VENT RIDGE FLUE 1500 1500 1500 1500 2000 1500 1200 1500 BOUNDARY LINE BOUNDARIES Fig. 26 Vertical flue terminal positions Key to figure 26: 400mm measured diagonally from a pitched roof or 500mm in regions with heavy snow fall.
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Pre-Installation Horizontal flue terminal positions BOUNDARY LINE DORMA SKYLIGHT OPENING OPPOSITE 2000 1500 1200 1500 1200 1000 BOUNDARY LINE BELOW GROUND OPEN LIGHT WELL <1000 BOUNDARIES 25 100 25 100 0010021442-001 Fig. 27 Horizontal flue terminal positions Key to figure 27: The terminal must be at least 1500mm from the opening or vent when sited below the window or 600mm when sited to either side 200mm below eaves and 75mm below gutters, pipe and drains.
Pre-Installation [10] 300mm to an internal or external corner. 300mm above a surface, such as the ground/ floor level or roof surface. * If the terminal section is less than 150mm and has two screws securing it to the elbow, the terminal section will not require a supporting bracket.
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Pre-Installation ±45° 180° ≥140 1,500 ≥ 5 ≥ 5 0 0 5 0 0 ±80° ±80° EXCLUSION ZONE EXCLUSION ZONE EXCLUSION ZONE 1500 1200 BOUNDARY LINE OPENING FLUE TERMINAL GUARD OPPOSITE 7 716 191 176 2000 BOUNDARY LINE Fig. 28 Plume re-direct and plume management terminal positions Key to figure 28 - Plume re-direct terminal positions: Key to figure 28 - Plume management terminal positions: 600mm distance facing a surface or a boundary line, unless it will...
Pre-Installation [11] Below balcony or overhange. The air intake clearance can be Condensate discharge reduced to 150mm providing the flue exhaust outlet has a 200mm clearance. [12] 1,200mm between terminals facing each other Full details on condensate discharge. [13] Internal/external corners. The air intake clearance can be reduced ▶...
Pre-Installation Condensate pipe work - Unheated internal areas Condensate pump Figure 31 NOTICE: Where direct connection to a “gravity discharge” pipe work is not Unheated internal areas. physically possible, or where very long internal runs would be required to reach a suitable discharge point, condensate should be removed using a Although the large volume siphon will reduce the risk of freezing, proprietary condensate pump, of a specification recommended by the...
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Pre-Installation NOTICE: Condensate waste disposal ▶ Care should be taken when siting a soak-away to avoid causing damage to existing services If no other discharge method is possible then the use of an externally run condensate drainage pipe terminating at a suitable foul water discharge point, or purpose-designed soak away, may be considered.
Pre-Installation Open drain or gully with external air break 400mm min. Figure 34 25mm min. Where the pipe terminates over an open drain or gully and there is a risk 500mm min. of ground flooding, then the additional requirement below is recommended: •...
▶ The Building Services Compliance Guide recommends that a primary water cleanser is fitted to the system. ▶ Worcester Bosch recommend fitting a filter that will help remove both magnetite and non-magnetic debris. Worcester offers two filters that helps remove both magnetite and non-magnetic debris;...
▶ In cases where all attempts to find a micro leak have failed, Risk of damage to appliance or accessories. Worcester, Bosch Group supports the use of Fernox F4 leak sealer. ▶ All the previous pre-installation sections must be read and requirements met before starting the appliance or flue installations.
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Installation Unpacking 0010023424-001 Fig. 37 Unpacking Additional requirements for roof space installations appliance installation point. This will allow access for installation, normal use and servicing. • The unpacked appliance can now be moved into the loft space • Two sets of steps should be used. •...
Installation Position the appliance WARNING: Flue turret ▶ Ensure the mains gas supply is isolated before starting any work ▶ The flue turret has an in-built 3° angle giving the flue assembly the rise and follow all relevant safety precautions. from the appliance to ensure the condensate flows back to the appliance.
Installation Carry handles For transportation of the appliance always use the carry handles [1] and [2] (with the control unit in the closed position). 0010023273-001 Fig. 39 Transport, lifting and handling Preparing the appliance installation NOTICE: Incorrect mounting can cause material damage. If the appliance is mounted incorrectly, it may fall off the wall.
Installation ▶ Apply a smear of silicone lubricant to the seal to ease connection later. 0010023239-001 00100 Fig. 41 Connections on the gas and the water side Heating flow valve Hot water Gas isolator Cold Water inlet Keyless filling link Heating return valve Preparing the wallframe ▶...
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Installation Fitting the condensate pipework ▶ Secure the pipe to the wall at the last joint. It is recommended the lifting operation is carried out by 2 people, ▶ Ensure the pipe protrudes through the wall frame by 25mm. observing all precautions for safe lifting of heavy objects ▶...
Installation Flue turret/adaptor installation ▶ Remove the three inner flue tube retaining screws [1]. – The inner tube will be held in place in the appliance. NOTICE: ▶ Check the appliance flue seal [2] is correctly seated and apply Flue installation silicone grease.
Installation Electrical connection 5.5.1 Installer connections Connect external accessories DANGER: ▶ Flip down the control appliance ( Fig. 51). Risk of electric shock! ▶ Open the cover. ▶ Isolate electrical components from the power supply (230 V AC) (fuse, circuit breaker) and secure against unintentional re- connection before carrying out any work.
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▶ Remove link and connect the on/off temperature controller. ▶ Connect the protective earth for power supply. External control system with EMS bus control, Worcester intelligent wall mounted controls, Boiler IQ. Power supply (power cable) 230V ▶ Connect 2 core cable.
– Control for appliance Pre-heat function, optional. Hot water time controller connects to * LR terminal, remove pre-wired link (only use when a Worcester controller has been fitted that does not have DHW pre-heat time control available or no Worcester controller fitted).
▶ In cases where all attempts to find a system micro leak have failed, ▶ Check the gas type specified on the identification plate matches that Worcester, Bosch Group supports the use of Fernox F4 leak sealer. of the gas supply.
Commissioning If pressure is not being maintained: ▶ Check tightness of expansion vessel and heating system. The pressure gauge and pressure information within the control panel Starting the appliance display menu, will show a different reading. This is due to the accuracy of the digital sensor and is normal.
Commissioning 6.3.2 Turn on the appliance Combustion casing removal Set the language the first time the appliance is turned on. ▶ Remove the combustion cover. ▶ To scroll through the languages, press the or the key. ▶ To select the desired language, press the OK key. When the display shows Siphon fill.
Commissioning Checking gas inlet pressure ▶ Exit the chimney sweep mode. ▶ Switch off the appliance, close the gas isolator, remove the pressure 6.6.1 Checking the gas supply pressure gauge and tighten the screw. ▶ Switch off the appliance and close the gas isolator. ▶...
▶ Check and zero the analyser in fresh air as specified by the manufacturer. ▶ The air/gas ratio valve is factory set and must not be adjusted during commissioning unless this action is recommended following contact with the Worcester, Bosch Group help line 0330 123 3366. Greenstar 8000 Style – 6720883864 (2019/02)
Check CO and combustion Set boiler to ratio at minimum rate minimum rate. Turn off boiler and Boiler is operating call Worcester, Bosch CO < 350ppm satisfactorily. Group help line. CO/CO ratio No further action 0330 123 3366 <...
Commissioning 6.11 Flue gas analysis 6.12 Finishing commissioning NOTICE: 6.12.1 Fitting the combustion casing Combustion testing ▶ Combustion testing must be carried out by a competent qualified person. Testing must not be attempted unless the person carrying out the combustion check is equipped with a calibrated Flue Gas Analyser conforming to BS 7967 and is competent in its use.
▶ Show the customer how to safely isolate the appliance. ▶ Advise the customer where they can find information on the Worcester, Bosch Group website, www.worcester-bosch.co.uk. ▶ Advise the customer that outside temperatures will affect the output of the appliance, especially the DHW.
▶ Press the d key. For full terms and conditions, please visit: The value is not saved. ▶ Enter modified settings. www.worcester-bosch.co.uk/guarantee-terms-and-conditions ▶ Affix label to the appliance in a visible location. Guarantee registration Your appliance/product carries a guarantee against faulty material or manufacture subject to Terms and Conditions.
Settings in the service menu Service menu 7.2.1 Overview of the service menu – Mx.heat.outp % Benchmark – Standby time – Clock inh. T. off – Actual temp. – Clock inh. T. on – DHW flow rate – Hot water –...
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Settings in the service menu – Burner – Ignition – Fan – Pump – 3-way valve – HC1 pump – Ionisat.oscill. – Solar pump Reset – Default setting – Fault history – Hidden menu: Reset Maintenance Landlord Demo mode Greenstar 8000 Style – 6720883864 (2019/02)
Settings in the service menu 7.2.2 Benchmark and Info menu Menu item Comment/restriction Actual temp. Flow temperature in °C DHW flow rate Hot water flow rate in l/min Hot water temp.Outlet temperature in °C Table 17 Benchmark menu Menu item Comment/restriction Current status ...
Settings in the service menu 7.2.3 Settings menu The menu is adapted to your system automatically. Some menu items are only available if the system has been set up accordingly. The menu items The factory settings are highlighted in the following table. are only displayed in systems in which the corresponding system components are installed, e.g.
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Settings in the service menu Menu item Settings/adjustment range Comment/restriction Pump overrun • 1...2...60 minutes Run-on time of the heating pump: pump run-on time begins at the end of the heat requirement. • 24 h: 24 hours Min.syst.pressure • 1...2...3 bar Target pressure •...
Settings in the service menu Menu item Settings/adjustment range Comment/restriction Heating curve Req. odr. temp. • Off When connecting a weather-compensated control unit, no adjustment to the appliance is required. The system • On control unit optimises this setting. This service function activates a simple, weather-compensated controller with a linear heating curve.
Inspection and maintenance 7.2.5 Reset menu Menu item Settings/adjustment range Comment/restriction Default setting Restore? All settings of the heat source are reset to the respective default setting. The system needs to be re-commissioned following this reset. Fault history Reset? Reset the maintenance first. The fault history of the heat source is deleted.
Inspection and maintenance Component access Removing bottom panel 1. Push in the clip securing the bottom panel. 2. Pull bottom panel sidewards to release from service position and remove. 0010019013-001 Fig. 73 Removing outer case Fan pressure test NOTICE: Fan pressure test ▶...
▶ Check that the siphon is not restricted or blocked. causes have been checked, please contact the Worcester Bosch Group ▶ Check the exhaust paths for restrictions.
Inspection and maintenance Cleaning the siphon and heat exchanger ▶ Remove the burner and clean its components. WARNING: Gaskets and seals - gas related components ▶ Replace gaskets and seals when disturbing gas related components (e.g. burner, electrode assembly etc.), after cleaning the heat exchanger.
Inspection and maintenance 1. Remove the non-return valve. 3. Remove expansion foam (pull towards you). 2. Check the non-return valve for contamination and cracks. 4. Undo fan connection and remove screw and seal. 5. Remove fan. 0010007068-001 Fig. 79 Non-return valve in the air-gas manifold ▶...
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Inspection and maintenance ▶ Remove the cleaning access cover [1] and seal [2]. ▶ Using the brush, clean the heat exchanger from top to bottom. 0010023710-001 0 010 007 128-001 Fig. 82 Access cover removal Fig. 84 Cleaning brush ▶ Using the cleaning blade, working from the bottom to the top, to ▶...
Inspection and maintenance 8.9.5 Checking electrodes ▶ Remove the electrode set with gasket. ▶ Check electrodes for contamination. ▶ Clean or replace electrodes if required. ▶ Install electrode set with new gaskets. 3 - 4 Nm 0010023585-001 0 010 007 129-001 Fig.
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Inspection and maintenance 1. Unlock the condensate trap. ▶ Press on the gasket in the required order. When the gasket is correctly inserted, the pin is visible in the recess 2. Pull the condensate trap forwards and tilt to the left for draining. and is flush with the top edge of the gasket.
▶ The gas valve and venturi are factory set and should not need to be adjusted if found to be out of tolerance and when all other possible causes have been checked, please contact the Worcester Bosch Group Helpline 0330 123 3366.
Fan pressure. Flue gas analysis. 4 mm Only use Worcester, Bosch Group original spare parts with this appliance. Non Worcester, Bosch Group original spare parts will invalidate the guarantee (if applicable) and any warranty. ▶ A comprehensive list of appliance spares can be found on the website www.worcester-bosch.co.uk/spares...
Replacement parts Overheat thermostat removal Pressure relief valve removal ▶ Remove two electrical connectors from thermostat. ▶ Unscrew [1] the sensor [2]. 0010023622-001 ▶ Open the cover Fig. 51. ▶ Remove the condensate trap Fig. 90. ▶ Pull the spring up [1]. ▶...
Replacement parts 1. Unplug the plug. 2. Unscrew the union nut. 0010017098-001 Fig. 102 Removing the strainer from the cold water pipe 1. Pull out the flow turbine. 0010017781-001 Fig. 100 Unplugging the plug and unscrewing the union nut 1. Remove the 2 screws. 2.
▶ Remove the screws. ▶ Pull out the 3-way valve. ▶ Press the cable retaining clip. This fault finding information is for guidance only. Worcester cannot be ▶ Unplug the plug. held responsible for costs incurred by persons not deemed to be competent.
Fault finding and diagnosis Fault category W (maintenance codes) 10.1.2 Fault code table Fault text on the display, description Remedy 200 O Boiler in heating mode – 201 O Boiler in hot water mode – 202 O Boiler in anti-cycle mode –...
Fault finding and diagnosis Fault text on the display, description Remedy 2920 V Fault in flame monitoring – 2927 B Flame failed during burner operation 1. Open the main shut-off valve. 2. Open the appliance shut-off valve. 3. Shut down the appliance and check the gas line. 4.
Environmental protection and disposal Appliance faults Remedy Violent ignition, poor ignition. ▶ Check the ignition transformer with service function t01 for misfiring, replace if required. ▶ Check the gas type. ▶ Check the gas supply pressure. ▶ Check the power supply. ▶...
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Technical Specifications/Logs GR8700iW 30 GR8700iW 35 Unit Natural gas Propane Natural gas Propane Minimum rated heat output 80/60 °C (P Maximum flow temperature °C Maximum flow temperature possible °C Maximum permissible operating pressure (PMS) Available pump head at 20 K ( °C) system temperature rise Domestic Hot Water DHW Minimum heat input Maximum rated heat input (net) (Q...
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Technical Specifications/Logs GR8700iW 40 GR8700iW 45 Unit Natural gas Propane Natural gas Propane Maximum rated heat input (net) (Q 34.4 34.4 34.4 34.4 Maximum rated heat output 40/30 °C 35.2 35.2 35.7 35.7 Maximum rated heat output 50/30 °C (P 35.0 35.0 36.0...
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Technical Specifications/Logs GR8700iW 50 Unit Natural gas Propane Gas flow maximum rate – 10 minutes from lighting Natural Gas – Propane Gas (LPG) kg/h – Central Heating (CH) Maximum rated heat input (net) (Q 34.4 34.4 Maximum rated heat output 40/30 °C 36.0 36.0 Maximum rated heat output 50/30 °C (P...
Technical Specifications/Logs 12.7 Electrical wiring 230V 230V 13 9 0010023241-001 Fig. 108 Electrical wiring pressure sensor Heating block temperature limiter Air/gas ratio control valve Ignition transformer Hot water temperature sensor [10] Flow Turbine Flow temperature sensor at flow pipe [11] Fan Flow temperature sensor at heating block [12] Control cable of the heating pump Flame sensing electrode...
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Technical Specifications/Logs [15] Display [16] Code plug [17] Terminal strip for external accessories ( terminal assignment Tab. 5.5.1, page 36) [18] 3-way valve [19] Connecting lead [20] Earth (PE) [21] Earth bar [22] Not used Greenstar 8000 Style – 6720883864 (2019/02)
Technical Specifications/Logs 12.8 Gas boiler system commissioning checklist This Commissioning checklist is to be completed in full by the competent person who commissioned the appliance as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty.
Technical Specifications/Logs 12.10 Service record It is recommended that your heating system is serviced annually and that the Service record is completed. Service Provider Before completing the Service record below, please ensure that you have carried out the service as described in the manufacturer’s instructions. Always use the manufacturer’s recommended spare parts.
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