Bosch Worcester Greenstar Ri ErP + Series Installation And Maintenance Instructions Manual

Wall hung rsf gas fired condensing appliance

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Page 1 Installation and Maintenance Instructions Wall hung rsf gas fired condensing appliance Greenstar Ri ErP + For open vented & sealed system central heating systems & indirect mains fed domestic hot water These appliances are for use with: Natural Gas or LPG (Cat.
Page 2: Table Of Contents
Contents CONTENTS KEY TO SYMBOLS AND SAFETY PRECAUTIONS ... . 4 INSTALLATION ........31 Key to symbols .
Page 3 Contents FAULT FINDING AND DIAGNOSIS ..... . 58 Fault finding ........59 OPERATIONAL FUNCTIONS .
Page 4: Key To Symbols And Safety Precautions
KEY TO SYMBOLS AND SAFETY PRECAUTIONS List entries, first and second levels KEY TO SYMBOLS AND SAFETY • A single component/item PRECAUTIONS • A component/list, made up of multiple parts/items. – Sub component or sublist of main component/list. KEY TO SYMBOLS –...
Page 5: Safety Precautions
KEY TO SYMBOLS AND SAFETY PRECAUTIONS SAFETY PRECAUTIONS Health and safety The appliance contains no asbestos and no substances have been used IF YOU SMELL GAS in the construction process that contravene the COSHH Regulations A gas leak could potentially cause an explosion. If you smell gas, observe (Control of Substances Hazardous to Health Regulations 1988).
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 270mm 590mm* 390mm *600mm to top of case front 6720813283-02.1Wo Fig. 1 Appliance CHECK LIST Qty. Do not use the pre-formed copper pipes supplied with the appliance for the gas supply. - HARDWARE LITERATURE PACK: These copper pipes are for water only.
Page 8: Technical Data
APPLIANCE INFORMATION TECHNICAL DATA Natural Gas Appliances DESCRIPTION NATURAL GAS UNIT 12kW 15kW 18kW 21kW 24kW Gas flow rate - Max. 10 minutes from lighting Natural Gas G20 m³/h 0.95 1.30 1.63 1.96 2.26 2.60 Central Heating Max. rated heat input (net) 9.24 12.32 15.40...
Page 9 APPLIANCE INFORMATION LPG Appliances DESCRIPTION UNIT 12kW 15kW 18kW 21kW 24kW Gas flow rate - Max. 10 minutes from lighting Propane Gas (LPG) kg/h 0.71 0.96 1.20 1.44 1.77 1.91 Central Heating Max. rated heat input (net) 9.24 12.32 15.40 18.48 21.54 24.62...
Page 10: Energy Efficiency
APPLIANCE INFORMATION Energy efficiency Natural Gas appliances 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 7733600306 7733600307 7733600308 7733600309 7733600310 7733600311 Product type – – 12Ri 15Ri 18Ri...
Page 11 APPLIANCE INFORMATION LPG appliances 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 7733600300 7733600301 7733600302 7733600303 7733600304 7733600305 Product type – – 12Ri 15Ri 18Ri 21Ri 24Ri ErP +...
Page 12: Appliance Main Components
APPLIANCE INFORMATION APPLIANCE MAIN COMPONENTS Air/Gas Manifold Power and fault indicator (blue) Sensor - appliance flow Wiring connections cover Flow pipe Burner indicator (green) Return pipe Appliance ON/OFF switch Removable servicing panel Condensate connection Electrode assembly Syphon / Trap Overheat thermostat Gas inlet connection Silicon tube - Heat Exchanger air vent Mains cable inlet...
Page 13: Internal Wiring Diagram
APPLIANCE INFORMATION Internal wiring diagram SPARK TRANSFORMER 230V~ CH TEMPERATURE CONTROL ON/OFF SWITCH Slow 2 A fuse, AC 230 V DIAGNOSTIC CODE INTERFACE MODE PLUG SWITCH Norm LP NPLR Green Earth Colour sequence Blue Violet Orange COMMON 230V MAINS SUPPLY Fig.
Page 14: Pre-Installation
PRE-INSTALLATION WATER SYSTEMS AND PIPE WORK PRE-INSTALLATION PLASTIC PIPE WORK: • Any plastic pipe work must have a polymeric barrier with 600mm NOTICE: All the following Pre-Installation sections must (minimum) length of copper pipe connected to the appliance. be read and requirements met before starting appliance or flue installations.
Page 15 PRE-INSTALLATION SYSTEM FILL SYSTEM LAYOUTS EXAMPLES: S PLAN LAYOUT - OPEN VENT SYSTEM FILL Heating Mains S PLAN LAYOUT supply return Hose union Test point Temporary hose AA = Auto Air vent CV = Check Valve CV = Check Valve SV = Stop Valve 150 mm SYSTEM MAKE UP...
Page 16: Condensate Discharge
PRE-INSTALLATION SEALED SYSTEM Y PLAN LAYOUT Condensate discharge The central heating sealed system must be filled using a WRAS approved Full details on condensate discharge. filling loop or comply with figure 3 for System fill. ▶ Follow the latest version of BS6798 and HHIC guidance.
Page 17: Internal Connections
PRE-INSTALLATION 4.3.2 INTERNAL CONNECTIONS CONDENSATE PUMP In order to minimise risk of freezing during prolonged cold spells, the Where “gravity discharge” to an internal termination is not physically following methods of installing condensate drainage pipe should be possible, or where very long internal runs would be required to reach a adopted, in order of priority.
Page 18: External Connection Considerations
PRE-INSTALLATION 4.3.3 External connection considerations ▶ 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 NOTICE: Rainwater or external drain disposal internal pipe section is as smooth as possible. Untreated condensate must not be allowed to flow into FITTING AN EXTERNAL AIR BREAK streams or rivers...
Page 19: Pressure Relief Pipe Work
PRV temperatures and pressures. Worcester, Bosch Group endorses a PRV or a combined PRV/ Condensate internal discharge system, provided that a Hotun hiflo tundish is employed. The tundish is manufactured by RA Tech UK and is WRAS approved, information on the tundish can be found at www.hotun.co.uk.
Page 20: Appliance Location And Clearances
PRE-INSTALLATION APPLIANCE LOCATION AND CLEARANCES 4.5.3 COMPARTMENTS: Follow the requirements of BS6798 and BS5440 Part 2 and note: 4.5.1 Installation • Minimum clearances must be maintained. This appliance is only suitable for installing internally within a property at • An access door is required to install, service and maintain the a suitable location onto a fixed, rigid surface at least the same size as the appliance and any ancillary equipment.
Page 21: Rooms Containing A Bath Or Shower
PRE-INSTALLATION 4.5.6 ROOMS CONTAINING A BATH OR SHOWER NOTICE: Any switch or appliance control using mains electricity must not be within reach of a person using the bath or shower. • The installation must be in accordance with the latest edition of the IET Wiring Regulations BS7671.
Page 22: Plumbing Manifold
PRE-INSTALLATION PLUMBING MANIFOLD 4.6.1 CONNECTIONS Heating System 22mm compression fittings Function From left case Diameter of edge pipe 22mm compression fittings 55mm 22mm Use the fittings supplied in the Hardware literature pack: Condensate 210mm 22mm Cylinder & CH Flow 285mm 22mm Do not use the pre-formed copper pipes supplied with Cylinder &...
Page 23: 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 24 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 6,400 15,000 High level horizontal flue 4,600 13,000 Table 27 Table 24...
Page 25: Flue Terminal Positions
PRE-INSTALLATION Flue terminal positions CAUTION: Flue terminal positions ▶ All measurements are the minimum clearances required. ▶ Terminals must be positioned so to avoid combustion products entering the building. 4.8.1 Vertical flue terminal positions RIDGE VENT RIDGE FLUE 1500 1500 1500 1500 2000...
Page 26: Horizontal Flue Terminal Positions
PRE-INSTALLATION 4.8.2 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 6720821670-08.1Wo Fig. 22 Horizontal flue terminal positions 6 720 821 670 (2018/06)
Page 27 PRE-INSTALLATION Key to Figure 22: 200mm below eaves and 75mm below gutters, pipe and drains. The dimension below eaves, gutters, pipes and drains can be reduced to 25mm, as long as the flue terminal is extended by 100mm past any overhang. The telescopic flue joint must be sealed with suitable silicone sealant if it is external to the building.
Page 28: Plume Re-Direct And Plume Management Terminal
PRE-INSTALLATION 4.8.3 Plume re-direct and plume management terminal positions Maximum and minimum plume management lengths: ▶ A minimum distance of 500mm must be maintained between the plume management outlet and the flue air intake. ▶ The maximum plume management length is 4.5 metres for the appliances detailed on the front of this manual. ▶...
Page 29 PRE-INSTALLATION Key to Figure 23 - Plume re-direct terminal positions: [15] If a plume management kit is installed within the confines of a carport or other covered, partially enclosed extension, then the This feature allows some basic plume re-direction options on a exhaust terminal must be positioned at least 1200mm away from standard telescopic horizontal flue terminal.
Page 30: Cleaning Primary Systems
01242 546717 recommends that a primary water cleanser is fitted to www.adey.com the system. FERNOX 0870 601 5000 ▶ Worcester Bosch recommend fitting a filter that will www.fernox.com help remove both magnetite and non-magnetic debris. SENTINEL 0800 389 4670 ▶ Worcester offers two filters that helps remove both www.sentinel-solutions.net...
Page 31: Installation
INSTALLATION 3. Remove the top carton (5). INSTALLATION 4. Remove the outer cardboard sleeve (6). 5. Remove the plastic cover (7). WARNING: All the previous “Pre-Installation” sections must be read and the requirements met before starting appliance or flue installation. UNPACKING THE WALL FRAME &...
Page 32: Position The Appliance
INSTALLATION POSITION THE APPLIANCE Wall mounting template & flue opening SAFETY: WARNING: All relevant safety precautions must be undertaken. Protective clothing, ▶ Ensure the mains gas supply is isolated before footwear, gloves and safety goggles must be worn as appropriate. starting any work and follow all relevant safety FIXING THE MOUNTING FRAME: precautions.
Page 33: Outer Case Removal
INSTALLATION OUTER CASE REMOVAL APPLIANCE CONNECTION 1. Undo the two captive screws securing appliance casing at the bottom CAUTION: of the appliance. ▶ ISOLATE THE MAINS GAS SUPPLY BEFORE 2. Undo the two screws securing appliance casing at the top of the STARTING ANY WORK AND OBSERVE ALL RELEVANT appliance.
Page 34: Condensate Connection
INSTALLATION 5.5.1 CONDENSATE CONNECTION Return Flow Never terminate or discharge into any open source, including; sink, bath, shower, bidet, toilet etc. NOTICE: Condensate disposal ▶ Follow the recommendations given in section 4.3 “Condensate pipe work” for all condensate disposal installation. ▶...
Page 35: Flue Turret/Adaptor Installation
INSTALLATION 6720806944-84.1Wo Fig. 32 Flue turret centre 127mm [W] 195mm ▶ Align the flue turret/vertical adaptor to the appliance flue outlet with flat facing [3] to the rear of the appliance. WALL The flue turret/adaptor should be pushed straight down, on to the appliance.
Page 36: Electrical Connections
INSTALLATION ELECTRICAL CONNECTIONS CAUTION: Isolate the mains electrical supply before starting any work and observe all relevant safety precautions. The appliance is already wired with a mains supply cable. A spare strain relief block is supplied in case the pre- wired cable is replaced.1 ▶...
Page 37: Commissioning
COMMISSIONING EXTERNAL WIRING CENTRE COMMISSIONING System components wired into terminal strip in accordance with system manufacturers instructions. PRE-COMMISSIONING CHECKS 230V WARNING: ELECTRIC SHOCK MAINS SUPPLY ▶ ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS ▶...
Page 38: Filling The System
▶ In cases where all attempts to find a micro leak have failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer. 6720804530-12.1Wo Fig.
Page 39: Starting The Appliance
COMMISSIONING WATER TREATMENT PRODUCTS NOTICE: RESET Suitable water treatment products can be obtained from the following ▶ Do not press the blue power indicator to reset the manufacturers: appliance. ADEY 01242 546717 3. To reset the lockout turn the appliance thermostat control to www.adey.com minimum, then passed minimum where the control knob will click at reset position, wait 5 seconds then turn to maximum.
Page 40: Checking The Gas Rate
▶ The gas valve is factory set and must not be adjusted during commissioning if found to be out of tolerance, 2.5 mbar 1.5 mbar please contact the Worcester, Bosch Group help line drop drop 0330 123 3366. 29.5 - 42.5 mbar 6720644744-45.2Wo...
Page 41 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 <...
Page 42: Finishing Commissioning
▶ 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.
Page 43: Appliance Guarantee
Bosch Thermotechnology Ltd. • To ensure the continued efficient operation of the appliance it must be •...
Page 44: Checking Gas Inlet Pressure
SERVICE AND SPARES COMPONENT ACCESS LOWERING THE APPLIANCE CONTROLS TO THE SERVICE POSITION: Removing outer case 1. Remove two screws securing the control. 1. Undo and remove two screws securing appliance casing at the top of 2. Pull the control forward. the appliance.
Page 45: Checking Flue Integrity
SERVICE AND SPARES CHECKING FLUE INTEGRITY FAN PRESSURE TEST The integrity of the flue system and performance of the appliance can be This test is to determine if the heat cell requires checked via the flue turret sample points. cleaning/attention. Flue gas sample point Air inlet sample point Table 33 Key to figure 50...
Page 46: Flue Gas Analysis
SERVICE AND SPARES FAN PRESSURE TEST 3. Clean the sump with a suitable brush. ▶ Check the exhaust path and flue for restriction. ▶ Re-check the Fan Pressure readings Fig. 53 Fan pressure test ▶ Remove the cover and connect a digital manometer to the fan 6720644744-40.1Wo pressure test point.
Page 47: Setting The Air/Gas Ratio
SERVICE AND SPARES SETTING THE AIR/GAS RATIO CLEANING THE HEAT EXCHANGER NOTICE: THE SETTING OF THE GAS RATIO MUST BE NOTICE: COMBUSTION TESTING CARRIED OUT BY A COMPETENT PERSON. SETTING OF ▶ Combustion testing must be carried out by a THE GAS RATIO MUST NOT BE ATTEMPTED UNLESS competent person.
Page 48 SERVICE AND SPARES 1. Refer to figure 60 and rotate fan and air/gas manifold assembly BAFFLE REMOVAL around the top of the heat exchanger until it stops at the lug. 1. Refer to figure 62and remove top baffle. ▶ Lift up assembly and remove from appliance. 2.
Page 49: Syphon Removal And Cleaning
SERVICE AND SPARES CLEANING THE PRIMARY HEAT EXCHANGER NOTICE: CO/CO CHECKS ▶ Refer to figure 64 and access the heat exchanger flue ways by ▶ If the joint between the Air/Gas manifold and heat inserting the cleaning brush (7 716 192 312) through the top access exchanger is disturbed, replace the sealing gasket.
Page 50: Replacement Of Parts
Commissioning. Damaged O-rings or gaskets must be replaced. 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.
Page 51: Overheat Thermostat
SERVICE AND SPARES 7.8.3 OVERHEAT THERMOSTAT 7.8.4 FLUE OVERHEAT THERMOSTAT (WITH GROMMET) Refer to figure 68 for removal. To remove and replace the thermostat either: ▶ Remove two electrical connectors from thermostat. ▶ Using a small terminal screwdriver, prise the thermostat and grommet 3.
Page 52: Lowering The Appliance Controls To The Service
SERVICE AND SPARES 7.8.5 LOWERING THE APPLIANCE CONTROLS TO THE SERVICE 1. Refer to figure 73 and undo bottom gas connection to gas valve. POSITION: 2. Undo two securing screws on the underside of casing. 1. Remove two screws securing control. ▶...
Page 53: Air Pressure Switch
SERVICE AND SPARES ▶ Undo the securing nut at the top of the heat exchanger and remove the 1. Remove the two screws retaining the pressure switch to the bracket. retaining plate assembly (1). 2. Refit the new Air pressure switch to the bracket. Disconnect spark electrodes and flame sensor connection.
Page 54: Electrode Assembly And Burner
SERVICE AND SPARES FLAP VALVE ASSEMBLY 1. Twist the mounting flange clockwise to release. 2. Pull mounting flange off the flap valve assembly. 3. Pull rubber flap off flap valve assembly. ▶ To replace the flap valve: – Press the two lugs on the back of the flap into the two slots in the flap valve assembly.
Page 55: Heat Exchanger
SERVICE AND SPARES 6720802047-05.1Wo Fig. 82 Clamping plate detail 6720802047-03.1Wo Fig. 81 Initial location of the clamping plate Retaining plate assembly Fig. 83 Clamping plate secured Clamping plate Gasket 7.8.12 HEAT EXCHANGER Bracket ▶ Drain the system. Underside view of the clamping plate ▶...
Page 56: Syphon Removal
SERVICE AND SPARES 1. Refer to figure 85 and re move the three screws securing the turret to 1. Refer to figure 88 and lift the heat exchanger up to clear. the top of the appliance. 2. Pull the heat exchanger forward from the case. 2.
Page 57: Access To Electrical Control Panel
SERVICE AND SPARES 7.8.14 ACCESS TO ELECTRICAL CONTROL PANEL 7.8.16 PCB ▶ Remove three screws retaining the control cover (1). ▶ Remove two screws securing the control. ▶ Remove the control cover[1]. ▶ Pull the control forward. ▶ Lower the control to align the slots at the top of the control with the lugs on the appliance framework.
Page 58: Fault Finding And Diagnosis
FAULT FINDING AND DIAGNOSIS FAULT FINDING AND DIAGNOSIS This fault finding information is for guidance only. Worcester cannot be held responsible for costs incurred by persons not deemed to be competent. This fault finding system assumes that the appliance has been operating normally until the time of failure (i.e.
Page 59: Fault Finding
FAULT FINDING AND DIAGNOSIS Fault finding Blue light Fault Possible solution/check indication No light No power at control ▶ Check board – Mains supply voltage to the appliance. – Appliance mains switch is ON. – Fuse F1 - 2A Slow blow. ▶...
Page 60: Operational Functions
OPERATIONAL FUNCTIONS OPERATIONAL FUNCTIONS Appliance function Fig. 93 appliance function 6 720 821 670 (2018/06)
Page 61: Protection Function
OPERATIONAL FUNCTIONS Protection function AUTOMATIC INTERNAL FROST FUNCTION Internal boiler Internal boiler Pump switches off temperature Pump runs temperature after a 3 minute between rises above 9°C overrun period 8°C & 5°C Boiler automatic frost function (monitors internal boiler primary temperature) Central heating Internal boiler Internal boiler...
Page 62: Component Characteristics
OPERATIONAL FUNCTIONS Component Characteristics 9.3.5 Code plug numbers Gas type Appliance Code plug number 9.3.1 Flow temperature (NTC) Sensor resistances Natural Gas 9Ri ErP + Temperature [ °C ± 10%] Resistance [ Ω] 12Ri ErP + 35,975 15Ri ErP + 28,516 18Ri ErP + 22,763...
Page 63 Notes 6 720 821 670 (2018/06)
Page 64 Notes 6 720 821 670 (2018/06)
Page 65 Notes 6 720 821 670 (2018/06)
Page 66 GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. CONTROLS Optimum start control Fitted...
Page 67 SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider SERVICE 01 SERVICE 02 ² % ² % ² % ² % SERVICE 03 SERVICE 04 ² % ²...
Page 68 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 6 720 821 670 (2018/06)

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Bosch Worcester Greenstar Ri ErP + Series Installation And Maintenance Instructions Manual

1 Key to Symbols and Safety Precautions

2 Regulations

3 Appliance Information

4 Pre-Installation

5 Installation

6 Commissioning

7 Service and Spares

8 Fault Finding and Diagnosis

9 Operational Functions