Worcester GREENSTAR 24i junior Instruction Manual
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Worcester GREENSTAR 24i junior Instruction Manual

Wall hung rsf gas-fired condensing combination boiler installation, commissioning & service
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See also: Instructions for Installation and Servicing , Instruction Manual
THE APPLIANCE IS FOR USE WITH
NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13 & C33)
NATURAL GAS:
WORCESTER GREENSTAR 24i junior GC NUMBER 47-311-86
WORCESTER GREENSTAR 28i junior GC NUMBER 47-311-87
LIQUID PETROLEUM GAS:
WORCESTER GREENSTAR 24i junior GC NUMBER 47-311-90
WORCESTER GREENSTAR 28i junior GC NUMBER 47-311-91
interval record, printed within this
manual
GB/IE
CHECKLIST & service

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  • Page 1 THE APPLIANCE IS FOR USE WITH NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13 & C33) NATURAL GAS: WORCESTER GREENSTAR 24i junior GC NUMBER 47-311-86 WORCESTER GREENSTAR 28i junior GC NUMBER 47-311-87 LIQUID PETROLEUM GAS: WORCESTER GREENSTAR 24i junior GC NUMBER 47-311-90...

  • Page 2: Contact Information

    • Do not lift and twist at the same time. • Lift and carry the boiler close to the body • Wear protective clothing and gloves to protect from any sharp edges INSTALLATION &...

  • Page 3: Table Of Contents

    LAYOUT & COMPONENTS PRE-INSTALLATION CLEANING PRIMARY SYSTEMS MAINS SUPPLY WATER SYSTEMS & PIPEWORK CONDENSATE PIPEWORK PRESSURE RELIEF PIPEWORK BOILER LOCATION & CLEARANCES PLUMBING MANIFOLD FLUE TERMINAL POSITIONS FLUE OPTIONS INSTALLATION UNPACKING THE WALL FRAME WALL MOUNTING TEMPLATE / FLUE OPENING...

  • Page 4: Safety Precautions & Symbols

    DO CALL YOUR GAS COMPANY A Benchmark Checklist is provided by the manufacturer for the installer to complete including their CORGI registration number to confirm that the boiler has been installed, commissioned and serviced according to the manufacturer’s instructions. IMPORTANT: The completed Benchmark Checklist will be required in the event of any warranty work and may be required by the local Building Control Inspector.

  • Page 5: Product View

    INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05) GENERAL INFORMATION STANDARD PACKAGE: A - Wall hung gas fired condensing combi boiler for central heating and domestic hot water B - Boiler support frame C - Hardware literature pack...

  • Page 6: Technical Data

    Appliance protection rating Appliance protection rating with mechanical or RF mechanical timer fitted IP Permissible ambient temperatures Nominal capacity of appliance Noise output level (Max central heating) Packaged boiler weight Total boiler weight Lift weight SEDBUK TECHNICAL DATA TECHNICAL DATA...

  • Page 7: Layout & Components

    14 IGNITION AND FLAME SENSE ELECTRODES 15 OVERHEAT THERMOSTAT 16 FLAME VIEWING MIRROR 17 SECURING NUT, AIR / GAS MANIFOLD CLAMP 18 SENSOR - BOILER FLOW 19 FLUE AIR PRESSURE SWITCH CONNECTION 20 FLUE OVERHEAT THERMOSTAT 21 ACCESS POINT FOR CLEANING HEAT...

  • Page 8: Layout & Components

    10 PLATE TO PLATE DHW 32 SYSTEM PUMP 36 FLOW TURBINE 37 UNUSED PORT 38 AUTO AIR VENT 39 FLOW CONNECTION FROM BOILER 40 DHW SENSOR 41 CH FLOW CONNECTION TO 42 DHW OUT CONNECTION 43 COLD WATER IN CONNECTION...

  • Page 9: Cleaning Primary Systems

    IMPORTANT: All the following Pre-Installation sections must be read and requirements met before starting boiler or flue installation. CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior...

  • Page 10: Mains Supply

    • IPX4D. NOTE: this is reduced to IP20 if the following mechanical timers are fitted: 7 716 192 036 or 7 716 192 037. • All pipes to the boiler must be cross-bonded. • Wiring must comply with IEE wiring regulations. GAS SUPPLY: •...

  • Page 11: Water Systems & Pipework

    PLASTIC PIPEWORK: • Any plastic pipework must have a polymeric barrier with 600mm (minimum) length of copper or steel pipe connected to the boiler. • Plastic pipework used for underfloor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approx.

  • Page 12: Condensate Pipework

    2 Internal waste drainage system 3 Soil/vent stack 4 External drainage system 5 External condensate absorption point A - Condensate from boiler B - Sink C - 22mmØ plastic condensate pipe D - Gulley E - Internal soil and vent stack F - Serviceable waste trap (75mm min) G - 300mm x 100mmØ...

  • Page 13: Pressure Relief Pipework

    8 716 107 336b (11/05) PRESSURE RELIEF PIPEWORK PRESSURE RELIEF PIPEWORK: IMPORTANT: The pressure relief valve is a safety device for the boiler and if activated may discharge boiling water steam through the relief valve drain pipe. Care should be taken when siting the...

  • Page 14: Boiler Location & Clearances

    This boiler is only suitable for installing internally within a property at a suitable location onto a fixed, rigid non-combustible surface at least the same size as the boiler and capable of support- ing the boiler weight. COMPARTMENTS: Follow the requirements of B S6798 and BS5440 Part 2 and note: •...

  • Page 15: Boiler Location & Clearances

    Electrical switches, fused spur and socket out let s must not be sit uat ed in t he bathroom. BOILER LOCATION & CLEARANCES...

  • Page 16: Plumbing Manifold

    22mm compression fittings Use the fittings supplied in the Lit/Hardware pack. • If the boiler pipes are to be run behind the appliance ensure that the pipes pass through the slot in the yellow plastic guide (A). This is fitted to the boiler frame.

  • Page 17: Flue Terminal Positions

    This could be a nuisance, for example, near security lighting. 75mm • The air inlet/outlet duct and the terminal of 200mm the boiler must not be closer than 25mm to any combustible material. 200mm Detailed recommendations on protection of 150mm combustible materials are given in BS 5440:1.

  • Page 18: Flue Options

    STANDARD FLUE HORIZONTAL Ø100 MAX 686 A x 1 MIN 250 A x 1* Ø125 MAX 1070 A x 1 250 A x 1* * Requires cutting MAXIMUM FLUE HORIZONTAL Ø100 - 4600mm A x 1 + B x 5 Ø125 - 13000mm A x 1 + B x 13 MAXIMUM FLUE VERTICAL START + 1 BEND...

  • Page 19: Ancillary Items

    • Two sets of steps should be used. • Two people should share the lifting of the boiler up to the loft hatch, where the boiler is entered into the loft space tilted and slid on its back into the loft.

  • Page 20: Wall Mounting Plate Flue Opening

    This allows the heating system and mains water connec- tions to be filled and checked prior to boiler installation. This kit can be used in conjunction with the optional filling loop 7 716 192 281(not sup- plied with the boiler).

  • Page 21: Unpacking The Appliance

    5. With the outer packaging removed and the inner sleeve (B) still in place gently lay the boiler on its back. 6. The boiler will lie at an angle to the floor to allow the boiler outer casing (E) to be removed. The inner sleeve (B) opens as shown.

  • Page 22: Boiler Connections

    2. Pull the extended tab/lever forward and down until there is no further travel. 2 & 4 3. Hang the boiler on to the wall mounting frame by the two brackets positioned left and right at the top rear of the appliance.

  • Page 23: Boiler Connections

    (F) from the retaining bracket. 6. Make connections to the heating system. Connect the gas supply to the boiler gas cock 22mm compression. Connect mains water in and DHW out. 7. Connect the expansion vessel flexible pipe to the hydraulic manifold situated left of the pump.

  • Page 24: Flue Installation

    Edge of case 200mm Turret Clamp FLUE INSTALLATION WALL 189mm 93mm (250mm min) Flue INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior FLUE INSTALLATION HORIZONTAL FLUE (60/100mm diameter) For vertical flues and 80/125mm horizontal flues, please refer to separate instructions supplied with the flue kit.
  • Page 25 Clamp Clamp 2380mm 734mm Extension Cut Length Required Length 94mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05) FLUE INSTALLATION MEASURING THE FLUE (Extension Flue Kits): ONLY CUT EXTENDED FLUE LENGTHS As with the Standard Flue measure from the outside wall to the centre line of the flue turret.

  • Page 26: Flue Installation

    ( C ) over the notches to secure. 4 Assemble elbow to boiler using the three screws (see below). Note: Screws are in boiler not in flue kit. FITTING THE ELBOW: • Flue elbow should push directly down and not be twisted into correct position.

  • Page 27: Condensate Connections

    INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05) CONDENSATE CONNECTION CONDENSATE CONNECTION: Never terminate or discharge into any open source, including; sink, bath, shower, bidet, toilet etc. Note: any external condensate pipework should be protected with weather resistant insulation to help prevent freezing.

  • Page 28: Electrics

    ELECTRICITY SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS Mains supply to the boiler must be through a fused double pole isolator situated adjacent to the appliance. The isolator must have a contact separation of 3mm minimum in all poles.

  • Page 29: Position Of Wired Components

    POSITION OF WIRED COMPONENTS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior POSITION OF WIRED COMPONENTS 8 716 107 336b (11/05)

  • Page 30: Pre-Commissioning Checks

    3 Check that the condensate pipe has been connected to the syphon. 4 Check pressure relief drain pipe (J) is correctly fitted and securely tightened. IMPORTANT: If the boiler is not to be commissioned immediately then: after successfully completing all of the checks and any rectification work,...

  • Page 31: Filling The System

    Fill the system via a WRAS approved filling loop to 1 bar then turn the valve anti-clock- wise to close. Vent (A) any air from the boiler heat exchanger using a suitable container to collect any water. Ensure tube outlet (B) is...

  • Page 32: Starting The Appliance

    Turn the boiler thermostat control (C) to maximum. The burner on indicator (D) illuminates GREEN when the burner has lit. If the boiler fails to light the BLUE power indicator (B) and reset button (E) will flash alternately. To reset press and hold the reset button (E) for 2 seconds.

  • Page 33: Water Treatment

    6 Fill system via a WRAS approved filling loop to between 1 and 2 bar. 7 Vent all radiators; retighten vents when complete (M). Vent any air from the boiler heat exchanger using a suitable container to collect any water (N).

  • Page 34: Commissioning

    It will be necessary to run water through the domestic hot water circuit to ensure that the boiler will not cycle on low heating demands. A - On/off button B - On/off and fault indicator (BLUE)

  • Page 35: Replace Outer Casing

    2 The bottom panel slides onto two ledges (C) either side of the boiler frame. Hold the panel up against the underside of the boiler and slide towards the rear until it is fully engaged. HANDOVER: Complete the Benchmark checklist.

  • Page 36: Inspection And Service

    CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS S U P P LI E S B E FOR E STARTI NG ANY WOR K AN D OB S E RVE ALL RELEVANT SAFETY PRECAUTIONS. IMPORTANT: AFTER REPLACEMENT OF ANY COMPONENTS ALWAYS CHECK FOR GAS SOUNDNESS WHERE RELEVANT AND CARRY OUT FUNCTIONAL CHECKS AS DESCRIBED IN COMMISSIONING.
  • Page 37 Remove bottom panel by pulling it forward and off. 1.1 Undo and remove 2 screws (A) securing boiler casing at the top of the appliance. 1.2 Undo but do not remove the 2 screws (B) securing boiler casing at the bottom of the appliance.
  • Page 38 DHW circuits. This is to allow sufficient time for the setting procedure. It will be necessary to run water through the DHW circuit to ensure that the boiler will not cycle on low heating demands. 1 Press and HOLD service button (F) for 10 •...
  • Page 39 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05) INSPECTION AND SERVICE COMBUSTION TESTING MUST BE CARRIED OUT BY A COM PETE NT PE R SON. IT M UST NOT BE ATTEMPTED UNLESS THE PERSON CARRYING OUT THE COMBUSTION CHECK I S E Q U I P P E D W I T H A C O M B U S T I O N ANALYSER CONFORMING TO BS 7927 AND...
  • Page 40 Remove stainless steel viewing mirror (F). Rotate fan and air/gas manifold assembly (G) around the top of the heat exchanger until it stops at the lug. Lift up assembly and remove from boiler. Disconnect spark electrode and flame sensor connections (J). Remove clamping plate (K).
  • Page 41 Clean around sealing surface on sump and replace access cover (P). Using a suitable container to collect water from syphon connection at the base of the boiler flush heat exchanger with water. Re-assemble ensuring that the lower baffle (N) and the top baffle (M) are refitted correctly.

  • Page 42: Replacement Of Parts

    INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 1. Removing outer case 1.1 Undo 4 screws (A) securing boiler casing. 1.2 Pull case forward and remove. To remove bottom tray, pull forward on the tag on the underside of the tray.
  • Page 43 Pull valve up and forward out of boiler. Disconnect electrical connections. Replace valve with new seals and check for gas soundness. Isolate gas supply at boiler gas cock.
  • Page 44 T2.5H 250V F1 T500L 250V F3 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 9. Access to boiler control components Remove 3 screws (A) and remove cover from control. 10. PCB fuse Remove fuse F1(B) from the PCB and replace.
  • Page 45 (E) upwards and slide the control support bracket (F) to the left. 12.3 Support the control and unclip control support cable (G) from the boiler frame. Remove the support cable and fit to the new control. Remove appropriate cable restraints from the new control box.
  • Page 46 (shaded) around the top of the heat exchanger until the lug on the air/gas manifold is visible. 14.4 Lift up assembly and remove from boiler. 14. Pressure switch 14.1 Remove electrical connections (C). 14.2 Slacken top retaining screw and remove bottom screw.

  • Page 47: Replacement Of Parts

    18.1 Remove clip from plastic elbow on the flow pipe and pull flow pipe away from heat exchanger. 18.2 Remove plastic nut from the bottom of the boiler. 18.3 Rotate lever to release return pipe. 18.4 Undo flue connection from sump. Pull heat exchanger assembly up to clear.
  • Page 48 REPLACEMENT OF PARTS 21.1 22.1 22.2 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior REPLACEMENT OF PARTS 19. Diverter valve motor 19.1 Insure the appliance is in service mode (there is no need to drain the appliance). Disconnect the electrical connector from the diverter valve motor.
  • Page 49 8 716 107 336b (11/05) REPLACEMENT OF PARTS 23.2 23. Pump head Ensure the boiler is fully drained (see draining the appliance). Disconnect the electrical connection from the bottom of the pump. 23.1 Remove the four Allen bolts (A) securing the pump at each corner.
  • Page 50 To refit, follow the above in reverse. Ensure any seals that have been disturbed are renewed. 28. CH pressure relief valve Remove the hydraulic block from the boiler (See Removing the Hydraulic Block). 28.1 Remove the spring clip from the Pressure relief valve housing.
  • Page 51 To refit, follow the above in reverse. Ensure any seals that have been disturbed are renewed. 30. DHW Heat exchanger Remove the Hydraulic block from the boiler (See Removing the Hydraulic Block). 30.1 Undo the two screws (B) securing the plastic housings to the heat exchanger.
  • Page 52 32. Expansion vessel The expansion vessel can be replaced with the boiler in position if there is a side exit flue fitted and there is a minimum clearance of 340mm above the boiler casing. If vertical flue is fitted then a similar clearance to one side and the flue is required.

  • Page 53: Setting The Gas/Air Ratio

    DHW circuits. This is to allow sufficient time for the setting procedure. It will be necessary to run water through the DHW circuit to ensure that the boiler will not cycle on low heating demands. 33.2 5.1 Connect manometer to inlet pressure point 5.2 Turn central heating control to maximum;...

  • Page 54: Short Parts List

    REPLACEMENT OF PARTS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior SHORT PARTS LIST WORCESTER Part No. 8 717 204 453 0 GC No. H26 536 Burner 8 718 120 609 0 WORCESTER Part No. H26 538 GC No.

  • Page 55: Conversion

    2.2 Undo bottom gas connection to gas valve. 2.3 Undo two securing screws (B) on the underside of casing. Pull valve up and forward out of boiler. Disconnect electrical connections. Fit plastic retaining nut to the outlet of the gas valve from the kit and hand tighten.

  • Page 56: Fault Finding & Diagnosis

    NOTE : This fault finding information is for guidance only. Worcester 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.

  • Page 57: Central Heating Function

    CENTRAL HEATING FUNCTION INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior CENTRAL HEATING FUNCTION 8 716 107 336b (11/05)

  • Page 58: Dhw Function

    PREHEAT AND DHW FUNCTION INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior PREHEAT AND DHW FUNCTION 8 716 107 336b (11/05)

  • Page 59: Protection Function

    PROTECTION FUNCTION Boiler temperature Run autofroststat below 8°C function Pump run 5 seconds Pump antiseize every 24hrs INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior PROTECTION FUNCTION 8 716 107 336b (11/05)

  • Page 60: Gas Boiler Commissioning Checklist

    THERMOSTATIC RADIATOR VALVES AUTOMATIC BYPASS TO SYSTEM FOR ALL BOILERS CONFIRM THE FOLLOWING THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER’S INSTRUCTIONS? THE SYSTEM CLEANER USED THE INHIBITOR USED FOR THE CENTRAL HEATING MODE, MEASURE & RECORD...

  • Page 61: Service Interval Record

    Service Interval Record Below. Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions. Always use the manufacturer’s specified spare part when replacing all controls SERVICE 1...

  • Page 62: Check List

    Pack Number Check List Greenstar 24i Junior/28i Junior Hardware/Literature Pack Item Greenstar 24i Junior/28i Junior Installation/Servicing Instructions...1 Users Instructions ...1 Consumer Guarantee Card ...1 Sealing Pack...1 Compression Nut 22mm ... 3 Compression Ring 22mm ... 3 Compression Nut 15mm ... 3 Compression Ring 15mm ...

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