Summary of Contents for Worcester Greenstar 8000 Life Series
Page 1
Installation and Maintenance Instructions Gas fired condensing combi boiler Greenstar 8000 Life GR8300iW 30 C | GR8300iW 35 C | GR8300iW 40 C | GR8300iW 45 C | GR8300iW 50 C...
Table of contents Pressure relief valve removal .....59 Explanation of symbols and safety instructions Replacing the gas valve ......59 Checking the strainer in the cold water pipe and Explanation of symbols the flow turbine.
Gas Emergency Service on 0800 111 999. prosecution. ▶ L.P.G. boilers: Call the supplier’s number on the • If you are in any doubt, contact the Worcester side of the gas tank. Technical help-line H Risk to life from carbon monoxide poisoning (0330 123 3366).
Page 5
Explanation of symbols and safety instructions H Health and safety ▶ Refer to the manufacturer’s information when installing non Worcester components and systems The appliance contains no asbestos and no to the Worcester appliance. substances have been used in the construction...
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 –...
Product Information Scope of delivery Appliance type Part number Gas Council number GR8300iW 45 C LPG 7 738 100 852 47-800-20 GR8300iW 50 C LPG 7 738 100 853 47-800-19 Table 2 Type overview The name of the appliance consists of the following parts: •...
Page 8
Product Information Description Dimensions (mm) W Flue centre from appliance left side D Flue centre from rear of appliance Table 3 Appliance and flue outlet dimensions Function From left Diameter of pipe case edge 1 Condensate Outlet 58mm 22mm • Rubber push fit connection 2 CH Flow 90mm 22mm...
Pre-Installation [13] Air-gas manifold with non-return valve • All system connections, taps and mixing valves must be capable of [14] Ignition transformer sustaining a pressure of 3 bar. [15] Flue • Radiator valves should conform to BS 2767:10. [16] Ignition electrodes •...
Pre-Installation Checking the size of the expansion vessel Sealed primary system - 2 x central heating zones: To determine whether an additional expansion vessel is required: Follow • Requirement for new builds if the floor area of a property is over the steps below: 150m ▶...
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 ▶...
▶ Inspection hatches should be located at changes of direction. ▶ If this is not possible, bends should be viewable from both directions. Refer to the manual supplied with the Worcester, Bosch Group flue kit for complete installation instructions. Flue kit part numbers Fig.
Pre-Installation Horizontal high level flue assembly Part number Flue Ø Description 7 719 002 430 60/100 Vertical balanced flue kit 60/100 mm 7 719 002 431 80/125 Vertical balance flue kit 383 mm - 603 mm Table 8 Flue kit assembly part numbers 4.4.1 Flue length The maximum flue length will depend on the following factors:...
Page 16
Pre-Installation • Flue length [L] (adaptor bend included in length calculation) • Flue length [L] (initial bend included in length calculation) – Maximum flue length as stated in "Horizontal maximum flue – Maximum flue length as stated in "Horizontal maximum flue lengths".
Pre-Installation Vertical balanced flue with 45° elbow offset 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. A = 300 mm B = 500 mm Fig.
Page 18
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: when sited below the window or 600mm when sited to either side or above.
Page 19
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 0010021442-002 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 unvented window. surface, such as the ground/ floor level or roof surface. [16] The dimension below eaves, balconies and car ports can be * If the terminal section is less than 150mm and has two screws reduced to 25mm, as long as the flue terminal is extended to clear securing it to the elbow, the terminal section will not require a any overhang.
Pre-Installation Key to figure 28 - Plume re-direct terminal positions: The exhaust terminal can also be routed though the roof of the carport providing 25mm clearance is provided around the flue This feature allows some basic plume re-direction options on a pipe to any flammable material and that it extends at least 300mm standard telescopic horizontal flue terminal.
Pre-Installation 4.5.1 Appliance siphonic condensate trap The appliance has a large capacity condensate trap reducing the risk of condensate discharge pipe work freezing up in prolonged cold temperatures. The expanded siphonic operation discharges every 10 to 20 minutes. Resulting in: •...
Pre-Installation ▶ The external run be kept as short as possible and should not exceed three metres. Max. Additional precaution against freezing must be taken if the external pipe run exceeds 3m. ▶ The pipe should be run internally as far as possible before going externally and the pipe diameter should be increased to a minimum diameter of 32mm before it passes through the wall to the exterior.
Page 24
Pre-Installation Condensate soak away considerations Before deciding to use a purpose-made soak away the history of the locality and the ability of the surrounding area to disperse the condensate should be taken into account, e.g. areas prone to flooding and ground with a high clay content can result in an increased risk of freezing causing the condensate pipe to become blocked with ice and the boiler to shut down, Although it is possible to increase the size of the soak away and the area...
Pre-Installation • In all normal circumstances a PRV discharge pipe installation as 400mm min. described above is suffice to meet all but the most exceptional 25mm min. circumstances. – Where the PRV discharge pipe could be susceptible to damage, 500mm min. vandalism, freezing etc that could cause either a blockage or restriction in the ability to discharge safely then a tundish should be considered.
▶ The Building Services Compliance Guide recommends that a primary www.adey.com water cleanser is fitted to the system. FERNOX 0870 601 5000 ▶ Worcester Bosch recommend fitting a filter that will help remove both www.fernox.com magnetite and non-magnetic debris. SENTINEL 0800 389 4670 Worcester offers two filters that helps remove both magnetite and www.sentinel-solutions.net...
Installation Installation NOTICE: Risk of damage to appliance or accessories. ▶ All the previous pre-installation sections must be read and requirements met before starting the appliance or flue installations. CAUTION: Risk of injury through incorrect lifting and carrying! ▶ Only lift a manageable weight, or ask for help. ▶...
Page 28
Installation Unpacking 0010023424-001 Fig. 36 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. 38 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.
Page 31
Installation ▶ Apply a smear of silicone lubricant to the seal to ease connection later. 0010023239-001 00100 Fig. 40 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 pre-plumbing manifold ▶...
Installation Fitting the drain pipe on the heating pressure relief valve 0010023577-001 Fig. 44 Fitting the pipe on the (heating) pressure relief valve Hanging the appliance 0010023429-001 Before hanging the appliance Fig. 45 Hanging the boiler 1. Remove the orange plastic protective cover strip fitted to the appliance internal pipes by tilting the appliance forward, taking care 5.
Installation 2,000mm 1,000mm 52mm 104mm 0010013472-001 Fig. 47 Slope for condensate disposal ▶ Remove the three inner flue tube retaining screws [1]. – The inner tube will be held in place in the appliance. ▶ Check the appliance flue seal [2] is correctly seated and apply silicone grease.
Installation Electrical connection 5.5.1 Installer connections Connect external accessories DANGER: ▶ Flip down the control appliance ( Fig. 50). 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.
Page 35
Function Protective earth bar External control system with EMS bus control, ▶ Connect the protective earth for power supply. Worcester intelligent wall mounted controls, Boiler IQ. Power supply (power cable) ▶ Connect 2 core cable. 230V Pre-wired cable (Live and Neutral)
– 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).
Locate the filling link and follow the instructions for re-pressurising the exchanger. system. ▶ In cases where all attempts to find a system micro leak have failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer. 0010023634-001 Fig. 58 Greenstar 8000 Life – 6720883865 (2019/02)
Commissioning ▶ Re-pressurise the system. 6.3.1 Control panel overview – Pull the lever [1] down to start the filling process. ▶ When the pressure, shown on the display, reaches between the 1 and 1.5 bar, – Release the lever [1] to stop the filling process. ▶...
Commissioning During the siphon filling program, the symbol appears alternately Checking gas inlet pressure with the flow temperature on the display. 6.6.1 Checking the gas supply pressure The siphon filling mode is interrupted when the chimney sweep mode is ▶ Switch off the appliance and close the gas isolator. started.
Commissioning ▶ Check for gas tightness. 32 - 45 29.5 - ≤ 40 kw: 1.5 ≤ 40 kw: 28 - 41 42.5 > 40 kw: 2.5 > 40 kw: 27 - 40 mbar range Table 16 If the pressure drops are greater than shown below, then this would indicate a problem with the pipe work or connections within the system.
CO and combustion checks can be undertaken. commissioning unless this action is recommended following contact The flow chart is given for guidance, the details of the checks are given in with the Worcester, Bosch Group help line 0330 123 3366. the following sections: Zero the analyser Set boiler to ≥...
Commissioning 6.10 Checking flue integrity Flue integrity check ▶ The combustion casing must be fitted whilst this test is carried out. ▶ Refit the test point plugs after the test has been completed. The integrity of the flue system and performance of the appliance can be checked via the flue turret/adaptor sample points.
▶ 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.
Settings in the service menu ▶ To return to the next higher menu level, press the d key. Settings in the service menu Changing the setting values Many appliance functions can be set and checked in the service menu. ▶ Select the menu item with the OK key. Operating the service menu ▶...
Page 45
Settings in the service menu Table 18 Menu 1: Display of information Menu 2 (L.2) Hydraulic settings ▶ Press the ( key and * key at the same time, until L.A is displayed. ▶ Keep pressing the arrow key , until L.2 is displayed. The basic settings are depicted as highlighted in the following table.
Page 46
Settings in the service menu Service function L.3 Settings/adjustment range Remark/restriction 3-CA DHW mode • 0: Comfort mode, the appliance is held Short waiting time in comfort mode, when constantly at the set temperature domestic hot water is extracted. The appliance therefore switches on, even if no domestic hot •...
Page 47
Settings in the service menu Service function L.4 Settings/adjustment range Remark/restriction 4-A5 Burner runtime • 10 ... 60 This service function is only available, if service function 4-A4 is set to 1. Elapsed time x 100 of the system since commissioning 4-A6 Appliance runtime •...
Page 48
Settings in the service menu Service function L.4 Settings/adjustment range Remark/restriction 4-d2 Minimum system pressure • 0.8...1.1 bar 4-d3 Target system pressure • 1.3...1.7 bar 4-d4 Max. refilling time • 5...30...240 s 4-d5 Blocking time • 1...12...52 weeks 4-d6 Maximum refills •...
Inspection and maintenance The basic settings are depicted as highlighted in the following table. Service function L.0 Settings/adjustment range Remark/restriction 0-A1 Manual mode • OFF Allows manual control of heating during loss of RF Key signal.Set the desired heating flow •...
Inspection and maintenance 0010019013-001 Fig. 71 Removing outer case Fan pressure test NOTICE: Fan pressure test ▶ The appliance must be running at maximum output in chimney sweep mode for the fan pressure test, ( chapter 6.4). 0010023671-001 Fig. 70 Removing bottom panel Removing front cover 1.
If the manometer reading shows the heat exchanger requires causes have been checked, please contact the Worcester Bosch Group cleaning, then carry out the following checks. Helpline 0330 123 3366.
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 2. Check the non-return valve for contamination and cracks. 5. Remove fan. 0010007068-001 Fig. 77 Non-return valve in the air-gas manifold ▶ Install the non-return valve. ▶ Install the air-gas manifold. 8.9.3 Fan removal 0010023760-001 1. Undo connection of venturi. Fig.
Page 54
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. 80 Access cover removal Fig. 82 Cleaning brush ▶ Using the cleaning blade, working from the bottom to the top, to ▶...
Inspection and maintenance ▶ Install electrode set with new gaskets. 0010026738-001 Fig. 86 Installing electrode set ▶ Check integrity of seal of electrode set. Using a mirror to check for misting. 0 010 007 129-001 Fig. 84 Cleaning debris ▶ Refit the cleaning access cover assembly in reverse order the new seal [2], and the access cover [1].
▶ 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.
Inspection and maintenance NOTICE: Combustion testing ▶ The setting of the air/gas ratio must be carried out by a competent registered gas engineer, such as a Gas Safe registered engineer or British Gas engineer. ▶ Setting of the air/gas ratio must not be attempted unless the person carrying out the test is equipped with a flue gas analyser conforming to BS7927 and is competent in its use.
▶ Also after re-assembly, carry out the following checks: Fan pressure. Flue gas analysis. 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.
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. 50. ▶ Remove the condensate trap Fig. 88. ▶ Pull the spring up [1]. ▶...
Replacement parts 2. Unscrew the union nut. 0010017098-001 Fig. 100 Removing the strainer from the cold water pipe 1. Pull out the flow turbine. 0010017781-001 Fig. 98 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 –...
Page 63
Fault finding and diagnosis Fault text on the display, description Remedy 1075 W Short circuit of the temperature sensor at 1. Replace the temperature sensor. the heating block 2. Replace the connecting lead to the temperature sensor. 3. Replace the control appliance. 1076 W No signal from the temperature sensor at 1.
Environmental protection and disposal Fault text on the display, description Remedy 2970 B Pressure drop in heating system too rapid – 2971 B System pressure too low 1. Vent the heating system. 2. Top up water until the preset pressure is reached. 3.
Technical Specifications/Logs Batteries Technical Specifications/Logs Batteries must not be disposed together with your household waste. Used batteries must be disposed of in local collection systems. 12.1 Technical data 12.1.1 Specifications Combi Greenstar 8000 Life GR8300iW 30 GR8300iW 35 Unit Natural gas Propane Natural gas Propane...
Page 66
Technical Specifications/Logs GR8300iW 30 GR8300iW 35 Unit Natural gas Propane Natural gas Propane Permissible ambient temperature short time/long time °C 0–50/40 0–50/40 0–50/40 0–50/40 Nominal capacity of the appliance Total packaged weight Total appliance weight (excluding packaging) Lift weight (without front and side panels) 1) Propane/butane mixture for fixed containers with capacity up to 15 000 l 2) The Gas Rate provided assuumes the accepted NG average calorific value of 34-9 MJ/m net .
Page 67
Technical Specifications/Logs GR8300iW 40 GR8300iW 45 Unit Natural gas Propane Natural gas Propane Maximum power consumption (running) Maximum power consumption (stand-by) Energy efficiency index (EEI) heating pump – ≤ 0.23 ≤ 0.23 ≤ 0.23 ≤ 0.23 General data Expansion vessel capacity 10.0 10.0 10.0...
Technical Specifications/Logs GR8300iW 50 Unit Natural gas Propane Flue Flue gas temperature max. load DHW demand °C 73/56 73/56 Flue gas temperature 80/60 °C, max/min load °C 73/56 73/56 Flue gas temperature 40/30 °C, max./min load °C 55/30 55/30 level at max. rated heat output (after 10 minutes) 10.8 level at min.
Technical Specifications/Logs 12.7 Electrical wiring 230V 230V 13 9 0010023241-001 Fig. 106 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...
Page 72
Technical Specifications/Logs [15] Display [16] Code plug [17] Terminal strip for external accessories ( terminal assignment Tab. 5.5.1, page 34) [18] 3-way valve [19] Connecting lead [20] Earth (PE) [21] Earth bar [22] Not used Greenstar 8000 Life – 6720883865 (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.
Need help?
Do you have a question about the Greenstar 8000 Life Series and is the answer not in the manual?
Questions and answers