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GREENSTAR 24i/28i JUNIOR

1. 6720643895 69 1Wo Fig 86 Primary sensor and overheat thermostat WORCESTER 6 720 644 741a 2010 10 Bosch Group 51 SERVICE AND SPARES 6 8 4 FLUE OVERHEAT THERMOSTAT WITH GROMMET To remove and replace the thermostat either Using a small terminal screwdriver prise the thermostat and grommet from the plastic housing Take care not to damage the plastic housing or 1 Release the flue connection from the sump 2 Push the flue tube up 6720643895 71 1Wo Fig 87 Lower exhaust section Remove electrical connections gt Push the flue limit thermostat in from the sump Retrieve the thermostat from the sump well N IN SA 2 6720643895 70 1Wo Fig 88 Remove thermostat To replace push the thermostat and grommet gently back into the opening until contact with the locating ridge is felt 6 8 5 MOVING CONTROLS TO SERVICE POSITION To remove the following components require the control box must be moved in to the service position Gas valve Syphon PCB Fuse gt Transformer NOTICE REPLACEMENT OF THE GAS N VALVE MUST NOT BE CARRIED OUT IF A CO CO ANALYSER IS NOT AVAILABLE 1 Remove the screw securing control panel 2 Gently pu
2. Fig 120 Hydraulic block removal part 2 The block will still contain an amount of water which will spill out if the block is tilted This is not essential but makes the removal of the hydraulic block easier Lower the pressure relief connector by pulling the lever forward and down 2 Undo the two screws securing the hydraulic block to the chassis located top left top right of the housing Fig 119 Hydraulic block removal part 1 3 Lift the left hand side of the block slightly 4 Manoeuvre the block out starting at the right hand side Torefit follow the above in reverse Ensure any seals that have been disturbed are renewed 6 8 26 CH PRESSURE RELIEF VALVE Remove the hydraulic block from the boiler See 6 8 25 Removing the Hydraulic Block 1 Release the spring clip from the Pressure Relief Valve housing 2 Withdraw the Pressure Release Valve from its housing 6720643895 105 1Wo Fig 121 PRV removal Torefit follow the above in reverse Ensure any seals that have been disturbed are renewed 62 WORCESTER Bosch Group 6 720 644 741a 2010 10 SERVICE AND SPARES 6 8 27 DHW PRESSURE RELIEF VALVE 6 8 28 DHW PLATE HEAT EXCHANGER NOTICE DEVICE REMOVAL N gt If the hydraulic block has already been removed from the appliance steps 3 and 4 are all that is required to remove the DHW pressure
3. Fig 100 Refer to figure 101 1 Lift the heat exchanger up to clear 2 Pull the heat exchanger forward from the case 6720643895 83 1Wo Om 7 dis of A Fig 101 Heat exchanger removal 6720643895 115 1Wo Reassemble and check combustion as stated in the gas co nversion section 6 6 IN NOTICE CO CO CHECKS If the joint between the Air Gas manifold and heat exchanger is disturbed sealing gasket must be replaced After completing the service of the appliance the CO CO must be checked and set to the limits shown in Setting the air gas ratio on page 47 56 6 720 644 741a 2010 10 WORCESTER Bosch Group SERVICE AND SPARES 6 8 11 ACCESS TO BOILER CONTROL COMPONENTS 1 Remove three screws 2 Remove cover from control 1 1 6720643895 40 1Wo 6 8 12 PCB FUSE Remove fuse holder with fuse F1 1 from the PCB and replace with a new fuse Le 0 Fees 9 rrr HEEE 8 ST10 ST6 j p 588 SE 7 o 2 E 7 O 3 2 D S Q S
4. Fig 103 Fuse locations Spare fuses are clipped into the underside of the electrical cover 1 T2 5H 250V 2 T500L 250V 3 T1 6L 250V 1 es 2 s i 6720643895 75 1Wo Fw eg eg Ww Fig 104 Spare fuses 6 8 13 TRANSFORMER PCB Refer to figure 105 Disconnect all electrical connections from the control Remove five screws retaining the rear panel of the control Remove the rear panel 3 Remove the transformer cover 6720643895 76 1Wo REFITTING THE CONTROL BOARD COVER Ensure that all wires are fully within the control board Align the front right hand corner of the cover with the front right hand corner of the control board Align the rear right hand Holding the cover level slide the cover onto the control board ensuring that the incoming cables at the top are held clear WORCESTER 6 720 644 741a 2010 10 Bosch Group 57 SERVICE AND SPARES 6 8 14 REPLACING CONTROLS NOTICE N Do not replace the control unit if a CO CO analyser is NOT available The control unit is supplied within its plastic housing The complete unit must be replaced Refer to figure 106 1 Remove all electrical connections from the control PCB including where cables run through restraints These can be unclipped from the plastic moulding noting their position 2 Carefully remove t
5. 6720643895 65 1Wo Fig 84 Cleaning heat exchanger NOTICE Heat exchanger baffles The baffles 1 and 2 must be refitted into the heat exchanger in the order shown in figure 82 Failure to do so may result in damage to the boiler NOTICE CO CO CHECKS N gt If the joint between the Air Gas manifold and heat exchanger is disturbed the sealing gasket must be replaced After completing the service of the appliance the CO CO must be checked and set to the limits shown in Setting the air gas ratio on page 47 Whenreplacing the burner gasket ensure that the clamping plate is fully tightened down to the heat exchanger CLEANING THE SYPHON There is no need to remove the Syphon to clean To drain debris from the syphon release the clips and remove the drainage cap from the bottom of the syphon Catch the debris and condensate from the syphon into a suitable container 50 WORCESTER Bosch Group 6 720 644 741a 2010 10 SERVICE AND SPARES 6 8 REPLACEMENT OF PARTS CAUTION TURN OFF THE GAS SUPPLY N AND ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS NOTICE REPLACEMENT OF N COMPONENTS After replacement of any components always check for gas tightness where relevant and carry out functional checks as described in Commissioning Damaged O rings or gaskets must be replaced 6 8 1
6. 44 3 PRE INSTALLATION POM MM n REA 11 6 3 Checking flue integrity 44 3 1 Cleaning primary systems 11 6 4 Fan pressure test 45 3 2 Mains supply RD E Mae etapa ae 12 6 5 Flue gas analysis 004 46 3 2 1 Electrical supply Beers ware ee Bae ELE 12 6 6 Setting the air gas ratio 47 3 2 2 Equipotential earth bonding 12 6 6 1 Setting the CO CO2 47 3 2 3 Gas supply eese 12 6 7 Cleaning the heat exchanger 48 3 2 4 Water supply uen 12 6 8 Replacement of parts 51 3 3 Water systems and pipe work 13 6 8 1 Removing outer case 51 3 4 Condensate pipe work ernennen 14 6 8 2 primary sensor CH NTC 51 3 41 Internal connections 14 583 Overheatthermostat essen 51 3 4 2 External connections I 15 6 8 4 Flue overheat thermostat 3 5 Pressure relief pipe work 17 with grommet 52 3 6 Boiler location and clearances 18 6 8 5 Moving controls to service position 52 3 6 1 Installation 2 00008 18 6 8 6 Gas valve bi oc oo wh A 53 3 6 2 Servicing clearances 6 8 7 Air gas manifold and fan assembly 53 Ventilated compartments eeng 18 6 8 8 HERE 54 3 6 3 Compartments ee 18 6 8 9 Electrode assembly and burner 55 3 6 4 Bathrooms gt ys ORE SH POTENS 18 6 8 10 Heat exchanger 55 3 6 5 Boiler clearances Unventilated 6 8 11 Access to
7. 4 INSTALLATION WARNING All the previous Pre N Installation sections must be read and the requirements met before starting boiler or flue installation 4 1 UNPACKING WALL FRAME amp ANCILLARY ITEMS CAUTION LIFTING AND CARRYING N Only lift a manageable weight or ask for help Bend the knees and keep the back straight with feet apart when lifting or putting down heavy objects DO NOT lift and twist at the same time Lift and carry object close to the body Wall mounting frame Wall mounting template Inner packaging Installer pack Bottom panel Front fascia NO VO P WN Hr Syphon assembly 6720643895 16 1Wo Fig 20 Unpacking IMPORTANT HANDLING INSTRUCTIONS It is advised that two people are used to carry the carton from the van to the point of delivery Once the carton has been delivered the outer carton is removed first Care should be taken when releasing the straps If a sharp implement is used make sure the outer carton is not pierced and that the implement is used in such a way so that it may not cause personal injury All sharp objects must be covered or the blade retracted after use and put away in a safe place Care should be taken when lifting the boiler from the base and the proper technique for safe lifting of any heavy object should be strictly observed Additional requirements for roof space installation The
8. Telephone No Telephone No Gas Safe Register No Gas Safe Register No Comments Comments Signature Signature Service 9 Date Engineer Name Service 10 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Gas Safe Register No Comments Comments Signature Signature Worcester Bosch Group Cotswold Way Warndon Worcester WR4 9SW Tel 0844 892 9900 Worcester Bosch Group is a brand name of Bosch Thermotechnology Ltd worcester bosch co uk 6 720 644 741a 2010 10 WORCESTER BOSCH GROUP TECHNICAL SUPPORT 0844 892 3366 APPOINTMENTS 0844 892 3000 SPARES 01905 752571 LITERATURE 0844 892 9800 TRAINING 01905 752526 SALES 01905 752640 WORCESTER Bosch Group
9. 34 WORCESTER Bosch Group 6 720 644 741a 2010 10 INSTALLATION 230 V ROOM STAT CLOCK ST10 The figures below show the options of room thermostat with programmer programmer only or room thermostat only The programmable thermostat may be a H hard wired or RF type This diagram is applicable for the hard wired unit and the receiver section of the RF pack Room Thermostat Programmer 230V MAINS SUPPLY NEL neutral green yellow SSV SOO LRLSNSN L ST10 6720643895 42 1Wo Fig 49 Room thermostat and Programmer il Series connector Not supplied Make the connector safe once wired in ROOM THERMOSTAT ONLY DT20 Twin Channel Room Thermostat 230V Programmer green yellow MT10 Mechanical Timer ab OSO SOO LRLSNs NL ST10 6720643895 41 1Wo Fig 50 Room thermostat only PROGRAMMABLE THERMOSTAT Programmable 230V Thermostat green yellow live neutral d switched live OSO SOO LRLSNSN L ST10 6720643895 44 1Wo Fig 51 Programmable thermostat il The link between the Live L and Common C may already be fitted as part of the Programmable thermostat if not then a link will need to be wired in Remove the link between Lg and Ls Connect external controls
10. 6 720 644 741a 2010 10 WORCESTER Bosch Group COMMISSIONING 5 5 STARTING THE APPLIANCE CAUTION RUNNING THE APPLIANCE N Never run the appliance when the appliance system is empty or partially filled 1 2 3 4 5 6 7 8 Ss D TEE N fs C CA reset t eco Fig 61 Control panel Switching the appliance on off Turn the boiler CH temperature control 1 to maximum The burner on indicator 2 illuminates GREEN when the Turn on mains power supply the power on indicator burner has lit 5 illuminates BLUE Turn on any external controls If the boiler fails to light the BLUE power indicator 5 Setthe thermostatic radiator controls to maximum and reset button 7 will flash temperature Settheclock programmer to continuously ON and the NOTICE RESET room thermostat to maximum temperature Do not press the blue power indicator to reset the boiler Central heating temperature control To reset press and hold the reset button 7 for more 2 Burner indicator Green than two seconds The boiler will be reset 3 Service button 4 Cover or optional Programmer 5 Power ON and fault indicator Blue 6 ECO button 7 Reset button 8 System pressure gauge Tab 22 Control panel legend WORCESTER 6 720 644 741a 2010 10 as Bosch Group COMMISSIONING 5 6 C
11. EA Pressure relief valve 8 716 106 431 0 GC No H09 750 Expansion vessel 8 716 105 5450 GC No H05 206 QOOooooo Seals kit 99000000 8 716 107 2240 oN a J GC No H10 876 O Oyo m SUD 66 6 720 644 741a 2010 10 WORCESTER Bosch Group FAULT FINDING AND DIAGNOSIS 7 FAULT FINDING AND DIAGNOSIS 7 1 FAULT FINDING This fault finding system assumes that the appliance has D be competent This fault finding information is for guidance only Worcester cannot be held responsible for costs incurred by persons not deemed to been operating normally until the time of failure i e not a first installation error PRELIMINARY CHECKS Preliminary electrical system checks are the first electrical checks to be carried out The electronic control system for this boiler incorporates a blue central indicator This normally during a fault finding procedure On completion of the Service Fault Finding task which has required the breaking and remaking of electrical connections check confirms the permanent mains supply but by flashing at different rates during a fault provides a guide to the a EARTH CONTINUITY cause as listed b SHORT CIRCUIT CHECK c POLARITY and d RESISTANCE TO EARTH Blue light Lockout indication reset button Fault Possible solution check Off Off No power at Permanent mains supply to boiler control board Fuse F1 2 5A
12. The data label must be updated to show the Low NOx variant data peel off the larger portion of the green label and apply over the original data label The boiler must be identified as a Low NOx variant peel off the smaller portion of the green label and apply to the bottom right corner of the fascia 36 WORCESTER Bosch Group 6 720 644 741a 2010 10 COMMISSIONING 5 2 PRE COMMISSIONING CHECKS Check that the condensate pipe 1 has been connected to the syphon CAUTION ISOLATE THE MAINS N ELECTRICITY SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS Check that the service and water pipes are connected to the correct position on the manifold TE le N E E 227 j P ET 6720643895 24 1Wo G720643895 47 Fig 56 Pipe fittings Fig 58 Syphon connection Ensure that the washers have been fitted to the water connections and the bonded washer to the gas connection on the manifold Referring to figure 59 check pressure relief drain pipe 1 is correctly fitted and securely tightened CH Flow 22mm DHW 15mm Gas inlet 22mm Domestic cold mains water in 15mm CH Return 22mm Check the gas type specified on the identification plate 1 on the inside of the flap matches that of the gas supply veo P WN HG 6720643895 46 1Wo Fig
13. 1 Wall hung gas fired condensing combi boiler for central heating and domestic hot water 2 Wall mounting frame 3 Hardware literature pack see checklist 4 Bottom Panel 5 Fascia panel 6 Syphon assembly Tab 5 6 6 720 644 741a 2010 10 WORCESTER Bosch Group APPLIANCE INFORMATION 2 2 TECHNICAL DATA DESCRIPTION NATURAL GAS LPG Low NOx 24i 24i amp 28i 28i 24i 28i UNIT junior junior junior junior junior Domestic Hot Water Minimum heat input Maximum rated heat output Maximum rated heat input net Gas flow rate Max 10 minutes from lighting Natural Gas G20 Propane Gas LPG Maximum mains inlet pressure Minimum mains inlet pressure working for max flow Minimum mains inlet pressure working for operation Domestic Hot Water temperature setting Domestic Hot Water specific rate 30 C rise Max Domestic Hot Water flow rate 40 C rise 15 kW 7 00 7 00 9 64 9 64 kW 24 28 24 28 kW 24 49 28 57 24 49 28 57 Low NOx only m h 2 59 appliesto 3 02 kg h Central 1 9 2 2 bar 10 Heating 10 10 10 bar 1 3 1 3 1 3 1 3 bar 0 2 0 2 0 2 0 2 C 55 55 55 55 l min 11 5 13 4 11 5 13 4 l min 8 6 10 8 6 10 Central Heating Maximum rated heat input net kw 24 62 13 4 24 62 24 62 24 62 Maximum rated heat output 40 30 C kW 25 67 13 97 25 67 25 67 25 67 Maximum rated h
14. 3 Cleanliness of the heat cell plus blockages in the condensate disposal 46 6 720 644 741a 2010 10 WORCESTER Bosch Group SERVICE AND SPARES 6 6 SETTING THE AIR GAS RATIO NOTICE THE SETTING OF THE GAS RATIO N MUST BE CARRIED OUT BY A COMPETENT PERSON SETTING OF THE GAS RATIO MUST NOT BE ATTEMPTED UNLESS THE PERSON CARRYING OUT THE TEST IS EQUIPPED WITH A COMBUSTION ANALYSER CONFORMING TO BS 7927 AND IS COMPETENT IN ITS USE 6 6 1 SETTING THE CO CO When running in the service mode the boiler will operate both the central heating and DHW circuits This is to allow sufficient time for the setting procedure It will be necessary to run sufficient water through the DHW circuit to ensure that the boiler will not cycle on low heating demands Refer to section 5 6 1 and ensure that the gas inlet pressure is correct before continuing To adjust the CO CO it will be necessary to first operate the boiler at maximum output Press and hold down the service button for more than 10 seconds until illuminated The blue power indicator will flash Turn central heating control to maximum the boiler will then go to maximum output The control will resume normal operation after 15 minutes or if the service button is pressed for over a second Measure the CO CO and check against the table 24 below If required set the minimum CO CO via adjuster 2 on the gas valve until the c
15. of the gas ratio must not be attempted unless the person is equipped with a combustion analyser conforming to BS 7927 and is competent in its use Remove electrical connector from fan Remove wire clip from gas valve outlet then pull the gas pipe free from gas valve see figure 90 6720643895 60 1Wo Fig 92 Undo the securing nut at the top of the heat exchanger and remove the retaining plate assembly 1 NOTICE The valve will require setting N follow procedure Setting the air gas ratio Disconnect spark electrodes and flame sensor connection This will prevent damage to the electrodes and sensor when the air gas manifold is rotated WORCESTER 6 720 644 741a 2010 10 Bosch Group 53 SERVICE AND SPARES Rotate fan and air gas manifold assembly 1 around the top of the heat exchanger until the lug on the air gas manifold is visible P A 6720643895 63 1Wo Fig 93 Rotate the air gas manifold assembly Fig 94 Dismantling the air gas manifold assembly Lift up assembly and remove from boiler FLAP VALVE ASSEMBLY NOTICE After re assembly check the CO 1 Twist the mounting flange clockwise to release N CO levels as described in sec
16. 10 342 418 Q Bottom solenoid 190 Q 10 171 209 Q Combustion CO level Flue condition Blocked flue Blocked condensate pipe or frozen condensate Gas valve adjustment lgnition electrodes harness connections Check for condition and continuity Otherwise replace control board Slow flash Flashing Flue overheat Heat exchanger baffles removed and not refitted mesiy reset Heat exchanger Heat exchanger blocked on flashes required off overheat Water pressure All air vented Pump harness connections Water leaks blockage Safety thermostats low voltage wiring harness connections Otherwise replace control board Fast flash Off Volatile lockout Temperature sensors Fan does not run Check condition and continuity of leads sensors Fan 230V a c across the live purple and neutral brown Fanlead Check continuity Code plug Is code plug missing or not inserted properly Fast flash Flashing Internal fault Replace control board 2 pulses No light Not a fault code Service mode selected to minimum press service button to return to normal 5 pulses No light Not a fault code Service mode selected to maximum press service button to return to normal Tab 27 68 6 720 644 741a 2010 10 WORCESTER Bosch Group FAULT FINDING AND DIAGNOSIS 7 1 1 CIRCUIT DIAGRAM T Fan wiring Live purple Neutral brown FLOW TEMP
17. Central Heating Flow Temperature C Central Heating Return Temperature lec COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm Yes O No O If yes and if required by the manufacturer has a water scale reducer been fitted What type of scale reducer has been fitted DOMESTIC HOT WATER MODE Measure and Record Gas Rate mu or U Jem Burner iting Pressure at maximum rate mbar R as Inlet Pressure at maximum rate Cold Water Inlet Temperature Hot water has been checked at all outlets Yes Temperature Water Flow Rate CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer s instructions and or BS5546 BS6798 If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation fitted ALL INSTALLATIONS If required by the manufacturer record the following co 1 96 OR CO Jus OR CO CO Ratio The heating and hot water system complies with the appropriate Building Regulations Yes The boiler and associated products have been installed and commissioned in accordance with the manufacturer s instructions Yes The operation of the boiler and system controls have been demonstrated to and understood by the customer Yes The manufacturer s literature including Benchmark Checklist and Service Record has been explained and left with the customer Yes Commissioning Engineer s Signature Customer s Si
18. SENSOR NTC SPARK ELECTRODES FLAME SENSE ELECTRODE OVERHEAT STAT Colour sequence t FLUE OVERHEAT STAT SAFETY SOLENOID IL o s SAFETY E SOLENOID T E DHW TEMP SENSOR NTC MAINS SUPPLY PUMP SUPPLY 230V EXTERNAL CONTROLS OPTION Colour sequence t armer CH TEMPERATURE CONTROL Fuse F1 slow 2 5 A AC 230 V TRANSFORMER 0000 000 DIAGNOSTIC INTERFACE sr IM Fig 127 i Junior circuit diagram WORCESTER 24V CONTROLS OPTION PLUG IN POINT under blanking cover on fascia PUMP Fuse F3 slow T 0 5 A sp C Fuse F2 s lo sis C CODE PLUG EXTERNAL FROST STAT OPTIONAL ER w T1 6A ST18 DIVERTER VALVE FLOW TURBINE ST9 PRE WIRED LINK 6720644741 08 1Wo WORCESTER 6 720 644 741a 2010 10 Bosch Group 69 FAULT FINDING AND DIAGNOSIS CENTRAL HEATING FUNCTION 7 2 OML 60L 568E990279 SpUuOdeVS QT YEM se3 pue 1003201 yleds doe spuo es 0g uns uey spuooes p sejnului l se3 pue E uns duing uaNuns uonus 330 SHA y eds ONE seg NO dung AONANDAS NOILINOI umop NO uonisod H2 ul SAIEA JUAN qouy Jo u02 HO QNV NO pony 9 78 0 1 awweusoud a nyesadws NO anvwaa p
19. wiring centre must be common and through either a common fused double pole isolator or a fused three pin plug and unswitched socket The isolator shall be situated next to the boiler for new systems and where practicable replacement boilers The isolator must have a contact separation of 3mm minimum between all poles Any system connected to the boiler must not have a separate electrical supply e Use a 3A fuse in both situations ACCESS TO ELECTRICAL CONNECTIONS Remove boiler casing to access control panel Refer to figure 46 1 Remove the screw securing the control panel 2 Lower the control panel into the horizontal service position 6720644741 04 1Wo Fig 46 Moving control panel into the service position When stripping wires always ensure copper strands do not fall into the control box Refer to figure 47 1 Unscrew the three screws in the control panel 2 Remove the connections cover 1 7 6720643895 40 1Wo Pass the 230 V mains power cable from the control box through the grommet at the right hand side of the pre plumbing manifold and route to the mains isolator next to the boiler SI Fuse F1 2 5A SI2 Fuse F2 0 5A SI3 Fuse F3 1 5A ST6 Frost thermostat connection ST10 Mains in amp external controls connections Tab 20 Fig 48 Electrical connector information
20. 49 SERVICE AND SPARES ACCESS COVER REMOVAL Refer to figure 83 1 Remove the two pozi drive screws 2 Remove the access cover 3 Remove the gasket 6720643895 112 1Wo Re LAr S Fig 83 Access cover removal CLEANING THE PRIMARY HEAT EXCHANGER Refer to figure 84 Access the heat exchanger flue ways by inserting the cleaning brush 7 716 192 312 through the top access hole in the casing removal of panel shown in figure 80 Clean heat exchanger flue ways using the cleaning brush removing any debris from the access point in the sump Clean around the sealing surface on the sump Replace the access cover 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 2 and the top baffle 1 are refitted correctly Referto figure 81 when re fitting the burner to ensure that it fits centrally within the heat exchanger and location tabs are situated in location holes Ensure seal is replaced with new seal and is correctly fitted Check the syphon unit is clean before refitting to boiler Reassemble and check combustion as stated in SETTING THE AIR GAS RATIO section on page 47 BE REMOVED TO CLEAN The heat exchanger is shown removed from the boiler to illustrate cleaning more clearly il THE HEAT EXCHANGER DOES NOT HAVE TO
21. 7 716 192 036 or 7 716 192 037 Wiring must comply with the latest IEE wiring regulations 3 2 2 EQUIPOTENTIAL BONDING MAIN EQUIPOTENTIAL BONDING Main equipotential bonding is carried at the origin of the electrical installation and connected to the main electrical earthing terminal Metal pipes can be used as bonding conductors if joints are metal to metal and electrically continuous The IEE Wiring Regulations BS 7671 2008 require that extraneous conductive parts must be connected to the main electrical earth The main bonding of incoming metallic services must be as close as practical to their entry point before any branch pipe work and a maximum of 600mm from an internal meter Bonding conductors must be copper and the same size as other bonding conductors and not less than 10mm The bonding conductors must be permanently fixed to the metal pipes with clamps and labels to BS 951 ina visible position to allow for inspection SUPPLEMENTARY BONDING Supplementary bonding is normally carried out in an area of increased shock risk e g bathrooms Consult a qualified electrician for them to determine if the installation requires supplementary bonding as specified in the 17th edition of the IEE Wiring regulations BS 7671 2008 3 2 3 GAS SUPPLY Boilers using Natural Gas NG must be connected to a governed meter Liquid Petroleum Gas LPG must be connected to a regulator Installation and conne
22. INSTALLATION 4 3 UNPACKING THE APPLIANCE 1 Outer carton Inner sleeve unwrap from front Packing base Protective wrapping Appliance outer case Remove outer carton 1 and place safely away from the working area 2 With the outer packaging removed and the inner Fa sleeve 2 still in place gently lay the boiler on its back The boiler will lie at an angle to the floor to allow the boiler outer casing 5 to be removed C The inner sleeve 2 opens as shown in figure 24 E 3 Remove the protective wrapping 4 SEN 1 Undo but do not remove the two screws at the bottom of the boiler Fig 23 Lay boiler down a fk WN v 2 Undo the two screws at the top see fig 25 3 Remove the outer case 5 Remove any packaging within the boiler and the packaging base 3 CAUTION Hanging the boiler Remove the plastic strip fitted to pipes before hanging the boiler 2 6720643895 20 1Wo 1 2 m 6720643895 18 1Wo Fig 22 Remove outer carton E y i o E e Ki E A E Fig 25 Outer case screw removal WORCESTER 6 720 644 741a 2010 10 Bosch Group INSTALLATION 4 4 BOILER CONNECTIONS CAUTION ISOLATE THE MAINS GAS N SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS GAS AND WATER CONNECTIONS Remove wall mounting template and secure the wall mountin
23. LIVE supply to terminal Ls gt Connect external controls LIVE return to terminal Lp Live Return Lg is sometimes referred to as Call for Heat or Switched Live Connect external controls NEUTRAL to terminal Ns Some devices do not require connection of a neutral i e battery powered devices OPTIONAL EXTERNAL FROST STAT CONNECTION ST6 Frost Thermostat LEE kl FR FS NP LP ST6 6720643895 43 1Wo Fig 52 Frost thermostat Connect frost thermostat cables to terminals Fs amp Fr These are not polarity sensitive gt The external frost thermostat only operates the pump see page 72 for internal frost protection WORCESTER 6 720 644 741a 2010 10 Bosch Group 35 COMMISSIONING 5 COMMISSIONING 5 1 CONVERT BOILER TO LOW NOx NOTICE Low NOx N The Low NOx performance is achieved just by changing the code plug No setting need to be made The boiler can be converted to a Low NOx version The Low NOx specifications can be found in the Technical Data on page 7 The setting are only applicable to the central heating function of the boiler CAUTION N ISOLATE THE MAINS ELECTRICAL SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS The Greenstar i Junior combi boiler range require a new code plug to convert them to low NOx variants Each conversion kit is specific to the boiler size refer to the table
24. REMOVING OUTER CASE 1 Undo the two screws securing the top of the boiler casing 2 Undo the two screws securing the bottom of the boiler casing Pull case forward and remove To remove bottom tray pull forward on the tag on the underside of the tray N b n o9 e e o9 a E Fig 85 Remove outer case To gain access to the following components he outer case has to be removed Primary sensor Overheat thermostat Flue limit thermostat 6 8 2 PRIMARY SENSOR CH NTC Refer to figure 86 for removal 1 Remove electrical connection by pulling upwards Squeeze retaining clip on plastic moulding of sensor and pull back and up until clear of pocket in heat exchanger 2 Pull forward to remove completely Coat new sensor with heat conductive paste and replace 6 8 3 OVERHEAT THERMOSTAT Refer to figure 86 for removal Remove two electrical connectors from thermostat 3 Slacken and remove fixing screw and thermostat 3 When replacing ensure thermostat sits correctly on surface of the casting with the left hand side of thermostat sitting up against the shoulder It is essential that the mating surface of the thermostat is coated with heat conductive paste
25. WITH THE OWNER OR AT THE GAS METER AFTER INSTALLATION OR SERVICING THE BENCHMARK CHECKLIST CAN BE FOUND IN THE BACK PAGES OF THE INSTALLATION MANUAL ABBREVIATIONS USED IN THIS MANUAL Diameter NG Natural Gas LPG Liquid Petroleum Gas CH Central Heating DHW Domestic Hot Water PRV Pressure Relief Valve NTC Negative Temperature Coefficient sensor IP Ingress Protection RCD Residual Current Device TRV Thermostatic Radiator Valve WRAS Water Regulations Advisory Scheme SEDBUK Seasonal Efficiency of Domestic Boilers in the United Kingdom Tab 3 Abbreviations WORCESTER 6 720 644 741a 2010 10 Bosch Group KEY TO SYMBOLS AND SAFETY PRECAUTION 1 2 SAFETY PRECAUTIONS IF YOU SMELL GAS CALL NATIONAL GAS EMERGENCY SERVICE ON 0800 111 999 LPG BOILERS CALL THE SUPPLIER S NUMBER ON THE SIDE OF THE LPG TANK TURN OFF THE ECV EMERGENCY CONTROL VALVE AT THE METER REGULATOR gt DO NOT TURN ELECTRICAL SWITCHES ON OR OFF DO NOT STRIKE MATCHES OR SMOKE PUT OUT NAKED FLAMES OPEN DOORS AND WINDOWS KEEP PEOPLE AWAY FROM THE AFFECTED AREA BOILER OPERATION This boiler must only be operated by a responsible adult who has been instructed in understands and is aware of the boiler s operating conditions and effects DEN ChINGN LICENSED INSTALLER FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS w
26. bar equal to a static head of 7 5m 22ft A Schraeder type valve is fitted to the expansion vessel to allow for pressure adjustment if required If an extra expansion vessel is fitted to the central heating return adjust this to the same pressure as the appliance internal expansion vessel refer to separate instructions with the extra expansion vessel 6 If required increase system pressure back to 1 bar 7 Rotate the adjustable pointer on the pressure gauge to record the set system pressure 8 Isolate and remove filling loop connection to system or if using the optional integral filling connection not supplied with the boiler remove the key and place in its storage position on the bottom cover of the boiler ENSURE THAT THE SYSTEM HAS BEEN CLEANED AS ON PAGE 11 OF THESE INSTRUCTIONS FLUSHING Central Heating gt gt Switch off the boiler Open all drain cocks and drain the system while the appliance is hot Close drain cocks and add a suitable flushing agent at the correct strength for the system condition in accordance with the manufacturer s instructions Run the boiler system at normal operating temperature for the time stated by the manufacturer of the flushing agent Drain and thoroughly flush the system to remove the flushing agent and debris INHIBITOR Central Heating gt Check drain cocks are closed and all radiator valves are open before adding a suitable inhibitor compatible with alumin
27. be used Refer to the 60 100 Horizontal Flue Instruction manual provided in the telescopic flue kit Adjusting the telescopic flue length la L gt 570 mr ba 350 mm 6720643895 30 1Wo Fig 33 Standard telescopic flue Extend tube 1 by withdrawing from tube 2 to achieve the flue length required between 350 570mm Secure with screw provided and seal joint with the aluminium tape supplied 4 5 2 REDUCING THE TELESCOPIC FLUE LENGTH Ensure that the TOP label is facing up il before securing the flue section to the turret The flue terminal MUST be fitted with the TOP label uppermost to allow the correct fit and use of the plume management system 1 6720643895 31 1Wo Fig 34 Reducing the standard terminal Remove securing screws 3 to detach the terminal assembly from the turret Slide terminal section 2 from the terminal assembly and discard Touse terminal 1 without cutting remove the location lug 4 on the inner flue tube 5 and remove any burrs To reduce the flue length further 265 mm gt 130 mm MIN 6 5 6720643895 32 2Wo Fig 35 Further reduction Mark the length required for the terminal F as shown min 130mm and cut square taking care not to damage the tubes Remove any burrs and chamfer the outer edge of the tubes to assist ease of connection and prevent seal damage The alumini
28. below Boiler type Gas type Code plug no 24kW i junior kit NG 1130 28kW i junior kit NG 1131 Tab 21 Code plug number ACCESS TO CODE PLUG Remove boiler casing to access control panel 1 Remove the screw securing the control panel 2 Lower the control panel into the horizontal service position 1 Referring to figure 53 unscrew the three screws in the control panel 2 Remove the connections cover 1 7 6720643895 40 1Wo Fig 53 Removing the connection cover 6720645222 09 1Wo Fig 54 Connector locations Identify ST18 the code plug and connector 6720645222 10 1Wo Fig 55 Remove and replace the code plug 1 Refer to figure 55 and remove the code plug from the controller cut the tie securing the plug to the boiler chassis and discarded the plug and tie 2 The new code plug tie and low NOx labels are found in a plastic bag attached to the left hand side wall of the boiler under the control panel Fit the code plug from the kit making sure that code plug is secured to the boiler chassis with the new tie Confirm that the number on the code plug corresponds to the boiler type in table 21 Replace the control panel cover Move the control panel into the operational position and secure Replace the boiler casing UPDATE DATA LABEL The data label is located on the right hand inside wall of the boiler refer to item 1 of figure 57
29. boiler control components 57 EE m 6 8 12 PCB Fuse cese 57 3 6 6 Installation clearances Unventilated 6 8 13 Transformer POB a u a a 57 compartments M RSEN S 19 6 8 14 Replacing controls 58 3 7 Plumbing manifold 5 20 6 8 15 Syphon removal 22 222222 59 3 7 1 Connections acc Pc M M C 20 6 8 16 Diverter valve motor 59 3 8 Flue options p qe E 21 6 8 17 Diverter valve 2 oo sonen 59 3 9 Flue terminal positions cst emi re 6 8 18 Auto air vent 60 3 10 Plume management terminal positions 24 6 8 19 DHW Temperature sensor 60 6 8 20 Pumpbhead 020 60 A INSTALLATION ecceceececeees 25 6 8 21 Flow sensor flow restrictor housing and 4 1 Unpacking wall frame amp ancillary items 25 filter 2 goede ee e E ar 61 4 2 Wall mounting template amp flue openings 26 6 8 22 Flow regulator llle 61 4 3 Unpacking the appliance 27 6 8 23 Drain tan 61 4 4 Boiler connections 28 6 8 24 Pressure gauge eese 61 4 5 Flue installation 222222 30 6 8 25 Hydraulic block removal 62 4 5 1 Measuring the flue Standard flue 30 6 8 26 CH Pressure relief valve 2 2222 62 4 5 2 Reducing the telescopic flue length 30 6 8 27 DHW Pressure relief valve 63 4 5 3 Installing the telescopic flue 31 6 8 28 DHW plate heat exchanger 63 4 5 4 Flue terminal plume re direct
30. cm area 61 cm Low level Minimum free Minimum free area 122 cm area 61 cm Tab 11 Compartment ventilation 930 mm mu MA mm Zen above elbow _ _ Using 100 mm flue kit 1080mm 5mm i Using 125 mm flue kit 5mm 1100 mm i25 mm 600 mm 3 UNES 200 mm Fig 14 Ventilated compartment Minimum clearance to removable door ae Minimum clearance required for servicing Tab 12 Minimum clearances 3 6 3 COMPARTMENTS Follow the requirements of BS6798 and BS5440 Part 2 and note Minimum clearances must be maintained An access door is required to install service and maintain the boiler and any ancillary equipment e If fitting the boiler into an airing cupboard use a non combustible material to separate the boiler from the airing space The material can be perforated up to a maximum hole size of 13mm 3 6 4 BATHROOMS A boiler fitted with a non mechanical timer or with no timer can be installed in zone 2 or outside the shaded area A boiler with a mechanical timer or RF mechanical timer with room thermostat must only be installed outside the shaded area Additional RCD Residual Current Device protection may be required Refer to the latest IEE wiring regulations 600 mm 600 mm 600mm radius 6720643895 10 1Wo Fig 15 Bathroom installations 18 WORCESTER Bosch Group 6 720 644 741a 2010 10 PRE INSTALLATION 3 6 5 BOILER CLE
31. frame and reconnect the flexible pipe to pump manifold and secure with the clip Expansion vessel replacement Removing the Boiler gt Isolate electrical supply Isolate system and gas connections at the service valves Drain the boiler Disconnect electrical supply and any external controls Disconnect flue connection from the boiler Undo connection to boiler at the service valves 6720643895 98 1Wo EIN Fig 126 Removing expansion vessel from wall frame Release the clip from expansion vessel connection to the pump manifold Carefully lift the boiler off the mounting frame Remove the expansion vessel retaining screw Lift the expansion off the cross beam Pull the expansion vessel towards you to remove v CO Nl Hr V Replace expansion vessel in the reverse order and refit the boiler to the mounting frame Follow the commissioning procedure in this manual 64 6 720 644 741a 2010 10 WORCESTER Bosch Group SERVICE AND SPARES 6 9 SHORT PARTS LIST Fan 8 717 204 453 0 GC No H26 536 Burner 8 718 120 619 0 GC No H26 538 Gas Valve 8 716 111 3250 GC No H26 540 s Control board E HT3 Bus enabled Lb le 8 748 300 6500 Flue overheat thermostat grommet type 8 716 506 267 0 Electrodes including gasket 8 718 107 087 0 boilers Control box a
32. inus eunjejeduia J9AQ Spuooes q WeM 440 9 SED 9 78 nun RW aunyesaduiay Arew ld ji umop nys Jeuung Fig 129 Pre heat and DHW 71 6 720 644 741a 2010 10 WORCESTER Bosch Group FAULT FINDING AND DIAGNOSIS 7 4 PROTECTION FUNCTION AUTOMATIC INTERNAL FROST FUNCTION Internal boiler temperature between 8 C amp 5 C Internal boiler Pump switches off Pump runs temperature after a 3 minute rises above 9 C overrun period Boiler automatic frost function monitors internal boiler primary temperature Internal boiler Central heating temperature demand switches rises above 12 C off Internal boiler temperature below 5 C Central heating demand is activated Pump switches off after a 3 minute overrun period PUMP OVERRUN FUNCTION End of boiler demand Pump runs for 3 minutes central heating or to dissipate heat from domestic hot water the boiler into the system PUMP ANTISEIZE FUNCTION No central heating Pump runs 5 seconds A central heating demand demand after every 24hrs from activated pump runs a 24hr period last time pump ran normally 6720643895 111 1Wo Fig 130 Protection functions 72 6 720 644 741a 2010 10 WORCESTER Bosch Group FAULT FINDING AND DIAGNOSIS WORCESTER 6 720 644 741a 2010 10 m Bosch Group This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a m
33. relief valve Ensure the system is fully drained Remove the electrical connection to the pump e v v ow Remove the metal clip to the right of the pump head to release the pump housing 2 Slide the pump housing to the left and withdraw from the appliance 3 Remove the spring clip from the pressure relief valve housing 4 Withdraw the pressure relief valve Fig 122 DHW pressure relief valve gt To refit follow the above in reverse Ensure any seals that have been disturbed are renewed Disconnect all pipes connected to the pump housing Remove the Hydraulic block from the boiler il See 6 8 25 removing the Hydraulic Block 1 Undo the two screws securing the plastic housing to the heat exchanger 2 Remove the heat exchanger 6720643895 96 1Wo Fig 123 DHW heat exchanger gt To refit follow the above in reverse Ensure any seals that have been disturbed are renewed 6 8 29 BYPASS VALVE 1 Remove the two spring clips at either end of the copper bypass pipe 6720643895 97 1Wo Fig 124 Removing the bypass valve Undo the screw securing the left hand plastic housing to the heat exchanger Move the housing to the left to free up the one end of the pipe Remove the pipe from the right hand housing to reveal the bypass valve 2 Using a pair of pliers pull out the bypass valve from the housing gt To refit follow the above in reverse Ensure any seals are
34. renewed WORCESTER 6 720 644 741a 2010 10 Bosch Group 63 SERVICE AND SPARES 6 8 30 EXPANSION VESSEL The expansion vessel can be replaced with the boiler in position if there is a side exit flue fitted and a minimum clearance of 340mm above the boiler casing If a vertical flue is fitted then a similar clearance to one side of the flue is required If this clearance is not available then the boiler will need to be removed from the mounting frame to gain access to the expansion vessel Alternatively a second vessel of at least the capacity of seven litres can be fitted to the return from the heating system as close as possible to the boiler Expansion vessel replacement Boiler in place gt Isolate mains power from the boiler Lower the control panel to the service position gt Isolate the boiler from the heating system and cylinder return if internal diverter valve is fitted using service valves Drain the boiler v At the pump manifold release the clip and disconnect the expansion vessel hose v N 6720643895 99 1Wo Fig 125 Removing the expansion vessel 1 Remove screw 1 retaining the vessel to the top of the boiler casing 2 Pull the vessel up 2 and out over the flue system or to one side if fitted with a vertical flue Remove the flexible hose from the expansion vessel and fit to the replacement vessel using a new seal Reassemble expansion vessel into wall
35. the boiler fails the fan pressure test then before Fig 71 Set boiler to maximum adjusting the air gas ratio try the following Check the syphon is not blocked When running in the service mode the 1 Remove the screws securing the sump cover il boiler will operate both the Central Heating 2 Remove the sump cover and DHW circuits This is to allow sufficient 3 Clean the sump and heat exchanger with a suitable time for setting procedure brush It will be necessary to run water through the DHW circuit to ensure that the boiler will not cycle on low heating demands Check the exhaust path and flue for restriction Re check the Fan Pressure readings FAN PRESSURE cant S Oe 4 S me 1 1 g 6720643895 112 1Wo S Fig 74 Sump access Fig 72 Fan pressure test point WORCESTER 6 720 644 741a 2010 10 45 Bosch Group SERVICE AND SPARES 6 5 FLUE GAS ANALYSIS COMBUSTION TEST Connect the flue gas analyser to the flue gas sampling point as shown in the figure below Run the boiler at maximum output for at least 10 minutes Check the CO CO readings against the information in table 24 CO CO settings on page 47 6720643895 101 1Wo Fig 75 Combustion test If the boiler fails the combustion test check 1 Air intake for restriction 2 Diaphragm in the fan for correct operation
36. the gas valve 6720643895 63 1Wo Fig 80 Rotate air gas manifold g L ji N 6720643895 72 1Wo FN Fig 78 Gas valve connection Remove electrical connector and earth wire from fan To prevent damage to the electrodes when removing the air gas manifold disconnect the leads to the electrodes Disconnect spark electrode and flame sensor connections 48 6 720 644 741a 2010 10 WORCESTER Bosch Group SERVICE AND SPARES BURNER REMOVAL Refer to figure 81 1 Remove clamping plate 2 Remove spark flame electrode assembly and seal from the top of the heat exchanger 3 Remove burner 6720643895 61 1Wo Fig 81 Burner removal Checking and cleaning the electrode assembly NOTICE Cleaning N Do not use wire wool to clean the electrodes Inspect the condition of the electrodes and ceramics replace if necessary Use a plastic scouring pad to clean the electrodes BAFFLE REMOVAL Refer to figure 82 1 Remove top baffle 2 Remove lower baffle If the lower baffle is stuck it may be il necessary to use the baffle removal tool from the heat exchanger cleaning kit 7 716 192 312 as shown in figure 82 4 6720643895 64 1Wo Fig 82 Baffle removal WORCESTER 6 720 644 741a 2010 10 Bosch Group
37. the pressure gauge to the fascia 4 Remove the gauge 4 taking care not to damage or kink the capillary 5 Withdraw the spring clip from the pressure sensing head housing 6 Remove the pressure sensing head and pressure gauge capillary from the housing NOTICE Heat damage N Route the plastic capillary tube away from the pump to ensure that the pipe is not melted against a hot pump body Torefit follow the above in reverse DO NOT omit the washer from the capillary when fitting a replacement gauge WORCESTER 6 720 644 741a 2010 10 Bosch Group 61 SERVICE AND SPARES 6 8 25 HYDRAULIC BLOCK REMOVAL Remove the syphon assembly il Refer to Syphon assembly removal page 59 Ensure the appliance has been fully drained Disconnect the electrical connections to the NTC sensor turbine and pump Undothe nuts securing the copper water pipes to the manifold there is no need to remove the gas pipe Remove the syphon Release the spring clip securing the expansion vessel pipe to the plastic housing and remove the pipe Release the spring clip securing the pressure gauge sensing head to the plastic housing and remove the sensing head 1 Release the locking devices that secure the two copper water pipes leading to the combustion chamber by squeezing the two tabs together and rotating anticlockwise viewed from above Take care not to snag the harness
38. wall mounting frame through the template The wall mounting template has been sized il to allow for minimum clearances of 5mm sides 200mm base and 30mm above a 100mm diameter flue elbow REAR FLUE OUTLET The drawing opposite shows the boiler wall mounting template with the flue centre lines of both the 100 mm and 125 mm flue systems 3 Mark centre line of flue to be used 3 the external diameter of the hole can also be marked if required gt Ifa 100 mm diameter flue is to be used a 125 mm diameter hole is required However if using the weather sealing collar by pushing it through from inside the property then a 150 mm diameter hole is required to accommodate this The flue turret of the 100 mm flue has an in built 3 angle lf extensions are to be added then the complete flue must rise at an angle of 3 Drill hole using a core drill or similar SIDE OUTLET 4 Mark from the centre line of the wall mounting template to the wall which the flue will pass through 4 Allow for a rise of 52mm per metre length of flue to give a 3 angle Clear any debris from the site An optional filling loop 7 716 192 281 is available to fill the system not supplied with the boiler Fig 21 Marking the flue position A Zen GR Junior Wall Template EENSTAR Si amp i d System 6720643895 17 1Wo 26 6 720 644 741a 2010 10 WORCESTER Bosch Group
39. water circuit is fully drained Disconnect the electrical connection from the sensor 1 Withdraw the spring clip 2 Withdraw the sensor from the housing 6720643895 87 1Wo To refit follow the above in reverse 6 8 20 PUMP HEAD Ensure the boiler is fully drained Disconnectthe electrical connection from the bottom of the pump NOTICE Water damage N Protect the Control unit from water ingress when removing the Pump head 1 Remove the four Allen bolts securing the pump at each corner 2 Gently pull the pump towards you and remove N 6720643895 88 1Wo DI Reie JN EN Fig 115 Pump head removal gt To refit follow the above in reverse 60 WORCESTER Bosch Group 6 720 644 741a 2010 10 SERVICE AND SPARES 6 8 21 FLOW SENSOR FLOW RESTRICTOR HOUSING AND FILTER Ensure the domestic hot water circuit is fully drained Disconnect the electrical connection to the turbine 1 Remove the spring clip from the housing and move the brass pipe to one side Remove the wire mesh filter from the free end of the pipe and clean thoroughly Insert the wire mesh filter with the round end first 6720643895 90 1Wo Fig 116 Flow sensor 2 Withdraw the flow sensor and filter from the housing Using the cartridge tag w
40. 10 10 Bosch Group APPLIANCE INFORMATION 2 3 LAYOUT WE 15 6720643895 02 1Wo Fig 1 Main boiler components 8 6 720 644 741a 2010 10 WORCESTER Bosch Group APPLIANCE INFORMATION 1 Expansion Vessel 26 Left side hand hold for lifting boiler 2 Flow temperature sensor NTC 27 Plate to Plate heat exchanger 3 Removable panel for servicing 28 Gas valve 4 Electrode assembly 29 Flue air pressure switch connection not used 5 Overheat thermostat 30 Fan 6 Securing nut Air Gas manifold clamp 31 Fan guard 7 Silicon tube heat exchanger air vent 32 Manual vent point 8 Heat exchanger 33 Fan pressure test point 9 Flue over heat thermostat 34 Air Gas manifold 10 Access panel Heat exchanger sump cleaning 35 Compact hydraulic left mounting point 11 Right side hand hold for lifting boiler 36 Flow connector from heat exchanger 12 Pump 37 Expansion vessel hose connection point 13 Diverter valve assembly body 38 Auto air vent 14 Diverter valve actuator stepper motor 39 Return connection to heat exchanger 15 Diverter valve protective cover 40 Flow turbine 16 Drain point 41 Unused port 17 Central Heating CH return isolator 42 Compact hydraulic right mounting point 18 Domestic Cold Wa
41. 59 Pressure relief drain pipe NOTICE If the boiler is not to be N commissioned immediately then after successfully completing all of the checks and any rectification work Close the gas valve Close the water shut off valve Isolate the gas supply gt Isolate the electricity supply Label appropriately 6720643895 113 1Wo Fig 57 Identification plate Turn on the main gas supply check the gas pipe work connections and rectify any leaks WORCESTER 6 720 644 741a 2010 10 m Bosch Group COMMISSIONING 5 3 FILLING THE SYSTEM 1 Turn on the water main and open the system valves 2 Open all radiator valves 3 Fill the system via a WRAS approved filling loop to 1 bar then turn the valve anti clockwise to close 4 Vent 1 any air from the boiler heat exchanger using a suitable container to collect any water Ensure tube outlet 2 is directed away from the fan or any other electrical component to prevent any water damage Also place a suitable cover over the fan to prevent any spillage of water on to electrical connections Ensure the cover is removed after venting Lh lt lt TEn Anne 6720643895 51 1Wo Fig 60 Venting 5 Vent all radiators tighten when completed and check the system and correct any leaks The boiler integral expansion vessel is pre charged to 0 75
42. 6 Bottom panel installation NOTICE Every time the power to the N appliance is turned off and on the appliance enters a learning mode and may take some time to optimise the boiler performance This time is variable and is dependant on hot water and central heating demand 5 7 4 HAND OVER Complete the Benchmark Gas Boiler Commissioning Checklist The Benchmark Checklist can be found at the rear of these instructions Open the fascia cover by gently pressing the centre top of the cover Setupthe controls and show the user how to operate all the controls shown in the User Guide Ensure that the user guide is left with the boiler or homeowner If the appliance is unused and exposed to freezing conditions shut off all the mains supplies and drain the system and boiler 42 WORCESTER Bosch Group 6 720 644 741a 2010 10 SERVICE AND SPARES 6 SERVICE AND SPARES 6 1 INSPECTION AND SERVICE CAUTION TURN OFF THE GAS SUPPLY AND N ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS NOTICE COMPONENTS N After replacement of any components always check for gas tightness where relevant and carry out functional checks as described in Commissioning Damaged O rings or gaskets must be replaced NOTICE Service work must be carried out N by a competent registered engineer such as British Gas or Gas Saf
43. ALLATION 3 4 CONDENSATE PIPE WORK NOTICE N Where a new or replacement boiler is being installed access to an internal gravity discharge point should be one of the factors considered in determining boiler location The condensate pipe must be a minimum of 22 mm plastic pipe The condensate pipe work must fall at least 50 mm per metre towards the outlet and should take the shortest practicable route Ensure there are no blockages in the pipe run Key to condensate illustrations Syphon trap Soil and vent stack Minimum 450mm and up to three storeys Visible air break at plug hole Sink or basin with integrated overflow 75 mm sink waste trap s ol oi Pi oj y m Condensate pump 3 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 gravity to a suitable internal foul water discharge point such as an internal soil and vent stack A suitable permanent connection to the foul waste pipe should be used manufacturer s instructions should be followed 22mm 1 3 6720644744 06 1Wo Fig 6 Disposal to soil vent stack Alternatively if the first option is n
44. ARANCES UNVENTILATED COMPARTMENTS The tables below show the options for the minimum space required to install and service the boiler inside an unventilated compartment 3 6 6 INSTALLATION CLEARANCES UNVENTILATED COMPARTMENTS CAUTION CLEARANCES N Top and bottom clearances must not be reduced below the values shown in table 13 as they are the minimum clearances required for servicing Unventilated Compartment Installation Clearances millimetres The suggested total unventilated compartment minimum clearances are Side Above Below Front to removable door 400 170 approx 30 above the elbow 200 100 Tab 13 Minimum unventilated compartment clearances If Side Clearances are Reduced millimetres If total side clearance is reduced to Increase height clearances to approx OR Front clearance to Combined left and right clearances Combined top and bottom clearances removable door must excluding the appliance excluding the appliance be increased to 350 441 129 300 523 161 250 617 200 200 717 243 150 856 295 100 1012 358 50 1202 434 Tab 14 Reduced side clearances If Front Clearance is Reduced millimetres If front clearance to Increase overall height clearancesto OR Increase total side clearance to removable door is reduced to approx Combined left and right Combined top and bottom clearances excluding the clearances excluding the appl
45. ARTIFICALLY SOFTENED WATER N MUST NOT BE USED TO FILL THE CENTRAL HEATING SYSTEM FLUSHING THE SYSTEM Fill the system with cold water and check for leaks Open all drain cocks and drain the system Close drain cocks and add a suitable flushing agent compatible with aluminium at the correct strength for the system conditions in accordance with the manufacturer s instructions The pH value of the system water must be less than 8 or the appliance guarantee will be invalidated Circulate the flushing agent before the boiler is fired up Run the boiler system at normal operating temperature as directed by the manufacturer of the flushing agent Drain and thoroughly flush the system to remove the flushing agent and debris It may be necessary to use a power flushing machine to aid the cleansing procedure in some circumstances Close the drain cocks and refill with fresh water and a suitable inhibitor Vent any air from the boiler and system WORCESTER 6 720 644 741a 2010 10 Bosch Group 11 PRE INSTALLATION 3 2 MAINS SUPPLY 3 2 1 ELECTRICAL SUPPLY Supply 230V 50 Hz 140 Watts Cable PVC insulated 0 75 mm 24 x 0 2 mm temperature rated to 90 C External 3A fuse to BS1362 The appliance must be earthed This appliance must not be connected to a three phase supply e IPX4D NOTICE This is reduced to IP20 if the following mechanical timers are fitted
46. INSTALLATION COMMISSIONING AND SERVICING INSTRUCTIONS WALL HUNG RSF GAS FIRED CONDENSING COMBINATION BOILER GREENSTAR 24i 28i JUNIOR FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER The appliance is for use with Natural Gas or L P G Cat Il 2H3P type C13 C33 amp C53 Model GC Number Natural Gas 24ijunior 47 311 86 28 ijunior 47 311 87 Liquid Petroleum Gas 24ijunior 47 311 90 28 ijunior 47 311 91 6720643356 00 1Wo benchmarf g THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS WORCESTER Bosch Group o T m o d o g bd St N t St ce o N N o CONTENTS CONTENTS 5 6 2 Checking the gas rate 41 1 KEY TO SYMBOL AND SAFETY PRECAUTION 3 5 6 3 Domestic hot water 41 1 1 Explanation of symbols 3 5 7 Finishing commissioning 42 1 2 Safety precautions css arena 4 5 7 1 Replace outer casing 42 5 7 2 Fitting fascia flap 42 5 7 3 Installing bottom panel 42 2 APPLIANCE INFORMATION y siiis raid 6 5 7 4 Handover eee eee eens 42 2 1 Appliance nassen 6 2 2 Technical data 7 2 3 Layout ee eee eee nn eee 8 SERVICE AND SPARES esses 43 6 1 Inspection and service 43 6 2 Check the gas inlet pressure
47. OMMISSIONING and preset at the factory for operation on the gas type defined on the data plate No measurement of the combustion values are necessary provided there is a meter installed allowing the gas rate to be checked DO NOT ADJUST THE AIR GAS RATIO VALVE NOTICE The combustion settings on this N gas fired boiler have been checked adjusted When running in the service mode the boiler il will operate both the central heating and the domestic hot water circuits This is to allow sufficient time for this part of the commissioning procedure 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 Having checked That the boiler has been installed in accordance with the installation instructions The integrity of the flue system and flue seals as described in section 6 3 of this manual The integrity of the boiler combustion circuit and relevant seals 5 6 1 CHECKING THE GAS INLET PRESSURE The inlet pressure to the appliance must be checked using the following procedure MEASURING THE INLET PRESSURE D TA e i e a 9 o a e 1 A e 0 e amp LII em 6720643895 53 1Wo Fig 62 Inlet pressure test point Close gas isolation valve Slacken the screw in the inlet pressure test point 1 and connect a manometer Open ga
48. ance or other public access where it could cause a hazard The pressure relief drain pipe 1 from the boiler should be at least 15mm diameter copper pipe and run downwards away from any electrical equipment or other hazard preferably to an external drain or soak away Pipe 1 should be finished with a partial bend near the outlet to face the external wall as shown to help prevent freezing 6720643895 08 1Wo Fig 13 Pressure relief pipe work 2 Outside wall 13 Drain pipe 4 External drain Tab 10 Key to fig 7 WORCESTER 6 720 644 741a 2010 10 i Bosch Group PRE INSTALLATION 3 6 BOILER LOCATION AND CLEARANCES 3 6 1 INSTALLATION This boiler is only suitable for installing internally within a property at a suitable location onto a fixed rigid surface at least the same size as the boiler and capable of supporting the boiler weight NOTICE N No surface protection is required against heat transfer from the boiler 3 6 2 SERVICING CLEARANCES VENTILATED COMPARTMENTS Figure 14 shows the minimum space required to install and service the boiler in a ventilated compartment e Ifa boiler is installed in a compartment with clearances less than shown in the tables 13 14 or 15 ventilation is required Refer to table 11 for ventilation requirements Direct to outside To room or Vent position internal space High level Minimum free Minimum free area 122
49. anifold There are two handling holes incorporated into the inner casing left and right in the lower section of the appliance 1 AN o dd I 1o ill A 6720643895 22 1Wo Fig 28 Hanging the boiler 28 WORCESTER Bosch Group 6 720 644 741a 2010 10 INSTALLATION i Connect the expansion vessel flexible pipe to the NOTICE The pressure relief connector hydraulic manifold situated to the left of the pump must be repositioned after the boiler has l y been correctly mounted to the wall Remove and discard the plastic cap from the mounting frame expansion vessel flexible pipe 1 Refer to figure 30 release the retaining clip 1 il To ease assembly of components apply 2 Remove and discard the orange plastic blanking plug silicone lubricant to sealing surfaces 2 from the pressure vessel connection at the hydraulic manifold 1 Push the lever on the pressure relief connector UP until the stop on the inside of the handle is over the shoulder of the metal bracket to secure in place _ Ir 6720643895 27 1Wo Fig 30 Expansion vessel connection 1 Refer to figure 31 and insert the expansion vessel flexible pipe it to the fitting on the pump 6720643895 26 1Wo 2 Secure in place with the wire retaining clip Fig 29 PRVin the up position 2 Remove the screw from the control panel retaining bracket and lower the contr
50. bed in section 6 6 air gas ratio setting 58 WORCESTER Bosch Group 6 720 644 741a 2010 10 SERVICE AND SPARES 6 8 15 SYPHON REMOVAL Removal of the syphon assembly will give access to the Auto Air Vent D To release the syphon from the sump 1 Disconnect the discharge hose at the plumbing manifold 2 Using a screwdriver disengage the retaining clip on top of the syphon 3 Pull the syphon towards you and remove the complete assembly 6720643895 56 1Wo Fig 110 Syphon removal 6 gt gt 8 16 DIVERTER VALVE MOTOR Connect electrical power to the appliance Enter the service mode to ensure that the diverter valve is in the mid position there is no need to drain the appliance Electrically isolate the appliance Remove diverter valve cover if fitted Disconnect the electrical connector from the diverter valve motor Pull the motor assembly towards you The assembly will slide free from the valve To fit the new diverter valve motor slide the body into the housing Ensure that H section of the motor actuator is fitted correctly into valve body Re connect the electrical connection Re fit the protective cover if available 6720643895 84 1Wo Fig 111 Diverter valve and motor 6 8 17 DIVERTER VALVE il To ease asse
51. below gutters pipes and drains 1 200 mm between terminals facing each other 300 mm to an internal or external corner il Installations in car ports are not recommended 14 15 The dimension below eaves balconies and car ports can be reduced to 25 mm as long as the flue terminal is extended to clear any overhang Any external flue joints must be sealed with suitable silicon sealant 300 mm above below and either side of an opening door air vent or opening window WORCESTER 6 720 644 741a 2010 10 Bosch Group 23 PRE INSTALLATION 3 10 PLUME MANAGEMENT TERMINAL POSITIONS All measurements in millimetres Plume management deflector Balcony Drainpipe Fig 19 Plume terminal positions Eo SCH k Ee Flue Exhaust gt Outlet Air Intake m P 6720643895 14 1Wo NOTICE All measurements are the minimum clearances required Refer to figure 18 for all concentric flue terminal positions unless the flue position is specified on the figure above Plume terminal positions Terminals must be positioned so to avoid combustion products entering the building Support the flue at approximately one metre intervals and at a change of direction use suitable brackets and fittings Key to illustration 1 600 mm distance to a boundary or surface facing a boundary unless it will cause a nuisance BS 5440 Part 1 recommends that
52. boiler should be first unpacked before ascending ladder to loft space 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 Once the appliance is removed from its packaging check the contents against the packing list NOTICE N Before installing the appliance ensure that the system has been cleaned as explained on page 11 1 Remove straps and open the top of the boiler packaging 2 Remove the wall mounting frame 1 and wall mounting template 2 and from the packaging 3 Remove the boiler bottom panel 5 front fascia 6 hardware literature pack 4 and syphon assembly 7 from the carton WORCESTER 6 720 644 741a 2010 10 Bosch Group 25 INSTALLATION 4 2 WALL MOUNTING TEMPLATE amp FLUE OPENINGS WARNING BEFORE DRILLING N ENSURE THAT THERE ARE NO PIPES ELECTRICAL CABLES DAMP PROOF COURSES OR OTHER HAZARDS SAFETY All relevant safety precautions must be undertaken Protective clothing footwear gloves and safety goggles must be worn as appropriate FIXING THE WALL MOUNTING FRAME The boiler wall mounting template shows the relative positions of the flue and the top and bottom fixing of the wall mounting frame 1 Fix the wall mounting template to the wall in the desired position 2 Drill 4 holes for the
53. care is taken when siting terminals in relation to boundaries 2 Internal external corners The air intake clearance can be reduced to 150 mm providing the flue exhaust outlet has a 300 mm clearance 3 The flue cannot be lower than 1 000 mm from the top of the light well due to the build up of combustion products 1 200 mm between air intake and facing terminal 5 Clearance no less than 200 mm from the lowest point of the balcony or overhang Installations in car ports are not recommended 6 1 200 mm from an opening in a car port on the same wall i e door or window leading into dwelling Using a Plume Management Kit the air intake measurement can be reduced to 150 mm providing the flue exhaust outlet has a 300 mm clearance Plume kits running horizontally must have a 10 fall back to the boiler for proper disposal of condensate For details on specific lengths see relevant boiler Technical amp Specification information This feature allows some basic plume re direction options on a standard telescopic horizontal flue terminal 300 mm minimum clearances to a opening e g window However the minimum clearance to an opening in direction that the plume management is facing must be increased to 1 500 mm Where the flue is less than 150 mm to a drain pipe and plume re direction is used the deflector should not be directed towards the drainpipe 24 6 720 644 741a 2010 10 WORCESTER Bosch Group INSTALLATION
54. cific instruction is given reference should be made to the relevant British Standard codes of Practice BS7074 1 Code of practice for domestic and hot water supply BS6891 Installation of low pressure gas pipe work up to 28mm R1 BS5546 Installation of gas hot water supplies for domestic purposes EN12828 Central heating for domestic premises BS5440 1 Flues and ventilation for gas appliances of rated heating not exceeding 7OkW net Flues BS5440 2 Flues and ventilation for gas appliances of rated heating not exceeding 70kW net Air Supply BS7593 Treatment of water in domestic hot water central heating systems BS6798 Installation of gas fired boilers of rated input up to 70kW net Irish Standards The relevant Irish standards should be followed including ECTI National rules for electrical installations e IS 813 2002 for Domestic Gas Installations LPG Installations An appliance using L P G must not be installed in a room or internal space below ground level unless one side of the building is open to the ground Timber framed building Where the boiler is to be fitted to a timber framed building the guidelines laid down in BS5440 Part 1 and IGE Gas Installations in Timber Frame Buildings should be adhered to Potable water All seals joints and compounds including flux and solder and components used as part of the secondary domestic water system must be approved by WRAS CH Water Artificia
55. ction of the gas supply to the boiler must be in accordance with BS6891 Under no circumstance should be size of the gas supply pipe be less than 22 mm The meter or regulator and pipe work to the meter must be checked preferably by the gas supplier This is to ensure that the equipment is in good working order and can meet the gas flow and pressure requirements in addition to the demand from any other appliance being served 3 2 4 WATER SUPPLY WATER MAINS PRESSURE Minimum mains water pressure 1 3 bar for 24 and 28i Junior for maximum performance Maximum mains fed water pressure 10 bar If necessary fit a pressure reducing valve NOTICE Non return flow back prevention N devices including those associated with water meters fitted to the mains water supply can cause a pressure build up which could damage the boiler and other household appliances Where the mains water supply has a non return flow back prevention valve fitted a mini expansion vessel 1 should be connected to the mains water inlet pipe 2 between the non return valve 3 and the boiler 4 as shown below 6720643895 04 1Wo il Mini expansion vessel part no 7 716 102 105 Mains water inlet pipe Non return valve BR UJN Boiler USE IN HARD WATER AREAS Normally there is no need for water treatment to prevent scale formation as the maximum temperature of the HW heat exchanger is limited by the e
56. densate 35 mm 22 mm 7 Pressure Relief Valve 367 mm 15mm gt E i Tab 17 Key to figures 16 amp 17 Fig 16 Pipe dimensions 20 6 720 644 741a 2010 10 WORCESTER Bosch Group PRE INSTALLATION 3 8 FLUE OPTIONS Condensfit IT Maximum total flue length mm FLUE TYPE 60 100 80 125 il Telescopic horizontal flue assembly 570 1 070 2 Horizontal flue extension 4 600 13 000 3 Horizontal flue with 1 x 90 bend 2 600 11 000 4 Horizontal flue with 2 x 90 bends N A 11 000 5 High level horizontal flue 4 600 13 000 6 High level horizontal flue with 2 x 90 bends 2 600 11 000 7 High level horizontal flue with 3x 90 bends N A 9 000 8 Vertical balanced flue assembly 6 400 15 000 9 Vertical balanced flue with 2 x 90 bends 2 400 11 000 10 Vertical balanced flue with 2 x 45 bends 4 400 13 000 Tab 18 Flue options The Greenstar series has the option of two horizontal 60 100 RSF telescopic and extended telescopic and two horizontal 80 125 RSF telescopic and extended telescopic flue systems and two vertical RSF 60 100 or 80 125 flue systems The flue systems have different maximum flue lengths The next page shows various fluing options Refer to the Flue option table above for the straight flue lengths required to achieve the maximum flue length NOTICE Fffective flue lengths N each 90 bend used is equivalent to 2 metres of straight flue each 45 bend used is equiva
57. e 6720643895 57 1Wo Fig 67 Remove outer case 2 Lowering boiler control to the service position Remove screw 1 securing the control panel Pull the panel 2 forward into the service position 6720644741 04 1Wo Fig 68 Control panel into service position WORCESTER 6 720 644 741a 2010 10 Bosch Group 43 SERVICE AND SPARES 6 2 CHECK THE GAS INLET PRESSURE Refer to section 5 6 1 for more information NOTICE N Ensure that the gas inlet pressure is satisfactory with all other gas appliances working Do not continue with the other checks if the correct gas inlet pressure can not be achieved Checkthe gas supply working pressures in the system conform to the readings shown in the table below Allowed mbar pressure drop across regulator pipework across gas control boiler na EEE 32 45 2 5 29 5 42 5 1 5 mbar range 28 41 6 3 CHECKING FLUE INTEGRITY The integrity of the flue system and performance of the boiler can be checked via the flue turret sample points Flue gas sample point 1 Air inlet sample point 2 Tab 23 Key to figure 69 6720643895 67 1Wo Fig 69 Flue test points With the boiler case on and the boiler running at maximum Insert the analys
58. e registered personnel NOTICE SERVICE MUST NOT BE N ATTEMPTED IF A CO CO ANALYSER IS NOT AVAILABLE To ensure the continued efficient operation of the appliance it must be checked at regular intervals The frequency of servicing will depend upon the particular installation conditions and usage however an annual service is recommended The extent of the service required by the appliance is determined by the operating condition of the appliance when tested by fully qualified engineers The service interval record sheet at the rear of these instructions must be completed after each service INSPECTION 1 Check that the terminal and the terminal guard if fitted are clear and undamaged If the appliance is in a compartment or cupboard check that the specified service space around the appliance is clear Check all the joints and connections in the system and remake any that show signs of leakage Refill and re pressurise if applicable as described in Commissioning Operate the appliance and take note of any irregularities Refer to Fault Finding on page 67 for rectification procedures COMPONENT ACCESS 1 Removing outer case Remove bottom panel by pushing it fully back and then pulling it forward and down to remove Undo and remove two screws 1 securing boiler casing at the top of the appliance Undo but do not remove the two lower screws 2 Pull case forward and remov
59. eans of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference Feliu Pel cf aT A GFT EE Customer Name eS Telephone Number Address Boiler Make and Model Boiler SerialNumber ttt ttt ttt ttt de te te te EE EE Et Commissioned by print name Gas Safe Register Number Company Name Telephone Number Company Address S Commissioning Date To be completed by the customer on receipt of a Building Regulations Compliance Certificate Building Regulations Notification Number if applicable CONTROLS Tick the appropriate boxes Time and Temperature Control to Heating Room Thermostat and Programmable Load Weather Optimum Start Programmer Timer O Room Thermostat Compensation Control Time and Temperature Control to Hot Water Cylinder Thermostat and Programmer Timer Combination Boiler Heating Zone Valves Fitted Not Required Hot Water Zone Valves Fitted Not Required Thermostatic Radiator Valves Fitted _ Not Required _ Automatic Bypass to System Fitted Not Required Boiler Interlock Provided ALL SYSTEMS The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer s instructions Yes O What system cleaner was used What inhibitor was used Quantity litres CENTRAL HEATING MODE Measure and Record Gas Rate U i OR E77 Burner Operating Pressure if applicable mbar R s Inlet Pressure mi O Ga bar
60. eat output 50 30 C kW 25 45 13 85 25 45 25 45 25 45 Maximum rated heat output 80 60 C kW 24 24 Maximum flow temperature SE 82 82 Maximum permissible operating pressure bar 2 5 2 Available pump head at 21 C system temperature rise m 2 0 2 0 Flue Flue gas temperature 80 60 C rated min load C 79 64 79 65 Flue gas temperature 40 30 C rated min load C 55 38 55 39 CO level at max rated heat output after 30 minutes 11 0 11 0 CO level at min rated heat output after 30 minutes 8 8 8 8 8 8 10 5 10 5 NOx class 5 5 5 5 5 NOx rating mg kWh 66 38 66 69 69 Condensate Maximum condensate rate l h 2 0 1 02 2 0 2 0 2 0 pH value approx 4 8 4 8 4 8 4 8 4 8 Electrical Electrical power supply voltage a c V 230 230 230 230 230 Frequency Hz 50 50 50 50 50 Maximum power consumption W 140 140 140 140 140 General data SEDBUK band A A A A A Appliance protection rating IP X4D X4D X4D X4D X4D Appliance protection rating with mechanical or RF IP 20 20 20 20 20 mechanical timer fitted Permissible ambient temperatures C 0 50 0 50 0 50 0 50 0 50 Nominal capacity of appliance litre 3 9 3 9 3 9 3 9 3 9 Noise output level Max central heating dBA 42 42 42 42 42 Total boiler weight kg 37 5 37 5 S us 37 5 37 5 Lift weight kg 27 1 27 1 27 1 27 1 27 1 SEDBUK 90 1 90 1 90 1 91 8 91 8 Tab 6 Technical data i Junior S WORCESTER 6720644 741a 20
61. embly 8 717 207 937 Used on i junior boilers Control box as 8 717 207 939 mbly Flow regulator Type E 10 litre blue 8 716 141 0570 Used on 28 i junior ala Gasket burner Seal Inner case mantel Flow regulator C 5 A 8 716 110 534 0 8 716 106 635 0 G Type E 8 litre lt 4 gt white di Q 8 716 141 0540 NS p Used on 24 i junior DHW Pressure relief valve Pump assembly temperature DHW 3 speed sensor NTC ur 8 714 500 081 0 GC No H02 538 8 717 401 0290 GC No H02 526 8 716 106 3550 GC No H02 527 Pressure gauge 8 718 224 344 0 vg Flow sensor 8 716 107 2230 GC No H02 529 Used on 25Si amp 24 i junior delt boilers Heat exchanger 12 plate 8 716 106 686 0 GC No H02 538 Used on I m 305i amp u N WS 28 i junior E 3 boilers JU Heat exchanger 16 plate 8 716 106 685 0 GC No Ho2 531 By pass valve 8 716 106 434 0 GC No H02 532 Diverter valve assembly 8 716 106 845 0 GC No H02 533 Diverter valve motor 8 716 106 847 0 GC No H02 534 Flow temperature sensor NTC 8 716 106 6880 GC No H26 542 High limit stat 8 707 206 196 0 GC No H26 584 WORCESTER 6 720 644 741a 2010 10 Bosch Group 65 SERVICE AND SPARES Automatic air vent Fusing element set 8 744 503 010 0 Containing Fuse F1 2 5 Amp Fuse F2 1 6 Amp
62. emperature control 8 PRV pipe connection point 16 Service mode button Tab 8 Additional boiler components 10 6 720 644 741a 2010 10 WORCESTER Bosch Group PRE INSTALLATION 3 PRE INSTALLATION 3 1 CLEANING PRIMARY SYSTEMS NOTICE N All the following Pre Installation sections must be read and requirements met before starting boiler or flue installations CAUTION N ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS INHIBITOR Add a suitable inhibitor or combined inhibitor anti freeze if the system is exposed to freezing conditions to the heating system in accordance with the manufacturer s guidelines NOTICE N Debris from the system can damage the boiler and reduce efficiency Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance warranty WARNING Sealing agents N The addition of sealing agents to the system water is not permitted as this can cause problems with deposits left in the heat exchanger BEFORE CLEANING THE SYSTEM Ensure that the system and pipe work is in good working order Where possible keep the existing boiler circulating pump in place when flushing the system FOLLOW THE GUIDANCE OF BS7593 Treatment of water in domestic hot water central heating and also the flushing guidelines below NOTICE
63. er probe into the air intake test point Allow the readings to stabilise and check that Op is equal to or greater than 20 6 CO is less than 0 2 If the readings are outside these limits then this indicates that there is a problem with the flue system or combustion circuit 6720643895 104 1Wo Fig 70 Flue integrity test 44 WORCESTER Bosch Group 6 720 644 741a 2010 10 SERVICE AND SPARES 6 4 FAN PRESSURE TEST Remove the cover and connect a digital manometer to This test is to determine if the heat cell the fan pressure test point requires cleaning attention After measurement replace test point cover The pressure will read negative refer to the chart in figure 73 SETTING THE BOILER TO MAXIMUM 1 Press and HOLD service button for more than 10 NOTICE seconds N The boiler must be run at maximum output 2 Set the Central Heating temperature to maximum for Fan Pressure test and the Flue Gas The service button will illuminate continually and analysis the blue power indicator will pulse 5 times The boiler will stay in this mode for 15 minutes FANIPRESSHRE TEST unless the service button is pressed again NG Boilers 28 i Junior Ey 3 24 Junio ERT 5 mbar LPG Boilers 28 i Junior Ty 24 i Junior Ey Z 8 mbar 6720644741 07 1Wo Fig 73 Fan pressure readings 6720644741 12 1Wo If
64. f this method is chosen then the following measures should be adopted The external run be kept as short as possible and not exceed three metres The pipe should be run internally as far as possible before going externally and the pipe diameter should be increased to 32mm before it passes through the wall to the exterior The pipe should be insulated using suitable waterproof and weather resistant insulation The external pipe should take the shortest and least exposed route to the discharge point and should fall as steeply as possible away from the boiler with no horizontal runs in which condensate might stand 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 blockage by leaves may offer further protection from wind chill Pipe drainage will be improved if the end is cut at 45 angle as opposed to a straight cut m q N 777 13 we N S XX 6720644744 10 1Wo Fig 10 External disposal WORCESTER 6 720 644 741a 2010 10 Bosch Group 15 PRE INSTALLATION CONDENSATE SOAK AWAY The condensate drainage pipe may be run above or below the ground to the soak away The examples shown on this page run above ground The soak away must use a 100mm plastic tube with two rows of three 12 mm holes on 25 mm centres and 50 mm fr
65. g frame to the wall with the appropriate fixings for the boiler weight and wall type System pipes may be run vertically upwards behind the boiler or below it See Plumbing Manifold Section on page 20 1 CH flow 22mm 2 CH return 22mm 3 Gas inlet 22mm 4 Domestic Cold Water inlet 15mm 5 DHW outlet 15mm If using the optional filling loop 7 716 192 281 not supplied with the boiler fit it before hanging the boiler on the wall frame The bonded washer supplied is for the Gas il connection only Fit sealing washers to service valves before hanging boiler E E x X UI 6720643895 24 1Wo Fig 26 Sealing washers NOTICE Before hanging the boiler onto the N wall mounting frame ensure that the pressure relief valve connection is in the DOWN position This is located on the right hand side of the wall frame at the rear Apply a smear of silicone lubricant to the seal to ease connection later 1 Pull the extended lever forward and down until there is no further travel 6720643895 116 1Wo Fig 27 PRV connection in the down position CAUTION Hanging the boiler N Remove the plastic strip fitted to pipes before hanging the boiler Hangthe boiler on to the wall mounting frame by the two brackets positioned left and right at the top rear of the appliance Do not lift the appliance by the air gas m
66. gnature To confirm satisfactory demonstration and receipt of manufacturer s literature Service Record It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed Service Provider Before completing the appropriate Service Record below please ensure you have carried out the service as described in the manufacturer s instructions Always use the manufacturer s specified spare part when replacing controls Service 1 Date Engineer Name Service 2 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Gas Safe Register No Comments Comments Signature Signature Service 3 Date Engineer Name Service 4 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Gas Safe Register No Comments Comments Signature Signature Service 5 Date Engineer Name Service 6 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Operative ID No Comments Comments Signature Signature Service 7 Date Engineer Name Service 8 Date Engineer Name Company Name Company Name
67. he boiler will be in Economy mode with pre heat no longer active WORCESTER 6 720 644 741a 2010 10 Bosch Group 41 COMMISSIONING 5 7 FINISHING COMMISSIONING 5 7 1 REPLACE OUTER CASING Replace outer casing making sure that the securing points are properly located Replace top two screws 1 Tighten bottom two screws 2 6720644741 06 1Wo rl gt 2 ES S em 3 X CABLE NS f NI G gt a B HA E Fig 65 Fitting case 5 7 2 FITTING FASCIA FLAP Present the flap up to the appliance with the hinge pins facing the appliance Engagethe left hand pin into the grey pivot The hinge pin and pivot hole are both square rotate the flap to ensure that the pin is located in the pivot Support the flap in your left hand and with your right hand bend the right side down This should enable you to engage the right hand pin in the pivot Rotate the flap to ensure that the pins and pivots are located securely Close the flap 5 7 3 INSTALLING BOTTOM PANEL 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 there is no more movement Slide the panel forward until it is fully engaged 6720643895 55 1Wo Fig 6
68. he system pressure gauge from the fascia by parting the plastic retaining lugs securing the gauge in place Take care not to damage or kink the capillary tube 3 Remove the code plug The code plug should be left attached to the frame of the boiler by its plastic safety thread Fig 106 Replacing the controls Refer to figure 107 1 Remove the three screws retaining the front fascia making sure to support the fascia when removing the last screw 2 Remove the front fascia Fig 107 Fascia removal Refer to figure 108 1 Using a suitable tool press the button upwards 2 Slide the control support bracket to the left 6720643895 79 1Wo Fig 108 Control unit release Refer to figure 109 Support the control and unclip control support cable 1 from the boiler frame Remove the support cable and fit to the new control Remove appropriate cable restraints from the new control box 6720643895 80 1Wo Fig 109 Fit control unit to the boiler Re connect support cable 1 to the boiler and all electrical connections and system to the new control Ensure that the code plug is re fitted to the new control If this is not done the boiler will indicate an error and will not function Replace the fascia to the new control and secure the system pressure gauge back in the fascia NOTICE N After re assembly check the CO CO levels as descri
69. here there is no risk of personal injury or material losses and are identified by the symbol shown on the left They are bordered by horizontal lines above and below the text ADDITIONAL SYMBOLS Symbol Meaning a step in an action sequence gt a reference to a related part in the document or to other related documents a list entry a list entry second level Tab 1 Symbols SYMBOLS USED IN THIS MANUAL Domestic Hot Water Central Heating Hot Water Storage Cylinder Domestic Cold Water Supply Electrical Supply Gas Supply e xe ng Tab 2 Commonly used symbols PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION THESE INSTRUCTIONS ARE APPLICABLE TO THE WORCESTER APPLIANCE MODEL S STATED ON THE FRONT COVER OF THIS MANUAL ONLY AND MUST NOT BE USED WITH ANY OTHER MAKE OR MODEL OF APPLIANCE THE INSTRUCTIONS APPLY IN THE UK AND IRELAND ONLY AND MUST BE FOLLOWED EXCEPT FOR ANY STATUTORY OBLIGATION THIS APPLIANCE MUST BE INSTALLED BY A GAS SAFE REGISTERED COMPETENT PERSON FAILURE TO INSTALL CORRECTLY COULD LEAD TO PROSECUTION IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER TECHNICAL HELPLINE 0844 892 3366 DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER PLEASE LEAVE THESE INSTRUCTIONS WITH THE COMPLETED BENCHMARK CHECKLIST OR A CERTIFICATE CONFIRMING COMPLIANCE WITH IS 813 EIRE ONLY AND THE USER MANUAL
70. iance appliance 50 511 505 25 596 569 Tab 15 Reduced front clearances WORCESTER 6 720 644 741a 2010 10 19 Bosch Group PRE INSTALLATION 3 7 PLUMBING MANIFOLD 3 7 1 CONNECTIONS Heating System 22mm compression fittings DHW 15mm compression fittings Gas 22mm compression fitting Tab 16 Use the fittings supplied in the Hardware literature pack If the boiler pipes are to be run behind the appliance ensure that the pipes pass through the slot in the white cardboard guide A This is fitted to the boiler frame Further guidance on pipe routing can be found printed on the boiler template supplied with the boiler For further ease of fitting an optional Vertical Pre piping Assembly kit is available comprising five pre formed copper pipes and an earth bonding strip Part number 7 716 192 570 To cover the pipe work under the boiler down to the counter top an optional Below boiler pipe cover can be used Part number 7 716 192 608 WORCESTER 6720643895 11 1W Fig 17 Plumbing manifold From left Diameter Function case edge of pipe 1 CHFlow 70 mm 22mm 2 DHW Outlet 135 mm 15 mm 3 Gas 200 mm 22mm i 4 Domestic Cold Mains In 267 mm 15 mm 5 CH Return 330mm 22mm 5 6 Con
71. ion 32 6 8 29 Bypass valve SOLER ECL Ce 63 4 6 Condensate connection ease rues 33 6 8 30 Expansion vessel MOTTO 64 4 Electrical anne 34 6 9 Short parts USE seen 65 5 COMMISSIONING enne 36 FAULT FINDING AND DIAGNOSIS sce dicis 67 5 1 Convert boiler to low nox 36 7 1 Fault finding PP IQ LE LO E 67 5 2 Pre Commissioning checks 37 e a N Be een me CS EE 7 3 Preheat and DHW function 71 5 5 Starting the appliance 39 7 4 Protection function 72 5 6 Commissioning lees 40 5 6 1 Checking the gas inlet pressure 40 2 6 720 644 741a 2010 10 WORCESTER Bosch Group KEY TO SYMBOLS AND SAFETY PRECAUTION 1 KEY TO SYMBOLS AND SAFETY PRECAUTION 1 1 EXPLANATION OF SYMBOLS WARNING SYMBOLS Safety instructions in this document are N framed and identified by a warning triangle which is printed on a grey background Electrical hazards are identified by a A lightning symbol surrounded by a warning triangle Signal words indicate the seriousness of the hazard in terms of the consequences of not following the safety instructions NOTICE indicates possible damage to property or equipment but where there is no risk of injury CAUTION indicates possible injury WARNING indicates possible severe injury DANGER indicates possible risk to life IMPORTANT INFORMATION Notes contain important information in i cases w
72. ithdraw the flow restrictor housing If the regulator housing has become stuck a pair of long nosed pliers may be used to grip the housing Apply silicone lubricant to the seals to ease assembly Torefit follow the above in reverse Ensure any seals that have been disturbed are renewed 6 8 22 FLOW REGULATOR Remove the flow restrictor housing See Removing the flow sensor flow restrictor housing and filter 6720643895 91 1Wo Fig 117 Flow regulator Using a small Allen key or similar push the flow restrictor cartridge out of the housing gt To refit follow the above in reverse Ensure any seals that have been disturbed are renewed Turbine Flow Restrictor 24 i white 28 i blue Filters 4 Flow restrictor housing w N m Tab 25 Flow regulator parts 6 8 23 DRAIN TAP Ensure the appliance has been fully drained 1 Rotate the drain tap fully anticlockwise and push in 2 Withdraw the drain tap from its housing 6720643895 89 1Wo Fig 118 Drain tap and pressure gauge removal Apply silicone lubricant to the seals to ease assembly Torefit follow the above in reverse Ensure any seals that have been disturbed are renewed 6 8 24 PRESSURE GAUGE Referto figure 118 Ensure the appliance has been fully drained see draining the appliance 3 Prisethe lugs apart 3 securing
73. ium or combined inhibitor anti freeze if the system is exposed to freezing conditions to the heating system water in accordance with the manufacturers instructions The pH value of the system water must be less than 8 or the appliance warrantee will be invalidated Fill system via a WRAS approved filling loop to between 1 and 2 bar Vent all radiators tighten vents when complete Vent any air from the boiler heat exchanger using a v Ww v Vv suitable container to collect any water Ensure tube outlet is directed away from the fan or any other electrical component to prevent damage Also place a suitable cover over the fan to prevent any spillage of water onto electrical connections Ensure the cover is removed after venting Vent all radiators Re pressurise if necessary to 1bar Set all controls to maximum Record the date when the inhibitor was added to the system on the warrantee card An optional filling loop 7 716 192 281 is il available to fill the system not supplied with the boiler NOTICE The concentration of inhibitor in the system should be checked every 12 months or sooner if system content is lost The adding sealing agents to system water is not recommended this can cause problems with deposits in the heat exchanger 5 4 WATER TREATMENT NOTICE N ARTIFICIALLY SOFTENED WATER MUST NOT BE USED TO FILL THE CENTRAL HEATING SYSTEM 38
74. lectronic control In areas where temporary water hardness exceeds 200 ppm consideration may need to be given to the fitting of a scale prevention device In such circumstances the advice of the local water authority should be sought 12 WORCESTER Bosch Group 6 720 644 741a 2010 10 PRE INSTALLATION 3 3 WATER SYSTEMS AND PIPE WORK PLASTIC PIPE WORK Any plastic pipe work must have a polymeric barrier with 600mm minimum length of copper pipe connected to the boiler Plastic pipe work used for underfloor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approximately 50 C PRIMARY SYSTEMS CONNECTIONS VALVES All system connections taps and mixing valves must be capable of sustaining a pressure up to 3 bar Radiator valves should conform to BS2767 10 All other valves should conform to BS1010 Thermostatic radiator valves TRV s must be used on all radiators within the sleeping accommodation but not the radiator where the room thermostat is sited This must be fitted with lock shield valves and left open Adrain cock is required at the lowest point in the system An air vent is required at all the high points in the system The boiler is equipped with an automatic il internal by pass SHOWERS BIDETS If a shower head can be immersed in water or comes closer than 25mm from the top edge of a bath or showe
75. lent to 1 metre of straight flue Plume management kits are available for the il 60 100 horizontal flue system Refer to the manual supplied with the Plume Management kits for complete installation instructions WORCESTER 6 720 644 741a 2010 10 Bosch Group 21 PRE INSTALLATION CE 350mm 570mm 5 130 mm Min Pie rog eg 500 mm E SS x 300mm i aA d TS i n Flat roof ES L u v 6720643895 12 1Wo 22 6 720 644 741a 2010 10 WORCESTER Bosch Group PRE INSTALLATION 3 9 FLUE TERMINAL POSITIONS All measurements in millimetres Fig 18 Flue terminal positions Drainpipe 6720643895 13 2Wo N NOTICE All measurements are the minimum clearances required Terminals must be positioned so to avoid combustion products entering the building Support the flue at approximately one met
76. ll the panel forward 6720644741 04 1Wo Fig 89 Control panel to service position 52 WORCESTER Bosch Group 6 720 644 741a 2010 10 SERVICE AND SPARES 6 8 6 GAS VALVE Refer to figure 90 Isolate gas supply at boiler gas cock 1 Remove wire clip from gas valve outlet 2 Pull the gas pipe free from the gas valve If the pipe will not pull out unscrew the nut to aid removal EN Aso Fig 90 Gas valve upper connection 6720643895 72 1Wo Refer to figure 91 1 Undo bottom gas connection to gas valve 2 Undo two securing screws on the underside of casing Pull valve up and forward out of boiler Disconnect electrical connections Replace valve with new seals and check for gas tightness 6720643895 73 1Wo Fig 91 Gas valve lower connection 6 8 7 AIR GAS MANIFOLD AND FAN ASSEMBLY The following components require the i air gas manifold and fan assembly to be removed Fan electrode assembly Burner Heat exchanger NOTICE N If the joint between the Air Gas manifold and heat exchanger is disturbed the sealing gasket must be replaced After re assembly combustion must be checked using the procedure in the section Setting the Air Gas ratio Measurement and setting if necessary
77. lly softened water must not be used to fill the central heating system BOILER FEATURES AND CHECKLIST Pre wired and pre plumbed Galvanised steel inner frame Digital control system Automatic ignition Direct burner ignition electrodes Built in frost protection Built in fault finding diagnostics Modulating automatic gas valve Combustion air fan with speed regulator CH temperature sensor amp control Pump anti seizure protection Flue gas temperature sensor Condensate syphonic trap DHW flow sensor Plate type DHW heat exchanger CHECK LIST HARDWARE LITERATURE PACK Qty Greenstar 24i 28i Junior Installation 1 Commissioning and Servicing Instructions 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 3 Fibre Washer 18 6 x 13 5 x 1 5 2 Fibre Washer 23 9 x 17 2 x 1 5 2 Bonded Washer 3 4 1 Syphon assembly 1 Installation instructions 1 Warranty Return Envelope 1 Tab 4 Hardware lit pack checklist WORCESTER 6 720 644 741a 2010 10 Bosch Group APPLIANCE INFORMATION 2 APPLIANCE INFORMATION 2 1 APPLIANCE Depth to wall When fitted to wall frame 6720644741 01 1Wo STANDARD PACKAGE
78. mation refer to the 60 100 il Horizontal Flue kit Instruction Manual ADDITIONAL NOTES AND REMINDERS Ensure that all cut lengths are square and free from burrs The flue is sealed when assembled correctly and the components are pushed fully home The flue is set at an angle of 3 or 52mm per metre length 2m gt im 52mm 104mm 26720644842 10 1Wo Fig 39 Slope for condensate disposal WORCESTER 6 720 644 741a 2010 10 Bosch Group 31 INSTALLATION 4 5 4 FLUE TERMINAL PLUME RE DIRECTION The flue discharge can be re directed allowing some plume redirection control alternatively a complete plume management system can be fitted to the flue terminal RE DIRECTING THE FLUE DISCHARGE 1 Remove screws 1 and rotate the terminal end 2 through 180 NOTICE DO NOT rotate the complete N terminal assembly 1 Refit the terminal end 2 and secure with screws 1 2 Loosen screws 3 and rotate the entire outlet assembly to redirect the plume Tighten screws 3 to secure in the required position The flue terminal outlet has built in stops to limit rotation for horizontal fluing to allow condensate to run back into the boiler for safe disposal Do not attempt to force beyond the limit stops Fig 40 Plume redirection NOTICE Outlet position N gt The flue terminal outlet position must follow those stated in the relevant appliance instruc
79. mbly of components apply silicone lubricant to sealing surfaces Ensure the appliance has been fully drained Disconnect the electrical connector from the diverter valve motor Remove the diverter valve cover if fitted Undo the two screws holding the valve to the plastic housing Withdraw the valve and clean the valve chamber if necessary To refit follow the above in reverse Ensure any seals that have been disturbed are renewed WORCESTER 6 720 644 741a 2010 10 Bosch Group 59 SERVICE AND SPARES 6 8 18 AUTO AIR VENT Removal of the syphon assembly will give il access to Auto air vent Refer to page 59 Ensure the appliance has been fully drained gt Use a screwdriver or similar to rotate the air vent anticlockwise as shown below S 6720643895 85 1Wo Fig 112 Auto air vent 1 Lift the air vent 1 out of the housing and remove y 6720643895 86 1Wo Fig 113 Auto air vent removal NOTICE N The O ring must be fitted to the Auto air vent and NOT the hydraulic block otherwise the Auto air vent will be difficult to fit Apply silicone lubricant to the O ring to ease assembly gt To refit follow the above in reverse 6 8 19 DHW TEMPERATURE SENSOR Ensure the domestic hot
80. o Fig 42 Remove blanking cap NOTICE Pull the fan lead DHW NTC sensor N lead and ignition cable out of the way when fitting the syphon to ensure that they are not trapped by the syphon assembly or discharge hose To fit the syphon assembly Remove orange seal retainer and discard 6720643895 103 1Wo Fig 43 2 Push the discharge hose onto the wall frame connector until fully engaged bug 2 Fig 44 Fitting syphon Maintenance There is no need to remove the Syphon Assembly for servicing unless cleaning is required To drain debris from the syphon during the annual service Release the clips and remove the drainage cap 1 from the bottom of the syphon Empty the debris and condensate from the syphon into a suitable container Ensure that the drainage cap and seal are completely clean Re fit the drainage cap to bottom of the syphon 6720644741 09 1Wo WORCESTER 6 720 644 741a 2010 10 Bosch Group 33 INSTALLATION 4 7 ELECTRICAL CAUTION ISOLATE THE MAINS N ELECTRICITY SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS The boiler is pre wired with a mains supply il cable A spare strain relief block is supplied in case the pre wired cable is not used The mains supply to the boiler must be either The mains electrical supply to the boiler and system
81. o a septic tank or cesspit Continued Key to condensate illustrations 8 68mm PVCu strap on fitting 9 100 mm minimum plastic pipe 10 Drainage holes ibat Limestone chippings 12 Bottom of sealed tube 13 Insulate and increase pipe size 14 Pipe work transition 15 External air break 16 Air gap 17 External rain water pipe into foul water 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 FITTING AN EXTERNAL AIR BREAK Referto figure 9 when a rain water down pipe that goes directly into a sewer that carries both rainwater and foul water is used to dispose of condensate An air break must be installed in the 43 mm pipe work between the boiler condensate outlet and the drainpipe outside the property to avoid flooding during adverse weather conditions S 7 S 13 OY _ a 2 Disposal into a rainwater down pipe 8 6720644744 09 1Wo Fig 9 Condensate drainage pipe can be run above or below ground il Where the pipe terminates over an open drain or gully the pipe should terminate below the grating level but above water level in order to minimise wind chill at the open end designe d soak away may be considered The use of a drain cover such as those used to prevent I
82. o figure 79 and undo the securing nut on the NOTICE COMBUSTION TESTING ne top of the heat exchanger and remove the retaining Combustion testing must be carried out plate assembly by a competent person Testing must not be attempted unless the person carrying out the combustion check is equipped with a Combustion Analyser conforming to BS 7927 and is competent in its use NOTICE CO CO CHECKS N If the joint between the Air Gas manifold and heat exchanger is disturbed the sealing gasket must be replaced After completing the service of the appliance the CO CO must be checked and set to the limits shown in Setting the air gas ratio on page 47 6720643895 60 1Wo Fig 9 Securing nut mer Se specia EEA SIE ae 1 Refer to figure 80 and rotate fan and air gas manifold specifically designed for cleaning the heat exchanger If required order 7 716 192 312 assembly around the top of the heat exchanger until it stops at the lug gt Isolate the power to the appliance and remove outer 2 Remove the cover panel by removing retaining screw case and base panel P Lift up assembly and remove from boiler 1 Refer to figure 78 and remove the clip from gas valve outlet If the plastic elbow can not be easily removed undo the nut to push the plastic elbow out of the fitting 2 Pull the gas outlet elbow free from
83. ol panel into the service position 3 Make connections to the heating system Connect the gas supply to the boiler gas cock 22mm compression Connect mains water in and DHW out 5 PEM VEN gt NER Nes Fig 31 Connect the pressure relief drain pipe to 15mm compression joint using the compression nut and olive supplied in the literature hardware pack WORCESTER 6 720 644 741a 2010 10 oe Bosch Group INSTALLATION 4 5 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 To ease assembly of flue components apply silicone lubricant to sealing surfaces Basic instructions for the 60 100mm diameter flue are shown below Edgei of 200 mm case 6720643895 29 1Wo Fig 32 Flue turret centre 4 5 1 MEASURING THE FLUE STANDARD FLUE Measure from the outside of the wall to the centre line of the flue turret to determine length L Subtract 50mm from the length L to give the correct dimension to the flue elbow connection Ifthe length L falls within the telescopic range of 350 to 570mm then no cutting will be required Ifthe required length is less than 350mm the standard telescopic flue can be modified refer to following section Iftherequired length is greater than 570mm then flue extensions will have to
84. om the bottom of the tube The holes must face away from the house The tube must be surrounded by at least 100 mm of limestone chippings to a depth of 400 mm Minimum hole size for the condensate soak il away must be 400mm deep by 300mm In temperature or exposure the use of a proprietary trace he situations where there are likely to be extremes of ating system for external pipe work incorporating an external frost thermostat should be considered If such a system is used the requirement to use 32mm pipe do es not apply however all other guidance above and the instructions for the trace heating system should be closely followed NOTICE Unheated internal areas N Internal pipe runs in unheated areas such as lofts basements and garages should be treated as external runs 500mm min 6720644744 11 1Wo Fig 11 Soak away 25mm min 6720644744 12 1Wo Fig 12 Condensate pump to external disposal 16 6 720 644 741a 2010 10 WORCESTER Bosch Group PRE INSTALLATION 3 5 PRESSURE RELIEF PIPE WORK NOTICE N The pressure relief valve is a safety device for the boiler and if activated may discharge boiling water or steam through the relief valve drain pipe Care should be taken when siting the outlet pipe so that it does not cause an obstruction or discharge above a window entr
85. onad Diop ees QNVIA3G payunow epey NO Mddns 431108 yes uonesiiqejs lt HoNanoas ONILVAH CNV LHSM Y3MOd N 0 IVHlN3O 40 ON puooes oT NOILIND OTLS and SNIVIN uonejnpow ye pay yul 40 uej NO Jawweisold surew Jo pue jejsouueui wooy en eA Jas anoge 2 G SI AN e1eduJa 19 eM JI uMop jnus eJnje1eduua J9AQ Spuooes o UnJJ9AO0 Ue 440 9A e sey unJ Jang duund ajnuiw e Fig 128 CH function WORCESTER 6 720 644 741a 2010 10 70 Bosch Group FAULT FINDING AND DIAGNOSIS PREHEAT AND DHW FUNCTION 7 3 OMT 9T TvZVV90C 9 spuooes OT wem gem pue 1N09901 y eds dois uognq 093 pue puewap MHA Jewwesold Jo uoneuiquioo e ue dois duind doe 340 9 VA Sexo Aq Jas S SIU peni si jeujure480Jd j spuooes 104 uognq 093 Suip ou pue sulssaid Aq 19S juiod Jes MO eq QNVIA3G o0T ISB Je aaa 5 59 weds 1vV3H3 d aunyesadwa analyse 0 ON anvW3a uone npow EE puewap yeay 1vV3H J d aldyse oouis ue 4 AONANOAS NOILINSI aon QNV peisenboi Spuooes o yesyaud ai sunJ ue4 x pereurun NO dung NO sojnulul leap ees an 2 dn uonisod MHG UI 43MOd 440 NOILINDI en 9A VA sen 9 J9J9AIq SPUO93S p ZU ses pue d3Nunga uoniusi 9 59 a nyesadwe aN3 yes spuewap QNVI 3G analyse 0 Jeujo e eulquny MHG uoge npow J9 0 Aoud mo q ue ANYWA pesiu8029J 4 o uedo dej OILS3I NOG an LA Jos oAoqe 9 8 S euynye1edujo Jayem JI uMOop
86. or Fuse F3 0 5A Transformer primary coil below 60 Q both secondary coil below 10 Q Otherwise replace control board On Off Boiler not Live demand at ST10 Lg from external room thermostat timer operating during Fascia mounted timer if fitted central heating CH knob in winter position demand Wok Diverter valve Control board Boiler operating Some older thermostats containing capacitors may give a low without live voltage return at ST10 Lg when the thermostat contacts are demand at ST10 open Lg from external Check that there is no permanent live at ST10 Lg from another room thermostat source timer Boiler not Ensure cold inlet DHW outlet are correctly piped i e are not operating during crossed piped hot water Flow Turbine test demand CH ok Check for 5 volts d c across red and black wires Check for 2 5 volts d c across the yellow and red wires with the water flowing Check diverter and motor and control board Boiler not Fan operating during Control board any demand Tab 27 WORCESTER 6 720 644 741a 2010 10 Bosch Group 67 FAULT FINDING AND DIAGNOSIS Blue light Lockout indication reset button Fault Possible solution check Slow flash Flashing Ignition lockout Gas present and at correct pressure mostly reset gt Gas valve off flashes required Check that there is 35V d c to each solenoid pn Check the resistance of each solenoid Top solenoid 380 Q
87. orrect measurement is set Remove dust cap with flat bladed screw driver Using a 4mm Allen key adjust CO Replace dust cap Check that the CO is less than 200ppm Return to maximum and re check the CO CO gt If correct press the service button the button will cease to be illuminated and the blue power indicator will be permanently illuminated Re assemble and refit boiler case 6720643895 66 1Wo Fig 77 Gas valve adjustment 6720644741 13 1Wo Fig 76 Setting the boiler Refer to table 24 and check the CO CO at maximum and if required adjust for maximum using a 2 5mm Allen key Check CO is less than 200ppm Set the central heating control to minimum The boiler will go to minimum power CO CO settings for Greenstar i Junior CO CO should be measured after 10 minutes Gas type CO min CO max Natural gas 9 896 0 5 8 8 0 5 L P G 11 0 0 5 10 5 0 5 NOTE When checking an existing appliance the tolerance is 0 5 If checking after cleaning or component replacement or for adjustment when the reading obtained is outside the tolerances given above then the tolerance is 0 2 CO less than 200 ppm 0 002 ratio Tab 24 CO CO settings WORCESTER 6 720 644 741a 2010 10 Bosch Group 47 SERVICE AND SPARES 6 7 CLEANING THE HEAT EXCHANGER 1 Refer t
88. ot continue commissioning until the correct gas pressure is achieved 40 WORCESTER Bosch Group 6 720 644 741a 2010 10 COMMISSIONING 5 6 2 CHECKING THE GAS RATE gt v v v v v yv The gas rate should be measured at the gas meter after 10 minutes operation at maximum See technical data section at the front of this manual Where a gas meter is not available e g L P G the CO CO must be checked to the units shown in the setting of the air gas ratio refer to section 6 6 If pressure and gas rate are satisfactory press the service button again and the boiler will return to normal operation If left in the service mode the control will return to normal operation after 15 minutes Close the gas isolation valve Remove the manometer Re seal the screw in the gas inlet pressure test point Open the gas isolation valve Ensure that there are no gas leaks Replace the outer case 5 6 3 DOMESTIC HOT WATER Controlling the hot water temperature The hot water temperature is set to approximately 55 C at the factory DOMESTIC HOT WATER PRE HEAT Pre heat reduces the time taken to produce hot water at the tap and is controlled by the ECO button gt Press the ECO button to select either state When the ECO button is not illuminated the boiler will be in pre heat mode which will reduce the time taken to produce hot water at the tap OR When the ECO button is illuminated t
89. ot possible an internal kitchen or bathroom waste pipe washing machine waste pipe etc can be used a 100mm 5 J L t I 22mm Mm D 4 e min S A X S 6 B Fig 7 Disposal to a waste pipe CONDENSATE PUMP Where gravity discharge to an internal termination is not physically possible or where very long internal runs would be required to reach a suitable discharge point condensate should be removed using a proprietary condensate pump of a specification recommended by the boiler or condensate pump manufacturer The pump outlet pipe should discharge to a suitable internal foul water discharge point such as an internal soil and vent stack internal kitchen or bathroom waste pipe washing machine waste pipe etc A suitable permanent connection to the foul waste pipe should be used 22mm 6720644744 08 1Wo Fig 8 Condensate pump disposal 14 WORCESTER Bosch Group 6 720 644 741a 2010 10 PRE INSTALLATION 3 4 2 EXTERNAL CONNECTIONS NOTICE Freezing conditions N Pipe work length should be kept to a minimum and the route as vertical as possible Where pipe work is subjected to extreme cold or wind chill a weather proof insulation should be used NOTICE Condensate waste N Care should be taken when siting a soak away to avoid obstructing existing services Condensate waste must not be terminated int
90. r tray spill over level then an anti syphon device must be fitted to the shower hose Bidets with direct hot and cold mains water can be used with the approval of the local water authority and must be the over rim flushing type with shrouded outlets to prevent the fitting of hand held sprays SEALED PRIMARY SYSTEM NOTICE ARTIFICALLY SOFTENED WATER N MUST NOT BE USED TO FILL THE CENTRAL HEATING SYSTEM The CH sealed system must be filled using a WRAS approved filling loop or comply with figure 4 for system fill Where the system volume is more than 100 litres or exceeds 2 65 bar at maximum heating temperature an extra expansion vessel 2 must be fitted as close as possible to the appliance in the central heating return Pressurise the extra expansion vessel 2 to the same figure as the expansion vessel built into the appliance Do not use galvanised pipes or radiators SYSTEM FILL Heating Mains return supply Hose union SV bessones 4 Temporary hose CV Check Valve SV Stop Valve 6720643895 05 1Wo Fig 4 System fill TYPICAL SEALED SYSTEM all pill pill 6720643895 06 1Wo KI A Fig 5 Sealed system 1 Appliance expansion vessel CH 2 Extra expansion vessel CH return 3 Pressure relief discharge 4 Drain cock 5 Radiators Tab 9 Keyto fig 5 WORCESTER 6 720 644 741a 2010 10 Bosch Group 13 PRE INST
91. re intervals and at a change of direction use suitable brackets and fittings Flue bracket part numbers 100mm 7 716 191 092 125mm 8 716 110 272 Key to illustration 1 Flue clearance must be at least 300 mm from the ground Terminal guards must be fitted if the flue is less than 2 metres from the ground or if a person could come into contact with the flue terminal 600 mm distance to a boundary unless it will cause a nuisance BS 5440 Part 1 recommends that care is taken when siting terminals in relation to boundaries 600 mm minimum clearance from a skylight to a vertical flue Vertical flue clearance 500 mm to non combustible building material and 1 500 mm clearance to combustible building material The dimension below eaves gutters pipes and drains can be reduced to 25 mm as long as the flue terminal is extended to clear any overhang Any external flue joints must be sealed with a suitable silicon sealant 500 mm clearance to any vertical structure on a roof 600 mm to room sealed flue or 1 500 mm to an open flue 1 500 mm between a vertical flue terminal and a window or dormer window 10 11 12 13 400mm from a pitched roof or in regions with heavy snow fall 500 mm The flue cannot be lower than 1 000 mm from the top of a light well due to the build up of combustion products 2 000 mm below a Velux window 600 mm above or to either side of the Velux window 200 mm below eaves and 75 mm
92. s Safety Installation and Use Regulations Flue systems must not be modified in any way other than as described in the fitting instructions Any misuse or unauthorised modifications to the appliance flue or associated components and systems could invalidate the warranty The manufacturer accepts no liability arising from any such actions excluding statutory rights SERVICING Advise the user to have the system serviced annually by a competent qualified Gas Safe registered engineer Approved spares must be used to help maintain the economy safety and reliability of the appliance IMPORTANT The service engineer must complete the Service Record on the Benchmark Checklist after each service INSTALLATION REGULATIONS Current Gas Safety Installation amp 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 IEE Regulations Building Regulations Building Standards Scotland Consolidation Building Regulations Northern Ireland local water by laws Health amp Safety Document 635 The Electricity at Work Regulations 1989 and any other local requirements WORCESTER Bosch Group 6 720 644 741a 2010 10 KEY TO SYMBOLS AND SAFETY PRECAUTION British Standards Where no spe
93. s isolation valve Measure the pressure with the boiler running at maximum Press service button for more than ten seconds and set Central Heating temperature to maximum The service button will lit continually and the blue power indicator will pulse five times quickly Check the gas supply working pressure at the gas valve inlet point is no less than Ensure inlet pressure is satisfactory with all il other gas appliances working GAS PRESSURE WITHIN THE SYSTEM Refer to the figures below for natural gas or L P G gas pressures The pressure at the boiler must not be less than the pressure read at the meter minus 1 mbar The pressure drop from the meter to the gas valve must not be more than 2 5 mbar The pressure at the gas valve must not be less than the pressure read at the meter minus 2 5 mbar If the pressure drops are greater than shown below then this would indicate a problem with the pipe work or connections within the system Natural Gas Gas Control valve 19 23 mbar 16 5 20 5 mbar Boiler inlet 1 mbar m 1 5 mbar drop drop 6720644744 44 1Wo 18 22 mbar Fig 63 Natural gas pressures Gas Control valve Regulator L P G 28 41 mbar Boiler inlet 2 5 mbar E 1 5 mbar drop drop 29 5 42 5 mbar Fig 64 L P G pressures 6720644744 45 1Wo NOTICE Do n
94. ter mains DCW isolator 43 Pressure relief valve 19 System pressure gauge 44 CH return connection to service valve 20 Control panel in service position 45 DCW in connection to service valve 21 Cover external wiring connections 46 Internal by pass 22 Cover transformer and PCB 47 DHW out connection 23 Gas inlet connection 22 mm 48 CH flow connection to service valve 24 Domestic Hot Water DHW connection 49 Pressure gauge connection point 25 Central Heating CH flow isolator 50 DHW temperature sensor NTC Tab 7 Boiler components 35 36 27 37 12 46 Hydraulic block components Fig 2 6720643895 03 1Wo WORCESTER 6 720 644 741a 2010 10 Bosch Group APPLIANCE INFORMATION 672 644741 03 1Wo Fig 3 Additional components 1 Burner ON indicator light green 9 CH return isolator 2 Power ON OFF indicator fault diagnostic light blue 10 DCW mains in isolator 3 Position for optional programmer 11 Gas inlet connection 22 mm amp isolator 4 Reset button 12 DHW connection 5 System pressure gauge 13 CH flow isolator 6 ECO button 14 Condensate connection 7 Boiler identification label 15 CH t
95. that the clamping plate is firmly tightened down on top of the heat exchanger Replace the clamping plate 6720643895 61 1Wo Fig 96 Electrode assembly and burner 6 8 10 HEAT EXCHANGER gt Isolate flow and return valves then drain the boiler Remove syphon Remove the air gas manifold and fan Refer to figure 97 1 Remove the clip from plastic elbow on the flow pipe 2 Pull flow pipe away from heat exchanger DU o7 _ VE e Ai N 6720643895 82 1Wo Fig 97 Flow pipe removal Refer to figure 98 1 Remove the three screws securing the turret to the top of the boiler 2 Turn the upper exhaust connector anticlockwise to release from the hook 3 Pull the upper exhaust connector down 6720643895 114 1Wo Fig 98 Upper exhaust assembly WORCESTER 6 720 644 741a 2010 10 Bosch Group 55 SERVICE AND SPARES Refer to figure 99 1 Release the clip 2 Move the lower exhaust connector up Remove the complete exhaust assembly 6720643895 71 1Wo F Fig 99 Release lower exhaust connection Refer to figure 100 1 Unscrew the plastic nut 2 Remove the nut from the bottom of the boiler 3 Rotate lever to release the return pipe
96. tion 6 6 2 Pull mounting flange off the flap valve assembly Setting the air gas ratio 3 Pull rubber flap off flap valve assembly 6 8 8 FAN Toreplace the flap valve 1 Remove two screws retaining the fan to the air gas Press the two lugs on the back of the flap into the manifold two slots in the flap valve assembly 2 Remove the air gas manifold 3 Remove the screw 4 Remove the retaining plate 5 Remove three screws and the mixing chamber Re assemble with new fan ensuring seals are correctly fitted 6720643895 117 1Wo Fig 95 Flap valve assembly 54 6 720 644 741a 2010 10 WORCESTER Bosch Group SERVICE AND SPARES 6 8 9 ELECTRODE ASSEMBLY AND BURNER Refer to figure 96 Disconnect spark electrodes and flame sensor connection Remove clamping plate 1 Remove spark flame electrode assembly from heat exchanger Remove the seal from the top of the heat exchanger Remove the burner WO N v Replace new burner in correct position Ensure that burner tabs as shown in figure 96 fit correctly their respective locations v NOTICE Heat exchanger seal N gt If the joint between the Air Gas manifold and heat exchanger is disturbed the sealing gasket must be replaced After re assembly the combustion must be checked using the procedure in the section 6 6 Setting the Air Gas ratio Ensure that the seal is fitted CAUTION Clamping plate N Ensure
97. tion manual When redirecting the flue discharge the outlet terminal must be at least 1500mm from any opening in the direction of the discharge to prevent combustion products from entering the building J 1 7 6720643895 119 1Wo Fig 41 Plume distance to opening i Opening in building Flue discharge Plume deflector gt IM Minimum 1500mm from an opening in the building Tab 19 Key to figure 41 32 WORCESTER Bosch Group 6 720 644 741a 2010 10 INSTALLATION 4 6 CONDENSATE CONNECTION Never terminate or discharge into any open source including sink bath shower bidet toilet etc NOTICE Any external condensate pipe work N must be protected with weather resistant insulation to help prevent freezing 1 Push the syphon onto the sump assembly until the lug on the sump is fully engaged with the slot on the back of the syphon assembly and the clip is engaged in the top of the syphon Ensure that the condensate drain is a 22mm diameter plastic pipe The pipe must fall at least 50mm per metre towards the outlet NOTICE Do not use solvents adhesive or N lubricant when pushing the pipe onto the rubber connector il Do not use lubricants or sealing compounds 1 Remove the sump blanking cap from the sump Fill syphon with 200 to 250 millilitres of water I 6720643895 36 1W
98. um tape is not required when reducing the terminal 30 WORCESTER Bosch Group 6 720 644 741a 2010 10 INSTALLATION 4 5 3 INSTALLING THE TELESCOPIC FLUE Refer to figure 36 1 Set the flue length to the distance required secure with screws provided 2 Seal the joint with the aluminium tape provided 3 Slide the inner wall seal onto the terminal 4 If fitting from inside the building slide the outer wall seal onto the terminal 6720644842 08 1Wo Fig 36 Telescopic flue The turret securing screws are from the boiler and are not in flue kit Refer to figures 37 amp 38 1 Remove the three inner flue tube retaining screws 2 The inner tube will be held in place in the appliance 2 Check the boiler flue seal is correctly seated and apply silicone grease 3 Position terminal through the flue opening in the wall to the outside of the building by the distance shown 4 Align the flue turret to the boiler flue outlet with flat facing 1 to the rear of the boiler The flue turret should be pushed straight down on to the boiler 6720643895 35 1Wo Fig 37 Fit the screws removed in step 1 to secure flue turret gt If fitting the outer seal from outside the building slide the outer wall seal onto the terminal as shown 6720643895 33 1Wo Fig 38 Telescopic flue installation For more infor
99. ww centralheating co uk Benchmark places responsibilities on both manufacturers and installers The purpose is to ensure that customers are provided with the correct equipment for their needs that it is installed commissioned and serviced in accordance with the manufacturer s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference Installers are required to carry out installation commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the scheme Visit centralheating co uk for more information HEALTH AND SAFETY The appliance contains no asbestos and no substances have been used in the construction process that contravene the COSHH Regulations Control of Substances Hazardous to Health Regulations 1988 COMBUSTION AND CORROSIVE MATERIALS Do not store or use any combustible materials paper thinners paints etc inside or within the vicinity of the appliance Chemically aggressive substances can corrode the appliance and invalidate any warranty FITTING AND MODIFICATIONS Fitting the appliance and any controls to the appliance may only be carried out by a competent engineer in accordance with the current Ga

GREENSTAR 24i/28i JUNIOR

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