Worcester Gas boiler Manuel utilisateur

UK/IE

INSTALLATION INSTRUCTIONS

WALL HUNG RSF GAS FIRED CONDENSING BOILER

GREENSTAR i SYSTEM OPTIONAL

INTEGRAL DIVERTER VALVE

6720645222-00.2Wo

FOR CENTRAL HEATING SYSTEMS AND INDIRECT FED DOMESTIC HOT WATER

6 720 645 222a (2012/05)

Diverter valve kits contain:

1 Copper return pipe

1 Brass service valve

1 15mm Compression nut

1 15mm Olive

1 Diverter valve motor

1 Diverter valve harness

2Screws

2Codeplugs

1Codeplugtie

Diverter valve kit numbers

12kW 7 716 192 566

15kW 7 716 192 567

18kW 7 716 192 568

24kW 7 716 192 409

Code plug numbers

12i System Natural gas 1118

L.P.G. 1119

15i System Natural gas 1122

L.P.G. 1123

18i System Natural gas 1126

L.P.G. 1127

24i System Natural gas 1114

L.P.G. 1115

CONTENTS

6 720 645 222a (2012/05)

CONTENTS

1 KEY TO SYMBOL AND SAFETY PRECAUTIONS . 3

1.1 Explanation of symbols . . . . . . . . . . . . . . . 3

1.2 Safety precautions . . . . . . . . . . . . . . . . . . 4

2 PLUMBING MANIFOLD . . . . . . . . . . . . . . . . . . . . 6

3 BOILER CONNECTIONS . . . . . . . . . . . . . . . . . . . 7

3.1 Assembly of the internal cylinder return

pipe to the boiler . . . . . . . . . . . . . . . . . . . . 7

3.2 Gas and water connections . . . . . . . . . . . . 8

4 fITTING THE DIVERTER VALVE & CODE PLUG 10

4.1 Fitting the diverter valve motor: . . . . . . . 10

4.2 Access to the code plug . . . . . . . . . . . . . 10

4.3 Fitting the code plug . . . . . . . . . . . . . . . . 11

4.4 Fitting the cylinder temperature sensor . 11

4.5 Diverter valve and sensor connections . . 11

5 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5.1 Internal diverter valve with a

vented cylinder . . . . . . . . . . . . . . . . . . . . . 12

5.2 Internal diverter valve with an unvented

cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5.3 Position of wired components . . . . . . . . 14

6 PRE-COMMISSIONING CHECKS . . . . . . . . . . . 15

7 BOILER FUNCTION . . . . . . . . . . . . . . . . . . . . . . 16

7.1 Fault finding . . . . . . . . . . . . . . . . . . . . . . 16

7.2 Boiler function . . . . . . . . . . . . . . . . . . . . . 17

7.3 Protection function . . . . . . . . . . . . . . . . . 18

KEY TO SYMBOLS AND SAFETY PRECAUTIONS

6 720 645 222a (2012/05) 3

1 KEY TO SYMBOLS AND SAFETY PRECAUTIONS

1.1 EXPLANATION OF SYMBOLS

WARNING SYMBOLS

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

ADDITIONAL SYMBOLS

SYMBOLS USED IN THIS MANUAL

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 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.

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 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:

Safety instructions in this document are

framed and identified by a warning triangle

which is printed on a grey background.

Electrical hazards are identified by a

lightning symbol surrounded by a warning

triangle.

Notes contain important information in

cases where 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.

Symbol Meaning

Ba step in an action sequence

Æa reference to a related part in the

document or to other related documents

•a list entry

–a list entry (second level)

Tab. 1 Symbols

Domestic Hot Water

Central Heating

Hot Water Storage Cylinder

Domestic Cold Water Supply

Electrical Supply

Gas Supply

Tab. 2 Commonly used symbols

ØDiameter

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

KEY TO SYMBOLS AND SAFETY PRECAUTIONS

6 720 645 222a (2012/05)

1.2 SAFETY PRECAUTIONS

IF YOU SMELL GAS:

BCALL NATIONAL GAS EMERGENCY SERVICE ON

0800 111 999

BLPG BOILERS CALL THE SUPPLIER‘S NUMBER ON

THE SIDE OF THE LPG TANK

BTURN OFF THE ECV (EMERGENCY CONTROL VALVE)

AT THE METER

BDO NOT TURN ELECTRICAL SWITCHES ON OR OFF

BDO NOT STRIKE MATCHES OR SMOKE

BPUT OUT NAKED FLAMES

BOPEN DOORS AND WINDOWS

BKEEP 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.

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 Gas 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 & 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 & Safety

Document 635 (The Electricity at Work Regulations

1989) and any other local requirements.

KEY TO SYMBOLS AND SAFETY PRECAUTIONS

6 720 645 222a (2012/05) 5

British Standards:

Where no specific 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 70kW (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

•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:

Artificially softened water must not be used to fill the

central heating system.

PLUMBING MANIFOLD

6 720 645 222a (2012/05)

2 PLUMBING MANIFOLD

CONNECTIONS:

•Heating System: 22mm compression fittings

•Gas: 22mm compression fitting

•Cylinder Return 15mm compression fitting

•Use the fittings supplied in the Hardware literature

pack and the Optional Diverter Valve Kit.

If the boiler pipes are to be run behind the appliance

ensure that the pipes pass through the slot in the

guide (9). This is fitted to the boiler frame.

Fig. 1 Pipe dimensions

Fig. 2 Plumbing manifold with wall frame

NOTICE: Fitting the service valve

BRefer to figure 2

BThe service valve (7) from the Optional

Diverter Valve Kit must be fitted and

secured to the wall mounting frame with

two screws (8) supplied, before the wall

mounting frame is fitted to the wall.

Further guidance on pipe routing can be

found printed on the boiler template

(supplied with the boiler).

123

456

6720645222-12.1Wo

#Function

From left

case edge

Diameter

of pipe

1 CH and cylinder flow 70 mm 22 mm

2Gas 200 mm 22 mm

3CHReturn 330 mm 22 mm

4Condensate 35 mm 22 mm

5 Pressure Relief Valve 367 mm 15 mm

6 Cylinder return 267 mm 15mm

Tab. 4 Key to figures 1 & 2

6720644222-01.1Wo

BOILER CONNECTIONS

6 720 645 222a (2012/05) 7

3 BOILER CONNECTIONS

3.1 ASSEMBLY OF THE INTERNAL CYLINDER RETURN PIPE TO THE BOILER

Use the packaging as protection, turn the boiler on its left hand side to enable fitting of the hot water return pipe.

BMove the control panel into the service position by removing the screw from the retaining bracket.

1. Loosen the two retaining screws to free the back clamping plate on the hydraulic block as shown in figure 3.

2. Remove the brass bung assembly from the hydraulic block by removing the screw and sliding it free from the flange

on the clamping plate. Make sure that the other brass bung assembly is retained in place.

3. Remove the copper pipe from the Optional Integral Diverter Valve Kit and feed the flat end of the pipe through the

rear of the boiler as shown.

4. Before fitting the pipe, check that the seal is in position on the plastic moulding. Slide the flat end of the pipe under

the flange on the hydraulic block clamping plate ensuring that pipe is located correctly.

5. Secure the clamping plate by re-tightening the two screws (1) loosened in step 1.

Fig. 3 Hot water return pipe fitting

CAUTION: CYLINDER RETURN PIPE

BThe following must be completed before the boiler is mounted onto the wall mounting frame

2. 5.

6720645222-02.1Wo

BOILER CONNECTIONS

6 720 645 222a (2012/05)

3.2 GAS AND WATER CONNECTIONS

BRemove template and secure the wall mounting frame

to the wall with the fittings supplied.

BSystem pipes may be run vertically upwards behind

the boiler or below it.

See Plumbing Manifold Section on page 6.

1. CH and cylinder flow (22mm),

2. Gas inlet (22mm),

3. Cylinder return(15mm),

4. CH return (22mm)

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.

BFit sealing washers to service valves before hanging

boiler.

Fig. 4 Sealing washers

1. Pull the extended tab/lever forward and down until

there is no further travel.

Fig. 5 PRV connection in the down position

BHang the 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 manifold. There

are two handling holes incorporated into the inner

casing left and right in the lower section of the

appliance.

Fig. 6 Hanging the boiler

CAUTION:

BISOLATE THE MAINS GAS SUPPLY

BEFORE STARTING ANY WORK AND

OBSERVE ALL RELEVANT SAFETY

PRECAUTIONS.

The bonded washer supplied is for the Gas

connection only.

NOTICE: Before hanging the boiler onto the

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.

1. 2. 3. 4.

6720645222-04.1Wo

CAUTION: Caps or plastic strip fitted to

pipes must be removed before hanging the

boiler.

NOTICE: The pressure relief connector

must be repositioned after the boiler has

been correctly mounted to the wall

mounting frame.

6720643895-116.1Wo

6720643895-22.1Wo

BOILER CONNECTIONS

6 720 645 222a (2012/05) 9

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.

Fig. 7 PRV in the up position

BRemove the screw from the control panel retaining

bracket and lower the control panel into the service

position.

BMake connections to the heating system and cylinder.

Connect the gas supply to the boiler gas cock 22mm

compression.

To connect the expansion vessel flexible pipe to the

hydraulic manifold situated to the left of the pump:

BRemove and discard the plastic cap from the

expansion vessel flexible pipe.

1. Refer to figure 8, release the retaining clip.

2. Remove and discard the orange plastic blanking plug

(2) from the pressure vessel connection at the

hydraulic manifold.

Fig. 8 Blanking plug removal

1. Refer to figure 9 and insert the expansion vessel

flexible pipe it to the fitting on the pump.

2. Secure in place with the wire retaining clip.

Fig. 9 Expansion vessel connection

BConnect the pressure relief drain pipe to 15mm

compression joint using the compression nut and

olive supplied in the literature/hardware pack.

6720644743-17.1Wo

6720645222-05.1Wo

6720645222-06.1Wo

FITTING THE DIVERTER VALVE AND CODE PLUG

6 720 645 222a (2012/05)

4 FITTING THE DIVERTER VALVE AND CODE PLUG

4.1 FITTING THE DIVERTER VALVE

MOTOR:

1. Remove the diverter blanking plate by pulling it

forwards to free it from its location.

Fig. 10 Removing Diverter valve blanking plate

1. To fit the diverter valve motor, push the motor into the

housing until the motor “clicks” securely into place,

ensuring that the actuator arm locates into the middle

of the “H” receptor on the motor.

2. Connect the plug of the diverter valve motor harness

into the socket on the diverter valve motor.

3. Slide the protective cover over the diverter valve

motor.

Fig. 11 Fitting Diverter motor and cover

4.2 ACCESS TO THE CODE PLUG

1. Referring to figure 12, unscrew the three screws in

the control panel.

2. Pull off the connections cover.

Fig. 12 Removing the connection cover

BIdentify ST18, the code plug and connector.

Fig. 13 Connector locations

6720645222-07.1Wo

3. 2.

6720645222-08.1Wo

NOTICE: RESET THE CONTROL BOARD

Following changes to the wiring of ST15 and

ST8 the control board will need to be reset

to recognise the new connection.

To reset the control board:

BHold the Service mode “Spanner” and the

Eco buttons down for at least five

seconds.

1. 1.

6720643895-40.1Wo

6720645222-09.1Wo

ST15

ST17

ST10 ST8

ST6

ST18

Ce manuel convient aux modèles suivants

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