Worcester GREENSTAR 24i junior Manuel utilisateur

THE APPLIANCE IS FOR USE WITH

NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13, C33 & C53)

NATURAL GAS:

24i junior GC NUMBER 47-311-86

28i junior GC NUMBER 47-311-87

LIQUID PETROLEUM GAS:

24i junior GC NUMBER 47-311-90

28i junior GC NUMBER 47-311-91

UK/IE

INSTRUCTION MANUAL

INSTALLATION, COMMISSIONING & SERVICING

WALL HUNG RSF GAS FIRED CONDENSING COMBINATION BOILER

GREENSTAR 24i jjuunniioorr/ 28i jjuunniioorr

FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED

DOMESTIC HOT WATER

INSTALLATION &

SERVICING INSTRUCTIONS

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior

8 716 115 166b (03/2009)

WATER TREATMENT:

FERNOX 01799 550811

www.fernox.com

SENTINEL 0800 389 4670

www.sentinel-solutions.net

FLUE TERMINAL GUARDS:

TOWER FLUE COMPONENTS LTD.

Vale Rise, Tonbridge TN9 1TB

01732 351555

SAFETY & REGULATIONS

INSTALLATION AND SERVICING INSTRUCTIONS 2

SAFETY PRECAUTIONS & SYMBOLS 4

INSTALLATION REGULATIONS 4

APPLIANCE INFORMATION

GENERAL INFORMATION 5

TECHNICAL DATA 6

LAYOUT & COMPONENTS 7

PRE-INSTALLATION

CLEANING PRIMARY SYSTEMS 9

MAINS SUPPLY 10

WATER SYSTEMS & PIPEWORK 11

CONDENSATE PIPEWORK 12

PRESSURE RELIEF PIPEWORK 13

BOILER LOCATION & CLEARANCES 14

PLUMBING MANIFOLD 16

FLUE OPTIONS 17

FLUE TERMINAL POSITIONS 18

INSTALLATION

UNPACKING THE WALL FRAME 20

WALL MOUNTING TEMPLATE / FLUE OPENING 21

UNPACKING THE APPLIANCE 22

BOILER CONNECTIONS 23

FLUE INSTALLATION 25

CONDENSATE CONNECTIONS 28

ELECTRICS 29

POSITION OF WIRED COMPONENTS 30

COMMISSIONING

PRE-COMMISSIONING CHECKS 31

FILLING THE SYSTEM 32

STARTING THE APPLIANCE 33

WATER TREATMENT 34

COMMISSIONING 35

FINISHING COMMISSIONING 36

SERVICING & SPARES

INSPECTION AND SERVICE 37

REPLACEMENT OF PARTS 43

SETTING THE AIR/GAS RATIO 55

SHORT PARTS LIST 56

CONVERSION KITS

L.P.G. CONVERSION 57

FAULT FINDING & DIAGNOSIS

FAULT FINDING 58

CENTRAL HEATING FUNCTION 59

PREHEAT AND DHW FUNCTION 60

PROTECTION FUNCTION 61

BENCHMARK CHECKLIST

SERVICE INTERVAL RECORD SHEET

CONTENTS

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior

8 716 115 166b (03/2009)

SAFETY &

REGULATIONS

APPLIANCE

INFORMATION

PRE -

INSTALLATION

INSTALLATIONCOMMISSIONING

SERVICING

& SPARES

CONVERSION

KITS

FAULT FINDING

& DIAGRAMS

SAFETY PRECAUTIONS

& INSTALLATION REGULATIONS

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior

8 716 115 166b (03/2009)

SAFETY &

REGULATIONS

GENERAL INFORMATION

700mm*

400mm

330mm

GENERAL INFORMATION

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior

8 716 115 166b (03/2009)

APPLIANCE

INFORMATION

(When fitted to wall frame)

Depth to wall

Check List

Hardware/Literature pack

Item Qty.

Greenstar 24i Junior/28i Junior Installation/Servicing Instructions.....1

Users Instructions ..........................................................................................1

Consumer Guarantee Card .........................................................................1

Syphon assembly............................................................................................1

Installation instructions...........................................................................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

Irish Guidelines Leaflet .................................................................................1

Warranty Return Envelope ...........................................................................1

ESTANDARD PACKAGE:

A - Wall hung gas fired condensing combi boiler

for central heating and domestic hot water

B - Boiler support frame

C -Hardware literature pack (see checklist)

D -Bottom Panel

E - Fascia panel

F - Syphon assembly

SPECIFICATIONS:

•Pre-wired and pre-plumbed

•Galvanised steel inner frame

•Digital control system

•Automatic ignition

•Direct burner ignition electrodes

•Built-in frost thermostat

•Built-in fault finding diagnostics

•Modulating automatic gas valve

•Combustion air fan with speed regulator

•CH temperature sensor & control

•Pump anti-seizure protection

•Flue gas temperature limiter

•Condensate trap & syphon

•DHW flow sensor & temperature control

•Plate type DHW heat exchanger

*710mm to top case front

TECHNICAL DATA INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior

8 716 115 166b (03/2009)

TECHNICAL DATA

APPLIANCE

INFORMATION

DESCRIPTION NATURAL GAS L.P.G.

UNIT 24 iJunior 28 iJunior 24 iJunior 28 iJunior

Domestic Hot Water

Min. heat input KW 7.3 8 7. 3 8 9.64 9.64

Max. rated heat output KW 24 28 24 28

Max. rated heat input KW 24.49 28.57 24.49 28.57

Gas flow rate - Max. 10 minutes from lighting

Natural Gas G20 m3/h 2.59 3.02 - -

Propane Gas (LPG) kg/h - - 1.9 2.22

Max. mains inlet pressure bar 10 10 10 10

Min. mains inlet pressure (working) for max flow bar 1.3 1.3 1.3 1.3

Min. mains inlet pressure (working) for operation bar 0.2 0.2 0.2 0.2

Domestic Hot Water temperature setting °C 55 55 55 55

Domestic Hot Water specific rate - 30°C rise l/min 11.5 13.4 11.5 13.4

Max. Domestic Hot Water flow rate - 40°C rise +/— 15% l/min 8.6 10 8.6 10

Central Heating

Max. rated heat input KW 24.62 24.62 24.62 24.62

Max. rated heat output 40/30°C KW 25.67 25.67 25.67 25.67

Max. rated heat output 50/30°C KW 25.45 25.45 25.45 25.45

Max. rated heat output 80/60°C KW 24 24 24 24

Max. flow temperature °C 82 82 82 82

Max. permissible operating pressure bar 2.5 2.5 2.5 2.5

Available pump head at 21°C system temperature rise m 2.0 2.0 2.0 2.0

Flue

Flue Gas Temp. 80/60°C, rated/min. load °C 78/63 78/64 79/64 79/65

Flue Gas Temp. 40/30°C, rated min. load °C 54/35 54/36 55/38 55/39

CO2level at max. rated heat output (after 30 mins) %9.8 9.8 11.0 11.0

CO2level at min. rated heat output (after 30 mins) %9.2 9.2 10.5 10.5

NOx - class 5 5 5 5

Condensate

Max. condensation rate l/h 2.0 2.0 2.0 2.0

pH value, approx. 4.8 4.8 4.8 4.8

Electrical

Electrical power supply voltage AC...V 230 230 230 230

Frequency Hz 50 50 50 50

Max. power consumption W140 140 140 140

General Data

SEDBUK band A A A A

Appliance protection rating IP X4D X4D X4D X4D

Appliance protection rating with mechanical or

RF mechanical timer fitted

IP 20 20 20 20

Permissible ambient temperatures °C 0-50 0-50 0-50 0-50

Nominal capacity of appliance Itr 3.9 3.9 3.9 3.9

Noise output level (Max central heating) dB(A) 42 42 42 42

Total boiler weight kg 39.5 39.5 39.5 39.5

Lift weight kg 27.1 27.1 27.1 27.1

SEDBUK %90.1 90.1 91.8 91.8

LAYOUT & COMPONENTS

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior

8 716 115 166b (03/2009)

APPLIANCE

INFORMATION

The diagram opposite shows the controls in the

servicing position and excludes the outer case.

1 AIR / GAS MANIFOLD

2 SENSOR - BOILER FLOW

3 IGNITION AND FLAME SENSE ELECTRODES

4 OVERHEAT THERMOSTAT

5 RETAINING BRACKET

6 EXPANSION VESSEL

7 REMOVABLE PANEL FOR SERVICING

8 SILICONE TUBE (HEAT EXCHANGER

AIR VENT)

9 SECURING NUT, AIR / GAS MANIFOLD

CLAMP

10 FAN DRIP GUARD

11 HEAT EXCHANGER

12 WALL MOUNTING FRAME

13 FLUE OVERHEAT THERMOSTAT

14 SYSTEM PRESSURE GAUGE

15 PUMP

16 DRAIN POINT

17 CH RETURN

18 CONTROL PANEL IN SERVICE POSITION

19 MAINS COLD WATER IN

20 COVER FOR EXTERNAL WIRING

CONNECTIONS

21 GAS INLET CONNECTION 22mm

COMPRESSION

22 DHW OUT

23 ACCESS COVER FOR TRANSFORMER

& PCB

24 CH FLOW

25 SYPHON OUTLET CONNECTION

(22mm PLASTIC PIPE)

26 PLATE TO PLATE DHW HEAT

EXCHANGER

27 ACCESS POINT FOR CLEANING

HEAT EXCHANGER/SUMP

28 GAS VALVE

29 FAN

30 MANUAL VENT POINT

31 FAN PRESSURE TEST POINT

32 FLUE AIR PRESSURE SWITCH

CONNECTION (BLANKED OFF ON THIS

APPLIANCE)

LAYOUT & COMPONENTS

LAYOUT & COMPONENTS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior

8 716 115 166b (03/2009)

APPLIANCE

INFORMATION

14 SYSTEM PRESSURE GAUGE

15 SYSTEM PUMP

26 PLATE TO PLATE DHW HEAT

EXCHANGER

33 FLOW TURBINE

34 COMPACT HYDRAULIC MOUNTING

SCREW (2) TO BOILER

35 PRESSURE RELIEF VALVE

36 DIVERTER VALVE

37 CH RETURN CONNECTION TO SERVICE

VALVE

38 DRAIN TAP

39 COLD WATER IN CONNECTION

40 INTERNAL BYPASS WITHIN PLASTIC

MOULDING

41 DHW OUT CONNECTION

42 CH FLOW CONNECTION TO SERVICE

VALVE

43 DHW SENSOR

44 FLOW CONNECTION FROM BOILER

HEAT EXCHANGER

45 AUTO AIR VENT

46 UNUSED PORT

47 FAULT RESET BUTTON

48 ECO BUTTON

49 MAINS ON/OFF INDICATOR/

DIAGNOSTIC LIGHT (BLUE)

50 CH TEMPERATURE CONTROL

51 POSITION FOR OPTIONAL

PROGRAMMER

52 SERVICE MODE BUTTON

53 BURNER ON INDICATOR LIGHT (GREEN)

54 MASTER SWITCH ON/OFF

CLEANING PRIMARY SYSTEMS

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior

8 716 115 166b (03/2009)

PRE -

INSTALLATION

CLEANING PRIMARY SYSTEMS

BEFORE CLEANING THE SYSTEM:

ENSURE THE SYSTEM AND PIPEWORK

IS IN GOOD WORKING ORDER

WHERE POSSIBLE KEEP THE EXISTING

BOILER/CIRCULATING PUMP IN PLACE

WHEN FLUSHING THE SYSTEM.

FOLLOW GUIDANCE OF BS7593:

TREATMENT OF WATER IN DOMESTIC

HOT WATER CENTRAL HEATING AND

ALSO FLUSHING GUIDELINES SET OUT

BELOW.

CLEANING THE PRIMARY SYSTEM:

IMPORTANT: ARTIFICIALLY SOFTENED

WATER MUST NOT BE USED TO FILL THE

CENTRAL HEATING 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 condition 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

IMPORTANT: All the following Pre-Installation sections must be read and

requirements met before starting boiler or flue installation.

CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND

OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.

IMPORTANT: 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.

MAINS SUPPLY INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior

8 716 115 166b (03/2009)

PRE -

INSTALLATION

MAINS WATER EXPANSION VESSEL:

A - Mini expansion vessel, part No. 7 716 102 105

B - Mains water inlet

C - Non-return valve

D - Boiler

ELECTRIC SUPPLY:

• Supply: 230V - 50Hz, 140 watts

• Cable: PVC insulated 0.75mm2(24 x 0.2mm)

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.

• IPX4D.

NOTE: this is reduced to IP20 if the

following mechanical timers are fitted:

7 716 192 036 or 7 716 192 037.

• Wiring must comply with latest IEE wiring

regulations.

GAS SUPPLY:

• Boilers using NG must be connected to a

governed meter.

• LPG boilers must be connected to a

regulator.

• Installation and connection of the gas supply

to the boiler must be in accordance with

BS6891.

• Under no circumstances should the size of

the gas supply pipe be less than that of the

appliance inlet connection.

• The meter or regulator and pipework to the

meter must be checked, preferably by the gas

supplier, to ensure it 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.

WATER SUPPLY:

Water mains pressure:

• Minimum mains water pressure 1.3 bar for

maximum performance.

• Maximum mains fed water pressure 10 bar.

If necessary, fit a pressure reducing valve.

• Where the mains water supply has a non-

return, back flow prevention valve fitted, a

mini expansion vessel (A) should be connect-

ed to the mains water inlet pipe (B) between

the non-return valve (C) and the boiler (D) as

shown opposite.

Use in hard water areas:

Normally there is no need for water treatment to

prevent scale formation as the maximum tem-

perature of the DHW heat exchanger is limited

in the electronic circuit.

In areas where temporary water hardness

exceeds 200ppm, 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.

IMPORTANT: Non-return, back flow pre-

vention devices (including those associ-

ated with water meters) fitted to the

mains water supply can cause a pres-

sure build up which could damage the

boiler and other household appliances.

MAINS SUPPLY

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