Bosch GREENSTAR 24i junior User Manual

THE APPLIANCE IS FOR USE WITHNATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13 & C33)NATURAL GAS:WORCESTER GREENSTAR 24i junior GC NUMBER 47-311-86WORCE

MAINS SUPPLYELECTRIC SUPPLY:• Supply: 230V - 50Hz, 140 watts • Cable: PVC insulated 0.75mm2(24 x 0.2mm)temperature rated to 90°C.• External 3A fuse to

WATER SYSTEMS & PIPEWORKPLASTIC PIPEWORK:• Any plastic pipework must have a polymeric barrier with 600mm (minimum) length of copper or steel pipe

CONDENSATE PIPEWORKCONDENSATE PIPEWORK:• The condensate pipe must be a minimum of 22mmØ plastic pipe.• The condensate pipework must fall at least 50mm

PRESSURE RELIEF PIPEWORKPRESSURE RELIEF PIPEWORK:• The pressure relief drain pipe (M) from the boiler should be at least 15mm diameter copper pipe and

BOILER LOCATION & CLEARANCESINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/05)13PRE -

BOILER LOCATION & CLEARANCESINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/05)14PRE -

PLUMBING MANIFOLDCONNECTIONS:Heating System: 22mm compression fittingsDHW: 15mm compression fittingsGas: 22mm compression fittingsUse the fittin

PRE -INSTALLATIONFLUE TERMINAL POSITIONS• The flue must be fitted and terminated in accordance with the recommendations of BS5440 : Part 1.• The flue

FLUE OPTIONSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/05)17PRE -INSTALLATIONFLUE OPT

IIMPORTANT: All the previous Pre-Installation sections must be readand requirements met before starting boiler or flue installation.EFABCCDGUNPACKING

SYMBOLS USED IN THIS MANUAL:WORCESTER:TECHNICAL: 08705 266241SERVICE: 08457 256206SPARES: 01905 752571LITERATURE: 01905 752556TRAINING: 01905 752526SA

WALL MOUNTING PLATE FLUE OPENINGINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/05)19INSTA

476UNPACKING THE APPLIANCEUNPACKING THE APPLIANCEA - Outer cartonB - Inner sleeve (unwraps from front)C - Packaging baseD - Protective wrappingE - App

AEDBBOILER CONNECTIONSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/05)21INSTALLATIONHan

BOILER CONNECTIONSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/05)22INSTALLATIONBOILER

FLUE INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/05)23INSTALLATIONFLUE INS

FLUE INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/05)24INSTALLATIONFLUE INS

FLUE INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/05)25INSTALLATIONABCDEA -

CONDENSATE CONNECTION:Never terminate or discharge into any opensource, including; sink, bath, shower, bidet,toilet etc.Note: any external condensate

ELECTRICSA12BELECTRICSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/05)27INSTALLATIONCAU

POSITION OF WIRED COMPONENTSCOMMISSIONINGPOSITION OF WIRED COMPONENTSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28

SAFETY & REGULATIONSSAFETY PRECAUTIONS & SYMBOLS 3INSTALLATION REGULATIONS 3APPLIANCE INFORMATIONGENERAL INFORMATION 4TECHNICAL DATA 5LAYOUT &

PRE-COMMISSIONING CHECKSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/05)29COMMISSIONING

FILLING THE SYSTEMINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/05)30COMMISSIONINGFILLIN

ADFCBGEHISwitching the appliance on/off:1  Turn on mains power supply Turn on any external controlsSet the thermostatic radiator controls to maximum

WATER TREATMENTENSURE THAT THE SYSTEM HAS BEENCLEANED AS ON PAGE 8 OF THESEINSTRUCTIONS.FLUSHING (Central Heating):1 Switch off the boiler (A).  Open

COMMISSIONINGTHE COMBUSTION FOR THE APPLIANCEIS FACTORY SET. NO ADJUSTMENT IS REQUIRED IF THEGAS INLET PRESSURE IS CORRECT.CHECKING GAS INLET PRESSURE

FINISHING COMMISSIONINGINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/05)34COMMISSIONINGF

INSPECTION AND SERVICE To ensure the continued efficient operationof the appliance it must be checked atregular intervals.  The frequency of servici

INSPECTION AND SERVICEComponent Access1. Removing outer case1. Remove bottom panel by pulling it forward and off.1.1 Undo and remove 2 screws (A) secu

INSPECTION AND SERVICESetting Boiler to Maximum.NOTE: When running in the service mode, theboiler will operate both the Central Heating andDHW circuit

INSPECTION AND SERVICETo Clean the Heat Exchanger1 With outer case and base panel removed and the power isolated from the appliance, remove the cover

SAFETY PRECAUTIONS& INSTALLATION REGULATIONSINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336

INSPECTION AND SERVICE4 Remove electrical connector from fan.5 Undo and remove securing nut (E) from the top of the heat exchanger.6 Remove stainless

QINSPECTION AND SERVICEINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/05)40SERVICING&

CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINSSUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALLRELEVANT SAFETY PRECAUTIONS.IMPORTANT: AFTER

REPLACEMENT OF PARTS5. Moving boiler control to serviceposition5.1 Remove screw (A) securing control.5.2 Gently pull forward.6. Gas valve Isolate gas

REPLACEMENT OF PARTS9. Access to boiler control components Remove 3 screws (A) and remove cover from control.10. PCB fuse Remove fuse F1(B) from the

12.3REPLACEMENT OF PARTS12. Replacing control The control is supplied within its plastichousing. The complete unit must be replaced. Remove ALL elect

REPLACEMENT OF PARTS13. Air / gas manifold and fanassembly Remove electrical connector from fan. Remove wire clip from gas valve outlet thenpull gas

REPLACEMENT OF PARTS15. Fan15.1Remove 3 screws (A) retaining mixing chamber.15.2Remove 2 screws (B) retaining the fan to the air/gas manifold.15.3Remo

REPLACEMENT OF PARTS19. Diverter valve motorInsure the appliance is in service mode (there is no need to drain the appliance).Disconnect the electri

REPLACEMENT OF PARTS23. Pump headEnsure the boiler is fully drained (see draining the appliance).Disconnect the electrical connection from the botto

GENERAL INFORMATIONSTANDARD PACKAGE:A - Wall hung gas fired condensing combi boiler forcentral heating and domestic hot waterB - Boiler support frameC

REPLACEMENT OF PARTS27. Hydraulic BlockEnsure the appliance has been fully drained (see draining the appliance).Disconnect the electrical connection

REPLACEMENT OF PARTS29. Plastic protection deviceEnsure the system is fully drained (see draining the appliance).Disconnect all pipes connected to t

REPLACEMENT OF PARTS31. Bypass valveRemove the Hydraulic block from the boiler (See Removing the Hydraulic Block).31.1Remove the two spring clips at

33. Setting the CO2Note: When running in the service mode, theboiler will operate both the central heating &DHW circuits. This is to allow suffici

SHORT PARTS LIST1 FanWORCESTER Part No. 8 717 204 453 0GC No. H26 5362 BurnerWORCESTER Part No. 8 718 120 609 0GC No. H26 5383 Gas valveNG WORCESTER P

1.1 1.2A2.22.32.13CBTHE GAS / AIR RATIO MUST BERESET AFTER CONVERSION. THEPROCEDURE CAN BE FOUND INTHE REPLACEMENT PARTS SECTIONOF THIS MANUAL.4.1 4.2

FAULT FINDINGINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/05)55FAULT FIN DING& DIAG

CENTRAL HEATING FUNCTIONNOYESPOWERSWITCH ONCENTRALHEATINGDEMANDFan tostartspeed.Diverter valvein CH positionPump ON.IGNITIONSEQUENCE(see detail)BLUELI

Wait5 secondsIGNITIONSEQUENCE(see detail)PREHEAT AND DHW FUNCTIONNOYESPOWERSWITCH ONTap open(recognisedby flow turbine)Diverter valvein DHWpositionPum

PROTECTION FUNCTIONBoiler temperaturebelow 8°CRun autofroststatfunctionPump antiseizePump run 5 secondsevery 24hrsPROTECTION FUNCTIONINSTALLATION &

TECHNICAL DATAINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior8 716 107 336b (11/05)5TECHNICAL DATAAPPLIANCEI

CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxesTIME & TEMPERATURE CONTROL TO HEATING

SERVICE INTERVAL RECORDIt is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record

EXCELLENCE COMES AS STANDARDWorcester, Bosch GroupCotswold Way, Warndon, Worcester WR4 9SW.Tel. 01905 754624 Fax. 01905 754619Worcester, Bosch Group i

LAYOUT & COMPONENTSThe diagram opposite shows the controls in theservicing position and excludes the outer case. 1 AIR / GAS MANIFOLD2FAN3 AIR / G

LAYOUT & COMPONENTS10 PLATE TO PLATE DHW HEAT EXCHANGER32 SYSTEM PUMP36 FLOW TURBINE37 UNUSED PORT38 AUTO AIR VENT39 FLOW CONNECTION FROM BOILER H

CLEANING PRIMARY SYSTEMSBEFORE CLEANING THE SYSTEM:ENSURE THE SYSTEM AND PIPEWORK ISIN GOOD WORKING ORDERKEEP THE EXISTING BOILER/CIRCULATING PUMP WHE