Worcester GREENSTAR 29 Benutzerhandbuch

Installation and Servicing Instructions

GREENSTAR 29 HE Conventional

Wall mounted condensing boiler

6 720 610 577-00.10

HE Conventional

GC-Number Natural Gas: 41 311 56

GC-Number LPG: 41 311 57

6 720 611 137 GB (03.02) OS

6 720 611 137 GB (03.02)

Contents

Safet precautions 3

S mbols 3

1 Details of the appliance 4

1.1 EC Declaration of Conformity 4

1.2 Standard package 4

1.3 Description of appliance 4

1.4 Accessories 5

1.5 Casing dimensions 5

1.6 Layout of appliance 6

1.7 Function 7

1.8 Electrical wiring diagram 8

1.9 Technical data 9

2 Installation regulations 10

3 Installation 11

3.1 Important remarks 11

3.2 System 11

3.3 Siting the appliance 13

3.4 all mounting frame assembly 14

3.5 Pre-piping the system 14

3.6 Fitting the appliance 15

3.7 Checking the connections 16

3.8 Flue Systems 16

3.8.1 Siting the Flue Terminal 17

3.8.2 Installation of the flue 18

3.8.3 Flue duct preparation and assembly 20

4 Electrical connections 21

4.1 Connecting the appliance 21

4.2 iring to your system 22

5 Commissioning 23

5.1 Commissioning 23

5.2 Switching the appliance on/off 24

5.3 Switching on the System 24

5.4 System controls 24

5.5 Frost protection 24

5.6 Fault Condition 25

6 Individual settings 26

6.1 Mechanical settings 26

6.1.1 Setting the boiler flow temperature 26

6.2 Settings on the Bosch Heatronic 26

6.2.1 Operating the Bosch Heatronic 26

6.2.2 Setting the anti-cycle time

(Service Function 2.4) 27

6.2.3 Setting the maximum flow temperature

(Service Function 2.5) 27

6.2.4 Setting the switching difference

(Service Function 2.6) 27

6.2.5 Setting the heating output

(Service Function 5.0) 27

6.3 Setting the gas/air ratio 28

7 Converting the appliance to different

gas t pes 29

7.1 Setting the gas/air ratio 29

7.2 Testing combustion air/flue gas

at set heat output 31

7.2.1 Testing the O

or CO

level

in the combustion air 31

7.2.2 Testing CO and CO

8 Maintenance 32

8.1 Pre-Service Check List 33

8.2 Description of servicing operations 34

8.3 Replacement of Parts 37

8.3.1 PCB control board and transformer 37

8.3.2 Fan Assembly 38

8.3.3 Sensors 38

8.3.4 Gas Valve 38

8.3.5 Electrode assembly 39

8.3.6 Pressure Relief Valve 39

8.3.7 Burner 39

8.3.8 Primary Heat Exchanger 39

9 Appendix 40

9.1 Fault Codes 40

9.2 Short parts list 41

9.3 Heating settings (N.G) 41

9.4 Heating settings (L.P.G) 41

9.5 Operational Flow diagram 42

6 720 611 137 GB (03.02)

Safet precautions

If ou smell gas

Turn off gas service cock at the meter.

Open windows and doors.

Do not operate any electrical switches.

Extinguish any naked flames.

Telephone your gas company.

If ou smell fumes from the appliance

Switch off appliance (see page 24).

Open windows and doors.

Fitting and modifications

Fitting of the appliance or any controls to the appli-

ance may only be carried out by a competent engi-

neer in accordance wth the Gas Safety (Installation

and Use) Regulations.

Flue systems must not be modified in any ways other

than as described in the fitting instructions.

This appliance is supplied for fitting to fully pumped,

sealed and open vent systems only.

Maintenance

The user is recommended:

to have the system

regularly serviced in order to ensure that it functions

reliably and safely.

Use only original spare parts!

Combustible materials

Do not store or use any combustible materials

(paper, thinners, paints etc.) in the vicinity of the

appliance.

Health and safet

This appliance contains no asbestos products.

There is no potential hazard due to the appliance

being electrically unsafe.

There are no substances used in the construction

that are a potential hazard in relation to the COSHH

Regulations (Control of Substances Hazardous to

Health Regulations).

Combustion air/Ambient atmosphere

The combustion air/ambient atmosphere should be

kept free of chemically aggressive substances (e.g.

halogenated hydrocarbons which contain chlorine or

fluorine compounds). This will prevent corrosion.

Instructions to the customer

Explain to the customer how the appliance works

and how to operate it.

Advise the user that he/she must not make any mod-

ifications to the appliance or carry out any repairs on

it.

These instructions are to be left with the user or at

the Gas meter.

Important: These instructions apply in the UK only.

S mbols

Safet instructions

in this document

are identified by a warning-triangle sym-

bol and are printed on a grey back-

ground.

Notes

containing important information

are identified by the symbol shown on the

left. They are bordered by horizontal lines

above and below the text.

6 720 611 137 GB (03.02)

Details of the appliance

1 Details of the appliance

1.1 EC Declaration of Conformit

This appliance is in accordance with the applicable

requirements of the Gas Appliance Directive, Boiler

Efficiency Directive, Electromagnetic Compatibility

Directive and the Low Voltage Directive.

1.2 Standard package

• Gas condensing boiler

• all mounting frame

• Clamp for securing flue duct kit

• Fixings (screws etc.)

• Set of documentation for appliance

• Pre-plumbing manifold

• Condensate drain pipe.

1.3 Description of appliance

• all-mounted appliance, siting not dependent on

room size

• Natural gas models are low-emission appliances

• Multifunction display

• Bosch Heatronic control system

• Automatic ignition

• Modulating control

• Full safety systems incorporating Bosch Heatronic

with flame ionisation monitoring, solenoid valves and

temperature sensors

• Concentric flue/air duct with testing point for

/CO

• Regulated speed fan

• Pre-mix burner

• Temperature control for boiler flow

• Safety temperature limiter in 24 V electrical circuit

• Flue gas temperature limiter (105 °C)

• Condensate Trap

• Connecting possibility for 3 port or 2 x 2 port

motorised valve systems

• Suitable for fully pumped sealed and open vent sys-

tems.

CE-0085 BL 0507

Category

2H 3P

Appliance Type

, C

Table 1

6 720 611 137 GB (03.02)

Details of the appliance

1.4 Accessories

• Standard horizontal flue kit at 100 mm outside

diameter for flues upto 4 m in length.

• Flue duct kits for horizontal (125 mm outside

diameter) for flue lengths upto 13 m and vertical flue

systems for flue lengths upto 15 m. Fitting instruc-

tions are sent with these kits.

• Security kit.

1.5 Casing dimensions

Fig. 1

all mounting frame and Manifold assembly

101

Outer case

103

Facia cover

Standard Concentric Horizontal Flue System: (Ø 100 mm)

min. 310 mm

Alternative Concentric Flue System: (Ø 125 mm) min. 250

Standard Concentric Horizontal Flue System: 158 mm

Alternative Concentric Flue System: 121 mm

Standard Concentric Horizontal Flue System: 105 mm

Alternative Concentric Flue System: 130 mm

For servicing the appliance

min.

850

440 395

200

360

861

906

200

6 720 610 601- 01.3O

101

103

120

600

6 720 611 137 GB (03.02)

Details of the appliance

1.6 La out of appliance

Fig. 2

Heatronic control

4.4

Y-S-module

Heat exchanger safety temperature limiter

Testing point for gas supply pressure

Flue gas temperature limiter

Safety valve

Automatic air vent

Air gas Mixer unit

32.1

Electrode assembly

Temperature sensor in boiler flow

Flow pipe

Adjustable gas flow restrictor

Adjusting screw for min. gas flow volume

102

Inspection window

120

Fixing points

221.1

Flue duct

221.2

Combustion air intake

226

Fan assembly

295

Appliance type sticker

234

Testing point for combustion products

234.1

Testing point for combustion air

271

Flue duct

349

Cover plate for twin flue duct connection

358

Condensate trap

361

Drain valve

415

Cover plate for cleaning access

416

Condensate collector

417

Clip for fixing outer case

418

Data plate

423

Siphon

6 720 611 137-01.1 O

102

416

415

32.1

418

423

226

234.1

271

221.1

221.2

358

361

4.4

417

234

349

120

295

6 720 611 137 GB (03.02)

Details of the appliance

1.7 Function

Fig. 3

Bosch Heatronic control

4.4

Y-S-module

Temperature limiter, heat exchanger

Testing point for gas supply pressure

Flue gas temperature limiter

Manifold

Safety valve

Automatic air vent

Mixer unit

29.1

Bi-metallic thermostat for combustion air compensation

Burner

32 Flame sensing electrode

33 Igniter electrode

35 Heat exchanger with cooled combustion chamber

36 Temperature sensor in boiler flow

43 Boiler flow

45 Gas inlet

47 Return

52 Solenoid valve 1

52.1 Solenoid valve 2

55 Filter

56 Gas valve CE 427

57 Main valve disc

61 Reset button

63 Adjustable gas flow restrictor

64 Adjusting screw for min. gas inlet flow volume

69 Control valve

84 Motor (optional extra)

88 3-way valve (optional extra)

221 Flue duct

226 Fan

229 Inner casing

234 Testing point for flue gas

234.1 Testing point for combustion air

317 Display

358 Condensate trap

361 Drain valve

423 Siphon

443 Diaphragm

6 720 611 137-02.1O

29 30

226

229 234

234.1

29.1

45 47

43 13

52.1

358

max

ECO

317

221

4.4

361

443

6 720 611 137 GB (03.02)

Details of the appliance

1.8 Electrical wiring diagram

Fig. 4

4.1 Ignition transformer

4.4 Y-S-module

6Temperature limiter, heat exchanger

9Flue gas temperature limiter

32 Flame sensing electrode

33 Ignition electrode

36 Temperature sensor in primary flow

52 Solenoid valve 1

52.1 Solenoid valve 2

56 Gas valve CE 427

61 Reset button

135 Master switch

136 Temperature control for boiler flow

151 Fuse, slow 2.5 A, AC 230 V

153 Transformer

161 Link

226 Fan

300 Code plug

302 Earth connection

310 Function control (Service only)

312 Fuse, slow T 1,6 A

313 Fuse, slow T 0,5 A

317 Digital display

328 Terminal block for AC 230 V Mains supply

363 Indicator lamp for burner

364 Indicator lamp for power supply

365 “Chimney sweep” button

366 Service button

367 No function

52.1

230 V

135

25 V

230V/AC

153 136

151 124789

161

226

300

LNLs

328

302

310

312

313

317 363

364 365 366

ECO

367

4.1

6 720 611 137-03.1O

mains supply

o - orange bl - black r - red

4.4

6 720 611 137 GB (03.02)

Details of the appliance

1.9 Technical data

Units Natural gas Propane

Max. rated heat output net 40/30˚C central heating

Max. rated heat output net 50/30˚C central heating

Max. rated heat output net 80/60˚C central heating

29.3

29.0

27.4

29.3

29.0

27.4

Max. rated heat input net k 27.7 27.7

Min. rated heat output net 40/30˚C

Min. rated heat output net 50/30˚C

Min. rated heat output net 80/60˚C

8.4

8.3

7.4

11.6

11.4

10.5

Min. rated heat input net k 7.6 10.8

Maximum gas flow rate - After 10 minutes from lighting

Natural Gas G20 (CVnet 34.02 MJ/m3)m

3/h 2.9 -

LPG G31 (CVnet 88 MJ/m3) kg/h - 2.1

Gas suppl pressure

Natural Gas G20 (CVnet 34.02 MJ/m3) mbar 20 -

LPG G31 (CVnet 88 MJ/m3) mbar - 37

Flue

Flue gas temp. 80/60˚C, rated/min. load ˚C 67/55 67/55

Flue gas temp. 40/30˚C, rated/min. load ˚C 43/32 43/32

Residual delivery pressure

(inc. pressure drop in air intake duct) Pa 80 80

CO2 level at max. rated heat output

CO2 level at min. rated heat output %

%9.2

8.8 10.8

10.5

NOx-class 5 5

SEDBUK figure, Band A 1)

1) The value is used in the UK Government Standard Assessment Procedure (SAP) for the energy rating of dwellings. The test data

from which it has been calculated have been certified by DVG .

% 90.7 90.7

Condensate

Max. condensation rate (tR = 30˚C) l/h 2.3 2.3

pH-value, approx. 4.8 4.8

General Data

Electrical power supply voltage AC ... V 230 230

Frequency Hz 50 50

Max. power consumption 43 43

Noise output level dB(A) 36 36

Appliance protection rating IP X4D X4D

Max. flow temperature ˚C nom. 90 nom. 90

Minimum static head m 1.0 1.0

Maximum static head m 30.0 30.0

Permissible ambient temperatures ˚C 0 - 50 0 - 50

Nominal capacity of appliance l 3.75 3.75

eight (excluding packing) kg 38 38

Table 2

6 720 611 137 GB (03.02)

Installation regulations

Condensate anal sis, mg/l

Flue s stem

Elbow - 90 ° Equivalent length 2 m

Bend - 45 ° Equivalent length 1m

Gas suppl

2 Installation regulations

Gas Safety (Installation & Use) Regulations: All gas

appliances must be installed by a competent person.

Failure to install correctly could lead to prosecution.

The manufacturers notes must not be taken, in any way,

as overriding statutory obligations.

The appliance must be installed in accordance with the

current IEE iring Regulations, local Building Regula-

tions, Building Standards (Scotland) (Consolidation),

bye-laws of the local ater Company, Health and

Safety Document 635 (Electricity at ork Regulations

1989) and any other local requirements.

Product Liability regulations indicate that, in certain cir-

cumstances, the installer can be held responsible, not

only for mistakes on his part but also for damage result-

ing from the use of faulty materials. e advise the

installer to avoid any risk by using only quality approved

branded fittings.

The relevant British Standards should be followed i.e.

• BS 6798: Specification for the installation of gas

fired hot water boilers of rated input not exceeding

60k

• BS 5449: Central Heating for Domestic Premises

• BS 5546: Installation of gas hot water supplies for

domestic purposes

• BS 5440:1: Flues and ventilation for gas appliances

of rated input not exceeding 70 k (net): Flues

• BS 5440:2: Flues and ventilation for gas appliances

of rated input not exceeding 70 k (net): Air

Supply

• BS 6891: Installation of low pressure gas pipework

installations up to 28mm (R1).

• BS 6700: Domestic water supply (when relevant)

• BS 7671: Requirements for Electrical Installation.

These instructions must be followed.

Ammonium 1.2 Nickel 0.15

Lead ≤ 0.01 Mercury ≤ 0.0001

Cadmium ≤ 0.001 Sulphate 1

Chromium ≤ 0.005 Zinc ≤ 0.015

Halogenated

hydrocarbons ≤ 0.002

Tin ≤ 0.01

Hydrocarbons 0.015 Vanadium ≤ 0.001

Copper 0.028 pH-value 4.8

Table 3

HORIZONTAL 100 mm Standard

Overall Diameter of Duct mm 100

Max.

4 m

Flue Terminal / Duct

Assembly Length mm 600

Extension Duct Length mm 1000

Table 4

VERTICAL 100 mm – Standard

Overall Diameter of Duct mm 100 Max.

6.4 m

(incl.

flue

assem-

bly)

Flue Terminal / Duct

Assembly mm 600

Extension Duct Assembly mm 1000

Table 5

ALTERNATIVE HORIZONTAL 125 mm FLUE

SYSTEM

Overall Diameter of Duct mm 125 Max.

13 m

(inclu-

ding

turret)

Flue Terminal / Duct Assembly mm 1030

Extension Duct Length mm 1000

Table 6

VERTICAL 125 mm FLUE SYSTEM

Overall Diameter of Duct mm 125

Max.

15 m

Flue Terminal / Duct Assembly mm 1360

Extension Duct Length mm 1000

Table 7

Total length of gas suppl pipe

(metres)

Pipe diameter

(mm)

369

Gas discharge rate (m3/h)

8.7 5.8 4.6 22

18.0 12.0 9.4 28

Table 8

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