GREENSTAR WALL MOUNTED CONDENSING BOILER FOR CENTRAL HEATING AND MAINS FED DOMESTIC HOT WATER INSTALLATION AND SERVICING INSTRUCTIONS Cat II 2H 3P appliance GC NUMBERS Greenstar ZWBR 7-25 A23 (N.G.) 47 311 44 Greenstar ZWBR 11-25 A31 (L.P.G.
Contents 1. 2. 3. 4. 5. 6. 7. 8. 9. Installation Regulations .............................................. Page Introduction.................................................................. Page Technical Data .............................................................. Page Siting the Appliance .................................................... Page Flue Systems ................................................................ Page Siting the Flue Terminal ............................................
Fig. 1. Appliance water flow diagram. Charging Point Automatic Air Vent Automatic Air Vent Water to Water Heat Exchanger Expansion Vessel Heat Exchanger Condensate Trap Pump Drain Pressure Relief Valve Siphon Diverter Valve Drain Flow Switch CH CH Domestic Hot Condensate & Relief Domestic Cold Supply Return Valve Drain Flow Water Out 3.
Table 3 Overall Diameter of Duct mm 100 Flue Terminal/Duct Assembly Length mm 600 Part No. 7 719 001 885 Extension Duct Length mm 1000 Part No. 7 719 001 888 Max. 2m HORIZONTAL 100mm ALTERNATIVE HORIZONTAL 125mm FLUE SYSTEM Overall Diameter of Duct 125mm VERTICAL BALANCED FLUE KIT comprises: ACCESSORIES Extension Flue Kit 100mm 1 x 1 Flue Terminal Assembly Part No. 7 719 001 892 Part No. 7 719 001 890 1 x Vertical Adaptor Vertical Adaptor 90° Elbow Part No.
Fig. 2. Casing dimensions and clearances. 4. Siting the Appliance The appliance is not suitable for external installation. 115 No special wall protection is required. Ensure that the wall can support the appliance. Refer to the IGE publication “Guide for Gas Installations in Timber Framed Housing” where appropriate, IGE/UP/7:1998.
If the terminal is less than 2m above a surface to which people have access then a guard must be fitted. The guard must be evenly spaced about the terminal with a space of 50mm in each direction and fixed with plated screws. A guard, can be obtained from Tower Flue Components, Vale Rise, Tonbridge TN9 1TB. 6. Siting the Flue Terminal The flue must be installed in accordance with BS 5440:1 and the Building Regulations.
The filling point must be at low level and arranged as shown in Figs. 6 and 7 8. Air Supply The pressure relief valve is set to operate at 3 bar. A separate air supply for combustion is not required. If the appliance is in a cupboard or compartment then, because of the low casing losses, it is not necessary to have additional ventilation for the boiler. There must be no connection to the mains without the approval of the local water company.
10. Domestic Hot Water 11. Electrical Any regulations specified by the local water company must be observed. Supply: 230V ~ 50Hz 140 watts. External fuse 3A. Protection IPX4D. Mains cable: PVC insulated 0.75mm 2 (24 x 0.20mm) to BS 6500–Table 6. Temperature rated 100°C. The final 600mm of the mains cold water connection to the appliance should be made in copper tube only. It must be possible to isolate the appliance The appliance must be earthed.
Fig. 8. Pictorial wiring diagram. o - orange g - green bl - black 21 o bl 27 25 o 28 29 30 g g g g o bl 22 p - purple 26 24 20 r - red 31 r 23 r r o bl bl bl p bl bl 13 11 14 12 19 15 17 16 18 25V 8 230V AC 9 10 3 7 4 328 1 2 5 6 Fan Module Mains Input Pump Fan 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Fuse 2.5A, 230V AC Fuse 0.5A Fuse 1.
Fig. F1. Standard Flue. 12. Installation The standard 100mm diameter horizontal flue system is suitable for lengths upto 2m. Flues upto 670mm do not require an extension duct assembly. Terminal Assembly Flues between 670mm 1620mm require 1 extension duct assembly. Flue Turret Flues between 1620mm and 2000mm require 2 extension duct assemblies. Maximum 670mm Flue Sample Point NOTE: Flue lengths between 670mm and 730mm cannot be accomodated. Outer Wall Refer to Fig.F1,F2 and F3.
Fig. F4. Flue Components. Duct Clamp Flue Turret Extension Air Duct Turret Clamp Extension Flue Duct Terminal Assembly Fig. 10. Marking the position of the side flue opening. Fig. 9. Wall mounting assembly.
Fig. 13. Condensate discharge system. Fig.12. Removal of casing Syphon Casing Syphon Drain Pipe Security Screw (partially unscrew) Drain NOTE We should state that: Altough the Tundish is supplied, it may be more suitable to connect directly to the 3/4 " connection on the syphon with the plastic pipe supplied. Casing Clip (2) Fig. 14. Inner Casing Controls / Components.
Fig. 15. Lower Controls / Components. CERAPUR: Diagram 10b 26/3/99 Inner Casing Gas Valve Manual Air Vent and Siphon Fill Gas Valve Inlet Pressure Test Point Pump Pump Cap 2 1 3 Pressure Guage 4 Syphon Boiler Drain Plug Fixing Screw Fixing Screw Diverter Valve Facia Fixing Screw Using the template or the wall mounting plate mark the positions of the fixing holes and the position of the rear, if applicable, flue. Drill, plug and fix the wall mounting plate to the wall.
A condensate neutralisation kit is available. The condensate drain pipe and fittings must be made of plastic (NO OTHER MATERIALS SHALL BE USED) with a minimum diameter of 22mm. Mark off the lengths shown onto the ducts and cut to length. The cuts must be square and free from burrs. Terminal assembly outer (air) duct - L-70mm inner (flue) duct - L-50mm the measurement is made from the ridge at the terminal indicating the outer face of the wall. Refer to Fig.F7.
Connect a drain to the relief valve outlet ensuring that it does not discharge onto electric components or where it might be a hazzard. The pipe must be not less than 15mm in diameter. Open the heating system valves on the manifold and all the radiator valves. Fill the system through the WRc approved filing connection to a pressure of about 1.5 bar and check for water soundness. Refer to Fig.6 and 7.
Fig. 17. Facia. 4 5 6 7 8 9 10 11 12 3 2 1 1 Appliance identification sticker 9 'ECO' button 2 Master switch 10 Indicator lamp for burner on 3 Indicator lamp for power on 11 Temperature control for DHW on ZWRB 4 Temperature control for CH flow 12 Pressure guage 5 Setting button (also refered to as 'Chimney Sweep' button) 6 Reset button 7 Digital display 8 Service button Switching on Switching on the Heating Turn on the heating temperature control knob to E.
Domestic Hot Water Temperature Control Lock-Out Mode Turn the control knob to set the discharge temperature between 40°C (Min) and 60°C (Max) - this temperature does not appear on the display. If a lock-out occurs the reset button lights and the display shows a fault code. Press the reset button to restart the appliance (flow temperature appears on the display). Open a tap and check that the hot water is available in a few seconds. Close the tap.
Pump Anti-Seizure Device Changing the Maximum Heating Output If the pump has not operated for 24 hours then it will be switched on for a period of 5 minutes to prevent seizure. Central Heating Flow Temperature The heating output of the appliance can be reset, from the factory set maximum, if required, to match the maximum heating load. The maximum heat output is automatically available for the domestic hot water.
Changing the Maximum Central Heating Flow Temperature Turn the hot water temperature control knob clockwise until the required output level is reached. Central Display Heat Heating Output Level Input kw Output kw (MAX) (NET) ( Non-condensing Mode) 99 24 23 85 20.6 19.6 65 15.8 15 55 13.5 12.7 The maximum central heating flow temperature can be reset from the factory set maximum of 88°C to between 35°C and 88°C . Turn the heating temperature control knob to 'E'. NOTE: Net Input = 0.
Changing the Control Mode for Heating Operation NOTE: This controls the operation of the pump-it does not change the pump speed. The factory setting is 2 for the boiler to operate with a room thermostat fitted. It is not necessary to change the setting if an outside temperature compensator is fitted. The control will automatically adjust to Mode 3. Turn the central heating temperature control anti-clockwise until 2.2 appears - after 5 seconds the mode setting of 2 (factory setting) appears.
14. Instructions For The User Completion of Commissioning Note: Operating with a lower heating flow temperature will result in the appliance operating in the much more efficient condensing mode. To ensure that the rooms are properly heated the radiators must be sized accordingly. Instruct the user in the efficient and safe operation of the appliance and hand over the user’s leaflet. Describe the operation and function of the controls. Set the appliance and external controls to the user’s requirements.
3. After 5 seconds a figure wil appear on the display followed by 0.0 and the flashing of the buttons. Refer to Fig.S2. Fig. S4.. Fig. S2.. 6. To enter the change press and hold both buttons until appears. Refer to Fig.S5. Fig. S5.. 4. Turn the CH temperature control until 8.5 appears followed after 5 seconds, by 1. Refer to Fig.S3. Fig. S3.. The boiler will now operate as set by controls. IMPORTANT : The siphon check programme must be reset after the service has been completed i.
Fig.19 . Burner body. Fan Assembly Fan Connector Fan Assembly Fixing Screws Burner Body Fixing Screw Burner Body Split Pin Burner Body Fixing Mixing Tube Spark Electrode Assembly Air Flow Tube Sight Glass Gas Flame Sense Electrode Remove the cabinet . Refer to Fig. 12. Check that the condensate trap and syphon are clear and clean, if necessary, by draining and refilling. Remove the yellow cap at the base of the siphon to drain. See Fig. 30. Fig. 20. Burner plate position.
Brush any dust from the controls using a soft non-metallic brush and battery operated vacuum cleaner. Fig. 21. Facia connections cover. If any parts need replacing then refer to Section 16. Facia On completion of the service check for gas soundness and the correct operation of the appliance as described in Section 12. Refit the cabinet and check that the controls are set to the user’s requirements. 4 5 3 E 2 I 0 1 7 Lower Facia cover (clip-on) 16.
Fig. 23. Pressure gauge Fig. 25. Gas valve. Pump Pre-mixing Tube Diverter Valve 2 1 O-Ring 3 4 Air Distributor Head Nut Seal Inner Case Base Pressure Gauge Head Seal Side Casing Facia Assembly Gas Valve Solenoids Gas Valve Fixing Screw Support Bracket Throttle Disk (LPG only) Fig. 24. Pump, manual air vent, diverter valve. Seal Seal Manual Air Vent and Syphon Fill Bypass Pipe Fixing Screws Pump To replace the control board and/or transformer remove the cover panel.
Domestic Hot Water Outlet Temperature Sensor Lower the facia. Drain and remove the siphon. Pull off the connections, orange leads. Remove the clip and pull out the sensor. Refer to Fig.14. A small quantity of water will be released. Prime the siphon. Fig. 27. Sightglass. Frame Manual Air Vent Drain the appliance. Pull off the tube and unscrew the insert from the body. Refer to Fig.15. Refill, vent and re-pressurise the appliance. Prime the siphon.
Burner Assembly Remove the inner case cover. Unscrew the fan assembly. Refer to Fig.19. Remove the split pins from the front fixings of the burner assembly and unscrew and remove the fixings. Loosen the rear fixing nut, it is not necessary to remove this nut, and carefully remove burner assembly. The perforated burner flame strip can be removed. NOTE: The burner flame strip must be replaced as shown in Fig.20.
Primary Heat Exchanger Refer to Figs. 14,15 and 33. Drain the appliance. Lower the facia and remove the inner casing cover. Remove the control module, the air flow switch and the plastic air distributor from the gas valve. Disconnect and remove the sensors and the flue thermostat from the bottom left-hand side of the heat exchanger. Disconnect and remove the hot water flow pipe from the front of the heat exchanger. Remove the gas supply pipe to the fan.
17. Parts List Key 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Description Sensor – Flue gas temp. Qty GC 1 WHS/Bosch 8 729 000 144 0 Sensor – CH flow temp. Sensor – DHW inlet temp.
Mains switch ON. Green light ON. 30 Pre-heat mode **. Pump on diverter valve operates. Fan to maximum speed. Ignition spark for 5 sec. 10 sec. wait. Fan to start speed. Air pressure switch closes. Gas valve opens. Fan runs to purge gas from burner. No Burner lights. Red light ON. Ignition sequence Hot water demand. Heat store satisfied Air pressure check. Repeats 5 times before lock-out. Pump ON. Fan to maximum speed. Diverter valve operates. Yes Air pressure switch check.
Mains switch ON. Repeats 5 times before lock-out. Green light ON. CH demand. Burner light ON. Pump ON. Fan to maximum speed. Fan runs to purge gas from burner. No Burner lights. Red light ON. Ignition sequence Ignition spark for 5 sec. Room thermostat and/or mains programmer (or link) ON AND Electronic facia programmer (if fitted) ON AND CH control knob ON. Yes Air pressure switch check. 3 min wait. Burner stabilises at maximum input for 10 secs. CH demand satisfied.
19. Fault Finding NOTE: This information is for guidance only. Worcester Heat Systems cannot be held responsible for costs incurred by persons not deemed to be competent. Preliminary Checks: Electrical system checks are the first actions to be carried out during a fault finding procedure. On completion of the service or a fault finding task which ha s necesitated the breaking and remaking of electrical connections, check (a) Earth Continuity, (b) Short Circuit, (c) Polarity, (d) Resistance to Earth.
Display State EA 4 No ionisation (flame sense) current. Check that the gas cock is open and for sufficient gas pressure. Check power to the gas valve. Check spark and flame sense electrodes and leads. F7 4 Incorrect ionisation (flame sense) signal. Check electrode and lead for splits or cracks. FA 4 Ionisation (flame sense) current remains after normal shut down i.e burner does not go off. Check gas valve wiring and solenoids.
EXCELLENCE COMES AS STANDARD Worcester Heat Systems Limited, Cotswold Way, Warndon, Worcester WR4 9SW. Telephone: (01905) 754624. Fax: (01905) 754619. Bosch Care Call (0990) 266241 This booklet is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or appearances are changed in the interests of continued improvement. All goods sold are subject to our official Conditions of Sale, a copy of which may be obtained on application.
