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THE APPLIANCE IS FOR USE WITH
NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13 & C33)
NATURAL GAS:
WORCESTER GREENSTAR 24i junior GC NUMBER 47-311-86
WORCESTER GREENSTAR 28i junior GC NUMBER 47-311-87
LIQUID PETROLEUM GAS:
WORCESTER GREENSTAR 24i junior GC NUMBER 47-311-90
WORCESTER GREENSTAR 28i junior GC NUMBER 47-311-91
GB/IE
CHECKLIST & service
interval record, printed within this
manual
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CONTACT INFORMATION INSTALLATION & SERVICING INSTRUCTIONS WORCESTER: PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION. TECHNICAL: 08705 266241 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 SERVICE: 08457 256206 ANY OTHER MAKE OR MODEL OF APPLIANCE. SPARES: 01905 752571 LITERATURE: 01905 752556 THE INSTRUCTIONS APPLY IN THE UK ONLY AND MUST BE FOLLOWED EXCEPT FOR ANY TRAINING: 0190
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CONTENTS SAFETY & REGULATIONS SAFETY PRECAUTIONS & SYMBOLS 3 INSTALLATION REGULATIONS 3 APPLIANCE INFORMATION GENERAL INFORMATION 4 TECHNICAL DATA 5 LAYOUT & COMPONENTS 6-7 PRE-INSTALLATION CLEANING PRIMARY SYSTEMS 8 MAINS SUPPLY 9 WATER SYSTEMS & PIPEWORK 10 CONDENSATE PIPEWORK 11 PRESSURE RELIEF PIPEWORK 12 BOILER LOCATION & CLEARANCES 13-14 PLUMBING MANIFOLD 15 FLUE TERMINAL POSITIONS 16 FLUE OPTIONS 17 INSTALLATION UNPACKING THE WALL FRAME 18 WALL MOUNTING TEMPLATE / FLUE OPENING 19 UNPACKI
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SAFETY PRECAUTIONS INSTALLATION REGULATIONS IF YOU SMELL GAS: Gas Safety (Installation & Use) Regulations 1998: All gas appliances must be installed by a competent person in accordance with the above ✗ DON’T SMOKE OR STRIKE MATCHES regulations. Failure to install appliances correctly ✗ DON’T TURN ELECTRICAL SWITCHES ON OR OFF could lead to prosecution. The appliance must be installed in accordance ✓ DO PUT OUT NAKED FLAMES with, and comply to, the current: Gas Safety ✓ DO OPEN DOORS AND WINDOWS
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GENERAL INFORMATION STANDARD PACKAGE: A - Wall hung gas fired condensing combi boiler for central heating and domestic hot water B - Boiler support frame C -Hardware literature pack D - Bottom Panel (When fitted to wall frame) B Depth to wall A 330mm 700mm D C SPECIFICATIONS: 400mm Pre-wired and pre-plumbed Galvanised steel inner frame Digital control system Automatic ignition Direct burner ignition electrodes D Built-in frost thermostat Built-in fault finding diagnostics Modulating automatic ga
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TECHNICAL DATA DESCRIPTION NATURAL GAS L.P.G. UNITS 24i junior 28i junior 24i junior 28i junior Domestic Hot Water Min. heat input KW 7.38 7.38 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 3 Natural Gas G20 m /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.
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LAYOUT & COMPONENTS The diagram opposite shows the controls in the servicing position and excludes the outer case. 1 AIR / GAS MANIFOLD 2FAN 3 AIR / GAS ADJUSTMENT SCREW 4GAS VALVE 5 INLET PRESSURE TEST POINT 6 EXPANSION VESSEL 7 WALL MOUNTING FRAME 8 COVER FOR EXTERNAL WIRING CONNECTIONS 9 CONDENSATE CONNECTION FROM HEAT EXCHANGER 10 PLATE TO PLATE DHW HEAT EXCHANGER 11 FLUE PRESSURE SWITCH 12 FAN PRESSURE TEST POINT 13 MANUAL VENT POINT 14 IGNITION AND FLAME SENSE ELECTRODES 15 OVERHEAT THE
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LAYOUT & COMPONENTS 10 PLATE TO PLATE DHW HEAT EXCHANGER 32 SYSTEM PUMP 36 FLOW TURBINE 37 UNUSED PORT 38 AUTO AIR VENT 39 FLOW CONNECTION FROM BOILER HEAT EXCHANGER 40 DHW SENSOR 41 CH FLOW CONNECTION TO SERVICE VALVE 42 DHW OUT CONNECTION 43 COLD WATER IN CONNECTION 44 CH RETURN CONNECTION TO SERVICE VALVE 45 DIVERTER VALVE 46 PRESSURE RELIEF VALVE 47 COMPACT HYDRAULIC MOUNTING SCREW (2) TO BOILER 48 CH TEMPERATURE CONTROL 49 MAINS ON/OFF INDICATOR/ DIAGNOSTIC LIGHT (BLUE) 50 SERVICE MOD
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CLEANING PRIMARY SYSTEMS IMPORTANT: All the following Pre-Installation sections must be read and requirements met before starting boiler or flue installation. 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 CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND appliance will invalidate the appliance OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. warranty. BEFORE CLEANING THE SYSTEM
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MAINS SUPPLY ELECTRIC SUPPLY: • Supply: 230V - 50Hz, 140 watts 2 • Cable: PVC insulated 0.75mm (24 x 0.2mm) temperature rated to 90°C. • External 3A fuse to BS1362. • The appliance must be earthed. • IPX4D. NOTE: this is reduced to IP20 if the following mechanical timers are fitted: 7 716 192 036 or 7 716 192 037. • All pipes to the boiler must be cross-bonded. • Wiring must comply with IEE wiring regulations. GAS SUPPLY: • Boilers using NG must be connected to a governed meter. • LPG boilers
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WATER SYSTEMS & PIPEWORK PLASTIC PIPEWORK: • Any plastic pipework must have a polymeric barrier with 600mm (minimum) length of copper or steel pipe connected to the boiler. • Plastic pipework used for underfloor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approx. 50°C. The pipework from the boiler to the blending valve must be in copper or steel (protected from corrosion). PRIMARY SYSTEMS CONNECTIONS/VALVES: • All sy
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CONDENSATE PIPEWORK CONDENSATE PIPEWORK: • The condensate pipe must be a minimum of 22mmØ plastic pipe. • The condensate pipework must fall at least 50mm per metre towards the outlet and should take the shortest practicable route. • The pipework must follow one of the options shown opposite into an internal serviceable trap (min. 75mm) such as a sink/washing machine) or discharge direct into a vent stack (E) 450mm min. above pipe invert or into a gulley (D) below ground but above the w
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PRESSURE RELIEF PIPEWORK PRESSURE RELIEF PIPEWORK: IMPORTANT: The pressure relief valve is a safety device for the boiler and if activated may discharge boiling water steam through the relief valve drain pipe. Care should be taken when siting the outlet pipe so that it does not cause an obstruction or discharge above a window, entrance or other public access where it could cause a hazard. • The pressure relief drain pipe (M) from the boiler should be at least 15mm diameter copper pipe and run
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SERVICING CLEARANCES BOILER LOCATION & VENTED COMPARTMENT CLEARANCES This boiler is only suitable for installing internally within a property at a suitable location onto a fixed, rigid non-combustible surface at least the same size as the boiler and capable of support- ing the boiler weight. COMPARTMENTS: Follow the requirements of BS6798 and Using 100mm flue kit BS5440 Part 2 and note: 1080mm • Minimum clearances must be maintained Using 125mm flue kit • An access door is required to install, s
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BOILER LOCATION & CLEARANCES BATHROOMS: If the appliance is fitted in conjunction with a mechanical or RF mechanical timer, the 1 1 appliance can only be fitted in zone 3 . 2 Otherwise the appliance can be fitted in both 2 3 3 zones 2 and 3 . See IEE wiring regulations. IMPORTANT: any switch or appliance control using mains electricity must not be able to be touched by a person using the bath or shower. Electrical switches, fused spur and socket outlets must not be situated in the bathroo
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PLUMBING MANIFOLD Gas Supply (alternative from above appliance) 22mm CH Flow 22mm DHW OUT 15mm CONNECTIONS: Heating System: 22mm compression fittings DHW IN (alternative from CH Return 22mm DHW: 15mm compression fittings above appliance) Gas: 22mm compression fittings 15mm Use the fittings supplied in the Lit/Hardware pack. • If the boiler pipes are to be run behind the appliance ensure that the pipes pass through the slot in the yellow plastic guide (A). This is fitted to the boiler fra
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FLUE TERMINAL POSITIONS • The flue must be fitted and terminated in Minimum dimensions of flue terminal positions for balanced room sealed flues with accordance with the recommendations of fanned draught: BS5440 : Part 1. • The flue must not cause an obstruction. DRWG. TERMINAL POSITION DISTANCE • Discharge and any noise from the flue outlet REF: must not cause a nuisance. 1 A Directly below an opening, air brick, opening windows, etc. 300mm • Flue gases have a tendency to plume and in 1
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FLUE OPTIONS MAXIMUM FLUE VERTICAL STANDARD FLUE HORIZONTAL START + 2 BENDS • The diagrams (opposite) show the A components used and the maximum flue A F length for each configuration of 100mm and B 125mm flues. C Ø100 • Shaded flue components indicate the MAX 686 A x 1 standard 100mm horizontal flue. Ø100 - 2600mm MIN 250 A x 1* • Only straight flue sections can be reduced in A x 1 + C x 2 + B x 4 + length and cut. Fx1 Ø125 • The flue terminal end can be fitted from the MAX 1070
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UNPACKING WALL FRAME AND IIMPORTANT: All the previous Pre-Installation sections must be read and requirements met before starting boiler or flue installation. ANCILLARY ITEMS LIFTING AND CARRYING PRECAUTIONS: • Lift only a manageable weight, or ask for help. • When lifting or putting things down, bend the knees, and keep the back straight and feet apart. 1 • Do not lift and twist at the same time. • Lift and carry objects close to the body A - Straps A B - Outer carton C - Installer pac
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WALL MOUNTING TEMPLATE A FLUE OPENING X 4 CAUTION: Ensure there are no pipes, electric cables, damp proof courses or other hazards before drilling. X 4 SAFETY: All relevant safety precautions must be undertaken. Protective clothing, footwear, gloves and safety USE APPROPRIATE goggles must be worn as appropriate. FIXINGS FOR FIXING THE MOUNTING FRAME: WEIGHT AND WALL TYPE • The boiler template shows the relative positions of the flue and the top and bottom fixing of the mounting frame. Fix t
