GREENSTAR 12Ri ErP Installation, Commissioning And Servicing Instructions

Text of GREENSTAR 12Ri ErP User Guide:

• GREENSTAR 12Ri ErP, APPLIANCE INFORMATION Greenstar Ri ErP - 6 720 813 283 (2015/07)8 3.3 Energy efficiency NATURAL GAS APPLIANCES The following product data satisfy the requirements of the EU Regulations No. 811/2013 and No. 812/2013 supplementing Directive 2010/30/EU. Product data Symbol Unit 7733600074 7733600072 7733600070 7733600068 Product type – – 12Ri ErP NG 15Ri ErP NG 18Ri ErP NG 24Ri ErP NG Condensing boiler – – Yes Yes Yes Yes Low temperature boiler – – No No No No B1 boiler – – No No N

• GREENSTAR 12Ri ErP, INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS WALL HUNG RSF GAS FIRED CONDENSING BOILER Greenstar Ri ErP 6720644744-00.1Wo FOR OPEN VENTED & SEALED CENTRAL HEATING SYSTEMS & INDIRECT MAINS FED DOMESTIC HOT WATER 6 720 813 283 (2015/07) If you smell gas: ▶ Well away from the building: call the National Gas Emergency Service on 0800 111 999. ▶ L.P.G. boilers: Call the supplier’s number on the side of the gas tank. These appliances are for use with: Natural Gas or L.P.G. (Cat. II 2H 3P type C13, C33 & C53) Model GC Number Natural Gas 12Ri ErP 41-406-41 15Ri ErP 41-406-43 18Ri ErP 41-406-45 24Ri ErP 41-406-47 LPG 1

• GREENSTAR 12Ri ErP, APPLIANCE INFORMATION Greenstar Ri ErP - 6 720 813 283 (2015/07) 9 LPG appliances The following product data satisfy the requirements of the EU Regulations No. 811/2013 and No. 812/2013 supplementing Directive 2010/30/EU. Product data Symbol Unit 7733600075 7733600073 7733600071 7733600069 Product type – – 12Ri LPG 15Ri LPG 18Ri LPG 24Ri LPG Condensing boiler – – Yes Yes Yes Yes Low temperature boiler – – No No No No B1 boiler – – No No No No Cogeneration space heater (CHP) – – No No No No Combination heater – – No No No No Rated heat output P rated kW 12 15 18 24 Seasonal space heating energy efficiency  s % 91919192 En

• GREENSTAR 12Ri ErP, KEY TO SYMBOLS AND SAFETY PRECAUTIONS Greenstar Ri ErP - 6 720 813 283 (2015/07) 3 1 KEY TO SYMBOLS AND SAFETY PRECAUTIONS 1.1 Key to symbols Warnings The following keywords are defined and can be used in this document: • NOTICE indicates a situation that could result in damage to property or equipment. • CAUTION indicates a situation that could result in minor to medium injury. • WARNING indicates a situation that could result in severe injury or death. • DANGER indicates a situation that will result in severe injury or death. Important information Additional symbols Examples of additional symbols used A numbered step in an action sequen

• GREENSTAR 12Ri ErP, SERVICE AND SPARES Greenstar Ri ErP - 6 720 813 283 (2015/07)40 7.8.4 FLUE OVERHEAT THERMOSTAT (WITH GROMMET) To remove and replace the thermostat either: ▶ Using a small terminal screwdriver, prise the thermostat and grommet from the plastic housing. Take care not to damage the plastic housing. -or- 1.Release the flue connection from the sump. 2.Push the flue tube up. Fig. 69 Lower exhaust section ▶ Remove electrical connections. 1.Push the flue limit thermostat in from the sump. ▶ Retrieve the thermostat from the sump well. Fig. 70 Remove

• GREENSTAR 12Ri ErP, REGULATIONS Greenstar Ri ErP - 6 720 813 283 (2015/07) 5 2Regulations Installation regulations Current Gas Safety (Installation & Use) Regulations: All gas appliances must be installed by a competent person in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution. The appliance must be installed in accordance with, and comply to, the current: Gas Safety Regulations, IET Regulations, Building Regulations, Building Standards (Scotland) (Consolidation), Building Regulations (Northern Ireland), local water by-laws, Health & Safet

• GREENSTAR 12Ri ErP, APPLIANCE INFORMATION Greenstar Ri ErP - 6 720 813 283 (2015/07) 7 3.2 TECHNICAL DATA DESCRIPTION NATURAL GAS LPG UNIT 12Ri 15Ri 18Ri 24Ri 12Ri 15Ri 18Ri 24Ri Gas flow rate - Max. 10 minutes from lighting Natural Gas G20 m³/h 1.3 1.63 1.96 2.6 ---- Propane Gas (LPG) kg/h ----0.96 1.20 1.44 1.91 Central Heating Max. rated heat input (net) kW 12.32 15.40 18.48 24.62 12.32 15.40 18.48 24.62 Min. heat input kW 3.45 4.62 5.54 7.38 5.95 5.95 9.64 9.64 Maximum rated heat output 40/30 °C kW 12.85 16.06 19.28 25.67 12.85 16.06 19.28 25.67 Maximum r

• SERVICE AND SPARES Greenstar Ri ErP - 6 720 813 283 (2015/07) 33 7 SERVICE AND SPARES 7.1 INSPECTION AND SERVICE • To ensure the continued efficient operation of the appliance it must be checked at regular intervals. • The frequency of servicing will depend upon the particular installation conditions and usage however, an annual service is recommended. • The

• GREENSTAR 12Ri ErP, SERVICE AND SPARES Greenstar Ri ErP - 6 720 813 283 (2015/07) 47 7.9 SHORT PARTS LIST Fan 8 716 116 067 0 GC No. H26 536 Burner 12 & 15Ri: 8 716 116 379 0 GC No. H26 537 18 & 24Ri: 8 716 120 619 0 GC No. H26-538 Gas Valve 12/15/18 & 24Ri 8 716 111 325 0 GC No. H26 540 Control board 8 718 687 164 0 H26-541 Flue overheat thermostat (grommet type) 8 710 506 267 0 Electrodes (including gasket) 8 718 107 087 0 Gasket - burner WB6 8 716 110 534 0 Seal - Inner case/mantel 8 716 106 635 0 H26-545 Flow temperature sensor - (NTC) 8 716 106 688 0 GC No. H26 542 Air pressure switch 8 716 106 633 0 G.C. No. H26 543 Seals kit 8 716 107

• GREENSTAR 12Ri ErP, PRE-INSTALLATION Greenstar Ri ErP - 6 720 813 283 (2015/07)14 Fig. 10 Condensate pump disposal 4.4.2 EXTERNAL CONNECTIONS If no other discharge method is possible then the use of an externally run condensate drainage pipe terminating at a suitable foul water discharge point, or purpose-designed soak away, may be considered. If this method is chosen then the following measures should be adopted: ▶ The external run be kept as short as possible and not exceed 3 metres. ▶ The pipe should be run in

• GREENSTAR 12Ri ErP, SERVICE AND SPARES Greenstar Ri ErP - 6 720 813 283 (2015/07)34 7.2 CHECKING GAS INLET PRESSURE Refer to section 6.5.1 for checking the gas inlet pressure 7.3 CHECKING FLUE INTEGRITY The integrity of the flue system and performance of the boiler can be checked via the flue turret sample points. Fig. 50 Flue test points ▶ With the boiler case on and the boiler running at maximum. ▶ Insert the analyser probe into the air intake test point. ▶ Allow the readings to stabilise and check that: –O 2 is equal to, or greater than 20.6% –CO 2 is less than 0.2% ▶ If the readings are outside these limits the

• GREENSTAR 12Ri ErP, COMMISSIONING Greenstar Ri ErP - 6 720 813 283 (2015/07)32 6.7 FINISHING COMMISSIONING 6.7.1 REPLACE THE OUTER CASE: Replace outer casing making sure that the securing points are properly located. 1.Replace top two screws. 2.Re-tighten bottom two screws. Fig. 46 Replacing outer case 6.7.2 INSTALL THE BOTTOM PANEL The cut out in the bottom panel fits easily over the syphon elbow and outlet, however care should be taken not to disturb any sealed components. 1.Hook the lip at the back of the bottom panel over the angled edge at the base of the connections manifold. 2.Push up into position. 3.Secure in position the screw provided. Fig. 47 Bottom

• SERVICE AND SPARES Greenstar Ri ErP - 6 720 813 283 (2015/07) 37 1.Refer to figure 60 and rotate fan and air/gas manifold assembly around the top of the heat exchanger until it stops at the lug. ▶ Lift up assembly and remove from boiler. 2.Remove the cover panel by removing retaining screw. Fig. 60 Rotate air/gas manifold BURNER REMOVAL Refer to figure 61 1.Re

• GREENSTAR 12Ri ErP, CONTENTS Greenstar Ri ErP - 6 720 813 283 (2015/07)2 CONTENTS 1 KEY TO SYMBOLS AND SAFETY PRECAUTIONS . . . . . . . . . . . . 3 1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3 APPLIANCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3.1 Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

• GREENSTAR 12Ri ErP, COMMISSIONING Greenstar Ri ErP - 6 720 813 283 (2015/07)28 EXTERNAL WIRING CENTRE System components wired into terminal strip in accordance with system manufacturers instructions. Fig. 36 External wiring centre Refit electric control panel covers: ▶ Refit panel and secure with screws. 6 COMMISSIONING 6.1 PRE-COMMISSIONING CHECKS ▶ Check that the gas service pipe and water pipes are connected to the correct position on the manifold. 1.Gas inlet (22mm) 2.Flow (22mm) 3.Return (22mm) Fig. 37 ▶ Check the gas type specified on the identification plate (1) matches that of the gas supply. Fig. 38 Data plate location ▶ Turn on the mai

• GREENSTAR 12Ri ErP, SERVICE AND SPARES Greenstar Ri ErP - 6 720 813 283 (2015/07) 43 7.8.10 ELECTRODE ASSEMBLY AND BURNER ▶ Refer to figure 80 and disconnect spark electrodes and flame sensor connection. ▶ Remove clamping plate. 1.Remove spark/flame electrode assembly from heat exchanger. 2.Remove the seal from the top of the heat exchanger. 3.Remove the burner. ▶ Replace new burner in correct position. ▶ Ensure that burner tabs, as shown in figure 80, fit correctly their respective locations. ▶ Ensure that the seal is fitted. ▶ Replace the clamping plate. Fig. 80 Electrode assembly and burner 7.8.11 RE-ASSEMBLY OF THE BURNER CLAMPING PLATE ▶ Ensure that the new

• PRE-INSTALLATION Greenstar Ri ErP - 6 720 813 283 (2015/07)16 Fig. 16 Ventilated compartment 4.6.3 COMPARTMENTS: Follow the requirements of BS6798 and BS5440 Part 2 and note: • Minimum clearances must be maintained. • An access door is required to install, service and maintain the boiler and any ancillary equipment. • If the boiler is installed in an unventila

• GREENSTAR 12Ri ErP, FAULT FINDING AND DIAGNOSIS Greenstar Ri ErP - 6 720 813 283 (2015/07) 51 8.3 PROTECTION FUNCTION Fig. 93 Protection function Internal boiler temperature between 8°C & 5°C Boiler automatic frost function (monitors internal boiler primary temperature) Internal boiler temperature below 5°C Internal boiler temperature rises above 9°C Pump runs Pump switches off after a 3 minute overrun period Internal boiler temperature rises above 12°C Central heating demand switches off Pump switches off after a 3 mi

• GREENSTAR 12Ri ErP, PRE-INSTALLATION Greenstar Ri ErP - 6 720 813 283 (2015/07) 19 High level horizontal flue High level horizontal flue with additional elbows High level horizontal flue with additional elbows Vertical balanced flue assembly Vertical balanced flue with elbow offset (2 x 90 ° bends) Vertical balanced flue with elbow offset (2 x 45 ° bends) Maximum flue length (mm) 60/100 80/125 High level horizontal flue 4,600 13,000 Table 22 Maximum flue length (mm) 60/100 80/125 High level horizontal flue with 2 x 90° bends 2,600 11,000 Table 23 Maximum flue length (mm) 60/100 80/125 High level horizontal flue with 3 x 90° bends N/A 9,000 Tab

• GREENSTAR 12Ri ErP, PRE-INSTALLATION Greenstar Ri ErP - 6 720 813 283 (2015/07)18 4.8 FLUE OPTIONS 4.8.1 Flue lengths The flue systems have different maximum flue lengths The Greenstar series has the option of two horizontal 60/100 RSF (telescopic and longer telescopic) and one horizontal 80/125 RSF (telescopic) flue system and two vertical RSF (60/100 or 80/125) flue systems: Refer to the following example Flue options for the maximum flue lengths. Horizontal high level flue assembly TELESCOPIC HORIZONTAL FLUE ASSEMBLY Extended horizontal flue Horizontal flue with additional elbow (1 x 90 ° bend) Horizontal flue with additional elbows (2 x 90 ° bends) WARNING: Flue systems

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