Table of Contents
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GREENSTAR
WALL MOUNTED CONDENSING BOILER FOR CENTRAL HEATING
AND MAINS FED DOMESTIC HOT WATER
INSTALLATION AND
SERVICING INSTRUCTIONS
Cat II
appliance
2H 3P
GC NUMBERS
Greenstar ZWBR 7-25 A23 (N.G.) 47 311 44
Greenstar ZWBR 11-25 A31 (L.P.G.) 47 311 45
THIS APPLIANCE IS FOR USE ON SEALED PRIMARY SYSTEMS ONLY
IMPORTANT: THESE INSTRUCTIONS APPLY IN THE UK ONLY
THESE INSTRUCTIONS ARE TO BE LEFT WITH THE USER OR AT THE GAS METER
This appliance must be installed by a competent person in accordance
with the Gas Safety (Installation and Use) Regulations 1998
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Table of Contents
Related Manuals for Bosch Greenstar ZWBR 7-25 A 23
Summary of Contents for Bosch Greenstar ZWBR 7-25 A 23
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Page 1: Servicing Instructions
GREENSTAR WALL MOUNTED CONDENSING BOILER FOR CENTRAL HEATING AND MAINS FED DOMESTIC HOT WATER INSTALLATION AND SERVICING INSTRUCTIONS Cat II appliance 2H 3P GC NUMBERS Greenstar ZWBR 7-25 A23 (N.G.) 47 311 44 Greenstar ZWBR 11-25 A31 (L.P.G.) 47 311 45 THIS APPLIANCE IS FOR USE ON SEALED PRIMARY SYSTEMS ONLY IMPORTANT: THESE INSTRUCTIONS APPLY IN THE UK ONLY THESE INSTRUCTIONS ARE TO BE LEFT WITH THE USER OR AT THE GAS METER... -
Page 2: Table Of Contents
Contents Domestic Hot Water ............ Page 8 Installation Regulations ..........Page 2 Electrical................ Page 8 Introduction..............Page 2 Installation ..............Page 10 Technical Data .............. Page 3 Commissioning ............Page 15 Siting the Appliance ............ Page 5 Instructions to the User ..........Page 21 Flue Systems .............. -
Page 3: Technical Data
Fig. 1. Appliance water flow diagram. Charging Point Automatic Automatic Vent Vent Expansion Water Vessel Water Heat Heat Exchanger Exchanger Condensate Trap Pump Drain Pressure Relief Valve Diverter Siphon Valve Flow Drain Switch Domestic Condensate & Relief Domestic Hot Cold Supply Return Valve Drain Water Out... - Page 4 Table 3 HORIZONTAL 100mm Overall Diameter of Duct Flue Terminal/Duct Assembly Length Extension Duct Length ALTERNATIVE HORIZONTAL 125mm FLUE SYSTEM VERTICAL 125mm FLUE SYSTEM Overall Diameter of Duct Overall Diameter of Duct Flue Terminal/Duct Assembly Flue Terminal/Duct Assembly Length 1360 Extension Duct Length –...
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Page 5: Siting The Appliance
Fig. 2. Casing dimensions and clearances. 4. Siting the Appliance The appliance is not suitable for external installation. The appliance may be installed in any room subject to the requirements of the IEE Wiring Regulations or the electrical provisions of the Building Regulations applicable in Scotland relevant to appliances fitted in rooms containing baths or showers. -
Page 6: Siting The Flue Terminal
If the terminal is less than 2m above a surface to which people 6. Siting the Flue Terminal have access then a guard must be fitted. The guard must be evenly spaced about the terminal with a space of 50mm in each The flue must be installed in accordance with BS 5440:1 and the direction and fixed with plated screws. -
Page 7: Air Supply
The filling point must be at low level and arranged as shown in 8. Air Supply Figs. 6 and 7 The pressure relief valve is set to operate at 3 bar. A separate air supply for combustion is not required. There must be no connection to the mains without the approval If the appliance is in a cupboard or compartment then, because of the local water company. -
Page 8: Domestic Hot Water
10. Domestic Hot Water 11. Electrical Any regulations specified by the local water company must be Supply: 230V ~ 50Hz 140 watts. External fuse 3A. Protection observed. IPX4C. Mains cable: PVC insulated 0.75mm (24 x 0.20mm) to The final 600mm of the mains cold water connection to the BS 6500–Table 6. - Page 9 Fig. 8. Pictorial wiring diagram. o - orange g - green bl - black r - red p - purple bl bl bl bl 230V Module Mains Input Pump Fuse 2.5A, 230V AC DHW temperature sensor Fuse 0.5A Water pressure switch (flow switch) Fuse 1.6A DHW inlet sensor Control unit connection...
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Page 10: Installation
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 Flues between 670mm 1620mm require 1 extension duct Assembly assembly. Flue Turret Maximum 670mm... - Page 11 Fig. F4. Flue Components. Duct Clamp Flue Extension Air Duct Turret Turret Clamp Extension Flue Duct Terminal Assembly Wall Sealing Plates Fig. 10. Marking the position of the side flue Fig. 9. Wall mounting assembly. opening. Support Wall Mounting Lugs Plate Drilling point for Centre line of...
- Page 12 Fig. 13. Condensate discharge system. Fig.12. Removal of casing Syphon Manifold Assembly Casing Syphon Drain Pipe Security Screw (remove) Drain Casing Clip (2) Fig. 14. Inner Casing Controls / Components. Fan Assembly Fan Assembly Fixing Screws (2) Automatc Air Vent (Expansion Vessel) Burner Assembly Automatic Air Vent...
- Page 13 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 Pressure Guage Syphon Boiler Drain Plug Fixing Screw Fixing Screw Diverter Valve Facia Fixing Screw Using the template or the wall mounting plate mark the...
- Page 14 A condensate neutralisation kit is available. Mark off the lengths shown onto the ducts and cut to length. The The condensate drain pipe and fittings must be made of plastic cuts must be square and free from burrs. (NO OTHER MATERIALS SHALL BE USED) with a minimum Terminal assembly outer (air) duct - L-750mm diameter of 22mm.
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Page 15: Commissioning
Connect a drain to the relief valve outlet ensuring that it does not Open the heating system valves on the manifold and all the discharge onto electric components or where it might be a radiator valves. Fill the system through the WRc approved filing hazzard. - Page 16 Fig. 17. Facia. 9 10 Appliance identification sticker 'ECO' button Master switch Indicator lamp for burner on Indicator lamp for power on Temperature control for DHW on ZWRB Temperature control for CH flow Pressure guage Setting button (also refered to as 'Chimney Sweep' button) Reset button Digital display Service button...
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Page 17: Switching Off
Room Temperature Control Lock-Out Mode Optional Junkers control If a lock-out occurs the reset button lights and the display shows a fault code. Set the temperature control knob to the required setting. Press the reset button to restart the appliance (flow temperature Set the outside temperature control unit, if fitted to the appears on the display). - Page 18 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.
- Page 19 Changing the Maximum Central Heating Flow Temperature Turn the hot water temperature control knob clockwise until the The maximum central heating flow temperature can be reset required output level is reached. from the factory set maximum of 88°C to between 35°C and Central 88°C .
- Page 20 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 only necessary to change the setting if an outside temperature compensator is fitted.
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Page 21: Instructions To The User
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 Instruct the user in the efficient and safe operation of the condensing mode. To ensure that the rooms are properly heated appliance and hand over the user’s leaflet. - Page 22 3. After 5 seconds a figure wil appear on the display followed by Fig. S4.. 0.0 and the flashing of the buttons. Refer to Fig.S2. Fig. S2.. 6. To enter the change press and hold both buttons until appears. Refer to Fig.S5. Fig.
- Page 23 Fig.19 . Burner body. Fan Assembly Fan Connector Fan Assembly Fixing Screws Burner Body Fixing Screw Burner Body Split Burner Body Fixing Mixing Tube Spark Electrode Assembly Air Flow Tube Sight Glass Flame Sense Electrode Remove the cabinet . Refer to Fig. 12. Fig.
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Page 24: Replacement Of Parts
Brush any dust from the controls using a soft non-metallic brush Fig. 21. Facia connections cover. and battery operated vacuum cleaner. 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. - Page 25 Fig. 23. Pressure gauge Fig. 25. Gas valve. Pump Pre-mixing Tube Diverter Valve O-Ring Head Distributor Seal Inner Pressure Case Gauge Base Head Seal Side Casing Facia Gas Valve Assembly Solenoids Valve Fixing Screw Support Bracket Throttle Disk Fig. 24. Pump, manual air vent, diverter valve. Seal Seal Manual Air Vent...
- Page 26 Domestic Hot Water Outlet Temperature Sensor Fig. 27. Sightglass. 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.
- Page 27 Burner Assembly Siphon Remove the inner case cover. Disconnect the pipe to the siphon. Unscrew the fan assembly. Refer to Fig.19. Remove the yellow plug to drain the siphon. Remove the split pins from the front fixings of the burner Unscrew the securing nut from beneath the the side facia and assembly and unscrew and remove the fixings.
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Page 28: Short Parts List
17. Parts List Key Description Qty GC WHS/Bosch 1 Sensor – Flue gas temp. 8 729 000 144 0 3 Sensor – CH flow temp. 8 714 500 054 0 4 Sensor – DHW inlet temp. 8 714 500 049 0... -
Page 29: Fault Finding
18. 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. - Page 30 Display State Condition Action 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. Incorrect ionisation (flame sense) Check electrode and lead for splits or signal.
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Page 32: 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.