Installation and maintenance instructions manual [PDF] (80 pages)
- Brand: Worcester
- Model: Greenstar 8000 Life GR8300iW 30 C
- Format: PDF
- Key Aspects: Hardware Verification Checklists, Control Panel and Interface Navigation, Best Practices for Everyday Use
- Updated: 18.04.2026
- Source File: 1538414.pdf
- Pages: 80
- Description: Installation instructions for the Worcester Greenstar 8000 Life GR8300iW 30 C.
Document Preview & Text Transcription
6720883864 (2019/02) UK/IE
Installation and Maintenance Instructions
Gas fired condensing combi boiler
Greenstar 8000 Style
GR8700iW 30 C | GR8700iW 35 C | GR8700iW 40 C | GR8700iW 45 C | GR8700iW 50 C |
GR8700iW 30 CB | GR8700iW 35 CB | GR8700iW 40 CB | GR8700iW 45 CB | GR8700iW 50 CB
Table of contents
Greenstar 8000 Style – 6720883864 (2019/02)
2
Table of contents
1
Explanation of symbols and safety instructions . . . . . . . . . . . 3
1.1
Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2
General safety instructions . . . . . . . . . . . . . . . . . . . . . . . 4
2
Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3
Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1
About the appliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2
Misuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3
Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4
Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5
Appliance type overview . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6
Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.7
Pipe work positions and flue outlet. . . . . . . . . . . . . . . . . 8
3.8
Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.9
Product data for energy consumption. . . . . . . . . . . . . .10
4
Pre-Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.1
System preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.1.1
Artificially softened water . . . . . . . . . . . . . . . . . . . . . . .11
4.1.2
Water systems and pipe work . . . . . . . . . . . . . . . . . . . .11
4.1.3
System layouts examples. . . . . . . . . . . . . . . . . . . . . . . .12
4.1.4
System fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.2
Mains supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.2.1
Electrical supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.2.2
Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.2.3
Water supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.3
Appliance location and clearances . . . . . . . . . . . . . . . .14
4.3.1
Appliance location . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4.3.2
Rooms containing a bath or shower . . . . . . . . . . . . . . .15
4.3.3
Appliance clearances. . . . . . . . . . . . . . . . . . . . . . . . . . .15
4.4
Flue systems considerations . . . . . . . . . . . . . . . . . . . . .16
4.4.1
Flue length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
4.4.2
Flue options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
4.4.3
Plume management system. . . . . . . . . . . . . . . . . . . . . .18
4.4.4
Flue terminal positions . . . . . . . . . . . . . . . . . . . . . . . . .19
4.4.5
Plume re-direct and plume management terminal
positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.5
Condensate discharge . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.5.1
Appliance siphonic condensate trap. . . . . . . . . . . . . . .24
4.5.2
Condensate pipe work. . . . . . . . . . . . . . . . . . . . . . . . . .24
4.5.3
Internal connections . . . . . . . . . . . . . . . . . . . . . . . . . . .25
4.5.4
External connections . . . . . . . . . . . . . . . . . . . . . . . . . . .25
4.6
Pressure relief discharge . . . . . . . . . . . . . . . . . . . . . . . .27
4.6.1
Pressure relief pipe work. . . . . . . . . . . . . . . . . . . . . . . .27
4.6.2
Alternative PRV connections - Combined PRV/
condensate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
4.7
Cleaning primary systems . . . . . . . . . . . . . . . . . . . . . . .28
4.7.1
Flushing the system . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
5.1
Position the appliance . . . . . . . . . . . . . . . . . . . . . . . . . .31
5.1.1
Mounting frame fixing . . . . . . . . . . . . . . . . . . . . . . . . . .31
5.2
Appliance connections . . . . . . . . . . . . . . . . . . . . . . . . .32
5.3
Hanging the appliance . . . . . . . . . . . . . . . . . . . . . . . . . .33
5.4
Flue turret/adaptor installation . . . . . . . . . . . . . . . . . . .35
5.5
Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.5.1
Installer connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.5.2
Cable preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.5.3
External controls - domestic installations. . . . . . . . . . . 38
6
Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.1
Pre-Commissioning checks. . . . . . . . . . . . . . . . . . . . . . 39
6.2
Water treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.2.1
Filling the appliance and adding Inhibitor. . . . . . . . . . . 39
6.2.2
Adjusting the operating pressure of the heating
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.3
Starting the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.3.1
Control panel overview . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.3.2
Turn on the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.3.3
Siphon filling mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.4
Chimney sweep mode . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.5
Combustion casing removal . . . . . . . . . . . . . . . . . . . . . 41
6.6
Checking gas inlet pressure. . . . . . . . . . . . . . . . . . . . . . 42
6.6.1
Checking the gas supply pressure. . . . . . . . . . . . . . . . . 42
6.7
Checking the gas rate. . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.8
Checking for gas leaks during operation. . . . . . . . . . . . 43
6.9
CO and combustion check. . . . . . . . . . . . . . . . . . . . . . . 43
6.10
Checking flue integrity. . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.11
Flue gas analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.12
Finishing commissioning. . . . . . . . . . . . . . . . . . . . . . . . 45
6.12.1 Fitting the combustion casing. . . . . . . . . . . . . . . . . . . . 45
6.12.2 Fitting the appliance casing. . . . . . . . . . . . . . . . . . . . . . 46
6.12.3 Appliance/product guarantee . . . . . . . . . . . . . . . . . . . . 47
7
Settings in the service menu . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.1
Operating the service menu . . . . . . . . . . . . . . . . . . . . . 47
7.2
Service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.2.1
Overview of the service menu. . . . . . . . . . . . . . . . . . . . 48
7.2.2
Benchmark and Info menu. . . . . . . . . . . . . . . . . . . . . . . 50
7.2.3
Settings menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.2.4
Function check menu. . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.2.5
Reset menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8
Inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.1
Inspection and maintenance considerations . . . . . . . . 54
8.2
Resources for inspection and maintenance . . . . . . . . . 54
8.3
Inspection and maintenance steps . . . . . . . . . . . . . . . . 54
8.4
Component access . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.5
Fan pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.6
Check working gas inlet pressure . . . . . . . . . . . . . . . . . 56
8.7
Flue gas analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.8
Checking the flue integrity. . . . . . . . . . . . . . . . . . . . . . . 56
8.9
Cleaning the siphon and heat exchanger . . . . . . . . . . . 57
8.9.1
Checking the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.9.2
Checking the non-return valve in the air-gas
manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.9.3
Fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8.9.4
Cleaning the heat exchanger . . . . . . . . . . . . . . . . . . . . . 58
8.9.5
Checking electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.9.6
Cleaning the siphon . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.10
Setting the air/gas ratio. . . . . . . . . . . . . . . . . . . . . . . . . 62
8.10.1 Checking and, if required, adjusting the gas/air
ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Table of contents
3
Greenstar 8000 Style – 6720883864 (2019/02)
1
Explanation of symbols and safety instructions
1.1
Explanation of symbols
Warnings
In warnings, signal words at the beginning of a warning are used to
indicate the type and seriousness of the ensuing risk if measures for
minimising danger are not taken.
The following signal words are defined and can be used in this document:
DANGER:
DANGER indicates that severe or life-threatening personal injury will
occur.
WARNING:
WARNING indicates that severe to life-threatening personal injury may
occur.
CAUTION:
CAUTION indicates that minor to medium personal injury may occur.
NOTICE:
NOTICE indicates that material damage may occur.
Important information
The info symbol indicates important information where there is no risk to
people or property.
Additional symbols
Table 1
9
Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
9.1
Draining the appliance . . . . . . . . . . . . . . . . . . . . . . . . . .63
9.2
Overheat thermostat removal . . . . . . . . . . . . . . . . . . . .64
9.3
Pressure sensor removal . . . . . . . . . . . . . . . . . . . . . . . .64
9.4
Pressure relief valve removal . . . . . . . . . . . . . . . . . . . . .64
9.5
Replacing the gas valve . . . . . . . . . . . . . . . . . . . . . . . . .64
9.6
Checking the strainer in the cold water pipe and
the flow turbine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
9.7
Checking/replacing the motor of the 3-way valve. . . . .65
9.8
Replacing the 3-way valve . . . . . . . . . . . . . . . . . . . . . . .66
9.9
Replacing the plate heat exchanger. . . . . . . . . . . . . . . .66
9.10
Following inspection/maintenance . . . . . . . . . . . . . . . .66
10 Fault finding and diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
10.1
Operating and fault displays . . . . . . . . . . . . . . . . . . . . .66
10.1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
10.1.2 Fault code table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
10.1.3 Faults that are not displayed . . . . . . . . . . . . . . . . . . . . .68
11 Environmental protection and disposal . . . . . . . . . . . . . . . . .69
12 Technical Specifications/Logs . . . . . . . . . . . . . . . . . . . . . . . . .69
12.1
Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
12.1.1 Specifications Combi . . . . . . . . . . . . . . . . . . . . . . . . . . .69
12.2
Ionisation current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
12.3
Component resistance characteristics . . . . . . . . . . . . .73
12.3.1 Sensor values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
12.4
Code plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
12.5
Pump characteristic map of the heating pump. . . . . . .73
12.6
Setting values for central heating output . . . . . . . . . . .74
12.7
Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
12.8
Gas boiler system commissioning checklist . . . . . . . . .77
12.9
Inspection and maintenance checklist . . . . . . . . . . . . .78
12.10 Service record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Symbol
Meaning
▶
a step in an action sequence
a reference to a related part in the document
•
a list entry
–
a list entry (second level)
Explanation of symbols and safety instructions
Greenstar 8000 Style – 6720883864 (2019/02)
4
1.2
General safety instructions
H Please read these instructions carefully before
starting installation.
• 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 any other
make or model of appliance.
• These instructions apply in the UK and Ireland only
and must be followed except for any statutory
obligations.
• This appliance must be installed by a competent
registered gas engineer, such as a Gas Safe
registered engineer including a British Gas
engineer. Failure to install correctly could lead to
prosecution.
• If you are in any doubt, contact the Worcester
Technical help-line
(0330 123 3366).
• Distance learning and training courses are available
from Worcester.
• The BENCHMARK Commissioning Checklist can be
found on page 77 of this Installation manual.
H Notes for the target group
These installation instructions are intended for gas,
plumbing, heating and electrical contractors. All
instructions must be observed. Failure to comply with
instructions may result in material damage and
personal injury, including danger to life.
▶ Read the installation instructions (heat source,
heating controller, etc.) before installation.
▶ Observe the safety instructions and warnings.
▶ Observe national and regional regulations,
technical rules and guidelines.
▶ Record all work carried out.
H Intended use
The appliance may only be used for heating water or
domestic hot water in domestic properties.
▶ Observe the details on the data plate and the
specifications (installation manual) to ensure
correct use of this appliance.
▶ Worcester Bosch offer flue gas systems which are
suitable for use with the appliance. It is the
responsibility of the designer/installer of the flue to
ensure this flue gas system operates correctly and
in a safe manner.
H If you smell gas
A gas leak could potentially cause an explosion. If you
smell gas, observe the following rules:
▶ Prevent flames or sparks:
– Do not smoke, use a lighter or strike matches.
– Do not operate any electrical switches or unplug
any equipment.
– Do not use the telephone or ring doorbells.
▶ Turn off the gas at the meter or regulator.
▶ Open windows and doors.
▶ Warn your neighbours and leave the building.
▶ Prevent anyone from entering the building.
▶ Move 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.
H Risk to life from carbon monoxide poisoning
There is a risk to life from escaping flue gases
▶ Do not modify the flue gas system.
▶ Ensure that flue pipes and gaskets are undamaged.
If flue pipes are damaged or leaking:
▶ Turn off and isolate the appliance.
▶ Open windows and doors.
▶ If necessary, leave the building and warn your
neighbours.
▶ Prevent anyone from entering the building.
▶ Rectify any damage to the flue system immediately.
H Installation and maintenance
Installation and maintenance must only be carried out
by a competent registered gas engineer, such as Gas
Safe registered engineer or British Gas engineer.
▶ Carry out a gas tightness test after completing work
on gas-carrying components.
▶ Only use original spares.
H Electrical work
Electrical work must only be carried out by a qualified
electrician:
▶ Before starting electrical work;
– Ensure that the electricity supply is safely
Isolated and secured to prevent inadvertent re-
connection.
Information on safe isolation can be found in the
Health and Safety Executive guidance HSG85.
– Using test equipment approved to GS38 to
confirm that the electricity supply is
disconnected.
▶ Refer to the manufacturer’s information when
installing non Worcester components and systems
to the Worcester appliance.
