Gas conversion kit instructions
Wall hung RSF gas fired condensing boiler
Greenstar Ri ErP range appliances
6720813340-00.1Wo
For converting gas type on condensing wall hung appliances
6 720 817 026(2015/04)
UK/IE
Contents
Contents
1
Key to symbols and safety instructions . . . . . . . . . . . 3
1.1
Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . 3
2
Gas Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.1
Gas conversion Kits . . . . . . . . . . . . . . . . . . . . . . 5
2.1.1 Code plug identification . . . . . . . . . . . . . . . . . . . 5
2.2
Gas conversion . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2.1 Replacing the code plug . . . . . . . . . . . . . . . . . . . 5
2.2.2 Identifying the conversion . . . . . . . . . . . . . . . . . 6
2.3
Combustion Checks . . . . . . . . . . . . . . . . . . . . . . 7
2.3.1 Flue gas test point . . . . . . . . . . . . . . . . . . . . . . . 7
2.3.2 CO/CO2 values . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3.3 Gas valve initial set up . . . . . . . . . . . . . . . . . . . . 8
2.3.4 Appliance mode selector . . . . . . . . . . . . . . . . . . 8
2.3.5 Setting the CO2 . . . . . . . . . . . . . . . . . . . . . . . . . 9
2
Ri ErP gas conversion kit – 6 720 817 026 (2015/04)
Key to symbols and safety instructions
1
Key to symbols and safety instructions
1.1
Key to symbols
Warnings
Safety instructions in this document are
framed and identified by a
warning triangle which is printed on a grey
background.
A step in an action sequence
A sequence of defined actions or steps carried out in order to
complete a task.
▶ Action
▶ Next action
▶ etc
A reference to a related part in the document or to other
related documents.
To refer the reader to a specific figure/table/section within the
manual.
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.
 e.g. figure 1.
Important information
1.2
This symbol indicates important information
where there is no risk to people or property.
Additional symbols
Symbol
Meaning
1.
a numbered step in an action sequence
▶
a step in an action sequence

a reference to a related part in the document or to
other related documents
1
•
a reference number to identify or refer to a part or
item
a list entry
–
a list entry (second level)
Table 1
Examples of additional symbols used
A numbered step in an action sequence
A sequence of numbered steps or actions carried out in a
specific order to complete a task.
1. First action
2. Second action
3. Third action
etc.
Ri ErP gas conversion kit – 6 720 817 026 (2015/04)
A reference number to identify or refer to a part or item.
In a related figure, items or parts identified by a sequential
number.
List entries, first and second levels
• A single component/item
• A component/list, made up of multiple parts/items.
– Sub component or sublist of main component/list.
– etc.
Safety precautions
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.
▶ 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.
Intended use:
This boiler must only be used as a heating appliance in a sealed
hot water heating system for domestic purposes.
Any other use is considered inappropriate. Any damage that
results from such use is excluded from liability.
3
Gas Conversion
Installation, Commissioning and Servicing Instructions:
Installation, commissioning and servicing must only be carried
out by a competent, Gas Safe registered engineer.
▶ Carry out a gas tightness test after completing work on gascarrying components.
▶ Only use original spares.
Electrical work:
Electrical work must only be carried out by a qualified
electrician.
▶ Before starting electrical work:
– Isolate the mains electrical supply and secure against
unintentional reconnection.
– Check for zero potential.
▶ Also see connection diagrams of other system
components.
Handover to the user:
When handing over, instruct the user how to operate the
heating system and inform them about its operating
conditions.
▶ Explain how to operate the heating system and draw the
user's attention to any safety-relevant action.
▶ Explain that modifications and repairs must only be carried
out by an authorised contractor.
▶ Advise the user to have the system serviced annually by a
competent, Gas Safe registered engineer.
▶ Leave the installation instructions with the completed
Benchmark Checklist (or a certificate confirming
compliance with IS 813, Eire only) and the operating
instructions with the user or at the gas meter.
2
Gas Conversion
NOTICE: Carrying out gas conversion
▶ Read these instructions with the
appliance Installation, Commission
and Servicing Instructions.
CAUTION: Mains supplies
▶ Turn off the gas supply and isolate the
electrical mains supply before starting
any work on the appliance and observe
all relevant safety precautions.
4
The installation/assembly must be carried
out by a GAS SAFE registered Engineer.
▶ Please read these instructions in
conjunction with the appliance
Installation, Commissioning and
Servicing Instructions carefully before
starting any work.
▶ Observe all the safety precautions
described in the Installation,
Commissioning and Servicing
Instructions for the Greenstar Ri ErP
range appliance.
▶ Observe National and Regional
Regulations, Technical rules and
Guidelines.
▶ Record all work carried out.
NOTICE: Combustion testing
▶ Combustion testing must be carried out
by a competent person. Testing must
not be attempted unless the person
carrying out the combustion check is
equipped with a calibrated Combustion
Analyser conforming to BS 7927 and is
competent in its use.
NOTICE: CO/CO2 Checks
▶ After completing the service of the
appliance, the CO/CO2 must be
checked to the limits shown in the
relevant Installation, Commissioning
and Servicing instructions
NOTICE: Appliance siting
▶ This appliance must not be installed into
a room or internal space below ground
level when it is intended for use with
LPG (Propane - G31). This does not
preclude the installation into a room or
space that is in a basement on one side
of the building but is open to ground
level on the opposite side.
Ri ErP gas conversion kit – 6 720 817 026 (2015/04)
Gas Conversion
2.1
Gas conversion Kits
To convert from or to natural gas or LPG, a Gas Conversion kit
is required.
2.2
Gas conversion
CAUTION: Mains supplies
▶ Turn off the gas supply and isolate the
electrical mains supply before starting
any work on the appliance and observe
all relevant safety precautions.
The kit comprises:
• Gas pipe and nozzle assembly
• Heat Control Module (HCM)
•
Labels to confirm the new gas type
2.1.1 Code plug identification
Gas type
Appliance
Code plug
number
NG
12Ri ErP
034
LPG
12Ri ErP
035
NG
15Ri ErP
036
LPG
15Ri ErP
037
NG
18Ri ErP
038
LPG
18Ri ErP
039
NG
24Ri ErP
040
LPG
24Ri ErP
041
Accessing the code plug
Electrical cover removal
▶ Remove the three screws [2] retaining the electrical cover.
▶ Remove the electrical [1] cover.
1
Code plug numbers
ST1
1
###
6720817026-01.1Wo
# ### ###
Fig. 1
2
Fig. 2
6720817026-02.1Wo
Table 2
2.2.1 Replacing the code plug
Removing the electrical cover
Code plug number identification
[1] Identification number
Ri ErP gas conversion kit – 6 720 817 026 (2015/04)
5
Gas Conversion
Replacing the code plug
▶ Remove the code plug [3] from the socket and cut the
tether from the appliance (a new tether is supplied with the
conversion kit).
▶ Connect the new code plug [4] and the tether, ensure the
correct code plug is fitted, refer to table 2, page 5.
2.2.2 Identifying the conversion
Appliance data label
From the gas conversion kit
• White label comes in the NG kit and is used for converting
to natural gas (NG) from LPG.
• Yellow label comes in the LPG kit and is used for converting
to LPG from natural gas (NG).
▶ Peel off the larger label [1] and apply over the original data
label [2] on the inside of the appliance.
– The edge of the new label should be positioned so that
it covers the line referring to the adjustment of the gas.
The top four lines [3] of the original data should remain
uncovered thus maintaining the original serial number
of the appliance.
3
2
1
4
3
0086
6720817026-03.1Wo
Fig. 3
2
Code plug replacement
The electrical cover should not be refitted
until the combustion checks have been
completed.
1
00
0086
6720817026-04.1Wo
Fig. 4
6
Appliance data label
Ri ErP gas conversion kit – 6 720 817 026 (2015/04)
Gas Conversion
Appliance identification label update
▶ To identify the appliance gas conversion variant for the end
user, peel off the smaller label [4] and apply behind the
original label [5] on the bottom panel as shown.
– The original appliance identification label must not be
covered or removed as it shows appliance type and
serial number.
2.3
Combustion Checks
▶ Refer to the Installation, Commissioning and Serving
Instructions for full details on combustion check.
In addition to the CO and CO/CO2 ratio checks also check
the minimum and maximum CO2 percentage reading.
2.3.1 Flue gas test point
1
6720817026-06.1Wo
2
5
4
Fig. 5
6720817026-05.1Wo
3
Appliance identification label update
When the gas conversion kit has been fitted:
▶ Carry out Commissioning section from the Installation,
commissioning and service instructions.
Fig. 6
Combustion test point
[1] Flue gas sample point
[2] Flue turret flue gas blank plug
[3] Flue adaptor flue gas blank plug
2.3.2 CO/CO2 values
N.G. Appliances (measured after 10 minutes)
Output
CO2 Reading CO Reading
12Ri ErP
9.65% ± 0.2
Maximum setting
(0.002 ratio)
8.65% ± 0.2
12Ri ErP
Minimum setting
15/18/24Ri ErP
Less than 200ppm
(0.002 ratio)
9.2% ± 0.2
Minimum setting
Table 3
Less than 200ppm
(0.002 ratio)
9.8% ± 0.2
Maximum setting
15/18/24Ri ErP
Less than 200ppm
Less than 200ppm
(0.002 ratio)
N.G. CO/CO2 settings
L.P.G. Appliances (measured after 10 minutes)
Output
Less than 200ppm
Maximum setting
(0.002 ratio)
12/15/18/24Ri ErP 10.5% ± 0.2
Less than 200ppm
Minimum setting
(0.002 ratio)
Table 4
Ri ErP gas conversion kit – 6 720 817 026 (2015/04)
CO2 Reading CO Reading
12/15/18/24Ri ErP 11.0% ± 0.2
L.P.G. CO/CO2 settings
7
Gas Conversion
2.3.3 Gas valve initial set up
▶ Remove the brass dust cap [3] with a flat bladed screw
driver.
▶ Gently turn Min adjuster [2] and Max adjuster [1] adjuster
clockwise until they stop.
– Do not continue to turn the adjusters.
▶ Once the boiler has ignited, please refer to the following
sections to adjust Min/Max CO2 to the correct values.
MAX
2.3.4 Appliance mode selector
Ensure the boiler has mains electrical supply and there is a
demand from the external controls.
▶ Remove the mode adjustment tool [1] clipped inside the
electrical cover.
▶ Insert the tool into the switch.
▶ Using the tool to set the mode of the appliance for the
combustion checks, starting in maximum mode.
The power indicator will flash and the boiler will stay in this
mode for 15 minutes if no further change is made to the
switch.
1
2.5 mm
1
MIN
2
6720817026-09.1Wo
4 mm
3
Gas valve initial set up
Maximum setting
Output N.G.
7 ½ turns
2 ½ - 2 ¾ turns
18Ri ErP
3 ¾ turns
2 ½ turns
15Ri ErP
3 ½ - 3 ¾ turns
2 ½ turns
12Ri ErP
3½
2 ½ turns
Table 5
NORM
MIN
Number of turns
Number of turns
from gas valve fully from gas valve fully
wound home
wound home
ErP
24Ri
MAX
Minimum setting
MAX
MIN
NORM
N.G. initial set up
Maximum setting
Minimum setting
2
6720817026-07.1Wo
Fig. 7
Fig. 8
Appliance mode selector
Number of turns
Number of turns
from gas valve fully from gas valve fully
wound home
Output L.P.G. wound home
24Ri ErP
4 ¼ turns
2 ¾ turns
18Ri ErP
2 turns
2 ¾ turns
15Ri ErP
2 turns
2 ¾ turns
12Ri ErP
1 ¾ turns
2 ¾ turns
Table 6
8
L.P.G. initial set up
Ri ErP gas conversion kit – 6 720 817 026 (2015/04)
Gas Conversion
2.3.5 Setting the CO2
▶ Run the boiler at maximum output for at least 10 minutes.
▶ Refer to tables 3 & 4 and check the CO/CO2 at maximum.
– Adjust the maximum CO2 setting via the 2.5mm allen
key adjustment point [1] to the correct value.
▶ Set the mode switch to minimum.
▶ Refer to tables 3 & 4 and check the CO/CO2 at minimum.
– Adjust the minimum CO2 setting via the 4mm allen key
adjustment point [2] to the correct value.
▶ Return the appliance to maximum mode and re-check the
CO/CO2.
If the value is within tolerance and no further adjustments
have been made.
▶ Replace the brass dust cap [3] and return the appliance to
normal mode.
MAX
1
2.5 mm
MIN
4 mm
Fig. 9
6720817026-08.1Wo
2
Gas valve adjustment
▶ With the combustion checks completed:
– Re-fit the electrical panel.
– Re-fit the appliance outer case.
Ri ErP gas conversion kit – 6 720 817 026 (2015/04)
9
Notes
10
Ri ErP gas conversion kit – 6 720 817 026 (2015/04)
Notes
Ri ErP gas conversion kit – 6 720 817 026 (2015/04)
11
WORCESTER, BOSCH GROUP:
Worcester, Bosch Group
Cotswold Way, Warndon, Worcester WR4 9SW.
Tel. 0330 123 9559
Worcester, Bosch Group is a brand name of
Bosch Thermotechnology Ltd.
worcester-bosch.co.uk
6 720 817 026 (2015/04)
TECHNICAL SUPPORT:
0330 123 3366
APPOINTMENTS:
0330 123 9339
SPARES:
0330 123 9779
LITERATURE:
0330 123 9119
TRAINING:
0330 123 0166
SALES:
0330 123 9669