To Clean The Siphon/Condensate Trap; Setting The Air/Gas Ratio - Worcester GREENSTAR 35 CDi Installation, Commissioning And Servicing Instructions

SERVICING AND SPARES

6.1.7 TO CLEAN THE SIPHON/CONDENSATE TRAP

1. Pull condensate hose out of the trap.
2. Remove trap from boiler.
▶ Clean the trap and check that the connection to the heat exchanger is
clear.
▶ Fill the condensate trap with approximately 250 millilitres of water
and refit in reverse order.
2.
1.
Fig. 68 Siphon removal
6.2

SETTING THE AIR/GAS RATIO

NOTICE: Air/Gas ratio
▶ The setting of the gas ratio must be carried out by a
competent person.
Setting the air/gas ratio must not be attempted unless
the person carrying out the operation is equipped
with a combustion analyser conforming to BS 7927
and is competent in its use.
SETTING THE CO
2
When fitted with the optional diverter valve (not
supplied) and running in performance test mode, the
boiler will only operate the central heating circuits.
If fitted to an S or Y plan system, the system must only be
run in central heating mode.
This is to allow sufficient time for this part of the
commissioning procedure.
1. Connect manometer to inlet test point on the gas valve.
▶ To adjust the CO it will be necessary to first operate the boiler at
2
maximum output.
▶ Press and hold down the performance test button for 10 seconds until
illuminated.
2. Turn central heating control to maximum; the boiler will then go to
maximum output.
The control will resume normal operation after 15
minutes or if the performance test button is pressed for
over a second.
3. Using a flat blade screwdriver set the CO
referring to the table below.
CO should be measured 10 minutes after firing the
2
appliance.
40
6 720 812 175-37.1O
via the max adjuster
2
CO setting
2
Gas type maximum
30CDI System
Natural gas 9.6% ±0.4
LPG 11.5% ±0.4
35CDI System
Natural gas 9.6% ±0.4
LPG 11.5% ±0.4
NOTE:
When checking an existing appliance the tolerance is 0.4%.
If checking after cleaning or component replacement or for adjustment
when the reading is outside the tolerance given above, then the
tolerance is 0.2%
CO - less than 200 ppm (0.002 ratio)
Table 32
▶ Measure the gas inlet pressure at the gas valve test point; it should be
a maximum of 2.5mbar less than the pressure at the meter for natural
gas and a maximum of 4mbar less than the pressure at the regulator
for LPG.
4. Set the central heating control to minimum. This will make the boiler
go to minimum power.
5. Measure the CO ; it should now be at the figure for minimum output.
2
▶ If not, use a 4mm Allen key to adjust the min adjustment on the gas
valve until correct.
▶ Return to maximum and re-check the CO
▶ If correct press and hold down the performance test button for two
seconds; the button will cease to be illuminated and the blue power
indicator will be permanently illuminated.
▶ Remove manometer and re-seal inlet pressure point on gas valve.
▶ Refit anti tamper cover onto the max adjuster.
▶ Replace the brass screw over the min adjuster on the valve.
▶ Re-assemble and refit boiler case.
Max
adjust
Min
adjust
4mm
Inlet pressure
test point
Fig. 69 Setting the Air/Gas ratio
CO setting
2
minimum
9.0% ±0.4
10.5% ±0.4
9.0% ±0.4
10.5% ±0.4
.
2
6720647361-48.1Wo
6 720 812 175 (2014/07)