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Installation, commissioning and servicing instructions
Wall hung RSF gas fired condensing system boiler
Greenstar CDi Classic System
For central heating systems and indirect fed domestic hot water
ErP
The appliance is for use with:
Natural Gas or L.P.G. (CAT II 2H3P type C13 & C33)
Natural Gas:
30CDi Classic System
35CDi Classic System
L.P.G:
30CDi Classic System
35CDi Classic System
UK/IE
ErP
GC number 41-406-37
ErP
GC number 41-406-39
ErP
GC number 41-406-38
ErP
GC number 41-406-40
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Table of Contents
Related Manuals for Bosch Worcester Greenstar CDi Classic System ErP Series
Summary of Contents for Bosch Worcester Greenstar CDi Classic System ErP Series
- Page 1 Installation, commissioning and servicing instructions Wall hung RSF gas fired condensing system boiler Greenstar CDi Classic System For central heating systems and indirect fed domestic hot water The appliance is for use with: Natural Gas or L.P.G. (CAT II 2H3P type C13 & C33) Natural Gas: 30CDi Classic System GC number 41-406-37...
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Page 2: Table Of Contents
Contents Contents KEY TO SYMOLS AND SAFETY PRECAUTIONS ... . . 3 SERVICING AND SPARES ......37 Key to symbols . -
Page 3: Key To Symols And Safety Precautions
KEY TO SYMOLS AND SAFETY PRECAUTIONS PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE KEY TO SYMOLS AND SAFETY PRECAUTIONS STARTING INSTALLATION. These instructions are applicable to the Worcester appliance model(s) Key to symbols stated on the front cover of this manual only and must not be used with Warnings any other make or model of appliance. -
Page 4: Safety Precautions
KEY TO SYMOLS AND SAFETY PRECAUTIONS Safety precautions INSTALLATION REGULATIONS Current Gas Safety (Installation & Use) Regulations: If you smell gas All gas appliances must be installed by a competent person in A gas leak could potentially cause an explosion. If you smell gas, observe accordance with the above regulations. -
Page 5: Appliance Information
APPLIANCE INFORMATION STANDARD PACKAGE: APPLIANCE INFORMATION Wall hung gas fired condensing system boiler for central heating and domestic hot water General information Wall mounting plate with hanging bracket BOILER FEATURES Pre-plumbing manifold • Pre-wired and pre-plumbed Hardware pack • Galvanised steel inner frame •... -
Page 6: Layout & Components
APPLIANCE INFORMATION Layout & components 6 720 815 724-06.1O Fig. 3 Controls in the servicing position excluding the outer case 6 720 815 724 (2015/11) - Page 7 APPLIANCE INFORMATION Ignition electrode and flame sense Heat exchanger Overheat thermostat Access point for cleaning heat exchanger Low Energy Modulating pump reset Pressure relief valve Boiler drain point CH return Cover for external wiring connections Control panel in service position System pressure gauge Gas inlet connection 22mm compression 6 720 812 175-08.1O...
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Page 8: Technical Data
APPLIANCE INFORMATION Technical data NATURAL GAS L.P.G. NATURAL GAS L.P.G. 30CDi Classic 30CDi Classic 35CDi Classic 35CDi Classic Product type System System System System Domestic hot water Min. heat input 11.5 11.5 Max. rated heat output 30.9 30.9 35.0 35.0 Max. -
Page 9: Product Data On Energy Consumption
APPLIANCE INFORMATION Product data on energy consumption The following product data satisfy the requirements of the EU Regulations No. 811/2013, No. 812/2013, No. 813/2013 and No. 814/2013 supplementing Directive 2010/30/EU. Product data Symbol Unit 7 738 100 244 7 738 100 233 7 738 100 236 7 738 100 237 Product type –... -
Page 10: Pre-Installation
PRE-INSTALLATION Water treatment products PRE-INSTALLATION Suitable water treatment products can be obtain from the following manufacturers: Cleaning primary systems FERNOX 0870 601 5000 CAUTION: MAINS SUPPLIES www.fernox.com ▶ Isolate the mains supplies before starting any work SENTINEL 0800 389 4670 and observe all relevant safety precautions. -
Page 11: Condensate Discharge
PRE-INSTALLATION • A drain cock is required at the lowest point on the system. Condensate discharge 3.4.1 Appliance siphonic condensate trap S plan layout The appliance has a large capacity siphonic condensate trap reducing the risk of condensate discharge freezing up in prolonged cold temperatures. -
Page 12: Internal Connections
PRE-INSTALLATION 3.4.3 Internal connections Condensate pump In order to minimise risk of freezing during prolonged cold spells, the Where “gravity discharge” to an internal termination is not physically following methods of installing condensate drainage pipe should be possible, or where very long internal runs would be required to reach a adopted, in order of priority. - Page 13 PRE-INSTALLATION ▶ The pipe should be run internally as far as possible before going externally and the pipe diameter should be increased to 32mm before it passes through the wall to the exterior. ▶ The external pipe should take the shortest and least exposed route to the discharge point, and should "fall"...
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Page 14: Boiler Internal Drain
PRE-INSTALLATION Boiler internal drain The CDI Classic has the facility to drain the water direct from the boiler through the condensate pipe. 6 720 815 723-02.2O 6720646608-123.1Wo Fig. 15 Pressure relief pipe work Fig. 14 Drain tap positions Outside wall If the boiler uses a soakaway or a condensate pump: Drain pipe ▶... - Page 15 PRE-INSTALLATION VENTILATION BATHROOMS: This is a room sealed appliance and does not require any air for A boiler fitted without an optional timer or with no timer can be installed combustion from inside the property. in zone 2 or outside the shaded area . The requirements of BS 6798 and BS 5440 regarding ventilation do not Additional RCD (Residual Current Device) protection may be required.
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Page 16: Plumbing Manifold
PRE-INSTALLATION Plumbing manifold CONNECTIONS: Heating system: 22 mm compression fittings NOTICE: DHW: 15 mm compression fittings ▶ IF FITTING OPTIONAL INTEGRAL DIVERTER Gas: 22 mm compression fittings VALVE install the pipe work as shown in figure 18 Use the fittings supplied in the Hardware pack. (also see additional information in the document supplied with the diverter valve kit). -
Page 17: Flue Options
PRE-INSTALLATION Flue options The Greenstar CDi Classic System has the option of three horizontal Horizontal extended flue with 1x90° bends RSF (60/100 telescopic, 60/100 longer telescopic and 80/125 Flue option 3 100mmØ 125mmØ telescopic) flue systems and two vertical RSF (60/100 or 80/125) 30CDi 6,400mm 16,500mm... - Page 18 PRE-INSTALLATION 350 mm - 570 mm 130 mm Min 500 mm 300 mm Flat roof 6720643895-12.1Wo Fig. 20 6 720 815 724 (2015/11)
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Page 19: Flue Terminal Positions
PRE-INSTALLATION 3.10 Flue terminal positions All measurements in millimetres 52mm 104mm 1,500 1,500 300 300 300 300 1,200 Boundary Line Fig. 21 Flue terminal positions NOTICE: ▶ All measurements are the minimum clearances required. ▶ Terminals must be positioned so to avoid combustion products entering the building. ▶... -
Page 20: Plume Management Terminal Positions
PRE-INSTALLATION 3.11 Plume management terminal positions All measurements in millimetres Flue terminal guard 7 716 191 176 ±45° Plume re-direction: 180° Flue Exhaust Outlet 1,500 Air Intake ±80° 1,200 Boundary Line Fig. 22 Plume terminal positions NOTICE: ▶ All measurements are the minimum clearances required. ▶... -
Page 21: Installation
INSTALLATION INSTALLATION NOTICE: All the previous Pre-Installation sections must be read and requirements met before starting boiler or flue installation. Unpacking wall frame and ancillary items LIFTING AND CARRYING PRECAUTIONS: WARNING: ▶ Lift only a manageable weight, or ask for help. ▶... -
Page 22: Wall Mounting Plate And Flue Opening
INSTALLATION Wall mounting plate and flue opening FLUE OUTLET ▶ Follow the Fig. 24 to mark the centre of the flue for rear outlet (3) or CAUTION: Ensure there are no pipes, electric cables, for side outlet (4). damp proof courses or other hazards before drilling. ▶... -
Page 23: Unpacking The Appliance
INSTALLATION Unpacking the appliance 1. With the wall frame and ancillary items removed lay the carton (A) on its back. 2. Open the carton bottom flaps and fold under boiler. Do not remove the packaging base. 3. Stand carton (A) with boiler upright on the packaging base (B). 4. -
Page 24: Fitting The Appliance/Boiler Connections
INSTALLATION Fitting the appliance/boiler connections Do not lift by the top case panel. CAUTION: Isolate the mains gas supply before starting any work and observe all relevant safety precautions. GAS AND WATER CONNECTIONS: ▶ System pipes may be run vertically upwards behind the boiler or below it. -
Page 25: Flue Installation
INSTALLATION Flue installation HORIZONTAL FLUE (60/100 mm diameter) 570 mm For vertical flues and 80/125mm horizontal flues, please refer to separate Flue Kit instructions. 350 mm Apply silicone lubricant to the sealing surfaces of the flue components to ease assembly of flue components. WALL 6720643895-30.1Wo 85 mm... -
Page 26: Installing The Standard Flue
INSTALLATION 4.5.4 Installing the standard flue 4.5.5 Flue terminal plume re-direction: 1. Set the flue length to the distance required, secure with screw and The flue discharge can be re-directed allowing some plume redirection seal joint with the aluminium tape supplied. control, alternatively, a complete plume management system can be Slide the inner wall seal (1) onto the terminal (2) as shown. -
Page 27: Condensate Connection
INSTALLATION Condensate connection Never terminate or discharge into any open source, including; sink, bath, shower, bidet, toilet etc. Any external condensate pipe work of excessive runs should be protected with weather resistant insulation to help prevent freezing. ▶ Ensure that the condensate drain is 22mm diameter plastic pipe. It must fall at least 52mm per metre towards the outlet ▶... -
Page 28: Electrical (Without Diverter Valve)
▶ A fascia mounted programmer/timer should not be fitted unless optional integral diverter valve is used. ▶ Refer to manufacturers instructions when connecting external parts to the wiring centre. Worcester, Bosch Group cannot be held responsible for wiring errors. 6 720 815 724 (2015/11) -
Page 29: Electrical (With Optional Diverter Valve)
INSTALLATION Electrical (with optional diverter valve) CAUTION: ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS Danger of short circuit: When connecting the cables ensure that no cable pieces fall into the Heatronic. 230V CYLINDER STAT Mains supply to the boiler must be through a fused double pole isolator situated adjacent to the appliance. -
Page 30: Position Of Wired Components
INSTALLATION Position of wired components PRE WIRED LINK FLAME SENSE SPARK ELECTRODE ELECTRODES FLOW NTC OVERHEAT STAT FLUE OVERHEAT VALVE STAT SAFETY SOLENOID SAFETY SOLENOID PUMP CONTROL PUMP CONTROL PUMP MAINS SUPPLY Earth PUMP SUPPLY 230V EXTERNAL Neutral Supply CONTROLS WIRING Live Supply CENTRE... -
Page 31: Commissioning
COMMISSIONING 3. Check that the pressure relief connector, located on the right hand COMMISSIONING side at the bottom of the wall frame, in its up position. Pre- commissioning checks CAUTION: MAINS SUPPLIES ▶ Isolate the mains supplies before starting any work and observe all relevant safety precautions. -
Page 32: Starting The Appliance
COMMISSIONING Starting the appliance 3. If the boiler fails to light the BLUE power indicator (M) and reset button (E) will flash alternately. NOTICE: Never run the appliance when the appliance/ To reset press and hold the reset button (E) for 2 seconds. The boiler system is empty or partially filled. -
Page 33: Commissioning
COMMISSIONING ▶ The concentration level of inhibitor in the system NOTICE: THE COMBUSTION FOR THE APPLIANCE IS should be checked every 12 months or sooner if FACTORY SET. system content is lost. NO ADJUSTMENT IS REQUIRED IF THE GAS INLET ▶... -
Page 34: Checking The Gas Rate
COMMISSIONING Gas pressure within the system 5.5.2 Checking the gas rate Refer to the figure below for natural gas pressures. ▶ The gas rate should be measured at the gas meter after 10 minutes operation at maximum. The pressure at the boiler must not be less than the pressure read at the See technical data section at the front of this manual. -
Page 35: Co And Combustion Checks
▶ The air/gas ratio valve is factory set and must not be adjusted during commissioning unless this action is recommended following contact with the Worcester, Bosch Group help line 0330 123 3366. Zero the analyser > 20.6%... -
Page 36: Finishing Commissioning
COMMISSIONING Finishing commissioning The boiler has been factory set, so there should be no need to adjust combustion settings. REPLACE OUTER CASING: 1. Replace outer casing making sure that the securing points are properly located. ▶ Press the clip (A) downwards to secure casing on top. ▶... -
Page 37: Servicing And Spares
Commissioning. ▶ Operate the appliance and take note of any irregularities. Call up the last fault stored by the Bosch Heatronic, Service Function .0. Refer to Fault Finding for rectification procedures. Fig. 58 Flue integrity test... -
Page 38: Component Access
SERVICING AND SPARES 6.1.2 Component access Removing outer case 1. Remove bottom panel by pulling it forward and off. 2. Undo but do not remove the 2 screws (A) securing boiler casing at the bottom of the appliance. 3. Pull upwards to release the clip (B) on top of the boiler. 4. - Page 39 SERVICING AND SPARES reset 6720647361-23.2Wo Fig. 61 Control panel ▶ Press and HOLD performance test button (J) for 10 seconds and set Central Heating temperature to maximum. – The performance test button will illuminate continually. – The boiler will stay in this mode for 15 minutes unless the central performance test button is pressed again.
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Page 40: To Clean The Heat Exchanger
SERVICING AND SPARES 6.1.4 To Clean the Heat Exchanger ▶ Remove outer case and base panel and isolate the appliance from power. 1. Remove cleaning access cover (B), seal (C) and metal plate (D) securing it, if present. 6720803599-04.1Wo Fig. 66 ▶... -
Page 41: To Check The Diaphragm In Burner Cover
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. -
Page 42: Replacement Of Parts
SERVICING AND SPARES Replacement of parts setting setting Gas type maximum minimum CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE 30CDI Classic System THE MAINS SUPPLIES BEFORE STARTING ANY WORK Natural gas 9.6% ±0.4 9.0% ±0.4 AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. 11.5% ±0.4 10.5% ±0.4 35CDI Classic System... - Page 43 SERVICING AND SPARES Moving boiler control to service position 3. Primary sensor 1. Press in the centre of the white plastic clip securing the control panel ▶ Press retaining clip on plastic moulding and pull upwards until clear and slide down to release. of pocket in heat exchanger.
- Page 44 SERVICING AND SPARES 7. Gas valve 10. PCB fuse ▶ Isolate gas supply at boiler gas cock. ▶ Remove fuse (B) from the PCB and replace. ▶ Pull out air inlet tube (A). ▶ There is a spare fuse clipped into the cover. ▶...
- Page 45 SERVICING AND SPARES 12. Fan assembly 13. Electrode assembly NOTICE: Air/Gas ratio WARNING: Electrode gasket ▶ After re-assembly the combustion must be checked ▶ Do not remove the electrode assembly unless a new using the procedure in the section “Setting the air/ gasket is available for re-assembly.
- Page 46 SERVICING AND SPARES 15. Burner ▶ Remove the burner (H). ▶ Replace new burner in correct position. ▶ Ensure that a new seal (K) is used, refer to fig. 84. 6 720 812 175-16.1O Fig. 82 Release air/gas manifold 3. Remove air/gas manifold (I) Fig.
- Page 47 SERVICING AND SPARES 18. Diverter valve ▶ Ensure the appliance has been fully drained. ▶ Disconnect the electrical connector from the diverter valve motor. ▶ Undo the two screws holding the valve to the plastic housing. 6 720 812 175-19.1O Fig.
- Page 48 SERVICING AND SPARES 21. Pump head 25. Drain tap ▶ Ensure the appliance has been fully drained. ▶ Ensure the appliance has been fully drained. 1. Disconnect the electrical connections from the pump following 1. Withdraw the drain pipe from the drain tap. steps: To do this, remove retaining spring from the drain pipe.
- Page 49 SERVICING AND SPARES 26. Hydraulic block ▶ Ensure the appliance has been fully drained. ▶ Disconnect the electrical connections to the NTC, Turbine and pump. ▶ Undo the nuts securing the copper water pipes to the manifold (there is no need to remove the gas pipe). ▶...
- Page 50 SERVICING AND SPARES 27. ch pressure relief valve ▶ Remove the Hydraulic block from the boiler (26. Hydraulic block). 1. Remove the spring clip from the Pressure relief valve housing. 2. Withdraw the pressure release valve (A) from its housing. ▶...
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Page 51: Short Parts List
SERVICING AND SPARES Short parts list Burner Burner skin seal 8 717 204 453 0 8 718 006 658 0 8 711 004 168 0 GC No. H26 536 GC No. E27 200 GC No. E27 201 Gas valve WHS Temperature limit Electrodes 8 718 221 347 0... -
Page 52: Fault Finding & Diagnosis
This fault finding information is for guidance only. The first electrical checks to be carried out during a fault-finding procedure. Worcester, Bosch Group cannot be held responsible for On completion of the Service/Fault-Finding task which has required the costs incurred by persons not deemed to be competent. -
Page 53: Central Heating Function
FAULT FINDING & DIAGNOSIS Central heating function 6720647472-29.1Wo 6 720 815 724 (2015/11) -
Page 54: Cylinder Heat Function
FAULT FINDING & DIAGNOSIS Cylinder heat function The cylinder heat function is available only with the optional diverter valve fitted. 6720647472-30.1Wo 6 720 815 724 (2015/11) -
Page 55: Protection Function
FAULT FINDING & DIAGNOSIS Protection function Run autofroststat Boiler temperature below 8 o C function Pump runs 5 seconds Pump antiseize every 24 hours DHW demand active Holiday mode Frost protection active set to ON All other demands not active 6720647472-31.1Wo 6 720 815 724 (2015/11) - Page 56 Notes 6 720 815 724 (2015/11)
- Page 57 Notes 6 720 815 724 (2015/11)
- Page 58 SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider SERVICE 01 SERVICE 02 ² % ² % ² % ² % SERVICE 03 SERVICE 04 ² % ²...
- Page 59 GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. CONTROLS Optimum start control Fitted...
- Page 60 0330 123 9119 TRAINING: 0330 123 0166 SALES: 0330 123 9669 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 6 720 815 724...