Worcester 29CDi Classic Installation, Commissioning And Servicing Instructions

Greenstar cdi classic erp wall hung rsf gas fired condensing combination boiler

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Page 1 FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER The appliances are for use with: Natural Gas or L.P.G. (Cat. II 2H3P type C13, C33 & C53) Natural Gas: 29CDi Classic GC number 47-406-65 34CDi Classic GC number 47-406-67...
Page 2: Table Of Contents
CONTENTS CONTENTS KEY TO SYMBOLS ........3 COMMISSIONING .
Page 3: Key To Symbols
If you are in any doubt, contact the Worcester Technical helpline (0330 123 3366). The following keywords are defined and can be used in this document: Please leave these instructions with the completed BENCHMARK •...
Page 4 KEY TO SYMBOLS manufacturer's instructions by competent persons and that it meets the All radiators must have TRVs fitted, where reasonable, in all rooms requirements of the appropriate Building Regulations. except bathrooms and rooms with thermostats. The Benchmark Checklist can be used to demonstrate compliance with BUILDING REGULATIONS PART L 1B 2013 - BOILER REPLACEMENT Building Regulations and should be provided to the customer for future For boiler replacement on an existing system, it is not necessary to zone...
Page 5: Appliance Information
APPLIANCE INFORMATION APPLIANCE INFORMATION GENERAL INFORMATION STANDARD PACKAGE: Wall hung gas fired condensing combi boiler for central heating and domestic hot water Wall mounting plate with hanging bracket Pre-plumbing manifold Hardware pack ErP energy label Literature pack - Installation instructions - User instructions - Wall mounting template Bottom panel...
Page 6: Layout & Components
APPLIANCE INFORMATION LAYOUT & COMPONENTS 6 720 815 725-06.1O Fig. 3 Boiler components 6 720 815 725 (2015/05)
Page 7 APPLIANCE INFORMATION The diagram opposite shows the controls in the servicing position and excludes the outer case REMOVABLE TOP CASE PANEL FOR SERVICING IGNITION ELECTRODES AND FLAME SENSE ELECTRODE HEAT EXCHANGER OVERHEAT THERMOSTAT reset ACCESS POINT FOR CLEANING HEAT EXCHANGER PLATE TO PLATE DHW HEAT EXCHANGER LOW ENERGY MODULATING PUMP PRESSURE RELIEF VALVE...
Page 8: Technical Data
APPLIANCE INFORMATION TECHNICAL DATA NATURAL GAS L.P.G 29CDi 34CDi 38CDi 42CDi 29CDi 34CDi 38CDi 42CDi Classic Classic Classic Classic Product type Classic Classic Classic Classic Domestic hot water Min. heat input 11.5 11.5 14.5 14.5 Max. rated heat output 30.9 35.0 40.0 42.0...
Page 9: Product Data On Energy Consumption
APPLIANCE INFORMATION NATURAL GAS L.P.G 29CDi 34CDi 38CDi 42CDi 29CDi 34CDi 38CDi 42CDi Classic Classic Classic Classic Product type Classic Classic Classic Classic Appliance protection rating with mechanical or RF mech. timer fitted Permissible ambient temperatures °C 0-50 0-50 0-50 0-50 0-50 0-50...
Page 10: Pre-Installation
PRE-INSTALLATION Product data Symbol Unit 7 738 100 252 7 738 100 253 7 738 100 246 7 738 100 247 Product type – – 38CDi 38CDi 42CDi 42CDi Classic Classic Classic Classic Condensing boiler – – Combination heater – –...
Page 11: Mains Supply
(3) and the boiler (4) as shown below ▶ In cases where all attempts to find a micro leak have failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer. WATER TREATMENT PRODUCTS...
Page 12: Water Systems And Pipe Work
PRE-INSTALLATION WATER SYSTEMS AND PIPE WORK TYPICAL SEALED SYSTEM PLASTIC PIPE WORK: • Any plastic pipe work must have a polymeric barrier with 600mm (minimum) length of copper pipe connected to the boiler. • Plastic pipe work used for underfloor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approximately 50 °C.
Page 13: Condensate Pipe Work
PRE-INSTALLATION CONDENSATE PIPE WORK NOTICE: ▶ Where a new or replacement boiler is being installed, access to an internal “gravity discharge” point should be one of the factors considered in determining boiler location. ▶ The condensate pipe must be nominally 100mm 22mm Ø...
Page 14: External Connections
PRE-INSTALLATION 3.4.2 EXTERNAL CONNECTIONS NOTICE: Freezing conditions ▶ When the position of the boiler prevents internal routing, we recommend installing a CondenseSure siphon to significantly reduce the risk of freezing. ▶ Pipe work length should be kept to a minimum and the route as vertical as possible.
Page 15: Boiler Internal Drain
PRE-INSTALLATION BOILER INTERNAL DRAIN NOTICE: Unheated internal areas. The CDI Classic has the facility to drain the water direct from the ▶ Internal pipe runs in unheated areas such as lofts, boiler through the condensate pipe. basements and garages should be treated as external runs and consideration should be given to using a CondenseSure siphon.
Page 16: Pressure Relief Pipe Work
600mm** For installations in a cellar or basement, there is an accessory that is available from Worcester that allows the pressure relief valve to be fitted remotely from the boiler. This accessory can be used when there is difficulty accessing an external drain.
Page 17: Plumbing Manifold
PRE-INSTALLATION BATHROOMS: A boiler fitted with a non-mechanical timer or with no timer can be installed in zone 2 or outside the shaded area. A boiler with a mechanical timer or RF mechanical timer with room thermostat must only be installed outside the shaded area. Additional RCD (Residual Current Device) protection may be required.
Page 18: Flue Options
Horizontal extended flue with 2x90° bends maximum of 4500mm of plume management. Flue option 4 100mmØ 125mmØ For example on a 29CDi Classic if the plume management effective 29CDi 4,900mm 14,500mm length was 1500mm, the internal flue would be reduced to 5200mm.
Page 19 PRE-INSTALLATION 350 mm - 570 mm 130 mm Min 500 mm 300 mm Flat roof 6720643895-12.1Wo Fig. 22 6 720 815 725 (2015/05)
Page 20: 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. 23 Flue terminal positions NOTICE: ▶ Check the internal lengths against the plume management required, refer to section 3.9 for more information, flue lengths become significantly shorter with increasing plume management length.
Page 21: 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. 24 Plume terminal positions NOTICE: ▶ All measurements are the minimum clearances required. ▶...
Page 22: Installation
INSTALLATION INSTALLATION WARNING: 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 23: Unpacking The Appliance
INSTALLATION UNPACKING THE APPLIANCE 1. With the wall frame and ancillary items removed (see section 4.1), 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: Wall Mounting Plate And Flue Opening
INSTALLATION WALL MOUNTING PLATE AND FLUE OPENING FLUE OUTLET ▶ Follow the Fig. 28 to mark the centre of the flue for rear outlet (3) or CAUTION: for side outlet (4). ▶ Ensure there are no pipes, electric cables, damp ▶...
Page 25: Fitting The Appliance/Boiler Connections
INSTALLATION FITTING THE APPLIANCE/BOILER CONNECTIONS Do not lift by the CAUTION: Isolate the mains gas supply before starting top case panel. 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 26: Flue Installation
INSTALLATION FLUE INSTALLATION HORIZONTAL FLUE (60/100mm diameter) For vertical flues and 80/125mm horizontal flues, please refer to separate Flue Kit instructions. 635mm Apply silicone lubricant to the sealing surfaces of the Min. 500mm flue components to ease assembly of flue components. cut length WALL 85 mm...
Page 27: 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 28: 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 29: Electrical
INSTALLATION ELECTRICAL 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 inside the control panel. Mains supply to the boiler must be through a fused double pole isolator situated next to the appliance.
Page 30: Position Of Wired Components
Blue FROST STAT ST17 Yellow Green (OPTIONAL) Black Yellow EMS BUS contacts Grey Blue (for FX/Sense controls) Black WORCESTER 24V CONTROLS OPTION, PLUG IN POINT (under blanking cover on fascia) Grey White 230V~ Black Orange Orange Orange Orange White Black...
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, is in the up position. PRE-COMMISSIONING CHECKS CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS 1.
Page 32: Starting The Appliance
COMMISSIONING ▶ Once the system has been filled to a pressure of 1.5 bar push the lever [1] back into closed position. reset 6 720 812 176-13.1O Fig. 49 Stop filling the system ▶ Vent all radiators, retighten when completed and check the system 6720647361-23.2Wo and correct any leaks.
Page 33: Water Treatment
▶ In cases where all attempts to find a micro leak have failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer. 6 720 815 725 (2015/05)
Page 34: Checking The Gas Inlet Pressure
COMMISSIONING 5.5.1 CHECKING THE GAS INLET PRESSURE Meter Gas Control The inlet pressure to the appliance must be checked using the following Natural Gas valve procedure: < 2.5mbar difference MEASURING THE INLET PRESSURE 19 - 23 mbar 16.5 - 20.5 mbar Boiler inlet 1 mbar 1.5 mbar...
Page 35: Checking The Gas Rate
COMMISSIONING 5.5.2 CHECKING THE GAS RATE ▶ The gas rate should be measured at the gas meter after 10 minutes operation at maximum. See technical data section at the front of this manual. – Press the Performance test button (J) for more than ten seconds and set Central Heating temperature to maximum.
Page 36: Co And Combustion Checks
Check and zero the analyser in fresh air as specified by the manufacturer. ▶ 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 Set boiler to >...
Page 37: 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 38: Servicing And Spares
SERVICING AND SPARES 6.1.1 CHECKING FLUE INTEGRITY SERVICING AND SPARES The integrity of the flue system and performance of the boiler can be checked via the flue turret sample points. CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE Flue gas sample point THE MAINS SUPPLIES BEFORE STARTING ANY WORK Air inlet sample point AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.
Page 39: 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 two 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 40: To Clean The Heat Exchanger
SERVICING AND SPARES ▶ Press and HOLD the Performance test button (J) for 10 seconds and NOTICE: Air/Gas ratio set Central Heating temperature to maximum. ▶ After servicing the CO/CO must be checked using – The Performance test button will illuminate continually. the procedure in the section “Setting the air/gas –...
Page 41: To Clean The Burner
SERVICING AND SPARES 3. Clean the heat exchanger from top to bottom using the brush. 6 720 812 175-16.1O Fig. 68 3. Remove the burner (H) and clean components. Do not use a wire brush. 6720803599-04.1Wo ▶ Refit the clean out cover plates in reverse order using a new seal (C) and tighten screws.
Page 42: To Clean The Condensate Trap
6.1.7 TO CLEAN THE CONDENSATE TRAP Gas type setting maximum CO setting minimum 1. Pull condensate hose out of the trap. Greenstar 29CDi Classic and 34CDi Classic 2. Remove trap from boiler. Natural gas 9.6% ±0.4 9.0% ±0.4 ▶ Clean trap and check that the heat exchanger connection is clear.
Page 43: Replacement Of Parts
SERVICING AND SPARES REPLACEMENT OF PARTS MOVING BOILER CONTROL TO SERVICE POSITION CAUTION: 1. Press in the centre of the white plastic clip securing the control panel ▶ TURN OFF THE GAS SUPPLY AND ISOLATE THE and slide down to release. MAINS SUPPLIES BEFORE STARTING ANY WORK 2.
Page 44 SERVICING AND SPARES 6 720 815 725-21.1O Fig. 74 Replacing parts 7. GAS VALVE ▶ Isolate gas supply at boiler gas cock. ▶ Pull out air inlet tube (A). ▶ Undo top gas connection (B) to gas valve. ▶ Undo bottom gas connection (C) to gas valve. ▶...
Page 45 SERVICING AND SPARES 8. SIPHON To remove and replace the siphon: ▶ Pull condensate hose out of the trap. ▶ Remove siphon from the boiler. ▶ Fit the new siphon to the sump and ensure that condensate discharge pipe is firmly connected to the outlet pipe work. Fig.
Page 46 SERVICING AND SPARES 13. ELECTRODE ASSEMBLY WARNING: Electrode gasket ▶ Do not remove the electrode assembly unless a new gasket and heatshield are available for re-assembly. ▶ Disconnect spark electrodes and flame sensor connection. ▶ Remove two screws (F). ▶ Remove spark/flame electrode assembly (G) from heat exchanger. ▶...
Page 47 SERVICING AND SPARES 15. BURNER 3. Remove screw at the top of the heat exchanger (C). ▶ Remove the burner (H). ▶ Unscrew the flow pipe (D). ▶ Replace new burner in correct position. ▶ Ensure that a new seal (K) is used, refer to fig. 84. 6 720 812 175-19.1O Fig.
Page 48 SERVICING AND SPARES 18. DIVERTER VALVE 20. DHW TEMPERATURE SENSOR ▶ Ensure the appliance has been fully drained. ▶ Ensure the domestic hot water circuit is fully drained. ▶ Disconnect the electrical connector from the diverter valve motor. ▶ Disconnect the electrical connection from the sensor. ▶...
Page 49 SERVICING AND SPARES 22. PRESSURE GAUGE 25. DRAIN TAP ▶ Ensure the appliance has been fully drained. ▶ Ensure the appliance has been fully drained. ▶ Withdraw the spring clip from the pressure sensing head housing. 1. Withdraw the drain pipe from the drain tap. To do this, remove retaining spring from the drain pipe.
Page 50 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 51 SERVICING AND SPARES 27. CH PRESSURE RELIEF VALVE 28. PLASTIC PROTECTION DEVICE ▶ Remove the Hydraulic block from the boiler ( 26. Hydraulic Block). ▶ Ensure the system is fully drained. ▶ Disconnect all pipes connected to the pump housing. 1.
Page 52: Short Parts List
SERVICING AND SPARES 29. DHW HEAT EXCHANGER ▶ Remove the Hydraulic block from the boiler (See Removing the Hydraulic Block). ▶ Undo the two screws (B) securing the plastic housings to the heat exchanger. ▶ Remove the heat exchanger. ▶ To refit, follow the above in reverse. ▶...
Page 53 SERVICING AND SPARES Diverter valve Diverter valve motor Control sensor - assembly8 716 106 8 716 106 847 0 primary8 714 500 845 0 GC No. H02 534 087 0 GC No. H02 533 GC No. E74 536 Heat Exchanger Pressure relief valve Auto Air Vent inspection cover seal...
Page 54: Fault Finding & Diagnosis
When a hot tap is turned on and only cold water is delivered, and the Worcester, Bosch Group cannot be held responsible for boiler does not fire up, the first thing to check would be to see if the hot costs incurred by persons not deemed to be competent.
Page 55: Central Heating Function
FAULT FINDING & DIAGNOSIS CENTRAL HEATING FUNCTION 6720647361-59.2Wo 6 720 815 725 (2015/05)
Page 56: Preheat And Dhw Function
FAULT FINDING & DIAGNOSIS PREHEAT AND DHW FUNCTION 6720647361-60.2Wo 6 720 815 725 (2015/05)
Page 57: Protection Function
FAULT FINDING & DIAGNOSIS PROTECTION FUNCTION Run autofroststat Boiler temperature function below 8 Pump runs for Pump antiseize 5 seconds every 24 hours DHW demand active Holiday mode Frost protection active set to ON All other demands not active 6720647361-61.1Wo 6 720 815 725 (2015/05)
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
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 0166 SALES: SALES: 0330 123 9669 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 6 720 815 725 (2015/05)

This manual is also suitable for:

34cdi classic 42cdi classic 38cdi classic

Worcester 29CDi Classic Installation, Commissioning And Servicing Instructions

1 Key to Symbols

2 Appliance Information

3 Pre-Installation

4 Installation

Commissioning

6 Servicing and Spares

Fault Finding & Diagnosis