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INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS
WALL HUNG RSF GAS FIRED CONDENSING REGULAR BOILER
GREENSTAR CDi CLASSIC REGULAR
FOR OPEN VENTED AND SEALED CENTRAL HEATING SYSTEMS AND INDIRECT 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 Regular
40CDi Classic Regular
LIQUID PETROLEUM GAS:
30CDi Classic Regular
40CDi Classic Regular
UK/IE
ErP
ErP
GC Number 41-406-33
ErP
GC Number 41-406-35
ErP
GC Number 41-406-34
ErP
GC Number 41-406-36
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Table of Contents
Related Manuals for Bosch Worcester GREENSTAR CDi CLASSIC REGULAR ErP Series
Summary of Contents for Bosch Worcester GREENSTAR CDi CLASSIC REGULAR ErP Series
- Page 1 INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS WALL HUNG RSF GAS FIRED CONDENSING REGULAR BOILER GREENSTAR CDi CLASSIC REGULAR FOR OPEN VENTED AND SEALED CENTRAL HEATING SYSTEMS AND INDIRECT DOMESTIC HOT WATER THE APPLIANCE IS FOR USE WITH NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13 &...
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Page 2: Table Of Contents
CONTENTS CONTENTS KEY TO SYMBOLS AND SAFETY PRECAUTIONS ... . 3 SERVICING AND SPARES ......34 Key to symbols . -
Page 3: Key To Symbols And Safety Precautions
KEY TO SYMBOLS AND SAFETY PRECAUTIONS PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE KEY TO SYMBOLS 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 KEY TO SYMBOLS AND SAFETY PRECAUTIONS their needs, that it is installed, commissioned and serviced in BS7593 - Treatment of water in domestic hot water central heating accordance with the manufacturer's instructions by competent persons systems and that it meets the requirements of the appropriate Building BS6798 - Installation of gas fired boilers of rated input up to 70kW (net) Regulations.
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Page 5: Appliance Information
APPLIANCE INFORMATION APPLIANCE INFORMATION General information Boiler features and checklist • Pre-plumbed • Galvanised steel inner frame • Digital control system • Automatic ignition • Direct burner ignition electrodes • Built-in frost protection • Built-in fault finding diagnostics • Automatic gas valve •... -
Page 6: Technical Data
APPLIANCE INFORMATION TECHNICAL DATA NATURAL GAS L.P.G 30CDi Classic 40CDi Classic 30CDi Classic 40CDi Classic Product type Regular Regular Regular Regular Heating Max. rated heat input 30.9 42.0 30.9 42.0 Max. rated heat output net 40/30°C 32.1 43.7 32.1 43.7 Max. -
Page 7: 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 7 738 100 245 7 738 100 235 7 738 100 232 7 738 100 234 Product type –... -
Page 8: Layout & Components
PRE-INSTALLATION Layout & components [11] Flow [12] Trap / Siphon [13] Condensate hose (22 mm outlet connection) [14] Inlet pressure test point [15] Gas valve [16] Air/gas adjustment screw [17] Testing point for fan pressure [18] Fan [19] Primary sensor [20] Auto air vent [21] Removable top case for servicing [22] Blank plate... -
Page 9: Mains Supply
PRE-INSTALLATION ▶ Run the boiler/system at normal operating temperature as directed WATER SYSTEMS & PIPE WORK by the manufacturer of the flushing agent. PLASTIC PIPEWORK: ▶ Drain and thoroughly flush the system to remove the flushing agent • Any plastic pipe work must have a polymeric barrier with 600 mm and debris. - Page 10 PRE-INSTALLATION S AND Y PLAN SYSTEM: NOTICE: Bypass ▶ Generally a bypass is not necessary on a Y plan system as one of the ports is open to flow. Static head - Minimum static head 250mm measured from the highest point in the heating system (top surface of the appliance or the highest point in the heating system) to the water level in the feed and expansion tank...
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Page 11: 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 22mm Ø... -
Page 12: External Connections
PRE-INSTALLATION 3.4.2 External connections FITTING AN EXTERNAL AIR BREAK • Refer to figure 14 when a rain water down pipe is used to dispose of NOTICE: Freezing conditions condensate. ▶ When the position of the boiler prevents internal • An air break must be installed in the 43mm pipe work, between the routing, we recommend installing a CondenseSure boiler condensate outlet and the drainpipe, outside the property, to siphon to significantly reduce the risk of freezing. -
Page 13: Boiler Internal Drain
PRE-INSTALLATION CONDENSATE SOAK AWAY Boiler internal drain • The condensate drainage pipe may be run above or below the ground The CDI Regular has the facility to drain the water direct from the to the soak away. The examples shown on this page run above boiler through the condensate pipe. -
Page 14: Plumbing Manifold
PRE-INSTALLATION Do not operate the appliance if the flue terminal fitted on the outside wall PLUMBING MANIFOLD or roof is obstructed or damaged. CONNECTIONS: Heating System: 22mm compression fittings 960mm Gas: 22mm compression fittings 20mm* Use the fittings supplied in the Hardware pack. PREPLUMBING With the plumbing manifold installed, pipe work can be installed to the valves on the manifold. -
Page 15: Flue Options
PRE-INSTALLATION Flue options The Greenstar CDi Classic Regular 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 16 PRE-INSTALLATION 350 mm - 570 mm 130 mm Min 500 mm 300 mm Flat roof 6720643895-12.1Wo Fig. 21 6 720 815 723 (2015/05)
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Page 17: Flue Terminal Positions
PRE-INSTALLATION Flue terminal positions All measurements in millimetres 52mm 104mm 1,500 1,500 300 300 300 300 1,200 Boundary Line Fig. 22 Flue terminal positions NOTICE: ▶ All measurements are the minimum clearances required. ▶ Terminals must be positioned so to avoid combustion products entering the building. ▶... -
Page 18: Plume Management Terminal Positions
PRE-INSTALLATION 3.10 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. 23 Plume terminal positions NOTICE: ▶ All measurements are the minimum clearances required. ▶... -
Page 19: 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 20: Wall Mounting Plate And Flue Opening
INSTALLATION Wall mounting plate and flue opening FLUE OUTLET ▶ Follow the Fig. 25 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 21: 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 22: Fitting The Appliance Boiler Connections
INSTALLATION Do not use the frame as a handle 6 720 815 725-11.1O Fig. 28 Fitting the appliance boiler connections CAUTION: Isolate the mains gas supply before starting any work and observe all relevant safety precautions. GAS AND WATER CONNECTIONS: •... - Page 23 INSTALLATION Do not lift by the top case panel Handling hole (both sides) 6 720 815 723-04.1O Fig. 30 Hang the boiler 3. Lower the control panel into the service position by releasing the white catch on the retaining bracket. 4.
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Page 24: 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. 570 mm 350 mm Apply silicone lubricant to the sealing surfaces of the flue components to ease assembly of flue components. WALL 85 mm 6720643895-30.1Wo... -
Page 25: 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 26: Condensate Connection
• An adaptor (A) in 22 mm pipe is contained in the fitting pack. instructions. ▶ Refer to manufacturers instructions when connecting external parts to the wiring centre. Worcester, Bosch Group cannot be held responsible for wiring errors. 6 720 815 723 (2015/05) - Page 27 INSTALLATION The mains supply to the boiler must be fed through a fused double pole isolator situated adjacent to the appliance. The isolator must have a contact separation of 3 mm minimum in all poles. 8. External Pump (ST2): ▶ Connect NEUTRAL wire to terminal (Nz) ▶...
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Page 28: 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 MAINS SUPPLY PUMP SUPPLY Earth 230V EXTERNAL CONTROLS Neutral Supply WIRING Live Supply CENTRE Live Return Colour sequence CH TEMPERATURE CONTROL... -
Page 29: Commissioning
COMMISSIONING Filling the system COMMISSIONING 1. Ensure all system and boiler drain points are closed. 2. For sealed systems fill the system using a WRAS approved filling loop Pre-commissioning checks to a pressure of 1 bar. CAUTION: Isolate the mains gas supply before starting 3. -
Page 30: Starting The Appliance
COMMISSIONING STARTING THE APPLIANCE 3. Run the boiler/system at normal operating temperature for the time stated by the manufacturer of the flushing agent. NOTICE: Never run the appliance when the appliance/ 4. Drain and thoroughly flush the system to remove the flushing agent system is empty or partially filled. -
Page 31: Checking The Gas Inlet Pressure
COMMISSIONING 5.6.1 Checking the gas inlet pressure Refer to the figure below for L.P.G gas pressures. The inlet pressure to the appliance must be checked using the following The pressure at the boiler must not be less than the pressure read at the procedure: meter minus 2.5 mbar. -
Page 32: 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 Set boiler to >... -
Page 33: 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 34: Servicing And Spares
Refill and re-pressurise if applicable as described in 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. 54 Flue integrity test... -
Page 35: Component Access
SERVICING AND SPARES 6.1.3 Component Access Adjusting boiler control to service position. Removing outer case 1. Pull down the catch securing the control panel. 1. Remove bottom panel by pulling it forward and off. 2. Gently pull forward until it comes to rest in service position. 2. -
Page 36: To Clean The Heat Exchanger
SERVICING AND SPARES 2. Loosen any deposits in the heat exchanger from top to bottom using the cleaning blade. Fig. 58 Fan pressure test point • Pressure readings in the black area will indicate that the heat exchanger requires attention/cleaning. •... -
Page 37: To Check The Diaphragm In Burner Cover
SERVICING AND SPARES 6.1.7 To Check the Diaphragm in Burner Cover 4. Carefully withdraw diaphragm (J) from fan intake tube and check for soiling and splits. ▶ Refit diaphragm (J) the correct way round into the fan intake tube 6 720 812 175-15.1O Fig. -
Page 38: Setting The Air/Gas Ratio
SERVICING AND SPARES Setting the air/gas ratio NOTICE: Air/Gas ratio ▶ The setting of the gas ratio must be carried out by a adjust 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. -
Page 39: Replacement Of Parts
SERVICING AND SPARES Replacement of parts CAUTION: Isolate the mains gas supply before starting any work and observe all relevant safety precautions. NOTICE: After replacement of any components always check for gas tightness where relevant and carry out functional checks as described in commissioning. Any O-rings or gaskets that are disturbed during servicing must be replaced. - Page 40 SERVICING AND SPARES 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. ▶ Undo two securing screws (D)on the underside of casing. ▶...
- Page 41 SERVICING AND SPARES 9. ACCESS TO BOILER CONTROL COMPONENTS 12. Fan assembly ▶ Remove 3 screws (A) and remove cover from control. NOTICE: Air/Gas ratio 10. PCB fuse ▶ After re-assembly the combustion must be checked using the procedure in the section “Setting the air/ ▶...
- Page 42 SERVICING AND SPARES 13. Electrode assembly WARNING: Electrode gasket ▶ Do not remove the electrode assembly unless a new gasket is 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 43 SERVICING AND SPARES ▶ Refer to section 6.1.8 “Re-assembly of the burner cover” ▶ Ensure that a new seal (K) is used, refer to fig. 81. 6 720 812 174-23.1O Fig. 85 Heat exchanger removal 3 19. DRAIN TAP ▶ Remove clip (G) ▶...
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Page 44: Short Parts List
SERVICING AND SPARES Short parts list Burner 8 717 204 453 0 8 718 006 658 0 GC No. H26 536 GC No. E27 200 Burner skin seal Gas valve 8 711 004 166 0 8 718 221 347 0 GC No. -
Page 45: Fault Finding & Diagnosis
This fault finding information is for guidance only. On completion of the Service/Fault-Finding task which has required the Worcester Bosch cannot be held responsible for costs breaking and remaking of electrical connections, check: incurred by persons not deemed to be competent. -
Page 46: Heating Function
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 47 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 48 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 6 720 815 723 (2015/05)