Bosch WORCESTER GREENSTAR CDi Instruction Manual

Wall hung rsf gas-fired condensing combination boiler

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Instruction manual (60 pages)

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INSTRUCTION MANUAL

INSTALLATION, COMMISSIONING & SERVICING

WALL HUNG RSF GAS-FIRED CONDENSING COMBINATION BOILER

GREENSTAR CDi

FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER

THE APPLIANCE IS FOR USE WITH

NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13, C33 & C53)

NATURAL GAS:

LIQUID PETROLEUM GAS:

UK/IE

27CDi GC NUMBER 47-406-12

30CDi GC NUMBER 47-406-14

37CDi GC NUMBER 47-406-08

42CDi GC NUMBER 47-406-10

27CDi GC NUMBER 47-406-13

30CDi GC NUMBER 47-406-15

37CDi GC NUMBER 47-406-09

42CDi GC NUMBER 47-406-11

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Page 1 INSTRUCTION MANUAL INSTALLATION, COMMISSIONING & SERVICING WALL HUNG RSF GAS-FIRED CONDENSING COMBINATION BOILER GREENSTAR CDi FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER THE APPLIANCE IS FOR USE WITH NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13, C33 & C53) NATURAL GAS: 27CDi GC NUMBER 47-406-12 30CDi GC NUMBER 47-406-14...
Page 2: Contact Information
THIS APPLIANCE MUST BE INSTALLED BY A CORGI REGISTERED, COMPETENT PERSON. FAILURE TO INSTALL CORRECTLY COULD LEAD TO PROSECUTION. IF YOU ARE IN ANY DOUBT CONTACT WORCESTER, BOSCH GROUP TECHNICAL WATER TREATMENT: HELPLINE. DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER FERNOX 01799 550811 BOSCH.
Page 3: Table Of Contents
SETTING THE AIR/GAS RATIO SHORT PARTS LIST CONVERSION KITS L.P.G. CONVERSION FAULT FINDING & DIAGNOSIS FAULT FINDING CENTRAL HEATING FUNCTION PREHEAT AND DHW FUNCTION PROTECTION FUNCTION INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi CONTENTS 6 720 614 564b (2008/02)
Page 4: Safety Precautions
WRAS. IMPORTANT: ARTIFICIALLY SOFTENED WATER MUST NOT BE USED TO FILL THE CENTRAL HEATING SYSTEM INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi SAFETY PRECAUTIONS 6 720 614 564b (2008/02) & INSTALLATION REGULATIONS...
Page 5: General Information
Pump anti-seizure protection Flue gas temperature limiter Condensate trap & syphon DHW flow sensor & temperature control Plate type DHW heat exchanger Modulating circulating pump INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi GENERAL INFORMATION 6 720 614 564b (2008/02)
Page 6: Technical Data
Noise output level (at DHW inlet pressure 3 bar) dB(A) Total boiler weight (lift weight) 48.5 48.5 48.5 48.5 48.5 48.5 48.5 48.5 Packaged boiler weight INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi TECHNICAL DATA 6 720 614 564b (2008/02)
Page 7: Layout & Components
24 AIR / GAS ADJUSTMENT SCREW 25 TESTING POINT FOR FAN PRESSURE 26 FAN 27 PRIMARY SENSOR 28 EXPANSION VESSEL 29 REMOVABLE TOP CASE PANEL FOR SERVICING INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi LAYOUT & COMPONENTS 6 720 614 564b (2008/02)
Page 8 58 SYSTEM PRESSURE GAUGE 59 POSITION FOR OPTIONAL TEXT DISPLAY WITH INTELLIGENT FUNC- TIONALITY OR TIMER 60 DISPLAY 6 720 614 562-02.1O INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi LAYOUT & COMPONENTS 6 720 614 564b (2008/02)
Page 9: Cleaning Primary Systems
• Drain and thoroughly flush the system to remove the flushing agent and debris. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi CLEANING PRIMARY SYSTEMS 6 720 614 564b (2008/02)
Page 10: Mains Supplies
In such circumstances, the advice of the local water authority should be sought. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi MAINS SUPPLIES 6 720 614 564b (2008/02)
Page 11: Water Systems & Pipework
6 720 611 927 - 02.1O • Do not use galvanised pipes or radiators. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi WATER SYSTEMS & PIPEWORK 6 720 614 564b (2008/02)
Page 12: Condensate Pipework
M & F bend and the drainpipe, outside the property, to avoid flooding during adverse weather conditions. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi CONDENSATE PIPEWORK 6 720 614 564b (2008/02)
Page 13: Pressure Relief Pipework
6 720 611 927 - 03.1O (L), as shown, to help prevent freezing. • Use waterproof pipe insulation in exposed positions and for external pipework. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi BOILER LOCATION & CLEAR- 6 720 614 564b (2008/02) ANCES...
Page 14: Servicing Clearances
Electrical switches, fused spur and socket outlets must not be situated in the 600mm radius bathroom. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi BOILER LOCATION & CLEARANCES 6 720 614 564b (2008/02)
Page 15: Plumbing Manifold
CH flow 22 mm DHW Out 15 mm Mains Gas Supply 22 mm CH return 22 mm Mains Water In 15 mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi PLUMBING MANIFOLD 6 720 614 564b (2008/02)
Page 16: Flue Terminal Positions
52mm fall 104mm fall or at least 52mm for each metre away from the boiler to ensure condensate flows back into the boiler. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi FLUE TERMINAL POSITIONS 6 720 614 564b (2008/02)
Page 17 2 metres from the ground or if a person could come into contact with the flue terminal. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi FLUE OPTIONS 27CDi 6 720 614 564b (2008/02)
Page 18: Flue Options
125mmØ 37 CDi 4,600mm 14,400mm 27 CDi 8,000mm 21,000mm 42 CDi 12,000mm 30 CDi 5,000mm 14,000mm 37 CDi 3,700mm 15,200mm 42 CDi 10,500mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi FLUE OPTIONS 6 720 614 564b (2008/02)
Page 19: Important Handling Instructions
Before installing appliance ensure system 6 720 614 039-04.1O has been cleaned as explained on page 9. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi UNPACKING WALL FRAME AND 6 720 614 564b (2008/02) ANCILLARY ITEMS...
Page 20: Wall Mounting Plate Flue Opening
Clear away any debris. FIXING THE PRE-PLUMBING MANIFOLD: Mount the pre-plumbing manifold on the 2 lower screws and secure the screws. Pre-plumbing manifold INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi WALL MOUNTING PLATE 6 720 614 564b (2008/02) FLUE OPENING...
Page 21: Charging Link (Filling Loop)
Blanking Plug Stop Tab Charging Link Assembly Mains Water Control Inlet Connection Screw Charging Key M4 Screw Charging and Washer Filter Stop Tab INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi CHARGING LINK (FILLING LOOP) 6 720 614 564b (2008/02)
Page 22: Unpacking The Appliance
10. Remove the outer case. 11. Remove the protective packaging (G) from the electrode assembly. Do not use the frame as handle INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi UNPACKING THE APPLIANCE 6 720 614 564b (2008/02)
Page 23: Gas And Water Connections
22mm 15mm 22mm 15mm 22mm bracket to secure in place. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi FITTING THE APPLIANCE 6 720 614 564b (2008/02) BOILER CONNECTIONS...
Page 24: Flue Installation
Ø60mm PLUME MANAGEMENT KIT (7-716-191-086) replaces the plume deflector in the Ø60/100mm telescopic flue terminal. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi FLUE INSTALLATION 6 720 614 564b (2008/02)
Page 25 NOTE: The aluminium tape is not required when reducing the terminal. 130mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi FLUE INSTALLATION 6 720 614 564b (2008/02)
Page 26: Top View
This is to allow condensate to run back into the boiler for safe disposal. Do not attempt to force the terminal outlet beyond the limit stops. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi FLUE INSTALLATION 6 720 614 564b (2008/02)
Page 27: Condensate Connection
It must fall at least 50 mm per metre towards the outlet. • An adaptor (A) in 22 mm pipe is contained in the fitting pack. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi CONDENSATE CONNECTION 6 720 614 564b (2008/02)
Page 28: Electrical
9. Refit control panel cover: Refit panel and secure with screws (B). Bring the control panel to its upper position and fix it with screw (A). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi ELECTRICAL 6 720 614 564b (2008/02)
Page 29: Position Of Wired Components
Fuse, slow T 0.5 A Orange Orange Orange 230V/AC Orange Fuse, slow T1.6 A White Black Purple ST18 DIAGNOSTIC CODE INTERFACE 6 720 612 485-01.1O PLUG INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi POSITION OF WIRED 6 720 614 564b (2008/02) COMPONENTS...
Page 30: Pre-Commissioning Checks
Stop in locked position 22mm 15mm 22mm 15mm 22mm INSTALLATION & SERVICING INSTRUC- TIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi PRE-COMMISSIONING CHECKS 6 720 614 564b (2008/02)
Page 31: Gas Supply
Open gas cock on the boiler and purge the gas supply to the boiler ensuring that the room is well ventilated. Test gas supply for soundness as described in BS 6891. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi FILLING THE SYSTEM 6 720 614 564b (2008/02)
Page 32: Starting The Appliance
To reset press and hold the reset button (E) for 2 seconds. The boiler will be reset. CAUTION: DO NOT PRESS POWER INDICATOR (B) TO RESET BOILER. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi STARTING THE APPLIANCE 6 720 614 564b (2008/02)
Page 33: Water Treatment
* compatible with aluminium. The pH value of the system water must be less than 8 or the appliance guarantee will be invalidated. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi WATER TREATMENT 6 720 614 564b (2008/02)
Page 34: Commissioning
Inlet Test Nipple When the ECO button is illuminated the M - Holiday button boiler will be in Economy mode with pre-heat no longer active. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi COMMISSIONING 6 720 614 564b (2008/02)
Page 35: Finishing Commissioning
If the appliance is unused and exposed to freezing conditions; shut off all the mains supplies and drain the system and boiler. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi FINISHING COMMISSIONING 6 720 614 564b (2008/02)
Page 36: Inspection And Service
Call up the last fault stored by the Bosch Heatronic, Service Function .0. Refer to Fault Finding for rectification procedures. 6720611927-07.1O INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi INSPECTION AND SERVICE 6 720 614 564b (2008/02)
Page 37: Component Access
30CDi - 4.1 mbar 37CDi - 3.9 mbar 42CDi - 4.8 mbar Pressures measured below these figures will indicate that the heat exchanger will require cleaning. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi INSPECTION AND SERVICE 6 720 614 564b (2008/02)
Page 38 • There is a special accessory kit available specifically designed for cleaning the heat exchanger. If required order 7 719 001 996. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi INSPECTION AND SERVICE 6 720 614 564b (2008/02)
Page 39 2.2 Clean the heat exchanger from top to bottom using the brush. Refit the clean out coverplates in reverse order using a new seal (C) and tighten screws. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi INSPECTION AND SERVICE 6 720 614 564b (2008/02)
Page 40 Fill the condensate trap with approximately 1/4 litre of water and refit in reverse order. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi INSPECTION AND SERVICE 6 720 614 564b (2008/02)
Page 41: Replacement Of Parts
Remove expansion vessel from boiler. Set the pressure of the new vessel to that required by the system. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi INSPECTION AND SERVICE 6 720 614 564b (2008/02)
Page 42 Fill the condensate trap with approxi- mately 1/4 litre of water and refit in reverse order. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi REPLACEMENT OF PARTS 6 720 614 564b (2008/02)
Page 43 Transformer / PCB Disconnect all electrical connections from the control. Remove 5 screws (C) retaining the rear panel of the control and remove panel. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi REPLACEMENT OF PARTS 6 720 614 564b (2008/02)
Page 44 Remove spark/flame electrode assembly (G) from heat exchanger. 12.3 12.4 Check CO/CO 2 levels as described on the “setting of the air/gas ratio” section. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi REPLACEMENT OF PARTS 6 720 614 564b (2008/02)
Page 45 Burner Remove the burner (H). Replace new burner in correct position. Ensure that a new seal (K) is used. 14.2 14.3 14.4 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi REPLACEMENT OF PARTS 6 720 614 564b (2008/02)
Page 46 Unscrew the flow pipe (D). 16.4 Undo flue connection (E) from sump (F). Pull flue pipe up. Remove the heat exchanger. 16.1 16.2 16.3 16.4 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi REPLACEMENT OF PARTS 6 720 614 564b (2008/02)
Page 47 Disconnect the electrical connection from the sensor. Withdraw the spring clip. Withdraw the sensor (D) from the housing. To refit, follow the above in reverse. 20.1 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi REPLACEMENT OF PARTS 6 720 614 564b (2008/02)
Page 48 25.2 Withdraw the drain tap from its housing. To refit, follow the above in reverse. Ensure any seals that have been disturbed are renewed. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi REPLACEMENT OF PARTS 6 720 614 564b (2008/02)
Page 49 Withdraw the pressure release valve (A) from its housing. To refit, follow the above in reverse. Ensure any seals that have been disturbed are renewed. 27.1 27.2 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi REPLACEMENT OF PARTS 6 720 614 564b (2008/02)
Page 50 29.2 Remove the heat exchanger. To refit, follow the above in reverse. Ensure any seals that have been disturbed are renewed. 29.2 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi REPLACEMENT OF PARTS 6 720 614 564b (2008/02)
Page 51: Setting The Air/Gas Ratio
Remove manometer and re-seal inlet pressure point on gas valve. Fit new plastic seal to outlet adjuster (B). Re-fit brass cap over valve adjuster (C). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi SETTING THE GAS/AIR RATIO 6 720 614 564b (2008/02)
Page 52: Short Parts List
Worcester Part No. 1 904 522 740 0 GC No. E27 305 24 Fuse 0.5 Amp F3 Worcester Part No. 1 904 522 730 0 GC No. E27 300 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi SHORT PARTS LIST 6 720 614 564b (2008/02)
Page 53: Conversion
THE GAS/AIR RATIO MUST BE RESET AFTER CONVERSION. REFER TO THE SERVICE & SPARES - SETTING GAS/AIR RATIO SECTION OF THIS MANUAL. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi L.P.G. CONVERSION 6 720 614 564b (2008/02)
Page 54: Fault Finding & Diagnosis
FAULT FINDING NOTE: This fault finding information is for guidance only. Worcester Bosch cannot be held responsible for costs incurred by persons not deemed to be competent. The electronic control system for this boiler incorporates a blue central indicator. This normally confirms the permanent mains supply but, by flashing during a fault, provides a guide to the cause as listed.
Page 55: Central Heating Function
CENTRAL HEATING FUNCTION INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi CENTRAL HEATING FUNCTION 6 720 614 564b (2008/02)
Page 56: Preheat And Dhw Function
PREHEAT AND DHW FUNCTION INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42 CDi PREHEAT AND DHW FUNCTION 6 720 614 564b (2008/02)
Page 57: Protection Function
PROTECTION FUNCTION INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi PROTECTION FUNCTION 6 720 614 564b (2008/02)
Page 58: Gas Boiler Commissioning Checklist
GAS BOILER 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. Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.
Page 59: Service Record
SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.
Page 60 5. Is the incoming gas pressure at least 18mbar with the boiler at maximum output? Dedicated to heating comfort Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 01905 754624 Fax. 01905 754619 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. worcester-bosch.co.uk 6 720 614 564b (2008/05)

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