Table of Contents
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INSTALLATION COMMISSIONING AND SERVICING INSTRUCTIONS
WALL HUNG RSF GAS FIRED CONDENSING COMBINATION BOILER
GREENSTAR CDi CLASSIC
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 type C13, C33)
Natural Gas: 29CDi GC number 47-406-34
34CDi GC number 47-406-36
38CDi GC number 47-406-38
42CDi GC number 47-406-10
L.P.G.: 29CDi GC number 47-406-35
34CDi GC number 47-406-37
38CDi GC number 47-406-39
42CDi GC number 47-406-11
UK/IE
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Table of Contents
Related Manuals for Worcester 34CDi GC 47-406-37
Summarization of Contents
KEY TO SYMBOLS
1.1 Key to Symbols
Provides a guide to symbols used in the manual.
1.2 Safety Precautions
Outlines essential safety measures and warnings for installation and operation.
APPLIANCE INFORMATION
2.1 General Information
Introduces the appliance and its standard package contents.
2.2 Layout & Components
Details the physical arrangement and identification of boiler parts.
2.3 Technical Data
Presents key specifications, performance figures, and dimensions of the boiler.
PRE-INSTALLATION
3.1 Cleaning Primary Systems
Guidelines for preparing the heating system, including flushing and water treatment.
3.2 Mains Supply
Covers requirements for electrical, gas, and water connections.
3.3 Water Systems and Pipe Work
Instructions for plumbing, including plastic pipe work and system connections.
3.4 Condensate Pipe Work
Guidance on routing and connecting the condensate drain pipe.
3.4.1 Internal connections
Methods for internal condensate drainage, prioritizing gravity.
3.4.2 External connections
Procedures for external condensate disposal, including soakaways and rainwater pipes.
3.5 Pressure Relief Pipe Work
Instructions for installing the pressure relief valve discharge pipe safely.
3.6 Boiler location & clearances
Specifies required spaces around the boiler for installation and maintenance.
Servicing Clearances
Details minimum clearances needed for accessing components during servicing.
3.7 Plumbing manifold
Explains the connections and pipe work for the plumbing manifold.
3.8 Flue options
Lists available flue systems and their maximum lengths for different boiler models.
3.9 Flue terminal positions
Provides minimum clearance requirements for flue terminal placement.
3.10 Plume management terminal positions
Specifies clearances for plume management kits to avoid re-entry of combustion products.
INSTALLATION
4.1 Unpacking wall frame and ancillary items
Instructions for safely unpacking and handling the boiler and its accessories.
Lifting and Carrying Precautions
Safety guidelines for lifting and moving the boiler and its parts.
Important Handling Instructions
Advice on safe unpacking and handling procedures to prevent injury.
4.2 Wall mounting plate flue opening
Guidance on positioning and drilling for the wall mounting plate and flue.
4.3 Charging link (filling loop)
Details the procedure for fitting and using the charging link for system filling.
4.4 Unpacking the appliance
Step-by-step guide to removing the boiler from its packaging.
Removing Outer Case
Instructions on how to safely remove the boiler's outer casing.
4.5 Fitting the appliance/boiler connections
Instructions for connecting the boiler to the system pipes.
Gas and Water Connections
Specific guidance for connecting gas, cold water, DHW, and CH pipes.
4.6 Flue installation
Procedures for installing various flue configurations.
Horizontal Flue
Details for installing horizontal flue systems.
4.6.1 Ø60/100mm Telescopic flue kit
Information on standard and longer telescopic flue kits.
4.6.2 Ø60mm Plume management kit
Guidance on fitting the plume management system.
4.6.3 Adjusting the standard terminal length
How to set the correct length for telescopic flue terminals.
4.6.4 Installing the standard flue
Steps for fitting the standard telescopic flue and seals.
4.6.5 Flue terminal plume re-direction
Methods for redirecting flue discharge to manage plume dispersal.
Re-directing the flue discharge
Specific steps for adjusting the terminal outlet position.
4.7 Condensate connection
Ensures proper connection of the condensate drain to a suitable discharge.
4.8 Electrical
Details wiring requirements for the boiler and external controls.
Access to electrical connections
Steps to access and make electrical connections to the control panel.
4.9 Position of wired components
Diagram showing the location of various wired components.
COMMISSIONING
5.1 Pre-commissioning checks
Initial checks before starting the boiler, including pipe connections and gas supply.
5.2 Filling the system
Procedure for filling the central heating system with water and venting.
5.3 Starting the appliance
Steps to safely power up and start the boiler for the first time.
Switching the Appliance On/Off
How to operate the boiler's power and control buttons.
5.4 Water treatment
Guidelines for system flushing and adding inhibitors.
Flushing (Central Heating)
Detailed steps for flushing the heating system before adding inhibitor.
Inhibitor (Central Heating)
Instructions on adding and checking inhibitor levels in the system.
5.5 Commissioning
Steps to ensure the boiler operates correctly and safely.
5.5.1 Checking the gas inlet pressure
Procedure for measuring and verifying gas inlet pressure.
Measuring the Inlet Pressure
Specific steps and test points for checking gas inlet pressure.
5.5.2 Checking the gas rate
Method for measuring the gas consumption rate at maximum output.
5.5.3 Domestic hot water
How to control and adjust the domestic hot water temperature.
5.5.4 Domestic hot water pre-heat
Information on the pre-heat function and its control via the ECO button.
5.6 Finishing commissioning
Final steps including replacing casing, handover, and user demonstration.
Replace Outer Casing
Instructions for refitting the boiler's outer casing after servicing.
Installing Bottom Panel
How to fit the bottom panel onto the boiler frame.
Handover
Steps for completing documentation and demonstrating controls to the user.
SERVICING AND SPARES
6.1 Inspection and Service
Routine checks and service procedures to maintain boiler performance.
Inspection
Visual checks of the terminal, clearances, and system connections.
6.1.1 Component Access
Guidance on accessing internal components for servicing.
Removing Outer Case
Steps to remove the boiler's outer casing for component access.
6.1.2 Fan Pressure Test
Procedure to test fan pressure and diagnose heat exchanger condition.
Set the Boiler to Maximum
How to put the boiler into performance test mode for servicing.
Fan Pressure Test
Performing the fan pressure test and interpreting results.
6.1.3 To Clean the Heat Exchanger
Instructions for cleaning the heat exchanger using a brush.
6.1.4 To Clean the Burner
Steps for removing and cleaning the burner components.
6.1.5 To Check the Diaphragm in Burner Cover
How to inspect the diaphragm for damage or soiling.
6.1.6 To Clean the Condensate Trap
Procedure for removing and cleaning the condensate trap.
6.2 Setting the Air/Gas Ratio
Detailed instructions for adjusting air and gas mixture for optimal combustion.
Setting the CO2
Performing CO2 measurements and adjustments at maximum and minimum outputs.
6.3 Replacement of Parts
Step-by-step guides for replacing various boiler components.
Removing Outer Case
How to remove the outer case to access internal parts.
Moving Boiler Control to Service Position
Steps to swing out the control panel for easier access.
Primary Sensor
Guidance on removing and replacing the primary temperature sensor.
Overheat Thermostat
Procedure for replacing the overheat thermostat.
Flue Limit Thermostat
How to remove and replace the flue limit thermostat.
Expansion Vessel
Steps for draining and replacing the expansion vessel.
Gas Valve
Instructions for removing and replacing the gas valve.
Siphon
Procedure for removing and replacing the condensate siphon.
Access to Boiler Control Components
How to access the PCB and related components.
PCB Fuse
Guidance on locating and replacing the fuse on the PCB.
PCB Removal
Steps for removing the Printed Circuit Board (PCB).
Fan Assembly
Instructions for removing and replacing the fan unit.
Electrode Assembly
How to remove and replace the spark/flame electrode assembly.
Air/Gas Manifold
Procedures for removing and refitting the air/gas manifold.
Burner
Instructions for removing and replacing the burner assembly.
Heat Exchanger
Steps for removing and replacing the main heat exchanger.
Diverter Valve Motor
How to remove and replace the diverter valve motor.
Diverter Valve
Procedure for removing and replacing the diverter valve.
Auto Air Vent
Steps for removing and replacing the auto air vent.
DHW Temperature Sensor
Guidance on removing and replacing the DHW temperature sensor.
Pump Head
Instructions for removing and replacing the pump head.
Pressure Gauge
Procedure for removing and replacing the pressure gauge.
Flow Sensor, Flow Restrictor Housing and Filter
How to access and remove the flow sensor assembly.
Flow Restrictor
Steps for removing and replacing the flow restrictor cartridge.
Drain Tap
Procedure for removing and replacing the drain tap.
Hydraulic Block
Instructions for removing and replacing the hydraulic block assembly.
CH Pressure Relief Valve
How to remove and replace the central heating pressure relief valve.
Plastic Protection Device
Procedure for removing and refitting the plastic protection device.
DHW Heat Exchanger
Steps for removing and replacing the domestic hot water heat exchanger.
6.4 Short Parts List
A list of common spare parts with their part numbers.
FAULT FINDING & DIAGNOSIS
7.1 Fault Finding
Guide to identifying and diagnosing common boiler faults using error codes.
Preliminary Checks
Initial electrical system checks to perform when diagnosing faults.
7.2 Central heating function
Flowchart illustrating the boiler's operation during central heating demand.
7.3 Preheat and DHW function
Flowchart detailing the boiler's operation for hot water demand and preheat.
7.4 Protection function
Explains the boiler's built-in safety and protection features.
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