Worcester GREENSTAR 30CDi Installation, Commissioning And Servicing Instructions
  1. Manuals
  2. Brands
  3. Worcester Manuals
  4. Boiler
  5. GREENSTAR 30CDi Classic System ErP 41-406-37
  6. Installation, commissioning and servicing instructions

Worcester GREENSTAR 30CDi Installation, Commissioning And Servicing Instructions

Greenstar cdi classic regular wall hung rsf gas fired condensing regular boiler, for open vented and sealed central heating systems and indirect domestic hot water
Hide thumbs Also See for GREENSTAR 30CDi:
Table of Contents

Advertisement

Quick Links

See also: Technical Information , Instructions for Using
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 Regular GC Number 41-311-71
40CDi Regular GC Number 41-311-72
LIQUID PETROLEUM GAS:
30CDi Regular GC Number 41-311-73
40CDi Regular GC Number 41-311-74
UK/IE

Advertisement

Table of Contents
loading

Related Manuals for Worcester GREENSTAR 30CDi

Summary of Contents for Worcester GREENSTAR 30CDi

  • 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 &...

  • Page 2: Table Of Contents

    CONTENTS CONTENTS KEY TO SYMBOLS AND SAFETY PRECAUTIONS ... . 3 SERVICING AND SPARES ......31 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 STARTING INSTALLATION. PRECAUTIONS These instructions are applicable to the Worcester appliance model(s) stated on the front cover of this manual only and must not be used with KEY TO SYMBOLS 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.

  • Page 5: Appliance Information

    APPLIANCE INFORMATION APPLIANCE INFORMATION GENERAL INFORMATION STANDARD PACKAGE: Wall hung gas fired condensing regular boiler for central heating and domestic hot water Wall mounting plate Hanging bracket Hardware pack 1 Hardware pack 2 Literature pack Flow pipe Return pipe 1 Return pipe 2 Trap / Siphon Outlet Connection (22mm Plastic Pipe) Pre-plumbing manifold with water and gas connections...

  • Page 6: Technical Data

    APPLIANCE INFORMATION TECHNICAL DATA NATURAL GAS L.P.G DESCRIPTION UNITS 30CDi 40CDi 30CDi 40CDi 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. rated heat output net 50/30°C 31.8 43.3 31.8 43.3 Max.

  • Page 7: Layout & Components

    PRE-INSTALLATION LAYOUT & COMPONENTS 13. CONDENSATE HOSE 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 PANEL FOR SERVICING 22.

  • Page 8: Mains Supply

    PRE-INSTALLATION ▶ Run the boiler/system at normal operating temperature as directed by CONNECTIONS/VALVES: the manufacturer of the flushing agent. • All system connections, taps and mixing valves must be capable of ▶ Drain and thoroughly flush the system to remove the flushing agent sustaining a pressure up to 3 bar.
  • Page 9 PRE-INSTALLATION S AND Y PLAN SYSTEM: SEALED SYSTEM LAYOUT SEALED SYSTEM LAYOUT 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...

  • Page 10: 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 11: External Connections

    PRE-INSTALLATION 3.4.2 EXTERNAL CONNECTIONS FITTING AN EXTERNAL AIR BREAK • Refer to figure 13 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 12: Boiler Location & Clearances

    PRE-INSTALLATION • Minimum clearances must be maintained Minimum hole size for the condensate soak away must be • An access door is required to install, service and maintain the boiler 400mm deep by 300mmØ . and any ancillary equipment. • If an airing cupboard is adapted to house a boiler, then the airing spaces must be separated from the boiler compartment by a In situations where there are likely to be extremes of temperature or noncombustible partition.

  • Page 13: Plumbing Manifold

    PRE-INSTALLATION BATHROOMS: Additional RCD (Residual Current Device) protection may be required. Flow 22mm Refer to the latest IEE wiring regulations. NOTICE: Any switch or appliance control using 230 V Return 22mm mains electricity must not be able to be touched by a person using the bath or shower.

  • Page 14: Flue Options

    PRE-INSTALLATION FLUE OPTIONS The Greenstar CDi has the option of three horizontal RSF (60/100 Horizontal extended flue with 2x90° bends telescopic, 60/100 longer telescopic and 80/125 telescopic) flue Flue option 4 100mmØ 125mmØ systems and two vertical RSF (60/100 or 80/125) regular flue systems: 30CDi 4,900mm 14,500mm...
  • Page 15 PRE-INSTALLATION 350 mm - 570 mm 130 mm Min 500 mm 300 mm Flat roof 6720643895-12.1Wo 6 720 806 548 (2013/02)

  • Page 16: 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. 19 Flue terminal positions NOTICE: ▶ All measurements are the minimum clearances required. ▶ Terminals must be positioned so to avoid combustion products entering the building. ▶...

  • Page 17: Plume Management Terminal Positions

    PRE-INSTALLATION 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. 20 Plume terminal positions NOTICE: ▶ All measurements are the minimum clearances required. ▶...

  • Page 18: 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 19: Wall Mounting Plate Flue Opening

    INSTALLATION WALL MOUNTING PLATE FLUE OPENING FIXING THE PRE-PLUMBING MANIFOLD: CAUTION: Ensure there are no pipes, electric cables, ▶ Mount the pre-plumbing manifold on the two lower screws and secure damp proof courses or other hazards before drilling. the screws. SAFETY: All relevant safety precautions must be undertaken.

  • Page 20: 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 21: Fitting The Appliance Boiler Connections

    INSTALLATION 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: • If there is greater than 600mm clearance below the appliance it is possible to fit the flow and return pipes, supplied, with the boiler installed on the wall.If clearance is less than 600 mm below the appliance it may be necessary to fit the flow and return pipes before hanging the appliance.

  • Page 22: 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 23: 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 24: 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. 6 720 806 548 (2013/02)
  • Page 25 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) ▶...

  • Page 26: 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 27: Commissioning

    COMMISSIONING COMMISSIONING PRE-COMMISSIONING CHECKS CAUTION: Isolate the mains gas supply before starting any work and observe all relevant safety precautions. 1. Check that the service and water pipes are connected to the correct position on the manifold. A - CH flow (22mm) B - CH return (22mm) C - Gas inlet (22mm) 2.

  • Page 28: 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 29: 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 pressure at the boiler must not be less than the pressure read at the The inlet pressure to the appliance must be checked using the following meter minus 2.5 mbar.
  • Page 30 COMMISSIONING INSTALLING BOTTOM PANEL: 2. The bottom panel slides onto two ledges (C) either side of the boiler frame. ▶ Hold the panel up against the underside of the boiler and slide towards the rear until it is fully engaged. HANDOVER: ▶...

  • Page 31: Servicing And Spares

    ▶ Operate the appliance and take note of any irregularities. Call up the Adjusting boiler control to service position. last fault stored by the Bosch Heatronic, Service Function .0. Refer to 1. Pull down the catch securing the control panel.

  • Page 32: Fan Pressure Test

    SERVICING AND SPARES 6.1.1 FAN PRESSURE TEST FAN PRESSURE TEST Clean the Heat Ex. Heat Ex. ok This test is to determine if the heat cell requires cleaning/ attention NG Boilers 40 CDi: - 5.2 30 CDi: - 4.1 SET THE BOILER TO MAXIMUM The boiler must operate at maximum output for the Fan mbar Pressure test and Flue Gas Analysis.

  • Page 33: To Clean The Burner

    SERVICING AND SPARES 3. Clean the heat exchanger from top to bottom using the brush. 3. Remove the burner (H) and clean components. Do not use a wire brush. 6.1.4 TO CHECK THE DIAPHRAGM IN BURNER COVER 6720803599-04.1Wo 4. Carefully withdraw diaphragm (J) from fan intake tube and check for ▶...

  • Page 34: Setting The Air/Gas Ratio

    SERVICING AND SPARES ▶ Fill the condensate trap with approximately 250 millilitres of water setting setting and refit in reverse order Gas type maximum minimum Greenstar 30CDi Natural gas 9.6% ±0.4 9.0% ±0.4 11.5% ±0.4 10.5% ±0.4 Greenstar 40CDi Natural gas 9.7% ±0.4...

  • Page 35: 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 36 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 37 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 ▶ Remove fuse (B) from the PCB and replace. using the procedure in the section “Setting the air/gas ratio.”...
  • Page 38 SERVICING AND SPARES ▶ Re-assemble with the new gasket and secure with the screws (F) 3. Remove air/gas manifold (I) removed earlier. Fig. 65 Electrode assembly 14. AIR/GAS MANIFOLD Fig. 68 Air/gas manifold WARNING: Air/Gas manifold 4. Open air/gas manifold (I). ▶...
  • Page 39 SERVICING AND SPARES 1. Remove plastic nut (A) from the base of the inner casing 19. DRAIN TAP ▶ Remove clip (G) ▶ Unscrew nut (H) ▶ Replace drain tap. Fig. 71 Heat exchanger removal 1 2. Remove return pipe at the bottom of heat exchanger. 6720648547-36.

  • Page 40: 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 41: Fault Finding & Diagnosis

    This fault finding information is for guidance only. first electrical checks to be carried out during a fault-finding procedure. Worcester Bosch cannot be held responsible for costs On completion of the Service/Fault-Finding task which has required the incurred by persons not deemed to be competent.

  • Page 42: Heating Function

    FAULT FINDING & DIAGNOSIS HEATING FUNCTION 6720648547-24.1Wo 6 720 806 548 (2013/02)
  • Page 43 NOTES 6 720 806 548 (2013/02)
  • Page 44 6 720 806 548 (2013/02)
  • Page 45 6 720 806 548 (2013/02)
  • Page 46 Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect the customer’s statutory rights. If yes, and if required by the manufacturer, has a water scale reducer been fitted? CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798 If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation fitted?

  • Page 47: Service Record

    Service Record It is recommended that your heating system is serviced regularly and that the appropriate Service Interval 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 48 LITERATURE: 0844 892 9800 TRAINING: 01905 752526 SALES: 01905 752640 Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0844 892 9900 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. worcester-bosch.co.uk 6 720 806 548 (2013/02)

This manual is also suitable for:

Greenstar 40cdiGreenstar 40cdi

Table of Contents