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Summary of Contents for GREENSTAR 30CDi System

Page 1: ...NSTAR 25CDi GC NUMBER 47 311 92 WORCESTER GREENSTAR 30CDi GC NUMBER 47 311 93 WORCESTER GREENSTAR 37CDi GC NUMBER 47 406 08 WORCESTER GREENSTAR 42CDi GC NUMBER 47 406 10 LIQUID PETROLEUM GAS WORCESTER GREENSTAR 25CDi GC NUMBER 47 311 96 WORCESTER GREENSTAR 30CDi GC NUMBER 47 311 97 WORCESTER GREENSTAR 37CDi GC NUMBER 47 406 09 WORCESTER GREENSTAR 42CDi GC NUMBER 47 406 11 INSTRUCTION MANUAL INSTAL...

Page 2: ...ER OF THIS MANUAL ONLY AND MUST NOT BE USED WITH ANY OTHER MAKE OR MODEL OF APPLIANCE THE INSTRUCTIONS APPLY IN THE UK ONLY AND MUST BE FOLLOWED EXCEPT FOR ANY STATUTORY OBLIGATION THIS APPLIANCE MUST BE INSTALLED BY A COMPETENT PERSON FAILURE TO INSTALL CORRECTLY COULD LEAD TO PROSECUTION IF YOU ARE IN ANY DOUBT CONTACT WORCESTER BOSCH TECHNICAL HELPLINE DISTANCE LEARNING AND TRAINING COURSES ARE...

Page 3: ... INSTALLATION CONDENSATE CONNECTION ELECTRICAL POSITION OF WIRED COMPONENTS COMMISSIONING PRE COMMISSIONING CHECKS FILLING THE SYSTEM STARTING THE APPLIANCE WATER TREATMENT COMMISSIONING FINISHING COMMISSIONING SERVICING SPARES INSPECTION AND SERVICE REPLACEMENT OF PARTS SETTING THE GAS AIR RATIO SHORT PARTS LIST CONVERSION KITS L P G CONVERSION FAULT FINDING DIAGNOSIS FAULT FINDING CENTRAL HEATIN...

Page 4: ...e engineer must complete the Service Record in the Benchmark section after each service INSTALLATION REGULATIONS Gas Safety Installation Use Regulations All gas appliances must be installed by a competent person in accordance with the above regulations Failure to install appliances correctly could lead to prosecution The appliance must be installed in accordance with and comply to the current Gas ...

Page 5: ...rature pack H Bottom panel I Trap I Syphon Outlet Connection 22 mm Plastic Pipe B D SPECIFICATIONS Pre wired and pre plumbed Galvanised steel inner frame Digital control system Automatic ignition Direct burner ignition Built in frost thermostat boiler protection Built in fault finding diagnostics Modulating automatic gas valve Combustion air fan with speed regulator CH temperature sensor control P...

Page 6: ...6 58 83 58 87 58 Flue Gas Temp 40 30 C rated min load c 51 33 55 33 60 35 66 35 51 33 55 33 60 35 66 35 C02 level at max rated heat output 9 6 9 6 9 7 9 7 11 5 11 5 11 5 11 5 C02 level at min rated heat output 9 0 9 0 9 1 9 1 10 5 10 5 10 5 10 5 NOx class 5 5 5 5 5 5 5 5 Condensate Max condensation rate 2 3 2 7 2 7 2 7 2 3 2 7 2 7 2 7 pH value approx 4 8 4 8 4 8 4 8 4 8 4 8 4 8 4 8 Electrical Elec...

Page 7: ...PLATE TO PLATE DHW HEAT EXCHANGER 7 PUMP 8 SYSTEM PRESSURE GAUGE 9 DRAIN POINT 10 MAINS COLD WATER IN 11 CH RETURN 12 CHARGING LINK ASSEMBLY 13 GAS INLET CONNECTION 22 mm COMPRESSION 14 COVER FOR EXTERNAL WIRING CONNECTIONS 15 CONTROL PANEL IN SERVICE POSITION 16 ACCESS COVER FOR TRANSFORMER PCB 17 DHWOUT 18 CH FLOW 19 TRAP I SYPHON OUTLET CONNEC TION 22 mm PLASTIC PIPE 20 INLET PRESSURE TEST POIN...

Page 8: ...ERTER VALVE 46 PRESSURE RELIEF VALVE 47 COMPACT HYDRAULIC MOUNTING SCREW 2 TO BOILER 47 I I I I I I I 46 I I I 45 48 CH TEMPERATURE CONTROL 49 MAINS ON OFF INDICATOR DIAGNOS TIC LIGHT BLUE 50 DHW TEMPERATURE CONTROL 51 CENTRAL HEATING BOOST BUTTON 52 SERVICE BUTTON 53 BURNER ON INDICATOR LIGHT GREEN 54 MASTER SWITCH ON OFF 55 HOLIDAY BUTTON 56 ECO BUTTON 57 FAULT RESET BUTTON 58 SYSTEM PRESSURE GA...

Page 9: ... the appliance warranty BEFORE CLEANING THE SYSTEM ENSURE THE SYSTEM AND PIPEWORK IS IN GOOD WORKING ORDER KEEP THE EXISTING BOILER CIRCULATING PUMP WHERE POSSIBLE OR USE A POWER FLUSHING MACHINE TO AID THE CLEANSING PROCEDURE BEFORE INSTALLING A NEW BOILER CLEANING THE PRIMARY SYSTEM Fill the system with cold water and check for leaks 2 Open all drain cocks and drain the system 3 Close drain cock...

Page 10: ...e meter to the boiler For olive connections we recommend using gas pipes with minimum 0 9 mm wall thickness WATER SUPPLY Water Mains Pressure Minimum mains water pressure 1 5 up to 2 5 bar see technical data on page 6 for maximum performance Maximum mains fed water pressure 10 bar If necessary fit a pressure reducing valve IMPORTANT Non return back flow pre vention devices including those associat...

Page 11: ...rmostat On boiler only replacement jobs it is recom mended but not mandatory to fit a TRV on each radiator It is however a requirement for energy conservation purposes to recom mend to the customer that a TRV is fitted to each radiator An automatic bypass may be required downstream of the pump in order to main tain the minimum flow rate through the appli ance A drain cock is required at the lowest...

Page 12: ... internally Should this not be possi ble and the only available route is external the following conditions should be observed Pipe work length should be kept to a minimum and the route as vertical as possible Where pipe work could be subjected to extreme cold or wind chill a weather proof insulation should be used Alternatively the condensate pipework could be increased to a minimum 32 mm without ...

Page 13: ...the boiler into an airing cupboard use a non combustible perforated material maximum hole sizes of 13mm to separate the boiler from the airing space BOILER CLEARANCES The diagram opposite shows the m1n1mu space required to install and service the boiler VENTILATION This is a room sealed appliance and does not require any air for combustion from inside the property If the appliance is fitted into a...

Page 14: ...ings IMPORTANT any switch or appliance control using 230 V mains electricity must not be able to be touched by a person using the bath or shower Electrical switches fused spur and socket outlets must not be situated in the bath aoomm room 750mm For further information about bathroom installa lions please consult Operational Procedures Part 20 Electricity 2250mm 600mm radius 6720611927 13 10 BOILER...

Page 15: ...ING MANIFOLD CONNECTIONS Heating System 22 mm compression fittings DHW 15 mm compression fittings Gas 22 mm compression fittings Use the fittings supplied in the Hardware pack PREPLUMBING With the plumbing manifold installed pipework can be installed to the valves on the manifold The system can be filled without the boiler being connected using the charging link assembly see page 23 The valves can...

Page 16: ... fanned draught to an opening in the building fabric formed for the purpose of accommodating a built in element such as a window frame 2 Not recommended See instructions supplied with vertical flue kits FLUE TERMINAL POSITIONS The flue must be fitted and terminated in accordance with the recommendations of BS5440 Part 1 The flue must not cause an obstruction Discharge and any noise from the flue o...

Page 17: ...ength for each configuration of 100 mm and 125 mm 0 flues Shaded flue components indicate the stan dard 100 mm 0 horizontal flue Only straight flue sections can be reduced in length and cut The flue terminal end can be fitted from the inside or outside of the building Fixing kits are supplied with the flue exten sion kits Horizontal125 mm 0 and Vertical100 mm and 125 mm 0 flue kits are available w...

Page 18: ...rizontal flue Only straight flue sections can be reduced in length and cut The flue terminal end can be fitted from the inside or outside of the building Fixing kits are supplied with the flue exten sion kits Horizontal 125 mm 0 and Vertical 100 mm and 125 mm 0 flue kits are available with separate instructions Contact your supplier or Worcester Bosch A c D _QH IP 0 v B EB F Q A Standard horizonta...

Page 19: ...ngth for each configuration of 100 mm and 125 mm 0 flues Shaded flue components indicate the stan dard 100 mm 0 horizontal flue Only straight flue sections can be reduced in length and cut The flue terminal end can be fitted from the inside or outside of the building Fixing kits are supplied with the flue exten sion kits Horizontal125 mm 0 and Vertical100 mm and 125 mm 0 flue kits are available wi...

Page 20: ...ions can be reduced in length and cut The flue terminal end can be fitted from the inside or outside of the building Fixing kits are supplied with the flue exten sion kits Horizontal 125 mm 0 and Vertical 100 mm and 125 mm 0 flue kits are available with separate instructions Contact your supplier or Worcester Bosch A c D _QH IP 0 v B EB F Q A Standard horizontal flue 1 00 mm 0 shown B Straight flu...

Page 21: ...t two people are used to carry the carton from the van to the point of delivery Once the carton has been delivered the top of the carton is opened If a sharp imple ment is used make sure the carton is not pierced and that the implement is used in such a way so that it may not cause person al injury All sharp objects must be covered or the blade retracted after use and put away in a safe place 1 Th...

Page 22: ...manifold Secure wall mounting plate with hanging bracket with 3 screws supplied with the boiler Do not fully fasten the lower 2 screws Use the horizontal slots in the wall mounting plate to level the hanging bracket mark the 4th hole and drill Fix and secure the hanging bracket with both screws FLUE OUTLET Follow the diagram opposite to mark the centre of the flue for rear outlet 1 2 or for side o...

Page 23: ... Charging Link Fit two M4 screws complete with washers to each of the two connections NB It is not possible to access the third screw hole so this can be left Do not attempt to turn the brass hexagon connectors 1 3 Ensure that the white plastic Control Screw on the Charging Link is turned fully into its closed position see diagram 1 3 Open the isolating valves on both the DHW inlet and CH return c...

Page 24: ...r carton A and place safely away from the working area 5 Remove the protective wrapping C 6 Lie the boiler on its back 7 Remove the packaging base B and place safely away from the working area REMOVING OUTER CASE 8 Loosen but do not remove the 2 screws E securing boiler casing at the bottom of the appliance 9 Pull upwards to release the clip F on top of the boiler and pull the case upwards 10 Remo...

Page 25: ...ition This is located on the right hand of the wall frame at the rear 2 Pull the extended tab lever forward and down until there is no further travel 3 Hang the boiler on to the hanging brack et The lugs pass through the rectangular holes in the boiler back panel Take care not to disturb the washers on the connections NOTE It is recommended that this lifting operation is carried out by 2 people ob...

Page 26: ...iameter flue are shown below MEASURING THE FLUE Standard Flue Measure from the outside wall to the centre line of the flue turret length L Subtract 52 mm from the length L to give the correct dimension to the flue elbow con nection The terminal section should be cut to this dimension however it must not be shorter than 250 mm After cutting the end must be square and free from burrs to prevent dama...

Page 27: ...gth of the standard flue 634 mm from length L Subtract the usable length of the turret 52 mm from length L Subtract 960 mm for each full length exten sian from the figure Cut one of the extensions to the remainder Cut both tubes square taking care not to distort the tubes Remove any burrs EXAMPLE Length L 2380 mm Subtract Standard Flue 634 mm Subtract Turret 52mm Subtract Full Extension 960 mm Cut...

Page 28: ...et section to the outside and fit the outer flue collar C over the notches to secure 4 Assemble turret to boiler using the three screws see below Note Screws are in boiler or in flue kit FITTING THE TURRET Flue turret should push directly down and not be twisted into correct position Fit turret onto appliance and retain with three screws NOTE The clamping plate flat should be at the rear of the ap...

Page 29: ...rge into any open source including sink bath shower bidet toilet etc Note any external condensate pipework of excessive runs should be protected with weather resistant insulation to help prevent freezing Ensure that the condensate drain is 22 mm diameter plastic pipe It must fall at least 50 mm per metre towards the outlet An adapter A in 22 mm pipe is contained in the fitting pack CONDENSATE CONN...

Page 30: ...e Run cable over the main crossbar and through the cable clamp C ensuring there is ample cable to reach the connectors Turn cable clamping screw D clockwise to secure cable and replace clamp C into control panel 6 Mains power 230 V connection ST10 Separate wires from cable end and strip to 6mm Connect LIVE wire to terminal L Connect NEUTRAL wire to the terminal N Connect EARTH wire to the earth co...

Page 31: ...MER 4 13J I I Colc n Jnce r u TEM TURE CONTROL l rn l cH TEM _ _ hII _ _ o o D 0 PERMURE t 4 CONTROL ST6 4 o D 99 1 ST4 2 o o ST19 lilli II STS 1 o o 1 1 1 1 5 1 F o D Fuse slow lQLJ NsN L J Al2 c 2 5A AC230V L TRANSFORMER Jt 230V lf 4 f J rl 9 I I I I I 1 1230V AC I LI W ST1 nnnn DIAGNOSTIC UUUU INTERFACE 230 V EXTERNAL FROST STAT OPTIONAL Fuse slow T 0 5 A Fuse slow T1 6 A ST17 ST9 ST18 CODE PLU...

Page 32: ... iden tification plate F matches that of the gas supply Turn on the main gas supply check the gas pipework connections and rectify any leaks 3 Check that the pressure relief connector located on the right hand side at the bottom of the wall frame in its up position 4 Check that the condensate pipe has been connected to the adapter IMPORTANT If the boiler is not to be com missioned immediately then...

Page 33: ... a pres sure of 1 bar turn the white control screw C to its closed position 8 Vent all radiators retighten when completed and check the system and correct any leaks The boiler integral expansion vessel is precharged to 0 75 bar equal to a static head of 7 5 meters 22 ft A Schraeder type valve is fitted to the expansion vessel to allow for pressure adjustment if required If an extra expansion vesse...

Page 34: ...seconds the display will show the flow temperature 3 Turn the CH temperature control C to maximum The burner on indicator D illumi nates GREEN when the burner has lit NOTES The first time the appliance is switched on a once only venting function is activat ed The heating pump then switches on and off at intervals This sequence lasts about 8 minutes The display shows shows 00 in alternation with th...

Page 35: ...ng agent G 4 Drain H and thoroughly flush the system to remove the flushing agent and debris 1 INHIBITOR Central Heating 5 Check drain cocks are closed J and all radiator valves are open K before adding a suitable inhibitor or combined inhibitor anti freeze if the system is exposed to freez ing conditions to the heating system water L in accordance with the manufacturers instructions 6 Fill via th...

Page 36: ...ng at maximum Check the gas supply working pressure at the gas valve inlet point N G minimum 18 mbar L P G 37 mbar 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 Ensure inlet pressure is satisfactory with all other gas appliances working Replace controls cover NOTE This boiler is designed with a differen...

Page 37: ...ING 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 HAN DOVER Complete the Benchmark check list Open the facia cover by gently pressing the centre top of the cover D Set up the controls and show the user how to operate all the controls shown in the Use...

Page 38: ...d The extent of the service required by the appliance is determined by the operating condition of the appliance when tested by fully qualified engineers INSPECTION 1 Check that the terminal and the terminal guard if fitted are clear and undamaged 2 If the appliance is in a compartment or cup board check that the specified service space around the appliance is clear 3 Check all the joints and conne...

Page 39: ...emove 2 Adjusting boiler control to service position 2 1 Remove screw X securing control 2 2 Gently pull forward until it comes to rest in service position Primary Heat Exchanger There is a special accessory kit available specifically designed for cleaning the heat exchanger If required order 7 719 001 996 3 Check fan pressure at the test point next to the fan using an electronic manometer The boi...

Page 40: ...ton M Holiday button Press and HOLD central heating boost button L for 10 seconds and set Central Heating temperature to maximum The central heating boost button will illumi nate continually The boiler will stay in this mode for 15 minutes unless the central heating boost button is pressed again 2 Pull the cover off and connect a manome ter to the fan pressure test point After measurement replace ...

Page 41: ...ION CHECK IS EQUIPPED WITH A COMBUSTION ANALYSER CONFORMING TO BS 7927 AND IS COMPETENT IN IT S USE To Clean the Heat Exchanger Remove outer case and base panel and isolate the appliance from power 1 Remove cleaning access cover B seal C and metal plate D securing it if pre sent 2 1 Loosen any deposits in the heat exchanger from top to bottom using the cleaning blade 2 2 Clean the heat exchanger f...

Page 42: ... diaphragm J from fan intake tube and check for soiling and splits Carefully refit diaphragm J the correct way round into the fan intake tube Note The flaps of the diaphragm J must open upwards Re assemble burner in reverse order using a new seal K Adjust gas air ratio Refer to section Setting the gas air ratio To Clean the Condensate Trap 5 1 Pull condensate pipe out of the adapter 5 2 Remove tra...

Page 43: ... do not remove the 2 screws A securing boiler casing at the bottom of the appliance 1 2 Pull upwards to release the clip B on top of the boiler 1 3 Pull case forward and remove 2 Moving boiler control to service position 2 1 Remove screw X securing control 2 2 Gently pull forward 3 Primary sensor Press retaining clip on plastic moulding and pull upwards until clear of pocket in heat exchanger Sepa...

Page 44: ...Replace valve with new seals and check for gas soundness Note The valve will require setting follow pro cedure Setting the gas air ratio in the gas conversion section 8 Siphon 8 1 Pull condensate pipe out of the adapter 8 2 Remove trap from boiler Clean trap and check that the connection to the heat exchanger is clear Fill the condensate trap with approxi mately 1 4 litre of water and refit in rev...

Page 45: ... 9 Access to boiler control components Remove 3 screws A and remove cover from control 10 PCB fuse Remove fuse B from the PCB and replace There is a spare fuse clipped into the cover 11 Transformer I PCB Disconnect all electrical connections from the control Remove 5 screws C retaining the rear panel of the control and remove panel REPLACEMENT OF PARTS ...

Page 46: ... from fan Remove condensate trap see page 42 12 1 Undo the union connection A Remove wire clip B from air gas adjustment assembly C then pull gas pipe down 12 2 Unscrew two screws D 12 3 Remove fan from boiler 12 4 Remove three screws retaining the air gas adjustment assembly E Reassemble with new fan assuring that seals are correctly fitted 13 Electrode assembly Disconnect spark electrodes and fl...

Page 47: ...etely iso lated from the gas supply 14 2 Remove the clips C and unscrew the two bolts D Unscrew and remove the two hexagon screws E securing the fan Slacken fully the rear securing bolt F 14 3 Remove air gas manifold I 14 4 Open air gas manifold 1 Carefully withdraw diaphragm J from fan intake tube and check for soiling and splits 15 Burner Remove the burner H Replace new burner in correct posi li...

Page 48: ...Remove plastic nut A from the base of the inner casing 16 2 Remove return pipe at the bottom of heat exchanger 16 3 Remove screw at the top of the heat exchanger C Unscrew the flow pipe D 16 4 Undo flue connection E from sump F Pull flue pipe up Remove the heat exchanger INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI 30CDI 37CDI 42 co ORCESTER 6 720 613 700a 2006 11 Bosch ...

Page 49: ...Diverter valve Ensure the appliance has been fully drained Disconnect the electrical connector from the diverter valve motor Undo the two screws holding the valve to the plastic housing 18 1 Withdraw the valve B and clean the valve chamber if necessary To refit follow the above in reverse Ensure any seals that have been dis turbed are renewed 19 Auto air vent Ensure the appliance has been fully dr...

Page 50: ...lectrical connection to the turbine Remove the spring clip from the hous ing and move the brass pipe to one side 23 1 Withdraw the flow sensor and filter from the housing Using the cartridge tag withdraw the flow restrictor housing If the regulator housing has become stuck a pair of long nosed pliers may be used to grip the housing To refit follow the above in reverse Ensure any seals that have be...

Page 51: ...ressure gauge to its bracket and remove the gauge Release the locking devices that secure the two copper water pipes lead ing to the combustion chamber by squeezing the two tabs together and rotating anticlockwise viewed from above Undo the two screws securing the hydraulic block to the chassis located top left top right of the housing Lift the left hand side of the block slightly then manoeuvre t...

Page 52: ...he pres sure relief valve housing 28 2 Withdraw the pressure relief valve A To refit follow the above in reverse Ensure any seals that have been dis turbed are renewed 29 DHW Heat exchanger 29 1 29 2 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 abov...

Page 53: ... is pressed for over a second 5 3 Using a flat blade screwdriver set the C02 via adjuster B using table below Note C02 should be measured 10 minutes after firing the appliance Gas type Ico2 setting IC setting max1mum m1mmum Greenstar 25CDi and 30CDi Natural gas I 9 6 0 2 1 9 0 0 2 LPG I 11 5 0 2 1 10 5 0 2 Greenstar 37CDi and 42CDi Natural gas I 9 7 0 2 1 9 1 0 2 LPG I 11 5 0 2 1 10 5 0 2 Check CO...

Page 54: ...itre light green WHS Part No 8 716 105 869 0 GC No H31 959 12 Pressure relief valve DHW WHS Part No 8 717 401 029 0 14 15 GC No H02 526 Pump assembly WHS Part No 8 716 106 354 0 GC No H22 463 14 Pressure gauge WHS Part No 8 717 208 107 0 GC No H02 528 15 Flow sensor WHS Part No 8 716 107 223 0 16 17 16 GC No H02 529 DHW temperature sensor WHS Part No 8 714 500 081 0 GC No H02 538 18 Heat exchanger...

Page 55: ...e of the building but open to ground on the opposite side Installation Regulations In addition to those specified in the main booklet the following standard applies when converting to an LPG appliance BS 5842 Domestic Propane Gas Burning Installations All conversions will require the air gas ratio to be set correctly for the gas used The procedure for setting the air gas ratio is at the rear of th...

Page 56: ...in communication to TD200 or and RT10 Check electrical connections b1 Code plug not detected Insert code plug correctly test and replace if necessary C6 Fan speed too low Check fan lead and connector and fan replace as necessary E2 CH flow NTC sensor defective Check CH flow NTC sensor and connecting lead E9 Safety temp limiter in CH flow has tripped Check system pressure check safety temp limiters...

Page 57: ...G rr DEMAND Diverter valve in CH position Pump ON LOCKOUT Fan to start speed Gas valve OFF Fan overrun 30 seconds IGNITION SEQUENCE see detail GREEN FLAME LIGHT ON 1 IGNITION SEQUENCE I Spark BURNER ignition LIT 4 seconds NO I NO I Stop spark 5th Wait attempt 10 seconds 1 10 second stabilisation period YES Over temperature shut down if water temperature is 5 c above set value f Fan gas modulation ...

Page 58: ...DOMESTIC HOT WATER DEMAND priority over all other demands Diverter valve inDHW position Pump ON PREHEAT DEMAND YES LOCKOUT Burner shut down if primary temperature g5 c Diverter valve opens toCH Over temperature Gas valve OFF shut down if water temperature is 1o c above set value Fan gas modulation to achieve set temperature 4o 5o c GREEN Fan to IGNITION FLAME SEQUENCE ___ start LIGHT speed see det...

Page 59: ...tat function Pump run 5 seconds every 24hrs DHW demand active Frost protection active All other demands not active ORCESTER INSTALLATION SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDc 42CD Bosch Group 6 720 613 700a 2006 11 PROTECTION FUNCTION PROTECTION FUNCTION ...

Page 60: ...CING EXCELLENCE COMES AS STANDARD Worcester Bosch Group Cotswold Way Warndon Worcester WR4 9SW Tel 01905 754624 Fax 01905 754619 Worcester Bosch Group is a trading name of BBT Thermotechnology UK Ltd www worcester bosch co uk 6 720 613 700a 2006 11 OSW ...

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