Worcester 550CDi Instruction Manual Download

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INS

ALL

TION

INSTALLATION & SERVICING INSTRUCTIONS

UNPACKING THE BOILER

8 716 115 219b (09.2008)

IMPORTANT: All the previous Pre-Installation sections must be read and
requirements met before starting boiler or flue installation.

Take care not to damage the boiler panels or
the floor and note that the boiler may contain
some water due to factory testing.

Unpacking:

Undo the ties securing the carton to the

pallet

If a sharp implement is used, care must be
taken not to pierce the carton or cause injury.

2 Before removing the carton it is advised

that the top flaps are opened and the
ancillary items (A, B, C & D) are removed
and set to one side.

The carton can now be lifted off the

boiler.

Remove the plastic bag protecting the

boiler surfaces and place safely away from
the working area.

Remove 2 screws at the rear of the board

securing the board to the pallet.

Slide the boiler and board off the pallet.

Grip the outer sides of the front panel

pull and lift away from retaining lugs.

Remove securing screw, at the front of

the boiler, from the pallet.

Remove remaining screws, at the rear of

the boiler, from the pallet.

The boiler is mounted on small wheels

and two people are recommended to move
the boiler from the board taking care not
to damage the panels or the floor.

Remove the rubber plug (E) from the

boiler pipework by pulling down.

At all times the correct method for handling
heavy objects should be strictly observed.

GENERAL HANDLING GUIDELINES:

Lift only a manageable weight, or ask for

help.

When lifting, bend the knees, and keep

the back straight and feet apart.

Do not lift and twist at the same time.

Lift and carry items close to the body

Wear protective clothing and gloves to

protect from any sharp edges

THIS BOILER IS NOT SUITABLE FOR ROOF
SPACE INSTALLATION.

A - Mounting frame

B - Installation pack

C - Literature pack

D - Condensate waste pipe & non-return
valve

UNPACKING THE BOILER

Summary of Contents for 550CDi

Page 1: ...AL GAS GREENSTAR HIGHFLOW 440CDi GC NUMBER 47 406 24 GREENSTAR HIGHFLOW 550CDi GC NUMBER 47 406 25 LIQUID PETROLEUM GAS GREENSTAR HIGHFLOW 440CDi GC NUMBER 47 406 26 GREENSTAR HIGHFLOW 550CDi GC NUMBER 47 406 27 GREENSTAR HIGHFLOW 440CDi 550CDi FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER FLOOR STANDING RSF GAS FIRED CONDENSING COMBINATION BOILER ...

Page 2: ...he United Kingdom Store the appliance in a dry area prior to installation THIS BOILER IS NOT SUITABLE FOR ROOF SPACE INSTALLATION IMPORTANT HANDLING INSTRUCTIONS It is advised that at least two people are involved in the transfer of the packaged appliance from the van to the point of installation A suitable truck should be used The boiler is secured to a wooden board with screws It is advised that...

Page 3: ...PTIONS 18 INSTALLATION UNPACKING THE BOILER 19 MOUNTING FRAME FIXING FLUE OPENING 20 MOUNTING FRAME CONNECTIONS 21 FLUE LENGTHS FLUE MEASURING CUTTING 22 FLUE MEASURING CUTTING 23 FLUE INSTALLATION 25 STANDARD FLUE INSTALLATION 26 EXTENDED FLUE INSTALLATION 27 FLUE TERMINAL PLUME MANAGEMENT 28 CONDENSATE GAS WATER CONNECTIONS 29 PRESSURE RELIEF VALVE OUTLET 30 ELECTRICAL 31 COMMISSIONING PRE COMMI...

Page 4: ...uding statutory rights SERVICING Advise the user to have the system regularly serviced by a competent qualified engineer such as British Gas or other CORGI registered personnel using approved spares to help maintain the economy safety and reliability of the appliance IMPORTANT The service engineer must complete the Service Record in the Benchmark Log Book after each service Failure to install appl...

Page 5: ...e wired and pre plumbed Galvanised steel inner frame Bosch Heatronic control system Automatic ignition Direct burner ignition electrodes Built in frost thermostat Built in fault finding diagnostics Modulating automatic gas valve Combustion air fan with speed regulator CH temperature sensor control DHW flow sensor temperature control Integral water circulating pump with anti seizure protection Seal...

Page 6: ...lighting Natural Gas G20 m2 h 3 1 4 4 Propane Gas LPG kg h 2 3 3 2 Gas supply pressure Natural Gas G20 mb 20 20 LPG Propane Gas G31 mb 37 37 Flue Flue Gas Temp 80 60 C rated min load C 67 55 67 55 67 55 67 55 Flue Gas Temp 40 30 C rated min load C 43 32 43 32 43 32 43 32 CO2 level at max rated heat output 9 4 9 4 10 8 10 8 CO2 level at min rated heat output 8 6 9 0 10 4 10 4 NOx classification cla...

Page 7: ... FOR FILLING LOOP 21 DHW FLOW SENSOR 22 CH FLOW ISOLATION VALVE 23 DHW OUTLET 24 GAS ISOLATION VALVE 25 MAINS WATER INLET ISOLATION VALVE 26 CH RETURN ISOLATION VALVE 27 RUNNER WHEEL ON MOUNTING FRAME 28 OPTIONAL FILLING LINK WITH PRESSURE GAUGE PART NO 7 716 192 599 29 CIRCULATING PUMP 30 CONDENSATE PUMP ASSEMBLY 31 GAS VALVE 32 EXPANSION VESSEL 33 AIR GAS ADJUSTMENT SCREW SEALED 34 HEAT CELL 35 ...

Page 8: ...NING THE SYSTEM ENSURE THE SYSTEM AND PIPEWORK ARE IN GOOD WORKING ORDER USE 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 mains water to the recommended pressure and check for leaks Open all drain cocks and drain the system Close drain cocks and...

Page 9: ...ns water pressure 1 2 bar for maximum performance Maximum mains fed water pressure 10 bar If necessary fit a pressure reducing valve IMPORTANT Non return back flow prevention devices including those associated with water meters fitted to the mains water supply can cause a pressure build up which could damage the boiler and other household appliances Where the water main supply has a non return bac...

Page 10: ...ion and connection of the gas supply to the boiler must be in accordance with BS6891 Under no circumstances should the diameter of the gas supply pipe be less than that of the appliance inlet connection The meter or regulator and pipework to the boiler must be checked preferably by the gas supplier to ensure it is in good working order and can meet the gas flow and pressure requirements in additio...

Page 11: ... s must be used on all radiators except the radiator where the room thermostat is sited this must be fitted with lockshield valves and left open All installations should have TRV s fitted to radiators within the sleeping accommodation Drain cocks are required at all the lowest points on the system Air vents are required at all high points on the system SEALED PRIMARY SYSTEM Where the system volume...

Page 12: ...be used with the approval of the local water authority and must be the over rim flushing type with shrouded outlets to prevent the fitting of hand held sprays DOMESTIC HOT WATER Taps and mixing valves must be capable of sustaining a pressure up to 10 bar Hot water temperature and flow rate are affected by the size and insulation of pipework making up the distribution system and are controlled by t...

Page 13: ...ds the outlet and should take the shortest practicable route The pipework must follow one of the options shown opposite or discharge directly into a vent stack min 450mm above pipe invert or into a gully below ground but above the water level Wherever possible the condensate discharge pipe work should be routed and terminated internally Should this not be possible and the only available route is e...

Page 14: ...any electrics or other hazard preferably to an external drain or soakaway Pipe A should be finished with a partial bend near the outlet to face the external wall as shown to help prevent freezing A Drain pipe B Outside wall PRESSURE RELIEF PIPEWORK IMPORTANT Debris from the system can damage the boiler and reduce efficiency Failure to comply with the guidelines for the use of water treatment with ...

Page 15: ... required to install service and maintain the boiler and any ancillary equipment If fitting 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 1 INSTALLATION CLEARANCES Diagram 1 shows the minimum space required to install the boiler only 2 SERVICE CLEARANCES Diagram 2 opposite shows the minimum space...

Page 16: ...ide the shaded area Additional RCD Residual Current Device protection may be required Refer to the latest IEE wiring regulations 25mm 100mm 200mm 100mm 25mm 625mm 800mm C B D 1050mm 5 VENTING COMPARTMENTS 4 AIRING CUPBOARD CLEARANCES 4 AIRING CUPBOARD CLEARANCES Diagram d opposite shows the minimum space required to install and service the boiler within an airing cupboard 5 VENTING COMPARTMENTS If...

Page 17: ...ing manifold The system can be filled without the boiler being connected using an optional charging link assembly B The valves can be closed enabling the DHW and CH systems to be tested The boiler can be installed at a later date RUNNING PIPES BEHIND THE BOILER The frame should sit against the wall not the skirting board with enough room for the pipework Do not cross a pipe over another The area a...

Page 18: ...0mm 52mm fall 104mm fall 500mm 300mm 500mm clearance to any vertical structure on a roof 600mm to another flue or 1500mm to an open flue 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 outlet must not cause a nuisance Flue gases have a tendency to plume and in certain weather...

Page 19: ...light well due to the build up of combustion products 300mm to an internal or external corner 1500mm between a vertical flue terminal and a window or dormer window 400mm from a pitched roof or in regions with heavy snow fall 500mm 2000mm below a Velux window 600mm above or to either side of the Velux window mm 300mm 1500mm 300mm Window RAINPIPE 300mm above below and either side of an opening door ...

Page 20: ...l straight flue length for each extra flue bend excluding the flue elbow by 2000mm for 90 1000mm for 45 Flue Extension lengths Horizontal Vertical Ø60 100mm 950mm Horizontal Vertical Ø80 125mm 950mm Flue Terminal lengths Horizontal Ø60 100mm 530mm Horizontal Ø80 125mm 1200mm Vertical Ø60 100mm 1140mm Vertical Ø80 125mm 1365mm PRE INSTALLATION INSTALLATION SERVICING INSTRUCTIONS 18 ROOM SEALED FLUE...

Page 21: ... pallet Slide the boiler and board off the pallet 4 Grip the outer sides of the front panel pull and lift away from retaining lugs Remove securing screw at the front of the boiler from the pallet Remove remaining screws at the rear of the boiler from the pallet The boiler is mounted on small wheels and two people are recommended to move the boiler from the board taking care not to damage the panel...

Page 22: ...mum service clearance as shown Ensure the mounting frame is level and mark fixing points C Secure mounting frame A to the floor using appropriate fixings not supplied Clear any debris from the site FLUE OPENING Follow the diagram opposite to mark the centre of the flue 1 2 for rear opening 2 3 for side opening or 1 4 for top opening Measurements shown include the minimum service clearances NOTE Al...

Page 23: ... AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS GAS AND WATER CONNECTIONS Ensure all pipework is clean and each pipe is in the correct position as shown opposite Push in each pipe in turn and tighten the fitting to secure A CH flow 22mm B DHW flow 22mm C Gas inlet 22mm D Mains water inlet 22mm E CH return 22mm F Mounting frame MOUNTING FRAME CONNECTIONS A B C D E F ...

Page 24: ...th for a horizontal Ø60 100mm flue or a Ø60mm plume management system if used as stated in this Instruction Manual or Flue Manual Cutting the flue to an exact measure is not normally required as the telescopic flue terminal allows for adjustment 1 Measure the flue length L from the boiler inner case A along the flue route to the outside wall D Note the terminal end projects beyond the outside wall...

Page 25: ...nal assembly and discard To use terminal A without cutting remove the location lug D on the inner flue tube E and remove any burrs To reduce the terminal length further 4 Mark the length required for the terminal A as shown min 130mm and cut square taking care not to damage the tubes Remove any burrs and chamfer the outer edge of the tubes to assist ease of connection and prevent seal damage NOTE ...

Page 26: ... INSTRUCTIONS 24 FLUE MEASURING CUTTING 8 716 115 219b 09 2008 FLUE MEASURING CUTTING FLUE OUTLETS L or P 1 Remove seal B from flue adaptor A 2 Cut square to mark as shown deburr and clean 3 Replace seal B L P L L P A B A B B 1 2 3 1 3 2 ...

Page 27: ...nsion vessel can be unhooked by removing the retaining screw on the hinge lowered and moved to the side Take care not to overstretch the flexible pipe connections 5 Release four screws H to remove the inner case cover I A 1 B C 2 D E 3 F G 5 H I CONVERT FROM REAR FLUE OUTLET The boiler is supplied ready to fit a rear flue outlet To flue from the sides or top of the boiler follow the procedure belo...

Page 28: ...g slide the outer wall seal K onto terminal B 3 Position terminal B through the flue opening in the wall to the outside of the building by the distance shown and then pull back to create a seal The flue terminal B MUST be fitted with the label marked TOP uppermost to allow the correct fit and use of the plume management system If fitting from the outside of the building slide the outer wall seal K...

Page 29: ...the boiler inner casing E Secure using three hexagonal bolts F 4 Push fit adaptor G into elbow H until secured by the clip 5 Push fit the adaptor G into the inner flue extension B and push elbow H into flue outlet J until secured by the retaining clips 6 Slide a support clamp C not supplied onto additional flue extensions B Working from the boiler fit the extension s with support clamp s as requir...

Page 30: ...d 1 Remove screws A and terminal end B 2 Spread the extra grease supplied into the groove that runs around the terminal outlet C to ensure a good seal is retained 3 Rotate the detached end section B to plume deflecting position as shown and refit using screws A 4 Loosen screws D and rotate the terminal end B C to redirect the plume DO NOT rotate the complete flue terminal assembly Retighten screws...

Page 31: ... adaptor K to the discharge outlet Never terminate or discharge into any open source including sink bath shower bidet toilet etc Note Any external condensate pipework should be protected with weather resistant insulation to help prevent freezing The flexible pipe supplied can only be used inside the property CAUTION ISOLATE THE MAINS GAS AND WATER SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RE...

Page 32: ...t a length of 15mm copper pipe A to the P R V drain pipe B The P R V drain pipe B should be at least 15mm diameter and run down away from any electrics or other hazard IMPORTANT The pressure relief valve is a safety device for the boiler and if activated may discharge boiling water or steam through the P R V drain pipe Auto air vent Remove the auto air vent cap C and discard B C A C ...

Page 33: ... wires from cable end and strip to 6mm Connect LIVE wire to terminal L Connect NEUTRAL wire to terminal N Connect EARTH wire to connector NOTE Make the EARTH wire longer so that if the cable is snagged the EARTH wire is the last to be pulled out 7 Optional frost thermostat connection ST6 Connect frost thermostat supply wire to terminal Fs Connect frost thermostat return wire to terminal FR 8 230V ...

Page 34: ...e matches that of the gas supply Turn on the main gas supply check the gas pipework connections and rectify any leaks 3 Check the flue is correctly fitted and the connections are secure 4 Check the condensate pipework is correctly fitted and connected 5 Check the CH circulating pump is set to 3 Note The CH circulating heating pump is preset to number 3 and should not be altered IMPORTANT If the bo...

Page 35: ... fitted to the expansion vessel to allow for pressure adjustment if required If an extra expansion vessel is fitted to the central heating return adjust this to the same pressure as the appliance internal expansion tank refer to separate instructions with the extra expansion vessel 6 Briefly open the pressure relief valve to test its operation 7 Close the tank drain valve Disconnect the integral f...

Page 36: ...es are open Add a suitable inhibitor or combined inhibitor anti freeze if the system is exposed to freezing conditions to the heating system in accordance with the manufacturers instructions The inhibitor or combined inhibitor anti freeze must not cause damage to the materials within the boiler aluminium stainless steel copper and brass and any other materials components within the system Open ven...

Page 37: ...the reset button E for 2 seconds CAUTION DO NOT PRESS THE POWER INDICATOR B TO RESET THE BOILER THE COMBUSTION FOR THE APPLIANCE IS FACTORY SET NO ADJUSTMENT IS REQUIRED IF THE GAS INLET PRESSURE IS CORRECT CHECKING THE GAS INLET PRESSURE The inlet pressure to the appliance must be checked using the following procedure SETTING THE BOILER TO MAXIMUM Press boost button for ten seconds and set temper...

Page 38: ...nto retainers G Push top of door to engage clips HANDOVER Complete the Benchmark log book at the rear of the manual Set up the controls and show the user how to operate all the controls shown in the User Guide Instruct the customer how to repressurise the system If the appliance is unused and exposed to freezing conditions advise the customer of the precautions necessary to prevent damage to the b...

Page 39: ...ed by the Bosch Heatronic Service Function 6A Refer to Fault Finding under the Fault Finding Diagrams section for display codes and rectification procedures SERVICE FUNCTION Setting boiler to maximum Note when running in the heating boost mode the boiler will operate both the Central Heating and DHW circuits This is to allow sufficient time for setting procedure It will be necessary to run water t...

Page 40: ... to swing control panel assembly D outwards to its full extent 3 Pull clip E outwards to release expansion vessel F 4 Swing expansion vessel F outwards Note for easier access to the inner case the expansion vessel can be unhooked by removing the retaining screw on the hinge lowered and moved to the side Take care not to overstretch the flexible pipe connections 5 Release four screws G to remove th...

Page 41: ...if present 3 Unscrew the condensation trap cap and place a suitable container underneath To Remove Condensate pump Disengage condensate pipe from condensate pump Remove condensate pump from base panel After servicing the heat exchanger fill the condensate trap with approximately 1 4 litre of water and refit in reverse order To Clean the Heat Exchanger 4 A Loosen any deposits in the heat exchanger ...

Page 42: ...this pressure is exceeded then an extra expansion vessel must be fitted into the system return as close as possible to the appliance If the system does not retain the pressure the expansion vessel and the heating system should be checked for leaks Electrical wiring Check the electrical wiring for physical damage and replace any damaged wires To check the diaphragm in burner cover Carefully withdra...

Page 43: ... the water circuits PCB CONTROL BOARD TRANSFORMER Access to boiler control components Remove screws A to release the cover from the controller PCB Fuse Remove the fuse B and replace with a spare that are clipped on the inside of the controller cover Transformer PCB Disconnect all electrical connections from the control Remove the screws C retaining the rear panel of the control and remove the pane...

Page 44: ...ndensate tank Take care as there may be condensate remaining in the pipe Carefully remove the condensate pump G from the boiler and pour any excess condensate into a suitable container for safe disposal Diverter valve motor Ensure that the appliance is in service mode there is no need to drain the appliance Disconnect the electrical connector K from the diverter valve motor L Pull the motor L towa...

Page 45: ...ce with paste supplied Re assemble Tank overheat thermostat D Remove screws retaining plastic cover Remove cover and disconnect 2 electrical connections Unscrew 2 hexagon studs Replace sensor coating surface with paste supplied Re assemble Flow sensor flow regulator assembly E Shut off mains water at inlet valve and drain DHW circuit Disconnect inline connector Remove 2 retaining clips F Remove fl...

Page 46: ...on connection at the top of the vessel Set the pressure of the new vessel to that required by the system Pressure relief valve Drain the appliance Disconnect drain pipe from valve D Undo nut retaining valve to flow pipe Undo nut connecting pressure gauge Remove valve Replace sealing washer and fit a new valve Condensate trap Move control and pressure vessel into service position Remove inner case ...

Page 47: ...ar securing nut E Remove the burner coverplate F Remove the burner skin G Re assemble the new burner in reverse order inspect seal H for damage and replace if necessary After re assembly check CO CO2 levels as described in the section Setting the air gas ratio Primary heat exchanger Isolate appliance from the power supply Turn off all isolation valves Drain down appliance Move control and pressure...

Page 48: ...tput Press and hold down the boost button B for 10 seconds Turn temperature control C to maximum the boiler will then go to maximum output Note the control will resume normal operation after 15 minutes or if the boost button B is pressed for more than 1 second 3 Remove plastic cap and using a flat bladed screwdriver set the CO2 via adjuster D referring the table opposite Note CO2 should be measure...

Page 49: ... sensor primary Part No 8 714 500 087 0 GC No E74 536 9 Temperature limit Flue or heat exchanger Part No 8 722 963 858 0 GC No H08 291 10 Thermistor sensor DHW Part No 8 716 142 302 0 GC No 375 696 11 Thermister sensor tank Part No 8 716 142 319 0 GC No 379 785 12 Overheat thermostat Tank Part No 8 716 103 217 0 GC No E82 394 13 Heat exchanger 440CDi Part No 8 716 108 212 0 GC No H22 465 550CDi Pa...

Page 50: ...code plug number 440CDi 1701 550CDi 1703 Refit panel B and secure with three screws A Change gas pipe 4 Rotate gas pipe D anti clockwise pull upwards and remove gas pipe 5 Replace with new conversion gas pipe E push downwards and rotate clockwise to lock into position Conversion label Replace existing label with new conversion label Adjust the CO2 level After re assembly check CO CO2 levels as des...

Page 51: ...alve Flame sense spark Primary NTC Tank NTC Tank Overheat High Level sensor Condensate pump DHW NTC turbine Primary overheat Flue overheat 1 in series Outdoor temp NTC Norm closed pre linked NP LP FS FR ST19 LZ NZ FAULT FINDING DIAGRAMS INSTALLATION SERVICING INSTRUCTIONS 49 ELECTRICAL WIRING DIAGRAM 8 716 115 219b 09 2008 ELECTRICAL WIRING DIAGRAM Red Yellow White Pink Red Yellow Black Green Oran...

Page 52: ...r u p r e n r u b m o r f h t 5 t p m e t t A LO K C T U O r e n r u B s e s i l i b a t s t r a t s t a r o f d e e p s 0 1 5 s d n o c e s F n a s e c u d e r r e v o 5 1 s d n o c e s r e l i o B d e s u n u g n o l r o f d o i r e p O N E Y S F n i m n a d e e p s r o f 9 0 s d n o c e s m u m i n i M t u p n i t a e h r o f n i m 5 1 e r u t a r e p m e t r e v O r e t a w f i n w o d t u h s...

Page 53: ...a e h d e r e v i l e d n i a t n i a m t e s e r u t a r e p m e t l o r t n o c r e s u y b 5 4 5 6 C n a f e t a l u d o M o t t u p n i t a e h c o t k n a t e g r a h t e s e r u t a r e p m e t l o r t n o c r e s u y b 5 6 7 5 C d n a m e d f o d n E T d e i f s i t a s k n a c e h C t k k n a r u t a r e p m e t e r a e n l l i t s t i s I t n i o p t e s S A G V L A E V F O F n a f e u n ...

Page 54: ...stat check gas supply and igniter electrode check CH NTC and lead check system pressure and pump check electrical connector contacts software pcb error check electrode assembly dry pcb check gas valve and leads press reset button again Display Code A5 A7 A8 b1 b2 b3 b4 b5 b6 b7 C6 D3 D5 D6 EA E2 E9 F0 F1 F7 FA Fd Fault description Tank NTC defect DHW NTC defect EMS coms error Code plug not detecte...

Page 55: ... manufacturer record the following CO2 OR CO ppm OR CO CO2 Ratio The heating and hot water system complies with the appropriate Building Regulations Yes The boiler and associated products have been installed and commissioned in accordance with the manufacturer s instructions Yes The operation of the boiler and system controls have been demonstrated to and understood by the customer Yes The manufac...

Page 56: ...Signature SERVICE 7 Date Energy Efficiency Checklist completed Yes No Engineer Name Company Name Telephone Number CORGI ID Number Comments Signature SERVICE 9 Date Energy Efficiency Checklist completed Yes No Engineer Name Company Name Telephone Number CORGI ID Number Comments Signature SERVICE 2 Date Energy Efficiency Checklist completed Yes No Engineer Name Company Name Telephone Number CORGI ID...

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Page 60: ...ing 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 8 716 115 219b 09 2008 ...

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