Worcester GREENSTAR 29CDi Classic ErP Installation, Commissioning And Servicing Instructions Download Page 1

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UK/IE

INSTALLATION COMMISSIONING AND SERVICING INSTRUCTIONS

WALL HUNG RSF GAS FIRED CONDENSING COMBINATION BOILER

GREENSTAR CDi CLASSIC

ErP

6 72

0 812 176-00.1O

FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER

6 720 815 725 (2015/05)

The appliances are for use with:
Natural Gas or L.P.G. (Cat. II 2H3P type C13, C33 & C53)

Natural Gas:
29CDi Classic

ErP

GC number 47-406-65

34CDi Classic

ErP

GC number 47-406-67

38CDi Classic

ErP

GC number 47-406-69

42CDi Classic

ErP

GC number 47-406-71

L.P.G.:
29CDi Classic

ErP

GC number 47-406-66

34CDi Classic

ErP

GC number 47-406-68

38CDi Classic

ErP

GC number 47-406-70

42CDi Classic

ErP

GC number 47-406-72

Summary of Contents for GREENSTAR 29CDi Classic ErP

Page 1: ...ATER 6 720 815 725 2015 05 The appliances are for use with Natural Gas or L P G Cat II 2H3P type C13 C33 C53 Natural Gas 29CDi Classic ErP GC number 47 406 65 34CDi Classic ErP GC number 47 406 67 38C...

Page 2: ...t 26 4 5 2 60 mm Plume management kit 26 4 5 3 Adjusting the standard terminal length 26 4 5 4 Installing the standard flue 27 4 5 5 Flue terminal plume re direction 27 4 6 Condensate connection 28 4...

Page 3: ...eywords at the start of a warning indicate the type and seriousness of the ensuing risk if measures to prevent the risk are not taken This symbol indicates important information where there is no risk...

Page 4: ...013 If the installation is in a new build property or is a first time installation in an existing property heating systems must conform to current building regulations Part L1a All new heating systems...

Page 5: ...hung gas fired condensing combi boiler for central heating and domestic hot water B Wall mounting plate with hanging bracket C Pre plumbing manifold D Hardware pack E ErP energy label F Literature pac...

Page 6: ...APPLIANCE INFORMATION 6 720 815 725 2015 05 6 2 2 LAYOUT COMPONENTS Fig 3 Boiler components 2 3 4 5 6 8 15 9 10 13 12 14 16 17 20 23 24 25 26 27 28 1 22 21 18 19 7 6 720 815 725 06 1O 11...

Page 7: ...AN PRESSURE TEST POINT 26 FAN 27 PRIMARY SENSOR 28 EXPANSION VESSEL Table 3 Main boiler components 6 34 41 33 29 30 32 31 6 720 812 176 07 1O 7 40 8 41 36 35 37 38 39 9 29 FLOW TURBINE 30 UNUSED PORT...

Page 8: ...0 5 10 5 8 6 12 3 15 5 15 5 Min rated heat output net 80 60 C kW 7 7 7 7 9 4 9 4 7 7 11 0 13 9 13 9 Min rated heat input net kW 8 0 8 0 9 8 9 8 8 0 11 5 14 5 14 5 Max flow temperature nominal C 90 90...

Page 9: ...asonal space heating energy efficiency s 92 92 92 92 Energy efficiency class A A A A Useful heat output At rated heat output and high temperature regime 1 1 High temperature regime means 60 C return t...

Page 10: ...30 0 30 0 30 0 At 30 of rated heat output and low temperature regime 2 2 Low temperature means for condensing boilers 30 C for low temperature boilers 37 C and for other heaters 50 C return temperatur...

Page 11: ...the boiler must be in accordance with BS6891 Under no circumstance should the size of the gas supply pipe be less than 22 mm The meter or regulator and pipe work to the meter must be checked preferabl...

Page 12: ...t hot and cold mains water can be used with the approval of the local water authority and must be the over rim flushingtypewithshroudedoutletstopreventthefittingofhandheld sprays SEALED PRIMARY SYSTEM...

Page 13: ...ould be removed using a proprietary condensate pump of a specification recommended by the boiler or condensate pump manufacturer The pump outlet pipe should discharge to a suitable internal foul water...

Page 14: ...from wind chill Pipe drainage will be improved if the end is cut at 45 as opposed to a straight cut Fig 14 External disposal CONDENSATE SOAK AWAY Thecondensatedrainagepipemayberunaboveorbelowthegroun...

Page 15: ...a soakaway or a condensate pump Use an esxternal drain point on the system to prevent excess system water being drawn through the saokaway or condensate pump NOTICE Unheated internal areas Internal pi...

Page 16: ...tition The partition may be perforated if required by holes not exceeding 13 mm in diameter If the appliance is fitted into a cupboard or a compartment is built around the appliance after installation...

Page 17: ...d installed pipe work can be installed to the valves on the manifold The pipes can be run below the boiler or alternatively up behind the boiler RUNNING PIPES BEHIND THE BOILER If the boiler pipes are...

Page 18: ...2 0 metres of straight flue Each 45 bend used is equivalent to 1 0 metre of straight flue Telescopic horizontal flue Flue option 1 100mm 125mm 29CDi ErP 570mm 600mm 34CDi ErP 570mm 600mm 38CDi ErP 570...

Page 19: ...PRE INSTALLATION 6 720 815 725 2015 05 19 Fig 22 350 mm 570 mm 130 mm Min Flat roof 300 mm 500 mm Pitched roof 2 3 4 5 6 10 9 8 7 1 6720643895 12 1Wo...

Page 20: ...e and drains 16 The dimension below eaves balconies and car ports can be reduced to 25mm as long as the flue terminal is extended to clear any overhang External flue joints must be sealed with suitabl...

Page 21: ...mthelowestpointofthebalcony or overhang 9 1 200mm from an opening in a car port on the same wall e g door or window leading into the dwelling 10 600mm distance to a surface facing a terminal unless it...

Page 22: ...ked before ascending ladder to loft space Two sets of steps should be used Two people should share the lifting of the boiler up to the loft hatch where the boiler is entered into the loft space tilted...

Page 23: ...ackaging 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 releas...

Page 24: ...r rear outlet 3 or for side outlet 4 For the 60 100 mm flue make a 125 mm diameter hole through the wall using a core drill or similar For flues using an optional weather collar fitted from inside the...

Page 25: ...the system pipes Connect the gas supply to the boiler gas cock 22mm compression Connect cold water in and DHW out to the boiler s 15mm compression connectors Connect the CH flow and CH return pipes to...

Page 26: ...ith plume management extension components Fig 34 60mm PLUME MANAGEMENT KIT 7 716 191 086 replaces the plume deflector in the 60 100mm telescopic flue terminal 4 5 3 ADJUSTING THE STANDARD TERMINAL LEN...

Page 27: ...e terminal 2 as shown Fig 38 Flue installation 4 5 5 FLUE TERMINAL PLUME RE DIRECTION The flue discharge can be re directed allowing some plume redirection control alternatively a complete plume manag...

Page 28: ...onnection Aligntheinstallationsideplasticpipeworkthroughthepre plumbing manifold Connect the installation side plastic pipework to the end of the condensate hose Push the plastic pipework inside the c...

Page 29: ...or 7 Optional external frost thermostat connection ST6 Connect frost thermostat supply LIVE to terminal FS Connect frost thermostat SWITCHED LIVE to terminal FR 8 230V room thermostat and or external...

Page 30: ...y 230V EXTERNAL CONTROLS OPTION WORCESTER 24V CONTROLS OPTION PLUG IN POINT under blanking cover on fascia EMS BUS contacts for FX Sense controls Outside sensor FW 100 Live Supply Live Return Neutral...

Page 31: ...ck that the condensate pipe has been connected to the adaptor Fig 47 5 2 FILLING THE SYSTEM Ensure all system and boiler drain points are closed Remove the bottom panel if fitted Open the isolating va...

Page 32: ...DHW temperature control I Central heating temperature control J Performance test button K Service button L Burner indicator GREEN M On off and fault indicator BLUE N Automatic air vent Fig 50 Control...

Page 33: ...when the inhibitor was added to the system on the guarantee card 5 5 COMMISSIONING Fig 52 Control panel NOTICE ARTIFICIALLY SOFTENED WATER MUST NOT BE USED TO FILL THE CENTRAL HEATING SYSTEM The pH va...

Page 34: ...er to the figure below for natural gas pressures The pressure at the boiler must not be less than the pressure read at the meter minus 1 mbar Thepressuredropfromthemetertothegasvalvemustnotbemorethan...

Page 35: ...15 minutes Close the gas isolation valve Remove the manometer Re seal the screw in the gas inlet pressure test point Open the gas isolation valve Ensure that there are no gas leaks Replace the outer c...

Page 36: ...nalysermusthavebeencalibratedas specified by the manufacturer The installer must be competent in the use of the analyser Check and zero the analyser in fresh air as specified by the manufacturer The a...

Page 37: ...the panel up against the underside of the boiler and slide towards the rear until it is fully engaged HANDOVER Complete the Benchmark check list The fascia cover is opened by pulling the flap D towar...

Page 38: ...performance of the boiler can be checked via the flue turret sample points Fig 59 Flue turret test points With the boiler case on and the boiler running at maximum output refer to paragraph SET THE B...

Page 39: ...ol panel A ON OFF button B Cover or optional plug in controller C Display D System pressure gauge E Reset button F ECO button G Holiday button H DHW temperature control I Central heating control J Per...

Page 40: ...R 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 present Fig 66 Cleaning heat exchanger 2 Loosen any dep...

Page 41: ...e fan Slacken fully the rear securing bolt F Remove the burner cover plate G Fig 68 3 Remove the burner H and clean components Do not use a wire brush Fig 69 6 1 6 TO CHECK THE DIAPHRAGM IN BURNER COV...

Page 42: ...seal inlet pressure point on gas valve Fit new plastic sealing cover onto the max adjuster Replace the brass screw over the min adjuster on the valve Re assemble and refit boiler case Fig 71 Setting...

Page 43: ...from connector coat new sensor with heat conductive paste and replace 4 OVERHEAT THERMOSTAT Remove two electrical connectors from thermostat Unscrew the sensor 5 FLUE LIMIT THERMOSTAT Remove electric...

Page 44: ...tion C to gas valve Undo two securing screws D on the underside of casing Pull valve up and forward out of boiler Disconnect electrical connections Replace valve with new seals and check for gas tight...

Page 45: ...or from fan Remove condensate trap see page 41 1 Undo the union connection A from the top of the gas valve Remove wire clip B from air gas adjustment assembly C then pull gas pipe down 2 Unscrew two s...

Page 46: ...Check that the boiler is completely isolated from the gas supply Fig 81 Top panel 2 Remove clips C and unscrew the two bolts D Unscrew and remove the two hexagon screws E securing the fan Slacken ful...

Page 47: ...D Fig 88 Heat exchanger removal 3 4 Undo flue connection E from sump F Pull flue pipe up Remove the heat exchanger Fig 89 Heat exchanger removal 4 17 DIVERTER VALVE MOTOR There is no need to drain the...

Page 48: ...ut of the housing and remove To refit follow the above in reverse Fig 92 Auto Air Vent removal 20 DHW TEMPERATURE SENSOR Ensure the domestic hot water circuit is fully drained Disconnect the electrica...

Page 49: ...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 h...

Page 50: ...ssure relief valve Disconnect the drain pipe from the drain tap see e g step 1 in Fig 96 Release the locking devices that secure the two copper water pipes leading to the combustion chamber by squeezi...

Page 51: ...PLASTIC PROTECTION DEVICE Ensure the system is fully drained Disconnect all pipes connected to the pump housing Remove the electrical connection to the pump Withdraw the metal clip to the right of the...

Page 52: ...valve 8 718 221 347 0 GC No H56 469 Temperature limit sensor 8 722 963 858 0 GC No H08 291 Electrodes 8 716 771 932 0 GC No H22 458 Flow reg Type E 11 litre brown8 716 107 044 0 Flow reg Type E 12 li...

Page 53: ...trol sensor primary8 714 500 087 0 GC No E74 536 Heat Exchanger inspection cover seal 8 710 103 153 0 Pressure relief valve 8 716 106 431 0 GC No H09 750 Auto Air Vent 8 716 106 445 0 Flue overheat th...

Page 54: ...d the breaking and remaking of electrical connections check a EARTH CONTINUITY b SHORT CIRCUIT CHECK c POLARITY d RESISTANCE TO EARTH You can also use this menu item to check the hot water flow rate a...

Page 55: ...setpoint by 10K Diverter Value in CH position pump ON Gas value OFF Fan overrun 30 seconds Over temperature shut down if water temperature exceeds set value CH setpoint 90 seconds stabilisation period...

Page 56: ...DHW position Pump ON 5th attempt Spark ignition 4 seconds Stop spark Wait 10 seconds BURNER LIT IGNITION SEQUENCE see details GREEN FLAME LIGHT ON DEMAND END DEMAND END Fan gas modulation to achieve s...

Page 57: ...7 5 PROTECTION FUNCTION Holiday mode set to ON All other demands not active Frost protection active DHW demand active Pump runs for 5 seconds every 24 hours Pump antiseize Run autofroststat function...

Page 58: ...SKRQH 1R DV VDIH UHJLVWHU 1R 5HFRUG W PD UDWH 2 SSP AND 2 W PLQ UDWH KHUH 3RVVLEOH 2 SSP AND 2 RPPHQWV 6LJQDWXUH SERVICE 04 DWH QJLQHHU QDPH RPSDQ QDPH 7HOHSKRQH 1R DV VDIH UHJLVWHU 1R 5HFRUG W PD UDW...

Page 59: ...HU LQWHUORFN 3URYLGHG ALL SYSTEMS 7KH V VWHP KDV EHHQ XVKHG DQG FOHDQHG LQ DFFRUGDQFH ZLWK 6 DQG ERLOHU PDQXIDFWXUHU V LQVWUXFWLRQV Yes KDW V VWHP FOHDQHU ZDV XVHG KDW LQKLELWRU ZDV XVHG 4XDQWLW OLWUH...

Page 60: ...9669 Worcester Bosch Group Cotswold Way Warndon Worcester WR4 9SW Tel 0330 123 9559 Worcester Bosch Group is a brand name of Bosch Thermotechnology Ltd worcester bosch co uk 6 720 815 725 2015 05 WORC...

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