Worcester Greenstar CDi Compact Installation, Commissioning And Servicing Instructions Download Page 54

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FAULT FINDING AND DIAGNOSIS

6 720 803 800 (2012/11)

FAULT FINDING AND DIAGNOSIS

7.1

INTERNAL WIRING DIAGRAM

EMS

230V
IN

230V
OUT

FR FS LR LR

PUMP SUPPLY

FLAME SENSE
ELECTRODE

SPARK
ELECTRODES

FLOW

NTC

MAX SAFETY NTC

FLUE
STAT

DIVERTER

VALVE

DHW
NTC

RETURN

NTC

FAN

FLAME SENSE
GROUND

GAS

VALVE

SAFETY

SOLENOID

SAFETY

SOLENOID

FLOW

TURBINE

DHW INLET NTC

(PREHEAT OPTION)

PUMP CONTROL

PUMP

Purple

White

Black

Fan wiring:
Live = Brown
Neutral = Blue

Fuse, slow

EMS BUS point

HCM (at rear of PCB)

Worcester 24V controls point

F 5A H 230 V

X11

X12

DIAGNOSTIC
INPUT

DHW TEMPERATURE
CONTROL

CH TEMPERATURE
CONTROL

LCD DISPLAY

Black

Blue

Red

Green

Blue

Red

Blue

Orange

Blue

Brown

Purple

Black

Green

Yellow

Red

White

Yellow

Orange

Red

Blue

Red

Blue

Green

Black

G/Y

6720646608-03.3Wo

PRE WIRED LINK

Red

Orange

White

Yellow

Blue

Brown

Red

Blue

Orange

SPARK

GENERATOR

White

Summary of Contents for Greenstar CDi Compact

Page 1: ...EATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER 6 720 803 800 2012 11 The appliances are for use with Natural Gas or L P G Cat II 2H 3P type C13 C33 53 Natural Gas 28CDi Compact GC number 47 406 44 32...

Page 2: ...5 1 Checking the gas inlet pressure 33 5 5 2 Checking the gas rate 34 5 5 3 Gas rating test 34 5 5 4 Checking for leaks during operation 34 5 6 Domestic hot water 35 5 7 Finishing commissioning 35 5...

Page 3: ...le or property Symbol Explanation Step in an action sequence Cross reference to another part of the document List entry List entry second level Table 1 Domestic Hot Water Central Heating Hot Water Sto...

Page 4: ...ngineer must complete the Service Record on the Benchmark Checklist after each service INSTALLATION REGULATIONS Current Gas Safety Installation Use Regulations All gas appliances must be installed by...

Page 5: ...l mounting frame 3 Integral Filling Loop kit 4 Hardware literature pack Greenstar CDi Compact Installation Commissioning and Servicing Instructions User guide Boiler fascia guide Wall mounting templat...

Page 6: ...800 2012 11 6 2 2 LAYOUT Fig 1 Main boiler components 49 48 47 46 45 44 43 42 41 40 39 38 37 36 28 56 55 54 53 50 52 31 30 29 32 33 35 12 13 14 1 2 3 4 5 6 7 8 6720646608 02 4Wo 51 17 18 19 20 21 24...

Page 7: ...ectrode assembly 3 CH return isolating valve 31 Maximum safety sensor NTC 4 DCW mains isolating valve 32 Auto air vent 5 Gas isolating valve 33 Aluminium Silicon Heat exchanger 6 DHW outlet connection...

Page 8: ...64 69 66 73 66 79 66 Flue gas temperature 40 30 C rated min load C 48 36 51 36 52 36 50 37 52 37 54 37 CO2 level at max rated heat output after 10 minutes 9 1 9 1 9 1 10 6 10 6 10 6 CO2 level at min r...

Page 9: ...ted to a governed meter Liquid Petroleum Gas LPG must be connected to a regulator Installation and connection of the gas supply to the boiler must be in accordance with BS6891 Under no circumstance sh...

Page 10: ...s with direct hot and cold mains water can 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 spray...

Page 11: ...s an internal soil and vent stack internal kitchen or bathroom waste pipe washing machine waste pipe etc A suitable permanent connection to the foul waste pipe should be used Fig 7 Condensate pump dis...

Page 12: ...event blockage by leaves may offer further protection from wind chill Pipe drainage will be improved if the end is cut at 45 as opposed to a straight cut Fig 9 External disposal CONDENSATE SOAK AWAY T...

Page 13: ...ss door is required to install service and maintain the boiler and any ancillary equipment If fitting the boiler into an airing cupboard use a non combustible material to separate the boiler from the...

Page 14: ...2 608 Fig 15 Pipe dimensions Fig 16 Plumbing manifold Heating System 22mm compression fittings DHW 15mm compression fittings Gas 22mm compression fittings Further guidance on pipe routing can be found...

Page 15: ...ue each 45 bend used is equivalent to 1 metre of straight flue Plume management kits are available for the 60 100 horizontal flue system Part number 7 716 191 086 Refer to the manual supplied with the...

Page 16: ...PRE INSTALLATION 6 720 803 800 2012 11 16 350 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 17: ...600mm to room sealed flue or 1 500 to an open flue 15 200mm below eaves and 75mm below gutters pipe and drains 16 The dimension below eaves balconies and car ports can be reduced to 25mm as long as th...

Page 18: ...y 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 will cause a nuisance BS5...

Page 19: ...Literature pack with wall mounting template 4 Integral Filling Loop kit 5 Front fascia panel 6 PRV installer connection elbow IMPORTANT HANDLING INSTRUCTIONS It is advised that two people are used to...

Page 20: ...arkthecentrelineofthefluetobeused 3 theexternaldiameterof the hole can also be marked if required If a 100mm diameter flue is to be used a 125mm diameter hole is required However if using the weather...

Page 21: ...r and the packaging base 3 Leave the V shaped support 5 in place until the boiler is ready to be hung on the wall frame then remove 4 4 PRE PLUMBING BOILER CONNECTIONS PLUMBING THE CONDENSATE DRAIN PI...

Page 22: ...fer to figure 30 Fig 30 Fitting the Filling link 1 CH return connection 2 Blanking plugs x 2 3 Filling link assembly 4 Filling key 5 White control screw 6 Filter 7 M4 screws and washers x 4 8 DHW inle...

Page 23: ...e the pre plumbing connector Unscrew the PRV outlet pipe from the pre plumbing connector Remove the two screws 1 holding the pre plumbing connector in place Remove the temporary PRV pre plumbing conne...

Page 24: ...ut not removed before inserting the expansion vessel pipe into pump manifold see fig 36 3 Secure in place with the wire retaining clip Fig 36 Expansion vessel connection CONNECTING THE SIPHON OUTLET 1...

Page 25: ...turret and secure the terminal end with the screws 3 To reduce the flue length further Fig 41 Further reduction Markthelengthrequiredfortheterminalasshown min 130mm and cut square taking care not to d...

Page 26: ...E DISCHARGE 1 Unclip 1 2 the terminal end and rotate through 180 2 Refit to the terminal ensuring that the clips 1 2 are engaged and secure 3 Loosen screws 3 and rotate the entire outlet assembly to r...

Page 27: ...Installer access cover 2 Remove the Installer access cover Fig 48 Removing the installer access cover Low voltage connections Fig 49 Low voltage connectors 1 Opening in building 2 Flue discharge 3 Plu...

Page 28: ...on the back of the Programmer Timer with the slots in the control panel Fig 52 Connecting the Programmer Timer 3 Push the Programmer Timer in to engage with the slots in the control panel 4 Pull the P...

Page 29: ...3 EXISTING INSTALLATIONS Forboilerreplacementsonanexistingsystem itisnotnecessarytozone the upstairs and downstairs separately compliance with the zone requirements can be achieved by a single room th...

Page 30: ...ly Turn on the main gas supply carry out a tightness test on the gas pipe work with the boiler gas pipe isolating valve open and connections Rectify any leaks Check that the condensate pipe has been c...

Page 31: ...system to remove the flushing agent and debris INHIBITOR Central Heating Check drain cocks are closed and all radiator valves are open before adding a suitable inhibitor compatible with aluminium or c...

Page 32: ...itial start up the following screens are displayed 1 All the symbols are displayed for approximately two seconds 2 The control will run an internal test for approximately 30 seconds 3 Whentheinternalt...

Page 33: ...psymbolandthewordMAX will flash SCREEN DISPLAY DESCRIPTION All possible screen symbols This screen is displayed briefly duringboilerstartupandshows all the symbols that could be displayed Alpha Numeri...

Page 34: ...5 5 3 GAS RATING TEST Ensure all other gas appliances are isolated 1 Settheboilertomaximumoutputbypressing andthe button together for at least 5 seconds The chimney sweep symbol 1 will be displayed at...

Page 35: ...case 5 7 2 SECURING THE CONTROL PANEL 4 Raise the control panel 5 Push the control panel up to engage the top edge under the case 6 Lift the catches with your fingers 7 Press the bottom of the contro...

Page 36: ...e documented as a part of the Benchmark Checklist The boiler has been used only for the normal domestic purposes for which it was designed This guarantee does not affect your statutory rights GUARANTE...

Page 37: ...on circuit e g missing or dislodged seals Fig 71 Flue integrity test 6 3 COMPONENT ACCESS To gain access to the components remove the outer case 1 Remove the two screws securing the control panel 2 Re...

Page 38: ...manometer reading is in the black area of the chart then carry out the following checks Check that the siphon is not blocked Check the exhaust paths for restrictions Clean the heat exchanger with a su...

Page 39: ...NG THE HEAT EXCHANGER The following items will have to be removed to gain access to the heat exchanger for cleaning Lower the control panel into the service position Remove the case Disconnect electri...

Page 40: ...aded cleaning tool and brush Visually inspect the inside of the heat exchanger by shining a torch from the top down into the sump area When there is little or no light visible this would suggest that...

Page 41: ...s securing the bottom of the case 6 Release the two catches on top of the boiler 7 Pull the case towards you and remove On completion of the heat exchanger cleaning and re assembly perform the fan pre...

Page 42: ...rom the wall frame connector 2 Rotate the siphon body clockwise to release the bayonet connection 3 Pull the siphon body down and away from the boiler Fig 85 Syphon removal 6 8 4 PRIMARY SENSOR CH NTC...

Page 43: ...ir vent When re assembling ensure that the O ring is fitted to the Auto air vent and NOTthe heat exchanger otherwisethe Air ventwill be difficult tofit Apply silicone grease to the O ring to ease asse...

Page 44: ...ean and free of debris Fig 92 Sump seal COMBUSTION AIR INLET AND GAS PIPE DISCONNECTION 1 Rotate the combustion air inlet pipe anticlockwise to release from the fan assembly and pull away from the fan...

Page 45: ...Lift the transformer from the retaining clip Fig 97 Ignition transformer 6 8 12 ELECTRODE ASSEMBLY To remove the spark electrode assembly 1 Undo and remove the two nuts securing the electrode assembl...

Page 46: ...exchanger Fig 100 Burner and gasket 6 8 14 HEAT EXCHANGER HEAT EXCHANGER DISCONNECTION 1 Undo the flow and return connections 2 Pull both the flow and return pipes away from the heat exchanger Replace...

Page 47: ...sensor from the pipe Fig 104 DHW temperature sensor 6 8 17 PUMP HEAD 1 Disconnect the main electrical connector from the bottom of the pump 2 Remove the four screws securing the pump head 3 Pull the...

Page 48: ...he flow regulator can be further broken down into 1 Spacers 2 Flow regulator 3 Flow regulator housing Fig 107 Flow regulator assembly 6 8 20 PRESSURE GAUGE Ensure that the boiler is fully drained 1 Ca...

Page 49: ...GER 1 Undo and remove the retaining screw 2 Rotate the left hand side of the heat exchanger towards you and slide out to the left Fig 113 Remove plate heat exchanger When replacing the heat exchanger...

Page 50: ...s valve Fig 115 Bypass valve Whenre assembling inreverseorder ensurethatanysealsthathave been disturbed are replaced 6 8 28 ACCESS TO BOILER CONTROL COMPONENTS 1 Release the three captive screws retai...

Page 51: ...it the new control unit in the reverse order Attach support strap to the new control unit Fit the HCM removed from the old control unit into the retainer and reconnect the cable Reconnect all the cabl...

Page 52: ...ect the electrical supply and any external controls Disconnect the flue from the boiler Undo the connections to the boiler at the service valves Lower the control panel into the service position At th...

Page 53: ...18 684 213 0 Used on 32CDi Compact Flow regulator 13 litre E W LP Olive green 8 718 688 409 0 Used on 36CDi Compact Flow NTC 8 718 688 801 0 Flow turbine 8 717 002 132 0 Diverter valve assembly 8 716...

Page 54: ...P CONTROL PUMP Purple White Black Fan wiring Live Brown Neutral Blue Fuse slow EMS BUS point HCM at rear of PCB Worcester 24V controls point F 5A H 230 V X7 X6 X5 X3 X11 X4 X12 DIAGNOSTIC INPUT DHW TE...

Page 55: ...FAULT FINDING AND DIAGNOSIS 6 720 803 800 2012 11 55 7 2 CENTRAL HEATING FUNCTION Fig 123 Central Heating function...

Page 56: ...erature exceeds a predefined limit for primary or outlet Gas valve OFF Fan overrun 30 seconds Spark ignition and gas 4 seconds NO YES PREHEAT displayed AND 20 minutes since last pre heat demand AND te...

Page 57: ...FAULT FINDING AND DIAGNOSIS 6 720 803 800 2012 11 57 7 4 PROTECTION FUNCTION Fig 125 Protection function...

Page 58: ...ure too high 220 E9 Safety sensor shorted 221 E9 Safety sensor disconnected 222 E2 Flow sensor shorted 223 E2 Flow sensor disconnected 224 E9 MAX thermostat activated 225 Difference between flow and s...

Page 59: ...ommunication error 311 CUS locked 312 CUS blocked 313 CUS reported error condition 314 Mains disconnected during super lockout 315 Several times lack of water flow 316 E9 Flue gas sensor temperature t...

Page 60: ...Information menu 349 EF CH Boil Detect large delta T despite minimum burner load 350 E2 Flow sensor shorted 351 E2 Flow sensor disconnected 353 Burn temporarily blocked due to no 20 minute continuous...

Page 61: ...This is the current temperature from the Maximum safety sensor This sensor is mounted on the front of the heat exchanger i11 DHW flow temperature The current DHW flow temperature i12 DHW temperature s...

Page 62: ...sed for adjusting all Menus 1 2 3 and Test Fig 128 Menu 2 selection ok max min max min e 2 3 1 0 4 bar 1 ok eco reset e C F Menu 1 max min max min e 2 3 1 0 4 bar 1 ok eco reset e C F Eco C F Menu 1 C...

Page 63: ...w temperature hysteresis negative tolerance only This sets the temperature drop beforetheburnerre starts 6 K is the default This is used in conjunction with the Anti fast cycle time The range is from...

Page 64: ...d Note When maximum boiler output is required for CO CO2 testing this parameter is ignored and full power is delivered for the duration of the test 3 2B Maximum flow temperature This limits the upper...

Page 65: ...ESETTING THE TEST COMPONENT After completing the test Press the button the value 1 will flash Press the arrow button the value will change to a flashing 0 Press to confirm the change a will display fo...

Page 66: ...is OK then the fan will be heard running t3 Pump test Checking the basic pump operation The pump will run for a maximum of 45 seconds If the pump is OK then the pump will be heard running t4 Three way...

Page 67: ...ter a defined period of time Reset button Fan not running or airflow blocked D1 240 Return sensor error Reset button Sensor wet or damaged the boiler will block for 300 secs before this condition 241...

Page 68: ...place control board FA 306 False flame error Reset button Flame detected after burner stop FD 231 Mains power error Reset button Electrical power interruption FA 364 Gas valve EV2 leak test failed Res...

Page 69: ...nisation detected after ignition No flame is detected The boiler will block during 4 attempts before going to Locking fault EF 349 Central heating boil detect Large delta T despite minimum burner The...

Page 70: ...ffect the customer s statutory rights If yes and if required by the manufacturer has a water scale reducer been tted CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with...

Page 71: ...er Name Company Name Telephone No Gas Safe Register No Comments Signature Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature Date Engineer Name Company Name Telephone...

Page 72: ...Worcester Bosch Group is a brand name of Bosch Thermotechnology Ltd worcester bosch co uk 6 720 803 800 2012 11 WORCESTER BOSCH GROUP TECHNICAL SUPPORT 0844 892 3366 APPOINTMENTS 0844 892 3000 SPARES...

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