Worcester Greenstar FS 30CDi Regular Installation, Commissioning And Servicing Instructions Download Page 1

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Installation, Commissioning and Servicing Instructions

Floor standing RSF gas fired condensing regular boiler

Greenstar FS 30CDi

ErP

& 42CDi

ErP

Regular

6720648568-00.1W

For sealed or open vent central heating systems

6 72

0 818 079 (2016/04)

The appliances are for use with:
Natural Gas or L.P.G. (Cat. II 2H3P type C13, C33, C53 &C93)

Natural Gas:
FS 30CDi

ErP

Regular, GC number 41-406-62

FS 42CDi

ErP

Regular, GC number 41-406-64

L.P.G.:
FS 30CDi

ErP

Regular, GC number 41-406-63

FS 42CDi

ErP

Regular, GC number 41-406-65

Summary of Contents for Greenstar FS 30CDi Regular

Page 1: ...648568 00 1Wo For sealed or open vent central heating systems 6 720 818 079 2016 04 The appliances are for use with Natural Gas or L P G Cat II 2H3P type C13 C33 C53 C93 Natural Gas FS 30CDi ErP Regul...

Page 2: ...ommissioning checks 24 5 2 Filling the system 24 5 3 Water treatment 25 5 4 Starting the appliance 25 5 4 1 Switching the appliance on off 25 5 4 2 Initialization 26 5 4 3 Display messages 26 5 5 Chec...

Page 3: ...mmonly used symbols 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 any other make or model of appliance Th...

Page 4: ...pairs must only be performed by a competent registered gas engineer such as a Gas Safe registered engineer or British Gas engineer Advisetheusertohavethesystemservicedannuallybyacompetent registered g...

Page 5: ...al rules for electrical installations IS 813 for Domestic Gas Installations LPG Installations An appliance using LPG must not be installed in a roomor internal space below ground level unless one side...

Page 6: ...al gas network gas m3 h 3 19 4 29 Test gas G20 1014Btu ft3 37 78MJ m3 m3 h 3 27 4 4 Propane Gas LPG kg h 2 3 3 3 Gas supply pressure Natural Gas G20 mb 20 20 LPG Propane Gas G31 mb 37 37 Flue Flue Gas...

Page 7: ...ure at heater inlet and 80 C flow temperature at heater outlet P4 kW 30 0 30 0 40 8 40 8 At 30 of rated heat output and low temperature regime 2 2 Low temperature means for condensing boilers 30 C for...

Page 8: ...APPLIANCE INFORMATION Greenstar FS CDi ErP 6720818079 2016 04 8 2 4 Layout and components Fig 2 Layout and components...

Page 9: ...anking covers flue outlets 13 Air sample point 14 Burner ignition electrodes 15 Heat cell high limit thermostat 16 Inner casing 17 Gas valve 18 Condensate trap 19 Mounting frame 20 Return connection 2...

Page 10: ...terby passtotheprimarywater filling point of the heat system 3 2 Mains supply 3 2 1 Electrical supply Supply 230V 50 Hz Cable PVC insulated 0 75 mm2 24 x 0 2mm temperature rated to 90 C to BS EN50525...

Page 11: ...Fig 3 System fill CV Check Valve SV Stop valve AA Auto Air vent Pressure gauge If the external filling link is sited away from the boiler or the boiler does not have a pressure gauge then a pressure g...

Page 12: ...onsidered If this method is chosen then the following measures should be adopted The external run be kept as short as possible and not exceed three metres The pipe should be run internally as far as p...

Page 13: ...eofaproprietarytrace heatingsystemforexternalpipe work incorporating anexternal frostthermostat shouldbeconsidered If such a system is used the requirement to use 32mm pipe does not apply However all...

Page 14: ...rated from the boiler space by a non combustible partition as described in BS 6798 Fig 13 Airing cupboard clearances 3 5 3 Vented compartments If the clearances available are less than those stated fo...

Page 15: ...accessible provision must be made for service and inspection Voids containing concealed flues must have at least one inspection hatch no less than 300mm square Flue joints within the void must not be...

Page 16: ...E INSTALLATION Greenstar FS CDi ErP 6720818079 2016 04 16 350 mm 570 mm Flat roof 300 mm 500 mm Pitched roof 120 mm 120 mm 2 3 4 5 6 10 9 8 7 1 L L L L L L L L L L 6720648568 17 1Wo 120 mm 120 mm 120...

Page 17: ...roof 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 to25mm aslongas...

Page 18: ...mmfromanopeninginacarportonthesamewalle g door or window leading into the dwelling 10 600mmdistancetoasurfacefacingaterminal unlessitwillcause anuisance BS 5440 Part1 recommendsthatcare is taken when...

Page 19: ...er from the pallet taking care not to damage the panels or the floor Slide the boiler off the pallet GENERAL HANDLING GUIDELINES Lift only a manageable weight or ask for help When lifting bend the kne...

Page 20: ...from the site Fig 20 Positioning 1 Mounting frame 2 Manifold connections 3 Mounting frame fixing point 4 Wall 5 Gas and water pipe work not supplied 6 Boiler FLUE OPENING Follow the information in fi...

Page 21: ...condensate waste pipe 8 to adaptor 11 and secure with clip 10 Connect adaptor 11 to 21 5mm plastic pipe and terminate appropriately as described in section 3 4 NOTICE Flue installation Refer to the F...

Page 22: ...onto the rails and align the gas water connections and the flue Secure boiler to mounting frame 6 with screw 13 Place the two larger valve sealing washers shown shaded onto valves A C Place the bonde...

Page 23: ...0 3 External pump must be wired back to the boiler Connect the pump LIVE to terminal Lz Connect the pump NEUTRAL to terminal Nz Connect the EARTH wire to the earth connector block next to ST10 Refit a...

Page 24: ...n the water main stop cock Open vented system only Turn on the water to the system header tank and allow the system to fill Sealed System Locate the pressure gauge externally on the system Fill the sy...

Page 25: ...N OFF indicator fault diagnostic light blue 7 Temperature control 8 Service engineer button 9 Service menu button 10 Burner ON indicator light green 5 4 1 Switching the appliance on off Turn on mains...

Page 26: ...ment after pressing one button except reset button Key acknowledgement after pressing two buttons simultaneously Key acknowledgement after pressing button longer than 3 seconds save function The displ...

Page 27: ...esstheServiceengineerbutton 8 again and the boiler will return to normal operation If left in the Service mode the control will return to normal operation after 15 minutes Re seal the screw in the gas...

Page 28: ...have been calibrated as specified by the manufacturer Theinstallermustbecompetentinthe use of the analyser Check and zero the analyser in fresh air as specified by the manufacturer The air gas ratio v...

Page 29: ...that the specified service space around the appliance is clear 3 Check all the joints and connections in the system and remake any that show signs of leakage Refill and re pressurise if applicable as...

Page 30: ...ol pressure test With the boiler running at maximum output measure the fan pressure The pressure will read negative refer to the chart in figure 43 below Fig 43 Fan control pressure readings If the ma...

Page 31: ...ng possible causes Refer to section 5 5 1 and check the gas inlet pressure Confirm the correct fan pressure Air intake for restrictions Check the diaphragm in the fan for damage replace if damaged Che...

Page 32: ...nsate pump and the pipe from the trap Reconnect the condensate disposal pipe Fig 46 Condensate trap access 6 7 4 Cleaning the heat exchanger Fig 47 Cleaning kit If the Heat Exchanger requires cleaning...

Page 33: ...andle of the brush to remove debris from the condensate tray Place a suitable container under the sump condensate outlet to collect any water and debris Pour water into the top of the heat exchanger t...

Page 34: ...tion chamber cover Remove plastic cap and using a flat bladed screwdriver Set the maximum CO2 or using the adjuster 3 Replace the combustion chamber cover Check the maximum CO2 referring to table 13 C...

Page 35: ...rd Remove the screws 3 retaining the rear panel of the control and remove the panel After re assembly check that the CO CO2 levels are as described in the section Setting the air gas ratio on page 34...

Page 36: ...ult finding and Diagrams section Remove the 15mm flexible tube 1 from the pump by rotating anti clockwise and pulling up Remove the black flexible pipe 2 from the condensate pump Take care as there ma...

Page 37: ...securingthevalvetothe gas air tube Transfer the inlet pipe assembly to the new gas valve Reconnect the plastic union 4 to the gas valve Reconnect the solenoid connection 2 Re attach the black rubber t...

Page 38: ...te trap Remove the internal flue elbow and tube from the boiler sump Releasethereturnpipeunion 10 atthebaseoftheheatexchanger Remove the plastic nut 11 from the base of the inner casing Release the re...

Page 39: ...PLY PUMP SUPPLY SPARK TRANSFORMER FLAME SENSE ELECTRODE SPARK ELECTRODES FLOW NTC OVERHEAT STAT FLUE OVERHEAT STAT ST1 DIAGNOSTIC INTERFACE CODE PLUG Fuse F1 slow T2 5 A H 230 V ST6 CH TEMPERATURE CON...

Page 40: ...MAND FLAME LIGH T ON Stop spark Wait 10 seconds 5th attempt LOCK OUT 10 second stabilisation period Fan gas modulation to achieve set temperature 40 82 C Gas valve OFF Pump run 3 minutes Fan run 30 se...

Page 41: ...detected Check gas is present ignition electrodes and harness flame sense electrode and harness and operation of gas valve Replace as necessary E2 Primary NTC defect Check primary NTC sensor and leads...

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Page 43: ...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 44: ...Worcester Bosch Group is a brand name of Bosch Thermotechnology Ltd worcester bosch co uk 6720818079 2016 04 WORCESTER BOSCH GROUP TECHNICAL SUPPORT 0330 123 3366 APPOINTMENTS 0330 123 9339 SPARES 033...

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