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KEY TO SYMBOLS AND SAFETY PRECAUTIONS

Greenstar FS CDi 

ErP 

6720818079 (2016/04)

4

1.2

Safety precautions

Instructions for the target group

These installation instructions are intended for registered gas fitters, 
plumbers, heating engineers and electricians. All instructions must be 
observed. Failure to comply with these instructions may result in 
material damage and/or personal injury, including possible loss of life.
▶ Read these installation instructions before installation.
▶ Observe safety instructions and warnings.
▶ Observe national and regional regulations, technical rules and 

guidelines.

▶ Keep a record of all work carried out.

Determined use

The product is not intended for commercial use.
The product may only be used in a domestic situation for the heating of 
central heating water and for DHW heating in a closed-loop DHW and 
heating systems.

Any other use is considered inappropriate. Any damage that may result 
from misuse is excluded from liability.

If you smell gas

A gas leak could potentially cause an explosion. If you smell gas, observe 
the following rules:
▶ Prevent flames or sparks:

– Do not smoke, use a lighter or strike matches.
– Do not operate any electrical switches or unplug any equipment.
– Do not use the telephone or ring doorbells.

▶ Turn off the gas at the meter or regulator.
▶ Open windows and doors.
▶ Warn your neighbours and leave the building.
▶ Prevent anyone from entering the building. 
▶ Move well away from the building: call the National Gas Emergency 

Service on 0800 111 999.

▶ L.P.G. boilers: Call the supplier’s number on the side of the gas tank.

Risk to life from poisoning by flue gas

There is a risk to life from escaping flue gas.
▶ Never modify any parts for the flue gas routing.
▶ Ensure that flue pipes and gaskets are not damaged.

Installation, commissioning and servicing

Installation, commissioning and servicing must only be carried out by a 
competent, registered gas engineer, such as a Gas Safe registered 
engineer or British Gas engineer.
▶ Carry out a gas tightness test after completing work on gas-carrying 

components.

▶ Only use original spares.

Electrical work

Electrical work must only be carried out by a qualified electrician:
▶ Before starting electrical work;

– Ensure that the electricity supply is safely Isolated and secured to 

prevent inadvertent re-connection. 
Information on safe isolation can be found in the Health and 
Safety Executive guidance HSG85.

– Using test equipment approved to GS38 confirm that the 

electricity supply is disconnected.

▶ Refer to the manufacturer’s information when installing other 

components with Worcester equipment within the system.

Handover to the user

When handing over, instruct the user how to operate the heating system 
and inform the user about its operating conditions.
▶ Explain how to operate the heating system and draw the user's 

attention to any safety relevant action.

▶ Explain that modifications and repairs must only be performed by a 

competent, registered gas engineer, such as a Gas Safe registered 
engineer or British Gas engineer.

▶ Advise the user to have the system serviced annually by a competent, 

registered gas engineer, such as a Gas Safe registered engineer or 
British Gas engineer.

▶ Leave the installation instructions with the completed Benchmark 

Checklist (or a certificate confirming compliance with IS 813, Eire 
only) and the operating instructions with the user or at the gas meter.

Boiler operation

This appliance can be used by children aged from 8 years 
and above and persons with reduced physical, sensory or 
mental capabilities or lack of experience and knowledge, if 
they have been given supervision or instruction concerning 
use of the appliance in a safe way and understand the 
hazards involved. Children shall not play with the 
appliance. Cleaning and user maintenance shall not be 
made by children without supervision.

Servicing

Advise the user to have the system serviced annually by a competent, 
registered gas engineer, such as a Gas Safe registered engineer or 
British Gas engineer. Approved spares must be used to help maintain 
the economy, safety and reliability of the appliance.

Important

 

The service engineer must complete the Service Record on the 
Benchmark Checklist after each service.

Benchmark places responsibilities 
on both manufacturers and 
installers.
The purpose is to ensure that 
customers are provided with the 

correct equipment for their needs, that it is installed, commissioned and 
serviced in accordance with the manufacturer's instructions by 
competent persons and that it meets the requirements of the 
appropriate Building Regulations. The Benchmark Checklist can be used 
to demonstrate compliance with Building Regulations and should be 
provided to the customer for future reference. 
Installers are required to carry out installation, commissioning and 
servicing work in accordance with the Benchmark Code of Practice 
which is available from the Heating and Hot water Industry Council who 
manage and promote the scheme. 
Visit 

centralheating.co.uk

 for more information.

Health and safety

The appliance contains no asbestos and no substances have been used 
in the construction process that contravene the COSHH Regulations 
(Control of Substances Hazardous to Health Regulations 1988).

Combustion and corrosive materials

Do not store or use any combustible materials (paper, thinners, paints 
etc.) inside or within the vicinity of the appliance.
Chemically aggressive substances can corrode the appliance and 
invalidate any warranty.

Fitting and modification

Fitting the appliance and any controls to the appliance may only be 
carried out by a competent engineer in accordance with the current Gas 
Safety (Installation and Use) Regulations.
Flue systems must not be modified in any way other than as described in 
the fitting instructions. Any misuse or unauthorised modifications to the 
appliance, flue or associated components and systems could invalidate 
the warranty. The manufacturer accepts no liability arising from any 
such actions, excluding statutory rights.

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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