Worcester GREENSTAR 30CDi Classic System ErP 41-406-37, Installation, Commissioning And Servicing Instructions

Page 1: ...i CLASSIC SYSTEM 6 7 2 0 8 1 2 1 7 6 0 0 1 O FOR CENTRAL HEATING SYSTEMS AND INDIRECT FED DOMESTIC HOT WATER 6 720 812 175 2014 07 The appliance is for use with Natural Gas or L P G CAT II 2H3P type C13 C33 Natural Gas 30CDi GC number 41 406 37 35CDi GC number 41 406 39 L P G 30CDi GC number 41 406 38 35CDi GC number 41 406 40 ...

Page 2: ... mm Plume management kit 24 4 5 3 Adjusting the standard terminal length 24 4 5 4 Installing the standard flue 25 4 5 5 Flue terminal plume re direction 25 4 6 Condensate connection 26 4 7 Electrical without diverter valve 27 4 8 Electrical with optional diverter valve 28 4 9 Position of wired components 29 5 COMMISSIONING 30 5 1 Pre commissioning checks 30 5 2 Filling the system 30 5 3 Starting t...

Page 3: ...Electrical Supply Gas Supply Table 2 Commonly 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 These instructions apply in the UK and Ireland only and must be followed except for any statutory obligations This appliance must be installed by a GAS SAFE regist...

Page 4: ...e or associated components and systems could invalidate the warranty The manufacturer accepts no liability arising from any such actions excluding statutory rights SERVICING Advise the user to have the system serviced annually by a competent qualified Gas Safe registered engineer Approved spares must be used to help maintain the economy safety and reliability of the appliance IMPORTANT The service...

Page 5: ...ture sensor control Pump anti seizure protection Flue gas temperature sensor Condensate siphonic trap Modulating circulating pump If the optional integral diverter valve kit is fitted Fig 1 Overall dimensions Fig 2 Standard package G A max 360 mm max 760 mm 440mm 6 720 812 175 26 1O STANDARD PACKAGE A Wall hung gas fired condensing system boiler for central heating and domestic hot water B Wall mo...

Page 6: ...CE INFORMATION 6 720 812 175 2014 07 6 2 2 LAYOUT COMPONENTS Fig 3 Controls in the servicing position excluding the outer case 1 2 3 4 6 11 7 8 9 10 12 16 19 20 21 22 23 24 18 17 14 13 15 5 6 720 812 175 06 1O ...

Page 7: ...5 26 27 28 5 25 6 29 30 7 31 32 25 Compact hydraulic mounting screw 2 to boiler 26 Flow connection from boiler heat exchanger 27 Auto air vent 28 Unused port 29 Optional integral diverter valve position 30 Return connection to service valve 31 Internal bypass within plastic moulding 32 Flow connection to service valve 33 Position for optional control 34 Display 35 Fault reset button 36 ECO button ...

Page 8: ...d at 21 C system temperature rise m 2 2 2 2 Gas flow rate Max 10 minutes from lighting Natural Gas G20 m3 h 3 2 3 7 Propane Gas LPG kg h 2 4 2 7 Flue Flue Gas Temp 80 60 C rated min load Max Min C 76 58 76 58 81 58 81 58 Flue Gas Temp 40 30 C rated min load Max Min C 55 33 55 33 58 33 58 33 CO2 level at max rated heat output 9 6 11 5 9 6 11 5 CO2 level at min rated heat output 9 0 10 5 9 0 10 5 NO...

Page 9: ...ith the DWTA code of practice and manufacturer s guidelines WATER TREATMENT PRODUCTS Suitable water treatment products can be obtain from the following manufacturers 3 2 MAINS SUPPLY 3 2 1 GAS SUPPLY Boilers using Natural Gas NG must be connected 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 acco...

Page 10: ... the appliance A drain cock is required at the lowest point on the system An air vent is required at the highest point on the system A Diverter Valve B Automatic Bypass C Radiator Valve Flow D Lockshield Valve Return E Extra expansion Vessel The sealed system must be filled using a WRAS approved filling loop or comply with the diagram opposite for System fill Wherethesystemvolumeismorethan100litre...

Page 11: ...ld 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 discharge point such as 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 ...

Page 12: ...e pipe terminates over an open drain or gully the pipe should terminate below the grating level but above water level in order to minimise wind chill at the open end The use of a drain cover such as those used to prevent 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 11 External disposal CONDEN...

Page 13: ...hould be at least 15mm diameter copper pipe and run downwards away from any electrical equipment or other hazard preferably to an external drain or soak away Pipe 1 should be finished with a partial bend near the outlet to face the external wall as shown to help prevent freezing Fig 14 Pressure relief pipe work Minimumholesizeforthecondensatesoakawaymustbe 400mm deep by 300mmØ NOTICE Unheated inte...

Page 14: ...heapplianceiftheflueterminalfittedontheoutsidewall or roof is obstructed or damaged Fig 15 Minimum clearances COMPARTMENTS Follow the requirements of BS6798 and BS5440 Part 2 and note Minimum clearances must be maintained An access 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 ...

Page 15: ... ThevalvescanbeclosedenablingCHsystemtobetested Theboilercan be installed at later date RUNNING PIPES BEHIND THE BOILER If the boiler pipes are to be run behind the appliance ensure that the pipespassclosetothewallasshowninthediagramopposite andwithin the pipe guide Alternatively an optional pre bent pipe kit can be purchased part number 7 716 192 651 Fig 18 Without optional diverter valve NOTICE ...

Page 16: ...E 80 125 flue systems Each 90 bend used is equivalent to 2 metres of straight flue Each 45 bend used is equivalent to 1 metre of straight flue Telescopic horizontal flue Flue option 1 100mmØ 125mmØ 30CDi System 570mm 600mm 35CDi System 570mm 600mm Table 16 Option 1 Horizontal extended flue Flue option 2 100mmØ 125mmØ 30CDi System 7 900mm 18 500mm 35CDi System 7 000mm 16 000mm Table 17 Option 2 Hor...

Page 17: ...PRE INSTALLATION 6 720 812 175 2014 07 17 350 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 18: ...to an open flue 15 200mm below eaves and 75mm below gutters pipe and drains 16 Thedimensionbeloweaves balconiesandcarportscanbereduced to 25mm as long as the flue terminal is extended to clear any overhang External flue joints must be sealed with suitable silicon sealant 17 Flue clearance must be at least 300mm from the ground Terminal guards must br fitted if the flue is less than 2 metres from t...

Page 19: ...s than 200mm from the lowest point of the balcony 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 BS5440 Part1recommendsthatcareistakenwhensiting terminals in relation to surfaces facing a terminal 200 300 150 200 8 4 5 3 2 9 200 600 All measurements in...

Page 20: ...r should be first unpacked 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 wheretheboilerisenteredintotheloftspacetiltedandslidonitsback into the loft Once the appliance is removed from its packaging check the contents against the packing list Fig 21 A Carton B Wall mounting plate C Hanging bracket D Pre ...

Page 21: ...t 3 or for side outlet 4 Forthe60 100mm Ø fluemakea125 mmdiameterholethroughthe wall using a core drill or similar For flues using an optional weather collar fitted from inside the building make a 150 mm Ø hole Clear away any debris Drill the hole preferably using a core drill Remove the mounting template Place the hanging bracket on the wall mounting plate Place the wall mounting plate with hangi...

Page 22: ...packaging 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 release the clip F on top of the boiler and pull the case upwards 10 Remove the outer case 11 Remove the protective packaging G from the electrode assembly A Outer carton B Packaging base C Protective wrap...

Page 23: ...ressure relief connector UP until the stop on the inside of the handle is over the shoulder of the metal bracket to secure in place CAUTION Isolate the mains gas supply before starting any work and observe all relevant safety precautions The accessibility to the preplumbing manifold can be improved by removing the condensate trap see also page 40 NOTICE Beforehangingtheboileronthewallmounting plat...

Page 24: ...n 500mm and can be used with plume management extension components Fig 31 Ø60mm PLUME MANAGEMENT KIT 7 716 191 086 replaces the plume deflector in the Ø60 100mm telescopic flue terminal 4 5 3 ADJUSTING THE STANDARD TERMINAL LENGTH 1 Extend tube 1 by withdrawing from tube 2 to achieve the flue lengthrequired 350 570mmforthestandardtelescopicflueor570 to 790mm for the longer telescopic flue Secure w...

Page 25: ...the terminal 2 as shown Fig 35 4 5 5 FLUE TERMINAL PLUME RE DIRECTION The flue discharge can be re directed allowing some plume redirection control alternatively a complete plume management system can be fitted to the flue terminal RE DIRECTING THE FLUE DISCHARGE 1 Using a suitable tool release the clips 1 2 the terminal end and rotate through 180 1 Refit to the terminal ensuring that the clips 1 ...

Page 26: ...lign the installation side plastic pipework through the pre plumbing manifold Connect the installation side plastic pipework to the end of the condensate hose Pushtheplasticpipeworkinsidethecondensatehoseatleast25mm Fig 38 Condensate connection 1 Opening in building 2 Flue discharge 3 Plume deflector 4 Minimum 1500mm from an opening in the building Table 26 Key to figure 37 6720643895 119 1Wo 1 3 ...

Page 27: ...ct room thermostat LIVE supply to terminal LS Connect room thermostat SWITCHED LIVE return to terminal LR Connect room thermostat NEUTRAL to terminal NS 8 Refit control panel cover Refit panel and secure with screws B Bring the control panel to its upper position and secure by sliding the white plastic clip up Fig 39 Electrical connections CAUTION ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTI...

Page 28: ...al FR 8 Cylinder thermostat or cylinder temperature sensor a Hot water channel Volt free cylinder thermostat ST8 cylinder thermostat wires to terminals 7 and 9 b Hot water cylinder temperature sensor ST15 connect the included plug to the cable Snap out the plastic tongue and insert the cable Insert the plug on the PCB at ST15 9 Refit control panel cover Refit panel and secure with screws B Bring t...

Page 29: ...OVERHEAT STAT FLUE OVERHEAT STAT ST1 DIAGNOSTIC INTERFACE CODE PLUG Fuse F1 slow 2 5 A AC 230 V Fuse F3 slow T 0 5 A Fuse F2 slow T1 6 A ST6 DHW TEMPERATURE CONTROL CH TEMPERATURE CONTROL Neutral Supply EMS BUS contacts Live Supply Live Return Neutral Live Colour sequence Orange Orange Red Red 7 8 9 B B 4 2 1 A F Blue Purple White Black FAN Colour sequence EXTERNAL FROST STAT OPTIONAL PRE WIRED LI...

Page 30: ... system and correct any leaks The boiler integral expansion vessel is precharged to 0 75bar equal to a static head of 7 5meters 22ft A Schraeder type valve is fitted to the expansion vessel to allow for pressure adjustment if required If an extra expansion vessel is fitted to the central heating return adjusttothesamepressureastheapplianceinternalexpansiontank refer to separate instructions with t...

Page 31: ...ent all radiators retighten vents when complete 8 Re pressurise if necessary to 1bar Set all controls to maximum Record the date when the inhibitor was added to the system on the guarantee card NOTICE Never run the appliance when the appliance system is empty or partially filled A On off button B Cover or position for optional plug in control C Display D System pressure gauge E Reset button F ECO ...

Page 32: ...bitor in the system should be checked every 12 months or sooner if system content is lost The addition of sealing agents to the system water is not recommended as this can cause problems with deposits left in the heat exchanger FERNOX 0870 601 5000 www fernox com SENTINEL 0800 389 4670 www sentinel solutions net Table 28 When fitted with the optional diverter valve not supplied and running in perf...

Page 33: ...ral heating boost mode the control will return to normal operation after 15 minutes Re seal the screw in the gas inlet pressure test point 5 5 2 CHECKING THE GAS RATE The gas rate should be measured at the gas meter after 10 minutes operation at maximum See technical data section at the front of this manual Where a gas meter is not available e g L P G the CO CO2 must be checked to the units shown ...

Page 34: ...e correct type as specified in BS 7967 Before use the analyser must have been calibrated as specified by the manufacturer The installer must be competent in the use of the analyser Checkandzerotheanalyserinfreshairasspecifiedby the manufacturer The air gas ratio valve is factory set and must not be adjusted during commissioning unless this action is recommended following contact with the Worcester...

Page 35: ...f the boiler frame Hold 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 towards you Set up the controls and show the user how to operate all the controls shown in the User Guide Place the user guide into the tray E on the inside of the facia cover Ifthea...

Page 36: ... the boiler running at maximum output refer to paragraph SET THE BOILER TO MAXIMUM page 37 Ensure that the probe reaches the centre of the air intake adjust the cone on the probe so that it seals the sample point and correctly positions the end of the probe Insert the analyser probe into the air intake sample point Allow the readings to stabilise and check that O2 is equal to or greater than 20 6 ...

Page 37: ...61 27 4Wo 2 3 1 1 6 720 812 175 14 1O 2 Thistestistodetermineiftheheatcellrequirescleaning attention When fitted with the optional diverter valve not supplied and running in performance test mode the boiler will only operate the central heating circuits If fitted to an S or Y plan system the system must only be run in central heating mode This is to allow sufficient time for this part of the commi...

Page 38: ...posits in the heat exchanger from top to bottom using the cleaning blade Fig 63 3 Clean the heat exchanger from top to bottom using the brush 6 720 812 175 39 1O FAN PRESSURE TEST Clean the Heat Ex Heat Ex ok NG Boilers 0 6 5 4 3 2 1 8 7 mbar 30 CDi 35 CDi 3 9 5 3 LPG Boilers 0 6 5 4 3 2 1 8 7 mbar 30 CDi 35 CDi 3 9 5 3 6 720 812 175 35 1O NOTICE Air Gas ratio After servicing the CO CO2 must be ch...

Page 39: ...fully the rear securing bolt F Remove the burner cover plate G Fig 66 3 Remove the burner H and clean components Do not use a wire brush Fig 67 6 1 6 TO CHECK THE DIAPHRAGM IN BURNER COVER 4 Carefully withdraw diaphragm J from fan intake tube and check for soiling and splits Carefullyrefitdiaphragm J thecorrectwayroundintothefanintake tube Re assemble the burner in the reverse order using a new se...

Page 40: ... illuminated and the blue power indicator will be permanently illuminated Remove manometer and re seal inlet pressure point on gas valve Refit anti tamper cover onto the max adjuster Replace the brass screw over the min adjuster on the valve Re assemble and refit boiler case Fig 69 Setting the Air Gas ratio NOTICE Air Gas ratio The setting of the gas ratio must be carried out by a competent person...

Page 41: ...nector 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 electrical connections Push the flue limit thermostat into the sump Retrieve the thermostat from the sump well 6 EXPANSION VESSEL Drain the appliance 6 1 Remove locking screw D 6 2 Undo the union connection E at the b...

Page 42: ...SERVICING AND SPARES 6 720 812 175 2014 07 42 Fig 72 Replacing parts 3 4 5 6 1 6 2 D E 6 720 812 175 34 1O ...

Page 43: ...ap and check that the connection to the heat exchanger is clear Fillthecondensatetrapwithapproximately1 4litreofwaterandrefit in reverse order Fig 74 Siphon removal 9 ACCESS TO BOILER CONTROL COMPONENTS Remove 3 screws A and remove cover from control 10 PCB FUSE Remove fuse B from the PCB and replace There is a spare fuse clipped into the cover Fig 75 Component and fuse access 11 PCB REMOVAL To ga...

Page 44: ...e with the new gasket and secure with the screws F removed earlier Fig 78 Electrode assembly 14 AIR GAS MANIFOLD 1 Remove cover panel A by removing screws B Check that the boiler is completely isolated from the gas supply Fig 79 Top panel 2 Remove clips C and unscrew the two bolts D Unscrew and remove the two hexagon screws E securing the fan Slacken fully the rear securing bolt F NOTICE Air Gas r...

Page 45: ...o fig 82 Fig 83 Burner removal 16 HEAT EXCHANGER Isolate flow and return valves and drain the boiler Remove condensate trap see page 43 Remove fan assembly see page 44 1 Remove plastic nut A from the base of the inner casing Fig 84 Heat exchanger removal 1 2 Remove return pipe at the bottom of heat exchanger Fig 85 Heat exchanger removal 2 3 Remove screw at the top of the heat exchanger C Unscrew ...

Page 46: ...tor Undo the two screws holding the valve to the plastic housing Fig 89 Diverter valve removal 1 Withdraw the valve B and clean the valve chamber if necessary To refit follow the above in reverse Ensure any seals that have been disturbed are renewed 19 AUTO AIR VENT Ensure the appliance has been fully drained 1 Use a screwdriver or similar to rotate the air vent anticlockwise 2 Lift the air vent C...

Page 47: ...he nut on the rear of the pressure gauge Removethepressuresensingheadandpressuregaugecapillaryfrom the housing To refit follow the above in reverse DO NOT leave out the washer from the capillary when fitting a replacement gauge 25 DRAIN TAP Ensure the appliance has been fully drained 1 Withdraw the drain pipe from the drain tap To do this remove retaining spring from the drain pipe 2 Rotate the dr...

Page 48: ...e gauge to its bracket and remove the gauge 3 Release the locking devices that secure the two copper water pipes leading to the combustion chamber by squeezing the two tabs together and rotating anticlockwise viewed from above 4 Undo the two screws securing the hydraulic block to the chassis located top left top right of the housing 5 Lift the left hand side of the block slightly 6 Manoeuvre the b...

Page 49: ...aulic block from the boiler 26 Hydraulic block 1 Remove the spring clip from the Pressure relief valve housing 2 Withdraw the pressure release valve A from its housing To refit follow the above in reverse Ensure any seals that have been disturbed are renewed Fig 94 2 1 A 6 720 812 175 25 1O ...

Page 50: ... 8 718 221 728 0 GC No H22 463 Pressure gauge 8 717 208 107 0 GC No H02 528 Diverter valve assembly 8 716 106 845 0 GC No H02 533 Diverter valve motor 8 716 106 847 0 GC No H02 534 Control sensor primary 8 714 500 087 0 GC No E74 536 Flue sample plug air intake 8 716 111 253 0 Flue overheat thermostat 8 710 506 267 0 Auto Air Vent 8 716 106 445 0 Flue sample plug 8 716 111 252 0 Control unit 8 737...

Page 51: ...tent Display code Description Remedy A7 Hot water NTC sensor defective Check hot water NTC sensor and connecting lead for circuit breaks short circuits A8 Break in communication to FX controls Check electrical connections b1 Code plug not detected Insert code plug correctly test and replace if necessary C6 Fan speed too low Check fan lead and connector and fan replace as necessary E2 CH flow NTC s...

Page 52: ...tion pump ON Gas value OFF Fan overrun 30 seconds Over temperature shut down if water temperature is 5 o C above set value 10 seconds stabilisation period Gas value OFF Pump run 3 minutes Fan run 30 seconds Fan gas modulation to achieve set temperature 35 88 0 C Fan to start speed Spark ignition 4 seconds 5th attempt Stop spark wait 10 seconds Room thermostst and or mains programmer ON or link fit...

Page 53: ...mp ON Spark ignition 4 seconds 5th attempt Stop spark Wait 10 seconds BURNER LIT YES YES NO NO LOCKOUT Fan to start speed IGNITION SEQUENCE see details GREEN FLAME LIGHT ON Fan gas modulation to achive set temperature 75 o C Gas valve OFF Pump run 3 minutes Fan run 30 seconds DEMAND END Wait 5 seconds Burner shut down it primary temperature 94 o C until 84 o C Over temperature shut down if water t...

Page 54: ...7 54 7 4 PROTECTION FUNCTION Holiday mode set to ON All other demands not active Frost protection active DHW demand active Pump runs 5 seconds every 24 hours Pump antiseize Run autofroststat function Boiler temperature below 8oC 6720647472 31 1Wo ...

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Page 57: ...6 720 812 175 2014 07 57 NOTES ...

Page 58: ...6 720 812 175 2014 07 58 NOTES ...

Page 59: ...6 720 812 175 2014 07 59 NOTES ...

Page 60: ...Worcester Bosch Group is a brand name of Bosch Thermotechnology Ltd worcester bosch co uk 6 720 812 175 2014 07 WORCESTER BOSCH GROUP TECHNICAL SUPPORT 0330 123 3366 APPOINTMENTS 0330 123 9339 SPARES 0330 123 9779 LITERATURE 0330 123 9119 TRAINING 0330 123 0166 SALES 0330 123 9669 ...