Worcester GREENSTAR 35CDi Classic System ErP 41-406-39, Installation And Servicing Instructions

Page 1: ... 39 N G GC NUMBER 47 311 40 L P G CE 97 0086 APPLIANCE OUTPUTS Natural Gas LPG Propane Domestic Central Domestic Central Hot Water Heating Hot Water Heating Minimum 9 0 kW 9 0 kW 12 9 kW 12 9 kW Maximum 35 17 kW 25 0 kW 35 17 kW 25 0 kW IMPORTANT THESE INSTRUCTIONS APPLY IN THE UK ONLY AND MUST BE LEFT WITH THE USER OR AT THE GAS METER Read the instructions before starting work they have been writ...

Page 2: ...w code of practice to encourage the correct installation commissioning and servicing of domestic central heating boilers and system equipment The Log book is a vital document that must be completed by the installer at the time of installation It confirms that the boiler has been installed and commissioned according to the manufacturers instructions Without the completion of the Log book manufactur...

Page 3: ...protection 2 9 Safety 2 9 1 The appliance must not be operated with the inner casing cover removed 2 9 2 The gas and electricity supplies must be turned off before servicing or working on the appliance 2 9 3 Temperaturemonitoringcontrolsarefittedtopreventoverheating 2 9 4 Automatic frost protection is provided which will protect the appliance when no heat demand is present 2 9 5 Automatic pump sei...

Page 4: ...L FIX 125 5 0 INTERNAL FIX 150 6 0 STANDARD FLUE MINIMUM LENGTH 100 4 0 MAXIMUM LENGTH 1000 39 3 EXTENDED FLUE MAXIMUM LENGTH 2000 78 7 FLUE ASSEMBLY DIAMETER 110 4 3 Table 2 PUMP HEAD BOILER OUTPUT HEAD MIN FLOW RATE FLOW RETURN DIFFERENTIAL kW Btu h Metres Feet L min Gal Min C F 9 0 30 700 4 2 13 6 11 7 2 57 11 C 20 F 25 0 85 300 2 08 6 67 21 57 4 75 16 5 C 30 F Table 3 MECHANICAL SPECIFICATIONS...

Page 5: ... SPECIFIC RATE AT 35 RISE 16 7 l min MAXIMUM DOMESTIC HOT WATER FLOW RATE FROM APPLIANCE AT 40 RISE 12 6 l min 15 NOx CLASSIFICATION Class 3 MAXIMUM FLUE GAS MASS FLOW RATE 129 5 kg h SEDBUK NUMBER 78 9 SEDBUK BAND D Table 5 DOMESTIC HOT WATER TEMPERATURE RISE DISCHARGE RATE l min 10 11 12 13 TEMPERATURE RISE C 50 45 5 41 5 38 5 Table 6 GAS SUPPLY SYSTEM BASED ON NG G20 TOTAL LENGTH OF GAS SUPPLY ...

Page 6: ...5440 2 must be followed Refer to Section 2 4 6 4 8 The pipe connection positions on the manifold are shown in Fig 4 and on wall template allowing the system to be pre piped and flushed before the appliance is fitted Refer to Section 2 4 6 4 8 1 Always consider the possibility that the pipes may need to be separated from the appliance after installation 4 9 LPG Installation Refer to Section 1 10 5 ...

Page 7: ...type valve allows the pressure to be increased if the static head is greater than 5 metres 7 5 1 If the expansion vessel fails then it must be replaced with the designated spare part 7 6 Refer to BS 7074 1 BS5449 and Table 9 for a guide to the available system capacity 7 7 The maximum system design pressure is 1 5 bar If the pressure is above 2 6 bar when the appliance is at maximum temperature th...

Page 8: ...o need for water treatment to prevent scale formation 8 17 If the water hardness is very high then an anti scaling device can be considered Further information is available from WHS Technical Information Department Telephone 0990 266241 8 18 The installation of a scale inhibitor must be strictly in accordance with the requirements of the local water company 9 1 The appliance requires 4 12 m h of n...

Page 9: ...clamp Green Yellow 13 1 2 3 4 5 6 7 8 9 10 11 12 1 ST12 Mains 9 Fuse F2 2 Fuse F1 10 Cable Entry Clamp 3 Earth Screw 11 ST13 24volt Controls 4 ST8 Room Thermostat not used and External Control 12 Main Harness and Clamp Mains Voltage 13 Control Panel Pivot 5 Cable Entry Screw Clamp Point 6 Earth Tag 7 ST15 Pump 8 ST1 Fan Fig 11 Facia Connections Cover 1 2 3 4 5 1 Control Panel Fixing Screws 2 Facia...

Page 10: ... MAINS IN ST1 LINK ST8 ST15 Y e l l o w B l a c k B l a c k Red White 1 Spark Generator 2 6 Way In Line Connector 3 2 Way In Line Connector 4 Gas Valve 5 Flow Switch 6 DHW Sensor 7 Spark Electrode 8 Sense Electrode 9 CH Pump 10 DHW Pump 11 Pump Relay PCB 12 CH Sensor 13 Fan 14 Overheat Cut Off Thermostat 15 Air Pressure Switch Fig 15 Replacement Fuses 1 2 3 4 5 1 Control Panel Pivot 4 Facia Panel ...

Page 11: ...IN CONTROL BOARD Convert AC to low voltage electrics Electronics Electronics Electronics Relay CH Pump Fan 2 speed DWH Pump Electronics Optional Link Spark Settings Mains Indicator Transformer Green Indicators Fuse F1 2A Slow LIVE IN ST 12 Pin L ST 12 Pin N On Off Switch Fuse F2 1 25A Slow Spark Electrodes CH Demand Indicator DHW Demand Indicator Flame Detect Indicator ST8 Ns ST8 Lr Room Thermosta...

Page 12: ...nt 4 Overheat Thermostat 5 Air Pressure Switch 6 Flue Hood 7 Overheat Thermostat Phial 8 Combustion Chamber Cover 9 Flame Sense Electrode 10 Burner 11 Central Heating Pump 12 Domestic Hot Water Pump 13 Pressure Gauge Connection 14 Relief Valve 15 Bypass Adjuster 16 Drain Point 17 Flow Return Manifold 18 Domestic Hot Water Expansion Vessel Connection optional 19 Domestic Hot water Flow Control Asse...

Page 13: ... from inside the room then it must be fitted through the wall before the wall mounting plate assembly is fitted to the wall Refer to Section 11 8 9 11 5 2 Fit the plugs and fix the plate manifold assembly to the wall 11 5 3 Check that the assembly is properly aligned before tightening the screws 11 5 4 Notches on the manifold indicate the centrelines of the pipe connections 11 6 Gas and water pipe...

Page 14: ...is stage tighten the screws Seal the unused openings using the cabinet blanking plate assembly Refer to Fig 24 25 1 Electrical connections 5 Air Flow Sensor 2 Fan Assembly 6 Flue Duct Clamp Fixing Screw 7 Air Flow Sensor 3 Fan Mounting Plate Fixing Screw 4 Fan Casing 8 Flue Sample Tube 14 Fig 21 Casing and Control Panel Fixing Screws Fig 22 Fan and Air Flow Sensor Fixing Fig 23 Fan Motor Connectio...

Page 15: ...d Refer to Fig 26 11 7 7 Lift the appliance onto the wall mounting plate manifold assembly ensuring that the connections fully enter the manifold fittings after it is supported at the top 11 7 8 Secure the gas and water connections 11 7 9 Fit a discharge pipe to the relief valve leading it away from any electrics or where it might be a hazard The pipe must not be less than 15mm in diameter and mus...

Page 16: ...e duct enters the fan outlet by 20mm before tightening the clamp as shown in Fig 36 Note Remove the flue hood clamp wing nut when a side flue arrangement is used Replace and tighten the wing nut after re fitting the fan 11 9 8 Re connect the tubes and electrical connections to the fan and air flow sensor ensuring that they are correctly positioned and to the flue sample tube The RED tube is to the...

Page 17: ... it should be used in accordance with the inhibitor manufacturers instructions Suitable flushing agents and inhibitors are available from Betz Dearborn Tel 0151 4209563 and Fernox Tel 01799 550811 Instructions for use are supplied with these products 12 1 Domestic hot water circuit Confirm that the mains water supply has been flushed out at installation If not it will be necessary to disconnect th...

Page 18: ...2 18 Check Pressure The boiler should light at minimum burner pressure of 1 5mbar G20 or 6 0mbar G31 and immediately increase to a maximum of 14 2mbar G20 or 34 7mbar G31 The pressures have been set at the factory and no adjustment of the gas valve should be necessary If the maximum pressure is not correct then check that the inlet pressure to the appliance is 20mbar G20 or 37mbar G31 Refer to Sec...

Page 19: ... 14 2 2 If the appliance is in a compartment or cupboard check that the service space around the appliance is clear Refer to Fig 3 14 2 3 Check all the joints and connections in the system and re make any that show signs of leakage Refill and re pressurise as described in Section 12 4 8 Commissioning 14 2 4 Operate the appliance and take note of any irregularities Refer to Section 18 Fault Finding...

Page 20: ...n off the heating flow and return valves at the appliance Refer to Fig 26 Fit a tube to the drain connection and open about one turn by turning anti clockwise Close the drain tap when the water flow from the appliance has stopped Refer to Fig 41 15 3 2 DHW Circuit Turn off the mains cold water supply at the appliance Refer to Fig 26 Open a hot tap below the level of the appliance to drain the dome...

Page 21: ... Carefully pull off the leads at the electrode assembly Unscrew the two screws and remove the spark electrode assembly from the burner Refer to Fig 43 15 4 3 Flame Sensing Electrode Remove the inner casing cover Separate the electrode lead in line connector Release the locknut on the support bracket and remove the sensing electrode from the burner Refer to Fig 44 15 4 4 Burner and Manifold Remove ...

Page 22: ...ise wait until the burner pressure has stopped increasing and then slowly turn the CH gas pressure adjuster anti clockwise until the burner pressure is 8 3mbar for natural gas G20 or 19 0mbar for propane G31 Refer to Fig 51 5 After completing the adjustments check the pressure settings in both modes of operation and re adjust as necessary 15 4 12 Transformer Follow the instructions given in Sectio...

Page 23: ...cessary Take care not to mark the mating surfaces if this done Set to maximum Refill and pressurise as described in Section 12 4 8 Commissioning 15 4 21 Expansion Vessel Lower the facia Drain the primary system Refer to 15 3 1 Unscrew the fixing screw Release the vessel connection to the system by pushing the clip upwards and remove the vessel Note There will be a small amount of water in the vess...

Page 24: ...e new seals and gaskets where necessary Refill and pressurise as described in Section 12 4 8 Commissioning 15 4 25 Air Pressure Switch Remove the inner casing cover Remove the switch by carefully prising away from the mounting tabs of the horseshoe bracket Ensure that the connections are correctly made to the new switch Refer to Fig 61 24 Fig 55 Primary CH Sensor Fig 56 Domestic Hot Water Sensor F...

Page 25: ...ot Water Heat Exchanger 3 Cold Water Inlet 4 O Ring 5 Domestic Hot Water Flow 6 1 2 5 3 4 1 Fixing Clip 2 5 O Ring 2 Clip Locating Channel 6 Appliance Back Panel 3 Primary Heat Exchanger 4 Clip Locating Groove 4 5 5 1 2 3 1 Air Pressure Switch 2 Electrical Connection 3 Electrical Connection 4 Air Flow Sensing Tube Connections REAR Positive FRONT Negative 5 Plastic horseshoe mounting bracket 5 ...

Page 26: ...o Air Vent Intermes 24 371 528 Heat Exchanger Primary Giannoni 25 E02 833 Air Pressure Switch Huba 26 E02 836 Gasket O ring Pack Water Worcester 27 E02 837 Gasket O ring Pack Gas Worcester 28 299 357 Fuse Pack Worcester 29 324 822 Inlet Water Filter Worcester 30 E02 832 Main Harness Worcester 31 E02 826 Spark Electrode Lead Worcester 1 8 716 101 971 0 1 8 716 101 972 0 1 8 716 142 127 0 1 8 716 12...

Page 27: ...b DEMAND END Pump continue four minutes Fan continue fifteen seconds CENTRAL HEATING FUNCTION AND AND AND 17 Operational Flow Diagrams DOMESTIC HOT WATER FUNCTION MAIN SWITCH ON Green Light On Flow switch On Tap open DOMESTIC HOT WATER DEMAND Priority over CH demand HW light On Pump On Fan high 2 Seconds then Low Speed Ignition Sequence Burner on Four second ramp to max gas pressure Fan Speed Chan...

Page 28: ...Run pump for four minutes Monitor central heating sensor Return to normal off state AUTOFROSTAT FUNCTION Within four minutes of last hot water demand AND primary temperature above 80 C If heat demand has occured in last 30 minutes Run pump until primary drops to 80 C If heat demand has NOT occured in last 30 minutes Run pump until primary drops to 80 C If primary temperature still increases above ...

Page 29: ...Worcester Heat Systems cannot be held responsible for costs incurred by per sons not deemed to be competent Preliminary Checks Electrical system checks are the first actions to be carried out during a fault finding procedure On completion of the Service or a fault finding task which has necessitated the breaking and remaking of electrical connections check a Earth Continuity b Short Circuit c Pola...

Page 30: ...easure resistance across the two pairs of adjacent pins on the transformer Is any pair above 100 ohms Replace transformer FAIL POINT B No No Yes Yes Green diode is damaged Replace control board Section 15 4 11 FAIL POINT C Red diode is damaged Replace control board Section 15 4 11 Is there a link at terminal ST13 pins 1 and 2 Is there an electronic programmer at position ST5 at right hand end of b...

Page 31: ...ection 15 4 20 or replace cable Remove pump connector ST15 from control board and retsart boiler in CH mode Is there mains 230V pump output from board No Is there mains 230V across pins 1 2 of terminal X3 of pump relay PCB No Separate 6 way in line connector and check continuity across terminals of orange wires which run to back of boiler TAKE CARE NOT TO DAMAGE TERMINAL Is there continuity No Is ...

Page 32: ...Replace gas valve Section 15 4 1 Remove inner cover Reset and restart the boiler Does a spark occur across the electrodes Remove the 5 way connector from the gas valve and measure the DC voltage across the violet and grey wires and then brown and yellow wires during the spark period Is there 20 30V DC in both cases Replace gas valve Section 15 4 1 Repair or replace flame sensor Section 15 4 3 or w...

Page 33: ...ector and check continuity of red wires to determine a harness fault Repair or replace wiring Is the multiway connector at board position ST16 pushed fully home on to the board Push fully home FAIL POINT I Sensor Fault No No No Yes Yes Yes Test resistance across contacts 12 13 red wires Is it between 1 kohm and 30 kohm Is there continuity from contacts 12 and 13 to CH sensor No Repair or replace h...

Page 34: ...re Fault No Yes No No Replace control board Section 15 4 11 No Replace control board Section 15 4 11 No Yes Yes Yes Yes No Yes Does the burner ignite burner light on before fault occurs Pressure switch has opened during operation Check flue for blockage Also investigate sense tubes and pressure switch Gain access to and remove electrical connectors from pressure switch and restart boiler Is there ...

Page 35: ...pipe Repair or replace sensor Section 15 4 18 Water temperature very low low gas pressure with all knobs set to maximum Remove multiway connector from board position ST16 Is the resistance across contacts 1 and 2 blue wires below 60 ohms Remove blue top connector from gas valve Is there continuity along blue wires to multiway connector Is the gas set to correct pressure Set pressure No No Repair w...

Page 36: ...nterests of continued improvement All goods sold are subject to our official Conditions of Sale a copy of which may be obtained on application PUBLICATION 8 716 115 059a 05 08 Worcester Heat Systems Limited Cotswold Way Warndon Worcester WR4 9SW Telephone 01905 754624 Fax 01905 754619 Technical Helpline 0990 266241 This manual is to be used in conjunction with the variant part number of the bar co...