Worcester Greenstar FS 30CDi Installation, Commissioning And Servicing Instructions

Floor standing rsf gas fired condensing regular boiler for sealed or open vent central heating systems

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Instruction manual (52 pages)

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Page 1 Installation, Commissioning and Servicing Instructions Floor standing RSF gas fired condensing regular boiler Greenstar FS 30CDi & 42CDi Regular For sealed or open vent central heating systems The appliances are for use with: Natural Gas or L.P.G. (Cat. II 2H3P type C13, C33, C53 &C93)
Page 2: Table Of Contents
Contents Contents KEY TO SYMBOLS AND SAFETY PRECAUTIONS ... . 3 SERVICING AND SPARES ......29 Key to symbols .
Page 3: Key To Symbols And Safety Precautions
Failure to install correctly could lead to prosecution. • CAUTION indicates a situation that could result in minor to medium injury. If you are in any doubt, contact the Worcester Technical help-line (0330 123 3366). • WARNING indicates a situation that could result in severe injury or death.
Page 4: Safety Precautions
Refer to the manufacturer’s information when installing other Fitting and modification components with Worcester equipment within the system. Fitting the appliance and any controls to the appliance may only be Handover to the user carried out by a competent engineer in accordance with the current Gas When handing over, instruct the user how to operate the heating system Safety (Installation and Use) Regulations.
Page 5: Appliance Information
CHECK LIST - LITERATURE PACK: Qty. Where no specific instruction is given, reference should be made to the Greenstar FS 30CDi & FS 42CDi Installation, Commissioning relevant British Standard codes of Practice. and Servicing Instructions BS7074:1 Code of practice for domestic and hot water supply...
Page 6: Technical Data
APPLIANCE INFORMATION Technical data DESCRIPTION UNITS Natural Gas L.P.G FS 30CDi FS 42CDi FS 30CDi FS 42CDi Central Heating Max. rated heat output net 40/30°C 32.1 43.7 32.1 43.7 Max. rated heat output net 50/30°C 31.8 43.3 31.8 43.3 Max. rated heat output net 80/60°C 40.8 40.8 Max.
Page 7: Product Data On Energy Consumption
APPLIANCE INFORMATION Product data on energy consumption The following product data satisfy the requirements of the EU Regulations No. 811/2013, No. 812/2013, No. 813/2013 and No. 814/2013 supplementing Directive 2010/30/EU. Product data Symbol Unit 7731600102 7731600103 7731600104 7731600105 Product type –...
Page 8: Layout And Components
APPLIANCE INFORMATION Layout and components Fig. 2 Layout and components Greenstar FS CDi 6720818079 (2016/04)
Page 9 APPLIANCE INFORMATION Item Control panel Master switch for ON/OFF Burner ON indicator light (green) Service Menu button Service engineer button Display Reset button Not used Not used Temperature control 230V Mains ON/OFF indicator & fault diagnostic light (blue) Blanking covers - flue outlets Air sample point Burner ignition electrodes Heat cell high limit thermostat...
Page 10: Pre-Installation
It is recommended that a primary water filter is fitted It is possible to have an ion exchange water softener fitted to the cold to the system. Worcester offers two filters that helps water system of the property. However, the boiler requires an untreated remove both magnetite and non-magnetic debris;...
Page 11: Water Systems And Pipe Work
PRE-INSTALLATION Water systems and pipe work PRIMARY SYSTEM PLASTIC PIPEWORK: SYSTEM Layout: • Any plastic pipe work must have a polymeric barrier with 600mm Key to system layout illustrations (minimum) length of copper connected to the boiler. Boiler • Plastic pipe work used for under floor heating must be correctly Heating vent (min.
Page 12: Condensate Pipe Work
PRE-INSTALLATION FULLY PUMPED SEALED PRIMARY SYSTEM: Alternatively if the first option is not possible an internal kitchen or bathroom waste pipe, washing machine waste pipe etc. can be used. • A pressure relief valve [11] (spring loaded safety valve set to operate Ensure that the condensate drain pipe is connected “down stream”...
Page 13 PRE-INSTALLATION FITTING AN EXTERNAL AIR BREAK Continued - Key to condensate illustrations • Refer to figure 9 when a rain water down pipe is used to dispose of Pipe work transition condensate. Insulate and increase pipe size NOTICE: Appliance damage External rain water pipe into foul water An air break must be installed in the 43mm pipe External air break...
Page 14: Boiler Location And Clearances
PRE-INSTALLATION Boiler location and clearances 3.5.2 Airing cupboard clearances The dimensions below show the minimum space required to install and • This is a floor-standing boiler and is only suitable for installing on the service the boiler within an airing cupboard. floor, internally in a property.
Page 15: Rooms Containing A Bath Or Shower
PRE-INSTALLATION 3.5.4 Rooms containing a bath or shower Flue options NOTICE: Any switch or appliance control using mains CAUTION: Non accessible flue systems: electricity must not be within reach of a person using the Where a flue system is not going to be accessible, bath or shower.
Page 16 PRE-INSTALLATION 350 mm - 570 mm 120 mm 500 mm 300 mm Flat roof 120 mm 120 mm 120 mm 120 mm Greenstar FS CDi 6720818079 (2016/04)
Page 17: Flue Terminal Positions
PRE-INSTALLATION Flue terminal positions All measurements in millimetres 52mm 104mm 1,500 1,500 300 300 300 300 1,200 Boundary Line Fig. 16 Flue terminal positions NOTICE: All measurements are the minimum clearances required. Terminals must be positioned so to avoid combustion products entering the building. Support the flue at approximately one metre intervals and at a change of direction, use suitable brackets and fittings: - flue brackets 100mm x 1 - part number: 7 716 191 177 - flue bracket 100mm x 6 - part number: 7 716 191 178...
Page 18: Plume Management Terminal Positions
PRE-INSTALLATION Plume management terminal positions All measurements in millimetres Plume re-direction: Flue terminal guard 7 716 191 176 ±45° 180° Flue Exhaust Outlet 1,500 ±80° Air Intake 5 0 0 ±80° 1,200 Boundary Line Fig. 17 Plume terminal positions Maximum and minimum plume management lengths: A minimum distance of 500mm must be maintained between the plume management outlet and the flue air intake.
Page 19: Installation
INSTALLATION INSTALLATION CAUTION: ROOF SPACE THIS BOILER IS NOT SUITABLE FOR ROOF SPACE INSTALLATION. NOTICE: Boiler start up All the previous Pre-Installation sections must be read and requirements met before starting boiler or flue installation. Unpacking the boiler NOTICE: BOILER HANDLING The correct method for handling heavy objects should be strictly observed, at all times.
Page 20: Mounting Frame Fixing And Flue Opening
INSTALLATION Mounting frame fixing and flue opening CAUTION: Ensure there are no pipes, electric cables, damp proof course or other hazards before drilling. Safety All relevant safety precautions must be undertaken. Protective clothing, footwear, gloves and safety goggles must be worn as appropriate. CAUTION: ISOLATE THE MAINS GAS SUPPLY BEFORE 70.5 STARTING ANY WORK AND OBSERVE ALL RELEVANT...
Page 21: Flue Measuring And Cutting
INSTALLATION All dimensions in mm Flue length guide Flue length range (mm) Number of extensions - 265 None 310 - 530 None 530 - 750 None 750 - 1260 1260 - 1480 1480 - 2210 2210 - 2430 2430 - 3160 3160 - 3380 3380 - 4000 Table 11 Flue extension guidance up to 4000mm...
Page 22 INSTALLATION Max. 4500mm 8 10 Min. 200mm 6720648665-39.1Wo Fig. 23 Condensate connection (See Pre-Installation section for condensate pipe work running from the adaptor [11] to the discharge outlet). Never terminate or discharge into any open source, including; sink, bath, shower, bidet, toilet etc. Any external condensate pipe work should be protected with weather resistant insulation to help prevent freezing.
Page 23: Electrical
INSTALLATION Electrical CAUTION: ISOLATE THE 230V ELECTRICITY SUPPLY 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 The mains electrical supply to the boiler and system wiring centre must be common and through either a...
Page 24: Commissioning
Refer to manufacturers instructions when connecting external parts to rectification work, shut off the gas supply and the wiring centre. electrically isolate the boiler. Worcester, Bosch Group cannot be held responsible for wiring errors. Complete the installation part of the Guarantee Registration Card. Do not...
Page 25: Water Treatment
In cases where all attempts to find a micro leak have failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer. Fig. 32 Turning on the appliance Turn the temperature control [7] to maximum. The burner on indicator [10] illuminates green when the burner has lit.
Page 26: Initialization
COMMISSIONING 5.4.2 Initialization The boiler runs for 15 minutes at minimum heating The appliance performs a self test at initial switch on that takes output to fill the condensate trap. This occurs every time approximately 10 seconds. the mains supply has been interrupted. During the test, the display shows for the first two seconds.
Page 27: Checking Gas Inlet Pressure
COMMISSIONING Checking gas inlet pressure Meter Gas Control Natural Gas valve 5.5.1 Measuring the inlet pressure < 2.5mbar The inlet pressure to the appliance must be checked using the following difference procedure: 19 - 23 mbar 16.5 - 20.5 mbar Boiler inlet 1 mbar 1.5 mbar...
Page 28: Co And Combustion Check
Check and zero the analyser in fresh air as specified by 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, Bosch Group help line 0330 123 3366. Zero the analyser >...
Page 29: Finishing Commissioning
SERVICING AND SPARES Finishing commissioning SERVICING AND SPARES At the time of commissioning, complete all relevant Inspection and service sections of the Benchmark Checklist located on the inside back pages of this document. CAUTION: ISOLATE THE GAS SUPPLY Ensure that the gas supply is safely Isolated and Engage top panel [1] onto rear retainers [2] and lower front of panel secured to prevent inadvertent re-connection.
Page 30: Service Function
Re-check the fan pressure readings. If the boiler, after completing the above checks, fails the fan pressure test then contact Worcester, Bosch Group for advice. After the measurements are taken switch the boiler off. Disconnect the manometer and replace the test point cover.
Page 31: Checking The Flue Integrity
SERVICING AND SPARES Checking the flue integrity Check the diaphragm in the fan for damage, replace if damaged. Check the diaphragm for correct operation, the diaphragm opens The appliance combustion cover must be fitted whilst towards the fan. this test is being performed. Cleanliness of the heat cell, plus blockages in the condensate disposal.
Page 32: To Clean The Condensate Trap
SERVICING AND SPARES Cleaning the heat exchanger 6.7.3 To clean the condensate trap 6.7.4 Remove the condensate pump refer to page 36. WARNING: Cleaning access cover Remove the screw retaining the trap Do not remove the cover unless a new gasket is Rotate the condensate trap anti-clockwise by 90°...
Page 33 SERVICING AND SPARES Press at the bottom to remove the metal plate [3], if fitted. Using the brush, clean the heat exchanger from top to bottom. 6720818079-20.1Wo 6720818079-18.1Wo Fig. 51 Fig. 49 Remove metal plate Use the handle of the brush to remove debris from the condensate Using the cleaning blade, working from the bottom to the top, to tray.
Page 34: Re-Assembly Of The Burner Cover
SERVICING AND SPARES Hand tighten the bolts and then use a spanner to tighten the bolts a Setting the air/gas ratio further half turn. NOTICE: SETTING THE AIR/GAS RATIO The air/gas ratio is factory set and should not normally need adjustment Only adjust if the values are still out of range when all other possible causes have been checked NOTICE: COMBUSTION TESTING...
Page 35: Replacement Parts
GAS TYPE max setting min setting COMMISSIONING SECTION. The CO should be measured after 10 minutes Greenstar FS 30CDi NOTICE: Service work Any service work must be carried out by competent Natural Gas 9.4 ±0.2% 8.6 ±0.2% registered gas engineer, such as a British Gas or LPG (propane) 10.8 ±0.2%...
Page 36: Fan Assembly
SERVICING AND SPARES Spare Fuse order T1.6A L250V F2 T500mA L250V F3 T2.5A H250V F1 6720818079-10.1Wo Fig. 56 Fan assembly 6.9.4 Condensate pump: Disconnect the electrical connections in the control box, see wiring schematic in the ‘Fault finding and Diagrams’ section. Remove the 15mm flexible tube [1] from the pump by rotating anti- clockwise and pulling up.
Page 37: Condensate Trap
SERVICING AND SPARES Flue Temperature limiter [5] 6.9.8 Gas valve: Check that the gas cock is turned off. Remove the connector. Disconnect the black rubber tube [1] from the gas valve. Using a small terminal screwdriver, prise the sensor and grommet Remove the solenoid connections [2] at the side of the gas valve.
Page 38: 6.9.10 Burner
SERVICING AND SPARES 6.9.10 Burner 6.10 Short parts list WARNING: Burner Burner 8 737 703 148 Do not remove the burner unless a new gasket is GC No. E27 200 available for re-assembly. Turn the gas cock and the master switch to their OFF positions. Fan 42kW Isolate the appliance from the power supply.
Page 39: Fault Finding And Diagrams
FAULT FINDING AND DIAGRAMS FAULT FINDING AND DIAGRAMS Electrical wiring diagram DIAGNOSTIC CODE PLUG PRE WIRED LINK INTERFACE ST18 230V~ Pink Green or Orange Orange Violet Blue SPARK Fuse F1, slow TRANSFORMER T2.5 A, H 230 V ST10 FS FR CH TEMPERATURE CONTROL Colour sequence...
Page 40: Boiler Function
FAULT FINDING AND DIAGRAMS Boiler function Greenstar FS CDi 6720818079 (2016/04)
Page 41: Fault Finding
FAULT FINDING AND DIAGRAMS Fault finding This fault finding information is for guidance only. Worcester Bosch cannot be held responsible for costs incurred by persons not deemed to be competent. The electronic control system for this boiler incorporates a blue central indicator. This normally confirms the permanent mains supply, but, by flashing during a fault, provides a guide to the cause as listed.
Page 42 GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. CONTROLS Optimum start control Fitted...
Page 43 SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider SERVICE 01 SERVICE 02 ² % ² % ² % ² % SERVICE 03 SERVICE 04 ² % ²...
Page 44 0330 123 9779 LITERATURE: 0330 123 9119 TRAINING: 0330 123 0166 SALES: 0330 123 9669 Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0330 123 9559 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. worcester-bosch.co.uk 6720818079 (2016/04)

This manual is also suitable for:

Greenstar fs 42cdi regular

Worcester Greenstar FS 30CDi Installation, Commissioning And Servicing Instructions

1 Key to Symbols and Safety Precautions

2 Appliance Information

3 Pre-Installation

4 Installation

5 Commissioning

6 Servicing and Spares

7 Fault Finding and Diagrams