Worcester GREENSTAR 35 CDi Installation, Commissioning And Servicing Instructions
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Worcester GREENSTAR 35 CDi Installation, Commissioning And Servicing Instructions

Wall hung rsf gas fired condensing system boiler. for central heating systems and indirect fed domestic hot water.
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See also: Instructions for Installation and Servicing , Instructions for Using
INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS
WALL HUNG RSF GAS FIRED CONDENSING SYSTEM BOILER
GREENSTAR 30/35 CDi CLASSIC SYSTEM
FOR CENTRAL HEATING SYSTEMS AND INDIRECT FED DOMESTIC HOT WATER
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
UK/IE

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Summary of Contents for Worcester GREENSTAR 35 CDi

  • Page 1 INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS WALL HUNG RSF GAS FIRED CONDENSING SYSTEM BOILER GREENSTAR 30/35 CDi CLASSIC SYSTEM FOR CENTRAL HEATING SYSTEMS AND INDIRECT FED DOMESTIC HOT WATER 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...

  • Page 2: Table Of Contents

    CONTENTS CONTENTS KEY TO SYMOLS AND SAFETY PRECAUTIONS ... . . 3 SERVICING AND SPARES ......36 Key to symbols .

  • Page 3: Key To Symols And Safety Precautions

    Keywords at the start of a warning indicate the type and prosecution. seriousness of the ensuing risk if measures to prevent If you are in any doubt, contact the Worcester Technical helpline the risk are not taken. (0330 123 3366).

  • Page 4: Safety Precautions

    KEY TO SYMOLS AND SAFETY PRECAUTIONS SAFETY PRECAUTIONS INSTALLATION REGULATIONS Current Gas Safety (Installation & Use) Regulations: IF YOU SMELL GAS All gas appliances must be installed by a competent person in A gas leak could potentially cause an explosion. If you smell gas, observe accordance with the above regulations.

  • Page 5: Appliance Information

    APPLIANCE INFORMATION STANDARD PACKAGE: APPLIANCE INFORMATION Wall hung gas fired condensing system boiler for central heating and domestic hot water GENERAL INFORMATION Wall mounting plate BOILER FEATURES Hanging bracket • Pre-wired and pre-plumbed Pre-plumbing manifold • Galvanised steel inner frame Hardware pack •...

  • Page 6: Layout & Components

    APPLIANCE INFORMATION LAYOUT & COMPONENTS 6 720 812 175-06.1O Fig. 3 Controls in the servicing position excluding the outer case 6 720 812 175 (2014/07)
  • Page 7 APPLIANCE INFORMATION Ignition electrode and flame sense Heat exchanger Overheat thermostat Access point for cleaning heat exchanger Pump reset Pressure relief valve Boiler drain point CH return Cover for external wiring connections Control panel in service position System pressure gauge Gas inlet connection 22mm compression 6 720 812 175-08.1O Drain hose...

  • Page 8: Technical Data

    APPLIANCE INFORMATION TECHNICAL DATA NATURAL GAS L.P.G. NATURAL GAS L.P.G. DESCRIPTION UNIT 30CDi System 30CDi System 35CDi System 35CDi System Domestic hot water Min. heat input 11.5 11.5 Max. rated heat output 30.9 30.9 35.0 35.0 Max. rated heat input 30.9 30.9 35.0...

  • Page 9: Pre-Installation

    PRE-INSTALLATION WATER TREATMENT PRODUCTS PRE-INSTALLATION Suitable water treatment products can be obtain from the following manufacturers: CLEANING PRIMARY SYSTEMS FERNOX 0870 601 5000 CAUTION: MAINS SUPPLIES www.fernox.com ▶ Isolate the mains supplies before starting any work SENTINEL 0800 389 4670 and observe all relevant safety precautions.

  • Page 10: Water Systems & Pipe Work

    PRE-INSTALLATION WATER SYSTEMS & PIPE WORK S plan layout PLASTIC PIPE WORK: • Any plastic pipe work must have a polymeric barrier with 600 mm (minimum) length of copper or steel pipe connected to the boiler. • Plastic pipe work used for underfloor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approx.

  • Page 11: Condensate Pipe Work

    PRE-INSTALLATION CONDENSATE PIPE WORK NOTICE: ▶ Where a new or replacement boiler is being installed, access to an internal “gravity discharge” point should be one of the factors considered in determining boiler location. ▶ The condensate pipe must be nominally 22mm Ø...

  • Page 12: External Connections

    PRE-INSTALLATION 3.4.2 EXTERNAL CONNECTIONS FITTING AN EXTERNAL AIR BREAK • Refer to figure 10 when a rain water down pipe is used to dispose of NOTICE: Freezing conditions condensate. ▶ Pipe work length should be kept to a minimum and the •...

  • Page 13: Boiler Internal Drain

    PRE-INSTALLATION PRESSURE RELIEF PIPE WORK Minimum hole size for the condensate soak away must be 400mm deep by 300mmØ . NOTICE: ▶ The pressure relief valve is a safety device for the boiler and if activated may discharge boiling water or In situations where there are likely to be extremes of temperature or steam through the relief valve drain pipe.

  • Page 14: Boiler Location & Clearances

    PRE-INSTALLATION BOILER LOCATION & CLEARANCES COMPARTMENTS Follow the requirements of BS6798 and BS5440 Part 2 and note: This boiler is only suitable for installing internally within a property at a suitable location onto a fixed, rigid non-combustible surface at least the •...

  • Page 15: Plumbing Manifold

    PRE-INSTALLATION PLUMBING MANIFOLD CONNECTIONS: Heating system: 22 mm compression fittings NOTICE: DHW: 15 mm compression fittings ▶ IF FITTING OPTIONAL INTEGRAL DIVERTER VALVE Gas: 22 mm compression fittings install the pipe work as shown in figure 17 (also Use the fittings supplied in the Hardware pack. see additional information in the document PREPLUMBING supplied with the diverter valve kit).

  • Page 16: Flue Options

    PRE-INSTALLATION FLUE OPTIONS The Greenstar CDi Classic has the option of three horizontal RSF (60/ Horizontal extended flue with 2x90° bends 100 telescopic, 60/100 longer telescopic and 80/125 telescopic) flue Flue option 4 100mmØ 125mmØ systems and two vertical RSF (60/100 or 80/125) regular flue systems: 30CDi System 4,900mm 14,500mm...
  • Page 17 PRE-INSTALLATION 350 mm - 570 mm 130 mm Min 500 mm 300 mm Flat roof 6720643895-12.1Wo 6 720 812 175 (2014/07)

  • Page 18: Flue Terminal Positions

    PRE-INSTALLATION 3.10 FLUE TERMINAL POSITIONS All measurements in millimetres 52mm 104mm 1,500 1,500 300 300 300 300 1,200 Boundary Line Fig. 19 Flue terminal positions NOTICE: ▶ All measurements are the minimum clearances required. ▶ Terminals must be positioned so to avoid combustion products entering the building. ▶...

  • Page 19: Plume Management Terminal Positions

    PRE-INSTALLATION 3.11 PLUME MANAGEMENT TERMINAL POSITIONS All measurements in millimetres Flue terminal guard 7 716 191 176 ±45° Plume re-direction: 180° Flue Exhaust Outlet 1,500 Air Intake ±80° 1,200 Boundary Line Fig. 20 Plume terminal positions NOTICE: ▶ All measurements are the minimum clearances required. ▶...

  • Page 20: Installation

    INSTALLATION INSTALLATION NOTICE: All the previous Pre-Installation sections must be read and requirements met before starting boiler or flue installation. UNPACKING WALL FRAME AND ANCILLARY ITEMS LIFTING AND CARRYING PRECAUTIONS: WARNING: ▶ Lift only a manageable weight, or ask for help. ▶...

  • Page 21: Wall Mounting Plate And Flue Opening

    INSTALLATION WALL MOUNTING PLATE AND FLUE OPENING FLUE OUTLET ▶ Follow the Fig. 22 to mark the centre of the flue for rear outlet (3) or CAUTION: Ensure there are no pipes, electric cables, for side outlet (4). damp proof courses or other hazards before drilling. ▶...

  • Page 22: Unpacking The Appliance

    INSTALLATION UNPACKING THE APPLIANCE 1. With the wall frame and ancillary items removed lay the carton (A) on its back. 2. Open the carton bottom flaps and fold under boiler. Do not remove the packaging base. 3. Stand carton (A) with boiler upright on the packaging base (B). 4.

  • Page 23: Fitting The Appliance/Boiler Connections

    INSTALLATION FITTING THE APPLIANCE/BOILER CONNECTIONS Do not lift by the top case panel. CAUTION: Isolate the mains gas supply before starting any work and observe all relevant safety precautions. GAS AND WATER CONNECTIONS: ▶ System pipes may be run vertically upwards behind the boiler or below it.

  • Page 24: Flue Installation

    INSTALLATION FLUE INSTALLATION HORIZONTAL FLUE (60/100 mm diameter) 570 mm For vertical flues and 80/125mm horizontal flues, please refer to 350 mm separate Flue Kit instructions. Apply silicone lubricant to the sealing surfaces of the flue components to ease assembly of flue components. WALL 6720643895-30.1Wo Fig.

  • Page 25: Installing The Standard Flue

    INSTALLATION 4.5.4 INSTALLING THE STANDARD FLUE 4.5.5 FLUE TERMINAL PLUME RE-DIRECTION: 1. Set the flue length to the distance required, secure with screw and The flue discharge can be re-directed allowing some plume redirection seal joint with the aluminium tape supplied. control, alternatively, a complete plume management system can be Slide the inner wall seal (1) onto the terminal (2) as shown.

  • Page 26: Condensate Connection

    INSTALLATION CONDENSATE CONNECTION Never terminate or discharge into any open source, including; sink, bath, shower, bidet, toilet etc. Any external condensate pipe work of excessive runs should be protected with weather resistant insulation to help prevent freezing. ▶ Ensure that the condensate drain is 22mm diameter plastic pipe. It must fall at least 52mm per metre towards the outlet ▶...

  • Page 27: Electrical (Without Diverter Valve)

    ▶ A fascia mounted programmer/timer should not be fitted unless optional integral diverter valve is used. ▶ Refer to manufacturers instructions when connecting external parts to the wiring centre. Worcester, Bosch Group cannot be held responsible for wiring errors. 6 720 812 175 (2014/07)

  • Page 28: Electrical (With Optional Diverter Valve)

    INSTALLATION ELECTRICAL (WITH OPTIONAL DIVERTER VALVE) CAUTION: ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS Danger of short circuit: When connecting the cables ensure that no cable pieces fall into the Heatronic. 230V CYLINDER STAT Mains supply to the boiler must be through a fused double pole isolator situated adjacent to the appliance.

  • Page 29: Position Of Wired Components

    2.5 A, AC 230 V TRANSFORMER EXTERNAL FROST STAT ST17 (OPTIONAL) EMS BUS Yellow contacts Grey Blue Black WORCESTER 24V CONTROLS PLUG IN POINT Blue (NOT USED) 230V~ Fuse F3, slow T 0.5 A Orange Fuse F2, slow T1.6 A Orange White Black ST18...

  • Page 30: Commissioning

    COMMISSIONING 3. Check that the pressure relief connector, located on the right hand COMMISSIONING side at the bottom of the wall frame, in its up position. PRE- COMMISSIONING CHECKS CAUTION: MAINS SUPPLIES ▶ Isolate the mains supplies before starting any work and observe all relevant safety precautions.

  • Page 31: Starting The Appliance

    COMMISSIONING STARTING THE APPLIANCE 3. If the boiler fails to light the BLUE power indicator (M) and reset button (E) will flash alternately. To reset press and hold the reset button (E) for 2 seconds. The boiler NOTICE: Never run the appliance when the appliance/ will be reset.

  • Page 32: Commissioning

    COMMISSIONING ▶ The concentration level of inhibitor in the system NOTICE: THE COMBUSTION FOR THE APPLIANCE IS should be checked every 12 months or sooner if FACTORY SET. system content is lost. NO ADJUSTMENT IS REQUIRED IF THE GAS INLET ▶...

  • Page 33: Checking The Gas Rate

    COMMISSIONING GAS PRESSURE WITHIN THE SYSTEM 5.5.2 CHECKING THE GAS RATE Refer to the figure below for natural gas pressures. ▶ The gas rate should be measured at the gas meter after 10 minutes operation at maximum. The pressure at the boiler must not be less than the pressure read at the See technical data section at the front of this manual.

  • Page 34: Co And Combustion Checks

    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 35: Finishing Commissioning

    COMMISSIONING FINISHING COMMISSIONING The boiler has been factory set, so there should be no need to adjust combustion settings. REPLACE OUTER CASING: 1. Replace outer casing making sure that the securing points are properly located. ▶ Press the clip (A) downwards to secure casing on top. ▶...

  • Page 36: Servicing And Spares

    SERVICING AND SPARES 6.1.1 CHECKING FLUE INTEGRITY SERVICING AND SPARES The integrity of the flue system and performance of the boiler can be checked via the flue turret sample points. INSPECTION AND SPARES Flue gas sample point CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE Air inlet sample point THE MAINS SUPPLIES BEFORE STARTING ANY WORK Table 30 Key to figure 55...

  • Page 37: Fan Pressure Test

    SERVICING AND SPARES 6.1.3 FAN PRESSURE TEST This test is to determine if the heat cell requires cleaning/ attention SET THE BOILER TO MAXIMUM When fitted with the optional diverter valve (not supplied) and running in performance test mode, the boiler will only operate the central heating circuits.

  • Page 38: To Clean The Heat Exchanger

    SERVICING AND SPARES FAN PRESSURE TEST NOTICE: Air/Gas ratio Clean the Heat Ex. Heat Ex. ok ▶ After servicing the CO/CO must be checked using the procedure in the section “Setting the air/gas ratio” NG Boilers on page 40. - 5.3 35 CDi: ▶...

  • Page 39: To Clean The Burner

    SERVICING AND SPARES 6 720 812 175-16.1O Fig. 66 3. Remove the burner (H) and clean components. 6720803599-04.1Wo Do not use a wire brush. Fig. 64 ▶ Refit the clean out cover plates in reverse order using a new seal (C) and tighten screws.

  • Page 40: To Clean The Siphon/Condensate Trap

    SERVICING AND SPARES 6.1.7 TO CLEAN THE SIPHON/CONDENSATE TRAP setting setting 1. Pull condensate hose out of the trap. Gas type maximum minimum 2. Remove trap from boiler. 30CDI System ▶ Clean the trap and check that the connection to the heat exchanger is Natural gas 9.6% ±0.4 9.0% ±0.4...

  • Page 41: Replacement Of Parts

    SERVICING AND SPARES REPLACEMENT OF PARTS CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. NOTICE: After replacement of any components always check for gas tightness where relevant and carry out functional checks as described in the commissioning section.
  • Page 42 SERVICING AND SPARES 6 720 812 175-34.1O Fig. 72 Replacing parts 6 720 812 175 (2014/07)
  • Page 43 SERVICING AND SPARES 7. GAS VALVE 10. PCB FUSE ▶ Isolate gas supply at boiler gas cock. ▶ Remove fuse (B) from the PCB and replace. ▶ Pull out air inlet tube (A). ▶ There is a spare fuse clipped into the cover. ▶...
  • Page 44 SERVICING AND SPARES 12. FAN ASSEMBLY 13. ELECTRODE ASSEMBLY NOTICE: Air/Gas ratio WARNING: Electrode gasket ▶ After re-assembly the combustion must be checked ▶ Do not remove the electrode assembly unless a new using the procedure in the section “Setting the air/gas gasket is available for re-assembly.
  • Page 45 SERVICING AND SPARES 15. BURNER ▶ Remove the burner (H). ▶ Replace new burner in correct position. ▶ Ensure that a new seal (K) is used, refer to fig. 82. 6 720 812 175-16.1O Fig. 80 Release air/gas manifold 3. Remove air/gas manifold (I) Fig.
  • Page 46 SERVICING AND SPARES 18. DIVERTER VALVE ▶ Ensure the appliance has been fully drained. ▶ Disconnect the electrical connector from the diverter valve motor. ▶ Undo the two screws holding the valve to the plastic housing. 6 720 812 175-19.1O Fig.
  • Page 47 SERVICING AND SPARES 21. PUMP HEAD 25. DRAIN TAP ▶ Ensure the appliance has been fully drained. ▶ Ensure the appliance has been fully drained. 1. Disconnect the electrical connections from the pump following steps: 1. Withdraw the drain pipe from the drain tap. To do this, remove retaining spring from the drain pipe.
  • Page 48 SERVICING AND SPARES 26. HYDRAULIC BLOCK ▶ Ensure the appliance has been fully drained. ▶ Disconnect the electrical connections to the NTC, Turbine and pump. ▶ Undo the nuts securing the copper water pipes to the manifold (there is no need to remove the gas pipe). ▶...
  • Page 49 SERVICING AND SPARES 27. CH PRESSURE RELIEF VALVE ▶ Remove the Hydraulic 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. ▶...

  • Page 50: Short Parts List

    SERVICING AND SPARES SHORT PARTS LIST Burner Burner skin seal 8 717 204 453 0 8 718 006 658 0 8 711 004 168 0 GC No. H26 536 GC No. E27 200 GC No. E27 201 Gas valve WHS Temperature limit Electrodes 8 718 221 347 0...

  • Page 51: Fault Finding & Diagnosis

    This fault finding information is for guidance only. The first electrical checks to be carried out during a fault-finding procedure. Worcester, Bosch Group cannot be held responsible for On completion of the Service/Fault-Finding task which has required the costs incurred by persons not deemed to be competent.

  • Page 52: Central Heating Function

    FAULT FINDING & DIAGNOSIS CENTRAL HEATING FUNCTION 6720647472-29.1Wo 6 720 812 175 (2014/07)

  • Page 53: Cylinder Heat Function

    FAULT FINDING & DIAGNOSIS CYLINDER HEAT FUNCTION The cylinder heat function is available only with the optional diverter valve fitted. 6720647472-30.1Wo 6 720 812 175 (2014/07)

  • Page 54: Protection Function

    FAULT FINDING & DIAGNOSIS PROTECTION FUNCTION Run autofroststat Boiler temperature below 8 o C function Pump runs 5 seconds Pump antiseize every 24 hours DHW demand active Holiday mode Frost protection active set to ON All other demands not active 6720647472-31.1Wo 6 720 812 175 (2014/07)
  • Page 55 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 56 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 57 NOTES 6 720 812 175 (2014/07)
  • Page 58 NOTES 6 720 812 175 (2014/07)
  • Page 59 NOTES 6 720 812 175 (2014/07)
  • Page 60 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 6 720 812 175 (2014/07)

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