Worcester Greenstar FS 30CDi Regular Instruction Manual
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Worcester Greenstar FS 30CDi Regular Instruction Manual

Worcester floor standing rsf gas-fired condensing regular boiler
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INSTRUCTION MANUAL
INSTALLATION COMMISSIONING & SERVICING
FLOOR STANDING RSF GAS-FIRED CONDENSING REGULAR BOILER
GREENSTAR
FS 30CDi & FS 42CDi Regular
FOR SEALED OR OPEN VENT CENTRAL HEATING SYSTEMS
8 716 115 216b (09.2008)
THE APPLIANCE IS FOR USE WITH
NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13, C33, C53 &C93)
NATURAL GAS:
GREENSTAR FS 30CDi REGULAR GC NUMBER 41-406-03
GREENSTAR FS 42CDi REGULAR GC NUMBER 41-406-04
LIQUID PETROLEUM GAS:
GREENSTAR FS 30CDi REGULAR GC NUMBER 41-406-05
GREENSTAR FS 42CDi REGULAR GC NUMBER 41-406-06
UK/IE

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  • Page 1 THE APPLIANCE IS FOR USE WITH NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13, C33, C53 &C93) NATURAL GAS: GREENSTAR FS 30CDi REGULAR GC NUMBER 41-406-03 GREENSTAR FS 42CDi REGULAR GC NUMBER 41-406-04 LIQUID PETROLEUM GAS: GREENSTAR FS 30CDi REGULAR GC NUMBER 41-406-05...
  • Page 2 SUCH AS A BRITISH GAS OR OTHER CORGI REGISTERED PERSONNEL. WEBSITE: worcester-bosch.co.uk FAILURE TO INSTALL CORRECTLY COULD LEAD TO PROSECUTION. IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER TECHNICAL SUPPORT WATER TREATMENT: HELPLINE. FERNOX 01799 550811 DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER, fernox.com...

  • Page 3: Table Of Contents

    CONTENTS SAFETY & REGULATIONS SAFETY PRECAUTIONS INSTALLATION REGULATIONS APPLIANCE INFORMATION GENERAL INFORMATION TECHNICAL DATA LAYOUT & COMPONENTS PRE-INSTALLATION CLEANING PRIMARY SYSTEMS MAINS SUPPLIES WATER SYSTEMS & PIPEWORK CONDENSATE PIPEWORK BOILER LOCATION & CLEARANCES MOUNTING FRAME CONNECTIONS FLUE OUTLET POSITIONS ROOM SEALED FLUE OPTIONS INSTALLATION UNPACKING THE BOILER MOUNTING FRAME FIXING / FLUE OPENING...

  • Page 4: Safety Precautions

    SAFETY PRECAUTIONS INSTALLATION REGULATIONS IF YOU SMELL GAS: Failure to install appliances correctly could lead to prosecution. DON'T SMOKE OR STRIKE MATCHES. DON'T TURN ELECTRICAL SWITCHES ON OR OFF. This appliance must be installed by a competent registered engineer, such as British DO PUT OUT NAKED FLAMES.

  • Page 5: General Information

    GENERAL INFORMATION STANDARD PACKAGE: A - Floor standing gas fired regular boiler B - Mounting frame complete with pre- plumbing manifold assembly C - Literature pack D - Condensate hose and non-return valve SPECIFICATIONS: Pre-wired and pre-plumbed. Galvanised steel inner frame. Bosch Heatronic control system.

  • Page 6: Technical Data

    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: Layout & Components

    LAYOUT & COMPONENTS The diagram opposite shows the controls in the servicing position and excludes the outer case, inner covers and wiring. 1 CONTROL PANEL 2 MASTER SWITCH FOR ON/OFF 3 BURNER ON INDICATOR LIGHT (GREEN) 4 SERVICE BUTTON 5 BOOST BUTTON (SERVICE ONLY) 6 DISPLAY 7 RESET BUTTON 8 NOT USED...

  • Page 8: Cleaning Primary Systems

    CLEANING PRIMARY SYSTEMS IMPORTANT: All the following pre-installation sections must be read and IMPORTANT: requirements met before starting boiler or flue installation. Debris from the system can damage the boiler and reduce efficiency. Failure to comply with the guidelines for the use of water treatment with the appliance CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK will invalidate the appliance warranty.

  • Page 9: Mains Supplies

    MAINS SUPPLIES ELECTRICAL SUPPLY: • Supply: 230V - 50Hz. • Cable: PVC insulated 0.75mm (24 x 0.2mm) temperature rated to 90°C. • External 3A fuse to BS1362. • The appliance must be earthed. • It must be possible to isolate the appliance from the electrical supply with at least a 3mm contact separation in both poles supplying the appliance.

  • Page 10: Water Systems & Pipework

    WATER SYSTEMS & PIPEWORK PRIMARY SYSTEM PLASTIC PIPEWORK: • Any plastic pipework must have a polymeric barrier with 600mm (minimum) length of copper pipe connected to the boiler. • Plastic pipework used for underfloor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approx.
  • Page 11 WATER SYSTEMS & PIPEWORK S PLAN LAYOUT S & Y PLAN OPEN VENT PRIMARY SYSTEM: Generally a by-pass is not necessary on a Y plan min. 250mm min. 250mm system as one of the parts is open to flow. • The feed and expansion cistern (N) must be positioned to provide a static head (M) of at least 250mm above the highest point in the heating system.

  • Page 12: Condensate Pipework

    CONDENSATE PIPEWORK IMPORTANT: Visible air break • Ensure there are no at plug hole blockages in the pipe run • Sink with Care should be taken when Condensing integral siting a soak-away to avoid Boiler overflow 100mm obstructing existing services Insulation or increase pipe size •...

  • Page 13: Boiler Location & Clearances

    1: INSTALLATION CLEARANCES BOILER LOCATION & CLEARANCES 410mm 1200mm • This boiler is only suitable for installing 600mm internally within a property at a suitable location onto a fixed rigid non-combustible surface at least the same size as the boiler and capable of supporting the boiler weight.
  • Page 14 BOILER LOCATION & CLEARANCES 4: AIRING CUPBOARD CLEARANCES 600mm 625mm 4: AIRING CUPBOARD CLEARANCES: Diagram '4' opposite shows the minimum space equired to install and service the boiler 100mm within an airing cupboard. 200mm 25mm 5: VENTING COMPARTMENTS: 5: VENTING If the clearances are less than those stated COMPARTMENTS for options '3' &...

  • Page 15: Mounting Frame Connections

    MOUNTING FRAME CONNECTIONS CONNECTIONS: Water: 28mm compression fittings Gas: 22mm compression fitting. RUNNING PIPES BEHIND THE BOILER: • The frame should sit against the wall (not the skirting board) with enough room for the pipework. • Do not cross a pipe over another. •...

  • Page 16: Flue Outlet Positions

    • The flue must be fitted and terminated in accordance with the recommendations of BS5440 : Part 1. • The flue must not cause an obstruction. • Discharge and any noise from the flue outlet must not cause a nuisance. •...
  • Page 17 FLUE OUTLET POSITIONS NOTES: Plume management kits are available for 100mm horizontally terminated flues. Please refer to the installation instructions supplied with the plume management kits. If plume redirection is utilised, the clearance from any opening must be increased in the direction of the plume to 1500mm.

  • Page 18: Room Sealed Flue Options

    ROOM SEALED FLUE OPTIONS L= Ø100mm 130 - 530mm L= Ø125mm 9000mm L= Ø125mm 350 - 1200mm The diagrams (opposite) show the components used and the maximum flue length for each configuration of 100mm and 125mm flues. • Only straight flue sections can be reduced Min.

  • Page 19: Unpacking The Boiler

    UNPACKING THE BOILER IMPORTANT: All the previous Pre-Installation sections must be read and requirements met before starting boiler or flue installation. Take care not to damage the boiler panels or the floor and note that the boiler may contain some water due to factory testing. Unpacking: Undo the ties securing the carton to the pallet...

  • Page 20: Mounting Frame Fixing / Flue Opening

    All dimensions in mm MOUNTING FRAME FIXING & 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 70.5 appropriate.

  • Page 21: Mounting Frame Connections

    MOUNTING FRAME CONNECTIONS CAUTION: ISOLATE THE MAINS GAS SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. GAS AND WATER CONNECTIONS: Ensure all pipework is clean and each pipe is in the correct position as shown opposite. Push in each pipe in turn and tighten the fitting to secure.

  • Page 22: Flue Lengths/Flue Measuring & Cutting

    (L) to check the maximum flue Appliance description L max. length is not exceeded: Greenstar FS 30CDi Regular 4000mm 2000mm for each extra 90° bend. Greenstar FS 42CDi Regular 4000mm 1000mm for each extra 45°...
  • Page 23 FLUE MEASURING & CUTTING Flue bends: Connecting flue bends increases the effective pipe length and an allowance must be made for the different connectors. 950mm The example opposite shows dimensions 1145mm for two 90° bends connected to a standard flue extension. Adjusting the standard terminal length: Extend tube (A) by withdrawing from tube (B) to achieve the flue length required,...
  • Page 24 FLUE MEASURING & CUTTING FLUE OUTLETS (X or Y): Remove seal (B) from flue adaptor (A). Cut square to mark, as shown, deburr and clean. Replace seal (B). FLUE MEASURING & CUTTING INSTALLATION & SERVICING INSTRUCTIONS 8 716 115 216b (09.2008)

  • Page 25: Flue Installation

    FLUE INSTALLATION Grip the outer sides of the front panel (F) pull and lift away from retaining lugs. Remove retaining screw (B) to swing control panel assembly (A) outwards to its full extent. Remove screws (C) from inside of casing. Lift front of top panel (D) to release.

  • Page 26: Standard Flue Installation

    STANDARD FLUE INSTALLATION NOTE: To ease assembly of the flue components, lightly grease seals lightly with the solvent-free grease supplied. Check all the seals are seated properly in the grooves provided and are in good condition. All flue joints must be sealed to prevent leakage of condensate and flue products.

  • Page 27: Flue Terminal Plume Management

    FLUE TERMINAL PLUME MANAGEMENT The flue discharge can be redirected allowing some plume management control, alternatively, a complete plume management system can be fitted to the flue terminal. Redirecting the flue discharge: Important: should you wish to use the plume deflector please use the additional grease enclosed to ensure that an adequate seal is retained.

  • Page 28: Condensate, Gas & Water Connections

    CONDENSATE, GAS & WATER CONNECTIONS CONDENSATE CONNECTION: The condensate pump (G) fills up and periodically discharges through the flexible condensate pipe (H) between 200mm to 4500mm from floor level. After this point the condensate flows, due to gravity, down the 21.5mm plastic pipe to the outlet.

  • Page 29: Electrical

    ST19 Refer to manufacturers instructions when connecting external parts to the wiring centre. Worcester, Bosch Group cannot be held responsible for wiring errors. INSTALLATION & SERVICING INSTRUCTIONS ELECTRICAL 8 716 115 216a (07.2008)

  • Page 30: Pre-Commissioning Checks

    PRE-COMMISSION CHECKS CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. Check that the service and water pipes are connected to the correct valve on the manifold; A - CH flow (28mm) B - Gas inlet (22mm) C - CH return (28mm) Check all system and boiler drain points are closed.

  • Page 31: Filling The System

    FILLING THE SYSTEM Open all system and radiator valves. Turn on the water main stop cock. Open vented systems only; Turn on the water to the system header tank and allow the system to fill. Pressure gauge located externally on the system;...

  • Page 32: Starting The Appliance

    STARTING THE APPLIANCE IMPORTANT: Never run the appliance when the appliance or system is empty or unpressurised. Switching the appliance on/off: Turn on mains power supply. Turn on any external controls. Set the thermostatic radiator controls to maximum. Set the clock/programmer to continuously ON and the room thermostat to maximum temperature.

  • Page 33: Water Treatment

    WATER TREATMENT IMPORTANT: Debris from the system can damage the boiler and reduce efficiency. Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance warranty. FLUSHING (Central Heating): Switch off the boiler. Open vented systems only: turn off the water to the system header tank.

  • Page 34: Finishing Commissioning

    FINISHING COMMISSIONING Engage top panel (D) onto rear retainers (E) and lower front of panel into position. Secure with screws (C). Swing control panel assembly (A) into the boiler. Secure with screw (B). Locate bottom corners of the front panel (F) into retainers (G).

  • Page 35: Inspection And Service

    INSPECTION & SERVICE CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS IMPORTANT: Any service work must be carried out by competent registered IMPORTANT: AFTER REPLACEMENT OF ANY COMPONENTS ALWAYS CHECK FOR engineers, such as British Gas or other GAS SOUNDNESS WHERE RELEVANT AND CARRY OUT FUNCTIONAL CHECKS CORGI registered personnel.
  • Page 36 INSPECTION & SERVICE Grip the outer sides of the front panel (F) pull and lift away from retaining lugs. Remove retaining screw (B) to swing control panel assembly (A) outwards to its full extent. Release four screws (H) to remove the inner case cover (J).
  • Page 37 INSPECTION & SERVICE IMPORTANT: AFTER COMPLETING THE APPLIANCE SERVICE THE CO/CO MUST BE CHECKED AND SET TO THE LIMITS IN THE SECTION “AIR/GAS RATIO”. Primary Heat Exchanger: There is a special accessory kit available (No. 840) specifically designed for cleaning the heat exchanger.
  • Page 38 INSPECTION AND SERVICE Burner: Check that the boiler is completely isolated from the gas supply. Remove the clips (A), castellated nuts (B1) and springs (B2) from the studs (B). Unscrew and remove the two hexagon headed screws (C) securing the fan. Remove nut (D1) from the rear stud (D).

  • Page 39: Replacement Of Parts

    REPLACEMENT PARTS CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS ELECTRICAL SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. DRAIN THE BOILER/SYSTEM WHERE NECESSARY AND PROTECT ANY ELECTRICS IMPORTANT: Any service work must be FROM WATER INGRESS DURING COMPONENT REPLACEMENT. carried out by competent registered engineers, such as British Gas or other IMPORTANT: Refit or replace any components removed from the appliance in the...
  • Page 40 REPLACEMENT PARTS Fan Assembly: Undo lower pipe union on gas pipe (E). Remove fan lead and earth connector. The earth connector has a positive clip fixing. Remove fixing screws (C) attaching fan (A) to the burner cover (B). Remove fan (A) with gas pipe (E) and mixer unit (D).
  • Page 41 REPLACEMENT PARTS Sensors: Check that the appliance is electrically isolated. Flow temperature sensor (A): Remove the connector. Release the sensor clip and withdraw the sensor. Apply heat transfer paste to the replacement sensor. Safety temperature limiter (B): Remove the connectors. Unscrew the sensor.
  • Page 42 REPLACEMENT PARTS Condensate trap: Move control panel into service position. Remove inner case door. Remove screw retaining trap (F) and push trap downwards until clear. Remove trap from boiler along with pipe to condensate pump. Gas valve: Check that the gas cock is turned off. Remove condensate pump.
  • Page 43 REPLACEMENT PARTS Electrode assembly: Switch off the master switch. Isolate appliance from the power supply. Move control panel into service position. Release 4 screws to remove inner case door. Remove the leads from the electrodes. Unscrew the two fixing screws (B) and carefully remove the electrode assembly (A).

  • Page 44: Setting The Gas/Air Ratio

    SETTING THE AIR/GAS RATIO IMPORTANT: The appliance is set at the factory and adjustment to the CO settings (air/gas ratio) is only required where the appliance has been stripped down and assembled or if the fan, burner or gas valve are replaced or the appliance has been converted to a different gas type.

  • Page 45: Short Parts List

    SHORT PARTS LIST 1 Burner: Part No. 8 718 006 658 0 (GC No. E27 200) 2 Fan assembly: 30kW Part No. 8 717 204 410 0 (GC No. H66-918) 42kW Part No. 8 717 204 453 0 (GC No. H26-536) 3 Temperature sensor: Part No.

  • Page 46: L.p.g. Conversion

    L.P.G. CONVERSION Change code plug: Release three screws (A) to remove cover (B). Remove and dispose of the existing code plug (C). Replace with new conversion code plug. N.G. code plug number: FS 30CDi 1704 FS 42CDi 1706 L.P.G. code plug number: FS 30CDi 1705 FS 42CDi 1707 Refit panel (B) and secure with three...

  • Page 47: Electrical Wiring Diagram

    ELECTRICAL WIRING DIAGRAM FLAME SENSE SPARK ELECTRODE ELECTRODES Orange or Green PRIMARY FLOW NTC PRIMARY OVERHEAT FLUE OVERHEAT Orange SAFETY Violet SOLENOID Blue SAFETY SOLENOID EXTERNAL PUMP PUMP CONTROL MAINS HIGH LEVEL SUPPLY SENSOR Earth EXTERNAL PUMP CONDENSATE WIRING CENTRE SUPPLY PUMP Y or S PLAN...

  • Page 48: Central Heating Function

    BOILER FUNCTION INSTALLATION & SERVICING INSTRUCTIONS CENTRAL HEATING FUNCTION 8 716 115 216b (09.2008)

  • Page 49: Fault Finding

    FAULT FINDING NOTE ; This fault finding information is for BOILER - FAULT CODES AND CONDITIONS guidance only. Worcester, Bosch Group cannot be held responsible for costs incurred by persons Display not deemed to be competent. Fault description: Check, repair/replace as necessary:...
  • Page 50 GAS BOILER 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. Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.

  • Page 51: Service Record

    SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.
  • Page 52 Dedicated to heating comfort Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW Tel. 01905 754624 Fax. 01905 754619 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. worcester-bosch.co.uk 8 716 115 216b (09.2008)

This manual is also suitable for:

Greenstar fs 30cdiGreenstar fs 42cdi

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