Bosch WORCESTER GREENSTAR 25CDi User manual

GREENSTAR CDi
Ȓ'
WALL HUNG RSF GAS-FIRED CONDENSING COMBINATION BOILER
FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER
THE APPLIANCE IS FOR USE WITH
NATURAL GAS OR LP.G. (Cat II 2H3P TYPE C13 C33)
NATURAL GAS:
WORCESTER GREENSTAR 25CDÍ GC NUMBER 47-311-92
WORCESTER GREENSTAR 30CDÍ GC NUMBER 47-311-93
WORCESTER GREENSTAR 35CDÍ GC NUMBER 47-311-94
WORCESTER GREENSTAR 40CDÍ GC NUMBER 47-311-95
LIQUID PETROLEUM GAS:
WORCESTER GREENSTAR 25CDÍ GC NUMBER 47-311-96
WORCESTER GREENSTAR 30CDÍ GC NUMBER 47-311-97
WORCESTER GREENSTAR 35CDÍ GC NUMBER 47-311-98
WORCESTER GREENSTAR 40CDÍ GC NUMBER 47-406-01
5^/ORCESTER
INSTRUCTION MANUAL
INSTALLATION, COMMISSIONING
SERVICING _______
ÇbenchmariÇ j
Bosch Group

CONTACT INFORMATION INSTALLATION SERVICING INSTRUCTIONS
WORCESTER BOSCH:
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
TECHNICAL:
SERVICE:
SPARES:
LITERATURE:
TRAINING:
SALES:
WEBSITE:
08705 266241
08457 256206
01905 752571
01905 752556
01905 752526
01905 752640
www.worcester-bosch.co.uk
THESE INSTRUCTIONS ARE APPLICABLE TO THE WORCESTER BOSCH 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.
THE INSTRUCTIONS APPLY IN THE UK ONLY AND MUST BE FOLLOWED EXCEPT FOR ANY
STATUTORY OBLIGATION.
THIS APPLIANCE MUST BE INSTALLED BY A COMPETENT PERSON. FAILURE TO INSTALL
CORRECTLY COULD LEAD TO PROSECUTION.
WATER TREATMENT:
FERNOX 01799 550811
www.fernox.com
SENTINEL 0151 420 9595
www.betzdearborn.com/sentinel
FLUE TERMINAL GUARD:
TOWER FLUE COMPONENTS
VALE RISE
TONBRIDGE
TN9 1TB
IF YOU ARE IN ANY DOUBT CONTACT WORCESTER BOSCH TECHNICAL HELPLINE.
DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER
BOSCH.
PLEASE LEAVE THESE INSTRUCTIONS THE USER GUIDE AND THE COMPLETED
BENCHMARK LOG BOOK OR A CERTIFICATE CONFIRMING COMPLIANCE WITH IS 813
(EIRE ONLY) WITH THE USER OR AT THE GAS METER AFTER INSTALLATION OR SERVIC 
ING.
ABBREVIATIONS USED IN THIS MANUAL:
0 Diameter
NG Natural Gas
LPG Liquid Petroleum Gas
CH Central Heating
DHW Domestic Hot Water
IP Ingress Protection
SEDBUK Seasonal Efficiency of Domestic Boilers in the United Kingdom
STORE THE APPLIANCE IN A DRY AREA
PRIOR TO INSTALLATION.
SYMBOLS USED IN THIS MANUAL:
Domestic hot water
Time clock CH only
Central heating
Program mer/timer
A
Cold water main supply
Room thermostat
LIFTING AND CARRYING PRECAUTIONS:
• Lift only a manageable weight, or ask for
help.
• When lifting the boiler, bend the knees,
and keep the back straight and feet apart.
• Do not lift and twist at the same time.
• Lift and carry the boiler close to the body
• Wear protective clothing and gloves to
protect from any sharp edges
Electricity supply
Gas supply
Wait time period
s —
SERVICING INSTRUCTIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDi/30CDi/35CDi/40 CDi
6 720 611 927b(04/05)
^NORCESTER
Bosch Group

CONTENTS
SAFETY & REGULATIONS
SAFETY PRECAUTIONS
4
INSTALLATION REGULATIONS
4
APP LIANCE INFORMATION _____________________________________________________________
GENERAL INFORMATION 5
TECHNICAL DATA ________________________________________________________________6
LAYOUT COMPONENTS 7-8
PRE- INSTALLATION ____________________________________________________________________
CLEANING PRIMARY SYSTEMS 9
MAINS SUPPLIES 10
WATER SYSTEMS PIPEWORK __________________________________________________ 11
CONDENSATE PIPEWORK ______________________________________________________ 12
BOILER LOCATION CLEARANCES ___________________________________________ 13-14
PLUMBING MANIFOLD __________________________________________________________ 15
FLUE TERMINAL POSITIONS _____________________________________________________ 16
FLUE OPTIONS 17-20
INST ALLATION _________________________________________________________________________
UNPACKING WALL FRAME AND ANCILLARY ITEMS ~21~
WALL MOUNTING PLATE / FLUE OPENING ________________________________________ 22
CHARGING LINK (FILLING LOOP) ________________________________________________ 23
UNPACKING THE APPLIANCE 24
FITTING THE APPLIANCE / BOILER CONNECTIONS ________________________________ 25
FLUE INSTALLATION __________________________________________________________ 26-28
CONDENSATE CONNECTION ___________________________________________________ 29
ELECTRICAL ___________________________________________________________________ 30
POSITION OF WIRED COMPONENTS 31
COM MISSIONING _____________________________________________________________________
PRE-COMMISSIONING CHECKS ________________________________________________ 32
FILLING THE SYSTEM ________________________________________________________ 33
STARTING THE APPLIANCE 34
WATER TREATMENT ____________________________________________________________ 35
COMMISSIONING ______________________________________________________________ 36
FINISHING COMMISSIONING 37
SER VICING & SPARES __________________________________________________________________
INSPECTION AND SERVICE __________________________________________________ 38-42
REPLACEMENT OF PARTS ____________________________________________________ 43-52
SETTING THE GAS/AIR RATIO ____________________________________________________ 53
SHORT PARTS LIST 54
CON VERSION KITS _____________________________________________________________________
L.P.G. CONVERSION 55
FAU LT FINDING & DIAGNOSIS ___________________________________________________________
FAULTFINDING _________________________________________________________________ 56
CENTRAL HEATING FUNCTION __________________________________________________ 57
PREHEAT AND DHW FUNCTION 58
PROTECTION FUNCTION 59
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDi/30CDi/35CDi/40CDi
6 720 611 927b (04/05)
CONTENTS
^WORCESTER
Bosch Group

SAFETY PRECAUTIONS
INSTALLATION REGULATIONS
SAFETY
REGULATIONS
IF YOU SMELL GAS:
X DON ’ T SMOKE OR STRIKE MATCHES
X DON ’ T TURN ELECTRICAL SWITCHES ON OR OFF
✓ DO PUT OUT NAKED FLAMES
✓ DO OPEN DOORS AND WINDOWS
✓ DO KEEP PEOPLE AWAY FROM THE AREA AFFECTED
✓ DO TURN OFF THE CONTROL VALVE AT THE METER
✓ TELEPHONE YOUR GAS COMPANY
A Benchmark Log Book is provided by the manufacturer for the installer to complete
including their CORGI registration number to confirm that the boiler has been installed,
commissioned and serviced according to the manufacturer ’ s instructions.
IMPORTANT: The completed Benchmark Checklist will be required in the event of any
warranty work and may be required by the local Building Control Inspector.
HEALTH & SAFETY
The appliance contains no asbestos and no substances have been used in the
construction process that contravene the COSHH Regulations (Control of Substances
Hazardous to Health Regulations 1988).
COMBUSTIBLE AND CORROSIVE MATERIALS
Do not store or use any combustible materials (paper, thinners, paints etc.) inside or
within the vicinity of the appliance.
Chemically aggressive substances, such as halogenated hydrocarbons containing
chlorine or fluorine compounds can corrode the appliance and invalidate any warranty.
FITTING & MODIFICATIONS
Fitting the appliance and any controls to the appliance may only be carried out by a
competent engineer in accordance with the Gas Safety (Installation and Use)
Regulations 1998.
Flue systems must not be modified in any way other than as described in the fitting
instructions. Any misuse or unauthorised modifications to the appliance, flue 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
engineer (such as British Gas or CORGI registered personnel) using approved spares,
to help maintain the economy, safety and reliability of the appliance.
IMPORTANT - The service engineer must complete the Service Record in the
Benchmark section after each service.
Gas Safety (Installation Use) Regulations:
All gas appliances must be installed by a
competent person in accordance with the above
regulations. Failure to install appliances correctly
could lead to prosecution.
The appliance must be installed in accordance
with, and comply to, the current: Gas Safety
Regulations, IEE Regulations, Building
Regulations, Building Standards (Scotland)
(Consolidation), Building Regulations (Northern
Ireland), local water by-laws, Health Safety
Document 635 (The Electricity at Work
Regulations 1989) and any other local
requirements.
British Standards:
The relevant British Standards should be followed,
including:
BS7074:1 : Code of practice for domestic and hot
water supply
BS6891 : Installation of low pressure gas
pipework up to 28mm (R1)
BS5546 : Installation of gas hot water supplies for
domestic purposes
EN:12828 : Central heating for domestic premises
BS5440:1 : Flues and ventilation for gas appli 
ances of rated heating not exceeding 70kW (net) :
Flues
BS5440:2 : Flues and ventilation for gas appli 
ances of rated heating not exceeding 70kW (net) :
Air Supply
BS7593 : Treatment of water in domestic hot
water central heating systems
BS 6798 : Installation of gas fired boilers of rated
input up to 70kW (net)
Where no specific instruction is given, reference
should be made to the relevant British Standard
codes of Practice.
L.P.G. Installation:
An appliance using L.P.G. must not be installed in
a room or internal space below ground level unless
one side of the building is open to the ground.
Timber framed buildings:
Where the boiler is to be fitted to a timber framed
building the guidelines laid down in BS5440: Part
1 and IGE "Gas Installations in Timber Frame
Buildings ” should be adhered to.
Potable water:
All seals, joints and compounds (including flux
and solder) and components used as part of
the secondary domestic water system must be
approved by WRAS.
s
SAFETY PRECAUTIONS
INSTALLATION REGULATIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDi/30CDi/35CDi/40 CDi
6 720 611 927b (04/05)
^fORCESTER
Bosch Group

GENERAL INFORMATION
STANDARD PACKAGE:
A-
Wall hung gas fired condensing combi boil 
er for central heating and domestic hot water
Wall mounting plate
Hanging bracket
Pre-plumbing manifold
Hardware pack
Charging Link Assembly
B-
C-
D-
E-
F-
G - Literature pack
H - Bottom panel
I - Trap / Syphon Outlet Connection
(22 mm Plastic Pipe)
67 20611927-11. 10
APPLIANCE
INFORMATION
440mm
SPECIFICATIONS:
Pre-wired and pre-plumbed
Galvanised steel inner frame
Digital control system
Automatic ignition
Direct burner ignition
Built-in frost thermostat (boiler protection)
Built-in fault finding diagnostics
Modulating automatic gas valve
Combustion air fan with speed regulator
CH temperature sensor control
Pump anti-seizure protection
Flue gas temperature limiter
Condensate trap syphon
DHW flow sensor temperature control
Plate type DHW heat exchanger
Modulating circulating pump
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25COI/30CDÍ/35COÍ/4OCDI
6 720 611 927b (04/05)
4
GENERAL INFORMATION

TECHNICAL DATA
AAPPLIANCE
INFORMATION
DESCRIPTION
UNITS
25CDÍ
NATURAL GAS
25CDÍ
L.P.G.
30CDi 35CDÍ 40CDÍ
30CDÍ
35CDÍ
Domestic hot water
Min. heat input
kW
8.0
8.0
8.0 9.8 9.1 9.1 9.1
Max. rated heat output
kW
25.8 30.9 35.0
40.0
25.8
30.9
35.0
Max. rated heat input
kW
25.8 30.9 35.0 40.0
25.8
30.9
35.0
Max. mains inlet pressure
bar
10 10
10
10
10 10 10
Min. mains inlet pressure (working) for max flow
bar
1.2 1.4 1.5
1.7
1.2 1.4 1.5
Min. mains inlet pressure (working) for operation
bar
0.2
0.2
0.2 0.2 0.2
0.2
0.2
Domestic Hot Water temperature range
°C
40-60 40-60 40-60
40-60
40-60
40-60 40-60
Domestic Hot Water specific rate - 30°C rise
l/min
11.0
13.3 16.5
17.3
11.0
13.3 16.5
Max. Domestic Hot Water flow rate - 40°C rise +/ — 15%
l/min
9
11
12
14
9
11
12
Central Heating
Max. rated heat input
kW
25.8 30.9 30.9 30.9
25.8
30.9
30.9
Max. rated heat output net 40/30°C
kW
26.8
32.1 32.1 32.1
26.8
32.1
32.1
Max. rated heat output net 50/30°C
kW
26.6 31.8
31.8 31.8 26.6
31.8 31.8
Max. rated heat output net 80/60°C
kW
25.0 30.0 30.0 30.0 25.0
30.0 30.0
Min. rated heat output net 40/30°C
kW
8.6
8.6
8.6
10.6
9.8
9.8
9.8
Min. rated heat output net 50/30°C
kW
8.6 8.6
8.6
10.5
9.7
9.7
9.7
Min. rated heat output net 80/60°C
kW
7.7 7.7 7.7
9.4
8.7
8.7
8.7
Mtn. rated heat input net
kW
8.0
8.0 8.0 9.8
9.1
9.1
9.1
Max. flow temperature
°C nom. 90
nom. 90
nom. 90 nom. 90 nom. 90
nom. 90 nom. 90
Max. permissible operating pressure
bar
3.0
3.0
3.0 3.0
3.0
3.0
3.0
Available pump head at 21 °C system temperature rise
m
2222
2
22
Gas flow rate - Max. 10 minutes from lighting
Natural Gas G20
m 3 /h
2.6
3.2
3.7
4.4
Propane Gas (LPG)
kg/h -
2.0
2.4
2.7
Flue
Flue Gas Temp. 80/60°C, rated min. load
°C
70/58
76/58 76/58
86/58
70/58 76/58
76/58
Flue Gas Temp, 40/30°C, rated min. load
°C
51/33
55/33 55/33 58/35
51/33
55/33
55/33
CO2 level at max. rated heat output
%
9.6
9.6
9.6
9.7
10.8
10.8
10.8
CO2 level at min. rated heat output
%
9.0 9.0 9.0
9.1
10,5
10.5
10.5
NOx - class
555555
5
Condensate
Max. condensation rate
l/h
2.3
2.7 2.7 2.7
2.3 2.7 2.7
pH value, approx.
4.8 4.8
4.8 4.8 4.8
4.8 4.8
Electrical
Electrical power supply voltage
AC...V
230 230 230 230 230 230
230
Frequency
Hz
50
50
50
50 50
50
50
Max. power consumption
W
125 135
160
170
125
135
160
General Data
SEDBUK
band
A
A
AA A
A
A
Appliance protection rating
IP
X4D
X4D
X4D X4D X4D X4D X4D
Appliance protection rating with mechanical or RF mech. timer fitted
IP
20 20
20
20 20 20
20
Permissible ambient temperatures
°C
0-50
0-50 0-50
0-50 0-50 0-50
0-50
Nominal capacity of appliance
1
3.75 3.75 3.75
3.75 3.75
3.75 3.75
Noise output level
dB(A) 40
44
44
47
40
44
44
Total boiler weight (lift weight)
kg
48.5
48.5
48.5 48.5 48.5 48.5 48.5
Packaged boiler weight
kg
57
57 57 57
57
57
57
SEDBUK
%
90.3 90.3
90.3
90.2 90.3 90.3
90.3
TECHNICAL DATA
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDÍ/30CDÍ/35CDÍ/40 CDi
6 720 511 927b (04/05)
Bosch Group

LAYOUT COMPONENTS
The diagram opposite shows the controls in the
servicing position and excludes the outer case.
1 FLAME VIEWING WINDOW
2 IGNITION ELECTRODE AND FLAME
SENSE ELECTRODE
3 HEAT EXCHANGER
4 OVERH EAT TH ERMOSTAT
5 ACCESS POINT FOR CLEANING HEAT
EXCHANGER
6 PLATE TO PLATE DHW
HEAT EXCHANGER
7 PUMP
8 SYSTEM PRESSURE GAUGE
9 DRAIN POINT W
10 MAINS COLD WATER IN
11 CH RETURN
12 CHARGING LINK ASSEMBLY
13 GAS INLET CONNECTION 22 mm
COMPRESSION
14 COVER FOR EXTERNAL WIRING
CONNECTIONS
15 CONTROL PANEL IN SERVICE
POSITION
16 ACCESS COVER FOR TRANSFORMER
PCB
17 DHW OUT
18 CH FLOW
19 TRAP/SYPHON OUTLET CONNEC 
TION (22 mm PLASTIC PIPE)
20 INLET PRESSURE TEST POINT
21 TRAP/SYPHON
22 GAS VALVE
23 DHW TEMPERATURE SENSOR
24 AIR/GAS ADJUSTMENT SCREW
25 TESTING POINT FOR FAN PRESSURE
26 FAN
27 PRIMARY SENSOR
28 EXPANSION VESSEL
29 REMOVABLE TOP CASE PANEL FOR
SERVICING
APPLIANCE
INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25COi/30CDi/35CDi/40CDi
6 TSO 611 927b (04/05)
LAYOUT COMPONENTS
i^fORCESTER
Bosch Group

LAYOUT COMPONENTS
APPLIANCE
INFORMATION
PLATE TO PLATE DHW HEAT
EXCHANGER
DRAIN POINT
SYSTEM PUMP
FLOW TURBINE
UNUSED PORT
AUTO AIRVENT
FLOW CONNECTION FROM BOILER
HEAT EXCHANGER
DHW SENSOR
CH FLOW CONNECTION TO SERVICE
VALVE
DHW OUT CONNECTION
COLD WATER IN CONNECTION
CH RETURN CONNECTION TO SER 
VICE VALVE
DIVERTER VALVE
PRESSURE RELIEF VALVE
COMPACT HYDRAULIC MOUNTING
SCREW (2) TO BOILER
CH TEMPERATURE CONTROL
MAINS ON/OFF INDICATOR/DIAGNOS-
TIC LIGHT (BLUE)
DHW TEMPERATURE CONTROL
CENTRAL HEATING BOOST BUTTON
SERVICE BUTTON
BURNER ON INDICATOR LIGHT
(GREEN)
MASTER SWITCH ON/OFF
HOLIDAY BUTTON
ECO BUTTON
FAULT RESET BUTTON
SYSTEM PRESSURE GAUGE
POSITION FOR OPTIONAL
PROGRAMMER
DISPLAY
LAYOUT COMPONENTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDi/30CDi/35COi/40 CD!
5 720 611 927b (04/05)
S^ORCESTER
Bosch Group

CLEANING PRIMARY SYSTEMS
IMPORTANT: All the following Pre-Installation sections must be read and
requirements met before starting boiler or flue installation.
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 appli 
ance will invalidate the appliance warranty.
CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND
OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.
BEFORE CLEANING THE SYSTEM:
ENSURE THE SYSTEM AND PIPEWORK IS
IN GOOD WORKING ORDER
KEEP THE EXISTING BOILER/
CIRCULATING PUMP WHERE POSSIBLE
OR USE A POWER FLUSHING MACHINE
TO AID THE CLEANSING PROCEDURE
BEFORE INSTALLING A NEW BOILER.
CLEANING THE PRIMARY SYSTEM:
1 Fill the system with cold water and check
for leaks.
2 Open all drain cocks and drain the system.
3 Close drain cocks and add a suitable
flushing agent at the correct strength for
the system condition in accordance with
the manufacturer ’ s instructions.
INSTALLATION
► Circulate the flushing agent before the
boiler is fired up.
4 Run the boiler/system at normal operating
temperature as directed by the manufacturer
of the flushing agent.
5 Drain and thoroughly flush the system to
remove the flushing agent and debris.
Flushing
Agent
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDi/30CDi/35CDi/40CDi
6 720 611 927b (04/05)
CLEANING PRIMARY SYSTEMS
^WORCESTER
Bosch Group

MAINS SUPPLIES
INSTALLATION
MAINS WATER EXPANSION VESSEL:
A - Mini expansion vessel, part No. 7 716 102 105
B - Mains water inlet pipe
C - Non-return valve
D - Boiler
D
A
“ " k r ’ *.
ELECTRIC SUPPLY:
• Supply: 230V - 50Hz
(See Technical Data for IP ratings.)
• Cable: PVC insulated 0.75m
(24 x 0.2mm) temperature rated to 90°C.
• External 3A fuse to BS1362.
• The appliance must be earthed.
• All pipes to the boiler must be cross 
bonded.
• Wiring must comply with I EE wiring regula 
tions and any local regulations which may
apply to fixed wiring to a stationary appli 
ance.
GAS SUPPLY:
• Boilers using NG must be connected to a
governed meter.
• LPG boilers must be connected to a
regulator.
• Installation and connection of the gas sup 
ply to the boiler must be in accordance with
BS6891.
• Under no circumstances should the size of
the gas supply pipe be less than that of the
appliance inlet connection.
• The meter or regulator and pipework to the
meter must be checked, preferably by the
gas supplier, to ensure it is in good working
order and can meet the gas flow and pres 
sure requirements in addition to the demand
from any other appliance being served. This
does not include the pipework from the
meter to the boiler.
WATER SUPPLY:
Water Mains Pressure:
• Minimum mains water pressure 1.5 up to
2.5 bar (see technical data on page 6) for
maximum performance.
• Maximum mains fed water pressure 10 bar.
If necessary, fit a pressure reducing valve.
IMPORTANT: Non-return back flow pre 
vention devices (including those associat 
ed with water meters) fitted to the mains
water supply can cause a pressure build
up which could damage the boiler and
other household appliances.
• Where the mains water supply has a non 
return, back flow prevention valve fitted, a
mini expansion vessel (A) should be con 
nected to the mains water inlet pipe (B)
between the non-return valve (C) and the
boiler (D) as shown opposite.
Use in hard water areas:
Normally there is no need for water treatment
to prevent scale formation as the maximum
temperature of the DHW heat exchanger is
limited by the electronic control circuit.
In areas where the temporary water hardness
exceeds 200 ppm consideration may need to
be given to the fitting of a scale prevention
device. In such circumstances the advice of
the local water authority should be sought.
MAINS SUPPLIES
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDÍ/30CDI/35CDI/40 CDS
6 720 611 927b (04/05)
^W orcester
Bosch Group