Bosch Worcester Greenstar CDi Conventional Series User manual

GREENSTAR CDi CONVENTIONAL
WALL HUNG RSF GAS-FIRED CONDENSING REGULAR BOILER
FOR OPEN VENTED AND SEALED CENTRAL HEATING SYSTEMS AND INDIRECT
DOMESTIC HOT WATER
THE APPLIANCE IS FOR USE WITH
NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13 & C33)
NATURAL GAS:
WORCESTER GREENSTAR 30CDi Conventional
GC NUMBER 41-311-71
WORCESTER GREENSTAR 40CDi Conventional
GC NUMBER 41-311-72
LIQUID PETROLEUM GAS:
WORCESTER GREENSTAR 30CDi Conventional
GC NUMBER 41-311-73
WORCESTER GREENSTAR 40CDi Conventional
GC NUMBER 41-311-74
INSTRUCTION MANUAL
INSTALLATION, COMMISSIONING
&SERVICING (}enchmarf)

CONTACT INFORMATION
WORCESTER BOSCH:
TECHNICAL: 08705 266241
SERVICE: 08457 256206
SPARES: 01905 752571
LITERATURE: 01905 752556
TRAINING: 01905 752526
SALES: 01905 752640
WEBSITE: www.worcester-bosch.co.uk
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
STORE THE APPLIANCE IN A DRY AREA
PRIOR TO INSTALLATION.
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
INSTALLATION &
SERVICING INSTRUCTIONS
INSTALLATION & SERVICING INSTRUCTIONS
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
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.
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
SYMBOLS USED IN THIS MANUAL:
Central heating
Time clock
Hot water storage cylinder Programmer/timer
f Electricity supply
Room thermostat
Gas supply Wait time period
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDI/40CDI Coc,ectlocal ~ORCESTER
6 720 614 556a (2007/07) Bosch Group

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
PLUMBING MANIFOLD
FLUE TERMINAL POSITIONS
FLUE OPTIONS
INSTALLATION
UNPACKING WALL FRAME AND ANCILLARY ITEMS
WALL MOUNTING PLATE I FLUE OPENING
PIPEWORK
UNPACKING THE APPLIANCE
FITTING THE APPLIANCE I BOILER
CONNECTIONS
FLUE INSTALLATION
CONDENSATE CONNECTION
ELECTRICAL
POSITION OF WIRED COMPONENTS
COMMISSIONING
PRE-COMMISSIONING CHECKS
FILLING THE SYSTEM
STARTING THE APPLIANCE
WATER TREATMENT
COMMISSIONING
FINISHING COMMISSIONING
SERVICING & SPARES
INSPECTION AND SERVICE
REPLACEMENT OF
PARTS
SETTING THE GAS/AIR RATIO
SHORT PARTS LIST
CONVERSION KITS
L.P.G. CONVERSION
FAULT FINDING & DIAGNOSIS
FAULT FINDING
HEATING FUNCTION
PROTECTION FUNCTION
4
4
5
6
7
8
9
10
11
12-13
14
15
16-17
18
19
20
21
22
23-25
26
27-28
29
30
31
32
33
34
35
36-40
41-47
48
49
50
51
52
53
~ORCESTER
Bosch Group
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30COi/40CDI Conven\1onal
6 720 614 556a (2007/07) CONTENTS

SAFETY PRECAUTIONS
IF YOU SMELL GAS:
X DON'T SMOKE OR STRIKE MATCHES
X DON'T TURN ELECTRICAL SWITCHES ON OR OFF
V' DO PUT OUT NAKED FLAMES
V' DO OPEN DOORS AND WINDOWS
V' DO KEEP PEOPLE AWAY FROM THE AREA AFFECTED
V' DO TURN OFF THE CONTROL VALVE AT THE METER
V' TELEPHONE THE NATIONAL GAS EMERGENCY SERVICE ON 0800111999
(/Jenc!Jmorl()
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.
INSTALLATION REGULATIONS
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, IE E 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.
CHwater:
Artificially softened water must not be used to
fill the central heating system.
SAFETY PRECAUTIONS INSTALLATION & SERVICING INSTRUCTIONS
FOR WORCESTER BOSCH GREENSTAR 30CDI/40CDI Coc,ectlocal ~ORCESTER
& INSTALLATION REGULATIONS 6 720
614 556a (2007/07) Bosch Group

max.
760mm
c
0
GENERAL INFORMATION
STANDARD PACKAGE:
A- Wall hung gas fired condensing boiler for
central heating and indirect domestic hot
water
B - Wall mounting plate
C -Hanging bracket
D - Hardware
pack 1
E - Hardware
pack 2 (gas cock)
F - Literature
pack
G - Bottom panel
H - Trap I Syphon Outlet Connection
(22 mm Plastic Pipe)
J - Flow pipe
K - Return pipe 1
L - Return pipe 2
M - Pipework mounting bracket
N - Gas
cock support plate
0 - Braising template
B
~
~ &N~M
~ "" ""
' L H
""' SPECIFICATIONS:
0 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
temperature sensor & control
External
pump anti-seizure protection
Flue gas temperature limiter
Condensate trap & syphon
~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CD,/40CD' Conven\1onal
GENERAL INFORMATION
Bosch Group
6 720 614 556a (2007/07)

TECHNICAL DATA
NATURAL GAS L.P.G.
DESCRIPTION UNITS 30CDi 40CDi 30CDi 40CDi
Heating
Max. rated heat input kW 30.9 42.0 30.9 42.0
Max. rated heat output net 40/30°C kW 32.1 43.7 32.1 43.7
Max. rated heat output net 50/30°C kW 31.8 43.3 31.8 43.3
Max. rated heat output net 80/60°C kW 30.0 40.8 30.0 40.8
Min. rated heat output net
40/30°C kW 8.6 10.6 12.4 15.7
Min. rated heat output net
50/30°C kW 8.6 10.5 12.3 15.5
Min. rated heat output net
80/60°C kW 7.7 9.4 11.0 13.9
Min. rated heat input net
kW 8.0 9.8 11.5 14.5
Max. flow temperature
•c
nom. 90 nom. 90 nom. 90 nom. 90
Max. permissible operating pressure bar 3.0 3.0 3.0 3.0
Gas
flow rate- Max. 10 minutes from lighting
Natural Gas G20
m3/h 3.2 4.4
Propane Gas (LPG) kg/h 2.4 3.3
Flue
Flue Gas Temp. 80/60°C, rated min. load
•c
76/58 87/58 76/58 87/58
Flue Gas Temp. 40/30°C, rated min. load
•c
55/33 58/35 55/33 58/35
C02 level at max. rated heat output % 9.6 9.7
11.5 11.5
C02 level at min. rated heat output % 9.0
9.1 10.5 10.5
NOx- class 5 5 5 5
Condensate
Max. condensation rate 1/h 2.7 3.7 2.7 3.7
pH value, approx. 4.8 4.8 4.8 4.8
Electrical
Electrical power supply voltage
AC .. .V 230 230 230 230
Frequency Hz 50 50 50 50
Max. power consumption w approx. 70 approx. 100 approx. 70 approx. 100
General Data
SEDBUK band A A A A
Appliance protection rating IP X4D X4D X4D X4D
Permissible ambient temperatures
•c
0-50 0-50 0-50 0-50
Nominal capacity of appliance I 3.5 3.5 3.5 3.5
Noise output level dB(A)
43 47 43 47
Total boiler weight (lift weight)
kg
39.5 39.5 39.5 39.5
Packaged boiler weight
kg
48 48 48 48
SEDBUK % 90.1 90.2 90.1 90.2
TECHNICAL DATA
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDI/40CDI Coc,ectlocal ~ORCESTER
6 720 614 556a (2007/07)
Bosch Group

23 --
22
21
20 ------------------------------
~ORCESTER
Bosch Group
'11
48 49
2
3
4
--- 5
------ 7
8
9
:::;-->(
-o ' _'·->·60
---------57
I ·-----·56
I ---55
I
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30COi/40CDI Conven\1onal
6 720 614 556a (2007/07)
LAYOUT & COMPONENTS
The diagram opposite shows the controls in the
servicing position
and excludes the outer case.
FLAME VIEWING WINDOW
2 IGNITION ELECTRODE AND FLAME
SENSE ELECTRODE
3 HEAT EXCHANGER
4 OVERHEAT THERMOSTAT
5 ACCESS POINT FOR CLEANING HEAT
EXCHANGER
6 CONDENSATE HOSE
7 DRAIN POINT
8 TRAP I SYPHON OUTLET
CONNEC-
TION (22 mm PLASTIC PIPE)
9 RETURN
10 GAS INLET CONNECTION 22 mm
COMPRESSION
11 COVER FOR EXTERNAL WIRING
CONNECTIONS
12 CONTROL PANEL IN SERVICE
POSITION
13 ACCESS COVER FOR TRANSFORMER
&PCB
14 FLOW
15 INLET PRESSURE TEST POINT
16 TRAP I SYPHON
17 GAS VALVE
18 AIR I GAS ADJUSTMENT SCREW
19 TESTING POINT FOR FAN PRESSURE
20 FAN
21 PRIMARY SENSOR
22 AUTO AIR VENT
23 REMOVABLE TOP CASE PANEL FOR
SERVICING
48 TEMPERATURE CONTROL
49
MAINS ON/OFF INDICATOR/DIAGNOS-
TIC LIGHT (BLUE)
51 BOOST BUTTON
52 SERVICE BUTTON
53 BURNER ON INDICATOR LIGHT
(GREEN)
54 MASTER SWITCH ON/OFF
55 NOT USED
56 NOT USED
57 FAULT RESET BUTTON
60 DISPLAY
LAYOUT & COMPONENTS

IMPORTANT: All the following Pre-Installation sections must be read and
requirements met before starting boiler or flue installation.
CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND
OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.
1 4
2 5
3
KEY
@
Valve
~
Flushing
Agent
CLEANING PRIMARY SYSTEMS
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.
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:
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.
~ 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.
CLEANING PRIMARY SYSTEMS INSTALLATION & SERVICING INSTRUCTIONS
FOR WORCESTER BOSCH GREENSTAR 30CDI/40CDI Coc,ectlocal ~ORCESTER
6 720 614 556a (2007/07) Bosch Group

~ORCESTER
Bosch Group
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30COi/40CDI Conven\1onal
6 720 614 556a (2007/07)
MAINS SUPPLIES
ELECTRIC SUPPLY:
Supply:
230V- 50Hz
(See Technical Data for IP ratings.)
Cable: PVC insulated 0.75mm2
(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 lEE 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.
For olive connections we recommend using
gas pipes with minimum 0.9
mm wall thick-
ness.
MAINS SUPPLIES

'
E
L
SYSTEM FILL
Heating return
Hose
WATER SYSTEMS & PIPEWORK
----~
'
--------------F
... ------D
Heating
return
Cylinder return
S PLAN LAYOUT
Y PLAN LAYOUT
SEALED SYSTEM LAYOUT
Heating flow
SYSTEM MAKE UP
Heating return Auto
Mains
supply
Stop cock
Make up
vessel
WATER SYSTEMS & PI PEWORK
PLASTIC PIPEWORK:
• Any plastic pipework must
have a polymeric
barrier with 600 mm (minimum) length of
copper or steel pipe connected to the boiler.
Plastic pipework used for underfloor heating
must be correctly controlled with a thermo-
static blending valve limiting the temperature
of the circuits to approx. 50°C.
The pipework from the boiler to the blending
valve must be
in copper or steel (protected
from corrosion).
CONNECTIONSNALVES:
• All system connections, taps and mixing
valves must be capable of sustaining a pres-
sure up to 3 bar.
Radiator valves should conform to
BS2767:10.
Do not use galvanised pipes or radiators.
• All other valves should conform to BS1010.
On new installations, or extensions to exist-
ing systems where a radiator previously did
not exist, each radiator should be fitted with
a
TRV, except the one fitted in the same
room/area
as the room thermostat.
On boiler only replacement jobs, it is recom-
mended, (but not mandatory,) to fit a TRV on
each radiator. It is, however, a requirement,
for energy conservation purposes, to recom-
mend to the customer that a TRV is fitted to
each radiator.
• An automatic bypass may be required,
(downstream
of the pump), in order to main-
tain the minimum flow-rate through the appli-
ance.
• A drain cock should be fitted at the low-
est point of the heating circuit and
beneath the appliance.
• An air vent is required at the highest point
on the system.
SandY PLAN SYSTEM:
A Static Head -Minimum static head 250mm
measured from the highest point
in the heat-
ing system (top surface of the appliance or
highest point
in the heating system) to the
water level
in the feed and expansion tank.
B Heating Vent (22mm minimum)
C Primary Cold Feed (15mm minimum)
D Diverter Valve
E Pump
F Automatic Bypass
G Radiator Valve (Flow)
H Lockshield Valve (Return)
FULLY PUMPED SEALED SYSTEM:
The sealed system must be filled using a
WRAS approved filling loop or comply with
the diagram opposite for System fill
Do not use galvanised pipes or radiators.
Expansion Vessel
Pressure Gauge
K Relief
Valve
L Stop Valve Fixed Cylinder Type or sealed
systems approved connection
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDI/40CDI Coc,ectlocal ~ORCESTER
6 720 614 556a (2007/07)
Bosch Group