Worcester Greenstar CDi User manual

USER INSTRUCTIONS &
CUSTOMER CARE GUIDE
6 720 611 927-00.1O
THE APPLIANCE IS FOR USE
WITH NATURAL GAS OR L.P.G.
(Cat II 2H3P TYPE C13 & C33)
NATURAL GAS:
27CDi GC-Number 47-406-12
30CDi GC-Number 47-406-14
37CDi GC-Number 47-406-08
42CDi GC-Number 47-406-10
LIQUID PETRLOLEUM GAS:
27CDi GC-Number 47-406-13
30CDi GC-Number 47-406-15
37CDi GC-Number 47-406-09
42CDi GC-Number 47-406-11
GREENSTAR CDi
WALL HUNG RSF GAS-FIRED CONDENSING
COMBINATION BOILER
FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED
DOMESTIC HOT WATER

2GREENSTAR 27CDi/30CDi/37CDi/42CDi
6 720 614 059b (2007/07)
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 GUARDS:
TOWER FLUE COMPONENTS
Vale Rise, Tonbridge TN9 1TB
USER INSTRUCTIONS & CUSTOMER
CARE GUIDE
PLEASE READ THESE INSTRUCTIONS
CAREFULLY BEFORE OPERATING YOUR
APPLIANCE
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 SHOULD BE FOLLOWED EXCEPT FOR
ANY STATUTORY OBLIGATION.
IF YOU ARE IN ANY DOUBT CONTACT THE
WORCESTER BOSCH TECHNICAL HELPLINE.
DISTANCE LEARNING AND TRAINING COUR-
SES ARE AVAILABLE FROM WORCESTER
BOSCH.
THIS APPLIANCE MUST BE INSTALLED BY A
COMPETENT PERSON. FAILURE TO INSTALL
CORRECTLY COULD LEAD TO
PROSECUTION.
PLEASE LEAVE THIS GUIDE, THE INSTALLA-
TION INSTRUCTIONS AND THE COMPLETED
BENCHMARK LOG BOOK WITH THE USER OR
AT THE GAS METER AFTER INSTALLATION.
ABBREVIATIONS USED IN THIS BOOK:
NG - Natural Gas
LPG - Liquid Petroleum Gas
CH - Central Heating
SEDBUK - Seasonal Efficiency of Domestic
Boilers in the United Kingdom
USER INSTRUCTIONS &
CUSTOMER CARE GUIDE

GUARANTEE MAINTENANCE ENERGY
SAVING
USING YOUR
APPLIANCE INTRODUCTION
CONTENTS
INTRODUCTION
EXCELLENCE COMES AS STANDARD 4
SAFETY PRECAUTIONS 5-7
GENERAL NOTES 8-11
USING YOUR APPLIANCE
CONTROLS 12
OPERATING THE APPLIANCE 13-15
Switching the appliance on/off 13
Setting the central heating temperature 13
Controlling central heating 13
Frost protection 14
Controlling domestic hot water 14
Holyday setting 15
Fault condition 15
ENERGY SAVING
TIPS ON ENERGY SAVING 16-17
MAINTENANCE
MAINTAINING YOUR APPLIANCE 18
FAULT FINDING 19
FAULT OR BREAKDOWN 20-21
GUARANTEE
YOUR GUARANTEE 22
GUARANTEE REGISTRATION 23
CONTENTS
WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi
6 720 614 059b (2007/07)
3

EXCELLENCE
COMES AS STANDARD
WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi
6 720 614 059b (2007/07)
EXCELLENCE COMES AS
STANDARD
Thank you for purchasing a Greenstar
27CDi/30CDi/37CDi/42CDi gas-fired
condensing combination boiler manu-
factured by Worcester Bosch. The com-
pany prides itself on manufacturing boi-
lers to the strictest quality control stan-
dards throughout every stage of produc-
tion. Worcester Bosch has led the field
in innovative appliance design and per-
formance for more than 40 years. This
heritage means all products are of
exceptional quality and proven reliability.
The Greenstar range in particular is
extremely energy efficient, converting up
to 97% of gas consumed into heat, offe-
ring you economical running costs and
value for money. It sits in SEDBUK
Band A, and is therefore amongst the
top energy rated appliances available.
There is also the reassurance of our no-
nonsense 2 years parts and labour gua-
rantee - backed up by Worcester Total
Cover, an optional complete maintenan-
ce scheme to keep your boiler operating
at peak condition and efficiency.
To find out more about Worcester
Bosch log onto www.worcester-
bosch.co.uk.
4
INTRODUCTION

INTRODUCTION
SAFETY PRECAUTIONS
SAFETY
PRECAUTIONS
WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi
6 720 614 059b (2007/07)
5
IF YOU SMELL GAS:
6DON’T SMOKE OR STRIKE
MATCHES
6DON’T TURN ELECTRICAL
SWITCHES ON OR OFF
4DO PUT OUT NAKED FLAMES
4DO OPEN DOORS AND
WINDOWS
4DO KEEP PEOPLE AWAY FROM
THE AREA AFFECTED
4DO TURN OFF THE CONTROL
VALVE AT THE METER
4TELEPHONE THE NATIONAL GAS
EMERGENCY SERVICE ON
0800 111999
BENCHMARK STANDARD
‘Benchmark’ is a code of practice for
correctly installing, commissioning and
servicing of domestic water heating
appliances.
A Benchmark Checklist is provided by
the manufacturer for the installer to
complete ALL details together with their
CORGI registration number and sign to
confirm that the boiler has been instal-
led and commissioned 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 used in the construction
process that contravene the COSHH
Regulations (Control of Substances
Hazardous to Health Regulations 1988).

SAFETY
PRECAUTIONS
WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi
6 720 614 059b (2007/07)
6
COMBUSTIBLE AND CORROSIVE
MATERIALS
Do not store or use any combustible
materials (paper, thinners, paints etc.)
inside or within the vicinity of the appli-
ance.
Chemically aggressive substances, such
as halogenated hydrocarbons containing
chlorine or fluorine compounds can cor-
rode the appliance and invalidate any
warranty.
FITTING & MODIFICATIONS
Fitting the appliance, any controls to the
appliance and removal of the outer
casing may only be carried out by a
competent engineer in accordance with
the Gas Safety (Installation and Use)
Regulations.
Flue systems must not be modified in
any way other than as described in the
Installation Instructions and any misuse
or unauthorised modifications to the
appliance, flue or associated compo-
nents and systems could invalidate the
warranty. The manufacturer accepts no
liability arising from any such actions.
This does not affect your statutory rights.
SAFETY PRECAUTIONS
INTRODUCTION

SAFETY
PRECAUTIONS
WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi
6 720 614 059b (2007/07)
7
SERVICING
The user is recommended to have the
system regularly serviced by a compe-
tent, qualified engineer (such as British
Gas or CORGI registered personnel)
using original spares, to help maintain
the economy, safety and reliability of the
appliance and to have the Service
Record completed in the Benchmark
Checklist.
The appliance should be serviced annu-
ally after installation unless the particular
installation conditions and usage
demand more frequent services.
IMPORTANT - ensure that the service
engineer completes the Service Record
in the Benchmark Checklist after each
service.
SAFETY PRECAUTIONS
INTRODUCTION

GENERAL
NOTES
WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi
6 720 614 059b (2007/07)
8
INTRODUCTION
GENERAL NOTES
To get the best from your appliance plea-
se read these instructions carefully.
SEALED HEATING SYSTEMS
This appliance is fitted to a sealed hea-
ting system which is pre-pressurised.
Your installer will advise you of the mini-
mum and maximum pressure which
should be indicated on the pressure
gauge.
Check regularly that the pressure is
maintained and contact your installer or
maintenance engineer if a permanent
significant drop in pressure is indicated
on the pressure gauge. If the system
loses pressure it should be re-pressuri-
sed and the cause of the fall investiga-
ted.
CENTRAL HEATING SYSTEMS
During the first few hours of operation of
the central heating system, check that all
radiators are being heated at an even
rate. If the top of a radiator is at a lower
temperature than the bottom then it
should be vented by releasing air
through the venting screw at the top of
the radiator. Ask your installer to show
you how this is done.
This boiler is fitted to a sealed system;
repeated venting will reduce the quantity
of water in the system and this must be

GENERAL
NOTES
WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi
6 720 614 059b (2007/07)
9
replenished for safe and satisfactory
operation of the appliance.
Should water leaks be found in the
system or if excessive venting is requi-
red, then a service engineer must be
contacted to inspect the installation and
rectify any fault.
Only additives that are compatible with
aluminium may be used in the system.
Any incompatible additive used will inva-
lidate the guarantee.
PLUMING AND CONDENSATE DRAIN
This is a condensing appliance and the
terminal will, at times give out a plume of
water vapour. This is quite normal.
The appliance also produces quantities
of condensate which is discharged regu-
larly by a siphon within the boiler via a
pipe to drain. This pipe must not be
blocked or altered in any way.
CLEARANCES
Your installer will have provided adequa-
te space around the appliance for safety
and servicing access. Do not restrict this
space with the addition of cupboards,
shelves etc. next to the appliance.
*600 mm service clearance required to a
fixed surface
(**20 mm from removable door or panel)
GENERAL NOTES
mm mm
+ 30mm
above elbow
5mm
5mm
600mm
200mm
*600mm
(**20mm)
INTRODUCTION

GENERAL
NOTES
WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi
6 720 614 059b (2007/07)
10
ROOM THERMOSTAT
A room temperature controller and pro-
grammer should be fitted to control the
central heating. Refer to the instructions
supplied with the thermostat for informa-
tion on siting and setting.
THERMOSTATIC RADIATOR VALVES
It is recommended that this type of valve
is fitted to all but one of the radiators (or
at least those in the sleeping accommo-
dation). The remaining radiator, which
must be where the room thermostat is
located, should be uncontrolled and
must be left open. The thermostatic
radiator valves should conform to the
requirements of BS2767:10.
GENERAL NOTES
INTRODUCTION

GENERAL
NOTES
WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi
6 720 614 059b (2007/07)
11
VENTILATION
This is a room sealed appliance and
does not require any air for combustion
from inside the property. If the appliance
is fitted into a cupboard or a compart-
ment is built around the appliance after
installation, then the compartment must
be separated from the boiler space by a
perforated non-combustible partition as
described in BS 6798.
Notwithstanding the requirements of BS
6798 and BS 5440 there is no need for
ventilation openings to be provided in
the compartment because of the low
heat loss from the appliance casing, if
the clearances shown are maintained.
Do not operate the appliance if the flue
terminal fitted on the outside wall or roof
is obstructed or damaged.
PUMP ANTI-SEIZURE
If there has been no heating demand for
24 hours the boiler will run the system
pump for a few seconds to reduce the
possibility of pump seizure during long
periods of inactivity, which is usually
more frequent during the summer
months.
GENERAL NOTES
INTRODUCTION

CONTROLS WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi
6 720 614 059b (2007/07)
12
A
D
F
L
C
B
G
H
M
E
I
K
J
6 720 611 928-01.1O
minmin
5
A - MASTER SWITCH FOR ON/OFF
B - MAINS ON/OFF INDICATOR +
FAULT DIAGNOSTIC LIGHT
C - CENTRAL HEATING TEMPERA-
TURE CONTROL
D - BURNER ON INDICATOR LIGHT
(GREEN)
E - FAULT RESET BUTTON
F - SERVICE BUTTON
G - DOMESTIC HOT WATER TEMPE-
RATURE CONTROL
H - ECO BUTTON (DOMESTIC HOT
WATER PRE-HEAT ON/OFF)
I - SYSTEM PRESSURE GAUGE
J - POSITION FOR OPTIONAL
PROGRAMMER
K - DISPLAY
L - CENTRAL HEATING BOOST
BUTTON
M - HOLIDAYBUTTON
CONTROLS
USING YOUR
APPLIANCE

USING YOUR
APPLIANCE
OPERATING
THE APPLIANCE
WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi
6 720 614 059b (2007/07)
13
SWITCHING THE APPLIANCE ON/OFF
Switching on
BSwitch on the appliance by pressing
the master switch.
The indicator light shows blue
• The boiler runs for 15 minutes at mini-
mum heating output to fill the conden-
sate trap, the display (K) alternates bet-
ween “-II-” and the central heating flow
temperature. This occurs every time the
mains supply has been interrupted.
Switching off
BSwitch off the appliance by pressing
the master switch.
The blue indicator light goes out.
SETTING THE CENTRAL HEATING
TEMPERATURE
BTurn the central heating temperature
control to the desired level, between
40 °C and 90 °C.
BWhen the burner is lit, the green indi-
cator light underneath the on/off switch
is illuminated.
CONTROLLING CENTRAL HEATING
BSet the timer to the correct time.
BSet room thermostat to the desired
room temperature.
BSet the thermostatic radiator valves to
the desired settings.
OPERATING THE APPLIANCE

OPERATING
THE APPLIANCE
WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi
6 720 614 059b (2007/07)
14
FROST PROTECTION
BLeave master switch on.
BTurn the central heating temperature
control to .
If the temperature falls to 5 °C within the
boiler it will fire to avoid the possibility of
freezing.
BAdd a suitable anti-freeze fluid to the
water in the central heating system.
BIf remote pipework is likely to be sub-
jected to freezing conditions, ensure the
installer has fitted a frost thermostat in
the area to protect the pipework.
CONTROLLING THE HOT WATER
TEMPERATURE
BThe hot water temperature can be set
to between approx. 40 °C and 60 °C
using the temperature control .
DOMESTIC HOT WATER PRE-HEAT
Pre-heat reduces the time taken to pro-
duce hot water at the tap and is control-
led by the ECO button.
Activating pre-heat mode:
BPress the ECO button until it goes off.
When the ECO button is not illumina-
ted the boiler will be in pre-heat mode
(which will reduce the time taken to pro-
duce hot water at the tap).
Re-establishing ECO mode:
BPress the holiday button until it lights up.
When the ECO button is illuminated
the boiler will be in ECO mode with no
pre-heat available.
OPERATING THE APPLIANCE
USING YOUR
APPLIANCE

OPERATING
THE APPLIANCE
WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi
6 720 614 059b (2007/07)
15
HOLYDAY SETTING
Activating holiday mode:
BPress the holiday button until it lights up.
Central heating is switched off; the frost
protection remains active.
Re-establishing normal operating mode:
BPress the holiday button until it goes off.
The appliance goes into normal opera-
ting mode.
FAULT CONDITION
In the unlikely event of a fault occurring
while the appliance is in operation:
The reset button will flash once per
second and the mains indicator (blue
light) will flash also. The display shows a
fault code.
BTo reset boiler press the reset button.
The reset button will no longer be illumi-
nated and the mains indicator will stop
flashing.
The boiler will function normally, depen-
dent on programmer and room thermo-
stat settings.
If the fault remains and cannot be clea-
red by pressing the reset button, or if
fault persists contact British Gas for
assistance, giving a description of the
fault and, if possible, the fault code from
the display.
OPERATING THE APPLIANCE
USING YOUR
APPLIANCE

WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi
6 720 614 059b (2007/07)
16 TIPS ON
ENERGY SAVING
Heating economically
The boiler is designed to provide a high
level of comfort while keeping gas con-
sumption and the resulting environmen-
tal effect as low as possible. The gas
supply to the burner is controlled accor-
ding to the level of demand for heat.
The boiler continues to operate with a
low flame if the demand for heat redu-
ces. The technical term for this process
is modulating control. Modulating con-
trol reduces temperature fluctuations
and provides even distribution of heat
throughout the home. This means that
the boiler may stay on for relatively long
periods but will use less gas than an
appliance that continually switches on
and off.
TIPS ON ENERGY SAVING
Central heating systems with room
thermostats/thermostatic radiator
valves
The central heating control on the boiler
should be set to the maximum rated tem-
perature of the central heating system.
The temperature of each room can be
set individually (except primary room with
the room thermostat) using the thermo-
static radiator valves.
Roof insulation
Around 30% of the heat loss from a pro-
perty is through the roof. Replace any
old insulation with new insulation, prefe-
rably of around 200 mm thickness or
more.
Window frames
Single glazed windows, particularly
those with steel frames, can lose a great
deal of heat. Consideration should be
given to replacement with PVCu or woo-
den framed double glazed units.
Curtains
Lined curtains, or heavier full length cur-
tains can provide excellent insulation.
However, always ensure that the curtains
do not drape over radiators.
ENERGY
SAVING

WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi
6 720 614 059b (2007/07)
17
TIPS ON
ENERGY SAVING
Draughts
Try to ensure that draughts around
doors, windows, letterboxes and keyho-
les etc. are reduced by using a suitable
draught excluder. Warning - Do not block
or seal any air vents that are installed to
ensure the central heating boiler opera-
tes safely.
Room thermostats
Reducing the setting of the room ther-
mostat by 1 °C can reduce fuel con-
sumption by up to 10%.
New control systems
Upgrade your heating control system if
necessary with the latest equipment
available. The minimum level of control is
a programmer, interlocking room thermo-
stat and thermostatic radiator valves.
Radiators
More often than not radiators will be
sited underneath a window, so the warm
air from the radiator heats the colder
incoming air from the window. The per-
formance of the radiator will be affected
if the curtains are allowed to drape over
the radiator or shelves are fitted above it.
The positioning of furniture and tables in
front of the radiator should also be avoi-
ded.
It is advisable to manually adjust all
radiator thermostatic valves every 2-3
months to prevent them sticking. It is
also important that the plastic tops of all
valves are always in position and not
cracked or damaged to prevent acci-
dents. Care should be taken when vacu-
um cleaning carpets to avoid damage to
valves and pipework.
The heating system and the outputs of
the radiators have been carefully selec-
ted by your installer. The temperature
obtainable in any given room is depen-
dent on all radiators being operated at
the same time. If you decide to turn off
radiators in unused rooms, spare
bedrooms etc., you may experience
slightly lower room temperatures in
rooms adjacent to unheated rooms.
TIPS ON ENERGY SAVING
ENERGY
SAVING

WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi
6 720 614 059b (2007/07)
18 MAINTAINING
YOUR APPLIANCE
Your new Greenstar 27CDi/30CDi/
37CDi/42CDi gas-fired appliance repre-
sents a long term investment in a reliab-
le, high quality product.
In order to realise its maximum working
life, and to ensure it continues to opera-
te at peak efficiency and performance, it
is essential that your boiler receives
regular servicing and maintenance
checks from a competent person
beyond the initial 2 year guarantee
period.
If you would like to know more about a
Worcester Bosch service contract, plea-
se tick the appropriate box on your war-
ranty registration card.
If your Greenstar 27CDi/30CDi/37CDi/
42CDi should fail to operate correctly or
requires servicing please contact the
Worcester Bosch Service Department
(see inside front cover for details).
Details of the boiler including the Gas
Council number can be found under the
controls cover flap on the boiler.
MAINTAINING YOUR
APPLIANCE
MAINTENANCE

WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi
6 720 614 059b (2007/07)
19
FAULT
FINDING
FAULT FINDING
This table gives information on basic
operating system problems.
In the unlikely event of a boiler fault
please read the following page tho-
roughly before contacting Worcester
Bosch.
Problem Cause Remedy
Desired room temperature
is not reached
Thermostatic radiator
valve(s) set too low
Increase thermostatic
radiator valve setting(s)
Temperature control for CH
flow on boiler set too low
Increase CH flow tempera-
ture control setting
Air trapped in heating
system
Bleed radiators and rechar-
ge heating system
Desired room temperature
exceeded by large amount
Radiators are too hot Turn down thermostatic
radiator valves / room ther-
mostat
Reduce central heating
temperature on boiler
Heating stays on for too
long
Clock is incorrectly set Check setting
No on/off indicator Momentary power failure Switch off appliance at
master switch, wait a few
seconds then switch on
again
Hot water temperature too
low
Temperature set too low
Programmer setting
Water flow at tap too high
Check setting
Check setting
Reduce flow rate at tap
Hot water temperature too
high
Temperature set too high Check setting
MAINTENANCE

MAINTENANCE
WORCESTER BOSCH GREENSTAR 27CDi/30CDi/37CDi/42CDi
6 720 614 059b (2007/07)
20 FAULT OR
BREAKDOWN
This appliance is supported in the UK
by Worcester, Bosch Group.
Specialist factory trained Service
Engineers are available to attend a
breakdown occurring on this appliance.
No charge will be made for parts
and/or labour providing:
BAn appliance fault is found and the
appliance has been installed within the
past 24 months. Reasonable evidence
of this must be supplied on request. i.e.
the Benchmark Checklist.
A call-out charge will be made where:
BThe appliance has been installed for
over 24 months.
OR
BEvidence cannot be provided that the
first year service inspection has been
carried out (ie. an entry in the
Benchmark Checklist).
OR
BOur Field Service Engineer finds no
fault with the appliance (see Note).
OR
BThe cause of breakdown is misuse or
with other parts of your plumbing/hea-
ting system, or with equipment not sup-
plied by Worcester Bosch.
FAULT OR BREAKDOWN