Worcester GREENSTAR 30CDi Classic System ErP 41-406-37 Manuals

1 Greenstar gas-fired condensing boilers from Worcester. Making a positive difference to your life, your fuel bills and the environment. 2 The comfort of knowing that every Worcester Greenstar boiler can save you money. In the 2012 survey of Which? members who own a boiler, no other brand beat the Worcester Greenstar range of gas-fired condensing boilers for efficiency and reliability for the second year running. This is why all of the boilers tested from the Greenstar range qualify to be a Which? Best Buy. In addition to receiving 23 Best Buy recommendations, the latest Which? report also looked at boiler servicing contracts, where the Worcester, Bosch Group brand came top for the fifth consecutive year. Call 0844 892 3000 or visit www.worcester-bosch.co.uk to find out more. By appointment to Her Majesty The Queen Boiler Manufacturer Worcester, Bosch Group T/A Bosch Thermotechnology Ltd. 3 Worcester is a market leader in high efficiency, condensing boiler technology and all of our products are designed to deliver heating and hot water comfort. Our Greenstar range of gas-fired condensing boilers can help reduce your fuel bills and your carbon footprint. We are also leading the way in environmentally friendly heating and hot water production through our commitment to developing innovative renewable energy solutions. All of the boilers in the brochure are available as natural gas or LPG models. Inside this brochure you will find all you need to know about the Worcester options available and how we can help make it easy for you and your qualified installer to find the right boiler for your home and lifestyle. Contents Page Wherever you live, Worcester keeps it feeling like home. 4 Worcester. Trusted for half a century. 5 If your heating system is over 10 years old, it’s not as efficient as it could be. 6 Which type of condensing boiler is right for you? 8 The all-new Greenstar CDi Compact. 10 Greenstar condensing boiler range. 12 Heating control options. 20 Greenstore unvented cylinders. 24 Greenfloor heating. 26 Worcester CondenseSure and Greenstar System Filter. 28 Greenstar gas-fired boiler technical overview. 29 Greenstar Plus - Hybrid. 30 Even more ways of providing heating and hot water comfort to you. 31 We’re as committed to the environment as we are to our customers. 32 Worcester. At your service. 34

UK/IE INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS WALL HUNG RSF GAS FIRED CONDENSING SYSTEM BOILER GREENSTAR 30/35 CDi CLASSIC SYSTEM 6 720 812 176-00.1O FOR CENTRAL HEATING SYSTEMS AND INDIRECT FED DOMESTIC HOT WATER 6 720 812 175 (2014/07) 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 CONTENTS 6 720 812 175 (2014/07) 2 CONTENTS 1 KEY TO SYMOLS AND SAFETY PRECAUTIONS . . . . . . . . . . . . . 3 1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 APPLIANCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.2 Layout & components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3 PRE-INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3.1 Cleaning primary systems . . . . . . . . . . . . . . . . . . . . . . . . . 9 3.2 Mains supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3.2.1 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3.3 Water systems & pipe work . . . . . . . . . . . . . . . . . . . . . 10 3.4 Condensate pipe work . . . . . . . . . . . . . . . . . . . . . . . . . 11 3.4.1 Internal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3.4.2 External connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.5 Boiler internal drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3.6 Pressure relief pipe work . . . . . . . . . . . . . . . . . . . . . . . 13 3.7 Boiler location & clearances . . . . . . . . . . . . . . . . . . . . . 14 3.8 Plumbing manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.9 Flue options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 3.10 Flue terminal positions . . . . . . . . . . . . . . . . . . . . . . . . . 18 3.11 Plume management terminal positions . . . . . . . . . . . . 19 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 4.1 Unpacking wall frame and ancillary items . . . . . . . . . . 20 4.2 Wall mounting plate and flue opening . . . . . . . . . . . . . 21 4.3 Unpacking the appliance . . . . . . . . . . . . . . . . . . . . . . . . 22 4.4 Fitting the appliance/boiler connections . . . . . . . . . . . 23 4.5 Flue installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 4.5.1 Ø 60/100 mm Telescopic flue kit . . . . . . . . . . . . . . . . . 24 4.5.2 Ø 60 mm Plume management kit . . . . . . . . . . . . . . . . . 24 4.5.3 Adjusting the standard terminal length: . . . . . . . . . . . . 24 4.5.4 Installing the standard flue . . . . . . . . . . . . . . . . . . . . . . 25 4.5.5 Flue terminal plume re-direction: . . . . . . . . . . . . . . . . . 25 4.6 Condensate connection . . . . . . . . . . . . . . . . . . . . . . . . 26 4.7 Electrical (without diverter valve) . . . . . . . . . . . . . . . . 27 4.8 Electrical (with optional diverter valve) . . . . . . . . . . . . 28 4.9 Position of wired components . . . . . . . . . . . . . . . . . . . 29 5 COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.1 Pre- commissioning checks . . . . . . . . . . . . . . . . . . . . . 30 5.2 Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.3 Starting the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5.4 Water treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5.5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 5.5.1 Checking the gas inlet pressure . . . . . . . . . . . . . . . . . . 32 5.5.2 Checking the gas rate . . . . . . . . . . . . . . . . . . . . . . . . . . 33 5.6 CO and Combustion checks . . . . . . . . . . . . . . . . . . . . . 34 5.7 Finishing commissioning . . . . . . . . . . . . . . . . . . . . . . . 35 6 SERVICING AND SPARES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6.1 Inspection and spares . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6.1.1 Checking flue integrity . . . . . . . . . . . . . . . . . . . . . . . . . 36 6.1.2 Component access . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6.1.3 Fan pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 6.1.4 To Clean the Heat Exchanger . . . . . . . . . . . . . . . . . . . . 38 6.1.5 To Clean the Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 6.1.6 To Check the Diaphragm in Burner Cover . . . . . . . . . . 39 6.1.7 To Clean the Siphon/Condensate Trap . . . . . . . . . . . . 40 6.2 Setting the air/gas ratio . . . . . . . . . . . . . . . . . . . . . . . . 40 6.3 Replacement of parts . . . . . . . . . . . . . . . . . . . . . . . . . . 41 6.4 Short parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 7 FAULT FINDING & DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 51 7.1 Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 7.2 Central heating function . . . . . . . . . . . . . . . . . . . . . . . . 52 7.3 Cylinder heat function . . . . . . . . . . . . . . . . . . . . . . . . . . 53 7.4 Protection function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 KEY TO SYMOLS AND SAFETY PRECAUTIONS 6 720 812 175 (2014/07) 3 1 KEY TO SYMOLS AND SAFETY PRECAUTIONS 1.1 KEY TO SYMBOLS WARNINGS The following keywords are defined and can be used in this document: • NOTE indicates a situation that could result in damage to property or equipment. • CAUTION indicates a situation that could result in minor to medium injury. • WARNING indicates a situation that could result in severe injury or death. • DANGER indicates a situation that will result in severe injury or death. IMPORTANT INFORMATION ADDITIONAL SYMBOLS SYMBOLS USED IN THIS MANUAL PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION. Warnings in this document are identified by a warning triangle printed against a grey background. Keywords at the start of a warning indicate the type and seriousness of the ensuing risk if measures to prevent the risk are not taken. This symbol indicates important information where there is no risk to people or property. Symbol Explanation ▶ Step in an action sequence  Cross-reference to another part of the document • List entry – List entry (second level) Table 1 Domestic Hot Water Central Heating Hot Water Storage Cylinder Domestic Cold Water Supply Electrical Supply Gas Supply Table 2 Commonly used symbols These instructions are applicable to the Worcester 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. These instructions apply in the UK and Ireland only and must be followed except for any statutory obligations. This appliance must be installed by a GAS SAFE registered, competent person. Failure to install correctly could lead to prosecution. If you are in any doubt, contact the Worcester Technical helpline (0330 123 3366). Please leave these instructions with the completed BENCHMARK CHECKLIST, (or a certificate confirming compliance with IS 813, Eire only) and the user manual with the owner or at the gas meter after installation or servicing. Distance learning and training courses are available from Worcester. The BENCHMARK CHECKLIST can be found in the back of this Installation manual. Table 3 Ø Diameter NG Natural Gas LPG Liquid Petroleum Gas CH Central Heating DHW Domestic Hot Water DCW Domestic Cold Water PRV Pressure Relief Valve NTC Negative Temperature Coefficient (sensor) IP Ingress Protection RCD Residual Current Device TRV Thermostatic Radiator Valve ECV Emergency Control Valve WRAS Water Regulations Advisory Scheme SEDBUK Seasonal Efficiency of Domestic Boilers in the United Kingdom Table 4 Abbreviations use in this manual KEY TO SYMOLS AND SAFETY PRECAUTIONS 6 720 812 175 (2014/07) 4 1.2 SAFETY PRECAUTIONS IF YOU SMELL GAS A gas leak could potentially cause an explosion. If you smell gas, observe the following rules. ▶ Prevent flames or sparks: – Do not smoke, use a lighter or strike matches. – Do not operate any electrical switches or unplug any equipment. – Do not use the telephone or ring doorbells. ▶ Turn off the gas at the meter. ▶ Open windows and doors. ▶ Warn your neighbours and leave the building. ▶ Prevent anyone from entering the building. ▶ Well away from the building: call the National Gas Emergency Service on 0800 111 999. BOILER OPERATION: This boiler must only be operated by a responsible adult who has been instructed in, understands and is aware of the boiler’s operating conditions and effects. Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer's instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference. Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the scheme. Visit centralheating.co.uk for more information. HEALTH AND 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 boiler. Chemically aggressive substances 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 current Gas Safety (Installation and Use) Regulations. 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 Gas Safe registered engineer. Approved spares must be used to help maintain the economy, safety and reliability of the appliance. IMPORTANT The service engineer must complete the Service Record on the Benchmark Checklist after each service. INSTALLATION REGULATIONS Current 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: Where no specific instruction is given, reference should be made to the relevant British Standard codes of Practice. BS7074:1 - Code of practice for domestic and hot water supply BS6891 - Installation of low pressure gas pipe work up to 28mm (R1) BS5546 - Installation of gas hot water supplies for domestic purposes EN12828 - Central heating for domestic premises BS5440:1 - Flues and ventilation for gas appliances of rated heating not exceeding 70kW (net): Flues BS5440:2 - Flues and ventilation for gas appliances of rated heating not exceeding 70kW (net): Air Supply BS7593 - Treatment of water in domestic hot water central heating systems BS6798 - Installation of gas fired boilers of rated input up to 70kW (net) Irish Standards The relevant Irish standards should be followed, including: • ECTI National rules for electrical installations • IS 813:2002 for Domestic Gas Installations. LPG Installations 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 building: 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. CH Water: Artificially softened water must not be used to fill the central heating system.