Worcester Greenstar FS 30CDi Regular Manuals

Installation, Commissioning and Servicing Instructions Floor standing RSF gas fired condensing regular boiler Greenstar FS 30CDiErP & 42CDiErP Regular 6720648568-00.1Wo For sealed or open vent central heating systems 6 720 818 079 (2016/04) The appliances are for use with: Natural Gas or L.P.G. (Cat. II 2H3P type C13, C33, C53 &C93) Natural Gas: FS 30CDi ErP Regular, GC number 41-406-62 FS 42CDi ErP Regular, GC number 41-406-64 L.P.G.: FS 30CDi ErP Regular, GC number 41-406-63 FS 42CDi ErP Regular, GC number 41-406-65 Contents Greenstar FS CDi ErP 6720818079 (2016/04) 2 Contents 1 KEY TO SYMBOLS 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 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.3 Product data on energy consumption . . . . . . . . . . . . . . . 7 2.4 Layout and components . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3 PRE-INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.1 Cleaning primary systems . . . . . . . . . . . . . . . . . . . . . . . 10 3.2 Mains supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.2.1 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.2.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.3 Water systems and pipe work . . . . . . . . . . . . . . . . . . . . 11 3.4 Condensate pipe work . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.4.1 Internal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.4.2 External connections . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.5 Boiler location and clearances . . . . . . . . . . . . . . . . . . . 14 3.5.1 Boiler clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 3.5.2 Airing cupboard clearances . . . . . . . . . . . . . . . . . . . . . 14 3.5.3 Vented compartments . . . . . . . . . . . . . . . . . . . . . . . . . 14 3.5.4 Rooms containing a bath or shower . . . . . . . . . . . . . . . 15 3.6 Flue options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.7 Flue terminal positions . . . . . . . . . . . . . . . . . . . . . . . . . 17 3.8 Plume management terminal positions . . . . . . . . . . . . 18 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4.1 Unpacking the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4.2 Mounting frame fixing and flue opening . . . . . . . . . . . . 20 4.3 Flue measuring and cutting . . . . . . . . . . . . . . . . . . . . . . 21 4.4 Condensate, gas and water connections . . . . . . . . . . . 21 4.5 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 4.5.1 PCB Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 5 COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 5.1 Pre-commissioning checks . . . . . . . . . . . . . . . . . . . . . . 24 5.2 Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 5.3 Water treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 5.4 Starting the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 25 5.4.1 Switching the appliance on/off: . . . . . . . . . . . . . . . . . . 25 5.4.2 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 5.4.3 Display messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 5.5 Checking gas inlet pressure . . . . . . . . . . . . . . . . . . . . . 27 5.5.1 Measuring the inlet pressure . . . . . . . . . . . . . . . . . . . . 27 5.5.2 Checking the gas rate . . . . . . . . . . . . . . . . . . . . . . . . . . 27 5.6 CO and combustion check . . . . . . . . . . . . . . . . . . . . . . 28 5.7 Finishing commissioning . . . . . . . . . . . . . . . . . . . . . . . 29 6 SERVICING AND SPARES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 6.1 Inspection and service . . . . . . . . . . . . . . . . . . . . . . . . . . 29 6.2 Service function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 6.3 Service inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 6.4 Fan pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 6.5 Checking the flue integrity . . . . . . . . . . . . . . . . . . . . . . . 31 6.6 Flue gas analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 6.7 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 6.7.1 To clean the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 6.7.2 To check the flap valve in the fan intake . . . . . . . . . . . . 31 6.7.3 To clean the condensate trap . . . . . . . . . . . . . . . . . . . . . 32 6.7.4 Cleaning the heat exchanger . . . . . . . . . . . . . . . . . . . . . 32 6.7.5 Re-assembly of the burner cover . . . . . . . . . . . . . . . . . . 34 6.8 Setting the air/gas ratio . . . . . . . . . . . . . . . . . . . . . . . . . 34 6.9 Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 6.9.1 Draining the appliance: . . . . . . . . . . . . . . . . . . . . . . . . . . 35 6.9.2 PCB control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 6.9.3 Fan assembly: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6.9.4 Condensate pump: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6.9.5 Sample points: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6.9.6 Sensors: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6.9.7 Condensate trap: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 6.9.8 Gas valve: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 6.9.9 Electrode assembly and heatshield: . . . . . . . . . . . . . . . 37 6.9.10 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 6.9.11 Primary heat exchanger: . . . . . . . . . . . . . . . . . . . . . . . . 38 6.10 Short parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 7 FAULT FINDING AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . 39 7.1 Electrical wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . 39 7.2 Boiler function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 7.3 Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 KEY TO SYMBOLS AND SAFETY PRECAUTIONS Greenstar FS CDi ErP 6720818079 (2016/04) 3 1 KEY TO SYMBOLS AND SAFETY PRECAUTIONS 1.1 Key to symbols Warnings The following keywords are defined and can be used in this document: • NOTICE 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 competent registered gas engineer, such as a Gas Safe registered engineer or British Gas engineer. Failure to install correctly could lead to prosecution. If you are in any doubt, contact the Worcester Technical help-line (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. 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 UK ErP Energy related Products DWTA Domestic Water Treatment Association Table 3 Abbreviations use in this manual KEY TO SYMBOLS AND SAFETY PRECAUTIONS Greenstar FS CDi ErP 6720818079 (2016/04) 4 1.2 Safety precautions Instructions for the target group These installation instructions are intended for registered gas fitters, plumbers, heating engineers and electricians. All instructions must be observed. Failure to comply with these instructions may result in material damage and/or personal injury, including possible loss of life. ▶ Read these installation instructions before installation. ▶ Observe safety instructions and warnings. ▶ Observe national and regional regulations, technical rules and guidelines. ▶ Keep a record of all work carried out. Determined use The product is not intended for commercial use. The product may only be used in a domestic situation for the heating of central heating water and for DHW heating in a closed-loop DHW and heating systems. Any other use is considered inappropriate. Any damage that may result from misuse is excluded from liability. 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 or regulator. ▶ Open windows and doors. ▶ Warn your neighbours and leave the building. ▶ Prevent anyone from entering the building. ▶ Move well away from the building: call the National Gas Emergency Service on 0800 111 999. ▶ L.P.G. boilers: Call the supplier’s number on the side of the gas tank. Risk to life from poisoning by flue gas There is a risk to life from escaping flue gas. ▶ Never modify any parts for the flue gas routing. ▶ Ensure that flue pipes and gaskets are not damaged. Installation, commissioning and servicing Installation, commissioning and servicing must only be carried out by a competent, registered gas engineer, such as a Gas Safe registered engineer or British Gas engineer. ▶ Carry out a gas tightness test after completing work on gas-carrying components. ▶ Only use original spares. Electrical work Electrical work must only be carried out by a qualified electrician: ▶ Before starting electrical work; – Ensure that the electricity supply is safely Isolated and secured to prevent inadvertent re-connection. Information on safe isolation can be found in the Health and Safety Executive guidance HSG85. – Using test equipment approved to GS38 confirm that the electricity supply is disconnected. ▶ Refer to the manufacturer’s information when installing other components with Worcester equipment within the system. Handover to the user When handing over, instruct the user how to operate the heating system and inform the user about its operating conditions. ▶ Explain how to operate the heating system and draw the user's attention to any safety relevant action. ▶ Explain that modifications and repairs must only be performed by a competent, registered gas engineer, such as a Gas Safe registered engineer or British Gas engineer. ▶ Advise the user to have the system serviced annually by a competent, registered gas engineer, such as a Gas Safe registered engineer or British Gas engineer. ▶ Leave the installation instructions with the completed Benchmark Checklist (or a certificate confirming compliance with IS 813, Eire only) and the operating instructions with the user or at the gas meter. Boiler operation This appliance can be used by children aged from 8 years and above and persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge, if they have been given supervision or instruction concerning use of the appliance in a safe way and understand the hazards involved. Children shall not play with the appliance. Cleaning and user maintenance shall not be made by children without supervision. Servicing Advise the user to have the system serviced annually by a competent, registered gas engineer, such as a Gas Safe registered engineer or British Gas 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. 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 Hot water 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). Combustion 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 can corrode the appliance and invalidate any warranty. Fitting and modification 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.