GREENSTAR 30CDi System - Bolton Boiler Company

GREENSTAR 30CDi System - Bolton Boiler Company
GREENSTAR 30CDi System
WALL HUNG RSF GAS-FIRED CONDENSING BOILER
R SEALED CENTRAL HEATING SYSTEMS
DIRECT FED DOMESTIC HOT WATER
—
THE APPLIANCE IS FOR USE WITH
NATURAL GAS OR L.P.G. (Cat ll 2H3P TYPE C13 & C33)
NATURAL GAS: 30CDi System GC-Number 41-311-93
LIQUID PETROLEUM GAS: 30CDi System GC-Number 41-311-97
INSTRUCTION MANUAL
INSTALLATION, COMMISSIONING
& SERVICING
AN Benchmark)
Bosch Group
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.
+ Lift only a manageable weight, or ask for
help.
* When lifting the boiler, bend the knees,
* 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
LIFTING AND CARRYING PRECAUTIONS:
and keep the back straight and feet apart.
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:
© 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:
Domestic hot water Time clock CH only
Jl Central heating
Programmer/timer
Hot water storage cylinder Room thermostat
4 Electricity supply
Gas supply
—
A Cold water main supply “ Wait time period
INSTALLATION &
SERVICING INSTRUCTIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System AMORCESTER
6 720 612 452b (2006/01) Bosch Group
CONTENTS
SAFETY & REGULATIONS
SAFETY PRECAUTIONS 4
INSTALLATION REGULATIONS 4
APPLIANCE 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
INSTALLATION
UNPACKING WALL FRAME AND ANCILLARY ITEMS 18
WALL MOUNTING PLATE / FLUE OPENING 19
UNPACKING THE APPLIANCE 20
FITTING THE APPLIANCE / BOILER CONNECTIONS 21
FLUE INSTALLATION 22-24
CONDENSATE CONNECTION 25
ELECTRICAL 26-27
POSITION OF WIRED COMPONENTS 28
COMMISSIONING
PRE-COMMISSIONING CHECKS 29
FILLING THE SYSTEM 30
STARTING THE APPLIANCE 31
WATER TREATMENT 32
COMMISSIONING 33
FINISHING COMMISSIONING 34
SERVICING & SPARES
INSPECTION AND SERVICE 35-39
REPLACEMENT OF PARTS 40-48
SETTING THE GAS/AIR RATIO 49
SHORT PARTS LIST 50
CONVERSION KITS
L.P.G. CONVERSION 51
FAULT FINDING & DIAGNOSIS
FAULT FINDING 52
CENTRAL HEATING FUNCTION 53
CYLINDER HEAT FUNCTION 54
PROTECTION FUNCTION 55
SAFETY &
REGULATIONS
APPLIANCE
INFORMATION
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CONVERSION SERVICING
& SPARES
FAULT FINDING
& DIAGRAMS
AMORCESTER INSTALLATION á: SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System
Bosch Group 6 720 612 45%b (2006/01)
CONTENTS я
SAFETY PRECAUTIONS INSTALLATION REGULATIONS
= 2 IF YOU SMELL GAS: Gas Safety (Installation & Use) Regulations:
> > All gas appliances must be installed by a
ris , competent person in accordance with the above
< = . ON > prin re ON OR OFF regulations, Failure to Install appliances correctly
m .
a could lead to prosecution.
v DO PUT OUT NAKED FLAMES
v DO OPEN DOORS AND WINDOWS The appliance must be installed in accordance
v DO KEEP PEOPLE AWAY FROM THE AREA AFFECTED with, and comply to, the current: Gas Safety
Y DO TURN OFF THE CONTROL VALVE AT THE METER Regulations, IEE Regulations, Building
Regulations, Building Standards (Scotland)
y TELEPHONE THE NATIONAL GAS EMERGENCY SERVICE ON 0800 111999 (Consolidation), Building Regulations {Northern
—_— EEE
(benchmark
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.
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
556891 : 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
B55440:1 : Flues and ventilation for gas appli-
ances of rated heating not exceeding 70kW (net) :
Flues
B55440:2 : 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 bollers 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 B55440: 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.
SAFETY PRECAUTIONS
& INSTALLATION REGULATIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDI System AMORCESTER
6 720 612 452b (2006/01) Bosch Group
GENERAL INFORMATION
STANDARD PACKAGE:
A - Wall hung gas fired condensing system
boiler for central heating and domestic hot
water
- Wall mounting plate
- Hanging bracket
- Pre-plumbing manifold
- Hardware pack
Literature pack
- Bottom panel
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- Trap / Syphon Outlet Connection
(22 mm Plastic Pipe)
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SPECIFICATIONS:
G E Pre-wired and pre-plumbed
Galvanised steel inner frame
Digital control system
Automatic ignition
Direct burner ignition
Built-in frost thermostat (boiler protection)
F 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
Modulating circulating pump
AMORCESTER INSTALLATION á: SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System G E N E RAL | N FO R MATIO N
Bosch Group 6 720 612 45%b (2006/01)
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TECHNICAL DATA
NATURAL GAS
L.P.G.
DESCRIPTION UNITS 30CDi System 30CDi System
Domestic hot water
Min. heat input kW 8.0 11.5
Max. rated heat output kW 30.9 30.9
Max. rated heat input kW 30.9 30.9
Domestic Hot Water temperature range °C 40-70 40-70
Central Heating
Max. rated heat input kW 30.9 30.9
Max. rated heat output net 40/30°C kW 32.1 32.1
Max. rated heat output net 50/30°C kW 31.8 31.8
Max. rated heat output net 80/60°C kW 30.0 30.0
Min. rated heat output net 40/30°C kW 8.6 12.4
Min. rated heat output net 50/30°C kW 8.6 12.3
Min. rated heat output net 80/60°C kW 7.7 11.0
Min. rated heat input net kW 8.0 11.5
Max. flow temperature °C nom. 90 nom. 90
Max. permissible operating pressure bar 3.0 3.0
Available pump head at 21°C system temperature rise m 2 2
Gas flow rate - Max. 10 minutes from lighting
Natural Gas G20 m3/h 3.2
Propane Gas (LPG) kg/h 2.4
Flue
Flue Gas Temp. 80/60°C, rated min. load °C 76/58 76/58
Flue Gas Temp. 40/30°C, rated min. load °C 55/33 55/33
CO» level at max. rated heat output % 9.6 11.5
CO» level at min. rated heat output % 9.0 10.5
NOx - class 5 5
Condensate
Max. condensation rate 1/h 2.7 2.7
pH value, approx. 4.8 4.8
Electrical
Electrical power supply voltage AC... V 230 230
Frequency Hz 50 50
Max. power consumption W 150 150
General Data
SEDBUK band A A
Appliance protection rating IP X4D X4D
Appliance protection rating with mechanical or RF mech. timer fitted IP 20 20
Permissible ambient temperatures °C 0-50 0-50
Nominal capacity of appliance | 3.75 3.75
Noise output level dB(A) 43 43
Total boiler weight (lift weight) kg 46.5 46.5
Packaged boiler weight kg 54 54
SEDBUK % 90.1 90.1
TECHNICAL DATA
6 720 612 453b (2006/01)
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System AMORCESTER
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
но 4 OVERHEAT THERMOSTAT
ACCESS POINT FOR CLEANING HEAT
eee 2 EXCHANGER
PUMP
SYSTEM PRESSURE GAUGE
DRAIN POINT
CH RETURN
4 10 GAS INLET CONNECTION 22 mm
COMPRESSION
11 COVER FOR EXTERNAL WIRING
CONNECTIONS
12 CONTROL PANEL IN SERVICE
| q POSITION
1 енннененеееннееттоетостотт 5 13 ACCESS COVER FOR TRANSFORMER
& PCB
14 CH FLOW
15 TRAP / SYPHON OUTLET CONNEC-
TION (22 mm PLASTIC PIPE)
16 INLET PRESSURE TEST POINT
17 TRAP / SYPHON
18 GAS VALVE
19 AIR / GAS ADJUSTMENT SCREW
ee В 20 TESTING POINT FOR FAN PRESSURE
We YES dr LE er | 21 FAN
= WE F< LA Г, , ESO BY 22 PRIMARY SENSOR
‘ \ RTT 7 23 EXPANSION VESSEL
1 => 7 A LS = 24 REMOVABLE TOP CASE PANEL FOR
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AMORCESTER INSTALLATION á: SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System LAYO UT 8 CO M PO N E NTS
Bosch Group 6 720 612 45%b (2006/01)
LAYOUT & COMPONENTS
25 COMPACT HYDRAULIC MOUNTING
SCREW (2) TO BOILER
26 FLOW CONNECTION FROM BOILER
HEAT EXCHANGER
27 AUTO AIR VENT
28 UNUSED PORT
29 SYSTEM PUMP
PRESSURE RELIEF VALVE
OPTIONAL INTEGRAL DIVERTER VALVE
POSITION
RETURN CONNECTION TO SERVICE
VALVE
DRAIN POINT
INTERNAL BYPASS WITHIN PLASTIC
MOULDING
FLOW CONNECTION TO SERVICE
VALVE
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APPLIANCE
INFORMATION
SYSTEM PRESSURE GAUGE
DISPLAY
FAULT RESET BUTTON
ECO BUTTON (ONLY IN CONJUNCTION
WITH OPTIONAL DIVERTER VALVE)
HOLIDAY BUTTON (ONLY IN CONJUNC-
TION WITH OPTIONAL DIVERTER
VALVE)
DHW TEMPERATURE CONTROL (ONLY
IN CONJUNCTIÓN WITH OPTIONAL
DIVERTER VALVE)
MAINS ON/OFF INDICATOR/DIAGNOS-
TIC LIGHT (BLUE)
CH TEMPERATURE CONTROL
POSITION FOR OPTIONAL TEXT
DISPLAY WITH INTELLIGENT FUNC-
TIONALITY OR TIMER
CENTRAL HEATING BOOST BUTTON
SERVICE BUTTON
BURNER ON INDICATOR LIGHT
(GREEN)
6 720 612 458-1010 48 MASTER SWITCH ON/OFF
LAYOUT & COMPONENTS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System AMORCESTER
6 720 612 452b (2006/01) Bosch Group
CLEANING PRIMARY SYSTEMS
IMPORTANT: All the following Pre-Installation sections must be read and IMPORTANT: Debris from the system can
damage the boiler and reduce efficiency.
requirements met before starting boiler or flue installation. 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
4 KEEP THE EXISTING BOILER/
CIRCULATING PUMP WHERE POSSIBLE
OR USE A POWER FLUSHING MACHINE
7 “. Tm TO AID THE CLEANSING PROCEDURE
7 ` ” `
í COOL. NO “ У Л. ПТ BEFORE INSTALLING A NEW BOILER.
\
| | ! CLEANING THE PRIMARY SYSTEM:
/ \ AI, JE ПИ 1 Fill the system with cold water and check
/ ver for leaks.
`
4 1 “a A 2 Open all drain cocks and drain the system.
Uns 3 Close drain cocks and add a suitable
flushing agent at the correct strength for
the system condition in accordance with
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the manufacturer’s instructions.
5 » Circulate the flushing agent before the
_ . boiler is fired up.
as ^^ me 4 Run the boiler/system at normal operating
/ Ш a >, temperature as directed by the manufacturer
| of the flushing agent.
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\ Ш | Ш, / remove the flushing agent and debris.
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AMORCESTER INSTALLATION á: SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System CLEAN | NG PR | MARY SYSTE MS
Bosch Group 6 720 612 45%b (2006/01)
MAINS SUPPLIES
ELECTRIC SUPPLY:
+ Supply: 230V - 50Hz
(See Technical Data for IP ratings.)
+ Cable: PVC insulated 0.75mm?2
(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 IEE wiring regula-
tions and any local regulations which may
apply to fixed wiring to a stationary appliance.
GAS SUPPLY:
+ Bollers using NG must be connected to a
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
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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 thickness.
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CD Syst A
MAINS SUPPLIES | System WORCESTER
6 720 612 453b (2006/01) Bosch Group
S PLAN LAYOUT
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WITH EXTERNAL DIVERTER VALVE
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SYSTEM LAYOUT WITH OPTIONAL
INTERNAL DIVERTER VALVE FITTED
(NOT SUPPLIED WITH BOILER)
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< Cylinder return A Y return
| Cylinder flow +
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L— 5 Heating flow
SYSTEM FILL SYSTEM MAKE UP
Make up
Heating return Heating retum Auto vessel
+
air vent
Non
Non return Non return
Hose valve valve return valve 1000mm (39in)
| return | _ above the
Mains highest point of
A supply the system
Stop ı Stop cock
cock М
Test cock
Temporary hose
WATER SYSTEMS & PIPEWORK
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).
CONNECTIONS/VALVES:
+ 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.
* All other valves should conform to BS1010.
* On new installations, or extensions to exist-
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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 is required at the lowest point
on the system.
* An air vent is required at the highest point
on the system.
Diverter Valve
Automatic Bypass
Radiator Valve (Flow)
Lockshield Valve (Return)
Extra expansion Vessel
NB A drain cock should be fitted at the
lowest point of the heating circuit and
beneath the appliance.
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OPTIONAL INTERNAL DIVERTER VALVE:
* The sealed system must be filled using a
WRAS approved filling loop or comply with
the diagram opposite for System fill
* Where the system volume 1s more than
100 litres or exceeds 2.65 bar at maximum
heating temperature an extra expansion ves-
sel (E) must be fitted as close as possible to
the appliance in the central heating return.
* Pressurize the extra expansion vessel (E) to
the same figure as the expansion vessel
built into the appliance.
* Do not use galvanised pipes or radiators.
* NB A drain cock should be fitted at the
lowest point of the heating circuit and
beneath the appliance.
AMORCESTER INSTALLATION á: SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System
Bosch Group 6 720 612 45%b (2006/01)
WATER SYSTEMS € PIPEWORK
CONDENSATE PIPEWORK
1 2 CONDENSATE PIPEWORK:
] С * The condensate pipe must be a minimum of
| À 22 mm © plastic pipe.
The condensate pipework must fall at least
50 mm per metre towards the outlet and
should take the shortest practicable route.
* The pipework must follow one of the options
D shown opposite into an internal serviceable
trap (min. 75 mm) such as a sink/washing
machine) and discharge direct into a vent stack
(E) min. 450 mm above pipe invert or into a gul-
3 4 ley (D) below ground but above the water level.
+ Wherever possible the condensate dis-
E charge pipe work should be routed and ter-
> GC minated internally. Should this not be possi-
— Asp Y ble, and the only available route 1s external,
5 . ll the following conditions should be
> Е D observed:
= Y Pipe work length should be kept to a
= Invert | minimum and the route as vertical as
«= possible.
Where pipe work could be subjected to
1 Internal sink/washing machine extreme cold or wind chill, a weather
drain proof insulation should be used.
2 Internal waste drainage system Alternatively the condensate pipework
3 Soil/vent stack could be increased to a minimum 32 mm
4 External drainage system without the requirement to insulate.
> mi condensate absorption IMPORTANT: Ensure there are no block-
A - Condensate from boiler ages in the pipe run.
B - Sink
C - 22 mm J plastic condensate pipe
D - Gulley
E - Internal soil and vent stack
F- Serviceable waste trap (75 mm min)
G - 300 mm x 100 mm & sealed plastic
tube
H - Ground level
J- Drainage holes 50 mm from base of
tube (12 mm 9 at 25 mm centres) PRESSURE RELIEF PIPEWORK
facing away from building
emt “a, K - Limestone chippings IMPORTANT: The pressure relief valve is a
e N safety device for the boiler and if activated
/ \ may discharge boiling water or steam
through the relief valve drain pipe.
Care should be taken when siting the out-
; let pipe so that it does not cause an
eh д} / obstruction or discharge above a window,
“N „” entrance or other public access where it
could cause a hazard.
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* The pressure relief drain pipe (M,O) from
> y N the boiler should be at least 15 mm diameter
\ copper pipe and run downwards away from
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any electrics or other hazard, preferably to
an external drain or soakaway.
N | e xX 7 * Pipe (M) should be finished with a partial
d NS J bend, near the outlet to face the external
| Ne e” L- Outside wall wall (as shown) to help prevent freezing.
<> M, O - Drain pipe * Use waterproof pipe insulation in exposed
6 720 611 927 - 03.10 N - External drain positions and for external pipework.
CO N D E NSATE P| PEWO RK INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDI System AMORCESTER
6 720 612 452b (2006/01) Bosch Group
SERVICING CLEARANCES 960 mm + BOILER LOCATION &
To CLEARANCES
Ms + 30 nm To
207 above elbow _- | В В
A - This boiler is only suitable for installing internally
within a property at a suitable location onto a
fixed, rigid non-combustible surface at least the
same size as the boiler and capable of support-
ing the boiler weight.
COMPARTMENTS:
Follow the requirements of BS6798 and
BS5440 Part 2 and note:
* Minimum clearances must be maintained
Using 100 mm flue kit '
-1112 mm '
Using 125 mm flue kit '
- 1152 mm '
' 20 mm
' to removable door 1 !
An access door Is required to install, service
and maintain the boiler and any ancillary
equipment.
600 mm ' If fitting the boiler into an airing cupboard
| ors mico — use a non-combustible perforated material
or service | . .
у - (maximum hole sizes of 13mm) to separate
- - the boiler from the airing space.
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> . BOILER CLEARANCES:
>“ The diagram opposite shows the minimum
space required to install and service the boller.
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 cup-
board or a compartment is built around the
appliance after installation, then the compart-
ment 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.
AMORCESTER INSTALLATION á: SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System B O | LE R LO CATIO N 8 CLEARAN CES
Bosch Group 6 720 612 45%b (2006/01)
BOILER LOCATION &
CLEARANCES
600mm 600mm
Ms BATHROOMS:
I 750mm The boiler can be installed in zones 2 or 3. If a
mechanical or RF mechanical timer or text dis-
play with room thermostat (IP 20 only) is fitted
© (2) (1) (1) the boiler can only be installed in zone 3.
(2) (3) 2250mm A Non mechanical timer can be installed in
zone 2,
os — See |EE wiring regulations.
— ——-
(See Technical Data for IP ratings.)
О IMPORTANT: any switch or appliance
control using 230 V mains electricity must
not be able to be touched by a person
using the bath or shower.
Electrical switches, fused spur and socket
outlets must not be situated in the bath-
600mm room.
=
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|
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=
For further information about bathroom installa-
750mm . .
tions please consult Operational Procedures
© © Part 20, Electricity.
(2) © 2250mm
ос _—
600mm radius
6 720 611 927-1310
BO | LE R LO CAT О N & CLEARAN CES INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDI System AMORCESTER
6 720 612 452b (2006/01) Bosch Group
IMPORTANT: IF FITTING OPTIONAL INTEGRAL DIVERTER VALVE install the pipework as
shown in the diagramm on the left side (see also additional informations in the document
coming with the diverter valve kit).
If no diverter valve is fitted install the pipework as shown in the diagramm on the right side.
Cylinder Flow (alternative from
above appliance) 15 mm
fra a Gas Supply (alternative from above appliance) 22 mm
|
a+ 8
| Е Cylinder Return (alternative
|
|
|
||)
CH Flow N | Ч from above appliance) 15 mm
(alternative | | | E i
| |
from above | | | | CH Return (alternative from
appliance) il + above appliance) 22 mm
22mm AT MH HIT
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22 mm
р»
6720612 458-2710
t 1 I
CH flow 22 mm | i B I eH return 22 mm a
Î !
Cylinder Flow 15 mm E A
Cylinder Return 15 mm \
Mains Gas Supply 22 mm
PLUMBING MANIFOLD
CONNECTIONS:
Heating System: 22 mm compression fittings
DHW: 15 mm compression fittings
Gas: 22 mm compression fittings
Use the fittings supplied in the Hardware
pack.
PREPLUMBING
With the plumbing manifold installed,
pipework can be installed to the valves on the
manifold.
The valves can be closed enabling CH sys-
tem to be tested. The boiler can be installed
at later date.
RUNNING PIPES BEHIND THE BOILER
If the boiler pipes are to be run behind the
appliance ensure that the pipes pass close to
the wall as shown in the diagram opposite,
and within the pipe guide.
A Gas Supply (alternative from above
| appliance) 22 mm
CHFlow [3 pm
. | |
(alternative | | J; cH Return (alternative from
from above | | J .
| | je above appliance) 22 mm
appliance)
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6720 612 455-0310
Î t CH return
Mains Gas Supply 22 mm a 22 mm
AMORCESTER INSTALLATION á: SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System
Bosch Group 6 720 612 45%b (2006/01)
PLUMBING MANIFOLD
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INSTALLATION
Minimum dimensions of flue terminal positions for balanced room sealed flues with
fanned draught:
DRWG. | TERMINAL POSITION DISTANCE
REF:
A Directly below an opening, air brick, opening windows, etc. 300mm
B Above an opening, air brick, opening window, etc. 300 mm
С Horizontally to an opening, air brick, opening window, etc. 300 mm
D Below gutters, soil pipes or drain pipes 75mm
E Below eaves 200mm
Below balconies or car port roof (lowest point) 200mm
From a vertical drain pipe or soll pipe 150mm
From an internal or external corner 300mm
Above ground, roof or balcony 300mm
From a surface facing the terminal 600mm
From a terminal facing the terminal 1200mm
From an opening in the car port (e.g. door, window) into the dwelling 1200mm
Vertically from a terminal on the same wall 1500mm
Horizontally from a terminal on the same wall 300mm
From a non combustible vertical structure on the roof *
Above intersection with roof *
Adjacent to windows or openings on pitched and flat roofs 600mm
Below windows or openings on pitched roofs 2000mm
he
In addition, the terminal should not be nearer than 150mm (fanned draught) to an opening
in the building fabric formed for the purpose of accommodating a built-in element such as a
window frame.
2 Not recommended.
* See instructions supplied with vertical flue kits.
boundary
6 720 611 927-14.30
FLUE TERMINAL POSITIONS
+
/
The flue must be fitted and terminated in
accordance with the recommendations of
BS5440 : Part 1.
The flue must not cause an obstruction.
Discharge and any noise from the flue outlet
must not cause a nuisance.
Flue gases have a tendency to plume and in
certain weather conditions a white plume of
condensation will be discharged from the
flue outlet. Where this could be a nuisance,
for example, near security lighting, an alter-
nate position should be found.
The air inlet/outlet duct and the terminal of
the boiler must not be closer than 25mm to
any combustible material.
Detailed recommendations on protection of
combustible materials are given in
BS 5440:1
A protective terminal guard must be fitted if
the terminal is 2m or less above a surface to
which people have access.
The guard must be spaced equally (mini-
mum 50 mm) around the flue and fixed to
the wall with plated screws. See Contact
Information (inside front cover).
FLUE TERMINAL POSITIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDI System AMORCESTER
6 720 612 452b (2006/01) Bosch Group
FLUE OPTIONS
STANDARD FLUE HORIZONTAL MAXIMUM FLUE VERTICAL
START + 2 BENDS
* The diagrams (opposite) show the compo-
©) А Е El ZA nents used and the maximum flue length for
Bi each configuration of 100 mm and
125 mm O flues.
9100 © С + Shaded flue components indicate the stan-
MAX 686 mm A x1 2100 - 5900 mm 7 dard 100 mm © horizontal flue.
MIN 250 mm Ax 1° Ах1 + Сх 2 + Вх 8 * Only straight flue sections can be reduced
3125 + Fx1 in length and cut.
MAX 1070 mm Ax 1 9125 - 16500 mm The flue terminal end can be fitted from the
MIN 250 mm Ax 1* Ax1+Cx2+ Bx18 inside or outside of the building.
* Requires cutting + Ex * Fixing kits are supplied with the flue exten-
sion kits.
+ Horizontal 125 mm @ and Vertical 100 mm
and 125 mm @ flue kits are available with
MAXIMUM FLUE HORIZONTAL MAXIMUM FLUE VERTICAL separate instructions. Contact your supplier
| START + 3 BENDS or Worcester Bosch. -
A e
He T#- A Fo 2 <
2? B Be A C D <
с a (DTT 2
2100 - 7900 mm
Ax1+ Bx8
2100 - 3900 mm
B
Ax1+Cx3 E F
=
+ Bx7 + Fx1 |
3125 - 18500 mm 125 - 14500 mm
Ах1 + Вх 18 Ах 1 + Сх 3 A - Standard horizontal flue (100 mm © shown)
+ Bx17 + Fx 1 B - Straight flue extension
C - Flue bend, 90°
D - Flue bends, 45°
E - Vertical terminal (vertical adaptor supplied
with terminal)
MAXIMUM FLUE VERTICAL START + 1 BEND MAXIMUM FLUE VERTICAL F - Vertical adaptor (used with horizontal
| WITH 2 X 45° BENDS > terminal)
Ра А Е
1 B
B (A
CA © D > Calculating the flue length:
2100 - 7900 mm Measure the total flue length required, noting
Ax14+ Cx1+ Bx9 9100 ; 7400 mm = that the maximum straight flue length including
4 РУ? (including terminal) the terminal is:
Bx8+ Dx2 + Ex1 Horizontal 60/100 mm &: 7900 mm
2125 - 18500 mm 9125 - 16500 mm Horizontal 80/125 mm ©: 18500 mm
Ax1+ Cx1+ Bx19 (including terminal) Vertical 60/100 mm &: 9400 mm
+ Fx1 Bx17 + Dx 9 +E x1 Vertical 80/125 mm 6: 18500 mm
Then reduce the total straight flue length for
each extra flue bend (excluding the turret) by:
2000 mm for 90°
MAXIMUM FLUE HORIZONTAL + 1 BEND VERTICAL FLUE WITH 1000 mm for 45°
2 X 90° BENDS
Flue extension total lengths:
Horizontal & Vertical 80/100 mm &: 960 mm
Horizontal & Vertical 80/125 mm &: 1000 mm
(PET A
Mz B
E
а © В Г Flue terminal total lengths:
Horizontal 60/100 mm ©: 800 mm
9100 - 5900 mm © A, Horizontal 80/125 mm 2: 1200 mm
Axt+ Bx7+CX1 2100 - 5400 mm Vertical 60/100 mm @: 1140 mm
2125 - 16500 mn (including terminal) Vertical 80/125 mm 9: 1365 mm
Ax1+ Bx17+Cx1 Bx7+ Cx2 +Ex1
2125 - 14500 mm
(including terminal)
Bx16+ Cx2 +Ex1 6 720 611 027-0810
AMORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi Systern FLUE OPTIONS
Bosch Group 6 720 612 45%b (2006/01)
IMPORTANT: All the previous Pre-Installation sections must be read UNPACKING WALL FRAME
and requirements met before starting boiler or flue installation.
AND ANCILLARY ITEMS
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.
- Carton
- Wall mounting plate
- Hanging bracket
- Pre-plumbing manifold
Hardware pack
- Literature pack
- Bottom panel
I OTMDOQOUT
- Trap / Syphon Outlet Connection
(22 mm Plastic Pipe)
Upper support (polystyrene)
IMPORTANT HANDLING INSTRUCTIONS
* Itis advised that two people are used to
carry the carton from the van to the point of
delivery.
* Once the carton has been delivered, the
top of the carton is opened. If a sharp imple-
ment is used make sure the carton is not
pierced and that the implement is used in
such a way so that it may not cause person-
al injury. All sharp objects must be covered
or the blade retracted after use and put
away In a safe place.
» 1. The upper support is now removed with
the components (bottom panel, pre-plumb-
ing manifold, fixings, documentation set,
charging link, hanging bracket).
» 2. The boiler wall mounting plate can now
be pulled out.
Additional requirements for roof space installa-
tion:
* The boiler should be first unpacked before
ascending ladder to loft space.
* Two sets of steps should be used.
* Two people should share the lifting of the
boiler up to the loft hatch, where the boiler
is entered into the loft space tilted and slid
on its back into the loft.
Once the appliance is removed from its pack-
aging check the contents against the packing
list.
Before installing appliance ensure system
TT а has been cleaned as explained on page 9.
6 720 612 548-0410
U N PACKI N G WALL FRAM E AN D INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System AMORCESTER
ANCILLARY ITEMS 6 720 612 458 (2006/01) Bosch Group
X 4 10mm © WALL MOUNTING PLATE
FLUE OPENING
CAUTION: Ensure there are no pipes, elec-
! tric cables, damp proof courses or other
hazards before drilling.
All relevant safety precautions must be under-
— Z _ —T D | Pres SAFETY:
. taken. Protective clothing, footwear, gloves and
220 mm — safety goggles must be worn as appropriate.
VF
со
~J
3
3
FIXING THE POSITION OF THE WALL
| MOUNTING PLATE:
* The diagram opposite shows the relative
00
positions of the flue and the fixing of the wall
mounting plate, the mounting plate and pre-
plumbing manifold.
» Place the wall mounting plate against the
wall in the desired position.
» Mark 3 fixing points through the holes (A, B,
C) in the wall mounting plate.
» Drill the 3 holes for wall mounting plate, wall
hanging bracket and pre-plumbing manifold.
» Secure wall mounting plate with hanging
bracket with 3 screws (supplied with the
| boiler). Do not fully fasten the lower 2
screws.
Г
©
» Use the horizontal slots in the wall mounting
plate to level the hanging bracket, mark the
— JJ hde B 4th hole and drill.
/ » Fix and secure the hanging bracket with
O / hoe C both screws.
o
FLUE OUTLET
» Follow the diagram opposite to mark the
centre of the flue for rear outlet (1, & 2) or
for side outlet (2 & 3).
** Note: increase this height by 52 mm for
6 720 612 349-0210
every 1000 mm of horizontal length that the
flue outlet is away from the boiler.
» For the 60/100 mm I flue make a 125 mm
diameter hole through the wall using a core
drill or similar.
For flues using an optional weather collar,
fitted from inside the building make a
150 mm $ hole.
» Clear away any debris.
FIXING THE PRE-PLUMBING MANIFOLD:
» Mount the pre-plumbing manifold on the 2
Ц lower screws and secure the screws.
6720612 458-2810
AMORCESTER INSTALLATION 8: SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System WALL MO U NTI NG PLATE
Bosch Group 6 720 612 453b (2006/01) FLUE OPENING
UNPACKING THE APPLIANCE
UNPACKING THE APPLIANCE
- Outer carton
- Packaging base
- Protective wrapping
- Screws
- Clip
A
B
C
D - Appliance outer case
E
F
G - Protective packaging
» 1. With the wall frame and ancillary items
removed (see p.21), lay the carton (A) on its
back.
» 2. Open the carton bottom flaps and fold
under boiler. Do not remove the packaging
base.
» 3. Stand carton (A) with boiler upright on
the packaging base (B).
» 4. Remove outer carton (A) and place safely
away from the working area.
» 5. Remove the protective wrapping (C)
» 6. Lie the boiler on its back.
» 7. Remove the packaging base (B) and
place safely away from the working area.
REMOVING OUTER CASE
» 8. Loosen but do not remove the 2 screws
(E) securing boiler casing at the bottom of
the appliance.
» 9. Pull upwards to release the clip (F) on top
of the boiler and pull the case upwards.
» 10. Remove the outer case.
» 11. Remove the protective packaging (G)
from the electrode assembly.
Do not use
the frame
as handle
If fitting the optional integral diverter valve,
the copper pipes within the kit should be
fitted to the boiler before hanging on the
wall mounting frame. See the instructions
supplied with the optional diverter valve
kit.
U N PACKI N G TH E APPLIAN CE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System AMORCESTER
6 720 612 452b (2006/01) Bosch Group
== = ==
- “
Do not lift by the
top case panel.
Handling
hole
6720612 455-0510
15mm 15mm
22mm 22mm 22mm 22mm
-— = — =
-
22mm 99mm,’ \22mm 22mm 929mm,"
\ 7 A /
« 1Bmm 15mm» ых /
FITTING THE APPLIANCE
BOILER CONNECTIONS
CAUTION: ISOLATE THE MAINS GAS
SUPPLY BEFORE STARTING ANY WORK
AND OBSERVE ALL RELEVANT SAFETY
PRECAUTIONS.
GAS AND WATER CONNECTIONS:
» System pipes may be run vertically upwards
behind the boiler or below it. See Plumbing
Manifold Section on page 15.
A - CH flow (22 mm),
B - CH return (22 mm),
C - Gas inlet (22 mm),
If optional diverter valve is to be fitted
(1.1 and 5.1):
D - Cylinder flow (15 mm),
E - Cylinder return (15 mm)
» 1. Fit sealing washers to service valves
before hanging boiler.
» Remove dust caps from connections on
boiler.
NOTE: The accessibility to the preplumbing
manifold can be improved by removing the
condensate trap (see also page 39).
IMPORTANT: Before hanging the boiler onto
the wall mounting plate ensure that the pres-
sure relief valve connection is in the DOWN
position. This is located on the right hand side
of the wall frame at the rear.
» 2. Pull the extended tab/lever forward and
down until there is no further travel.
» 3. Hang the boiler on to the hanging brack-
et. The lugs pass through the rectangular
holes in the boiler back panel.
Take care not to disturb the washers on the
connections.
NOTE: It is recommended that this lifting
operation is carried out by 2 people,
observing all precautions for the safe lifting
of heavy objects.
Do not lift by the top case panel. There are
two handling holes incorporated into the
inner casing left and right in the lower sec-
tion of the appliance.
» 4. Lower the control panel into the service
position by removing the screw (X) from the
retaining bracket.
» 5. Make connections to the heating system.
» Connect the gas supply to the boiler gas
cock 22 mm compression.
» 5.1. If optional diverter valve is to be fitted:
Connect cylinder flow and return.
IMPORTANT: The pressure relief connector
must be repositioned after the boiler has been
correctly mounted to the wall mounting plate.
» 6. Push the lever on the pressure relief con-
nector UP until the stop on the inside of the
handle is over the shoulder of the metal
bracket to secure in place.
AMORCESTER INSTALLATION á: SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System
Bosch Group 6 720 612 45%b (2006/01)
FITTING THE APPLIANCE
BOILER CONNECTIONS
FLUE INSTALLATION
HORIZONTAL FLUE
(60/100 mm diameter)
For vertical flues and 80/125 mm horizontal flues,
please refer to separate Flue Kit instructions.
NOTE: to ease the assembly of flue components,
apply silicone lubricant to sealing surfaces.
| | The instructions for the 60/100 mm diameter flue
! are shown below.
| | MEASURING THE FLUE (Standard Flue):
' » Measure from the outside wall to the centre
| | line of the flue turret (length L).
» Subtract 52 mm from the length L to give
Edge of--—-—-.—.— нее the correct dimension to the flue elbow con-
case | | nection.
|. 220 mm —
» The terminal section should be cut to this
dimension, however it must not be shorter
than 250 mm.
LL TT » After cutting the end must be square and
_——L AT free from burrs to prevent damage to the
153 mm
€ flue seals.
Y
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| 6720611927-06.10
Turret Flue
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CD Syst A
FLUE INSTALLATION | System WORCESTER
6 720 612 453b (2006/01) Bosch Group
0 -
| 2380mm |
|
| |
o o o ÿ 0
| | |
|
ий
52 mm 960 mm 734 mm 634 mm
Turret Extension Cut Length Standard Flue
Required Length |
A
0
D
>
6 720 611 927-0510
FLUE INSTALLATION
MEASURING THE FLUE (Extension Flue Kits):
ONLY CUT EXTENDED FLUE LENGTHS
» As with the Standard Flue measure from the
outside wall to the centre line of the flue tur-
ret (length L).
» Subtract the usable length of the standard
flue (634 mm) from length L.
» Subtract the usable length of the turret
(52 mm) from length L.
» Subtract 960 mm for each full length exten-
sion from the figure.
» Cut one of the extensions to the remainder.
» Cut both tubes square taking care not to distort
the tubes.
» Remove any burrs.
EXAMPLE:
LengthL = 2380 mm
Subtract Standard Flue — 634 mm
Subtract Turret — 52 mm
Subtract Full Extension — 960 mm
Cut Length = 734 mm
NOTE: Where extensions are reduced, cut
length which DOES NOT contain the seal.
ADDITION OF FLUE BENDS:
When flue bends are being used an allowance
of 94 mm per bend must be allowed from the
centre line of the bend. In the example shown
using a flue extension (960 mm) with 2 bends
will achieve a total length of 1148 mm.
AMORCESTER INSTALLATION á: SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System
Bosch Group 6 720 612 45%b (2006/01)
FLUE INSTALLATION
A - Standard Flue
B - Internal Wall Seal
C - External Wall Seal
D - Clamp
E - Extension Duct
| 1]
== Y AR OT
FLUE INSTALLATION
ASSEMBLING THE FLUE
1 Slide inner collar (B) onto terminal (A)
2 Additional extensions or bends:
Push fit all extensions/bends/terminal
together and secure connections with
clamps (D). The slope of the terminal outlet
must face downwards.
FITTING THE FLUE
3 Fit the terminal (A) through the flue opening
in the wall, exposing the plastic outlet
section to the outside and fit the outer
flue collar ( C ) over the notches to secure.
4 Assemble turret to boiler using the three
screws (see below).
Note: Screws are in boiler or in flue kit.
FITTING THE TURRET:
* Flue turret should push directly down and
This screw should not be twisted into correct position.
be fitted last for » Fit turret onto appliance and retain with
"| easier installation three screws.
| NOTE: The clamping plate flat should be at
i
the rear of the appliance.
ADDITIONAL NOTES AND REMINDERS:
* Ensure that all cut lengths are square and
free from burrs.
* The flue, when assembled, is fully sealed
and components are pushed home.
* The flue is set at an angle of 3° or 52 mm
per additional 1m length of extension used.
Flat at back
This screw should
be fitted last for
easier installation
6 720611 927-2110
FLUE INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDI System AMORCESTER
6 720 612 452b (2006/01) Bosch Group
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CONDENSATE CONNECTION
Never terminate or discharge into any open
source, including; sink, bath, shower, bidet,
toilet etc.
Note: any external condensate pipework of
excessive runs should be protected with
weather resistant insulation to help prevent
freezing.
Ensure that the condensate drain is 22 mm
diameter plastic pipe. It must fall at least
50 mm per metre towards the outlet.
An adapter (A) in 22 mm pipe is contained
in the fitting pack.
AMORCESTER INSTALLATION á: SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System
Bosch Group 6 720 612 45%b (2006/01)
CONDENSATE CONNECTION
LIVE=@
NEUTRAL =)
SWITCHED LIVE=§)
,° CONTROLS
SS OS
“aw
“= = =
7 .-- ``
777 EXTERNAL”.
J WIRING CENTRE
1 158
| [0-6
1158
ООО °
ST10
D | (©) Île |
- 5 N
5 = :
O | | = I
Ш
ELECTRICAL
(WITHOUT DIVERTER VALVE)
CAUTION: ISOLATE THE MAINS
ELECTRICITY SUPPLY BEFORE STARTING
ANY WORK AND OBSERVE ALL
RELEVANT SAFETY PRECAUTIONS
Danger of short circuit: When connecting
the cables ensure that no cable pieces fall
into the Heatronic.
Note: Mains supply to the boiler must be
through a fused double pole isolator situated
adjacent to the appliance. The isolator must
have a contact separation of 3 mm minimum in
all poles.
Access to electrical connections:
» Remove boiler casing to access control panel.
1. Lower the control panel into the service
position by removing the screw (X) from the
retaining bracket.
2. Unscrew the three screws (B) on the back
of the control panel and pull off the connec-
tions cover.
3. Unclip cable clamp (C).
4, Cut off the tapered cable entry to fit cable
diameter required.
5. Turn cable retaining screw (D) anti-clockwise.
Run cable over the main crossbar and
through the cable clamp (C), ensuring there
is ample cable to reach the connectors.
Turn cable clamping screw (D) clockwise to
secure cable and replace clamp (C) into
control panel.
Mains power 230 V connection (ST10):
» Separate wires from cable end and strip to
>
6 mm
» Connect LIVE wire to terminal (L)
» Connect NEUTRAL wire to the terminal (N)
» Connect EARTH wire to the earth connec-
юг (==)
NOTE: Earth cable to be longer so that it
pulls out last if mains cable is snagged.
External controls wiring box (ST10):
Remove link
Connect wiring box LIVE supply to terminal (Ls)
Connect wiring box LIVE return to terminal (LR)
Connect wiring box NEUTRAL to terminal (Ns)
Refit control panel cover:
y ту E y y y y XN
Refit panel and secure with screws (B).
Bring the control panel to its upper position
and fix it with screw (A).
NOTES:
Description of the wiring box see proprietary
Instructions.
External diverter valve (s) and all other 230V
parts are not supplied with the boiler.
A facia mounted programmer/timer should
not be fitted unless optional integral diverter
valve is used (see next page).
Refer to manufacturers instructions when
connecting external parts to the wiring cen-
tre. Worcester Bosch cannot be held
responsible for wiring errors.
ELECTRICAL
(WITHOUT DIVERTER VALVE)
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDI System AMORCESTER
6 720 612 452b (2006/01) Bosch Group
ELECTRICAL (WITH
OPTIONAL DIVERTER VALVE)
CAUTION: ISOLATE THE MAINS
ELECTRICITY SUPPLY BEFORE STARTING
ANY WORK AND OBSERVE ALL
RELEVANT SAFETY PRECAUTIONS
Danger of short circuit: When connecting
LIVE=@ the cables ensure that no cable pieces fall
NEUTRAL =© into the Heatronic.
SWITCHED LIVE =@
Note: Mains supply to the boiler must be
through a fused double pole isolator situated
7.. e Ts 8a Lem TTI ER . adjacent to the appliance. The isolator must
y и” FROST |. ‚” E >, nave а contact separation of 3 mm minimum in
,” THERMOSTAT ты ‚ NO | |
LILI EN и CYLINDER STAT CN Access to electrical connections:
r---777777 7777770000 Г ileal » Remove boiler casing to access control panel.
\ | 4. Lower the control panel into the service
| | > > | position by removing the screw (X} from the
и / retaining bracket.
/ \ / 2. Unscrew the three screws (B) on the back
/ \ / of the control panel and pull off the connec-
> 7 tions cover.
. Unclip cable clamp (C).
Cut off the tapered cable entry to fit cable
diameter required.
8b „er“ al a . 5. Turn cable retaining screw (D) anti-clockwise.
и” | EN Run cable over the main crossbar and
CYLINDER N through the cable clamp (C), ensuring there
” TEMPERATURE SENSOR a is ample cable to reach the connectors.
Turn cable clamping screw (D) clockwise to
secure cable and replace clamp (C) into
control panel.
. Mains power 230 V connection (ST10):
» Separate wires from cable end and strip to
6 mm
» Connect LIVE wire to terminal (L)
» Connect NEUTRAL wire to the terminal (N)
» Connect EARTH wire to the earth connec-
tor ( +)
uccsssonneseesosansenss NOTE: Earth cable to be longer so that it
pulls out last if mains cable is snagged.
7. Optional external frost thermostat connec-
|] tion (ST6):
» Connect frost thermostat supply wire to
terminal (Fs)
» Connect frost thermostat return wire to
terminal (FR)
. Cylinder stat or cylinder temperature sensor:
8a » Hot water channel Volt-free cylinder stat
ST10 (ST8): Cylinder Stat wires to terminals 7
i I and 9.
() _0 © NOTES: Do not break the link on termi-
— | nals 8 and 9.
( ) The cylinder stat must be volt-free, Le. not
О lo” connected to any voltage source,
O Do not set the cylinder stat to tempera-
tures above 70°C, to avoid very long cylin-
der heating periods without CH function.
8b » Hot water cylinder temperature sensor
(ST15):
Connect the included plug to the cable.
Snap out the plastic tongue and insert the
cable.
Insert the plug on the PCB ST15.
10. Refit control panel cover:
» Refit panel and secure with screws (B).
» Bring the control panel to its upper position
and fix it with screw (A).
Lon
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6 720612 458-11.10
AMORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System ELECTRICAL
Bosch Group 6720 612 4586 (2006/01) (WITH OPTIONAL DIVERTER VALVE)
POSITION OF WIRED
FLAME SENSE SPARK
ELECTRODE ELECTRODES
Orange
Orange
FLOW NTC
1 HEAT
— T= EXCHANGER
OVERHEAT
> FAN STAT
=
-5 CC =r &
= А С —
— = С —
Po +
o
о
VALVE FLUE
OVERHEAT
STAT
SAFETY Black
DIVERTER
VALVE
SAFETY (Optional)
Red
SOLENOID e
PUMP pump ie
CONTROL Broce
White
Е Black —
Purple
MAINS
SUPPLY
Earth 4
— PUMP
- SUPPLY
o -
2 Г
WIRING [UU т So
CENTRE E----—- 1 Colour sequence 32 DHW
L_p-____ al 2 TEMPERATURE
ls AA CONTROL
CHTEM- Cl e B| 91D
CONTROL | $9 $ 44H STE 4| OH
1 2| OH
5 ST4 ST19
0 ye ST 1 on
| LF Le Ns Ly A| 0-0)
Г a a —
ST10 Fuse, slow =
SPARK STS —
TRANSFORMER 2.5 A, AC 280 Y НН Red
grange
ST17 Yellow
reen
230 Y EXTERNAL Black
FROST STAT 3
(OPTIONAL) #7
—1
ST9 SF Orange
3
3
3
Fuse, slow T 0.5 A 3
5
«Е 3* ange =
Fuse, slow T1.6 A White
Black
Purple
ST1 0000 DIAGNOSTIC conte
INTERFACE PLUG 6 720 612 458-0610
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System AMORCESTER
6 720 612 452b (2006/01) Bosch Group
POSITION OF WIRED COMPONENTS
6 720 612 458-0710
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ENTOR
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PRE-COMMISSIONING
CHECKS
CAUTION: ISOLATE THE MAINS
SUPPLIES BEFORE STARTING ANY
WORK AND OBSERVE ALL RELEVANT
SAFETY PRECAUTIONS
» 1. Check that the service and water pipes
are connected to the correct position on the
manifold.
A - CH flow (22mm),
B - CH return (22mm),
C - Gas inlet (22mm),
» 2. Check the gas type specified on the iden-
tification plate (F) matches that of the gas
supply. Turn on the main gas supply, check
the gas pipework, connections and rectify
any leaks.
» 3. Check that the pressure relief connector,
located on the right hand side at the bottom
of the wall frame, in its up position.
» 4. Check that the condensate pipe has been
connected to the adapter.
IMPORTANT: If the boiler is not to be com-
missioned immediately then: after sucess-
fully completing all of the checks and any
rectification work, close the gas and water
valves, shut off the gas supply and electri-
cally isolate the boiler.
AMORCESTER INSTALLATION á: SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System
Bosch Group 6 720 612 45%b (2006/01)
PRE-COMMISSIONING CHECKS
nat
Wa
6 720 612 458-08.10
FILLING THE SYSTEM
Ensure all system and boiler drain points are
closed.
For sealed systems fill the system using a
WRAS approved filling loop to a pressure of
1 bar.
Vent all radiators, retighten when completed
and check the system and correct any leaks.
The boiler integral expansion vessel is
precharged to 0.75 bar (equal to a static
head of 7.5 meters [22 ft]). A Schraeder
type valve is fitted to the expansion vessel to
allow for pressure adjustment if required.
If an extra expansion vessel is fitted to the
central heating return, adjust to the same
pressure as the appliance internal expan-
sion tank, refer to separate instructions with
the extra expansion vessel.
Briefly open the pressure relief valve to test
its operation.
Refill the system up to 1 bar.
GAS SUPPLY
>
>
Open gas cock on the boiler and purge the
gas supply to the boiler ensuring that the
room is well ventilated.
Test gas supply for soundness as described
in BS 6891.
FILLING THE SYSTEM
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDI System AMORCESTER
6 720 612 452b (2006/01) Bosch Group
STARTING THE APPLIANCE
IMPORTANT: Never run the appliance
when the appliance/system is empty
or partially filled.
SWITCHING THE APPLIANCE ON/OFF:
1 » Turn on mains power supply.
» Turn on any external controls.
Set the thermostatic radiator controls to
maximum temperature.
Set the clock/programmer to continuously
ON and the room thermostat to maximum
temperature.
DA 2 A- On/off button
= B - On/off and fault indicator (BLUE)
oT = C - Central heating temperature control
D - Burner indicator (GREEN)
FEET E - Reset button
N Ш = F - Service button
a IN || ] G - DHW temperature control (only in
TE | conjunction with optional diverter valve)
ps H - ECO button (only in conjunction with
optional diverter valve)
| - System pressure gauge
J - Cover or optional programmer with
intelligent functionality
6 720612 458-1210
К - Display
L - Central heating boost button
M - Holiday button (only in conjunction with
optional diverter valve)
N - Automatic air vent
» Press button (A) and the power on indica-
tor (B) illuminates BLUE. After a few seconds
the display will show the flow temperature.
3 » Turn the CH temperature control (C) to
maximum. The burner on indicator (D) illumi-
nates GREEN when the burner has lit.
NOTES:
* The first time the appliance Is switched on, a
once-only venting function is activated. The heat-
ing pump then switches on and off at intervals.
This sequence lasts about 8 minutes. The dis-
play shows shows о° in afternation with the CH
flow temperature. The automatic air vent (N)
must be open, please verry.
* The boiler nuns for 15 minutes at mmimum
heating output to fill the condensate trap, the dis-
play (K) alternates between “II-” and the central
heating flow temperature. This occurs every time
the mains supply has been interrupted.
4 » If the boiler fails to light the BLUE power
indicator (B) and reset button (E) will flash
alternately.
To reset press and hold the reset button (E)
ds e” for 2 seconds. The boiler will be reset.
CAUTION: DO NOT PRESS POWER
INDICATOR (B) TO RESET BOILER.
AMORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System STARTING THE APPLIANCE
Bosch Group 6 720 612 45%b (2006/01)
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WATER TREATMENT
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.
ENSURE THAT THE SYSTEM HAS BEEN
CLEANED AS ON PAGE 9 OF THESE
INSTRUCTIONS.
FLUSHING (Central Heating):
1, » Switch off the boiler (A).
> Open all drain cocks (B) and drain the
system (C) while the appliance is hot.
2. » Close drain cocks (D) and add a suitable
flushing agent (E) at the correct strength for
the system condition in accordance with the
manufacturer's instructions.
3. » Run the boiler/system at normal operating
temperature (F) for the time stated by the
manufacturer of the flushing agent (G).
4. » Drain (H) and thoroughly flush the system
to remove the flushing agent and debris (1).
INHIBITOR (Central Heating):
5. » Check drain cocks are closed (J) and all
radiator valves are open (K) before adding a
suitable inhibitor (or combined inhibitor/
anti-freeze if the system is exposed to freez-
ing conditions) to the heating system water
(L) in accordance with the manufacturers
instructions.
6 Fill via a WRAS approved filling loop to
between 1 and 2 bar.
7. » Vent all radiators; retighten vents when
complete (N).
8. » Re-pressurise if necessary to 1 bar (Q).
» Set all controls to maximum (R).
> Record the date when the inhibitor was
added to the system on the guarantee card.
NOTE: The concentration level of inhibitor in
the system should be checked every 12
months or sooner if system content is lost,
The addition of sealing agents to the system
water Is not recommended as this can cause
problems with deposits left in the heat
/ }
a | > te...” exchanger,
A
15
KEY
Valve
Flushing
Agent
О Inhibitor
8720 617 032-0810
* compatible with aluminium. The pH
value of the system water must be less
than 8 or the appliance guarantee will
be invalidated.
W ATER TREATMENT INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30 - ANORCESTER
720612 4536 |
Bosch Group
NOTE: When fitted with the optional COMMISSIONING
diverter valve (not supplied) and run-
ning in central heating boost mode, THE COMBUSTION FOR THE APPLIANCE
the boiler will operate both central IS FACTORY SET.
heating and hot water circuits . NO ADJUSTMENT IS REQUIRED IF THE
If fitted to an S or Y plan system, the GAS INLET PRESSURE IS CORRECT.
system must only be run in central
heating mode. CHECKING GAS INLET PRESSURE:
This is to allow sufficient time for this The inlet pressure to the appliance must be
> part of the commissioning procedure. checked using the following procedure:
SETTING THE BOILER TO MAXIMUM:
1 » Press central heating boost button (L) for
a
ten seconds and set Central Heating tem-
7
Man
perature to maximum.
* The central heating boost button will illumi-
nate continually.
MEASURING THE INLET PRESSURE:
2 » Slacken the screw in the inlet pressure
= Po
test point and connect a manometer.
» Measure the pressure with the boiler
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6 720 612 458-1310
running at maximum.
» Check the gas supply working pressure at
the gas valve inlet point:
Г
Е)
N.G. minimum 18 mbar
“aa L.P.G. 37 mbar
“a » The gas rate should be measured at the
>, gas meter after 10 minutes operation at
N maximum. See technical data section at the
\ front of this manual.
O — om
IN | \ » Ensure inlet pressure is satisfactory with
K
all other gas appliances working.
» Replace controls cover. NOTE: This boiler
is designed with a differential of 20°C
across the heating system.
IMPORTANT: Do not continue
| — — эй |] СО се? «= М i commissioning until the correct
gas inlet pressure is achieved.
» If pressure is satisfactory press the central
heating boost button (L) again and the boil-
er will return to normal operation.
+ If left in the central heating boost mode the
control will return to normal operation after
15 minutes.
» Re-seal the screw in the gas inlet pressure
[
— =
—
test point.
À - On/off button
B - On/off and fault indicator (BLUE)
C - Central heating temperature control
D - Burner indicator (GREEN)
E - Reset button
F - Service button
G - DHW temperature control (only in
conjunction with optional diverter valve)
H - ECO button (only in conjunction with
optional diverter valve)
| - System pressure gauge
J - Cover or optional programmer
К - Display
L - Central heating boost button
M - Holiday button (only in conjunction with
optional diverter valve)
AMORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System COMMISSIONING
Bosch Group 6 720 612 45%b (2006/01)
FINISHING COMMISSIONING
The boiler has been factory set, so there
should be no need to adjust combustion
settings.
REPLACE OUTER CASING:
1 Replace outer casing making sure that the
securing points are properly located.
> Press the clip (A) downwards to secure
casing on top.
» Retighten bottom two screws (В).
INSTALLING BOTTOM PANEL:
2 The bottom panel slides onto two ledges
(C) either side of the boiler frame.
» Hold the panel up against the underside
of the boiler and slide towards the rear until
it is fully engaged.
HANDOVER:
» Complete the Benchmark check list.
> Open the facia cover by gently pressing the
centre top of the cover (D).
» Set up the controls and show the user how
to operate all the controls shown in the User
Guide.
> Place the user guide into the tray (E) on the
inside of the facia cover.
В 720 612 349-0510
If the appliance is unused and exposed to
freezing conditions; shut off all the mains
supplies and drain the system and boiler.
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6 720 612 468-3010
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FINISHING COMMISSIONING INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR SOCO ee AMORCESTER
E 720 617 453b (2006/0 Bosch Group
CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS
SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL
RELEVANT SAFETY PRECAUTIONS.
IMPORTANT: AFTER REPLACEMENT OF ANY COMPONENTS ALWAYS
CHECK FOR GAS SOUNDNESS WHERE RELEVANT AND CARRY OUT
FUNCTIONAL CHECKS AS DESCRIBED IN COMMISSIONING.
ANY O-RING OR GASKET THAT APPEARS DAMAGED MUST BE
REPLACED.
6 720 612 349-0710
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INSPECTION AND SERVICE
IMPORTANT: Any service work must be
carried out by competent registered engi-
neers such as British Gas or Corgi regis-
tered engineer.
* To ensure the continued efficient operation
of the appliance it must be checked at regu-
lar intervals.
+ The frequency of servicing will depend upon
the particular installation conditions and
usage. However, an annual service is rec-
ommended.
* The extent of the service required by the
appliance is determined by the operating
condition of the appliance when tested by
fully qualified engineers.
INSPECTION
1. Check that the terminal and the terminal
guard, if fitted, are clear and undamaged.
2. If the appliance is in a compartment or cup-
board check that the specified service
space around the appliance is clear.
3. Check all the joints and connections in the
system and remake any that show signs of
leakage. Refill and re-pressurise if applica-
ble as described in Commissioning.
» Operate the appliance and take note of
any irregularities. Call up the last fault stored
by the Bosch Heatronic, Service Function
.0. Refer to Fault Finding for rectification
procedures.
4. Please consult Operational Procedures
Part 11, Servicing Policy.
AMORCESTER INSTALLATION á: SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System
Bosch Group 6 720 612 45%b (2006/01)
INSPECTION AND SERVICE
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INSPECTION AND SERVICE
-"
COMPONENT ACCESS
1. Removing outer case
1. Remove bottom panel by pulling it forward
and off.
1.1 Undo but do not remove the 2 screws
(A) securing boiler casing at the bottom of
the appliance.
1.2 Pull upwards to release the clip (B) on top
1.3 |
of the boiler.
1.3 Pull case forward and remove.
5,
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2. Adjusting boiler control to
service position
2.1 Remove screw (X) securing control.
2.2 Gently pull forward until it comes to
rest in service position.
6720612 458-1410
SERVICING
& SPARES
Primary Heat Exchanger
There is a special accessory kit available
specifically designed for cleaning the heat
exchanger. If required order 7 719 001 9986.
3. » Check fan pressure at the test point next
to the fan using an electronic manometer
» The boiler must be run at maximum output.
Pressure will read negative and be greater
than:
3.9 mbar
» Pressures measured below these figures
will indicate that the heat exchanger will
require cleaning.
| N SPECTIO N AN D S E RVICE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDI System AMORCESTER
6 720 612 452b (2006/01) Bosch Group
— — ен
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6 720 612 458-1510
INSPECTION AND SERVICE
Setting Boiler to Maximum.
NOTE: When fitted with the optional diverter
valve (not supplied) and running in central
heating boost mode, the boiler will operate
both central heating and hot water circuits.
If fitted to an S or Y plan system, the system
must only be run in central heating mode.
- On/off button
- On/off and fault indicator (BLUE)
- Central heating temperature control
- Burner indicator (GREEN)
- Reset button
- Service button
G U Q U >
- DHW temperature control (only in
conjunction with optional diverter valve)
H - ECO button (only in conjunction with
optional diverter valve)
| - System pressure gauge
J - Cover or optional text display with
intelligent functionality
K - Display
L - Central heating boost button
M - Holiday button (only in conjunction with
optional diverter valve)
1 » Press and HOLD central heating boost
button (L) for 10 seconds and set Central
Heating temperature to maximum.
* The central heating boost button will illumi-
nate continually.
* The boiler will stay in this mode for 15
minutes unless the central heating boost
button is pressed again.
2 » Pull the cover off and connect a manome-
ter to the fan pressure test point.
» After measurement replace test point
cover.
Pressure will read negative and be greater than:
3.9 mbar
* Pressures measured below these figures
will indicate that the heat exchanger will
require cleaning.
* There 1s a special accessory kit available
specifically designed for cleaning the heat
exchanger. If required order 7 719 001 996.
AMORCESTER INSTALLATION á: SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System
6 720 612 452b (2006/01)
Bosch Group
INSPECTION AND SERVICE
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INSPECTION AND SERVICE
COMBUSTION TESTING MUST BE CARRIED
OUT BY A COMPETENT PERSON. IT MUST
NOT BE ATTEMPTED UNLESS THE PERSON
CARRYING QUT THE COMBUSTION CHECK
IS EQUIPPED WITH A COMBUSTION
ANALYSER CONFORMING TO BS 7927 AND
IS COMPETENTINITS USE,
To Clean the Heat Exchanger
» Remove outer case and base panel and
isolate the appliance from power.
1. » Remove cleaning access cover (B), seal
(C) and metal plate (D) securing it, if pre-
sent.
2.1 » Loosen any deposits in the heat exchanger
from top to bottom using the cleaning blade.
ЕН 2.2» Clean the heat exchanger from top to bot-
/ E D tom using the brush.
= Dé
» Refit the clean out coverplates in reverse
order using a new seal (C) and tighten
screws.
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INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi Syst A
INSPECTION AND SERVICE System WORCESTER
6 720 612 453b (2006/01) Bosch Group
INSPECTION AND SERVICE
pT PO
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To Clean the Burner
1. » Remove cover panel (A) by removing the
screws (B).
» Check that the boiler is completely isolat-
ed from the gas supply.
2. » Remove the clips (C) and unscrew the
two bolts (D).
» Unscrew and remove the two hexagon
М
JE
screws (E) securing the fan.
» Slacken fully the rear securing bolt (F).
» Remove the burner cover plate (G).
3. » Remove the burner (H) and clean compo-
nents. Do not use a wire brush.
a
>»
To Check the Diaphragm
in Burner Cover
4. » Carefully withdraw diaphragm (J) from fan
intake tube and check for soiling and splits.
» Carefully refit diaphragm (J) the correct
way round into the fan intake tube.
Note: The flaps of the diaphragm (J) must
open upwards.
6 720 612 458-1710
» Re-assemble burner in reverse order using
a new seal (K).
» Adjust gas/air ratio. Refer to section
“Setting the gas/air ratio”.
To Clean the Condensate Trap
5.1 » Pull condensate pipe out of the adapter.
5.2» Remove trap from boiler.
» Clean trap and check that the connection
to the heat exchanger is clear.
» Fill the condensate trap with approxi-
mately 1/4 litre of water and refit in reverse
order.
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AMORCESTER INSTALLATION á: SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System
Bosch Group 6 720 612 45%b (2006/01)
INSPECTION AND SERVICE
SERVICING
& SPARES
CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS
SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL
RELEVANT SAFETY PRECAUTIONS.
и = == == == == == == == == = В ооо о о —
6 720 612 458-1810
REPLACEMENT OF PARTS
IMPORTANT: AFTER REPLACEMENT OF
ANY COMPONENTS ALWAYS CHECK FOR
GAS SOUNDNESS WHERE RELEVANT
AND CARRY OUT FUNCTIONAL CHECKS
AS DESCRIBED IN COMMISSIONING.
ANY O-RING OR GASKET THAT APPEARS
DAMAGED MUST BE REPLACED.
1. Removing outer case
1. » Remove bottom panel by pulling it forward
and off.
1.1 » Loosen but do not remove the 2 screws
(A) securing boiler casing at the bottom of
the appliance.
1.2» Pull upwards to release the clip (B) on top
of the boiler.
1.3» Pull case forward and remove.
2. Moving boiler control to service
position
2.1 » Remove screw (X)securing control.
2.2» Gently pull forward.
3. Primary sensor
» Press retaining clip on plastic moulding
and pull upwards until clear of pocket in
heat exchanger.
» Separate sensor from connector, coat
new sensor with heat conductive paste and
replace.
4. Overheat thermostat
» Remove two electrical connectors from
thermostat.
» Unscrew the sensor.
5. Flue limit thermostat
» Remove electrical connections.
» Unscrew thermostat from flue.
6. Expansion Vessel
» Drain the appliance.
6.1 » Remove locking screw (D).
6.2» Undo the union connection (E) at the bot-
tom of the expansion vessel.
» Remove expansion vessel from boiler.
» Set the pressure of the new vessel to that
required by the system.
REPLACEMENT OF PARTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDI System AMORCESTER
6 720 612 452b (2006/01) Bosch Group
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REPLACEMENT OF PARTS
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7. Gas valve
» Isolate gas supply at boiler gas cock.
» Push air inlet tube (A) upwards.
7.1 » Undo top gas connection (B) to gas valve.
71 » Undo bottom gas connection (C) to gas
valve.
7.2» Undo two securing screws (D) on the
underside of casing.
» Pull valve up and forward out of boiler.
» Disconnect electrical connections,
» Replace valve with new seals and check
for gas soundness.
Note: The valve will require setting, follow pro-
cedure “Setting the gas/air ratio” in the gas
conversion section.
8. Siphon
8.1 » Pull condensate pipe out of the adapter.
8.2» Remove trap from boiler.
» Clean trap and check that the connection
to the heat exchanger is clear.
» Fill the condensate trap with approxi-
mately 1/4 litre of water and refit in reverse
order.
LANORCESTER
Bosch Group
INSTALLATION á: SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System
6 720 612 452b (2006/01)
REPLACEMENT OF PARTS
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REPLACEMENT OF PARTS
9. Access to boiler control
components
» Remove 3 screws (A) and remove
cover from control.
10. PCB fuse
» Remove fuse (B) from the PCB and
replace.
» There is a spare fuse clipped into the
cover.
11. Transformer / PCB
» Disconnect all electrical connections
from the control.
» Remove 5 screws (C) retaining the
rear panel of the control and remove
panel.
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SERVICING
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R E PLACE M E NT O F PARTS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System AMORCESTER
6 720 612 452b (2006/01) Bosch Group
REPLACEMENT OF PARTS
IMPORTANT: AFTER REASSEMBLY
THE COMBUSTION MUST BE
CHECKED USING THE PROCE-
THE GAS AIR RATIO”. MEASURE-
SARY) OF THE GAS RATIO MUST
NOT BE ATTEMPTED UNLESS THE
PERSON IS EQUIPPED WITH A
COMBUSTION ANALYSER CON-
FORMING TO BS 7927 AND IS COM-
PETENT IN ITS USE.
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13.
Fan assembly
» Remove electrical connector from fan.
» Remove condensate trap
(see page 39).
» Undo the union connection (A).
» Remove wire clip (B) from air/gas
adjustment assembly (C) then pull gas
pipe down.
» Unscrew two screws (D).
» Remove fan from boller.
» Remove three screws retaining the
air/gas adjustment assembly (E).
» Reassemble with new fan assuring that
seals are correctly fitted.
Electrode assembly
» Disconnect spark electrodes and flame
sensor connection.
» Remove two screws (F).
» Remove spark/flame electrode assem-
bly (G) from heat exchanger.
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AMORCESTER INSTALLATION á: SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System
Bosch Group 6 720 612 45%b (2006/01)
REPLACEMENT OF PARTS
SERVICING
& SPARES
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6 720 612 458-2210
REPLACEMENT OF PARTS
14.
14.1
14.2
14.3
14.4
15.
Air/gas manifold
» Remove cover panel (A) by removing
the screws (B).
» Check that the boiler is completely iso-
lated from the gas supply.
» Remove the clips (C) and unscrew the
two bolts (D).
» Unscrew and remove the two hexagon
screws (E) securing the fan.
» Slacken fully the rear securing bolt (F).
» Remove air/gas manifold (I)
» Open air/gas manifold (1).
» Carefully withdraw diaphragm (J) from
fan intake tube and check for soiling and
splits.
Burner
» Remove the burner (H).
» Replace new burner in correct posi-
tion.
» Ensure that a new seal (K) is used.
REPLACEMENT OF PARTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDI System AMORCESTER
6 720 612 452b (2006/01) Bosch Group
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REPLACEMENT OF PARTS
16.
16.1
16.2
16.3
16.4
Heat exchanger
» Isolate flow and return valves and drain
the boiler.
» Remove condensate trap
(see page 39).
» Remove fan assembly (see page 43).
» Remove plastic nut (A) from the base
of the inner casing.
» Remove return pipe (B) at the bottom
of heat exchanger.
» Remove screw at the top of the heat
exchanger (C).
» Unscrew the flow pipe (D).
» Undo flue connection (E) from
sump (F).
» Pull flue pipe up.
» Remove the heat exchanger.
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AMORCESTER INSTALLATION á: SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System
Bosch Group 6 720 612 45%b (2006/01)
REPLACEMENT OF PARTS
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» Disconnect the electrical connector
7 17. Diverter valve motor (if fitted)
у There is no need to drain the appliance.
/ » Disconnect the electrical connector
/ from the diverter valve motor.
| 171 » Pull the motor assembly (A) towards
\ you. The assembly will slide free from the
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\ | A = / » To refit, follow the above in reverse.
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AN 0 eL = a > Note: In case of problems when refitting
NE MRS | |
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6 U FE 18. Diverter valve
ADD N Wel à » Ensure the appliance has been fully
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» Undo the two screws holding the valve
to the plastic housing.
18.1 » Withdraw the valve (B) and clean the
valve chamber if necessary.
» To refit, follow the above in reverse.
Ensure any seals that have been dis-
turbed are renewed.
19. Auto air vent
» Ensure the appliance has been fully
drained.
191 » Use a screwdriver or similar to rotate
the air vent anticlockwise.
» Lift the air vent (C) out of the housing
and remove.
19.2
» To refit, follow the above in reverse.
REPLACEMENT OF PARTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDI System AMORCESTER
6 720 612 452b (2006/01) Bosch Group
on WE EE EE
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21.2
21.3
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25.
25.1
25.2
Pump head
» Ensure the appliance has been fully
drained.
» Disconnect the electrical connections
from the pump following steps 1 to 4.
» Remove the four Allen bolts (A) secur-
ing the pump at each corner.
» Gently pull the pump towards you and
remove,
» To refit, follow the above in reverse.
Pressure gauge
» Ensure the appliance has been fully
drained.
» Withdraw the spring clip from the pres-
sure sensing head housing.
» Undo the nut on the rear of the pres-
sure gauge.
» Remove the pressure sensing head
and pressure gauge capillary from the
housing.
» To refit, follow the above in reverse.
DO NOT omit the washer from the capil-
lary when fitting a replacement gauge.
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Drain tap
» Ensure the appliance has been fully
drained.
» Rotate the drain tap fully anticlockwise.
» Withdraw the drain tap from its housing.
» To refit, follow the above in reverse.
Ensure any seals that have been dis-
turbed are renewed.
AMORCESTER INSTALLATION á: SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System
Bosch Group 6 720 612 45%b (2006/01)
REPLACEMENT OF PARTS
REPLACEMENT OF PARTS
26. Hydraulic Block
» Ensure the appliance has been fully
drained.
» Disconnect the electrical connections
to the NTC, Turbine and pump.
» Undo the nuts securing the copper
water pipes to the manifold (there is no
need to remove the gas pipe).
» Release the spring clips securing
these water pipes to the plastic housing
and remove the pipes.
» Release the spring clip securing the
expansion vessel pipe to the plastic
housing and remove the pipe.
» Undo the nut securing the pressure
gauge to its bracket and remove the
gauge.
» Release the locking devices that
secure the two copper water pipes lead-
ing to the combustion chamber by
squeezing the two tabs together and
rotating anticlockwise (viewed from
above).
26.1 » Undo the two screws securing the
hydraulic block to the chassis (located
top left/top right of the housing).
26.2 » Lift the left hand side of the block
slightly, then manoeuvre the block out,
starting with the right hand side.
» Take care not to snag the harness or
pressure gauge bracket.
NOTE: the block will still contain a small
amount of water, which will spill if the
block is tilted.
» To refit, follow the above in reverse.
Ensure any seals that have been dis-
turbed are renewed.
27. CH pressure relief valve
» Remove the Hydraulic block from the
boiler (See Removing the Hydraulic
Block).
271 » Remove the spring clip from the
Pressure relief valve housing.
27.2 » Withdraw the pressure release valve
(A) from its housing.
» To refit, follow the above in reverse.
Ensure any seals that have been dis-
SERVICING
& SPARES
turbed are renewed.
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INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System AMORCESTER
6 720 612 452b (2006/01) Bosch Group
REPLACEMENT OF PARTS
THE SETTING OF THE GAS RATIO MUST BE CARRIED OUT BY A COMPETENT PERSON.
SETTING OF THE GAS RATIO MUST NOT BE ATTEMPTED UNLESS THE PERSON CARRYING QUT
THE CONVERSION IS EQUIPPED WITH A COMBUSTION ANALYSER CONFORMING TQ BS 7927
AND IS COMPETENT IN ITS USE.
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SETTING THE GAS/AIR RATIO
5. Setting the CO,
NOTE: When fitted with the optional diverter
valve (not supplied) and running in central
heating boost mode, the boiler will operate
both central heating and hot water circuits. This
is to allow sufficient time for the setting proce-
dure.
If fitted to an 5 or Ÿ plan system, the system
must only be run in central heating mode.
5.1» Connect manometer to inlet pressure
point on the gas valve.
» To adjust the COg it will be necessary to
first operate the boiler at maximum output,
> Press and hold down the central heating
boast button (A) for 10 seconds until illumi-
nated.
5.2» Turn central heating control to maximum;
the boiler will then go to maximum output.
Note: The control will resume normal opera-
tion after 15 minutes or if the central heating
boost button is pressed for over a second,
5.3» Using a flat blade screwdriver set the
COs via adjuster (B) using table below.
Note: CO 5 should be measured 10 minutes
after firing the appliance.
Gas type CO, setting | CO, setting
maximum minimum
Natural gas 9.6 % +02 9.0% +02
LPG 11.5 96 +02 10.5 % +02
» Check CO is less than 200 ppm.
» Measure the inlet pressure; it should be a
minimum of 18 mbar for natural gas and
37 mbar for LPG.
5.4» Set the central heating control to mini-
mum. This will make the boiler go to mini-
mum power.
5.5» Measure the CO»; it should now be at the
figure for minimum output. If not adjust (C)
on the gas valve until correct.
» Return to maximum and re-check the
CO». If correct press and hold down the
07
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central heating boost button for 2 seconds;
the button will cease to be illuminated and
the blue power indicator will be permanently
illuminated.
» Remove manometer and re-seal inlet pres-
sure point on gas valve.
> Fit new plastic sealing cover on to outlet
adjuster (B).
» Fit white cover over valve adjuster (C) and
secure with black security tag.
» Remove red arrow from data plate and fit
new one in correct position for gas type.
» Re-assemble and refit boiler case.
» Re-connect mains electrical supply and
check boiler operation as stated in the com-
missioning section.
» Fit new label from kit over existing label on
the appliance bottom panel.
WORCESTER INSTALLATION & SERVICING INSTRUCTIONS
Bosch Group Me MLR eM
SETTING THE GAS/AIR RATIO
SHORT PARTS LIST
1 Fan
Part No. 8 717 204 453 0
GC No. H26 536
2 Burner
Part No. 8 718 006 658 0
GC No. E27 200
3 Burner skin seal
Part No. 8 711 004 168 0
GC No. E27 201
4 Gas valve
Part No. 8 716 107 053 0
GC No. H26 539
5 Temperature limit sensor
Part No. 8 722 963 858 0
GC No, HO8 291
6 Electrodes
Part No. 8 718 107 0890
GC No. H22 458
7 Pump assembly
Part No, 8 716 106 3540
GC No. H22 463
8 Pressure gauge
Part No. 8 717 208 107 0
GC No. HO? 528
9 Diverter valve assembly
Part No. 8 716 106 845 0
GC No. H02 533
10 Diverter valve motor
Part No. 8 716 106 847 0
GC No, HO? 534
11 Control sensor - primary
Part No. 8 714 500 0870
GC No. E74 536
12 Service booklet
Part No. 6 720 612 361 0
GC No, TO BE CONFIRMED
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6 720 612 452b (2006/01) Bosch Group
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L.P.G. CONVERSION
ISOLATE MAINS ELECTRICAL
SUPPLY AND REMOVE OUTER CASE
AS SHOWN IN THE INSTALLATION,
COMMISSIONING & SERVICING
INSTRUCTIONS
THE CONVERSION MUST BE CARRIED OUT
BY A COMPETENT PERSON. IT MUST NOT
BE ATTEMPTED UNLESS THE PERSON
CARRYING OUT THE CONVERSION 15
EQUIPPED WITH A COMBUSTION ANALYSER
CONFORMING TO BS 7927 AND 15
COMPETENT IN ITS USE.
Important: The appliance shall not be installed
Into a room or Internal space below ground
level when It is intended for use with LPG
(propane - G31). This does not preclude the
Installation into a room or space which 1s a
basement on one side of the building but open
to ground on the opposite side.
Installation Regulations
In addition to those specified in the main
booklet the following standard applies when
converting to an LPG appliance: BS 5842
Domestic Propane Gas Burning
Installations.
All conversions will require the air gas ratio to
be set correctly for the gas used. The
procedure for setting the air gas ratio is at
the rear of these instructions.
1. Moving boiler control to service
position
» Remove boiler case, as described on
page 36.
1.1 » Remove screw (X) from retaining bracket.
1.2» Lower control panel into service position.
2. Code plug
2.1 » Remove 3 screws (D) retaining plastic
cover at rear of control box and remove.
2.2» Replace code plug (E) with new one sup-
plied with conversion kit.
Gas type Code plug | Diverter valve
No. installed
Natural Gas | 1018 No
LPG 1019 No
Natural Gas | 1002 Yes
LPG 1003 Yes
» Replace plastic cover.
» Place control in normal position and
secure with screw.
THE GAS / AIR RATIO MUST BE
RESET AFTER CONVERSION. THE
PROCEDURE CAN BE FOUND IN
THE REPLACEMENT PARTS
SECTION OF THIS MANUAL.
AMORCESTER INSTALLATION á: SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System
Bosch Group
6 720 612 452b (2006/01)
L.P.G. CONVERSIÓN
CONVERSION
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& DIAGRAMS
FAULT FINDING
NOTE: This fault finding information is for guidance only. Worcester Bosch cannot be held responsible for costs incurred by persons not deemed to
be competent.
The electronic control system for this boiler incorporates a blue central indicator. This normally confirms the permanent mains supply but, by flashing
during a fault, provides a guide to the cause as listed.
This fault finding system assumes that the appliance has been operating normally until the time of failure (i.e. not a first installation error).
PRELIMINARY CHECKS: Preliminary electrical system checks are the first electrical checks to be carried out during a fault-finding procedure.
On completion of the Service/Fault-Finding task which has required the breaking and remaking of electrical connections, check
(a) EARTH CONTINUITY, (b) SHORT CIRCUIT CHECK, (c) POLARITY and (d) RESISTANCE TO EARTH.
An optional text display is avaliable which gives a text description of the service functions of the boiler
Display code Description Remedy
A7 Hot water NTC sensor defective. Check hot water NTC sensor and connecting lead for
circuit breaks/short circuits,
A8 Break in communication to TD200 or/and RT10. Check electrical connections.
b1 Code plug not detected. Insert code plug correctly, test and replace if necessary.
C6 Fan speed too low. Check fan lead and connector, and fan; replace as
necessary.
E2 CH flow NTC sensor defective. Check CH flow NTC sensor and connecting lead.
ES Safety temp. limiter in CH flow has tripped. Check system pressure, check safety temp. limiters,
check pump operation, check fuse on pcb, bleed appli-
ance.
EA Flame not detected. Is gas cock turned on? Check gas supply pressure,
power supply, igniter electrode and lead, ionisation
sensing electrode and lead, flue duct and CO level.
FO Internal error. Check electrical connector contacts, programmer inter-
face module ignition leads are not loose; replace pcb if
necessary.
F7 Flame detected even though appliance switched off. Check electrode assembly, dry pcb. Flue clear?
FA Flame detected after gas shut off. Check gas valve and wiring to gas valve. Clean conden-
sation trap and check electrode assembly. Flue clear?
Fd Reset button pressed by mistake. Press reset button again.
More detailed fault finding procedures are described in the Service booklet for the Engineer number 6 720 612 361.
FAULT FINDING
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDI System AMORCESTER
6 720 612 452b (2006/01) Bosch Group
CENTRAL HEATING FUNCTION
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Bosch Group
6 720 612 453b (2006/01)
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System AMORCESTER
CYLINDER HEAT FUNCTION
PROTECTION FUNCTION
Boiler temperature Run autofroststat
below 8°C function
Pump run 5 seconds
Pump antiseize >> every 24hrs
> DHW demand active
Holiday mode
set 2 ON* »| Frost protection active
All other demands not
active
у
* The holiday mode is available only with the optional diverter valve fitted.
& DIAGRAMS
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AMORCESTER INSTALLATION á: SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 30CDi System PROTE CTIO N F U NCTIO N
Bosch Group 6 720 612 45%b (2006/01)
INSTRUCTION MANUAL
INSTALLATION, COMMISSIONING
& SERVICING
EXCELLENCE COMES AS STANDARD
Worcester, Bosch Group
Cotswold Way, Warndon, Worcester WR4 95W.
Tel. 01905 754624 Fax. 01905 754619
Worcester, Bosch Group 1s a trading name of
BBT Thermotechnology UK Ltd.
www.worcester-bosch.co.uk
6 720 612 453b (2006/01) OSW
Zea
Bosch Group
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