Bosch GREENSTAR 30CDi Installation, Commissioning And Servicing Instructions

[Page 1] Bosch GREENSTAR 30CDi System

UK/IE INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS WALL HUNG RSF GAS FIRED CONDENSING REGULAR BOILER GREENSTAR CDi CLASSIC REGULAR FOR OPEN VENTED AND SEALED CENTRAL HEATING SYSTEMS AND INDIRECT DOMESTIC HOT WATER 6 720 806 548 (2013/02) T...

[Page 2] Bosch GREENSTAR 30CDi System

CONTENTS 6 720 806 548 (2013/02)2 CONTENTS 1 KEY TO SYMBOLS AND SAFETY PRECAUTIONS . . . . . . . . . . . . 3 1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.2 Safety precautions . . . . . . . . . . . . . . ....

[Page 3] Bosch GREENSTAR 30CDi System

KEY TO SYMBOLS AND SAFETY PRECAUTIONS 6 720 806 548 (2013/02) 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: • NOTE indicates a situation that could result...

[Page 4] Bosch GREENSTAR 30CDi System

KEY TO SYMBOLS AND SAFETY PRECAUTIONS 6 720 806 548 (2013/02)4 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 appro...

[Page 5] Bosch GREENSTAR 30CDi System

APPLIANCE INFORMATION 6 720 806 548 (2013/02) 5 2 APPLIANCE INFORMATION 2.1 GENERAL INFORMATION Fig. 1 Overall dimensions Fig. 2 Standard package STANDARD PACKAGE: 1 Wall hung gas fired condensing regular boiler for central heating and domestic hot ...

[Page 6] Bosch GREENSTAR 30CDi System

APPLIANCE INFORMATION 6 720 806 548 (2013/02)6 2.2 TECHNICAL DATA NATURAL GAS L.P.G DESCRIPTION UNITS 30CDi 40CDi 30CDi 40CDi Heating Max. rated heat input kW 30.9 42.0 30.9 42.0 Max. rated heat output net 40/30°C kW 32.1 43.7 32.1 43.7 Max. rated...

[Page 7] Bosch GREENSTAR 30CDi System

PRE-INSTALLATION 6 720 806 548 (2013/02) 7 2.3 LAYOUT & COMPONENTS Fig. 3 Boiler layout and components The diagram above shows the controls in the servicing position and excludes the outer case. 1. FLAME VIEWING WINDOW 2. IGNITION ELECTRODE AND ...

[Page 8] Bosch GREENSTAR 30CDi System

PRE-INSTALLATION 6 720 806 548 (2013/02)8 ▶ Run the boiler/system at normal operating temperature as directed by the manufacturer of the flushing agent. ▶ Drain and thoroughly flush the system to remove the flushing agent and debris. ▶ It may...

[Page 9] Bosch GREENSTAR 30CDi System

PRE-INSTALLATION 6 720 806 548 (2013/02) 9 S AND Y PLAN SYSTEM: SYSTEM LAYOUT: S PLAN LAYOUT Fig. 5 S plan Y PLAN LAYOUT Fig. 6 Y plan SEALED SYSTEM LAYOUT Fig. 7 Sealed system NEW BUILD SYSTEM LAYOUTS The latest Part L1a regulation for new installat...

[Page 10] Bosch GREENSTAR 30CDi System

PRE-INSTALLATION 6 720 806 548 (2013/02)10 3.4 CONDENSATE PIPE WORK 3.4.1 INTERNAL CONNECTIONS In order to minimise risk of freezing during prolonged cold spells, the following methods of installing condensate drainage pipe should be adopted, in or...

[Page 11] Bosch GREENSTAR 30CDi System

PRE-INSTALLATION 6 720 806 548 (2013/02) 11 3.4.2 EXTERNAL CONNECTIONS If no other discharge method is possible then the use of an externally run condensate drainage pipe terminating at a suitable foul water discharge point, or purpose-designed soa...

[Page 12] Bosch GREENSTAR 30CDi System

PRE-INSTALLATION 6 720 806 548 (2013/02)12 In situations where there are likely to be extremes of temperature or exposure, the use of a proprietary trace-heating system for external pipe work, incorporating an external frost thermostat, should be c...

[Page 13] Bosch GREENSTAR 30CDi System

PRE-INSTALLATION 6 720 806 548 (2013/02) 13 BATHROOMS: Additional RCD (Residual Current Device) protection may be required. Refer to the latest IEE wiring regulations. BATHROOM INSTALLATIONS Fig. 17 Bathroom installations 3.6 PLUMBING MANIFOLD CONNEC...

[Page 14] Bosch GREENSTAR 30CDi System

PRE-INSTALLATION 6 720 806 548 (2013/02)14 3.7 FLUE OPTIONS The Greenstar CDi has the option of three horizontal RSF (60/100 telescopic, 60/100 longer telescopic and 80/125 telescopic) flue systems and two vertical RSF (60/100 or 80/125) regular fl...

[Page 15] Bosch GREENSTAR 30CDi System

PRE-INSTALLATION 6 720 806 548 (2013/02) 15 350 mm - 570 mm 130 mm Min Flat roof 300 mm 500 mm Pitched roof 2 3 4 5 6 10 9 8 7 1 6720643895-12.1Wo ...

[Page 16] Bosch GREENSTAR 30CDi System

PRE-INSTALLATION 6 720 806 548 (2013/02)16 3.8 FLUE TERMINAL POSITIONS Fig. 19 Flue terminal positions Key to illustration 1. 300mm adjacent to a boundary line. 2. The dimension below eaves, balconies and car ports can be reduced to 25mm, as long as...

[Page 17] Bosch GREENSTAR 30CDi System

PRE-INSTALLATION 6 720 806 548 (2013/02) 17 3.9 PLUME MANAGEMENT TERMINAL POSITIONS Fig. 20 Plume terminal positions Key to illustration 1. This feature allows some basic plume re-direction options on a standard telescopic horizontal flue terminal. ...

[Page 18] Bosch GREENSTAR 30CDi System

INSTALLATION 6 720 806 548 (2013/02)18 4 INSTALLATION 4.1 UNPACKING WALL FRAME AND ANCILLARY ITEMS LIFTING AND CARRYING PRECAUTIONS: IMPORTANT HANDLING INSTRUCTIONS • It is advised that two people are used to carry the carton from the van to the p...

[Page 19] Bosch GREENSTAR 30CDi System

INSTALLATION 6 720 806 548 (2013/02) 19 4.2 WALL MOUNTING PLATE FLUE OPENING SAFETY: All relevant safety precautions must be undertaken. Protective clothing, foot wear, gloves and safety goggles must be worn as appropriate. FIXING THE POSITION OF TH...

[Page 20] Bosch GREENSTAR 30CDi System

INSTALLATION 6 720 806 548 (2013/02)20 4.3 UNPACKING THE APPLIANCE 1. With the wall frame and ancillary items removed, 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 ...

[Page 21] Bosch GREENSTAR 30CDi System

INSTALLATION 6 720 806 548 (2013/02) 21 4.4 FITTING THE APPLIANCE BOILER CONNECTIONS GAS AND WATER CONNECTIONS: • If there is greater than 600mm clearance below the appliance it is possible to fit the flow and return pipes, supplied, with the boil...

[Page 22] Bosch GREENSTAR 30CDi System

INSTALLATION 6 720 806 548 (2013/02)22 4.5 FLUE INSTALLATION HORIZONTAL FLUE (60/100mm diameter) For vertical flues and 80/125mm horizontal flues, please refer to separate Flue Kit instructions. Fig. 28 4.5.1 Ø60/100MM TELESCOPIC FLUE KIT: Standard...

[Page 23] Bosch GREENSTAR 30CDi System

INSTALLATION 6 720 806 548 (2013/02) 23 4.5.4 INSTALLING THE STANDARD FLUE 1. Set the flue length to the distance required, secure with screw and seal joint with the aluminium tape supplied. Slide the inner wall seal (1) onto the terminal (2) as sh...

[Page 24] Bosch GREENSTAR 30CDi System

INSTALLATION 6 720 806 548 (2013/02)24 Fig. 36 Plume distance to opening 4.6 CONDENSATE CONNECTION Never terminate or discharge into any open source, including; sink, bath, shower, bidet, toilet etc. • Ensure that the condensate drain is 22 mm dia...

[Page 25] Bosch GREENSTAR 30CDi System

INSTALLATION 6 720 806 548 (2013/02) 25 Fig. 37 Control panel access 8. External Pump (ST2): ▶ Connect NEUTRAL wire to terminal (Nz) ▶Connect LIVE wire to terminal (Lz) ▶ Connect EARTH wire to earth bracket (E) 9. Refit control panel cover: ▶...

[Page 26] Bosch GREENSTAR 30CDi System

INSTALLATION 6 720 806 548 (2013/02)26 4.8 POSITION OF WIRED COMPONENTS Fig. 39 Wired components EXTERNAL PUMP FSFR NP LP NZ LZ L N S N L SLR ST8 ST2 ST9 ST18 ST5 ST4 ST10 Earth MAINS SUPPLY PUMP SUPPLY SPARK TRANSFORMER FLAME SENSE ELECTRODE SPARK ...

[Page 27] Bosch GREENSTAR 30CDi System

COMMISSIONING 6 720 806 548 (2013/02) 27 5 COMMISSIONING 5.1 PRE-COMMISSIONING CHECKS 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. ...

[Page 28] Bosch GREENSTAR 30CDi System

COMMISSIONING 6 720 806 548 (2013/02)28 5.4 STARTING THE APPLIANCE 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/...

[Page 29] Bosch GREENSTAR 30CDi System

COMMISSIONING 6 720 806 548 (2013/02) 29 5.6.1 CHECKING THE GAS INLET PRESSURE The inlet pressure to the appliance must be checked using the following procedure: MEASURING THE INLET PRESSURE Fig. 43 Inlet pressure test point ▶ Close gas isolation ...

[Page 30] Bosch GREENSTAR 30CDi System

COMMISSIONING 6 720 806 548 (2013/02)30 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 ...

[Page 31] Bosch GREENSTAR 30CDi System

SERVICING AND SPARES 6 720 806 548 (2013/02) 31 6 SERVICING AND SPARES 6.1 INSPECTION AND SPARES • To ensure the continued efficient operation of the appliance it must be checked at regular intervals. • The frequency of servicing will depend upo...

[Page 32] Bosch GREENSTAR 30CDi System

SERVICING AND SPARES 6 720 806 548 (2013/02)32 6.1.1 FAN PRESSURE TEST SET THE BOILER TO MAXIMUM Fig. 50 Control panel [1] Display [2] Reset button [3] Not used [4] Not used [5] ON/OFF and fault indicator (Blue) [6] Central heating temperature contro...

[Page 33] Bosch GREENSTAR 30CDi System

SERVICING AND SPARES 6 720 806 548 (2013/02) 33 3. Clean the heat exchanger from top to bottom using the brush. ▶ Refit the clean out cover plates in reverse order using a new seal (C) and tighten screws. 6.1.3 TO CLEAN THE BURNER 1. Remove cover ...

[Page 34] Bosch GREENSTAR 30CDi System

SERVICING AND SPARES 6 720 806 548 (2013/02)34 ▶ Fill the condensate trap with approximately 250 millilitres of water and refit in reverse order Fig. 55 Siphon removal 6.2 SETTING THE AIR/GAS RATIO SETTING THE CO 2 1. Connect manometer to inlet te...

[Page 35] Bosch GREENSTAR 30CDi System

SERVICING AND SPARES 6 720 806 548 (2013/02) 35 6.3 REPLACEMENT OF PARTS Removing outer case 1. Remove bottom panel by pulling it forward and off. 2. Loosen but do not remove the two screws (A) securing boiler casing at the bottom of the appliance. ...

[Page 36] Bosch GREENSTAR 30CDi System

SERVICING AND SPARES 6 720 806 548 (2013/02)36 Fig. 59 Sensors 7. GAS VALVE ▶ Isolate gas supply at boiler gas cock. ▶ Pull out air inlet tube (A). ▶ Undo top gas connection (B) to gas valve. ▶ Undo bottom gas connection (C) to gas valve. ▶...

[Page 37] Bosch GREENSTAR 30CDi System

SERVICING AND SPARES 6 720 806 548 (2013/02) 37 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...

[Page 38] Bosch GREENSTAR 30CDi System

SERVICING AND SPARES 6 720 806 548 (2013/02)38 ▶ Re-assemble with the new gasket and secure with the screws (F) removed earlier. Fig. 65 Electrode assembly 14. AIR/GAS MANIFOLD 1. Remove cover panel (A) by removing screws (B). ▶ Check that the b...

[Page 39] Bosch GREENSTAR 30CDi System

SERVICING AND SPARES 6 720 806 548 (2013/02) 39 1. Remove plastic nut (A) from the base of the inner casing Fig. 71 Heat exchanger removal 1 2. Remove return pipe at the bottom of heat exchanger. Fig. 72 Heat exchanger removal 2 3. Remove screw at...

[Page 40] Bosch GREENSTAR 30CDi System

SERVICING AND SPARES 6 720 806 548 (2013/02)40 6.4 SHORT PARTS LIST Fan 8 717 204 453 0 GC No. H26 536 Burner 8 718 006 658 0 GC No. E27 200 Burner skin seal 8 711 004 166 0 GC No. E27 201 Gas valve 8 718 221 347 0 GC No. H56 469 Temperature limit s...

[Page 41] Bosch GREENSTAR 30CDi System

FAULT FINDING & DIAGNOSIS 6 720 806 548 (2013/02) 41 7 FAULT FINDING & DIAGNOSIS 7.1 FAULT FINDING The electronic control system for this boiler incorporates a blue central indicator. This normally confirms the permanent mains supply but, by...

[Page 42] Bosch GREENSTAR 30CDi System

FAULT FINDING & DIAGNOSIS 6 720 806 548 (2013/02)42 7.3 HEATING FUNCTION POWER SWITCH ON BLUE LIGHT ON GREEN FLAME LIGHT ON END OF BOILER DEMAND BOILER DEMAND LOCKOUT BURNER LIT? IGNITION SEQUENCE IGNITION SEQUENCE (see details) YES YES NO NO 3 ...

[Page 43] Bosch GREENSTAR 30CDi System

6 720 806 548 (2013/02) 43 NOTES ...

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6 720 806 548 (2013/02)44 ...

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[Page 46] Bosch GREENSTAR 30CDi System

Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect the customer’s statutory rights. If yes, and if required by the...

[Page 47] Bosch GREENSTAR 30CDi System

Service Record It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out...

[Page 48] Bosch GREENSTAR 30CDi System

Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0844 892 9900 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. worcester-bosch.co.uk 6 720 806 548 (2013/02) WORCESTER, BOSCH GROUP: TECHNICAL SUPPORT: 0844 89...