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  4. 29CDi GC 47-406-34
  5. Installation, Commissioning And Servicing Instructions

Worcester 29CDi GC 47-406-34 Installation, Commissioning And Servicing Instructions

Manual is about: WALL HUNG RSF GAS FIRED CONDENSING COMBINATION BOILER

Summary of 29CDi GC 47-406-34

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    Uk/ie installation commissioning and servicing instructions wall hung rsf gas fired condensing combination boiler greenstar cdi classic for sealed central heating systems and mains fed domestic hot water 6 72 0 803 599 (2012/06) the appliances are for use with: natural gas or l.P.G. (cat. Ii type c1...

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    Contents 6 720 803 599 (2012/06) 2 contents 1 key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.1 key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.2 safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . ....

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    Key to symbols 6 720 803 599 (2012/06) 3 1 key to symbols 1.1 key to symbols warnings the following keywords are defined and can be used in this document: • note indicates a situation that could result in damage to property or equipment. • caution indicates a situation that could result in minor to ...

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    Key to symbols 6 720 803 599 (2012/06) 4 manufacturer's instructions by competent persons and that it meets the requirements of the appropriate building regulations. The benchmark checklist can be used to demonstrate compliance with building regulations and should be provided to the customer for fut...

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    Appliance information 6 720 803 599 (2012/06) 5 2 appliance information 2.1 general information fig. 1 overall dimensions fig. 2 standard package standard package: a wall hung gas fired condensing combi boiler for central heating and domestic hot water b wall mounting plate c hanging bracket d pre-p...

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    Appliance information 6 720 803 599 (2012/06) 6 2.2 layout & components fig. 3 boiler components 1 2 3 4 5 6 8 15 9 10 11 13 12 14 16 17 20 23 24 25 26 27 28 29 22 21 18 19 7 6720647361-03.1w o.

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    Appliance information 6 720 803 599 (2012/06) 7 fig. 4 hydraulics fig. 5 control panel the diagram opposite shows the controls in the servicing position and excludes the outer case 1 flame viewing window 2 ignition electrodes and flame sense electrode 3 heat exchanger 4 overheat thermostat 5 access ...

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    Appliance information 6 720 803 599 (2012/06) 8 2.3 technical data natural gas l.P.G description units 29 34 38 42 29 34 38 42 domestic hot water min. Heat input kw 8.0 8.0 9.8 9.8 11.5 11.5 14.5 14.5 max. Rated heat output kw 30.9 35.0 40.0 42.0 30.9 35.0 40.0 42.0 max. Rated heat input kw 30.9 35....

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    Pre-installation 6 720 803 599 (2012/06) 9 3 pre-installation 3.1 cleaning primary systems before cleaning the system: b ensure that the system and pipe work is in good working order. B where possible keep the existing boiler/circulating pump in place when flushing the system. Follow the guidance of...

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    Pre-installation 6 720 803 599 (2012/06) 10 use in hard water areas: normally there is no need for water treatment to prevent scale formation as the maximum temperature of the hw heat exchanger is limited by the electronic control. In areas where temporary water hardness exceeds 200 ppm, considerati...

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    Pre-installation 6 720 803 599 (2012/06) 11 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 order of priority. Wherever possible, the condensate ...

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    Pre-installation 6 720 803 599 (2012/06) 12 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 soak away, may be considered. If this method is chosen ...

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    Pre-installation 6 720 803 599 (2012/06) 13 fig. 14 soak away fig. 15 condensate pump to external disposal 3.5 pressure relief pipe work • the pressure relief drain pipe (1) from the boiler should be at least 15mm diameter copper pipe and run downwards, away from any electrical equipment or other ha...

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    Pre-installation 6 720 803 599 (2012/06) 14 servicing clearances compartments follow the requirements of bs6798 and bs5440 part 2 and note: • minimum clearances must be maintained. • an access door is required to install, service and maintain the boiler and any ancillary equipment. • if fitting the ...

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    Pre-installation 6 720 803 599 (2012/06) 15 3.7 plumbing manifold connections: heating system: 22mm compression fittings dhw: 15mm compression fittings gas: 22mm compression fittings use the fittings supplied in the hardware pack. 1. Ch flow 22 mm 2. Dhw out 15 mm 3. Mains gas supply 22 mm 4. Mains ...

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    Pre-installation 6 720 803 599 (2012/06) 16 3.8 flue options the greenstar cdi has the option of three horizontal rsf (60/100 telescopic, 60/100 longer telescopic and 80/125 telescopic) flue system and two vertical rsf (60/100 or 80/125) regular flue systems: the systems have different maximum flue ...

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    Pre-installation 6 720 803 599 (2012/06) 17 350 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.

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    Pre-installation 6 720 803 599 (2012/06) 18 3.9 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 the flue terminal is extended to clear any overha...

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    Pre-installation 6 720 803 599 (2012/06) 19 3.10 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. 300mm minimum clearances to a opening e.G. Window....

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    Installation 6 720 803 599 (2012/06) 20 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 point of delivery. • once the carton has been deliver...

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    Installation 6 720 803 599 (2012/06) 21 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 the wall mounting plate: • the diagram opposite shows...

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    Installation 6 720 803 599 (2012/06) 22 4.3 charging link (filling loop) b fully close the isolating valves on both the cold water inlet and ch return connections. B check that the gas and water connections are tight. 1. Unscrew the blanking plugs from both the cold water inlet and ch return connect...

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    Installation 6 720 803 599 (2012/06) 23 4.4 unpacking the appliance 1. With the wall frame and ancillary items removed (see page 22), 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 th...

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    Installation 6 720 803 599 (2012/06) 24 4.5 fitting the appliance/boiler connections gas and water connections: b system pipes may be run vertically upwards behind the boiler or below it. See plumbing manifold section on page 15. A - ch flow (22mm), b - ch return (22mm), c - gas inlet (22mm), d - dh...

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    Installation 6 720 803 599 (2012/06) 25 4.6 flue installation horizontal flue (60/100mm diameter) for vertical flues and 80/125mm horizontal flues, please refer to separate flue kit instructions. Fig. 25 4.6.1 Ø60/100mm telescopic flue kit: standard telescopic flue 350 - 570mm , part number: 7 716 1...

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    Installation 6 720 803 599 (2012/06) 26 4.6.4 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 shown. If fitting from inside the building; slide the ...

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    Installation 6 720 803 599 (2012/06) 27 fig. 33 plume distance to opening 4.7 condensate connection never terminate or discharge into any open source, including; sink, bath, shower, bidet, toilet etc. B ensure that the condensate drain is 22mm diameter plastic pipe. It must fall at least 52mm per me...

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    Installation 6 720 803 599 (2012/06) 28 4.8 electrical danger of short circuit: when connecting the cables ensure that no cable pieces fall inside the control panel. Access to electrical connections: b remove boiler casing to access control panel. 1. Slide the white plastic clip down to release the ...

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    Installation 6 720 803 599 (2012/06) 29 4.9 position of wired components fs fr np lp l n s n l s l r st8 st9 st17 st18 st5 st4 st10 earth mains supply pump supply pump control spark transformer 230v~ flame sense electrode spark electrodes flow ntc overheat stat diverter valve flue overheat stat st1 ...

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    Commissioning 6 720 803 599 (2012/06) 30 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) d - dhw outlet (15mm) e - cold water inlet (15mm) 2. Che...

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    Commissioning 6 720 803 599 (2012/06) 31 9. Refill the system up to 1 bar. Turn the white control tap (c) to its closed position and then remove the charging key by turning back to its “unlock” position and withdrawing. 10. Place the charging key (d) in its storage position (e) on the bottom cover o...

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    Commissioning 6 720 803 599 (2012/06) 32 5.4 water treatment ensure that the system has been cleaned as on page 9 of these instructions. Flushing (central heating): b switch off the boiler. B open all drain cocks and drain the system while the appliance is hot. B close drain cocks and add a suitable...

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    Commissioning 6 720 803 599 (2012/06) 33 b if left in the performance test mode the control will return to normal operation after 15 minutes. B close the gas isolation valve and remove the manometer. B re-seal the screw in the gas inlet pressure test point. B open the gas isolation valve and check f...

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    Commissioning 6 720 803 599 (2012/06) 34 5.6 finishing commissioning replace outer casing: 1. Replace outer casing making sure that the securing points are properly located. B press the clip (a) downwards to secure casing on top. B retighten bottom two screws (b). Fig. 43 fitting outer case installi...

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    Servicing and spares 6 720 803 599 (2012/06) 35 6 servicing and spares 6.1 inspection and service • to ensure the continued efficient operation of the appliance it must be checked at regular intervals. • the frequency of servicing will depend upon the particular installation conditions and usage. Ho...

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    Servicing and spares 6 720 803 599 (2012/06) 36 6.1.2 fan pressure test set the boiler to maximum fig. 47 control panel [a] on/off button [b] cover or optional plug-in controller [c] display [d] system pressure gauge [e] reset button [f] eco button [g] holiday button [h] dhw temperature control [i] ...

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    Servicing and spares 6 720 803 599 (2012/06) 37 6.1.3 to clean the heat exchanger b 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 present. Fig. 50 cleaning heat exchanger 2. Loosen any deposits...

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    Servicing and spares 6 720 803 599 (2012/06) 38 3. Remove the burner (h) and clean components. Do not use a wire brush. 6.1.5 to check the diaphragm in burner cover 4. Carefully withdraw diaphragm (j) from fan intake tube and check for soiling and splits. B carefully refit diaphragm (j) the correct ...

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    Servicing and spares 6 720 803 599 (2012/06) 39 b fit new plastic sealing cover onto the max adjuster. B replace the brass screw over the min adjuster on the valve. B re-assemble and refit boiler case. Fig. 51 setting the air/gas ratio 6.3 replacement of parts removing outer case 1. Remove bottom pa...

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    Servicing and spares 6 720 803 599 (2012/06) 40 3. Primary sensor b press retaining clip on plastic moulding and pull upwards until clear of pocket in heat exchanger. B separate sensor from connector, coat new sensor with heat conductive paste and replace. 4. Overheat thermostat b remove two electri...

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    Servicing and spares 6 720 803 599 (2012/06) 41 7. Gas valve b isolate gas supply at boiler gas cock. B pull out air inlet tube (a). B undo top gas connection (b) to gas valve. B undo bottom gas connection (c) to gas valve. B undo two securing screws (d)on the underside of casing. B pull valve up an...

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    Servicing and spares 6 720 803 599 (2012/06) 42 12. Fan assembly b remove electrical connector from fan. B remove condensate trap (see page 37). 1. Undo the union connection (a) from the top of the gas valve. B remove wire clip (b) from air/gas adjustment assembly (c) then pull gas pipe down. 2. Uns...

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    Servicing and spares 6 720 803 599 (2012/06) 43 3. Remove air/gas manifold (i) fig. 63 air/gas manifold 4. Open air/gas manifold (i). B carefully withdraw diaphragm (j) from fan intake tube and check for soiling and splits. Fig. 64 diaphragm 15. Burner b remove the burner (h). B replace new burner i...

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    Servicing and spares 6 720 803 599 (2012/06) 44 17. Diverter valve motor there is no need to drain the appliance. B disconnect the electrical connector from the diverter valve motor. 1. Pull the motor assembly (a) towards you. The assembly will slide free from the valve. B to refit, follow the above...

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    Servicing and spares 6 720 803 599 (2012/06) 45 21. Pump head b ensure the appliance has been fully drained. 1. Disconnect the pump connections following steps i to iv. 2. Remove the four allen bolts (a) securing the pump at each corner. 3. Gently pull the pump towards you and remove. B to refit, fo...

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    Servicing and spares 6 720 803 599 (2012/06) 46 fig. 76 drain tap removal 26. Hydraulic block b ensure the appliance has been fully drained. B disconnect the electrical connections to the ntc, turbine and pump. B undo the nuts securing the copper water pipes to the manifold (there is no need to remo...

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    Servicing and spares 6 720 803 599 (2012/06) 47 27. Ch pressure relief valve b remove the hydraulic block from the boiler (see removing the hydraulic block). 1. Remove the spring clip from the pressure relief valve housing. 2. Withdraw the pressure release valve (a) from its housing. B to refit, fol...

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    Servicing and spares 6 720 803 599 (2012/06) 48 6.4 short parts list fan 8 716 116 067 0 gc no. H26 536 burner 8 718 006 658 0 gc no. E27 200 burner skin seal 8 711 004 168 0 0gc no. E27 201 gas valve 8 718 221 347 0 gc no. H56-469 temperature limit sensor 8 722 963 858 0 gc no. H08 291 set of elect...

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    Fault finding & diagnosis 6 720 803 599 (2012/06) 49 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 flashing during a fault. The seven segment display on the ...

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    Fault finding & diagnosis 6 720 803 599 (2012/06) 50 7.2 central heating function power switch on blue light on green flame light on end of boiler demand central hea t ing demand lockout burner lit? Ignition sequence ignition sequence (see details) yes yes no no burner restarts after anticycle time ...

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    Fault finding & diagnosis 6 720 803 599 (2012/06) 51 7.3 preheat and dhw function power switch on blue light on lockout prehea t demand yes no no yes eco button not illuminated * (i.E. Preheat requested) burner threshold during pre-heat. Burner on: supply temperature and 20 minutes since last pre-he...

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    Fault finding & diagnosis 6 720 803 599 (2012/06) 52 7.4 protection function holiday mode set to on all other demands not active frost protection active dhw demand active pump runs for 5 seconds every 24 hours pump antiseize run autofroststat function boiler temperature below 8 o c 6720647361-61.1wo.

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    Fault finding & diagnosis 6 720 803 599 (2012/06) 53.

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    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 manufacturer, has a water scale reducer been fitted? Co...

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    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 the service as described in the manufacturer’s in...

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    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 6 720 803 599 (2012/06) worcester, bosch group: technical support: 0844 892 3366 appointments: 0844 892 3000 spares: 01905 7...