Worcester_WM-gas-combi_Technical
Technical and Specification Information
Greenstar CDi Classic Series
Greenstar CDi Compact Series
*
Greenstar Si Compact Series
Greenstar i Series
NEW
Greenstar combi gas-fired condensing
wall mounted boiler range
NEW
Greenstar i
series
*Source: Which? 2014 survey published in Sept 2014.
Greenstar i not available at time of survey.
1
The reception and main entrance
at our Worcester headquarters
Contents
Page
The Greenstar combi condensing boiler range
4-5
Key features of the range
6-7
Greenstar CDi Classic features and benefits
8-9
Inside story – Greenstar CDi Classic
10 - 11
Greenstar CDi Compact features and benefits
12 - 13
Inside story – Greenstar CDi Compact
14 - 15
Greenstar Si Compact features and benefits
16 - 17
Inside story – Greenstar Si Compact
18 - 19
Greenstar i features and benefits
20 - 21
services to ensure you have all you require in
Inside story – Greenstar i
22 - 23
Worcester and you. Making a difference.
2
As part of the Bosch Group, Worcester
supported by an experienced technical
“At Worcester we recognise the vital role you
products are designed and manufactured to
services team which is able to provide
play in the specification and installation of
provide customers with the highest levels of
comprehensive support and advice
energy efficient appliances in homes across
quality and reliability which are synonymous
from designing system layouts through
the UK. We will continue to invest in our
with the Bosch name throughout the world.
to installation.
products, people, facilities and added value
As part of Europe’s largest supplier of
Worcester is dedicated to providing energy
order to deliver only the best solutions to your
Controls
24 - 25
heating products, Worcester, Bosch Group
efficient gas- and oil-fired condensing
customers’ requirements.”
Wave – smart heating control
26 - 27
has the UK-based resources and support
boilers, as well as an extensive range of
ErP easy as ABC
28 - 29
capability to offer you the value-added
renewable technologies. All of our products
Carl Arntzen,
Site preparations and guidance
30 - 33
solutions you deserve. Worcester employs
have been developed and introduced with
Managing Director,
Greenstar combi installation requirements
34 - 36
a nationwide network of Service Engineers
the aim of helping the UK to achieve the
Bosch Thermotechnology Ltd.
Greenstar System Filter
37
and technically trained Field Sales Managers
Government’s efficiency targets.
Worcester Keyless Filling Link
38 - 39
Condensate pipework
40 - 41
The Worcester CondenseSure siphon
42 - 43
Flue Gas Heat Recovery Unit
44 - 45
Horizontal and vertical flue terminal positioning
46 - 47
Horizontal fluing options
48 - 51
Vertical fluing options
52 - 54
Plume management positioning and system options
55 - 58
Accessories
59 - 63
Training
64 - 66
After-sales
67
3
The Greenstar combi gas-fired wall mounted condensing boiler range
NEW
Greenstar Si Compact
Greenstar i
Greenstar CDi Classic
*
Greenstar CDi Compact
The Greenstar combi series is part of a market-leading
As part of our commitment to offer installers high quality
In 2014, the Greenstar CDi Classic was improved
range of energy-saving gas-fired boilers. Renowned for
products and innovative heating solutions, Worcester is
with a number of extra features.
their energy efficiency, reliability, ease of installation and
dedicated to continuously improving its entire range of
servicing, more than 2 million Greenstar combi boilers have
combi boilers.
was replaced with the Greenstar i, an ErP compliant boiler
been installed in homes across the UK.
4
*Source: Which? 2014 survey published in Sept 2014. Greenstar i not available at time of survey.
In 2015, the UK’s best selling boiler, the Greenstar i Junior,
In 2013, we launched the revolutionary Greenstar CDi
with a host of new features including a larger condensate
Compact and Si Compact models, which includes the
siphon to remove freezing† issues and an easy to use
innovative WB7 heat exchanger to combine both compact
control panel with a scrolling text display and higher hot
dimensions with a high efficiency.
water flow rates.
†Provided 32mm pipework not exceeding 3 metres in length is used.
5
†
Key features of the range
The Greenstar combi range at a glance
Winner of Which? Best Buy awards
ECO mode
in 2011, 2012, 2013 and 2014
With the ECO mode button activated, the ‘keep hot’
For four consecutive years, in a survey of
facility is de-energised and the hot water will be
Which? members, the Worcester Greenstar
heated from cold. A slight delay should be expected
gas-fired condensing boiler range has been
before the hot water is at full temperature when in
presented with Best Buy awards†. In the
ECO mode. By selecting ECO mode, less gas will be
latest survey, no other manufacturer scored
used as energy is used only on demand.
Part No.
Fluing options
Highly efficient, highly cost-effective
The Greenstar combi range has a full range of
All Worcester Greenstar wall mounted condensing
Condensfit II™ flue options in both 60/100mm
combi boilers have an ErP ‘A’ rating for both hot
and 80/125mm diameters and include a plume
water and space heating which means they are over
deflector as standard.
38CDi
Classic
42CDi
28CDi
32CDi
36CDi
25Si
30Si
Classic Compact Compact Compact Compact Compact
25i
30i
NG
7 738 100 248 7 738 100 250 7 738 100 252 7 738 100 246 7 716 130 234 7 716 130 235 7 716 130 236 7 716 130 230 7 716 130 232 7 733 600 012 7 733 600 005
LPG
7 738 100 249 7 738 100 251 7 738 100 253 7 738 100 247 7 716 130 237 7 716 130 238 7 716 130 239 7 716 130 231 7 716 130 233 7 733 600 031 7 733 600 032
7.7kW
7.7kW
9.4kW
9.4kW
7.03kW
7.03kW
7.03kW
7.03kW
7.03kW
7.14kW
7.14kW
Max
30.9kW
35kW
40kW
42kW
28kW
32kW
36kW
25kW
30kW
25kW
30kW
Flow rate at 35ºC ∆T
(± 15%)
12.3l/min
14.3l/min
16.4l/min
17.2l/min
11.4l/min
13.1l/min
14.7l/min
10.2l/min
12.3l/min
10.2l/min
12.3l/min
Flow rate at 40ºC ∆T
(± 15%)
11l/min
12l/min
14l/min
15l/min
10l/min
11.5l/min
12.9l/min
9l/min
10.8l/min
9l/min
10.8l/min
7.7kW
7.7kW
9.4kW
9.4kW
7.03kW
7.03kW
7.03kW
7.03kW
7.03kW
7.2kW
7.2kW
30kW
30kW
30kW
30kW
24kW
24kW
24kW
24kW
24kW
24kW
24kW
–
–
–
–
–
–
–
–
–
13kW
13kW
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
(optional)
(optional)
(optional)
(optional)
(optional)
(optional)
(optional)
(optional)
(optional)
(optional)
(optional)
(optional)
(optional)
(optional)
(optional)
–
–
–
–
–
(optional)
(optional)
9
9
9
9
9
9
9
9
9
9
9
Min
Output kW to
central heating (CH) Max
90% efficient.
34CDi
Classic
Min
Output kW to DHW
higher for reliability and customer satisfaction.
29CDi
Classic
Boiler
Maximum output kW
to central heating (CH)
with low NOx option
Modulating control
Electronic ignition
Integrated filling link
Earth Bonding Strip
Remote PRV
Condensing in DHW
The Greenstar condensing combi range –
features and benefits at a glance
Low NOx options
5 year guarantee
Energy-saving & environmental
Time & labour-saving installation
End user comfort and convenience
Worcester’s commitment to reduce emissions from
All Worcester Greenstar combi
• All models are compliant with the
• Wall frame allows space for pipes
• Full 5 year guarantee on parts and
gas-fired condensing boilers sees all Greenstar
boilers are offered with a full 5 year
combi boilers achieve NOx values <40mg/kWh.
guarantee* on parts and labour as well
This enables the appliances to achieve 3 credits
as a 10 year guarantee* on the primary
under the Code for Sustainable Homes. The
heat exchanger*. Registration can be by
Greenstar i can be programmed to achieve a
post, telephone, online or via the new app.
•
ErP ‘A’ rating for heating and
Register from your smart device
Guarantees can now be registered
Pre-heat facility
from a smart device using the new
All Greenstar combi models have an in-built
app which can scan the boiler’s serial
‘keep hot’ facility which will keep the primary water
number to save you time entering it.
•
hot water
•
Simple and intelligent control
options are available to optimise
boiler efficiency
low NOx value. All other boilers are low NOx
as standard.
ErP Directive
• Low electrical consumption in
standby mode
• Aluminium-silicon heat exchangers
deliver high efficiency and reliability
• All wall hung Greenstar gas-fired
within the heat exchanger hot – approximately
combi boilers condense in
2.5 litres volume. This will ensure that hot water is
DHW mode
behind the boiler as standard
labour as well as a 10 year guarantee
Vertical pre-piping assembly
on the primary heat exchanger*
available as an accessory
•
• Boiler protection plans available
Full range of Condensfit II™
for both new and out-of-guarantee
flue options
Worcester Greenstar boilers
• Multi-directional fluing means
boiler can be sited in a wider
variety of places
• The boiler comes pre-wired and
with the ability to be pre-plumbed.
• Bosch renowned quality
and reliability
• Built-in boiler frost protection
• Small dimensions – Greenstar CDi
Compact, Si Compact and i models
• ECO mode for energy-saving
fuel consumption.
• Modulating pump which uses less
delivered almost instantly to the opened outlet.
electricity than a fixed speed pump
• Anti-cycle control.
6
*Terms and conditions apply.
†Source: Which? 2014 survey published in Sept 2014. Greenstar i not available at time of survey. *Subject to terms and conditions.
7
Greenstar CDi Classic
Features and benefits
The top-of-the-range, award-winning Greenstar CDi Classic is a high
Updated features based on
WB5 heat exchanger
performance boiler that is suitable for small, medium and large-sized
installer feedback
The Worcester WB5 heat exchanger
properties with one or two bathrooms. It has set the benchmark within
Following on from your feedback
has been designed to optimise clean
the industry for efficiency, reliability and ease of installation, while
new features have been added to
burning combustion over an extra-
achieving a market-leading flow rate up to 17.2 l/min.
the CDi Classic including a larger
large surface area. Each heat
condensate siphon, which eliminates
exchanger is factory-set and 100%
The Greenstar CDi Classic offers the opportunity to range-rate the central
the risk of frozen condensate and
tested so, as long as the gas inlet
heating output to perfectly match the properties’ requirements which
means an external CondenseSure
pressure is correct, commissioning
reduces cycling and improves efficiency further.
will not be required†.
is straightforward. The heat
The CDi Classic range includes a
exchanger requires minimal
With more than 2 million Greenstar combi boilers installed in the UK, the
paper wall mounting template to
servicing which means fewer spare
ever popular Worcester Greenstar CDi Classic, with its advanced features
aid installation.
parts during its lifetime. The heat
and future-proof technology, still sets the standard for premium quality,
The pump has also been upgraded
exchanger can be cleaned in situ via
high-efficiency combi boilers.
to a more efficient model which
an inspection hatch, again saving
meets the forthcoming ErP
time during service.
WB5
Heat Exchanger
On the primary
heat exchanger*
legislation.
The Greenstar CDi Classic also achieves 3 credit points within the Code for
Sustainable Homes.
For more information on
ErP, see pages 28-29.
Installation benefits
Environmental benefits
End user benefits
• Standard wall frame allows space for pipes • ErP ‘A’ rated for both heating and
behind the boiler now supplied with a
paper template to aid positioning of holes
• Can be serviced entirely from the front
with easy access to parts and components
• Split wall-mounting jig provided as
standard for pre-plumbing of all
7 connections – gas, water, PRV &
condensate connections before the
•
•
and reliability
• SEDBUK A rating of up to 89.4%
• Energy-saving anti-cycle and
(2009 rating)
modulation control
• WB5 heat exchanger delivers high
• Fully modulating pump for reduced
efficiency and reliability
electricity consumption and quieter
• Low electrical consumption when in
operation
• Condenses in CH and DHW mode, resulting
standby mode
• NOx emissions of 35mg/kWh –
boiler is on the wall
achieves 3 credits under the Code
Remote PRV can be positioned higher in
for Sustainable Homes
the system for cellar installations
• Heat exchanger delivers high efficiency
hot water
in greater efficiency and fuel savings
• Low electrical consumption when in
standby mode
• All boilers and components are 100%
Earth bonding strip fitted as standard
recyclable, achieving Worcester’s zero
which saves time and money when
waste to landfill objective.
• In-built Keyless Filling Link making system
re-pressurisation easy
• Full 5 year guarantee on parts and labour*
• 10 year guarantee on Worcester primary
connecting and wiring
• Clear display on fascia for temperature
heat exchanger*
• Boiler protection plans available
• Part of the Which? Best Buy range for
and commissioning settings
• Short-circuit proof PCB design that
removes the need for fuses in the low
voltage circuits
• Full range of Condensfit II™ horizontal and
vertical flue options with optional plume
The Greenstar CDi Classic boiler is
recommended by the Energy Saving
Trust (EST). The Energy Saving Trust
is a non-profit organisation that
provides free and impartial advice
on how to save energy.
gas-fired condensing boilers.
management kit available means boiler can
be sited in a wide variety of places.
8
*Terms and conditions apply. †Provided 32mm pipework not exceeding 3 metres in length is used.
9
Inside story – Greenstar CDi Classic
Technical data
Down firing low NOx burner
Aluminium/silicon WB5
primary heat exchanger
Expansion vessel
Pre-mix fan
Secondary DHW plate heat exchanger
Large
condensate
siphon
Automatic air vent
Gas valve
ErP compliant modulating pump
Diverter valve
Drain point
PCB board
Mains cable
pre-wired to
control board
Boiler
Greenstar
29CDi Classic
Greenstar
34CDi Classic
Greenstar
38CDi Classic
Greenstar
42CDi Classic
Height
760mm (max)
760mm (max)
760mm (max)
760mm (max)
Width
440mm
440mm
440mm
440mm
Depth
360mm (max)
360mm (max)
360mm (max)
360mm (max)
Weight – lift
47.5kg
47.5kg
47.5kg
47.5kg
ErP Seasonal space heating energy efficiency class
A / 92%
A / 92%
A / 92%
A / 92%
A
A
A
A
2009 SEDBUK efficiency – natural gas
89.1%
89.1%
89.0%
89.4%
SAP comparative hot water efficiency
71.2
72.3
71.5
72.0
Heating flow / return connections
(compression)
22mm
22mm
22mm
22mm
Hot / cold water connections
(compression)
15mm
15mm
15mm
15mm
Pressure relief valve (compression)
15mm
15mm
15mm
15mm
Condensate connection (plastic pipe)
22mm
22mm
22mm
22mm
Gas connection (compression)
22mm
22mm
22mm
22mm
Primary water content
3.75 ltr
3.75 ltr
3.75 ltr
3.75 ltr
Minimum domestic inlet pressure
for maximum DHW flow rate
1.4bar
1.5bar
1.7bar
1.9bar
Minimum domestic inlet pressure
to operate the appliance
0.2bar
0.2bar
0.2bar
0.2bar
Maximum domestic inlet pressure
10bar
10bar
10bar
10bar
1.9 ltr/min
1.9 ltr/min
1.9 ltr/min
1.9 ltr/min
DHW flow rate @ 35ºC∆T†
12.3 ltr/min
14.3 ltr/min
16.4 ltr/min
17.2 ltr/min
DHW flow rate @ 40ºC∆T††
11 ltr/min
12 ltr/min
14 ltr/min
15 ltr/min
Output to central heating (natural gas)
7.7 - 30kW
7.7 - 30kW
9.4 - 30kW
9.4 - 30kW
Wall mounting jig and paper template
9
9
9
9
9
9
9
9
9 (optional)
9 (optional)
9
9 (optional)
9 (optional)
9
9 (optional)
9 (optional)
9
9 (optional)
9 (optional)
9
Maximum vertical flue
(100mm dia.) inc. terminal
9,400mm
8,000mm
7,500mm
7,500mm
Maximum vertical flue
(125mm dia.) inc. terminal
18,500mm
16,000mm
16,000mm
16,000mm
Maximum horizontal flue
(100mm dia.)
7,900mm
7,000mm
6,000mm
6,000mm
Maximum horizontal flue
(125mm dia.)
18,500mm
16,000mm
12,500mm
12,000mm
33.3mg/kWh
33.3mg/kWh
21.8mg/kWh
21.8mg/kWh
5
5
5
5
X4D
X4D
X4D
X4D
ErP Water heating energy efficiency class
Minimum flow rate to
operate the appliance
Keyless filling link
Pressure gauge
Plug-in timers
Intelligent controls
Condensing in DHW mode
Central heating
temperature
control
On/off
button
Optional
programmer
Operational
status light
Digital
display
Pressure
gauge
Domestic
hot water
temperature control
NOx classification – natural gas
NOx class
Ingress protection (IP)
†Values for industry comparisons. ††Designed operational flow rate.
10
Greenstar CDi Classic fascia with
optional Comfort I RF plug-in twin
channel programmer fitted
11
Greenstar CDi Compact
Features and benefits
The revolutionary Worcester Greenstar CDi Compact is part of our
WB7 heat exchanger
Friction stir welding
top-of-the-range CDi boiler series and is part of our next generation
At the heart of the Greenstar CDi
Friction stir welding is a solid state
of wall-mounted combi boilers. Suitable for small, medium and large-
Compact is the ground-breaking
machining process where the metal
sized properties with one or two bathrooms, the Greenstar CDi Compact,
WB7 heat exchanger, which uses
is softened rather than melted,
with hot water outputs of up to 36kW, is best suited to properties that
advanced friction stir welding† to
giving improved quality, reliability
demand high outputs from an appliance that can fit within a standard
create more passageways than
and performance.
kitchen cupboard.
traditional heat exchangers. These
channels provide more efficient
Widely used for demanding
Available with DHW flow rates of 11.4, 13.1 and 14.7 l/min, the CDi
circulation, resulting in a more
applications in the aviation, marine
Compact is the smallest and most efficient wall mounted condensing
effective heat transfer and
and automotive sectors, it has
combi boiler Worcester has produced and comes with a host of design
quieter operation.
enabled Worcester to manufacture
a more compact heat exchanger,
features for ease of installation, use and servicing.
Designed, tested and manufactured
reducing the overall size of the
Its ease of installation and cupboard size dimensions are thanks to the
within Bosch Thermotechnology
boiler while delivering a high power
ultra-compact WB7 heat exchanger, easy-access hydraulics and colour-
Ltd., the WB7 heat exchanger
ratio of up to maximum 36kW.
coded wiring connectors. The boiler comes supplied with an innovative
delivers high output despite its
wall-mounting jig that allows installers to easily pre-plumb the condensate,
compact size.
WB7
Heat Exchanger
On the primary
heat exchanger*
CH flow, DHW outlet, gas, DCW inlet, PRV installer connection & CH return
For more information on
without the boiler being on the wall.
ErP, see pages 28-29.
The Greenstar CDi Compact along with its low NOx emissions, obtains
End user benefits
3 credit points within the Code for Sustainable Homes standard.
• Simple and intelligent control options
available, optimising boiler efficiency and
Installation benefits
Environmental benefits
• Robust, metal wall-mounting jig for safe,
• ErP ‘A’ rated for both heating and hot water
• SEDBUK A rating of 89.8% (2009 rating)
• Ability to fix a maximum heating
secure, hassle-free fixing
• Split jig design for optimum lift weight.
The expansion vessel has a simple drop
temperature – meaning no matter how
lock mechanism that connects directly
much you turn the dial, the temperature
onto the hydraulic unit
will not exceed that maximum setting
• LCD boiler display for operation
•
exchanger reduces raw material
diagnostics data
usage during manufacturing
of the boiler for easy maintenance
• Electrical connections accessible from the
front of the boiler
• Maximum flue lengths of 6m 60/100mm
flue and 15m 80/125mm flue
• Pre-set combustion settings for fast
delivery needs
• Fully modulating pump for reduced
electricity consumption and quieter
operation
• Built-in frost protection of the boiler and
the surrounding pipes
• Includes internal keyed filling link
• Optional Worcester Keyless Filling Link
achieves 3 credits under the Code
available as an upgrade, making system
for Sustainable Homes
re-pressurisation easy
• Hot water pre-heat accessory
• Full 5 year guarantee on parts and labour*
• 10 year guarantee on Worcester primary
(Part Number 7 716 192 735) allows
it to be used in conjunction with other
Commissioning Checklist data available on
solar thermal
vertical flue options with optional plume
• Pre-heat and ECO modes to suit hot water
•
• NOx emissions of 35mg/kWh –
heat sources, such as Greenskies
• Full range of Condensfit II™ horizontal and
in greater efficiency and fuel savings
Low electrical standby consumption
commissioning and with Benchmark
the boiler display
• Condenses in CH and DHW mode, resulting
• Precision engineered WB7 heat
status, commissioning features and
Double-seal siphon located at the front
fuel consumption
• All boilers and components are 100%
The Greenstar CDi Compact boiler is
recommended by the Energy Saving
Trust (EST). The Energy Saving Trust
is a non-profit organisation that
provides free and impartial advice
on how to save energy.
heat exchanger*
• Boiler protection plans available.
recyclable, achieving Worcester’s zero
waste to landfill objective.
management kit available.
12
†The friction stir welding process is used under license from The Welding Institute. *Terms and conditions apply.
13
Inside story – Greenstar CDi Compact
Technical data
Expansion vessel
(hidden)
Boiler
Greenstar
28CDi Compact
Greenstar
32CDi Compact
Greenstar
36CDi Compact
Height
680mm*
680mm*
680mm*
Width
390mm
390mm
390mm
Depth
280mm
280mm
280mm
Weight – lift
32.9kg
32.9kg
32.9kg
ErP Seasonal space heating energy efficiency class
A / 93%
A / 93%
A / 93%
A
A
A
2009 SEDBUK efficiency – natural gas
89.8%
89.8%
89.8%
SAP comparative hot water efficiency
74.9
75.0
74.7
Heating flow / return connections
(compression)
22mm
22mm
22mm
Hot / cold water connections
(compression)
15mm
15mm
15mm
Pressure relief valve (compression)
15mm
15mm
15mm
Condensate connection (compression)
22mm
22mm
22mm
Gas connection (compression)
22mm
22mm
22mm
Primary water content
2.2 ltr
2.2 ltr
2.2 ltr
Minimum domestic inlet pressure
for maximum DHW flow rate
1.6bar
1.6bar
1.6bar
ErP compliant
modulating pump
Minimum domestic inlet pressure
to operate the appliance
0.2bar
0.2bar
0.2bar
Diverter valve
(hidden)
Maximum domestic inlet pressure
10.0bar
10.0bar
10.0bar
DHW flow rate @ 35ºC∆T†
11.4 ltr/min
13.1 ltr/min
14.7 ltr/min
DHW flow rate @ 40ºC∆T††
10.0 ltr/min
11.5 ltr/min
12.9 ltr/min
Output to central heating
7.03 - 24kW
7.03 - 24kW
7.03 - 24kW
9
9
9
9
9
9
9 (optional)
9 (optional)
9
9 (optional)
9 (optional)
9
9 (optional)
9 (optional)
9
Maximum vertical flue
(100mm dia.) inc. terminal
6,000mm
6,000mm
6,000mm
Maximum vertical flue
(125mm dia.) inc. terminal
15,000mm
15,000mm
15,000mm
Maximum horizontal flue
(100mm dia.)
6,000mm
6,000mm
6,000mm
Maximum horizontal flue
(125mm dia.)
15,000mm
15,000mm
15,000mm
NOx classification – natural gas
35mg/kWh
35mg/kWh
35mg/kWh
5
5
5
X4D
X4D
X4D
Pre-mix fan
Automatic air vent
Down firing
low NOx burner
ErP Water heating energy efficiency class
Aluminium/silicon
WB7 primary
heat exchanger
Gas valve
Secondary DHW
plate heat exchanger
Pressure relief valve
Condensate siphon
Wall mounting jig
Filling link
Plug-in timers
PCB board
Intelligent controls
Condensing in DHW mode
Mains cable
pre-wired to
control board
Operational
status light
Central heating
temperature control
Digital display
Domestic hot
Optional water temperature
control
programmer
Pressure
gauge
NOx class
Ingress protection (IP)
*690mm to top of casing curve. †Values for industry comparisons. ††Designed operational flow rate
Greenstar CDi Compact fascia with optional
FW100 weather compensation controller fitted
14
15
Greenstar Si Compact
Features and benefits
The Greenstar Si Compact has a host of performance-enhancing features,
WB7 heat exchanger
Innovation at its best
including the revolutionary WB7 heat exchanger which enables the
Greenstar Si Compact boilers use
The WB7 heat exchanger is an
appliances to deliver DHW flow rates of 10.2 and 12.3 l/min despite
the same ground-breaking WB7
industry first for Worcester,
their compact size.
heat exchanger as CDi Compact
Bosch Group. State-of-the-art
appliances.
friction stir welding† technology
improves reliability, as the welding
Similarly to the CDi Compact, particular care has been taken with the design
of the hydraulic unit. Key components are positioned to provide easy access,
Although compact in size, the WB7
method eliminates the risk of
whilst the Heatronic 4i control box makes commissioning simpler. This menu-
heat exchanger offers outstanding
potential weak points and stress
driven unit features an LCD display which shows boiler status symbols and
levels of performance and is
fractures occurring.
system and commissioning parameters as well as giving access to service and
designed and built to provide
maintenance codes and diagnostics.
long-term reliability.
The compact design makes the Greenstar Si Compact ideal for a variety of
locations, including kitchens, utility rooms, bathrooms, airing cupboards,
WB7
Heat Exchanger
lofts or garages.
On the primary
heat exchanger*
The Greenstar Si Compact achieves 3 credit points within the Code for
Sustainable Homes.
For more information on
ErP, see pages 28-29.
End user benefits
• Highly reliable and efficient
heat exchanger
Installation benefits
Environmental benefits
•
•
• SEDBUK A rating of 89.8% (2009 value)
• Precision engineered heat exchanger
Can be installed in a standard kitchen
cupboard or compartment without the
need for ventilation
• Robust, metal wall mounting jig for safe,
secure, hassle-free fixing
• Split jig design for optimum lift weight
(32.9kg). The expansion vessel has
a simple drop lock mechanism that
connects directly onto the hydraulic unit
•
LCD boiler display for operation status,
commissioning features and diagnostics
•
modulation control
• Simple and intelligent control options
available, optimising boiler efficiency
and fuel consumption
• Comfort and ECO modes to suit hot water
options available
• Low electrical consumption when in
delivery needs
• Maximum central heating output 24kW
• Optional Worcester Keyless Filling
standby mode
•
• NOx emissions of 35mg/kWh –
Lower fan speed at higher output
of the boiler for easy maintenance
for Sustainable Homes
• Maximum flue lengths of 6m 60/100mm
• Energy-saving anti-cycle and
• Anti-cycle and modulation control
• Simple and intelligent control
achieves 3 credits under the Code
front of the boiler
in greater efficiency and fuel savings
delivers high efficiency and reliability
Double seal siphon located at the front
• Electrical connections accessible from the
• Condenses in CH and DHW mode, resulting
ErP ‘A’ rated for both heating and hot water
Link available, making system
re-pressurisation easy
• Full 5 year guarantee on parts and labour*
• 10 year guarantee on Worcester primary
• All boilers and components are 100%
recyclable, achieving Worcester’s zero
heat exchanger*
• Boiler protection plans available.
waste to landfill objective.
flue and 15m 80/125mm flue
• Pre-set combustion settings for fast
commissioning and with Benchmark
Commissioning Checklist data available
on the boiler display
The Greenstar Si Compact boilers are
recommended by the Energy Saving
Trust (EST). The Energy Saving Trust
is a non-profit organisation that
provides free and impartial advice on
how to save energy.
• Full range of Condensfit II™ horizontal and
vertical flue options with optional plume
management kit available.
16
†The friction stir welding process is used under license from The Welding Institute. *Terms and conditions apply.
17
Inside story – Greenstar Si Compact
Technical data
Expansion vessel
(hidden)
Pre-mix fan
Automatic air vent
Down firing
low NOx burner
Aluminium/silicon
WB7 primary
heat exchanger
Gas valve
ErP compliant
modulating pump
Secondary DHW
plate heat exchanger
Boiler
Greenstar
25Si Compact
Greenstar
30Si Compact
Height
690mm (max)*
690mm (max)*
Width
390mm
390mm
Depth
280mm (max)
280mm (max)
Weight – lift
32.9kg
32.9kg
ErP Seasonal space heating energy efficiency class
A / 93%
A / 93%
A
A
2009 SEDBUK efficiency – natural gas
89.8%
89.8%
SAP comparative hot water efficiency
74.7
74.2
Heating flow / return connections (compression)
22mm
22mm
Hot / cold water connections (compression)
15mm
15mm
Pressure relief valve (compression)
15mm
15mm
Condensate connection (plastic pipe)
22mm
22mm
Gas connection (compression)
22mm
22mm
Primary water content
2.2 ltr
2.2 ltr
Minimum domestic inlet pressure
for maximum DHW flow rate
1.6bar
1.6bar
Minimum domestic inlet pressure
to operate the appliance
0.2bar
0.2bar
Maximum domestic inlet pressure
10bar
10bar
2 ltr/min
2 ltr/min
10.2 ltr/min
12.3 ltr/min
ErP Water heating energy efficiency class
Minimum flow rate to operate the appliance
DHW flow rate @ 35ºC∆T†
Diverter valve (hidden)
Condensate siphon
Pressure relief valve
8.9 ltr/min
10.7 ltr/min
Output to central heating (natural gas)
7.03 - 24kW
7.03 - 24kW
Wall mounting jig
9
9 (optional)
9 (optional)
9 (optional)
9
9
9 (optional)
9 (optional)
9 (optional)
9
Maximum vertical flue (100mm dia.) inc. terminal
6,000mm
6,000mm
Maximum vertical flue (125mm dia.) inc. terminal
15,000mm
15,000mm
6,000mm
6,000mm
DHW flow rate @ 40ºC∆T††
Filling link
Plug-in timers
Intelligent controls
PCB board
Condensing in DHW mode
Mains cable
pre-wired to
control board
Operational
status light
Maximum horizontal flue (100mm dia.)
Central heating
temperature control
Digital display
Domestic hot
Optional water temperature
control
programmer
Pressure
gauge
Maximum horizontal flue (125mm dia.)
15,000mm
15,000mm
NOx classification – natural gas
35mg/kWh
35mg/kWh
5
5
X4D
X4D
NOx class
Ingress protection (IP)
*Measured to the top or front of the curve height. †Values for industry comparisons. ††Designed operational flow rate.
Greenstar Si Compact fascia with optional
MT10 mechanical timer fitted
18
19
Greenstar i
Features and benefits
NEW
The Greenstar i combi boiler builds on the popular features of the
Information at your fingertips
WB3 heat exchanger
market-leading Greenstar i Junior, while introducing a host of new
The digital display includes a
The Greenstar i uses the
features. These improvements include enhanced performance, an
‘quick info’ button to provide
proven WB3 aluminium/silicon
intuitive control panel and design improvements that make installation
information on the boiler’s status,
heat exchanger.
and maintenance easier.
DHW and flow temperature, clear
Available with DHW flow rates of 10.2 and 12.3 l/min, higher than the
text descriptions for quick boiler
As part of our Total Quality Initiative
diagnostic and flow detection.
programme, Worcester tests
i Junior, to deliver excellent hot water performance in apartments and
its boilers and heat exchangers
small to medium-sized properties with one bathroom.
using its own recipe to replicate
contaminated heating system water.
The new Heatronic i control panel features familiar ‘up and down’ buttons,
similar to the simple adjustment of a TV remote control, for changing
This contains iron dust, quartz
flow temperature and DHW temperature. The ability to easily alter flow
sand, hemp fibre and other
temperature enables users to either accelerate heat-up time or use lower
contaminates found in such
flow temperatures to increase energy-saving condensing.
system water samples. This testing
WB3
Heat Exchanger
On the primary
heat exchanger*
procedure ensures that all our
The Greenstar i is supplied with a pre-assembled wall frame, as well as a
new angled mounting hook that makes installation over countertops even
easier. The mounting points are the same as for the Greenstar i Junior so
heat exchangers are proven to be
For more information on
ErP, see pages 28-29.
robust and efficient over the
Detailed scrolling digital display
boiler’s lifetime.
that replacement can be straightforward.
The wall-mounting jig allows installers to quickly pre-plumb the condensate,
CH flow, DHW outlet, gas, DCW inlet, PRV installer connection and CH
return without the boiler being on the wall.
Installation benefits
Environmental benefits
End user benefits
• Lift weight of just 31.7kg
• Simple switch – same dimensions as
• ErP ‘A’ rated for both heating and hot water
• SEDBUK A rating of 89.6% (2009 value)
• Increased comparative DHW efficiency
• Fully compatible with Worcester
• Simple and intelligent control options
i Junior
• Expansion tank pre-installed in boiler
• Familiar, reliable components
• WB3 heat cell and hydraulic group same
as i Junior
•
• Low-energy modulating pump
• Simple weather compensation sensor
accessory which increases system efficiency
for ease of access
by 2%, ErP Class II control
of Benchmark logbook
• Text descriptions of error codes
• Cross-pipe detection
• Large condense siphon which removes
fuel consumption
• Excellent energy efficiency
• Improved hot water performance from
plug-in controls
Smart design increases internal space
• Front casing can be removed easily
• All items serviceable from the front
• Benchmark menu for easier completion
available, optimising boiler efficiency and
previous i Junior
• Larger condensate siphon to prevent risk
of freezing condensate†
• Improved output and flow rates for
• Ability to programme for low NOx
• Anti-cycle and modulation control
• Low electrical consumption when in
increased water comfort
• ‘Quick set’ optimised heating and hot
water temperatures
• Optional Worcester Keyless Filling
stand by mode
• All boilers and components are 100%
Link available, making system
recyclable, achieving Worcester’s zero waste
re-pressurisation easy
• Eco/Pre-heat toggle mode
• Full 5 year guarantee on parts and labour*
• 10 year guarantee on Worcester primary
to landfill objective.
the need for CondenseSure accessory.
heat exchanger*
• Boiler protection plans available.
20
*Terms and conditions apply. †Provided 32mm pipework not exceeding 3 metres in length is used.
21
Inside story – Greenstar i
Technical data
Down firing low NOx burner
Aluminium/silicon WB3
primary heat exchanger
Pre-mix fan
Greenstar 25i
Greenstar 30i
Height
710mm (max)*
710mm (max)*
Width
400mm
400mm
Depth
330mm (max)*
330mm (max)*
Weight – lift
31.7kg
31.7kg
ErP Seasonal space heating energy efficiency class
A / 93%
A / 93%
A
A
2009 SEDBUK efficiency – natural gas
89.6%
89.6%
SAP comparative hot water efficiency
73.2
72.1
Heating flow / return connections (compression)
22mm
22mm
Hot / cold water connections (compression)
15mm
15mm
Pressure relief valve (compression)
15mm
15mm
Condensate connection (plastic pipe)
22mm
22mm
Gas connection (compression)
22mm
22mm
Primary water content
3.9 ltr
3.9 ltr
Minimum domestic inlet pressure
for maximum DHW flow rate
1.3bar
2.0bar
Minimum domestic inlet pressure
to operate the appliance
0.2bar
0.2bar
Secondary DHW
plate heat exchanger
Maximum domestic inlet pressure
10bar
10bar
2.9 ltr/min
2.9 ltr/min
Automatic air vent
DHW flow rate @ 35ºC∆T†
10.2 ltr/min
12.3 ltr/min
DHW flow rate @ 40ºC∆T††
9 ltr/min
10.8 ltr/min
Output to central heating (natural gas)
7.2 - 24kW**
7.2 - 24kW**
Wall mounting jig
9
9 (optional)
9 (optional)
9 (optional)
9
9 (optional)
9 (optional)
9 (optional)
Internal
expansion vessel
Gas valve
Large
condensate siphon
Boiler
ErP compliant
modulating pump
Diverter valve
ErP Water heating energy efficiency class
Minimum flow rate to activate DHW demand
Filling link
Plug-in timers
Intelligent controls
Mains cable
pre-wired to
control board
PCB board
Operational
status light
Pressure
gauge
Optional
programmer
Central heating
temperature control
Domestic hot water
temperature control
Maximum vertical flue (100mm dia.) inc. terminal
6,400mm
6,400mm
Maximum vertical flue (125mm dia.) inc. terminal
15,000mm
15,000mm
Maximum horizontal flue (100mm dia.)
4,600mm
4,600mm
Maximum horizontal flue (125mm dia.)
13,000mm
13,000mm
NOx classification – natural gas
49mg/kWh
49mg/kWh
NOx classification with low NOx code plug – natural gas
39mg/kWh
39mg/kWh
5
5
X4D
X4D
NOx class
Ingress protection (IP)
*Measured to the top or front of the curve height. **13kW with low NOx code plug fitted.
†Values for industry comparisons. ††Designed operational flow rate.
Greenstar i fascia with Comfort plug-in
twin channel programmer fitted
22
23
Controls
5 year guarantee
When purchased and installed at the same time, the guarantee period for a Worcester control will match that
of a Greenstar gas-fired boiler*.
Advanced intelligent controls
FW100 – Weather compensation controller – Part no. 7 716 192 067
Comfort II RF wireless programmable room thermostat and plug-in RF receiver –
• Boiler output automatically adjusts to precisely meet the heat demands
P
Part no. 7 733 600 002
EFFICIENCY
of the property according to outside temperature conditions at
ma
maximum
efficiency
EFFICIENCY
• All the features of Comfort and Comfort I PLUS…
• 6 adjustable heating temperatures per day
• Set programme at the room thermostat
• Remote access to boiler diagnostic codes
• Back lit display.
+4%
Programmable unit with six switching points a day for control of both
• Pr
ce
central
heating and hot water pre-heat
Choice of six selectable weekly programmes
• Ch
Can be integral to the boiler or wall-mounted
• Ca
Has factory-set heatcurves for various different heating systems
• Ha
+3%
Mechanical timers
(radiators, underfloor etc.)
• Manual-override that can boost or reduce heating if required.
MT10 mechanical timer (for use with all models) – Part no. 7 716 192 036
• The simplest Worcester device
• Analogue clock for setting on and off times for heating.
FR110 – Programmable room thermostat – Part no. 7 716 192 066
• Intelligent programmable room thermostat
• Load compensation
• Choice of six selectable weekly programmes
• Six switching points a day for central heating and hot water pre-heat
• Boiler output automatically adjusted to precisely meet the heat demand
EFFICIENCY
+3%
M
MT10RF
mechanical timer (for use with all models) – Part no. 7 716 192 037
• Simple installation
• Analogue display has comfort and economy time and temperature periods
• No need for separate room thermostat
• No wiring.
of the property at maximum efficiency
• Maximises the condensing boiler’s operation.
EFFICIENCY
+1%
FR10 – Intelligent room thermostat – Part no. 7 716 192 065
Controls at a glance
24
FR10
EFFICIENCY
+3%
FR110
FW100
Wave
1
*Terms and conditions apply.
Hard wired
Radio frequency
Plug-in
Optimum start
Programmable
room thermostat
Room thermostat
Auto switch –
BST/GMT
Boiler flow
temp compensation
9
9
9
9
9
9
9
9
9 9
9
9
9
I
1%
–
–
V
3%
V
3%
V
3%
V
3%
VI
4%
VI
4%
i
•
• Enhanced load compensation for increased efficiency
• No wiring required
• Extremely reliable RF signal.
All the features of Comfort PLUS…
9
–
Si Compact
Part
Pa no. 7 733 600 001
9
–
CDi Compact
Comfort II RF
Comfort
I RF wireless room thermostat and plug-in twin channel programmer –
Co
9
9
9
9
9
9
9
MODEL
CDi Classic
Comfort I RF
9
9
9
9 9
9
9
9
9 9
9 9
9 9 9 9
9 9 9
9 9 9
9 9
9
9
9
9 9 9
9 9
9 9
9 9 9 9
9 9
9
9
9 9 9
9 9
9 9
Efficiency benefit
Comfort
9
TEMPERATURE CONTROL CONNECTION TYPE EFFICENCY
ErP Class
MT10RF
9
9
7 day
MT10
• Simple menu navigation
• 7-day time control for heating and hot water
• Heating programme visualisation bar.
Internet
Comfort plug-in twin channel programmer – Part no. 7 733 600 003
Intelligent
Control
option
Digital
NEW Greenstar Comfort controls
Mechanical
Comfort controls.
TIME CONTROL
24 hour
MOUNT
Hot water
TYPE
• Maximises the condensing boiler’s operation
• For use with a 230V programmer. Not compatible with Worcester
Central heating
+3%
Wall mounted
of the property at maximum efficiency
EFFICIENCY
Fascia mounted
• Load compensation
• Boiler output automatically adjusted to precisely meet the heat demand
9
9
91
91
91
91
91
91
91
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
Manufactured after 16th January 2007 with software version CF12.10 onwards.
25
Worcester Wave – smart control
for heating and hot water
The Wave is the first of a new generation of
Worcester controls.
Quick to install
The Wave is quick and easy to install:
The Wave is a smart, internet-connected
programmable control for central heating
and hot water which can be operated using a
smart device.
• Only requires a 2-core wire connection between the
The Wave’s innovative programming enables it to
have an ‘intelligent conversation’ with the boiler
and take advantage of advanced control features
such as weather and load compensation.
• The Wave uses online data which significantly reduces
control and the boiler.
EMS 2 Wire
• All other connections are via the Wi-Fi network.
• The Wave does not need an external wired sensor
Greenstar boiler
Wave
unlike standard weather compensation controls.
installation time and cost to the end user.
Wi-Fi signal
Wi-Fi
(in home)
External access
(away from home)
Router
As with all room heating controls the Wave should
be sited where it can monitor the overall temperature
of the property.
Enhanced energy efficiency
External access
(away from home)
In the ErP Directive, smart controls like the Wave is a
Internet
Phone
Class VI control, adding 4%* to the overall system
Simple to use, providing an easy handover
efficiency, resulting in lower fuel bills.
The Wave’s intuitive and modern design ensures it is very
simple to operate using either its in-built touchscreen or via
The Wave’s energy efficiency features include:
•
EFFICIENCY
Charts of heating and hot water usage so the homeowner
+4%*
can easily identify where potential savings could be made.
•
the Wave app.
When the room temperature is turned down a leaf symbol
• Users simply download the Wave app to their compatible
device to take control of their heating system from
will appear to indicate additional savings are being made.
anywhere in the world where an internet connection
Adapting to the homeowner’s needs
is available.
• There are no subscription fees or chargeable app add-ons,
Each Wave unit is supplied with a pre-set programme that
can then be easily modified to suit the user’s requirements.
Features
Benefits
Only a low voltage 2-core
wire connection between the
controller and the boiler
Easy to install, all other
connections are via the
Wi-Fi network
Remote control of heating
AND hot water via app
Programme the heating
system from outside the home
Load and weather
compensation via the internet
(no outdoor sensor required)
Allows the boiler to modulate
its performance to meet the
needs of each household
Intuitive and modern design
Ensures easy programming
and control of the boiler,
resulting in a simple hand over
with the end-user
of charge.
Ensures increased comfort
and energy savings
No subscription fees or
chargeable app add-ons
One-off cost
• ‘Pairing’ with up to eight devices, automatically sensing
each control and there are a number of helpful videos to
when people are at home.
provide further detail on specific functions.
• Sensing to an individual device can be turned off
•
• Should the Wave temporarily lose the internet connection,
if required.
it will continue to operate as an intelligent heating
The Wave will remember preferred programme settings
and hot water control simply by using the last saved
to make these easily available and features a ‘holiday
Compatibility with Worcester Greenstar boilers
programme’, requiring just a start and finish date.
Ideal for homes and small businesses, the Wave is
• Unlike most other smart heating controls, the Wave
combination and system* boilers. It can also be retrofitted
additional energy savings and comfort.
for use with previous Worcester EMS-bus appliances.
• For security and peace of mind, all of the Wave’s data is
other parties.
Wave compatible devices:**
programme settings.
compatible with all current Worcester Greenstar gas-fired
can also programme the hot water settings, providing
All you need is:
• Worcester Wave control
• Worcester compatible boilerˆ
• Wi-Fi enabled broadband router – 802.11 b/g
• Wave app on a compatible Apple® or Android™ device.
Apple® devices running iOS 5.1 and higher
Android™ devices running 2.2, 2.3 or 4.0 and higher
26
• An installation and operating manual is provided with
The Wave’s advanced user features include:
owned by the user, ensuring no information is shared with
Energy graphs, presence
detection and many more
features come as standard
therefore updates to the app software are completely free
**Correct at time of printing. *When installed with a gas-fired boiler the Wave is a Class V control giving a 3% system efficiency benefit.
When the weather compensation feature is enabled it increases to 4% and becomes a Class VI control.
Part number
Description
7 716 192 072
Wave
*When installed with an optional Worcester Diverter Valve. ˆCorrect at time of printing. For the latest list of compatible boilers see the Worcester website.
27
What about systems that contain
What about controls?
different products?
The ErP Directive covers all products that
In these circumstances, there is a responsibility to
consume energy, such as boilers, heat pumps,
provide a package label when combining a heating
solar thermal etc. It also includes controls,
appliance with a temperature control and/or solar
which are defined using ‘classes’. These run
device, cylinder or a supplementary heating
from Class I (a simple on/off room stat) through
appliance (for example, a two-boiler cascade with
to Class VIII (multi-sensor room control for use
a combined total output of under 70kW).
with modulating heating appliances).
The person who puts that package together will
Each control class equates to a certain percentage
need to produce a package document known as
uplift in system efficiency e.g. a class VI weather
a fiche (data table) and label that provides the
compensating control and room thermostat will add
What is ErP?
combined energy efficiency rating rather than
4% efficiency to the heating system. Details of the
The ErP Directive, which is a new regulation set by
ratings of each individual component.
controls class for each Worcester control can be
the European Union, is designed to drive
found on pages 24-25.
improvements in the efficiency and performance of
For example, this could be the merchant’s
heating and hot water products. Its purpose is to
responsibility if they supply a complete package
ensure that end users are aware of the level of
under one part number or the installer if the
energy efficiency inherent within their appliances.
items are bought individually under separate
As such, the Directive will help improve the overall
part numbers.
efficiency of the housing stock, while enabling
homeowners to reduce their energy bills. The ErP
In either circumstance, Worcester will provide an
regulations cover boilers, combination boilers,
online tool that makes calculating the overall
heat pumps and other heating appliances up
package efficiency of a Worcester system effortless.
to 400kW.
What is Energy Labelling?
The Energy Labelling involves a label which we are
familiar with today on washing machines and
televisions at the point of sale. The Energy Labelling
Product A
regulations introduce Europe-wide energy labelling
Model
name
ErP easy as ABC with Worcester
requirements for boilers, combination boilers,
water heaters and other heating products up to
70kW and hot water cylinders under 500 litres.
CH
efficiency
band
DHW
efficiency
band
How will the labelling scheme work?
The new Energy Labelling Directive will introduce
new efficiency classes from A++ to G alongside
the existing SEDBUK rating for boilers in the
domestic and light commercial sectors.
Most condensing boilers will fall within the
A band, which requires them to achieve more
than 90% seasonal efficiency, while renewable
technologies such as heat pumps will likely
be in the A+ or A++ bands (depending on
flow temperature).
Sound
power
level
Maximum
heating
output
The Energy Labelling obligation under the
Energy Related Products (ErP) Directive
comes into force on the 26th September 2015.
Worcester will have a number of measures in
place to support you including:
An online tool which creates product
and heating system labels
ErP will be covered in all Worcester
training courses
ErP experts – our technical and
customer support teams can answer
all your questions.
ErP Technical Support: 0330 123 3641
Email: [email protected]
28
29
Site preparations and guidance
Installation and service clearances
Important: bathroom locations and clearances
conventional boiler, for these reasons:
The minimum clearances shown below should be allowed
•
The boiler comes supplied with a wall-mounting
for installation and servicing. Compartment ventilation
bracket (Greenstar CDi Classic) or a wall-mounting
would only be required at these clearances for the
jig (Greenstar CDi Compact, Greenstar Si Compact and
Greenstar i range. All Greenstar gas-fired boilers do not
Greenstar i)
require compartment ventilation so long as minimum
+30mm
above elbow
or shower
• Electrical switches (other than pull cords), fused spurs
and socket outlets must not be situated in the bathroom
Using 100mm
flue kit
– 1,070mm
page 31.
and CDi Compact (also available as an optional extra on
5mm
5mm
20mm to
removable
door
+30mm
above elbow
both the Greenstar Si Compact and Greenstar i)
be installed in zone 2.
• Additional Residual Current Device (RCD) protection may
be required.
200mm
Using 100mm
flue kit
– 1,130mm
Using 125mm
flue kit
– 1,170mm
The appliances are only to be installed internally within a
property, at a suitable location onto a fixed, rigid surface,
Refer to the latest IEE wiring regulations.
5mm
Clearances for Greenstar i
5mm
20mm to
removable
door
capable of supporting its weight.
600m
m
m
600m
Boiler location
IEE regulations applicable, and in Scotland the electrical
provisions with respect to installation in a room containing
Mounting on a combustible surface
a bath or shower.
Clearances for Greenstar CDi Classic
a combustible surface without the need for surface
m
600m
m
750m
m
particular attention is drawn to the requirements of the
200mm
600m
2
2
The appliance may be installed in any room, although
600mm front
clearance
for service
that is at least the same size as the appliance and is
All Greenstar wall-mounted boilers can be sited on
outside the shaded area. A boiler with any other timer
fitted (or blanking panel for an optional programmer) can
600mm front
clearance
for service
Optional plug-in timers
Siting of appliance
• A boiler fitted with a mechanical timer or RF mechanical
timer (receiver) or FW100 controller may only be installed
Using 125mm
flue kit
– 1,110mm
450mm
960mm
• Plug-in filling link provided with the Greenstar CDi Classic
pre-formed copper pipe lengths.
must not be within reach of a person using the bath
installation and service clearances are maintained, see on
less connections
•
• Built-in boiler frost protection
• Vertical pre-piping assembly accessory providing
• The boiler must not be installed in Zone 1
• Any switch or appliance control using mains electricity
1
1
2
2
2
Radi
u
600m s
m
2
2
1
2250mm
• Zero pressure governor gas valve with fully modulating fan
• Highly versatile multi-directional fluing system
• Combined ignition and control board means
410mm
930mm
2250mm
All combi boilers require less installation time than a
2
1. The room in which the appliance is installed does not
protection. EN482, Section 6.4.1.3 states no means
Radius 600mm
require a purpose-provided air vent.
400mm
880mm
for protection of combustible surfaces are necessary if
2. If the appliance is installed in a cupboard or
the temperature of the wall does not exceed the room
compartment with dimensions that allow the following
+30mm
above elbow
temperature by more than 60ºC. Testing of Greenstar
minimum clearances, then no ventilation is required:
gas-fired wall mounted boilers has shown that this
Compartment installation
building, the guidelines laid down in BS 5440:Part 1 and
the Gas Safe publication “Gas Installations in Timber Frame
Using 125mm
flue kit
– 1,100mm
5mm
Buildings” should be adhered to.
20mm to
removable
door
The appliances may be installed into an airing cupboard
600mm front
clearance
for service
if required. Use a non-combustible perforated material
Greenstar
Position of Greenstar CDi Compact
CDi
Classic
appliance
& Si Compact
In front
200mm
the airing space. See section “Boiler location”
Clearances for Greenstar CDi Compact and Si Compact
600m
m
2
100mm
200mm
200mm
200mm
Right side
5mm
5mm
200mm*
Left side
5mm
5mm
200mm*
30mm
30mm
30mm
600m
m
750m
Greenstar i
20mm
Above
flue elbow
m
2
20mm
Below
(max. hole sizes of 13mm) to separate the boiler from
on page 31.
600m
Minimum unventilated clearance
(to removable door)
5mm
m
1
2,250mm
However, if the appliance is to be fitted in a timber frame
Using 100mm
flue kit
– 1,060mm
1
2* 2*
2
2
Radiu
s
600m
m
2
2
1
2
2,250mm
temperature is not exceeded.
Radius 600mm
*This can be reduced to 50mm for one side, provided that the total side
clearances add up to 400mm or more.
*Without the end wall, zone 2 must extend 600mm from the bath
30
31
Wall preparation
Pipework connections
The following diagrams show the wall-mounting jigs which
After fixing the jig to the wall, the appliance can be lifted
enable a simple and straightforward method of attaching
onto the jig and the union connections tightened. The
the boiler to the wall surface.
pipework can be routed behind the boiler without the
need for an additional wall spacing frame.
All Greenstar wall-mounting jigs have pre-drilled fixing
points and options that make hanging a Worcester
1
Greenstar quick and easy.
7
2
3
4
1
5
2
6
3
Pipework connections – Greenstar CDi Classic
From left
case edge
55mm
Function
1 Condensate drain
2 CH flow
Greenstar CDi Compact and
Greenstar Si Compact wall-mounting jig
Greenstar i wall-mounting jig
Casing dimensions
6
7
Pipework connections – Greenstar i
Diameter
of pipe
22mm
Function
1 Condensate drain
From left
case edge
38mm
Diameter
of pipe
22mm
85mm
22mm
2 CH flow
70mm
22mm
3 DHW outlet
148mm
15mm
3 DHW outlet
135mm
15mm
4 Gas
212mm
22mm
4 Gas
200mm
22mm
5 DCW mains in
278mm
15mm
5 DCW mains in
265mm
15mm
6 CH return
343mm
22mm
6 CH return
330mm
22mm
7 Pressure relief valve
375mm
15mm
7 Pressure relief valve
364mm
15mm
Depth to wall (when fitted to wall frame)
Depth to wall (when fitted to wall frame)
5
Greenstar i
Greenstar CDi Classic
Greenstar CDi Classic wall-mounting jig
4
Optional pre-piping assembly kit
360mm
280mm
The vertical pre-piping assembly kits comprises a set of
1
pre-formed copper pipes. More information on this and
330mm
other time-saving accessories can be found on page 62.
750mm†
2
700mm*
680mm†
3
4
5
7
6
Greenstar CDi Compact and Si Compact
Pipework connections –
Greenstar CDi Compact & Si Compact
Function
1 Condensate drain
400mm
440mm
390mm
Greenstar CDi Classic
Greenstar CDi Compact and Si Compact
Greenstar i
†760mm to top of casing front.
†690mm to top of casing front.
*710mm to top of casing front.
32
2 CH flow
From left
case edge
33mm
Diameter
of pipe
22mm
65mm
22mm
3 DHW outlet
130mm
15mm
4 Gas
195mm
22mm
5 DCW mains in
260mm
15mm
6 PRV drain
291mm
15mm
7 CH return
325mm
22mm
33
Greenstar combi installation requirements
Installation of the Greenstar combi boiler range must be
Optional Worcester
Natural gas supply
Mains cold water supply
in accordance with the relevant requirements of the Gas
integral filling link
Listed below is a representative example. Figures
Water Authority requirement
Safety (Installation Use) Regulations (as amended), current
The Worcester integral filling
for other appliances can be found in the relevant
A direct mains cold water connection is permitted by
IEE Wiring Regulations, local Building Regulations, Building
link simply connects between
installation manuals.
Water Authorities. However, it is recommended that
Standards (Scotland) regulations and bylaws of the local
the cold main connection and
water company and Health and Safety Document No. 635
the heating return circuit on
reference be made to local requirements. In the event
Model
Gas rate
4.40m3/hr
(Electricity at Work Regulations 1989). It should also be
the wall-mounting jig
42CDi Classic
in accordance with the relevant recommendations of the
(part no. 7 716 192 281).
36CDi Compact
3.93m3/hr
30Si Compact
3.24m3/hr
30i
3.24m3/hr
following British Standards:
BS 6798; EN 12828; BS 5546:1; BS 5440:1; BS 5440:2;
Worcester Keyless Filling Link
BS 6891; BS 7074; BS 7593.
The Worcester Keyless
of difficulty, please contact Worcester Technical
Support Department.
Cold water connection
Connection should be made as shown in the pipework
detail and the appliance installed generally in accordance
Filling Link is an innovative
The gas meter and supply pipes must be capable of
Gas Safety (Installation and Use) Regulations state that all
accessory which has been
supplying this quantity of gas in addition to the demand
gas appliances must be installed by a Gas Safe registered
specially designed to be
from any other appliance being served. It is important that
Wherever possible, the cold supply to the appliance should
person in accordance with the above regulations. Failure
directly connected to a wall
a gas supply pipe of at least 22mm diameter is used. Under
be the first connection off the mains supply, in order to
to install appliances correctly could lead to prosecution.
mounted Worcester Greenstar
no circumstances should the size of the gas supply pipe be
minimise hot water flow reduction when cold water services
combi boiler. Its simple lever
less than that of the appliance inlet connection. The meter
are operated. The final 600mm of piping to the appliance
The manufacturer’s notes must not be taken in any way as
operation makes system
outlet governor should be capable of ensuring a dynamic
should be of copper only.
overriding statutory regulations.
re-pressurisation easy for both the installer and end user
pressure of 20mbar (8in wg) at the appliance. Particular
alike, and eliminates the problems caused when a separate
consideration should be given to the resistance to gas flow
Sealed primary systems
filling link or loop has been mislaid or lost. This feature is
created by elbows, bends etc. Pipework should be sized to
The Worcester Greenstar combi boilers are supplied
supplied as standard with the Greenstar CDi Classic and
overcome this resistance.
complete with all the necessary components to form a
an accessory for the Greenstar CDi Compact, Si Compact
sealed primary system. Included are an expansion vessel,
and i. For further details see pages 38 and 39
Liquid Petroleum Gas (LPG) supply
a pressure relief valve (set at 3bar), an automatic air vent
(part no. 7 716 192 610).
Listed below is a representative example. Figures
Valves and joints
installation manuals.
D
It is very important that all valves and joints are able to
of approximately 83 litres can be accommodated. Refer to
sustain a working pressure of up to 3bar (45psi). Particular
BS 7074:Part 1 for more information.
care should be exercised when fitting radiator valves and
42CDi Classic
3.30kg/hr
only those of high quality to BS 2767:10 should be used.
36CDi Compact
2.80kg/hr
All other valves and fittings should comply with BS 1010.
30Si Compact
2.33kg/hr
30i
2.38kg/hr
pH level of the water does not exceed 8. Levels in excess of
Loss of water pressure from a sealed system will require
Model
C
A
With an initial system pressure of 0.5bar, a system capacity
this could be detrimental to the heat exchanger.
MAINS WATER EXPANSION VESSEL:
A - Mains water inlet pipe
B - Non-return valve
C - Mini expansion vessel, Part No. 7 716 192 105
D - Boiler
for other appliances can be found in the relevant
and a pressure gauge.
It is important with an aluminium heat exchanger that the
with the layout shown on page 33.
B
Gas rate
Cold water pressure
To achieve the stipulated flow rate, a working cold water
mains pressure of 1.3bar is required.
continuous recharging with fresh water and consequential
The gas tank or bottles must be capable of supplying
The use of a suitable inhibitor will provide a resistance to
introduction of air. Air is highly corrosive and will
this quantity of gas at a nominal pressure of 37mbar
However, for the Greenstar CDi Classic range to achieve the
this. Contact Sentinel (Tel: 0800 3894670 or visit
considerably reduce life expectancy of radiators, pumps etc.
(14.8in wg) at the appliance.
stipulated flow rate, a working cold water mains pressure of
Plastic pipework
Electricity supply
www.sentinel-solutions.net) or Fernox (Tel: 0870 601 5000
or visit www.fernox.com) for further details.
between 1.2 and 1.9bar is required (dependent on model).
The use of plastic pipework is acceptable. However, some
A 3amp fused three pin plug and unswitched shuttered
The appliance will operate at a minimum working pressure
System filling and re-pressurising
plastics are permeable to oxygen and must be avoided. Only
socket outlet (both complying with BS 1362) or preferably a
of only 0.2bar (3psi); however a reduced hot water flow
Worcester Greenstar combi boilers are fitted to a sealed
pipework with a polymeric barrier should be used. Please
double pole isolator with a contact separation of 3mm in all
rate should be expected. Back-flow prevention devices,
heating system which is pressurised. To maintain optimum
note that the first 600mm of pipework connected to the
poles supplying the appliance should be used.
including water meters, can prevent the expansion of hot
system pressure, two options may be used: an optional
boiler must be of copper or steel.
Worcester integral filling link or external filling loop.
water into the cold water main. However, this can result in a
The appliance electrical circuits are also protected by an
pressure build-up that may cause damage to the boiler and
internal 2amp fuse. The appliance must be earthed.
household devices such as showers, washing machines, etc.
In these cases, we recommend that a mini-expansion vessel
(Part No. 7 716 192 105) be fitted adjacent to the boiler in
the cold water main.
34
35
The Worcester
Greenstar System Filter
Hot water supply
Use in hard water areas
At the centre of this innovative design is a highly powerful
All Worcester Greenstar boilers are fitted with a
As the maximum temperature of the domestic hot water
magnet that removes the magnetic debris (magnetite) that
flow regulator set to achieve a 40°C temperature rise.
heat exchanger is limited by the electronic control circuit,
is present in the heating system water. The central location
This ensures comfortable bathing during the colder
there is normally no need for water treatment to prevent
of the magnet ensures that magnetite is collected quickly
winter months.
scale accumulation.
and retained, maximising the overall protection. Any
non-magnetic debris is caught by the twin-action cyclonic
For the Greenstar CDi Classic range, a domestic hot water
In areas where exceptional water conditions prevail,
trap, a proven technology that offers a capacity to collect
flow regulator, set to give an optimum flow rate of between
consideration may need to be given to the fitting of a device
up to 200g of magnetite a year.
9 and 15l/min ±15% (dependent on model) is fitted to the
capable of preventing scale. In such circumstances, the
cold supply of the hot water heat exchanger.
advice of the local water authority should be sought.
The Greenstar CDi Compact flow regulators are sized
Guarantee
between 10l and 13l.
Worcester Greenstar combi appliances are offered with a
The Greenstar System Filter has been extensively
tested in simulated systems, proving its effectiveness
in removing iron oxide, magnetite, limescale particles,
casting sand, welding debris, non-magnetic metal flakes,
full 5 year guarantee* on parts and labour and a 10 year
Modern condensing boilers are precision-engineered and
A domestic hot water flow regulator, set to give an
guarantee* on the primary heat exchanger*. Ongoing service
designed to run with a clean water heating system. Over
optimum flow rate of between 8 and 11l/min ±15%
and maintenance contracts can be arranged through the
time, dirty system water will damage a boiler and its
(dependent on model) is fitted to the cold supply of the
Worcester Customer Service Department.
components, causing failures and shortening the life of the
overall system.
hot water heat exchanger in the Greenstar Si Compact
and Greenstar i combis.
paint particles and other system pollutants.
Features
Benefits
Highly effective filter
Safeguards the boiler against
damage and protects the
efficiency of the system.
Saves up to 6% a year on
energy bills*
Prevent blockages in radiators
A warmer home and
quieter system
Please contact our guarantee
registration advisors on
Damaged boiler and system components
As with all mains-fed systems, the flow rate of water
0330 123 2552 or visit
• Blockages in primary
obtainable from individual taps will vary in relation to the
www.worcester-bosch.co.uk/
number of taps operating simultaneously, and will depend
guarantee
heat exchanger
• Increased wear on pumps
• Blocked valves.
Proven technology that
High powered internal magnet can capture up to 200g
of magnetite
Therefore, in order to avoid excessive starvation of flow
Reduced efficiency
Cylindrical design
Increased performance –
better installation options
to individual taps, flow balancing may be required by the
• Energy efficiency loss
Twin-action – magnetic and
non-magnetic filtration
Instantly effective against a
wide range of system debris
No power consumption or
moving parts
No electrical wiring
connection or supply needed.
Zero running costs and no
failure of components
Can be installed under the
boiler or away from the
appliance
Flexibility
One-way valve for adding
system chemicals
Removes the need to isolate
a section of the system when
carrying out servicing and
maintenance
effects of system debris
Worcester, Bosch Group
specification and design
Reliability of components
and filter
and pollutants, allowing
*Independent research carried out by GASTEC at CRE
upon the cold mains supply available to the property.
On all Greenstar On the primary
combi appliances* heat exchanger*
use of proprietary constant volume flow regulators or
equivalent to a boiler being
Ball-o-Fix valves.
reduced from A rated efficiency
to D rated, resulting in fuel wastage
• Blocked radiators can reduce
Hot water systems
Taps and valves
efficiency and heating comfort.
Hot and cold taps and mixing valves used with the
Greenstar combi appliances must be suitable for
A highly-effective solution from the brand you can trust
operating at a mains pressure and temperatures of
The Worcester Greenstar
System Filter has been
65°C (150°F).
specifically designed to
combat the damaging
homeowners to protect their
Installation
boiler or heat pump for a
The filter can be installed almost anywhere in a heating
fraction of its cost. The filter
is suitable for 22mm piped
heating systems.
The Greenstar System Filter is easy to
install and service
system, however to maximise the effectiveness, it should be
placed before the boiler and after the last radiator.
Product info
Part number
36
*Subject to terms and conditions.
7 716 192 609
37
The Worcester Keyless Filling Link –
easy to install, simple to operate
Innovative design
Worcester Greenstar gas-fired combi boilers are designed to
deliver maximum efficiency and performance, however the
Nominal flow
direction
heating system will occasionally need to be re-pressurised
for optimum performance.
3
Traditional methods involve using a built-in key or connecting
3
an external filling loop, an operation which can be confusing
for the end user.
1
The new Worcester Keyless Filling Link has been developed
to make system filling quick and easy for both the installer
and the end user. The new Greenstar CDi Classic combi
boilers are supplied with the Worcester Keyless Filling Link
as standard.
Fewer call-outs
Back flow
relief port
Some end users find conventional filling loops and separate
filling links difficult to attach and use. There is also the
2
possibility that a separate link can be lost or mislaid, often
leading to the installer being called out simply to top up the
system. The innovative Keyless Filling Link relieves the end
Innovative design features ensure the Worcester Keyless Filling Link delivers reliable, trouble-free performance without
user of these problems, leading to reduced call outs.
risking backflow or overfilling. These include:
Quick to install, easy to use
1 Valve orientation that uses water
The Worcester Keyless Filling Link connects directly to the
Worcester Greenstar gas-fired combi boiler wall mounting
frame with no hose or key to connect, making installations
Whenever the system needs to be re-pressurised,
the blue lever is simply pulled down until the correct
pressure is achieved.
2 Simple and intuitive pull-down lever
pressure to aid valve sealing and
to fill the system
3 Twin check valves to prevent
backflow of system water
prevent overfilling
quick and simple. As the Filling Link is always connected to
the appliance, the end user will never need to find a key or
connect a separate loop to the system.
The Worcester Keyless Filling Link has a host of benefits
For the installer
For the end user
Quick to install and operate
Simple lever operation, no key or hose required
Reduced risk of call-outs to top up the system
No risk of the end user losing or misplacing the
filling link
Added value for the end user
Easy to maintain optimum boiler performance
Guaranteed Worcester quality
Peace of mind
WRAS approved
For safe use as a filling link with the domestic water supply
Product info
Part number
38
7 716 192 610
39
External connections
Condensate pipework
Greenstar CDi Classic and Greenstar i
The Greenstar CDi Classic and Greenstar i have a large
Siphon
trap
capacity siphonic condensate trap reducing the risk of
condensate discharge freezing up in prolonged cold
temperatures.
Important points to consider when siting a condensate
drainage pipe:
Like the CondenseSure siphon accessory, the expanded
•
siphonic operation discharges every 15 to 20 minutes,
Where a new or replacement boiler is being installed,
access to an internal “gravity discharge” point should
be one of the factors considered in determining
Soil
& vent
stack
• Increased velocity and flow rate
• With only 3 to 4 siphonic actions per hour, the
condensate pipework is empty for longer
• The condensate pipe must be a minimum of 22mm dia.
• Eliminated freezing potential.
plastic pipe
• The condensate pipework must fall at least 52mm per
Min. 450mm &
up to 3 storeys
22mm dia.
practicable route
• Ensure there are no blockages in the pipe run.
parameters listed below are adhered to.
To maximise the effectiveness of this product the
installer should:
• Keep the external pipework as short as possible. An
Internal connections
external run pipe diameter should be increased to a
Fig. 1 Disposal to soil vent stack
minimum of 32mm and not exceed 3 metres
cold spells, the following methods of installing a condensate
• Ensure a fall of at least 2.5º over horizontal sections
• Minimise the number of bends and connectors
• Remove burrs after cutting pipe
• Remove surplus solvent from the interior of the pipe.
drainage pipe should be adopted, in order of priority.
Wherever possible, the condensate drainage pipe should
be routed and terminated so that the condensate drains
Siphon
trap
away from the boiler, under gravity, to a suitable internal
foul water discharge point, such as an internal soil and vent
stack. A suitable permanent connection to the foul waste
Visable air break
at plug hole
Sink with
integrated
overflow
100mm
pipe should be used. (see fig. 1)
Fig. 2 Disposal to a waste pipe
be required to reach a suitable discharge point, condensate
Visable air break
at plug hole
should be removed using a proprietary condensate pump,
of a specification recommended by the boiler or condensate
Sink with
integrated
overflow
pump manufacturer.
The pump outlet pipe should discharge to a suitable internal
stack, internal kitchen, bathroom or washing machine waste
pipe, etc. A suitable permanent connection to the foul waste
Fig. 3 Condensate pump disposal
400mm deep by 300mm dia.
In situations where there are likely to be extremes of
does not apply, however all other guidance above, and the
instructions for the trace heating system, should be
closely followed.
Unheated internal areas
Condensate waste
Internal pipe runs in unheated areas such as lofts,
•
Care should be taken when siting a soak away to avoid
basements and garages should be treated as external runs,
obstructing existing services.
with consideration given to using a CondenseSure siphon.
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 (fig. 4), or purpose-
100mm dia.
100mm
dia. min.
plastic pipe
designed soak away (fig. 5), may be considered. Please see
installation and servicing instructions for more details.
Insulate
& increase
pipe size
12mm dia. 300mm
500mm min.
External
rain water
pipe into
foul water
Pipework
transition
External
air break
Pipework
transition
Drainage
holes
Siphon
trap
43mm 90º
male/female
bend
68mm dia. PVCu
strap on fitting
Insulate
& increase
pipe size
25mm
25mm
50mm
25mm
25mm min.
100mm
dia. min.
plastic
pipe
Air gap
Fig. 4 Disposal into a rainwater down pipe
40
limestone chippings to a depth of 400mm
• Minimum hole size for the condensate soak away must be
such a system is used, the requirement to use 32mm pipe
75mm sink
waste trap
Condensate
pump
• The tube must be surrounded by at least 100mm of
CondenseSure siphon to minimise the risk of freezing
Siphon
trap
22mm
dia.
away from the house
an external frost thermostat) should be considered. If
75mm min.
pipe should be used. (see fig. 3)
50mm from the bottom of the tube. The holes must face
routing, we recommend installing a Worcester
foul water discharge point such as an internal soil and vent
Siphon
trap
two rows of three 12mm holes on 25mm centres and
heating system for external pipework (that incorporates
using a CondenseSure siphon.
physically possible, or where very long internal runs would
• The examples shown run above ground
• The soak away must use a 100mm dia. plastic tube with
• When the position of the boiler prevents internal
• Weather-proofing insulation must be sized when not
Condensate pump
the ground to the soak away
temperature or exposure, the use of a proprietary trace
route as vertical as possible
75mm sink
waste trap
Condensate soak away (see fig. 6)
Freezing conditions
75mm min.
be used. (see fig. 2)
Fig. 5 External disposal
Greenstar CDi and Si Compact
• Pipework length should be kept to a minimum and the
22mm dia.
kitchen, bathroom or washing machine waste pipe, etc. can
Where “gravity discharge” to an internal termination is not
25mm min.
• The condensate drainage pipe may be run above or below
For a 48 hour period at -15°C provided the installation
metre towards the outlet and should take the shortest
Alternatively, if the first option is not possible, an internal
Pipework
transition
resulting in:
Siphon
trap
boiler location
In order to minimise the risk of freezing during prolonged
Insulate
& increase
pipe size
Limestone chippings
400mm
Drainage min.
holes
Bottom of sealed tube
Fig. 6 Soak away
41
The Worcester
CondenseSure siphon
With temperatures as low as -20ºC being experienced
Ease of installation
Fitting to a combi boiler
in very cold winters, practices such as externally run
The CondenseSure has been designed with ease of
condensate discharge pipework are now being questioned.
installation in mind and is suitable for most boiler
applications. For maximum effectiveness, it should
The Worcester CondenseSure siphon has been designed to
be installed immediately beneath the boiler where
allow a more flexible approach to boiler siting.
it is clipped on to the boiler’s heating flow pipe and
4
connected to its siphonic trap. If this is not practical,
Tested to extreme temperatures
the CondenseSure can be wall-mounted away from the
The Worcester CondenseSure siphon has been extensively
boiler and connected to a 32mm condensate discharge
tested under simulated extreme weather conditions, proving
pipe. However, this will sacrifice the benefit of warming
its effectiveness in preventing frozen condensate at -15ºC
the condensate prior to discharge and therefore slightly
for a sustained period of 48 hours.
reduce its performance.
1
2
3
CondenseSure principle of operation
Within most condensing boilers, there is an internal siphon
2
which holds around 100ml of condensate before being
Siphon
trap
released down the condensate discharge pipe. A typical
5
high-efficiency condensing boiler will generate up to
2 litres of condensate an hour (dependant on output
and temperature) and this will result in the in-built siphon
The CondenseSure insulating jacket helps to retain the temperature
of the condensate.
6
7
External pipework
3000mm max.
discharging approximately every 3 minutes. With this
CondenseSure
2.5º fall min.
frequency of discharge, it is unlikely that the condensate
A universal fitting for new and existing installations
pipework is ever empty of condensate, consequently
Although developed specifically for Worcester Greenstar
increasing the potential for freezing of the pipework in
gas- and oil-fired boilers, the Worcester CondenseSure
2. Siphon mounting screws
prolonged sub-zero temperatures.
can also be fitted to any make of condensing boiler for
3. Siphon body
32mm OD pipe
1. Foam backing with double-sided tape
both new and retrofit installations. The CondenseSure
4. Foam insert (used with regular or system boilers)
The CondenseSure siphon connects to the boiler
can provide a simple solution which eliminates the need
A typical installation using CondenseSure
condensate discharge outlet and collects the condensate
for re-siting both the new boiler and the system pipework
The CondenseSure installation parameters
6. CH flow pipe
into a larger volume before releasing it into the
when replacing an existing non-condensing appliance. The
The CondenseSure will protect an externally-run condensate
7. Boiler DHW outlet pipe
discharge pipe.
CondenseSure can easily be fitted to existing installations
discharge pipe from freezing for 48 hours at -15°C providing
to provide peace of mind in extreme weather conditions.
the following installation parameters are met:
Additional installation considerations include:
•
• There is a fall on the discharge pipe of at least 2.5 degrees
• The discharge pipe diameter is not less than 32mm
•
•
•
•
With this expanded siphonic operation, the discharge from
The externally-run pipe length does not exceed 3 metres
the CondenseSure increases to every 15 to 20 minutes,
resulting in:
• Increased velocity and flow rate
• Only 3 to 4 siphonic actions per hour, meaning the
condensate pipework is empty for longer
• Significantly decreased or even eliminated
freezing potential.
42
Features
Benefits
No power consumption
No electrical wiring
connection or supply needed,
meaning zero running costs
Whilst it is not necessary to insulate the pipework, it may
No moving parts
No failure of components
be a consideration if longer lengths or if lower external
Can be installed on new or
existing installations
Suitable for any gas- or
oil-fired condensing boilers
temperatures are expected.
Can be attached to 22mm
heating flow pipework
Uses ‘free’ energy from the
pipe to heat the condensate
Under boiler or remote
installation
Flexibility
No electrical connections
No electrician needed
No pipe insulation needed
Cost-saving and aesthetically
pleasing
in diameter.
The CondenseSure
clips onto the
22mm heating
flow pipe using
the ‘free’ heat
to raise the
condensate
temperature.
5. Foam cover
Keeping any external pipework as short as possible
Minimising the number of bends and connections
Removal of burrs after cutting pipe
Removal of surplus solvent from the interior of the pipe.
The CondenseSure has no working parts to breakdown,
does not use any energy and has no electrical connections,
so there is no Part P requirement.
Product info
Part number
7 716 192 746
43
A highly efficient solution
Flue Gas Heat
Recovery Unit
Colder flue gases
leave FGHR via
flue system
Recognised
under the
Green Deal
Save energy and reduce CO2 emissions with
the EcoFlo FGHR unit.
Understanding the need for specifiers and house builders
to have a cost effective method of achieving SAP target
emission rates, Worcester has introduced the EcoFlo Flue
Gas Heat Recovery (FGHR) unit which is compatible with
2
the latest range of Greenstar CDi Compact and Si Compact
combi boilers.
How the FGHR works
The FGHR is connected directly to the flue of the Greenstar
boiler. Its heat exchanger extracts residual energy from the
flue gases exiting from the boiler. This energy is then used
3
to pre-warm the water that is fed into the combi boiler
reducing the amount of gas required to reach the desired
1
hot water temperature.
Hot flue gases from CDi Compact or
Si Compact combi condensing boiler
The table below highlights the positive impact that the
specification of an EcoFlo FGHR unit can have on a
1 Cold mains water enters the
property’s SAP assessed Dwelling Emission Rate (DER),
EcoFlo unit.
allowing the example Target Emission Rate (TER) to be met
and exceeded.
2 Cold water passes through the heat
3 Pre-heated water leaves the EcoFlo
exchange coil and is heated by the
speeding up the heating of hot
hot waste flue gases from the boiler.
water, reducing gas consumption
and CO2 emissions.
Feature
Benefit
For the Specifier…
SAP listed FGHR unit enables the heating system
to meet SAP target emission rates for new build properties
TER
DER
% Difference
from TER
Savings on building fabric such as insulation can be achieved
Worcester Si Compact
15.47
15.56
-0.58
Can be used as an energy saving measure to improve
domestic EPC ratings
Worcester Si Compact + EcoFlo
15.57
14.96
+3.30
For the Installer…
SAP 2009 calc based on: Mid terrace house (3 bed) – 100m²
Cavity wall – 0.25 W/m²;.K Roof – 0.1 W/m²;.K Floors – 0.12 W/m².K; Openings – 1.4 W/m²K.
Accredited thermal bridges
Q50 – 5; 3 intermittent fans; Standard programmer, room thermostat and TRV with radiators
More cost-effective than other solutions such as solar thermal
or heat pumps
Ease of installation
Property receives a higher energy rating and occupier
achieves lower fuel bills
No additional training required for a competent installer
For the End User…
When fitted to a Greenstar combi, it reduces the amount
of gas used to provide hot water
Reduction in gas bills for homeowners
Recognised as a energy saving measure under the
Green Deal scheme
Eligible for Green Deal finance
Product info
Part number
7 733 600 047
SAP Assessors select Muelink & Grol EcoFlo as the FGHR unit
44
45
Horizontal and vertical flue terminal positioning
All measurements in millimetres
2m
1m
2
25
25
104mm
52mm
16
3
1,500
600
13
400
300
500
12
14
2
200
300
1
5
300
300
1,500
7
8
600
500
600
1,200
4
300 300
6
15
300
18
600
10
600
9
16
11
300 300
300 300
25
300
17
300
Boundary Line
Note
Key to illustration
• All measurements are the minimum clearances required
• Terminals must be positioned so as to avoid combustion products
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
entering the building
• Support the flue at approximately one metre intervals and at a
change of direction, use suitable brackets and fittings.
Flue bracket part numbers:
3.
46
300mm above, below and either side of an opening door,
air vent or opening window.
10. 600mm diagonally to an opening door, air vent or
opening window.
clear any overhang. External flue joints must be sealed with
11. 300mm to an internal or external corner.
suitable silicon sealant.
12. 2,000mm below a Velux window, 600mm above or to either
1,500mm between a vertical flue terminal and a window or
dormer window.
7 716 191 177 (100mm dia.)
9.
7 716 191 178 (100mm dia. x 6)
4.
1,200mm between terminals facing each other.
7 716 191 179 (125mm dia.)
5.
Vertical flue clearance, 300mm adjacent to a boundary line.
6.
600mm distance to a boundary line, unless it will cause a
side of the Velux window.
13. 400mm from a pitched roof or 500mm in regions with
Terminal guards must be fitted if the flue is less than 2 metres
from the ground or if a person could come into contact with
the flue terminal.
18. 600mm distance to a surface facing a terminal, unless it will
cause a nuisance. BS 5440: Part 1 recommends that care
is taken when siting terminals in relation to surfaces facing
a terminal.
heavy snowfall.
14. 500mm clearance to any vertical structure on a roof, 600mm
to room sealed flue or 1,500 to an open flue.
nuisance. BS 5440:Part 1 recommends that care is taken when
15. 200mm below eaves and 75mm below gutters, pipe and drains.
siting terminal in relation to boundary lines.
16. The dimension below eaves, balconies and car ports can be
7.
600mm minimum clearance from a skylight to a vertical flue.
reduced to 25mm, as long as the flue terminal is extended to
8.
Vertical flue clearance, 500mm to non-combustible
clear any overhang. External flue joints must be sealed with
building material, and 1,500mm clearance to combustible
suitable silicon sealant.
building material.
17. Flue clearance must be at least 300mm from the ground.
• Installations in car ports are not recommended
• The flue cannot be lower than 1,000mm from the top of a light
well due to the build-up of combustion products
• Dimensions from a flue terminal to a fanned air inlet to be
determined by the ventilation equipment manufacturer.
47
Greenstar combi boiler range
horizontal fluing options
™
Accessories
The Greenstar combi boiler range offers the choice of
2 differently sized horizontal RSF flue systems, a 100mm
Components
diameter telescopic flue kit including a plume management
kit, and a 125mm diameter telescopic flue kit. Both systems
Part No.
™
100mm
Standard telescopic flue kit
(350 - 570mm)
7 716 191 171
Long telescopic flue kit
(570 - 790mm)
7 716 191 083 Extension flue kit (960mm*)
7 716 191 172 2m flue extension
125mm
7 716 191 133 Short flue extension (220mm*)
Greenstar CDi Classic series
Minimum flue length
Description
7 716 191 082
detail the permissible lengths.
Flue diameter
350mm*
7 716 191 085 45º bend
7,900mm
18,500mm
34CDi Classic
7,000mm
16,000mm
38CDi Classic
6,000mm
12,500mm
42CDi Classic
6,000mm
12,000mm
Greenstar CDi Compact and Si Compact series
7 719 002 432
High level horizontal
flue adaptor
350mm*
405mm
Maximum flue length
6,000mm
15,000mm
405mm
Maximum flue length
4,600mm
13,000mm
7 716 191 082
Part No. 100mm
7 716 191 082
7 716 191 083
Part No. 125mm
7 719 003 702
Part No. 125mm
7 719 003 702
7 719 003 666
Maximum lengths (mm) & no. of components required
Maximum lengths (mm) & no. of components required
Greenstar CDi Classic series
Greenstar 29CDi Classic
570
1
100mm
7 716 191 178 Support bracket kit (6 pack)
125mm
600
1
125mm 18,500
7 719 003 702 Standard telescopic flue kit
7 719 003 666 Extension flue kit (960mm*)
7 719 003 664 90º bend
350mm*
Part No. 100mm
100mm
*Dimensions when fitted
Greenstar i series
Minimum flue length
Components
7 716 191 177 Support bracket kit
125mm diameter
Minimum flue length
Components
7 716 191 084 90º bend
405mm
Maximum flue length
29CDi Classic
7 719 003 665 45º bend
7 719 002 433
*Can be cut to 130mm. Please refer to instructions.
Greenstar 34CDi Classic
100mm
570
1
100mm
125mm
600
1
125mm 16,000
100mm
570
1
100mm
125mm
600
1
125mm 12,500
100mm
the installation:
Part No. 7 716 191 082
• The concentric flue system must be inclined at
1
up to 7
1
up to 16
1
up to 6
1
up to 13
1
up to 6
1
up to 12
6,000
1
up to 6
1
up to 15
100mm
4,600
1
up to 4
125mm 13,000
1
up to 13
condensate to drain back into the boiler
• A white plume of condensation will be emitted from
600mm (125mm dia.) of flue duct including terminal
the terminal because the appliance operates at high
(as measured from centre of flue outlet)
efficiency. Care must be taken when selecting the flue
1 x weather sealing plate
terminal position
• To achieve a maximum flue length, one of the extension
Note: The short flue extension (100mm dia.) may be used
Note: The maximum flue length must be reduced by the
flue kits will need to be cut so that the permitted
as an alternative to the standard extension as required up to
following amounts for each bend used.
maximum flue length is not exceeded
the maximum flue lengths stated (Part No. 7 716 191 133).
• Horizontal flue options 1-6 illustrate common flue
installations. Other configurations of the flue system are
possible up to, and not exceeding, the stated maximum
flue lengths.
48
up to 19
Greenstar i series
3º (52mm per metre) from the appliance, to allow
Part No. 7 719 003 702
6,000
125mm 15,000
1 x internal collar
1
Greenstar CDi Compact and Si Compact series
100mm
The following criteria should be noted when planning
1 x internal plate
6,000
125mm 12,000
*Dimensions when fitted
1 x weather sealing ring
up to 8
Greenstar 42CDi Classic
High level horizontal
flue adaptor
570mm (100mm dia.) of flue duct
1 x flue turret elbow
7,000
1
Greenstar 38CDi Classic
Greenstar i series
1 x flue turret elbow
125mm dia. standard telescopic flue kit
7,900
Greenstar CDi Compact and Si Compact series
7 716 191 179 Support bracket kit
100mm dia. standard telescopic flue kit
Option 2: Extension flue horizontal
100mm diameter
have different maximum lengths. The following diagrams
Horizontal RS flue
Option 1: Standard horizontal flue assembly
45º bend
90º bend
Greenstar CDi Classic
60/100mm flues
750mm
1,500mm
Greenstar CDi Classic
80/125mm flues
1,000mm
2,000mm
Greenstar CDi Compact and
Si Compact – all flue sizes
1,000mm
2,000mm
Greenstar i – all flue sizes
1,000mm
2,000mm
49
Option 4: Extension flue horizontal and upwards
Option 3: Extension flue horizontal
using a second 90º bend
Option 5: Extension flue upwards and horizontal
using a second 90º bend
Option 6: Extension flue upwards and horizontal
using a third 90º bend
Components
Part No. 100mm
7 716 191 082
7 716 191 083
7 716 191 084
Part No. 125mm
7 719 003 702
7 719 003 666
7 719 003 664
Components
Part No. 100mm
7 716 191 082
7 716 191 083
7 716 191 084
7 719 002 432
Maximum lengths (mm) & no. of components required
Part No. 125mm
7 719 003 702
7 719 003 666
7 719 003 664
7 719 002 433
Greenstar 29CDi Classic
Maximum lengths (mm) & no. of components required
100mm
6,400
125mm 16,500
1
up to 6
1
Greenstar 29CDi Classic
1
up to 17
1
100mm
Greenstar 34CDi Classic
100mm
5,500
125mm 14,000
125mm 18,500
4,500
125mm 10,500
4,500
125mm 10,000
4,000
125mm 13,000
2,600
125mm 11,000
1
1
up to 19
1
1
Greenstar 34CDi Classic
1
up to 14
1
100mm
7,000
125mm 16,000
1
up to 7
1
1
1
up to 16
1
1
1
up to 4
1
Greenstar 38CDi Classic
1
up to 11
1
100mm
6,000
125mm 12,500
up to 6
1
1
1
up to 13
1
1
up to 4
1
Greenstar 42CDi Classic
1
up to 10
1
100mm
6,000
125mm 12,000
1
up to 6
1
1
1
up to 12
1
1
up to 4
1
Greenstar CDi Compact and Si Compact series
1
up to 13
1
100mm
125mm 15,000
1
up to 3
1
Greenstar i series
1
up to 11
1
100mm
4,600
125mm 13,000
Part No. 100mm
7 716 191 083
7 716 191 084
7 719 002 432
Part No. 100mm
7 716 191 082
7 716 191 083
7 716 191 084
7 719 002 432
Part No. 125mm
7 719 003 702
7 719 003 666
7 719 003 664
7 719 002 433
Part No. 125mm
7 719 003 702
7 719 003 666
7 719 003 664
7 719 002 433
Maximum lengths (mm) & no. of components required
Maximum lengths (mm) & no. of components required
Greenstar 29CDi Classic
Greenstar 29CDi Classic
100mm
6,400
125mm 16,500
1
up to 6
2
1
100mm
1
up to 17
2
1
125mm 14,500
100mm
5,500
125mm 14,000
100mm
4,500
125mm 10,500
1
up to 6
2
1
100mm
1
up to 14
2
1
125mm 12,000
up to 6
1
1
1
up to 15
1
1
100mm
4,500
125mm 10,000
up to 4
1
1
1
up to 13
1
1
100mm
4,000
125mm 13,000
2,600
125mm 11,000
Note: The short flue extension (100mm dia.)
may be used as an alternative to the standard
Note: The maximum flue length must be reduced by the
following amounts for each bend used.
lengths stated (Part No. 7 716 191 133).
50
1
1
up to 15
3
1
4,000
1
up to 4
3
1
1
up to 12
3
1
2
1
100mm
3,000
1
up to 3
3
1
1
up to 11
2
1
125mm
8,500
1
up to 9
3
1
Greenstar 42CDi Classic
1
up to 4
2
1
100mm
3,000
1
up to 3
3
1
1
up to 10
2
1
125mm
8,000
1
up to 8
3
1
Greenstar CDi Compact and Si Compact series
1
up to 4
2
1
100mm
1
up to 13
2
1
125mm 11,000
2,000
1
up to 2
3
1
1
up to 11
3
1
1
up to 9
3
1
Greenstar i series
1
up to 3
2
1
1
up to 11
2
1
Note: The short flue extension (100mm dia.)
may be used as an alternative to the standard
45º bend
90º bend
extension as required up to the maximum flue
Greenstar CDi Classic
60/100mm flues
750mm
1,500mm
lengths stated (Part No. 7 716 191 133).
Greenstar CDi Classic
80/125mm flues
1,000mm
Greenstar CDi Compact and
Si Compact – all flue sizes
Greenstar i – all flue sizes
extension as required up to the maximum flue
3
up to 4
Greenstar i series
100mm
up to 5
1
Greenstar CDi Compact and Si Compact series
1
1
Greenstar 38CDi Classic
Greenstar 42CDi Classic
1
4,900
Greenstar 34CDi Classic
Greenstar 38CDi Classic
1
6,000
Components
7 716 191 082
Greenstar 34CDi Classic
1
1
Greenstar i series
100mm
1
1
Greenstar CDi Compact and Si Compact series
100mm
up to 8
up to 6
Greenstar 42CDi Classic
100mm
1
1
Greenstar 38CDi Classic
100mm
7,900
Components
125mm
9,000
45º options available
Note: The maximum flue length must be reduced by the
following amounts for each bend used.
45º bend
90º bend
Greenstar CDi Classic
60/100mm flues
750mm
1,500mm
2,000mm
Greenstar CDi Classic
80/125mm flues
1,000mm
2,000mm
1,000mm
2,000mm
Greenstar CDi Compact and
Si Compact – all flue sizes
1,000mm
2,000mm
1,000mm
2,000mm
Greenstar i – all flue sizes
1,000mm
2,000mm
51
Greenstar combi boiler range
vertical fluing options
™
Accessories
The Greenstar combi boiler range offers the choice of
2 differently sized vertical RSF flue systems, 100mm and
Components
125mm. Both systems have different maximum lengths.
Part No.
7 719 002 430
™
Pitc
roo hed
f
Description
Vertical 1,090mm balanced
flue kit (inc. adaptor)
Pitc
roo hed
f
7 716 191 083 Extension flue kit (960mm*)
Flue diameter
100mm
125mm
Minimum flue length
1,090mm
1,365mm
Maximum flue length (inc. adaptor)
29CDi Classic
9,400mm
18,500mm
34CDi Classic
8,000mm
16,000mm
38CDi Classic
7,500mm
16,000mm
42CDi Classic
7,500mm
16,000mm
Greenstar CDi Compact and Si Compact series
(inc. adaptor)
500mm
300mm
Flat roof
L=
100mm dia. 1,090mm
125mm dia. 1,365mm
7 716 191 084 90º bend
7 716 191 085 45º bend
7 716 191 090 Flashing – flat roof
*Dimensions when fitted
125mm diameter
1,090mm
1,365mm
6,000mm
15,000mm
Vertical 1,365mm balanced
7 719 002 431
flue kit (inc. adaptor)
7 719 003 666 Extension flue kit (960mm*)
Greenstar i series
7 719 003 664 90º bend
Minimum flue length
1,090mm
1,365mm
Components
Components
Part No. 100mm
7 719 002 430
Part No. 100mm
7 719 002 430
7 716 191 083
Part No. 125mm
7 719 002 431
Part No. 125mm
7 719 002 431
7 719 003 666
Maximum lengths (mm) & no. of components required
Maximum lengths (mm) & no. of components required
Greenstar 29CDi Classic
Greenstar 29CDi Classic
100mm
1,090
1
100mm
125mm
1,365
1
125mm 18,500
Greenstar 34CDi Classic
(inc. adaptor)
6,400mm
15,000mm
7 716 191 090 Flashing – flat roof
7 716 191 091 Flashing – pitched roof
100mm dia. vertical balanced flue kit
1 x flue terminal assembly
1 x fire stop spacer
100mm
1,090
1
100mm
125mm
1,365
1
125mm 16,000
Greenstar 38CDi Classic
The following criteria should be noted when planning
1
up to 9
1
up to 18
8,000
1
up to 8
1
up to 16
1
up to 7
1
up to 16
1
up to 7
1
up to 16
Greenstar 38CDi Classic
*Dimensions when fitted
1 x weather sealing collar
9,400
Greenstar 34CDi Classic
7 719 003 665 45º bend
Maximum flue length
Flat roof
7 716 191 133 Short flue extension (220mm*)
7 716 191 091 Flashing – pitched roof
Maximum flue length
500mm
300mm
7 716 191 172 2m flue extension
Greenstar CDi Classic series
Minimum flue length
Option 2: Vertical balanced flue system maximum height
100mm diameter
The following diagrams detail the permissible lengths.
Vertical RSF flue
Option 1: Minimum height
100mm
1,090
1
100mm
125mm
1,365
1
125mm 16,000
7,500
1 x vertical adaptor
the installation:
Greenstar 42CDi Classic
Part No. 7 719 002 430
• Because the appliance operates at high efficiency, a
100mm
1,090
1
100mm
1,365
1
125mm 16,000
Greenstar 42CDi Classic
7,500
white plume of condensation will be emitted from the
125mm
125mm dia. vertical balanced flue kit
terminal. Care must be taken when selecting the flue
Greenstar CDi Compact and Si Compact series
Greenstar CDi Compact and Si Compact series
1 x flue terminal assembly
terminal position
100mm
1,090
1
100mm
125mm
1,365
1
125mm 15,000
1 x weather sealing collar
• To achieve a maximum flue length, one of the extension
1 x fire stop spacer
flue kits will need to be cut so that the permitted
1 x vertical adaptor
maximum flue length is not exceeded
Part No. 7 719 002 431
• Vertical flue options 1-4 illustrate common flue
installations. Other configurations of the flue system are
Greenstar i series
6,000
1
up to 5
1
up to 14
1
up to 6
1
up to 14
Greenstar i series
100mm
1,090
1
100mm
125mm
1,365
1
125mm 15,000
6,400
possible up to, and not exceeding, the stated maximum
flue lengths.
Note: The short flue extension (100mm dia.)
may be used as an alternative to the standard
Note: The maximum flue length must be reduced by the
following amounts for each bend used.
45º bend
90º bend
Greenstar CDi Classic
60/100mm flues
750mm
1,500mm
Greenstar CDi Classic
80/125mm flues
1,000mm
2,000mm
Greenstar CDi Compact and
Si Compact – all flue sizes
1,000mm
2,000mm
Greenstar i – all flue sizes
1,000mm
2,000mm
extension as required up to the maximum flue
lengths stated (Part No. 7 716 191 133).
52
53
Plume management
terminal positioning
Option 4: Vertical balanced flue system
with two 90º bends
Option 3: Vertical balanced flue system
with two 45º bends
All measurements in millimetres
Flue terminal guard 7 716 191 176
±45°
Plume re-direction:
100
600
1
180°
Flue exhaust
outlet
10
1,500
Air intake
±80°
6
200
300
2
200
5
600
Components
Components
150
200
Part No. 100mm
Part No. 125mm
7 719 002 430
7 719 002 431
7 716 191 083
7 719 003 666
7 716 191 085
7 719 003 665
Part No. 100mm
Part No. 125mm
7 719 002 430
7 719 002 431
7 716 191 083
7 719 003 666
300
7 716 191 084
300
3
7 719 003 664
150
Maximum lengths (mm) & no. of components required
Maximum lengths (mm) & no. of components required
Greenstar 29CDi Classic
Greenstar 29CDi Classic
300
7
150
150
300
8
200
300
150
1,200
300 300
25
25
600
9
10
4
Boundary line
100mm
7,900
125mm 16,500
1
up to 7
2
100mm
1
up to 16
2
125mm 14,500
Greenstar 34CDi Classic
100mm
6,500
125mm 14,000
6,000
125mm 14,000
1
up to 6
2
100mm
1
up to 14
2
125mm 12,000
6,000
125mm 14,000
4,000
125mm 13,000
up to 6
2
100mm
1
up to 14
2
125mm 12,000
4,400
125mm 13,000
2
1
up to 14
2
Note
1
up to 4
2
1
up to 11
2
4,500
1
up to 4
2
1
up to 11
2
Greenstar 42CDi Classic
1
up to 6
2
100mm
1
up to 14
2
125mm 12,000
4,500
100mm
2,000
1
up to 12
1
125mm 11,000
up to 4
2
100mm
1
up to 13
2
125mm 11,000
Note: The short flue extension (100mm dia.)
may be used as an alternative to the standard
up to 4
2
1
up to 11
2
1
up to 1
2
1
up to 10
2
For details on specific lengths see relevant boiler Technical &
products entering the building
2,400
Specification information.
7.
1
up to 2
2
1
up to 10
2
on a standard telescopic horizontal flue terminal. 300mm
Greenstar CDi Classic
60/100mm flues
45º bend
90º bend
750mm
1,500mm
Greenstar CDi Classic
80/125mm flues
1,000mm
2,000mm
Greenstar CDi Compact and
Si Compact – all flue sizes
1,000mm
2,000mm
Greenstar i – all flue sizes
1,000mm
2,000mm
Clearances no less than 200mm from the lowest point of the
balcony or overhang.
9.
1,200mm from an opening in a car port on the same wall e.g.
door or window leading into the dwelling.
10. 600mm distance to a surface facing a terminal, unless it will
minimum clearances to an opening in the direction that the
cause a nuisance. BS 5440: Part 1 recommends that care is
plume management is facing, must be increased to 1,500mm.
taken when siting terminals in relation to surfaces facing
Where the flue is less than 150mm to a drainpipe, and plume
a terminal.
re-direction is used, the deflector should not be directed
Note: The maximum flue length must be reduced by the
following amounts for each bend used.
300mm clearance.
8.
This feature allows some basic plume re-direction options
Internal/external corners. The air intake clearance can be
reduced to 150mm providing the flue exhaust outlet has a
change of direction, use suitable brackets and fittings.
minimum clearances to a opening, e.g. window. However the
extension as required up to the maximum flue
lengths stated (Part No. 7 716 191 133).
“Plume terminal positions”
• Terminals must be positioned so as to avoid combustion
Greenstar i series
1
a 300mm clearance. Plume kits running horizontally must have
a 10° fall back to the boiler for proper disposal of condensate.
1.
1
can be reduced to 150mm providing the flue exhaust outlet has
• Support the flue at approximately one metre intervals and at a
1
Using a Plume Management Kit, the air intake measurement
unless the flue position is specified on the figure above
Key to illustration
up to 3
6.
• All measurements are the minimum clearances required
• Refer to pages 46-47 for all concentric flue terminal positions
Greenstar CDi Compact and Si Compact series
1
Greenstar i series
100mm
5,000
1
Greenstar CDi Compact and Si Compact series
100mm
up to 6
Greenstar 38CDi Classic
Greenstar 42CDi Classic
100mm
1
Greenstar 34CDi Classic
Greenstar 38CDi Classic
100mm
6,400
towards the drainpipe.
2.
300mm adjacent to a boundary line.
3.
Plume Management Kit air intake can be reduced to 150mm
providing the flue exhaust outlet is no less than 300mm
adjacent to a boundary line.
4.
1,200mm between terminals facing each other.
5.
600mm distance to a boundary line, unless it will cause a
• Installations in car ports are not recommended
• The flue cannot be lower than 1,000mm from the top of a
light well due to the build up of combustion products
• Dimensions from a flue terminal to a fanned air inlet to
be determined.
nuisance. BS 5440:Part 1 recommends that care is taken when
siting terminal in relation to boundary lines.
54
55
Plume management system options
Plume management system
™
Accessories
60mm dia. plume management kit
Components
1 x terminal bend
Part No.
Description
For Greenstar CDi Classic boilers, the 100mm dia.
Condensfit II™ telescopic flue and plume management
internal flue length is immediately reduced by 2,000mm
system measuring
when the minimum plume management of 500mm is used.
60mm diameter
1 x extension 500mm
Fig A
1 x outlet assembly
7 716 191 086 Plume management kit
For the Greenstar CDi Compact and Si Compact boilers,
1 x clamp pack
7 716 191 087 Extension (1,000mm)
the 100mm dia. internal flue is immediately reduced by
Part No. 7 716 191 086
7 716 191 088 90º bend
1,000mm when the minimum plume management of 500mm
is used.
7 716 191 089 45º bend (pair)
500mm
(min) (M)
L (max)
7 716 191 176
Plume management
terminal guard round
Greenstar i boilers are able to use the maximum 100mm
dia. internal flue length of 4,500mm regardless of the
amount of plume management selected.
Standard plume management system
External plume management bends still need to be allowed
The flue terminal outlet has built-in stops which limits the
Any plume management extensions as far as the first elbow
rotation for horizontal fluing, allowing the condensate to
must rise by at least 173mm per metre (10º). Further
run back into the boiler for safe disposal. Do not attempt to
subsequent extensions must rise by 52mm (3º) to ensure
Furthermore, for both the Greenstar CDi Classic,
force beyond the limit stops.
that condensate flows back to the boiler.
CDi Compact and Si Compact, the internal flue length must
for. For more information, see below.
Fig B
be reduced by 700mm for every additional 1,000mm of
plume management, refer to the table below.
4,500mm
(max) (M)
60mm dia. plume management system
Min. 1,500mm
To ensure that the maximum total straight flue length along
Opening in building
e.g. window
the plume management route is not exceeded, the following
L (max)
should be added to dimension (M):
50
Direction of
flue discharge
m
0m
50
0m
m
500
m
For plume management options with 60mm dia. extensions,
Direction of
m
±80°
• 1,500mm for each extra 90º bend
• 750mm for each extra 45º bend
flue discharge
please refer to page 58.
Min. 1,500mm
The effective 100mm dia. internal flue length can be
Opening in building
e.g. window
determined by adding together all the straight flue lengths
and the effective lengths of the bends used. Allowances for
90º and 45º bends are detailed on pages 48-54.
Effective straight flue lengths for telescopic flue with plume management
Terminal exclusion zone
56
Re-directing flue discharge from a 60mm dia.
plume management outlet
Boiler
Fig. A
Maximum straight flue length (L) with minimum
plume management length 500mm (M)
Fig. B
Maximum straight flue length (L) with maximum
plume management length 4,500mm (M)
29CDi Classic
5,900mm
3,100mm
34CDi Classic
5,000mm
2,200mm
38CDi Classic
4,000mm
1,200mm
42CDi Classic
4,000mm
1,200mm
CDi Compact and
Si Compact series
5,000mm
2,200mm
i series
4,500mm
4,500mm
57
Plume management system
Plume management system with angled termination
Greenstar combi boiler range accessories
Greenstar combi boiler controls
MT10 mechanical timer
MT10RF mechanical
RF thermostat
Comfort plug-in twin
channel programmer
Comfort I RF wireless
room thermostat
and plug-in twin
channel programmer
Worcester Part No.
7 716 192 036
Worcester Part No.
7 716 192 037
Worcester Part No.
7 733 600 003
Worcester Part No.
7 733 600 001
Comfort II RF wireless
programmable room
thermostat and
plug-in RF receiver
FR10 intelligent
room thermostat^
FR110 programmable
room thermostat
FW100 weather
compensation controller
Worcester Part No.
7 733 600 002
Worcester Part No.
7 716 192 065
Worcester Part No.
7 716 192 066
Worcester Part No.
7 716 192 067
Wave
Weather sensor*
Worcester Part No.
7 716 192 072
Worcester Part No.
7 716 192 764
Components
Part No. 60mm
7 716 191 086
Maximum lengths (mm) & no. of components required
Greenstar CDi Classic, CDi Compact*, Si Compact and i series
60mm
500
Components
Part No. 60mm
1
7 716 191 086
7 716 191 087
Maximum lengths (mm) & no. of components required
Greenstar CDi Classic, CDi Compact*, Si Compact and i series
Plume management system with extensions
60mm
4,500
1
up to 4
Plume management system with extensions and 45º bends
Components
Part No. 60mm
7 716 191 086
7 716 191 087
Maximum lengths (mm) & no. of components required
Greenstar CDi Classic, CDi Compact*, Si Compact and i series
60mm
4,500
1
up to 4
Plume management system with extensions and 45º bend
Components
Part No. 60mm
7 716 191 086
7 716 191 087
7 716 191 089
Maximum lengths (mm) & no. of components required
Greenstar CDi Classic, CDi Compact*, Si Compact and i series
60mm
3,000
1
up to 3
2
Components
Part No. 60mm
7 716 191 086
7 716 191 087
7 716 191 089
Maximum lengths (mm) & no. of components required
Greenstar CDi Classic, CDi Compact*, Si Compact and i series
60mm
3,750
1
up to 4
1
*NOTE: For CDi Classic, CDi Compact and Si Compact
you must refer to the table on page 57 to calculate your
horizontal flue lengths and plume management lengths.
58
^For use with MT10 or Comfort only. *For use with Greenstar i only.
59
Greenstar combi boiler range accessories
Condensfit II™ 60/100mm & 80/125mm
horizontal & vertical flue accessories
60
Standard telescopic
flue kit (100mm dia.)
Standard telescopic
horizontal flue kit
(125mm dia.)
Long telescopic flue kit
(100mm dia.)
Vertical BF kit
(100mm dia.)
90º bend
(125mm dia.)
High level horizontal
flue adaptor (100mm dia.)
High level horizontal
flue adaptor (125mm dia.)
Support bracket kit
(100mm dia.)
Worcester Part No.
7 716 191 082
Worcester Part No.
7 719 003 702
Worcester Part No.
7 716 191 171
Worcester Part No.
7 719 002 430
Worcester Part No.
7 719 003 664
Worcester Part No.
7 719 002 432
Worcester Part No.
7 719 002 433
Worcester Part No.
7 716 191 177
Vertical BF kit
(125mm dia.)
1,000mm extension kit
(100mm dia.)
1,000mm extension
(125mm dia.)
2m flue extension
(100mm dia.)
Support bracket kit 6 pack
(100mm dia.)
Support bracket kit
(125mm dia.)
Worcester Part No.
7 719 002 431
Worcester Part No.
7 716 191 083
Worcester Part No.
7 719 003 666
Worcester Part No.
7 716 191 172
Worcester Part No.
7 716 191 178
Worcester Part No.
7 716 191 179
Short flue extension
220mm (100mm dia.)
45º bend
(100mm dia.)
45º bend
(125mm dia.)
90º bend
(100mm dia.)
Worcester Part No.
7 716 191 133
Worcester Part No.
7 716 191 085
Worcester Part No.
7 719 003 665
Worcester Part No.
7 716 191 084
61
Greenstar combi boiler range accessories
Additional accessories
62
Filling link†
Worcester keyless
filling link*
Vertical pre-piping
assembly for CDi Classic
Vertical pre-piping
assembly for CDi Compact,
Si Compact and i combi
Pitched roof flashing kit
(100mm & 125mm dia.)
Plume management
terminal guard round
(60mm dia.)
Worcester Part No.
7 716 192 281
Worcester Part No.
7 716 192 610
Worcester Part No.
7 716 192 607
Worcester Part No.
7 716 192 713
Worcester Part No.
7 716 191 091
Earth bonding strip†
Domestic hot water
combi pre-heat accessory
for CDi Compact
Plume management kit
(60mm dia.)
Extension
(60mm dia., 1,000mm)
Worcester Part No.
7 716 192 686
Worcester Part No.
7 716 192 735
Worcester Part No.
7 716 191 086
Worcester Part No.
7 716 191 087
45º bend
(60mm dia.)
90º bend
(60mm dia.)
Worcester
CondenseSure siphon#
Flat roof flashing kit
(100mm & 125mm dia.)
Worcester Part No.
7 716 191 089
Worcester Part No.
7 716 191 088
Worcester Part No.
7 716 192 746
Worcester Part No.
7 716 191 090
*Greenstar CDi Compact, Si Compact and Greenstar i accessory only – supplied as standard with Greenstar CDi Classic.
†Supplied as standard with Greenstar CDi Classic. #Greenstar CDi Compact, Si Compact and Greenstar i accessory only – built into Greenstar CDi Classic.
Greenstar System Filter
WB3 cleaning tool
Worcester Part No.
7 716 191 176
Worcester Part No.
7 716 192 609
Worcester Part No.
7 733 600 091
WB5 cleaning tool
WB7 cleaning tool
Remote PRV kit**
Flue Gas Heat
Recovery Unit
Worcester Part No.
7 719 001 996
Worcester Part No.
7 746 901 479
Worcester Part No.
7 716 161 071
Worcester Part No.
7 733 600 047
**For CDi Classic and Greenstar i only.
63
Total training experience
from Land’s End to John O’Groats
Gas-fired product courses
Worcester has always been committed to setting the
College-linked Learning
As a market leader in gas-fired condensing boilers, we aim
Gas-fired condensing boiler courses
industry standard for expert professional training and
As well as offering training at our own centres, Worcester
to ensure the highest levels of competence and expertise
this is reflected in the scope and content of the courses,
has established close partnerships with many colleges
in the installation of all Worcester Greenstar gas-fired
• Greenstar CDi Classic gas-fired condensing combi boilers.
• Greenstar CDi Compact and Greenstar Si Compact gas-
venues and options available.
around the UK, equipping them with our latest products.
products. We run intensive training courses for installers,
We offer training on our entire range of domestic and
Worcester has worked closely with leading colleges and
commercial heating technologies as well as industry-led
independent training centres for more than 20 years – a
courses. All tuition is handled by expert heating specialists,
successful enterprise which in 2007 was enhanced further
Our comprehensive gas-fired condensing boiler training
combining classroom theory with, practical hands-on
with the launch of the College Links Learning Scheme.
courses include product overview, inspection and cleaning
Mobile training
of components, CO and CO2 analysis of flue gas, removal
of compact hydraulics, service mode functions and fault
We can also bring training to you. We have mobile vehicles
finding on ‘live and demo’ appliances.
commissioning engineers and operatives involved with
experience. Keep up-to-date with legislation and experience
hands-on-training with our new technologies.
To increase your skills, expertise and value in the
fully equipped with operational Greenstar gas-fired boilers,
market place, trust Worcester’s unique and proven
dry strip-down models and even a Greensource air to air
total training concept.
heat pump. Our 7.5 tonne mobile oil vehicle is also available
for hands-on oil product training and OFTEC assessments.
Training centres throughout the UK
Worcester
Call now for more information 0330 123 0166.
Worcester’s award-winning, state-of-the-art Training
servicing and fault finding.
thermostat, FR10, FR110, FW100, and solar controls).
System
& Regular
Highflow CDi &
FS CDi Regular
Controls
Duration
1 Day
1 Day
1 Day
1 Day
1 Day
1 Day
1 Day
Cost
Free*
Free*
Free*
Free*
Free*
Free*
Free*
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Guide to the
varied range
of control
options that are
available
Worcester
D
D
D
D
D
D
Clay Cross
U
U
U
U
U
U
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Training course covers
Commissioning
storey brick buildings. Here installers can get to grips with
College links
training centres
Servicing
Maintenance
Course locations
system design and operation.
Elgin
Wakefield
Opened in Summer 2013, the Wakefield Training and
Wakefield
Dundee
Assessment Academy boasts a large gas laboratory which
features our entire range of Greenstar gas-fired appliances,
a flushing area, wet and dry boilers and a light commercial
Fife
West Thurrock
Johnstone
College Links†
Borders
Mobile†
Ayr
area with a cascade of Worcester GB162 boilers. There is a
Durham
solar room with fully working components from our entire
Greenskies solar range and a pitched roof for practical
Comfort range, NEW Wave internet connected room
Greenstar i
Training centres
T
gas appliances, clearly demonstrating the importance of
• Greenstar Controls (covers MT10, MT10RF, NEW Greenstar
CDi Compact
& Si Compact
open-plan domestic training areas with life-size singleGreenskies solar thermal systems working with Greenstar
gas-fired condensing combi and regular boilers.
CDi Classic
Installation
arena at our headquarters in Worcester. Facilities include
• Greenstar i gas-fired condensing combi boilers.
• Greenstar system & regular gas-fired condensing boilers.
• Greenstar Highflow CDi & FS CDi Regular floor standing
Greenstar
Overview
Specification
Academy is an innovative and spacious high tech training
fired condensing combi boilers.
U
D
D
*A holding fee of £65 applies to free courses and is refunded on attendance of the course. If a booking is cancelled more than 10 working days before
the course date, the fee will be fully refunded. The fee is non-refundable if a cancellation is made less than 10 working days before the course date.
†Please contact Worcester Training for specific colleges and mobile dates.
Workington
Belfast
U
U
U
U
D
D
D
training, as well as a large commercial training room.
Burnley
West Thurrock and Clay Cross
W
Wakefield
Dublin
Clay Cross
Further academies are located at West Thurrock in
Wrexham
Essex and Clay Cross in Derbyshire, both of which offer
Worcester
a comprehensive choice of courses.
Tredegar
Cambridge
West Thurrock
Wiltshire
Camborne
64
Paignton
65
Additional product and
industry training courses
A complete after-sales service
The diversity of products in today’s heating industry gives you the opportunity to expand your expertise, whilst offering
As part of the worldwide Bosch Group, Worcester strives to
Spares
more choice to your customers. Worcester provides comprehensive training from all its academies on its entire range of
maintain the highest possible standards of after-sales care.
Genuine replacement parts for all supported Worcester
products are readily available from stock, or on a next day
technologies. Call us on 0330 123 0166 to order a full course training brochure or to book yourself onto a training course,
alternatively, you can visit www.worcester-bosch.co.uk/training
Worcester Contact Centre
delivery basis. Visit www.worcester-bosch.co.uk/spares
Should you require support, our award winning Contact
to find your local stockist.
Oil-fired product courses
Worcester commercial product courses
Centre team, based at our head office in Worcester, are
• Greenstar Danesmoor & Heatslave II high efficiency
• Greenspring CWi47 water heater.
• GB162 overview.
• GB162 domestic.
• GB162 commercial.
• Greenstar Heat Distribution Unit.
• Commercial ACS training and assessment – CODNCO1.
ready to take your calls. Whatever your query our contact
Customer Technical Support
centre operators along with our nationwide team of
The Worcester Technical Helpline is a dedicated phone
engineers are ready to help you.
line – committed to providing a comprehensive service to
condensing oil-fired boilers.
• Oil advanced fault finding.
• OFTEC 50.
• OFTEC 101/105e, OFTEC 600a and OFTEC
101/105e/600a.
complement the brand name and quality of our products.
Tel: 0330 123 9559
Our experienced team of technical experts provides
answers to queries of a technical nature across the entire
Opening times
Worcester range.
Renewable product courses
Bosch commercial product courses
Monday – Friday: 7.00am – 8.00pm
• Renewables overview.
• Greenskies solar.
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• Introduction to heat pumps.
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• GB312 & GB402 overview.
• Solar thermal product overview.
• GWPL Gas Absorption Heat Pumps overview.
• CHP overview.
• Commercial controls overview.
Saturday: 8.00am – 5.00pm
Technical Support
Sunday: 9.00am – 12 noon
Tel: 0330 123 3366
Bank Holidays: 8.00am – 4.30pm
Fax: 01905 752 741
Email: [email protected]
Opening times
Industry focused courses
Monday – Friday: 7.00am – 8.00pm
• Hot water systems & safety.
• Chemical water treatment.
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Saturday: 8.30am – 4.00pm
certification.
• IDHEE domestic heating design.
• Domestic ACS training and assessment – reassessment.
Bank Holidays: 8.00am – 4.30pm
ErP Technical Helpline
Tel: 0330 123 3641
Email: [email protected]
CCN1 + 3 appliances.
•
QCF Level 3 Award
– Air source and ground source heat pumps.
– Air to water and split air to water heat pumps.
– Solar thermal.
• MCS Made Easy.
• Green Deal.
• LPG Changeover.
• WRAS Water Regulations.
66
67
Useful numbers
Customer Service
Sales
Engineer Appointments
Tel: 0330 123 9669
Email: [email protected]
[email protected]
or telephone 0330 123 9339
Spare Parts
Service Enquiries
Tel: 0330 123 9779
Email: [email protected]
[email protected]
or telephone 0330 123 9559
Technical Helpline (Pre & Post Sales)
Guarantee Registration
Tel: 0330 123 3366
To register your Worcester guarantee,
[email protected]
please visit our website
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Renewables Technical Helpline
download our guarantee
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registration app or
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telephone 0330 123 2552
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Guarantee
app
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Literature
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