- Worcester, Bosch Group
Technical and Specification Information
Greenstar CDi Classic Regular Series
Greenstar Ri Series
Greenstar CDi Classic System Series
Greenstar i System Series
Greenstar regular and system gas-fired
condensing wall mounted boiler range
NEW
Greenstar
Sense &
System Filter
1
Worcester and you. Making a difference.
2
As part of the Bosch Group, Worcester
supported by an experienced technical
products are designed and manufactured to
services team which is able to provide
provide customers with the highest levels of
comprehensive support and advice
quality and reliability which are synonymous
from designing system layouts through
with the Bosch name throughout the world.
to installation.
As part of Europe’s largest supplier of
Worcester is dedicated to providing energy
heating products, Worcester, Bosch Group
efficient gas- and oil-fired condensing
has the UK-based resources and support
boilers, as well as an extensive range of
capability to offer you the value-added
renewable technologies. All of our products
solutions you deserve. Worcester employs
have been developed and introduced with
a nationwide network of Service Engineers
the aim of helping the UK to achieve the
and technically trained Field Sales Managers
Government’s efficiency targets.
The reception and main entrance
at our Worcester headquarters
Contents
Page
The Greenstar regular and system 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 - 13
Greenstar Ri features and benefits
14 - 15
Inside story – Greenstar Ri
16 - 19
Greenstar i System features and benefits
20 - 21
Inside story – Greenstar i System
22 - 25
ErP easy as ABC
26 - 27
services to ensure you have all you require in
The Greenstore unvented cylinder series
28 - 29
order to deliver only the best solutions to your
Controls
30 - 31
customers’ requirements.”
Wave – smart heating control
32 - 33
“At Worcester we recognise the vital role you
play in the specification and installation of
energy efficient appliances in homes across
the UK. We will continue to invest in our
products, people, facilities and added-value
Greenstar Wiring Centre
34
Carl Arntzen,
Site preparations and guidance
35 - 40
Managing Director,
Installation requirements
41 - 43
NEW Greenstar System Filter
44 - 45
Condensate pipework
46 - 47
The Worcester CondenseSure siphon
48 - 49
Horizontal and vertical flue terminal positioning
50 - 51
Horizontal fluing options
52 - 55
Vertical fluing options
56 - 58
Plume management positioning and system options
59 - 62
Accessories
63 - 66
Training
67 - 69
After-sales
70
Bosch Thermotechnology Ltd.
3
Greenstar 27i System
The Greenstar regular
and system boiler range
The Greenstar boilers are a market-leading range of
Gas and LPG options
energy-saving condensing wall-mounted gas-fired boilers.
Greenstar regular and system boilers are manufactured in
both natural gas and Liquid Petroleum Gas (LPG) variants.
Higher efficiency, highly cost-effective
This gives a full range of fuel options and eliminates
All Worcester Greenstar wall mounted gas-fired condensing
the need for fuel conversion.
boilers have an ErP ‘A’ rating for space heating which means
they are over 90% efficient.
5 year guarantee
All Worcester Greenstar regular and system
Winner of Which? Best Buy awards in 2010 - 2015/16
boilers are offered with a full 5 year guarantee*
For six consecutive years, in a survey of Which? members,
on parts and labour as well as 10 year
the Worcester Greenstar gas-fired condensing boiler range
guarantee* on the primary heat exchanger*.
has been presented with Best Buy awards. In the latest
survey, no other manufacturer scored higher for reliability.
4
*Subject to terms and conditions.
The Greenstar regular range at a glance
30CDi Classic 40CDi Classic
Regular
Regular
12Ri
15Ri
18Ri
24Ri
27Ri
30Ri
NG
7 738 100 245
7 738 100 232
7 733 600 074
7 733 600 072
7 733 600 070
7 733 600 068
7 733 600 064
7 733 600 066
LPG
7 738 100 235
7 738 100 234
7 733 600 075
7 733 600 073
7 733 600 071
7 733 600 069
7 733 600 065
7 733 600 067
Min
7.7kW
9.4kW
4kW
5kW
6kW
8kW
7.03kW
7.03kW
Max
30kW
40.8kW
12kW
15kW
18kW
24kW
27kW
30kW
9
9
9
9
9
9
–
–
–
–
–
–
9
9
9
9
9
9
9
9*
9
9
9*
9
Part No.
Output kW to
central heating
(CH)
CH temperature control
DHW temperature control
Modulating gas control
*When an optional Worcester Comfort control and Greenstar Wiring Centre is used.
The Greenstar system range at a glance
30CDi
Classic
System
Part
No.
NG
35CDi
Classic
System
9i System 12i System 15i System 18i System 21i System 24i System 27i System 30i System
7 738 100 244 7 738 100 236 7 733 600 011 7 733 600 010 7 733 600 009 7 733 600 008 7 733 600 007 7 733 600 006 7 733 600 060 7 733 600 062
LPG 7 738 100 233 7 738 100 237 7 733 600 033 7 733 600 034 7 733 600 035 7 733 600 036 7 733 600 037 7 733 600 038 7 733 600 061 7 733 600 063
Output
Min
kW to
central
heating Max
(CH)
7.7kW
7.7kW
3.1kW
3.1kW
4.6kW
4.6kW
7.2kW
7.2kW
7.03kW
7.03kW
30kW
34kW
9.2kW
12.2kW
15.3kW
18.4kW
21.6kW
24.6kW
27kW
30kW
CH
temperature
control
9
9
9
9
9
9
9
9
9
9
DHW
temperature
control
9*
9*
9*
9*
9*
9*
9*
9*
9*
9*
Modulating
gas control
9
9
9
9
9
9
9
9
9
9
*When a Worcester optional control and internal diverter valve kit is used.
5
Key features of the range
Optional plug-in controls
A wide choice of optional controls is available
with the Greenstar system series, provided the
optional diverter valve accessory is installed, to
enable your customers to select the type of control
which best suits their individual requirements.
The choice ranges from a simple-to-operate digital
programmer to sophisticated wireless programmers,
room thermostats and wired intelligent controls.
These controls employ the latest digital technology
and deliver high levels of functionality to maximise
The Greenstar regular and system range
energy savings without compromising on
comfort. By using low voltage power and wireless
technology, the optional controls avoid the need to
Why choose a Worcester Greenstar
comply with Part P of the Building Regulations. For
regular or system boiler?
more information, see pages 30-33.
Worcester’s extensive range of regular and system
boilers, now with Central Heating (CH) outputs
from 9kW to 40kW, deliver high energy-efficiency
and lower running costs for homeowners. System
variants achieve higher SAP or NHER ratings for new
build properties when used in conjunction with a
Greenstore unvented cylinder.
ErP A+ rated system
In well-insulated new homes, where hot water
An ErP rating of ‘A+’ on heating can
performance is more of a factor than heating, the
be achieved by the Greenstar 12i - 24i
combination of a Greenstar system boiler and
System boilers when installed with
Greenstore unvented cylinder may enable a system
either a Wave or Sense II and optional
boiler with a lower CH output to be used. This
diverter valve.
or Sense II
reduces energy consumption even further while
reducing the need for larger diameter gas pipes to
The complete system solution
allow for an easier installation.
Our Greenstore unvented and solar compatible
unvented hot water cylinders provide fast re-heat
Staying in control
times with excellent heat retention properties.
All Greenstar system boilers are compatible with
The combination of a Greenstar system or regular
S and Y plan systems or can be used with a full
boiler and a Greenstore unvented cylinder delivers
range of Worcester intelligent plug-in controls when
hot water to the taps at mains pressure, filling
installed with an optional Worcester diverter valve
baths quickly and ensuring that showers are
kit. As well as enhancing energy efficiency, this
powerful and invigorating. For more information
arrangement means the boiler houses the diverter
see pages 28-29.
valve, reducing the need to install additional valves
and cabling.
6
NEW Worcester Greenstore unvented cylinder range
Solar water heating
When used in conjunction with a Greenstore solar
compatible unvented cylinder, Greenstar regular and system
boilers can be fully integrated with a Greenskies solar water
heating system, which has the potential to provide up to
60%† of annual hot water requirements. Even if solar water
heating is not required at the time of installation, installing
a solar compatible unvented cylinder will enable the system
to be upgraded easily in the future.
Fluing options
The Greenstar regular and system range features 2 different
sizes of multi-directional room sealed flue (RSF) systems,
100mm or 125mm diameter. Flues can be run horizontally
Greenskies Solar-Lifestyle, Solar-Lito and
Greenstore solar compatible unvented cylinder
or vertically with additional 90º or 45º in-line bends
allowing changes of direction to provide an extremely
flexible and versatile fluing system. This enables the
appliance to be sited virtually anywhere. More details are
shown on pages 50-62.
The Greenstar condensing regular and system range –
features and benefits at a glance
Energy-saving & environmental
Time- & labour-saving installation
End user comfort and convenience
• All models are ErP compliant
• ErP ‘A’ rating for heating
• SEDBUK A rating up to 89.8%
• Wall frames and jig allow space for
• Full 5 year parts and labour
(2009 value)
• Simple and intelligent control
options are available to optimise
boiler efficiency**
•
•
pipes behind the boiler as standard
• Vertical pre-piping assembly
available as an accessory
• Full range of Condensfit II™
flue options
• Multi-directional fluing means
Low electrical consumption in
boiler can be sited in a wider
standby mode
variety of places
Aluminium-silicon heat exchangers
deliver high efficiency and reliability
• Anti-cycle control
• The Greenstar CDi Classic Regular,
27Ri, 30Ri and 12Ri regular models,
guarantee as well as a 10 year
guarantee on the primary
heat exchanger*
• Bosch renowned quality
and reliability
• Built-in boiler frost protection
• Compact dimensions –
Greenstar 27i and 30i System
•
• Earth bonding strip as standard
• Controls behind flap on all models
with CDi Classic System boilers
(excluding 12-24Ri) minimises the
Optional diverter valve accessory
• Optional wiring centre accessory
as well as Ri models
risk of tampering with controls.
on 27Ri and 30Ri models.
CDi Classic System, 27i, 30i, 12i
and 9i System models deliver NOx
values below 40mg/kWh – achieving
3 credits under The Code for
Sustainable Homes.
**Optional diverter valve accessory must be installed with System boilers when using Worcester controls. Optional Greenstar Wiring Centre must be installed with
Regular boilers when using Worcester controls – 27Ri and 30Ri only. *Terms and conditions apply. †Energy Saving Trust.
7
Greenstar CDi Classic
Regular and System
Features and benefits
Our top-of-the-range regular and system boilers are suitable for
larger properties that demand high outputs – typically with more than
three bedrooms. The Greenstar CDi Classic Regular is available with
CH outputs of 30kW and 40kW whilst the Greenstar CDi Classic System
is available in outputs of 30kW and 35kW.
The Greenstar CDi Classic Regular and System range uses the proven
Worcester WB5 aluminium-silicon heat exchanger which features an extralarge surface area to optimise combustion efficiency. Other energy-saving
features include low electrical consumption in standby mode and anti-cycle
control. The System range also benefits from a modulating pump and the
ability to be paired with any of our digital and intelligent controls*.
The Greenstar CDi Classic Regular and System range can be combined with
our Greenskies solar thermal panels to provide efficient heating comfort
and reducing the property’s carbon footprint.
For more information on
ErP, see pages 26-27.
Installation benefits
Environmental benefits
•
• ErP ‘A’ rated for heating
• SEDBUK A rating of over 89% (2009 value)
• WB5 heat exchanger delivers
Boiler design and wall-mounting bracket
allows space for pipes behind boiler
• Vertical pre-piping assembly accessory
providing pre-formed copper pipe lengths
allows top exit from the boiler
• Earth bonding strip supplied as standard
• Remote PRV option that can be
positioned higher in the system for
basement or cellar installations**
high efficiency
• Digital and intelligent control options
available, optimising boiler efficiency and
fuel consumption*
• Modulating pump uses less electricity than
a fixed speed pump**
•
• Low electrical consumption when the
boiler is in standby mode
• A rigid 22mm compression gas connection,
eliminates the need for pre-fabricating the
• Lead-free components
gas pipe onto the isolating valve
• Compatible with Worcester Greenskies
solar thermal
• Multi-directional fluing enables boiler to be
located in a wider variety of places
• Electronic ignition eliminates the need for
a pilot light
• Full range of Condensfit II™ flue options
in both 60/100mm and 80/125mm
• Anti-cycle and modulation control
diameters with optional plume
• All boilers and components are
Compatible with S and Y plan systems
management kit available
100% recyclable.
• Clear display on fascia for temperature and
commissioning settings
• Short-circuit proof PCB design that
removes the need for fuses in low
voltage circuits.
8
*With installation of optional integral diverter valve for System variants.
**System variants only.
Features based on installer feedback
The pump for the System boiler range has
The Greenstar CDi Classic Regular
also been upgraded to a more efficient
and System boilers including a larger
model which meets ErP legislation.
condensate siphon which reduces the risk
In addition, as an optional accessory,
of frozen condensate and in most cases
Worcester now offers a remote PRV** that
means an external CondenseSure will not
can be positioned higher in the system for
be required.
basement or cellar installations.
The Greenstar Classic range also now
WB5 heat exchanger
includes a paper wall mounting template
The Worcester WB5 heat exchanger
to aid installation.
has been designed to optimise clean
burning combustion over an extra-large
The water in the appliance can be drained
surface area.
using the combined appliance and
condensate drain. This removes the need to
Each heat exchanger is 100% tested and
connect an external hose saving the installer
requires minimal servicing.
WB5
Heat Exchanger
On the primary
heat exchanger†
time on servicing and maintenance.
End user benefits
• Which? Best Buy award-winning boiler
• Condenses in heating modes for optimum
efficiency during operation
• Highly reliable heat exchanger
• Part of the Which? Best Buy range for
gas-fired condensing boilers
• Simple and intelligent control options*
for improved boiler efficiency and
user comfort
• Modulation control reduces electrical
consumption
• Built-in frost protection for the boiler and
surrounding pipes
• All models are available in natural gas
and LPG options
• Full 5 year parts and labour guarantee†
• 10 year guarantee on Worcester primary
heat exchanger†
The Greenstar CDi Classic
Regular and System 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.
†Terms and conditions apply. *With installation of optional integral diverter valve for System variants.
• Boiler protection plans available
• Bosch renowned quality and reliability.
9
Inside story –
Greenstar CDi Classic Regular
Down firing
low NOx burner
Automatic air vent
Aluminium/silicon
WB5 primary
heat exchanger
Pre-mix fan
Condensate siphon
Gas valve
Drain point
PCB
Central heating
temperature control
On/off
button
Operational
status light
Digital display
Greenstar CDi Classic Regular fascia
10
Technical data
Boiler
Greenstar 30CDi Classic Regular Greenstar 40CDi Classic Regular
Height
760mm (max)
760mm (max)
Width
440mm
440mm
Depth
360mm (max)
360mm (max)
Weight – dry
39.5kg
39.5kg
ErP Seasonal space heating energy efficiency class
A / 92%
A / 92%
89.2%
89.2%
Heating flow / return connections
22mm compression
22mm compression
Condensate connection
22mm plastic pipe
22mm plastic pipe
Gas connection
22mm compression
22mm compression
7.7 - 30kW
9.4 - 40.8kW
9
9
9
9
9
9
Maximum vertical flue (100mm dia.) inc. terminal
9,400mm
7,500mm
Maximum vertical flue (125mm dia.) inc. terminal
18,500mm
16,000mm
Maximum horizontal flue (100mm dia.)
7,900mm
6,000mm
Maximum horizontal flue (125mm dia.)
18,500mm
12,500mm
NOx classification – natural gas
30mg/kWh
29mg/kWh
5
5
55dB(A)
60dB(A)
X4D
X4D
SAP efficiency – natural gas
Output to central heating
Wall mounting jig
Fault diagnostic display
Flow and return pipes supplied to allow pipes behind installation
NOx class
Noise output level
Ingress protection (IP)
11
Inside story –
Greenstar CDi Classic System
Down firing
low NOx burner
Expansion vessel
Pre-mix fan
Aluminium/silicon
WB5 primary
heat exchanger
Automatic air vent
Condensate siphon
Gas valve
ErP compliant
modulating pump
Drain point (hidden)
PCB
Pressure gauge
Operational
status light
Central heating
temperature control
On/off
button
Optional
programmer
Digital Pressure
display gauge
Domestic hot water
temperature control*
Greenstar CDi Classic System fascia
with Comfort plug-in twin channel
programmer fitted
12
*Only used with installation of optional integral diverter valve.
Technical data
Greenstar 30CDi Classic System
Greenstar 35CDi Classic System
Height
760mm (max)*
760mm (max)*
Width
440mm
440mm
Depth
360mm (max)
360mm (max)
Weight – dry
46.5kg
46.5kg
ErP Seasonal space heating
energy efficiency class
A / 92%
A / 92%
SAP efficiency – natural gas
89.2%
89.2%
Heating flow / return connections
22mm compression
22mm compression
Condensate connection
22mm plastic pipe
22mm plastic pipe
Gas connection
22mm compression
22mm compression
PRV connection
15mm compression
15mm compression
3.75 ltr
3.75 ltr
7.7 - 30kW
7.7 - 34kW
9
9
Boiler
Primary water content
Output to central heating
Wall mounting jig
Diverter valve kit
Plug-in timers
Intelligent controls
9
9
9
(optional)
(optional)
(optional)
9
9
9
(optional)
(optional)
(optional)
9
9
9
9
Maximum vertical flue (100mm dia.) inc. terminal
9,400mm
8,000mm
Maximum vertical flue (125mm dia.) inc. terminal
18,500mm
16,000mm
Maximum horizontal flue (100mm dia.)
7,900mm
7,000mm
Maximum horizontal flue (125mm dia.)
18,500mm
16,000mm
NOx classification – natural gas
30mg/kWh
30mg/kWh
5
5
X4D
X4D
Modulating pump
Fault diagnostic display
NOx class
Ingress protection (IP)
*Measured to the top or front of the curve height.
13
Greenstar Ri regular
Features and benefits
The Greenstar Ri is available in 6 models with CH outputs of 12kW, 15kW,
18kW, 24kW, 27kW and 30kW, making the range suitable for a wide range
of households with stored hot water systems.
All Greenstar Ri boilers are compact enough to be installed in a standard
kitchen cabinet and are a one-man lift, with the 12kW to 24kW models
weighing just 22.6kg, the lightest in their class.
The 12kW to 24kW models have a fascia-mounted heating temperature
control and neon operational status indicator, while the 27kW and 30kW
models feature the Heatronic 4i control box which, for the first time, enables
an optional Worcester plug-in control to be used with a regular boiler*.
By using the optional Greenstar Wiring Centre, the 27kW and 30kW boilers
can be used with a choice of Worcester wireless controls, for added energy
savings and end-user convenience. See page 34 for more details on the
Greenstar Wiring Centre.
Greenstar Ri boilers can be used with our range of Greenstore unvented and
solar compatible unvented cylinders for boiler only and boiler/solar water
For more information on
ErP, see pages 26-27.
heating systems.
All boilers feature reduced electrical consumption in stand-by mode,
anti-cycling and modulation control.
Installation benefits
Environmental benefits
• Robust, steel wall-mounting frame
• ErP ‘A’ rated for heating
• SEDBUK A rating over 88.8%
allows space for pipes behind the boiler
(2009 values) for all models
• One man lift
• Compatible with S and Y plan systems
• Choice of wireless programmers and room
All
models
available
as
natural
gas
and
LPG
thermostats, optimising boiler efficiency
•
and fuel consumption*
• Full range of Condensfit II™ flue options in
both 60/100mm and 80/125mm diameters
• Low electrical consumption when the
boiler is in standby mode
• Multi-directional fluing enables boiler to be
located in a wider variety of places.
• Heat exchangers deliver high efficiency
and reliability
• Compatible with Worcester Greenskies
solar thermal
• Electronic ignition eliminates the need for
the pilot light
• Anti-cycle and modulation control
• 12, 27 and 30kW models have ultra low
NOx emissions – 3 credits under Code for
Sustainable Homes.
14
*With installation of optional Greenstar Wiring Centre on 27 and 30kW models.
WB3 heat exchanger
Quality guaranteed
Greenstar Ri 12, 15, 18 and
As part of our Total Quality
24kW boilers use the proven
Initiative programme, Worcester
WB3 aluminium/silicon heat
tests its boilers and heat
exchanger. The heat cell has
exchangers using its own formula
an extra-large surface area for
to replicate contaminated heating
enhanced heat exchange efficiency.
system water. This contains iron
dust, quartz sand, hemp fibre and
WB7 heat exchanger
other contaminates typically found
Greenstar Ri 27kW and 30kW
in such system water samples. This
models feature the new WB7 heat
testing procedure ensures that all
exchanger which uses advanced
of our heat exchangers are proven
friction stir welding^ manufacturing
to be robust and efficient over the
technology to create more
boiler’s lifetime.
passageways than traditional heat
WB3
Heat Exchanger
WB7
On the primary
Heat Exchanger heat exchanger†
exchangers. As a result, the WB7
heat exchanger delivers very high
outputs relative to its size.
End user benefits
• Which? Best Buy award-winning boiler
• Extremely reliable and efficient
heat exchangers
• Compact dimensions – can be installed in
a standard-sized kitchen cupboard
• Part of the Which? Best Buy range for
gas-fired condensing boilers
• Option of wireless programmers and
room thermostats for higher efficiency
and user comfort*
• Built-in frost protection of the boiler and
the surrounding pipes
• Full 5 parts and labour guarantee†
• 10 year guarantee on Worcester primary
heat exchanger†
• Boiler protection plans available.
The Greenstar Ri 27 and 30kW models
The Greenstar Ri regular 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.
†Terms and conditions apply. ^The friction stir welding process is used under license from The Welding Institute.
15
Inside story – Greenstar 12Ri - 24Ri
Down firing
low NOx burner
Pre-mix fan
Aluminium/silicon
WB3 primary
heat exchanger
Gas valve
Condensate
siphon
Operational
status light
PCB
On/off switch
16
Central heating
temperature control
Technical data
Boiler
Greenstar 12Ri
Greenstar 15Ri
Greenstar 18Ri
Greenstar 24Ri
Height
600mm
600mm
600mm
600mm
Width
390mm
390mm
390mm
390mm
Depth
270mm
270mm
270mm
270mm
Weight – dry
22.6kg
22.6kg
22.6kg
22.6kg
ErP Seasonal space heating
energy efficiency class
A / 91%
A / 91%
A / 91%
A / 92%
SAP efficiency – natural gas
88.8%
88.8%
88.8%
89.2%
Heating flow / return connections
22mm compression
22mm compression
22mm compression
22mm compression
Gas connection
22mm compression
22mm compression
22mm compression
22mm compression
1.1 litres
1.1 litres
1.1 litres
1.1 litres
82ºC
82ºC
82ºC
82ºC
Output to central heating
4 - 12kW
5 - 15kW
6 - 18kW
8 - 24kW
Maximum vertical flue (100mm dia.)
inc. terminal
6,400mm
6,400mm
6,400mm
6,400mm
Maximum vertical flue (125mm dia.)
inc. terminal
15,000mm
15,000mm
15,000mm
15,000mm
Maximum horizontal flue (100mm dia.)
4,600mm
4,600mm
4,600mm
4,600mm
Maximum horizontal flue (125mm dia.)
13,000mm
13,000mm
13,000mm
13,000mm
NOx classification – natural gas
35mg/kWh
54mg/kWh
76mg/kWh
59mg/kWh
5
5
4
5
45dB(A)
48dB(A)
49dB(A)
49dB(A)
X4D
X4D
X4D
X4D
Primary water content
Maximum flow temperature
NOx class
Noise output level
Ingress protection (IP)
17
Inside story – Greenstar 27 & 30Ri
Fan
Aluminium/silicon primary
WB7 heat exchanger
Gas valve
Condense trap
PCB
Central heating temperature
control and reset
Operational
status light
Optional programmer*
Greenstar 27Ri & 30Ri fascia with optional Comfort I RF
wireless room thermostat and plug-in twin channel programmer*
18
*When an optional Worcester Greenstar Wiring Centre is used.
Technical data
Boiler
Greenstar 27Ri
Greenstar 30Ri
Height
600mm
600mm
Width
390mm
390mm
Depth
270mm
270mm
Weight – dry
22.7kg
22.7kg
ErP Seasonal space heating energy efficiency class
A / 92%
A / 93%
89.0%
89.0%
Heating flow / return connections
22mm compression
22mm compression
Gas connection
22mm compression
22mm compression
1.83 litres
1.83 litres
82ºC
82ºC
7.03 - 27kW
7.03 - 30kW
9
9
9 (optional)
9 (optional)
Maximum vertical flue (100mm dia.) inc. terminal
6,000mm
6,000mm
Maximum vertical flue (125mm dia.) inc. terminal
15,000mm
15,000mm
Maximum horizontal flue (100mm dia.)
6,000mm
6,000mm
Maximum horizontal flue (125mm dia.)
15,000mm
15,000mm
NOx classification – natural gas
31mg/kWh
31mg/kWh
5
5
51dB(A)
53dB(A)
X4D
X4D
SAP efficiency – natural gas
Primary water content
Maximum flow temperature
Output to central heating
Wall mounting jig
Plug-in timers
NOx class
Noise output level
Ingress protection (IP)
19
Greenstar i System
Features and benefits
The popular Greenstar i System range has been enhanced with a host
of new features. This means the Greenstar i System boilers are now
suitable for an even wider range of properties with the 9kW model being
particularly suitable for homes with high levels of thermal insulation.
The Greenstar i System 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 previous
Greenstar i System models so that direct replacements are straightforward.
Added to this the wall-mounting jig allows installers to quickly pre-plumb
the condensate, CH flow, gas, PRV installer connection and CH return
without the boiler being on the wall.
The new Heatronic i control panel features familiar ‘up and down’ buttons,
for adjusting the flow temperature, which are similar to the simple
adjustment of a TV remove control. This enables users to easily alter the
flow temperature allowing heat-up times to be accelerated (higher flow
Addition of two
new output models –
9kW and 21kW variants.
*
temperatures) or for energy saving condensing levels (achieved with lower
flow temperatures) to be increased.
For more information on
Installation benefits
Environmental benefits
• Lift weight of just 30.9kg
• Simple switch – same dimensions as
• ErP ‘A’ rated for heating
• SEDBUK A rating of over 89.0%
previous Greenstar i System models**
• Expansion tank pre-installed in boiler
• Familiar, reliable components
• WB3 heat cell and hydraulic group – same
as previous Greenstar i System models**
• Smart design increases internal space for
ease of access**
• Front casing can be removed easily
• All items serviceable from the front
• Benchmark menu for easier completion of
Benchmark logbook**
• Text descriptions of error codes**
• Large condense siphon which removes the
need for CondenseSure accessory**.
20
ErP, see pages 26-27.
(2009 value)
• Fully compatible with Worcester
plug-in controls with the installation
of an optional integral diverter valve
• Low-energy modulating pump
• Simple weather compensation
sensor accessory**
• Ability to programme for low NOx**
• Anti-cycle and modulation control
• Low electrical consumption when in
stand by mode
• All boilers and components are 100%
recyclable, achieving Worcester’s zero
waste to landfill objective.
*Greenstar 15i to 24i System models (NG and LPG) or Greenstar 12i System (NG only) only when installed with optional diverter valve.
**Greenstar 9i to 24i System models only.
Information at your fingertips
WB7 heat exchanger
The digital display includes a ‘quick
Greenstar i System 27 and 30kW
info’ button to provide information
models use the new WB7 heat
on the boiler’s status and flow
exchanger which uses advanced
temperature, as well as clear
friction stir welding^ manufacturing
text descriptions for quick boiler
technology to create more
diagnostic and flow detection.
passageways than traditional
heat exchangers. As a result, the
WB3 heat exchanger
WB7 heat exchanger delivers high
Greenstar i System 9, 12, 15,
outputs relative to its size.
18, 21 and 24kW boilers use the
proven WB3 aluminium/silicon
heat exchanger. The heat cell has
an extra-large surface area for
enhanced heat exchange efficiency.
WB3
Heat Exchanger
WB7
Heat Exchanger
On the primary
heat exchanger*
End user benefits
• Part of the Which? Best Buy range for
gas-fired condensing boilers
• Simple and intelligent control options
available, optimising boiler efficiency and
fuel consumption†
• Excellent energy efficiency
• Larger condensate siphon to prevent risk
of freezing condensate††
• ‘Quick set’ optimised heating temperature**
• Full 5 year guarantee on parts and labour*
• 10 year guarantee on Worcester primary
heat exchanger*
• Boiler protection plans available.
The Greenstar i System 9 to 24kW models
The Greenstar i System 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.
^The friction stir welding process is used under license from The Welding Institute.
*Terms and conditions apply.
†With installation of optional integral diverter valve.
**Greenstar 9i to 24i System models only.
††Provided 32mm pipework not exceeding 3 metres in length is used.
21
Inside story – Greenstar 9i - 24i System
Down firing low NOx burner
Pre-mix fan
Aluminium/silicon
WB3 primary
heat exchanger
Expansion vessel
Gas valve
Large condensate siphon
ErP compliant
modulating pump
Mains cable pre-wired
to control board
PCB
Operational
status light
Pressure gauge
Optional
programmer
Central heating
temperature control
Domestic hot water
temperature control*
Greenstar 9i - 24i System fascia with Comfort
plug-in twin channel programmer fitted
22
*Only used with installation of optional integral diverter valve.
Technical data
Boiler
Height
Width
Depth
Greenstar
9i System
Greenstar
12i System
Greenstar
15i System
Greenstar
18i System
Greenstar
21i System
Greenstar
24i System
710mm (max)* 710mm (max)* 710mm (max)* 710mm (max)* 710mm (max)* 710mm (max)*
400mm
400mm
400mm
400mm
400mm
400mm
330mm (max)* 330mm (max)* 330mm (max)* 330mm (max)* 330mm (max)* 330mm (max)*
Weight – lift
30.9kg
30.9kg
30.9kg
30.9kg
30.9kg
30.9kg
ErP Seasonal space heating
energy efficiency class
A / 93%
A / 94%
A / 94%
A / 94%
A / 94%
A / 94%
SAP efficiency – natural gas
89.8%
89.8%
89.7%
89.7%
89.7%
89.7%
22mm
compression
22mm
compression
22mm
compression
22mm
compression
22mm
compression
22mm
compression
Pressure relief valve
15mm dia.
15mm dia.
15mm dia.
15mm dia.
15mm dia.
15mm dia.
Condensate connection
22mm
plastic pipe
22mm
plastic pipe
22mm
plastic pipe
22mm
plastic pipe
22mm
plastic pipe
22mm
plastic pipe
Gas connection
22mm
compression
22mm
compression
22mm
compression
22mm
compression
22mm
compression
22mm
compression
3.9 ltr
3.9 ltr
3.9 ltr
3.9 ltr
3.9 ltr
3.9 ltr
3.1 - 9.2kW
3.1 - 12.2kW
4.6 - 15.3kW
4.6 - 18.4kW
7.2 - 21.6kW
7.2 - 24.6kW
9
9
9
9
9
9
Heating flow / return connections
Primary water content
Output to central heating
Wall mounting jig
9
9
9
9
9
9
Plug-in timers
(optional)
Diverter valve kit
(optional)
(optional)
(optional)
(optional)
(optional)
(optional)
Maximum vertical flue
(100mm dia.) inc. terminal
6,400
6,400
6,400
6,400
6,400
6,400
Maximum vertical flue
(125mm dia.) inc. terminal
15,000
15,000
15,000
15,000
15,000
15,000
Maximum horizontal flue
(100mm dia.)
4,600
4,600
4,600
4,600
4,600
4,600
Maximum horizontal flue
(125mm dia.)
13,000
13,000
13,000
13,000
13,000
13,000
36mg/kWh
45mg/kWh
42mg/kWh
50mg/kWh
49mg/kWh
49mg/kWh
5
5
5
5
5
5
X4D
X4D
X4D
X4D
X4D
X4D
NOx classification – natural gas
NOx class
Ingress protection (IP)
9
(optional)
9
(optional)
9
(optional)
9
(optional)
9
(optional)
9
*Measured to the top or front of the curve height.
23
Inside story – Greenstar 27 & 30i System
Expansion vessel
(hidden)
Fan
Aluminium/silicon primary
WB7 heat exchanger
Gas valve
ErP compliant
modulating pump
Condense trap
Pressure relief valve
PCB
Operational
status light
Central heating
temperature
control
Digital
display
Optional
programmer
Pressure
gauge
Domestic hot water
temperature control*
Greenstar 27i & 30i System fascia with Comfort
plug-in twin channel programmer fitted
24
*Only used with installation of optional integral diverter valve.
Technical data
Greenstar 27i System
Greenstar 30i System
Height
690mm (max)*
690mm (max)*
Width
390mm
390mm
Depth
280mm (max)
280mm (max)
Weight – lift
27.3kg
27.3kg
ErP Seasonal space heating
energy efficiency class
A / 92%
A / 92%
SAP efficiency – natural gas
89.0%
89.0%
Heating flow / return connections
22mm compression
22mm compression
Condensate connection
22mm plastic pipe
22mm plastic pipe
Gas connection
22mm compression
22mm compression
PRV valve connection
15mm compression
15mm compression
Primary water content
2.1 ltr
2.1 ltr
7.03 - 27kW
7.03 - 30kW
9
9
Boiler
Output to central heating
Wall mounting jig
Plug-in timers
Diverter valve kit
9
9
(optional)
(optional)
9
9
(optional)
(optional)
Maximum vertical flue (100mm dia.) inc. terminal
6,000mm
6,000mm
Maximum vertical flue (125mm dia.) inc. terminal
15,000mm
15,000mm
Maximum horizontal flue (100mm dia.)
6,000mm
6,000mm
Maximum horizontal flue (125mm dia.)
15,000mm
15,000mm
NOx classification – natural gas
31mg/kWh
31mg/kWh
5
5
X4D
X4D
NOx class
Ingress protection (IP)
*Measured to the top or front of the curve height.
25
What is ErP?
The ErP Directive, which is a new regulation set by
the European Union, is designed to drive
improvements in the efficiency and performance of
heating and hot water products. Its purpose is to
ensure that end users are aware of the level of
energy efficiency inherent within their appliances.
As such, the Directive will help improve the overall
efficiency of the housing stock, while enabling
homeowners to reduce their energy bills. The ErP
regulations cover boilers, combination boilers,
heat pumps and other heating appliances up
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
Model
name
Product A
regulations introduce Europe-wide energy labelling
requirements for boilers, combination boilers,
water heaters and other heating products up to
70kW and hot water cylinders under 500 litres.
CH
efficiency
band
How will the labelling scheme work?
A++
A+
A
B
C
D
E
F
G
A
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).
26
Sound
power
level
dB
2015
kW
811/2013
Maximum
heating
output
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
combined energy efficiency rating rather than
4% efficiency to the heating system.
ratings of each individual component.
This means that Greenstar 12i - 24i System boilers,
For example, this could be the merchant’s
which have a standard heating efficiency of 94%,
responsibility if they supply a complete package
will increase to 98% with the addition of the Wave*,
under one part number or the installer if the
making an ErP ‘A+’ class system. Details of the
items are bought individually under separate
controls class for each Worcester control
part numbers.
can be found on pages 30-31.
In either circumstance, Worcester will provide
an online tool that makes calculating the
overall package efficiency of a Worcester
system effortless.
ErP easy as ABC with Worcester
The Energy Labelling obligation under the
Energy Related Products (ErP) Directive
came into force on the 26th September 2015.
Worcester has a number of measures in
place to support you including:
An online label generator 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]
*Optional diverter valve accessory must be installed with System boilers when
using Worcester controls.
27
Efficient hot water storage
solutions from Worcester
Worcester is proud to offer the Greenstore range of high
The Worcester Greenstore cylinder series is fully compatible
efficiency unvented cylinders which offer excellent hot
with a wide range of non-Worcester boilers and solar
water comfort for properties with a stored DHW supply.
panels, although to achieve the optimum system solution it
Designed by Worcester. Developed by Bosch
Worcester Greenstore cylinders, which are manufactured
by Bosch, are available in both an unvented (SC) and solar
is recommended that a Greenstore cylinder is coupled with
either a Greenstar high efficiency boiler or Greenskies solar
panel installation.
compatible unvented (TC) option. The Greenstore unvented
Why choose an unvented cylinder?
SC is available in seven different models ranging from
• High performance due to
SC-90 to SC-300. The Greenstore solar compatible cylinders
unrestricted mains pressure at
are available in five options ranging from TC-150 to TC-300.
hot water outlets
• A perfect replacement for low efficiency copper vented
cylinder installations
• Stainless steel, delivering durability
• Siting flexibility – no need to locate the cylinder directly
underneath a cold water storage cistern.
28
*Terms and conditions apply.
The Greenstore unvented series
The Greenstore unvented SC cylinder benefits consumers who do not
require solar compatibility, but are looking for a cylinder which offers
high levels of insulation, excellent flow rate and outstanding re-heat
performance. The Greenstore unvented range is also ideal for consumers
*
who require a smaller capacity of hot water storage, with the unvented
series being available in SC-90 and SC-120 variants.
The Greenstore unvented solar compatible series
All of the models in the solar compatible Twin Coil (TC) cylinder series
feature high levels of insulation and dedicated solar volumes in compliance
with current Building Regulations, SAP 2012 and the Microgeneration
Certification Scheme (MCS). Worcester's Greenstore solar compatible
stainless steel cylinders have been specifically designed for use with solar
*
heating installations, combined with boiler back-up.
Greenstore unvented cylinder series at a glance
Unvented
Greenstore
Greenstore
Greenstore
Greenstore
Greenstore
Greenstore
Greenstore
SC-90 Cylinder SC-120 Cylinder SC-150 Cylinder SC-180 Cylinder SC-210 Cylinder SC-250 Cylinder SC-300 Cylinder
Part no.
7 716 842 027
7 716 842 028
7 716 842 029
7 716 842 030
7 716 842 031
7 716 842 032
7 716 842 033
Height
835mm
1,035mm
1,285mm
1,490mm
1,665mm
1,860mm
2,155mm
Diameter
570mm
570mm
570mm
570mm
570mm
570mm
570mm
26kg
31kg
36kg
40kg
44kg
48kg
54kg
Heat exchanger
surface area
0.657m2
0.657m2
0.657m2
0.657m2
0.845m2
0.845m2
0.845m2
Volume domestic
hot water
93 litres
123 litres
161 litres
191 litres
216 litres
246 litres
292 litres
Standing
heat loss – 24hr
1.008kWh
/24hrs
1.296kWh
/24hrs
1.632kWh
/24hrs
1.824kWh
/24hrs
1.944kWh
/24hrs
2.136kWh
/24hrs
2.304kWh
/24hrs
ErP energy
efficiency class/
Standing
heat loss
B / 42W
C / 54W
C / 68W
C / 76W
C / 81W
C / 89W
C / 96W
Greenstore
TC-210 Cylinder
Greenstore
TC-250 Cylinder
Greenstore
TC-300 Cylinder
Weight – dry
Solar
compatible
Greenstore
Greenstore
TC-150 Cylinder TC-180 Cylinder
7716 842 040
7 716 842 041
7 716 842 042
7 716 842 043
7 716 842 044
1,285mm
1,490mm
1,665mm
1,860mm
2,155mm
570mm
570mm
570mm
570mm
570mm
41kg
45kg
50kg
54kg
60kg
Heat exchanger
surface area
0.657m2
0.657m2
0.845m2
0.845m2
0.845m2
Volume domestic
hot water
157 litres
187 litres
211 litres
241 litres
287 litres
Standing
heat loss – 24hr
1.632kWh
/24hrs
1.824kWh
/24hrs
1.944kWh
/24hrs
2.136kWh
/24hrs
2.304kWh
/24hrs
Dedicated
solar volume
65 litres
65 litres
105 litres
115 litres
115 litres
ErP energy
efficiency class/
Standing
heat loss
C / 68W
C / 76W
C / 81W
C / 89W
C / 96W
Part no.
Height
Diameter
Weight – dry
29
Controls
System boilers – optional diverter valve required
System boilers using a Worcester control option are incompatible with Y or S plan systems and must have
the optional diverter valve kit fitted.
Regular boilers – Greenstar Wiring Centre required
Greenstar 27Ri and 30Ri boilers using a Comfort I RF or Comfort II RF control must use an optional
Greenstar Wiring Centre. This total solution is compatible with both Y and S plan systems.
NEW Greenstar Sense controls
Sense I – Intelligent room thermostat – Part no. 7 738 110 054
Load compensation feature for increased efficiency
Boiler output automatically adjusted to precisely meet the heat demand
of the property at maximum efficiency
EFFICIENCY
+3%
Maximises the condensing boiler’s operation
Ideal when replacing an existing, less efficient wired room thermostat.
Sense II – Weather compensation controller – Part no. 7 738 111 064
Intelligently interacts with the boiler to provide weather compensation
via a wired outdoor sensor
Solar thermal optimisation in conjunction with MS100 solar module
EFFICIENCY
+4%
Displays the amount of energy recovered from a solar system
Service reminder function
Enables an A+ ErP system efficiency to be achieved when installed with
any Greenstar 12-24i System boilers.
Sense II
Greenstar Comfort controls
Comfort plug-in twin channel programmer – Part no. 7 733 600 003
Simple menu navigation
7-day time control for heating and hot water
Heating programme visualisation bar.
Comfort I RF wireless room thermostat and plug-in twin channel programmer –
Part no. 7 733 600 001
All the features of Comfort PLUS…
Enhanced load compensation for increased efficiency
EFFICIENCY
+3%
No wiring required
Extremely reliable RF signal.
Comfort II RF wireless programmable room thermostat and plug-in RF receiver –
Part no. 7 733 600 002
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.
30
EFFICIENCY
+3%
NEW Intelligent Solar Module
MS100 – Part no. 7 738 110 144
Maximum solar control and efficiency via the Greenstar Sense II control
Only one control to explain to the end user
Displays the solar performance on Greenstar Sense II
Clear colour coded plug-in connections for ease of installation
Supplied with solar and cylinder sensors.
Controls at a glance
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^.
Comfort II RF
Sense I†
Sense II
MS100
Wave
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
9
9
9 9 9
9
3%
V
3%
V
3%
VI** 4%**
–
–
VI
4%
27i & 30i System
V
9i-24i System
–
CDi Classic System
–
MODEL
27Ri and 30Ri
Hard wired
Radio frequency
Plug-in
Boiler flow
temp compensation
Optimum start
Programmable
room thermostat
Room thermostat
TEMPERATURE CONTROL CONNECTION TYPE EFFICIENCY
Auto switch –
BST/GMT
7 day
24 hour
Hot water
Central heating
Wall mounted
Fascia mounted
Internet
9
TIME CONTROL
Efficiency benefit
Comfort I RF
MOUNT
ErP Class
Comfort
Intelligent
Control
option
Digital
TYPE
91 92 9
93 91 92 9
93 91 92 9
9 9
1
9 92 9
91 92 9
91 92 9
1 Manufactured after 16th January 2007 with software version CF12.10 onwards. 2 Manufactured after February 2011. 3 With Greenstar optional wiring centre.
†Must be used with an external proprietary 230V timer. **When the Greenstar Sense II is installed as a room thermostat.
^Terms and conditions apply.
31
Worcester Wave – smart control
for heating and hot water
The Wave is the first of a new generation of
Worcester controls.
The Wave is a smart, internet-connected
programmable control for central heating
and hot water which can be operated using a
smart device.
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.
EFFICIENCY
+4%*
Enhanced energy efficiency
Adapting
ti
tto th
the h
homeowner’s
’ needs
d
In the ErP Directive, smart controls like the Wave is a
Each Wave unit is supplied with a pre-set programme that
Class VI control, adding 4%* to the overall system efficiency
can then be easily modified to suit the user’s requirements.
for heating, resulting in lower fuel bills. This increases
the ErP rating to ‘A+’ for the Greenstar i, Si Compact
and CDi Compact on heating.
The Wave’s advanced user features include:
‘Pairing’ with up to eight devices, automatically sensing
when people are at home.
The Wave’s energy efficiency features include:
Sensing to an individual device can be turned off
Charts of heating and hot water usage so the
if required.
homeowner can easily identify where potential savings
The Wave will remember preferred programme settings
could be made.
to make these easily available and features a ‘holiday
When the room temperature is turned down a leaf
programme’, requiring just a start and finish date.
symbol will appear to indicate additional savings are
Unlike most other smart heating controls, the Wave
being made.
can also programme the hot water settings, providing
Load and weather compensation via the Internet so
additional energy savings and comfort.
no outdoor sensor is required. This allows the boiler
For security and peace of mind, all of the Wave’s data
to modulate its performance to meet the needs of the
is owned by the user, ensuring no information is shared
household with optimum efficiency.
with other parties.
Wave compatible devices:**
Apple® devices running iOS 5.1 and higher
Android™ devices running 2.2, 2.3 or 4.0 and higher
32
**Correct at time of printing. *Factory default setting of the Wave is as 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.
Quick to install
The Wave is quick and easy to install:
Only requires a 2-core wire connection between the
EMS 2 Wire
control and the boiler.
Greenstar boiler
All other connections are via the Wi-Fi network.
The Wave does not need an external wired sensor
Wave
unlike standard weather compensation controls.
The Wave uses online data which significantly reduces
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.
External access
(away from home)
Internet
Phone
Simple to use, providing an easy handover
The Wave’s intuitive and modern design ensures it is very
simple to operate using either its in-built touchscreen or via
the Wave app.
Users simply download the Wave app to their
compatible device to take control of their heating
system from anywhere in the world where an internet
connection is available.
There are no subscription fees or chargeable app
add-ons, therefore updates to the app software are
completely free of charge.
An installation and operating manual is provided with
each control and there are a number of helpful videos to
provide further detail on specific functions.
Should the Wave temporarily lose the internet
connection, it will continue to operate as an intelligent
Compatibility with Worcester Greenstar boilers
heating and hot water control simply by using the last
Ideal for homes and small businesses, the Wave is
saved programme settings.
compatible with all current Worcester Greenstar gas-fired
combination and system* boilers. It can also be retrofitted
for use with previous Worcester EMS-bus appliances.
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.
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.
33
Greenstar
Wiring Centre
Enabling plug-in, fascia mounted digital timers and
programmers for Greenstar 27Ri and 30Ri regular boilers
The Greenstar Wiring Centre is a major benefit for installers
and end users, allowing the use of Worcester’s plug-in
Greenstar Comfort I and II, to be used on the new Greenstar
27Ri and 30Ri regular boilers. This enables digital timers and
programmers to control the heating and hot water for regular
boilers systems. The wiring centre clearly distinguishes
whether the cylinder needs hot water or if the home needs
heating and, to maximise comfort and efficiency, responds by
operating the boiler at different temperatures for each.
Features and benefits
Simple, time-saving installation
An innovative feature of the Greenstar Wiring Centre is
Allows Greenstar Comfort I and II to be used with our
that it allows the pump to be wired into the wiring centre,
Greenstar 27Ri and 30Ri regular boilers – controls both
rather than going through the household between the airing
heating and hot water
cupboard and the boiler. In replacement installations, this
Enables properties to use a wireless room thermostat
means the existing 3-core cable between the boiler and pump
which allows a wider choice of controls options
can be utilised to carry communication signals (EMS-BUS)
Pump is wired directly into the Wiring Centre and not to
from the wiring centre to the boiler. Experience shows this
the boiler
can save as much as half a day of installation time.
Simple system-type selector (S or Y plan) – simple, clear
wiring connections
The Greenstar Wiring Centre uses simple, clear, colour-coded
Up to three Greenstar Wiring Centres can be linked
connections and is supplied with a cylinder sensor and
together to control up to eight zones
unique retaining device as standard.
Supplied complete with cylinder sensor and unique
retaining device
Please note: When used with our Greenstar Comfort
Compatible with Worcester Greenstore unvented
controls no hot water temperature adjustment is available.
cylinders and third party unvented and vented cylinders*
To ensure Legionella protection, hot water will be stored
IP44 safety rating increases possible installation
at a pre-set temperature of 60°C. Please refer to Technical
locations.
Bulletins TB 0096a & TB 0100a on our website for further
guidance. If water temperatures below 60°C are required
at hot water outlets, then we recommend the use of a
Product info
thermostatic blending valve on the hot water outlet from
Part number
7 738 110 116
the cylinder.
Boiler located
in kitchen
Wiring Centre located in airing cupboard
Greenstar 27Ri and 30Ri
boiler located in kitchen
Fuse spur
Fuse spur
10-way
wiring centre
Greenstar Wiring Centre
located in airing cupboard
Fuse spur
Greenstar
Wiring Centre
Pump
2-core, BUS, BUS, E
3-core, SL, N, E
DHW cylinder
DHW cylinder
Existing boiler system layout
34
Pump
System layout with a Greenstar Wiring Centre
*Please check with the manufacturer. Makes replacement boiler installation much easier.
Site preparations and guidance
Siting of appliance
450mm
960mm
The appliances are to only be installed internally within a
property, at a suitable location onto a fixed, rigid surface,
+30mm
above elbow
that is at least the same size as the appliance and is capable
of supporting its weight.
Mounting on a combustible surface
All Greenstar wall-mounted boilers can be sited on a
combustible surface without the need for surface protection.
EN482, Section 6.4.1.3 states no means for protection of
Using 100mm
flue kit
– 1,130mm
Using 125mm
flue kit
– 1,170mm
combustible surfaces is necessary if the temperature of the
5mm
5mm
20mm to
removable
door
600mm front
clearance
for service
wall does not exceed the room temperature by more than
60ºC. Testing of Greenstar gas-fired wall-mounted boilers has
200mm
shown that this temperature is not exceeded.
Clearances for Greenstar CDi Classic Regular and System
However, if the appliance is to be fitted in a timber frame
building, the guidelines laid down in BS 5440:Part 1 and
400mm
870mm
the Gas Safe publication “Gas Installations in Timber Frame
Buildings” should be adhered to.
+30mm
above elbow
The appliances may be installed into an airing cupboard
if required. However, a non-combustible perforated material
(max. hole sizes of 13mm) must be used to separate the
boiler from the airing space. See section “Boiler location”
on page 36.
Using 100mm
flue kit
– 970mm
Using 125mm
flue kit
– 1,010mm
Installation and service clearances
5mm
5mm
20mm to
removable
door
600mm front
clearance
for service
The minimum clearances shown below should be allowed
for installation and servicing. All models, with the exception
200mm
of the 12Ri - 24Ri range, do not require compartment
ventilation so long as minimum installation and service
Clearances for Greenstar 27Ri & 30Ri
clearances are maintained, see opposite.
400mm
870mm
+30mm
above elbow
Using 100mm
flue kit
– 970mm
Using 125mm
flue kit
– 1,010mm
5mm
5mm
20mm to
removable
door
600mm front
clearance
for service
200mm
Clearances for Greenstar 12Ri-24Ri
35
400mm
880mm
+30mm
above elbow
+30mm
above elbow
Using 100mm
flue kit
– 1,060mm
Using 125mm
flue kit
– 1,100mm
410mm
930mm
Using 100mm
flue kit
– 1,070mm
5mm
5mm
Using 125mm
flue kit
– 1,110mm
5mm
20mm to
removable
door
5mm
25mm to
removable
door
600mm front
clearance
for service
600mm front
clearance
for service
200mm
200mm
Clearances for Greenstar 27i & 30i System
Clearances for Greenstar 9i-24i System
Boiler location
The appliance may be installed in any room, although
particular attention is drawn to the requirements of the
IEE regulations applicable and, in Scotland, the electrical
1. The room in which the appliance is installed does not
require a purpose-provided air vent.
2. If the appliance is installed in a cupboard or
provisions with respect to installation in a room containing
compartment with dimensions that allow the following
a bath or shower.
minimum clearances, then no ventilation is required:
Compartment installation
Min. unventilated clearance (to removable door)
Greenstar CDi Classic
Regular & System
Greenstar
12Ri-24Ri
Greenstar
27Ri & 30Ri
Greenstar
9i-24i System
Greenstar
27i & 30i System
20mm
100mm
20mm
20mm
20mm
200mm
200mm
200mm
200mm
200mm
Right side
5mm
200mm*
5mm
5mm
5mm
Left side
5mm
200mm*
5mm
5mm
5mm
30mm
30mm
30mm
30mm
30mm
Position of appliance
In front
Below
Above flue elbow
*This can be reduced to 50mm for one side, provided that the total side clearances add up to 400mm or more.
Important: bathroom locations and clearances
600m
m
• The boiler must not be installed in Zone 1
• Any switch or appliance control using mains electricity
600m
m
600m
m
must not be within reach of a person using the bath
• A boiler fitted with an FW100 controller may only be
1
2* 2*
1
2
installed in the area outside of zone 2. A boiler with
2
1
any other timer fitted (or blanking panel for an optional
programmer) can be installed in zone 2
Radius 600mm
• Additional Residual Current Device (RCD) protection
may be required.
Refer to the latest IEE wiring regulations.
36
*Without the end wall, zone 2 must extend 600mm from the bath
2
2,250mm
and socket outlets must not be situated in the bathroom
2,250mm
or shower
• Electrical switches (other than pull cords), fused spurs
Wall preparation
The following diagrams show the wall-mounting jigs which
For all boilers, the pipework can be routed behind the boiler
enable a simple and straightforward method of attaching
without the need for an additional wall-spacing frame.
the boiler to the wall surface.
Greenstar CDi Classic Regular
wall-mounting jig
Greenstar 27Ri & 30Ri wall mounting jig
Greenstar 12Ri-24Ri wall mounting jig
Greenstar CDi Classic System boiler
wall-mounting jig
Greenstar 27i & 30i System boiler
wall-mounting jig
Greenstar 9i-24i System boiler
wall-mounting jig
37
Casing dimensions
(When fitted to wall frame) Depth to wall
(When fitted to wall frame) Depth to wall
270mm
360mm
270mm
600mm
750mm*
390mm
440mm
390mm
Greenstar CDi Classic Regular and System
Greenstar 27Ri & 30Ri
Greenstar 12Ri-24Ri
*760mm to top of casing front.
Depth to wall (when fitted to wall frame)
280mm
(When fitted to wall frame) Depth to wall
330mm
700mm†
680mm**
390mm
400mm
Greenstar 27i & 30i System
Greenstar 9i-24i System
**690mm to top of casing front.
†710mm to top of casing front.
38
600mm
Pipework connections – regular boilers
3
1
1
2
2
3
4
4
Greenstar CDi Classic Regular (front view)
Greenstar 27Ri & 30Ri (rear view)
Pipework connections – Greenstar CDi Classic Regular
Function
1 Condensate drain
2 CH flow
From left
case edge
Diameter
of pipe
55mm
22mm
Pipework connections – Greenstar 27Ri & 30Ri
From left
case edge
Diameter
of pipe
1 CH return
312mm
22mm
Function
85mm
22mm
2 CH flow
247mm
22mm
3 Gas
212mm
22mm
3 Gas
65mm
22mm
4 CH return
343mm
22mm
4 Condensate drain
33mm
22mm
1
2
4
3
Greenstar 12Ri-24Ri (rear view)
Pipework connections – Greenstar 12Ri-24Ri
From left
case edge
Diameter
of pipe
1 CH return
350mm
22mm
2 CH flow
285mm
22mm
Function
3 Gas
4 Condensate drain
55mm
22mm
210mm
22mm
39
Pipework connections – system boilers
1
1
2
5
3
2
4
Greenstar CDi Classic System
4
5
Greenstar 27i & 30i System
Pipework connections – Greenstar CDi Classic System
Function
1 Condensate drain
3
From left
case edge
55mm
Diameter
of pipe
22mm
85mm
22mm
2 CH flow
Pipework connections – Greenstar 27i & 30i System
Function
1 Condensate drain
2 CH flow
From left
case edge
33mm
Diameter
of pipe
22mm
65mm
22mm
3 Gas
212mm
22mm
3 Gas
195mm
22mm
4 CH return
343mm
22mm
4 Pressure relief valve
291mm
15mm
5 Pressure relief valve
375mm
15mm
5 CH return
325mm
22mm
Optional accessory
The vertical pre-piping assembly kit comprises a set of
pre-formed copper pipes.
CDi Classic System 7 716 192 651
1
i System (9 to 30kW) 7 716 192 713.
5
2
3
4
Greenstar 9i-24i System
Pipework connections – Greenstar 9i-24i System
Function
1 Condensate drain
2 CH flow
40
From left
case edge
38mm
Diameter
of pipe
22mm
70mm
22mm
3 Gas
200mm
22mm
4 CH return
330mm
22mm
5 Pressure relief valve
364mm
15mm
Installation requirements
Installation of the Greenstar regular and system boiler range
Plastic pipework
must be in accordance with the relevant requirements of
The use of plastic pipework is acceptable. However, some
the Gas Safety (Installation Use) Regulations (as amended),
plastics are permeable to oxygen and must be avoided. Only
current IEE Wiring Regulations, local Building Regulations,
pipework with a polymeric barrier should be used. Please
Building Standards (Scotland) regulations and bylaws of
note that the first 600mm of pipework connected to the
the local water company and Health and Safety Document
boiler must be of copper or steel.
No. 635 (Electricity at Work Regulations 1989). It should
be in accordance with the relevant recommendations of the
Open vented primary systems
following British Standards:
The Greenstar regular boiler range is designed for
connection to an open vented fully pumped heating and
BS 6798; BS 5449; BS 5546:1; BS 5440:1; BS 5440:2;
hot water system.
BS 6891.
The following points are for guidance only. The system
Gas Safety (Installation and Use) Regulations. All gas
installation should be carried out in accordance with
appliances must be installed by a Gas Safe registered
BS 5449:Part 1.
person in accordance with the above regulations. Failure to
install appliances correctly could lead to prosecution.
The cistern must be arranged to provide a minimum static
head of 0.25 metres above the top of the highest point in
The manufacturer’s notes must not be taken in any way as
the heating circuit.
overriding statutory regulations.
Air in the appliance is expelled through the vent pipe or
It is important with an aluminium heat exchanger that the
dissipated into the system. Manual air vents should be
pH level of the water does not exceed 8. Levels in excess of
fitted at any high points in the system.
this could be detrimental to the heat exchanger.
The boilers can be used on a sealed system but a third
The user of a suitable inhibitor will provide a resistance
party sealed system installation kit must be utilised.
to this. Contact Sentinel (Tel: 0800 389 4670 or visit
www.sentinel-solutions.net ) or Fernox (Tel: 0870 601 5000
Y plan
F&E
or visit www.fernox.com) for further details.
AAV
RT
CYL
CT
Protecting the heating system from dirty water
IV HC IV
It is a requirement of the building standard, BS 7593,
MPV
or
DIV
that all heating systems should be chemically flushed
and cleansed and then an inhibitor added to help
BC
prevent future corrosion taking place. It is also beneficial
B
WV
PR
R
LSV
and best practice within the building regulations to
install a system filter.
S plan
F & EC
AV
RT
CYL
CT
IV HC IV
ZV
ZV
ABV
BC
B
PR
WV
R
LSV
41
Sealed primary systems – regular boilers
Greenstar system boiler diverter valve kit
The system should be installed in compliance with the
Greenstar system boilers can be adapted to house an
requirements of BS 5449: Part1. The system must be fitted
in-built diverter valve. The optional integral diverter valve
with a spring loaded safety valve set to operate at 3bar
kit allows the user to control the supply of heat to the hot
(45 psi) and the pipe connections made through the system
water cylinder from the boiler. A choice of Worcester plug-in
must be capable of sustaining a pressure of up to 3bar.
controls must be used.
Manual air vents should be fitted at any high points in
System filling and make-up
the system.
To comply with the Water Authority requirements, the
system should be filled via a temporary hose connection
The following is a list of major items which must be fitted to
to the mains cold water supply, with a double check valve
the system:
assembly and test point fitted to the mains water side of a
1. Safety valve – 3bar
temporary circuit.
2. Pressure gauge – 0 - 4bar
3. Expansion vessel
Valves and joints
4. Automatic air vent
It is very important that all valves and joints are able to
sustain a working pressure of up to 3bar (45psi). Particular
Typical fully pumped sealed system
care should be exercised when fitting radiator valves and
only those of high quality to BS 2767:10 should be used.
All other valves and fittings should comply with BS 1010.
Loss of water pressure from a sealed system will require
continuous recharging with fresh water and consequential
introduction of air. Air is highly corrosive and will
considerably reduce life-expectancy of radiators, pumps etc.
Air supply
Worcester Greenstar system boilers are room-sealed
Sealed primary systems – system boilers
appliances; the room in which it is installed does not
Worcester Greenstar System boilers are supplied complete
therefore require a purpose-provided combustion air vent.
with all the necessary components to form a sealed primary
system. Included are an expansion vessel, a pressure
Natural gas supply
relief valve (set at 3bar), an automatic air vent and a
Gas supply pipework must be sized to ensure a maximum
pressure gauge.
1mbar pressure drop between the meter and appliance
inlet, +1.5mbar across the appliance to the gas valve
With an initial system pressure of 0.5bar a system capacity
test point.
of approximately 83 litres can be accommodated. Refer to
BS 7074:Part 1 for more information.
Listed below is a representative example. Figures for other
appliances can be found in the relevant installation manuals.
The system should be installed in compliance with the
Model
requirements of BS 5449: Part 1.
Manual air vents should be fitted at any high points in
the system.
24Ri
2.6m3/hr
30Ri
3.2m3/hr
40CDi Classic Regular
4.4m3/hr
24i System
2.6m3/hr
30i System
3.24m3/hr
30CDi Classic System
42
Gas rate
3.2m3/hr
The gas meter and supply pipes must be capable of
Guarantee
supplying this quantity of gas in addition to the demand
Worcester Greenstar regular and system appliances
from any other appliance being served. Particular
are offered with a full 5 year guarantee* on parts and
consideration should be given to the resistance to gas
labour and a 10 year guarantee* on the primary heat
flow created by elbows, bends etc.
exchanger*. Ongoing service and maintenance
contracts can be arranged through the Worcester
Greenstar 12Ri - 24Ri regular & 9i - 24i System models
Customer Service Department.
Provided that the correct gas supply working pressure and
gas rate can be achieved (refer to BS 6891) then it may be
Please contact our guarantee
possible to reduce the gas supply pipe diameter to 15mm.
registration advisors on
0330 123 2552 or visit
Generally speaking, the appliance would need to be within
www.worcester-bosch.co.uk/
3 to 4 metres of the gas meter. However, this will depend
guarantee
on the distribution pipe size and route.
On all Greenstar
On the primary
regular and system heat exchanger*
appliances*
Liquid Petroleum Gas (LPG) supply
Listed below is a representative example. Figures
for other appliances can be found in the relevant
installation manuals.
Model
Gas rate
24Ri
1.9kg/hr
30Ri
2.3kg/hr
40CDi Classic Regular
3.3kg/hr
24i System
1.91kg/hr
30i System
2.33kg/hr
30CDi Classic System
2.4kg/hr
The gas tank or bottles must be capable of supplying this
quantity of gas at a nominal pressure of 37mbar (14.8in wg)
at the appliance.
Electricity supply
A 3amp fused three pin plug and unswitched shuttered
socket outlet (both complying with BS 1362) or preferably a
double pole isolator with a contact separation of 3mm in all
poles supplying the appliance should be used.
The appliances’ electrical circuits are also protected by an
internal fuse. The appliance must be earthed.
*Subject to terms and conditions.
43
The NEW Greenstar
System Filter
NEW
Available in 22mm and 28mm, the Worcester Greenstar System Filter has
been specifically designed to combat the damaging effects of system debris
and pollutants, allowing homeowners to protect their boiler or heat pump
for a fraction of its cost.
Inspired by installer feedback, the new filter has been designed to
make installation and servicing simpler than ever before. In addition the
performance has been improved resulting in a greater collection of debris
from the system.
Please note: CIBSE heating guide recommends, for a condensing boiler
system, anything running continuously over 23kW is likely to require
28mm pipework and therefore a 28mm filter. However, this will be
dependent on the system layout and pressure drop.
NEW features and improvements
Over-tightening prevention feature
Isolation valve indicators
The removable lid has been designed to prevent over-
The isolation valves can be opened using a single 90º
tightening and damage to the O-ring seal, eliminating the
turn, with red and green indicators showing when the
risk of leaks.
filter is in operation.
or
Bi-directional flow
Stronger magnet
Engineered to allow a bi-directional flow, enabling it to be
A larger powerful internal magnet safeguards the boiler and
installed anywhere along the return circulation pipework
wider system components.
between the last radiator and the boiler.
44
28mm version now available
Pipe cut template
A larger version is now available for use in larger
A cutting guide is supplied with the filter for use in
heating systems.
measuring exact lengths of pipe to cut at the point at which
the filter is being installed.
Easy to fit
Easy to service
Although the Greenstar System Filter shares its name with
The Greenstar System Filter has been designed to make
our high efficiency gas and oil-fired boilers, it can also be
servicing and maintenance simple by using the special
fitted to any typical domestic heating system.
spanners supplied and a radiator bleed key.
Installation
The filter can be installed anywhere in a heating system, except between the boiler and on the feed and expansion pipes
on an open vent system. To maximise the effectiveness it should be placed on the primary heating return before the
boiler and after the last radiator.
6
6
2
1
4
7
3
M
5
3. Pump
7
4. Radiator
5
M
OK
Open vented system
2. Open vent tank
4
4
OK
1. Boiler
1
1
Sealed system*
5
OK
5. System filter
6. Cylinder
Combi
*When a system boiler has an internal diverter valve and two returns, the system filter should be put on the heating return and not the cylinder return.
Product info
Part numbers
WARNING MAGNETIC FIELD.
7 733 600 236 (22mm)
7 733 600 237 (28mm)
Powerful
magnetic field
Can be harmful to
pacemaker wearers.
45
Condensate pipework
Important points to consider when siting a condensate
drainage pipe:
• 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
Siphon
trap
boiler location
Soil
& vent
stack
• The condensate pipe must be a minimum of 22mm dia.
plastic pipe
• The condensate pipework must fall at least 52mm per
metre towards the outlet and should take the shortest
Min. 450mm &
up to 3 storeys
22mm dia.
practicable route
• Ensure there are no blockages in the pipe run.
Internal connections
In order to minimise the risk of freezing during prolonged
Fig. 1 Disposal to soil vent stack
cold spells, the following methods of installing a condensate
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
Sink with
integrated
overflow
100mm
pipe should be used. (see fig. 1)
Alternatively, if the first option is not possible, an internal
Visable air break
at plug hole
22mm dia.
75mm min.
kitchen, bathroom or washing machine waste pipe, etc. can
be used. (see fig. 2)
75mm sink
waste trap
Condensate pump
Where “gravity discharge” to an internal termination is not
Fig. 2 Disposal to a waste pipe
physically possible, or where very long internal runs would
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
foul water discharge point such as an internal soil and vent
stack, internal kitchen, bathroom or washing machine waste
pipe, etc. A suitable permanent connection to the foul waste
Siphon
trap
75mm min.
75mm sink
waste trap
pipe should be used. (see fig. 3)
22mm
dia.
Condensate
pump
Fig. 3 Condensate pump disposal
46
External connections
Greenstar CDi Classic Regular, Greenstar CDi Classic
System and Greenstar i System
Siphon
trap
The Greenstar CDi Classic and Greenstar i have a large
capacity siphonic condensate trap reducing the risk
Insulate
& increase
pipe size
of condensate discharge freezing up during periods of
prolonged cold temperatures.
Like the CondenseSure siphon accessory, the expanded
Pipework
transition
25mm min.
siphonic operation discharges every 15 to 20 minutes,
resulting in:
Fig. 5 External disposal
• Increased velocity and flow rate
• With only 3 to 4 siphonic actions per hour, the
Condensate soak away (see fig. 6)
condensate pipework is empty for longer
• Eliminated freezing potential.
• The condensate drainage pipe may be run above or below
the ground to the soak away
For a 48 hour period at -15°C provided the installation
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
external run pipe diameter should be increased to a
minimum of 32mm and not exceed 3 metres
• 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.
• The examples shown run above ground
• The soak away must use a 100mm dia. plastic tube with
two rows of three 12mm holes on 25mm centres and
50mm from the bottom of the tube. The holes must face
away from the house
• The tube must be surrounded by at least 100mm of
limestone chippings to a depth of 400mm
• Minimum hole size for the condensate soak away must be
400mm deep by 300mm dia.
In situations where there are likely to be extremes of
temperature or exposure, the use of a proprietary trace
Greenstar Ri, Greenstar 27i and 30i System
heating system for external pipework (that incorporates
Freezing conditions
an external frost thermostat) should be considered. If
• When the position of the boiler prevents internal
such a system is used, the requirement to use 32mm pipe
routing, we recommend installing a Worcester
does not apply, however all other guidance above, and the
CondenseSure siphon to minimise the risk of freezing
instructions for the trace heating system, should be
• Pipework length should be kept to a minimum and the
closely followed.
route as vertical as possible
• Weather-proofing insulation must be sized when not
using a CondenseSure siphon.
Unheated internal areas
Internal pipe runs in unheated areas such as lofts,
Condensate waste
basements and garages should be treated as external runs,
• Care should be taken when siting a soak away to avoid
with consideration given to using a CondenseSure siphon.
obstructing existing services.
If no other discharge method is possible, then the use of
an externally-run condensate drainage pipe terminating at
100mm dia.
a suitable foul water discharge point (fig. 4), or purpose-
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
Siphon
trap
Pipework
transition
External
air break
Pipework
transition
Drainage
holes
Siphon
trap
Fig. 4 Disposal into a rainwater down pipe
68mm dia. PVCu
strap on fitting
50mm
25mm
25mm min.
100mm
dia. min.
plastic
pipe
Air gap
43mm 90º
male/female
bend
Insulate
& increase
pipe size
25mm
25mm
Limestone chippings
400mm
Drainage min.
holes
Bottom of sealed tube
Fig. 6 Soak away
47
The Worcester CondenseSure
With climate change and extreme weather variations
becoming increasingly common, and very cold winters with
temperatures as low as -20ºC being experienced, practices
such as externally-run condensate discharge pipework are
now being questioned.
The CondenseSure auxiliary siphon has been designed to
allow a more flexible approach to boiler siting.
Tested to extreme temperatures
The CondenseSure has been extensively tested under
simulated extreme weather conditions and proved its
effectiveness in preventing frozen condensate at -15ºC
for a sustained period of 48 hours.
CondenseSure principle of operation
Within most condensing boilers, there is an internal siphon
which holds around 100ml of condensate before being
released down the condensate discharge pipe. A typical
high-efficiency condensing boiler will generate up to 2
The CondenseSure insulating jacket helps to retain the temperature
of the condensate.
litres of condensate an hour (dependant on output and
temperature) and this will result in the in-built siphon
A universal fitting for new and existing installations
discharging approximately every 3 minutes. With this
Although developed specifically for Worcester Greenstar
frequency of discharge, it is unlikely that the condensate
gas- and oil-fired boilers, the Worcester CondenseSure
pipework is ever empty of condensate, consequently
can also be fitted to any make of condensing boiler for
increasing the potential for freezing of the pipework in
both new and retrofit installations. The CondenseSure
prolonged sub-zero temperatures.
can provide a simple solution which eliminates the need
for re-siting both the new boiler and the system pipework
The CondenseSure siphon connects to the boiler
when replacing an existing non-condensing appliance. The
condensate discharge outlet and collects the condensate
CondenseSure can easily be fitted to existing installations
into a larger volume before releasing it into the
to provide peace of mind in extreme weather conditions.
discharge pipe.
With this expanded siphonic operation, the discharge from
Features
the CondenseSure is every 15 to 20 minutes, resulting in:
No electrical supply needed
• Increased velocity and flow rate
• With only 3 to 4 siphonic actions per hour,
Zero running costs and no wiring connection, so no
the condensate pipework is empty for longer
• Significantly decreased or even eliminated
freezing potential.
need for an electrician to install.
Compatible with all boilers
Can be installed on new or existing installations and is
suitable for any gas- or oil-fired condensing boilers.
Uses ‘free’ energy
By attaching the CondenseSure to the 22mm heating
flow pipework the energy from the pipe is used to heat
the condensate.
Installation flexibility
Can be installed under the boiler or remotely.
No pipe insulation needed
Cost-saving and aesthetically pleasing.
48
Ease of installation
Fitting to a system boiler
The CondenseSure has been designed with ease of
installation in mind and is suitable for most boiler
applications. For maximum effectiveness, it should
be installed immediately beneath the boiler where
it is clipped on to the boiler’s heating flow pipe and
4
connected to its siphonic trap. If this is not practical,
1
the CondenseSure can be wall-mounted away from the
2
boiler and connected to a 32mm condensate discharge
pipe. However, this will sacrifice the benefit of warming
the condensate prior to discharge and therefore slightly
3
reduce its performance.
2
Siphon
trap
5
6
7
External pipework
3000mm max.
CondenseSure
2.5º fall min.
32mm OD pipe
1. Foam backing with double-sided tape
2. Siphon mounting screws
3. Siphon body
4. Foam insert (used with regular or system boilers)
A typical installation using CondenseSure
5. Foam cover
The CondenseSure installation parameters
6. CH flow pipe
The CondenseSure will protect an externally-run condensate
7. Cylinder flow pipe (CDi Classic System only)
discharge pipe from freezing for 48 hours at -15°C providing
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
•
•
•
•
The externally-run pipe length does not exceed 3 metres
in diameter.
Whilst it is not necessary to insulate the pipework, it may
be a consideration if longer lengths or if lower external
temperatures are expected.
The CondenseSure
clips onto the
22mm heating
flow pipe using
the ‘free’ heat
to raise the
condensate
temperature.
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
49
Horizontal and vertical flue terminal positioning
All measurements in millimetres
2m
1m
2
25
104mm
52mm
3
1,500
600
2
1
5
300
300
1,500
7
8
600
500
600
4
1,200
300 300
6
9
Boundary Line
Note
Key to illustration
• All measurements are the minimum clearances required
• Terminals must be positioned so as to avoid combustion
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
products entering the building
• Support the flue at approximately one metre intervals and at a
clear any overhang. External flue joints must be sealed with
suitable silicon sealant.
change of direction, use suitable brackets and fittings.
Flue bracket part numbers:
3.
1,500mm between a vertical flue terminal and a window or
dormer window.
7 716 191 177 (100mm dia.)
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
nuisance. BS 5440:Part 1 recommends that care is taken when
siting terminal in relation to boundary lines.
7.
600mm minimum clearance from a skylight to a vertical flue.
8.
Vertical flue clearance, 500mm to non-combustible
building material, and 1,500mm clearance to combustible
50
building material.
40
0
25
16
45
13
300
500
12
14
200
300
15
300
600
600
10
16
11
300 300
17
300 300
25
300
9.
18
300
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.
11. 300mm to an internal or external corner.
12. 2,000mm below a Velux window, 600mm above or to either
side of the Velux window.
13. 400mm from a pitched roof or 500mm in regions with
17. Flue clearance must be at least 300mm from the ground.
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.
15. 200mm below eaves and 75mm below gutters, pipe and drains.
16. The dimension below eaves, balconies and car ports can be
reduced to 25mm, as long as the flue terminal is extended to
• 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.
clear any overhang. External flue joints must be sealed with
suitable silicon sealant.
51
Greenstar regular and system boiler range
horizontal fluing options
™
Accessories
The Greenstar regular and system boiler range offers the
choice of 2 differently sized horizontal RSF flue systems,
Components
a 100mm diameter telescopic flue kit including a plume
Part No.
100mm diameter
management kit, and a 125mm diameter telescopic flue
kit. Both systems have different maximum lengths. The
7 716 191 082
Standard telescopic flue kit
(350 - 570mm)
7 716 191 171
Long telescopic flue kit
(570 - 790mm)
following diagrams detail the permissible lengths.
™
Horizontal RS flue
Flue diameter
100mm
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 30CDi Classic Regular and 30CDi Classic System
Minimum flue length
350mm*
405mm
Maximum flue length
7,900mm
18,500mm
7 716 191 084 90º bend
7 716 191 085 45º bend
Greenstar 40CDi Classic Regular
Minimum flue length
350mm*
405mm
Maximum flue length
6,000mm
12,500mm
Description
7 719 002 432
High level horizontal
flue adaptor
7 733 600 048^
High level horizontal
telescopic flue kit
7 716 191 177 Support bracket kit
Greenstar 12Ri-24Ri and 9i-24i System models
7 716 191 178 Support bracket kit (6 pack)
Minimum flue length
350mm*
405mm
Maximum flue length
4,600mm
13,000mm
*Dimensions when fitted
125mm diameter
Greenstar 27Ri & 30Ri and 27i & 30i System models
Minimum flue length
350mm*
405mm
Maximum flue length
6,000mm
15,000mm
7 719 003 702
Standard telescopic flue kit
(405 - 600mm)
7 719 003 666 Extension flue kit (960mm*)
7 719 003 664 90º bend
Greenstar 35CDi Classic System
Minimum flue length
350mm*
405mm
Maximum flue length
7,000mm
16,000mm
7 719 003 665 45º bend
7 719 002 433
*Can be cut to 130mm. Please refer to instructions.
High level horizontal
flue adaptor
7 716 191 179 Support bracket kit
*Dimensions when fitted. ^For use with high level horizontal flue adaptor.
100mm dia. standard telescopic flue kit
1 x flue turret elbow
570mm (100mm dia.) of flue duct
The following criteria should be noted when planning
1 x weather sealing ring
the installation:
1 x internal collar
• The concentric flue system must be inclined at
Part No. 7 716 191 082
3º (52mm per metre) from the appliance, to allow
condensate to drain back into the boiler
125mm dia. standard telescopic flue kit
• A white plume of condensation will be emitted from
1 x flue turret elbow
the terminal because the appliance operates at high
600mm (125mm dia.) of flue duct including terminal
efficiency. Care must be taken when selecting the flue
(as measured from centre of flue outlet)
terminal position
1 x weather sealing plate
• To achieve a maximum flue length, one of the extension
1 x internal plate
flue kits will need to be cut so that the permitted
Part No. 7 719 003 702
maximum flue length is not exceeded
• 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.
52
Option 1: Standard horizontal flue assembly
Components
Option 2: Extension flue horizontal
Components
Part No. 100mm
7 716 191 082
Part No. 125mm
7 719 003 702
Maximum lengths (mm) & no. of components required
Greenstar 30CDi Classic Regular and 30CDi Classic System
100mm
570
1
125mm
600
1
Greenstar 40CDi Classic Regular
100mm
570
1
125mm
600
1
Greenstar 12Ri-24Ri and 9i-24i System models
100mm
570
1
125mm
600
1
Greenstar 27Ri & 30Ri and 27i & 30i System models
100mm
570
1
125mm
600
1
Greenstar 35CDi Classic System
100mm
30
1
125mm
30
1
Part No. 100mm
7 716 191 082
7 716 191 083
Part No. 125mm
7 719 003 702
7 719 003 666
Maximum lengths (mm) & no. of components required
Greenstar 30CDi Classic Regular and 30CDi Classic System
100mm
7,900
125mm 18,500
1
up to 8
1
up to 18
Greenstar 40CDi Classic Regular
100mm
6,000
125mm 12,500
1
up to 6
1
up to 12
Greenstar 12Ri-24Ri and 9i-24i System models
100mm
4,600
125mm 13,000
1
up to 5
1
up to 13
Greenstar 27Ri & 30Ri and 27i & 30i System models
100mm
6,000
125mm 15,000
1
up to 6
1
up to 15
Greenstar 35CDi Classic System
100mm
7,000
125mm 16,000
1
up to 7
1
up to 16
Note: The 100mm dia. short flue extension
Note: The maximum flue length must be reduced by the
(Part No. 7 716 191 133) and 100mm dia. 2m flue extension
following amounts for each bend used.
(Part No. 7 716 191 172) may be used as an alternative to
the standard extension as required up to the maximum flue
lengths stated.
45º bend
90º bend
Greenstar CDi Classic Regular
& System 60/100mm flues
750mm
1,500mm
Greenstar CDi Classic Regular
& System 80/125mm flues
1,000mm
2,000mm
Greenstar Ri & i System –
all size flues
1,000mm
2,000mm
53
Option 4: Extension flue horizontal and upwards
Option 3: Extension flue horizontal
using a second 90º bend
Components
Part No. 100mm
Part No. 125mm
7 716 191 082
7 719 003 702
7 716 191 083
7 719 003 666
7 716 191 084
7 719 003 664
Maximum lengths (mm) & no. of components required
Greenstar 30CDi Classic Regular and 30CDi Classic System
100mm
6,400
125mm 16,500
1
up to 6
1
1
up to 16
1
4,500
125mm 10,500
1
up to 4
1
1
up to 10
1
2,600
125mm 11,000
1
up to 3
1
1
up to 11
1
4,000
125mm 13,000
1
up to 4
1
1
up to 13
1
5,500
125mm 14,000
7 719 002 432
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
Greenstar 30CDi Classic Regular and 30CDi Classic System
100mm
7,900
1
up to 6
1
1
up to 14
1
1
up to 8
1
1
1
up to 18
1
1
Greenstar 40CDi Classic Regular
100mm
6,000
1
up to 6
1
1
1
up to 12
1
1
Greenstar 12Ri-24Ri and 9i-24i System models
100mm
4,600
1
up to 5
1
1
1
up to 13
1
1
Greenstar 27Ri & 30Ri and 27i & 30i System models
100mm
6,000
125mm 15,000
Greenstar 35CDi Classic System
100mm
7 716 191 084
125mm 13,000
Greenstar 27Ri & 30Ri and 27i & 30i System models
100mm
7 716 191 083
125mm 12,500
Greenstar 12Ri-24Ri and 9i-24i System models
100mm
7 716 191 082
125mm 18,500
Greenstar 40CDi Classic Regular
100mm
Components
Part No. 100mm
1
up to 6
1
1
1
up to 15
1
1
Greenstar 35CDi Classic System
100mm
7,000
125mm 16,000
1
up to 7
1
1
1
up to 16
1
1
Note: The 100mm dia. short flue extension
Note: The maximum flue length must be reduced by the
(Part No. 7 716 191 133) and 100mm dia. 2m flue extension
following amounts for each bend used.
(Part No. 7 716 191 172) may be used as an alternative to
the standard extension as required up to the maximum flue
lengths stated.
54
45º bend
90º bend
Greenstar CDi Classic Regular
& System 60/100mm flues
750mm
1,500mm
Greenstar CDi Classic Regular
& System 80/125mm flues
1,000mm
2,000mm
Greenstar Ri & i System –
all size flues
1,000mm
2,000mm
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
7 719 002 432
Part No. 125mm
7 719 003 702
7 719 003 666
7 719 003 664
7 719 002 433
Components
Part No. 100mm
7 716 191 082
7 716 191 083
7 716 191 084
7 719 002 432
Greenstar 30CDi Classic Regular and 30CDi Classic System
Part No. 125mm
7 719 003 702
7 719 003 666
7 719 003 664
7 719 002 433
100mm
Maximum lengths (mm) & no. of components required
1
up to 7
2
1
Maximum lengths (mm) & no. of components required
1
up to 16
2
1
Greenstar 30CDi Classic Regular and 30CDi Classic System
Greenstar 40CDi Classic Regular
100mm
100mm
6,400
125mm 16,500
4,500
125mm 10,500
2,600
125mm 11,000
4,000
125mm 13,000
5,500
125mm 14,000
3
1
3
1
2
1
1
up to 10
2
1
Greenstar 40CDi Classic Regular
100mm
3,000
1
up to 2
3
1
1
1
up to 3
up to 11
2
1
125mm
8,500
1
up to 8
3
1
1
Greenstar 12Ri-24Ri and 9i-24i System models
2
3
1
125mm
9,000
1
up to 9
1
up to 4
2
1
Greenstar 27Ri & 30Ri and 27i & 30i System models
1
up to 13
2
1
100mm
2,000
125mm 11,000
Greenstar 35CDi Classic System
100mm
up to 5
up to 14
up to 4
Greenstar 27Ri & 30Ri and 27i & 30i System models
100mm
1
1
1
Greenstar 12Ri-24Ri and 9i-24i System models
100mm
4,900
125mm 14,500
1
up to 6
2
1
1
up to 14
2
1
1
up to 2
3
1
1
up to 11
3
1
Greenstar 35CDi Classic System
100mm
4,000
125mm 12,000
1
up to 4
3
1
1
up to 12
3
1
45º options available
Note: The 100mm dia. short flue extension
Note: The maximum flue length must be reduced by the
(Part No. 7 716 191 133) and 100mm dia. 2m flue extension
following amounts for each bend used.
(Part No. 7 716 191 172) may be used as an alternative to
the standard extension as required up to the maximum flue
lengths stated.
45º bend
90º bend
Greenstar CDi Classic Regular
& System 60/100mm flues
750mm
1,500mm
Greenstar CDi Classic Regular
& System 80/125mm flues
1,000mm
2,000mm
Greenstar Ri & i System –
all size flues
1,000mm
2,000mm
55
Greenstar regular and system boiler range
vertical fluing options
The Greenstar regular and system boiler range offers the
™
Accessories
choice of 2 differently sized vertical RSF flue systems,
Components
100mm and 125mm. Both systems have different
Part No.
100mm diameter
maximum lengths. The following diagrams detail the
permissible lengths.
7 719 002 430
Vertical 1,090mm balanced
flue kit (inc. adaptor)
7 716 191 083 Extension flue kit (960mm*)
™
Vertical RSF flue
Description
7 716 191 172 2m flue extension*
Flue diameter
100mm
125mm
7 716 191 133 Short flue extension (220mm*)
Greenstar 30CDi Classic Regular,
30CDi Classic System & 35CDi Classic System
Minimum flue length
Maximum flue length
(inc. adaptor)
7 716 191 084 90º bend
1,090mm
1,365mm
9,400mm
18,500mm
7 716 191 085 45º bend
7 716 191 090 Flashing – flat roof
7 716 191 091 Flashing – pitched roof
Greenstar 40CDi Classic Regular
Minimum flue length
Maximum flue length
(inc. adaptor)
1,090mm
1,365mm
7,500mm
16,000mm
125mm diameter
Greenstar 12Ri-24Ri and 9i-24i System models
Minimum flue length
Maximum flue length
(inc. adaptor)
*Dimensions when fitted
1,090mm
1,365mm
6,400mm
15,000mm
7 719 002 431
Vertical 1,365mm balanced
flue kit (inc. adaptor)
7 719 003 666 Extension flue kit (960mm*)
Greenstar 27Ri & 30Ri and 27i & 30i System models
7 719 003 664 90º bend
Minimum flue length
7 719 003 665 45º bend
Maximum flue length
(inc. adaptor)
1,090mm
1,365mm
6,000mm
15,000mm
7 716 191 090 Flashing – flat roof
7 716 191 091 Flashing – pitched roof
100mm dia. vertical balanced flue kit
*Dimensions when fitted
1 x flue terminal assembly
1 x weather sealing collar
The following criteria should be noted when planning
1 x fire stop spacer
the installation:
1 x vertical adaptor
• Because the appliance operates at high efficiency, a
Part No. 7 719 002 430
white plume of condensation will be emitted from the
terminal. Care must be taken when selecting the flue
125mm dia. vertical balanced flue kit
1 x flue terminal assembly
terminal position
• To achieve a maximum flue length, one of the extension
1 x weather sealing collar
flue kits will need to be cut so that the permitted
1 x fire stop spacer
maximum flue length is not exceeded
1 x vertical adaptor
Part No. 7 719 002 431
• Vertical flue options 1-4 illustrate common flue
installations. Other configurations of the flue system are
possible up to, and not exceeding, the stated maximum
flue lengths.
56
Option 1: Minimum height
Option 2: Vertical balanced flue system maximum height
Pitc
roo hed
f
Pitc
roo hed
f
500mm
Flat roof
300mm
500mm
300mm
Flat roof
L=
100mm dia. 1,090mm
125mm dia. 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 30CDi Classic Regular and 30CDi Classic System
Greenstar 30CDi Classic Regular and 30CDi Classic System
100mm
1,090
1
100mm
125mm
1,365
1
125mm 18,500
Greenstar 40CDi Classic Regular
9,400
1
up to 9
1
up to 18
Greenstar 40CDi Classic Regular
100mm
1,090
1
100mm
7,500
125mm
1,365
1
125mm 16,000
1
up to 7
1
up to 15
Greenstar 12Ri-24Ri and 9i-24i System models
Greenstar 12Ri-24Ri and 9i-24i System models
100mm
1,090
1
100mm
125mm
1,365
1
125mm 15,000
6,400
1
up to 6
1
up to 14
Greenstar 27Ri & 30Ri and 27i & 30i System models
Greenstar 27Ri & 30Ri and 27i & 30i System models
100mm
1,090
1
100mm
125mm
1,365
1
125mm 15,000
Greenstar 35CDi Classic System
6,000
1
up to 5
1
up to 14
Greenstar 35CDi Classic System
100mm
1,090
1
100mm
8,000
125mm
1,365
1
125mm 16,000
1
up to 8
1
up to 16
Note: The 100mm dia. short flue extension
Note: The maximum flue length must be reduced by the
(Part No. 7 716 191 133) and 100mm dia. 2m flue extension
following amounts for each bend used.
(Part No. 7 716 191 172) may be used as an alternative to
the standard extension as required up to the maximum flue
lengths stated.
45º bend
90º bend
Greenstar CDi Classic Regular
& System 60/100mm flues
750mm
1,500mm
Greenstar CDi Classic Regular
& System 80/125mm flues
1,000mm
2,000mm
Greenstar Ri & i System –
all size flues
1,000mm
2,000mm
57
Option 4: Vertical balanced flue system
with two 90º bends
Option 3: Vertical balanced flue system
with two 45º bends
Components
Components
Part No. 100mm
7 719 002 430
7 716 191 083
7 716 191 085
Part No. 100mm
7 719 002 430
7 716 191 083
7 716 191 084
Part No. 125mm
7 719 002 431
7 719 003 666
7 719 003 665
Part No. 125mm
7 719 002 431
7 719 003 666
7 719 003 664
Maximum lengths (mm) & no. of components required
Maximum lengths (mm) & no. of components required
Greenstar 30CDi Classic Regular and 30CDi Classic System
Greenstar 30CDi Classic Regular and 30CDi Classic System
100mm
7,900
125mm 16,500
1
up to 7
2
100mm
6,400
1
up to 6
2
1
up to 16
2
125mm 14,500
1
up to 14
2
Greenstar 40CDi Classic Regular
100mm
6,000
125mm 14,000
Greenstar 40CDi Classic Regular
1
up to 5
2
100mm
4,500
1
up to 4
2
1
up to 13
2
125mm 12,000
1
up to 13
2
Greenstar 12Ri-24Ri and 9i-24i System models
100mm
4,400
125mm 13,000
Greenstar 12Ri-24Ri and 9i-24i System models
1
up to 4
2
100mm
2,400
1
up to 2
2
1
up to 12
2
125mm 11,000
1
up to 10
2
Greenstar 27Ri & 30Ri and 27i & 30i System models
100mm
4,000
125mm 13,000
Greenstar 27Ri & 30Ri and 27i & 30i System models
1
up to 3
2
100mm
1
up to 12
2
125mm 11,000
Greenstar 35CDi Classic System
100mm
6,500
125mm 14,000
2,000
1
1
2
1
up to 10
2
Greenstar 35CDi Classic System
1
up to 6
2
100mm
5,000
1
up to 5
2
1
up to 14
2
125mm 12,000
1
up to 12
2
Note: The 100mm dia. short flue extension
Note: The maximum flue length must be reduced by the
(Part No. 7 716 191 133) and 100mm dia. 2m flue extension
following amounts for each bend used.
(Part No. 7 716 191 172) may be used as an alternative to
the standard extension as required up to the maximum flue
lengths stated.
58
45º bend
90º bend
Greenstar CDi Classic Regular
& System 60/100mm flues
750mm
1,500mm
Greenstar CDi Classic Regular
& System 80/125mm flues
1,000mm
2,000mm
Greenstar Ri & i System –
all size flues
1,000mm
2,000mm
Plume management terminal positioning
All measurements in millimetres
Flue terminal guard 7 716 191 176
±45°
Plume re-direction:
100
600
1
Flue exhaust
outlet
180°
10
1,500
Air intake
±80°
6
200
300
2
200
5
600
150
200
300
300
3
150
300
7
150
150
300
8
200
300
150
1,200
300 300
25
25
600
9
10
4
Boundary line
Note
6.
• All measurements are the minimum clearances required
• Refer to pages 50-51 for all concentric flue terminal positions
can be reduced to 150mm providing the flue exhaust outlet has
a 300mm clearance. Plume kits running horizontally must have
unless the flue position is specified on the figure above
a 10° fall back to the boiler for proper disposal of condensate.
“Plume terminal positions”
For details on specific lengths see relevant boiler Technical &
• Terminals must be positioned so as to avoid combustion
products entering the building
Specification information.
7.
• Support the flue at approximately one metre intervals and at a
300mm clearance.
8.
Key to illustration
This feature allows some basic plume re-direction options
on a standard telescopic horizontal flue terminal. 300mm
minimum clearances to a opening, e.g. window. However the
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.
1.
Using a Plume Management Kit, the air intake measurement
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
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 by the ventilation equipment manufacturer.
nuisance. BS 5440:Part 1 recommends that care is taken when
siting terminal in relation to boundary lines.
59
Plume management system options
Plume management system
™
Accessories
60mm dia. plume management kit
Components
1 x terminal bend
Part No.
Description
60mm diameter
1 x extension 500mm
1 x outlet assembly
7 716 191 086 Plume management kit
1 x clamp pack
7 716 191 087 Extension (1,000mm)
Part No. 7 716 191 086
7 716 191 088 90º bend
7 716 191 089 45º bend (pair)
7 716 191 176
Plume management
terminal guard round
Standard plume management system
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
force beyond the limit stops.
that condensate flows back to the boiler.
Min. 1,500mm
Opening in building
e.g. window
50
Direction of
flue discharge
m
0m
50
0m
m
500
m
Direction of
m
flue discharge
±80°
Min. 1,500mm
Opening in building
e.g. window
Terminal exclusion zone
60
Re-directing flue discharge from a 60mm dia.
plume management outlet
For Greenstar CDi Classic System and Regular boilers, the
Condensfit II™ telescopic flue and plume management
100mm dia. internal flue length is immediately reduced by
system measuring
2,000mm when the minimum plume management of 500mm
Fig A
is used.
For the Greenstar 27i & 30i System and 27Ri & 30Ri boilers,
the 100mm dia. internal flue is immediately reduced by
1,000mm when the minimum plume management of 500mm
is used.
L (max)
Greenstar 9i-24i System and 9-24Ri boilers are able to use
the maximum 100mm dia. internal flue length of 4,600mm
regardless of the amount of plume management selected.
External plume management bends still need to be allowed
Fig B
for. For more information, see below.
Furthermore, for the Greenstar CDi Classic System and
Regular, 27i System, 30i System, 27Ri and 30Ri boilers, the
internal flue length must be reduced by 700mm for every
additional 1,000mm of plume management, refer to the
4,500mm
(max) (M)
table below.
60mm dia. plume management system
To ensure that the maximum total straight flue length along
L (max)
the plume management route is not exceeded, the following
should be added to dimension (M):
• 1,500mm for each extra 90º bend
• 750mm for each extra 45º bend
For plume management options with 60mm dia. extensions,
please refer to page 62.
The effective 100mm dia. internal flue length can be
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 53-55.
Effective straight flue lengths for telescopic flue with plume management
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)
30CDi Classic Regular & System
5,900mm
3,100mm
35CDi Classic System
5,000mm
2,200mm
40CDi Classic Regular
4,000mm
1,200mm
12Ri-24Ri models
4,600mm
4,600mm
9i-24i System models
4,600mm
4,600mm
27Ri & 30Ri,
27i & 30i System models
5,000mm
2,200mm
61
Plume management system
Plume management system with angled termination
See terminal exclusion zone diagram
on page 60
Components
Part No. 60mm
7 716 191 086
Maximum lengths (mm) & no. of components required
Greenstar CDi Classic Regular & System, Ri & i System 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 Regular & System, Ri & i System 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 Regular & System, Ri & i System 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 Regular & System, Ri & i System 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 Regular & System, Ri & i System series*
60mm
62
3,750
1
up to 4
1
*NOTE: You must refer to the table on page 61 to calculate
your horizontal flue lengths and plume management lengths.
Greenstar regular and system boiler
range accessories
Comfort plug-in twin
channel programmer*
Comfort I RF wireless
room thermostat
and plug-in twin
channel programmer**
Comfort II RF wireless
programmable room
thermostat and
plug-in RF receiver**
Comfort wall
mounting plate kit
Worcester Part No.
7 733 600 003
Worcester Part No.
7 733 600 001
Worcester Part No.
7 733 600 002
Worcester Part No.
7 733 600 039
Sense I intelligent
room thermostat^^
Sense II weather
compensation controller
MS100 Solar Module*
Wave*
Worcester Part No.
7 738 110 054
Worcester Part No.
7 738 111 064
Worcester Part No.
7 738 110 144
Worcester Part No.
7 716 192 072
Greenstar
Wiring Centre^
RS telescopic flue kit
(100mm dia.)
Long telescopic flue kit
(100mm dia.)
Standard telescopic
horizontal flue kit
(125mm dia.)
Worcester Part No.
7 738 110 116
Worcester Part No.
7 716 191 082
Worcester Part No.
7 716 191 171
Worcester Part No.
7 719 003 702
Vertical BF kit
(100mm dia.)
Vertical BF kit
(125mm dia.)
1,000mm extension kit
(100mm dia.)
2m flue extension
(100mm dia.)
Worcester Part No.
7 719 002 430
Worcester Part No.
7 719 002 431
Worcester Part No.
7 716 191 083
Worcester Part No.
7 716 191 172
*Greenstar system boilers only. **27Ri and 30Ri, CDi Classic System, 9i-24i System and 27i & 30i System.
†27i & 30i System. ^27Ri and 30Ri only. ^^For use with external proprietary 230V programmer.
63
Greenstar regular and system boiler
range accessories
Short flue extension
220mm (100mm dia.)
1,000mm extension
(125mm dia.)
45º bend
(100mm dia.)
45º bend
(125mm dia.)
Worcester Part No.
7 716 191 133
Worcester Part No.
7 719 003 666
Worcester Part No.
7 716 191 085
Worcester Part No.
7 719 003 665
90º bend
(100mm dia.)
90º bend
(125mm dia.)
High level horizontal
flue adaptor (100mm dia.)
High level horizontal
flue adaptor (125mm dia.)
Worcester Part No.
7 716 191 084
Worcester Part No.
7 719 003 664
Worcester Part No.
7 719 002 432
Worcester Part No.
7 719 002 433
Security fixing
Support bracket kit
(100mm dia.)
Support bracket kit 6 pack
(100mm dia.)
Support bracket kit
(125mm dia.)
Worcester Part No.
7 716 192 261
Worcester Part No.
7 716 191 177
Worcester Part No.
7 716 191 178
Worcester Part No.
7 716 191 179
Optional 30kW CDi Classic
System diverter valve kit
Optional 9-24kW i System
diverter valve kit
Optional 27kW i System
diverter valve kit
Optional 30kW i System
diverter valve kit
Worcester Part No.
7 719 002 746
Worcester Part No.
7 733 600 089
Worcester Part No.
7 733 600 220
Worcester Part No.
7 733 600 221
64
Optional 35kW CDi Classic
System diverter valve kit
Vertical pre-piping
assembly for
CDi Classic System
Vertical pre-piping
assembly for
9i to 30i System*
Worcester Part No.
7 716 192 651
Worcester Part No.
7 716 192 713
Worcester Part No.
7 716 192 686
Plume management kit
(60mm dia.)
Extension
(60mm dia., 1,000mm)
90º bend
(60mm dia.)
45º bend
(60mm dia.)
Worcester Part No.
7 716 191 086
Worcester Part No.
7 716 191 087
Worcester Part No.
7 716 191 088
Worcester Part No.
7 716 191 089
Flat roof flashing kit
(100mm & 125mm dia.)
Pitched roof flashing kit
(100mm & 125mm dia.)
Plume management
terminal guard round
(60mm dia.)
Worcester Part No.
7 716 191 090
Worcester Part No.
7 716 191 091
Worcester Part No.
7 716 191 176
Worcester Part No.
7 738 112 011
*Includes two 15mm copper pipes for use with an optional diverter valve. #Supplied as standard with CDi Classic System.
Earth bonding strip#
65
Greenstar regular and system boiler
range accessories
Greenstar System Filter
(22mm)
Greenstar System Filter
(28mm)
Remote PRV kit**
Worcester
CondenseSure siphon
Worcester Part No.
7 733 600 236
Worcester Part No.
7 733 600 237
Worcester Part No.
7 716 161 071
Worcester Part No.
7 716 192 746
WB3 cleaning tool
WB5 cleaning tool
Greenstore
Unvented Cylinders
Greenstore
Solar Compatible
Unvented Cylinders
Worcester Part No.
7 733 600 091
Worcester Part No.
7 719 001 996
WB7 cleaning tool
Worcester Part No.
SC-90
7 716 842 027
SC-120
7 716 842 028
Worcester Part No.
TC-150
7 716 842 040
SC-150
7 716 842 029
TC-180
7 716 842 041
SC-180
7 716 842 030
TC-210
7 716 842 042
SC-210
7 716 842 031
TC-250
7 716 842 043
SC-250
7 716 842 032
TC-300
7 716 842 044
SC-300
7 716 842 033
Worcester Part No.
7 746 901 479
66
**For CDi Classic System and Greenstar i System only.
Total training experience
from Land’s End to John O’Groats
Worcester has always been committed to setting the
College-linked Learning
industry standard for expert professional training and
As well as offering training at our own centres, Worcester
this is reflected in the scope and content of the courses,
has established close partnerships with many colleges
venues and options available.
around the UK, equipping them with our latest products.
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
combining classroom theory with, practical hands-on
with the launch of the College Links Learning Scheme.
experience. Keep up-to-date with legislation and experience
hands-on-training with our new technologies.
Mobile training
We can also bring training to you. We have mobile vehicles
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
Academy is an innovative and spacious high tech training
arena at our headquarters in Worcester. Facilities include
open-plan domestic training areas with life-size single-
Training centres
T
storey brick buildings. Here installers can get to grips with
College links
training centres
Greenskies solar thermal systems working with Greenstar
gas appliances, clearly demonstrating the importance of
system design and operation.
Elgin
Wakefield
Opened in Summer 2013, the Wakefield Training and
Dundee
Assessment Academy boasts a large gas laboratory which
Fife
features our entire range of Greenstar gas-fired appliances,
Johnstone
a flushing area, wet and dry boilers and a light commercial
Borders
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
Workington
Belfast
training, as well as a large commercial training room.
Burnley
West Thurrock and Clay Cross
Wakefield
W
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
Paignton
67
Gas-fired product courses
As a market leader in gas-fired condensing boilers, we aim
Gas-fired condensing boiler courses
to ensure the highest levels of competence and expertise
• Greenstar CDi Classic gas-fired condensing combi boilers.
• Greenstar CDi Compact and Greenstar Si Compact
in the installation of all Worcester Greenstar gas-fired
products. We run intensive training courses for installers,
commissioning engineers and operatives involved with
servicing and fault finding.
Our comprehensive gas-fired condensing boiler training
courses include product overview, inspection and cleaning
of components, CO and CO2 analysis of flue gas, removal
of compact hydraulics, service mode functions and fault
gas-fired condensing combi boilers.
• Greenstar i gas-fired condensing combi boilers.
• Greenstar system & regular gas-fired condensing boilers.
• Greenstar Highflow CDi & FS CDi Regular floor standing
gas-fired condensing combi and regular boilers.
• Greenstar Controls (covers MT10, MT10RF, Greenstar
Comfort range, Wave internet connected room thermostat,
NEW Greenstar Sense range and solar controls).
finding on ‘live and demo’ appliances.
Greenstar
Overview
CDi Classic
CDi Compact
& Si Compact
Greenstar i
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
Specification
Installation
Commissioning
Servicing
Maintenance
Course locations
Wakefield
West Thurrock
College Links†
Mobile†
U
U
U
U
D
D
D
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.
68
Additional product and
industry training courses
The diversity of products in today’s heating industry gives you the opportunity to expand your expertise, whilst offering
more choice to your customers. Worcester provides comprehensive training from all its academies on its entire range of
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
Oil-fired product courses
Worcester commercial product courses
• 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.
condensing oil-fired boilers.
• Oil advanced fault finding.
• OFTEC 50.
• OFTEC 101/105e, OFTEC 600a and OFTEC
101/105e/600a.
Renewable product courses
Bosch commercial product courses
• Renewables overview.
• Greenskies solar.
• Greenskies advanced solar.
• Introduction to heat pumps.
• Greenstore ground source heat pumps.
• Greensource air to air heat pumps.
• GB312 & GB402 overview.
• Solar thermal product overview.
• GWPL Gas Absorption Heat Pumps overview.
• CHP overview.
• Commercial controls overview.
Industry focused courses
• Hot water systems & safety.
• Chemical water treatment.
• Construction skills F-Gas training/assessment
certification.
• IDHEE domestic heating design.
• Domestic ACS training and assessment – reassessment.
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.
• LPG Changeover.
• WRAS Water Regulations.
69
A complete after-sales service
As part of the worldwide Bosch Group, Worcester strives to
Spares
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
Worcester Contact Centre
delivery basis. Visit www.worcester-bosch.co.uk/spares to
Should you require support, our award winning Contact
find your local stockist.
Centre team, based at our head office in Worcester, are
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
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.
Monday – Friday: 7.00am – 8.00pm
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
Monday – Friday: 7.00am – 8.00pm
Saturday: 8.30am – 4.00pm
Bank Holidays: 8.00am – 4.30pm
ErP Technical Helpline
Tel: 0330 123 3641
Email: [email protected]
70
Notes
71
Useful numbers
Customer Service
Sales
Service Enquiries
Tel: 0330 123 9669
Email: [email protected]
[email protected]
or telephone 0330 123 9559
Spare Parts
Guarantee Registration
Tel: 0330 123 9779
To register your Worcester
[email protected]
guarantee, please visit our website
worcester-bosch.co.uk/guarantee,
Technical Helpline (Pre & Post Sales)
download our guarantee
Tel: 0330 123 3366
registration app or
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Guarantee
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telephone 0330 123 2552
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