BBT3593g Gas System T+Spec_ErP E05_15.indd

BBT3593g Gas System T+Spec_ErP E05_15.indd
Technical and Specification Information
Greenstar CDi Classic
System Series
Greenstar i System Series
Greenstar system gas-fired condensing
wall mounted boiler range
NEW
Greenstar i
series
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 system boiler range
4-5
Key features of the range
6-7
Greenstar CDi Classic System features and benefits
8-9
Inside story – Greenstar CDi Classic System
10 - 11
Greenstar i System features and benefits
12 - 13
Inside story – Greenstar 9i - 24i System
14 - 15
energy efficient appliances in homes across
Inside story – Greenstar 27i & 30i System
16 - 17
the UK. We will continue to invest in our
The Greenstore unvented cylinder series
18 - 19
products, people, facilities and added-value
Controls
20 - 21
Wave – smart heating control
22 - 23
ErP easy as ABC
24 - 25
Site preparations and guidance
26 - 29
Carl Arntzen,
Installation requirements
30 - 31
Managing Director,
Greenstar System Filter
32 - 33
Condensate pipework
34 - 35
The Worcester CondenseSure auxiliary siphon
36 - 37
Horizontal and vertical flue terminal positioning
38 - 39
Horizontal fluing options
40 - 42
Vertical fluing options
43 - 45
Plume management positioning and system options
46 - 49
Accessories
50 - 53
Training
54 - 56
After-sales
57
“At Worcester we recognise the vital role you
play in the specification and installation of
services to ensure you have all you require in
order to deliver only the best solutions to your
customers’ requirements.”
Bosch Thermotechnology Ltd.
3
The Greenstar system boiler range
The Greenstar system range is part of a market-leading
Why choose a system boiler?
range of energy-saving condensing wall-mounted
A system boiler heats the central heating system
gas-fired boilers.
directly and produces hot water that is stored in a hot
water cylinder. When used in combination with a high
Higher efficiency, highly cost-effective
performance Worcester Greenstore unvented cylinder rather
All Worcester Greenstar wall mounted condensing system
than a vented cylinder, the result is fast hot water response
boilers have an ErP ‘A’ rating for space heating which means
times at the taps, more powerful showers and faster-filling
they are over 90% efficient.
baths – all with more economical running costs.
A system boiler and unvented hot water cylinder removes
the feed, expansion and cold water storage cisterns needed
in the roof space, creating a ‘dry loft’. This reduces the risk
of leaks or freezing and frees up the loft for other uses.
4
Greenstar 27i System
The Greenstar system range at a glance
Part No.
30CDi Classic System
35CDi Classic System
NG
7 738 100 244
7 738 100 236
LPG
7 738 100 233
7 738 100 237
7.7kW
7.7kW
30kW
34kW
9
9*
9
9
9
9
9
9*
9
9
9
9
Min
Output kW to
central heating (CH) Max
CH temperature control
DHW temperature control
Modulating gas control
Natural gas
LPG boiler
Electronic ignition
Part No.
9i System
12i System
15i System
18i System
21i System
24i System
27i System
30i System
NG
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
7 733 600 033
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
3.1kW
3.1kW
4.6kW
4.6kW
7.2kW
7.2kW
7.03kW
7.03kW
9.2kW
12.2kW
15.3kW
18.4kW
21.6kW
24.6kW
27kW
30kW
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
Min
Output kW to
central heating (CH) Max
CH temperature control
DHW temperature control
Modulating gas control
Natural gas
LPG boiler
Electronic ignition
*When a Worcester optional control and internal diverter valve kit is used.
5
Key features of the range
Why choose a Worcester Greenstar system boiler?
Staying in control
Worcester’s extensive range of system boilers,
All Greenstar system boilers are compatible with
now with Central Heating (CH) outputs from
S and Y plan systems or can be used with a full
9kW to 35kW, deliver high energy-efficiency and
range of Worcester intelligent plug-in controls when
lower running costs for homeowners. They also
installed with an optional Worcester diverter valve
achieve higher SAP or NHER ratings for new
kit. As well as enhancing energy efficiency, this
build properties when used in conjunction with a
arrangement means the boiler controls the pump
Greenstore unvented cylinder.
directly, reducing the need to install additional
valves and cabling.
Optional plug-in controls
A wide choice of optional controls is available
with the Greenstar system series 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 intelligent controls. These controls
employ the latest digital technology and deliver high
levels of functionality to maximise energy savings
without compromising on comfort. By using low
The Greenstar System range
voltage power and wireless technology, the optional
controls avoid the need to comply with Part P of
In well-insulated new homes, where hot water
the Building Regulations.
performance is more of a factor than heating, the
combination of a Greenstar boiler and Greenstore
The complete system solution
unvented cylinder may enable a system boiler with
Our Greenstore unvented and solar compatible
a lower CH output to be used. This reduces energy
unvented hot water cylinders provide fast re-heat
consumption even further while reducing the
times with excellent heat retention properties.
need for larger diameter gas pipes to allow for
The combination of a Greenstar system boiler
an easier installation.
and a Greenstore unvented cylinder delivers
hot water to the taps at mains pressure, filling
All boilers in the range feature reduced electrical
baths quickly and ensuring that showers are
consumption in stand-by mode, along with anti-
powerful and invigorating. For more information
cycling and modulation control. Most models are
on our Greenstore unvented cylinder range,
compact enough to be installed in a standard
see pages 18-19.
kitchen cupboard without the need for ventilation.
Winner of Which? Best Buy awards
in 2011, 2012, 2013 and 2014
For four consecutive years, in a survey of
Which? members, the Worcester Greenstar
gas-fired condensing boiler range has been
presented with Best Buy awards.* In the
latest survey, no other manufacturer scored
higher for reliability and customer satisfaction.
NEW Worcester Greenstore unvented cylinder range
6
*Source: Which? 2014 survey published in Sept 2014.
†
Solar water heating
Fluing options
When used in conjunction with a Greenstore solar
The Greenstar system range features 2 different sizes of
compatible unvented cylinder, Greenstar system boilers can
multi-directional room sealed flue (RSF) systems, 100mm or
be fully integrated with a Greenskies solar water heating
125mm diameter. Flues can be run horizontally or vertically
system, which has the potential to provide up to 60% of
with additional 90º or 45º in-line bends allowing changes
annual hot water requirements. Even if solar water heating
of direction to provide an extremely flexible and versatile
is not required at the time of installation, installing a solar
fluing system. This enables the appliance to be sited
compatible unvented cylinder will enable the system to be
virtually anywhere. More details are shown on pages 40-49.
upgraded easily in the future.
Gas and LPG options
Greenstar system boilers are manufactured in both
natural gas and Liquid Petroleum Gas (LPG) variants.
This gives a full range of fuel options and eliminates
the need for fuel conversion.
5 year guarantee
All Worcester Greenstar system boilers are
offered with a full 5 year guarantee* on parts
and labour as well as 10 year guarantee* on
the primary heat exchanger*.
Greenskies Solar-Lux, Solar-Lifestyle, Solar-Lito and
Greenstore solar compatible unvented cylinder
The Greenstar condensing system range –
features and benefits at a glance
Energy-saving & environmental
Time- & labour-saving installation
End user comfort and convenience
• All models are compliant with the
• Wall frames and jig allow space for
• Full 5 year guarantee on parts and
ErP Directive
• ErP ‘A’ rating for heating
• SEDBUK A rating up to 89.8%
(2009 value)
• Simple and intelligent control
options are available to optimise
boiler efficiency
•
Low electrical consumption in
standby mode
• Aluminium-silicon heat exchangers
deliver high efficiency and reliability
• Anti-cycle control
• The Greenstar CDi Classic System,
27 and 30i System models and
pipes behind the boiler as standard
• Vertical pre-piping assembly
available as an accessory
•
labour as well as a 10 year guarantee
on the primary heat exchanger*
• Boiler protection plans available
9i - 30i System models come
for both new and out-of-guarantee
pre-wired
Worcester Greenstar boilers
•
• Full range of Condensfit II™
All models come pre-plumbed
flue options
• Multi-directional fluing means
boiler can be sited in a wider
variety of places
• Optional diverter valve accessory
• Earth bonding strip as standard with
• Bosch renowned quality
and reliability
• Built-in boiler frost protection
• Compact dimensions –
Greenstar i System models
• Controls behind flap – aesthetically
pleasing and minimises the risk of
tampering with controls.
CDi Classic System boilers.
12i System deliver NOx values
below 40mg/kWh – achieving
3 credits under The Code for
Sustainable Homes.
*Subject to terms and conditions. †Source: Which? 2014 survey published in Sept 2014.
7
Greenstar CDi Classic System
Features and benefits
The award-winning Greenstar CDi Classic System is now available in
2 outputs, 30kW and the new 35kW. Our top-of-the-range system boilers
are suitable for larger properties that demand high outputs – typically
with more than three bedrooms.
The Greenstar CDi Classic System range uses the proven Worcester WB5
aluminium-silicon heat exchanger which features an extra-large surface area
to optimise combustion efficiency. Other energy-saving features include
low electrical consumption in standby mode, anti-cycle control and a
modulating pump.
The Greenstar CDi Classic System range can be combined with our
Greenskies solar thermal panels to provide efficient heating comfort and
reducing the property’s carbon footprint.
Greenstar CDi Classic System boilers are compatible with the full range of
Worcester digital wireless and intelligent controls*.
For more information on
ErP, see pages 24-25.
Installation benefits
Environmental benefits
• Boiler design and wall-mounting bracket
• ErP ‘A’ rated for heating
• SEDBUK A rating of 89.2% (2009 value)
• WB5 heat exchanger delivers
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 cellar installations
• Compatible with S and Y plan systems
• A rigid 22mm compression gas
connection, eliminating the need for
pre-fabricating the gas pipe onto the
isolating valve
• Multi-directional fluing enables boiler to
be located in a wider variety of places
• Full range of Condensfit II™ flue options
in both 60/100mm and 80/125mm
diameters with optional plume
management kit available
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
• Lead-free components
• Compatible with Worcester Greenskies
solar thermal
• Electronic ignition which eliminates
the need for a pilot light
• Anti-cycle and modulation control
• All boilers and components are
100% recyclable.
• Clear display on fascia for temperature
and commissioning settings
• Short-circuit proof PCB design that
removes the need for fuses in the low
voltage circuits.
8
*With installation of optional integral diverter valve.
NEW features based on
WB5 heat exchanger
installer feedback
The Worcester WB5 heat exchanger
Following on from your feedback new
has been designed to optimise clean
features have been added to the CDi Classic
burning combustion over an extra-large
System including a larger condensate
surface area.
siphon which reduces the risk of frozen
condensate and in most cases means an
Each heat exchanger is factory set and
external CondenseSure will not be required.
100% tested so, as long as the gas inlet
The CDi Classic System range includes
pressure is correct, commissioning is
a paper wall mounting template to
straightforward.
aid installation.
The heat exchanger requires minimal
The pump has also been upgraded to a
servicing which means fewer spare parts
more efficient model which meets the
during its lifetime.
WB5
Heat Exchanger
forthcoming ErP legislation. In addition, as
On the primary
heat exchanger†
an optional accessory, Worcester now offers
a remote PRV that can be positioned higher
in the system for basement installations.
End user benefits
• Condenses in heating modes for optimum
efficiency during operation
• Highly reliable heat exchanger
• Simple and intelligent control options*
for improved boiler efficiency and
user comfort
• Modulation control reduces electrical
consumption
• Built-in frost protection of the boiler and
surrounding pipes
• All models are available as natural gas
and LPG
• Full 5 year guarantee on parts and labour†
• 10 year guarantee on Worcester primary
heat exchanger†
• Boiler protection plans available
• Bosch renowned quality and reliability
• Which? Best Buy award-winning quality.
The Greenstar CDi Classic System boiler is recommended
by the Energy Saving Trust (EST). The Energy Saving
Trust is a non-profit organisation that provides free and
impartial advice on how to save energy.
†Terms and conditions apply. *With installation of optional integral diverter valve.
9
Inside story – Greenstar CDi Classic
System condensing boiler
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
10
*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%
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
2009 SEDBUK efficiency – natural gas
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.
11
Greenstar i System
Features and benefits
NEW
The popular Worcester Greenstar i System range has been enhanced with
a host of new features and the addition of two new higher output models.
Complementing current CH outputs, we have expanded our range to
include a 9kW and 21kW variant. This means Worcester 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 and 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 replacement can be
straightforward. The wall-mounting jig allows installers to quickly pre-plumb
the condensate, CH flow, gas, DCW inlet, 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,
similar to the simple adjustment of a TV remote control, for adjusting flow
temperature. The ability to easily alter flow temperature enables users to
either accelerate heat-up time or use lower flow temperatures to increase
energy-saving condensing.
ErP, see pages 24-25.
Installation benefits
Environmental benefits
• Lift weight of just 30.9kg
• Simple switch – same dimensions as
• ErP ‘A’ rated for heating
• SEDBUK A rating of up to 89.8%
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
• Cross-pipe detection
• Large condense siphon which removes the
need for CondenseSure accessory.
12
For more information on
(2009 value)
• Fully compatible with Worcester
plug-in controls
• 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.
Information at your fingertips
WB3 heat exchanger
The digital display includes a ‘quick
Greenstar i System 9, 12, 15,
info’ button to provide information
18, 21 and 24kW boilers use the
on the boiler’s status and flow
proven WB3 aluminium/silicon
temperature, clear text descriptions
heat exchanger. The heat cell has
for quick boiler diagnostic and
an extra-large surface area for
flow detection.
enhanced heat exchange efficiency.
WB7 heat exchanger
Greenstar i System 27 and 30kW
models use the new WB7 heat
exchanger which uses advanced
friction stir welding* manufacturing
technology to create more
passageways than traditional
WB3
Heat Exchanger
WB7
Heat Exchanger
On the primary
heat exchanger**
heat exchangers. As a result, the
WB7 heat exchanger delivers high
outputs relative to its size.
Detailed scrolling digital display
End user benefits
• 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
• Optional Worcester Keyless Filling
Link available, making system
re-pressurisation easy
• 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.
††Provided 32mm pipework not exceeding 3 metres in length is used.
13
Inside story – Greenstar 9i - 24i System
condensing boilers
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
14
*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 / 93%
A / 93%
A / 93%
A / 93%
A / 93%
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
2009 SEDBUK efficiency –
natural gas
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.
15
Inside story – Greenstar 27 & 30i System
condensing boilers
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
16
*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%
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
2009 SEDBUK efficiency – natural gas
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.
17
The Greenstore unvented cylinder series
Developed by Worcester. Built by Bosch.
Worcester offers a range of Greenstore high-efficiency unvented cylinders which provide
excellent hot water comfort for properties with a stored DHW supply. They are available in
both an unvented and solar compatible unvented option. The Greenstore unvented cylinder
is available in seven different models ranging from 93L to 292L. The Greenstore solar
compatible unvented cylinders are available in five options ranging from 158L to 287L.
The Worcester Greenstore unvented cylinder series is fully compatible with a wide range of
non-Worcester boilers and solar panels, although to achieve the optimum system solution,
it is recommended that a Greenstore unvented cylinder is coupled with either a Greenstar
high-efficiency boiler or Greenskies solar panel installation.
*
The Greenstore unvented series
The Greenstore unvented 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 solar compatible unvented series
All of the models in the solar compatible unvented 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 unvented stainless steel cylinders have been specifically designed for use
with solar heating installations, combined with boiler back-up.
18
*Terms and conditions apply.
Features and benefits
Energy efficiency – high levels of heat retention
Outstanding re-heat performance
A critical factor that affects the performance and the
When supplying large volumes of hot water to multiple
overall efficiency of any hot water storage cylinder is
outlets simultaneously, a cylinder’s re-heat performance is
the level of insulation that it can provide. Greenstore
crucial to providing a continuous flow.
unvented cylinders feature extremely high heat retention
levels, made possible by the 65mm of factory-fitted EPS
Worcester Greenstore unvented cylinders feature high-
(Expanded Polystyrene) insulation.
quality heat exchange coils maximising heat transfer and
providing quick hot water replenishment.
As well as satisfying the new-build requirements of SAP,
the benefits could include lower energy consumption and
Cost-effective hot water solution
heating bills for the end user.
Everything you need with Greenstore unvented cylinder
models can be ordered via a single part number. You will
receive a full G3 accessory kit including:
• Tundish (15/22mm)
• Inlet control group
• 2-port motorised valve
• Expansion vessel
• Dual thermostat
• Connection set
• Solar high limit thermostat (solar compatible series only).
All of the G3 accessories are pre-adjusted. These high
quality controls have been specifically selected to ensure a
high flow rate performance with a minimum pressure drop,
allowing the Greenstore unvented cylinders to perform well
even in low pressure areas.
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
36kg
40kg
44kg
48kg
54kg
161 litres
191 litres
216 litres
246 litres
292 litres
1.35kWh/24hrs
1.54kWh/24hrs
1.67kWh/24hrs
1.93kWh/24hrs
2.17kWh/24hrs
B / 53
B / 55
B / 59
B / 63
C / 81
Greenstore
TC-210 Cylinder
Greenstore
TC-250 Cylinder
Greenstore
TC-300 Cylinder
26kg
31kg
Weight – dry
Volume domestic
93 litres
123 litres
hot water
Standing
0.72kWh/24hrs 1.06kWh/24hrs
heat loss – 24hr
ErP energy
efficiency class/
A / 30
B / 44
Standing
heat loss (W)
Solar
compatible
Part no.
Height
Diameter
Greenstore
Greenstore
TC-150 Cylinder TC-180 Cylinder
7 716 800 542
7 716 800 543
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
50kg
54kg
60kg
211 litres
241 litres
287 litres
1.42kWh/24hrs
1.52kWh/24hrs
1.93kWh/24hrs
105 litres
115 litres
115 litres
B / 59
B / 63
C / 81
41kg
45kg
Weight – dry
Volume domestic
158 litres
187 litres
hot water
Standing
1.27kWh/24hrs 1.31kWh/24hrs
heat loss – 24hr
Dedicated
65 litres
65 litres
solar volume
ErP energy
efficiency class/
B / 53
B / 55
Standing
heat loss (W)
19
Controls
5 year guarantee
When purchased and installed at the same time, the guarantee period for a Worcester control will match
that of a Greenstar gas-fired boiler*.
Optional diverter valve required
System boilers using a Worcester control option are compatible with Y or S plan systems provided the
optional diverter valve kit is fitted.
Advanced intelligent controls
FW100 – Weather compensation controller – Part no. 7 716 192 067
Boiler output automatically adjusts to precisely meet the heat demands
• Bo
of the property according to outside temperature conditions at maximum
ef
efficiency
EFFICIENCY
+4%
Programmable unit with six switching points a day for control of both
• Pr
ce
central
heating and hot water pre-heat
Choice of six selectable weekly programmes
• Ch
Can be integral to the boiler or wall-mounted
• Ca
• Has factory-set heatcurves for various different heating systems
(radiators, underfloor etc.)
• Manual-override that can boost or reduce heating if required.
FR110 – Programmable room thermostat – Part no. 7 716 192 066
• Intelligent programmable room thermostat
• Load compensation
• Choice of six selectable weekly programmes
• Six switching points a day for central heating and hot water pre-heat
• Boiler output automatically adjusted to precisely meet the heat demand
EFFICIENCY
+3%
of the property at maximum efficiency
• Maximises the condensing boiler’s operation.
FR10 – Intelligent room thermostat – Part no. 7 716 192 065
• Load compensation
• Boiler output automatically adjusted to precisely meet the heat demand
of the property at maximum efficiency
EFFICIENCY
+3%
• Maximises the condensing boiler’s operation
• For use with a 230V programmer. Not compatible with Worcester Comfort
controls.
20
*Terms and conditions apply.
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 –
Co
Part
Pa no. 7 733 600 001
• All the features of Comfort PLUS…
• Enhanced load compensation for increased efficiency
• No wiring required
• Extremely reliable RF signal.
EFFICIENCY
+3%
Comfort II RF wireless programmable room thermostat and plug-in RF receiver –
Part
no. 7 733 600 002
P
EFFICIENCY
• All the features of Comfort and Comfort I PLUS…
• 6 adjustable heating temperatures per day
• Set programme at the room thermostat
• Remote access to boiler diagnostic codes
• Back lit display.
+3%
Controls at a glance
Comfort II RF
FR10
FR110
FW100
9
9
9
9
9
9
9 9
9
9
9
9 9
9 9
9 9
9 9
9 9
9 9
ISM1
Wave
1
2
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
V
3%
V
3%
V
3%
V
3%
VI
4%
–
–
VI
4%
27i & 30i System
–
9i-24i System
–
MODEL
CDi Classic System
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
91 92 9
91 92 9
9
1
2
9 9 9
91 92 9
91 92 9
91 92 9
Manufactured after 16th January 2007 with software version CF12.10 onwards.
Manufactured after February 2011.
21
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.
Enhanced energy efficiency
In the ErP Directive, smart controls like the Wave is a
Class VI control, adding 4%* to the overall system
efficiency, resulting in lower fuel bills.
The Wave’s energy efficiency features include:
EFFICIENCY
• Charts of heating and hot water usage so the homeowner
+4%*
can easily identify where potential savings could be made.
•
When the room temperature is turned down a leaf symbol
will appear to indicate additional savings are being made.
Adapting to the homeowner’s needs
Each Wave unit is supplied with a pre-set programme that
can then be easily modified to suit the user’s requirements.
Features
Benefits
Only a low voltage 2-core
wire connection between the
controller and the boiler
Easy to install, all other
connections are via the
Wi-Fi network
Remote control of heating
AND hot water via app
Programme the heating
system from outside the home
Load and weather
compensation via the internet
(no outdoor sensor required)
Allows the boiler to modulate
its performance to meet the
needs of each household
Intuitive and modern design
Ensures easy programming
and control of the boiler,
resulting in a simple hand over
with the end-user
The Wave’s advanced user features include:
• ‘Pairing’ with up to eight devices, automatically sensing
when people are at home.
• Sensing to an individual device can be turned off
if required.
• The Wave will remember preferred programme settings
to make these easily available and features a ‘holiday
programme’, requiring just a start and finish date.
• Unlike most other smart heating controls, the Wave
can also programme the hot water settings, providing
additional energy savings and comfort.
• For security and peace of mind, all of the Wave’s data is
owned by the user, ensuring no information is shared with
Energy graphs, presence
detection and many more
features come as standard
Ensures increased comfort
and energy savings
No subscription fees or
chargeable app add-ons
One-off cost
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
22
**Correct at time of printing. *When installed with a gas-fired boiler the Wave is a Class V control giving a 3% system efficiency benefit.
When the weather compensation feature is enabled it increases to 4% and becomes a Class VI control.
Quick to install
The Wave is quick and easy to install:
• Only requires a 2-core wire connection between the
control and the boiler.
EMS 2 Wire
• All other connections are via the Wi-Fi network.
• The Wave does not need an external wired sensor
Greenstar boiler
Wave
unlike standard weather compensation controls.
• 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 heating
and hot water control simply by using the last saved
Compatibility with Worcester Greenstar boilers
programme settings.
Ideal for homes and small businesses, the Wave is
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.
23
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).
24
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. Details of the
ratings of each individual component.
controls class for each Worcester control can be
found on pages 20-21.
For example, this could be the merchant’s
responsibility if they supply a complete package
under one part number or the installer if the
items are bought individually under separate
part numbers.
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
comes into force on the 26th September 2015.
Worcester will have a number of measures in
place to support you including:
An online tool which creates product
and heating system labels
ErP will be covered in all Worcester
training courses
ErP experts – our technical and
customer support teams can answer
all your questions.
ErP Technical Support: 0330 123 3641
Email: [email protected]
25
Site preparations and guidance
All system boilers are easier to install than conventional
Installation and service clearances
boilers and consequently require less time. The major
The minimum clearances shown below should be allowed
benefits of the Greenstar system boiler are:
for installation and servicing. All models do not require
• Built-in pump, expansion vessel, pressure relief valve
compartment ventilation so long as minimum installation
and pressure gauge
and service clearances are maintained, see below.
• There is less pipework
• There is no feed and expansion cistern in the loft space.
450mm
960mm
The System series also features:
• The boiler comes pre-wired and pre-plumbed
• The boiler can be connected to either low-pressure
+30mm
above elbow
open-vent cylinders or mains pressure unvented units
• The boiler is compatible with S and Y plan systems
• The boilers come supplied with a wall-mounting jig
• A siphonic condensate trap is pre-plumbed within the boiler
• Automatic gas pressure adjustment
• Highly versatile multi-directional fluing system
• Combined ignition and control board means
Using 100mm
flue kit
– 1,130mm
Using 125mm
flue kit
– 1,170mm
5mm
5mm
20mm to
removable
door
600mm front
clearance
for service
fewer connections.
200mm
Siting of appliance
The appliances are to only be installed internally within a
property, at a suitable location onto a fixed, rigid surface,
Clearances for Greenstar CDi Classic System
that is at least the same size as the appliance and is capable
of supporting its weight.
400mm
880mm
Mounting on a combustible surface
+30mm
above elbow
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
combustible surfaces is necessary if the temperature of the
wall does not exceed the room temperature by more than
60ºC. Testing of Greenstar gas-fired wall-mounted boilers has
shown that this temperature is not exceeded.
However, if the appliance is to be fitted in a timber frame
building, the guidelines laid down in BS 5440:Part 1 and
the Gas Safe publication “Gas Installations in Timber Frame
Using 100mm
flue kit
– 1,060mm
Using 125mm
flue kit
– 1,100mm
5mm
5mm
20mm to
removable
door
600mm front
clearance
for service
200mm
Buildings” should be adhered to.
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 27.
26
Clearances for Greenstar 27i & 30i System
Important: bathroom locations and clearances
410mm
930mm
• The boiler must not be installed in Zone 1
• Any switch or appliance control using mains electricity
+30mm
above elbow
must not be within reach of a person using the bath
or shower
• Electrical switches (other than pull cords), fused spurs
Using 100mm
flue kit
– 1,070mm
Using 125mm
flue kit
– 1,110mm
and socket outlets must not be situated in the bathroom
5mm
• A boiler fitted with an FW100 controller may only be
5mm
installed in the area outside of zone 2. A boiler with
any other timer fitted (or blanking panel for an optional
25mm to
removable
door
programmer) can be installed in zone 2.
• Additional Residual Current Device (RCD) protection
600mm front
clearance
for service
may be required.
200mm
Refer to the latest IEE wiring regulations.
Clearances for Greenstar 9i-24i System
600m
m
600m
Boiler location
m
600m
The appliance may be installed in any room, although
m
provisions with respect to installation in a room containing
a bath or shower.
1
2* 2*
1
2
1. The room in which the appliance is installed does not
2
1
require a purpose-provided air vent.
2
2,250mm
IEE regulations applicable and, in Scotland, the electrical
2,250mm
particular attention is drawn to the requirements of the
Radius 600mm
2. If the appliance is installed in a cupboard or
compartment with dimensions that allow the following
minimum clearances, then no ventilation is required:
Compartment installation
*Without the end wall, zone 2 must extend 600mm from the bath
Min. unventilated clearance
(to removable door)
Greenstar
CDi Classic
System
Greenstar
9i-24i
System
Greenstar
27i & 30i
System
In front
20mm
20mm
20mm
Below
200mm
200mm
200mm
Right side
5mm
5mm
5mm
Left side
5mm
5mm
5mm
Above flue elbow
30mm
30mm
30mm
Position of
appliance
27
Wall preparation
The following diagrams show the wall-mounting jigs which
The Greenstar CDi Classic System boiler wall-mounting
enable a simple and straightforward method of attaching
jig has additional optional fixing points and provides
the boiler to the wall surface.
improved engagement. After fixing the jig to the wall,
the boiler can be lifted onto the jig and the union
The new design wall-mounting jig for the Greenstar i System
connections tightened.
boiler is made from lightweight steel.
For all boilers, the pipework can be routed behind the boiler
without the need for an additional wall-spacing frame.
Greenstar CDi Classic System boiler
wall-mounting jig
Greenstar 9i-24i System boiler
wall-mounting jig
Greenstar 27i & 30i System boiler
wall-mounting jig
Casing dimensions
Depth to wall (when fitted to wall frame)
280mm
(When fitted to wall frame) Depth to wall
330mm
360mm
700mm†
680mm**
750mm*
440mm
390mm
400mm
Greenstar CDi Classic System
Greenstar 27i & 30i System
Greenstar 9i-24i System
*760mm to top of casing front.
**690mm to top of casing front.
†710mm to top of casing front.
28
Pipework connections
1
1
2
5
3
2
4
4
5
Greenstar 27i & 30i System
Greenstar CDi Classic 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 (CDi Classic System
7 716 192 651, i System (9 to 30kW) 7 716 192 713)
comprises a set of pre-formed copper pipes.
1
5
2
3
4
Greenstar 9i-24i System
Pipework connections – Greenstar 9i-24i System
Function
1 Condensate drain
2 CH flow
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
29
Installation requirements
Installation of the Greenstar system boiler range must
The system should be installed in compliance with the
be in accordance with the relevant requirements of the
requirements of BS 5449: Part 1.
Gas Safety (Installation Use) Regulations (as amended),
current IEE Wiring Regulations, local Building Regulations,
Manual air vents should be fitted at any high points in
Building Standards (Scotland) regulations and bylaws of
the system.
the local water company and Health and Safety Document
No. 635 (Electricity at Work Regulations 1989). It should
System filling and make-up
be in accordance with the relevant recommendations of the
To comply with the Water Authority requirements, the
following British Standards:
system should be filled via a temporary hose connection
to the mains cold water supply, with a double check valve
BS 6798; BS 5449; BS 5546:1; BS 5440:1; BS 5440:2;
assembly and test point fitted to the mains water side of a
BS 6891.
temporary circuit.
Gas Safety (Installation and Use) Regulations. All gas
Valves and joints
appliances must be installed by a Gas Safe registered
It is very important that all valves and joints are able to
person in accordance with the above regulations. Failure to
sustain a working pressure of up to 3bar (45psi). Particular
install appliances correctly could lead to prosecution.
care should be exercised when fitting radiator valves and
only those of high quality to BS 2767:10 should be used.
The manufacturer’s notes must not be taken in any way as
All other valves and fittings should comply with BS 1010.
overriding statutory regulations.
Loss of water pressure from a sealed system will
Sealed primary systems
require continuous recharging with fresh water and
Worcester Greenstar System boilers are supplied complete
consequential introduction of air. Air is highly corrosive
with all the necessary components to form a sealed primary
and will considerably reduce life-expectancy of radiators,
system. Included are an expansion vessel, a pressure
pumps etc.
relief valve (set at 3bar), an automatic air vent and a
pressure gauge.
Greenstar system boiler diverter valve kit
Greenstar system boilers can be adapted to house an
With an initial system pressure of 0.5bar a system capacity
in-built diverter valve. The optional integral diverter valve
of approximately 83 litres can be accommodated. Refer to
kit allows the user to control the supply of heat to the hot
BS 7074:Part 1 for more information.
water cylinder from the boiler. A choice of Worcester plug-in
controls must be used.
It is important with an aluminium heat exchanger that the
pH level of the water does not exceed 8. Levels in excess of
Plastic pipework
this could be detrimental to the heat exchanger.
The use of plastic pipework is acceptable. However, some
plastics are permeable to oxygen and must be avoided. Only
The use of a suitable inhibitor will provide a resistance
pipework with a polymeric barrier should be used. Please
to this. Contact Sentinel (Tel: 0800 3894670
note that the first 600mm of pipework connected to the
or visit www.sentinel-solutions.net) or Fernox
boiler must be of copper or steel.
(Tel: 0870 601 5000 or visit www.fernox.com)
for further details.
Air supply
Worcester Greenstar system boilers are room-sealed
Greenstar system boilers are fitted with a manual
appliances; the room in which it is installed does not
reset button and are suitable for use with a sealed
therefore require a purpose-provided combustion air vent.
primary system.
30
Natural gas supply
Electricity supply
Gas supply pipework must be sized to ensure a maximum
A 3amp fused three pin plug and unswitched shuttered
1mbar pressure drop between the meter and appliance
socket outlet (both complying with BS 1362) or preferably a
inlet, +1.5mbar across the appliance to the gas valve
double pole isolator with a contact separation of 3mm in all
test point.
poles supplying the appliance should be used.
Listed below is a representative example. Figures
The Greenstar CDi Classic System boilers’ electrical circuits
for other appliances can be found in the relevant
are also protected by an internal 2.5amp fuse, while the
installation manuals.
Greenstar 9 to 30i System models use a 5amp fuse. The
appliance must be earthed.
Model
30CDi Classic System
Gas rate
3.2m3/hr
30i System
3.24m3/hr
24i System
2.6m3/hr
Guarantee
Worcester Greenstar system appliances are offered with
a full 5 year guarantee* on parts and labour and a 10 year
guarantee* on the primary heat exchanger*. Ongoing service
and maintenance contracts can be arranged through the
The gas meter and supply pipes must be capable of
Worcester Customer Service Department.
supplying this quantity of gas in addition to the demand
from any other appliance being served. Particular
Please contact our guarantee
consideration should be given to the resistance to gas
registration advisors on
flow created by elbows, bends etc.
0330 123 2552 or visit
www.worcester-bosch.co.uk/
Greenstar 9i - 24i System models
guarantee
Provided that the correct gas supply working pressure and
On all Greenstar
On the primary
system appliances* heat exchanger*
gas rate can be achieved (refer to BS 6891) then it may be
possible to reduce the gas supply pipe diameter to 15mm.
Generally speaking, the appliance would need to be within
3 to 4 metres of the gas meter. However, this will depend
on the distribution pipe size and route.
Liquid Petroleum Gas (LPG) supply
Listed below is a representative example. Figures
for other appliances can be found in the relevant
installation manuals.
Model
30CDi Classic System
Gas rate
2.4kg/hr
30i System
2.33kg/hr
24i System
1.91kg/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.
*Subject to terms and conditions.
31
The Worcester Greenstar System Filter
Modern condensing boilers are precision-engineered and
designed to run with a clean water heating system. Over
time, dirty system water will damage a boiler and its
components, causing failures and shortening the life of the
overall system.
Damaged boiler and system components
• Blockages in primary heat exchanger
• Increased wear on pumps
• Blocked valves.
Reduced efficiency
• Energy efficiency loss equivalent to a boiler being
reduced from A rated efficiency to D rated, resulting
in fuel wastage
• Blocked radiators can reduce efficiency and
heating comfort.
The Greenstar System Filter has been extensively
tested in simulated systems, proving its effectiveness
in removing iron oxide, magnetite, limescale particles,
casting sand, welding debris, non-magnetic metal flakes,
A thermal graphic of a
blocked radiator
Debris in the system blocks the
efficient flow of water around
the system, thus affecting the
radiator’s heat distribution.
paint particles and other system pollutants.
How the Greenstar System Filter removes
debris from the system water.
A highly effective solution from the brand you can trust
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. The filter is suitable
for 22mm piped heating systems.
At the centre of this innovative design is a highly powerful
magnet that removes the magnetic debris (magnetite) that
is present in the heating system water. The central location
of the magnet ensures that magnetite is collected quickly
Installation
and retained, maximising the overall protection. Any
The filter can be installed almost anywhere in a heating
non-magnetic debris is caught by the twin-action cyclonic
system, however to maximise the effectiveness, it should be
trap, a proven technology that offers a capacity to collect
placed before the boiler and after the last radiator on the
up to 200g of magnetite a year.
return pipework.
32
Features
Benefits
Safeguards the boiler against damage and
Highly effective filter
protects the efficiency of the system. Saves up
to 6% a year on energy bills*
Prevent blockages in radiators
High powered internal magnet
Cylindrical design
A warmer home and quieter system
Proven technology that can capture up to 200g
of magnetite
Increased performance – better installation
options
Twin-action – magnetic and non-magnetic
Instantly effective against a wide range of
filtration
system debris
No electrical wiring connection or supply
No power consumption or moving parts
needed. Zero running costs and no failure of
components
Can be installed under the boiler or away from
the appliance
Flexibility
Removes the need to isolate a section of
One-way valve for adding system chemicals
the system when carrying out servicing and
maintenance
Worcester, Bosch Group specification
and design
Reliability of components and filter
*Independent research carried out by GASTEC at CRE
Product info
Part number
7 716 192 609
33
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.
pipe should be used. (see fig. 3)
75mm sink
waste trap
22mm
dia.
Condensate
pump
Fig. 3 Condensate pump disposal
34
External connections
Greenstar CDi Classic System and Greenstar i System
The Greenstar CDi Classic and Greenstar i have a large
Siphon
trap
capacity siphonic condensate trap reducing the risk
of condensate discharge freezing up during periods of
Insulate
& increase
pipe size
prolonged cold temperatures.
Like the CondenseSure siphon accessory, the expanded
siphonic operation discharges every 15 to 20 minutes,
Pipework
transition
25mm min.
resulting in:
• Increased velocity and flow rate
• With only 3 to 4 siphonic actions per hour, the
condensate pipework is empty for longer
• Eliminated freezing potential.
Fig. 5 External disposal
Condensate soak away (see fig. 6)
• The condensate drainage pipe may be run above or below
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 ground to the soak away
• 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
Greenstar 27i and 30i System
temperature or exposure, the use of a proprietary trace
Freezing conditions
heating system for external pipework (that incorporates
• When the position of the boiler prevents internal
an external frost thermostat) should be considered. If
routing, we recommend installing a Worcester
such a system is used, the requirement to use 32mm pipe
CondenseSure siphon to minimise the risk of freezing
does not apply, however all other guidance above, and the
• Pipework length should be kept to a minimum and the
route as vertical as possible
• Weather-proofing insulation must be sized when not
using a CondenseSure siphon.
instructions for the trace heating system, should be
closely followed.
Unheated internal areas
Condensate waste
Internal pipe runs in unheated areas such as lofts,
•
Care should be taken when siting a soak away to avoid
basements and garages should be treated as external runs,
obstructing existing services.
with consideration given to using a CondenseSure siphon.
If no other discharge method is possible, then the use of
an externally-run condensate drainage pipe terminating at
a suitable foul water discharge point (fig. 4), or purpose-
100mm dia.
designed soak away (fig. 5), may be considered. Please see
100mm
dia. min.
plastic pipe
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
35
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
Benefits
No power consumption
No electrical wiring
connection or supply needed,
meaning zero running costs
No moving parts
No failure of components
Can be installed on new or
existing installations
Suitable for any gas- or
oil-fired condensing boilers
Can be attached to 22mm
heating flow pipework
Uses ‘free’ energy from the
pipe to heat the condensate
Under boiler or remote
installation
Flexibility
No electrical connections
No electrician needed
No pipe insulation needed
Cost-saving and aesthetically
pleasing
the CondenseSure is every 15 to 20 minutes, resulting in:
• Increased velocity and flow rate
• With only 3 to 4 siphonic actions per hour,
the condensate pipework is empty for longer
• Significantly decreased or even eliminated
freezing potential.
36
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
37
Horizontal and vertical flue terminal positioning
All measurements in millimetres
2
25
3
1,500
600
2
1
5
300
300
1,500
600
1,200
4
6
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
•
products entering the building
reduced to 25mm, as long as the flue terminal is extended to
Support the flue at approximately one metre intervals and at a
clear any overhang. External flue joints must be sealed with
change of direction, use suitable brackets and fittings.
suitable silicon sealant.
Flue bracket part numbers:
3.
7 716 191 177 (100mm dia.)
1,500mm between a vertical flue terminal and a window or
dormer window.
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
38
building material.
2m
1m
25
104mm
52mm
16
13
400
300
500
12
14
200
300
7
8
600
500
300 300
15
300
600
9
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.
39
Greenstar system boiler range
horizontal fluing options
™
Accessories
The Greenstar system boiler range offers the choice of
2 differently sized horizontal RSF flue systems, a 100mm
Components
diameter telescopic flue kit including a plume management
kit, and a 125mm diameter telescopic flue kit. Both systems
Part No.
100mm diameter
have different maximum lengths. The following diagrams
7 716 191 082
Standard telescopic flue kit
(350 - 570mm)
7 716 191 171
Long telescopic flue kit
(570 - 790mm)
detail the permissible lengths.
™
Horizontal RS flue
Flue diameter
100mm
Description
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 System model
Minimum flue length
350mm*
405mm
Maximum flue length
7,900mm
18,500mm
7 716 191 084 90º bend
7 716 191 085 45º bend
7 719 002 432
Greenstar 35CDi Classic System model
Minimum flue length
30mm
30mm
Maximum flue length
7,000mm
16,000mm
High level horizontal
flue adaptor
7 716 191 177 Support bracket kit
7 716 191 178 Support bracket kit (6 pack)
*Dimensions when fitted
Greenstar 9i-24i System models
Minimum flue length
350mm*
405mm
Maximum flue length
4,600mm
13,000mm
125mm diameter
7 719 003 702
Greenstar 27i & 30i System models
Standard telescopic flue kit
(405 - 600mm)
7 719 003 666 Extension flue kit (960mm*)
Minimum flue length
350mm*
405mm
Maximum flue length
6,000mm
15,000mm
7 719 003 664 90º bend
7 719 003 665 45º bend
*Can be cut to 130mm. Please refer to instructions.
7 719 002 433
100mm dia. standard telescopic flue kit
1 x flue turret elbow
High level horizontal
flue adaptor
7 716 191 179 Support bracket kit
*Dimensions when fitted
570mm (100mm dia.) of flue duct
1 x weather sealing ring
1 x internal collar
The following criteria should be noted when planning
Part No. 7 716 191 082
the installation:
• The concentric flue system must be inclined at
125mm dia. standard telescopic flue kit
3º (52mm per metre) from the appliance, to allow
1 x flue turret elbow
condensate to drain back into the boiler
600mm (125mm dia.) of flue duct including terminal
• A white plume of condensation will be emitted from
(as measured from centre of flue outlet)
the terminal because the appliance operates at high
1 x weather sealing plate
efficiency. Care must be taken when selecting the flue
1 x internal plate
terminal position
Part No. 7 719 003 702
• To achieve a maximum flue length, one of the extension
flue kits will need to be cut so that the permitted
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.
40
Option 1: Standard horizontal flue assembly
Option 3: Extension flue horizontal
using a second 90º bend
Components
Part No. 100mm
Components
7 716 191 082
Part No. 100mm
7 716 191 082
7 716 191 083
7 716 191 084
Maximum lengths (mm) & no. of components required
Part No. 125mm
7 719 003 702
7 719 003 666
7 719 003 664
Greenstar 30CDi Classic System
Maximum lengths (mm) & no. of components required
Part No. 125mm
7 719 003 702
100mm
570
1
Greenstar 30CDi Classic System
125mm
600
1
100mm
6,400
125mm 16,500
Greenstar 35CDi Classic System
1
up to 6
1
1
up to 16
1
1
up to 6
1
1
up to 14
1
1
up to 3
1
1
up to 11
1
1
up to 4
1
1
up to 13
1
100mm
30
1
Greenstar 35CDi Classic System
125mm
30
1
100mm
5,500
125mm 14,000
Greenstar 9i-24i System
100mm
570
1
Greenstar 9i-24i System
125mm
600
1
100mm
2,600
125mm 11,000
Greenstar 27i & 30i System
100mm
570
1
Greenstar 27i & 30i System
125mm
600
1
100mm
4,000
125mm 13,000
Option 2: Extension flue horizontal
Components
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
7,900
125mm 18,500
(Part No. 7 716 191 133) and 100mm dia. 2m flue extension
(Part No. 7 716 191 172) may be used as an alternative to
Greenstar 30CDi Classic System
100mm
Note: The 100mm dia. short flue extension
1
up to 8
1
up to 18
the standard extension as required up to the maximum flue
lengths stated.
Greenstar 35CDi Classic System
100mm
7,000
125mm 16,000
1
up to 7
1
up to 16
1
up to 4
1
up to 13
Note: The maximum flue length must be reduced by the
following amounts for each bend used.
Greenstar 9i-24i System
100mm
4,600
125mm 13,000
Greenstar 27i & 30i System
100mm
6,000
125mm 15,000
1
up to 6
1
up to 15
45º bend
90º bend
Greenstar CDi Classic
System 60/100mm flues
750m
1,500mm
Greenstar CDi Classic
System 80/125mm flues
1,000mm
2,000mm
Greenstar i System –
all size flues
1,000mm
2,000mm
41
Option 4: Extension flue horizontal and upwards
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
Maximum lengths (mm) & no. of components required
Greenstar 30CDi Classic System
100mm
7,900
125mm 18,500
Components
1
up to 8
1
1
1
up to 18
1
1
Greenstar 35CDi Classic System
100mm
7,000
125mm 16,000
4,600
125mm 13,000
up to 7
1
1
1
up to 16
1
1
1
up to 4
1
1
6,000
125mm 15,000
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
1
up to 13
1
1
1
up to 6
1
1
1
up to 15
1
1
Greenstar 30CDi Classic System
100mm
4,900
125mm 14,500
Greenstar 27i & 30i System
100mm
7 716 191 082
Maximum lengths (mm) & no. of components required
1
Greenstar 9i-24i System
100mm
Part No. 100mm
up to 5
3
1
1
up to 14
3
1
Greenstar 35CDi Classic System
100mm
4,000
125mm 12,000
Option 5: Extension flue upwards and horizontal
using a second 90º bend
1
1
up to 4
3
1
1
up to 12
3
1
up to 9
3
1
1
up to 2
3
1
1
up to 11
3
1
Greenstar 9i-24i System
125mm
9,000
1
Greenstar 27i & 30i System
100mm
2,000
125mm 11,000
45º options available
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
Note: The 100mm dia. short flue extension
Maximum lengths (mm) & no. of components required
(Part No. 7 716 191 133) and 100mm dia. 2m flue extension
Greenstar 30CDi Classic System
(Part No. 7 716 191 172) may be used as an alternative to
100mm
6,400
125mm 16,500
1
up to 7
2
1
the standard extension as required up to the maximum flue
1
up to 16
2
1
lengths stated.
Greenstar 35CDi Classic System
100mm
5,500
125mm 14,000
1
up to 6
2
1
Note: The maximum flue length must be reduced by the
1
up to 14
2
1
following amounts for each bend used.
1
up to 2
2
1
1
up to 11
2
1
Greenstar 9i-24i System
100mm
2,600
125mm 11,000
Greenstar 27i & 30i System
100mm
4,000
125mm 13,000
42
1
up to 4
2
1
1
up to 13
2
1
45º bend
90º bend
Greenstar CDi Classic
System 60/100mm flues
750m
1,500mm
Greenstar CDi Classic
System 80/125mm flues
1,000mm
2,000mm
Greenstar i System –
all size flues
1,000mm
2,000mm
Greenstar system boiler range
vertical fluing options
The Greenstar system boiler range offers the choice of
™
Accessories
2 differently sized vertical RSF flue systems, 100mm and
Components
125mm. Both systems have different maximum lengths.
Part No.
100mm diameter
The following diagrams detail the permissible lengths.
7 719 002 430
™
Vertical RSF flue
Description
Vertical 1,090mm balanced
flue kit (inc. adaptor)
7 716 191 083 Extension flue kit (960mm*)
Flue diameter
100mm
125mm
7 716 191 172 2m flue extension*
Greenstar 30CDi & 35CDi Classic System
Minimum flue length
Maximum flue length
(inc. adaptor)
7 716 191 133 Short flue extension (220mm*)
1,090mm
1,365mm
7 716 191 084 90º bend
9,400mm
18,500mm
7 716 191 085 45º bend
1,090mm
1,365mm
6,400mm
15,000mm
1,090mm
1,365mm
6,000mm
15,000mm
Greenstar 9i-24i System models
Minimum flue length
Maximum flue length
(inc. adaptor)
7 716 191 090 Flashing – flat roof
7 716 191 091 Flashing – pitched roof
*Dimensions when fitted
Greenstar 27i & 30i System models
Minimum flue length
Maximum flue length
(inc. adaptor)
125mm diameter
7 719 002 431
Vertical 1,365mm balanced
flue kit (inc. adaptor)
7 719 003 666 Extension flue kit (960mm*)
100mm dia. vertical balanced flue kit
7 719 003 664 90º bend
1 x flue terminal assembly
7 719 003 665 45º bend
1 x weather sealing collar
7 716 191 090 Flashing – flat roof
1 x fire stop spacer
7 716 191 091 Flashing – pitched roof
1 x vertical adaptor
Part No. 7 719 002 430
*Dimensions when fitted
125mm dia. vertical balanced flue kit
The following criteria should be noted when planning
1 x flue terminal assembly
the installation:
1 x weather sealing collar
• Because the appliance operates at high efficiency, a
1 x fire stop spacer
white plume of condensation will be emitted from the
1 x vertical adaptor
terminal. Care must be taken when selecting the flue
Part No. 7 719 002 431
terminal position
• To achieve a maximum flue length, one of the extension
flue kits will need to be cut so that the permitted
maximum flue length is not exceeded
• 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.
43
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 System
Greenstar 30CDi Classic System
100mm
1,090
1
100mm
125mm
1,365
1
125mm 18,500
Greenstar 35CDi Classic System
9,400
1
up to 9
1
up to 18
Greenstar 35CDi Classic System
100mm
1,090
1
100mm
125mm
1,365
1
125mm 16,000
Greenstar 9i-24i System
8,000
1
up to 8
1
up to 16
1
up to 6
1
up to 14
1
up to 5
1
up to 14
Greenstar 9i-24i System
100mm
1,090
1
100mm
125mm
1,365
1
125mm 15,000
Greenstar 27i & 30i System
6,400
Greenstar 27i & 30i System
100mm
1,090
1
100mm
6,000
125mm
1,365
1
125mm 15,000
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.
44
45º bend
90º bend
Greenstar CDi Classic
System 60/100mm flues
750m
1,500mm
Greenstar CDi Classic
System 80/125mm flues
1,000mm
2,000mm
Greenstar i System –
all size flues
1,000mm
2,000mm
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 System
Greenstar 30CDi Classic System
100mm
7,900
125mm 16,500
1
up to 8
2
100mm
1
up to 16
2
125mm 14,500
Greenstar 35CDi Classic System
100mm
6,500
125mm 14,000
4,400
125mm 13,000
1
up to 6
2
100mm
1
up to 14
2
125mm 12,000
4,000
125mm 13,000
up to 6
2
1
up to 14
2
5,000
1
up to 5
2
1
up to 12
2
1
up to 2
2
1
up to 11
2
1
1
2
1
up to 10
2
Greenstar 9i-24i System
1
up to 4
2
100mm
1
up to 13
2
125mm 11,000
Greenstar 27i & 30i System
100mm
1
Greenstar 35CDi Classic System
Greenstar 9i-24i System
100mm
6,400
2,400
Greenstar 27i & 30i System
1
up to 3
2
100mm
1
up to 12
2
125mm 11,000
2,000
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
System 60/100mm flues
750m
1,500mm
Greenstar CDi Classic
System 80/125mm flues
1,000mm
2,000mm
Greenstar i System –
all size flues
1,000mm
2,000mm
45
Plume management terminal positioning
All measurements in millimetres
Flue terminal guard 7 716 191 176
±45°
Plume re-direction:
100
600
1
180°
Flue exhaust
outlet
10
1,500
Air intake
±80°
6
200
300
2
200
5
600
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 38-39 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
nuisance. BS 5440:Part 1 recommends that care is taken when
siting terminal in relation to boundary lines.
46
• 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.
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
Re-directing flue discharge from a 60mm dia.
plume management outlet
47
For Greenstar CDi Classic System boilers, the 100mm dia.
Condensfit II™ telescopic flue and plume management
internal flue length is immediately reduced by 2,000mm
system measuring
when the minimum plume management of 500mm is used.
Fig A
For the Greenstar 27i & 30i System boilers, the 100mm dia.
internal flue is immediately reduced by 1,000mm when the
minimum plume management of 500mm is used.
Greenstar 9i-24i System boilers are able to use the
500mm
(min) (M)
L (max)
maximum 100mm dia. internal flue length of 4,500mm
regardless of the amount of plume management selected.
External plume management bends still need to be allowed
for. For more information, see below.
Furthermore, for both the Greenstar CDi Classic System,
Fig B
and 27i & 30i System boilers, the internal flue length must
be reduced by 700mm for every additional 1,000mm of
plume management, refer to the table below.
60mm dia. plume management system
4,500mm
(max) (M)
To ensure that the maximum total straight flue length along
the plume management route is not exceeded, the following
should be added to dimension (M):
L (max)
• 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 49.
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 41-42.
Effective straight flue lengths for telescopic flue with plume management
Boiler
48
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 System
5,900mm
3,100mm
35CDi Classic System
5,000mm
2,200mm
9i-24i System models
4,500mm
4,500mm
27i & 30i System models
5,000mm
2,200mm
Plume management system
Plume management system with angled termination
Components
Part No. 60mm
7 716 191 086
Maximum lengths (mm) & no. of components required
Components
Greenstar CDi Classic System* and i System series
60mm
500
Part No. 60mm
1
7 716 191 086
7 716 191 087
Maximum lengths (mm) & no. of components required
Greenstar CDi Classic System* and 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 System* and 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 System* and 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
*NOTE: For CDi Classic System and i System (27 and 30kW)
Greenstar CDi Classic System* and i System series
60mm
3,750
1
up to 4
you must refer to the table on page 48 to calculate your
1
horizontal flue lengths and plume management lengths.
49
Greenstar system boiler
range accessories
50
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
Intelligent
system package*
Worcester Part No.
7 733 600 003
Worcester Part No.
7 733 600 001
Worcester Part No.
7 733 600 002
Worcester Part No.
7 719 002 824
FR10 intelligent
room thermostat
FR110 programmable
room thermostat
FW100 weather
compensation controller
ISM1 intelligent
solar module
Worcester Part No.
7 716 192 065
Worcester Part No.
7 716 192 066
Worcester Part No.
7 716 192 067
Worcester Part No.
7 716 192 068
Wave
RS telescopic flue kit
(100mm dia.)
Long telescopic flue kit
(100mm dia.)
Standard telescopic
horizontal flue kit
(125mm dia.)
Worcester Part No.
7 716 192 072
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 30CDi Classic System only.
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
Support bracket kit
(100mm dia.)
Support bracket kit 6 pack
(100mm dia.)
Support bracket kit
(125mm dia.)
Optional 30kW CDi Classic
System diverter valve kit
Worcester Part No.
7 716 191 177
Worcester Part No.
7 716 191 178
Worcester Part No.
7 716 191 179
Worcester Part No.
7 719 002 746
Optional 9-24kW i System
diverter valve kit
Optional 27kW i System
diverter valve kit
Optional 30kW i System
diverter valve kit
Optional 35kW CDi Classic
System diverter valve kit
Worcester Part No.
7 733 600 089
Worcester Part No.
7 733 600 220
Worcester Part No.
7 733 600 221
Worcester Part No.
7 738 112 011
51
Greenstar system boiler
range accessories
52
Vertical pre-piping
assembly for
CDi Classic System
Vertical pre-piping
assembly for
9i to 30i System*
Earth bonding strip#
Plume management kit
(60mm dia.)
Worcester Part No.
7 716 192 651
Worcester Part No.
7 716 192 713
Worcester Part No.
7 716 192 686
Worcester Part No.
7 716 191 086
Extension
(60mm dia., 1,000mm)
90º bend
(60mm dia.)
45º bend
(60mm dia.)
Flat roof flashing kit
(100mm & 125mm dia.)
Worcester Part No.
7 716 191 087
Worcester Part No.
7 716 191 088
Worcester Part No.
7 716 191 089
Worcester Part No.
7 716 191 090
Pitched roof flashing kit
(100mm & 125mm dia.)
Plume management
terminal guard round
(60mm dia.)
Greenstar System Filter
Worcester
CondenseSure siphon
Worcester Part No.
7 716 191 091
Worcester Part No.
7 716 191 176
Worcester Part No.
7 716 192 609
Worcester Part No.
7 716 192 746
*Includes two 15mm copper pipes for use with an optional diverter valve.
#Supplied as standard with CDi Classic System.
WB3 cleaning tool
WB5 cleaning tool
Worcester Part No.
7 733 600 091
Worcester Part No.
7 719 001 996
WB7 cleaning tool
Worcester Part No.
7 746 901 479
Remote PRV kit**
Greenstore SC Cylinders
Greenstore TC Cylinders
Worcester Part No.
SC-90
7 716 842 027
Worcester Part No.
TC-150
7 716 800 542
SC-120
7 716 842 028
TC-180
7 716 800 543
SC-150
7 716 842 029
TC-210
7 716 842 042
SC-180
7 716 842 030
TC-250
7 716 842 043
SC-210
7 716 842 031
TC-300
7 716 842 044
SC-250
7 716 842 032
SC-300
7 716 842 033
Worcester Part No.
7 716 161 071
**For CDi Classic System and Greenstar i System only.
53
Total training experience
from Land’s End to John O’Groats
Worcester has always been committed to setting the
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As well as offering training at our own centres, Worcester
this is reflected in the scope and content of the courses,
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venues and options available.
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Call now for more information 0330 123 0166.
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54
Cambridge
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Gas-fired product courses
As a market leader in gas-fired condensing boilers, we aim
Gas-fired condensing boiler courses
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• Greenstar CDi Classic gas-fired condensing combi boilers.
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Greenstar
Overview
CDi Classic
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& Regular
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Controls
Duration
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D
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Guide to the
varied range
of control
options that are
available
Worcester
D
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Clay Cross
U
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D
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D
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D
D
D
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D
D
Training course covers
Specification
Installation
Commissioning
Servicing
Maintenance
Course locations
Wakefield
West Thurrock
College Links†
Mobile†
U
U
U
U
D
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D
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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
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†Please contact Worcester Training for specific colleges and mobile dates.
55
Additional product and
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The diversity of products in today’s heating industry gives you the opportunity to expand your expertise, whilst offering
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alternatively, you can visit www.worcester-bosch.co.uk/training
Oil-fired product courses
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• Greenstar Danesmoor & Heatslave II high efficiency
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56
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products are readily available from stock, or on a next day
Worcester Contact Centre
delivery basis. Visit www.worcester-bosch.co.uk/spares
Should you require support, our award winning Contact
to find your local stockist.
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]
57
Notes
58
Notes
59
Useful numbers
Customer Service
Sales
Engineer Appointments
Tel: 0330 123 9669
Email: [email protected]
[email protected]
or telephone 0330 123 9339
Spare Parts
Service Enquiries
Tel: 0330 123 9779
Email: [email protected]
[email protected]com
or telephone 0330 123 9559
Technical Helpline (Pre & Post Sales)
Guarantee Registration
Tel: 0330 123 3366
To register your Worcester guarantee,
[email protected]
please visit our website
www.worcester-bosch.co.uk/registration,
Renewables Technical Helpline
download our guarantee
Email: [email protected]
registration app or
or telephone 0330 123 9229
telephone 0330 123 2552
ErP Technical Helpline
Guarantee
app
Tel: 0330 123 3641
[email protected]
Training
Tel: 0330 123 0166
[email protected]
Literature
Email: [email protected]
or download instantly from our website
or telephone 0330 123 9119
Calls to 03 numbers cost no more than a national rate call to an 01 or 02 number and must count towards any inclusive minutes in the same way as 01 and 02 calls.
These rules apply to calls from any type of line, including mobile, BT, other fixed phone line or payphone. Calls from mobiles and some other networks may vary.
Calls to and from Bosch Thermotechnology Ltd may be recorded for training and quality assurance purposes.
worcester-bosch.co.uk
In partnership with
FD
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1964
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This leaflet is accurate at the date of printing, but may be superseded and should be disregarded if specification and/or appearances are changed in the interest
of continued improvement. The statutory rights of the consumer are not affected. Apple is a trademark of Apple Inc., registered in the U.S. and other countries.
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Worcester, Bosch Group,
Cotswold Way, Warndon,
Worcester, WR4 9SW
BBT3593
Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd.
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