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 126.96.36.199 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 College-linked Learning industry standard for expert professional training and As well as offering training at our own centres, Worcester this is reflected in the scope and content of the courses, has established close partnerships with many colleges venues and options available. around the UK, equipping them with our latest products. We offer training on our entire range of domestic and Worcester has worked closely with leading colleges and commercial heating technologies as well as industry-led independent training centres for more than 20 years – a courses. All tuition is handled by expert heating specialists, successful enterprise which in 2007 was enhanced further combining classroom theory with, practical hands-on with the launch of the College Links Learning Scheme. experience. Keep up-to-date with legislation and experience hands-on-training with our new technologies. Mobile training We can also bring training to you. We have mobile vehicles To increase your skills, expertise and value in the fully equipped with operational Greenstar gas-fired boilers, market place, trust Worcester’s unique and proven dry strip-down models and even a Greensource air to air total training concept. heat pump. Our 7.5 tonne mobile oil vehicle is also available for hands-on oil product training and OFTEC assessments. Training centres throughout the UK Worcester Call now for more information 0330 123 0166. Worcester’s award-winning, state-of-the-art Training Academy is an innovative and spacious high tech training arena at our headquarters in Worcester. Facilities include open-plan domestic training areas with life-size single- Training centres T storey brick buildings. Here installers can get to grips with College links training centres Greenskies solar thermal systems working with Greenstar gas appliances, clearly demonstrating the importance of system design and operation. Elgin Wakefield Opened in Summer 2013, the Wakefield Training and Dundee Assessment Academy boasts a large gas laboratory which Fife features our entire range of Greenstar gas-fired appliances, Johnstone a flushing area, wet and dry boilers and a light commercial Borders Ayr area with a cascade of Worcester GB162 boilers. There is a Durham solar room with fully working components from our entire Greenskies solar range and a pitched roof for practical Workington Belfast training, as well as a large commercial training room. Burnley West Thurrock and Clay Cross Wakefield W Dublin Clay Cross Further academies are located at West Thurrock in Wrexham Essex and Clay Cross in Derbyshire, both of which offer Worcester a comprehensive choice of courses. Tredegar West Thurrock Wiltshire Camborne 54 Cambridge Paignton Gas-fired product courses As a market leader in gas-fired condensing boilers, we aim Gas-fired condensing boiler courses to ensure the highest levels of competence and expertise • Greenstar CDi Classic gas-fired condensing combi boilers. • Greenstar CDi Compact and Greenstar Si Compact gas- in the installation of all Worcester Greenstar gas-fired products. We run intensive training courses for installers, commissioning engineers and operatives involved with servicing and fault finding. Our comprehensive gas-fired condensing boiler training courses include product overview, inspection and cleaning of components, CO and CO2 analysis of flue gas, removal of compact hydraulics, service mode functions and fault fired condensing combi boilers. • Greenstar i gas-fired condensing combi boilers. • Greenstar system & regular gas-fired condensing boilers. • Greenstar Highflow CDi & FS CDi Regular floor standing gas-fired condensing combi and regular boilers. • Greenstar Controls (covers MT10, MT10RF, NEW Greenstar Comfort range, NEW Wave internet connected room thermostat, FR10, FR110, FW100, and solar controls). finding on ‘live and demo’ appliances. Greenstar Overview CDi Classic CDi Compact & Si Compact Greenstar i System & Regular Highflow CDi & FS CDi Regular Controls Duration 1 Day 1 Day 1 Day 1 Day 1 Day 1 Day 1 Day Cost Free* Free* Free* Free* Free* Free* Free* D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D Guide to the varied range of control options that are available Worcester D D D D D D Clay Cross U U U U U U D D D D D D D D D D D D D D D D D D D D Training course covers Specification Installation Commissioning Servicing Maintenance Course locations Wakefield West Thurrock College Links† Mobile† U U U U D D D U D D *A holding fee of £65 applies to free courses and is refunded on attendance of the course. If a booking is cancelled more than 10 working days before the course date, the fee will be fully refunded. The fee is non-refundable if a cancellation is made less than 10 working days before the course date. †Please contact Worcester Training for specific colleges and mobile dates. 55 Additional product and industry training courses The diversity of products in today’s heating industry gives you the opportunity to expand your expertise, whilst offering more choice to your customers. Worcester provides comprehensive training from all its academies on its entire range of technologies. Call us on 0330 123 0166 to order a full course training brochure or to book yourself onto a training course, alternatively, you can visit www.worcester-bosch.co.uk/training Oil-fired product courses Worcester commercial product courses • Greenstar Danesmoor & Heatslave II high efficiency • Greenspring CWi47 water heater. • GB162 overview. • GB162 domestic. • GB162 commercial. • Greenstar Heat Distribution Unit. • Commercial ACS training and assessment – CODNCO1. condensing oil-fired boilers. • Oil advanced fault finding. • OFTEC 50. • OFTEC 101/105e, OFTEC 600a and OFTEC 101/105e/600a. Renewable product courses Bosch commercial product courses • Renewables overview. • Greenskies solar. • Greenskies advanced solar. • Introduction to heat pumps. • Greenstore LECP ground source heat pumps. • Greensource air to air heat pumps. • GB312 & GB402 overview. • Solar thermal product overview. • GWPL Gas Absorption Heat Pumps overview. • CHP overview. • Commercial controls overview. Industry focused courses • Hot water systems & safety. • Chemical water treatment. • Construction skills F-Gas training/assessment certification. • IDHEE domestic heating design. • Domestic ACS training and assessment – reassessment. CCN1 + 3 appliances. • QCF Level 3 Award – Air source and ground source heat pumps. – Air to water and split air to water heat pumps. – Solar thermal. • MCS Made Easy. • Green Deal. • LPG Changeover. • WRAS Water Regulations. 56 A complete after-sales service As part of the worldwide Bosch Group, Worcester strives to Spares maintain the highest possible standards of after-sales care. Genuine replacement parts for all supported Worcester products are readily available from stock, or on a next day Worcester Contact Centre delivery basis. Visit www.worcester-bosch.co.uk/spares 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 TE O OMEST I ITU D H E 1964 E S ER I TAL ENG INE MEN ON NG & EN EATI VIR CH INS T 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. App Store is a service mark of Apple Inc. Google Play and Android are trademarks of Google Inc. Part No. 8 716 116 715 E 05/15 PAPERS MADE WITH FREE TM 100% CHLORINE BLEACHED PULP 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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