Greenstar 28CDI Compact Combi
Technical and Specification Information
Greenstar CDi Classic Series
Greenstar CDi Compact Series
Greenstar Si Compact Series
Greenstar i Junior Series
Greenstar combi gas-fired condensing
wall mounted boiler range
NEW
Greenstar
Comfort
controls
1
Worcester and you. Making a diff
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 combi condensing boiler range
4-5
Key features of the range
6-7
Greenstar CDi Classic features and benefits
8-9
Inside story – Greenstar CDi Classic
10 - 11
Greenstar CDi Compact features and benefits
12 - 13
Inside story – Greenstar CDi Compact
14 - 15
Greenstar Si Compact features and benefits
16 - 17
Inside story – Greenstar Si Compact
18 - 19
Greenstar i Junior features and benefits
20 - 21
services to ensure you have all you require in
Inside story – Greenstar i Junior
22 - 23
order to deliver only the best solutions to your
Controls
24 - 25
customers’ requirements.”
Wave – smart heating control
26 - 27
Site preparations and guidance
28 - 33
Carl Arntzen,
Greenstar combi installation requirements
34 - 36
Managing Director,
Greenstar System Filter
37
Worcester Keyless Filling Link
38 - 39
Condensate pipework
40 - 41
The Worcester CondenseSure siphon
42 - 43
Flue Gas Heat Recovery Unit
44 - 45
Horizontal and vertical flue terminal positioning
46 - 47
Horizontal fluing options
48 - 51
Vertical fluing options
52 - 54
Plume management positioning and system options
55 - 58
Accessories
59 - 63
Training
64 - 66
After-sales
67
ference.
“At Worcester we recognise the vital role you
play in the specification and installation of
energy efficient appliances in homes across
the UK. We will continue to invest in our
products, people, facilities and added value
Bosch Thermotechnology Ltd.
3
The Greenstar combi gas-fired wall
Greenstar Si Compact
Greenstar CDi Classic
The Greenstar combi range is part of a market-leading
range of energy-saving gas-fired boilers. Renowned for
their energy efficiency, reliability, ease of installation and
servicing, more than 2 million Greenstar combi boilers have
been installed in homes across the UK.
4
mounted condensing boiler range
Greenstar i Junior
Greenstar CDi Compact
As part of our commitment to offer installers high quality
In 2014, the Greenstar CDi Classic has been improved
products and innovative heating solutions, Worcester is
with a number of extra features including the addition of a
dedicated to continuously improving its entire range of
built-in large siphonic trap, which uses the same principle
combi boilers.
as the CondenseSure, a Cross Bonding Strip and Keyless
Filling Link now fitted as standard. In addition, as an
In 2013, we launched the revolutionary Greenstar CDi
optional accessory, Worcester now offers a remote PRV
Compact and Si Compact models, which includes the
that can be positioned higher in the system for cellar or
innovative WB7 heat exchanger to combine both compact
basement installations.
dimensions with a high efficiency.
5
Key features of the range
Winner of Which? Best Buy awards
Keep hot facility
in 2011, 2012, 2013 and 2014
All Greenstar combi models have an in-built
For four consecutive years, in a survey of
‘keep hot’ facility which will keep the primary water
Which? members, the Worcester Greenstar
within the heat exchanger hot – approximately
gas-fired condensing boiler range has been
2.5 litres volume. This will ensure that hot water is
presented with Best Buy awards.* In the
delivered almost instantly to the opened outlet.
latest survey, no other manufacturer scored
higher for reliability and customer satisfaction.
ECO mode
With the ECO mode button activated, the ‘keep hot’
Highly efficient, highly cost-effective
facility is de-energised and the hot water will be
All Worcester Greenstar condensing combi boilers
heated from cold. A slight delay should be expected
have an annual A rated efficiency (SEDBUK 2005
before the hot water is at full temperature when in
value) of over 90%, efficiently producing heating
ECO mode. By selecting ECO mode, less gas will be
and hot water for the home. Non-condensing boilers
used as energy is used only on demand.
achieve around 78% efficiency.
The Greenstar Si Compact
has the same fascia with an
intuitive in-built display as the
Greenstar CDi Compact
Low NOx options
Central heating mode
Worcester’s commitment to reduce emissions from
On a central heating demand, the boiler will initially
gas-fired condensing boilers sees all Greenstar
fire at minimum output before modulating upwards
combi boilers achieve NOx values <40mg/kWh.
to meet the system’s actual requirement.
This enables the appliances to achieve 3 credits
under the Code for Sustainable Homes. The i Junior
Fluing options
requires a low NOx code plug which is available
The Greenstar combi range has a full range of
as an optional accessory. All other boilers are low
Condensfit II™ flue options in both 60/100mm
NOx as standard.
and 80/125mm diameters and include a plume
deflector as standard.
Hot water mode
Whenever a hot water tap is turned on, the
5 year guarantee
incoming mains water will activate a flow turbine
All Worcester Greenstar combi
which, via the electronic control system, ignites
boilers are offered with a full 5 year
the pre-mix burner. Boiler output is automatically
guarantee* on parts and labour as well
boosted to maximum in order to heat the incoming
as 10 year guarantee* on the primary
cold water as it passes through the heat exchanger.
heat exchanger*.
Electronic controls modulate the boiler output to
ensure an accurate hot water temperature.
6
*Terms and conditions apply.
*
The Greenstar combi range at a glance
29CDi
Classic
Boiler
Part No.
34CDi
Classic
38CDi
Classic
42CDi
28CDi
32CDi
36CDi
25Si
30Si
Classic Compact Compact Compact Compact Compact
24i
Junior
28i
Junior
NG
7 738 100 248 7 738 100 250 7 738 100 252 7 738 100 246 7 716 130 234 7 716 130 235 7 716 130 236 7 716 130 230 7 716 130 232 7 716 130 220 7 716 130 222
LPG
7 738 100 249 7 738 100 251 7 738 100 253 7 738 100 247 7 716 130 237 7 716 130 238 7 716 130 239 7 716 130 231 7 716 130 233 7 716 130 221 7 716 130 223
Min
7.7kW
7.7kW
9.4kW
9.4kW
7.03kW
7.03kW
7.03kW
7.03kW
7.03kW
7.2kW
7.2kW
Max
30.9kW
35kW
40kW
42kW
28kW
32kW
36kW
25kW
30kW
24kW
28kW
Flow rate at 35ºC ∆T
(± 15%)
12.3l/min
14.3l/min
16.4l/min
17.2l/min
11.4l/min
13.1l/min
14.7l/min
10.2l/min
12.3l/min
9.8l/min
11.4l/min
Flow rate at 40ºC ∆T
(± 15%)
11l/min
12l/min
14l/min
15l/min
10l/min
11.5l/min
12.9l/min
8.9l/min
10.7l/min
8.6l/min
10l/min
7.7kW
7.7kW
9.4kW
9.4kW
7.03kW
7.03kW
7.03kW
7.03kW
7.03kW
7.2kW
7.2kW
30kW
30kW
30kW
30kW
24kW
24kW
24kW
24kW
24kW
24kW
24kW
–
–
–
–
–
–
–
–
–
13kW
13kW
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
(optional)
(optional)
(optional)
(optional)
(optional)
(optional)
(optional)
(optional)
(optional)
(optional)
(optional)
(optional)
(optional)
(optional)
(optional)
–
–
–
–
–
–
–
9
9
9
9
9
9
9
9
9
–
–
Output kW to DHW
Min
Output kW to
central heating (CH) Max
Maximum output kW
to central heating (CH)
with low NOx code plug
Modulating control
Electronic ignition
Integrated filling link
Earth Bonding Strip
Remote PRV
Condensing in DHW
The Greenstar condensing combi range –
features and benefits at a glance
Energy-saving & environmental
Time & labour-saving installation
End user comfort and convenience
• SEDBUK A rating of 90.1%
• Wall frame allows space for pipes
• Full 5 year guarantee on parts and
and above (2005 value)
•
Simple and intelligent control
•
options are available to optimise
boiler efficiency
•
•
• Aluminium-silicon heat exchangers
electricity than a fixed speed pump –
• Anti-cycle control.
flue options
Worcester Greenstar boilers
Multi-directional fluing means
pre-plumbed
• There is no need to install a hot
water cylinder
•
Greenstar CDi Classic and
CDi Compact only
for both new and out-of-guarantee
variety of places
• Modulating pump which uses less
•
• Boiler protection plans available
Full range of Condensfit II™
• The boiler comes pre-wired and
and Si Compact condense in
DHW mode
on the primary heat exchanger†
boiler can be sited in a wider
deliver high efficiency and reliability
• Greenstar CDi Classic, CDi Compact
labour as well as a 10 year guarantee
Vertical pre-piping assembly
available as an accessory
• Low electrical consumption in
standby mode
behind the boiler as standard
There is no need to install a
• Bosch renowned quality
and reliability
• Built-in boiler frost protection
• Small dimensions –
Greenstar CDi Compact, Si Compact
and i Junior models
• ECO mode for energy-saving fuel
consumption
storage tank in the roof space
• Controls behind flap – aesthetically
There is less pipework in the
pleasing and minimises the risk of
heating system.
tampering with controls.
*Source: Which? 2014 survey published in Sept 2014. †Subject to terms and conditions.
7
Greenstar CDi Classic
Features and benefits
NEW
FEATURES
The top-of-the-range, award-winning Greenstar CDi Classic is a high
performance boiler that is suitable for small, medium and large-sized
properties with one or two bathrooms. It has set the benchmark within
the industry for efficiency, reliability and ease of installation, while
achieving a market-leading output of up to 42kW.
The Greenstar CDi Classic offers the opportunity to range-rate the central
heating output to perfectly match the properties’ requirements which
reduces cycling and improves efficiency further.
With more than 2 million Greenstar combi boilers installed in the UK, the
ever popular Worcester Greenstar CDi Classic, with its advanced features
and future-proof technology, still sets the standard for premium quality,
high-efficiency combi boilers.
The Greenstar CDi Classic also achieves 3 credit points within the Code
for Sustainable Homes and has an A rated annual efficiency of up to 90.2%
(SEDBUK 2005 value).
Installation benefits
Greenstar CDi Classic is
available with DHW flow rates
of 12.3, 14.3, 16.4 and
17.2 l/min
Environmental benefits
• Standard wall frame allows space for pipes • SEDBUK A rating of up to 90.2%
behind the boiler now supplied with a
paper template to aid positioning of holes
• Can be serviced entirely from the front
with easy access to parts and components
• Split wall-mounting jig provided as
standard for pre-plumbing of all
•
efficiency and reliability
• Low electrical consumption when in
standby mode
• NOx emissions of 35mg/kWh –
achieves 3 credits under the Code
condensate connections before the
for Sustainable Homes
• All boilers and components are 100%
Remote PRV can be positioned higher in
recyclable, achieving Worcester’s zero
the system for cellar installations
waste to landfill objective.
Earth bonding strip fitted as standard
which saves time and money when
connecting and wiring
• Full range of Condensfit II™ horizontal and
vertical flue options with optional plume
management kit available means boiler can
be sited in a wide variety of places
• 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
• WB5 heat exchanger delivers high
7 connections – gas, water, PRV &
boiler is on the wall
•
(2005 value)
NEW features based on
WB5 heat exchanger
installer feedback
The Worcester WB5 heat exchanger
Following on from your feedback
has been designed to optimise clean
new features have been added to
burning combustion over an extra-
the CDi Classic including a larger
large surface area. Each heat
condensate siphon, which reduces
exchanger is factory-set and 100%
the risk of frozen condensate and
tested so, as long as the gas inlet
in most cases means an external
pressure is correct, commissioning
CondenseSure will not be required.
is straightforward. The heat
The CDi Classic range includes a
exchanger requires minimal
paper wall mounting template to
servicing which means fewer spare
aid installation.
parts during its lifetime. The heat
The pump has also been upgraded
exchanger can be cleaned in situ via
to a more efficient model which
an inspection hatch, again saving
meets the forthcoming ErP
time during service.
WB5
Heat Exchanger
On the primary
heat exchanger*
legislation.
End user benefits
• Heat exchanger delivers high efficiency
and reliability
• Energy-saving anti-cycle and
modulation control
• Fully modulating pump for reduced
electricity consumption and quieter
operation
• Condenses in CH and DHW mode, resulting
in greater efficiency and fuel savings
• Low electrical consumption when in
standby mode
• In-built Keyless Filling Link 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
• Part of the Which? Best Buy range for
The Greenstar CDi Classic boiler is
recommended by the Energy Saving
Trust (EST). The Energy Saving Trust
is a non-profit organisation that
provides free and impartial advice
on how to save energy.
*Terms and conditions apply.
gas-fired condensing boilers.
9
Inside story – Greenstar CDi Classic
Down firing low NOx burner
Aluminium/silicon WB5
primary heat exchanger
Expansion vessel
Pre-mix fan
Secondary DHW plate heat exchanger
Condensate siphon
Automatic air vent
Gas valve
Modulating circulating pump
Diverter valve
Drain point
PCB board
Mains cable
pre-wired to
control board
Central heating
temperature
control
10
Pressure gauge
On/off
button
Optional
programmer
Operational
status light
Digital
display
Greenstar CDi Classic fascia with
optional Comfort I RF plug-in twin
channel programmer fitted
Pressure
gauge
Domestic
hot water
temperature control
Technical data
Boiler
Greenstar
29CDi Classic
Greenstar
34CDi Classic
Greenstar
38CDi Classic
Greenstar
42CDi Classic
Height
760mm (max)
760mm (max)
760mm (max)
760mm (max)
Width
440mm
440mm
440mm
440mm
Depth
360mm (max)
360mm (max)
360mm (max)
360mm (max)
47.5kg
47.5kg
47.5kg
47.5kg
90.1% / A rated
90.1% / A rated
90.2% / A rated
90.2% / A rated
92% / A rated
92% / A rated
91.9% / A rated
92.2% / A rated
2009 SEDBUK value – natural gas
89.1%
89.1%
89.0%
89.4%
2009 SEDBUK value – LPG
90.1%
90.1%
90.0%
90.4%
Heating flow / return connections
(compression)
22mm
22mm
22mm
22mm
Hot / cold water connections
(compression)
15mm
15mm
15mm
15mm
Pressure relief valve (compression)
15mm
15mm
15mm
15mm
Condensate connection (plastic pipe)
22mm
22mm
22mm
22mm
Gas connection (compression)
22mm
22mm
22mm
22mm
Primary water content
3.75 ltr
3.75 ltr
3.75 ltr
3.75 ltr
Minimum domestic inlet pressure
for maximum DHW flow rate
1.4bar
1.5bar
1.7bar
1.9bar
Minimum domestic inlet pressure
to operate the appliance
0.2bar
0.2bar
0.2bar
0.2bar
Maximum domestic inlet pressure
10bar
10bar
10bar
10bar
1.9 ltr/min
1.9 ltr/min
1.9 ltr/min
1.9 ltr/min
DHW flow rate @ 35ºC∆T†
12.3 ltr/min
14.3 ltr/min
16.4 ltr/min
17.2 ltr/min
DHW flow rate @ 40ºC∆T††
11 ltr/min
12 ltr/min
14 ltr/min
15 ltr/min
Output to central heating (natural gas)
7.7 - 30kW
7.7 - 30kW
9.4 - 30kW
9.4 - 30kW
Wall mounting jig and paper template
9
9
9
9
9
9
9
9
Plug-in timers
9 (optional)
9 (optional)
9 (optional)
9 (optional)
Optimising room
temperature controller
9 (optional)
9 (optional)
9 (optional)
9 (optional)
Intelligent controls
9 (optional)
9
9 (optional)
9
9 (optional)
9
9 (optional)
9
Maximum vertical flue
(100mm dia.) inc. terminal
9,400mm
8,000mm
7,500mm
7,500mm
Maximum vertical flue
(125mm dia.) inc. terminal
18,500mm
16,000mm
16,000mm
16,000mm
Maximum horizontal flue
(100mm dia.)
7,900mm
7,000mm
6,000mm
6,000mm
Maximum horizontal flue
(125mm dia.)
18,500mm
16,000mm
12,500mm
12,000mm
33.3mg/kWh
33.3mg/kWh
21.8mg/kWh
21.8mg/kWh
5
5
5
5
X4D
X4D
X4D
X4D
Weight – lift
2005 SEDBUK value – natural gas
2005 SEDBUK value – LPG
Minimum flow rate to
operate the appliance
Keyless filling link
Condensing in DHW mode
NOx classification – natural gas
NOx class
Ingress protection (IP)
†Values for industry comparisons. ††Designed operational flow rate.
11
Greenstar CDi Compact
Features and benefits
The revolutionary Worcester Greenstar CDi Compact is the newest
addition to our top-of-the-range CDi boiler series and is part of our next
generation of wall-mounted combi boilers. Suitable for small, medium
and large-sized properties with one or two bathrooms, the Greenstar
CDi Compact, with hot water outputs of up to 36kW, is best suited to
properties that demand high outputs from an appliance that can fit
within a standard kitchen cupboard.
Available with DHW flow rates of 11.4, 13.1 and 14.7 l/min, the CDi
Compact is the smallest and most efficient wall mounted condensing
combi boiler Worcester has produced and comes with a host of design
features for ease of installation, use and servicing.
Its ease of installation and cupboard size dimensions are thanks to the
ultra-compact WB7 heat exchanger, easy-access hydraulics and colourcoded wiring connectors. The boiler comes supplied with an innovative
wall-mounting jig that allows installers to easily pre-plumb the condensate,
Greenstar CDi Compact is
available with DHW flow rates
of 11.4, 13.1 and 14.7 l/min
CH flow, DHW outlet, gas, DCW inlet, PRV installer connection & CH return
without the boiler being on the wall.
The Greenstar CDi Compact achieves an A rated annual efficiency of
90.5% (SEDBUK 2005 value) and, along with its low NOx emissions,
obtains 3 credit points within the Code for Sustainable Homes standard.
Installation benefits
Environmental benefits
• Robust, metal wall-mounting jig for safe,
• SEDBUK A rating of 90.5% (2005 value)
• Ability to fix a maximum heating
secure, hassle-free fixing
• Split jig design for optimum lift weight.
The expansion vessel has a simple drop
lock mechanism that connects directly
onto the hydraulic unit
• LCD boiler display for operation
status, commissioning features and
diagnostics data
•
Double-seal siphon located at the front
•
Electrical connections accessible from the
of the boiler for easy maintenance
front of the boiler
• Maximum flue lengths of 6m 60/100mm
flue and 15m 80/125mm flue
• Pre-set combustion settings for fast
much you turn the dial, the temperature
will not exceed that maximum setting
• Precision engineered WB7 heat
exchanger reduces raw material
usage during manufacturing
• All boilers and components are
100% recyclable
• Low electrical standby consumption
• NOx emissions of 35mg/kWh –
achieves 3 credits under the Code
for Sustainable Homes
• Hot water pre-heat accessory
(Part Number 7 716 192 735) allows
commissioning and with Benchmark
it to be used in conjunction with other
Commissioning Checklist data available on
heat sources, such as Greenskies
the boiler display
solar thermal
• Full range of Condensfit II™ horizontal and
12
temperature – meaning no matter how
• All boilers and components are 100%
vertical flue options with optional plume
recyclable, achieving Worcester’s zero
management kit available.
waste to landfill objective.
WB7 heat exchanger
Friction stir welding
At the heart of the Greenstar CDi
Friction stir welding is a solid state
Compact is the ground-breaking
machining process where the metal
WB7 heat exchanger, which uses
is softened rather than melted,
advanced friction stir welding† to
giving improved quality, reliability
create more passageways than
and performance.
traditional heat exchangers. These
channels provide more efficient
Widely used for demanding
circulation, resulting in a more
applications in the aviation, marine
effective heat transfer and
and automotive sectors, it has
quieter operation.
enabled Worcester to manufacture
a more compact heat exchanger,
Designed, tested and manufactured
reducing the overall size of the
within Bosch Thermotechnology
boiler while delivering a high power
Ltd., the WB7 heat exchanger
ratio of up to maximum 36kW.
WB7
Heat Exchanger
delivers high output despite its
On the primary
heat exchanger*
compact size.
End user benefits
• Simple and intelligent control options
available, optimising boiler efficiency and
fuel consumption
• Condenses in CH and DHW mode, resulting
in greater efficiency and fuel savings
• Comfort and ECO modes to suit hot water
delivery needs
• Fully modulating pump for reduced
electricity consumption and quieter
operation
• Built-in frost protection of the boiler and
the surrounding pipes
• Includes internal keyed filling link
• Optional Worcester Keyless Filling Link
available as an upgrade, making system
re-pressurisation easy
The Greenstar CDi Compact boiler is
recommended by the Energy Saving
Trust (EST). The Energy Saving Trust
is a non-profit organisation that
provides free and impartial advice
on how to save energy.
• Full 5 year guarantee on parts and labour*
• 10 year guarantee on Worcester primary
heat exchanger*
• Boiler protection plans available.
†The friction stir welding process is used under license from The Welding Institute. *Terms and conditions apply.
13
Inside story – Greenstar CDi Compact
Expansion vessel
(hidden)
Pre-mix fan
Automatic air vent
Down firing
low NOx burner
Aluminium/silicon
WB7 primary
heat exchanger
Gas valve
Modulating
circulating pump
Secondary DHW
plate heat exchanger
Diverter valve
(hidden)
Pressure relief valve
Condensate siphon
PCB board
Mains cable
pre-wired to
control board
Operational
status light
Central heating
temperature control
Digital display
Domestic hot
Optional water temperature
programmer
control
Greenstar CDi Compact fascia with optional
FW100 weather compensation controller fitted
14
Pressure
gauge
Technical data
Boiler
Greenstar
28CDi Compact
Greenstar
32CDi Compact
Greenstar
36CDi Compact
Height
680mm*
680mm*
680mm*
Width
390mm
390mm
390mm
Depth
280mm
280mm
280mm
Weight – lift
32.9kg
32.9kg
32.9kg
2005 SEDBUK value – natural gas
90.5% / A rated
90.5% / A rated
90.5% / A rated
2005 SEDBUK value – LPG
92.6% / A rated
92.6% / A rated
92.6% / A rated
2009 SEDBUK value – natural gas
89.8%
89.8%
89.8%
2009 SEDBUK value – LPG
90.9%
90.9%
90.9%
Heating flow / return connections
(compression)
22mm
22mm
22mm
Hot / cold water connections
(compression)
15mm
15mm
15mm
Pressure relief valve (compression)
15mm
15mm
15mm
Condensate connection (compression)
22mm
22mm
22mm
Gas connection (compression)
22mm
22mm
22mm
Primary water content
2.2 ltr
2.2 ltr
2.2 ltr
Minimum domestic inlet pressure
for maximum DHW flow rate
1.6bar
1.6bar
1.6bar
Minimum domestic inlet pressure
to operate the appliance
0.2bar
0.2bar
0.2bar
Maximum domestic inlet pressure
10.0bar
10.0bar
10.0bar
DHW flow rate @ 35ºC∆T†
11.4 ltr/min
13.1 ltr/min
14.7 ltr/min
DHW flow rate @ 40ºC∆T††
10.0 ltr/min
11.5 ltr/min
12.9 ltr/min
Output to central heating
7.03 - 24kW
7.03 - 24kW
7.03 - 24kW
9
9
9
9
9
9
Plug-in timers
9 (optional)
9 (optional)
9 (optional)
Optimising room
temperature controller
9 (optional)
9 (optional)
9 (optional)
Intelligent controls
9 (optional)
9
9 (optional)
9
9 (optional)
9
Maximum vertical flue
(100mm dia.) inc. terminal
6,000mm
6,000mm
6,000mm
Maximum vertical flue
(125mm dia.) inc. terminal
15,000mm
15,000mm
15,000mm
Maximum horizontal flue
(100mm dia.)
6,000mm
6,000mm
6,000mm
Maximum horizontal flue
(125mm dia.)
15,000mm
15,000mm
15,000mm
NOx classification – natural gas
35mg/kWh
35mg/kWh
35mg/kWh
5
5
5
X4D
X4D
X4D
Wall mounting jig
Filling link
Condensing in DHW mode
NOx class
Ingress protection (IP)
*690mm to top of casing curve. †Values for industry comparisons. ††Designed operational flow rate
15
Greenstar Si Compact
Features and benefits
The Greenstar Si Compact is the successor to the Greenstar Si combi boiler.
The all new Greenstar Si Compact has a host of performance-enhancing
features, including the revolutionary WB7 heat exchanger which enables the
appliances to deliver DHW flow rates of 10.2 and 12.3 l/min despite their
compact size.
Similarly to the CDi Compact, particular care has been taken with the design
of the hydraulic unit. Key components are positioned to provide easy access,
whilst the Heatronic 4i control box makes commissioning simpler. This menudriven unit features an LCD display which shows boiler status symbols and
system and commissioning parameters as well as giving access to service and
maintenance codes and diagnostics.
Building on installer feedback, the new Greenstar Si Compact has been
designed to make installation and commissioning easier and quicker and
comes supplied with a unique wall-mounting jig which enables the installer
to quickly pre-plumb all seven pipe connections without the boiler being
Greenstar Si Compact is
available with DHW flow
rates of 10.2 and 12.3 l/min
on the wall.
The Greenstar Si Compact offers an A rated annual efficiency of up to
90.5% (SEDBUK 2005 value).
Installation benefits
Environmental benefits
•
• SEDBUK A rating of 90.5% (2005 value)
• Precision engineered heat exchanger
Can be installed in a standard kitchen
cupboard or compartment without the
need for ventilation
• Robust, metal wall mounting jig for safe,
secure, hassle-free fixing
• Split jig design for optimum lift weight
(32.9kg). The expansion vessel has
a simple drop lock mechanism that
connects directly onto the hydraulic unit
•
LCD boiler display for operation status,
options available
• Low electrical consumption when in
standby mode
• Lower fan speed at higher output
• NOx emissions of 35mg/kWh –
commissioning features and diagnostics
achieves 3 credits under the Code
•
Double seal siphon located at the front
for Sustainable Homes
•
Electrical connections accessible from the
recyclable, achieving Worcester’s zero
front of the boiler
waste to landfill objective.
of the boiler for easy maintenance
• Maximum flue lengths of 6m 60/100mm
flue and 15m 80/125mm flue
• Pre-set combustion settings for fast
commissioning and with Benchmark
Commissioning Checklist data available
on the boiler display
• Full range of Condensfit II™ horizontal and
vertical flue options with optional plume
management kit available.
16
delivers high efficiency and reliability
• Anti-cycle and modulation control
• Simple and intelligent control
• All boilers and components are 100%
WB7 heat exchanger
Innovation at its best
Greenstar Si Compact boilers use
The WB7 heat exchanger is an
the same ground-breaking WB7
industry first for Worcester,
heat exchanger as CDi Compact
Bosch Group. State-of-the-art
appliances.
friction stir welding† technology
improves reliability, as the welding
Although compact in size, the WB7
method eliminates the risk of
heat exchanger offers outstanding
potential weak points and stress
levels of performance and is
fractures occurring.
designed and built to provide
long-term reliability.
WB7
Heat Exchanger
On the primary
heat exchanger*
End user benefits
• Highly reliable and efficient
heat exchanger
• Condenses in CH and DHW mode, resulting
in greater efficiency and fuel savings
• Energy-saving anti-cycle and
modulation control
• Simple and intelligent control options
available, optimising boiler efficiency
and fuel consumption
• EMS-BUS compatibility enables use with
Worcester intelligent controls series
• Comfort and ECO modes to suit hot water
delivery needs
• Maximum central heating output 24kW
• Includes internal keyed filling link
• 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
The Greenstar Si Compact boilers are
recommended by the Energy Saving
Trust (EST). The Energy Saving Trust
is a non-profit organisation that
provides free and impartial advice on
how to save energy.
heat exchanger*
• Boiler protection plans available.
†The friction stir welding process is used under license from The Welding Institute. *Terms and conditions apply.
17
Inside story – Greenstar Si Compact
Expansion vessel
(hidden)
Pre-mix fan
Automatic air vent
Down firing
low NOx burner
Aluminium/silicon
WB7 primary
heat exchanger
Gas valve
Circulating pump
Secondary DHW
plate heat exchanger
Diverter valve (hidden)
Condensate siphon
Pressure relief valve
PCB board
Mains cable
pre-wired to
control board
Operational
status light
Central heating
temperature control
Digital display
Domestic hot
Optional water temperature
programmer
control
Greenstar Si Compact fascia with optional
MT10 mechanical timer fitted
18
Pressure
gauge
Technical data
Boiler
Greenstar
25Si Compact
Greenstar
30Si Compact
Height
690mm (max)*
690mm (max)*
Width
390mm
390mm
Depth
280mm (max)
280mm (max)
32.9kg
32.9kg
2005 SEDBUK value – natural gas
90.5% / A rated
90.5% / A rated
2005 SEDBUK value – LPG
92.6% / A rated
92.6% / A rated
2009 SEDBUK value – natural gas
89.8%
89.8%
2009 SEDBUK value – LPG
90.9%
90.9%
Heating flow / return connections (compression)
22mm
22mm
Hot / cold water connections (compression)
15mm
15mm
Pressure relief valve (compression)
15mm
15mm
Condensate connection (plastic pipe)
22mm
22mm
Gas connection (compression)
22mm
22mm
Primary water content
2.2 ltr
2.2 ltr
Minimum domestic inlet pressure
for maximum DHW flow rate
1.6bar
1.6bar
Minimum domestic inlet pressure
to operate the appliance
0.2bar
0.2bar
Maximum domestic inlet pressure
10bar
10bar
2 ltr/min
2 ltr/min
10.2 ltr/min
12.3ltr/min
Weight – lift
Minimum flow rate to operate the appliance
DHW flow rate @ 35ºC∆T†
8.9 ltr/min
10.7 ltr/min
Output to central heating (natural gas)
7.03 - 24kW
7.03 - 24kW
Wall mounting jig
9
9 (optional)
9 (optional)
9 (optional)
9 (optional)
9
9
9 (optional)
9 (optional)
9 (optional)
9 (optional)
9
Maximum vertical flue (100mm dia.) inc. terminal
6,000mm
6,000mm
Maximum vertical flue (125mm dia.) inc. terminal
15,000mm
15,000mm
DHW flow rate @ 40ºC∆T††
Filling link
Plug-in timers
Optimising room temperature controller
Intelligent controls
Condensing in DHW mode
Maximum horizontal flue (100mm dia.)
6,000mm
6,000mm
Maximum horizontal flue (125mm dia.)
15,000mm
15,000mm
NOx classification – natural gas
35mg/kWh
35mg/kWh
5
5
X4D
X4D
NOx class
Ingress protection (IP)
*Measured to the top or front of the curve height. †Values for industry comparisons. ††Designed operational flow rate.
19
Greenstar i Junior
Features and benefits
With more than 1 million boilers already installed in the UK, the wellestablished award-winning Greenstar i Junior condensing boiler series,
with outputs of 24kW and 28kW are ideal for apartments and small to
medium-sized properties with one bathroom.
Greenstar i Junior appliances have DHW flow rates of 9.8 and 11.4 l/min,
making them suitable for a variety of locations, including kitchens, utility
rooms, bathrooms, airing cupboards, lofts or garages. They now feature a
number of enhancements including the addition of a DHW control to the
boiler fascia and the ability to be used with Worcester intelligent controls
for load and weather compensation. Switch mode power supply reduces
energy consumption in standby by 61% and lift weight by almost 1kg.
The Greenstar i Junior appliances come supplied with a pre-assembled
light weight wall frame, that has pre-drilled fixing points and options that
make hanging the appliance quick and easy. The wall-mounting jig allows
installers to quickly pre-plumb the condensate, CH flow, DHW outlet, gas,
DCW inlet, PRV installer connection & CH return without the boiler being
on the wall. Both models offer an A rated annual efficiency of up to 90.1%
(SEDBUK 2005 value).
Installation benefits
Environmental benefits
• Small dimensions
• SEDBUK A rating of 90.1%
Class-leading
lift
weight
26kg
(2005 value)
•
• Split wall-mounting jig design for a • EMS BUS enabled to allow
simple installation
• Robust, metal wall frame provided
as standard, allowing space for
pipes behind the boiler
intelligent and weather
compensation controls to be used
• Reduced energy consumption with
switch mode power supply
• Split wall-mounting jig provided as • WB3 heat exchanger delivers high
standard for pre-plumbing of all
7 connections – gas, water, PRV
and condensate connections
before the boiler is on the wall
•
Vertical pre-piping assembly is
available as an accessory
•
Full range of Condensfit II™
efficiency and reliability
• Anti-cycle and modulation control
• Intelligent and on/off control
options available
• Low electrical consumption when
in standby mode
• Both models achieve 3 credits
horizontal and vertical flue options
under the Code for Sustainable
with optional plume management
Homes when the optional Low
kit available.
NOx Code Plug is fitted
• All boilers and components
are 100% recyclable, achieving
Worcester’s zero waste to
landfill objective.
20
The Greenstar i Junior has
DHW flow rates of 9.8 and
11.4 l/min
DHW control added to fascia
Full suite of Worcester intelligent controls
The new Greenstar i Junior now has a DHW temperature
The Greenstar i Junior is now EMS-BUS enabled to allow
controller added to the boiler fascia to offer temperature
for further control and functionality of the heating system
control between 40°C and 60°C, while also allowing the
with the ability to use Worcester’s intelligent and weather
homeowner to control both their heating and hot water
compensation controls.
from the boiler’s interface.
DHW control added to the boiler fascia
Worcester intelligent & weather compensation controls
End user benefits
• Highly reliable and efficient WB3
heat exchanger
• DHW control added to the boiler fascia
• Energy-saving anti-cycle and
modulation control
• Simple and intelligent control options
available, optimising boiler efficiency
and fuel consumption
• Includes internal keyed filling link
• 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
• Part of the Which? Best Buy range for
gas-fired condensing boilers.
The Greenstar i Junior boilers are recommended by the
Energy Saving Trust (EST). The Energy Saving Trust is a
non-profit organisation that provides free and impartial
advice on how to save energy.
*Terms and conditions apply.
21
Inside story – Greenstar i Junior
Down firing low NOx burner
Aluminium/silicon WB3
primary heat exchanger
Pre-mix fan
Gas valve
Secondary DHW
plate heat exchanger
Condensate siphon
Automatic air vent
Circulating pump
Diverter valve
PCB board
Mains cable
pre-wired to
control board
Central heating
temperature
control
Optional
programmer
Operational Pressure
status light
gauge
Greenstar i Junior fascia with Comfort
plug-in twin channel programmer fitted
22
Domestic hot water
temperature control
Technical data
Boiler
Greenstar 24i Junior
Greenstar 28i Junior
Height
710mm (max)*
710mm (max)*
Width
400mm
400mm
Depth
330mm (max)*
330mm (max)*
26.2kg
26.2kg
2005 SEDBUK value – natural gas
90.1% / A rated
90.1% / A rated
2005 SEDBUK value – LPG
Weight – lift
91.8% / A rated
91.8% / A rated
2009 SEDBUK value – natural gas
89.1%
89.1%
2009 SEDBUK value – LPG
90.1%
90.1%
Heating flow / return connections (compression)
22mm
22mm
Hot / cold water connections (compression)
15mm
15mm
Pressure relief valve (compression)
15mm
15mm
Condensate connection (plastic pipe)
22mm
22mm
Gas connection (compression)
22mm
22mm
Primary water content
3.9 ltr
3.9 ltr
Minimum domestic inlet pressure
for maximum DHW flow rate
1.3bar
1.3bar
Minimum domestic inlet pressure
to operate the appliance
0.2bar
0.2bar
Maximum domestic inlet pressure
10bar
10bar
Minimum flow rate to operate the appliance
1.9 ltr/min
1.9 ltr/min
DHW flow rate @ 35ºC∆T†
9.8 ltr/min
11.4 ltr/min
DHW flow rate @ 40ºC∆T††
8.6 ltr/min
10 ltr/min
Output to central heating (natural gas)
7.2 - 24kW**
7.2 - 24kW**
Wall mounting jig
9
9 (optional)
9 (optional)
9 (optional)
9 (optional)
9
9 (optional)
9 (optional)
9 (optional)
9 (optional)
Maximum vertical flue (100mm dia.) inc. terminal
6,400mm
6,400mm
Maximum vertical flue (125mm dia.) inc. terminal
15,000mm
15,000mm
Maximum horizontal flue (100mm dia.)
4,600mm
4,600mm
Maximum horizontal flue (125mm dia.)
13,000mm
13,000mm
NOx classification – natural gas
66mg/kWh
66mg/kWh
NOx classification with low NOx code plug – natural gas
38mg/kWh
38mg/kWh
5
5
X4D
X4D
Filling link
Plug-in timers
Optimising room temperature controller
Intelligent controls
NOx class
Ingress protection (IP)
*Measured to the top or front of the curve height. **13kW with low NOx code plug fitted.
†Values for industry comparisons. ††Designed operational flow rate.
23
Controls
5 year guarantee
When purchased and installed at the same time, the guarantee period for a Worcester control will match that
of a Greenstar gas-fired boiler*.
Advanced intelligent controls
FW100 – Weather compensation controller – Part no. 7 716 192 067
Bo
output automatically adjusts to precisely meet the heat demands
• Boiler
of the property according to outside temperature conditions at maximum efficiency
Pr
unit with six switching points a day for control of both central heating and
• Programmable
ho water pre-heat
hot
Ch
of six selectable weekly programmes
• Choice
Ca be integral to the boiler or wall-mounted
• Can
Has
• Ha 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
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
• Maximises the condensing boiler’s operation
• For use with a 230V programmer. Not compatible with Worcester Comfort controls.
NEW 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.
Co
Comfort
I RF wireless room thermostat and plug-in twin channel programmer –
Pa no. 7 733 600 001
Part
• All the features of Comfort PLUS…
• Enhanced load compensation for increased efficiency
• No wiring required
• Extremely reliable RF signal.
24
*Terms and conditions apply.
Comfort II RF wireless programmable room thermostat and plug-in RF receiver –
P
Part no. 7 733 600 002
• All the features of Comfort and Comfort I PLUS…
• 6 adjustable heating temperatures per day
• Set programme at the room thermostat
• Remote access to boiler diagnostic codes
• Back lit display.
Mechanical timers
MT10 mechanical timer (for use with all models) – Part no. 7 716 192 036
• The simplest Worcester device
• Analogue clock for setting on and off times for heating.
M
MT10RF
mechanical timer (for use with all models) – Part no. 7 716 192 037
• Simple installation
• Analogue display has comfort and economy time and temperature periods
• No need for separate room thermostat
• No wiring.
Controls at a glance
FR10
FR110
FW100
Wave
1
2
Radio frequency
Boiler flow
temp compensation
9
9
9
9
9
9
9
9
9 9
9
9
9
9
9
92
92
92
92
92
92
92
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
91
91
91
91
91
91
91
Plug-in
Optimum start
Programmable
room thermostat
Room thermostat
Auto switch –
BST/GMT
7 day
24 hour
Hot water
Central heating
Wall mounted
Fascia mounted
Internet
Intelligent
9
9
9
9
9
9
i Junior
Comfort II RF
9
9
9
9 9
9
9
9
9 9
9 9
9 9 9 9
9 9 9
9 9 9
9 9
9
9
9
9 9 9
9 9
9 9
9 9 9 9
9 9
9
9
9 9 9
9 9
9 9
MODEL
Si Compact
Comfort I RF
9
TEMPERATURE CONTROL CONNECTION TYPE
CDi Compact
Comfort
9
9
TIME CONTROL
CDi Classic
MT10RF
MOUNT
Hard wired
MT10
Digital
Control
option
Mechanical
TYPE
9
9
9
Manufactured after July 2013.
Manufactured after 16th January 2007 with software version CF12.10 onwards.
25
Worcester Wave – smart control
for heating and hot water
The Wave is the first of a new generation of
Worcester controls.
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 forthcoming ErP Directive (Energy-related Products
Directive) coming out of Europe, smart controls like the
Wave are recognised as improving the system efficiency by
at least 4%, resulting in lower fuel bills.
The Wave’s energy efficiency features include:
• Charts of heating and hot water usage so the homeowner
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
ng 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
• For security and peace of mind, all of the Wave’s data is
owned by the user, ensuring no information is shared with
other parties.
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
26
additional energy savings and comfort.
Wave compatible devices:*
Apple® devices running iOS 5.1 and higher
Android™ devices running 2.2, 2.3 or 4.0 and higher
*Correct at time of printing
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.
27
Site preparations and guidance
All combi boilers require less installation time than a
Installation and service clearances
conventional boiler, for these reasons:
The minimum clearances shown below should be allowed
•
• The boiler comes supplied with a wall-mounting
for installation and servicing. Compartment ventilation
One-man lift (Greenstar i Junior)
would only be required at these clearances for the
bracket (Greenstar CDi Classic) or a wall-mounting
Greenstar i Junior range. The Greenstar CDi Classic,
jig (Greenstar CDi Compact, Greenstar Si Compact and
CDi Compact and Si Compact ranges do not require
Greenstar i Junior)
compartment ventilation so long as minimum installation
• Zero pressure governor gas valve with fully modulating fan
• Highly versatile multi-directional fluing system
• Combined ignition and control board means
and service clearances are maintained, see on page 29.
450mm
960mm
less connections
• Plug-in filling link provided with the Greenstar CDi Classic
+30mm
above elbow
and CDi Compact (also available as an optional extra on
both the Greenstar Si Compact and Greenstar i Junior)
• Optional plug-in timers
• Built-in boiler frost protection
• Vertical pre-piping assembly accessory providing
pre-formed copper pipe lengths.
Using 100mm
flue kit
– 1,130mm
Using 125mm
flue kit
– 1,170mm
Siting of appliance
The appliances are only to be installed internally within a
5mm
5mm
20mm to
removable
door
600mm front
clearance
for service
property, at a suitable location onto a fixed, rigid surface,
that is at least the same size as the appliance and is
200mm
capable of supporting its weight.
Mounting on a combustible surface
Clearances for Greenstar CDi Classic
All Greenstar wall-mounted boilers can be sited on
a combustible surface without the need for surface
400mm
880mm
protection. EN482, Section 6.4.1.3 states no means
for protection of combustible surfaces are necessary if
+30mm
above elbow
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
Buildings” should be adhered to.
The appliances may be installed into an airing cupboard
Using 100mm
flue kit
– 1,060mm
Using 125mm
flue kit
– 1,100mm
5mm
5mm
20mm to
removable
door
600mm front
clearance
for service
200mm
if required. Use a non-combustible perforated material
(max. hole sizes of 13mm) to separate the boiler from
the airing space. See section “Boiler location”
on page 29.
28
Clearances for Greenstar CDi Compact and Si Compact
Ventilation-free compartment installation – minimum clearances
410mm
930mm
+30mm
above elbow
+30mm
above elbow
Using 100mm
flue kit
– 1,080mm
200mm*
5mm
Using 125mm
flue kit
– 1,110mm
200mm*
5mm
20mm to
removable
door
100mm to
removable door
600mm front
clearance for
service
600mm front
clearance
for service
200mm
200mm
Clearances for Greenstar i Junior
Greenstar i Junior
*This can be reduced to 50mm for one side, provided that the total side
clearances add up to 400mm or more.
Boiler location
The appliance may be installed in any room, although
particular attention is drawn to the requirements of the
IEE regulations applicable, and in Scotland the electrical
provisions with respect to installation in a room containing
a bath or shower.
1. The room in which the appliance is installed does not
require a purpose-provided air vent.
2. If the appliance is installed in a cupboard or
compartment with dimensions that allow the following
minimum clearances, then no ventilation is required:
Compartment installation
Minimum unventilated clearance
(to removable door)
Greenstar
Position of Greenstar CDi Compact
appliance CDi Classic & Si Compact
In front
Greenstar
i Junior
20mm
20mm
100mm
200mm
200mm
200mm
Right side
5mm
5mm
200mm*
Left side
5mm
5mm
200mm*
30mm
30mm
30mm
Below
Above
flue elbow
*This can be reduced to 50mm for one side, provided that the total side
clearances add up to 400mm or more.
29
Important: bathroom locations and clearances
• The boiler must not be installed in Zone 1
• Any switch or appliance control using mains electricity
• A boiler fitted with a mechanical timer or RF mechanical
must not be within reach of a person using the bath
outside the shaded area. A boiler with any other timer
or shower
fitted (or blanking panel for an optional programmer) can
timer (receiver) or FW100 controller may only be installed
• Electrical switches (other than pull cords), fused spurs
be installed in zone 2.
and socket outlets must not be situated in the bathroom
• Additional Residual Current Device (RCD) protection may
be required.
Refer to the latest IEE wiring regulations.
600m
600m
m
m
m
2250mm
m
2
1
2
Radius 600mm
2
1
1
2
600m
m
m
*Without the end wall, zone 2 must extend 600mm from the bath
30
m
750m
2
Radi
u
600m s
m
2
600m
2
m
750m
1
2
600m
2,250mm
2
2250mm
2
600m
1
2* 2*
Radius 600mm
2
2
Radiu
s
600m
m
2
2
1
2
2,250mm
m
600m
Wall preparation
The following diagrams show the wall-mounting jigs which
enable a simple and straightforward method of attaching
the boiler to the wall surface.
All Greenstar wall-mounting jigs have pre-drilled fixing
points and options that make hanging a Worcester
Greenstar quick and easy.
After fixing the jig to the wall, the appliance can be lifted
onto the jig and the union connections tightened. The
pipework can be routed behind the boiler without the
need for an additional wall spacing frame.
Greenstar i Junior wall-mounting jig
Greenstar CDi Classic wall-mounting jig
Greenstar CDi Compact and Greenstar Si Compact wall-mounting jig
31
Casing dimensions
Depth to wall (when fitted to wall frame)
360mm
330mm
750mm†
700mm*
400mm
440mm
Greenstar CDi Classic
Greenstar i Junior
†760mm to top of casing front.
*710mm to top of casing front.
Depth to wall (when fitted to wall frame)
280mm
680mm†
390mm
Greenstar CDi Compact and Si Compact
†690mm to top of casing front.
32
Pipework connections
1
7
2
3
1
4
7
5
6
2
3
4
5
6
Greenstar i Junior
Greenstar CDi Classic
Pipework connections – Greenstar CDi Classic
From left
case edge
55mm
Function
1 Condensate drain
2 CH flow
Pipework connections – Greenstar i Junior
Diameter
of pipe
22mm
Function
1 Condensate drain
From left
case edge
35mm
Diameter
of pipe
22mm
85mm
22mm
2 CH flow
70mm
22mm
3 DHW outlet
148mm
15mm
3 DHW outlet
135mm
15mm
4 Gas
212mm
22mm
4 Gas
200mm
22mm
5 DCW mains in
278mm
15mm
5 DCW mains in
267mm
15mm
6 CH return
343mm
22mm
6 CH return
330mm
22mm
7 Pressure relief valve
375mm
15mm
7 Pressure relief valve
367mm
15mm
Optional pre-piping assembly kit
The vertical pre-piping assembly kits comprises a set of
1
pre-formed copper pipes. More information on this and
other time-saving accessories can be found on page 62.
2
3
4
5
7
6
Greenstar CDi Compact and Si Compact
Pipework connections –
Greenstar CDi Compact & Si Compact
Function
1 Condensate drain
2 CH flow
3 DHW outlet
From left
case edge
33mm
Diameter
of pipe
22mm
65mm
22mm
130mm
15mm
4 Gas
195mm
22mm
5 DCW mains in
260mm
15mm
6 PRV drain
291mm
15mm
7 CH return
325mm
22mm
33
Greenstar combi installation requirements
Installation of the Greenstar combi boiler range must be
Optional Worcester
in accordance with the relevant requirements of the Gas
integral filling link
Safety (Installation Use) Regulations (as amended), current
The Worcester integral filling
IEE Wiring Regulations, local Building Regulations, Building
link simply connects between
Standards (Scotland) regulations and bylaws of the local
the cold main connection and
water company and Health and Safety Document No. 635
the heating return circuit on
(Electricity at Work Regulations 1989). It should also be
the wall-mounting jig
in accordance with the relevant recommendations of the
(part no. 7 716 192 281).
following British Standards:
BS 6798; EN 12828; BS 5546:1; BS 5440:1; BS 5440:2;
Worcester Keyless Filling Link
BS 6891; BS 7074; BS 7593.
The Worcester Keyless
Filling Link is an innovative
Gas Safety (Installation and Use) Regulations state that all
accessory which has been
gas appliances must be installed by a Gas Safe registered
specially designed to be
person in accordance with the above regulations. Failure
directly connected to a wall
to install appliances correctly could lead to prosecution.
mounted Worcester Greenstar
combi boiler. Its simple lever
The manufacturer’s notes must not be taken in any way as
operation makes system
overriding statutory regulations.
re-pressurisation easy for both the installer and end user
alike, and eliminates the problems caused when a separate
Sealed primary systems
filling link or loop has been mislaid or lost. This feature is
The Worcester Greenstar combi boilers are supplied
supplied as standard with the Greenstar CDi Classic and
complete with all the necessary components to form a
an accessory for the Greenstar CDi Compact, Si Compact
sealed primary system. Included are an expansion vessel,
and i Junior. For further details see pages 38 and 39
a pressure relief valve (set at 3bar), an automatic air vent
(part no. 7 716 192 610).
and a pressure gauge.
Valves and joints
With an initial system pressure of 0.5bar, a system capacity
It is very important that all valves and joints are able to
of approximately 83 litres can be accommodated. Refer to
sustain a working pressure of up to 3bar (45psi). Particular
BS 7074:Part 1 for more information.
care should be exercised when fitting radiator valves and
only those of high quality to BS 2767:10 should be used.
It is important with an aluminium heat exchanger that the
All other valves and fittings should comply with BS 1010.
pH level of the water does not exceed 8. Levels in excess of
this could be detrimental to the heat exchanger.
Loss of water pressure from a sealed system will require
continuous recharging with fresh water and consequential
The use of a suitable inhibitor will provide a resistance to
introduction of air. Air is highly corrosive and will
this. Contact Sentinel (Tel: 0800 3894670 or visit
considerably reduce life expectancy of radiators, pumps etc.
www.sentinel-solutions.net) or Fernox (Tel: 0870 601 5000
or visit www.fernox.com) for further details.
Plastic pipework
The use of plastic pipework is acceptable. However, some
System filling and re-pressurising
plastics are permeable to oxygen and must be avoided. Only
Worcester Greenstar combi boilers are fitted to a sealed
pipework with a polymeric barrier should be used. Please
heating system which is pressurised. To maintain optimum
note that the first 600mm of pipework connected to the
system pressure, two options may be used: an optional
boiler must be of copper or steel.
Worcester integral filling link or external filling loop.
34
Natural gas supply
Mains cold water supply
Listed below is a representative example. Figures
Water Authority requirement
for other appliances can be found in the relevant
A direct mains cold water connection is permitted by
installation manuals.
Water Authorities. However, it is recommended that
Model
Gas rate
42CDi Classic
4.40m3/hr
36CDi Compact
3.93m3/hr
30Si Compact
3.24m3/hr
28i Junior
3.02m3/hr
The gas meter and supply pipes must be capable of
reference be made to local requirements. In the event
of difficulty, please contact Worcester Technical
Support Department.
Cold water connection
Connection should be made as shown in the pipework
detail and the appliance installed generally in accordance
with the layout shown on page 33.
supplying this quantity of gas in addition to the demand
from any other appliance being served. It is important that
Wherever possible, the cold supply to the appliance should
a gas supply pipe of at least 22mm diameter is used. Under
be the first connection off the mains supply, in order to
no circumstances should the size of the gas supply pipe be
minimise hot water flow reduction when cold water services
less than that of the appliance inlet connection. The meter
are operated. The final 600mm of piping to the appliance
outlet governor should be capable of ensuring a dynamic
should be of copper only.
pressure of 20mbar (8in wg) at the appliance. Particular
consideration should be given to the resistance to gas flow
created by elbows, bends etc. Pipework should be sized to
overcome this resistance.
MAINS WATER EXPANSION VESSEL:
A - Mains water inlet pipe
B - Non-return valve
C - Mini expansion vessel, Part No. 7 716 192 105
D - Boiler
Liquid Petroleum Gas (LPG) supply
Listed below is a representative example. Figures
D
for other appliances can be found in the relevant
installation manuals.
Model
C
A
B
Gas rate
42CDi Classic
3.30kg/hr
36CDi Compact
2.80kg/hr
30Si Compact
2.33kg/hr
28i Junior
2.22kg/hr
Cold water pressure
To achieve the stipulated flow rate, a working cold water
mains pressure of 1.3bar is required.
The gas tank or bottles must be capable of supplying
this quantity of gas at a nominal pressure of 37mbar
However, for the Greenstar CDi Classic range to achieve the
(14.8in wg) at the appliance.
stipulated flow rate, a working cold water mains pressure of
between 1.2 and 1.9bar is required (dependent on model).
Electricity supply
A 3amp fused three pin plug and unswitched shuttered
The appliance will operate at a minimum working pressure
socket outlet (both complying with BS 1362) or preferably a
of only 0.2bar (3psi); however a reduced hot water flow
double pole isolator with a contact separation of 3mm in all
rate should be expected. Back-flow prevention devices,
poles supplying the appliance should be used.
including water meters, can prevent the expansion of hot
water into the cold water main. However, this can result in a
The appliance electrical circuits are also protected by an
pressure build-up that may cause damage to the boiler and
internal 2amp fuse. The appliance must be earthed.
household devices such as showers, washing machines, etc.
In these cases, we recommend that a mini-expansion vessel
(Part No. 7 716 192 105) be fitted adjacent to the boiler in
the cold water main.
35
Hot water supply
Use in hard water areas
All Worcester Greenstar boilers are fitted with a
As the maximum temperature of the domestic hot water
flow regulator set to achieve a 40°C temperature rise.
heat exchanger is limited by the electronic control circuit,
This ensures comfortable bathing during the colder
there is normally no need for water treatment to prevent
winter months.
scale accumulation.
For the Greenstar CDi Classic range, a domestic hot water
In areas where exceptional water conditions prevail,
flow regulator, set to give an optimum flow rate of between
consideration may need to be given to the fitting of a device
9 and 15l/min ±15% (dependent on model) is fitted to the
capable of preventing scale. In such circumstances, the
cold supply of the hot water heat exchanger.
advice of the local water authority should be sought.
The Greenstar CDi Compact flow regulators are sized
Guarantee
between 10l and 13l.
Worcester Greenstar combi appliances are offered with a
full 5 year guarantee* on parts and labour and a 10 year
A domestic hot water flow regulator, set to give an
guarantee* on the primary heat exchanger*. Ongoing service
optimum flow rate of between 8 and 11l/min ±15%
and maintenance contracts can be arranged through the
(dependent on model) is fitted to the cold supply of the
Worcester Customer Service Department.
hot water heat exchanger in the Greenstar Si Compact
and i Junior combis.
Please contact our guarantee
registration advisors on
As with all mains-fed systems, the flow rate of water
0330 123 2552 or visit
obtainable from individual taps will vary in relation to the
www.worcester-bosch.co.uk/
number of taps operating simultaneously, and will depend
guarantee
upon the cold mains supply available to the property.
On all Greenstar On the primary
combi appliances* heat exchanger*
Therefore, in order to avoid excessive starvation of flow
to individual taps, flow balancing may be required by the
use of proprietary constant volume flow regulators or
Ball-o-Fix valves.
Hot water systems
Taps and valves
Hot and cold taps and mixing valves used with the
Greenstar combi appliances must be suitable for
operating at a mains pressure and temperatures of
65°C (150°F).
36
*Subject to terms and conditions.
The Worcester
Greenstar System Filter
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
and retained, maximising the overall protection. Any
non-magnetic debris is caught by the twin-action cyclonic
trap, a proven technology that offers a capacity to collect
up to 200g of magnetite a year.
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,
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
paint particles and other system pollutants.
Features
Benefits
Highly effective filter
Safeguards the boiler against
damage and protects the
efficiency of the system.
Saves up to 6% a year on
energy bills*
Prevent blockages in radiators
A warmer home and
quieter system
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.
Proven technology that
High powered internal magnet can capture up to 200g
of magnetite
Reduced efficiency
Cylindrical design
Increased performance –
better installation options
Twin-action – magnetic and
non-magnetic filtration
Instantly effective against a
wide range of system debris
No power consumption or
moving parts
No electrical wiring
connection or supply needed.
Zero running costs and no
failure of components
Can be installed under the
boiler or away from the
appliance
Flexibility
One-way valve for adding
system chemicals
Removes the need to isolate
a section of the system when
carrying out servicing and
maintenance
effects of system debris
Worcester, Bosch Group
specification and design
Reliability of components
and filter
and pollutants, allowing
*Independent research carried out by GASTEC at CRE
• 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.
A highly-effective solution from the brand you can trust
The Worcester Greenstar
System Filter has been
specifically designed to
combat the damaging
homeowners to protect their
boiler or heat pump for a
Installation
The filter can be installed almost anywhere in a heating
fraction of its cost. The filter
is suitable for 22mm piped
heating systems.
The Greenstar System Filter is easy to
install and service
system, however to maximise the effectiveness, it should be
placed before the boiler and after the last radiator.
Product info
Part number
7 716 192 609
37
The Worcester Keyless Filling Link –
easy to install, simple to operate
Worcester Greenstar gas-fired combi boilers are designed to
deliver maximum efficiency and performance, however the
NEW
heating system will occasionally need to be re-pressurised
for optimum performance.
Traditional methods involve using a built-in key or connecting
an external filling loop, an operation which can be confusing
for the end user.
The new Worcester Keyless Filling Link has been developed
to make system filling quick and easy for both the installer
and the end user. The new Greenstar CDi Classic combi
boilers are supplied with the Worcester Keyless Filling Link
as standard.
Fewer call-outs
Some end users find conventional filling loops and separate
filling links difficult to attach and use. There is also the
possibility that a separate link can be lost or mislaid, often
leading to the installer being called out simply to top up the
system. The innovative Keyless Filling Link relieves the end
user of these problems, leading to reduced call outs.
Quick to install, easy to use
The Worcester Keyless Filling Link connects directly to the
Worcester Greenstar gas-fired combi boiler wall mounting
frame with no hose or key to connect, making installations
quick and simple. As the Filling Link is always connected to
the appliance, the end user will never need to find a key or
connect a separate loop to the system.
38
Whenever the system needs to be re-pressurised,
the blue lever is simply pulled down until the correct
pressure is achieved.
Innovative design
Nominal flow
direction
3
3
1
Back flow
relief port
2
Innovative design features ensure the Worcester Keyless Filling Link delivers reliable, trouble-free performance without
risking backflow or overfilling. These include:
1 Valve orientation that uses water
2 Simple and intuitive pull-down lever
pressure to aid valve sealing and
to fill the system
3 Twin check valves to prevent
backflow of system water
prevent overfilling
The Worcester Keyless Filling Link has a host of benefits
For the installer
For the end user
Quick to install and operate
Simple lever operation, no key or hose required
Reduced risk of call-outs to top up the system
No risk of the end user losing or misplacing the
filling link
Added value for the end user
Easy to maintain optimum boiler performance
Guaranteed Worcester quality
Peace of mind
WRAS approved
For safe use as a filling link with the domestic water supply
Product info
Part number
7 716 192 610
39
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
40
External connections
Condensate soak away (see fig. 6)
Freezing conditions
• The condensate drainage pipe may be run above or below
•
When the position of the boiler prevents internal
routing, we recommend installing a Worcester
CondenseSure siphon to minimise the risk of freezing
• Pipework length should be kept to a minimum and the
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
route as vertical as possible
• Weather-proofing insulation must be sized when not
away from the house
• The tube must be surrounded by at least 100mm of
using a CondenseSure siphon.
limestone chippings to a depth of 400mm
• Minimum hole size for the condensate soak away must be
Condensate waste
•
Care should be taken when siting a soak away to avoid
400mm deep by 300mm dia.
obstructing existing services.
In situations where there are likely to be extremes of
If no other discharge method is possible, then the use of
temperature or exposure, the use of a proprietary trace
an externally-run condensate drainage pipe terminating at
heating system for external pipework (that incorporates
a suitable foul water discharge point (fig. 4), or purpose-
an external frost thermostat) should be considered. If
designed soak away (fig. 5), may be considered. Please see
such a system is used, the requirement to use 32mm pipe
installation and servicing instructions for more details.
does not apply, however all other guidance above, and the
instructions for the trace heating system, should be
Insulate
& increase
pipe size
closely followed.
External
rain water
pipe into
foul water
Siphon
trap
External
air break
Pipework
transition
Unheated internal areas
Internal pipe runs in unheated areas such as lofts,
basements and garages should be treated as external runs,
with consideration given to using a CondenseSure siphon.
Air gap
43mm 90º
male/female
bend
68mm dia. PVCu
strap on fitting
Fig. 4 Disposal into a rainwater down pipe
100mm dia.
Drainage
holes
Siphon
trap
12mm dia. 300mm
500mm min.
Siphon
trap
Pipework
transition
Pipework
transition
Insulate
& increase
pipe size
25mm min.
100mm
dia. min.
plastic pipe
Insulate
& increase
pipe size
25mm
25mm
50mm
25mm
25mm min.
100mm
dia. min.
plastic
pipe
Limestone chippings
400mm
Drainage min.
holes
Bottom of sealed tube
Fig. 6 Soak away
Fig. 5 External disposal
In addition to the condensate discharge options illustrated
on these pages and in the Installation, Commissioning
For full technical information on pipe size, insulation
and Servicing Instruction Manual, the new Worcester
and different condensate pipework methods, please
CondenseSure siphon provides an innovative alternative
see Installation, Commissioning and Servicing
for the prevention of freezing for externally run discharge
Instruction Manual.
condensate (see over for details).
41
The Worcester
CondenseSure siphon
With temperatures as low as -20ºC being experienced
in very cold winters, practices such as externally run
condensate discharge pipework are now being questioned.
The Worcester CondenseSure siphon has been designed to
allow a more flexible approach to boiler siting.
Tested to extreme temperatures
The Worcester CondenseSure siphon has been extensively
tested under simulated extreme weather conditions, proving
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 litres of condensate an hour (dependant on output
and temperature) and this will result in the in-built siphon
The CondenseSure insulating jacket helps to retain the temperature
of the condensate.
discharging approximately every 3 minutes. With this
frequency of discharge, it is unlikely that the condensate
A universal fitting for new and existing installations
pipework is ever empty of condensate, consequently
Although developed specifically for Worcester Greenstar
increasing the potential for freezing of the pipework in
gas- and oil-fired boilers, the Worcester CondenseSure
prolonged sub-zero temperatures.
can also be fitted to any make of condensing boiler for
both new and retrofit installations. The CondenseSure
The CondenseSure siphon connects to the boiler
can provide a simple solution which eliminates the need
condensate discharge outlet and collects the condensate
for re-siting both the new boiler and the system pipework
into a larger volume before releasing it into the
when replacing an existing non-condensing appliance. The
discharge pipe.
CondenseSure can easily be fitted to existing installations
to provide peace of mind in extreme weather conditions.
With this expanded siphonic operation, the discharge from
the CondenseSure increases to every 15 to 20 minutes,
resulting in:
Features
Benefits
• Increased velocity and flow rate
• Only 3 to 4 siphonic actions per hour, meaning the
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
condensate pipework is empty for longer
• Significantly decreased or even eliminated
freezing potential.
42
Ease of installation
Fitting to a combi 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. Boiler DHW outlet pipe
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
43
Flue Gas Heat
Recovery Unit
Save energy and reduce CO2 emissions with the
EcoFlo FGHR unit.
Understanding the need for specifiers and house builders to have
a cost effective method of achieving SAP target emission rates,
Worcester has introduced the EcoFlo Flue Gas Heat Recovery (FGHR)
unit which is compatible with the latest range of Greenstar CDi
Compact and Si Compact combi boilers.
How the FGHR works
The FGHR is connected directly to the flue of the Greenstar boiler.
Its heat exchanger extracts residual energy from the flue gases exiting
from the boiler. This energy is then used to pre-warm the water that
is fed into the combi boiler reducing the amount of gas required to
reach the desired hot water temperature.
The table below highlights the positive impact that the specification
of an EcoFlo FGHR unit can have on a property’s SAP assessed
Dwelling Emission Rate (DER), allowing the example Target Emission
Rate (TER) to be met and exceeded.
TER
DER
% Difference
from TER
Worcester Si Compact
15.47
15.56
-0.58
Worcester Si Compact + EcoFlo
15.57
14.96
+3.30
SAP 2009 calc based on: Mid terrace house (3 bed) – 100m²
Cavity wall – 0.25 W/m²;.K Roof – 0.1 W/m²;.K Floors – 0.12 W/m².K; Openings – 1.4 W/m².
K Accredited thermal bridges
Q50 – 5; 3 intermittent fans; Standard programmer, room thermostat and TRV with radiators
44
A highly efficient solution
Colder flue gases
leave FGHR via
flue system
Recognised
under the
Green Deal
2
3
1
Hot flue gases from CDi Compact or
Si Compact combi condensing boiler
1 Cold mains water enters the
EcoFlo unit.
2 Cold water passes through the heat
3 Pre-heated water leaves the EcoFlo
exchange coil and is heated by the
speeding up the heating of hot
hot waste flue gases from the boiler.
water, reducing gas consumption
and CO2 emissions.
Feature
Benefit
For the Specifier…
SAP listed FGHR unit enables the heating system
to meet SAP target emission rates for new build properties
More cost-effective than other solutions such as solar thermal
or heat pumps
Savings on building fabric such as insulation can be achieved
Can be used as an energy saving measure to improve
domestic EPC ratings
Property receives a higher energy rating and occupier
achieves lower fuel bills
For the Installer…
Ease of installation
No additional training required for a competent installer
For the End User…
When fitted to a Greenstar combi, it reduces the amount
of gas used to provide hot water
Reduction in gas bills for homeowners
Recognised as a energy saving measure under the
Green Deal scheme
Eligible for Green Deal finance
Product info
Part number
7 733 600 047
SAP Assessors select Muelink & Grol EcoFlo as the FGHR unit
45
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 products
1.
300mm adjacent to a boundary line.
2.
The dimension below eaves, balconies and car ports can be
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.
Flue bracket part numbers:
suitable silicon sealant.
3.
7 716 191 092 (100mm dia.)
1,500mm between a vertical flue terminal and a window or
dormer window.
7 716 191 173 (100mm dia. x 6)
4.
1,200mm between terminals facing each other.
7 716 191 174 (125mm dia.)
5.
Vertical flue clearance, 300mm adjacent to a boundary line.
7 716 191 177 (100mm dia.) – CDi Compact & Si Compact only
6.
600mm distance to a boundary line, unless it will cause a
7 716 191 178 (100mm dia. x 6) – CDi Compact & Si Compact only
nuisance. BS 5440:Part 1 recommends that care is taken when
7 716 191 179 (125mm dia.) – CDi Compact & Si Compact only
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
46
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.
47
Greenstar combi boiler range
horizontal fluing options
™
Accessories
The Greenstar combi boiler range offers the choice of
2 differently sized horizontal RSF flue systems, a 100mm
Components
diameter telescopic flue kit including a plume management
kit, and a 125mm diameter telescopic flue kit. Both systems
Part No.
100mm 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
7 716 191 083 Extension flue kit (960mm*)
7 716 191 172 2m flue extension
125mm
7 716 191 133 Short flue extension (220mm*)
Greenstar CDi Classic series
Minimum flue length
Description
350mm*
7 716 191 084 90º bend
405mm
7 716 191 085 45º bend
Maximum flue length
29CDi Classic
7,900mm
18,500mm
34CDi Classic
7,000mm
16,000mm
38CDi Classic
6,000mm
12,500mm
42CDi Classic
6,000mm
12,000mm
7 719 002 432
7 716 191 092 Support bracket kit
7 716 191 173 Support bracket kit (6 pack)
7 716 191 177
Support bracket kit
(CDi Compact & Si Compact)
7 716 191 178
Support bracket kit (6 pack)
(CDi Compact & Si Compact)
Greenstar CDi Compact and Si Compact series
Minimum flue length
350mm*
405mm
Maximum flue length
6,000mm
15,000mm
High level horizontal
flue adaptor
*Dimensions when fitted
125mm diameter
Greenstar i Junior series
Minimum flue length
350mm*
405mm
7 719 003 702 Standard telescopic flue kit
Maximum flue length
4,600mm
13,000mm
7 719 003 666 Extension flue kit (960mm*)
7 719 003 664 90º bend
*Can be cut to 130mm. Please refer to instructions.
7 719 003 665 45º bend
100mm dia. standard telescopic flue kit
High level horizontal
flue adaptor
1 x flue turret elbow
7 719 002 433
570mm (100mm dia.) of flue duct
7 716 191 174 Support bracket kit
1 x weather sealing ring
7 716 191 179
1 x internal collar
Part No. 7 716 191 082
Support bracket kit
(CDi Compact & Si Compact)
*Dimensions when fitted
The following criteria should be noted when planning
125mm dia. standard telescopic flue kit
the installation:
1 x flue turret elbow
• The concentric flue system must be inclined at
600mm (125mm dia.) of flue duct including terminal
3º (52mm per metre) from the appliance, to allow
(as measured from centre of flue outlet)
condensate to drain back into the boiler
1 x weather sealing plate
• A white plume of condensation will be emitted from
1 x internal plate
the terminal because the appliance operates at high
Part No. 7 719 003 702
efficiency. Care must be taken when selecting the flue
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
• Horizontal flue options 1-6 illustrate common flue
installations. Other configurations of the flue system are
possible up to, and not exceeding, the stated maximum
flue lengths.
48
Option 1: Standard horizontal flue assembly
Components
Option 2: Extension flue horizontal
Components
Part No. 100mm
7 716 191 082
Part No. 100mm
7 716 191 082
7 716 191 083
Part No. 125mm
7 719 003 702
Part No. 125mm
7 719 003 702
7 719 003 666
Maximum lengths (mm) & no. of components required
Maximum lengths (mm) & no. of components required
Greenstar CDi Classic series
Greenstar 29CDi Classic
100mm
570
1
100mm
7,900
125mm
600
1
125mm 18,500
Greenstar CDi Compact and Si Compact series
Greenstar 34CDi Classic
100mm
570
1
100mm
125mm
600
1
125mm 16,000
7,000
1
up to 8
1
up to 19
1
up to 7
1
up to 16
1
up to 6
1
up to 13
1
up to 6
1
up to 12
Greenstar 38CDi Classic
Greenstar i Junior series
100mm
570
1
100mm
6,000
125mm
600
1
125mm 12,500
Greenstar 42CDi Classic
100mm
6,000
125mm 12,000
Greenstar CDi Compact and Si Compact series
100mm
6,000
125mm 15,000
1
up to 6
1
up to 15
1
up to 4
1
up to 13
Greenstar i Junior series
100mm
4,600
125mm 13,000
Note: The short flue extension (100mm dia.) may be used
Note: The maximum flue length must be reduced by the
as an alternative to the standard extension as required up to
following amounts for each bend used.
the maximum flue lengths stated (Part No. 7 716 191 133).
45º bend
90º bend
Greenstar CDi Classic
60/100mm flues
750mm
1,500mm
Greenstar CDi Classic
80/125mm flues
1,000mm
2,000mm
Greenstar CDi Compact and
Si Compact – all flue sizes
1,000mm
2,000mm
Greenstar i Junior
– all flue sizes
1,000mm
2,000mm
49
Option 4: Extension flue horizontal and upwards
Option 3: Extension flue horizontal
using a second 90º bend
Components
Part No. 100mm
7 716 191 082
7 716 191 083
7 716 191 084
Part No. 125mm
7 719 003 702
7 719 003 666
7 719 003 664
Components
Part No. 100mm
7 716 191 082
7 716 191 083
7 716 191 084
7 719 002 432
Maximum lengths (mm) & no. of components required
Part No. 125mm
7 719 003 702
7 719 003 666
7 719 003 664
7 719 002 433
Greenstar 29CDi Classic
Maximum lengths (mm) & no. of components required
100mm
6,400
125mm 16,500
1
up to 6
1
Greenstar 29CDi Classic
1
up to 17
1
100mm
Greenstar 34CDi Classic
100mm
5,500
125mm 14,000
125mm 18,500
4,500
125mm 10,500
4,500
125mm 10,000
4,000
125mm 13,000
2,600
125mm 11,000
1
1
up to 19
1
1
1
up to 7
1
1
1
up to 16
1
1
1
up to 6
1
1
1
up to 13
1
1
1
up to 6
1
1
1
up to 12
1
1
Greenstar 34CDi Classic
1
up to 14
1
100mm
7,000
125mm 16,000
1
up to 4
1
Greenstar 38CDi Classic
1
up to 11
1
100mm
6,000
125mm 12,500
1
up to 4
1
Greenstar 42CDi Classic
1
up to 10
1
100mm
6,000
125mm 12,000
1
up to 4
1
Greenstar CDi Compact and Si Compact series
1
up to 13
1
100mm
Greenstar i Junior series
100mm
1
1
Greenstar CDi Compact and Si Compact series
100mm
up to 8
up to 6
Greenstar 42CDi Classic
100mm
1
1
Greenstar 38CDi Classic
100mm
7,900
6,000
125mm 15,000
1
up to 6
1
1
1
up to 15
1
1
1
up to 4
1
1
1
up to 13
1
1
1
up to 3
1
Greenstar i Junior series
1
up to 11
1
100mm
4,600
125mm 13,000
Note: The short flue extension (100mm dia.)
may be used as an alternative to the standard
Note: The maximum flue length must be reduced by the
following amounts for each bend used.
45º bend
90º bend
Greenstar CDi Classic
60/100mm flues
750mm
1,500mm
Greenstar CDi Classic
80/125mm flues
1,000mm
2,000mm
Greenstar CDi Compact and
Si Compact – all flue sizes
1,000mm
2,000mm
Greenstar i Junior
– all flue sizes
1,000mm
2,000mm
extension as required up to the maximum flue
lengths stated (Part No. 7 716 191 133).
50
Option 5: Extension flue upwards and horizontal
using a second 90º bend
Components
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. 100mm
7 716 191 082
7 716 191 083
7 716 191 084
7 719 002 432
Part No. 125mm
7 719 003 702
7 719 003 666
7 719 003 664
7 719 002 433
Part No. 125mm
7 719 003 702
7 719 003 666
7 719 003 664
7 719 002 433
Maximum lengths (mm) & no. of components required
Maximum lengths (mm) & no. of components required
Greenstar 29CDi Classic
Greenstar 29CDi Classic
100mm
6,400
125mm 16,500
1
up to 6
2
1
100mm
1
up to 17
2
1
125mm 14,500
5,500
125mm 14,000
1
up to 6
2
1
100mm
1
up to 14
2
1
125mm 12,000
4,500
125mm 10,500
4,500
125mm 10,000
4,000
125mm 13,000
2,600
125mm 11,000
1
up to 15
3
1
4,000
1
up to 4
3
1
1
up to 12
3
1
2
1
100mm
3,000
1
up to 3
3
1
1
up to 11
2
1
125mm
8,500
1
up to 9
3
1
Greenstar 42CDi Classic
1
up to 4
2
1
100mm
3,000
1
up to 3
3
1
1
up to 10
2
1
125mm
8,000
1
up to 8
3
1
Greenstar CDi Compact and Si Compact series
1
up to 4
2
1
100mm
1
up to 13
2
1
125mm 11,000
2,000
1
up to 2
3
1
1
up to 11
3
1
up to 9
3
1
Greenstar i Junior series
Greenstar i Junior series
100mm
1
up to 4
Greenstar CDi Compact and Si Compact series
100mm
3
1
Greenstar 42CDi Classic
100mm
up to 5
Greenstar 38CDi Classic
Greenstar 38CDi Classic
100mm
1
Greenstar 34CDi Classic
Greenstar 34CDi Classic
100mm
4,900
1
up to 3
2
1
1
up to 11
2
1
Note: The short flue extension (100mm dia.)
may be used as an alternative to the standard
125mm
9,000
1
45º options available
Note: The maximum flue length must be reduced by the
following amounts for each bend used.
45º bend
90º bend
Greenstar CDi Classic
60/100mm flues
750mm
1,500mm
Greenstar CDi Classic
80/125mm flues
1,000mm
2,000mm
Greenstar CDi Compact and
Si Compact – all flue sizes
1,000mm
2,000mm
Greenstar i Junior
– all flue sizes
1,000mm
2,000mm
extension as required up to the maximum flue
lengths stated (Part No. 7 716 191 133).
51
Greenstar combi boiler range
vertical fluing options
The Greenstar combi 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
Minimum flue length
1,090mm
1,365mm
Maximum flue length (inc. adaptor)
29CDi Classic
9,400mm
18,500mm
34CDi Classic
8,000mm
16,000mm
38CDi Classic
7,500mm
16,000mm
42CDi Classic
7,500mm
16,000mm
7 716 191 172 2m flue extension
Greenstar CDi Classic series
7 716 191 133 Short flue extension (220mm*)
7 716 191 084 90º bend
7 716 191 085 45º bend
7 716 191 090 Flashing – flat roof
7 716 191 091 Flashing – pitched roof
Greenstar CDi Compact and Si Compact series
Minimum flue length
Maximum flue length
(inc. adaptor)
*Dimensions when fitted
125mm diameter
1,090mm
1,365mm
6,000mm
15,000mm
7 719 002 431
Vertical 1,365mm balanced
flue kit (inc. adaptor)
7 719 003 666 Extension flue kit (960mm*)
Greenstar i Junior series
7 719 003 664 90º bend
Minimum flue length
Maximum flue length
(inc. adaptor)
1,090mm
1,365mm
6,400mm
15,000mm
7 719 003 665 45º bend
7 716 191 090 Flashing – flat roof
7 716 191 091 Flashing – pitched roof
100mm dia. vertical balanced flue kit
1 x flue terminal assembly
*Dimensions when fitted
1 x weather sealing collar
1 x fire stop spacer
The following criteria should be noted when planning
1 x vertical adaptor
the installation:
Part No. 7 719 002 430
• Because the appliance operates at high efficiency, a
white plume of condensation will be emitted from the
terminal. Care must be taken when selecting the flue
125mm dia. vertical balanced flue kit
terminal position
1 x flue terminal assembly
1 x weather sealing collar
•
To achieve a maximum flue length, one of the extension
1 x fire stop spacer
flue kits will need to be cut so that the permitted
1 x vertical adaptor
maximum flue length is not exceeded
Part No. 7 719 002 431
• Vertical flue options 1-4 illustrate common flue
installations. Other configurations of the flue system are
possible up to, and not exceeding, the stated maximum
flue lengths.
52
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 29CDi Classic
Greenstar 29CDi Classic
100mm
1,090
1
100mm
125mm
1,365
1
125mm 18,500
Greenstar 34CDi Classic
9,400
1
up to 9
1
up to 18
1
up to 8
1
up to 16
1
up to 7
1
up to 16
1
up to 7
1
up to 16
Greenstar 34CDi Classic
100mm
1,090
1
100mm
125mm
1,365
1
125mm 16,000
Greenstar 38CDi Classic
8,000
Greenstar 38CDi Classic
100mm
1,090
1
100mm
125mm
1,365
1
125mm 16,000
Greenstar 42CDi Classic
7,500
Greenstar 42CDi Classic
100mm
1,090
1
100mm
125mm
1,365
1
125mm 16,000
7,500
Greenstar CDi Compact and Si Compact series
Greenstar CDi Compact and Si Compact series
100mm
1,090
1
100mm
125mm
1,365
1
125mm 15,000
Greenstar i Junior series
6,000
1
up to 5
1
up to 14
1
up to 6
1
up to 14
Greenstar i Junior series
100mm
1,090
1
100mm
125mm
1,365
1
125mm 15,000
Note: The short flue extension (100mm dia.)
may be used as an alternative to the standard
6,400
Note: The maximum flue length must be reduced by the
following amounts for each bend used.
45º bend
90º bend
Greenstar CDi Classic
60/100mm flues
750mm
1,500mm
Greenstar CDi Classic
80/125mm flues
1,000mm
2,000mm
Greenstar CDi Compact and
Si Compact – all flue sizes
1,000mm
2,000mm
Greenstar i Junior
– all flue sizes
1,000mm
2,000mm
extension as required up to the maximum flue
lengths stated (Part No. 7 716 191 133).
53
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 29CDi Classic
Greenstar 29CDi Classic
100mm
7,900
125mm 16,500
1
up to 7
2
100mm
1
up to 16
2
125mm 14,500
Greenstar 34CDi Classic
100mm
6,500
125mm 14,000
6,000
125mm 14,000
1
up to 6
2
100mm
1
up to 14
2
125mm 12,000
6,000
125mm 14,000
4,000
125mm 13,000
up to 6
2
100mm
1
up to 14
2
125mm 12,000
4,400
125mm 13,000
2
1
up to 14
2
1
up to 4
2
1
up to 11
2
4,500
1
up to 4
2
1
up to 11
2
1
up to 4
2
1
up to 11
2
Greenstar 42CDi Classic
1
up to 6
2
100mm
1
up to 14
2
125mm 12,000
4,500
Greenstar CDi Compact and Si Compact series
1
up to 3
1
100mm
1
up to 12
1
125mm 11,000
Greenstar i Junior series
100mm
5,000
1
Greenstar CDi Compact and Si Compact series
100mm
up to 6
Greenstar 38CDi Classic
Greenstar 42CDi Classic
100mm
1
Greenstar 34CDi Classic
Greenstar 38CDi Classic
100mm
6,400
2,000
1
up to 1
2
1
up to 10
2
1
up to 2
2
1
up to 10
2
Greenstar i Junior series
1
up to 4
2
100mm
1
up to 13
2
125mm 11,000
Note: The short flue extension (100mm dia.)
may be used as an alternative to the standard
2,400
Note: The maximum flue length must be reduced by the
following amounts for each bend used.
45º bend
90º bend
Greenstar CDi Classic
60/100mm flues
750mm
1,500mm
Greenstar CDi Classic
80/125mm flues
1,000mm
2,000mm
Greenstar CDi Compact and
Si Compact – all flue sizes
1,000mm
2,000mm
Greenstar i Junior
– all flue sizes
1,000mm
2,000mm
extension as required up to the maximum flue
lengths stated (Part No. 7 716 191 133).
54
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 46-47 for all concentric flue terminal positions
can be reduced to 150mm providing the flue exhaust outlet has
a 300mm clearance. Plume kits running horizontally must have
unless the flue position is specified on the figure above
a 10° fall back to the boiler for proper disposal of condensate.
“Plume terminal positions”
For details on specific lengths see relevant boiler Technical &
• Terminals must be positioned so as to avoid combustion
products entering the building
Specification information.
7.
• Support the flue at approximately one metre intervals and at a
300mm clearance.
8.
Key to illustration
This feature allows some basic plume re-direction options
on a standard telescopic horizontal flue terminal. 300mm
minimum clearances to a opening, e.g. window. However the
Internal/external corners. The air intake clearance can be
reduced to 150mm providing the flue exhaust outlet has a
change of direction, use suitable brackets and fittings.
1.
Using a Plume Management Kit, the air intake measurement
Clearances no less than 200mm from the lowest point of the
balcony or overhang.
9.
1,200mm from an opening in a car port on the same wall e.g.
door or window leading into the dwelling.
10. 600mm distance to a surface facing a terminal, unless it will
minimum clearances to an opening in the direction that the
cause a nuisance. BS 5440: Part 1 recommends that care is
plume management is facing, must be increased to 1,500mm.
taken when siting terminals in relation to surfaces facing
Where the flue is less than 150mm to a drainpipe, and plume
a terminal.
re-direction is used, the deflector should not be directed
towards the drainpipe.
2.
300mm adjacent to a boundary line.
3.
Plume Management Kit air intake can be reduced to 150mm
providing the flue exhaust outlet is no less than 300mm
adjacent to a boundary line.
4.
1,200mm between terminals facing each other.
5.
600mm distance to a boundary line, unless it will cause a
• Installations in car ports are not recommended
• The flue cannot be lower than 1,000mm from the top of a
light well due to the build up of combustion products
• Dimensions from a flue terminal to a fanned air inlet to
be determined.
nuisance. BS 5440:Part 1 recommends that care is taken when
siting terminal in relation to boundary lines.
55
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
All plume management sections must rise by at least
rotation for horizontal fluing, allowing the condensate to
173mm per metre (10º) from the terminal to ensure that
run back into the boiler for safe disposal. Do not attempt to
condensate flows back into the boiler.
force beyond the limit stops.
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
56
Re-directing flue discharge from a 60mm dia.
plume management outlet
For Greenstar CDi Classic boilers, the 100mm dia.
Condensfit II™ telescopic flue and plume management
internal flue length is immediately reduced by 2,000mm
system measuring
when the minimum plume management of 500mm is used.
Fig A
For the Greenstar CDi Compact and Si Compact boilers,
the 100mm dia. internal flue is immediately reduced by
1,000mm when the minimum plume management of 500mm
is used.
500mm
(min) (M)
L (max)
Greenstar i Junior boilers are able to use the maximum
100mm dia. internal flue length of 4,600mm regardless of
the amount of plume management selected.
External plume management bends still need to be allowed
for. For more information, see below.
Fig B
Furthermore, for both the Greenstar CDi Classic,
CDi Compact and Si Compact, the internal flue length must
be reduced by 700mm for every additional 1,000mm of
plume management, refer to the table below.
4,500mm
(max) (M)
60mm dia. plume management system
To ensure that the maximum total straight flue length along
the plume management route is not exceeded, the following
L (max)
should be added to dimension (M):
• 1,500mm for each extra 90º bend
• 750mm for each extra 45º bend
For plume management options with 60mm dia. extensions,
please refer to page 58.
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 49-54.
Effective straight flue lengths for telescopic flue with plume management
Boiler
Fig. A
Maximum straight flue length (L) with minimum
plume management length 500mm (M)
Fig. B
Maximum straight flue length (L) with maximum
plume management length 4,500mm (M)
29CDi Classic
5,900mm
3,100mm
34CDi Classic
5,000mm
2,200mm
38CDi Classic
4,000mm
1,200mm
42CDi Classic
4,000mm
1,200mm
CDi Compact and
Si Compact series
5,000mm
2,200mm
i Junior series
4,600mm
4,600mm
57
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, CDi Compact*, Si Compact
and i Junior 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, CDi Compact*, Si Compact
and i Junior series
Plume management system with extensions
60mm
4,500
1
up to 4
Plume management system with extensions and 45º bends
Components
Part No. 60mm
7 716 191 086
7 716 191 087
Maximum lengths (mm) & no. of components required
Greenstar CDi Classic, CDi Compact*, Si Compact
and i Junior series
60mm
4,500
1
up to 4
Plume management system with extensions and 45º bend
Components
Part No. 60mm
7 716 191 086
7 716 191 087
7 716 191 089
Maximum lengths (mm) & no. of components required
Greenstar CDi Classic, CDi Compact*, Si Compact
and i Junior 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, CDi Compact and Si Compact
Greenstar CDi Classic, CDi Compact*, Si Compact
and i Junior series
60mm
58
3,750
1
up to 4
you must refer to the table on page 57 to calculate your
1
horizontal flue lengths and plume management lengths.
Greenstar combi boiler range accessories
Greenstar combi boiler controls
MT10 mechanical timer
MT10RF mechanical
RF thermostat
Comfort plug-in twin
channel programmer
Comfort I RF wireless
room thermostat
and plug-in twin
channel programmer
Worcester Part No.
7 716 192 036
Worcester Part No.
7 716 192 037
Worcester Part No.
7 733 600 003
Worcester Part No.
7 733 600 001
Comfort II RF wireless
programmable room
thermostat and
plug-in RF receiver
FR10 intelligent
room thermostat^
FR110 programmable
room thermostat
FW100 weather
compensation controller
Worcester Part No.
7 733 600 002
Worcester Part No.
7 716 192 065
Worcester Part No.
7 716 192 066
Worcester Part No.
7 716 192 067
Wave
Worcester Part No.
7 716 192 072
^For use with MT10 or Comfort only.
59
Greenstar combi boiler range accessories
Condensfit II™ 60/100mm & 80/125mm
horizontal & vertical flue accessories
60
Standard telescopic
flue kit (100mm dia.)
Standard telescopic
horizontal flue kit
(125mm dia.)
Long telescopic flue kit
(100mm dia.)
Vertical BF kit
(100mm dia.)
Worcester Part No.
7 716 191 082
Worcester Part No.
7 719 003 702
Worcester Part No.
7 716 191 171
Worcester Part No.
7 719 002 430
Vertical BF kit
(125mm dia.)
1,000mm extension kit
(100mm dia.)
1,000mm extension
(125mm dia.)
2m flue extension
(100mm dia.)
Worcester Part No.
7 719 002 431
Worcester Part No.
7 716 191 083
Worcester Part No.
7 719 003 666
Worcester Part No.
7 716 191 172
Short flue extension
220mm (100mm dia.)
45º bend
(100mm dia.)
45º bend
(125mm dia.)
90º bend
(100mm dia.)
Worcester Part No.
7 716 191 133
Worcester Part No.
7 716 191 085
Worcester Part No.
7 719 003 665
Worcester Part No.
7 716 191 084
90º bend
(125mm dia.)
High level horizontal
flue adaptor (100mm dia.)
High level horizontal
flue adaptor (125mm dia.)
Support bracket kit
(100mm dia.)
Worcester Part No.
7 719 003 664
Worcester Part No.
7 719 002 432
Worcester Part No.
7 719 002 433
Worcester Part No.
7 716 191 092
Support bracket kit
(125mm dia.)
Support bracket kit
6 pack (100mm dia.)
Support bracket kit–
CDi Compact & Si Compact
only (100mm dia.)
Support bracket kit –
CDi Compact & Si Compact
only (125mm dia.)
Worcester Part No.
7 716 191 174
Worcester Part No.
7 716 191 173
Worcester Part No.
7 716 191 177
Worcester Part No.
7 716 191 179
Support bracket kit 6 pack –
CDi Compact & Si Compact
only (100mm dia.)
Worcester Part No.
7 716 191 178
**For CDi Classic only.
61
Greenstar combi boiler range accessories
Additional accessories
62
Filling link†
Worcester keyless
filling link*
Vertical pre-piping
assembly for CDi Classic
Vertical pre-piping
assembly for CDi Compact
& Si Compact
Worcester Part No.
7 716 192 281
Worcester Part No.
7 716 192 610
Worcester Part No.
7 716 192 607
Worcester Part No.
7 716 192 713
Vertical pre-piping
assembly for i Junior
Earth bonding strip†
Domestic hot water
combi pre-heat accessory
for CDi Compact
Below boiler pipe cover
Worcester Part No.
7 716 192 733
Worcester Part No.
7 716 192 686
Worcester Part No.
7 716 192 735
Worcester Part No.
7 716 192 608
Plume management kit
(60mm dia.)
Extension
(60mm dia., 1,000mm)
45º bend
(60mm dia.)
90º bend
(60mm dia.)
Worcester Part No.
7 716 191 086
Worcester Part No.
7 716 191 087
Worcester Part No.
7 716 191 089
Worcester Part No.
7 716 191 088
*Greenstar CDi Compact, Si Compact and i Junior accessory only – supplied as standard with Greenstar CDi Classic.
†Supplied as standard with Greenstar CDi Classic.
Worcester
CondenseSure siphon#
Flat roof flashing kit
(100mm & 125mm dia.)
Pitched roof flashing kit
(100mm & 125mm dia.)
Plume management
terminal guard round
(60mm dia.)
Worcester Part No.
7 716 192 746
Worcester Part No.
7 716 191 090
Worcester Part No.
7 716 191 091
Worcester Part No.
7 716 191 176
Greenstar System Filter
WB3 cleaning tool
WB5 cleaning tool
WB7 cleaning tool
Worcester Part No.
7 716 192 609
Worcester Part No.
7 716 192 312
Worcester Part No.
7 719 001 996
Worcester Part No.
7 746 901 479
Remote PRV kit**
Flue Gas Heat
Recovery Unit
Worcester Part No.
7 716 161 071
Worcester Part No.
7 733 600 047
#Greenstar CDi Compact, Si Compact and i Junior accessory only – built in to Greenstar CDi Classic. **For CDi Classic only.
63
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
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. It also
Durham
contains a heat pump room with a full range of Greenstore
ground source, Greensource air source and Greenstar
Belfast
Plus hybrid heat pumps with a courtyard for all external
components. There is a solar room with fully working
components from our entire Greenskies solar range and
Burnley
Wakefield
W
Dublin
Clay Cross
a pitched roof for practical training, as well as a large
Wrexham
commercial training room.
Worcester
West Thurrock and Clay Cross
Tredegar
West Thurrock
Further academies are located at West Thurrock in
Essex and Clay Cross in Derbyshire, both of which offer
Wiltshire
a comprehensive choice of courses.
Camborne
64
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 Junior 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 ISM1).
finding on ‘live and demo’ appliances.
Greenstar
Overview
CDi Classic
CDi Compact
& Si Compact
i Junior
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.
65
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.
• Greensource air to water heat pumps.
• Greensource split air to water 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.
66
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
67
Useful numbers
Customer Service
Sales
Engineer Appointments
Tel: 0330 123 9669
Email: [email protected]
[email protected]
or telephone 0330 123 9339
Spare Parts
Service Enquiries
Tel: 0330 123 9779
Email: [email protected]
[email protected]
or telephone 0330 123 9559
Technical Helpline (Pre & Post Sales)
Guarantee Registration
Tel: 0330 123 3366
To register your Worcester guarantee,
[email protected]
please visit our website
www.worcester-bosch.co.uk/registration
Renewables Technical Helpline
or telephone 0330 123 2552
Email: [email protected]
or telephone 0330 123 9229
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. 8 716 116 716 D 01/15
PAPERS MADE WITH
FREE
TM
100% CHLORINE
BLEACHED PULP
Worcester, Bosch Group,
Cotswold Way, Warndon,
Worcester, WR4 9SW
BBT3594
Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd.
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement