Bosch WORCESTER GREENSTAR 25CDi GC, WORCESTER GREENSTAR 37CDi, WORCESTER GREENSTAR 30CDi, WORCESTER GREENSTAR 25CDi, WORCESTER GREENSTAR 42CDi Instruction Manual
GREENSTAR CDi
WALL
HUNG
RSF GAS-FIRED
CONDENSING
COMBINATION BOILER
FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER
IS
THE APPLIANCE
NATURAL GAS OR
NATURAL
LIQUID PETROLEUM GAS:
GAS:
WORCESTER
WORCESTER GREENSTAR 30CDi
WORCESTER GREENSTAR 37CDi
WORCESTER GREENSTAR 42CDi
WORCESTER GREENSTAR 25CDi
WORCESTER GREENSTAR 30CDi
WORCESTER GREENSTAR 37CDi
WORCESTER GREENSTAR 42CDi
FOR USE WITH
L.P.G.
(Cat
II
2H3P TYPE C13 & C33)
GREENSTAR 25CDi
INSTRUCTION
INSTALLATION,
&SERVICING
COMMISSIONING
GC
NUMBER 47-311-92
GC
NUMBER 47-311-93
GC
NUMBER 47-406-08
GC
NUMBER 47-406-10
GC
NUMBER 47-311-96
GC
NUMBER 47-311-97
GC
NUMBER 47-406- 09
GC
NUMBER 47-406-11
MANUAL
(}enchmarf)
CONTACT INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS
WORCESTER
TECHNICAL: 08705 266241
SERVICE: 08457
SPARES: 01905 752571
LITERATURE: 01905 752556
TRAINING: 01905 752526
SALES: 01905 752640
WEBSITE:
WATER TREATMENT:
OX 01799 550811
FERN
www.fernox.com
SENTINEL
www.betzdearborn.com/sentinel
TERMINAL GUARD:
FLUE
TOWER FLUE COMPONENTS
VALE
RISE
TONBRIDGE
TN9 1TB
BOSCH:
256206
www.worcester-bosch.co.uk
0151
420
9595
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
THESE
MODEL(S)
USED WITH ANY OTHER MAKE
THE INSTRUCTIONS APPLY
STATUTORY OBLIGATION.
THIS APPLIANCE MUST BE INSTALLED
CORRECTLY
IF YOU ARE
DISTANCE LEARNING
BOSCH.
PLEASE LEAVE
BENCHMARK
(EIRE ONLY) WITH THE USER OR
ING.
ABBREVIATIONS USED
INSTRUCTIONS
STATED
COULD
IN
ANY DOUBT CONTACT WORCESTER
LOG
ARE
APPLICABLE
ON THE FRONT COVER OF THIS MANUAL ONLY AND MUST NOT BE
OR
MODEL
IN
THE UK ONLY AND MUST BE FOLLOWED EXCEPT FOR ANY
LEAD
TO
PROSECUTION.
AND TRAINING
THESE
INSTRUCTIONS,
BOOK OR A CERTIFICATE CONFIRMING COMPLIANCE WITH IS
AT
THE
IN
THIS MANUAL:
TO THE
OF APPLIANCE.
BY
A COMPETENT PERSON. FAILURE
COURSES
THE
GAS
WORCESTER
BOSCH
ARE AVAILABLE FROM
USER
GUIDE
METER AFTER INSTALLATION OR SERVIC-
BOSCH
TECHNICAL HELPLINE.
AND
THE
APPLIANCE
TO
INSTALL
WORCESTER
COMPLETED
813
0 Diameter
NG
LPG Liquid Petroleum Gas
CH
DHW
IP Ingress Protection
SEDBUK
Natural Gas
Central Heating
Domestic Hot Water
Seasonal Efficiency of Domestic Boilers
in
the United Kingdom
STORE THE APPLIANCE IN A DRY AREA
PRIOR
TO
INSTALLATION.
LIFTING AND CARRYING PRECAUTIONS:
• Lift only a manageable weight, or ask for
help.
When lifting the boiler, bend the knees,
•
and keep the back straight and feet apart.
• Do not lift and twist at the same time.
• Lift and carry the boiler close to the body
• Wear protective clothing and gloves to
protect from
any
sharp edges
SYMBOLS USED IN
Domestic hot water
Central heating
•
Cold water
Electricity supply
supply
Gas
THIS
main
MANUAL:
supply
Time
clock C H only
Programmer/timer
Room
thermostat
Wait time period
INSTALLATION &
SERVICING INSTRUCTIONS
INSTALLATION & SERVICING INSTRUCTIONS
FOR
WORCESTER BOSCH GREENSTAR
25CDI/30CDI/37CDI/42
6 720
613
700a
(2006/11)
co;
~ORCESTER
Bosch
Group
CONTENTS
SAFETY & REGULATIONS
SAFETY PRECAUTIONS
INSTALLATION REGULATIONS
APPLIANCE INFORMATION
GENERAL INFORMATION
TECHNICAL
LAYOUT & COMPONENTS
PRE-INSTALLATION
CLEANING PRIMARY SYSTEMS
MAINS SUPPLIES
WATER SYSTEMS & PIPEWORK
CONDENSATE PIPEWORK
BOILER LOCATION & CLEARANCES
PLUMBING MANIFOLD
FLUE TERMINAL POSITIONS
FLUE OPTIONS
DATA
4
4
5
6
7-8
9
10
11
12
13-14
15
16
17-20
INSTALLATION
UNPACKING WALL FRAME AND ANCILLARY ITEMS
PLATE
WALL MOUNTING
CHARGING
UNPACKING THE APPLIANCE
FITTING THE APPLIANCE I BOILER
FLUE INSTALLATION
CONDENSATE CONNECTION
ELECTRICAL
POSITION OF WIRED COMPONENTS
LINK (FILLING LOOP)
I FLUE OPENING
CONNECTIONS
COMMISSIONING
PRE-COMMISSIONING
FILLING THE SYSTEM
STARTING THE APPLIANCE
WATER TREATMENT
COMMISSIONING
FINISHING
COMMISSIONING
CHECKS
SERVICING & SPARES
INSPECTION AND SERVICE
REPLACEMENT OF
SETTING THE GAS/AIR
SHORT
PARTS
PARTS
RATIO
LIST
21
22
23
24
25
26-28
29
30
31
32
33
34
35
36
37
38-42
43-52
53
54
CONVERSION KITS
L.P.G.
CONVERSION
FAULT
FINDING & DIAGNOSIS
FAULT
FINDING
CENTRAL HEATING FUNCTION
PREHEAT AND
PROTECTION FUNCTION
DHW
~ORCESTER
Bosch
Group
FUNCTION
INSTALLATION & SERVICING
6
720
613
700a
(2006/11)
INSTRUCTIONS
FOR
WORCESTER
BOSCH
GREENSTAR
25CDV30CDV37CDci42CDI
55
56
57
58
59
CONTENTS
SAFETY PRECAUTIONS
IF YOU SMELL GAS:
X DON'T
X DON'T TURN
V'
V'
V'
V'
V'
(/Jenc!Jmorl()
A Benchmark Log
including
commissioned and serviced according to the manufacturer's instructions.
HEALTH &
COMBUSTIBLE
FITTING & MODIFICATIONS
SERVICING
SMOKE
DO PUT
DO
OPEN
DO KEEP
DO TURN
TELEPHONE
their CORGI registration number
IMPORTANT: The completed Benchmark Checklist will be required
warranty
ELECTRICAL
OUT
NAKED
DOORS
PEOPLE
OFF
THE
Book
work
OR
STRIKE
MATCHES
SWITCHES
FLAMES
AND
WINDOWS
AWAY
FROM
THE
CONTROL
NATIONAL
is provided by the manufacturer for the installer
and may be required by the local Building Control Inspector.
VALVE AT
GAS
ON OR
OFF
THE
AREA
AFFECTED
THE
METER
EMERGENCY
to
confirm that the boiler has been installed,
SERVICE
ON
0800111999
to
complete
in
SAFETY
The
appliance
construction process that contravene the
Hazardous
Do not store or use any combustible materials (paper, thinners, paints etc.) inside or
within the vicinity
Chemically
chlorine or fluorine
Fitting the appliance and any controls
competent
Regulations 1998.
Flue systems must
instructions.
associated components and systems could invalidate the warranty. The manufacturer
accepts
Advise
engineer (such as British
to
help maintain the economy, safety and reliability
IMPORTANT-
Benchmark section after each service.
contains
to
Health Regulations 1988).
AND
of
aggressive
engineer
Any
no liability arising from any such actions, excluding statutory rights.
the
user
no
asbestos
and
no
COSHH
CORROSIVE MATERIALS
the appliance.
substances,
compounds
in
accordance
not
be modified
misuse
to
have
Gas
or
the
such as
can corrode the appliance and invalidate any warranty.
to
the appliance may only be carried out
with
the
in
any way other than as described
unauthorised
system
or
CORGI
modifications
serviced
registered personnel) using approved spares,
substances
Regulations (Control
halogenated
Gas
annually
of
hydrocarbons
Safety
to
by a competent, qualified
the appliance.
have
been
(Installation
the
appliance,
The service engineer must complete the Service Record
the event
used
of
Substances
containing
and
in
the fitting
of
in
Use)
flue
in
any
the
by
the
or
INSTALLATION REGULATIONS
Gas
Safety
(Installation
All
gas
appliances
competent person
regulations. Failure to install appliances correctly
could lead
The
with,
Regulations,
Regulations,
(Consolidation), Building Regulations (Northern
Ireland), local
Document
Regulations
requirements.
British Standards:
The
including:
BS7074:1
water
BS6891 : Installation
pipework up to 28mm
BS5546
domestic purposes
EN:12828:
BS5440:1
ances of rated heating not exceeding
Flues
BS5440:2
ances of rated heating not exceeding
Air
BS7593
water central heating systems
a
BS
input up to
Where no specific instruction is given, reference
should be made to the relevant British Standard
codes
L.P.G.
An
a room or internal space below ground level unless
one side of the building
Timber framed buildings:
Where the boiler
building the guidelines laid down
1 and
Buildings" should be adhered to.
to prosecution.
appliance must be installed
and
comply
IE E Regulations,
Building
water
635
1989)
relevant British Standards should be followed,
:Code
supply
: Installation of gas hot water supplies for
Central heating for domestic premises
: Flues and ventilation for gas appli-
: Flues and ventilation for gas appli-
Supply
: Treatment
6798 : Installation of gas fired boilers of rated
70kW
(net)
of
Practice.
Installation:
appliance using
is
IGE
"Gas
& Use)
Regulations:
must
be
installed
in
accordance with the above
in
to, the
current:
Standards
by-laws, Health &
(The
Electricity
and
any
of practice for domestic and hot
of
low
pressure
(R1)
of
water
in
L.P.G.
must not be installed
is
open to the ground.
to be fitted to a timber framed
in
Installations
in
Timber Frame
accordance
Gas
Safety
Building
(Scotland)
Safety
at
Work
other
local
70kW
(net) :
70kW
(net) :
domestic
BS5440:
by
gas
hot
Part
a
in
SAFETY PRECAUTIONS
& INSTALLATION REGULATIONS
INSTALLATION & SERVICING INSTRUCTIONS
FOR
WORCESTER BOSCH GREENSTAR
Potable water:
components
domestic
WRAS.
co;
(2006/11)
compounds
water system must be
~ORCESTER
All seals, joints and
and solder) and
the secondary
approved by
CHwater:
Artificially softened water must not be used to
fill the central heating system.
25CDI/30CDI/37CDI/42
613
700a
6 720
(including flux
used as
Bosch
Group
part
of
GENERAL INFORMATION
Bottom
(22 mm
PACKAGE:
gas
pack
pack
panel
Plastic Pipe)
STANDARD
A-
Wall hung
er for central heating and domestic hot water
Wall mounting plate
B -
C
- Hanging bracket
D - Pre-plumbing manifold
E - Hardware
F-
Charging Link Assembly
G - Literature
H -
I
- Trap I Syphon Outlet Connection
c
/
fired condensing combi boil-
B
max.
760mm
H
0
0
D
69~
I
SPECIFICATIONS:
Pre-wired and pre-plumbed
Galvanised steel inner frame
Digital control system
Automatic ignition
Direct burner ignition
Built-in frost thermostat (boiler protection)
Built-in fault finding diagnostics
Modulating automatic gas valve
Combustion air fan with speed regulator
CH
temperature sensor & control
Pump
anti-seizure protection
gas
Flue
Condensate trap & syphon
DHW
Plate
Modulating circulating
temperature limiter
flow
sensor & temperature control
type
DHW
heat exchanger
pump
~ORCESTER
Bosch
Group
INSTALLATION & SERVICING
6
720
613
700a
(2006/11)
INSTRUCTIONS
FOR
WORCESTER
BOSCH
GREENSTAR
25CDV30CDV37CDc!42CD'
GENERAL INFORMATION
TECHNICAL
NATURAL GAS L.P.G.
DESCRIPTION UNITS 25CDi
Central Heating
Max.
rated heat input
Max.
rated heat output net
Max.
rated heat output net
Max.
rated heat output net
Min. rated heat output net
Min. rated heat output net
Min. rated heat output net
Min. rated heat input net
Max.
flow temperature
Max.
permissible operating pressure bar 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5
Available pump head at
flow
rate-
Gas
Natural Gas
Propane Gas (LPG)
Flue
Flue
Gas
Flue
Gas
C02
level at
C02
level at
NOx-
class
Condensate
Max.
condensation rate 2.3 2.7 2.7 2.7 2.3 2.7 2.7 2.7
pH
value, approx. 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8
Electrical
Electrical
Frequency
Max.
power consumption w 135 150 160 175 135 150 160 175
General Data
SEDBUK
Appliance protection rating IP X4D X4D X4D X4D X4D X4D X4D X4D
Appliance protection rating with mechanical or
Permissible
Nominal
Noise output
Total
boiler weight (lift weight)
Packaged boiler weight
SEDBUK
Max.
G20
Temp.
80/60°C,
Temp.
40/30°C,
max.
min.
rated heat output
power supply voltage
ambient temperatures
capacity of appliance I 3.75 3.75 3.75 3.75 3.75 3.75 3.75 3.75
level (at
40/30°C
50/30°C
80/60°C
40/30°C
50/30°C
80/60°C
21
•c
system temperature rise m 2 2 2 2 2 2 2 2
10
minutes
rated min. load
rated min. load
rated heat output
DHW
inlet pressure 3 bar)
from
lighting
RF
mech. timer fitted IP 20 20 20 20 20 20 20 20
kW
kW
kW
kW
kW
kW
kW
kW
•c
nom.
•c
70/58
•c
51/33
% 9.6 9.6 9.7 9.7
% 9.0 9.0
AC
..
.V
Hz
band A A A A A A A A
•c
dB(A)
kg
kg
% 90.3
30CDi
25.8 30.9 30.9 30.9 25.8 30.9 30.9 30.9
26.8 32.1
26.6 31.8 31.8 31.8 26.6 31.8 31.8 31.8
25.0
8.6 8.6 10.6 10.6 12.4 12.4 15.7 15.7
8.6 8.6 10.5 10.5 12.3 12.3 15.5 15.5
7.7 7.7
8.0 8.0 9.8 9.8
90
nom.
2.6 3.2 3.9 4.4
76/58
55/33
5 5 5 5 5 5 5 5
230
50 50
0-50 0-50 0-50 0-50 0-50 0-50 0-50 0-50
40 44
48.5 48.5 48.5 48.5 48.5 48.5 48.5 48.5
57 57 57 57 57 57 57 57
37CDi 42CDi 25CDi
32.1
30.0
90.1
30.0 30.0 25.0 30.0
9.4 9.4
90
nom.
90
83/58
60/35
9.1 9.1
230
230 230 230 230 230 230
50
45 47
90.1 90.1
32.1
nom.
90
87/58
66/35
50 50
DATA
30CDi
26.8
11,0 11.0
11.5 11.5
nom.
90
nom.
2.0
70/58 76/58
51/33
55/33
11.5 11.5 11.5 11.5
10.5 10.5 10.5 10.5
40 44
90.3
37CDi 42CDi
32.1 32.1 32.1
30.0 30.0
13.9 13.9
14.5 14.5
90
nom.
90
nom.
2.4 2.9 3.3
83/58
60/35
50
90.1 90.1 90.1
50
45 47
87/58
66/35
50
90
TECHNICAL
DATA
INSTALLATION & SERVICING INSTRUCTIONS
FOR
WORCESTER BOSCH GREENSTAR
25CDI/30CDI/37CDI/42
6 720
613
700a
(2006/11)
co;
~ORCESTER
Bosch
Group
LAYOUT &
The
diagram opposite shows the controls
servicing position
COMPONENTS
and
excludes the outer
in
case.
the
28
·---------
27
------------
---
---
---
---
---
................
-- 3
. 5
12
FLAME VIEWING
2 IGNITION ELECTRODE AND FLAME
SENSE ELECTRODE
WINDOW
3 HEAT EXCHANGER
4 OVERHEAT THERMOSTAT
5 ACCESS POINT FOR CLEANING HEAT
2
EXCHANGER
6
PLATE
TO
HEAT EXCHANGER
7 PUMP
PLATE
DHW
8 SYSTEM PRESSURE GAUGE
9 DRAIN POINT
10
MAINS
COLD
WATER
4
6
7
8
11
CH
RETURN
12
CHARGING
13
GAS INLET CONNECTION 22
COMPRESSION
14
COVER FOR EXTERNAL
CONNECTIONS
15
CONTROL PANEL
POSITION
16
ACCESS COVER FOR TRANSFORMER
&PCB
17
DHWOUT
18
CH
FLOW
19
TRAP I SYPHON OUTLET
TION (22
20 INLET PRESSURE TEST POINT
21
TRAP I SYPHON
22 GAS
23
DHW
24 AIR I GAS ADJUSTMENT
25 TESTING POINT FOR
FAN
26
27
PRIMARY
28 EXPANSION VESSEL
29 REMOVABLE TOP CASE PANEL FOR
SERVICING
LINK ASSEMBLY
mm
PLASTIC PIPE)
VALVE
TEMPERATURE
SENSOR
IN
IN
SERVICE
SENSOR
FAN
mm
WIRING
CONNEC·
SCREW
PRESSURE
16 ·-
---
........
14
~ORCESTER
Bosch
Group
INSTALLATION & SERVICING
6
720
613
700a
(2006/11)
INSTRUCTIONS
FOR
WORCESTER
BOSCH
GREENSTAR
25CDV30CDV37CDci42CDI
LAYOUT &
COMPONENTS
LAYOUT & COMPONENTS
PLATE
TO
PLATE
DHW
6
EXCHANGER
DRAIN POINT
9
32 SYSTEM PUMP
36
FLOW TURBINE
37 UNUSED PORT
38
AUTO AIR VENT
39 FLOW CONNECTION FROM BOILER
HEAT EXCHANGER
DHW
40
41
SENSOR
CH FLOW CONNECTION
VALVE
42
DHW
OUT CONNECTION
43 COLD WATER
IN
44 CH RETURN CONNECTION
VALVE
VICE
45 DIVERTER
VALVE
46 PRESSURE RELIEF
47
COMPACT HYDRAULIC MOUNTING
SCREW
I
I
I
I
I
I
I
I
I
I
I
',,1
I
I 45
41
I
I
42
I
I
••
•••
•'
•'
I
•'
1'-,
I
I
I
',,
I
I
---•---47
I
I
I
I
I
I
I
''46
I
(2)
TO
HEAT
TO
CONNECTION
VALVE
BOILER
SERVICE
TO
SER-
'
'
',
' I
'I
;
I
I
t
LAYOUT & COMPONENTS
6720611927-10.10
INSTALLATION & SERVICING INSTRUCTIONS
FOR
WORCESTER BOSCH GREENSTAR
CH TEMPERATURE CONTROL
48
MAINS
49
ON/OFF
TIC LIGHT
DHW
50
51
TEMPERATURE CONTROL
CENTRAL HEATING
INDICATOR/DIAGNOS-
(BLUE)
BOOST
BUTTON
52 SERVICE BUTTON
53 BURNER ON INDICATOR LIGHT
(GREEN)
MASTER SWITCH
54
ON/OFF
55 HOLIDAY BUTTON
56 ECO BUTTON
57
FAULT
RESET BUTTON
58 SYSTEM PRESSURE GAUGE
59
POSITION FOR OPTIONAL
TEXT
DISPLAY WITH INTELLIGENT FUNC-
TIONALITY OR TIMER
60 DISPLAY
25CDI/30CDI/37CDI/42
6 720
613
700a
co;
(2006/11)
~ORCESTER
Bosch
Group
IMPORTANT:
requirements
CAUTION: ISOLATE
OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.
All
met
the
following
before
THE
MAINS SUPPLIES BEFORE STARTING ANY WORK AND
starting
Pre-Installation
boiler
or
flue
1
2
sections
installation.
4
5
must
be
read
and
CLEANING PRIMARY SYSTEMS
the
IMPORTANT: Debris from
damage
Failure to
the
ance will invalidate the appliance warranty.
BEFORE CLEANING THE SYSTEM:
ENSURE
IN
KEEP
CIRCULATING PUMP
OR USE
TO
BEFORE INSTALLING A NEW BOILER.
CLEANING THE PRIMARY SYSTEM:
2 Open
3
~
4
5
the
boiler and reduce efficiency.
comply
use
of
THE
GOOD
WORKING ORDER
THE EXISTING BOILER/
A POWER FLUSHING MACHINE
AID
THE
Fill
the
system with cold water
for
leaks.
all
drain cocks
Close drain cocks
agent at
flushing
the
system condition
the
manufacturer's instructions.
Circulate
boiler
is
fired
Run
the
boiler/system at
temperature
of
the
flushing agent.
Drain
and
remove
the flushing agent and debris.
with
water treatment with the appli-
SYSTEM
WHERE
CLEANSING
and
and
the
correct strength for
in
the
flushing agent before
up.
as
directed
thoroughly flush
system can
the
guidelines
AND PIPEWORK
POSSIBLE
PROCEDURE
and
check
drain
the
system.
add a suitable
accordance with
the
normal
operating
by
the
manufacturer
the
system to
for
IS
3
@
~
KEY
Valve
Flushing
Agent
~ORCESTER
Bosch Group
INSTALLATION & SERVICING
6
720
613
700a
(2006/11)
INSTRUCTIONS
FOR
WORCESTER
BOSCH
GREENSTAR
25CDV30CDV37CDci42CD•
CLEANING PRIMARY SYSTEMS
f
MAINS SUPPLIES
ELECTRIC SUPPLY:
230V-
Supply:
(See Technical Data for IP ratings.)
Cable: PVC insulated
(24 x 0.2mm) temperature rated to
External
The
appliance must
• All pipes to the boiler must be cross-bonded.
Wiring must comply with lEE wiring regula-
tions and
apply to fixed wiring to a stationary appliance.
GAS SUPPLY:
Boilers using
governed meter.
LPG boilers must be connected to a
regulator.
Installation
ply
to the boiler must be
BS6891.
Under no circumstances should the size
the gas supply pipe be less than that of the
appliance inlet connection.
The
meter or regulator and pipework to the
meter must be checked,
gas
supplier, to ensure it
order and can meet the gas
sure requirements
from any other
does not
meter to the
For
olive
gas pipes with
50Hz
0.
75mm2
90°C.
3A
fuse to BS1362.
be
earthed.
any
local regulations which
NG
must
be
connected to a
and connection of the gas sup-
in
accordance with
preferably
is
in
in
addition to the demand
appliance being served. This
include the pipework from the
boiler.
connections we recommend using
minimum
0.9
mm
may
by
the
good working
flow and pres-
wall thickness.
of
MAINS WATER EXPANSION VESSEL:
A-
Mini expansion vessel, part
B - Mains water
C-
Non-return valve
D-
Boiler
inlet pipe
B
\
\
c
\
\
\
\
No.7
716
\
\
~
'
,.."'
102 105
--------•
D
=
-
SUPPLY:
WATER
Water Mains Pressure:
Minimum mains water pressure
2.5 bar (see
maximum performance.
Maximum mains fed water pressure
If necessary, fit a pressure reducing valve.
IMPORTANT:
vention
ed
with
water
up
which
other
household
Where the mains water supply has a non-
return, back flow prevention valve fitted, a
mini expansion
nected to the mains water inlet pipe (B)
between the non-return
boiler (D) as shown opposite.
Use in hard
Normally there is no need for water
to
prevent
temperature
limited by
In areas where
exceeds
be
given
device. In such circumstances,
the
local water authority should
technical data
Non-return,
devices
supply
200 ppm, consideration may need
(including
water
meters)
can
cause a pressure
could
damage
appliances.
(A)
vessel
water
areas:
scale
formation
of
the
DHW
the
electronic control circuit.
the
temporary water hardness
to
the
fitting
of a scale
1.5
on
page
back
those
fitted
to
the
the
boiler
should be con-
valve (C) and the
as
the
heat
exchanger
the
be
up to
6)
for
10
bar.
flow
pre-
associat-
mains
build
and
treatment
maximum
is
to
prevention
advice
of
sought.
MAINS SUPPLIES
INSTALLATION & SERVICING INSTRUCTIONS
FOR
WORCESTER BOSCH GREENSTAR
25CDI/30CDI/37CDI/42
6 720
613
700a
(2006/11)
co;
~ORCESTER
Bosch
Group
WATER SYSTEMS &
PIPEWORK
PLASTIC
• Any plastic
CONNECTIONS/VALVES:
• All system connections, taps and mixing
• All other valves should conform
• An automatic bypass may be required,
• A drain
• An air vent is required at the highest point
PIPEWORK:
pipework
barrier with
copper
Plastic
must be correctly controlled with a thermo-
static blending valve limiting the temperature
of
the circuits to approx.
The
valve
from corrosion).
valves must be capable
sure up
Radiator
BS2767:10.
On
ing systems where a radiator previously did
not exist, each radiator
TRV, except the one fitted
a
room/area as the room thermostat.
On boiler only replacement jobs, it is recom-
mended, (but not mandatory,)
each radiator.
for energy conservation purposes,
mend
each radiator.
(downstream
tain the minimum flow-rate through the appli-
ance.
on the system.
on the system.
600
or steel pipe
pipework
pipework
must be
to
3 bar.
valves should conform
new
installations, or extensions to exist-
to
the customer that a TRV is fitted
cock
must have a polymeric
mm
(minimum) length
connected
used for underfloor heating
50°C.
from the boiler
in
copper
It is, however, a requirement,
of
the pump),
is required at the lowest point
to
or steel (protected
of
sustaining a pres-
should be fitted with
in
in
of
to
the boiler.
the blending
to
to
BS
1010.
the same
to
fit a TRV on
to
recom-
order to main-
to
TYPICAL
A-
B-
C-
p-
R-
SEALED
Appliance expansion vessel
- central heating
Extra expansion
- central heating return
cock
Drain
Pressure relief discharge
Radiators
SYSTEM
vessel
,,--,
, '
, '
I A I
\.
...
__
...
SHOWERS/BIDETS
If a shower head can be immersed
or
comes
closer than
edge
of
a bath
an
anti-siphon device must be fitted
then
the shower hose.
Bidets with
can be used (with the
water authority) and must be the over rim
flushing type with shrouded outlets to pre-
~ ~ ~~
~ ~
[
,l
c
6
720
611
927-02.10
vent the fitting
SEALED
The
the built-in filling link (see page 23).
Where
100
heating temperature
sel
to
the appliance
return.
Pressurize the extra expansion vessel (B) to
the same figure as the expansion
built
Do
direct
PRIMARY SYSTEM:
CH
sealed system must be filled using
the system volume is more than
litres or exceeds 2.65 bar at maximum
(B) must be fitted as close as possible
into the appliance.
not
use
galvanised
25
mm from the
or
shower tray spill over level
hot & cold mains water
approval
of
hand held sprays.
an
extra expansion ves-
in
the central heating
pipes
in
of
the local
vessel
or
radiators.
water
top
to
~ORCESTER
Bosch
Group
INSTALLATION & SERVICING
6
720
613
700a
(2006/11)
INSTRUCTIONS
FOR
WORCESTER
BOSCH
GREENSTAR
25CDV30CDV37CDci42CD•
WATER
SYSTEMS
& PIPEWORK
3
5
r1
----------
~1
lnvectlb
G
-
..............
25mm
m1n.
-- H
400mm
m1n.
..
r
: /
~1 ~·~---f--
m
"·------K
-------J
'•
CONDENSATE PIPEWORK
CONDENSATE PIPEWORK:
The
condensate pipe must be a minimum of
22
mm
0 plastic pipe.
The condensate
50
mm
per
take
should
The
pipework must follow
shown opposite into
trap
(min.
machine)
(E)
min.
450
ley
(D)
4
'I
'I
'I
'I
'I/~
'I
D
A+
~
~
'I
'I
:
~'
sink/washing
Internal
drain
2 Internal
3
4 External
5 External
A - Condensate from boiler
B-
C-
DE - Internal soil and vent stack
F
- Serviceable waste trap (75
G-
H - Ground level
waste
Soil/vent
point
Sink
22
Gulley
300
tube
stack
drainage
condensate
mm
0 plastic condensate pipe
mm
x 100
J - Drainage holes
tube
(12
mm
0 at 25
facing away from
K - Limestone chippings
"~\,
\
\
\
L-
M,O-
N-
Outside wall
Drain pipe
External drain
machine
drainage
system
absorption
mm
0 sealed plastic
50
mm
from base of
mm
building
system
mm
min)
centres)
IMPORTANT:
ages
PRESSURE RELIEF PIPEWORK
IMPORTANT:
safety
may
through
Care
let
obstruction
entrance
could
below ground but above
Wherever possible the condensate dis-
charge pipe work should
minated internally. Should this not be possi-
ble,
and the only available route is external,
the following conditions should be
observed:
Pipe work length should be kept to a
minimum and the route as
possible.
Where pipe work could be subjected to
extreme
proof
Alternatively the condensate pipework
could
without the requirement to insulate.
in
the
device
discharge
the
should
pipe
so
or
cause
The
pressure relief drain pipe (M,O) from
boiler should be at least
the
copper pipe and
electrics or other hazard, preferably to
any
an
external drain or soakaway.
Pipe (M) should
bend, near the outlet to face the external
(as shown) to help prevent freezing.
wall
Use waterproof pipe
positions and for
pipework
metre
towards
the
shortest
75
mm)
such
and
discharge direct into a vent stack
mm
above pipe
cold or wind chill, a weather
insulation should be used.
be
increased to a minimum
Ensure
pipe
run.
pressure
The
for
the
boiling
relief
valve
be
taken
that
it
does
or
discharge
other
public
a hazard.
run
be
external pipework.
must
fall
the
outlet
practicable route.
one
of
the
an
internal
serviceable
as
a sink/washing
invert
or into a
the
water
be
routed and ter-
vertical as
there
are
no
relief
valve is a
boiler
and
if
activated
water
or
steam
drain
pipe.
when
siting
the
not
cause
an
above
a window,
access
where
15
mm
downwards away from
finished with a partial
insulation
in
exposed
at
least
and
options
level.
32
block-
out-
it
diameter
gul-
mm
CONDENSATE PIPEWORK
INSTALLATION & SERVICING INSTRUCTIONS
FOR
WORCESTER BOSCH GREENSTAR
25CDI/30CDI/37CDI/42
6 720
613
700a
(2006/11)
co;
~ORCESTER
Bosch
Group
SERVICING
Using 1
-1112
Using 1 25 mm
-1152
CLEARANCES
00
mm
mm
mm flue kit
flue kit
~-
'20mm
'
to
removable door
600mm
'
front
for
'
clearance
service
-
+30mn
above elbow
'
200
mm '
5mm
BOILER LOCATION &
CLEARANCES
This boiler is only suitable for installing internally
within a
fixed, rigid
same size as the
ing the
property
boiler weight.
COMPARTMENTS:
Follow
the
BS5440
Minimum
access
• An
and maintain the
equipment.
• If fitting the boiler into
use a non-combustible perforated material
(maximum hole sizes
the boiler from the airing space.
BOILER CLEARANCES:
The
diagram
space required
at a suitable location
non-combustible surface at least the
boiler
and
capable
requirements
Part 2 and note:
clearances must
door
is required to install, service
boiler and any ancillary
opposite
to
install and service the boiler.
an
of
shows
of
be
airing
13mm)
onto
of
support-
BS6798
maintained
cupboard
to
separate
the
m1n1mu
and
a
VENTILATION
This is a room sealed appliance and
require any air for
property.
board
appliance
ment must be separated from the boiler
by a
described
Notwithstanding
and
openings
because
casing, if the clearances
Do
fitted on the outside wall
or
If the
or a compartment
perforated
BS
5440
to
of
not
operate the appliance if the flue terminal
damaged.
combustion
appliance
after installation, then the
non-combustible
in
BS
6798.
the requirements
there is
be
provided
the
low
is
is
no
need for ventilation
in
heat loss from the appliance
shown
or
roof is
does
from inside the
fitted
into a cup-
built
around
compart-
partition
of
BS
the
compartment
are maintained.
obstructed
not
the
space
as
6798
~ORCESTER
Bosch
Group
INSTALLATION & SERVICING
6
720
613
700a
(2006/11)
INSTRUCTIONS
FOR
WORCESTER
BOSCH
GREENSTAR
25CDV30CDV37CDci42CD•
BOILER LOCATION & CLEARANCES
®
@
CD
aoomm
CD
@
®
750mm
2250mm
BOILER LOCATION &
CLEARANCES
BATHROOMS:
The
boiler can be installed
mechanical or
play with room thermostat (IP 20 only)
boiler can only be installed
the
A Non mechanical timer can be installed in
zone
2.
See lEE wiring regulations.
(See Technical Data for
RF
in
zones 2 or
mechanical timer or text dis-
in
IP
ratings.}
zone
3.
If a
is
fitted
3.
600mm
radius
aoomm
@
®
6720611927-13.10
750mm
2250mm
IMPORTANT:
control using 230 V mains electricity
not
be
using
the
Electrical switches, fused
outlets
room.
For
further information about bathroom installa-
lions please consult Operational Procedures
20, Electricity.
Part
able
bath
must
any
to
or
not
switch
be
touched
shower.
be
situated
or
appliance
by a person
spur
and
in
the
must
socket
bath-
BOILER LOCATION & CLEARANCES
INSTALLATION & SERVICING INSTRUCTIONS
FOR
WORCESTER BOSCH GREENSTAR
25CDI/30CDI/37CDI/42
6 720
613
700a
(2006/11)
co;
~ORCESTER
Bosch
Group
c;J!:_
DHW
Out (alternative from above appliance)
15
mm
PLUMBING MANIFOLD
CH
Flow
•
(alternative
from above
appliance)
mm
22
l U Gas Supply (alternative from above appliance) 22
:~
c..~
H
c:;J!:_
~-
1
I
I
I
I
I
I
Mains Water
•
In
(alternative from above appliance)
CH
Return (alternative from above appliance) 22
mm
15
mm
mm
CONNECTIONS:
Heating System: 22
DHW:
Gas: 22
Use the
pack.
PREPLUMBING
With
pipework can be installed to the valves
manifold.
The
being
assembly
The
and
be
RUNNING PIPES
If
appliance ensure that the pipes pass close to
the
and within the pipe guide.
fittings
the
plumbing
system can be filled (without the boiler
connected)
(see page 23).
valves can be closed enabling the
CH
systems to be tested.
installed
the boiler pipes are to be
wall
at
as
15
supplied
later date.
shown
mm
compression fittings
mm
compression fittings
mm
compression fittings
in
the Hardware
manifold
using the
BEHIND
in
the diagram opposite,
installed,
charging
The
boiler can
THE BOILER
run
behind the
on
link
DHW
the
CH
flow
mm
22
DHW
Out
15
mm
Mains Gas Supply 22
Mains Water
~ORCESTER
Bosch
Group
mm
In
15
mm
INSTALLATION & SERVICING
6
720
613
700a
(2006/11)
INSTRUCTIONS
FOR
WORCESTER
•
BOSCH
CH
return 22
GREENSTAR
mm
25CDV30CDV37CDci42CDI
PLUMBING MANIFOLD
FLUE TERMINAL POSITIONS
Minimum
fanned
DRWG.
REF:
A'
B'
C'
D
E
F2
dimensions
draught:
TERMINAL
Directly
Above
Horizontally
Below
Below
Below
of
flue
terminal
POSITION
below
an
opening, air brick, opening
an
opening, air brick, opening window, etc.
to
an
opening, air brick, opening window, etc.
gutters, soil pipes or drain pipes 75mm
eaves
balconies or car
positions
port
roof (lowest point)
for
balanced
windows,
room
etc.
sealed
flues
DISTANCE
300mm
300mm
300mm
200mm
200mm
G From a vertical drain pipe or soil pipe 150mm
an
H From
I Above ground, roof or balcony
internal or external corner
J From a surface facing the terminal
K From a terminal facing the terminal
L2
From
an
opening
in
the car port
(e.g.
door, window) into the dwelling
M Vertically from a terminal on the same wall
N Horizontally from a terminal on the same wall
300mm
300mm
600mm
1200mm
1200mm
1500mm
300mm
0 From a non combustible vertical structure on the roof
p
Above intersection with roof
0 Adjacent to
R
Below
windows
windows
or openings on pitched and flat roofs
or openings on pitched roofs
*
*
600mm
2000mm
with
The flue must be fitted and terminated
accordance with the recommendations
BS5440
The flue must not cause
Discharge and any noise from the
must not cause a nuisance.
Flue gases have a tendency
certain weather conditions a white plume
condensation will be discharged from the
flue outlet.
for
nate position should be found.
The air
the boiler must not be closer than
any
Detailed
combustible materials are given
BS
• A protective terminal guard must be fitted if
the terminal is 2m or less above a surface to
which
The guard must be spaced
mum
the
Information (inside front cover).
: Part
1.
an
obstruction.
to
Where
this could be a nuisance,
example, near security lighting,
inlet/outlet
combustible material.
recommendations on protection
5440:1
people have access.
50
mm) around the flue and fixed to
wall with plated screws. See
duct
and the terminal
equally (mini-
in
of
flue outlet
plume and
an
alter-
25mm
in
Contact
of
in
of
to
of
In
addition, the terminal should not
in
the building
window
frame.
fabric
formed
2 Not recommended.
See
instructions supplied with vertical
*
be
for
the purpose
nearer than 150mm (fanned draught}
of
accommodating a built-in element
flue
kits.
to
an
opening
such
as a
FLUE TERMINAL POSITIONS
INSTALLATION & SERVICING INSTRUCTIONS
FOR
WORCESTER BOSCH GREENSTAR
25CDI/30CDI/37CDI/42
6 720
613
700a
(2006/11)
co;
~ORCESTER
Bosch
Group
STANDARD FLUE HORIZONTAL
0100
MAX 686
MIN 250
0125
MAX 1070
MIN 250
* Requires cutting
MAXIMUM FLUE HORIZONTAL
0100-
Ax1+Bx10
0125-
Ax
MAXIMUM FLUE VERTICAL START+ 1 BEND
mm
mm
mm
mm
10000
23000
1 + B x 23
Ax
Ax
Ax
Ax
mm
mm
1
1*
1
1*
--------~
MAXIMUM FLUE VERTICAL
START+
F
B
bi
L__
2 BENDS
0'----,
___
1 ' lu:z?' A
___..
co
0100-8000
A X 1 + c X 2 + B X
+
Fx
0125-
A X 1 + c X 2 + B X 22
+
Fx
MAXIMUM FLUE VERTICAL
START+ 3 BENDS
F
B
c 0
0100-6000
Ax1+Cx3
+Bxg+Fx1
0125-
Ax1+Cx3
+ B X
MAXIMUM FLUE VERTICAL
WITH 2 X 45°
1
21000
1
1gooo
21
mm
10
mm
mm
mm
+ F X 1
BENDS
FLUE
OPTIONS 25CDi
The
diagrams (opposite) show the components used and the
each configuration of
125
mm
0 flues.
• Shaded flue
dard 100
• Only
in
•
The
inside or outside of the
Fixing kits are supplied with the flue exten-
sion kits.
Horizontal125
and 125
separate instructions. Contact your
or Worcester Bosch.
mm
straight flue sections can be reduced
length and cut.
flue terminal end can be fitted from the
mm
A c D
QH
B
A-
Standard horizontal flue
B - Straight
C-
D E - Vertical terminal (vertical adaptor supplied
F-
flue extension
Flue
bend,
Flue
bends, 45°
with terminal)
Vertical adaptor (used with horizontal
terminal)
maximum
components indicate the stan-
0 horizontal flue.
mm
0 and Vertical100
0 flue kits
lb--l
i
goo
flue length for
mm
and
100
building.
are
available with
0
ED
(100
mm
supplier
v
F
fd_
0 shown)
mm
0 c
0100-
10000
mm
Ax1+Cx1+Bx11
+
Fx
1
0125-
23000
mm
A X 1 + c X 1 + B X 23
Fx
1
+
MAXIMUM FLUE
HORIZONTAL+
0 c
0100-
8000
mm
Ax1 + Bxg+Cx1
0125-
21000
mm
A X 1 + B X
21
+ c X 1
1 BEND
E
B
D V
0100-
g500
mm
(including terminal)
Bx10+Dx2+Ex1
0125-
21000
mm
(including terminal)
21
+ D X 2 + E X 1
B X
VERTICAL FLUE WITH
2 X
goo
BENDS
E
B
c
0
0100-
7500
mm
(including terminal)
Bxg+
Cx2
+Ex1
0125-
1gooo
mm
(including terminal)
Bx20+
Cx2
+Ex1
Calculating
Measure the total flue length required, noting
that the maximum straight flue length including
the terminal is:
Horizontal 60/100
Horizontal80/125
Vertical60/100
Vertical 80/125
Then reduce the total straight flue length for
each extra
2000
1000
Flue
Horizontal & Vertical 60/100
Horizontal & Vertical 80/125
Flue
Horizontal 60/100
Horizontal80/125
Vertical60/100
Vertical 80/125
6
720
611
927-08.1 0
the flue length:
mm
0:
10000
mm
0:
23000
mm
0:
11500
mm
mm
0:
23000
mm
flue bend (excluding the turret) by:
mm
for
goo
mm
for 45°
extension total lengths:
mm
mm
terminal total lengths:
mm
0:
800
mm
mm
0:
1200
mm
0:
1140
mm
mm
0:
1365
mm
mm
mm
0:
0:
mm
g5o
1000
mm
mm
~ORCESTER
Bosch
Group
INSTALLATION & SERVICING
6
720
613
700a
(2006/11)
INSTRUCTIONS
FOR
WORCESTER
BOSCH
GREENSTAR
25CDV30CDV37CDc!42CD•
FLUE
OPTIONS 25CDi
STANDARD FLUE HORIZONTAL
mm
mm
mm
mm
7goo
18500
18
Ax
Ax
Ax
mm
mm
PA
Ax
1
1*
1
1*
Q H I
0100
MAX
686
MIN 250
0125
MAX 1070
MIN 250
* Requires cutting
MAXIMUM FLUE HORIZONTAL
0100-
Ax1+Bx8
0125A X 1 + B X
MAXIMUM FLUE VERTICAL START+ 1 BEND
_____
,.,
MAXIMUM FLUE VERTICAL
.bi
~---~
2 BENDS
d II
START+
F
B
co
0100-
5goo
Ax1+Cx2+
+
Fx
1
0125-
16500
A X 1 + c X 2 + B X
+
Fx
1
MAXIMUM FLUE VERTICAL
START+ 3 BENDS
F
B
c 0
0100-
3goo
Ax1+Cx3
+Bx7+Fx1
0125-
14500
Ax1+Cx3
+Bx17+Fx1
MAXIMUM FLUE VERTICAL
WITH 2 X 45° BENDS
I
mm
mm
mm
mm
iPA
Bx8
18
FLUE
OPTIONS 30CDi
The
diagrams (opposite) show the components used and the maximum flue length for
each configuration of
mm
0 flues.
125
• Shaded flue
dard 100
Only
in
length and cut.
•
The
inside or outside of the building.
Fixing
sion kits.
Horizontal 125
and 125
separate instructions. Contact your
or Worcester Bosch.
A c D
components indicate the stan-
mm
straight flue sections can be reduced
flue terminal end can
kits
are
mm
_QH
B
A - Standard horizontal flue
B - Straight flue extension
C -
Flue
bend,
goo
D -
Flue
bends, 45°
E - Vertical terminal (vertical adaptor supplied
with terminal)
F-
Vertical adaptor (used with horizontal
terminal)
100
mm
and
0 horizontal flue.
be
fitted from the
supplied with the flue exten-
mm
0 and Vertical 100
0 flue kits
IP
are
available with
0
EB
(1
00
mm
supplier
v
F
Q
0 shown)
mm
0 c
0100-
7goo
mm
Ax1+Cx1+Bxg
+
Fx
1
0125-
18500
mm
Ax1+Cx1+Bx1g
+
Fx
1
MAXIMUM FLUE
bJ
Oc_
_
_JL_
_uc
iP A
0 c
0100-
5goo
mm
Ax1 + Bx7+Cx1
0125-
16500
mm
Ax1 + Bx17+Cx1
HORIZONTAL+
B
1 BEND
E
B
B
D V
0100-
7400
mm
(including terminal)
Bx8+Dx2+Ex1
0125-
16500
mm
(including terminal)
Bx17+
VERTICAL FLUE WITH
2 X
E
B
goo
BENDS
B
Dx2
+Ex1
c 0
0100-5400
(including terminal)
Bx7+
0125(including terminal)
Bx16+
Cx2
14500
Cx2
mm
+Ex1
mm
+Ex1
Calculating
Measure the total flue length required, noting
that the
the terminal is:
Horizontal 60/100
Horizontal 80/125
Vertical 60/100
Vertical 80/125
Then reduce the total straight flue length for
each extra flue bend (excluding the turret)
2000
1000
Flue
Horizontal
Horizontal & Vertical 80/125
Flue
Horizontal 60/100
Horizontal 80/125
Vertical 60/100
Vertical 80/125
6
720
611
927-08.1 0
the flue length:
maximum
mm
mm
extension total lengths:
terminal total lengths:
straight flue length including
mm
0:
7goo
mm
0:
18500
mm
0:
g400
mm
0:
18500
for
goo
for 45°
& Vertical 60/100
mm
0:
800
mm
0:
1200
mm
0:
1140
mm
0:
1365
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
0:
0:
g5o
1000
by:
mm
mm
FLUE
OPTIONS 30CDi
INSTALLATION & SERVICING INSTRUCTIONS
FOR
WORCESTER BOSCH GREENSTAR
25CDI/30CDI/37CDI/42
6 720
613
700a
(2006/11)
co;
~ORCESTER
Bosch
Group
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