Bosch Worcester Greenstar CDi Conventional, Worcester Greenstar 30CDi Conventional, Worcester Greenstar 40CDi Conventional Instruction Manual
GREENSTAR CDi CONVENTIONAL
WALL HUNG RSF GAS-FIRED CONDENSING REGULAR BOILER
FOR OPEN VENTED
DOMESTIC HOT
AND
WATER
SEALED CENTRAL HEATING SYSTEMS
AND
INDIRECT
THE APPLIANCE
NATURAL GAS
NATURAL
LIQUID PETROLEUM
INSTRUCTION
IS
FOR USE WITH
OR
L.P.G.
(Cat
II
2H3P TYPE C13 & C33)
GAS:
WORCESTER
WORCESTER GREENSTAR 40CDi Conventional
GAS:
WORCESTER GREENSTAR 30CDi Conventional
WORCESTER GREENSTAR 40CDi Conventional
GREENSTAR 30CDi Conventional
GC
NUMBER
GC
NUMBER
GC
NUMBER
GC
NUMBER
MANUAL
41-311-71
41-311-72
41-311-73
41-311-74
INSTALLATION, COMMISSIONING
&SERVICING
(}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
VALE
RISE
TONBRIDGE
TN9 1TB
BOSCH:
256206
www.worcester-bosch.co.uk
0151
420
9595
COMPONENTS
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
THESE
MODEL(S)
USED WITH ANY OTHER MAKE
THE INSTRUCTIONS APPLY
STATUTORY OBLIGATION.
THIS APPLIANCE MUST
CORRECTLY
IF YOU
DISTANCE LEARNING
BOSCH.
PLEASE LEAVE
BENCHMARK
(EIRE ONLY) WITH THE USER OR
INSTRUCTIONS
STATED
COULD
ARE
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
BE INSTALLED
LEAD
TO
PROSECUTION.
AND TRAINING
THESE
INSTRUCTIONS,
BOOK OR A CERTIFICATE CONFIRMING COMPLIANCE WITH IS
AT
TO THE
OF APPLIANCE.
BY
A COMPETENT PERSON. FAILURE
COURSES
THE
THE
GAS
WORCESTER
BOSCH
ARE AVAILABLE FROM
USER
TECHNICAL HELPLINE.
GUIDE
METER AFTER INSTALLATION OR SERVIC-
AND
BOSCH
THE
APPLIANCE
TO
INSTALL
WORCESTER
COMPLETED
813
ING.
ABBREVIATIONS USED
IN
THIS MANUAL:
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
Central heating
Hot water storage cylinder
Electricity supply
f
supply
Gas
THIS
MANUAL:
Time
clock
Programmer/timer
Room
thermostat
Wait time period
INSTALLATION &
SERVICING INSTRUCTIONS
INSTALLATION & SERVICING INSTRUCTIONS
FOR
WORCESTER BOSCH GREENSTAR 30CDI/40CDI Coc,ectlocal
6 720
614
556a
(2007/07)
~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
PLUMBING MANIFOLD
FLUE TERMINAL POSITIONS
FLUE OPTIONS
DATA
& CLEARANCES
4
4
5
6
7
8
9
10
11
12-13
14
15
16-17
INSTALLATION
UNPACKING WALL FRAME AND ANCILLARY ITEMS
WALL MOUNTING
PLATE
I FLUE OPENING
PIPEWORK
UNPACKING
FITTING
THE APPLIANCE
THE APPLIANCE I BOILER
CONNECTIONS
FLUE INSTALLATION
CONDENSATE CONNECTION
ELECTRICAL
POSITION OF WIRED COMPONENTS
COMMISSIONING
PRE-COMMISSIONING
CHECKS
FILLING THE SYSTEM
STARTING
THE APPLIANCE
WATER TREATMENT
COMMISSIONING
FINISHING
COMMISSIONING
SERVICING & SPARES
INSPECTION AND SERVICE
REPLACEMENT OF
SETTING THE GAS/AIR
SHORT
PARTS
PARTS
RATIO
LIST
18
19
20
21
22
23-25
26
27-28
29
30
31
32
33
34
35
36-40
41-47
48
49
CONVERSION KITS
L.P.G.
CONVERSION
FAULT
FINDING & DIAGNOSIS
FAULT
FINDING
HEATING FUNCTION
PROTECTION FUNCTION
~ORCESTER
Bosch
Group
INSTALLATION & SERVICING INSTRUCTIONS
6 720 614 556a (2007/07)
FOR
WORCESTER BOSCH GREENSTAR
30COi/40CDI
50
51
52
53
Conven\1onal
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
accepts
Advise
engineer (such as British
to
help maintain the economy, safety and reliability
IMPORTANTBenchmark section after each service.
contains
to
Health Regulations 1988).
AND
of
aggressive
engineer
Any
components
no liability arising from any such actions, excluding statutory rights.
the
user
no
asbestos
and
no
COSHH
substances
Regulations (Control
have
been
CORROSIVE MATERIALS
the appliance.
substances,
compounds
in
accordance
not
be modified
misuse
or
and systems could invalidate the warranty. The manufacturer
to
have
the
Gas
such as
can corrode the appliance and invalidate any warranty.
in
unauthorised
system
or
CORGI
halogenated
to
the appliance may only be carried out
with
the
Gas
any way other than as described
modifications
serviced
annually
registered personnel) using approved spares,
of
hydrocarbons
Safety
(Installation
to
the
appliance,
by a competent, qualified
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
CHwater:
Artificially softened water must not be used to
fill the central heating system.
FOR
WORCESTER BOSCH GREENSTAR 30CDI/40CDI Coc,ectlocal
6 720
614
556a
(2007/07)
~ORCESTER
Bosch
Group
GENERAL INFORMATION
STANDARD
A-
Wall hung
central heating and indirect domestic hot
water
B -
Wall mounting plate
- Hanging bracket
C
D - Hardware
E - Hardware
F - Literature
G -
Bottom
H - Trap I Syphon Outlet Connection
(22 mm
J - Flow pipe
K - Return pipe
L - Return pipe 2
M - Pipework mounting bracket
N - Gas
0 - Braising template
PACKAGE:
gas
pack
pack
pack
panel
Plastic Pipe)
cock
support
1
c
B
fired condensing boiler for
1
2 (gas cock)
plate
max.
760mm
~
~
~
' L H
0
&N~M
"" ""
""'
0
SPECIFICATIONS:
Pre-wired and pre-plumbed
Galvanised steel
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
temperature sensor & control
External
Flue
gas
Condensate trap & syphon
inner frame
pump
anti-seizure protection
temperature limiter
~ORCESTER
Bosch
Group
INSTALLATION & SERVICING
6
720
614 556a (2007/07)
INSTRUCTIONS
FOR
WORCESTER
BOSCH
GREENSTAR
30CD,/40CD'
Conven\1onal
GENERAL INFORMATION
TECHNICAL
NATURAL GAS L.P.G.
DESCRIPTION UNITS 30CDi 40CDi 30CDi 40CDi
Heating
Max.
rated heat input
Max.
rated heat output net
Max.
rated heat output net
Max.
rated heat output net
40/30°C
50/30°C
80/60°C
kW
kW
kW
kW
30.9 42.0 30.9 42.0
32.1
31.8 43.3 31.8 43.3
30.0 40.8
43.7
DATA
32.1
30.0
43.7
40.8
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 3.0 3.0 3.0 3.0
flow
rate-
G20
Temp.
Temp.
Max.
80/60°C,
40/30°C,
max.
min.
Gas
Natural Gas
Propane Gas (LPG)
Flue
Flue
Gas
Flue
Gas
C02
level at
C02
level at
NOx-
class
Condensate
Max.
condensation rate
40/30°C
50/30°C
80/60°C
10
minutes
rated min. load
rated min. load
rated heat output
rated heat output
from
lighting
kW
kW
kW
kW
•c
m3/h
kg/h 2.4 3.3
•c
•c
% 9.6 9.7
% 9.0
1/h
8.6 10.6 12.4 15.7
8.6 10.5 12.3 15.5
7.7
8.0 9.8
nom. 90 nom. 90
3.2 4.4
76/58
55/33 58/35 55/33
5 5 5 5
2.7 3.7 2.7 3.7
9.4 11.0 13.9
11.5
nom.
90 nom.
87/58
9.1
76/58
11.5
10.5 10.5
14.5
90
87/58
58/35
11.5
pH
value, approx. 4.8 4.8 4.8 4.8
Electrical
Electrical
Frequency
Max.
General
SEDBUK
Appliance protection rating IP X4D X4D X4D X4D
Permissible ambient temperatures
Nominal
Noise output
Total
Packaged boiler weight
SEDBUK
power supply voltage
power consumption w approx. 70 approx. 100 approx. 70 approx. 100
Data
capacity of appliance I 3.5 3.5 3.5 3.5
level
boiler weight (lift weight)
AC
..
.V
Hz
band A A A A
•c
dB(A)
kg
kg
%
230
50
0-50 0-50 0-50 0-50
43
39.5 39.5 39.5 39.5
48
90.1
230 230 230
50 50
47 43 47
48 48 48
90.2
90.1
50
90.2
TECHNICAL
DATA
INSTALLATION & SERVICING INSTRUCTIONS
FOR
WORCESTER BOSCH GREENSTAR 30CDI/40CDI Coc,ectlocal
6 720
614
556a
(2007/07)
~ORCESTER
Bosch
Group
23
--
22
21
20 ------------------------------
---
------ 7
LAYOUT &
The
diagram opposite shows the controls
servicing position
FLAME VIEWING
2
3
2 IGNITION ELECTRODE AND FLAME
SENSE ELECTRODE
3 HEAT EXCHANGER
COMPONENTS
and
excludes the outer
WINDOW
in
case.
the
4 OVERHEAT THERMOSTAT
5 ACCESS POINT FOR CLEANING HEAT
4
EXCHANGER
6 CONDENSATE
HOSE
7 DRAIN POINT
TRAP I SYPHON OUTLET
8
TION (22
mm
PLASTIC PIPE)
CONNEC-
9 RETURN
5
10 GAS INLET CONNECTION
COMPRESSION
11
COVER FOR EXTERNAL
CONNECTIONS
12
CONTROL PANEL
POSITION
IN
22
WIRING
SERVICE
mm
13 ACCESS COVER FOR TRANSFORMER
&PCB
14 FLOW
15
INLET PRESSURE TEST POINT
16 TRAP I SYPHON
17
GAS
VALVE
18 AIR I GAS ADJUSTMENT
19
TESTING POINT FOR
20
FAN
21
PRIMARY
SENSOR
SCREW
FAN
PRESSURE
22 AUTO AIR VENT
23
REMOVABLE TOP CASE PANEL FOR
8
SERVICING
9
48 49
'11
:::;-->(
-o
'
---------57
I ·-----·56
I
I
_'·->·60
---55
48
TEMPERATURE CONTROL
MAINS
49
51
52
53
54
55
56
57
60
ON/OFF
TIC LIGHT
BOOST
SERVICE BUTTON
BURNER ON INDICATOR LIGHT
(GREEN)
MASTER SWITCH
NOT USED
NOT USED
FAULT
RESET BUTTON
DISPLAY
INDICATOR/DIAGNOS-
(BLUE)
BUTTON
ON/OFF
~ORCESTER
Bosch
Group
INSTALLATION & SERVICING INSTRUCTIONS
6 720 614 556a (2007/07)
FOR
WORCESTER BOSCH GREENSTAR
30COi/40CDI
Conven\1onal
LAYOUT &
COMPONENTS
CLEANING PRIMARY SYSTEMS
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
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
2 Open
3
~
4
5
the
boiler and reduce efficiency.
comply
use
of
water treatment with the appli-
THE
SYSTEM
GOOD
WORKING ORDER
THE EXISTING BOILER/
A POWER FLUSHING MACHINE
AID
THE
CLEANSING
THE PRIMARY SYSTEM:
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
the
the
flushing agent before
up.
as
directed
thoroughly flush
the
system can
with
the
guidelines
AND PIPEWORK
WHERE
and
and
add a suitable
correct strength for
in
accordance with
POSSIBLE
PROCEDURE
and
drain
the
normal
operating
by
the manufacturer
the
system to
and
debris.
check
system.
the
for
IS
3
@
Valve
Flushing
Agent
~
KEY
CLEANING PRIMARY SYSTEMS
INSTALLATION & SERVICING INSTRUCTIONS
FOR
WORCESTER BOSCH GREENSTAR 30CDI/40CDI Coc,ectlocal
6 720
614
556a
(2007/07)
~ORCESTER
Bosch Group
MAINS SUPPLIES
ELECTRIC
Supply:
SUPPLY:
230V-
50Hz
(See Technical Data for IP ratings.)
Cable:
PVC
insulated 0. 75mm2
(24
x 0.2mm) temperature rated
External
3A
fuse
to
BS1362.
The appliance must be earthed.
• All pipes
to
the boiler must be crossbonded.
Wiring
must comply with
lEE
wiring regulations and any local regulations which may
apply to fixed wiring
to
a stationary appli-
ance.
GAS
SUPPLY:
Boilers
using
NG
must be
connected
governed meter.
LPG
boilers must be
connected
regulator.
Installation
to
the boiler must be
ply
and connection
of
the gas sup-
in
accordance with
BS6891.
Under no circumstances should the size
the
gas
supply pipe be less than that
appliance inlet connection.
The meter or
meter must be checked,
supplier,
gas
order and can meet the gas
sure requirements
from any other
does
meter to the
For olive connections
gas pipes with minimum 0.9
not
include the
regulator and
pipework
preferably by the
to
ensure it is
in
good
flow
in
addition
to
the demand
appliance being served. This
pipework
from the
boiler.
we
recommend using
mm
ness.
to
90°C.
to
to
a
of
to the
working
and pres-
wall thick-
a
of
the
~ORCESTER
Bosch
Group
INSTALLATION & SERVICING
6
720
614 556a (2007/07)
INSTRUCTIONS
FOR
WORCESTER
BOSCH
GREENSTAR
30COi/40CDI
Conven\1onal
MAINS SUPPLIES
'
E
----~
'
--------------F
S PLAN LAYOUT
Y PLAN LAYOUT
SEALED SYSTEM LAYOUT
WATER SYSTEMS &
PI
PEWORK
PLASTIC PIPEWORK:
Any plastic pipework must
•
barrier with
copper or
Plastic
must be
600
mm
steel pipe connected to the boiler.
pipework used for underfloor heating
correctly controlled with a thermo-
have
a polymeric
(minimum) length of
static blending valve limiting the temperature
of the circuits to approx.
The
pipework from the boiler to the blending
valve
must be
in
50°C.
copper or steel (protected
from corrosion).
CONNECTIONSNALVES:
• All
system connections, taps and mixing
valves must be capable of sustaining a pressure up to 3
bar.
Radiator valves should conform to
BS2767:10.
Do not use galvanised pipes or radiators.
• All other valves should conform to BS1010.
On
new installations, or extensions to existing systems where a radiator previously did
not exist, each radiator
TRV,
except the one fitted
a
room/area
as
the room thermostat.
should be fitted with
in
the same
On boiler only replacement jobs, it is recommended, (but not mandatory,) to fit a TRV
each radiator. It
for energy conservation purposes, to
mend to the customer that a
is,
however, a requirement,
TRV
is fitted to
recom-
each radiator.
• An automatic bypass
(downstream
of
the pump),
may
be required,
in
order to maintain the minimum flow-rate through the appliance.
• A drain
•
cock
should
be
fitted
at
the
low-
est
point
of
the
beneath
the
appliance.
heating
circuit
and
An air vent is required at the highest point
on
the system.
on
L
SYSTEM FILL
Heating return
Hose
...
------D
Heating
return
Cylinder return
SYSTEM
Heating return
Mains
supply
Stop
cock
MAKE
Auto
UP
Heating flow
Make up
vessel
SandY
PLAN SYSTEM:
A Static Head - Minimum static head 250mm
measured from the highest point
in
the heat-
ing system (top surface of the appliance or
in
highest point
level
water
B Heating
C Primary Cold Feed
D Diverter
the heating system) to the
in
the feed and expansion tank.
Vent (22mm minimum)
(15mm
minimum)
Valve
E Pump
F Automatic Bypass
G Radiator
H Lockshield
FULLY
The
WRAS
the diagram opposite for
Valve (Flow)
Valve
(Return)
PUMPED SEALED SYSTEM:
sealed system must be filled using a
approved filling loop or comply with
System fill
Do not use galvanised pipes or radiators.
Expansion
Pressure
Relief
K
L Stop
Vessel
Gauge
Valve
Valve
Fixed Cylinder Type or sealed
systems approved connection
WATER
SYSTEMS
& PIPEWORK
INSTALLATION & SERVICING INSTRUCTIONS
FOR
WORCESTER BOSCH GREENSTAR 30CDI/40CDI Coc,ectlocal
6 720
614
556a
(2007/07)
~ORCESTER
Bosch
Group
3
5
ri : ,/
-----------
,E
,./
~1
lnvectlb
G
25mm
m1n.
~
~
~-~
~
__ j __
Ir-------K
-------J
+
-- H
400mm
m1n.
4
A+
~
~
/,
/,/,
/,
/,/,
/,
/,
~
/,
~-
/,
D
CONDENSATE PIPEWORK
CONDENSATE PIPEWORK:
The
condensate pipe must be a minimum of
22mm0
The condensate
50
should
The
shown opposite into
trap
machine) and discharge direct into a vent
stack
into a
the water
Wherever possible the condensate discharge pipe work should
minated internally. Should this not be possible,
the following conditions should be
observed:
IMPORTANT:
ages
2 Internal
3
4 External
5 External
plastic pipe.
pipework
mm
per
metre
take
the
shortest
pipework must follow one of the options
(min.
75
mm)
(E)
min.
450
gulley (D) below ground but above
level.
and the only available route is external,
Pipe work length should be kept to a
minimum and the route as
possible.
Where pipe work could be subjected to
cold or wind chill, a weather
extreme
insulation should be used.
proof
Alternatively the condensate pipework
could
be
increased to a minimum
without the requirement to insulate.
Ensure
in
the
pipe
run.
Internal
sink/washing
waste
drainage
Soil/vent
stack
drainage
condensate
must
towards
such
the
outlet
practicable route.
an
internal serviceableas
a sink/washing
mm
above pipe invert or
be
routed and ter-
vertical
there
are
machine
system
system
absorption
fall
no
drain
at
and
as
32
block-
point
least
mm
A - Condensate from boiler
B-
Sink
C-
22
mm
0 plastic condensate pipe
D-
Gulley
E - Internal soil and vent stack
F
- Serviceable waste trap (75
G-
300
mm
x 100
mm
0 sealed plastic tube
H
- Ground level
J - Drainage holes
(12
mm
from
building
K - Limestone chippings
0 at 25
50
mm
from base of tube
mm
centres) facing away
mm
min)
~ORCESTER
Bosch
Group
INSTALLATION & SERVICING
6
720
614 556a (2007/07)
INSTRUCTIONS
FOR
WORCESTER
BOSCH
GREENSTAR
30COi/40CDI
Conven\1onal
CONDENSATE PIPEWORK
SERVICING
Using 1
-1112
Using 1 25 mm
-1152
CLEARANCES
00
mm flue kit
mm
flue kit
mm
~-
'20mm
'
to
removable door
600mm
'
front
clearance
'
for
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
COMPARTMENTS:
Follow
BS5440
• An
• If fitting the boiler into
BOILER CLEARANCES:
The
space required
property
boiler weight.
the
Minimum
access
and maintain the
equipment.
use a non-combustible perforated material
(maximum hole sizes
the boiler from the airing space.
diagram
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
of
be
airing
13mm)
shows
onto
of
support-
BS6798
maintained
cupboard
to
separate
the
m1n1mum
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
in
BS
5440
to
of
not
operate the appliance if the flue terminal
damaged.
combustion
appliance
after installation, then the
non-combustible
BS
6798.
the requirements
there is no need for ventilation
be
provided
the
low
is
fitted
is
in
the
heat loss from the appliance
shown
or
roof is
does
from inside the
into a cup-
built
around
compart-
partition
of
BS
compartment
are maintained.
obstructed
not
the
space
as
6798
CONDENSATE PIPEWORK
INSTALLATION & SERVICING INSTRUCTIONS
FOR
WORCESTER BOSCH GREENSTAR 30CDI/40CDI Coc,ectlocal
6 720
614
556a
(2007/07)
~ORCESTER
Bosch
Group
®
CD
CD
®
2250mm
BOILER LOCATION &
CLEARANCES
BATHROOMS:
The
boiler can
mechanical or
boiler can only
A Non mechanical timer can be installed in
2.
zone
See lEE wiring regulations.
(See Technical Data for
be
installed
RF
mechanical timer
be
installed
IP
in
zones 2 or
in
zone
ratings.}
is
3.
3.
If a
fitted the
600mm
radius
®
6
2250mm
720
611
927-13.10
IMPORTANT:
control using 230 V mains electricity
not
be
using
the
Electrical switches, fused
outlets
room.
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-
~QRCESTER
Bosch
Group
INSTALLATION & SERVICING INSTRUCTIONS
6 720 614 556a (2007/07)
FOR
WORCESTER BOSCH GREENSTAR
30COi/40CDI
Conven\1onal BOILER LOCATION & CLEARANCES
Flow
22
mm
Return 22
Mains Gas
mm
Supply
22
mm
PLUMBING MANIFOLD
CONNECTIONS:
Heating System: 22 mm compression fittings
mm
Gas: 22
Use the 22mm
the
appliance.
Use the fittings supplied
pack.
Use the
ance vertically
gramm on the left side) or use alternative connection method (as shown
the
the pipes for
supplied
upwards
right
side). For alternative
flow
compression fittings
copper
pipes provided with
in
pipes
to
connect
(as
in
and return.
the Lit/Hardware
the appli-
shown
in
the dia-
the diagramm on
connection
cut
PLUMBING MANIFOLD
INSTALLATION & SERVICING INSTRUCTIONS
Flow 22 mm
Mains Gas
22
mm
FOR
WORCESTER BOSCH GREENSTAR 30CDI/40CDI Coc,ectlocal
6 720
614
556a
0
Supply
(2007/07)
Return
22
mm
~ORCESTER
Bosch
Group
FLUE TERMINAL POSITIONS
Minimum
fanned
DRWG.
REF:
A'
B'
C'
D
E
F2
G From a vertical drain pipe or soil pipe 150mm
H From
I Above ground, roof or balcony
J From a surface facing the terminal
K From a terminal facing the terminal
L2
M Vertically from a terminal on the same wall
N Horizontally from a terminal on the same wall
dimensions
draught:
TERMINAL
Directly
Above
Horizontally
Below
Below
Below
From
of
flue
terminal
POSITION
below
an
opening, air brick, opening windows, etc.
an
opening, air brick, opening window, etc.
to
an
opening, air brick, opening window, etc.
gutters, soil pipes
eaves
balconies
an
an
opening
or
car port roof (lowest point)
internal or external corner
in
the car port
positions
or
drain pipes 75mm
(e.g.
door, window) into the dwelling
for
balanced
room
sealed
flues
DISTANCE
300mm
300mm
300mm
200mm
200mm
300mm
300mm
600mm
1200mm
1200mm
1500mm
300mm
0 From a non combustible vertical structure on the roof
p
Above intersection with roof
0 Adjacent
R
Below
windows
to
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
which
The guard must be spaced
mum
the wall with plated screws. See
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
terminal
people have access.
50
mm) around the flue and fixed
duct
and the terminal
is
2m or less above a surface to
equally (mini-
in
flue outlet
plume and
an
alter-
25mm
in
to
Contact
of
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 such as a
flue
kits.
to
an
opening
~ORCESTER
Bosch
Group
INSTALLATION & SERVICING INSTRUCTIONS
6 720 614 556a (2007/07)
FOR
WORCESTER BOSCH GREENSTAR 30CD•/40CD• Conven\•onal
FLUE TERMINAL POSITIONS
STANDARD FLUE HORIZONTAL
0100
MAX
686
mm
Ax
1
MIN 250
0125
MAX 1070
MIN 250
* Requires cutting
MAXIMUM FLUE HORIZONTAL
0100-
Ax1+Bx8
0125-
Ax1+Bx18
MAXIMUM FLUE VERTICAL START+ 1 BEND
mm
mm
mm
7goo
18500
Ax
Ax
mm
mm
Ax
1*
1
1*
0 c
0100-
7goo
mm
Ax1+Cx1+Bxg
+
Fx
1
0125-
18500
mm
Ax1+Cx1+Bx1g
+
Fx
1
MAXIMUM FLUE VERTICAL
START+
F 8 d
B
2 BENDS
~---~
I
IPA
co
0100-
5goo
mm
Ax1+Cx2+
+
Fx
1
0125-
16500
A X 1 + c X 2 + B X
+
Fx
1
MAXIMUM FLUE VERTICAL
START+
F
B
3 BENDS
c 0
0100-
3goo
Ax1+Cx3
+Bx7+Fx1
0125-
14500
Ax1+Cx3
+Bx17+Fx1
MAXIMUM FLUE VERTICAL
2 X 45° BENDS
WITH
E
B
D
0100-
7400
(including terminal)
Bx8+Dx2+Ex1
0125-
16500
(including terminal)
Bx17+
Dx2
Bx8
mm
18
mm
mm
mm
mm
+Ex1
FLUE OPTIONS 30CDi
CONVENTIONAL
•
The
diagrams (opposite) show the compo-
nents used and the maximum flue length for
100
mm
each configuration of
125
mm
0 flues.
• Shaded flue components indicate the standard 100
• Only straight flue sections can be reduced
in
•
The
inside or outside of the building.
Fixing kits
sion kits.
Horizontal125
and 125
separate instructions. Contact your supplier
or Worcester Bosch.
QH
B
A - Standard horizontal flue
B - Straight flue extension
C -
Flue
D -
Flue
E - Vertical terminal (vertical adaptor supplied
with terminal)
F-
Vertical adaptor (used with horizontal
terminal)
Calculating the flue length:
Measure the total flue length required, noting
that the maximum straight flue
the terminal is:
Horizontal
Horizontal 80/125
Vertical 60/100
Vertical 80/125
mm
0 horizontal flue.
length and cut.
flue terminal end can be fitted from the
are
supplied with the flue exten-
mm
0 and Vertical100
mm
0 flue kits
A c D
iP
bend,
goo
bends, 45°
60/100
mm
0:
mm
0:
mm
0:
g400
mm
0:
18500
and
are
available with
0
EB
(1
00
mm
length including
7goo
mm
18500
mm
mm
mm
mm
v
F
Q
0 shown)
MAXIMUM FLUE
bJ) 0
'-----_
'---ll<CI
IP A
0 c
0100-
5goo
mm
Ax1 + Bx7+Cx1
0125-
16500
mm
Ax1 + Bx17+Cx1
FLUE
OPTIONS 30CDi
CONVENTIONAL
HORIZONTAL+
B
1 BEND
VERTICAL FLUE WITH
2 X
goo
BENDS
E
B
c 0
0100-5400
(including terminal)
Bx7+
0125(including terminal)
Bx16+
INSTALLATION & SERVICING INSTRUCTIONS
Cx2
14500
Cx2
mm
+Ex1
mm
+Ex1
Then reduce the total straight flue length for
each extra flue bend (excluding the turret) by:
2000
mm
for
1000
mm
for 45°
Flue
extension total lengths:
Horizontal
Horizontal & Vertical 80/125
Flue
Horizontal
Horizontal 80/125
Vertical60/100
Vertical 80/125
6
720
611
927-08.10
FOR
WORCESTER BOSCH GREENSTAR 30CDI/40CDI Coc,ectlocal
& Vertical 60/100
terminal total lengths:
60/100
6 720
614
556a
goo
mm
mm
(2007/07)
mm
0:
g5o
mm
mm
0:
1000
mm
mm
0:
800
mm
mm
0:
1200
mm
0:
1140
mm
0:
1365
mm
~ORCESTER
Bosch
Group
STANDARD FLUE HORIZONTAL
Q
O{_
_ _j[_
_uiVY
A
0100
MAX
686
mm
Ax
1
MIN 250
0125
MAX 1070
MIN 250
* Requires cutting
MAXIMUM FLUE HORIZONTAL
Q
0100-
Ax1+Bx2
0125-
Ax1+Bx12
MAXIMUM FLUE VERTICAL START+ 1 BEND
O{_
_ _j[_
2600
12500
mm
mm
mm
Ax
Ax
_R
IV?
mm
mm
Ax
1*
1
1*
0 c
0100-
2600
mm
Ax1+Cx1+Bx3
+
Fx
1
0125-
12500
mm
A X 1 + c X 1 + B X
+
Fx
1
13
MAXIMUM FLUE VERTICAL
START+
F
B
2 BENDS
.bJ.
0
II
iPA
'-----~
co
0100-
N/A
0125-
10500
mm
A X 1 + c X 2 + B X
+
Fx
1
MAXIMUM FLUE VERTICAL
START+
F Q q
B
3 BENDS
c 0
0100-
N/A
0125-
8500
Ax1+Cx3
+Bx11
MAXIMUM FLUE VERTICAL
WITH
E
B
D
0100(including terminal)
Bx3+
0125(including terminal)
B X
+Fx1
2 X 45° BENDS
B
2goo
Dx2 + Ex1
14000
14
+ D X 2
mm
mm
mm
+EX
12
1
FLUE OPTIONS 40CDi
CONVENTIONAL
•
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
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
.b]H
B
A - Standard horizontal flue
B - Straight
C D E - Vertical terminal (vertical adaptor supplied
F-
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
flue extension
Flue
bend,
goo
Flue
bends, 45°
with terminal)
Vertical adaptor (used with horizontal
terminal)
the flue length:
maximum
mm
mm
100
mm
and
0 horizontal flue.
be
fitted from the
building.
supplied with the flue exten-
mm
0 and Vertical 100
0 flue kits
I
are
available with
supplier
&-'
straight flue length including
mm
mm
0:
0:
0
EB
(1
0:
2600
0:
12500
4goo
mm
16000
00
mm
mm
mm
mm
v
F
Q
0 shown)
mm
MAXIMUM FLUE
bJ
'L_O
_ _j[_.uiP A
HORIZONTAL+
B
0 c
0100-600
Ax1 + Bx1
0125-
Ax1 + Bx11
~ORCESTER
10500
Bosch
mm
Group
+Cx1
mm
+Cx1
INSTALLATION & SERVICING
6
720
614 556a (2007/07)
1 BEND
INSTRUCTIONS
VERTICAL FLUE WITH
2 X
goo
BENDS
E
B
B
c 0
0100-
N/A
0125-
12000
mm
(including terminal)
Bx13+
Cx2
+Ex1
FOR
WORCESTER
BOSCH
GREENSTAR
6
720
611
30CD•/40CD•
927-08.1 0
Conven\1onal
Then reduce the total straight flue length for
each extra
2000
1000
Flue
Horizontal
Horizontal & Vertical 80/125
Flue
Horizontal 60/100
Horizontal 80/125
Vertical 60/100
Vertical 80/125
flue bend (excluding the turret)
mm
for
goo
mm
for 45°
extension total lengths:
& Vertical 60/100
terminal total lengths:
mm
0:
mm
0:
mm
0:
1140
mm
0:
1365
FLUE
OPTIONS 40CDi
mm
mm
800
1200
mm
mm
0:
0:
mm
mm
g5o
1000
by:
mm
mm
CONVENTIONAL
Loading...