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INSTALLATION, COMMISSIONING, AND SERVICING INSTRUCTIONS

WALL HUNG RSF GAS FIRED CONDENSING COMBINATION BOILER

Greenstar CDi Compact

ErP

6720646608-00.1Wo

FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER

These appliances are for use with: Natural Gas or L.P.G. (Cat. II 2H 3P type C13, C33 & C53)

Model GC Number

Natural Gas 28CDi Compact

32CDi Compact 36CDi Compact

LPG 28CDi Compact

32CDi Compact 36CDi Compact

If you smell gas: ▶ Well away from the building: call the National Gas

Emergency Service on 0800 111 999.

▶ L.P.G. boilers: Call the supplier’s number on the

side of the gas tank.

ErP

47-406-77 47-406-79 47-406-81 47-406-78 47-406-80 47-406-82

6 720 813 276 (2015/07)

Contents

1 KEY TO SYMBOLS AND SAFETY INSTRUCTIONS . . . . . . . . . . . 3

1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 APPLIANCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.1 Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.4 Energy efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 PRE-INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.1 Cleaning primary systems . . . . . . . . . . . . . . . . . . . . . . . 11

3.2 Mains supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2.1 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2.3 Water supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.3 Water systems and pipe work . . . . . . . . . . . . . . . . . . . . 12

3.4 Condensate pipe work . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.4.1 Internal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.4.2 External connections . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.5 Pressure relief pipe work . . . . . . . . . . . . . . . . . . . . . . . 15

3.6 Boiler location and clearances . . . . . . . . . . . . . . . . . . . 16

3.6.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.6.2 Installation and servicing clearances . . . . . . . . . . . . . . 16

3.6.3 Compartments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.6.4 Bathrooms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.7 Plumbing manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.7.1 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.8 Flue options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.8.1 Flue lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.9 Flue terminal positions . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.10 Plume management terminal positions . . . . . . . . . . . . 21

3.10.1 Determine the plume management system length . . . 22

4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.1 Unpacking wall frame & ancillary items . . . . . . . . . . . . 23

4.2 Wall mounting template & flue opening . . . . . . . . . . . . 23

4.3 Unpacking the appliance . . . . . . . . . . . . . . . . . . . . . . . 24

4.4 Pre-plumbing boiler connections . . . . . . . . . . . . . . . . . 25

4.5 Hanging the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.6 Flue turret/adapter installation . . . . . . . . . . . . . . . . . . 28

4.7 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.7.1 Mounting optional plug-in controls . . . . . . . . . . . . . . . . 30

4.7.2 New complete system installations . . . . . . . . . . . . . . . 31

4.7.3 Existing installations . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5 COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.1 Pre-Commissioning checks . . . . . . . . . . . . . . . . . . . . . 33

5.2 Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.3 Water treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.4 Starting the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.4.1 Boiler start up screens . . . . . . . . . . . . . . . . . . . . . . . . . 35

5.5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5.5.1 Checking the gas inlet pressure . . . . . . . . . . . . . . . . . . 36

5.5.2 Checking the gas rate . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5.5.3 Gas rating test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5.5.4 Checking for leaks during operation . . . . . . . . . . . . . . 37

5.6 Domestic hot water . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5.6.1 Domestic hot water eco and preheat modes . . . . . . . . 37

5.7 CO and combustion checks . . . . . . . . . . . . . . . . . . . . . 38

5.8 Finishing commissioning . . . . . . . . . . . . . . . . . . . . . . . 39

5.8.1 Replacing the boiler case: . . . . . . . . . . . . . . . . . . . . . . . 39

5.8.2 Securing the control panel . . . . . . . . . . . . . . . . . . . . . . 39

5.8.3 Fitting the fascia flap . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5.8.4 Installing bottom panel . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5.8.5 Hand over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

5.8.6 Boiler guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6 SERVICE AND SPARES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6.1 Inspection and service . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6.2 Checking flue integrity . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6.3 Component access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

6.4 Checking the gas inlet pressure . . . . . . . . . . . . . . . . . . . 42

6.5 Fan pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

6.5.1 Setting the boiler to maximum . . . . . . . . . . . . . . . . . . . . 42

6.5.2 Fan pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6.6 Flue gas analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6.7 Cleaning the heat exchanger . . . . . . . . . . . . . . . . . . . . . 44

6.7.1 Cleaning the siphon . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

6.7.2 Cleaning the primary heat exchanger . . . . . . . . . . . . . . 45

6.8 Replacement of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

6.8.1 Removing the outer case . . . . . . . . . . . . . . . . . . . . . . . . 46

6.8.2 Draining the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

6.8.3 Syphon removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

6.8.4 Primary sensor (CH NTC) . . . . . . . . . . . . . . . . . . . . . . . . 47

6.8.5 Maximum safety sensor (NTC) . . . . . . . . . . . . . . . . . . . . 47

6.8.6 Flue overheat thermostat . . . . . . . . . . . . . . . . . . . . . . . . 47

6.8.7 Air Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

6.8.8 Auto air vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

6.8.9 Gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

6.8.10 Fan assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

6.8.11 Air/gas flap valve assembly . . . . . . . . . . . . . . . . . . . . . . 50

6.8.12 Ignition transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

6.8.13 Electrode assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

6.8.14 Burner housing, burner/ gasket . . . . . . . . . . . . . . . . . . . 51

6.8.15 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

6.8.16 Diverter valve motor and diverter valve removal . . . . . 52

6.8.17 DHW Temperature sensor (NTC) . . . . . . . . . . . . . . . . . . 53

6.8.18 Pump head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

6.8.19 Flow sensor, flow restrictor and filter removal . . . . . . . 53

6.8.20 Flow regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

6.8.21 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

6.8.22 Boiler return sensor (NTC) . . . . . . . . . . . . . . . . . . . . . . . 54

6.8.23 Drain tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

6.8.24 CH pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . 54

6.8.25 DHW pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . 55

6.8.26 DHW plate heat exchanger . . . . . . . . . . . . . . . . . . . . . . . 55

6.8.27 Hydraulic block removal . . . . . . . . . . . . . . . . . . . . . . . . . 55

6.8.28 Bypass valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

6.8.29 Access to boiler control components . . . . . . . . . . . . . . 56

6.8.30 Replacing the control unit . . . . . . . . . . . . . . . . . . . . . . . . 56

6.8.31 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6.9 Short parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

7 FAULT FINDING AND DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 60

7.1 Internal wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 60

7.2 Central heating function . . . . . . . . . . . . . . . . . . . . . . . . . 61

7.3 Preheat and DHW function . . . . . . . . . . . . . . . . . . . . . . . 62

7.4 Protection function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

7.5 Information and service menus . . . . . . . . . . . . . . . . . . . 64

7.5.1 Selecting the information menu . . . . . . . . . . . . . . . . . . . 65

7.5.2 Selecting service menus . . . . . . . . . . . . . . . . . . . . . . . . . 66

7.5.3 Menu 1 - System parameters . . . . . . . . . . . . . . . . . . . . . 66

7.5.4 Menu 2 - Boiler parameters . . . . . . . . . . . . . . . . . . . . . . 66

7.5.5 Reset to factory settings . . . . . . . . . . . . . . . . . . . . . . . . . 68

7.5.6 Menu 3 - Boiler maximum & minimum limits . . . . . . . . . 68

7.5.7 Using the test menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

7.6 Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

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1 Key to symbols and safety instructions

Key to symbols and safety instructions

1.1 Key to symbols

Warnings

Warnings in this document are identified by a warning triangle printed against a grey background. Keywords at the start of a warning indicate the type and seriousness of the ensuing risk if measures to prevent the risk are not taken.

The following keywords are defined and can be used in this document:

• NOTICE indicates a situation that could result in damage to property or equipment.

• CAUTION indicates a situation that could result in minor to medium injury.

• WARNING indicates a situation that could result in severe injury or death.

• DANGER indicates a situation that will result in severe injury or death.

Important information

This symbol indicates important information where there is no risk to people or property.

Additional symbols

Symbol Meaning

a numbered step in an action sequence

a step in an action sequence

 a reference to a related part in the document or to other

related documents a reference number to identify or refer to a part or item

a list entry

a list entry (second level)

Table 1 Symbols

Examples of additional symbols used

A numbered step in an action sequence

A sequence of numbered steps or actions carried out in a specific order to complete a task.

1. First action

2. Second action

3. Third action etc.

A step in an action sequence

A sequence of defined actions or steps carried out in order to complete a task. ▶Action ▶Next action ▶etc

A reference to a related part in the document or to other related documents.

To refer the reader to a specific figure/table/section within the manual.  e.g. figure 1.

A reference number to identify or refer to a part or item.

In a related figure, items or parts identified by a sequential number.

List entries, first and second levels

• A single component/item

• A component/list, made up of multiple parts/items. – Sub component or sublist of main component/list. –etc.

SYMBOLS USED IN THIS MANUAL

Domestic Hot Water

Central Heating

Hot Water Storage Cylinder

Domestic Cold Water Supply

Electrical Supply

Gas Supply

Table 2 Commonly used symbols

PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.

These instructions are applicable to the Worcester appliance model(s) stated on the front cover of this manual only and must not be used with any other make or model of appliance.

These instructions apply in the UK and Ireland only and must be followed except for any statutory obligations.

This appliance must be installed and serviced by a GAS SAFE registered, competent person. Failure to install correctly could lead to prosecution.

If you are in any doubt, contact the Worcester Technical helpline (0330 123 3366).

Please leave these instructions with the completed BENCHMARK CHECKLIST, (or a certificate confirming compliance with IS 813, Eire only) and the user manual with the owner or at the gas meter after installation or servicing.

Distance learning and training courses are available from Worcester. The BENCHMARK CHECKLIST can be found in the back of this

Installation manual.

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Key to symbols and safety instructions

ØDiameter NG Natural Gas LPG Liquid Petroleum Gas CH Central Heating DHW Domestic Hot Water DCW Domestic Cold Water DWTA Domestic Water Treatment Association PRV Pressure Relief Valve NTC Negative Temperature Coefficient (sensor) IP Ingress Protection RCD Residual Current Device TRV Thermostatic Radiator Valve ECV Emergency Control Valve WRAS Water Regulations Advisory Scheme SEDBUK Seasonal Efficiency of Domestic Boilers in the United

Kingdom

Table 3 Abbreviations use in this manual

1.2 Safety precautions

If you smell gas

A gas leak could potentially cause an explosion. If you smell gas, observe the following rules.

▶ Prevent flames or sparks:

– Do not smoke, use a lighter or strike matches. – Do not operate any electrical switches or unplug any equipment.

– Do not use the telephone or ring doorbells. ▶ Turn off the gas at the meter or regulator. ▶ Open windows and doors. ▶ Warn your neighbours and leave the building. ▶ Prevent anyone from entering the building. ▶ Well away from the building: call the National Gas Emergency Service

on 0800 111 999. ▶ L.P.G. boilers: Call the supplier’s number on the side of the gas tank.

Appliance operation:

This appliance can be used by children aged from 8 years and above and persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge, if they have been given supervision or instruction concerning the use of the appliance, in a safe way, and understand the hazards involved. Children shall not play with the appliance. Cleaning and user maintenance shall not be made by children without supervision.

Health and safety

The appliance contains no asbestos and no substances have been used in the construction process that contravene the COSHH Regulations (Control of Substances Hazardous to Health Regulations 1988).

Combustion and corrosive materials

Do not store or use any combustible materials (paper, thinners, paints etc.) inside or within the vicinity of the appliance.

Chemically aggressive substances can corrode the appliance and invalidate any warranty.

Fittings and modifications

Fitting the appliance and any controls to the appliance may only be carried out by a competent engineer in accordance with the current Gas Safety (Installation and Use) Regulations.

Flue systems must not be modified in any way other than as described in the fitting instructions. Any misuse or unauthorised modifications to the appliance, flue or associated components and systems could invalidate the warranty. The manufacturer accepts no liability arising from any such actions, excluding statutory rights.

Servicing

Advise the user to have the system serviced annually by a competent, qualified Gas Safe registered engineer. Approved spares must be used to help maintain the economy, safety and reliability of the appliance.

Important The service engineer must complete the Service Record on the

Benchmark Checklist after each service.

Flue System

Only use the approved Worcester Condensfit II flue system with this appliance.

Worcester original spare parts

Only use Worcester original spare parts with this appliance. Non Worcester original spare parts will invalidate the guarantee (if applicable) and any warranty.

Benchmark places responsibilities on both manufacturers and installers.

The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer's instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference.

Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the scheme. Visit centralheating.co.uk for more information.

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2Regulations

Installation regulations

Current Gas Safety (Installation & Use) Regulations: All gas appliances must be installed by a competent person in

accordance with the above regulations. Failure to install appliances correctly could lead to prosecution.

The appliance must be installed in accordance with, and comply to, the current: Gas Safety Regulations, IET Regulations, Building Regulations, Building Standards (Scotland) (Consolidation), Building Regulations (Northern Ireland), local water by-laws, Health & Safety Document 635 (The Electricity at Work Regulations 1989), EU Regulations No. 811/ 2013 - Energy Labelling and any other local requirements.

British standards

Where no specific instruction is given, reference should be made to the relevant British Standard codes of Practice.

BS7074:1 Code of practice for domestic and hot water supply BS6891 Installation of low pressure gas pipe work up to 28mm (R1) BS5546 Installation of gas hot water supplies for domestic purposes EN12828 Central heating for domestic premises BS5440:1 Flues and ventilation for gas appliances of rated heating not

exceeding 70kW (net): Flues BS5440:2 Flues and ventilation for gas appliances of rated heating not

exceeding 70kW (net): Air Supply BS7593 Treatment of water in domestic hot water central heating

systems BS6798 Installation of gas fired boilers of rated input up to 70kW (net)

L.P.G. Installations

An appliance using L.P.G. must not be installed in a room or internal space below ground level unless one side of the building is open to the ground.

Irish Standards

The relevant Irish standards should be followed, including:

• ECTI National rules for electrical installations

• IS 813:2002 for Domestic Gas Installations.

Regulations

Timber Framed Buildings

Where the boiler is to be fitted to a timber framed building the guidelines laid down in BS5440: Part 1 and IGE "Gas Installations in Timber Frame Buildings” should be adhered to.

Potable Water

All seals, joints and compounds (including flux and solder) and components used as part of the secondary domestic water system must be approved by WRAS.

CH Water

Artificially softened water must not be used to fill the central heating system.

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APPLIANCE INFORMATION

* 690mm to top of case front

680mm*

390mm

280mm

Depth to wall

(When fitted to wall frame)

6720813276-01.1Wo

3 APPLIANCE INFORMATION

3.1 Appliance

STANDARD PACKAGE

1. Wall hung gas-fired condensing combi boiler for central heating and

domestic hot water

2. Wall mounting frame

3. Integral Filling Loop kit

4. Hardware literature pack:

– Greenstar CDi Compact

and Servicing Instructions –User guide – Boiler fascia guide – Wall mounting template – Sealing Pack

5. PRV installer connection elbow

6. ErP label

7. Fascia panel

8. Bottom panel

ErP

Installation, Commissioning

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3.2 Layout

50 49 48 47 46 45 44 43 42

6720813276-02.1Wo

18 19

2526

APPLIANCE INFORMATION

Fig. 1 Main boiler components

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APPLIANCE INFORMATION

1 Wall mounting frame 30 Flow temperature sensor (NTC) 2 Expansion vessel 31 Electrode assembly 3 CH return isolating valve 32 Maximum safety sensor (NTC) 4 DCW mains isolating valve 33 Auto air vent 5 Gas isolating valve 34 Aluminium Silicon Heat exchanger 6 DHW outlet connection 35 Flueway 7 CH flow isolating valve 36 Sump assembly 8 Condensate drain connection 37 Pressure gauge connection point 9 Flue connector 38 Diverter valve actuator (stepper motor) 10 Air Pressure Switch 39 Diverter valve body 11 Main superstructure 40 Modulating pump 12 Case 41 Drain point 13 Case retaining screws 42 CH return connection to isolating valve 14 Bottom panel 43 PRV 15 Flue Overheat Thermostat 44 DCW in connection to isolating valve 16 Case retaining clips 45 PRV Connection pipe 17 Control panel 46 Gas pipe from isolating valve 18 Control panel menu buttons 47 DHW outlet pipe 19 Blank for optional programmer 48 DHW temperature sensor (NTC) 20 Diagnostic port - Worcester service engineer 49 CH flow pipe to isolating valve 21 Pressure gauge 50 Condensate siphon drain pipe 22 DHW temperature control 51 Condensate siphon 23 Boiler identification label 52 DHW Plate heat exchanger 24 Operation/fault indicator (blue) 53 Expansion vessel connection 25 Control panel flap 54 Return temperature (NTC) 26 Boiler fascia guide location 55 Gas valve 27 CH temperature control 56 Combustion air inlet 28 Boiler display 57 Ignition transformer 29 Fan

Table 4 Boiler components

BOILER FEATURES

• High pressure die-cast aluminium heat exchanger

• Low NOx emissions

• Fixed gas valve settings

• Direct burner ignition

• Zero pressure governor gas valve with fully modulating fan

• Display for boiler status and access to diagnostics, system and commissioning parameters

• Digital control system

• Memory retention after power interruption

• Low electrical power consumption during operation and stand-by modes

• Modulating pump

• Condensing in CH and DHW modes

• Three star Hot Water Comfort measured to EN13203 Part 1 in comfort mode with DHW pre-heat ON

• Eco mode, to use gas on demand

• Plate type DHW heat exchanger

• Ability to pre-plumb condensate drain, CH flow, DHW Outlet, Gas, DCW In, PRV and CH Return connections

• Siphonic condensate trap

• Galvanised steel wall mounting frame

• Standard wall frame provides vertical pipe route behind the boiler

• Compatible with all Worcester standard and intelligent controls

• Condensfit II flue systems 60/100 and 80/125mm allows plume re-direction as standard and ability to attach plume management kits

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APPLIANCE INFORMATION

3.3 Technical data

DESCRIPTION CDi Compact ErP

UNIT 28kW 32kW 36kW 28kW 32kW 36kW

Domestic Hot Water

Minimum heat input kW 7.15 7.15 7.15 7.15 7.15 7.15 Maximum rated heat output kW 28 32 36 28 32 36 Maximum rated heat input kW 28.57 32.65 36.7 28.57 32.65 36.7 Maximum mains inlet pressure (standing pressure) bar 10 10 10 10 10 10 Minimum mains inlet pressure (working) for max. flow bar 1.6 1.6 1.6 1.6 1.6 1.6 Minimum mains inlet pressure (working) for operation bar 0.2 0.2 0.2 0.2 0.2 0.2 Minimum required flow to fire the boiler l/min. 222222 Domestic Hot Water temperature range °C 40 - 60 40 - 60 40 - 60 40 - 60 40 - 60 40 - 60

Max. Domestic Hot Water flow rate - 40 °C rise  15%

l/min. 10.0 11.0 13.0 10.0 11.0 13.0

Gas flow rate - Max. 10 minutes from lighting

Natural Gas G20 m³/h 3.0 3.5 3.9 Propane Gas (L.P.G.) kg/h -2.22.5 2.8

Central Heating

Maximum rated heat input (net) kW 24.34 24.34 24.34 24.34 24.34 24.34 Maximum rated heat output 40/30 °C kW 25.31 25.31 25.31 25.31 25.31 25.31 Maximum rated heat output 50/30 °C kW 25.17 25.17 25.17 25.17 25.17 25.17 Maximum rated heat output 80/60 °C kW 24 24 24 24 24 24 Maximum flow temperature °C 82 82 82 82 82 82 Maximum flow temperature possible °C 86 86 86 86 86 86 Maximum permissible operating pressure bar 2.5 2.5 2.5 2.5 2.5 2.5 Available pump head at 20 °C system temperature rise m 2.0 2.0 2.0 2.0 2.0 2.0

Flue

Flue gas temperature 80/60 °C, rated/min. load °C 67/64 72/64 78/64 69/66 73/66 79/66 Flue gas temperature 40/30 °C, rated/min. load °C 48/36 51/36 52/36 50/37 52/37 54/37 CO2 level at max. rated heat output (after 10 minutes) % 9.1 9.1 9.1 10.6 10.6 10.6 CO2 level at min. rated heat output (after 10 minutes) % 8.5 8.5 8.5 9.6 9.6 9.6 NOx class 555555 NOx rating mg/kWh 35 35 35 46 46 46

Condensate

Maximum condensate rate l/h 2.5 2.5 2.5 2.5 2.5 2.5 pH value, approx. 4.8 4.8 4.8 4.8 4.8 4.8

Electrical

Electrical power supply voltage a.c. V 230 230 230 230 230 230 Frequency Hz 50 50 50 50 50 50 Maximum power consumption - running W 105 115 129 105 115 129 Maximum power consumption - stand-by W 111111

General data

Appliance protection rating IP X4D X4D X4D X4D X4D X4D Appliance protection rating with mechanical or

IP IP20 IP20 IP20 IP20 IP20 IP20

RF mechanical timer or FW100 module fitted Appliance protection rating with Sense II control fitted IP IPX2D IPX2D IPX2D IPX2D IPX2D IPX2D Permissible ambient operating temperatures °C 0 - 50 0 - 50 0 - 50 0 - 50 0 - 50 0 - 50 Nominal capacity of appliance litre 2.2 2.2 2.2 2.2 2.2 2.2 Total packaged weight kg 43.1 43.1 43.1 43.1 43.1 43.1 Total boiler weight 39.5 39.5 39.5 39.5 39.5 39.5 Lift weight kg 32.9 32.9 32.9 32.9 32.9 32.9 SEDBUK 2009 % 89.8 89.8 89.8 91.9 91.9 91.9

Table 5 Technical data

1) Greenstar CDi Compact

ErP

boilers are fitted with a flow regulator set to achieve a 40°C temperature rise. This ensures comfortable bathing during

the colder winter months.

Natural gas L.P.G.

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APPLIANCE INFORMATION

3.4 Energy efficiency

Natural gas appliances

The following product data satisfy the requirements of the EU Regulations No. 811/2013 and No. 812/2013 supplementing Directive 2010/30/EU.

Product data Symbol Unit 7733600053 7733600055 7733600056

Product type – – 28CDi Compact

ErP

32CDi Compact Condensing boiler – – Yes Yes Yes Low temperature boiler – – No No No B1 boiler – – No No No Cogeneration space heater (CHP) – – No No No Combination heater – – Yes Yes Yes Rated heat output P Seasonal space heating energy efficiency 

rated

kW 24 24 24

%94 94 94

Energy efficiency class – – A A A

Useful heat output

At rated heat output and high temperature regime At 30% of rated heat output and low temperature regime

P P

kW 24 24 24

kW 8.1 8.1 8.1

Useful efficiency

At rated heat output and high temperature regime At 30% of rated heat output and low temperature regime



% 88.8 88.8 88.8 % 99.5 99.5 99.5

Auxiliary electricity consumption

At full load el At part load el In standby mode P

max

min

kW 0.029 0.029 0.029 kW 0.014 0.014 0.014 kW 0.001 0.001 0.001

Other items

Standby heat loss P Ignition burner power consumption P

stby

ign

kW 0.078 0.078 0.078

kW 0 0 0 Emissions of nitrogen oxides NOx mg/kWh 25 25 25 Annual energy consumption Q Sound power level, indoors L

kWh - - -

dB(A) 52 52 52

Additional data for combination heaters

Declared load profile – – XL XL XL Daily electricity consumption Q

kWh 0.144 0.137 0.141

elec

Annual electricity consumption AEC kWh 32 30 31 Daily fuel consumption Q

kWh 20.667 20.741 20.702

fuel

Annual fuel consumption AFC GJ 18 18 18 Water heating energy efficiency 

%85 85 85

Water heating energy efficiency class – – A A A

Table 6 Product data for energy consumption according to the EU regulations no. 811/2013 and no. 813/2013

1) High temperature regime means 60 °C return temperature at heater inlet and 80 °C feed temperature at heater outlet.

2) Low temperature means for condensing boilers 30 °C, for low-temperature boilers 37 °C and for other heaters 50 °C return temperature (at heater inlet).

ErP

36CDi Compact

ErP

CDi Compact

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APPLIANCE INFORMATION

LPG appliances

The following product data satisfy the requirements of the EU Regulations No. 811/2013 and No. 812/2013 supplementing Directive 2010/30/EU.

Product data Symbol Unit 7733600057 7733600058 7733600059

Product type – – 28CDi Compact

ErP

32CDi Compact

ErP

36CDi Compact Condensing boiler – – Yes Yes Yes Low temperature boiler – – No No No B1 boiler – – No No No Cogeneration space heater (CHP) – – No No No Combination heater – – Yes Yes Yes Rated heat output P Seasonal space heating energy efficiency 

rated

kW 24 24 24

%94 94 94

Energy efficiency class – – A A A

Useful heat output

At rated heat output and high temperature regime At 30% of rated heat output and low temperature regime

P P

kW 24 24 24

kW 8.1 8.1 8.1

Useful efficiency

At rated heat output and high temperature regime 1)  At 30% of rated heat output and low temperature regime 2) 

% 88.8 88.8 88.8

% 99.5 99.5 99.5

Auxiliary electricity consumption

At full load el At part load el In standby mode P

max

min

kW 0.029 0.029 0.029 kW 0.014 0.014 0.014 kW 0.001 0.001 0.001

Other items

Standby heat loss P Ignition burner power consumption P

stby

kW 0.078 0.078 0.078 kW000

ign

Emissions of nitrogen oxides NOx mg/kWh 25 25 25 Annual energy consumption Q Sound power level, indoors L

kWh

dB(A) 52 52 52

Additional data for combination heaters

Declared load profile – – XL XL XL Daily electricity consumption Q

kWh 0.144 0.137 0.141

elec

Annual electricity consumption AEC kWh 32 30 31 Daily fuel consumption Q

kWh 20.667 20.741 20.702

fuel

Annual fuel consumption AFC GJ 18 18 18 Water heating energy efficiency 

%85 85 85

Water heating energy efficiency class – – A A A

Table 7 Product data for energy consumption

1) High temperature regime means 60 °C return temperature at heater inlet and 80 °C feed temperature at heater outlet.

2) Low temperature means for condensing boilers 30 °C, for low-temperature boilers 37 °C and for other heaters 50 °C return temperature (at heater inlet).

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PRE-INSTALLATION

4PRE-INSTALLATION

4.1 Cleaning primary systems

CAUTION:

▶ ISOLATE THE MAINS SUPPLIES BEFORE STARTING

ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.

NOTICE: All the following pre-installation sections must be read and requirements met before starting the boiler or flue installations.

NOTICE:

▶ Debris from the system can damage the boiler and

reduce efficiency. Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance guarantee and contravene the Building Regulations.

▶It is recommended that you fit a primary water

cleanser to the system. Worcester recommends fitting a filter that will help remove both magnetite and non-magnetic debris.

BEFORE CLEANING THE SYSTEM:

▶ Ensure that the system and pipe work is in good working order. ▶ Where possible keep the existing boiler/circulating pump in place

when flushing the system.

FOLLOW THE GUIDANCE OF BS7593:

Treatment of water in domestic hot water central heating and also the flushing guidelines below.

NOTICE: Artificially softened water must not be used to fill the central heating system.

FLUSHING THE SYSTEM

▶ Fill the system with cold water and check for leaks. ▶ Open all drain cocks and drain the system. ▶ Close drain cocks and add a suitable flushing agent compatible with

aluminium at the correct strength for the system conditions in accordance with the manufacturer‘s instructions.

The pH value of the system water must be less than 8 or the appliance guarantee will be invalidated.

▶ Circulate the flushing agent before the boiler is fired up. ▶ Run the boiler/system at normal operating temperature as directed by

the manufacturer of the flushing agent.

▶ Drain and thoroughly flush the system to remove the flushing agent

and debris.

▶ It may be necessary to use a power flushing machine to aid the

cleansing procedure in some circumstances.

▶ Close the drain cocks and refill with fresh water and a suitable

inhibitor.

▶ Vent any air from the boiler and system.

Inhibitor

Add a suitable inhibitor or combined inhibitor/anti-freeze, if the system is exposed to freezing conditions, to the heating system in accordance with the DWTA code of practice and manufacturer‘s guidelines.

Water treatment products

Suitable water treatment products can be obtain from the following manufacturers:

FERNOX 0870 601 5000 or www.fernox.com SENTINEL 0800 389 4670 or www.sentinel-solutions.net

Artificially softened water

It is possible to have an ion exchange water softener fitted to the cold water system of the property. However, the boiler requires an untreated cold water connection taken from the mains supply, before the water softener, to the primary water filling point of the heating system.

4.2 MAINS SUPPLY

4.2.1 Electrical supply

• Supply: 230V - 50 Hz

• Cable: PVC insulated 0.75mm 90 °C.

• External 3A fuse to BS1362.

• The boiler must be earthed.

• This boiler must not be connected to a 3 phase supply.

• IPX4D.

NOTICE: IP rating change IP rating IPX4D is reduced to IP20 if the following

controls are fitted; MT10, 7 716 192 036 or MT10RF, 7 716 192 037 or FR100 7 716 192 067. This is reduced to IPX2D when the Sense II 7 738 111 064 is fitted.

• Wiring must comply with the latest edition of BS 7671 (IET wiring

regulations).

4.2.2 Gas supply

To ensure that the equipment is in good working order and can meet the gas flow and pressure requirements, in addition to the demand from any other appliance being served, the following applies:

• Boilers using Natural Gas (NG) must be connected to a governed

meter.

• Liquid Petroleum Gas (LPG) must be connected to a regulator.

• Installation and connection of the gas supply to the boiler must be in

accordance with BS6891.

• Gas pipe sizing should be calculated to ensure no more than the

permitted mbar drop between the meter/governor to the appliance inlet. ( Commissioning section).

• The meter or regulator and pipe work to the meter must be checked,

preferably by the gas supplier.

(24 x 0.2mm) temperature rated to

WARNING: Sealing agents ▶ Normally the addition of sealing agents to the system

water is not permitted as this can cause problems with deposits left in the heat exchanger.

▶ In cases where all attempts to find a micro leak have

failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer.

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PRE-INSTALLATION

4.2.3 Water supply

Water mains pressure:

• Minimum mains water pressure for maximum performance: refer to the Technical data in section 3.3.

• Maximum mains fed water pressure 10 bar. If necessary fit a pressure reducing valve.

NOTICE: Non return, back flow prevention devices (including those associated with water meters) fitted to the mains water supply can cause a pressure build up which could damage the boiler and other household appliances.

• Where the mains water supply has a non-return, back flow prevention valve fitted, a mini expansion vessel (1) should be connected to the mains water inlet pipe (2) between the nonreturn valve (3) and the boiler (4) as shown below.

The boiler is equipped with an internal by-pass. The internal bypass is not intended to be a substitute for an external system bypass. An external automatic bypass should be used if the system flow can be significantly adjusted or stopped by zone valves and thermostatic radiator valves (TRV).

SHOWERS/BIDETS:

• If a shower head can be immersed in water or comes closer than 25mm from the top edge of a bath or shower tray spill over level then an anti-siphon device must be fitted to the shower hose.

• Bidets with direct hot and cold mains water can be used (with the approval of the local water authority) and must be the over rim flushing type with shrouded outlets to prevent the fitting of hand held sprays.

6720643895-04.1Wo

1 Mini expansion vessel - part no. 7 716 192 105 2 Mains water inlet pipe 3 Non return valve 4Boiler

Use in hard water areas:

Normally there is no need for water treatment to prevent scale formation as the maximum temperature of the DHW heat exchanger is limited by the electronic control.

In areas where temporary water hardness exceeds 200 ppm, consideration may need to be given to the fitting of a scale prevention device. In such circumstances, the advice of the local water authority should be sought.

4.3 Water systems and pipe work

PLASTIC PIPE WORK:

• Any plastic pipe work must have a polymeric barrier with 600mm (minimum) length of copper pipe before being connected to the boiler.

• Plastic pipe work used for underfloor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approximately 50°C.

PRIMARY SYSTEMS CONNECTIONS/VALVES:

• 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.

• All other valves should conform to BS1010.

• Thermostatic radiator valves (TRV’s) must be fitted to all rooms except bathrooms and the room in which the room thermostat is fitted.

• A drain cock is required at the lowest point(s) in the system.

• An air vent is required at the high point(s) in the system.

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PRE-INSTALLATION

CV = Check Valve SV = Stop Valve

SV SV

Test point

Temporary hose

Hose union

Heating

return

Mains

supply

5 5

6720643895-06.1Wo

5 5

6720646608-04.1Wo

400

600

800

1000

1200

1400

1600

0.8

0.6

0.7

0.5

0.4

0.3

0.2

0.1

4 3 2

6720813276-13.1Wo

Flow Rate (l/hr)

Pressure (bar)

200

SEALED PRIMARY SYSTEM:

NOTICE: Artificially softened water must not be used to

fill the central heating system.

• The CH sealed system must be filled using a WRAS approved filling loop or comply with figure 2 for system fill.

• Where the system volume is more than 100 litres or exceeds 2.65 bar at maximum heating temperature, an extra expansion vessel (2) must be fitted as close as possible to the appliance in the central heating return.

• Pressurise the extra expansion vessel (2) to the same figure as the expansion vessel built into the appliance, (approximately 0.75 bar).

• Do not use galvanised pipes or radiators.

SYSTEM FILL

Fig. 2 System fill

TYPICAL SEALED SYSTEM

Available pump head

In order to save as much energy as possible and the minimise the possibility of water circulation noise, a low characteristic should be chosen.

The pump map can be selected within 2.1C in the Boiler settings menu list:

• 0 (pump variable speed setting)

• 1 (constant pressure low)

• 2 (constant pressure low/middle)

• 3 (constant pressure middle/high)

• 4 (constant pressure high)

The factory setting is:

4 (constant pressure high)

Constant pressure head

If the constant pressure head option (1 - 4) is chosen, the differential pressure between the CH flow and return will be kept at the corresponding value. When the CH system is cold and the radiator TRVs are fully open, the pump will be running faster to try and maintain the pressure differential. When the TRVs start to close and the resistance of the CH system increases, the pump speed reduces to maintain the pressure.

The setting (1 - 4) to be selected is dependent upon the resistance and heat load of the CH system. The hig her these are, the higher the pressure constant

Fig. 3 Sealed system

Fig. 4 Sealed system with zone valves

1 Appliance expansion vessel - CH 2 Extra expansion vessel - CH return 3 Pressure relief discharge 4 Drain cock 5Radiators 6 Zone valves

Table 8 Key to figs. 3 and 4

4.4 Condensate pipe work

NOTICE:

▶ 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 boiler location.

▶ The condensate pipe must be nominally

22mm Ø plastic pipe.

▶ The condensate pipe work must fall at least 52mm

per metre towards the outlet and should take the shortest practicable route.

▶ Ensure there are no blockages in the pipe run.

Key to condensate illustrations 1 Condensate discharge from boiler 2 Soil and vent stack 3 Minimum 450mm and up to three storeys 4 Visible air break at plug hole 5 Sink or basin with integrated overflow 6 75mm sink waste trap 7 Condensate pump * Condensate trap of 75mm already incorporated into the boiler

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PRE-INSTALLATION

100mm

75mm

min.

22mm Ø

6720644744-07.3Wo

4.4.1 Internal connections

In order to minimise risk of freezing during prolonged cold spells, the following methods of installing 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 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 pipe should be used.

22mm Ø

Fig. 5 Disposal to soil vent stack

Alternatively if the first option is not possible an internal kitchen or bathroom waste pipe, washing machine waste pipe etc. can be used. Ensure that the condensate drain pipe is connected “down stream” of the waste trap.

6720644744-06.3Wo

22mm Ø

Fig. 7 Condensate pump disposal

4.4.2 External connections

NOTICE: Freezing conditions

▶ When the position of the boiler prevents internal

routing, we recommend installing a CondenseSure siphon to significantly reduce the risk of freezing.

▶ Pipe work length should be kept to a minimum and

the route as vertical as possible.

▶ Weather proof insulation must be used, if not using a

CondenseSure siphon.

NOTICE: Condensate waste ▶ Care should be taken when siting a soak-away to

avoid obstructing existing services.

75mm

min.

6720644744-08.3Wo

Continued - Key to condensate illustrations

8 PVCu strap on fitting 9 100mm Ø minimum plastic pipe 10 Drainage holes 11 Limestone chippings 12 Bottom of sealed tube 13 Insulate and increase pipe size 14 Pipe work transition 15 External air break

Fig. 6 Disposal to a waste pipe

CONDENSATE PUMP

Where “gravity discharge” to an internal termination is not physically possible, or where very long internal runs would be required to reach a suitable discharge point, condensate should be removed using a proprietary condensate pump, of a specification recommended by the boiler or condensate 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 or bathroom waste pipe, washing machine waste pipe etc. A suitable permanent connection to the foul waste pipe should be used.

16 Air gap 17 External rain water pipe into foul water 18 43mm 90° male/female bend * Condensate trap of 75mm already incorporated into the boiler

If no other discharge method is possible then the use of an externally run condensate drainage pipe terminating at a suitable foul water discharge point, or purpose-designed soak away, may be considered. If this method is chosen then the following measures should be adopted:

▶ Use a CondenseSure siphon to help prevent the condensate freezing. ▶ The external run be kept as short as possible and not exceed 3

metres.

▶ The pipe should be run internally as far as possible before going

externally and the pipe diameter should be increased to 32mm before it passes through the wall to the exterior. The pipe should be insulated using suitable waterproof and weather resistant insulation, if not using a CondenseSure siphon.

▶ The external pipe should take the shortest and least exposed route to

the discharge point, and should "fall" as steeply as possible away from the boiler, with no horizontal runs in which condensate might stand.

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PRE-INSTALLATION

▶ The use of fittings, elbows etc. should be kept to a minimum and any

internal “burrs” on cut pipe work should be removed so that the internal pipe section is as smooth as possible.

FITTING AN EXTERNAL AIR BREAK

• Refer to figure 8 when a rain water down pipe is used to dispose of

condensate.

• An air break must be installed in the 43mm pipe work, between the

boiler condensate outlet and the drainpipe, outside the property, to avoid flooding during adverse weather conditions.

18 8

Fig. 8 Disposal into a rainwater down pipe

6720644744-09.3Wo

Minimum hole size for the condensate soak away must be 400mm deep by 300mmØ .

In situations where there are likely to be extremes of temperature or exposure, the use of a proprietary trace-heating system for external pipe work, incorporating an external frost thermostat, should be considered. If such a system is used, the requirement to use 32mm pipe does not apply. However, all other guidance above and the instructions for the trace heating system, should be closely followed.

NOTICE: Unheated internal areas. ▶ Internal pipe runs in unheated areas such as lofts,

basements and garages should be treated as external runs and consideration should be given to using a CondenseSure siphon.

25mm min.

Condensate drainage pipe can be run above or below ground.

Where the pipe terminates over an open drain or gully, the pipe should terminate below the grating level, but above water level, in order to minimise “wind chill” at the open end.

The use of a drain cover (such as those used to prevent blockage by leaves) may offer further protection from wind chill.

Pipe drainage will be improved if the end is cut at 45° as opposed to a straight cut.

Fig. 9 External disposal

CONDENSATE SOAK AWAY

• The condensate drainage pipe may be run above or below the ground

to the soak away. The examples shown on this page run above ground.

• The soak away must use a 100mm Ø plastic tube with two rows of

three 12mm holes on 25mm centres and 50mm from the bottom of the tube. The holes must face away from the house.

• The tube must be surrounded by at least 100mm of limestone

chippings to a depth of 400mm.

25mm min.

6720644744-10.3Wo

Fig. 10 Condensate pump to external disposal

Fig. 11 Soak away

500mm min.

6720644744-12.3Wo

25mm min.

400mm

min.

6720644744-11.2Wo

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PRE-INSTALLATION

6720646608-123.1Wo

1060/1100mm***

880mm

300mm

400mm

170/210mm***

600mm**

5mm

200mm

20mm*

6720646608-122.1Wo

4.5 Pressure relief pipe work

NOTICE:

▶ The pressure relief valve is a safety device for the

boiler and if activated may discharge boiling water or steam through the relief valve drain pipe.

▶ Care should be taken when siting the outlet pipe so

that it does not cause an obstruction or discharge above a window, entrance or other public access where it could cause a hazard.

• The pressure relief drain pipe (1) from the boiler should be at least 15mm diameter copper pipe and run downwards, away from any electrical equipment or other hazard, preferably to an external drain or soak away.

• The pressure relief drain pipe (1) should be finished with a partial bend, near the outlet to face the external wall (as shown) to help prevent freezing.

4.6 Boiler location and clearances

4.6.1 Installation

This appliance is only suitable for installing internally within a property at a suitable location onto a fixed, rigid surface at least the same size as the appliance and capable of supporting the appliance weight.

No surface protection is required against heat transfer from the appliance.

The appliance must be installed where:

• An engineer can gain clear and safe access to work on the product or component, including making adequate provision for visual inspection of flues in voids.

• The homeowner can gain clear and safe access to the controls, check, top up or reset the appliance.

• Products in loft cavities must have permanent fixed lighting, a permanent fixed retractable ladder and a fixed floor area sufficient to allow access for normal use and servicing directly under and around the product and between and the access hatch.

4.6.2 Installation and servicing clearances

Fig. 12 Pressure relief pipe work

[2] Outside wall [1, 3] PRV drain pipe [4] External drain

Fig. 13 Unventilated compartment

[*] Minimum clearance to removable door [**] Minimum clearance required for servicing [***] Height for either 60/100 flue or 80/125 flue

4.6.3 Compartments

Follow the requirements of BS6798 and BS5440 Part 2 and note:

• Minimum clearances must be maintained.

• An access door is required to install, service and maintain the boiler

and any ancillary equipment.

• If fitting the boiler into an airing cupboard use a non-combustible

material to separate the boiler from the airing space. The material can be perforated up to a maximum hole size of 13mm.

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PRE-INSTALLATION

6720646608-124.3Wo

Radius 600mm

600mm

2250mm

6720646608-05.1Wo

1 2 3 4 5 6 7

6720646608-06.2Wo

5 6

4.6.4 Bathrooms

Please check the IP rating of any control to be used on this appliance. Only certain controls can be fitted when the appliance is inside of the shaded area.

An appliance with blanking panel or controls that do not change the IP rating can be installed in zone 2.

Additional RCD (Residual Current Device) protection may be required. Consult the latest version of BS7671 (IET wiring regulations).

Fig. 14 Bathroom installations

[2*] Without the end wall, zone 2 must extend 600mm from the bath

4.7 Plumbing manifold

4.7.1 Connections

Heating System 22mm compression fittings DHW 15mm compression fittings Gas 22mm compression fittings

Use the fittings supplied in the Hardware literature pack.

Further guidance on pipe routing can be found printed on the boiler template (supplied with the boiler).

• For further ease of fitting, an optional Vertical Pre-piping Assembly kit is available, comprising four pre-formed copper water pipes. Part number: 7 716 192 713.

Fig. 15 Pipe dimensions

Fig. 16 Plumbing manifold

No. Function

From left case edge

Diameter of pipe

1 Condensate drain 33mm 22mm 2CH Flow 65mm 22mm 3 DHW Outlet 130mm 15mm 4Gas 195mm 22mm 5 DCW Mains In 260mm 15mm 6PRV drain 291mm 15mm 7CH Return 325mm 22mm

Table 9 Key to figures 15 & 16

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PRE-INSTALLATION

6720806945-19.1Wo

6720806945-21.1Wo

4.8 Flue options

WARNING: Flue systems

▶ Only use Worcester, Bosch approved flue systems,

no other manufacturer’s flue systems have been approved for use with Worcester appliances.

CAUTION: Non accessible flue systems: ▶ Where a flue system is not going to be accessible,

provision must be made for service and inspection.

▶ Voids containing concealed flues must have at least

one inspection hatch no less than 300mm square.

▶ Flue joints within the void must not be more than 1.5

metres from the edge of the inspection hatch.

▶ Inspection hatches should be located at changes of

direction.

▶ If this is not possible, bends should be viewable from

both directions.

NOTICE: Effective flue lengths: ▶ each 90° bend is equivalent to 2 metres of straight flue ▶ each 45° bend is equivalent to 1 metre of straight flue

Plume management kits are available for the 60/100 horizontal flue system, Part number 7 716 191 086. Refer to the manual supplied with the Plume Management kits for complete installation instructions

Part number Flue Description

7 716 191 082 60/100 Telescopic horizontal flue assembly 7 716 191 171 60/100 Longer telescopic horizontal flue

assembly

7 733 600 048 60/100 Horizontal high level telescopic flue

kit 7 719 003 702 80/125 Telescopic horizontal flue assembly 7 719 002 430 60/100 Vertical flue assembly 7 719 002 431 80/125 Vertical flue assembly

Table 10 Flue kit part numbers

Telescopic horizontal flue assembly

60/100 mm

350 mm - 570 mm

130 mm Min

6720806945-18.1Wo

Flue length (mm)

60/100 80/125

Telescopic horizontal flue assembly 180 - 570 405 - 600 Longer telescopic horizontal flue assembly 570 - 790 N/A

Table 12

Extended horizontal flue

Maximum flue length

(mm)

60/100 80/125

Extended horizontal flue 6,000 15,000

Table 13

Horizontal flue with additional elbow (1 x 90 ° bend)

4.8.1 Flue lengths

The flue systems have different maximum flue lengths The Greenstar series has the option of two horizontal 60/100 RSF

(telescopic and longer telescopic) and one horizontal 80/125 RSF (telescopic) flue system and two vertical RSF (60/100 or 80/125) flue systems:

Refer to the following example Flue options for the maximum flue lengths.

Horizontal high level flue assembly

60/100 mm

383 mm - 603 mm

130 mm Min

Flue length (mm)

60/100 80/125

Horizontal high level telescopic flue assembly 202 - 603 N/A

Table 11

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Maximum flue length

(mm)

60/100 80/125

Horizontal flue with 1 x 90° bend 4,000 13,000

Table 14

Horizontal flue with additional elbows (2 x 90 ° bends)

Maximum flue length

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(mm)

60/100 80/125

Horizontal flue with 2 x 90° bends 2,000 11,000

Table 15

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PRE-INSTALLATION

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A = 300 mm

B = 500 mm

High level horizontal flue

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Maximum flue length

(mm)

60/100 80/125

High level horizontal flue 6,000 15,000

Table 16

High level horizontal flue with additional elbows

Vertical balanced flue assembly

Maximum flue length

(mm)

60/100 80/125

Vertical balanced flue assembly 6,000 15,000

Table 19

Vertical balanced flue with elbow offset (2 x 90 ° bends)

Maximum flue length

(mm)

60/100 80/125

High level horizontal flue with 2 x 90° bends 4,000 13,000

Table 17

High level horizontal flue with additional elbows

Maximum flue length

(mm)

60/100 80/125

High level horizontal flue with 3 x 90° bends 2,000 11,000

Table 18

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Maximum flue length

(mm)

60/100 80/125

Vertical balanced flue with 2 x 90° bends 2,000 11,000

Table 20

Vertical balanced flue with elbow offset (2 x 45 ° bends)

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Maximum flue length

(mm)

60/100 80/125

Vertical balanced flue with 2 x 45° bends 4,000 13,000

Table 21

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4.9 Flue terminal positions

600

300

200

300

1,200

Boundary Line

1,500

All measurements in millimetres

300

500

600

300

600

400

300

500

600

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300

52mm

104mm

PRE-INSTALLATION

Fig. 17 Flue terminal positions

NOTICE:

▶ All measurements are the minimum clearances required. ▶ Terminals must be positioned so to avoid combustion products entering the building. ▶ Support the flue at approximately one metre intervals and at a change of direction, use suitable brackets and fittings.

(flue bracket 100mm part number: 7 716 191 177, flue brackets 100mm x 6 part number: 7 716 191 178, flue bracket 125mm part number: 7 716 191 179).

Key to illustration

1. 300mm adjacent to a boundary line.

2. The dimension below eaves, gutters, pipes and drains can be reduced to 25mm, as long as the flue terminal is extended to clear any overhang. External flue joints must be sealed with suitable silicon sealant.

3. 1,500mm between a vertical flue terminal and a window or dormer window.

4. 1,200mm between terminals facing each other.

5. Vertical flue clearance, 300mm adjacent to a boundary line unless it will cause a nuisance. BS 5440:Part 1 recommends that care is taken when siting terminal in relation to boundary lines

6. 600m distance to a boundary line, unless it will cause a nuisance. BS 5440:Part 1 recommends that care is taken when siting terminal in relation to boundary lines.

7. 600mm minimum clearance from a skylight to a vertical flue.

8. Vertical flue clearance, 500mm to non-combustible building material, and 1,500mm clearance to combustible building material.

9. 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. This does not apply to building protrusions less than 450mm.

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 heavy snow fall.

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.

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16. The dimension below eaves, balconies and car ports can be reduced to 25mm, as long as the flue terminal is extended to clear any overhang. External flue joints must be sealed with suitable silicon sealant.

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.

Note:

▶ 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.

▶ A flue terminal guard should be fitted over a terminal,

if persons could come into contact with the terminal, or it could be subject to damage and where the terminal is less than 2,000mm from the finished floor level.

PRE-INSTALLATION

4.10 Plume management terminal positions

All measurements in millimetres

Plume re-direction:

180°

±80°

200

300

150

200

150

1,200

Fig. 18 Plume terminal positions

Boundary Line

600

300

1,500

150

300

±45°

Flue Exhaust Outlet

Air Intake

300

150

Flue terminal guard 7 716 191 176

300

150

200

100

600

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600

Maximum and minimum plume management lengths: ▶ A minimum distance of 500mm must be maintained between the plume management outlet and the flue air intake. ▶ The maximum plume management length is 4.5 metres for the appliances detailed on the front of this manual. ▶ The 45° bend is equivalent to 0.75 metres of straight plume management and the 90° bend is equivalent to 1.5 metres.

NOTICE:

▶ All measurements are the minimum clearances required. ▶ Refer to previous page for all concentric flue terminal positions unless the flue position is specified on the figure above “Plume

terminal positions”. ▶ Terminals must be positioned so to avoid combustion products entering the building. ▶ Support the flue at approximately one metre intervals and at a change of direction, use suitable brackets and fittings.

Key to illustration

1. 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 minimum clearances to an opening in the direction that the plume management is facing, must be increased to 1,500mm. Where the flue is less than 150mm to a drainpipe and plume redirection is used the deflector should not be directed towards the drainpipe.

2. 300mm adjacent to a boundary line.

3. Plume Management kit air intake can be reduced to 150mm providing the flue exhaust outlet is no less than 300mm adjacent to a boundary line.

4. 1,200mm between terminals facing each other.

5. 600mm distance to a boundary line, unless it will cause a nuisance. BS 5440:Part 1 recommends that care is taken when siting terminal in relation to boundary lines.

6. Using a Plume Management kit the air intake measurement can be reduced to 150mm providing the flue exhaust outlet has a 300mm clearance. The initial horizontal run from the terminal elbow must have a minimum 10° fall back, (stop tabs in the elbow prevent less than 10°) to the appliance for proper disposal of condensate. Any further horizontal runs can be 3°.

– For details on specific lengths see relevant appliance Technical &

Specification information.

7. Internal/external corners. The air intake clearance can be reduced to 150mm providing the flue exhaust outlet has a 300mm clearance.

8. 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 cause a

nuisance. BS 5440: Part 1 recommends that care is taken when siting terminals in relation to surfaces facing a terminal.

Note:

▶ 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.

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PRE-INSTALLATION

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±80°

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4.10.1 Determine the plume management system length

Effective straight flue length for telescopic flue with plume

management

Minimum plume length

500mm (M)

Maximum flue length

5,000mm (L)

Maximum plume length

5,000mm (M)

Maximum flue length

2,200mm (L)

Note: Measurement M plume length ▶ Measurement M must be a minimum of 500mm and

must not exceed 4,500mm for a 60mm plume management system used with the horizontal Ø 60/ 100mm flue.

Minimum plume management length

The minimum plume length should be calculated to ensure that the air inlet and exhaust have a minimum distance of 500mm between them ( figure 19). The plume management can be in any configuration, within the parameters of the plume management installation instructions, as long as it does not terminate inside the shaded area.

WARNING: Minimum plume management length. The minimum distance of 500mm must be maintained between air inlet and exhaust.

▶ Do not terminate the plume management inside the

shaded area shown in figure 19

Flue length versus plume management length

Fig. 20 Effective lengths L and M

4,500

3,500

2,500

Fig. 19 Terminal exclusion zone

NOTICE: Cutting the 500mm pipe If the 500mm plume management pipe kit is cut, an

additional elbow will be required to join the pipe work. ▶ The Plume management extension kit contains the

components required for such a configuration.

1,500

500

Min

1,000 2,000 3,000 4,000 5,000 6,000

Fig. 21 Effective flue lengths versus plume management lengths

[Min] Minimum plume kit length 500mm [M] Plume management length allowed (mm) [L] Effective flue length (mm) [1] 25 & 30Si Compact [2] Maximum plume length for all boilers

Refer to figure 21 to determine the appropriate plume length (M) versus the flue length (L). The lengths for both plume and flue are the effective lengths, which includes the effective length of any bends plus the straight lengths. The graph can be used to calculate:

• Effective flue length if a specific effective plume length is required.

• Effective plume length if a specific effective flue length is required.

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+ 53 hidden pages

worcester Greenstar ErP Compact CDI 28, Greenstar ErP Compact CDI 28 LPG, Greenstar ErP Compact CDI 32, Greenstar ErP Compact CDI 32 LPG, Greenstar ErP Compact CDI 36 User guide

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

1 Key to symbols and safety instructions

1.1 Key to symbols

Warnings

Important information

Additional symbols

SYMBOLS USED IN THIS MANUAL

PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.

1.2 Safety precautions

2Regulations

Installation regulations

British standards

L.P.G. Installations

Irish Standards

Timber Framed Buildings

Potable Water

CH Water

3 APPLIANCE INFORMATION

3.1 Appliance

3.2 Layout

3.3 Technical data

3.4 Energy efficiency

Natural gas appliances

LPG appliances

4PRE-INSTALLATION

4.1 Cleaning primary systems

Inhibitor

Water treatment products

Artificially softened water

4.2 MAINS SUPPLY

4.2.1 Electrical supply

4.2.2 Gas supply

4.2.3 Water supply

Water mains pressure:

SHOWERS/BIDETS:

Use in hard water areas:

4.3 Water systems and pipe work

PLASTIC PIPE WORK:

PRIMARY SYSTEMS CONNECTIONS/VALVES:

SEALED PRIMARY SYSTEM:

SYSTEM FILL

TYPICAL SEALED SYSTEM

Available pump head

Constant pressure head

4.4 Condensate pipe work

4.4.1 Internal connections

4.4.2 External connections

4.5 Pressure relief pipe work

4.6 Boiler location and clearances

4.6.1 Installation

4.6.2 Installation and servicing clearances

4.6.3 Compartments

4.6.4 Bathrooms

4.7 Plumbing manifold

4.7.1 Connections

4.8 Flue options

Telescopic horizontal flue assembly

Extended horizontal flue

Horizontal flue with additional elbow (1 x 90 ° bend)

4.8.1 Flue lengths

Horizontal high level flue assembly

Horizontal flue with additional elbows (2 x 90 ° bends)

High level horizontal flue

High level horizontal flue with additional elbows

Vertical balanced flue assembly

Vertical balanced flue with elbow offset (2 x 90 ° bends)

High level horizontal flue with additional elbows

Vertical balanced flue with elbow offset (2 x 45 ° bends)

4.9 Flue terminal positions

4.10 Plume management terminal positions

4.10.1 Determine the plume management system length

Minimum plume management length

Flue length versus plume management length