Greenstar Combi Gas-fired Condensing Wall Mounted Boiler

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Technical and Specification InformationGreenstar CDi Classic SeriesGreenstar CDi Compact SeriesGreenstar Si SeriesGreenstar i Junior SeriesGreenstar combi gas-fired condensingwall mounted boiler rangeNEWGreenstarCDi Classic &CDi Compact

Worcester and you. Making a diff2As part of the Bosch Group, Worcestersupported by an experienced technicalproducts are designed and manufactured toservices team which is able to provideprovide customers with the highest levels ofcomprehensive support and advicequality and reliability which are synonymousfrom designing system layouts throughwith the Bosch name throughout the world.to installation.As part of Europe’s largest supplier ofWorcester is dedicated to providing energyheating products, Worcester, Bosch Groupefficient gas- and oil-fired condensinghas the UK-based resources and supportboilers, as well as an extensive range ofcapability to offer you the value-addedrenewable technologies. All of our productssolutions you deserve. Worcester employshave been developed and introduced witha nationwide network of Service Engineersthe aim of helping the UK to achieve theand technically trained Field Sales ManagersGovernment’s efficiency targets.

The reception and main entranceat our Worcester headquartersference.ContentsPageThe Greenstar combi condensing boiler range4-5Key features of the range6-7Greenstar CDi Classic features and benefits8-9Inside story – Greenstar CDi Classic10 - 11Greenstar CDi Compact features and benefits12 - 13Inside story – Greenstar CDi Compact14 - 15energy efficient appliances in homes acrossGreenstar Si and i Junior features and benefits16 - 17the UK. We will continue to invest in ourInside story – Greenstar Si and i Junior18 - 19products, people, facilities and added valueOptional plug-in controls20 - 21Site preparations and guidance22 - 27Greenstar combi installation requirements28 - 30The Worcester Greenstar System Filter31Carl Arntzen,Condensate pipework32 - 33Managing Director,The Worcester CondenseSure auxiliary siphon34 - 35Horizontal and vertical flue terminal positioning36 - 37Greenstar combi boiler rangehorizontal fluing options38 - 41Greenstar combi boiler rangevertical fluing options42 - 44“At Worcester we recognise the vital role youplay in the specification and installation ofservices to ensure you have all you requirein order to deliver only the best solutions toyour customers’ requirements.”Bosch Thermotechnology Ltd.Plume management positioning and system options 45 - 48Greenstar combi boiler range accessories49 - 53Greenfloor heating54Worcester training55 - 57After-sales583

The Greenstar combi gas-fired wallNEWGreenstar SiGreenstar CDi Classic*The Greenstar combi range is part of a market-leadingrange of energy-saving gas-fired boilers. Renowned fortheir energy efficiency, reliability, ease of installation andservicing, more than 2 million Greenstar combi boilers havebeen installed in homes across the UK.4*Greenstar CDi Compact was launched after the 2012 Which? Survey.

mounted condensing boiler rangeNEWGreenstar i JuniorGreenstar CDi CompactNow part of the range is the all-new, revolutionaryincreased domestic hot water performance, a new magneticGreenstar CDi Compact series, which has an innovativeflap and reduced standby electrical consumption.heat exchanger designed to combine high outputs withcompact dimensions.For lower hot water output applications, the Greenstarrange also offers the Si and i Junior series, which areAlso, the new and improved Greenstar CDi Classic, hasideal for apartments and other small properties withrecently undergone a number of enhancements includingone bathroom.5

Key features of the rangeWinner of 23 Which? Best Buy awardsKeep hot facilityin 2011 and 2012.All Greenstar combi models have an in-builtFor the second year running, in a survey of Which?‘keep hot’ facility which will keep the primary watermembers, the Worcester Greenstar gas-firedwithin the heat exchanger hot – approximatelycondensing boiler range scooped 23 Best Buy2.5 litres volume. This will ensure that hot water isawards.* In the latest survey, no other manufacturerdelivered almost instantly to the opened outlet.scored higher on reliability and customer satisfaction.ECO modeHighly efficient, highly cost effectiveWith the ECO mode button activated, the ‘keep hot’Greenstar condensing combi boilers have an annualfacility is de-energised and the hot water will beA rated efficiency (SEDBUK 2005 value) of overheated from cold. A slight delay should be expected90%, efficiently producing heating and hot water forbefore the hot water is at full temperature when inthe home. Non-condensing boilers achieve aroundECO mode. By selecting Eco mode, less gas will be78% efficiency.used as energy is used only on demand.The Greenstar CDi Compactfascia with the intuitivein-built displayLow NOx optionsCentral heating modeWorcester’s commitment to reduce emissions fromOn a central heating demand, the boiler will initiallygas-fired condensing boilers sees all Greenstarfire at minimum output before modulating upwardscombi boilers achieve NOx values 40mg/kWh. Thisto meet the system’s actual requirement. Electronicenables the appliances to achieve 3 credits undercontrols within the boiler continually monitor thethe Code for Sustainable Homes. With Si andheating flow and return temperature and increasei Junior models this is achieved using the Low NOxor decrease the output on demand.Code Plug supplied with the appliance. When fitted,the central heating output is reduced to 13kW.Fluing optionsThe Greenstar combi range has a full range ofHot water modeCondensfit II flue options in both 60/100mmWhenever a hot water tap is turned on, theand 80/125mm diameters and includes a plumeincoming mains water will activate a flow turbinedeflector as standard. This versatile flue systemwhich, via the electronic control system, ignitescan be run horizontally or vertically.the pre-mix burner. Boiler output is automaticallyboosted to maximum in order to heat the incomingcold water as it passes through the heat exchanger.Electronic controls modulate the boiler output toensure an accurate hot water temperature.6

*The Greenstar combi range at a glance29CDiClassicBoilerPart ssic Compact Compact Compact25Si30Si24iJunior28iJuniorNG7 738 100 216 7 738 100 218 7 738 100 222 7 713 331 019 7 716 130 234 7 716 130 235 7 716 130 236 7 716 130 139 7 716 130 140 7 716 130 141 7 716 130 142LPG7 738 100 217 7 738 100 219 7 738 100 223 7 713 331 020 7 716 130 237 7 716 130 238 7 716 130 239 7 716 130 146 7 716 130 145 7 716 130 148 7 716 130 W30kW24kW28kWFlow rate at 35ºC T( inFlow rate at 40ºC T( W30kW30kW30kW24kW24kW24kW24kW24kW24kW24kWMaximum output kWto central heating (CH)with low NOx code plug–––––––13kW13kW13kW13kWCH temperature control DHW temperaturecontrol ––Modulating control Electronic ignition In-built filling link (optional)(optional)(optional)(optional)Condensing in DHW ––––Output kW to DHWMinOutput kW tocentral heating (CH) MaxEnergy-saving & environmentalTime & labour-saving installationEnd user comfort and convenience SEDBUK A rating of 90.1% Wall frame allows space for pipes 10 year guarantee on Worcesterand above (2005 value) Simple and intelligent controloptions are availableto optimise boiler efficiency Low electrical consumption instandby mode behind the boiler as standard Vertical pre-piping assemblyavailable as an accessory Full range of Condensfit II flue options Multi-directional fluing meansAluminium-silicon heat exchangersboiler can be sited in a widerdeliver high efficiency and reliabilityvariety of placesGreenstar CDi Classic and CDiCompact condense in DHW mode Modulating pump which uses lesselectricity than a fixed speed pump –Greenstar CDi Classic andCDi Compact only Anti-cycle control. The boiler comes pre-wired andpre-plumbed There is no need to install a hotwater cylinder There is no need to install astorage tank in the roof space There is less pipework in theprimary heat exchanger† Boiler protection plans availablefor both new and out of guaranteeWorcester Greenstar boilers Bosch renowned qualityand reliability Built-in boiler frost protection Compact dimensions –Greenstar CDi Compact,Si and i Junior models ECO mode for energy saving fuelconsumption Controls behind flap – aestheticallypleasing and minimises the risk oftampering with controls.heating system.*Source: Which? 2012 survey published in Sept 2012. Greenstar CDi Compact was launched after the survey. †Subject to terms and conditions.7

Greenstar CDi ClassicFeatures and benefitsThe top-of-the-range award-winning Greenstar CDi Classic is a highperformance boiler that is suitable for small, medium and large-sizedproperties with one or two bathrooms. It has set the benchmark withinthe industry for efficiency, reliability and ease of installation, whileachieving a market leading output of up to 42kW.The Greenstar CDi Classic offers the opportunity to range-rate the centralheating output to perfectly match the properties requirements whichreduces cycling and improves efficiency further.As well as being the flagship boiler in our Greenstar combi range, theupgraded CDi Classic now benefits from a number of new improvementsincluding higher domestic hot water flow rates of 12.3, 14.3 and 16.4 tocompliment the already class-leading 17.2 l/min performance.The improvements to the control box now includes lead-free componentsGreenstar CDi Classic isavailable with DHW flow ratesof 12.3, 14.3, 16.4 and17.2 l/minfor environmental benefits, a clearer display for temperatures andcommissioning settings, and a new short-circuit proof PCB design thatremoves the need for fuses on the low voltage circuits. The control boxcasing is more water resistant due to the removal of the transformer, whilethe lift weight of the appliance has also been reduced to 47.5kg.The Greenstar CDi Classic achieves 3 credit points within the Code forSustainable Homes and has an A rated annual efficiency of up to 90.2%(SEDBUK 2005 value).Installation benefitsEnvironmental benefits Standard wall frame allows space for SEDBUK A rating of up to 90.2%pipes behind the boiler Can be serviced entirely from thefront with easy access to partsand components All models available as natural gas andLPG for a range of properties Split wall mounting jig providedas standard for pre-plumbing of all7 connections - gas, water, PRV &condensate connections for ease andspeed of installation Full range of Condensfit II horizontal andvertical flue options with optional plumemanagement kit available Multi-directional fluing means boiler canbe sited in a wider variety of places.8(2005 value) WB5 heat exchanger delivers highefficiency and reliability Low electrical consumption when instandby mode Achieves 3 credits under the Code forSustainable Homes All boilers and components are100% recyclable.

WB5 heat exchanger2 million installed and stillThe Worcester WB5 heat exchangergoing stronghas been designed to optimise cleanWith more than 2 million Greenstarburning combustion over an extraCombi boilers installed in thelarge surface area. Each heatUK, the ever popular Worcesterexchanger is factory set and 100%Greenstar CDi Classic, with itstested so, as long as the gas inletadvanced features and future-proofpressure is correct, commissioningtechnology, still sets the standardis straightforward. The heatfor premium quality, high efficiencyexchanger requires minimalcombi boilers.servicing which means fewer spareparts during its lifetime. The heatexchanger can be cleaned in-situ viaan inspection hatch, again savingtime during service.WB5Heat ExchangerOn the primaryheat exchanger*End user benefits Heat exchanger delivers high efficiencyand reliability Energy-saving anti-cycle andmodulation control Condenses in DHW mode, resulting ingreater efficiency and fuel savings Low electrical consumption when instandby mode 5 year guarantee on plate heat exchanger* 10 year guarantee on Worcester primaryheat exchanger* Boiler protection plans available Part of the Which? Best Buy range forgas-fired condensing boilers Fully modulating pump for reducedelectricity consumption and quieteroperation.The Greenstar CDi Classic boiler is recommended by theEnergy Saving Trust (EST). The Energy Saving Trust is anon-profit organisation that provides free and impartialadvice on how to save energy.*Terms and conditions apply.9

Inside story – Greenstar CDi ClassicDown firing low NOx burnerAluminium/Silicon primaryWB5 heat exchangerExpansion vesselPre-mix fanSecondary DHW plate heat exchangerCondensate siphonAutomatic air vent (hidden)Pressure gaugeGas valveModulating pumpDiverter valveDrain pointMain cablepre-wired tocontrol boardCentral heatingtemperature atus lightDigitaldisplayGreenstar CDi Classic fascia with optionalDT10RF fittedPressuregaugeDomestichot watertemperature control

Technical dataBoilerGreenstar29CDi ClassicGreenstar34CDi ClassicGreenstar38CDi ClassicGreenstar42CDi ClassicHeight760mm (max)760mm (max)760mm (max)760mm (max)Width440mm440mm440mm440mmDepth360mm (max)360mm (max)360mm (max)360mm (max)47.5kg47.5kg47.5kg47.5kg90.1% / A rated90.1% / A rated90.2% / A rated90.2% / A rated92% / A rated92% / A rated91.9% / A rated92.2% / A rated2009 SEDBUK value – natural gas89.1%89.1%89.0%89.4%2009 SEDBUK value – LPG90.1%90.1%90.0%90.4%Heating flow / return connections(compression)22mm22mm22mm22mmHot / cold water connections(compression)15mm15mm15mm15mmPressure relief valve (compression)15mm15mm15mm15mmCondensate connection (plastic pipe)22mm22mm22mm22mmGas connection (compression)22mm22mm22mm22mmPrimary water content3.75 ltr3.75 ltr3.75 ltr3.75 ltrMinimum domestic inlet pressurefor maximum DHW flow rate1.4bar1.5bar1.7bar1.9barMinimum domestic inlet pressureto operate the appliance0.2bar0.2bar0.2bar0.2barMaximum domestic inlet pressure10bar10bar10bar10bar1.9 ltr/min1.9 ltr/min1.9 ltr/min1.9 ltr/minDHW flow rate @ 35ºC T†12.3 ltr/min14.3 ltr/min16.4 ltr/min17.2 ltr/minDHW flow rate @ 40ºC T††11 ltr/min12 ltr/min14 ltr/min15 ltr/minOutput to central heating (natural gas)7.7 - 30kW7.7 - 30kW9.4 - 30kW9.4 - 30kW Plug-in timers (optional) (optional) (optional) (optional)Optimising roomtemperature controller (optional) (optional) (optional) (optional) (optional) (optional) (optional) (optional) Maximum vertical flue(100mm dia.) inc. terminal9,400mm8,000mm7,500mm7,500mmMaximum vertical flue(125mm dia.) inc. terminal18,500mm16,000mm16,000mm16,000mmMaximum horizontal flue(100mm dia.)7,900mm7,000mm6,000mm6,000mmMaximum horizontal flue(125mm 3mg/kWh21.8mg/kWh21.8mg/kWh5555X4DX4DX4DX4DWeight – lift2005 SEDBUK value – natural gas2005 SEDBUK value – LPGMinimum flow rate tooperate the applianceWall mounting jigFilling linkIntelligent controlsCondensing in DHW modeNOx classificationNOx classIngress protection (IP)†Values for industry comparisons. ††Designed operational flow rate.11

Greenstar CDi CompactFeatures and benefitsThe revolutionary Worcester Greenstar CDi Compact is the newestaddition to our top-of-the-range CDi boiler series and is part of our nextgeneration of wall-mounted combi boilers. Suitable for small, mediumand large-sized properties with one or two bathrooms, the CDi Compact,with hot water outputs of up to 36kW, is best suited to properties thatdemand high outputs from an appliance that can fit within a standardkitchen cupboard.Available with DHW flow rates of 11.4, 13.1 and 14.7 l/min, the CDi Compactis the smallest and most efficient condensing combi boiler Worcester hasproduced and comes with a host of design features for ease of installation,use and servicing.Its ease of installation and cupboard size dimensions are thanks to thenew ultra-compact WB7 heat exchanger, easy access hydraulics and colourGreenstar CDi Compact isavailable with DHW flow ratesof 11.4, 13.1 and 14.7 l/mincoded wiring connectors. The boiler comes supplied with an innovative wallmounting jig that allows installers to easily pre-plumb the condensate, CHflow, DHW outlet, gas, DCW inlet, PRV installer connection & CH return.The Greenstar CDi Compact achieves an A rated annual efficiency of 90.5%(SEDBUK 2005 value) and, along with its low NOx emissions, obtains 3 creditpoints within the Code for Sustainable Homes standard.Installation benefitsEnvironmental benefits Robust metal wall mounting jig for safe, SEDBUK A rating of 90.5% (2005 value) Ability to fix a maximum heatingsecure, hassle-free fixing Split jig design for optimum lift weight.The expansion vessel has a simple dropmuch you turn the dial, the temperaturelock mechanism that connects directlywill not exceed maximum settingonto the hydraulic unit Boiler display for operation status,commissioning features anddiagnostics data Double seal siphon located at the frontof the boiler for easy maintenance Electrical connections accessible from thefront of the boiler Colour-coded wiring connectors for errorfree connection and removal Maximum flue lengths of 6m horizontaland 15m vertical Pre-set combustion settings for fastcommissioning and with BenchmarkCommissioning Checklist data availableon the boiler display Full range of Condensfit II horizontal andvertical flue options with optional plumemanagement kit available.12temperature – meaning no matter how Precision engineered WB7 heatexchanger reduces raw materialusage during manufacturing All boilers and components are100% recyclable Low electrical standby consumption Achieves 3 credits under the Code forSustainable Homes Coming soon: hot water pre-heat featureallows it to be used in conjunction withother heat sources, such as Greenskiessolar thermal (additional accessoryis required).

WB7 heat exchangerFriction stir weldingAt the heart of the Greenstar CDiFriction stir welding is a solid stateCompact is the ground-breakingmachining process where the metalWB7 heat exchanger, which usesis softened rather than melted,advanced friction stir welding† togiving improved quality, reliabilitycreate more passageways thanand performance.traditional heat exchangers. Thesechannels provide more efficientWidely used for demandingcirculation, resulting in a moreapplications in the aviation, marineeffective heat transfer andand automotive sectors, it hasquieter operation.enabled Worcester to manufacturea more compact heat exchanger,Designed, tested and manufacturedreducing the overall size of thewithin Bosch Thermotechnologyboiler while delivering a high powerLtd., the WB7 heat exchangerratio of up to maximum 36kW.WB7Heat Exchangerdelivers high output despite itscompact size.On the primaryheat exchanger*To view a video of the frictionstir welding process, please nd user benefits Simple and intelligent control optionsavailable, optimising boiler efficiency andfuel consumption Condenses in central heating anddomestic hot water modes for optimumefficiency during operation Comfort and ECO modes to suit hot waterdelivery needs Fully modulating pump for reducedelectricity consumption and quieteroperation Built-in frost protection of the boiler andthe surrounding pipes 5 year guarantee on plate heat exchanger* 10 year guarantee on Worcester primaryheat exchanger* Boiler protection plans available.The Greenstar CDi Compact boiler is recommended bythe Energy Saving Trust (EST). The Energy Saving Trust isa non-profit organisation that provides free and impartialadvice on how to save energy.*Terms and conditions apply. †The friction stir welding process is used under license from The Welding Institute.13

Inside story – Greenstar CDi CompactExpansion vessel(hidden)FanAluminium/Silicon primaryWB7 heatexchangerGas valveModulating pumpDiverter valve(hidden)Secondary DHW plateheat exchangerPressurerelief valveCondense trapComing soon:Domestic HotWater CombiPre-heat(accessory)PCB BoardMain cablepre-wired tocontrol boardCentral heatingtemperature control14Operationalstatus lightDigital displayDomestic hotOptional water temperatureprogrammercontrolGreenstar CDi Compact fascia with optionalFW100 weather compensating controller fittedPressuregauge

Technical dataBoilerGreenstar28CDi CompactGreenstar32CDi CompactGreenstar36CDi mDepth280mm280mm280mmWeight – lift32.9kg32.9kg32.9kg2005 SEDBUK value – natural gas90.5% / A rated90.5% / A rated90.5% / A rated2005 SEDBUK value – LPG92.6% / A rated92.6% / A rated92.6% / A rated2009 SEDBUK value – natural gas89.8%89.8%89.8%2009 SEDBUK value – LPG90.9%90.9%90.9%Heating flow / return connections(compression)22mm22mm22mmHot / cold water connections(compression)15mm15mm15mmPressure relief valve (compression)15mm15mm15mmCondensate connection (compression)22mm22mm22mmGas connection (compression)22mm22mm22mmPrimary water content2.2 ltr2.2 ltr2.2 ltrMinimum domestic inlet pressurefor maximum DHW flow rate1.6bar1.6bar1.6barMinimum domestic inlet pressureto operate the appliance0.2bar0.2bar0.2barMaximum domestic inlet pressure10.0bar10.0bar10.0barDHW flow rate @ 35ºC T†11.4 ltr/min13.1 ltr/min14.7 ltr/minDHW flow rate @ 40ºC T††10.0 ltr/min11.5 ltr/min12.9 ltr/minOutput to central heating7.03 - 24kW7.03 - 24kW7.03 - 24kW Plug-in timers (optional) (optional) (optional)Optimising roomtemperature controller (optional) (optional) (optional) (optional) (optional) (optional) Maximum vertical flue(100mm dia.) inc. terminal6,000mm6,000mm6,000mmMaximum vertical flue(125mm dia.) inc. terminal15,000mm15,000mm15,000mmMaximum horizontal flue(100mm dia.)6,000mm6,000mm6,000mmMaximum horizontal flue(125mm dia.)15,000mm15,000mm15,000mmNOx Wall mounting jigFilling linkIntelligent controlsCondensing in DHW modeNOx classIngress protection (IP)*690mm to top of casing curve. †Values for industry comparisons. ††Designed operational flow rate15

Greenstar Si and i JuniorFeatures and benefitsProviding efficient heating and hot water performance, the wellestablished award-winning Worcester Si and i Junior condensing boilerseries, with outputs of up to 30kW and 28kW respectively,are ideal for apartments and small to medium-sized properties withone bathroom.The Greenstar Si combi boilers with DHW flow rates of 10.2 and12.3l/min, give slightly higher flow rates than an i Junior range. They alsofeature hot water temperature and central heating controls for improvedboiler performance. Si combi boilers can be installed in a variety oflocations, including kitchens, utility rooms, bathrooms, airing cupboards,lofts or garages. Greenstar Si combi boilers are compatible with the fullrange of Worcester mechanical, digital and intelligent controls.The Greenstar i Junior has DHW flow rates of 9.8 and 11.4 l/min, featuresa central heating temperature control and can be used with Worcester’smechanical and digital and wireless controls.Both ranges come supplied with a pre-assembled light weight wall frame,that have pre-drilled fixing points and options that make hanging theappliance quick and easy. The wall mounting jig allows installers to quicklypre-plumb the condensate, CH flow, DHW outlet, gas, DCW inlet, PRVinstaller connection & CH return. Both ranges offer an A rated annualefficiency of up to 90.1% (SEDBUK 2005 value).Installation benefitsEnvironmental benefits Small dimensions Class-leading lift weight 27kg Split wall mounting jig design for SEDBUK A rating of 90.1%a simple installation Wall mounting jig provided asstandard for pre-plumbing of allefficiency and reliability Anti-cycle and modulation control Simple and intelligent (Greenstar7 connections - gas, water, PRV &Si only) control options availablecondensate connections for ease Low electrical consumption whenand speed of installation Robust metal wall frame providedin standby mode Both achieve 3 credits under theas standard allows space for pipesCode for Sustainable Homes whenbehind the boilerthe Low NOx Code Plug is fitted. Vertical pre-piping assembly isavailable as an accessory Full range of Condensfit II horizontal and vertical flue optionswith optional plume managementkit available.16(2005 value) Heat exchanger delivers highGreenstar Si is available withDHW flow rates of 10.2 and12.3 l/min and the Greenstari Junior has DHW flow rates of9.8 and 11.4 l/min

WB3 heat exchangerQuality guaranteedGreenstar Si and i Junior boilersAs part of our Total Quality Initiativeuse the WB3 heat exchangerprogramme, Worcester testswhich is manufactured by Boschits boilers and heat exchangersThermotechnology Ltd. and isusing its own recipe to replicateguaranteed for 10 years.contaminated heating system water.This contains iron dust, quartz sand,The aluminium-silicon heathemp fibre and other contaminatesexchanger has an extra-large surfacefound in such system waterarea for enhanced heat exchangesamples. This testing procedureefficiency. As a result they deliverensures that all our heat exchangersefficiencies of up 90.1% (SEDBUKare proven to be robust and2005 rating).efficient over the boiler’s lifetime.WB3Heat ExchangerOn the primaryheat exchanger*End user benefits Highly reliable and efficientheat exchanger Energy saving anti-cycle and modulationcontrol Simple and intelligent control optionsavailable, optimising boiler efficiencyand fuel consumption 5 year guarantee on plate heat exchanger* 10 year guarantee on Worcester primaryheat exchanger* Boiler protection plans available Part of the Which? Best Buy range forgas-fired condensing boilers.The Greenstar Si and i Junior boilers are recommendedb

The Greenstar combi range is part of a market-leading range of energy-saving gas-fired boilers. Renowned for their energy efficiency, reliability, ease of installation and servicing, more than 2 million Greenstar combi

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