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Bosch WORCESTER Greenstar CDi Classic Series Technical Information
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Bosch WORCESTER Greenstar CDi Classic Series Technical Information

Gas-fired condensing wall mounted boiler range
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Technical and Specifi cation Information
Greenstar combi gas-fi red condensing
wall mounted boiler range
NEW
Greenstar
Combi range
Greenstar CDi Classic Series
Greenstar CDi Compact Series
Greenstar Si Compact Series
Greenstar i Junior Series
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Summary of Contents for Bosch WORCESTER Greenstar CDi Classic Series

  • Page 1 Technical and Specifi cation Information Greenstar CDi Classic Series Greenstar CDi Compact Series Greenstar Si Compact Series Greenstar i Junior Series Greenstar combi gas-fi red condensing wall mounted boiler range Greenstar Combi range...
  • Page 2 Worcester and you. Making a diff As part of the Bosch Group, Worcester supported by an experienced technical products are designed and manufactured to services team which is able to provide provide customers with the highest levels of comprehensive support and advice...

  • Page 3: Table Of Contents

    32 - 34 Carl Arntzen, The Worcester Greenstar System Filter Managing Director, The Worcester Keyless Filling Link 36 - 37 Bosch Thermotechnology Ltd. Condensate pipework 38 - 39 The Worcester CondenseSure siphon 40 - 41 Horizontal and vertical fl ue terminal positioning 42 - 43 Horizontal fl...
  • Page 4 The Greenstar combi gas-fi red wall Greenstar Si Compact Greenstar CDi Classic The Greenstar combi range is part of a market-leading range of energy-saving gas-fi red boilers. Renowned for their energy effi ciency, reliability, ease of installation and servicing, more than 2 million Greenstar combi boilers have been installed in homes across the UK.
  • Page 5 mounted condensing boiler range Greenstar i Junior Greenstar CDi Compact Now part of the range are the all-new, revolutionary hot water performance, a new magnetic fl ap and reduced Greenstar CDi Compact and Si Compact models, which standby electrical consumption. have an innovative WB7 heat exchanger designed to combine both compact dimensions with a high effi...

  • Page 6: Key Features Of The Range

    Key features of the range Winner of Which? Best Buy awards Keep hot facility in 2011, 2012 and 2013 All Greenstar combi models have an in-built For three consecutive years, in a survey of ‘keep hot’ facility which will keep the primary water Which? members, the Worcester Greenstar within the heat exchanger hot –...
  • Page 7 • boiler effi ciency Full range of Condensfi t II™ Worcester Greenstar boilers • • Low electrical consumption in fl ue options Bosch renowned quality • standby mode Multi-directional fl uing means and reliability • • Aluminium-silicon heat exchangers boiler can be sited in a wider Built-in boiler frost protection •...
  • Page 8 Greenstar CDi Classic Features and benefi ts The top-of-the-range, award-winning Greenstar CDi Classic is a high performance boiler that is suitable for small, medium and large-sized properties with one or two bathrooms. It has set the benchmark within the industry for effi ciency, reliability and ease of installation, while achieving a market-leading output of up to 42kW.
  • Page 9 WB5 heat exchanger 2 million installed and still The Worcester WB5 heat exchanger going strong has been designed to optimise clean With more than 2 million Greenstar burning combustion over an extra- combi boilers installed in the large surface area. Each heat UK, the ever popular Worcester exchanger is factory-set and 100% Greenstar CDi Classic, with its...

  • Page 10: Inside Story - Greenstar Cdi Classic

    Inside story – Greenstar CDi Classic Down fi ring low NOx burner Aluminium/Silicon primary WB5 heat exchanger Expansion vessel Pre-mix fan Secondary DHW plate heat exchanger Condensate siphon Automatic air vent (hidden) Pressure gauge Gas valve Modulating pump Diverter valve Drain point Domestic Central heating...
  • Page 11 Technical data Greenstar Greenstar Greenstar Greenstar Boiler 29CDi Classic 34CDi Classic 38CDi Classic 42CDi Classic Height 760mm (max) 760mm (max) 760mm (max) 760mm (max) Width 440mm 440mm 440mm 440mm Depth 360mm (max) 360mm (max) 360mm (max) 360mm (max) Weight – lift 47.5kg 47.5kg 47.5kg...
  • Page 12 Greenstar CDi Compact Features and benefi ts The revolutionary Worcester Greenstar CDi Compact is the newest addition to our top-of-the-range CDi boiler series and is part of our next generation of wall-mounted combi boilers. Suitable for small, medium and large-sized properties with one or two bathrooms, the Greenstar CDi Compact, with hot water outputs of up to 36kW, is best suited to properties that demand high outputs from an appliance that can fi...
  • Page 13 Worcester to manufacture a more compact heat exchanger, Designed, tested and manufactured reducing the overall size of the within Bosch Thermotechnology boiler while delivering a high power On the primary Ltd., the WB7 heat exchanger ratio of up to maximum 36kW.

  • Page 14: Inside Story - Greenstar Cdi Compact

    Inside story – Greenstar CDi Compact Expansion vessel (hidden) Aluminium/ silicon primary WB7 heat exchanger Gas valve Modulating pump Diverter valve Secondary DHW plate (hidden) heat exchanger Pressure relief valve Condense trap PCB board Main cable Domestic hot Pressure Mains Central heating Optional water temperature...
  • Page 15 Technical data Greenstar Greenstar Greenstar Boiler 28CDi Compact 32CDi Compact 36CDi Compact Height 680mm* 680mm* 680mm* 390mm 390mm 390mm Width 280mm 280mm 280mm Depth 32.9kg 32.9kg 32.9kg Weight – lift 2005 SEDBUK value – natural gas 90.5% / A rated 90.5% / A rated 90.5% / A rated 2005 SEDBUK value –...
  • Page 16 Greenstar Si Compact Features and benefi ts The Greenstar Si Compact is the successor to the Greenstar Si combi boiler. The all new Greenstar Si Compact has a host of performance-enhancing features, including the revolutionary WB7 heat exchanger which enables the appliances to deliver DHW fl...
  • Page 17 WB7 heat exchanger Innovation at its best Greenstar Si Compact boilers use The WB7 heat exchanger is an the same ground-breaking WB7 industry fi rst for Worcester, Bosch heat exchanger as CDi Compact Group. State-of-the-art friction appliances. stir welding† technology improves...

  • Page 18: Inside Story - Greenstar Si Compact

    Inside story – Greenstar Si Compact Expansion vessel (hidden) Aluminium/ Silicon primary WB7 heat exchanger Gas valve Circulating pump Secondary DHW plate heat exchanger Diverter valve (hidden) Pressure Condense trap relief valve PCB Board Main cable pre-wired to control board Domestic hot Pressure Mains...
  • Page 19 Technical data Greenstar Greenstar Boiler 25Si Compact 30Si Compact Height 690mm (max)* 690mm (max)* 390mm 390mm Width 280mm (max) 280mm (max) Depth 32.9kg 32.9kg Weight – lift 2005 SEDBUK value – natural gas 90.5% / A rated 90.5% / A rated 2005 SEDBUK value –...
  • Page 20 Greenstar i Junior Features and benefi ts With more than 1 million boilers already installed in the UK, the well- established award-winning Greenstar i Junior condensing boiler series, with outputs of 24kW and 28kW are ideal for apartments and small to medium-sized properties with one bathroom.
  • Page 21 DHW control added to fascia Full suite of Worcester intelligent controls The new Greenstar i Junior now has a DHW temperature The Greenstar i Junior is now EMS-BUS enabled to allow controller added to the boiler fascia to offer temperature for further control and functionality of the heating system control between 40°C and 60°C, while also allowing the with the ability to use Worcester’s intelligent and weather...

  • Page 22: Inside Story - Greenstar I Junior

    Inside story – Greenstar i Junior Down fi ring low NOx burner Aluminium/Silicon primary Pre-mix fan WB3 heat exchanger Gas valve Secondary DHW plate heat exchanger Condensate siphon Automatic air vent Circulating pump Diverter valve Drain point Main cable pre-wired to control board Pressure gauge Central heating...
  • Page 23 Technical data Boiler Greenstar 24i Junior Greenstar 28i Junior Height 710mm (max)* 710mm (max)* Width 400mm 400mm Depth 330mm (max)* 330mm (max)* Weight – lift 26.2kg 26.2kg 2005 SEDBUK value – natural gas 90.1% / A rated 90.1% / A rated 2005 SEDBUK value –...

  • Page 24: Optional Plug-In Controls

    Optional plug-in controls Increased SAP ratings As well as all Greenstar combi models achieving very high SAP ratings for dwellings, the addition of an intelligent fl ow temperature ‘compensating’ controller can further increase these ratings, as well as being part of the recommended best practice, as covered by the CHeSS design standard.
  • Page 25 DT10RF Digistat – Part no. 7 716 192 052 • 24hr programmable room thermostat offering different room temperatures over six switching periods a day • No wiring • Fascia-mounted receiver includes timer for HW pre-heat. DT10RF Optimiser – similar to the DT10RF Digistat but with the following additional features –...

  • Page 26: Site Preparations And Guidance

    Site preparations and guidance All combi boilers require less installation time than a Installation and service clearances conventional boiler, for these reasons: The minimum clearances shown below should be allowed • One-man lift (Greenstar i Junior) for installation and servicing. Compartment ventilation •...
  • Page 27 Ventilation-free compartment installation – minimum clearances 410mm 930mm +30mm +30mm above elbow above elbow 200mm* Using 100mm flue kit – 1,080mm 200mm* Using 125mm flue kit 20mm to – 1,110mm 100mm to removable removable door door 600mm front 600mm front clearance for clearance service...
  • Page 28 Important: bathroom locations and clearances • • The boiler must not be installed in Zone 1 A boiler fi tted with a mechanical timer or RF mechanical • Any switch or appliance control using mains electricity timer (receiver) or FW100 controller may only be installed must not be within reach of a person using the bath outside the shaded area.
  • Page 29 Wall preparation The following diagrams show the wall-mounting jigs which enable a simple and straightforward method of attaching the boiler to the wall surface. All Greenstar wall-mounting jigs have pre-drilled fi xing points and options that make hanging a Worcester Greenstar quick and easy.
  • Page 30 Casing dimensions Depth to wall (when fi tted to wall frame) 360mm 330mm 750mm† 700mm* 400mm 440mm Greenstar CDi Classic Greenstar i Junior †760mm to top of casing front. *710mm to top of casing front. Depth to wall (when fi tted to wall frame) 280mm 680mm†...
  • Page 31 Pipework connections Greenstar i Junior Greenstar CDi Classic Pipework connections – Greenstar CDi Classic Pipework connections – Greenstar i Junior From left Diameter From left Diameter Function case edge of pipe Function case edge of pipe 1 Condensate drain 55mm 22mm 1 Condensate drain 35mm...

  • Page 32: Greenstar Combi Installation Requirements

    Greenstar combi installation requirements Installation of the Greenstar combi boiler range must be Optional Worcester integral fi lling link in accordance with the relevant requirements of the Gas The Worcester integral fi lling Safety (Installation Use) Regulations (as amended), current link simply connects between IEE Wiring Regulations, local Building Regulations, Building the cold main connection...
  • Page 33 Natural gas supply Mains cold water supply Listed below is a representative example. Figures Water Authority requirement for other appliances can be found in the relevant A direct mains cold water connection is permitted by installation manuals. Water Authorities. However, it is recommended that reference be made to local requirements.
  • Page 34 Junior combis. Please contact our guarantee registration advisors on As with all mains-fed systems, the fl ow rate of water 0844 892 2552 or visit www.worcester-bosch.co.uk/ obtainable from individual taps will vary in relation to the guarantee number of taps operating simultaneously, and will depend upon the cold mains supply available to the property.

  • Page 35: The Worcester Greenstar System Filter

    The Worcester Greenstar maintenance System Filter has been Worcester, Bosch Group Reliability of components specifi cation and design and fi lter specifi cally designed to combat the damaging...

  • Page 36: The Worcester Keyless Filling Link

    The Worcester Keyless Filling Link – easy to install, simple to operate Worcester Greenstar gas-fi red combi boilers are designed to deliver maximum effi ciency and performance, however the heating system will occasionally need to be re-pressurised for optimum performance. Traditional methods involve using a built-in key or connecting an external fi...
  • Page 37 Innovative design Nominal fl ow direction Back fl ow relief port Innovative design features ensure the Worcester Keyless Filling Link delivers reliable, trouble-free performance without risking backfl ow or overfi lling. These include: Valve orientation that uses water Simple and intuitive pull-down lever Twin check valves to prevent pressure to aid valve sealing and to fi...

  • Page 38: Condensate Pipework

    Condensate pipework Important points to consider when siting a condensate drainage pipe: • Where a new or replacement boiler is being installed, access to an internal “gravity discharge” point should Soil Siphon be one of the factors considered in determining &...
  • Page 39 External connections Condensate soak away (see fig. 6) • Freezing conditions The condensate drainage pipe may be run above or below • the ground to the soak away When the position of the boiler prevents internal • routing, we recommend installing a Worcester The examples shown run above ground •...

  • Page 40: The Worcester Condensesure Siphon

    The Worcester CondenseSure siphon With temperatures as low as -20ºC being experienced in very cold winters, practices such as externally run condensate discharge pipework are now being questioned. The Worcester CondenseSure siphon has been designed to allow a more flexible approach to boiler siting. Tested to extreme temperatures The Worcester CondenseSure siphon has been extensively tested under simulated extreme weather conditions, proving...
  • Page 41 Ease of installation Fitting to a combi boiler The CondenseSure has been designed with ease of installation in mind and is suitable for most boiler applications. For maximum effectiveness, it should be installed immediately beneath the boiler where it is clipped on to the boiler’s heating fl ow pipe and connected to its siphonic trap.

  • Page 42: Horizontal And Vertical Fl Ue Terminal Positioning

    Horizontal and vertical fl ue terminal positioning All measurements in millimetres 1,500 1,500 1,200 Boundary Line Note Key to illustration • 300mm adjacent to a boundary line. All measurements are the minimum clearances required • Terminals must be positioned so as to avoid combustion products The dimension below eaves, balconies and car ports can be entering the building reduced to 25mm, as long as the fl...
  • Page 43 104mm 52mm 300 300 300 300 300mm above, below and either side of an opening door, 17. Flue clearance must be at least 300mm from the ground. air vent or opening window. Terminal guards must be fi tted if the fl ue is less than 2 metres 10.

  • Page 44: Horizontal Fl Uing Options

    Greenstar combi boiler range horizontal fl uing options ™ Accessories The Greenstar combi boiler range offers the choice of 2 differently sized horizontal RSF fl ue systems, a 100mm Components Part No. Description diameter telescopic fl ue kit including a plume management 100mm diameter kit, and a 125mm diameter telescopic fl...
  • Page 45 Option 1: Standard horizontal fl ue assembly Option 2: Extension fl ue horizontal Components Components Part No. 100mm Part No. 100mm 7 716 191 082 7 716 191 082 7 716 191 083 Part No. 125mm Part No. 125mm 7 719 003 702 7 719 003 702 7 719 003 666 Maximum lengths (mm) &...
  • Page 46 Option 3: Extension fl ue horizontal Option 4: Extension fl ue horizontal and upwards using a second 90º bend Components Components Part No. 100mm 7 716 191 082 7 716 191 083 7 716 191 084 Part No. 125mm 7 719 003 702 7 719 003 666 7 719 003 664 Part No.
  • Page 47 Option 5: Extension fl ue upwards and horizontal Option 6: Extension fl ue upwards and horizontal using a second 90º bend using a third 90º bend Components Components Part No. 100mm 7 716 191 082 7 716 191 083 7 716 191 084 7 719 002 432 Part No.

  • Page 48: Vertical Fl Uing Options

    Greenstar combi boiler range vertical fl uing options ™ The Greenstar combi boiler range offers the choice of Accessories 2 differently sized vertical RSF fl ue systems, 100mm and Components Part No. Description 125mm. Both systems have different maximum lengths. 100mm diameter The following diagrams detail the permissible lengths.
  • Page 49 Option 1: Minimum height Option 2: Vertical balanced fl ue system maximum height 500mm Flat roof 300mm 500mm Flat roof 300mm 100mm dia. 1,090mm 125mm dia. 1,365mm Components Components Part No. 100mm 7 719 002 430 Part No. 100mm 7 719 002 430 7 716 191 083 Part No.
  • Page 50 Option 4: Vertical balanced fl ue system Option 3: Vertical balanced fl ue system with two 45º bends with two 90º bends Components Components Part No. 100mm Part No. 100mm 7 719 002 430 7 716 191 083 7 716 191 085 7 719 002 430 7 716 191 083 7 716 191 084...
  • Page 51 Plume management terminal positioning All measurements in millimetres Flue terminal guard 7 716 191 176 ±45° Plume re-direction: 180° Flue exhaust outlet 1,500 Air intake ±80° 1,200 Boundary line Note Using a Plume Management Kit, the air intake measurement • All measurements are the minimum clearances required can be reduced to 150mm providing the flue exhaust outlet has •...
  • Page 52 Plume management system options ™ Plume management system Accessories 60mm dia. plume management kit Components Part No. Description 1 x terminal bend 60mm diameter 1 x extension 500mm 7 716 191 086 Plume management kit 1 x outlet assembly 1 x clamp pack 7 716 191 087 Extension (1,000mm) Part No.
  • Page 53 For Greenstar CDi Classic boilers, the 100mm dia. Condensfi t II™ telescopic fl ue and plume management internal fl ue length is immediately reduced by 2,000mm system measuring when the minimum plume management of 500mm is used. Fig A For the Greenstar CDi Compact and Si Compact boilers, the 100mm dia.
  • Page 54 Plume management system Plume management system with angled termination Components Part No. 60mm 7 716 191 086 Maximum lengths (mm) & no. of components required Components Greenstar CDi Classic, CDi Compact*, Si Compact and i Junior series Part No. 60mm 7 716 191 086 7 716 191 087 60mm...
  • Page 55 Greenstar combi boiler range accessories Greenstar combi boiler controls DT20RF digital RF MT10RF mechanical DT20 twin channel MT10 mechanical timer thermostat with twin RF thermostat digital programmer channel programmer Worcester Part No. Worcester Part No. Worcester Part No. Worcester Part No. 7 716 192 036 7 716 192 037 7 716 192 038...
  • Page 56 Greenstar combi boiler range accessories Condensfit II™ 60/100mm & 80/125mm horizontal & vertical flue accessories Standard telescopic Standard telescopic Long telescopic flue kit Vertical BF kit horizontal flue kit flue kit (100mm dia.) (100mm dia.) (100mm dia.) (125mm dia.) Worcester Part No. Worcester Part No.
  • Page 57 90º bend High level horizontal High level horizontal Support bracket kit (125mm dia.) flue adaptor (100mm dia.) flue adaptor (125mm dia.) (100mm dia.) Worcester Part No. Worcester Part No. Worcester Part No. Worcester Part No. 7 719 003 664 7 719 002 432 7 719 002 433 7 716 191 092 Support bracket kit–...
  • Page 58 Greenstar combi boiler range accessories Additional accessories Vertical pre-piping Worcester keyless Vertical pre-piping Filling link† assembly for CDi Compact filling link assembly for CDi Classic & Si Compact Worcester Part No. Worcester Part No. Worcester Part No. Worcester Part No. 7 716 192 281 7 716 192 610 7 716 192 607...
  • Page 59 Plume management Worcester Flat roof flashing kit Pitched roof flashing kit terminal guard round CondenseSure siphon (100mm & 125mm dia.) (100mm & 125mm dia.) (60mm dia.) Worcester Part No. Worcester Part No. Worcester Part No. Worcester Part No. 7 716 192 746 7 716 191 090 7 716 191 091 7 716 191 176...
  • Page 60 To enable us to meet the growing demand for training we Call 0330 123 9119 for your copies, or visit have invested in additional facilities at the award-winning www.worcester-bosch.co.uk for information training academy at our Worcester headquarters. In addition on Web Based Learning.
  • Page 61 Gas-fi red product courses As a market leader in gas-fired condensing boilers, we Gas-fired condensing boiler courses aim to ensure the highest levels of competence and Greenstar CDi Classic gas-fired condensing combi boilers. expertise in the installation of all Worcester gas-fired Greenstar CDi Compact and NEW Greenstar Si Compact products.
  • Page 62 0330 123 0166 to order a full course training brochure provides comprehensive training from all its academies or to book yourself onto a training course, alternatively, on its entire range of technologies. you can visit www.worcester-bosch.co.uk/training Oil-fi red product courses Worcester commercial product courses Greenstar oil-fi red products.
  • Page 63 A complete after-sales service All the technical advice As part of the worldwide Bosch Group, Worcester strives to maintain the highest possible standards of after-sales care. you need In addition to the no-nonsense parts and labour Spares guarantee applicable to all Worcester products, you and...
  • Page 64 These rules apply to calls from any type of line, including mobile, BT, other fi xed phone line or payphone. Calls from mobiles and some other networks may vary. Calls to and from Bosch Thermotechnology Ltd may be recorded for training and quality assurance purposes.

This manual is also suitable for:

Worcester greenstar cdi compact seriesWorcester greenstar si compact seriesWorcester greenstar i junior seriesWorcester greenstar 29cdi classicWorcester greenstar 34cdi classicWorcester greenstar 38cdi classic ... Show all

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