Bosch GREENSTAR 30CDi System User guide

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Greenfloor heating series
Technical and Specification Information Greenfloor heating series

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Worcester and you. Making a difference.
As part of the Bosch Group, Worcester
products are designed and manufactured to
provide customers with the highest levels of
quality and reliability which are synonymous
with the Bosch name throughout the world.
As part of Europe’s largest supplier of
heating products, Worcester, Bosch Group
has the UK-based resources and support
capability to offer you the value-added
solutions needed to drive your business
forward. Worcester employs a nationwide
network of Service Engineers and technically
trained Field Sales Managers supported by
an experienced award winning technical
services team which is able to provide
comprehensive support and advice
from designing system layouts through
to installation.
Worcester is dedicated to providing energy
efficient gas- and oil-fired condensing
boilers, as well as an extensive range of
renewable technologies. All of our products
have been developed and introduced
with the aim of reducing climate change,
helping the UK to achieve the Government’s
efficiency targets.

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Contents Page
Worcester Greenfloor heating 4 - 8
Greenfloor pipe fixing methods 9
Floor constructions 10 - 11
Greenfloor controls 12
Product compatibility 13
Installation requirements 14 - 16
General requirements 17 - 18
Components 19 - 21
Specification and Design Service 22
Greenfloor heating series
components and accessories 23 - 26
Worcester training 27 - 29
After-sales 30
“At Worcester we recognise the vital role you
play in the specification and installation of
energy efficient appliances in homes across
the UK. We will continue to invest in our
products, people, facilities and support
services to ensure you can continue to deliver
only the best solutions to your customers’
requirements.”
Carl Arntzen,
Managing Director,
Bosch Thermotechnology Ltd.
The reception and main entrance
at our Worcester headquarters

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Worcester Greenfloor heating
Global responsibility for nature and the environment
As part of the Bosch Group, Worcester is committed to
environmental protection. With product development being
prioritised in the interests of people’s safety, the economical
use of resources and environmental sustainability.
In just a few short years, Britain’s domestic heating and
hot water industry has changed dramatically.
With approximately 25% of the UK’s carbon dioxide
emissions being produced by home energy consumption,
75% of which is for the provision of heating and hot water,
such change is not only inevitable but crucial.
Words and expressions such as “renewable energy”,
“sustainable technology” and “carbon footprint” have
become part of everyday conversation and have been
fuelled by extreme weather and stark television images
of melting polar ice caps.
Worcester, Bosch Group, whilst continuing to satisfy the
daily demands for heating and hot water comfort, has taken
a lead in developing solutions which reduce the impact on
the environment by reducing CO2 emissions – not only for
today but well into the future.
As part of this philosophy we are proud to introduce
high efficiency Greenfloor heating systems. Part of the
Total System Solution offering from Worcester, Greenfloor
heating systems deliver efficient heating in their own right
as well as facilitating the use of low carbon technologies
such as air source and ground source heat pumps and
condensing boilers.
Greenfloor heating is suitable for both new build and
refurbishment applications, offering a number of major
benefits over traditional radiator systems. By operating at
lower temperatures, underfloor heating helps to increase
the efficiency of the boiler or heat pump and reduces
overall running costs. Unlike radiator systems underfloor
distributes heat more evenly, increasing user comfort
whilst helping to reduce dust and the risk of house mites.
Greenfloor provides a complete underfloor heating
package that’s robust and reliable. The range includes
PE-Xc pipe with a choice of different pipe fixing methods
and manifolds for between 2 and 16 zones. These
are complemented by controls and a full range of
other accessories.
The pipe fixing methods are designed to make installation
quick and easy and can be used with traditional sand and
cement screed, wet screed or as a dry construction system
to suit the requirements of each property.

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Greenfloor features and benefits
Heat from a radiator travels up and around the
walls and ceiling of a room first, losing much of
its useful heat in the process...
...while the heat from underfloor heating is
evenly distributed from the surface of the floor
throughout the whole living space.
Features Benefits
PE-Xc Pipe, protected against thermal
ageing and stress fracture Flexible and durable
Pre-insulated pipe positioning panels Quick and easy installation
Stainless steel manifolds Robust and durable
Full suite of wireless and wired
control systems Suits any type of installation
Uses radiant heat Less circulation of dust than with
radiators, cleaner air for home
Requires lower working temperatures Maximises the efficiency of condensing
boilers and heat pumps
Eliminates the need for radiators Creates space on walls and allows
unrestricted layout within a room
Complements Worcester gas- and
oil-fired boilers, ground source and
air to water heat pumps
Complete heating and hot water
solutions from one source

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Greenfloor heating
Worcester’s Greenfloor heating system uses a water-filled
pipe system that turns the floor into a large surface area
radiator. The pipe system gently warms the space above it
through a combination of radiant energy and heat conduction.
In a modern, well-insulated space where heat loss factors
have been taken into consideration, underfloor heating can
act as the primary heating source and, in most cases, no
other space heating methods will be required.
Underfloor heating operates with lower water temperatures
than traditional radiator systems. This makes it the perfect
complement for Worcester’s ground source and air to water
heat pumps. As well as space heating, Worcester heat
pumps are able to provide a constant supply of hot water
throughout the year.
The low return water temperature of underfloor heating
also makes it suitable for use with Worcester condensing
boilers, ensuring they remain at their optimum efficiency,
with significant energy savings.
As there are no radiators to take up space, Worcester
Greenfloor systems also provide maximum flexibility within
the property. They can also be used with a wide range of
floor coverings, including parquet, carpeting, marble or tiles.
Underfloor heating is a system where every component is
important to overall performance. Worcester Greenfloor
systems provide a comprehensive selection of high quality
system components, while offering considerable flexibility
to meet all of a project’s needs.
System components
Greenfloor heating systems comprise a number of elements:
• PE-Xc system pipe
• Stainless steel manifolds
• Manifold cabinets
• Pump and mixing stations
• Pipe fixing methods
• Controls.
All Greenfloor systems are supplied complete with all
components and connections. Any specialist tools that
are necessary are also available from Worcester.
Greenfloor PE-Xc system pipe
The Greenfloor PE-Xc system
pipe is oxygen impermeable
and highly flexible for ease
of installation. The pipe is
available in two sizes to
suit the panel system
(see table below).
System pipe is available in coils, with a reel available to ease
unwinding, reduce waste and avoid the need for couplings.
Pipe and pipe fixing method compatibility
Pipe positioning panel 14 x 2mm 16 x 2mm
Stapler panel systems 14 x 2mm 16 x 2mm
Dry construction system 14 x 2mm –
Timber suspended floor 14 x 2mm 16 x 2mm
Pipe 14 x 2mm 16 x 2mm
PE-Xc Yes Yes
Coil length (standard) 200m 200m
Coil length (long) 750m 650m
Max. operating pressure 6bar 6bar
Max. operating temperature 90ºC 90ºC
Min. bend radius 70mm 80mm

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Greenfloor stainless steel manifolds
All Greenfloor manifolds are manufactured from stainless
steel and include flow meters for accurate system
commissioning. A full range of accessories is available
including ball valves and connectors.
The pre-assembled stainless steel manifolds serve 2-16
zone applications. They are supplied with integrated valves
providing a filling and draining facility and automatic air
vents. In the event of additional zones being required,
manifolds can be joined together. The flow rate can be
accurately set on flow meters for safe and rapid setting
of the values provided by the Worcester Design Service.
The return manifold provides threaded connections for
installation of electronic actuators.
Manifold cabinets
Greenfloor manifold cabinets are constructed from 1mm
galvanised sheet steel. The recessed type allow a flush
finish to a plastered wall and feature pre-punched side
openings for manifold connections and pipe penetrations
at the top and bottom. They are also height adjustable
to align with the screed thickness. A surface mounted
version is also available. Both the recessed and surface
mounted cabinets are lockable to prevent unauthorised access.
Height 350mm
Depth 62mm
Material Stainless steel
Flow meters Yes
Flow & return heat source 1"
Flow & return to underfloor zones (PE-Xc pipe) ¾"
Note: for a two zone system, the manifold width is
200mm. For each additional zone added, the manifold
width increases by 50mm. The maximum number of
zones is 16.
Manifold cabinets
Surface
mounted
VSS-A
560
VSS-A
700
VSS-A
1000
VSS-A
1300
Width 560mm 700mm 1,000mm 1,300mm
Height 700mm 700mm 700mm 700mm
Depth 150mm 150mm 150mm 150mm
Recessed VSS-U
560
VSS-U
700
VSS-U
1000
VSS-U
1300
Width 560mm 700mm 1,000mm 1,300mm
Height
(adjustable) 780-880mm 780-880mm 780-880mm 780-880mm
Depth
(adjustable) 115-165mm 115-165mm 115-165mm 115-165mm

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Greenfloor offers a number of pump and mixing stations to
satisfy the needs of each individual installation.
FRS pump and mixing station
The FRS standard pump and mixing station features a fixed
value thermostatic injection valve, which is commissioned
on site by the installer to the specification provided by
the Worcester Design Service. The flow water temperature
will be maintained constantly at a safe and efficient level.
The FRS also includes a high limit thermostat to protect
the heated floor area from excessive temperatures using a
circulating pump and temperature gauge. Each installation
of an FRS will also require an FRS connection set, available
from Worcester, to allow an easy and speedy connection to
the Greenfloor stainless steel manifold.
Alternatively, a choice of advanced controls featuring
weather compensation is available.
VRS pump and mixing stations
The VRS weather compensated pump and mixing stations
are available to suit up to both a 7kW and 10kW installation
and fit directly to the Greenfloor stainless steel manifold.
The VRS station features a modulating circulating pump,
electronic mixing valve and an intelligent controller. This
feature, through input gathered by the supplied flow
temperature and outdoor sensors, adjusts the output
temperature based upon external conditions.
KMS pump and mixing stations
The KMS remote pump and mixing stations feature the
same proven components and method of operation as
the VRS pump and mixing stations. The KMS provides
the flexibility of mounting the station away from the
Greenfloor manifold and is available to suit up to both
15kW and 25kW installations.
All Greenfloor pump and mixing stations are provided
with comprehensive installation, commissioning and
user instructions. Further support on planning
and specifying the system can be provided by the
specialist Worcester Design Services team.
Single room extensions
The RMS pump and mixing station is designed to offer a
simple underfloor heating control solution for single rooms.
The RMS connects into the existing flow and return circuit
of the central heating system and features a circulation
pump and a temperature limiting valve on the return side.
It is possible for the circulation pump to be electrically
supplied via a proprietary room thermostat to provide an
interlock as well as to aid energy efficiency. Please note
that the RMS single room pump and mixing station relies
upon the existing central heating system’s controls to be
‘calling for heat’ to achieve warming of the floor. To achieve
a greater level of independent control, an FRS standard
pump and mixing station should be selected.
FRS standard pump and mixing station
Greenfloor pump and mixing stations

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Greenfloor offers a range of pipe fixing methods
to suit every project.
Greenfloor pipe positioning panels
Greenfloor pipe positioning
panels are ideal for use in
new and existing buildings
and can be used with cement
or pumped liquid screed.
The channels on the panels
ensure that optimum spacing
of the pipe coils are achieved.
Pipe is fixed using a press-
stud action which enables fixing without clamps. The panels
are available with and without insulation.
Greenfloor pipe fixing methods
Pipe positioning panels 30 11 Light
Length 900mm 900mm 900mm
Width 1,447mm 1,447mm 1,447mm
Depth 48mm 29mm 18mm
Thermal insulation (Rl)0.75m2k/W 0.37m2k/W None
Sound insulation 28dB None None
Unit of delivery 10.4m210.4m210.4m2
Installation centres
110mm/
165mm/
220mm
110mm/
165mm/
220mm
110mm/
165mm/
220mm
Greenfloor staple panels
Greenfloor staple panels
are easy to assemble and
very cost-efficient. They are
supplied as a rolled panel
and manufactured from
foamed polystyrene with a
fully bonded, tear-proof and
waterproof woven fabric
coating. The imprinted
installation grid allows for system-compatible pipe spacing,
as well as quick and easy pipe fixing when using our
Greenfloor clip rails or staples.
Greenfloor dry construction system
The Greenfloor dry
construction system provides
the ideal solution for dry
construction in buildings of
all ages. They are particularly
popular with timbered floors
where a water-based screed
is undesirable. The system
is based on working with
dry construction panels while using steel spreader plates
into which the pipe is pressed. Easy to work with, the
system enables serpentine or spiral installations and can
accommodate even the most complex of room geometries.
Greenfloor timber suspended floor system
Greenfloor clip rail and
staples provide a simple cost
effective solution. It is ideal
for when fixing pipe to floor-
grade insulation between the
joists of a timber suspended
floor. Tongue & groove or
chipboard flooring can then
be laid directly across
the joists.
Staple panels 35mm roll 30mm roll
Width 1,000mm 1,000mm
Depth 35mm 30mm
Thermal insulation (Rl)0.78m2k/W 0.67m2k/W
Sound insulation 29dB 29dB
Unit of delivery 12m212m2
Timber suspended floor system Clip rail
Length 1,000mm
Width 40mm
Height 25mm
Unit of delivery 100m
Installation centres 50mm
Dry construction system Panel Straight
plate
Curved
plate
Length 1,000mm 750mm 245mm
Width 625mm 120mm 125mm
Depth 25mm 0.5mm 0.5mm
Thermal insulation (Rl)0.56m2k/W N/A N/A
Sound insulation None N/A N/A
Unit of delivery 13.1m250 pieces 25 pieces
Installation centres 125mm/250mm N/A 125mm

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Flooring
Flooring underlay
Staple panel
Concrete base
Clip rail
Sub floor
Clip rail fixing pins
Greenfloor PE-Xc pipe
Pipe staple
Edging
insulation
strip
Screed
Greenfloor offers a choice of fixing methods making it suitable for all types of floor construction in new build
and existing properties. It is most frequently used with ceramic, wood or laminate floor coverings, but can also
be used with carpets and vinyls.
Flooring
Flooring underlay
Screed
Pipe positioning panel
Concrete base
Sub floor
Greenfloor PE-Xc pipe
Edging
insulation
strip
Greenfloor staple panel system with clip rail
Floor constructions
Greenfloor pipe positioning panel system