Bosch GREENSTAR 30CDi System User guide

1
Greenfloor heating series
Technical and Specification Information Greenfloor heating series

2
2
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.

3
3
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

4
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.

5
5
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

6
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

7
7
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

8
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

9
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

10
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

11
Flooring
Flooring underlay
Dry screed system foil
Dry construction panel
Wooden or
concrete floor
Greenfloor PE-Xc pipe
Heat conducting plate
Edging
insulation
strip
Greenfloor dry construction panel system
Flooring
Flooring underlay
Clip rail
Joist
Support batten
Floor grade insulation
Clip rail fixing pins
Greenfloor PE-Xc pipe
Pipe staple
Flooring boards
Greenfloor timber suspended floor system

12
Greenfloor controls are optimised for use with
Greenfloor heating systems. The range of products
includes wiring centres and components for individual
room temperature control.
Room thermostats
Single room controls allow the temperature in each room
to be set individually. The temperature is controlled by the
thermostat in relation to variable factors such as solar heat
gains, electrical devices and people. They are available as
230V wired controls or as wireless (RF) versions. Single
room thermostats are available as wall mounted models.
Wired programmable room thermostats are available as
flush mounted models.
Wiring centres
Greenfloor wiring centres provide a quick, simple and safe
means of wiring together room thermostats and actuators.
The wired unit can be used with up to six 230V room
thermostats, or programmable room thermostats. It can
also operate up to 14 actuators. There is the facility to
connect a time control which enables a night set-back mode
and an interlock to stop the manifold circulating pump from
operating. It also turns off the heat source (when all valves
are closed).
The wireless unit will receive
signals from up to eight
wireless thermostats and can
be wired to a maximum of
16 actuators. The unit is
supplied complete with a 7
day programmer that allows
each zone to be programmed independently
and works harmoniously with Worcester’s wireless
(RF) room thermostat. To stop the manifold circulating
pump running and turning off the heat source, the unit
incorporates an interlock.
Actuators
The 230V actuators are
supplied by the Greenfloor
wiring centres and control
the water flow through each
zone, according to the room
thermostat’s demand signal.
They consume as little energy
as just 2 Watts.
Greenfloor controls
230V wiring centre
Control Room
thermostat
Programmable
room thermostat
Wiring
centre Actuator
Wired 230V
option Yes Yes Yes Yes
Wireless
(RF) option Yes No Yes Yes

13
13
Product compatibility
Greenfloor heating is designed to work with all Greenstar gas and oil-fired boilers and appropriate renewable technologies.
Gas-fired boilers
Combi
Greenstar CDi Classic series
Greenstar CDi Compact series
Greenstar Si Series
Greenstar i Junior series
Greenstar Highflow CDi series
System
Greenstar 30CDi Classic System
Greenstar i System series
Regular
Greenstar CDi Classic Regular series
Greenstar Ri series
Greenstar FS CDi Regular series
Oil-fired boilers
Combi
Greenstar Heatslave series
Greenstar Heatslave External series
System
Greenstar Camray System series
Greenstar Camray Utility System series
Greenstar Camray External System series
Regular
Greenstar Danesmoor WM series
Greenstar Camray series
Greenstar Camray Utility series
Greenstar Utility series
Greenstar Camray External series
Renewable technology
Ground source heat pumps
Greenstore LECP System Ground Source Heat Pump series
Greenstore LECP Combination Ground Source Heat Pump series
Air to water heat pumps
Greensource Air to Water Heat Pump series
Greensource Split Air to Water Heat Pump series
Solar
Greenskies Solar-Lux series
Greenskies Solar-Lifestyle series
Greenskies Solar-Lito series
*
*Greenstar CDi Compact not included for 2012 Which? Survey.

14
Pipe fixing methods
Before a suitable Greenfloor pipe fixing method
can be selected, consideration must be given to
the following factors:
• The desired finished floor level and the available
depth for installation
• The heat output required from the floor to accommodate
the heat loss of the room and building
• The type of floor that Greenfloor will be installed within
• The desired floor finish.
Wet screed floors
Screed
Greenfloor pipe positioning panels and Greenfloor staple
panels are designed for use with either a standard sand
and cement screed or a pumped liquid screed. Typically
a 75mm screed depth is used.
Greenfloor pipe positioning panels
Greenfloor pipe positioning panels offer flexibility in
achieving a balance of the finished floor level against
the available installation depth. The panels are available
with either 30mm or 11mm of polystyrene insulation.
Alternatively an option with no insulation provides the
ease and convenience of the panel fixing method and
relies on the floor grade insulation installed on site.
Greenfloor pipe positioning
panels offer a number of
advantages over other pipe
fixing methods, while allowing
an experienced installer a one
man installation. Working
with a 200m coil, Greenfloor
PE-Xc system pipe can simply
be walked into the pre-formed castellated sections of the
panel. Greenfloor pipe positioning panel installations are
also much easier to adjust should last minute changes be
required to the layout of the installation. There are no clips
to release, no damage to the panels and the pipe can easily
be relaid to the revised requirements. Greenfloor pipe
positioning panels deliver a highly professional finish to the
installation procedure, prior to pressure testing and the
screed being laid.
Installation requirements
Greenfloor staple panels
Greenfloor staple panels are made of polystyrene insulation
and are coated with a fully bonded, tear and waterproof
woven fabric. This has a number of advantages, particularly
in avoiding the situation with floor grade insulation where
the staples can pull out.
The Greenfloor staple panel also provides an installation grid
at 50mm intervals for easy spacing of the Greenfloor PE-Xc
system pipe. This is applied directly to the staple panel using
staples and a stapler available from Worcester. Greenfloor
staple panels are available in a choice of two installation
thicknesses, 30mm and 35mm. It is recommended to fix the
Greenfloor PE-Xc system pipe with Greenfloor staples every
300mm. More staples may be necessary on bends.
The pipe spacing will be specified as part of the package
of information supplied by the Worcester Design Service.
Once the Greenfloor PE-Xc system pipe is installed, pressure
testing must be carried out prior to the screed being laid.
Greenfloor staples and Greenfloor clip rail
Both of these products offer an alternative method of
installing Greenfloor. A particularly low installation cost can
be achieved by simply fixing the Greenfloor PE-Xc system
pipe to the floor grade insulation installed on site.
Greenfloor staples, installed using the Greenfloor stapler or
Greenfloor clip rail, or a combination of the two, provides a
robust fixing method prior to the screed being laid.
We recommend fixing the Greenfloor PE-Xc system pipe
with Greenfloor staples every 300mm, while more staples
may be necessary on bends.
Greenfloor clip rails should be fixed to the floor grade
insulation using the self adhesive backing. This should be
done prior to Greenfloor rail fixing pins being pushed into
the insulation through the clip rail. This will provide a robust
and secure fixing.
Greenfloor clip rails should be fixed at no more than
1,000mm spacing between clip rails and no more than
500mm spacing from wall edges. They should be installed
at 90° to the coldest external wall.
After applying the Greenfloor PE-Xc system pipe, pressure
tests must be completed prior to the screed being laid.

15
15
Dry screed floors
Greenfloor dry construction
panels offer an alternative to
the traditional approach of
installing Greenfloor PE-Xc
system pipe within 75mm
of wet screed. The dry
construction panel system
is designed to be installed
directly over an existing floor surface; this may be designed
as part of a new construction or a retrofit at a later date.
Greenfloor dry construction panels can also offer a solution
where an existing floor is not able to withstand the weight
or loading of a traditional wet screed, for example on
timber suspended floors.
The dry construction panels are laid over the existing floor
surface and feature an interlock system to ensure secure
installation of each panel to the next. Once the installation
of the dry construction panels is complete, Greenfloor heat
conducting plates are installed.
The Greenfloor heat conducting plates allow the heat
from the PE-Xc system pipe to radiate over a wider area
to provide an even heat output. They are available in both
straight and curved sections.
The curved sections allow for a 180° bend at the edge
of the installation area prior to installing the next
straight section.
On completion of the installation of the Greenfloor
dry construction panels and heat conducting plates,
the Greenfloor PE-Xc 14mm system pipe can be installed.
Once the system pipe is installed, the Greenfloor dry screed
system foil is placed over the whole area.
This provides an intermediate layer to minimise the
risk of movement or expansion noise against the
finished floor surface.
For pressure testing directions see page 17.
Timber suspended floors
Greenfloor offers a simple and effective solution for timber
suspended floors which is particularly suitable for retrofit
installations. Timber battens are fixed to run the length
of the joists to provide a platform upon which the floor
grade insulation can be installed. Greenfloor staples or
clip rails can then be used to secure the Greenfloor PE-Xc
pipe. Installation centres can be as close as 100mm to
ensure maximum heat output is available for a comfortable,
efficient and effective heating system.
This style of installation is only recommended for use
in timber suspended floors at 1st floor level and above.
Ground floor installations should, wherever practical,
employ a wet screed installation. This allows for maximum
efficiency and avoids the risk of the ventilated area below
drawing heat away from the floor surface. In all cases, the
installer must plan for maximising thermal insulation and
minimising drafts.
Greenfloor timber suspended floor installations must
successfully pass the same test criteria as a Greenfloor dry
screed floor installation.
For pressure testing directions see page 17.
Flooring
boards
Support
batten
Clip rail staple
Pipe staple
Clip
rail
Joist Floor grade
insulation
Greenfloor
PE-Xc pipe
FlooringFlooring
underlay

16
Installation depths
Below are the required depths for your chosen floor fixing method in addition to the allowance for insulation in accordance
with the current Building Regulations (excluding final floor finish).
Greenfloor staple and clip rail systems
Timber suspended floor application shown.
Timber suspended floor
or concrete base
Dry construction
panel
Greenfloor
PE-Xc pipe
FlooringFlooring
underlay
Edging
insulation strip
Dry screed
system foil
Heat
conducting plate
Concrete base Insulation
Greenfloor
PE-Xc pipe
FlooringScreed Flooring
underlay
Edging
insulation strip
Sub floor
Pipe staple
Clip rail staple
Clip
rail
Flooring
boards
Support
batten
Clip rail staple
Pipe staple
Clip
rail
Joist Floor grade
insulation
Greenfloor
PE-Xc pipe
FlooringFlooring
underlay
Concrete base Insulation
Greenfloor
PE-Xc pipe
FlooringScreed Flooring
underlay
Edging
insulation strip
Sub floor
Pipe positioning
panel
Greenfloor dry construction panel system
Screed type Dry construction panel
Dry
0.2mm – system foil
0.5mm – heat conducting plate
25mm – dry construction panel
25.7mm in total
Greenfloor pipe positioning panel system
Screed type Pipe positioning panel – 30mm
Wet
75mm – screed
30mm – pipe positioning panel
105mm in total
Screed type Pipe positioning panel – 11mm
Wet
75mm – screed
11mm – pipe positioning panel
86mm in total
Screed type Pipe positioning panel – Light
Wet
75mm – screed
0mm – pipe positioning panel
75mm in total
Greenfloor staple panel system
Screed type Staple panel – 30mm
Wet
75mm – screed
30mm – staple panel
105mm in total
Screed type Staple panel – 35mm
Wet
75mm – screed
35mm – staple panel
110mm in total

17
17
General requirements
Insulation to Building Regulations requirements
In all instances, all floors must be insulated to the latest
Building Regulations requirements. The thermal resistance
of the pipe positioning, staple or dry construction panels
may be calculated as part of the building’s insulation
programme or seen as an extra over the minimum
compliance standard already planned.
Pressure testing
Once the PE-Xc system pipe is installed and connected
to the Greenfloor stainless steel manifold, the installation
must be pressure tested using the following procedure.
• Ensure the Greenfloor installation is isolated from the
heat source using the valves between the pump and
mixing station and the stainless steel manifold.
• Flush and fill each loop individually using a mains
cold water supply by ensuring only the manual
isolating valve and flow meter, for the current
loop, are open when being flushed.
• Once all loops are flushed of air and filled, connect
a suitable pressurisation pump to one of the fill and
drain points on the manifold.
• Open each of the loops fully using the manual isolating
valves and flow meters.
• Increase the pressure using the pump to 6 bar. An initial
decrease can be expected as the Greenfloor PE-Xc system
pipe expands. Following this decrease the pressure
should be adjusted back to 6 bar. No other decrease
should be seen. This test pressure must be successfully
witnessed for at least 1 hour.
• After successful completion of the pressure test at 6 bar,
the wet screed or floor finish can be laid. The pressure
test should be maintained throughout the laying of the
screed or floor finish. This protects the system pipe
from deformation and allows any damage incurred to be
immediately noticed.
Laying wet screed
• The screed should be laid
as soon as possible after
successful pressure testing
of the Greenfloor installation.
• This should be supplied
and installed in accordance
with British Standards and
the flooring manufacturer’s
instructions.
• As wet screed cures, it
releases heat. As a result a
slight increase in pressure may be observed.
• Once laid, all screeds require a period of time to cure.
Curing periods are typically 21 days, but British Standards
and the manufacturer’s instructions must be followed.
For the first 3-4 days the screed must not be walked on.
Any pressure could introduce a weak spot to the screed
and the potential for cracking in the future.
• After the initial period has passed the screed can be
walked on.
• The screed must then be covered with both a polythene
barrier to maintain moisture levels and a protective
plywood layer to prevent damage. At all times the screed
supplier’s instructions must be followed.
• At the end of the curing period, the system pressure
should be adjusted to the normal working pressure of
1.5 bar by draining off via the fill and drain point.
• The isolating valves between the pump and mixing station
and the stainless steel manifold can then be opened to
connect the heat source circuit with the Greenfloor
installation.
• The heat source can then be turned on to aid the
drying process.
• The temperature in the Greenfloor installation should be
limited to 25°C for 3 days, then increased for a further
4 days to approximately 40°C.
• It is suggested the screed is left to thoroughly dry for a
further 7 day period. However this may be reduced so
long as the installer of the finished floor is satisfied that
any remaining moisture levels are within the specification
of the finished floor product.
• The Greenfloor installation should be switched off and
the screed allowed to cool for 3 days before installation
of the finished floor product commences.

18
Accommodating expansion
All installations must be provided around the perimeter
with a means of accommodating the expansion of the
screed or the dry construction components. This takes the
form of the Greenfloor edging insulation strip.
Wet screed expansion
Large areas of screed floor
(over 40m2) may also require
regular Greenfloor expansion
joint sections to physically
separate the screed. These
are self adhesive and fix easily
to the floor fixing method. If
Greenfloor pipe positioning
panels are being used, a
Greenfloor rounded section should be installed
to provide a level platform upon which to install
the expansion joint section.
Wherever a screed expansion joint is added, the Greenfloor
PE-Xc system pipe should be protected by a Greenfloor
expansion protection tube to a distance of 300mm in
each direction.
Further information on wet and dry screed expansion
can be found in the British Standards and Building
Regulations as well as from the screed suppliers.
Floor finishes for dry screed installations
• The finished floor must be installed immediately after
pressure testing is complete to protect the installation.
• Laminate floor finishes with interlocking joints must be a
minimum of 7mm thick.
• Plywood or chipboard floor finishes can be used but
should be a minimum of 15mm thick with glued tongue
and groove edges.
• Alternatives to plywood or chipboard fi nishes offering a
lower resistance to heat output are also available.
Further information can be found at your local builder’s
merchants.
Preparing for commissioning
• Before the Greenfloor installation is operated the system
pressure must be reduced to normal working pressure of
1.5 bar by draining off via the fill and drain point.
• The isolating valves between the pump and mixing
station and the stainless steel manifold can then be
opened to connect the heat source circuit with the
Greenfloor installation.

19
Components
Greenfloor PE-Xc pipe and manifolds
Greenfloor PE-Xc system pipe
Greenfloor PE-Xc system pipe
is available in two different
diameters and two different
lengths. There is a choice of
14mm dia. and 16mm dia. pipe,
each with a 2mm side wall.
The selection of the diameter
depends on each particular
installation and will be specified
as part of the package of information provided by the
Worcester Design Service. This is dependent upon
factors such as total pipe length and pressure loss
throughout the installation.
Domestic installers will find the 200m long coils the most
practical and easiest to work with. If installing regularly, for
example on construction sites, it may be more practical to
specify the larger coils which are available – 14mm dia. as a
750m coil or 16mm dia. as a 650m coil. These much larger
coils will reduce the amount of off-cuts. The coil is best
handled when using a pipe reel and stand which are available
from Worcester, and enables the pipe to be supported and
easily uncoiled.
Greenfloor PE-Xc system pipe is guaranteed for a period
of 25 years.
Greenfloor stainless steel manifolds
Greenfloor stainless steel
manifolds are available in a
range of sizes to accommodate
applications from 2 to 16 zones.
It is also possible to connect
two manifolds together. For
example if an extension to
the Greenfloor installation is
required, or to accommodate
unforeseen circumstances at
installation stage.
The number of ports required on the manifold depend
on a number of factors including:
• The number of rooms in the property
• The size of the rooms
• The heat loss of the room and building
• The heat output required from the floor
• Limiting any one pipe run to no more than 120m,
from the manifold and back.
Greenfloor stainless steel manifolds feature flow connections
on the lower manifold section. Incorporated flow meters
allow each zone to be accurately commissioned.
The zone specifications and the optimum number of ports
will be provided in the package of information provided by
the Worcester Design Service.
The outlets of the manifold are ¾" and easily connect with
Greenfloor PE-Xc system pipe using ¾" to 14mm or 16mm
adaptors, according to the diameter of the pipe specified.
The upper manifold section contains the return connections,
again using ¾" adaptor fittings, the Greenfloor PE-Xc system
pipe can be easily connected. Each port on the return
manifold includes a 30mm threaded connection which
incorporates a manual isolating valve and is expected to be
replaced with a 230V actuator. This enables full control over
each zone using either a wired or wireless control platform
and wiring centre.
Each manifold section also features a fill and drain point
with a sealing cap provided, an automatic air vent and
1" connections to the chosen Greenfloor pump and
mixing station.
Greenfloor manifold cabinets
A Greenfloor manifold
cabinet may be specified
and selected to offer a
neat and tidy finish to
the installation.
Available as either flush
mounted, which can be
recessed into a wall prior
to final plastering taking
place, or surface mounted,
which fits directly to a
finished wall surface.

20
Components
Greenfloor controls, pump and mixing stations
Greenfloor offers a number of combinations of controls
and Greenfloor pump and mixing stations to suit individual
installation needs.
Comprehensive wiring instructions are supplied with
each bespoke installation design provided by the
Worcester Design Service, in addition to those supplied
with the product. These are available to download from
our website at www.worcester-bosch.co.uk/ufhwiring
Greenfloor controls – wireless (RF)
The Greenfloor wireless
wiring centre provides a very
easy to install control system
without the restrictions
of running cables to each
individual room thermostat.
The Greenfloor wireless
wiring centre features a 7 day programmer which enables
each of the zones connected to be controlled completely
independently. Within each zone a Greenfloor surface
mounted wireless room thermostat is fitted and through
a simple pairing process is set to control the appropriate
230V actuator outputs within the wiring centre.
The wiring centre is capable of receiving signals from
a maximum of 8 surface-mounted wireless room
thermostats and is able to provide output to a maximum
of 16 actuators. The wiring centre also provides two
separate volt-free interlock relays, one to control the
heat source and one to control the Greenfloor pump
and mixing station’s circulation pump.
In larger installations it is possible to use more than
one wiring centre. The wiring centres are to be wired in
harmony to control the heat source and the Greenfloor
pump and mixing station’s circulation pump.
Greenfloor controls – 230V wired
The Greenfloor 230V wiring
centre provides an easy to
install control system where
running cables to each
individual room thermostat
is not a barrier, for example
in new build and major
renovation installations.
Clearly identified and spring loaded connections mean
installing cables can be completed efficiently.
The Greenfloor 230V wiring centre is capable of receiving
inputs from a maximum of 6 230V room temperature
devices and is able to provide output to a maximum of
14 actuators. The wiring centre also provides an interlock
relay to control the heat source and the Greenfloor pump
and mixing station’s circulation pump.
Pump and mixing station installed at manifold Pump and mixing station
installed remote of manifold
Fixed value flow temperature Weather compensated flow temperature
Wireless
Wireless wiring centre
FRS standard pump
and mixing station
Wireless wiring centre
VRS 7 weather compensated
pump and mixing station
OR
VRS 10 weather compensated
pump and mixing station
Wireless wiring centre
KMS 15 remote pump
and mixing station
OR
25 remote pump
and mixing station
Wired
230V wiring centre
FRS standard pump
and mixing station
230V wiring centre
VRS 7 weather compensated
pump and mixing station
OR
VRS 10 weather compensated
pump and mixing station
230V wiring centre
KMS 15 remote pump
and mixing station
OR
KMS 25 remote pump
and mixing station