Bosch Worcester GREENSTAR CDi CLASSIC REGULAR ErP... User guide

UK/IE
INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS
WALL HUNG RSF GAS FIRED CONDENSING REGULAR BOILER
GREENSTAR CDi CLASSIC REGULAR ErP
6 720 812 176-00.1O
FOR OPEN VENTED AND SEALED CENTRAL HEATING SYSTEMS AND INDIRECT DOMESTIC HOT WATER
6 720 815 723 (2015/05)
THE APPLIANCE IS FOR USE WITH NATURAL GAS OR L.P.G.
(Cat II 2H3P TYPE C13 & C33)
NATURAL GAS:
30CDi Classic Regular ErP GC Number 41-406-33
40CDi Classic Regular ErP GC Number 41-406-35
LIQUID PETROLEUM GAS:
30CDi Classic Regular ErP GC Number 41-406-34
40CDi Classic Regular ErP GC Number 41-406-36

CONTENTS
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CONTENTS
1 KEY TO SYMBOLS AND SAFETY PRECAUTIONS . . . . . . . . . . . . 3
1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 APPLIANCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Product data on energy consumption . . . . . . . . . . . . . . . 7
2.4 Layout & components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 PRE-INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Cleaning primary systems . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Mains supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2.1 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Water systems & pipe work . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Condensate pipe work . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4.1 Internal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4.2 External connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5 Boiler internal drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.6 Boiler location & clearances . . . . . . . . . . . . . . . . . . . . . 13
3.7 Plumbing manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.8 Flue options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.9 Flue terminal positions . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.10 Plume management terminal positions . . . . . . . . . . . . 18
4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 Unpacking wall frame and ancillary items . . . . . . . . . . 19
4.2 Wall mounting plate and flue opening . . . . . . . . . . . . . 20
4.3 Unpacking the appliance . . . . . . . . . . . . . . . . . . . . . . . . 21
4.4 Fitting the appliance boiler connections . . . . . . . . . . . 22
4.5 Flue installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.5.1 Ø60/100mm Telescopic flue kit: . . . . . . . . . . . . . . . . . 24
4.5.2 Ø60mm Plume management kit: . . . . . . . . . . . . . . . . . 24
4.5.3 Adjusting the standard terminal length: . . . . . . . . . . . . 24
4.5.4 Installing the standard flue . . . . . . . . . . . . . . . . . . . . . . 25
4.5.5 Flue terminal plume re-direction: . . . . . . . . . . . . . . . . . 25
4.6 Condensate connection . . . . . . . . . . . . . . . . . . . . . . . . 26
4.7 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.8 Position of wired components . . . . . . . . . . . . . . . . . . . 28
5 COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.1 Pre-commissioning checks . . . . . . . . . . . . . . . . . . . . . . 29
5.2 Condensate connection . . . . . . . . . . . . . . . . . . . . . . . . 29
5.3 Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.4 Starting the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.5 Water treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.6.1 Checking the gas inlet pressure . . . . . . . . . . . . . . . . . . 31
5.6.2 Checking the gas rate . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.7 CO and Combustion checks . . . . . . . . . . . . . . . . . . . . . 32
5.8 Finishing commissioning . . . . . . . . . . . . . . . . . . . . . . . 33
6 SERVICING AND SPARES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.1 Inspection and spares . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.1.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.1.2 Checking flue integrity . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.1.3 Component Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.1.4 Fan pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.1.5 To Clean the Heat Exchanger . . . . . . . . . . . . . . . . . . . . 36
6.1.6 To Clean the Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.1.7 To Check the Diaphragm in Burner Cover . . . . . . . . . . 37
6.1.8 Re-assembly of the burner cover . . . . . . . . . . . . . . . . . 37
6.1.9 To Clean the Condensate Trap . . . . . . . . . . . . . . . . . . . 37
6.2 Setting the air/gas ratio . . . . . . . . . . . . . . . . . . . . . . . . 38
6.3 Replacement of parts . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.4 Short parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7 FAULT FINDING & DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 45
7.1 Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.2 Protection function (external pump) . . . . . . . . . . . . . . 45
7.3 Heating function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

KEY TO SYMBOLS AND SAFETY PRECAUTIONS
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1 KEY TO SYMBOLS AND SAFETY PRECAUTIONS
1.1 Key to symbols
Warnings
The following keywords are defined and can be used in this document:
•NOTE indicates a situation that could result in damage to property or
equipment.
•CAUTION indicates a situation that could result in minor to medium
injury.
•WARNING indicates a situation that could result in severe injury or
death.
•DANGER indicates a situation that will result in severe injury or
death.
Important information
Additional symbols
SYMBOLS USED IN THIS MANUAL
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE
STARTING INSTALLATION.
1.2 SAFETY PRECAUTIONS
If you smell gas
A gas leak could potentially cause an explosion. If you smell gas, observe
the following rules.
▶ Prevent flames or sparks:
– Do not smoke, use a lighter or strike matches.
– Do not operate any electrical switches or unplug any equipment.
– Do not use the telephone or ring doorbells.
▶ Turn off the gas at the meter.
▶ Open windows and doors.
▶ Warn your neighbours and leave the building.
▶ Prevent anyone from entering the building.
▶ Well away from the building: call the National Gas Emergency Service
on 0800 111 999.
BOILER OPERATION:
This boiler must only be operated by a responsible adult who has
been instructed in, understands and is aware of the boiler’s
operating conditions and effects.
Benchmark places
responsibilities on both
manufacturers and installers.
The purpose is to ensure that
customers are provided with
the correct equipment for
Warnings in this document are identified by a warning
triangle printed against a grey background.
Keywords at the start of a warning indicate the type and
seriousness of the ensuing risk if measures to prevent
the risk are not taken.
This symbol indicates important information where
there is no risk to people or property.
Symbol Explanation
▶ Step in an action sequence
Cross-reference to another part of the document
• List entry
– List entry (second level)
Domestic Hot Water
Central Heating
Hot Water Storage Cylinder
Domestic Cold Water Supply
Electrical Supply
Gas Supply
Table 1 Commonly used symbols
These instructions are applicable to the Worcester appliance model(s)
stated on the front cover of this manual only and must not be used with
any other make or model of appliance.
These instructions apply in the UK and Ireland only and must be
followed except for any statutory obligations.
This appliance must be installed by a GAS SAFE registered,
competent person. Failure to install correctly could lead to
prosecution.
If you are in any doubt, contact the Worcester Technical help-line
(0330 123 3366).
Please leave these instructions with the completed BENCHMARK
CHECKLIST, (or a certificate confirming compliance with IS 813, Eire
only) and the user manual with the owner or at the gas meter after
installation or servicing.
Distance learning and training courses are available from Worcester.
The BENCHMARK CHECKLIST can be found in the back of this
Installation manual.
Ø Diameter
NG Natural Gas
LPG Liquid Petroleum Gas
CH Central Heating
DHW Domestic Hot Water
DCW Domestic Cold Water
PRV Pressure Relief Valve
NTC Negative Temperature Coefficient (sensor)
IP Ingress Protection
RCD Residual Current Device
TRV Thermostatic Radiator Valve
ECV Emergency Control Valve
WRAS Water Regulations Advisory Scheme
SEDBUK Seasonal Efficiency of Domestic Boilers in the U.K.
Table 2 Abbreviations use in this manual

KEY TO SYMBOLS AND SAFETY PRECAUTIONS
6 720 815 723 (2015/05)4
their needs, that it is installed, commissioned and serviced in
accordance with the manufacturer's instructions by competent persons
and that it meets the requirements of the appropriate Building
Regulations. The Benchmark Checklist can be used to demonstrate
compliance with Building Regulations and should be provided to the
customer for future reference.
Installers are required to carry out installation, commissioning and
servicing work in accordance with the Benchmark Code of Practice
which is available from the Heating and Hot water Industry Council who
manage and promote the scheme.
Visit centralheating.co.uk for more information.
HEALTH AND SAFETY
The appliance contains no asbestos and no substances have been used
in the construction process that contravene the COSHH Regulations
(Control of Substances Hazardous to Health Regulations 1988).
COMBUSTIBLE AND CORROSIVE MATERIALS:
Do not store or use any combustible materials (paper, thinners, paints
etc.) inside or within the vicinity of the boiler.
Chemically aggressive substances can corrode the appliance and
invalidate any warranty.
FITTING & MODIFICATIONS
Fitting the appliance and any controls to the appliance may only be
carried out by a competent engineer in accordance with the current Gas
Safety (Installation and Use) Regulations.
Flue systems must not be modified in any way other than as described in
the fitting instructions. Any misuse or unauthorised modifications to the
appliance, flue or associated components and systems could invalidate
the warranty. The manufacturer accepts no liability arising from any
such actions, excluding statutory rights.
SERVICING
Advise the user to have the system serviced annually by a competent,
qualified Gas Safe registered engineer. Approved spares must be used
to help maintain the economy, safety and reliability of the appliance.
IMPORTANT
The service engineer must complete the Service Record on the
Benchmark Checklist after each service.
INSTALLATION REGULATIONS
Current Gas Safety (Installation & Use) Regulations:
All gas appliances must be installed by a competent person in
accordance with the above regulations. Failure to install appliances
correctly could lead to prosecution.
The appliance must be installed in accordance with, and comply to, the
current: Gas Safety Regulations, IET Regulations, Building Regulations
(England), Building Standards (Scotland) (Consolidation), Building
Regulations (Wales), Building Regulations (Northern Ireland), local
water by-laws, Health & Safety Document 635 (The Electricity at Work
Regulations 1989) and any other local requirements.
EU Regulations No. 811/2013 - Energy Labelling.
British Standards:
Where no specific instruction is given, reference should be made to the
relevant British Standard codes of Practice.
BS7074:1 - Code of practice for domestic and hot water supply
BS6891I - Installation of low pressure gas pipe work up to 28mm (R1)
BS5546 - Installation of gas hot water supplies for domestic purposes
EN12828 - Central heating for domestic premises
BS5440:1 - Flues and ventilation for gas appliances of rated heating not
exceeding 70kW (net): Flues
BS5440:2 - Flues and ventilation for gas appliances of rated heating not
exceeding 70kW (net): Air Supply
BS7593 - Treatment of water in domestic hot water central heating
systems
BS6798 - Installation of gas fired boilers of rated input up to 70kW (net)
Irish Standards
The relevant Irish standards should be followed, including:
• ECTI National rules for electrical installations
• IS 813:2002 for Domestic Gas Installations.
LPG Installations
An appliance using L.P.G. must not be installed in a room or internal
space below ground level unless one side of the building is open to the
ground.
Timber framed building:
Where the boiler is to be fitted to a timber framed building the guidelines
laid down in BS5440: Part 1 and IGE "Gas Installations in Timber Frame
Buildings” should be adhered to.
Potable water:
All seals, joints and compounds (including flux and solder) and
components used as part of the secondary domestic water system must
be approved by WRAS.
CH Water:
Artificially softened water must not be used to fill the central heating
system.

APPLIANCE INFORMATION
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2 APPLIANCE INFORMATION
2.1 General information
Boiler features and checklist
• Pre-plumbed
• Galvanised steel inner frame
• Digital control system
• Automatic ignition
• Direct burner ignition electrodes
• Built-in frost protection
• Built-in fault finding diagnostics
• Automatic gas valve
• Modulating combustion air fan with speed regulator
• CH temperature sensor & control
• Pump anti-seizure protection
• Flue gas temperature sensor
• Condensate siphonic trap
Standard package
Fig. 1 Overall dimensions
Fig. 2 Standard package
Key to Fig. 1 and 2:
[1] Wall hung gas fired condensing regular boiler for central heating
and domestic hot water
[2] Wall mounting plate with hanging bracket
[3] Hardware pack 1
[4] Hardware pack 2
[5] Literature pack:
Installation instructions
User instructions
Wall mounting template
[6] Flow pipe
[7] Return pipe 1
[8] Return pipe 2
[9] Pre-plumbing manifold with water and gas connections
[10] ErP energy label
[11] Bottom panels
1
max.
360 mm
max.
760 mm
440mm
11
11
6 720 812 174-14.1O
6 720 812 174-01.1O
5
4
3
68
7
9
10
10
2

APPLIANCE INFORMATION
6 720 815 723 (2015/05)6
2.2 TECHNICAL DATA
NATURAL GAS L.P.G
Product type
30CDi Classic
Regular ErP
40CDi Classic
Regular ErP
30CDi Classic
Regular ErP
40CDi Classic
Regular ErP
Heating
Max. rated heat input kW 30.9 42.0 30.9 42.0
Max. rated heat output net 40/30°C kW 32.1 43.7 32.1 43.7
Max. rated heat output net 50/30°C kW 31.8 43.3 31.8 43.3
Max. rated heat output net 80/60°C kW 30.0 40.8 30.0 40.8
Min. rated heat output net 40/30°C kW 8.6 10.6 12.4 15.7
Min. rated heat output net 50/30°C kW 8.6 10.5 12.3 15.5
Min. rated heat output net 80/60°C kW 7.7 9.4 11.0 13.9
Min. rated heat input net kW 8.0 9.8 11.5 14.5
Max. flow temperature °C nom.90 nom.90 nom.90 nom.90
Max. permissible operating pressure bar 2.5 2.5 2.5 2.5
Gas flow rate - Max. 10 minutes from lighting
Natural Gas G20 m3/h 3.2 4.4 --
Propane Gas (LPG) kg/h --2.4 3.3
Flue
Flue Gas Temp. 80/60°C, rated min. load Max/Min °C 76/58 87/58 76/58 87/58
Flue Gas Temp. 40/30°C, rated min. load Max/Min °C 55/33 58/35 55/33 58/35
CO2 level at max. rated heat output % 9.6 9.7 11.5 11.5
CO2 level at min. rated heat output % 9.0 9.1 10.5 10.5
NOx - class 5555
Condensate
Max. condensation rate I/h 2.7 3.7 2.7 3.7
pH value, approx. 4.8 4.8 4.8 4.8
Electrical
Electrical power supply voltage AC...V 230 230 230 230
Frequency Hz 50 50 50 50
Max. power consumption W approx.70 approx.100 approx.70 approx.100
General Data
SEDBUK band AAAA
Appliance protection rating IP X4D X4D X4D X4D
Permissible ambient temperatures °C 0-50 0-50 0-50 0-50
Nominal capacity of appliance I 3.5 3.5 3.5 3.5
Total boiler weight (lift weight) kg 39.5 39.5 39.5 39.5
Packaged boiler weight kg 48 48 48 48
SAP 2009 annual efficiency % 89.2 89.2 90.2 90.2
SAP 2005 seasonal efficiency (SEDBUK) % 90.2 90.1 92.1 92.0
Table 3 Technical data

APPLIANCE INFORMATION
6 720 815 723 (2015/05) 7
2.3 Product data on energy consumption
The following product data satisfy the requirements of the EU Regulations No. 811/2013, No. 812/2013, No. 813/2013 and No. 814/2013
supplementing Directive 2010/30/EU.
Product data Symbol Unit 7 738 100 245 7 738 100 235 7 738 100 232 7 738 100 234
Product type – – 30CDi Classic
Regular ErP
30CDi Classic
Regular ErP LPG
40CDi Classic
Regular ErP
40CDi Classic
Regular ErP LPG
Condensing boiler – – Yes Yes Yes Yes
Rated heat output Prated kW 30 30 41 41
Seasonal space heating energy efficiency s%92 92 92 92
Energy efficiency class – – A A A A
Useful heat output
At rated heat output and high temperature regime 1)
1) High temperature regime means 60 °C return temperature at heater inlet and 80 °C feed temperature at heater outlet.
P4kW 30.0 30.0 40.8 40.8
At 30 % of rated heat output and low temperature regime 2)
2) Low temperature means for condensing boilers 30 °C, for low-temperature boilers 37 °C and for other heaters 50 °C return temperature (at heater inlet).
P1kW 10.0 10.0 13.6 13.6
Useful efficiency
At rated heat output and high temperature regime 1) 4% 88.2 88.2 88.2 88.2
At 30 % of rated heat output and low temperature regime 2) 1% 97.5 97.5 96.9 96.9
Auxiliary electricity consumption
At full load elmax kW 0.058 0.058 0.090 0.090
At part load elmin kW 0.030 0.030 0.036 0.036
In standby mode PSB kW 0.004 0.004 0.004 0.004
Other items
Standby heat loss Pstby kW 0.048 0.048 0.048 0.048
Emissions of nitrogen oxides NOx mg/kWh 30 30 29 29
Sound power level, indoors LWA dB(A) 55 55 60 60
Table 4 Product data for energy consumption

PRE-INSTALLATION
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2.4 Layout & components
Fig. 3 Boiler layout and components. The diagram shows the controls
in the servicing position and excludes the outer case.
Fig. 4
[1] Ignition electrode and flame sense electrode
[2] Heat exchanger
[3] Overheat thermostat
[4] Access point for cleaning heat exchanger
[5] Drain point
[6] Return
[7] Gas connection 22 mm compression
[8] Drain hose
[9] Cover for external wiring connection
[10] Control panel in service position
[11] Flow
[12] Trap / Siphon
[13] Condensate hose (22 mm outlet connection)
[14] Inlet pressure test point
[15] Gas valve
[16] Air/gas adjustment screw
[17] Testing point for fan pressure
[18] Fan
[19] Primary sensor
[20] Auto air vent
[21] Removable top case for servicing
[22] Blank plate
[23] Display
[24] Fault reset button
[25] Not used
[26] Not used
[27] ON/OFF and fault indicator (blue)
[28] Temperature control
[29] Performance test button
[30] Service button
[31] Burner indicator (green)
[32] ON/OFF button
The diagram above shows the controls in the servicing position and
excludes the outer case.
3 PRE-INSTALLATION
3.1 Cleaning primary systems
BEFORE CLEANING THE SYSTEM:
▶Ensure that the system and pipe work is in good working order.
▶Where possible keep the existing boiler/circulating pump in
place when flushing the system.
FOLLOW THE GUIDANCE OF BS7593:
Treatment of water in domestic hot water central heating and also the
flushing guidelines below.
FLUSHING THE SYSTEM
▶ Fill the system with cold water and check for leaks.
▶ Open all drain cocks and drain the system.
▶ Close drain cocks and add a suitable flushing agent compatible with
aluminium at the correct strength for the system conditions in
accordance with the manufacturer‘s instructions.
The pH value of the system water must be less than 8 or the
appliance guarantee will be invalidated.
▶ Circulate the flushing agent before the boiler is fired up.
6 720 812 174-07.1O
10
20
21
19
11
12
13
14
16
17
18
15
5
1
3
4
6
7
8
2
9
1
2
34
5
6
max
reset
eco
6 720 812 174-08.1O
22 23
24
25
26
27
28
29
30
31
32
NOTICE:
▶ All the following Pre-Installation sections must be
read and requirements met before starting boiler or
flue installations.
CAUTION:
▶ ISOLATE THE MAINS SUPPLIES BEFORE STARTING
ANY WORK AND OBSERVE ALL RELEVANT SAFETY
PRECAUTIONS.
NOTICE:
Debris from the system can damage the boiler and
reduce efficiency.Failure to comply with the guidelines
for the use of water treatment with the appliance will
invalidate the appliance warranty.
NOTICE: ARTIFICALLY SOFTENED WATER MUST NOT
BE USED TO FILL THE CENTRAL HEATING SYSTEM.

PRE-INSTALLATION
6 720 815 723 (2015/05) 9
▶ Run the boiler/system at normal operating temperature as directed
by the manufacturer of the flushing agent.
▶ Drain and thoroughly flush the system to remove the flushing agent
and debris.
▶ It may be necessary to use a power flushing machine to aid the
cleansing procedure in some circumstances.
▶ Close the drain cocks and refill with fresh water and a suitable
inhibitor.
▶ Vent any air from the boiler and system.
INHIBITOR
Add a suitable inhibitor or combined inhibitor/anti-freeze, if the system
is exposed to freezing conditions, to the heating system in accordance
with the DWTA code of practice and manufacturer‘s guidelines.
Water treatment
Suitable water treatment products can be obtain from the following
manufacturers:
3.2 MAINS SUPPLY
3.2.1 Electrical supply
• Supply: 230V - 50 Hz, 140 Watts
• Cable: PVC insulated 0.75 mm2 (24 x 0.2 mm) temperature rated to
90°C.
• External 3A fuse to BS1362.
• The appliance must be earthed.
• This appliance must not be connected to a three phase supply.
• IPX4D.
• Wiring must comply with the latest IET wiring regulations.
3.2.2 Gas supply
• Boilers using Natural Gas (NG) must be connected to a governed
meter.
• Liquid Petroleum Gas (LPG) must be connected to a regulator.
• Installation and connection of the gas supply to the boiler must be in
accordance with BS6891.
• Under no circumstance should be size of the gas supply pipe be less
than 22 mm.
• The meter or regulator and pipe work to the meter must be checked,
preferably by the gas supplier. This is to ensure that the equipment is
in good working order and can meet the gas flow and pressure
requirements, in addition to the demand from any other appliance
being served.
3.3 WATER SYSTEMS & PIPE WORK
PLASTIC PIPEWORK:
• Any plastic pipe work must have a polymeric barrier with 600 mm
(minimum) length of copper or steel pipe connected to the boiler.
• Plastic pipe work used for underfloor heating must be correctly
controlled with a thermostatic blending valve limiting the
temperature of the circuits to approximately 50°C.
The pipe work from the boiler to the blending valve must be in copper
or steel (protected from corrosion).
CONNECTIONS/VALVES:
• All system connections, taps and mixing valves must be capable of
sustaining a pressure up to 3 bar.
• Radiator valves should conform to BS2767:10.
• Do not use galvanised pipes or radiators.
• All other valves should conform to BS1010.
• On new installations, or extensions to existing systems where a
radiator previously did not exist, each radiator should be fitted with a
TRV, except the one fitted in the same room/area as the room
thermostat.
• On boiler only replacement jobs, it is recommended, (but not
mandatory,) to fit a TRV on each radiator. It is, however, a
requirement, for energy conservation purposes, to recommend to
the customer that a TRV is fitted to each radiator.
• An automatic bypass may be required, (downstream of the pump), in
order to maintain the minimum flow-rate through the appliance.
• An air vent is required at the highest point on the system.
SEALED PRIMARY SYSTEM:
• The CH sealed system must be filled using a WRAS approved filling
loop or comply with figure 5 for system fill.
• An expansion vessel, of a size suitable for the system, must be fitted
as close as possible to the appliance in the central heating return.
• Also fit a pressure gauge, a 3 bar pressure relief valve and stop cock
(fixed cylinder type or sealed system approved connection).
•Do not use galvanised pipes or radiators.
SYSTEM FILL
Fig. 5 System fill/System make-up
WARNING: Sealing agents
▶ The addition of sealing agents to the system water is
not permitted as this can cause problems with
deposits left in the heat exchanger.
FERNOX 0870 601 5000
www.fernox.com
SENTINEL 0800 389 4670
www.sentinel-solutions.net
NOTICE: Artificially softened water must not be used to
fill the central heating system.
SYSTEM FILL
CV = Check Valve
SV = Stop Valve
SV SV
Test point
Temporary hose
Hose union CV
CV
Heating
return
Mains
supply
SYSTEM MAKE UP
AA = Auto Air vent
CV = Check Valve
SV
CV
AA
Make up
vessel
Heating
return
1000 mm (39 in)
above the highest
point of the system.
Fill point
6720644743-08.1Wo

PRE-INSTALLATION
6 720 815 723 (2015/05)10
S AND Y PLAN SYSTEM:
system layout:
Fig. 6 S plan
Fig. 7 Y plan
Fig. 8 Sealed system
new build system layouts
The latest Part L1a regulation for new installations require separate zone
controls for the central heating.
Fig. 9 Open vent with two heating zones
Fig. 10 Sealed system with two heating zones
NOTICE: Bypass
▶ Generally a bypass is not necessary on a Y plan
system as one of the ports is open to flow.
1 Static head -
Minimum static head 250mm measured from the highest
point in the heating system (top surface of the appliance or
the highest point in the heating system) to the water level in
the feed and expansion tank
2 Heating vent (22mm minimum)
3 Primary cold feed (15mm minimum)
4 Diverter/Zone valve
5 Pump, maximum power 90 Watts
6 Automatic bypass
7 Radiator valve (Flow)
8 Lock shield valve (Return)
9 Expansion vessel
10 Pressure gauge
11 3 bar pressure relief valve
12 Stop cock
Table 5 Key to figures 7, 8, 9 & 10
NOTICE: A drain cock should be fitted at the lowest
point of the heating circuit and beneath the appliance.
8
7
1
3
2
4
6
5
150 mm
max
M
M
6 720 812 174-12.1O
8
7
1
3
2
4
5
150 mm
max
M
6 720 812 174-11.1O
MCW
8
7
4
10
12
11
9
5M
6 720 812 174-13.1O
8
7
1
3
2
4
6
5
150 mm
max
M
MM
6 720 812 174-10.1O
6 720 812 174-09.1O
8
7
4
6
5
M
MM
MCW 12
10 11
9

PRE-INSTALLATION
6 720 815 723 (2015/05) 11
3.4 Condensate pipe work
3.4.1 Internal connections
In order to minimise risk of freezing during prolonged cold spells, the
following methods of installing condensate drainage pipe should be
adopted, in order of priority.
Wherever possible, the condensate drainage pipe should be routed and
terminated so that the condensate drains away from the boiler under
gravity to a suitable internal foul water discharge point such as an
internal soil and vent stack. A suitable permanent connection to the foul
waste pipe should be used.
Fig. 11 Disposal to soil vent stack
Alternatively if the first option is not possible an internal kitchen or
bathroom waste pipe, washing machine waste pipe etc. can be used.
Ensure that the condensate drain pipe is connected “down stream” of
the waste trap.
Fig. 12 Disposal to a waste pipe
CONDENSATE PUMP
Where “gravity discharge” to an internal termination is not physically
possible, or where very long internal runs would be required to reach a
suitable discharge point, condensate should be removed using a
proprietary condensate pump, of a specification recommended by the
boiler or condensate pump manufacturer.
The pump outlet pipe should discharge to a suitable internal foul water
discharge point such as an internal soil and vent stack, internal kitchen
or bathroom waste pipe, washing machine waste pipe etc. A suitable
permanent connection to the foul waste pipe should be used.
Fig. 13 Condensate pump disposal
NOTICE:
▶ Where a new or replacement boiler is being installed,
access to an internal “gravity discharge” point should
be one of the factors considered in determining
boiler location.
▶ The condensate pipe must be nominally
22mm Ø plastic pipe.
▶ The condensate pipe work must fall at least 52mm
per metre towards the outlet and should take the
shortest practicable route.
▶ Ensure there are no blockages in the pipe run.
Key to condensate illustrations
1 Condensate discharge from boiler
2 Soil and vent stack
3 Minimum 450mm and up to three storeys
4 Visible air break at plug hole
5 Sink or basin with integrated overflow
6 75mm sink waste trap
7 Condensate pump
* Condensate trap of 75mm already incorporated into the boiler
2
22mm Ø
1
3
6720644744-06.3Wo
100mm
75mm
min.
4
5
6
1
22mm Ø
6720644744-07.3Wo
75mm
min.
4
7
5
6
1
22mm Ø
6720644744-08.3Wo

PRE-INSTALLATION
6 720 815 723 (2015/05)12
3.4.2 External connections
If no other discharge method is possible then the use of an externally run
condensate drainage pipe terminating at a suitable foul water discharge
point, or purpose-designed soak away, may be considered. If this
method is chosen then the following measures should be adopted:
▶ Use a CondenseSure siphon to help prevent the condensate freezing.
▶ The external run be kept as short as possible and not exceed three
metres.
▶ The pipe should be run internally as far as possible before going
externally and the pipe diameter should be increased to 32mm
before it passes through the wall to the exterior. The pipe should be
insulated using suitable waterproof and weather resistant insulation,
if not using a CondenseSure siphon.
▶ The external pipe should take the shortest and least exposed route to
the discharge point, and should "fall" as steeply as possible away
from the boiler, with no horizontal runs in which condensate might
stand.
▶ The use of fittings, elbows etc. should be kept to a minimum and any
internal “burrs” on cut pipe work should be removed so that the
internal pipe section is as smooth as possible.
FITTING AN EXTERNAL AIR BREAK
• Refer to figure 14 when a rain water down pipe is used to dispose of
condensate.
• An air break must be installed in the 43mm pipe work, between the
boiler condensate outlet and the drainpipe, outside the property, to
avoid flooding during adverse weather conditions.
Fig. 14 Disposal into a rainwater down pipe
Where the pipe terminates over an open drain or gully, the pipe should
terminate below the grating level, but above water level, in order to
minimise “wind chill” at the open end.
The use of a drain cover (such as those used to prevent blockage by
leaves) may offer further protection from wind chill.
Pipe drainage will be improved if the end is cut at 45° as opposed to a
straight cut.
Fig. 15 External disposal
NOTICE: Freezing conditions
▶ When the position of the boiler prevents internal
routing, we recommend installing a CondenseSure
siphon to significantly reduce the risk of freezing.
▶ Pipe work length should be kept to a minimum and
the route as vertical as possible.
▶ Weather proof insulation must be used, if not using a
CondenseSure siphon.
NOTICE: Condensate waste
▶ Care should be taken when siting a soak-away to
avoid obstructing existing services.
Continued - Key to condensate illustrations
8 PVCu strap on fitting
9 100mm Ø minimum plastic pipe
10 Drainage holes
11 Limestone chippings
12 Bottom of sealed tube
13 Insulate and increase pipe size
14 Pipe work transition
15 External air break
16 Air gap
17 External rain water pipe into foul water
18 43mm 90° male/female bend
* Condensate trap of 75mm already incorporated into the boiler
Condensate drainage pipe can be run above or below
ground.
18 8
13
14
17
15
16
1
6720644744-09.3Wo
25mm min.
14
13
1
6720644744-10.3Wo

PRE-INSTALLATION
6 720 815 723 (2015/05) 13
CONDENSATE SOAK AWAY
• The condensate drainage pipe may be run above or below the ground
to the soak away. The examples shown on this page run above
ground.
• The soak away must use a 100mm Ø plastic tube with two rows of
three 12mm holes on 25mm centres and 50mm from the bottom of
the tube. The holes must face away from the house.
• The tube must be surrounded by at least 100mm of limestone
chippings to a depth of 400mm.
In situations where there are likely to be extremes of temperature or
exposure, the use of a proprietary trace-heating system for external pipe
work, incorporating an external frost thermostat, should be considered.
If such a system is used, the requirement to use 32mm pipe does not
apply. However, all other guidance above and the instructions for the
trace heating system, should be closely followed.
Fig. 16 Soak away
Fig. 17 Condensate pump to external disposal
3.5 Boiler internal drain
The CDI Regular ErP has the facility to drain the water direct from the
boiler through the condensate pipe.
Fig. 18 Drain tap positions
If the boiler uses a soakaway or a condensate pump:
▶ Use an external drain point on the system to prevent excess system
water being drawn through the soakaway or condensate pump
3.6 Boiler location & clearances
This boiler is only suitable for installing internally within a property at a
suitable location onto a fixed, rigid non-combustible surface at least the
same size as the boiler and capable of supporting the boiler weight.
COMPARTMENTS:
Follow the requirements of BS6798 and BS5440 Part 2 and note:
• Minimum clearances must be maintained
• An access door is required to install, service and maintain the boiler
and any ancillary equipment.
• If an airing cupboard is adapted to house a boiler, then the airing
spaces must be separated from the boiler compartment by a
noncombustible partition. The partition may be perforated, if
required, by holes not exceeding 13 mm in diameter.
• If the appliance is fitted into a cupboard or a compartment is built
around the appliance after installation, then the compartment must
be built or lined by a non-combustible material.
BOILER CLEARANCES:
The diagram opposite shows the minimum space required to install and
service the boiler.
VENTILATION
This is a room sealed appliance and does not require any air for
combustion from inside the property.
The requirements of BS 6798 and BS 5440 regarding ventilation do not
apply, with the Greenstar CDi Regular ErP boiler. There is no need for
ventilation openings to be provided in the compartment because of the
low heat loss from the appliance casing, if the clearances shown are
maintained.
Minimumholesizeforthecondensatesoakawaymustbe
400mm deep by 300mmØ .
NOTICE: Unheated internal areas.
▶ Internal pipe runs in unheated areas such as lofts,
basements and garages should be treated as
external runs.
13
14
10
500mm min.
25mm min.
400mm
min.
1
12
11
9
6720644744-11.3Wo
9
10
25mm min.
14 13
1
7
6720644744-12.3Wo
NOTICE:
No surface protection is required against heat transfer
from the boiler.
6 720 815 723-02.2O

PRE-INSTALLATION
6 720 815 723 (2015/05)14
Do not operate the appliance if the flue terminal fitted on the outside wall
or roof is obstructed or damaged.
BATHROOMS:
Additional RCD (Residual Current Device) protection may be required.
Refer to the latest IET wiring regulations.
BATHROOM INSTALLATIONS
Fig. 19 Bathroom installations
3.7 PLUMBING MANIFOLD
CONNECTIONS:
Heating System: 22mm compression fittings
Gas: 22mm compression fittings
Use the fittings supplied in the Hardware pack.
PREPLUMBING
With the plumbing manifold installed, pipe work can be installed to the
valves on the manifold.
RUNNING PIPES BEHIND THE BOILER
If the boiler pipes are to be run behind the appliance ensure that the
pipes pass close to the wall as shown in the diagram opposite, and within
the pipe guide.
Fig. 20 Behind the boiler pipe run
* Minimum clearance to removable door
** Minimum clearance required for servicing
*** Height for either 60/100 or 80/125 flue
Table 6 Minimum clearances
NOTICE: Any switch or appliance control using 230 V
mains electricity must not be able to be touched by a
person using the bath or shower. Electrical switches,
fused spur and socket outlets must not be situated in
the bathroom.
1130/1170mm***
960mm
380mm
450mm
170/210mm***
600mm**
5mm
5mm
200mm
20mm*
6720803599-10.1Wo
6720646608-124.3Wo
2*
Radius 600mm
1
212
2
1
600mm
600mm 600mm
2250mm
2250mm
2*
Return 22mm
Flow 22mm
Mains Gas Supply 22mm
6720806548-03.1Wo

PRE-INSTALLATION
6 720 815 723 (2015/05) 15
3.8 Flue options
The Greenstar CDi Classic Regular ErP has the option of three horizontal
RSF (60/100 telescopic, 60/100 longer telescopic and 80/125
telescopic) flue systems and two vertical RSF (60/100 or 80/125)
regular flue systems:
The systems have different maximum flue lengths for different boiler
outputs and different plume management lengths.
For every extra 1000mm of plume management after the first 500mm,
the internal 60/100 flue length must be reduced by 700mm, up to a
maximum of 4500mm of plume management.
For example on a 30CDi Classic Regular ErP if the plume management
effective length was 1500mm, the internal flue would be reduced to
5200mm.
This page and the page opposite shows various flue options with the
straight flue lengths required to achieve the maximum flue length.
Maximum horizontal flue lengths (L)
Boiler model 100mmØ 125mmØ
No Plume
management
+ 500mm
of plume
management
+4500mm
of plume
management
No plume
management
available
30CDi 7,900mm 5,900mm 3,100mm 18,500mm
40CDi 6,000mm 4,000mm 1,200mm 12,500mm
Table 7 Maximum horizontal flue lengths
Maximum vertical flue lengths
Boiler model 100mmØ 125mmØ
30CDi 9,400mm 18,500mm
40CDi 7,500mm 16,000mm
Table 8 Maximum vertical flue lengths
NOTICE: 60/100 Flue systems:
▶ Each 90° bend used is equivalent to 1.5 metres of
straight flue.
▶ Each 45° bend used is equivalent to 0.75 metres of
straight flue.
NOTICE: 80/125 flue systems:
▶ Each 90° bend used is equivalent to 2 metres of
straight flue.
▶ Each 45° bend used is equivalent to 1 metre of
straight flue.
Telescopic horizontal flue
Flue option 1 100mmØ 125mmØ
30CDi 570mm 600mm
40CDi 570mm 600mm
Table 9 Flue option 1
Horizontal extended flue
Flue option 2 100mmØ 125mmØ
30CDi 7,900mm 18,500mm
40CDi 6,000mm 12,500mm
Table 10 Flue option 2
Horizontal extended flue with 1x90° bends
Flue option 3 100mmØ 125mmØ
30CDi 6,400mm 16,500mm
40CDi 4,500mm 10,500mm
Table 11 Flue option 3
Horizontal extended flue with 2x90° bends
Flue option 4 100mmØ 125mmØ
30CDi 4,900mm 14,500mm
40CDi 3,000mm 8,500mm
Table 12 Flue option 4
High level horizontal extended flue
Flue option 5 100mmØ 125mmØ
30CDi 7,900mm 18,500mm
40CDi 6,000mm 12,500mm
Table 13 Flue option 5
High level horiz. extended flue with 2x90° bends
Flue option 6 100mmØ 125mmØ
30CDi 6,400mm 16,500mm
40CDi 4,500mm 10,500mm
Table 14 Flue option 6
High level horiz. extended flue with 3x90° bends
Flue option 7 100mmØ 125mmØ
30CDi 4,900mm 14,500mm
40CDi 3,000mm 8,500mm
Table 15 Flue option 7
Vertical balanced extended flue
Flue option 8 100mmØ 125mmØ
30CDi 9,400mm 18,500mm
40CDi 7,500mm 16,000mm
Table 16 Flue option 8
Vertical balanced extended flue with 2x90° bends
Flue option 9 100mmØ 125mmØ
30CDi 6,400mm 14,500mm
40CDi 4,500mm 12,000mm
Table 17 Flue option 9
Vertical balanced extended flue with 2x45° bends
Flue option 10 100mmØ 125mmØ
30CDi 7,900mm 16,500mm
40CDi 6,000mm 14,000mm
Table 18 Flue option 10

PRE-INSTALLATION
6 720 815 723 (2015/05)16
Fig. 21
350 mm - 570 mm
130 mm Min
Flat roof
300 mm
500 mm
Pitched
roof
2
3
4
5
6
10
9
8
7
1
6720643895-12.1Wo

PRE-INSTALLATION
6 720 815 723 (2015/05) 17
3.9 Flue terminal positions
Fig. 22 Flue terminal positions
Key to illustration
1. 300mm adjacent to a boundary line.
2. The dimension below eaves, balconies and car ports can be reduced
to 25mm, as long as the flue terminal is extended to clear any
overhang. External flue joints must be sealed with suitable silicon
sealant.
3. 1,500mm between a vertical flue terminal and a window or dormer
window.
4. 1,200mm between terminals facing each other.
5. Vertical flue clearance, 300mm adjacent to a boundary line.
6. 600mm distance to a boundary line, unless it will cause a nuisance.
BS 5440:Part 1 recommends that care is taken when siting terminal
in relation to boundary lines.
7. 600mm minimum clearance from a skylight to a vertical flue.
8. Vertical flue clearance, 500mm to non-combustible building
material, and 1,500mm clearance to combustible building material.
9. 300mm above, below and either side of an opening door, air vent or
opening window.
10.600mm diagonally to an opening door, air vent or opening window.
11.300mm to an internal or external corner.
12.2,000mm below a Velux window, 600mm above or to either side of
the Velux window.
13.400mm from a pitched roof or 500mm in regions with heavy snow
fall.
14.500mm clearance to any vertical structure on a roof, 600mm to
room sealed flue or 1,500 to an open flue.
15.200mm below eaves and 75mm below gutters, pipe and drains.
16.The dimension below eaves, balconies and car ports can be reduced
to 25mm, as long as the flue terminal is extended to clear any
overhang. External flue joints must be sealed with suitable silicon
sealant.
17.Flue clearance must be at least 300mm from the ground. Terminal
guards must be fitted if the flue is less than 2 metres from the ground
or if a person could come into contact with the flue terminal.
18.600mm distance to a surface facing a terminal, unless it will cause a
nuisance. BS 5440: Part 1 recommends that care is taken when
siting terminals in relation to surfaces facing a terminal.
16
600
300
200
300
1,200
Boundary Line
1,500
1,500
All measurements in millimetres
2
1
12
11
10
9
5
18
7
6
13
15
4
3
17
14
300 300
300 300
300
300 300
500
600
300
600
600
400
300
25
8
300
500
600
6720643895-13.3Wo
300
25
225 16
2m
1m
52mm 104mm
NOTICE:
▶ All measurements are the minimum clearances required.
▶ Terminals must be positioned so to avoid combustion products entering the building.
▶ Support the flue at approximately one metre intervals and at a change of direction, use suitable brackets and fittings
(flue brackets 100mm part number: 7 716 191 177,
flue brackets 100mm x 6 part number:7 716 191 178,
flue bracket 125mm part number: 7 716 191 179).
Note:
▶ Installations in car ports are not recommended.
▶ The flue cannot be lower than 1,000mm from the top
of a light well due to the build up of combustion
products.
▶ Dimensions from a flue terminal to a fanned air inlet
to be determined by the ventilation equipment
manufacturer.

PRE-INSTALLATION
6 720 815 723 (2015/05)18
3.10 Plume management terminal positions
Fig. 23 Plume terminal positions
Key to illustration
1. This feature allows some basic plume re-direction options on a
standard telescopic horizontal flue terminal.
300mm minimum clearances to a opening e.g. window.
However the minimum clearances to an opening in the direction that
the plume management is facing, must be increased to 1,500mm.
Where the flue is less than 150mm to a drainpipe and plume re-
direction is used the deflector should not be directed towards the
drainpipe.
2. 300mm adjacent to a boundary line.
3. Plume Management kit air intake can be reduced to 150mm
providing the flue exhaust outlet is no less than 300mm adjacent to a
boundary line.
4. 1,200mm between terminals facing each other.
5. 600mm distance to a boundary line, unless it will cause a nuisance.
BS 5440:Part 1 recommends that care is taken when siting terminal
in relation to boundary lines.
6. Using a Plume Management kit the air intake measurement can be
reduced to 150mm providing the flue exhaust outlet has a 300mm
clearance.
Plume kits running horizontally must have a 10° fall back to the boiler
for proper disposal of condensate.
For details on specific lengths see relevant boiler Technical &
Specification information.
7. Internal/external corners. The air intake clearance can be reduced to
150mm providing the flue exhaust outlet has a 300mm clearance.
8. Clearances no less than 200mm from the lowest point of the balcony
or overhang.
9. 1,200mm from an opening in a car port on the same wall e.g. door or
window leading into the dwelling.
10.600mm distance to a surface facing a terminal, unless it will cause a
nuisance. BS 5440: Part 1 recommends that care is taken when
siting terminals in relation to surfaces facing a terminal.
200
300
150
200
8
4
5
3
2
9
200
600
All measurements in millimetres
300
300
150
150
300
300
25
25
150
1,200
300
200
10
100
600
Plume re-direction:
180°
±80°
1
7
±45°
Flue Exhaust
Outlet
Air Intake
6
10
Boundary Line
6720643895-14.2Wo
150
300
300
Flue terminal guard 7 716 191 176
600
1,500
NOTICE:
▶ All measurements are the minimum clearances required.
▶ The minimum length plume management length is 500mm to a maximum of 4500mm, this includes two 90° bends.
Refer to section 3.8 and table 7 for further information on internal flue lengths.
▶ Subsequent 45° bends = 750mm and 90° = 1500mm.
▶ For each metre (1000mm) of plume management length the internal flue length is reduced by 700mm.
▶ Refer to previous page for all concentric flue terminal positions unless the flue position is specified on the figure above “Plume
terminal positions”.
▶ Terminals must be positioned so to avoid combustion products entering the building.
▶ Support the flue at approximately one metre intervals and at a change of direction, use suitable brackets and fittings.
Note:
▶ Installations in car ports are not recommended.
▶ The flue cannot be lower than 1,000mm from the top
of a light well due to the build up of combustion
products.
▶ Dimensions from a flue terminal to a fanned air inlet
to be determined by the ventilation equipment
manufacturer.

INSTALLATION
6 720 815 723 (2015/05) 19
4 INSTALLATION
4.1 Unpacking wall frame and ancillary items
LIFTING AND CARRYING PRECAUTIONS:
IMPORTANT HANDLING INSTRUCTIONS
• It is advised that two people are used to carry the carton from the van
to the point of delivery.
• Once the carton has been delivered, the top of the carton is opened.
If a sharp implement is used make sure the carton is not pierced and
that the implement is used in such a way so that it may not cause
personal injury. All sharp objects must be covered or the blade
retracted after use and put away in a safe place.
1. The upper carton cover [14] and support [13] are now removed
with the components (bottom panel [12], pre-plumbing manifold
with water and gas connections [11], hardware packs x2 [4] and
[5], documentation set [6], hanging bracket [3]).
2. Remove the flow [7] and return pipes [8] and [9].
3. The boiler wall mounting plate [2] can now be pulled out.
Additional requirements for roof space installation:
• The boiler should be first unpacked before ascending ladder to loft
space.
• Two sets of steps should be used.
• Two people should share the lifting of the boiler up to the loft hatch,
where the boiler is entered into the loft space tilted and slid on its
back into the loft.
Once the appliance is removed from its packaging check the contents
against the packing list.
Fig. 24 Contents
[1] Carton
[2] Wall mounting plate
[3] Hardware pack 1
[4] Hardware pack 2
[5] Literature pack
[6] Flow pipe
[7] Return pipe 1
[8] Return pipe 2
[9] Pre-plumbing manifold with water and gas connections
[10] Bottom panel
[11] Upper carton support (polystyrene)
[12] Carton cover
[13] ErP energy label
NOTICE: All the previous Pre-Installation sections
must be read and requirements met before starting
boiler or flue installation.
WARNING:
▶ Lift only a manageable weight, or ask for help.
▶ When lifting the boiler, bend the knees, and keep the
back straight and feet apart.
▶ Do not lift and twist at the same time.
▶ Lift and carry the boiler close to the body.
▶ Wear protective clothing and gloves to protect from
any sharp edges.
NOTICE: Before installing appliance ensure system
has been cleaned as explained on page 8.
11
4
1
3
2
3.
12
10
1.
5
7
8
9
6
2.
6 720 815 723-01.1O
13

INSTALLATION
6 720 815 723 (2015/05)20
4.2 Wall mounting plate and flue opening
SAFETY:
All relevant safety precautions must be undertaken. Protective clothing,
foot wear, gloves and safety goggles must be worn as appropriate.
FIXING THE POSITION OF THE WALL MOUNTING PLATE:
• Fig. 25 shows the relative positions of the flue and the fixing of the
wall mounting plate including hanging bracket and pre-plumbing
manifold.
Fig. 25 Mounting template
▶ Fix the wall mounting template, supplied with the literature pack, to
the wall.
▶ Drill holes for wall mounting plate and pre-plumbing manifold:
– at least one of the holes A,
– at least one of the holes B (preferably use left hole),
– hole C,
– hole D.
▶ If required: make a hole in wall for the flue pipe.
FLUE OUTLET
▶ Follow the Fig. 25 to mark the centre of the flue for rear outlet (3) or
for side outlet (4).
▶ For the 60/100mm Ø flue make a 125 mm diameter hole through
the wall using a core drill or similar.
For flues using an optional weather collar, fitted from inside the
building make a 150 mm Ø hole.
▶ Clear away any debris.
▶ Drill the hole, preferably using a core drill.
▶ Remove the mounting template.
▶ Place the wall mounting plate with hanging bracket against the wall in
the desired position.
▶ Secure wall mounting plate with four screws (supplied with the
boiler). Do not fully fasten the lower two screws.
▶ Mount the pre-plumbing manifold on the two lower screws and
secure the screws.
Fig. 26 Wall mounting plate and pre-plumbing manifold
CAUTION: Ensure there are no pipes, electric cables,
damp proof courses or other hazards before drilling.
4. 1.
2.
2.
2.
3.
85 mm
6 720 812 175-27.1O
hole C hole D
hole A
min. 225 mm
min. 5 mm
2.
hole B
Hanging
bracket
6 720 812 174-21.1O
holes B
holes A
hole C hole D