Worcester GREENSTAR 25CDi GC User manual

RCDi
D CONDENSING COMBINATION BOILER
AND MAINS FED DOMESTIC HOT WATER
THE APPLIANCE IS FOR USE WITH
NATURAL GAS OR L.P.G. (Cat
II 2H3PTYPE C13 & C33)
NATURAL GAS:
WORCESTER GREENSTAR 25CDi
GC NUMBER 47·311-92
WORCESTER GREENSTAR 30CDi
GC NUMBER 47-311-93
WORCESTER GREENSTAR 37CDi
GC NUMBER 47-406-08
WORCESTER GREENSTAR 42CDi
GC NUMBER 47-406-10
LlOUID PETROLEUM GAS:
WORCESTER GREENSTAR 25CDi
GC NUMBER 47-311-96
WORCESTER GREENSTAR 30CDi
GC NUMBER 47-311-97
WORCESTER GREENSTAR 37CDi
GC NUMBER 47-406- 09
WORCESTER GREENSTAR 42CDi
GC NUMBER 47-406-11
INSTRUCTION MANUAL
INSTALLATION, COMMISSIONING
&SERVICING

CONTACT INFORMATION INSTALLATION &SERVICING INSTRUCTIONS
WORCESTER BOSCH:
TECHNICAL: 08705 266241
SERVICE: 08457 256206
SPARES: 01905 752571
LITERATURE: 01905 752556
TRAINING: 01905752526
SALES: 01905 752640
WEBSITE: www.worcester-bosch.co.uk
WATER TREATMENT:
FERNOX 01799550811
www.fernox.com
SENTINEL
0151 4209595
www.betzdearbom.com/sentinel
FLUE TERMINAL GUARD:
TOWER FLUE COMPONENTS
VALE RISE
TONBRIDGE
TN91TB
STORE THE APPLIANCE IN A DRY AREA
PRIOR TO INSTALLATION.
LIFTING AND CARRYING PRECAUTIONS:
• Lift only a manageable weight,
or askfor
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
PLEASE READTHESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
THESE INSTRUCTIONS ARE APPLICABLE TO THE WORCESTER
BOSCH 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.
THE INSTRUCTIONS
APPLY IN THE UK ONLY AND MUST BE FOLLOWED EXCEPT FOR ANY
STATUTORY OBLIGATION.
THIS APPLIANCE MUST BE INSTALLED BY A COMPETENT PERSON. FAILURE
TO INSTALL
CORRECTLY COULD LEAD
TO PROSECUTION.
IF YOU ARE
IN ANY DOUBT CONTACT WORCESTER BOSCH TECHNICAL HELPLINE.
DISTANCE LEARNING AND TRAINING
COURSES ARE AVAILABLE FROM WORCESTER
BOSCH.
PLEASE LEAVE THESE INSTRUCTIONS, THE USER GUIDE AND THE COMPLETED
BENCHMARK LOG BOOK OR A CERTIFICATE CONFIRMING COMPLIANCE WITH IS 813
(EIRE ONLy)WITH THE USER OR AT THE GAS METERAFTER INSTALLATION OR SERVIC-
ING.
ABBREVIATIONS USED
IN THIS MANUAL:
o Diameter
NG Natural Gas
LPG Liquid Petroleum Gas
CH Central Heating
DHW Domestic Hot Water
IP Ingress Protection
SEDBUK Seasonal Efficiency of Domestic Boilers
in the United Kingdom
SYMBOLS USED IN THIS MANUAL:
TIme clock C H only
Domestic hot water
Central heating Programmer/timer
Cold water
main supply Room thermostat
Electricity supply Wait time period
Gas supply
INSTAlLATION & SERVICI>.'G INSTRUCTIONS FOR WORCESTIER BOSCH GREEN STAR 2SCDvaOCDil37CDV42 CDi ~ORCESTER
INSTALLATION & 6
'1'20 61 a 700. (:2006/11) Bolch Grow>
SERVICING INSTRUCTIONS

CONTENTS
SAFETY & REGULATIONS
SAFETY PRECAUTIONS 4
INSTALLATION REGULATIONS 4
APPLIANCE INFORMATION
GENERAL INFORMATION 5
TECHNICAL
DATA 6
LAYOUT & COMPONENTS
7-8
PRE-INSTALLATION
CLEANING PRIMARY SYSTEMS 9
MAINS SUPPLIES 10
WATER SYSTEMS & PIPEWORK 11
CONDENSATE PIPEWORK
12
BOILER LOCATION & CLEARANCES 13-14
PLUMBING MANIFOLD 15
FLUE TERMINAL POSITIONS 16
FLUE OPTIONS 17-20
INSTALLATION
UNPACKING WALL FRAME AND ANCILLARY ITEMS
21
WALL MOUNTING PLATE / FLUE OPENING 22
CHARGING LINK (FILLING LOOP) 23
UNPACKING THE APPLIANCE 24
FIniNG THE APPLIANCE / BOILER CONNECTIONS
25
FLUE INSTALLATION 26-28
CONDENSATE CONNECTION 29
ELECTRICAL
30
POSITION OF WIRED COMPONENTS
31
COMMISSIONING
PRE-COMMISSIONING CHECKS 32
FILLING THE SYSTEM
33
STARTING THE APPLIANCE 34
WATER TREATMENT 35
COMMISSIONING
36
FINISHING COMMISSIONING
37
SERVICING & SPARES
INSPECTION AND SERVICE 38-42
REPLACEMENT OF
PARTS
43-52
SEHING THE GAS/AIR RATIO
53
SHORT PARTS LIST 54
CONVERSION KITS
L.P.G. CONVERSION 55
FAULT FINDING & DIAGNOSIS
FAULT FINDING
56
CENTRAL HEATING FUNCTION 57
PREHEAT AND
DHW FUNCTION 58
PROTECTION FUNCTION 59
INSTALLATION & SERVICII% II<STRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDil30CDil37CDV42CDi
~ORCESTER
CONTENTS
6720 613 700. (2006/11)
Bosch Group

SAFETY PRECAUTIONS INSTALLATION REGULATIONS
IF YOU SMELL GAS:
.x DON'T SMOKE OR STRIKE MATCHES
X
DON'T TURN ELECTRICAL SWITCHES ON OR OFF
V' DO PUT OUT NAKED FLAMES
V' DO OPEN DOORS AND WINDOWS
V' DO KEEP PEOPLE AWAY FROM THE AREA AFFECTED
V' DO TURN OFF THE CONTROL VALVE AT THE METER
V' TELEPHONE THE NATIONAL GAS EMERGENCY SERVICE ON 0800111999
(/Iend/morlO
A Benchmark Log Book is provided by the manufacturer for the installer to complete
including their
CORGI registration number to confirm that the boiler has been installed,
commissioned and serviced according to the manufacturer's instructions.
IMPORTANT: The completed Benchmark Checklist will be required in the event of any
warranty work and
may be reqUired by the local Building Control Inspector.
HEALTH & 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).
COMBUSTIBLEAND CORROSIVE MATERIALS
Do not store or use any combustible materials (paper, thinners, paints etc.) inside or
within the vicinity
of the appliance.
Chemically aggressive
substances, such as halogenated hydrocarbons containing
chlorine or fluorine compounds 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 Gas Safety (Installation and Use)
Regulations 1998.
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
engineer (such as British Gas or CORGI registered personnel) using approved spares,
to help maintain the economy, safety and reliability
of the appliance.
IMPORTANT « The service engineer must complete the Service Record in the
Benchmark section after each service.
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 curren!:
Gas Safety
Regulations, lEE Regulations, Building
Regulations, Building Standards {Scotland}
(Consolidation), Building Regulations (Northern
Ireland), local water by-laws, Health &
Safety
Document 635 (The Electricity at Work
Regulations 1989) and any other local
requirements.
British Standards:
The relevant British Standards should be followed,
including:
BS7074:1 :Code
of practice for domestic and hot
water supply
BS6891 : Installation of low pressure gas
pipeworkupto 28mm {R1}
BS5546 : Installation of gas hot water supplies for
domestic purposes
EN :12828 :Central heating for domestic premises
BS5440:1 : Rues and ventilation for gas appli-
ances
of rated heating notexceeding 70kW (net) :
Rues
BS5440:2 : Rues and ventilation for gas appli-
ances
of rated heating not exceeding 70kW {net} :
Air Supply
BS7593 : Treatment of water in domestic hot
watercentral heating systems
BS 6798 : Installation of gas lired boilers
of rated
input up to 70kW {net}
Where no specific instruction is given, reference
should be made to the relevant British Standard
codes
of Practice,
L.P.G_ Installation:
An appliance using
L.P.G. must not be installed in
a room or internal space belowground level unless
one side
of the building is open tothe ground.
limber framed buildings:
Where the boiler is to be litted to a timber framed
building
the guidelines laid down in BS5440: Part
1 and
IGE "Gas Installations in limber 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.
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25C0J3OCQ;/37CQV42 C~i ~ORCESTER
SAFETY PRECAUTIONS 6
7'20 61 3 700. (2006/11) Bosch Group
& INSTALLATION REGULATIONS

max.
760mm
GENERAL INFORMATION
STANDARD PACKAGE:
A - Wall hung gas fired condensing combi boil-
erforcentral heating
and domestic hot water
B - Wall mounting plate
C - Hanging bracket
D - Pre-plumbing manifold
E - Hardware pack
F - Charging Link Assembly
G - Literature pack
H· Bottom panel
I Trap I Syphon Outlet Connection
(22 mm Plastic Pipe)
c
/ B
D
SPECIFICATIONS:
Pre-wired and pre-plumbed
Galvanised steel inner frame
Digital control system
Automatic ignition
Direct burner ignition
Built-in frost thermostat {boiler protection}
Built-in fault finding diagnostics
Modulating automatic gas valve
Combustion airfan with speed regulator
CH temperature sensor &control
Pump anti-seizure protection
Aue gas temperature limiter
Condensate trap & syphon
DHW flow sensor &temperature control
Plate type
DHW heat exchanger
Modulating circulating pump
o
...
~WORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CovaOCOil37CDV42CDi
GENERAL INFORMATION
6720 613 7000 (2006/11)
BolIch Group

TECHNICAL DATA
NATURAL GAS L.P.G.
DESCRIPTION UNITS 25CDi
30CDi 37CDi 42CDi 25CDi 30CDi 37CDi 42CDi
Central Heating
Max. rated heat input
kW
25.8 30.9 30.9 30.9 25.8 30.9 30.9 30.9
Max. rated heat output net 40/30°C kW
26.8 32.1
32.1
32.1
26.8
32.1
32.1
32.1
Max. rated heat output net 50/30°C
kW
26.6 31.8 31.8 31.8 26.6 31.8 31.8 31.8
Max. rated heat output net 80/60°C
kW
25.0 30.0 30.0 30.0 25.0 30.0 30.0 30.0
Min. rated heat output net
40/30·C
kW 8.6
8.6 10.6 10.6 12.4 12.4 15.7 15.7
Min. rated heat output net
50/30°C
kW
8.6 8.6 10.5 10.5 12.3 12.3 15.5 15.5
Min. rated heat output net
80/60·C
kW 7.7 7.7
9.4 9.4 11,0 11.0 13.9 13.9
Min. rated heat input net
kW
8.0 8.0 9.8 9.8
11.5
11.5
14.5 14.5
Max. flow temperature
·C
nom. 90 nom. 90 nom. 90 nom. 90
nom. 90 nom. 90 nom. 90 nom. 90
Max. permissible operating pressure bar 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5
Available pump head at 21°C system temperature rise m 2 2 2 2 2 2 2 2
Gas
flow rate· Max. 10 minutes from lighting
Natural Gas G20
2.6 3.2 3.9 4.4
Propane Gas (LPG) 2.0 2.4 2.9 3.3
Flue
Flue Gas Temp. 80/60·C, rated min. load
·C
70/58 76/58 83/58 87/58 70/58 76/58
83/58 87/58
Flue Gas Temp. 40/30·C, rated min. load
·C
51/33
55/33 60/35 66/35
51/33 55/33 60/35 66/35
CO2 level at max. rated heat output
C¥o
9.6 9.6
9.7 9.7 11.5
11.5
11.5 11.5
CO
2 level at
min. rated heat output % 9.0 9.0
9.1 9.1 10.5 10.5 10.5 10.5
NOx -class 5 5 5 5 5 5 5 5
Condensate
Max. condensation rate 2.3 2.7 2.7 2.7 2.3 2.7 2.7 2.7
pH value, approx. 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8
Electrical
Electrical power supply voltage AC
... V
230 230 230 230
230 230 230 230
Frequency Hz 50
50
50 50 50 50 50 50
Max. power consumption W 135 150 160 175 135 150 160 175
General Data
SEDBUK band A A A A A A A A
Appliance protection rating IP X4D X4D X4D X4D X4D X4D X4D X4D
Appliance protection rating with mechanical
or RF mech. timer fitted
IP
20
20 20 20
20 20 20 20
Permissible ambient temperatures
·C
0-50 0-50 0-50 0-50 0-50 0-50 0-50 0-50
Nominal capacity
of appliance I 3.75 3.75
3.75 3.75 3.75 3.75 3.75 3.75
Noise output level (at
DHW inlet pressure 3 bar) dB(A)
40 44 45 47 40
44 45 47
Total boiler weight (lift weight) kg 48.5 48.5 48.5 48.5 48.5 48.5 48.5 48.5
Packaged boiler weight kg 57 57
57 57 57 57 57
57
SEDBUK
% 90.3
90.1 90.1 90.1 90.3 90.1
90.1
90.1
INSTALlATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH (lREENSTAR 25CDil3OCDVB7CDil42 CD; AORCESTER
TECHNICAL DATA
6720 613700. (2006/11) Bosch Group

LAYOUT & COMPONENTS
28·
27
26 ---
25 ---
24·-
23 --
22
21 -----
20
16 .--
.. -
............. ,..~- .... ' ....
2
.. -
--- 3
.- .-- -_.------ ---_.
.. ,.,~,.." ....... "
..........
4
__ ._____________________ . 5
6
7
8
9
10
••••••••••
14
The diagram opposite shows the controls in the
servicing position and excludes the outer case.
FLAME VIEWING WINDOW
2 IGNITION ELECTRODE AND FLAME
SENSE ELECTRODE
3 HEAT EXCHANGER
4 OVERHEAT THERMOSTAT
5 ACCESS POINT FOR CLEANING HEAT
EXCHANGER
6 PLATE TO PLATE DHW
HEAT EXCHANGER
7 PUMP
8 SYSTEM PRESSURE GAUGE
9 DRAIN POINT
10 MAINS COLD WATER IN
11 CH RETURN
12 CHARGING LINK ASSEMBLY
13 GAS INLET CONNECTION 22 mm
COMPRESSION
14
COVER FOR EXTERNAL WIRING
CONNECTIONS
15 CONTROL PANEL IN SERVICE
POSITION
16 ACCESS COVER FOR TRANSFORMER
& PCB
17
DHWOUT
18 CHFLOW
19 TRAP I SYPHON OUTLET CONNEC·
TION (22
mm PLASTIC PIPE)
20 INLET PRESSURE TEST POINT
21 TRAP I SYPHON
22 GAS
VALVE
23 DHW TEMPERATURE SENSOR
24 AIR I GAS ADJUSTMENT SCREW
25 TESTING POINT FOR FAN PRESSURE
26
FAN
27 PRIMARY SENSOR
28 EXPANSION VESSEL
29 REMOVABLE TOP CASE PANEL FOR
SERVICING
~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV3OCDil37CDV42CDi LAYOUT & COMPONENTS
6720 613 7003 (2006/11)

LAYOUT & COMPONENTS
6 PLATE TO PLATE DHW HEAT
EXCHANGER
9 DRAIN POINT
32 SYSTEM PUMP
36 FLOW TURBINE
37 UNUSED PORT
38 AUTO AIR VENT
39 FLOW CONNECTION FROM BOILER
HEAT EXCHANGER
40 DHW SENSOR
41 CH FLOW CONNECTION TO SERVICE
VALVE
42 DHW OUT CONNECTION
43 COLD WATER
IN CONNECTION
44 CH
RETURN CONNECTION TO SER·
VICE
VALVE
45 DIVERTER VALVE
46 PRESSURE RELIEF VALVE
47 COMPACT HYDRAULIC MOUNTING
SCREW (2) TO BOILER
I
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40
I•
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t"
45
I '"
I',
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41 •••• I 9
~
~"
4'3
- ........ '"'-
l,,,, 48 CH TEMPERATURE CONTROL
, I 49 MAINS ON/OFFINDICATOR/DIAGNOS-
'I
TIC LIGHT (BLUE)
I
t
50 DHW TEMPERATURE CONTROL
I
51 CENTRAL HEATING BOOST BUTTON
52 SERVICE BUTTON
53 BURNER ON INDICATOR LIGHT
(GREEN)
54 MASTER SWITCH ON/OFF
55 HOLIDAY BUTTON
56 ECO BUTTON
57
FAULT RESET BUTTON
58 SYSTEM PRESSURE GAUGE
59 POSITION FOR OPTIONAL
TEXT
DISPLAY WITH INTELLIGENT FUNC·
TIONALITY OR TIMER
60 DISPLAY
6720611027-10,10
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDi!3OCDV37CO;;42 CD, ~ORCESTER
LAYOUT & COMPONENTS
6720 613700. (2006/11)

1
3
IMPORTANT: All the following Pre-Installation sections must be read and
requirements met beforestarting
boiler or flue Installation.
CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND
OBSERVE ALL RELEVANT
SAFETY PRECAUTIONS.
2 /
I
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\
,..z::==;.....~ I
""--- ..........
,'" ",
""'------~
5
CLEANING PRIMARY SYSTEMS
IMPORTANT: 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 appli-
ance will invalidate the appliance warranty.
BEFORE CLEANING THE SYSTEM:
ENSURE THE
SYSTEM AND PIPEWORK IS
IN
GOOD WORKING ORDER
KEEP THE EXISTING BOILER/
CIRCULATING PUMP
WHERE POSSIBLE
OR USE A POWER FLUSHING MACHINE
TO AID THE CLEANSING PROCEDURE
BEFORE INSTALLING A NEW BOILER.
CLEANING THE PRIMARY SYSTEM:
Fill the system with cold water and check
for leaks.
2 Open all drain cocks and drain the system.
S Close drain cocks and add a suitable
flushing agent
at the correct strength for
the system condition
in accordance with
the manufacturer's instructions.
Circulate the flushing agent before the
boiler is fired up.
4 Run the boiler/system at normal operating
temperature as directed by the manufacturer
of the flushing agent.
5 Drain and thoroughly flush the system to
remove the flushing agent and debris.
,....---- ... ,
," ' ....
/ ,
I '
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t I
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'...... ~;
4
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... -----
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KEY
Valve
Flushing
Agent
~ORCESTER INSTALLATION & SERViCING INSTRUCTIONS FOR WORCESTER EiCSCH GREFNSTAR 25CDiI3OCDi/37COil42CDi CLEANING
PRIMARY SYSTEMS
6720 613 700a (2006/11)
BoIIc:h Group

MAINS SUPPLIES
ELECTRIC SUPPLY:
f • Supply: 230V -
50Hz
(See Technical Data for IP ratings.)
• Cable: PVC insulated 0.75mm2
(24 x 0.2mm) temperature rated to 90"C.
• Extemal3A fuse to BS1362.
• The appliance must be earthed.
• All pipes
to the boiler must be cross-bonded.
• Wiring must comply with lEE wiring regula-
tions and
any local regulations which may
apply to fIXed wiring to a stationary appliance.
GAS SUPPLY:
• Boilers using
NG must be connected to a
govemed meter.
•
LPG boilers must be connected to a
regulator.
• Installation and connection
of the gas sup-
ply to the boiler must
be in accordance with
8S6891.
• Under no circumstances should the size
of
the gas supply pipe be less than that of the
appliance inlet connection.
• The meter
or regulatorand pipeworkto the
meter must
be checked, preferably by the
gas supplier, to ensure it is
in good working
orderand can meet
the gas flow and pres-
sure requirements in addition to the demand
from any other appliance being served. This
does
not include the pipework from the
meter to the boiler.
•
For olive connections we recommend using
gas pipes with minimum 0.9 mm wall thickness.
WATER SUPPLY:
Water Mains Pressure:
• Minimum mains water pressure 1.5
up to
2.5 bar (see technical data on page 6) for
maximum performance.
• Maximum mains fed water pressure 10 bar.
If necessary, fit a pressure reducing valve.
IMPORTANT: Non-return, back flow pre-
MAINS WATER EXPANSION VESSEL:
vention devices (including those associat-
A - Mini expansion vessel, part No.7 716 102 105 ed
with water meters) fitted to the mains
8 - Mains water inlet pipe
water supply can cause a pressure build
C - Non-return valve
up which could damage the boiler and
D - Boiler
other household appliances.
• Where the mains water supply has a non-
return, backflow prevention valve fitted, a
mini expansion vessel (A) should
be con-
nected to the mains water inlet pipe (B)
B C between the non-return valve (C) and the
,. \
\ \
\ , \ boiler (D) as shown opposite.
\
\ \
Us~ in ~ard ~ater ~real>:
~
Normally there is no need for water treatment
to prevent scale formation as the maximum
II
temperature of the DHW heat exchanger is
limited by the electronic control circuit
In areas where the temporary water hardness
exceeds 200 ppm, consideration may need to
be given to the fitting of a scale prevention
device. In such circumstances, the advice of
the local water authority should be sought
INSTALLATION & SERVICING INSTRUCTIONS FOR W0~CESTER 80SCH GREENSTAR 25CDvaOCDi/37CDil42 CDi ~ORCESTER
MAINS SUPPLIES
57'20613700. (2006/11)
BoschGrouD

TYPICAL SEALED SYSTEM
A - Appliance expansion vessel
-central heating
B -Extra expansion vessel
-central heating return
C -Drain
cock
P - Pressure reliefdischarge
R· Radiators
c
.
;p
c
6720611927 - 02.10
WATER SYSTEMS &PIPEWORK
PLASTIC PIPEWORK:
o Any plastic pipework must have a polymeric
barrier with
600 mm (minimum) length of
copper or steel pipe connected to the boiler.
o Plastic pipeworkused for underfloor heating
must be correctly controlled with a thermo-
static blending valve limiting the temperature
of the circuits to approx. 50·C.
The pipeworkfrom the boiler to the blending
valve must be in copper
or steel (protected
from corrosion).
CONNECTIONSNALVES:
o All system connections, taps and mixing
valves must be capable
of sustaining a pres-
sure
up to 3 bar.
o Radiator valves should conform to
BS2767:10.
o All othervalves should conform to BS1010.
o On newinstallations, or extensions to exist-
ing systems where a radiator previously did
not exist, each radiator should be fitted with
a TRV, except the one fitled
in the same
room/area as the rocm thermostat.
o On boiler only replacement jobs, it is recom-
mended, (but not mandatory,)
to fit a TRV on
each radiator. It is, however, a requirement,
forenergy conservation purposes, to recom-
mend
to the customer that a TRV isfitted to
each radiator.
o An automatic bypass may be required,
(downstream
of the pump), in order to main-
tain the minimum flow-rate through the appli-
ance.
o A drain cock is required at the lowest point
on the system.
• An air vent is required
at the highest point
on the system.
SHOWERS/BIDETS
o If a shower head can be immersed in water
or comes closer than 25 mm from the top
edge of a bath or shower tray spillover level
then an anti-siphon device must be fitted
to
the shower hose.
• Bidets with direct hot & cold mains water
can be used (with the approval
of the local
water authority) and must be the over rim
flushing type with shrouded outlets to pre-
vent the fitting
of hand held sprays.
SEALED PRIMARY SYSTEM:
• The
CH sealed system must be filled using
the built-in filling link (see page 23).
• Where the system volume is more than
100 litres or exceeds 2.65 bar at maximum
heating temperature an extra expansion ves-
sel (B) must
be fitted as close as possible
to the appliance in the central heating
return.
o Pressurize the extra expansion vessel (B) to
the same figure
as the expansion vessel
built into the appliance.
o Do not use galvanised pipes or radiators.
~RCESTER
INSTALLAllON & SERVICING 'NSTRUCTIONSFOR WORCESTER BOSCH GREENSTAR 25CovaOCDV37CDV42CO;
WATER SYSTEMS &PIPEWORK
6 7?0 613 700. (2006/11)

3 4
jl
q
Ji/E
25mm
mLn.
- H
400mm
min.
A.=- 1
L-J
[]6
Invert ~.
C G
M
L
o
N
6720611 927 - 03.10
Internal sink/washing machine
drain
2 Internal waste drainage system
3
Soil/vent stack
4 External drainage system
5 External condensate absorption
point
A - Condensate from boiler
8 - Sink
C -
22 mm 0 plastic condensate pipe
D Gulley
E - Internal soil and vent stack
F - Serviceable waste trap (75
mm min)
G -
300 mm x 100 mm 0 sealed plastic
tube
H - Ground level
J Drainage holes 50 mm from base of
tube (12 mm 0 al 25 mm centres)
facing away from building
K -Limestone chippings
L Outside wall
M,O· Drain pipe
N-
External drain
CONDENSATE PIPEWORK
CONDENSATE PIPEWORK:
• The condensate pipe must
be a minimum of
22 mm 0 plastic pipe.
• The condensate pipework must fall at least
50 mm per metretowards the outlet and
should take the shortestpracticable route.
• The pipeworkmustfollow one of the oplions
shown opposile into
an internal serviceable
trap
(min. 75 mm) such as a sink/washing
machine) and dischargedirect into a vent stack
(E) min. 450 mm above pipe inver! orinto a gul-
ley (O) below ground bulabove the water level.
• Wherever possible the condensate dis-
charge pipe work should be routed and ter-
minated internally. Should this not be possi-
ble, and the only available route is external,
the following conditions should
be
observed:
Pipe work length should be kept
to a
minimum and the route asvertical as
possible.
Where pipe workcould
be subjected to
extreme cold or wind chill, a weather
proof insulation should
be used.
Altematively the condensate pipework
could be increased to a minimum
32 mm
without the requirement
10 insulate.
IMPORTANT: Ensure there are no block-
ages in
the pipe run.
PRESSURE RELIEF PIPEWORK
IMPORTANT: The pressure relief valve is a
safety devicefor
the boiler and if activated
may discharge boiling water
or steam
through
the reliefvalve drain pipe.
Care should be taken when siting the out-
let pipe so that it does notcause an
obstruction or discharge above a window,
entrance
or other public access where it
could cause a hazard.
• The pressure relief drain pipe (M,O) from
the boiler should
be at least 15 mm diameter
copper pipe and run
downwards away from
any electrics or other hazard, preferably to
an external drain or soakaway.
• Pipe (M) should
be finished with a partial
bend, near the outlet to face the external
wall (as shown) to help prevent freezing.
• Use waterproof pipe insulation in exposed
positions and for external pipework.
INSTALLATiON & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GR£ENSTAR 25COV3OCD'137CDil42 COi ~ORCESTER
CONDENSATE PIPEWORK 672C 613
700. (2006/' 1)
Bosch Group

above elbow
Using 1 00 mm flue kit
-1112mm
Using 125 mm flue kit
5mm
-1152 mm
600mm
, front clearance
, for service
SERVICING CLEARANCES ~_ ~
BOILER LOCATION &
+30rrm
, 200mm '
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 support-
ing the boiler weight.
COMPARTMENTS:
Follow the requirements of 886798 and
885440 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 fitting the boiler into an airing cupboard
use a non-combustible perforated material
(maximum hole sizes of 13mm) to separate
the boiler from the airing space.
BOILER CLEARANCES:
The diagram opposite shows the mini
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. If the appliance is filted into a cup-
board
or a compartment is built around the
appliance after installation, then the compart-
ment must be separated from
the boiler space
by a perforated non-combustible partition
as
described in 88 6798.
Notwithstanding
the requirements of B8 6798
and
B8 5440 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.
Do not operate the appliance if the flue terminal
filted on the outside wall or roof is obstructed
or damaged.
~RCESTER
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25C0i/3OCOil37CDil42CDi BOILER LOCATION &CLEARANCES
6720613700.(2006/11)

BOILER LOCATION &
CLEARANCES
®
750mm
®
600mm radius
750mm
2250mm
BATHROOMS:
The boiler can be installed in zones 2 or 3. If a
mechanical or RF mechanical timer or text dis-
play with room thermostat
(lp 20 only) is fitted
the boiler can only be installed in zone 3.
A Non mechanical timer can be installed in
zone
2.
See lEE wiring regulations.
(See Technical Data for
IP ratings.)
IMPORTANT: 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 bath-
room.
For further information about bathroom installa-
tions please consult Operational Procedures
Part 20. Electricity.
2250mm
6: 720611927-13.10
INSfALLATION & SERVICING INSfRucnONS FOR WORCESTER BOSCH GREENSfAR 2SCDil3OCD,/37CD,'42 CD, ~ORCES1ER
BOILER LOCATION & CLEARANCES
6720 613 700a (2006111)

~ DHW Out (alternative from above appliance} 15 mm
6Gas Supply (alternative from above appliance) 22 mm
CHAow
(altemative
from above
appliance}
22mm
'.
. ',
CH return 22 mm
CHfiow
22mm
DHW Out 15mm
Mains Gas Supply 22 mm
Mains Water In 15 mm
CH Return (alternative from above appliance} 22 mm
o
PLUMBING MANIFOLD
CONNECTIONS:
Heating System: 22
mm compression fittings
DHW: 15 mm compression fittings
Gas:
22 mm compression fittings
Use the
fittings supplied in the Hardware
pack.
PREPLUMBING
With the plumbing manifold installed,
pipework can be installed to the valves on the
manifold.
The system can be filled (without the boiler
being
connected} using the charging link
assembly (see page 23).
The valves can be closed enabling the DHW
and CH systems to be tested, The boiler can
be installed at later date.
RUNNING PIPES BEHINDTHE 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.
~ORCESTER INSTALLATION & SERVICING INSTRUCTiONS FOR WORCESTER BOSCH GREENSTAR 25CDV3OCDiI37CD",42CDi PLUMBING MANIFOLD
6'1'206137ooa(2006/11)

FLUE TERMINAL POSITIONS
Minimum dimensions of flue terminal positions for balanced room sealed flues with
fanned draught:
• The flue must be filted and terminated in
accordance with the recommendations
of
8S5440 : Part 1.
DRWG.
REF:
TERMINAL POSITION
DISTANCE
A'
8'
C'
Directly below an opening, air brick, opening windows, etc.
Above
an opening, air brick, opening window, etc.
Horizontally
to an opening, air brick, opening window, etc.
300mm
300mm
300mm
D Below gutters, soil pipes or drain pipes 75mm
E Below eaves 200mm
F'
G
Below balconies or car portroof (lowest point)
From a vertical drain pipe or soil pipe
200mm
150mm
H From
an internal or extemal corner
300mm
I Above ground, roof or balcony 300mm
J From a surface facing the terminal
600mm
K From a terminal facing the terminal 1200mm
L'
From an opening in the car port (e.g. door, window) into the dwelling 1200mm
M Vertically from a terminal on the same wall 1500mm
N Horizontallyfrom a terminal on the same wall 300mm
0 From a non combustible vertical structure on the roof *
P Above intersection with roof *
0 Adjacent to windows or openings
on pitched and flat roofs
600mm
R Below windows or openings
on pitched roofs 2000mm
• The flue must not cause
an obstruction.
• Discharge and any noise from the flue outlet
must not cause a nuisance.
• Flue gases have a tendency to plume and in
certain weather conditions a white plume
of
condensation will be discharged from the
flue outlet. Where this could be a nuisance,
for example, near security lighting,
an alter-
nate position should be found.
• The air inlet/outlet
duct and the terminal of
the boiler must not be closer than 25mm to
any combustible material.
Detailed recommendations on protection
of
combustible materials are given in
BS 5440:1
• A protective terminal guard must be fitted
if
the terminal is 2m or less above a surface to
which people have access.
The guard must be spaced equally (mini-
mum
50 mm) around the flue and fixed to
the wall with plated screws. See Contact
Information (inside front cover).
In addition, the terminal should not be nearer than 150mm (fanned draught) to an opening
in the building fabric formed for the purpose
of accommodating a built-in element such as a
window
frame.
2 Not recommended.
*See instructions supplied with vertical Hue kits.
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDi/3OCOiI37CDV42 COl ~ORCESTER
FLUE TERMINAL POSITIONS
67'20513700. (2006111)

STANDARD FLUE HORIZONTAL
0100
MAX 686 mm A x1
MIN
250 mm A x l'
0125
MAX 1070 mm Ax 1
MIN
250 mm Ax l'
• Requires cutting
MAXIMUM FLUE HORIZONTAL
0100·10000 mm
Ax 1+ B x 10
0125· 23000 mm
Ax 1 + B x 23
MAXIMUM FLUE VERTICAL START + 1 BEND
FQq
IpA
L-''--~~~'. B
() C
0100·10000 mm
Ax1+Cxl+Bx11
+ Fx 1
0125·23000 mm
A x1 + C x1 + B x23
+ Fx1
MAXIMUM FLUE HORIZONTAL + 1 BEND
[
OJ
B
o C
0100 . 8000 mm
Ax1 + Bx9+Cxl
0125 . 21000 mm
Ax1 + Bx 21 +C x1
MAXIMUM
FLUE VERTICAL
START + 2 BENDS
F
.61. QIE9A
BC?=:=::z!i
cO
0100 - 8000 mm
A J( 1 + C x2 + B x 10
+ F xl
0125·21000 mm
A x 1 + C x 2 + B x 22
+ Fx 1
MAXIMUM FLUE VERTICAL
START + 3 BENDS
F bl. q. ·LEiP
B C=:::=:-:::::=:::J
C ()
0100 • 6000 mm
Axl+Cx3
+Bx9+Fx1
0125·19000 mm
Ax1 +Cx3
+ Bx21 + Fxl
MAXIMUM FLUE VERTICAL
WITH 2 X 45° BENDS
E
B
o
0100·9500 mm
(including terminal)
B x 10 + 0 x 2 +
Ex 1
0125·21000 mm
(including terminal)
Bx21 + Dx2 +Ex1
VERTICAL FLUE WITH
2 X 90" BENDS
E 5
B
~=-=-:l
C 0
0100 7500mm
(including terminal)
Bx9+ Cx2 +Exl
0125 -19000 mm
(including terminal)
Bx20+ Cx2 +Ex1
6120 611 927-08.10
FLUE OPTIONS 25CDi
• The diagrams (opposite) show the compo-
nents used
and the maximum flue length for
each configuration of 100
mm and
125
mm 0 flues.
• Shaded
flue components indicate the stan-
dard 100
mm 0 horizontal flue.
• Only straight flue sections can be reduced
in length and cut.
•
The flue terminal end can be fitted from the
inside or outside of the building.
• Fixing kits are supplied with the flue exten-
sion kits.
• Horizontal 125
mm 0 and Vertical 100 mm
and 125 mm 0 flue kits are available with
separate instructions. Contactyour supplier
or Worcester Bosch.
A C o
f!!)
V
B F
C ········',,··:'.<··'1
.bd.
A· Standard horizontal flue (100 mm 0 shown)
B· Straight flue extension
C· Flue bend, 90"
O· Flue bends, 45°
E· Vertical terminal {vertical adaptor supplied
with terminal}
F· Vertical adaptor (used with horizontal
terminall
Calculating the flue length:
Measure the total flue length required, noting
that the
maximum straight flue length including
the terminal is:
Horizontal 60/100
mm 0: 10000 mm
Horizontal 80/125 mm 0: 23000 mm
Vertical 60/100 mm 0: 11500 mm
Vertical 80/125 mm 0: 23000 mm
Then reduce the total straight flue length for
each extra flue bend (excluding
th e turre t) by:
2000mm for 90°
1000
mm for 45°
Rue extension total lengths:
Horizontal & Vertical 60/100
mm 0: 960 mm
Horizontal &Vertical 80/125 mm 0: 1000 mm
Flue terminal total lengths:
Horizontal 60/100
mm 0: 800 mm
Horizontal 80/125 mm 0: 1200 mm
Vertical 60/100 mm 0: 1140 mm
Vertical 80/125
mm 0: 1365 mm
~WORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENST~R 25CDil3OCDil37C0iI42COi
FLUE OPTIONS 25CDi
6720 613 700a (2006/11)

STANDARD FLUE HORIZONTAL
I.ot----.-.---.-.---.- ..... -~
0100
MAX 686 mm A x 1
MIN 250 mm Ax 1*
0125
MAX 1070 mm Ax 1
MIN
250mm Ax1*
• Requires cutting
MAXIMUM FLUE HORIZONTAL
I'
0100 - 7900 mm
Ax1 + Bx8
0125 . 18500 mm
Ax 1 + B x18
MAXIMUM FLUE VERTICAL START + 1 BEND
Fa a-IW
A
1/,":.·, ::...... .• B
@ C
0100 - 7900 mm
Ax1+Cx1+Bx9
+ Fx 1
0125 - 18500 mm
A x1 + C x1 + B x 19
+ Fx 1
MAXIMUM FLUE HORIZONTAL + 1 BEND
QH -11iP A
~:::::::=::J B
o C
0100 - 5900 mm
Ax1 + Bx7+Cx1
0125 - 16500 mm
A x1 + B x17 +C x1
MAXIMUM FLU E VERTICAL
START + 2
BENDS
F g o-··I¥PA
B I·' . :,-,: .•
C@
0100 - 5900 mm
Ax1 +Cx2+ Bx8
+ Fx 1
0125 - 16500 mm
A x 1 + C x 2 + B x 18
+ Fx 1
MAXIMUM FLUE VERTICAL
A
START + 3
BENDS
F
.•. h':.:=• .,., gu~'L=\.c=·~771_ ..
, ... \.... . ....
B
C
0100 - 3900 mm
Ax1+Cx3
+Bx7+Fx1
0125 - 14500 mm
Ax1 +Cx3
+ Bx17 + Fx1
MAXIMUM FLUE VERTICAL
WITH 2 X 45· 8ENOS
E
8
o
0100· 7400 mm
(including
termin(!1)
Bx8+ Dx2 + Ex1
0125·16500 mm
(including terminal)
Bx17+ Ox2 +Ex1
VERTICAL FLUE WITH
2 X
90· BENDS
E
~
••
C 0
0100 5400 mm
(including terminal)
8x7+ Cx2 +Ex1
0125· 14500 mm
(including terminal)
Bx16+ Cx2 +Ex1
6 120 $11 921-08.10
FLUE OPTIONS 30CDi
• The diagrams (opposite) show the compo-
nents used and the maximum flue length for
each configuration of 100 mm and
125
mm 0 flues.
• Shaded flue components indicate the stan-
dard 100 mm 0 horizontal flue.
• Only straight flue sections can be reduced
in length and cut.
•
The flue terminal end can be fitted from the
inside
or outside of the building.
• Fixing kits are supplied with the flue exten-
sion kits.
• Horizontal 125
mm 0 and Vertical 100 mm
and 125 mm 0 flue kits are available with
separate instructions.
Contact your supplier
or Worcester Bosch.
A C o
@
8
A - Standard horizontal flue (100 mm 0 shown)
B - Straight flue extension
C Flue bend,
90·
o-Flue bends, 45·
E - Vertical terminal (vertical adaptor supplied
with terminal)
F - Vertical adaptor (used with horizontal
terminal)
Calculating the flue length:
Measure the total flue length required, noting
that the maximum straight flue length including
the termin;ll is:
Horizonta(SO/100
mm 0: 7900 mm
Horizontal 80/125 mm 0: 18500 mm
Vertical 60/100 mm 0: 9400 mm
Vertical 80/125 mm 0: 18500 mm
Then reduce the total straight flue length for
each extraflue bend (excluding
the turret) by:
2000 mm for 90·
1000 mm for 45·
Flue extension total lengths:
Horizontal & Vertical 60/100
mm 0: 960 mm
Horizontal &Vertical 80/125 mm 0: 1000mm
Rue terminal t?t<:!llengths:
Horizontal 60/100 mm
0: 800 mm
Horizontal 80/125 mm 0: 1200 mm
Vertical 60/100 mm 0: 1140 mm
Vertical 80/125 mm
0: 1365 mm
INSTALLATION'" SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDil3OCDil37COil42 co; ~ORCESTER
FLUE OPTIONS 30CDi
6720 613 700a (2006/11)

FLUE OPTIONS 37CDi
STANDARD FLU E HORIZONTAL
I..t"."".- •. --"--""""'"""~
bJia'" -".iI? A
0100
MAX 686 mm A x 1
MIN
250mm A x 1*
0125
MAX 1070 mm Ax 1
MIN 250mm Ax 1*
* Requires cutting
MAXIMUM FLUE HORIZONTAL
bJ!d':O-ln,-W
[2,. . ." .•
0100 " 3000 mm
Ax1 + Bx3
0125·15000 mm
A xl + Bx14
MAXIMUM FLUE VERTICAL START + 1 BEND
FQ oc"~· =.I""·.· •. ".,EP""·· A
,-,-FL""'",'.",,' '-'-'--,"-~''-'l'' B
@C
0100·3000 mm
Ax1+Cxl+Bx4
+ Fx 1
0125 ·15000 mm
A
xl + C x 1 + B x 15
+ Fx 1
MAXIMUM FLUE HORIZONTAL + 1 BEND
@n rlilP A
C::Z:::='~ B
o C
0100· 1000mm
Ax1+Bxl+Cx1
0125 • 13000 mm
A x1 + Bx 13 + C x 1
MAXIMUM FLUE VERTICAL
START + 2 BENDS
F~~LWA
B C:::::::::::: .. ==.f
C@
0100· 1000 mm
Axl+Cx2+ Bx3
+ F xl
0125 -13000 mm
A xl +C x 2 + B x 14
+ Fx 1
MAXIMUM FLUE VERTICAL
START + 3 BENDS
A
F
kl.~"::W
B
IT·; .. ·· ..
C
0100 - N/A
0125 -11000 mm
Axl +Cx3
+ Bx 13 + F xl
MAXIMUM FLUE VERTICAL
WITH 2 X
45· BENDS
E
B
D
0100 - 4000 mm
(including terminal)
Bx4+ Dx2 + Ex 1
0125 -14000 mm
(including terminal)
Bx14+ Dx2 +Exl
VERTICAL FLUE WITH
2X 90· BENDS
E B
B t
C 0
0100·2000 mm
(including terminal}
Bx3+ Cx2 +Ex 1
0125 -12000 mm
(including terminal}
Bx13+ Cx2 +Exl
8720 611 g27-oS.10
• The diagrams (opposite) show the compo-
nents used and
the maximum flue length for
each configuration
of 100 mm and
125
mm 0 flues.
• Shaded flue components indicate the stan-
dard 100
mm 0 horizontal flue.
• Only straight flue sections can be reduced
in length and cut.
•
The flue terminal end can be fitted from the
inside or outside of the building.
•
FIxing kits are supplied with the flue exten-
sion kits.
• Horizontal 125
mm 0 and Vertical 100 mm
and 125 mm 0 flue kits are available with
separate instructions. Contactyour supplier
or British Gas.
A C o
()
V
B F
Q
A - Standard horizontal flue (100 mm 0 shown)
B - Straight flue extension
C -
Flue bend, 90·
0" Flue bends, 45·
E· Vertical terminal (vertical adaptor supplied
with terminal)
F· Vertical adaptor (used with horizontal
terminal)
Calculating the flue length:
Measure the total flue length required, noting
that the maximum straight flue length including
the terminal is:
Horizontal 60/100
mm 0: 3000 mm
Horizontal 80/125 mm 0: 15000 mm
Vertical 60/100 mm 0: 6000 mm
Vertical 80/125 mm 0: 16000 mm
Then reduce the total straight flue length for
each extra flue bend (excluding
the turret) by:
2000 mm for 90·
1000 mm for 45°
Rue extension total lengths:
Horizontal & Vertical 60/100
mm 0: 960 mm
Horizontal &Vertical 80/125 mm 0: 1000 mm
Flue terminal total lengths:
Horizontal 60/100
mm 0: 800 mm
Horizontal 80/125 mm 0: 1200 mm
Vertical 60/100 mm 0: 1140 mm
Vertical 80/125 mm 0: 1365 mm
INSTAUATtOI; & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDif3OCDif37CDV42CDi
~WORCESTER
FLUE OPTIONS 37CDi
6720613 700a (2006/1 !)
BolchGroup

STANDARD FLUE HORIZONTAL
14- •..• __ •.....••. _..•... ...;
I
0100
MAX 686mm Ax1
MIN 250 mm Ax l'
0125
MAX 1070 mm Ax 1
MIN 250 mm Ax l'
* Requires cutting
MAXIMUM FLUE HORIZONTAL
0100 . 2600 mm
Ax1+Bx2
0125·12500 mm
A xl + Bx 12
MAXIMUM FLUE VERTICAL START + 1 BEND
F~ Q' . ""'W
A
1-1 B
@ C
0100·2600 mm
Ax1+Cxl+8x3
+ Fx 1
0125· 12500 mm
A x 1 + C x 1 + B x 13
+ Fx 1
MAXIMUM FLUE HORIZONTAL + 1 BEND
Do '···'··1 liP A
C=====:::3" B
o C
0100· 600 mm
Ax1+8x1+Cx1
0125·10500 mm
Axl + Bxll +Cxl
MAXIMUM FLUE VERTICAL
START + 2
BENDS
F E1 IG~WilP A
B 1-,' ..... . ,::.
cO
0100· N/A
0125 . 10500 mm
A x 1 + C x 2 + B x 12
+ Fx 1
MAXIMUM FLUE VERTICAL
START + 3
BENDS
F
~" ,·'~13,fP
B
c" . '" "'. ,.,.:. >.
C
0100· N/A
0125 8500 mm
Axl +Cx3
+Bx11+Fxl
MAXIMUM FLUE VERTICAL
WITH 2 X 45° BENDS
E
, . .. ,
B
D
0100 - 2900 mm
(including terminal)
8x3+ Dx2 + Ex1
0125 - 14000 mm
(including terminal)
B x 14 + D x 2 +
Ex 1
VERTICAL FLUE WITH
2 X 90° BENDS
E
t1
8
..
C 0
0100 - N/A
0125 - 12000 mm
(including terminal)
Bx13+ Cx2 +Exl
6 720 611 927-08.10
FLUE OPTIONS 42CDi
• The diagrams (opposite) show the compo-
nents used and the maximum flue length
for
each configuration of 100 mm and
125
mm 0 flues.
• Shaded flue components indicate the stan-
dard
100 mm 0 horizontal flue.
• Only straight flue sections can
be reduced
in length and cut.
• The flue terminal end can be fitted from the
inside oroutside
of the building.
• Fixing kits are supplied with the flue exten·
sion kits.
• Horizontal 125 mm 0 and Vertical 100 mm
and 125
mm 0 flue kits are available with
separate instructions. Contactyour supplier
or Worcester Bosch.
A D
@fT'Ii?P
V
B F
Jd.
A - Standard horizontal flue (100 mm 0 shown)
B Straightflue extension
C Flue bend,
90°
D· Flue bends, 45°
E· Vertical terminal (vertical adaptor supplied
with terminal)
F - Vertical adaptor (used with horizontal
terminal)
Calculating the flue length:
Measure the total flue length required, noting
that the maximum straight flue length including
the terminal is:
Horizontal 60/100 mm
0: 2600 mm
Horizontal 80/125 mm
0: 12500 mm
Vertical 60/100 mm 0: 4900 mm
Vertical 80/125 mm
0: 16000 mm
Then
reduce the total straight flue length for
each extra flue bend (excluding the turret) by:
2000 mm for 90°
1000 mm for 45°
Rue extension total lengths:
Horizontal &Vertical 60/100 mm
0: 960 mm
Horizontal & Vertical 80/125 mm 0: 1000 mm
Flue terminal
total lengths:
Horizontal
60/100 mm 0: 800 mm
Horizontal 80/125 mm
0: 1200 mm
Vertical 60/100 mm
0: 1140 mm
Vertical 80/125 mm
0: 1365 mm
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV3OCDiiSTCDi142 CDi ~ORCESTER
FLUE OPTIONS 42CDi
6720613700a (2006111)