Worcester GREENSTAR 29CDi Classic ErP User guide

UK/IE
INSTALLATION COMMISSIONING AND SERVICING INSTRUCTIONS
WALL HUNG RSF GAS FIRED CONDENSING COMBINATION BOILER
GREENSTAR CDi CLASSIC ErP
6 720 812 176-00.1O
FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER
6 720 815 725 (2015/05)
The appliances are for use with:
Natural Gas or L.P.G. (Cat. II 2H3P type C13, C33 & C53)
Natural Gas:
29CDi Classic ErP GC number 47-406-65
34CDi Classic ErP GC number 47-406-67
38CDi Classic ErP GC number 47-406-69
42CDi Classic ErP GC number 47-406-71
L.P.G.:
29CDi Classic ErP GC number 47-406-66
34CDi Classic ErP GC number 47-406-68
38CDi Classic ErP GC number 47-406-70
42CDi Classic ErP GC number 47-406-72

CONTENTS
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CONTENTS
1 KEY TO SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 APPLIANCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Layout & components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Product data on energy consumption . . . . . . . . . . . . . . . 9
3 PRE-INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 Cleaning primary systems . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Mains supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2.1 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2.3 Water supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Water systems and pipe work . . . . . . . . . . . . . . . . . . . . 12
3.4 Condensate pipe work . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4.1 Internal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4.2 External connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.5 Boiler internal drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.6 Pressure relief pipe work . . . . . . . . . . . . . . . . . . . . . . . 16
3.7 Boiler location & clearances . . . . . . . . . . . . . . . . . . . . . 16
3.8 Plumbing manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.9 Flue options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.10 Flue terminal positions . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.11 Plume management terminal positions . . . . . . . . . . . . 21
4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.1 Unpacking wall frame and ancillary items . . . . . . . . . . 22
4.2 Unpacking the appliance . . . . . . . . . . . . . . . . . . . . . . . . 23
4.3 Wall mounting plate and flue opening . . . . . . . . . . . . . 24
4.4 Fitting the appliance/boiler connections . . . . . . . . . . . 25
4.5 Flue installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.5.1 Ø60/100 mm Telescopic flue kit . . . . . . . . . . . . . . . . . 26
4.5.2 Ø60 mm Plume management kit . . . . . . . . . . . . . . . . . 26
4.5.3 Adjusting the standard terminal length . . . . . . . . . . . . 26
4.5.4 Installing the standard flue . . . . . . . . . . . . . . . . . . . . . . 27
4.5.5 Flue terminal plume re-direction: . . . . . . . . . . . . . . . . . 27
4.6 Condensate connection . . . . . . . . . . . . . . . . . . . . . . . . 28
4.7 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.8 Position of wired components . . . . . . . . . . . . . . . . . . . 30
5 COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.1 Pre-commissioning checks . . . . . . . . . . . . . . . . . . . . . . 31
5.2 Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.3 Starting the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.4 Water treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.5.1 Checking the gas inlet pressure . . . . . . . . . . . . . . . . . . 34
5.5.2 Checking the gas rate . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.5.3 Domestic hot water . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.5.4 Domestic hot water pre-heat . . . . . . . . . . . . . . . . . . . . 35
5.6 CO and Combustion checks . . . . . . . . . . . . . . . . . . . . . 36
5.7 Finishing commissioning . . . . . . . . . . . . . . . . . . . . . . . 37
6 SERVICING AND SPARES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.1 Inspection and service . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.1.1 Checking flue integrity . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.1.2 component access . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.1.3 Fan pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.1.4 To Clean the Heat Exchanger . . . . . . . . . . . . . . . . . . . . 40
6.1.5 To Clean the Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.1.6 To Check the Diaphragm in Burner Cover . . . . . . . . . . 41
6.1.7 To Clean the Condensate Trap . . . . . . . . . . . . . . . . . . . 42
6.2 setting the air/gas ratio . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.3 Replacement of parts . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.4 Short parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7 FAULT FINDING & DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 54
7.1 No hot water on opening a tap (new installation) . . . . 54
7.2 Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.3 Central heating function . . . . . . . . . . . . . . . . . . . . . . . . 55
7.4 Preheat and DHW function . . . . . . . . . . . . . . . . . . . . . . 56
7.5 Protection function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

KEY TO SYMBOLS
6 720 815 725 (2015/05) 3
1 KEY TO SYMBOLS
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 their needs, that
it is installed, commissioned and serviced in accordance with the
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 helpline
(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
6 720 815 725 (2015/05)4
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.
The guarantee of this product is dependant on the Benchmark checklist
being completed and the actions undertaken.
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).
COMBUSTION AND 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 can corrode the appliance and
invalidate any guarantee.
FITTING AND 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 guarantee. 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.
BUILDING REGULATIONS PART L 1A 2013
If the installation is in a new build property or is a first time installation in
an existing property, heating systems must conform to current building
regulations Part L1a.
All new heating systems in dwellings must have at least two heating
zones. Each of these zones will be operated separately by both time and
temperature controls.
The exception to this are single storey, open plan dwellings where the
living area is more than 70% of the total useable floor area. Then this
type of dwelling can be controlled as one zone.
All radiators must have TRVs fitted, where reasonable, in all rooms
except bathrooms and rooms with thermostats.
BUILDING REGULATIONS PART L 1B 2013 - BOILER REPLACEMENT
For boiler replacement on an existing system, it is not necessary to zone
the system, compliance with the zone requirements can be achieved by
a single room thermostat or programmable room thermostat.
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
BS6891 Installation of low pressure gas pipe work up to 35mm (R1¼ )
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.
BOILER FEATURES
• Pre-wired and pre-plumbed
• Galvanised steel inner frame
• Digital control system
• FX/Greenstar Sense controls
• 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
• DHW flow sensor & temperature control
• Plate type DHW heat exchanger
• Low Energy Modulating pump

APPLIANCE INFORMATION
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2 APPLIANCE INFORMATION
2.1 GENERAL INFORMATION
Fig. 1 Overall dimensions
Fig. 2 Standard package
STANDARD PACKAGE:
A Wall hung gas fired condensing combi boiler for central
heating and domestic hot water
B Wall mounting plate with hanging bracket
C Pre-plumbing manifold
D Hardware pack
E ErP energy label
F Literature pack
- Installation instructions
- User instructions
- Wall mounting template
G Bottom panel
G
A
max.
360 mm
max.
760 mm
440mm
6 720 812 175-26.1O
B
C
FD
E
6 720 815 725-02.1O

APPLIANCE INFORMATION
6 720 815 725 (2015/05)6
2.2 LAYOUT & COMPONENTS
Fig. 3 Boiler components
2
3
4
5
6
8
15
9
10
13
12
14
16
17
20
23
24
25
26
27
28
1
22
21
18
19
7
6 720 815 725-06.1O
11

APPLIANCE INFORMATION
6 720 815 725 (2015/05) 7
Fig. 4 Hydraulics
Fig. 5 Control panel
The diagram opposite shows the controls in the servicing position
and excludes the outer case
1 REMOVABLE TOP CASE PANEL FOR SERVICING
2 IGNITION ELECTRODES 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 LOW ENERGY MODULATING PUMP
8 PRESSURE RELIEF VALVE
9 DRAIN HOSE
10 DCW MAINS ISOLATING VALVE
11 CH RETURN ISOLATING VALVE
12 CHARGING LINK ASSEMBLY
13 COVER FOR EXTERNAL WIRING CONNECTIONS
14 CONTROL PANEL IN SERVICE POSITION
15 SYSTEM PRESSURE GAUGE
16 GAS ISOLATING VALVE
17 DHW OUTLET CONNECTION
18 CH FLOW ISOLATING VALVE
19 CONDENSATE DRAIN CONNECTION
20 CONDENSATE SIPHON
21 INLET PRESSURE TEST POINT
22 GAS VALVE
23 DHW TEMPERATURE SENSOR (NTC)
24 AIR / GAS - ADJUST MAXIMUM SETTING SCREW
25 FAN PRESSURE TEST POINT
26 FAN
27 PRIMARY SENSOR
28 EXPANSION VESSEL
Table 3 Main boiler components
6
34
41
33
29
30
32 31
6 720 812 176-07.1O
7
40
8
41
36
35
37 38 399
29 FLOW TURBINE
30 UNUSED PORT
31 RETURN CONNECTION TO BOILER HEAT EXCHANGER
32 AUTO AIR VENT
33 EXPANSION VESSEL CONNECTION
34 FLOW CONNECTION FROM BOILER HEAT EXCHANGER
35 DHW SENSOR
36 CH FLOW CONNECTION TO PRE-PLUMBING MANIFOLD
37 DHW OUT CONNECTION TO PRE-PLUMBING MANIFOLD
38 DCW IN CONNECTION FROM PRE-PLUMBING MANIFOLD
39 CH RETURN CONNECTION FROM PRE-PLUMBING MANIFOLD
40 DIVERTER VALVE
41 COMPACT HYDRAULIC MOUNTING SCREW (2) TO BOILER
42 CH TEMPERATURE CONTROL
43 MAINS ON/OFF INDICATOR/DIAGNOSTIC LIGHT (BLUE)
44 DHW TEMPERATURE CONTROL
45 PERFORMANCE TEST BUTTON
46 SERVICE BUTTON
47 BURNER ON INDICATOR LIGHT (GREEN)
48 MASTER SWITCH ON/OFF
49 HOLIDAY BUTTON
50 ECO BUTTON
51 FAULT RESET BUTTON
52 DISPLAY
53 POSITION FOR OPTIONAL PLUG-IN CONTROL
Table 4 Hydraulics and control panel
48
47
46
45
42
43
15
53 52
51
50
49
44
1
2
34
5
6
max
2
3
1
04
bar
1
reset
eco
1
2
34
e
6
maxmin
6 72 812 176-26.1O

APPLIANCE INFORMATION
6 720 815 725 (2015/05)8
2.3 TECHNICAL DATA
NATURAL GAS L.P.G
Product type
29CDi
Classic ErP
34CDi
Classic ErP
38CDi
Classic ErP
42CDi
Classic ErP
29CDi
Classic ErP
LPG
34CDi
Classic ErP
LPG
38CDi
Classic ErP
LPG
42CDi
Classic ErP
LPG
Domestic hot water
Min. heat input kW 8.0 8.0 9.8 9.8 11.5 11.5 14.5 14.5
Max. rated heat output kW 30.9 35.0 40.0 42.0 30.9 35.0 40.0 42.0
Max. rated heat input kW 30.9 35.0 40.0 42.0 30.9 35.0 40.0 42.0
Max. mains inlet pressure bar 10 10 10 10 10 10 10 10
Min. mains inlet pressure (working) for
max flow
bar 1.4 1.5 1.7 1.9 1.4 1.5 1.7 1.9
Min. mains inlet pressure (working) for
operation
bar 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
DHW temperature range °C 40-60 40-60 40-60 40-60 40-60 40-60 40-60 40-60
*Maximum DHW flow rate - 40°C rise
15%
l/min 11 12 14 15 11 12 14 15
Central Heating
Max. rated heat input kW 30.9 30.9 30.9 30.9 30.9 30.9 30.9 30.9
Max. rated heat output net 40/30°C kW 32.1 32.1 32.1 32.1 32.1 32.1 32.1 32.1
Max. rated heat output net 50/30°C kW 31.8 31.8 31.8 31.8 31.8 31.8 31.8 31.8
Max. rated heat output net 80/60°C kW 30.0 30.0 30.0 30.0 30.0 30.0 30.0 30.0
Min. rated heat output net 40/30°C kW 8.6 8.6 10.6 10.6 8.6 12.4 15.7 15.7
Min. rated heat output net 50/30°C kW 8.6 8.6 10.5 10.5 8.6 12.3 15.5 15.5
Min. rated heat output net 80/60°C kW 7.7 7.7 9.4 9.4 7.7 11.0 13.9 13.9
Min. rated heat input net kW 8.0 8.0 9.8 9.8 8.0 11.5 14.5 14.5
Max. flow temperature (nominal) °C 90 90 90 90 90 90 90 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
temp. rise
m22222222
Gas flow rate - Max. 10 minutes from lighting
Natural Gas G20 m3/h 3.3 3.7 4.2 4.4 - --
Propane Gas (LPG) kg/h - --2.4 2.7 3.1 3.3
Flue
Flue Gas Temp. 80/60°C, rated min. load
Max/Min
°C 76/58 81/58 83/58 86/58 76/58 81/58 86/58 87/58
Flue Gas Temp. 40/30°C, rated min. load
Max/Min
°C 55/33 58/33 65/35 66/35 55/33 58/33 65/35 66/35
CO2level at max. rated heat output % 9.6 9.6 9.7 9.7 11.5 11.5 11.5 11.5
CO2level at min. rated heat output % 9.0 9.0 9.1 9.1 10.5 10.5 10.5 10.5
NOx - class 55555555
Condensate
Max. condensation rate l/h 2.7 2.7 2.7 2.7 2.7 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 150 160 170 175 150 160 170 175
Energy efficiency index (EEI) heating
pump
– 0,23 0,23 0,23 0,23 0,23 0,23 0,23 0,23
General Data
SAP 2009 annual efficiency % 89.1 89.1 89.0 89.4 90.1 90.1 90.0 90.4
SAP 2005 seasonal efficiency (SEDBUK) % 90.1 90.1 90.2 90.2 92.0 92.0 91.9 92.2
Appliance protection rating IP X4D X4D X4D X4D X4D X4D X4D X4D
Table 5 Technical data

APPLIANCE INFORMATION
6 720 815 725 (2015/05) 9
2.4 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.
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
Total boiler weight (lift weight) kg 47.5 47.5 47.5 47.5 47.5 47.5 47.5 47.5
Packaged boiler weight kg 56 56 56 56 56 56 56 56
NATURAL GAS L.P.G
Product type
29CDi
Classic ErP
34CDi
Classic ErP
38CDi
Classic ErP
42CDi
Classic ErP
29CDi
Classic ErP
LPG
34CDi
Classic ErP
LPG
38CDi
Classic ErP
LPG
42CDi
Classic ErP
LPG
Table 5 Technical data
* Greenstar CDi Classic ErP combi boilers are fitted with a flow regulator set to achieve a 40°C temperature rise. This ensures comfortable
bathing during the colder winter months.
Product data Symbol Unit 7 738 100 248 7 738 100 249 7 738 100 250 7 738 100 251
Product type – – 29CDi
Classic ErP
29CDi
Classic ErP LPG
34CDi
Classic ErP
34CDi
Classic ErP LPG
Condensing boiler – – Yes Yes Yes Yes
Combination heater – – Yes Yes Yes Yes
Rated heat output Prated kW 30 30 30 30
Seasonal space heating energy efficiency s%9292 9292
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 30.0 30.0
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 10.0 10.0
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 97.5 97.5
Auxiliary electricity consumption
At full load elmax kW 0.058 0.058 0.058 0.058
At part load elmin kW 0.030 0.030 0.030 0.030
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 30 30
Sound power level, indoors LWA dB(A) 55 55 55 55
Additional data for combination heaters
Declared load profile – – XL XL XL XL
Daily electricity consumption Qelec kWh 0.178 0.178 0.175 0.175
Annual electricity consumption AEC kWh 39 39 39 39
Daily fuel consumption Qfuel kWh 23.174 23.174 23.339 23.339
Annual fuel consumption AFC GJ 1,416 1,416 1,426 1,426
Water heating energy efficiency wh %8686 8686
Water heating energy efficiency class – – A A A A
Table 6 Product data for energy consumption

PRE-INSTALLATION
6 720 815 725 (2015/05)10
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.
▶ Run the boiler/system at normal operating temperature as directed
by the manufacturer of the flushing agent.
Product data Symbol Unit 7 738 100 252 7 738 100 253 7 738 100 246 7 738 100 247
Product type – – 38CDi
Classic ErP
38CDi
Classic ErP LPG
42CDi
Classic ErP
42CDi
Classic ErP LPG
Condensing boiler – – Yes Yes Yes Yes
Combination heater – – Yes Yes Yes Yes
Rated heat output Prated kW 30 30 30 30
Seasonal space heating energy efficiency s%9292 9292
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 30.0 30.0
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 10.0 10.0
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 97.5 97.5
Auxiliary electricity consumption
At full load elmax kW 0.052 0.052 0.052 0.052
At part load elmin kW 0.028 0.028 0.028 0.028
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 20 20 20 20
Sound power level, indoors LWA dB(A) 55 55 55 55
Additional data for combination heaters
Declared load profile – – XL XL XL XL
Daily electricity consumption Qelec kWh 0.171 0.171 0.171 0.171
Annual electricity consumption AEC kWh 38 38 38 38
Daily fuel consumption Qfuel kWh 22.388 22.388 22.377 22.377
Annual fuel consumption AFC GJ 1,368 1,368 1,367 1,367
Water heating energy efficiency wh %8484 8787
Water heating energy efficiency class – – A A A A
Table 7 Product data for energy consumption
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 guarantee.
NOTICE: ARTIFICIALLY SOFTENED WATER MUST NOT
BE USED TO FILL THE CENTRAL HEATING SYSTEM.

PRE-INSTALLATION
6 720 815 725 (2015/05) 11
▶ 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 PRODUCTS
Suitable water treatment products can be obtain from the following
manufacturers:
ARTIFICIALLY SOFTENED WATER
It is possible to have an ion exchange water softener fitted to the cold
water system of the property. However, the boiler requires an untreated
cold water connection taken from the mains supply, before the water
softener, to the primary water filling point of the heating system.
Alternatively there are water softening/treatment devices that do not
adjust or alter the pH levels of the water. With these devices it may not
be necessary to provide an untreated water by-pass to the primary water
filling point of the heat system.
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 the 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.
3.2.3 WATER SUPPLY
WATER MAINS PRESSURE:
• Minimum mains water pressure: 1.5 up to 2.5 bar for maximum
performance.
• Maximum mains fed water pressure 10 bar. If necessary fit a
pressure reducing valve.
• Where the mains water supply has a non-return,
back flow prevention valve fitted, a mini expansion vessel (1) should
be connected to the mains water inlet pipe (2) between the non-
return valve (3) and the boiler (4) as shown below
Fig. 6
USE IN HARD WATER AREAS:
Normally there is no need for water treatment to prevent scale formation
as the maximum temperature of the HW heat exchanger is limited by the
electronic control.
In areas where 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.
WARNING: Sealing agents
▶ Normally the addition of sealing agents to the system
water is not permitted as this can cause problems
with deposits left in the heat exchanger.
▶ In cases where all attempts to find a micro leak have
failed, Worcester, Bosch Group supports the use of
Fernox F4 leak sealer.
FERNOX 0870 601 5000 or www.fernox.com
SENTINEL 0800 389 4670 or www.sentinel-solutions.net
NOTICE: Non-return, back flow prevention devices
(including those associated with water meters) fitted to
the mains water supply can cause a pressure build up
which could damage the boiler and other household
appliances.
1 Mini expansion vessel
2 Mains water inlet pipe
3 Non return valve
4 Boiler
1
4
32
6720643895-04.1Wo

PRE-INSTALLATION
6 720 815 725 (2015/05)12
3.3 WATER SYSTEMS AND PIPE WORK
PLASTIC PIPE WORK:
• Any plastic pipe work must have a polymeric barrier with 600mm
(minimum) length of copper 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.
PRIMARY SYSTEMS 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.
• All other valves should conform to BS1010.
• Thermostatic radiator valves (TRV’s) must be used on all radiators
within the sleeping accommodation but not the radiator where the
room thermostat is sited. This must be fitted with lock-shield valves
and left open.
• A drain cock is required at the lowest point in the system.
• An air vent is required at all the high points in the system.
SHOWERS/BIDETS:
• If a shower head can be immersed in water or comes closer than
25mm from the top edge of a bath or shower tray spill over level then
an anti-siphon device must be fitted to the shower hose.
• Bidets with direct hot and 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 prevent the fitting of hand held
sprays.
SEALED PRIMARY SYSTEM:
• The CH sealed system must be filled using a WRAS approved filling
loop or comply with figure 7 for system fill.
• Where the system volume is more than 100 litres or exceeds 2.65
bar at maximum heating temperature, an extra expansion vessel (2)
must be fitted as close as possible to the appliance in the central
heating return.
• Pressurise the extra expansion vessel (2) to the same figure as the
expansion vessel built into the appliance.
•Do not use galvanised pipes or radiators.
SYSTEM FILL
Fig. 7 System fill
TYPICAL SEALED SYSTEM
Fig. 8 Sealed system
Fig. 9 Sealed system with zone valves
An external automatic bypass will need to be installed if
a system with two-port motorised valves is installed.
NOTICE: ARTIFICIALLY SOFTENED WATER MUST NOT
BE USED TO FILL THE CENTRAL HEATING SYSTEM
CV = Check Valve
SV = Stop Valve
SV SV
Test point
Temporary hose
Hose union CV
CV
Heating
return
Mains
supply
6720643895-05.1Wo
1 Appliance expansion vessel - CH
2 Extra expansion vessel - CH return
3 Pressure relief discharge
4 Drain cock
5 Radiators
6 Zone valves
Table 8 Key to figs. 8 and 9
44
1
2
3
5 5
55
6720643895-06.1Wo
4
6
4
2
3
5 5
55
M
M
6720646608-04.1Wo
1

PRE-INSTALLATION
6 720 815 725 (2015/05) 13
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. 10 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. 11 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. 12 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
6 720 815 725 (2015/05)14
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 prevent the condensate freezing.
▶ The external run be kept as short as possible and not exceed 3
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 13 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. 13 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. 14 External disposal
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.
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.
Minimumholesizeforthecondensatesoakawaymustbe
400mm deep by 300mmØ .
18 8
13
14
17
15
16
1
6720644744-09.3Wo
25mm min.
14
13
1
6720644744-10.3Wo

PRE-INSTALLATION
6 720 815 725 (2015/05) 15
Fig. 15 Condensate pump to external disposal
Fig. 16 Soak away
3.5 BOILER INTERNAL DRAIN
The CDI Classic ErP has the facility to drain the water direct from the
boiler through the condensate pipe.
Fig. 17 Drain tap positions
If the boiler uses a soakaway or a condensate pump:
▶ Use an esxternal drain point on the system to prevent excess system
water being drawn through the saokaway or condensate pump
NOTICE: Unheated internal areas.
▶ Internal pipe runs in unheated areas such as lofts,
basementsandgaragesshouldbetreatedasexternal
runs and consideration should be given to using a
CondenseSure siphon.
25mm min.
14 13
1
7
6720644744-12.3Wo
13
14
10
500mm min.
25mm min.
400mm
min.
1
12
11
9
6720644744-11.3Wo
9
10
6 720 815 723-02.2O

PRE-INSTALLATION
6 720 815 725 (2015/05)16
3.6 PRESSURE RELIEF PIPE WORK
• The pressure relief drain pipe (1) from the boiler should be at least
15mm diameter copper pipe and run downwards, away from any
electrical equipment or other hazard, preferably to an external drain
or soak away.
• Pipe (1) should be finished with a partial bend, near the outlet to face
the external wall (as shown) to help prevent freezing.
Fig. 18 Pressure relief pipe work
[2] Outside wall
[1, 3] PRV drain pipe
[4] External drain
REMOTE PRESSURE RELIEF VALVE KIT
For installations in a cellar or basement, there is an accessory that is
available from Worcester that allows the pressure relief valve to be fitted
remotely from the boiler. This accessory can be used when there is
difficulty accessing an external drain.
The part number for this kit is: 7 716 161 071
3.7 BOILER LOCATION & CLEARANCES
This boiler is only suitable for installing internally within a property at a
suitable location onto a fixed, rigid 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 non-
combustible 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 Classic ErP Combi 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.
Do not operate the appliance if the flue terminal fitted on the outside wall
or roof is obstructed or damaged.
SERVICING CLEARANCES
Fig. 19
NOTICE:
▶ The pressure relief valve is a safety device for the
boiler and if activated may discharge boiling water or
steam through the relief valve drain pipe.
▶ Care should be taken when siting the outlet pipe so
that it does not cause an obstruction or discharge
above a window, entrance or other public access
where it could cause a hazard.
1
2
3
4
2
3
4
1
2
6720646608-123.1Wo
NOTICE:
No surface protection is required against heat transfer
from the boiler
* Minimum clearance to removable door
** Minimum clearance required for servicing
*** Height for either 60/100 flue or 80/125 flue
Table 9 Minimum clearances
1130/1170mm***
960mm
380mm
450mm
170/210mm***
600mm**
5mm
5mm
200mm
20mm*
6720803599-10.1Wo

PRE-INSTALLATION
6 720 815 725 (2015/05) 17
BATHROOMS:
A boiler fitted with a non-mechanical timer or with no timer can be
installed in zone 2 or outside the shaded area.
A boiler with a mechanical timer or RF mechanical timer with room
thermostat must only be installed outside the shaded area.
Additional RCD (Residual Current Device) protection may be required.
Refer to the latest IET wiring regulations.
BATHROOM INSTALLATIONS
Fig. 20 Bathroom installations
3.8 PLUMBING MANIFOLD
CONNECTIONS:
Heating System: 22mm compression fittings
DHW: 15mm compression fittings
Gas: 22mm compression fittings
Use the fittings supplied in the Hardware pack.
1. CH Flow 22 mm
2. DHW Out 15 mm
3. Mains Gas Supply 22 mm
4. Mains Water In 15 mm
5. CH Return 22 mm
PRE-PLUMBING
With the plumbing manifold installed, pipe work can be installed to the
valves on the manifold.
The pipes can be run below the boiler or alternatively up behind the
boiler.
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.
Alternatively a pre-formed pipe kit can be purchased:
part number 7 716 192 607
Fig. 21 Plumbing manifold
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.
2* Without the end wall, zone 2 must extend 600mm from the bath
6720646608-124.3Wo
2*
Radius 600mm
1
212
2
1
600mm
600mm 600mm
2250mm
2250mm
2*
# Function Pipe Ø
1 CH flow 22mm
2 DHW out 15mm
3 Gas 22mm
4 DCW in 15mm
5 CH Return 22mm
6 Condensate 22mm
7 Pressure relief valve 15mm
3
4
1
5
7
6
2
6 720 812 176-02.1O
5
1
2
3
4

PRE-INSTALLATION
6 720 815 725 (2015/05)18
3.9 FLUE OPTIONS
The Greenstar CDi Classic 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 29CDi Classic ErP if the plume management effective
length was 1500mm, the internal flue would be reduced to 5200mm.
This page and the next page show various flue options with the maximum
straight flue lengths allowed to remain within 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
29CDi ErP 7,900mm 5,900mm 3,100mm 18,500mm
34CDi ErP 7,000mm 5,000mm 2,200mm 16,000mm
38CDi ErP 6,000mm 4,000mm 1,200mm 12,500mm
42CDi ErP 6,000mm 4,000mm 1,200mm 12,000mm
Table 10 Maximum horizontal flue lengths
Maximum vertical flue lengths (L)
Boiler model 100mmØ 125mmØ
29CDi ErP 9,400mm 18,500mm
34CDi ErP 8,000mm 16,000mm
38CDi ErP 7,500mm 16,000mm
42CDi ErP 7,500mm 16,000mm
Table 11 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 2.0 metres of
straight flue.
▶ Each 45° bend used is equivalent to 1.0 metre of
straight flue.
Telescopic horizontal flue
Flue option 1 100mmØ 125mmØ
29CDi ErP 570mm 600mm
34CDi ErP 570mm 600mm
38CDi ErP 570mm 600mm
42CDi ErP 570mm 600mm
Horizontal extended flue
Flue option 2 100mmØ 125mmØ
29CDi ErP 7,900mm 18,500mm
34CDi ErP 7,000mm 16,000mm
38CDi ErP 6,000mm 12,500mm
42CDi ErP 6,000mm 12,000mm
Horizontal extended flue with 1x90° bends
Flue option 3 100mmØ 125mmØ
29CDi ErP 6,400mm 16,500mm
34CDi ErP 5,500mm 14,000mm
38CDi ErP 4,500mm 10,500mm
42CDi ErP 4,500mm 10,000mm
Horizontal extended flue with 2x90° bends
Flue option 4 100mmØ 125mmØ
29CDi ErP 4,900mm 14,500mm
34CDi ErP 4,000mm 12,000mm
38CDi ErP 3,000mm 8,500mm
42CDi ErP 3,000mm 8,000mm
High level horizontal extended flue
Flue option 5 100mmØ 125mmØ
29CDi ErP 7,900mm 18,500mm
34CDi ErP 7,000mm 16,000mm
38CDi ErP 6,000mm 12,500mm
42CDi ErP 6,000mm 12,000mm
High level horiz. extended flue with 2x90° bends
Flue option 6 100mmØ 125mmØ
29CDi ErP 6,400mm 16,500mm
34CDi ErP 5,500mm 14,000mm
38CDi ErP 4,500mm 10,500mm
42CDi ErP 4,500mm 10,000mm
High level horiz. extended flue with 3x90° bends
Flue option 7 100mmØ 125mmØ
29CDi ErP 4,900mm 14,500mm
34CDi ErP 4,000mm 12,000mm
38CDi ErP 3,000mm 8,500mm
42CDi ErP 3,000mm 8,000mm
Vertical balanced extended flue
Flue option 8 100mmØ 125mmØ
29CDi ErP 9,400mm 18,500mm
34CDi ErP 8,000mm 16,000mm
38CDi ErP 7,500mm 16,000mm
42CDi ErP 7,500mm 16,000mm
Vertical balanced extended flue with 2x90° bends
Flue option 9 100mmØ 125mmØ
29CDi ErP 6,400mm 14,500mm
34CDi ErP 5,000mm 12,000mm
38CDi ErP 4,500mm 12,000mm
42CDi ErP 4,500mm 12,000mm
Vertical balanced extended flue with 2x45° bends
Flue option 10 100mmØ 125mmØ
29CDi ErP 7,900mm 16,500mm
34CDi ErP 6,500mm 14,000mm
38CDi ErP 6,000mm 14,000mm
42CDi ErP 6,000mm 14,000mm

PRE-INSTALLATION
6 720 815 725 (2015/05) 19
Fig. 22
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
6 720 815 725 (2015/05)20
3.10 FLUE TERMINAL POSITIONS
Fig. 23 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, unless it
will cause a nuisance. BS 5440:Part 1 recommends that care is taken
when siting terminal in relation to boundary lines.
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:
▶ Check the internal lengths against the plume management required, refer to section 3.9 for more information, flue lengths become
significantly shorter with increasing plume management length.
▶ 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
(100mm flue bracket part number: 7 716 191 177,
flue brackets 100mm x 6 part number:7 716 191 178,
125mm flue bracket 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.