Worcester Greenstar FS 42CDi Regular User manual

UK/IE
INSTRUCTION MANUAL
INSTALLATION COMMISSIONING & SERVICING
8 716 115 216b (09.2008)
THE APPLIANCE IS FOR USE WITH
NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13, C33, C53 &C93)
NATURAL GAS:
GREENSTAR FS 30CDi REGULAR GC NUMBER 41-406-03
GREENSTAR FS 42CDi REGULAR GC NUMBER 41-406-04
LIQUID PETROLEUM GAS:
GREENSTAR FS 30CDi REGULAR GC NUMBER 41-406-05
GREENSTAR FS 42CDi REGULAR GC NUMBER 41-406-06
GREENSTAR
FS 30CDi & FS 42CDi Regular
FOR SEALED OR OPEN VENT CENTRAL HEATING SYSTEMS
FLOOR STANDING RSF GAS-FIRED CONDENSING REGULAR BOILER

INSTALLATION & SERVICING INSTRUCTIONS
CONTACT INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS
CONTACT INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 216b (09.2008)
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
THESE INSTRUCTIONS ARE APPLICABLE TO THE PRODUCT 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 & EIRE ONLY AND MUST BE FOLLOWED EXCEPT
FOR ANY STATUTORY OBLIGATION.
THIS APPLIANCE MUST BE INSTALLED BY A COMPETENT REGISTERED ENGINEER,
SUCH AS A BRITISH GAS OR OTHER CORGI REGISTERED PERSONNEL.
FAILURE TO INSTALL CORRECTLY COULD LEAD TO PROSECUTION.
IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER TECHNICAL SUPPORT
HELPLINE.
DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER,
PART OF THE BOSCH GROUP.
PLEASE LEAVE THESE INSTRUCTIONS, THE USER GUIDE AND THE COMPLETED
BENCHMARK LOG BOOK (AT THE BACK OF THIS MANUAL) OR A CERTIFICATE
CONFIRMING COMPLIANCE WITH IS 813 (EIRE ONLY) WITH THE USER OR AT THE
GAS METER AFTER INSTALLATION OR SERVICING.
WORCESTER, BOSCH GROUP:
MAIN RECEPTION: 01905 754624
MAIN FAX: [phone]
TECHNICAL: 08705 266241
SERVICE: 08457 256206
SPARES: 01905 752571
LITERATURE: 01905 752556
TRAINING: 01905 752526
SALES: 01905 752640
WEBSITE: worcester-bosch.co.uk
WATER TREATMENT:
FERNOX 01799 550811
fernox.com
SENTINEL 0800 389 4670
sentinel-solutions.net
FLUE TERMINAL GUARDS:
TOWER FLUE COMPONENTS
VALE RISE, TONBRIDGE, TN9 1TB
TEL: [phone]
tfc-group.co.uk
ABBREVIATIONS:
Ø Diameter
NG Natural Gas
LPG Liquid Petroleum Gas
CH Central Heating
DHW Domestic Hot Water
TRV Thermostatic Radiator Valve
IP Ingress Protection
RSF Room sealed flue
N/A Not allowed
SEDBUK Seasonal Efficiency for Domestic Boilers in the United Kingdom
Store the appliance in a dry area prior to
installation.
IMPORTANT HANDLING INSTRUCTIONS:
It is advised that two people are involved in
the transfer of the packaged appliance from
the van to the point of installation.
A suitable truck should be used.
The boiler is secured to a wooden board with
screws. It is advised that no attempt should
be made to move the packaged appliance
without the use of a suitable truck.
Before removing the carton it is advised that
the top flaps are opened and the ancillary
items removed and set to one side.
The carton can now be lifted off the boiler.
Remove the plastic bag protecting the boiler
surfaces and place safely away from the
working area.
Remove the boiler (complete with board) from
the pallet before removing the securing screws.
The boiler is mounted on small wheels and
can now be slid off the board and guided into
the installation position.
Care should be taken not to damage any
panels.
Two people are required to move the appliance
from the board into the installation position.
GENERAL HANDLING GUIDELINES:
• Lift only a manageable weight, or ask for
help.
• When lifting, bend the knees, and keep the
back straight and feet apart.
• Do not lift and twist at the same time.
• Lift and carry items close to the body
• Wear protective clothing and gloves to
protect from any sharp edges
SYMBOLS USED IN THIS MANUAL:
Domestic hot water
Central heating
Room thermostat
Frost thermostat
Wait time period
Programmer/timer OFF
Programmer ON CH only
Programmer ON DHW only
Programmer ON CH and DHW
Cold water main supply
Electricity supply
Fuel supply
COMMERCIAL INSTALLATION:
IF INSTALLING A GROUP OF APPLIANCES TOGETHER, ON COMMERCIAL PREMISES,
THAT TOTALS MORE THAN 70KW, THEN THE APPLIANCES MUST BE INSTALLED IN
ACCORDANCE WITH THE REQUIREMENTS OF IGE/UP/10 THEREFORE A COMMERCIAL
GAS QUALIFICATION WILL BE REQUIRED.

INSTALLATION & SERVICING INSTRUCTIONS CONTENTS
SAFETY &
REGULATIONS
FAULT FINDING
& DIAGRAMS
APPLIANCE
INFORMATION
PRE-
INSTALLATION
INSTALLATIONCOMMISSIONING
SERVICING
& SPARES
CONVERSION
KITS
CONTENTS
1
8 716 115 216b (09.2008)
SAFETY & REGULATIONS
SAFETY PRECAUTIONS 2
INSTALLATION REGULATIONS 2
APPLIANCE INFORMATION
GENERAL INFORMATION 3
TECHNICAL DATA 4
LAYOUT & COMPONENTS 5
PRE-INSTALLATION
CLEANING PRIMARY SYSTEMS 6
MAINS SUPPLIES 7
WATER SYSTEMS & PIPEWORK 8
CONDENSATE PIPEWORK 10
BOILER LOCATION & CLEARANCES 11
MOUNTING FRAME CONNECTIONS 13
FLUE OUTLET POSITIONS 14
ROOM SEALED FLUE OPTIONS 16
INSTALLATION
UNPACKING THE BOILER 17
MOUNTING FRAME FIXING / FLUE OPENING 18
MOUNTING FRAME CONNECTIONS 19
FLUE LENGTHS/FLUE MEASURING & CUTTING 20
FLUE INSTALLATION 23
STANDARD FLUE INSTALLATION 24
FLUE TERMINAL PLUME MANAGEMENT 25
CONDENSATE, GAS & WATER CONNECTIONS 26
ELECTRICAL 27
COMMISSIONING
PRE-COMMISSIONING CHECKS 28
FILLING THE SYSTEM 29
STARTING THE APPLIANCE 30
WATER TREATMENT 31
FINISHING COMMISSIONING 32
SERVICING & SPARES
INSPECTION AND SERVICE 33
REPLACEMENT OF PARTS 37
SETTING THE GAS/AIR RATIO 42
SHORT PARTS LIST 43
CONVERSION KITS
L.P.G. CONVERSION 44
FAULT FINDING & DIAGRAMS
ELECTRICAL WIRING DIAGRAM 45
CENTRAL HEATING FUNCTION 46
FAULT FINDING 47
BENCHMARK CHECKLIST AT REAR OF MANUAL

SAFETY &
REGULATIONS
INSTALLATION & SERVICING INSTRUCTIONS
SAFETY PRECAUTIONS INSTALLATION REGULATIONS
2SAFETY PRECAUTIONS &
INSTALLATION REGULATIONS
8 716 115 216b (09.2008)
IF YOU SMELL GAS:
DON'T SMOKE OR STRIKE MATCHES.
DON'T TURN ELECTRICAL SWITCHES ON OR OFF.
DO PUT OUT NAKED FLAMES.
DO OPEN DOORS AND WINDOWS.
DO KEEP PEOPLE AWAY FROM THE AREA AFFECTED.
DO TURN OFF THE CONTROL VALVE AT THE METER.
DO CALL YOUR GAS COMPANY.
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:
A Benchmark Log Book is provided, at the back of this manual, 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 Log Book 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). Where applicable, the CE mark indicates
compliance with relative EU Directives.
COMBUSTIBLE AND CORROSIVE MATERIALS:
Do not store or use any combustible materials (paper, thinners, paints etc.) inside
or within the vicinity of the appliance.
The combustion air must be kept clear of chemically aggressive substances, which
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 these instructions and the relevant Installation
Regulations.
Flue systems must not be modified in any way other than as described in the fitting
instructions.
Any misuse or unauthorised modifications to the appliance, flue or associated
components and systems could invalidate the warranty. The manufacturer accepts
no liability arising from any such actions, excluding statutory rights.
SERVICING:
Advise the user to have the system regularly serviced by a competent, qualified
engineer (such as British Gas or other 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 Log Book after each service.
Failure to install appliances correctly could
lead to prosecution.
This appliance must be installed by a
competent registered engineer, such as British
Gas or other CORGI registered personnel, in
accordance with, and comply to, the current:
Gas Safety (Installation & Use) Regulations
1998, IEE 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), IS 813 (Eire) and
any other local requirements.
The relevant Standards should be followed,
including:
BS7074:1 : Code of practice for domestic
heating and hot water supply
BS6891 : Installation of low pressure gas
pipework up to 32mm (R11/4)
BS EN:12828 : 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)
Where no specific instruction is given,
reference should be made to the relevant
codes of Practice.
L.P.G. Installation:
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 buildings:
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.
IMPORTANT:
Artificially softened water must not be used
to fill the central heating system.

STANDARD PACKAGE:
A - Floor standing gas fired regular boiler
B - Mounting frame complete with pre-
plumbing manifold assembly
C - Literature pack
D - Condensate hose and non-return valve
SPECIFICATIONS:
Pre-wired and pre-plumbed.
Galvanised steel inner frame.
Bosch Heatronic control system.
Automatic ignition.
Direct burner ignition electrodes.
Built-in frost thermostat.
Built-in fault finding diagnostics.
Modulating automatic gas valve.
Combustion air fan with speed regulator.
CH temperature sensor & control.
Flue gas temperature limiter.
Condensate trap & pump.
APPLIANCE
INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS 3
GENERAL INFORMATION
GENERAL INFORMATION
8 716 115 216b (09.2008)
400mm
600mm
850mm
A
B
C
D

APPLIANCE
INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS
4
TECHNICAL DATA
TECHNICAL DATA 8 716 115 216b (09.2008)
DESCRIPTION UNITS Natural Gas L.P.G
FS 30CDi FS 42CDi FS 30CDi FS 42CDi
Central Heating
Max. rated heat output net 40/30°C kW 32.1 43.7 32.1 43.7
Max. rated heat output net 50/30°C kW 31.8 43.3 31.8 43.3
Max. rated heat output net 80/60°C kW 30 40.8 30 40.8
Max. rated heat input net kW 30.9 42 30.9 42
Min. rated heat output net 40/30°C kW 8.6 10.8 11.6 13.5
Min. rated heat output net 50/30°C kW 8.6 10.7 11.4 13.4
Min. rated heat output net 80/60°C kW 7.7 9.6 10.5 12.0
Min. rated heat input net kW 8 10 10.8 12.5
Max. flow temperature °C 88 88 88 88
Max. permissible operating pressure bar 2.65 2.65 2.65 2.65
Gas flow rate - Max. 10 minutes from lighting
Natural Gas G20 m3/h 3.27 4.4 - -
Propane Gas (LPG) kg/h - - 2.3 3.3
Gas supply pressure
Natural Gas G20 mb 20 20
LPG (Propane) Gas G31 mb - - 37 37
Flue
Flue Gas Temp. 80/60°C, rated min. load °C 67/55 67/55 67/55 67/55
Flue Gas Temp. 40/30°C, rated min. load °C 43/32 43/32 43/32 43/32
CO2level at max. rated heat output % 9.4 9.4 10.8 10.8
CO2level at min. rated heat output % 8.6 9.0 10.4 10.4
NOx- classification class 5 5 5 5
Condensate
Max. condensation rate l/h 2.7 3.7 2.7 3.7
pH value, approx. 4.8 4.8 4.8 4.8
Electrical
Electrical power supply voltage AC...V 230 230 230 230
Frequency Hz 50 50 50 50
Max. power consumption (without pump) W 60 80 60 80
General Data
SEDBUK (Band A) % 90.5 90.3 91.9 91.1
Appliance protection rating IP x4D x4D x4D x4D
Permissable ambient temperatures °C 0 - 50 0 - 50 0 - 50 0 - 50
Nominal capacity of appliance Itr 3.75 3.75 3.75 3.75
Noise output level (at maximum CH output) dB(A) 37 37 37 37
Weight (excluding packaging) kg 55.1 55.1 55.1 55.1

APPLIANCE
INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS 5
LAYOUT & COMPONENTS
LAYOUT & COMPONENTS
8 716 115 216b (09.2008)
The diagram opposite shows the controls in
the servicing position and excludes the outer
case, inner covers and wiring.
1 CONTROL PANEL
2 MASTER SWITCH FOR ON/OFF
3 BURNER ON INDICATOR LIGHT (GREEN)
4 SERVICE BUTTON
5 BOOST BUTTON (SERVICE ONLY)
6 DISPLAY
7 RESET BUTTON
8 NOT USED
9 NOT USED
10 TEMPERATURE CONTROL
11 MAINS ON/OFF INDICATOR & FAULT
DIAGNOSTIC LIGHT (BLUE)
12 BOSCH HEATRONIC III SERIES CONTROL
BOARD
13 AUTO-AIR VENT
14 FLOW PIPE
15 THERMISTOR
16 HEATCELL
17 AIR/GAS ADJUSTMENT SCREW (SEALED)
18 CONDENSATE PUMP ASSEMBLY
19 RUNNER WHEEL
20 FLOW CONNECTION
21 GAS ISOLATION VALVE
22 RETURN CONNECTION
23 MOUNTING FRAME
24 CONDENSATE SIPHON
25 GAS VALVE
26 INNER CASING
27 HEATCELL HIGH LIMIT THERMOSTAT
28 BURNER IGNITION ELECTRODES
29 BLANKING COVERS - FLUE OUTLET
30 CASE 'KNOCK-OUT' PANEL - FLUE
31 CASE SIDE PANEL LEFT HAND
32 CASING SUPPORT STRUT
33 COMBUSTION AIR MODULATING FAN
34 FLUE GAS SAMPLING POINT
35 DATA LABEL
100mmØ HORIZONTAL FLUE
COMPONENTS (Kit Part No. 7 716 191 155)
A - 90° ELBOW
B - ADAPTOR
C - CONNECTOR
D - INNER WALL FLUE COLLAR
E - TELESCOPIC TERMINAL ASSEMBLY
F - OUTER WALL FLUE COLLAR
FLUE KITS:
Vertical 100mmØ Part No. 7 716 191 156
Vertical 125mmØ Part No. 7 716 191 158
Horizontal 125mmØ Part No. 7 716 191 157
A
B
C
D
E
F
1
27
28
30
32
34
35
29
31
33
26
25
15
14
16
19
13
17
18
20
21
22
23
24
1
12
10 11
2
3
4
5
6
7
8
9

PRE-
INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS
6
CLEANING PRIMARY SYSTEMS
CLEANING PRIMARY SYSTEMS
CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK
AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.
IMPORTANT: All the following pre-installation sections must be read and
requirements met before starting boiler or flue installation.
8 716 115 216b (09.2008)
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 appliance
will invalidate the appliance warranty.
BEFORE CLEANING THE SYSTEM:
ENSURE THE SYSTEM AND PIPEWORK ARE
IN GOOD WORKING ORDER.
USE 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 mains water to
the recommended pressure and check for
leaks.
Open all drain cocks and drain the system.
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.
Run the boiler and system at normal
operating temperature in accordance with
the manufacturer's instructions.
Drain and thoroughly flush the system to
remove the flushing agent and any debris.

PRE-
INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 216b (09.2008)
7
MAINS SUPPLIES
MAINS SUPPLIES
ELECTRICAL SUPPLY:
• Supply: 230V - 50Hz.
• Cable: PVC insulated 0.75mm2
(24 x 0.2mm) temperature rated to 90°C.
• External 3A fuse to BS1362.
• The appliance must be earthed.
• It must be possible to isolate the appliance
from the electrical supply with at least a
3mm contact separation in both poles
supplying the appliance.
• Wiring between the appliance and the
electrical supply must comply with IEE
wiring regulations and any local regulations
which may apply for fixed wiring to a
stationary appliance.
• External pump must be wired back to the
boiler.
• Any system connected to the boiler must
not have a separate electrical supply.
WATER SUPPLY:
• Connections to the water supply must not
be made without the authority of the local
water company.
GAS SUPPLY:
• Boilers using NG must be connected to a
governed meter.
• LPG boilers must be connected to a
regulator.
• Installation and connection of the gas
supply to the boiler must be in accordance
with BS6891.
• Under no circumstances should the
diameter of the gas supply pipe be less
than that of the appliance inlet connection.
• The meter or regulator and pipework to
the boiler must be checked, preferably by
the gas supplier to ensure it 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.

PRE-
INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 216b (09.2008)8 716 115 216b (09.2008)
8WATER SYSTEMS & PIPEWORK
WATER SYSTEMS & PIPEWORK
Heating return Auto
air vent Non return
valve
Stop
cock
Make up
vessel
1000mm
above the
highest point
of the system
PRIMARY SYSTEM PLASTIC PIPEWORK:
• Any plastic pipework must have a polymeric
barrier with 600mm (minimum) length of
copper pipe connected to the boiler.
• Plastic pipework used for underfloor
heating must be correctly controlled with
a thermostatic blending valve limiting the
temperature of the circuits to approx. 50°C.
The pipework from the boiler to the
blending valve must be in copper.
PRIMARY SYSTEM CONNECTIONS/VALVES:
• Do not use galvanised pipes or radiators.
• All system connections, taps and mixing
valves must be capable of sustaining a
pressure of 3 bar.
• Radiator valves should conform to
BS2767:10.
• All other valves should conform to BS1010.
• On new installations TRV’s must be used
on all radiators except the radiator where
the room thermostat is sited, this must be
fitted with lockshield valves and left open.
All installations should, at least, have TRV's
fitted to radiators within the sleeping
accommodation.
• An automatic bypass valve must be
connected between the heating flow and
return where TRV's are used on all radiators
unless one of the parts is open to flow
(refer to “Water Systems and Pipework
section).
• A drain cock should be fitted at all the
lowest points of the heating circuit.
• Air vents are required at all high points on
the system.
FILLING PRIMARY SEALED SYSTEMS:
• Filling the primary system must comply
with one of the methods shown opposite.
• The filling point must be at low level and
must never be a permanent direct fixing
to the mains water supply.
• Filling loops must be WRAS approved.
Fill point
Heating return
Hose
return
Non
return
valve
Non
return
valve
Test cock
Stop
cock
Water main
supply
Stop
cock
Temporary
hose

WATER SYSTEMS & PIPEWORK
PRE-
INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 216b (09.2008)
9
WATER SYSTEMS & PIPEWORK
S & Y PLAN OPEN VENT PRIMARY SYSTEM:
Generally a by-pass is not necessary on a Y plan
system as one of the parts is open to flow.
• The feed and expansion cistern (N) must
be positioned to provide a static head (M)
of at least 250mm above the highest point
in the heating system.
• The heating vent (B) and cold feed (C)
pipes must rise continuously from the
appliance.
• The heating vent pipe (B) must be at least
Ø22mm.
• No valve shall be fitted in the heating vent
pipe (B) or the cold feed and expansion
pipe (C).
FULLY PUMPED SEALED PRIMARY SYSTEM:
• A pressure relief valve (K) (spring loaded
safety valve set to operate at 3 bar) must
be fitted to the heating return pipe as close
as possible to the boiler.
• An expansion vessel (I) must be fitted to
the heating return pipe close to the boiler
and pressurised for the system volume
according to the instructions supplied with
the vessel.
• A pressure gauge (J) (3 bar min.) must be
fitted to the heating return pipe.
• An automatic air vent must be fitted.
• Stop valve (L) must be a fixed cylinder
type or sealed systems approved
connection.
K
I
J
L
Mains cold water
Cylinder return
Heating flow
D
G
Hot water flow
H
Heating
return
SEALED SYSTEM LAYOUT
BC
E
G
H
D
150mm max.
Y PLAN LAYOUT
S PLAN LAYOUT
M
min. 250mm
BC
150mm max.
G
DH
E
F
M
min. 250mm
M
min. 250mm
M
min. 250mm
A - Boiler.
B - Heating vent (min. Ø22mm).
C - Primary cold feed (min. Ø15mm).
D - Diverter valve.
E - Pump.
F - Automatic by-pass.
G - Radiator valve (flow).
H - Lockshield valve (return).
I - Expansion vessel.
J - Pressure gauge.
K - Relief valve.
L - Stop valve.
M- Static head.
N - Feed & expansion cistern.
A
N
A
N
N
A

Soil & vent stack
22mmØ
minimum
450mm
and up to
3 storeys
Invert
Condensate drainage pipe can be
run above or below ground
25mm
Bottom of
tube sealed
Limestone
chippings Hole depth
400mm min.
by 300 Ø
Drainage holes
22mmØ condensate
drainage pipe, max external
length 3 metres
Diameter 100mm
min. plastic tube
500mm min.
75 mm
min.
Condensing
Boiler
22mmØ
plastic pipe
75mm sink
waste trap
Open end of
condensate drainage
pipe directly into gully
below grating but
above water level
Visible air break
at plug hole
22 mm Ø plastic condensate
drainage pipe running
through the external wall
External
air break
Air gap
External rain water
pipe into foul water
68 mm Ø PVC-u
strap on fitting
43 mm 90°
M & F bend
100mm
Sink with
integral
overflow
Insulation or
increase pipe size
Insulation or
increase pipe size
Insulation or
increase pipe size
-
Fitting an external air break
Use the situation opposite when a rain water
down pipe is used to dispose of condensate
and the down pipe goes directly into an
existing sewer that carries both rainwater
and foul water.
An air break must be installed in the
32/43 mm pipework, between the boiler
condensate outlet and the drainpipe, outside
the property, to avoid flooding during
adverse weather conditions.
CONDENSATE PIPEWORK:
• The condensate pipe must be a minimum of
22mm Ø plastic pipe.
• The condensate pipework must fall at
least 50 mm per metre towards the outlet
and should take the shortest practicable
route.
• The pipework must follow one of the options
shown opposite or discharge directly into a
vent stack min. 450mm above pipe invert or
into a gully below ground but above the water
level.
• Wherever possible the condensate
discharge pipe work should be routed and
terminated internally. Should this not be
possible, and the only available route is
external, the following conditions should be
observed:
External pipe work
- Pipe work length should be kept to a
minimum and the route as vertical as
possible.
- Where pipe work is subjected to
extreme cold or wind chill, a weather
proof insulation should be used.
Alternatively the condensate pipework
could be increased to a minimum
diameter of 32mm without the
requirement to insulate.he pipe run
IMPORTANT:
• Ensure there are no
blockages in the pipe run
• Care should be taken when
siting a soak-away to avoid
obstructing existing services
• Condensate waste must not
be terminated into a septic
tank or cesspit
Condensate soakaway
The condensate drainage pipe may be run
above or below the ground to the soakaway.
The example shown opposite runs above
ground level.
The soakaway must use a 100mm diameter
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.
Condensing
Boiler
Condensing
Boiler
PRE-
INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 216b (09.2008)
10 CONDENSATE PIPEWORK
CONDENSATE PIPEWORK

PRE-
INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 216b (09.2008)
11
BOILER LOCATION & CLEARANCES
• This boiler is only suitable for installing
internally within a property at a suitable
location onto a fixed rigid non-combustible
surface at least the same size as the boiler
and capable of supporting the boiler
weight.
• The boiler is not suitable for external
installation unless a suitable enclosure is
provided.
COMMERCIAL INSTALLATION:
• If installing more than one appliance in a
modular or cascade arrangement in a
commercial premises, that total more than
70kW, then additional ventilation is needed
to comply with the Dangerous Substances
and Explosive Atmospheres Regulations
(DSEAR).
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 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.
1: INSTALLATION CLEARANCES:
Diagram 1 shows the minimum space required
to install the boiler only.
2: SERVICE / VENTED CUPBOARD
CLEARANCES:
Diagram 2 opposite shows the minimum space
required to service the boiler only.
 25mm to a removable door
3: UNVENTED COMPARTMENT
CLEARANCES:
Diagram 3 shows the minimum space required
to install and service the boiler inside an
unvented compartment.
*
Space required for unvented areas with a
removable door or panel.
**This space can be reduced to 50mm for one
side only as long as both the side clearances
add up to the total of both the side
measurements shown or more.
BOILER LOCATION &
CLEARANCES
600mm
800mm 600mm
900mm
50mm
100mm**
100mm**
200mm*
600mm
5mm
5mm
410mm
1200mm
600mm
15mm
5mm
5mm
410mm
1200mm
1: INSTALLATION CLEARANCES
2: SERVICE / VENTED
CUPBOARD CLEARANCES
3: UNVENTED
COMPARTMENT CLEARANCES
1450mm
865mm
25mm

PRE-
INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS
12 BOILER LOCATION & CLEARANCES 8 716 115 216b (09.2008)
BOILER LOCATION &
CLEARANCES
600mm
2250mm
600mm
2250mm
600mm
600mm radius
750mm
750mm
2250mm
m
2250m
11
2
2
11
2
2
25mm 100mm
200mm
100mm
25mm
625mm 600mm
C
B
D
1050mm
5: VENTING
COMPARTMENTS
4: AIRING CUPBOARD
CLEARANCES
4: AIRING CUPBOARD CLEARANCES:
Diagram '4' opposite shows the minimum
space r
eq
equired to install and service the boiler
within an airing cupboard.
5: VENTING COMPARTMENTS:
If the clearances are less than those stated
for options '3' & '4' (above) then ventilation
must be provided as described in BS 5440.
A minimum of 2 air vents (C) of equal size
must be fitted, one at low level and another
at high level onto the same wall using the
same air for circulation.
Minimum free area required for venting:
For air directly from outside:
FS 30CDi 155cm2
FS 42CDi 217cm2
For air from internal space/room:
FS 30CDi 310cm2
FS 30CDi 433cm2
100mm
6: BATHROOMS:
IMPORTANT:
Any switch or appliance control using mains
electricity must not be within reach of a
person using the bath or shower.
Electrical switches, fused spurs and socket
outlets must not be situated in the bathroom.
This boiler is IP X4 rated and can be installed
in zone 2, however where possible positions
outside zone 2 should be sought.
Additional RCD (Residual Current Device)
protection may be required.
Refer to the latest IEE wiring regulations.

MOUNTING FRAME CONNECTIONS
PRE-
INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 216b (09.2008)
13
CONNECTIONS:
Water: 28mm compression fittings
Gas: 22mm compression fitting.
RUNNING PIPES BEHIND THE BOILER:
• The frame should sit against the wall (not
the skirting board) with enough room for
the pipework.
• Do not cross a pipe over another.
• The area around a rear flue outlet must
be avoided.
MOUNTING FRAME
CONNECTIONS
28mm
A22mm

PRE-
INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS
14 FLUE OUTLET POSITIONS 8 716 115 216b (09.2008)
• The flue must be fitted and terminated in accordance
with the recommendations of BS5440 : Part 1.
• 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 alternate 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: Part 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 (minimum 50 mm)
around the flue and fixed to the wall with plated
screws. See Contact Information (inside front cover).
NOTE: All measurements are the minimum
clearances required.
Terminals must be positioned so to
avoid combustion products entering
the building.
Deduct one metre off the total flue length for every 45° bend used
Deduct two metres off the total flue length for every 90° bend used
The flue turret has a built-in angle of 3° to
ensure that the condensate flows back to
the boiler for safe disposal via the
condensate waste pipe.
All horizontal flue sections must rise by 3°
or at least 52mm for each metre away from the
boiler to ensure condensate flows back
into the boiler.
600mm minimum
clearance from
a skylight to a
vertical flue
500mm
Vertical flue clearance 500mm
to non-combustible building
material, and 1,500mm clearance
to combustible building material
600mm distance to a boundary,
unless it will cause a nuisance.
BS 5440: Part 1 recommends
that care is taken when siting
terminals in relation to boundaries
200mm below eaves
and 75mm below
gutters, pipes and drains
200mm
25mm
DRAI
N
VEL
U
500mm
600mm
600mm
500mm
Boundary
1000mm 1000mm
52mm fall 104mm fall
500mm
300m
m
500mm clearance to
any vertical structure
on a roof, 600mm to
another flue or 1500mm
to an open flue.

PRE-
INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS 15
FLUE OUTLET POSITIONS
8 716 115 216b (09.2008)
FLUE OUTLET POSITIONS
Flue clearances 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.
NOTE: All measurements are the minimum
clearances required. Terminals must
be positioned so to avoid combustion
products entering the building
1,200mm from an opening on the
same wall (ie: door or window
leading into a dwelling) in a carport
with both sides open, to prevent the
build up of combustion products.
Clearance no less than
200mm from the lowest point
of the balcony or overhang
The flue cannot be
lower than 1000mm
from the top of a light
well due to the build up
of combustion products
300mm to an
internal or
external corner
1500mm between a vertical flue
terminal and a window
or dormer window
400mm from a pitched roof
or in regions with heavy
snow fall 500mm
2000mm below a Velux window,
600mm above or to either side
of the Velux window
5mm 300mm
1500mm
300mm
Window
D
RAINPIPE
300mm above,
below and either
side of an opening
door, air vent or
opening window
1200mm between terminals
facing each other
1200mm
1500mm
400mm
DORMER
WINDOW
VELUX WINDOW
300mm
300mm
300mm
3
00mm
8 716 115 089a
Plume management kits are available for
100mm horizontally terminated flues.
Please refer to the installation instructions
supplied with the plume management kits.
If plume redirection is utilised, the
clearance from any opening must
be increased in the direction of the
plume to 1500mm.
NOTES:
Plume deflector
Min.
1500 mm
Opening
in building
Direction of
flue discharge
NOTE:
Installations in carports
are not recommended

The diagrams (opposite) show the
components used and the maximum flue
length for each configuration of 100mm and
125mm flues.
• Only straight flue sections can be reduced
in length by cutting.
• The 100mm horizontal flue terminal can
be fitted from inside or outside the
building.
IMPORTANT:
All horizontal sections must rise away
from the boiler by 52mm per metre (3°)
to allow the condensate to drain back
to the boiler.
A - Horizontal terminal
B - Straight flue extension
C - Flue bend 90°
D - Flue bend 45°
E - Vertical Terminal
Calculating the flue length:
Measure the total flue length (L) required,
noting that the maximum straight flue length
including the terminal is:
Horizontal Ø60/100mm: 4000mm
Horizontal Ø80/125mm: 13000mm
Vertical Ø60/100mm: 6400mm
Vertical Ø80/125mm: 15000mm
Then reduce the total straight flue length for
each extra flue bend (excluding the flue elbow)
by:
2000mm for 90°
1000mm for 45°
Flue Extension lengths:
Horizontal & Vertical Ø60/100mm: 950mm
Horizontal & Vertical Ø80/125mm: 950mm
Flue Terminal lengths:
Horizontal Ø60/100mm: 530mm
Horizontal Ø80/125mm: 1200mm
Vertical Ø60/100mm: 1140mm
Vertical Ø80/125mm: 1365mm
PRE-
INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS
16 ROOM SEALED FLUE OPTIONS 8 716 115 216b (09.2008)
ROOM SEALED FLUE OPTIONS
E
D
C
B
B
B
C
B
D D
B
C C
B
C C
B
C C C
E
B
D
D
C
E
B
C
L= Ø100mm 130 - 530mm
L= Ø125mm 350 - 1200mm
L
Ø100mm x4
Ø125mm x12
L
L= Ø100mm 310 - 4000mm
L= Ø125mm 350 - 13000mm
L= Ø100mm 2000mm
L= Ø125mm 11000mm
Ø100mm x2
Ø125mm x10
L
Ø100mm x2
Ø125mm x10
L=Ø100mm 2000mm
L=Ø125mm 11000mm
L= Ø125mm 9000mm
Ø125mm x8
L
L= Ø125mm 9000mm
Ø125mm x8
Min.
120mm
L
L= Ø125mm 7000mm
Ø125mm x6
Min.
120mm
L
L= Ø100mm 4400mm
L= Ø125mm 13000mm
Ø100mm x4
Ø125mm x12
Min.
120mm
L
L=Ø100mm 2400mm
L=Ø125mm 11000mm
Ø100mm x2
Ø125mm x10
Min.
120mm
L
L
A
A
A
A
A
A
A
A

INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS 17
UNPACKING THE BOILER
8 716 115 216b (09.2008)
IMPORTANT: All the previous Pre-Installation sections must be read and
requirements met before starting boiler or flue installation.
Take care not to damage the boiler panels
or the floor and note that the boiler may
contain some water due to factory testing.
Unpacking:
1Undo the ties securing the carton to the
pallet
If a sharp implement is used, care must be
taken not to pierce the carton or cause injury.
2
Before removing the carton it is advised
that the top flaps are opened and items
A, B, C and D are removed and set to one
side.
3The carton can now be lifted off the
boiler.
Remove the plastic bag protecting the
boiler surfaces and place safely away from
the working area.
Remove 2 screws at the rear of the board
securing the board to the pallet.
Slide the boiler and board off the pallet.
The boiler is mounted on small wheels
and it is recommended that two people
are used to move the boiler from the board,
taking care not to damage the panels or
the floor.
At all times the correct method for handling
heavy objects should be strictly observed.
GENERAL HANDLING GUIDELINES:
Lift only a manageable weight, or ask for
help.
When lifting, bend the knees, and keep
the back straight and feet apart.
Do not lift and twist at the same time.
Lift and carry items close to the body
Wear protective clothing and gloves to
protect from any sharp edges
A - Mounting frame
B - Installation pack
C - Literature pack
D - Condensate waste pipe & non-return valve
UNPACKING THE BOILER
3
1
2
A
B
C
D

INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS
18 MOUNTING FRAME FIXING &
FLUE OPENING
8 716 115 216b (09.2008)
MOUNTING FRAME FIXING &
FLUE OPENING
38mm
XY Z
All dimensions in mm
20 65 65
CB A
A
D
E
3
X123
2
1
4
Z
Y
143
123
743
267
B
20
FDD
70.5
CAUTION: Ensure there are no pipes,
electric cables, damp proof course or other
hazards before drilling.
SAFETY:
All relevant safety precautions must be
undertaken. Protective clothing, footwear,
gloves and safety goggles must be worn as
appropriate.
MOUNTING FRAME/PIPEWORK POSITIONS:
A - Mounting frame.
B - Manifold connections.
C - Mounting frame fixing point.
D - Wall.
E - Gas and water pipework (not supplied).
F - Boiler.
FIXING THE MOUNTING FRAME:
Position the mounting frame (A) on the
floor against the wall with manifold
connections (B) facing away from the wall
(D) ensuring there is enough space for the
pipework (E).
Allow the minimum space from each side
of the frame (A) for the boiler overhang (F)
and minimum service clearance, as shown.
Ensure the mounting frame is level and
mark fixing points (C).
Secure mounting frame (A) to the floor
using appropriate fixings (not supplied).
Clear any debris from the site.
FLUE OPENING:
Follow the diagram opposite to mark the
centre of the flue (1, & 2) for rear opening,
(2 & 3) for side opening or (1 & 4) for top
opening.
Measurements shown include the minimum
service clearances.
NOTE: All horizontal flue sections must rise away
from the boiler by 52mm per meter to
ensure that condensate flows back into
the boiler for safe discharge via the
condensate waste pipe.
Cover the mounting frame manifold
assembly (A) to protect the manifold
connections.
Make an opening (X or Z) through the wall
using a core drill or similar at a size relative
to the wall thickness as shown below:
Wall Flue opening Flue opening
thickness 60/100mmØ 80/125mmØ
150 - 240mm 127mmØ 152mmØ
240 - 330mm 127mmØ 152mmØ
330 - 420mm 127mmØ 162mmØ
420 - 500mm 140mmØ 162mmØ
Where the flue terminal can only be fitted
from inside the building, increase the opening
to 150mmØ to allow the optional weather
collar to fit through the opening for 60/100
flue.
Clear away any debris.
3
123